Manual Honda 2 Desmontaje

1 .
Removethe control lever mounting bolt trom the 14, Cleanthe inlet opening of the ATF strainer thor-
torque converterside of the torque converterhous- oughly with compressedair, then checkthat it is in
good condition,and the inletopeningis not clogged
ing. (4WD)
or damaged.
Removethe ATF feed pipes from the servo body,
secondaryvalvebody,lock-upvalvebody,and main
valvebody.
For'97 - 98 models:
Removethe two boltssecuringthe ATF strainerand
servodetentbase,then removethe strainerand the
base.
For'99 - 00 models;
Removethe ATFstrainer{one bolt).
4. For'97 - 98 models:
Removethe seven bolts securingthe servo body,
then remove the servo body and separatorplate'
For'99 - 00 models:
Removethe eight bolts securingthe servo body, INLET OPENING
then removethe servobody and separatorplate'
5 . B e m o v et h e t h r e e b o l t s s e c u r i n gt h e s e c o n d a r y
valve body, then remove the secondaryvalve body'
stop shaft bracket,and separatorplate.
1 5 . Test the ATF strainer by pouring clean ATF through
6. Removethe eight bolts securingthe ATF lubrication the inlet opening,and replaceit if it is clogged or
plate and lock-upvalve body, then removethe ATF damaged.
lubricationplate,lock-upvalve body' and separator
plate.
7. Removethe one bolt securingthe regulatorvalve

body,then removethe regulatorvalvebody'
8. Removethe stator shaft and stop shaft.
9. Removethe detentspringfrom the detentarm, then

remove the control shaft from the torque converter
houslng.
10. Removethe detentarm and detentarm shaft from

the main valvebody.
1 1 . R e m o v et h e f i v e b o l t s s e c u r i n gt h e m a i n v a l v e
body,then removethe main valvebody.
When removingthe main valve body, do not let the
eight checkballsfall out.
1 2 . R e m o v et h e A T F p u m p d r i v e n g e a r s h a f t , t h e n
removethe ATF PumPgears.
13. Removethe main separatorplate with two dowel

prns.
www.emanualpro.com 14-191
Valve Body
Repair
NOTE:This repair is only necessaryif one or more of 5. R e m o v et h e # 6 0 0 p a p e r . T h o r o u g h l y w a s h t h e
the valvesin a valve body do not slidesmoothlyin their entire valve body in solvent,then dry it with com-
bores.Usethis procedureto free the varves. pressedar.
'1.
S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r Coatthe valvewith ATF,then drop it into its bore, lt
about30 minutes. shoulddrop to the bottomof the bore underits own
weight. lf not, repeatstep 4, then retest.lf the valve
2. Carelullytap the valve body so the stickingvalve still sticks,replacethe valvebody.
drops out of its bore. lt may be necessaryto use a
small screwdriverto pry the valve free. Be careful
not to scratchthe bore with the screwdriver.
,l
Inspectthe valve for any scutf marks.Use the ATF-
soaked#600 paper to polish off any burrs that are
on the valve,then wash the valvein solventand dry
it with compressedair.
4. Roll up half a sheet of ATF-soaked #600 paper and

insertit in the valve bore of the stickingvalve.
Twist the paper slightly,so that it unrolls and fits
the bore tightly,then polishthe bore by twistingthe
w
paperas you push it in and out.
N O T E :T h e v a l v e b o d y i s a l u m i n u ma n d d o e s n , t
requiremuch polishingto removeany ourrs.
1. Removethe valve.and thoroughlyclean it and the

valve body with solvent. DrV all parts with com-
pressedair,then reassembleusingATFas a lubricant.
14-192
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Valve
Assembly
NOTE; . Set the spring in the valve,and installit in the valve
Coatall partswith ATF beforeassembly. b o d y . P u s ht h e s p r i n g i n w i t h a s c r e w d r i v e rt,h e n
installthe springseat.
. l n s t a l tl h e v a l v e ,v a l v es p r i n g ,a n d c a p i n t h e v a l v e
body.and securewith the roller.
SEAT
u>o
VALVE EODY
Installthe valve,spring,and cap in the valve body.

Pushthe caD,then installthe cliP.
VALVE BODY
VALVE
CAP
ValveGaps
Description
C a p s w i t h o n e p r o j e c t e dt i p a n d o n e f l a t e n d a r e Capswith hollow ends are installedwith the hollow
i n s t a l l e dw i t h t h e f l a t e n d t o w a r d t h e i n s i d eo f t h e end awayfrom the insideof the valveooov.
valvebody. Capswith notchedends are installedwith the notch
Capswith a projectedtip on each end are installed towardthe insideof the valvebodv.
w i t h t h e s m a l l e rt i p t o w a r d t h e i n s i d eo f t h e v a l v e Capswith flat ends and a holethroughthe centerare
b o d y .T h es m a l lt i p i s a s p r i n gg u i d e . installedwith the smaller hole toward the inside of
the valvebody.
TOWARDOUTSIDEOFVALVEAODY TOWAROOUTSIDEOFVALVEBODY
EEEE
TOWARDINSIDEOF VALVEBODY TOWAROINSII'C OF VALVE BODY
C a p sw i t h o n e p r o j e c t e dt i p a n d a h o l l o w e n d a r e Capswith flat ends and a groovearoundthe cap are

installedwith the tip toward the inside of the valve installedwith the groovedside toward the outsideof
body.The tip is a springguide. the valvebody.
Capswith one projectedtip and flat end are installed
with the tip toward the insideof the valve bodv. The
tip is a spring guide. The groove is a valve cao clio
g ui d e .
TOWARD OUTSID OF VALVE BOOY TOWARDOUTSIOOFVAIVE BODY
TOWARDINSIDEOF VALVEBOOY
TOWARDI'{SIDEOF VALVEEOOY
14-194
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ATFPump
Inspection
1. I n s t a l tl h e A T F p u m p g e a r sa n d A T F p u m p d r i v e n 2. Measurethe side clearanceof the ATF pump drive
g e a r s h a f t i n t h e m a i n v a l v e b o d y L u b r i c a t ea l l and drivengears.
p a r t sw i t h A T F , a n d i n s t a l lt h e A T F p u m p d r i v e n
gearwith its groovedand chamferedsidefacingup ATF Pump Gears Side {Radial}Cloarance:
Standard (Newl:
ATF Pump Drive Gear
0.105- 0.1325mm {0.004- 0.005in}
ATF Pumo Driven Gear
0.035- 0.0625mm {0.0014- 0.0025in)
ATF PUMP ORIVE
MAIN VAI-VEBOOY
fl
L /
ATF PUMP
DRIVENGEAR
ATF PUMP Inspeclteeth{or wear and damage
DRIVEGEAR
I n s p e c tt e e t h f o r w e a r a n d d a m a g e ,
3. Removethe ATF pump driven gear shaft Measure

the thrust clearanceof the ATF pump driven gear-
to-valvebody.
MAIN VALVE AOOY ATF Pumo Drive/DrivenGearThrust (AxiallClearance:

Standard (Nw): 0.03- 0.05 mm {0'001- 0 002 inl
ServiceLimit: 0.07 mm 10.003in)
ATF PUMP
ORIVENGEAR
Main Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. Do not usea magnetto removethe checkballs;it may magnetizethe balls.
t clean all partsthoroughlyin solventor carburetorcleaner,and dry them with compressed
ai.. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damageo.
. C h e c k a lvl a l v e s f o r f r e em o v e m e n tl .f a n y f a i l t o s l i d e f r e e l y , s e e V a l v e B o d y R e p a i r o n p a g e . t 4 _ 1 9 2 .
. Coatall partswith ATF during reassembly.
I-2 SHIFTVALVE
VALVECAPCLIP
2ND ORIFICE
CONTROLVALVE
SPRINGSEAT
@
U K BALLS,8
ACCUMULATOR
CHOKE
VAI-VE
FELIFVALVE
MAIN VALVEBOOY
Inspectfor wear, scratches,
and sconng.
sERVOCONInOL
:,/\^._.^,
14-196
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CHECKBALL
i)L ) CHECKBALLS
lo
lST ACCUMULATOR
CHOKE
MAIN VALVEBODY CHECKEALL

(Sectionalview)
SPRINGSPECIFICATIONS U n i t :m m ( i n )
Standard {New)
No. Springs
Wire Dia. o.D. FroeLength No. of Coils
'13.4
o Reliefvalvespring 1 . 1( 0 . 0 4 3 ) 8.6 (0.339) 3 7 . 1( 1 . 4 6 1 )
35.0(1.3781 10.9
Modulatorvalvespring 1.4(0.055) 9.4 (0.370)
@ CPBvalvespring 0.9 (0.03s) 8 . 1( 0 . 3 1 9 ) 41.2 \1.8581
@ 1-2shift valvespring 0.9 (0.035) 7.6 (0.299) 4 1 . 3( 1 . 6 2 6 )
2nd orificecontrolvalvespring 0.7 (0.028) 6.6 (0.260) 34.8(1.370)
@ Servo control valve sPring 1.0t0.039) 8 . 1{ 0 . 3 1 9 ) 5 2 . 1( 2 . 0 5 1 ) 20.8
SecondaryValve Body
NOTE:
' clean all partsthoroughlyin solventor carburetorcleaner.and dry them with compressed
air. Blow out aUpassages,
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
t checkall valvesfor free movement.rf anyfair to sridefreery.seevarveBody Repair page
on 14-192.
. Coatall partswith ATFduring reassembly.
. The CPCvalveis installedin the secondaryvalve body,held in placeby the lock
bolt.
VALVECAP
t*-1 2.3 SHIFTVALVE
@,.-
.t'tr.,
,rr'^'//u
"/ ./
3-' SHIFTVALVE
ilTH EXHAUSTVALVE
SECONOARY VALVEBODY
Inspectfor wear, scratches,and
scorang.
3.4 ORIFICECONTROLVAL
N"*,"o"*
VALVESLEEVE
ROLLER
SPRINGSPEC!FICATIONS
U n i t :m m ( i n )
Standald {Nswl
No. Springs
Wire Dia. o.D. FreeLength No. of Coils
o 3 4 shiftvalvespring 0.9 (0.035) 7.6 (0.299) 57.Oi.2.2441 26.A
@ 2-3shift valvespring 0.9 (0.035) 7.6 (0.299) 57.O12.244J 26.8
o 4th exhaustvalvespring 0.9{0.035) 6.1 (0.240t 3 6 . 4( 1 . 4 3 3 ) 19.5
@ 3-4 orificecontrolvalvespring 0.6 {0.024} 6.6 (0.2601 37.9(1.492) 31.6
14-198
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RegulatorValve Body
NOTE:
o Cleanall parts thoroughlyin solventor carburetorcleaner,and dry them with com-
pressedair. Blow out all passages.
. Checkallvalvesforfreemovement.lf anyfail toslidefreely,seeValveBody Repairon page l4-192.
'1. Holdthe regulatorspringcap in placewhile removingthe stop bolt. The regulatorspringcap is spring loaded Once
the stop bolt is removed,releasethe springcap slowly so it does not pop out.
2. is the reverseorderof disassembly.

Reassembly
NOTE:
. Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe spring cap into the valve
body,and tightenthe stop bolt.
REGULATOR SPSING CAP
STOPBOLT
6x1.0mm
12N.m11.2 8.? tbt.fil
REGULATOR VALVEBODY
lnspectfor wear,scratches,
ano scoflng.
REGULATOR
VALVE
Standard {New}
No, Springs
wire Dia. o.D. F ee Length No. ot Coils
o RegulatorvalvespringA 1 . 8( 0 . 0 7 1 ) 14.7(0.579) 87.8(3.457)

'11.0
Regulatorvalvespring B 1 . 8( 0 . 0 7 1 ) 9.6 (0.378) 44.0t1.7321
@ Statorreactionspring 4 . 5( 0 . 1 7 7 ) 35.4(1.394) 3 0 . 3( 1 . 1 9 3 ) 1.9
@ Coolerreliefvalvespring 1.0{0.039) 8 . 4{ 0 . 3 3 1 ) 3 3 . 8( 1 . 3 3 1 )
,6 Torque convertercheckvalve spring
'97 Model 't2.0
1.1(0.043) 8 . 4( 0 . 3 3 1 ) 36.4(1.433)
'98 - 00 Models 1.2lO.O47l 8 . 4( 0 . 3 3 1 ) 32.4 11.2761 12.7
a, Lock-upcontrolvalvespring 0.7 t0.028) 6.6 (0.260) 38.0(1.496) 14.'l
ServoBody
NOTE:
' cleanall partsthoroughly in solventor carburetorcleaner,and dry them with compressedair, Blow
out all passages.
. Replacethe valve body as an assemblyif any partsare worn or damaged.
ACCUMULATOR
COVER
3ROSUBACCUMULATOR
O-RING
Feplace.
1STACCUMULATOR
PISTON
@"- -tP
fi,
SERVO
RVOVAL\VE/SHIFT
IRKSHAFT
FORK S
-.t l@
SPR|NGRETATNER
,/
il
3RDACCUMULATOR g O.RING
Replace.
\_)
SNAPRING
SNAPRING
SPRINGSPECIFICATIONS
U n i t :m m { i n )
Standard lNewl
No. Springs
Wire Dia, o.D. FreeLongth No. of Coil3
o 1staccumuiatorspring 2.1 (0.083) 16.0(0.6301 89.r (3.508)
@ 4th accumulatorspringA 2.6 {0.102) 17.0(0.669) 88.4(3.480) 14.2
J6
4th accumulatorspring B 2 . 3( 0 . 0 9 1 ) 't0.2
t0.402] 5 1 . 6( 2 . 0 3 1 ) 13.8
@ 3rd accumulatorspringA 2 . 8( 0 . 1 1 0 ) 17.5(0.689) 94.3(3.713) 15.9
.A 3rd accumulatorspringB 2.1 (0.083) 3 1 . 0( 1 . 2 2 0 ) 38.2(1.504) 2.6
\o, 2nd accumulatorspringC 2.2 (0.087l- 1 4 . 5{ 0 . 5 7 1 ) 68.0{2.677) 13.9
o 2nd accumulatorspringA 2.4 (0.094) 29.0 11.1421 39.0fi.535) 2.9
@ 2nd accumulatorspringB r.6 (0.063) 9.0 (0.354) 20.7(0.815) o.l
@ 3rd sub accumulatorspring 2 . 7{ 0 . 1 0 6 ) 17.0(0.669) 39.0(1.535) 6.3
14-200
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Lock-upValve Body
bly
Disassembly/lnspection/Reassem
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry them with compressedair. Blow out all passages.
. C h e c k a lvl a l v e s f o r f r e em o v e m e n tl .f a n y f a i l t os l i d ef r e e l y s, e e V a l v eB o d yR e p a i r o np a g e1 4 - 1 9 2 .
. Coatall partswith ATF duringreassembly.
LOCK.UPSHIFTVALVE
'\ \
\-.xlO
/
\ @-tr
,^ ,As'. \"o...*
LOCK-UPVALVEEODY
VALVECAP
Inspectlor wear,scratches,
and scoring.
LOCK-UPTIMINGVAL
\uo.*"or".,,
SPRINGSPECIFICATIONS
Unit:mm (in)
Standard lNewl
No. Springs
Wire Dia. o.D. Fle Length No. of Coils
O Lockup shiftvalvespring 0.9(0.035) 7.6 (0.299) 73.1 t2.902), 32.0

( Lock-uptiming valvespring 0.9(0.035) 8 . 1( 0 . 3 1 9 ) 8 1 . 4( 3 . 2 0 5 ) 47.8
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14-201
Mainshaft
NOTE:
. Lubricateall partswith ATFduring reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Beforeinstallingthe O-rings.wrap the shaftsplineswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
. Installthe conicalspringwasherin the directionshown.
. Inspectconditionof the sealingrings.lf the sealingrings are worn, distorted,ordamaged,replacethem (seepage 14-
2041.
LOCKNUTIFLANGENUT)
19 x 1.25mm
78 N.m {8.O kgf.m,58 lbl.ftl CONICAL SPRINGWASHER
Replace.
Replace.
Left-hand threads
lST CIUTCH
ASSEMBI.Y
SNAP RING
o-Rtt{Gs
THRUST Replace.
THRUSTNEEDLE WASHEB
BARING THRUST WASHCR
4TH GEAR THRUST NEEOI
BEARIl{G
I{EEDLEBEARIIIG
MAINSI{AFT lST GEAR

Check splinesfor excessive BEARII{GS
wear ano damage. rST GEAR
Check bearingsurfacetor scoring, COLLAR
scratchesand excessivewear. TXBUST 1{EEDLE
BEARIl{G TnANSMtSSIOt{
4TH GEAR COLLAR
HOUSII{GBEARII{G
2ND/4TH CLUTCX
o-Brr{Gs
THRUSTWASHER,36.5 r 55 mm
Selective part
THRUSTNEEDLE
SEARING
2NO GEAR
SEALINGRltrlG, NEEDLEEEARING
29 mm
THRUST NEEDI-E
BEARING
Install the sealing ring
mating faces as shown
SET RING
NEEDLEEEARING
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14-202
Inspection
Clearance
Measurement 3. Tightenthe mainshaftlocknutto 29 N.m (3.0kgf.m,
22 tbf.ft).
1. Removethe mainshaftbearingfrom the transmis-
sion housing lsee page 14-227l.. The mainshaftlocknuthas left-handthreads.
2. Assemblethe mainshaftparts,but do not installthe

O-rings,
CONICALSPRINGWASHER
29 N.m (3.Okst.m, 22 lbt.frl
lST CLUTCHASSEMELY
THRUST WASHER Hold 2nd gear againstthe 2nd clutch,then measure

the clearancebetween2nd gear and 3rd gearwith a
1ST GEAB COLLAR
feelergauge. Take measurementsin at leastthree
TRAI{SMISSION places,and usethe averageas the actualclearance.
HOUSIf{G BEARING
SNAP RII{G
STANDARD:0.05- 0.13 mm (0.002- 0.005in)
THRUST WASI{ER
GEAR COLLAR 3RD GEAR 2'{D GEAR

2[{D/4TH CLUTCH
ASSEMALY
THRUST WASHER
.5r55mm
Selective part
THBUST IIEEDLE
EEARII{G
2ND GAR
EEARIt{G
FEELERGAUGC
TI{RUST NEEOLE
BEARII{G
THRUSTWASHER.
36.5 x 55 mm
MAII{SHAFT
(cont'd)
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14-203
Mainshaft SealingRings
Inspection(cont'dl Replacement
I t t h e c l e a r a n c ei s o u t o f s t a n d a r d ,r e m o v e t h e The sealingrings(35 mm and 29 mm) are syntheticresin
thrustwasherand measureits thickness. with chamferedends.Checkthe conditionof the sealing
rings,and replacethem only if they are worn, distorted,
or oamageo.
NOTE:Apply ATFto all partsduringassembly.
1. For a better fit, squeezethe sealing ring together

slightlybeforeinstallingthem.
Selectand install a new washer,then recheckthe

and makesure it is within standard.
clearance,
THRUSTWASHER36.5 x 55 mm
No. Part Number Thickness

1 9 0 4 4 1- P G 4 , 0 1 0 4 . 0 0m m ( 0 . 1 5 7
in)
2 90442-PG4-010 4 . 0 5m m ( 0 . 1 5 9
in)
90443-PG4-010 4 . 1 0m m { 0 . 1 6 1i n ) Installnew sealingrings on the mainshaft.
90444-PG4-010 4 . 1 5m m { 0 . 1 6 3i n )
After installingthe sealingrings, verify the follow-
90445-PG4-010 4 . 2 0m m ( 0 . ' 1 6i5n ) ing:
6 90446-PG4-010 4 . 2 5m m { 0 . 1 6 7i n )
. The sealingringsare fully seatedin the groove.
1 90447-PG4-010 4 . 3 0m m ( 0 . 1 6 9i n ) . The sealingringsare not twisted.
8 90448-PG4-010 4 . 3 5m m ( 0 . 1 7 1i n ) . T h e c h a m f e r e de n d s o f t h e s e a l i n g r i n g s a r e
properlyjoined.
I 90449-PG4-010 4 . 4 0m m ( 0 . 1 7 3i n )
10 90450-PG4-000 4 . 4 5m m ( 0 . 1 7 5i n l
SEALINGRING
Installthe sealingring
matingfacesas shown.
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14-204
Countershaft
NOTE:
. Lubricateall pans with ATF beforereassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement.
. Beforeinstallingthe O-rings,wrap the shaftspllneswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
. Installthe conicalspringwasherin the directionshown.
LOCKNUTIFLANGENUTI
23 x 1.25mm
103-0-103N.m CONICAL SPRING
RVERSEGEAR
t 1 0 . 5- 0 - 10.5 kgl.m, WASHER
7 5 . 9- 0 - 75.9 lbt.lr) Replace.
Replace.
Lelt.hand threads
NEEOLEBEARING
REVERSE
SELECTOR
REVERSE
SELECTOR
HUB
lST GEAR
COUNTERSHAFT 4TH GEAR
Check splinesfor excessive
wear and damage.
NEEDLEEEARING I{EEDLEBEARING
Check bearingsurfacefor scoring,
scratchesand excessivewear. OISTANCECOLLAR.
28 mm lST GEARCOLLAR
Selective part
2NO GEAR TRANSn SSTON

HOUSI G BEARING
3RD GEAR
NEEDLEBEARING
3RD GEARCOLLAR
THRUSTNEEOLEBEARING
SPLINEDWASHER
3RO CLUTCHASSMBLY
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14-205
Gountershaft
Disassembly/Reassembly
1. Removethe reverseselectorhub and countershaft 2. Assemblethe parts on the countershaftas shown
4th gear using a universaltwo-jaw lor three-jaw) below.
puller as shown. Placea shaft protector between
t h e p u l l e ra n d c o u n t e r s h a ftto p r e v e n td a m a g i n g NOTE;
the countershaft. . Lubricateall partswith ATF during reassembly.
. B e f o r e i n s t a l l i n gt h e O - r i n g s .w r a p t h e s h a f t
s p l i n e sw i t h t a p e t o p r e v e n td a m a g i n gt h e O -
rings.
{ C o m m e r c i a l l ya v a i l a b l e )
4TH GEAR
BEARI'{G
DISTANCECOLLAR, 28 mm
Selectiveoart
GEAR
REVERSE
SELECTORHUB
THRUST ]{EEOLAEARIIIG
SEARII{G
.TH GEAR
GEAR COLLAR
THRUST I{EEDLEEEARII{G
WASHER
3RO CLUTCH ASSEMBLY
O-RINGS
Replace.
14-206
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Inspection
3. Installthe reverseselectorhub on the countershaft ClearanceMeasurement
sub-assembly, and pressthe hub using the special
tool and a pressas shown. NOTE: Lubricateall partswith ATF duringassembly.
1. Removethe countershaftbearing from the trans-

missionhousinglsee page14-227).
2. Assemblethe countershaftparts using the special

tool and a pressas describedon this page. Do not
installthe O-ringsduring inspection.
RVERSSELECTOR
HUB
DRIVERto mm l.D.
07746- 0030100
GEAR
NEEDLEBEARING
DISTANCECOLLAR, 28 mm
REVERSE
SEI.ICTOR Selective part
HUB
2NO GEAR
THRUST NEEDLEBEARING
COUNTERSHAFT
SU&ASSEMBLY
GEAR
NEEOLEBEARING
GEAR COLIAR
THRUSTNEEDLEBEARING
WASHER
CLUTCHASSEMBLY
(cont'd)
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14-207
Countershaft
Inspection(cont'd)
3. I n s t a l lt h e c o u n t e r s h a fst u b - a s s e m b lpy a r t s ,t h e n 5. Measurethe clearancebetweenthe 2nd gear and
i n s t a l l t h ep a r kg e a ru s i n ga p r e s sa n da c o l l a r . the 28 mm distancecollarwith a feelergauge.
4. Tightenthe locknutto 29 N.m (3.0 kgf.m,22 lbf.ft). NOTE:Takemeasurementsin at leastthree places,

The countershaftlocknuthasleft-handthreads. and usethe averageas the actualclearance.
0.10- 0.18mm (0.004- 0.007in)

STANDARD:
LOCKNUT OISTANCECOLLAR,
Le{t-hand
threads 2NO GEAR 28 mm
CONICALSPRING
WASHER
PABKGEAR/ONE.WAY
CLUTCH/1STGEAR
ASSEMBLY
NEEDLEBEANING
lST GEARCOLLAR
TRANSMISSIONHOUSING
AEARING
REVERSEGEAR
COLLAR
FEELERGAUGE
6. lf the clearanceis out ot standard,removethe dis-
tancecollar,and measureits width.
7. Selectand installa new distancecollar,then recheck.

COUNTERSHAFT
SUB.ASSEMBLY DISTANCECOLLAR,28mm
No. Part Number widrh

1 90503-PCg-000 3 9 . 0 0m m ( ' 1 . 5 3i5n )
2 90504-PCg-000 0 m ( 1 . 5 3 9i n )
3 9 . ' 1m
? 90505-PCg-000 3 9 . 2 0m m { 1 . 5 4 3i n )
90507-PCg-000 3 9 . 3 0m m ( l . 5 4 7i n )
90508*PCg-000 3 9 . 0 5m m ( l . 5 3 7i n )
90509-PCg-000 3 9 . 1 5m m ( l . 5 4 1i n )
7 90510-PCg-000 3 9 . 2 5m m { 1 . 5 4 5i n )
8 90511-PCg-000 3 8 . 9 0m m { L 5 3 1i n )
9 90512-PCg-000 3 8 . 9 5m m ( 1 . 5 3 3i n )
8. After selectinga new distancecollar. recheckthe

clearanceand makesureit is within standard.
14-208
www.emanualpro.com
One-way Glutch
Disassembly/lnspection/Reassem
bly
1. Separatecountershaft1st gear from the park gear 3. Inspectthe oartsas follows;
by turningthe parkgear in the directionshown.
PARKGEAR
InspectIor wear
andsconng.
PARKGEAR
COUNTERSHAFT
lST GEAR ONE.WAYCLUTCH
Inspectfor damage
and taultymovement,
2. Removethe one-wayclutchby prying it up with the
tip of a screwdriver.
COUNTERSHAFT
IST GEAR ONE.WAYCLUTCH
Installin this direction.
lST GEAR
Inspectfor wear
and scortng.
4. After the parts are assembled, hold countershaft lst

gear. and turn the park gear in the direction shown
to be sure it turns freely. Also make sure the park
gear does not turn in the opposite direction.
ONE.WAYCLUTCH
lST GEAR
,ISTGEAR
COUNTERSHAFT
SCREWDRIVER
Sub-shaft
NOTE:
. Lubricateall partswith ATF beforereassembly.
. Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
. Beforeinstallingthe O-rings,wrap the shaftsplineswith tapeto preventdamagingthe O-rings.
TRAi{SMTSStONtl()UStNG
IST.HOLOCLUTCH
ASSEMBLY
6 x 1.0 mrr
12 1{.m
o,Rtl{GS
ll.2 ksl.m, 8.7 lbt.ftl Replace.
TI{RUST WASI{ER
SUB.SHAFT THFUST TEEOLC
Check splines tor excessive BEARI G
wear ano damage, I{EEDLE BARI G
Check bearing surlace for scoring,
scralches and excessive wear-
t{EEDLEBEARING
STOP
www.emanualpro.com
14-210
1. Removethe ATF guidecap by pushingthe sub-shaft
insidethe transmissionhousing.
R e m o v et h e 1 s t - h o l dc l u t c ha s s e m b l yb y p u l l i n g ,
then removingthe sub-shaft.
Installnew O-ringson the sub-shaft.
NOTE:Wrap the shaft splineswith tape to prevent

damagingthe O-rings.
P l a c et h e s u b - s h a f ti n t h e t r a n s m i s s i o nh o u s i n g ,
and installthe'lst-holdclutchassembly,
I n s t a l lt h e n e w A T F g u i d e c a p u s i n g t h e s p e c i a l
tools.Installit in the directionshown.
ATTACHMENT,
32x35mm
07746- 0010t00
www.emanualpro.com
14-211
Sub-shaftBearings
Replacement
NOTE:Lubricateall partswith ATF beforereassembly. 4. Installa new needle bearing in the housing using
the sOecialtools and a oressas shown.
1. E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s .t h e n
push the bearing out of the transmissionhousing
usingthe specialtools and a pressas shown.
c
I
32x35mm
077/46- qt10t(x,
ATTACHMENT, E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n
ai:lx 68 mm
insert the ball bearing part-way into the housing
07746 - 00105q)
using the specialtools and a pressas describedin
Removethe needlebearingstop. step 1. Installthe bearingwith the groove facing
outsidethe housing.
Removethe needlebearingfrom the transmission
housingusinga drift. Releasethe pliers,then push the bearingdown into
t h e h o u s i n gu n t i l t h e s n a p r i n g s n a p si n p l a c e
aroundit.
7. After installingthe ball bearingverifythe fottowing:
. The snap ring is seatedin the bearingand hous-

Ing grooves.
. The ring end gap is correct.
ENDGAP:0-7mm
l0 - 0.28 inl
SNAPRING
14-212
www.emanualpro.com
Glutch
lllustratedlndex
3RDCLUTCH
CLUTCHPISTON
RETURNSPRING
NETAINER CLUTCHPLATES
Standardthicknoss:
RING 2.00 mm 10.079inl
CLUTCHDISCS
Standardthickne$:
1.94mm (0 0?6 inl SNAPFING
lST CLUTCH
CLUTCHDISCS
Standardthicknca3:
1.9amm 10.076 inl
SNAPRING CLUTCHDRUM
CHECKVALVE
(cont'd)
Clutch
lllustratedIndex(cont'dl
2ND/4THCLUTCH
CLUTCHPLATES
Stendardthickness:
OISCSPRING 2.00
mm {0.079in)
[* I CLUTCH
I 2ND CLUTCH
CLUTCHPISTON
sPl
Repl6ce.
I
uoavEnr"
CLUTCHPLATES
Standardthicknesai
2.00 mm {0.079inl
SNAPRING
14-214
www.emanualpro.com
lST-HOLDCLUTCH
thickness:
RETURNSPRING
cLUTCHPISTON
O.RINGS
/
Clutch
Disassembly
l. Removethe snap ring, then removethe clutch end 3. I n s t a ltlh e s p e c i atlo o l sa s s h o w n .
plate,clutchdiscsand plates.
CLUTCHSPNING
SCREWORIVER COMPRESSOR
ATTACHMENT
07LAE- PX40100
SNAP RING
-'=*.=:--
'..p
2. Removethe discspring.
CLUTCHSPRING
COMPRESSOR
1ST,2ND, 4TH lST-HOLDCLUTCH: ATTACHMENT
07LAE- PX4010Oor
DISCSPRING 07HAE- PL50100
CLUTCH
COMPRESSOR
AOLTASSEMBLY
07GAE- FGao2OO
or
OTGAE. PG4O2OA
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40t00
CLUTCHDBUM
3RDCLUTCH:
DISCSPRING
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX4010Oor
07HAE- PL50100
CLUTCHSPRING
COMPRESSOR
BOLTASSEMBLY
07GAE- PG0200 or
OTGAE- PG4O2OA
14-216
www.emanualpro.com
CAUTION: lf either end ot the specialtool issetover an 5. Removethe snap ring, Then removethe specialtools,
area of the spring retainer which is unsupported by the springretainerand returnspring.
return spring, the retainer may be damaged. B sure the
specialtool is adiusted to have lull contact with the
spring retainer.
Do not s6t h6re. SPRIlIG RETAINER
Wrap a shop rag aroundthe clutchdrum, and apply

air pressureto the ATF passageto removethe pis-
ton.
Placea finger tip on the other end while applying
arr pressure.
OSHA.APPROVED
SPRINGRETAINER
4. Compressthe returnspring.
Glutch
Reassembly
NOTE: 3. Installth pistonin the clutchdrum. Apply pressure
. Clean all parts thoroughly in solvent or carburetor and rotate it to ensure proper seating, Lubricatethe
cleaner,and dry them with compressedair. pistonO-ringwith ATF betoreinsta ing the piston.
. Blow out all passages.
o Lubricateall parts with ATF before reassembly. NOTE:Oo not pinchthe O-ringby installingthe pis_
ton with too muchforce.
1. Inspectthe checkvalve;if it's loose,replacethe pis_
ton.
CLUTCH DRUM
CHECK VALVE
4. Installthe return spring, and spring retainer,then

2. Installnew O-ringson the clutchpiston. positionthe snap ring on the retainer.
SI{AP RING
SPAI'{G RETAIIIER
REIURN SPRING
CLUTCH DRUM
PtsTot{
14-218
www.emanualpro.com
5. Installthe specialtoolsas shown CAUTION:It sither end of the spscial tool is sot
over an area of the spring retainl which is unsup'
ported by the return spring, the retainer may be
CLUTCHSPRING damaged. Be sure the specialtool is adiusted to
COMPRESSOR have full contaqt with th spring ratainel.
ATTACHMENT
07LAE- PX40100
Set here.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT Do notsethere.
07LAE- PX40100or
CLUTCHSPRING O?HAE- PL5O1OO
COMPRESSOR
BOLTASSEMALY
07GAE- PG{0200or
OTGAE- PG|(IMA TOOL
SPECIAL
CLUTCHSPRING
COMPRESSOR
SPRINGRETAINER
ATTACHMENT
07LAE- PXaOI0o 6. Compressthe returnspring.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX4010O
ol
07HAE- PL50100
CLUTCHSPRING
COMPBESSOR
AOL| ASSEMALY
07GAE- PG/9t200ot
OTGAE- PG/(,20A
(cont'd)
Clutch
(cont'd)
Reassembly
7. Installthe
s n a pr i n g . 1 0 . Soakthe clutchdiscsthoroughlyin ATF for a mini_
m u m o f 3 0 m i n u t e s . B e f o r ei n s t a l l i n gt h e p l a t e s
and discs,make sure the insideof the clutchdrum
is free of din or otherforeignmatter
' t 1 . Starting
with a clutch plate, alternatelvinstall the
clutch platesand discs.Installthe clutch end plate
with its flat sidetowardthe disc.
CLUTCHEI{D PI.ATE
Installin this directior.
S AP RIIG
8. Removethe specialtools.
9, Installthe discspring in the directionshown.
1ST,2ND, 4TH, lST-HOLDCLUTCH:

otsc sPfitl{c
CLUTCH CLUTCHEI{D PLATE
12. Installthe snap ring.
SCREWDRIVER
3RD CLUTCH:
Dlsc sPRrrtc
CIUTCH ORUM
14-220
www.emanualpro.com
13. Measurethe clearancebetweenthe clutchend plate lST CLUTCHEND PLATES
and top disc with a dial indicator.Zerothe dial indi-
Mark Thicknass
catorwith the clutchend platelowered,and lift it up 'I
2 2 5 5 1 P 5 6- N 0 0 2 . 1m m ( 0 . 0 8i3n )
to the snap ring. The distancethat the clutch end
2 22552-P56-N00 2.2mm (0.087 in)
plate movesis the clearancebetweenit and the top
3 22553 - P56 N00 2 3 m m ( 0 . 0 9 1i n )
dtsc.
22554-P56-NOo 2 . 4 m m ( 0 . 0 9 4i n )
5 2 2 5 5 5 P 5 6- N 0 0 2 . 5 m m { 0 . 0 9 8i n )
NOTE:Takemeasurementsin at leastthree places'
6 22556 P56- N00 2 6 m m ( 0 . 1 0 2i n )
and usethe averageas the actualclearance.
7 22557 - P56 N00 2 . 7 m m ( 0 . 1 0 6i n )
8 2 2 5 5 8- P 5 6 N 0 0 2 . 8m m ( 0 . 1 1 0i n )
Clutch End Ptate-to-TopDisc Clearance:
I 2 2 5 5 9- P 5 6 N 0 0 2 . 9r n m ( 0 . 1 1 4i n )
ServiceLimit 10 22s60- P56 N00 3 . 0m m ( 0 . 1 1 8i n )

Clutch
'l st 0.65- 0.85mm (0.026- 0.033in)
2ND and 4TH CLUTCHEND PLATES
2nd 0.40- 0.60mm (0.016- 0.024in)
3rd 0.40- 0.60mm (0.016- 0.024in) Mark Parl Number Thickness
4th 0.40- 0.60mm (0.016- 0.024in) 6 22556-P56-N00 2 . 6m m ( 0 . 1 0i2n )
lst-hold 0.50- 0.80mm (0.020- 0.031in) 1 22557 P56- N00 2 . 7m m ( 0 . 1 0i6n )
8 22558-P56-N00 2 . 8m m ( 0 . 1 1i0n )
22559-P56-N00 2 . 9m m ( 0 . 1 1 4
in)
10 2 2 5 6 0- P 5 6 N 0 0 3 . 0m m ( 0 . 1 1 8i n )
'11 22561 PDM- 000 3 . 1m m ( 0 . 1 2 2i n l
12 22562- PDM- 000 3 . 2m m { 0 . 1 2i6n )
13 22563 PDM- 000 3 . 3m m ( 0 . 1 3i 0n )
22564 PDM- 000 3 . 4 m m ( 0 . 1 3 4i n )
2 2 5 6 5 P D M- 0 0 0 3 . 5m m ( 0 . 1 3i8n )
22566 PDM- 000 3 . 6m m 1 0 . 1 4i n2 )
17 22567-PDM-000 3 . 7m m ( 0 . 1 4 6
in)
SNAPRING 3RDCLUTCHEND PLATES
Mark Part Number Thiclness

I 2 2 5 5 8 P 5 6- N 0 0 2 . 8m m ( 0 . 1 1 0i n l
9 2 2 5 5 9 P 5 6- N 0 0 2 . 9m m ( 0 . 1 1 4i n )
10 22560 P56- N00 3 . 0m m ( 0 . 1 1i 8n )
11 22561 PD[4 - 000 3 . 1m m ( 0 . 1 2i2n )
12 - PDM 000
22562 3.2mm (0.126 in)
t3 22563-PDM-000 3 . 3m m ( 0 . 1 3i0n )
'14 3 . 4m m ( 0 . 1 3 4i n )
22564-PDN4-000
15 22565-PD[,l-000 3 . 5 m m ( 0 . 1 3 8i n )
22566 PDM- 000 3 . 6m m ( 0 . 1 4 2i n )
't1 - PoM- 000
22567 3 . 7m m { 0 . 1 4 6i n )
1 4 . lf the clearanceis not within the servicelimits,select

lST-HOLDCLUTCHEND PLATES
a new clutchend platefrom the followingtable
Thickness
NOTE: lf the thickestclutch end plate is installed, 2255r-PS5-003 2 . 1 m m ( 0 . 0 8 3i n )
but the clearanceis still over the standard,replace 2 2 5 5 2- P S 5 - 0 0 3 2 . 2 m m { 0 . 0 8 7i n )
the clutchdiscsand clutchplates. 3 22553 PS5- 003 2.3mm (0.091
in)
MARK 2 2 5 5 4 , P S 5- 0 0 3 2 . 4 m m ( 0 . 0 9 4i n )
rnictness 2 2 5 5 5 P S 5- 0 0 3 2 . 5 m m ( 0 . 0 9 8i n )
--l----T
-
I
- :
I
6
7
2 2 5 5 6 P S 5- 0 0 3
22557- PSs 003
2 . 6m m { 0 . 1 0 2i n )
2 . 7m m ( 0 . 1 0 6i n )
CLUTCHEND PLATE
Differential
lllustratedIndex
'lWD: 2WDl
SETRING,80 mm SETnlNG,80 mm
part
Selective Sel6ctive part
A
10x 1.0mm 1 0x 1 . 0m m
103N.m (10.5kgt.m, 103N.m {10.5kg[.m,
?5.9 tbtftl 75.9 tbt.ftl
Left-handthreads
FINALORIVENGEAR
,U
lnspectfor excessivewear,
Installin this direction.
,gBc FINALORIVENGEAR
Inspectfor excessivewear,
Installin thls direction.
BALLBEARING BALLBEABING
Inspectfor rough Inspectfor rough
DIFFERENTIAI.
CARRIER
DIFFERENTIAI. Inspectfor cracks.
CARRIER
lnspectfor cracks.
ROLLER,5
x 10 mm
TRANSFERSHAET
DNlvE GEAR SPEEDOMETER
Inspectfor excessive DRIVEGEAR
Installin this
direction.
SPEEDOMETER
DRIVEGEAR
Installin this
direction.
SNAPRING
Installin this
direction.
BALLBEARING
SNAPRING
Installin this
direction.
BALLBEARING
Inspectfor rough movement,
14 -2 2 2
www.emanualpro.com
BacklashInspection BearingReplacement
1. Placethe differentialassemblyon V-blocks. NOTE:Checkbearingsfor wear and rough movement.
lf bearingsare OK, removalis not required.
lnstallthe driveshaftand intermediateshaft on the
differentialassemblY. 1. Removethe bearingsusinga bearingpuller.
Checkthe backlashof both piniongears. PULLER

BEARING
(Commercially
available)
STANDARD:0.05- 0.15 mm (0.002- 0.006in)
DIALINDICATOR
l n s t a l l n e w b e a r i n g s u s i n g t h e s P e c i a lt o o l
ASSEMBLY
OIFFEBENNAL snown.
PRESS
It the backlashis out of standard, replacethe difter-
entialcarrier.
Differential
DifferentialCarrierReplacement
NOTE:The illustrationshows the 4WD automatictrans- Installthe final drivengearon a new differentialcar-
missiondifferential;
the 2WDdifferentialis similar. rier with its chamferedside facing the carrier and
the transferdrive gear (4WD),
1. Removethe snap ring from the differentialcarrier.
Tightenthe boltsto the specifiedtorque.
N O T E : T h e 2 W D d i f f e r e n t i a tb o l t h a s l e f t - h a n d
threads,
1 0x 1 . 0m m
103N.m 110.5 kd.m,
7s.9 rbr.ft)
FINALDRIVENGEAR
Removethe 5 x 15 mm roller (4WD)or 5 x 10 mm

roller(2WDland the speedometerdrive gear.
TRANSFERSHAFT
SPEEDOMETER
DRIVEGEAR RoI I FP
5 x 15 mm (/tWD) {4WDl
5 x 10mm {2WDl
Installthe speedometerdrive gear with its cham-
fered side facingthe carrier.Align the cutout on the
bore of the speedometerdrive gear with the 5 x 15
mm roller(4WD)or 5 x 10 mm roller(2WD).
7. A l i g n t h e h o o k e de n d o f t h e s n a p r i n g w i t h t h e
spring pin in the pinion shaft.then installthe snao
ring in the differentialcarriergroove
SNAP RING
Hookedend Installin this direction.
PINIONSHAFT
Removethe bolts securingthe final drivengear and
the transfershaft drive gear (4WD),then replacethe
differentialcarrier. SPRINGPIN GROOVE
14-224
www.emanualpro.com
Oil SealReplacement
1. Removethe oil sealfrom the transmissionhousing. 3. lnstallthe oil seal in the transmissionhousingusing
the specialtools as shown.
DRIVER
077a9- 0010000
OIL SEAL
Replace. ATTACHMEMT
079r?- slx[ax)
R e m o v et h e o i l s e a l f r o m t h e t o r q u e c o n v e r t e r 4. Installthe oil seal in the torque converterhousing

housing. usingthe specialtoolsas shown.
-.].
OIL SEAL
Replace. TOROUECONVERTER
HOUSING
Differential
Side ClearanceInspection
1. Instsllthe 80 mm set ring in the transmissionhous- 4. Tap on the transmissionhousingside of the diffsr
Ing, entialassemblywith the specialtool to seatthe dif-
ferentialassemblv.
DBIVERilo m.n LO.

0t746 - 0030100
SET RING,80 mrn
Measurethe clearancsbetweenthe 80 mm set ring

and the bearingouter racewith a feelergauge,
Installthe differentialassemblyin the torque con- STANDARD:0 - 0.15 mm (0 - 0.006inl

verterhousingusingthe specialtool.
FEEI..ER
GAUGE
lf the clearanceis out of standard,removerne set
ring and measurs its thickness.
7. Selectand instslla new 80 mm set ring.
SETRING,80 mm
Part Numbor Thicknoss

90414-689-000 2.50mm (0.098in)
90415-689-000 2.60mm (0.102in)
Installthe transmissionhousingon the torque con- 90416-689-000 2.70mm (0.106inl
verter housing,and tighten the transmissionhous- 90417-689-000 2 . 8 0m m ( 0 . 1 1 0in)
ing mountingbolts (seepages14-252and t4-253). 90418-689-000 2 . 9 0m m ( 0 . 1 1 4i n )
90419-PH8-000 3.00mm (0.t'18inl
TOROUE:4a N.m l/r.5 kgf.m, 33 tbt.ftl
Recheckthe clearance,and make sure it is within
standard.
14-226
www.emanualpro.com
HousingBearings
Transmission
Mainshaft/CountershaftBearingsReplacement
1. Expandeach snap ring with snap ring pliers,then Expandeach snap ring with snap ring pliers,then
push the bearingsout of the transmissionhousing coat the new bearingswith ATF and insert them
usingthe specialtools and a pressas shown. part-way into the housing using the specialtools
and a pressas shown. Installthe bearingswith the
Do not removethe snap rings unlessit's necessary groovefacingoutsidethe housing.
to cleanthe groovesin the housing.
R e l e a s et h e p l i e r s ,t h e n p u s h t h e b e a r i n g sd o w n
i n t o t h e h o u s i n gu n t i l t h e r i n g s s n a p i n p l a c e
a r o u n dt h e m .
077/49- 0010000
ATTACHMENT
MAINSHAFTBEARING . Mainshaft BearingInstallation:
ATTACHMENT,72 x 75 mm
07746- 0010600
. CountershaftBearing Instsllation:
DFIVER
077a9- 001(xx)o 077'16- 0010500
ATTACHMENT 4. After installingthe bearings,verifythe following:
. T h e s n a p r i n g s a r e s e a t e di n t h e b e a r i n ga n d
housrnggrooves.
. The snap ringsdo not bind.
. The ring end gapsare correct,
ENDGAP:0-7rnm
l0 - 0.28in)
ATTACHMENT
. Mainshaft Bearing Romoval:
077/16- 0010600
. CountqrshaftBearing Removal: SNAPRING
07746- 0010500
TransmissionHousingBearings
Sub-shaftBearingReplacement
1. Expand the snap ring with snap ring pliers, then E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n
push the bearingout of the transmissionhousing coat the new bearingwith ATF and insert it part-
usingthe specialtools and a pressas shown. way into the housingusing the specialtools and a
pressas shown. lnstallthe bearingwith the groove
Do not removethe snap ring unlessit,s necessary facingoutsidethe housing.
to cleanthe groovein the housing.
Releasethe pliers,then push the bearingdown into
the housinguntilthe ring snapsin placearoundit.
DRIVER
07743- 0010mo
ATTACHMENT,
{i:l x 68 mm
07746- 0010500
GROOVE
After installingthe bearing,verifythe following:

ATTACHMEI{T, SNAP RI]TG
5:l x 68 mm
. The snap rjng is seatedin the bearingand hous_
07r{5 - @10500 ing grooves.
. The snap ring does not bind.
. The ring end gap is correct,
DRIVER ENDGAP:0-7mm
07749- tDl(xx)o
ATTACHMENT,
6:l x 68 mm
077a6- (X,r0500
SNAPRING
14-228
www.emanualpro.com
TorqueGonverterHousingBearings
MainshaftBearing/OilSeal Replacement
1. t e a r i n ga n d o i l s e a l u s i n g
R e m o v et h e m a i n s h a f b 3. Installa new oil sealflush with the torqueconverter
the soecialtool. housing.
07749- 0010000
SLIDEHAMMER,
3/8" - 16
(Commercially
available)
ATTACHMENT,
07?46- 0010m0
ADJUSTABLEEEARING
PULLER,25 - 40 mm
07736- A010008or
07736- A01000A
Installa new mainshaftbearinguntil it bottoms in

the torqueconverterhousing.
ATTACHMENT,
62x68mm
07746- 0010500
www.emanualpro.com
14-229
TorqueGonverterHousing
Bearings GontrolLeverAssembly
CountershaftBearingReplacement Replacement
1. Removethe countershaftbearingusing the special Checkthe conditionand movementof the control lever
tool. assembly,lf the control lever assemblybinds or does
not move smoothly.replaceit.
1. Removethe 6 x 1.0mm bolt and lockwasher.

SLIOEHAMMER,
3la" -16 2. Removethe changeshafttrom the torqueconverter
(Commercially
available) housing.
3. Removethe controlleverassemblyfrom the control

shaft.
4. Installthe new controlleverassemblyin the reverse

order of disassembly,until it bottoms in the torque
converterhousing.
ADJUSTABLE BEARING
PULLER,25- 40mm
07736- A0100OBol COUNTERSHAFT
07736- A01m0A BEARING
Installthe ATF guide ptate.
I n s t a l la n e w c o u n t e r s h a fbt e a r i n g i n t h e t o r q u e
converterhousing.
DRIVER
077i19- 001m00
LOCKWASHER
Replace.
ATF GUIDEPLATE
14-230
www.emanualpro.com
Reverseldler Gear ParkStop
lnstallation ustment
Inspection/Adi
't. Setthe parkleverin the E position.
1. lnstallthe reverseidler gear'
Measurethe distancebetweenthe park pawl shaft

and the parkleverrollerpin as shown.
72.9- 73.9mm {2.87- 2.91in)

STANDARD:
',.A\
Measuring
\t/
PARKSTOP
lnstallthereverseidler gear shaftholderand needle
PARKPAWLSHAFT
bearinginto the transmissionhousing,then tighten
the bolts.
6 x 1.0 mm lf the measurementis out of standard,selectand

12 N.ft ll.2 kgl']n, i n s t a l lt h e a p p r o p r i a t ep a r k s t o p f r o m t h e t a b l e
a.7 rbl.frl below.
PARKSTOP
PARKSTOP
Mark Part Number Lt L2
1 2 4 5 3 7 - P A g - 0 0 3 1 1 . 0 0m m 11.00mm
(0.433in) (0.433in)
2 4 5 3 8 - P A g - 0 0 3 1 0 . 8 0m m 10.65mm
(0.425in) (0.419
in)
2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m 1 0 . 3m
0m
(0.417 in) (0.406 in)
After replacingthe park stop. make sure the dis-

tanceis within standard.
TransferAssembly
lllustrated Index
www.emanualpro.com
O TRANSFERHOUSING
O o-RINGReplace.
O TRANSFERHOUSINGROLLERBEARING
@ TRANSFERSHAFT
O TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDROLLERBEARING
O TRANSFERSHAFTCOLLAR
@ THRUSTSHIM,25 mm Selectivepart
) TRANSFERDRtvE GEAR(HYPoIDGEAR}
@ coNtcAL SPRtNGWASHERReptace,
@ TRANSFER SHAFTLOCKNUT,22x 1.25mm Left-handrhreads,replace.
(D TAPEREDROLLEREEARING
@ TAPEREDROLLEREEARINGOUTERRACE
(} THRUSTSHIM,68 mm Selectivepart
@ O-RINGReplace.
@ TRANSFER coVER A
(} TRANSFERCOVERB
@ o-RINGReplace.
(9 TRANSFERDRIVENGEARSHAFT(HYPOIDGEAR)
@ THRUSTSHIM,35 mm Selectivepart
@ TAPEREDROLLERBEARING
@ TRANSFER SPACERReptace.
@ TAPEREDRoLLERBEARTNG OUTERRACE
@ TAPEREDROLLERBEARINGOUTERRACE
@ TAPEREDBOLLERBEARTNG
@ olL SEALReplace.
@ COMPANION FLANGE
@ o-RINGReplace.
@ BACK-UPRING
@ coNtcAL SPRtNGWASHERReptace.
@ TRANSFER DRIVENGEARSHAFTLOCKNUT,22x 1.25mm Replace.
TOROUESPECIFICATIONS
Boh/Nut No. Torque Value Size Remarks

6A 1 2 N ' m ( 1 . 2k g f . m , 8 . 7l b f . f t ) 6x1.0mm
8C 24 N.m (2.4kgf.m,17 lbnft) 8 x 1 . 2 5m m
22L 1 1 8N . m( 1 2 . 0k g i m , 8 7 I b i f t ) 22 x 'l.25mm Transfershaft locknut:
Left handthreads
22H 132 216 N.m (13.5 22.0kgf.m, 2 2 x 1 . 2 5m m Transferdriven gear shaft locknut
98 - 159lbift) Tighteningtorque:dependingon
Total StartingTorquevalue
www.emanualpro.com
14-233
TransferAssembly
Inspection
N O T E : T o p r e v e n td a m a g et o t h e t r a n s f e rh o u s i n g , TransferGear (Hypoid gear) Tooth Contact Inspection
always use soft jaws or equivalentmaterialsbetween
the transferhousingand the vise. 5, Removetransfercover B, then apply PrussianBlue
to both sides of the transfergear teeth lightly and
Trsnsfer Gear (Hypoid gear) Backl8shMasuremnt
1 . S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s
snown.
2. Measurethe transfergear backlash.
STANDARD:0.06 - 0.16 mm {0.02- 0.06 in)
DIALINDICATOR
TRANSFERDRIVEGAR
6. Rotatethe companionflangein both directionsuntil

the transfergear rotatesone full turn in both direc-
COMPANIONFLANGE tions.
7. Checkthe transfergear tooth contact pattern.The

Total Starting Torque Meagurgmnt pattern should be centered on the gear tseth as
snown.
3, Rotatethe companionflange severaltimes to seat
the taperedrollerbearing.
4. M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o nf l a n g e
side)usinga torquewrenchas shown,
STANDARD:
2.68- 3.,17N.m
(27.3- 35.,1kgf.cm,23.7- 30.7 lbf.inl
TRANSFER
SHAFT
8. lf the statrting torque measurementor the tooth

contact pattern are not correct, disassemblethe
transferassembly,replaceworn or damagedparts,
and reassembleit.
14-234
www.emanualpro.com
Disassembly
1. Removethe transfercoversA and B. P u t a 1 4 m m A l l e nw r e n c hi n t h e g e a r s i d e o f t h e
transfer shaft, then secure the Allen wrench in a
benchvise.
Removethe transfershaft locknut and the conical

spring washer.The transfershaft locknut has left
handthreads.
1a mm ALLENWRENCH
5. Removethe transfer shaft, transfer drive gear, 25

mm thrust shim, transfershaft collar,and tapered
rollerbearingfrom the transferhousing.
TRANSFERSHAFT
2. Cutthe locktabs of the locknutusinoa chisel.
THRUSTSHIM,
25 mrn
LOCKTAB Selectivepart
CONICALSPRING
WASHER
Replace.
(cont'd)
www.emanualpro.com
14-235
TransferAssembly
Disassembly(cont'd)
Securethe transfer housing in a bench vise with 9. Removethe transferdriven gear shaft,then remove
soft iaws. To preventdamageto the transferhous- the transfer spacer from the transfer driven gear
ing, always use soft jaws or equivalentmaterials shaft.
betweenthe transferhousingand the vise.
7. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e ,
then loosenthe transferdrivengearshaft locknut. TRANSFER
DRIVEN
GEARSHAFT
COMPANION
FLANGE
HOI.DER
07RAB- TB4lll0A or
OTRAB- TB&TOB
HOLDER HAITDI..E
07JAB_ (x)1020a
Removethe transferdrivengear shaft locknut,coni- 1 0 . Removethe oil seal and the taperedroller bearing
cal spring washer, back-upring, O-ring.and com- from the transferhousing.
panionflange.
OILSEAL
Feplace-
TAPEREOROLLER
BEARING
O.RING
Replace.
BACK-UP
RING
CONICAL
SPRINGWASHEN
Replace.
TRANSFERHOUSING
GEARSHAFTLOCKNUT
Replace.
14-236
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TransferDriveGearBearing TransferDrivenGearShaft
Replacement BearingReplacement
NOTE:Coatall partswith ATFduring reassembly. NOTE: Coat all parts with ATF during reassembly.
1. Removethe taperedrollerbearingfrom the transfer 1. Removethe taperedrollerbearingfrom the transfer

drive gear usingthe specialtools and a press. drivengearshaft usinga pressand a collar.
BANf{GSEPARATO
0 - 1112'
(Commercially
available) (Comm6rcially
availablel
Installthe new taperedroller bearingin the transfer 2. Installthe 35 mm thrust shim on the transferdriven
drivegear usingthe specialtoolsand a press. gear shaft,
3, Installthe new taperedrollerbearingon the transfer

d r i v e n g e a r s h a f t u s i n g t h e s p e c i a lt o o l s a n d a
press.
PNESS DRIVERiO mm l.D.

