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General l nformati on
Chassi s and Pai nt Codes . . . . . . . . . . . . . . . . . . . . . . . 1-2
l denti fi cati on Number Locati ons ......... 1-10
Warni ng/Cauti on Label Locati ons ....... 1-11
Under-hood Emissions Control
Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 15
Lift and Support Points
Li f t and Saf et y St ands . . . . . . . . . . . . . . . . . . . . . . . 1-19
Fl oor Jack . . . . . . . . . . . . . . . . . . . . . . . 1-20
Towi ng . . . . . . . . . 1-21
Service Precautions
Pafts Marki ng Locati ons ..,................. 1-22
Precautions for Real-time 4WD
(Four-wheel
Dri vel . . . . . . . . . . . . . . . . . . . . . . . . . . 1
-23
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U.S. 1997 Model
Vehicle ldentification Number
J HLRD184* VC000001
JHL: HONDA MOTOR CO., LTD
HONDA, Mul ti purpose
Passenger Vehi cl e
(MPV)
line, Body and Engine Type
RDl : CR V/82084
Body Type and Transmission Type
8: 5-door/4-soeed Automati c
Vehicle Grade
(Series)
4: LX
5: LX
(wi th
ABS)
Check Digit
Model Year
Vt 1997
C: Sai tama Factory i n Japan
(Sayama)
Chassis and Paint Codes
(o
COLOR LABEL
B-84P
NH- 552M
NH-592P
R-94
Supermari ne Bl ue Pearl
Cypress Green Pearl
Sebri ng Si l ver Metal l i c
Fl amenco Bl ack Pearl
San Mari no Red
Vehicle ldentif ication Number
and Federal Motor Vehicle
INT. COLOR
WPE F
EXT. COLOR
B-84P
KA S2B A1 C
1-2
to
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U.S. 1998 Model
J HLRD174* WC000001
JHL: HONDA MOTOR CO., LTD
HONDA. Mul ti purpose
Passenger Vehi cl e
(MPV)
Line, Body and Engine Type
RD1:CR-V/82084
RD2: CR'V/82084
Body Type and Transmission Type
7: 5-door/s-soeed Manual
8; 5-door/4-soeed Automati c
C: Sai tama Factory i n Japan
(Sayama)
B20B4t 2.01 DOHC Sequenti al Mul ti port
Fuel -i nj ected engi ne
MDLA: 4-speed Automatic
M4TA: 4-speed Automati c
SBXM: s- speed Manual
MDLA, SBXM: 1000001
-
M4TA: 3000001
-
B-84P
G-82P
NH-552M
NH-592P
R-94
Supermari ne Bl ue Pearl
Cypress Green Pearl
Sebri ng Si l ver Metal l i c
Fl amenco Bl ack Pearl
San Mari no Red
Vehicle ldentification Number
and Canadian Motor Vehicle
COLOR LABEL
INT. COLOR
TYPE F
EXT. COLOR
8.84P
KA S2B A1 C
1- 3
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Chassis and Paint Codes
U.S. 1999 Model
Vehicle ldentification Number
J HLRDI T4* XC000001
JHL: HONDA MOTOR CO., LTD
HONDA. Mul ti purpose
RDlt CR-vlB20Z2
RD2t CR-V1B2OZ2
Body Type and Transmission Type
7: 5-door/5-speed Manual
8: 5-door/4-spsed Automati c
4: LX
6: Ex
Chock Digit
Model Year
X: 1999
C: Sai tama Factory i n Japan
(Sayama)
B2OZ2:2.0 | DOHC Sequenti al Mul ti port
Fuel -i nj ected engi ne
MDLA: 4-speed Automatic
MDMA: 4-speed Automati c
SBXM: s-speed Manual
MDLA: 2000001-
MDMA: 1000001-
SBXM: 2000001-
B-84P
B-92P
G.95P
NH-578
NH-552M
R,81
Supermari ne Bl ue Pearl
Ni ghthawk Bl ack Pearl
Cl over Green Pearl
Taffeta White
Sebri ng Si l ver Metal l i c
Mi l ano Red
Vehicle ldentification Number
and Canadian Motor Vehicle
COLOR LABEL
INT. COLOR
TYPE F
EXT. COLOR
B.84P
KA S2B A1 C
1- 4
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U. S. 2000 Model
JHLRD174* YC000001
JHL: HONDA MOTOR CO., LTD
HONDA, Mul ti purpose
Passenger Vehi cl e
(MPV)
Line. Body and Engine Type
RDlt CR-V/82022
RD2i CR-v/BzOz2
Body Type and Transmission Type
7: 5-door/s-speed Manual
8: 5 door/4-soeed Automati c
Cr Sai tama Factory i n Japan
(Sayama)
B20Z2t 2.0 I DOHC Seouenti al Mul ti Dort
Fuel -i nj ected engi ne
MDLA; 4-speed Automati c
MDMA: 4-speed Automati c
SBXM: s-speed Manual
MDLA: 3000001-
MDHA: 2000001-
SBXM: 2000001-
Ni ghthawk Bl ack Pearl
El ectron Bl ue Pearl
Cl over Green Pearl
Taffeta White
Sebri ng Si l ver Metal l i c
Mi l ano Red
B-92P
B-95P
G-95P
NH-578
NH-552M
R-81
Saf ety Standard Certif ication.
l r l . . V
COLOR LABEL
INT. COLOR
TYPE F
EXT, COLOR
8.92P
KA S2B A1 C
1- 5
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Chassis and Paint Codes
Canada 1997 Model
JHLRD185* V C 800001
HONDA MOTOR CO., LTD
HONDA, Mul ti purpose
Passenger Vehi cl e
(MPV)
Line, Body and Engine Type
RDl : CR-V/B2084
Body Typ and Transmission Typ
8: s-door/4-soeed Automatic
C: Sai tama Factory i n Japan
(Sayama)
B20g4t 2.0 | DOHC Seouenti al Mul ti Dort
Fuel -i nj ected engi ne
MDMA- 1000001
MDMA: 4-speed Automati c
SDMA: 4-speed Automati c
Supermari ne Bl ue Pearl
Cypress Green Pearl
Sebri ng Si l ver Metal l i c
Fl amenco Bl ack Pearl
San Mari no Red
B-84P
G-82P
NH-552M
NH-592P
R-94
Vehicle ldentification Number
and Canadian Motor Vehicle
Saf ety Standard Certifi cation.
COLOR LABEL
INT. COLOR
TYPE F
EXT. COLOR
B-84P
KC S2B C2 C
1- 6
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Canada 1998 Model
JHL RD1 7 4* WC800001
JHL: HONDA MOTOR CO., LTD
HONDA, Mul ti purpose
Passenger Vehi cl e
(MPV)
Lino, Body and Engine Type
RD1: CR-V/82084
Body Type and Transmission Type
7: 5-door/s-speed Manual
8: 5-door/4-speed Automati c
C: Sai tama Factory i n Japan
(Sayama)
82084:2.0 | DOHC Sequenti al Mul ti port
Fuel -i nj ected engi ne
M4TA: 4-speed Automati c
SBXM: 5-speed Manual
SBXM: 1000001-
M4TA: 3000001*
Supermari ne BIue Pearl
Cypress Green Pearl
Sebri ng Si l ver Metal l i c
Fl amenco Bl ack Pearl
San Mari no Red
B-84P
G-82P
NH-552M
NH-592P
R-94
COLOR LABEL
INT. COLOR
TYPE F
EXT. COLOR
8.84P
KC S2B C2 C
1-7
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Canada 1999 Model
Vehicle ldentification Number
JHL RDl T 4* XC800001
JHL: HONDA MOTOR CO., LTD
HONDA, Mul ti purpose
Passen0er Vehi cl e
{MPV)
Line, Body and Engin6 Type
RD1: CB-Y/B2OZ2
Eody Typ6 and Transmi$ion Type
7: 5-door/5-speed Manual
8: s-door/4-speed Automatic
4: LX
5: EX
Chock Digit
Model Yeal
X: 1999
C: Sai tama Factory i n Japan
{Sayama)
Chassis and Paint Codes
COLOR LABEL
B20Z2i 2.0 I DOHC Sequenti al Mul ti port
Fuel -i nj ected engi ne
MDMA: 4-speed Automati c
SBXM: s-speed Manual
B-84P
a-92P
G.95P
NH.552M
R-81
Supermari ne Bl ue Pearl
Ni ghthawk Bl ack Pearl
Cl over Green Pearl
Sebri ng Si l ver Metal l i c
Mi l ano Red
Vehiclo ldentification Number
and Canadian Motor Vehicle
Safety Standard Certification.
INT. COLOR
TYPE F
EXT. COLOR
B-84P
KC S2B C2 C
1- 8
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JHL RDl 7 4* Y C 800001
Manulacturer, Make and
Type of Vehicle
JHL: HONDA MOTOR CO., LTD
HONDA, Mul ti purpose
Passenger Vehi cl e
(MPV)
Line, Body and Engine Type
RDlt CR-VlB2oZ2
Body Type and Transmission Type
7: 5-door/s-soeed Manual
8: 5-door/4-sDeed Automatic
Vehicle Grade
(Seriesl
4: LX
5: EX
Check Digit
Model Year
Yr 2000
Factory Code
C: Sai tama Factory i n Japan
(Sayama)
Serial Number
82022:2.0 | DOHC Sequenti al Mul ti port
Fuel -i nj ected engi ne
MDMA: 4-speed Automati c
SBXM: s-speed Manual
Eternal Bl ue Pearl
Ni ghthawk Bl ack Pearl
Cl over Green Pearl
Sebri ng Si l ver Metal l i c
Mi l ano Red
Napl es Gol d l Vetal l i c
B-96P
B-92P
G-95P
NH-552M
R-81
YR-524M
Vohicle ldentification Number
and Canadian Motor Vohicle
OOLOR LABEL
tNr coL0R
TYPE F
EXT. COLOR
B-92P
KC S2B C2 C
1- 9
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ldentification Number Locations
Vehicle ldentification Number lVlNl
Vehicl ldentific.tion Number tvtNl
-
Transmission Numb6r lManudl)
1 - 1 0
Transmission Numbor {Aulomaticl Engine Numbel
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Warni ng/Cauti on
Label Locati ons
C: DRIVER MODULE WARNING
A WARNING
THE AI REAG I NFLATOR I S EXPLOSI VE AND, I F
ACCIDENTALLY DEPLOYED, CAN SERIOUSLY HURT
OR KILL YOU.
. DO NOT USE ELECTRICAL TEST EOUIPMENT OR
PROBING DEVICES.
THEY CAN CAUSE ACCIDENTAL DEPLOYMENT.
. NO SERVTCEABLE PARTS l NSl DE. DO NOT
DISASSEMBLE.
. PLACE AIRBAG UPRIGHT WHEN REMOVED
. FOLLOW SERVI CE MANUAL I NSTRUCTI ONS
CAREFULLY.
A: CABLE REEL CAUTION
TNSTALLATION OF THE SRS CABLE REEL IS CRITICAL
TO THE PBOPER OPERATION OF THE SRS SYSTEM.
REFER TO THE SERVICE MANUAL FOR DETAILED
INSTALLATION INSTRUCTIONS.
(cont' d)
1- 11
B: DRIVER MODULE DANGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACT WITH ACID, WATER OR HEAVY METALS
SUCH AS COPPER, LEAD OR MERCURY MAY
PRODUCE HARMFUL AND IRRITATING GASES OR
EXPLOSIVE COMPOUNDS. STOMGE TEM PERATURES
MUST NOT EXCEED 2OO" F { 1OO' C} .
FOR PROPER
HANDUNG, STORAGE, AND DISPOSAL PROCEDURES.
REFER TO SERVICE MANUAI- SRS SUPPI.EMENT,
POTSON
CONTAI NS POI SONOUS SODI UM AZI DE AND
POTASSIUM NITRATE.
FIRST AID
t F CONTENTS ARE SWALLOWED, I NDUCE
VOMITING. FOR EYE CONTACT, FLUSH EYES WITH
WATER FOR 15 MINUTES. IF GASES IFROM
ACID
OR WATER CONTACTI ARE INHALED, SEEK FRESH
AI R. I N EVERY CASE, GET PROMPT MEDI CAL
ATTENTION.
KEEP OUT OF REACH OF CHILDREN
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Warning/Caution
Label Locations
(cont'dl
(U. S. A.
model onl yl
E: STEERING COLUMN NOTTCE
tHOODI
NOTICE
TO PREVENT SRS DAMAGE, REMOVE STEERING WHEEL
BEFORE REMOVING STEERING SHAFT CONNECTING BOLT.
F: MONITOR NOTICE
NOTICE
. NO SERVICEABLE PARTS tNStoE.
. REFER TO SERVI CE MANUAL FoR DETAI LED
rNsrRucTtoNs.
{U. S. A. modol onl yl
o: SRS WARNING
{HOOD}
SUPPLEMENTAL RESTRAINT SYSTEM {SRSI
THI S VEHI CLE I S EOUI PPED WI TH DRI VER AND FRONT
SEAT PASSENGER AIRBAGS,
ALL SRS ELECTRI CAL WI RI NG AND CONNECTORS ARE
COLORED YELLOW.
TAMPERI NG WI TH, DI SCONNECTI NG OR USI NG
ELECTRICAL TEST EOUIPMENT ON THE SRS WIRING CAN
MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL
FIRING OF THE INFLATOR.
A WARNING
THE AI RBAG I NFLATOR I S EXPLOSI VE AND. I F
ACCIDENTALLY DEPLOYED, CAN SEBIOUSLY HURT YOU.
FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.
1- 12
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G: FRONT SEAT PASSENGER AIRBAG MODULE DANGEN
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACT WITH ACID, WATER. OR I{EAVY METALS SUCH
AS COPPER. T.EAD. OR MERCURY MAY PRODUCE HARMFUL
AND I RRI TATI NG GASES OR EXPLOSI VE COMPOUNDS.
STORAGE TEMPERATURES MUST NOT EXCEED 2OO"F
I l OO' C) . FOR PROPER HANDLI NG, STORAGE, AND
DISPOSAL PROCEDURES REFER TO THE SERVICE MANUAL,
SRS SUPPLEMENT.
POTSON
CONTAINS POTSONOUS SODIUM AZIDE ANO POTASSIUM
NITRATE.
FIRST AID
IF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR
EYE CONTACT, FLUSH EYES WI TH WATER FOR 15
MINUTES. IF GASES
(FROM
ACID OR WATEN CONTACT)
ARE I NHALEO. SEEK FRESH AI R. I N EVERY CASE, GET
PROMPT MEDICAL ATTENTION.
KEEP OUT OF REACH OF CHI LDREN.
A WARNING
THE AI RBAG I NFLATOR I S EXPLOSI VE AND, I F
ACCI DENTALLY DEPLOYED, CAN SERI OUSLY HURT OR
KI LL YOU.
. DO NOT USE ELECTRI CAL TEST EOUI PMENT OR
PROBING DEVICES,
THEY CAN CAUSE ACCIDENTAL DEPLOYMENT.
. NO SERVICEABI-E PARTS lNSlDE. DO NOT DISASSEMBII.
. PLACE AIRBAG UPRIGHT WHEN REMOVEO.
. FOLLOW SERVIC MANUAL INSTRUCTIONS CAREFULLY
H: PASSENGER INFORMATION lU S.A. modell
{U. S. A. ' 97 model }
AIEBAG SEE OTHER SIDE,
{U. S. A. ' 98
-
00 model sl
AIRBAG WARNING
FLIP VISOR OVER.
l: SRS INFORMATION
l U.s.A.' 97
model
i
lcanada
'97
-
00 modls I
CAUTION
TO AVOID SERIOUS INJURY:
. FOR MAXIMUM SAFEW PROTECTION lN ALL TYPES OF
CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY
8ELT.
o OO NOT INSTALL REARWARD-FACING CHILO SEATS lN
ANY FRONT PASSENGER SEAT POSITION.
. DO NOT SIT OR LEAN UNNECESSARILY CLOSE TO THE
AIRBAG.
. DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR
BETWEEN THE AIRBAG AND YOURSELF.
. SEE THE OWNER' S MANUAL FOR FURTHER
INFORMATION AND EXPLANATIONS
. THE SRS MUST BE INSPECTED TEN YEARS AFTER lT lS
INSTALLED.
. THE DATE OF I NSTALLATI ON l S SHOWN ON THE
DRIVER'S DOORJAMB.
l U. S. A. ' 98
-
00 model s)
WARNING
DEATH OR SERIOUS INJURY CAN OCCUR'
. CHI LDREN 12 ANO UNDER CAN BE KI LLED BY THE
AIRBAG.
. THE BACK SEAT lS THE SAFEST PLACE FOR CHILDREN.
. NEVER PUT A REAR- FACI NG CHI LD SEAT l N THE
FRONT.
o SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG
. ALWAYS USE SEAT BELTS AND CHll-D RESTRAINTS.
. THE SRS MUST BE TNSPECTED TEN YEAnS AFTER lT lS
INSTALLED.
. THE OATE OF I NSTALLATI ON l S SHOWN ON THE
DRIVER'S DOORJAMB.
J: FRONT PASSENGER AIRBAG WARNING
l U. S. A. ' 98
-
00 model s)
WARNING
CHI LDREN CAN BE KI LLED OR I NJURED 8Y THE
PASSENGER AIRBAG.
THE BACK SEAT IS THE SAFEST PLACE FOR CI{ILDREN 12
AND UNDER.
MAKE SURE ALL CHILDREN USE SEAT BELTS OR CHILD
SEATS.
K: FRONT SEATBELT TENSIONER WARNING
WABNING
EXPLOSIVE MATERIAL INSIDE
YOU CAN BE SERIOUSLY HURT OR BURNED,
. DO NOT TAMPER OR DISASSEMBLE
NO SERVICEABLE PARTS INSIDE.
. REFER TO SERVICE MANUAL FOR COMPLETE
INSTRUCTIONS.
(cont' d)
1 - 1 3
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Warning/Caution
Label Locations
(cont'd)
VACUUM HOSE ROUTING
DIAGRAM
lUndor-hood
Emissions Control Lrb6ll
ENGINE COOLANT
INFORMATION
SERVICE
INFORMANON
{Under-hood
Emission3
Control l.rbell
STEERING
COLUMN NOTICE
(se page
1-12)
RAOIATOR CAP
CAUTION
AIR CONDITIONING
INFORMATION
(Canada
model)
1- 14
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Under-hood
Emi ssi ons Control
Label
Emission Group ldentification
(1997
model l
Exampl e:
VACUUM HOSE ROUTING DIAGRAM
LOADED IM TEST]NG OF PERMANENT fOUB WHEEL OSVE OR TRACT ON CONTROL'EOLJIPPED
VEHTCLES MUST BE CONDUCTED ON A IOUR WHEEL DR VE SPEEO SYNCHRON ZED
ANON LOADEDTESTPBO(EOUBEMUSIBEPERFORMEO
50ST
(50
Statesl:
THIS VEHICLE CONFOBMS TO U.S. EPA AND STATE OF
CALI FORNI A REGULATI ONS APPLI CABLE TO 1997
MODEL YEAR NEW LIGHT DUTY TRUCKS.
49ST {49 Statos/Federall:
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO 1997 IVIODEL YEAR NEW LIGHT DUTY
TRUCKS.
CAL
(Calitornial:
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALI FORN I A REGULATI ONS APPLI CABLE TO
' 1997
MODEL YEAR NEW TLEV LI GHT DUTY TRUCKS
PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED
I NTO COMMERCE FOR SALE I N THE STATE OF
CALIFORNIA.
Ii /PORTANT VEHICLE INFORIMATION
ENGINE FAMILY VHN2 OIJCrcK
DISPIACEMENT' 2 OLITER
EVAPORAT VE f AM]LY VNNl0778YMBP
CATALYST
REfERTOSEBVICEMANUALfORAODITIONAL
NFORMATON.
TUNT I-]P CONDITIONS
ENGINE AT NORI\,!AL OPERATNG TEMPERATURE,
ALLACCESSOR ES TL]RNED OFF COOLING FAN OIF
TRANSM1SSION NNEUTRAL
NO OTHEB ADJUSTMENIS NEEDED
ap'
| \6( Zror
' .
ND \. 61F L
r
TNIS VENICLE CONFORMS TO U.S EPA REGUI.ATIONS
APPI CASLE TO I99] MODET YEAR NW L GNI DUTY TRACKS
@
Engi ne Fami l y:
vHN2. o l JGKE
Engi ne and Evaporati ve
Fami l i es
T_fT
Model Year
I I
v: 1s97
| L
Manufaqturer
i
HN: Honda I
Displacement
Class
1: Li ght Duty Vehi cl e
Fuol Systom ,nd Numbr of valves
J: El ectroni c Sequenti al Mul ti port
Inj ecti on
(three
or more val ves
per
cyl i nder)
Fuel Type
G: Gasol i ne
Standard
F: 49 or 50 States Tier 1
K: 49 or 50 States Tier 1
1: Cal i forni a Ti er 1
2: Cal i forni a TLEV
3: Cal i forni a LEV
4: Cal i forni a ULEV
"r0", "*,
T|
V: 1997
Manufacturer
HN: Honda
Catalyst
E, F, G, H: Three Way Catal yst
OBD
K
-
T: OBD Equi pped
Evaporative Family:
Storago System
1: Cani ster
Canistor Working Capacity
(gramsl
Canister Conf igulation
A: Pl asti c Housi ng
(Cl osed Bottom)
B: Pl asti c Housi ng
(OPen
Bottom)
Fusl System
Y: Fuel Inj ecti on
Fuel Tank
M: Metal
Standard
A: Current Evap
B: Enhanced Evap
Wild C.rd
V H N l O T T B Y M B P
1 - 1 5
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Under-hood Emissions
Control Label
Emission Group ldentification
(1998
model l
Example:
50ST
{50 States}:
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALI FORNI A REGULATI ONS APPLI CABLE TO 1998
MODEL YEAR NEW LIGHT DUTY TRUCKS,
/$ST (itg
Statos/Fodsrsll:
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO 1998 MODEL YEAR NEW LIGHT DUTY
TRUCKS.
CAL {California}:
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALI FORNI A REGULATTONS APPLI CABLE TO 1998
MODEL YEAR NEW TLEV LI GHT DUTY TRUCKS
PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED
I NTO COMMERCE FOR SALE I N THE STATE OF
CALIFORNIA.
DwlF\ AIo|NG oB cha\Gtftc I + coot r\r -s msoru1or or FoNoA-IEaoTTxD-ibl
1'v!
Lrff
EzEcoo-aN' a\D wATfB. M w r
or_ut-ir coolqNt, oR-l;ir,FEaFEf-
ENGINE MAY BE SEflIOUSLYSIONTENEO.
DSEPLACI CoOTANT AnEs 85 itNlgsloF
@
MILIS l@0 rnl, wHrcHEvEs coMEs
TNEREAFTR, REPLACE EvEny fmAFSl m
m M[Es i@ kml, wHcHrvEB coMEs
DCHEC(ONADOCOOLqNTATTHE RSSEFVETANX. NOTTHE iAD]ATOR.
DFOR FUFTNEfr INFO8MATION ON IN COOT]NC SYSIEM NEAD THE OWNEN'S MANUAL,
.
CHECK W|TH YOUR NONDA OEALEF.
@
GD
IMPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFOEMS TO I], S. EPA
FEGIJLAIIONSAPPLICASLE TO 1993 MOOEL
YAF NEW LIGHT DUIYTNUCXS.
CATALYST
rwqHozst2l/sFt/osD l cERI|FtEO
vAlvttAsH lrr0.l010.02nm
i col o) EX: 01310. 02mm
SPAS( PIUG GAP I.O IINM
lDLl SPTED 750 I 50
rym
686,13G96
PROCEOURESI
2.0 L
TlNt UPCoND/ToNS: ENGINE AT NOiM
IEMPETAIURT,ALLACCESSORIESTUNNI
fAN OFf. TRAI1SMISSON IN NEUTMI
NO OIIIER AOJUSTI\TFIIS IIEEOED.
1 - 1 6
Engi ne and Evaporati ve Fami l i es
Engine Family: W HNX T O2.O UF1
Modl Year
W: 1998
Manufacturer Subcods
HNX: HONDA
Family Typo
V: LDV
T: LDT
Displacomsnt
Soqunco Characiors
Evaporative Fami Family:
Model Yeat
W: 1998
Manufastu16r Subcode
HNX: HONDA
Family Type
E: EVAP
R; EVAP/ORVR
Canister Work Capacity
Sgquonco Charaqtsrs
W HNX EOOSOAAB
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Emission Group ldentification
(1999
model )
Exampl e:
50 state TLEV + NLEV {Unrestricted}
THI S VEHI CLE CONFORMS TO U. S. EPA NLEV
REGULATI ONS APPLI CABLE TO 1999 MODEL YEAR
NEW TLEV LI GHT DUTY TRUCKS ANO CALI FORNI A
REGULATI ONS APPLI CABLE TO 1999 MODEL YEAR
NEW LIGHT DUTY TRUCKS.
'.WNEN AOO NG OR CNANGINC THE COOLANT. USE @SOLU
I ON Of FONOA U-ECo-q.NOEDI
mcrtniuvcoourr mo wlttt NEVEF oILLJTE THE CooLANT,0RTHE LIFE 0F TNE
"Eifil:$o""niii?i,THffi ffi'"R @
M LEs lmo rhl, wNrcHEVEn coMEs
i'lrt^t orrrr, ^,r*a, rurr"* os @
M LEs 1@ kmr wNICHEVER coMEs
}CNECK OR ADD COOLANT AT THE RESER!' E TAN( NOT IHE NADIATOS
DFOfi fWTHEF NFORMATION ON THE COOL NC SYSTEM READ THE OWNER'S MANUAL'
'
CHECK WIIH YOUS HONOA OEALER.
GD
IMPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFOAMSTOU. S EPA NLEV
FEGULANONS APPLICCBLI TO 1999 MODL
YEA8 NEW TIEV LIGHT DUTY ]nUCKS AND
CALIFORNIA REGULATIONS APPLICASLE IO 19S9
MOOEL YEAR NEW TLEV LIGHT DUTY IFIJCKS,
,|
F --' -
Ll: .-.-,1
I rFrll
\=#_H*
CATALYST
VALVE IASN lN:010r0.02 mm
l CoLDj EX 0131002 mm
SPA8K PLUG GAP 10- l l nm
IDLE SPEED 130 t 5{ rPm
OBDIICERT]ATD
2 0 1
TUNE I]PCONDIIIONS INGINEAT NOB
TEI\'PERATUR ATL ACCESSOS ES TLJRN
FAN OFf IRANSMSSION N NEL]TML
NO OINER ADJUSTMTNTS NEEOEO.
JL
Iooro nr tist rc orn svtncrE MUsT BE coMoufitooNArounwNEElDslvE
SPEED
iitriunor mo ovuvo uenn orr Enw sE a NoN.loaDE D rEsr PRoCE ouRE MU sT 8E Pf Rr-
Engine and Evaporative
Families
Engine Family:
X HNX T02,O UA2
Model Year
X: 1999
Manutao{urer Subcode
HNX: HONDA
Family Type
V: LDV
T: LDT
Displacoment
Saquence Charactors
Evaporative Family:
X HNX EOO8OAAB
Model Yoal
X: 1999
Manutacturar Subcode
HNX: HONDA
Family Typo
E: EVAP
R: EVAP/ORVR
Canbter Work Capacity
Squonce Chartsters
1-17
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Under-hood
Emissions
Control Label
Emission
Group ldentification
(2000
model)
Example:
DWFEN aDD r,tc
0R ChA\CtN! rlt cooraN. ust MsoLU- oN or fioNpA
q-af6MrNp-ol
lfi ;!,."5:P!$t:1t9ffilf 1
\rvEn u u'r +-E coo|-d',r os-Fiiiiifi-'
DREpf cE coolaNrAFTEBt3tlomistoR@MtLEs
r@km),wH ctlEvrscoMEs
T|E8EAFTER, BEprAcE EVEny ErdFst oB
@
MttEs lmr,t, ffitcHEVER coMEs
DCIIICX OF ADD COOLA\ I I' -FE
AISIRVI TAI{I\. NOI THE MDIAIOR
":3lliJ#fl
"lj,9lx6L;T&Iji(0or|]\G
s,5TEM 8r!D TrE owrEp s MA\u.r.
m
IMPORTANT VEHICLE INFORMATION
IHIS \/IHICLE CONFONMS TO U. S. EPA NLEV
SEGULATIONS APPIJCq3LE TO 2OOO IVOOEL
YEAF NEW T!!V LIGHT DUTY TBUCKS AND
CALIFONNIA SEGULATIONS APPLICASLE TO 2OOO
MOOL YIAA NEW TLEV LIGHT.OUTY TFIJCKS.
CATALYST
vALvt LA5h tN:0,10r0.02 mm
{ C0t 0l El : 0. 13! 002 mh
SPAn( PLUGGAP 1. 0- 11mm
l Dl E SPEEo 734150l pm
O8O CENTFIED
?.0 t
TUNI UP CoNDIToNS: ENGINE AT NORM
TTMPERAIURE ATLACCESSORIES fu BNI
TAN OFF TiANSMISS ON IN NUTRAL
NO OTHER AD.ILJSTMENIS NEEDEO.
.l-L
|oAoEDr/MTESTNG oFTHsvtHrctE uLrst
gt
couolorooN,{raua.wxEtt
onuspreo
syNoiRoN zEo DvNAMoMETER. olrEiwsE. A NoN.LoAoEo rEsr
pBocEounr
uust sr
pair
1
50 State TLEV + NLEV
(Unrestricied,
THI S VEHI CLE
CONFORMS TO U. S. EPA NLEV
REGULATI ONS
APPLI CABLE TO 2OOO MODEL YEAR
NEW TLEV LI GHT DUTY TRUCKS AND CALI FORNI A
REGULATI ONS
APPLI CABLE TO 2OOO MODEL YEAR
NEW LIGHT DUTY TRUCKS.
1 - 1 8
Engine and Evaporative
Families
Engine Family: Y HNX TO2.O UA2
Model Yar
Y: 2000
Manufaqturer Subcodo
HNX: HONDA
Family Type
V: LDV
T: LDT
Displacement
Saquenco Charasters
Evaporative Family:
Y HNX EOOSOAAB
Modol Yea.
Y: 2000
Manufacturer Subcode
HNX: HONDA
Family Type
E: EVAP
R: EVAP/ORVR
Canister Work Capacity
Soquenca Charactet3
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Lift and Support
Points
Lift and Safety Stands
ffi When heaw rear components such as suspension, Iuel tank, spare tire and tailgate are to b lemoved, place
!iiii-'rn"t r""igtrt in the trunk before hoisting. When substantial weight is removed flom the lear ot the vehicle, the
center of
gravity may change and can cause the vehicle to tip fotward on the hoist'
NOTE: Si nce each ti re/wheel assembl y wei ghs approxi matel y 30 l bs
(14
kg), pl aci ng the front wheel s i n the cargo area can
assi st wi th wei ght di stri buti on.
1. Pl ace the l i ft bl ocks as shown.
2. Rai se the hoi st a few i nches
(centi meters), and rock the vehi cl e to be sure i t i s fi rml y supported.
3. Rai se the hoi st to ful l hei ght, and i nspect the l i ft poi nts for sol i d support'
NOTE: Use the same suppon
poi nts to support the vehi cl e on safety stands'
LIFT BLOCKS
REAR SUPPORT POIMT
FRONT SUPPORT POINT
1 - 1 9
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Lift and Support Points
1 .
Fl oor Jack
Bl ock the rear wheel s when rai si ng the front of the
vehi cl e; bl ock the front wheel s when rai si ng the rear
of the vehi cl e.
Pl ace the bl ocks behi nd and ahead of the wheel s,
Rai se the vehi cl e hi gh enough to i nsert the safety
stanos.
Adj ust and pl ace
the safety stands so the vehi cl e
wi l l be approxi matel y l evel , then l ower the vehi cl e
onto them.
Front:
Cent er t he
j ack
bracket in the middle
of the
jack
lift platform.
Always usg safety standg when working on or under
any vehicle that is supported by only a
iack.
Nevor attempt to use a bumper
j ack
for ti fti ng or
supporting ths vehicl.
Rsar:
JACK LIFT PLATFORM
Center the
iack
bracket i n t he mi ddl e
of the
iack
lift platform.
1-20
JACK LIFT PLATFORM
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Towing
l f t he vehi cl e needs t o be t owed, cal l a
pr of essi onal
towi ng servi ce. Never tow the vehi cl e behi nd another
vehj cl e wi th
j ust
a rope or chai n. l t i s very dangerous.
Emergency Towing
There are three
popul ar
methods of towi ng a vehi cl e.
Flat-bed Equipment
-
The operator loads the vehicle on
the back of a truck. Thi s i s the best way of transporti ng the
vehi cl e.
Wheel Lift Equipment
-
The tow truck uses tlvo
pivoting
arms that go under the ti res l front or rear) and l i fts them
of f t he gr ound. The ot her t wo t i r es r emai n on t he
gr ound. The vehi cl e' s suspensi on and body can be
seri ousl y damaged i f thi s method of towi ng i s attempted.
Sl i ng-type Equi pment
-
The tow truck uses metal cabl es
wi th hooks on the ends. These hooks go around parts of
the frame or suspensi on and the cabl es l i ft that end of
the vehi cl e off the ground. The vehi cl e' s suspensi on and
body can be seri ousl y damaged i f thj s method of towi ng
i s at t empt ed. Thi s met hed of t owi ng t he CR- V i s
unaccePtabl e.
The onl v recommended way of towi ng the CR-V i s on a
f l at - bed t r uck. Two wheel dr i ve CR- V' s may al so be
towed wi th al l four wheel s on the ground.
Towi ng t he f our - wheel dl i ve CR- v wi t h onl y t wo
wheel s on the ground wi l l damage parts of the 4wD
system. It this vehicle is damaged, it should be towed
on a flat-bed truck ol trailel.
It the 2 wheel drive CR-v is towed wiih all tour wheels
on the ground, do the following:
Manual Transmission
. Rel ease the parki ng brake.
. Shi ft the transmi ssi on i n Neutral
Automatic Transmission
. Rel ease the
parki ng brake.
. Sta rt the engi ne.
. Shi ft to
l D.l
posi ti on. then
E
posi ti on.
. Turn off the engi ne.
l mpr oper t owi ng pr epar at i on wi l l damage t he
transmi ssi on. Fol l ow the above procedure exactl y. l f
you cannot shift the transmission or start the engine,
the vehicle must be transported on a flat-bed truck.
lf the vchicle is towed with four wheels on the ground,
il is best to tow the vehicle no larther than 50 miles
(80
km), and keep the speed below 35 mph {55 km/h).
Tryi ng to l i ft or tow the vehi cl e by i he bumpers wi l l
cause serious damage. The bumpers ale not dosigned
to support the vehicle's weight.
Front:
Rear:
lOwlNG HOOKS .nd
TIE DOWN BRACKETS
TIE DOWN BRACKET
1-21
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Service Precautions
Parts Marking Locations
To deter vehi cl e theft, cenai n maj or components are marked wi th the vehi cl e i denti fi cati on number
{Vl N). Ori gi nal parts
wi l l have sel f-adhesi ve l abel s or l abel s attached wi th a break-off bol t. Repl acement body parts
wi l l have sel f-adhesi ve
l abel s, and repl acement engi ne and transmi ssi on parts
wi l l be stamped wi th a code tor spare
parts.
NOTE:
. Be careful nottodamagethe parts
marki ng l abel sduri ng body repai rs. Maskthe l abel s before repai nti ng.
'
Label l ocati on l etters wi thout parenthesi s
i ndi cate ori gi nal parts. Letters wi th parenthesi s
i ndi cate repl acement pans.
A,
(A):
Engi ne
B,
(B):
Transmi ssi on
C,
(C):
Front Bumoer
D,
(D);
Hood
E,
(E):
Tai l gate
F, (F):
Rear Bumper
G,
(G):
Front Fenders
(Lefr
and Ri ght)
H,
{H): Front Doors
(Left
and Ri ght}
l ,
(l ):
Rear Doors (Left
and Ri ght)
J,
(J):
Outer Si de Panel
(Left
and Ri ght)
1-22
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Precautions for Real-time 4WD
(Four-wheel
Drivel
Under nor mal condi t i ons, t he vehi cl e i s i n 2WD
( f r ont - wheel
dr i ve) . However , t he syst em wi l l i nst ant l y t r ansmi t
appropri ate dri vi ng force to the rear wheel s {dependi ng on the dri vi ng force of the front wheel s and the road condi tons)
The Real -ti me 4WD-Dual Pump System does not have a manual swi tch to di sabl e the 4WD system. Whenever servi ce
work requi res spi nni ng the front or rear wheel s wi th the engi ne, al ways l i ft up and support the vehi cl e so al l l our wheel s
are off the ground (see page 1- 19).
1-23 www.emanualpro.com
Specifications
Standards and Servi ce Li mi ts ............... 2-2
Desi gn Speci f i cat i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Body Speci fi cati ons ..........2-14
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MEASUREMENT STANDAFD INEWI SERVICE LIMIT
l gni t i on coi l Rat ed vol t age V
Pr i mar y wi ndi ng r esi st ance 0 at 68' F
( 20' C)
1 2
0. 63 0. 77
l gni t i on wi r e Besi st ance at 68"F
(20
C) kt l 25 max.
Fi ri ng order 1 3 4 - 2
Spark
pl ug Type
Gap
See Sect i on 4
1. 0
-
1. 1
( 0. 039 -
0. 043)
l gni t i on t i mi ng At i dl e BTDC 1 6 1 2 { Re d )
Al t er nat or bel t *r Def l ect i on wi t h 98 N { 10 kgf , 22 l bf ) 8. 5 11. 510. 33 0. 45) wi t h used bel t
5. 5
-
8. 0
(0. 22 -
0. 31) wi t h new bel t
Bel t t ensi on N {kgf , l bt )
Measured wi t h bek t ensi on gauge
340
-
490 {35
-
50, 77 110) wi t h used bel t
690 880
(70
90, 150
-
200i wi t h new bel t
Al t ernat or Output A
(at
13.5 V, hot and 6,000 alternator rpm AII
M/I
Brush l engt h
95
90
10. 5
( 0. 41)
1. 5
(0. 06i
St ani ng mot or Output kW A/f
Mi ca dept h Mf i
Commut at or runout
Commut at or O. D.
Brush l engt h
Brush spri ng t ensi on N
(kgf ,
l bf )
1 . 1
1 . 0
0. 5
-
0. 8 {0. 02
-
0. 03)
0, 0. 02
( 0
0. 0008)
27. 9 28. 0
( 1. 0984
1. 1024)
14. 0 14. 5
(0. 55
0. 57)
13. 7
-
17. 7
(1. 40 -
1. 80, 3. 09
-
3. 97)
0. 2
(0. 008)
0. 0s
(0. 002)
27. 0
( 1. 06)
9. 0
(0. 35)
Standards and Service Limits
Engine Electrical
-
Section 4
' 1
When usi ng a new bel t , ddi ust def l ect i on t o new val ue. Run t he engi ne f or 5 mi nut es t hen t ur n i t of { . Beadi ust def l ect i on t o used bel t val ue.
Cylinder Head/Valve Train
-
Section 6
MEASUREMENT STANDARD {NEW} SERVICE LIMIT
Compressi on 250 rpm and Nomi nal
wi de open t hrot t l e Mi ni mum
kPa
(kgf l cm' , psi ) Maxi mum vari at i on
1 ,230
i'12 .5 , 11Al
930
(9. s,
135)
200 12. 0, 2al
Cyl i nder head Warpage
Hei ght 131. 95
-
132. 05 { 5. 195
-
5. 199)
0. 05 {0. 002)
Camshaft End pl ay
Camshaf t t o hoi der oi l cl ear ance
Tot al runout
Cam l obe hei ght
' 97, ' 98
model s l N
EX
' 99, ' 00
model s l N
EX
0. 05 0. 1s
(0. 002
0. 006)
0. 030
-
0. 069
(0. 0012 -
0. 0027)
0. 03 { 0. 001) max.
33.204 \1.30721
33. 528 {1. 3200)
33. 1 16
\ 1 . 321 4)
33. 528 {' 1. 3200)
0. 5
(0. 02)
0. 15
(0. 006)
0. 04
(0. 002)
Val ve cl earance
(Col d)*
l N
EX
Val ve st em O. D. l N
EX
St em' t o-gui de cl earance l N
EX
0. 08
-
0. 12
(0. 003
0. 005)
0. 16 0. 20
(0. 006 -
0. 008)
6. 580
-
6. 590
(0. 2591
0. 2594)
6. 550
-
6. 560
(0. 2579
0. 2s83)
0. 02
-
0. 05 {0. 00t 0. 002)
0. 05
-
0. 08
(0. 002
0. 003)
u* to.rutt
6. 52l O. 257l
0. 08 {0. 003i
0. ' 1t
(0. 004)
wi dt h t N
EX
St em i nst al l ed hei ght l N
EX
1. 25
-
1. 55
(0. 049 -
0. 061)
1. 25 1. 55
( 0. 049 -
0. 061)
40. 765
-
41. 235 {1. 6049 1. 6234)
42.765
-
43.235i'1.6837
-
1.70221
2. 0
(0. 08)
2. 0 (0. 08)
41. 485 {1. 6333}
43. 485 {1. 7120i
Val ve spr i ng Fr ee l engt h l N
EX
42. 36
(1. 668i
44.32 t1 .1 451
Val ve gui de I , D, I N
EX
I nst al l ed hei ght t N
EX
6. 61 6. 63 10. 260
-
0. 261)
6. 61 6. 63 {0. 260
-
0. 261i
13. 75
-
14. 25 10. 541 0. 561i
15. 75
-
16. 25
{0. 620 0. 640i
6. 6510. 2621
6. 65
(0. 262i
*:
Measured bet ween t he camshaf t and rocker arm,
2-2
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Engine Block
-
Section 7
o
o
*1:
' 97, ' 98
model s 15 mm
(0. 6
i n)
' 99, ' 00
model s 20 mm
(0. 8
i ni
Uni t of l engt h: mm
( i n)
MEASUREMENT STANDARD
(NEWI
SERVICE LIMIT
Cyl i nder bl ock Warpage of deck surface
Bore di amet er
Bore t aper
0. 07
(0. 003) max.
84. 00
-
84. 02
(3. 307
3. 308)
0. 10
(0. 004)
84. 07
(3. 310)
0. 05
(0. 002)
Pi st on Ski rt O. D. *1t rom bot t om of skart
Cl earance i n cyl i nder
Groove wi dt h {For ri ngi Top
Second
oi l
83. 98
-
83. 99
(3. 306 -
3. 307)
0. 01
-
0. 04
(0. 0004 -
0. 00161
1. 240
-
1. 250 {0. 0488
-
0. 0492)
1. 220 1. 230 {0. 0480
-
0. 0484)
2. 805 2. 825 10. 1104
-
0. 1112)
83. 97
(3. 306)
0. 05 {0. 002)
1. 26
(0. 0s0)
1. 25
(0. 049)
2. 44l o. 112l
Pi st on ri ng Ri ng-t o' groove cl earance ToP
Second
Ri ng end gap ToP
Second
oi l
0. 055
-
0. 080
(0. 0022 0. 0031)
0. 035 0. 060
(0. 0014 -
0. 0024)
0. 20 0. 30
(0. 008 -
0. 012)
0. 40
-
0. 55
(0. 016
0. 022)
0. 20
-
0. 50
(0. 008 -
0. 020)
0. 13
(0. 005)
0. 13
(0. 005)
0. 60
(0. 024)
0. 70
(0. 028)
0. 70
(0. 028)
Pi st on Pi n o.D.
Pi n-t o-pi st on cl earance
20. 996
-
21. 000
(0. 8266 -
0. 8268i
0. 010
-
0. 017
(0. 0004 -
0. 0007)
Connect i ng rod Pin-to-rod interference
Smal l end bore di amet er
Large end bore di amet er Nomi nal
End pl ay i nst al l ed on crankshaf t
0. 015
-
0. 032
(0. 0006 -
0. 0013)
20. 968
-20. 981
10. 8255
-0. 8260)
48. 0
(1. 89)
0. 15
-
0. 30 {0. 006
-
0. 012i oro to.oroi
Crankshaf t Mai n
j ournal di amet er
No. 1, 2, 4 and 5
i our nal s
No. 3
j ournal
Rod
i ournal
di amet er
Taper
Out ol round
End
pl ay
Bunout
54. 976
-
55. 000
(2. ' l 644 -
2. 1654)
54. 970 54. 994
(2. 1642 -
2. 1651)
44.976
-
45.000 /.1.1707
-
1.71111
0. 005
(0. 0002)max.
0. 005
(0. 0002) max.
0. 10
-
0. 35
(0. 004 -
0. 0 r 4)
0. 03
(0. 001)max.
0. 010
(0. 00041
0. 010
(0. 0004)
0. 45
(0. 0r8)
0. 04
(0. 002)
Beari ng Mai n beari ng-t o-i ournal oi l cl earance
No. 1, 2, 4 and 5
i our nal s
No. 3
j ournal
Rod beari ng-t o-, ournal oi l cl earance
0.024
-
0.042 10.0009 0.0017)
0.030
-
0.048
(0.0012 -
0.0019)
0.020
-
0.038
(0.0008
0.0015)
0.06
(0.002)
0.06
(0.002)
0.05
(0.002)
o
2-3
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Standards andService Limits
Engine Lubrication Section 8
Cooling Section 10
Fuel and Emissions Section 11
MEASUREMENT STANDARO {NEWI SERVICE LIMIT
Engi ne oi l Capaci t y
f
( US qt , l mp qt )
4. 6
(4. 9,
4. 0)I or engi ne overhaul
3. 8 { 4. 0, 3. 3) f or oi l change, i ncl udi ng f i l t er
3. 5
(3. 7,
3. 1) f or oi l change, wi t hout I i l t er
Oi l pump I nner-t o-out er rot or cl earance
Pump housi ng-t o-out er rot or cl earance
Pump housi ng-t o rot or axi al cl earance
0. 04
-
0. 16
(0. 002 -
0. 006)
0. 10
- 0. 19 ( 0. 004 -
0. 007)
0. 02
-0. 07
(0. 001 -
0. 003i
0. 20
(0. 008)
0. 20
(0. 008)
0. 15
(0. 006)
Rel i ef val ve Pressure set t i ng at engi ne oi l t emp. 176' F
(80' C)
kPa
(kgt/cm,, psi)
At ldle
At 3,000 rpm
70
(0. 7,
10) mi n.
340 { 3. 5, 50) mi n.
MEASUREMENT
STANDARO INEW}
Radi at or Cool ant capaci t y ,
(US q1, l mp qt )
l l ncl udi ng
engi ne, heat er,
I
Lcool i ng
l i ne and reservoi rl
Reservoi r capaci t y:
0. 61
( 0. 63
US qt , 0. 53l mp qt )
M/T
5. 9 {6. 2, 5. 2}t or overhaul
3. 9
(4. 1,
3. 4i f or cool ant change
6. 0
(6. 3,
5. 3i f or overhaul
4. 0
(4. 2,
3. 5) f or cool ant change
Radi at or cap Openi ng pressure kPa
(kgf / cm?, psi ) 93
-
123 ( 0. 95 -
1. 25, 14 18)
Thermost at Starts to open
'F
1"C)
Ful l y open
' F
("C)
Val ve l i f t at t ul l y open
169
-
176
(76 -
80)
194
(90)
8. 0 ( 0. 31i mi n.
Cool i ng f an Thermoswi t ch
"ON"
t emperat ure
"F
{' C)
Thermoswi t ch
"OFF"
t emperat ure
' F
(' C)
196
-
203
(91 -
95)
Subt ract 5
-
14 (3 -
8) t rom act ual
"ON"
t emperat ure
MEASUREMENT
STANDARD INEW}
Pressure regul at or Pressure with regulator vacuum hose disconnected
kPa (kgf l cm' , psi )
' 97, ' 98
model s
'99, '00
rnodels
260
-
31012. 7 3. 2, 38- 46)
270
-32012. 8
3. 3, 40
-
471
Fuel t ank
Capaci t y /
(US gal , l mp gal ) 58
( 15. 3,
12. 8)
E ngi ne l dl e speed wi t h headl i ght s and cool i ng f an of f rpm
' 97
model
' 98
model
' 99, ' 00
model s
MT AT {E or
E
posi t i on)
750 r 50
730 1 50
750 t 50
750 r 50
7301 50
Fast i dl e rpm
' 97
model
' 98
model
' 99, ' 00
model s
1, 5001 200
1, 600 r 200
1, 5001 200
1, 5001 200
1, 600 r 200
l dl e CO % 0. 1 max.
2-4
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Uni t of l engt h: mm l i n)
Clutch Section 12
Manual Transmission Section 13
MEASUREMENT STANDARD INEWI SERVICE LIMIT
Cl ut ch
pedal Pedal hei ght t o f l oor
Stroke
Free play
Pedal pl ay
Di sengagement hei ght t o f l oor
183
(7. 20)
135- 14515. 31
-
5. 71)
7
-
2210.24
-
0.41J
1- 9
( 0. 04- 0. 35)
7212. 83) mi n.
Cl ut ch surf ace runout 0.05
(0.002)
max. 0.r5
(0.006)
Clutch disc Ri vet head dept h
Thi ckness
1. 2
-
1. 710. 05- 0. 07)
8. 4 9. 1
( 0. 33, 0. 36)
0. 2
(0. 01)
6. 0 i 0. 24)
Pressure pl at e Warpage
Di aphragm spri ng f i nger al i gnment
0. 03
( 0. 001) max.
0. 6
(0. 02)
max.
0. 15
(0. 006)
0. 8
(0. 03)
MEASUREMNT STANDARD INEW} I
SERVICE I-IMIT
Transmi ssi on
f l ui d
Capaci t y f
(US qt , l mp qt i
1. 7 11. 8, 1. 4) f or oi l c hange
2. 1
( 2. 2,
1. 8) { or over haul
Mai nshaf t End
pl ay
Di amet er of bal l beari ng cont act area
(cl ut ch
si de)
Di amet er of needl e beari ng cont act area
Diameter of ball bearing contact area
(t ransmi ssi on housi ng si de)
Runout
0. ' 11
-
0. 18
(0. 004 -
0. 007)
27. 977
-
27. 990
(1. 1015 -
1. 1020)
37. 984
-
38. 000
(1. 4954- 1. 4961)
27. 987
-
28. 000
(1. 1018 -
1. 1024)
0. 02
(0. 0011max.
Adjust
27. 94
( 1. 100)
37. 93
(1. 493)
27. 94
(1. 100)
0. 05 {0. 002)
Mai nshat t 3rd and
4t h gears
LD.
End pl ay
Thi ckness 3rd gear
4th gear
43.009
-
43.025 1 1.6933
-
1.6939)
0.06
-
0.21
(0.002 -
0.008)
34. 92 34. 97 11. 375
-
1. 377)
31.42
-
31.4'7 11.237
,
1.2391
43. 08011. 6961)
0. 3
(0. 01)
34. 811. 37)
31. 311. 23)
Mainshaft sth
gear
LD.
End
pl ay
Thi ckness
43.009
-
43.02511.6933 1.6939)
0.06
-
0.21
(0.002 -
0.008)
30.92
-
30.97 {1.217
-
1.219)
43. 08011. 6961)
0. 3
( 0. 01)
30. 8
( 1. 21)
Count ershaf t Diameter ol needle bearing contact area
Di amet er oI bal l beari ng and needl e beari ng cont act
Diameter o{ 1st gear contact area
Runout
36. 000
-
36. 015 {1. 4173
-
1. 4179)
24.987
-
25.000
(0.9837 -
0.9843)
36. 984
-
37. 00011. 4561
-1. 4567)
0. 02
(0. 001)max.
3s.95
(1.415)
24.94
(0.982)
36.93
(1.4s4)
0.0s
(0.002)
count ershat t 1st
gear
LD.
End pl ay
Thi ckness
43.009
-
43.025
(1.6933
1.6939)
0.06
-
0.18
(0.002 -
0.007i
26.9s,27.00
(1.061 -
1.063)
43. 08
(1. 696)
0. 2310. 009)
Countershaft 2nd
gear
t.D.
End pl ay
Thi ckness
47.009
-
47.025
(1.8507 -
1.8514)
0.07
-
0.14 10.003
,0.006)
2As2
-
2a.97
l 1.139-1.1411
47. 08 {1. 854)
0. 18
(0. 007)
Spacer col l ar
(Mai nshaf t
4t h
and 5t h gears)
t.D.
o. D.
Lengt h
A
' l s
I
l e
31 .002
-
31 .O12 11 .2205
,
1 .2205)
37. 989
-
38. 000
(1. 4956
1. 4961)
56.45
-
56.55 Q.222
-
2.2261
26. 03, 26. 08
(1. 025 -
1. 027)
31. 06
( 1. 223)
37. 94
(1. 494)
26.01 t1 .0241
Reverse i dl er gear t.D.
Gear-to-reverse
gear shaft clearance
20. 01 6
-
20. 043
(0. 7880,
0. 7891)
0. 036
-
0. 084
(0. 0014 -
0. 0033)
20.09
(0.7909)
0.16010.0063)
Synchro ri ng Ri ng- t o- gear cl ear ance
( r i ng pushed agai nsl gear ) 0.85
-
r.10
(0.033
0.043) 0. 4
(0. 02)
Dual cone Cl earance
(ri ng pushed agai nst gear)
Out er synchro ri ng t o synchro cone
Synchro cone-to-gear
Out er synchro ri ng-t o-gear
0.5 1.0
(0.02
0.04)
0.5
-
1.0
(0.02 -
0.04)
0.95
-
1.68
(0.037 -
0.066)
0.3
(0.01)
0. 3
( 0. 01)
0.6
(0.02)
Shift fork Fi nger t hi ckness 3rdl 4t h shi f t l ork
Except above
Fork-to-synchro sleeve clearance
7.4
-
7.6
(0.29 -
0.30)
6.2
-
6.4
(0.24-
0.2s)
0.35
-
0.65
(0.0' t4 -
0.026)
' t,
torag)
www.emanualpro.com
Standards and Service Limits
Manual Transmission {cont' d}
-
Section 13
11:
f ul easuri ng poi nt s
A
A
'Ay"
-l-...
_{-P)
A'
*2:
Measuri ng poi nt s
MEASUREMENT STANDARO INEW) SERVICE LIMIT
Raverse shift Iork Pawl groove width
Fork-to-reverse idler gear clearance
Groove wi dt h*l at A
a t B
Fork-to-5th/reverse shift shaft clearance*'
at B'
' 13. 0
-
13. 3
(0. 5' j -
0. 52)
0. 5
-
1. 1
(0. 02 -
0. 04)
7.O5
-
7.25 i.0.21 4
-
0.2451
7. 4
-7. 7
t 0. 29 0. 301
0. 05
-
0. 35
(0. 002 -
0. 014)
0. 4, 0. 8
(0. 02
0. 03)
18
(0.07)
0.5 {0.02)
1.0
(0.04)
Shift arm A Shift fork diameter at contact area
Shift arm A-to-shitt tork shaft clearance
12. 9
-
13. 0
(0. 508 -
0. 512)
0. 2
-
0. 5
(0. 008-
0. 020) 0. 6 {0. 024i
Shi f t arm C Shi f t arm C' t o-shi f t arm B cl earance
Diameter of shift arm B contact area
0. 05 0. 25
(0. 002
0. 01)
r2. 9
-
13. 0
(0. 508 -
0. 512)
Sel ect arm Select arm'to-shift arm A clearance
Di amet er of shi f t arm A cont act area
0. 05
-
0. 25
(0. 002
0. 01)
7. 9
-
8. 0
( 0. 311 -
0. 31s)
Sel ect l ever o.D.
Transmi ssi on housi ng cl earance
15. 94r
-
15. 968
(0. 6276 -
0. 6287)
0. 032
-
0. 086
(0. 0013 -
0. 0034)
Shift lever o.D.
Sh i f t ar m cover cl ear ance
r5. 941
-
15. 968
(0. 6276 -
0. 6287)
0. 032
-
0. 127
(0. 0013 -
0. 0050)
Differential
carner
Pi ni on shaf t cont act area LD.
Carri er-t o-pi ni on shaf t cl earance
Driveshaft, intermediate shatt contact area LD,
Carrier-to-driveshaft clearance
Carrierto-interrnediate shaft clearance
18. 010 18. 028
(0. 7091 -
0. 7098)
0. 027
-
0. 057
(0. 0011 -
0. 0022)
28. 005
-
28. 025
(1. 1026,
1. 1033)
0. 025
-
0. 066
(0. 0010, 0. 0026)
0.055
-
0.091 10.0022
-
0.0036)
0. 1
(0. 004)
0. 12 { 0. 005i
0. 15
( 0. 006i
Differential
pi ni on gear
Backl ash
t.D.
Pi ni on gearto-pi ni on shaft cl earance
0.05-0.r5 {0.002
-
0.006)
18.042
-
18.066
(0.7103 -
0.7113)
0.059
-
0.095 10.0023
-
0.0037) oru ro.ooor
Di t f erent i al t apered rol l r besri ng prel oac
St ani ng t orque N. m
(kgf . cm,
l bl . i ni
1. 4 2. 5i ' 14 26, 12
-231
Adjust
Transter Di amet er of rol l er beari ng cont act area
Transler shaft {driven
gear
side}
Translor shaft {middle of shaft)
Transter drive gear
Transl or dri ven gear shaf t {dri ven
gear si de)
Transt er dri ven gear shaf t
(spl i ned
si de)
Trans{er gear backlash
Tot al st art i ng t orque N. m
(kgi cm,
l bi i n)
33. 984
-
34. 000
(1. 337 -
1. 339)
21. 977
-
27. 99011. 101 1. 1021
40. 002
-
40. 01811. 575
-
1. 576)
35. 002
-
35. 01811. 378
-
1. 379)
26. 975, 26. 988
(1. 062
1. 063)
0. 06
-
0. 16 {0. 002 0. 006)
2. 64 3. 41
\ 21. 3, 35. 4, 23. 1 30. t |
33. 93
(1. 336)
27 .92
(1
.O99)
39. 95
(1. 573)
34. 95
(1. 376)
26. 92
(1. 060)
Adjust
Adjust
2-6
www.emanualpro.com
Uni t of l engt h: mm
( i n)
Automatic Transmission Section 14
MEASUREMENT STANDARO INEW} SERVICE LIMIT
Transmi ssi on
f l ui d
Capaci t y I {US
qt , l mp q0 4WD
2WD
6. 8
(7. 2,
6. 0) f or overhaul
2. 9
(3. 1, 2. 6) f or f l ui d change
5. 9 {6. 2, 5. 2)f or overhaul
2. 7 {2. 9, 2. 4}f or f l ui d change
Hydraul i c
pressure
kPa
(kgflcm', psi)
Li ne pressure at 2, 000 rpm i n
LI I
or
El
posi t i on
830
-
880
(8. 5 -
9. 0, 120 130) 780
(8. 0,
1' t 0)
1sl cl ut ch pressure at 2, 000 rpm i n Da
posi t i on
1st -hol d cl ut ch
pressure
at 2, 000 rpm I n l posi t i on
2nd cl ut ch pressure at 2, 000 rpm i n El
posi t i on 800
-
850
(8. 2
4. 7, 120 1241 760 t 7. 7, 1101
3rd cl ut ch pressure at 2, 000 rpm i n
E
posi t i on (' 97,
' 98
model s), or
E
posi t i on wi t h O/ D OFF i ndi cat or
l i ght ON
(' 99, ' 00
model s)
4t h cl ut ch
pressure at 2, 000 rpm i n gl posi t i on (' 97,
' 98
model s), or E
posi t i on wi t h O/ D OFF i ndi cat or
l i ght oFF
(' 99, ' 00
model s)
St al l speed rpm
(Check
wi t h vehi cl e on l evel ground) 2, 550 2, 400, 2, 700
Cl ut ch i ni t i al cl earance 1st
2nd, 3r d, 4t h
' l st -hol d
Cl ut ch ret urn spri ng f ree l engt h 1st , 2nd, 3rd, 4t h
' 1st -hol d
Cl ut ch di sc t hi ckness
Cl ut ch pl at e t hi ckness 2nd, 3rd, 4t h
1st , 1st -hol d
0. 65
-
0. 85
(0. 026 -0. 033)
0. 40
-
0. 60
(0. 016 -
0. 024)
0. 5
-
0. 8
(0. 020 -
0. 031)
31 . 1 11 . 22)
34. 6
( 1. 36)
1. 88
-
2. 00
(0. 074 -
0. 079)
' r. 95
-
2. 05 {0. 077 0. 081)
' 1. 55-
1. 65
(0. 061 -
0. 065)
29. 1
( 1. 15)
32. 6
(r. 28)
Unt i l
grooves worn out
Di scol orat i on
Di scol orat i on
Cl ut ch end pl at e t hi ckness Mark 1
(l st i
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Mark 8
Mark I
Mark 10
2. 05
-
2. r0
(0. 081 -
0. 083)
2. 15 2. 20
(0. 085 -
0. 0871
2. 25 2. 30
(0. 089, 0. 091)
2. 35 2. 40 {0. 093
-
0. 094}
2. 45
-
2. 50 {0. 096- 0. 098}
2. 55
-
2. 60
(0. 100 -
0. 102)
2. 65
-
2. 70
(0. 104 -
0. 106)
2. 75 2. 80 i 0. 108
-
0. 110)
2. 85
-
2. 9010. r 12 0. 114)
2. 95
-
3. 0010. 116 0. 118)
Di scol or at i on
Di scol orat i on
Cl ut ch end pl at e t hi ckness Mark 6
{2nd, 4t h) Mark 7
Mark 8
Mark 9
Mar k 10
Mar k 11
l vl ark 12
Mar k 13
Mar k 14
Mar k 15
Mar k 16
Mark 17
2. 55 2. 60 10. 100
-
0. 102)
2. 65 2. 70( 0. 104, 0. 106)
2. 75
-
2. 80
(0. 108
0. 110)
2. 85
-
2. 90
( 0. 112 - 0. r r 4)
2. 95 3. 00
( 0. 116- 0. 118)
3. 05
-
3. 10
( 0. 120 -
0. 122)
3. 15 3. 20
( 0. 124- 0. 126)
3. 25
-
3. 30
(0. 128
0. 130)
3. 35
-
3. 40
(0.
r32
-
0. 134)
3. 45
-
3. 50
(0. 136 -
0. 138)
3. 55 3. 60
( 0. 140 -
0. 142)
3. 65
-
3. 70
(0. 144 -
0. 146)
Di scol orat i on
Di scol or at i on
Cl ut ch end pl at e t hi ckness Mark 8
{3rdi
Mark I
Mar k 10
Mar k 11
Mar k 12
Mar k 13
Mar k 14
Mar k 15
Mar k 16
Mar k 17
2. 75
-
2. 80
( 0. 108
0. 110)
2. 85- 2. 90
( 0. 112 -
0. 114)
2. 95
-
3. 00
( 0. 116 -
0. 1' j 8)
3. 05 3. 10
(0. 120 -
0. 122)
3. 15- 3. 20 { 0. 124 0. 126)
3. 25
-
3. 30
(0. 128 -
0. r30)
3. 35
-
3. 40
(0. 132 -
0. r34i
3. 45
-
3. 50
(0. 136 -
0. 138)
3. 55
-
3. 60 {0. 140
-
0. 142)
3. 65
-
3. 70 {0. 144
-
0. r46)
Di scol orat i on
Di scol or at i on
Cl ut ch end pl at e t hi ckness Mark 1
( 1st
hol d) Mar k 2
Mark 3
No mark
Mark 6
Mark 7
2. 05 2. 10
(0. 081 -
0. 0831
2. r5 2. 20
(0. 085 -
0. 087)
2. 25
-
2. 30 {0. 089
-
0. 091}
2. 35
-
2. 40 10. 093
-
0. 094i
2. 45
-
2. 50
(0. 096-
0. 098i
2. 55
-
2. 60
(0. r00 -
0. 102)
2. 65
-
2. 70
(0. r04 -
0. 106)
(cont' d)
2-7
www.emanualpro.com
Standards and ServiceLi mi ts
Section 14 Automatic Transmission
(cont'd)-
MEASUBEMENT STANDARD {NEW} SERVICE LIMIT
Transmi ssi on Di amet er of needl e beari ng cont act area
On mai nshaf t st at or shaf t beari ng
On mai nshaf t 2nd gear
On mai nshaf t 4t h gear
col l ar
On mai nshaf t 1st gear col l ar
On count ershat t
(t orque
convert er housi ng si de)
On count ershaf t 3rd
gear
On count ershaf t 4t h gear
On count ershaf t reverse gear col l ar
On count ershaf t 1st gear col l ar
On sub-shaf t {t ransmi ssi on housi ng si dei
On sub shaf t 4t h gear col l ar
On reverse i dl er gear shaf t
I nsi de di amet er of needl e beari ng cont act area
On mai nshaf t 1st gear
On mai nshaf t 2nd gear
On mai nshaf t 4t h gear
On count ershaf t 1st gear
On count ershaf t 3rd gear
On count ershaf t 4t h gear
On count ershaf t reverse gear
On sub-shaf t 4t h gear
On reverse i dl er gear
f l everse i dl er gear shaf t hol der l . D.
End pl ay
Mai nshaf t 1st gear
Mai nshaf t 2nd gear
Mai nshaf t 4t h gear
Count ershaf t 1st gear
Count ershaf t 3rd gear
Countershaft 4th gear
Sub-shaft 4th gear
Reverse i dl er gear
Countershaft reverse gear
Sel ect or hub O. D.
Mai nshaf t 4t h gear col l ar l engt h
Mai nshaf t 4t h gear col l ar f l ange t hi ckness
Mai nshaf t 1st gear col l ar l engt h
23. 980- 23. 993
(0. 9441 -
0. 9446)
35. 975 35. 99' !
(1. 4163
1. 4169)
31. 975 31. 991
( 1. 2589
1. 2595i
30.975
-
30.991 11.2195
-
1.2201l'
36. 004
-
36. 017
(1. 4175 -
1. 4180)
35. 980 35. 996
(1. 4165
1. 4172)
27. 980
-
27. 993
( 1. 1016 -
1. 1021i
31. 975- 31. 991
( 1. 2589 - ' j . 2595i
31. 975- 31. 991
( 1. 2589 -
1. 2595)
25. 991
-
26. 000
(1. 0233 -
1. 0236)
22. 9935
-
23. 006s
(0. 9053
0. 9058)
13. 990
-
r4. 000
(0. 5508 -
0. 5512)
35. 000 35. 016
(1. 3780
1. 3786)
41. 000
-
41. 016
( 1. 6142 -
1. 6148)
38. 000
-
38. 016
(1. 4961 -' 1. 4967)
38. 000
-
38. 016
(1. 496' 1 -
1. 4967)
41. 000 41. 016
( 1. 6142
1. 6148)
33. 000
-
33. 016
(1. 2992
1. 2998)
38. 000
-
38. 016
(1. 4961 -
1. 4967)
32. 000
-
32. 016
(1. 2598 -
1. 2605)
18. 007
-
18. 020
(0. 7089 -
0. 7094)
14. 416 14. 434
(0. 5676
0. 5683)
0. 05
-
0. 16 {0. 002
-
0. 006)
0. 05
-
0. 13
(0. 002 -
0. 005)
0. 05, 0. ' 16
(0. 002
0. 006)
0. 1 0. 5
(0. 004
0. 020)
0. 05 0. 17 {0. 002 0. 007)
0. 10 0. 18
(0. 004
0. 007)
0. 0s 0. 17
(0. 002 -
0. 007)
0. 05
-
0. 18
(0. 002 -
0. 007)
0. 10, 0. 25( 0. 004 0. 010)
51. 87
-
51. 90
(2. 042 -
2. 043)
49. 50
-
49. 55
(1. 9488 -
| . 9508)
4. 435 4. 525
( 0. 1746- 0. 1781)
27. 00, 27. 05 { 1. 063' 1. 065i
Wear or damage
Wear or damage
Wear or damage
Wear or damage
il*=lo'. d"'.n"n"
Wear or damage
Count ershaf t di st ance col l ar l engt h 38. 97
-
39. 00
(1. 534 -
1. 535)
39. 02 39. 05
(1. 536,
1. 537)
39. 07 39. 10
(1. 538
1. 539)
39. 12
-
39. 15
( 1. 540 -
1. 541)
39. 17
-
39. 20
(1. 542 *
1. 543)
39. 22
-
39. 25 11. 544
-
1. 545)
39. 27 39. 30 1' 1. 546
-
1. 547i
38. 87 38. 90 {1. 530 1. 531)
38. 92 38. 95
(1. s32
1. 533)
Count ershaf t 3rd
gear
col l ar l engt h
Count ershaf t reverse gear col l ar l engt h
Count ershaf t reverse gear col l ar f l ange
t hi ckness
Count ershaf t 1st gear
col l ar l engt h
Count ershaf t l st gear col l ar f l ange t hi ckness
Sub-shaf t 4t h gear col l ar l engt h
Sub shat t 4t h gear col l ar f l ange t hi ckness
21.15
-
21.20 rc.4327
-
0.4346)
14. 5, 14. 6
(0. 57' t ,
0. 575)
2. 4
-
2. 6
(0. 094 -
0. 102)
14. 5
-
14. 6
(0. 571 -
0. 575)
2. 4
-
2. 6
(0. 094 -
0. 102)
24. 0 24. 1
(0. 945
0. 949)
2. 95
-
3. 10
( 0. 116 -
0. 122)
Wear or damage
Wear or damage
Wear or damage
2-8
www.emanualpro.com
2-9
Automatic Transmission
-
Section 14
o
Uni t of l engt h: mm
(i n)
o
MEASUREMENT STANDARD
(NEWI
SERVICE LIMIT
Transmi ssi on Mai nshaf t 2nd gear t hr ust washer t hi ckness 3. 97
-
4. 00 10. 156
-
0. 157)
4. 02
-
4. 05 {0. 158
-
0. 159)
4. 07
-
4. 1010. 160 0. 161)
4. 12
-
4. 15
( 0. 162 -
0. 163)
4. 17 4. 20
(0. 164
0. 165)
4. 22
-
4. 25 10. 166
-
0. 167 )
4. 27
-
4. 30
(0. 168 -
0. 169)
4. 32 4. 35
( 0. 170- 0. 171)
4. 37
-
4. 40
(0. 172
0. 173)
4. 42
-
4. 45
(0. 174 -
0. r75)
I
I
I
Wear or damage
Thrust washer t hi ckness
l ' rai nshaf t bal l beari ng l ef t si de
Mai nshaf t 1st gear
Count ershaf t 3rd gear spl i ned washer
Sub-shaft 4th gear
thrust washer
2. 95 3. 05
( 0. 116
0. 120)
2. 43
-
2. 50
(0. 096 -
0. 098)
4. 9s
-
5. 00
(0. 195 -
0. 197)
2. 93
-
3. 00
( 0. 115 -
0. 1181
Wear or damage
t
I
Wear or damage
One-way cl ut ch cont act area LD.
Count ershaf t 1st gear
Parki ng gear
Mai nshaf t f eed pi pe A, O. D.
(at
15 mm t rom end)
Mai nshaf t f eed pi pe B, O. D.
(at
30 mm f rom end)
Count ershaf t t eed pi pe
O. D. l at 15 mm f rom end)
Sub-shaf t f eed pi pe O. D.
(at
15 mm f rom end)
Mai nshat t seal i ng ri ng t hi ckness
(29
mm and 35 mm)
Mai nshaf t bushi ng I . D.
Mai nshaf t bushi ng l . D.
Count ershaf t bushi ng l . D.
Sub shat t bushi ng LD.
Mai nshaf t seal i ng ri ng groove wi dt h
83. 339 83. 365
(3. 2810
3. 2821)
66. 685
-
66. 698
(2. 6254 -
2. 6259)
8.97
-
8.98
(0.353 -
0.354)
5.97 5.98 {0.2350
-
0.2354)
7. 97
-
7. 98
(0. 3138 -
0. 3142)
7. 97
, 7. 98 (0. 3138 -
0. 3142)
1. 87
-
1. 97
(0. 074-0. 078)
6. 018
-
6. 030
(0. 2369 -
0. 2374)
9. 000
-
9. 015
(0. 3543 -
0. 3549)
8. 000
-
8. 022
(0. 3150-0. 3158)
8. 000
-
8. 022
(0. 3150
0. 3158)
2. 025
-
2. 075
(0. 0797
0. 0811)
Wear or damage
Wear or damage
8. 95
(0. 352)
5. 95
(0. 234)
7. 95
(0. 313)
7. 95 {0. 313)
1 . 42 $. O72)
5. 045
(0. 2380)
9. 03
(0. 356)
8. 03
(0. 316)
8. 03
(0. 316)
2. 095
(0. 082)
ATF pump ATF pump gear si de cl earance
ATF pump gear' t o body cl earance Dri ve
Dri ven
ATF pump dri ven gear LD.
ATF pump dri ven gear shaf t O. D.
0. 03
-
0. 05
(0. 001 -
0. 002)
0. 1050 0. 1325
(0. 004,
0. 005)
0. 0350
-
0. 0625 10. 001
-
0. 002)
14. 016* 14. 034
(0. 5518
0. 5525)
13. 980
-
13. 990 {0. 5504 0. 5508)
0. 0710. 003)
Wear or damage
Wear or damage
Regul at or
valve body
Seal i ng r i ng cont act ar ea l . D, 35. 000 35. 025 {1. 3780
-
1. 3782) 35. 050
(1. 3799)
Stator shaft I nsi de of di amet er oI beari ng cont act area
On t orque convener si de
On ATF pump
si de
2't .o00 27 .021 I
'1
.063
,
1 .064)
29. 000
-
29. 01311. r 417 1. 1422)
Wear or damage
Wear or damage
Shi f t i ng devi ce and
parki ng brake con'
t rol
Reverse shi t t f ork f i nger t hi ckness
Parking brake
pawl
Parki ng gear
5.90
-
6.00 {0.232,0.236) 5. 40
(0. 213)
l Wear
or ot her def ect
Servo body Shi f t f ork shat t bore l . D.
Shi f t f ork shat t val ve bore l . D.
14. 000
-
14. 010
(0. 55' l 2 -
0. 5516)
37. 000
-
37. 039
(1. 4567 -
1. 4582) 37. 045
(1. 4585)
Differential
car r i er
Pi ni on shaf t cont act area LD.
Carri ert o-pi ni on shaf t cl earance
Dri veshaf vi nt ermedi at e shaf t cont act are l . D. 2WD
4WD
Carri er t o dri veshal t cl earance
Carri er-t o-i nt ermedi at e shaf t cl earance
' 18. 010
-
18. 028 10. 709
-
0. 710)
0. 023
-
0. 057 {0. 001
-
0. 002}
26. 025
-
26. 045
(1. 0246 -
1. 0254)
28. 025
-
28. 045
(1. 103 -
1. 104)
0. 045
-
0. 08610. 002 0. 003)
0. 075
-
0. 111 10. 003- 0. 004)
0. r {0. 004)
0. 12
(0. 005)
0. 15
(0. 006)
Differential
prnron gear
Backl ash
t.D.
Pi ni on gear' to-pi ni on shaft cl earance
0.05
-
0.15
(0.002 -
0.006)
18.062
-
18.066
(0.7103 -
0.7113)
0.055
-
0.095 10.0022
-
0.0037) otu to.oout
Set r i ng- t o- bear i ng out er r ace cl ear ance 0 0. 15
(0 -
0. 006) Adjust
Transf er Di amet er of rol l er beari ng cont act area
Transf er shaf t
(t ransf er gear si de)
Transf er shaf t
(mi ddl e
of shaf t )
Transfer drive gear
Transf er dri ven gear shaf t {dri ven
gear si de)
Transf er dri ven gear shaf t {spl i ned si de)
Transf er gear backl ash
Tot al st art i ng t orque N. m
(kgf . cm,
l bf . i n)
38. 485 38. 500
(1. 515 -
1. 516)
27 .917
-
21 .990 |.1.101
-
1.102)
40. 002
-
40. 018
(1. 575 -
1. 576)
35. 002 35. 018
(1. 378 -
1. 379)
26. 975 26. 988
(1. 062 -' l . 063)
0. 060 0. 160
(0. 002 -
0. 006)
2. 64
-
3. 41
127. 3
-
35. 4, 23. 1 30. 71
38. 43
( 1. 513)
27. 92
(1. 099)
39. 95
(1. 573)
34. 95
(1. 376)
26. 92
(1. 060)
Adi ust
Adi ust
(cont' d)
www.emanualpro.com
Standards and Service Limits
Automatic Transmission
(cont' dl -
Section 14
Differential
(4WDl *
Section 15
MEASUREMENT STANOABD {NEW'
Steering Section 17
*
When usi ng a new bel t , adj ust def l ect i on or t ensi on t o new val ues. Run t he engi ne f or 5 mi nut es t hen t urn i t of f .
Readj ust del l ect i on or t ensi on t o used bel t val ues.
MEASUREMENT
STANDARO INEWI
Wire Dia. o. D. Fiee Length No. of Coils
Spri ngs Regul at or val ve spri ng A
Regul at or val ve spri ng B
St at or react i on spri ng
Modul at or val ve spri ng
Torque convener check val ve spri ng
'97
model
'98
-
00 models
Cool er rel i ef val ve spri ng
Rel i ef val ve spri ng
2nd ori l i ce cont rol val ve spri ng
1-2 shi t t val ve spri ng
2 3 shi f t val ve spri ng
3-4 shi f t val ve spri ng
1st accumul at or spri ng
4t h accumul at or spri ng B
4t h accumul at or spri ng A
2nd accumul at or spri ng A
3rd accumul at or spri ng A
2nd accumul at or spri ng B
3rd accumul at or spri ng I
3rd sub accumul at or spri ng
2nd accumul at or spri ng C
Lock-up shi f t val ve spri ng
Lock-up t i mi ng val ve spri ng
Lock' up cont rol val ve spri ng
3' 4 ori f i ce cont rol val ve spri ng
Servo cont rol val ve spri ng
CPB val ve spri ng
4t h exhaust val ve spri ng
1. 8 10. 071)
1. 8 i 0. 071)
4. 5
( 0. 177)
1. 4 {0. 055)
1. 1
(0. 043)
1. 2
(0. 047)
1. 0
(0. 039)
1. 1
( 0. 043)
0. 7
(0. 028)
0. 9
(0. 035)
0. 9
(0. 035)
0. 9
(0. 03s1
2. 1
(0. 083)
2. 3
(0. 091)
2. 6
(0. 102)
2. 410. 094)
2. 8
( 0. 110)
1. 6
(0. 063)
2. 1
(0. 083)
2. 7 {0. r06)
2. 2l O. OA7)
0. 9
(0. 035)
0. 9
(0. 035)
0. 7
(0. 028)
0. 6
(0. 024)
1. 0
(0. 039)
0. 9
(0. 035)
0. 9
(0. 035)
14. 7
(0. 579)
9. 6
(0. 378)
35. 4 {1. 394}
9. 4
(0. 370)
8. 4
(0. 331)
8. 4
(0. 331)
8. 4
(0. 331)
8. 6
(0. 3391
6. 6
(0. 260i
7. 6 {0. 299}
7. 6 {0. 299)
7. 6 {0. 299)
16. 0
(0. 630)
10.2 to.402l
17. 0
(0. 669)
29. 0 \ 1. 1421
' r7. 510. 689)
9. 0
(0. 354)
31. 0
( 1. 220)
17. 0 (0. 669)
14. 510. 571)
7. 610. 299i
8. 1 { 0. 319}
6. 6
(0. 260)
6. 6
(0. 260i
8. 1
(0. 319)
8. 1 {0. 319)
6. t
(0. 240)
87. 8
(3. 457)
44. 011. 1321
3 0 . 3 1 r . 1 9 3 )
35. 0 {1. 378)
36. 4 {1. 433)
32. 4 t l . 216J
33. 8 { r . 331)
37. 1
( 1. 461)
34. 8
(1. 370)
41. 3
(1. 626)
57 . 0
(2. 2441
57 .0 12.2441
89. 1
(3. 508)
51. 6
( 2. 031)
88. 4
(3. 480)
39. 011. s35)
94. 313. 713)
20. 7 10. 8r5)
38. 2
(1. 504)
39. 0
(1. 535)
68. 0
(2. 677)
73.7 12.902)
8r . 4
( 3. 205)
38. 0 f l . 496)
37. 9
(1. 492)
52. 1
( 2. 051)
41 .2 t\ .A5Al
36. 4
(1. 4331
r 1. 0
1. 9
10. 9
12.O
12.7
8. 2
13. 4
22. 0
26.4
26. 8
13. 8
14. 2
2. 9
15. 9
2. 6
6. 3
32. 0
47. A
20. 8
' 18. 3
' 19. 5
Capaci t y f
( US qt , l mp ql ) 1. 2
( 1. 3,
1. 1) at over haul
1. 0
( 1. 1,
0. 91 at f l ui d change
MEASUREMENT STANDARD INEWI
St eeri ng wheel Rot at i onal pl ay
at st eeri ng wheel ci rcumf erence
St ani ng l oad at st eeri ng wheel ci rcumf erence
N {kgf , l bl ) Engi ne runni ng
0- 10
( 0 -
0. 39)
29
(3. 0, 6. 6)
Gearbox Angle of rack$uide-screw loosened lrom locked position
'97, '98
models
'99, '00
models
10" 1 5"
20" MAX.
Pump Pump pressure wi t h shut of f val ve cl osed
kPa
(kgvcm,, psi)
6, 900
-
7, 800 (70
80, 995 1, 138)
Power steering
f l ui d
Recommended t l ui d
Fl ui d capaci t y For overhaul
I {US
qt , l mp q0 For reservoi r
Honda power
st eeri ng f l ui d.
0. 85
(0. 90, 0. 75)
0. 4 {0. 42, 0. 35)
Power st eeri ng
bel t *
Def l ect i on wi t h 98 N {1O kgl , 22l ht )
bet ween pul l eys
11. 0 14. 5
(0. 43
0. 57)wi t h used bel t
7. 5
-
10. 0
(0. 30
0. 40) wi t h new bel t
Bel t t ensi on N {kgt , l bf }
Measured wi t h bel t t ensi on gauge
390
-
540
(40 -
55, 88
-
121) wi t h used bel t
740-880
(75
90, 165 198)wi t h new bel t
2-10
www.emanualpro.com
t o
l
Suspension Section 18
Brakes Sec'tion 19
Air Conditioning Section 22
*
When usi ng a new bel t , adj ust def l ect i on or t ensi on t o new val ues. Run t he engi ne f or 5 mi nut es t hen t urn i t of f .
Readj ust def l ect i on or t ensi on t o used bel t val ues.
o
Uni t of l engt h: mm {i n)
MEASUREMENT STANDARD {NEW)
Wheel al i gnment Camber Front
Rear
Cast er Front
Tot al t oe Front
near
Front wheel t urni ng angl e I nward wheel
Out ward wheel
0"00' 1 1'
-
1"00' 1 1'
2"10' ! 1"
0 J 3 ( 0 1 1 / 8 )
r N 2 r i ( 1/ 161
1/ r 6)
37"00' ! 2
31' 30' (Ref erencei
Wheel beari ng End
pl ay Front
Rear
0
-
0. 05 {0- 0. 002}
0
-
0. 05
(0
0. 002i
Ri m runout Al umi num wheel Axi al
Badi al
St eel wheel Axi al
Radi al
STANOARD
(NEW)
SERVICE LIMIT
0
-
0. 7
(0
0. 03)
0, 0. 7
( 0 -
0. 03)
0 1. 0
(0 -
0. 04)
0
-
1. 0 {0
-
0. 04)
2. 0
(0. 08)
' r. 5
{0. 06)
2. 0 {0. 08)
1. s
(0. 06)
MEASUREMENT STANDARD INEWI
Parki ng brake
l ever
Pl ay i n st roke at 196 N
(20
kgf , 44l bf )
l ever f orce
To be l ocked when Dul l ed: 2
-
6 not ches
Foot brake pedal Pedal hei ght
(wi t h
t l oor mat removed)
Free pl ay
NT
155
(6
1/ 8)
161
( 6
5/ 16)
1 5
(1/ 16 -
3/ 16)
Mast er cyl i nder Pi st on-t o-pushrod cl earance 0
-
0. 4
(0-
0. 02)
Di sc brake Di sc t hi ckness Front
' 97, ' 98
model s
' 99, ' 00
model s
Di sc runout
Di sc paral l el i sm
Pad t hi ckness
Front
Front
Front
STANDARD {NEW' SERVICE LIMIT
22. 9
-
23. 1
(0. 902 -
0. 909)
23. 6 23. 8
(0. 929 -
0. 937)
10. 5
-
11. 5
(0. 4' t
0. 45)
21. 0
(0. 83)
21. 0
(0. 83)
0. 10 {0. 004)
0. 015
(0. 0006)
1. 6
(0. 06)
Rear brake drum LD.
Li ni ng t hi ckness
2r9. 9 220. 0
(8. 657 -
8. 661)
3. 9
-
4. 5
( 0. 15 -
0. 18)
221. O 8. 7011
2. 0
(0. 08)
MEASUREMENT STANDARD {NEWI
Ai r condi t i oni ng Lubri cant t ype:
KEI HI N SP 10
(P/ N
38897
-
Pl 3
-
A01AH or 38899
-
Pl 3
-
A01)
Lubri cant capaci t y Condenser
mf {f l oz, l mp oz) Evaporat or
Li ne or hose
Receiver
25
(5/ 6, 0. 9)
40 {1 1/ 3, 1. 4)
10 { 1/ 3, 0. 4)
10( . ] / 3, 0. 4)
Compressor
(KEI HI N)
Lubri cant t ype: SP 10
Lubri cant capaci t y ml
({l
02, l mp oz}
Stator coil resistance at 68'F
(20"C)
O
Pulley-to-pressuae
plate clearance
130' 3' {4 1f i ' 3o, 4. 6; "}
3. 05
-
3. 35
0. 51 0. 15
(0. 02
1 0. 006)
Compressor bel t * Def l ect i on wi t h 98 N
(10
kgl , 22l bl i
bet ween
pul l eys
7. 5
-
10. 5 {0. 30
-
0. 41) wi t h used bel t
5. 0
-
7. 0
(0. 20 -
0. 28) wi t h new bel t
Bel t t ensi on N
(kgf ,
l bf )
Measured wi t h bel t t ensi on gauge
390
-
540
( 40
55, 88- 120) wi t husedbel t
740
-
880 {75 90, 170
-
200) with new belt
2-11
www.emanualpro.com
Design Specifications
ITEM METRIC ENGLI SH NOTES
DI MENSI ONS Overal l l engt h
Overal l wi dt h
Overal l hei ght
Wheel base
Track Front
Rear
Seat i ng capaci t y
4, 510 mm
1, 750 mm
1, 608 mm
2,622 mrn
1, 533 mm
1, 534 mm
5 l f
177. 6 i n
68. 9 i n
63. 3 i n
103. 2 i n
60. 4 i n
60. 4 i n
WEI GHT
(USA)
Gross vehi cl e wei ght rat i ng (GVWR)
|
4, 165 t bs
WEI GHT (CANADA)
Gross vehi cl e wei ght rat i ng
(GVWR)
1, 900 kg
ENGI NE Type
Cyl i nder arrangement
Bore and stroke
Di spl acement
Compressi on rat i o
' 97, ' 98
mooers
' 99, ' 00
model s
Val ve t rai n
Lubrication system
Oi l pump di spl acement at 6, 000 engi ne rpm
Wat er pump di spl acement at 7, 600 engi ne rpm
Fuel requi red
Water-cooled, 4-stroke DOHC
gasol i ne engi ne
I nl i ne 4-cyl i nder, t ransverse
84. 0 x 89. 0 mm
. 1, 973
cm3
(m{)
9. 2
3. 31 x 3. 50 i n
120 cu- i n
9. 6
Bel t dri ven, DOHC
4 val ves per cyl i nder
Forced and wet sump, trochoid pump
501
(53
US qt , 44 l mp qt )/ mi nut e
1401
(148
US qt , 123 l mp qt )/ mi nut e
UNLEADED gasol j ne
wi t h 86
Pump Oct ane Number or Hi gher
STARTER Type
Normal out put
Nomi nal vohage
Hour rat i ng
Di rect i on of rot at i on
Wei ght
Pl anet ary gear reduct i on
A/ T: 1. 1 kW
M/T: 1.0 kW
12V
30 seconds
Clockwise as viewed from gear end
3. 7 kg 8. 2 l bs Approx.
CLUTCH Clutch type
Cl ut ch l aci ng area
MIT
MIT
Si ngl e pl at e dry, di aphragm spri ng
Torque convert er
203 cm, 31. 5 sq-i n
TRANSMI SSI ON Transmi ssi on t ype
Primary redLrction
MIT Synchronized s-speed torward, 1 reverse
El ect roni cal l y cont rol l ed
4-speed automatic, 1 reverse
Direct I : 1
Type Manual t ransmi ssi on
Gear rat i o 1st
2nd
3rd
4th
5th
Reverse
3. 500
1. 956
1. 344
1. 071
0. 812
3. 000*, . 3. 461*'
*1:
' 97
-
99 model s
*2:
' 00
model
Fi nal reduct i on Gear t ype
Gear rat ao
Si ngl e hel i cal gear
4.562
Transf er 0. 434
Rear di f f er ent i al 2. 533
Type Aut omat i c t ransmi ssi on
Gear rat i o 1st
2nd
3rd
4th
Reverse
2. 722
1. 079
0. 711
1. 955
Fi nal reduct i on Gear t ype
Gear rat i o
Si ngl e hel i cal gear
4. 357
Transfer 0.393
2-12
www.emanualpro.com
--
-
METRIC ITEM ENGLI SH NOTES
AI R CONDI TI ONI NG Cool i ng capaci t y 3, 520 Kcal / h
j
14, 000 BTU/ h
Compressor Type/ manut act urer
No. of cyl i nder
CaPaci t y
Max. speed
Lubri cant capaci t y
Lubri cant t ype
Scrol l / KEl Hl N
85. 7 mf / rev
|
5. 23 cu' i n/ rev
10, 000 rpm
1 3 0 mf
1
a l g I l o z
sP- 10
Condenser Type Corrugat ed f i n
Evaporat or Type Corrugat ed f i n
Bl ower Type
Mot or i nput
Speed cont rol
Max. capaci t y
Si r occo f an
200 w 112 v
4-Speeo
440 m3/h 15,500 cu fvh
Temperat ure cont rol
Compressor cl ut ch Type
Power consumpt i on
Dry, si ngl e pl at e, pol y-V-bel t dri ve
40 W max. / 12 V At 68' F
(20
C)
Bef ri gerant Type
Ouant i t y
HFC-134a 1R-134a)
zoo
o'
g 24j
an
oz
STEERI NG SYSTEM Type
Overal l rat i o
Turns, lock to lock
St eeri ng wheel di amet er
Power assisted, rack and
pinion
SUSPENSI ON Type Front
Bear
Shock absorber Front and Rear
I ndependent doubl e wi shbone, coi l spri ng
wi t h st abi l i zer
I ndependent doubl e wi shbone, coi l spri ng
wi t h st abi l i zer
Tel escopi c, hydraul i c ni t rogen gas t i l l ed
WHEEL ALI GNMENT Camber
Caster
Tot al t oe
Front
hear
Front
Front
Rear
0 i n
l n 1/ 16 i n
0 m m
l n 2 m m
0'
-
r"00'
2.10'
BRAKE SYSTEM Tvpe
Pad surface area
Li ni ng sur f ace ar ea
Par ki ng br ake
Front
Rear
Front
Rear
Tvpe
Power-assi st ed sel t -ad, ust i ng
ventilated disc
Power assisted self-adiusting drum
49 cm, x 2 7. 6 sq-i n x 2
73 cm, x2 11. 3 sq- i n x 2
Mechani cal act uat i ng, rear t wo wheel brakes
Drum brake
TIRE Si ze and pressure See t i re i nl ormat i on l abel .
ELECTRI CAL Baftery
Starter
Alternator
I n under-dash f use/ rel ay box
In under hood fuse/relay box
I n underhood ABS f use/ rel ay box
Headl i ght s
Front t urn si gnal l i ght s
Front parki ng l i ght s
Front si de marker l i ght s
Rear si de marker l i ght s
Rear t urn si gnal l i ght s
Erake/parking lights
Back-up l i ght s
Cei l i ng l i ght s {f ronvrear)
Li cense
pl at e l i ght
Spot l i ght s
Hi gh mount brake l i ght
l gni t i on key l i ght
Asht ray l i ght
Gauge l i ght s
I ndi cat or l i ght s
l l l Lrmi nat i on and
pi l ot I i ght s
Heat er i l l umi nat i on l i ght s
12 V, 36 AH/ s HR
12V 1. 0, 1. 1 kW
1 2 V 1 0 0 A
7. 5 A, 10 A, 15 A, 20 A
7. 5 A, 10 A, 15 A, 20 A, 30 A, 40 A
' 100
A
7. 5 4, 20 A. 40 A
12V 60/ 55 W
12 V- 21 W
(' 97
model ),
12 V
-
27 W
( ' 98- 00
model s)
12V 5 W {' 97 model ), 3 CP
(' 98 -
00 model s)
1 2 V - 8 W
1 2 V , 3 C P
1 2 V- 2 1 W
12 V 2115 W
1 2 V 2 1 CP
( 1 8
W)
1 2 V - 8 W
1 2 V - 8 W
1 2 V - 5 W
1 2 V
- 2 1 W
1 2 V- 1 . 4 W
1 2 V 1 . 4 W
1 2 V 1 . 4 W, 3 W, 3 . 4 W
12V- 0. 84W, 1. 12 W, 1. 4 W, 3 W, LED
12 V
-
0. 84 W, 1. 4 W, LED
1 2 V , 1 . 4 W
2-13
www.emanualpro.com
Body Specifications
Uni t : mm
( i n)
2-14
www.emanualpro.com
Mai ntenance
Lubri cat i on Poi nt s
. . . . . . . . . . . . 3-2
Maintenance Schedule for 1997 Model
(Normal Condi t i ons) . . . ". 3-4
Mai ntenance Schedul e for 1997 Model
(Severe
Condi ti ons)
."... 3-6
Maintenance Schedule for 1998
-
2000 Models
(Normal Condi t i onsl . . ' . " 3-8
Maintenance Schedule for 1998
-
2000 Models
(severe
Condi ti onsl
' ....' 3-10
I
www.emanualpro.com
Lubrication Points
For the detai l s of l ubri cati on poi nts and type of l ubri cants to be appl i ed. refer to the i l l ustrated i ndex and vari ous work pro-
cedures
(such
as Assembl y/Reassembl y, Repl acement, Overhaul , Instal l ati on, etc.) contai ned i n each secti on.
Recomm6nded Engine Oil
Engi ne oi l vi scosi ty for ambi ent temperature ranges
100' F
-30 -20 .10
0 10 20 30 40'c
r1:
Al ways use Genui ne Honda Manual Transmi ssi on Fl ui d {MTF). Usi ng motor oi l can cause sti ffer shi fti ng because i t
does not contai n the orooer addi ti ves.
*2:
Al ways use Genui ne Honda Premi um Formul a Automati c Transmi ssi on Fl ui d
(ATF).
Usi ng a non-Honda ATF can affect
shi ft
qual i tv.
+3r
Al ways use Genui ne Honda DOT 3 Brake Fl ui d. Usi ng a non-Honda brake fl ui d can cause corrosi on and decrease the
l i fe of the system.
*4:
Al ways use Genui ne Honda Power Steeri ng Fl ui d. Usi ng any other type of power steeri ng fl ui d or automati c transmi s-
si on fl ui d can caused i ncreased wear and poor steeri ng i n col d weather.
API SERVICE LABEL
/,.*-G\
/.'z-\e\
t / 6 A E \ l
l-;-1 5w-30 /---l
w
API CERTIFICATION SEAL
ffi
-20
0 20
NO. LUBRICATION POINTS LUBRICANT
Engi ne
API Servi ce Grade: Use SJ
"Energy
Conservi ng" grade oi l . The oi l
cont ai ner may al so di spl ay t he API Cert i t i cat i on seal shown
bel ow. Make sure i t says
"For
Gasol i ne Engi nes. " SAE vj scosi t y:
See chart bel ow.
2
Transmi ssi on Manual Genui ne Honda MTF*1
Aut omat i c Genui ne Honda Premi um Formul a Aut omat i c Transmi ssi on Fl ui d
(ATF)*'
3 Rear di f f erent i al Genui ne Honda CVT Fl ui d
4 Brake l i ne
(i ncl udes
ABS l i ne) Genui ne Honda DOT 3 Brake Fl ui d*3
5 Cl ut ch Li ne Brake f l ui d DOT 3 or DOT 4*3
6 Shi f t l ever pi vot s ( Manual
t r ansmi ssi on) Grease wi t h mol ybdenum di sul t i de
1 Rel ease f ork
(Manual
t ransmi ssi on) LJrea Grease UM264 P/ N 4' 1211
-
PYs
-
305
I Power st eer i ng gear box
Steering grease P/N 08733
-
B070E
Thr ot t l e cabl e end { Dashboar d l ower panel hol el Si l i cone grease
1 0
l 1
1 2
1 4
Throt t l e cabl e end
(Throt t l e
l i nk)
Brake mast er cyl i nder
pushrod
Pedal l i nkage
Bat t ery t ermi nal s
Fuel f i l l l i d
Cl ut ch mast er cyl i nder pushrod
Mul t i purpose grease
1 6
1 7
1 8
1 9
20
Hood hi nges and hood l ock
Tai l gat e hi nges
Hat ch gl ass hi nges
Door hi nges, upper and l ower
Door openi ng det ent
Honda Whi t e Li t hi um Grease
2 1
22
Cal i per Pi st on seal , Dust seal ,
Cal i per pi n, Pi st on
Shi l t cabl e and sel ect cabl e {Manual t ransmi ssi on)
Si l i cone gr ease
23 Brake l i ne i oi nt s
(Front
and rear wheel house) Rust prevent i ves
24 Power st eeri ng syst em Genui ne Honda Power St eeri ng Fl ui d-.
25
Ai r condi t i oni ng compressor Compressor oi l : SP 10 l P/ N 38897
-
P13
-
A0l AH or
38899- P13- A01)
For Ref ri gerant : HFC 134a (R, 134a)
3-2
www.emanualpro.com
NOTE: Lubri cate al l hi nges, l atches, and l ocks once a year.
In corrosi ve areas, more frequent l ubri cati on i s necessary.
We recommend Honda Whi te Li thi um Grease.
3- 3
www.emanualpro.com
Mai ntenance Schedul e
(for
1997 Model )
Normal Condi ti ons
o
z
o _ u
b 6 <
x : 3
+ : l
o
z
r E
: o ?
E J
' o q
3c)
I
!
g
6
E
9 9 E
] :
; E
Z o
N . j
z 0
!
. 9
E
6
-
5
P
= ! 3 8
i i n t c
: d J 9 E
o : : c u ?
; ;
e 6 - -
r
i F : r l !
b ; z ! ! 9
E 5 8 3 . 3 3
H ; < X o a
5 3 o ! a 6
! ; . = ! e g
! ? ! ? 3 < r <
. 9
E
tr

E
. E
P o
o
a l . 9
: 3 E
I
=
(9
;
= <
q s
I
(9
;
. j :
9 >
E
3 p
; 3
t *
- ?
! o
. i E
(, . -
c 9
f 9
6
,t
e i 6 l
* : : : " i
3 E i { :
e: 3E. e
= 9 t t i
E E e X g
3 I : E 3
E ! E E *
9 ! o : l
: ; ; 5
q
: . . : : i
. ; ; 6 i
9 = 9 ;
H : 6
g - :
: t 9 ; o
d 6 ; d 9
. g
E
.9
s
3
. 9
E
; ;
E :
o o
E
E
E
>
a
6
s
a a a a a a
E
-9
E
-
a a a a a a a
a a
. 9
:
o a a a a a a o
a
a a a
a a a a a a a
a a a a a
a a a a a a a
a
a a
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E
E
'5
=
s
!
E
:
:
a
E
;
E
.E
!
.
!
. E
!
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E
3
p
. 9
p
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E
6
t
=
E
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s
;
; 5
i q
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o 3 i
: E E
d r 3
>
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=
;
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I
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o l
3 l
P I
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- g l
n l
P I
3 l
9 i l
; l
EI
> l
2 l
l
Q I
z l
P t
a l
, : I
3-4
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' o e
9 9 .
e i
* , ' :
o d
. q E
} E
+ E
d o c i
c _
9 6 ;
E #
I
3 [
5
'o
9l '3
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F 5
; E
9 =
9
' d o
F
E
Q o F
! ! x
. y c
: q I
J _ t r
; 9 9
n 9 ;
1t J- O
: 9 i i
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E t x
o r
c
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g
3 . 9 > ;
F E = F
o i : * o
; T e
o
z
o o l {
FET
d
F
o
z
o
-
d ! v !
= ; - e
6 F :
6 E ,i3 3
E
I
E
l a
3 :
: h
;
6 o
i -
i t
o i E
F P
6 0
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t q !
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3
6
a
a
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a
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E
.s
E
E
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6 : . !
3 F F
6 E 3
l
I
?
I
3-5
www.emanualpro.com
Mai ntenance Schedul e
(for
1997 Model l
O
Severe Conditions
o
l e
E
, E
. 9
T
_9
, 9
E
ui &,
l e
- u :
6 s
; -

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o
E
4
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. 2
I
, 9
;
f,
6
3 i
a l
g l
'6
1
o l
? l
= i
, PI
o
E
;
E
z
o _ u
+ 1 P
F
o
z
= o
' ;
c?
E J
I
I
-9
!
j
E
P e !
E E 7
.: .'j
6
t l .
9 - - 6
i , i i
q . ,
z o
z o
E
; !
= Y
i s * 9 c
g I i i " . ^
E d
- - ; -
r
k F ! ' r I !
H 6 b e +
F. t ei i . :
i i t i # >
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tr
o
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E :
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o ,
- J . 9
+ B
I
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; <
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a E
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! 9. _j
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r
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f
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c >
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E
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3 p
e t
; 3
t l l
: o
; t
E '
i ;
( 9 -
e s
:
. e ; f i
: E: : " i
Y
5 Y = l
9 0 s F 6
i
f i - - i f
E a g X s
s i !
E
9
X
5 > =
B
i i d : . s F
E ! E E g
F i F P :
P ; . : a :
l ; ; ; i
3 = e ;
* 1 E * E
d b J d 9
E
E
E
-
a
5
a o a a a
E
E
.i
=
E
6
a a
o a a a a O
a a a a a a a
a a O
a
o
a a a a a a
a a a o
a a a a a a
a
a
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a
6
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3
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p
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3
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E
p
:
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E
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d
=
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g
, 9 :
; , E
c 3 ;
; E P
3-6
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.!2
y
o
F !
q
d 5 :
.l'
o
o
6 \
o
E 6
i O i r
p E
;
> o ) :
P g
I
= R
. :
; i
i
- o
. + :
Z o F E
E. E E P
t l r
q
:
i i ;
;
15
: Y
!
o
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I
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3
z
n O
0 3
E
5
E r
e
:
E ! c =
PE - E . .

c _
e E
n
. a
=
or F
r : 1 , = y
5 6 9 :
n
6 3
: ; 9
p. 3
: - E :
e a 6 i . : =
i 3 ; e E
7 >
q
r :
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q
I
5
: g F
. s
H
! b : . . e e x
. Y c 7' Y . r . >
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L O . = : > >
3 ;
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;
e E
i i c b *
E =
:
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r ' i
= ;
b - " F : {
;
+ . 8
3 h 3 3 i l
j
P I i
-
6 * o
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0 6
v
i . Y Y
! F : o 9 ; q , n 4
a E ! b . E ; : 3
9 q c o a h r o
( J
; E ; ; 1 E r 9
f ' = = , ; g
9
. : ^ c , ^ ; L > - . ;
E;
EEg : ! i
g S a l l : :
;
6 6
9 : _ . 1 . > 9 :
t
o f . = ? y , a \ z '
Fq , ! ! : ! ! f r : i
Eo
! c = o u u r r
! o - o : P o
H F I
; " " '
5 F
i ; 9 6
z o
3-7
z
9, o) l
g Er
ct
F
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6
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c o q
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c 6
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: E
. 9
--
.9
F P
; o -
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5
c . - -
t - E
9t
o
;
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g
=
a
E
.
ri
t
E
E
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a
a
a
o
a
a
a
a
a
a
o
o
a
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a
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.:
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f
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p
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a
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6 E 3
www.emanualpro.com
Maintenance Schedule
(for
1998
-
2000 Models)
o
Normal Condi ti ons
o
z
o _ u
{ : 9
+ : N
F
o
z
9 d
. E
E d
E J
3
:
6
!
E
o o E
r l
! L i :
o
2 ?
* F 9
r <x
i i
i
E
B
i
q = Y
h E n a
q
s i l i : .
E ;
*;= - ^
i 6 : l . *
: ; = : - - o
F E t r 5 S 1
6 ! ; :
a 3
; ; ; i B:
t i
? ?
' 6 6
EE
o o
trtr
5 A
.E
a o r :
cj ct
6
E ' ' i - ;
3 = ? ;
' r
p
^i ..i i
1 3 9 :
r
! ! =
' E o o
P
! i 3 3 !
= ; k E
I
.s
(5
!
l _
. j :
c >
E
E
o P
p !
!. ii
: :
* c
: a
3 9
l 9
=
e E S l
: : - G .
5 <
d 9 i
= 9 ' t i
E E e X e
+ i > = i
; i i 5 e
: = F ! - \
! ; ! a ;
a; i
6
s
i E : P O
s = ; s E
. !
E
. !
. !
3
. 9
. 9
; t
5 >
6 - a
E
=
:
E
-
a
!
a a a a a a
E
e
E
a a a a a a a
a a
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a a a a o a a a
a a a a
a a a a a a a
a a a a a
a a a a a a a
a a a
E
E
E
s
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a
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3
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3-8
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I
o
'6
c)
v ;
t E
o P -
E E
E
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c q :
o X t 7
t 5 E
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* c e
h o
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n 9 ;
a;
r ] J a-
t i
E : !
a o
z
o T
E
: d s
E' .g > ;
; : = I
a E t
e
< i 9 r f
o
o
z
o _ u
b 6 <
6t
F
o
z
9
c o *
E
I
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! =
3
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i E
. 9
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a
n z
9 *
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6 6
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3
a
a
a
a
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o
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p
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2
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E
;
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3 F p
3- 9
www.emanualpro.com
Maintenance Schedule
(for
1998
-
2000 Models)
O
Severe Conditions
o
6
;
-E
.9
:
.9)
.l
:
E
= ;
- 9 c
> i i
-i .:
- xi
& , 6 =
R 3 !
! c 6 . -
j !
. : *
3 : : t
: 4 3 ; :
P : - e C F
g : , . !
o - -
i F Y e E
! ; 3 _
l P
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l o
I E
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.9
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s
3
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E
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6 .
s >
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z
a
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+ l
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5 l
i l
: l
3 l
i \ t
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E I
l
F I
o l
9 l
; l
: l
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, PI
o
z
o _ 4
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r l 9
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F
z
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5 E
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t * -
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z * 9
I
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i
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E g e Y . :
s I N I ! ;
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r
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h E z ! : i 9
E E ; e 1
e =
a
q : :
6 g o - . ! 5 . 6
; ; ; i F 3
o 6 a
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EE
o o
EE
= a
{ a i
; i 3
a - - q
e q o ? R
s=
k;
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l n
c
c i . i i
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I
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i i
q . . . "
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I
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f
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E
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o E
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i b
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s 3= l
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t 3 = E
e E S
t
i i ; t
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i r :

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E E 3 i g
E E ; b F
j = - ; H
: 2 6 a n
i i 6 : . s F
E E . E S e
- i i d : 1
9 ; . :
6 :
l ; ; " 3
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a c ; a :
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3- 10
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F E
o
9 ) Y o )
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o d
:
-:'
o
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6 : o
t i
=
9 6 E
i c
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t
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6
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F 3 T P J
t r g d
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h
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, = : > >
q :
x . Y t t
6 . = ! ! : '
e E
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= =
o ( J
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Engi ne El ectri cal
Speci af Tool s . . . . . . . . . . . . . 4-2
Starting System
Component Locat i on I ndex . . . . . . . . . . . . 4-3
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starter Test ........... 4-5
St art er Sol enoi d Test . . . . . . . . . . . . . . . . . . . . . . 4' 5
St art er Repl acement . . . . . . . . . . . . . . . . . . . . . . . 4-7
Fi el d Wi ndi ng Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
St art er Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . 4-8
Brush I nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . , . , 4-9
Overrunning Glutch Inspection ...... 4-9
Armat ure l nspect i on and Test . . . . . . . . 4-10
Brush Hol der Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
St art er Reassemb| y . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 2
Perf ormance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 3
lgnition System
Component Locat i on I ndex . . . . . . . . . . . . 4-14
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
lgnition Timing Inspection and
Set t i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Di st ri but or Repl acement . . . . . . . . , . . . . . . . . 4-17
Di st ri but or Overhaul . . . . . . . . . . . . . , , . . . . . . . . . 4-18
lgnition Control Module
(lCM)
Input
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . 4- 19
f gni t i on Coi l Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2O
lgnition Wire Inspection and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Spark Pl ug I nspect i on . . . . . . . . . . . . . . . . . . . . . 4-21
- +
ENGINE
Charging System
Component Locat i on I ndex . . . . . . . . . . . . 4-22
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . 4-23
Troubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Al t ernat or Repl acement . . . . . . . . . . , . . . . . . . 4-30
Al t ernat or Overhaul . . . . . . . , , . . . . . . . . . . . . . . . . 4-31
Rectifier Test .........4-32
Alternator Brush Inspection ........... 4-32
Rot or Sl i p Ri ng Test . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Stator Test ............. 4-33
Alternator Belt Inspection and
Adi ust ment . . . . . . . . 4-34
Gruise Control
Component Location Index .,,,........ 4-36
Ci rcui t Di agram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Cont rol Uni t I nput Test . . . . . . . . . . . . . . . . . . . 4-38
Main Switch Test/Replacement ..... 4-40
Set/Resume Switch Test/
Repl acement . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . 4' 40
Actuator Test ....,,., 4-41
Actuator Replacement ...............,.... 4-42
Actuator Cable Adiustment ............ 4-43
Cl ut ch Swi t ch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Brake Swi t ch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Actuator Solenoid Test .............. ...,. 4-44
Act uat or Di sassembl y . . . . . . . . . . . . . . . . . . . . . 4-45
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Special Tools
Ref. No. Tool Number Description
Oty
I
Page Reference
o
-o
o
A973X
-
041 XXXXX
07JGG
-
001010A
07PAZ
-
0010100
Vacuum Pump/Gauge, 0 30 i n.Hg.
Bel t Tensi on Gauge
SCS Servi ce Connector
4-41
434
4- 16
*
Incl uded i n the Bel t Tensi on Gauge Set, T/N 07JGG
-
0010004
o
@
o
4-2
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Starting
System
Component
Location Index
BATTERY
Test, section 23
CLUTCH INTERLOCK
swtTcH {M/T)
Test, page 4-43
Swi t ch
posi t i on adi ust ment ,
sect i on 12
I
A/T GEAR POSITION SWITCH {A/T}
Test , sect i on 14
Reol acement . sect i on 14
Test , page 4 5
Sol enoi d Test , page 4-6
Replacement,
page 4-7
Overhaul ,
page 4 8
Reassembl y,
page 4-12
Performance Test,
Page
4-13
4-3
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Starting System
Ci rcui t Di agram
IGN TION
SWITCH
/
BAI
\
-+o
cf-.|
\i7 I
BLKMHT
I
I
I
t l
t l
ELKMHT BLK'WHT
STARTEF
CUl RELAY
I A/T GEAR PosrroN!
i
swrTcH (A/T)
|
l / o N Eo r N\ |
l \ p. s i t on /
:
! - - - _ - - ___J
f';--"-l
I
TNTERLooK
I
fYl""yl, I
GRY
I
GRN
8LK
Gl 0l
UNDER.HOOD FUSE/RELAY 8OX
N0.41 (100A) N0.42 (40A)
-.1
BLKRED
I
IGNITION CONTROL
MOoULE ( CM)
STARTEB
(Field wnd ng lype)
4-4
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Starting System
Starter Test
NOTE: The ai r temperature must be between 59 and
' 100' F
(15
and 38"C) before testi ng.
Recommended Procedure:
. Use a staner system tester.
. Connect and oper at e t he equi pment i n accor dance
wi th the manufacturer' s i nstructi ons.
. Test and troubl eshoot as descri bed.
Alte.nate Procedure:
. Use the fol l owi ng equi pment:
-
Ammeter, 0
-
400 A
-
Vol tmeter, 0
-
20 V
(accurate
wi thi n 0.1 vol t)
Tachomet er , 0
-
1, 200 r pm
. Hook up a vol tmeter and ammeter as shown.
NOTE: After thi s test, or any subsequent repai r. reset
the ECM/PCM to cl ear any codes
(see
secti on 1 1).
Check the Starter Engagement:
' 1.
Remove the No. 44
(15
A) fuse from the under-hood
fuse/rel ay box.
2. Turn the i gni ti on swi tch to START
(l l l )
wi th the shi ft
l ever i n
E
or
E
posi ti on (A/T)
or wi th the cl utch
pedal depressed {M/T). The starter shoul d crank the
eng i ne.
. l f the starter does not crank the engi ne, go to
step 3.
. l f i t cranks the engi ne errati cal l y or too sl owl y, go
t o
" Check
f or Wear and Damage" on t he next
page.
NEGATIVE TERMINAL
4.
5.
6.
7.
8.
Check the battery, battery
posi ti ve cabl e, ground.
staner cut rel ay, and the wi re connecti ons for l oose-
ness and corrosi on. Test agai n.
l f the staner sti l l does not crank the engi ne, go to
step 4.
Unpl ug the connector
(BLK
/VHT wi re and sol enoi d
termi nal ) from the starter.
Connect a
j umper
wi re from the baftery posi ti ve (+)
termi nal to the sol enoi d termi nal .
The starter shoul d crank the engi ne.
. l f t he st ar t er st i l l does not cr ank t he engi ne,
remove i t, and di agnose i ts i nternal probl em.
. l f the starter cranks the engi ne, go to step 6.
Check the i gni ti on swi tch
(see
secti on 23).
Check the starter cut rel ay {see secti on 23}.
Check the IVT gear position switch
(A/T)
or the clutch
interlock switch
(M[).
Check for an open i n the wi re between the i gni ti on
swi tch and starter.
( cont ' d)
4-5
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Starting System
Starter Test
(cont'dl
Check lor Wear and D8mage
The s t ar t er s houl d c r ank t he engi ne s moot hl y and
st eadi l y. l f t he st aner engages, but cr anks t he engi ne
errati cal l y, remove i t, and i nspect the starter dri ve gear
and torque converter ri ng gear or fl ywheel ri ng gear for
oamage.
Check the dri ve gear overrunni ng cl utch for bi ndi ng or
sl i ppi ng when t he ar mat ur e i s r ot at ed wi t h t he dr i ve
gear hel d. l f damaged, repl ace the gears.
Check Cranking Voltage and Current Draw
Cranki ng vol tage shoul d be no l ess than 8.7 vol ts on Ay' T
model s, and 8.0 vol ts on M/T moders.
Current draw shoul d be no more than 230 amperes on
A,/T model s, and 200 amperes on M/T model s.
l f cranki ng vol tage i s too l ow, or current draw too hi gh,
check for:
. dead or l ow battery.
a open ci r cui t i n st ar t er ar mat ur e commut at or seg,
ments.
. starter armature draggi ng.
. shorted armature wi ndi ng.
. excessi ve drag i n engi ne.
Check Cranking rpm
Engi ne speed duri ng cranki ng shoul d be above 100 rpm.
l f speed i s too l ow, check for:
a l oose baftery or starter termi nal s.
. excessl vel y worn staner brushes
. open ci rcui t i n commutator segments.
. di rty or damaged hel i cal spl i nes or dri ve
gear.
a defecti ve dri ve gear
overrunni ng cl utch.
Check Starter Disengagement
Wi th the shi ft l ever i n
@
or
@
posi ti on (A,i T)
or wi th the
cl utch pedal depressed {M/T). turn the i gni ti on swi tch to
START
(l l l ).
and rel ease to ON
(l l ).
The starter dri ve gear shoul d di sengage from the torque
conver t er r i ng gear or f l ywheel r i ng gear when you
rel ease the key.
l f the dri ve gear hangs up on the torque converter ri ng
gear or fl ywheel ri ng gear, check for
. sol enoi d pl unger and swi tch mal functi on.
. di rty dri ve gear assembl y or damaged overrunni ng
cl ut ch.
Starter Solenoid Test
1. Check the hol d-i n coi l for conti nui ty between the S
t er mi nal and l he ar mat ur e housi ng
( gr ound) .
The
coi l i s OK i f there i s conti nui ty.
STARTER
B TERMINAL
MOUNTING NUT
9 N.m 10.9 kgtm,
7 tbtftl
TERMINAL
ARMATURE
HOUSING
(GROUND}
BLK/WHT
WIRE
Check the pul l i n coi l for conti nui ty between the S
and M termi nal s. The coi l i s OK i f there i s conti nui ty.
2.
4-6
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RE
Starter Replacement
1 .
B TERMINAL
MOUNNNG NUT
I N.m
(0.9
kgl.m,
7 rbt ftl
Remove t he t wo bol t s hol di ng t he st ar t er . t hen
remove the starter.
4. I nst al l i n t he r ever se or der of r emoval . When
i nst al l i ng t he st ar t er cabl e, make sur e t hat t he
crimped side ofthe ring terminal is facing out,
Crimped side of ring
t ermi nal
TERMINAL
Connect the battery positive cable and negative cable
to the batterv.
Disconnect the battery negative cable.
Di sconnect the starter cabl e from the B termi nal on
the sol enoi d. then di sconnect the BLK/WHT wi re
from the S termi nal .
STARTER
l 0 x 1. 25 mm
4,1 N.m {4.5 kgf.m,
33 tbt.ftl
5 .
o
Field Winding Test
Check for conti nui ty between the brushes. l f there' s
no conti nui ty, repl ace the armature housi ng,
Check for conti nui ty between each brush and the
ar mat ur e housi ng
{ gr ound) .
l f t her e i s cont i nui t y.
repl ace the armature housi ng.
t .
ERUSHES
4-7
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Starting System
Starter Overhaul
STARTER SOLENOID
STARTER SOLENOI D
Test , page 4 6
OVEBRUNNI NG
CLUTCH
w
-6^l
MOLYBDENUM
DI SULFI DE
SPRI NG CLI P
Repl ace.
BBUSH HOLDER
Test , page 4-12
ARMATURE HOUSI NG
ARMATURE
I nspect i on and Test . page 4-10
..'...:|@{
MOLYBDENUM
DI SULFI DE
BAUSH
I nsPecl on, page 4-9
ARUSH
GEAR HOUSI NG
4-A
END COVER
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Brush Inspection
Measure the brush l ength. l f i t i s not wi thi n the servi ce
l i mi t, repl ace the brush
(or
brush hol der assembl y).
Brush Lsngth
Standard {Newl : 14.0
-
I' 1.5 mm
(0.55 -
0.57 i nl
Servico Limit: 9.0 mm
(0.35
in)
NOTE: To seat new brushes after i nstal l i ng them i n thei r
hol ders. sl i p a stri p of #500 or #600 sandpaper, wi th the
gri t si de up, over the commutator and smoothl y rotate
the armature. The contact surface of the brushes wi l l be
sanded to the same contour as the commutator.
BRUSH
4-9
2.
1 .
Overrunni ng Cl utch Inspecti on
Sl i de the overrunni ng cl utch al ong the shaft. Does i t
move freel y? l f not, repl ace i t.
Rotate the overrunni ng cl utch both ways. Does i t
l oc k i n one di r ec t i on and r ot at e s moot hl y i n
reverse? l f i t does not l ock i n ei ther di recti on or i t
l ocks i n both di recti ons, reDl ace i t.
3. l f the starter dri ve gear i s worn or damaged, repl ace
t he over r unni ng cl ut ch assembl y; t he gear i s not
avai l abl e separatel y.
Check the condi ti on of the torque converter ri ng gear
or the fl ywheel ri ng gear i f the starter dri ve gear
teeth are damaged.
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Starting System
Armature Inspection and Test
1. I nspect t he ar mat ur e f or wear or damage due t o
contact wi th the fi el d wi ndi ng. l f there i s wear or
damage. repl ace the armature.
Check the commutator surface. l f the surface i s di rty
or burnt, resurface wi th emery cl oth or a l athe wi th-
i n the tol l owi ng speci fi cati ons, or recondi ti on wi th
#500 or #600 sandDaoer.
l nspect f or damage.
4-10
3. Check t he commut at or di amet er . l f commut at or
di amet er i s bel ow t he ser vi ce l i mi t , r eol ace t he
armal ure.
Commutator Diameter
Standard
(Newl :
27.9
-
28.0 mm
(1.09 -
1.10 i n)
Servi ce Li mi l r 27.0 mm
(1.06
i nl
l f t he commut at or r unout i s wi t hi n t he ser vi ce
l i mi t, check the commutator for carbon dust or
brass chi ps between the segments.
l f the commutator runout i s not wi thi n the ser-
vi ce l i mi t, repl ace the armature.
Commutator Runout
Standard
(Newl :
0
-
0.02 mm
(0 -
0.0008 i n)
Servi ce Li mi t: 0.05 mm {0,002 i nl
4. Measure the commutator runout.
www.emanualpro.com
I
NOT GOOD
5. Check the mi ca depth. l f necessary, undercut the
mi ca wi th a hacksaw bl ade to achi eve proper depth.
l f t he ser vi ce l i mi t cannot be mai nt ai ned, r eDl ace
the armature.
MICA DEPTI{
Commutator Mica Depth
Standard
(Nsw):
0.5
-
0.8 mm
10.02
-
0.03 inl
Servico Limit: 0.2 mm
(0.008
in)
Check for conti nui ty between the segments of the
commutator. l f an open ci rcui t exi sts between any
segments. repl ace the armature.
6.
COMMUTATOR
4-11
7. Pl ace the armature on an armature tester. Hol d a
hacksaw bl ade on the armature core.
l f the bl ade i s attracted to the core or vi brates whi l e
the core i s turned. the armature i s shorted. Repl ace
the armature.
8. Wi th an ohmmeter, check that no conti nui ty exi sts
between the commutator and armature coi l core,
and between the commutator and armature shaft. l f
there i s conti nui ty. repl ace the armature,
cotL coRE
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Starting System
Brush Holder Test
1. Check that there i s no conti nui ty between the O and
O brush hol ders. l f there i s conti nui tv, repl ace the
brush hol der assembl y.
O BRUSH HOLDER @ BRUSH HOLDER
Insert the brush i nto the brush hol der, and bri ng the
brush i nto contact wi th the commutator, then attach
a spri ng scal e to the spri ng. Measure the spri ng ten-
si on at the moment the spri ng l i fts off the brush.
SPRING SCALE
Spri ng Tensi on: 13.7
-
17.7 N
(1.40 -
1.80 kgf, 3.09
-
4.00 l bf)
4-12
Starter Reassembly
NOTE: Use the i l l ustrati on on page 4I as reference for
reassemDty.
1. Pry back each brush spri ng wi th a screwdri ver, then
posi ti on the brush about hal fway out ol i ts hol der,
and rel ease the spri ng to hol d i t there.
2. Instal l the armature i n the housi ng. Next, pry back
each brush spri ng agai n, and push the brush down
unti l i t seats agai nst the commutator, then rel ease
the spri ng agai nst the end of the brush.
- E ^
F*4#-@
6 t t a
a l
l a
t l
l l
3. I nst al l t he end on t he br ush hol der .
ft
cover
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, r
1 .
?
Performance Test
Di sconnect the wi re from termi nal N4.
Make a connect i on as descr i bed bel ow usi ng as
heavy a wi re as possi bl e (preferabl y
equi val ent to
the wi re used for the vehi cl e).
Connect the battery as shown. l f the starter pi ni on
pops out. i t i s worki ng properl y. To avoi d damagi ng
the starter, do not l eave the battery connected for
more than 10 seconds.
3.
i e
Di sconnect the battery from the M termi nal . l f the
pi ni on does not retract, the hol d-i n coi l i s worki ng
pr oper l y. To avoi d damagi ng t he st ar t er , do not
l eave the battery connected for more than 10 sec
onds.
@ o
12V
BATTERY
4-13
5. Di sconnect the battery al so from the body. l f the
pi ni on retracts i mmedi atel y, i t i s worki ng properl y,
To avoi d damagi ng the starter, do not l eave the bat-
terv connected for more than 10 seconds.
6.
7.
Cl amp the starter fi rml y i n a vi se.
Connect the starter to the battery as descri bed i n
t he di agr am bel ow, and conf i r m t hat t he mot or
starts and keeps rotating.
8, l f the el ectri c current and motor soeed meet the
speci fi cati ons when the battery vol tage i s at 11.5 V,
the starter i s worki ng properl y.
Specifications:
Maker El ectri c current Motor speed
DENSO 90 A or l ess
3,000 rpm or
more
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lgnition System
Component Location Index
IGNITION TIMING CONTROL SYSTEM
. l dl e speed Inspecti on/Adj ustment, secti on 11
. Inspecti on and Seni ng. page 4-16
DISTRIBUTOR
Repl acement , page
4-17
Overhaul , page
4-18
l gni t i on Coi l Test , page
4, 20
l gni t i on Cont rol Modul e CM)
I nput Test , page 4, 19
SERVICE CHECK CONNECTOR
(2P)
lwi.c colo6: BRN rnd BLKI
TEST TACHOMETER
SPARK PLUGS
I nspect i on, page
4-21
WIRES
4-14
I nspect i on and Test , page 4-20
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Ci rcui t Di agram
IGNIT ON
SW TCH
UNDEF, DASH
FUSEi RELAY BOX
6\ l;;l Eci,.pcM
i{Hr6-(-\9-'-'*'.--EII
V
' i l
IGN TION
W]BES
SPARK
PLUGS
I l :
' 99
-
00 model s
Gt01
4-15
UNDEF.HOOD FUSE/RELAY 8OX
f l - -
r
TDC Top dead cenler
CKP Cran[shan poslion
CYP Cyl nder posr l on
TDC/CKP/CYP SENSOR
BLK/YEL
l ^
IGNITION
cot L
IGN]TION CONTROL
MODULE (CM)
/
Has buil-if
\
I
no|se
l
i
l '
i - - ,
-
BLU
l l
i f r
I BLU BLU
I
l l / '
i
|
|
resr
I TACHOMETER
I
I
tott"to*
LTTCHoMEIEB
j
' 97
-' 98
model s
IJltfi
--cMFcr,r
I
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lgnition System
5.
l gni ti on Ti mi ng Inspecti on and Setti ng
2.
1 . Check the i dl e speed, and adj ust i t i f necessary
(see
secti on 1 1).
Pul l out the servi ce check connector 2P
(BRN
and
BLK wi res) from the connector hol der l ocated under
the dash on the front passenger si de, then connect
the scs servi ce connector
(P/N
07PAz
-
0010100) to
i t.
Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(A/T
i n
N
or
E,
Mff i n neutral ) unti l the
radi ator fan comes on, then l et i t i dl e.
Connect the ti mi ng l i ght to the No. I i gni ti on wi re,
then poi nt the l i ght toward the poi nter on the ti mi ng
belt cover.
Check t he i gni t i on t i mi ng i n no l oad condi t i ons:
headl i ghts, bl ower fan, rear wi ndow defogger, and
ai r condi ti oner are not operati ng.
l gni ti on Ti mi ng:
M/T: 16" 12" BTDC
(RED)
i dl i ng i n neutral
Al Tt' 16" !2" BTDC
(RED)
i dl i ng i n
E
or
E
CRANKSHAFT
PULLEY
4-16
6. l f necessary, adj ust the i gni ti on ti mi ng as fol l ows.
Loosen the di stri butor mounti ng bol ts, and turn the
di stri butor i gni ti on
(Dl )
housi ng countercl ockwi se to
advance the ti mi ng or cl ockwi se to retard the ti m-
t no,
7.
8.
MOUNTING BOLTS
24 N.m {2.4 kgf m, 17 lbtft}
Ti ghten the di stri butor mounti ng bol ts, and recheck
t he i gni t i on t i mi ng.
Di sconnect the SCS servi ce connector from the ser-
vi ce check connector.
To RETARD
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e
o
I '
Distributor Replacement
Removal :
1. Di sconnect the connector from the di stri butor.
2. Di sconnect the i gni ti on wi res from the di stri butor
i gni t i on
( Dl )
cap.
3. Remove t he mount i ng bol t s f r om t he di st r i but or ,
then remove the di stri butor from the cyl i nder head.
CAMSHAFT
END
MOUNTING BOLTS
8 x 1.25 mm
2,1N.m {2.,1kgrf.m, 17 lbf ftl
lnstallation:
1. Bri ng the No. 1 pi ston to compressi on stroke TDC.
2. Coata new O-ri ng wi th engi ne oi l , then i nstal l i t.
3. Al i gn the l ug on the end of the di stri butor and i ts
mati ng grooves i n the camshaft end, then sl i p the
di stri butor i nto posi ti on.
NOTE: The l ug on the end of the di stri butor and i ts
mati ng grooves i n the camshaft end are both offset
to el i mi nate the possi bi l i ty of i nstal l i ng the di stri bu-
tor 180o out of ti me.
4. Instal l the mounti ng bol ts, and ti ghten them l i ghtl y.
5. Connect the i gni ti on wi res to the di stri butor i gni ti on
(Dl )
cap as shown,
No. 1
CYLINDER
MARK
6. Connect the connector to the di stri butor.
7. Set the i gni ti on ti mi ng
(see previ ous page).
8. After setti ng the i gni ti on ti mi ng, ti ghten the mount-
i ng bol ts.
4-17
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lgnition System
Distributor Overhaul
CAP SEAL
Check f or damage.
DISTRIBUTOR IGNITION IDII ROTOR
OISTRIBUTOR IGNITION {DII CAP
Check for cracks, wear,
damage, and t o! l i ng.
Cl ean or repl ace.
O.RING
Repl ace.
b
OISTBIBUTOR IGI{ITION IDO HOUSING
Check for cracks and damage.
IGNITION COIL
Test, page 4 20
@_
IGNITION CONTROL
MODULE {ICMI
I nput Test , page 4-19
LEAK COVEN
4- 18.
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l gni ti on Control Modul e
(l CMl
Input Test
NOTE:
. See secti on 11 when the mal functi on i ndi cator l amp
( Ml L)
comes on.
. Perform an i nput test for the i gni ti on control modul e
( l CM)
af t er f i ni shi ng t he f undament al t est s f or t he
i gni ti on system and the fuel and emi ssi ons systems.
.
' 97
-' 98
model s: The tachometer shoul d operate nor-
mal l y i f t he I CM i s OK.
L Remove the di stri butor i gni ti on
(Dl )
cap, the di stri b-
utor i gni ti on
(Dl )
rotor, and the l eak cover.
2. Di sconnect the wi res from the l CM.
8LU WI RE
{'97
-
'98
models}
4-19
7.
Turn the i gni ti on swi tch ON {l l ). Check for vol tage
between the BLK,^/EL wi re and body ground. There
shoul d be battery vol tage.
. l f there i s no battery vol tage, check the BLK/rEL
wi re betl veen the i gni ti on swi tch and the l cl vl .
. lf there is baftery voltage, go to step 4.
Tur n t he i gni t i on swi t ch ON
( l l ) .
Check f or vol t age
between the WHT/BLU wi re and body ground. There
shoul d be battery vol tage.
. l f there i s no batteryvol tage, check:
-
i gni ti on coi l .
-
WHT/BLU wi re between the ICM and i gni ti on
cor l .
. l f there i s battery vol tage, go to step 5,
' 97
model : Di sconnect the ECM/PCM connector A
( 32P) .
Check f or cont i nui t y on t he YEL/ GRN wi r e
between the ICM and ECM/PCM. There shoul d be
conti nui ty.
'98
-
00 models: Disconnect the ECM,PCM connector
B
(25P).
Check for conti nui ty on the YEUGRN wi re
between the ICM and ECM/PCM. There shoul d be
conti nui ty.
Check for conti nui ty on the YEUGRN wi re to body
ground. There shoul d be no conti nui ty.
Reconnect the ECM/PCl vl connector.
' 97
-' 98
model s: Check for conti nui ty on the BLU
wi re between the test tachometer connector and the
l CM. There shoul d be conti nui ty.
' 97
- ' 98
model s: Check f or cont i nui t y on t he BLU
wi re to body ground. There shoul d be no conti nui ty.
l f al l the tests are normal , repl ace the l CM.
9.
' 10.
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lgnition System
lgnition Coil Test
Usi ng an ohmmeter, measure resi stance between the
termi nal s. l f the resi stance i s not wi thi n sDeci fi cati ons,
repl ace the i gni ti on coi l .
NOTE: Resi stance wi l l vary wi th the coi l temperature;
speci fi cati ons are at 68"F
(20' C).
Plimary Winding Resistance
{Between the A and B terminals):
0.6it
-
0.77 0
Secondary Winding Resistance
{Between the A and secondary winding terminals):
12.8
-
19.2 kO
TERMINAL A {+l
4-20
e o
lgnition Wire Inspection and Test
1 . Car ef ul l y r emove t he i gni t i on wi r es by pul l i ng on
the rubber boots. Do not bend the wi res; you mi ght
break them i nsi de.
Check the condi ti on of the i gni ti on wi re termi nal s. l f
any termi nal i s corroded, cl ean i t, and i f i t i s broken
or di storted, repl ace the i gni ti on wi re.
IGNITION WIRE
Connect the ohmmeter probes and measure resi s-
tance.
lgnition Wire Resistance:
25 kO max. at 68'F 120'Cl
IGNITION WIRE
4. l f t he resi st ance exceeds 25 kO, repl ace t he i gni t i on
wi re.
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Spark Pl ug Inspecti on
Inspect the el ectrodes and cerami c i nsul ator for:
.
l mproper
gap
.
Oi l -f oul i ng
.
Carbon deposi t s
.
Cracked cent er
el ect rode i nsul at or
Burned or worn electrodes may be caused by:
. Advanced i gni ti on ti mi ng
. Loose spark pl ug
. Pl ug heat range too hot
. Insuffi ci ent cool i ng
Fouled plug may be caused by:
. Retarded i gni ti on ti mi ng
. Oi l i n combust i on chamber
. Incorrect spark
pl ug gap
. Pl ug heat range too col d
. Excessi ve i dl i ng/l ow speed runnang
. Cl ogged ai r cl eaner el ement
. Deteri orated i gni ti on wi res
I
2. Check the el ectrode
gaP.
. Adj ust the gap wi th a sui tabl e
gappi ng tool .
Electrode Gap
Standard
1.1 3 ' mm
(0.043
Loo. i n)
Repl ace the pl ug i f the center el ectrode i s rounded
as shown bel ow:
Spark Plugs
'97
-
'98
modsls:
ROUNDEO
ELECTRODE
,--, /
( - - /
| | r--'--'--r
-.--
l-:=---:1
:
ZFR5F- 11
( NGK)
KJ16CR- 111
( DENSO)
'99
-
00 models;
ZFR6F- 11
( NGK)
KJ2OCR-111
(DENSO)
Appl y a smal l
quanti ty of anti -sei ze compound to
the pl ug threads, and screw the pl ugs i nto the cyl i n-
der head fi nger-ti ght. Then torque them to 18 N' m
(1.8
kgf.m. 13l bf.ft).
4-21
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Charging System
Component Location Index
ALTERNATOR
CHARGING SYSTEM LIGHT
(l n
t he gauge assembl y)
Test, page
4-24
BATTERY
Test,
Troubl eshoot i ng, page
4-24
Repl acement , page 4-30
Overhaul , page
4-31
Rectifjer Test, page 4,32
ALTERNATOR BELT
I nspect i on and Adj ust ment , page 4 34
4-22
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4-23
Ci rcui t
BATTERY
Di agram
UNDES.HOOD FUSUFtAY BOX
WHT/8tK
l.
(
tot,o,
)
Y
8LI(YEL
I GNI TON
SWITCH
GRN/RED
N0.41 (1Cr0A)
,-a\
N0.42 (40A)
ECM/PCM
V
I
WHT/RED
ALTERNATOR
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Gharging System
Troubleshooting
l f the chargi ng system l i ght does not come on or does not go off, or the battery i s dead or l ow, test the fol l owi ng i tems i n
the order l i sted bel ow:
1. Battery
(see
secti on 23)
2. Chargi ng system l i ght
3. Vol tage
4. Al ternator control system
(U.S.A.
model )
5. Al ternator/regul ator
Charging System Light Test
ALTERNATOR 4P CONNECTOR
{U. S, A. model l
(BLK/ YEL)
2
3
Wi re sade of
f emal e t ermi nal s
I
I
I
ALTERNATOR 3P CONNECTOR
lCaneda model'
I emal e t er mi nal s
[ ] : Canada model
Chsrging Systom Light Check:
Turn t he i gni t i on swi t ch ON {l l ),
and make sure t he chargi ng sys
t em l i ght comes on.
Check for a blown No. 15 17.5 Al
fuse and a blown charging sys-
t em l i ght bul b. l f t he t usa . nd
bulb are OK, repair th open in
th WHT/BLU wire.
Does t he chargi ng syst em
l i ght come on?
Chargi ng Syst em Li ght Check
{com'd}:
St art t he engi ne.
Does t he chargi ng syst em
light go offf
Perform the Alte.nator/Regulator
Test
lsee
page +281.
Voltage Check:
Measure t he vol t age at t he No. I
l No. 2i t ermi nal of t he 4P [ 3Pl con-
nector with the ignition switch ON
{ ) .
Ropair the open in the BLK/YEL
wiae betwoen the altemator and
under-da3h luso/relay box.
ls there battery voltage?
(To
next page)
4-24
www.emanualpro.com
i n
(From previ ous page)
Does the charging system
l i ght come on?
Ch6ck the L circuil:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he 4P [ 3P] con-
nector from the alternator.
3. Turn t he i gni t i on swi t ch ON
(l l ).
Repair the short to ground in the
WHT/BLU wire.
[ ]: Canada model
(cont' d)
4-25
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Charging System
Troubleshooting (cont'dl
'97
modol: Alternator Control System Test
{U.S.A. model)
NOTE: Before testi ng, check proper
operati on ofthe ELD by checki ng for a DTC
(see
secti on
.11).
CAUTION: Be sure to use a voltmeter
with ils positive
terminal connected to
battery positive
and hs negative termi-
nalto the 4P connector terminal No. 2.
BATTERY
Wi re si de of
f emal e t ermi nal s
{WHT/GRNI
ALTERNATOR
irP
CONNECTOR
ALTEFNATOR
4P CONNECTOR
Chock f or a short i n t he ci rcui t
IALTC line):
1. Di sconnect t he 4P connect or
from the alternator.
2. St art t he engi ne, and t urn t he
headl i ght s t hi gh beami ON.
3. Me8sure voltage between the
4P connect or t er mi nal No. 2
and t he posi t i ve
t ermi nal of
the battery.
l s t h e r e l Vo r l e s s ?
Check f or an open i n t he wi re
(ALTC
linel:
1. Tur n t he headl i ght and i gni -
t i on swi t ch OFF.
2. Disconnect the 32P connector
from the ECN4/PCM.
3. Check t or cont i nui t y bet ween
t he EcM/ PcM 32P connect or
t ermi nal No. 30 and al t ernat or
4P connect or t ermi nal No. 2-
Repair open in the wi.e betwoen
the atternator and ECM/PCM.
l s t here cont i nui t y?
Check f or a shorl i n t he wi ro
IALTC line):
1. Tur n t he headl i ght and i gn; ,
I | on swrt cn UFF
2. Di sconnect t he 32P connect or
f rom t he EcM/ PcM.
3. Check t or cont i nui t y bet ween
t he ECM/ PCN4 32P connect or
t e r mi n a l No . 3 0 a n d b o d y
ground.
Subslitute a known-good ECM/
PCM, and recheck.
It prescribed
voha96 b now avail-
abl e, repl ace t he ori gi nal ECM/
PCM.
l s t here cont i nui t y?
Rprir short in the wire between
the altornator and the ECM/PCM.
ECM/PCM CONNECTOR A I32PI
,/1./
1
8 10
./ l./
t 4 16 17 18 t9 20 21
21
26 27 2A 29 30
32
Wire side of
]
ALTC
f emal e t ermi nal s
I t WHT/ cRNl
t l
WHT/GRN)
f emal e t ermi nal s
I
1
ECM/PCM CONNECTOR A {32P}
,/ ,/
4 6
8 10
,/1,/
1 4 16 l 7 t 8
'19
20 21 23 21
27 2A 2S 30 :t2
Wire side of
I
ALTC
f emal e t ermi nal s
{WHT/ GRNI
f)
4-26
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R
'oR
l
u
'98
-'9O
modols: Alternator Contlol SYstem Te3t
(U.S.A'
model)
NOTE: Before testi ng, check
proper operati on of the ELD by checki ng for a DTC
(see
secti on 11)
EATTERY
CAUTION: Be surc to uso a voltmetor
with its oo3itive torminel connccted to
battery
po3hivo tnd its negativo teami'
nal to the 4P connector torminal No 2.
ECM,/PCM CONNECTOR
c {31P)
Wi re si de ol
f emal e t ermi nal s
c
IWHT/GRN)
Wi re si de ol
t emal e t ermi nal s
ALTERNATOR
4P CONNECTOR
ALTC
IWHT/GBNI
ECM/PCM CONNECTOR C {31P}
(cont' d)
Chock tor . short in tha circuit
IALTC lino):
1. Di sconnoct t he 4P connect or
Irom the alternator.
2. St art t he engi ne, and t urn t he
headl i ght s
(hi gh
beam) ON.
3. Measure voltage between the
4P connect or t ermi nal No. 2
and t he
posi t i ve t ermi nal oI
the battsry.
l st her e 1V or l ess?
Check f or an opon i n t he wi re
IALTC line):
1. Tur n t he headl i ght and i gni -
t i on swi t ch OFF.
2. Di sconnect t he 31P connect or
f rom t he ECM/ PCM.
3. Check t or cont i nui t y bet ween
t h6 ECM/ PCM 31P connect or
t ermi nal No. 2 and al t ernat or
4P connect or t ermi nal No. 2.
Ropair open in the wiro between
the ahornrtor and ECM/PCM.
Chack l or a rhort i n t ho wi re
{ALTC
lincl:
' ! .
Tur n t he headl i ght and i gni '
t i on swi t ch OFF.
2. Di sconnect t he 31P connect or
Irom the ECM/PCM.
3. Ch6ck f or cont i nui t y bet ween
t he ECM/ PCM 31P connect or
t e r mi n a l No . 2 a n d b o d y
ground.
Substituto . known-good ECM/
PCM, .nd rochock.
lf
prdcdbd voltage b now av.il-
abl e, repl . ce t he ori gi nal ECM/
rcM.
Rcpair rhort in thc wire b.twcon
th. ahGrn.tol.nd the EcM/PcM.
4-27
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Ghargi ng System
Troubl eshooti ng (cont' d)
Alternator/Regulator Test
NOTE: Make sure the battery i s suffi ci entl y charged
(see
secti on 23).
FIELD
SELECTOR
TEST
swtTcH
I
VOLTMEIER
POSmVE
t
NEGATIVE TESTER
CABI.E {BLKI
(BED)
TESTER
INDUCTIVE
PICK.UP
{GRN) CABLE IREDI
Ahernator/Regulator Test (cont'd)l
I Rel ease t he accel erat or pedal ,
and l et t he engi ne i dl e.
2 Make sure al l accessori es are
t urned of f . Turn t he sel ect or
swi t ch t o posj t i on 2
(chargi ng).
3 Remove t he i nduct i ve pi ck
up,
and zero t he ammet er.
{ Pl ace t he i nduct i ve pi ck- up
over t he bat t ery ground
cabl e
so t hat t he arrow poi nt s
t o t he
baf t ery negat i ve t ermi nal .
5 . Ra i s e t h e e n g i n e s p e e d t o
2 000 rpm, and hol d i r t here.
I
(
T
I
WHT WIRE
Alternator/Regulator Test:
1 . Co n n e c t a Su n VAT- 4 0 ( o r
equr val ent t est er ) , and t ur n
t he sel ect or swi t ch t o posi t i on
1{ sr ani ng) .
2. Shi f t t o neut ral (A/ T
i n
E
or
N)
p o s i t i o n ,
a n d s t a r t t h e
e n g a n e . Ho l d t h e e n g i n e a t
3, 000 rpm wi t h no l oad unt i l
t he r adi at or f an comes on,
t hen l et i t i dl e.
3 . Ra i s e t h e e n g i n e s p e e d t o
2, 000 rpm, and hol d i t t here.
l s t he vol t age over 15. 1 V?
l s t he vol t age l ess t han 13. 5 V?
Altarnator/Regulator Test (cont'd:
Appl y a l oad wi t h a VAT- 40 unt i l
t he bat t er y v ol t age dr ops t o
bet ween 12
-
13. 5 V.
To next page
4-28
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From
previ ous page
The charging sy3tem b OK.
l s t he amperage 65 A or more?
Aharnator/Regulator Tesl
(cont'd):
Wi t h t he engi ne speed st i l l at
2. 000 rom, f ul l l i el d t he al t ernat or.
CAUTION: The voh.ge will tise quickly whon th. ahornato. is tull-li.lded Do not allow
the voltage to exceod 18 V; it mry damago the .loctrictl 3yaiGm.
NOTE: Attach a
probe
to a VAT-40Iull tield test lead, and inseft the
probe into the tull field
access hol e at t he back of t he al t emat or' Swi t ch t he f i el d sel ect or t o t he
"A
l Ground)"
posi -
t i on moment ari l y. and check t he amperage readrng.
REGULATOR
(Located inside
the ond coverl
FULL FIELD
ACCESS HOLE
4-29
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Charging System
Alternator Replacement
' t .
Di sconnect the battery negati ve termi nal fi rst, then
the posi ti ve termi nal .
Di sconnect the 4P
(or
3P) connector and WHT wi re
from the al ternator.
WHT WIRE
4-30
'll
Remove the adj usti ng bol t and mounti ng nut, then
remove the al ternator bel t.
Pul l out the through bol t, then remove the al ternator.
THROUGH BOLT
l l ^
I }
v
N
i r
T
n
MOUNTING NUT
10 x 1. 25 mm
44 N.m 14.5 kgf.m.
33 tbtftt
t
o.
LOCKNUT
8 x 1 .25 mm
24 N.m (2.4
kgt m, 17 lbl.ft,
Instal l the al ternator i n reverse order of removal .
Adj ust the al ternator bel t tensi on after i nstal l ati on
(see page 4-34).
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,T
Al ternator Overhaul
NOTE: Do not remove the pul l ey unl ess the front bear-
i ng needs repl acement.
To l oosen the pul l ey l ocknut, use the tool s as shown. l f
necessary, use an i mpact wrench.
PULLEY LOCKNUT
111 N. m
(11. 3 kgf . m, 81. 7 l bf . f t )
FRONT BEARI NG
CAUTION: Do not get grease
or oi l on t he sl i p ri ngs.
BRUSH HOLDER
INSULATOB
"'^.^t%
THROUGH BOLT
PULLEY
PULLEY LOCKNUT
111 N. m {11. 3 kgf . m, 81. 7 l bf , f t )
RECTIFIER
ASSY
Test . page 4 32
PULLEY
BEARING INSULATOR
COVER
REAR HOUSI NG
4-31
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Charging System
I
Rectifier Test
NOTE: The di odes are desi gned to al l ow current to pass
i n one di recti on whi l e bl ocki ng i t i n the opposi te di rec
t i on. Si nce t he al t er nat or r ect i f i er i s made up of ei ght
di odes
(four pai rs), each di ode must be tested for conti
nui ty i n both di recti ons wi th an ohmmeter that has di ode
checki ng capabi l i ty; a total of 16 checks.
' l .
Check for conti nui ty i n each di recti on between
-
t he B and P t er mi nal s.
-
E
( gr ound)
and P t er mi nal s.
Al l di odes shoul d have cont i nui t y i n onl y one di r ec-
t i on.
2. l f any of the di odes fai l s, repl ace the recti fi er assem-
bl y.
(Di odes
are not avai l abl e separatel v.)
4-32
1 .
Alternator Brush Inspection
2.
Remove the end cover, then take out the brush hol der
by removing its two screws.
Measur e t he l engt h of t he br ushes wi t h a ver ni er
cal r per .
Alternator Brush Length:
Standard
(Newl :10.5
mm 10.41 i nl
Servi ce Li mi t: 1.5 mm {0.06 i n)
l f the brushes are l ess than the servi ce l i mi t, repl ace
the al ternator brush assembl v.
VERNIER CALIPER
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Rotor Slip Ring Test
1. Check the resi stance between the sl i p ri ngs.
There shoul d be 1.8
-
3.0 ohms.
. l f resi stance meets the speci fi cati on,
go to step 2
. l f r esi st ance does not meet t he speci f i cat i on,
repl ace the al ternator.
SLI P RI NGS
Check that there i s no conti nui ty between the sl i p
ri ngs and the rotor or rotor shaft.
l f the rotor fai l s ei ther conti nui ty check, repl ace the
al ternator.
ROTOR SHAFT
4-33
Stator Test
1. Check that there i s conti nui ty between each pai r of
l eads.
Check that there i s no conti nui ty between each l ead
and the coi l core.
It the coi l fai l s ei ther conti nui ty check, repl ace the
al ternator.
LEADS
corL coRE
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Charging System
Alternator Belt Inspection
and Adjustment
NOTE: When usi ng a new bel t, fi rst adj ust the defl ecti on
or tensi on to the val ues for the new bel t, then readj ust
the defl ecti on or tensi on to the val ues for the used bel t
after runni ng engi ne for fi ve mi nutes.
Deflection methodi
Appl y a f or ce of 98 N
( 10
kgt , 22l bl l , and measur e t he
defl ecti on between the al ternator and crankshaft pul l ey.
Detlection:
Used Bel t:8.5
-
11.5 mm (0.33 -
0.45 i nl
New Beft: 5.5
-
8.0 mm
10.22
-
0.31 inl
NOTEr l f the bel t i s worn or damaged, repl ace i t.
Measure here
4-34
Belt tension gauge m6thod:
Attach the bel t tensi on gauge
to the bel t and measure the
tensi on. Fol l ow the gauge
manufacturer' s i nstructi ons.
Tensi on:
Used Belt:340
- /0
N
(35 -
50 kgf, 77
-
1r0 tbf)
New Belt: 690
-
880 N
(70 -
90 kgf, 150
-
200 tbt)
NOTE: l fthe bel t i s worn or damaged, repl ace i t.
www.emanualpro.com
lf adjustment is necessary:
1. Loosen the mounti ng nut and the l ocknut.
2. Move the al ternator to obtai n the proper bel t ten-
si on, then reti ghten the nuts.
LOCKNUT
8 x 1. 25 mm
MOUNTING NUT
10 x 1.25 mm
14 N.m {4.5 kgl.m.33 lbf.ft)
Recheck the defl ecti on or tensi on of the bel t.
NOTE: For the power steeri ng
pump bel t and A,/C
compressor bel t adj ustments, refer to secti on 17 and
secti on 22.
24 N. m
(2. 4
kgt m, ' 17 l bf f t )
4-35
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Gruise Control
Component Locati on Index
CRUISE CONTROL UNIT
Input Test, page
4 38
CRUISE INDICATOR LIGHT
(Bui l t
i nt o gauge assembl y)
Bul b Locat i ons. sect i on 23
swtTcH
Test , page 4- 44
SET/RESUME SWITCH
Test, page 4 40
Bepl acement , page 4-40
ACTUATOfi ASSEMBLY
and VACUUM TANK
Test , page 4 41
Sol enoi d Test , page 4 44
CLUTCH INTERLOCK
swrTcH
{M/T)
Test, page 4-43
Swi t ch poski on
adj ust ment ,
sect i on 12
Pedal Hei ght Adj ust ment ,
sect i on 19.
ACTUATOR
CAELE
Adj ust ment , page
4-43
A/T GEAB POSITION
swlTcH (A/Tl
Test,
secti on
' 14
+36
I
BAT
(
I
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UNDER.OASH FUSARELAY BOX
INDICATOR
LIGHT
(0.84W)
l P
I OS E T
5 2 6 7 1 2 8 1 3
CRUI SE CONTROT UNLT 10
1 1 1 1 4
COMEI NATON
L GH'I SWITCH
f7
I
RED/BLK
Gi rcui t Di agram
*:
' 98
00 model s wi t h
Aut omat i c Transmi ssi on.
J
BRAK
LGHTS
PNK BLK BLK
I
L_l
t l
4F\ / l r , mcer n I I
Y{"^ i?tr'.flffi'JF ) l
I
t
l oN
: Pedar rereasedl /l
8LK BLK
T I
G101 G401
CRUI SE
CONTROL
ACTUATOR
t '
BLK
n
:
G202
IGNIT ON
SWITCH UNDER.HOOD FUSEi RELAY BOX
No 41 (100A) No 42 (404)
4-37 www.emanualpro.com
Crui se Control
Control Unit Input Test
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons.
precauti ons, and procedures i n the SRS
secti on
(241
before performi ng repai rs or seryi ce.
' 1.
Remove the dri ver' s dashboard l ower cover and knee bol ster {see secti on 20).
2. Di sconnect the
' l 4P
connector from the control uni t.
3. Inspect the connector and socket termi nal s to be sure they are al l maki ng good contact
l f the termi nal s are bent, l oose, or corroded, repai r them as necessary, and recheck the system.
l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the connector.
-
l f any test i ndi cates a
probl em. fi nd and correct the cause, then recheck the system.
-
l f al l the i nput tests
prove
OK, the control uni t must be faul ty; repl ace i t.
*:
' 98
-
00 model s wi t h
Aut omat i c Transmi ssi on.
Wi re si de ol f emal e t ermi nal s
4-38
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Disconnest the lilP connector from the control unit.
Csvity Wire Test condition
Rconnct tho 14P connGctor to the control unit.
Test: Desired result Possible cause it result is not obtained
BRNAr'VHT
Under al l condi t i ons Check f or resi st ance t o
groundl
There shoul d be 80
-
120 o.
Faul ty actuator sol enoi d
Poor ground (G202)
An open i n the wi re
1 BRN
Under al l condi t i ons Check f or resi st ance t o groundl
There shoul d be 40
-
60 0.
11 BRN/BLK
Under al l condi t i ons Check f or resi st ance t o ground:
There shoul d be 70
-
110 O.
2 GRY
l gni t i on swi t ch ON
(l l ),
mai n swi t ch ON and
brake pedal depressed,
t hen rel eased
Check f or vol t age t o ground:
There shoul d be 0 V wi t h t he pedal
depressed and bat t ery vol t age wi t h
t he pedal rel eased.
.
Faul ty brake swi tch
.
An open i n the wi re
BLK
Under al l condi t i ons Check f or cont i nui t y t o
ground:
There shoul d be cont i nui t y.
.
Poor ground (G401)
.
An open i n t he wi re
5 GRNMHT
Brake pedal depressed,
then rel eased
Check f or vol t age t o ground:
There shoul d be bat t ery vol t age wi t h
t he pedal depressed, and 0 V wi t h
t he pedal rel eased.
Bl own No. 52 1' 15 Al f use i n t he
under-hood f use/ rel ay box
Faul t y brake swi t ch
An open i n t he wi re
LT GRN/
RED
Set button pushed Check f or vol t age t o ground:
There shoul d be bat t ery vol t age.
Bl own No. 52 {' 15 A} fuse i n the
under-hood fuse/rel ay box
Faul ty horn rel ay
Faul ty sevresume swi tch
Faul ty cabl e reel
An open i n the wi re
7
LT GRN/
BLK
Resume button pushed
10 RED/BLU
l gni t i on swi t ch ON l l l ) At t ach t o ground:
Crui se i ndi cat or l i ght i n t he gauge
assembl y shoul d come on.
El own bul b
Bl own No. 25
(7. 5
A) t use i n t he
under-dash f use/ rel ay box
Faul t y di mmi ng ci rcui t i n t he gauge
assembl y
An open i n t he wi re
ELU^r'r'HT
l gni t j on swi t ch ON {l l }
and mai n swi t ch ON;
rai se t he f ront of t he
vehi cl e, bl ock one wheel
and rot at e t he ot her
wheel sl owl y.
Check for voltage between the
ELUA/ VHT @ and BLK O t ermi nal sl
There shoul d be 0
-
5 V or more
-0 -
5 V or more repeat edl y.
Faul t y vehi cl e speed sensor
(VSS)
An open i n t he wi re
r3 LT GRN
l gni t i on swi t ch ON {l l }
and mai n swi t ch ON
Check f or vol t age t o ground:
There shoul d be bat t ery vol t age.
Bl own No. 14
(7. 5
A) f use i n t he
under-dash f use/ rel ay box
Faul t y mai n swi t ch
An open i n t he wi re
l 4 PNK
A'/T: Shift lever in
E, E
o t E
lvl/T: Clutch pedal
rel easeo
Check f or cont i nui t y t o ground:
There shoul d be cont i nui t y.
NOTE: There shoul d be no cont i nu-
i t y when t he shi f t l ever i s i n ot her
posi t i ons or when t he cl ut ch pedal i s
oepresseo.
Faulty A/f gear position switch 1A,/Tl
Faul t y or mi sadj ust ed cl ut ch swi t ch
fi{/r)
Poor gr ound ( G101)
An open i n t he wi re
BLU
St art t ho engi ne. t urn
t he mai n swi t ch ON, and
dri ve t he vehi cl e over 25
mph
(40
km/ h)wi t h t he
crurse cont rol set
Check f or vol t age t o ground:
There shoul d be approx. 5 V
.
Faul t y crui se cont rol uni t
.
Shod t o ground
*:
' 98
-
00 model s wi th Automati c Transmi ssi on.
4-39
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Cruise Control
1 .
Main Switch Test/Replacement
Careful l y pry the swi tch out of the i nstrument panel .
Di sconnect the 6P connector from the swi tch,
Termi nal si de of mal e
rermtnats
6P CONNECTOR
/
Check for conti nui tv between the termi nal s i n each
swi tch posi ti on
accordi ng to the tabl e.
l f there i s no conti nui ty, repl ace the swi tch.
BULES {0.84 Wt
\
Termi nal
;;;
-_\
5 6
OFF G-
@
o G (9
,{)
ON G
@
-o
o-
@
-o
4-40
Set/Resume Switch
Test/Replacement
1 . Di sconnect the baftery negati ve cabl e, then di scon-
nect the posi ti ve cabl e, and wai t at l east three mi n-
utes.
Di sconnect the dri ver' s ai rbag and front passenger' s
ai rbag connectors
(see
secti on 24).
Remove the dashboard l ower cover and knee bol ster.
Di sconnect the 6P connector between the cabl e reel
sub harness and the mai n wi re harness.
4.
Wi re si de of t emal e t ermi nal s
Check for conti nui ty
6P connector i n each
the tabl e.
between the termi nal s of the
swi tch posi ti on
accordi ng to
\
Termi nal
;;;
--_l
2
SET
( ON)
o-
-o
RESUME
( ON)
Cf- c
a
l f there i s conti nui ty. and i t matches the tabl e,
the swi tch i s OK.
l f there i s no conti nui ty i n one or both posi ti ons,
go to step 6.
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n-
n-
6. Remove the two screws. then remove the swi tch.
Check for conti nui ty between the termi nal s i n each
swi tch posi ti on accordi ng to the tabl e.
. l f there i s conti nui ty, and i t matches the tabl e,
repl ace the cabl e reel .
. l f there i s no conti nui ty i n one or both posi ti ons,
replace the switch.
l f al l tests prove OK, reconnect the cabl e reel sub-
harness connector.
Reconnect the dri ver' s ai rbag and front passenger' s
ai rbag connectors, and rei nstal l the access panel on
the steeri ng wheel .
Reconnect the battery posi ti ve cabl e. then the nega-
ti ve cabl e.
Af t er connect i ng t he ai r bag connect or s, conf i r m
proper system operation: Turn the ignition switch ON
(l l );
the SRS i ndi cator l i ght shoul d come on for about
six seconds and then go off.
, s
r.
1 e
t o
7.
l
9.
10.
SET/ RESUME
\
Terminal
t*,r*
-__\
l 2 3
SET ION)
o-
---o
RESUME
(ON)
o-
---o
1 1 .
4-41
1 .
Actuator Test
Di sconnect the actuator cabl e trom the actuator rod
and the 4P connector.
Connect battery power to the No. 4 termi nal and
ground to the No. 1, No. 2 and No. 3 termi nal s,
Connect a vacuum pump to the vacuum hose. Then
appl y vacuum to the actuator.
VACUUM PUMP GAUGE
0- 30 i n. Hg.
A973X- 041- XXXXX
Termi nal si de ot
mal e termi nal s
The actuator rod shoul d
pul l i n compl etel y. l f the rod
pul l s i n onl y part-way or not at al l , check for a l eak-
i ng vacuum Ii ne or defecti ve sol enoi d.
ACTUATOB ROD
(cont ' d)
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Cruise Gontrol
Actuator Test
(cont'dl
5. Wi th vol tage and vacuum sti l l appl i ed, try to pul l
the
actuator rod out by hand. You shoul d not be abl e to
pul l
i t out. l f
you
can. i t i s defectrve.
8.
9.
7.
Di sconnect ground from the No. 3 termi nal . The actu-
ator rod shoul d return. l f i t does not return, but the
vent hose and fi l ter are not pl ugged,
the sol enoi d
valve assembly is defective.
Repeat steps 2 through 5. and di sconnect ground
from the No. l termi nal . The actuator rod shoul d
return. l f i t does not return, but the vent hose and
fi l ter are not pl ugged,
the sol enoi d val ve assembl y
is defective.
l f you repl ace the sol enoi d val ve assembl y, be sure
to use new O-ri ngs on each sol enoi d.
Di sconnect power and ground from the 4P connector.
Disconnect the vent hose from the actuator. Connect
a vacuum pump to the actuator vent hose port,
and
appl y vacuum. The actuator rod shoul d pul l i n com-
pl et el y. l f not , t he vacuum val ve i s st uck open.
Repl ace the actuator,
4-42
I
' t .
Actuator Replacement
3.
4.
7.
Ar
Pul l back the boot. and l oosen the l ocknut. Then di s-
connect the cabl e from the bracket.
Di sconnect the cabl e end from the actuator rod.
1 .
4.
.J.
Di sconnect the 4P connector from the actuator.
Di sconnect the vacuum hose from the vacuum tank.
Pul l out the vent hose.
Remove the three mounti ng bol ts and the actuator
wi th the bracket.
ACTUATOR
ACTUATOR
CABLE
l f necessary, di sconnect the cabl e end from the l i nk-
age over the accel erator pedal , then turn the grom-
met 90' i n the bul khead. and remove the cabl e.
Instal l i n the reverse order of removal , and adj ust
free pl ay at the actuator rod after connecti ng the
cabl e
(see page 4-43).
I
6.
I
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Actuator Cable Adiustment
' 1.
Check that the actuator cabl e operates smoothl y
wi th no bi ndi ng or sti cki ng.
Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(A,/T
i n
E
or
E
posi ti on, M/T i n neutral )
unti l the radi ator fan comes on, then l et i t i dl e.
Measure the amount of movement of the actuator
rod unti l ths cabl e pul l s on the accel erator l ever
(engi ne
speed starts to i ncrease). Free pl ay shoul d
be 11 t 1. 0 mm
( 0. 43
i 0. 04 i n) .
LOCKNUT FREE PLAY: 11 t 1.0 mm
10.43 r 0.04 in)
l f free pl ay i s not wi thi n specs, l oosen the l ocknut,
and turn the adj usti ng nut as requi rsd,
NOTE: l f necessary, check the throttl cabl e frso
pl ay (se
secti on 11), then recheck the actuator rod
free play.
Reti ghten the l ocknut, and recheck the free pl ay.
st
t e
ACTUATOR ROD
Clutch Switch Test
1. Di sconngct t hs 2P connect or f rom t he cl ut ch swi t ch.
CLUTCH SWITCH 2P CONNECTOR
Termi nal si de of
mal e t ermi nal s
2.
5 .
Remove the cl utch swi tch,
Check for conti nui ty between the termi nal s accord-
i ng to the tabl e.
4. l f necessary, repl ace the swi tch or adj ust the
pedal
hei ght
(see
secti on t2).
\
Termi nal
Clutch Switch \
OEPRESSED
RELEASED o o
4-43 www.emanualpro.com
Cruise Control
Brake Switch Test
1. Di sconnect the 4P connector from the swi tch,
2. Remove the brake swi tch.
Termi nal si de of mal e
t ermt nal s
Check f or cont i nui t y bet ween t he t ermi nal s accord-
i ng t o t he t abl e.
lf necessary, replace the switch or adjust
pedal height
(see
section 19).
{P CONNECTOR
\
Termi nal
;;;;-t
1 5
RELEASED O-
---o
PUSHED o-
-o
4-44
ACTUATOR
Actuator Solenoid Test
1. Di sconnect the 4P connector from the actuator.
Termi nal si de of
mal e termi nal s
Check for resi stance between the termi nal s accord-
i ng to the tabl e.
NOTE: Resi stance wi l l vary sl i ghtl y wi th tempera-
ture; speci fi ed resi stance i s at 68"F
(20"C).
VALVE
I
I
I
To VACUUM
TANK
\
Termi nal
il',",""*(t)
_\
1 3
VENT SOLENOID
40- 600
o-
- o
VACUUM SOLENOID
o
---o
30- 500
SAFEW SOLENOID
4 0 - 6 0 0
o-
---o
VACUUM
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Actuator Disassembly
ACTUATOR ERACKET
VALVES
Test , page 4- 44
VACUUM
TANK
) r d'
!
l
l
ACTUATOR CABLE
4-45
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Engi ne
Engi ne RemovaUl nst al l at i on . . . . . . . . . . . . . . . . 5-1
Cyl i nder Head/Val ve Trai n ................... 6-1
Engi ne Bf ock . . . . . . . . . . . . . . . . . . . . . 7- 1
Engi ne Lubri cat i on . . . . . . . . . . . 8-1
Intake Mani fol d/Exhaust System ........ 9-1
Cool i ng . . . . . . . . . 10-1
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Engi ne RemovaUl nstal l ati on
Engi ne Removal /l nstal l ati on
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5- 2
l nst al l at i on . . . . . . . . . . . . . . . . . . . . . 5- 12
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Engi ne RemovaUl nstal l ati on
Removal
@
a Make sure
iacks
and safety stands are placed properly
and hoist brackets are attached to the correct oosi-
tions on the engine.
. Make sure the vehicle will not roll oft stands and fall
while you are working under it.
NOTEI
. Use f ender cover s t o avoi d damagi ng pai nt ed sur -
faces.
o To avoi d damage. unpl ug the wi ri ng connectors care-
ful l y whi l e hol di ng the connector porti on.
l vl ark al l wi ri ng and hoses to avoi d mi sconnecti on.
Al so, be sure that they do not contact other wi ri ng or
hoses, or i nterfere wi th other parts.
Secure the hood i n the open posi ti on.
Di sconnect the battery negati ve termi nal fi rst, then the
posi ti ve termi nal .
Di sconnect the battery cabl es from the under-hood
fuse/rel ay box and battery posi ti ve termi nal .
1 .
2.
4. Remove the batterv and batterv base.
BATTERY
BASE
I x 1. 25 mm
24 N.m
(2.4
kgf.m,
17 tbnft)
-t'.-e
F
F
Y
5. Remove the i ntake ai r duct and ai r cl eaner housi no.
INTAKE AIB
I
6.
7.
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6. Di sconnect the engi ne control modul e
(ECM)/power-
trai n control modul e
(PCM)
connectors from the ECM/
PCM.
7. Di sconnect the mai n wi re harness connector.
Remove the grommet and wi re harness cl amps, then
pul l out the EcM/Pcl vl connectors.
6 x 1 . 0 mm
11 N. m 11. 1 kgl . m, 8l bf . f t l
CONNECTOR
GROMMET
L Di sconnect the engi ne wi re harness connectors on
the l eft si de of the engi ne compartment.
ENGINE WIRE
HARNESS CONNECTORS
(cont' d)
5-3
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Engi ne Removal /l nstal l ati on
Removal
(cont'dl
Remove the crui se control actuator
(see
secti on 4).
Remove t he mount i ng bol t and l ock bol t , t hen
remove the P/S pump bel t and pump.
10.
1 t .
MOUNNNG BOLT
8 x 1. 25 mm
2a N.m 12.4 kg{.m, 17 lbtftl
P/S PUMP
BELT
LOCK BOLT
I x 1. 25 mm
24 N.m {2.4 kgtm,
'17
lbf.ftl
12. Loosen the i dl er pul l ey bracket bol t and adj usti ng
bol t, then remove the ai r condi ti oni ng
(A,/C)
com-
pressor bel t.
ID1TR PULI.f,Y ARACKET BOLT
10 r 1. 25 mm
a{ N.m 14.5lgtm,33 lbf.ft)
ADJUSTING BOLT
LOCKNUT
8 x 1. 25 mm
24 N.m {2.4 kgf.m, 17 lbf.ftl
5-4
13. Rel i eve fuel pressure
{see secti on 11).
@
Do not 3mok6 whi l worki ng on th6
tugl systsm. Koep open flam or spark away from
the work area. Drai n fuel onl y i nl o an approved
container.
14. Remove the evaporati ve emi ssi on
(EVAP)
control
cani ster hose and tuel feed hose.
33 N.m
(3.4
kgt.m,
2s tbf.ft)
,%l
*ryft
'fltr
\ ' t , f
EVAP CC
CANISTER HOSE
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he
'.n
! d
' 15.
Remove the brake booster vacuum hose, fuel return
hose and vacuum hose.
'97
-
98 modals:
BRAKE BOOSTER
VACUUM HOSE
' ol
FUEL RETURN
HOSE
'99
-
00 modob:
BRAKE BOOSTER
VACUUM HOSE
' 16.
Remove the throttl e cabl e by l ooseni ng the l ocknut,
then sl i p the cabl e end out of the accel erator l i nk-
age. Take care not to bend the cabl e when remov-
i ng i t. Al ways repl ace any ki nked cabl e wi th a new
one.
97
-
98 modeb:
99
-
00 modob:
THROTTLE
CABLE
ADJUSTING
NUT
(cont' d)
5- 5
LOCKNUT
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Engi ne Removal /l nstal l ati on
Removal
(cont'd)
17. Di sconnect the power
steeri ng pressure
{psp} swi tch
connector, and remove the wi re harness cl amo.
Remove the sl ave cyl i nder and cl utch hose bracket
(Mrr).
NOTE:
. Do not di sconnect the pi pe/hose
assembl y.
. Do not operate the cl utch pedal
once the sl ave
cyl i nder has been removed.
. Take care not to bend the pi pe/hose
assembl y.
5-6
18.
19. Di sconnect the transmi ssi on ground
cabl e
(M/T).
Remove t he cot t er pi ns,
t hen r emove t he st eel
washers, pl asti c
washers, shi ft cabl e, and sel ect cabl e
from the l evers
(M/T).
sElEcr
CABI."E
21. Remove the cabl e bracket from the cl utch housi ng
(M/T).
GROUND CABI."E
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22. Remove the radi ator caP.
!@
use care when removing the radiatol
cap to avoid scalding by hot coolani or steam.
23. Rai se the hoi st to ful l hei ght
24. Remove the front ti res/wheel s.
25. Remove the
guard bar and spl ash shi el d.
8 x 1. 25 mm
2,1 N.m {2.4 kgf,m, 17 lbl ft)
6 x 1 . 0 mm
9.8 N.m {1.0 kgf.m, GUARD BAR
7.2 tbf.rr)
Loosen t he dr ai n
pl ug i n t he r adi at or . Dr ai n t he
engi ne cool ant
(see page 10-51.
Drai n the transmi ssi on oi l or fl ui d. Rei nstal l the drai n
plug using a new washer lsee
section 13
(M/T)
or sec-
tion 14
(ly'T)].
Drai n the engi ne oi l . Rei nstal l the drai n bol t usi ng a
new washer {see
page 8-4).
Bemove the A,/C compressor. Do not di sconnect the
!y'C hoses.
SPLASH
26.
27.
28.
29.
ER
lC
EB
30. Di sconnect the
pri mary
heated oxygen sensor
(prl -
mary HO2S) connector. then remove exhaust
pi pe A
'97
-
98 U.S. models
(Cslifornia):
PRIMARY HO2S
CONNECTOR
GASKET
Repl ace.
SELF-LOCKING NUT
8 x 1. 25 mm
22 N.m 12.2 kgf.m,
16 lbf.ftl
Repl ace.
8 x 1. 25 mm
16 N.m {1.6 kgf.m.
12 tbt.ftl
Repl ace.
SELF.LOCKING NUT
10 x 1. 25 mm
54 N.m 15.5
kgf.m,
.() tbf.frl
Replace.
NUT
'97
-
98 U.S. modls {Except
California):
'99
-
00 models:
PRIMARY HO2S
CONNECTOR
GASKETS
Repl ace.
GASKET
Repl ace.
SELF.LOCKING
8 x
' l . 25
mm
22 N.m
(2.2 kgf m,
16 rbf.ftl
Repl ace.
SELF.LOCKING
NUT
8 x 1. 25 mm
16 N. m 11. 6
kgf . m,
12 tbt fr)
Repl ace.
10 x 1. 25 mm
54 N.m 15.5
kgt.m,
40 rbt.ftl
Repl ace.
{cont' d)
5-7
www.emanualpro.com
Engi ne RemovaUl nstal l ati on
OOI{TROL PI
Removal
(cont' dl
31. Remove the shi ft cabl e. Take care not to bend the
cabl e when removi ng i t. Al ways repl ace any ki nked
cabl e wi th new one
(Afl -).
SNAP PIN
sHtFT CABtt
OOVEB
8 x 1.25 mm
t2 N.m 12.2 lgtr'l'',,
16 tbf.ftl
Remove the ri ght damper fork
(see
secti on 18).
Di sconnect the suspensi on l ower arm bal l
j oi nts (see
secti on 18),
Remove the dri veshafts
(see
secti on t6). Coat al l
preci si on-fi ni shed
surface wi th cl ean engi ne oi l . Ti e
pl asti c
bags over the dri veshaft ends.
5- 8
34.
Make marks on the transfer compani on fl ange and
propel l er
shaft as shown. Use these marks to set the
propel l er shaft i n the proper posi ti on
when rei n-
stal l i ng
(4WD).
Remove the four bol ts securi ng the propel l er
shaft,
then separate the
propel l er
shaft from the transfer
compani on fl ange
(4WD).
E x 1.25 mm
32 N.m 13.3 lgt.m, 24 lbt'ftl
Replce.
37. Lower the hoi st,
www.emanualpro.com
rd
t e
n-
38. Remove t he upper and l ower r adi at or hoses and
heater hoses.
39. Remove t he t r ansmi ssi on
gr ound cabl e and hose
cl amp
(A,/T).
GBOUI {DCABLE 6x 1, 0 mm
11 N.m 11.1 lof'm,
I tbf.ftl
40. Remove t he ATF cool er hoses, t hen
pl ug t he ATF
cool er hoses and, n"" l Af I ).
rt,
BT
6 x l , 0 mm
A/C HOSE
41.
42.
Remove the radi ator
(see page 10"4).
Remove the IVC hose cl amp.
9.8
'm
lt.o
klt m,
l.2tutal
(cont' d)
5- 9
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Engi ne RemovaUl nstal l ati on
Removal
(cont'dl
43. Attach the chai n hoi st to the engi ne.
5- 10
www.emanualpro.com
44. Remove the left and right front mounts and brackets
Repl ace.
M/T:
MOUNT/BRACKET
Alf I
45. Remove the rear mount bracket mounti ng bol t.
REAB MOUNT
UPPER
47. Remove the transmission mount bracket, then remove
the transmission mount.
46. Remove the uDper bracket.
Check that the engi ne^ransmi ssi on i s compl etel y free
of vacuum hoses, fuel and coolant hoses, and electri-
cal wi r i ng.
Sl owl y rai se the engi ne approxi matel y 150 mm
(6
i n)'
Check once again that all hoses and wires are discon-
nected from the engi nenransmi ssi on.
Rai se the engi ne al l the way, and remove i t from the
vehi cl e.
49.
1
TRANSMISSION
MOUNT BMCKET
50.
5- 1
www.emanualpro.com
En
gi ne
Removal /l nstal l ati on
Instal l ati on
Bracket Bolts Torque Specifications:
10 x 125 mm
il,a
t*m {4.5 tgt'm,
d, tbtft)
8 r 1. 25 mm
24 N.m 12.4 kg{.m;
17 tbt frl
10 x 1.25 mrn
,L
il.tn {1.5 tgt m, :|:l lbf'ft}
P/S PUMP
BRACKET
SIDE EIIGII{E
i'OUT{T BRACKET
10 x 1.25 mm
54 t$m 15.5 tgfm,
iO
lbflrl
ALTERI{ATOR
BNACKET
A/C @MPRESSOR
BRACIGT
t0 r 125 ]nm
a,l t+Jn ll.5 lgf-rn,
3 tbf{tl
5- 12
t t 1.25 m.D
2a
'tn (2,4
kgt ft,
17 tbtftl
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Engine Installation:
l nstal l the engi ne i n the reverse order of removal .
Rei nstal l the mount bol ts/nuts i n the fol l owi ng sequence
Fai l ure to fol l ow these procedures may cause excessrve
noi se and vi brati on. and reduce bushi ng l i fe.
1. I nst al l t he t r ansmi ssi on mount and br acket . t hen
ti ghten the bol ts on the frame si de. Do not ti ghten
the bol ts/nuts on the transmi ssi on si de.
A/T:
12 x 1.25 mm
6,a N.m 16.5
kgtr.m,
47 tbt f0
R
R
TM'{SMISSION
MOUNT
M/T:
TRANSMISSION
MOUNT BRACKEY
TRANSMISSION
MOUNT
12 x 1. 25 mm
64 N.m {6.5 kgt.m,
!,
m,
47 tbl.ft)
2. Instal l the upper bracket, then ti ghten the nuts i n the
numbered seauence.
O
12 x 1. 25 mm
7a N.m {7.5 kgf'm,
54 tbf.trl
A
12r1. 25mm
7il N.m 17.5
kgl'm,
5,r lbt.ft)
3. Instal l the rear mount bracket mounti ng bol t.
ti ghten the bol t.
MOUNN G BOLT
Replace.
Do not
(cont' d)
5- 13
www.emanualpro.com
En gi ne
RemovaUl nstal l ati on
Instal l ati on
(cont' d)
4. Ti ght en t he bol t / nut s on t he t r ansmi ssi on mount
bracket in the numbered sequence.
AIT:
@
12 x 1.25 mm
?4 N.m {t.5 kgt.h,
5,4lbf.ftl
O 12 x 1.25 mm
6l
.m (6.5
kgt m,
47 tbt{r}
M/T:
i ?. 12 x 1. 25 mm
74 N. m {7. 5 kgf ' m.
s/r tbr.ftl
,,.....\.L}
@' . . . , ' . . 4:
a1l 12 x 1. 25 mm
64 N.m
{6.5 kgf.m,
47 lbf.ft)
5- 14
5. Ti ghten the rear mount bracket mounti ng bol t.
59 N.m {6.0 lgl'm, ait lbf.ftl
Replace.
12 x 1. 25 mm
www.emanualpro.com
Loosen t h i s nut ,
i ! 12 x 1. 25 mm
g
N.m {6.5 kgf.m, 47 lbf.ftl
Repl ace.
6. Instal l the ri ght front mounvbracket, then ti ghten the
bol ts i n the numbered sequence.
A/T:
(D
to x t.zs mm
44 N.m {4.5 kgf m, 33 lbf.ft)
M/T:
O 12 x 1. 25 mm
64 N.m 16.5 kgf.m. 47 lbf.ft)
Repl ace.
Loosen t hi s nut .
O
10 x r.25 mm
4/t N.m 14.5 kgt.m, 33 lbf.ft)
7. Instal l the l eft front mount, then ti ghten the bol ts/nut
i n the numbered seouence.
O
t2 r 1.25 mm
8il N.m 18.5
kgt.m, el |bfftl
O
12 x 1. 25 mm
59 N.m 16.0 kgt ln,
,
lbfttl
Replace.
@
l o x 1.25 mm
a,a N.m 14.5 kgf.m,
33 tbf.trl
{cont' d)
5- 15
www.emanualpro.com
Engi ne Removal /l nstal l o
cton
Installation
(cont'd)
8. Ti ghten the nut on the ri ght front mount.
Al Ti
59
.m
16.0 tgt m,
(l
lbfftl
Replace.
Ml Ti
12 x' 1. 25 mm
59 N.m 16,0 kgt m,
/(}
lbt ttl
Reol ace.
5- 16
9. Perform the fol l owi ng checks and adj ustments:
.
Check that the spri ng cl i p on the ends of the dri ve-
shaft and i ntermedi ate shaft cl i cks i nto pl ace.
Use
new spri ng cl i ps.
. Adj ust the shi ft cabl e
(see
secti on l 4).
. Adj ust the throttl e cabl e
(see
secti on 11).
. Refi l l the engi ne wi th engi ne oi l
(see page
g-4).
. Refi l l the transmi ssi on wi th oi l or fl ui d
(see
sec-
t i on 13 or 14) .
. Refi l l the radi ator wi th engi ne cool ant
(see page
10_5) .
. Bl eed ai r f r om t he c ool i ng s y s t em wi t h t he
heater val ve open
(see
page l 0-5).
. Cl ean the battery posts
and cabl e termi nal s wi th
sandpaper, assembl e them, then appl y grease
to
Drevent corrosron.
.
Inspect for fuel l eakage (see
secti on 1l ).
After assembl i ng fuel l i ne pans,
turn on the i gni -
ti on swi tch
(do
not operate the starter) so that
the fuel pump
operates for approxi matel y two
seconds and the fuel Ii ne pressuri zes.
Repeat t hi s oper at i on t wo or t hr ee t i mes, and
check for fuel l eakage at any poi nt
i n the fuel l i ne.
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Mount and Brackst Bolts/Nuts Torqus Value Specitications:
A:
' 10
x 1. 25 mm
64 N.m 16.5 kgI.m, 47 lb{.ftl
B: 12 x 1. 25 mm
59 N.m 16.0 kgf.m, 43 lblft)
Repl ace.
C: 14 x 1. 5 mm
8:l N.m
(8.5
kgt.m, 6r lbl'ft)
Repl ace.
D: 10 x 1, 25 mm
,t4
N.m
(4.5 kgf'm,33 lbIft)
Er 12 x 1. 25 mm
83 N.m 18.5 kgf.m, 61 lbl.ftl
5-17
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Cyl i nder Head/Val ve Trai n
Speci af Tool s . . . . . . . . . . . . . 6-2
Valve Clearance
Adi ust ment . . . . . . . . . . . . 6-3
Valve Seals
Replacement
(cylinder
head
removal not requi redl . . . . . . . . . . . . . . . . . 6-5
Crankshaft Pulley and Pulley Bolt
Repl acement . . . . . . . . . 6-7
Timing Belt
I l l ust rat ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
I nspect i on . . . . . . . . . . . . . , 6-9
Tensi on Adj ust ment . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Removal . . . . . . . . . . . , . . . . . 6-10
l nst al l at i on . . . . . . . . . . . . . 6-11
Crankshaft Speed Fluctuation
(CKFI
Sensor
Repl acement . . . . . . . . . 6-13
Cylinder Head
l l l ust rat ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Removal . . . . . . . . . . . . . . . . . 6- 16
Warpage . . . . . . . . . . . . . . . . 6-27
lnstallation ............. 6-30
Camshafts
l nspect i on . . . . . . . . . . . . . . 6-22
Valves, Valve Springs and Valve Seals
Removal . . . . . . . . . . . . . . . . , 6-23
l nst al l at i on . . . . . . . . . . . . . 6-29
Valve Guides
Val ve Movement . . . . . . . . . . . . , , , , . , . . . . . . . . . . . . 6-25
Repl acement . . . . . . . . . 6-25
Reami ng . . . . . . . . . . . . . . . . . 6-27
Valve Seats
Recondi t i oni ng . . . . . . 6-28
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Special Tools
Ref. No. I Tool Number
Description
(Xy
I
Page Refereflce
o
,61
A)
07JAA
-
001020A
07JAB
-
00' 10204
OTMAB
_
PY3O1OA
07757
-
PJ1010A
07942
-
6570100
07984
-
657010D
Socket, 19 mm
Hol der Handl e
Pul l ey Hol der Attachment,50 mm, Offset
Val ve Spri ng Compressor Anachment
Val ve Gui de Dri ver, 6.6 mm
Val ve Gui de Reamer, 6.6 mm
1 6-1
1
|
6-7
r
I
6-7
1 6- 23, 29
1
I
6-25,26
'l
| 6-27
a!)
a!)
c--E-rr------------
6-2
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Valve Clearance
Adiustment
Adj ust the val ves onl y when the cyl i nder head tempera-
ture i s l ess than 100"F
(38"C).
1. Remove the cyl i nder head cover.
Remove the mi ddl e cover
(see page 6-11).
Set the No. 1 pi ston at TDC. The
"UP"
mark on the
pul l eys shoul d be at the top, and the TDC marks on
the pul l eys shoul d al i gn wi th the
poi nters on the back
POINTER POINTER
Adj ust the val ves on No. 1 cyl i nder.
Intake: 0.08
-
0.12 mm
(0.003 -
0.005 i nl
Exhaust: 0.16
-
0.20 mm
(0.006 -
0.008 in)
Loosen the l ocknut, and turn the adi ustment screw
unti l the feel er gauge sl i des back and forth wi th a
sl i ght amount of drag.
LOCI(NUT
9 x 0.75 m.n
Adiusting Screw Locations:
INTAKE
No. 4 No. 3 No. 2
(cont' d)
6- 3
25 N.m 12.5 kgf.m, 18lbf.ft)
EXHAUST
No. 1
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Valve Clearance v
Adjustment
(cont'dl
6. Ti ghten the l ocknut, and check the cl earance agaj n.
Repeat the adj ustment i f necessary.
GAUGE
Rotate the crankshaft 180" counterclockwise
(camshaft
pul l ey turns 90' ).
The
"UP"
marks shoul d be on the exhaust si de. Adj ust
the val ves on No. 3 cyl i nder.
.UP"
MARKS
7.
8. Rotate the crankshaft 180" countercl ockwi se to bri nq
No. 4 pi ston to TDC.
The
"UP"
marks shoul d be poi nti ng strai ght down.
Adj ust the val ves on No. 4 cyl i nder.
Rotate the crankshaft 180' countercl ockwi se to bri no
No.2 pi ston to TDC.
The
"UP"
marks shoul d be on the i ntake si de. Adi ust
the val ves on No. 2 cyl i nder.
Instal l the cyl i nder head cover
(see page 6-32).
Retorque the crankshaft pul l ey bol t
(see page 6-7).
10.
1 1 .
"UP"
MARKS
"UP"
MARKS
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Valve Seals
Replacement
(cylinder
head removal not required)
The procedure shown bel ow appl i es when usi ng the i n-
car val ve spr i ng compr essor
( Snap- on
YA8845 wi t h
YA8845-2A 7/8" auachment). Use approved eye protec-
ti on.
1. Turn the crankshaft so that the No. 1 and the No. 4
pi stons are at top dead center
(TDC).
2. Remove the cyl i nder head cover.
3. Remove the di stri butor.
4. Loosen and di sconnect t he t i mi ng bel t f r om t he
camshaft pul l eys.
5. Remove the camshaft hol der bol ts. then remove the
camshaft hol ders, the camshafts and rocker arms.
lntake Valve Seals
6. Usi ng the 6 mm bol ts suppl i ed wi th the tool , mount
t he t wo upr i ght s t o t he cyl i nder head at t he end
camshaft hol ders. The upri ghts fi t as shown.
7. Insert the cross shaft through the top hol e of the
two upri ghts,
at.
9.
Sel ect the 7/8 i n. di ameter l ong compressor attach-
ment, and fasten the attachment to the front hol e of
the l ever arm wi th the speed pi n suppl i ed.
Posi ti on the pi ston at TDC, and i nsen an ai r adaptor
i nto the spark pl ug hol e. Pump ai r i nto the cyl i nder
t o keep t he val ve cl osed whi l e compr essi ng t he
spri ngs and removi ng the val ve keepers.
10. Put shop towel s over the oi l passages to prevent
t he val ve keeper s f r om f al l i ng i nt o t he cyl i nder
head.
Posi ti on the l ever arm under the cross shaft so the
l ever i s perpendi cul ar to the shaft and the compres-
sor attachment rests on top of the retai ner for the
spri ng bei ng compressed. Use the rear posi ti on sl ot
on the l ever as shown,
' t1.
OIL PASSAGE
OIL PASSAGES
(cont' d)
6-5
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Valve Seals
12.
Replacement
(cylinder
head removal not requiredl
(cont'dl
Usi ng an upward moti on on the l ever arm, compress
the val ve spri ng and remove the keepers from the
val ve stem. Sl owl y rel ease pressure on the spri ng.
Repeat step 11 for the other val ve i n that cyl i nder.
Remove the val ve seal s
(see page 6-24).
Instal l the val ve seal s
(see page 6-29).
l nstal l the spri ngs, the retai ners and the keepers i n
reverse order of removal .
' 17.
Repeat steps 9 to 16 for the other three cyl i nders.
Exhaust valve Seals
18. Usi ng the 5 mm bol ts suppl i ed wi th the tool , mount
t he t wo upr i ght s t o t he cyl i nder head at t he end
camshaft hol ders. The upri ghts fi t as shown.
19. Insert the cross shaft through the bottom hol e of
the two upri ghts.
Sel ect the 7/8 i n. di ameter short compressor attach
ment, and fasten the attachment to the No. 4 hol e of
the l ever arm wi th the speed pi n suppl i ed.
Posi ti on the
pi ston at TDC, and i nsert an ai r adaptor
i nto the spark
pl ug hol e. Pump ai r i nto the cyl i nder
t o keep t he val ve cl osed whi l e compr essi ng t he
spri ngs and removi ng the val ve keepers.
13.
14.
15.
16.
20.
t 1
22. Put shop towel s over the oi l passages to prevent
t he val ve keeper s f r om f al l i ng i nt o t he cyl i nder
neao.
23. Posi ti on the l ever arm under the cross shaft so the
l ever i s perpendi cul ar to the shaft and the compres-
sor attachment rests on top of the retai ner for the
spri ng bei ng compressed. Use the rear posi ti on sl ot
on the l ever as shown.
Usi ng a downward moti on on the l ever arm, com-
press the val ve spri ng and remove the keepers from
t he val ve st em. Sl owl y r el ease pr essur e on t he
spr i ng.
Repeat step 24 for the other val ve i n that cyl i nder.
Remove the val ve seal s
(see page 6-24).
Instal l the val ve seal s
(see page 6-29).
Instal l the spri ngs, the retai ners and the keepers i n
reverse order of removal .
Repeat steps 21 to 28 on the other three cyl i nders.
24.
21.
28.
29.
o- o
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Crankshaft Pul l ey and Pul l ey Bol t
Replacement
When i nstal l i ng and ti ghteni ng the pul l ey, fol l ow the procedure bel ow.
Cl ean, remove any oi l , and l ubri cate poi nts shown bel ow.
C: Cl ean
x I Remove any oi l
a: Lubri cate
CRANKSHAFT
PULLEY
X
X X
X
o
X
X
X
X
CRANKSHAFT
oooo
-
oooo
o
o
o
o
o
o
o
o
Crankshaft pulley bolt size and torque value:
14 x 1.25 mm
177 N' m
(18.0
kgf.m, 130 l bt.ftl
NOTE: Do not use an i mpact wrench when i nstal l i ng.
HOLDER ATTACHMENT.
50 mm, OFFSET
OTMAB
-
PY3Ol OA
SOCKET, 19 mm
07JAA
-
001020A
{or Commerci al l y avai l abl e}
WASHER
^
oooo
6r.
R
o".
6-7
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Ti mi ng Bel t
l l l ustrated Index
Cl
k
6
CYLI NDER HEAD
COVER
Ref er t o
page 6-32
when i nst al l i ng.
6 x 1 . 0 mf i
11 N. m { 1. 1 kgt m,
8.0 rbtft)
HEAD COVER GASKET
Repl ace when l eaki ng,
damaged or det eri orat ed.
Appl y l i qui d
gasket at
t he ei ght corners of t he
WASHER
Repl ace i f damaged
or det eri orat ed,
RUEBER SEAL
Repl ace i l damaged
ot det et i orat ed.
kgf.m,
\
@
7.2 tbtft)
TIMING BELT
I nspect i on,
page 6-9
Adj ust ment , page 6-9
Removal ,
page 6-10
I nst al l at i on,
page 6-1 1
8 x 1. 25 mm
37 N. m
(3. 8 kst . m, 27 l bf f t l
MIDOLE COVER
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
1.2lbt.ftl
RUBBER SEALS
Repl ace when damaged
or det eri orat ed,
LOWER COVER
TIMING BELT
ORIVE PULLEY
Repl acement ,
page 6' 7
ADJUSTING BOLT
10 x 1. 25 mm
54 N.m
(5.5
kgl.m, 40 lbf.ft)
CNANKSHAFT PULLEY
nepl acement , page 6-7
l nst al l wi t h concave
surf ace f aci ng out ,
Remove any oal and cl ean,
BOLT
CRANKSHAFT SPEEO
FLUCTUATION ICKF}
SENSOR
6 x 1 . 0 mm
9. 8Nm( 1. 0kgl . m,
7.2 tbl.ft)
14 x 1. 25 mm
177 N. m
(18. 0 kgf ' m,
130 tbf.fr)
Repl acement ,
Page
6-7
Do not use an i mpact
wrench when i nst al l i ng.
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1 .
2.
Inspection
Remove the cyl i nder head cover.
l nspect the ti mi ng bel t for c.acks and oi l or cool ant
s oak i ng. Repl ac e t he bel t i f i t i s oi l or c ool ant
soaked. Remove any oi l or sol vent that gets on the
bel t.
l nspect t hi s
area for wear.
After i nspecti ng, retorque the crankshaft pul l ey bol t
to 177 N.m
(18.0
kgnm, 130 l bf.ft).
Instal l the cyl i nder head cover
(see page 6-32).
3.
Tension Adjustment
NOTE:
. Al ways adj ust the ti mi ng bel t tensi on wi th the engi ne
cot o.
. Al ways rotate the crankshaft countercl ockwi se when
vi ewed f r om t he pul l ey si de. Rot at i ng i t cl ockwi se
may r esul t i n i mpr oper adi ust ment of t he bel t t en-
si on.
' 1.
Remove the cyl i nder head cover
2. Set the No. 1 pi ston at TDC
(see page.6-12).
3. Rotate the crankshaft fi ve or si x revol uti ons to set
the bel t.
Set the No. 1 pi ston at TDC.
Loosen the adj usti ng bol t 1/2 turn
(180' )
onl y.
4.
5.
ADJUSTING BOLT
5,4 N.m
(5.5
kgf.m,
40 tbtftl
For adi ust ment onl y,
7 .
8.
Rotate the crankshaft countercl ockwi se three teeth
on the camshaft pul l ey.
Ti ghten the adj usti ng bol t to the speci fi ed torque.
After adj usti ng, retorque the crankshaft pul l ey bol t to
177 N.m
(18.0
kgf.m, 130 l bf.ft).
Instal l the cyl i nder head cover
(see page 6-32). 9.
rot at i on,
6- 9
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Timing Belt
Removal
Repl ace the ti mi ng bel t at 105,000 mi l es
(168,000
km)
accordi ng to the mai ntenance schedul e {normal condi -
ti ons/severe condi ti ons). l f the vehi cl e i s regul arl y dri ven
i n ei ther of the fol l owi ng condi ti ons, repl ace the ti mi ng
bel t at 60,000 mi l es
(U.S.A.l
100.000 km
(Canada).
-
l n very hi gh temperatures
(over
110' F, 43"C).
-
In very l ow temperatures
(under -20"F. -29"C).
Turn the crankshaft pu\ley so the No. 1 piston is at
top dead center
(TDC).
Remove the guard
bar and spl ash shi el d
(see page
5-7 ).
Loosen the mounti ng bol t and l ock bol t. then remove
the power steering
(P/S) pump belt.
MOUNNNG BOLT
8 x 1.25 rnm
1 .
2.
,l
4. Loosen the i dl er pul l ey bracket bol t and adj usti ng
bol t, then remove the ai r condi ti oni ng
(l VC)
compres
sor bel t
(see page
5-4).
6- 10
24 N.m {2.4 kgt.m, 17 lbf.ftl
24 N.m 12.4 kgf.m, lt lbf.ftl
5. Loosen the mounti ng nut and l ocknut, then remove
the al tefnator bel t.
LOCKNUT
I x 1. 25 mm
2a N.m 12.4 kgt m, 17 lblftl
6.
10 x 1, 25 mm
4,1 N.m
(,1.5
kgt m, 33 lbtftl
Remove the crui se control actuator
(see
secti on 4).
Suppor t t he engi ne wi t h a
j ack,
t hen r emove t he
upper br ac k et . Mak e s ur e t o pl ac e a c us hi on
between the oi l Dan and the i ack.
12 x 1. 25 mm
74 N.m
(7.5
kgf m, 54 lbtftl
7.
BRACKET
AELT
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8. Remove the cyl i nder head cover.
NOTE: Refer to page 6-32 when i nstal l i ng the cyl i n-
der head cover.
Remove the crankshaft pul l ey (see page 6-7).
Remove the mi ddl e cover and l ower cover. Do not
use these covers to store removed i tems.
9.
10.
1 1 .
MTDDLE
6x1. 0mm
COVER
9. 8 N. m {1. 0 kgt m,
LOWER
COVER
9.8 N.m (1.0
kgt.m, 7.2 lbf.ftl
Mark the di recti on of rotati on on the ti mi ng bel t.
Loosen the adj usti ng bol t 180' . Push the tensi oner to
remove tensi on from the ti mi ng bel t, then reti ghten
the adi usti ng bol t.
AINUSTING BOLT
54 N.m
(5,5
kgt m,
.(} tbf.rrl
12.
13. Remove t he t i mi ng bel t .
Instal l ati on
Instal l the ti mi ng bel t i n the reverse order of removal ;
Onl y key poi nts are descri bed here,
1. Set the ti mi ng bel t dri ve pul l ey so that the No. 1 pi ston
is at top dead center
(TDC).
Align the groove on the
ti mi ng bel t dri ve pul l ey to the poi nter on the oi l pump.
GROOVE
DRIVE PULLEY
Cl ean.
2. Set the camshaft pulleys so that the No. I piston is at
TDC. Al i gn the TDC marks on the camshaft pul l eys to
the pointers on the back cover.
POI NTER
CAMSHAFT
PULLEY
Cl ean.
POINTER
r - t
(cont ' d)
6 - 1 1
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Ti mi ng Bel t
Installation
(cont'd)
3. Instal l the ti mi ng bel t ti ghtl y i n the sequence shown.
O
Ti mi ng bel t dri ve pul l ey (crankshaft)
J
@
Adj ust-
i ng pul l ey
=r
@
Water pump pul l ey r
@
Exhaust
camshaft pul l ey
--)
@
Intake camshaft pul l ey.
NOTE: Make sure the ti mi ng bel t dri ve pul l ey and
camshaft
pul l eys are at TDC.
4. Loosen and reti ghten the adj usti ng bol t to tensi on
the ti mi ng bel t.
5. Cl ean. t hen i nst al l t he l ower cover and mi ddl e
cover.
Instal l the crankshaft pul l ey, then ti ghten the pul l ey
bol t
(see page 6-7).
Rotate the crankshaft pul l ey about fi ve or si x turns
countercl ockwi se so that the ti mi ng bel t posi ti ons
on the pul l eys.
Adj ust the ti mi ng bel t tensi on {see
page 6-9).
1.
6-12
9. Check that the crankshaft pulley and camshaft pulleys
are both at TDC.
POINTER ON
l f the camshaft pul l eys are not posi ti oned at TDC,
remove the ti mi ng bel t. adj ust the posi ti on fol l owi ng
the procedure on page 6-11. then rei nstal l the ti mi ng
belt.
Instal l the cyl i nder head cover
(see page 6-32).
After i nstal l ati on, adj ust the tensi on on each bel t.
. See secti on 4 for al ternator bel t tensi on adj ust-
menr.
. See secti on 22 for
NC compressor bel t tensi on
adj ustment.
. See secti on 17 for P/S pump bel t tensi on adj ust-
ment.
10.
1 1 .
12.
POINTER
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CKF Sensor
Repl acement
1 .
|o|'ln PUUCY BMCKET SOLI
l0 r 1.25 mm
14
.m
14.5 kgl.m,3:' lbtftl
Remove the guard bar and spl ash shi el d
(see page
5-7 t.
Loos en t he l oc k bol t and mount i ng bol t , t hen
remove the P/S pump bel t.
MOUNTING BOLT
8 x 1.25 mm
PUMP
BELT
Loosen the adj usti ng bol t and i dl er pul l ey bracket
bol t, then remove the Ay' C comDressor bel t.
ADJUSTING BOLT
LOCKNUT
8 x 1. 25 mm
24 N.m {2.4 kgf.m, 17 lbf.ft)
24 N.m
(2.{
kgf.m, 17 lbf.ttl
24 N.m 12.4 lgf.m, 17 lbl.ftl
4. Loosen the l ocknut and mounti ng nut, then remove
the al ternator bel t.
LOCKNUT
8 x 1. 25 mm
24 N.m
(2.4
kgl.m, 17 lbtftl
10 x 1 .25 mm
a4 N.m
(4.5
kgt m, 33 lbtft)
E
6.
7.
aJ.
Remove the cyl i nder head cover.
Remove the crankshaft pul l ey (see page 6-7).
Remove the mi ddl e cover and the l ower cover.
Di sconnect the CKF sensor connector, then remove
the CKF sensor.
6 x 1 . 0 mm
11 N. m {1. r kgnm, 8. 0 l bf f t )
9. I nst al l t he CKF sensor i n reverse order of removal .
BELT
CKF SENSOR
6- 13
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Gyl i nder Head
lllustrated Index
To avoi d damage, wai t unti l the engi ne cool ant temperature drops bel ow 100' F
(38' C)
before removi ng the cyl i nder head.
6 x 1 . 0 mm
9.8 N.m
(1.0
kgI.m, 7.2 lbf.ft)
WASHER
Repl ace when damaged
or det eri orat ed,
CYLINDER HEAD
COVEB
Ret er t o page 6 32 when
i nst al l i ng cyl i nder head cover.
HEAO COVER GASKET
Bepl ace when l eaki ng,
damaged or det eri orat ed.
Appl y l i qui d gasket at
t he ei ght corners of t he
RUBEER SEAL
Repl ace i f
or det er i or at ed,
8 x 1. 25 mm
24 N. m (2. 4
17 tbtft)
See sect i on 4.
CYLI NDEB
HEAD PLUG
Repl ace-
---..-@ 0+---.."...-
s<--
KEY
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m.
7.2 tbf.fo
Appl y engi ne oi l t o t he
t hreads.
CAMSHAFT
HOLDER
DOWEL
PI N
OIL SEAL
Repl ace.
CAMSHAFT
PULLEY
8 x 1. 25 mm
37 N.m {3.8 kgf.m,
27 tbtft)
OI L SEAL
Repl ace.
6 x 1 . 0 mm
9. 8 N. m
(1. 0 kgl . m, 7. 2l bt f t l
6- 14
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-?E
handl i ng a metal gasket. take care not to fol d i t or damage the contact surface.
Pri or to reassembl i ng, cl ean al l the parts i n sol vent, dry them and appl y l ubri cant to any contact
parts.
CYLINDER HEAD BOLT
11 x 1. 5 mm
85 N.m {8.7 kgf.m,6:} lbf.ft)
Ti ght eni ng,
page
6' 30.
Appl y engi ne oi l t o t he t hreads.
VALVEKEEPERS
\
END PIVOT BOLT
63 N.m
16.4
kgl m, 46 lbf.ft)
EXHAUSY VALVE
SEAL
Repl ace.
EXHAUST VALVE
GUI DE
I nspect i on, page 6-25
Repl acem6nt ,
page 6-25
Reami ng, page 6-27
10 x 1. 25 mm
4,0 N.m
{i1.5 kgf.m.
33 rbf.ft)
GASKET
Repl ace.
OIL CONTROL
ORIFICE
Cl ean.
EXHAUST VALVE
SPRING
SPRING BETAINER
INTAKE VALVE
SPRING
INTAKE VALVE SEAL
Repl ace.
VALVE SPRING
SEAT
INTAKE VALVE
GUI DE
Removal ,
page 6-16
Warpage, page 6 27
Val ve seat recondi t i oni ng,
page 6 28
I nst al l at i on,
page 6-30
EXHAUST
VALVE
INTAKE VALVE
Removal , page 6-23
I nst al l at i on, page 6-29
CYLINDER HEAO
HEAD
O.RING
Repl ace.
8 x 1. 25 mm
24 N.m
(2.4
kgf.m,
17 tbf.ft)
DOWEL PIN
6- 15
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Gyl i nder Head
Removal
Engi ne removal i s not requi red for thi s procedure.
l !@
Make sure
i acks
and safety stands are
placed properly, and hoist blackels ale attachgd to the
correct position on the engine.
NOTE:
o Use f ender cover s t o avoi d damagi ng pai nt ed sur -
faces.
o To avoi d damage, unpl ug the wi ri ng connectors care-
ful l y whi l e hol di ng the connector porti on.
. To avoi d damagi ng the cyl i nder head, wai t unti l the
engi ne cool ant temperature drops bel ow 100"F
(38' C)
before l ooseni ng the retai ni ng bol ts.
. Mark al l wi ri ng and hoses to avoi d mi sconnecti on.
Al so, be sure that they do not contact other wi ri ng or
hoses, or i nterfere wi th other parts.
2.
4.
5.
1 . Di sconnect the negati ve termi nal from the battery.
Drai n the engi ne cool ant
(see page 10-5). Remove
the radi ator cap to speed drai ni ng.
Remove the i ntake ai r duct and ai r cl eaner housi ng
(see page
5-2).
Remov e t he mount i ng bol t and l oc k bol t , t hen
r emove t he power st eer i ng
( P/ S) pump bel t and
pump (see page 5-4).
Loosen the i dl er pul l ey bracket bol t and adj usti ng
bol t, then remove the ai r condi ti oni ng
(A,/C)
com,
pressor bel t.
ADJUSTI NG
BOLT
ADJUSTING BOLT
LOCKNUT
8 x 1. 25 mm
24 N m {2.4 ksf.m, 17 lbttt}
IOLER PULLEY BBACKET BOLT
10 x 1. 25 mm
44 N.m {4.5 kgtm, 33 lbf ft)
t t \ a A
o - I o
6. Loosen the l ocknut and mounti ng nut, then remove
the al ternator bel t.
LOCKNUT
8 x 1. 25 mm
24 N.m (2.4
kgf.m, 17 lbt.ftl
10 x 1. 25 mm
44 N.m
(4.5
kgt.m. 33 lbf.ft)
7. Remove the P/S OUmo bracket.
l 0 x 1. 25 mm
44 N.m
(4.5
kgf.m,
33 rbf.ft)
BELT
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8. Remove the throttl e cabl e by l ooseni ng the l ocknut,
then sl i p the cabl e end out of the throttl e l i nkage.
Take care not to bend the cabl e when removi ng i t.
Always replace any kinked cable with a new one.
'97
-
98 modols:
'!X,
-
00 modob:
9. Rel i eve fuel
pressure (see
secti on 11).
@
Do not smoke whi l e worki ng on the
fuel systom. Kop opon flame or sparks away from
ths work area. Drai n fuol onl y i nto an approved
containgr.
' 10,
Remove the evaporati ve emi ssi on
(EVAP)
control
cani ster hose and fuel feed hose.
CANISTER HOSE
{cont' d)
6-17
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Gylinder Head
Removal
(cont'dl
' 11.
Remove the brake booster vacuum hose. fuel return
hose, and vacuum hose.
'97
-
98 modsls:
VACUUM
HOSE
BRAKE BOOSTEB
VACUUM HOSE
6- 18
BRAKE BOOSTER
12. Remove the breather hose and oosi ti ve crankcase
venti l ati on
(PCV)
hose,
'97
-
98 models:
BREATHEB
HOSE
PCV HOSE
'99
-
00 models:
BREATHER
HOSE
PCV HOSE
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13. Remove the upper radi ator hose, heater hose and
water bypass hose.
WATER BYPASS
UPPEB
RADIATOR
HOSE
1 7
HEATER
HOSE
Remove t he engi ne wi r e har ness connect or s and
wi re harness cl amps from the cyl i nder head and the
i ntake mani fol d.
o Four fuel i nj ector connectors
. Engi ne cool ant t emper at ur e
( ECT)
sensor con-
necl or
. Radi ator fan swi tch connector
. Cool ant temperature
gauge sendl ng unl t connec-
tor
. Throttl e
posi ti on sensor connector
. Mani fol d absol ute
pressure
{MAP) sensor con-
nector
Pri mary heated oxygen sensor
(pri mary HO2S)
connector
l dl e ai r control
(l AC)
val ve connector
Di stri butor connector
Remove the spark
pl ug caps and di stri butor from the
cyl i nder head.
Remove the crui se control actuator
(see
secti on 4).
Suppor t t he engi ne wi t h a
j ack,
t hen r emove t he
upper br ac k et . Mak e s ur e t o pl ac e a c us hi on
between the oi l pan and the
i ack
(see page 6-10).
a
18. Remove the cyl i nder head cover.
19. Inspect the ti mi ng bel t
(see page 6-9).
CYLINDER
(cont' d)
6- 19
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Cylinder Head
Removal
(cont'dl
Remove the ti mi ng bel t
(see page
6-10).
Remove the camshaft pul l eys
and back cover. 2' t.
BACK COVER
6-20
22. Bemove the exhaust manifold
i ng nuts.
'97
-
98 U.S. modsls
(Californial:
GASKET
Repl ace.
SELF.LOCKING NUT
54 N.m {5.5 kgf.m, .{) lbf.ftl
Repl ace.
'97
-
98 U.S. models {Excepi Calitornia}:
'99
-
0O modeb:
GASKETS
Repl ace.
bracket and self-lock-
'r
EXHAUST MANIFOLD
BRACKET
10 x 1. 25 mm
44 N.m 14.5 kgf,m,
33 rbf.ft)
SELF.LOCKING NUT
10 x 1 . 25 mm
54 N.m {5.5 kgt.m, 40 lbtft}
Repl ace.
10 x 1. 25 mm
4il N.m
(4.5
kgf.m,
33 tbf.ftl
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23. Remove t he i nt ake mani f ol d mount i ng bol t s and
water bvDass hose.
8 x 1. 25 mm
2,1 N.m 12.4
kgt.m,
17 tbf.ft)
24. Loosen t he l ocknut s and adj ust i ng screws,
INTAKE
No. 3 No. 2 No. 1
No. 3 No. 2 No. 1
EXHAUST
No. 4
27. Remove the cyl i nder head.
6-21
25. Remove the camshaft hol der bol ts, then remove the
camshaft hol ders and rocker arms. Make note of the
rocker arm Dosi ti ons.
26. Remove t he cyl i nder head bol t s. To pr event
warpage, unscrew the bolts in sequence 1/3 turn at a
time; repeat the sequence until all bolts are loosened.
CYLINDER HEAD BOLTS LOOSENING SEOUENCE:
ROCKER ARM
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Camshafts
4.
Inspection
1 .
7.
Loosen the adj usti ng screws.
Remove the camshaft hol ders.
Mark the rocker arms, then remove them.
Rei nst al l t he camshaf t and hol der s. Ti ght en t he
camshaft hol der bol ts i n a cri sscross pattern, begi n-
ni ng wi th the i nner bol ts.
9.8 N.m
(1.0
kgf.m.7.2 l bf.ft)
Seat the camshafts by pushi ng them toward the di s-
tri butor end of the head wi th a screwdri ver.
Zer o t he di al i ndi c at or agai ns t t he end of t he
camshaft, push the camshaft back and forth and
read the end pl ay.
Camshaft End Play:
Standard l Newl : 0.05
-
0.15 mm
10.002
-
0.005 in)
Service Limit: 0.5 mm
(0.02
in)
Unscrew the camshaft hol der bol ts two turns at a
t i me, i n a cr i sscr oss pat t er n, Then r emove t he
camshaft hol der bol ts from the cvl i nder head.
Li f t t he camshaf t s out of t he cyl i nder head. wi pe
them cl ean, then i nspect the l i ft ramps, Repl ace the
camshaft i f any l obes are
pi tted,
scored, or exces-
si vel y worn.
Cl ean the camshaft
j ournal
surfaces i n the cyl i nder
head, then set the camshaft back i n Dl ace. Pl ace a
pl asti gage
stri p across each
j ournal .
Instal l the camshaft hol ders. and torque the bol ts to
the val ues and i n the sequence shown on page 6-31.
NOTE: Do not rotate the camshafts during inspection.
8.
10.
6-22
11. Remove the camshaft hol ders. Measure the wi dest
porti on of pl asti gage on each
j ournal .
Camshatt-to HoldGr Oil Clearance:
Standard {Newl: 0.030
-
0.069 mm
{0.0012
-
0.0027 in}
Servico Limit: 0.15 mm
(0.006
in)
12. l f camshaft-to-hol der oi l cl earance i s out of tol er-
ance:
. And t he camshaf t has al r eady been r epl aced,
you must repl ace the cyl i nder head.
. l f the camshaft has not been repl aced, fi rst check
total runout wi th the camshaft suoDorted on V-
bl ocks.
Camshaft Total Runout:
Standard
(N6w):
0.03 mm
(0.001
in) max.
Service Limit 0.04 mm
(0.(X)2
in)
Rotat6 camshatt
whi l e measuri ng.
-
l f the total runout of the camshafts i s wi thi n tol -
erance, repl ace the cyl i nder head
-
l f the total runout i s out of tol erance, repl ace the
camshafts and recheck. l f the oi l cl earance i s sti l l
out of tol erance, repl ace the cyl i nder head.
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Valves, Valve Springs
and Val ve Seal s
13. Measure the cam l obe hei ght.
Cam Lobe Height Standard
(Newl
'97
-
98 models:
INTAKE: 33.20,1mm
(1.3072
i n)
EXHAUST: 33.528 mm
(1.3200
i nl
'99
-
00 models:
INTAKE: 33.716 mm 11.327t1i n)
EXHAUST:33.528 mm
(1.3200
i n)
I nspect t hi s area l or wear.
Removal
l dent i f y t he v al v es and v al v e s pr i ngs as t hey ar e
removed so that each i tem can be rei nstal l ed i n i ts ori gi -
nal Dosi ti on.
1. Usi ng an appropri ate-si zed socket and
pl asti c mal l et.
l i ghtl y tap the val ve retai ner to l oosen the val ve keeP
ers before i nstal l i ng the val ve spri ng compressor'
2. Instal l the spri ng compressor. Compress the spri ng
and remove the val ve keeper.
VALVE SPRING COMPRESSOR
KD No. 3&!. whh *'5 JAW o.
VALVE SPRING COMPRESSOR
ATTACHMEUT
07757
-
PJ1010A
(cont' d)
6-23
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Valves, Valve Springs and Valve Seals
Removal
(cont' dl
3. Instal l the val ve gui de seal remover.
VALVE GUIDE SEAL REMOVER
LISLE P/N 57900 or KD3350 or equivalent
(Commerci al l v
avai l abl e)
4. Remove the val ve seal .
6-24
Intake Valve Dimensions
A Standard
{New}: 30.85
-
31.15 mm
B Standard
(New):
G Standard
{Newl:
C Service Limiti
D Standard
l Newl :
D Service Limit:
B Standard
(Newl:
C Standard
{New):
C Service Limit:
D Standard
l Newl :
D Service Limit:
11.21s
-
1.226 inl
103.80
-
10/t.10 mm
{i[.087
-
4.098 in)
6.580
-
6.590 mm
(0.2591 -
0.2594 i n)
6.55 mm
(0.258
inl
1.35
-
1.65 mm
(0.053 -
0.05s in)
1.15 mm
(0.045
i n)
11. 096
-
1. 108 i n)
10,1.00
-
10,1.30 mm
(il.09i[ - it.l06
in)
6.550
-
6.560 mm
10.2579
-
0.2583 inl
6.52 mm
(0.257
i nl
1.65
-
1.95 mm
10.065
-
0.077 i n)
1.45 mm
(0.057
i nl
Exhausi Valv Dimensions
A Standard
(Newl :
27.85
-
28.15 mm
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Val ve Gui des
Valve Movement
1. Measur e t he
gui de- t o- st em cl ear ance wi t h a di al
i ndi cator whi l e rocki ng the stem i n the di recti on of
normal thrust
(wobbl e
method),
lntake Valve Stem-to-Guide Clearance:
Standard
(Newl :
0.04
-
0.10 mm
(0.002 -
0.004 i n)
Servi ce Li mi t 0.16 mm
(0.006
i n)
Exhaust Valve Stem-to-Guide Clearance:
Standard {Newl :
0.10
-
0.16 mm
(0.004 -
0.006 inl
Servi ce Li mi t: 0,22 mm
(0.009 i nl
l f t he meas ur ement ex c eeds t he s er v i c e l i mi t ,
recheck usi ng a new val ve.
l f the measurement i s now wi thi n the servi ce l i mi t,
reassembl e usi ng a new val ve.
l f the measurement sti l l exceeds the l i mi t, subtract the
O.D. of the val ve stem, measured wi th a mi crometer,
from the l .D. of the val ve gui de, measured wi th an
i nsi de mi crometer or bal l gauge.
Take t he measur ement s i n t hr ee
pl aces al ong t he
val ve stem and three
pl aces i nsi de the val ve gui de
The di fference between the l argest gui de measure-
ment and t he smal l est st em measur ement shoul d
not exceed the servi ce l i mi t.
lntake Valve Stem-to-Guide Clearance:
Standard
(New):
0.02
-
0.05 mm
{0.001
-
0.002 i n)
Service Limit: 0.08 mm
(0.003
in)
Exhaust Valve Stem-to-Guide Clearance:
Standard
(New):
0.05
-
0.08 mm
(0.002 -
0.003 i n)
Servi ce Li mi t: 0.11 mm
(0.004
i n)
2.
3.
Replacement
1. As i l l ustrated bel ow, use a commerci al l y avai l abl e
ai r-i mpact val ve
gui de dri ver attachment modi fi ed
t o f i t t he di amet er of t he val ve gui des. I n most
cases, the same procedure can be done usi ng the
sDeci al tool and a conventi onal hammer.
VALVE GUIDE DRIVER
(Commerci al l v
avai l abl e)
2.
3.
(0.25 inl
I
_,1-r
,_T-_
l r l
' 11. 3
mm
(0.{,r
in}
or
VALVE GUIDE DRIVER, 6.6 mm
0t9a:I
-
G5t01q)
Sel ect t he
pr oper r epl acement
gui des. and chi l l
t hem i n t he f r eezer sect i on of a r ef r i ger at or f or
about an hour.
Use a hot pl ate or oven to evenl y heat the cyl i nder
head to 300"F
(150"C).
Moni tor the temperature wi th
a cooki ng thermometer. Do not get the head hofter
than 300' F
(150"C);
excessi ve heat may l oosen the
val ve seaIs.
6. 4 mm
CAUTION: To avoid burns, uss heavy
gloves when
handling the heated cylinder head.
(cont' d)
6-25
*]--
sz mm
'
l2.21inl
www.emanualpro.com
Valve Guides
Replacement
(cont'dl
5.
Worki ng from the camshaft si de, use the dri ver and
an ai r hammer t o dr i ve t he gui de
about 2 mm
( O. l
i n) t owar ds t he combust i on chamber . Thi s wi l l
knock of f some of t he car bon and make r emoval
easi er. Hol d the ai r hammer di rectl y i n l i ne wi th the
val ve gui de
to prevent
damagi ng the dri ver.
CAUTION: Always wear satety goggles
or a face
shield when driving valve guidss.
Turn the head over and dri ve the gui de
out toward
the camshaft si de of the head.
l i a val ve gui de won' t move, dri l l i t out wi th a 8.0
mm
(5/16
i n) bi t, then try agai n. Dri tt gui des onty i n
extreme cases; you coul d damage the cyl i nder head
i f the gui de breaks.
Remove the new gui de(s)
from the freezer, one at a
tl me, as you need them.
6.
7.
6-26
'o
C'
8. Appl y a thi n coat of cl ean engi ne oi l to the outsi de
of the new val ve gui de. Instal l the gui de from the
camshaft si de of the head; use the speci al tool to
dri ve the gui de i n to the speci fi ed i nstal l ed hei ght. l f
you have al l 16 gui des
t o do,
you
mav have t o
reheat the head.
Valve Guide Installed Height:
Intake: 13.75
-
1i 1.25 mm
{0.5,[1
-
0.561 in)
Exhaust: 15.75
-
16.25 mm
(0.620 -
0.640 inl
ATTACHMENT
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Cyl i nder
Head
Reami ng
NOTE: For new val ve gui des onl y.
1. Coat the reamer and the val ve gui de wi th cutti ng oi l .
2. Rotate the reamer cl ockwi se the ful l l ength of the
val ve gui de bore.
Cont i nue t o r ot at e t he r eamer cl ockwi se whi l e
removi ng i t from the bore.
Thoroughl y wash the gui de i n detergent and water
to remove anY cutti ng resi due.
Check cl earance wi th a val ve
(see page 6-25).
Veri fy that the val ves sl i de i n the i ntake and exhaust
val ve gui des wi thout exerti ng
pressure.
3.
4 .
5.
6.
vALvE GUI DE REAMER, 6. 6 mm
0798i1
-
657010O
REAMER HANDLE
e
Warpage
NOTE: lf camshaft-to-holder oil clearances
(see page G22)
are not wi thi n speci fi cati on, the head cannot be resur-
faced.
l f camshaft-to-hol der oi l cl earances are wi thi n speci fi ca-
ti ons, check the head for warpage. Measure al ong the
edges, and three ways across the center.
. i f warpage i s l ess than 0.05 mm
(0.002
i n) cyl i nder
head resurfaci ng i s not requi red
l f warpage i s between 0.05 mm
(0.002
i n) and 0.2 mm
(0.008
i n), resurface cyl i nder head.
Maxi mum resurface l i mi t i s 0.2 mm
(0.008
i n) based
on a hei ght of 132.0 mm
(5.20
i n).
Cylindr Hesd Height:
Standard {New}: 131.95
-
132.05 mm
15.195
-
5.199 i nl
PRECISION STRAIGHT EDGE
6-27
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Valve Seats
Recondi ti oni ng
l f the gui des are worn
(see page
6-25), repl ace them
(see
page
e25) before recondi ti oni ng the val ve seats.
1. Renew the val ve seats i n the cyl i nder head usi ng a
valve seat cutter.
Car ef ul l y cut a 45o seat , r emovi ng onl y enough
materi al to ensure a smooth and concentri c seat.
Bevel the upper edge of the seat wi th the 30. cutter
and the lower edge of the seat with the 60" cutter.
Check wi dth of seat and adj ust acco.di ngl y.
Make one more very l i ght pass
wi th the 45o cutter to
remove any possi bl e
burrs caused bv the other cut-
ters.
Valve Seat Width
(lntake
and Exhaust):
Standard {N.w}: 1.25
-
1.55 mm
(0.049 -
0.051 in)
Servica Limit: 2.0 mm
(0.08
in)
o
o
5. After resurfaci ng the seat, i nspect for even val ve
seati ng: Appl y Prussi an Bl ue compound to the val ve
face, and i nsert the val ve i n i ts ori gi nal l ocati on i n
the head, then l i ft i t and snap i t cl osed agai nst the
seat several ti mes.
ACTUAL
SEATING
SURFACE
VALVE
SEAT
7.
PRUSSIAN
The actual val ve seati ng surface, as shown by the
bl ue compound, shoul d be centered on the seat.
. l f i t i s too hi gh
(cl oser
to the val ve stem), you
must make a second cut wi th the 60" cutter to
move i t down, then one more cut wi th the 45"
cutter to restore seat width.
. l f i t i s too l ow
(cl oser
to the val ve edge), you
must make a second cut wi th the 30. cutter to
move it up, then one more cut with the 45. cutter
to restore seat width.
NOTE: The fi nal cut shoul d al wavs be made wi th
the 45" cutter,
Insert the i ntake and exhaust val ves i n the head,
and measure val ve stem i nstal l ed hei oht.
Intake Vslve Siem Instslted Height:
Standard {Newl:
it0.765 -
41.235 mm
11.6049
-
1.6234 i nl
Sarvico Limit:
itl.il85
mm
(1.6333
in)
Exhaust Valve Stem Installed H6ight:
Standard {New}: 42.755
-
.235 mm
11 .61137
-
1 .7022 inl
/(|.,185
mm
(1.7120
in)
VALVE STEM
INSTALLED HEIGHT
8. l f val ve stem i nstal l ed hei ght i s over the servi ce
l i mi t. repl ace the val ve and recheck. l f i t i s sti l l over
t he ser vi ce l i mi t . r epl ace t he cyl i nder head; t he
val ve seat i n the head i s too deeo.
Servico Limit:
f-]
6-28
www.emanualpro.com
Val ves, Val ve Spri ngs and Val ve Seal s
l nstal l ati on
Coat the val ve stems wi th oi l . Insert the val ves i nto
the val ve gui des.
Check that the val ves move up and down smoothl y.