0t7a5 - 00:I)100
I
ATTACHMENT,
n
l()x50mm
07LAD- PWSo6o1
GEAR
ru
ATTACHMENT.
35 mm l.D.
0t715 - 0030400
www.emanualpro.com
14-237
TransferAssembly
TransferHousingRollerBearing TransferCoverA BearingOuter
Replacement RaceReplacement
NOTE;Coatall partswith ATF du.ing reassembly. NOTE:Coatall partswith ATF during reassembly.
1. Removethe roller bearingfrom the transferhous 1. Removethe taperedroller bearingouter racefrom

Ing. t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e r t o a l m o s t
212"F llOO"Clusing a heat gun. Do not heat the
coverover 212"F(100"C).
Installthe 68 mm thrustshim in transfercoverA.
Installthe new roller bearingusingthe specialtools Installthe tapered roller bearing outer race using
and a press. the specialtools and a p.ess.
ATTACHMENT,
62x68mm
07746- 0010500
TRANSFERHOUSING
14-238
www.emanualpro.com
TransferHousingBearingOuterRaceReplacement
NOTE: Coat all parts with ATF during reassembly. Bearing Outer Rac6Locations
and SpecialTool Applications
1. Removethe taperedroller bearingouter racefrom
the transferhousing.
TRANSTER HOUSING
vi.w
Sacttonal ATTACHMENT,
62x68mm
077a5- @105dt
ATTACHI'E'{T,
{i:l x 6t mm
07746 - rDl05rr0
TRANSFERHOUSING ATTACHMENT,
52x55mm
07t46 - dtroa{x,
Install th new tapered roller bearing outer race

usingthe specialtoolsand a press.
DRIVER
077$ - 0010(ro0
TransferAssembly
Reassembly
NOTE: EXAMPLE:
. While reassembling the transferassembly:
. Checkand adjustthe transfergeartooth contact. C: EXISTING35 mm X: REPLACEMENT 35 mm
. Measureand adjustthe transfergear backlash. THRUSTSHIM THRUSTSHIM
. Checkand adjustthe taperedroller bearingstan- Thickness:
C=1.05mm Thickness:X=??mm
ing torque.
. Coatall pans with ATFduring reassembly.
. R e p l a c et h e t a p e r e dr o l l e rb e a r i n ga n d t h e b e a r i n g
outer raceas a set if eitherpart is replaced.
. Replacethe transferdrive gear and the transferdri- Number: A=+2 Numbe.: B=-'l
ven gearshaftas a set if eitherpart is replaced.
Outline of Assembly
1 . Selectthe 35 mm thrusi shim.

Psrtorm this procedute if the transter driven gar
shaft or the tapered roller bearing on the transfer Ar EXISTINGTRANSFER B: REPLACEMENTTRANSFER
driven gear shaft is replaced. DRIVENGEARSHAFT DRIVENGEARSHAFT
"x = A - B . c-
2. Prea$emble the parts to check and adiust transtel 100 100
gear backlashand transfer gear tooth contact. 2 - 1
'-
100 100
3 . Disassemblethe parts, then assemble the transler = 0.02+ 0.0'l+ 1.05
driven gsar shaft and its related pans. =1.08{mm)
4. Measure and adjust the starting torque oI the S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s so f l 0 8 m m

transfer driven gear shaft tapered roller bearing. (0.043in). lf the taperedroller bearingon the transfer
drivengear shaftis replaced.
5. Assemblethe transfer shaft and its related parts.
M e a s u r et h e t h i c k n e s so f t h e r e p l a c e m e nbt e a r i n g
6. Measureand adiust the total starting torque. and the existingbearing,and calculatethe difference
of the bearjngthickness.Adjust the thicknessof the
35 mm Thrust Shim Selection existing35 mm thrust shim by the amount of differ-
ence in bearingthickness,and selectthe replacement
L Selectthe 35 mm thrust shim if the transferdriven 3 5 m m t h r u s ts h i m .
gearshaftor the taperedrollerbearingon the trans-
fer drivengearshaft is replaced. THRUSTSHIM,35 mm
Calculate t h e t h i c k n e s so f t h e 3 5 m m t h r u s t s h i m Shim No. Part Number Thickness

usingthe formula below. 41361- PS3- 000 0 . 7 2m m ( 0 . 0 2i8n )
41362-PS3-000 0.75 mm {0.030in}
F o R M U L A :-+* - + c = x c 41363-PS3-000 0.78 mm (0.03'1in)
D 41364-PS3-000 0.81 mm (0.032in)
A: Numberon the existingtransferdrivengear shaft
41365-PS3-000 0.84mm (0.033an)
B; Numberon the replacementtransferdriven gear
F 41366-PS3-000 0.87 mm (0.034in)
shaft
C: Thicknessofthe existing35 mm thrustshim 4 1 3 6 7 - P S 3 - 0 0 0 0.90 mm (0.035in)
X : T h i c k n e s sn e e d e df o r t h e r e p l a c e m e n3t 5 m m H 4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in)
t h r u s ts h i m 41369-PS3-000 0.96mm 10.038
in)
41370-PS3-000 0.99 mm (0.039in)
N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n o e a r K 4 r371- PS3- 000 1 . 0 2m m ( 0 . 0 4 0i n
shaftis shown in 'll100mm. 41372-PS3-000 1 . 0 5m m ( 0 . 0 4 1i n
M 41373-PS3-000 1.08mm (0.043in
N 41374-PS3-000 '1.11 m m 1 0 . 0 4 i4n
14-240
www.emanualpro.com
Transfer Gear BscklashInspectionand TransferGear 5. Installthe transferdriven gear shaft in the transfer
Tooth Contact Inspection housing.Do not install the transfer spaceron the
transferdrivengearshaft in this step.
2. Installthe 35 mm thrust shim on the transferdriven
g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g
usingthe specialtools and a press. TRANSFER
DRIVER{0 mm LD.
- 0030100
077146
6. Installthe companionflange,conicalspringwasher,
TRANSFER
DRTVEN ;;. 745- 0O304O0
GEARSHAFT u, and locknut on the transfer driven gear shaft. Do
not install the O-ring and the back-upring on the
transfergear shaftin this step.
Placethe taperedrollerbearingon the bearingouter
race of the companionflange side of the transfer
housrng. TRANSFERHOUSING
I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g
usingthe specialtools.
OIL SEALDRIVER
ATTACHMENT
07JAD- PH80101
COMPANION
FLANGE
{cont'd)
TransferAssembly
(cont'd)
Reassembly
7. Securethe transfer housing in a bench vise with 9. I n s t a l lt h e t r a n s f e rs h a f t i n t h e t r a n s f e rh o u s i n g ,
soft jaws, then installthe specialtool on the com- then installthe taperedrollerbearing,transfershaft
panion flange. To preventdamageto the transfer collar.25mm thrust shim, transferdrive gear,coni-
housing,alwaysuse soft jaws or equivalentmateri- cal springwasher,and locknuton the transfershaft.
als betweenthe transferhousingand the vise.
NOTE:
Tighten the locknut while measuringthe starting . Coat the threads of the locknut. and the shaft
'1.39
torque so the startingtorque is within 0.98- with ATF beforeinstallingthe locknut.
-
N.m (10.0- 14.2kgf.cm,8.68 12.3lbnin). . Do not stakethe locknutin this step.
NOTE:
Coat the threads of the locknut, and the shaft
with ATF beforeinstallingthe locknut.
Do not stakethe locknutin this step.
STARTINGTOROUE:
0.98- 1.39N.m
{10.0- 14.2kgrf.cm,8.68- 12.3lbf'inl
COMPANION
FLANGE TRANSFER
HOLDER
THRUSTSXIM,
25 mm
Selectivepan
TRANSFERDRIVE
GEAR
CONICALSPRING
WASHER
Replace.
07JAB- @1020A
14-242
www.emanualpro.com
1 0 . Put a 14 mm Allen wrench in the gear side of the 1 3 . Rotatethe companionflange severaltimes to seat
transfer shaft, then secure the Allen wrench in a the taperedrollerbearing.
benchvise.
1 4 . Set a dial indicatoron the companionflange,then
1 1 . Tightenthe transfershaftlocknut. measurethe transfergear backlash.
NOTE: 0.06- 0.16mm {0.02- 0.06inl

STANDARD:
. The transfershaftlocknuthas left-handthreads. DIAL INOICATOR
. Do not stakethe locknutin this step.
TOROUE:118 N'm 112.0kgf.m, 87 lbf.ftl
TOROUEWRENCH
FLANGE
COMPANION
1 5 . l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d .
removethe transfershaft locknutand replacethe 25
m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m
thrust shim. then recheckthe measurement. Do not
use more than two 25 mm thrust shims to adiust
the transfergear backlash.
THRUSTSHIM,25 mm
Shim No. Part Numbor Thickness

1 2 . Temporarilyinstallthe transfercoverA without t h e I 2 9 4 1 1 - P 1 C - 0 0 0 1.70mm (0.067in)
O-ring. 2 2 9 4 1 2 - P 1 C - 0 0 0 1.73mm (0.068in)
2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in)
TRANSFERHOUSING 4 2 9 4 1 4 - P 1 C - 0 0 0 1.79mm (0.070in)
2 9 4 1 5 - P l C - 0 0 0 1.82mm (0.072in)
6 2 9 4 1 6 - P 1 C - 0 0 0 1.85mm (0.073ini
7 29417-PlC-000 1.88mm (0.074in)
d 2 9 4 1 8 - P 1 C - 0 0 0 1 . 9 1m m { 0 . 0 7 5i n )
2 9 4 1 9 - P 1 C - 0 0 0 1.94mm (0.076in)
10 2 9 4 2 0 - P t C - 0 0 0 1 . 9 7m m ( 0 . 0 7 i8n )
11 29421- P1C- 000 2.00 mm (0.079in)
2 9 4 2 2 - P 1 C - 0 0 0 2.03mm 10.080 in)
2 9 4 2 3 - P ' 1 C - 0 0 0 2.06 mm (0.081in)
14 29424-P1C-000 2.09mm 10.082 in)
TRANSFERCOVERA 2 9 4 2 5 - P 1 C - 0 0 0 2 . 1 2m m ( 0 . 0 8 i3n )
16 29426-P1C-000 2.'15mm (0.085in)
17 29427- P1C-O00 2 . 1 8m m ( 0 . 0 8 6i n )
18 29428-PlC-000 2.21 mm (0.087in)
g tt el 19 2 9 4 2 9 - P 1 C - 0 0 0 2.24mm {0.088in)
/Fr
E g 9-r'r.ru--
g 24 N.m
24 12.4|kgt.m, 17 lbf.ftl
N.m 12.4
(cont'd)
TransferAssembly
(cont'dl
Reassembly
16. Apply PrussianBlue to both sides of the transfer 19. lf the transfergear tooth contactis incorrect,adjust
gearteethlightlyand evenly. the transfergear tooth contactwith a 35 mm or 25
m m t hr u s ts h i m .
NOTE:
. To selecta 35 mm thrust shim, referto page 14,
240.
. D o n o t u s e m o r e t h a n t w o 3 5 m m s h i m st o
adjustthe transfergeartooth contact.
. To selectthe 25 mm thrust shim, refer to page
14-243.
. D o n o t u s e m o r e t h a n t w o 2 5 m m s h i m st o
adjustthe transfergeartooth contact.
Toe Contact
U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e
transferdriven gear shaft toward the transferdrive
gear. Becausethis movement causesthe transfer
1 7 . Rotatethe companionflangein both directionsuntil gear backlashto change,move the transferdrive
the transfergear rotatesone full turn in both direc- gear away from the transferdriven gear shaft to
tions. adjustthe transfergear backlashas follows:
. I n c r e a s et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
1 8 . Checkthe transfergeartooth contactpattern. shrm.
. R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim by the amount of increasedthicknessof
CORRECT
TOOTHCONTACT
PATTERN the 25 mm thrustshim.
Heel Contact
U s e a t h i n n e r3 5 m m t h r u s t s h i m t o m o v e t h e
transfer driven gear shaft away from the transfer
d r i v e g e a r .B e c a u s et h j s m o v e m e n tc a u s e st h e
transfer gear backlashto change,move the trans-
NCONRECTTOOTH CONTACTPATTERN fer drive gear toward the transferdriven gear shaft
to adjustthe transfergearbacklash asfollows:
. R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t
TOE CONTACT shim.
. I n c r e a s et h e t h i c k n e s so f t h e 6 8 m m t h r u s t
shim by the amount of reducedthicknessof
t h e 2 5 m m t h r u s ts h i m .
HEELCONTACT Flank Contaqt

Use a thinner thrust shim to move the transfer
drive gear toward the transferdriven gear shaft.
Flankcontactmust be adjustedwithin the limits
o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h
FLANKCONTACT e x c e e d st h e l i m i t s ,a d j u s t a s d e s c r i b e du n d e r
Heel Contact.
FaceContaqt
Use a thickerthrust shim to move the transfer
FACECONTACT drive gear away from the transfer driven gear
shaft. Facecontactmust be adjustedwithin the
limits of the transfergear backlash.lf the back-
l a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d
underToe Contact.
14-244
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20. Removethe partson the transfershaft,and remove 23. Removethe transterdrivengear shaftand the com-
the transfershaftfrom the transferhousinq. panionflange,
TRANSFERSHAFT 24. Installthe new transferspaceron the transferdri-

v e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r
housrng.
TRANSFERDRIVEN
TRANSFERHOUSING GEARSHAFT
TFANSFERSPACER
TAPEFEDROLLER
lnstallin this direction.
BEARNG
Replace.
TRANSFER
COLLAR
THRUSTSHIM,25 mm
TRANSFERDRIVE Selectivepan
GEAR
CONICALSPRING
WASHER
Replace.
Replace.
Transfr Driven Gear Shaft Starting Torque Inspsction

and Adjustment
25. Installthe companionflange, O-ring,back-upring.
21. Secure the transfer housing in a bench vise with conical spring washer and locknut on the transfer
soft jaws, To preventdamage,alwaysuse soft jaws drivengear shaft.
or equivalentmaterialsbetweenthe transferhous-
ing and the vise. NOTE:
. C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t r a n s f e r
2 2 . I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e , shaftwith ATF beforeinstallingthe locknut.
then removethe transferdriven oear shaft locknut . Installthe conicalspring washerin the direction
and the conicalspringwasher. shown,
COMPANION FLANGEHOLDER
07RAB- TB,010Aol TRANSFERHOUSING
07RAB- TB,010B
O.RING
Replace.
CONICALSPRING
WASHER
Replace.
BACK.UPRING
LOCKNUT
Replace.
(cont'd)
TransferAssembly
(cont'd)
Reassembly
Secure the transfer housing in a bench vise with 28. Stakethe locknutinto the transferdriven gear shaft
soft jaws. To preventdamage,alwaysuse soft jaws usinga 3,5 mm punchas shown.
or equivalentmaterialsbetweenthe transferhous-
ing and the vise.
27. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e ,
then tighten the transferdriven gear shaft locknut
while measuringthe startingtorque of the transfer 0.7- 1.2mm
drivengearshaft. {0.03- 0.05 inl
PUNCH
STARTINGTOROUE: 3.0- 3.5 mm
1 0 . 1-2 0 . 1 {i n l
0.s8- 1.39N.m
{10.0- 14.2kgf.cm,8.68- 12.3lbf.in)
TIGHTENINGTOROUE: .,.-
,.,\ \
132- 216 N.m
{13.5- 22.0 kgf.m, 98 - 159 lbf.ft)
t)
t
--/./
NOTE;
. Rotatethe companion flange several times to Point to be
staked.
seatthe taperedrollerbearing,then measurethe
startingtorque, 29. Install the transfer shaft in the transfer housing,
. l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 , 2 then installthe taperedroller bearing,transfershaft
kgf.cm, 12.3 lbf.in), replacethe transfer spacer collar,25 mm thrust shim,transterdrive gear,coni-
a n d r e a s s e m b l et h e p a r t s . D o n o t a d j u s t t h e cal springwasher,and transfershaft locknuton the
torquewith the locknutloose. transfer shaft,
. lf the tightening torque exceeds216 N.m (22.0
kgf.m,159 lbf'ft),replacethe transferspacerand NOTE:
reassemble the parts. . Coatthe threadsof the locknutand translershaft
. W r i t e d o w n t h e m e a s u r e m e no t f the starting with ATF beforeinstallingthe locknut.
torque: it is used to measurethe total starting . Installthe conicalspring washer in the direction
rorque. snown.
TRANSFERSHAFT
COi'PANIOI{FLANGE
HOLDER
07MB - TBi(tloA ot
O'RAB - TB,.|}IOB
TRANSFERHOUSII{G
THRUSTSHIM.25 mrt|
Selectivepart
TOFOUE
WRENCH
HOLDERHANDLE CONICALSPRING
07JAB- 001020A WASHER
Replace.
Replace.
14-246
www.emanualpro.com
30. Put a 14 mm Allen wrench in the gear side of the Total Starting Tolqu Inspctionand Adiustment
transfer shaft. then secure the Allen wrench in a
benchvise. Tightenthe transfershaft locknut.{The 32. TemDorarilvinstalltranstercover A without the O-
locknuthas left-handthreads,) flng.
TOROUE:118 N.m (12.0kgf.m, 87 lbt.ft) HOUSING
TMNSFER COVERA
e

v
E-
8x1.25mm
r? bt'ftl
24 N'm {2.i1kgt'm,
14 mm ALI-ENWRENGH
5J. Securethe transfer housing in a bench vise with
soft jaws, then rotatethe companionflangeseveral
times to fit the tapered roller bearing.To prevent
al Stakethe locknuton the transfershaft using a 3.5 damage,alwaysuse soft jaws or equivalentmateri-
mm ounch. als betlveenthe transferhousingand the vise.
34. Measurethe total startingtorque.
TOTALSTARTINGTOROUE:
1.70- 2.08N.m {17.3- 21.2kgl.cm,15.0- 18.i1lbf.in}
+ Transler Driven Gear Sh8ft Starting Torque Value
0.7- 1.2.nm
lwroto down in step 27).
{0.0:1-0.C5in}
PU CH
3.0 - 3.5 rnm
(cont'd)
TransferAssembly
Reassembly(cont'dl
35. RemovetaansfercoverA. 37. Selectthe 68 mm thrustshim.
36. lf the measurementis out of specification,remove THRUSTSHIM,58 mm

t h e 6 8 m m t h r u s t s h i m f r o m t r a n s f e rc o v e r A b y
h e a t i n gt h e c o v e rt o a l m o s t2 1 2 " F( 1 0 0 " Cu) s i n ga Shim No. Part Number Thickness
heat gun. Do not heat the cover higher than 212"F zv 2 3 9 7 4 - P 1 C - O 2 0 1.41mm (0.056in)
( 1 0 0 ' C ) .L e t t h e c o v e r c o o l t o r o o m t e m p e r a t u r e zw 2 3 9 7 5 - P 1 C - O 2 0 1.44mm (0.057in)
beforeadjustingthe startingtorque, zx 23976-P1C-020 '1.47mm (0.058in)
ZY 23977- P1C- O20 1.50mm (0.059in)
go to
lf the measurementis within the specification,
zz 23978-P1C-020 1.53mm 10.060 in)
step 40. '1.56mm
23941 PW5- 000 {0.061in)
B 23942-PWs-000 1.59mm 10.063 in)
c 23943- PWs 000 1.62mm (0.064in)
D 23944-PW5-000 1.65mm {0.065in}
HEATGUN E 23945 PWs- 000 1.68mm (0.066in)
F 23946 PWs- 000 1.71mm (0.067in)
G 23947 PWs- 000 1.74mm (0.069ini
23948-PW5-000 1.77mm (0.070ini
23949 PW5 000 1 . 8 0m m ( 0 . 0 7 i1n ,
J 2 3 9 5 0 - P W s - 0 0 0 1.83mm {0.072ini
K 23951- PWs- 000 1.86mm (0.073in
L 23952 PW5- 000 1.89mm (0.074in
23953 PWs- 000 1.92mm (0.076in
N 23954 PW5- 000 1.95mm (0.077in
o 23955 PW5 000 1.98mm (0.078in
P 23956- PWs 000 2.01mm (0.079in
o 23957-PW5-000 2.04mm (0.080in
R 23958,PWs 000 2.07mm (0.081in
s 23959-PW5-000 2.10mm (0.083in
T 23960 PW5- 000 2 . 1 3m m ( 0 . 0 8 i4n
U 2396'1 PW5- 000 2 . 1 6m m ( 0 . 0 8 i5n
23962 PWs 000 2 . 1 9m m ( 0 . 0 8 i6n
23963- PW5 000 2.22mm (0.087in
X 23964- PW5 000 2.25mm (0.089in
23965 PW5- 000 2.28mm (0.090in
z 23966 PWs 000 2.31mm (0.091in
23967-PWs-000 2.34mm (0.092in
AB 23968-PWs-000 2.37mm (0.093in)
AC 2 3 9 6 9 - P W s - 0 0 0 2.40mm (0.094in)
AD 23970-PW5-000 2.43mm (0.096in)
M 23941 PW8 000 2.46mm (0.097in)
BZ 23942-PW8-000 2.49mm (0.098in)
cz 23943- PW8 000 2.52mm (0.099in)
DZ 23944 PW8- 000 2 . 5 5m m ( 0 . 1 0 i0n )
EZ 23945-PW8-000 2 . 5 8m m ( 0 . 1 0 i2n )
14-248
www.emanualpro.com
3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l 40. Installthe new O-ringson transfercoversA and B,
tools. then installthecoverson the transferhousing
DRIVER 6x1.0mm
PRESS
12 N.m 11.2kgt.D,
07743- 0010000
8.7 rbf.ftl TRANSFENCOVERB
Replace.
O.RING
AEARINGOUTERRACE Replace.
ATTACHMENT,
62x68mrr|
077a6- (x)10500
39. After replacingthe 68 mm thrust shim. recheckand

m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e
8 r 1.25rnm
specification.
24 N.m 12.4kgl.m, 17 lbf'ftl
www.emanualpro.com
Transmission
Reassembly
NOTE:
. The illustrationshowsthe 4WDautomatictransmission;the 2WDis similar.
. Cleanall partswith ATF.
. Replacethe followingparts:
- O-rings
- Lockwashers
- Gaskets
- Sealingwashers
- Locknutsand conicalspringwashersof eachshaft
SERVO
DETENT
6x1.0mm ATF FEEDPIPES BASE
ATF FEEDPIPE 1 4 5m m (37 -98 modebonlyl
ATF LUBRICATION
PLATE 6x1.0mm
/
DOWELPIN 2 Bolts
'99 - 00 models: 1 Bolts
LOCK.UPVALVE
BODY ATF FEEOPIPE ATF
STRAINER
LOCK.UPSEPARATOR
PLATE
40 mm
REGULATOR
BODY
VALVE
DOWELPIN j
I
coNrRoL
SHAFT
'-\t
6x1.0mm '112mmll, 6x1,0mm
VALVESPRING '97 - 98 models:
18olts
COOLERBELIEFVALVE DETENT r l T 7 Bolts
'99- 00 models:8Bolts
TOROUECONVERTER ARM
CHECKVALVE SHAFT
SERVOBODY
STATORSHAFT ('97- 98 models)
O.RING SERVO
STOPSHAFT SEPARATOR
PLATE
CHECKBALLS18' 6x1.0mm
3 Bolts
ATF FEEDPIPE
1 1 2m m STOPSHAFT
BRACKET
6x1.0mm 105.8
) / SECONDARY
5 Eolts
MAIN VALVEEOOY
/,,!.,::
(./ afF FEEO
VALVEBODY
,/ ptpEs OOWELPIN
ATF PUMP DRIVEN 8x40mm
GEARSHAFT
SECONDARY
ATF PUMPDRIVEN SEPARATOR
d---.- PLATE
--.-
CONTROLI.EVERMOUNTINGBOLT
6x1.0ftm
14 N.m (1.4 kgt.m, 10 tbf.ft)
(4WD)
SERVO BODY
('99- 00models)
EP,---
!ir{+*a\ r
MAIN SEPARATOR
PLATE fpffi4i
ATF PUMP x*hi
DRIVEGEAR _ \zl
DOWELPIN TOBOUE HOUSING
14-250
www.emanualpro.com
1 . Installthe suction pipe collar and the ATF magnet 8. Installthe servo body and separatorplate on the
{2WD)in the torque converter housing, if necessary. secondaryvalve body ('97 - 98 models: seven bolts,
'99 - 00 models:eight bolts).
lnstallthe main seDaratorDlateand the two dowel
pins on the torqueconverterhousing, 9 . lnstallthe servo detentbase ('97- 98 modelsonly)
and the ATF strainer('97 - 98 models:two bolts,'99 -
Installthe ATF pump drive gear.ATF pump driven 00 models:one boltl.
gear,and ATF pump drivengear shafton the torque
converterhousing.InstalltheATF pump drivengear 1 0 . Tightenthe five bolts on the main valve body to 12
with its groovedand chamferedsidefacingdown. N'm (1.2kgf.m,8.7 lbf.ft).
ATF PUMP
GEAR 1 l . Makesure the ATF pump drive gear and ATF pump
d r i v e n g e a r s h a f t m o v e s m o o t h l y .l f t h e y d o n ' t ,
loosenthe bolts on the main valve body,and disas-
semblethe valve bodies.Realignthe ATFpump driv-
en gear shaft and reassemblethe valve bodies,then
ATF PUMP D{IVEf{ retightenthe boltsto 12 N.m (1.2kgim, 8.7 lbf.ft).
GEARSHAFT
CAUTION: Failureto align the ATF pump driven
ATF PUi'P gear shaft corroctly will rosult in a seizsd ATF pump
ORIVENGEAR drive gear or ATF pump drivon gear shaft.
Grooved and chamtered

side faces separator MAIN SPAR/ATOR
plate. PLATE
Loosely install the main valve body with five bolts.

Makesurethe ATFpump drivegearrotatessmoothly
in the normaloperatingdirection,and the ATF pump
driven gear shaft moves smoothly in the axial and
normal operatingdirections.
Installthe secondaryvalve body, separatorplate, ATF PUMP ATF GEAR

5.
DRIVEGEAR DBIVENGEAR SHAFT
and two dowel pins on the main valve body. Do not
installthebolts. Installthe stator shaft and stop shaft
o. Installthe control shaft in the housing along with 1 3 . Installthe bolts and the stop shaft bracketon the
the manualvalve. secondaryvalve body, then tighten the bolts (three
bolts).
7. lnstall the detent arm and arm shaft in the main
valve body, then hook the detentarm spring to the 1 4 . Installthe torqueconvertercheckvalve,coolerrelief
detentarm. valve,and valvespringsin the regulatorvalve body,
then install the regulatorvalve body on the main
SEBVOSEPARATOR
PLATE valvebody {one boltl.
1 5 . Installthe lock-upvalve body, separatorplate,two

dowel pins and lubricationplate(eightbolts).
DETENTARM
SHAFT 1 6 . Installtheone ATFfeed pipe in the main valvebody,
CONTROL
SHAFT the three ATF feed pipes in the secondaryvalve, the
three ATF feed pipes in the servo body and the one
OETENTARM ATF feed pipe in the lock-upvalve body.
OETENTARM SPRING NOTE:lnstallthe 105.8mm ATF feed pipe with its

filter side away from the secondaryvalve body; the
filter is on the 105.8mm ATF feed pipe, which is
MANUAL VAIVE onlv on the '98 - 00 models, (cont'd)
Transmission
(cont'd)
Reassembly
TRANSMISSION
HOUSINGMOUNNNG BOLT
10 x L25
4,1N.m {/
4WD: 19
2WD: 18
TRANSMISSIONHANGER
t
f, l
llf,
6xl.0mm
12 N.m (1.2 kgl.m,
g il /
8.7rbt.ft)
MAINSHAFTSPEED COUNTERSHAFT
BEVERSEGEAB
SENSOB
LOCKWASHER
MAINSHAFT
SUB.ASSEMBLY REVERSE
SHIFT
FORK
NEEDLEBEARING
DOWELPIN
14x 20 rnm REVERSE
SELECTOR
OOWELPIN
14x25mm
TRANSMISSIONHOUSING
GASKET
COUNTERSHAFT
SUB.ASSEMBLY
DIFFERENTIAL
ASSEMBLY
DOWELPIN
14x25mm
TRANSFESASSEMBLY
(4wDl
14-252
www.emanualpro.com
1 7 . Installthe sub-shaftassemblyin the transmission Installthe reversegear with the collar and needle
housing(seepage 14-210and 14-2'111. bearingon the countershatt.
2 4 . Align the spring pin on the control shaft with the
1 8 . lnstall the ATF magnet (4WD) in the transmission transmissionhousinggroove by turningthe control
housing,if necessary. shaft.
SPRING
SPRING PIN
PIN CONTROL SHAFT
1 9 . Installthe reverseidler gear and gear shaft holder
(seepage 14-231).
20. Installthe differentialassemblyin the torque con-

verterhousing.
21. A s s e m b l et h e m a i n s h a f ta n d c o u n t e r s h a f ts u b -
assembly(seepage 14-206and 14 207],, then install
them togetherin the torqueconverterhouslng.
COUNTERSHAFT
SUB-ASSEMBLY
TRANSMISSION
HOUSING
25. Placethe transmissionhousingon the torque con-

v e r t e r h o u s i n gw i t h a n e w g a s k e ta n d t h e t h r e e
dowel pins,
Make sure that the mainshaftspeed sensor is not
i n s t a l l e do n t h e t r a n s m i s s i o nh o u s i n g b e f o r e
h o u s i n go n t h e t o r q u e
i n s t a l l i n gt h e t r a n s m i s s i o n
converterhousing.
2 6 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n g m o u n t i n g b o l t s
alongwith the transmissionhangerand the connec-
tor bracket,then torque the bolts in two or more
steosin the seouenceshown.
NOTE:The illustrationshows the 4WD automatic

Turn the shift fork so the large chamferedhole is transmission.The 4WD has 19 transmissionhous-
facing the fork bolt hole. then installthe shift fork ing mountingbolts;the 2WD has 18 bolts.
with the reverseselectorand torque the lock bolt.
Bendthe locktab againstthe bolt head. TOROUE:44 N.m {,[.5kgf.m, 33 lbf'ft)
TNANSMISSION
SHIFI FORK
LOCK WASHER
Beplace.
'l.O mm
6 r
4 N.m
(1.4 ksl.m. 1O lbt.ft)
Large chamfered hole
{cont'd)
Transmission
(cont'd)
Reassembly
Install the mainshaft speed ssnsor (with new O- 33. Install the old locknut and the old conical spring
ring)on the transmissionhousing. washeron ths countershaft. Tightenthe old locknut
to seat the park gear to the specifiedtorque,then
28. I n s t a l lt h e p a r k l e v e r o n t h e c o n t r o l s h a f t , t h e n remove th washer and locknut. The locknut has
installthe lock bolt with a new lock washer.Do not left-handthreads. Do not use an impact wrench.
bend the lock tab of the lock washer in this step; Always usea torquewrenchto tightenthe locknut.
bend it after checkingthe park pawl engagementin
step45. TOROUE:103 N.m {10.5kgf.m, 75.9 lbnft)
Assemblethe one-wayclutchand the park gear on

the countershaft1stgear(seepage l4-2Og).
Lubricatethese pans with ATF:

. Countershaft threads
. Old locknutthreadsand flat end
. Old conicalspringwasher
. Park gear contact area with conical spring
wasner
3 1 . Installthe countershaft1st gear collar,needlebear-

ing, and the countershaft1st gear/parkgear assem-
bly on the countershaft.
Installthe park pawl shaft. pawl spring, pawl. and

p a w l s t o p o n t h e t r a n s m i s s i o nh o u s i n g ,t h e n
engagethe pawl with th parkgear.
PARKGEAR
PARXGEAR PAWL STOP

34. Slip the specialtoolontothe mainshaft.
ONE.WAYCLUTCH I
I
a
LOCK BOLT
PAWLSHAFT
BEARING
COUNIERSHAFT
COUNTERSHAFT MAINSHAFT
lST GEARCOLLAR 07GAB- PF50101or
07GAB- PF501q)
14-254
www.emanualpro.com
5C. Installthe sub-shaftlst gear on the sub-shaft. 4 1 . T i g h t e nt h e l o c k n u t st o t h e s p e c i f i e dt o r q u e .
Mainshaftand countershaftlocknutshave left-hand
36. Installthe mainshaft1st gear collar, mainshaft1st threads.Do not use an impactwrench.Always use
gear,needlebearing,thrust needlebearing,and the a torquewrenchto tightenthe locknuts.
thrustwasheron the mainshaft.
LOCKNUTTOROUE:
Wrap the shaft splineswith tape to preventO-ring MAINSHAFT: 78 N.m (8.0 kgf'm, 58 lbf'ft)
damage,then installnew O-ringson the mainshaft 103 N.m (10.5kgf.m, 75.9 lbf'ft)
COUNTERSHAFT:
SUB-SHAFT: 93 N.m {9.5 kgf'm, 69 lbf'ft|
,te
lnstallthe1stclutchassemblvon the mainshaft
MAINSHAFT
SU8-SHAFT LOCKNUT
LOCXNUT Left-handthreads
lST CLUTCH PIN COUNTENSHAFT
ASSEMELY 8 mm pin, LOCKNUT
commercially threads
Left-hand
SUB.SHAFT available
lST GEAR
O.RINGS
THRUSTWASHER
.A/.b"'
"wt IHRUST NEEDLE
BEANING
NEEDLEBEARING
MAINSHAFT
1ST GEAR
CONICALSPBINGWASHRS
lnstallin this direction-
MAINSHAFT
1STGEAR 42. Stake each locknut using a 3.5 mm punch.
COLLAB
0.7- 1.2mm
39. A l i g n t h e h o l e o f t h e s u b - s h a f tl s t g e a r w i t h t h e {0.03- 0.05inl
hole of the transmissionhousing,then insert an 8
mm pin to hold the sub-shaftwhile tighteningthe PUNCH
sub-shaftlocknut. 3.0- 3.5mm
10.12- 0.1ilinl
40. Install new conical spring washers and new lock-

nuts on each shaft.Installthe washersin the direc-
tion shown.
LOCKNUT
Pointto be
staked.
(cont'd)
Transmission
Reassembly
lcont'd)
Set the parklever in @ position,then verifythat the 47. Install the control lever assemblv on the control
parkpawl engagesthe parkgear. shaft. (4WDl
44. lf the pawl does not engagefully, checkthe distance

b e t w e e nt h e p a r k p a w l s h a f t a n d t h e p a r k l e v e r
rollerpin (seepage 14-231).
Tightenthe lockbolt and bendthe locktab.
6 r 1 . Om m
1o tbf'frl
6x1.0mm
14 N.m 11.4kg{.m,
10 tbf.ftl
CONTROL
LEVER
PARKGEAR ASSEMBLY
PARKPAWL
46. Installthe end coverwith two dowel pins and a new 48. Set the A/f gear position switch to E] position.
gasket {twelve bolts).
NOTE: The Aff gear position switch cticks in N]
TOROUE:12 N.m (1.2 kgf.m, 8.7 tbf.ft) position,
6 x 1.0mm EOLTHOLE
{Usedin step50.)
END COVER
A/T GEARFOSMON SWNCH
14-256
www.emanualpro.com
49. Set the control shaft to E position,and installthe Cleanthe areaswhere the transferassemblycon-
A,/Tgear positionswitchon it. tacts the transmissionwith solvent or carburetor
cleaner,dry with compressedair, then coatthe con-
CONTROLSHAFT tact areaswith ATF. (4WD)
Installthe transferassemblywith a new O-ring.Do
,.
not allow dust or otherforeignparticlesto enterthe
N
((,,,
l( * N
transmission.
O.RING
Replace-
{4WD)
$*\.t+-
'gtt - 00 MoDELS
{6 position3}
T
50. I n s t a l lt h e A / T g e a r p o s i t i o n s w i t c h c o v e r , t h e n
installthe harnessclamps of the AviTgear position
switch harnesson the end cover and the transmis-
s i o nh o u s i n g .
6x1.0mm
12 N.m 11.2kgt.m, 10 r 1.25mm
8.7 tbf.ftl a,aN'm 14.5kgt'm, 33 lbf'ftl
lnstallthe cooler lineswith the line bolts and new
sealingwashers.
6xl.0mm
12 N.m 11.2kgf'm,
8,7 TOROUE:28 N.m 12.9kgif'm.21 lbf'ft)
54. Installthe ATF dipstick.

CONTROLSHAFT
55. lnstallthe breathercap on the breatherpipe so its
arrow pointsto the transmissionhanger.
HARNESSCLAMP
HARNESSCLAMP
TRANSMISSION
TorqueConverter/DrivePlate
6 x 1.0 rnin
12 N..t| {1.2 kgt.m, 8.7 lbt.frl
12 x 1.0mm
74 .m (7.5 lgt.m, 54 tbt.ft)
Torque in I crisscross oattern.
o
0o
DBIVCPTATE
14-258
www.emanualpro.com
Transmission
lnstallation
1. Flushthe ATF cooler as describedon page 14-264 6. Install the transmission housing mounting bolt
and 14-265. (front side).
Installthe torque converterassemblyon the main-
shaftwith a new O-ring. TRANSMISSIONHOUSINGMOUNNNG BOLT
lnstallthe starteron the transmissionhousing,and {FRONTSIDE)
installthe 14 mm dowel pins in the torqueconverter 12x 1.25mm
6,1N m (6 5 kgl m, 47 lbf'ftl
housing.
44 N.m {{.5 kgf.m,
33 rbf.f0
14 mm DOWELPIN
7. Installthe transmissionmount bracket.Tightenthe

bolt loosely,then tighten the nuts to the specified
torque,and tightenthe bolt to the specifiedtorque.
12 x 1,25mm
6,aN.ft (6.5kgtm,47 rbf.ft)
t@
P l a c et h e t r a n s m i s s i o no n a j a c k , a n d r a i s e i t t o
TRANSMISSIONMOUNT
enginelevel.
BRACKET
Anach the transmissionto the engine,then install
the rear engine mounting bolts and the transmis-
sion housingmountingbolt (rearsidel.
REARENGINEMOUNTINGBOLTS
la x 1.5mm
8:l N.m (8.5 kgf.m, 61 lbf.ftl
12 x 1.25 mm
74 N.m (7.5 kgf.m,
s{ tbtftl
TBANSMISSIONMOUNT
MOUNTINGBOLT{REARSIDEI
12x 1.25mm
6il N.m 16.5kgd.m,47 tbt.ttl (cont'd)
Transmission
Installation(cont'dl
8. Installthe transmissionhousingmountingbolts. 1 3 . C o n n e c t h e A T F c o o l e r h o s e st o t h e A T F c o o l e r
lines(seepage14-266).
. ATF COOLER
LINE
'i'l'r
' , : , . )-
10 x 1.25mm CLAMP
44 N.m (4.5kgf.m, 12x 1.25mm
33 tbtftl 64 N.m 16.5kg{.m,
TRANSMISSION HOUSING MOUNTING
BOLTS FRotrtT a7 tbt.ftl
12x 1.25mm MOUNT/ARACKET
54N.m16,5kgf.m,a7lbtftl
't4. Install
the rightfront mounvbracket.
9. Removethe transmissionjack. 1 5 . Installnew set rings on the ends of the intermediate

10. Attach the torque convenerto the drive plate with shaftand the driveshaft.
eight bolts. Rotatethe crankshaftas necessarvto
tightenthe bolts to 'll2 of the specifiedtorque,then 1 6 . Cleanthe areaswhere the intermediateshaft con_
to the final torque, in a crisscrosspattern. After tacts the transmission{differential)with solvent or
tightening the last bolt. check that the crankshaft carburetorcleaner,and dry with compressedair.
rotatesfreelv. Then installthe intermediateshaft in the differen_
DRIVEPLATE tial, While installingthe intermediateshaft,be sure
6x1.0mln
12 N.m (1.2tgt m,
not to allow dust or other foreign paniclesto enter
8.t lbf.frl the transmission.
8 x 1.25mm
2a N.m 12.5kgf'm,
18 tbt.ftl
6x1.0mm
12 N.m {1.219{.m,
8.7 tbtft,
STIFFENER
l0 x 1.25mm
12 x t.25 mm 39 N.m 14.0kgt.n,
34 N.m 13.5kgf.rn,25 lbf.ft) 44 N.rn (4.5kgt m, 33 lbtftl SETRING 29 tbf.ftl
Replace.
1 1 . Installthe torque convenercover and the rear stiff_
ener.
1 2 . Tightenthe crankshaftpulleybolt as necessary(see
INTERMEDIATE
SHAFT
section5).
14-260
www.emanualpro.com
17. Installthe right and left driveshafts(seesection18). 19, Installthe propellershaft to the transferassembly
While installingthe right driveshaftin the differen- by aligningthe referencemarks(4WD).
tial, be sure not to allow dust or other foreignparti-
clesto enterthe transmission. MARKS
REFERENCE
NOTE:
. Cleanthe areaswhere the right driveshaftcon-
tacts the transmission(differential)with solvent
or carburetorcleaner,and dry with compressed
air.
. Turn the right and left steeringknucklefully out-
ward, and slide the right driveshaftinto the dif- 8 x 1.25mm
ferentialuntil you feel its spring clip engagethe 32 N.m (3.3 kgt'm,2ir blft)
Feplace.
side gear. Slidethe left driveshaftinto the inter-
\
mediateshaft until you feel the spring clip of the
intermediate shaftengagethe left driveshaft, @_
18. Installright damper fork, then installthe right and
left ball joints on each lower arm with the castle
nutsand new cotterpins (seesection18).
DAMPERPINCHBOLT
10 x 1.25mm
43 N.m 14.{kgf.m,
32 rbr.ftl SHAFT
PROPELLER
20. lnstallthe shift cable.
4WD:
I n s t a l lt h e s h i f t c a b l e w i t h t h e c o n t r o l p i n , t h e n
secureit with the snap Din. Do not bend the shift
cableexcessivelv.
DAMPER
FORX
SELF.LOCKING NUT CONTROL

12 x 1,25mm Replace.
LEVER
6/t N m (6.5kg{.m,a7 lbtft)
Replace.
CASTLE
12 x 1.25mm
49 - 59 N.m
15.0- 6.0 kgl m, 36 - {3 lbtftl
8 x 1.25mm
22 N.m 12.2l'glm,
SHIFTCAALE 16 rbt.ftl
COVER
(cont'd)
www.emanualpro.com
14-261
Transmission
Installation(cont'dl
2WD: 24. Installthesplashshieldand guard bar,
Installthe controlleverwith a new lockwasherto the
controlshaft.Donot bendtheshiftcableexcessivelv.
SHIFTCABLE
8 r 1.25mm
22 N.m
|'2.2 kgt.m, SPLASHSHIELD
16 rbf.ft) 8 x 1.25
24 N.m {2.akgl.m,
17 tbt.ftl GUAROBAR
SI{IFT CAELE
COVER 6r1.0|r|m
9.8N.ml1.0lgf.m,7.2tbtftl
LOCKWASHER 6 x 1.0 mm
Replace. 14 N.m 11.4kgt.m,
10 tbr.frl
25. Connectthe mainshaftspeedsensor,the shift con-
trol solenoidvalve,and the linearsolenoidconnec_
lnstalltheshift cablecover. tors,
22. Installexhaustpipe A.
23. Connectthe primaryheatedorygen sensor(primary

HO2S) connector.
SHIFTCONTROLSOLENOID
GASKETS VALVECONNECTOR
Replace.
10 x 1.25m.n SELF-LOCKING NUT

5r N.m {5.5 kgf.m, 8 ! 1.25mm
40 tbtftl 16 N.m {1.6kgf.m,
Replace. 12 lbf.ftt
Replace.
SELF.LOCKING
8 x 1.25mm
22 N.m {2,2kgt.m, l5 lbt.ftl
14-262
www.emanualpro.com
26. Connectthe vehiclespeed sensor(VSS).the coun- 28. Instailthe transmissionground cable terminal on
tershaft speed sensor. and the A,/Tgear position t h e t r a n s m i s s i o nh a n g e r ,a n d i n s t a l lt h e r a d i a t o r
switch connectors, hoseclampon the transmissionhanger,
29. Connectthe startercablesto the starter,and install

VEHICLESPEEO the harnessclamDon the clamDbracket.Makesure
the crimpedside of the startercablering terminalis
facingout.
CLAMPBRACKET
STARTEB
CABLE
SPEEDSENSOA
CO'{NECTOR
STARTER
CAAtf,
30. I n s t a l lt h e a i r c l e a n e rh o u s i n ga s s e m b l ya n d t h e
2 7 . Connectthe lock-upcontrol solenoidvalve connec- intakeair duct.
t o r , t h e n i n s t a l lt h e h a r n e s sc l a m p o n t h e c l a m p
bracket. 3 1 . Refillthe transmissionwith ATF (seepage 14-161).
HARNESSCI-AMP Connectthe batterypositiveterminaland negative

RADIATORHOSE terminal.
CLAMP
Setthe parkingbrake,Startthe engine,and shift the
transmissionthroughall gearsthreetimes.
34. Checkthe shift cable adjustment (see page 14-271]-.
C h e c kt h e t r o n t w h e e l a l i g n m e n ta n d a d j u s t i t i f
needed(seesection18).
Let the engine reachnormal operatingtemperature

(the radiatorfan comeson) with the transmissionin
E or N position,then turn it off and checkthe ATF
LOCK-UPOONTROL
level{seepage14-160).
TRANSMISSION
GROUNDCAB1I SOLENOIDVALVE
TERMINAL CONNECTOR 37. Performa roadtest (seepage 14-157and 14-158).
6x1.0mm
12 N'm (1.2kgi.m,
8.? tbtftl
Transmission
CoolerFlushing
@@ To prevent in;ury to face and eyos, atways 7. With the water and air valvesoff, attachthe water and
wear safety glassesot a face shield when using the air suppliesto the flusher.(Hotwaterif available.)
tlansmission flusher.
This procedureshould be performedbeforereinstalling

the transmission.
L Checkequipmentfor wear and cracksbeforeusing.

Replaceany worn or crackedcomponents.
2. Usingthe measuringcup.fill the tankwith 21 ounces

{approximately213lull) ol biodegradableflushing
fluid (J35944- 20). Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
contaaner.
S e c u r et h e f l u s h e r f i l l e r c a p , a n d p r e s s u r i z et h e
flusherwith compressedair to 550 - 829 kpa (5.6_
8 . 4 5 k g f / c m , ,8 0 - 1 2 0 p s i )T. h e a i r l i n e s h o u l d b e 8 . Turn on the water valve for 1Oseconds.lf water
equippedwith a water trap to ensurea dry air sys- does not flow through the cooler, it is completely
tem. plugged,cannotbe flushed,and must be replaced.
Hangthe flusherunderthe vehicle. Depressthe triggerto mix the flushingfluid into the
water flow. Usethe wire clip to hold the trigger down.
5. Attachthe flusherdischargehose to the return line
of the transmissioncoolerusinga clamp. 1 0 . While flushingwith the water and flushingfluid for
two minutes,turn the air valve on for five seconds
Connectthe drain hoseto the inlet line on the trans- every 15- 20 secondsto createa surgingaction.
missioncoolerusinga clamp. AIR PRESSURE: MAX 845 kpa(8.45kgf/cmr,t20 psi)
IMPORTANT: 1' I. Turn the water valve off. Releasethe trigger,then

Securelyclampthe oppositeend ofthe drainhoseto a reversethe hosesto the cooler so you can flush in
bucketor floor drain. the oppositedirection.Repeatsteps8 through 10.
12. Releasethe trigger,and rinsethe coolerwith wate.

for one minute.
1 3 . Turn the water valve off, and the water supplyoff.
1 4 . Turn the air valve on for two minutes,or until no

DISCHARGE
moistureis visibleleavingthe drain hose.Residual
HOSE
m o i s t u r e i n t h e c o o l e r o r l i n e s c a n d a m a g et h e
transmission.
Removethe flusherfrom the cooler line.Attachthe

drain hoseto a container.
t
Air lp Water to. Installthe transmission,and leave the drain hose
attachedto the coolerline.
TnAI{SrfiSStoN coot"R
FLUSHER
{Comm.rcidly.v.il.bt.l
K.r -Moor. J38,t{15.A
or aquival.nt
14-264
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1 7 . Makesurethe transmissionis in E position. TOOL MAINTENANCE
F i l l t h e t r a n s m i s s i ow
n i t h A T F ,a n d r u n t h e e n g i n e
for 30 secondsor until approximately0.951 {1.0US 1. mpty and rinse the flusher after each use. Fill the
qt., 0.8 lmp qt.) is discharged. flusherwith water and pressurizeit, then flush the
dischargelineto ensurethat the unit is clean.
1 8 . R e m o v et h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r
returnhoseto the transmission(seepage14-266). 2. lf dischargeliquiddoes not foam, the orificemay be
blocked.
1 9 . Refillthe transmissionwith ATF to the proper level
( s e ep a g el 4 ' 1 6 1) . 3. To clean,disconnectthe largecouplingnut from the
flusher.
FILLERCAP FILTER COUPLING

NUT
I I
- 0 - - D -@q
\
II \
ORIFICE
O.RING
4. Removethe in-linefilterfrom the dischargesideand

cleanit if necessary.
5. The fluid orificeis locatedbehindthe filter.