Instal l the spri ng seats on the cyl i nder head.
Instal l the val ve seal s usi ng the speci al tool .
NOTE: Exhaust and i ntake val ve seal s are not i nter-
1 .
changeabl e.
WHITE
SPRING
BLACK
SPRING
INTAKE VALVE SEAL EXHAUST VALVE SEAL
VALVE GUIDE
SEAL INSTALLER
lCommercially available)
KO3372 or equivalnt
ot
07GAD
-
PH70100
VALVE SPRING COMPRESSOR
lComm6rcially
available)
KD No. 383, with *35 JAw or
7.
Instal l the val ve spri ng and val ve retai ner. Pl ace the
end of the val ve spri ng wi th cl osel y wound coi l s
toward the cyl i nder head,
Instal l the val ve spri ng compressor. Compress the
spri ng, and i nstal l the val ve keepers.
VALVE SPRIT{G OOMPfi ESSOR
ATTACHMENT
0775'
-
PJ1010A
Li ghtl y tap the end of each val ve stem two or three
ti mes wi th a
pl asti c
mal l et to ensure proper seati ng
of the valve and valve keepers, Tap the valve stem
onl y al ong i ts axi s so you do not bend the stem.
PLASTE
6-29
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Cyl i nder Head
Instal l ati on
Instal l the cyl i nder head i n the reverse order of removal :
1. Cl ean the cyl i nder head and bl ock surfaces.
2. Cl ean the oi l control ori fi ce. Instal l the cyl i nder head
gasket, dowel pi ns
and the oi l control ori fi ce on the
cyl i nder bl ock. Al ways use a new cyl i nder head gas-
ket.
CYLII{DER HEAD
GASKET
Rpl ace.
DOWEL PIN
O.RING
Ropl ace.
DOWEL
PIN
OIL CONTBOL
ORIFICE
Cl ean.
Appl y cl ean engi ne oi l t o t he bol t t hreads and under
t he bol t heads.
4. Ti ghten the cyl i nder head bol ts i n two steps. In the
fi rst step ti ghten al l bol ts, i n sequence, to about 29
N.m {3.0 kgf.m,22 l bf.ft); i n the fi nat step, ti ghten i n
the same sequence to 85 N.m
(8.7
kgf.m,63 l bf.ft).
Use a beam-type torque wrench. When usi ng a pre-
set-type torque wrench, be sure to ti ghten sl owl y
and do not overti ghten.
l f a bol t makes any noi se whi l e you
are torqui ng i t,
l oosen the bol t, and reti ghten i t from the 1st step.
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Ti ght en t he i nt ake mani f ol d mount i ng bol t s
( see
page 6-21).
Instal l the exhaust mani fol d bracket. and ti ghten the
new sel f-l ocki ng nuts (see page 6-20).
6- 30
www.emanualpro.com
7. Pl ace the rocker arms on the
pi vots
and the val ve
st ems. Put t he r ocker ar ms i n t hei r or i gi nal
posi -
l rons.
l nstal l the camshafts, then i nstal l the oi l seal s wi th
the open si de
(spri ng) faci ng i n. Make sure that the
keyways on the camshafts are faci ng up and the No.
1 pi ston i s at TDC.
Cl ean and dry the cyl i nder head mati ng surfaces.
Appl y l i qui d
gasket (P/N
08718
-
0001 or 08718
-
0OO3) to the head mati ng surfaces of the No. 1 and
No. 6 camshaf t hol der s on bot h t he i nt ake and
exhaust si de.
L
No. I
EXHAUST
II{TAKE
Appl y l i qui d gasket to th shaded areas.
' t' t,
' 10.
l nstal l the camshaft hol ders.
NOTE:
o
" 1"
or
" E'
mar ks ar e st amped on t he camshaf t
hol ders.
. The ar r ows mar ked on t he camshaf t hol der s
shoul d
poi nt at the ti mi ng bel t.
Ti ghten each bol t i n two steps to ensure that the
rockers do not bi nd on the val ves.
Wipe off the excess liquid
gasket from the No. 1 and
No. 6 camshaft holders with a shop towel,
Specified torque:
9.8 N.m
(1.0
kgf.m, 7.2 lbf.ft)
Apply engine oil to the bolt ihreads.
I?,ITAKE
EXHAUST
(cont' d)
6- 31
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Cyl i nder Head
Installation
(cont'dl
' 13.
Al i gn t he mar ks on t he cyl i nder head pl ug
t o t he
cyl i nder head upper surface, then i nstal l the cyl i n
der head pl ug i n t he end of t he cyl i nder head.
CYLINOER HEAD
PLUG
Repl ace.
l nstal l the back cover.
To set the camshafts at TDC posi ti on
for the No. l
pi st on, al i gn t he hol es i n t he camshaf t s wi t h t he
hol es i n the No. l camshaft hol ders and i nsert 5.0
mm pi n punches
i n the hol es. Instal l the keys i nto
the camshaft grooves.
37 N m
(3.8
*gl.m, 27 lbt.tr)
9.8 N.m (1.0
kgtm,
7.2|hrftl
Push the camshaft pul l eys onto the camshafts. then
ti ghten the retai ni ng bol ts to the torque speci fi ed.
6-32
1 4 .
KEYS
I x 1. 25 mm
6 x 1 . 0 mm
Instal l the ti mi ng bel t
(see page 6-1 1).
Adj ust the val ve cl earance
(see page
6-3).
Thor oughl y cl ean t he head cover gasket and t he
groove.
l nstal l the head cover gasket i n the groove
of the
cyl i nder head cover. Seat the head cover gasket i n
the recesses for the camshaft fi rst, then work i t i nto
the groove
around the outsi de edges. Make sure the
head cover gasket is seated securely in the corners
of the recesses wi th no gap.
17.
' 18.
19.
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21.
22.
Check that the mati ng surfaces are cl ean and dry.
Appl y l i qui d gasket, part No. 08718
-
0001 or 08718
-
0003, to the head cover gasket at the ei ght corners
of the recesses.
NOTE:
. Do not i nstal l the parts i f fi ve mi nutes or more
hav e el aps ed s i nc e appl y i ng l i qui d gas k et .
Instead, reappl y l i qui d gasket after removi ng ol d
resi due.
. After assembl y. wai t at l east 30 mi nutes before
fi l l i ng the engi ne wi th oi l .
Appl y l i qui d gasket to
the shaded areas.
Hol d the head cover gasket i n the groove by pl aci ng
your fi ngers on the camshaft hol der contacti ng sur-
faces
(top
of the semi ci rcl esl .
Once t he cyl i nder head cover i s on t he cyl i nder
head, slide the cover slightly back and forth to seat
the head cover
gasket.
Inspect the cover washers. Repl ace any washer that
is damaged or dete(iorated.
23.
24.
25. Ti ghten the nuts i n tvvo or three steps. In the fi nal
step, ti ghten al l nuts, i n sequence. to 9.8 N.m
(1.0
kgf.m, 7.2 lbf.ft).
Check t hat al l t ubes, hoses and connect or s ar e
installed correctly.
26.
6- 33
www.emanualpro.com
Engi ne Bl ock
Speci af Tool s . . . . . . . . . . . . . 7-2
l l l ust rat ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Flywheel and Drive Plate
Repl acement . . , . , . . . . 7-5
Connecting Rod and Grankshaft
End Pl ay . . . . . . . . . . . . . . . . . 7- 6
Mai n Beari ngs
Cf earance . . . . . . . . . . . . . . . 7
-7
Sel ect i on . . . . . . . . . . . . . . . . 7-8
Connecting Rod Bearings
Cl earance . . . . . . . . . . . . . . . 7-8
Sel ect i on . . . . . . . . . . . . . . . . 7-9
Pistons and Crankshaft
Removal . . . . . . . . . . . . . . . . . 7-9
Crankshaft
I nspect i on . . . . . . . . . . . . . . 7-11
Pistons
f nspect i on . . . . . . . . . . . . . . 7-12
f nst af l at i on . . . . . . . . . . . . . 7-20
Cylinder Block
I nspect i on . . . . . . . . . . . . . . 7-13
Piston Pins
Removal . . , . . . . . . . , , . . . . . 7-14
I nst al l at i on . . . . . . . . . . . . . 7-15
I nspect i on . . . . . . . . . . . . . . 7-16
Connecting Rods
Sel ect i on . . . . . . . . . . . . . . . . 7
-14
Piston Rings
End Gap . . . . . . . . . . . . . . . . . 7
-17
Ring-to-Groove Clearance ............... 7
-17
Repl acement . . . . . . . . . 7-18
Al i gnment . . . . . . . . . . . . . . 7-18
Crankshaft Oil Seal
l nst al l at i on . . . . . . . . . . . . . 7-19
Crankshaft
l nst al f at i on . . . . . . . . . . . . . 7-20
Oil Seals
f nst al f at i on . . . . , . . , . . . . . 7-23
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Special Tools t l
Ref, No. I Tool Numbor Description Oty Page Reterence
o
@
@
/6
@
o
@
@
@
@
07GAF
-
PH60300
07HAF
-
P120102
07LAB
-
PV00100
07LAD
-
PT30101
07LAF
-
PR30100
07948
-
S800101
07749
-
0010000
07973
-
PE00310
07973
-
PE00320
07973
-
6570500
07973
-
6570600
Pi ston Pi n Base l nsert
Pi ston Base Head
Ri ng Gear Hol der
Seal Dri ver
Pi l ot Col l ar
Seal Dri ver Attachment. 76 x 80 mm
Dri ver
Pi ston Pi n Dri ver Shaft
Pi ston Pi n Dri ver Head
Piston Base
Pi ston Base Spri ng
,l
1
I
I
1
1
1
1
1
1
1
7 - 1 4 , 1 5
1- ' t 4, 15
1-5
1-23
7- 14, 15
7- ' t 9, 24
7
-'t9,
24
1- 14, 15
7- 14, 15
7- ' t 4, 15
7- 14, 15
e
E
E
g
o
a @
0
o @
7-2
www.emanualpro.com
l l l ustrated l ndex
I
Luori ""t" "tl i nternal parts wi th engi ne oi l duri ng reassembl y.
Appl y l i qui d gasket to the mati ng surfaces of the ri ght si de cover and oi l pump case before i nstal l i ng them.
Jse l i qui d gasket, Part No. 08718
-
0001 or 08718
-
0003.
:l ean the oi l pan gasket mati ng surfaces before i nstal l i ng the oi l pan.
WASHER
Repl ace.
76
x 1. 0 mm
y'
t:n- l .zxstm, 8.7 l bl ftl
9
oIL PAN
OIL PAN GASKET
Repl ace.
to
page 1-22
when i nst al l i ng
BEARING CAP
OOWEL PI N
CRANKSHAFT OIL SEAL
1 1 x 1 . 5 mm
76 N.m {7.8 kgl.m, 56 lbf.ft}
Appi y engi ne oi l t o t he bol t
t hreaos.
NOTE: Af t er l orqui ng
each cap, t urn t he crankshaf t
t o check f or bi ndi ng. 6 x 1 . 0 mm
9, 8 N. m
(1, 0
kgf . m,
7 .2 tbt.lrl
n
MAIN BEARINGS
Sel ect i on, page 7 8
NOTE: New mai n beari ngs must
be sel ect ed by mat chi ng t he crank
and bl ock i dent i f i cat i on marki ngs.
otL
6 x' 1. 0 mm
9. 8 N. m {1. 0 kgt m,
7.2 tbf.ftl
BAFFI.f PLATE
9. 8 N. m 11. 0 kgt m,
7.2 tbt+tl
12 x 1. 0 mm
/ , 71N
n 17 . 5
&it
ks{ m 5a lbtft) {a/Tl
GASKET
Repl ace.
OIL PUMP
I nst al l at i on,
page
7-19
Repl ace.
ln
6 WASHER IA/T}
Overhaul ,
page 8-8
Removal / l nspect i on,
page 8-9
Appl y l i qui d gasket
to mating surface.
8 x 1. 25 mm
ORIVE PLATE IA/T)
Check f or cracks.
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgt . m, 7. 2 l bt f t )
2a N.m
(2.a
kgt.m,---\6/
CRANIGHAFT SEAL
I nst al l at i on, page
8-10
Replace-
6 x 1 . 0 mm
9.8 N.m l'1.0 kgf.m,7.2 lbf.ft)
RIGHT SIDE COVER
Appl y l i qui d gasket
t o mat i ng surf ace,
O.RING
Repl ace.
THRUST WASHERS
Grooved sides face outlvard,
NOTE: Thrust washer t hi ckness
i s l i xed and must not be changed
by gri ndi ng or shi mmi ng.
(cont ' d)
7- 3
6 x 1 . 0 mm
www.emanualpro.com
lllustrated Index
(cont'd)
NOTE: New rod beari ngs
(see pages 7-91.
must be sel ected by matchi ng connecti ng rod assembl y and crankshaft i denti fi cati on marki ngs
PISTON INSTALLANON DIRECTION:
Lubri cate al l i nternal parts wi th engi ne oi l
duri ng reassembl y.
EXHAUST
INTAKE
PISTON RINGS
Replacement.
page 7-18
Measurdment ,
page 7-17
Al i gnmnt ,
page 7-18
PISTON
I nspect i on,
page 7-12
l1\AAtr\
\9q9Q9e/
PISTON PIN
Removal ,
page 7-14
I nst al l at i on,
page 7-15
Inspection.
page 7-16
ENGINC BLOCK
Cylinder bore inspection.
pago 7-13
Warpage inspoction,
Page
7-'13
CONNECTING ROD BEARING CAP
l nst al l at i on,
page 7-20
NOTE: I nst al l t he caps so t he
beari ng recess i s on t he
same si de as t he recess
i n t he rod.
CONNECTING ROD CAP
8 x 0. 75 mm
31 N.m {3.2 kgl.m.
23 tbf.ftl
CONNECTING
COiINECI'ING ROD
BEARINGS
Clearance,
page 7-8
Solection.
page 7-9
NUT
End
play, page 7-6
Sel ect i on,
page 7-14
Inspect the top ot each cylinder bore
f or carbon bui l d up or a ri dge
bel ore removi ng t he
pi st on.
Remove t he ri dge i f necessary,
page 7-10
Appl y engi ne oi l t o t he bol t t hr eads.
NOTE: Af t er t orqui ng each beari ng
cap, rot at e t he crankshaf t t o check f or
bi ndi ng.
7-4
www.emanualpro.com
Flywheel and Drive Plate
Replacement
Manual Transmission:
Remove the ei ght fl ywheel bol ts, then separate the fl y-
wheel from the crankshaft fl ange. After i nstal l ati on, ti ght-
en the bol ts i n the sequence shown.
ENGI NE
BLOCK
12 x 1. 0 mm
103 N.m
110.5 kgf.m,
76 lbf.ft)
Automatic Transmission:
Remove the ei ght dri ve pl ate bol ts, then separate the
dri ve pl ate from the crankshaft fl ange. After i nstal l ati on,
ti ghten the bol ts i n the sequence shown.
RING GEAR
I nspect ri ng gear
t eet h f or wear or damage,
RI G GEAR HOTDER
07LAB
-
PV001|X)
12 x 1. 0 mm
7a N. m
(7.5
kgt.m,5a lbf.ftl
/
AzXi{'jA\Ao
7-5,
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Connecting Rod and Crankshaft
End Pl ay
1. Measure the connecti ng rod end pl ay wi th a feel er
gauge.
Connecting Rod End Play:
Stsndard
(Nsw):
0.15
-
0.30 mm
{0.006
-
0.012 i n)
Servi ce Li mi t: 0./t0 mm 10.016 i n)
2. l f the connecti ng rod end
pl ay i s out-of-tol erance,
i nstal l a new connecti ng rod.
l f i t i s sti l l out-of-tol erance, repl ace the crankshaft
{see
pages 7-9 and 7-20).
7- 6
3. Push the crankshaft fi rml y away from the di al i ndi -
c at or , and z er o t he di al agai ns t t he end of t he
cr ankshaf t . Then
pul l
t he cr ankshaf t f i r ml y back
t owar d t he i ndi cat or ; t he di al r eadi ng shoul d not
exceed the servi ce l i mi t.
Crankshaft End Play:
Stand.rd
(New):
0.10
-
0,35 mm
(0.004 -
0.014 i nl
Servi ce Li mi t: 0.45 mm
(0.018
i nl
4. l f end
pl ay i s excessi ve, i nspect the thrust washers
and thrust surface on the crankshaft. Reol ace oans as
necessar y. Thr ust washer t hi ckness i s f i xed and
must not be changed ei t her by gr i ndi ng or shi m-
mr ng.
SCREWORIVER
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Mai n Beari ngs
2.
3.
1 .
4.
Cl earance
To check mai n bear i ng- t o- j our nal oi l cl ear ance,
remove the mai n caps and beari ng hal ves.
Cl ean each mai n
j our nal
and bear i ng hal f wi t h a
cl ean shop towel .
Pl ace a stri p of pl asti gage across each mai n
j ournal .
NOTE: l f the engi ne i s sti l l i n the vehi cl e when you
bol t t he mai n cap down t o check cl ear ance, t he
wei ght of the crankshaft and fl ywheel wi l l fl atten
the pl asti gage further than
j ust
the torque on the
cap bol t, and gi ve you an i ncorrect readi ng. For an
accur al e r eadi ng, suppor t t he cr ank wi t h a
j ack
under the counterwei ghts and check onl y one bear-
I ng aI a I r me.
Rei nst al l t he bear i ngs and caps, t hen t or que t he
bol ts,
1st step:25 N' m
(2.5
kgf.m, 18l bf.ft)
Final siep: 76 N'm 17.8 kgl.m, 56 lbf.ftl
NOTE: Do not rotate the crankshaft duri ng i nspec-
tron.
Remove t he bear i ng cap agai n, and measur e t he
wi dest part of the pl asti gage.
Main Bearing.to.Journal Oil Clearance:
Stand8.d {New):
No. 1, 2, 4, 5 Jour nsl s:
0.02i1- 0.0i12 mm
(0.0009 -
0.0017 inl
No. 3 Journal :
0.030
-
0.0i 18 mm
(0.0012 -
0.0019 i nl
Service Limit: 0.06 mm 10.002 in)
l f the pl asti gage measures too wi de or too narrow,
( r emov e
t he engi ne i f i t ' s s t i l l i n t he v ehi c l e) ,
remove the crankshaft, and remove the upper hal f
of the beari ng. Instal l a new, compl ete beari ng wi th
the same col or code
(sel ect
the col or as shown on
the next page).
and recheck the cl earance, Do not
f i l e, shi m, or scr ape t he bear i ngs or t he caps t o
adj ust the cl earance.
l f the pl astj gage shows the cl earance i s sti l l i ncor-
rect, try the ne)d l arger or smal l er beari ng {the col or
l i sted above or bel ow that one), and check agai n. l f
the proper cl earance cannot be obtai ned by usi ng
the appropri ate l arger or smal l er beari ngs, repl ace
the crankshaft and start over.
7.
7- 7
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Mai n Beari ngs Connecting Rod Bearings
Selection
Crankshaft Bore Code Location
Letters have been stamDed on the end of the bl ock as a
code Jor the si ze of each of the 5 mai n
j ournal
bores.
Use t hem, and t he number s or bar s st amped on t he
crank
(codes
for mai n
j ournal
si ze), to choose the correct
beanngs.
l f the codes are i ndeci pherabl e because of an accumul a-
t i on of di r t and dust . do not scr ub t hem wi t h a wi r e
brush or sc.aper. Cl ean them onl y wi th sol vent or deter-
gent.
Main Journ.l Cod. Locrtions lNumbcB oi Bar3l
Bearing ld.ntif icrtion
Col or code i s
on t he edge of
t he bear i ng.
7- 8
I c D
""""""""
Smal l erbeari ng(rhi cker)
Gr een
Green
El acl Alue
Clearance
Remove the connecti ng rod cap and beari ng hal f.
Cl ean the crankshaft rod
j ournal
and beari ng hal f
wi th a cl ean shop towel .
Pl ace the pl asti gage across the rod
j ournal .
Rei nstal l the beari ng hal f and cap, and torque the
nuts.
1 .
7.
Torqus: 31 N.m
(3.2
kgf.m. 23 lbf.ft)
NOTE: Do not rotate the crankshaft duri ng i nspec-
t i on.
Remove the rod cap and beari ng hal f, and measure
the wi dest part of the pl asti gage.
Connesting Rod Bearing-to-Journal Oil Clearancc:
Standard {Newl: 0.020
-
0.038 mm
{0.0008
-
0.0015 in)
Service Limit: 0.05 mm {0.002 inl
l f the pl asti gage measures too wi de or too narrow,
remove the upper hal f of the beari ng, i nstal l a new.
compl ete beari ng wi th the same col or code {sel ect
the col or as shown on the next page), and recheck
the cl earance. Do not fi l e, shi m, or sc.ape the bear-
i ngs or the caps to adj ust the cl earance.
l f the pl asti gage shows the cl earance i s sti l l i ncor
rect, try the next l arger or smal l er beari ng {the col or
l i sted above or bel ow that one). and check cl ear-
anc e agai n. l f t he pr oper c l ear anc e c annot be
obtai ned by usi ng the appropri ate l arger or smal l er
beari ngs. repl ace the crankshaft and start over.
PLASTIGAGE
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Pistons and
Crankshaft
Selection
Connecting Rod Code Location
Numbers have been stamped on the si de of each con-
necti ng rod as a code for the si ze of the bi g end. Use
l hem, and the l etters stamped on the crankshaft
(codes
for rod
j ournal
si ze), to choose the correct beari ngs.
l f the codes are i ndeci Dherabl e because of an accumul a-
t i on of di r t and dust , do not scr ub t hem wi t h a wi r e
brush or scraper. Cl ean them onl y wi th sol vent or deter-
gent.
8aring ldentif ication
aol or code i s on t he
edge ol
t ne Deanng.
Lar ger bi g end bor e
---------------r.
sma er bearino {thicker)
Red Pi nk Green
Pi nk Green Brown
Green Br own Bl ack
Green Brown El ack Bl ue
Hal f of number i s
st amped on beanng
cap and t he ot hel
hal f i s st amped on
rod.
Connecting Rod Journal Code Locations {Lettersl
l l A o r t l l
l l B o ' l l l l
l l c o t r l l l l
I l-..
ilril
I
t - l
Smal l er
' od
Smal l er
beanng
( t hi cker )
2 3 4
Removal
Remove the oi l pan assembl y.
Remove the ri ght si de cover.
1 .
Remove the oi l screen.
Remove the oi l pump.
OI L SCREEN
(cont' d)
7- 9
OI L PUMP
5. Remove the baffl e pl ate.
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Pistons and Crankshaft
Removal
(cont'dl
6. Remove the bol ts. To prevent warpage, unscrew the
bol t s i n sequence 1/ 3 t ur n at a t i me; r epeat t he
sequence unti l al l bol ts are l oosened.
Remove the rod caps/beari ngs and mai n caps/bear-
i ngs, Keep al l caps/beari ngs i n order
Li ft the crankshaft out of the engi ne. bei ng careful
not to damage the
j ournal s.
7.
7- 10
9.
10.
Remove the upper bearing halves from the connecting
rods, and set them aside with their respective caps.
Rei nstal l the mai n caps and beari ngs on the engi ne
i n proper order.
l f
you
can f eel a r i dge of met al or har d car bon
around the top of each cvl i nder, remove i t wi th a
r i dge r eamer . Fol l ow t he r eamer manuf act ur er ' s
i nst r uct i ons. l f t he r i dge i s not r emoved, i t may
damage the pi stons as they 8re
pushed out.
12.
1 1 .
14.
Use the wooden handl e of a hammer to dri ve the
pi stons out.
13. Rei nstal l the connecti ng rod beari ngs and caps after
removi ng each pi ston/connecti ng rod assembl y.
To avoi d mi xup on reassembl y, mark each pi ston/
connecti ng rod assembl y wi th i ts cyl i nder number.
NOTE: The exi sti ng number on the connecti ng rod
does not i ndi cate i ts posi ti on i n the engi ne, i t i ndi -
cates the rod bore si ze.
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Crankshaft
Inspection
1. Cl ean the crankshaft oi l passages wi th pi pe cl eaners
or a sui tabl e brush.
2. Check the keyway and threads.
Alignment
3. Measur e t he r unout on al l mai n
j our nal s
t o make
sure the crank i s not bent. The di fference between
measur ement s on each j our nal must not be mor e
than the servi ce l i mi t.
Crankshaft Total Indicated Runout:
Standard l New):0.03 mm
(0.001
i n) max.
Service Limit: 0.04 mm
{0.002 in)
DIAL INDICATOR
Rotate two complete
revol ut | ons.
Suppon wi t h l at he-
l ype t ool or V-bl ocks.
Out-of-Round and TaDer
4. Measure out-of-round at the mi ddl e of each rod and
mai n
j ournal
i n two
pl aces.
The di fference between
measur ement s on each
l our nal
must not be mor e
than the servi ce l i mi t.
Journal Out-of-Round:
Standard
(Newl :0.005
mm 10.0002 i nl max.
Servi ce Li mi t: 0.010 mm
(0.000i 1i n)
Measure out-ol'
round at mi ddl e.
Measure t aper
at edges.
5. Measure taper at the edges of each rod and mai n
j ournal .
The di fference between measurements on
each i our nal must not be mor e t han t he ser vi ce
l i mi t .
Journal Taperi
Standard {Newl : 0.005 mm 10.0002 i nl max.
Servi ce Li mi t: 0.010 mm
(0.0004
i nl
7- 11
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Pistons I
Inspection
L Check each
pi ston for di storti on or cracks.
Measure the pi ston di ameter at di stance A from the
bottom of the skirt.
A:
' 97
-
98 model s 15 mm 10.5 i nl
'99
-
00 models 20 mm 10.8 inl
Piston Diameter:
Standard
(New):
8:1.980
-
txl.990 mm
(3.3063 -
3.3067 inl
Service Limit: 83.970 mm {3.3059 inl
SKI RT DI AMETER
7- 12
3. Cal cul ate the di fference between the cyl i nder bore
di ameter
(see page 7-13) and the pi ston di ameter.
Piston-to-Cylinder Clearance:
Standard {New): 0.010
-
0.040 mm
{0.0004
-
0.0016 i nl
Service Limit: 0.05 mm {0.002
in}
l f the cl earance i s near or exceeds the servi ce l i mi t,
i nspect the pi ston and cyl i nder bl ock for excessi ve
wear.
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Cyl i nder Bl ock
Inspection
Measur e wear and t aper i n di r ect i ons X and Y at
three l evel s i n each cyl i nder. l f the measurements i n
any cyl i nder are beyond the Servi ce Li mj t, repl ace
the bl ock.
Cvl i nder Bol e Si ze:
Standard {Newl :84.00
-
84.02 mm
{3.307
-
3.308 i nl
Servi ce Li mi t: 84,07 mm
(3.310
i nl
Bore TaDer:
Limit: {Difterence between first and third measure-
ment) 0.05 mm {0.002 i n)
2. Check the top of the bl ock for warpage.
Measure al ong the edges and across the center as
sh own.
SURFACES TO BE MEASURED
Engine Block Warpage:
Standard
(New):0.07
mm
(0.003
i n) max.
Servi ce Li mi t: 0.10 mm {0.004 i nl
PRECI SI ON STRAI GHT EDGE
7- 13
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Piston Pins Connecti ng Rods
Assembl e t he Pi st on Pi n Tool s as shown.
PISTON BASE HEAO
07HAF
-PL20102
PISTON BASE
07973
-
6570500
Adj ust the l ength A of the pi ston pi n dfl ver.
A: 49.70 mm 11.957 i n)
PIN DRIVER HEAI
PE00320
\
R
Ir1
nT---
u
ffi-"""-
u_ll
3. Pl ace the pi ston on the pi ston base, and press the
pi n out wi th a hydraul i c press. Make sure that the
recessed porti on of the pi ston al i gns wi th the l i ps
on t he col l ar .
7- 14
Removal
1 .
PISTON
07973
-
PISTON PIN BASE INSERT
07GAF
-
PH60300
PISTON PIN DRIVER SHAFT
07973
-
PEt 0310
PILOT COLLAR
07LAF
-
PR30100
Embossod mark f aci ng up.
Selection
Each rod fal l s i nto one of four tol erance ranges
(from
0
to + 0.024 mm
{0 to + 0.0009 i n). i n 0.006 mm
(0.0002
i n)
i ncrements) dependi ng on the si ze of i ts bi g end bore.
l t' s then stamped wi th a number 1.1.2,3, or 4) i ndi cati ng
the range.
You may f i nd any combi nat i on ot 1, 2, 3, or 4 i n any
engr ne.
Normal Bore Size:
,18.0
mm
(1.89
in)
Inspect the connecti ng rod for cracks and heat damage.
CONNECTING ROD BORE
REFENENCE NUMBER
Hal f of number i s st amped on
beari ng cap, t he ot her hal f on
connect no roo.
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Piston Pins
lnstallation
The arrow must face the
t i mi ng bel t si de ot t he
engi ne and t he connect i ng
rod oil hole must face the
rear of t he engi ne.
CONNECTING ROO
otL Hor.E
1. Adjust the length B of the
piston pin
driver and shaft.
B: 49.70 mm
(1.957
i n)
PISTON PIN DRIVER SHAFT
0t973
-
Pqxtlo
Pl ace the pi ston on the
pi n i n wi t h a hydr aul i c
recessed portion of the
on the pi ston base head.
ffi*r,"ron'nl
PILOT COLLAR
OTLAF
-
PF3O1(x'
PISTON PIN BASE INSERT
07GAF
-
PH6o3ttO
PISTON BASE HEAD
OTHAF
-
PL2O102
PISTON BASE
07973
-
6670500
pi ston base and
press the
press. Make sure that the
pi ston al i gns wi th the l ugs
7- 15
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Piston Pins
l Measure t he di amet er of t he
pi st on pi n.
Piston Pin Diameter:
St andard l Newl : 20. 996
-
21. 000 mm
{0.8266
-
0.8268 in}
20.998
-
21.002 mm
(0.8267 -
0.8268 in)
Inspection
1.
Oversize:
2. Zeto the di al i ndi cator to the
pi ston pi n di ameter.
7- 16
3. Measur e t he pi st on pi n t o pi st on cl ear ance. l f t he
pi s t on pi n c l ear anc e i s gr eat er t han 0. 024 mm
(0.0009
i nL remeasure usi ng an oversi zed pi ston pi n.
NOIE: Al l repl acement pi ston pi ns are oversi ze.
Piston Pin-to-Piston Clearance:
Standard l Newl : 0.010
-
0.017 mm
10.0004
-
0.0007 i n)
Check the di fference betl veen the pi ston pi n di ame-
ter and the connecti ng rod smal l end di ameter.
Piston Pin-to-Connecting Rod Interference:
Standard
(New):
0.015
-
0.032 mm
(0.0006 -
0.0013 i nl
4.
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Pi ston Ri ngs
End Gap
2.
1 . Usi ng a pi st on, push a new r i ng i nt o t he cyl i nder
bore 15
-
20 mm
(0.6
0.8 i n) from the bottom
Meas ur e t he pi s t on r i ng end- gap wi t h a f eel er
ga uge:
. l f the gap i s too smal l , check to see i f you have
the proper ri ngs for your engi ne.
. l f the gap i s too l arge, recheck the cyl i nder bore
di ameter agai nst the wear l i mi ts on page 7
' 13.
Pi ston Ri ng End-Gap:
Top Ri ng
Standard
(Newl :0.20
-
0.30 mm
10.008
-
0.012 i nl
Service Limit: 0.60 mm {0.024
inl
Second Ring
Standard lNew): 0.i10
-
0.55 mm
{0.016
-
0.022 i nl
Servi ce Li mi t: 0.70 mm
(0.028
i n)
Oi l Ri ng
Standard
(Newl :
0.20
-
0.50 mm
10.008
-
0.020 i n)
Service Limit: 0.70 mm
(0.028
in)
PISTON RING
--:4
ll
END GAP
-1f-
Ri ng-to-Groove Gl earance
After i nstal l i ng a new set of ri ngs, measure the ri ng-to-
groove cl earances:
Top Ring Clearance:
Standard {New}: 0.055
-
0.080 mm
10.0022
-
0.0031 i nl
Service Limit: 0.13 mm 10,005
inl
Second Ring Clearance:
Standard {Newl : 0.035
-
0.060 mm
{0.001' l
-
0.0024 i nl
Service Limit: 0,13 mm 10.005
inl
7- 17
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Piston Rings
2.
Replacement
1 . Usi ng a ri ng expander, remove the ol d pi ston ri ngs.
Cl ean al l t he r i ng gr oov es t hor oughl y wi t h a
squared-off broken ri ng or a ri ng gtoove cl eaner
wi th a bl ade to fi t the pi ston grooves.
The top ri ng groove
i s 1.2 mm
(0.042
i n) wi de, rhe
second ri ng groove i s 1.2 mm
(0.042
i n) wi de, and
t he oi l r i ng gr oove i s 2. 8 mm
( 0. 11
i n) wi de. Fi l e
down a bl ade i f necessary.
Do not use a wi re brush to cl ean ri ng l ands, or cut
ri ng l ands deeper wi th cl eani ng tool .
3. I nst al l t he new r i ngs i n t he pr oper
sequence and
posi ti on (shown
i n the ri ght col umn).
NOTE: l fthe pi ston i s to be separated from the con-
necti ng rod, do not i nstal l new ri ngs yet.
7- 18
RING EXPANDER
Al i gnment
l . Instal l the ri ngs as shown.
Piston Ring Dimensions:
|- T f
B
+
k - ' 1
A
Top Ring
{standard}:
A: 3.1 mm
(0.12
i n)
B: 1.2 mm
10.05 i nl
Second Ring
(standard):
A: 3.' 1 mm
(0.
f 3 i n)
B: 1.2 mm
(0.05
i n)
NOTE: The manuf ac t ur i ng mar k s mus t
upward.
be t ac i ng
MARK
z:-\
r opnr NG+S
SECOND RING +
,A-\
o**^o(
ffi+-sPAcER
\zu-\
v
TOP RING
'97
-
98 models:
'99
-
O0 modls:
l-;
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Crankshaft Oi l Seal
Rotate the ri ngs i n thei r grooves to make sure they
do not bi nd.
Posi ti on the ri ng end gaps as shownl
SECOND RING GAP
Appror.90"
DO NOT posi t i on any ri ng gap
at piston thrust surfaces,
OIL RING
GAP
Appror.
90'
TOP RI.IIG GAP
SPACER GAP
DO NOT position any ring gap
i n l i ne wi t h t he pi st on pi n hol e. OIL RING GAP
1 .
l nstal l ati on
The seal mati ng surface on the bl ock shoul d be dry
Appl y a l i ght coat of oi l to the crankshaft and to the
l i p of t he seal .
Dri ve the crankshaft oi l seal squarel y i nto the ri ght
sroe cover.
DRIVER
l nst al l seal wi t h t he
part number si de
f aci ng out .
Confi rm that the cl earance i s equal al l the way around
wi th a feel er gauge.
Cl earance:0.5
-
0.8 mm {0.02
-
0.03 i nl
NOTE| Refer to pages 7 23 and 8-10 for i nstal l ati on
of the oi l oumD si de crankshai t oi l seal .
0. 5- 0. 8 mm
{O. 02 0. 03 i n)
7- 19
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Pistons
Crankshaft
Instal l ati on
1. Appl y a coat of engi ne oi l to the ri ng grooves
and
cyl i nder bores.
It the crankshaft i s al ready i nstal l ed.
2. Set the crankshatt to BDC for each cyl i nder.
3. Remove the connecti ng rod caps, and sl i p short sec
ti ons of rubber hose over the threaded ends of the
connecti ng rod bol ts.
4. l nstal l the ri ng compressor, and check that the bear-
ang i s securel y i n pl ace.
5. Posi ti on the pi ston i n the cyl i nder, and tap i t i n usi ng
t he wooden handl e of a hammer . Mai nt ai n down-
ward force on the ri ng compressor to prevent
ri ngs
trom expandi ng before enteri ng the cyl i nder bore.
6. Stop after the ri ng compressor pops free, and check
t he c onnec t i ng r od- t o- c r ank j our nal
al i gnment
before pushi ng pi ston i nto pl ace.
7. Instal l the rod caps wi th beari ngs, and torque the
NUI S I O:
31 N.m
(3.2
kgf.m,23 tbf.ft)
Appl y engi ne oi l to the bol t threads.
lf the crankshaft is not installed:
2. Remove the rod caps and beari ngs, and i nstal l the
fl ng compressor.
3. Posi t i on t he pi st on i n t he cyl i nder , and t ap i t i n
usi ng t he wooden handl e of a hammer . Mai nt ai n
downward force on the ri ng compressor to prevent
ri ngs from expandi ng before enteri ng the cyl i nder
oore,
4. Posi ti on al l the pi stons
at top dead center.
The arrow must f ace
t he t i mi ng bel t si de
of t he engi ne.
CONNECTI NG ROO
OI L HOLE
RUBBER HOSES
7
-20
\ -
\
3.
4.
1 .
6.
Instal l ati on
Appl y a coat of engi ne oi l to the mai n beari ngs and
rod beari ngs.
I nser t t he bear i ng hal ves i n t he cyl i nder bl ock and
connect| ng rods.
Hol d the crankshaft so the rod
j ournal s
for cyl i nders
No. 2 and No. 3 ar e st r ai ght down.
Lower the crankshaft i nto the bl ock, seati ng the rod
j our nal s
i nt o c onnec t i ng r ods No. 2 and No. 3.
Instal l the rod caps and nuts fi nger ti ght.
outward.
Rotate the crankshaft cl ockwi se, and seat the
j our
nal s i nt o connect i ng r ods No. 1 and No. 4, I nst al l
the rod caps and nuts fi nger-ti ght. Instal l the caps
so t he bear i ng r ecess i s on t he same si de as t he
recess an the rod.
Check t he r od bear i ng cl ear ance wi t h pl ast i gage
(see page 7 8). then l orque the capnuts.
Torque:
3l N.m
13.2 kgf.m, 23 lbt.ftl
Apply engine oil to the bolt thleads.
5.
7. I nst al l t he t hr ust washer s on t he No. 4
j our nal .
Li ne up t he mark when
i nst al l i ng connect i ng r od
c ap.
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Coat the thrust washer surtaces and bol t threads
wi th oi l .
Instal l the mai n beari ng caps.
Check cl earance wi th pl asti gage (see page 7-7), then
ti ghten the beari ng cap bol ts i n 2 steps.
First slsp: 25 N.m {2.5
kgf'm, 18 lbf'ft}
Sscond step: 76 N'm
(7.8
kgf'm. 56 lbf'ft)
MAIN BEARING CAP BOLTS TIGHTENING SEOUENCE
NOTE: Whenever any crankshaft or connecti ng rod
beari ng i s repl aced, i t i s necessary after reassembl y
t o r un t he engi ne at i dl i ng speed unt i l i t r eaches
normal operati ng temperature, then conti nue to run
i t for approxi matel Y 15 mi nutes.
10. Cl ean and dry the ri ght si de cover mati ng surfaces.
Appl y l i qui d gasket, part No. 08718
-
0001 or 08718
-
0003, evenl y to the bl ock mati ng surface of the
ri ght si de cover and to the i nner threads of the bol t
hol es. Instal l i t on the cyl i ndr bl ock
1 1 ,
6 x 1 . 0 mm
9.E N.m {1.0 kgt m,
7.2 tbf.ft)
NOTE:
. Do not i nstal l the parts i f fi ve mi nutes or more
have el apsed si nce appl yi ng t he l i qui d gasket .
Instead, reappl y l i qui d gasket after removi ng the
ol d resi due.
. After assembl y, wai t at l east 30 mi nutes before
f i l l i ng t he engi ne wi t h oi l .
(cont' dl
7- 21
RIGHT SIDE
OOWEL PINS
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Crankshaft
12.
Instal l ati on
(cont' d)
1 4 .
13.
Appl y l i qui d gasket
to the oi l pump mati ng surface
of the bl ock.
Appl y a l i ght coat of oi l to the crankshaft, the l i p of
the seal , and the O-ri ngs.
Appl y grease
to the l i ps of the oi l seal s.
Al i gn the i nner rotor wi th the crankshaft, then i nstal l
the oi l pump. When the pump i s i n pl ace,
cl ean any
excess grease off the crankshaft, then check that the
oi l seal l i ps are not di stoned.
6 x 1 , 0 mm
9.8 N.m {1.0 kg{.m,
,.2 tbf.ftl
I
{ /
^ I
GASKET
(. . 6 Repl ace.
"[z
O-RI NG
Repl ace.
OI L PUMP
6 x 1 . 0 mm
9,8 N.m
11.0 kg{.m,
7.2lbt.trl
8 x 1. 25 mm
24 N. m {2. 4 kgf . m,
17 t bt . f t l
7
-22
,'t ./o,
DowEL PtN
// |
16. Appl y l i qui d gasket on
cover matrng areas.
CYLINDER
BLOCK
the oi l pump and ri ght si de
Appl y l i qui d gsket
to these
pornts.
17. Instal l the oi l pan gasket and oi l pan. Wai t no
than fi ve mi nutes after appl yi ng l i qui d gasket.
OIL PAN
OIL PAN
GASKET
Repl ace.
Appl y l i qui d gasket
t o t hese por nt s,
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Oi l Seal s
18. Ti ghten the bol ts and nuts fi nger ti ght at si x
poi nts.
Tighten all bolts and nuts, starting from nut
O.
clock-
wi se i n three steps. Excessi ve ti ghteni ng can cause
di storti on ot the oi l pan gasket and oi l l eakage.
Torque: 12 N.m
(1.2
kgt.m,8.7 lbtft)
19.
1 .
lnstallation
Dry the crankshaft oi l seal housi ng.
Appl y a l i ght coat of grease to the crankshsft and to
the l i ps of the seal s.
Usi ng the speci al tool , dri ve i n the ti mi ng
pul l ey-end
seal unti l the dri ver bottoms agai nst the oi l
pump.
When the seal i s i n pl ace, cl ean any excess grease
off the crankshaft and check that the oi l seal l i p i s
not di storted,
SEAL DRIVER
OTLAD
-
PT3O1OA
l nst al l seal wi t h t he
part s number si de
f aci ng out .
(cont' d)
7-23
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Oi l Seal s
Instal l ati on
(cont' dl
4. l /easure the fl ywheel -end seal thi ckness and the oi l
seal housi ng depth. Usi ng the speci al tool , dri ve the
fl ywheel end seal i nto the rear cover to the
poi nt
where the cl earance between the bottom of the oi l
seal and the ri ght si de cover i s 0.5
-
0.8 mm
(0.02 -
0.03 i n)
(see page 7-19). Al i gn the hol e i n the dri ver
attachment wi th the
pi n
on the crankshaft.
DRI VER
ATTACHMENT
7 6 x 8 0 mm
07948
-
5800101
I nst al l seal wi t h t he
number si de f aci ng
out ,
<:
7
-24
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Engi ne Lubri cati on
Speci af Tool s . . . . . . . . . . . . . ". ""' 8- 2
l l l ust r at ed I ndex . . . . . . . . . . .
. ' . . . 8- 3
Engi ne Oi l
I nspect i on
. . . . . . . . . . . . ' . . ' . . . ' . . ' 8- 4
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . . . . . . . . . . .
8- 4
Oi l Fi l t er
Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8- 5
Oil Pressure Switch
Test i ng
". . . . . 8- 7
Oi l Pressure
Testi ng
....' .' 8-7
Oi l Pump
Over haul . . . . .
. . . . . . . . . . . , . . . . . . . . . 8- 8
Removal /l nspecti on/l nstal l ati on
....' .' 8-9
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Special Tools
Ret. No.
I Tool Number
I
Description
Oty
i
Pagc Roforance
o OTLAD
_
PT3O1OA
079' 12
-
6110001
Seal Dri ver
Oi l Fi l ter Wrench
1
1
8- 10
8-6
8-2
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lllustrated Index
OIL CONTROL
ORIFICE
OI L PUMP
Overhaul ,
page 8-8
Removal / l nspect i on,
page 8 I
Appl y l i qui d gasket t o
mat i ng surf ace of engi ne bl ock.
'99
-
00 models:
KNOCK SENSOR
31 N.m {3.2 kgf.m.23 lbl.ft)
ENGINE OIL PRESSURE SWITCH
18 N. m {1. 8 kgt m, 13l bl . f t )
1/ 8 i n. BSPT
(Bri t i sh
St andard
Pi pe Taper) 28 Threads/ i nch.
Use
proper l i qui d seal ant .
O-RI NG
DOWEL PIN
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbl.ft)
8 x 1. 25 mm
24 N.m 12.4
kgf.m,
17 tbf.ft)
BAFFLE PLATE
kgt m, 7. 2 l bt f t l
Repl ace.
6 x 1 . 0 mm
9. 8 N. m 11. 0
kgf m,
7.2 tbf.ftl
OIL PAN
GASKET
Repl ace.
OI L PAN
Bef ert o page 7 22
when i nst al l i ng.
6 x 1 . 0 mm
12 N. m 11. 2 kgl m, 8. 7 l bl f t l
WASHEB
Repl ace.
DRAIN BOLT
4, 1N. m {, 1. 5 kgf ' m, 33 l bf f t )
Do not overt i ght en.
' - -
\ / o- Rr NG
\ ,/
Reptace.
\^ ./
v, /
U
6 x 1 . 0 mm
9. 8 N. rn {1. 0
SCREEN
8- 3
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Engi ne Oi l
Inspection
2.
1 . Park the vehi cl e on l evel ground, and turn off the
engi ne. Al l ow t he oi l a f ew mi nut es t o dr ai n back
i nto the oi l pan
so the di psti ck wi l l show the actual
l evet,
Make certai n that the oi l l evel i ndi cated on the di p-
sti ck i s between the upper and l ower marks. Insert
the di psti ck careful l y to avoi d bendi ng i t.
l f t he l evel has dr opped cl ose t o t he l ower mar k,
add oi l unti l i t reaches the upper mark.
8-4
Replacement
CAUTION: Remove the drai n pl ug caretul y whi te the
engino is hot; the hot oil may cause scalding.
1. War m up t he engi ne.
2. Dr ai n t he engi ne oi l .
WASHER
Rpl ace.
ORAIN BOL
4il N.m {4.5 kgtm,33 lbf.ft)
Do not overtighten.
3. Rei nstal l the drai n bol t wi th a new washer, and refi l l
wi th the recommended oi l .
Requi rement API Servi ce Grade: Use
"Energy
Conservi ng
"
SJ or
"Energy
Conservi ng l l " SH grade oi l . SAE
5W
-
30 preferred:
You can al so
use an oi l that bears the API
CERTIFICATION mark.
Capaci ty 3. 5 {
( 3. 7
US qt , 3. 1 l mp qt )
at oi l change.
3. 8 /
( 4. 0
US qt , 3. 3
l mp qr )
at oi l change i ncl udi ng fi l ter.
4.6 {
(4.9
US qt, 4.0 l mp qt)
after engi ne overhaul .
Change
Inl erval
Every 7,500 mi l es
(12,000
km) or
12 months (Normal
condi ti ons)
Every 3,750 mi l es
(6,000
km) or 6
months (Severe
condi ti ons).
NOTE: Under nor mal c ondi t i ons , t he oi l f i l t er
shoul d be repl aced at every other oi l change. Under
severe condi ti ons, the oi l fi l ter shoul d be repl aced
at each oi l change.
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Oil Filter
The numbers i n the mi ddl e of the API Servi ce l abel tel l
you
the oi l ' s SAE vi scosi ty or wei ghl . Sel ect the oi l for
your vehi cl e accordi ng to thi s chart:
Ambi ent Temperat ure
100 F
4 0 c -30 -20 -10
An oi l wi t h a vi scosi t y of 5 W
-
30 i s pr ef er r ed f or
i mpr oved f uel economy and year - r ound pr ot ect i on i n
the vehi cl e. You may use a 10 W
-
30 oi l i f the cl i mate i n
your
area i s l i mi ted to the temperature range shown on
the chart.
API SERVICE LABEL
Run t he engi ne t or mor e t han
check for oi l l eakage.
4.
three mi nutes, then
Replacement
CAUTION: After the engine has been tun, ths exhaust
pipes will be hot; be carelul when working around the
exhaust manitold.
1. Remov e t he oi l f i l t er wi t h t he s pec i al oi l f i l t er
wrench.
l nsoect the threads and rubber seal on the new fi l ter.
Wi pe off the seat on the engi ne bl ock, then appl y a
l i ght coat of oi l to the fi l ter rubber seal .
NOTE: Use onl y fi l ters wi th a bui l t-i n bypass system.
oi l t o rubber seal
i nst al l i ng.
-G
Derore
(cont' d)
8-5
I nspect t hr eads and
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Oi l Fi l ter
Replacement
(cont'd)
Instal l the oi l fi l ter by hand.
Af t er t he r ubber seal seat s, t i ght en r he oi l f i l t er
cl ockwi se wi th the speci al tool .
Tighten: 7/8 turn clockwise
Ti ghteni ng torque:22 N.m
(2.2
kgt' m 16l bt.ft)
OIL FILTER WRENCH
07912- 61 10001
8- 6
Some fi l ters have ei ght numbers
(1
to 8) pri nted
on
the surface of the fi l ter.
The fol l owi ng expl ai ns the procedure for ti ghteni ng
fi l ters usi ng these numbers.
l ) Make a mark on the cyl i nder bl ock under the num-
ber that shows at the bottom of the fi l ter when the
rubber seal i s seated.
2) Ti ghten the fi l ter by turni ng i t cl ockwi se seven
numbers from the makes poi nt. For exampl e, i f a
mark i s made under the number 2 when the rub-
ber seal i s seated, the fi l ter shoul d be ti ghtened
unti l the number 1 comes up to the marked poi nt.
Number when rubber
seal i s seat ed.
Number af t er t i ght eni ng.
5. After i nstal l ati on. fi l l the engi ne wi th oi l up to the
speci fi ed l evel , run the engi ne for more than three
mi nutes, then check for oi l l eakage and oi l l evel .
GAUTION: Installation using other than the above
procedure
coul d resul t i n seri ous engi ne damage
due to oi l l eakage.
MARK
Number when r ub-
ber seal i s seated
5 6 7 IJ
Number after ti ght-
eni ng
8 1 2 3 4 6 7
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Oil Pressure Switch
Oil Pressure
Testing
Remove the YEL/RED wi re from the engi ne oi l pres-
sure swrtcn.
Check for conti nui ty between the posi ti ve termi nal
and the engi ne {ground).
There shoul d be conti nui ty
wi th the engi ne stopped. There shoul d be no conti -
nui ty wi th the engi ne runni ng.
L
PRESSURE SWTCH
18 N. m {1. 8 kgf . m,
13 tbr.ftl
Appl y l i qui d seal ant
t o t he t hreads,
l f the swi tch fai l s
l evel . l f the engi ne
orl pressure.
to operate, check the engi ne oi l
oi l l evel i s OK, check the engi ne
Testing
l f the oi l pressure warni ng l i ght stays on wi th the engi ne
runni ng, check the engi ne oi l l evel . l f the oi l l evel i s cor-
rect:
L Connect a tachometer.
2. Remove t he engi ne oi l
an oi l pressure gauge.
ADAPTER
(1/8" -
28, BSTP)
(Commerci al l y avai l abl e)
pressure swi t ch. and i nst al l
OI L PRESSURE GAUGE
{Commerci al l y
avai l abl e)
4.
ENGINE OIL PRESSURE
SWTTCH MOUNNNG
HOt-E
Start the engi ne. Shut i t off i mmedj atel y i f the gauge
regi sters no oi l pressure. Repai r the probl em before
conti nui ng.
Al l ow the engi ne to reach operati ng temperature
(fan
comes on at l east twi ce). The pressure shoul d be:
Engino Oil Temperature: 176'F
(80'C)
Engine Oil Pressure:
At l dl e: 70 kPa
(0.7
kgt/cm', 10 psil
mi ni mum
Ai 3,000 rpm: 3/r0 kPa {3.5 kgt/cm', 50 psi)
mi ni mum
lf oil pressure in not within specifications, inspect the
oi l
pump (see page 8-9).
8-7
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Oi l Pump
Overhaul
6 x l . 0 mm
9.8 N m
(1.0
kg,t m, 7.2 lbf ftl
6 x 1 . 0 mm
5 N. m {0. 5 kgt m. 4l bt f t }
OUTER ROTOR
I nspect i on, pages
8-9, 1O
PUMP COVER
l nspect i on, pages
8-9, 10
Appl y l i qui d gasket
t o t he mat i ng surf ace of
t he cyl i nder bl ock
when anst al l i ng.
REI-IEF VALVE
Val ve must sl i de f reel y
i n t he housi ng bore.
Repl ace t he val ve i f i t i s scored.
8 x 1. 25 mm
2{ N.m
(2.4
kgf m,
17 tbf.fi)
DOWEL PI N
8- 8
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1 .
2.
3.
RemovaUl nspecti on/l nstal l ati on
Dr ai n t he engi ne oi l .
Turn the crankshaft, and al i gn the whi te groove on
the crankshaft pul l ey wi th the poi nter on the l ower
cover.
Remove the cyl i nder head cover and mi ddl e cover.
Remove the power steeri ng pump bel t, ai r condi -
ti oner bel t and the al ternator bel t.
Remove t he cr ankshaf t
pul l ey, and r emove t he
l ower cover.
6. Remove the ti mi ng bel t.
7. Remove the dri ve pul l ey.
8. Remove the oi l pan and oi l screen.
9. Remove the oi l
pump.
orL
PUMP
OLRING
Repl ace.
5.
OIL SCREEN
10.
l l .
Remove the screws from the pump housi ng, then
separate the housi ng and cover.
Check the i nner-to-outer rotor radi al cl earance on
the
pump rotor. l f the i nner-to-outer rotor cl earance
exceeds t he ser vi ce l i mi t . r epl ace t he i nner and
outer rotors.
lnner Rotor-to Outar Rotor Radial Clearance
Standard {Newl : 0.04
-
0.16 mm
{0.002
-
0.006 inl
Service Limit: 0.20 mm
(0.008
in)
Check the housi ng-to-rotor axi al cl earance on the
pump rotor. l f the housi ng-to-rotor axi al cl earance
exceeds the servi ce l i mi t. repl ace the set of i nner
and outer rotors and/or the pump housi ng.
Housing-to-Rotor Axial Clearance
Standard {New): 0.02
-
0.07 mm
{0.001
-
0.003 i n)
So| ' i ce Li mi t: 0.15 mm
(0.006
i nl
(cont' d)
8-9
HOUSI NG
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Oi l Pump
13.
Removal/lnspection/lnstallation
(cont'd)
Check the housi ng-to-outer rotor radi al cl earance. l f
the housi ng-to-outer rotor radi al cl earance exceeds
the servi ce l i mi t, reDl ace the set of i nner and outer
rotors and/or the pump housi ng,
Housing-to-Outer Rotor Radial Clearance
Standard l Newl : 0.10
-
0.19 mm
{0.004
-
0.007 in}
Service Limit: 0.20 mm {0.008 inl
Inspect both rotors and the pump housi ng for scor-
i ng or other damage. Repl ace pans i f necessary.
Remove the ol d oi l seal from the oi l pump.
Gentl y tap i n the new crankshaft oi l seal unti l the
speci al tool bottoms on the pump.
14.
15.
16.
8- 10
17. Reassembl e t he oi l pump, appl yi ng l i qui d t hr ead
l ock to the
pump housi ng screws.
Check that the oi l pump turns freel y.
Appl y a l i ght coat ot oi l to the seal l i p.
Cl ean and dry the oi l pump mati ng surfaces.
Instal l the two dowel pi ns and a new O-ri ng on the
cyl i nder bl ock.
Appl y l i qui d gasket, part No. 08718-0001 or 08718-
0003, to the cyl i nder bl ock mati ng surface of the oi l
pump. Appl y the l i qui d gasket evenl y, i n a narrow
bead centered on the mati ng surface. Do not appl y
l i qui d gasket to the O-ri ng grooves.
Appl y l i qui d gasket to the i nner threads of the bol t
nol es.
18.
19.
20.
21.
Appl y l i qui d
gasket al ong t he
broken l i ne.
PUMP HOUSI NG
NOTE:
. Do not i nstal l the pans i f fi ve mi nutes or more have
el apsed si nce appl yi ng l i qui d gasket. Instead, reappl y
l i qui d gasket after removi ng ol d resi due.
.
After assembl y, wai t at l east 30 mi nutes betore fi l l i ng
the engi ne wi th oi l .
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24. Appl y grease to the l i p of the oi l pump seal .
Instal l the oi l pump onto the crankshaft. When the
pump i s i n pl ace, cl ean any excess grease off the
crankshaft and check that the oi l seal l i p i s not di s-
torted.
l nstal l the oi l screen.
Instal l the oi l pan
{see
page 7-22). 2't .
8 x 1. 25 mm
24 N.m 12.4 kgf.m,
'17
tbf.ft)
O-RI NG
Appl y engi ne oi l
Repl ace.
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
1 .2lbfitl
DOWEL
PI N
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m.
7.2 tbtftl
OI L PUMP
6 x 1 . 0 mm
9 . 8 Nm( 1 . 0 k g f . m,
7.2 tbt ft)
OI L SCBEEN
8 - 1 1
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Intake Manifold/Exhaust System
Intake Mani fol d
Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Exhaust Mani fol d
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Exhaust Pipe and Muffler
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
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Intake Mani fol d
Repl acement
NOTE:
. Use new O-ri ngs and gaskets when reassembl i ng.
. Check for fol ds or scratches on the surface of the gasket.
. Repl ace wi th a new gasket i f damaged.
'97
-
98 models:
INTAK MANIFOLD
Repl ace i f cr acked or
i f mat i ng sur f aces ar e
oamageo,
INTAKE AIR
TEMPERATURE
{I ATI SENSOR
22 N.n 12.2 kgl.m,
16 rbf.ftl
8 x 1. 25 mm
22 N.m 12.2 kgtm.
't6
tbf ft)
8 x 1. 25 mm
22 N.m |.2.2 kgl.rn,
'16
tbt ftl
I x 1. 25 mm
24 N m 12. 4 kgf m.
17 tbf.ft)
INTAK
BRAC}
INTAKE MANIFOLO
BRACKET B
('98
modell
8 x 1. 25 mm
23 N m
(2. 3 kgt m,
17 tbf.ftl
I x 1. 25 mm
24 N. m 12. 4 kgf . m,
17 tbf.ft)
8 x 1. 25 mm
24 N.m (2.4
kgf.m,
17 tbf.ft)
9-2
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'99
-
O0 modol3:
6 x 1 . 0 mm
9.8 N.m 11.0 kg{.m,
7.2 tbtltl
NESONATOR
6 x 1 . 0 mm
9.8 N.m {1.0 kgf.m,
7.2 rbr.ftt
O-RING
Repl ace.
Appl y oi l t o O-RI NG
bet ore i nst al l i ng.
RESONATOR
CHAMBER
BRACKET
GASKET
Repl ace.
IAT SENSOR
2:2N.m l2.2kgl.n,
16 tbtftl
O.RING
Repl ace.
l
O.RING
Repl ace.
8 x 1. 25 mm
24 N.m 12.4 kgt m,
17 tbt frl
INTAKE MANIFOLD
Repl ace i t cracked or
i f mat i ng surf aces are
oamageo.
8 x 1. 25 mm
22 N.m 12.2 kgl.m,
16 rbf.ftt
IAC VALVE
8 x 1. 25 mm
23 N.m
(2.3
kgf.m,
17 tbf.ft,
INTAKE MANIFOLD
22 N.m 12,2 kgl.m,
16 rbf f t l
("\"-\
K\*}Gt
W\qu
u
N,1\J
'n\
.a,,-\\J "
\ G)s
BRACKET
9-3
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Exhaust Manifold
Repl acement
NOTE:
. Use new gaskets and sel f-l ocki ng nuts when reassembl i ng.
. Check for fol ds or scratches on the surface of the gasket.
. Repl ace wi th a new gasket i f damaged.
'97
-
98 U.S. models
(Calilornia):
8 x 1. 25 mm
31 N.m
(3.2 kgf.m, 23 lbtft)
Repl ace.
I x 1. 25 mm
24 N.m
(2.4
kgl.m,
1? tbf.ft)
8 x 1. 25 mm
24 N. m
(2. i 1kgt . m,
17 lbf.ftl
EXHAUST
MANI FOLO
10 x 1. 25 mm
44 N.m 14.5
kgf.m, 33 lbf.ft)
SELF.LOCKING NUT
8 x 1. 25 mm
31 N m 13.2 kgt.m, 23 lbt'ft)
Repl ace.
EXHAUST MANIFOLD
BRACKET
10 x 1. 25 mm
44Nm{ 4. 5kg{ . m.
33 lbf.ftl
NN
9-4
www.emanualpro.com
'97
-
98 U.S. models {Except California):
'99
-
00 models:
8 x
' 1. 25
mm
31 N. m {3. 2 kgl . m, 23 l bl . f t )
Bepl ace.
8 x 1. 25 mm
31 N.m {3.2 kgf.m.23 lbf.ft)
Repl ace.
MANIFOLD
6 x 1 . 0 mm
9.8 N m 11.0 kgf.m, 7.2 lbf.ft)
COVER
(v/\
NL-]
\\ r-------.
\ \ '
' r
\F=
\\/ ,l
BRACKET
44 N.m {4.5 kgf.m, 33 lbtftl
9- 5
www.emanualpro.com
Exhaust Pipe and Muffler
Replacement
NOTE: Use new
gaskets and sel f-l ocki ng nuts when reassembl i ng.
7
-
98 U.S. models
(Calitornial:
GASKET
Repl ace.
SELF.LOCKING NUT
10 x 1. 25 mm
33 N.m {3.4 kgt m, 24 lbl.ft)
Repl ace.
MUFFLER
SELF.LOCKING NUT
I x 1. 25 mm
22 N.m
(2.2 kg{.m, 16lbt'ftl
Repl ace.
Ti ght en t he nut s i n st ePs,
al t ernat i ng si de-t o-si de.
PRIMARY HO2S
44 N.m {{.5 kgl.m,
33 tbt.ft)
TWC
Inspection, see section
SECONDARY HO2S
4il N.m lil.5
kgtm,
33 tbf.ft)
GASKET
Repl ace.
1 l
S*S:--t-..-_
EXHAUST
PIPE A
NUT
10 x 1. 25 mm
54 N.m 15.5
kgi.m,40lbf'tt)
Repl ace.
GASKET
Repl ace.
SELF.LOCKING NUT
8 x 1. 25 mm
22 N.m
(2.2
kgf.m,
r 6 tbt.ft)
Repl ace.
Ti ght en t he nut s i n
st eps, a' t ernat i ng
si de-t o-si de.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbt.ltl
SELF.LOCKING NUT
8 x 1. 25 mm
16 N. m {1. 6 kgt . m,
12 tbt fr)
Repl ace.
www.emanualpro.com
'97
-
98 U.S. models
(Except
Californial:
'99
-
00 models:
GASKET
Repl ace.
SELF.LOCXING NUT
l 0 x 1. 25 mm
33 N.m 13.4 kgl.m, 24 lbtft)
Repl ace.
SELF.LOCKING NUT
8 x 1. 25 mm
22 N.m
(2.2
kgf.m, 16 lbl.ft)
Repl ace.
Ti ght en t he nut s i n st eps,
al t ernat i ng si de t o si de.
SECONDARY HEATED
OXYGEN SENSOR
{SECONDARY HO2SI
4il N.m 14.5 kgl.m,
33 tbf.ftl
THREE WAY CATALYTIC
CONVERTER
(TWCI
l nspect i on, see sect i on 11
MUFFLER
PRIMABY HEATED
OXYGEN SENSOR
(PRTMARY
HO2S)
44 N.m
(4.5
kgf.m,
33 tbf.ftl
GASKETS
Repl ace.
SELF-LOCKING NUT
8 x 1. 25 mm
16 N. m 11. 6 kgf . m,
12 tbf.ftt
Repl ace.
SELF.LOCKING
NUT
8 x 1. 25 mm
22 N,m 12,2
kgi'm,
16 tbf.ftl
Repl ace.
Ti ght en t he nut s i n
st eps, al t ernat i ng
si de-t o-sade.
9. 8 N. m {1. 0 kgf . m,
7.2 rbf.ft)
x 1. 0 mm
NUT
10 x 1. 25 mm
5a N.m
(5.5
kgl.m,40 lbf ftl
Repl ace.
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Cool i ng
f f f ust r at ed I ndex . . . . . . . . . . . . . . . . 1O- 2
Radi ator
Rep| acement . . . . . . . . . . . , . . . . , . . . . . . . . . . . . . . . . . . . . . . 10- 4
Engi ne Cool ant Refi l l i ng and
Bl eedi ng . . , . , . . . . . . . . . . . . . . . . . 10- 5
Cap Test i ng . . . . . . . . . . . . . . . . . . . . 10- 7
Test i ng . . . . . . 10- 7
Thermostat
Rep| acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 8
Testi ng ...... 10-9
Water Pump
l l l ust r at ed l ndex . . . . , . . . . . . . 10- 10
Inspecti on . 10-1 1
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . 10- 1 1
Fan Gontrol
Component Locati on Index ............... 10-12
Ci r cui t Di agr am . . . . . . . . . . . . . 10- 13
Fan Motor Testi ng ......... 10-14
Radi ator Fan Swi tch Testi ng ............. 10-14
Cool ant Temperature Gauge
Gauge Test i ng . . . . . . . . . . . . . . . 10- 15
Cool ant temperature Sendi ng
Uni t Test i ng . . . . . . . . , . . . . . . . 10- 15
www.emanualpro.com
l l l ustrated Index
CAUTION: The system is under high pressure when the
engine is hot. To avoid danger ol releasing scalding engine
coolant, remove the cap only when the engine is cool.
Total Cooling System Capacity fincluding 0.6 I
(0.63
US
qt, 0.53 lmp qt) for heater and reservoirl:
A/T: 5.9 { {6.2 US qt, 5.2 l mp qt)
M/T: 6.0 f
(6.3
US
$,
5.3 l mp qt)
det eri orat i on and repl ace i f necessar, .
Check al l hose cl amps and ret i ght en i f necessary.
l f any engi ne cool ant spi l l s on t he
body, ri nse i t of f i mmedi at el y.
Check al l cool i ng syst em hoses
pai nted porti ons of the
f or damage, l eaks or
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m.
1.2 tbl.ftl
RADIATOR
Engi ne cool ant ref i l l i ng and bl eedi ng,
page 10-5
Leak t est ,
page 10 7
I nspect sol dered
j oi nt s
and
seams f or l eaks.
Bl ow out di n f rom bet ween
core f i ns wi t h compressed ai r.
l f i nsect s, et c. , are cl oggi ng
radiator, wash them off with
low pressure water.
RADIATOR CAP
Pressure test,
page 10-7
ATF COOLER
HOSE
Rel er t o sect i on 14
when i nst al l i ng.
LOWER
cusHroN
6 x 1 . 0 mm
7 N.m
(0.7
kgf.m, 5 lbf ftl
FAN MOTOR
10-2
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Engi ne Hose Connecti ons:
FAST IDLE THERMO
VALVE
(A/T
onlyl
IDLE AIR CONTROL
I I AC}VALVE
TEF BYPASS
HOSE
THERMOSTAT
HOUSING
CONNECTING
PI PE
VALVE
HOSES
10- 3
www.emanualpro.com
Radiator
1 .
2.
3.
4.
Repl acement
CONDENSER
FAN,/SHROUD
ASSEMBLY
Dr ai n t he engi ne cool ant .
Remove t he upper and l ower r adi at or hoses, and
ATF cool er hoses.
Di sconnect the fan motor connector.
Remove the radi ator upper bracket, then pul l up the
r aot al or ,
5. Remove t he f an shr oud assembl i es and ot her par t s
from the radi ator.
6. l nstal l the radi ator i n the reverse order of removal .
NOTE:
. Set the upper and l ower cushi ons securel y.
. Fi l l the radi ator wi th engi ne cooi ant and bl eed the ai r.
RADIATOR CAP
RADIATOR
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m,
7.2 tbl.trl
6 x 1 . 0 mm
7 N.m
(0.?
kgd.m, 5 lbl.ftl
UPPER MDIATOR HOSE
Rel er t o sect i on 14
when i nst al l i ng.
DRAIN PLUG
LOWER CUSHION
LOWER TOR HOSE
RADIATOR
ASSEMBLY
6 x 1 . 0 mm
7 N.|n 10.7 kgt.m,
5 tbt.ftl
rriItriiii
10-4
www.emanualpro.com
Engi ne Cool ant Refi l l i ng and Bl eedi ng
1. Sl i de the heater l emperature control l ever to maxi
mum heat.
Make sure the engi ne and radi ator are cooi to the
t ouch.
2. Remove the radi ator caP.
3. Loosen t he dr ai n pl ug, and dr ai n t he cool ant .
4. Remove the drai n bol t from the cyl i nder bl ock.
DRAIN PLUG
DRAIN BOLT
78 N.m {8.0 ksl.m, 58 lbtft}
10- 5
6.
7.
Appl y l i qui d gasket to the drai n bol t threads, then
rei nstal l the bol t wi th a new washer and ti ghten i t
securel y.
Ti ghten the radi ator drai n pl ug securel y.
Remove, drai n and rei nstal l the reservoi r' Fi l l the
tank hal fway to the MAX mark wi th water, then up
to the MAX mark wi th anti treeze.
(cont' d)
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Radiator
Engi ne Cool ant Refi l l i ng and Bl eedi ng
(cont' dl
Mi x t he r ecommended ant i f r eeze wi t h an equal
amount of water i n a cl ean contai ner.
NOTE:
. Al ways use Genui ne Honda Anti freeze/Cool ant.
Usi ng a non-Honda cool ant can resul t i n corro-
s\on, ca\rsng t\e coo\\ng sys\em \o ma\lunct\on
o. fai l .
For best corrosi on protecti on,
the cool ant con-
cent r at i on must be mai nt ai ned year - r ound
at
50% mi ni mum. Cool ant concentrati ons l ess than
50% may not provi de
suffi ci ent protecti on
agai nst
cor r osi on or f r eezi ng. Cool ant concent r at i ons
greater
than 60% wi l l i mpai r cool i ng effi ci ency
and are not recommended.
Do not use addi ti onal rust i nhi bi tors or anti -rust
products;
they may not be compati bl e wi th the
cool ant.
Engine Coolant Refill Capacity Iincluding 0.6 /
10.63
US
$,
0.53 lmp qtl for hoater and ressrvoirl:
A/T: 3.9 f
{4.1 US
$,
3.4 lmp qtl
M/T: 1.O t
14.2 US
$,
3.5 lmp qrl
10- 6
9. Pour cool ant i nto the radi ator uD to the base of the
fi l l er neck. When pouri ng
engi ne cool ant. do not l et
cool ant spi l l on any el ectri cal pans
or the pai nt. l f
any cool ant spi l l s, ri nse i t oft i mmedi atel y.
Start the engi ne, and l et i t run unti l i t warms up
(the
radiator fan comes on at least twice).
Turn off the engi ne. Check the l evel i n the radi ator,
add cool ant i f needed.
Put the radi ator cap on ti ghtl y. then run the engi ne
agai n and check for l eaks.
1 1 .
10.
12.
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Cap Testing
1 .
2.
Remove the radi ator cap, wet i ts seal wi th engi ne
cool ant, then i nstal l i t on the
pressure tester.
Appl y a pressure of 93
-
123 kPa
(0.95 -
1.25 kgfl cm' ,
14
-
18 psi ) .
Check for a drop i n pressure.
l f the pressure drops, repi ace the cap.
RADIATOR PNESSURE TESTER
l Commerci al l y
avai l abl e)
3.
RADIATOR
ADAPTOR
(f or 32 mm neck, l ow
Prof i l e)
2.
3.
Testing
1 . Wai t unti l the engi ne i s cool , then careful l y remove
t he r adi at or cap and f i l l t he r adi at or wi t h engi ne
cool ant t o t he t op oI t he f i l l er neck.
Attach the pressure tester to the radi ator, and appl y
a pressure of 93
-
123 kPa
(0.95
-
1,25 kgf/cm' , 14
-
18 psi ) .
Inspect for engi ne cool ant l eaks and a drop i n pres-
sur e.
Remove the tester, and rei nstal l the radi ator cap.
Check f or engi ne oi l i n t he cool ant and/ or cool ant i n
t he engi ne oi l .
RAOIATOR PRESSURE
TESTER
(Commerci al l y
avai l abl e)
4.
5.
ADAPTOR
(f or
32 mm neck,
l ow prof i l e)
10-7 www.emanualpro.com
Thermostat
Repl acement
THERMOSTA
I nst al l wi t h pi n up.
THERMOSTAT
HOUSING
RUBBER SEAL
Repl ace.
RADIATOB FAN
swtTcH
24 N. m {2. 4 kgt m, l 7 l bt . f t l
THERMOSTAT
COVER
12 N. m
(1. 2
kgl . m,
8.7 tbtftl
6 x
' 1. 0
mm
10- 8 www.emanualpro.com
Testing
Repl ace the thermostat i f i t i s open at room temperature.
To test a cl osed thermostat:
1. Suspend the thermostat i n a contai ner of water. Do
not l et the thermometer touch the bottom of the hot
contai ner.
THERMOMETER
THERMOSTAT
Heat the water, and check the temperature wi th a
thermometer. Check the temperature at whi ch the
thermostat fi rst opens, and at whi ch i t i s ful l y open.
Measure the l i ft hei ght of the thermostat when ful l y
open.
STANDARD THERMOSTAT
Li ft hei ght: above 8.0 mm
(0.31
i n)
Starts openi ng: 169
-
176' F
(76 -
80' C)
Ful l y open: 194' F
(90' C)
10- 9 www.emanualpro.com
Water Pump
lllustrated Index
ENGINE COOLANT
TEMPERATURE IECTI
SENSOR
18 N. m 11, 8 kgt . m,
13 tbt.ftl
COOLANT
TEMPERATURE
GAUGE
UNI T
6 x 1 . 0 mm
9.8 N'm (1.0
kgf.m,
7.2 tbt frl
9 N.m {0.3 kgf.m,
7 tbf.ftt
Appl y l i qui d gasket
t o t he t hreads.
WATER OUTLET
COVER
Appl y l i qui d gasker part No.
087' 18
-
0001 or 08718
-
0003
to the mating surface.
RADIATOR FAN SWITCH
2il N.m (2.i1
kgl.m,
17 tbfft)
WATER PUMP
l nspecti on, page
10-11
O-RING
Replac.
6x l , 0mm
12 N.tn n.2 lgl.rn,
8.7 tbf'ft)
CONNECTING
PIPE
6 x 1 . 0 mm
12 N.m 11.2 kgf.m,
8.7 tbtftl
10- 10 www.emanualpro.com
Inspection
1 .
2.
Remove the ti mi ng bel t
(see
secti on 6)
Tur n t he wat er
pump pul l ey count er cl ockwi se.
Check that i t turns freel y.
Check for si gns of seal l eakage.
NOTE: A smal l amount ol
"weepi ng"
from the bl eed
hol e i s normal .
BIIED HOLE
Replacement
1. Remove the ti mi ng bel t
(see
secti on 6).
2. Remove the water pump by removi ng fi ve bol ts
3, Inspect, repai r and cl ean the O-ri ng
groove and the
mati ng surface wi th the cyl i nder bl ock.
Repl ace.
6 x 1 . 0 mm
't2
N.m 11 2 kgf m.
8.7 tbf.ftl
4. lnstall the water
pump in the reverse order of removal.
-<o
@-
I
I
10- 1 1
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Fan Control
Component Locati on Index
UNDEB. HOOD
FUSE/RELAY BOX
RADIATOR FAN RELAY
Test , see sect i on 23
BADIATOR FAN
Removal , page 10- 10
Test , page
10- 14
BADIATOR FAN MOTOR
Removal , page 10- 2
CONDENSER
FAN MOTOR
f t f l E f f l t r l
t lrt
r-1 a-l
@u! l f l ] l
10- 12
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Ci rcui t Di agram
UNDER OASH
FUSEiRELAY BOX
6;\ E;';l
wHTsLka
rtF' ,*",El -l
I
RAOIATOR
FAN
SWITCH
f Cl osed
: Above)
L
199oF { 930C)
J
BLK/ RED
I
L^,^,.,
T*'
I
BLK
I
I
oro,
IGNITION SWITCH
No. 41{ 100A) N0. 42140A)
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Fan Control
Fan Motor Testing
1. Di sconnect t he 2P connect or .
Termi nal si de
of
mal e termi nal s
Test the motor by connecti ng battery power
to the
No. 2 t er mi nal and gr ound
t o t he No. 1 t er mi nal .
l f the motor fai l s to run or does not run smoothl y,
reptace rt.
RADIATOR FAN MOTOR
10- 14
Radiator Fan Switch Testing
E@
Removi ng the radi ator fan swi tch whi l e
the engine is hot can cause the coolant to spray out, seri-
ously scalding you.
Always let the enginc and radiator
cool down before removing the radiator fan switch.
1. Remove the radi ator fan swi tch from the thermostat
housi ng (see page
10
' 10).
2. Suspend t he r adi at or f an swi t ch i n a cont ai ner of
water as shown.
Heat the water, and check the temperature wi th a
thermometer. Do not l et the thermometer touch the
bottom of the hot contai ner.
Measure the conti nui ty between the A and B termi -
nal s accordi ng to the tabl e.
Bl eed the ai r from the cool i ng system after i nstal l i ng
the radi ator fan swi tch (see page 10-5).
\
Termi nal
op".*i-
Tr"ip".a*"
\.
B
SWITCH
ON
196
-
203"F
{91
-
95.C)
o-
--o
OFF
5
-
14"F (3 -
8.C)
l ower than the tem-
per at u r e wh en i t
goes on
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Gool ant
Temperature Gauge
Gauge Testi ng
1. Check t he No. 25
( 7. 5 A) f use i n t he under - dash
fuse/rel ay box before testi n9.
2. Make sure the i gni ti on swi tch i s OFF, then di scon-
nect the YEL/GRN wi re from the cool ant tempera-
t ur e sendi ng uni t . and gr ound i t wi t h a
j umper
wi r e.
YEL/GRN
WIRE
Tur n t he i gni t i on s wi t c h ON { l l ) . Chec k t hat t he
poi nt er of t he cool ant t emper at ur e
gauge st ar t s
movi ng t owar d t he
" H"
mar k. Tur n t he i gni t i on
swi tch OFF before the poi nter reaches
"H"
on the
gauge di al . Fai l ur e t o do so may damage t he gauge.
l f t he poi nt er of t he gauge does not move at al l ,
check for an open i n the YEL/GRN wi re.
l f the wi res are OK, repl ace the cool ant temperature
gauge.
l f t he cool ant t emper at ur e
gauge wor ks, t est t he
cool ant temperature sendi ng uni t.
5.
COOLANT TEMPERATURE
Cool ant Temperature Sendi ng Uni t
Testing
1. Di sconnect the YEUGRN wi re from the cool ant tem
perature sendi ng uni t.
COOLANT TEMPERATURE
POSITIVE
TERMINAL
YEL/GRN WIRE
(Covered wi th
i nsul ati on)
2. Usi ng an ohmmeter, measure the change i n resi s-
tance between the posi ti ve termi nal and the engi ne
( gr ound) wi t h t he engi ne col d and wi t h t he engi ne
at operati ng temPerature.
Temperature 133.F
(56' C)
1A5
-
212F
(8s
-
100' c)
Resi stance
( 0)
137 4 6 - 3 0
3. l f the readi ngs are substanti al l y di fferent from the
speci ti cati ons above, i nspect the cool ant l evel and
t he cool i ng syst em. l f t he cool i ng syst em i s OK,
repl ace the sendi ng uni t.
1 0 - 1 5 www.emanualpro.com
Fuel and Emi ssi ons
Speci al Tool s ...................... 11-2
Component Locations
l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . 11- 3
Svstem Description
Vacuum Connect i ons . . . . . . . . . . . , . . . . , . , . . . . . . . . . . . . . . . . . 1 1- 9
El ect r i cal Connect i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 15
Syst em Connect or s . , . , , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . , . 1 1- 36
Troubl eshooti ng
Tr oubl eshoot i ng Pr ocedur es, . , . . . . . . . . . . . . . . . . . . . . . 11- 60
Engi ne Control Modul e/Powertrai n Conttol
Modul e Termi nal Arrangement .............., 11-67
Di agnosti c Troubl e Code Chart .................... 1 t-75
How to Read Fl owcharts .......,.....,.,............... I 1-79
PGM-Fl System
System Descri pti on .................,.,.,,,............... 1 1-80
Troubl eshooti ng Fl owcharts
Engi ne Control Modul e/Powertrai n
Control Modul e ........11-52
Mani fol d Absol ute Pressure Sensor ............. 11-90
Intake Ai r Temperature Sensor .................... 1 1-95
Engi ne Cool ant Temperature Sensor .,..,.,.... 1 1-99
Throttl e Posi ti on Sensor ...........,.....,.,.,..,...... I 1' 103
Pri mary Heated Orygen Sensor
(Sensor
1) ... 11-110
Secondary Heated Oxygen Sensor
{ Sensor 2l . . . . . . . . . . . . . . . . . . 1 1- 117
Heated Oxygen Sensor Heater ..................... 11-121
Fuef Suppl y System ......11-124
Random Mi sfi re ,....,.,..... 11-126
Mi sti re Detected i n One Cyl i nder .....-........... 11-128
Knock Sensor . . . . . . . . . . . . . . . . 11- 130
CKP/ TDC/ CYP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 131
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . 1 1- 135
Barometri c Pressure Sensor .....,...,...,.,,........ 1 1-137
El ectri cal Load Detector ...,.,.......................... 1 1-138
CKF Sensor ................,.,,
' 11-112
ECM/PCM l nternaf Ci rcui t ............................. 11' 117
HO2S Repl acement .,.,.,. 11-148
ldle Control System
System Descri pti on ............ 11-149
Troubleshooting Flowcharts
l dl e Control System ...... 11-150
fdl e Ai r Control Val ve ......................,............. 11-152
Ai r Condi t i oni ng Si gnal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 1- 155
Al t er nat or FR Si gnal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 159
Starter Swi tch Si 9na1 .................................... t l -161
Power Steeri ng Pressure Swi tch Si gnal ...... 11-162
Br ake Swi t ch Si 9na1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 166
Fast l dl e Ther mo Val ve . , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . , . , . 11- 168
l dl e speed setti ng .............. 11-169
Fuel Supply System
Fuel Li nes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 171
Fuef Tube/Oui ck-Conneci Fi tti ngs ..................... 11
-175
System Descri pti on ............ 11-178
Fuel Pr essur g . . . . . . . . . . . . . . . . . . . . . . 11- 178
Fuel Ini ectors ................,..... 11-179
Fuel Pr essur e Re9u1at or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . , . . . . , f 1- 181
Fuef Fi fter ....,.,.,.,,,,.,............11-142
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 183
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 184
Fuel Gauge Sendi ng Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 1- 185
Low Fuel Indi cator System ...........,.,..,............... 1 1-185
PGM- FI Mai n Rel ay . . . . . . . . . . . . . 11- 187
Fue| Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 191
Intake Air System
System Descri pti on ............ 11-193
Ai r Cl eanel , . , . , . . . . . . . . . . . . . . . . . . . . . 11- 194
Throttl e Cabl e ..................... 11-194
Thr ot t l e Body. . . . . . . . . . . . . . . . . . . . . . 11- 196
Emission Control System
System D$cri pti on ...,....,.,. 11-199
Tai l pi pe Emi ssi on ............... 11-199
Three Way Catal yti c Converter ..................,.,...,, 11-199
Posi ti ve Crankcase Venti l ati on System .,.,,,,.,.., 11-2O1
Evaporati ve Emi ssi on Control s .........,.,.,............ 11-203
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Speci al Tool s
Ref. No. Tool Number Descri pti on Oty Page Reference
q
t 3'
, 3 ) l
6 r l
A973X_041
_XXXXX
07JAZ 0010008
07PAZ
,
0010100
07sAz
-
001000A
07405
-
0040001
Vacuum Pump/ Gauge, 0
-
30 i n. Hg
Vacuum/Pressure Gauge, 0 4 i n.Hg
SCS Servi ce Connector
Backprobe Set
Fuel Pressure Gauge
1
1
2
1
'11-201
. 208,214,
215, 2' t 6, 217
, 220,
221
,
222, 223, 224
11 207
,
224
11-60, 83, 88, 1 16,
128,200,205
11-62
11- 178, 181
Speci al Tool s
I
11- 2
www.emanualpro.com
Component
Locations
l ndex
'97
-
98 models:
MANIFOLD ABSOLUTE
PRESSURE IMAP} SENSOR
Troubl eshoot i ng, Page
1 1-90
THROTTLE POSITION
(TP}
SENSOR
Troubl eshoot i ng, page 1 1-103
toLE AtR CONTROL llAcl
VAI-VE
Troubl eshooti ng,
page 1 1-152
EVAPORATIVE EMISSION
(EVAP)
CONTROL CANISTER VENT SHUT
VALVE t'98 modll
Troubl eshoot i ng,
page 11' 213
INTAKE AIR TEMPERATURE
IIATI SENSOR
Troubleshooting.
page 1
'l
-95
ELECTRICAL LOAD
DETECTOR IELD)
(USA
modol)
Troubl eshoot i ng,
page 1 1-138
VEHICLE SPEED
SENSOR
(VSS)
Troubl eshoot i ng,
page 11' 135
CRANKSHAFT
POSTTtON/
POWER STEERING PRESSURE
lPsPl swtrcH
Troubl oshoot i ng,
page 1 1-162
TOP OEAD CENTER/
CYLINDER
POStTtON
{CKP/TDC/CYP} SENSOR
(Bui l t
i nt o t he di st ri but or)
Troubl eshoot i ng, page 1 l -131
CMNKSHAFT SPEED
FLUCTUATION ICKF} SENSOR
Troubl eshoot i ng.
page 1' ! -142
ENGINE COOLANT
TEMPERATURE
IECTI SENSOR
Troubl eshoot i ng,
page 11 99
EVAPORATIVE
IVAP) PURGE CONTROL
SOLENOID VALVE
Troubf eshooting,
page 1 1'2o5, 213
(cont' d)
1 1 - 3
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Component Locations
Index
(cont' dl
39
-
00 models:
MANIFOLD ABSOLUTE
PRESSURE I MAPI SENSOR
Troubl eshoot i ng, page
1 1-90
THROTTLE POSITION {TP)
SENSOR
Troubl eshoot i ng, page 1 1-103
IDLE AIR CONTROL OACI VALVE
Troubl eshoot i ng, page 1 1-152
EVAPOBATIVE EMISSION {EVAPI
CONTROL CANISTER VENT SHUT
VALVE
Troubl eshoot i ng, page 1 1-213
EVAPORATIVE EMISSION
(EVAPI
PURGE CONTROI-
SOLENOID VALVE
Troubl eshoot ang, page 1 1-2' 13
ELECTRICAL LOAO
OETECTOR
{ELD) IUSA modet)
Troubl eshoot i ng, page
I 1-138
INTAKE AIR TEMPERATURE
(IAT)
SENSOR
Troubl eshoot i ng, page
11 95
POWEB STEERING PRESSURE
tPsPt swtTcH
Troubl eshooti ng, page 11 162
VEHICLE SPEED
SENSOR
IVSSI
Troubl eshoot i ng,
page 11' 135
CRANKSHAFT
POSTTTON/
TOP OEAD CENTER/
CYLI NDER
POStTtON
{CKP/TDC/CYP) SENSOR
(Bui l t
i nt o t he di st ri but or)
Troubl eshoot i ng, page 11 131
CRANKSHAFT SPEED
FLUCTUATION ICKN SENSOR
Troubl eshoot i ng, page 1 1-142
SENSOR
Troubl eshoot i ng, page
' 11
130
ENGINE COOLANT
TEMPERATURE
{ECT)SENSOR
Troubl eshoot i ng, page 11 99
11- 4
www.emanualpro.com
DATA LINK CONNECTOR {DLC) I16P}
Troubl eshoot i ng Procedures, page 1 1' 60
PRIMARY HEATED OXYGEN SENSOR
{PRI MARY HO2SI {SENSOR
1)
Troubl eshool i ng,
page 11 110
SECONDARY HEATED OXYGEN
SENSOR
{SECONDARY HO2S) {SENSOR 2)
Troubl eshoot i ng, page 1 1-1 17
'97
-
98 models:
AIR CLEANER
Repl acement ,
page 1 1' 194
Troubl eshoot i ng, page 1
' l
-200
THROTTLE BODY
(TB)
I nspect i on, page 11 196
Removal , page 11-197
Di sassembl y, page 1 1-' 198
POWERTRAIN CONTROL MODULE
(PCM) (A/TI
Troubl eshoot i ng Procedures, page 1 1-60
Troubl eshoot i ng. page 1 1' 82
THROTTLE CABLE
I nspect i on/ Adj ust ment , page 1 1-1 94
I nst al l at i on, page 11- 195
VENTILATION
(PCV)
VALVE
I nspect i on,
page 1 1-201
FAST IDLE VALVE
(A/T}
(cont' d)
1 1- 5
PGM-FI
MAIN RELAY
Rel ay Test i ng, page
11-l 87
Troubl eshoot i ng. page 1' 1 188
SERVICE CHECK CONNECTOR {2PI
Troubl eshoot i ng Procedures, page 1 1-60
,a'=_-_
WAY CATALYTIC
I nspect i on,
page 1 1- 168
www.emanualpro.com
Component Locations
Index
{cont'd)
39
- q,
models:
THROTTLE BODY ITB)
I nspect i on, page 1 1-196
Removal , page 11- 197
Di sassembl y, page 11 198
THROTTLE CABLE
I nspect aon/ Adj ust ment , page 1 1 194
I nst al l at i on, page I l ' 195
AIR CLEANER
Rpl acomenl ,
page 1 1-194
CRANKCASE
VENTILATION IFCVI VALVE
l nspect i on,
page 11 201
FAST IDLE THERMO VALVE IA/T)
I nspect i on,
page 11' 168
1 1- 6
www.emanualpro.com
FUEL PRESSURE
REGULATOR
Test i ng, page 11- 181
Repl acement , page 11 181
FUEL PUMP
Test i ng, page 11 183
Repl acement ,
page 11 183
FUEL GAUGE SENDING UNIT
Test i ng, page 11 185
'97
model:
'98
model:
FUEL PULSATION DAMPER
EVAPORATIVE EMISSION
IEVAP) CONTROL CANISTER
Troubl eshoot i ng. page 1' l -205
FUEL FILTER
Repl acement , page 11 182
FUEL INJECTORS
Repl acement ,
page 1 1-179
FUEL FEED PIPE
FUEL VAPOR PIPE
FUEL
FITTINGS
FUEL FI LL
CAP
EVAPORATIVE EMISSION
IEVAPI TWO WAY VALVE
Test i ng, page 11 224
TANK
Repl acement , page 11 191
-CONNECT
Precaut i ons, page 1 1-175
Di sconnect i on,
page 11 175
Connect i on,
page 1 1-176
FUEL FILTER
Repl acement ,
page 11 182
FUEL FEED PI PE FUEL VAPOR PIPE
FUEI- TANK
Repl acement ,
page 1l 191
FUEL TUBE/OUICK.CONNECT
FITTINGS
Precaut i ons, page 11
' 175
Di sconnect i on, page 11 175
Connect i on, page 11 176
FUEL PUMP
Test i ng, page 11 183
Repl acement , page 11 183
FUEL GAUGE SENDI NG UNI T
Test i ng,
page 1l ' 185
FUEL FILL CAP
FUEL TANK PRESSURE
SENSOR
Troubl eshoot i ng, page 1 l -209
FUEL PULSATION DAMPER
EVAPORATIVE
EMTSSTON
I EVAPI
CONTROL
CANISTER
VENT
SHUT VALVE
Troubl eshoot i ng,
page 11' 213
EVAPORATIVE EMISSION
IEVAPI CONTROL CANISTER
Troubi eshoot i ng, page 1 1
-213
FUEL RAI L
FUEL
Fepl acement ,
page 1 1-179
FUEL PRESSURE
NEGULATOR
Test i ng,
page 11-181
Repl acement , Page
11 181
EVAPORATIVE EMISSION
{EVAP) EYPASS
SOLENOID VALVE
Troubl eshoot i ng, page 1 1' 213
VAPORATIVE EMISSION
{EVAP) TWO WAY VALVE
Test i ng, page 11 224
(cont ' d)
www.emanualpro.com
Gomponent
Locations
Index
lcont'd)
'99
- (X)
modols:
FUEL TANK
Repl acement ,
page 11- 191
FUEL FEED PIPE
FUEL FILTER
Repl acement ,
page 11 182
FUEL VAPOR PIPE
FUEL
FITTINGS
FUEL PUMP
Test i ng,
page
' 11
183
Repl acement ,
page 1 1_183
FUEL GAUGE SENDING UNIT
Test i ng, page 11-185
FUEL FI LL CAP
EVAPORATIVE EMISSION
IEVAP) CONTROL
Troubl eshoot i ng, page 1 1-213
FUEL PULSATION DAMPER
FUEL RAIL
FUEL
Repl acement ,
page 1 1-179
EVAPORATIVE
EMtSStON
I EVAP)
CONTROL
CANISTER
VENT
SHUT VALVE
Troubl eshooti ng,
page 11- 213
FUEL TANK PRESSURE
SENSOR
Troubl eshoot i ng,
page 1' l ' 208
EVAPORATIVE EMISSION
{EVAP) TWO WAY VALVE
Test i ng, page 11-224
FUEL PRESSURE
REGULATOR
Test i ng, page 11-181
Repl acement , page 11 181
,CONNECT
PrecaLrt i ons, page 1 1-175
Di sconnect i on,
page 1 1-175
Connect i on,
page 176
EVAPORATIVE EMISSION
{EVAPI BYPASS
SOLENOID VALVE
Troubl eshoot i ng,
page 11 213
www.emanualpro.com
Vacuum Gonnecti ons
'97
model:
To EVAPORATIVE EMISSION IEVAPI
TWO WAY VALVE
EVAPOBAIIVE
EMt SSt ON
IEVAPI
CONTROL
CANISTER
EVAPORATIVE
EMtSStON
tvaP)
PURGE CONTROL
SOLENOID VALVE
FRONT OF
VEHICLE
PBESSURE
REGULATOR
{cont' d)
1 1 - 9
www.emanualpro.com
System Description
Vacuum Connecti ons
(cont' dl
'97
model:
ENGI NE
COOLANT
IT
r | l l
O
PRIMARY HEATED oxYGEN sENsoR {PRIMARY Ho2s,
SENSOR lt
O
SECONDARY HEATED oxYGEN sENsoR {SECoNDARY
HO2S. SENSOR 2l
)
MANIFOLD ABSOLUTE PRESSURE (MAPI
SENSOR
@ ENGINE cooLANT TEMPERATURE
{EcT} sENsoR
O
INTAKE AIR TEMPERATURE (IAI}
sENsoR
@ CRANKSHAFT SPEED FLUCTUATION ICKFI SENSOR
O
| DLE ArR coNTRoL {tAc)vALvE
@
FAST IDLE THERMo vALvE
O
THRoTTLE EoDY ITB)
@
FUEL INJEcTon
O FUEL PULSATIoN oAMPER
@ FUEL FILTEn
(}
FUEL PRESSURE REGULATOR
FUEL PUMP
FUEL TANK
FUEL TANK EVAPORATIVE EMISSION (EVAPIVALVE
AIR CLEANER
RESONATOR
POSITIVE CRANKCASE VENTILATION {PCVI VALVE
EVAPORATIVE EMISSION {EVAP} PURGE CONTROL
SOI.'ENOID VALVE
EVAPORATIVE EMISSION {EVAP) CONTROL CANISTER
EVAPORATIVE EMISSION {EVAPI TWO WAY VALVE
THREE WAY CATALYTIC CONVERTER
(TWC)
@
(D
(D
o
@
(}
@
@
@
@
1 1 - 1 0
www.emanualpro.com
'98
model:
To EVAP THREE
WAY VALVE
To EVAP
TWO WAY VALVE
EVAP
PURGE
CONTROL
SOLENOID
VALVE
FRONT OF
VEHICLE
(cont' d)
11- 11
www.emanualpro.com
System Description
I
I
I
Vacuum Connections
(cont'dl
'98
model:
C
PRIMARY HEATEO OXYGEN SENSOR
(PRIMARY HO2S,
SENSOR 1)
(,
SECONDARY
HEATEO OXYGEN SENSOR ISECONDARY
HO2S, SENSOR 2)
(!)\\\\ss\SNBSS\\\ETRESS\RE\\NQ\SE\SSR
G)
ENGINE COOLANT TEMPERATUBE
(ECT)
SENSOR
O
INTAKE AIR TEMPERATURE {IAT} SENSOR
@
CRANKSHAFT SPEED FLUCTUATION
(CKFI SENSOR
O IDLE AIR CONTROL
(IAC)
VALVE
@
FAST IDLE THERMO VALVE
(A/T)
O
THROTTLE BODY
(TBI
(0)
FUEL INJECTOR
.1' FUEL PULSATION DAMPER
.14 FUEL FILTER
(i
FUEL PRESSURE REGULATOR
14 FUEL PUMP
(D
FUEL TANK
@
FUEL TANK EVAPORATIVE EMISSION {EVAPI VALVE
C]
AIR CLEANER
(O
RESONATOR
1iC POSITIVE CRANKCASE VENTILATION
(PCV) VALVE
6 \$REE$IN\
gN\
NL$\C CON\ER\ER
(TNC\
ti\
q\
rpos,xr\tE
qN\rssros
\E\ aP\ cqN\RoLcaNtsrR
@
EVAPORATIVE EMISSION IEVAP)
PURGE CONTROL
SOLENOID VALVE
q3
EVAPORATIVE EMISSTON IEVAP}
CONTROL CANISTER
VENT SHUT VALVE
@
EVAPORATIVE EMISSION
(EVAP) TWO WAY VALVE
i
EVAPORATIVE EMISSION {EVAP)
BYPASS SOLENOID
VALVE
9
FUEL TANK PRESSURE SENSOR
Oi EVAPORATIVE EMISSION {EVAP)
THREE WAY VALVE
Qd PURGE JOI NT
G/T only)
f
-i *' ";-t
\ COOLANT
J
t
U
11- 12
www.emanualpro.com
'99
-
00 models:
To EVAP THREE
WAY VALVE
To EVAP
TWO WAY VALVE
EVAP
PURGE
CONTROL
SOLENOID
VALVE
FUEL
PRESSURE
REGULATOR
FRONT OF
VEHICLE
(cont' d)
1 1 - 1 3
www.emanualpro.com
System Description
Vacuum Connections
(cont'dl
'99
- q)
models:
ENGINE
COOLANT
t
o
o
o
@
o
@
@
@
@
@
@
@
@
@
(t
PRIMARY HEATED OXYGEN SENSOR IPRIMARY HO2S,
SENSOR 1l
SECONDARY HEATED OXYGEN SENSOR {SECONDARY
HO2S. SENSOR 2l
MANIFOLD ABSOLUTE PRESSURE
(MAPI
SENSOR
ENGINE COOLANT TEMPERATURE IECN SENSOR
INTAKE AIR TEMPERATURE IIATI SENSOR
CRANKSHAFT SPEED FLUCTUATION {CKF) SENSOR
KNOCK SENSOR
(KS}
IDLE AIR CONTROL IIACI VALVE
FAST IDLE THERMO VALVE {A/T}
THROTTLE BODY
(TB}
FUEL INJECTOR
FUEL PULSATION DAMPER
FUEL FILTER
FUEL PRESSURE REGULATOR
FUEL PUMP
FUEL TANK
FUEL TANK EVAPORATIVE EMISSION
(EVAPI
VALVE
AIR CLEANER
RESONATOR
POSITIVE CRANKCASE VENTILATION
(PCV}
VALVE
THREE WAY CATALYTIC CONVERTER ITWCI
EVAPORATIVE EMISSION {EVAPI CONTROL CANISTER
EVAPORATIVE EMISSION IEVAPI PURGE CONTROL
SOLENOID VALVE
EVAPORATIVE EMISSION {EVAPI CONTROL CANISTEF
VENT SHUT VALVE
EVAPORATIVE EMISSION IEVAPI TWO WAY VALVE
EVAPONANVE EMISSION {EVAPI AYPASS SOLENOID
VALVE
FUEL TANK PRESSURE SENSOB
EVAPORATIVE EMISSION IEVAPI THREE WAY VALVE
PURGE JOINT
@
@
@
@
@
@
@
@
@
@
@
@
11- 14
www.emanualpro.com
El ectri cal Connecti ons
-' 97
Model
f_
--- --- -t
_
l -1r -l l a^^^ ti rr
n l
(.J
no 3wrcx (
-]lrL
t
-'o.:\ - ' t l
Dl"ii
\
H T
:
v
l- I
tl
I - 6,
I
4
'
^li lGPl f----;;l
t l
t l
T
FUEL ll'tlEcToes
oa 9I3
aEt30F
TDC
3ErcON
ctP
SErAOi
CKF
3EN30F
TO EIIF-
* f
ct ovEu
A' lGI
aztL@,
Xo. 2
|NJ2 3
ca tDcP [{J3 A2
cra Tltcl
||tL
Gt ct(iP?
er2 cxP{
cfl ct(Ftr
1
Dta ELtr
c|| v!]3 TL T'
t
^cc ^r? to l/C CLUTCfl BELAY
to i^Ol^toh F tl REI Y,
@III'C|{AEi FA'I iEL Y
rtT
c. K.uirE
uNx
coi||lEctoh
SERVICE
Cl|ECK
@ NEqroi
I
^ca 6
d
__-l
b
qr
3c3
ila
ALTF CI'
r t : usA
EII ATPI{P
E
6u
I
)r^ l
t * f
r l
E
t'-
bI. ATPfi
B2a AtPtX
E' TPDI
Att lE
FOgn
3wltc
gi7
alP:l
I
I
ON
Ei. ATPI D{ND tir
FUSES :
(D
BACK uP
(RADro) (7.sr0.
@ "o^n ttot
(tuo)'
(D
BATfERY
(IOOA) *
o rcl
(4oA)*
GAIXIE
ASSEIBLY
(DFt
E/ flsA).
@ No.13 FUEL PU P
('l5A)
O
No. 2s METER
(7.5A)
(D
NO.
'I5
ALTERNATOR SP SENSOB
(7.5A) *
O No. 3i STABTER SIGNAL
(7.5A)
*:
In lhc und?r.lrood tu$/rclay bor
(cont ' d)
1 1 - 1 5
www.emanualpro.com
System Description
El ectri cal Connecti ons
-' 97
Model
(cont' dl
EVAP PUFGE CONIROI SOLENOIO VALVE
SPEOSENSOR
COUNERSHAFI
SPEEDSENSOF
CONTNOL SOIENOID VALVE A
PFESSUhE COI{TFOL
sotENotD vALvE
Tor lEiLocK coNtFol UNlt
1 1 - 1 6
IERi'INAL LOCATIONS
www.emanualpro.com
YEL/BLU
FED/BI(
HO2S
(SErOR r)
l-
(cont' d)
11- 17
www.emanualpro.com
System Description
El ectri cal Connecti ons
-' 97
Model
(cont' dl
No.2 FUEL IIUECIOF
cl09
1 1 - 1 8
www.emanualpro.com
BLK,TEL
JflI
BLU rdHT
- Frrt\rFEl
, | |
L-fJl
alx
-----L+
|
l-
CONDENSERFAN FELAY
*1 : USA
(cont' d)
1 1 - 1 9
www.emanualpro.com
System Description
El ectri cal Connecti ons
-' 97
Model
(cont' dl
c
-F
BLKj
BLxj
E
-F
ARN
BLK
h-
rF
BRN:
eLKr
8Rt,l,' BLxj
ARN,' BI.K.
c113
E
11-20
www.emanualpro.com
cat.,auxt
LT GAN
BLVBLU
RED
GRN
BLU,
an12
*".r".o'- )
Inor.".o"*
(cont' d)
11-21
GAUGE ASSEI'BLY
i
I
enr2-{
I
I
A,ry GEAB POSINON SWITCH
CONTROL UNIT
www.emanualpro.com
System Description
Electrical Gonnections
-'97
Model
lcont'd)
|l
/8LU
l I
U
t,l
T
WHT/LU
wltT/BLr(
(
WHT/BLK
wltT/GRt{
, J
I
. l
c352
CRN/FEO
BLU/ORN
GRI{/FO
ALU/'IVHT
T"*,,*.
UNOER]IOOD
fUSE,/FEIAY 8OX
IVTII/BLU
-
".*
_f
I
Btur,tvrr
I
BLU/W8T
-.'|
,ato"n
L
;rfi
""r
_g!:f
BLK/FED
'I_
FUSE/BELAY BOX
*2:
USA
rcl ({0A}
HOiX sIOf 05A)
r'tc3r srAaIES
SG|I|^L 05 )
11-22
www.emanualpro.com
(From p!9.1r-221
ca32
**r2",-*J
YEVGRN
-1
YEvErK
--
I
BLU?'I'HT
___-I
GRN,/YEL
--
I
YEVGnN
--
"*
--1
PGII.FI
UAIN RELAY
C56-2
//--\
-
trru^n
-- -]
(
,
)
_ B L K
-
i \ , /
I
-
\_-,/
dL
FUEL PUMP
11-23
www.emanualpro.com
System Description
El ectri cal Connecti ons
-' 98 -
00 Model s
POSll|O|l
S TClt
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(7.5A)
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lo ^/c clwclr hEL Y
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coittct{3F F l{ FCLAY
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'98
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TANK
PRESSUFE
SENSOF
TESTTACHOiIETER
coNr{EctoB
lo CRUISE CoNTEOLUNIT+r
EVAPPURGE CONTROL SOIENOID VAIVE
sp: r osENsoF*1
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H02S
(SENSOF 1)
rcrocrsgrson*'
(cont' d)
11-25
EVAP CONIFOL CANISTEF VETIT SHUTVALVE
TERI/lINAL LOCATIONS
www.emanualpro.com
System Description
El ectri cal Connecti ons
-
' 98
-
00 Model s
(cont' dl
!to2srfic
SECOiD hY
HO2a
(aE
toh 2)
11-26
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ct sEt{goh
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I
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www.emanualpro.com
Ii l
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sExsoF
I
t r
1 t - : r E I
l l Y
s. nsoR
I
l - |
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No. 3 FUE! IiUECIOn
(cont' d)
11-27
r - l
l _ , I
www.emanualpro.com
System Description
El ectri cal Connecti ons
-' 98 -
00 Model s
l cont,dl
+
l M
-
+ sL(
yEL JJ{FiE-l
l-- sLU wnf
- li,"+l
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|
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r l r A/ T
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*4:
'99
-
00 models
F
>r t
- 4 .
"
l---r
' a
11-28
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el rcvrl J-l
".o"*'-{l
-- 3
|
CONTROI
soLENOroVALV
ca6l
tT GFtt/wxt ,o""r"*Jffil
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I
sotEtrolo vALvE
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GR / 8LX' -11-
|
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PRESSUBE
SENSOF
To CRt ISE
coNtFol u|{lt
*1 : A/T
(cont' d)
11-29
www.emanualpro.com
System Description
Electrical Conneetions
-'98 -
00 Models
(cont'dl
fJ
- l
F
l
BRN/
aLKl
c121
r=r
BRN/
eLxr
F]
T
l
BLKt
f : t
T
9RN/
atx'
fJ
!l
BRN/
gLxl
fJ
T
BRN/
aLKl
IIAINSIIAFI SPEED SENSOF
c119
clll
--l
| 3 |
A/t cLulctl
PFESSURE COIiTTHOL
SOIENOID VALVE
t
STNFT @NTFOL
SOICNOIDVALVE
c115
1 1 - 3 0
www.emanualpro.com
n"t,l onrJ
1 " r . ]
g
L : ]
- * " {
I
-
GRN/BLK
I
-
LTGRN1
-
]
-BIK/BLU -.,]
r.I=
-*i -
]
-::'",1
r-YEL.-
l--
cRN
--_l
*I : A/T
+3:
' 98
model
(cont' d)
REO
Bt uT
1 1- 31
www.emanualpro.com
System Description
El ectri cal Connecti ons
-' 98 -
00 Model s
(cont,dl
OVE&ORVE OFF
[{DtcatoR LlfP
C UqE AASEr|ELY
A/I GEAA PO3MON SWITCH
*tnzaeo'
)
,r*ear_oo,
11- 32
@lillFo|. ur{tT
* 1:
Nf
*4:
'99
-
00 modets
www.emanualpro.com
F c$3 c.r'
L*_"."{h
cl/I crxl
-*^;1n-;"*,
I *,,,,".u:][
u l
-
wF /BLx
__1
c35lI
,-wnrzEr-x{
E|.UflTT'
YEVORN
8uc{rHr
--l
-!"'*
clfz
u|,|oEF-ftooD
FUAE/NEIAY BOI
=- B ITEFY
r-t
Lh-v
I
BMIG STITCH
cal7
9q/wHr
Et&{lll
BLX/WFI
YEL
{cont' d)
1 1 - 3 3
www.emanualpro.com
System Description
El ectri cal Connecti ons
-' 98 -
00 Model s
(cont' dl
PGU.FI
MAII{ BEIAY
cssr
cs6-2
,z-_\
- YEL / GBN-
- f
p
\
- BLx- - l \ . /
|
-
"---.,
_L
FUEL PUI{P
11- 34
www.emanualpro.com
System Description
System Gonnectors
[Engine
Compartmentl
-'97
Model
MAIN WIRE
HARNESS
UNOER.HOOD
FUSE/RELAY
80x
1 1- 36
..'.'.'
ct21
cl 11
cl 16
www.emanualpro.com
cl . t 7
r-r=-
l r
2 l
c 6
eFr
1 1
2 l
c l 15
l r , r l A
w
Ft
RE!'wr
--l
ft'-cRN/sLK,
lll
c l 1 1
t l 2 l
I 3 l . l
f,_rr'Hr-lwHr'-------
T!-Isrf,-*--/r*".er* l
-;--
BLi'uF
I]]l
c129
.__1-..']..-r
1 1
2 3 l
ffl.E*--------
l O st x, YEL I
TtlBru/"Nr----
c354.'
'-{-l-r
fd,sLK
rHr-----l
t-rlBL(
I
1 9 cFNnEo I
c35l
l4;i;1_s;:a
riiiltTf,n
*2:
USA
Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them {for exampl e, YEUBLKl
and YEUBLK, are not the same).
O: Rel ated to Fuel and Emi ssi ons System.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne): Vi ew from wi re si de
NOTE: o
(cont' d)
11-37
www.emanualpro.com
System Description
System Gonnectors
[Engine
Compartment]
-'97
Model
{cont'd)
MAIN WIRE
HARNESS
ENGINE
WIBE
HARNESS
www.emanualpro.com
cr08
1 1
2 l
tildK"ri t
ltlB$jrma -
cr07
rfjl
l l . 2 l
titna.
tl
t F l
t 0
r--=
l r
2 l
cltxt
r--q
l l
2 l
l';FELM
----l
lEl;. I
{ ' )
\:)
t.;ERN,f
-_-]l
Ttl;Eor-L -
c105
tusAl
-+
l l
2 l
l 3 l . l
A
u)
li e@;----
lEl*",]! l
cr03
r__F
1 1
2 l
I T'*---
film----t
c105
r#-r
l r , 2
3 l
[--1;N,/ruo; ]
t,Id&Yr
l]]l
|.-T;s,,. -
o
o I
NOTE: . Di f f er ent wi r es wi t h t he same col or have been gi ven a number suf f i x t o di st i ngui sh t hem
( f or
exampl e,
YEUBLK1 and YEUBLK' are not the same).
. O: Rel ated to Fuel and Emi ssi ons Svstem.
.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s {si ngl e outl i ne): Vi ew from wi re si de
1 1- 39
www.emanualpro.com
System Description
System Gonnectors
lDash
and Floor]
-'97
Model
MAIN WIRE
HARNESS
DASHBOARD WIRE
HANNESS
REAR HEATED OXYGEN
SENSOR SUA HARNESS
WIRE HARNESS
www.emanualpro.com
cat2
titT
T)l
filsl].Mr
t]l
FT-I
l5l'ri":'*l]]l
r$r
l t 4. l
' l
riTLiGN
I111
rtTa*
--]]l
lo-6dN'!Hnl
[tltu/cs
.]l
lwittost crui.! comrol)
l r
2 l
w
lolZmlvv{-l
l@is',t'A'
-l
f.T-
t-l
t.-f f
c426
rrFr-r
|
1 1 2 3 l . l
t';l;Kvi-l
fol**"---
NOTE:
o
a
Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e.
YEUBLKl and YEUBLK' are not the same).
O: Rel ated to Fuel and Emi ssi ons Svstem.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne): Vi ew from wi re si de
(cont' d)
1 3
I 9 t 0 1' l , t \ . / r\ . 2 18
t , /
20
1 2 5 6
/ 9 1ol,/
/
13 1a115 16
./ t a
I
11-41
www.emanualpro.com
System Description
System Gonnectors
[Dash
and Floor]
-'97
Model
(cont'dl
DASHEOARD WIRE
HARNESS
MAIN WIRE
HARNESS
11-42
www.emanualpro.com
o
I a 5 9 t o
1 t 12 13 l 6
'11
l 8 l 9
-t
i
(}
NOTE: o
a
a
Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e,
YEUBLKI and YEUBLK' are not the same).
O: Rel ated to Fuel and Emi ssi ons Svstem.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne); Vi ew from wi re si de
(cont'd)
11-43
www.emanualpro.com
S)stern Dessr\ptron
ENGINE
WIRE
HARNESS
c1z2
(PCM.AI
System Connectors lDash
and Floor]
-'97
Model {cont'd)
MAIN WIRE
HARNESS
//l
tao,
{PCM.D}
11-44
www.emanualpro.com
1 2 \ 3 1 5 6
16
1 8
iJq
11 12 13 r a 1 5
' 11
l 8
cr25 tPCM-Cl
ct23 {PCM-Al
c124 (PCM,B)
cr26 tPicM-ol
Di f f er ent wi r es wi t h t he same col or have been
gi ven a number suf f i x t o di st i ngui sh t hem
( f or
exampi e,
YEUBLKT and YEUBLK2 are not the same).
O: Rel ated to Fuel and Emi ssi ons Svstem.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne): Vi ew from wi re si de
NOTE: o
o
o
,,
.t
o
a n
1 2 3 a 5 X 6 7 A 9 1 0
r r l 1 2
13 l a t 5 t 6 1 1 t 8 19 20
!t
o
lit
D
o
o
n
n
ii)
o
a
1 2 5 6 8 9 1 0
1 1 1 1 2 t 3 !i l
' 16
I t
't8
t9 20
11- 45 www.emanualpro.com
System Description
System Connectors
lEngine
Gompartment]
-'98
Model
MAIN WIRE
HARNESS
UNDER.HOOD
FUSE/RELAY
BOX
ENGINE
w|RE
HARNESS
*2:
USA
11-46
www.emanualpro.com
fr fr
ct 10
fr
I6rc;iEiF--l
IltIYEr,
- ll
ct t 5
fr
ffi
\,v
tdTiaotfi-----l
IETcRll,aLX'
---l
t ' l t l
[ . 1 . 1
lSlwHr
-------
l o GnNAUC I
TdTBLx/YEL -
fdBtx
vNP
-----1
c t 19
fr
l6lcnN'
-'l
l o
eLU'
,
L4.lrl
ldTcRN/BrF-----
lO iEo/BL( |
tsTYE'Jrr
-1
G361
fr
lSTLr GRr/wHr---
F ]ilwH-----
f ' Tt f r l
tdFLxr-----l
I O BL|^EL I
l6l6tu/rJHr' -
c354*'
r'ft]
16T816rr-----l
l ol
"."
I
l O
GF&aEp
I
NOTE; . Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLK1
and YEUBLK, are not the s8me).
. O: Rel ated to Fuel and Emi ssi ons System.
.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne); Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i nel : Vi ew from wi re si de
(cont' dl
SLKI
Lr sLU T
cRY T
11- 47
www.emanualpro.com
System Description
System Connectors lEngine
Compartmentl
-'98
Model
(cont'd)
MAIN WIRE
ENGINE
WIRE
HARNESS
www.emanualpro.com
c t5
{usa)
t ' l t l
I ' l . l
Ttlrsrtsu .
ftT,,tHr/FEpi l
r'ftr
IET$'rmc' I
ftlarxrEl--
--
l
ftlwn/srt -
NOTE: o
a
Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e,
YEUBLKl and YEUBLK, are not the same).
o: Rel ated to Fuel and Emi ssi ons Svstem,
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ow from termi nal si de
-
Connector wi th femal e termi nal s {si ngl e outl i ne): Vi ew from wi re si de
(cont' d)
1 1- 49
www.emanualpro.com
System Description
System Gonnectors
lEngine
Compartment]
-'99 -
00 Models
MAIN WIRE
HAENESS
UNDER.HOOO
FUSE/RELAY
BOX
ENGINE
WIRE
HARNESS
www.emanualpro.com
c118
ffi
cl17
ffi
c116
ft
15
ffi
c114
A
,g
rdTnEDlllHr------
l6lcRN/Buc -
c121
ffi
c l 11
ffir
l i l r l
t-lwHn-----t
I ' I GRNt sLI ' I
f"l".*,.
1l
trhlx,l/vH?
----
Ef f i - f f i f f i f f i
c135 Gt51 Gt52
Di fferent wi res wi th the same col or have been
gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLK1
and YEUBLK, are not the same).
O: Rel atsd to Fuel and Emi ssi ons System,
-
Connector wi th mal e termi nal s {doubl e outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne): Vi ew from wi re si de
(cont' d)
c129
f'ftf
t6-tBrK
-----_l
l l Br xr Er I
lShLU^,/Nrr
l]l
ElzTt)
IiTYvnED-----l
TdTcFN/rHr, -
FfREp/cFr l
Gt54.'
-El-
l 1 l 2
3 l
ldTBLxr'rtvii------
TitlBL. l
I o cFN/Frp
l
*2:
USA
NOTE: o
a
a
'1)
1 1 - 5 1
www.emanualpro.com
System Description
System Gonnectors [Engine
Compartment]
-'99 -
00 Models
{cont'dl
MAIN WIRE
HARNESS
11-52 www.emanualpro.com
c108
ffi
FfBLK//EL---l
l
-IREor/Ar
-l
c107
ffi
|iTYEULX' I
-rfnri-r
--
c105
{Canadal
r'fifl
fi'Iw|r/nE
D.
-'-l
T'TBt(ryEL
-_-l
t lnrtsrr
t]l
c105
(usA)
F I r t
l s l r l
filBLKry.L I
fu-,wHrcn[
ll]
ftl-wNr/sr't
l]l
TaTtNanEc!
---l
c133
A
v
riaF.\rjrr. I
ttInEoYEr,
- l]l
c104
l 1
2 l
f -T;iE;;n
----
I
' WNT]FEDI
L
c103
I r
z l
lrlBR,r
tll
c134
c303
fil
FEp/Bru
----l
NOTE:
. Di f f er ent wi r es wi t h t he same col or have been gi ven a number suf f i x t o di st i ngui sh t hem
( f or
exampl e.
YEUBLK' and YEUBLK' are not the same).
. O: Rel ated to Fuel and Emi ssi ons Svstem.
.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s {si ngl e
outl i ne): Vi ew from wi re si de
c137
10
ffi
c109
ffi
l-!. IYEUBLK.
---l
1" 1" " '
-
1 1- 53
www.emanualpro.com
System Description
\
System Connectors
[Dash
and Floorl
-'98 -
00 Models
DASHBOARD WIRE
HART{ESS
REAR HEATED OXYGEN
SENSOR SUBHAR ESS
Ita|l{ wtRE
HARIIIESS
LEFT SIDE
WIRE HAR ESS
11- 54
www.emanualpro.com
c4r2
l l , Vt ' l l
6fswYv-ii----
E-r-
--
F lwir,L(
-l
lwlrhot|t crub. 6.trroll
-ftr
w
rdT6iffi---l
ET-----
l.T--
---l
a
a
I ' X . l
l ' l . l
l-i'f iifiN
-----l
ftTGRY
----
fdlGiffil
fdlw{rcftr 1
r'TfifiI
TdliL,,rw{r-----
l @ cRM / Hr ' I
lO
wt{r D' I
TofuLr/,txl-
---l
NOTE:
o Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e,
YEVBLK1 and YEUBLK' are not the same).
O: Rel ated to Fuel and Emi ssi ons System.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne): Vi ew from wi re si de
(cont'd)
1 1- 55
n
o
!E!E!t
LT GRN
3 a
I 9 r ol r r / l / l t
l /
r . l , / za
2 a a
/ t e
tol./
/ l l El 1. l t 6
r . l
/
t l
tHrBLt l
www.emanualpro.com
System Description
System Connectors
lDash
and Floorl
-'98 -
00 Models
(cont'd]
c510
DASHBOARD WIRE
HARNESS
MAI N WI EE
HARNESS
'4: '99
-
00 models
1 1- 56
www.emanualpro.com
rE0
c508
*4: ' 99 -00
model s
NOTE: . Di f f erent wi res wi t h t he same col or have been
gi ven a number suf f i x t o di st i ngui sh t hem
(f or
exampl e,
YEUBLKT and YEUBLK' are not the samol .
O: Rel ated to Fuel and Emi ssi ons System
-
Connector wi th mal e termi nal s {doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s {si ngl e outl i ne); Vi ew from wi re si de
(cont' d)
c546
a.a
\:9
rdTYEcii------
ETGRN/Brxi
lll
fSliaGFNr-
- lll
c580
r,'ffijt
v l 5 l 6 l
1-t""'
-----l
l o l L r c RN, I
I O IsLKM/Hr
l r l I
I t lYErrLU I
T-ilcirrlLrr
l]l
c552
trLtzl
|.-l.T'|
ffi
rcrBr.
l--l
I a l YEUcnN I
ftTYEL' BrK
-
t
c760
mJv
l.f.T'-]
F6EFN-----
t 2 l I
ftTYEUsr.
''l
Tst YEr
-
t
c76t*.
, - + , ,
l r l 2 l 3 l 1 l
ftTcll-l
I O I BL K I
ftTwHr/BL(---'1
f.ft1. -
a
2 3 a 6 E 9 10
1 l 12 13 15 16 1 118 19 20
|l!
.,
YEL
11-57
www.emanualpro.com
System Description
ENGINE
WIRE
HARNESS
System Conneetors
lDash
and Floorl
-'98 -
00 Models
(cont'dl
DASHBOARD
WIRE HARNESS
MAIN WIB
HARNESS
c,47
(ECM/PCM.A}
c121
(ECM/PCM-8)
n
lno,
(PCM.D}
www.emanualpro.com
t 2 3 a 1 I
12 t 3l t a
't5
t 0 1 1 t 8 t 9
c't22
c126
(PCM-O)*,
ot33
c124 {ECM/ PCM. B}
C,r47
(ECM/PCM-Al
c121*3
c127'.
cl25 tECM/PCM-C)
c132
o
*1:4,/T ' 1
al l
*3:
'98
model
' 4:' 99 -
00 model s
NOTE:
. Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them {for exampl e,
YEUBLK1 and YEUBLK' are not the same).
. O: Rel ated to Fuel and Emi ssi ons Svstem.
.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne): Vi ew from wi re si de
tt
3 6 , 10
1 t 12 l 3 l 6 17 l a t 9
1 1 - 5 9
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Troubleshooting
Troubleshooting Procedures
How To Begi n Troubl eshooti ng
When the Mal functi on i ndi cator Lamp
(Ml Ll
has been reported on, or there i s a dri veabi l i ty probl em,
use the appropri -
ate
procedure
bel ow to di agnose and repai r the probl em.
A. When the MIL has come on:
1. Connect the Honda PGM Tester or an OBD Il scan tool to the 16P Data Li nk Connector
(DLC)
l ocated behi nd the
ri ght si de of the center consol e.
Turn the i gni ti on swi tch ON
(l l ).
Check the DTC and note i t. Al so check and note
the freeze frame data.
Refer to the Di agnosti c Troubl e Code Chart and
begi n troubl eshooti ng.
NOTE:
. SeetheOBDl l scan tool or Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons.
. The scan tool or tester can read the Di agnosti c Troubl e Codes
(DTC),
freeze frame data, current data, and other
Engi ne Control Modul e
(ECM}/Powertrai n
Control Modul e
(PCM)
data.
. Freeze frame data i ndi cates the engi ne condi ti ons when the fi rst mal functi on, mi sfi re or fuel tri m mal functi on was
detected. l t can be useful i nformati on when troubl eshooti no.
B. When the MIL has not come on, but there i s a dri veabi l i ty probl em, refer to the Symptom Chart on page 11-64.
C. DTCs wi l l be i ndi cated by the bl i nki ng of the Mal functi on Indi cator Lamp {Ml L) wi th the SCS servi ce connector con-
nected.
Connect the SCS servi ce connector to Servi ce Check Connector as shown. {The 2P Servi ce Check Connecror rs
l ocated behi nd the ri ght si de of the center consol e.) Turn the i gni ti on swi tch ON 0l ).
DATA LINK CONNECTOR I16PI
1 1- 60
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l l . Engi ne Controt Modul e
(EcM)/Powertrai n Control Modul e {PCM)
Reset Procedure
Ei ther of the fol l owi ng acti ons wi l l reset the ECM/PCM.
. use the oBD l l scan tool or Honda PGM Tester to cl ear the ECM' s/PCM' s memory.
(see
the oBD l l scan tool or
Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons )
. Turn the i gni ti on swi tch oFF. Remove the BACK UP
(RADIO) (7.5
A) fuse from the under-hood fuse/rel ay box for 10
seconos.
l l l . Fi nal Procedure {thi s
procedure must be done after any troubl eshooti ng)
1. Remove the SCS Servi ce Connector i f i t i s connected. l f the SCS servi ce connector i s connected. and there are no
DTCS stored i n the ECM/PCM, the MIL wi l l stay on when the i gni ti on swi tch i s turnsd oN
(l l ).
2. Do the ECM/PCM Reset Procedure.
3. Turn the i gni ti on swi tch OFF
4. Di sconnect the OBD l l scan tool orHonda PGM Tester from the Data Li nk Connector
(
16P)'
(cont' d)
1 1- 61
BACK UP {RADIOI I7,5
AI FUSE
FUSE/RELAY BOX
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Troubleshooting
Troubleshooting Procedures (cont'd)
l f the i nspecti on for a parti cul ar
code requi res vol tage or resi stance checks at the EcM/pcM connectors, remove the ri ght
ki ck panel .
Unbol t the EcM/PcM. and connect the backprobe sets and a di gi tal mul ti meter as descri bed bel ow, check the
system accordi ng to the procedure
descri bed for the appropri ate code(s) l i sted on the fol l owi ng pages.
How to Us6 tho Backprobe S6ts
Backp.obo Adapto.
BACKPROBE SET
connect the backprobe adapters to the stacki ng patch
cords. and connect the cords to a mul ti meter. Usi ng the wi re i nsul a-
ti on as a
gui de
for the contoured ti p of the backprobe adapter, gentl y
sl i de the ti p i nto the connector from the wi re si de
unti l i t comes i n contact wi th the termi nal end of the wi re.
DIGITAI. MULTIMETER
(Commarci.lly
rvrilabl.l or
KS- AHM- 32- @3
@@)@)c,
11- 62
o'SAZ
- (xtlqDA
lTwo requir.dl
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CAUTION:
. Puncturing the insulation on a wile can cause
poor ot intelmittent electrical conneciions.
. Bring the tester probe into contact with th terminal from the terminal side of wire htrness Gonnectors in the engine
comoartment. Fol temale connectols,
iust
touch lightly whh the tester
probe and do not insgrt lhe probe.
(cont' d)
1 1- 63
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Troubleshooting
Troubleshooting
Procedures
(cont'dl
Symptom Chart
Li sted bel ow are symptoms and probabl e
causes for probl ems
that DO NOT cause the Mal functi on Indi cator Lamp
(Ml L)
to
come on. l f the MIL was reported on, go
to page 11-60.
Troubl eshoot each probabl e
cause i n the order l i sted
(from
l eft to ri ght) unti l the symptom i s el i mi nated,
The probabl e
cause and troubl eshooti ng page reference can be found bel ow.
Other Probabl e Causes for an engi ne that wi l l not start:
-
Compressi on
-
Intake ai r l eakage
-
Engi ne l ocked up
-
Ti mi ng bel t
-
Starti ng system
-
Overheati ng
-
Battery
SYMPTOM
PROBABLE CAUSE
Engi ne wi l l not sta rt
4, 2, 3, 5, 20,
' t 5,
1
Hard starti ng
2, 4, 12,17, 14,
' t9
Col d fast i dl e too l ow
7, a, 9, 6, 17
Col d fast i dl e too hi gh
7 , 8 , 9 , 1 1 , 1 0
l dl e speed fl uctuates
9, 7, 8,
' t 1,
10
Mi sfi re or rough runni ng
Troubleshoot for misfire on pages
'11-126,
1|21
LOl/\/ power
2, 10,11, 13,
' 17,
18,20
Engi ne st al l s
2, 4, 12, 1, 20, 9, 5,
' t 6
Probable Cause List
(For
the DTC Ch8rt, see page
ll-75.)
Probable Cause Page
System
Engine controt ruoaute (ecvtffi
'I
11-42
I 1- 178 Fuel oressure
PGM-Fl mai n rel av
l gni ti on system
Crankshatt Posi ti on/Top Dead Center/Cyl i nder
posi ti on
sensor ci rcui t
Intake Ai r Temperature (l AT)
sensor ctrcul r
l dl e Ai r Control (l AC)
Vatve
Fast i dl e thermo val ve
l dl e speed adj ustment
Throttle body
Throftl e cabl e
Mani fol d Absol ute P."""rr"ffi
Throftl e Posi ti on (TP)
sensor
Barometri c pressur" (gnno-
Ay' T gear posi ti on
si gnal
Brake swi tch si gnal
Ai r Cl eaner
Three Way Catalytic Converter
(TWC)
Evaporati ve emi ssi on (EVAP)
control
Contami nated fuel
1 1- 187
Secti on 4
5
' t1-' t31,146
6 I
't-95
7 11-152
8 1' l - 168
1 1- 169
1 0
11- 196
' 11
11- ' 194
1 2
'1 'l
-90
1 1- 103
1 4 11-137
1 5 Secti on 14
16 1 1- 166
1 7 r 1- 194
18 1 1, 199
' 19
11-203
20
11- 64
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ECM/PCM Data
By connecti ng the OBD l l scan tool or the Honda PGM Tester to the 16P data l i nk connector
(OLC), vari ous data can be
retri eved from the ECM/PCM. The i tems l i sted i n the tabl e bel ow conform to the SAE recommended
practi ce
The Honda PGM Tester al so reads data beyond that recommended by SAE.
understandi ng thi s data wi l l hel p to fi nd the causes of i ntermi ttent fai l ures or engi ne probl ems.
NOTE:
The
' ,operati ng
val ues" gi ven bel ow are approxi mate val ues and may be di fferent dependi ng on the envi ronment and
the i ndi vi dual vehi cl e.
Unl ess noted otherwi se.
"at
i dl e speed" means i dl i ng wi th the engi ne compl etel y warmed up, transmi ssi on i n posi ti on
Park or neutral and the A,./C and al l accessori es turned otf.
Data Desc.iption
Oprating Valuo Freeze Data
Di agnosti c
Troubl e Code
(DTC)
l f the ECM/PCM detects a probl em, i t wi l l store i t as a
code consi sti ng of one l etter and tour numbers
Dependi ng on the
probl em, an SAE-defi ned code
(Poxxx)
or a Honda-defi ned code
(P' l xxx)
wi l l be output to the
tester.
l f no probl em i s detected,
there i s no output.
YES
Engi ne Speed The ECN4/PCN4 computes engi ne speed from the si gnal s
sent from the Crankshaft Posi ti on sensor.
Thi s data i s used for determi ni ng the ti me and amount of
fuel i ni ecti on.
Nearl y the same as
tachometer i ndi cati on
At i dl e speed:
' 97
-
98 model s:
750 t 50 rpm
' 99
-
00 model s:
730 f 50 rpm
YES
Vehi cl e Speed The ECM/PCM converts
pul se si gnal s from the Vehi cl e
Speed Sensor
(VSSI
i nto speed data.
Nearl y the same as
speedometer i ndi cati on
YES
Mani fol d
Absol ute
Pressure
(MAP)
The absol ute
pressure caused i n the i ntake mani fol d by
engi ne l oad and speed.
Wi th engi n6 stopped:
Nearl y the same as atmo-
spheri c
pressure
At i dl e speed:
2a
-
41 kPa {210
-
310
mmHg, 8. 3
-
12. 2 i nHg)
YES
Engi ne Cool ant
Temperature
{ECT)
The ECT sensor converts cool ant temperature i nto vol t-
age and si gnal s the ECM/PCM. The sensor i s a thermi stor
whose i nternal resi stance changes wi th cool ant tempera-
ture. The ECM/PCM uses the vol tage si gnal s from the
ECT sensor to determi ne the amount of i nj ected fuel
Wi th col d engi ne:
Same as ambi ent temPer-
ature and IAT
Wi th engi ne warmed uP:
approx. 163
-
2' 12' F
(73 -
100"c)
YES
Heated Oxygen
Sensor
(HO25)
(Pri mary,
Sensor 1)
(Secondary
Sensor 2)
The Heated Oxygen Sensor detects the oxygen content i n
the exhaust gas and sends vol tage si gnal s to the
ECMi PCM. Based on these si gnal s, the ECM/PCM control s
the ai rl fuel rati o. When the oxygen content i s hi gh
(that i s.
when the rati o i s l eaner than the stoi chi ometri c rati o), the
vol tage si gnal i s l ower.
When the orygen content i s l ow
(that
i s, when the rati o
i s ri cher than the stoi chi ometri c rati o), the vol tage si gnal
i s hi gher .
0. 0
-
1. 25 V
At i dl e speed:
about 0.1
-
0.9
NO
(cont' d)
1 1- 65
www.emanualpro.com
Troubl eshooti ng
Troubleshooting
Procedures
(cont'd)
Data
Descliption
Operating Value Freezo Data
HO2S
Feedback
Loop Status
Loop status i s i ndi cated as
"open"
or
"cl osed".
Cl osed: Based on the HO2S output, the ECM/pCM deter-
mi nes the ai rl fuel rati o and control s the amount of
i nj ected fuel .
Open: i gnori ng HO2S output, the ECM/pCi M refers to si g,
nal s from the TP, MAP, and ECT sensors to control the
amount of i nj ected fuel .
At i dl e speed: cl osed
YES
Short Term
Fuel Tr i m
The ai rl fuel rati o correcti on coeffi ci ent for correcti ng the
amount of i nj ected fuel when HO2S feedback i s i n the
cl osed l oop status. When the si gnal from the HO2S i s
weak, short term fuel tri m gets hi gher, and the ECM/PCM
i ncreases the amount of i nj ected fuel . The ai rl fuel rati o
gradual l y gets ri cher, causi ng a hi gher HO2S output.
Consequentl y. the short term fuel tri m i s l owered. and
the ECM/PCM reduces the amount of i nj ected fuel .
Thi s cycl e keeps the ai rfuel rati o cl ose to the stoi chi o-
metri c rati o when i n cl osed l ooD status.
t:20y"
YES
Long Term
Fuel Tr i m
Long term fuel tri m i s computed from shon term fuel
tri m and i ndi cates changes occuri ng i n the fuel suppl y
system over a l ong peri od.
l f l ong term fuel tri m i s hi gher than 1,00. the amount of
i nj ected fuel must be i ncreased. l f i t i s l ower than L00.
the amount of i nj ected fuel must be reduced.
! 20%
I nt ake Ai r
Temperature
(IAT)
The IAT sensor converts i ntake ai r temperature i nto vol t-
age and si gnal s the ECrU/PCM. When i ntake ai r tempera-
ture i s l ow, the i nternal resi stance of the sensor
i ncreases, and the vol tage si gnal i s hi gher.
Wi th col d engi ne:
Same as ambi ent temper-
ature and ECT
YES
Throttl e
Posi ti on
Based on the accel erator pedal posi ti on,
the openi ng
angl e of the throttl e val ve i s i ndi cateo.
At i dl e speed:
approx. 10%
l gni t i on
Ti mi ng
l gni ti on ti mi ng i s the i gni ti on advance angl e set by the
ECM/PCM. The ECM/PCM matches i gni ti on ti mi ng to the
dri vi ng condi ti ons.
At i dl e speed: 16' 1 4.
BTDC wi th the SCS ser-
vtce connector connected.
NO
Cal cul ated
Load Val ue
(cLV)
CLV i s the engi ne l oad cal cul ated from the MAp data. At i dl e speed:
2A
-
410/o
At 2,500 rpm wi th no l oad:
13
-
260/o
YES
_
1 1_66
www.emanualpro.com
Powertrain Control Module Terminal Arrangement
-'97
Model
FCM CONNECTOR A
(32P)
NOTE: Standard battery voltage is 12 V.
Wi re si de of l emal e t ermi nal s
frminal
numlreJ
Wire
color
Telminal
nama
Description
Signal
YEL
l NJ 4
( No. 4 FUEL
I NJECTOR)
Drives No. 4 {uel injector. Wi t h engi ne runni ng: dut y cont rol l ed
2 BLU
l NJ3
( No. 3 FUEL
I NJECTOR)
Dri ves No. 3l uel i nj ect or.
RED
l NJ2 { No. 2 FUEL
I NJECTOR)
Dri ves No. 2 t uel i nj ect or.
BRN
l NJl
( No.
l FUEL
I NJECTOR)
Dri ves No. 1 f uel i nj ect or.
5 BLK WHT
SO2SHI C
(SECONDARY
HEATED OXYGEN SEN
SOR HEATER CONTROL)
D ves secondary heated oxygen
sensor heater.
With ignition switch ON {ll): battery voltage
Wi t h f ul l y warmed up engi no runni ng: dut y
controlled
6 BLKAr'YHT
PO2SHTC
(PRI MARY
HEATED OXYGEN
SENSOR HEATER
CONTROL}
Drives
primary heated oxygen
sensor heater,
With ignition switch ON lll): battery voltage
with fully warmed up engine running: duty
controll6d
I 8RN/ BLK LGl
(LOGI C
GROUND} Ground forthe PCM control circuit. Less t han 1. 0 V at al l t i mes
1 0 BLK PG1 l POWER GROUND} Ground for the PCM power circuit.
l 1 YEUELK
I GPl l POWER SOURCE} Power source for the PCM control
ci rcui t .
With ignition switch ON
(ll):
battery voltage
With ignition switch OFF: 0 V
12 BLI(BLU
I ACV {I DLE AI R
CONTROL VALVE}
Drives IACV. Wi t h ngi ne runni ng: dut y cont rol l ed
REDryEL
PCS
(EVAP
PURGE
CONTFOL SOLENOI D
VALVE)
Drives EVAP
purge control
sol enoi d val ve.
Wi t h engi ne runni ng, engi ne cool ant
below 154'F
(68"C):
battery voltage
Wi t h engi ne runni ng, engi ne cool ant
above 154"F
(68"C):
duty controlled
1 6 GRN/ VEL
FLR
(FUEL PUMP RELAY) Dri ves I uel pump rel ay. 0 V for two seconds after turning ignition
switch ON lll), then battery voltage
1 1 8LI (RED
ACC
(A,/C
CLUTCH
RELAY}
Drives Ay'C clutch relay. With comoressor ON: 0 V
With compressor OFF: baftery voltage
1 8 GRN/ ORN
MI L
(MALFUNCTI ON
INDICATOR LAMP}
Dri ves Ml L.
With MIL turned ON: 0 V
With MIL turned OFF: baftery voltage
19* WHT/GRN
ALTC
(ALTERNATOR
CONTROL}
Sends al t ernat or cont rol si gnal . Wi t h t ul l y warmed-up engi ne runni ng:
battery voltage
Duri ng dri vi ng wi t h smal l el ect ri cal l oad: 0 '
20 YEUGRN
I CM
(I GNI TI ON
CONTROL
MODULE)
Sends i gni t i on
pul se. With ignition switch ON
(ll):
baftery voltage
Wi t h engi ne runni ng:
pul ses
22 BRN/ BLK LG2
(LOGI C
GROUND} Ground t or t he PCM cont rol ci rcui t . Less t han 1. 0 V at al l t i mes
23 BLK PG2 {POWER GROUND} Ground l or t he PCM
power
ci rcui t .
24 YEUBLK
I GP2 {POWER SOURCE} Power source for the PCM control
ci rcui t .
With ignition switch ON
(ll):
battery voltage
Wi t h engi ne swi t ch OFF: 0 V
27 GRN
FANC
(RADI ATOR FAN
CONTROL)
Drives radiator {an relay. Wi t h radi at or f an runni ng: 0 V
With radiator fan stopped: baftery voltage
*:
USA
{cont' d)
11-67
www.emanualpro.com
Troubleshooting
PCM CONNECTOR B I25PI
Powertrain Control Module Terminal Arrangement
-'97
Model
(cont'dl
Wi re si de of f emal e t ermi nal s
PCM CONNECTOR B I25P}
NOTE: Standard battery vol tage i s l 2 V.
1 1- 68
L
Terminel
number color
Terminal
name
Oescription Signal
1
LS 1A/T CLUTCH
PRESSURE CONTROL
SOLENOI D VALVE
-)
Drives A,/T clutch pressure control
sol enoi d val ve
Wi t h i gni t i on swi t ch ON
(l l ):
dut y con-
t rol l ed
2 RED
LS +
(A"/T
CLUTCH
PRESSURE CONTROL
SOLENOI D VALVE +)
Drives A,/T clutch pressure control
sol enoi d val ve
Wi t h i gni t i on swi t ch ON
(l l )r
dut y con
t rol l ed
3 8LU/ / EL
SHA
(SHI FT
CONTROL
SOLENOID VALVE A)
Dr i ves shi f t cont r ol sol enoi d val ve A. I n 2nd, R posi t i on. i n 2nd and 3rd gear i n
D4, D3 position: Battery voltage
I n l st gear i n D4, D3 posi t i on, i n 4t h gear
i n D4 posi t i on: 0 V
4 GRN/ BLK
LC B
(LOCK-UP
CONTFOL
SOLENOID VALVE B)
Dri ves l ock-up cont rol sol enoi d
val ve B,
Wi t h f ul l l ock-up; Baf t ery vol t age
Wi t h hal f l ock-up: dut y cont rol l ed
5 YEL
LC A
(LOCK.UP
CONTROL
SOLENOID VALVE A)
Dri ves l ock-up cont rol sol enoi d Wi t h l ock' up ON: bat t ery vol t age
Wi t h l ock-up OFF: 0 V
I PNK
ATPD3
(Ay'T
GEAR
POSITION SWITCH}
Det ect s A/ T gear posi t i on swi t ch
si gnal .
_
I n D3 posi t i on: 0 V
l n any ot her posi t i on: bat t ery vol t age
11 GRN/VVHT
SHB
(SHI FT
CONTROL
SOLENOI D VALVE 8}
Dri ves shi f t cont rol sol enoi d val ve B. I n 1st , 2nd posi t i on, i n 1st and 2nd gear i n
D4, D3 posi t i on: Bat t ery vol t age
I n R posi t i on, ; n 3rd gear i n 04, D3, i n 4t h
gear i n D4 posi t i on: 0 V
12 WHT/ BED
I LU
(I NTERLOCK
CONTROL UNI Ti
Det ect s i nt erl ock cont rol unh si gnal . Wi t h i gni t i on swi t ch ON
(l l )and
brake
pedal
depressed: battery voltage
GRN/ BLK
D4I ND
(04
I NDI CATOR
LI GHT}
Dri ves Dl i ndi cat or l i ght . Wi t h D4 i ndi cat or l i ght t urned ON: bat t ery
vol t age
Wi t h D4 i ndi cat or l i ght t urned OFF: 0 V
1 4
NMSG
( MAI NSHAFT
SPEED SENSOR GROUND}
Ground tor mainshaft speed sensor.
RED
NM
(MAI NSHAFT
SPEED
SENSOR)
Detects mainshaft speed sensor
sr gnal ,
Wi t h engi ne runni ng: pul ses
16
ATPR
(A"/T
GEAR
POSI TI ON SWI TCH)
Detects A/T gear position switch
s r gnal .
I n Rp o s i t i o n : 0 V
I n any ot her posi t i on: bat t ery vol t age
1' l BLU
ATP2
(A./T
GEAR
POSI TI ON SWI TCH)
Detects A/T gear position switch
sr g nal ,
I n 2nd posi t i on: 0 V
I n any ot her
posi t i on:
bat t ery vol t age
1 8 BRN
ATP1
(4,,/T
GEAR
POSTTTON SWTTCH)
Detects A/T gear position switch
sr g nal ,
l n l st posi t i on:
0 V
I n any ot her posi t i on: bat t ery vol t age
22 GBN
NCSG
(COUNTERSHAFT
SPEED SENSOR GROUND)
Ground t or count ershaf t speed
sensor,
23 BLU
NC
(COUNTERSHAFT
SPEED SENSOR)
Detects countershaft speed sensor
srgnal .
Wi t h agni t i on swi t ch ON
(l l ),
and l ront
wheel s rot at i ng: pul ses
24 YEL
ATPD4
(M
GEAR
POSI TI ON SWI TCH)
Detects A,/T gear position switch
srgnal .
I n D4 posi t i onr 0 V
I n any ot her posi t i on: bat t ery vol t age
25 LT GRN
ATPNP {A/ T GEAR
POSI TI ON SWI TCH)
Detects A/T gear position switch
si gnal .
I n park or neut ral : 0 V
I n any ot her posi t i on: about 5 V
www.emanualpro.com
PCM CONNECTOR C
(31PI
ferminal
number
Wire
color
Termi nal
name
Doscription
Si gnal
't
BLUiRED
CKFP
(CKF
SENSOR P
SIDE)
Detects CKF sensor. Wi t h engi ne r unni ng: pul ses
2 BLU
CKPP
(CKP
SENSOR P
SIDE)
Detects CKP sensor. Wi t h engi ne runni ng:
pul ses
3 GRN
TDCP
(TDC
SENSOR P
SI DE)
Detects TDC sensor. Wi t h engi ne runni ng: pul ses
4 YEL
CYPP
(CYP
SENSOR P
SI DE)
Detects cYP sensor. Wi t h engi ne runni ng: pul ses
5 BLU,frED
ACS
(A/C
SWTTCH
SIGNAL)
Detects A,/C switch signal. With AJC switch ON: 0 V
With A,/C switch OFF: battery voltage
BLU/ORN
STS
(STARTER SWITCH
SIGNAL)
Detects starter switch signal. With starter switch ON
(lll):
baftery
vol tage
With staner switch OFF: 0 V
7 BRN
SCS
(SERVICE
CHECK
SIGNAL)
Detects service check connector
si gnal
(the
si gnal causi ng a DTC
i ndi cati on)
Wi t h t he connect or connect ed: 0 V
Wi t h t he connect or di sconnect ed: about
5 V or battery voltage
8 LT BLU
K-LINE Sends and receives scan tool
srgnal .
Wi th i gni ti on swi tch ON
(l l ): pul ses
10 WHT/BLU
VBU
UP)
(VOLTAGE BACK Power source tor the PCM
control ci rcui t. Power source for
the DTC memory
Bat t ery vol t age at al l t i mes
1 1 WHT/RED
CKFM
(CKF
SENSOR M
SI DE)
Ground f or CKF sensor si gnal .
12 WHT
CKPM
(CKP
SENSOR I\4
SIDE)
Ground l or CKP sensor si gnal .
13 RED
TDCM
(TDC
SENSOR M
SI DE}
Ground for TDC sensor si gnal .
1 4 BLK
CYPM
(CKP
SENSOR M
SIDE}
Ground for CYP sensor si gnal .
1 6 GRN
PSPSW
(P/S
PRESSURE
swtTcH)
Det ect s PSP swi t ch si gnal . At i dl e wi t h st eeri ng wheel i n st rai ght
ahead
posi t i on: 0 V
At i dl e wi t h st eeri ng wheel at f ul l l ock:
battery voltage
1 7 WHT/RED
ALTF
(ALTERNATOR FR
SIGNAL)
Detects al ternator FR si gnal . Wi t h f ul l y warmed up engi ne runni ng:
0 V-bat t ery vol t age {dependi ng on
el ect ri cal l oad)
18 BLUA/VHT
VSS
(VEHICLE SPEED
SENSOR)
Detects VSS si gnal .
Wi rh i gni t i on swi t ch ON
(l l )
and f ront
wheel s rot at i ng: cycl es 0 V
-
5 V or bat -
tery voltage
Wi re si de of f emai e t ermi nal s
PCM CONNECTOR C {31PI
NOTE: Standard battery vol tage i s 12 V.
(cont' d)
www.emanualpro.com
Troubleshooting
Powertrain Gontrol Module Terminal Arrangement
-'97
Model
(cont'd)
PCM CONNECTOR O {16PI
PCM CONNECTOR D
(I6P)
Wi re si de of f 6mal e t ermi nal s
NOTE: Standard battery voltage is 12 V.
f.rminal
numbcr
Wir! color Trminal nam6 Description Si gnal
1 RED/BLK
TPS ffHROTTLE
POSITION SENSOR}
Detects TP sensor signal. Wi th throttl e ful l v oDen: about 4.8 V
Wi th throttl e ful l v cl osed: about 0.5 V
RE D,4/VHT
ECT
(ENGINE
COOLANT
TEMPERATURE
SENSOR
Detects ECT sensor signal. Wi th i gni ti on swi tch ON {l l ): about
0.1
-
4.8 V
(dependi ng
on engi ne
cool ant temperature)
RED/GRN
MAP
(MANIFOLD
ABSOLUTE PRESSURE
SENSOR)
Detects MAP sensor si gnal . Wi th i gni ti on swi tch ON
(l l ):
about 3 V
At i dl e; about 1.0 V
(dependi ng
on engi ne speed)
YEURED
VCCl
(SENSOR
VOLTAGE)
Powr source for MAP sensor. Wi th i gni ti on swi tch ON
(l l ):
about 5 V
Wi th i gni ti on swi tch OFF: 0 V
E
G R N/WHT
BKSW
(BRAKE
SWITCH)
Detects brake switch signal. Wi th brake pedal rel eased:0 V
With brake pedal depressed: battery
voltage
7 WHT
PHO2S
(PRIMARY
HEATED OXYGEN
SENSOR SENSOR 1)
Detects heated primary oxygen
sensor
(sensor
1) si gnal .
With throttle fully opened from idle with
ful l y warmed up engi ne: above 0.6 V
Wi th throttl e qui ckl y
cl osed: bel ow
0.4 v
8 RED//E L
IAT
(INTAKE
AIR TEM.
PERATURE SENSOR)
Detects IAT sensor signal. Wi th i gni ti on swi tch ON l l l ): about
0.1
-
4.8 V
(dependi ng
on i ntake ai r
temperaturel
10 YEUBLU
VCC2
(SENSOR
VOLT-
AGEI
Provides sensor voltage. Wi th i gni ti on swi tch ON
(l l ):
about 5 V
Wi th i gni ti on swi tch OFF: 0 V
1 1 GRN/BLK
SG2
(SENSOR
GROUND)
Sensor ground. Less than 1.0 V at al l ti mes
12 GRN/WHT
SGl
(SENSOR
GROUND)
Ground for MAP sensor. Less than 1.0 V at al l ti mes
1 3 RED/YE L
SHO2S SG
(SECONDARY
HEATED
OXYGEN SENSOR,
SENSOR 2 GROUND)
Ground for secondary heated
orygen sensor
(sensor
2).
1 4 WHT/RED
SHO2S
(SECONDARY
HEATED OXYGEN
SENSOR, SENSOR 2)
Detects secondary heated
orygen sensor
(sensor
2)
si gnal ,
With throttle fully opened from idle with
ful l y warmed up engi ne; above 0.6 V
Wi th throttl e
qui ckl y
cl osed: bel ow
0. 4 v
16* GRN/RED
EL
(ELD)
Detects ELD si gnal . Wi th parki ng l i ghts turned on at i dl e
about 2.5
-
3.5 V
Wi th l ow beam headl i ghts turned on
at i dl e: about 1. 5
-
2. 5V
1- 70 www.emanualpro.com
Engine/Powertrain Control Module Terminal Arrangement
-
38
-
00 Models
ECM/PCM CONNECTOR A
(32P}
, / . /
5 a
I
sca
,/ l,/
t 5 I t
sTs
n 2l
s!u CI
Wi re si de ot f emal e t ermi nal s
ECM/FCM CONNECTOR A {32P)
NOTE: Standard baftery vol tage i s
' 12
V.
D93cription Signal
3 BLU
2WBS {EVAP BYPASS
SOLENOI D VALVE)
Drives EVAP bvoass solonoid valve. Wi t h i gni r i on swi t ch ON { l l ) r bat t er y vol t age
LT GRNMHT
VSV {EVAP CONTROL CANIS
TEB VENT SHUT VALVE)
D.ives EVAP controlcanisler vent shut With ig^ition switch ON
(ll):
battery voltage
5' ,
BLU
CRS
( CRUI SE
CONTROL SI G'
NAL)
Shift Oown signalinputfrcm cruise con When cr ui se cont r ol i s used:
pul ses
6 RED/YEL
PCS (EVAP PURGE CONTROL
SOLENOID VALVE)
Drives EVAP purge controlsolonoid valve. Wi t h engi ns r unni ng, engi ne cool ant , bel ow 154' F
(68'C)r battery voltage
Wi t h engi ne r unni ng, engi ne cool ant , above 154"F
{6a'C}r duty conl.olled
8 ELIOWHT
SO2SHTC
( SECONDARV
HEATED OXYGEN SENSOR
HEATER CONTROL)
Drives sacondary heated oxygen sensor With ignition switch ON
(ll):
banery voltage
Wi t h f ul l y war med up engi ne r unni ng: dut y
10 BRN
SCS
(SERVICE
CHECX SIGNAL) Detects seNics check conneclor signal
( he
si gnal causi ng a DTC i ndi cat j on)
wi t h r he l er mi nal connect ed: 0 v
Wi t h t he r er mi nal di sconnect edr about 5 v or
l 4 ' r
GRN/8LK
D4I ND ( D4I NDI CATOR) +3
DI ND
( D I NDI CATORTI
Drives D4*3. Dr'indicaior light. W, r h 04' , O" i ndr cat or l i ght t ur ned O\ bat t er ,
Wi t h D4*3, D*. i ndi cat or l i ght t ur ned OFFr 0 V
16 GRNI/EL
FLR
( FUEL PUMP RELAY) Drivss fusl pump relay. 0 V f or i wo seconds af t er r u' ni n9 i gn' l i on swi l ch
ON lll), then banery voltage
1 7 AL|(/RED
ACC
(I/C
CLUTCH RELAY} Drives l,/C clurch rclay. Wi t h compr essor ONr 0 V
With compressor OFF: battery voltage
18 GRN/ORN
MIL
(MALFUNCTION INDICA.
TOR LIGHT)
Drivs MlL. Wi t h Ml Lt ur ned ON: 0 V
With MIL turned OFF: battery voltage
19 BLU NEP
( ENGI NE
SPEED PULSE) Outputs engine spsed pulse. Wi t h sngi ne r unni n9: pul ses
20 GRN
FANC {RADIATOR FAN CON
TROL)
Drives r6diator fan rslay. Wi t h r adaat or f an r unni ng: 0 V
With radaatorfan stopped: battery vollage
21 8LU/t/EL K- LI NE Sends and r ecei vs scan t ool si gnal . With ignition switch ON (ll): p'rlses
23 WHT/RED
SHO2S
(SECONDARY
HEATED
OXYGEN SENSOR. SENSOR 2i
Detects secondary hatd oxygen sensor With throttle fully opened from idle wilh fully
wal med up engi ne: above 0. 6 V
with rhrottle quickly closed: below 0-4 V
21 BLU/WHT
STS
(STARTER SWITCH SIG,
NAL}
Dotocts srarter switch signal. Whh staner switch ON (lll): batlery voltage
With srarter switch OFF: 0 V
26 GBN
PSPSW {P/S PsESSUFE
SWITCH SIGNAL)
Detecrs PSP switch signal. At idle with steeing whel in stBighl ahead position: 0 V
At idls with nee ng wheel al full lockr banory voltage
2f BLU/BEO
ACS
(Ir'C
SWTCH SIGNAL} Dtects ly'C switch signal. With Ay'C switch ON:0 V
With l/C swilh OFF: about 5 V
2A' \
WHT/NED
SLU {INTERLOCK CONTROL
UNI T)
Orives interlock control unil. Wi t h i gni l i on swi t ch ON
( l l ) and
br ake pedal
depressed: battery vohage
29 LT GRN
PTANK
( FUEL
TANK PRES'
SURE SENSOR)
Detocts fueltank pressure sensor signal. Wi t h agni t i on swi t ch ON
( l l )
and f uel f i l l cap
opensd; about 2.5 v
GBN/ FED
EL
( ELD} Detects ELD signal. Wi r h paai ng r i ght st umed on at i dl e: about 2. 5
-
3. 5 V
Wi t h l ow beam headl i ght s t umed on at i dl e:
about 1. 5- 2. 5V
GRN/WHT
BKSW (BRAKE SWTTCH) Dstcts brake switch signal. Wi r h br ake pedal r el eased: 0 V
With brake pedal depressed: battery vollage
13:
' 98
modsl
15:
USA
(cont' d)
11- 71 www.emanualpro.com
Troubleshooting
Engine/Powertrain Control Module Terminal Arrangement
-
'98
-
00 Models
(cont'd)
ECM/PCM CONNECTOR B {25PI
Wi re si de of f emal e t ermi nal s
ECM/PCM CONNECTOR B I25PI
*2t
MlT
*3:
' 98
model
"4:
' 99
-
00 model s
NOTE: Standard baftery vol tage i s l 2
Ierminal
numbt
Wire color Termi nsl name Description Si gnal
1 YEUBLK
IGPl
(POWER
SOURCE) Power source for the ECM/PCl vl
control ci rcui t.
with
age
with
i gni ti on swi tch ON
(l l ):
battery vol t-
i gni ti on swi tch OFF:0 V
BLK
PG1
( POWER
GROUND} Ground f or t he ECM/ PCl vl cont rol
ci rcui t .
Less t han 1. 0 V at al l t i mes
RED
l NJ2
( No.
2 FUEL I NJEC-
roR)
Dri ves No. 2 I uel i nj ect or.
Wi t h engi ne runni ng: dut y cont rol l ed
BLU
l NJ3 1No. 3 FUEL I NJEC-
TOR)
Dri ves No. 3I uel
j nj ect or.
YEL
l NJ4 { No. 4 FUEL I NJEC-
TOR)
Dri ves No. 4 f uel i nj ect or.
8*1
WHT
LS-
(A"/T
CLUTCH PRES.
SURE CONTROL SOLE,
NOID VALVE
_
SIDE)
A,/T clutch
pressure control
sol enoi d val ve power suppl y
negati ve termi nal .
Wi t h i gni t i on swi t ch ON
(l l ):
dut y
cont rol l ed
9 YEUBLK
IGP2 IPOWER SOURCE) Power source for the ECN,I/PCM
control ci rcui t.
Wi t h i gni t i on swi t ch ON
(l l l :
baf t ery
vol t age
Wi t h i gni t i on swi t ch OFF: 0 V
1 0 BLK
PG2
(POWER
GROUND} Ground f or t he ECM/ PCM cont rol
crrcurt .
Less t han
' 1. 0
V at al l t i mes
'
BRN
l NJl
( No.
1 FUEL I NJEC
TOR)
Dri ves No. l t uel i nj ect or. Wi t h engi ne runni ng: dut y cont rol l ed
YEUGRN
rcM {rGNrTroN coN-
TROL MODULE)
Sends i gni t i on pul se. Wi t h i gni t i on swi t ch ON
(l l ):
bat t ery
vol t age
Wi t h engi ne runni ng: pul ses
17*1 RED
LS+
(A,,IT
CLUTCH PRES
SURE CONTROL SOLE-
NOID VALVE + SIDE)
A,/T clutch pressure control
sol enoi d val ve power suppl y
posi ti ve termi nal
Wi t h i gni t i on swi t ch ON
(l l ):
dut y
cont rol l ed
19* .
PNK
ODIND
(OVER-DRIVE
OFF INDICATOR}
Drives OVER-DRIVE OFF
i ndi cator l i ght.
Wi t h OVER-DRI VE OFF i ndi cat or l i ght
t urned ON: 0 V
Wi t h OVER-DRI VE OFF i ndi cat or l i ght
turned OFF: battery voltage
20 BRN/BLK
LG1
(LOGIC
GROUND) Ground for the ECM/PCM control
ci rcui t.
Less t han 1. 0 V at al l t i mes
WHT/BLU
VBU
(VOLTAGE
BACK
UP)
Power source for the ECM/PCM
control ci rcui t.
Power source forthe DTC memory.
Bat t ery vol t age at al l t i mes
22 BRN/BLK
LG2
(LOGIC
GROUND) Ground f or t he ECN4/ PCM cont rol
ct rcut t ,
Less t han 1. 0 V at al l t i mes
23 BLVBLU
IACV {IDLE AIR CON.
TROL VALVE)
Dri ves I AC val ve. Wi t h engi ne runni ng: dut y cont rol l ed
11- 72
www.emanualpro.com
ECM/PCM CONNECTOF C
(31PI
Wi re si de o{ f emal e t ermi nal
ECM/PCM CONNECTOR C
(31P)
NOTE: Standard battery vol tage i s 12 V.
Termidal
D.3cription Si gnal
8LI(WHT
POzSHTC {PRIII4ABY HEATED
OXYGEN SENSOR HEATER
CONTROL)
Drivss prim6ry h$ted oxygsn sensor Wilh ignition switch ON
(ll):
baneryvoltsge
With ftrllywarmsd up ngine runnang: duty
2" WHT/GBN
ALTC
(ALTERNATOR CON,
TROL)
Sonds alternalor control signsl. With fully wafmod up ngine rnningr banry
voltago
Du ng driving with small elsctrical lo6d: 0 v
3 ' 1
FED/8LU KS
( KNOCK
SENSOR) Dstects KS signal. With engine knockang: pulses
5 WHT/RED
ALTF
(ALTERNATOR FR SIG-
NAL}
Detects alternator FR signal. Wt h f ul l ywar med up ngi ne r unni ng: 0 V- bat t er y
voltag {dpending on slsctrical load)
1 GRN,4trHT SG1
( SENSOR
680UND} Ground for l/tAP sensor. Lss than 1.0 v 6t all times
8 BLU CKPP
(CKP
SENSOF P SIDE) Datcls CKP s6nsor. Wi t h ngi n r unni ngr
pul ss
9 CKPI.,I| {CKP SENSOF M SIDE) Ground for CKP snsor.
1 5
PHO2S {PRIMARY HEATED
OXYGEN SENSOR, SENSOR 1)
Detocts pfimary he6t6d oxygen ssnsor
{ sonsor 1) si gnal .
with ihfottls fully opened from idle with fully,
walm6d up engins: above 0.6 V
With throttlo quickly clossd: below 0.4 v
1 7 RED/GRN
MAP (MANIFOLD ABSOLUTE
PRESSURE SENSOR)
D6tects MAP snsor sign6l. Wi t h i gni t i on swi t ch ON
( l l ) : about 3 V
At i dl s: aboul 1. 0 V { dspsndi ng on engi ne speed)
18 GRN/BLK SG2
( SENSOB
GNOUNDi
Lsss than 1.0 V at all tims
19 YEUBED
VCCl {SENSOR VOLTAGE) Power soufce to MAP snsor. With ignition switch ON
(ll): about 5 V
With ignition switch OFF:0 V
20 GRN TDCP {TDC SENSOR P SIDE) Derecis TDC sensor. Wi t h engi ne f unni ng:
Pul ses
2 l RED TDCM ITDC SENSOR M SID) Ground for TDC sensor.
22 BLU/RED CKFP
( CKF
SENSOR PSI DE) Dstscts CKF snsor. With sngins running: pulsss
23 BLU/WHT
VSS
(VEHICLE
SPEED SEN-
soR)
Dstscrs vss signal. Wi t h i gni t i on swi t ch ON
( l l ) and f r ont wheel s
rotaringrcyclss 0 v- 6bout 5 V or banry voltage
25 RED//EL
IAT
(INTAKE
AIR TEMPERA'
TURE SENSOB)
Detacts IAT sensor signal. With igniiion switch ON
(ll):
about 0.1
-
4.8 V
(dpnding on iniate air tmpraturc)
26 REO/WHT
ECT {ENCINE COOLANT
TEMPERATURE SENSOR)
oetscts ECT sensor signal. With ignition switch ON (ll): about 0.1 4.8 V
{doponding on 6ngin coolanl lemper6tu16)
27 RED/BLK
TPS (THROTTLE POSITION
SENSOR)
Dotects TP sensor signrl. with rhrottls fully opn: aboui 4.8 v
with throtrl6 fullyclosed: about 0.5 v
2A YEUBLU
VCC2lSENSOR VOLTAG} Provids snsor voltage. With ignilion switch ON
(ll):
about 5 V
Whh ignition switch OFF: 0 V
29 YEL CYPP ICYP SENSO8 P SIDE) Dsrscts CYP sensor. With ngins runningr pulsss
30 BLK CYPM
(CYP
SENSOR M SIDE) Ground for CYP sansor.
31 WHT/RED CKFM {CKF SENSOR M SIDE) 6.ound lof CKF ssnsor signal.
11.
AfT
13.
'94
model
' 2: M/ T 14: ' 99-
0o modsl s
.5:
USA
(cont' d)
11- 73 www.emanualpro.com
Troubleshooting
Powertrain Control Module Terminal Arrangement
-'98 -
00 Models
(cont'dl
PCM CONNECTOR D
(16P)
NOTE: Standard battery vol tage i s 12 V.
i 1: A/ T * 3: ' 98
model
' 2:
M/T
*4:' 99
00 models
ECM/PCM CONNECTOR D {16P}
Wi re si de of l emal et ermi nal s
Ds4ription Sign!l
YEL
LC A {LOCK,UP CONTBOL
SOLENOID VALVE A)
Orivs lock'up conrrol solenoid valve A. With lock-up ON: b6ttery voltags
Wi t h l ock- up OFF: 0 V
2+1 GBN,M/HT
SHB ( SHI FT
CONTROL
SOLENOIO VALVE B)
Dr i ves shi f t cont r ol sol enoi d val ve B. In 1st, 2nd position, in lst and 2nd gear an D4, D3
(D)11 position: battery vohag
In P, R, N position, in 3rd geaf in D1, D3 (D)*.
position, in 4th gear in D4 (D)*r positionr0 V
GRN/ BLK
LC 8 (LOCK,UP
CONTROL
SOLENOID VALVE B}
Drives lock up controlsolenoid valve B. With full lock-up: 8attery voitage
With half lock'uprduty controlled
BLK/YEL
VBSOL (BATTERY
VOLTAGE
FOR SOLENOI D VALVE}
Powr source of solenoid valvs. With ignition switch ON
(ll):
batteryvoltage
With ignition switch OFF| 0 V
ATPR {AI GEAE POSITION
SWITCH)
Delscls A/T gear posrtion swirch srgnal.
In any other positjon: battsry voltage
BLU,ryEL
SHA
(SHIFT
CONTROL
SOLENOID VALVE A)
Drives shift conrrol solenoid valvp A. In 2nd, R position, an 2nd and 3rd ge6r in D4, D3
(D)r' posilion: batlery voltage
In 1st gear in 04, 03 {D)}.
position, in 4th gear in
D4 ( D) *. posi t i on, i n P, N posi t i on: 0 V
PNK
ATPD3 (AT
GEAR POSITION
swrTcH)
Detects A,/T gar poshion swirch sign6l. I n D3 posi t i on: 0 V
h any other posiiion:
banryvoltage
PNK
ODSW
( OVER. DBI VE
SWI TCH) Detects OVEF-DRIVE swirch sagnal. With Ovor Drivs OFF
(O/D
OFF indicator light
t ur ned ON) : 0 V
Wilh Ovsr Drivs ON
(O/D
OFF indicrto.lasht
turned OFF): about 5 V
9' ' YEL
ATPDI}3, O}I {AT GEAR
POStTtON SWTTCH)
Dotcts A/T gar position swirch signal. I n D4r 3, O*. posi t i on: 0 V
In any other posilion:
battery voltage
10. , BLU
NC
(COUNIERSHAFT
SPEED
SENSOR)
Detscts counlrshaft speed sensor With ignition switch ON
(ll),
and ffonr wheels
RED
NM I I VAI NSHAFT SPEED
SENSOB)
Detects mainshaft speed sensor sign6ls. Wi l h engi ne r unni ng: pul ses
NMSG { MAI NSHAFTSPEED
SENSOB GBOUND)
Ground for mainshaft speed sensor-
' 13*1
LT GRN
ATPNP (AT
GEAR POSITION
swtTcH)
Delects A,/T gear position switch signat. I n par k or nut r al : 0 V
h any other posilion: about 5 V
8LU
ATP2 (AT
GEAR POSFION
swrTcH)
Dstects A,/T gear position switch signal.
h any othsr position: battery voltsgs
15. ' BRN
ATP1 {AT GEAR POSITION
swrTcH)
Detscts A/T gear position switch signal.
In any other position: htteryvoltage
t 6' ' GRN
NCSG { COUNTERSHAFT
SPEED SENSOR GROUND}
Grouod for counterchaft sped snsor.
11- 74
www.emanualpro.com
Diagnostic Trouble Code
(DTCI
Chart
*:
These DTCS wi l l be i ndi cated by the bl i nki ng of the Mal functi on Indi cator Lamp
(Ml L)
wi th the SCS servi ce connector
connected.
**:
The E
(E)*u
i ndi cator ti ght and the Mal functi on Indi cator Lamp
(Ml L)
may come on si mul taneousl y.
*1'
AIT
*3
' 97
model
+5;
' 99
-
00 model s
*2:
Ml T
*4:' 98
model
{cont' d)
11- 75
DTC
(MlL
indication*l
Detection ltem Probable Cause Pago
P0107
(3)
Mani fol d Absol ute
Pressu.e Ci rcui t
Low Input
Open or short i n MAP sensor ci rcui t
MAP sensor
ECMiPCM
't 'l-90
P0108 {3)
Mani fol d Absol ute
Pressure Ci rcui t
Hi gh I nput
Open i n MAP sensor ci rcui t
MAP sensor
ECM/PCM
11-92
P01 1 1* 3
( 10)
Intake Ai r
Temperature Ci rcui t
Range/Performance Probl em
.
IAT sensor
11- 95
P0112
( 10)
l ntake Ai r
Temperature Ci rcui t
Low Input
Short i n IAT sensor ci rcui t
IAT sensor
ECM/PCM
1 1-96
P0113
( 10)
l ntake Ai r
Temperature Ci rcui t
Hi gh l nput
Open i n IAT sensor ci rcui t
IAT sensor
ECM/PCM
'I
1-97
P0116
(86)
Engi ne Cool ant
Temperature Ci rcui t
Range/Performance Probl em
ECT sensor
Cool i ng system 1 1-99
P0117
( 6)
Engi ne Cool ant
Temperature Ci rcui t
Low Input
Short i n ECT sensor ci rcui t
ECT sensor
ECM/PCM
1 1- 100
P0118
( 6)
Engi ne Cool ant
Temperature Ci rcui t
Hi gh I nput
Open i n ECT sensor ci rcuj t
ECT sensor
ECM/PCM
11- 101
P0122 \11
Throttl e Posi ti on
Ci rcui t
Low Input
Open or short i n TP sensor ci rcui t
TP sensor
ECM/PCM
11- 103
P0123
l7l
Throftl e Posi ti on
Ci rcui t
Hi gh I nput
Open i n TP sensor ci rcui t
TP sensor
ECM/PCM
11- 107
P0131
( 1)
Pri mary Heated Oxygen Sensor
Circuit Low Voltage
(Sensor
1)
Short i n Pri mary HO2S {Sensor 1)
circuit
Pri mary HO2S
(Sensor
1)
Fuel suppl y system
ECM/PCM
1 1-1 10
P0132
( 1)
Pri mary Heated Orygen Sensor
Ci rcui t Hi gh Vol tage
(Sensor
1)
Open i n Pri mary HO2S
(Sensor
1) ci rcui t
Pri mary HO25
(Sensor
1)
ECM/PCM
' 11
1 1 3
P0133
( 61)
Primary Heated Oxygen Sensor
Sl ow Response
(Sensor
1)
.
Pri mary HO2S
(Sensor
1)
.
Exhaust system 11
' I
16
P0135
( 41)
Pri mary Heated Oxygen Sensor
Heater
Ci rcui t Mal functi on
{Sensor 1)
.
Open or short i n Pri mary HO2S
(Sensor
' l )
heater ci rcui t
.
ECM/PCM
11-12' l
www.emanualpro.com
Troubleshooting
Diagnostic Trouble Code
(DTCI
Chart
(cont'd)
*:
These DTCS wi l l be i ndi cated by the bl i nki ng o{ the Mal functi on Indi cator Lamp
(Ml L)
wi th the SCS servi ce connector
connected.
**:
The
E
(El *s
i ndi cator l i ght and the Mal functi on Indi cator Lamp {Ml L) may come on si mul taneousl y,
*1;
A/T
*3:
' 97
model
*5:
' 99
-
00 model s
*2:
Ml T
*4:
' 98
model
11- 76
DTC
l Ml L i ndi cat i onl
Detection hem Probable Caus. Page
P0137
(63)
Secondary Heated Oxygen Sensor
Circuit Low Voltage
{ Sensor 2)
Shon in Secondary HO2S
(Sensor
2) circuat
Secondary HO2S
(Sensor
2)
ECM/ PCM
' n-1t 7
P0138
(63)
Secondar y Heat ed Oxygen Sensor
Ci r cui t Hi gh Vol t age
Open i n Secondary HO2S
(Sensor
2) ci rcui t
Secondary HO2S
(Sensor
2)
EC|\il/PCM
1 11 1 8
P0139 {63)
Secondary Heated Oxygen Sensor
l Sensor 2i
Secondary HO2S
(Sensor
2)
11- 120
P0141
( 65)
Second6ry Heated Oxygen Sensor Heater
Ci r cui t Mal f unct i on
( Sensor
2)
Open orshon i n Secondary HO2S
(Sensor
2)
heat er ci rcui t
EC|V/PCtu
1 1
' t 2 l
P0r 71 ( 45)
System Too Lean Fuel supply system
Pr i mar y HOzS
( Sensor
1)
Contaminated fuel
Exhaust l eakage
1 1124
P0112
(45)
System Too Rich Fuel supplv system
Pri mary HO2S
(Sensor
1)
Contaminated fuel
11 124
and
Po3ol
l tr \
P0302
112 |
P0303
173 i
P0304 \74 t
Random Mistire lgnition system
Fuel supply system
I AC val ve
Cont ami nat ed f uel
Lack of f uel
11- 126
P0301
/ 71 \
P0302
112 |
P0303
173 |
P0304
\ 7
4l
-
Cyl i nder 1
-
Cyl i nder 2
Cyl i nder 3
-
Cyl i nder 4
Misfire Detected
Fuel i nj ect or
Fuel injector circuit
lgnition system
't't
127
P0325*5 {23)
Knock Sensor {KS) Circuit Malfunction Open or shon in Knock Sensor
(KS)
circuit
Knock Sensor
( KS)
ECM/PCt\4
11- 130
P033s { 4}
Crankshaft Position
Sensor Circuit
Crankshaft Position Sensor
Crankshaft Positaon Sensor circuit
E Cl\,l/PC l\,'!
11- 131
P0336
( 4)
Crankshaft Position Sensor
Range/Performance
Crankshaft Position Sensor
Timing belt skipped teeth
11, 131
P0420 { 67)
Catalyst System Efficiency Below
Threshold
Three Way Catalytic convener
Secondary HO2S {Sensor 2)
't1-200
P0441*3
( 92)
Evaporative Emission
Cont r ol Syst em
Insulficient Purge Flow
EVAP Purge Control Solenoid valve
EVAP Purge Control Solenoid valve circuit
Throttle
gody
(purge port)
Tubi ng
PCM
' I t
205
P0451*5
Fuel Tank Pr essur e Sensor Ci r cui t
Bange/Performance
Fuel Tank Pressure Sensor
ECM/PCM
t ' t -208
( 91i
Fuel Tank Pressure Sensor
Circlit Low Input
Opsn orShort in FuelTank Pressure Sensor circuit
Fuel Tank Pressure Sensor
ECM/PCt\4
11-209
P0453*r . 5 { 91)
Fuel Tank Pr essur e Sensor Ci r cui t
Hi gh I nput
Open in Fuel Tank Pressure Sensor circuit
Fuel Tank Pressure Sensor
ECt /PCt\.1
1 1 - 2 1 1
www.emanualpro.com
DTC
(Ml L
i ndi cati onl
Dotection ltom Probable Cause Page
P0500 t17)*,
Vehi cl e Speed
Sensor Ci rcui t
Mal functi on
Vehi cl e Speed Sensor
Vehi cl e Speed Sensor ci rcu i t
ECtVI
1 1- 135
P0501 l 17J* 1
Vehi cl e Speed
Sensor Ci rcui t
Mal f unct i on
Vehi cl e Speed Sensor
Vehi cl e Speed Sensor ci rcui t
PCM
1 1 - 1 3 5
P0505
(14)
l dl e Cont rol
System
Mal f unct i on
IAC val ve
Throttle Body
Fast i dl e thermo val ve*1
1
' ] -
150
P0700
P0715
PO720
P0730
P0740
P0753
P0758
Aut omat i c
Transaxl e
Sect i on l 4
P1106
( 13)
Barometri c
Pressure Ci rcui t
Range/Performance Problem
ECM/PCM
(Baro
sensor)
11-137
P1107
(13)
Barometri c
Pressure Ci rcui t
Low InPut
.
ECM/PCM {Baro sensor)
11-137
P1108
( 13)
Barometri c
Pressure Ci rcui t
Hi gh Inpur
ECM/PCM {Baro sensor)
1 1 , 1 3 7
P1121
(7)
Throttle Position
Lower Than
Expected
.
TP sensor
11- 109
P1122
(7)
Throttl e Posi ti on
Hi gher Than
Expected
'
TP sensor
1 1-' 109
P112a
(5)
Mani fol d Absol ute
Pressure Lower Than
Expected
.
MAP sensor
11- 94
P1129
(5)
Mani f ol d Absol ut e
Pressure Hi qherThan
Expected
'
MAP sensor
1l - 94
P1297
(20)
Electrical Load
Det ect or Ci rcui t
Low I nput
Electrical Load Detector
Electrical Load Detector circuit
ECM/PCM
1 1- 138
P1298
(20)
El ectri cal Load
Detector Ci rcui t
Hi gh Input
El ect ri cal Load Det ect or
El ect ri cal Load Det ect or ci rcui t
ECM/ PCM
11- 140
P1300' 3
P0301
P0302
P0303
P0304
7 l
72
13
14
Random l vl i sf i re
l gni ti on system
Fuel suppl y system
MAP sensor
IAC valve
Contami nated fuel
Lack offuel
11-126
*:
These DTCS wi l l be i ndi cated by the bl i nki ng of the Mal functi on Indi cator Lamp {Ml L} wi th the SCS servi ce connector
connected.
**:The
E
(E])+s
i ndi cator l i ght and the Mal functi on Indi cator Lamp
(Ml L)
may come on si mul taneousl y.
*1:A,./T "3:
' 97
model
+5:
' 99
-
00 model s
*2:
M/T
*4:' 98
model
{cont' d)
11- 77
www.emanualpro.com
Troubleshooting
Diagnostic Trouble Code
(DTCI
Ghart
(cont'd)
r:
These DTCS wi l l be i ndi cated by the bl i nki ng oJ the Mal functi on Indi cator Lamp
(Ml L)
wi th the SCS servi ce connector
connected.
**:
The
Di
(E)*5
i ndi cator l i ght and the Mal functi on tndi cator Lamp
(Ml L)
may come on si mul taneousl y.
*1:
A[f
*3;' 97
model
*5:
' 99
-
00 model s
*21M/f *4:
' 98
model
11- 78
DTC
{Ml L i ndi cati on}
Detection ltem Probable Cause Pagc
P1336 154)
Crankshaft Speed
Fl uctuati on Sensor
Intermi ttent Interrupti on
.
CKF sensor
11-142
P1337 i 54)
Crankshaft Speed
Fl uct uat i on Sensor
No Si gnal
CKF sensor
CKF sensor ci rcui t
ECM,FCM
11-142
P1359
(8)
Crankshaft Position/Too Dead
Center Sensorrcyl i nder Posi ti on
Connector Disconnection
'
CKP/TDC/CYP sensor circuit
1 1 - 1 4 6
P1361
( 8)
Top Dead Center
Sensor Intermi ttent
Interrupti on
1 1 - 1 3 1
P1362
(8)
Top Dead Center
Sensor No Si gnal
TDC sensor
TDC sensor ci rcui t
ECM/PCM
1 1 - 1 3 1
P1381
(9)
Cyl i nder Posi ti on Sensor
Intermi ttent Interrupti on
.
CYP sensor
11- 131
P1382 (9)
Cyl i nder Posi ti on Sensor
No Si gnal
CYP sensor
CYP sensor ci rcui t
ECM/PCM
1 1 - 1 3 1
P1456n. * {90}
Evaporati ve Emi ssi on
Control System Leak Detected
(Fuel Tank
System)
Fuel f i l l cap
Vacuum connecti on
Fuel t ank
Fuel tank prossure sensor
EVAP bypass solenoid valve
EVAP two way valve
EVAP control canister vent shut valve
EVAP control canister
EVAP purge control sol enoi d val ve
11-213
Pr457n. s
{90)
Evaporati ve Emi ssi on
Control System Leak Detected
(EVAP
Control Cani ster Svstem)
Vacuum connecti on
EVAP control cani ster
Fuel tank
pressure
sensor
EVAP bypass solenoid valve
EVAP two way valve
EVAP control cani ster vent shut val ve
Fuel t ank
EVAP
purge
control sol enoi d val ve
11- 219
P1508
( 14)
l dl e Ai r Control
Val ve Ci rcui t
Fai l ure
IAC valve
IAC valve circuit
ECM/PCM
11-152
Pr607 (-)
Engi ne Cont rol Modul e, Powert rai n
Cont rol Modul e I nt ernal Ci rcui t
Fai l ure A
.
ECM,FCM
11-147
P1705
P1706
P1753
P1758
P1768
Aut omat i c
Transaxl e
Secti on
' 14
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How to Read Flowcharts
A fl owchart i s desi gned to be used from start to fi nal repai r. l t' s l i ke a map showi ng you the shortest di stance. But beware:
l f you go off the
"map"
anywhere but a
"stop"
symbol , you can easi l y get l ost.
brARn
t.-OotO tw"t
Descri bes the condi ti ons or si tuati on to start a troubl eshooti ng fl owchart.
FcTl oNl
Asks you to do somethi ng; perform a test, set up a condi ti on etc.
@
Asks you about the resul t of an acti on, then sends you i n the appropri ate troubl eshooti ng di recti on.
fS-OPl
The end of a seri es of acti ons and deci si ons, descri bes a fi nal repai r acti on and someti mes di rects you to
(bol d
type) an earl i er part of the fl owchart to confi rm your repai r.
NOTE:
. The term
"l ntermi ttent
Fai l ure" i s used i n these charts. l t si mpl y means a system may have had a fai l ure, but i t checks
out OK at thi s ti me. l f the Mal functi on Indi cator Lamp
(Ml L)
on the dash does not come on, check for poor connecti ons
or l oose wi res at al l connectors rel ated to the ci rcui t that you are troubl eshooti ng
(see
i l l ustrati on bel ow).
. Most of the troubl eshooti ng fl owcharts have you reset the Engi ne Control Modul e
(EcM)/Powertrai n
Control Modul e
(PCM)
and try to dupl i cate the Di agnosti c Troubl e Code
(DTC).
l f the probl em i s i ntermi ttent and you can' t dupl i cate the
code, do not conti nue though the fl owchart. To do so wi l l onl y resul t i n confusi on and, possi bl y, a needl essl y repl aced
ECM/PCM,
o
"Open"
and
"Short"
are common el ectri cal terms. An open i s a break i n a wi re or at a connecti on. A short i s an acci -
dental connecti on of a wi re to ground
or to another wi re. l n si mpl e el ectroni cs, thi s usual l y means somethi ng won' t
work at al l . In compl ex el ectroni cs
(l i ke
ECM' S/PCM' S), thi s can someti mes mean somethi ng works, but not the way i t' s
suooosed to.
LOOSE
11- 79
www.emanualpro.com
PGM-FI System
System Description
I NPUTS
CKP/TDC/CYP Sensor
CKF Sensor
MAP Sensor
ECT Sensor
IAT Sensor
TP Sensor
Pri mary HO2S
Secondary H02S
vss
KS*5
BARO Sensor
ELD*6
Starter Si gnal
ALT FR Si gnal
Ai r Condi ti oni ng Si gnal
Ay' T Gear Posi ti on Si gnal *1
Baftery Vol tage
(l GN.1)
Brake Swi tch Si gnal
PSP Swi tch Si gnal
Fuel Tank Pressuae Sensor*4.
*5
Countershaft Speed Sensor*1
Mai nshaft Speed Sensor*r
OVER-DRIVE Swi tch Si gnal *s
ENGINE CONTROL MODULE
(ECM)/
POWERTRAIN CONTROL MODULE
(PCM)
OUTPUTS
|iuel
1"j""- Th,rhg ""d Drrafr";-l
Et*-.nt"tdt"cont.orl
to,r*,c;;trffi;]
l.----.---:. .
Lrgnrnon
| l mrng Lonrror
I
Ecir/PcM
B*k',p Fr""il]
m;"t-ll-r*'io*l
Fuel Inj ectors
PGM-Fl Mai n Rel ay
(Fuel
Pump)
MI L
IAC Val ve
Ay' C Compressor Cl utch Rel ay
Radi ator Fan Rel ay
Condenser Fan Rel ay
ALT
tcM
EVAP Purge Control Sol enoi d
Valve
Pri mary HO2S Heater
Secondary H02S Heater
EVAP Bypass Sol enoi d Val ve*a
*5
EVAP Control Cani ster Vent Shut
DLC
Lock-up Control Sol enoi d Val ve*l
Shi ft Control Sol enoi d Val ve*1
Ay'T Clutch Pressure Control
Sol enoi d Val ve*1
D4 Indi cator Li ght' 1
*3, *a
D Indi cator Li ght,l
*5
OVER-DRIVE OFF Indi cator
Li ghl *t
*:
* 1:
A/ T
{ 3: ' 97
model
' 2:
M/f
+4:' 98
model
*5:
' 99
-
00 model s
"6:
USA
PGM-Fl System
The PGM-Fl system on thi s model i s a sequenti al mul ti port fuel i nj ecti on system.
Fuel iniecior Timing and Duration
The ECM/PCM contai ns memori es for the basi c di scharge durati ons at vari ous engi ne speeds and mani fol d pressure. The
basi c di scharge durati on, after bei ng read out from the memory, i s further modi fi ed by si gnal s sent from vari ous sensors
to obtai n the fi nal di scharge durati on.
ldle Air Control
l dl e Ai r Control Val ve
(l AC
Val ve)
When the engi ne i s col d, the Ay' C compressor i s on, the transmi ssi on i s i n gear, the brake pedal i s depressed, the P/S l oad
i s hi gh, or the al ternator i s chargi ng, the ECM/PCM control s current to the IAC Val ve to mai ntai n the correct i dl e speed.
lgnition Timing Control
o The ECM/PCM contai ns memori es for basi c i oni ti on ti mi ng at vari ous engi ne speeds and mani fol d ai r fl ow rates.
l gni ti on ti mi ng i s al so adj usted for engi ne cool ant temperature.
. A knock control system was adopted whi ch sets the i deal i g ni ti on ti mi ng for the octane rati ng of the gasol i ne used.*s
Other Control Funstions
1. Starti ng Control
When the engi ne i s started. the ECM/PCM provi des a ri ch mi xture by i ncreasi ng fuel i nj ector durati on.
2. Fuel Pump Control
. When the i gni ti on swi tch i s i ni ti al l y turned on
(l l ).
the ECMi PCM suppl i s ground to the PGM-FI mai n rel ay that
suppl i es current to the fuel pump for two seconds to pressuri ze the fuel system.
. When the engi ne i s runni ng, the ECM/PCM suppl i es ground to the PGM-FI mai n rel ay that suppl i es current to the
fuel oumo.
. When the engi ne i s not runni ng and the i gni ti on i s on, the ECM/PCM cuts ground to the PGM-FI mai n rel ay whi ch
cuts current to the fuel pump.
1 1- 80
www.emanualpro.com
Fuel Cut-off Control
. Duri ng decel erati on wi th the throttl e val ve cl osed, current to the fuel i nj ectors i scutoffto i mprovefuel economyat
speeds over 970 rpm
(' 97 -
98 model s), 920 rpm
(' 99 -
00 model sl .
. Fuel cut-off acti on al so takes pl ace when engi ne speed exceeds 6,500 rpm
(' 97 -
98 model s), 6900 rpm
(' 99 -
00
model s), regardl ess of the posi ti on of the throttl e val ve, to protect the engi ne from over-rewi ng.
Wi th Ay' T model . the PCM cuts the fuel at engi ne speeds over 5,000 rpm when the vehi cl e i s not movi ng.*'
4,./C Comoressor Clutch Relav
When the ECM/PCM recei ves a demand for cool i ng from the ai r condi ti oni ng system, i t del ays the compressor from
bei ng energi zed, and enri ches the mi xture to assure a smooth transi ti on to the Ay' C mode.
Evaporati ve Emi ssi on
(EVAP)
Purge Control Sol enoi d Val ve
When the engi ne cool ant temperature i s above 154"F
(68' C),
the ECM/PCM control s the EVAP
purge
control sol enoi d
val ve whi ch control s vacuum to the EVAP purge control cani ster,
Alternator Control
The system control s the vol tage generated at the al ternator i n accordance wi th the el ectri cal l oad and dri vi ng mode.
whi ch reduces the engi ne l oad to i mprove the fuel economy.
PCM Fail-saf e/Back-up Functions
1. Fai l -safe Functi on
When an abnormal i ty occurs i n a si gnal from a sensor, the ECM/PCM i gnores that si gnal and assumes a
pre-pre
grammed val ue for that sensor that al l ows the engi ne to conti nue to run.
2. Back-up Functi on
When an abnormal i ty occurs i n the ECM/PCM i tsel f, the fuel i nj ectors are control l ed by a back-up ci rcui t i ndependent
of the system i n order to
permi t mi ni mal dri vi ng.
3. Sel f-di agnosi s Functi on IMal functi on Indi cator Lamp
(Ml L)l
When an abnormal i ty occurs i n a si gnal from a sensor, the ECM/PCM suppl i es ground for the MIL and stores the DTC
i n erasabl e memory. When the i gni ti on i s i ni ti al l y turned on {l l ), the ECM/PCM suppl i es ground for the MIL for two
seconds to check the MIL bul b condi ti on.
4. Two Trio Detection Method
To prevent fal se i ndi cati ons, the Two Tri p Detecti on Method i s used for the HO2S*1, fuel meteri ng-rel ated. i dl e control
system, ECT sensor and EVAP control system sel f-di agnosti c functi ons. When an abnormal i ty occurs, the ECM/PCM
stores i t i n i ts memory. When the same abnormal i ty recurs after the i gni ti on swi tch i s turned OFF and ON
(l l )
agai n,
the ECM/PCM i nforms the dri ver by l i ghti ng the Ml L. However, to ease troubl eshooti ng, thi s functi on i s cancel l ed
when you j ump
the servi ce check connector, The MIL wi l l then bl i nk i mmedi atel y when an abnormal i ty occurs.
5. Two
(or
Three) Dri vi ng Cycl e Detecti on Method {' 97 model )
A
"Dri vi ng
Cycl e" consi sts of starti ng the engi ne, begi nni ng cl osed l oop operati on, and stoppi ng the engi ne. l f mi sfi r-
ing that increases emissions or EVAP control system malfunction is detected during two consecutive driving cycles.
or TWC deteri orati on i s detected duri ng three consecuti ve dri vi ng cycl es, the ECM/PCM turns the MIL on. However, to
ease troubl eshooti ng, thi s functi on i s cancel l ed when you j ump
the servi ce check connector. The MIL wi l l then bl i nk
i mmedi atel y when an abnormal i ty occurs.
*1:
' 97
-
98 model s
*2:
' 99
-
00 model s
5.
www.emanualpro.com
PGM-FI System
Powertrain Control Module
{PCM}
-'97
Model
NOTE: l f t hi s sympt om i s i nt ermi f t ent , check f or a l oose f use No. 25 METER
(7. 5
A) i n t he
underdash f {rse/ rel ay box, a
poor
connect i on at PCM t ermi nal A18, or an i nt ermi t t ent
open i n t he GRN/ ORN wi re bet ween t he PCM
(A18)
and t he gauge assembl y.
PCM OON ECTOR A {32P}
Wire side of female terminals
PCM CONNECTOR A {32PI
Wi re si de ot t emal e t ermi nal s
11-42
The Malfunction lndicator LamD
(Ml L)
nev6r comes on {even l or
t wo seconds) af t er i gni t i on i s
t urned on
(l l l ,
or i t ' s on di ml y
and flickers.
Turn t he i gni t i on swi t ch ON {l l }.
-
Rep. i r short or opon i n t ho
wire batween No. 25 METER
(7.5
Alfuso and gauge a$m-
bt y.
-
R6pl.c No. 25 METER 17.5 Al
fus.
l s t he chargi ng syst em l i ght on?
Try t o st an t he engi ne.
Does t he engi ne st art ?
Chock t or. n open i n t h6 wi re3
{PG1, PG2l i nesl :
1. Turn the ignition switch ON
(ll).
2. Measur e vol t age bet ween
body ground and PCM con-
nect or t ermi nal s A10 and A23
i ndi vi dual l y.
Check for an opn in the wir6 or
bul b
(Ml L
l i nl :
1. Turn t he i gni t i on swi t ch OFF.
2. Connect t he PCM connect or
t ermi nal A18 t o body ground
wi t h a
i umper
wi re.
3. Turn the ignition switch ON {ll).
npei r open i n t ho wi r el sl
hwoon PCM and Glol
(loc!t.d
at thc tha.mo3tat houling thrt
htd moro th.n 1.0 V.
l s t hore l ss t han 1. 0 V?
Subst i t ut o . known-good PCM
and rcheck. ll symptom/indica-
tion goss away, rcplaca the origi-
nal PCM.
-
R6pai . open i n t h. wi l ei
belwoon rcM lAl8l dnd g.uge
a3rombly.
-
Roolac the MIL bulb.
l s t he MI L on?
Subst i t ut 6 a known-good PCM
and rocheck. ll 3ymptom/indica-
tion goes away, replace the o.igi-
n.l PCM.
PGl IBLKI
www.emanualpro.com
NOTE:
.
When t here i s no Di agnost i c Troubl e Code
(DTC)
st ored, t he MI L wi l l st ay on i f t he SCS
servi ce connect or i s connect ed and t he i gni t i on swi t ch i s on.
.
l f t hi s svmot om i s i nt ermi t t ent , check f or:
-
A l oose Fl E/ M
(15
Ai f use i n t he underdash t use/ rel ay box
-
A l oose No. 13 FUEL PUMP {15 A) f use i n t he under-dash f use/ rel ay box
-
An i nt ermi t t ent short i n t he wi re bet ween t he PCM
(C7)
and t he servi ce check con-
-
An i nt ermi t t ent short i n t he wi re bet ween t he PCM
(A18)
and t he
gauge
assembl y
-
An intermittent shon in the wire betlveen the PCM
(D4)
and the MAP sensor
-
An i nt ermi f t ent short i n t he wi re bet ween t he PCM {D10) and t he TP sensor.
PGM-Fl mai n rel ay.
' See
t he OBD l l scan t ool or Honda PGM Test er user' s manual s l or speci l i c operat i ng
i nst ruct i ons,
NOTE: An open or short i n t he wi re bet ween t he PCM
(C8)
and t he DLC wi l l keep t he
scan t ool or Honda PGM Test er l rom communi cat i ng wi t h t he PCM. You shoul d i ot erpret
t hi s as no DTCS are i ndi cat ed.
PCM CONNECTOR
c l3lPl
scs .BRNI
l To
page 11 84) Wi re si d6 of f mal e t ermi nal g
(cont' dl
11- 83
The Malfunciion lndicator Lamo
{MlL) stavs on o. comes on aftel
two seconds,
Check t he Oi egnosi i c Troubl e
Code
(DTC):
1. Connect an OBD l l scan t ool
or Honda PGM Test er.
2. Turn t he i gni t i on swi t ch ON 1l l i .
3. Read t he DTC wi t h t he scan
t ool or Honda PGI I Test er.
Go to troubleshooting
procedures
(s page 11501.
Are any DTCI s) i ndi cat ed?
Ch6ck lh6 DTC by MIL indication:
1. Turn t he i gni t i on swi t ch OFF.
2. Connect t he SCS servi ce con-
nect or t o t he ser vi ce check
connect or.
3. Turn t he i gni t i on swi t ch ON
(l l ).
-
Repair opon or short in wi.6
bet ween t he PCM
(C8)
and
Data Link Connector.
-
Go to troubloshooting
proce-
durs {3ee
page 11-601.
Does t he MI L i ndi cat e any DTc?
Try t o st art t he engi ne.
Does t he engi ne st art ?
Check t or a shor t i n t he wi r e
{SCS l i ne):
1. Turn t he i gni t i on swi t ch OFF
and t ur n t he i gni t i on swi t ch
oN f l t ).
2. Measure vol t age bet ween t he
PCM connect or t er mi nal C7
and body
ground.
Repai r short t o body
ground i n
the wire between PCM lCTl and
service check connector.
l s t here approx. 5 V?
(To page 1' l -84)
www.emanualpro.com
Powertrai n Control Modul e
(PCM)
-' 97
Model
(cont' dl
( Fr om page 11 83)
Check for a short in the wire
(MlL
l i ne):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he PCM connect or
A {32P).
3. Turn t he i gni t i on swi t ch ON
(l l ).
Repai r short t o body ground i n
the wire between the PCM {418}
and Ml L.
l s t he MI L ON?
Subst i t ut e a known- good PCM
and r echeck. l f sympt om/ i ndi ca-
tion goes away. replace the origi-
nal PCM.
I nspect Fl E/ M
(15
A) f use i n t he
undeFhood fuse/relay box.
-
Reoai r shod i n t he wi r e
bet ween Fl E/ M {15 A} f use
and PGM-FI main relav.
-
Replace FIE/M 115 A)fuse.
I nspect No. 13 FUEL PUMP
(15
Ai
f use i n t he underdash f use/ rel ay
-
Repai r shor t i n l h wi r e
bolween No. 13 FUEL PUMP
115 A) I use and PGM-FI mai n
-
Repl ace No. 13 FUEL PUMP
115
A) f use.
Check loJ a short in a sensor:
1. Turn t he i gni t ; on swi t ch ON
(l l ).
2. Di sconnect t he 3P connect or
of each sensor one at t i me:
.
MAP sensor
( To page 11- 85)
11- 84
www.emanualpro.com
(From page 11-84)
Reolace the Sensor that caused
the lighl lo go out.
Does the MIL go off.,
Check f or a short i n t he wi res
lvCC linesl:
1. Turn t he i gni t i on swi t ch oFF.
2. Di sconnect t he PCM connec
t or D
(16P).
3. Check f or cont i nui t y bet ween
body
ground and PCM connec
t or t ermi nal s D4 and Dl 0 i ndi
vi dual l y.
Repair shorl lo body ground
in the wile between the PCM
{D4} and the MAP sensor.
Repair short to body ground in
t h wi re bet ween t he PCM
lol0l and the TP sensor.
Check tor an open in the wires
l l GP l i ne3l :
1. Di sconnect t he f uel i nj ect or
connectors and IAC valve con
2. Turn t he i gni t i on swi t ch ON
(l l i .
3. [ , 4easur e vol t age bet ween
body gr ound and PCM con'
nect or t ermi nal s A' 11 and A24
i ndi vi dual l y.
-
Repai r open i n t he wi r e( sl
boiween the PCM 1A11, A24)
and the PGM-Fl main relav.
-
Chck l or poor connect i ons
or loose wires at ihe PGM-FI
main relay.
-
Tesi l he PGM-FI mai n rel av
{see
p. g6 1l -1871.
Check f or an open i n t he wi res
{LG l i nesl :
1. Turn t he i gni t i on swi t ch OFF.
2, Reconnect al l sensor connec-
t ors,
3. Reconnect the PCM connector
D
( 16P) .
4. Turn t he i gni t i on swi t ch ON
(l l ).
5, M easu r e vol t age bet ween
body
gr ound and PCM con
nect or t ermi nal s Ag a^d 422
i ndi vi dual l y.
R6pai r open i n t he wi r e{ sl
between the PCM {A9. A22l and
G101 {located at the thetmostat
housing) that had more than 1.0 V.
l s t her e l ess t han 1. 0 V?
Subst i t ut o a known-good PCM
and rechck. It symptom/indica-
tion goos away, replace the origi-
nal PCM.
PCM CONNECTOR D
(16PI
VCCl NEL/RED}
Wi re si de of f emal e t ermi nal s
PCM CONNECTOR A
(32PI
Wi r e si de of l emal e t er mi nal s
1 1- 85
www.emanualpro.com
PGM-FI System
Tho Maltunction Indicator Lamo
(MlL)
n6Yor como3 on leven lor
two laconds) rft6r tho ignhion is
turnod ON {lll.
Turn t h6 i gni t i on swi t ch ON
(l l ).
-
Repai r l hort or opcn i n t ho
wi r e bet ween t he No. 25
METER 17. 5 Al f u3e snd t he
gauge assembly.
-
Repl . co t he No. 25 METER
17.5 Al fus.
l s t he l ow oi l pressure
l i ght on?
Try to start the engine.
Chock for an opsn in th wiro or
bul b {Ml L l i ne, :
1. Turn the ignition switch OFF.
2. Connect t he ECM/ PCM con-
nect or t ermi nal A18 t o body
ground wi t h a
i umper
wi re.
3. Turn the ignition switch ON
(ll).
Rep. i r open i n t he wi . os
botween the ECM/FCM lA18l
and the gaugo
rasombly.
Roplece the MIL bulb.
l s t h6 MI L on?
Substitute a known-good ECM/
PCM and rochock. lf rymptom/
i ndi cat i on goes eway, repl ace
tho o gind ECM/PCM.
Turn t he i gni t i on swi t ch OFF.
I nspect t he Fl E/ M 115 A) t use
i n t he undeFhood f use/ rel ay
box.
-
Repai r shor t i n t he wi r e
bet ween l he Fl E/ M
(15
Al
f usG and t he PGM- Fl m. i n
.slay.
-
Ropl sce t h Fl E/ M ( 15
Al
fu3.
I nspect t he No. 13 FUEL PUMP
( 15
A) f use i n t he under - dash
fuse/relay box.
-
Repai r shor t i n t h6 wi r e
bet ween t ho No. 13 FUEL
PUMP 115 A) l use and t he
PGM-FI main .elay.
-
ReDl ace t ho No. 13 FUEL
PUMP 115 Al tuse.
Engine Gontrol Module/Powertrain Control Module
(ECM/PCM) -
'98
-
00 Models
NOTE:
.
lf this symptom is intermittent, check tor:
-
A l oose Fl E/ M {15 A) f use i n t he under-hood f use/ rel ay box
-
A l oose No. 25 METER {7. 5 A) f use i n t he under-dash f use/ rel ay box
-
A l oose No. 13 FUEL PUMP
(15
Al f use i n t he underdash f use/ rol ay box
-
An i nt ermi f t ent short i n t he wi re bet ween t he ECM/ PCM
(A18)
and t he gauge assem-
-
An i nt rmi f t ent short i n t he wi re bet ween t he ECM/ PCM
(C19)
and t he MAP sensor
-
An i nt ermi f t ent short i n t he wi re bet ween rhe ECM/ PCM
(C28),
t he TP sensor, t he
EGR val ve l i f t sensor and/ or {uel t ank Dressure sensor
-
A l aul t y PGM-FI mai n rel ay
ECM/PCM CONNECTOR A
(32P}
Wi re si de of f emal e t ermi nal s
(To page 11-871
www.emanualpro.com
Chck tor rn opon in tha wiioa
(lGP lino.):
1. Disconnectthe fuel injctor and
IAC valve connectors.
2. Turn the ignition switch ON {ll}.
3. Measur e vol t age bet ween
body ground and ECM/ PCM
connct or t ermi nal s B' l and
89 i ndi vi dual l y.
-
Repai i opon i n t h6 wi rc{3l
betw.6n tho ECM/PCM
(B1.
Bgl l nd t ho PGM- FI mai n
roby.
-
Chock for poor connactions
or loo3 wiJo3 at the PGM-FI
main ralry.
-
T. st t he PGM-FI mt i n r. l ay
(soo p.ge 11-1871.
ls there battery voltage?
Chack for an opon in tho wire3
{PG, LG lino3l:
1. Reconnect t he l uel i ni ect or
and I AC val ve connect ors.
2. Measur e vol t age bet ween
body ground and ECM/ PCM
connect or t ermi nal s 82, 810,
820 and 822 i ndi vi dual l y.
B. pai r open i n t he wi r ol t l
b. t wocn t ho ECM/ PCM . nd
G101 lloc.t6d rt th. thormoiat
houingl that had mo.e than 1 .0 V.
l st here l esst han 1. 0 V?
Chock f or a shon i n t he wi ra3
{VCCI, VCC2 lin..l:
Measure vol t age bet ween body
ground and ECM/PCN4 connector
terminals C19 and C28 individuallv.
Chock lor a short in r snsor:
Whi l e measur i ng vol t age
betwoen body ground and ECM/
PCM connect or t er mi nal s C19
and C28 i ndi vi dual l y, di sconnecl
the 3P connector ol each sensor
one at t i me:
.
TP sensor
.
Fuel t ank pressure sensor
l s t here approx. 5 V?
Rooair ahort in tho wire btwoen
tho MAP sen3or. TP sensor, Fuel
t ank Dreaaure Sonsor and t he
ECM/PCM tC19, C28).
ls there approx. 5 V?
Sub3lhuio . known-good ECM/
PCM .nd rcch6ck. lf tymptom/
i ndi c. t i on go. 3 away, rapl . ce
th. original ECM/PCM.
Repl ece t he r onsor t ht t had
approx. 5 V.
(From page 11-86)
l cont' d)
r
2 8
I 10 11
't3
17
19 20 21 23
vXv)
iiP2
rELlBLK)
I GPl
(YEL/BLK)
ECM/FCM CONNECTOR A {25PI
Wi re si de of l emal e t ermi nal s
(YEL/RED)
Wi re si de of
l emal e t ermi nal s
ECM/PCM CONNECTOR C {3'IP}
| 2 i 3 7 E s /
't6
17 18 19 20 21\22
26 27 2el E 30 31
vcc2
(YEL/BLUI
kt
vccl
11-47
www.emanualpro.com
PGM-FI System
Engine Control Module/Poweftrain Control Module
(ECM/PCM) -
'98
-
00 Models
(cont'dl
NOTE:
.
When there is no Diagnostic Trouble Code IDTC) stored, the MIL will stay on iI the SCS
service connector is connected and the ignition switch is ON
(ll).
.
lf this symptom is intermittent, check for:
-
An intermittent short in the wire between the ECM/PCM
(A10)
and the service check
connoct or
-
An i nt ermi t t ent short i n t he wi re bet ween t he ECM/ PCM
(At 8l
and t he gauge
assemDt y
.
See t he OgD l l scan t ool or Honda PGM Test er user' s manual s f or speci f i c operat i ng
rnst ruct i ons.
ECM/FCM CONNECTOF A {32P)
Wi re si de of f emsl e t 6rmi nal s
The Malfunction lndicator Lamo
lMlll 3lays on or comes on after
two 3econds.
Check t he Di rgnost i c Troubl o
Cod
(DTCI:
' 1.
Connect a scan t ool or Honda
PGM Tester.
2. Turn t he i gni t i on swi t ch ON
(l l ).
3. Read t he DTC wi t h t he scan
t ool or Honda PGM Test er.
Go to troublGhooting procadura.
(3c prg l lS0l
check tho DTc by MIL indication:
1. Turn t he i gni t i on swi t ch OFF.
2. Connect the SCS service con-
nect or t o t he servi ce check
connector,
3. Turn t he i gni t i on swi t ch ON
(l l ).
Ropair op.n ol Bhort in wiro
b.twe.n thc ECM/FCtrl
(A21)
and D.i. Link Connoctor.
Go to troublo3hootlng proc-
dur6. lt o
pag.
11.6lrl
Does t he MI L i ndi cat e any DTC?
Try to start the engine.
Sub3titute r known"good ECM/
PCM .nd roch.ck. lt .ymptom/
i ndi c. t i on gooa awsy, repl . co
the origin.l ECM/PCM.
Does t he engi ne st an?
Check t or a 3hort i n t he wi re
ISCS linel:
1. Turn t he i gni t i on swi t ch OFF
and t urn t he i gni t i on swi t ch
oN { ) .
2- Measur e vol t age bet ween
body gr ound
and t he ECM/
PCi , connecl or t ermi nal A10.
Ropria ahort to body ground
in
tho wi.c Mwe.n tho ECM/PCM
lA10l and aarvic. check connsc-
tor.
l To
page 1l -89)
1 1 - 8 8
www.emanualpro.com
Check tor a short in the wire
(MlL
linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the ECM/PCM con
nector A
(32P).
3. Turn the ignition switch ON
(lli.
Repai r short t o body
ground i n
the wire btwe.n the ECM/PCM
lA18) and tho MlL.
Substituto a known-good ECM/
PCM .nd recheck. lf symptom/
i ndi cat i on
goo3 . way, repl ace
th original ECM/PCM.
(From page 11-88)
1- 89
www.emanualpro.com
PGM-FI System
Manifold Absolute Pressure
(MAPI
Sensor
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
POl 07: A l ow i nput
(hi gh
vacuum) probl em
i n the
Mani fol d Absol ute Pressure
(MAP)
sensor,
The MAP sensor convens mani fol d absol ute pressure
i nto el ectri cal si gnal s and i nputs the ECM/pCM.
OUTPUI
VOLTAGE
t vl 3. s
3.0
2. 5
2. O
1. 5
1. 0
0. 5
o
. 5 r o - 1 5 ^
1 o
lin.H9) GAUGE
READIT{G
l mmHgl
30 25
100 200 300 a00 5oo 6fi, 7d)
MAP SENSOR 3P CONNECTOR IC131I
vccl
(YEL/RED}
Th6 MIL has ben reoorted on.
DTC P0107 is 3tored.
Problom verification:
1. Turn the ignition switch ON lll).
2. Check the lvlAP with the scan
root .
lrtormittem tailu.e, lystam b OK
at thb timo. Check tor poor con-
noctions or loosa wird at C131
(MAP
rensor) and rt t he ECM/
PCM.
l s approx. 101 kPa
(760
mmHg,
30 i n. Hg), 2. 9 V i ndi cat ed?
Check for an op6n in wi.o IVCC1
l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he MAP sensor
connector,
3. Turn the ignition switch ON {ll}.
4. Measure voltage between the
MAP sensor connect or No. 1
t ermanal and No. 2 t ermi nal .
Roprir opn in the wir6 bstween
tho ECM/PCM (D4,
C19*l and the
MAP sensor.
l s t here approx. 5 V?
( To page 11- 91)
1 1 - 9 0
Wiro side ol temale terminals
www.emanualpro.com
{From
page 11-90)
Chock tor .n open or short in the
MAP 3n30r:
Check t he MAP wi t h t he scan
t ool .
l s approx. 2 kPa
(15
mmHg,
0. 6 i n. Hg), 0. 1 V or l ess i ndi -
cated?
Chock f or a l hort i n t he wi re
(MAP linol:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he ECM/ PCM
connect or D
(16P), (C
131P))*.
3. Check f or cont i nui t y bet ween
the MAP sensor connector No.3
terminal and body
ground.
Rp.ir 3hort in the wire bstwcen
tho ECM/PCM
(D3, C17') rnd tho
MAP 3rnsoi.
Sub3lilut. . known-good ECM/
PCM and rocheck. lf normal MAP
k indic.tcd, r.pl.co thc originrl
ECM/PCM.
MAP SENSOR 3P CONNECTOR
(C131I
Wi re si de of l gmal e t ermi nal s
(cont' d)
1 1- 91
www.emanualpro.com
PGM-FI System
Manifold Absolute Pressure
(MAP)
Sensor
(cont'd)
[tn,t nn-]
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0108: A hi gh vol tage
(l ow
vacuum) probl em i n the
| j g
Mani fol d Absol ute Pressure
(MAP)
sensor.
MAP SENSOR 3P CONNECTOR IC131I
Wire side of female terminals
vccl
IYEL/RED}
PCM CONNECTOR D I16PI
JUMPER WI RE
sGl
IGRN/WHTI
Wi r e si de of l emal e t er mi n6l s
1
(To page 11, 93)
' :
' 98
-
00 model s
1-92
tcRN/wHrll IIRED/GRN|
The MIL has boen reported on.
DTC m108 is slored.
Problem veritication:
1 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
the radiator fan comes on, then
let it idle.
2. Check t he MAP wi t h t he scan
t ool .
Intermittent tailuro, system i3 OK
at this time. Check tor ooor con-
nections or loose wires at C131
IMAP s6nsor) snd the ECM/rcM.
l s 101 kPa {760 mmHg, 30 i n. Hg),
2. 9 V or hi gher i ndi cat ed?
Check I or an open i n t he MAP
sensor:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he MAP sensor
3P connect or.
3. lnstall a
jumper
wire between
t he MAP sensor 3P connect or
t ermi nal s No. 3 and No. 2.
4. Turn t he i gni t i on swi t ch ON {l l ).
5. Check t he MAP wi t h t he scan
t ool .
l s 10' l kPa
(760
mmHg, 30 i n. Hg),
2. 9 V or hi gher i ndi cat ed?
Check for an open in wire
(SGl
l i Del :
1. Remove t he
j umper
wi re.
2. Measure vol t age bet ween t he
MAP sensor 3P connector ter-
mi nal s No. 1 and No- 2.
R6p.ir open in the wire betwoen
the ECM/PCM (D12,
CTrl and the
MAP sensor.
l s t here approx. 5 V?
Check f or an open i n t he wi re
(MAP
line):
1. Turn t he i gni t i on swi t ch OFF.
2. l nst al l a
i umper
wi re on t he
PCM connect ors bet ween D3
and D12.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Check t he MAP wi rh t he scan
tool.
Ropair opon in the wire between
the PCM {D3, .nd the MAP son-
3(' t.
l s 101 kPa 1760 mmHg, 30 i n. Hg),
2. 9 V or hi gher i ndi cat ed?
YES
www.emanualpro.com
(From page 11-92)
Check f or an open i n t he wi re
{MAP
l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. I nst al l a
j umPer wi r e on t he
ECM/PCM connectors betlveen
C7 and C17.
3. Turn t he i gni t i on swi t ch ON
(l l )
4. Check t he MAP wi t h t he scan
t ool .
Bopair opn in the wi.es between
the ECM/PCM
(c1?l and the MAP
5en30t.
l s 101 kPa
(760 mmHg, 30 i n. Hg),
2. 9 V or hi gher i ndi cat ed?
Substitute a known'good ECM/
PCM and recheck. lf normal MAP
k indicated, replace the o.iginal
ECM/PCM,
I
(cont' d)
1 1 - 9 3
www.emanualpro.com
PGM-FI System
Manifold Absolute Pressure
(MAP)
Sensor
(cont'dl
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1128: Mani fol d Absol ute
pressure
(MAp)
l ower than
exoected.
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P' l 129: Mani fol d Absol ute Pressure
(MAP)
hi gher than
expected.
l
-
The MIL has be6n rported on.
-
DTC Pl128 is stored.
Problom verification:
1. Turn t he i gni t i on swi t ch ON 1l l i .
2. Check t he MAP wi t h t he scan
t ool ,
l s 54. 1 kPa
(406
mmHg, 16. 0 i n. Hg),
1. 61 V or hi gher i ndi cat ed?
I to.mittent failure, 3ydom i! OK
al thbtimc,
-
The MIL has boen reportod on.
-
DTC Pl129 is stored.
Problem veritication:
1 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad l i n Park or neut ral ) unt i l
t he r adi at or f an comes on,
t hen I et i t i dl e.
2. Check t he MAP wi t h t he scan
t ool ,
l s 43. 3 kPa
(325
mmHg, 12. 8 i n. Hg),
' 1. 32
V or l ess i ndi cat ed?
Intarmittani fuilure, systom i3 OK
at this time.
11- 94
www.emanualpro.com
The IAT Sensor i s a temperature dependant resi stor
(thermi stor). The resi stance of the thermi stor decreases as the i ntake
ai r temDerature i ncreases as shown bel ow
RESISTANCE IKOI
Intake Air Temperature
(lAT)
Sensor
1P0111 |
(' 97
model )
The scan tool i ndi cates Di agnosti c Troubl e code
(DTC)
P0111: A ranoe/performance
probl em i n
the l ntake Ai r TemDerature
(l AT)
Sensor ci rcui t.
. 3' aa ro. r?a arl ,.t r.fl
20 0 to ao ao aa ioo t2otocl
INTAKE AIB TEMPERATURE
-
The MIL has been reported on.
-
DTC P0111 is stored.
-
Or lrom Probable Cause List.
Problem vetification:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he I AT sensor 2P
connect or,
3. Remove t he I AT sensor.
4. Reconnect t he I AT sensor 2P
connect or,
5. Leave t he I AT sensor et posed
t o ambi ent t emPerat ure.
6. Tur n t he i gni t i on swi t ch ON
fl r).
7. check t he I AT wi t h t he scan
t ool -
Rplace the IAT son3or.
Check the IAT sensor output:
1. Warm t he I AT sensor wi t h a
hai r dryer.
2. Check t he I AT wi t h t he scan
t ool .
Di d t he I AT ri se 2. 0' F
(1. 0' C)
or more f rom t he ambi ent
temperature?
Intermittent f.ilure, aY3tem is OK
ai this tim6.
Replace the IAT sensor.
(cont' d)
1 1- 95
www.emanualpro.com
PGM-FI System
Intake Air Temperature (lAT)
Sensor
(cont'dl
The scan tool i ndi cates Di agnosti c Troubl e code
(DTC)
P0112: A l ow vol tage (hi gh
temperature) probl em
i n the
Intake Ai r Temperature
0AT) sensor ci rcui t.
The IAT Sensor i s a temperature dependant resi stor (thermi stor).
The resi stance of tho thermi stor decreases as the i ntake
ai r temperature i ncreases as shown bel ow.
RESISTANCE
IKO)
i ' )
) 2 /
A
tAr
9)
(RED/YEU
-L
-.
32 aa rorr 1?a 2ra 2aa
f.el
-m
0 20 rto
ao i0 too l2ofcl
INTAKE AIR TEMPERATUR
I t t he engi ne i s warm, i t wi l l b hi gh-
er t han ambi ent t emperat ure.
IAT SENSOR 2P CONNCCTOR (C'33I
-
The MIL has been reDoned on.
-
OTC m112 is stored,
-
Or from Probable Caus List.
Problem vsrification:
1. Turn t he i gni t i on swi t ch ON f l t ).
2. Check t he I AT wi t h t he scan
t ool .
l s 302' F
(150' C)
or hi gher
(or
H- L i mi t i n Ho n d a mo d e o f
PGM Test eri or 0 V i ndi cat ed?
l s t he correct ambi ent t emper-
at ure i ndi cat ed, , ?
Beploce tho IAT sensor.
Intermittent failure, system i3 OK
at this time. Ch6ck for poor con-
nectiona o. loose wires rt C133
{lAT snsorl and rt th6 ECM/pCtr4.
Check for a short in the IAT sen-
sot:
1. Di sconnect t he I AT sensor 2p
2. Check t he I AT wi t h t he scan
t ool .
l s 302"F {150"C) or hi gher {or
H- L i mi t i n Ho n d a mo d e o f
PGM Test er) or 0 V i ndi cat ed?
Raplace the lAT aensor.
Chck for a short in the wir6 llAt
l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the ECM/PCM con-
nect or {D
(16P},
C
(31P)' ).
3. Check f or cont i nui t y bet ween
the IAT sensor 2P connector ter
mi nal No. 2 and body ground.
Repair short in the wi.o botween
th6 ECM/rcM
{D8, C25*l and th6
IAT 3ensor.
Substitute a known-good ECM/
PCM and recheck. lf normel IAT
is indicaled, replace the original
ECM/PCM,
*:
' 98
-
00 model s
1 1- 96
Wi 16 si de of f emsl e t ermi nal s
www.emanualpro.com
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0113: A hi gh vol tage
(l ow
temperature)
probl em i n the
Intake Ai r Temperature
(l AT)
sensor ci rcui t.
IAT SENSOR 2P CONNECTOR ICl33I
sG2
{GRN/BIIO
JUMPEN WNE
IAT IRED/YELI
Wire side ol female terminals
YES
_! ! 7r qd9l l _____-
FCM CONNECTOR O IT6PI
IAT IRED/YEL)
sG2
IGRN/BLK}
JUMPER w|BE
Wi re si de of femal e termi nal s
l
(cont' d)
11-97
The MIL has been reported on.
OTC P0113 is stored.
Problem vrification:
1. Turn t he i gni t i on swi t ch ON
(l l ).
2. Check t he I AT wi t h t he scan
t ool ,
Intermiftent failure, syatem is OK
at this time. Ch.ck for Door con-
nections or loose wires at c133
l l AT s6nsor l and at t he ECM/
PCM.
l s
-4' F (-20"C)
or l ess
(or
L Li mi t
i n Honda mode of PGM Test er)or
5 V i ndi cat ed?
Check lor an open in the IAT sen-
sor:
1. Di sconnect t he I AT sensor 2P
connector,
2. Connect the IAT sensor 2P con
nect or t er mi nal s No. 1 and
No. 2 wi t h a
, umper
wi re.
3. Check t he i nt ake ai r t empera'
t ure wi t h t he scan t ool .
l s
-4' F (-20"C)
or l ess
(or
L-Li mi t
i n Honda mode oI PGM Test er)or
5 V i ndi cat ed?
Replace the IAT sensor.
Check l or en opan i n t he wi res
llAT, SG2 lines):
1. Turn t he i gni t i on swi t ch OFF.
2. Connect PCM connect or t er-
mi n a l s D8 a n d D1 1 wi t h a
3. Turn t he i gni t i on swi t ch ON l l l ).
4. Check t he I AT wi t h t he scan
t ool .
Rgpair open in the wires btween
t he PcM
(D8.
D11) and rhe I AT
3en30r,
l s
-4"F
{-20"C) or I ess
(or
Ll i mi t
i n Honda mode ot PGM Test er)or
5 V i ndi cat ed?
(To page 11-98)
www.emanualpro.com
PGM-FI System
Check f or an open i n t he wi res
{l AT, SG2l i nes):
1. Turn t he i gni t i on swi t ch OFF.
2. Connect ECM/ PCM connect or
t ermi nal s C18 and C25 wi t h a
j umper
wi re.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Check t he I AT wi t h t he scan
t ool .
l s
-4' F
1-20"C) or l ess
(or
L l i mi t
i n Honda mode of PGM Test eri or
5 V i ndi cat ed?
Repsir opn in the wirca batween
the ECM/PCM
1C18, C25l and the
IAT snsor.
Substitute a known-good ECM/
PCM rnd recheck, lf normal IAT
is indicated, leplaco the originsl
ECM/PCM.
Intake Air Temperature
(lATl
Sensor
(cont'd)
(From page 11, 97)
'l
ECM/PCM CINNECTOR C t3lPl
2 5 7 I I
./
16 17 18 19 20 21 22
23
4 Wp,
29 c) 31
sG2
IAT {RED/YELI
{GRN/BLK)
JUMPER WIRE
Wi re si de of f ernal e t ermi nal s
I
1 1- 98
www.emanualpro.com
Engi ne Gool ant Temperature
(ECTI
Sensor
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0116: A range/performance
probl em i n the Engi ne
Cool ant Temperature
(ECT)
Sensor ci rcui t.
The ECT Sensor i s a temperature dependant resi stor
(thermi stor). The resi stance of the thermi stor decreases as the engi ne
cool ant temperature i ncreases as shown bel ow
RESISTANCE
t k0l
NOTE: l f DTC P0117 and/or P0118 are stored at the same
bl eshoot DTC P0116.
Possible Cause
a ECT sensor deteri orati on
. Mal functi on i n the thermostat and cool i ng system
Troubleshooting Flowchart
- 4
32 68 r 0a r a0176 212 2aE { ' r )
-2O
O 20
ito
tO .o ! t2O I c)
ENGINE COOLANT TEMPERATURE
ti me as DTC P0116, troubl eshoot those DTCS fi rst, then trou-
THERMISTON
-
The MIL has ben roported on.
-
DTC P01'16 is stored.
Probl6m verification:
1 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
t he r adi at or f an comes on,
t hen l et i t i dl e.
2. Wi t h t he scan t ool , check t he
ECT.
Intermittent failure, sYstem b OK
at this tim6. Check lhe thermo-
stat and the cooling 5y3tom.
l s 176
-
200' F
(80 -
93"C) or
0. 4- 0. TVi ndi cat ed?
Check t he t hermost at and t he
cool i ng syst em. I t t hy are OK,
reolace the ECT seNor.