Clean it with the pick stored in the bottom of the
tank handle,or blow it cleanwith air.
6. all parts.
Reassemble
ATFCoolerHoses
Gonnection
'1. Connectthe ATF
coolerhosesto the ATF coolerlines.then securethem with the cliDs.
2. Facethe tabs of the clips of the transmissionside toward the radiator,and facethe tabs of the ATF coolerside down-
ward.
CLIP
F a c et a b s t o w a r d r a d i a t o r .
ATF COOLERLINE
ATF COOLERLINE
TRANSMISSION
6-8mm
(0.2- 0.3 inl
ATF COOLER
HOSECLAMP
2-rlmm
10.1- 0.2inl
CLIP
Facetabs downward.
14-266
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Shift Lever
Removal/lnstallation
SRS componentsare located in this area. Reviewthe R e m o v et h e f l a n g e n u t s a n d b o l t s s e c u r i n gt h e
SRS componentlocations,precautions,and procedures steeringcolumn,then lowerthe steeringcolumn.
in the SRSsection(24)beforeperformingrepairsor ser-
vrce.
22 N.m (2.2kgf.m, 16 lbt.ftl
1. Removethe instrumentpanel lower cover and the
columncovers(seesection171.
2. Shift to N position,then removethe lock pin from

the cableadjuster.
3. Separatethe shift cablefrom the cableadjuster,Do

not bendthe shift cableexcessively.
ADJUSTERROD
SHIFTCABLE
FLANGE NUTS
16N m (1.6kgl m, 12lbt'ftl
Disconnectthe shift lock solenoidand the park pin

switchconnector.
Removethe bolts securingthe shift leverassembly,

then removethe shift leverassembly.
7. lnstallthe shift lever assemblyin the reverseorder

of removal.
NOTE;
. Make sure the lock pin is seatedsecurelyin the
cableadjuster.
. Replacethe lock pin if it does not snap over the
cableadjustersecurely.
Checkthe cableadjustmentafter installingthe shift

lever(seepage14-27'l).
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14-267
Shift Lever
-'97 - 98 Models
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions.and proceduresin the SRS
section(24)beforeperformingrepairsor service.
Apply siliconegreaseto theseparts'

. Movablepartsof the shift lever,
. Movablepartsof the shift lock mechanism.
. Slidingsurfaceson the detentof the controlcheckerand detentguide.
SHIFTLOCKSOLENOID
SPRING
SCREW
2.5 N.m {0.25kgtm, 1.8 lbtftl
SHIFTLOCK
SHIFTLOCKSOLENOID
SCREW PLUNGER
2.5 N.m {0.25kg{.m,
1.8rbf.ft) SHIFTLOCK
EXTENSION
DETENTSPFING
STOP
SHIFTLEVER DETENTGUIDE
CONTROLBRACKET
9.3 N.m 10.95kgtm,

PARKPIN SWITCH 6.8 tbrft)
CONNECTOR
SHIFTLOCK
RELEASELEVER
SPRING
9.3 N.m {0.95kgf.m,

6.8 tbf.ftl
SHIFTLEVER
LINK
9.3 N.m (0.95kgt.m,

6.8 tbf.ftl
SHIFTCAALE
KNOB
7 N.m {0.7 kgf.m.5 tbt.fr} I N.m 10.9kgt.m,
7 rbf.ftl
14-268
www.emanualpro.com
-'99 - 00 Models
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresin the SRS
Apply siliconegreaseto theseparts:

. Movablepartsof the shift lever.
. Movablepartsof the shift lockmechanism.
. Slidingsurfaceson the detentof the controlcheckerand detentguide.
NOTE:Adjustthe clearancebetweenthe O/Dswitchwires and the edge ofthe shift levercontrolbracketafter reassembly
(seepage 14-270).
SHIFTLOCK SHIFTLOCKSOLENOID
RELEASELEVER SPRING
SCREW
2.5 N.m {0.25kgf.m,1.8lbtft)
SHIFTLOCKSOLENOID
SHIFTLOCKSOLENOIO
PLUNGER
SCREW
2.5 N.m (0.25kgl.m, 1.8 lbl.ft)
DETENTSPRING
SHIFTLEVERCONTROL SHIFTLOCKEXTENSION
BRACKET
STOP
PARKPIN SWITCH_
o/DswtTcH DETENTGUIDE
CONNECTOB 9.3 N.m {0.95kgf.m, 6.9 lbl.ftl
SCREW
2.5 N.m {0.25kgt m,
1.8 tbf.ftl
SHIFTLOCKBELEASE
LEVERSPRING
PARK PIN
9.3 N.m {0.95kgl.m, swrTcH
6.9 lbtfr)
HARNESSCLAMP
ERACKET
SCREW
2.5 N.m {0.25kgf.m,
1.8 tbl.f0
9.3 N.m 10.95kgtm, CONTROLCHECKER

6.9 tbf.ft)
SHIFTLEVERKNOB
6 - 1 2N . m
{0.6- 1.2 kgt'm,
4 - 8.7 tbnft)
LOCKNUT SHIFTLEVER
7 N.m {0.7kgl.m, BUSHING
5 tbf.ftl
o/DswtTcH
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14-269
Shift Lever
Adjustment-'99 - 00 Models
Over-Drive(O/DlSwitch Wire Clearance
NOTE: Be sure to adjust the clearancebetween the O/D Securethe wireswith the harnessclamp.
switch wires and the shift lever control bracket after
replacingthe O/D switch and park pin switch,and after Move the shift leverto eachposition,and verifythat
reassemblingthe shift lever. lf there is the slack in the there is a clearancebetweenthe wires and bracket
wires or the wires are kept tight, the wires may have in eachposition.
Dreaks.
lf the wires are kept tight in any position,read.iust
1. Shiftthe shift leverinto E positron. the clearance.
2. Pull or push the wires to adjust the clearance Installthe shift lever assemblyon the steeringcol-
betweenthe wires and the edge of the shift lever umn.
controlbracketto 13 mm (0.5in).
7. Move the shift lever to each position, and make
SHIFTLEVERBRACKET sure that the wires are kept away from any parts
suchas the steeringcolumn.
14-270
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DetentSpringReplacement
1. Installthe detent spring on th shift lever control 4. Put the detent spring roller in E position on the
bracket,and installthescrewloosely. detentguide,then tightenthe screwto the specified
torque,
Shift the shift lever to E position.
lnssrt a 0.5 mm (0.02 in) wire gap gauge between '97 - 98 Modeb:
the control chockerdetent and the shift lever,then
hold the shift lever againstthe El position in the DETENTSPRING
controlchecker.
SHIFI LEVER
2.5 N.m 10.25kgf.m, 1.8lbl.ftl
GAPGAUGE
SCREW
2.5 N.m 10.25kgl.m, 1.8lbtftl
Shift Gable
Adjustment
SRScomponentsare locatedin this area.Reviewthe SRS 4. Checkthat the hole in the cable adjusteris aligned
componentlocations,precautions,
and proceduresin the with the hole in the adjusting rod. There are two
SRSsection(241beforeperformingrepairsor service. holes in the cableadjuster.They are positioned90"
apart to allow cable adjustmentsln l/4 turn incre-
1. Release
the steeringtilt lever. ments.
2. Removethe accesscover from the lower column

cover.
CABLEADJUSTER
LOCKPIN
AOJUSTING
noo
K\ffi
/* 1
snenrftc Y
6-,> Cabls Cable Exact
Too Short Too Long Alignment
TILTLEVER
I
ACCESSCOVER
ADJUSTER
7 N.m(0.7kg{.m,
5 tbf.ft) lf not perfectlyaligned, loosenthe locknut on the
shittcable.and adjustas required.
3. Shift to E position.then removethe lock pin from
the cableadjuster. Tightenthe locknut.
7 . Installthe lock pin on the adjuster.lf you feel the

lock pin bindingas you reinstallit, the cable is still
out of adjustmentand must be readjusted.
M a k e s u r e t h e l o c k p i n i s s e a t e ds e c u r e l yi n t h e
a d j u s t e r .R e p l a c et h e l o c k p i n i f i t d o e s n o t s n a p
over the cableadjustersecurely.
a Move the shift leverto eachgear,and verifythat the

A/T gear position indicator follows the A"/Tgear
position switch.
1 0 . S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
gears.lf any gear does not work properly,refer to
troubleshooting on page 14-'153 thru 14-156.
' l1 . Insertthe ignition key into
the key cylinderon the
upper column cover, and verify that the shift lock
teverreteases.
14-2 7 2
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Replacement
SRScomponentsare locatedin this area.Reviewthe SRS Removethe shift cablecover.
componentlocations,precautions,and proceduresin the
SRSsection{24}before performing repairsor service. Removethe shiftcable.
1. Removethe instrumentpanel lower cover and the 4WD:

columncovers(seesection17). Removethe snap pin and control pin,then separate
the shiftcablefrom the controllever.
2. Shift to E position,then removethe lock pin from
the cableadiuster.
CONTROLPIN
CABLEADJUSTER
SHIFTCABLE
LOCKPIN
ADJUSTING t r 1.25mm
SHIFTCABLE ROO SHIFT 22 N.n 12.2*glrn.
LOCKNUT BRACKET COVER 16tbf.trl
29 N.m {3.0 kgl.m,
2j2lbf.trl
2WDi
L o o s e nt h e l o c k n u t ,t h e n r e m o v et h e s h i f t c a b l e Removethe control lever, then separatethe shift
from the shift cablebracket. cablefrom the controlshaft.
R e m o v et h e n u t s e c u r i n gt h e s h i f t c a b l e h o l d e r , SHIFT CABI-E
then removethe shiftcable.
CONTROL
SHAFT
STUOBOLT
8 x 1.25mm
22 N.m
12.2 kgl-m,
16 tbf.frl
SHIFTCABLE
6x1.0mm COVER
12 N.m {1.2 kgf.m,
8.7tbtfrl LOCKWASHER 6x LOmm
14 N.m {1.4kgf.m,
10 tbt.lrl
(cont'd)
Shift Gable
Replacement(cont'd)
7. Removethe nuts securingthe shift cable holder,
then removethe shiftcable.
GROMMET STUDBOLT
SHIFTCABLE
f-'
6x 1.0mm
12 N.m 11.2kgtm,
8.7 tbf.ftl
I n s t a l lt h e s h i f t c a b l e l n t h e
removat.
NOTE:
. Do not bent the shift cable excessivelywhen
installingit.
. Make sure the lock pin is seatedsecurelyin the
cableadjuster.
. Replacethe lock pin if it does not snap over the
cableadjustersecurely.
Checkthe cableadjustmentafterinstallingit.
14-274
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Differential
Rear Differential
S p e c i aT l o o l s. . . . . . . . . . ...........15-2
Description
R e a rD i f f e r e n t i a .l . . . . . . . . . . . . . . . . . . . . . . . 1 . .5. .-.4. . . .
H y d r a u l i cF l o w . . . . . . . . . . . . , . .1 5 - 6
Real-time4WD-DualPump System
T r o u b | e s h o o t i n .9. . . . . . . . . . . . . . . . . . . . . . . 1 . .5. .-.1. .0. .
RearDifferentialAssembly
T r o u b l e s h o o t i n .g. . . . . . . . . . . . . . . . . . . . . . . 1 . .5. .-.1. .3. .
Maintenance
D i f f e r e n t i aFl l u i d . . . . . . . . . . . . 15-14
Rear DifferentialAssembly
l l l u s t r a t e dI n d e x . . . . . . . . . . .. 15-15
Removal/lnstallation ....15-16
DifferentialCarrierAssembly
L e a kR e p a i r . . . . . . . . . . . . . . .1. .5. .-.1 8
OilSeals
R e p l a c e m e n.t. . , . . . . . . . . . . . . . . . . . . . . . . . . .1. 5 . .-.1. .9. . . .
Disassembly . . . . . . . . . . , . . . .1. 5. .-,2 0
Reassembly . . . . . . . . . . . . . . .1. .5. .-.2 3
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SpecialTools
Ret. No. Tool Number Oescription otv PageRelernce
o J - 38592 TransferCaseOil Seallnstaller 1 15-20

@ 07GAD- PH7020'1 SealDriver 1 15-19
aa 07JAB- 0010204 H o l d e rH a n d l e 1 tc-zt, z9
@ OTRA_ BT B 4 0 l O B F l a n g eH o l d e r 1 15-21,25
/il -
07749 0010000 Driver 1 15-19
tol 07965- 6920101 Hub Dis/Assembly Tool 1 15-19
6\
15-2
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15-3
Description
RearDifferential
Outline
The Real-time4WD-DualPump Systemmodel has a hydraulicclutchand a differentialmechanismin the rear differential
assembly.Under normalconditions,the vehicleis driven by the front wheels.However,dependingon to the drivingforce
of the front wheels and the road conditions.the systeminstantlytransmitsappropriatedrivingforce to the rear wheels
without requiringthe driverto switchbetween2WD (trontwheel drive)and 4WD(fourwheel drive).The switchingmecha-
nism between2WD and 4WDis integratedinto the reardifferentialassemblyto makethe systemlight and compact.
ln addition,the dual-pumpsystemswitchesoff the rear-wheel-drive forcewhen brakingin a forwardgear.This allowsthe
brakingsystemto work properlyon modelsequippedwith an Anti-lockBrakingSystem(ABS).
Construction
The rear differentialassemblyconsistsof the torque control differentialcase assemblyand the rear differentialcarrier
assembly.The torque control differentialcase assemblyconsistsof the differentialclutch assembly,the companion
flange,and the oil pump body assembly.The reardifferentialcarrierassemblyconsistsof the differentialmechanism.The
differentialdrive and drivengearsare hypoidgears.
The oil pump body assemblyconsistsof the front oil pump, the rear oil pump,the hydrauliccontrolmechanism,and the
clutch piston.The clutch piston has a disc spring that constantlyprovidesthe differentialclutchassemblywith a preset
torqueto Dreventabnormalsound.
The clutchguide in the differentialclutchassemblyis connectedto the propellershaft via the companionflange,and it
receivesthe drivingforce lrom the transferassembly.The clutchguide rotatesthe clutchplate and the front oil pump in
the oil pump body.
The clutchhub in the differentialclutchassemblyhas a clutchdisc that is splinedwith the hypoid drive pinion gear.The
hypoiddrivegear drivesthe rearoil pump.
The front and rearoil pumpsare trochoidalpumps.The rearoil pump capacityis 2.5 percentlargerthat the front oil pump
to handlethe rotationdifferencebetweenthe front and rear wheelscausedby worn front tires and tight corner braking.
The oil pumps are designedso the fluid intakeworks as a fluid dischargewhen the oil pumps rotatein reverse.Genuine
HondaCVTfluid is usedinsteadof differentialfluid.
Operation
Whenthere is a differencein rotationspeedbetweenthe front wheels(clutchguide)and rearwheels(hypoiddrivengear),
hydraulicpressurefrom the front and rear oil pumps engagesthe differentialclutch,and drive force from the transler
assemblyis appliedto the rearwheels.
The hydraulicpressurecontrolmechanismin the oil pump body selects4WD mode when the vehicleis startedabruptly,
or when acceleratingin a forward or reversegear (causingrotationdifferencebetweenthe front and rear wheels).or
when brakingin reversegear {whendecelerating). lt switchesto 2WD modewhen the vehicleis drivenat a constantspeed
in forwar! or reversegear (whenthere is no rotationdifferencebetweenthe front and rearwheels),or when brakingin a
fo rward gear (whendecelerating).
To protectthe system,the differentialclutchassemblyis lubricatedby hydraulicpressuregeneratedby the oil pumps in
both 4WDand 2WD modes.Also,the thermalswitchrelievesthe hydraulicpressureon the clutchpistonand cancels4WD
mode if the temDeratureof the differentialfluid risesabovenormal.
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REARDIFFERENTIAL
ASSEMBLY
TOROUECONTROLOIFFERENTIAL
OIFFERENTIAL
CARRIER
OILPUMPBODY
OIFFERENTIAL
CLUTCH HYPOIDDRIVE
PINIONGEAR
ASSEMBLY
DIFFERENTIAL
CLUTCHGUIDE
HYPOIDRINGGEAR
COMPANIONFLANG
CLUTCHHUB
REAROIL PUMP
CLUTCHPLATE
FRONTOIL PUMP
HOUSING
DIFFERENTIAI-
CLUTCHDISC
HYDRAULICCONTROLSYSTEM
DISCSPRING FRONTOIL PUMP

CLUTCHPISTON REAROII- PUMP
DIFFEREMT|AL
CLUTCH
ASSEMBI-Y
THERMALSWITCH RELIEFVALVE OIL STRAINER
Description
HydraulicFlow
Forward Start and Accelerationl4WD)
Duringa forwardstartand forwardacceleration, the dual pump systemcan engagefour wheeldrive.
lf the front wheelsspin fasterthan the rearwheels,the front oil pump spinsfasterthan the rearoil pump.The front pump
draws fluid through checkvalve B and dischargesit. Some of the dischargedfluid is drawn in the by the rear oil pump.
The remainingfluid will passthroughcheckvalve E into the clutchpiston.There,hydraulicpressureis regulatedby two
orifices.
The regulatedhydraulicpressureat the clutchpistonpushesthe platesand discsof the clutchtogetherto form a connec-
tion. The engagedclutchthen passesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRrFtcEs FRONTOIL PUMP REAROILPUMP
Forward Driving at Constant Speed lzWD)

When drivingforwardat a constantspeed(cruising), the dual pump systemfunctionsin two wheeldrive mode.
The rotationspeedof the front and rearwheelsis the same,so the speedof the front and rearpumps is alsothe same.
Fluid dischargedby the front oil pump is drawn in by the rear oil pump and is circulatedthrough the system.Because
there is no pressurebuilt up at the clutchpiston,the clutchdoes not engage,and the vehicleremainsin 2WD (frontwheel
drive).
FRONTOIL PUMP
15-6
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Forward Decelerationl2WDl
Duringforwarddeceleration, the dual pump systemfunctionsin two wheeldrive mode.
Becauseof brakingcharacteristics, the speedof the rearwheels may exceedthe speedol the front wheelsduring deceler-
ation.lf so, the rearoil pump spinsfasterthan the front oil pump.
F l u i dd i s c h a r g ebdy t h e r e a ro i l p u m p i s s i m p l yd r a w n i n a g a i nb y t h e r e a rp u m p a n d r e c i r c u l a t e B
d .e c a u s teh e r ei s n o
pressurebuilt up at the clutch piston.the clutch piston does not engage,and the vehicleremainsin 2WD (front wheel
drive).
REAROILPUMP
ReverseStart and Acceleration(4WD)

Duringreversestartand reverseacceleration, the dual pump systemcan engagefour wheeldrive.
lf the front wheelsspin fasterthan the rear wheels,the front oil pump spinsfasterthan the rear oil pump. The front oil
pump drawsin fluid throughcheckvalveA and dischargesit. {Notethat in reverse,the directionof the pumps is the oppo-
site of that duringforwarddriving.)
Some of the fluid that is dischargedby the front oil pump is drawn in by the rear oil pump. The remainingfluid passes
throughcheckvalveF into the cylinderof the clutchpiston,where it is regulatedby two orifices.
The regulatedhydraulicpressureat the clutchpistonmay forcethe platesand discsof the clutchtogetherto form a con-
nectlon.The engagedclutchpassesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRtFtcEs FRONTOIL PUMP
{cont'd)
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15-7
Description
HydraulicFlow (cont'dl
ReverseDriving at Constant Speed l2WD)
when driving in reverseat a constantspeed,the dual pump systemfunctionsin two wheeldrive mode.
The rotationspeedof the front and rearwheelsis the same,so the speedof the front and rearpumps is alsothe same,
Fluiddischargedby the front oil pump is drawn in by the rearoil pump and is circulatedthroughthe system.But,because
the there is a differencein the capacitybetweenthe two pumps,fluid flows through checkvalve E, and then through ori-
Iices.This fluid lubricatesand coolsthe clutchassemblyand bearings.
ls this condition,only a low pressureis built up at the clutchpiston.Thereforethe clutchdoes not engage,and the vehicle
remainsin 2WD (frontwheeldrive).
ReverseDecelerationl/tWDl
Duringreversedeceleration, the dual pump systemcan engagefour wheeldrive.
When deceleratingin reversedirection,the speedof the rear wheels may exceedthe speedof the front wheels (due to
enginebraking).In this condition,the rearoil pump drawsfluid throughcheckvalvesB and C. Fluid dischargedfrom the
rearoil pump then flows throughcheckvalveE to the clutchpiston.There,pressureis regulatedby two orifices.
The regulatedhydraulicpressureat the clutchpiston may forcethe platesand discsof the clutchtogetherto form a con,
nection.The engagedclutchpassesdrivingforcefrom the transferassemblyto the rearwheels,producing4WD.
oRtFtcEs REAROIL PUMP
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Thermal Switch Operation l2WD)
During4WDoperation,pressure-regulated fluid is in contactwith the clutchpistonand the thermalswitch.
lf the temperatureof the fluid in the differentialgoes too high, the thermalswitch pushesopen the reliefvalve R. This
causesthe pressurein the clutchpistonto drop, and 4WD mode is disengaged.
THERMALSWITCH RELIEFVALVE
RelietValve Operation
When the fluid pressuregoes higherthan the reliefvalvespringforce,checkvalve R opens.Pressureappliedat the clutch
pistonis held constant.This featureadds stabilityby preventingthe rearwheeldrive systemfrom experiencingexcessive
to rque.
RELIEFVALVE
Real-time4WD-DualPumpSystem
(AutomaticTransmissionl
Troubleshooting
When starting and accelerating in forward gesrs {4WD When starting and accelerating in revGrsggear {4WD
model model
1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l sa r e o f f t h e 1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e
ground (seesection1). ground (seesection1).
2. Makea mark on eitherNo. ' I o r N o . 2 p r o p e l l e r Makea mark on eitherNo. 1 or No. 2 propeller

shaft. shaft.
PROPELLER
SHAFT PROPELLER
SHAFT
Startthe engine,and let it run until it warms up (the Startthe engine.and let it run until it warms up (the
radiatorfan comeson at leasttwice). radiatorfan comeson at leasttwicei.
With the engineat idle.shiftto the E position. With the engineat idle,shift to the E position.
A p p l y t h e p a r k i n gb r a k ef i r m l y . a n d m e a s u r et h e A p p l y t h e p a r k i n gb r a k ef i r m l y , a n d m e a s u r et h e
time it takesthe propellershaftto rotate10 times. time it takesthe proDellershaftto rotate10times,
. lf the measuredtime is more than 10 seconds, . lf the measuredtime is more than 10 seconds,
the 4WDsystemis normal. the 4WDsystemjs normal.
. l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t, h e r e i s a . l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t, h e r e i s a
problem in 4WD system. Checkthe differential problem in 4WD system. Checkthe differential
f l u i d . l f t h e d i f f e r e n t i af l u i d i s n o r m a l ,r e p l a c e fluid. lf the differentialfluid is normal, reolace
the torquecontroldifferentialcasekit. the torquecontroldifferentialcasekit.
15-10
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(ManualTransmissionl
Troubleshooting
When starting and acceleratingin forward gears (4WD When starting and acceleratingin reversegear (4WD
mode) model
1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e 1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e
ground{seesection1) ground (seesection1).
2. Startthe engine,and let it run until it warms up (the Startthe engine,and let it run until it warms up (the
radiatorfan comeson at leasttwlce). radiatorfan comeson at leasttwice)
3. W i t h t h e e n g i n ea t i d l e , s h i f t i n t o 1 s t g e a r a n d 3. With the engine at idle, shift into reversegear and

releasethe clutch. releasethe clutch.
Applythe parkingbrakefirmlY Apply the parkingbrakefirmlY
. lf the enginestalls,the 4WDsystemis normal. . lf the enginestalls,the 4WDsystemis normal.

. lf the enginecontinuesrunning,there is a prob- . lf the enginecontinuesrunning,there is a prob-
lem in 4WDsystem.Checkthe differentialfluid. lf lem in 4WD system.Checkthe differentialfluid lf
the differentialfluid is normal,replacethe torque the differentialfluid is normal,replacethe torque
controlditferentialcasekit. controldifferentialcasekit.
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Real-time4WD-DualPumpSystem
Troubleshooting(AutomaticTransmission/Manual
Transmission)
Whon d6c6l6ratingin a torward gear {2WD mode} When deceleratingin reversegear (4WD mod)
1. Blockthe front wheels,raisethe left rearwheel.and 1. Blockthe front wheels.raisethe left rearwheel,and
supportit with a safetystandas shown. suppo( it with a safetystandas shown.
WHEELCHOCKS
WHEELCHOCKS
Hold the tire and turn it counterclockwise

continu- Hold the tire and turn it clockwisecontinuouslvfor
ouslvfor more than one rotation. more than one rotation.
lf the rotation of the wheel does not gradually lf the rotation of the wheel gradually feels heaw.
feel heavywhile rotating,the 2WD systemwhen the 4WD systemwhen deceleratingin reversegear
decelerating in a forwardgear is normal. is normal,
lf the rotationof the wheelgraduallyfeelsheavy, lf the rotationof the wheeldoes not graduallyfeel
there is a problem in the system.Checkthe dif- heavy,there is a problem in the system.Check
ferentialfluid, lf the fluid is normal,reDlacethe t h e d i f f e r e n t i afl l u i d . l f t h e f l u i d i s n o r m a l .
torouecontroldifferentialcasekit. reolacethe torquecontroldifferentialcasekit,
15-12
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RearDifferentialAssemblY
Troubleshooting
Most problemsin the unit are to be diagnosedby identifyingnoisesfrom the gearsor bear'ngs'
components'
care shouldbe takenduringdiagnosisnot to confusedifferentialnoiseswith thosefrom otherdrivetra'n
Symptom ProbableCause Remedy
. Fluidleveltoo low . Add fluid

Will not go into 4WD mode
. Incorrectfluid type . Replace
Will not returnto 2WD mode Incorrectfluid type Drainand fill the differential
Gearor bearingnoises Fluidleveltoo low Add fluid

Incorrectfluid type Drain and fill the differential
Damagedor chippedgears Replacethe differential carrier
assemory
. Fluidleveltoo low . Add fluid
Overheating
. Incorrectfluid type . Drain and fill the differential
F l u i dl e a k Fluidleveltoo high Lowerto properlevel

Cloggedbreatherhose Cleanor replace
Worn or damagedoil seal Replace
Damagedsealingwasher Replace
Loosemountingboltsor inade- Recheck torqueor aPPIYsealant
quatesealing
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15-13
Maintenance
DifferentialFluid
!@ Make sure lifts are placed properly lsee C l e a nt h e d r a i n p l u g , t h e n r e i n s t a l il t w i t h a n e w

section 1). washer, and refill the differentialwith the recom-
mendedfluid to the properlevel.
1. With the vehicleon levelground,inspectdifferential
f l u i dw i t h e n g i n eO F F . NOTErlf you disassembly the differential,
checkthe
fluid levelagain after the 4WD systemcheckis fin-
2. Removethe oil filler plug, then checkthe leveland ished.Add fluid if necessary.
conditionof the fluid.
Reinstallthe oil filler plug with a new washer.
Fluid Capacity
Proper Level 1.0/ {1.1US $, 0.9 lmp qt) at tluid change
1.2/ {1.3US $, 1.1lmp qt) at oyerhaul
Recommended fluid:
GenuineHondaCVT Fluid
o|I FII.IIR PI-UG

4t N.m la.8kgl.m,35 lbl.ftl
T h e f l u i d l e v e lm u s t b e u p r o t h e f i l l h o l e .l f i t i s
below the hole, add the recommendedfluid until it
runs out, then reinstallthe oil filler plug with a new
wasner.
4. l f t h e d i f f e r e n t i atll u i d i s d i r t y , r e m o v et h e d r a i n
p l u g ,a n d d r a i nt h e f l u i d .
DMIN PLUG
a7 N.m 14.8kgl.m, 35 lbt.ftl
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1 5 -1 4
lllustratedIndex
6xl.0m
12 N.m (1.2 kgf m,8.7 lbt'ftl
DOWELPINS
COMPANIONFLANGE
O.RING
Replace.
BACK-UPRING
LOCKNUT,24 mm
Replace.
118N.m (12.0kgtm. 6x1.0mm
87 rbt ft) 12 N.m 11.2kgt'm,8.7 lbf'ft|
OIL SEAL
Replace.
PRESSURE
PLATE
CLUTCHHUB/PLATES/DISCS
CLUTCH
DIFFERENNAL
ASSEMBLY
OIL PUMPDRIVESHAFT
THBUSTNEEDLE
""t",at\( AEARING
'd'
CLUTCHGUIDE
OILPUMP
PIN
e
MAGNET
OIL STRAINER
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15-15
l!!@ Make sure tifts are ptaced property lsee 5, Placea transmissionjack underthe rear differential
section 11. assembly,then removethe right mountingbracketB
andthe left mountingbracket8.
1. Drainthe differentialflujd (seepage 15-14).
2. Mark the propellershaft and companionflange of

the rear differentialassemblyso they can be rein-
stalledin theiroriginalpositions.
PROPELLERSHAFT COMPA'{IONFLANGE
12 POtt'lT BOLI
8 x 1.25mm
32 N.m 13.3tgf.m. 2a lbtft,
Removethe breathertube from the breathertube
Mark fitting.
BREATHER
TUBEflTNNG
Removethe propellershaftfrom the reardifferential

assemory.
Removethe reardifferentialdamper.
12x 1.25mm
5,1N.m 15,5kgf.m, iO tbf.fO
15-16
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7. Insertthe edge of the screwdriverinto the groove 10. Remove the rear difterentialmounting bracketA
locatedunder the differentialhousing Pry out the from the reardifferentialassembly.
driveshaftinboardiointwith a screwdraver.
12 x 1.25 fifi
N.m {7.0 lgf.m. 5l lbl.tt)
NOTE:Take care not to damagethe differentialoil
sealand differentialring when prying out the differ-
entialinboardjoint. REARDIFFERENTIAL
MOUNTINGBRACKETA
REANDFFERENTI,AL
DIFFERENTIAL ASSEMBLY
1 1 .Installthe rear differentialassemblyin the reverse

orderof removal.
Notetheseitemsduringreassembly
8. Removethe mountingboltsand the washers. . lnstallthe breathertube to the breathertube joint
properly.
. Duringthe propellershaft installation,align the
m a r k s o n t h e p r o p e l l e rs h a f t a n d c o m p a n i o n
flange.
. Reiillthe rear differentialwith the recommended
fluidto the properlevel{seepage15-14).
DRIVESHAFT
MOUNTING BOLTS
'10x 1.25mm
,19N'm (5 0 kgf m, 36 lbtftl
Lower the rear differentialassemblyon the trans-
missionjack,then removethe reardriveshaftsfrom
the rear difterentialassembly.
DifferentialCarrierAssembly
LeakRepair
'1. Remove
t h e b o l t s i n a c r i s s c r o s so a t t e r n .t h e n Installthe differentialhousing.then torquethe bolts
removethe differentialhousing. in a crisscrosspatternin severalsteps.
I x 1.25mm I n s t a ltlh e o i l s e a l s( s e ep a g e1 5 - 1 9 ) .
22 N.m 12.2kgl.m, 16 tbtftl DIFFERENTIAL
HOUSING
2. Apply liquid gasketto the sealingsurfaceof the dit-

ferentialhousing,and notetheseitems:
. Use liquidgasket(P/N08718- 000'1).
. R e m o v ea n y d i r t o r f l u i d f r o m t h e s e a l i n gs u r -
lace.
. lf 20 minutes have passedafter applying liquid
gasket,reapplyit beforeyou assemblethe hous-
ings. Allow it to cure at least 30 minutes after
assemblybeforefilling differentialwith ftuid.
DIFFERENTIAL
HOUSING
15-18
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Oil Seals
Replacement
1. Removethe oil sealsfrom the differentialhousing. 2. Installthe oil sealssquarelyusingthe specialtools.
Be carelulnot to damagethe lip ol the oil seals.
Right side:
Rightside:Installationdepth of the oil seal is 9 mm
(0.35in) belowthe edgeof the differentialhousing.
OILSEAL
HUB DIS/ASSEMBLYTOOL
07965- 6920101
OIL SEAL
Left side: Left side: Installthe oil seal flush with the edge of
the differentialcarrierassembly.
OIL SEAL
(cont'd)
Oil Seals RearDifferentialAssembly
Replacement(cont'd) Disassembly
3. Removethe oil seal from the toroue control differ- 1. Removethe breathertube,the drain plug and the oil
entialcase. f i l l e rp l u g .
BREATHER
TUBE
OIL FILI.IRPLUG
DRAIT{PLUG
Installthe oil sealsquarelyusingthe specialtool.

carefulnot to damagethe lip of the oil seal.
Raisethe locknuttab from the groove of the clutch

guide, making sure that the tab completelvclears
the grooveto preventdamagingthe clutchguide.
L(rcKNUT,24 mm
Replace.
15-20
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3. Installthespeclaltoolson the companionflange, 7. R e m o v et h e l o c k n u t ,t h e d i s c s p r i n gw a s h e r ,t h e
back-upring,the O-ringand the companionflange.
HOIIIER HANDTI
o'JAB - OO102nA LOCKNUT,24 mm
Feplace.
@r/
v-.,. DISCSPRINGWASHER,24 mm
ao/ BACX.UPRING
U
rA*..- O.N|NG
Replace.
zzft
h\@fr\ COMPANIONFLANGE
8 x 1.25mm
32 N m {33 tgt m,24lbf ftl
Loosenthe locknutcounterclockwise so that its tab

comesout from the groovein the clutchguide.
LOCKNUT,24 mm
8. Removethe torque controldifferentialcaseand the
dowel pins.
5. Tightenthe locknuttill its tab alignswith the groove.
6. Removeany dirt from inside of the groove in the

clutchguide,then loosenthe locknut.
LOCKNUT.2,1mm
Tab
(cont'd)
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Rear DifferentialAssembly
Disassembly(cont'dl
9 . R e m o v et h e s h i ma n dt h e c l u t c hq u i d e . 1 1 . R e m o v et h e t h r u s tn e e d l eb e a r i n ga n d t h e o i l p u m p
driveshaft.
d"HIM'30mm
CLUTCHGUIDE
and the pressure

1 0 . Removethe clutchhub/plates/discs 1 2 . Removethe oil pump body assembly,the oil pump
prare. pin,the magnet,and the oil strainer.
OIL PUMPBODYASSEMBLY
CLUTCHHUB/PLATES/OISCS
k
ffi -:*
_zz
PRESSURE
PLArE MAGNET
@- OIL PUMPPIN
OIL STRAINER
Inspectfor damage
or clogging.
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15-22
Reassembly
1. Apply CVTfluid to the rubberof the oil strainer,then 3. Tightenthe oil pump body assemblymounting
installthe oil strainer,the magnet,and the oil pump bolts.
pin to the differential
carrier.
4. I n s t a l lt h e o i l p u m p d r i v e s h a f tb y a l i g n i n g t h e p r o -
jection of the oil pump driveshaftwith the groove of
the front oil pump in the oil pump body assembly.
MAGNET
THRUSTNEEDLEBEABING
OIL PUMPPIN
-n lnstallin thisdirection.
Projection
6x1.0mm
12 N.m 11.2kg{.m,8.7 lbl.ft}
CWfluid
DIFFERE]TTIALCARRIER
ASSEMBLY
2. Alignthe oil pump pin with the grooveof the rearoil 5. Installthe thrust needlebearing.
pump in the pump body assembly, then installthe oil
pump body assemblyto the differentialcarrierassem- Installthe pressureplate assemblyby aligningthe
oty. projectionof the pressureplate with the groove of
OIL PUMP BODYASSEMBLY the oil pump driveshaft.
PRESSURE
PLATE
OILPUMP
DRIVESHAFT
( c o n t ' d)
(cont'dl
Reassembly
7. then alignthe pro-
Installthe clutchhub/plates/discs, 10. lnstallthe dowel pins and toroue controldifferential
jectionof the plateswith the discs. case.
sHlM, 30 mm TOROUECONTNOL
,/ 6x1.0mm
.A-\,/r 12 N.m 11.2tgf m,8.7lbt.ftl
\-7
CLUTCHGUIDE
CLUTCHHUA/PLATES/
Dtscs
8. c l u t c hg u i d ea n dt h e 3 0 m m s h i m .
Installthe
9. A p p l y l i q u i d g a s k e tt o t h e s e a l i n gs u r f a c eo f t h e
t o r q u e c o n t r o l d i f f e r e n t i a lc a s e ,a n d n o t e t h e s e 11. Installthe companionflange,O-ring,back-upring,
rlems: discspringwasher,and the locknut.
. Use liquidgasket(P/N08718- 0001).
. Removeany dirt or fluid from the sealing sur- NOTE:Apply CW fluid to the O-ring.
face.
. lf 20 minutes have passedafter applying liquid
,24mm
gasket,reapplyit beforeyou assemblethe hous-
ings. Allow it to cure at least 30 minutes after DISCSPRINGWASHER,
assemblybeforefilling differentialwith fluid. 2a mm
TOBOUE CONTROL
DIFFERENNAL @+-_alcr-upnwc
/r-
lnstallin this direction.
K@#/
COMPANIONFLAI{GE
--- Apply liquidgaskot
15-24
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1 2 . I n s t a l tl h e s p e c i a tl o o l s t o t h e c o m p a n i o nf l a n g e , 14. lnstallthe breathertube.
then tightenthe locknutto specifiedtorque.
TOROUE:118N.m (12.0kgf-m,87lbf'ft)
BREATHER
TUAE
HOLDEBHANDLE
07JAB- @1020A
OIL FILI..ERPLUG
47 N.m 14.8kgf.m,
35 tbt frl
WASHENS
Replace.
DRAIN PLUG
4? N'm l4.E tgf.m, 35 lbf'ftl
I x I .25 mm
32 N'm (3.3kgt m, 24 lbtftl
t5. Installthedrain plug and the oilfiller plug with

Stakethe locknuttab into the groove in the clutch wasners.
guide.
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Driveshafts
Special Tools.......... ...........
16-2
Driveshafts
Inspection ......................
l6-3
FrontDriveshafts
Removal ....16-3
Disassembly ...................
16-5
Reassembly ....................
16-g
Installation .....................
16-17
IntermediateShaft
Removal ....16-19
Disassembly ...................
16-19
Reassembly ....................
16-20
Installation .....................
16-21
RearDriveshafts
Removal .... 16-22
Disassembfy ...................
16-22
Reassembfy ....................
16-24
Installation .....................
16-29
PropellerShaft
Inspection . 16-29
RemovaUlnstallation ....16-30
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Rf. No. Tool Number Dscription Otv PageRolsrenca
o 07JAF- SH20400 Attachment 1

'l
16-16
07LAD- PW50601 Attachment,40x 50 mm LD. 16-18
07MAC- S100200 B a l lJ o i n tR e m o v e r , 2 m
8m 1 16-4
@ 07746- 0010300 Attachment,42 x 47 mm 1 16-16
07746- 0010400 Attachment,52 x 55 mm 1 1 6 - 1 71, 8
\D' 07746- 0030400 Attachment,35 mm l.D. 1 16-17
o 07749- 0010000 Driver ,l
'I
1 7 ,1 8
@ 07965- SD90100 Suppon Base 16-16
@ 07xAc - 0010200 T h r e a d e dA d a p t e r , 2 4
x 1 . 5m m 1 16-7
o arl
T
!.,
o)
16-2
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Driveshafts Front Driveshafts
Inspection Removal
Boot Damago 1 . Loosenthe wheel nutsslightly.
Check the boots on the driveshaft for cracks, damago,
leakinggrease,and loose boot bands.lf any damagsis Raisethe front of the vehicle,and suppon it with
found, replacethe boot and boot bands. safetystandsin the properlocations(seesection1).
Looso Splines ? Removethe wheel nuts and front wheels.

Turn the driveshaftby hand,and make sure th splins
and joint are not excessivelyloose.lf damageis found,
replacethe inboardjoint.
Twisting or Crscking
Make sure the driveshaftis not twisted or crackod.
Replaceit if necessary.
DRIVESHAFT
SPINDLENUT
24 x 1.5mm
Replace. FRONTWHEEL
lf the right driveshaftis to be removed, drain the

transmission fluid {seesction13or 14).lt is not nec-
essaryto drain the transmissionfluid when the left
driveshaftis removed.
Lift up locking tab on the spindle nut, then remove

the nut,
6. Removethe self-locking
nut and flangebolt,
FLANGEBOLT
10 x 1.25mm
SELF"LOCKINGNUT
12 x 1.25mm
Replace.
7. Remove the damper fork,
(cont'd)
Front Driveshafts
Removal (cont'd)
Removethe cotterpin from the lower arm ball ioint 12. Pull on the inboardjoint, and removethe driveshaft
castlenut, and removethe nut. from the differentialcase or bearingsupportas an
assembly.Do not pull on the driveshaft,the inboard
joint may come apart. Pull the driveshaftstraight
out to avoid damagingthe differentialoil sealor the
intermediate shaftouter seal.
07MAC- SLm2m
Installa 12 mm hex nut on the ball joint. Makesure

the hex nut is flush with the balljoint pin end,or the
threadedsectionof the ball joint pin might be dam-
aged by the specialtool.
Left driveshaft:
i0. Usethe specialtool as shown in section'18to sepa- Removethe left driveshaftfrom the bearingsuppon
rate the ball joint and lower arm, Be caretulnot to by tapping on the inboard joint of the driveshaft
damagethe ball joint boot, lf necessary, apply pen- with a olastichammer.
etratingtype lubricantto loosenthe ball joint,
BEARINGSUPPORT
1 l . Pry out the driveshaftassemblywith a pry bar, as
shown, to force the set ring at the driveshaftend
past the groove. Be careful not to damagethe oil
sealswhen prying.
PRY BAR
16-4
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Disassembly
13, Pullthe knuckleoutward,and removethe driveshaft InboardJoint Sid:
inboard joint from the differentialcase or bearing
suoDort. 1, Carefullyclamp the driveshaftin a vise with soft
jaws, then remove the set ring from the inboard
joint.
KNUCKLE
2. Removethe boot bands.Take care not to damage
the boot,
. lf the boot band is a lockingtab type, pry up the
lockingtabs with a screwdriver,and lift up the
end of the band.
. l f t h e b o o t b a n di s a w e l d e dt y p e o r a l o w p r o f i l e
type, carefullycut the boot band with a pair of
diagonalcutters.
. lf the boot band is a double loop type. lift up the
band bend.
Locking Tab
DRIVESHAFT
1 4 . Removethe driveshaftoutboardjoint from the front

wheel hub usinga plastichammer.
PLASTICHAMMER
SET BING
Replace.
Welded
DRIVESHAFT
{cont'd)
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16-5
Front Driveshafts
Disassembly(cont'd)
Double Loop 4, Mark the rollersand spiderto identifythe locstions
of the rollerson the sDider,then removethe rollers.
BEARING
REMOVER
(Commercially
available) DRIVESHAFT
DRIVESHAFT
Mark
Removethe circlip,
Mark the spider and driveshaft to identify the posi-

tion ofthe spideron the shaft.
7. Removethe spiderusinga bearingremover,

Mark each roller and inboard joint to identify the
locationsof the rollersand groovesin the inboard Wrap the splines on the driveshaftwith vinyl tape to
joint. Thon remove the inboard ioint on the shop preventdamageto the bootsand dynsmicdamper,
towel. Be careful not to drop the rollers when sepa-
ratingthem from the inboardjoint.
INBOARDBOOT
INBOARDJOINT
Checksplinesfor wearor damage.
Checkinside bore for wear. DRIVESHAFT
Inspectfor cracks.
DYNAMICDAMPER
q
Rsmove the inboard boot and dvnamic d a m p e r .
Take care not to damage the boot and d y n a m i c
damDer.
16-6
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Outboard Joint Side: DRIVESHAFT
1. L i f t u p t h e t h r e e t a b s w i t h a s c r e w d r i v e r ,t h e n
remove the boot bands,Take care not to damage PAINTMARK
the boot.
NOTE:
. lf the boot band is a double loop type, lift up the
bandbend.
. lf the boot band is a welded type, cut the boot
band.
. l f t h e b o o t b a n di s a l o c k i n g t a b s t y p ep.r y u p t h e
tabswith a screwdriver,and lift up the end of the
oano. 5, CarefullvclamDthe driveshaftin a vise.
THREADED AOAPTER,2iIx 1.5 mm
EarClamp 07xAc - 0010200
TAB
EAR CLAMP BAND

Replace. Slidehammc..5/8'x lS Throad
(Commerically,
available)
2. Slidethe outboardboot to the inboardioint side. o. Removethe outboardjoint using a specialtool as
shown.
7. Removethe driveshatttrom the vise
8. Removethe stop ring from the driveshaft.
DRIVESHAFT
Wipe off the greaseto exposethe driveshaftand

the outboardjoint innerrace.
Markthe driveshaftat the same positionof the out-

boardjoint end with paint.
STOPRING
Replace.
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Front Driveshafts
Reassembly
Notetheseitemsduringreassembly
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
partswith solvent.
o *4@] :Thoroughlypackthe inboardand outboardjoints and both joint bootswith the joint greaseincludedin the
new driveshaftset.
. The'98 Canadamodel andall '99 - 00 modelsusea TPE(Thermoplastic PolyesterElastomer)outboardjoint boot.
Usethe ear clamptype boot band in the outboardboot set.
Greasequantity:
Inboard Joint: All models 120- 130 g (i1.2- 4.6 oz)
Left inboard joint splines (Al: 0.5 - 1.0 g (0.018- 0.035oz)
Outboard Joint: '97 model and'98 USA model 130- 140 g (4.6-,1.9 oz)
'98 Canadamodel and all '99 - 0Omodels 140-
150 g 14.9- 5.3 oz)
SETRING INBOARO
JOINT
Replace.
LEFTINBOARO
JOINT SPIOER
INBOARDBOOT
(Al
SPLINES: -6r
P a c kc a v i t y w i t h g r e a s e .
wtn grease.
BANDS
DYNAMICDAMPER
STOPRING
Replace.
OUTBOARDBOOTITPE)*I
-611
-/ Pack cavity with grease.
DOUELE BAND+' EARCLAMPBAND*1
Replace. Replace.
__G1
P a c k c a v i t y wrtn grease.
OUTBOARDBOOT*'
(RUBBERI
-Grj
Pack cavity wtrn grease.
*l: '98 Canadamodels,all '99-00models
*2: '97- 98 models(except'98Canadamodel)
16-8
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Inboard Joint Side: 5. Fit the rollersto the spider.
1. Wrap the splineswith vinyl tape to preventdamage NOTE:

to the boot and dynamicdamper. . Reinstallthe rollersto their originalpositionson
the spiderby aligningthe marks.
. Hold the driveshaft pointed up to prevent the
DRIVESHAFT rollersfrom fallingoff.
\ ,..',NYL rAPE
V6
uu.oa.Dsoo.
F
,",^_Y,C@
I n s t a l lt h e i n b o a r d b o o t t o t h e d r i v e s h a f t ,t h e n
removethe vinyl tape.Takecare not to damagethe
boot.
Installthe spideronto the driveshaftby aligningthe Packthe inboardjoint with the joint greaseincluded
markon the spiderand the end of the driveshaft. in the new driveshaftset,
Greasequantity: 120- 130 g {4.2- 4.6 oz)

@+-crncr-rr Left inboad ioint splines@:0.5 - 1.0 g (0.018- 0.m5
ozl
4. F i t t h e c i r c l i p i n t o the driveshaft groove. Always

rotatethe circlipin its grooveto makesure it is fully
seated.
(cont'd)
www.emanualpro.com
16-9
Front Driveshafts
Reassembly
{cont'd)
7. Fit the inboard joint onto the driveshaft,and note Left: 508 - 513 mm 120- 2O.2inl
theseitems:
Reinstallthe inboardjoint onto the driveshaftby

aligningths markson the inboardjoint with the
markson the rollers.
Holdthe driveshaftso the inboardjoint pointsup
to prevent it from falling off.
Right: AT model 520 - 525 mm {20.5- 20.7 in)

MT mod6l 515 - 520 mm (20.3- 20.5 inl
I I
/\
/,?:..{
t
\
Sptine
airection
-flm+dm@
lffi
t Y l 9. Positionthe dynamic damper to the specifications
as snown.
:\
ROLLERHOLDER Left:299.5t 2 mm 111.8r O.l inl

Right:299.5t 2 mm 111.810.1inl
Adjustthe lengthof the driveshaftsto the specifica-

tions shown. then adjustthe boots to halfway
betweenfull compressionand full e)dension.Make
surethe endsof the bootsseat in the groovesof the
driveshaftand Ioint.
OUTBOAROJOINT
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16-10
10. Set the double loop band onto the boot or dynamic 1 3 . Threadthe free end of the band through the nose
damper with the band end toward the front of the sectionof a commerciallyavailableboot band tool
vehicle. (KD-3191 o r e q u i v a l e n t )a. n d i n t o t h e s l o t o n t h e
winding mandrel.
'14. Place wrench
a on the winding mandrelof the boot
OOUBLELOOPBAND b a n d t o o l . a n d t i g h t e nt h e b a n d u n t i l t h e m a r k e d
spot on the band meetsthe edgeof the clip.
BOOTBANDTOOL
(KD-3191
or equivalentl Markon band.
WINDING
MANDREL
11. Pull up the slackin the band by hand.
12. Make a mark on the band 10 - 14 mm (0.4- 0.6 in)

from the clip.
CLIP
1 5 . Lift up the boot band tool to bend the free end of

the band 90 degreesto the clip, Center-punchthe
clip,then fold over the remainingtail onto the clip.
HAMMER
(cont'd)
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1 6 - 11
Front Driveshafts
(cont'd)
Reassembly
16. Unwind the boot band tool. and cut off the excess Outbosrd Joint Sids:
free end of the band to leavea 5 - 10 mm (0.2- 0.4
in) tail protrudingfrom the clip. 1. Wrap the splineswith vinyl tape to preventdamage
to the boot.
5 - 1 0m m
10.2- 0.4 in,
OUTBOARDBOOT
VINYLTAPE
1 7 . Bendthe band end by tappingit down with a ham-

mer,
NOTE;
. Makesurethe band does not move,
. Removeany greaseremainingon the surround-
ing surfaces.
2, I n s t a l lt h e b o o t b a n d a n d o u t b o a r d b o o t , t h e n
removethe vinyl tape.Takecare not to damagethe
boot.
3. Installthe stop ring into the driveshaftgroove.
DRIVESHAFT
18, Installthe new set ring.
16 -1 2
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4. lnsertthe driveshaftinto the outboardioint until the 6. Checkthe alignmentof the paint markwith the out-
stop ring is closeon the joint. boardjoint end.
DRIVESHAFT DRIVESHAFT
1. Packthe outboardjoint with the joint greaseincluded

in the new joint boot set.
To completelyseat the outboardjoint, pick up the
driveshaftand joint. and drop them from about 10 Greasequantity:
cm (4 to 5 inches)onto a hard surface,Do not use a Outboard ioini: '97 model and '98 USA model
hammeras excessiveforce may damagethe drive- 130- 140 g {,1.6- ,0.9oz}
shaft. '98 C8n8d8modsl 8ndall '99- 00 models
ll0 - tso g {i1.9- 5.3 ozl
DRIVESHAFT
i/,,,t|:l,r;;:,:.'i,,1;'/l
(cont'd)
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1 6 - 13
Front Driveshafts
Reassembly(cont'd)
8. Fit the boot ends onto the driveshaftand outboard 11. Closethe ear portion of the band with a commercially
lornt. availableboot band pincersKENT-MOORE J-35910or
OUTBOARDBOOTfiPE) equivalent.
OUTBOARD
BOOT
OUTBOARDBOOT
OUTBOARD
JOINT BOOTBAND PINCERS
KENT.MOORE J-35910
Installthe boot bands, or equivalent
. F o r a l l ' 9 7 m o d e l sa n d ' 9 8 USA models, go to
step 13. EARPORTION
. For'98 Canadamodelsand all '99 - 00 models,
go to step 10.
12. Checkthe clearancebetween the closed ear Dortion
10. Set the ear clamp band by threadingthe tab into the of the band, lf the clearanceis not within the stan-
holesof the band. dard,closethe ear portionof the bandfurther.
6.0 mm 10.24in) MAX
3.0mm {0.12in} MAX
16 -1 4
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13. Fit the boot ends onto the driveshaftand the out- 1 5 . Pull up the slackin the band by hand.
boardjoint.
1 6 . Mark a positionon the band 10 - 14 mm (0.4- 0.6
in.)from the clip.
CLIP
14. Fit the doublelooDboot bandsonto the boot ends
1 7 . Threadthe free end of the band through the nose

sectionof a commerciallyavailableboot band tool
(KD-3191 o r e q u i v a l e n t la, n d i n t o t h e s l o t o n t h e
winding mandrel.
BOOTBANDTOOL
(Commercially
available) Mark spot.
or equivalent
KD-3191
(cont'd)
Front Driveshafts
(cont'dl
Reassembly
1 8 . Placea wrenchon the winding mandrelof the boot 21, Bendthe bandby tappingit down with a hammer.
b a n d t o o l , a n d t i g h t e nt h e b a n d u n t i l t h e m a r k e d
spot on the band meetsthe edgeof the clip. N O T E :M a k e s u r e t h e b a n d a n d t h e c l i p d o e s n o t
i n t e r f e r ew i t h a n y t h i n g ,a n d t h e b a n d d o e s n o t
1 9 . Lift up the boot band tool to bend the free end of m o v e , R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r -
the band90" to the clip. Center-punch the clip,then roundingsurfaces.
fold over the remainingtail onto the clip.
BAND END
CLIP
20. Unwind the boot band tool. and cut off the excess
free end of the bandto leavea 5 - 10 mm (0.2- 0.4
in) tail protrudingfrom the clip.
16-16
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Front Driveshafts
lnstallation
1. Installthe outboardioint into the knuckle. 4. Cleanthe areaswhere the driveshaftcontactsthe
differentialthoroughly with solvent or carburetor
c l e a n e r ,a n d d r y w i t h c o m p r e s s e da i r . I n s e r tt h e
inboardend of the driveshaftinto the differentialor
KNUCKLE i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n g l o c k s i n t h e
groove.
INBOARD
JOINT
Replace.
INBOARDJOINT
OUTBOARDJOINT
Apply0.5- 1.0g (0,02- 0.04oz)of specifiedgreaseto

the whole sDlinedsurfaceof the intermediateshaft.
After applyinggrease.removethe greasefrom the
splinedgroovesat intervalsof 2 - 3 splinesand from 5. lnstallthe knuckleon the lower arm. Be careful not to
the set ring groove so air can bleed from the inboard damagethe ball joint boot. Wipe off the greasebefore
ioint. tighteningthe nut at the ball joint.Torquethe castle
nut to the lower torque specification. then tightenit
SETRING only far enoughto alignthe slot with the pin hole.Do
Replace. not alignthe nut by loosening. lnstalla new cotterpin.
SET RING
CASTLENUT COTTERPIN
Installa new set ring onto the driveshaftor interme- 12 x 1.25mm Replace.
diateshaftgroove. 49-59Nm On reassembly,
(5.0- 6.0 kgl'm, bendthe cotterpin
36 - 4:l lbl.ft)
(cont'd)
Front Driveshafts IntermediateShaft
Installation{cont'd} Removal
Installthe damperfork over the driveshaftand onto 1 . Drainthe transmissionoil or fluid (seesection13 or
t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r 14).
fork so the aligning tab is alignedwith the slot in
the damperfork. Removethe left driveshaft(seepage16-3).
FLANGE BOLT
10x 1.25mm Removethe threedowel bolts.
N.m{4.i1kst.n,32lbf.ftl ALtcNtNGTAB
12x 1.25mm
64 N.m {6.5 kgf.m, 47 lbf.ftl
Replace.
7. Loosely install the flange bolts and the new self-
locking nut.
8. Apply oil to the seating surface of the new spindle nut.
Removethe intermediateshaft from the differential.
FRONTWHEEL i WHEELNUT 12 x 1.5mm
108N.m (11.0kgf.m,80lbf.ftl Holdthe intermediateshaft horizontaluntil it is clearof
the differentialtopreventdamageto the differentialoil
seal.
INTERMEDIATE
SHAFT
SPINDLENUT
24 x 1.5mm
245 N.m
{25.0ksf.m, 181 lbf.ft)
NOTE:Attertightening.
usea driftto
stakethespindle
nutshoulder
against thedriveshaft.
9. Installa new spindlenut,then tightenthe nut.
10. Cleanthe mating surfacesof the brakedisc and the
wheel. then install the front wheel with the wheel
nuts,
1'1. Tighten the flange bolts and the new setf-locking
nut with the vehicle'sweight on the damper.
12. Refillthe transmissionwith recommendedfluid (see
section13or 14).
13. Checkthe front wheel alignment.and adjust if nec-
essary(seesection 18).
16-18
www.emanualpro.com
Disassembly
NOTE:Be carefulnot to damagethe metal rings on the 6. Pressthe intermediateshaft bearingout of the bear-
intermediateshaftduringdisassembly. ing supportusingthe specialtoolsand a press
'1. Removethe set ring.
ORIVER
07749- 001q)00
ATTACHMENT,
tl2x 17 mm
FLOATINGRUBBER 07745- 0010300
DAMPER
Checkfor deterioration
ano oamage,
OUTERSEAL SET RING

RePlace Replace.
Removethe intermediateshatt outer seal from the

bearingsupport.
Removethe e)dernalcirclip.
4. Pressthe intermediateshaft out of the shaft bearing

Press
INTERNALCIRCLIP + ATTACHMENT
o?JAF_ SH20it00
INTERMEDIATE SHAFT
Checklor damage.
5. Remove the internal circlip.
IntermediateShaft
Reassembly
Notetheseitemsduring reassembly:
partswith solvent.
. Be carefulnot to damagethe metal ringson the intermediate
shaftduring reassembly.
BEARINGSUPPORTRING DOWELEOLT
10 x 1.25mm
39 N.m 14.0kg'tm, 29lbf.ft)
EXTERNALCIRCLIP
Packthe interior
SHAFTRING
INTERMEDIATE of the outerseal.
2.0-3.5 g {0.07-0.r2 oz}
INTERNALCIRCLIP
BEARINGSUPPORT
OUTERSEA-
Replace.
'L
Pressthe intermediateshaft bearinginto the bear- Seat the internal circlip in the groove of the bearing
ing supportusingthe specialtools and a press. support.
Press
Prcss
t I
W--
L!
SHAFT
INTERMEDIATE
ATTACHMENT,
52x55mm
07746- 0010400
ATTACHMENT.35 mm l.D.
07746- 0030400
Pressthe intermediateshaft into the shaft bearing

usingthe specialtools and a press.
16-20
www.emanualpro.com
lnstallation
4. Seatthe externalcirclip in the groove of the inter- 1. Cleanthe areaswhere the intermediateshaft con-
mediateshaft. tactsthe transmission(differential) thoroughlywith
solvent or carburetorcleaner,and dry with com-
Press pressedair. Insen the intermediateshaft assembly
into the differential.Holdthe intermediateshaft hor-
+ DRNER izontalto preventdamageto the differentialoil seal.
07749- 0010000
Packthe interior
of the outerseal.
ATTACHMENT, INTERMEOIATE
SHAFT
2.0- 3.59 {0.07- 0.12oz)
52x55mm
07746- 0010400
OUTERSEAL
ATTACHMENT.
40 x 50 mm l.D.
EXTERNAL 07LAD- PW50601
CIRCLIP
Installthe outer seal into the bearingsupportusing 2. Installthe three dowel bolts,then torquethem.
the specialtools. The seal should be flush with the
bearingsupport.
OOWELBOLTS
6. I n s t a l lt h e n e w s e t r i n g i n t h e i n t e r m e d i a t e
shaft 10x 1.25mm
groove. 39 N.m {4.0kgf.m,29 lbtftl
RearDriveshafts
Removal Disassembly
't. Loosenthe rear
whel nuts slightly. NOTE:
a Due to the amount of work requiredto replaceone
Raisethe rear of the vehicle,and support it with damaged boot, it is best to replace both boots at the
safety stands in the proper locations(seesection 1), sametime.
. Theseinstructionsare for the inboardjoint.The same
Removethe wheel nuts and rearwheets. procedureappliesto the outboardjoint.
1, Removethe set ring from the inboardjoint,
BOOTBAND
Replace.
SPINDLENUT INBOARDJOINT
WHEELNUT
22 x 1.5mm 1 2x 1 . 5m m
Replace. 2. Removethe boot band.
- lf the boot band is a double loop type, raisethe

4. L i f t u p t h e l o c k i n gt a b o n t h e s p i n d l e n u t . t h e n band bendas shown,
removethe nut.
Remove the rear driveshaftsfrom the rear differen-

tial assembly(seesection15),
DOUSLELOOPBAND
Replace.
Removethe rear driveshaft outboard joint from the
trailingarm and rear hub usinga plastichammeror
a puller if necessary.
OUTBOARDJOINT TRAILINGARM
16-22
www.emanualpro.com
3. Mark each roller and inboard joint to identify the 8. Wrap the splineson the driveshaftwith vinyl tapeto
locationsof rollersand groovesin the inboardjoint. preventdamageto the boots.
Then removethe inboardjoint on the shop towel.
INBOARDJOINT
Checksplinesand driveshaftring INEOARDBOOT
for wearor damage, Inspectfor cracking,
Checkinsideborefor wear. RING splittingand wear.
DRIVESHAFT
Inspect{or cracks,
M.rks
DRIVE
SHOPTOWEL
Marks
Remove the boot band and boot from the drive-
Markthe rollersand spiderto identifythe locations shaft. Take care not to damagethe boot.
of the rollerson the sgider,then removethe rollers,
1 0 . Removethe vinyl tape.
DRIVESHAFT
ROLLER '11. Inspectthe driveshaftfor damageand otherfaults.
0\
tI Mark
CIRCLIP
Removethe circlip.
Mark the spider and driveshaftto identifythe posi-

tion of the spideron the shaft.
7. Removethe spiderusinga bearingremover.
RearDriveshafts
Reassembly
partswith solvent,
o r''..@El: Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
set.
Greasequantity:
fnboard Joint/Outboard Joint: 80 - 90 g 12.8- 3.2 ozl
LEFTINBOARDJOINT
SETRING (withsmalldriveshaftring)
Replace.
\@ CIRCLIP
BOOTBANOS
Beplace.
DRIVESHAFT
RINGS
DRIVESHAFT
RIGHTINBOARDJOINT
(withlargedriveshaftring)
Packcavity with grease.
BOOTBANOS
Replace.
ROLI.ER
.6{
Pack cavity with grease. OUTBOARDJOINT
16-24
www.emanualpro.com
'1. Wrap the splineswith vinyl tape to preventdamage 6. Reinstallthe rollersto their originalpositionson the
to the boots. spider by aligning the marks.After installation,make
sure to hold the driveshaftpointed straight up to pre-
vent the rollersfrom fallingoff.
ROLLER
VINYLTAPE
lnstallthe boots onto the driveshaft,and seat the

smallend of the bootsinto the grooveson the drive-
shaft,lf the smallendsof the bootsare not seatedin
t h e g r o o v e s ,t h e b o o t l e n g t h a d i u s t m e n tw i l l b e
rncorrect. 7. Packthe joint and the boot with the joint grease
includedwith the new boot.
Removethe vinyl tapefrom the end of the driveshaft.
Greasequantity: 80 - 90 s {2.8- 3.2 o2)
Installthe spideronto the driveshaftby aligningthe
mark on the spiderwith the mark on the end of the
driveshaft.
lnstalla new circlip into the end g.oove on the drive-

shaft. Rotatethe circlip in its groove to make sure its
fullv seated.
(cont'd)
RearDriveshafts
(cont'd)
Reassembly
8. Installthe joint by holdjngthe driveshaftstraightup 10. Set the double loop band onto the boot with the
and aligningthe markson the joint with the marks bandend towardthe front of the vehicle,
on the rollers,
9. Adjustthe positionof the jointsto the specifications

shown. then adjustthe boots halfwaybetweenfull
compressionand full extension.Makesurethe ends
of the bootsare seatedin the groovesin the joints.
1 1 . Pull up the slackin the band by hand.
Inboard ioint lngth:
153- 157mm {6.02- 6.18inl 12. M a k ea m a r ko n t h e b a n d 1 0 - 1 4 m m ( 0 . 4- 0 . 6 i n )
from the clip.
CLIP
Outboard ioint l6ngth:

l/l:' - 147 mm {5.63- 5.37 in}
16-26
www.emanualpro.com
1 3 . Threadthe free end of the band through the nose 16. Unwind the boot band tool, and cut off the excess
sectionof a commerciallvavailableboot band tool free end of the band to leavea 5 - 10 mm (0.2- 0.4
(KD-3191 o r e q u i v a l e n t )a, n d i n t o t h e s l o t o n t h e in) tail protrudingfrom the clip.
winding mandrel,
1 4 . Placea wrench on the winding mandrelof the boot

band tool, and tighten the band until the marked
spot on the band meetsthe edgeof the clip.
5-10mm
(0.2- 0.4in)
BOOTBANDTOOL
(KD-3191
or equivalent) Markon band.
WINDING
MANDREL
Lift up the boot band tool to bend the free end of

the band 90 degreesto the clip, Center-punchthe 17. Bendthe band end by tapping it down with a ham-
clip,then fold overthe remainingtail onto the clip. mer.
NOTE:
HAMMER . Makesurethe banddoes not move.
. R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r r o u n d i n g
surfaces.
(cont'd)
www.emanualpro.com
16-27
RearDriveshafts
(cont'd)
Reassembly lnstallation
'1. lnstall
18. Installthe new set ring into the driveshaftgroove. the outboardjoint into the trailingarm.
SETRING
Replace.
ICI Installthe rear driveshaftsinto the rear differential

SET RINGGROOVE assembly(seesection15).
Apply a small amount of engine oil to the seating

surfaceof the new spindlenut.
WHEELNUT 12x 1.5mm

108N.m (11.0kgt.m,80lbtftl
SPINDLE NUT22 x 1.5mm

181 N.m (18.5kgf.m, 134lbl.ftl Replace.
Installa new spindlenut, then torquethe nut. After

tightening,usea driftto stakethe spindlenut shoulder
againstthe driveshaft.
Cleanthe mating surfacesof the brakedisc and the

wheel, then install the rear wheel, and torque the
wheel nuts.
16-2A
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PropellerShaft
Inspection
UnivarsalJoint and Boots PropellorShaft Runout
1. Shiftthe transmissionto Neutral. 6. Installa dial indicatorwith its needleon the centerof
No, 1 or No.2 propellershaft.
2. Raisethe vehicleoff the ground,and supportit with
safetystandsin the properlocations(seesection1). 7. Turn the other propellershaft slowly and checkthe
runout.Repeatthis procedurefor the other propeller
3. Checkthe cente.supportbearingfor excessiveplay shaft.
or rattle.It the centersupporthas excessiveplay or
raftle,replacethe propellershaftassembly. No. 1 PropellerShaft Runout:
ServiceLimit: t.5 mm (0.06in)
No.1 PROPET_LER
SHAFT
Checkthe universaljoint boots for damageand dete- No. 2 PropellerShaft Runout:

rioration.lt the boots are damagedor deteriorated, ServiceLimit: 1.5 mm {0.06inl
replacethe propellershaftassembly.
Checkthe universaljoints for excessiveplay or rattle.

lf the universaljoints have excessiveplay or rattle,
replacethe propellershaftassembly.
lf the runout on either oroDellershaft exceedsthe

servicelimit, replacthe propellershaftassembly.
www.emanualpro.com
16-29
PropellerShaft
RemovaUlnstallation
1, Removethe propellershaftprotectors. 4, Removethe centersupportbearingmountingbolts.
No. 1 PROPELLER
SHAFT
SHAFT
PROPELLER
PROTECTOR
FLANGEBOLT
I x 1.25 mm
22 N.m (2.2kg{.m. 16lbl'ft)
SHAFT
No. 2 PROPELLER SELF-LOCK|NGBOLT uErrrEnDurrr.r'rI I'EAnrNu
10x 1.25mm
39N'm14.0kg{.rn,29lbtftl
Replace.
Mark the No. I propellershaft and transferassem-

FLANGEBOLT bly acrosstheir jointsas shown.
8 x 1.25mm
22 N.m 12.2kgf.m, 16lbf.ft) o. Removethe four 12-pointbolts, and remove the No.
1 propellershaft from the transferassembly,
PNOPELLER
SHAFT
PROTECTOR
2. Mark the No. 2 propellershaft and rear differsntial

acrosstheirjointsas shown. No. 'l PROPELLER
SHAFT
Removethe four 12-pointbolts. and remove the No.