(cont' d)
1 1- 99
www.emanualpro.com
PGM-FI System
Engine Coolant Temperature
(ECTI
Sensor
{cont'd)
[F011'
The.scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0117: A l ow vol tage
(hi gh
temperature) probl em i n the
:
Engi ne Cool ant Temperature
(ECT)
sensor ci rcui t.
ECT SENSOR 2P CONNECTOR {C114I
Wi re si de of f emal e t ermi nal s
-
The MIL has been rooortod on.
-
DTC ml17 is sto.od.
Problem verification:
1. Turn the ignition switch ON {ll).
2. Check t he ECT wi t h t he scan
t ool ,
Intermittont f.ilure, sysiom is OK
at thk time. Check for
poor
con-
nections or loo3e wire3 at C1lil
(ECT
sensorl and et t he ECM/
PCM.
l s 302"F
(150' C)
or hi gher
(or
H Li mi t i n Honda mode ot
PGM Test er) or 0 V i ndi cat ed?
Check for a Bhort in the ECT sen-
301:
' 1.
Di sconnect t he ECT sensor 2P
connefior,
2. Check t he ECT wi t h t he scan
t ool .
l s 302"F
(150"C)or
hi gher
(or
H-Li mi t i n Honda mode of
PGM Test er) or 0 V i ndi cat ed?
Check f or r shor l i n t he wi r s
(EgT
l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the ECM/PCM con-
nect or D
(16P), (C (31P)*1.
3. Check t or cont i nui t y bet ween
the ECT sensor 2P connectorter
minal No. 1 and bodyground.
Repair short in the wir between
the ECM/FCM (D2,
C26rl ,nd th6
ECT senaor.
l s t here cont i nui t y?
Substitute a known-good ECM/
PCM and recheck. It normal ECT
i! indicatod, replaco the oiiginal
ECM/PCM.
*: ' 98
-
00 model s
1- 1
www.emanualpro.com
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P0118: A hi gh vol tage {l ow temperature)
probl em i n the
Engi ne Cool ant Temperature
(ECT)
sensor ci rcui t.
ECT SENSOR 2P CONNECTOB
(C11ill
ECT
(ncD/wlrT)
ECT
IREDAAIHT)
Wirc side of lemale terminals
sG2
(GRN/8LKI
PCM CONNECTOR D {T6PI
JUMPER WIRE
JUi,IPEB WNE
IGRN/BLX}
Wi re si de oI f emal e t ermi nal s
(cont' d)
1 1 - 1 0 1
The MIL has ben reported on.
DTC P01'18 is stord.
Problem verification:
1. Turn t he i gni t i on swi t ch ON {l l ).
2. Check t he EcT wi t h t he scan
t ool -
Intermiftent tailu.,3ystem is OK
at this time, Checl foJ
poor
con-
nction3 or loose wires et C1'14
(ECT
ren3or) and at t he ECM/
PCM.
l s
-4"F (-20' C)
or l ess
(or
L-Li mi t
i n Honda mode ot PGM Test er) or
5 V i ndi cat ed?
Check for an open in the ECT sen-
1. Di sconnect t he ECT sensor 2P
connect or.
2. Connect t he ECT sensor 2P
connect or t ermi nal s No. 1 and
No. 2 wi t h a
j umper wi re.
3. Check t he ECT wi t h t he scan
tool.
ls
-4'F (-20'C)
or less
(or
L'Limit
i n Honda mode of PGM Test er)or
5 V i ndi cat ed?
Check f or an open i n t he wi i es
{ECT, SG2 lines):
1. Turn t he i gni t i on swi t ch OFF.
2. Connect PCM connect or t er
mi n a l s D2 a n d D1 1 wi t h a
i umper
wi re.
3. Turn the ignition switch ON {ll}.
4. Check t he ECT wi t h t he scan
t ool ,
l s
-4"F (-20' C)
or l ess
(or
L-Li mi t
i n Honda mode of PGM Test eri or
5 V i ndi cat ed?
Repair open in th6 wire! botwen
t he PCM l D2, D' l 1l and t he ECT
3n30t.
(' 97
model )
(To page 11-102)
www.emanualpro.com
PGM-FI System
Chack l or an open i n t he wi res
(ECT,
SG2 lines):
1. Turn t he i gni t i on swi t ch OFF.
2. Connect ECM/ PCM connect or
t ermi nal s C18 and C26 wi t h a
3. Turn the ignition switch ON
(ll).
4. Check t he ECT wi t h t he scan
t ool .
l s
-4"F (-20"C)
or l ess (or
L-Li mi t
i n Honda mode of PGM Test erl or
5 V i ndi cat ed?
Ralpair open in tho wir6s b6twen
tho ECM/PCM 1C18, c26l 6nd tho
ECT sensor.
Substitute a known-good ECM/
PCM and rech.ck. lf normal ECT
is indicrted, replace ths originsl
ECM/PCM.
Engine Goolant Temperature
(ECTI
Sensor
(cont'dl
( Fr om page 11 101)
ECM/PCM OONNECTOR C 13lPI
(GRN/BLK)
JUMPER WIRE
Wi re si de of t emal e t ermi nal s
1 7 I 9
,/ 16 17
't8 '19
20 n
ECT IRED/WHTI sG2
11- 102
www.emanualpro.com
Throttle Position
(TPl
Sensor
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0122: A l ow i nput
(vol tage) probl em i n the Throttl e
Posi ti on
(TP)
sensor ci rcui t.
The TP Sensor i s a
potenti ometer. l t i s connocted to the throttl e val ve shaft. As the throttl e posi ti on changes, the throftl e
posi ti on sensor vari es the vol tage si gnal to the ECM/PCM.
'97
mod6l: BRUSH
HOI,I'ER
OUTPUT VOLTAGE IVI
5
4
3
2
1
0
THROITLE
OPCNIiIG
FUTI
IHROTTI"E
TP SENSOR 3P CONNECTOR {Cl3OI
vcc2
IYEL/BLUI
Wi.6 6ide ot fgmale terminsls
PCM CONNECTOR D I16PI
Wi re si de of f emal e t ermi nal s
(GRN/BLX)
-
The MIL h.3 been reoorted on.
-
OTC m122 b 3tored.
Problem vorificalion:
1 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral l unt i l
t he r adi at or f an comes on,
t hen t urn t he i gni t i on swi t ch
OFF.
2. Turn the ignition switch ON
(ll).
3. Check t he t hr ot t l e
posi t i on
wi t h t he scan t ool .
ls there approx. 10% when the
throttle is fully closed and
approx.90% when the throttle
is fully opened?
Intormittent feilu?e, 3y3tem is OK
at thb iime. Check tor poor con-
nodiona or loose wiros at C130
tTP loNorl .nd rt th PCM.
Check t or an open i n t he wi re
{vOC2linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he TP sensor 3P
connect or,
3. Turn the ignition switch ON lll).
i l . Measure vol t age bet ween
the TP sensor 3P connector ter-
mi nal s No. 1 and No. 3.
l s t here approx. 5 V?
Check to. an open in wir6 {VCC2
l i nel :
Measure vol t age bet ween PCM
connect or t ermi nal s 010 and D11.
Ch6ck to. an opon or shon in TP
sonaol:
1. Turn t he i gni t i on swi t ch OFF.
2, At t he sensor si de, measure
r esi st ance bet ween t he TP
sensor 3P connector terminals
No. 1 and No. 2 wi t h t he t hrot -
t l e f ul l y cl osed.
Repair open in the wirc between
PCM {D10} and TP 3ensor.
l s t here approx. 5 V?
Sub3tituto . known-good PCM
and rechock. It
proscribed volt-
ag. b now availablo. rcplaco th6
originsl PCM,
Termi nal si de of mal e t ermi nal s
(cont' d)
( To page 11- 104)
1 1 - 1 0 3
www.emanualpro.com
PGM-FI System
(From page 11 103)
l s t here approx. 0. 5
-
0. 9 kO?
Chock for an open or short in the
TP sensor:
Measure resi st ance bet ween t he
TP sensor 3P connect or t er mi n-
n a l s No . 2 a n d No . 3 wi t h t h e
throttle t!lly closed.
l s t here approx. 4. 5 kO?
Check t o. an open i n t he PCM
(TPS
l i nel l
1. Reconnect t he TP sensor 3P
connector.
2. Turn t he i gni t i on swi t ch ON
(l l ).
3. Measur e vol t age bet ween
PCM connect or D
(16P)
t ermi -
nal s D1 and D1l .
Subst i t ut e a known-good PCM
and recheck. It orescribod volt-
age is now available, roplaco the
o.iginal PCM.
l s t here approx. 0. 5 V when t he
throftle is fully closed and
approx. 4.5 V when the throttle
i s f ul l y opened?
Repair short in the wire bstween
t he PCM l Dl )snd t he TP ssnso. .
Throttle Position
(TP)
Sensor
(cont'd)
TP SENSOR 3P CONNECTOR
Termi nal si de of mal e t ermi nal s
PCM CONNECTOR D I16PI
TPS
IREO/
BLK)
SG2
(GRN/BLKI
Wi re si de ol f emal e t ermi nal s
11- 104
I
www.emanualpro.com
'98
-
00 model3:
The MIL has boon reDortod on.
DTC m122 b rtorod.
P.oblom veiification:
1. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
t he r adi at or t an comes on,
t hen t urn t he i gni t i on swi t ch
OFF.
2. Turn the ignition switch ON lll).
3. Check t he t hr ot t l e
posi t i on
wi t h t he scan t ool .
l s t here approx. 10% when t he
throttle is fully closed and
approx. 90% when the throttle
is fully opened?
Intarmittent failure. system is OK
at thia time. Check for poor con-
nctions or loolo wires rt C130
ITP s.nsorl and.t the ECM/FCM.
Check for an opon or short in tho
wire {VCC2 linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he TP sensor 3P
connedor,
3. Turn the ignition switch ON
(ll).
4. Meas! r e vol t age bet ween
the TP snsor 3P connector ter-
mi nal s No. 1 and No. 3.
l s t here approx. 5 V?
Check lor an opon in wiro IVCC2
l i nel :
Measure vol t age bet ween ECM/
rcM connector terminals C'18 and
c2a.
Chock for en opn or Bhort in TP
3an30r:
1. Turn t he i gni t i on swi t ch OFF.
2. At t he sensor si de, measure
r esi st ance bet ween t he TP
sensor 3P conneclor terminals
No. 1 and No. 2 with the throt-
t l e f ul l y cl osed.
B.psir opon in the wire b{woon
tho ECM/PCM {C281 and th6 TP
3en!xtt.
l s l her approx. 5 V?
Subslitute e known-good ECM/
PCM .nd r.chock. lf pro3cribed
voltrge iB now rYrilablo, replaca
th. originll ECM/PCM.
TP SENSOR 3P CONNECTOR {C130}
sG2
IGRN/BLKI
vcc2
IYEUBLUI
Wire side oI Iemale lerminals
Wi re si d6 of t emal e t ermi nal s
Termi nal si de of mal e t ormi nal s
(cont' d)
1 1 - 1 0 5
ECM/PCM CONNECTOR C
(31P}
sG2IGRN/BLKI
a -
, l
1 8
s l . / | 1 3 5
/ 1 6 17
l rs] zol zr
zzl
23 25 27)
gJ
l zgi 3o
sr
I
T ^
vccz {YEL/8LUl
(To page 11-106)
www.emanualpro.com
PGM-FI System
TP SENSOR 3P CONNECTOR
Terminal side of mal6 terminals
(GRN/BLKI
Wi re si de ol t emal e t ormi nal s
Throttle Position
(TPl
Sensor
(cont'dl
(From p6ge 11-105)
ls there approx. 0.5
-
0.9 kO?
Chock for rn opn or 3hort in tho
TP sonsor
Measure resistance between the
TP sensor 3P connector terminals
No. 2 and No. 3 with the throttle
fully closed.
ls thre approx. 4.5 k0?
Check lor an open in the ECM/
PCM ITPS linel:
1. Reconnect t he TP sensor con'
nector.
2. Turn the ignition switch ON {ll).
3. Measur e vol t age bet ween
ECM/ PCM connect or C
(31P)
t ermi nal s C18 and C27.
ls thgre 6pprox.0.5 V when the
throttle is Iully closed and
approx.4.5 V when the throttle
is lully opened?
Subrtituto . known-good ECM/
PCM rnd rocheok. lI
pro.cribed
voltaga ia now rvailablc, rcpl.ce
th. o.igln.l ECM/PCM.
Raoai. ahort in th wira lrltw.an
the ECM/PCM
(C181
lnd th TP
3n3rot.
ECM/PCM CONNECTOR C {31P}
I 3 7 l
l a I
16 17 t 8 19l m
23 27 t l l 2e30 31
TPS IRED/BLK)
Lle
{9}
1 1 - 1 0 6
www.emanualpro.com
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0123: A hi gh vol tage probl em i n the Throttl e Posi ti on
(TP)
sensor ci rcui t.
TP SENSOR 3P @]{NECTOR IC13O}
sG2
(GnN/Br.Xl
vocr
tYEt /8LU)
{GBIT/BLKI
(cont' d)
11- 107
Wiro side of fom.le terminals
PCM CON'{ECTOF D I16PI
Wire side ot female terhinals
The MIL hlr brn r.9ort.d on.
DTC P0123 ir stored.
Pioblom vorificltion:
1. St ar t t he ongi n6. Hol d t h
ongi ne at 3, 000 rpm wi t h no
l oad {i n Park or neut ral ) unt i l
t h6 r adi at or f an comes on.
t hen t urn t he i gni t i on swi t ch
OFF,
2. Turn the ignition switch ON
(ll).
3. Check t he t hr ot t l e
posi t i on
wi t h t he scan t ool .
Intarmittant tailuro, ryrtern b OK
at this timo. Chock lor poor con-
nections or loo3o wir3 at C130
ITP 3orcorl .nd at tho ECM/FCM.
ls there spprox. 1oyo when tho
throttle is Iully closed and
approx.90% when the throttle
is tully opend?
Choct toJ an opcn in th6 TP s6n-
3t']:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he TP sensor 3P
connectol,
3. Turn the ignition switch ON
(ll).
4. At the wir6 harnoss side, mea-
suro vol t age bet weon t hg TP
sensor 3P connector trminals
No. 1 and No. 3.
l s t here approx. 5 V?
Chack f or an oDan i n t ha wi ra
(SG2
linel:
M6asu16 vol t age b6t ween PCM
connctor terminals Dl0 and D'! 1.
R.pai. opcn in tha wira botwcon
t ho PcM {o111 rnd t he TP 3en-
3(' t,
ls there approx. 5 V?
(' 97
model )
(To page 11-108)
www.emanualpro.com
PGM-FI System
(From page 11-107)
Check l or an open i n t he wi rc
(SG2l i ne):
Measure vol t age bet ween ECM/
PCM connect or C
(31P)
t ermi nal s
C18 and C28.
Ropair open in th wire betweon
rhe ECM/ PCM
(Cl 81
. nd t he TP
56nSOl,
l s t here approx. 5 V?
Substitute a known-good ECM/
PCM and rocheck. l f pre3cri bed
voltago is now avaibble, replace
tho origin.l ECM/PCM,
Throttle Position
(TP)
Sensor
(cont'dl
ECM/PCM CONNECTOR C {31PI
Wi re si de of t emal e t ermi nal s
1 1 - 1 0 8 www.emanualpro.com
-
The MIL has been reported on.
-
DTC Pl 121 i s st ored,
Problem veritication:
1. Turn t he i gni t i on swi t ch ON
(l l ).
2. Check t he t hr ot t l e posi t i on
wi t h t he scan t ool .
l s 14. 1%
(12. 97. )*
or hi gher
indicated when the throttle is
f ul l y opened?
Intormittent failur6, systom is OK
at this lime.
-
The MIL has ben reoorted on.
-
OTC P1122 is dored.
Problem verification:
1. Turn t he i gni t i on swi t ch ON l l l ).
2. Check t he t hr ot t l e
posi t i on
wi t h t he scan t ool .
l s' 17. 670
(16. 9%)'
or l ess
indicated when the throftle is
lully closed?
IntermitteDt tailu.o, system is OK
at thb time.
Pl 121
l Thescantool
i ndi cates Di agnosti c Troubl e Code {DTC) Pl 121;Throttl e Posi ti on
(TP)
l owerthan expected.
I
Pl 122 |
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1122: Throttl e Posi ti on
(TP)
hi gherthan expected.
*: ' 99 -
00 model s
1 - 1 0 9
www.emanualpro.com
PGM-FI System
Primary Heated Oxygen Sensor
(Primary
HO2S)
(Sensor
1)
The Heated Oxygen Sensors
(HO2S)
detect the oxygen content i n the exhaust gas and si gnal the ECM/PCM. In operati on,
the ECM/PCM recei ves the si gnal s from the sensor and vari es the durati on duri ng whi ch fuel i s i ni ected. To stabi l i ze the
sensor' s output, the sensor has an i nternal heater. The Pri mary HO2S
(Sensor
1) i s i nstal l ed i n exhaust pi pe A.
HO2S:
ztRcoNtA
EI.IMENT
sNsoR
TERMINALS
VOLTAGE IVI
HEATEB
TERMINALS
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0131: A l ow vol tage
Oxygen Sensor
(HO2S)
{Sensor 1} ci rcui t,
RICH
-
AIR.
.
LEAN
FUEL
NATO
probl em i n the Pri mary Heated
37
-
98 model s:
HEATER
The MIL has been reoorted on.
DTC P0131 is stoied.
Problem verification:
1. Do t he ECM/ PCM Reset Pro-
ceoure.
St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
t he radi at or f an comes on.
Test -dri ve wi t h t he A/ T i n
E
position (M/T
in 4th gear)
Check t he Pr i mar y HO2S
{Sensor 1} output voltage with
t he scan t ool duri ng accel era-
tion using wide open throttle.
Intermittent f.ilure, system is OK
at this time. Check fo. poor
con-
nections or loose wirer at C111
(Primary
HO2S, SeGor 1) and at
rh ECM/FCM.
Check the fuel pressure (see page
11- 178) .
Repair the fuel supply system.
{ To
page 11' 111}
1 1 - 1 1 0
www.emanualpro.com
{ Fr om
page 11- 110}
Check tor a shorl in the HO2S:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he Pri mary HO2S
(Sensor' 1i
4P connect or.
3. St art t he engi ne and l et i t i dl e.
4. Check t he Pr i mar y HO2S
(Sensor
1)out put vol t age wi t h
t he scan t ool .
Replace the HO2S {Sensor 1). Does it stay at 0.1 V or less?
Check f or a short i n t he wi r
(PH02S linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the ECM/PCM con-
nect or
(D (16P),
C
(31P)*).
3. Check t or cont i nui t y bet ween
t he Pri mary HO2S {Sensor 1)
4P connect or t er mi nal No. 1
and body ground.
Repair short in tho wire botwesn
the ECM/PCM lD7, C16*) .nd th6
Prim.ry HO2S
(Snsor
11.
Substituto a known-good ECM/
PCM and recheck. ll 3ympiom/
indication goes away. raplace th.
origin.l ECM/PCM.
PRIMARY HO2S ls.n.or
'l
I 4P CONNECTOR
(Cl111
PHO2S
---'t
rwHTr T-T-l
T- 1
1 2 l
6 t l r r l
Y
r___J_J
L
Wi re si de of t emal e t ermi nal s
(cont' d)
11- 111
www.emanualpro.com
PGM-FI System
'99
-
00 models:
-
The MIL has bsen reported on.
-
DTC P0131 ir storod.
Problem ve fication:
1. Do t he ECM/ PCM Reset Pro-
cedure,
2. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad {i n Park or neut ral ) unt i l
l he radi at or t an comes on.
3. Check t he Pr i mar y HO2S
(Sensor
1) oltput voltage with
t he scan t ool duri ng accel era-
tion using wide opn throttle.
Inl.rmittant failura, 3yrtam i! OK
at thb tim.. Ch.ck tor poor
con-
nectiona oa looaa wlraa al C111
{Pri|n.ry HO2S, Son3or 1l .nd .t
tho ECM/FCM,
Does the voltage stay at 0.5 V
or l ess?
Check tho fuel pressure (see pago
1r , 178) .
R.p.ir th. ful lupply ry!t.m.
Chock lor a short in tho HO2S:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the Primary HO2S
(Sensor
1) 4P connect or.
3. St 6rt t he engi ne and l ot i t i dl e.
4. Check t he Pr i mar y HO2S
(Sensor
1) output voltage with
t he scan t ool ,
Does it stay 6t 0.5 V or less? Rephc. th6 HO2S
(S.n3or
11.
Chock f or a short i n t ho wi rc
(PHO2S
lino):
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the ECM/PCM con-
nect or C
(31P).
3. Check tor continlity between
t he Pri mary HO2S {Sensor
' l }
4P connect or t ermi nal No. I
and body ground.
Ragah rhort in tha wira balwoan
t h. ECM/ PCM { Cl 61 r nd t hc
Prirn.ry HO2S
(S.n3or
11.
Substltut6 a known-good ECM/
PCM and recheck. lf rymptom/
indicrtion
00os
away, raplaco thc
original ECM/PCM.
Primary Heated Oxygen Sensor
(Primary
HO2SI
(Sensor
1l
(cont'd)
PRIMARY HO2S
(Son.or
1l aP CONNECTOR |C111)
PHO2S
T--1
rwHTr f-T---]
- - 1
1 2 l
I t--- 1
t 6 ) l s l r l
v
L__r__J
_L
Wi re si de ol f emal e t ermi nal s
11- 112
www.emanualpro.com
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0132: A hi gh vol tage probl em i n the Pri mary Heated
Oxygen Sensor {Pri mary HO2S)
(Sensor
1) ci rcui t.
'97
-
98 models:
PHO2S
IWHTI
sG2
IGRN/
BLK}
Wi re si de ot f emal e t ermi nal s
PCM CONNECTOR D {16PI
JUMPER WIRE
PHO2S IWHTI SG2 IGRN/BLK}
Wi re si de of t emal e t ermi nal s
I
(cont'dl
1 1 - 1 1 3
Problem verification:
1. Do t he ECM/ PCM Resot Pro,
ceout e,
2. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad (i n
Park or neut ral ) unt i l
t he radi at or f an comes on.
3. Test-drive with the Ay'T in
E
posi t i on (M/ T
i n 4t h gear).
4. Check t he Pr i mar y H02S
{Sensor 1}out put vol t age wi t h
t he scan t ool duri ng decel era-
t i on usi ng compl et el y cl osed
throttle.
Intormittent l.ilure, 3ystem ia OK
at thb timo. Chcck fo.
poor
con-
nect i ons 01 l ooso wi . es at C111
{Pri m! ry HO2S, Sensor 1} and
ECM/PCM.
Does the voltage stay at 1.0 V
Check for an open in th6 Primary
H()2S:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he Pri mary HO2S
(Sensor
1) connect or-
3. Connect t he Pr i mar y HO25
l Sensor 1) 4P connect or t ermi -
nal s No. 1 and No. 2 wi t h a
j umper
wi re.
4. Turn t he i gni t i on swi t ch ON
(l l ).
5. Check t he Pr i mar y HO2S
(Sensor
1) output voltage with
the scan tool,
l s t here 1. 0 V or more?
Chck for an opon in the wires
(PHO2S,
SG2linesl:
1. Turn t he i gni t i on swi t ch OFF.
2. Connect PCM connect or t er-
mi n a l s D7 a n d Dl 1 wi t h a
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Check t he Pr i mar y HO2S
{Sensor 1) output voltage with
the scan tool.
Roprir opon in the wire betweon
t ho PCM { D7 01 D11l and t he
Primsry HO2S {S6nsor 1).
l s t here 1. 0 V or more?
{ ' 97 model }
{ To
page
11- 114)
www.emanualpro.com
PGM-FI System
Primary Heated Oxygen Sensor lPrimary
HO2S)
{Sensor
1}
{cont'dl
( Fr om page' 11- l 13)
ECM/PCM CONNECTOR C {31PI
11- 114
Ch. ck f or an open i n t he wi re
(PHO2S linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Connect ECM/ PCM connect or
t ermi nal s C16 and C18 wi t h a
3. Turn t he i gni t i on swi t ch ON {l l ).
4. Check t he Pr i mar l y H02S
(Sensor
1) out put vol t age wi t h
t he scan t ool .
Rp.ir open in the wire bqtwen
t he ECM/ PCM
( C161
and t h
Primary HO2S
(Sen.or'l).
l s t here 1, 0 V or more?
Substitute a known-good ECM/
PCM and rachck. l t 3ympt om/
i ndi cat i on
goos
away, repl ace
the origin.l ECM/PCM.
www.emanualpro.com
'99
-
00 modols:
Th6 Mll has bon reDortod on.
DTC ml32 is itorod.
Problem vorification:
' 1.
Do t he ECi ! 4/ PCM Reset Pro
cedure,
St ar t t he ongi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
t he radi at or f an comes on.
Check t he Pr i mar y HO2S
l Sensor 1) out put vol t age wi t h
the scan tool during decelela-
t i on usi ng compl et el y cl osed
throftle.
Int.rmitt .fi tailuro, syltom b OK
at thit tima. Check for poor con-
nactiona oi loo3a wirar !t Cltl
(Primrry
HO2S, S.nror 1) .nd .t
th. ECM/FCM.
Doos the voitage stay at 1.5 V
or more?
Check for an opsn in the Prlmary
HO2S:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he Pri mary HO2S
(Sensor
1)connect or.
3. Connect t he Pr i mar y HO2S
(Sensor
1) 4P connector t6rmi-
nal s No. 1 and No. 2 wi t h a
iumperwire.
4. Turn the ignition switch ON
(ll).
5, Check t he Pr i msr y H02S
(Sensor
1) output voltage with
the scan tool,
l st here 1. 5 V or more?
Check f or an op6n i n t h6 wi ro
{PHO2S line):
1. Turn t ho i gni t i on swi t ch OFF.
2. Connect ECM/PCM connector
t ermi nal s C16 and C18 wi t h a
i umper
wi re.
3. Turn t he i gni t i on swi t ch ON l l l ).
4. Check t he Pr i mar y HO2S
(Sensor
1) out put vol t age wi t h
t he scan t ool .
Ropair opon in thc wire bc{w.cn
t he ECM/ PCM { Cl 6} . nd t he
Primary HO2S {Snror 1}.
l s t here 1. 5 V or more?
Substituto a known-good ECM/
PCM snd rochock. l f 3ympt om/
indicetion goa
awry, roplaca tho
origin.l ECM/PCM.
PRIMARY HOzS
(S6n!or 1l aP
CoNNECTOR lcltl)
Pt()2s
IWHTI
sG2
{GRN/
BTJ(I
Wire side of tem6le terminsls
ECM/PCM CONNECTOR C
(31P}
IGRN/BLKI
JUMPER WIRE
Wi re si de ol t emal e t 6rmi n6l s
(cont'd)
- 1
1 5
2 7 8 9
/ 1 6 17
't8
19120 A 22
23 E 29
g)
31
PHO2S {WHTI sG2
1 1
www.emanualpro.com
PGM-FI System
Primary Heated Oxygen Sensor
(Primary
HO2S) lSensor
1)
(cont'd)
tFO133 \ l he
scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0133: A sl ow response
probl em i n the Pri mary Heated
:
Oxysen Sensor
(Primarv HO2S\ (Sensor
1) circuit.
Description
By control l i ng the ai rl fuel rati o wi th a Pri mary HO2S
(Sensor
1) and a Secondary HO2S
(Sensor
2), the deteri orati on of the
Pri mary HO2S
(Sensor
1) can be eval uated by i ts feedback peri od. When the feedback peri od of the HO2S exceeds a cer
tai n val ue duri ng stabl e dri vi ng condi ti ons, the sensor wi l l be
j udged
as deteri orated.
When deteri orati on has been detected duri ng two consecuti ve tri ps, the MIL comes on and DTC P0133 wi l l be stored.
NOTE: l f DTC P0131, P0132 and/or P0135 are stored at the same ti me as DTC P0133. troubl eshoot those DTCS fi rst, then
troubl eshoot DTC P0133.
Possible Cause
. Pri mary HO2S
(Sensor
1) Deteri orati on
. Pri mary HO2S Heater
(Sensor
1) Deteri orati on
. Exhaust system l eakage
Troubleshooting Flowchart
-
The MIL has b6n reoorted on.
-
DTC P0133 is stored.
Problem Verilication:
' 1.
Do t he ECM/ PCM Reset Pro
cedure.
2. Connect t he scan t ool .
3. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad l i n Park or neut ral i unt i l
t he radi at or f an comes on.
4. Connect t he SCS servi ce con
nector.
5. Test -dri ve under t he f ol l owi ng
condat i ons,
55 mph
(89
km/ h) st eady
speed
-
M i n
@
posi t i on (E posi
t i on and Over Dri ve ON)*,
(M/ T
i n st h gear)
-
Until readiness code comes
Intermittent failure, system is OK
at this time. Check tor poor con-
nect i ons or l oose wi res at C111
(Primary
HO2S, Sensor 1) and al
the ECM/PCM.
Replace the Primary HO2S {Sen-
sor 11.
1 1 - 1 1 6
www.emanualpro.com
Secondary Heated Oxygen Sensor
(Secondary
HO2S)
(Sensor
2)
The scan tool i ndi cates Di agnosti c Troubl e code
(DTC)
P0137: A l ow vol tage
probl em i n the secondary Heated
Oxygen Sensor
(Secondary HO2S)
(Sensor
2) ci rcui t.
SECONDARY HO2S ls.nlor 2)
4P CONNECTOB lC721l
Wi re si de of l emal e t ermi nal s
(cont' d)
11- 117
The MIL hrs been reported on.
DTC P0137 is stored.
Problem veritication:
1. Do t he ECM/ PCM Reset Pro'
cedure.
2 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi l h no
l oad
(i n
Park or neut ral ) unt al
t he radi at or {an comes on,
3. Check t he Secondar y H02S
l Sensor 2) out put vol t age at
3,000 rpm with the scan tool.
lnlermittent failure, 3ystem i5 OK
at this time. Check tor Poor
con'
noction3 or loose wires at C127
{locatod on ECM/PCM bracket},
C721
(Secondary HO2S, Sensor
2l and at the ECM/PCM.
Does the voltage stay at 0.3 V
or l ess?
Check for a short in the Secondary
HO2S:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he Secondar y
HO2S lSensor 2) 4P connector.
3. St art t he engi ne.
4. Check t he Secondar y HO25
(Sensor 2) output with the scan
t ool .
Check l or a shor t i n t he wi r e
(SHO2S
l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. Di sco n nect t he ECM/ PCM
connect or {D
(16P}, A
(32P}' ).
3. Check for continuity between
t he Secondary HO2S
(Sensor
2i 4P connect or t ermi nal No. 1
and body ground.
Reoair short in the wire btwoen
rhe ECM/ PCM | D14, 423*l and
the Secondary HO2S {Sensor
2).
Substitute a known-good ECM/
PCM and rocheck. l f sympt om/
i ndi cat i on
goes away, repl ace
the original ECM/PCM.
*:
' 98
-
00 modei s
www.emanualpro.com
PGM-FI System
Secondary Heated Oxygen Sensor
(Secondary
HO2SI
(Sensor
2l
(cont'dl
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0138: A hi gh vol tage probl em
i n the Secondary Heated
Oxygen Sensor
(Secondary
HO2S)
(Sensor
2) ci rcui t.
SECONDABY HO2S
(Sonror
2)
1P CONNECTOR rC721 l
sHo2s
{WHT/REDI
sH()2sG
IGFN/WHTI
Wire side of female terminals
PCM COI{NECTOR D {16PI
sHo2sG
(RED/YELI
JUMPER WIRE
Wi rc si de ol l emal e t ermi nal s
{ To
page
11- 119)
1 1 - 1 1 8
The MIL hra bon Eported on,
OTC m138 b stor.d.
PJoblcm v6dtic.tion:
1. Do t he ECM/ PCM Resot Pro-
cedure,
St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) t rnt i l
the radiator lan comes on.
Check t he Secondary HO2S
(Sensor
2) out pl . rt vol t age at
3,000 rpm with the scan tool.
Int.rmitto tailurc, syst.m b OK
rt ihi! timo. Chack fo. poo.
oon-
noctioni or looaa wiiaa at C127
lloc.ted on EcM/PcM br.cket),
C721
(Second!ry
llO2S, Sonlol
2).nd at th. ECM/PCM.
Does the voltage stay at 0.6 V
or more?
Chock for an opon in the Socondary
HO2S:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he Secondar y
HO2S
(Sensor
2) 4P connector.
3. Connect the Socondary HO2S
(Sensor
2) 4P connect or t er-
mi nal s No. 1 and No. 2 wi t h a
4. Turn the ignition switch ON {ll}.
5. Check t he Secondar y HO2S
{Sensor 2) output voltage with
t he scan t ool .
l s t here 0. 6 V or more?
Ch6ck for an open in thg wiro3
(SH()2S,
SG2 line3l:
1. Turn t he i gni t i on swi t ch OFF.
2. Connect rcM connector termi-
nal s 014 and D13 wi t h a
J!mper
wite.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Check t he Scondar y HO2S
( Snsor
2) out put vol t age
wi t h t he scan t ool .
Rapair op6n in tho wir. b{woan
t ho PcM l Dl a or Dl 3l . nd t ho
S.condlry HO2S {Senlor 21.
l st here 0. 6 V or more?
(' 97
model )
www.emanualpro.com
( Fr om page 11- 118)
Check f or an open i n t ha wi re
ISH()2S linel:
1. Turn t h i gni t i on swi t ch OFF.
2. Connect ECM/ PCM connect or
t ermi nal s A23 and C18 wi t h a
i umper
ware.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Check t he Secondary HO2S
(Sensor
2) output voltage with
t he scan t ool .
Repair opon in tho wire botwaen
t he ECM/ PCM l A23l and t he
Second.ry HO2S
(Sonsot 21.
ls there 0.6 V or more?
Substitute a known.good ECM/
PCM .nd recheck. It symptom/
i ndi cat i on
goes rway, repl ace
the origin.l ECM/PCM.
(' 98 -
00 model s)
ECM/PCM CONNECTORS
A l32Pl
Wi re si de of f omal e t ermi nal s
L _ . _ . _ _ _
I
SHO2S W}iT/RED)
| JUMpER W;RE
(cont' d)
1 1 - 1 1 9
www.emanualpro.com
PGM-FI System
Secondary Heated Oxygen Sensor
(secondary
HO2SI
(sensor
2l
(cont,d)
l Tol 3al
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0139: A sl ow response probtem
i n the Secondary Heated
-
Uxygen Sensor (HO2S) (Sensor
2l ci rcui t.
-
The MIL has ben reoorted on.
-
DTC P0139 is storad.
Problm ve.itication:
1. Do t he ECM/ PCM Reset Pro
cedure,
St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad (i n
Park or neut ral ) unt i l
t he radi at or f an comes on.
Check t he Secondar y HO2S
(Sonsor
2) output at 3,000 rpm
with the scan tool.
lntehittont failure, 3ystem is OK
at this time. Chock for poor
con-
nections o. loose wi.es at C127
(located
on ECM/PCM brackt),
C721 {Secondary HO2S, Sensor 2l
and at the EcM/PcM.
Does t he vol t age st ay wi t hi n
0. 3
-
0. 6 V f or t wo mi nut es?
11- 120
www.emanualpro.com
Heated Oxygen Sensor
(HO2S|
Heater
The scan tool i ndi catos Di agnosti c Troubl e Code
(DTC)
P0135: A probl em i n the Pri mary Heated Oxygen Sensor
{Pri marv HO2S)
(Sensor
1) Heater ci rcui t.
The scan tool indicates Diagnostic Trouble Code
(DTC)
P0141: A
problem in the Secondary Heated Oxygen Sensor
(Secondary
HO2S)
(Sensor
2) Heater circuit.
Fol 3sl
Fo11t l
PBIMARY HO2S ls.n.or ll 4P
CONNECTOR
(CI
1 1 I, SECONDARY
HO2S ls.n.o.2l aP CONNECTOR
lc721l.
Termi nal si de of mal e t rmi nal s
PRIMARY HO2S lson.o. 1l aP
CONNECTOR {Cl 1 1 }, SECONDARY
HO2S ls.nror 21 4P CONNECTOR
tcr21l.
so2sHTc
tBLK/WHn.
PO2SHTC
(BLK/
WHTI
tGl
IBLKAAIHTI'
Wire sid of lemale terminals
(' 97
model : To page
' 11-122)
(' 98 -
00 model s: To page 11-' 123)
*:
P0141
(' 97 model : To page' 11-122)
1' 98
-
00 model sl To
page 11-123)
(cont'd)
11- 121
-
Th6 MIL h.. bocn roponod on.
-
DTC P0135, and/oi mlal are
stored.
Probl.m verification:
1. Do t he ECM/ PCM Resot Pro-
cedure,
2. St art t he engi ne.
Int.rrnittaii frilurc, awtom ir OK
at thi3 time. Chock lor
poor
con-
n.ctiona or loosa wiro3 !t C111
lPrim.ry HO2S, Sen3o. 11. C12?
llocatcd on ECM/PCM br.ck.t),
C721 lsocond.ry Ho2s, s.n3or
2r and at tho ECM/PCM.
Ch.ck ior an opon or shoYt in the
HO2S:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnoct the Ho2s
(Primary
or Secondary*)
(Sensor
1 or
Sensor 2)4P conneclor.
3. At t he HO2S si de, measur e
resistance between the HO2S
4P connect or t ermi nal s No. 3
and No. 4.
l s t here 10
-
40 0?
Check f or cont i nui t y bet ween
body ground and t he HO2S 4P
connect or t er mi nal s No. 3 and
No. 4 i ndi vi dual l y.
Check tor an op6n or 3hort in the
wi res I PO2SHTC, SO2SHTC'
l i nel :
1. Turn t he i gni t i on swhch ON {l l ).
2. Moasure voltage between the
HO2S 4P connect or t ermi nal s
No. 3 and No. 4.
www.emanualpro.com
PGM-FI System
Heated Oxygen Sensor
IHO2S)
Heater
(cont'd)
{' 97 model )
( Fr om
page l 1- 121)
PRIMARY HO2S (S.nsor
1) ap CONNECTOR
{ cl 111
|
1 1 2
|
|.i-l
1 3
. l
'ot
X-
tErK/ (9
YELI -L
Wi re si de of f emal e t ermi nal s
SECONDARY HO2S
ISENSOR 21 4P CONNECTOR
lcr21l,
IGl IBLK/WHTI
Wi re si de ol f emal e t ermi nal s
Wi re si de of f emal e t ermi nal s
So2HTCIALK/WHTI* PO2SHTCIBLK/WHTI
Chock for en open or lhort in the
wire
(lG1
line):
Measur e vol t age bet ween t he
HO2S 4P connect or t ermi nal No.
3
( secondar y:
No. 4) and body
ground,
Reprir op6n or 3hort in thc wirc
betwo.n th No. 15 ALTERNA-
TOR SP SENSOR
(7.5
Al fu!. rnd
tho HO2S (Primary.
Socond.ry*).
Chck f or an open i n t he wi re
(PO2SHTC,
SO2SHTC. lin):
1. Turn t he i gni t i on swi t ch OFF.
2. Reconnect t he HO2S 4P con-
3. Di sconnect t he PCM connec-
tor A
(32P).
4. Turn t he i gni t i on swi t ch ON
(l l ).
5. Measur e vol t age bet ween
PCM connect or t rmi nal s 46
and A10 (A5
and A10)*.
Bepair opon in the wiro botwoon
the PcM
(A6.
A5lr and tho Ho2s
{Prim.ry, Socond!ryr}.
l s t hero 0. 1 V or l ess?
Subst i t ut e a l nown-good PCM
and recheck. lt 3ymptom/indica-
tion goes away, .oplaco the origi-
nal PCM.
Check f o. a ahort i n t he wi re
IPO2SHTC, SO2SHTC. lins):
1. Turn t he i gni ri on swi t ch OFF.
2. Di sconnect t he PCM con-
nector A {32P).
3. Check lor continuily between
t he PCM connect or t ermi nal
46
(A5)*
and body ground.
Bopair short in the wire lrotwsen
tho PC{r4
{A6, A5rl and the HO2S
lPiimary, Scondary.l.
Subst i t ut e a known-good PCM
and .echgck. lf 3ymptom/indica-
tion gos awry. repl.cethe origi-
nal PCM.
11- 122
www.emanualpro.com
Check for an open in the witoa
(l GP, l Gl ' l i no):
Mgasure voitage between the pri-
mary HO2S 4P connector terminal
No. 3
(secondary HO2S: No. 4) and
body ground.
Bepair opan or short in tho wilo
bdtween th6 nlo. 15 ALTERNATOR
SP SENSOR 17.5 Al fu$ .nd th6
HO2S {Primrry,
Scondtrytl.
Chock lor sn opon in the wires
IPO2SHTC, SO2SHTC' lincl:
1. Turn t he i gni t i on swi t ch OFF.
2. Reconnect t he HO2S 4P con-
nector.
3. Disconnect the ECM/PCM con-
nector C
(31P) (ECM/PCM
con-
neaor A
(32P))*.
4. Turn t he i gni t i on swi t ch ON
(l l ).
5. Moasur e vol t age bet ween
ECM/PCM connector terminals
82 and Cl
(82
and A8)*.
Repsir opsn in tha wire between
tho ECM/PCM
(C1, A8.) .nd the
HO2S lPrimsry, Socond.ry*}.
l s t here 0. 1 V or l ess?
Sub.titute a known-good ECM/
PCM and rocheck. lf iymptom/
i ndi crt i on goes away, repbce
the original ECM/PCM.
(' 98
-
00 model s)
Wi re si de of f emal e t ermi nal s
ECM/FCM CONNECTORS
IGl IBLK/WHT}
PRIMARY HO2S {S.n3or
1l aP CONNECTOR
l c111l
1 1
2 l
r--T -
l 3 t . l
L-.IJ------J
lcl
/5'
tErK/
g,
YELI
I
Wi re si de of f emal e t ermi nal s
SECONDARY HO2S
{SENSOR 2} 4P CONNECTOR
(c7211'
PGl
(BLK}
l From
page 11-12' ! )
Chock l or a short i n t he wi . es
(PO2SHTC,
SO2SHTC' linol:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the EcM/PcM con-
nector C {31P) lECM/PCM con-
nector A
(32P))*.
3. Check for continuity between
ECM/ PCM connect or t ermi nal
Cl
(A8)*
and body ground.
Roolir 3hort in th. wiro betwoon
the ECM/PCM lC1, A8'l and the
HO2S
(Primary,
S6condary*).
l s t here cont i nui t y?
Sub3tituie s known-good ECM/
PCM and rech6ck. It symptom/
i ndi cai i on goes away. l gpl aco
th6 origin.l ECM/PCM.
Wi re si de of l emal e t ermi nal s
: P0' 14' l
11-123
www.emanualpro.com
PGM-FI System
Fuel Supply System
[POl i i l
The"""ntool i ndi cates Di agnosti c Troubte Code
(DTC)
p0' 171:Thefuet
system i stoo l ean.
[Fo17ZJ
rh""""ntool i ndi cates Di agnosti c Troubte code {DTc)
p0172:Thefuel
svstem i stoori ch.
Description
By moni tori ng the Long Term Fuel rri m, l ong term mal functi ons i n the fuel system wi l l be detected.
l f a mal functi on has been detected duri ng two consecuti ve tri ps, the MIL wi l l come on and DTc
p0171
and/or
pol 72
wi l l be
stored.
NOTE: l f someof the DTCS l i sted bel ow are stored atthesameti meas DTC P017' l and/or
p0172,
troubl eshoot those DTcs
fi rst, then troubl eshoot DTC P0171 and/or PO1i 2.
P0107, P0108, P1128, P' 1129: MAP Sensor
P0135: Pri mary HO2S
(Sensor
1)Heater
P0137, P0138: Secondary HO2S
{Sensor 2)
P0141: Secondary H02S
(Sensor
2) Heater
P0441*r: EVAP System l nsuffi ci ent Purge Ftow
P1456*,, P'l457
*?i
EVAP System Insufficient
purge
Ftow
Possible Cause
DTC P0171
too l ean
* 1: ' 97
model
*2:
' 98
-
00 model s
Fuel Pump i nsuffi ci ent fl ow/pressure
Fuel Feed Li ne cl ogged. l eaki ng
Fuel Pressure Regul ator stuck open
Fuel Fi l ter cl ogged
Fuel Inj ector cl ogged, ai r l eakage
Gasol i ne doesn' t meet Owner' s Manual spec.
Pri mary HO2S
(Sensor
1) deteri orated
Val ve Cl earance
Exhaust l eak
Fuel Pressure Regul ator cl ogged, stuck cl osed
Fuel Return Pi pe cl ogged
Fuel Inj ector l eaki ng
Gasol i ne doesn' t meet Owner' s Manual spec.
Pri mary H02S
(Sensor
1) deteri orated
EVAP Purge Control Sol enoi d Val ve l eaki ng, stuck opened
Val ve Cl earance
DTC P0172
flch
11- 124
www.emanualpro.com
Troubleshooting Flowchart
-
The MIL has been rePorted on
-
DTC P0171 andlot P0172 are
stored,
Check the lu6l
pressuro regulator
and tusl relum PiPe.
l s t he l Lrel pressure t oo hi gh
Check lhe Primaty HO2S:
1 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad
(i n Park ot neut ral ) unt i l
t he radi at or f an comes on
2 . Ch e c k t h e Pr i ma r y HO2 S
( Se n s o r 1 ) o u t Pu t wi t h t h e
scan t ool .
Check l h f uel
pumP. f uel f aed
pipe. fuel fiher, and luel
Prossurc
.eguhior.
Does i t st ay at l esst han 0. 3 V
or more t han 0. 6 V?
Check f or a st i cki ng or l eaki ng
EVAP
pur ge cont r ol sol enoi d
Wi t h a vacuum
pump, aPPI Y vacu
um t o t he EVAP
Pur ge
cont r ol
sol enoi d val ve f r om t he i nt ake
mani f ol d si de.
Does i t hol d vacuum?
Check t h6 val ve cl earancs and
adjust il necessary. It the valv
cl earances are OK, repl ace t he
fuel iniectors.
www.emanualpro.com
PGM-FI System
Random Mi sfi re
lF()gool", tftod-'
and some or
lpiogol
throughTo3oti
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0300*,, P1300*1 and some of
po30t - pO3O4;
Random
mi sfi re.
Descriotion
Mi sfi re detecti on i s accompl i shed by moni tori ng the crankshaft speed wi th the crankshaft speed fl uctuati on (cKF)
sensor
whi ch i s attached to the crankshaft.
l fmi sfi ri ng strong enough to damage the catal yst i s detected, the MIL wi l l bl i nk duri ng the ti me of i ts occurrence, and DTc
P0300*' , P1300*1 and some of DTCs P03ol through P0304 wi l l be stored. Then, after mi sfi re has ceased, the MtL wi l l come
on,
l f mi sfi ri ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl es, the MIL wi l l come on, and DTc
and some of DTCS
p0301
through
p0304
wi

be stored.
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as a mi sfi re DTc, troubl eshoot those DTcs fi rst. then
troubl eshoot the mi sfi re DTC.
P0106, P]128, P1' 129; MAp sensor
P0171. P0172; Fuet meteri ng
P0505: ldle Control Svstem
P1336, P1337; CKF sensor
P1361, P1362: TDC sensor
Pl 381. Pl 382: CYP sensor
P1508: IAC val ve
*1:,97
model
*2:
' 98
-
00 model s
Possiblo Caus
. Fuel pump i nsuffi ci ent fuel pressure,
amountoffl ow
. Fuel l i ne cl oggi ng. bl ockage, l eakage
. Fuel fi l ter cl oggi ng
a Fuel pressure
regul ator stuck open
.
Di stri butormal functi on
. l gni ti on coi l wi re open, l eakage
. l gni ti on control modul e mal functi on
.
Val ves carbon deposi t
a Compressi on l ow
a Fuel does not meet Owner' s Manual spec., l ack offuel
Troubleshooting
By test-dri vi ng, determi ne the condi ti ons duri ng whi ch mi sfi re occurs. Dependi ng on these condi ti ons, test i n the order
descri bed i n the tabl e bel ow.
\
Possi bl e cause
[
;;;;-
-....
Crankshaft
speed fluctuation
sensor
Fuel
pressure
Distributor and
lgnition wires
tcM
Valve
Cl earance
Condi ti on
secti on 6 11- 178
section 23 section 23 section 6
Onl y l ow rpm and l oad
,6)
o
Only accelerating
o
o o
Onl y hi gh rpm and l oad
o @
,a'
@
Not specification
G\
o @
o @
NOTE: l f mi sfi re doesn' t recur, some possi bl e
causes are fuel that doesn' t meet owner' s manual spec, l ack of fuel , carbon
deposits on spark plu9,
etc.
11- 126
www.emanualpro.com
Misfire Detected in One Cylinder
Ipffi 1]
Thescantoot i ndi cates Di agnosti c Troubl e Code
(DTC) P0301: Cyl i nder 1 mi sfi re detected.
l F03O2l 16".""n toot i ndi cates Di agnosti c Troubl e Code
(DTC) P0302; Cyl i nder 2 mi sfi re detected.
I
P0303 | fne scan tool i ndi cates Di agnosti c Troubl e Code
(DTC) P0303: Cyl i nder3 mi sfi re detected.
l F0i l 04l 16" ""un tool i ndi cates Di agnosti c Troubl e Code
(DTC)
PO3O4: Cyl i nder 4 mi sfi re detected
Description
Mi sfi re detecti on i s accompl i shed by moni tori ng the crankshaft speed wi th the crankshaft speed fl uctuati on
(CKF)
sensor
whi ch i s attached to the crankshaft.
l f mi si i ri ng strong enough to damage the catal yst i s detected, the MIL wi l l bl i nk duri ng the ti me of i ts occurrence. and DTC
P0301, P0302, P0303 and/or P0304 wi l l be stored. Then, after the mi sfi re has ceased, the MIL wi l l come on.
l f mi sfi ri ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl es. the MIL wi l l come on, and DTc
P0301, P0302, P0303 and/or P0304 wi l l be stored.
NOTE: l J some of the DTcs l i sted bel ow are stored at the same ti me as a mi sfi re DTc, troubl eshoot those DTcs fi rst, then
troubl eshoot the mi sfi re DTC.
P0107, P0108, P' n2a, P1129t MAP sensor
Po'17
'l
,
P0112t Fuel suPP|Y system
P0441: EVAP i nsuffi ci ent
Purge
fl ow
P1336, P1337: CKF sensor
P1359, Pl 361, P1362: TDC sensor
Pl 381, P1382: CYP sensor
Possible Cause
. Fuel i nj ector cl oggi ng, fuel l eakage, ai r l eakage
. Fuel i nj ector ci rcui t open or shorted
. Spark
pl ug carbon deposi ts, foul i ng, mal functi on
. l gni ti on wi res open, l eaki ng
. Di stri butor mal functi on
. Compressi on l ow
. Val ve cl earance out of speci fi cati on
(cont' d)
11- 127
www.emanualpro.com
PGM-FI System
Misfire Detested in One Cylinder
(cont'dl
Troubl93hooting Flowchart
The illu stration shows
' 97
-
98 model s, ' 99
-
00 model s
are si mi l ar.
NOTE:
. l f
t here i s no f reeze dat a ol mi sf i ri ng,
j ust
cl ear t he DTC.
. l f
t here i s no f reeze dat a ot mi sf i ri ng,
t est dri ves under vari ous condi t i ons
are necessary,
-
Th. MIL h!3 b6on r.portod on.
-
DTC m30r, P0302, m303. or
P0304 is indicated.
Ch.ck tho fuol inicctor tunction:
St art t he engi no, and l i st en f or I
cl i cki ng sound at t he f uol i nj ect or
i n t he probl m
cyl i nder.
Check f or an open or short i n t he
harness bet ween t he ECM/ PCM
and the luel injector.
Boprir opan or 3hort in tha wlre.
-
Roplaco th. tuel inioctor.
-
Subst i t ut . . known- good
ECM/ PCM . nd r ochock. I t
3ym pt om/ i ndi cat i on go. 3
aw. y, r epl ace t he ol i gi nal
ECM/PCM.
Problom vorification:
1. Atter chacking the lreze data,
do t he ECM/ PCM Reset Pro-
cedure.
2. Exchange t he spark pl ug f rom
t he
probl em
cyl i nder wi t h one
ol anot her cyl i nder.
3. Connect the SCS service con-
nector.
4. Tost -dri ve t he vohi cl e several
times in the rango ol the freeze
data.
(To page' 11-129)
11- 128 www.emanualpro.com
( Fr om page 11- 128)
lntormittent misfire due lo spark
pl ug f oul i ng, et c.
(no mi sl i re at
t hi s t i m).
ls DTC P0301, P0302, P0303,
or P0304 i ndi cat ed?
ooes t he mi sf i re occur i n t he
ot her cyl i nder?
Replace the faulty spark
Plug.
Check lor fuel iniector maltunc-
t | on:
1 . Ex c h a n g e t h e f u e l i n j e c t o r
f r o m t h e
p r o b l e m c y l i n d e r
wi t h one f rom anot her cyl i n-
der.
2. Let t he engi ne i dl e f or t wo mi n
utes.
3. Test ' dri ve t he vehi cl e several
times in the range of the freeze
dat a,
l nt ermi t t ent mi sf i ro due l o bad
contrct in the fuel iniector con-
nector {no misfire at this time).
l s DTC P0301, P0302, P0303,
or P0304 indicated?
Does t he mi sf i re occur i n t he
ot her cyl i nder?
Replace lhe faulty luel inlector.
Check following items
-
Valvo clearance
-
Cvlinder lak-down
-
Compression
-
Crsnkshaft Speed Fluctuation
ICKF) sensol
NOTE: l f t here i s no f reeze dat a of mi s
f i ri ng, t est dri ves under vari ous condi _
t i ons are necessary.
11- 129
www.emanualpro.com
PGM-FI System
Knock Sensor
{KSl
(' 99 -
00 model s) The scan tool i ndi cates Di agnosti c Troubl o Code
(DTC)
P0325: A mal functi on i n the ci rcui t of
the Knock Sensor
(KS).
ECM/PCM CONNECTOR C 131P}
Wi re si de of f emal e t ermi nal s
KS 1P CONNECTOR IC13?'
KS
IRED/BLU)
KS
(BED/BLU)
Wire side ol female
t ermt nal s
ECM/PCM CONNECTOR
c
(31P)
-
The MIL has been rooorted on.
-
DTC m325 is storod.
Problem verification:
1. Do t he ECM/ PCi r, Reset Pro
cedure,
2 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad (i n
Park or neut ral ) unt i l
t he r adi at or t an comes on,
t hen l et i t i dl e.
3. Hol d t he engi ne at 3, 000
-
4,000 rpm for at least 60 sec-
onds,
Intermittent lailu.e, 3ystom is OK
at thi3 tim.
(te3t
drive m.y be
nacalLrYr.
Chock t o. poor
connsct i ons ol
loora wiros rt C137 lknock aon-
.o.
(KS))
and ar the ECM/FCM.
Chck tor a short in the wir6 {KS
linel:
1. Turn t he i gni t i on swi t ch OFF.
2, Di sconnect t he knock sensor
l P connect or.
3. Check l or cont i nui t y bet ween
ECM/ PCM connect or t er mi
nal s C3 and body ground.
Replil rhort in the n irg b6{wocn
tho ECM/PCM lc:ll and the knock
sngr1.
Check f o. . n open i n t he wi re
{KS l i ne):
Check f or cont i nui t y bet ween
ECM/PCM connector terminal C3
and knock sensor connect or t er,
mi nal No. 1.
B.pair opon in the wirc lrotween
lho ECM/PCM lctl and thc knock
acnsor.
l s t here cont ; nui t y?
Subst i t ut e a known-good knock
sensor and recheck.
ls DTC P0325 indicated?
Bcpl.ce the original knock 3nsor,
Substituto a known-good ECM/
PCM and .echeck. lf 3ymptom/
i ndi cat i on goes
away, repl ace
the original ECM/PCM.
NOTE: Torque the knock s6nsor to
31 N.m
(3.2
kgl.m, 23 lbf.ft).
1 1 - 1 3 0
Wi re si de ot f emal e t ermi nal s
www.emanualpro.com
tro-rsl
1Tffi61
tF136t
fPfa6r-1
tF138tl
I-Pi382l
Crankshaft Position/Top Dead Genter/Gylinder
Position
(CKP/TDC/CYPI
Sensor
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0335; A mal functi on i n the Crankshaft Posi ti on
(CKP)
sensor ci rcui t,
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0336: A range/performance
probl em i n the Crankshaft
Posi ti on {CKP) sensor ci rcui t.
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC)
P1361: Intermi ttent i nterrupti on i n the Top Dead Center
(TDC)
sensor ci rcui t.
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1362: No si gnal i n the Top Dead Center
(TDC)
sensor
ci .cui t.
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1381: Intermi ttent i nterrupti on i n the Cyl i nder Posi ti on
(CYP)
sensor ci rcui t.
The scan toot i ndi cates Di agnosti c Troubl e Code {DTC)
P1382: No si gnal i n the Cyl i nder Posi ti on
(CYP}
sensor
ci rcui t.
Description
The CKP Sensor determi nes ti mi ng for fuel i nj ecti on and i gni ti on of each cyl i nder and al so detects engi ne speed. The TDC
Sensor determi nes i gni ti on ti mi ng at start-up {cranki ng)
and when crank angl e i s abnormal . The CYP Sensor detects the
posi ti on of No.
' t
cyl i nder for sequenti al fuel i nj ecti on to each cyl i nder. The CKP/TDC/CYP Sensor i s bui l t i nto the di stri bu-
ror.
NOTE: l f DTC P1359 i s stored atthesameti meas DTC P0335, P0336, Pl 361, P1362, P1381 and/or P1382, troubl eshoot DTC
P1359 fi rst, then troubl eshoot those DTCS.
DISTRIBUTOR lOP
CoNNECTOR
(Cl211
TDCP IGRNI
Termi nal si de of
mal e t ermi nal s TIrcM IREOI
'97
model:
-
The MIL has ben reported on.
-
DTC P0335, P0336, P136' 1,
P1362, Pl341 and/oi P1382 are
stored.
Problem verific.tion:
1. Do t he PCM Reset Procedure.
2. St art t he engi ne.
Intermittent lailure, 3yd6m i3 OK
at thb tims. Chcck tor poor con-
nections ol looso wire3 si C12'l
ldistributor) .nd .t the PCM.
ls DTC P0335, P0336, P1361, P1362,
P1381 and/or P1382 indicated?
Ch. ck f or an open i n t ho CKP/
TDC/CYP sensor:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he di st ri but or 10P
connect or.
3. Measure resi st ance bet ween
t he t ermi nal s of t he i ndi cat ed
sensor
(see
t abl e).
Repl ace t ho di st ri but or i gni t i on
housing {sea 3ection 41.
ls there 350
-
700 o?
(To page 11-132)
CYPP IYELI
CYPM
(BLKI
SENSOE DTC
SENSOB PCM
ERMI NAI
WI RE
COLOR
CKP
P0335
P0336
l c2 8LU
8 c12
TDC
P1361
P1352
2 GRN
9 c13 RED
CYP
P' I381
P1342
3 c4 YEL
' t 0
c14 BLK
{cont' d)
1 1 - 1 3 1
www.emanualpro.com
PGM-FI System
Grankshaft Position/Top Dead Center/Cylinder Position
(CKP/TDC/CYPI
Sensor
(cont'd)
DISTRIBUTOR
10P CONNECTOR t Cl 2l )
CKP P
I BLUI
TDC P {GRNI
PCM CONNECTORS C I31P)
CKP P TDC P CYP P
I BLU) I GRNI I YEL}
Termi nal si de of
mal e t ermi nal s
IREDI IBLK)
Wi re si de of
femal e termi nal s
{WHT)
{ Fr om
page 1' 1- 131)
Check f or a short i n t he CKP/
TDC/CYP sensor:
Ch e c k f o r c o n t i n u i t y t o b o d y
ground on bot h t ermi nal s of t he
i ndi cat ed sensor i ndi vi dual l y
(see
t abl e on page 1l 131) .
Rpl ac t he di st ri but or i gni t i on
housing {see section 4}.
l s t here cont i nui t y?
Chck f o. an open i n t he wi res
{CKP/TDC/CYP lines):
' 1.
Reconnect t he di st ri but or 10P
connect or.
2. Di sconnect PCM connect or C
( 31P) .
3. Measure resi st ance bet ween
t he t ermi nal s of t he i ndi cat ed
sensor on t he PCM connect or
l seet abl e on page 1l 131) .
Repair open in the indicated sen-
sor wires {se6 table on page 11-
131) .
l s t here 350
-
700 0?
Check t or a short i n t he wi res
{CKP/TDC/CYP linesll
Check f or cont i nui t y bet ween
body ground
and PCM connect or
t ermi nal s C2, C3 and/ or C4 i ndi vi d-
RDair short in the indicatod sen-
sor wires lsee table on page 11-
13r I .
l s t here cont i nui t y?
Subst i t ut e a known-good PCM,
and recheck. lf symptom/indica-
tion goes
away, rplace lhe origi-
nal PCM.
CKP P TDC P CYP P
www.emanualpro.com
TDCP
(GRN)
CYPP
(YEL}
TDCM
(REDI
'98
-
00 models:
'98
model:
DISTRIBUTOR 1OP
CoNNECTOR
(C121)
CYPM IBLKI
Termi nal si de of mal e t ermi nal s
'99
-
00 modelr:
DISTRIBUTOR 8P
coNNECTOR {C121)
TDC M
(RED}
Termi nal si de of mal e termi nal s
CKP P
{BLU)
'98
modeli TDC P {GRNI
CKP M
IWHT)
TOC P
I GRNI
CYP P
(YEL)
(RED)
CYP M
(BLKI
M
f emal e t ermi nal s
(cont' d)
1 1 - 1 3 3
TDC P
(GNN}
CYP P I YEL}
CYP M IBLKI
SENSOR DTC
SENSOR
ERMI NAT
):'99 mode
ECM/ PCM
I ERMI NAI
WI RE
COLOR
CKP
P0335
P0336
1 t 2) c8 BLU
8
( 6)
c9
TDC
P1361
Pl 362
2
( 3)
c20 GBN
9
( 7)
c21 RED
CYP
P] 381
P] 382
3
( 4)
c29 YEL
10 { 8) c30 BLK
ECM/PCM CONNECTOFS C {31P)
The MIL ha3 been reoorted on.
DTC P0335. P0336, P1361,
P1362. P1381 andlor P13V are
stord,
Problem verification:
1. Do t he ECM/ PCM Reset Pro
cedure.
2. St art t he engi ne.
Intermittant tailure, svstom is OK
at this time. Check for poor con-
nections or loose wirgs al C121
{di st ri but o. l . nd at t he ECM/
PCM.
ls DTC P0$5, m$6, Pl361, P1362,
P1381 and/or Pl382 indicated?
Check f or an open i n t h6 CKP/
TDC/CYP sensor:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he di st ri but or 10P
(8P)*
connect or.
3, Measure resi st ance bet ween
t he t ermi nal s of t he i ndi cat ed
sensor {see t abl e).
Rephce the distributor ignition
houaing l3e9 3oction 4).
l s t here 350 700 0?
Check f or a short i n t he CKP/
TDC/CYP snsor:
Ch e c k f o r c o n t i n u i t y t o b o d y
ground on bot h t ermi nal s of t he
i ndi cat ed sensor i ndi vi dual l y
(see
t abl e).
Replaco tho distributor ignition
housing lsee soction
tll.
Check for an opn in th6 wires
ICKP/TDC/CYP linesl:
1. Reconnect t he di st ri but or 10P
(8P)*
connect or.
2. Di sconnect ECM/ PCM connec-
t or C
(31P).
3. Measure resi st ance bet ween
t he t ermi nal s of t he i ndi cat ed
sensor on t he ECM/ PCM con
nect or
(see
t abl e).
Repair open in the indicated sen-
sor wires lsee t.ble).
l s t here 350 700 O?
(To page 11-134)
' : ' 99
-
00 model s
www.emanualpro.com
PGM-FI System
Grankshaft Position/Top Dead Center/Cylinder Position
(CKP/TDC/CYPI
Sensor {cont'd}
(From page 11 133)
ECM/PCM CONNECTOR C {3IPI
Wi re si de of f emal e t ermi nal s
Chock l or r 3hon i n t ho wi rer
ICKP/TDC/CYP lin6):
Check f or cont i nui t y bet ween
body ground and ECM/ PCM con-
nect or t ermi nal s C8, C20 and/ or
C29 i ndi vi dual l y.
Rep.ir lhort in ths indicated son-
aor wiroa 136o table on prge 11-
133).
Substituto r known-good ECM/
PCM, and .6chock. tf 3ymptom/
i ndi cat i on goe3 swey, repl rce
tho original ECM/PCM.
11- 134
www.emanualpro.com
Vehicle Speed Sensor
(VSSI
lPosoo-]-'. |posol l-'
'97
modol:
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC} P0500*' or P0501*r: A range/perfor-
mance i n the Vehi cl e Speed Sensor
(VSS)
ci rcui t.
*
I ; A/T
*2i
Mfi
FCM CONNECTORS
A t32Pl
LG1
(BRN/BLK)
NOTE: Do not use t he engi ne t o t ur n t ho
f ront wheel s wi t h t h6 rear wheel s on t he
ground. The 4WD syst em wi l l engage and
t he vehi cl e wi l l suddenl v I urch f orward.
Wire side ot female terminals
LGl
{BRN/BLKI
(cont' d)
1 1 - 1 3 5
The MIL hes boen roported on.
DTC m501 is 3tord.
Problom verificetion:
1. Test ' dri ve t he vohi cl e.
2. Check t he vehi cl e speed wi t h
t he scan t ool ,
lntormittent tailure,
rystom
b OK
at thia timo. Chock tor poor con-
nection3 or 10o3o wires rt C129
lvss) .nd rr rhe Pcfr4,
l s t he correct speed i ndi cat ed?
Chock for an open in tho PiCM:
1. Turn t he i gni t i on swi t ch OFF.
2. Block the rear wheels and set
t he
parki ng
brake.
3. Jack up the lront of the vehicle
and suppor t i t wi t h sal et y
stands.
4. Turn the ignition switch ON
(ll).
5. Elock the right front wheel and
sl owl y rot at e t he l ef t t ront
wheel by hand.
6. Measur e vol t age bet ween
PCM connect or t ermi nal s C18
and A9.
Substitulc a known-good PCM
and .och6ck. It symptom/indicd.
tion go.a away, .cplaco tho origi-
nel FCM.
Doest he vol t age pul se 0 V
and 5 V or battery voltage?
Check for a .hort in the PCM:
L Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he PCM con'
nect or C
(31P).
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. El ock t he r i ght f r ont wheel
and slowly rotate the left front
5. Measure vohage between PCM
connect or t ermi nal s C18 and
A9.
Substituto e known-good PCM
and rochock. f rymptom/indica-
tion goos rwry, roplsc. tho origi-
nal FCM.
Doest he vol t age pul se 0 V
and 5 V or bat t ery vol t age?
-
Repai r shor t i n t he wi r e
bet ween t he PCM l C18l ,
crui se cont rol uni t , speodo-
meter, and VSS,
-
Repai r opon i n t he wi r e
between the PCM {C181 .nd
rhe vss.
-
f wire is OK. tost lho VSS l3oo
soction 231.
www.emanualpro.com
PGM-FI System
Vehicle Speed Sensor
(VSSI
{cont'd}
'98
-
00 models:
ECM/PCM CONNECTORS
B t25Pl
NOTE (4WD):
Do not use t he engi ne t o t urn
t he f ront wheel s wi t h t he rear wheel s on t he
ground. The 4WD syst em wi l l engage and
t he vehi cl e wi l l suddenl y l urch f orward.
Wi re si de of f emal e t ermi nal s
-
The MIL ha3 been reDoned on.
-
DTC P0500" or P0501*1 i 3
3torod.
Probl6m verification:
1. Test -dri ve t he vehi cl e.
2. Check t he vehi cl e speed wi t h
t he scan t ool ,
Intermittont failu.e, svstem is OK
at thk time. Check for poor con-
nection! or loose wiros at C129
lvss) .nd ar the EcM/PcM.
ls the correct speed indicated?
Check f or rn open i n t he ECM/
PCM:
l Turn t he i gni t i on swi t ch OFF.
2. El ock t he rear wheel s and set
t he parki ng
brake.
3. Jack up the front oI the vehicle
and suppor t i t wi t h sat et y
st ands.
4. Turn the ignition switch ON {ll}.
5. Block the right front whoel and
sl owl y rot at e t he l et t f ront
6. Measur e vol t age bet ween
ECM/ PCM connect or t er mi -
nal s 820 and C23.
Substitute a known-good ECM/
PCM and rochock. ll symptom/
indicetion
9063
away, .oplace th
origin.l ECM/PCM.
Does the voltage pulse
between
0 V and 5 V or battery voltage?
Check f or a short i n t he ECM/
PCMI
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect ECM/ PCM con
nect or C 131P).
3. Turn the ignition swilch ON {ll).
4. Bl ock t he r i ght f r ont wheel
and slowly rotate the left front
5. Moasure voltage between ECM/
PCM connect or t ermi nal s 820
and C23.
Sub.titute a known-good ECM/
PCM and rschock. It rymptom/
i ndi cat i on goos . w. y. repl ece
rhe original ECM/PCM.
Does the voltage pulse
betlveen
0 V and 5 V or battery voltage?
-
R. pai r shor t i n t he wi r o
betwen the ECM/PCM lC23)
.nd tho VSS.
-
Ropr i r open i n t h6 wi r e
botweon the ECM/PCM lc23l
and th6 vss.
-
I t wi rc i s OK, t e3t i he VSS
(!e
soetion 23).
B
(25P)
1
*2:Mft
1 - 1 3 6
www.emanualpro.com
Barometric Pressure
(BARO)
Sensor
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1106: A range/performsnce probl em i n the Barometri c
Pressure {BARO) Sensor ci rcui t.
The MIL has been reDorted on.
OTC Pl 106 b sl ored.
Problem ve.ification:
1. Oo t he ECM/ PCM reset pro'
ceoure.
2. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad
(; n
Park or neut ral ) unt i l
the radiator lan comes on, then
l et i t i dl e.
3. Connect t he SCS servi ce con-
nector,
4. Test ' dri ve wi t h t he A/ T i n
E
position, M/T in 4th gear.
5. Accel erat e I or f i ve seconds
using wide open throttle.
Intermittent fsilure, sy3tom i5 OK
at this time.
l s DTC P1106 i ndi cat ed?
Substitute a known-good ECM/
PCM . nd recheck. I t sympt om/
indication goes away, replace the
origioal ECM/PCM.
fTiloz l
tP11o8l
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1107: A l ow
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
Pl 108: A
ci rcui t.
vol tage probl em i n the Baro sensor ci rcui t.
hi gh vol tage probl em i n the Baro sensor
-
The MIL h.3 ben roportd on.
-
OTC Pl 10? or Pl 108 i 3 st ored.
Problom veritic.lion:
L Do t he ECM/ PCM Reset Pro-
cedure.
2. Turn t he i gni t i on swi t ch ON
(l l i .
Intarmittoni failure, lystom b OK
at thb time.
l s DTC P1107 or P1108 i ndi cat ed?
Sub3tituto a known-good ECM/
PCM and rcch6ck. ll symptom/
i ndi cat i on
9oo3
away. . opl aco
rho o.igin.l ECM/PCM.
www.emanualpro.com
PGM-FI System
Elestrical Load Detector
(ELDI (USA
Modell
The scan tool i ndi ctes Di agnosti c Troubl e Code
(DTC)
P1297: A l ow vol tage probl em i n the El ectri cal Load
Detector
(ELD)
ci rcui t.
'97
model:
ELD 3P CONNECTOR {C354I
--+-
l 1 L 2 l 3 l
l e r -
O)
tcnrulaeot
Y
Wi re si de ot f emal e t ermi nal s
PCM CONNECTOR D I16P)
Wi re si de of f emal e t ermi nal s
Problem vsriticltion:
1. Do t he PCM Feset Procedure.
2. St art t he engi ne.
3. Turn on t he headl i ght s.
Intormittent lailuic, 3vstom k OK
at thk time. Ch.ck tor poor con-
nections or loose wiro3 at C127
(loc.ted
on PCM b.sckot), C354
{ELO, .nd at tho FCM.
l s DTC P1297 i ndi cat ed?
Ch.ck for 3hort in lho ELD:
Measure vol t age bet ween body
ground and t he ELD 3P connect or
t er mi nal No. 3.
l s t here approx. 4. 5 V?
Check for a short in tho wire IEL
l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect PCM connector D
( 16P) .
3. Check f or cont i nui t y bet ween
body ground
and PCM connec
t or t ermi nal D16.
Rcpair 3hort in tho $rire botwon
the PcM lDl6l and tho ELD.
Substituto a known-good PCM
and rocheck. lf 3ymptom/indic.-
tion goos !w!y, repl.ce the origi-
nal PCM.
1 1 - 1 3 8
www.emanualpro.com
98
-
00 mod6l3:
-
OTC P l17 is 3tored.
Problcm vcrificrtion:
1. Do t he ECM/ PCM Reset Pro-
cedure,
2. St art t he engi ne.
3. Turn on t he headl i ght s.
Intcrmittent tailuro, ryrtom ir OK
!t thi3 timo. Ch.ck tor poor con-
nectiont or looao wire! at CXl54
IELD) rnd at rh6 ECM/PCM,
ls DTC P1297 indicated?
Chock for 3hort in tho ELD:
Measure vol t age bet ween body
ground and t he ELD 3P connect or
t ermi nal No. 3.
ls there approx. 4.5 V?
Chcck lor a 3horl in tho wiio
(EL
l i nol :
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect ECM/ PCM con-
nector A
(32P).
3. Check for continuity between
body ground and ECM/ PCM
connctortrminal A30.
Ropair shon in thc wira botwocn
tho PcM
(A301
rnd rho ELD.
Sub.tituto a known.good ECM/
PCM .nd rocheck. ll lymptom/
i ndi cat i on gocs . w! y. repl sce
th6 o.iginal ECM/PCM,
ELD 3P CONNECTOR ICAs4I
f _ l ,
I 2 l 3 l
-
l---
r'.
&)
iGRN/RED)
T
Wi re si de of t emal e t ermi nal s
ECM/PCM CONNECTOR A I32P)
Wi re si d6 of f emal e t ermi nal s
(cont'd)
- 139
1 1
www.emanualpro.com
PGM-FI System
Electrical Load Detestor
(ELDI (USA
Model)
(cont'dl
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) Pl 298; A hi gh vol tage
probl em i n the El ectri cal Load
Detector
(ELD)
ci rcui t.
97 modsl:
ELD 3P CONNECTOR {C35,'I
Wi re si do oI l emal e t ermi nal s
r
l z l r l
--T_ow
/6\
IBLKI
Y
Repail opn in th. wire btwsn
t ho No. 15 ALTERNATOR SP
SENSOR 17. 5 A) t use i n t he
under-dl rh f uso/ r. l ay box and
th6 ELD.
EL {GRN/NEDI
PCM CONNECTORS
Problam verification:
1. Do t he PCM Reset Procedure.
2. St art t he engi ne.
3. Turn on t he headl i ght s.
Intermittent tailuro, systcm is OK
.t this time. Chack for ooor con-
noction! or looro wire3 at C127
{locaied on PCM brackot), C35{
{ELDI and .t tho PCM.
Chack f or an opan i n t ho wi l e
l l Gl l i nol :
1. Tur n t hg i gni t i on and head-
l i ght s OFF.
2. Disconnect the ELD 3P connector.
3. Turn the ignition switch ON {ll).
4. M6asur e vol t age bt wen
body ground and t he ELD 3P
connoct or t ermi nal No. 1.
Chock l ol ! n open i n t he wi re
IGND linel:
' 1.
Turn t he i gni t i on swi t ch and
headl i ght s OFF.
2. Di sconnect t he ELD 3P con
neqor,
3. Check for continuity between
body ground
and t he ELD 3P
connect or t ermi nal No. 2.
Ropair opon in th6 wi.e betweon
th. ELD connector rnd GiO2,
Ch.ck lo. an open in th wiro
(EL
line):
Check for continuity between the
ELD 3P connect or t ermi nal No. 3
and PCM connect or t ermi nal 016.
Chock f or . mal f unct i on i n t he
ELD:
1. Reconnect t he ELD 3P con-
neclor,
2. St art t he engi ne and al l ow i t
t o i dl e.
3. Whi l e measur i ng vol t age
bet ween PCM connect or t er
mi nal s 016 and A9. t ur n t he
headl i ght s on
(l ow).
l s t here cont i nui t yT
R6pafu op6n in tho wire between
t he PCM {D161snd t h6 ELD.
Subltituto . known-good PCM
and rachock, f symptom/indic.-
tion goes awry, ropl.ce the origi-
n.l PCM.
Does t he vol t age drop?
Wi re si de of l emal e t ermi nal s
11- 140
Wi re si de of l emal e t ermi nal s
www.emanualpro.com
38
-
00 modeb:
Problem verification:
1. Do t he ECM/ PCM Reset Pro
ceoure.
2. St an t he engi ne.
3- Turn on t he headl i ght s.
Intermittent feilure, sysl.m is OK
at this time. Check for ooor con-
nections or loose wires at C354
(ELDI
and at the ECM/PCM.
l s DTC P1298 i ndi cat ed?
Check l or an open i n t he wi re
(l G1
l i ne):
' 1.
Tur n t he i gni t i on and head-
l i ght s OFF.
2. Disconnect the ELD 3P connector.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4, Measu r e vol t age bet ween
body ground and t he ELD 3P
connect or t ermi nal No.
' 1.
Reprir open or short in th6 wire
bot weon t he No. 15 ALTERNA-
TOR SP SENSOR {7.5 Al fuse in
t he under-drah f use/ rel ay box
and the ELD.
Check t or an opon i n t ho wi re
{GND line}:
1. Turn t he i gni t i on swi t ch and
headl i ght s OFF.
2. Di sconnect t he ELD 3P con
nector.
3. Check for continuity between
body ground and t he ELD 3P
connect or t ermi nal No. 2,
Repair opon in the wire between
the ELD conneclor and GilO2.
Ched( fo. an opn in the wir
(EL
linel:
Check for continuity between the
ELD 3P connect or t ermi nal No. 3
and ECM/ PCM connect or t ermi -
nal A30.
Repair opn in tha wile botwecn
the EcM/PCM lA30l .nd rhe ELD.
Check for s malfunction in lhe ELD:
1. Reconnect t he ELD 3P con-
nector.
2. St art t he engi ne and al l ow i t
t o i dl e.
3 . Wh i l e me a s u r i n g v o l t a g e
between ECM/PCM connector
t ermi nal s A30 and 820, t urn
t he headl i ght s on
(l ow).
Substiiute a known-good ECM/
PCM and recheck. It symptom/
i ndi cat i on goos away, repl ace
the original ECM/PCM.
ELO 3P CONNECTOR {c35/rl
Wi re si de of f emal e t ermi nal s
Wi re si de of f emal e t ermi nal s
Wi re si de ot t emal e t ermi nal s
ELD 3P CONNECTOR {C35,lt
EL I GRN/ RED}
Wi re si de of f emal e
t ermrnars
ECM/PCM CONNECTORS
A l32P)
11- 141 www.emanualpro.com
PGM-FI System
Grankshaft Speed Fluctuation
(CKF)
Sensor
fF13361l
Tj ":""l .tool i ndi cates Di agnosti c Troubl e Code
(DTCI
P1336: Intermi ttent i nterrupti on i nthe Crankshaft Speed
:
Fl uctuati on
(CKF)
sensor ci rcui t.
The scan tool indicates Diagnostic Trouble Code
(DTC)
P1337: No signal in the Crankshaft Speed Fluctuation
(CKF)
sensor circuit.
Description
The di agnosti c system has a pul ser rotor on the crankshaft and a pul se pi ck-up
sensor on the engi ne bl ock. The ECM/PCM
moni tors the crankshaft speed fl uctuati on based on the CKF sensor si gnal , and
j udges
that an engi ne mi sfi re occurred i f
the fl uctuati on goes beyond a predetermi ned l i mi t.
37 mod.l:
CKF SENSOR 2P CONNECTOR IClO4I
T:]
l - r ' r
Ll l
l 1
z L l
' ' ' '
CKF P
I l cKF M
talu/aeot fdJ twxrneor
\-7
Terminal side of male terminals
(To page 11-113)
11- 142
-
Tho MIL ha3 been reported on.
-
DTC P1336 and/ or P1337 are
stored.
Problem verificrtion:
1. Do t he PCM Reset Procedure.
2. St art t he engi ne.
Intermittent {ailure, systom is OK
.l thia timo. Ch6ck tor poor con-
nections or loose wir$ at Clorl
ICKF sonsorl .nd at tho PCM.
Chock tor an opon in th6 CKF .en'
30r:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he CKF sensor 2P
connector,
3, M easur e t he r esi st ance
bet ween t he CKF sensor 2P
connect or t ermi nal s No.
' l
and
No . 2 .
l s t here 1. 6-3. 2 kO?
Check fo. a short in the CKF 3en-
sot:
Check f or cont i nui t y bet ween
body ground
and t he CKF sensor
2P connect or t ermi nal s No. 1 and
No. 2 i ndi vi dual l y.
CKF SENSOR
www.emanualpro.com
{ Fr om
page 11- 142)
Chock to. an open in the wires
(CKF
lin06l:
1. Reconnect t he CKF sensor 2P
connector,
2. D; sconnect t he PCM connec-
t or C
( 31P) .
3. Measure resi st ance bet ween
PCM connect or t ermi nal s C1
a n d Cl 1 .
Ropair open in the wire betwoon
t ho PCM l cl , Cl 1l and t h6 CKF
!6naor.
l s t here 1. 6
-
3. 2 k0?
Chock t or a short i n t he wi res
(CKF
lino3):
Check f or cont i nui t y bet ween
body ground and PCM connector
t er mi nal Cl .
Rcoair short in thc wire btween
the PCM {Cl I and the CKF .en!o..
Subsi i t ut o r known-good PCM
and r6chock. lf symptom/indica-
tion goe3 away, roplaco the origi-
n.l rcM.
PCM CONNECTOR C 13lPI
Wi re si de of l emal e t ermi nal s
CKF P
I ELU/ REDI
(cont' d)
11- 143 www.emanualpro.com
PGM-FI System
Grankshaft Speed Fluetuation
(CKFI
Sensor
(cont'dl
.98
-
00 modols:
CKF SENSOR 2P CONNECTOR IClO'I
r-:-i-_l
t r _ - |
l 1
2 l l
, , - '
CKF P I I CKF M
tsLuneotTOl wlrrneo)
\7
Termi nal si de of mal e t ermi nal s
r : l
t !
El
.KFP
XA"*."
talu rneor
\:f
f
rwxvneor
ECM/PCM CONNECTOR C
(31P)
CKF P
IBLU/REDI
CKF M
(WHT/BEOI
Wi16 side of l6male terminals
1 2 7 8
__l
-l
I
(o
T
16 17 16
't9
20 21 22
,/
2s 26 27 28 29 3() 3l
M
-
The MIL has boon reported on.
-
DTC P1336 and/ or P1337 are
stored.
ProblGm verification:
1. Do t he ECM/ PCM Reset Pro-
cedure,
2. St an t he engi ne.
Inte.mittant failuro, 3y*om b OK
at thb tima. Chack lor ooor con-
nections or looso wirea at C10a
{ CKF sensor l and. t t he ECM/
PCM,
Chgck forun open in tho CKF son-
sori
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the CKF sensor 2P
connector.
3. Measur e t he r esi st ance
bet ween t he CKF sensor 2P
connect or t ermi nal s No. 1 and
No . 2 .
l st here 1. 6
-
3. 2 kO?
Check for a short in the CKF sen-
Check l or cont i nui t y bet ween
body ground
and t he CKF sensor
2P connect or t ermi nal s No. 1 and
No. 2 i ndi vi dual l y.
Check for an open in the wires
ICKF linca):
1. Feconnect t he CKF sensor 2P
connector.
2. Disconnect ECM/PCM connec-
t or C
( 31P) .
3. Measure resi st ance bet ween
ECM/ PCM connect or t er mi '
nal s C22 and C31.
Repair opon in the wir6 botwoon
the ECM/PCM 1C22,
glll
lnd th6
CKF s6n3or.
l s t here 1. 6
-
3. 2 kO?
(To page 11' 1451
11-144 www.emanualpro.com
( Fr om page 11- 144)
Check f or a shorl i n t he wi res
(CKF
lines):
Check l or cont i nui t y bet ween
body ground and ECM/ PCM con
nect or t ermi nal C22.
Repair short in tho wire between
the ECM/PCM {C221 and rh. CKF l s t here cont i nui t y?
Substitute a known-good ECM/
PCM and recheck. lf svmptom/
i ndi cat i on goes away. repl ace
the original ECM/PCM.
ECM/PCM CONNECTOR C
(31PI
Wi re si de of f emal e t ermi nal s
CKF P
{BLU/ RED)
11- 145
www.emanualpro.com
PGM-FI System
Crankshaft Position/Top Dead Center/Cylinder Position
(CKP/TDC/CYP)
Sensor
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
Center/Cvlinder Position tCKP/TDC/CYP) sensor circuit.
P1359: A probl em i n the Crankshaft Posi ti on/Top Dead
-
The MIL has been reoorted on.
-
DTC P1359 is stored.
Problem verific.tion:
1. Do t he ECM/ PCM Reset Proce-
dure.
2. St art t he engi ne. l f t he engi ne
won' t st art , crank i t cont i nu-
ousl yf or at l east 15 seconds.
Intermitteni lailure, system is OK.
Check f or ooor connect i ons or
loos wires al C121 {distributor}
and at the ECM/PCM.
l s DTC P1359 i ndi cat ed?
Check f or poor connect i ons or
l oose wi res bet ween t he di st ri bu'
t or and t he EcM/ PcM.
Substitute a known-good ECM/
PCM, and recheck. ll symplom/
indication goes away, replace the
original ECM/PCM.
11- 146
www.emanualpro.com
ECM/PCM Internal Ci rcui t
l Fi 6oi l
Th" """n tool i ndi cates Di agnosti c Troubl e Code {DTC) P1607: An ECM/PCM Internal Ci rcui t Probl em.
-
The MIL has been reoorted on.
-
DTC PlmT is slor6d.
Problom veritication:
1. Do t he ECM/ PCM Reset Pro
2. Turn t he i gni t i on swi t ch ON
(l l ).
3, Wai t t hree seconds,
l s DTC P1607 i ndi cat ed?
Sub3tiiut a known-good ECM/
PCM and recheck. l f sympt om/
indication goes away, replace the
original ECM/rcM.
11- 147 www.emanualpro.com
PGM-FI System
HO2S Replacement
1. Di sconnect the HO2S 4P connector, and remove the
HO2S.
PRIMARY H02S:
PRIMARY HO2S
4P CONNECTOR
02 SENSOR
WRENCH
PRIMARY
HO2S
44 N.m
{4. 5 kgt m, 33l bf . f t l
SECONDARY HO2S:
SECONDARY HO2S
4,0 N.m
(4.5
kg{.ft, 33 lbtftl
2. Instal l the HO2S i n reverse order of removal .
11- 148 www.emanualpro.com
ldle Control System
System Description
The i dl e speed of the engj ne i s control l ed by the l dl e Ai r Control
(l AC)
Val ve'
The val ve changes the amount of ai r bypassi ng i nto the i ntake mani fol d i n response to el ectri c current control l ed by the
ECM/PCM. When the l Ac val ve i s acti vated, the val ve opens to mai ntai n the proper i dl e speed.
YEL/ From PGM' FI
BLK
TMAI N
RELAY
VARIOUS
SENSORS
4.
IAC VALVE
INTAKE MANIFOLD
After the engi ne starts, the IAC val ve opens for a certai n ti me. The amount of ai r i s i ncreased to rai se the i dl e speed
about 150
-
300 rpm.
when the cootant temperature ts row, the l Ac val ve i s opened to obtai n the proper fast i dl e speed The amount o{
bvoassed ai r i s thus control l ed i n rel ati on to the engi ne cool ant temperature
When the i dl e speed i s out o{ speci fi cati on and the scan tool does not i ndi cate Di agnosti c Troubl e Code
(DTC)
P0505
or P1508, check the fol l owi ng i tems:
.
Adj ust the i dl e speed
(see page 11-169, 170)
.
Ai r condi t i oni ng si gnal
( seepagel l - 1551
.
ALT FR si gnal
( see page 1l - 159)
.
Starter swi tch si gnal
(see page 11-16' 1)
.
A,/T gear posi ti on si gnal
(see
secti on 14)
.
PSP swi t ch si gnal
( seepagel l - 162)
.
Brake swi tch si gnal
(see page 11-165)
.
Fast i dl et her moval ve
( see page' 11 168)
.
Hoses and connecttons
.
IAC val ve and i ts mounti ng O-ri ngs
l f the above i tems are normat, suDsl i tute a known-good IAC val ve and readj ust the i dl e speed {see
page 11-169, 170)
l f the i dl e speed sti l l cannot be adj usted to speci fi cati on
(and
the scan tool does not i ndi cate DTC P0505 or Pl 508)
after IAC val ve reol acement, substi tute a known-good ECM/PCM and recheck l f symptom
goes away' repl ace the
ori gi nal ECM/PCM.
11- 149
www.emanualpro.com
ldle Control System
ldle Control System
I
P0505
|
The scan tool i ndi cates Di agnosti c T.oubl e Code
(DTCI
PO5O5: l dl econtrol svstem mattuncti on.
NOTE: l f DTC P1508 i s stored at the same ti me as DTC P0505, troubl eshoot DTC P1508 fi rst. then troubl eshoot DTC
p0505.
Possibls Cause
. IAC val ve mechani cal mal functi on
. Throttl e body cl ogged port, i mproper adl ustment
. Intake mani fol d gasket l eakagi ng
. Intake ai r hose l oose l eakagi ng
. Vacuum hose l eakagi ng
a ECT sensor i ncorrect output
. Throttl e Posi ti on sensor i ncorrect output
Troubleshooting Flowchart
The MIL has been reDorted on.
DTC P0505 is sto.ed.
Problem verificationi
1. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
the radiator Ian comes on, then
let it idle.
2. Wi t h t he scan t ool , check t he
l ol l owi ng i t ems.
-
Throttle position
should be
approx. 10% with the throt-
tle {ully closed.
-
Engi ne cool ant t emper a
t ure shorJl d be 194
-
205' F
(90 -
96"C).
l f t hey are not wi t hi n t he
spec. , repai r t he f aul t y sen-
sor ci rcui t .
3 Check t he engi ne speed at
i dl e wi t h no-l oad condi t i ons:
headl i ght s, bl ower f an. rear
def ogger, radi at or l an, and ai r
condi t i oner are not operal i ng,
Inte.mittent failure. syltem is OK
at this time.
l s i t 750 {730)* i 50 rpm?
l s i l 700 (680)'
rpm or l ess?
{ To
page
11- 151)
( To page
1' l - 151)
l : ' 99 -
00 model s
www.emanualpro.com
(From page 11-150)
{ Fr om
page 11- 150}
THERMO VALVE
(A/T
onlyl
Check the IAC valve:
Di sconnect t he 2P connect or f rom
t he I AC val ve.
Does t he engi ne speed droP
or t he engi ne st al l ?
Adiust the
(basel idl speed lsee
page 11-169, 1t 0). I t i he ba3e i dl e
speed cannot be adiustd, clean
the Dorts in the throttle body.
UPPER
Check the tast idle lhermo valve:
1. Turn t he i gni t i on swi t ch OFF.
2. Remove t he i nt ake ai r duct
from the throttle body.
3. St art t he engi ne and l et i t i dl e.
4. Put your f i nger on t he l ower
pon i n t he t hrot t l e body.
Check engine cool.nt level and for
air in the cooling sy3lem. lf OK,
reolace the f.st idle thermo valve.
Does t he engi ne speed drop?
Put your I i nger on t he uPPer
Port
i n t he t hrot t l e body.
Check f or vacuum l eaks, make
sure t he t hrot t l e val ve i s com'
pletely clo3ed. and repair as nec-
Does t he engi ne speed droP?
Adjust the idle spoed lsee Page
11-169. 1701. l f t he adi ust ment
does not correct l he
probl em,
r.olace the IAC valve.
www.emanualpro.com
ldle Control System
ldle Air Control
llAC)
Valve
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
Pl 508: A probtem
i n the l dl e Ai r Controt fl AC) varve
circuit.
The IAC Val ve changes the amount of ai r bypassi ng the throttl e body i n response to a current si gnal from the ECM/PCM i n
order to mai ntai n the proper i dl e speed.
37 model;
IAC VALVE 2P CONNECTOR {C132}
,f\
rcp'
# IYEL/BI.(I
I 2 f - 1
- d )
Y
Wir side of female terminals
PCM CONNECTOR A I32PI
tacv
I BLK/
BLU)
From AIR To INTAKE
CLEANER MANIFOLD
Wi re si de of f emal e t ermi nal s
The MIL has beon .eportd on.
OIC Pl508 is sto.ed.
Problem veiification:
1. Do t he PCM Reset Procedure.
2. St art t he engi ne, and warm i t
up t o normal operat i ng t em-
perat ure.
Inte.mittent failure, systcm b OK
at thi3 time. Check tor poo. con-
nections or loose wircs at C132
(lAC
v.lvel and at the PCM.
l s DTC Pl 508 i ndi cat ed?
Check l or an open i n t he wi r6
{lGPl lins}:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he I AC val ve 2P
connect or.
3. Turn the ignition switch ON {ll).
4. Measure voltage between body
ground
and t he I AC val ve 2P
connector term inal No.2.
Repair open in the wire trctwoon
t ha I AC v! l v6 and t he PGM-Fl
main relly.
Chock for an opan o. short in tho
wi.e
(lACv
linel:
1. Turn t he i gni t i on swi t ch OFF
and reconnect t he I AC val ve
2P connect or.
2. Disconnect the PCM conneclor
A
(32P).
3. Turn the ignition switch ON {ll).
4, Measur e vol t age bet ween
body ground
and PCM con-
nect or t ermi nal A12.
{ To
page
1l - 153)
www.emanualpro.com
Bepair opn or short in the wire
betweon th PCM {A121 and the
IAC vrlve.
l s t here baf t ery vol t age?
Check the IAC valve function:
Moment ari l y connect PCM con'
nect or t er mi nal s A12 and A10
wi t h a i umoer wi re several t i mes,
Does t he I AC val ve cl i ck?
Substitute . known-good PCM
and rcheck, lt 3ymptom/indica-
tion goes away, replaco the origi_
nal PCM,
( Fr om page 11- 152)
Wi re si de of f emal e t ermi nal s
1- 153
www.emanualpro.com
The MIL has boen r.ported on.
DIC Pl 508 b 3tored.
Problem veritication:
L Do t he ECM/ PCM Reset Pro-
cedure.
2. St art t he engi ne, and warm i t
up t o normal operat i ng t em-
perature.
Intrmittent failure, systom is OK
al lhis timo. Check lor poor
con-
nections or looro wirca at C132
(lAc
vrlvel and .t rho EcM/PcM.
l s DTC P1508 i ndi cat ed?
Chock t or an open i n t he wi r6
l l GPl l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he I AC val ve 2P
connector,
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Measure voltage between body
ground
and t he I AC val ve 2P
con nector termina I No, 2.
Repair opon in the wira botwoon
t he I AC val ve and t ho PGM-FI
main aalay.
Check tor an open or short in the
wire
(IACV
linel:
1. Turn t he i gni t i on swi t ch OFF
and reconnect t he I AC val ve
2P connector.
2. Di sconnect ECM/ PCM con-
nector B {25P).
3. Turn the ignition switch ON {ll}.
4. Measur e vol t age bet ween
body ground
and ECM/ PCM
connect or t ermi nal 823.
Ropair open or short in thg wire
between tho ECM/FCM lB23l and
the IAC valve.
ls there battery voltage?
Check the IAC valve func,tion:
Moment ari l y connect ECM/ PCM
connect or t ermi nal s 823 and 82
wi t h a
j umper
wi re several t i mes.
Does t he I AC val ve cl i ck?
Subslitute . known-good ECM/
PCM . nd rechock. l f sympt om/
i ndi cat i on goes
aw. y, repl ac.
th original ECM/PCM.
ldle Air Control
(lAC)
Valve
{cont'd}
'98
-
00 models:
IAC VALVE 2P CONNECTOR {C132I
F\
rcpt
*l tYELrBLxl
I 2 / ' -
-
rf)
Y
Wire side ot fem.le terminals
ECM/PCM CONNECTOR B
(25PI
Wi re si de of f emal e t ormi nal s
2 5 8
9
'to
1l 13 t 7
19 20 21 22 23
tAcv
(BLK/BLUI
v
PG1
{BLKI
1 2 | t 3 4 5 8
9 1 0 1 1 13 17
19 20 | 121) 22
tAcv
(BLK/
BLU)
JUMPER WI RE
www.emanualpro.com
Ai r Condi ti oni ng Si gnal
Thi s si gnal s the EcM/PcM when there i s a demand for cool i ng from the ai r condi ti oni ng system.
'97
modol:
Wi re si de of l emal e t ermi nal s
PCM CONNECTOR C
(31PI
ACS IBLU/RED)
PCM CONNECTOR A
(:TIPI
(cont' d)
1 1- 1 55
Chock f or a shorl i n t hc wi ro
(ACS linol:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he A/ C
pressure
switch 2Pconneclor.
3. Turn t he i gni t i on swi t ch ON
(l l ).
, 1.
[ I easu r e vol t age bet ween
PCM connect or t ermi nal s C5
and A9.
Check for . .hon in the wire IAGS
linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect PCM connect or C
( 31P) .
3. Check for continuity between
body
ground and PCM con-
nect or t ormi nal C5.
Reoaii short in tho wire btwoen
rh6 PCM
(Csl
and the A/C pres-
3urc 3witch.
-
Subcdtrte a known{ood PCM
and recheck. lf pr6actibed volt-
age is now av{ilable, roplace
the origind PCM,
-
Soe the eir conditionor in3pc-
lion lsee soction 221.
Check t or an opon i n t he wi t e
(ACC lino):
1. TLrrn t he i gni t i on swi t ch OFF.
2. Roconnect t he A/ C pressure
switch 2P connector.
3. Turn the ignition switch ON
(ll).
4. Moment a r i l y connect PCM
connect or t er mi nal s A9 and
417 wi t h a
i umper
wi re sev'
eral t i mes,
Wi re si de of f emal e t ermi nal s
JUMPER WIRE
(To page 11-156)
Wi re si de oI I emal e t ermi nal s
www.emanualpro.com
ldle Gontrol System
Ai r Condi ti oni ng Si gnal
(cont' dl
(From page 11-' 155)
JUMPER
WIRE
UNOER.HOOD FUSE/RELAY
BOX 9P CONNECTOR tqt52)
1 2 3 I
5 6 I
ACC IBLK/R
Wi re si de of
ACC IBLK/REDI
Wi re si de of f emal e
t ermrnat s
A t32Pl
PCM CONNECTORS
C t3rp)
Wi re si de ol l emal e t ermi nal s
Ch6ck f or an open i n t h wi re
(ACC
linel:
Moment ari l y connect t he under-
hood fuse/relay box 9P connector
t er mi nal No. 5 t o body gr ound
wi t h a
j umper
wi re several t i mes.
l s t here a cl ; cki ng noi se f rom
t he 4! / C compressor cl ut ch?
l s t here a cl i cki ng noi se f rom
t he 4! / C compressor cl ut ch?
See ai r condi i i oner i nspect i on
{see section 221.
Repai. op6n in the wire betwoen
t he PcM
( A17)
and t ho A/ C
clutch relay.
Check the A/C operation:
1. St art t he engi ne.
2. Turn t he bl ower swi t ch ON.
3. Turn the A"/C switch ON.
Check f or an open i n t he wi re
(ACS
line):
Measure vol t age bet ween PCM
connect or t ermi nal s Ag and C5.
Does the A,/C operate?
Air conditioning signal is OK.
Repair open in the wire between
the PCM lCSl and the A/C awitch.
l s t here l ess t han 1. 0 V?
-
Subqtitute a known-good FCM
.nd rch6ck. lt 3ymptom/indi-
cation goes
awav, replece the
original rcM.
-
Soe th eir conditioner in3pec-
tion
(s6
aec.tion 22).
www.emanualpro.com
'98
-
00 models:
ECM/PCM CONNECTORS
ECM/PCM CONNECTOR A
(32PI
Wi re si de of f emal e t ermi nal s
ECM/PCM CONNECTORS
A
(32P1
ACC
(BLK/REOI
LG1
(BRN/BLKI
{cont' d)
11- 157
A {32P1
Check f or a shot t i n t he wi re
{ACS linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he A/ C
Pressure
switch 2P connector.
3. Turn t he i gni t i on swi t ch ON
(l l )
4. Measur e vo l t age bet ween
ECM/ PCM connect or t er ml
nal s A27 and 820.
Check tor . short in the wire IACS
l i nel :
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect ECM/PCM connec-
tor A
(32P).
3. Check f or cont i nui t y bet ween
body
ground and ECM/ PCM
connect or t ermi nal A27.
ls there battery voltage?
R.oak short in the wile between
rhe ECM/PCM
(A271
and the A/C
Dressure switch.
l s t here cont i nui t v?
Sub6titute a known{ood ECM/
rcM and recheck. lf pte6cribed
vol t age i 3 now avai l abl e, re'
pl.ce the origioal ECM/rcM.
See ih6 air conditioner inspec-
tion
(s6e
section 221.
Check f or an open i n t he wi re
(ACC
line):
' 1.
Turn t he i gni t i on swi t ch OFF.
2. Reconnect t he A/ C
Pressure
switch 2P conneclor.
3. Turn the ignition switch ON
(ll).
4. Moment ar i l y connect ECM/
PCM connect or t ermi nal s A17
and 820 wi t h a
j umPer
wi r e
several l l mes,
{To
page 11 158) JUMPER WIRE
www.emanualpro.com
ldle Control System
Ai r Gondi ti oni ng Si gnal
(cont' d)
JUMPER
WIRE
UNDER-HOOD FUSE/RELAY
BOX 9P CONNECTOR {G'52I
2 3 a
5 5 8 9
ACC
(BLK/R
Wire side ot
ACC
(BLK/RED'
Wire side otfemale
t ermi nal s
ECM/PCM CONNECTORS
Wi re si d of f emal e t ormi nal s
(From page
' 11, 157)
Check I or dn opon i n t he wi ro
IACC linel:
Moment ari l y connect t he under-
hood fuse/relay box 9P connector
t er mi nal No. 5 t o body gr ound
wi t h a
j umper
wi re several t i mes.
l s t here a cl i cki ng noi se l rom
the
y'y'C
compressor clutch?
l s t here a cl i cki ng noi se f rom
tho A,/C comprossor clutch?
Sae ri r condi t i onal i n3pact i on
lroa saction 221.
Repai. open in th6 wiro lrtwlan
the ECM/PCM
lAl7l .nd tho A/C
clutch rolay.
Check tho op.ration of tho A/C:
1. St an t he engi ne.
2. Turn t he bl ower swi t ch ON.
3. Turn the Ay'C switch ON.
ChGGk f or an open i n t he wi . e
IACS linel:
Measure vol t age bet weon ECM/
PCM connect or t er mi nal s A27
and 820.
Does the !y'C operate?
Air conditioning 3ignal i3 OK.
Rap.ir opon in the wir6 bdtunaan
rh. Ecil/FcM
lA27l rnd rh. A/c
rwitch.
l s vol t age l ess t han 1. 0 V?
Sub6lftna a known{ood ECM/
PCM and rechock. l f symp-
t om/ i ndi cet i on goes away.
roplace the original ECM/rcM.
See the ah conditionor inspoc-
tion {3e section 22},
www.emanualpro.com
Alternator
(ALT)
FR Signal
Thi s si gnal s the ECM/PCM when the Al ternator
(ALTI
i s chargi ng.
,97
modet:
PCM GONNECTORS
wi re si de of f emal e t ermi nal s
ALT CONNECTOR
(C1O5I
lP
r-F- ALT F
l l l 2l l w| { f r REDl
| 3 . r - ' l
-
lruueen
wne
c
(31P|
wire side ol fmale terminals
PCM CONNECTOR C I31P)
3Pr
JUMPER
WIRE
Inspection ot ALT FR Signal.
Check l or a shor t i n t he wi r e
{ALT F line}:
1. Di sconnect t he 4P 13Pi * con
nector from the ALT.
2. Turn t he i gni t i on swi t ch ON
(l l )
3, Measur e vol t age bet ween
PCM connect or t ermi nal s C17
and A9.
Check f or a short i n t he wi re
(ALT
F linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he negat i ve bat '
tery cable from the battery.
3. Di sconnect PCM connect or C
( 31P) .
4. Check f or cont i nui t y bet ween
body
gr ound and PCM con
nect or t ermi nal C17.
l s t here approx. 5 V?
Check th ope.ation of the ALT:
1. Turn t he i gni t i on swi t ch OFF
2. Reconnect t he ALT 4P {3Pi *
connect or t o t he ALT.
3. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
t he r adi at or f an comes on,
t hen l et i t i dl e.
4. Measur e vol t age bet ween
PCM connect or t ermi nal s C17
and A9.
Ropeir short in the wir6 betweon
the PCM lC17l and the ALT.
Subst i t ut . a known-good PCM
and recheck. lf prescribed volt-
age is now availablo, replace the
ori gi nal PCM.
Does t he vol t age decrease when
headl i ght s and rear def ogger are
t urned on?
ALT FR signal b OK.
Chd( for an opn in tho wire IALT
F linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he negat i ve bat -
tery cable lrom the battery.
3. Di sconnect PCM connect or C
(31P).
4. Di sconnect t he 4P
(3P)*
con-
nector lrom the ALT.
5. Connect the ALT 4P
(3P)*
con-
nect or t ermi nal No. 4
(No.
1)*
t o body ground wi t h a
i umper
6. Check for continuity between
body
ground and PCN4 con'
nect or t ermi nal Cl 7.
Repai r open wi . e bet ween t he
PCM lCl7l and the ALT.
l s t here cont i nui t y?
ALT F IWHT/REDI
Wi re si de of f emal e t ermi nal s
1 1 - 1 5 9
www.emanualpro.com
ldle Gontrol System
Alternator
(ALT)
FR Signal
(cont'dl
'98
-
00 modols:
ALT CONNECTOR
(C1I}5I
4P
rH]
Arr F
l ' l ' l t wHr / REo)
l 3 l a F 1
I
JUMPER WIRE JUMPER
+ WIRE
ECM/PCM CONNECTORS
Wi re si de of f emal e t ermi nal s
ECM/PCM CONNECTOR C {31PI
Wi re si de of f emal e t ermi nal s
Wi re si de of f emal e t ermi nal s
ECM/PCM CONNECTOR C {31P}
":
Canada
1 1- 160
B
(25P)
Inspction of ALT FR Signsl.
Check fo. a shon in th. wire {ALT
F linel:
1. Di sconn6ct t he 4P
(3P)*
con-
nector from the ALT.
2. Turn t he i gni t i on swi t ch ON {l l ).
3. Measure voltage between ECM/
PCM connect or t ermi nal s C5
and 820.
Chck for a sho.t in iho wirc
lAlT
F lino):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnecl t he negat i ve bat ,
tery cable from the battery.
3. Disconnect ECM,PCM connec-
t or C
( 31P) .
4. Check f or cont i nui t y bet woen
body ground and ECM/ PCM
connect or t ermi nal c5.
l s t here approx. 5 V7
Check the opcration of the ALT:
1. Turn t he i gni t i oo swi t ch OFF.
2. Reconnect rhe ALT 4P
(3P)*
connector to the ALT.
3. St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral ) unt i l
t he r adi at or l an comes on,
t hen l et i t i dl e.
4. Measure voltage between ECM/
PCM connect or t ermi nal s C5
and 820.
Roprir lhort in tho wirc bstween
tho ECM/PCM {Csl and the ALT.
Substitut. r known-good ECM/
PCM and roch.ck. It Droscrib.d
voltage b now lvrilabls, .eplacc
th. o.igin!l ECM/PCM.
Does the voltage decrease when
headl i ght s and rear def ogger are
t urned on?
ALT FR 3ignol is OK,
Chock lor an opon in tha wire (ALT
F linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he negat i ve bat -
tery cable from the battery.
3. Di sconnect ECM/ PCM con-
nect or C
(31P).
4. Di sconnect t he 4P
13P)* con,
nector from the ALT.
5. Connect t he ALT 4P {3P)* con-
nect or t ermi nal No. 4 1No. 1)*
t o body ground
wi t h a
j umper
6. Check for continuity betwen
body ground
and ECM/ PCM
connect or t ermi nal C5.
Rspri r opan wi ro bat w. en t ho
ECM/PCM lcsl .nd th. ALT.
l s t here cont i nui t y?
AI.T F IWHT/REDI
ALT F {WHT/REDI
Wi re si de ot I emal e t ermi nal s
www.emanualpro.com
Starter Switch Signal
Thi s si gnal s the ECM/PCM when the engi ne i s cranki ng.
'97
model:
A {32P}
'98
-
00 models:
Transmi ssi on i n E or E
posi t i on.
LGl
(BBN/ BLK)
PCM CONNECTORS
Wi re si de of f emal e t ermi nal s
ECM/PCM CONI{ECTORS
STS
(BLU/ORNI
c t31P)
NOTE:
.
M/T: Cl utch
pedal must be depressed.
.
A/T: Transmi ssi on i n E orE
posi ti on
Check for an opan ot short in the
wire
(STS linel:
Measure vol t age bet ween PCM
connect or t er mi nal s C6 and Ag
wi t h t he i gni t i on swi t ch i n t he
st art
(l l l ) posi t i on.
lnspect the No. 31 STARTER SIG-
NAL
(7. 5
A)I l l se i n t he under' dash
ls there battery voltage?
-
Reoair short in the wire be-
tween the PCM lc6l and th.
No. 31 STARTER SIGNAL 17 5
A) t use ot t he PGM-FI mai n
reray.
-
Reolace the No. 31 STARTER
SI GNAL t 7. 5 Al t u. e.
Starter swiich signal i3 OK.
Repair opon in the wire betweon
r h6 PCM l c6l and t he No 31
STARTER SIGNAL 17.5
A)fuse.
A
(32P)
Wi re si de oI f emal e t ermi nal s
Check tor an open or short in the
wir
(STS line):
Measure vol t age bet ween ECM/
PCM connect or t er mi nal s A24
and 820 wi t h t he i gni t i on swi t ch
i n t he st art posi t i on
(l l l ).
I nspect t he No. 31 STARTER SI G
NAL
(7. 5
A){use i n t he under-dash
l s t here bat t ery vol t age?
-
Reoai r shor l i n t he wi r e
betwen the ECM/PCM lA2,fl
and the No, 31 STARTER SIG-
NAL t7.5 Al tu3 ot the PGM'
Fl main rclay.
-
Repl.c. tho No. 31 STARTER
SIGNAL 17.5 Al fu3e.
Starter switch 3ignal is OK.
Repair opon in tho wire between
the ECM/PCM {A241 and the No
31 STARTER SIGNAL
(7.5
A) tu3e
1 1 - 1 6 1
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ldle Gontrol System
Power Steering Pressure
(PSP)
Switch Signal
Thi s si gnal s the ECM/PCM when the power
steeri ng l oad i s hi gh.
'97
model:
*:
Do not hol d t he st eer i ng wheel at t ul l
l ock f or mor e t han f i ve seconds,
Wi re si de of f emal e t ermi nal s
PSP SWTTCH 2P CONNECTOR
1C135)
PSP SW
(GRN)
JUMPER T_7 1 \
vnRE
t--f
r)
GND IBLK}
Wire 3id6 of female terminals
Inspection ot PSP switch signal.
Check for an open in the wire {PSP
SYV line):
1. Turn t he i gni t i on swi t ch ON
(l l ).
2. Measur e vol t age bet ween
PCN4 connect or t ermi nal s C16
and A9.
Check tor an open in lhe wire (PSP
SW linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the PSP switch 2P
connecror,
3. Turn the ignition switch ON
(ll).
4. At t he harness si de, connect
t he PSP swi t ch 2P connect or
t e r mi n a l s No . 1 a n d No . 2
wi t h a
j umper
wi re.
5, Measut e vol t age bet ween
PCM connect or t ermi nal s C16
and A9.
l s t here l ess t han 1. 0 V?
-
Ropsi r open i n t he wi . e be-
twoon the PCM lcl6l and the
PSP switch.
-
Ropdir open in BLK wire be-
t ween t he PSP swi t ch and
G101.
l s t here l ess t han 1. 0 V?
Check the operation oI lhe PSP
switch:
1. St an t he engi ne
2. Turn t he st eeri ng wheel t o t he
f ul l l ock posi t i on*.