2 propellershaft from the rear differential.
No.2 PROPELLER
SHAFT 12.POINTBOLT
8 x 1.25mm
32 N.m 13.3kst m, 24 lbtftl
12.POINTBOLT TRANSFER
8 x 1.25mm ASSEMBLY
32 N.m 13.3kgt'm, 2,1lbf.ft)
7. Installthe propellershafts in the reverseorder of

removal.Make sure to align the marks on the pro-
REARDIFFERENTIAL pller shafts with the marks on the rear differential
and the transferassemblv.
16-30
www.emanualpro.com
Steering
SpecialToofs 17-2 *SteeringColumn

.............
ComponentLocations Removal/lnstallation .......17-2O
................
Index................ .......17-3 lnspection ..............17-21
Troubleshooting SteeringLock Replacement............ 17-22
GeneralTroubleshooting................17-4 Power Steering Hoses,Lines
Noiseand Vibration.........................
17-8 FfuidLeakageInspection................. 17-23
FluidLeaks .............
17-10 Repfacement ..........17-23
Inspection and Adiustment Power SteeringPump
SteeringOperation..........................
17-12 Repfacement ..........17-24
Power Assist Check Disassembly ...........17-25
With VehicleParked....................
17-12 fnspection ..............
17-26
SteeringLinkageand Gearbox .......17-13 Reassembly ............
17-28
Pump Belt 17-14 Power Steering Gearbox
RackGuideAdjustment...................l7-15 Removal .................
17-31
FluidRep|acement...................,,.,....
17-15 Disassembly ...........17-34
PumpPressure Check.................,,...
17-16 Reassembly ............
17-40
*SteeringWheel
Ball Joint Boot Replacement..........17-50
Removal .................
17-18 Installation .............
17-51
Disassembly/Reassembly............... 17-18
4'%/b .......... -r'-7--a/
SUPPLEN\EN\AL RES\RA(N\ SYSTES{\(SRS\
This model has an SRSwhich includesa driver'sairbagin the steeringwheel hub. a passenger's airbagin the dashboard
abovethe glove box ('97 - 00 models),and seat belt tensionersin the seat belt retractors('98 - 00 models).Information
necessaryto safelyservicethe SRSis includedin this ServiceManual.ltems markedwith an asterisk(*) on the contents
pageinclude,or are locatednear,SBScomponents.Servicing.disassembling or replacingtheseitemswill requirespecial
precautionsand tools,and shouldonly be done by an authorizedHondaoearer.
To avoid rendering the SRS inoperative, which could lead to peFonal iniury or death in the event of a sevore trontal
collision. allSRS servicework must be performod by an authorized Honda dealer.
lmproper service procedurgs, including incorrect removal and installalion of the SRS, could lead to personal iniury
causedby unintontional deployment of th airbags {'97 - 00 models),and seat belt tensioners ('98 - 00 modelsl.
Do not bump the SRS unit. Otherwise, the system may lail in case ot a collision, or the airbags may deploy when the
ignition switch is ON (lll.
SRS electricalwiring harnessesare identitied by yellow colof coding. Ralatedcomponents are located in the steering
column, front console,dashboard,dashboard lower panel, and in the dashboardabove the glove box. Do not use elec-
trical test equipment on these cilcuits,
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Ret. No, I Tool Numbel Description fty PageReference
'l
o 07GAF- PH70100 PilotCollar 11-39
07HAG- SF10100 PistonSealRingGuide 1 17-44
o 07GAG- SD40200or
- SD4O2OA
PistonSealRingSizingTool 1 11-44
OTGAG
-@ -
07JGG 001010A BeltTensionGauge 1 1 7- 1 4
't]-31
3m 1
r OTNAD_ SR3O2OA CylinderEndSealRemoverAttachment 1 17-37
o 07NAG SR30900or ValveSealRingSizingTool 1
't7-4'l
07NAG, SR3OgOA
@ 07RAK- 5040110 P/SJoint Adaptor(Pump) 1 1 7 - ' t 61, 7
rol 07RAK- 5040120 P/SJoint Adaptor(Hose) 1 1 7 - 1 61, 7
@ 07406- 0010001or P/SPressureGauge 1 11-16,17
07406- 0010004
o 07725- 0030000 UniversalHolder 1 17-26,30
't]-42,43
@ 0 7 7 4 6- 0 0 1 0 1 0 0 Attachment,32 x 35 mm 1
't1-42,
@ 07749- 0010000 Driver 1 43
(} ,l
07916- SA50001 LocknutWrench,40 mm 11-15
07974- SA50200or SleeveSealRingSizingTool 1 't]-42
@
07974- SA5050A
@ 07974- SA50800 BallJoint BootClip Guide 1 11-42,50
* Includedin the BeltTensionGaugeSet 07TGG- 001000,4
o @
,l-
,/:\ =tt
\J I
o @ @
aA)
l:I /\L----.--.--------_
o (D (9 @ @ @
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17-2
ComponentLocations
lndex
Notetheseitemsduringdisassembly:
' lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has beenfound
defectiveor damageddur-
ing transit,storageor service.it shouldbe deployed(seesection24),
a Beforeremovingthe gearbox,removethe driver.sairbagassemblyand steeringwheel.
. After installingthe gearbox,checkthe wheelalignmentand adjustif necessary.
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresanthe

SRs
section(24)beforeperformingrepairsor servrce.
STEERINGWHEEL
Removal,page17,18
Disassembly/Reassembly, page1?,18
page17-19
Installation,
DRIVER'SAIRBAGASSEMBLY
Removal/lnstallation,
see section24
STEERINGGEARBOX
RackGuideAdjustment,page17-15
Removal,page17-31
Disassembly, page17-34
Reassembly, page17,40
page17,51
Installation,
VALVEBODYUNIT
Overhaul,page17-38
STEERINGCOLUMN
page17-20
Removal/lnstallation.
pagel7 21
Inspection,
SteeringLockReplacement, page17 22
CABLEREEL
see section24
tcNrnoNswtTcH
See sction23
STEERINGHOSES,LINES
Replacement.page l7-23
RESERVOIR
FluidR6placement. page17 15 END BALLJOINT
Fluid Leakagelnspection,page 17-23 BallJointBootReplacement,
page17-50
PumpBeltInspection and
Adjustment, pag t7-14
PumpPressure Check,page17-16ot 17-1j
Replacemont, page17-24
Disassembly,pa96 17,25
Inspection,page 17-26
Reassembly.page17-28
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17-3
Troubleshooting
g
GeneralTroubleshootin
Checkthe followingbeforeyou begin:
. Hasthe suspensionbeenmodifiedin a way that would affectsteering?
. Are tire sizes,tire varietyand air pressurecorrect?
. ls the steeringwheeloriginalequipmentor equivalent?
. ls the power steeringpump belt properlyadjusted?
. ls steeringfluid reservoirfilledto properlevel?
. ls the engineidle speedcorrectand steady?
HardSteering(Checkthe powerassist,see page17-12.lf the forceis over 29 N (3.0kgl 6.6 lbfl, proceedwith this troubleshooting.i
C h e c kt h e p u m p f l u i d p r e s s u r e
(seepage17-16or 17-17).
Measuresteadystate lluid pres- Abnormalthiid
pressure(Iluid Checkthe teed and return circuit lines and hose
sure at idle with the pressurecon- betweenthe gearbox and pump for clogging and
trol valve and the shut-offvalve (it pressureis too
high) deformation.
so equipped) fullyopen.
The fluid pressureshould be 1,500
kPa(15kgf/cm,,213 psi)orless.
Normallineand hose
Normal
Faultyvalvebody unit
C h e c kt h e p u m p f l u i d p r e s s u r e
(seepage17-16or l7-17).
Measurepump reliefpressureat Checkthe flow controlvalve(seepage17 26).
i d l e w i t h t h e p r e s s u r ec o n t r o l Reliefpressure . Checkthe valvlor smooth movementin the hous-
valve and the shut'off valve lil so too low ing.
equipped) fullyclosed. . Checkthe relief valve for leaks.
The fluid pressureshould be 6,900
7,800kPa (70- 80 kgflcm,, 1,000
- 1,140psi).
Normalreliefpressure Abnormal
Go to page 17 5 Faultypump assembly Faultyflow control valve
1 7 -4
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Checkthe force requiredto turn
the wheellseepage17 12).
Startthe engineand measurethe
force requiredto turn the wheel
to the right and left.Difference of Abnormal Deformed
t h e f o r c e r e q u i r e dt o t u r n t h e
wheel to the right and to the left
shouldbe 2.9 N (0.3 kgf,0.7 lbt)
or less,
Not deformed Faultycylinderlines
the rackguide
Readjust
(seepage17-15)
AdjustmentOK
Normal
Bent
I
Faultysteeringgearbox
Compairthe steeringto another

alikevehicle.
(cont'd)
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17-5
Troubleshooting
(cont'dl
GeneralTroubleshooting
lf the problemis not correctedby

Assist(excessively
lightsteering)at Checkthe rack guide for proper adjustingthe rack guide, adjust
high speed. adjustment(seepage17-15). t h e f r o n t w h e e l a l i g n m e n t( s e e
section18).
Shockor vibrationwhen wheelis Checkthe rack guide for proper

turnedto full lock. adjustment(seepage17'15).
Adjustthe rackguide.
Rackguideis adiustedproperly.
adjustingthe rack guide,replace
C h e c kt h e b e l t f o r s l i p p a g ea n d the gearbox.
adjustas necessary (seepage17-14).
Steeringwheelwill not return

smoothly.
A a n d B c y l i n d e rl i n e sa r e n o r
mal, checkwheel alignment(see W h e e l a l i g n m e n ti s a b n o r m a l ,
section18). adjustas needed.
Wheelalignmentis normal.
l f t h e m e a s u r e m e n tasr e o u t o f
Checkthe steeringwheel opera-
s p e c i f a c a t i o n as d
, j u s tt h e r a c k
tion and power assistcheck(see guade.
page 17-121.

adjustingthe rackguide,replace
the gearbox,
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Unevenor roughsteering. Ad,usttherackguide(seepage17-15).
ll the problemis not correctedby

adjustingthe rack guide,replace
the gearbox.
Adjustthe belttension.Replacethe
Beltslippingon pulley.
belt,if necessary(seepage17-14).
l f t h e e n g i n es t a l l sw h e n t h e
wheel is turnedwhile the vehicle
ldlespeedlow or erratic. is stopped or moving at low
speed,adjustthe idle speed(see
section111.
Checkpower steeringlluid level.lf

Air in reservoir,or check power the level is excessivelylow check
steeringtluid level. for leaks in the system.Add fluid
to the specifiedlevel.
lf fluid levelis OK, checkO-rings

a n d s e a l so n b o t h e n d s o f t h e
p u m p i n l e t h o s e ,a n d t h e P / S
p u m p h o u s i n gm a t i n gs u r l a c e s
and drive shaft oil seal for suc
tion leaks.Checkthe reservoirfor
cracks,Replaceparts as neces-
Steeringwheel kicksback P u m p b e l t s l i p p i n go n p u l l e y Adjustthe belt tension(seepage

duringwide turns. (pumpstopsmomentarily). 17-14)
or replace belt.
Checkif pump pressureis normal

Installthe power steeringpres- and the gauge needletravel is 500
sure gauge, Closethe pressure k P a ( 5 k g l / c m , ,7 1 p s i ) o r l e s s .
control valve and shut off valve (if Checkthe flow controlvalve if the
so equipped)fully and measure needletravelexceeds500 kPa (5
the pump pressure(seepage 17-16 kgflcm',71 psi). lI the flow control
ot 17 17). valve is normal, replacethe pump
as an assembly,
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7-7
Troubleshooting
NoiseandVibration
NOTE:Pumpnoisein first 2 - 3 minutesafterstartingin cold weatheris normal.
Humming Humming due to pulsationof fluid is normal, particularlywhen the wheel is

turnedwith the vehiclestooDed.
lf equippedwith automatictrans-
m i s s i o n ,t h e h u m c o u l d b e t h e Confirm by temporarily removing
torqueconverteror pump noase. the pump belt.
Feedhose (high-pressure)
touch-
Beposition the feed hose.
ing the frame.
Rattleor chattering Loosesteeringshaft connector, C h e c ka n d t i g h t e n , o r r e p l a c e

tie-rod,or balljoint. parts as necessary,
Columnshaftwobbling. Roplacethe columnassembly.
Checkthe rack guide for proper

Adjust,if necessary.
adjustment(seepage17-15).
Rattlingsound and feeling when turning the steeringwheel right and left with th
engineOFFis normal.
Pump noise,though not loud,from the valvebody unit can be heardwhen turn-
ing the steeringwheelto full lockin eitherdirection.This is normal.Do not hold
the steeringwheelat full locklor morethan five secondswhen inspecting.
17 -8
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Checkthe fluid lev1.
Gratingnois Cavitationcausedby air bubbles l t l o w , f i l l t h e r e s e r v o i rt o t h e
Pumpnoise
trom pump in the fluid. properlevel.and checkfor leaks.
Tightenor roplaceas necessary,
Checkfor a crushedinlet hoseor

a loose hose clamp allowing air
into the suctionside of the sys
t e m . C h e c kt h e r e s e r v o i rf o r
cracks.Tighten or replaceas nec-
Checkthe driveshaftoil seal.
Pump noise up to 2 - 3 minutes

after starting in cold weather is ll pump noiseis abnormallyloud,
removeand inspectthe pump for
Pumpnoise normal,Comparepump noiseat
wear and damage(see page 17-
operatrngtemperatureto another
vehicle. 251.
Tightenor replacethe pulley.

Raftleor chattering l I s h a f t i s l o o s e , r e p l a c et h e
pump.
Troubleshooting
FluidLeaks
Checkthe gearboxassemblyfor oil leakscarefully.Oil can leakout ot variouspoints,dependingon locationof the faulty
rings.Checkthe followingbeforeremovingthe gearboxfrom the frame.
oil seals/seal
Leakingfrom the oil seal on the Replace the valve oil seal from
SteeringGearbox
top of the valvehousing. the valve housing.
Leakingfrom cylinder end into Replace the valve oil seal from
left tie rod boot. the pinion shaft.
Replacethe cylinderend seal on

the valvebody unit side.
Leakingfrom cylinder end into Replacethe cylinderend seal on

right tie-rod boot. the cylinderend side.
Leakinglrom the shaftupperend

sectionor pin engagementsec- R e p l a c et h e v a l v e b o d y u n i t .
tion of the pinionshaft.
Tightenthe connector.It it's still

Leakingfrom cylinderlineA or B
(attlarenut). leaking,replacethe line,cylinder
connections
or valvehousing.
L e a k i n gc a u s e db y a d a m a g e d
Replace
cylinderlineA or B.
cylinderlineA or B.
Leakingfrom pump outlet hose Tightenthe connector.ll it's still

and returnlinejoint fittingon the leaking,replacethe line,joint fit-
valvebody unit {attlarenut}. ting or valvehousing,
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17 -1 0
B e p l a c et h e h o u s i n g O - r i n g s .
if the housing still leaks, replace
the pump.
Reservoir is overfilled.
P u l l o f f t h e h o s e a n d d r a i nt h e
reservoirto the properlevel.
Air leakin suctionsideof the sys-

tem (reservoir,pump inlet hose,
front pump seal).
Tightenthe fifting. lf it's still leak-

PumpoLrtlethose L e a k i n ga t t h e t h r e a d e d f i f t i n g . ing, replacethe O-ringor pump
(high-pressure) outlethose,
Leakingat the swagedjoint. the pump outlethose.

Replace
Leakingbecauseof damage,dete' Replace

or repairas necessary.
Pumpinlet hose or improperassembly,
rioration,
(low pressure)
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17-1
Inspectionand Adjustment
Steering Operation PowerAssistCheckwith
VehicleParked
Placethe front wheels in the straight ahead position.
and measurethe distancethe steering wheel can be 1. Checkthe power steeringfluid level (see page 17-
turnedwithout movingthe front wheels. 15)and pump belttension(seepage 17-14).
ROTATIONALPLAY:0 - 10 mm (0 - 0.39 inl 2. Startthe engine,allow it to idle, and turn the steer-
ing wheel from lock-toiockseveraltimes to warm
lf the play exceedsthe limit, perform rack guide adjust- u p t h ef l u i d .
ment (seepage17-15).
lf the play is still excessiveafter rackguide adjustment, 3. Aftacha springscaleto the steeringwheel,With the
inspectthe steeringlinkageand gearbox as described engine idling and the vehicleon a clean.dry floor,
on the nextpage. pull the scaleas shown and read it as soon as the
tires beginto turn.
ROTANONALPLAY
+i r
f::1-t E
SPRING
SCALE
(Commercially
available)
The scaleshould read no more than 29 N (3.0 kgf,

6 . 6 l b f l . l f i t r e a d sm o r e , c h e c kt h e g e a r b o xa n d
oumo.
17-12
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SteeringLinkageand Gearbox
PINIONSHAFTGROMMET
Inspoctfor damageand deterioration.
STEERINGJOINTS
Checkfor loosejoint bolts.
NE-RODLOCKNUT
CheckIor loose locknut.
BALLJONT AOOT
Inspoctlor damageand deterioration.
Se page 17-50for replacemont.
Inspectfor loose mounting bolts.

GEARBOXMOUNTINGCUSHIONS
lnsp6ctfor dgterioration. BOOT
lnspectfor damaganddterioration.
END AAtL JOINT
Inspectfor faulty movement
ano oamag.
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17-13
PumpBelt
When using a new belt.first adjustthe deflectionor ten- Measurementwithout Belt Tension Gauge:
sion to the values for the new belt, then readjustthe Apply a force ot 98 N (10 kgf,22 lbt) and measurethe
deflectionor tensionto the valuesfor the used belt after deflectionbetweenthe power steering pump and the
runningenginefor five minutes. crankshaftoullevs.
Inspection Deflection:
UsedBelt:11.0- 1i1.5mm {0.'(l - 0.57in)
Notetheseitemsduring inspection: New Belt: 7.5 - 10.0mm {0.30- 0.39 in)
a lf there are cracksor any damageevidenton the belt,
replaceit with a new one.
. Followthe manufacturer's instructionslor the tension
gauge.
'1. Remove
the P/Sreservoirfrom the bracket,and set Measurehere.
it aside.
2. Attach the belt tension gauge to the belt with the

gaugefacetowardthe engine,and measurethe ten-
sion of the belt.
Removethe belt tension gauge carefullyto avoid

hittingthe gaugeresetlever.
PULLEY
CRANKSHAFT
Tension:
Used Belt: 390 - 540 N {40 - 55 kgf, 88 - 121 lbf) Adiustment
New Belt: 7,[0- 840 N (75 - 90 kgf, 165- 198 lbf)
'1.
L o o s e nt h e p o w e r s t e e r i n gp u m p m o u n t i n g b o l t
and pump lockbolt.
PUMPMOUNNNG BOLT
24 N'm(2.4kgf'm,17lbfftl
PUMPLOCKBOLT
24N.m12.4kgf.m,17lbf.ftl
Adjust the belt tensionby moving the power steer-

PULLEY
CRANKSHAFT ing pump with a 1/2" drive breakerbar to obtainthe
p r o p e rb e l t t e n s i o n ,t h e n r e t i g h t e nt h e m o u n t i n g
bolt and lockbolt.
Start the engine and turn the steeringwheel from

lock-to-lockseveraltimes,then stop the engineand
recheckthe deflectionof the belt.
17 -1 4
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RackGuide Adjustment Fluid Replacement
1 . Setthe wheelsin the straightaheadposition. Checkthe reseryoirat regularintervals,and add the rec-
ommendedfluid as necessary.
Loosenthe rack guide screw locknutwith the spe- CAUTION: Always use Gsnuine Honda Power Steering
cialtool,then loosenthe rackguidescrew. Fluid-V or S. Using any other type of power steering
For'98 - 00 models,removethe rack guide screw. tluid or automatic transmissionfluid can causeincreassd
R e m o v et h e o l d s e a l a n tf r o m r a c k g u i d e s c r e w wear and poor steering in cold w3athel.
threadedsection,and apply new sealantto the first SYSTEMCAPACITY:
three threads.Looselyinstallthe rack guide screw 0.85 liter {0.90US. qt. 0.75 lmp.qtl
on the steeringgearbox. at disasssmbly
RESERVOIR CAPACITY:
0.,1liter (0.42US. gt, 0.35 lmp.qi)
RACKGUIDESCREW
UPPENLEVELLINE
LOWERLEVELLINE
1 . Raisethe reservoir.then disconnectthe returnhose

to drainthe reservoir.Takecare not to spill the fluid
on the body and parts.Wipe off any spilledfluid at
once.
LOCKNUT
25 N.m
12.5kgt m, 18lbtftl
5. Tightenthe rack guide screwto 25 N.m (2.5 kgf'm,

18 lbf.ft),then loosenit.
4. R e t i g h t e nt h e r a c k g u i d e s c r e w t o 3 . 9 N ' m ( 0 . 4
kgf.m, 2.9 lbf.ft),then back it off to specifiedangle.
2, Connecta hose of suitablediameterto the discon-
SpecifiedReturn Anglo: nectedreturn hose,and put the hose end in a suit-
37 model: 10 r 5" ablecontainer.
'98 - 00 modeb: 20' Max 3. Stan the engine.let it run at idle,and turn the steer-
ing wheel from lock-to-lockseveral times. When
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
screw. engine.Discardthe fluid.
4. Beinstallthereturnhoseon the reservoar.
6. Checkfor tight or loose steeringthrough the com- 5. Fillthe reservoirto the upperlevelline,
pleteturningtravel. 6. Startthe engineand run it at fast idle.then turn the
steeringfrom lock-to-lock severaltimes to bleedair
7. Performfollowinginspections: from the system.
. Steeringoperation(seepage17-12). 7. Recheckthe fluid leveland add some if necessary.
. Powerassistwith vehicleparked Do not fill the reservoirbeyondthe upperlevelline.
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lnspectionand Adjustment
PumpPressureGheckWith T/N 07406- 0010001
Checkthe fluid pressureas follows to determinewhether 5. Fully open the shut-off valve.
the troubleis in the pump orgearbox.
PRESSURE
1. Checkthe powsr steeringfluid level (see page 17- CONTROLVALVE
15),and pump belttension(seepage17-14).
2. Disconnectthe pump outlet hose from the pump

outlet with care so as not to spill the powr steering
iluid on the frame and other pans. thon installthe
P/Sjoint adapter(pumplon the pump outlet.
6 x 1.0mm BOLT
{Partoftool)
FEEDHOSEFITTING
PUMPOUTLETHOSE
11 N.m ll.1 kgl.m, E lbf.ftl

6. Fullyopenthe pressurecontrolvatve.
P/S PRESSURE GAUGE
07('6 - 0010001
7. Startthe engineand let it idle.
6 x t.0 mm BOLT
{Partoftool) 8. Turn the steeringwheel from lock-to-lockseveral
11 N.m times to warm the fluid to operating temperature.
(1.1kgt m, 8 lbf.tr)
9, Measuresteady-statefluid pressurewhile the engine

is idling. lf the pump is in good condition,the gauge
should read lessthan 1,500kPa(15 kgf/cmr,213 psi).
lf it reads high, checkthe outlet hose or valve bodv
unit (seeGeneralTroubleshooting).
10. Close the pressure control valve, then close the

shut-off valve gradually until the pressuregauge
nsedle is stable.Readthe pressure.
CAUTION: Do not kap tha prca3un control valvo

clorod mo.c thon 5 srconds or thc pump cluld bo
damEgodby ovor-hoating.
Connectthe P/Sjoint adapter (hose)to the p/S pres- 11. lmmodiatelyopenthe pressurecontrolvalvefullv.
sure gauge,then connectthe pump outlet hose to
the P/Sioint adspter(hose). lf the pump is in good condition,the gaugeshould
read at least 6,900- 7,800 kpa (70 - 80 kgflcmr,
I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e p / S j o i n t '1,000- 1.140psi).
A low readingmeanspump out-
adapter(pump), put is too low for full assist.Repairor replacethe
DUMD.
17-1 6
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PumpPressureCheckWith T/N 07406- 001000A
Checkthe fluid pressureas follows to determinewhether 5. Open the pressure controlvalve fully.
the troubleis in the pump or gearbox.
1. Checkthe power steeringtluid level (see page 17- PRESSURE

CONTROLVALVE
151,and pump belttension(seepage 17-14).
2. Disconnectthe pump outlet hose from the pump

outletwith careso as not to spill the power steering
fluid on the frame and other parts,then installthe
P/Sjoint adapter(pump)on the pump outlet.
6 x 1.0mm BOLT
(Partoftool)
FEEDHOSEHfNNG
PUMPOUTLETHOSE
1'l N.m 11.1kgf.m,8lbfft)
Startthe engineand let it idle.

P/S PRESSURE GAUGE
07406- 001000A
7 . Turn the steering wheel from lock-to-lockseveral
6 x 1.0 mm BOLT timesto warm the tluid to operatingtemperature.
(Partol tool)
11 N.m
(1.r kg{.m,8lbf'ft| Measuresteady-statefluid pressurewhile the engine
is idling.It the pump is in good condition,the gauge
shouldread1,500kPa(15koflcm' ,213psi).lf it reads
high. checkthe outlet hose or valve body unit {see
GeneralTroubleshooting),
Closethe-pressurecontrolvalve graduallyand read

the oressure.
CAUTION: Do not keep the pressurs control valve

closed more then 5 seconds or the pump could bo
damaged by overheating.
1 0 . lmmediatelyopenthe pressurecontrolvalvefully.
lf the pump is in good condition,the gauge should

Connectthe P/Sjoint adapter (hose)to the P/S pres- read at least 6,900 - 7;800 kPa (70 - 80 kgflcm' ,
sure gauge,then connectthe outlet hoseto the P/S 1,000- 1.140psi), A low readingmeanspump out-
joint adapter(hose). Dut is too low for {ull assist.Repairor replacethe
oumo.
I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e P / S j o i n t
adapter(pumpl.
SteeringWheel
Removal
SRS componentsare located in this area. Reviewthe 3. Loosenthe steeringwheel bolt, then install a steering
SRScomponentlocations,precautions,and procedures wheelpulleron the steeringwheeland removeit.
vice. Notetheseitemswhen removingthe steeringwheel:
. Do not tap on the steeringwheel or the steering
1. Align the front wheelsstraightahead.then remove columnshaftwhen removingthe steeringwheel.
the driver's airbag assembly(seesection24) from . lf you threadthe puller bolts into the wheel hub
the steeringwheel. morethan five threads,the boltswill hit the cable
reel and damageit. To preventthis, installa pair
2. Disconnectthe horn connectorand cruise control of jam nutsfive threadsup on eachpullerbolt.
switch connectors.
STEERINGWHEELBOLT
39 N.m 14.0kgt.m,29 lbtftl
CONTROL
SWITCHESCONNECTOR
STEERINGWHEELEOLT
STEERINGWHEEL
EOSSCOVERPLATE WHEELBODYCOVER
_^M
@, h
"\
BODY
COVERCAP
ACCESSPANEL
17- 1 8
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lnstallation
1. Beforeinstallingthe steeringwheel, make sure the 2. Installthe steeringwheel on to the steeringcolumn
front wheelsare alignedstraightahead,then center shaft,makingsurethe steeringwheel shaftengages
the cablereel.Do this by first rotatingthe cablereel the cable reel and cancelingsleeve.Do not tap on
clockwise until it stops. Then rotate it counterclock- the steeringwheel or steeringcolumn shatt when
wise approximatelytwo turns. The arrow mark on instailingthe steeringwheel
the cablereel labelshouldpoint straightup.
CABLEREEL
ARROWMARK
HOLE
Installthe steeringwheel bolt, and tighten it to 39

N.m (4.0 kgf.m, 29 lbf.ft).
Connectthe horn connectorand the cruisecontrol

switchconnectors,
Installthe driver's airbag assembly,and confirm

propersystemoperation(seesection24).
SteeringColumn
SRS componentsare located in this area. Review the 1. Removethe steeringwheel (seepage 17-18).
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor ser- Remove the driver's side dashboard lower cover
vice. and kneebolster(seesection20),
Notetheseitemswhen removingthe steeringcolumn: Removethe columncovers.

. Before removing the steering column, remove the
driver'sairbag assemblyand cable reel (seesection With A"/T,move the shift lever to the E position,
24). and removethe shift cable from the column. and
. Beforeremovingor installing,set the columnshaft in set it aside(seesection14).
the neutralpositionby pullingup the steeringcolumn
to uppermostposition,then lower it 8 mm (5/16in). Remove the combinationswitchassemblyfrom the
Tightentilt lever. steeringcolumn shaft by disconnecting
the connec-
FULLSTROKE: tors, and removing the two screws.
23 mm 10.9in)
8 mm (5/16) Disconnectthe steeringjoint from the enginecom-
MAXIMUMUPPER panment.
POSTTTON
7. R e m o v et h e s t e e r i n g c o l u m n b y r e m o v i n g t h e
attachingnuts and bolts.
MAXIMUM LOWER
POSTTTON
TILT LEVER
SHAFTCENTER
1 1 1m m 1 0 0m m 5mm
UPPER
COLUMNCOVER
COMAINANONSWITCHASSEMBLY
JOINT COVER BOOTBAND
9,8 N.m l r .0 kgf.m,7 lbf.fO
JOINT DUSTSEAL
22 N.m (2.2kgl.m, 16lbtftl
JOINT
COLUMNBMCKET
LOWERATTACHINGBOLTS
39 N.m lir,o kgf.m, 29 lbf.ft)
UPPERATTACHINGNUTS LOWERCOLUMNCOVER
16 N.m lr.6 kgf.m, 12 lbf.ftl
17-20
www.emanualpro.com
22 N.m (2.2 kgf.m, 16lbt.ftl
8. is the reverseofthe removalprocedure.

Installation
Notetheseitemsduring installation:
. Be sure the wires are not caught or pinchedby
any partswhen installingthe column.
a Make sure the wire harnessis routed and fas-
SIEERING JOIMT
tened properly.
. Make sure the connectorsare properlyconnected.
. Make sure the steeringjoint is connectedas fol-
lows:
a. lnsertthe uDperend of the steeringjoint onto
UPPERJOINT BOLT
the steeringshaft (line up the bolt hole with Bolt must IineuP
the flat ot the shaft). with fl6t on shaft.
b. Slip the lower end of the steeringioint onto
the Dinionshaft (lins up the bolt holewith the Flatponion.
groovearoundthe shaft).and installthelower
ioint bolt. Be sure that the lower joint bolt is JOINT
STECRING
securelyin the groovein the pinionshaft'
c. Pullon the steeringjoint to makesurethat the
steeringjoint is JullYseated. LOWER JOINTBOLT
Then installthe upperjoint bolt and tightenit. Boltmustlineupwith
groovearoundon shaft,
Inspection
Checkthe steeringcolumn ball bearingand the steer- . Checkthe absorbingplates,absorbingplate guides
ing joint bearingsfor play and proper movement.lf and slidingcapsulesJordistortionand breakage.
there is noisyor if there is excessiveplay,replacethe ReDlacethe column as an assemblyif they are dis-
steeringcolumn as an assemblY torted or broken.
Checkthe retainingcollar for damage.lf it is dam-
aged,replacethe retainingcollar. SLIDINGCAPSUII
This part is attached
PLASl'tC to the column bracket
INJECTIONS with the plastic injections.
ABSOBBING
PLATE
FETAININGCOLLAR
ABSORBING
PLATEGUIDE
SHIFT I.EVER
Seesection 14. |GNMON SWTTCH
See section23.
(cont'd)
SteeringColumn
Inspection(cont'dl SteeringLockReplacement
1 . Move the tilt lever from the loose position to the 1 . Bemovethe steering column (see page 17-20).
l o c k p o s i t i o n3 t o 5 t i m e s ; t h e n m e a s u r et h e t i l t
lever preload10 mm (0.4in) from the end of the tilt Centerpunchthe shearbolt, and drill bolt head off
rever. with a 5 mm (3/16in) drill bit.
Preload:70 - 90 N (7 - 9 kgf, 15 - 20 lbf) Removethe shear bolt from the switch body. Be
carefulnot to damagethe switchbody when remov-
l f t h e m e a s u r e m e n ti s o u t o f t h e s p e c i f i c a t i o n . ing the shearbolt.
adjustthe preloadusingthe tollowingprocedures.
Insertthe ignitionkey and turn it to "1".
a. Loosenthe tilt lever,and set the steeringcolumn
in the neutralposition. Push the lock pin down, and pull out the steering
lockbody from the steeringcolumn.
b , R e m o v et h e 6 m m l o c k b o l t . a n d r e m o v e t h e
stop. Be carefulnot to loosenthe tilt leverwhen
installingthe stop or tighteningthe 6 mm lock
bolt.
NLT LOCKBOLT
SPRINGSCALE Tighten the lock bolt with
the tilt leverraised.
SHEARBOLT
Replace.
L-_
I n s e r t t h e i g n i t i o n k e y t o t h e n e w s t e e r i n gl o c k
6 mm LOCKBOLT
7 N.m(0,7kgf.m,S tbtftl body,and turn it to "1".
7 . Push the lock pin down, and insen the steering lock
Adjustthe preloadby turningthe tilt lockbolt left body into the steeringcolumn until it clicksinto place.
or ri9ht.
8 . Looselyinstallthenew shearbolt.
d . Pull up the tilt lever to the uppermostposition.
and installthe stop. Checkthe preloadagain. lf Checktor proper operation of the steeringwheel
t h e m e a s u r e m e n its s t i l l o u t o f s p e c i f i c a t i o n , lock,and that the ignitionkeyturns freely.
r e p e a tt h e a b o v e p r o c e d u r e sa . t h r o u g h c . t o
adjust. 1 0 . Tightenthe shearbolt untilthe hex headtwistsoff.
TWIST.OFF
PORNON
SHEARBOLT
1 7- 2 2
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PowerSteeringHoses,Lines
Fluid LeakageInspection
HOSESand LINES
. lnspecthosesfor damage.leaks.interferenceand twisting
. Inspectfluid linesfor damage,rustingand leakage.
. Checkfor leaksat hoseand line joints and connections.
FEEDHOSE
37N.m13.8kgf.m,27lbtft) RETURNLINEJOINT
28 N.m (2.9kgf.m.21 lbf.ftl
CYLINDERLINES
17 N.m (1.7kgf.m. 12 lbf.ftl
FOWERSTEERINGPRESSURE SWITCH
12 N.m (1.2kgf.m,8.7 lbtft)
GEARBOX.nd VALVEBODYUNll
Checkfor leaksat the mating surface
and flare nut connections.
CYLINDER
26 N.m (2.7 kgf.m, 20 lbf.ft)
FEEDHOSE
11 N.m
('1.1kgt.m, 8 lbf.ftl
SUCTIONHOSE
PUMPASSEMBLY
Checkfor leaksatthe pump
seal.inletand outletfittings.
Replacement
Notetheseitemsduring installation:
. Connecteachhoseto the correspondingline securely
until it contactsthe stop on the line. Installthe clamp
or adjustableclampat the specifieddistancefrom the
hoseend as shown.
. Checkall clamDsfor deteriorationor deformation;
replacewith the clampsnew onesif necessary.
. Add the recommendedpower steering fluid to the
specifiedlevelon the reservoirand checkfor leaks.
ADJUSTABLEHOSECLAMP:la) HOSECLAMP:lbl
. P o s i t i o nt h e a d j u s t a b l eh o s e c l a m p s a t t h e p o i n t s . Positionthe hose clamps at the points indicatsdby
indicatedby (a) in the drawingabove. (b) in the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop. . Slidethe hoseoverthe line until it contactsthe stop,
2.0 - 4.0 mm 2.5- 5.5mm

www.emanualpro.com 10.01- 0.22 in) 10.08 - 0.16inl {0.01- 0.22 in}
17 -23
PowerSteeringPump
Replacement
1. Placea suitablecontainerunderthe vehicle. 7 . Connectthe pump inlet hoseand pump outlethose.
Tightenthe pump fittingssecurely.
Drainthe powersteeringfluid from the reservoir.
Looselyinstallthe pump in the pump bracketwith
Removethe belt by looseningthe pump mounting the mountingbolt and lockbolt.
bolt and pump lock bolt.
Installthe pump belt.
PUMPOU'I.TT HOSE
11 N.m (1.1 kgf.m, Notetheseitemsdu.ing belt instsllation:
PUMPMOUNNNG BOI.T E rbf.ti)
24 N.m12.4kgtm, 17lbl.ftl . Make sure that the power steering belt is proper-
ly positionedon the pulleys.
. Do not get power steering fluid or greaseon the
power steering belt or pulley faces,Cleanoff any
fluid or greasebeforeinstallation
FOWERSTEER G EELT
PUTrlY
1 0 . Adiustthe pump belt (seepage17-141.
'l
l. Fill the reservoirto the upper level line (see page
't7-151..
PUMPLOCKBOLT
24 N.m(2.4kg{.m,1, tbfttl
Cover the IVC compressorwith several shop towels

to protectit from spilledpowersteeringfluid.
Disconnectthe pump inlet hose and pump outlet
hose from the pump, and plug them. Takecare not
to spill the lluid on the body or parts.Wipe off any
spilledfluid at once.
R e m o v et h e p u m p m o u n t i n gb o l t a n d p u m p l o c k
bolt, then removethe pump. Do not turn the steer-
ing wheelwith the pump removed.
Coverthe openingof the pump with a pieceof tape

to preventforeignmaterialfromenteringthe pump.
17-24
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Disassembly
. The powersteeringcomponentsare madeof aluminum,Avoid damagingthe componentsduringassembly.
. Cleanthe disassembled partswith a solvent,and dry them with compressedair. Do not dip the rubber parts in a sol-
vent.
. Always replacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem.
. Replacethe pump as an assemblyifthe partsindicatedwith asterisk(*)areworn ordamaged.
FLANGEBOLTS ROLLER
20 N.m 12.0kgt'm,
1a tbf,ft) PUMPCOVERSEAL
.PUMP COVER *OUTERSIDEPLATE
.PUMP CAM RING
*PUMPHOUSING
5l x 2.4 mm O-RING
Repiace.
13x 1.9mm O-RING

Replace.
PUMPSEALSPACER
INLETJOINT
PUMPDRIVESHAFT
FLANGEBOLTS
11 N.m 11.1kgt m,
8 tbf.ft)
PULI.-EY NUT
fl N.m (6.5kgf.m,
/r7 lbf.ftl
(cont'd)
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17 -25
PowerSteeringPump
Disassembly(cont'dl Inspection
1 . Drainthe fluid from the pump. Flow Control Valve
Hold the steering pump in a vise with soft jaws. 1. Checkthe flow control valve for wear, burrs, and
hold the pulley with the specialtool, and remove other damageto the edges of the grooves in the
the pulleynut and pulley.Be carefulnot to damage valve.
the pump housingwith the jaws of the vise. '97 '98 - 0Omodls:
model:
UNIVERSAL HOLDER FLOW FLOWCONTBOL

VALVE
07725- 0030000 CONTROLVALVE
Checkfor Checkfor damage

damageto edges. to edges.
Inspd the bore of the flow controlvalvetor scratches
or wear.
Slip the valve back in the pump, and checkthat it

moves in and out smoothly.lf OK, go to step 4; if
not, replacethe pump as an assembly.The flow
controlvalveis not availableseparately.
L o o s e nt h e f l o w c o n t r o l v a l v e c a p w i t h a h e x
wrench,and removeit. CONTROLVALVE
Removethe O,ring,flow controlvalveand spring.
Removethe inletjoint and O-ring.
Removethe pump coverand pump coverseal.
7 . Removethe outer side plate,pump cam ring, pump

rotor,pump vanes,side plateand O-rings.
4. Attacha hoseto the end of the valveas shown.
Removethe snap ring, then removethe sub-valve
from the pump housing.
FLOWCONTROL
VALVE HOSE
9 . Removethe circlip, then remove the pump drive
shaft by tappingthe shaft end with the ptasticham-
mer.
1 0 . Removethe pump sealspacerand pump seal.
17-26
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5. Submergethe valve in a containerof power steer- Ball Bearing:
ing fluid or solvent,and blow in the hose.lf air bub- '1. Inspectthe ball bearingby rotatingthe outer race
bles leakthroughthe valve at lessthan 98 kPa
(1.0kgflcm' ,14.2psi),repairit as follows('97model). slowly. lf any play or roughnessis felt, replacethe
For'98 - 00 models,the flow control valve cannot b a l lb e a r i n g .
be disassembled; replacethe pump as an assembly
AIR PRESSURE
BALLEEARING
POWERSTEENING
FLUIDor SOLVENT
6. For'97 model only, hold the bottom end of the

valvewith a open end wrench.Unscrewthe seatin 2. Replacethe ball bearingusinga press.
the top end of the valve,and removeany shims,the
relielcheckball,reliefvalveand reliefvalvespring.
RELIEF ALVE
Remove lnstall
RELIEFCHECKBALL
{w@r Press
I
Press
SEAT
9 N.m
(0.9kgf.m, 6.5 lbfft) I
RELIEFVALVE
SPRING
Hold this end with
a open eno wrencn. FLOWCONTBOLVALVE
7. C l e a na l l t h e p a r t s i n s o l v e n t ,d r y t h e m o t f , t h e n
reassembleand retestthe valve. lnstallwith the
r e d s h a e l d e ds i d e
facing down.
T h e r e l i e f p r e s s u r ei s a d j u s t e da t t h e f a c t o r y b y
addingshims underthe checkball seat lf you found
NOTErSuPPortthe innerrace
shims in your valve,be sure you reinstallas many with the tool securelY-
as you took out.
8, lf the flow control valve tests OK, reinstallit in the

pump. It the flow controlvalvestill leaksair, replace
the pump as an assembly.The flow controlvalve is
not availableseparately.
PowerSteeringPump
Reassembly
'1.
Align the pin of the sub-valvewith the oil passage 5. Coatthe pump coversealwith power steeringfluid,
in pump housing,and push down the sub-valve. and installit into the groovein the pump cover.
Installthe snsp ring properly.
OIL PASSAG ROLLERSET HOLES

Alignthe pin of
the oil passage.

OUTERSIDEPLATE
#q
;1..*
5 mrh ROLLER
PUMPHOUSING \
SNAP RING
Installthe new pump seal(with its groovedside fac-

ing in) into the pump housingby hand,then install
PUMPCOVER
the pump sealspacer.
Positionthe pump drive shaft in the pump housing, lnstallthe oute. side plateoverthe two rollers.
then drive it in usinga 29 mm socketas shown,
PUMPCAMRING
,O mm CIRCLIP
29 mm SOCKET
H
go
un.t SHAFT
BALLBEARfNG /=\ PUMPDRIVE
grlu,e ROLLERSET HOLES
/ /ffi\
1 /\ t\v4
t/\ Y PUMP
SEALSPAC,ER
# I F
ry^\i- d
@.--#$i":*'
ROLLERS
PUMPHOUSING 7. Set the pump cam ring over the two rollerswith the
"' " markon the cam ring upward.
4, Installthe 40 mm circlipwith its radiusedside fac-

Ing out.
17 -2A
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8. Asssmble pump rotor to the pump cover, 12. Coatthe O-ringwith power steeringfluid, and posi-
tion it into the pump housing.
9. Set the 10 vanes in the groovesin the rotor, Make FLANGEBOI-TS
surethat the round ends of the vanesare in contact 20 N.m (2.0kgt m,
with the slidingsurfaceof the cam ring. 14 tbf.ft)
PUMPROTOR
51 x 2.4 mm O-RING
Replace.
1 3 . lnstallthe pump cover assemblyin the pump hous-

ing.
1 4 . Coat the tlow control valve with power steering

fluid.
1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
installit into the groovesin the side plate.
FLOWCONTROL
137modol)
VALVE Eg
15.2x 2.4 mm O.RING
('97 modell
SPRING 16.7x'1.8mm O-RING
SII'E PLATE I
15.2 x 2-1 ftm GRING
Replace.
ROL1IR SET HOI,E
Gfooves.
SETHOTT
FLOW CONTBOL
VALVE
l'98 - 0Omodeltl
FLOW CONTROL
VALVE CAP
49 N.m (5.0kgl.m,
36 tbf.ft)
'15. Installthe flow controlvalveand springin the pump

housing.
BOLI-ERS
1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
installit on the flow controlvalvecap.
1 1 . Installthe side plateon the cam ring by aligningthe
rollerset holesin the side Dlatewith the rollers. 1 7 . Installthe flow controlvalvecap on the pump hous-
ing,and tightenit. (cont'd)
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17-29
PowerSteeringPump
Reassembly(cont'dl
'18.
C o a t t h e O - r i n g w j t h p o w e r s t e e r i n gf l u i d , a n d 21. Holdthe pulleywith the speciattoot, and tightenthe
installit into the groovesin the inletjoint. p u l l e yn u t .
'13x '1.9
FLANGEBOLTS Replace.
11 N.m 11.1kgf.m, r
8 rbf.ft) E
1 9 . Installthe inletjoint on the pump housing. Checkthat the pump turns smoothlyby turning the
pulleyby hand.
20. I n s t a l lt h e p u l l e y a s s h o w n b e l o w . t h e n l o o s e l y
installthe pulley nut. Hold the steeringpump in a
vise with soft jaws. Be careful not to damagethe
pump housingwith the jaws of the vise.
17-30
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PowerSteeringGearbox
Removal
Notetheseitemsduring removal: 7. Removethe cotterpin from the nut, and removethe
. Using solventand a brush,wash any oil and dirt off castle nut {'97 - 98 models) or hex nut ('99 - 00
the valve body unit its lines,and the end if the gear- models).
box. Blow dry with compressedair.
. Be sure to removethe steeringwheel beforediscon-
nectingthe steeringjoint. Damageto the cable reel
can occur.
. With 4WD.tilt the enginewith a jack to expandthe
clearancebetween the transfer assembly and rear
beam when removingthe steeringgearboxfrom the
rearoeam.
Do not removethe steeringgearboxby removingthe
transferassemblyfrom the transmission.
1. Drainthe power steeringfluid as describedon page

'17-15.
Raisethe vehicle,and suppon it on safetystandsin

the properlocations(seesection1).
Removethe front wheels,
Removethe drive/s airbagassembly{seesection24).
Removethe steeringwheel{seepage 17-18).
Removethe steeringjoint bolts, then disconnectthe

steeringjoint by moving the joint toward the column.
COTTERPIN
Replace.
UPPERJOINT BOLT Installthe 10 mm hex nut on the ball joint. Be sure

that the 10 mm hex nut is flush with the ball joint
pin end, or the threadedsectionof the ball joint pin
might be damagedby the specialtool. Referto sec-
tion 18 for ball joint removerusageinstruction,Be
carefulnot to damagingthe ball joint boot.
Separatethe tie-rodball joint and knuckleusingthe

specialtool.
1 0 . Removethe right and left tie-rodends,then extend

the rackall the way to the right.
1 1 . Removethe TWC(seesection9).
Disconnectthe shift linkagefrom the transmission

(M/T:see section 13,A/T: see section 14).
1 3 . With 4WD. separatethe propeller shaft and transfer

assembly(seesection161.
LOWERJOINT BOLT
(cont'd)
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17-31
Removal(cont'dl
1 4 . L o o s e nt h e 1 4 m m f l a r e nut, and disconnectthe 4WD:Stepr 18-22
pump outlethose.
18. Removetherighttront mount,then applyvinyl tape
to the sideframe to protectit from the transmission
AN'USTABLEHOSECLAMP coverand stop bolt.
12 x 1.25 fiiA
Replace. x 1,25mm
RIGHTFRONTMOUNT
Vinyltapeor SIDEFRAME
14mm FLARE
NUT equivalgntmaterial.
15. Loosenthe adjustablehose clamp and disconnect

'19. Remove the left front mount, then apply vinyl tape
the returnhose,
to the side frame to protect it from the stop bolt.
16. Loosenthe 16 mm flare nut, and removethe return
hosejoint.
17. After disconnecting the hosesand lines,plug or seal

them with a pieceof tape or equivalentto prevent
foreign maisrialsfrom enteringthe valve body unit.
NOTE:
. Do not loosenthe cylinderline A and B between
the valvebody unit and cylinder.
. With 2WD, continue to step 23.
10x 1.25mm
Vinyltapor
equivalntm6terial.
STOPBOLT
17 -32
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20. Removethe rearmount bracketand rear mount. 22. Jack up the engineand tilt the enginebackuntil the
transferassemblyis loweredapproximately40 mm
REARMOUNT (1.57in).
12x 1.25mm Notetheseitemswhen tiltingthe engine:

Replace. . Checkthat the wire harnesses,hosesand pipes
are not caughtby any surroundingparts.
. Do not tilt the enginemore than necessary.
.Lowerapproximately
'40 mm (1.57in)
REARMOUNT BRACKET 12 x 1.25mm

Replace.
14x 1.5mm
ASSEMBLY
Replaco.
2 1 . P l a c ea j a c k u n d e r t h e e n g i n e b l o c k i n t h e a r e a Removethe stiffenerolate.
shown,
NOTE:Somestiffenerplatemountingbolts a.e also
used as gearboxmounting bolts.The gearboxwill
tilt to the sidewhen theseboltsare removed.
STIFFENER
PLATE
?*
JACK.UPPOINT
(cont'd)
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17-33
Removal(cont'dl Disassembly
24. Removethe mountingbrackets. Steering RackDisassembly
Notetheseitemswhen disassembling:
. Beforedisassemblingthe gearbox,wash it off with
solventand a brush.
. Do not dip sealsand O-ringsin solvent.
1. Removethe steeringgearbox(seepage 17-31).
2. Removeairtube and clips.
MOUNTINGBRACKETS
AIR TUBE
25. lvlovethe steeringgearboxto the right so the left
rack end clearsthe rear beam, then placethe left
rackend belowthe rearbeam.
3. Removethe boot bandsand tie-clips.
STEEBINGGEARBOX
Move the steeringgearboxto the left, and tilt the

left sidedown to removeit.
With 4WD. remove the steering gearbox through
the clearancebetweenthe transfer assemblyand
propellershaft. 4. Pullthe bootsawayfrom the endsof the gearbox.
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17 -3 4
5. Hold the steeringrackwith a wrench {'98- 00 mod- 8. RemovecylinderlinesA and B from the gearbox,
els: left end onlv), and unscrewthe rack end with
anotherwrench,Be carefulnot to damagethe rack
surfacewith the wrench,
LOCKWASHER
LINEA
CYLINDER
9 . Drain the fluid from the cylinderfittings by slowly
movingthe steeringrackbackand {orth.
Removethe two tlangebolts,then removethe valve

body unit from the gearbox. (See page 17-38for
6. L o o s e nt h e l o c k n u t ,t h e n r e m o v et h e r a c k g u i d e valvebody unit disassembly.)
screwand O-ring('97model).
DUSTCOVER
VINYLTAPE
RACKGUIDE
FLANGEBOLT
LOCKNUT
1 1 . Apply vinyl tape to stepped portion of the pinion

1. Removethe spring and the rack guide from the gearshaft,and removethe dust cover.
DOX. (cont'd)
Disassembly{cont'd}
12. Drill a 3 mm (0.12in) diameterhole approximately '12
14, Assemblea 12 x 1.25mm flangenut onto a x 175
2.5 - 3.0 mm (0.10- 0.12in) in depth in the staked mm grade 10 flangebolt as shown,Wrap the flange
point on the cylinder.Do not allow metal shavings portion of the bolt with vinyl tape to protect the
to enter the cylinder housing.After removing the cvlinder,
cylinderend, removeany burrsat the stakedpoint.
- 0.12inl
D.oth: 2.5- 3.0mm 10.10 12mmFLANGENUT
VINYLTAP tp/N90177- SLO- OOOI
1 5 . Installthe flange bolt into the end of the steering

r a c k u n t i l i t b o t t o m s i n t h e h o l e .t h e n b a c kt h e
flange bolt out 1/4 turn. Hold the flange bolt, and
tightenthe flangenut againstthe rackby hand.
Installthe bearingseparatoron the gearbox housing
CYUNOER as snown.
BEARINGSEPARATOR
0- 1112'
(Commercially
available)
13. Hold the gearboxusing using a C-clampas shown,
Loosenand removethe cvlinderend.
STEERINGRACK
CYLINDERND
1 7 . Set the gearbox in a press so the lelt side points

upward,then pressthe cylinderend seal and steer-
ing rack out of the gearbox.Hold the steeringrack
to keep it from fallingwhen pressedclear.Be care-
f u l n o t d a m a g et o i n n e r s u r f a c eo f t h e c y l i n d e r
housingwith the flangebolt.
17-36
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18. Removethe 12 mm bolt and nut trom the stsering 22. Carelully pry the piston sesl ring and O-ring off the
rack, piston rack.Be carefulnot to damagethe insideof
seal ring groove and piston edgeswhen removing
19. Remove the cylinder end seal from the steering the sealring.
racK.
Replace.
I
II
CI
20. lnsert a 24" long,3/8" drive extension and the spe- Replaco.
cial tool into the cvlinderfrom the left side. Make
sure that the specialtool is securelypositionedon
the backup ring edges. Be careful not damage to
innersurfaceof the cylinderwith the specialtool.
Prass
24 'LONG 3/8' DRIVEEXTENSION

(Commerciallvavailable)
BACKUPRING
CYLINDEREND SEAL
CYLINDERENDSEAL
REMOVERATTACHMENT
07NAD- SR3020A
2 1 . Set the gearboxin a press,then pressout the cylin-

der end sealand backupring from the gearbox.
Note these items when pressingthe cylinder end
seat:
. K e e pt h e t o o l s t r a i g h tt o a v o i d d a m a g i n gt h e
cylinderwall.Checkthe tool angle,and correctit if
necessary, when removingthe cylinderend seal.
. Use a pressto removethe cylinderend seal.Do
not try to removethe seal by strikingthe tool. lt
will breakthe backupring, and the cylinderend
sealwill remainin the gearbox. (cont'dl
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17-37
Disassembly(cont'd)
Valve Body Unit Dbassembly 2 6 . C h e c kf o r w e a r , b u r r s a n d o t h e r d a m a g et o t h e
edgesof the groovesin the sleeve.
23. Beforeremovingthe valvehousing,applyvinyltape
to solinesof the Dinionshaft. NOTE:The pinion shaft and sleeveare a precision
m a t c h e ds e t . l f e i t h e r t h e o i n i o n s h a f t o r s l e e v e
VALVEHOUSING
must be replaced,replaceboth partsas a set.
SLEEVESEALRINGS
Checkfor Deeloff or
Separatethe valve housingfrom the pinion shafv

valveusinga press. 27. Removethe circlipand sleevefrom the pinionshaft.
Checkthe innerwall of the valve housingwhere the

seal ring slideswith your finger.lf there is a step in
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valve housing.
Notetheseitemsduringinspection:
o There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valvehousingonly if the wall is stepped.
. When the valve housingis replaced,installnew
shim{s)on the bearingsurfaceof the housingto
adiustthe thickness.
C h e c kt h e i n s i d e o f v a l v e h o u s i n g
for a step in the wall.
17-38
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28. Usinga cutte. or an equivalenttool, cut and remove 3 0 . R e m o v et h e v a l v e o i l s e a l a n d b a c k u pr i n g ( ' 9 7
the four seal ringsfrom the sleeve.Be carefulnot to model)or wave washer ('98 - 00 models)from the
damagethe edgesot the sleevegroovesand outer pinionshaft.
surfacewhen removingthe sealrings.
. Inspectthe ball bearingby rotatingthe outer race
slowly. lf there is any excessiveplay, replacethe
SLEEVE pinionshaftand sleeveas an assembly.
. The pinion shaft and sleeveare a precisefit; do
n o t i n t e r m i xo l d a n d n e w D i n i o ns h a f t sa n d
sreeves,
BALLBEARING
WAVE WASHER
l'98 - 0Omodelsl
29. Using a cutter or an equivalenttool. cut the valve

PINION SHAFT
s e a l r i n g a n d O - r i n ga t t h e g r o o v e i n t h e p i n i o n
shaft. Removethe valve seal ring and O-ring. Be
carefulnot to damagethe edgesof the pinion shaft BACKUPRING
{'97 modell VALVEOIL SEAL
grooveand outer surfacewhen removingthe valve Replace.
sealrjng and O-ring. 3 1 . Pressthe valveoil sealand roller bearingout of the
valve housing using a hydraulicpress and special
tool shown below.
Cuftingslot position.
PILOTCOLLAR
ROLLERSEARING
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Reassembly
Notetheseitemsduring reassembly
. Cleanthe disassembled partswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a sol-
vent.
. Always replacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply the recommendedpowersteeringfluid to the partsindicatedin the assemblyprocedures.
. Do not allow dust.dirt, or othertoreignmaterialsto enterthe power steeringsystem.
. Usethe appropriatespecialtoolswhere necessary.
FLANGE BOLTS
20N.m(2.0kgl.m,14lbtftl
CYLINDERLINE A FLARENUTS
17 N.m 11.7 12 rbl.ftl
VALVEHOUSING
VALVEOIL SEAL
Beplace.
ROLLERBEARING
CYLINDEREND SEAL CIRCLIP

Replace. Replace.
\ BA.KUP RING
BACKUPRING
WAVEWASHER Replace.
HOUSING
97 model:
VALVESEALRING
Replace.
\/^" O.RING
Replace.
32 mm SHIMS
'97 mod6l only:
RACKGUIDESCREW
@---r-ocxr'rur
'97 model:
'98 model:
O-RING
Replace. '99 - 0Omod6ls:
'9? model only:
CYLINDER END '98 - (x) models:

69 N.m (7.0 kgf.m, 51 lbf.ft)
PISTONSEALRING
Replace.
STEERINGRACK
www.emanualpro.com
17-40
Valve Body Unh Roa$embly 8. Apply power steering fluid to the surface of the
v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n
1. Apply vinyl tape to the steppedportion of the pin- shaft.
ion shaft,and coat the surfaceof the vinyl tape with
the power steeringfluid. VALVEOIL SEAL Apply power steeringfluid to the insideof the spe-
Vinyl tape Replace. cial tool. Set the largerdiameterend of the special
(Stopp6d portion) Makesurethe springis tool overthe valvesealring.
seatedin the oil seal.
VALVESEALRING
Serling SIZNG TOOL
07NAG - SR309q'
E ot
07NAG - SR3oltoA
PINIONSHAFT
BACKUPRING
137 modell
\ /
WAVEWASHER
{'98- 00modelsl
Installthe backupring {'97 model)or wave washer
('98- 00 models).
Coat the inside surface of the new valve oil seal l r r . r j 1
with powersteeringfluid.
Installthe valveoil sealwith its groovedside facing
oppositethe bearing,then slide the valve oil seal
over the pinion shaft, being carefulnot to damage
tffifrE-r
r.] r\-''] 7
t h e s e a l i n gl i p . Usgth6 largr diameter Mak the valve seal ring
Apply vinyl tape to the splinesand steppedponion end of the special fit snuglyin the pinion
of the shaft, and coat the surfaceof the vinyl tape toollirst to make shatt using th6 other end
with the power steeringfluid. th valve seal ring {smallerdiameterend)ot
tit in the pinion the specialtool.
PINIONSHAFT shaft.
Vinyl trp
1 0 . Move the specialtool up and down severaltimes to

makethe valvesealring fit in the pinionshaft,
1 1 . Removethe soecialtool.
12. Turn the specialtool over,and set the smallerdiam-

eter end of the specisltool over the valveseal ring.
Move the specialtool up and down severaltimes to
m a k et h e v a l v e s e a l r i n g f i t s n u g l yi n t h e p i n i o n
shaft.
O.RING
Replace. Rplace-
Do not twist. Do not over-expand.
Fit the new O-ringin the grooveof the pinion shaft.

Then slide the new valve seal ring over the shaft
and in the grooveon the pinionshaft,
7 . Removethe vinyl tape from the pinionshaft. (cont'd)
www.emanualpro.com
17-41
(cont'd)
Reassembly
1 3 . Apply power steeringfluid to the surfaceof the spe- 18. Apply power steeringfluid to the surfaceof the pin-
cialtool. Set the new sealrings overthe specialtool ion shaft.Assemblethe sleeveover the Dinionshaft
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l . a n d b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e
e x p a n dt h e s e a l r i n g s .I n s t a l lt w o r i n g s a t a t i m e sleevewith the cutout in the shaft.Then installthe
Jromeachend ofthe sleeve. new circlipsecurelyin the pinionshaftgroove.
Notetheseitemswhen installingthe sealring: Notetheseitemsduring reassembly:

. Do not over-expand the sealring. Installthe resin . B e c a r e t u l n o t t o d a m a g et h e v a l v e s e a l r i n g
seal rings with care so as not to damagethem. when insertingthe sleeve.
A f t e r i n s t a l l a t i o nb, e s u r e t o c o n t r a c t h e s e a l . Installthe circlipwith its radiusedsidefacingout.
ringsusingthe specialtool{sizingtool).
CIRCLIP
. There are two types of sleeveseal rings: black
and brown. Do not mix the different types of
sleevesealringsas they are not compatible.
1 4 . Align the specialtool with each groove in the sleeve,

and slide a sleeveseal ring into each groove.After
installation,compressthe seal rings with your fin-
gerstemporarily.
BALLJOINT BOOTCLIPGUIDE
07974- SA508q)
SLEEVE
1 9 . Apply power steeringfluid to the seal ring lip of the

valveoil seal.then installthe seal in the valvehous-
ing using a hydraulicpressand specialtools. Install
the valve oil sealwith its groovedside facingthe tool.
ATTACHMENT,
1 5 . Apply power steeringfluid to the seal rings on the 32x35mm
sleeve,and to the ehtireinsidesurfaceof the special 077i16- (x)10100
tool.
SLEEVESEALRING
SIZINGTOOL
07974- SA502O0or
07974- SA5020A
VALVEOIL SEAL
Replace.
1 6 . Insertthe sleeveinto the specialtool slowly. Makesurethe
springis in the
't1. Move the sleeve each direction several times to oilseal.
makethe seal rings snuglyfit in the sleeve.Be sure
that the seal ringsare not turned up,
www.emanualpro.com
20. Pressthe new bearinginto the valve housingwith 2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
the stampedletterfacingup usinga hydraulicpress p r e s s . C h e c kt h a t t h e p i n i o n s h a f t / s l e e v et u r n s
and soecialtool. smoothlyby turningthe pinionshaft,
DRIVER
ATTACHMENT,
32x35mm
07746- 0010100
-
ROLLERBEARING
Letterstampedface
21. Apply vinyl tape to the pinion shaft, then coat the
vinyltape with powersteeringfluid.
Sealinglip tace. VALVEOIL SEAL
VALVEHOUSING
PINIONSHAFT
E
SLEEVESEAL
8e surethat the
sealringsare not
turnedup,then
install.
22, Insertthe pinion shaft into the valve housing. Be

carefulnot to damagethe valvesealrings.
23. Removethe vinyl tape from the pinion shaft,then

removeany residuefrom the tape adhesive.
(cont'd)
www.emanualpro.com
17-43
(cont'dl
Reassembly
Stecring RackR8assembly 31. Wrap vinyl tape aroundthe rackteeth and rack end
edges,then coat the surface of the tape with the
25. Coatthe pistonseal ring guide with power steering power steeringfluid. Make sure that the vinyl tape
fluid,then slideit onto the rack,big end first. is wrappedcarefullyso that there is no steppedpor-
tion.
26. Positionthe new O-ringand new pistonseal ring on
the sDecialtool, then slide them down toward the
big end of the tool.
a Do not over expandthe resin seal rings. Install
the resin seal rings with care so as not to dam-
age them. After installation,be sure to contract
the sealring usingthe specialtool (sizingtool).
a Replacethe piston'sO-ringand sealring as a set.
27. Pull rhe O-ringoff into the pistongroove,then pull

the pistonsealring off into the pistongrooveon top
of the O-ring. Coatthe insidesurfaceof the new cvlinderend
with powersteeringfluid.
PISTON
Installthe cylinderend seal onto the steeringrack
w i t h i t s g r o o v e d s i d e t o w a r d t h e p i s t o n .W h e n
installingthe cylinderend seal,be carefulnot dam-
agethe sealinglip faceof the sealwith the edgesor
teethof the steeringrack.
CYLINDER
ENDSEAL
24. Coatthe pistonseal ring and the insideof the spe-

cialtool with power steeringfluid.
PISTON
Replace
E
07GAG- SO4O200or
OTGAG- SD'()2OA
Make sure the
spring is in lhe cylinder
Carefullyslide the tool onto the rack and over the eno seal
pistonsealring.
30. Move the specialtool backand fonh severaltimes Removethe vinyl tape from the steeringrack,then
to makethe pistonseal ring fit snugly in the piston. removeany residuefrom the tape adhesive.
www.emanualpro.com
17-44
35. Install the new backup ring on the steering rack, 37. Installthe flange bolt into the end of the steering
then placethe cylinderend sealagainstthe piston. f a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h e
f l a n g eb o l t o u t 1 / 4 t u r n . H o l d t h e f l a n g eb o l t a n d
BACKUPRING tightenthe flangenut againstthe rackby hand.
Replace.
Prers
12 x'175 mm FLANGEBOLT
lP/N 90177- SLo- 0001
12 mm FLANGENUT
to. Greasethe steeringrackteeth,then insertthe steer-

ing rack into the gearboxhousing,Be carefulnot to
damageto inner surfaceof the cylinder wall with CYLINDERENDSEAL
the rackedges. Replace.
GEARBOXHOUSING 38. Installthe cylinderend seal into the bottom of the

cylinderby pressingon the bolt with a press,Do not
p u s h o n t h e b o l t w i t h e x c e s s i v ef o r c e a s i t m a y
damagethe cylinderend seal.
ia R e m o v et h e f l a n g e b o l t , a n d c e n t e rt h e s t e e r i n g
rack.
40. W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s ,a n d
coatthe surfaceof the tape with the power steering
fluid. Makesurethat the vinyl tape is wrappedcare-
fully so that there is no steppedportion.
(cont'dl
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17-45
(cont'dl
Reassembly
4l. Coatthe insidesurfaceof the new cvlinderend seal 46. Greasethe insidesurtaceof the cylinderend, then
with powersteeringfluid. installthe cylinderend by screwingit into the cylin-
der.
CYLINDEBENOSEAL
Replace. 41. Removethe C-clampfrom the gearbox.
Makesurethe spring
is in the cylinderend seal.
48. After tighteningthe cylinderend, stakethe point of
the cylindershown below.Stakethe cylinderin the
position oppositefrom where the stakewas removed
duringdisassembly,
NOTE:For '98- 00 models,go to step54.

Stake point, Depth: 1,0 mm (0.04inl
Staked
posrtron.
4.0mm {0.16in)
Groovedside.
42. Installthe cylinderend seal onto the steeringrack

with its groovedsidetowardthe piston.
43. P u s h i n t h e c y l i n d e r e n d s e a l w i t h y o u r f i n g e r .
When installingthe cylinderend seal,be carefulnot BUSHING
damagethe sealingfaceof the sealwith the threads
a n d b u r r s a t t h e s t a k e dp o s i t i o n o f t h e c y l i n d e r CYLINDEREND -tG
69 N.m (7.0kgf.m,51 lbtft) 8e carefulnot to damage
housing. the bushingwhen inserting
the cylinderend.
44. Removethe vinyl tape from the steeringrack,then
removeany residuefrom the tape adhesive. 49. Selectthe 32 mm shim(s)('97 modelonlv).
45. Holdthe gearboxusinga C-clampas shown. N O T E :O n l y r e i n s t a l tl h e o r i g i n a l3 2 m m s h i m ( s )

when the steeringgearboxis reassembledwithout
replacingthe pinionshaft.valve housing,and gear-
box housingwith new ones.
l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x
C.CLAMP
housingare replaced,selectthe new shim{s)as fol-
lows.
GEARBOX Shim selection:

Set the four 32 mm shims on the bearingsurfaceof the
g e a r b o x h o u s i n g .T o t a l t h i c k n e s so f t h e f o u r s h i m s
shouldequalno more than 0.70mm.
Shim set: four 32 mm shims (Thickness: 0.10 mm, 0.15
mm, 0.20mm, 0.25mm respectively)
N O T E :T h e f o u r 3 2 m m s h i m s d o n o t h a v et h i c k n e s s
identification marks.Measurethe thicknessof eachshim
usinga micrometer,and markthe shim for identification.
17-46
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5 0 . I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x .a n d Example:
tightenthe flangeboltsto the specifiedtorque. Measurementis 0.28mm (0.011in);
0 . 7 0 - 0 . 2 8 = 0 . 4 2m m ( 0 . 0 2 8 - 0 . 0 1=1 0 . 0 1 7i n )
VALVEBODY FLANGE BOLT
20 N.m12.0kgt.m,14lbtft)
T h e s e l e c t e ds h i m s s h o u l db e 0 , 2 5m m ( 0 . 0 1 0i n l a n d
0.15mm (0.006in) in thickness.
lf the required shim thicknessis 0.10 mm or less, no

shrmsare necessary.
53. Set the selected32 mm shims on the bearingsur-

faceof the gearboxhousing.
SHIM SET FLANGEBOLT

VALVEBODYUNIT 20 N.m (2.0 kgf.m, la lbl.frl
(fourshims)
/
a)
E? O.RING
E Replace.
-6{
ct. Measurethe clearancebetween the gearbox and
valve body unit using a feelergauge.Measurethe
c l e a r a n c ea t t h e p o i n l m i d w a y b e t w e e nt h e t w o
mountingbolts.
GAUGE
NEEDLEBEARING
-6lr
54. Coatthe new O-ringwith grease,and carefullyfit it
on the valvehousing.
Apply greaseto the needlebearingin the gearbox

housing.
D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m 56. Installthe valve body unit on the gearboxhousing

shims by subtractingthe clearanceobtainedin the by engaging the gears. Note the valve body unit
step "c" from the total thicknessof the four shims. installationposition(directionof line connection).
( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( C l e a r a n c e=)
Reouiredthicknessof the shims 5 7 . Tightenthe flangeboltsto the specifiedtorque.
Selectthe shims so that the total thicknessis close

to, but lessthan,the requiredthickness.
(cont'd)
(cont'dl
Reassembly
(
58. InstallthecylinderlinesA and B 6 3 . I n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e
steering rack.
Notetheseitemsduring reassembly: STEERINGRACKENO
. C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e sA a n d B LOCKWASHER 54 N.m (5.5kgf.m,40 lbtftl
thoroughly.The joints must be free of foreign Replace.
material,
. lnstall the cylinder lines A and B by tightening
the flare nuts by handfirst,then tightenthe flare
nutsto the soecifiedtorque.
17 N.m 11.7kgd.m,12lbf.ttl
STEERING
26 N.m {2.7 kgl.m, 20
64. Screwthe rackends into the rack.
Hold the steering rack with a wrench ('98 - 00 mod-

els: left end only), and tighten the rack ends. Be
careful not to damage the rack surface with the
CYLINDEF
LINEA wrench.
Greasethe sliding surface of the rack guide, and After tighteningthe rack ends, stakethe four sec-
installit onto the gear housing. tions of lockwasherwitha drift and a mallet.
60. For'97 model,applya thin coatof greaseto the new . Placethe wood blockon the presstable,then set
O-ring,and installit on the rackguidescrew. the lock washer section of the rack end on the
For'98 - 00 models.removethe old sealantfrom wood block securely.
the threadsof the rackguide screw.then apply new . Be sure the tool is aligned with the flat sections
sealantto the first threethreads. of the steering rack end before pressing.
RACKGUIOE . Stake the lock washer in the center of the flat
section of the steering rack end,
ROLLPIN PUNCH
lCommorcially.Y.il.blel
Snap-OnNo. PPR8or oquival.nt.
-6r
O-RING
nlcr cutDE R"Pl""u'
SCREW
LOCKNUT
37 model:
38 model:
NOTE: This drift has a flat

shoulderto prevent
puncturingof metalwasher.
ot. Installthe spring, rack guide screw and locknuton

the gear housing.
Adjustthe rack guide screw (seepage 17,15).After STEERINGRACK

adjusting,checkthat the rack moves smoothly by WOODENBLOCK
slidingthe rackright and left.
17-48
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67. Apply greaseto the circumferenceof the rack end 70. Adiust the air hose fitting positionof the boots by
housing. turning it as shown below.
LEFTBOOT RIGHTBOOT
{Viewedfromthe (Viewedtrom the
leftside) rightside)
+
ro
m
''rT.a'.
Front
, tri"
\,'tAr-
+ {,1@}tr
RACKENDGROOVE
)Fr1
.={@ / \
GREASE
SILICONE BOOT AIR HOSEFITTING
FIT'I'ING
68. A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
grooveson the rackends.
69. lnstall the boots in the rack end with the tie-rod
clips. 71. Installnew boot bandson the boot, and bend both
setsof lockingtabs.
NOTE:Installthe bootswith the rackin the straight
ahead position (right and left tie-rodsare equal in CAUTION: Stake the band locking tabs firmly.
length).
RACK ENO
NOTE: Wipe the greaseoff

the threadsection.
Lightlytap on the doubled-overportionsto reduce

their height.
Slide the rack right and left to be cenain that the

bootsare not deformedor twisted.
(cont'd)
TIE.RODCLIP
Reassembly(cont'd) BallJoint Boot Replacement
7 4 . C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t 't. Removethe boot set ring
and the boot.
boot,
CAUTION:Do not contaminatethe boot inslalla-
CYLINDER tion section with graase.
LINEA
Packthe interiorof the boot and lip with grease.
Wipe the greaseoff the sliding surfaceof the ball

pin.then packthe lower areawith freshgrease.
CAUTION:
. Keep greaseoff the boot installation section and
the tapered section of th ball pin.
. Do not allow dust, dirt, or other to.eign materi-
als to enter the boot.
EALLPIN TAPERED
SECTION
Wipe olf the grease.
CYLINDERLINE
75. Installthe clips on the cylinderlines,then clampthe

air tube with the clips. BOOT INSTALLATION
B(X)T IT{STALLATION SECTION
76. Apply vinyl tape to around the pinion shaft, and sEclroN Wipe offthe grease.
Wipe off the grease.
coat the surfaceof the tape with grease.
Installthe boot in the grooveof the boot installation
DUSTCOVER sectionsecurely.then bleedair.
Vinyl Tsp
Adjust the specialtool with the adjustingbott until
the end of the tool aligns with the groove on the
boot. Slidethe set ring over the tool and into posi-
VALVEOIL SEAL I|on.
CAUTION: After installing the boot, chock the batl

pin lapered section for grease contamination and
wipe it it ncessary.
VALVEBODYUNIT ADJUSTINGBOLT
Adiustthe depth
by turningthe bolt.
77. P a c kt h e i n t e r i o r o f t h e d u s t c o v e r a n d l i o w i t h
grease,then installdustcoveron the valvebodv unit.
SET RING
Removethe vinyl tapef.om the pinionshaft.
17-50
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lnstallation
1. Beforeinstallingthe gearbox,extendthe rackall the 5. I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x
waYto right. mounting bolts and stiffenerplate attachingbolts.
Be sure the air tube is not caught or pinched by
2. lnstallthe mounting cushion on the steerlnggear- stiffener plate. Installthe bolts loosely first. then
box. tightenthem securely.
3. Passthe right side of the steeringgearbox above NOTE:With 2WDcontinueto step 11.
and throughthe right sideof the rearbeam.Be care- PLATE
STIFFENER
ful not to bend or damagethe two power steering MOUNTINGBOLTS
38 N.m
:-
/
STEERINGGEARBOX
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t i n g
c u s h i o n .t h e n i n s t a l lt h e t w o g e a r b o xm o u n t i n g
b o l t s .P o s i t i o nt h e s p l i t p o r t i o no f t h e m o u n t i n g
cushionas shown. With 4WD,lower the iack,and returnthe engineto
the originalPosition.
MOUNTINGBBACKETS
1. l n s t a l lt h e r e a r m o u n t a n d r e a r m o u n t b r a c k e t .
Tightenthe mountingbolts in order:A, B and C.
10 x 1.25mm
6,aN.m
8.12 x 1,25mm
16.5kst.m, 47 lbl'ft)
59 N.m Rplace.
(6.0 kgt.m. *l lb{'ftl
Replace.
) \ ^
o ( ]
GEARBOXMOUNTING
BOLTS
39 N.m
14.0kgf.m, 29 lbf.ft)
Installation(cont'd)
8, Installthe left front mount. Tighten the mounting 11. Installthereturnhosejoint by tighteningthe 16 mm
boltsin order:A and B. flare nut.
B-12x 1,25mm
59Nm
(6.0 kgtm,, lbl.ftl RETURNHOSEJOINT:
LEFTFRONTMOUNT AD.'USTAB[THOSECLAMP 16 mm FLARENUT
Replaca. (Forinstallation 28 N.m
reterto page 17,23) 12.9kg{.m.21 lbt{t)
A-10x 1.25mm
4,1N.m
la.s kgt m, 33 lbf.ft)
9. Instsllthe right front mount, Tightenthe mounting

bolts in order:A and B.
14 mm FLARENUT
37 N.m
B-12x 1.25mm (3.8 ksf.m, 27 lbl'frl
59 N.m
16.0ks[.m, ,|:| lbf.ftl A-10x 1.25mm
Replace. a,aN.m
't2. Connectthe return

hose securely.and tighten the
adjustablehoseclamp.
1 3 . Connectthe pump outlet hose, and tighten the l4

mm flare nut.
NOTE: Makesure that there is no interference

betweenthe fluid lines,the rear beam or any other
parts.
10. Removethe vinyl type from the side frame (both

sides).
17-52
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't4. Centerthe steeringrackwithin its stroke. 17. Wipe off any greasecontaminationtrom the ball
joint taperedsectionand threadsthen reconnectthe
1 5 . Installthe steeringjoint, and reconnectthe steering tie-rod ends to the steeringknuckles.For'97 - 98
shaftand pinionshaft. models;torque the castle nut to the lower torque
s p e c i f i c a t i o nt,h e n t i g h t e n i t o n l y f a r e n o u g h t o
NOTE:Make surethe steeringjoint is connectedas alignthe slot with the pin hole.Do not align the nut
follows. by loosening.Installnew cotterpins.
TIE.ROOEND
a. Insenthe upperend of the steeringjoint onto the
steeringshaft (line up the bolt hole with the flat
on the shaft).
UPPER JOINTBOLT
22 N.m
12.2kgf.m,16lbl.ft,
HEXNUT
l'g!t - 00 modeb)
JOINT
STEERING il:l N.m
CAST1TNUT 14.4ksl.m,
(9t - 98 32 tbf.f0
modol!)
39 - iU N'm
lil.o - 4.8 kgl.m,
29 - 35 tbf.ftl
'99 - lD modeb:
COLUMN COTTER PIN

SHAFT LOWERJOINTBOLT RePlace.
22 N.m on reassembly,bend
12.2kgf.m,16lbtftl thecotterPinasshown.
UPPERJOINT BOLT 1 8 . With 4WD,connectthe propellershaft and transfer

Bolt must line up assembly(seesection16).
with tlat on shatt.
1 9 . Connectthe shift linkageto the transmission(M/T:
see section 13,A,/T;see section 14).
LOWERJOINT BOLT
Bolt must lineup with
groove around on shaft. 20. InstalltheTwc (seesection91.
PINION 2 1 . lnstallthe front wheels,

SHAFT
b, Slip the lower end of the steeringioint onto the 22. Fill the systemwith power steeringfluid, and bleed
pinionshaft. air from the system(seepage 17-15).
c. Installthe lower joint bolt (line up the bolt hole
with ths groove around the shaft).Be sure that 23. After installation.performthe followingchecks.
the lower joint bolt is securelyin the groove in . S t a r t t h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e
the pinionshaft. steering wheel from lock-to-lockseveraltimes to
d. Pull on the steeringjoint to make sure that the warm up the fluid. Checkthe gearboxfor leaks
steeringjoint is fully seated. (seepage17-23).
e, Installthe upperjoint bolt, . Adjustthe front toe (sesection18).
. Checkthe steeringwheel spokeangl.Adjust by
1 6 . Reinstallthe steeringwheel{seepage'17-19). turning the right and left tie-rodsequally,if nec-
essary.
Suspension
SpecialTools .............
18-2 Front Damper
ComponentLocations Removal 18-16
.................
lndex ................ ......18-3 Disassembly/lnspection 18-17
..................
WheelAlignment Reassembly 18-18
...........
18-4
Servicelnformation......................,.. lnstallation 18-18
.............
Camber ..................
18-4 RearSuspension
Caster............... ......18-5 SuspensionArms Replacement.....18-19
Front Toe Inspection/ Hub BearingUnit Replacement......18-20
Adiustment ........18-5 Upper Arm Bushing
RearToe Inspection/ Replacement .....18-23
Adiustment ........18-6 RearDamper
Turning Angle Inspection/ Removal 18-23
.................
Adiustment ........18-6 18-24
..................
Disassembly/1nspection
Wheel/HubInspection Reassembly 18-25
...........
18-7
BearingEnd Play .......................,...... .............
18-25
lnstallation
WheelRunout .......18-7
Front Suspension
SuspensionArms Replacement.....18-8
Knuckle/Hub Replacement............. 18-9
LowerBallJoint Replacement.......18-15
BallJoint Boot Replacement.......... 18-16
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S p e ci a l T ools
Ref.No. I Tool Number
o 07GAF- SE00l00 Hub Dis/Assembly Tool 1 r 8-'13

07GAG- SD40700 B a l lJ o i n tB o o tC l i pG u i d e 1 ' 1 81 6
/a 07JAF- SH20200 BallJoint RemoverBase 1 18-15
@ 0 7 L A D- S M 4 0 1 0 0 DriverAttachment,60 mm 1 1A-22
/6
3m 1 1a-1't,12
lol 07746- 0010200 DriverAttachment,3Tx 40 mm 1 1a-21
o 07749- 0010000 Driver 1 1 8 - 1 31, 4 , 2 1 , 2 2
@ 07947- 6340400 DriverAttachment,62 x 64 mm 1 18-13
6r 07965- SA50100 'l
Hub Dis/Assembly Tool 1a-22
@ 07965- 5400600 DriverAttachment I 1 8 -1 4
o 07965- S800100 BallJoint Remover/lnstaller 1 1 8 -1 5
@ 07965- S800200 BallJoint InstallerBase 1 18-15
@ 07965- SD90100 SupportBase I l8-14
@ 07974- SA50700 BallJoint BootClip Guide 1 18-16
c
f1
U
o,o .4.@ @,@,@,@
o o @ c0
18-2
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ComponentLocations
FrontSuspension:
BAR
STABILIZER
LOWERARM
Rear Suspension:
REAROAMPER
BAR
STABILIZER
ARM
UPPER
LOWERARM
COMPENSATOB
ARM
TRAILING ARM
WheelAlignment
Caster Camber
F o r p r o p e ri n s p e c t i o n / a d j u s t m eonf tt h e w h e e l a l i g n - Inspection
ment, checkand adjustthese items beforecheckinqthe
alignment: U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e ldo u r w h e e l
alagnment equipmentto measurewheel alignment(cast,
. Checkthat the suspensionis not modified. e r , c a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o wt h e e q u i p ,
. Checkthe tire sizeand tire pressure. ment manufacturer's instructions.
. Checkth( runoutof the wheelsand t;res,
. Checkthe suspensionball joints.(Hold a wheel with 1 . C h e c kt h e c a m b e ra n g l e .
your hands,and move it up and down and right and
leftto checkfor wobbling.) Camberangle:
Front: 0'00' 1 1"
Rear:- 1' :! 1"
2. lf out of specification,checkfor bent or damaged

suspensron components.
Inspection
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l
a l i g n m e net q u i p m e nt to m e a s u r ew h e e la l i g n m e n(tc a s t -
e r , c a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o wt h e e q u i p -
ment manufacturer's instructions.
1. Check the caster angle.
Caster angle: 2'10':t 1"
l f o u t o f s p e c i f i c a t i o n c, h e c k f o r b e n t o r d a m a g e d
s u s p e n s i o nc o m p o n e n t s .
18-4
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FrontToe Inspection/Adjustment RearToe Inspection/Adjustment
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l
alignmentequipmentto measurewheelalignment(caster, alignmentequipmentto measurewheelalignment(caster,
camber,toe, and turning angle).Follow the equipment camber.toe, and turning angle).Follow the equipment
manufacturer's instructions, manufacturer'sinstructions.
1. Checkthe tire pressure. 1. Releaseparking brake to avoid an incorrectmea-

surement.
Centerthe steeringwheel spokes.
Checkthe toe.
3. C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t
ahead. Ro8rtoe-in:2 :1 mm {lN l/16:t 1/16 in,
Fronttoe-in:0 i 3 mm {0 t 1/8 inl - lf adjustmentis required,go to step2.
- lf adjustmentis required,go on to step 4. - lf no adiustmentis required.remove alignment

equrpmenr.
- lf no adjustmentis required,remove alignment
equipment. Beforeadjustment,note the locationsof adjusting
boltson the right and left compensatorarms.
Loosenthe tie-rod locknuts,and turn both tie-rods
i n t h e s a m e d i r e c t i o nu n t i l t h e f r o n t w h e e l s a r e Loosenthe adjustingbolts, and slide the compen-
pointingstraightahead. satorarm in or out. as shown,to adiustthe toe.
FLANGEBOLT
'10x 1.5mm
6a N.m 16.5kgf.m, 47 lbf'ftl
sir N m (5.5kgJ.m,'O lbf.ft)
ARM
COMPENSATOR
Example:After the reartoe inspection,the wheel is 2
mm (0.08in) out of the specification.
5. Turn both tie-rodsequally until the toe readingon - M o v e t h e a r m s o t h e a d j u s t i n gb o l t m o v e s 2 m m
the wheel alignmentcomputeris correct. {0.08in) inwardfrom the positionrecordedbeforethe
adjustment.
A f t e r a d j u s t i n g t, i g h t e n t h e t i e - r o d l o c k n u t sa n d - The distancethe adjustingbolt is moved should be
repositionthe tie-rod boots if they are twisted or equalto the amountout-of-specification.
displaced.
5. Tightenthe adjustingbolts.
WheelAlignment
TurningAngle Inspection
U s e c o m m e r c i a l l y - a v a i l a bcloem p u t e r i z e fdo u r w h e e l
alignmentequipmentto measurewheelalignment(caster,
c a m b e r t, o e , a n d t u r n i n ga n g l e ) F
. o l l o wt h e e q u i p m e n t
manufacturer's instructions.
1. Turn the wheel right and left while applying the

brake, and measure the turning angle of both
wneets.
Turningangle:
Inwardwheel:37.00'
Outwardwheel lreference):
31.30'
2. l f t h e t u r n i n ga n g l eis not within the specifications,

c h e c kf o r b en t o r d a m a g e ds u s p e n s i o nc o m p o -
nenIs.
18-6
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Wheel/Hublnspection
BearingEndPlay WheelRunout
1 . Raisethe vehicleoff the ground,and makesure it is 1. Raisethe vehicleoff the ground,and makesure it is
securelysupported. securelysupported,
Removethe wheels,then reinstallthe wheel nuts. Checkfor bent or deformedwheels.
Attachthe dial gaugeas shown. Attachthe dial gaugeas shown.
Measurethe bearingend play by movingthe discor Measurethe wheel runoutby turningthe wheel.
drum inwardor outward.
Front and RearWhoel Axial Runout:
Front/Rear; Standard:
Standard:0 - 0.05 mm (0 - 0.002in) Steel Wheel: 0 - 1.0 mm {0 - 0.0i[ in]
AluminumWheel:0 - 0.7 mm l0 - 0.03in)
ServiceLimit: 2.0 mm 10.08inl
Measureend play at the

hub flange.
Front and RearWheel Radial Runout:
Standard:
Steel Whoal: 0 - 1.0 mm (0 - 0.04 inl
Rear: Aluminum Whoel: 0 - 0.7 mm {0 - 0.03 in}
Servics Limit: 1.5mm (0.06inl
Measureend play at centerof 108 N.m

the hub flange. {11.0kgf.m, q} lbf.ftl
It the bearingend play measurementis more than lf the wheel runout is more than the servicelimit,
the standard,replacethe wheelbearing. reolacethe wheel.
FrontSuspension
Suspension
ArmsReplacement
Notetheseitemsduring replacement:
. Replacethe self-lockingnuts afterremoval.
. The vehicleshouldbe on the ground beforeany boltsor nuts connectedto rubbermountsor bushingsare tightened.
. Beforetighteningthe upper and lower mountingnuts on the stabilizerlink,adjusrthe locationof the link with the sus-
p e n s i o nu n d e rv e h i c l el o a d .
. After installing the suspensionarm, checkthe front wheel alignment,and adjustif necessary(seepage 18-4|.
STABILIZER BAR STAEILIZER

FLANGEEOLTS Alignthe stabilizermark
10x 1.25mm with end of stabilizer
bushing.
54 N.m (5.5kgf.m,
40 tbf.ft)
STABILIZER
Checkfor bendingand damage.
UPPER ARM
Checkthe bushingfor deterioration
and damage.
BALLJOINT BOOT
. Checkfor deter'oration
FLANGEBOLT ano oamage,
1 { x 1 . 5m m Seepage18 16for boot
103N.m {10.5kgf.m, replacement.
76 tbf.ft)
FLANGEBOLT
8 x 1.25mm
22 N.m {2.2kg{.m,
16 tbf.ftl
LOWERARM
RUBBER BUSHING
and damage. o\ SELF.LOCKING NUT
..'.{l@3 1 4x 1 . 5m m
SILICONE GREASE Replace.
RUBBER BUSHINGS 83 N.m (8.5 kgt.m,61 lbt.ftl
FLANGEBOLT
1 4x 1 . 5m m
SELF-LOCKING NUT 89 N.m (9.'l kgl.m, 66 tbf.ft)
10 x 1.25rr|m 29 N.m (3.0kgf.m,22 lbf.ft)
DAMPERFOBK
Feplace.
Holdthe ballioint pin usinga hex wrenct Checkfor damage.
AOLT
BOOT 10x 1.25mm
Checkfor deterioration STABILIZER LINK !$ N.m (4.4 kgt.m,
ano oamage, Checkfor daftage. 32 rbf.ftl
SELF.LOCKING NUT
12 x 1.25mm
DAMPERFORK Beplace.
29 N.m {3.0 kgl.m, 2.2 lbf.ftl RUBBER BUSHING 64 N.m (6.5kgt.m, 47 lbf.ft)
Beforetighteningthe llangenut, Checkfor deterioration
positionthe balliointpin and damage.
in the middleof its rangeof travel,
with the suspensionundervehicleload.
18-8
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Knuckle/HubReplacement
. Replacethe selt-lockingnuts afterremoval.
. The vehicleshouldbe on the ground beforeany boltsor nutsconnectedto rubbermountsor bushingsare tightened.
. Torquethe castlenuts to the lowertorquespecifications, then tightenthem only far enoughto alignthe slotswith each
pin hole.Do not alignthe nuts by loosening.
o Use only genuineHondawheel weightsfor aluminumwheels.Non'genuinewheel weights may corrodeand damage
t h e a l u m i n u mw h e e l s .
. Onthealuminumwheels,removethe centercap from the insideof the wheelafter removingthe wheel.
. Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc.
. Beforeinstallingthe wheel.cleanthe matingsurfacesofthe brakediscand wheel.
. Wipe off the greasebeforetighteningthe nuts at the balljoints.
CASTLENUT
CALIPERMOUNTINGBOLT 1 0x 1 . 2 5m m
1 2x 1 . 2 5m m 39 - 47 N.m (i1.0- 4.8 kgf.m,29 - 35 lbf.ftl
108N.m (11.0kgtm.80 lbt.ftl
COTTERPIN
Replace.
WHEELBEARING
Beplace.
page18-13
Replacement,
CIRCLIP SPLASHGUARD
SCREW
5x0.8mm
LOWERBALLJOINT 4.9N.m {0.5kgf.m,3.6lbf.ft)
Inspectfor faulty
movementand wear, F R O N TH U B
Replacement, page'1815 C h e c kf o r d a m a g e a n d
SETRING Replacement,
page 18 10
BALLJOINTBOOT
ano oamage. COTTERPIN SPINOLENUT
Replace. 24 x 1.5mm
245 N.m {25.0kgI.m, 181 lbtft}
Replace.
CASTLENUT . Beforeinstallingthe spindlenut,apply
12x 1.25fim engineoil to the seatingsurfaceof the nut.
49 - 59 N.m 15.0- 6.0 kgt.m.36 - lbf.ft) . Aftertightening,usea driftto stakethe
spindlenut shoulderagainstthe spindle.
BRAKEDISC
Checkfor wear and
rust.
WHEELNUT
R e p l a c e m e n t ,p a g e 1 8 - 1 0
1 2x 1 . 5m m
I n s p e c t i o n ,s e c t i o n 1 9 .
108N.m
{11.0kgt m,
80 tbf.ftl
6 mm BRAKEDISCRETAININGSCREW
9.8 N.m (1.0kgtm, 7.2 lbtftl
(cont'd)
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18-9
FrontSuspension
(cont'dl
Replacement
Knuckle/Hub
1 . Loosenthe wheel nuts slightly. 7. Removethe 6 mm brakedisc retainingscrews,
Raisethe front of the vehicle,and make sure it is

secu.elysupported.
Removethe wheel nuts and wheel.
6 mm BRAKEDISC
RETAININGSCREWS
9.8 N.m
(1.0 kgl.m,7.2 lbf.ftl
8 x 1.25mm BOLTS
8. Screwtwo 8 x 1.25mm bolts into the discto push it

awav from the hub. Turn each bolt two turns at a
time to prevent cockingthe disc excessively,
SPINDLE NUT Removethe brakediscfrom the knuckle.

24x 1,5mm
245N.m(25.0kgf.m,181lbtft) Checkthe front hub for damageand cracks.
Replace.
Raisethe lockingtab on the spindle nut, then remove 1 1 . R e m o v et h e w h e e l s e n s o rf r o m t h e k n u c k l e( f o r
the nut. vehicleswith ABS). Do not disconnectthe wheel
sensor connector.
Removethe brakehosemountingbolts.
BRAKEHOSEMOUNTINGBOLT
8 x 1.25mm
22 N.m {2.2kgt m, 16 lbtft)
9.8 N.m
(1.0 kgf.m,
7.2 tbttrl
CALIPER MOUNTING BOLTS

12x 1.25mm
108N.m(11.0kgl.m,80 lbl.ft)
MOUNTING
BOLTS
Removethe caliper mounting bolts, and hang the 9.8 N.m
caliperassemblyto ona side.To preventdamaggto lr.0 kgf.m, ?.2lbf.ftl
t h e c a l i p e ra s s e m b l yo r b r a k e h o s e , u s e a s h o r t
pieceof wire to hangthe caliperfrom the undercar-
riage.
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18-10
12. Cleanany dirt or greaseoff the ball joint. 17. Oncethe specialtool is in place,turn the adjusting
bolt as necessaryto make the jaws parallel.Then
1 3 . Removethe cotter pin from the steeringarm, and h a n d - t i g h t e nt h e p r e s s u r eb o l t , a n d r e c h e c kt h e
removethe nut. jaws to makesurethey are still parallel.
14. Apply greaseto the specialtool on the areasshown.

This will ease installationof the tool and prevent
damageto the pressurebolt threads.
PRESSURE
BOLT
ADJUSTINGBOLT
tc. lnstalla 10 mm hex nut on the ball joint. Makesure

the hex nut is flush with the ball joint pin end to After makingthe adjustmentto the adjustingbolt,
prevent damage to the threaded end of the ball make sure the head of the adjustingbolt is in this
joint. positionto allow the jaw to pivot.
BALLJOINTREMOVER, 28 mm
07MAC- SL(x)2(x) 1 8 . With a wrench, tighten the pressurebolt until the
HEXNUT
ball joint shaft pops loosefrom the steeringarm.
@ wear eye protection. The balt ioint

HEX NUT can break loose suddenly and scatter dirt or other
10x 1.25mm dsbris in your eys.
('99 modcll
43 N.m
lit.a kgl.m.
1(| Removethe tool, then removethe nut from the end
32 tbtft) of the ball joint, and pull the ball joint out of the
steering/suspensionarm. Inspectthe ball joint boot.
6:)
and replaceit if damaged.
CASTLENUT
10x '1.25mm
l'97 - 98 modcls)
39 - 47 N.m
{4.0- 4.8
29- 3s rbtftt
COTTER 37 -98 models:

Replace. '99 -00 modol:
Onre6ssmbly,
bendthe cofterpin
16. Install the special tool as shown. Insert the jaws

carefully,makingsure you do not damagethe ball
joint boot. Adiust the jaw spacing by turning the
pressurebolt. lf necessary,apply penetratingtype
lubricantto loosenthe ball ioint.
(cont'dl
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1 8 - 11
FrontSuspension
Knuckle/HubReplacement(cont'd)
20. Removethe cotterpin from the lower arm ball joint 23. Removethe cotterpin from the upper ball joint cas-
castlenut, and removethe nut. tle nut, and removethe nut.
COTTERPIN
COTTERPIN Replace.
Replace. On reassembly,bend
On ra6ssembly, the cotterpin as shown.
bend the cofter pin
CASTI.ENUT CASTLENUT
12 x 1.25mm 10 x 1.25mm
ilg - 59 N.m (5.0 - 6.0 kgf.m, 36 - a3 lbf.ftl 39 - 47 N.m
14.0- ,4.8kgt m,
29 - 35 tbt.ftl
10 mm
nEMOVER,28 mm
07MAC_ SLtD2(xl
24. Installthe 10 mm hex nut on the ball joint.

Makesurethe hex nut is flush with the ball joint pin
end, or the threaded section of the ball joint pin
might be damagedby the balljoint remover.
25. Usethe specialtool as shown on page 18-11to sep-

CASTLENUT aratethe ball joint and knuckle.lf necessary,apply
12 x 1.25mm penetratingtype lubricantto loosenthe ball joint.
26. Pull the knuckleoutward, and remove the driveshaft

COITER PIN
Replace. outboardjoint from the knuckleby tapping the driv+
shaft end with a pl8stichammer,then removethe
BALLJOINTREMOVER,28 mm knuckle.
07MAC- Sl(xr2(x,
KNUCKI.E
Checklor damage.
Installa 12 mm hex nut on the ball joint. Make sure
the hex nut is flush with the balljoint pin end,or the
threadedsectionof the ball joint pin might be dam-
aged by the balljoint remover.
Usethe specialtool as shown on page 18-11to sep-

a r a t et h e b a l l j o i n t a n d l o w e r a r m . l f n e c e s s a r y ,
apply penetratingtype lubricantto loosenthe ball
joint.
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18-12
27. Separatethe hub from the knuckleusingthe special 29. Pressthe wheel bea.ingoutofthe knuckleusingthe
tool and a hydraulicpress.Takecare not to distort soecialtoolsand a Dress.
the splashguard.Hold on to the hub to keepit from
fallingwhen pressedclear.
DRIVER
HUBDIS/ASSEMELYTOOL 077,19- 0010000
07GAF- 5800100
ORIVER
ATTACHMENT,
62x64mm
07947- 6340400
FRONTHUB
SETTING
POINT
28. Removethe circlip and the splashguard from the

knuckle.
30. Pressthe wheel bearing inner race from the hub
using the specialtool, a bearing separator,and a
press.
Checkfor bendingand damage.

HU8OIS/ASSEMBLYTOOL
07GAF- SE00100
EEARING
SEPARATOR
O-1112in.
(Commercially
available)
{cont'd}
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18-13
Front Suspension
Knuckle/HubReplacement(cont'dl
3 1 . Wash the knuckleand hub thoroughlyin high flash 35. lnstallthe hub on the knuckleusingthe specialtools
point solvent before reassembly, shown and a hydraulicpress.Be carefulnot to dis-
tort the splashguard.
Pressa new wheel bearinginto the knuckleusing
t h e o l d b 6 a r i n g ,a p l a t e .t h e s p e c i a lt o o l , a n d a
press.Placethe wheel bearingon the knucklewith ORIVER
the pack seal side facing (metal color) toward the 077irg- 0010000
inside.Be careful not to damagethe sleeveof the
Dackseal.
DOUBLELIPSEAL
IBLACKCOLORI
SPLASHGUARO
SUPPORT BASE
0?965- SD90t00 lnstall the knuckle in the reverse order of removal,
and pay particular attention to the following items:
33. Installthe circlip securelyin the knucklegroove. . Be careful not to damage the ball joint boots
when installing the knuckle.
scREws r Torque a\\ mount\ng hardv{are to ths speci{ied
5 N.m 10.5kgl m, 4 lbl'tt) torquevalues,
o Torque the castle nuts to the lower torque speci
fications, then tighten them only iat enough to
align the slots with each pin hole. Do not align
the castlenut by loosening.
a lnstall new cotter pins on the castle nuts or hex
nut aftertorquing.
. Avoid twisting the sensorwires when installing
the wheel sensor.
. Before installing the brake disc, clean the mating
surfacesof the front hub and the inside of the
brakedisc.
. Beforeinstallingthe spindle nut, apply a small
amount of engine oil to the seatingsurfaceoJthe
nut. After tightening, use a drift to stakethe spin-
CIRCLIP dle nut shoulderagainstthe driveshaft.
34. Installthe splashguard and tightnthe screws. . Beforeinstallingthe wheel.cleanthe matingsur-
faceof the brakediscand the insideof the wheel.
. Checkthe front wheel alignment,and adjust it if
necessary {seepage 18-4).
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18-14
Lower BallJoint Replacement
'1.
Removethe knuckle(seepage 18-10). 8. Installthe ball joint boot and set ring usingthe spe-
cialtool {seepage18-16}.
Removethe boot by prying the set ring off.
Checkthe boot for deteriorationand damage.and

replaceit if necessary.
lnstallthe specialtools on the ball joint, and tighten

the castlenut.
8AI.I JOINT REMOVEN/INSTALLER
BAII JOINTBEMOVER
BASE
07JAF- SH2oe00
P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s
shown. then set the assemblyin a vise. Pressthe
ball joint out of the knuckle.
Placethe ball joint in positionby hand.
7. Installthe specialtools over the ball joint as shown, o Installthe knucklein the reverseorder of removal.
then pressthe balljoint in. and pay particularattentionto the followingitems:
BAII JOINT INSTAL1IR BASE

. Be careful not to damage the ball joint boots
when installingthe knuckle.
. Torque all mounting hardwareto the specified
torouevalues.
a Torquethe castlenuts to the lower torque speci-
fications,then tighten them only far enough to
align the slot with the pin hole. Do not align the
castlenut by loosening.
. Install new cotter pins on the castle nuts after
IOrqurng.
Avoid twisting the sensorwires when installing
the wheelsensor.
Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel.cleanthe matingsur-
faceof the brakediscand the insideof the wheel.
Checkthe front wheel alignment,and adjust it if
BALLJOINT HOUSINGSURFACE necessary(seepage18-4).
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18-15
FrontSuspension Front Damper
BallJoint Boot Replacement Removal
1 . Removethe set ring and the boot. 1, Removethe front wheels(seepage 18-10).
Packthe interiorof the boot and lip with grease.Do 2. Removethe damper pinch bolt from the top of the
not contaminatethe boot installationsectionwith damperfork.
grease.
DAMPERFORK
BALL PIT{TAPEFEOSCTION
DAMPER
PINCH
BOLT
'10x 1.25
B{rcYHSI SECTIO BOOT|NST SECTION

wip6 off tho gr6aso. Wipo otf th6 grors.
Wipe the greaseoff the sliding surfaceof the ball
pin, and pack it with fresh greass. Keep grease off
the boot installation section and the taoered section
of the ball pin.
Do not allow dust, dirt, or other foreign materialsto SELF.LOCKING NUT
enter the boot. 12x 1.25fifi
Replace.
Installthe boot in the grooveof the boot installation Removethe damper fork bolt and self-lockingnut
sectionsecurelv,then bleedair. from the bottom of the damper fork, then remove
the damperfork.
Installthe upper and lower ball joint boot set rings
usingthe specialtools as follows: Removethe damperby removingthe two nuts.
Lower ball joint: Adjust the special tool with the

adjustingbolt until the end of the tool alignswith
the groove on the boot. Slidethe set ring over the DAMPER
tool and into oosition.
Upper ball joint: Hold the tool over the ball joint,
then slidethe set ring overthe tool and into position.
AD'USN G BOLT
EAII JOINT Adjustth6 depthby
B(X)TCUP turningthe bolt.
GUttrE
UPPERBAI.I
Jott'trBoor:
07GAG - SO407q)
LOWEF BATI
JOIIYI EOOTI
0t97il - SA507lXl
After installing the boot, check the ball pin tapered

section for greasecontamination,and wipe it if nec-
gssary.
18-16
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Disassembly/
Inspection
Disass.mbly
SELF-LOCKING NUT
1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a s p r i n g c o m - 10 x 1.25mm
29 N.m (3.0kgl.m,22lbtftl
pressor accordingto the manufacturer'sinstruc- Replace.
tions,then removethe self-lockingnut. Do not com-
pressthe spring more than necessary to removethe DAMPERMOUNTINGWASHER
nur.
DAMPERMOUNTING
RUBBER
Check
for
10 mm SELF- ano oamage.
LOCKING
Replace. DAMPERMOUAMNGCOLLAR
DAMPERMOUNTING
BASE
DAMPERMOUNTING
RUBBER
Checkfor detrioration
STRUT ano oamage.
COMPRESSOR:
lComm6rciallyavailablo)
BRANICK@T/N MST-580A
or Mod6l 7200
or equivalent
Releasethe pressurefrom the spring compressor,
then disassemblethe damperas shown in the next
cotumn.
Inspection SPRINGMOUNTING
1. all parts,exceptfor the spring.

Reassemble
2. Pushon the damperassemblyas shown.