3. Measure voltage between PCM
connect or t ermi nal s C16 and
A9.
ls there battery voltage?
PSP switch signal is OK.
(To page
11-163)
www.emanualpro.com
{ Fr om
page 11 162)
PCM CONNECTORS
Wi re si de of f emal e t ermi nal s
c t3l Pl
Check f or a shor t i n t he PSP
swilch:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he 2P connect or
f rom t he PSP swi t ch.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. l l eas u r e vol t age bet ween
PCM connect or t ermi nal s C16
and A9.
Check tor a short in the wire
(PSP
SW l i nol :
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect PCM connect or C
( 31P) .
3. Check f or cont i nui t y bet ween
body ground and PCM connec-
t or t ermi nal C16.
Reoair short in the wire betwoon
r he PCM { C16) and t he PSP
3witch.
Subst i t ut e a known-good PCM
and rocheck. l f proscri bod vol t -
age b now available, replace the
original PCM.
(cont' d)
- 163
1 1
www.emanualpro.com
ldle Control System
Power Steering Pressure
(PSP)
Switch Signal
(cont'dl
'98
-
00 models:
*:
Do not hol d t he st eeri ng wheel at l ul l
l ock f or more t han f i ve seconds.
ECM/FCM CONNECTORS
PSP SwlTCH 2P CONNECTOR
ICl35}
PSP SW IGRNI
JUMpER f-7
T
\
wtRE
L-5
rl
GND
(3LX}
Wi re si de of l emal e t ermi nal s
Inspection of PSP swilch 3ignal.
Chck tor rn opon in the wire
(PSP
SW line):
1. Turn t he i gni t i on swi t ch ON {l l ).
2. Measure voltage betlveen ECM/
PCM connect or t ermi nal s 426
and 820.
Chock for an open in the wire IPSP
SW lin):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he PSP swi t ch 2P
connect or,
3. Turn the ignition switch ON
(ll).
4. At t he wi re si de. connect t he
PSP swi t ch 2P connect or t er
mi nal s No. 1 and No. 2 wi t h a
5. Measure voltage between ECM/
PCM connector terminals 426
and 820.
l s t here l ess t han 1. 0 V?
-
Ropai . open i n t he wi re be-
t weon t h6 ECM/ PCM
(A26)
and th6 PSP .witch.
-
R6p.ir open in BLK wire be-
t ween t ho PSP 3wi t ch and
G 1 0 1 ,
l st here l ess t han 1. 0 V?
Check the opration of the PSP
switch:
1. St an t he engi ne
2. Turn st eeri ng wheel t o t he f ul l
l ock posi t i on*.
3. Measure voltage btween ECM/
PCM connect or t ermi nal s A26
and 820.
ls there battery voltage?
PSP switch signal is OK.
Wi re si de of f emal e t ermi nal s
11- 164
( To page 11- 165)
www.emanualpro.com
{From
page 11 164i
Check f or a shor t i n t he PSP
switch:
1. Turn t he i gni t i on swi t ch OFF.
2, Di sconnect t he 2P connect or
f rom t he PSP swi t ch.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Measure voltage betlveen ECM/
PCM connect or t ermi nal s A26
and 820.
Check lor e 3hort in the wire IPSP
SW linell
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect ECM/ PCM con-
nector A
(32P).
3. Check f or cont i nui t y bet ween
body gr ound and ECM/ PCM
connector terminal A26.
ReDair short in the wir bstween
the ECM/PCM
(A26)
and the PSP
switch.
Substitute a known-good ECM/
PCM and rechock. It Drescribod
voltago is now available, roplace
the origin.l ECM/PCM,
ECM/PCM CONNECTORS
A l32Pl
Wi re si de of f emal e t ermi nal s
Wi re si de of f emal e t ermi nal s
1 1 - 1 6 5
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ldle Control System
Brake Switch Signal
Thi s si gnal s the ECM/PCM when the brake
pedal i s depressed.
(' 97
model )
' - - - - - _ - I l
PCM CONNECTORS
a t32P) D l l 6Pl
BKSW
(GRN/WHT)
Wi re si de of f emal e t ermi nal s
Inspction of Brak. Switch Signal.
Are t he brake l i ght s on wi t hout
pressi ng
t he brake pedal ?
I nspect t he HORN, STOP {15 A)
fuse in the undeFhood luse/ relay
box.
Do t he brake l i ght s come on?
Reoair short in the wire be-
tween th b.ake switch and
th6 HoRN, STOP {15 A)luso,
Replaco the HoRN, STOP
(15
Al fuse.
Repai r op6n i n t he wi r be-
tween the brake switch and
tho HORN, STOP
(15
Allus6.
Inspect the brrke switch
(see
aection l9l.
Check t ol . n open i n t he wi re
{BXSW linel:
1. Press t he brake
pedal .
2. Measure voltage between rcM
connector terminais D5 and Ag
with the brake pedal pressed.
Reprir open in the wire between
t he PcM l D5l r nd t he br ake
switch.
(To page
11-167)
1 1- 166 www.emanualpro.com
(From page 11-166)
Chock f or en open i n t he wi re
(BKSW line):
1. Press t he brake
pedal .
2. Measure vohage between ECM/
PCM connector terminals A32
and 820 wi t h t he brake
pedal
pressed.
Ropair opon in tha wire bstwson
r he ECM/ PCM l A32l r nd t he
brako switch.
Brake switch signd b OK.
ECM/FCM OONNECTORS
Wi re si de of f emal o t ermi nal s
11- 167
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ldle Control System
Fast ldle Thermo Valve
lA/T)
Description
To prevent errati c runni ng when the engi ne i s warmi ng
up, i t i s necessary to rai se the i dl e speed. The fast i dl e
t her mo val ve i s cont r ol l ed by a t her mowax pl unger .
When the engi ne i s col d, the engi ne cool ant surround-
i ng the thermowax contracts the pl unger, al l owi ng addi -
ti onal ai r to be bvDassed i nto the i ntake mani fol d so that
the engi ne i dl es faster. When the engi ne reaches operat-
i ng temperature. the val ve cl oses, reduci ng the amount
of ai r bypassi ng i nto the i ntake mani fol d.
IDLE
ADJUSTING
IDLE
THERMO
VALVE
AIR BYPASS VALVE
1 1 - 1 6 8
Inspgction
NOTE: The fast i dl e thermo val ve i s factory adj usted; i t
shoul d not be di sassembl ed.
1. Remove the i ntake ai r duct from the throttl e body.
2. Start the engi ne,
3. Put your fi nger over the l ower port i n throttl e body,
and make sure that there i s ai r fl ow wi th the engi ne
cold
(engine
coolant temperature below 86"F, 30'C).
l f there i s no ai r fl ow, repl ace the fast i dl e thermo
valve and retest,
O-RINGS
Repl ace.
11.0 kgfl.m, 7.2 lbl.ftl
Start the engine. Hold the engine at 3,000 rpm with no
l oad
(i n
Park or neutral ) unti l the radi ator fan comes
on, then let it idle.
Check that the valve is completely closed. lf the valve
is leaking, the idle speed will drop when you cover the
l ower pon. Check the engi ne cool ant l evel and for ai r
i n the engi ne cool i ng system {see secti on 10). l f the
cool i ng system i s OK, repl ace the fast i dl e thermo
valve and recheck.
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ldle Speed Setting
Inspoction/Adiustmont
37 modsl:
NOTE:
. Before setti ng the i dl e speed, check the fol l owi ng
i tems:
-
The MIL has not been reportsd on.
-
l gni t i on t i mi ng
-
Spark pl ugs
-
Ai r cl eaner
-
PCV system
.
l canada) Pul l the parki ng brake l ever up. Stan the
engi ne, then check that the headl i ghts are off.
1. Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(i n
Park or neutral ) unti l the radi ator fan
comes on, then l et i t i dl e.
Connect a tachometer or a Honda PGM Tester.
Di sconnect the 2P connector from the l dl e Ai r Con-
trol
(l AC)
val ve.
IAC VALVE
l f the engi ne stal l s, restart the engi ne wi th the accel -
erator pedal
slightly depr6ss6d, Stabilize the rpm at
1,000, then sl owl y rel ease the pedal unti l the engi ne
i dl es.
Check i dl i ng i n no- l oad condi t i ons: hsadl i ght s,
bl ower fan, rear dfogger, radi ator fan, and ai r con-
di ti oner are not operati ng.
ldle spood should b.:
{80 t 50 rpm {in
Park or noutr.ll
IDLE
7.
Adj ust the i dl e sp6ed,
i dl e adj usti ng screw.
i f necessary, by turni ng the
Turn the i gni ti on swi tch OFF.
Reconnect the 2P connector to the IAC valve, then
remove the BACK UP
(RAD| Ol (7.5
Al fuse i n the
under-hood fuse/rslav box for 10 seconds to reset
the PCM.
Restart and l et the engi ne i dl e wi th no-l oad condi -
ti ons for one mi nute, then check the i dl e speed.
NOTE:
(Canadal
Pullthe
parking
brake lever up. Stan
the engine, then check that the headlights are off.
ldlo Eped rhould be:
75O t 50 rpm
(in
P.rk or noutr.ll
Let the engi ne i dl 6 for one mi nute wi th the head-
l i ghts
(Low)
ON, and check th i dl speed.
ldle lpcod 3hould bo:
750 t 50 ]pm
(in
Park or nautlal)
Turn the headlights off. Let th engine idle for one
mi nute wi th the headl i ghts
(Low)
ON, heater fan
switch at Hl and air conditioner on. then check the idle
sDeeo.
ldl. specd should b6:
7d) 1 50 rpm {in Park or nautral}
l f the i dl e speed i s not wi thi n speci fi cati on, see the
symptom chart on
page 11-64.
(cont' d)
1 1- 169 www.emanualpro.com
ldle Control System
ldle Speed Setting
(cont'd)
38
-
0O mod6l3:
NOTE: Before setti ng the i dl e speed, check the fol l ow-
i ng i tems:
-
The MIL has not been reported on.
-
l gni ti on ti mi ng
-
Spark pl ugs
-
Ai r cl eaner
-
PCV system
1. Start the engi ne. Hol d the engi ne at 3.000 rpm wi th
no l oad
(i n
Park or neutral ) unti l the radi ator fan
comes on, then l et i t i dl e.
Connect a tachometer.
Disconnect the IAC valve 2P connector and the EVAP
purge control solenoid valve 2P connector.
CONTROL
SOLENOID VALVE
SOLENOID VALVE
l f the engi ne stal l s, restart the engi ne wi th the accel -
erato. pedal slightly depressed. Stabilize the rpm at
1,000, then sl owl y rel ease the pedal unti l the engi ne
i dl es.
Chek the idle in no-load conditions: headlights, blow-
er fan, rear defogger, radiator fan, and air conditioner
are not operating,
ldle speed should bo:
480 t 50 rpm {in PErk or noutrall
11- 170
l f necessary, adj ust the i dl e speed, by turni ng the
i dl e adj usti ng screw.
After adj usti ng the i dl e speed, recheck the i gni ti on
ti mi ng
(see
secti on 4). l f i t i s out of spec, go back to
steo 4.
tDt.E
6. Turn the i gni ti on swi tch OFF.
7. Reconnect the 2P connectors to the IAC val ve and
the EVAP purge
control sol enoi d val ve, then do the
ECM/PCM reset procedure.
8. Restart and i dl e the engi ne wi th no-l oad condi ti ons
for one mi nute, then check the i dl e speed.
ldle speod should be:
,98
model:
750 t 50 rpm tin Park or neutral)
'9!l
-
00 modsls:
730 i 50 lpm lin Psrk or neutral)
NOTE: l f the i dl e speed i ncreases to 780 t 50 rpm
(770
1 50 rpml *, thi s means the EVAP system i s
purgi ng the cani ster. To stop the
purgi ng
temporari -
l y, rai se the engi ne speed above 1,000 rpm wi th the
accel erator pedal , then sl owl y rel ease the pedal .
*:
' 99
-
00 model s
9. Let the engi ne i dl e for one mi nute wi th the head-
l i ghts
(Low)
ON, and check the i dl e speed.
ldle speed should be:
38 mod6l:
750 f 50 rpm
(in
Palk or neutrall
'99
-
00 modols:
730 t 50 rpm
(in
Palk or neutral)
10. Turn the headl i ghts off. Let the engi ne i dl e for one
mi nute wi th the heater fan swi tch at Hl and ai r con-
di ti oner on, then check the i dl e speed.
ldls spqed should be:
'98
model:
780 t 50 rpm
(in
Park or neutrall
'99
-
00 modls:
7701 50 rpm lin Park or neutral)
l f the i dl e speed i s not wi thi n speci fi cati on. see the
Symptom Chart on page 11-64.
ADJUSTING
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Fuel Supply System
Fuel Lines
Check f uel syst em l i nes, hoses, f uel f i l t er, and ot her component s f or damage, l eaks or det 6ri orat i on, and rpl ace i t neces-
sary.
'97
model:
33 N.m
(3.4
kg(.m, 2s lbf.ftl
27 N.m
12.8 kg{.m, 21 lbf.ft)
'98
model:
(cont' d)
11- 171
27 N.rn
(2.8
kgl.m, 21 lbf.ft)
www.emanualpro.com
Fuel Supply System
Fuel Lines
(cont'dl
'99
-
00 models:
33 N.m
(3. 4
kgl . m. 25l bt f t l
11- 172
www.emanualpro.com
'97
model:
Check al l hose cl amps, and reti ghten i f necessary.
FUEL
FILTER
/\
{"2
,"1
<,,
I
___--tJ
B
FUEL TUBE/
OUICK-CONNECT
FITTINGS
EVAPORATIVE
EMISSION {EVAP}
CONTBOL
CANISTER
' ^ s
,4\-') |
I
ft\
q'l
I
/'------/
/ B
,
To FUEL
PRESSURE
REGULATOR
1 0 - 1 4 mm
(0.39 -
0.55 inl
(cont' d)
11- 173
Cl amp i n t he mi ddl e
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Fuel Supply System
Fuel Lines
(confd)
'98
- (X)
models:
Check al l hose cl amps, and reti ghten i f necessary.
SASE
GASKET
Repl ace.
FUEL
FILTER
To FUEL
PRESSURE
REGULATOR
1 0 - 1 4 mm
(0. 39 -
0. ss i n)
Cl amp i n t he mi ddl e
11- 174
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Fuel Tube/Ouick-Gonnect Fittings
Procautions
@
Do not smoke whils working on the fuel
syst6m, Koop open flames away from your work ar9a.
The fuel tube/qui ck-connect fi tti ngs assembl y connects
the i n-tank fuel pump wi th the fuel feed pi pe. For remov-
i ng or i nstal l i ng the fuel pump and fuel tank, i t i s neces-
sary to di sconnect or connect the qui ck-connect fi tti ngs.
Pay attenti on to fol l owi ng;
. The fuel tube/qui ck-connect fi tti ngs assembl y i s not
heat-resi stant; be careful not to damage i t duri ng wel d-
i ng or other heat-generati ng procedures.
. The fuel tube/qui ck-connect fi tti ngs assembl y i s not
aci d-proof; do not touch i t wi th a shop towel whi ch
was used for wi pi ng battery el ectrol yte. Rpl ace the
fuel tube/qui ck-connect fi tti ngs assembl y i f i t came
i nto contact wi th el ectrol yte or somethi no si mi l ar.
. When connecti ng or di sconnecti ng the fuel tube/qui ck-
connect fi tti ngs assembl y, be careful not to bend or
twist it excessively, Replace it if damaged,
A disconnected
quick-connect fittings can be reconnected,
but the retainer on the mating pipe cannot be reused once
it has been removed from the pipe. Replace tha retainer
. repl aci ng the fuel pump.
. repl aci ng the fuel feed pi pe,
. i t has been removed from the Di oe,
. i t i s damaged.
RCTAINER
FUEL TUBE
CONNECTOR
CONNECTOR
RETAINER
11- 175
Disconnection
!@
Do not smoke while working on the fuel
syst6m. Keep open flames away from your work area.
1. Di sconnect the battery negati ve cabl e.
2. Remove the fuel fi l l cap to rel i eve fuel pressure i n
the tank.
3. Rel i eve fuel pressure (see page 11-178).
4. Check the fuel qui ck-connect fi tti ngs for di rt, and
cl ean i f necessary.
5. Hol d the connector wi th one hand and press
down
the retai ner tabs wi th the other hand. then
pul l
the
connector off.
NOTE:
. Be careful not to damage the pi pe or other parts.
Do not use tool s,
. l f the connector does not move, keep the retai ner
tabs pressed down, and al ternatel y pul l and push
the connector unti l i t comes off easi l y.
. Do not remove the retai ner from the pi pe; once
removed, the retai ner must be repl aced wi th a
new one.
LOCKII{G PAWL
RETANEN TAB
@NNCCTOR
Press down.
6. Check the contact area of the pi pe for di rt and dam-
age.
. l f the surface i s di rW, cl ean i t
. lf the surface is rusty or damaged, replace the fuel
pump or fuel feed pi pe,
CONTACT ANEA
{cont' d}
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Fuel Supply System
Fuel Tube/Ouick-Connect Fittings
{cont'd)
7. To prevent damage and keep out forei gn matter.
cover the di sconnected connector and oi oe end wi th
pl asti c bags.
PL TSnC EAGS
11- 176
Connection
E!@
Do not smoke white working on the fuel
system. Keep oper flamss away flom your work atea.
1. Check the pi pe
contact area for di n and damage,
and cl ean i f necessary.
Insen a new retai ner i nto the connector i f the retai ner
is damaged, or after
. repl aci ng the fuel pump.
. repl aci ng the fuel feed pi pe.
. removi ng the retai ner from the pi pe.
AASE
GASKET
Beplace.
COiITACT AiEA
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3. Before connecti ng a new fuel tube/qui ck-connect fi t-
t i ng assembl y, r emove t he ol d r et ai ner f r om t he
mati ng pi pe.
wi t h t he
t abs pul l ed
apart, remove
and di scard
t he ret arner
Ncw FUEL TUBE/
OUICK.CONNECT
FI?TING ASSEMBLY
4. Al i gn the qui ck-connect fi tti ngs wi th the pi pe. and
al i gn the retai ner l ocki ng pawl s wi th the connector
grooves. Then press the qui ck-connect fi tti ngs onto
the pi pe unti l both retai ner pawl s l ock wi th a cl i ck-
I ng sound.
NOTE: l f i t i s hard to connect, put a smal l amount of
new engi ne oi l on t he pi pe end.
5. Make sure the connection is secure and that the pawls
are fi rml y l ocked i nto pl ace; check vi sual l y and by
pul l i ng the connector.
Reconnect the battery negati ve cabl e, and turn the
i gni t i on swi t ch ON
( l l ) .
The f uel pump wi l l r un f or
about two seconds, and fuel pressure wi l l ri se. Repeat
two or three ti mes, and check that there i s no l eakage
i n the fuel suppl y system.
6.
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Fuel Supply System
System Description
The fuel suppl y system consi sts of a fuel tank, i n-tank
hi gh-pressure fuel pump. PGM-Fl mai n rel ay, fuel fi l ter,
fuel
pressure regul ator, fuel i nj ectors, and fuel del i very
and return l i nes. Thi s system del i vers pressure-regul at-
ed fuel to the fuel i nj ectors and cuts the fuel del i very
when the engi ne i s not runni ng.
Fuel Pressure
Relieving
Before di sconnecti ng fuel pi pes or hoses, rel ease pres-
sure from the system by l ooseni ng the 12 mm banj o
bol t on the too of the fuel fi l ter.
Do not smoke while working on the fuel system.
Kep open flames or sparks away from your work
area,
Be sure to rel i eve fuel pressure whi l e the i gni ti on
switch is off.
Wri te down the frequenci es for the radi o' s preset
buttons.
Di sconnect the battery negati ve cabl e from the bat-
tery negati ve termi nal .
Remove the fuel fi l l cap.
Use a box end wrench on the 12 mm banj o bol t at
the fuel fi l ter whi l e hol di ng the fuel fi l ter wi th anoth-
er wrench.
Pl ace a rag or shop towel over the
' 12
mm banj o bol t.
Sl owl y l oosen the 12 mm banj o bol t one compl ete
rurn
12 mm BANJo
BOLT
1 .
SHOP TOWEL
NOTE: Repl ace the washers whenever the 12 mm
bani o bol t i s l oosened or removed.
11- 178
Inspection
1, Rel i eve fuel pressure.
2. Remove the 12 mm banj o bol t on the fuel fi l ter whi l e
hol di ng the fuel fi l ter wi th another wrench. Attach
the 12 mm fuel pressure adapter bol t and the speci al
tool .
FUEL PRESSURE
REGULATON
FUEL
PRESSURE
GAUGE
07406
-
0040001
The i l l ust rat i on shows
'97
-
98 models,
' 99
-
00 model s are si mi l ar.
Start the engi ne. Measure the fuel pressure wi th the
engi ne i dl i ng and the vacuum hose of the fuel pres-
sure regul ator di sconnected from the fuel pressure
regul ator and pi nched. l f the engi ne wi l l not start,
turn the i gni ti on swi tch on
(l l ),
wai t for two seconds,
turn i t off, then back on agai n and read the fuel
pressure.
Pressure should be:
'97
-
98 modls:
260
-31O
kPa 12.7
-
3.2 kgf/cm,, 38
-
46 psil
'99
-
0O models:
270
-
32O kPa Q.A
-
3.2 kgf/cm',
ifo - /U psil
Reconnect vacuum hose to the fuel pressure regulator.
Prgs3ure should be:
'97
-
98 models:
210
-
25O kPa 12.1- 2.6 kgf/cm', 30
-
37 psi)
'99
-
00 models:
22O
-26iJ
kPa 12.2
-
2.7 kgt/cm', 31
-
38
psi)
l f the fuel
pressure
i s not as speci fi ed, fi rst check the
fuel pump (see page 11- 183). l f the fuel pump i s OK,
check the fol l owi ng:
. l f t he f uel pr essur e i s hi gher t han speci f i ed,
i nspect for:
-
Pi nched or cl ogged fuel return hose or l i ne.
-
Faul ty fuel pressure regul ator
(see page 11-
181) .
. lf the fuel pressure is lower than specified. inspect
for:
-
Cl ogged fuel fi l ter.
-
Faul ty fuel pressure regul ator
(see page 11-
1811.
-
Fuel l i ne l eakage.
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Fuel Injectors
R6placomoni
1. Rel i eve the fuel pressure (see page
11-178).
2. Remove the resonato. chamber
(' 99 -
00 model s).
O.RING
Bepl ace.
Disconnect the connectors from the fuel injectors, and disconnect the IAT sensor 2P connector
('97 -
98 models) and
EVAP purge control solenoid valve 2P connctor
('97 -
98 models),
Disconnect the PCV valve and the vacuum hose from the fuel pressure regulator.
Pl ace a shop towel over the fuel return hose, then di sconnect i t from the fuel pressure regul ator.
Remove the retai ner nuts on the fuel rai l .
Di sconnect the fuel rai l .
7, Remove the fuel injectors from the intake manifold.
'97
-
98 model3:
EVAP PURGE CONTROL
SOLENOID VALVE 2P CONNECTOR
IAT SENSOR
FUEL PULSATION
2P CONNECTOR
12 N. m
{1.2 kgt'm,
8.7 tbtft)
FUEL
PRESSURE
REGULATOR
O.RING
FUEL
PRESSURE
REGULATOR
CUSHION
O.RING
Repl ace.
CUSHION
RING
Repl ace.
SEAL
RING
Repl ace.
Repl ace.
SEAL
RING
Repl ace.
S
11- 179
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Fuel Supply System
Fuel Injectors
{cont'dl
8. Sl i de new cushi on ri ngs onto the fuel i nj ectors.
9, Coat newO- r i ngswi t h cl ean engi ne oi l , and put t hem ont hef uel i ni ect or s.
' 10.
l nsert the fuel i nj ectors i nto the fuel rai l fi rst.
11. Coat newseal r i ngswi t hcl ean engi neoi l , and pr ess t hem i nt o t he i nt ake mani f ol d
12. To
prevent damage to the O-ri ngs, i nstal l the fuel i nj ectors i n the fuel rai l fi rst, then i nstal l them i n the i ntake mani -
fol d.
FUEL RAI L
The i l l ! st rat i on shows
' 97
-98
model s, ' 99
-
00 model s
are si mi l ar.
13. l nstal l and ti ghten the retai ner nuts.
14. Connect the vacuum hoses and fuel return hose to the fuel pressure regul ator.
15. Connect the PCV val ve.
16. Connect the connectors to the fuel i nj ectors, the IAT sensor
(' 97
-
98 model s), and the EVAP purge control sol enoi d
val ve {' 97
-
98 model s).
Coat a new O-ri ng wi th cl ean engi ne oi l , and i nstal l the resonator chamber
(' 99 -
00 model s).
Turn the ignition switch ON
(ll),
but do not operate the starter. After the fuel pump runs for approximately two seconds,
the fuef pressure i n the fuel l i ne ri ses. Repeat thi s two or three ti mes, then check whether there i s any fuel l eakage.
11.
18.
1 1 - 1 8 0
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Fuel Pressure Regulator
Tesiing
1. Attach the speci al tool and the 12 mm fuel
pressure
adapter bol t to the fuel fi l ter
(see page 1l -178)
2. Start the engi ne.
Prasgure should be:
'97
-
98 models;
260
-
310 kPa
(2.7 -
3.2 kgl /cm' ,38
-,16
psi )
'9!t
-
00 models:
27O
-
32o kPa l2-8
-
3.3 kgf/cm', 40
- /l7 psil
(with
the lugl
pressure rsgulator vacuum hose dis-
connested and
pinched)
FUEL
PRESSURE
GAUGE
07406
-
0040001
FUEL PRESSURE
NEGULATOR
The i l l ustrati on shows
' 97
-
98 model s,' 99
-00
model s
are si mi l ar.
Reconnect the vacuum hose to the fuel pressure
regul al or.
Check that the fuel pressure ri ses when the vacuum
hose from the fuel pressure regul ator i s di sconnect-
ed agarn.
l f t he f uel pr essur e di d not r i se, r epl ace t he f uel
pressure regul ator.
4.
CLAMP
Replacement
' 1.
Pl ace a shop towel under the fuel pressure regul a-
tor, then rel i eve fuel pressure
(see page 11-1781.
2. Di sconnect the vacuum hose and fuel return hose.
3. Remove the two 6 mm retai ner bol ts and the fuel
pressure regural or.
12 N. m
(1. 2
kgf . m,
8.7 tbf.ft)
The i l l ustrati on shows
' 97
-
98 model s,
' 99
00 model s
are si mi l ar.
Appl y cl ean engi ne oi l to a new O-ri ng. and careful l y
i nstal l i t i nto i ts proper posi ti on.
Instal l the fuel pressure regul ator i n the reverse
order of removal ,
Repl ace.
1 1 - 1 8 1
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Fuel Supply System
Fuel Filter
Replacamont
.
Do not smoke whilo working on tuol syslom,
Keep open flame away from your
work area.
. While rsplscing ths fuolfihor. bo careful to kop a safe
distanca betweon baftsry tarminals and any tools,
The fuel filter should be replaced whenever the fuel Dres-
sure drops bel ow the speci fi ed val ue* wi th the fuel pres-
sure regul ator vacuum hose di sconnected and pi nchedl
after maki ng sure that the fuel pump
and the fuel
pres-
sure regul ator are OK.
i:
'97
-
98 modelsi 260
-
310 kPa 12.7
-
3.2 kgllcm2,3g
-
46 psil
'99
-
00 mod6fs: 270
-
320 kP8 12.8
-
3.2 kgilcm2, 40
-
il7psi)
1, Pl ace a shop towel under and around the fuel fi l ter.
2. Rel i eve fuel pressure (see page
l 1-l 7B).
3. Remove the engi ne wi re harness bracket and power
steeri ng feed hose cl amp.
4. Remove the banj o bol t and the fuel feed
pi pe
whi l e
supporti ng the fuel fi l ter wi th another wrench. as
snown.
Remove the fuel fi l ter cl amp and fuel fi l ter,
Instal l the new fuel fi l ter i n the reverse orde. of
removal , and note these i tems:
. When assembl i ng, use new washers as shown.
. Cl ean t he f l ar ed
j oi nt
of hi gh pr essur e
noses
thoroughl y before reconnecti ng them.
11- 182
12 mm
SEAUNG
BOLT
33 hl.m
l3.a kgt m,
25 lbt frl
9.8 N.|n
11.0 kgf'm,
t.2 tbt.ftl
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Fuel Pump
Testing
lf you suspect a problem with the fuel pump, check that
the fuel
pump actual l y runs; when i t i s oN
(l l ), you wi l l
hear some noi se i f you hol d your ear to the fuel fi l l port
wi th the fuel fi l l cap removed. The fuel pump shoul d run
for two seconds when ignition switch is first turned ON
(ll).
lf the fuel pump does not make noise, check it as follows:
1. Fol d the l eft rear seat cushi on forward, and remove
the base frame cover
(see
section 20).
2, Remove the access
panel
from the fl oor.
3. Make sure the i gni ti on swi tch i s OFF, then di scon-
nect the fuel
pumP
5P connector.
4. Connect the PGM-FI mai n rel ay 7P connector termr-
nal No. 4 and No, 5 wi th a
j umper
wi re.
PGM.FI MAIN
RELAY 7P CONNECTOR
(Cit:}2l
I'TtlJil
t f
- r ' - r
l
l . l 5 l 5 1 7 l
,frTt-
, a t \
FUEL
pUMp Lr-
.
tcl tyEL/cRNl
rYEL/cRNl
I
I
JUMPER
Wir side of
WIRE
femal e termi nal s
5. Check that battery voltage is available between the
fuel pump 5P connector termi nal No. 4 and body
ground when the i gni ti on swi tch i s turned ON
(l l ).
FUEL PUMP 5P CONNECTOR {C562}
1 2
3 a 5
l f bat t er y vol t age i s avai l abl e, check t he f uel
pump ground. l f the ground i s OK, repl ace the
fuel oumo.
l f there i s no vol tage, check the wi re harness
(see
page 11- 188) .
FUEL PUMP
(YEL/GRNI
wi re si de of
f emal e t ermi nal s
Raplac6mont
1. Fol d the l eft rear seat cushi on forward, and remove
the base frame cover
(see
secti on 20).
2. Remove the access
panel from the fl oor.
3, Rel i eve the fuel pressure (see page 11-178).
4. Di sconnect the fuel l i nes.
5. Di sconnect the 5P connector from the fuel pump.
6. Remove the fuel
pump mounti ng nuts.
7. Remove the fuel
pump from the fuel tank.
I ns t al l t he f uel pump i n t he r ev er s e or der of
removal .
8.
1 1 - 1 8 3 www.emanualpro.com
Fuel Supply System
Fuel Gauge
Tssting
NOTE: Refer to secti on 23 for the fuel gauge system ci r-
cui t di agram.
' 1.
Check the No. 25 METER
(7.5
A) fuse i n the under-
dash fuse/relay box before testing.
2. Fol d the l eft rear seat cushi on forward, and remove
the base frame cover {see secti on 20).
3. Remove the access panel from the fl oor.
4. Di sconnect the 5P connector from the fuel pump.
5. Measure vol tage between the 5P connector termi -
nal s No.2 and No. 5 wi th the i gni ti on swi tch ON
(
).
There shoul d be between 5 and 8 V.
FUEL PUMP
5P CONNECTOR
tc56al
a
a
Wire side of female trminals
l f the vol tage i s as speci fi ed, go
to step 6.
l f the vol tage i s not as speci fi ed, check for:
-
an open i n the YEUBLK or BLK wrre.
-
poor ground (c552).
11- 184
7.
Turn the i gni ti on swi tch OFF.
Attach a
j umper
wi re between the No. 2 and No. 5
termi nal s, then turn the i gni ti on swi tch ON fl l ).
Check that the poi nter
of the fuel gauge starts mov-
i ng toward the
"F"
mark. Turn the i gni ti on swi tch
OFF before the poi nter
reaches
"F"
on the gauge
di al . Fai l ure to do so may damage the l uel gauge.
NOTE: The fuel gauge i s a bobbi n
(cross-coi l )
type,
hence the fuel l evel i s conti nuousl y i ndi cated even
when t he i gni t i on swi t ch i s OFF, and t he poi nt er
moves more sl owl y than that of a bi metal type.
. l f the poi nter of the fuel gauge
does not move at
al l . repl ace the gauge.
. l f the gauge i s OK, i nspect the fuel gauge
send-
i ng uni t .
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Fuel Gauge Sendi ng Uni t
Tgsting
@
Do not smoke while working on tho fuel
systom. Keop open flamo 8waY from your work araa.
1. Fol d the l eft rear seat cushi on forward, and remove
the base frame cover
(see
secti on 20).
2. Remove the access
panel .
3. Wi th the i gni ti on swi tch OFF. di sconnect the 5P con-
nector from the fuel
pump.
4. Rel i eve fuel
pressure (see page 11-178).
5. Di sconnect the fuel l i nes.
6. Remove the fuel pump,
7. Measure the resi stance between the No. 2 and No. 5
terminals at E
(EMPTY),
1/2
(HALF
FULL) and F
(FULL)
by movi ng the fl oat.
l f you do not get the above readi ngs, repl ace the
fuel
pump.
11- 185
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Fuel Supply System
Low Fuel Indicator System
Indicator Light Testing
NOTE: Refer to secti on 23forthe l owfuel l ndi cator ci rcui t
cl ragram.
1. Check the No. 25 METER
(7.5
A) fuse i n the under-
dash fuse/relay box before testing.
2. Park the vehi cl e on l evel ground.
@
Do not smoke whi l e worki ng on the
fuel system. Keep open flame away trom the work
aroa. Drain fuel only into an approved container.
Dr ai n t he f uel i nt o an aoDr oved cont ai ner . Then
i nstal l the drai n bol t wi th a new washer.
Add l ess than 8 f
(2.1
U.S. Gal . 1.8 l mp. Gal ) of fuel ,
and turn the i gni ti on swi tch ON {l l ). The l ow fuel i ndi -
cator l i ght shoul d come on wi thi n four mi nutes.
INDICATON LIGHT
. l f the l i ght comes on wi thi n four mi nutes, go to
step 8.
. l f t he l i ght does not come on wi t hi n f our mi n-
utes. go
to step 5.
Remove the seat cushi on
(see
secti on 20).
Remove the fuel tank access panel
from the fl oor,
and disconnect the 5P connector from the fuel pump,
Connect the No. 1 and No. 2 termi nal s wi th a
j umper
wi re.
. l f t he l i ght comeson, checkt he sendi ng uni t .
. l f the l i ght does not come on, check for:
-
an open i n t he GRN/ yEL wi r e bet ween t he
fuel uni t and fuel gauge
assembl y.
-
bl own bul b.
-
poor ground (G552).
FUEI- PUMP 5P CONNECTOR
(C562)
JUMPER WIRE
IGRN/YEL}
7.
1 1- 1 86
Wi re si d ol t eml e t ermi nal s
8. Add 4 / of fuel
(1.1
U.S. Gal , 0.9 l mp. Gal ). The l i ght
shoul d go off wi thi n four mi nutes.
. lJ the light does not go off, check for:
-
a short in the GRNA/EL wire between the fuel
gauge sendi ng uni t and fuel gauge assembl y.
-
faul ty gauge assembl y.
. l f the l i ght goes off, the l ow fuel i ndi cator l i ght i s
oK.
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PGM-FI Mai n Rel ay
Description
The PGM-Fl mai n rel av actual l v contai ns two i ndi vi dual
rel ays. Thi s rel ay i s l ocated at the
passenger si de of the
cowl . One rel ay i s energi zed whenever the i gni ti on i s on
whi ch suppl i es t he bat t er y vol t age t o t he ECM/ PCM,
power
to the fuel i nj ectors, and power for the second
rel ay. The second rel ay i s energi zed for two seconds
when the i gni ti on i s swi tched on, and when the engi ne
i s runni ng, to suppl y
power to the fuel pump
PGM.FI
MAIN RELAY
Belay Testing
NOTE: l f t he engi ne st ar t s and cont i nues t o r un, t he
PGM-FI mai n rel ay i s OK.
1. Remove t he gl ovebox and t he
passenger ' s dash-
board l ower cover
(see
secti on 20).
2. Remove the PGM-FI mai n rel ay
3. Aftach the battery
posi ti ve
termi nal to the No. 2 ter-
mi nal and the battery negati ve termi nal to the No. 1
termi nal of the PGM-Fl mai n rel ay. Then check for
conti nui ty between the No. 5 termi nal and No. 4 ter-
mi nal of the PGM-FI mai n rel ay
. l fthere i s conti nui ty,
go on to step 3.
. l f there i s noconti nui ty, repl acethe PGM-Fl mai n
rel av and retest.
No . 2
To l GN. 1
To GROUND
To ST. SWITCH
To ECM/PCM
CONNECTOR
TERMI NAL A16
(FLR)
To BAT O
To FUEL PUMP
To ECM/PCM
CONNECTOR
TERMINAL
(411
and A24,
Bl . nd Bgal
(I GP)
To FUEL PUMP
98
-
00 models
Attach the batterv Dosi ti ve termi nal to the No. 5 ter-
mi nal and the battery negati ve termi nal to the No. 3
termj nal of the PGM-Fl mai n rel ay. Then check that
there i s conti nui ty between the No. 7 termi nal and
No. 6 termi nal of the PGM-FI mai n rel ay.
. l f there i s conti nui ty, go on to step 4.
. l f there i s noconti nui ty, repl acethe PGM-Fl mai n
rel ay and retest.
Attach the batterv oosi ti ve termi nal to the No.6 ter-
mi nal and the battery negati ve termi nal to the No. 1
termi nal of the PGM-Fl mai n rel ay. Then check that
there i s conti nui tv between the No. 5 termi nal and
No. 4 termi nal of the PGM-Fl mai n rel ay.
. l f there i s conti nui ty, the PGM-Fl mai n rel ay i s OK.
. l f t her e i s nocont i nui t y, r epl acet he PGM- FI mai n
5.
(cont' d)
11- 147
No . 5 No . 5
rel ay and retest.
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Fuel Supply System
PGM-FI Main Relay
(cont'dl
Troubleshooting
lc(}21
PGM.FI MAIN RELAY 7P CONNECTOR
GND
trTr]--Flq
FI,Til'I
A
Y
Wi re si de ot f emal e t ermi nal s
-
Engine will not start.
-
I nsDect i on ol PGM-FI mai n
relay and relay harness,
Check f o. an open i n t he wi re
I GND l i nol :
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he PGM Fl mai n
rel ay 7P connect or.
3. Check f or cont i nui t y bet ween
t he PGM' FI mai n rel ay 7P con-
nect or t ermi nal No. 3 and body
ground.
Repair opcn in th wire between
t he PGM-FI mai n rel av and G101.
Check tor an open or short in the
wiro
(BAT
line):
Measur e vol t age bet ween t he
PGM' FI mai n rel ay 7P connect or
t ermi nal No. 7 and body ground.
-
Repai . open or short i n l he
wi r6 bel ween t he PGM-FI
main relay and the Fl E/M
(15
Al fu3e.
-
Repl ace t h6 FI E/ M
(15
Al t us6
in th under-hood fuse/.6lay
ls there baftery voltage?
Check lor an open or short in the
wire (lGl
line):
L Turn the ignition switch ON
(ll).
2. Measure the voltage between
t he PGM-FI mai n rel ay 7P con
nectorterminal No. 5 and body
ground.
-
Repai r open or shorl i n t he
wire between the FGM-FI main
r el ay and t he No. 13 FUEL
PUMP 115 A) tuse.
-
Replaco the No. 13 RJEL PUMP
115 A) luse in the und6.-d$h
fuso/ relav box.
Check for an open or short in the
wire {STS line):
1. Turn t he i gni t i on swi t ch t o t he
START
(l l l ) posi t i on.
NOTE:
.
M/ T: Cl ut ch pedal
must be
depressed.
.
A/ T: Transmi ssi on i n
E
or
El posi t i on.
2. Measure the voltage between
t h e PGM- Fl ma i n r e t a y 7 P
connect or t ermi nal No. 2 and
body ground. -
Repai r open or short i n t he
wire betwen the PIGM-FI m.in
rclay and th No. 31 STARTER
SlGllAL 17.5 A) tuse.
-
Repl.ce the No. 31 STARTER
SI GNAL 17. 5 Al t use i n t he
under-dash tuse/relay box.
(' 97
model : To page
11-189)
( ' 98
00model s: To page 1l 190)
1 1 - 1 8 8
www.emanualpro.com
l From
page 11 188)
Ch6ck l or an open i n t he wi r
{FLR l i ne):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he PCM connec-
t or A
(32P).
3. Check f or cont i nui t y bet ween
the PGM-FI main relay 7P con-
nector terminal No. 1 and PCM
connect or t ermi nal A16.
Repair open in the wire be{weon
t he PCM l Al 6l and t he PGM-FI
main relay.
Check f or an open i n t he wi rs
{l GP1, l GP2l i ns):
' 1.
Reconnect t he PCM connect or
A
( 32P) .
2. Reconnect t he PGM' Fl mai n
rel ay connect or.
3. Turn t he i gni t i on swi t ch ON
(l l i .
4. Measure voltage between PCM
connect or t ermi nal s A11 and
A10, and bet ween A24 and
A10.
-
Repair open in the wir bet'
ween th PCM {A11, A2ia} end
the PGM-FI main relay.
-
Reolsce the PGM-FI main rolaY.
l s t here bat t ery vol t age?
Check tor an open in the PCM:
1. Turn t he i gni t i on swi t ch OFF.
2, Measu r e vol t age bet ween
PCM connect or t ermi nal s A16
a n d A1 0 wh e n t h e i g n i t i o n
switch is first turned ON {ll) for
Substitute a known-good PCM
and recheck. lf
ptesctibed volttge
is now available, roplaco tho orig'
i n. l PCM.
l s t here
' 1. 0
V or l ess?
Check t he PGM- Fl m. i n. el aV
(see page 11-187).
(' 97 model )
IGRN/YELI
-t
PGM.FI MAIN RELAY 7P CONNECTOR
(C432I
FLR
Wi re si de of l emal e t ermi nal s
IGP2
(YEL/BLK)
(cont' d)
_l
1 1- 1 89 www.emanualpro.com
Fuel Supply System
PGM-FI Main Relay
(cont'dl
('98 -
00 models)
-l
(From page
11, 188)
Check l or an open i n t he wi re
(FLR
line):
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the ECM/PCM con
nector A
(32P1.
3. Check f or cont i nui t y bet ween
t he PGM-FI mai n rel ay 7P con-
nector terminal No.
'1
and ECM/
PCM connector terminal 416.
Repaia open in the wire between
t he EcM/ PcM
l Al 5l . nd t he
PGM-FI m.in relay.
Check for an open in the wires
l l cPl , l GP2l i nos):
1. Reconnect the ECM/PCN4 con-
nector I
(25P).
2. Reconnect t he PGM Fl mai n
retay connector.
3. Turn the ignition switch ON l).
4, Measur e vol t age bet ween
ECM/PCM connector terminals
B1 and 82, and bet ween 89
and 82.
Ropai. open in tho wire b6t-
wen th. ECM/PCM
lBt, Btl
.nd the FGM-FI main rd.y.
Rplac th6 FGM+| main retay,
Chock for an open in the ECM/
PCM:
1. Turn t he i gni t i on swi t ch OFF.
2, Measur e vol t age bet ween
ECM/PCM connector terminals
416 and 82 when t he i gni t i on
switch is first turned ON
(tl)
for
Subrtitute e known-good ECM/
PCM and recheck. lf prescribsd
voltage b now ovrihble, replaco
the originel ECM/PCM.
l s t here 1. 0 V or l ess?
Chec k t he PGM- FI mai n. el av
( s6e page 11- 1871.
PGM.FI MAIN RELAY 7P CONNECTOF (C2)
Wi re si d of f emal e t ermi nal s
ECM/PCM CONNECTOR B I25PI
IGP2
(YEL/BLKI
ECM/PCM CONNECTORS
a t32Pl
Wire side of female terminals
Wi re si de of f mal e t ermi nsl s
1 1 - 1 9 0
Dde"Jt;;li
L-F-T--
PGl
(BLK}
3 8
s
l 1 0 11 13 17
19 20 21 22
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Fuel Tank
Replacement
1. Rel i eve the fuel pressure
(see page 11-178).
2. Fol d the l eft rear seat cushi on forward, and remove the base frame cover {see secti on 20).
3. Remove the access
panel from the fl oor.
4. Di sconnect the 5P connector 1C562)
and 6P connector
(C580) (' 98-00
model s)'
5. Di sconnect the fuel return hose and
qui ck-connect fi tti ngs {see
page 11-175}
6. Jack up the vehi cl e, and support i t wi th
j ackstands.
7. Remove the mi ddl e fl oor beam.
8. Remove the drai n bol t, and drai n the fuel i nto an approved contaaner.
g.
Di sconnect the hoses
(see page 11-173, 174). sl i de back the cl amps. then twi st hoses as
you pul l , to avoi d damagi ng
them.
10. Pl ace a
j ack,
or other suppon, under the tank
11. Remove the strap nuts, and l et the straps fal l free
12. Remove the fuel tank. l f i t sti cks on the u ndercoat appl i ed to i ts mount, carefu l l y pry i t off the mount,
' 13.
l nstal l the drai n bol t wi th a new washer, then coat the drai n bol t wi th Noxrust 1248'
Al l ow the Noxrust to dry for 20 mi nutes.
14. Instal l
parts i n the reverse order of removal .
'97
modol:
AOCESS PANEL
CONNECTOR
@
Do not smoke while working on fuol systam Keep open flame away from
your work area'
DRAIN EOLT
49 N.m
15.0 kgf'm,
36 rbt frl
(cont' d)
1 1 - 1 9 1 www.emanualpro.com
Fuel Supply System
Fuel Tank
(cont'd)
,98
-
00 models:
6P CONNECTOR
38 N.m
(3. 9
ksf . m, 28l bt f t l
I
5P CONNECTOR
I
\
11- 192
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Intake Air System
System Description
The system suppl i es ai r for al l engi ne needs. l t consi sts of the i ntake ai r pi pe, Ai r Cl eaner, i ntake ai r duct, Throttl e Body
(TB),
l dl e Ai r Control
(l AC)
Val ve, fast i dl e thermo val ve, and i ntake mani fol d. A resonator i n the i ntake ai r pi pe provi des
addi ti onal si l enci ng as ai r i s drawn i nto the system.
INTAKE MANIFOLD
YEL|
-
- Fiom PGM'FI
BLK
T
MAIN RELAY
I DLE
THERMO
lJ-
_iuo'u'j"'
INTAKE
AIR DUCT
vaRtous
SENSORS
FESONATON
THROTTLE
BODY
(TB)
1 1 - 1 9 3
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Intake Air System
Ai r Cl eaner
Air Cleaner Eloment Rsplacomsnt
NOTE: Do not cl ean the ai r cl eaner el ement by bl owi ng
i t off wi th compressed ai r,
AIR CLEANER ELEMENT
No.mal conditions:
Repl ace ai r cl eaner el ement every
30, 000 mi l es {48, 000 km) or 24
mont hs whi chever comes f i rst .
Severe condition3:
Repl ace ai r cl eaner el ement every
15, 000 mi l es 124, 000 km) or 12
mont hs whi chever comes t i rst .
m
11- 194
Throttle Cable
Inrpection/Adiustmcnt
1. Stan the engine. Hold the engine at 3,000 rpm with no
load
(in
Park or neutral) until the radiator fan comes
on, then let it idle.
2. Check that the throttl e cabl e operates smoothl y wi th
no bi ndi ng or sti cki ng. Repai r as necessary,
3. Check cabl e free pl ay at the throttl e l i nkage. Cabte
defl ecti on shoul d be 10- 12 mm
(3/8 -
1l 2i n.l .
'97
-
98 modols:
CABLE
BRACKET
LOCKNUT
DEFLECTION
1 0 - 1 2 mm
BI A- 112 i ^l
'99
-
0O modsls:
l f defl ecti on i s not wi thi n specs, l oosen the l ocknut,
turn the adj usti ng nut unti l the defl ecti on i s as speci -
fi ed, then reti ghten the l ocknut.
Wi th the cabl e properl y
adj usted. check the throttl e
val ve to be sure i t opens ful l y when you push
the
accelerator pedal
to the floor. Also check the throt-
tl e val ve to be sure i t returns to the i dl e posi ti on
whenever you release the accelerator pedal.
DEFLECTION
l 0 - 1 2 mf t
Bla
-
112 inl
NUT
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lnstellation
1. Open the throttl e val ve ful l y, then i nstal l the throttl e
cabl e i n the throttl e l i nkage, and i nstal l the cabl e
housi ng i n the cabl e bracket.
97
-
98 modols:
THRoTTLE LINKAGE
CABLE
INNER CABLE
- (Xl
modols:
LOCKNUT
'99
2. Sta.t the engi ne. Hol d the engi ne at 3.000 rpm wi th
no l oad
(i n
Park or neutral ) unti l the radi ator fan
comes on, then l et i t i dl e.
Hol d the cabl e sheath, removi ng al l sl ack from the
cabl e.
Set the locknut on the cable bracket.
Adi ust the adj usti ng nut so that i ts free pl ay i s 0 mm.
Rimove the cable sheath from the throttle bracket,
reset the adj usti ng nut and ti ghten the l ocknut.
ADJUSTING
BRACKET
'97
-
98 modals:
l here shoul d be
no clearance.
AD.'USTING NUT
'99
-
00 modeb:
CABLE
BRACKET
9. 8 N. m
l'1.0
kgt'm,
7.2 tbr.ft)
9. 8 N. m
(1.0
kg{.m,
7.2lbllrl
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Intake Air System
Throttle Body
Doscription
The throttl e body i s a si ngl e-barrel si de-draft type. The
l ower porti on of the throttl e val ve i s heated by engi ne
cool ant from the cyl i nder head. The i dl e adj usti ng screw
whi ch regul ates the bypass ai r i s l ocated on the top of
the throttl e bodv.
The i l l ust rat i on shows
' 97
-
98 model s, ' 99
-
00 rnodel s
are si mi l ar.
1 1 - 1 9 6
lnspection
Check that the throttl e cabl e operates smoothl y wi thout
bi ndi ng or sti cki ng.
l f there are any abnormal i ti es, check for:
. Excessi ve wear or pl ay i n the throftl e val ve shaft.
. Sticky or binding throttle lever at the fully closed posi-
tton.
. Cl earance between throttl e stop screw and throttl e
l ever at the ful l y cl osed posi ti on.
97
-
98 models:
THROTTLE LINKAGE
Replace the throttle body if there is excessive play
in the
throttl e val ve shaft or i f the shaft i s bi ndi ng or sti cki ng.
THROTTLE LINKAGE
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Removal
'97
-
98 models:
MAP SENSOR
R \ t
,:4W)
TP SENSOR
FAST IDLE THERMO
VALVE
(A/T
onlyl
'99
-
O0 models:
TP SENSOR
a
F(
\g-.-'
22 N.m
12.2
kgl m,
16 t bt f t )
FAST IDLE THERMO
VALVE lA/T only)
NOTE:
. Do not adj ust the throttl e stop screw.
. After reassembl y, adj ust the throftl e cabl e
(see page 11-194).
. The TP sensor i s not removabl e.
(cont' d)
11- 197
GASKET
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Intake Air System
Throttle Body
(cont'd)
Disassembly
O-RING {A/l only)
Repl ace.
IDLE THERMO
VALVE
(A/T
only)
ADJUSTING
SCREW
9.8 N.m
(1. 0
kgl . m, 7. 2 l bf . f t l
The i l l ust rat i on shows' 97
-
98
model s, ' 99 00 model s are si mi l ar.
1 1 - 1 9 8
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Emission Control System
System Description
The emi ssi on cont r ol syst em i ncl udes, a Thr ee Way
Catalytic Converter {TWC), Positive Crankcase Ventilation
(PCV)
svstem and Evaporati ve Emi ssi on
(VAP)
Control
system. The emission control system is designed to meet
federal and state emission standards.
Tai l pi pe Emi ssi on
Inspsction
!@
Do not smoke during this procsdura. Keep
any open tlame away from your work area.
1. Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
( i n
Par k or neut r al ) unt i l t he r adi at or f an
comes on, then l et i t i dl e,
Connect a tachometer.
Check and, i f necessary, adj ust the i dl e speed,
(see
page 11- 169, 170) .
Warm up and cal i brate the CO meter accordi ng to the
meter manufacturer' s i nstructi ons.
Check i dl e CO wi th the headl i ghts, heater bl ower, rear
wi ndow defogger, cool i ng fan, and ai r condi ti oner off.
(Canada)
Pul l the parki ng brake l ever up. Start the
engi ne, then check that the headl i ghts are off.
CO met er shoul d i ndi cat e 0. 1% maxi mum.
4.
Three Way Catalytic Converter
(TWCI
DsscriDtion
Three Way Catalytic Convertsr lTwcl:
The Three wav Catal vti c Converter
(TWC)
i s used to
convert hydrocarbons
(HC),
carbon monoxi de
(CO),
and
oxi des of ni trogen
(NOx)
i n the exhaust gas to carbon
di oxi de
(COr),
di ni trogen
(Nr)
and water vapor,
{cont' d)
1 1 - 1 9 9
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Emission Control System
Three Way Catalytic Converter
{TWCI
(cont'd}
1P0420
Thescantool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0420: Catal yst system effi ci ency bel owthreshol d.
DescriDtion
Thi s system eval uates the catal yst' s capaci ty by means of the HO2S
(Pri mary
and Secondary) output duri ng stabl e dri vi ng
condi ti ons. l f deteri orati on has been detected duri ng three consecuti ve dri vi ng cycl es, the MIL comes on and DTC P0420 wi l l
be stored.
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as DTC P0420, troubl eshoot those DTCS fi rst. then
troubl eshoot DTC P0420.
P0137, P0138: Secondary HO2S
(Sensor
2)
P0141: Secondary HO2S
(Sensor
2) Heater
Possible Cause
. IWC Deteri orati on
. Exhaust system l eakage
Troubleshooting Flowchart
-
The MIL has been reDoried on.
-
DTC P0420 is stored.
Problem verification:
1. Do t he ECM/ PCM Reset Proce
dure,
2 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut ral i unt i l
t he radi at or f an comes on.
3. Connect t he SCS servi ce con
nect or.
4. Test-drive 40
-
55 mph
(64 -
88
km/ h) f or approx. l wo mi nut es.
Then decel erat e f or at l east 3
seconds wi t h t he t hrof t l e com
pl et el y cl osed. Then r educe
t he vehi cl e speed t o 35 mph
156 km/ h) , and t r y t o hol d i t
u n t i l t h e r e a d i n e s s c o d e
Intermittent tailure. system is OK
at this time.
l s DTC P0420 i ndi cat ed?
Check the TWC
(see
section 9).
lI nocessary, replace the TwC.
11-200
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Positive Grankcase Ventilation
(PGVI
System
Description
The Posi t i ve Cr ankcase Vent i l at i on
( PCV)
svst em i s
designed to prevent
blow-by gas from escaping to the
atmosphere. The PCV val ve contai ns a spri ng-l oaded
pl unger, When the engi ne starts, the pl unger i n the PCV
valve is lifted in proportion
to intake manitold vacuum and
the blow-by gas is drawn directly into the intake manifold.
-: BLOW.BY VAPOR
-: FRESH AIR
i/lAlrllFOLD
Inspoction
1. Check the PCV hoses and connecti ons for l eaks and
cl oggi ng.
'97
-
98 models:
'99
- (X)
models:
BREATHER
HOSE
(cont' d)
11-201
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Emission Control System
Positive Crankcase Ventilation
(PCV)
System
(cont'dl
2. At i dl e, make sure there i s a cl i cki ng sound from the
PCV val ve when the hose between the PCV val ve
and i ntake mani fol d i s l i ghtl y pi nched
wi th your fi n-
gers or pl i ers.
'97
-
98 models:
'99
-
00 modelsi
l f there i s no cl i cki ng sound, check the PCV val ve
grocrmet for cracks or damage, l f the grommet i s
OK, reDl ace the PCV val ve and recheck.
Gent l y pi nch her e.
Gent l y
pi nch
here.
11-202
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EVAP PURGE CONTROL SOLENOI D VALVE DUTY CONTROLLED AFTER
STARTI NG ENGI NE
ENGINE COOLANT TEMPERATURE ABOVE 154"F
(68' C)
Evaporati ve Emi ssi on
(EVAP)
Control s
Description:
The evaporati ve emi ssi on control s are desi gned to mi ni mi ze the amount of fuel vapor escapi ng to the atmosphere. The
system consi sts of the fol l owi ng components:
A. Evaporative Emission
(EVAPI
Control Canister
An EVAP control cani ster i s used for the temporary storage of fuel vapor unti l the l uel vapor can be purged from the
EVAP control cani ster i nto the enqi ne and burned.
B. Vapor Purge Coni rol System
EVAP control cani ster purgi ng i s accompl i shed by drawi ng fresh ai r through the EVAP control cani ster and i nto a pon
on the i ntake mani fol d. The purgi ng vacuum i s control l ed by the EVAP purge control sol enoi d val ve.
C. Fuel Tank Vapor Control System
When fuel vapor pressure i n the fuel tank i s hi gher than the set val ue of the EVAP two way val ve, the val ve opens and
regul ates the fl ow ot fuel vapor to the EVAP control cani ster.
'97
model:
EVAP
PURGE
CONTROL
VALVE
From
No. 15
BLK/
/ ALTERNATOR
YEL
I
sP SENSOR r7. s At
(i n
t he under-dash
fuse/relay box)
VARIOUS
SENSOR
FEESH AIF
BLK
I
FUEI- TANK
(cont' d)
11-203
INTAKE MANIFOLD
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Emission Gontrol System
Evaporative Emission
(EVAP)
Controls
(cont'dl
'98
-
0O models:
EVAP
THREE WAY
VALVE
EVAP
CONTROL
CANISTER
VENT SHUT
VALVE
'EL/BLU
._^_-:.*,"..
<3|ltAIS"o[..^,
1i n t he under-dash
t use/ rel ay box)
Frofi
BLK/WHT
<
NO. 15
GRN/ BLK
BLU
EVAP
BYPASS
SOLENOID
EVAP PURGE
CONTROL
SoLENOtO
VALVE
L
LT GRN/WHT
,
RED/YEL
MANIFOLD
VARIOUS
SENSOR
EVAP
TWO WAY
VALVE
VALVE
FUEL TANK
SLK
11-204
www.emanualpro.com
'97
model:
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0441: Evaporati ve Emi ssi on
(EVAP)
control system
i nsuffi ci ent purge fl ow.
Description
By moni tori ng the purge l i ne vacuum wi th the MAP sensor, the PCM can detect i nsuffi ci ent EVAP control system purge
fl ow.
Possiblo Cause
. EVAP Purge Control Sol enoi d Val ve
. EVAP Purge Control Sol enoi d Val ve Ci rcui t
. EVAP Control Cani ster
. Vacuum Li nes
. PCM
Troubleshooting Flowchart
EVAP PURGE CONTROL
SO1TNOID VALVE 2P
CoNNECTOR
(C108)
( v)
Y
L
Wire side of female
t ermrnal s
(cont'd)
11-205
Th MIL has ben reooited on.
DTC P0441 is .tored.
Problem verificationl
1 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
l oad
(i n
Park or neut . al ) unt i l
t he radi at or f an comes on.
2. Do the PCM Reset Procedure.
3. Connect t he SCS servi ce con-
nector,
4. Test drive under following con'
ditions on the road.
-
without any electrical load
-
Transmi ssi on i n
@
or
@
position
-
Engi ne speed bet ween
1
,2OO
-
2,4OO rpfi.
-
Decelerate from 50 mph
(80
km/ h)t o 15 mph
(24
km/ h)
Intermittent trilure, sydern is OK
at this time. Check for Door con-
nections or loose wir3 at C108
I EVAP
purge cont rol sol onoi d
valvol .nd at the PCM.
l s DTC P0441 i ndi cat ed?
Check tor an open in the wire
(lcl
linel:
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he EVAP pur ge
cont rol sol enoi d val ve 2P con-
nect or.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Measure voltage between body
ground and t he EVAP purge
control solenoid valve 2P con-
nect or t ermi nal No.
' 1,
Rpafu open in thc wir6 btwen
thG EVAP
purge control solenoid
valve and the No. 15 ALTEBNA-
TOR SP SENSOR
(7.5
A)fuse.
ls there batlery voltage?
(To page 11' 206)
www.emanualpro.com
Emission Control System
Evaporative Emission
(EVAP)
Controls
(cont'dl
(From page 11-205)
PCM CONNECTOR A (32PI
JUMPER wlRE
PCS IRED/YELI
Wire side of female terminais
PG1 (BLKI
Chsck t h6 EVAP purgo cont rol
solonoid valve:
' L
Reconnect t he EVAP pur ge
cont rol sol enoi d val ve 2P con-
nect or.
2. Connect PCM connector termi
n a l s 4 1 5 a n d A1 0 wi t h a
Chscl to. an op6n or 3hort in th
wiro
(PCS
lin6):
Measure vol t age bet ween PCM
connect or t ermi nal A15 and body
grouno,
Does t he sol enoi d val ve cl i ck
when t he
j umper
i s connect ed?
Chock for . .hort in tho wiJe IPCS
l i ne):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he PCM connec-
t or A
(32P).
3. Di sconnect t he EVAP purge
cont rol sol enoi d val ve 2P con-
nector,
4. Check f or cont i nui t y bet ween
body ground and PCM con-
nect or t ermi nal A15.
ls there battery voltage?
Rooair short in tho wir6 bctween
the EVAP purge
control 3olenoid
valvo and tho PCM
(A151.
Ropair open in the wir6 betwoon
the EVAP pu]go control .olonoid
v.lve end the PCM
(A15).
Check the vacuum lin6:
Check t he vacuum l i nes of EVAP
syst em t or mi srout i ng, l eakage,
brsakago and cl oggi ng.
Are t he vacuum l i nes OK?
(To pago 11' 207)
11-206 www.emanualpro.com
Chack i ho EVAP purge cont rol
solenoid valve:
1. Di sconnect t he vacuum hose
trom the EVAP controlcanister.
2, Connect t he vacuum
pump
t o
t he hose and appl y vacuum,
Does i t hol d vacuum?
Chgck thg EVAP control csnbter:
1. Reconnect the vacuum hose to
the EVAP control canister.
2. Connect a vac! um gauge t o
the
purge
air hose.
3. Connect PCM connect or t er
mi n a l s A1 5 a n d 4 1 0 wi t h a
j umper
wi re.
4. St an t he engi ne.
5. Check t he vacuum.
Check t he EVAP t wo way val ve
(see page
11' 224).
Does the EVAP two way valve
work properl y?
Rapbce the EVAP two wey valve.
Subst i t ut e a known-good PCM
and rechock. It symptom/indica-
tion
gocs
away, roplacg tho origi-
nrl rcM.
(From page 11-206)
JUMPEF WIRE
<\
EVAP CONTNOL
CANISTER
VACUUM
PUMPI
GAUGE,
0- 30 i n. Hg
4973X
-
0il1
-
xxxxx
VACUUM/PRESSURE
GAUGE
0- 4 i n. Hg
07JA2
-
ml(x)o8
wire side of female terminals
{cont' d)
-207
1 1
www.emanualpro.com
Emission Control System
Evaporative Emission
(EVAP)
Controls
(cont'd)
99
-
00 models:
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P0451: The Fuel Tank Pressure sensor ci rcui t range/
oerformance Drobl em.
ECM/PCM CONNECTORS
SG2 {GRN/BLK)
Wi re si de of {emal et ermi nal s
FUEL TANK
PRESSURE
SENSOR
VACUUM
PUMP/ GAUGE. 0
-30
i n. H9
A973X
-
041
-
XXXXX
-
The MIL har been rooortd on.
-
DTC P0451 b storod.
Check lor th6 tu6l tank prssure
len30r:
1. Do t he ECM/ PCM Reset Proce,
oure.
2. Remove t he f uel f i l l cap.
3. Turn t he i gni t i on swi t ch ON
(l l ).
4. Moni t or t he FTP Sensor vol t
a g e wi t h t h e Ho n d a PGM
Test er , or measur e vol t age
between ECM/PCM connector
t ermi nal s A29 and C18.
Chock t ho vacuum l i n6s t or
rGlriction o. blockago repair as
necessary. lf OK, roplace the fuel
tank Drer3ur sentor.
l s t here approx. 2. 5 V?
Check for the fuel tank
piessure
Sensot:
L Disconnect the hose between
t he EVAP t wo way val ve and
the fuel tank pressure sensor at
the EVAP two way valve end.
2. Connect a vacuum pump
t o
t he open end of t hat hose.
3. Turn the ignition switch ON
(lll.
4. Moni t or t he FTP Snsor vol t -
age wi t h t he Honda PGM
Test er , or measur e vol t age
between ECNI/PCNI connector
t er mi nal s A29 and C18, and
caref ul l y appi y vacuum on t he
hose one stroke at a time.
5. The vol t age shoul d smoot hl y
drop f rom t he st ani ng approx.
2. 5 V down t o approx. 1. 5 V.
STOP appl yi ng vacuum when
t he vol t age drops t o approx.
1. 5 V or damage t o t he t uel
t ank pr essur e
sensor may
Does the voltage drop to approx.
1. 5 V and hol d?
Intermittent tailuro. sv3tem is OK
at this tim. Chack to. poor
con-
nct i on6 or 10036 hose at f u6l
t ank pres3ure
i onsor and f uel
trnk.
a t32Pl
PTANK ILT GRNI
WAY VALVE
11-208
www.emanualpro.com
'98
-
00 modls:
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0452: A l ow vol tage probl em i n the Fuel Tank Pressure
sensof.
The fuel tank Dressure sensor converts fuel tank absol ute
pressure i nto el ectri cal si gnal s and i nputs the ECM/PCM.
OUTPUT
VOLTAGE
tvl
{.5
0, 5
-?
KPA
(-50
mmHg,
-2
in.Hgl
+7 kPr
l5O mmHg,
2 in.Hgl
PRESSURE
ECM/PCM CONNECTOR A
(32P)
Wi re si de ot f emal e t ermi nal s
FUEL TANK
PRESSURE SENSOR
3P CONNECTOR tc6a6l
voc2
(YEL/BLUI
Wi re si de ol f smal e t ermi nal s
(cont' d)
11-209
Th. MIL has been reoorted on.
DTC m452 is stored.
Check the vacuum lin6:
Check t he vacuum l i nes of t he f uel
t ank
pressure sensor f or mi srout
i ng, l eakage, breakage and cl og-
gi ng.
Are t he vacuum l i nes OK?
Problem veriticstion:
1. Do t he ECM/ PCM Reset
Procedure-
2. Remove t he l uel f i l l cap.
3. Tur n t he i gni t i on swi t ch ON
f l r).
4. Moni t or t he FTP Sensor vol t '
age wi t h t he Honda PGM
Test er , or measur e vol t age
bet ween body
gr ound and
ECM/ PCM t ermi nal A29.
Intermittent failuro, system is OK
at this lima. Chack lor Door con-
nections or loose wi.es at C580
llocrted rt access
panell,
C646
lluel tank Daessure sensor) and
at the ECM/PCM.
l s l here approx. 2. 5 V?
Check lor an open in wir lVeC2
l i ne):
1. Turn t he i gni t i on swi t ch OFF.
2. Rei nst al l t he f uel f i l l cap.
3. Disconnect the fuel tank pres-
sure sensor 3P connect or,
4. Turn t he i gni t i on swi t ch ON
(l l ).
5- Measure voltage between the
f Lrel t ank pressure sensor 3P
connect or No. 1 t ermi nal and
No. 2 t er mi nal .
Replir opon in the wire btwen
th6 tuel tank pressure lensot and
the ECM/PCM {A29).
l s t here approx. 5 V?
YES
( To page 11- 210)
www.emanualpro.com
Emission Control System
Evaporative Emission
(EVAP)
Controls
(cont'dl
FUEL TANK
PRESSUNE SENSOR
3P CONNECTOR tc646l
Wire side of female terminals
(From page l 1' 209)
Check l or a short i n t he wi re
IPTANK Iine}:
Measure voltage betlveen the fuel
tank pressure sensor 3P connector
No. 3t ermi nal and No. 2t ermi nal .
l s t here approx. 5 V?
Check f or a short i n t he wi re
(PTANK
line):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sco n nect t he ECM/ PCM
connect or A {32P).
3. Check for continuity between
t he f uel t ank pressure
sensor
3P connect or No. 3 t ermi nal s
and body ground.
Repair short in the wira betwgon
the fuel trnk prossure
s6nsor and
tho ECM/PCM lA29).
Sub.tituto a known-good ECM/
PCM and rcheck. lf 3ymptom/
i ndi cat i on goer
! way. repl ace
th6 original ECM/PCM.
11- 210
www.emanualpro.com
'98
-
00 modals:
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0453: A hi gh vol tage
probl em i n the Fuel Tank Pressure
sensor.
ECM/PCM CONNECTOR A {32PI
Wi re si do ot f ema16 t rmi nal s
FUEL TANX
Pf,ESSUBE SENSOR
3p CONNECTOR {C6,a6l
vcc2
IYEL/BLUI
sG2
IGRN/BLKI
sG2
(GRN/BLK}
Wi re si de ot f emal e t ermi nal s
PTANK
ILT GRNI
(cont ' d)
11- 211
PTANK ILT GRN)
1 2 3
Thc MIL has b6on ropottcd on.
DTC mia53 is dorcd.
Ch6ck tho vacuum linos:
Check t he vacuum l i nes of t he
f uel t ank
pressure sensor l or mi s-
rout i ng, l eakage, breakage and
cl oggrng.
Are t he vacuum l i nes OK?
Problorn verif ication:
1. Do t he ECM/ PCM Reset
Procedute.
2. Remove t he f uel f i l l cap.
3. Turn t he i gni t i on swi t ch ON
{ [ ) .
4. Moni t or t he FTP Sensor vol t -
age wi t h t he Honda PGM
Test er, or measure vol t age
bet ween body
gr ound and
ECM, PCM t ermi nal 429.
Intarmittent tailuro, sv3iom b OK
at this timo. Chock for
poor
con-
nection3 or loo$ wire3 at C580
(locstod
.t .cc$r
p.nell, C6a6
(fucl
tank
pros3ure son3orl and
.t the ECM/FCM.
l s t here approx. 2. 5 V?
Check l or an open i n t ho wi ro
l SG2l i n6l :
1. Turn t he i gni t i on swi t ch OFF.
2. R6i nst al l t he I uel f i l l cap.
3. Disconnect the Iu6l tank pres_
sure sensor 3P connect or,
4. Turn the ignition switch ON
(ll).
5. Masure voltago between the
t uel t ank
pressure sensor 3P
connect or t ermi nal s No.
' !
and
No . 2 .
Replir opn in th. wi.c b{ween
tha fuel tank Dio'sute
sansot and
tho EC|,/PCM {Cl8}.
l s t here approx. 5 V?
Chck f or an opon i n t ho wi ro
(PTANK
linel:
Measur e vol t age bet ween t he
f uel t ank
pressure sensor 3P con-
nect or No. 3 t ermi nal and No. 2
t ermi nal .
l s t here approx. 5 V?
\To
page 11-212)
www.emanualpro.com
Emission Control System
Check f o. an open i n t he wi re
(PTANK
l i nel :
Measure vol t age bet ween ECM/
PCM connector terminals A29 and
c18.
Ropair open in the wire betweon
the ECM/PCM {A291 and tho fuol
tank pressule 3ensor.
l s t here approx. 5 V?
Substitute a known-good ECM/
PCM and recheck. lf symptom/
i ndi cat i on goes
away, rpl ace
tho originrl ECM/PCM.
Evaporative Emission
(EVAP)
Controls
(cont'dl
( Fr om page 11, 211)
ECM/PCM CONNECTORS
SG2
(GRN/BLK}
Wi re si de of t emal e t ermi nal s
11- 212
-
PTANK {LT GRNI
www.emanualpro.com
'98
-
00 models:
The scan tool i ndi cates Di agnosti c Troubl e code
(DTC)
P1456: Evaporati ve Emi ssi on
(EVAP)
control system l eak
detected {fuel
tank system).
Troubleshooting Flowchart
-
The MIL has been reported on.
-
DTC P1456 is stored.
Check the fuel fill cap:
Chec k t he f uel f i l l c ap
( t he
c aP
must be a gr ay OEM cap and be
t i ght ened at l east t hr ee
"cl i cks"
t o
pr oper l y seal t he syst em) -
l s t he proper f uel f i l l cap i nst al l ed
and
properl y t i ght ened?
Replace or tighton the cap.
Check the lueltill cap seal:
Check t he f uel f i l l cap seal .
Replace the luelfiller
pipe.
l s t he t uel f i l l er pi pe damaged?
Fuel t i l l caD i s OK. Do t he l uel
t ank
pressure Sensor t est
(see
page 11-2111.
(EVAP
Purge con-
trol solenoid valve tsl
(see
Page
11-2151. 1r ' : ' 99
-
00 model s
(cont' d)
11-213 www.emanualpro.com
Emission
Control System
Fuel tank pros3ure
sensor tost.
(The
continuetion of DTC Pl456
t.oubls3hooting.,
Chock the tusl trnk pr3sure
sen-
sor:
1. Remove t he f uel f i l l csp.
2. Turn the ignition switch ON fll).
3. Moni t or t he FTP Sensor voh-
age wi t h t h Honda PGM
Test er , or measur e vol t age
between ECM/PCM connctor
t ermi nal s A29 and C18.
Choct t hs vacuum l i nsr f or
ra3triction o. blockago ropair a!
nect*rary. It OK, replaca the fu6l
tank praituJc
sentot.
ls there approx. 2.5 V?
Check the fuel t nk pressuae
3en-
sor:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the hose between
t he EVAP t wo way val ve and
the tueltank pressure
sensor at
the EVAP two way valve end.
3. Connect a vacuum pump
t o
t he open end of t hat hose.
4. Turn the ignition switch ON 0l).
5. Moni t or t he FTP Sensor vol t -
age wi t h t he Honda PGM
Test et , or measure vol t age
between ECM/PCM connector
t er mi nal s 429 and C18, and
caref ul l y appl y vacuum on t he
hose one stroke at a lime.
6. The vol t age shoul d smoot ht y
drop from the staning approx.
2. 5 V down t o approx. 1. 5 V.
St op appl yi ng vacuum when
t he vol t age drops t o approx.
1. 5 V or damage t o t he f uel
t ank pr essur e
sensor f i ay
occur,
Fu.l tank pressu.c
anlor b OK.
Oo t hc EVAP pul ge
cont rol
solenoid valve toat
(3 prgo
11-
2151.
Does the voltage drop to approx.
1. 5 V and hol d?
Evaporative Emission
(EVAPI
Controls
(contd)
l P14s6l ("ont , a)
ECM/PCM CONNECTORS
SG2 IGRN/BLKI
Wi re si de oI f emal e t ermi nal s
FUEI- TANK
PRESSURE
SENSOR
VACUUM
PUMP/GAUGE,0
-
30 i n.Hg
A973X
- ill -
xxxxx
EVAP TWO
WAY VALVE
11- 214 www.emanualpro.com
EVAP
purge cont rol 3ol noi d
valve test.
{Tho continu.tion of DTC Plil56
trouble3hootin9.)
Check t he EVAP
purge cont rol
solenoid valve:
1. Di sconnect t he vacuum hose
t rom t he EVAP cont rol cani s-
t er , and connect a vacuum
pump t o t he hose.
2. Turn t he i gni t i on swi t ch ON
(l l ).
3. Appl y vacuum t o t he hose.
EVAP
purge cont l ol sol enoi d
v.lvo is OK. Do the EVAP bypai3
solenoid valve test
(see
Page
11-
2161
Does t he val ve hol d vacuum?
Check t ho EVAP purge cont rol
solenoid valve:
' t .
Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he EVAP
Pur ge
cont rol sol enoi d val ve 2P con-
nector,
3. Check for continuity between
t he EVAP
pu r ge cont r ol
sol enoi d val ve 2P connect or
t e r mi n a l N o . 2 a n d b o d Y
ground,
Check f or s short i n t he wi re
{PCS l i nel :
1. D i scon nect t he ECM/ PCM
connect or A {32P).
2. Check f or cont i nui t y bet ween
t he EVAP
pur ge cont r ol
sol enoi d val ve 2P connect or
t e r mi n a l No . 2 a n d b o d y
ground.
neprir short in tho wite bot$reon
the ECM/FCM lAGl and thc EVAP
purge control 3olenoid valve.
l s t her e cont i nui t y?
Substitut a known-good ECM/
PCM and recheck. lf symptom/
i ndi cat i on
goe3 away. repl . ce
thc originsl ECM/PCM.
VACUUM
PUMP/ GAUGE, 0
-
30 i n. Hg
A973X
-
041
-
xxxxx
EVAP
CONTROL
CANISTER
EVAP PURGE CONTROL SOLENOID
VALVE 2P CONNECTOR
(Cl08}
Wi re si de of
f emal e
t ermi nal s
(cont' d)
-215
1 1
www.emanualpro.com
Emission
Control System
Evaporative Emission (EVAPI
Controls
(cont,dl
1T1456I
(conro)
VAP
BYPASS
SoLENOtO
VALVE
ECM/PCM CONNECTOR A I32P)
Wi re si de of f emal e t ermi nal s
VACUUM
PUMP/
GAUGE.
0
-30
i n. Hg
A373X
-
041
-
xxxxx
EVAP BYPASS SOLENOID
VALVE 2P CONNECTOR lcorlTl
2WBS
(BLU}
I
I
Wi re si de of
f emal e
t ermrnat s
t Gl
IBLK/WHT}
EVAP bypa3s solenoid valve test.
(The
continuation ot DTC P1456
troubleshooting.l
Check the EVAP bypass sotenoid
1. Di sconnect t he vacuum hose
from the EVAP two way valve,
and connect a vscuum pump
t o t he hose,
2. Connect t he ECM/ PCM con-
nector terminal 43 to the body
ground
wi t h a
j urnper
wi re.
3. Turn t he i gni t i on swi t ch ON 0t ).
4. Appl y vacuum t o t he hose.
EVAP bypass sol enoi d val ve/
EVAP two way valve is OK. Do
t h6 EVAP cont rol crni st er vent
shut vafve le3t
lso
page
11-2'111.
Does t he val ve hol d vacuurn?
Check f or an opn i n t he wi r
(2WBS
line):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he EVAP bypass
sol enoi d val ve 2P connect or.
3. Check for continuity between
t he EVAP bypass so t eno i d
val ve 2P connect or t er mi nal
No. 2 and body ground.
Repair open in the wire between
the EVAP bypass solenoid valv.
and ECM/PCM lA3).
Chack t or an op6n i n t he wi re
l l cl l i ne):
1. Turn t he i gni t i on swi t ch ON l ).
2. Measure vol t age bet ween t he
EVAP bypass sol enoi d val ve
2P connect or t er mi nal No. l
and body ground.
Replace the EVAP byps.,s solonoid
vatus and O-ring3.
Ropair o,pen in the wire botwoen
th6 EVAP bypa$ sotenoid vatvo
and No. 15 ALTERNATOR Sp
SENSOR (7. 5
Al t uso.
2WBS (BLU}
/ 3
7,x
4 l 6 o / to
-/
, /
16 17 18
't9
20 211/ z3
26 27 2A 29 solT 32
JUMPER WIRE
11- 216 www.emanualpro.com
EVAP control canister vent shut
valve lst,
lThe conlinualion ot DTC P1456
troubleshooting.)
Check the EVAP control cankter
vent 3hut valve:
1. Di sconnect t he vacuum hose
from the EVAPthree way valve,
and connect a vacuum
PUmP
to the hose.
2. Turn t he i gni t i on swi t ch ON
(l l ).
3. Appl y vacuum t o t he hose
EVAP control crnisier vent lhul
val ve i s OK. Do t he v. cuum
hoses and connections te3l lsee
page 11-218).
Does t he val ve hol d vacuum?
Chock the EVAP control canbtel
vent shul valvo:
1. Turn t he i gni t i on sw; t ch OFF.
2. Di sconnect t he EVAP cont rol
cani st er vent shut val ve 2P
connect or.
3. Check f or cont i nui t y bet l veen
the EVAP control canister vent
shut val ve 2P connect or t ermi -
nal No. 1 snd body
ground.
Roplac the EVAP contlol canbt]
venl shut valve and O-ring.
Chock l or a short i n t he wi re
(VSV lino)r
1. Di sco n nect t he EcM/ PCN4
connoct or A
(32P).
2. Check f or cont i nui t y bet ween
the EVAP control canister vent
shut val ve 2P connect or t ermi -
nal No. 1 and body
ground.
Reorir 3hort in tho wiro bgtweon
the EC1I/I/PCM lAal .nd the EVAP
codrol canbtor vent shut valv6.
Substitute a known.good ECM/
PCM and recheck. lf symptom/
i ndi crt i on
goes awaY, repl ace
the original ECM/PCM.
VACUUM
PUMP/ GAUGE, 0
-
30 i n. Hg
A973X
-
041
-
XXXXX
EVAP
THREE
VALVE EVAP
CONTROL
CANISTER
EVAP CONTROL
CANISTER VENT SHUT
VALVE 2P CONNECTOR IC361)
r+
l 1 t 2 l
f
1
VSV
(o)
tLT cnrulwxrt
1
Wi re si de of f emal e t ermi nal s
EVAP
CONTROL
CANISTER
VENT
SHUT
VALVE
O.RING
Repl ace.
ILT GRN/WHT)
(cont' d)
- 217
1 1
www.emanualpro.com
Emission Control System
Evaporative Emission
IEVAPI Controls
(cont'd)
lTi,t56l
("onto)
Vacuum hoses and connections
telit.
(The
continuarion of DTC P1456
troubleshooiing.l
Check t he vacuum ho3es and
connect|ons:
Check t he f ol l owi ng par t s f or
l eaks at at mospher i c p r essu r e
{see
page
11-204).
.
Fuel t ank
.
Fuel f i l l cap
.
Fuel f i l l pi pe
.
EVAP two way valve
.
Fuel t ank pressure
sensor
Repair or replaco the parts.
Substitute a known-good ECM/
PCM and recheck. l f sympt om/
i ndi cat i on goes
away, repl ac
the original ECM/PCM.
11- 218
www.emanualpro.com
'98
-
00 modls:
The scan tool i ndi cates Di agnosti c Troubl e code
(DTc)
P1457: Evaporati ve Emi ssi on
(EVAP)
Control system l eak
detected
(EVAP
control cani ster system).
Troubl6shooting Flowchart
(' 98 model onl y) _]
I
-
The MIL has been rePorted on.
-
DTC P1,157 is storod.
Do t he f uel t ank
Pressure
sensor
t est {see
page 11-214).
ls the {ueltank
pressure sensor OK?
Do t he EVAP
Pur ge
cont l ol
solenoid valve test lsea Page
1l_
220t.
(cont' dl
11-219 www.emanualpro.com
Emission
Control System
Evaporative
Emission
(EVAP)
Controls
(cont,dl
iTl457l
("ont' or
AP
CONTROL
CANISTER
Ropair opn in th6 wire between
the EVAP purge
control 3olenoid
velve and ths ECM/PCM (A61.
VACUUM
PUMP/GAUGE, O-30 i N.Hg
A973X
-
0rl
-
xxxxx
' \)
Wi re si de of l emal e t ermi nal s
EVAP PURGE CONTROL SOI.ENOID
VALVE 2P CONNECTOR (Cl08)
PCS
IRED/YELI
f emal e
t ermanal s
ECM/PCM CONNECTOR A {32P}
PCS (RED/YELI
, / 3
4 5 8 /
't0
,,/
14
,/
't6
17 18 l 9 20 24
,/ 26 29 30
JUMPER
WIRE
-
The MIL has been reported on.
-
DTC P1457 is stored.
{EVAP
purge
cont rol sol enoi d
valve test.l*
Check t he EVAP purge
conrrol
30lenoid velve:
L Di sconnect t he vacuum hose
f rom t he EVAP conl rol cani s,
t er , and connect a vacuum
pump
t o t he hose.
2. Connect t he ECM/ PCM con
nect or t ermi nal A6 t o t he body
ground
wi t h a
j umper
wi re.
3. Turn t he i gni t i on swi t ch ON
(t l ).
4. Appl y vacuum t o t he hose.
EVAP pur ge
cont r ol sol enoi d
valve is OK. Oo the EVAP bypass
solenoid valve t3t {see
psge
1l-
221t .
Does t he val ve hol d vacuum?
Check f or an open i n t he wi re
(PCS
l i ne):
1. Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he EVAP pur ge
cont rol sol enoi d val ve 2P con
nect or,
3. Check f or cont i nui t y bet ween
t he EVAP pu r ge cont r ol
sol enoi d val ve 2P connect or
t e r mi n a l N o . 2 a n d b o d y
grouno,
l s t here cont i nui t y?
Check f or an open i n t he wi re
(l Gl
l i ne):
1. Turn t he i gni t i on swi t ch ON t ).
2. Measure voltage between the
EVAP bypass solenoid valve 2p
coonect or t ermi nal No. 1 and
body ground.
ls there battery voltage?
Repah open in lhe wir6 betwoen
the EVAP pu.ge
cont.ol solonoid
vdlvo and No. 15 ALTERNATOR
SP SENSOR {7.5 Al fu!.
*:
Cont i nued f rr
' 98
model
1
-220
www.emanualpro.com
EVAP bypass solenoid valv test.
{The continuation of DTC P1457
troubleshooting.l
Check the EVAP bypass 3olenoid
1. Di sconnect t he vacuLl m hose
from the EVAP two way valve,
and conned a vacuum PUmP
t o t he hose.
2. Turn t he i gni t i on swi t ch ON
(l l ).
3. Appl y vacuum t o t he hose
EVAP bvpas3 30l snoi d vrl vo/
EVAP t wo way v. l ve i s OK. Do
the EVAP control canisler vent
3hut v.lve te3l
(see
Psge11'2221.
Does t he val ve hol d vacuum?
Ch6ck the EVAP byp.ss solenoid
' 1.
Turn t he i gni t i on swi t ch OFF
2. Di sconnect t he EVAP bypass
sol enoi d val ve 2P connect or.
3. Check {or cont i nui t y bet ween
t he EVAP bypass sol eno i d
val ve 2P connect or t er ml nal
No. 2 and body
ground
ReDlace the EVAP bypass 3olenoid
valve and O-rings.
Check f or a shor t i n l he wi r e
{2WBS linel:
1. Di sconnect ECM/ PCM connec
t or A
(32P).
2. Check lor continuity betlveen
t he EVAP bypass sol eno i d
val ve 2P connect or t ermrnal
No. 2 and body
ground.
Rcpsir short in th. wire bgtwoen
the EcM/PCtrl lA3l
lnd the EVAP
bypa$ solenoid valvo.
l s t here cont i nui t Y?
Sub3tiiute . known'good ECM/
PCM End recheck. l I sYmpt om/
i ndi cat i on
goe3 away, t ePl ace
t he ori gi nal ECM/ PCM.
EVAP
BYPASS
FUELTANK
PRESSUBE
SENSOR
SOLENOID
VALVE
EVAP TWO WAY
VALVE
VACUUM
PUMP/
GAUGE,
0- 30 i n. Hg
A973X
-
041
-
xxxxx
EVAP AYPASS SOLENOID
VALVE 2P CONNECTOR
(C647}
q
@)
T
t . ' - +l
t 1 t ? l
|
2wBs
(d1
terul
Y
-L
Wi re si de of
f emal e
t ermi nal s
2WBS
(BLU}
(cont'd)
11-221
www.emanualpro.com
Emission
Control
System
Evaporative
Emission
(EVAP)
Controls
(cont,dl
lT145il
("ont'o)
EVAP
THREE
VATVE
\
' t
VACUUM
PUMP/ GAUGE, 0
-
30 i n. Hs
A973X
-
041
-
xxxxx
WIRE
ECM/PCM CONNECTOR A {32PI
vsv
Wi re si de of f emal e t ermi nal s
EVAP
CONTROL
CANISTER
EVAP CONTROL
CANISTER VENT SHUT
VALVE 2P CONNECTOR {C361}
riEr
r+J
I
vsv
/A\
{Lr GRN/WHT|
Y
I
Wi re si de of f emal e t ermi nal s
CANISTEF
VENT
SHUT
VALVE
EVAP
CONTROL
(}BING
Replace.
ffi
l r c r
e
(BLK/wHr)
I
11-222
EVAP control canistor vent shut
valve t6t.
(The
continuation of DTC
p1457
troublahooting.)
Chcck the EVAP control c.nirt6l
vent ahut vrlve:
1. Di sconnect t he vacuum hose
trom the EVAP thre way valve,
and connect a vacuum pump
to the hose.
2. Connect the ECM,PCM conn6c,
t or t er mi nal A4 t o t he body
ground
with a
jumper
wire.
3. Turn the ignition switch ON fil).
4. Appl yvacuum t o t he hose.
EVAP control crni3ter v6nt shut
velve b OK. Do the canistsr sys-
lern loak test {3ee
page
11-2231.
Does t he val ve hol d vacuum?
Check f or an open i n t he wi re
IVSV linGll
1. Turn t he i gni t i on swj t ch OFF.
2. Di sconnect t he EVAP cont rol
cani st er vent shut val ve 2p
connector.
3. Check for continuity between
the EVAP control canister vent
shul valve 2P connector termi-
nal No. l and body ground.
Ropril op6n in tho wire botweon
the EVAP control canister v6nt
shut v. l ve and t he ECM/ PCM
(A41.
Check t or an open i n t he wi re
(lGl
line):
1. Turn the ignition switch ON l).
2. Measure voltage between the
EVAP control canister vent shut
val ve 2P connect or t errni nal
No. 1 and body ground.
Roplace thG EVAP cont.ol canis-
ter Yent shut velve and O-ring.
Repai. opon in the wire betwoen
th6 EVAP control canister vont
shut valve .nd No. 15 ALTERNA-
TOB SP SENSOR
t?.5 Alfus6.
{LT GRN/WHT)
3 6 a 10
l 4 / 1 6 17 l 8
't9
20 2l 23 24
26 27 2a 29 30
JUMPER
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Canbter system leak test
{The
continuation of DTC P1457
trouble3hootin9.)
Chock the EVAP control canister
vent shut valve line and connoc'
t onS:
1. Turn t he i gni t i on swi t ch OFF
2. Connect t o t hree' way t ee f i t _
t i ngs i nt o t he hose f rom t he
EVAP cont rol cani st er t o t he
EVAP two way valve. Connect
t he f uel t ank
pressure sensor
t o one of t he t ee f i t t i ngs and
the vacuum
PumP
to the other'
3. Remove t he vent hose f rom
the EVAP control canister vent
shut val ve and cap t he
Pon
t o
seal t he f resh ai r vent I or t he
EVAP control canister.
4. Turn t he i gni t i on swi t ch ON
(l l ).
5. Whi l e moni t or i ng t he FTP
Sensor vol t age wi t h t he Honda
PGM Test er , or measur ang
vol t age bet ween ECM/ PCM
connect or t ermi nal s A29 and
C18 sl owl y
PumP
t he vacuum
pump using a stroke every 1
-
2 seconds.
6. Cont i nue t o
PumP
vacuum
unt i l t hat vol t age dr oPs t o
approx. 1. 5 V.
NOTE: Ma k e s u r e t h a t t h e
engi ne cool ant t emPer at ur e
st i l l above 95' F
(35' Cl and
Your
vacuum
PumP
has no l eak
7. Moni t or t hat vol t age f or 20
seconds.
Check t he EVAP
Pu. ge
cont rol
sol enoi d val ve l i ne and connec-
tions:
1. Turn t he i gni t i on swi t ch OFF.
2 . Di s c o n n e c t t h e
Pu r g e
l a n e
hose f rom t he EVAP cont rol
cani st er and
Pl ug
t he
Port
3. Turn t he i gni t i on swi t ch ON
(l l i .
4. Whi l e moni t or i ng t he FTP
Sensor vol t age wi t h t he Honda
PGM Test er , or measur i ng
vol t age bet ween ECM/ PCM
connect or t ermi nal s A29 and
Cl 8 sl owl y PumP
t he vacuum
pump using a stroke every 1
-
2 seconds.
5. Cont i nue t o
pump vacuum
unt i l t hat vol t age dr oPs t o
approx. 1-5 V.
NOTE: Ma k e s u r e t h a t t h e
engi ne cool ant t emPer at ur e
st i l l above 95' F
(35"C)
and
Your
vacuum
pump has no l eak-
6. Moni t or t hat vol t age t or 20
seconds.
Doest he vol t age drop t o 1. 5 V
and hol ds at l east 20 seconds?
lGpct the EVAP control cani3tel
vent 3hut valvo line and connec_
tion5.
Inlpect tho EVAP
Putge
control
solenoid valvo line and connec'
tion3. It th6y lro OK, do the EVAP
two way valve te3t
(seo page 11-
2211.
Does t he vol t age dr op t o 1. 5 V
and hol ds at l east 20 seconds?
Reolace the EVAP conirol canister.
EVAP
BYPASS
SOLENOID
VALVE
FUEL TANK
EVAP
CONTROL
VENT
SHUT
VALVE
EVAP
CONTROL
CANISTER
SENSOR
EVAP TWO WAY
VALVE
EVAP
THREE
VALVE
ttrrL
t a
VACUUM
PUMP/
GAUGE,
0
-
30 i n. Hg
A973X
-
041
-
XXXXX
FITTINGS
ECM/PCM CONNECTORS
A {32P)
PTANK ILT GRN)
c
(31Pt
SG2 {GRN/BLK)
Wi re si de of f emal e t ermi nal s
{cont' d)
11-223
www.emanualpro.com
Emission
Control
System
Evaporative
Emission
(EVAP)
Controls
(cont,dl
Evaporative Emission (EVAP)
Two Way Valve Testing
'97
model:
1. Remove the fuel fi l l cap.
2. Remove t he vapor I i ne f r om t he EVAP t wo way
val ve on the fuel tank, and connect i t to a T_fi tti ng
f r om a v ac uum gauge
and a v ac uum pump
as
shown.
VACUUM,/
PRESSURE GAUGE
otJAz
-
001 rDoB
T-FITTING
VACUUM
PUMP/GAUGE,
0
-
30 i n. Hg
A973X-041-XXXXX
3. Appl y v ac uum s l owl y and c ont i nuous l v
whi l e
watchi ng the gauge.
The vacuum shoul d stabi l i ze
momentari l y at 0.7
-
2.0 kpa
(5 -
1S mmHg, 0.2
_
0.6
i n. Hg) .
l f t he v ac uum
s t abi l i z es
( v al v e
opens ) bel ow
0. 7 k Pa
( 5
mmHg, 0. 2 i n, Hg) or abov e 2. 0 k pa
(15
mmHg, 0.6 i n.Hg), i nstal l a new val ve and retest.
4. Move the vacuum pump
hose from the vacuum fi t_
ti ng to the pressure
fi tti ng, and move the vacuum
gauge
hose from the vacuum si de to the pressure
si de as shown.
PiESSURE
SIDE
5. Sl owl y pressuri ze
the vapor l i ne whi l e watchi ng the
gauge.
The pressure
shoul d stabi l i ze at 1.3
-
4.7 kpa
( 0 -
35 mmHg, 0. 4
-
1. 4 i n. Hg) .
. l f t he pr essur e
moment ar i l y st abi l i zes
( val ve
opens) at 1.3
-
4.7 kpa
(10 -
35 mmHg, 0.4
_
1.4
i n. Hg), the val ve i s OK.
. l f th6 pressure
stabi l i zes bel ow 1.3 kpa
fi o mmHg,
0.4 i nrHg) or above 4.7 kpa
(35
mmHg, 1.4 i n.Hg),
install a new valve and retest.
T-FITTING
11-224
.98
-
0O models:
1. Remove the fuel fi l l cap.
2. Remove t he vapor l i ne f r om t he EVAP t wo way
val ve
{l ocated above the EVAP control cani ster). and
connect i t t o a T- f i t t i ng f r om vacuum gauge
and
vacuum pump
as shown.
VACUUM/PRESSUFE
VACUUM PUMP/
GAUGE, 0
-
30 i n. Hg
A973X
-
041
-
xxxxx
5.
Appl y v ac uum s l owl y and c ont i nuous l y whi l e
watchi ng the gauge.
The vacuum shoul d stabi l i ze momentari l y
at O.g
_
2.1 kPa
(6 -
16 mmHg, 0.2
-
0.6 i n.Hg).
l f t he v ac uum s t abi l i z es ( v al v e
opens ) bel ow
0. 8 k Pa ( 6
mmHg, 0. 2 i n. Hg) or abov e 2. 1 k pa
(16
mmHg, 0.6 i n.Hg), i nstal l a new val ve and retest.
Move the vacuum pump
hose from the vacuum fi t-
ti ng to the pressure
fi tti ng. and move the vacuum
gauge
hose from the vacuum si de to the
pressure
si de as shown.
Sl owl y pressuri ze
the vapor l i ne whi l e watchi ng the
gauge.
The pressure
shoul d stabi l i ze momentari l v above
1. 0 kPa
( 8
mmHg, 0. 3 i n. Hg) .
a l f t he pr essur e
moment ar i l y st abi l i zes ( val ve
opens) above 1. 0 kPa ( 8
mmHg. 0. 3 i n. Hg) , t he
val ve i s OK.
. l f the pressure
stabi l i zes bel ow
,| .0
kpa {g mmHg.
0.3 i n.Hg), i nstal l a new val ve and retest.
T-FITTING
www.emanualpro.com
Transaxl e
Cl ut ch
. . . . . . . . . . . 12- 1
Manual Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 1
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . 1 4- 1
Di fferenti al
... 15-1
Dri veshafts
... 16-1
www.emanualpro.com
Clutch
Speci af Tool s . . . . , . . . . . . . . . . . . . . . ' 12-2
l l l ustrated l ndex ........... .' ." 12' 3
Clutch Pedal
Adj ust ment
. . . . . . . . . ". ". "". 12-4
Clutch Master Cylinder
RemovaUlnstallation
'." 12'5
Sl ave Cyl i nder
Removal /l nstal l ati on
.' .. 12-6
Pressure Plate
RemovaUl nspecti on
..' ." 12-7
Clutch Disc
Removal /l nspecti on
."' .. 12-8
Flywheel
I nspect i on
. . . . . . . . . . . . . . . . . . . . . . 12-9
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 2-9
Clutch Disc, Pressure Plate
l nst al l at i on
. . . . . . . . . . . . . . . . . . . . ' 12-10
Release Bearing
Removal /l nspecti on
...... 12' 11
l nst af l at i on
. . . . . . . . . . . . . . . . . . . . . 12-12
www.emanualpro.com
Special Tools
Rel . No.
I Tool Number
Description
Oty Page Reference
a
IA
@
!c,
Lo,
OTJAF
-
PM70,I1A
07NAF
-
PR30l 00
07LAB
-
PV00100 or
07924
-
PD20003
07746 0010100
07749
-
0010000
07936
-
3710100
Cl utch Al i gnment Di sc
Cl utch Al i gnment Shaft
Ri ng Gear Hol der
Attachment, 32 x 35 mm
Dri ver
Ha nd l e
1
|
t 2- 7
1 12-7
, A,
' t0,
11
1 12- 7
, 9, 10, 1' l
I
1
I
12-10
1 12-10
1 12- 7
, a, 10, 11
b)
2-2 www.emanualpro.com
lllustrated Index
NOTE:
. Whenever the transmi ssi on i s removed, cl ean and
grease the rel ease beari ng sl i di ng surface
. l f t hepans mar k ed* ar er emov ed, t hec l ut c hhy dr aul i c s y s t emmus t bebl ed( s eepage12- 6) .
. Inspect the hoses for damage. l eaks. i nterference, and twi sti ng.
LOCK PIN
*CLUTCH
LINE
19 N. m
(1. 9
kgj . m,
14 tbtft)
8 x 1. 25 mm
13 N. m {1. 3 kgf m, 9. 4l bt f t )
PEDAL PIN
.RESEFVOIR
HOSE
*RESERVOIR
TANK
CLUTCH PEDAL
Adj ust ment , page 12-4
*CI-UTCH
MASTER CYLINDER
Femoval / l nst al l at i on,
page 12-5
6 x 1 . 0 mm
9.8 N.m
(1.0
kgf.m,
7.2 tbf.ft)
*CLUTCH
LINE
15 N. m
(1. 5 kgt m,
11 tbr.ft)
*CLUTCH
LINE
24 N.m {2.4 kgf.m,
17 tbf.ft)
CLUTCH DISC
Removal/lnspection, page 1 2-8
I nst al l at i on, page 12, 13
8 x 1. 25 mm
25 N.m {2.6 kgt m,
19 rbf.ftt
I x 1. 25 mm
22 N.m 12.2
kgl'm, 16lbfft)
.o-.9r
WM\ , " . 0- -
ffi -P"8Nml l oks{m'
FLYWHEEL
I nspect i on, page 12I
Repi acement ,
page 12-9
12 x 1. 0 mm
103 N. m
(10. 5 kgt m, 75. 9 l bf f t l
PRESSURE PLATE
Removal / l nspect i on,
page' 12-7
I nst al l at i on,
page' 12 13
RELEASE BEARING
Removal / l nspect i on,
page 12-1' !
I nst al l at i on,
page 12-12
*CLUTCH
LINE
15 N. m
(1. 5
kgt m,
11 tbf.ft)
12-3 www.emanualpro.com
Clutch Pedal
Adiustment
NOTE:
. To check t he cl ut ch i nt er l ock swi t ch and cl ut ch
swi tch, see secti on 23.
. The cl utch i s sel f-adj usti ng to compensate for wear.
CAUTION: lf there is no clearance bstwan the mas-
ter cylinder piston and push
rod, ths roloase bearing
i s hel d agai nsi the di aphragm spri ng, whi ch can
resuh in clutch slippage or other clutch probloms.
1. Loosen l ocknut A, and back off the cl utch swi tch
(or
sdj usti ng bol t) unti l i t no l onger touches the cl utch
peoar.
2. Loosen l ocknut C, and turn the push rod i n or out to
get the speci fi ed stroke
(@)
and hei ght
(@)
at the
cl utch oedal .
3. Ti ghten l ocknut C.
4. Thread i n the cl utch swi rch
(or
adj usti ng bol t) unti l
i t contacts the cl utch oedal .
7.
5.
8.
q
Turn the cl utch swi tch {or adj usti ng bol t} i n an addi -
ti onal 3/4 to 1 ful l turn.
Ti ghten l ocknut A.
Loosen l ocknut B on the cl utch i nterl ock swi tch.
Measure the cl earance between the fl oor board and
cl utch pedal wi th
the cl utch pedal ful l y depressed.
Rel ease the cl utch pedal 15
-
20 mm
(0.59 -
0.79 i n)
from the ful l y depressed posi ti on
and hol d i t there,
Adj ust the posi ti on
of the cl utch i nterl ock swi tch so
that the engi ne wi l l start wi th the cl utch pedal i n
thi s posi ti on.
Ti ghten l ocknut B. 10.
LOCKNUT B
9.8 N.m 11.0 kgf.m, 7.2 lbf.ftl
CLUTCH INTERLOCK SWITCH
CLUTCH SWTTCH
{or ADJUSTING BOLTI
L(rcKNUT A
9.8 N.m
{1.0 kg{.m,7.2 lbf.ftl
CLUTCH MASTER CYLINDER
PUSH ROD
Pedal in contact with swhch
LOCKNUT C
18 N. m (1. 8
kgf . m, 13l bt f t l
@ {STROKE at PEDAL): 135
-
1i ts mm
(5.31 -
5.71 i n}
@
(TOTAL
CLUTCH PEDAL FREE PLAY)i 7
-22mm (0.28-0.87
i n) i nctude the pedat ptay 1
-
9 mm
(0.0i t-
0.35 i nl
@
(GLUTC,H
PEDAL HE|GHTI: ltxt mm
(7.20
inl ro rhe ftoor
o
(CLUTCH
PEDAL DTSENGAGEMENT HEtcHTl: 72 mm {2.txt inl minimum to the floor
\ , /
a _ - _ - - /
12-4 www.emanualpro.com
Glutch Master Cylinder
Removal/lnstallation
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage
the
paint; if brake tluid does contact the
paint. wash
it off immediately with water.
. Pl ug the end ol the cl utch l i ne and l eservoi r hose
with a shop towel to prevent brake tluid trom coming
out.
The brake fl ui d may be sucked out through the top
of the master cyl i nder reservoi r wi th a syri nge.
Di sconnect the cl utch l i ne and reservoi r hose from
the cl utch master cyl i nder,
' t .
9.8 N.m 11.0 kst m,
7.2 tbf.ftl
CLUTCH
LINE
19 N'm 11 9 kgJ m'
14 lbf.frl
Remove t he reservoi r f rom t he engi ne compart ment
bul khead.
13 N. m t 1. 3 kgt . m, g. i l l bt f t )
4. Prv out the l ock
pi n, and pul l the
pedal pi n out of
the voke. Remove the nuts.
NUTS
I x 1. 25 mm
5, Remove the cl utch master cyl i nder.
CLUTCH MASTER
CYLINDEF
I nst al l t he cl ut ch mast er cyl i nder i n t he r ever se
order of removal .
NOTE: Bl eed the cl utch hydraul i c system {see
page
12-61.
12-5
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Sl ave Cyl i nder
RemovaUl nstal l ati on
CAUTION:
. Do nol spi l l brake tl ui d on the vehi cl e; i tmaydamage
the paint; if brake fluid dos contast the
paint,
wash
it off immediately with water.
. Plug the end of the clutch line with a shop towel to
prevcnt brake tluid from coming out.
.6| l ,Super Hi gh Temp Urea crease
(p/N
08798
-
9002).
: Brake Assembl y Lube or equi val ent rubber
grease.
1. Di sconnect the cl utch l i ne from the sl ave cvl i nder.
2. Remove the sl ave cyl i nder from the cl utch housi ng.
12-6
3. I nst al l t he sl ave cyl i nder i n t he r ever se or der ot
r emoval .
NOTEr Make sure the boot i s i nstal l ed on the sl ave
cyl i nder .
CLUTCH LINE
15 N.m
(i.S
kgf.m, lt tbf.ftl
SLAVE CYLINDER
.-lG
(P/ N
08798
-
90021
E x 1. 25 mm
22 N.m
(2.2
kgt.m,
16 tbtft)
(Brake
Assembl y
Lube)
Bl eed t he cl ut ch hydraul i c syst em.
Attach a hose to the bl eeder screw, and suspend
the hose i n a contai ner of brake fl ui d.
Make sure there i s an adequate suppl y of fl ui d at
the cl utch master cyl i nder, then sl owl y pump the
cl utch pedal unti l no more bubbl es appear at the
bl eeder hose.
Refi l l the cl utch master cyl i nder wi th fl ui d when
qone.
Al ways use Genui ne Honda DOT3 Br ake Fl ui d.
Usi ng a non Honda brake fl ui d can cause corro-
si on and decrease the l i fe of the system.
Confi rm cl utch operati on, and check for l eaki ng
f l ui d.
7.8 N.m
(0.8
kgf.m. 5.8 lbt.ft)
BLEEDER SCREW
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Pressure Plate
Removal /l nspecti on
1 . Check the di aphragm spri ng fi ngers for hei ght usi ng
the speci al tool s and a feel er gauge.
Standard l Newl :
0.6 mm {0.02
i n) max.
Service Limit: 0.8 mm
(0.03
in)
HANDLE
07936
-
3710100
CLUTCH ALIGNMENT DISC
OTJAF
-
PM7O11A
CI.UTCH ALIGNMENT SHAFT
07NAF
-
PR30100
FEELER GAUGE
l f the hei ght i s more than
the pressure
Pl ate.
the servi ce l i mi t, repl ace
2. l nst al l t he sDeci al l ool s as shown.
RING GEAR HOLDER
ADJUSTER NUT
ENGINE BLOCK
ADJUSTER BOLT
BOLT
NUT WASHER
To pr event war pi ng, unscr ew t he pr essur e pl at e
mounti ng bol ts i n a cri sscross pattern i n several
steps. then remove the pressure pl ate.
4. Inspect the
pressure pl ate surface for wear, cracks,
and bur ni ng.
5. Inspect the fi ngers of the di aphragm spri ng for wear
at the rel ease beari ng contact area.
Inspect for warpage usi ng a strai ght edge and feel er
gauge. Measure across the pressure pl ate.
Standard l New): 0.03 mm 10.001 i n) max.
Servi ce Li mi t: 0.15 mm
(0.006
i nl
6.
FEELER GAUGE
l f t h e wa r p a g e i s mo r e t h a n t h e s e r v i c e l i mi t ,
repl ace t he pressure pl at e.
PRESSURE PLATE
PRESSURE PLATE
12- 7
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Glutch Disc
Removal/lnspection
' 1.
Remove the cl utch di sc and speci al tool s.
CLUTCH DISC
Inspect the l i ni ng of the cl utch di sc for si gns of sl i p-
pi ng or oi l . l f the cl utch di sc i s burned bl ack or oi l
soaked, repl ace i t.
Measure the cl utch di sc thi ckness.
Standard
(New):
8.,1- 9.1 mm
(0.33 -
0.36 i n)
Service Limh: 6.0 mm
(0.2,1
in)
CLUTCH DISC
l f the thi ckness i s l ess than the servi ce l i mi t, reDl ace
the cl utch di sc.
12-8
4. Measure the ri vet depth from the l i ni ng surface to
the ri vets, on both si des.
Standard
(New):
1.2
-
1.7 mm 10.05
-
0.07 i n) mi n.
Service Limit: 0.2 mm
{0.008
inl
l f t he r i vet dept h i s l ess t han
repl ace the cl utch di sc.
t he ser vi ce l i mi t ,
LINI G SURFACE
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Flywheel
Inspection
2.
3.
L l nspect the ri ng gear teeth for wear and damage.
Inspect the cl utch di sc mati ng surface on the fl y-
wheel for wear, cracks, and burni ng
Measure the fl ywheel runout usi ng a di al i ndi cator
through at l east two ful l turns. Push agai nst the fl y-
wheel each ti me
you turn i t to take up the crank-
shaft thrust washer cl earance.
NOTE: The r unout can be measur ed wi t h engi ne
i nstal l ed.
Standard
(Newl:
0.05 mm
(0.002
in) max.
Servi ce Li mi t: 0.15 mm {0.006
i nl
l f the runout i s more than the servi ce l i mi t, repl ace
the fl ywheel and recheck the runout
Turn the i nner race ot the fl ywheel beari ng wi th your
fi nger. The beari ng shoul d turn smoothl y and qui -
etl y. Check that the beari ng outer race fi ts ti ghtl y i n
the tl ywheel . l f the race does not turn smoothl y, qui -
etl y, or fi t ti ght i n the fl ywheel , repl ace the beari ng.
FLYWHEEL
RING GEAR
FLYWHEEL
L
2.
Replacement
Instal l the speci al tool as shown.
Remove the fl ywheel mounti ng bol ts i n a cri sscross
pattern i n several steps, and remove the fl ywheel .
MOUNNNG
BOLTS
FLYWHEEL
(cont' d)
12-9
RING GEAR HOLDER
07LAB
-
PV00r00
ol
07924
-
PD20003
3. Remove the bal l beari ng from the fl ywheel .
BALL BEARING
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Flywheel Clutch Disc, Pressure Plate
Replacement
(cont'dl
Dri ve the new beari ng
speci al t ool s.
HANOLE DRIVER
07749-
ATTACHMET{T-
3 2 x 3 5 mm
07746
-O010100
FLYWHECI-
Al i gn the hol e i n the fl ywheel wi th the crankshaft
dowel pi n,
and i ns t al l t he f l y wheel . I ns t al l t he
mounti ng bol ts fi nger-ti ght.
I nst al l t he speci al t ool , t hen t or que t he f l ywheel
mounti ng bol ts i n a cri sscross pattern i n several
steps as shown.
Torque:
12 x 1.0 mm
r03 N.m (10.5
kgl.ln,
75.9 tbtftl
i nto the fl ywheel usi ng the
12-10
Instal l ati on
1. Instal l the ri ng gear hol der.
CLUTCH ALIGNMENT SHAFT
07NAF
-
PR30100
CLUTCH DISC
RING GEAR HOLDER
07LAB
_ pvoot(x)
or
07924
_
PD20003
Appl y grease to the spl i ne of the cl utch di sc, then
i nstal l the cl utch di sc usi ng the speci al tool s.
NOTE: Use onl y Super Hi gh Temp Ur ea Gr ease
(P/N
08798
-
9002).
l nstal l the pressure pl ate.
PRESSURE PLATE
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Rel ease Beari ng
4. Torque the mounti ng bol ts i n a cri sscross
pattern as
shown. Ti ghten the bol ts i n several steps to prevent
warpi ng the di aphragm spri ng.
8 x 1. 25 mm
25 N. m
(2. 6 kgf . m, 19l bf f t )
Remove the speci al tool s.