BUMPSTOPPLATE
..rg
BUMPSTOP g
DUST weaknessand
C h e c k for bendingand damage. damage,
Checkfor smooth operationthrough a full stroke,

b o t h c o m p r e s s i o na n d e x t e n s i o n .T h e d a m p e r
should move smoothly.lf it does not (no compres-
s i o n o r n o e x t e n s i o n )t ,h e g a s i s l e a k i n g a
, nd the
dampershouldbe replaced.
Checkfor oil leaks,abnormalnoises,or bindingdur-

ing these tests.
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Front Damper
1. Installthe damperunit on a springcompressor. 1 . Loosely install the damper on the frame with the
a l i g n i n gt a b f a c i n ginside,then loosely install tne
STRUTSPflNG COMPBESSOR: two flangenuts.
lcomm.rcillly .vrilrble) FLANGE NUT
BRANICKCT/N MST.sEOA -__---a-"- 10 x 1.25mm
g*- 59 N.m {5.0 kgt m, 43 tbf.ftl
or Mod.l 7200
or oquivtla | -,./
.46
-
--...
./ -4 A-
DAMPER
ASSEMBLY
SPRINGLOWERSEAT
Assemblethe damper in reverseorder of removal
ALIGNING
exceptthe damper mountingwasherand self lock-
TAB
ing nut. Align the bottom of the damperspring and
the springlower seatas shown.
Positionthe damper mountingbaseon the damper

unit as shown.
2, Installthe damperfork over the driveshaftand onto
t h e l o w e r a r m . I n s t a l lt h e f r o n t d a m p e r i n t h e
damperfork so the aligningtab is alignedwith the
slot in the damDerfork,
10x 1.25mm
il3 l+m
{4.4kgf'm,
Compressthe damperspring,
Installthe dampermountingrubber,dampermount-
ing washer,and a new 10 mm self-lockingnut.
NUT
SELF-LOCKING
10x 1.25mm
Zt N.m 13.0kgf.m, 22 lbf.ft) DAMPER
Replace. MOUNfING WASHER Replace.
3. Looselyinstallthe damper pinch bolt on the top of
the damperfork.
4. Looselvinstallthe damperfork bolt and a new self-
lockingnut on the bottom of the damperfork.
5. Raisethe knucklewith a floor iack until the vehiclejust
lifts off the safetvstand.
The lloor iack must b socurely posi-
tioned or personal iniury may result.
6. Tightenthe damperpinch bolt.
7. Tightenthe damperfork bolt and self-lockingnut.
8. Tightenthe flangenuts on top of the damper.
9. Installthe brakehose mounts with the brake hose
Hold the dampershaft,and tightenthe 10 mm self- mountingbolts.
lockingnut. 10. Installthefront wheel.
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18-18
RearSuspension
Suspension
ArmsReplacement
@ when the suspensionarms are to be removed, plsce additional weight in lhe trunk beto.o hoisting. when
substantial weight is removed from the rear of the vehicle, the center ot grsvity m8y chango causing the vehicle to tip
forward.
. Replacethe self-locking nuts afterremoval.
. Any boltsor nuts connectedto rubbermountsor bushingsshouldbe tightenedwith the vehicleon the ground.
. Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection,
ry (seepage 18-4),
. After installingthe suspensionarm, checkthe rearwheelalignment,and adjustif necessa
FLANGEBOLT STABILIZER BAR

10 x 1.25mm Checkfor bending STABILIZER
8AR
54 N.m (5.5kgt.m, or oamage.
--1/ t
40 lbf.ftt. \
FLANGEEOLT \ \A1(\
10 x 1.25mm
64 N.m 16.5kgf.m,47 lbf.ft) \a'v..:r
UPPERARM BUSHING
Checkfor deterioration il ,
and damage.
FLANGEBOLT 8 mm EOLTS
'l0 r 1.25mm
22 N.m {2.2 kgf.m, 16 bl.ftl
54 N.m (5.5 kgf.m,
40rbtft) stLtcoNE
TRAILINGARM
-6l
UPPERARM BUSHING
Checkfor bending
'anooamage. FLANGEBOLTS
10 x 1.25mm
stLtcoNE 39 N.m 14.0kgf.m, 29 lbf.ft)
.@i
COMPENSATOR UPPERARM
ARMBUSHING Checklor bendingor damage.
,/ FLANGEBOLT
// 10 x 1.25mm
s4 N.m 15.5kst'm, 40 lbf ftl
^/
COMPENSATOR
ARM BUSHING
FLANGENUT
10 x 1.25mm
29 N.m {3.0kg{.fl,22 lbf.ft}
Beforetighteningthe flangenut,
positionthe balljoint pin
in the middleof its rangeof
travel,with the suspension under
vehicleload.
FLANGEBOLT
64 N.m 16.5kgf.m, 47 lbtftl
10 x 1.25mm
SELF.LOCKING 54 N.m {5.5 kgf.m, 40 lbf.ft}
NUT
10 x 1.25mm 29 N.m (3.0kgl.m, 22 tbf.ft)
Replace. Checktor damage.
Holdthe ballioint pin usinga hexwrenct,,
and tightenthe self-lockingnut. LOWERARM BUSHING
and damage.
STABILIZER LINK LOWENARM BUSHING
. Checkfor bendingand damage.
. Checkthe bushingtor deterioration
damage.
and -6il
stLrcoNE
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RearSuspension
HubBearingUnit Replacement
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weights may corrodeand damage
t h e a l u m i n u mw h e e l s .
. Beforeinstallingthe brakedrum, cleanthe matingsurfacesof the rearhub and the brakedrum.
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakedrum and wheel.
FLANGEBOLI
12x 1,25mm
103N.m 110.5kgf.m,
76 tbtfr)
BACKINGPLATE
SPINDI-ENUT
2 2 x ' 1 . 5m m
181 N.m {18.5kgf.m, 134 lbf.ftl
Replace.
NOTE:Altertightening,usea drift
punchto lockthe spindlenut shoulder
intothe spindle.
BRAKESHOE
TRAILINGARM
Check{or cracking
ano oamage.
FLANGEBOLT
10x 1.25mm
64 N'm 16.5kgf.m, 4? lbt.ft)
Checkfor cracking
ano oamage.
BRAKEDRUM
Checkfor wear
ano oamage,
WHEELNUT
1 2x 1 . 5m m
108N.m {11.0kgt m,80lbtftl
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1A-20
't. Raisethe rear of the vehicle,and make
sure it is 7 . Disconnect
the brakeline from the wheelcylinder.
securelysupponed.
6. Removethe wheel sensorfrom the backing plate
Removethe rearwheel. ( f o r v e h i c l e sw i t h A B S ) . D o n o t d i s c o n n e c t h e
wheelsensorconnector.
Removethe brakedrum from the hub by threading
8 x,r.25 mm bolts into the drum to push it away a Removethe 12 mm flangebolts.
from the hub bearingunit. Turn each bolt two turns
at a time to preventcockingthe drum excessively.
8 x 1.25mm BOLTS
i+/3
',1 /
"@,1
/
-->- \ . ' - - 7J
SPINDLENUT WHEELNUT
r81 N.m t18.5kgt m, 134lbt'ftl 12 x 1.5 mm
Replace. 108N m 111.0kgf'm, 80 lbf ftl
4. R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut.
5. Removethe brakeshoes.
PULLER
available)
lCommercially
6. Removethe parking brakecable from the backing
plateusinga 12 mm offsetwrenchas shown.
1 0 . 4WD; Removethe backing plate/hubbearing unit
BACKINGPLATE from the rearaxlewith a pullerif necessary.
1 1 . Separatethe rear hub from the hub bearing unit

Notethe followingitemsduring disassembly:

. Takecare not to distort the backing plate.
. Hold on to the hub to keep it from falling when
DRIVERATTACHMENT,
37 x ilo mm
07746- 0010200
PARKINGARAKECABLE
(cont'd)
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1a-21
RearSuspension
Hub BearingUnit Replacement(cont'd)
't7. Installthe hub bearingunit onto the rear hub using
12, Pressthe wheel bearing inner race from the hub
usingthe tools,a bearingseparator,and a press. the specialtools and a press.
HUB DIS/ASSEMBLYTOOL
07965- SA50100 Prcss DRIVER
+
DRIVER
ATTACHMENT, 07749- 0010000
BEARING 60 mm
SEPARATOR 07LAO- SM40100
0 -,t 1/2 in {0 - 11i1.3
mml
(Commercially qvailable)
BEARING
13. Removethe 12 mm flangebolts.
HUB BEARINGUN]T O.RING REARHUB
1 8 . I n s t a l l t h e b a c k i n g p l a t e / h u b b e a r i n gu n i t o n t h e
trailing arm.
FLANGEBOLTS
12 x 1.25mm
103N.m 110.5kgf'm,75lbfft)
1 4 . R e m o v et h e h u b b e a r i n g u n i t f r o m t h e b a c k i n g
plate.
15. Installa new O-ringon the hub bearingunit.
FLANGEBOLTS
10x 1.25mm
64 N.m (6.5kgf.m, 47 lbf.ftl
19. Installthe hub bearingunit in the reverseorder of

removal,and pay particularattentionto the follow-
ing items:
. Before installingthe spindle nut, apply a small
amountof engineoil to the seatingsurfaceof the
nut, After tightening, use a drift to stakethe spin-
dle nut shoulderagainstthe driveshaft.
. Avoid twisting the sensorwires when installing
the wheelsensor,
. Fill the brakereservoirand bleed the brakesys-
16. Installthe hub bearingunit on the backingplate. tem {seesection19).
. Adjustthe parkingbrake(seesection191.
. Checkthe rear wheel alignment,and adjust it if
necessary(seepage 18-4).
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18-22
RearDamper
UpperArm BushingReplacement Removal
1. R e m o v et h e u p p e r a r m b u s h i n g a n d u p p e r a r m 't. Removethe rearwheels(seepage '18-21),
innerbushingas shown.
Removethe damper accesspanel and the damper
UPPER
ARM INNERBUSHING UPPER
ARM AUSHIT{G cap.
5. Removethe two flange nuts.

ACCESSPANEL
OAMPERCAP
REARUPPERARM
Mark a scribeline on the upper arm inner bushing
so it is in linewith the bolt mountingsurface.
4. Removethe flangebolts.
BOLT MOUNTII{G
SURFACE
Makea mark on the upperarm at two pointsso the

marks are in line and at a right angle with the arm
as shown in the drawing.
Drive in the upper arm inner bushingwith the

marks aligned until the leadingedge is flush with
the uoDerarm.
L o w e r t h e r e a r s u s p e n s i o n ,a n d r e m o v e t h e
damper.
Drive the upper arm bushing into the upper arm

untilthe leadingedge is flush with the upperarm.
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1a-23
RearDamper
Disassembly/lnspection
Disassembly SELF-LOCKING NUT
10x 1.25mm
29 N.m {3.0kgf.m,22 lbf.ft)
L Compressthe damper spring with the spring com- OAMPER
Beplace.
p r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r 'isn s t r u c - MOUNTING
WASHER
tions,then removethe self-lockingnut. Do not com-
pressthe spring more than necessary to removethe OAMPERMOUNTING
self-locking nut. RUBBER
C h e c kf o r
SELF-LOCKINGNUT deterioration
10 x 1.25mm ano oamage.
Replace. DAMPERMOUNTING
COLLAR
DAMPER
MOUNTINGBASE
DAMPERMOUNTING
RUBBER
Checkfor
deterioration
ano oamage.
STRUTSPRING
COMPRESSOR:
lCommercirlly avaihblo)
BRANICKO I/N MSI-580A DAMPER SPRINGMOUNTING
or Mod6l/7200or equivalent Checkfor weakness, RUBBER
Releasethe pressurefrom the spring compressor, compressron CheckIor deterioration
2.
the damperas shown on page 18-
then disassemble '"dd"^.s"' and damage.
25. BUMP STOP
Inspection
//F, Checkfor weakness
ano oamage.
DUSTCOVERPLATE
1. Reassemble all parts,exceptthe spring. BUMP STOPPLATE

2. Pushon the damperas shown.
DUSTCOVER
Checkfor bending
and damage.
DUSTCOVENBOOT
Checkfor deterioralion
ano oamage.
WOODENELOCK
DAMPER
3. Checkfor smooth operationthrough a full stroke,

b o t h c o m p r e s s i o na n d e x t e n s i o nT. h e d a m p e r
should move smoothly.lf it does not (no compres-
s i o n o r n o e x t e n s i o n )t ,h e g a s i s l e a k i n g a, n d t h e
dampershouldbe replaced.
4. Checkfor oil leaks,abnormalnoises,or bindingdur-
ino thesetests.
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1. I n s t a ltlh e d a m p e ru n i to n a s p r i n gc o m p r e s s o r , 1. L o w e r t h e r e a r s u s p e n s t o n a, n d p o s i t i o n t h e
d a m p e r .T h e s p r i n g s t o p o n t h e r i g h t d a m p e r
2 . Assemblethe reardamperin reverseorderof disas- should face rearward,and the s p r a n gs t o p o n t h e
sembly except the damper mounting washer and left dampershouldfaceforward.
self-lockingnut. Align the bottom of the damper
springand the springlower seatas shown.
STRUTSPBINGCOMPRESSOR:
DAMPERMOUNNNG (Commorcislly!v.ilablel
BRANICKCT/N MST.s8OA
SPRINGSTOP
2. Loosely install the two flange nuts.
FLANGENUTS
10x 1.25mm . .:
{9 N.m 15.0kgf.m,36 lbtft}-----.-*
:',,-
rigf't"n if'"""_nrr. in
qla^ 7
Step7.
3. Looselyinstallthe flangebolt.
3. Positionthe dampermountingbase on the damper
u n i ta s s h o w n . FLANGEEOLT
10 x 1.25mm
Compressthe damper spring with the spring com- 54 N.m 15.5kgt.m,
pressor. 40 tbI.ft)
I n s t a l lt h e d a m p e rm o u n t i n gw a s h e r ,a n d l o o s e l y
installa new self-locking nut.
SELF.LOCKINGNUT Raisethe rear suspensionwith a floor jack until the

10x 1.25mm vehiclejust lifts off the safetystand.
29 N.m (3.0
Replace. The floor iack must be securely posi-
@
iioned or personal iniury may result.
Tightenthe flangebolt.
6. Tighten the two flange nuts on the top of the

damperto the specifiedtorque.
7. Installthe dampercap and accesspanel.
Holdthe dampershaftwith a hex wrench,and tight- 8. Checkthe rearwheelalignment.and adjustif neces-

nut.
en the self-locking sary (seepage 18-4).
Brakes . . . . . . . . .1. .9 - 1
Anti-lockBrakeSystem (ABS) ............. 19-25
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Brakes
SpecialTools 19-2
............. MasterCylinder/BrakeBooster
ComponentLocations Removal/lnstallation 19-13
.......................
lndex ................ ......19-3 Master Cylinder
Inspectionand Adlustment Inspection/Disassembly ..............
19-14
BrakeSystem RubberParts PushrodClearanceAdiustment ......19-14
19-4
and BrakeBooster..........,,,.......... BrakeBoosterInspection...,.,,,,.......19-15
BrakePedal ............
19-5 RearDrum Brakes
ParkingBrake ........19-6 Inspection 19-15
..............
Bleeding 19'7
................. BrakeShoes
BrakeSystemIndicator...................19-8 Replacement .....19-r8
Front BrakePads Wheel CylinderReplacement.........19-20
Inspectionand Replacement..........19-9 BrakeHoses/Lines
Front BrakeDisc Specifications... 19-21
Inspection/Torque
DiscRunoutInspection...................19-11 HoseReplacement ..,,,19-22
....,...,.............
DiscThicknessand ParkingBrakeCable
Parallelism 19-11
Inspection........,........ Inspectionand Replacement..........19-23
Front BrakeCaliper
Disassembly/Reassembly ...............
19-12
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SpecialTools
Ref. No. Tool Number Description ety psge Reference

(, | 07JAG. SD40100 | PushrodAdiustmentcauge I r I tg_rt
19-2
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Gomponent Locations
lndex
ERAKESYSTEMINOICATOR
CircuitDiagram,page't9-8
PARKINGBRAKE
Adjustment,page19-6
'19-8
ParkingBrakeSwitchTest, page
PARKINGBRAKECABI..E
and Replacement,
Inspection
page19-23
BRAKEBOOSTER
page19-15
BrakeBoosterInspection,
page19 13
' -"''
)i't /'"''t,'..,
1...,. ,
\,,,.
'a.,
i ,.' I
.) ..)
t ^fl)
REARDRUM BRAKE
pago19-16
Inspection,
BrakeShoesReplacement,
page19-18
WheelCylinder
Replacement,page19-20
MASTERCYLINDER
page19-13
lnspection/Disassembly. Inspection/TorqueSpecification,pag'19-21
p a g e1 9 - 1 4 Hose Replacement,Page19-22
PushrodClearance Adjustment,
p a g e1 9 l d
BrakeFluidLevelSwitchTest, FrontBrakePads,page19-9
page19-8 FrontBrakeDisc.page19-11
FrontBrakeCaliper,page19-12
BrakeSystemRubberPartsand BrakeBooster
@-BrakeBooster (9-BrakeHoses
Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signsof fluid leakage.
lf the brakesdo not work properly,checkthe brake Replacethe brake hose with a new one if it is dam-
booster.Replacethe brakeboosteras an assemblyif a g e do r l e a k i n g .
it does not work properlyor if thereare signsof leak-
age. O-Caliper Piston Sal and Piston Boots
Checkbrakeoperationby applyingthe brakes.
@-Piston Cup and PressureCup Inspection Visuallycheckfor damageor signsof fluid leakage.lf
. Checkbrakeoperationby applyingthe brakes. the pedaldoes not operateproperly,the brakesdrag,
Visuallycheckfor damageor signs of tluid leakage. or there is damageor signs of fluid leakage,disas-
R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f t h e s e m b l ea n d i n s p e c t h e b r a k ec a l i p e r .R e p l a c et h e
pedaldoes not work properlyor if there is damageor boots and sealswith new ones wheneverthe brake
signsof fluid leakage. caliperis disassembled.
. Checkfor a differencein brakepedalstrokebetween @-WheelCylinder Piston Cup and Dust Cover

q u i c ka n d s l o w b r a k ea p p l i c a t i o n R
s .e p l a c e
the mas-. Checkbrakeoperationby applyingthe brakes.
ter cylinderif there is a differencein pedalstroke. Visuallycheckfor damageor signsof fluid leakage.lf
the pedaldoes not operateproperly,the brakesdrag,
or there is damageor signs of fluid leakage,replace
the wheelcvlinder.
19-4
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Brake Pedal
Pedal Hoight 4. Screw in the brakeswitch until its plunger is fully
1. Disconnectthe brakeswitch connector,loosenthe p r e s s e d( t h r e a d e de n d t o u c h i n g t h e p a d o n t h e
brake switch locknut, and back off the brake switch pedal arm), Then back otf the switch 1/4 turn to
until it is no longertouchingthe brakepedal. make 0.3 mm (0.01 in) of clearancebetween the
threadedend and pad. Tighten the locknutfirmly.
2. Lift up the carpet,At the insulatorcutout,measure Connectthe brake switch connecto.. Make sure that
the pedalheightfrom the middleof the right side of the brakelights90 off when the pedalis released
the oedalpad.
BRAKESWITCH
ERAKESWITCH
5. Checkthebrakepedalfreeplay as describedbelow
Pedal FreePlay
1. With the engine off. inspect the free play on the
pedalpad by pushingthe pedalby hand-
Standard Pedal Height (with floor m8i removed):
A/T: 161mm (5 5/16 in) FreePlay:1 - 5 mm (1/16- 3/16 in)
M/T: 155 mm {6 U8 in}
2. lf the pedalfree play is out of specification,
adiust
Loosenthe pushrodlocknut,and screwthe pushrod the brake switch. lf the pedal free play is insuffi-
in or out with pliersuntil the standardpedal height cient,it may resultin brakedrag.
from the floor is reached.Do not adjustthe pedal
heightwith the pushrodpressed.After adiustment,
tightenthe locknutfirmly. swtTcH
PEOALPAD
PEDALFREEPLAY
PUSHRODLOCKNUT
15 N.m
11.5kgj m, 11 lbf ftl
ParkingBrake
Inspeqtion 3. Releasethe parkingbrakelever.
1. Pull the parkingbrake lever with 196 N (20 kqf, 44

lbfl forceto fully applythe parkingbrake.
The parkingbrakelevershould be lockedwithin the
specifiednumberof clicks.
L.var LockodClicks:2 - 6
Adjust the parking brake by turning the adjusting

nut.
Checkthat the parkingbrakesdo not drag when the

rearwheelsare turned.Readjustif necessary.
Makesurethe parkingbrakesare fully appliedwhen

the parkingbrakeleveris pulledup fully.
2. Adjustthe parkingbrakeif the leverclicksare out of
specification. 7. Installtheparkingbrakecover.
Adiustment
1. Raisethe rear wheels off the ground. and support

the vehicle on safety stands.
@@ Bbck tho front whots betore iacking

up the rear ot tho vohicle.
2. Removethe parkingbrakecover
PARKINGBRAKECOVER
19-6
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Bleeding
CAUNON:
FRONT:
. Do not spill brake tluid on the vehicle. it may damage
the paint; if brake fluid does contaqt th paint, wash
it otf immodiately with water.
. Maks sure no dirt oy other forsign matter is allowsd
to contaminate the brake fluid.
NOTE:
. Do not reusethe drainedfluid.
. Always use GenuineHondaDOT3 BrakeFluid.Using
a n o n - H o n d ab r a k ef l u i d c a n c a u s ec o r r o s i o na n d
decreasethe life of the svstem.
. The reservoiron the mastercylindermust be at the
MAX (upper)level mark at the start of bleedingpro-
cedureand checkedafter bleedingeach brakecaliper
and wheelcylinder.Add fluid as required.
1, Makesure the brakefluid levelin the reservoiris at

the MAX (uDDer)levelline.
MAX {UPPER)LEVEL
LINE
RESERVOIR
MASTERCYLINDER
2. Havesomeoneslowly pump the brakepedalseveral

times,then applysteadypressu.e.
3. Loosenthe brakebleedscrewto allow air to escape
f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w
securely. BLEEO SCREW
7 N.m(0.?kgf.m,5 lbf.ftl
4. Repeatthe procedurefor eachwheelin the sequence
shown below until air bubblesno longer appearin
the tluid.
Refill the reservoir on the master cvlinder to the
MAX (upper)levelline.
ALEEDINGSEOUENCE:
O Front Right Gt RearRight
O Front Lefl O Rear Left
NOTE:Bleedthe front calipersfirst in the bleeding

procedure.
BrakeSystemIndicator
Circuit Diagram lNuLR.HorJD GNrT0ll UNDEB.DASH
St!ITCH FUSE]NEtAY
BOI
r l l A N l ]4 2 4 ! A
GBNiBEO
I
P A FN
KCB R A ( E
S\I'ICH
o\
lt j I ERAK
t uEU0 r E V E9r! 1I ( N
o P t ^ r ' f ., r' 1
|
BIK
-o-
I
:
G401
Parking BrakeSwitch Test Brake Fluid Level Switch Test
1. Removethe parkingbrakecover, 1. R e m o v et h e r e s e r v o i rc a p . C h e c kt h a t t h e f l o a t
movesup and down freely;if it doesn't,replacethe
2. Disconnectthe connectorfrom the parking brake reservoircap assembly.
switch.
2. Checkfor continuitybetweenthe terminalsin each
3. Checkfor continuitybetweenthe terminaland body switchpositionaccordingto the table.
ground in eachpositionaccordingto the table.
Terminal \ - r9''r 1 2
\ Positive
Body Ground Position
LeverPosition \ Terminal
FLOATUP
LeverUp --o
FLOATDOWN o
Lever Down
RESERVOIR
CAP
GROUND
NOTE(Canada):lf the parking brakeswitch is OK, but
the brake system indicatordoes not function, perform
the input test for the daytimerunninglightscontrol unit
(seesection23).
Switch contacts open at
proper fluid level.
19-8
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Front BrakePads
Inspectionand Replacement
4. U s i n g v e r n i e rc a l i p e r s ,m e a s u r et h e t h i c k n e s so f
Nsvgr u9e an air hose or dry brush to clean brake each brake pad lining.The measurementdoes not
assemblies. includethe pad backingplatethickness.
Use an OSHA approved vacuum cleaner to avoid
broathing brake dust. Brake PadThickness:
1. Loosenthe front wheel nuts slightly,then raisethe Standard: 10.5- 11.5mm {0.,11 - 0.45in)
v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l ys u p p o r t e d . Servics Limit: 1.6 mm (0.06in)
Removethe front wheels.
Removethe caliper bolt, and pivot the caliper up

out of the way. Checkthe hosesand pin boots for
damageand deterioration.
i)n. EACKINGPLATE
CALIPER
BOLT CALIPERBODY lf the brake pad thicknessis less than the service
limit. replacethe front padsand shimstogetheras a
3. Remove the pads, pad shims, and pad retainers. set.
Cleanthe caliperthoroughly;removeany rust, and

INNEBPADSHIMS checkfor groovesand cracks.
Checkfor weakness.
7. Checkthe brakediscfor damageand cracks.
L Installthe pad retainers.
'.'..i
#
I PAD RETAINERS
OUTERPADSHIM
Checkfor weakness.
(cont'd)
Front BrakePads
Inspection (cont'dl
and Replacement
9 . A p p l y M o l y k o t e M 7 7 g r e a s e o r D a i k a l u b5 2 8 D '11. Pushin the piston
so that the caliperwillfit over the
greaseto both sidesof the pad shims and the back pads. Make sure the piston boot is in position to
of the pads.Wipe excessgreaseoff the shims. p r e v e n td a m a g i n g i t w h e n p i v o t i n g t h e c a l i p e r
down.
ApplyMolykote
M77 CALIPERBOLT
49 N.m(5.0kgf.m,36 lbf.ftl
to both sides of shims.
INOICATOR
Apply MolykoteM77
or 0aikalub528D
to both sidesof shim.
INNERPAD
Pivot the caliperdown into position,being careful
not to damagethe pin boot. Installthe caliperbolt
and tightenit,
OUTERPAD
1 3 . Pressthe brake pedal severaltimes to make sure
the brakeswork, then test-drive.
N O T E : E n g a g e m e n ot f t h e b r a k e m a y r e q u i r e a
greater pedal stroke immediately after the brake
1 0 . l n s t a l lt h e b r a k e p a d s a n d p a d s h i m s c o r r e c t l y . pads have been replaced as a set. Several applica-
Installthe pad with the wear indicatoron the inside. tions of the brake pedal will restore the normal
pedal stroke.
. When reusing the pads, always reinstall the 1 4 . After installation, check for leaks at hose and line
brakepads in their originalpositionsto prevent joints and connections,and retighten if necessary.
loss of braking efficiency.
. Contaminatedbrake discs or pads reducestop-
ping ability.Keepgreaseoff the discsand pads.
19-10
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Front BrakeDisc
DiscRunoutInspection DiscThicknessand Parallelism
Inspection
l. Loosenthe front wheel nuts slightly,then raisethe
v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l ys u p p o r t e d . 1. Loosenthe front wheel nuts slightly,then raisethe
Removethe front wheels. vehicle, and make sure it is securely supported.
Removethe front wheels.
Removethe brakepads{seepage 19-9).
Removethe brakepads(seepage 19-9).
I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoroughly,and removeall .ust. Usinga micromater,measurediscthicknessat eight
points,approximately45'apan and 10 mm (0.4 in)
Use wheel nuts and suitableplain washersto hold in from the outeredgeof the disc.Replacethe brake
the disc securelyagainstthe hub, then mount a dial disc if the smallest measurementis less than the
i n d i c a t o ra s s h o w n , a n d m a a s u r et h e r u n o u t a t max. refinishinglimit.
10 mm (0.4in) from the outer edgeof the disc.
BrakeDi3c Runout:
ServiceLimit: 0.10 mm {0.00,0in)
Brake DiscThickness:
WHEEL NUTAND
PLAINWASHER
Standard:
108N.m{11kg{m, 80 lbf.ft) '97 - 98 modsls:
22.9 -23.1mm {0.90- 0.91 inl
'99 - 00 modls:
lf the disc is beyond the servicelimit, refinishthe
brake disc with an on-car brake lathe. The Kwik- 23.6- 23.8 mm {0.93- 0.94 in}
Lathe produced by Kwik-way ManufacturingCo. Max. RefinishingLimit:21.0 mm (o.txlin)
and the "Front Brake Disc Lathe" offered by Snap-
on ToolsCo. are approvedfor this operation. Brake Disc Parallelism:0.015mm {0.0006in} max.
M8x. RofinishLimit: 21.0 mm l0.8il in) NOTE:This is the maximum allowabledifference

betweenthe thicknessmeasurements,
NOTE:A new disc shouldbs refinishedif its runout
is greaterthan 0.10mm (0.004in). lf the disc is beyondthe servicelimit for parallelism,
refinishthe brake disc with an on-car brake lathe.
The Kwik-Latheproduced by Kwik-WayManufac-
turing Co. and the "Front BrakeDiscLathe" offered
by Snap-on Tools Co. are approved for this opera-
tron.
NOTE:Seesection18for brakedisc replacement.
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1 9 - 11
Front BrakeCaliper
. Never use an air hose or dry brush to clean brake assemblies.

. Usean OSHAapprovedvacuumcleanerto avoidbreathingbrakedust.
. Contaminatedbrake discs or pads reducestopping ability.
. When reusingthe pads,alwaysreinstallthebrakepadsin their originalpositionsto preventlossol brakingefficiency.
CAUTION:
. Do not spill brakefluid on the vehicle;it may damagethe paint; if brakefluid does contactthe paint,wash it off imme-
diatelYwith water.
NOTEI
. To preventspills,coverthe hosejointswith ragsor shoptowels.
. C l e a na l l p a n si n b r a k ef l u i da n d a i r d r y ;b l o wo u t a l l p a s s a g ews i t h c o m p r e s s eadi r .
. Beforereassembling, checkthat all partsare free of dust and otherforeignparticles.
. Replacepartswith new oneswheneverspecifiedto do so.
. Makesure no dirt or otherforeignmatteris allowedto contaminatethe brakefluid.
. D o n o t r e u s et h e d r a i n e df l u i d .
. A l w a y su s e G e n u i n eH o n d aD O T3 B r a k eF l u i d .U s i n ga n o n - H o n d ba r a k ef l u i d c a n c a u s ec o r r o s i o na n d d e c r e a s teh e
life of the system.
. C o a t h e p i s t o np, i s t o ns e a l ,a n dc a l i p e br o r ew i t h c l e a nb r a k ef l u i d .
. ReDlace all rubberoartswith new oneswheneverdisassembled.
. After installingthe front brakecaliperdo the following.
- Checkfor leaksat hoseand linejointsand connections, and retightenif necessary.
- Checkthe brakehosesfor interference and twistinq.
t".:jil
,,.'.1!!!!9!il: Rubber grease (Use recommended grease in the caliper set)
--6, Siliconegrease(use recommendedsealgreaseand p,n greasein the caliperset)

12 mm FLANGEBOLTS
I N N E RS H I M 113N.m (11.5kgtm,83lbf.ftl
I N N E RS H I M B WEABINDICATOR
ft \ i .@
irf"i:;;T::fl,-J'I",0 PIN B
i l 1
#
OUTERPAOSHIM
I
EANJO BOLT
# PIN BOOT
-Cr
34 N.m {3.5kgf m,25 lblftl
SEALING
Replace.
WASHERS
4dd*
ERAKEPADS
'f,-rre PADSPRING
PIN A
>
6-
/ tto*l "o"\ -6, {

t @ I
/ \ ' AFACKET
sLreo6cnew \ CALIPER
BOOY PADRETAINERS
I N m 10.9kStm, 6.5lbnft)
PISTONAOOT
\ PISTONSEAL
Replace.
CALIPEREOLTS Replace.
49 N.m {5.0kgl.m, 36lbf.ftl "..-a=a-.
PISTON ..,--"sEqri
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19-1 2
Master Cylinder/BrakeBooster
1, Disconnect the brakefluid levelswitchconnectors. 9. Removethe four boostermountingnuts.
2. Removethe reservoircap from the mastercylinder. ' 1 0 .P u l l t h e b r a k eb o o s t e rf o r w a r d u n t i l t h e c l e v i si s
3. R e m o v et h e b r a k ef l u i d f r o m t h e m a s t e rc v l i n d e r clearof the bulkhead.
reservoirwith a syringe. 1 1 . R e m o v et h e b r a k eb o o s t e rf r o m t h e e n q i n ec o m -
4. Disconnect the brakelinesfrom the mastercylinder. panment.
To preventspills,cover the line joints with rags or 12. Installthe brakeboosterand mastercylinderin the
shop towels. reverseorderof removal,and notetheseitems:
5. R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d
wasners. . When connectingthe brakelines,makesure that
6. Removethe mastercylinderfrom the brakebooster. there is no interferencebetweenthe brake lines
and other parts.
CAUTION: Be careful not to bend or damagethe . Be carefulnot to bend or damagethe brakelines
brakelineswhen removingthe mastercylinder. when installingthe mastercylinder.
Do not spill brake fluid on the vehicle; it may dam. . lf replacingthe mastercylinderor brakebooster,
age the paint; it brake fluid does cont.ct the paint, checkand adjust the pushrod clearancebefore
wash it oft immediately with water. installingthe mastercylinder(seepage19-14).
7. Disconnect the vacuumhosefrom the brakebooster. 1 3 . F i l l t h e m a s t e rc y l i n d e rr e s e r v o i r a

, n d b l e e dt h e
8. Removethe cotterpin and clevispin from the clevis. brakesystem(seepage 19-7).
Do not disconnectthe clevis by removing it from 1 4 . After installation,checkthe brakepedal height and
the operatingrod of the brakebooster.lf the clevis brakepedalfree play (seepage 19-5),and adjust if
i s l o o s e n e d ,a d j u s t t h e p u s h r o d l e n g t h b e f o r e necessary.
installingthe brakebooster(seepage 19-15).
15N.m{1.5kgtm, vAcuuM HosE

r r rbf.ft) |
/ | BRAKEFLUTD
LEvEL
To FrontCaliper(WithoutABS) swrrcHcoNNEcroRs
/l /
/ I I I COTTERPIN
\ neotace
\ I I /
l,/-- r o R e awr h e ect y l i n d e r s/ | I
To MasterCylinder
(WithoutABS)
To ModulatorUnit
*s
h ./-'''
Yli
/. I
(.S I /r:
// I I -#q
CLEVISPIN
(with ABs)
@-\
\
To FrontCaliper
)
^ :-,/
9i
\.
13 N.m 11.3kg{.m,
I rbf.ft)
PROPORTIONING
CONTROLVALVE
MASTERCYLINDER
BRAXEBOOSTER
15 N.m (1.5kgf.m,11 lbl.ftl
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Master Cylinder
Inspection/Disassembly PushrodClearance
Adjustment
CAUTION: Do not spill brake fluid onthe vehicle;it may NOTE:Mastercylinderpushrod-to-piston clearancemust
damsge the paint; il brake fluid does contact th6 paint. be checkedand adjustments made, if necessary.before
wash it off immodiately with water. installingthe mastercylinder.
NOTE: 1. Set the specialtool on the master cylinder body;

. Beforereassembling, checkthat all parts are free of push in the centershaft until the top ot it contacts
dust and otherforeignparticles. the end of the secondarypiston by turning the ad-
. Do not try to disassemblethe mastercylinderassem- justingnut.
bly. Replacethe mastercylinderassemblywith a new
pan it necessary,
. Make sure no dirt or other foreign matter is allowed PUSHRODADJUSTMENTGAUGE
07JAG- SD{o100
to contaminatethe brakefluid.
RESERVOIR SEAL SECONDARY

Checkfor damaoeand
deterioration,
MASTERCYLINDER
ADJUSTINGNUT
Without disturbingthe center shaft's position, in-
stallthe specialtool upsidedown on the booster.
RESERVOIR Installthe mastercylindernuts,and tightenthem to

Checkfor damage. the sDecifiedtoroue.
RODSEAL Connectthe boosteriniine with a vacuumgauge0 -

Checkfor damage
and deterioration. 101 kPa (0 - 760 mmHg, 30 in Hg) to the booster's
e n g i n e v a c u u m s u p p l y , a n d m a i n t a i na n e n g i n e
speedthat will deliver66 kPa(500mmH9,20 in Hg)
vacuum.
With a feeler gauge, measurethe clearancebetween

the gaugebody and the adiustingnut as shown.
--1
SILICONEGREASE Clearanco:0 - 0.4 mm (0 - 0.02 inl
VACUUM GAUGE
MASTERCYLINOER
lCommo.cidly 6vailablcl
Checkborefor wear,rustand damage. 0 - 101 kPt
l0 - 760 mm Hg, 30 in Hgl
MASTERCYLINDERNUT
15 N.m 11.5kgt m, 11 lbt.ftl
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19-14
BrakeBoosterInspection
l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y a n d FunctionalTest
adjusting nut is 0.4 mm (0.02in), the pushrod-to-
pistonclearanceis 0 mm. However.if the clearance 1. With the enginestopped,pressthe brakepedalsev-
betweenthe gaugebody and adjustingnut is 0 mm, e r a l t i m e s t o d e p l e t et h e v a c u u m r e s e r v o i rt.h e n
the pushrod-to-piston clearanceis 0.4 mm (0.02in) pressthe pedal hard, and hold it for 15 seconds.lf
o r m o r e . T h e r e f o r ei t m u s t b e a d j u s t e da n d t h e p e d a l s i n k s ,e i t h e r t h e m a s t e r c y l i n d e r i s
recheckd. bypassinginternally,or the brake system (master
cylinder,lines, modulator,proportioningvalve. or
6. lf clearanceis incorrect,loosenthe star locknut,and caliper)is leaking.
turn the adjusterin or out to adjust.
2. Startthe enginewith the pedalpressed.lf the pedal
. Adjustthe clearancewhile the specifiedvacuum sinksslightly.the vacuumboosteris operatingnor-
is appliedto the booster. mally.lf the pedalheightdoes not vary,the booster
. Holdthe cleviswhile adjusting. or checkvalveis faultv.
7 . Tightenthe star locknutsecurely. 3. With the enginerunning,pressthe brakepedallight-

ly. Apply just enough pressureto hold back auto-
8. Removethe specialtool. matic transmissioncreep. lf the brake pedal sinks
0 - 0.4mm (0- 0.02inl morethan 10 mm (3/8in.) in threeminutes,the mas-
ter cylinderis faulty.A slightchangein pedalheight
STARLOCKNUT
22 N.m when the Ay'Ccompressor cycles on and off is nor-
12.2kgt m. 16 lbtftl mal. (TheAy'Ccompressorloadchangesthe vacuum
availableto the booster.)
Leak Test
1 . Pressthe brakepedalwith the enginerunning,then

stop the engine. lf the pedal height does not vary
while pressedfor 30 seconds,the vacuum booster is
OK. lf the pedal rises,the booster is faulty.
With the engine stopped, press the brake pedal sev-

9 . Adjust the pushrodlength as shown if the booster eraltimes using normalpressure.Whenthe pedalis
is removed, first pressed.it shouldbe low, On consecutive
appli-
cations,the pedalheightshouldgraduallyrise.lf the
1 1 6 1 0 . 5m m
pedal position does not vary. check the booster
{4.6 t 0.02 inl
checkvalve.
Boostor ChockValve Test
1. Disconnectthe brake boostervacuum hose at the

booster.
2. Startthe engine,and let it idle.Thereshouldbe vac-

uum. lf no vacuum is available,the checkvalve is
not working properly. Replacethe brake booster
vacuumhoseand checkvalve.and retest.
ERAKEBOOSTER
VACUUM HOSE
(Checkvalveis built-in)
PUSHROD
LOCKNUT
1.5N.m11.5kgf.m.'11lbtfl)
1 0 . Install the master cylinder (see page 19-13).
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RearDrum Brakes
Inspection
a Never use an air hose or dry brush to clgan brake assemblies,

a Use an OSHA approved vacuum cleanerto avoid breathing brake dust.
rl Contaminatedbrake linings or drums reduce stopping ability.
a Block the front wheels betore iacking up lhe rear ot the vehicle,
1. Blockthe front wheels,loosenthe rear wheel nuts slightly,then raisethe vehicle,and make sure it is securelysup-
poned.Removethe rearwheels.
2. the parkingbrake,and removethe rearbrakedrum.

Release
I N.m {0.9kgl.m,5.5rbr.ft)
\ BACKINGPLATE
\ Markedleftand right.
\ PARKINGEBAKE I-EVER
196 Markedleft and right.
@ ADJUSTERBOLT
Checkratchetteeth
for wearand damage.
UPPERRETURN SPRING
Checkfor weakness
and damage.
CLEVISB CLEVISA
64 N.m 16.5kgl.m,
\L; 'l-'-'
I
t /
u-cllP
Replace.
47 lbt.ftl 6d/
WHEEL BRAKESHOE
Inspectfor leakage. see page19 17
Inspection,
Replacement, see lf brakeshoesareto be
page19-20 reused,markand reassemble
in sameposition.
LOWERRETURN
SPRING
SPRING Checkfor weakness
C h e c kf o r w e a k n e s s a n oo a m a g e .
ano oamage.
RETAINER SPRING
Installsecurelyon
l e n s r o np r n .
19-16
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Checkthe wheelcylinderfor leakage. 8. Measure the inside diameter of the brake drum
with insideverniercalioers,
Checkthe brakeliningsfor cracking,glazing,wear,
and contamination. Drum Insido Diamoter:
Standard: 219.9- 220.0mm (8.657- 8.661in)
Measurethe brake lining thickness.Measurement ServiceLimit: 221.0mm {8.700inl
does not includebrakoshoethickness.
BrakeLining Thicknoss:
Standard: 3.9-,1.5 mm {0.15- 0.18inl
SorviceLimil: 2.0 mm {0.08in}
WHEELCYLINOER
BRAKEDRUM
lf the inside diameter of the brake drum is more

LININGS than the servicelimit, replacathe brakedrum.
1 0 . Check the brake drum for scoring, grooves, and

cracKs.
lf the brakelining thicknessis lessthan the service
limit, replacethe brakeshoesas a set.
7. Checkthe bearingsin the hub unit for smooth oper-

ation; if the bearingrequireservicing.referto sec-
tion18.
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19-17
RearDrum Brakes
BrakeShoesReplacement
1. Removethe upperreturnspringwith the tool. 7. Removethe wave washer,parkingbrakelever.and
pivot pin from the brakeshoe by removingthe U-
l@ war eye protestionwhen using the cliD.
brske spring wrench.
U.CLIP
Replace.
\
\
w
\n
BRAKESHOE
RETAINER
SPRING BRAKESPRINGWBENCH
available)
{Commerciallv
TENSIONPIN
Apply brakecylindergrease(P/N:08733- 80202)or
equivalentrubber greaseto the sliding surfaceof
Removethe tension pins by pushing the retainer the pivot pin, 8nd insertthe pin into the brakeshoe.
s p r i n ga n dt u r n i n gt h e m .
Installthe parkingbrakelever and wave washeron
Lower the brake shoe assembly,and remove the the pivot pin, and securethem with a new U-clip.
lower return spring, Make sure not to damagethe
dust coveron the wheel cylinder, . lnstall the wave washer with its convex side fac-
Ing our.
the parkingbrakecablefrom the parking
Disconnect . Pinchthe U-clipsecurelyto preventthe pivot pin
brakelever. from comingout of the brakeshoe.
5. Removethe brakeshoe assembly, U-CLIP WAVE WASHER

Replace. Replace.
o. Removethe upper returnspring,self-adjuster
lever,
and self-adjusterspring, and separatethe brake
shoes.
UPPERRETURNSPRING
LEVER
SELF.ADJUSTER
19-18
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1 0 . C o n n e c tt h e p a r k i n g b r a k e c a b l e t o t h e p a r k i n g 15. Apply greaseon each sliding surface.Keepgrease
brakelever, or oil off the brakelinings.Wipe any excessgrease
off the parts.
1 1 , Cleanthe threadedportionsof clevisesA and B.
Coat the threads of the cleviseswith grease.To . Apply brakecylindergrease(P/N:08733- 8020E)
shortenthe clevises,turn the adiusterbolt. o r e q u i v a l e nrt u b b e rg r e a s et o t h e s l i d i n gs u r -
facesas shown.
UPPERRETURNSPRING
..4 S l r d r n sgu r f a c e
Apply rubbergrease
to slidingsurface.
Apply Molykote 44MA to the brake shoe ends

1 2 . Hook the self-adjusterspring to the self-adjuster and oppositeedgesof the shoesas shown.
leverfirst,then to the brakeshoe,
Installthe clevisesand upper return spring noting .. a Oppositeedgeof the shoe

the installationdirection.Be carefulnot to damage .: a) Brakeshoeends
the wheelcylinderdust covers. (Shoesideendsand backing
platecontactsurface)
1 4 . Installthelower returnspring.
(cont'd)
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RearDrum Brakes
(cont'd)
BrakeShoesReplacement WheelCylinderReplacement
16. Installthe brake shoes onto the backingplate. Be CAUTION:
carefulnot to damagethe wheel cylinderdust cov- . Do not spill brake fluid on th6 vehicle; it may damage
ers. the paint; if brako fluid doos contact tho paint, wash
it off immedialely whh water.
17. Installthe tensionpins and the retainersprings. . To pr6v6ni 3pills, cov6r th6 hose ioinls with rags ol
shop lowels,
. Use only a genuine Honda whoel cylinder spocial
bolt.
1 . Removethe brakeshoes{seepage '19-18).

UPPERRETURNSPRING
Disconnect
the brakeline,
SEALANT
BACKINGPLATE
15 N,m 11.5kgt m,
11 tbf.ftl
WHEELCYLINDER
TENSIONPINS
9 N.m 10,9kgf'm.
6.5 rbtft)
18. Hookthe upperreturnspringwith the tool.
@ wsar eye proieclion whon using tho

brtko spring wronch.
Removethe bolt and the wheel cylinder from the
1 9 . lnstallthebrakedrum. backingplate.
20. lf the wheel cylinder has been removed,bleed the Apply sealant betweenthe wheel cylinder and back-
brakesystem (see page 19-7). ing plate,and installthe wheelcylinder.
21. Pressthe brake pedal several times to set the self- Install the removed parts in the reverseorder of
adjustingbrake. removal.
Adjustthe parkingbrako(seepage 19-6). Fill the brakereservoirup. and bleedthe brakesys-

tem {seepage 19-7).
7. After installation.checkfor a leak at the line joint.

and retighten if necessary.
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19-20
BrakeHoses/Lines
Specifications
Inspection/Torque
leaks,interference,
1. Inspectthe brakehosesfor damage,deterioration, and twisting
2. Checkthe brakeIinesfor damage,rusting,and leakage.Also checkfor bent brakelines.
3. Checkfor leaksat hoseand line jointsand connections,

and retightenif necessary.
4. Checkthemastercylinder,proportioningcontrolvalve.and ABS modulatorunit for damageand leakage.
NOTE:Replacethe brakehoseclip wheneverthe brakehoseis serviced.
MASTERCYLINOER.Io.BRAKE LINE
15 N.m 11.5kgt m, 11 lbnftl
PROPORTIONING CONTROLVALVE.
Io-BRAKELINE
15 N.m (1.5 kgf.m. 11 lbl.ftl
BRAKELINE-Io-BRAKE HOSE
15 N.m 11.5kgd.m,11 lbf'ft)
CYLINDER
15 N.m 11.5kgf.m, 11 lbf.ft)
BLEEDSCREW
7 N.m 10.7kgf.m, 5 lbt.ftt
BRAKEHOSE-to-CALIPER
{8ANJO BOLTI
34 N.m (3.5kgf.m,25 lbf.ftl
BLEEDSCREW
9 N.m 10.9kgf.m, 6.5 lbf.ftl
with ABS:
www.emanualpro.com
19-21
BrakeHoses/Lines
HoseReplacement
CAUTION: Do not spill brak fluid on the vehicl;it m8y 6. Installthe brakehose on the knucklefirst, then con-
damage th paint; if brak lluid doos contact tho paint, nectthe brakehoseto the caliperwith the banjobolt
wash it off immediately with water. and new sealingwashers.
NOTE:
. Beforereassembling, checkthat all pans are free of
dust and otherforeignparticles. 6 mm HOSEBRACKET
. Replaceparts with new ones wheneverspecifiedto EOLTS
qo so, 9.8Nm BRAKEHOSE
(1.0kgf.m,7 lbf.ftl
'1.
Replacethe brakehose ifthe hose is twisted,cracked.
or if it leaks.
Disconnect the brakehosefrom the brakeline using

a 10 mm flarenut wrench.
BANJO BOLT
FLARENUT 34 N.m
WRENCH 13.5kgf.m, 25 lbl.ftl
(Commercially
available)
WASHERS
SEALING
Heplace.
BRAKEHOSE
7. Installthe brakehose on the upper brakehose bracket
Removeand discardthe brake hose cliD from the with a new b.akehoseclip.
brakehose.
Replace.
1 tbtftl
F
)
BRAKE
HOSEARACKET
8. Connectthe brakelineto the brakehose.
9 . After installingthe brakehose,bleedthe brakesys-

'19-7).
tem (seepage
Performthe followingchecks;
Removethe banjo bolt, and disconnectthe brake . Checkthe brakehoseand line joint for leaks,and
hosefrom the calioer. tighten if necessary.
. Checkthe brake hoses for interferenceand twist-
5. Removethe brakehosefrom the knuckle. Ing
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19-22
ParkingBrakeCable
Inspectionand Replacement
Inspection
The parkingbrakecablesmust not be bent or distorted,This will leadto stiff operationand prematurecablefailure.
Replacoment
l. the parkingbrakeswitchconnector.
Disconnect
2. Releasethe parkingbrakelever.and disconnectthe

parkingbrakecable.
3, Bemovethe parkingbrakeleverassembly.
'19-18).
4. Removethe parkingbrakeshoes{seepage
5. Removethe parkingbrake cable from the backing

plateusinga '12mm offsetwrenchas shown.
6. Installthecablein the reverseorderof removal.
PARKINGBRAKECABI-E
BRACKET
PABKINGARAKECABLE
Checktor or corroston,
PARKINGBRAKELEVER
Checkfor smooth
operation,
d
,"u/n*UM
-6l
(Slidingsurface)
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19-23
Anti-lockBrakeSystem (ABSI,'97- 00 Models
SpecialTools .............
19-26 DTC1r - 18:
ComponentLocations.........................
19-27 Wheel Sensor .... 19-45
Anti-lockBrakeSystem (ABS) -
DTC31 38:
Features/Construction.............
......,19-2A Solenoid .............
19-47
-
DTC51 53:
CircuitDiagram .........19-32
ABS PumpMotor .........................
19-49
ABS Control Unit Terminal
Arrangement ......... DTC 54:
19-34
Main Relay .........19-52
TroubleshootingPrecautions............. 19-36
DTC61:
DiagnosticTroubleGode(DTC) lgnitionVoltage ...........................
19-54
DiagnosticTroubleCode (DTC) DTC81:
Indication(SCSModel ................ 19-38 CentralProcessingUnit (CPU).... 19-55
DTGErasure(MESMode) ............... 19-39 Modulator Unit
Troubleshooting lndex ....................
19-40 Removal/lnstallation .......................
19-56
Troubleshooting ABS Control Unit
ABS IndicatorLight DoesNot Replacement ..,......19-57
ComeOn ............
19-41
Pulsers/WheelSensors
ABS IndicatorLight DoesNot
Go Off (No DTC)........................... Inspection ..............
19-57
19-43
Wheel SensorReplacement............ 19-58
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S p e ci a l Tools
Rel. No. I Tool Number Description Oty PageRelerence
o 07PAZ- 0010100 SCSServiceConnector 1 19-38
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19-26
ComponentLocations
show the '97 - 98 models.The '99 - 00 modelsare similar.

NOTE:The illustrations
SERVICECHECKCONNECTOR
{2PI
ABS CONTROLUNIT RIGHT-REAR

WHEELSENSOR
UNDER.HOOD ABS
FUSE/RELAYBOX
RIGHT.FRONT
WHEEL
SENSORCONNECTOR
RIGHT-FRONT
WHEELSENSOR WHEEL
RIGHT-REAB
SENSORCONNECTOR
MODULATORUNIT UNDER.DASHFUSE,/RELAY
8OX
WHEEL
LEFT.FRONT LEFT.FRONT
WHEELSENSOB
SENSOECONNECTOR
GAUGEASSEMBLY FUSE/RELAYAOX
UNDER.HOOO
IGl I(, AI FUSE
D!
trtrtr
[r D!
ABS INDICATOR HOBN/STOPI15 AI FUSE
UNDER-DASH
FUSE/NELAYBOX UNDER.HOODABS FUSE/RELAYBOX
METER{7.5AI FUSE ABS +B 120Al FUSE PUMPMOTOR('II AI FUSE
MOTORRELAY
www.emanualpro.com ABS {7.5AI FUSE MTR CHECK17.5AI FUSE
19-27
Anti-lock Brake System (ABS)
Features/Construction
When the brakepedalis pressedduring driving,the wheelscan lock beforethe vehiclecomesto a stop. In suchan event,
the maneuverability of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the
rearwheelsare locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate of the wheelsto
ensuremaximumgrip forcefrom the tires,and it therebyensuresmaneuverbility and stabilityof the vehicle.
The ABS calculates the slip rate of the wheelsbasedon the vehiclespeedand the wheel speed,then it controlsthe brake
fluid pressureto attainthe targetslip rate.
Grip Force of Tire and Road Surlace
COEFFICIENT
OF
FRICTION
TARGETSLIPRATE
RADIAL
OIRECTION
OF THE
ROTATIONAL
DIRECTION
SLIPRATE
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19-24
ABS Control
The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle
speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeed during decelerationbasedon the
rateof deceleration.
The ABS control unit calculatesthe slip rate of each wheel, and it transmitsthe control signal to the modulator unit
solenoidvalvewhen the slip rateis high
The pressurereductioncontrolhasthree modes:pressurereducing,pressureretaining,and pressureintensi{yingmodes.
ABS CONTROLI-INIT
Self-diagnosisFunction
The ABS controlunit is equippedwith a main cPU and a sub cPU, that checkeachotherfor problems.
The CPUscheckthe circuitof the system.
"systemdown mode" or the "controlinhibitionmode".
Whenthe CPUSdetectfailure,they shiftto the
MAIN SOLENOID DTC

MODE LIGHT
ABSINDICATOR Restancondition
RELAY VALVE
SYSTEM No Drive lgnition - oN (ll) Memory
ON Operation*r switch OFF
DOWN operatron inhibition
CONTROL No Drive lVemory
ON Operation Automatic
INHIBITION operaton inhibition
*1: ExceptCPUfailure
The self-diagnosis can be classitiedinto thesefour categories:
O : I n i t i adl i a g n o s i s
O: ExceptABS control
O; DuringABS control
@ : D u r i n gw a r n i n g
On-boardDiagnosisFunction
The ABS systemcan be diagnosedwith the HondaPGMTester.
The ALB Checkercannot be used with this system.For air bleeding.and checkingwheel sensorsignals,use the Honda
PGIMTester.Seethe HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
(cont'd)
Anti-lockBrakeSystem(ABS)
(cont'd)
Features/Gonstruction
ABS Modulator
The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the
d a m p j n gc h a m b e r .
The modulatorreducesthe caliperfluid pressuredirectly.lt is a circulating-type
modulatorbecausethe brakefluid circulates
throughthe caliper,reservoirandthe mastercylinder.
The hydrauliccontrolhasthree modes:pressurereduction,pressureretainingand pressureintensifyingmodes.
The hydrauliccircuitis the independent
four channel-type, one channelfor eachwheel.
SOLENOIDVALVE
PUMP MOTOR
t-
Pressureintensifyingmode:Inletvalveopen,outletvalveclosed,
Mastercylinderfluid is pumpedout to the caliper.
Pressureretainingmode: Inletvalveclosed,outletvalveclosed.
Caliperfluid is retainedby the inletvalveand outletvalve.
Pressurereductionmode: Inletvalveclosed,outletvalveooen
Caliperfluid flows throughthe outletvalveto the reservoir.
Motor operationmode: Whenstartingthe pressurereductionmode.the pump motor is ON.
WhenstoppingABS operation,the pump motor is OFF.
The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master
cylinder.
19-30
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Wheel Sensor
The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotatepast the wheel sensor'smagnetic
The AC frequencychangesin accordance
coil,AC currentis generated. with the wheel speed.The ABS controlunit detects
the wheelsensorsignalfrequencyand therebydetectsthe wheel speed
GEARPULSER
at LOW SPEED
F
wheel Spod and Modulatot Control
VEHICLS
EPEED
VEHICLESPEED
WHEELSPEED
PRESSU
OUTLET
VALVE
ON
OFF
INLET
VALVE
ON
OFF
MOTOR
ON
OFF
When the wheel speeddrops sharplybelow the vehiclespeed,the outlet valve opens momentarilyto reducethe caliper
fluid pressure.The pump motor startsat this time. As the wheel speedis restored.the inlet valve opens momentarilyto
increasethe caliDerfluid oressure.
CircuitDiagram
UNDFS
I]OODFISAFELAY
8OX
Cbsod:&rrc ped. deprelled
-tjF
wHT/GrN GFrlrr'vril
GNITION
*oJG\'*"
\F*,-
UNDER-HOOD
A8S FUSE/FELAY
BOX UNDER,DASH
FUSFJRELAYBOX M-OD
ULATORUNIT CONNECTOR
(O number)
3P CONNECTOR 20PCONNECTOR(O number)
t_--t l-|
3 5 6 J 8 9
l l ' " 1
1 0 1 1 12 1 3 ,/ 115 ,/ 19
ll3 2ir I
UNDER.HOOOA8S FUSE/RELAY
BOX {tT6TsF}
2P CONNECTOF(! numbor) UNDER-DASH
FUSE/RELAY
18PCONNECTOR
BOX
(E number) !]q:]j_1,
PUMP MOTORCONNECTOR
1 2 3 4
'12 1 3 | i 4
5 6 (tr
number)
EFIAKESWITCHCONNECTOR 9 10 / 7 18
l-4
| 1t x l 2 |
ASSEMBLY5P CONNECTOR ATi)
s a'l
fLr--'--.----1 ----.4- Terminal
sideoJlemaleterminals
l1)/l3l/l5l
Wiresideol femalelerminals
19-32
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Gil
I.]NII {NBK)
ABSCONTROL SEFVCE
CHEC(
-[rf$-n*'"
STOP
ra [m;]t ,BFN+BsN-,|
V
,ln
-
l'? g,l
Br(
--o-
. 8 :
G2 G101cr02
t Y
WIT/BLIJ
,r-,,..J A ^ l 0 l T AL M
'r6P)
|; i trr cor'hrEcroF
8LK
4
c1013,402
tG2,
rlr*r"t_._*h
r;c,
------
r"-!cc
Lffi- -
PMR,
Pf:
_-- -.^
t!94
.,._ PCOM,
-tL
t=
# 9
,,-:g
J*
t
t-
GRN/8I(
LT
x
pliirn
GFNmL---l Ilcrom.
4iq!A :C, IRE^R
BLr(-l
-
eli -.1
,-ry 5 BtK-L
5
)ECHECK HEELSENSOR
CONNECTOR
ABscoNTRoL-- uNrr26pcoNNEcroR 9E-FY!!
coNNF
:CTOR(2P) '97 model '98-99models
(o;fib;;;
e -r FRONT/ REAR FRONTIRIG-HT-REAR
lr z :ltl,/ a ,18 e tol/ 12li3l I' , f
iTtl\ /Jr lz !\
|ffi| 4 15 16)17
V I1sV l2'VIIU)4 p91
INK Termnal sideol Terminalsideol
ABScoNTRoL-- uNrr22pcoNNEcroR QAIA.L
coNNE
croR (16P) mateterminals maleterminals
i-;;i,;;)
=l------5o T?'--"r""""- LEFT.REAR
t,*---;T-
I r , / ,
ril| mtTl ./ 6 ,/ 8\
/nf'\
1./ 1F
l,'2 -14 i7 19 - ) 1. 2 2 1
#
| |
,z
F{ c7 r .4-;1
V L:J
Wiresideof lemaleterminals Terminalsideol
lemaleterminals
ABSControlUnit TerminalArrangement
ABS CONTROLUNIT26PCONNECTOR
Wire sideof femaleterminals
Teiminal Wiie
Voltrge
Terminal3ign
numbel color Teiminalnamgl Description Condhions
tdminals (lgnition Switch ON llll) Output voltago
PCOM Power sourcefor the solenoid ON OV
1 GRNn/VHT (Primary valve and pump motor. 1-GND ON
common) 6 OFF AC:3-6V
SCOM Power sourcefor the solenoid OFF
2 BLI(WHT (Secondary 2-GND theSCSseNice] A p p r o x . 3V
lConnect
common) \ connector I
BLVBLU (lgnition Detectsignitionswitch2
2) signal.(Systemactivatesignal) 3-GND BatteryVoltage
RRO Detocts right-rear wheel
4 BLUA/EL (Rear-right 53mVor aboveon
0) sensorsrgnat. (AC
Whenthe wheelis digitaltester
GRY RLO Detectsleft-rearwheelsensor range){Beference)
(Rear-left
0) srgnat. 6-19 turnedat 1 turn/second.
150mvtrp or above
FRO Detects right-front wheel on oscilloscope
8 GRN 8-21
(Fronr-right0) sensorsignal. Stops Approx.2.5V
STOP Detects
bfakeswitchsignal. Brakepedalpressed. BatteryVoltage
{Stop) (Prevents
unnecessaryABSoperation) 9-GND BrakeDedalreleased. OV
Detectsleft-frontwheelsensor 53mVorabove
srgnal. on
When the wheel is digitaltester
lAC
10 FLO
BRN^/VHT(Front-left turned at 1 turn/ range)(Reference)
0) 10-23
second. 150mvpporabove
onoscilloscope
Stops ADprox. 2.5 V
YEL RL-oUT Drivesleft-rearoutletsolenoid ON OV

(Rearleft
outlet) 12.GND ON
OFF AC:3-6V
RR.IN Drivesright-rear
inletsolenoid OFF
13 RED^/vHT (Rear-right
inlet)
13.GND lConnect SCSservice\
the Approx.3 V
\ connector I
14 B1
WHT/GRN (Baftery Powersourcefor the solenoid
1) valveandpumpmotor. 14.GND
82 Power sourcefor the solenoid Everytime BatteryVoltage
(Battery2) valve and pump motor. 15-GND
16 BLK GND2 Groundfor the ABScontrol

(Ground2) unit. 16-GND Below0.3V
't7 RR1
GRN/YEL(Rear-right Detectsright-rearwheel 't7-4
1) sensorsignal. 53 mV or above
R L 1 Detectsleft-rearwheelsensor on digitaltester
19 LT BLU (Rearieft 19-6 When the wheel is turned (AC range)
1) signal.
at l turn/second, (Reference)150
FR1
GRN/BLK(Front-right Detects right-front wheel
21-8 mVp-p or above
1) sensorsrgnat.
on oscilloscope
23 FL1 Detectsleft-frontwheelsensor
GBN/ORN 23-10
{Front-left1} sagnal. Stops Approx.2.5V
Drives left-rearinlet solenoid = ON OV
ON -9
RED RLIN AC:3-6V
(Rear-left
inlet) 25,GND
OFF
the
/Connect SCSservice] Approx.3 V
\ conneclor I
26 BLK GND3 Groundtor the ABScontrol
(Gtound
3) untI. 26-GND Below0.3V
19-34
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ABS CONTROLUNIT 22PCONNECIOR
Wire side ol lemale terminals
Voltage
Terminal Wire Terminal 3i9n Description Conditions
numDer color Terminal name (lgnition Switch ON (ll)l Output voltage
tominals
Drivesright-frontinlet ON OV
solenoidvalve. ON I
FR-IN .9 OFF AC:3-6V
1 RED/BLU (Front-right 1-GND ot
OFF
inlet) ur servicel
theSCS
lconnect A p p r o x . 3V
\ connedor l
Detects service check signal SCSserviceconnector OV
(Diagnostictrouble code connected.
BRN (Servicecheck 4.GND
indication) SCS service connector Approx.S V
signal)
disconnected.
DrivesABS indicator{The indi- lndicatorON Approx.2 V
cator goes off when ABS con- 7.GND
7 BLU/RED (Warning trol unit outputs battery volt-
ramp) lndicatorOFF BatteryVoltage
age).
FL-OUT Drives left-front outlet = ON OV
10 YEUBLK (Frontieft solenoidvalve. 1O-GND
ON I
outlet) OFF AC:3-6V
Drivesleft-frontinlet solenoid
FL-IN 11-GND
l'l RED/BLK (Front-left
inlet) OFF
FR-OUT Drivesright-frontoutlet theSCSservicq
lconnect A p p r o x . 3V
12-GND \ connector l
YEUBLU (Front-right solenoidvalve.
outlet)
Communicateswith Honda
14 LT BLU (Datalink PGM Tester. 14-GND Approx.5 V
connectod
DetectsPumPmotor drive Pump ON Battery Vollage
MCK 1 7 - G N D motor
17 BRN/YEL(Motorcheck) signal.
relay OFF OV
Drivespump motor relay. 6 ON OV
ON I
PMR OFF AC:3-6V
19 YEURED (Pumpmotor 19.GND cl)
OFF
reray, theSCSservice]
ponnecl A p p r o x . 3V
\ connector I
Drivesright-rear
outlet Pump ON OV
solenoidvalve. ON moror
RR-OUT 'a) rcray OFF AC:3 6V
BLU (Rear-right 21.GND
OFF
outlet)
lconnecttheSCSservice] A p p r o x . 3V
\ connector l
GND2 Ground for the ABS control 22.GND Below0.3V

BLK (Ground2) unit.
TroubleshootingPrecautions
ABS lndicalor
1 lf the systemis oK, the ABS indicatorgoes off two secondsafter turning the ignitionswitch oN
1l) wathoutstaning
the engine,and then comes on again and goes off after two seconds.This occursbecausethe ABS control unit
is
turnedon by the lG2 powersource.
2. The ABS indicatorcomeson when the ABS control unit detectsa problemin the system.However,even
thouoh the
systemis operatingproperly,the ABs indicatorwill come on too, underthe followingconditions:
. Signaldisturbance
. W h e e ls p i n
. Only drivewheelsrotate
. Batteryvoltagefluctuates
To determinethe actualcauseof the problem,questionthe customeraboutthe problem,takingtheseconditions
into
consideration:
3 When a problem is detectedand the ABS indicatorcomes on, the indicatorcan stay on until the ignition
switch is
turnedOFF,or it can automatically go off, dependingon the mode.
. Indicatorstayson untilthe ignitionswitchis turnedoff: Whenthe systemis in the systemdown
mode.
. Indicatorautomatically goesoff: Whenthe systemis in the controlinhibitionmode.
4 The ABS indicatorstayson when the systemis reactivatedwithout erasingthe DTC,but it goes off after starting
the
vehicle.
When the wheel sensorsystem is faulty and the ABS indicatorcomeson. the algorithmof the systemautomatically
turns
off the ABS indicatorafterthe wheelspeedsignalreturnsto the normalspeed.Also,when the DTc is erased,the
cpu is
resetandthe ABS indicatorgoesoff whenthe systemcheckedout normalby the initialdiagnosis.
Therefore,test-drivethe vehicleafterservicingthe wheel sensorsystem.and be surethat the ABS indicator
does not
c o m eo n .
5 When the ABS controlunit outputsbatteryvoltageto the gaugeassembly,the ABS indicatorooesoff.
DiagnosticTrouble Code (DTCI

1. The diagnostictroublecode (DTc)is memorizedwhen a problemis detectedand the ABS indicator
does not go off,
or when the ABS indicatorcomeson.
The DTc is not memorizedwhen the ABS indicatorcomeson unressthe cpu is activated,
2 The memorycan hold any numberof DTCs.However,when the same DTc is detectedtwice or more,
the taterone is
writtenover the old one.
Therefore,when the same problemis detectedrepeatedly,
it is recordedas one DTC.
3. The DTCsare indicatedin the orderof ascendingnumber,not in the orderthey occur.
4. The DTCSare memorizedin the EEPROM(non-volatile memorv).
Therefore,the memorizedDTcscannotbe canceledby disconnecting the battery.performthe specifiedproceduresto
erasethe DTCS.
Self-diagnosis
1. Self-diagnosiscan be classifiedinto thesefour categories:
' Initialdiagnosis: Performedright afterthe engine startsand untirtheABS indicatorgoes
off.
. ExceptABS control:Performedwhen the ABS is not functioning.
. DuringABS control:Performedwhen the ABS is functioning.
. Duringwarning: Performedwhen the ABS indicatoris ON.
2. The systemperformsthe fo|owing controrswhen a probremis detectedby the serf-diagnosis:
. ABS indicatorON
. Memorvof DTC
. Mode changetothe "systemdown mode,,or the ,,controlinhibitionmode,,.
MODE ABS INDICATOR MAIN SOLENOID

RELAY CPU Restartcondition DTC
VALVE
SYSTEM No Drive lgnition
DOWN ON Operation*r oFF- ON l) Memory
operation inhibition switch
CONTROL No Drive
INHIBITION ON Operation Automatic lMemory
operal|on inhibition
*1: ExceptCPUfailure
19-36
www.emanualpro.com
Kickback
'1. The motor operateswhen the ABS is functioning.and the fluid in the reservoiris forcedout to the mastercylinder,
causingkickbackat the brakepedal.
2. The ABS controlunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosisYou may
hearthe solenoidvalveoperateat this time, but it is normal
PumoMotol
1. The pump motor operateswhen the ABS is functioning
2. You may hearthe motor operateat this

The ABS control unit checksthe pump motor operationduring acceleration.
time, but it is normal.
BrakeFluidReplacement/Ail Bleeding
L Brakefluid replacement and air bleedingproceduresare the sameas for vehicleswithout ABS To easebleeding,start
with the front wheels.
Troubleshooting
1. The troubleshooting flowchartproceduresassumethat the causeof the problemis still presentand the ABS indicator
is still on. Followingthe flowchartwhen the ABS indicatordoes not come on can resultin incorrectdiagnosis.
2. Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions
for troubleshooting.
Self-diagnosisis made at varioustimes such as the initialdiagnosis,exceptABS control,during ABS control,during
acceleration,during the specifiedvehiclespeed,etc. Therefore,the symptom canngt be checkedunlessthe check
conditionsmatchwith the problemconditjons
3. When the ABS jndicatordoes not come on duringthe test-drive.but troubleshootingis performedbasedon the DTC,
checklor looseconnectors,poor contactof the terminals,etc.,beforeyou starttroubleshooting.
4. erasethe DTCand test-drivethe vehicle.Be surethe ABS indicatordoes not come on.
Aftertroubleshooting,
5. The connectorillustratjonsshow the femaleterminalswith a singleoutlineand the maleterminalswith a doubleout-

l ne.
ABS Function Test

To simulateABS operationand activatethe solenoidvalvesand pump, usethe HondaPGMTester.
Connectthe PGMTesterto the 16PDataLinkConnector(DLC).Whenthe SystemSelectmenu is displayed,selectthe ABS

TestMode menu,and follow the tester'sprompts.
DiagnosticTroubleCode(DTC)
DiagnosticTroubleGodeIDTCIIndication
NOTE:This operationcan also be donewith the HondapGM Tester.
1. Connectthe SCS service connector to the service check connector (2P) located on the passenger'sside of the center
consote.
2. Turn the ignitionswitchON (ll).

NOTE; Do not pressthe brakepedalwhenturningthe ignitionswitch.
3 Recordthe blinkingfrequencyof the ABS indicator.The brinkingfrequencyindicatesthe DTc.
4. Turn the ignition switch OFF.and remove the SCSserviceconnector.

NOTE:The MalfunctionIndicatorLamp (MlL) will stay on after the engine is startsdif the SCSseryicaconnecrorrs
connected.
5. Erasethe DTC.
Conditions for DTCindication

. The vehicleis stopped.
. The SCSserviceconnector is connectedbefore the ignition switch is turned ON flt).
. The brakepedalis released.
. The SCSserviceconnectorremainsconnectedduringthis procedure.
The DTC indication stops and the ABS control unit axecutostha softwaro lunction if at least one of tho following condi-
tions i3 satisfiod:
. The vehicleis not stoooed.
. The ABS controlunit receivesthe normalsignal(whichis for the ABS controlunit)from a HondapGM Tesrer.
. The SCSserviceconnectoris disconnectod duringthis procedure.
NQTE:The illustrationof gaugeassemblyshowsthe '97 - 98 models.The '99 - oo modelsare similar.
SEFVICECHECK
CONNESTORI2P} u.s.A.
GAUGEASSEMBLY
@
CANADA
A8S II{DEATOR
19-38
www.emanualpro.com
DTCErasure
NOTE:This operationcan also be done with the HondaPGMTester.
1. Connectthe SCSserviceconnectorto the servicecheckconnector(2P)locatedon the passenger'sside of the center

console.
2. Pressthe brakeoedal.
3. Turnthe ignitionswitchON (ll)while keepingthe brakepedalpressed.The ABS indicatorgoes off aftertwo seconds.
4. Afterthe indicatorgoes off, releasethe brakepedal.The indicatorcomeson afterfour seconds.
5. After the indicatorcomeson, pressthe brakepedalagain.The indicatorgoes off againafterfour seconds (the brake
oedalis still Dressed.)
6. Afterthe indicatorgoesoff, releasethe brakepedalagain.
7. Afterfour seconds.the indicatorblinkstwice for 0.3secondand the DTCis erased.
8. Confirmthe DTCindication,and checkthat the DTCwas erased.
NOTE:Always maintainthese steps.lf you disconnectthe SCSserviceconnectorand/orfail to operatethe brakepedal

accordingto the indicatorindication,the DTCwill not be erased.
Conditions for DTCerasure

. The vehicleis stopped.
. The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON (ll)
. The brakepedalis pressedbeforethe ignitionswitchis turnedON (ll).
. The SCSserviceconnectorremainsconnectedduringthis procedure.
The DTCerasurestops and the ABS control unit executesthe software funqtion it at least one of the following conditions
b satisfied:
. The vehicleis not stopped.
. The SCSserviceconnectoris disconnected duringthis service.
. TheABScontrolunit receivesthe normalsignal(whichis for the ABS controlunit)from a HondaPGMTester.
. The brakepedalis not operatedaccordingto the indicatorindication
. The DTCerasureis finished.
0.3sec.
ON
ABSINDICATOR
OFF
within3sc. I within3 sc. within3 sec. 0.3sec.
DEPRESSED
BRAKEPEDAL
RELEASED
lonitionswitch
dN (r)
DiagnosticTroubleCode(DTC)
TroubleshootingIndex
This operationcan also be done with the HondapGM Teste..
DETECTION
TIMING
I 4,, REFER
DTC 3
< Y
R DIAGNOSIS/SYMPTOM o 8
< i
to
< J
PROBLEM
TO
ct
z < = E E2E 2 = LOCATION
PAGE
E X
zd 9 3 eB28 ET
gl (J6 3
No OFF ABS indicatordoes not come on. 19,4'l
DTC ON ABS indicatordoes not go off. (No DTC) 19-43
't1
FR
13 Wheelsensor{open/shortto body ground/shortto FL
't5 oN* power) o o o o RR
19-45
17 RL
12 FR
't4
(chippedpulsergearlelectrical
Wheelsensor/Pulser FL
oN*
notse, o o o RR
19-45
18 RL
31 FR-IN
32 FR-OUT
FL.IN
34 Solenoid(open/short
to body ground/shortto FL-OUT
ON
power/stuck) o o o RB-IN
19-47
36 RR-OUT
37 RL-IN
38 RL.OUT
ON Motor lock o o 19-49
ON Motor stuckOFF o o 19-49
53 ON Motor stuckON o 19-49
54 ON Main relaystuckOFF o o o ia_at
6l ON lgnitionvoltage(low voltage/highvoltage) o o o o '19-54
81 ON o o o o 19-55
*: lf DTcs 11-18
{wheelsensorcodes)were detectedthe last time the vehiclewas driven,the ABs indicatorwi stav on
untilthe ignitionswitchis turnedON (ll),and the controlunit confirmsthat the wheelsensorsare OK,
19-4 0
www.emanualpro.com
Troubleshooting
ABS lndicator Does Not Come On
The ABS indicator does not

come on when ignition switch is
turnodON lll).
checkthe METER{7.5A} fuse in

t h e u n d e r C a s hf u s e / r e l a yb o x ,
and reinstaltthefuse if it is OK.
Reolacethe tuse and recheck.
Checkfor an open in the lcl ch-

cuil: GAUGEASSEMBLY5P CONNECTOR
1. Disconnect the gaugeassem-
bly 5P connector.
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltagebetween
the gauge assembly5P con-
n e c t o rt e r m i n a lN o . 5 a n d
body ground.
. Repairopen in the wire between Wire sideof femaleterminals
lhe METER{7.5 A) luse and tho
gaugeassembly.
ls there battery voltage? . Reolecethe under-dashfuse/
relay box. (Oponcircuit inside
the box.)
Checkthe ABS indicatorbulb in

the gaugeassembly.
Replacethe ABS indicator bulb.
Checkfor a short to power in the

WALPcircuit:
Measurethe voltagebetweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. 1 and bodyground.
Sepair short to power in the wite

ls there batteryvoltageT btweenthe gaugassembly
and the ABS control unil.
(To page 19 42)
(cont'd)
www.emanualpro.com
19-41
Troubleshooting
ABS IndicatorDoesNot ComeOn (cont'd)
(Frompage19'41)
Checkthe gruge essembly:

1. Turnthe ignitionswitchOFF.
GAUG ASSEMBLY5P CONNECTOR
2. Connectthe gauge assembly
5Pconnector, ---g-
3. Connectthe terminalNo. 3 to l1 t/l3_l/ |5|
b o d y g r o u n dw i t h a j u m p e r JUMPER I GNDIBLK}
wrBE
4. Turnthe ignitionswitchON (ll). I
L
Wiresideof femaleterminals
Reolacethe ABS indicator drive
Doesthe ABSindicatorcomeon?
circuit in the gaug assmbly.
.Repair open in the wire

between the gauge assembly
and body ground.
. Repair poor ground {G401,
c102l-
19-42
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ABS IndicatorDoesNot Go Off (No DTGI
- With engine running, the ABS
indicsior is ON.
- With the SCS serviceconnec-
tor conncted (s page 19381,
no DTCis indicated.
Checkthe ABS {7.5A) fuse in the

undeFdashfuse/relaybox, and
reinstallthe fuse if it is OK.
ReDlacelhe tuse and recheck.
Checkthe ABS +B (20 A) fuse in

t h e u n d e r h o o dA B S f u s e / r e l a y
box, and reinstallthe fuse if it is
oK.
Replacethe fuse and rocheck.
A8S CONTROLUNIT 26PCONNECTOR

IG2IBLK/BLU)
Checkfor sn open in the lG2 cir-
cuit:
1. Turnthe ignitionswitchON {ll).
2. Measurethe voltage between
the ABS controlunit 26Pcon-
body ground.
Repairopen in tho wire between

the ABS {7.5A} fu3e .nd the ABS
control unit,
ABS CONTROLU N 26P CONf{ECTOR

Check for an open in the 81 and
82 circuit:
M e a s u r et h e v o l t a g e b e t w e e n
bodygroundandterminalsNo. 14
and No. 15individually. {WHT/GRNI
Ropairopen in tho wi.e between

is there battery voltage? rhe ABS +B {20 A) fuse and the
ABS control unit.
Wire side of female terminals
(Topage19 44) (cont'd)
www.emanualpro.com
19-43
Troubleshooting
ABS IndicatorDoesNot Go Off (No DTC)(cont'dl
(Frompage19,43)
Check tor a short to body ground ABS CONTROLUNIT 22PCONNECTOR

in the WALPcircuil:
WALP{BLU/REDI
2. Disconnectthe ABS control
unit 22Pand gaugeassembly
5P connectors.
3. Checklor continuity between
body ground. Wire side of female terminals
Repair short to body ground in

the wire between the ABS con-
t.ol unh and the gaugeassembly.
Checkthe ABS control unit:

1. Connectthe ABS control unit
22Pconnector.
body ground. Check tor an open in the GND2 ABS CONTROLUNIT 26PCONNECTOR
circuit:
1. Connectthe ABS controlunit
26Pconnecto.terminalNo. 16
ls there batteryvoltage? to body groundwith a jumper
JUMPCR GND2IBLKI
2. Measurethe voltage between WIRE
n e c t o rt e r m i n a lN o . 7 a n d Wiresadeof femaleterminals
body ground.
. Repeir op6n in th6 wire ttetween

the ABS control unit and body
ground.
. Rep.ir poor ground {G401,
G4021.
Check lor loose ABS control unh

connectors. lf necesssry,substi-
tuie e lnown-good ABS control
unit and recheck.
Check tor an open in the WALP
circuit: GAUGEASSEMBLY5P CONNECTOF
Measurethe voltagebetweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. 1 and body ground.
WALPIBLU/FEDI
Repairop6n in the wi.e botwen

ls there batteryvoltage? the ABS control unit and th
gau9e assmbly.
Replacothe ABS indicator drive

circuit in the gauge assembly.
19-44
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DTC11- 18:WheelSensor
NOTE:The ABS indicatorcomeson only when the drive wheelsare turning and signaldisturbanceis detected,Therefore,test-
drive the car at a speedof 12 mph (20 km/h)or more afterturning the ignition switchfrom OFFto ON l), and if the ABS indica-
tor does not come on, the svstemis OK.
- With ths ignition switch ON

llll, the ABS indicatol does
not go ott.
- Atte. driving, the ABS indica-
lot comason.
tor connocted (s page 19.381,
DTGr 11 - 18 sre indbated. ABS CONTNOLUNIT 26PCONNECTOR
Checkthe whcol sensorcircuit: Appropriate

Terminal RRO FLO
DTC
1. Disconnectthe ABS control {0}srDE ( 1 ) S | D E IBLU/YEL} (BRN/WHTI
unit 26Pconnector. 1 1 ,l 2 l R i g h t - f r o n t ) No.8: Fno N o . 2 1 F: R1
2, Nleasure the resistance 13, 14 (Left-front) No.10rFLo No. 23: FLl
betweenthe appropriatewheel 15, 16 (Rightread No.4: RRo N o . 1 7 :R R 1
sensorl0) and 1'l)circuittermi-
nals{seetable). 17,l8 (Lsft-rear) No.6: RLo N o . 1 9R: L 1
RRTIGRN/YELI FLl IGFN/ORN}
. Ropairopn in th. {01o. lll cir- RLl (LT BLUI FRl IGRN/BLKI
cuit wire, oa short to the (01cir-
ls the resistanceOK? cuit wire in the lll circuit wiro
- betweon the ABS control unit
/Fronr:750 r,050o (20"C,68"F\ and th. appropriatewhasl sen-
\Rear: 950 -'1,450O (20"C,68'F,
sot.
. Roplacethe rpp.opriatc whe6l
Sensor.
Chocklor a short 10 power in the

wheel sensoaciacuil:
1. Reconnectthe ABScontrolunit
26Pconnector.
2. Startthe engine.
3. Measurethe voltage betlveen
nector appropriatewheel sen- NOTE:Judgementvalue for short
s o r ( 0 ) c i r c u i t t e r m i n a la n d
body ground(seetable).
Ropair lhort to pow.r in the l0l
ls there4 V or more? ot 11)circuit wiro between the
ABS control unit and the appro-
priate whool sen6or.
NO
NOTE:
. Normalvoltage: Approx.2 V
.0 V: Replace the ABScontrolunit.
. 4 V or more indicatesa shon to power.
Checkfor a short to body ground

in the whoal s.n3or cilcuit:
unit 26Pconnector.
2. Checklor cont;nuitybetween
nector appropriatewheel sen-
s o r { 0 ) c i r c u i t t e r m i n a la n d
body ground{se6table). . Ropairshort to body g.ound in
th6 {01 or {1} circuit wire
botweon th6 ABS cont.ol unit
and tho appropriatowheol son-
aot.
NO . Roplacetho appropriate wheel
(cont'dl
sensot.
(To page 19-46)
www.emanualpro.com
19-45
Troubleshooting
DTC11- 18:WheelSensor(cont'd)
C h e c kf o r c h i p p e d p u l s e r g e a r .
Rcplacs thc drive3haft or hub

unh. (Chippedpulsor goar.l
DTC 11, 13, 15. 17: Replacothe

ABS control unit.
OfC 12, 11, 16, 18: Th6 ABS con-
trol unit may have dstected dg-
n.l disturbsnc.
19-46
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DTC31 - 38:Solenoid
- With the ignition switch ON ABS CONTROLUNIT 22PCONNECTOR

{lD, tho ABS indicator does
not go off, or the ABS indic.- FL.OUTIYEL/8LKI
lor comes on whil6 ABS is
tunctioning.
- With th SCS service connoc-
DTC
Appropraate
tor connoctcd {sce page 1$381, Connector Terminal
DTCa31 - 38 ars indicatsd. 31:FR'lN 22P No. 1
32:FROUT 22P No. 12
3 3 :F L l N 22P N o .1 1
Checkfor a 3hori to power in th 34:FLOUT 22P No.10
solenoidci.cuit: 35:RR-lN 26P No.13
1 . D i s c o n n e ctth e A B S c o n t r o l
36:RR-OUT 22P No.21
untrtlr ano zbr connectors_
2. Startthe engine. 37: RLIN 26P No.25 Wiresideof femaleterminals
3. Measurethe voltage between 38:RL-OUT 26P No. 12
the appropriateABS control ABS CONTROLUNIT 26PCONNECTOR
unit connectorsolenoidcircuit
terminal and body ground (see
RL.OUT{YELI
table).
R p a i rs h o r t t o p o w e r i n t h e
ls there baReryvoltage? approp.iato solenoid circuit wire
betwen the ABS control unit
and the modulator unh.
Chockfor a short to body ground

in the solnoid circuit:
Checkfor continuity betweenthe
appropriatesolenoidcircuit termi- Wire sadeof femaleterminals
nalandbodyground(seetable).
. Ropair short to body ground in FL.OUTIYEL/BLKI

the appropriatosolenoid circuit
ls therecontinuity? wire betwoon the ABS control
unit and the modulator unit.
. Replacethe modulator unit.
Appropriate
DTC
Terminal
Checkthe ABS control unit:
1. Turnthe ignitionswitchOFF. 3 1 :F R l N No. 2i SCOM
2. Connectthe ABS controlunit 32:FR-OUT No. 2: SCOM
22Pand 26Pconnectors. 33: FLIN No.1:PCOM RL.OUT{YELI
3. Connectthe SCSservicecon- 34:FL-OUT No. 1:PCOM
nector.
35:RRIN No. 1: PCON4
5, Measurethe voltage between 36: RR-OUT No. 1: PCON4
the appropriateABS control 37rRL-lN No. 2: SCOM
unit 26PconnectorCOMcircuit 3a:RL-OUT No. 2: SCOM
terminaland body ground (see
table).
Checktor loose ABS control unit

ls thereapprox.3 V7 connectors. ll nece$ary, substi-
tut a known-good ABS control
unit and recheck.
PCOM
(To page l9-48) {GRN/WHTI
www.emanualpro.com
19-47
Troubleshooting
DTC31 - 38: Solenoid(cont'dl
A8S CONTROLUNIT 22PCONNECTOR
FL.OUTIYEL/BLK}
DTC Connector
3 1 :F R I N 22P No. 1
32:FR-OUT 22P No.12
33: FL-IN 22P No.11
34:FL OUT 22P No.10
35:RRIN 26P No.13
Checkfor an open in the solenoid 36:RR-OUT 22P No.21
circuit: 37:RLIN 26P N o .2 5
Measurethe voltage betweenthe 38:RL-OUT No. 12
appropriateABS controlunit con
nector solenoidcircuit terminal
and bodyground{seetable). Wire sideof femaleterminals
. Repair open in the appropriate
COM circuit wire botween the
ABS control unit and th modu-
lator unit. ABS CONTROLUNIT 26PCONNECTOR
ls thereapprox.3 V? . Repair open in the appropriate
solenoid circuit wire betwon
RI-.OUT{YEL)
lhe ABS control unit and the
modulator unit.
. Replaceih modulator unit.
Checkfor loos ABS control unil

connctors. lf nece$ary, substi-
tute a known-good ABS control
unit and rechock.
Wire sideof femaletermanals
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19-4 8
DTC51 - 53:ABS PumpMotor
- Wilh the ignition switch ON

{ll), the ABS indicator does
not go ott.
- With the SCS seruicoconnec-
tor connoctod {sce page 19381,
DTCa51 - 53 .re indicated.
c h e c k t h e M T R c H E c K ( 7 . 5A i
luse in the under-hoodABS
tuse/relaybox, and reinstallthe
luse if it is OK.
ABS CONTROLUNIT 22PCONNECTOR

Rsplacethe fuse and rech6ck.
N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y
groundfor a moment,and rochockthe tuse.
lf the fuse is blown,checklor a shon to body
groundin the MCKcircuit.
check the PUMP MOTOR(40 A)

fuse in the under-hoodABS fuse/
relay box, and reinstallthe fuse if
it is oK. Wire side of female terminals
Roolacelhe tusg and rocheck.
N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y
groundfor a moment,and recheckthe fuse,
lf the tuse is blown, checktor a short to body
ground in the wire betweenthe underhood
ABSfuse/relay box 6nd the pump motor.
Feplacethe pump motor r6ley.
Check the pump motor powel

sourccircuit:
Turn the ignitionswitchON (ll).
Ch6ckfo. a short to oowd in th6

Doesthe pump motoroperate? pump motor power sourca circuit:
Removethe pump motor relay.
Repairrhort to power in the wire

bclweon the under-hood ABS
Doesthe pump motor operateT
fuse/.6lay box and ihe ABS
pump motor.
Ch6cktor loos6 ABS control unit

connectors. lf necotsary, 3ubsti-
tute . known-good ABS control
unit and rocheck.
(cont'di
(To page19 50)

www.emanualpro.com
19-49
Troubleshooting
DTC51 - 53:ABS PumpMotor (cont'dl
UNDR-HOOO ABS
(Frompage19 49) FUSE/REI-AY
BOX
JUMPERWIRE
Chockthe pump motor ci.cuit:

1. Removethe pump motor relay.
2. Turn the ignitionswitchON {ll).
3. Connectthe pump motor relay
connector+B and MOTORter- Check for an open in the pump
minalswith a jumporwire for motor +B circuit:
a moment, 1. Turnthe ignitionswitchOFF.
2. Disconnectthe pump motor
TERMINAL TERMINAL
Doesthe pump motor operate? 4. Connectthe pump motorrelay PUMPMOTORCONNECTOB
connector+B and MOTORter Fr MOTOR+B {WHTI
minalswith a iumperwire. 12 lF-
5. Measurethe voltage beaveen (v)
the pump motor connector v
terminal No. l and body I
ground. Terminalsideof femaleterminals
Bepair opon in the wire botween

ls there battery voltage? the under-hoodABS fuse/relav
bor and the pump motor.
MOTOR+B IREDI MOTORGNDIBLKI

Check the pump motor opera- Terminal
tion: sideof
Connectthe battery(+)terminalto male
the pump motor connectortermi- terminals
nal No. 1, and the (-) terminalto
the terminalNo. 2 for a moment.
Reolacethe modulator unit.

Doesthe pump motoroperate?
lFaulty pump moto.l
Ch6ckfor a short to body ground Repairopen in the wire bstween

in the PMRcircuit: the pump motor and body ground, ABS CONTROLUNIT 22PCONNECTOR
1. Turnthe ignitionswitchOFF. or poo. ground {G3511.
unit 22Pconnector.
3. Checktor continuity between
t e r m i n a lN o . 1 9 a n d b o d y
ground.
Repairshort to body ground in

the wir6 botweenthe under-
hood ABS tuse/rclay box and th Wire sideof femaleterminals
ABS contlol unit.
{Topage19-51)
www.emanualpro.com
(Frompage19-50)
Chcck for .n opsn in the PCOM

circuit:
1. Turnthe ignitionswitchOFF. ) l--l
tr
2 . R e c o n n e ct h e A B S c o n t r o l
unit 22Pconnector.
3. Connectthe SCS servicecon-
r"r
nector.
t h e p u m p m o t o r r e l a yc o n -
n e c t o r P C O Mt e r m i n a l a n d
body ground.
Repairopon in the wire betwoen

ls thereapprox.3V? the under-hoodABS fuse/relay
box and tho ABS conlrol unh.
ABS CONTROLUNIT 22PCO NECTOR
Checkfor an open in tho PMRcir-

cuh:
Measurethe voltage betweenthe
ABS control unit 22P connector
terminalNo. 19and bodyground.
Ropairopen in tho wir6 botwagn

ls thereapprox.3 V? tho undcr-hood ABS fuse/rolay
box .nd the ABS control unit. Wire sideof femaleterminals
Ch.ck tor an opon in the MCK

ci.cuit:
2. Disconnectthe SCS service
connector.
the ABS controlunit 22Pcon
n e c t o rt e r m i n a l N o . 1 7 a n d
body ground while connect- 1 t0 1 1
ing the pump motor relay
connector+B and MOTORter-
minal with a jumper wire tor MCK IBRN,/YEL}
moment,
Repairopen in the wiro bdtween

ls there batteryvoltage? the under-hood ABS fus6/telay
box .nd the ABS control unit.
Chockfor loose ABS control unit

connectoas,It necsssary,substi-
tule a known-good ABS control
unit and aocheck.
www.emanualpro.com
Troubleshooting
DTG54:MainRelay
- With the ignition switch ON
(lll, the ABS indicator does
not go off.
tor connected {see page 19-381,
DTC54 is indicatod.
Checkthe ABS +B 120A) fuse in

the under-hoodABS luse/relay
box, and reinstallthe fuse if it is
oK.
FeDlacethe tu3e and recheck.
AAS CONTROLUNIT 26PCONNECTON
Chck tor an open in the 81, 82

circuit:
M e a s u r et h e v o l t a g e b e t w e e n IWHT/GRNI
body groundand the ABS control
unit26Pconnector terminalNo. 14
and No. 15individually.
Repairopen in the wiro bstweon Wire sideof femaleterminals

ls there batteryvoltage? th6 ABS conirol unit and the
under-hoodABS fuse/rolay box,

in the PMRcircuit:
L Turnthe ignitionswitchOFF. ABS COf{TROLUN]T 22PCONNECTOR
2. Removethe pump motor relay.
3 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pconnector.
4. Checklor continuitybetween
t e r m i n a lN o . 1 9 a n d b o d y
grouno.
Repair short to body ground in

the wire betweon the under-
hood ABS lGe/r.lay box and the
ABS control unit.

in the PCOM,SCOMcilcuit: PCOM scoM
1 . D i s c o n n e ctth e A B S c o n t r o l IGRN/WHTI {BLK/WHTI
unit 26Pconnector.
2. Checktor continuitybetween
body ground and the ABS con- . Rpair short to body ground in
t r o l u n i t 2 6 Pt e r m i n a l sN o - 1 th P1COM circuit wire between
and No.2 individually. the ABS control unit and the
und6r-hoodABS tuse/r6lay
oox.
ls therecontinuity? . R6p.ir short to body ground in
the PCOMor SCOMcircuit wire
betweon th6 ABS control unit
and lhe mod!lator unit.
. R . D l e c et h o m o d u l r t o r u n i t .
(Short circuit inside the unitl
(To page19-53)
www.emanualpro.com
ABS CONTROLUNIT 26PCONNECTOR
PCOM
(GRN/WHTI SCOM
Checkfo. a short to power in tha
PCOM,SCOMcircuhi
1. Startthe engine.
body ground and ABS control 'Repair short to powor in ths
unit 26P connectorterminals
No. I and No.2 individually. FCOM circuit wiro botwoon th
ABS control unit and the under-
hood ABS tuse/r.lay box.
. Repeir 3hort to power in tho Wiresideof temaleterminals
ls there8 V or more?
PCOM or SCOM circuit wire
betwegn tho ABS control unii
and ths modulator unh,
. R.placo tha modulatoi unit.
Tu.n tho ignhion switch OFFand
(Shon to power in.ido th6 unitl
connect thc SCS 3orviceconnec-
tor. Then turn thc ignition switch NOTE:8 V or more indicatesa shortto
ON (lll and measuretha voltago
botween the PCOM .nd SCOM
tsrminal3 and body gJound. It
ther6 is 0 V, .eplecotho ABS con-
trol unit.
www.emanualpro.com
Troubleshooting
DTC61:lgnitionVoltage
- Whh the .ngine running. the
ABS indicator b ON,
- With the SCS servicc connae
tor connoctod {sao prgo 1998},
DTC61 b indi)atod.
Problom vorification:
1. Erasethe DTC.
2. Start the engine.
Doesthe ABS indicatorcome on

Tho ryrtom i. OK rt thb timo.
and is DTC61 indicated?
Ch.ck the lG2 circuit:

Measurethe voltage betweonthe
ABS control unit 26P connector
terminalNo.3 and body ground.
Wiresideof temaletermioals
ls there18V or above?
lf the volt gc b 0 V, ch6d( to. an

oDn in lhe lG2 circuh.
I thole ir 12 - 17 V, subatilui. !
known-good ABS control unit .nd
rd|eck.
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DTC81:CentralProcessingUnit (CPUI
- with the ignition 3witch ON

{ll}. the ABS indicator does
not go off.
- Whh the SCS sewice connec-
tor connectod {see page 1938),
DTC81 b indicatod.
Problemvorific.tion:
L Eraserne u t L.
2. Test-drive
the vehicle.
Doesthe ABS indicatorcome on

and is DTC81 indicated? Rplaceth. ABS control unit.
The system is OK at this time.
www.emanualpro.com
19-55
ModulatorUnit
NOTE:
. Do not spill brakefluid on the vehicle;it may damagethe painu if brakefluid does contactthe paint,wash it off imme-
diatelywith water.
a Takecarenot to damageor deformthe brakelinesduring removaland installation.
. To preventthe brakefluidfromflowing,plug and coverthe hoseends and jointswith a shop towel or equivalentmate-
rial,
Romoval
1. the modulatorunit and Dumpmotor connectors.

Disconnect
2. the brakelines,then removethe modulatorunit.

Disconnect
lnstallation
1. Installthe modulatoru nit.then connectthe brakelines.Tightenthe flare nutsto 15 N.m (1.5kgf.m,11 lbf.ft).
2. Connectthe modulatorunit and oumo motor connectors.
3. Bleedthe brakesystem,staningwith the front wheels.
4. Startthe engine,and checkthat the ABS indicatorgoesoff.
5. Test-drivethe vehicle,and checkthat the ABS indicatordoes not come on,

'97 - 98 models.The'99 - 00 modelsare similar.
NOTE:This illustrationshowsthe
PUMPMOTOR
CONNECTOR
\ * \ MODULATONUNIT
I
,@
TORXEOLT
9.8N,m(1.0kgf.m.7.2lbf
ftl
www.emanualpro.com
19-56
Pulsers/Wheel
ABS ControlUnit Sensors
Replacement Inspection
L Removethe passenger's
side kickpanel. 1 . Checkthe front and rear pulserfor chippedor dam-
agedteeth.
Disconnect
the ABS controlunit connectors.
Measurethe air gap betweenthe wheel sensorand
pulserall the way aroundwhile rotatingthe pulser.
ABS CONTROLUNIT lf the gap exceeds1.0mm (0.04in),checkfor a bent
susDension arm.
Standard:o.il - 1.0 mm 10.02- 0.04 inl
Front/Rear
Removethe rear brakedrum to insDectthe rear wheol
sensorair gap,
0.4- 1.0mm
(0.02- 0.04 inl
CONNECTORS
Removethe ABS controlunit.
Installthe ABS control unit in the reverseorder of

removat.
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19-57
Sensors
Pulsers/Wheel
WheelSensorReplacement
NOTE;
. Be carefulwheninstallingthe sensorsto avoidtwistingthe wires.
. The torquevalueof the boltsis 9.8 N.m ( 1.0kgf.m,7 Ibf.ft).
Front
\all
6 mm BOLT
9.8 N.m {1.0kgtm. ?.2lbf'ft)
WHEELSENSOR
Rgar
1. Removethe hub bearingunit (seesection18).
2. Removethe tour backingplatebolts.
3, Pullthe backingplateaway from the trailingarm, then removethe wheel sensor.lt is not necessary
to disconnectthe
brakeline.
'97 - 98 models,The '99 - 00 modelsare similar.
NOTE:This illustrationshowsthe
6 mm BOLT
9,8 N.m 11.0kgf.m, 7.2lbf.ft)
WHEELSENSOR
www.emanualpro.com
19-58
Body
Bumpers RearWheelwellProtectol
Front Bumper Removaland Replacement .....20-90
fnstaflation .........20-72 FuelPipeProtectorReplacement...20-90
RearBumper Removaland RearAir Outlet Replacement..........20-91
fnstaflation .........20-74 *FrameRepairChart ..............................
20-106
'Dashboard
Front Grille
lnstrument PanelRemovaland Repfacement .........20-77
lnstallation .........20-47
Glass
Driver'sDashboardLower Coverand
ComponentLocationIndex ............ 20-29
KneeBolsterRemovaland
Installation .........20-48 Hood
Glove Box Removaland Replacement ......,,,20-75
lnstallation .........20-49 Adjustment ............20-76
CenterPocketRemovaland *lnterior Trim
lnstallation .........20-49 ComponentLocationIndex ............ 20-40
Center Dashboard Lower Cover Mirrors
Removaland lnstallation ............ 20-50
ComponentLocationIndex .........,,, 20-26
CenterPanelRemovaland
Moldings
Roof Molding Replacement............ 20-84
Power Window Switch Removaland
lnstallation .........20-51 Door MoldingsReplacement.......... 20-85
CenterAir Vent Removaland Openers
lnstallation .........20-51 ComponentLocationIndex ............ 20-92
Side Air Vent Removaland RearHatchGlass
fnstallation .........20-52 Replacement .........20-74
Side DefoggerTrim Removaland Disassemblyand Reassembly........20-79
fnstallation .........20-52 ............20-81
Adiustment
DashboardRemovaland RearWeatherstripReplacement....20-83
Seats
DashboardFrameReplacement.....20-55
ComponentLocationIndex ............ 20-56
Doors
Side Sill Panel
Component Location Index
Repfacement .........20-87
FrontDoor ,,...,,,,20-2
SpareTire Cover
RearDoor ...........20-4
20-88
EmblemInstallation........................
TailgateDoor ................................
20-6
Sub-frame ..................20-104
Fenderwell
Wiper/Washer
Front Wheelwell Protector
Replacement .....20-89 ComponentLocationlndex ,,,,,....... 20-97
Inner FenderReplacement.,.....,.,....
20-89
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Doors
ComponentLocationIndex
Front Door:
NOTE:Refertothe 1997SeriesHondaCR-VBody RepairManual(P/N61S1030)

forfrontdoor removat.
OOORCHANNELTAPE
INNER
WATHERSTRIP
OUTERMOLDING
MIRRORMOUNT
PLASTIC
COVER
COVER
----s
-re
,\//. r =::rR
ffi
*Y fl HINGE
l
POWERDOORLOCK
"\-,-.*
FRONTDOOR
PositionAdjustment,
page 20-22
CONTROLUNIT
t\q
efl-Nr2
/ *-8
ARMREST
FRONTDOORPANEL
Removaland lnstallation,
page20,7
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20-2
GLASSRUN
CHANNEL
REAR LOWER
CHANNEL
\ f \i \ \ \ \
t\\\
\\II
za\\l
@'-ua$
REGULATOR
page20-10
Replacement,
POWERWINDOW
MOTOR
CYLINDEB
PROTECTOR
k'"""'
OUTERHANOLE
page20-8
Replacement,
INNERHANOLE
@,
,;@
LATCH I
PROTECTOR
POWEN
wtNDow
POWEF swtTcH
ACTUATOB
(cont'd)
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20-3
Doors
GomponentLocationIndex(cont'dl
Rear Door:
NOTE: Refertothe 1997 Series Honda CR-V Bodv RepairManual (P/N 6151030)for rear door removal.
DOORCHANNELTAPE
INNERWEATHERSTRIP OUTERMOLOING
DOORPROTECTION
D \FR,
tu4
\a)Ei
PositionAdiustment,
ARMREST page 20-22 HINGE
ARMREST
@ BRACKET REARDOORPANEL
1'99- 00 models)
Removaland Installation,
page20 '11
dP
@ @
REARDOOR
('97-98 models)
Bemovaland Installation, o
page20-11
(Left side only,

'97 - 98 models)
('99- 00 models)
20-4
www.emanualpro.com
OUARTER
SEAL
OUARTER
GLASS
Replacement,
page20-13
GLASSRUN
CHANNEL
REARCHANNEL-\ -.-----_----_-""
UPPERCOLLAR
trw
-flHiili^'i--_Fffi ,6S
FRONTLOWER
CHANNEL
POWERWINDOW
MOTOR
REGULATOR
page20'13
Replacement,
STRIKER
Adjustment,page20 2L
l
INNRHANDLE
/ eoweawrruoow
sYtfcH
I s /*
I
/
W* M-q/
-\<SU
LATCH s g
fl
Replacement,
page20'13
LOCKROD
PROTECTOR CItr'
6,1-
iI
LATCH
PROTECTOB \
POWEBDOOR LOCK
LOCKACTUATOB CRANK
(cont'd)
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20-5
Doors
Component Location Index (cont'dl
Tailgate Door:
NOTE: Referto the 1997SeriesHondaCR-VBody RepairManual{P/N61S1030)

for tailgatedoor removal.
LICENSEPLATE
TRIM
TAILGATEDOOR page20-16
Replacement,
TAILGATEOOOR WEATHERSTRIP
PositionAdjustment,page20-23
HINGE HINGE
COVER
\ \
V I
illt
REARHATCHGLASSLATCH
page20 18
Replacement,
SUPPORTSTRUT
lVr
N
REARHATCHGLASS
ACTUATOR d+-BA^cKEr
page20-19
Replacement, d
LATCHSTOP
page20-17
Replacement,
REARHATCHGLASS
\A
Replacement,
page20'19 TAILGATEDOORLATCH
page20-17
Replacement,
TAILGATEDOOR
TAILGATEDOOR STRIKER
HANDLE Adjustment,page20-25
page20-16
Replacement,
k @ /
-6
%
\
TAILGATEDOORWEDGE
Adiustment,page 20-25
d\
FLEXIBLECARGO
HOOK
TAILGATEDOORPANEL
page20-15
www.emanualpro.com
20-6
Front Door PanelRemovaland Installation
NOTE:Takecarenot to scratchthe door paneland other >: Screw location3,3 >:Clip locttions
pans. A>, 1 g>,3
I
L Removethe innerhandle(seepage20-3).
eF**I f- fwi l.$ ; ^ r * l
2. Removethe speakercover,then removethe screws.
3
>: Scrwlocations,
ttv il
I
F:I
FRONTOOORPANEL
SPEAKER
COVER
Removethe screwsfrom the armrest.Releasethe

clipsthat hold the door panel,then removethe door
panel by pulling it upward.Disconnectthe speaker
connector.
NOTE:Removethe door panel with as little bend-

ing as possibleto avoidcreasingor breakingit.
TRIM PAD lnstallationis the reverseof the removalprocedure.

REMOVER
(Commercially
avaalable)
'..4' NOTE:Makesurethe connectoris pluggedin prop-
Snap-on efly.
*4177,ol ,mm+,----ZY"
equivalent {0.04in.) r
F -i
45 mm I
{1.77in.}
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20-7
Doors
FrontDoorOuterHandleReplacement
CAUTION: Put on gloves to protect your hands. 4. Pull out the outer handle,Pry the outer handlerod
out of its joint usingdiagonalcutters.
NOTE;Raisethe glassfully.
NOTE:
1 . Removel . To easereassembly, note location@ ofthe outer
. Door panel(seepage20-7) handlerod on the joint beforedisconnectingit.
. Plasticcover{seepage2O-2) . Takecare not to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
2. Disconnectthe cylinder rod. Removethe retainer door.
clip,then removethe lockcylinder.
LOCK
CYLINDER RETAINEB
CLIP
5. Removethe bolts securingthe o u t e r h a n d l e , t h e n

remove the cylinder protector.
>: Eolt locations,2
6 x ' 1 . 0m m
I N.m {0.9kgt.m,
7 rbf.ftl
OUTEB
HANDLE
5. Installationis the reverseof the removalprocedure.
NOTE:
. Makesureeachrod is connectedsecurely.
. Makesurethe door locksand opensproperly.
HANDLE
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20-8
FrontDoor LatchReplacement
CAUTION: Put on gloves to protect your hands, 3. Disconnectthe connector,and detachthe harness
clip from the door. Removethe screws,and remove
NOTErRaisethe glassfully. t h e l a t c ht h r o u g ht h e h o l ei n t h e d o o r .
'1. Remove: NOTE:Takecarenot to bendany of the rods.

. Door panel(seepage20-7)
. Plasticcover (see page 20-21 >: Screw locations,3
. O u t e rh a n d l e 6x1.0mm
6 N.m 10.6kgt m,
2. Removethe bolt,then move the rear lower channel 4 tbf.ft)
forward.
CYLINDER
>: Bolt location, 1 ROD
6xl.0mm OUTER
8 N.m (0.8kgf m, HANDLE
6 tbf ft) ROD
LOCKROD
PROTECTOR
CONNECTOR
HARNESS
CLIP
Installationis the reverseof the removalprocedure.
NOTE:
. Make sure the connectoris pluggedin properly,
and eachrod is connectedsecurely.
a Makesurethe door locksand opensproperly.
www.emanualpro.com
20-9
Doors
FrontDoorGlassand RegulatorReplacement
CAUTION: Put on gloves to protect your hands, 3. Disconnectthe connector,and detachthe harness
clip,then removethe regulatorthrough the hole in
1. Remove; the door.
. Door panel(seepage20-7)
. Plasticcover (see page 20-21 NOTE:
. Scribea line aroundthe rear roller guide bolt to
2. Carefullymove the glassuntil you can seethe bolts, show the originaladjustment.
then loosenthem. Slidethe guide to the front, then . When installingthe regulator,align the hole of
removethe glassfrom the guide.Carefullypull the the rollerguidetowardth rear.
glassout throughthe window slot.
NOTE:Takecare not to drop the glassinsidethe door. >: Bolt locations,6
6x1.0mm
8 N.m {0.8kgt.m,
>: Bolt locations,2 6 rbtft)
6xl.0mm
9.8Nm(1.0kgt.m. Roaru/ard
7.2 tbt.ftl
GLASS
Loosen,
REGULATOR
www.emanualpro.com
20-10
RearDoor PanelRemovaland
lnstallation
4. Greaseall the slidingsurfacesof the regulatorwhere
shown. NOTE:Takecarenot to scratchthe door paneland other
parts.
NOTE:lf it is necessaryto removethe power wrn-
dow motor from the regulator,scribea line across 1. Removethe innerhandle(seepage20-5).
the sectorgear and regulatorbeforeyou removethe
'99 - 00
power window motor. 2. Removethe screwsfrom the armrest.On
models,removethe screwfrom the beveragepor-
tion. Releasethe clipsthat hold the door panel,then
RGULATOF removethe door panelby pullingit upward.
NOTE:Removethe door panel with as little bend-

ing as possibleto avoidcreasingor breakingit.
TBIM PAD
REMOVER
(Commercially
available)
Snap-on
#4177,or lmm t_
equivalent {0.04in.) T r-----
/t5 mm I
>: Boh locations,3
11.77in.)
6x1.0mm
7 N.m lo.t kgf.m, >: Screw locelions >i Clip locations,6
5 tbf.ftl '97 - 98 models.3
'99 - 00 modols,4
POWERWINOOWMOTOR
REGULATOR
DOOBPANEL
ARMREST
o
i
4 EEVERAGE
HOLDEN
('99 00modelsi
^mi A
A '99 - 00 models:
NOTEi Rollthe glassup and down to see if it moves

freelywithout binding.Also make sure that there is \
no clearancebetlveenthe glassand glassrun chan (,1
nel when the glassis closed.Adjust the positionof

the glassas necessary(seepage20-20). 3. Installationis the reverseof the removalprocedure.
www.emanualpro.com
20-11
Doors
RearDoorOuter HandleReplacement
CAUTION: Put on gloves to protect your hands. 4, Pull out the outer handle.Pry the outer handlerod
out of its joint usingdiagonalcutters.
NOTE:Raisethe glassfully.
NOTE;
1. Remove: o To easereassembly, note location@ of the outer
. Door panel(seepage20-11) handlerod on the joint beforedisconnecting it.
. Plasticcover(seepage20-4) . Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
2. Remove the lock crank. then remove the screws door.
securing the latch.
>: Screw locations OUTERHANDLE

A>.3 B>,'l ROD
6x1.0mm
6 N.m 10.6kgf.m. ^
PCtlTn-i I
l
4 tbf.ft)
LOCKROD
PROTECTOR
Move the latch down, and remove the bolts secur- SHOPTOWEL
ing the outer handle,
>: Bolt locations.