Check the di aphragm spri ng fi ngers for hei ght
(see
page 12-7]'.
5.
6.
Removal /l nspecti on
1. Remove the rel ease fork boot from the cl utch hous-
I ng.
RELEASE
BEABING
RELEASE
FORK
BOOT
\
RELEASE FORK
Remove the rel ease fork and rel ease beari ng from
the cl utch housi ng.
Check the rel ease beari ng for pl ay by spi nni ng i t by
ha nd.
NOTE: The rel ease beari ng i s packed wi th grease.
Do not wash i t i n sol vent.
l f there i s excessi ve
pl ay, repl ace the rel ease bear-
i ng wi th a new one.
12-11
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Release Bearing
lnstallation
NOTE: Use onl y Super Hi gh Temp Urea Grease
(P/N
08798
-
9002).
1. Wi th the rel ease fork sl i d bet\i veen the rel ease bear-
i ng pawl s. i nstal l the rel ease beari ng on the mai n-
shaf t whi l e i nser t i ng t he r el ease t or k t hr ough t he
hol e i n the cl utch housi ng.
lPlN 08798
-
9002)
0. , 1- 1. 0
I
(0. 01 -
0 04 ozl
(P/N 08798
9002)
(P/N
08798 9002)
1. 0
-
1. 6 g
{0.0,1
-
0,06 ozl
-6.l
(P/N 08798
-
r iz]))
|
(,4\1t1t
/\[w
RELEASE
FORK
BOOT
Al i gn the detent of the rel ease fork wi th the rel ease
f or k bol t , t hen
pr ess t he r el ease f or k over t he
rel ease fork bol t sequarel v.
12-12
3. Move the rel ease l ork ri ght and l eft to make sure
that it tits
properly against the release bear'rng. and
that the rel ease beari ng sl i des smoothl Y.
Instal l the rel ease tork boot; make sure the boot
seal s around the rel ease fork and cl utch housi ng.
4.
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Manual Transmi ssi on
Diffrential
l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 38
Backl ash Inspesti on ..,....,.,.....................,......, 13-38
Fi nal Dri ven Gear Repl acement .................... 13-39
Tapered Roller Bearing
Repl acement ............. 13-39
Beari ng Outer Race Repl acement ......,.,........ 13-i 10
Tapered Roller Bearing Preload
Adi ustment ............... 13-i l 1
Oi l Seal Reol acement .................................... 13-/l :}
Transfer Assembly
l l l ustrated Index ............. 13-i l 4
Inspecti on ..,....,.,......,...... 13-46
Di sassembl y ................... 13-47
Transfer Drive Gear Bearing
Repl acement ...,..................,....................... 13-i l g
Transfer Driven Gear Shaft Bearing
Repl acement .............................................. 13-i l g
Transfer Shaft Disassembly/
Reassembl y .............. 13-50
Transler Cover A Bearing Outer Race
Rep1acement.........,.,.,..........,....,...,.........,., 13-50
Transter Housing Bearing Outer Race
ReD1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 51
Reassembl y ..-............,... 13-52
Mainshaft Bearing/Oil Seal
Bepl acement .................. 13-62
Countershaft Bearing
Repl acement .,,.,.,., ..,...... 13-63
Mainshaft Thrust Clearance
Adi ustment .................... 13-6,1
Transmission Assembly
Reassembl y .,.,.,.,..,.,....,., 13-67
fnstaffati on .,.,.............,... 13-72
Gearshift Mechanism
Over haul . . . . . . . . . . . . . . . . . . . . . . . . . 13- 17
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Special Tools
ll
Ref. No. I Tool Number Dsscription Oty
I
Page Roterence
o
o
,6)
@
-o
\9'
a
@
6r
@
o
@
@
@
@
@
@
@
@
@
07GAD
-
PG40100
07GAJ
-
PG20110
07GAJ
-
PG20130
07HAJ
-
PK40201
07JAC
-
PH80000
07JAD
-
PH80101
07JAD
-
PH80400
07LAD
-
PW50601
07RAB
-
0020000
07746
-
0010100
07746
-
0010300
07746
-
0010400
07746
-
0010500
07746
-
0010600
07746
-
0030100
07746
-
0030300
07746
-
0030400
07749
-
0010000
07947
-
SD90200
07979
-
PJ40001
Dri ver Attachment
Mai nshaft Hol der
Mai nshaft Base
Prel oad Inspecti on Tool
Adj ustabl e Beari ng Remover Set
Driver Attachment
Pi l ot, 28 x 30 mm
Attachment, 40 x 50 mm
Compani on Fl ange Hol der
Attachment,32 x 35 mm
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Attachment, 62 x 68 mm
Attachment, 72 x 75 mm
Dri ver, 40 mm l .D.
Attachment. 30 mm l .D.
Attachment, 35 mm l .D.
Handl e
Attachment
Magnet Stand Base
1
1
1
'l
1
1
1
1
1
1
'I
1
1
1
1
13-43
13-66
13-66
13-41
13-62. 63
13-43, 53
13-43
13-39, 49
13- 48, 54, 57, 58
13-18, 68
13-27,34, 62
13-40. 51
' t3-40,
50. 51, 61,
oz, oJ
13-40
13-27
,34,35, 49,
t J - 5 C
13-27,34
13-14,27.34, 40,
43, 49, 50, 51, 53,
61, 62, 63, 68
'13-49
13-66
*
Must be used wi th commerci al l y avai l abl e 3/8"
-
16 Sl i de Hammer.
o@( 9
ta\
o G)
,d, (oo@(9(}
@ o @
. A I A
a 5-z
Special Tools
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Mai ntenance
Back-up Light Switch
Transmi ssi on Fl ui d
NOTE: Check the fl ui d wi th the engi ne OFF and vehi cl e
on l evel
ground.
1. Remove t he f i l l er
pl ug. t hen check t he l evel and
condi ti on of the fl ui d.
FILLER PLUG
44 N.m {4.5 kgf.m. 33 lbf ftl
\ l l
Ptopet Level
\--ril /
HllllllTl
/
Hllllrlll /
_rf-F{--rno."."
l l
| | Replaco.
The fl ui d l evel must be up to the fi l l er hol e. l f i t i s
bel ow the hol e, add fl ui d unti l i t runs out. then rei n-
stal l the ti l l er pl ug wi th a new washer.
l f the transmi ssi on fl ui d i s di ny, remove the drai n
pl ug and drai n the fl ui d.
FILLEB PLUG
a,a N.m 14.5
kgf..n. 33 lbt'ftl
DRAIN PLUG
39 N m
(4.0 kgf.m, 29 lbf'ft)
WASHER
Repl ace.
Rei nst al l t he dr ai n
pl ug wi t h a new washer . and
refi l l the transmi ssi on fl ui d to the
proper l evel .
NOTE: The drai n
pl ug washer shoul d be repl aced at
every fl ui d change.
Rei nstal l the fi l l er pl ug wi th a new washer.
Fluid Capacity
1.7 / {1.8 US
qt, 1.5 l mp qtl at oi l change
2.1 ! 12.2 US
qt, 1.A lmp qtl at overhaul
Al wavs use Genui ne Honda Manual Transmi ssi on
Fl ui d
(MTF).
Usi ng motor oi l can cause sti ffer shi ft-
i nd because i t does not contai n the
proper addi ti ves.
Test/Replacement
1. Di sconnect the connectors from the swi tch.
Termi nal si de oI
mal e l ermi nal s
BACK.UP LIGHT SWTTCH
r 25 N.m 12.5 kgt m, 18 lbf.ftl
WASHER
Repl ace.
Check for conti nui ty between the No. 1 and No. 2
termi nal s.
. There shoul d be conti nui ty when the shi ft l ever
tnto reverse.
. Ther e shoul d be no cont i nui t y when t he shi f t
l ever i n posi ti on except reverse,
lf necessary, replace the switch.
13- 3
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Transfer Assembly
lnspection
@
Make sure tifts,
iacks,
and satety stands
are placed properly (see
section 1).
L Rai se the front of the vehi cl e, and support i t wi th
safety stands
(see
secti on 1).
2. Set the parki ng brake, and bl ock both rear wheel s
securel y.
3. Shi ft to neutral oosi ti on.
4. Make a reference mark across the DroDel l er shaft
and the transfer assembl y fl anges,
REFERENCE
8 x 1.25 mm
32 N.m
(3.3
kg{.m.
24 rbf.ftl
Repl ace.
Separ at e t he pr opel l er shaf t f r om t he t r ansf er
assemDty.
5.
13-4
6. Set a di al i ndi cator on the transfer assembl y fl ange,
then measure the transfer gear backl ash.
STANDARD: 0.06
-
0.16 mm
(0.002 -
0.006 in)
COMPAf{ION FI-ANGE
1. l f the measurement i s out of speci fi cati on, remove
the transfer assembl y and adj ust transfer gear back-
l ash
(see page 13-44 thru
' 13-61).
Check t he t r ansf er oi l seal f or damage and f l ui d
teaKs.
l f oi l seal repl acement i s requi red, remove the trans-
fer assembl y, repl ace the oi l seal , and adj ust the
total starti ng torque
(see page 13-44 thru 13-61).
NOTE: Do not repl ace the oi l seal when the transfer
assembl y i s i nstal l ed on the transmi ssi on.
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Removal
!@@
Make sure the lifts,
i8cks.
and safety stands
are
placed properly
{see section 1}.
1. Rai se the front of the vehi cl e, and support i t wi th
safety stands
(see
section 1).
2. Set the parki ng brake, and bl ock both rear wheel s
securel y.
3. Dr ai n t he manual t r ansmi ssi on f l ui d Rei nst al l t he
drai n
pl ug wi th a new seal i ng washer.
4. Di sconnect the heated oxygen sensor
(HO2S)
con-
nector.
SELF.L(rcKNG
NUT
Replace.
SELF-LOCKI'{G
NUT
Replac.
5. Remove exhaust oi pe A.
6. Make reference marks across the
propel l er shaft
and the transfer assembl y fl anges'
Separ at e t he
pr opel l er shaf t f r om t he t r ansf er
assembl y fl anges,
Remove the rear stiffener, then remove the transfer
assembl y.
NOTE: Whi l e servi ci ng the transfer assembl y, do
not al l ow dust or other forei gn parti cl es to enter the
transmi ssi on.
7.
REFEREI{CE i'ARKS
Replace.
Repl ace.
13- 5
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Transfer Assembly
lnstallation
1. Instal l a new O-ri ng on the transfer assembl y.
8 x 1. 25 mm
24 N.m
(2.4
kgt m,
17 rbt.ftl
10 x 1. 25 mm
44 N.m
(4.5
kgJ.m,
2.
DOWEL PIN
Repl ace.
TRANSFEB
ASSEMBLY
Cl ean the areas where the transfer assembl y con
tacts the transmi ssi on wi th sol vent or carburetor
cl eaner, and dry wi th compressed ai r. Then appl y
MTF to the contact areas.
Instal l the transfer assembl y on the transmi ssi on.
NOTE: Whi l e i nst al l i ng t he t r ansf er assembl y on
the transmi ssi on, do not al l ow dust or other forei gn
parti cl es to enter the transmi ssi on.
l nstal l the rear sti ffener.
Instal l the propel l er shaft to the transfer assembl y
by al i gni ng the reference marks,
8 x1. 25 mm
32 N.m 13.3 kg{.m,
24 tbf.ftl
REFERENCE MARKS
6. Instal l the exhaust
pi pe
A,
GASKET
EXHAUST PIPE A
HO2S CONNECTOR
10 x 1 .25 mm
54 N.m
(5.5
kgt m,
40 tbtftt
Replace.
SELF.LOCKING
NUT
8 x 1. 25 mm
16 N. m {1. 6 kgf . m,
12 tbt.ft)
Repl ace.
8 x 1.25 mm
zzN.m l2.2kg!-m,
16 rbf.trt
Replace.
7. Connect the heated oxygen sensor
(HO2S)
connector.
Rel i l l the transmi ssi on wi th MTF
(see page 13-3).
Start the engi ne, and run i t to normal operati ng tem-
per at ur e ( t he
r adi at or t an comes on) . Tur n t he
engi ne off. and check fl ui d l evel .
8.
9.
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Transmission
AssemblY
Removal
@
FMak. sw. iack"
and safety stands are placed propel-
ly, and hoist brackets are attached to collect
position
on the engine,
. Apply
parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
CAUTION: Use fender covers to avoid damaging
painted
surfaces.
1. Di sconnect the negati ve {-)
cabl e fi rst, then the
pos-
i ti ve
(+)
cabl e from the batterY.
2. Remove the i ntake ai r duct and ai r cl eaner housl ng
(see
secti on 5).
3. Remove the sl ave cyl i nder and cl utch hose bracket'
NOTE:
. Do not operate the cl utch
pedal once l he sl ave
cvl i nder has been removed.
. Take care not to bend the cl utch l i ne.
4. Di sconnect t he
ground cabl e.
st ar t er cabl es and t r ansmi ssi on
TRANSMISSION
GROUND CABLE
Di sconnect the back-up l i ght swi tch connector and
wi re harness cl amP.
(cont' d)
13-7
WIRE HARNESS CLAMP
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Transmission Assembly
Removal
(cont'dl
6. Remove t he cot t er pi ns,
washer s, pl ast i c washer s.
cabl e from the l evers.
t hen r emove t he st eel
shi f t cabl e, and sel ect
1.
8.
Remove the cabl e bracket from the cl utch housi ng.
Di sconnect the vehi cl e speed sensor
(VSS)
connec-
tor.
-------------.2
13- 8
9. Remove t he
bol ts.
f our upper t r ansmi ssi on mou nt i ng
10.
1 1 .
Drai n transmi ssi on fl ui d
(see page
' 13-3).
Remove the guard
bar and the spl ash shi el d.
MOUNNNG BOLTS
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12. Di sconnect the heated oxygen sensor
(HO2S) con-
nector, then remove the exhaust
pi pe A.
GASKET
Repl ace.
HO2S CONNECTOR
NUT
Repl ace.
EXHAUST
SELF.LOCKING
Repl ace.
GASKET
Replace.
Mark reference marks on the
j oi nt
of the transfer
and the
propel l er shaft.
8 x 1.25 mm
Repl ace.
Separ at e t he
pr opel l er shaf t f r om t he t r ansf er
assemDl y.
REFERENCE MABKS
14.
15. Remove the cotter
pi ns, and castl e nuts. then sepa-
rate the bal l i oi nts
from the l ower arm
(see
sectl on
18) .
OAMPER PINCH BOLT
CASTLE NUT
NUT
Repl ace.
17.
16.
DAMPER FORK
FOFK
EOLT
Repl ace.
Remove the ri ght damper tork bol t, then separate
ri ght damper fork and damPer.
Pry the ri ght dri veshaft out of the di fferenti al , and
pry
the l eft dri veshaft out of the i ntermedi ate shaft
(see
secti on 18).
Pul l out the i nboard
i oi nt,
and remove the ri ght and
l eft dri veshaft
(see
secti on 18).
Ti e pl asti c bags over the dri veshatt ends. Coat al l
preci si on fi ni shed surfaces wi th cl ean engi ne oi l
18.
19.
\
{cont' d}
13- 9
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Transmission Assembly
Removal
(cont'd)
20. Remove the i ntermedi ate shaft.
2 1 . Ti e pl asti c
bags over the both ends of the i ntermedi -
ate shaft. Coat al l preci si on
fi ni shed surfaces wi th
cl ean engi ne oi l .
Remove the rear engi ne sti ffene. and cl utch hous-
Ing cover.
1 3 - 1 0
23. Remove the ri ght front mounvbracket.
RIGHT FRONT
MOUNT/BRACKET
Pl ace a
j ack
under t he t r ansmi ssi on, r ai se i t
j ust
enough to take i t off of the mounts, then remove
the transmi ssi on mount bracket and transmi ssi on
mount.
TRANSMISSION MOUNT
MOUNT BRACKET
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25. Remove the transmi ssi on mounti ng bol ts and the
rear engi ne mounti ng bol ts.
REAR ENGINE MOUNTING BOLTS
Repl ace.
TRANSMISSION
Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the mai nshaft, then l ower i t on the transmi s-
si on
j ack.
NOTE: Take care not to bend the cl utch l i ne.
Remove the starter motor and hose cl amp from the
transmi ssi on housi ng.
STARTER
MOTOR
28. Remove the rel ease tork boot. rel ease beari ng, and
rel ease fork from the cl utch housi ng
RELEASE
BEANING
13- 1 1 www.emanualpro.com
Transmission
Assembly
lllustrated
Index
Refer to the drawi ng bel ow for the transmi ssi on di sassembl y/reassembl y.
Cl ean al l the pans
thoroughl y i n sol vent, and drv wi th comoressed ai r.
I
LuUri ""r" utt the parts wi th MTF before reassembl y.
NOTE:
t Thi s transmi ssi on uses no gaskets
between the maj or housi ngs; use l i qui d gasket (p/N
0g718
-
0001 or oE7l 8
-
0003)
(see page
13-69, 71).
. Al ways cl ean the magnet
@
whenever the transmi ssj on housi ng i s di sassembl ed.
. Inspect al l the beari ngs for wear and operati on.
C) sHrFr FoRK ASSEMBLY
. I ndex
page,
l 3- 21
(a
MAINSHAFT ASSEMBLY
. I ndex
page, 13- 23
(9
28 mm WASHER
)
28 mm SPRTNG WASHER
O
BALL BEARING
a6) OIL SEAL ReDlace.
(D
14 x 20 mm DOWEL
ptN
G) couNTERSHAFT ASSEMBLY
. l ndex
page,
13-28
NEEDLE SET PLATE
NEEDLE BEARING
OIL GUIOE C PLATE
MAGNET
DIFFERENTIAL ASSEMBLY
. l ndex
page, 13-38
O-nl NG Bepl ace.
TRANSFER ASSEMBLY
. I ndex
page,
' 13, 44
OI L SEAL Repl ace.
VEHICLE SPEED SENSOR
CLUTCH HOUSING
REVERSE LOCK CAM
REVEESE SHIFT HOLDER
REVERSE IDLE GEAR
REVERSE GEAR SHAFT
THRUST WASHER,20 x 36 x 2
COLLER, 15 x 20 x 20
aol
@
o
@
@
(D
i9
@
@
@
(9
@
@
@
e3
@
13- 12
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C)
TRANSMISSION HANGER
O
INTERLOCK BOLT
O 32 mm SEALING BOLT
@
STEEL BALL {5/16
in.)
)
SPRI NG 26. 1 mm {1. 03 i n. l
@
wasHER Replace.
O sET BALL scREw
@
WASHER Replace.
)
FLANGE BOLT
@ ol l SEAL Repl ace.
@
DRAIN PLUG
@
WASHER Replace.
@
FILLER PLUG
@
WASHER Repl ace.
(9
10 x 12 mm DOWEL PIN
(D
SPRI NG 25. 6 mm 11. 01
i n. l
'
THRUST WASHER
@}
SHIFT ARM C
(3
CONICAL SPRING WASHER
@
SPECTAL BOLT
8] SHIFT ARM COVER
@
OI L SEAL Repl ace.
!
SHIFT LEVER
@I
BREATHER CAP
(2!
SHIFT ARM SHAFT ASSEMBLY
@
SPRI NG PI N Repl ace.
O SELECT ARM
!}
THRUST WASHER
@
sTH/REVERSE SELECT
RETURN SPRING
@
SELECT RETURN SPRING
)
OIL GUTTER PLATE
@
78 mm SHI M
@
OIL GUIOE M PLATE
@ SELECT SPRING BOLT
@ OI L SEAL Repl ace.
@
SELECT LEVER
O
BACK.UP LIGHT SWITCH
@
WASHER Repl ace.
OO TRANSMISSION HOUSING
1 3 - 1 3 www.emanualpro.com
Transmission
Assembly
Disassembly
1. Remove the transfer assembl v.
O-RING
Repl ace.
Remove the shi ft arm cover assembl y, and wi De i t
cl ean of the seal ant.
SHIFT ARM COVER ASSEMBLY
10 x 12 mm DOWEL
pt N
13-14
3. Remove the i nterl ock bol t.
SELECT ARM
SHIFT ARM SHAFT
Turn the sel ect l ever countercl ockwi se, then remove
the shi ft arm A fi nger from the groove
of the shi ft
forks.
Tur n t he shi f t ar m shaf t count er cl ockwi se and
remove the sel ect arm fi nger from the groove
of the
shi ft arm A. then remove the shi ft arm shaft assem-
bl v.
Remove the vehi cl e speed sensor
(VSS).
5.
6.
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7. Remove the set bal l screws, washers, spri ngs, steel
bal l s. and back-uP l i ght swi tch.
STEEL BALL
D. 5/ 16 i n
8. Remove the fl ange bol t. drai n
pl ug, and fi l l er pl ug
DRAIN PLUG
WASHER
Repl ace.
LIGHT SWITCH
FILLER PLUG
WASHER
Repl ace.
FLANGE BOLT
9. Remove the transmi ssi on housi ng mounti ng bol ts
i n a cri sscross
pauern i n several steps.
10. Remove the 32 mm seal i ng bol t
Expand the snap ri ng on the countershaft bal l bear-
i ng, and remove i t from the
groove usi ng a pai r of
snap ri ng pl i er.
Separate the transmi ssi on housi ng from the cl utch
housi ng.
Remove t he dowel
pi ns, and wi pe i t cl ean of t he
seal ant.
' I
t .
(cont ' d)
1 3 - 1 5 www.emanualpro.com
Transmission
Assembly
Disassembly (cont'dl
14. Remove t he oi l gut t er pl at e, 78 mm shi m, and oi l
gui de M pl ate.
OIL GUIDE M PLATE
15. Remove the sel ect spri ng bol t.
OIL GUTTER PLATE
SELECT SPRING BOLT
1 3 - 1 6
18. Remove the oi l seal .
16. Remove the spri ng pi n usi ng the pi n punch
and a
pai r
of di agonal cutters.
PIN PUNCH, 5.0 mm
17. Remove the sel ect l ever, spri ngs, washer, and sel ect
arm.
SELCT LEVER
{
V
OIL SEAL
Repl ace.
THRUST WASHER
Repl ace.
SELECT ARM
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20.
2' t .
19. Remove the reverse l ock cam.
lf necessary, check the clearance of the reverse shift
hol der
(see page 13-20).
Remove the reverse shi ft hol der.
HOLOER
22.
'97
-
99 models: Remove the reverse gear shaft and
the reverse i dl er gear.
'00
model: Remove the reverse gear shaft, reverse
i dl er gear, thrust washer and the col l er.
13-17
23. Remove the mai nshaft and countershaft assembl i es
wi th the shi ft forks from the cl utch housi ng.
NOTE; Before removi ng the mai nshaft and counter-
shaft assembl i es, tape the mai nshaft spl i ne to pro-
tect it.
ASSEMBLY
Tape t he mai n'
shaf t spl i nes.
WASHER
SPRING WASHER
24. Remove the differential asssmbly.
COUNTEBSHAFT
HOUSING
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Shift Arm Cover/Shift Arm Shaft Assembly
Disassembly/Reassembly
Shift Arm Cover Assmbly
1. Remove the breather cap and set bal l screw, washer,
spri ng. and steel bal l .
BREATHER CAP
SPRING
L, 25. 6 mm
(1. 01 i n. l
T BALL SCREW
22 N.m 12.2 kgtm, 16lbf.ftl
Remove t he speci al bol t and coni cal spri ng washers.
SHIFT
ARM
COVER
THRUST WASHER
SHIFI ARM C
WASHER 8x1. 0mf t
SHIFT LEVER
29 N.m 13.0 kg{.m,
z2 tbt.ftl
ar m C, and t hr ust
Remove t he shi f t l ever , shi f t
washer from the shi ft arm cover.
Remove the oi l seal .
NOTE: l nstal l the thrust washer
face toward shi ft arm cover.
STEEL BALL
D. 5/ 16 i n,
1 3 - 1 8
wi th the al l oy sur-
3. Instal l i n the reverse order of removal .
5. Instal l the oi l seal i n to the shi ft arm cover usi no the
sDeci al t ool s.
HANOLE
07749
-
0010000
ATTACHMENT,
3 2 x 3 5 mm
077a6
-
0010100
OIL SEAL
Repl ace.
6. Reassembl e the shi ft arm cover i n the reve.se order
of di sassembl y.
Shift Arm Shaft Assembly
1. Remove the speci al bol ts and coni cal spri ng wash-
ers.
SPCCIAL BOLT
8 x 1 . 0 mm
29 N.m
(3.0
kgf.m,
SHIFTARMA 22IbI.ftI
CONICAL SPRING
SHIFT ARM SHAFT
SPECIAL BOLT
8 x 1 . 0 mm
29 N.m {3.0 kgf.m, 22 lbtft}
2. Remove t he i nt erl ock, shi f t
f rom t he shi f t arm shaf t .
SPRING
WASHER
arm A, and shi f t arm B
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2.
Cl earance InsPecti on
1. Measure the cl earance between the shi ft arm A and
sel ect arm.
Standard: 0.05
-
0 25 mm
(0.002 -
0'01 inl
Servi ce Li mi t:0.5 mm
(0.02
i n)
l f t he cl ear ance ar e mor e t han t he ser vi ce l i mi t ,
measure the di ameter of the sel ect arm pl n
Standard: 7.9
-
8.0 mm
(0.311 -
0.315 i n)
SELECT
ARM
l f the di ameter of the sel ect arm pi n i s l ess than
the servi ce l i mi t, repl ace the sel ect arm wrtn a
new one.
l f the di ameter of the sel ect arm
pi n i s wi thi n the
servi ce l i mi t, repl ace the shi ft arm A wi th a new
one.
SELECT ARM
SHIFT ARM A
SHIFT ARM C
SHIFT ARM B
3. Measure the cl earance between the shi ft arm B and
shi ft arm c.
Standard: 0.05
-
0.25 mm
(0.002
-
0.01 inl
Seryi ce Li mi t:0,5 mm
(0.02
i nl
l f t he cl ear ance ar e mor e t han t he ser vi ce l i mi t ,
measure the di ameter of the shi ft arm C.
Standard: 12.9
-
13.0 mm
(0
508
-
0.512 i n)
SHIFT ARM C
l f the di ameter of the shi ft arm C i s l ess than the
servi ce l i mi t, repl ace the shi ft arm C wi th a new
one.
l f t he di amet er of r he shi f t ar m C i s wi t hi n t he
servi ce l i mi t, repl ace the shi ft arm B wi th a new
o ne.
1 3 - 1 9
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Reverse Shift Holder
Clearance Inspection
1 . Measure the cl earances between the reverse shi ft
hol der and sth/reverse shi ft Di ece Di n.
Standard: A: 0.05
-
0.35 mm
(0.002 -
0.014 i n)
8: 0.4
-
0.8 mm 10.02
-
0.03 inl
Servi ce Li mi t: A: 0.5 mm
(0.02
i n)
B: 1.0 mm 10.0,[ i n]
2. l f t he cl ear ances ar e mor e t han t he ser vi ce l i mi t .
measure the wi dths of the groove i n the reverse
shi ft hol der.
Standard: A: 7.05
-
7.25 mm
{0.278
-
0.285 inl
B: 7.4
-
7.7 mm
(0.29 -
0.30 i nl
l f the wi dths of the grooves
are not wi thi n the
standard, repl ace the reverse shi ft hol der wi th a
new one.
l f the wi dths of the grooves are wi thi n the stan-
dard, repl ace the sth/reverse shi ft pi ece wi th a
new one.
PIECE PIN
REVERSE SHIFT HOLDER
13-20
3. Measure the cl earance between the reverse i dl er
gear and reverse shi ft hol der.
Standard: 0.5
-
1.1 mm
{0.02
-
0.0i 1 i n}
Servi ce Li mi t: 1.8 mm
(0.07
i n)
REVERSE
IDLER
GEAR
l f the cl earance i s more than the servi ce l i mi t. mea-
sure the wi dth ot the reverse shi ft hol der.
Standard: 13.0
-
13.3 mm
(0.512-0521i nl
It the wi dth i s not wi thi n the standard, repl ace
the reverse shi ft hol der wi th a new one.
l f the wi dth i s wi thi n the standard, reol ace the
reverse i dl er gear wi th a new one.
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Shift Fork Assembly
Disassembly/ReassemblY
I
eri or,o reassembl i ng, cl ean al l the
pans i n sol vent, dry them, and appl y l ubri cant to any contact
parts
1ST/2ND SHIFT FORK
SHIFT PIECE
PIN PUNCH, 5.0 mm
3RD/,|TH SHIFT FoRK
5TH/REVERSE
13-21
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Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sl eeve and synchro hub shoul d be
reol aced as a set.
1. Measure the cl earance between each shi ft fork and
i ts matchi ng synchro sl eeve.
Standard: 0.35
-
0.65 mm
10.01/t
-
0.026 inl
Service Limit: 1,0 mm {0.039 inl
SHIFT FORK
2. l f the cl earance exceeds the servi ce l i mi t. measure
the thi ckness of the shi ft fork fi ngers.
Standard:
l f the thi ckness of the shi ft fork fi nger i s l ess than
the standard, repl ace the shi ft fork wi th a new
one.
l f the thi ckness of the shi ft fork ti nger i s wi thi n
the standard, repl ace the synchro sl eeve wi th a
new one.
3rd/4th shift fork 7. 4
-
7. 6 mm
(0.29
-
0.30 i n)
1sv2nd shi ft fork
5th shift fork
6. 2
-
6. 4 mm
(0.24 -
0.25 i n)
3. Measure the cl earance between the shi ft fork and
the shi ft arm A.
Standard; 0.2
-
0.5 mm
(0.008-0.020
i n)
Service Limit: 0.6 mm
(0.02i1
in)
sTH/REVERSE
SHIFT PIECE ran,rru
lST/2ND
SI{IFT FORK
l f the cl earance exceeds the servi ce l i mi t, measure
the wi dth of the shi ft arm A.
Standard: 12.9
-
13.0 mm
10.508
-
0.512 i nl
l f the wi dth of the shi ft arm A i s l ess than the
standard, reDl ace the shi ft arm A wi th a new one.
l f the wi dth of the shi ft arm A i s wi thi n the stan-
dard, repl ace the shi ft fork or shi ft pi ece wi th a
new ones.
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Mainshaft Assembly
l ndex
Note the Iol l owi ng duri ng reassembl y:
. The 3rd/4th, and 5th synchro hubs, and the bal l beari ng are i nstal l ed wi th a
press.
. Instal l the angul ar bal l beari ng wi th the thi n-edged outer race faci ng the stop ri ng
pri or
to reassembl i ng, cl ean al l the parts i n sol vent, dry them, and appl y l ubri cant to any contact surfaces. The
3rd/4th and 5th svnchro hubs, however, shoul d be i nstal l ed wi th a press before l ubri cati ng them'
ANGULAR EALL BEARING
Check f or wear and operat i on.
Note the direction
of i nst al l at i on.
SYNCHRO RING
I nspect i on,
page l 3 37
SYNCHRO HUB
l nspect i on,
page 13-36
SYNCHRO SLEEVE
I nspect i on,
page 13 36
SPRING
SYNCHRO
SYOP RING
TAPER RING
BEARING
Check I or wear and operat aon.
COLLAR
RING
I nspect i on,
page 13-37
SYNCHRO SPRING
SYNCHRO HUB
I nspect i on,
page 13_36
SYNCHRO SLEEVE
I nspect i on, page 13 36
SPFING
RING
I nspect i on,
page 13_37
GEAR
I nspect i on,
page 13_25, 37
COLLAR
I nspect i on,
page 13-24, 25
GEAR
I nspect i on,
page 13 24, 37
I nspect i on,
page 13-37
3RD GEAR
I nspecl t on,
page 13 24, 37
BEARING
Check f or wear
ano oper al t on.
I nspect i on,
page 13 26
NEEDLE BEARING
Check f or wear and operat , on.
13-23
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Mainshaft Assembly
Clearance Inspection
NOTE; l f repl acement i s requi red, al ways repl ace the
synchro sl eeve and hub as a set.
L Support the beari ng i nner race wi th a socket. and
Dush down on the mai nshaft.
2. Measure the cl earance between 2nd and 3rd oears.
Siandard: 0.06
-
0.21 mm 10.002
-
0.008 in)
Servica Limit: 0.3 mm
(0.01
in)
l f the cl earance i s more than the servi ce l i mi t, mea-
sure the thi ckness of 3rd gear.
Standard: 34.92
-
34.97 mm {1.375
-
1.377 i n)
Service Limit 34.8 mm
(1.37
in)
3RD GEAR
l f the thi ckness of 3rd gear i s l ess than the ser-
vi ce l i mi t, repl ace 3rd gear wi th a new one.
l f the thi ckness of 3rd gear i s wi thi n the servi ce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one.
13-24
+
4. Measure the cl earance between 4th gear and the
spacer coIar,
Standard: 0.06
-
0.21 mm {0.002
-
0.008 in)
Servic Limit: 0.3 mm {0.01 inl
l f the cl earance i s more than the servi ce l i mi t, mea-
sure di stance
@
on the spacer col l ar,
Standard: 26.03
-
26.08 mm {1.025
-
1.027 inl
Service Limit: 26.01 mm {1.02,[ in]
o[-l:-g;;em
fp-rro.ERcoLLAR
6. tf di stance @
i s l ess than the servi ce l i mi t, repl ace
the sDacer col l ar wi th a new one.
l f di stance
@
i s wi thi n the servi ce l i mi t. measure
the thi ckness of 4th gear.
Standard: 31.42
-
31.' 17 mm 11.237
-
L239 i nl
Sarvi cc Li mi t:31.3 mm
{1.23
i n)
l f t he t hi ckness of 4t h gear i s l ess t han t he ser-
vi ce l i mi t , repl ace 4t h gear wi t h a new one.
l f t he t hi ckness of 4t h gear i s wi t hi n t he servi ce
l i mi t , repl ace t he 3rd/ 4t h synchro hub wi t h a new
one,
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7. Measure the cl earance between the spacer col l ar
and 5th gear.
Standard: 0.06
-
0.21 mm {0.002
-
0.008 in)
Service Limit: 0.3 mm {0.01 in)
MAINSHAFT
SPACER COLLAR
8.
SOCKET 5TH GEAR
l f the cl earance i s more than the servi ce l i mi t, mea-
sure di stance
@
on the spacer col l ar
Standard: 26.03
-
26.08 mm 11.025
-
1.027 in)
Srvico Limit: 26.01 mm
(1.024
in)
9.
SPACER
COLLAR
5TH GEAR
SIDE
l f di stance
@
i s l ess than the servi ce l i mi t, repl ace
the spacer col l ar wi th a new one.
l f di stance @
i s wi thi n the servi ce l i mi t, measure
the thi ckness of sth gear.
Standard: 30.92
-
30.97 mm
(1.217 -
1.219 i n)
Servi ce Li mi t: 30.8 mm
(1.21
i n)
r--\ ,,srH
GEAR
gt
Fq
I .J'-----!--\--J
- l
l f the thi ckness of 5th gear i s l ess than the ser-
vi ce l i mi t, repl ace 5th gear wi th a new one.
l i the thi ckness of sth gear i s wi thi n the servi ce
l i mi t , r epl ace t he st h synchr o hub wi t h a new
one.
Disassembly
1. Suppor t 5t h
gear on st eel bl ocks, and pr ess t he
mai nshaft out of the 5th synchro hub, as shown. Do
not use a
j aw-type pul l er, because i t can damage
the gear teeth.
PRESS
I
ACHMENT
In the same manner as above, support the 3rd gear
on steel bl ocks. and
press the mai nshaft out of the
3rd/4th svnchro hub, as shown.
PRESS
I
BLOCKS
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Mainshaft Assembly
Inspection
1 . I nspect t he gear sur f ace and bear i ng sur f ace f or
wear and damage, then measure the mai nshaft at
poi nts A, B, and C.
Standard:
A
(Bal l
beari ng surface): 27.987
-
28.000 mm
11. 1018
-
1. 1024 i nl
B
(Needle
bearing surfacel: 37.984
-
38.000 mm
(1.4954 -
1.4961 i nl
C {Bafl beari ng surfacel : 27.977
-27.990
mm
( 1. 1015 -
1. 1020 i nl
Servi ce Li mi t: A:27.94 mm
(1.100
i n)
B: 37.93 mm
(1.' 193
i nl
C: 27.94 mm 11.100 i nl
I nspect oi l passages I or cl oggi ng.
l f anv oart of the mai nshaft i s l ess than the servi ce
l i mi t. reol ace i t wi th a new one.
2. Inspect for runout.
Standard: 0.02 mm
(0.0008
i n) max.
Service Limit: 0.05 mm 10.002 inl
NOTE: Suppor t t he mai ns haf t at bot h ends
sh own.
l f the runout i s more than the servi ce l i mi t, reDl ace
the mai nshaft wi th a new one.
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Reassembly
NOTE: Refer to page 13-23 for reassembl y sequence.
1. Suppon 2nd gear on steel bl ocks as shown, then
i nst al l t he 3r d/ 4t h synchr o hub usi ng t he speci al
tool s and a press as shown.
NOTE: After i nstal l i ng, i nspect the operati on of the
3rd/ 4th synchro hub set.
PRESS
I
3RD/4TH
SYNCHRO HUB
DRIVER,
,l(}
mm l.O.
07746
-
0030'1 00
2.
2NO GEAR
Instal l the sth synchro hub usi ng the speci al tool s
and a press.
PRESS
I
DRl vER, 40 mm l . D.
077{6
-
00301(x)
ATTACHMENT,
35 mm l . D.
077i16
-
lx)3ollx)
sTH SYNCHBO HUB
3. I nst al l t he angul ar bal l bear i ng usi ng t he speci al
tool s and a oress. Note the di recti on of i nstal l ati on.
PRESS
I
077a6
-
0011x100
HANDLE
07749
-
0010000
ATTACHMENT,
/Vl x a7 mm
BALL BEARING
Not e t he di redi on
o{ i nst al l at i on.
13-27 www.emanualpro.com
Countershaft Assembly
Index
NOTE:
3
The 3rd, 4th. and sth gear are i nstal l ed wi th a press.
Pri or to reassembl i ng, cl ean al l the parts i n sol vent, dry them, and appl y l ubri cant to any contact surfaces. The 3rd,
4th, and sth gears, however. shoul d be i nstal l ed wi th a press before l ubri cati ng them.
LOCKNUT Replace.
127- o- 127N. m
1 1 3 - 0 -
1 3 k s t mi
\ 94- 0-
9. t r bt f t
/
IST/2ND SYNCHRO HUB
I nspect i on,
page 13 36
Check l or wear and
damage.
THRUST WASHER
I nspect i on,
page 13-29
DAMPER
WASHER
AEARING
Check f or wear and ooerat i on.
BEARING
Check f or wear and
operat i on.
GEAR
4TH GEAR
3RD GEAR
GEAR
SPNING
DOUBI.f CONE
I nspect i on,
page 13-37
1ST GEAR
I nspect i on,
page 13 29, 37
BEARING
Check t or wear and operat i on.
I nspect i on,
page 13-30, 37
NEEDLE BEARING
Check f or wear and oPerat i on
SPACER
Sel ect i on,
page 13-30
DAMPER
Check f or wear and damage.
DOUBLE CONE
I nspect i on,
page 13-37
SPRING
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Clearance Inspection
NOTE: l f repl acement us requi red, al ways repl ace the
synchro sl eeve and hub as a set.
1. Measur e t he cl ear ance bet ween t he l st oear and
thrust washer.
Standard: 0.06
-
0.18 mm
(0.@2 -
0.007 i n)
Servica Limit:0.23 mm {0.009 in)
THRUST WASHER
2. l f the cl earance i s more than the servi ce l i mi t, mea-
sure the thi ckness of the thrust washer.
Standsrd: 1.95
-
1.97 mm
(0.077 -
0.078 i n)
3. l f the thi ckness i s l ess than the standard, reDl ace the
thrust washer wi th a new one. l f the thi ckness i s
wi t hi n t he ser vi ce l i mi t , measur e t he t hi ckness of
t he 1st gear .
Standard: 26.95
-
27.00 mm
(1.061 -
1.063 i nl
l f the thi ckness of 1st gear i s l ess than the stan-
dard, repl ace 1st gear wi th a new one.
l f the thi ckness of l st gear i s wi thi n the standard.
repl ace 1sv2nd synchro hub wi th a new one.
{cont' d}
13-29 www.emanualpro.com
Countershaft Assembly
Cl earance Inspecti on
(cont' dl
4. Measure the cl earance between the 2nd
qear
and
3rd gear.
Standard: 0.07
-
0.1,1 mm
(0.003 -
0.006 i nl
Servi ce Li mi t:0.18 mm
(0.007
i nl
FEET.ER
GAUGE
!
t
. - ]
l f the cl earance i s more than the servi ce l i mi t. mea-
sure the thi ckness of the spacer.
Standard: 29.07
-
29.09 mm
(l .14i l -
1.145 i nl
13- 30
6. l f the thi ckness i s l ess than the standard, reDl ace the
spacer wrl n a new one.
l f the thi ckness i s wi thi n the standard, measure the
thi ckness of the 2nd gear.
Standal d: 28.92
-
28.97 mm
(1.139 -
1.141 i n)
l f the thi ckness of 2nd gear i s l ess than the stan-
dard, repl ace 2nd gear wi th a new one.
l f the thi ckness of l st gear i s wi thi n the standard,
repl ace 1sv2nd synchro hub wi th a new one.
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Disassembly
1 .
2.
Secur el y cl amp t he count er shaf t assembl y i n a
bench vi se wi th wood bl ocks.
SPRIiIG WASHEF
BETICH
vtsE
W(X)D BLOCKS
Rai se the l ocknut tab from the groove i n the coun-
tershaft, then remove the l ocknut and the spri ng
washer.
Remove the bal l beari ng usi ng a press as shown.
CHISEL
4. Remove the Jri cti on damper from the spacer usi ng a
press and a socket.
Suppor t l st gear on st eel bl ocks, and pr ess t he
countershaft out of 3rd gear.
PRESS
t
5.
PRESS
I
3RD GEAR
1ST GEAR
FRICTION DAMPER
I nspect l or wear and damage.
13- 31 www.emanualpro.com
Countershaft Assembly
Inspection
1. I nspect t he gear sur f ace and bear i ng sur f ace I or
wear and damage, then measure the countershaft
at poi nts A, B, and C.
Standa.d: A: 36.000
-
36.015 mm
11.,1173
-
f.i l l 79 i nl
B: 36.98/t
-
37.000 mm
{r.4561
-
1.4567 i nl
C: 24.987
-
25.000 mm
{0.98:17
-
0.9843 inl
Servi cs Li mi t: A:35,95 mm
(1.' 115
i n)
B: 36.93 mm
(1.454
i n)
C: 24.94 mm
(0.982
i n)
l f anv
part
of the countershaft i s l ess than the ser-
vi ce l i mi t. reol ace i t wi th a new one.
l nspect f or wear and damage.
13-32
2. Inspect for runout.
Standard: 0.02 mm 10.0008 inl max.
Service Limit: 0.05 mm {0.002 inl
NOTE: Suppor t t he count er shaf t at bot h ends as
shown.
Rot at e t wo compl et e revol ut i ons.
l f the runout exceeds the servi ce l i mi t, reDl ace the
countershaft wi th a new one.
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Reassembl y
Note these i tems duri ng reassembl y:
. Press the 3rd, 4th, and sth
gear on the countershaft
wi thout l ubri cati on.
. When i nstal l i ng the 3rd, 4th. and sth gears, suppon
the shaft on steel bl ocks and i nstal l the gears usi ng a
press.
. Refer to page 13-28 for reassembl y sequence.
1. Instal l the thrust shi m, needl e beari ng, 1st gear, and
fri cti on damper.
NOTE: Reassembl y the fri cti on damper on the l st
gear before i nstal l ati on.
rnrcrroru orn,leen
----.-4O)
l ST GEAR
NEEDLE BEARING
THRUST SHI M
2. Instal l the doubl e cone synchro.
3. Instal l the 1sv2nd synchro hub by al i gn the fri cti on
damper fi ngers wi th 1svznd synchro hub grooves.
(cont' d)
OUTER
lST/2ND
13- 33
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Countershaft Assembly
Reassembl y
(cont' dl
4. Reassembl y the fri cti on damper on the spacer usi ng
the sDeci al tool s and a Dress.
PRESS
t
ATTACHMENT,
U2t 47 mf i
07716
-
0010300
FRICTION DAMPER
I nspect f or wear and
damage.
I nst al l t he 2nd gear by al i gn t he
f i ngers wi t h 2nd gear grooves.
synchro cone the
GROOVE
13-34
6. Support the countershaft on a steel bl ock as shown
and i nstal l 3rd gear usi ng the speci al tool s and a
press.
3RO GEAR
7. l nstal l 4th gear usi ng the speci al tool s and a press.
PRESS
I
PRESS
t
ATTACHMENT,
35 mm LD.
07746
-
0030,100
www.emanualpro.com
8. Instal l sth
gear usi ng the speci al tool s and a press.
PRESS
I
DRIVER, 40 mm l.D.
07715
-
0030300
ATTACHMENT,
30 mm LD.
077,16
-
0030300
L I nst al l t he needl e bear i ng usi ng t he speci al t ool s
and a press, then i nstal l the beari ng outer race
PRESS
I
DRIVER. 40 mm l.D.
077{6
-
0030100
ATTACHMENT,
30 mm l . D.
07746
-
0030300
NEEDLE
BEASING
10. Instal l the bal l beari ng usi ng the speci al tool s and a
press.
PRESS
I
DRIVER. 40 mm LD.
07746
-
0030100
ATTACHMENT,
30 mm LD.
077a6
-
0030300
1 1 .Secur el y cl amp t he count er shaf t assembl y i n
bench vi se wi th wood bl ocks.
LOCKNUT
Repl ace.
Instal l the spri ng washer.
Instal l the new l ocknut to the correct torque, then
stake the l ocknut tab i nto the groove.
Torque: 127
+
0
+
127 N.m 113
-
0
+13
kgf.m,
94+0- 94| bf . f t )
12.
wooD slocKs
13- 35
www.emanualpro.com
Synchro Sleeve, Synchro Hub
Inspection
1 . Inspect gear teeth on al l synchro hubs and synchro
sl eeves f or r ounded of f cor ner s, whi ch i ndi cat e
I ns t al l eac h s y nc hr o hub i n i t s mat i ng s y nc hr o
sl eeve, and check for freedom of movement.
NOTE: l f r epl acement i s r equi r ed, al ways r epl ace
the synchro sl eeve and synchro hub as a set.
SYNCHRO
SLEEVE
SYNCHBO
HUB
13- 36
LONGER ?EETH
Instal l ati on
When assembl i ng the synchro sl eeve and synchro hub,
be sur e t o mat ch t he t hr ee set s of l onger t eet h
( ' 120
degrees apart) on the synchro sl eeve wi th the three sets
of deeper grooves i n the synchro hub. Do not i nstal l the
synchro sl eeve wi th i ts l onger teeth i n the l sv2nd syn-
chro hub sl ots because i t wi l l damage the spri ng ri ng.
SYNCHRO
SYNCHBO
SI.EEVE
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Synchro Ri ng, Gear
Inspection
Inspect the synchro ri ng and gear.
Ar l nspect the i nsi de of the synchro ri ng for wear.
B: l nspect the synchro sl eeve teeth and matchi ng
teeth on the synchro ri ng for wear
(rounded
of0.
C C
GOOO WORN
Cr Inspect the synchro sl eeve teeth and matchi ng
teeth on the gear tor wear
(rounded
off).
, , \ n
u
(-l
GOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface l or wear and roughness.
F: Inspect the teeth on al l gears for uneven wear,
scori ng, gal l i ng, and cracks.
2. Coat the cone surface of the
gear wi th oi l , and pl ace
the synchro ri ng on the matchi ng gear. Rotate the
synchro ri ng, maki ng sure that i t does not sl i p.
Measure the cl earance between the synchro ri ng
and gear al l t he way ar ound.
NOTE: Hol d the synchro ri ng agai nst the gear even-
l y whi l e measuri ng the cl earance.
Synchro Ring-to-Gear Clearance
Standard: 0.85
-
1.10 mm
(0.033 -
0.0,lil in)
Service Limit: 0.,1 mm 10.02 inl
Double Cone Synchro-lo-Goar Clearance
Standard:
@: {Outer
Synchro Ring to Synchto Conel
0.5
-
1.0 mm
(0.02 -
0.04 i n)
): {synchro
cone to Geal)
0.5
-
1.0 mm
(0.02 -
0.0i 1i nl
@: louter Synchro Ring to Gearl
0.95
-
1.68 mm
(0.037 -
0.056 i nl
Service Limit:
@:
0.3 mm
(0.01
i nl
@:
0.3 mm {0.01 i n}
@:
0.6 mm {0.02
i n)
l f the cl earance i s l ess than the servi ce l i mi t, repl ace
the synchro ri ng and synchro cone.
SYNCHRO SPRING
SYNCHRO
1 .
OUTER SYNCHRO RING
13-37 www.emanualpro.com
Differential
l ndex
NOTE: l f the
*
mark parts were repl aced, the tapered
rol l er beari ng prel oad must be adj usted
(see page 13-
41) .
*THRUST
SHIM
Adi ust ment ,
Page
13' 41
+BEARING
OUTER RACE
Bepl acement , page 13 40
I nspect f or wear and damage.
*TAPERED
ROLLER
BEARING
Repl acement , page l 3-39
I nspect f or wear and damage.
10 x 1. 0 mm
103 N.m {10.5 kgf m, 75.9 lbf.ft}
Left-hand threads
CARRIER
Backl ash i nspect i on, page 13 38
l nspect f or cracks.
FINAL DRIVEN GEAR
Repl acement , page 13-39
I nspect f or wear and damage
TRANSFER DRIVEN GEAR
Repl acement ,
page 13-39
I nspect {or wear and damage.
,,4\
W-
*TAPERED
ROLLER BEARING
Bepl acement , page 13' 39
I nspect f or wear and damage.
IEEARING
OUTER RACE
Repl acement , page 13-40
I nspect f or wear and damage.
.75
mm SHIM
13- 38
Backlash Inspection
1. Pl ace t he di f f er ent i al
i nst al l bot h axl es.
assembl y on V- bl ocks and
PINION GEARS
V-BLOCK
2. Measure the backl ash ot both pi ni on gears.
Standard
(Newl :
0.05
-
0.15 mm
(0.002 -
0.006 i nl
l f the backl ash i s not wi thi n the standard, reol ace
the di fferenti al carri er.
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Final Driven Gear RePlacement
L Remove the bol ts i n a cri sscross
pattern i n several
steps, and remove the fi nal dri ven
gear from the di f-
ferenti al carri er.
NOTE: The fi nal dri ven
gear bol ts have l eft-hand
threads.
10 x 1. 0 mm
103 N. m
(10. 5 kgf m, 75. 9l bf ' f t l
Lef t ' hand t hreads
FINAL DRIVEN GEAR
lnsoect {or weal and damage
TRANSFER ORIVEN GEAR
Inspect for wear and damage.
Instal l the fi nal dri ven
gear by ti ghteni ng the bol ts
i n a cri sscross
pattern i n several steps.
Tapered Roller Bearing
Repl acement
Note these i tems:
. The t aper ed r ol l er bear i ng and bear i ng out er r ace
shoul d be repl aced as a set.
. Inspect and adi ust the tapered rol l er beari ng
prel oad
whenever the tapered rol l er beari ng i s repl aced'
. Check the tapered rol l er beari ngs for wear and rough
rotati on. l f the tapered rol l er beari ngs are OK, remov-
al i s not necessary.
1. Remove the tapered rol l er beari ngs usi ng a beari ng
pul l er and a beari ng separator as shown.
Instal l new tapered rol l er beari ngs usi ng the speci al
tool as shown.
NOTE: Dr i ve t he t aper ed r ol l er bear i ngs on unt i l
they bottom agai nst the di fferenti al carrter.
PRESS
IJ
BEARING
SEPAFATOB
{Commerci al l y
ATTACHMENT,
,10
x 50 mm
07LAD
-
PWs060 l
BEARING
13- 39
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Differential
Bearing Outer Race Replacement
Note these i tems:
. The beari ng outer race and tapered rol l er beari ng
shoul d be repl aced as a set.
. l nspect and adj ust the tapered rol l er beari ng prel oad
whenever the tapered rol l er beari ng i s repl aced.
' 1.
Remove the oi l seal s from the transmi ssi on housi ng
and cl utch housi ng
(see
page
j 3-43).
2. Dri ve the beari ng outer race and thrust shi m out of
the transmi ssi on housi ng, or remove the beari ng
outer race and 75 mm shi m from the cl utch housi ng
by heat i ng t he c l ut c h hous i ng t o about 212" F
(100"C)
wi th a heat gun. Do not reuse the thrust
shi m i f the outer race was dri ven out.
TRANSMISSION
HOUSING:
ATTACHMENT
5 2 x 5 5 mm
07746
-
0010400
THRUST SHIM
BEARING
OUTER RACE
CLUTCH
HOUSING:
13-40
4, l nstal l the oi l seal
(see page
13-43).
3. Instal l the thrust shi m or 75 mm shi m and the bear-
i ng out er r ace i n t he t r ansmi ssi on housi ng and
cl utch housi ng usi ng the speci al tool s.
Note these i tems duri ng beari ng repl acement:
. Instal l the beari ng outer race squarel y.
. Check that there i s no cl earance between the
beari ng outer race, thrust shi m or 75 mm shi m
and housi ng.
TRANSMISSION
HOUSING:
HANDI-E
07749
-
00 xxto
ATTACHMENT,
62x68mm
077ir6
-
0010500
BEARING
OUIER RACE
THRUST
SHIM
CLUTCH
HOUSING:
HANDLE
07749
-
001tXX)o
ATTACHMENT.
7 2 x t 5 mm
07745
-
00106{x)
OUTER RACE
75 mm SHI M
www.emanualpro.com
Tapered Roller Bearing Preload Adiustment
l f any oJ the i tems l i sted bel ow were repl aced, the tapered
rol l er beari ng
prel oad must be adj usted.
. Transmi ssi on housi ng
. Cl utch housi ng
. Di fferenti al carri er
o Tapered rol l er beari ng and beari ng outer race
. Thrust shi m
. 75 mm sham
1. Remove t he bear i ng out er r ace and t hr ust shi m
from the transmi ssi on
housi ng
(see page 13-40)'
NOTE:
. Do not reuse the thrust shi m i f the beari ng outer
race was dri ven out.
. Let the transmi ssi on cool to room temperature i l
the beari ng outer race was removed by heati ng
the cl utch housi ng.
2. Do not use more than one thrust shi m to adj ust the
t aper ed bear i ng
pr el oad. Fi r st t r y t he same si ze
thrust shi m that was removed. There are no shi ms
used on the cl utch housi ng si de
SHIM THRUST
/A
After i nstal l i ng the thrust shi m, i nstal l the beari ng
outer race i n the transmi ssi on housi ng
(see page
13-40).
Wi t h t he mai nshaf t and count er shaf t
r emoved,
i nst al l t he di f f er ent i al assembl y, and t or que t he
cl utch housi ng and transmi ssi on
housi ng.
NOTE: l t i s not necessary to use seal i ng agent be-
tween the housi ngs.
TOBOUE; 8 x 1.25 mm: 27 N' m
(2.8
kgf'm, 20 lbt'ftl
Rotate the di fferenti al assembl y i n both di recti ons
to seat the tapered rol l er beari ngs.
Measure the tapered rol l er beari ng
prel oad at nor-
mal room temperature. Measure the starti ng torque
of the di fferenti al assembl y i n both di recti ons wi th
the speci al tool and a torque wrench.
STANDAFD: 1.4
-
2.5 N'm
{1/r
-
26 kgf'cm, 12
-
23 lbf in)
(cont' d)
4.
5.
07HAJ
-
PK4020'1
13-41 www.emanualpro.com
Differential
Tapered Roller Bearing Preload Adjustment
(cont'd)
7. l f the tapered rol l er beari ng prel oad i s not wi thi n
the standard, sel ect the thrust shi m whi ch wi l l gi ve
the correct tapered rol l er beari ng prel oad from the
fol l owi ng tabl e.
NOTE: Changi ng t he t hr ust shi m t o t he nexl si ze
wi l l i ncr ease or decr ease t aper ed r ol l er bear i ng
pr el oad about 0. 3
-
0. 4 N. m
( 3 -
4 kgf . cm, 2. 6
-
3.5 l bf.i n).
THRUST SHIM
8. Recheck the tapered rol l er beari ng prel oad.
Part Numbe. Thickness
41381
-
PX5 000 1. 90 mm
( 0. 0748
i n)
B 41382
-
PX5 000 1. 93 mm { 0. 0760 i n)
c 41383- PX5- 000
' 1.96
mm
(0.0772
i n)
n
41384- PX5- 000 1. 99 mm
( 0. 0783
i n)
E 41385- PX5- 000 2. 02 mm
( 0. 0795
i n)
F 41386- PXs- 000 2.05 mm
(0.0807
i n)
G 41387- PXs- 000 2. 08 mm
( 0. 0819
i n)
n 41388- PX5- 000 2. 11 mm
( 0. 0831
i n)
41389- PX5- 000 2. 14 mm
( 0. 0843
i n)
J 41390- PXs- 000 2.' 17 mm
(0,0854
i n)
K 41391
-
PX5
-
000 2.20 mm
(0.0866
i n)
4' 1392- PX5- 000 2.23 mm
(0.0878
i n)
M 41393- PX5- 000 2.26 mm
(0.0890
i n)
N 41394- PX5- 000 2.29 mm
(0.0902
i n)
o 41395, PXs
-
000 2.32 mm
(0.09' 13
i n)
P 41396- PX5- 000 2.35 mm
(0.0925
i n)
o 41397- PX5- 000 2.38 mm
(0.0937
i n)
4' t 398- PXs- 000 2.41 mm
(0.0949
i n)
S 41399- PXs- 000 2.44 mm
(0.0961
i n)
T 41400- PXs- 000 2.47 mm
(0.0972
i n)
41873- P16- 000 1. 66 mm
( 0. 0654
i n)
AB 41874- Pl 6- 000 1. 69 mm
( 0, 0665
i n)
AC 41875 P16
-
000
' 1.72
mm
(0.0677
i n)
AD 41876- P16- 000 1. 75 mm
( 0. 0689
i n)
AE 4 1 8 7 7 - P1 6 - 0 0 0 1. 78 mm ( 0. 0701
i n)
AF 41878- P16- 000 1. 81 mm
( 0. 07' 13
i n)
41879- P16- 000
' 1.84
mm
(0.0724i n)
AH 41880- P16- 000 1.87 mm {0.0736 i n)
13-42
9. How to sel ect the correct thrust shi m:
- 1)
Compar e t he t aper ed r ol l er bear i ng pr el oad
you get wi th the thrust shi m that was removed,
wi t h t he speci f i ed pr el oad
of 1. 4
-
2. 5 N. m
(14
--
26 kgfcm, 12-23l bti nl .
-2)
l f your measured tapered rol l er beari ng prel oad
i s l ess than speci fi ed. subtract yours
from the
speci fi ed,
l f your s i s mor e t han speci f i ed, subt r act t he
speci fi ed from your measurement.
For exampl e wi th a 2.17 mm
(0.0854
i n) thrust
shi ml
@
speci fi ed 2.5 N.m
(26
kgf.cm,23 l bi i n)
-
you measure 0.6 N.m
(6
kgf.cm,5 l bf.i n)
1.9 N.m
(20
kgi cm, 18 tbt.i n) tess
@
you measure 3.3 N.m
(34
kgf.cm,30 l bf.i n)
-
speci fi ed 2.5 N.m
(26
kgncm,23 l bf.i n)
0.8 N.m
(8
kgf.cm,7l bt.i n) more
Eac h s hi m s i z e up or down f r om s t andar d
mak es about 0. 3
-
0. 4 N. .
( 3 -
4 k gf ' c m,
2.6
-
3.5 l bf.i n) di fference i n tapered rol l er bear-
i ng pr el oad.
I n exampl e
@,
your measur ed t aper ed r ol l er
bear i ng pr el oad was 1. 9 N. m
( 20
k gf . c m,
18 l bf . i n) l ess t han st andar d so you need a
thrust shi m fi ve si zes thi cker than standard
{try
t he 2. 32 mm
( 0. 0913
i n) t hr us r s hi m. and
recheck).
l n exampl e
@,
your measurement was 0,8 N.m
{8 kgf.cm, 7 l bf.i n) more than standard, so you
need a thrust shi m two si zes thi nner
(try
the
2.1' l mm
{0.0831 i n) thrust shi m, and recheck).
www.emanualpro.com
Oil Seal Replacement
Transmi ssi on Housi ng:
1. Remove the oi l seal from the transmi ssi on housi ng
2. l nstal l the new oi l seal i nto the transmi ssi on
hous-
i ng usi ng the speci al tool s.
NOTE: Instal l oi l seal up to i 0.5 mm
(10.02
j n)
from
transmi ssi on housi ng end surface.
TRANSMISSION
HOUSING
PRESS
f
HANOLE
.--.'/'01119
-
@1OCIO0
DRIVER ATTACHMENT
-
PG4()r00
PI LOT, 28 x 30 mm
07JAO
-
PH80400
OIL SEAL
Replace.
OIL SEAL
Clutch Housing:
1. Remove the oi l seal from the cl utch housi ng.
HANDLE
l nstal l the new oi l seal i nto the cl utch housi ng usi ng
the speci al tool s.
NOTE: Instal l oi l seal up to t0.5 mm
(t0.02
i n) from
transmi ssi on housi ng end surface
CLUTCH
HOUSING
PRESS
I
07749
-
tx)l(xxto
DRIVER ATTACHMENT
OTJAD
-
PHM1Ol
PILOT, 28 x 30 mm
07JAD
-
PH8oaU)
Repl ace.
13- 43 www.emanualpro.com
Transfer Assembly
lllustrated Index
E ,AC
ea/
g B
e
www.emanualpro.com
O
TRANSFER HOUSING
@
O-RING Repl ace.
O
DAMPER HUB
G)
NEEDLE BEARING
G)
TRANSFER DRIVEN GEAR
G)
TRANSFER SHAFT
O
TAPERED ROLLER BEARING OUTER RACE
@
TAPERED ROLLER BEARING
)
TRANSFER SHAFT COLLAR
@
THRUST SHIM, 25 mm sel ecti ve
part
6D
TRANSFER DRIVE GEAR
(HYPOID
GEAR)
@
CONICAL SPRING WASHER RePl ace
GD
TRANSFER SHAFT LOCKNUT.22 x 1.25 mm Left-hand threads, repl ace'
E)
TAPERED ROLLER BEARING
@
TAPERED ROLLER BEARING OUTER RACE
@
THRUST sHl M. 68 mm sel ecti ve
part
O
o.Rl NG Repl ace.
@
TRANSFER COVER A
GD
TRANSFER COVER B
@
O-RING Repl ace.
)
TRANSFER DRIVEN GEAR SHAFT
(HYPOID
GEAR}
@
THRUST SHIM, 35 mm Sel ecti ve
Part
@
TAPERED ROLLER BEARING
@
TRANSFEB SPACEB RepIace.
@
TAPERED ROLLER BEARING OUTER RACE
@
TAPERED ROLLER BEARING OUTER RACE
@)
TAPERED ROLLER BEARING
@
ol L SEAL Repl ace.
@
COMPANION FLANGE
@
O-RING Repl ace.
@
BACK-UP RING
@
coNtcAL SPRING WASHEB Repl ace.
(o
TRANSFER DRIVEN GEAR SHAFT LOCKNUT,22 x 1.25 mm Replace.
TOROUE SPECIFICATIONS
Boh/Nut No.
Torque Value
Size
Remarks
6A
8C
22L
22H
12 N.m
(1.2
kgf.m.8.7 l bf.ft)
24 N.m {2.4
kgf.m, 17 l bf' ft)
118 N.m
(12.0
kgf.m, 86.8 l bf' ftl
132
-
216 N. m
( 13. 5
-
22. 0 kgf ' m,
97.6
-
159 l bf.ft)
6 x 1 . 0 mm
8 x 1. 25 mm
22 x 1 , 25 mm
22 x 1 . 25 mm
Transfer shaft l ocknut:
Lett-hand threads
Transfer driven
gear shaft locknut
Ti ghteni ng torque: dePendi ng on
Total Starti ng Torque vai ue
13-45
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Transfer Assembly
Inspection
NOTE: To pr event
damage t o t he t r ansf er housi ng,
al ways use soft
j aws
or equi val ent materi al s between
the transfer housi ng and the vi se.
Transter Gaar
(Hypoid
goar) Backlssh Masurement
1. Set a di al i ndi cat or on t he compani on f l ange as
shown.
2. Measure the transfer gear
backl ash.
STANDARD: 0.06
-
0.16 mm {0.002
-
0.006 in}
Total Sta.ting Torquo Msasuremont
3. Rotate the compani on fl ange several ti mes to seat
the tapered rol l er beari ng.
4. Measur e t he st ar t i ng t or que
( compani on
f l ange
si de) usi ng a torque wrench.
STANDARD:
2.68
-
3.47 N.m
{27.3
-
35.4 kgf.cm.23.7
-
30.7 tbt.in)
DIAL INDICATOR
COMPANION FLANGE
13- 46
Transfer Gear lHypoid
gearl Tooth Contaqt Inspction
5. Remove transfer cover B, then appl y Prussi an Bl ue
to both si des of the transl er gear teeth l i ghtl y and
evenl v.
Rotate the compani on fl ange i n both di recti ons unti l
the transfer gear rotates one ful l tul n i n both di rec-
ti ons.
Check the transfer gear
tooth contact pattern. 7.
l f the measurements or the tooth contact Dattern
are not wi thi n the standard. di sassembl e the trans-
fer assembl y, repl ace worn or damaged parts, and
reassembl e i t.
TRANSFER DRIVE GEAR
www.emanualpro.com
Disassembly
1 . Remove the transfer covers A and B.
TRANSFER
TRANSFEF
Repl ace.
Cut the l ocktabs ofthe l ocknut usi ng a chi sel . Keep
of the chiseled
particles out of the transfer housing
LOCKNUT LOCK TAB
at l
3. Hol d the transfer shaft wi th a 14 mm Al l en wrench
cl amped i n a bench vi se.
Loosen the transter shaft locknut. The transfer shaft
l ocknut has l ett-hand threads.
Remove the transfer shaft assembl y, transfer dri ve
gear,25 mm thrust shi m. transfer shaft col l ar. and
tapered rol l er beari ng from the transfer housi ng.
TRANSFER SHAFT
ASSEMBLY
TAPERED ROLLER
BEARING
TRANSFER SHAFT
COLLAR
TRANSFER
DRIVE
GEAR
THRUST SHIM,
25 mm
Sel ect i ve
pan
(cont' d)
14 mm ALLEN WRENCH
13-47
www.emanualpro.com
Transfer Assembly
Disassembly (cont'd)
Secure the transfer housi ng i n a bench vi se wi th
soft
jaws.
COMPANION FLANGE
HOLDER
07RAA
-
I nst al l t he speci al t ool on t he compani on f l ange,
then l oosen the transfer dri ven gear
shaft l ocknut.
Remove the transfer dri ven gear
shaft l ocknut, coni -
cal spri ng washer, back-up ri ng, O-ri ng, and com-
psni on
fl ange.
7.
TRANSFER DRIVEN
GEAR SHAFT LOCKNUT
Reol ace,
13- 48
9. Remove the transfer dri ven gear
shaft, then remove
the transfer spacer from the transfer dri ven gear
shaft.
TRANSFER ORIVEN
GEAR SHAFT
Remove the oi l seal and the tapered rol l er beari ng
from the transfer housi ng,
OIL SEAL
Replace.
TAPEREO ROLIIR
AEARING
TRANSFER HOUSING
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Transfer Drive Gear Bearing
Replacement
NOTE: Coat al l parts wi th MTF duri ng reassembl y.
1. Remove the tapered rol l er beari ng from the transfer
dri ve gear usi ng the speci al tool s and a press.
BEARING SEPARATOR, GEAR
o
-
1112"
{ Commer ci al l y
avai l abl e)
Instal l the new tapered rol l er beari ng i n the transfer
dri ve
gear usi ng the speci al tool s and a press
ATTACHMENT,
4 0 x 5 0 mm
07LAD
-
PW5lr601
ATTACHMENT,
3 7 x / Omm
07746
-
0010200
Transfer Driven Gear Shaft
Beari ng Repl acement
NOTE: Coat al l
parts wi th MTF duri ng reassembl y.
1. Remove the taDered rol l er beari ng from the transfer
dri ven
gear shaft usi ng a press and a col l ar.
BEARING SEPARATOR,
0
-
1112'
l Commerci al l y
avai l abl e)
l nstal l the 35 mm thrust shi m on the transter dri ven
gear shaft.
Instal l the new tapered rol l er beari ng on the transfer
dri ven
gear shaft usi ng the speci al tool s and a press.
NOTE: Use ol d transfer spacer for beari ng i nstal l a-
ti on, then di scard i t.
DRIVER 40 mm l.D.
07746
-
0030r00
13- 49 www.emanualpro.com
Transfer Assembly
Transfer Shaft Disassembly/
Reassembly
1. Support the transfer dri ven gear on steel bl ocks,
then press
the transfer shaft out of damper hub,
Al i gn the damper hub grooves
and transfer dri ven
gear teeth, and reassembl e the damper hub. needl e
beari ng, and transfer dri ven gear.
Instal l the transfer shaft usi ng a press.
13- 50
us I ng
Transfer Gover A Bearing Outer
Race Replacement
NOTE: Coat al l parts wi th MTF duri ng reassembl y.
1. Bemove the tapered rol l er beari ng outer race from
t r ansf er cover A by heat i ng t he cover t o al most
212" F
( 100oC)
usi ng a heat gun.
Do not heat t he
cover over 212"F
(100' C),
2. Instal l the 68 mm thrust shi m i n transfer cover A.
TRANSFER COVER A
ATTACXMCNT,
52x68mf t
07746
-
tD,t0500
I nst al l t he t apered rol l er beari ng out er race
t he speci al t ool s and a press.
BEARING OUTER RACE
BEARING OUTER RACE
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Transfer Housi ng Beari ng Outer Race Repl acement
NOTE: Coat al l parts wi th MTF duri ng reassembl y.
1. Remove the tapered rol l er beari ng outer race from
the transfer housi ng.
TBANSFER HOUSING
I nst al l t he new t aper ed r ol l er bear i ng out er r ace
usi ng the speci al tool s and a press
DRIVER
07749
-
0o1(xD0
TRANSFER HOUSING
BEARING OUTER
RACE
J
i=
\ l
DRIVER ATTACHMENT
13- 51
Bealing Outer Race Locations
and Special Tool APP|ications
TRANSFER HOUSING
Sect i onal Vi ew
ATTACHMENT,
6 2 x 6 8 mm
07746
-
0010500
ATTACHMENT,
62x68mm
07?a6
-
0010500
ATTACHMENT,
5 2 x 5 5 mm
07715
-
0010400
www.emanualpro.com
Transfer Assembly
Reassembly
Note these i tems duri ng reassembl y:
. Whi l e reassembl i ng the transfer assembl y:
-
Check and adj ust the transfer gear tooth contact.
-
Measure and adj ust the transfer gear
backl ash.
-
Check and adj ust the tapered rol l er beari ng start-
Ing rorque.
. Coat al l parts wi th MTF duri ng reassembl y.
. Repl ace t he t aper ed r ol l er bear i ng and t he bear i ng
outer race as a set i f ei ther part i s repl aced.
. Repl ace the transfer dri ve gear
and the transfer dri -
ven gear shaft as a set i f ei ther part i s repl aced,
Outl i ne of Assembl y
1 . Sel ect the 35 mm thrust shi m.
Perform thi s procedure
i f the transl er dri ven gear
shaft or the tapered rol l er beari ng on the transfer
dri ven gear shaft i s repl aced.
Preassembl e the parts
to check and adj ust transfer
gear backl ash and transfer gear
tooth contact.
Di sassembl e the parts,
then assembl e the transfer
dri ven gear shaft and i ts rel ated parts.
4. Measure and adj ust the stani ng torque of the trans-
fer dri ven gear shaft tapered rol l er beari ng.
5. Assembl e the transfer shaft and
j ts
rel ated parts.
6. Measure and adj ust the total starti ng torque.
35 mm Thrust Shim Seleqtion
1. Sel ect the 35 mm thrust shi m i f the transfer dri ven
gear shaft or the tapered rol l er beari ng on the trans-
fer dri ven gear shaft i s repl aced.
Cal cul at e t he t hi ckness of t he 35 mm t hr ust shi m
usi ng the formul a bel ow.
ronrvruu:fi--fr-+c=x
A: Number on the exi sti ng transfer dri ven gear
shaft
B: Number on the repl acement transfer dri ven gear
shaft
C: Thi ckness ofthe exi sti ng 35 mm thrust shi m
X: Thi ckness needed f or t he r epl acement 35 mm
thrust shi m
NOTE: The number on t he t r ansf er dr i ven gear
shaft i s shown i n 1/100 mm.
2.
3.
13-52
EXAMPLE:
C: EXISTING 35 mm
THRUST SHIM
Thicknoss: C=1.05 mm
X: REPLACEMET{T35 mm
THRUST SHIM
Thickness: X=?? mm
Number: A=+2
Number:
B-l
A: EXISTING TRANSFER
DRIVEN GEAR SHAFT
x =
A
-
B
- .
' -
100 100
-
2 - 1
100 100
' -
=
0.02 + 0.01 + 1.05
-' 1.08 (mm)
B: REPLACEMENT TRANSFER
DRIVEN GEAF SHAFT
Sel ect 35 mm t hr ust shi m t hi ckness ot
' 1. 08
mm
(0.043
i n). l f the tapered rol l er beari ng on the transfer
dri ven gear shaft i s repl aced.
Measur e t he t hi ckness of t he r epl acement bear i ng
and the exi sti ng beari ng, and cal cul ate the di fference
of the beari ng thi ckness. Adj ust the thi ckness of the
exi sti ng 35 mm thrust shi m by the amount of di ffer-
ence i n beari ng thi ckness. and sel ect the repl acement
35 mm thrust shi m. Do not use more than one 35 mm
thrust shi m to adj ust the transfer gear backl ash,
THRUST SHIM. 35 mm
Shi m No. Part Number Thickness
41361
-
PS3
-
000 0. 72 mm (0. 028
i n)
B 41362- PS3- 000 0. 75 mm
(0. 030
i n)
c 41363- PS3- 000 0. 78 mm
(0. 031
i n)
41364- PS3- 000 0. 81 mm (0. 032
i n)
E 41365- PS3- 000 0. 84 mm (0. 033
i n)
F 4r 366- PS3- 000 0. 87 mm (0. 034
i n)
41367- PS3- 000
0. 90 mm
(0. 035
i n)
n 41368- PS3- 000 0. 93 mm (0. 037
i n)
41369- PS3- 000 0. 96 mm {0. 038 i n)
41370- PS3- 000
0. 99 mm
(0. 039
i n)
41371
-
PS3
-
000 1. 02 mm
(0. 040
i n)
L 41372- PS3- 000 1. 05 mm
( 0. 041
i n)
41373- PS3- 000 1. 08 mm
(0. 043
i n)
N 4 1 3 7 4 - PS3 - 0 0 0 1. 11 mm
( 0. 044
i n)
www.emanualpro.com
Transter Gear Backl ash Inspecti on and Transfer Gear
Tooth Contaqt Inspection
2. l nstal l the 35 mm thrust shi m on the transfer dri ven
gear shaf t , t hen i nst al l t he t aper ed r ol l er bear i ng
usi ng the speci al tool s and a press.
NOTE: Use ol d l ransfer spacer for beari ng i nstal l a-
ti on, then di scard i t.
TRANSFER DRIVEN
GAR SHAFT
Instal l the beari ng outer race, then the tapered bear-
i ng on t he compani on f l ange si de ot t he t r ansf er
housi ng.
3.
OIL SEAL DRIVER
ATTACHMENT
07JAD
-
PH80101
DRIVER
077/tg
-
001qt00
Repl ace. TAPERED ROLLER
BEARING
I nst al l t he new oi l seal on t he t r ansf er housi ng
usi ng the speci al tool s.
5. Instal l the transfer dri ven
gear shaft i n the transfer
housi ng. Do not i nstal l the transfer spacer on the
transfer dri ven
gear shaft i n thi s step.
TRANSFER
HOUSING
Instal l the compani on fl ange. coni cal spri ng washer,
and l ocknut on the transfer dri ven
gear shaft. Do
not i nst al l t he O- r i ng and t he back- up r i ng on t he
transfer
gear shaft i n thi s step.
6,
COMPANION
FLANGE
CONICAL SPRING
di rect i on.
(cont' d)
13- 53
TRANSFER HOUSING
WASHER
www.emanualpro.com
Transfer Assembly
Reassembl y
(cont' d)
7. Secur e t he t r ansf er housi ng i n a bench vi se wi t h
soft
j aws,
then i nstal l the speci al tool on the com-
pani on fl ange. To prevent damage to the transfer
housi ng, al ways use soft
j aws
or equi val ent materi -
al s between the transfer housi ng and the vi se.
COMPANION FLANGE
HOLDER
07RAB
-
0020000
WRENCH
8. Ti ght en t he l ocknut whi l e measur i ng t he st ar t i ng
torque so the starti ng torque i s wi thi n 0.98
-
1.39
N.m
{10.0
-
14.2 kgf.cm. 8.68
-
12.3 l bf.i n).
NOTE:
. Coat t he t hr eads of t he l ocknut , and t he shaf t
wi th MTF before i nstal l i ng the l ocknut.
. Do not stake the l ocknut i n thi s step.
STARTING TOROUE:
0.98
-
1.39 N.m
(10.0 -
14.2 kgf.cm, 8.68
-
12.3 l bf.i n)
9. Instal l the transfer shaft assembl y i n the transfer
housi ng, t hen i nst al l t he t aper ed r ol l er bear i ng,
t r ansf er shaf t col l ar , 25 mm t hr ust shi m, t r ansf er
dri ve gear, coni cal spri ng washer, and l ocknut on
the transfer shaft.
NOTE:
. Coat t he t hr eads of t he l ocknut , and t he shaf t
wi th MTF before i nstal l i ng the l ocknut.
. Do not stake the l ocknut i n thi s step.
TRANSFER SHAFT
ASSEMBLY
TRANSFER
THRUST SHIM.
25 mm
Selective
part
COLLAR
TRANSFER DRIVE
GEAR
CONICAL SPRING
WASHER
Repl ace.
Repl ace.
www.emanualpro.com
TOROUE WRENCH
10. Hol d the transfer shaft wi th a 14 mm Al l en wrench
cl amped i n a bench vi se.
lil mm ALLEN WRENCH
Ti ghten the transfer shaft l ocknut.
NOTE:
. The transfer shaft l ocknut has l eft-hand threads,
. Do not stake the l ocknut i n thi s step.
TOROUE: 118 N.m
(12.0
kgf.m,86.8 lbf.ft)
Temporari l y i nstal l the transfer cover A wi thout the
O-ri ng.
1 1 .
rl0ustNG
TRANSFER COVER A
8 x L 2 5 mm
24 N.m
(2.4
kgt.m. 17 lbnftl
' 14.
Rotate the compani on fl ange several ti mes to seat
the tapered rol l er beari ng.
Set a di al i ndi cator on the compani on fl ange, then
measure the transfer gear backl ash.
STANDARD: 0.06
-
0.15 mm 10.002
-
0.006 i n)
COMPANION FLANGE
l f t he measur ement i s not wi t hi n t he st andar d,
remove the transfer shaft l ocknut and repl ace the 25
mm t hr ust shi m. Sel ect and i nst al l a new 25 mm
thrust shi m. then recheck the measurement. Do not
use more than one 25 mm thrust shi m to adj ust the
transfer
gear backl ash,
THRUST SHl M,25 mm
DIAL INDICATOR
Shi m No. Part Numbel Thickness
I 2941r
-
P1C
-
000 1.70 mm 10.067 i n
2 29412- Pl C- 000
' L73
mm
(0. 068
i n
3 29413- P1C- 000 1. 76 mm
(0. 069
i n
29414- Pl C- 000 1. 79 mm
(0. 070
i n
5 29415- P1C- 000 1. 82 mm
(0. 072
i n
6 2 9 4 1 6 - Pl C- 0 0 0 1. 85 mm
(0. 073
i n
7 294' 17- Pr C- 000 1. 88 mm
(0. 074
i n
8 294' 18- P1C- 0001. 91 mm
( 0. 075
i n)
29419- Pl C- 000 1. 94 mm
(0. 076
i n)
' 10
29420- P1C- 000 1. 97 mm 10. 078 i n)
1 1 29421
-
P1C
-
000 2.00 mm
(0.079
i n)
12 29422
-P1C -
000 2.03 mm
(0.080
i n)
13 29423- P1C- 000 2.06 mm
(0.081
i n)
l 4 29424- P1C- 000 2. 09 mm
(0. 082
i n)
29425-P' tC-000 2. 12 mm
( 0. 083
i n)
1 6 29426- P1C- 000 2. 15 mm
( 0. 085
i n)
1 7 29427
-P1C-000
2. 18 mm { 0. 086 i n)
' 18
29428- P1C- 000 2. 21 mm {0. 087 i n)
1 9 29429- P1C- 000 2. 24 mm 10. 088 i n)
(cont' d)
13- 55 www.emanualpro.com
Transfer Assembly
Reassembly
(cont'dl
16. Appl y Prussi an Bl ue to both si des of the transfer
gear teeth l i ghtl y and evenl y.
Rotate the compani on fl ange i n both di recti ons unti l
the transfer gear rotates one ful l turn i n both di rec-
ti ons.
Check the transfer gear tooth contact pattern.
CORREST TOOTH CONTACT PATTERN
INCORRECT IOOTH CONTACT PATTERN
TOE CONTACT
HEEL CONTACT
FLANK CONTACT
17.
18.
TRANSFER DRIVE GEAR
13- 56
FACE CONTACT
19. l f the transfer gear
tooth contact i s i ncorrect, adj ust
the transfer
gear
tooth contact wi th a 35 mm or 25
mm t hr ust shi m.
NOTE:
. To sel ect a 35 mm thrust shi m, refer to page
' 13-
. Do not use more than one 35 mm shi m to adj ust
the transfer gear tooth contact.
. To sel ect the 25 mm thrust shi m, refer to page
13-55.
a Do not use more than one 25 mm shi m to adj ust
the transfer
gear
tooth contact.
Toe Contact
Use a t hi cker 35 mm t hr ust shi m t o move t he
transfer driven gear shaft toward the transfer drive
gear. Because this movement causes the transfer
gear
backlash to change, move the transfer drive
gear away from the transfer driven gear shaft to
adj ust the transfer gear backl ash as i ol l ows;
. I ncr ease t he t hi ckness of t he 25 mm t hr ust
shi m.
. Reduce t he t hi ckness of t he 68 mm t hr ust
shi m bv the amount of i ncreased thi ckness of
the 25 mm thrust shi m.
Heol Contact
Use a thi nner 35 mm thrust shi m to move the
transfer driven gear shaft away from the transfer
dri ve gear. Because thi s movement causes the
transfer gear backlash to change, move the trans-
fer drive gear
toward the transfer driven
gear
shaft
to adjust the transfer gear backlash as follows:
. Reduce t he t hi ckness of t he 25 mm t hr ust
sh i m.
a I ncr ease t he t hi ckness of t he 68 mm t hr ust
shi m by the amount of reduced thi ckness of
t he 25 mm t hr ust shi m.
Flank Contact
Use a thi nner thrust shi m to move the transfer
dri ve gear toward the transfer dri ven gear shaft.
Fl ank contact must be adtusted wi thi n the l i mi ts
of t he t r ansf er gear
backl ash. l f t he backl ash
exceeds t he l i mi t s, adj ust as descr i bed under
Heel Contact.
Face Contsct
Use a thi cker thrust shi m to move the transfer
dri ve gear away from the transfer dri ven gear
shaft. Face contact must be adj usted wi thi n the
l i mi ts of the transj er gear backl ash. l f the back-
l ash exceeds t he l i mi t s, adj ust as descr i bed
under Toe Contact.
www.emanualpro.com
20. Remove the parts on the transfer shaft, and remove
the transfer shatt from the transfer housi nq.
TRANSFER SHAFT
TRANSFER HOUSING
TAPERED ROLLER
BEARING
TRANSFER SHAFT
COLLAR
TMNSFER DRIVE
GEAR
THRUST SHIM, 25 mm
Selective part
CONICAL SPRING
WASHER
Repl ace.
LOCKNUT
Repl ace.
Transter Driven Gear Shaft Starting Torque Inspection
and Adlustment
21. Secure the transfer housi ng i n a bench vi se wi th
soft iaws.
I nst al l t he speci al t ool on t he compani on f l ang,
then remove the transfer dri ven gear shaft l ocknut
and the coni cal spri ng washer.
COMPANION FLANGE HOLDER
22.
BACK.UP
Remove the transter dri ven gear shaft and the com-
pani on fl ange.
Instal l the new transfer spacer on the transfer dri -
ven gear shaf t , t hen i nst al l t hem i n t he t r ansf er
housi ng.
TRANSFER DRIVEN
GEAR SHAFT
TRANSFER SPACER
I nst al l i n t hi s di rect i on.
TRANSFER
25. Instal l the compani on fl ange, O-ri ng, back-up ri ng,
coni cal spri ng washer and l ocknut on the transfer
dri ven gear
shaft.
NOTE:
. Coat the threads of the l ocknut, O-ri ng and trans-
fer shaft wi th MTF before i nstal l i ng the l ocknut.
. Instal l the coni cal spri ng washer i n the di recti on
shown.
TRANSFER HOUSING
O.RING
COMPANION
FLANGE
CONICAL SPRING
WASHER
Replace.
LOCKNUT
Repl ace.
(cont ' d)
13-57
www.emanualpro.com
Transfer Assembly
Reassembly
(cont'dl
26. Secure the transfer housi ng i n a bench vi se wi th
soft
jaws.
COMPANION FLANGE HOLDER
07RAB
-
002tD00
27. I nst al l t he speci al t ool on t he compani on f l ange.
then ti ghten the transfer dri ven gear shaft l ocknut
whi l e measuri ng the starti ng torque of the transfer
dri ven gear shaft.
STARTING TOROUE:
0.98
-
1.39 N.m
{10.0
-
1i1.2 kgf.cm, 8.68
-
12.3 lbf in}
TIGHTENING TOROUE:
132
-
216 N.m
(13.5 -
22.0 kgf.m, 97.6
-
159 l bf.ft)
NOTE:
. Rot at e t he compani on f l ange sever al t i mes t o
seat the tapered rol l er beari ng, then measure the
startrng torque.
. l f t he st ar t i ng t or que exceeds 1. 39 N. m
( 14. 2
kgf.cm, 12.3 l bf.i n), .epl ace the transfer spacer
and r eassembl e t he par t s. Do not adj ust t he
torque wi th the l ocknut l oose.
. l f t he t i ght eni ng t or que exceeds 216 N. m
( 22. 0
kgf.m, 159 l bf' ft), repl ace the transfer spacer and
reassembl e the parts.
. Wr i t e down t he measur ement of t he st ar t i ng
torque: i t i s used to measure the total starti ng
torque.
28. Stake the l ocknut i nto the transfer dri ven oear shaft
usi ng a 3. 5 mm punch.
0. 7
-
1. 2 mm
(0.03 -
0.05 inl
Point to be
st aked.
Instal l the transfer shaft assembl v i n the transfer
housi ng, t hen i nst al l t he t aper ed r ol l er bear i ng,
transfer shaft col l ar, 25 mm thrust shi m, transfer
dri ve gear,
coni cal spri ng washer, and transfer shaft
l ocknut on the transfer shaft.
NOTE:
. Coat the threads of the l ocknut and transfer shaft
wi th MTF before i nstal l i ng the l ocknut.
. l nstal l the coni cal spri ng washer i n the di recti on
snown.
TMNSFER SHAFT
ASSEMBLY
TRANSFER HOUSING
TAPERED ROLLER
BEARING
TRANSFER SHAFT
COLLAR
TRANSFER DRIVE
GEAR
PUNCH
3. 0- 3. 5 mm
10. 12
-
0. 1a i nl
THRUST SHIM, 25 mm
Selective part
CONICAL SPRING
WASHEB
Repl ace.
LOCKNUT
Repl ace.
29.
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30. Hol d the transfer shaft wi th a 14 mm Al l en wrench
cl amDed i n a bench vi se.
NOTE: The l ocknut has l eft-hand threads.
TOROUE: 118 N.m
(12.0
kgt' m,86.8 l bf' ft)
31. Stake the l ocknut on the transfer shaft usi ng a 3.5
mm Dunch.
PUNCH
3. 0
-
3. 5 mm
{0. 12
-
0. 14 i nl
14 mm ALLEN WRENCH
Totsl Starting Torquo Inspoction and Adiustment
32. Temoorari l v i nstal l transfer cover A wi thout the O-
ri ng.
TRANSFER HOUSING
TRANSFER COVER A
o E l
l E
/Eh
v c
/E\
\g
8 x 1 .25 mm
24 N.m
(2.4
kg{ m, 17 lbtftl
5t . Secure the transfer housi ng i n a bench vi se wi th
soft
j aws.
then rotate the compani on fl ange several
ti mes to fi t the tapered rol l er beari ng,
TOROUE WRNCH
34. Measure the total starti ng torque.
TOTAL STARNNG TOROUE:
1.70
-
2.08 N.m 117.3
-
21.2 kgf.cm, 15.0
-
18.i 1 l bf i nl
+ Transter Driven Gear Shaft Starting Torque Value
(wrot
down in step 27).
(cont' d)
13- 59
www.emanualpro.com
Transfer Assembly
Reassembly
(cont'd)
Remove transfer cover A.
l f the measurement i s out of speci fi cati on, remove
t he 68 mm t hr ust shi m f r om t r ansf er cover A by
heat i ng t he cover t o al most 212' F
( 100' C)
usi ng a
heat gun. Do not heat the cover hi gher than 212F
( 100" C) .
Let t he cover cool t o r oom t emper at ur e
before adj usti ng the starti ng torque.
l I the measurement i s wi thi n the speci fi cati on, go to
step 40.
COVER A
BEARING OUTER RACE
35.
36.
HEAT GUN
13- 60
37. Sel ect the 68 mm thrust shi m.
THRUST SHIM, 68 mm
Shi m No. Part Number Thickne3s
zv 23914-P1C-020 1. 41 mm
(0. 056
i n)
zw 23975-P1C-020
' 1. 44
mm 10. 057 i n)
zx 23916 PlC
-020
' 1. 47
mm
(0. 058
i n)
ZI 23917
-P1C-O20
1. 50 mm
(0. 059
i n)
zz 23978- Pl C- 020 1. 53 mm
(0. 060
i n)
23941
-
PW5 000 1. 56 mm {0. 061 i n)
23942- PWs- 000 1. 59 mm
(0. 063
i n)
c 23943- PW5- 000
' t . 62
mm
(0. 064
i n)
D 23944 PW5
-
000 1. 65 mm
(0. 065
i n)
E 23945- PWs- 000 1. 68 mm
(0. 066
i n)
F 23946- PW5- 000 1. 71 mm 10. 067 i n)
G 23947- PW5- 000
' 1. 74
mm 10. 069 i n)
23948- PWs- 000 1. 77 mm
(0. 070
i n)
23949- PWs- 000 1. 80 mm
(0. 071
i n)
239s0- PW5- 000 1. 83 mm
(0. 072
i n)
K 23951
-
PW5
-
000 1. 86 mm
(0. 073
i n)
L 23952- PWs- 000 1. 89 mm {0. 074 i n)
239s3- PWs- 000 1. 92 mm {0. 076 i ni
N 23954- PW5- 000 1. 95 mm
(0. 077
i n)
o 23955- PW5- 000 1. 98 mm
(0. 078
i n)
P 23956
-
PW5
,
000 2. 01 mm
(0. 079
i n)
o 23957- PWs- 000 2. 04 mm
(0. 080
i n)
R 23958- PWs- 000 2. 07 mm
(0. 081
i n)
23959- PW5- 000 2. 10 mm
(0. 083
i n)
T 23960- PW5- 000 2. 13 mm
(0. 084
i n)
U 23961
-
PW5
-
000 2. 16 mm
(0. 085
i n)
23962- PW5- 000 2. 19 mm
(0. 086
n)
23963- PWs- 000 2.22 mm
(0.087
n)
X 23964- PWs- 000 2. 25 mm
(0. 089
n)
23965, PWs- 000 2. 28 mm 10. 090n)
23966- PW5- 000 2. 31 mm {0. 091 i n)
23967- PWs- 000 2. 34 mm
(0. 092
i n)
AB 23968- PWs- 000 2. 37 mm
(0. 093
i n)
AC 23969- PWs- 000 2. 40 mm {0. 094 i n}
AD 23970- PW5- 000 2. 43 mm (0. 096
i n)
M 23941
-
PW8
-
000 2. 46 mm {0. 097 ' n}
BZ 23942- PW8- 000 2. 49 mm (0. 098
i n)
cz 23943- PW8- 000 2. 52 mm {0. 099 i ni
DZ 23944- PW8- 000 2. 55 mm
(0. 100
i n)
EZ 23945- PW8- 000 2. 58 mm
( 0. 102
i ni
www.emanualpro.com
38. I nst al l t he 68 mm t hr ust shi m usi ng t he speci al
tool s.
DRIVER
077
-
001(xno
THRUST S1{IM,
68 mm
Selective
part
BEARING OUTER BACE
ATTACHMENT.
62x68mm
077a6
- (x)10500
39. After repl aci ng the 68 mm thrust shi m, recheck and
make sur e t he t ot al st ar t i ng t or que i s wi t hi n t he
soecification.
40. Coat t he new O- r i ngs wi t h MTF, i nst al l t hem on
transfer covers A and B, then i nstal l the covers on
the transfer housi ng.
6 x 1 . 0 mm
12 N. m 11. 2
kgf . m,
8.7 tbt.ft)
TRANSFER COVER B
TRANSFER
O.RING
Repl ace.
O.BING
Replace.
TRANSFER
COVER A
8 r 1. 25 mm
2,r N.m
(2.4
kgl.m. 17 lbtft)
13- 61 www.emanualpro.com
Mai nshaft Beari ng/Oi l Seal
Replacement
1. Remove the bal l beari ng usi ng the speci al tool .
3/8"
-16
SLIDE HAMMER
(Commerci al l y avai l abl e)
PULLER. 25
- , 10
mm
07736
-
A01000A
2. Remove the oi l seal from the cl utch housi ng.
13-62
BALL BEARING
3. Dri ve the new oi l seal i n from the transmi ssi on si de
usi ng the speci al tool s.
ATTACHMENT,
12x 17 .nfi
07746
-
0010300
Dri ve the new bal i beari ng i n from the transmi ssi on
si de usi ng the speci al tool s.
ATTACHMENT.
6 2 x 6 8 mm
07746
-
0010500
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Gountershaft Bearing
Replacement
1. Remove the retai ni ng
pl ate from the cl utch housi ng.
CLUTCH HOUSING
HETAINING PLATE
Remove the needl e beari ng usi ng the speci al tool ,
then remove the oi l gui de pl ate.
Repl ace.
3/8"
-16
SLIDE HAMMER
(Commerci al l y
avai l abl e)
CLUTCH TIOUSING
^'
ADJUSTABI.f BEARING
PULLER,25
-
40 mm
07736
-
A01(x)04
NEEDLE BEARING
Posi ti on the oi l gui de pl ate.
Dri ve the needl e beari ng usi ng the speci al tool s.
ATTACHMENT,
62x88mm
07746- 0t!105q)
NEEDII AEARING
Instal l the retai ni ng pl ate, and stake the bol t heads
i nto the groove i n the retai ni ng pl ate
6 x 1 . 0 mm
12 N.m
(1.2
kgt m,8.7 lbtftl
13- 63
www.emanualpro.com
Mainshaft Thrust Clearance
Adjustment
l . Remove the 78 mm shi m
the transmi ssi on housi ng.
4.
and oi l gui de pl ate from
Instal l the 3rd/4th synchro hub, spacer col l ar, sth
synchro hub, spacer, and bal l beari ng on the mai n-
shaft. then i nstal l the above assembl y i n the trans-
mi ssi on housi ng.
l nstal l the washer on the mai nshaft.
Measure di stance
@
between the end of the trans-
mi ssi on housi ng and washer,
NOTE:
. Use a strai ght edge and verni er cal i per.
. Measure at three l ocati ons and average the read-
I ng.
END ot
TRANSMISSION
MAINSHAFT
WASHER
3RD/4TH SYNCHRO HUB
SPACER COLLAR
sTH SYNCHRO HUB
SPACER
78 mm SHI M
13-64
BALL BEARING
5, Measure di stance
@
between the end of the cl utch
housi ng and beari ng i nner race.
NOTE:
. Use a strai ght edge and depth gauge.
. Measure at three l ocati ons and avorage the read-
I ngs.
END ot CLUTCH HOUSING
BEARING
Sel ect the
proper 78 mm shi m from the chan by
usi ng the formul a bel ow.
Shim Slection Formula:
From the measurements you made i n steps 4 and 5:
-1.
Add di stance
@
(step
5) to di stance
@
(step
4).
-2.
From thi s number. subtract 0.93
(whi ch
i s the
mi dpoi nt of the fl ex range of the cl utch housi ng
beari ng spri ng washer).
-3.
Take thi s number and compare i t to the avai l -
abl e shi m si zes i n the chart.
(For
exampl e)
A: 2.39 2.61
+ Bi O.22
-
0.93
=
2. 61
= 1. 68
Try the 1.68 mm
(0.0661
i n) shi m.
www.emanualpro.com
78 mm SHIM
Part Numbor Thickness
23941
-
P16
-
000 1. 20 mm
(0. 0472 i n)
23942- P16- 000 1. 23 mm
(0. 0484
i n)
c 23943- P16- 000
' 1. 26
mm
(0. 0496 i n)
u 23944- Pt 6- 000 1.29 mm
(0.0508
i n)
23945- P16- 000 1.32 mm
(0.0520n)
F 23946- P16
-
000 1.35 mm
(0.0531n)
G 23947- P16- 000 1.38 mm {0.0543n)
H 23948- P16- 000 1. 41 mm
(0. 0555
n )
23949- P16- 000 1. 44 mm
(0. 0567 i n)
23950- P16- 000 1. 47 mm
(0. 0579
i n)
K 23951
-
P16
-
000 1. 50 mm {0. 0591 i n}
L 23952- Pl 6- 000 1.53 mm
(0.0602
i n)
M 23953- P16- 000 1. 56 mm
(0. 0614
i n)
N 23954- P16- 000 1. 59 mm
(0. 0626
i n)
o 23955- P15- 000 1.62 mm
(0.0638
i n)
23956
-
P16
-
000 1. 65 mm
(0. 0650
i n)
23957- P16- 000 1. 68 mm
(0. 066' t
i n)
23958- P16
-
000 1. 71 mm
( 0. 0673
i n)
23959- P16- 000 1. 74 mm {0. 0685 i n)
T 23960- P16- 000 1. 77 mm {0. 0697 i nl
23961
-
P16
-
000 1.80 mm
(0.0709 i n)
23962- P16- 000 1.83 mm
(0.0720 i n)
23963- P16- 000
' 1.86
mm
(0.0732 i n)
X 23964- P16- 000 1. 89 mm
(0. 0744
i n)
23965- P16- 000 1. 92 mm
(0. 0756
i n)
z 23966- Pl 6- 000 1. 95 mm
(0. 0768 i n)
23967- Pl 6- 000 1.98 mm
(0.0780
i n)
AB 23968- P16- 000 2.01 mm
(0.0791 i n)
23969- Pl 6- 000 2.04 mm
(0.0803 i n)
AD 23970
-
Pl 6- 000 2. 07 mm { 0. 0815 i n)
AE 23971
-
P16
-
000 2. 10 mm {0. 0827 i n}
23972- P16- 000 2.13 mm
(0.0839 i n)
23973- P16- 000 2. 16 mm
(0. 0850
i n)
AH 23974- P16- 000 2.19 mm
(0.0862 i n)
AI 23975- P16- 000 2.22 mm 10.087
4 inl
AJ 23976- Pl 6- 000 2.25 mm {0.0886 i n}
AK 23977- P16- 000 2.28 mm {0.0898 i n)
23978- Pl 6- 000 2.31 mm
(0.0909 i n)
23979- Pl 6- 000 2.34 mm
(0.0921
i n)
AN 23980- P16- 000 2.37 mm
(0.0933
i n)
7, Check the thrust cl earance i n the manner descri bed
Delow.
NOTE: Measur ement shoul d be made at nor mal
room temperature.
-1.
Instal l the 78 mm shi m sel ected and oi l gui de
pl ate i n the transmi ssi on housi ng.
78 mm SHI M
OIL GUIDE PLATE
I nst al l t he spr i ng washer and washer on t he
bal l beari ng.
NOTE:
. Cl ean the spri ng washer, washer and thrust
shi m thoroughl y before i nstal l ati on.
. Instal l the spri ng washer, washer and thrust
shi m properl y.
WASHER
g
,-g
SPRTNG*ASHER
Instal l the mai nshaft i n the cl utch housi ng.
Pl ace the transmi ssi on housi ng over the mai n-
shaft and onto the cl utch housi ng.
Ti ghten the cl utch and transmi ssi on housi ngs
wi th several 8 mm bol ts.
NOTE: l t i s not necessary to use seal i ng agent
between the housi ngs.
Tap the mai nshaft wi th a pl asti c hammer.
- 2.
- 5.
(cont' d)
13- 65
www.emanualpro.com
Mainshaft Thrust Clearance
Adjustment
(cont'dl
-7.
Sl i de the mai nshaft base over the mai nshaft.
Attach the mai nshaft hol der to the mai nshaft as
fol l ows:
NOTE:
. Bac k - out t he mai ns haf t hol der bol t and
l oosen the two hex bol ts.
. Fi t the hol der over the mai nshaft so i ts l i p i s
towards the transmi ssi on.
. Al i gn the mai nshaft hol der' s l i p around the
gr oov e at t he i ns i de of t he mai ns haf t
spl i nes, then ti ghten the hex bol ts.
MAINSHAFT HOLDER
BOLT
MAINSHAFT EASE
07GAJ
-
PG20130
-9.
Seat the mai nshaft ful l y by tappi ng i ts end wi th
a pl asti c hammer.
-10.
Thread the mai nshaft hol der bol t i n unti l i t
j ust
cont act s t he wi de sur f ace of t he mai nshaf t
base.
07GAJ
-
PG20130
-8.
t--E-H
lf\f,A\ l\. xex
l"\y I
aors
t____=__)"n-____"8
\
MAINSHAFT
HOLDER
07GAJ
-
PG20110
-
11. Zer o a di al gauge ont he end of t he mai nshai t .
-12.
Turn the mai nshaft hol der bol t cl ockwi se; stop
t ur ni ng when t he di al gauge has r eached i t s
maxi mum movement, The readi ng on the di al
gauge i s the amount of mai nshaft end pl ay.
NOTE: Turni ng the mai nshaft hol der bol t more
t han 60 degr ees af t er t he needl e of t he di al
gauge stops movi ng may damage the transmi s-
si on.
MAINSHAFT HOLDER
07cru
-
PG20110
-13.
l f the readi ng i s wi thi n the standard, the cl ear-
ance rs correct.
l f t he r eadi ng i s not wi t hi n t he s t andar d,
recheck the shi m thi ckness.
Standard: 0.11
-
0.18 mm
(0.00i 1-
0.007 i nl
DIAL GAUGE
MAGNET STAND AASE
07979
-
PJ40001
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Transmission Assembly
Reassembly
1. Instal l the di fferenti al assembl y i n the cl utch hous-
I ng.
Instal l the spri ng washer and washer wi th the angl e
agai nst the cl utch housi ng as shown.
Tape the mai nshaft spl i nes. i nsert the mai nshaft
and countershaft i nto the shi ft forks, and i nstal l
them as an assembl v.
Tape t he mai nshat t
spl i nes.
DIFFERENTIAL ASSEMBLY
4.
' 97
-
99 model s: Instal l the reverse i dl e gaar and
reverse gear shaft i n the cl utch
housi ng.
' 00
model : Instal l the col l er, thrust washer, reverse
i dl er gear and the reverse gear shaft i n
the cl utch housi ng.
THRUST WASHER
COLLER
NOTE: Instal l the reverse gear shaft
(' 00
model ) i n
the di recti on shown.
5. Instal l the reverse shi ft hol der i n the cl utch housi ng
wi th the sth/reverse shi ft pi ece pi n posi ti oned i n the
slot of the reverse shift fork.
5 x 1 . 0 mm
15 N'm 11.5 kgt.m, 11 lbf.ftl
model
REVERSE SHIFT HOLDER
(cont'd)
13-67
www.emanualpro.com
Transmission Assembly
Reassembly
(cont'dl
6. Instal l the reverse l ock cam on the cl utch housi ng.
6 x 1 . 0 mm
15 N.m
(1.5
kgf.m, 11 lbf.ftl
REVERSE LOCK CAM
7. l nst al l t he oi l seal .
HANDLE
07749
-
001mO
ATTACHMENT,
3 2 x 3 5 mm
07745
-
0010100
OIL SEAL
Repl ace.
Instal l the sel ect l ever, spri ng washer, and spri ngs
on the sel ect arm.
SELECT LEVER
SELECT BETURN
SPRING
5TH/REVERSE
SELECT RETURN
SPRING PIN
Repl ace.
SELECT ARM
9. I nst al l t he sel ect ar m and spr i ng pi n.
13- 68
10. Appl y l i qui d gasket (P/N
08718
-
0001 or 08718
-
0003) to the sel ect spri ng bol t threads, then i nstal l
the sel ect spri ng bol t.
SELECT SPRING BOLT
39 N.m la.o
kgf'm,29lbtft)
' I
1. I nst al l t he oi l gui de M pl at e. 78 mm shi m, and oi l
guner pl ate i n the transmi ssi on housi ng.
NOTE: Sel ect t he 78 mm shi m accor di ng t o t he
measurements made on page 13-64,
OIL GUIDE M PLATE
www.emanualpro.com
12. Appl y l i qui d gasket to the surface of the transmi s-
si on housi ng as shown.
Note these i tems:
. Use l i qui d gasket (P/N
08718
-
0001 or 08718
-
0003).
. Remove the di rty fl ui d from the seal i ng surface.
. Seal the enti re ci rcumterence of the bol t hol es to
prevent fl ui d l eakage.
. l f 20 mi nutes have passed after appl yi ng l i qui d
gasket, reappl y i t and assembl e the housi ngs.
a Al l ow i t to cure at l east 20 mi nutes after assem-
bl y betore fi l l i ng the transmi ssi on wi th MTF.
Instal l the 14 x 20 mm dowel pi ns.
Set the stopper ri ng as shown. Pl ace the transmi s-
si on housi ng over the cl utch housi ng, bei ng careful
to l i ne up the shafts. Be sure to al i gn the stop ri ng
wi th the 5th shi ft fork fi nger ti p.
r3.
14.
TRANSMISSION HOUSING
SHIFT FORK
vk..*,
Al i gn poi nt
17.
the 32 mm seal i ng bol t.
15. Lower the transmi ssi on housi ng wi th the snap ri ng
pl i ers. and set the snap ri ng i nto the
groove of the
countershaft beari ng.
Check that the snap ri ng i s securel y seated i n the
groove of the countershaft beari ng.
Dimension A as installod: 3.6
-
6.3 mm
(0.142 -
0.2/8 in)
16.
32 mm SEALING BOLT
25 N m 12.5
kgf.m, 18 lbf.ftl
SNAP RING
(cont' d)
13- 69
Appl y l i qui d gasket ( P/ N
08718
-
0001 or 08718
-
0003) to the 32 mm seal i ng bol t threads, then i nstal l
SNAP RING PLIERS
DOWEL PINS
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Transmission Assembly
Reassembly
lcont'd)
18. Instal l transmi ssi on hanger, then ti ghten the bol ts i n
a cri sscross pattern i n several steps as shown.
8 x 1.25 mm bolis: 27 N.m
12.8
kgf.m,20 lbf'ft}
TRANSMISSION
HANGER
19. Instal l fl ange bol t,
pl ug.
washer s, dr ai n pl ug.
and f i l l er
FILLER PLUG
4,r N.m
(a.5
kgl.m,33lbtftl
DRAIN PLUG
39 N.m {4.0 kg{.m,29lbtftl
WASHER
Repl ace.
WASHER
13-70
20. I nst al l t he st eel bal l s, spr i ngs. washer s, set bal l
screws, back-up l i ght swi tch.
WASHER
Repl ace.
STEEL BALL
D, 5/ 16 i n
21. Instal l the vehi cl e speed sensor
(VSS).
VEHICI."E SPEED SENSOR
8 x 1. 25 mm
22 N.m 12.2 kgl.m, 16 lbt.ftl
SPRI NG L. 26. 1 mm 11. 03 i nl
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22. Turn the sel ect l ever and shi ft arm shaft counter-
cl ockwi se, then i nsert the shi ft arm shaft.
INTERLOCK EOLT
39 N.m
(4.0
kqt ft, 29 lbf ft)
SELECT ARM
SHIFT ARM A
Al i gn the shi ft arm A groove and sel ect arm fi nger
by turn the shi ft arm shaft and sel ect l ever cl ock-
wi se. then i nstal l the shi ft arm shaft assembl y.
Appl y l i qui d
gasket
(P/N
08718
-
0001 or 08718
-
OO03) to the threads, then i nstal l the i nterl ock bol t'
Appl y l i qui d gasket to the surface of the shi ft arm
cover as snown.
Note these i tems:
. Use l i qui d
gasket
(P/N
08718
-
0001 or 08718
-
0003).
. Remove the di rtv oi l from the seal i ng surface.
. Seal the enti re ci rcumference of the bol t hol es to
prevent oi l l eakage.
. l f 20 mi nutes have
passed after appl yi ng l i qui d
gasket. reappl y i t and assembl e the housi ngs.
a Al l ow i t to cure at l east 20 mi nutes after assem-
bl y betore fi l l i ng the transmi ssi on wi th MTF.
23.
-
->.-
(
SHIFT ARM SHAFT
SHIFT ARM COVER ASSEMBLY
10 x 12 mft DOWEL PIN
t 1
26. Instal l the shi ft arm cover assembl y.
I x 1.25 mm
27 N m 12.8 kgt m,20 lbf'ft)
Instal l the transfer assembl Y.
NOTE: Lubr i cat e MTF t o t he O- r i ng and cont act
areas.
10 x 1. 25 mm
44 N.m 14.5 kgf.m, 33 lbl.ftl
13-71
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Transmission Assembly
1 .
Installation
Check that the dowel pi ns
are i nstal l ed i n the cl utch
housi ng.
Appl y grease to the rel ease fork and rel ease bear-
i ng.
{P/N 08798
-
90021
{P/N 08798
-
9002)
0. {
-
1. 0 g
{0.0'l
-
0.04 ozl
RELEASE
BEARING
(P/N
08798
-
9002)
RELEASE
FORK
BOOT
?
(P/N
08798
-
9002)
' 1.0
-
1.6 g
{0.0,1- 0.06 o2l
Instal l the rel ease beari ng, rel ease fork, and rel ease
fork boot to the cl utch housi ng.
Instal l the starter motor and hose cl amp.
10 x 1. 25 mm
4{ N'm (4.5
kgf.m,
32 tbf.ftl
13-72
HOSE
5. Pl ace t he t r ansmi ssi on on t he t r ansmi ssi on
j ack,
and rai se i t to the engi ne l evel .
6. Instal l the transmi ssi on mounti ng bol ts and the rear
engi ne mounti ng bol ts.
TRANSMISSION
MOUNTING EOLT
12 x 1. 25 mn
7.
64 N.m {6.5 47 tbt.ft)
REAR ENGINE MOUNNNG BOLTS
Repl ace.
I t l x 1. 5 mm
8:l N.m 18.5 kgt m, 61 lbf.ft)
Ri se the transmi ssi on, then i nstal l the transmi ssi on
mount bracket and transmi ssi on mount.
. Tor que t he mount i ng bol t s and nut s i n t he
sequence shown.
. Check that the bushi ng are not twi sted or offset.
O. @:
12 x 1. 25 mm
64 N.m
(6.5
kgf.m, 47 lbf'ft)
O:
Temporary ti ghteni ng
@:
12 x 1. 25 mm
74 N.m
(7.5
kgf' m,54 l bf.ft)
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8. Instal l the ri ght front mounvbracket.
12 x 1 . 25 mm
64 N.m
(6.5 kgf'm,
47 tbf.ftl
Repl ace.
RIGHT FRONT
MOUNT/BBACKET
10 x 1. 25 mm
4,a N.m
(4.5 kgf m,
33 tbf ftl
I nst al l t he cl ut ch housi ng cover and r ear engi ne
stiffener.
6 x l 0 m m
12 N.m 11.2 kgt.m.
8.7 tbf.ft)
HOUSING
' 12
x 1. 25 mm
29 N.m 13.0 kgf.m. 22 lbf'ft)
8 x 1. 25 mm
24 N.m {2.5
kgf'm'
18 tbl.ft)
10 x
'l
.25 mm
44 N.m {4.5
kgf m,33 lbf ftl
10. Pour transmi ssi on fl ui d of 1 l i ter from the dri veshaft
i nserted hol e.
1 1. l nstal l the i ntermedi ate shaft {see secti on 18). Whi l e
i nstal l i ng the i ntermedi ate shaft i n the di fferenti al .
be sure not to al l ow dust and other forei gn parti cl es
to enter the transmi ssi on.
10 r 1. 25 mm
39 ttm 14.0 kgf.m,
29 tbt ftl
SET RING
Repl ace.
12. l nst al l t he dr i veshaf t s
( see
sect i on 18) . Whi l e
i nstal l i ng the dri veshaft(s) i n the di fferenti al , be sure
not to al l ow dust and other forei gn
pani cl es to enter
the transmi ssi on.
SET RING
Repl ace.
(cont' d)
13-73
INTERMEOIATE SHAFT
DRIVESHAFT
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Transmission Assembly
Installation
(cont'dl
13. I nst al l t he bal l j oi nt s ont o t he l ower arms.
DAMPER PINCH BOLT
10 x 1. 25 mm
43 N.m {a.a kgf.m,
32 rbfft)
SELF.LOCKING NUT
'12
x 1.25 |nm
6il N'm 16.5 kgtin, 47 lbtftl
Reolace.
Repl ace.
14.
PROPELI"ER SHAFT
13-74
12 x 1.25 mm
,19 -
59 N.m
(5.0 -
6.0 kgi.m, 36
-
lbfttl
Instal l the ri ght damper fork bol t.
Instal l the propel l er
shaft to the transfer assembl y
by al i gni ng the reference marks.
E x 1.25 mr'|
15.
REFERENCE MARKS
32 N.m 13.3 kst m, 2a lbf.ftl
TRANSFER
Instal l the exhaust pi pe
A, then connect the heated
oxygen sensor
(HO2S)
connector.
GASKETS
Repl ace.
HO2S CONNECTOR
10 x 1. 25 mm
5,1N.m 15.5 kgtm.
()
tbt fil
Replace.
SELF.LOCKING
SELF.LOCKING NUT
8 x 1. 25 mm
16 N.rn 11.6 kg{.m,
12l bt f r)
Replace.
GASKET
Replace.
8 x 1.25 rr|ln
22 N.m
(2.2
tgf.m, 16 lbl.ftl
Replac6.
' 17.
I nst al l t he guard
bar and t he spl ash shi el d.
SPLASH SHIEI.I)
I x 1. 25 mm
24 N.m l2.a kgf.m.
17 tbtft)
GUARD BAR
6 x 1 . 0 mm
9.8 N.m (1.0
kgf.m, 7.2 lbf.ft)
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18.
19.
Refi l l the transmi ssi on fl ui d
(see page 13-3)
Instal l the four upper transmi ssi on mounti ng bol ts.
12 x 1. 25 mm
6it N.m 16.5
kgf m,
il7 lbf.ftl
20. Connect the vehi cl e speed sensor
(VSS)
connector.
------------,-
VSS CONNECTOR
21, Instal l the cabl e bracket from the cl utch housi ng.
8 x 1. 25 mm
27 N.m
(2.8
kgt'm. 20 lbtftl
COTTER PIN
Rpl ace.
STEEL
WASHER
COTTEN PIN
Repl ace.
STEEL
WASHER
PLASTIC
WASHER
22.
) a
SELECT
CABLE
l nstal l the shi ft cabl e and sel ect cabl e to the l evers,
then i nstal l pl asti c washers, steel washers, and cot-
ter
prns,
Connect the back-up l i ght swi tch connector. and
i nstal l the wi re harness cl amP.
6x 1. 0mm
9.8 N.m {1.0 kgf.m,
HARNESS CLAMP
(cont' d)
13-75
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Transmission Assembly
Instal l ati on
(cont' dl
24. Connect the starter cabl es and transmi ssi on ground
caore.
TRANSMISSION
GROUND CABLE
Appl y grease
to the push rod on the sl ave cyl i nder,
then i nstal l the sl ave cyl i nder and cl utch hose bracket,
NOTE: Use onl y Super Hi gh Temp Ur ea Gr ease
{P/N 08798
-
9002).
CI-UTCH HOSE
BRACKET
8 x 1. 25 mm
22 N.m 12.2 kgi-m,
16 tbr.f0
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
7.2 rbf.ftt
_G1
(P/N
08798
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kg{. m,
7.2 tbt.ttl
13-76
-
9002)
26. Turn the breather cap so that the
"F"
mark poi nts at
the ri ght si de of the vehi cl e as shown.
27. I nst al l t he i nt ake ai r duct and ai r cl eaner housi ng
(see
secti on 5),
28. Connect the posi ti ve (+)
cabl e fi rst. then the nega-
ti ve
(-)
cabl e to the battery.
29. Check the l evel of the transm i ssi on f l u i d.
30. Check the cl utch operati on.
31. Shi ft the transmi ssi on and check for smooth opera-
t i on.
32. Check the front wheel al i gnment (see
secti on l 8).
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Gearshift
Mechanism
Overhaul
Note these i temsl
. InsDect rubber
parts
for wear and damage when di sassembl i ng'
. Check that the new cotter
pi n i s seated fi rml y.
. Be carel ul not to damage the
gui de pi pe when removi ng the cabl es'
CHANGE LEVER KNOS
8 N.m
(0.8
kgl.m, 5.8 lbf.ft)
SELECT CABLE
PLATES
Repl ace.
WASHEB
I
curur
( Pl N
I I
\ I I
\"1
a,
?-@
-.4'
-(
I
\
6 x
9. 8
Gui de
pi pe i n t he
DOOI,
COTTEF PIN
PLASTIC WASHER
GUIDE PIPES
SHIFT CABLE
' l . 0
mm
N.m {1.0 kgf.m, 7.2 lbf.ftl
(stLlcoNE
GREASEI
LEVER ASSEMBLY
8 x 1. 25 mm
13 N. m 11. 3
kgt ' m, 9. 4l bf f t )
FLOATING
COLLAR
13-77
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Automatic
Transmission
Speci al Tool s
. 14' 2
Oescr i pt i on
Gener al Oper at i on
. . . . . 14 3
Power Fl ow
. . . .
' 14_6
El ec t r oni c Cont r ol Sy s t em . . . . . . . . . 14_15
Hydr aul i c Cont r ol
. . 14 24
Hy dr aul i c Fl ow. . . . - . . . . . . . . . . . . . . . . . . . 14_29
Lock' up Sysl em
. . . ' t 4' 39
Electrical System
Componenl Locdl r ons
14 45
PCM Ci r cui l Dr agr am
( A/ T Cont r ol Svst em)
' 97
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . 14- 46
' 9 8 M o d e l
. . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 5 0
' 9 9
0 0 Mo d e l s . . . . . . . . . . . . 1 4 5 2
PCM Ter mi nal Vol t age/ Measur i ng Condi t i ons
A " / T Co n t r o l S y s t e m- ' 9 7 Mo d e l
. . . . . . . . 1 4 ' 4 8
A, / T Cont r ol Syst em
- ' 98
00 Model s . . . . . . 14 54
Tr oubl es hoot i ng Pr oc edur es . . . . . . . . . . - 14_56
Svmot om t o comoonent Char l
Ei ect r , cal Sysl em
- ' 97
Model . . 14 60
El ect r i cal Syst em
- ' 98 -
OO Model s . . . . . 14_62
El ect r i cal Tr oubl eshoot i ng
( ' 97
Model )
Tr oubl es hoot i ng Fl owahar t s . . . . . . . . . . . . . . 14_64
El ect r i cal Tr oubl eshoot i ng
( ' 98 -
00 Model s)
Tr oubl es hoot i nq Fl owc l t " n" . . . . . . . . . - . . 14- 93
El ect r i cal Tr oubl esl i oot i ng( ' 99
00Model s)
Tr oubl eshoot i no Fl owchar t
O/ D OFF I ndi cat or Li ght Does Not Come On 14 131
O/ D OFF I ndi cat or Li aht On Const ant l Y . . . . 1! - 132
O/ D OFF I ndi cat or Li ght Does Not Come On
Even Though O/ D Swi t ch l s Pr essed . . . . . - 14_133
Lock up Cont r ol Sol enoi d Val ve A, / B Assembl y
Tes t . . . . . . . . . . . . . . . . . . . . - . . . . . . . . .
. . 14- 135
Re p l a c e me n t
. . l l _ 1 3 5
Shi f r Cont r ol Sol enoi d Val ve Ay' B Assembl ,
Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14- 136
Repl ac ement . . . . . . . . . . . . . . -
. . 14' 136
Li near Sol enoi d Assembl Y
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 1 4 _ 1 3 7
Repl ac ement
. . . 14138
Mar nshaf t l count er shaf l Speed Sensor s
R e p l a c e m e n t
. . . - . . . 1 4 _ 1 3 8
A/T Gear Position Switch
Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . - . . .
. . . 14- 139
Repl acement
A/T Gear Position l ndi cat or
. . . . . . . . . . . . . . . . . . 14- 140
Val ve Eody
nepai r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . 14 192
Assembl y . . . . . . . . . . . . . . . . . . . .
. . 1{ _193
Val ve Caps
De s c i i p t i o n . . . . - . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 1 4 1 9 4
t nspei t i on . . . . . . . . . . . . . . . . . . .
. . 14' 195
N4ai n Val ve Body
Di sassembl y/ l nspect i on/ Reassembl v
- . . . . . . . . 14_196
Secondarv Val ve BodY
Di sassembl v4nspect ron/ Reassembl Y
. . . 14 198
Reoul at or Val ve Bodv
bi sassembt v, l nspi ct i on/ Reassembl v
. 14199
Servo Eodv
Di sassembl y/ l nspect i on/ Reassembl y
. . . . . . . 14' 200
Lock' uo Val ve BodY
Di s; ssembl y/ l nspect i on/ Reassembl y
. . . . . 14_201
Mai nshaf t
Di sassembl y/ l nspect i on/ Reassembl y
. . . . . . . . 14' 202
I nspect i on . . . . - . . . . . . . . . . . . . .
. . 11_203
Seal i ng Ri ngs
Rei l acei ent
. . . . . . . . . . . . 14' 204
Countershaft
Di sassembl y/ l nspect i on/ Reassembl y
. . . . . . . 11-205
Di sassembl y/ Reassemb| y
. . . . . . . . . . . . . . . . . . . 14_206
I nspedr on . . . . . . . . . . . . . . . . . . . . . . 14 207
One wav Cl ut ch
Di sassembl y/ l nspect i on/ Reassembl Y
. . . 11_209
Sub-shaf t
Di sassembl y/ l nspect i on/ Reassembl y
. . . . . . . 14-210
oi sassembl y/ Re6ssembl y
. . . . . . - . . . . . . . . . . 14- 211
Sub-shaf t Beari ngs
R e p l a c e me n t
. . . . . . . 1 4 ' 2 1 2
Cl ut ch
l l f ust rat ed I ndex . . . . . . . . . .
. . . 14-213
Di sassembl y
. . . . . . . . . . . 14- 216
Reassembf y
. . . . . . . . . . 14' 218
Differential
llfustrated Index "
14-222
Backl ash I nspect i on
. . . . . . . 14' 223
Beari ng Repi acement
. . 11-223
Di f f ere-nt i al Carri er Repl acement . . . . . . . . . . . 11-2?4
Oi f Seal Repl acement .
. . . 14' 225
Si de Cl earance l nspect i on . . - . . . . . . - . . . . . . . . . 11' 226
Transmi ssi on Housi ng Beari ngs
MainshaJVCountershaft Eearings
Re p f a c e me n t
. . . . . . . 1 4 2 2 1
Sub' si ral t Eeari ng Repl acement . . . . . . . . . . . 11' 224
Toroue Convert er Housi ng Beari ngs
Mai nshat t Eeari ng/ Oi l Se6l Repl acement
. . . l 4229
Count er shaf t Bea; i ng Repl acement . . . . . . . . . . 14- 230
I nput Test
-
' 97
-
98 Model s
I nput Test
' 99
-
00 Model s
Symptom to-Component Chart
Hydr aul i c Syst em . . . . . . . . . . . . . . .
Checki ng
Removal . . . ,
l l l ust r at ed I ndex
( 4WD)
I nt er l ock Syst em
I nt er l oc k Cont r ol Uni t l nput Tes t . - . . . . . - . . . . . . . - 14 144
*
Key I nt er l oc k Sol enoi d Tes t . - . . . . . - . . . . . . . . 14_146
*
Shi f t Lock Sol enoi d Test . . . . . . . . . . . . . . - . - . . . . . . . . . . . . 14 147
* Shi f t
Loc k Sol enoi dRepl ac ement . . . . . .
. . . . . . . 14 148
* par k pi n
Swi t ch Test
. . . . . . . . . 14 119
'
Park Pin Switch Replacement
-
' 97
-
98 Model s
. . . . . . . 14- 150
*
Park Pin Swirch/Over Drive
(O/Di
Switch
Repl ac emenl
' 99- 00Model s
. . . 14_151
over - Dr i ve
( O/ D)
Swi t ch { ' 99 00 [ 4odel s]
Tes t . . . . . . . . _. . . . . . . . . . . . . . . . . . . . .
. . . . . . . 14- 152
Hydr.ulic System
. . . . . . . . . . . . . . . _. . . . . . . . . . . . . . . t 4 142
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 143
Control Lever Assembly
R6pl acement . . . . . . , . ,
Rever se l dl er Gear
lllustrated lndex
. . . . . . . . . . 14- 230
14 231
11-231
1nst a1| at i on . . . . . . . . . . . . . . . . . .
Park Stop
I nspecl i on/ Adj ust menl
Transfer AssemblY
. . . . . . . 14. 232
Ro a d T e s t . . . . . . . . . . . . . - . . . . . . . . . . . . .
St al l Speed
Test . . . . . _. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 14- 159
Fl ui d Level
. . . . . . _. . . . . . . . . . . . . . . . . . . 14' 160
Di sessembl y . . . . . . . . .
. . . . . . . . . . . 14-235
Tr ansf er Dr i ve Gear Bear i ng
Repl acement
Tr ans{ er Dr i ven Gesf Shaf t Bear i ng
Repl acement
Tr ansf er Housi ng Rol l er Bear i ng
Repl acement
Tr ansf er Covr A Bear i ng Out er Race
Repl acement
Tr ansf er Housi ng Bear i ng Out er Race
Repl acement . . . . . . - . . , , , , , . . . . .
Reassembl v
Transmassaon
Beassembl y
. . . - . . . . . . . 14 250
Tor que Conver i er / Dr i ve Pl at e . . - . . . . . . . . . . . . . . . . 14_258
Transmi ssi on
l nst at l at i on . . . . . . . . . . . . . . . . . .
. . . . . . . 14' 259
Cool er Fl ushi ng
. . . . . . . . 11- 261
ATF Cooler Hoses
Connect i on. . . . . . . . . . . . . . . . . .
. . . . . . . 14-266
I
Shift Lever
Removal / l nst al l at i on
. . . 14' 261
Disassemblv/Reassemblv
-
'97
-
98 Models . . 14_264
Di sassembl i / Reassembl v
-' 99 -
00 Model s . 14-269
Over' Ori ve
(O/ D)
Swi t ch Wi re
Cl ear anceAdj ust ment .
- . . . . . . . . . . . 14' 270
De t e n t Sp r i n g Re p l s c e me n t . . - . . . . . . 1 4 ' 2 7 1
*Shi f t
Cabl e
A d i u s t me n t
. . . . . . . 1 4 ' 2 7 2
Repf acement . . . . . . . . . . . . . .
. 11' 273
14 157
11-237
11-237
14-238
$-234
11-239
14-240
Transmigrion
I ns pec l r on . . . . . , . . . . . . . . . . .
Tr ansf er Assembl y
Remov a1, . , , , . . . . . . . . . . . . . . ,
l ns t al l al i on . . . . . . . . . . . . . . . .
Tr ansmi ssi on
14 164
14- 165
14, 167
14- 169
End Cover / Tr ansmi ssi o
. 14' 174
Tr ans mi s s i on Hous i ng . . . . . . . . . . . . . . . . . 14- 176
Tor que Conver t er Housi ngl y' al ve Body. . - . . . - . 14 178
lllustrated lndex
(2WD)
End Cover / Tr ansmi ssi o
. . . . . . . 14 180
Tr ans mi s s i on Hous i ng . . . . . . . . . . . . . . . 14' 182
Tor que Conv ener Hous i ng/ r ' al v e Body . . . . . . - 14- 184
End Covef
Remov at . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 14' 186
Tr ansmi ssi on Housi ng
Remov al . . . . . . . . . . . . . . . . . . . . . .
. . 14_188
Torque Convener HousingA/alve BodY
Remov at . . . . . . . . . . . . . . . . - . . . . .
. - . . . . . 14- 190
www.emanualpro.com
Ref. No.
^
tl)
@
*rar
@
@
,-o
@
o
@
@
@
@
@
. - - @
@
@
@
@
@
@
@
@
@
Tool Number
Description
Oty
I
Pago Referonc
Mai nshaft Hol der
Cl utch Spri ng Compressor Bol t Assembl y
Housi ng Pul l er
Hol der Handl e
Oi l Seal Dri ver Aftachment
Attachment, 40 x 50 mm
Cl utch Spri ng Compressor Attachment
Ay' T Pressure Hose, 2210 mm
IVT Pressure Hose Adapter
SCS Service Connector
Compani on Fl ange Hol der
Backprobe Set
l VT Oi l Pressure Gauge Set w/Panel
A,/T Low Pressure Gauge w/Panel
Adj ustabl e Beari ng Pul l er, 25
-
40 mm
Anachment, 32 x 35 mm
Attachment, 37 x 40 mm
Attachment. 52 x 55 mm
Attachment. 62 x 68 mm
Attachment, 72 x 75 mm
Dri ver 40 mm l .D.
Attachment, 35 mm LD.
Dri ver
07GAB
-
PF50101 or
07GAB
-
PF50100
07GAE
-
PG40200 or
OTGAE
_
PG4O2OA
07HAC
-
PK40102
07JAB
-
001020A
07JAD
-
PH80101
07LAD
-
PW50601
07LAE
-
PX40100
OTMAJ
-
PY4O114
07MAJ
-
PY40120
07 PAZ
-
0010100
07RAB
-
TB4010A or
07RAB. TB40l OB
07sAz
-
001000A
07406
-
0020400
07406
-
0070300
07736
-
4010008 or
07736
-
A010004
07746
-
0010100
07746
-
0010200
07746
-
0010400
07746
-
0010500
07746
-
0010600
07746
-
0030100
07746
-
0030400
07749
-
0010000
07947
-
SD90200 Seal Dri ver Aftachment
1
1
1
1
,l
1
I
2
1
'l
1
I
1
1
1
1
1
1
I
1
14-181
,
254
14-216,219
14-189
't4-236,242,245,246
't
4-225, 241
14-237
14-216,2' t9
14- 161
14- 161
14-57
14-236,242,245,246
14-58, 157
14- 161
14- 161
'14-229,230
14-211, 2' t2
14-231
14-239
14-212, 227
,
228,229, 230, 238,
14-239, 249
14-221
,229
't
4-207
,
223,226, 237
,
241
14-237,241
1 +21 1, 2't2, 225, 227, 228, 229,
14-230, 237
,
238, 239, 24't, 249
' t4-225
l f the top arm i s too short, repl ace i t wi th 07SAC
- pOZ01OO1.
07HAE
-
PL50101 may be used to substi tute one of these tool s.
Must be used wi th commerci al l y avai l abl e 3/8"-16 sl i de hammer.
E----G
@@@@@
@
tvj
\r'
@ @
@)
14-2
www.emanualpro.com
Description
General Operati on
The Automati c transmi ssi on i s a 3-el ement torque converter and tri pl e-shaft el ectroni cal l y control l ed uni t whi ch provi des 4
speeds forward and 1 reverse speed The uni t i s posi ti oned i n l i ne wi th the engi ne'
There are two tvoes of automati c transmi ssi on on CR-V; the four-wheel dri ve
(4WD)
model
(' 97
-
00)' and the front-wheel
dri ve
(2WD)
model
(' 98
-
00).
Toroue Converter, Gars, and Clutches
The torque converter consi sts of a pump. turbi ne. and stator assembl y i n a si ngl e uni t. The torque converter i s connected to
the engi ne crankshatt. These
parts turn together as a uni t as the engi ne turns. Around the outsi de of the torque converter i s
a ri ng
gear whi ch meshes wi th the starter
pi ni on when the engi ne i s started. The torque converter assembl y serves as a fl y-
wheel whi l e transmi tti ng
power to the transmi ssi on mai nshaft.
The transmi ssi on has three
paral l el shafts: the mai nshaft. the countershaft, and the sub-shaft. The mai nshaft i s i n l i ne wi th
the engi ne crankshaft. The mai nshaft i ncl udes the 1st, 2nd. and 4th cl utches, and
gears l or 3rd,2nd,4th. reverse and 1st
(3rd gear i s i ntegral wi th the mai nshaft, whi l e reverse
gear i s i ntegral wi th the 4th gear). The countershaft i ncl udes the 3rd
cl utch and
gears for 3rd,2nd, 4th, reverse, 1st, and park. Reverse and 4th gears can be l ocked to the countershaft at i ts cen-
ter, provi di ng 4th gear or reverse, dependi ng on whi ch way the sel ector i s moved. The sub-shaft i ncl udes the l st-hol d
cl utch and gears for l st and 4th.
The gears on the mai nshaft are i n constant mesh wi th those on the countershaft and sub-shaft. When certai n combi nati ons
of gears are engaged by the ctutches,
power i s transmi tted from the mai nshaft to the countershaft to provi de
E, D!, tr, tr,
and
E
posi ti on (' 97 -
98 model s). and E. E, E,
and E
posi ti on
(' 99 -
00 model s)'
Electlonic Control
The el ectroni c controt system consi sts of the Powenrai n Control Modul e
(PCM),
sensors, a l i near sol enoi d, and four
sol enoi d val ves. Shi fti ng and l ock-up are el ectroni cal l y control l ed for comfortabl e dri vi ng under al l condi ti ons. The PCM i s
l ocated bel ow the dashboard, under the ki ck
panel on the
passenger' s si de.
Hydraulic Control
The val ve bodi es i ncl ude the mai n val ve body, the secondary val ve body, the regul ator val ve body, the servo body, and
the l ock up val ve body. They are bol ted to the torque converter housi ng. The mai n val ve body contai ns the manual val ve,
the 1-2 shi ft val ve, the 2nd ori fi ce control val ve. the CPB {Cl utch
Pressure Back-up) val ve, the modul ator val ve, the servo
control val ve. the rel i ef val ve, and ATF pump gears. The secondary val ve body contai ns the 2-3 shi ft val ve, the 3-4 shi ft
val ve, the 3,4 ori fi ce control val ve. the 4th exhaust val ve and the CPC
(Cl utch
Pressure Control ) val ve. The regul ator val ve
bodv contai ns the
pressure regul ator val ve, the torque converter check val ve, the cool er rel i ef val ve, and the l ock-up con-
trol val ve. The servo body contai ns the servo val ve whi ch i s i ntegrated wi th the reverse shi ft tork, and the accumul ators
The l ock-up val ve body contai ns the l ock-up shi ft val ve and the l ock-up ti mi ng val ve. The l i near sol enoi d and the shi ft con-
trol sol enoi d val ve Ay' B are bol ted to the outsi de of the transmi ssi on housi ng, and the l ock-up control sol enoi d val ve Ay' B i s
bol ted to the outsi de of the torque converter housi ng. Fl ui d trom the regul ator
passes through the manual val ve to the
vari ous control val ves. The cl utches recei ve fl ui d from thei r respecti ve feed pi pes or i nternal hydraul i c ci rcui t
ShiftControl Mechanism
i nput from vari ous sensors l ocated throughout the vehi cl e determi nes whi ch shi ft control sol enoi d val ve the PCM wi l l acti -
vate. Acti vati ng a shi ft control sol enoi d val ve changes modul ator
pressure, causi ng a shi ft val ve to move. Thi s
pressuri zes
a l i ne to one of the cl utches. engagi ng that cl utch and i ts correspondi ng
gear. The shi ft control sol enoi d val ves A and B are
control l ed by the PCM.
Lock-up Mechanism
tn E!
posi ti on (,97 -
98 modets) and i n
E
posi ti on (' 99
-
O0 model s), i n 3rd and 4th, and i n Del posi ti on i n 3rd
(' 97 -
98
model s) and i n
El
posi ti on wi th Over,Dri ve
(O/D)
i s OFF
(by pressi ng rhe O/D swi tchl i n 3rd
(' 99
-
00 model s), pressuri zed
fl ui d i s drai ned from the back of the torque converter through a fl ui d passage, causi ng the l ock-up
pi ston to be hel d
agai nst the torque converter cover, As thi s takes
pl ace, the mai nshaft rotates at the same speed as the engi ne crankshaft.
Together wi th hydraul i c control , the PcM opti mi zes the ti mi ng of the l ock-up mechani sm The l ock-up val ves control the
range of l ock-up accordi ng to l ock-up control sol enoi d val ves A and B, and the l i near sol enoi d. When l ock-up control
sol enoi d val ves A and B acti vate, the modul ator
pressure changes. The l ock-up control sol enoi d val ves A and B and the
l i near sol enoi d are control l ed by the PCM.
{cont' d)
14-3
www.emanualpro.com
Description
General Operati on
(cont' dl
Gsar Selection
'97
-
98 Models
The shi ft l ever has seven posi ti ons;
El
PARK,
ts
REVERSE,
N
NEUTRAL,
El l
1st through 4th ranges,
l pq 1st th.ough 3rd
ranges,
P
2nd gear,
and
[
1st gear
'99
-
00 Models
The shi tt l ever has si x posi ti ons;
El
PARK,
E REVERSE,
E
NEUTRAL.
E
,l st
through 4th ranges, and 1st through 3rd
(when
Over-Dri ve
(O/D)
i s OFF) ranges.
@
2nd gear,
and
E
1st gear.
Starti ng i s possi bl e
onl y i n
@
and
@
posi ti ons.
usi ng a sl i de-type. neutral -safety swi tch.
Automatic Transaxle
(A/T)
Gear Position Indicator
Thi s i ndi cator i n the i nstrument panel shows whi ch gear has been sel ected.
Transler Mochanism
{4WD}
The transfer mechani sm consi sts of the transfer shaft dri ve gear. the transfer shaft. the transfer dri ve gear,
the transfer dri v-
en gear
shaft, and the compani on fl ange, The transfer mechani sm assembl y i s on the rear si de ot the transmi ssi on. besi de
the di fferenti al . The transfer shaft dri ve gear on the fi nal dri ven gear dri ves the transfer shaft dri ven
qear.
power
i s transmi t-
ted to the rear di fferenti al vi a the transfer shaft and the Drooel l er shaft.
Clutches
The four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears.
When the hydraulic pressure is introduced into the clutch drum, the clutch piston
moves. This
presses
the friction discs and
steel plates
together, locking them so they don't slip. Power is then transmifted through the engaged clutch pack
to its hu$
mounted gear.
When hydraulic pressure
is bled from the clutch pack,
the piston releases the friction discs and steel plates,
and
they are free to slide past
each other. This allows the gearto
spin independently on its shaft, transmitting no power.
lst Clutch
The 1st cl utch engages/di sengages l st gear,
and i s l ocated at the end ofthe mai nshaft, j ust
behi nd the end cover.
The 1st cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed
pi pe
wi thi n the mai nshaft.
lst-hold Clutch
The 1st-hol d cl utch engages/di sengages 1st-hol d or
E
posi ti on,
and i s l ocated at the mi ddl e of the sub-shaft. The 1st-hol d
cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed
pi pe
wi thi n the sub-shaft.
2nd Clutch
The znd ci utch engages/di sengages 2nd gear, and i s l ocated at the mi ddl e of the mai nshaft. The 2nd cl utch i s
j oi ned
back-
to-back to the 4th cl utch. The 2nd cl utch i s suppl i ed hydraul i c pressure
through the mai nshaft by a ci rcui t connected to the
i nternal hydraul i c ci rcui t.
Position
Description
Reverse; reverse sel ect or engaged wi t h count ershaf t reverse gear and 4t h cl ut ch l ocked.
Al l cl ut ches rel eased.
General dri vi ng; st art s of f i n 1st , shi f t s aut omat i cal l y t o 2nd, 3rd, t hen 4t h, dependi ng on vehi cl e speed
and t hrof t l e posi t i on.
Downshi f t s t hrough 3rd, 2nd, and l st on decel erat i on t o st op.
The l ock-up mechani sm operat es; n 3rd and 4t h gear.
used for rapid cceleration at highway speeds and general
driving; stans off in 1st, shifts automatically to
2nd_t hen 3rd, dej endi ng on vehi cl e speed and t hrot t l e posi t i on. Downshi f t s t hrough l ower gears on decel -
erat i on t o st op. The l ock-up mechani sm comes i nt o operat i on i n 3rd gear.
Dri vi ng i n 2nd_gear; st ays i n 2nd gear, does not shi f t up and down. For engi ne braki ng or bet t er t rac_
t i on st art i ng of f on l oose or sl i ppery surf aces.
Dri vi ng i n 1st gear;
st ays i n 1st gear, does not shi f t up. For engi ne braki ng.
tll
PARK
t ! ! l l | EvEn>E
E NEUTRAL
El l
DRrvE
(' 97 -
sB)
E
DRrvE (' ss -
oo)
(1st
through 4th
)
E DRrvE {' 97
-
s8)
O
DRTVE with over-
Dri ve (O/D)
i s OFF
('99 -
00)
(1st
through 3rd)
E SECOND
E
FIRST
14-4
www.emanualpro.com
3rd Clutch
The 3rd cl utch engages/di sengages 3rd gear, and i s l ocated at the end of the countershaft, opposi te the end cover. The 3rd
cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed pi pe wi thi n the countershaft.
ilth
Clutch
The 4th cl utch engages/di sengages 4th gear, as wel l as reverse gear, and i s l ocated at the mi ddl e of the mai nshaft. The 4th
cl utch i s
j oi ned
back-to-back to the 2nd cl utch. The 4th cl utch i s suppl i ed hydraul i c
pressure by i ts ATF feed pi pe wi thi n the
mai nshaft.
One-way Clutch
The one-way clutch is positioned between the
park gear and the countershaft 1st gear, with the park gear splined to the counter-
shaft. The countershaft 1st gear provi des the outer race surface, and the park gear provi des the i nner race surface The
one,way cl utch l ocks up when power i s transmi tted from the mai nshaft l st gear to the countershaft 1st gear. The 1st
cl utch and gears remai n engaged i n the 1st, 2nd, 3rd, and 4th gear ranges i n the
l o],
pt,
E,
or
E
posi ti on The one-way
cl utch di sengages when the 2nd, 3rd, or 4th cl utches/gears are appl i ed i n the
l or, [d, E, or E
posi ti on'
Thi s i s because the i ncreased rotati onal speed of the gears on the countershaft over-ri de the l ocki ng
"speed
range" of the
one-wav cl utch. The one-wav cl utch free-wheel s when the l st cl utch i s engaged
l ST. HOLD
CLUTCH
1ST CLUTCH
MAINSHAFT
3RD CLUTCH
COUNTERSHAFT
TRANSFER
SHAFT DRIVE
GEAR
TRANSFER
ASSEMBLY
NOTE: The i l l ust r at i on shows t he 4WD
aut omat i c t r ansmi ssi on { sect i onal
vi ew)
t he 2WD t r ansmi ssi on does not have a
transfer assembl y and transfer shaft dri ve
gear on the di fferenti al assembl y.
2NO CLUTCH
4TH CLUTCH
INSIDE OF ONE.WAY
CLUTCH
ONE.WAY CLUTCH
OUTSIDE OF ONE.WAY
CLUTCH
The spr ags engage/
di sengage out si de
and i nsi de of t he
Spl i ned wi t h count er -
-
shaft
OVER.RIOING
LOCKING SPEED CONOITION LOCKING CONDITION
14-5,
www.emanualpro.com
Description
Power Flow
O: Operates, x: Doesn' t operate.
*
1: Al though the 1st cl utch engages, dri vi ng power
i s not transmi tted as the one_way cl utch sl i ps.
*2:
The one-way cl utch engages when accel erati ng. and sl i ps when decel eraung.
NOTE:
p!
and
Ipj
posi ti ons
are on the
' 97
-
' 98
model s;
El
posi ti on
i s on the
,99
-
OO model s.
*N
TOROUE
coN-
VERTER
1ST.
HOLD
CLUTCH
1ST GEAR
1ST
CLUTCH
2ND GEAR
2ND
CLUTCH
3RD GEAR
3RD
CLUTCH
4TH
REVERSE PARK
GEAR
GEAR CLUTCH
E o
o
E o
X o o
N o
Fi
or
E
1ST o o* ,
2ND o o* , o
3RD o o* 1
o
4TH o o* 1
o o
tr
or
E
Over-
Dri ve
(o/D)
i s OFF
' tsT
o o"
2ND o o* 1 o
3RD o o*r
o
tr o o* r o
tr o o o
14-6
www.emanualpro.com
E
Po3ition
Hydraul i c
pressure i s not appl i ed to the cl utches. Power i s not transmi tted to the countershaft.
The countershaft i s l ocked by the
park pawl i nterl ocki ng the
park gear,
E
Position
Engi ne power transmi tted from the torque converter dri ves the mai nshaft. but hydraul i c pressure i s not appl i ed to the
cl utches. Power i s not transmi tted to the countershaft. The countershaft 4th gear i s engaged wi th the reverse sel ector hub
and the countershaft by the reverse sel ector, when the shi ft l ever i s shi fted i n
E
posi ti on from E or
E
posi ti on. The
countershaft reverse gear i s engaged when shi fted from
E
posi ti on.
NOTE; The i l l ustrati on shows the 4WD automati c transmi ssi on; oower fl ow of the 2WD automati c transmi ssi on i s i denti -
cal to the 4WD exceDt for oarts related to the transfer assemblv.
PARK GEAR
SELECTOR
(cont' d)
COUNTERSHAFT
REVEBSE GEAR
14-7
www.emanualpro.com
Description
Power Flow
(cont'dl
E
Position
In
E
posi ti on, hydraul i c pressure i s appl i ed to the l st cl utch and the l st-hol d cl utch.
The power fl ow when accel erati ng i s as fol l ows:
1. Hydraul i c pressure i s appl i ed to the l st cl utch on the mai nshaft, and power i s transmi tted vi a the 1st cl utch to the mai n-
shaft 1st gear.
Hydraul i c pressure i s al so appl i ed to the l st-hol d cl utch on the sub-shaft. Power transmi tted to the mai nshaft 1st gear
i s conveyed vi a the countershaft 1st gear to the one-way cl utch, and vi a the sub-shaft 1st gear to the 1st-hol d cl utch.
The one-way cl utch i s used to dri ve the countershaft, and the 1st-hol d cl utch dri ves the countershaft vi a the 4th gears.
Power i s transmi tted to the fi nal dri ve gear, whi ch dri ves the fi nal dri ven gear, and the transfer shaft dri ve gear (4WD),
The transfer shaft dri ve gear dri ves the transfer shaft and the transfer dri ven gear shaft
(4WD).
NOTE; The i l l ustrati on shows the 4WD automati c transmi ssj on; power fl ow ot the 2WD automati c transmi ssi on i s i denti -
cal to the 4WD except for parts rel ated to the transfer assembl y.
SUB.SHAFT 4TH GEAR
SU8-SHAFT 1ST GEAR
4.
TOROUE
CONVERTER
lST.HOLD CLUTCH
SUB.SHAFT
1ST GEAR
lST CLUTCH
COUNTERSHAFT
ONE.WAY CLUTCH
FINAL DRIVE
GEAR
PARK GEAB
COUNTERSHAFT
4TH GEAR
FINAL DRIVEN GEAR
TRANSFER SHAFT ORIVE GEAR {4WD}
TRANSFER SHAFT {4WD}
14-8
TRANSFER DRIVEN GEAR SHAFT {4WD)
www.emanualpro.com
2.
L
E
Position
The power fl ow when decel erati ng i s as fol l ows:
Rol l i ng resi stance trom the road surface goes through the tront wheel s
(and
rear wheel s: 4WD) to the fi nal dri ve gear.
then to the sub-shaft l st gear vi a the 4th gear. and 1st-hol d cl utch whi ch i s appl i ed duri ng decel erati on.
The one-way cl utch i s free because the appl i cati on of torque i s reversed.
The counterforce conveyed to the countershaft 4th gear turns the sub-shaft 4th gear vi a the mai nshaft 4th gear. Si nce
hydraul i c
pressure i s al so appl i ed to the 1st cl utch. counterforce i s al so transmi tted to the mai nshaft. As a resul t,
engi ne braki ng can be obtai ned wi th' l st gear.
NOTE: The i l l ustrati on shows the 4WD automati c transmi ssi on;
power fl ow of the 2WD automati c transmi ssi on i s i denti -
cal to the 4WD except tor
parts
related to the transfer assembly.
J.
SUB.SHAFT 1ST GEAR
TOROUE CONVERTER
FINAL DRIVE GEAR
SUB.SHAFT
{TH GEAR
MAINSHAFT
lST GEAR
lST CLUTCH
MAINSHAFT
COUNTERSHAFT
REVERSE SELECTOR HUB
REVERSE SELECTOR
COUNTERSHAFT
IITH
GEAR
FINAL ORIVEN GEAR
TRANSFER SHAFT DRIVE GEAR {4WDI
TRANSFEB SHAFT {{WD)
{cont' d}
lST.HOLD CLUTCH
TRANSFER DRIVEN GEAR SHAFT {,lWDl
14-9 www.emanualpro.com
Description
Power Flow
lcont'd)
lst Gear
(8.
E or
E
positionl
In E, E, or
D
posi ti on, the opti mum gear i s sel ected from 1st, 2nd, 3rd, and 4th gears, accordi ng to condi ti ons such as
the balance between throttle opening
(engine
load) and vehicle speed.
1. Hydraul i c pressure i s appl i ed to the 1st cl utch, whi ch rotates together wi th the mai nshaft, and the mai nshaft 1st gear
rotates.
2. Power i s transmi tted to the countershaft 1st gear. whi ch dri ves the countershaft vi a the one-way cl utch.
3. Power i s transm i tted to the fi nal dri ve gear.whi ch
dri ves the fi nal dri ven gear and the transfer shaft dri ve gea r
(4WD).
4. The transfer shaft dri ve gear dri ves the transfer shaft and the transfer dri ven gear
shaft
(4WD).
NOTE:
o In
@, @, @,
or
E
posi ti on. hydraul i c pressure i s not appl i ed to the 1st-hol d cl utch.
. The i l l ustrati on shows the 4WD automati c transmi ssi on; power fl ow of the 2WD automati c transmi ssi on i s i denti cal
to the 4WD except for parts related to the transfer assembly.
CONVERTER
MAIiISHAFT
1ST
CLUTCH
MAINSHAFT
COUNTERSHAFT
FINAL OBIVE GEAR
ONE.WAY CLUTCH
PARK GEAR
FINAL DRIVEN GEAR
14-10
TRANSFER SHAFT DRIVE GEAR {4WD}
www.emanualpro.com
2nd cesr
(8,
E. E,
or
E
positionl
1. Hydraul i c
pressure i s appl i ed to the 2nd cl utch, whi ch rotates together wi th the mai nshaft, and the mai nshaft 2nd gear
rotales.
2. Power is transmitted to the countershaft 2nd gear, which drives the countershaft
3.
power
i s transmi tted to the fi nal dri ve
gear, whi ch dri vesthefi nal d ri ven gear and the transfer shaft dri ve gea r
(4WD)
4. The transfer shaft dri ve gear dri ves the transfer shaft and the transfer dri ven
gear shaft
(4WD).
NOTE:
. Hvdraul i c
pressure i s al so appl i ed to the 1st cl utch, but si nce the rotati on speed of 2nd gear exceeds that of l st gear.
power from 1st gear i s cut off at the one-way cl utch.
. The i l l ustrati on shows the 4WD automati c transmi ssi on;
power fl ow of the 2WD automati c transmi ssi on i s i denti cal
to the 4WD except for
parts
related to the transfer assembly.
CLUICH
TOROUE
COUNTERSHAFT
FINAL ORIVE GEAR
2NO GEAR
FINAL DRIVEN GEAF
TRANSFER SHAFT DBIVE GEAR {4WD}
TRANSFER SHAFT {4WDI
(cont' d)
TMNSFER DRIVEN GEAR SHAFT
(4WD)
14- 11
www.emanualpro.com
Description
Power Flow
(cont'd)
3rd Gear {8. @,
or
@
position)
1. Hydraul i c
pressure i s appl i ed to the 3rd cl utch. Power from the mai nshaft 3rd gear i s transmi tted to the countershaft
3rd gear.
2. Power i s transm i fted to the fi nal d ri ve gear, wh i ch d ri ves the f i nal dri ven gear and the transfer shaft dri ve gear (4WD).
3, The transfer shaft dri ve gear dri ves the transter shaft and the transfer dri ven gear shaft
(4WD).
NOTE:
. Hydraul i c pressure i s al so appl i ed to the 1st cl utch, but si nce the rotati on speed of 3rd gear exceeds that of 1st gear,
power from l st gear i s cut off at the one-way cl utch.
. The i l l ustrati on shows the 4WD automati c transmi ssi on; Dower fl ow of the 2WD automati c transmi ssi on i s i denti cal
to the 4WD except for parts rel ated to the transfer assembl y.
CONVERTEF
MAINSHAFT 3RD GEAR
COUNTERSHAFT
COUNTERSHAFT
3RO GEAR
3RD CLUTCH
DRIVEN GEAR
SHAFT DRIVE GEAR
(4WO)
TRANSFER SHAFT
(,lwDl
TRANSFER ORIVEN GEAN SHAFT
(4WD)
14-12
www.emanualpro.com
4th Goar
(E
or
D
positionl
1. Hydraul i c pressure i s appl i ed to the 4th cl utch, whi ch rotates together wi th the mai nshaft, and the mai nshaft 4th gear
rotates,
2. Power i s transmi tted to the countershaft 4th gear, whi ch dri ves the countershaft.
3. Power i s transm i fted to the f i nal d ri ve gear, whi ch dri ves the fi na I dri ven gear and the transfer shaft dri ve gear (4WD).
4. The transfer shaft dri ve gear dri ves the transfer shaft and the transfer dri ven gear shaft {4WD).
NOTE:
. Hydraul i c pressure i s al so appl i ed to the 1st cl utch, but si nce the rotati on speed of 4th gear exceeds that of 1st gear,
power from 1st gear i s cut off at the one-way cl utch,
. The i l l ustrati on shows the 4WO automati c transmi ssi on; power fl ow of the 2WD automati c transmi ssi on i s i denti cal
to the 4WD except for parts related to the transfer assembly.
ilTH
GEAR
TOROUE CONVERTER
.TH CLUTCH
COU'{TERSHAFT
REVERSE SELECTOR HUB
REVERSE SELECTOR
FINAL DRIVEN GEAR
TRANSFEB SHAFT DRIVE GEAB I'WD)
TNANSFER SHAFT I4WDI
{cont' d)
14-13
TMNSFER DRIVEN GEAR SHAFT
(4WDI
www.emanualpro.com
Description
Power Flow
(cont'dl
E
position
1. Hydraul i c pressure i s swi tched by the manual val ve to the servo val ve, whi ch movss the reverse shi ft fork to the
reverse posi ti on, The reverse shi ft fork engages wi th the reverse sel ector, the reverse sel ector hub, and the counter-
shaft reverse gear.
2. Hydraul i c pressure i s al so appl i ed to the 4th cl utch. Power i s transmi tted from the mai nshaft reverse gear vi a the
reverse idler gear to the countershaft reverse gear.
3. Rotati onal di recti on ofthe countershaft reverse gear i schanged vi athe reverse i dl ergear.
4. Power i s transmi tted to the fi nal dri vegear,whi ch dri vesthefi nal d ri ven gear a nd the transfer shaft dri ve
gesr (4WD).
5. The transfer shaft dri ve gear dri ves the transfer shaft and the transfer dri ven gear shaft
(4WD).
NOTE: The illustration shows the 4WD automatic.transmission; power flow of the 2wD automatic transmission is identical
to the 4WD except for parts related to the transfer assembly.
TOROUE CONVERTER MAINSHAFT REVERSE
COUNTERSHAFT
FINAL ORIVE
REVERSE IDLER
GEAR
COUNTERSHAFT
REVERSE GEAR
REVERSE SEITCTOR
HUB
REVERSE SELECTOR
REVEBSC SHIFT
FORK
FINAL OBIVEN GEAR
TRANSFER SHAFT DRIVE GEAR
{4WD)
TRANSFER SHAFT {4WD)
SERVO VAI-VE
14-14
TRANSFER DRIVEN GEAR SHAFT I4WD}
www.emanualpro.com
Electronic Control System
The el ectroni c control svstem consi sts of a Powertrai n Control Modul e
(PCM),
sensors, a l i near sol enoi d, and four sol enoi d
val ves. Shi fti ng and l ock-up are el ectroni cal l y control l ed for comfortabl e dri vi ng under al l condi ti ons. The PCM i s l ocated
bel ow the dashboard, under the ki ck panel on the passenger' s si de.
'97
-
98 Modls
PGM. FI
Control Sy3t6m
Throttl Poshion Sensor
Si gnal
Vehicle Sp.ed Sensor
Si gnal
Engino Coolant Tampereture
Service Check connector
Sonsor Signrl
A/T Control Sy3tem
INTERLOCK
Shift Cont.ol
Shift Control
Solenoid valve A
CONTROL UNIT
r
R Shift Control
Solenoid Valve B
N
Linear Solenoid
Dr
Lock-up Control
Ds
Lock-up Control
Solenoid Valve A
2
Lock-up Conirol
Sol6noid valvo B
1
M.inshaft Spoed Sensor
Signel
-D!
Indicator Light
Countrahaft Speed
sensor Si gnel
Selt-Oiagnosb signel
I
Sell-Diagnosis
Function
l -
{cont' d)
14-15
www.emanualpro.com
Description
PCM
PGM.FI
Control System
Throttle Position Sensor
Si gnel
Vehicle Speed Sensor
Si gnal
Engin Coolsnt Tomperature
Sen30r Signal
Service Chck Connectol
A/T Control Svstem
INTERLOCK
Shift Control
Shift Conlrol
Solenoid Valve A
CONTROL UNIT
r
R Shift Control
Solenoid Valve B
N
Linear Solenoid
D
Lock-up Control
2
Lock-up Control
Solenoid valve A
1
Lock-up Control
Solenoid Valve B
Over-Drive
Switch Signal
Mainshaft Speed Sensor
Signal
E
Indicator Light
Countershaft Speed
Sensor Signtl
Selt-Oiagnosis Signd
Self-Diagnosis
Func{ion
O/D OFF
Indicetor Light
Electronic Gontrol System
(cont'd)
'99
-
00 Models
14-16
www.emanualpro.com
Shift Control
The PCM determi nes whi ch gear shoul d be sel ected by vari ous si gnal s sent from sensors, and actuates the shi ft control
sol enoi d val ves A and B to control shi fti ng. Al so. a Grade Logi c Control System has been adopted to control shi fti ng i n E
anO E
(' gZ - gg),
and
E
(' 99 -
00) posi ti on whi l e the vehi cl e i s ascendi ng or descendi ng a sl ope, or reduci ng speeo.
Position Gear
Shift Control Solenoid
Valve A
Shift Control Solonoid
Valve B
E, E, Or
E
'I
st OFF ON
2nd ON ON
3rd ON OFF
E or E
4th OFF OFF
a 2nd ON ON
tr 1st OFF ON
E- Reverse ON OFF
*See
page
14-37 for reverse i nhi bi tor control descri pti on.
Lock-up Control
From sensor i nput si gnal s, the PCM determi nes whether to turn the l ock-up ON or OFF, and acti vates l ock-up control
sol enoi d val ve A and/or B accordi ngl y. Lock-up does not occur unti l the engi ne i s warm. The combi nati on of dri vi ng si g-
nal s to l ock-up control sol enoi d val ves A and B and the l i near sol enoi d
pressure
i s shown i n the tabl e bel ow.
Lock-up Conditions
Lock-up Control
Solonoid Valve A
Lock-up Control
Solenoid Valve B
Linear Solenoid
Pressuro
LOCK-Up \ Jrr OFF OFF Hi gh
Lock-up, Hal f ON
Duty operati on
OFF
-
ON
Lock-up, Ful l ON ON Hi sh
Lock-up
duri ng decel erati on
ON
Duty operati on
OFF
-
ON
Low
(cont' d)
14-17
www.emanualpro.com
Description
Electronic Control System
(cont'dl
Grade Logic Control System
How it works:
The PCM compares actual dri vi ng condi ti ons wi th memori zed dri vi ng condi ti ons, based on the i nput from the vehi cl e speed
sensor, the throttl e posi ti on sensor, the barometri c pressure sensor
(' 98
model ). the engi ne cool ant temperature sensor, the
brake swi tch si gnal , and the shi ft l ever posi ti on si gnal , to control shi fti ng whi l e the vehi cl e i s ascendi ng or descendi ng a
sl ope, or reduci ng speed.
SIGNALS DETECTED
Driving Rcsisl.nce
Judgemont ot Controlling Aroa
.
Normal Modo {Flrt ro.d mode}
.
Ascending Mode
.
Deacending Mode
.
Deceleration Mode
14-14
www.emanualpro.com
Ascending Control {37 Modol}
When the PCM determi nes that the vehi cl e i s cl i mbi ng a hi l l i n
E]
and
E
posi ti ons,
the system extends the engagement
area of 2nd gar and 3rd gear to prevent the transmi ssi on from frequentl y shi fti ng between 2nd and 3rd gears, and
between 3rd and 4th gears, so the vehicle can run smooth and have more power when needed.
NOTE:
. Shift schedules stored in ths PCM between 2nd and 3rd gears, and between 3rd and 4th gears.
enable the PCM's fuzzy
l ogi c to automati cal l y sel ect the most sui tabl e gear accordi ng to the magni tude of 8
gradi ent.
t Fuzzy l ogi c i s a form of arti fi ci al i ntsl l i gence that l ets computers respond to changi ng condi ti ons much l i ke a human
mi nd woul d.
3RD
- tlTH
ASCENoING MODE: UFhift Sch.dulc
- .
FLAT ROAD MODE
-----------.
: GRADUAL ASCENDI NG MODE
- - - - -
: STEEPASCENDING MODE
o 5 l )
F
FN1NS
7,.,.7a
: 2ND-3RD SHIFTING CHARACTERISTICS
CONTROL AREA
| 3RD-aTH SHIFTING CHARACTER|SnCS
CONTROL AREA
62 mph
1100
km/ h)
Vehicle .o..d
Asconding Conirol
('98 -
00 Mod.ls)
When the PCM determi nes that the vohi cl e i s cl i mbi ng a hi l l i n
E]
and
E
posi ti ons (' 98
model ), and i n
E]
posi ti on (' 99 -
00 models), the system extends the engagement srea of 2nd
gear
and 3rd gear to prevent the transmission from frequent-
ly shifting between 2nd and 3rd
gears,
and between 3rd and 4th
gears,
so the vehicle can run smooth and have more
power when needed.
NOTE: Shift schedulss stored in the PCM between 2nd and 3rd gears, and between 3rd and 4th gears, enable to selsct the
most sui tabl e gear accordi ng to th6 magni tude of a gradi nt.
ASCENDING MODE: Up.hift Sch.dul.
NN
: 2ND-3RD SXImNG CHARACTERISTICS
-
GoNTRoLAREA
VVVVVZ:IRD-ITHSHIFnNGCHARACTERISTICS
-
cot{TRoL AREA
8 5 0
o
6:l mph
11fl) km/hl
(cont'd)
2ND
-
3RD
2ND + 3RD 3RD + 4TH
Vahicl. sDctd
14-19
www.emanualpro.com
Description
Electronic Control System
(cont'd)
Descending Control
When the PCM determi nes that the vehi cl e i s goi ng down a hi l l i n E and
@
posi ti ons (' 97 -
98 model s). and i n
@
posi -
ti on {' 99
-
00 model s), the shi tt-up speed from 3rd to 4th gear and from 2nd to 3rd
(when
the throttl e i s cl osed) becomes
faster than the set speed for fl at road dri vi ng to wi den the 3rd gear and 2nd gear
dri vi ng areas. Thi s, i n combi nati on wi th
engi ne braki ng from the decel erati on l ock-up, achi eves smooth dri vi ng when the vehi cl e i s descendi ng. There are three
descendi ng modes wi th di fferent 3rd gear dri vi ng areas and 2nd gear dri vi ng areas accordi ng to the magni tude of a gradi -
ent stored i n the PCM. When the vehi cl e i s i n 4th gear, and you are decel erati ng when you are appl yi ng the brakes on a
steep hi l l , the transmi ssi on wi l l downshi ft to 3rd gear, When you accel erate, the transmi ssi on wi l l then return to hi gher
gear.
2ND -
3RD
3RD
- 4TH
o 5 0
F
DESCENDING MODE: Downshift Schodule
-
: FLAT ROAD MODE
----' -----'
I GRADUAL DESCENDI NG MODE
- - - - -
: MEDIUM OESCNOING MODE
. . . . .
: STEEP DESCENDI NG MODE
62 mph Vehicle sped
1100 km/hl
Deceleration Control
When the vehicle goes
around a corner, and needs to decelerate first and then accelerate, the PCM sets the data for deceleration
control to reduce the number of times the transmission shifts. When the vehicle is decelerating from speeds above 27 mph
(4i|
km,ih), the PCM shifts the transmission from 4th to 2nd earlier than normal to cope with upcoming acceleration,
14-20
www.emanualpro.com
Ci rcui t Di agram and Termi nal Locati onsr9T Model
IGNITIONSWITCH
LOC( UPCONTROL
LOCK UPCONTROL
SOLEITOIDVALVE B
sf Frc0|lltF0L
SOLENOIDVALVE A
sHrFr c0r{TnoL
SOLEI{OID VALVE B
UNEASSOLINOID
14-21
www.emanualpro.com
Description
Electronic Control System
(cont'd)
Ci rcui t Di agram and Termi nal Locati onsrgS Model
GNTI ONSWI TCN
LOCK-UPCONIFOL
SOLEIIO D VALVE A
LOCK-UPCONTSOL
SOLEI.IO 0 vALvE B
SBIFICONTROL
SOLEI DVALVE A
SH FTCONTFOL
SOLEiDID VALVE 8
LINAA SOLiDID
GNIION SWTCH
tGr
14-22
www.emanualpro.com
Circuil Diagram and Terminal Locations-'gg
-
00 Models
GN' ION SWITCN
LOC( UP C,ONTROL
SOLEID D VALVE A
LOCK.UPCON' IFO!
SOLENOIOVALVE B
SNIFT CONTAOT
SOLNOID VALVE A
SH]FT CONTROL
solEtiroro vArvE B
L NEAF SOLEI{OIO
pG2
IGPI
IGP2
vcc2
rGNloN SWrlCH
GI
PCM Connclor Tehrial Loaabm
14-23
www.emanualpro.com
Description
Hydraulic Control
The hydraul i c control system i s control l ed by the ATF pump, val ves, accumul ators, and el ectroni cal l y control l ed sol enoi ds.
The ATF pump i s dri ven by spl i nes on the end of the torque converter whi ch i s aftached to the engi ne. Fl ui d from the ATF
pump fl ows through the regul ator val ve to mai ntai n speci fi ed pressure, through the mai n val ve body, to the manual val ve,
di recti ng pressure to each cl utch. The val ve body i ncl udes the mai n val ve body, the regul ator val ve body, the l ock-up
val ve body, the secondary val ve body, the servo body, the l i near sol enoi d, the shi ft control sol enoi d val ve Ay' B assembl y,
and t he l ock- up cont r ol sol enoi d val ve A/ B assembl y. The shi f t cont r ol sol enoi d val ve A, / B assembl y and t he l i near
sol enoi d are bol ted on the outsi de of the transmi ssi on housi ng. The l ock-up control sol enoi d val ve A,/B assembl y i s bol ted
on the outsi de of the torque converter housi ng.
LINEAR
SHIFT CONTROL
SOLENOID VALVE A/B
ASSEMBLY
SECONDARY VALVE
BODY
REGULATOR
VALVE BOOY
VALVE BODY
SOLENOID VALVE A/B
ASSEMELY
N
ATF PUMP GEARS
14-24
www.emanualpro.com
Main Valve Sody
The mai n val ve body houses the manual val ve, the 1-2 shi ft val ve. the 2nd ori fi ce control val ve. the CPB val ve, the modu-
l ator val ve. the servo control val ve. and the rel i ef val ve. The pri mary functi ons of the mai n val ve body are to swi tch fl ui d
pressure on and off, and to control the hydraul i c
pressure goi ng to the hydraul i c control system.
CP8 VALVE 2ND ORIFICE CONTROL
VALVE
MODULATOR VALVE
RELIEF VALVE
1-2 SHIFT VALVE
MANUAL VALVE
MAIN VALVE
BOOY
SERVO CONTROI-
VALVE
Secondary valve Body
The secondary val ve body i s l ocated on the mai n val ve body, The secondary val ve body houses the 2-3 shi ft val ve, the 3-4
shi ft val ve, the 3-4 ori fi ce control val ve, the 4th exhaust val ve, and the CPC val ve'
3.' SHIFT VALVE
.TH EXHAUST VALVE
CPC VAL
(cont'd)
14-25
2.3 SHIFT VALVE
3na ORIFICE CONTROL
VALVE
VALVE
www.emanualpro.com
Description
Hydraulic Control
(cont'd)
Regulator Valve Body
The regul ator val ve body i s l ocated on the mai n val ve body. The regul ator val ve body consi sts of the regul ator vatve, the
torque converter check val ve. the cool er rel i ef val ve, and the l ock-up control val ve.
Lock-up Valve Body
The l ock-up val ve body, wi th l ock-up shi ft val ve and l ock-up ti mi ng val ve, i s l ocated on the regul ator val ve body.
LOCK. UP SHI FT
NMING VALVE
COOLER RELIEF VALVE
VALVE
14-26
www.emanualpro.com
Regulator Valve
The regul ator val ve mai ntai ns constant hydraul i c
pressure from the ATF
pump to the hydraul l c control system, whi l e al so
furni shi ng fl ui d to the l ubri cati ng system and torque converter. Fl ui d from the ATF pump fl ows through B and B' . Fl ui d
enteri ng from B fl ows through the val ve ori fi ce to the A cavi ty. Thi s pressure of the A cavi ty pushes the regul ator val ve to
the ri ght si de. and thi s movement of the regul ator val ve uncovers the fl ui d port to the torque converter and the rel i ef
val ve. The fl ui d fl ows out to the torque converter and the rel i ef val ve, and the regul ator val ve moves to the l eft si de.
Accordi ng to the l evel of the hydraul i c
pressure through B, the posi ti on of the regul ator val ve changes and the amount of
fl ui d from B,through the torque converter al so changes. Thi s operati on i s conti nued, mai ntai ni ng the l i ne pressure.
NOTE; When used,
"| eft"
or
"ri ght"
i ndi cates di recti on on the i l l ustrati on bel ow.
ENGINE NOT RUNNING
STATOR SHAFT ABM
Stator Reaction Hydraulic Pressurs Control
Increases i n hydraul i c pressure accordi ng to torque are performed by the regul ator val ve usi ng stator torque reacti on. The
stator shaft i s spl i ned to the stator i n the torque converter, and i ts arm end contacts the regul ator spri ng cap When the
vehi cl e i s accel erati ng or cl i mbi ng
(Torque
Converter Range), stator torque reacti on acts on the stator shaft, and the stator
arm
pushes the regul ator spri ng cap i n the di recti on of the arrow i n proporti on to the reacti on. The stator reacti on spri ng
compresses, and the regul ator val ve moves to i ncrease the l i ne pressure. Li ne
pressure reaches i ts maxi mum when the
stator torque reacti on reaches i ts maxi mum.
TOROUE CONVERTER
REGULATON VALVE
STATOR REACTION
TOR SPRING CAP
(cont' d)
ENGINE RUNNING
To TOROUE CONVERTER Lubtication
STATON
STA SHAFT
ATOF SHAFT ARM
14-27 www.emanualpro.com
Description
Hydraul i c Control
(cont' d)
Servo Body
The servo body i s l ocated on the secondary val ve body. The servo body contai ns the servo val ve
(whi ch
i s i ntegrated wi th
the reverse shi ft fork), and the accumul ators.
2ND ACCUMULATOR
3RD SUB
ACCUMULATOR
SERVO BODY
1ST ACCUMULATOR
SERVO VALVE/SHIFT
FORK SHAFT
14-28
www.emanualpro.com
Hydraul i c Fl ow
General Chart of Hydraulic Pressure
ATF
pump -
Regul ator Val ve
-a
Li nePressure
5
Modul ator Pressure
-
Li near Sol enoi d
|
-
Cl utch Pressure
L- Toroue Converter Pressure
L
LUbri cati on Pressure
Distribution ol Hydraulic Pressure
.
Regul ator Val ve
-"- Torque Converter Pressure
L- Lubri cati on Pressure
I
To regul ate Li ne Pressure
.
Manual Val ve To sel ect Li ne Pressure
-
Cl utch Pressure
.
Modul ator Val ve Modul ator Pressure
-- ----
Shi ft Control Sol enoi d Val ves
f-
Lock-up Control Sol enoi d val ves
L Li near Sol enoi d
.
1-2 Shi ft Val ve
---
.
2-3 Shi ft Val ve
--
t-
Cl utch Pressure
.
3-4 Shi ft Val ve
I
PORT NO, DESCRIPTION OF PRESSURE PORT NO, DESCRIPTION OF PRESSURE
1 LINE
1 5 l ST-HOLD CLUTCH
LIN E
1ST-HOLD CLUTCH
' t'
LINE
17 1ST-HOLD CLUTCH
2 LINE
18 1ST-HOLD CLUTCH
3 LINE
20 2ND CLUTCH
3' LINE
20A 2ND ACCUMULATOR
3" LINE
30 3RD CLUTCH
LINE
40 4TH CLUTCH
LINE
41 4TH CLUTCH
LINE
LINEAR SOLENOID
5
90 TOROUE CONVERTER
MODULATE
9 1 TOROUE CONVERTER
6A
MODULATE
(SHIFT
CONTROL SOLENOIO
VALVE A)
92 TOROUE CONVERTER
MODULATE
(SHIFT
CONTROL SOLENOID
VALVE B)
93 ATF COOLER
IVODULATE
(LOCK.UP CONTROL SOLENOID
VALVE A)
94 TOROUE CONVERTER
MODUTATE
(LOCK-UP
CONTROL SOLENOID
VALVE B)
95 LUBRICATION
6D'
MODULATE
(LOCK-UP CONTROL SOLENOID
VALVE B)
TOROUE CONVERTER
7 LIN E
97 TOROUE CONVERTER
8 LINE/CPC
99 SUCTION
I LINE
x DRAIN
10 1ST CLUTCH
HIX HI GH POSI TI ON DRAI N
{cont' d)
14-29 www.emanualpro.com
Description
Hydraulic Flow
(cont'dl
lll
Position
As the engi ne turns, the ATF pump
starts to operate. Automati c transmi ssi on fl ui d
(ATF)
i s drawn from
(99)
and di s-
charged i nto
(1).
Then, ATF fl owi ng from the ATF pump
becomes l i ne pressure (' l ).
Li ne pressure (1)
j s
regul ated by the
regul ator val ve. Torque converter i nl et pressure
{92) enters
(94)
of the torque conveTter through the l ock-up shi ft val ve and
di scharges i nto
(90)
The torque converter check val ve prevents
torque converter pressure from ri si ng. Under thi s condi -
ti on, hydraul i c pressure
i s not appl i ed to the cl utches.
NOTE;
. When used.
"| eft"
o.
"ri ght"
i ndi cates di recti on on the hvdraul i c ci rcutt.
. The hydraul i c ci rcui t shows the
' 97
-
98 model s
{7
posi ti ons};
the
' 99
-
00 model s
(6 posi ti ons)
i s si mi l ar.
'lF'.j.l
14- 30 www.emanualpro.com
B
Position
Li ne
pressure
{1) fl ows to the manual val ve and the modul ator val ve, Li ne pressure
(1)
changes to l i ne
pressure
(4)
and
1st-hol d cl utch
pressure at the manual val ve, and changes to modul ator
pressure at the modul ator val ve Modul ator
pres-
sure {6)
fl ows to the l eft ends of the 1-2 shi ft val ve and 3-4 shi ft val ve because shi ft control sol enoi d val ve A i s turned oFF
by the PcM. The 1-2 shi ft val ve and the 3-4 shi ft val ve are moved to the ri ght si de. Li ne pressure
(4)
becomes 1st cl utch
pressure
(10)
at the 1-2 shi ft val ve. 1st cl utch
pressure
(10)
i s appl i ed to the 1st cl utch, and the 1st cl utch i s engaged l st-
hol d cl utch
pressure
(18)
fl ows to the l st-hol ; cl utch vi a the 3-4 shi ft val ve and the 1-2 shi ft val ve Power i s transmi tted
onl y duri ng decel erati on through the 1st-hol d cl utch.
NOTE:
. When used,
"l eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t'
. The hvdraul i c ci rcui t shows the' 97
-
98 model s
(7 posi ti ons); the
' 99
-
O0 model s
(6 posi ti ons) i s si mi l ar'
(cont' d)
14-31 www.emanualpro.com
Description
Hydraul i c Fl ow
(cont' dl
l?J
Position
Li ne pressure
{1) fl ows to the manual val ve and the modul ator val ve. Li ne pressure (1}
changes to l i ne pressure (4)
at the
manual val ve, and changes to modul ator pressure at the modul ator val ve. But modul ator pressure
{6} does not fl ow to
each shi ft val ve because shi ft control sol enoi d val ves A and B are turned ON by the PCM. Li ne pressure (4) passes
through
the CPB val ve and the CPC val ve, and changes to l i ne pressure (5),
then fl ows to the
' l -2
shi ft val ve. Li ne pressure (5)
from
the 1-2 shi ft val ve changes to 2nd cl utch pressure (20)
at the 2-3 shi ft val ve. The 2nd cl utch pressure (20)
i s appl i ed to the
2nd cl utch, and the 2nd cl utch i s engaged, Li ne pressure (4) passes
through the 1-2 shi ft val ve and the ori fi ce, and changes
to l st cl utch pressure. The 1st cl utch pressure
{10) al so fl ows to the 1st cl utch. However, no power i s transmi tted because
of the one-way cl utch.
NOTE:
. When used,
"l eft"
or
"ri ght"
i ndi cates di recti on on the hvdraul i c ci rcui t.
. The hydraul i c ci rcui t shows the
' 97
-
98 model s (7 posi ti ons);
the
' 99
-
OO model s (6 posi ti ons)
i ssi mi l ar.
14-32 www.emanualpro.com
E] or E Position
('97 -
98 Models), and D
Position
('99 -
00 Modelsl
1. l st Gear
Fl ui d fl ow through the torque converter ci rcui t i s the same as i n
E]
posi ti on. Li ne
pressure fl ows to the manual val ve
and the modul ator val ve. Li ne pressure changes to modul ator
pressure
(6)
at the modul ator val ve and to l i ne pressure
{4) at the manual val ve. Modul ator
pressure (6) fl ows to the l eft end of the 1-2 shi ft val ve and the 3-4 shi ft val ve
because shi ft control sol enoi d val ve A i s turned oFF and B i s turned oN by the PcM. The 1-2 shi ft val ve i s moved to
the ri ght si de. Li ne
pressure
{4) changes to
' l st
cl utch
pressure
(10}
at the 1-2 shi ft val ve and the ori fi ce The 1st cl utch
pressure (10)
i s appl i ed to the 1st cl utch and the 1st accumul ator; the vehi cl e wi l l move as the engi ne
power i s trans-
mi tted.
NOTE:
. When used,
"l eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t.
. The hvd rau l i c ci rcui t shows th e
' 97
-
98 model s
(7 posi ti ons); the
' 99
-
00 model s {6
posi ti ons) i ssi mi l ar.
(cont' dl
14- 33
www.emanualpro.com
Description
Hydraulic Flow
(cont'dl
2nd Gsar
As the speed of the vehi cl e reaches the prescri bed
val ue. shi ft control sol enoi d val ve A i s turned ON by the
pCM.
Modul ator pressure (6A)
i n the l eft end of the 1-2 shi ft val ve i s rel eased by turni ng shi ft control sol enoi d val ve A ON.
The 1-2 shi ft val ve i s moved to the l eft si de and uncovers the port
to al l ow l i ne pressure (5)
to the 2-3 shi ft vatve. Li ne
pressure (5)
changes to 2nd cl utch pressure (20)
at the 2-3 shi ft val ve, The 2nd cl utch pressure
{20) i s appl i d to the
2nd cl utch. and the 2nd cl utch i s engaged.
Fl ui d fl ows by way of:
-
Li ne Pressure (4) +
CPB Val ve
-
Li ne Pressure (5) *
1-2 Shi ft Val ve
-
Li ne
pressure
(S) *
2-3 Shi ft Val ve
-
2nd Cl utch Pressure (20) -
2nd Cl utch
The hydraul i c pressure
al so fl ows to the l st cl utch. However, no power
i s transmi tted because of the one-wav ctutch.
NOTE:
. When used,
"| eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcurr_
' The hydraul i c ci rcui t shows the' 97
-
98 model s
(7 posi ti ons);
the
' 99
-
00 model s
(6 posi ti ons)
i s si mi l ar,
14-34 www.emanualpro.com
3. 3rd Gear
As the speed of the vehi cl e reaches the
prescri bed val ue. shi ft control sol enoi d val ve B i s turned OFF by the PCM.
Shi ft control sol enoi d val ve A remai ns ON. Modul ator
pressure
(6)
fl ows to the ri ght end of the 1-2 shi ft val ve and the
l eft end of the 2-3 shi ft val ve. The 2-3 shi ft val ve i s moved to the ri ght si de by modul ator
pressure
(68)
The 2-3 shi ft
val ve covers the port to stop l i ne prsssure
(5)
to the 2nd cl utch. and uncovers the 3-4 shi ft val ve as the 2-3 shi ft val ve
i s moved to the ri ght si de, Li ne
pressure (5)
becomes 3rd cl utch
pressure
(30)
at the 3-4 shi ft val ve. The 3rd cl utch
pressure (30)
i s appl i ed to the 3rd cl utch, and the 3rd cl utch i s engaged.
Fl ui d fl ows by way of:
-
Li ne pressure
(4) -
CPB Val ve
-
Li ne Pressure
(5) *
1-2 Shi ft Vai v
-
Li ne Pressure
(5)
*
2-3 Shi ft Val ve
-
Li ne Pressure
(5) *
3-4 Shi ft Val ve
-
3rd Cl utch Pressure
(30)
*
3rd Cl utch
The hvdraul i c Dressure al so fl ows to the 1st cl utch. However, no
power i s trsnsmi tted because of the one-way cl utch.
NOTE:
. When used,
"| eft"
or
"ri ght"
i ndi cates di recti on on ths hydraul i c ci rcui t.
. The hvdraul i c ci rcui t shows the
' 97
-
98 model s
(7 posi ti ons); the' 99
-
00 model s
(6 posi ti ons) i s si mi l ar.
(cont' d)
14- 35
www.emanualpro.com
Description
Hydraul i c Fl ow
(cont' d)
4th Gear llQ! or
E
Posirion)
As the speed of the vehi cl e reaches the prescri bed
val ue. shi ft control sol enoi d val ve A i s turned OFF by the
pCM,
Shi ft control sol enoi d val ve B remai ns OFF. Modul ator pressure (6)
fl ows to the l eft end of the 1-2 shi ft val ve and the
l eft end of the 3-4 shi ft val ve. Modul ator pressure (64)
i n the l eft end of the 1-2 shi ft val ve equal s modul ator pressure
(68)
i n the ri ght end of the 1-2 shi ft val ve. The 1-2 shi ft val ve remai ns at l eft si de by the tensi on of the val ve spri ng.
The 3-4 shi ft val ve i s moved to the ri ght si de by modul ator pressure (6A).
The 3-4 shi ft val ve covers the pon to the 3rd
cl utch and uncovers the port to the 4th cl utch as thi s val ve i s moved to the ri ght si de, The 4th cl utch pressure (41)
from the 3-4 shi ft val ve becomes 4th cl utch pressure (40)
at the manual val ve. The 4th cl utch pressure (40)
i s appl i ed
to the 4th cl utch, and the 4th cl utch i s engaged.
Fl ui d fl ows by way of:
-
Li ne pressure (4) +
CPB Val ve
-
Li ne Pressure (5) +
l -2 Shi ft Val ve
-
Li ne Pressure {5)
*
2-3 Shi ft Val ve
-
Li ne Pressure
(5) +
3-4 Shi ft Val ve
-
4th Cl utch Pressure
(41) +
Manual Val ve
-
4th Cl utch Pressure
(40)
+
4th Cl utch
The hydraul i c pressure
al so fl ows to the l st cl utch. However, no power i s transmi tted because of the one-wav cl utch.
NOTE:
. When used,
"l el t"
or
"
ti ght" i ndi cates di recti on on the hydraul i c ci rcui t.
. The hydrau l i c ci rcui t shows the
' 97
-
98 model s
(7 posi ti ons);
the
' 99
-
0O model s (6
oosi ti ons) i ssi mi l ar.
14-36
www.emanualpro.com
E
Position
Fl ui d fl ow through the torque converter ci rcui t i s the same as i n
N
posi ti on. Li ne pressure (1)
changes to l i ne
pressure (3)
and fl ows to the 1-2 shi ft val ve. Li ne pressure (3)
changes to l i ne
pressure (3' )
at the 1-2 shi ft val ve and fl ows to the servo
vai ve. The servo val ve i s moved to the ri ght si de
(Reverse range posi ti on) and uncovers the port to al l ow l i ne pressure (3")
to the manual val ve. Li ne pressure (3' )
from the 1-2 shi ft val ve fl ows through the servo val ve to the manual val ve and
changes to 4th cl utch
pressure (40).
The 4th cl utch
pressure (40)
i s appl i ed to the 4th cl utch, and the 4th cl utch i s engaged.
Rverse Inhibitor Control
When the
@
posi ti on i s sel ected whi l e the vehi cl e i s movi ng forward at speeds over 6 mph
(10
km/h), the PCM outputs the
1st speed si gnal to shi ft control sol enoi d val ves A and B; shi ft control sol enoi d val ve A i s turned OFF, shi ft control sol enoi d
val ve B i s turned ON. The 1-2 shi ft val ve i s moved to the ri ght si de and covers the
port to stop l i ne pressure
(3' )
to the
servo val ve. Li ne
pressure
{3' )
i s not appl i ed to the servo val ve, and 4th cl utch pressure
(40}
i s not appl i ed to the 4th
cl utch, as a resul t,
power
i s not transmi tted to the reverse di recti on.
NOTE:
. When used,
"l el t"
ot
"
ri ght" i ndi cates di recti on on the hydraul i c ci rcui t.
. The hvdraul i c ci rcui t shows the
' 97
-
98 model s
(7 posi ti ons); the
' 99
-
00 model s
(6 posi ti ons) i s si mi l ar'
(cont' d)
14-37 www.emanualpro.com
Description
Hydraul i c Fl ow
(cont' dl
E
Position
Fl ui d fl ow through the torque converter ci rcui t i s the same as i n
fl
posi ti on. Li ne pressure (
1) changes to l i ne pressure (3)
and fl ows to the 1-2 shi ft val ve. Li ne pressure (3)
changes to l i ne pressure
{3' ) at the 1-2 shi ft val ve and fl ows to the servo
val ve. The servo val ve i s moved to the ri ght si de
(Reverse
range posi ti on) and uncovers the port to al l ow l i ne pressure (3")
to the manual val ve as i n
E
posi ti on. Li ne pressure (3")
from the servo val ve i s i ntercepted by the manual val ve. Hydraul i c
pressure i s not suppl i ed to the cl utches, and power i s not transmi tted.
NOTE:
. When used,
"l eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t.
. The hydraul i c ci rcui t shows the
' 97
-
98 model s
(7 posi ti ons); the
' 99
-
00 model s
(6 posi ti ons)
i ssi mi l ar.
14-38 www.emanualpro.com
Lock-up System
TOROUE CONVERTER
In E posi ti on (' 97
-
98 model s) and i n
E
posi ti on (' 99 -
OO model s)
(3rd
and 4th), and E posi ti on (' 97 -
98 mod-
el s) and i n
E
posi ti on wi th Over-Dri ve
(O/D)
i s OFF
(by
pressi ng the O/D swi tch)
(' 99 -
00 model s)
(3rd), pressur-
i zed fl ui d i s drai ned from the back of the torque convert-
er through a fl ui d
passage, causi ng the l ock-up pi ston to
be hel d agai nst the torque converter cover, As thi s takes
Dl ace, the mai nshaft rotates at the same speed as th8
engi ne crankshaft. Together wi th the hydraul i c control ,
the PCM opti mi zes the ti mi ng of the l ock-up system.
Under certai n condl ti ons. the l ock-up cl utch i s appl i d
duri ng decel erati on, i n 3rd and 4th gear.
The l ock-up system control s the range of l ock-up sccord-
i ng to l ock-up control sol enoi d val ves A and B, and ths
l i near sol enoi d. When l ock-up control sol enoi d val ves A
and B acti vate. modul ator
pressure changes. Lock-up
control sol enoi d val ves A and B are mounted on the out-
si de of t he t or que conver t er housi ng, and t he l i near
sol enoi d i s mounted on the transmi ssi on housi ng. They
are control l ed bv the PCM.
The tabl e bel ow shows the l ock-up condi ti ons for l ock-up
control sol enoi d val ves and l i near sol enoi d
pressure.
LINEAR SOLENOID
PRESSURE
(cont' d)
LOCK.UP CONTROL
'
VALVE
LOCK.UP CONTROL
SOLENOID
VALVE
A B
MODULATOR
Pf,ESSURE
MAINSHAFT
COUNTERSHAFT
SUB.SHAFT
Lock-up
Condi ti ons
Lock-up Conirol
Solenoid valve
Linaal
Solenoid
Prgssuls
A B
Lock-up OFF OFF OFF Hi gh
Lock-up, Half ON
Duty operation
OFF
-
ON
Low
Lock-up, Ful l ON ON Hi gh
Lock-up
dur i ng
decel erati on
ON
Duty operation
OFF
-
ON
RELIEF VALVE
LOCK'UP TIMING
VALVE
COOLER RELIEF VALVE
ATF COOLER
ATF STRAINER
ATF PUMP
14- 39
www.emanualpro.com
Description
Lock-up System
(cont'dl
Lock-up Clutch
L Ooerati on
(cl utch
on)
With the lock-up clutch on, the fluid in the chamber between the torque convener cover and the lock-uD oiston is drained
off, and the converter fluid exerts pressure
through the piston against the torque converter cover, As a result, the conven-
er turbine is locked to the converter cover. This bipasses the converter, placing the vehicle in direct drive.
LOCK, UP PI STON
The power flows by way of:
Engi ne
+
Drive plate
Torque converter cover
I
Lock-up piston
t
Damper spri ng
{
Turbi ne
Mai nshaft
IOROUE
COVER
Operati on
(cl utch
off)
With the lock-up clutch off, the fluid flows in the reverse of
"clutch
on." As a result, the lock-up piston moves away from
the converter cover, and the torque converter lock-up is released.
Engi ne
I
Dri ve pl ate
{
Torque converter cover
{
Pump
I
Turbi ne
{
Mai nshaft
TOROUE
COVER
To ATF cooler
{(1
\\
n 1
INLET
t
J t l
or t
MAIf{SHAFT
MAII{SHAFT
14-40
www.emanualpro.com
TOROUE CONVERTER
No Lock-up
. Lock-up Control Sol enoi d Val ve A: OFF
. Lock-up Control Sol enoi d Val ve B: OFF
. Li near Sol enoi d Pressure: Hi gh
The pressuri zed fl ui d regul ated by the modul ator works
on both ends of the l ock-up shi ft val ve. Under thi s condi -
ti on, the pressures worki ng on both ends of the l ock-up
shi f t val ve ar e equal . and t he l ock- up shi f t val ve i s
moved t o t he r i ght si de by t he t ensi on of t he val ve
spri ng. Fl ui d trom the ATF pump wi l l fl ow through the
l eft si de of the l ock-up cl utch to the torque converter; the
l ock-up cl utch i s OFF.
NOTE: When usd,
"| eft"
and
"ri ght"
i ndi cates di recti on
on the hydraul i c ci rcui t.
+ LINEAR SOLENOID PRESSURE
(cont' d)
LOCK.UP CONTROL
SOI-ENOID VALVE
MOOULATOR
PRESSURE
MAINSHAFT
COUNTERSHAFT
RELIEF VALVE
LOCK-UP TI MI NG
VALVE
i COOLER RELIEF VALVE
ATF STRAINER
ATF COOLER
ATF PUMP
14-41
www.emanualpro.com
Description
Lock-up System
(cont'dl
a
a
Hal f Lock-up
Lock-up Control Sol enoi d Val ve A: ON
Lock-up Control Sol enoi d Val ve B: Duty Operati on
OFF
-
ON
Li near Sol enoi d Pressure: Low
The PCM swi tches sol enoi d val ve A on to rel ease modu-
l ator pressure i n the l eft cavi ty of the l ock-up shi ft val ve.
Modul ator pressure i n the ri ght cavi ty of the l ock-up
shi ft val ve overcomes the spri ng force, and the l ock-up
shi ft val ve i s moved to the l eft si de.
Li ne pressure i s then separated i nto the two passages
to
the torque converter; torque converter i nner pressure
enters i nto ri ght si de to engage the l ock-up cl utch, and
torque convener back Dressure enters i nto l eft si de to
di sengage the l ock-up cl utch.
Back pressure (F2)
i s regul ated by the l ock-up control
val ve, whereas the posi ti on of the l ock-up ti mi ng val ve
i s determi ned by l i near sol enoi d pressure and tensi on of
the val ve spri ng. Al so the posi ti on of the l ock-up control
val ve i s determi ned by the back pressure
of the l ock-up
control val ve. torque converter pressure (regul ated
by
the torque converter check val ve), and modul ator pres-
sure
(determi ned
by the l ock-up control sol enoi d val ve
B). The PCM swi tches l ock-up control sol enoi d val ve B
on and off rapi dl y
(duty
operati on), under certaj n condi -
ti ons, to regul ate back pressur (F2)
and l ock the torque
convertef.
NOTE: When used,
"l eft"
and
"ri ght"
i ndi cates di recti on
on the hvdraul i c ci rcui t.
+ LINEAR SOLENOID PRESSURE
TOFOUE CONVERTER
L(rcK.UP CONTROL
SOLENOID VALVE
A B
MODULATOR
PNESSURE
MAINSHAFT
COUNIERSHAFT
RELIEF VALVE
L(rcK-UP TIMING
VALVE
COOLER RELIEF VALVE
ATF STRAINER
14-42
ATF COOLER
ATF PUMP
www.emanualpro.com
TOROUE CONVEFTER
Ful l Lock-up
. Lock-up Control Sol enoi d Val ve A: ON
. Lock-up Control Sol enoi d Val ve B: ON
. Li near Sol enoi d Pressure: Hi gh
When t he v ehi c l e s peed f ur t her i nc r eas es , l i near
sol enoi d pressure i ncreases to hi gh i n accordance wi th
the l i near sol enoi d whi ch i s control l ed by the PCM.
The l ock up t i mi ng val ve over comes t he spr i ng f or ce
and moves to the l eft si de. Al so, thi s val ve cl oses the
fl ui d port l eadi ng to the l eft si de of the l ock-up control
val ve.
Under thi s condi ti on, modul ator pressure i n the l eft si de
of the l ock-up control val ve had al ready been rel eased
by the l ock-up control sol enoi d val ve B; the l ock-up con-
trol val ve i s moved to the l eft si de. As thi s takes pl ace,
torque converter back pressure i s rel eased ful l y, causi ng
the l ock-up cl utch to be engaged ful l y.
NOTE: When used.
"l eft"
and
"ri ght"
i ndi cates di recti on
on the hydraul i c ci rcui t.
+
LINEAR SOLENOIO PRESSURE
(cont' d)
LOCK-UP CONTROL
SOLENOID VALVE
MODULATOR
PRESSURE
MAINSHAFT
COUNTERSHAFT
SUB-SHAFT
RELI EF VALVE
LOCK. UP TI MI NG
VALVE
COOLER BELI EF VALVE
ATF STRAINER
ATF COOLER
ATF PUMP
14-43
www.emanualpro.com
Description
Lock-up System
(cont'dl
a
a
Decelelation Lock-up
Lock-up Control Sol enoi d Val ve A: ON
Lock-up Control Sol enoi d Val ve B; Duty Operati on
OFF
-
ON
Li near Sol enoi d Pressure: Low
The PCM swi tches sol enoi d val ve B on and off rapi dl y
under cer t ai n condi t i ons. The sl i ght l ock- up and hal f
l ock-up regi ons are mai ntai ned to l ock the torque con-
vener propeny.
NOTE: When used,
"l eft"
and
"ri ght"
i ndi cates di recti on
on the hydraul i c ci rcui t.
+ LINEAR SOLENOID PRESSURE
TOROUE CONVERTER
t
MOOULATOR
PRESSURE
MAINSHAFT
COUNTERSHAFT
SUB.SHAFT
ATF COOLER
RELIEF VALVE
LOCK.UP TIMING
VALVE
COOLER RELIEF VALVE
14-44
ATF STBAINER
ATF PUMP
www.emanualpro.com
Component Locations
ASSEMBLY
POWERTRAIN CONTROL
MODULE {PCMI
COUNTERSHAFT
SPEED SENSOR
AUTOMAIIC TRANSAXI.E
(A/T}
GEAR POSITION
swtTcH
\
CONTBOL UN]T
SHIFT CONTROL
SOLEM)ID VALVE
ASSEMBLY
SPEED SCNSOR
14-45
www.emanualpro.com
PCM Circuit Diagram
(A/T
Control System)
' 97
Model
UNDER.I]OOD FUSAFELAY BOX
EATTEFY
_ Y E L _
T-l
,
T T
- l
t_
-:
G101
' Fr-r.04
P-
r.-or..u
L
_a
TMEALOC(
BrKru
-<<
calTFoL
P_
*+rr
F-
onmrx
CFUISE
CONTFOL
UNIT
f-"".>
| [ " ' " ]
I l ,[-l
I I I
; ,
F_
pw
P_
eLu
F--
enN
UNDER DASN
M 25(7.54)
IGNITON
SWITCH
UNDEF OASN
FUSAFELAYSOX
oowEa-qar.
cor.lFo- MooLrE rpcMr
F \ &
*1
r*--'l_____O_=_
ATP I O! , ATP . ATD , A- P , A- P , A- P
N P l r N o l R 1 0 1 1 0 3 1 2 l l
Ar'TGEAR POS]TION
swt cN
14-46
www.emanualpro.com
SEr!5OR
V
I
I
t .
r h
nf
I
I
1",,
] '
I
YEI]BLK
I
-[
l
YEITILX
t ,
I
l-f?
POSrn0N
P POsITION
I
I
I r
SEFVICECHECK
CONNECTON
l"
8nN
I
I
H
I
BLX
{
G101
INTEFLOC( CONIFOL UNIT
KEY LCICI( SHIFI LOCX
ACCPUSNSW SOLEIJOIO IGI SOLEIOD PPNSW LI] ATPF GND
ENGINE
CooL,ANT
TEMPERATURE
SENSOF
www.emanualpro.com
PGM Terminal Voltage/Measuring Conditions
A/T Control System
-' 97
Model
The PCM termi nal vol tage and measuri ng condi ti ons are shown for the connector termi nal s that are rel ated to the Ay' T con-
trol system. The other PCM termi nal vol tage and measuri ng condi ti ons are descri bed i n secti on 11.
PCM Terminal Locations
A {32P} Connector B
(25P1
Connectol C {31PI Connector D {16P}Connect or
PCM CONNECTOR A {32P}
FCM CONNECTOR B
(25P)
Torminal Numbcr Si gnsl Description Measuring Conditions/Terminal Vohage
A9 LG1 Gr ound
( G101)
A10 PG1 Gr ound { G101)
At 1 I GPl Power supply system
(under-hood
Fuse 44 via main relav)
Wi th i gni ti on swi tch ON
(l l ):
Battery vol tage
Wi th i gni ti on swi tch OFF: 0 V
422 Ground
Ground
424 IG P2 Power supply system
(under-hood
Fuse 44 vi a mai n rel av)
Wi th i gni ti on swi tch ON
(l l ):
Battery vol tage
Wi th i gni ti on swi tch OFF: 0 V
Terminal Number Signal Description Measuring Conditions/Terminal Vohage
B1 LSM Li near sol enoi d power suppl y
negative electrode
l gni ti on swi tch ON
(l l ):
Pul si ng si gna
82 LSP Li near sol enoi d power suppl y
positive electrode
l gni ti on swi tch ON
(l l l :
Pul si ng si gna
B3 SHA Shi ft control sol enoi d val ve A
control
In
@, @
posi ti on, i n 2nd and 3rd gear i n E,
E posi ti on: Battery vol tage
In 1st gear i n E. F!
posi ti on, i n 4th gear i n E
posi ti on: 0 V
B4 LCB Lock-up control sol enoi d val ve B
control
Wi th ful l l ock-up: Battery vol tage
Wi th hal f l ock-up: Pul si ng si gnal
Wi th no l ock-up: 0 V
B5 LCA Lock-up control sol enoi d val ve A
control
When l ock-up i s ON: Baftery vol tage
Wi th no l ock-up: 0 V
86 to 87 Not used
B8 ATP D3 ,VT gear position
switch E posi-
ti on si gnal i nput
In E posi ti on: 0V
In other than E posi ti on:
Battery vol tage
89 to 810 Not used
14-48
www.emanualpro.com
PCM CONNECTOR B
(25P)
lcont'd)
PCM CONNECTOR C {31PI
PCM CONNECTOR D II6PI
Termi nal Numbel Si gnal Description Measuri ng Condi ti ons/Termi nal vol tage
8 1 1 SHB Shi ft control sol enoi d val ve B
control
In
E, E
posi ti on, i n 1st and 2nd gear i n -q,
Er posi ti on: Battery vol tage
In
B
posi ti on, i n 3rd
gear i n
qd, q:l ,i n
atn
gear i n D. posi ti on: 0 V
812 ILU l nterl ock control When i gni ti on swi tch i s ON
(l l ),
brake pedal
deDressed and accel erator oedal rel eased:0 V
B13 D4 I ND D4 Indi cator l i ght control When i gni ti on swi tch i s fi rst turned ON
(l l ):
6 V
or more for tl vo seconds
In l Dl l posi ti on: 6V or more
814 NMSG Mai nshaft speed sensor ground
815 NM Mai nshaft speed sensor si gnal
I npuI
Dependi ng on engi ne speed: Pul si ng si gnal
When engi ne i s stopped: 0 V
8 1 6 ATP R Ay'T gear position switch
E
posi ti on si gnal i nput
I n
E
posi t i on; OV
In other than E
posi ti on: Battery vol tage
817 ATP 2 Ay'T gear position switch E
posi-
ti on si gnal i nput
I nEpos i t i on: 0V
In other than E
posi ti on: Battery vol tage
B18 ATP 1 A/T gear posi ti on swi tch El
posi -
t i on si gnal i nput
I nEpos i t i on: 0V
In other than
E
posi ti on: Battery vol tage
819 t o 821 Not used
B22 NCSG Countershaft speed sensor ground
NC Countershaft speed sensor si gnal
I npur
Dependi ng on vehi cl e speed: Pul si ng si gnal
when vehi cl e i s stooped: 0 V
824 ATP D4 A/T gear position switch iql posi-
ti on si gnal i nput
I n E posi t i on: 0V
In other than lgal position: Baftery voltage
825 ATP NP Ay' T gear posi ti on swi tch E
and
N
posi ti on si gnal s i nput
In
E
and E
posi ti ons: 0V
In otherthan
@
and ffi
posi ti ons:5 V
Termi nal Number Si gnal Description Measuring Conditions/Terminal Voltage
SCS Servi ce check si gnal Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector open: 5 V
Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector connected wi th speci al tool : 0 V
c10 VBU Back-up power system
(under-hood
Fuse 47)
Al ways battery vol tage
Terminal Number Si gnal Description Measuring Conditions/Terminal Voltage
STOP SW Brake swi tch si gnal i nput Brake pedal pressedr Battery vol tage
Brake pedal rel eased: 0 V
14-49
www.emanualpro.com
PCM Circuit Diagram
(A/T
Gontrol System)
' 98
Model
UNOEF-HOOO FUSAFELAY sox
_ Y E L _
0 9 l D 0 l D l , l l D l 5
PNK BLU
F
rronr
f-'r'------}-'er'
F_
cRN
_______]_f-
PN(
F_
GFNTBLX
F_
gnN
*,',,,)83Hf'L
f
*'->
3111"?"
I
1*[-l
l l -
,I
I
Gro]
UNOEF-DASH
FUSE/BELAYBOX
I
rGD2 I
ocr
I
oG2
| V8 S0. I SIOP SW I CAs
ATP I Dl , ATP , ATP , A- P , ATP , A_P
N P l r N D l R l D 4 l D 3 1 2 l l
sr{rTat
14- 50
www.emanualpro.com
NIEFIOCX CONTAOLI]N T
KEYLOCX SH FILOCK
ACC PUSN SW SOLEIOLO 6] SOLENO1O PPINSW ILU ATP P GNO
SPEED
SENSOR
V
I
t-
JFj
I
gLUA|/H'I
I '
I
I
BLl(BLU
I
___L
V
PosrTroN
PPOSI TON
I '
I
t_
,T
l ' l '
YEUBLX WN I/8LI< V
T-T
l l
YEL]BLK WHTELK
l , l
IH
q**
l F I l : $". "
-T-
L
I s"'n Locr
erx v
l S0LEN00 |
vr L
4
__t
;,
--l
l
I
I
BqNLK
I
Gr 01
SERVCECHECX
CONNECTOF
l*
BFN
I
-T-
I
BLK
T
, l
T l '
BLU/YEL GFNAiI/N]
l l
t*l I
t ? t L
I SN FT CONTFOL
I SOLENOIDVALVE
I
AssEM4Y
I
-:
COTJNIEFSHAfI LNEAFSOLEID
SPEEDSENSOA
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PCM Circuit Diagram
(A/T
Control System)
' 99
-
00 Model s
IJNOER' HOOD FUSE/FELAY EoX
EATTERY
IJNOER DASII
FUS' /FELAYBOX
-]-
T
8LKryEL
l .
]T
I
BLX,' YEL
D9 100 | 0r 4 | Dr t I Bt g
GAUGEASSEMELY
Fffi[t**
f
L' om
{
+
sr&BrLr
--1
l-
LTGRN
BLKtsLU
FED
YEL
8LU
LI BLU
F-lwr-i
|--FED----.1
| - BFN- -
f-
Lr sLrJ
-l
, I ,
-r
G4o1
d
G401
A I P , O , 0 , A T P , A r P l O / D
0 4 t 5 w t 2 t r t N 0
)
{
:-\
!r' TGEAF POS]IION
14-52
www.emanualpro.com
NIEFLOCX CONTROL UNIT
XEY LOCX SHFILOCX
ACCP1JSHSW SOLENOID 61 SOLENO D PPNSW LL] A' PP GND
l 6
I
SLTBL!
l
Post i 0N
3
YEU8L(
?
I
YEUBLK
t ,
rt--r
| tr-r I
t 9i l
LJA
1
SNTFl LOCK
L
SOTENO D
YEL
SPEEO
SENSOn
Y
L
I
i-
Jr l
I
I
.l' .'1"
T--[T
POWEFTFALN CONTROL MODIJLE (PCM)
i " ' ] *
BFN BLU/IEL
I t
-tl
8FN BLI]IEL
Trt f7
l : I onx^*
tfJ
coNNEcroR
I
BLK
i
G10r
0r r 012 l Dr o
SERVCE
CHECK
CONNECIOF
LOC(,I]P CON'IBOL
SOLENOIDVALVE
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PCM Terminal Voltage/Measuring Conditions
A/T Control System
-'98 -
00 Models
The PCM termi nal vol tage and measuri ng condi ti ons are shown for the connector termi nal s that are rel ated to the A"/T con-
trol system. The other PCM termi nal vol tage and measuri ng condi ti ons are descri bed i n secti on 11.
FCM Connector Terminal Localions
NOTE: 819 and C3 t ermi nal s
are appl i ed t o' 99
-
00 model s.
o
(16Pt
T6rminal Number Si gnal Description Measuring Conditions/Terminal Voltage
A5 CRS Downshi ft si gnal i nput from
crui se control uni t
When crui se control i s used; Pul si ng si gnal
A10 scs Ti mi ng and adj ustment servi ce
check si gnal
(5
V from PCM)
Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector open:5 V
Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector
j umped
wi th speci al tool : 0 V
A14
(' 98
model )
D4 IND D4 i ndi cator l i ght control
{Vol tage from PCM turns D4 l i ght
oN)
When i gni ti on swi tch i s fi rst turned ON
(l l ):
Battery voltage for two seconds
In
E
position: Battery voltage
A14
(' 99 -
00 model s)
D IND D i ndi cator l i ght control
(Vol tage
from PCM turns D l i ght
oN)
When i gni ti on swi tch i s fi rst turned ON
(l l ):
Baftery voltage for two seconds
l n
E
posi ti on: Battery vol tage
428 ILU Interl ock control
(Vol tage
from PCM)
When i gni ti on swi tch ON {l l ), brake pedal
depressed, and accel erator
pedal
rel eased:
Battery voltage
A.32 STOP SW Brake swi tch si gnal i nput Brake pedal pressed; Battery vol tage
Brake pedal rel eased: 0 V
FCM CONNECTOR B I25P}
Terminal Number Signal Description Measuring Conditions/Terminal Voltage
B1 I GPl Power suppl y ci rcui t from mai n
rel ay vi a under-hood Fuse 44
Wi th i gni ti on swi tch ON {l l ): Battery vol tage
Wi th i gni ti on swi tch OFF: 0 V
82 PG1 Gr ound
( G101)
B8 LSM Li near sol enoi d power suppl y
negati ve el ectrode
IG P2 Power suppl y ci rcui t from mai n
rel ay
Wi th i gni ti on swi tch ON
(l l ):
Baftery vol tage
Wi th i gni ti on swi tch OFF: 0 V
810 PG2 Gr ound
( G101)
B17 Li near sol enoi d power suppl y
posi ti ve
el ectrode
Wi th i gni ti on swi tch ON
(l l ):
Pul si ng si gnal
819
(' 99 -
00 model s)
O/D IND Over-Dri ve
(O/D)
OFF i ndi cator
l i ght control
When i gni ti on swi tch i s fi rst turned ON
(l l ):
0 V for two seconds
O/D OFF i ndi cator l i ght ON:0 V
O/D OFF i ndi cator l i ght OFF: Battery vol tage
s20 Gr ound
( G101)
B21 VBU Back-up power
suppl y
(under-hood
Fuse 47)
Always battery voltage
B22 LG2 Gr ound
( G101)
14-54
www.emanualpro.com
Terminal Numbor Signal Description Measuring Conditions/Terminal Voltage
D1 LCA Lock-up control sol enoi d val ve A
control
Duri ng l ock-up condi ti ons: Baftery vol tage
Duri ng no l ock-up condi ti on: 0 V
D2 S H B Shi ft control sol enoi d val ve B
control
Battery vol tage i n fol l owi ng posi ti ons:
.
E, E
and posi ti ons
.
E,
-ql ,
and
E
posi ti ons i n l st and 2nd gear
0 V i n fol l owi ng posi ti ons:
.
E, E;,
and
E
posi ti ons i n 3rd gear
.
E
and
E
posi ti ons i n 4th gear
.
E, El ,
and
El
posi ti ons
D3 L CB Lock-up control sol enoi d val ve B
control
Duri ng ful l l ock-up condi ti ons: Battery vol tage
Duri ng hal f l ock-up condi ti ons; Pul si ng si gnal
D4 Not used
D5 VB SOL Power suppl y for sol enoi d val ves
(Under-hood
Fuse 15)
Wi th i gni ti on swi tch ON
(l l );
Battery vol tage
Wi th i gni ti on swi tch OFF: 0 V
D6 ATP R Ay'T gear position switch
B
posi ti on i nput
In
E
posi ti on: OV
In other than
E
posi ti on: Baftery vol tage
D7 S H A Shi ft control sol enoi d val ve A
control
Battery vol tage i n fol l owi ng posi ti ons:
.
E
posi ti on
.
E, E, and E
posi ti ons i n 2nd and 3rd gear
.
E
posi ti on
0 V i n fol l owi ng posi ti ons:
.
E
posi ti on
.
E. E, and E
posi ti ons i n l st gear
.
Erl
and
E
posi ti ons i n 4th gear
. EandEpos i t i ons
D8
{' 98
model }
ATP D3 Ay'T gear position switch
E
posi ti on i nput
In
E
posi ti on: 0V
In other than E
posi ti on: Baftery vol tage
D8
(' 99 -
00 model s)
O/D SW Over-Drive
(O/D)
switch signal
i nput
When Over-Dri ve {O/D) i s OFF
(O/D
OFF
i ndi cator l i ght i s ON): 0 V
When Over-Dri ve {O/D) i s ON {O/D OFF
i ndi cator l i ght i s oFF): Battery vol tage
D9 ATP D4 A/f gear position switch
E
posi ti on i nput
I n
E
posi t i on: 0V
In other than E
posi ti on: 5 V
D10 NC Countershaft sDeed sensor i nout Dependi ng on vehi cl e speed: Pul si ng si gnal
when vehi cl e i s stopped: Approx.0 V
Dl 1 NM Mai nshaft speed sensor i nput Dependi ng on vehi cl e speed: Pul si ng si gnal
When engi ne i s stopped: Approx. 0 V
D12 NMSG Mai nshaft speed sensor ground
D13 ATP NP A,/T gear position switch E
and
El
posi ti ons i nput
I nEandEpos i t i ons : 0V
In other than
E
and m
posi ti on: 5 V
D14 AlP 2 A/T gear position switch
El
posi ti on i nput
I nE posi t i on; 0V
In other than
E
posi ti on: Battery vol tage
D15 ATP 1 A,/T gear position switch
E
posi ti on i nput
I nEpos i t i on: 0V
l n other than
El
posi ti on: Battery vol tage
D16 NCSG Countershaft speed sensor
grouno
PCM CONNECTOR D
(16P)
14- 55
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Troubleshooting Procedures
Checking ths Diagnostic Trouble Code
(DTC)
with an O8D ll Scan tool or Honda PGM Tsster
When the PCM senses an abnormal i ty i n the i nput or output systems, the
El
(' 97 -
98) or
E
(' 99 -
O0) i ndi cator l i ght i n the
gauge assmbl y wi l l bl i nk. When the 16P Data Li nk Connector
(DLC)
{l ocated under the dash on the passenger' s
si de) i s
connected to the OBD l l Scan Tool or Honda PGM Tester as shown, the scan tool or tester wi l l i ndi cate the Di agnosti c
Troubl e Code
(DTC)
when the i gni ti on swi tch i s turned ON(l l ).
HONDA PGM TESTER ol
OBD II SCAN TOOL
l f the
E
or
E
i ndi cator l i ght or the MIL has been reported on, or i f a dri veabi l i ty probl em i s suspected, fol l ow thi s proce-
dure:
1. Connect the OBD l l Scan Tool
(conformi ng
to SAE J1978) or Honda PGM Tester to the 16P DLC.
(See
the OBD l l Scan
Tool or Honda PGM Tester user' s manual for speci fi c i nstructi ons. l f you are usi ng the Honda PGM Tester, make sure
it is set to the SAE DTC
Wpe).
2. Turn the i gni ti on swi tch ON
(l l ),
and observe the DTC on the screen
3. Record al l fuel and emi ssi on DTCS, A,,/T DTCS, and freeze data.
4. l f there i s a fuel and emi ssi ons DTC, fi rst check the fuel and emi ssi ons system as i ndi cated by the DTC
(except
for DTC
P0700). DTC P0700 means there i s one or more Ay' T DTC, and no Drobl ems were detected i n the fuel and emi ssi ons
ci rcui t of the PCM.
5. Wire down the radio station presets.
6. Reset the memory wi th the PGM Tester o. by removi ng the BACK UP fuse i n the under-hood fuse/rel ay box for more
than 10 seconds.
7. Drive the vehicle for several minutes at speeds over 30 mph
(50
km/hr), and then recheck for DTCS. lf the A/T DTC
returns,
9o
to the Symptom-to Component Chart on pages 14-60 and 14-61 for the
' 97
model s, and pages 14-62 and
14-63 for
' 98
-
00 model s. l f the OTC does not return, there was an i ntermi ttent
probl em
wi thi n the ci rcui t. Make sure
al l pi ns and termi nal s i n the ci rcui t are ti ght, and then go to step 8.
8. Reset the radi o Dreset stati ons, and set the cl ock.
DATA LINK CONNECTOR {16PI
[
-=.r,
ili
, i
/ i ,
v,.,
i
14- 56
www.emanualpro.com
Checking the Diagnostic Trouble Code IDTCI
with the Servic Check Connestol and Special Tool
when the PcM senses an abnormal i ty i n the i nput or output systems' the E
(' 97
-
98) or
E
(gS -
OO) i ndi cator l i ght i n the
gauge assembl y may bl i nk.
When the Servi ce Check Connector
(2P) (l ocated
under the dash on the passenger si de) i s connected wi th the speci al tool
as shown, the E
or
E
i ndi cator l i ght wi l l bl i nk the Di agnosti c Troubl e Code
(DTC)
when the i gni ti on swi tch i s turned ON
{ ) .
when the E
or
E
i ndi cator l i ght has been reponed on, connect the servi ce check connector
(2P)
to the speci al tool
Then turn ON
(l l )
the i gni ti on swi tch and observe the E
or
E
i ndi cator l i ght'
.AUGE AssEMaLY $1,"^f:tT"'ff,
SCS SERVICE CONNECTOR
07PAz
- (x!l0100
codes 1 through 9 are i ndi cated by i ndi vi dual short bl i nks. codes 1o and above are i ndi cated by a seri es of l ong and short
bl i nks. one l ong bl i nk equal s 1o short bl i nks. Add the l ong and short bl i nks together to determi ne the code. After deter-
mi ni ng the code, refer to the el ectri cal system symptom-to-component
chart on pages 14-60 and 14-61 for the
' 97
model ,
and
pages 14-62 and 14-63 tor the
' 98
-
00 model s.
Sr. DTC 1
S.. DTC 2
Long blink Shori blink! {fiv. timt l
Sc. DTC 15
(cont' d)
'99
-
O0 models
'97
-
98 models
Short blinl lonc.)
14-57
www.emanualpro.com
Troubleshooting Procedures
(cont'dl
L Remove the ki ck panel on the passenger' s
si de
(see
secti on 2O),
2. Remove the PCM, and turn i t over.
Inspect the ci rcui t on the PCM accordi ng to the troubl eshooti ng fl owchart wi th the speci al tool s and a di gi tal mul ti me-
ter.
How to Use the Backplobe Set
Connect the backprobe adapters to the stacki ng patch
cords, and connect the cords to a
i nsul ati on as a gui de
for the contoured ti p of the backprobe adapter, gentl y
sl i de the ti p
wi re si de unti l i t comes i n contact wi th the termi nal end of the wi re.
mul ti meter. Usi ng the wi re
i nto the connector from the
BACKPROBE
EACKPROBE SET
07sAz
-
001000a
{two requi red)
DIGITAL MULTIMETER
(Commercially
.v.ilablel
KS- AHM- 32- 003
ot oquivalont
KICK PANEL
14- 58
www.emanualpro.com
PCM Reset Procedure
' 1.
Turn the i gni ti on swi tch off
2. Remove the BACK UP fuse
(7.5
A) from the under-hood fuse/rel ay box for 10 seconds to reset the PCM.
NOTE:
. Di sconnecti ng the BACK Up fuse al so cancel s the radi o preset stati ons and cl ock setti ng Make note of the radi o
presets
before removi ng the fuse so you can reset them
. The PCM memorv can al so be cl eared by usi ng the OBD l l Scan Tool or Honda PGM Tester'
UNDER.HOOD
FUSE/RELAY BOX
Final Proceduro
This
procedure must be done after any troubleshooting.
1. Turn the i gni ti on swi tch OFF.
2. Reset the PCM.
3. Di sconnect the OBD l l Scan Tool or Honda PGM Tester from the Data Li nk Connector
(16P),
or remove the speci al tool
from the Servi ce Check Connector
(2P).
4. Turn the i gni ti on swi tch ON
(l l ),
and set the radi o
presets and cl ock setti ng'
5, To veri fy that the probl em i s repai red. test-dri ve the vehi cl e for several mi nutes at speeds over 30 mph
(48
km/h).
BACK UP IRADIO} {7.5 AI FUSE
14- 59 www.emanualpro.com
Symptom-to-Component
Chart
El ectri cal System
-' 97
Model
DTC*: The DTc i n parentheses
i s the code the l oa i ndi cator ri ght i ndi cates when the Data Li nk
Connector i s connected to the Honda
pGM
Tester.
DTC*
E Indicatol
Li ght
MIL
Detection ltem
Page
P 1753
( 1 )
Bl i nks ON Lock up control sol enoi d val ve A (see page 14-64)
P1758
\ 21
B l i nks ON Lock-up control sol enoi d val ve B (see page 14-66)
P 1705
( 5)
Bl i nks ON A,/T gear posi ti on swi tch
(short
to ground) (see page 14-68)
P1706
( 6)
OFF ON A,/T gear posi ti on swi tch {open) (see page 14-70)
P0753
\ 11
B l i nks ON Shi ft control sol enoi d val ve A (see page
14-72)
P0758
( 8)
Bl i nks ON Shi ft control sol enoi d val ve B (see page
14-74)
P0720
( 9)
Bl i nks ON Countershaft speed sensor
{see
page
14-76)
P0715
( 15)
B l i nks ON Mai nshaft speed sensor (see page
l 4-78)
P17 68
(
16)
Bl i nks ON Li near sol enoi d (see page 14-80)
P0740
{40)
OFF ON Lock-up control system (see page
14-82)
P0730
( 41)
OFF ON Shi ft control system (see page 14-84)
14- 60
www.emanualpro.com
NOTE: When the OBD l l Scan Tool or Honda PGM Tester i ndi cate DTC(s) for the automati c transmi ssi on control system'
the scan tool or tester i ndi cates code P0700 si mul taneousl y. code P07oo means a detecti on of some automati c transmi s-
si on
probl em i n the PGM-Fl control system
l f the sel f-di agnosti c E
i ndi cator l i ght does not bl i nk, perform an i nspecti on accordi ng to the tabl e bel ow.
NOTE: lf a customer describes the symptom for code P1706
(6),
it will be necessary to recreate the symptom by test-driv-
i ng, then recheck the OTC.
Symptom
Inspecti on Ref. page
E
i ndi cator l i ght i s on constantl y
(not
bl i nki ng) whenever the i gni ti on
swi tch i s ON
(l l ).
14-86
E
i ndi cator l i ght does not come on for two seconds after i gni ti on
swi tch i s fi rst turned ON
(l l ).
't
4-41
Shi ft l ever cannot be moved from
@
posi ti on wi th the brake
pedal
Dressed,
Check shi ft l ock system 14-89
l gni ti on key cannot be moved from ACC
(l ) posi ti on to LOCK {0)
posi
ti on wi th the shi ft l ever i n
E
posi ti on.
Check keY i nterl ock system 14- 91
14-61
www.emanualpro.com
Symptom-to-Component
Chart
Electrical System
-'98 -
00 Models
DTC*; The DTC i n the parentheses
i s the code the E or
E i ndi cator l i ght i ndi cates when the Data Li nk
Connector i s connected to the Honda
pGM
Tester.
DTC*
Et Indicatol
Lighr
(98)
E
Indicator
Light
('99 -
00)
MI L
Detestion ltom
Page
P1753
( 1 )
Bl i nks ON Lock-up control sol enoi d val ve A
{see
page 14-93)
P1758
(21
Bl i nks ON Lock-up control sol enoi d val ve B (see page 14-96)
P1705
(5)
Bl i nks ON A,/T gear posi ti on
swi tch
(shon
to grounol (see page 14-99)
P1706
(6)
OFF ON A,/T gear posi ti on
swi tch
(open) (see
page 14-103)
P0753
(71
Bl i n ks ON Shi ft control sol enoi d val ve A (see page
14-106)
P0758
( 8)
Bl i nks ON