2
6x1.0mm 5. Installationis the reverseofthe removalprocedure.
9.8 N.m {1.0 kgf.m,
7.2 rbf.ft)
NOTE:
a Makesurethe door locksand opensproperly.
. M a k e s u r e t h e o u t e . h a n d l er o d i s c o n n e c t e d
properly.
20-12
www.emanualpro.com
.
Rear Door Latch Replacement RearDoorGlass,OuarterGlassand
RegulatorReplacement
CAUTION: Put on gloves to protect your hands,
CAUTION: Put on gloves to protect your hands.
NOTE:Raisethe glassfully.
1. Remove:
1. Removel o Door panel(seepage20-11)
. Door panel(seepage20-11) . Plasticcover(seepage20-4)
. Plasticcover(seepage20-4)
. Outerhandle(seepage20-121 2. Carefullymove the glassuntil you can seethe bolts,
then loosenthem. Slide the guide to the rear,then
2. D i s c o n n e ctth e c o n n e c t o ra n d h a r n e s sc l i p , t h e n removethe glassfrom the guide.
removethe latchthroughthe hole in the door.
NOTE:Takecarenotto dropthe glassinsidethe door.
NOTE: Takecare not to bend any of the rods.
>: Boll locations,2
6x1.0mm
9.8N.m (1.0kgtm,
7.2 tb{ft)
GLASS
3. Installation is the reverse of the removal procedure.
NOTE:
. Makesuretheouterhandlerod andinnerhandle
properly.
rodareconnected
. Makesurethedoorlocksandopensproperly.
(cont'd)
www.emanualpro.com
20-13
Doors
RearDoorGlass,OuarterGlassand RegulatorReplacement(cont'd)
3. C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d 4. Removethe quarterglass.
s c r e w f r o m t h e r e a r c h a n n e l ,t h e n p u l l t h e r e a r
channelup as shown. Removethe glass from the
r e a rc h a n n e lC . a r e f u l l yp u l l t h e g l a s so u t t h r o u g h
the window slot.
NOTE:Takecare not to drop the glassinsidethe door.
>: Bolt,screwlocations
A>, t B>,1
-4 f\ -6 x 1.0 mm
rTmtl-larR '^S\\\-.-
WPU W)+ I N m i o . 8 k sm
f,
6 tbf.ftt
c>,1
CLIP Disconnectthe connector.and detachthe harness

clip, then removethe regulatorthrough the hole in
the door.
>: Bolt localions,4
6x1.0mm
8 N.m 10,8kgf.m,
6 tbtftl
REGULATOR
www.emanualpro.com
20-14
''
TailgateDoor PanelRemovaland
lnstallation
6. Greaseall the slidingsurfacesof the regulatorwhere
shown. N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d
other parts.
NOTE:lf it is necessaryto removethe power win-
dow motor from the regulator,scribea line across 1. R e m o v et h e c o v e r ,and remove the flexible cargo
the sectorgear and regulatorbeforeyou removethe hook and base.
powerwindow motor.
>: Screwlocations.2
REGULATOR FLEXIBLECARGO
SECTORGEAB HOOKBASE
@t"
COVER
POWER
wtNDow
MOTOR
i
>: Bolt locations.3
6x1.0mm
7 N.m 10.7kgf.m, FLEXIBLE
5 rbnftl CARGOHOOK
POWERWINDOWMOTOR
2. Removethe tailgatedoor lid,then removethe screws.
>: Screwlocations.2 >: CliP locations.
?11 |
HPI
,4| |
REGULATOR
7. lnstallationis the reverseof the removalprocedure.

TAILGATE
DOORLIO
NOTErRollthe glassup and down to seeif it moves
freelywithout binding.Also make sure that there is 3. Releasethe clips that hold the tailgatedoor panel,
no clearancebetweenthe glassand glassrun chan- then removethe tailgatedoor panel.
nel when the glassis closed.Adjustthe positionof
the glassas necessary{seepage20 20). Installationis the reverseof the removalprocedure.
replaceany damagedclips.
NOTE:lf necessary,
www.emanualpro.com
20-15
Doors
LicensePlateTrim Removaland TailgateDoorHandleReplacement
Installation
CAUTION; Put on gloves to protecl your hands,
CAUTION: Put on gloves to prolest your hands.
NOTE:Takecarenot to scratchthe tailgatedoor.
NOTE: Take care not to scratchthe licenseplate trim
and tailgatedoor. 1. Remove:
. Tailgatedoor panel(seepage20,15)
'1. Remove
the licenseolate. . Licenseplate
. Licenseplatetrim
2. Removethe tailgatedoor panel(seepage20-15).
2. Disconnectthe handlerod. Removethe nuts secur-
3. Removethe nuts, detachthe clip, then removethe ing the tailgatedoor handle,then removethe tail-
licenseolatetrim. gatedoor handleby pullingit out.
NOTE: Take care not to drop the nuts inside the NOTE:Takecarenot to bendthe handlerod.
tailgatedoor.
a: Nut locations,2
a: Nut loc.lions.4 6x1.0mm

9.8 N.m {1.0kgtm,
5x0.8mm 7.2 rbtft)
1.8Nm(0.18kgt.m.
1.3 rbf.ft)
TAILGATEDOOR
,Is
TAILGATE
DOOR
HANDLE
NOTE:
. Makesurethe handlerod is connectedproperly.
. Makesurethe tailgatedoor openspropedy.
NOTE:lf the clip is damaged,replaceit.
www.emanualpro.com
20-16
TailgateDoor Latchand LatchStop Replacement
CAUTION: Put on gloves to protect your hands. 3. Move the latch stop and latch down, then pry the
latchstop rod out of its joint usingdiagonalcutters.
NOTE:Takecarenotto scratchthe tailgatedoor. Removethe latchstop and latchthroughthe hole in
the tailgatedoor.
'1.
Removethe tailgatedoor panel(seepage20-15).
NOTE:
2. Disconnect the handlerod. Removethe bolts secur- . To easereassembly,note location@ of the latch
ing the latchstop and screwssecuringthe latch. stop rod on the joint beforedisconnectingit.
. Takecare not to bend the latch stop rod.
>: Bolt,screwlocations
A>,3 B>,3
6x1.0mm
''-t.-N
gta
-\S/r
t
BUSHING
(cont'd)
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20-17
Doors
TailgateDoor Latchand LatchStop RearHatchGlassLatch
Replacement(cont'd) Replacement
4. lnstallationis the reverseof the removalorocedure. NOTE: Takecare not to scratchthe tailgatedoor.
' 1 . R e m o v et h e t a i l g a t ed o o r p a n e (l s e e p a g e 2 0 - 1 5 ) .
NOTE:
. Makesure the handlerod and latchstop rod are
connectedproperly. 2. Disconnectthe connector.Removethe bolts secur-
a Make sure the tailgatedoor locks and opens prop- ing the latch,then removethe latch.
env.
. After installingthe latch stop and tailgate door >: Boh locations,3
latch,makesure that there is about 1 mm {0.039
6x1.0mm
in.l betweenthe linkA and link B of the latchstop. 9.8N.m {1.0kgI.m,
Adjust the joint position of the latch stop rod as 7.2 tbl.Itl
needed,then checkthe latchstop operation.(Pull
the tailgatedoor handlewhile you push on the REARHATCH
l a t c h s t o p k n o b ; t h e t a i l g a t ed o o r s h o u l d n o t GLASSLATCH
oDen.)
LATCHSTOP
KNOE
N O T E : M a k e s u r e t h e r e a r h a t c h g l a s s l o c k sa n d
opensproperly.
www.emanualpro.com
20-18
RearHatchGlassLockCylinder RearHatchGlassActuator
Replacement Replacement
NOTE:Takecarenot to scratchthe tailgatedoor. CAUTION: Put on gloves to protsct your hands.
1. Removethe tailgatedoor panel(seepage20-15). NOTE:Takecarenot to scratchthe tailgatedoor.
2. Removethe bolt securingthe lock cylinder. Turn 1. Remove;

and pull out the lock cylinder,and disconnectthe o Tailgatedoor panel(seepage20-'15)
cylinderrod, . Rearhatchglasslockcylinder
NOTE:Takecarenot to bendthe cylinderrod. 2. Disconnectthe connectorand the connectorclip.

R e m o v et h e b o l t s s e c u r i n gt h e a c t u a t o r ,t h e n
>: Boltlocation.1 removethe actuator.
6x1.0mm NOTE: Take care not to bend the cylinder rod or

9.8N.m {1.0kg .m, damagethe joint.
7.2 tbt.lll
>: Boltlocations,
3
6x1.0mm
9.8N.m 11.0kgt.m,
REARHATCHGLASS 7.2 tbt.ft)
CONNECTOR
CONNECTOR
REARHATCH
GLASS JOINT
J. Installationis the reverseof the removalprocedure. ACTUATOR
-6{
NOTE:
. Makesurethe cylinderrod is connectedproperly.
. Makesurethe rearhatchglassopensproperly. Installationis the reverseof the removalprocedure.
NOTE:
. M a k e s u r e t h e c y l i n d e rr o d a n d c o n n e c t o ra r e
connectedproperly.
. Greasethe joint of the cylinderrod.
. Makesurethe rearhatchglassopensproperly.
www.emanualpro.com
20-19
Doors
TailgateDoorWeatherstrip Frontand RearDoorGlass
Replacement Adjustment
Installthetailgatedoorweatherstrip
asshown. NOTE:
. Placethe vehicleon a firm, levelsurfacewhen adjust-
NOTE; ing the glass.
. Cleanthetailgate witha sponge
doorbondingsurface . Checkthe weatherstripsand glassrun channelfor dam-
dampened in alcohol. age or deterioration,and replacethem if necessary,
a Makesurethereare no wrinklesin the weatherstrip.
a Checkfor water leaks. 1. Remove:
. D o o rp a n e l( s e ep a g e s 2 0 - 7l l,l
> : Clip locations,2
. Plasticcover(seepages2O-2,41
i-t] |
/[L I oouere-rrceo 2. Adjustthe glass.
lE I aDHEsrvE
rAPE
ll 1T I Thickness: Front:
lll r.2mmlo.o5
in.)
I
Raisethe glassas far up as possible.and hold
A it againstthe glassrun channel.
Loosenthe roller guide bolts, and adjust the
lM
/L)
DOUBLE.FACED
ADHESIVETAPE
Thickne$:
1.2mm 10.05in.)
glassso it is parallelwith the glassrun channel.
GLASSRUN
g\ CHANNEL
BUTYL
SEALANT
Sealantarea,
ROLLER GUIDEBOLTS
6x1.0mm
8 N.m{0.8kgf.m,
5 tbffi)
Tightenthe rollerguide bolts.
Loosenthe front channelbolt.
e. Lowerthe glass.
l. Pushthe front channelagainstthe glass,then

tightenthe tront channelbolt.
www.emanualpro.com
20-20
Loosenthe rearchannelmountingbolts,
f. Lowerthe glass.
Push the rear channelagainstthe glass,then

tightenthe mountingbolts.
>: Bohlocationt2
5x1.0mm
8 N.m(0.8kgtm.6lbtft)
GLASS
6x1.0mm
8 N'm108 kg{m'
6 tbf.ftl
a, Raisethe glassfully.
o. Loosenthe regulatormountingbolts.
c. Pushthe glassforward.
o. Tightenthe regulatormountingbolts.
il
>: Bohlocations, 3. Checkthat the glassmovessmoothly.
6x1.0mm
8 N.m(0.8kgf.m,6 lbf.ft)
GLASS 4. Raisethe glassfully and checkfor gaps.
5. Checkthe glassoperation.
NOTE:Checkthat the glass contactsthe glass run

channelevenly.
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20-21
Doors
Frontand RearDoorGlass Frontand RearDoorPosition
Adiustment(cont'dl Adjustment
6. Checkfor water leaks. NOTE: Placethe vehicleon a firm, level surfacewhen
adiustingthe doors.
Spray water over the roof and on the sealingarea
as snown. After instailingthe door, checkfor a flush fit with the
body,then checklor equal gaps betweenthe front, rear.
NOTE: a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d
. Adjustthe water pressureas shown. body edgesshouldalso be parallel.Adjustat the hinges
. Do not soueezethe tio of the hose. as shown.
CAUTION:Placaa shop towel on the iack to prevent

damageto the door when loosening the door and hinge
-"'*r"i mounting bolts lor adiustment.
12 mm {0.47in.l ,'r)"f
#
(r\ tl
0.5 m (1.6ftl
DOORMOUNTING BOLTS
"1 I x 1.25mm
28 N.m12.9kgtr.m, 21 lbI.ftl
Loosenthe doormountingbolrsslighrly
HOSE to movethedoorlN or OUTuntil
it'sflushwith the bodv.lf necessary,
youcaninstallashimbehindone
hingeto makethedooredges
PARALLEL with the bodv.
300mm 111.8in.)
HINGEMOUNTINGBOLTS
8 x 1.25mm
28 N,m 12.9kgt.m. 21 lbl.ftl
Removethe innerfender,
loosenthe hingemounting
bolts,and movethe door
BACKWARDor FORWARD,
UP or DOWNas necessary
to equalizethe gaps.
Lowerthe glass.
7. Attachthe plasticcover,then installthe door panel

(seepages20-7,'l 1),
20-22
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..-
TailgateDoor PositionAdjustment
The door and body edges should be parallel.lf neces- NOTE: Placethe vehicleon a firm, level surfacewhen
sary,adjustthe door cushion. adjustingthe tailgatedoor.
A f t e r i n s t a l l i n gt h e t a i l g a t ed o o r . c h e c kf o r a f l u s h f i t
with the body, then checkfor equal gaps betweenthe
tailgatedoor edgesand the body.The tailgatedoor and
body edgesshouldalso be parallel.Adjust at the hinges
assnown.
CAUTION:Placea shop towel on the iack lo prevent

damage to the tailgale door when loosningthe tail-
gate door and hinge mounting bolts for adiustment.
ry.
oooRcusHroNs
HINGEMOUNYING
BOLTS
TAILGATE 8 x 1.25mm
DOOR 25 N.m 12.6kgt m,
DOOR
CUSHION 19 rbf.ftl
MOUNTINGsOLTS
Checkfor water leaks. 8 x 1.25mm
25 N.m {2.6 kgf.m,
19 tbf.ft)
NOTE:Do not squeezethe tip ofthe hose.
8x1.0mm
22 N'rrl 12.2kgl.m,
16 tbt.ftl
6xl.0mm
9.8N.m {1.0kgt m,
1.2 tbl.ltl
(cont'd)
www.emanualpro.com
20-23
Doors
TailgateDoor PositionAdiustment Frontand RearDoorStriker
(cont'd) Adjustment
The door and body edgesshouldbe parallel. Make sure the door latchessecurelywithout slamming
it, lf necessary,adjust the striker:The striker nuts are
fixed. The strikercan be adjustedslightly up or down,
a n di n o r o u t .
1. Loosenthe screws,then insert a shop towel between

the body and striker.
STRIKER
Inserta shoptowel
betweenthe body and
Checkfor water leaks.

Spray water over the tailgatedoor and on the sealing
areaas shown.
NOTE:
. Adjustthe water pressureas shown. scREws
8 x 1.25 mm
. Do not squeezethe tip ofthe hose. 18 N.m (1.8kgt.m,
13 rbf.ft)
-*4
l2 mm (0.47in.)
.*1:]* ,'r)"C
II
0.5m {1.6ft}
d3
"1 2. Lightlytightenthe screws.
J. Wrap the strikerwith a shop towel, then adjustthe

HOSE strikerby tappingit with a plastichammer.
CAUTION: Do not tap the striksr loo hard.

300 mm {11.8in.l
4. Loosenthe screws.and removethe shop towel.
5. Lightlytightenthe screws.
6. Holdthe outer handleout, and pushthe door against

the body to be sure the strikerallows a flush fit, lf the
door latchesproperly.tightenthe screwsand recheck.
20-24
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TailgateDoorStrikerAdjustment TailgateDoorWedgeAdjustment
Make sure the door latchessecurely without slamming 1. Loosenthe bolts,and move the tailgatedoor wedge
it. lf necessary,adjust the striker:The striker nuts are UP or DOWNto align it with the tailgatedoor wedge
fixed. The strikercan be adjustedslightly up or down, striker.Move the tailgatedoor wedge lN or OUT to
a n di n o r o u t . centerit. Then lightlytightenthe bolts.
1. Removethe tailgatedoor wedge.
2. L o o s e nt h e s c r e w s ,t h e n i n s e r t a s h o p t o w e l
betweenthe body and striker.
STRIKER
Insen a shoptowel
between the body and
Forward
TAILGATEOOOR
8 x 1.25mm
18 N.m (1.8kgf.m,
r 3 tbf.ft)
Holdthe tailgatedoor handleout, and push the tail-

gate door againstthe body to be sure the tailgate
door wedge allows a flush fit. lf the tailgate door
Lightlytightenthe screws. latchesproperly,tightenthe boltsand recheck.
4. Wrap the strikerwith a shop towel, then adjustthe

strikerby tappingit with a plastichammer.
CAUTION: Do not tap the striker too hard.
Loosenlhe screws,and removethe shoptowel.
Lightlytightenthe screws.
1. Hold the tailgatedoor outer handle out, and push

t h e t a i l g a t ed o o r a g a i n s t h e b o d y t o b e s u r e t h e
strikerallows a flush fit. lf the tailgatedoor latches
properly,tightenthe screwsand recheck.
Installthe tailgatedoor wedge,and adjustit.
www.emanualpro.com
20-25
Mirrors
MIRRORMOUNT
COVEB
POWERMIRBOR
page20 27
Replacement,
,//
MIRRORHOLDER
page20-27
Beplacement,
@
DAMPER
@
v
W w
REARVIEWMIRROR
page20-28
Replacement,
q COVER
www.emanualpro.com
20-26
PowerMirror Replacement PowerMirror HolderReplacement
NOTE:Takocarenot to scratchthe mirror,mirror mount CAUTION: Put on glovss to protest you. hands.
cover and door.
NOTE:Takecarenot to scratchthe mirror.
1. Lowerthe door glassfully.
1, C a r e f u l l yp u l l o u t t h e b o t t o m e d g e o f t h e m i r r o r
2. Carefullypry out the mirror mount coverby hand, holderbv hand.
HOOK ADHESIVE
, l
Disconnectthe connector.then remove the mirror

mountingboltswhile supponingthe mirror,
>: Bohlocations,
3
Separatethe mirror holder from the actuator bv

MIRROR slowly pullingthem apart.
Reattachthe hooks of the mirror holder to the actu-

ator, then Dositionthe mirror holder on the actua-
tor. Carefullypush the clip portions of the mirror
holderuntilthe mirror holderlocksinto place.
Checkthe actuatorooeration.
Installationis the reverseof the removalprocedure,
NOTE:Make sure the connectoris connectedprop-

efly.
www.emanualpro.com
20-27
Mirrors
RearviewMirror Replacement
CAUTION: When prying with a flat-tip screwdrivor,
wrap it whh a shop towel to prevent damage.
NOTE: Take care not to scratchthe cover or tear the

headliner.
1. Removethe cover usingthe end of a flat-tipscrew-

drtver.
HOOKS
Removethe rubberdamper.
>: Screwlocations,3
Remove the screws, then remove the rearview mir-

ror.
www.emanualpro.com
20-28
Glass
NOTE:The numbersafterthe part namesshow the quantitiesof the pans used.
Windshield:
MOLOING
U P P E RS E A L , 2 UPPERRUBBERDAM
1'00model)
UPPERFASTENER
('97- 99 models,and requiredfor
replacementor reinstallation
on '00 model)
FASTENER,2
(Self'adhesive type,glassside)
('97- 99 models,and requiredfor
replacement or reinstallation
o n ' 0 0m o d e l )
WINDSHIELD
page20-30
Replacement,
FASTENER,2
(Self-adhesive-type,
body side)
('97- 99 models,and
requiredlor replacement
tE-r or reinstallation
'00 model)
on
*@
SIDERUBBERDAM, 2
{'97-99 models,and
LOWERRUBBERDAM requiredfor replacement
('00model) or reinstallation
on
LOWERRUBBERDAM '00 model)
l'97 99 models,and requiredfor reDlacement
or reinstallation
on'00 modeli
Ouarter Glass:
OUABTERGLASS
page20-35
Replacement,
FASTENER, 1
(Clip-type,
body side)
\,o,,.,.*,,,
( S e l f a d h e s i v e - t y p e ,g l a s s s i d e )
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Glass
WindshieldReplacement
CAUTION: 4. Apply protective tape along the edge ot the dash-
. Put on gloves to protect your hands. board and body as shown. Using an awl, make a
. Use seat coversto avoid damaging any surfaces. hole through the rubber dam and adhesivefrom
inside the vehicle. Push a piece of piano wire
1. To removethe windshield,first removethe: through the hole, and wrap each end around a
. Rearviewmirror (seepage20-28) piece of wood.
. Sunvisorsand holders(seepage20-44l' PIANO PROTECTIVE
. Ceilinglight (seesection23) WIRE TAPE
. Grabhandle(seepage20-44)
. Frontdoor trim (seepage20-41)
RUBBER
UPPER
. F r o n tp i l l a rt r i m ( s e ep a g e2 0 - 4 1 )
. Windshieldwiper arms and cowl cover (seepage
20-98)
WINDSHIELD
2. Removethe moldingand glassbrackets.

ADHESIVE
NOTE:lf removingthe molding is difficult,cut the PROTECTIVE
moldlngwith a utility knife. TAPE
PIANO
WINDSHIELO
MOLDING
PROTECTIVE
TAPE
DASHBOARD
WINDSHIELD
LOWERRUBBER
ADHESIVE DAM
CAUTION: Hold the piano wire as closeto the wind-

shield as possibleto prevent damageto the body
and dashboard.
5. W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n o w i r e
backand fo(h in a sawingmotion,and carefullycut
through the rubber dams and adhesivearoundthe
e n t i r ew i n d s h i e l d .
3. P u l l d o w n t h e f r o n t D o r t i o no f t h e h e a d l i n e r( s e e
page20-44).
CAUTION: Take care not to bend the headliner

excessivsly,or you may break it. 6. C a r e f u l lrye m o v et h e w i n d s h i e l d .
www.emanualpro.com
20-30
7. Using a knife,scrapethe old adhesivesmooth to a 10. Glue the rubber dams and fastenersto the inside
thicknessof about 2 mm (0.08in.) on the bonding faceof the windshieldas shown
surfacearoundthe entirewindshieldopeningflange.
N O T E : B e c a r e f u ln o t t o t o u c h t h e w i n d s h i e l d
NOTE: where adhesivewill be applied,
a Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper >r Fastenerlocrtions. 2
bonding.
FASTENEB
. Removethe rubberdams and fastenersfrom the
oooy, \,@,--
. Maskoff surroundingsurfacesbeforepainting.
w,{,.
'>Yl
8. Cleanthe body bondingsurfacewith a spongedamp- 14mm -'- \l
enedin alcohol. 0.55in.l ALIGNMENT
MARKS
NOTE: After cleaning,keep oil, grease and water 1 3m m
(0.51in.)
from gettingon the surface. --r-r
9. lf the old windshieldis to be reinstalled, use a putty
knjfeto scrapeoff all tracesof old adhesiveand the ALIGNMENT
r u b b e r d a m s , t h e n c l e a nt h e w i n d s h i e l ds u r f a c e MARKS
with alcoholwhere new adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free

of water,oil and grease.
1 3m m
CAUTION:Avoid setting tho windshieldon its edges; (0.51in.l
small chips m8y later devolopinto cracks.
1 3m m
NOTE:Cleanthe shadowedarea. in.)
10.51
*ffi
ALIGNMENT
MARKS
1 2m m
(0.47in.l
WINDSHIELD
(cont'd)
www.emanualpro.com
20-31
Glass
WindshieldReplacement(cont'dl
1 1 . G l u et h e m o l d i n gs i d es e a la n d m o l d i n gu p p e rs e a l 1 2 . A l i g na n d g l u et h e m o l d i n gt o t h e e d g eo f t h e w i n d -
to the moldingon eachside. shield.
N O T E : B e c a r e f u ln o t t o t o u c h t h e w i n d s h i e l d
w h e r ea d h e s i v w
e illbeapplied.
a. With a brush,apply a light coat of primer (3lvlN-

200,or equivalent)to the edge ot the windshield
as shown,
b. Gluethe adhesivetapes l3M 4212,or equivalent)
to both bottomedgesof the windshield.
c . A l i g nt h e a l i g n m e n m
t a r ko n t h e m o l d i n gt o t h e
alignmentmarkof the windshield.
d. Gluethe moldingto the edgeof the windshield.
>: Alignment mark locations

ALIGNMENT Applyprimer
MARK here.
\ ln3ide , /
100mm {3.9in.l 100mm {3.9in.}
ADHESIVETAPE
Thic*ness:1.2mm (0.05in.)
r m m ( 0 . 1 6i n . )
W i d t h4
r0 mm (1.6in.l
www.emanualpro.com
20-32
'13. Installthe glass bracketsand fastenersto the body 16. With a sponge, apply a light coat of glass primer
as shown. around the edge of the windshieldas shown, then
lightlywipe it off with gauzeor cheesecloth.
>: Fastener 2
locations,
NOTE:
R-
Do not apply body primerto the windshield,and
do not get body and glassprimerspongesmixed
up.
N e v e r t o u c h t h e p r i m e d s u r f a c e sw i t h y o u r
hands.lf you do, the adhesivemay not bond to
the windshieldproperly,causinga leakafter the
windshieldis installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface.
//fu : Applyglassptimar hea.
14. Set the windshieldon the glassbrackets.then cen

ter it in the opening.Make alignmentmarks across
the windshieldand body with a greasepencilat the Applyglassprimer
four pointsshown. WINDSHIELD
NOTE|Be carefulnot to touch the windshieldwhere

adhesivewill be applied.
ALIGNMENT
MABK
Applyglassprimer 1 0 m m RUBBERDAM
to the molding. {0.4in.}
WINDSHIELD
WINDSHIELD
GLASS
BRACKETS
NOTE: Adjust the glass brack- MOLDING
etsto centerthe windshieldin
the opening,then tightenthe 12 mm 10.5in.)
15. Removethe windshield. (cont'd)
Glass
(cont'dl
WindshieldReplacement
17. With a sponge,apply a light coat of body primerto 20, Packadhesiveinto the cartridgewithout air pockets
t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e w i n d - to ensurecontinuousdelivery.Putthe cartridgein a
shield openingflange,Let the body primer dry for c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
at least10 minutes. the edgeof the windshieldas shown.
NOTE: NOTE:Apply the adhesivewithin 30 minutesafter

. Do not apply glassprimerto the body, and be care- applyingthe glassprimer.
ful not to mix up glassand bodyprjmersponges.
. Nevertouch the primed surfaceswith your hands.
12mm (0.47in.)
. Maskoff the dashboardbeforepaintingthe flange.
Ff oo*tt'u' Makea slightlythicker

beadat eachcorner.
///////l , apptvaoav primorhere.
16 mm {0.63in.l 8 mm {0.31in.l
7.8mm 10.30in.)
16 mm 8mm
10.fi in.) (0.31in.)
FASTENER
14.6mm
(0.57in.l
16 mm
{0.63in.)
WINOSHIELD
't8, Thoroughlymix the

adhesiveand hardenertogether
on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mixing.
. Followthe instructionsthat come with the adhe-
sive.
'19. Beforefilling a
cartridge,cut the end of the nozzle
as shown.
WINDSHIELO
Cut nozzleend
RUBBER
DAM
10 mm {0.39in.)
3mm
{0.1in.l
7 mm {0.27in,}
20-34
www.emanualpro.com
OuarterGlassReplacement
2 1 . U s e s u c t i o nc u p s t o h o l d t h e w i n d s h i e l do v e r t h e CAUTION:
opening,align it with the alignmentmarksmade in . Put on gloves to protct your hands.
s t e p 1 4 , a n d s e t i t d o w n o n t h e a d h e s i v eL. j g h t l y . Use seat covers to avoid damaging any surfaces.
push on the windshielduntil its edge is fully seated
on the adhesiveall the way around. 1. To removethe quarterglass,first removethe:
. Rearseat(seepage20-63)
NOTErDo not open or closethe doors until adhe- . Cargofloor lid and cargo storagebin (seepage
sive is dry. 20 431
. R e a rt r i m p a n e l a n d r e a r s i d e t r i m p a n e l ( s e e
SUCTTON ALIGNMENTMARK page 20-421
. Rearhatchglasssupportstrut (seepage20-78)
. Ouarterpillartrim panel(seepage20-421
. Taillight(seesection23)
NOTE:With the rear hatch glass support strut

removed,you will need to support the rear hatch
glassby hand.
2. From insidethe vehicle,use a knife to cut through

the quarterglassadhesiveall the way around.
NOTE:
. lf the quaner glassis to be reinstalled,
take care
22. Scrapeor wipe the excessadhesiveoff with a putty not to damagethe molding.
knifeor towel. . lf the molding is damaged.replacethe quarter
glass,molding,and clipsas an assembly.
NOTE:To removeadhesivefrom a paintedsurface . The quarter glasscan be reinstalledusing butyl
o r t h e w i n d s h i e l d ,w i p e w i t h a s o f t s h o p t o w e l tape.
dampenedwith alcohol.
L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
s p r a y w a t e r o v e r t h e w i n d s h i e l da n d c h e c k f o r
l e a k s .m a r k l e a k i n ga r e a s ,a n d l e t t h e w i n d s h i e l d
dry, then sealwith sealant.
NOTE:
. Let the vehiclestandfor at leastfour hours after
w i n d s h i e l di n s t a l l a t i o nl f. t h e v e h i c l eh a s t o b e
usedwithin the first four hours,it must be driven
. Keep the windshielddry for the first hour after

installation.
. Checkthat the ends of the side molding are set
underthe cowl cover.
2 4 . Reinstallall remainingremovedparts.
NOTE:
. Installthe rearviewmirror rubber damper after
t h ea d h e s i vhe a sd r i e dt h o r o u g h l , .
. A d v i s e t h e c u s t o m e rn o t t o d o t h e f o l l o w i n g
thingsfor two to threedays:
- S l a m t h e d o o r sw i t h a l l t h e w i n d o w sr o l l e d
up.
- Twist the body excess,vely{such as when
going in and out of drivewaysat an angle or (cont'd)
drivingover rough.unevenroads).
www.emanualpro.com
20-35
Glass
Ouarter Glass Replacement(cont'd)
lnside: Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
s u r f a c ea r o u n dt h e e n t i r e q u a r t e rg l a s s o p e n i n g
flange.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
b o n di n g .
. lf any of the clips are broken.removelhem trom
the body.
v\//,
/6\ /l
. Mask off surroundingsurfacesbefore applying
pnmer.
Cleanthe body bondingsurfacewith a spongedamp-

enedin alcohol.
NOTE:After cleaning,keep oil, grease and water

from gettingon the surface.
l f t h e o l d q u a r t e rg l a s si s t o b e r e i n s t a l l e du, s e a
putty knife to scrapeoff all tracesof old adhesive,
t h e n c l e a nt h e q u a r t e rg l a s ss u r f a c ew i t h a l c o h o l
where adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free

of water,oil and grease.
CAUTION: Avoid setting the quarter glass on its

edges;the molding can be permanently detormed.
NOTE:Cleanthe shadowedarea.
ADHESIVE
3. Carefullyremovethe quarterglass.
NOTEj Checkthe molding for damage,replacethe

qua.terglassif necessary.
20-36
www.emanualpro.com
7. Gluethe fastenerto the insideface of quarterglass 9. lf the old quarterglassis to be reinstalled, sealthe
as shown.lf the old quarterglassis to be reinstalled, body holewith pieceof urethanetape,Set the quar
applya lightcoatof primer(3M C-100,or equivalent), ter glassuprightin the openingand makealignment
then applybutyltapeto the quanerglassas shown. m a r k s a c r o s st h e q u a r t e rg l a s s a n d b o d y w i t h a
greasepencilat the threepointsshown.
NOTE:
. Be carefulnot to touch the quarterglasswhere
adhesivewill be aDplied.
. Do not peelthe separatoroff the butyl tape.
/'/.//// | Bttryl taee locationsl3M 8628,or equivalent)

Thickness:3.2 mm 10.13in.l
Width:5.4mm 10.25
in.)
>: Fastenoalocation, I
BUTYLTAPE FASTENER MOLDING
I
mr w-
> t \
1l mm
/ \ (0.43in.)
GLASS MOLDING
GLASS
ALIGNMENTMANK
400 mm (15.75in.)
8. lnstallthe fastenerto the bodv as shown.

>: Fastenerlocation, 1
1 0 . R e m o v et h e q u a r t e g
r lass.
(cont'd)
Glass
(cont'd)
OuarterGlassReplacement
11. With a sponge,apply a light coat of glassprimer to With a sponge,apply a light coat of body primerto
the insideface of the quaner glass,as shown,then the originaladhesiveremainingaroundthe quaner
lightlywipe it off with gauzeor cheesecloth. glassopeningflange.Let the body primer dry for at
least10 minutes.
NOTE:
. Do not apply body primer to the quarter glass, NOTE:
a n d d o n o t g e t b o d y a n d g l a s sp r i m e rs p o n g e s . Do not apply glass primer to the body, and be
m r x e du p . c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r
. Nevertouchthe primedsurfaceswith your hands. sponges.
It you do, the adhesivemay not bondto the quar- . Nevertouchthe primedsurfaceswith your hands.
ter glass properly.causinga leak after the quar
ter glassis installed. '/fu,
. Keep water, dust, and abrasivematerialsaway : Applybody primerhere.
from the primedsurface.
7///f ' aeerysra$primerhere.
1 0m m
{0.39in.)
BUTYLTAPE
'13.
Thoroughlymix the adhesiveand hardenertogether
on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mi x i n g .
. Followthe instructionsthat came with the adhe-
slve.
BUTYLTAPE
1 4 . Beforefilling a cartridge,cut the end of the nozzle
23 mm as snown.
MOLOING 10.90in.) 10 mm 10.39in.)
Cutnozzleend
10 mm {0.39in.)
GLASS
7 mm {0.27in.)
20-38
www.emanualpro.com
15. Packadhesiveinto the cartridgewithout air pockets 16. Use suctioncups to hold the quarterglassover the
to ensurecontinuousdelivery,Putthe canridgein a opening,alignthe clipsor the alignmentmarksmade
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d in step 9, and set it down on the adhesive.Lightly
the edgeof the quarterglassas shown. push on the quaner glass until its edges are fully
seatedon the adhesiveall the way around.
NOTE:
. lf the old quarterglass is to be reinstalled,peel N O T E :D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
the separatoroff the butyltape afterapplyingthe adhesiveis drv.
adhesive.
AUGNMENT
. Apply the adhesivewithin 30 minutesafterapply-
ing the glassprimer.
i:.8T".,1,/:AoHEsrvE
I rnm
(0.31in.)
BUTYL
TAPE
SUCTIONCUPS
1 1 . Scrapeor wipe the excessadhesiveoff with a putty

knifeor towel,
NOTE:To removeadhesivefrom a paintedsurface

or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
1 8 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r . t h e n
spray water over the quarter glass and check for
leaks.Mark the leakingareas,let the quarterglass
dry, then sealwith sealant.
NOTE:Let the vehiclestand for at leastfour hours

after quarterglass installation.lf the vehiclehas to
be usedwithin the first four hours,it must be driven
slowly.
GLASS 1 9 . Reinstallall remainingremovedparts.
NOTE:Advisethe customernot to do the following

thingsfor two to threedays:
. Slamthe doorswith all the windows rolledup.

. Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough,unevenroads).
lnteriorTrim
SRScomponentsare locatedin the areasmarkedwith an asterisk(*). Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRSsection(24)beforeperformingrepairsor service.
CENTERPILLAR FRONTPILLAR
UPPER TRIM TRIM
(seepage20 41)
CENTERPILLAR (seepage20-41)
LOWERTRIM PANEL FRONTSIDE
(seepage20 41) TRIM
(seepage20-41)
BEARSIDE HEADLINER
TEIM Removaland lnstallation,
(seepage20'41) page 20-44
OUARTERPILLAR
TRIM PANEL
(seepage20 42)
*CARPET
Replacement,
page20 45
CENTERCONSOLEIM/T}
Replacement,
page20-47
CENTENTABLE
(seepage20-45)
PARKINGBRAKE
COVER
(seepage 20-45)
TRUNKFLOOR
EXTENSION
(seepage20 43)
CARGOFRONT
SPACER
(seepage20 43)
TRIM
20-40
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Removaland Installation
CAUTION:
. Put on gloves to protect your hands,
. When prying with a tlat-tip screwdrivel, wrap it with protective tape to prevent damage.
. When removing the support strut of the rear hatch glass,you will need to open or closethe rear hatch glass by hand.
NOTE:Takecarenot to bendor scratchthe trim and panels.

>: Cliolocations
a>,5 B> , 8 c>,1 o>.2 e>,2
, | 'rrl
sl
elElw"lel
I l_lss-l
REARDOOR
FRONTSEATBELT TRIM
UPPER
BOLT
7/16- 20 UNF
32 N.m {3.3 kgf.m,
24 rbt.ft)
Apply liquidthread
PILLAR
CENTER
LOWERTRIM PANEL
REARSIDE
LOWER
ANCHOB
COVER
('98 00 models)
FRONTSEATBEL
LOWERANCHOR
BOLT
7/15- 20 UNF
32Nm(3.3kgf.m, REARSIDETRIM
24 tbt.ftl
tlemovethe rearseat
(seepage20 63).
ANCHOR
CAP
('97model)
{cont'd)
InteriorTrim
Removaland Installation(cont'd)
>i Clip loc.tions

a>,21 B>,4 c>,1 D > ,1 E>.! F> , 3
@wt
we@M REANSEATBELT
UPPERANCHORBOLT
7/16-20UNF
OUARTERPILLAR
TNIM PANEL
Removethe rear hatch glass
supportstrut (seepage
20-741.
32 N.m {3.3kgt.m,
24 rbt.ft)
REARDOOR
REARSIOE
TRIM PANEL
Removethe reat seat
(seepage20-63).
REAR
Disconnectthe accessory
socketconnectors,
F
CONNECTOR
2 6x1.0mm
5x1.0mm 9.8 N.m (1.0kgtm,
9.8N.m (1.0kgf.m, 7.2 tbf ftl
1.2lbt-lrl
TIEDOWN
HOOK
ffi TIE
oowN
HOOK
O\A
D
REARTRIM PANEL
Removethe cargo areafloor
6x1.0mm
9.8N.m (1.0kgt m,
7.2 tbf.ft)
STRIKER v
REARSEATBELT
LOWERANCHOREOLT
7/16- 20 UNF
32 N.m {3.3kgt.m,
and cargosloragebin.
24 tbl.frl
20-42
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>: Bolt, screw locations o: Nut locations,2 >: Clip locations
a>,3 B>,4 c>,2 0>,2 A>,8 B>,r
/\ rr. 6xl.Omm I |I .\ |I r- -E
I At tl1|r' t l'---llH- |
Nmr1.o
ksnm.l
m)b
-</ D
-<_/lbe.8
7.2 GlrrIIITTpl
tbr.rrl I 0pE v l| w I l--Tr@HP
| I v v v
TRUNK MAT
BUSHING LOCKASSEMBLY
l V^
I
> '%L
i l
v
"ro"*i*
TRUNKFLOOR
EXTENSIONS CARGOAREAFLOOR
FLOOR
SrO CARGOSTORAGEBIN
LID
l*,hl FLOORSIDEFRAME
CARGO
FRONT
TRIM
Insta,lationis the reverseof the removalprocedure.
NOTE:
. lf necessary,
r Beforeinstallingthe anchorbolts,makesurethereare no twistsor kinksin the seatbelts.
www.emanualpro.com
20-43
lnteriorTrim
Headliner
Removaland Installation
CAUTION: When prying with a tlat-tip screwdriver, 3. R e m o v et h e g r a b h a n d l e sf r o m the front and rear
wrap it with protective tape to prevent damage. passenger's sides.
NOTE: >r Screw locations,6

. Takecarenot to bendand scratchthe headliner.
o Be careful not to damagethe dashboardand other
interiortrim.
ry_l
1. Remove:
. Frontand reardoor sidetrim (seepage20-41)
. F r o n tp i l l a r t r i m( s e ep a g e2 0 - 4 1 )
. Centerpillarlowertrim panel(seepage20-41)
. Centerpillaruppertrim (seepage20 41)
. Rearseat(oneside,seepage20-63)
. Cargoareafloor and cargostoragebin
{seepage20-43)
. Reartrim panel (see page 20-421 COVER
. Rearsidetrim panel(oneside,see page20-42l,
. R e a rh a t c hg l a s ss u p p o r ts t r u t ( o n e s i d e , s e e 4. Removethe clips,then removethe headliner.
page20-78)
. Ouanerpillar trim panel {one side, see page 20- NOTE:An assistantis helpful when removing the
42) headliner.
. Ceilinglight,interiorlight and trunk light
(seesection23) >: Clip locations,9
. Rearviewmirror (seepage20-28)
2. Removethe sunvisorand holderfrom eachside.

HEADLINER
>: Scaew location3, 4
I
A\"r- |
Yr* || -
Pullout. OUARTER
TRIM
PANEL
suNvtsoR
5. Removethe headlinerthrough the rear hatch glass

openrng.
NOTE:
. W h e n r e i n s t a l l i ntgh e h e a d l i n etrh r o u g ht h e r e a r
h a t c h g l a s so p e n i n g ,b e c a r e f u ln o t t o f o l d o r
bend it, Also, be carefulnot to scratchthe body.
. C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e
securelyattachedto the trim.
20-44
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Carpet Replacement
SRScomDonents are locatedin this area.Reviewthe SRS 4. Removethe centertable and tableframe bracket.
componentlocations,precautions, and proceduresin the
SRSsection{24)beforeperformingrepairsor service. >: Bolt locations,4 a: Nut locations,4
CAUTION: Put on glovesto protect your hands. 8 x 1.25mm 8 x 1.25mm

22N.m l2.2kgl.n, 22 N.m 12.2kgf.m,
' 1 . Remove: 16 tbt ft) 16 tbtfrl
. Frontseat(seepage20-571
>: Clip locations,4
. Rearseat(seepage20 63)
. Kickpanel(seepage20-41) i l l
r i l l a rl o w e rt r i m p a n e l( s e ep a g e2 0 4 1 )
. C e n t ep
. Frontsidetrim {seepage20-41) , l
. Lowerconsolecover1A,/T model,see page20-49)
. Centerconsole(lM/Tmodel,see page2o-47)
CENTERTABLE
2. Removethe footrest.
>: Eoltlocaiions,2 Forwaad
6x1.0mm
9.8N.m {1.0kgf.m,
7.2 tbt.ttt
FOOTREST
3. Removethe parkingbrakecover.
>: Screwlocations,2
COVER
"
6bo" I l TABLEFRAME
BRACKET
{cont'd)
lnteriorTrim
(cont'dl
CarpetReplacement
5. Removethe centerlowercover(M/Tmodel). 8. Removethe clips, and releasethe fasteners.then
removethe carpet.
>: Cliplocations,2
-ffi] lN' NOTE:Takecarenot to damage,wrinkleor twist the

carpet.
>: Cliplocations.3
FASTENER
COVER
lnstallationis the reverseof the removalprocedure.
6. Removethe SRSunit covers. NOTE:

. Take care not to damage. wrinkle or twist the
>: Clip locations,2 carper.
FASTENER . Makesurethe seatharnessis routedcorrectly.
.dL I
tEu( |
SNSUNIT ('98- 00 models) . lf necessary,
- qf cARPET . Reaftachthe cut areas@ and @ ('97 model)or
I cut area @ ('98 - OOmodels)in the carpetwith
wire ties.
COVER
7. '97 model: Cut areas and

@ @ in the carpet,then
pullthe carpetback.
'98 - 00 models:Releasethe fastenerand cut area
@ in the carpet,then pull the carpetback.
20-46
www.emanualpro.com
Dashboard
GenterConsoleReplacement lnstrumentPanelRemovaland
Installation
M/T model:
CAUTION:
NOTE;Takecare not to scratchthe dashboardand related . When prying with a flat-tip screwdriver.wrap it with
parts, protestive tape, and apply prolestive tape around the
related parts, to provont damago,
1, Removethe shift lever knob.screwsand clips.then a Put on glovss to protect your hands.
removethe centerconsole.
NOTE: Takecare not to scratchthe dashboardand related
>: Screw location3,4 >: Clip locations.2 pans.
I
| #\
*K/
6-Emmmn> 1. Tilt the steeringcolumndown.
I 2. Removethe screws,and detachthe clips,then care-

fullv removethe instrumentoanel.
>: Screw locations,2 >: Clip locations,2
^ l r#sr\ |
arl = -, l
l ]
Remove the screws, then removethe centerupper

pocket.
>: Screw locations,4
PANEL
NOTE:lf necessary,
Dashboard
Driver'sDashboardLowerCoverand KneeBolsterRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRS 2. Removethe bolts.then removethe kneebolster.
componentlocations,precautions,
and proceduresin the
SRSsection(24)beforeperformingrepairsor service.
>: Boh locations,3
GAUTION:
6x1.0mm
. When prying with a tlat-tip screwdriver,wrap h with 9.8N.m ('1.0kgtm.
proteqtive tape, and apply protective tape around the 7.2 tbtftl
relatd parts, to prevent damage,
. Put on glovgsto protect your hands.
NOTE:Takecare not to scratchthe dashboardand related

pans.
1. R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n
removethe driver'sdashboardlower cover.Discon-
nectthe rearhatchglassopenerswitchconnector.
>: Screw locations,2 >: Cliplocations

A>,3 B > ,1
I rr.- | lr, l
GlTtrrrb
I
. - l
@,
r ' "| {l
|'l 1
REARHATCHGLASS
OPENERSWITCH
CONNECTOR
KNEEBOLSTEF
NOTE:Make surethe connectoris connectedprop-

erly.
20-48
www.emanualpro.com
Glove Box Removaland CenterPocketRemovaland
Installation Installation
CAUTION: A/T model:
. When prying with a flat-tip 3crewdriver,wrap it with
protective tape, and apply protoqtivetape around ths CAUTION: When prying with a tlat-tip screwdriver,
related parts, to prgveni damage. wrap it with protestive tape, and apply protective tape
. Put on glovegto protect your hands. around the related parts to prevent damage.
NOTE: Takecare not to scratchthe dashboardand related NOTE:Takecare not to scratchthe dashboardand related
oarts. oans.
1. Removethe glove box stopsfrom eachside. 1. Remove the lower console cover.
>: Scrgw locations,6 >: Clip locations

GLOVEBOX A>,2 B>,2
elsl
STOPS
6F@''
- Il
GLOVEBOX
Removethe bolts,then removethe glove box.

>i Boltlocations,2
COVER
Removethe screws,then carefullyinsert a flat-tip
screwdriverand push down on the top of the hook.
Removethe centerpocketwith the beverageholder,
Separatethe center pocket, beverageholder and

beverageholderbracket.

4. Installation
is the reverseof the removalorocedure.
www.emanualpro.com
20-49
Dashboard
CenterDashboardLowerGover CenterPanelRemovaland
Removaland Installation lnstallation
SRScomponentsare locatedin this area.Reviewthe SRS SRScomponentsare locatedin this area.Reviewthe SRS
and proceduresin the
componentlocations,precautions, comDonentlocations,precautions,and proceduresin the
SRSsection{24)beforeperformingrepairsor service SRSsection(24)beforeperforming repairsor servace.
CAUTION:
CAUTION: . When prying with a flat-tip screwdriver,wrap it with
. Whn prying with a flat-tip screwdrivet,wrap it with protective tape, and apply protectivetape around the
protective tap, and apply proteclive tape around the
relatgd parts to prevent damage.
rslated parts to prevenl damage. . Put on glovesto protect your hands.
NOTE:Takecare not to scratchthe dashboardand related
NOTE:Takecare not to scratchthe dashboardand related parts.
oarts.
1. Remove:
. Driver'sdashboardlowercover(seepage20-48)
1. Remove:
. Glovebox (seepage20-49)
. Driver'sdashboardlowercover(seepage20-48)
. Centerpocket(A,/Tmodel,seepage20-49)
. Centerconsole(M/Tmodel,see page20-47)
. Centerpocket(AVTmodel.seepage20-49)
. Centerupperpocket{M/Tmodel,see page20-47)
. Centerconsole (M/f model, see page 20-41l,
. Centerdashboardlowercover
. Centerupperpocket(M/Tmodel,see page2O-47J
2. Removethe bolts, and releasethe clips. then pull
2. R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s . t h e n out the centerpanel.Disconnect
the connectorsand
r e m o v e t h e c e n t e r d a s h b o a r dl o w e r c o v e r . antennalead.then removethe centerpanel.
Disconnect the connectors.
>: Bolt locations,2 >: Cliplocation3
>: Screw locationa,.a >: Clip loc.tion6,3 A> , 4 B>,2
I
tt t
I5 (8NEDL .t !^ u . I
- Il
6br" - l \lJS>,,
I is
\>ry
I r-,/'
\"P I AccEssoRy
I socKET CENTERPANEL AUOIOUNIT
CLIMATE CONTBOL
UNITCONNECTORS
NOTE:Make sure the connectorsand antennalead
are connectedproPerly.
3. Installationis the reverseof the removalprocedure-
N O T E : M a k e s u r e t h e c o n n e c t o r sa r e c o n n e c t e d
properly.
www.emanualpro.com
20-5 0
Power Window Switch Removal CenterAir Vent Removaland
and Installation Installation
CAUTION: CAUTION:
. When prying with a flat.tip screwdriver,wrap it with . When prying with a flat.tip screwdriver,wrap h with
protective tape, and apply protective tape around th protective tape, and apply proteqtivetape around the
related parts to ptavgnt damage. rolated parts to prevont damage.
. Put on glovesto protect your hands. . Put on gloves to protect your hands.
NOTE:Takecare not to scratchthe dashboardand related NOTE:Takecare not to scratchthe dashboardand related
parts. pans.
'L Removethe driver's dashboard lower cover (see 1. R e m o v et h e c e n t e ra i r v e n t . t h e n d i s c o n n e c t h e
page20-48). connector.
2. Gentlypush out the powerwindow switchfrom the NOTE:Carefullvinsen a flat-tio screwdriverunder

dashboard lower cover opening by hand. the clips,then pull out the centerair vent while pry-
Disconnect
the connectors. ing up the clips.
>: Cliplocations,
4 >:Cliplocations.,l
I
ffil
CENTERAIB VENT
POWERWTNOOW
SWITCH
Installationis the reverseof the removalprocedure,
NOTE;Make surethe connectoris connectedprop-
N O T E : M a k e s u r e t h e c o n n e c t o r sa r e c o n n e c t e d
properly.
www.emanualpro.com
20-51
Dashboard
Side Air Vent Removaland Side DefoggerTrim Removal and
lnstallation lnstallation
CAUTION: CAUTION:
. When prying with a flat-tip screwdriver,wrap it with . when prying whh a flat-tip sctewdriver, wrap it with
protec'tivetape, and apply protcctive tape around the protective tape, and apply protectiv tape around the
related parts to provent damage. relatgd parts to prevent damagg.
. Put on glovsto protect your hands. . Put on gloves to protect your hands.
NOTE:Takecare not to scratchthe dashboardand related NOTE:Takecare not to scratchthe dashboardand related
parts. oarts.
1. Driver'sside:Removethe Dowerwindow switch. 1. Driver'sside:Removethe sideair vent.
2. Driver'sside:Closethe vent, and gentlypushout the 2. Driver'sside:Gentlypush out the clipsfrom side air
c l i p s f r o m t h e p o w e r w i n d o w s w i t c h o p e n i n gb y vent openingby hand,then pull out the side defog-
hand,then pull out the side air vent. Disconnect the ger trim. Disconnectthe connector.
connector. Passenger'sside: Carefullyinsert a flat-tip screw-
Passenger'sside:Carefullyinsert a flat-tip screwdriver driver underthe clips,then pull out the side defog-
underthe clips.then pull out the side air vent while ger trim while prying up the clips.
pryingup the clips.
>: Clip locations,2
>: Cliplocations c 1
A>,2 B > ,1
f f- it l
sl4 POWERMIRROR
SWITCHCONNECTOR
TRIM
SIDEAIB VENT

3. is the reverseofthe removalprocedure.
Installation
www.emanualpro.com
20-52
DashboardRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRS 5. Removethe dashboardside cover. Disconnect the
componentlocations,precautions,and proceduresin the dashboardwire harnessconnectors, removethe nuts,
SRSsection{24)beforepreformingrepairsor service. then move the under-dashfuse/relaybox. Disconnect
t h e a n t e n n al e a d , a n d d e t a c ht h e h a r n e s sc l i p s .
CAUTION: Removethe connectorholder from the dashboard
. When prying with a flat-tip screwdriver,wrap h with frame. Unbolt the control unit/relay bracketfrom
protective tap, and apply protective tape around the behindthe middleof the dashboard.
related parts to prevgnt damage.
. Put on glovesto protct your hands. >: Clip locations.
ANTENNA
r t t l LEAD
NOTE:
. An assistantis helpfulwhen removingand installing
the dashboard.
sl l l l l HARNESS
. T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d v a n d
SRSMAIN
other relatedparts. HARNESS
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons.
UNDER.DASH
2. Disconnectthe negativebatterycable.and wait at FUSE/RELAY
BOX
leastthree minutesbeforebeginningwork.
OASHBOARD
Removei SIDECOVER
a Driver'sdashboardlower cover and knee bolster
(seepage20-48)
. L o w e r c o n s o l ec o v e r a n d c e n t e r p o c k e t ( A / T
6x1.0mm
model,seepage20-49) DASHBOARD9 . 8 N m 1 1 . 0 k g f . m ,
. C e n t e rc o n s o l ea n d c e n t e ru p p e r p o c k e t( M / T FFAME 7.2tbt.ftl
model,see page20-47)
. Centerdashboardlower cover(seepage20-50) CONNECTOR
. Powerwindow switch(seepage20-51) HOLDER
. Driver'sside air vent (seepage20-52)
. Driver'sside defoggertrim (seepage20-52)
Disconnect the driver'sairbagconnector,and lower 6. Removethe passenger's

dashboardlowercover.
the steeringcolumn(seesection17)
>: Scrw location, 1 D: Clip locations,
NOTE:To preventdamageto the steeringcolumn,

I n l
wrap it with a shop towel.
SF:oo
- lI -$t- I
ssj
PASSENGER'S
DASHBOARD
LOWERCOVER
I
{cont'd)
www.emanualpro.com
Dashboard
DashboardRemovaland Installation(cont'd)
7. the connectorsand harnesscliDS.
Disconnect
>: Boli loc.lions

a>,5 B>,1 c>,1
^5\h'.'_.
\fl)Prtu' 4fl\',r,' r$\'rmTrr':j,1.ff,ry-r,.,".
tltbt.ttl
W/* W)-
OASHBOARD
GUIDEPIN
c)-
CONNECIORS
CONNECTOR
Removethe bolts.then lift and removethe dashboard.
CAUTION: Use protective iape on the botlom of ths tront pillar trim.
NOTE:
. Makesurethe dashboardfits onto the guide pinscorrectly.
. Beforetighteningthe bolts,makesurethe dashboardwire harnessesare not pinched.
. Makesurethe connectorsand antennalead are connectedproperly.
20-54
www.emanualpro.com
DashboardFrameReplacement
CAUTION: Put on gloves to prolect your hands.
NOTE:Takecarenot to scratchthe dashboardand relatedparts.

GAUGE CENTERPANEL
a: Nut locations,3 INSTRUMENT {seepage20 50)
PANEL
6x1.0mm (seepage20 47)
9.8 N.rn 11.0kgf.m,
7.2 tbt.ftl \,.\
>i Screwlocations / ,.-------f,\
lu /A
A>,16
I w
\,r*
B>,2
^ l
-
S@t' 1l
c >,2
I
0" @ ll
D>.a DASHBOARD
wlRE HARNESS
^ l
0- F ll DASHBOARD
FRAME
>: Clip localions.2
.dr
-wr I
Ihll'rifi- |
FRONTPASSENGER'S
i
Installationis the reverseoI the removalorocedure.
NOTE:
. Makesurethe dashboardwire harnessesare not Dinched.
. Makesurethe connectorsand antennaleadare connectedproperly.
www.emanualpro.com
Seats
REARSEAIS
page20 63
Removaland lnstallation,
Disassembly
and Reassembly, page20 65
SeatLinkageDisassembly page20-67
and Reassembly,
ArmrestReplacement, page20-69
SeatCoverReplacement, page20-69
page20 57
Disassemblyand Reassembly, page2O-58
SeatLinkageDisassembly page20-60
and Reassembly,
ArmrestFleplacement,
page20 61
SeatCoverReplacernent,page20 61
www.emanualpro.com
20 -5 6
Front Seat Removaland Installation
CAUTION: When prying whh a tlat-tip screwdrivor,wrap 2. Lift up the driver's front seat,then disconnectthe
it with proteqtivetape to prevent damage. seatbeltswitchconnectorand harnessclips.
NOTE:Takecare not to scratchthe bodv or tear the seat >: Hrrnosscliploc.lions

covers.
1. Removethe seat track end cover, and removethe

bolts.
>: Bolt loc.tions

A>.3 B > ,1
I x 1.25mm 10x 1.25mm

22 N.m 37 N.m
i'2.2 kgl.m, 13.8kgt.m,
16 rbf.ftl 27 tbt.ftl
SEATBELTSW]TCH
CONNECTOR
Carefullyremove the front seat through the door

opening.
NOTE:An assistantis helpful when removingthe

front seat.
NOTE:Make sure the seat belt switch connectoris

connectedproperly(driver'sfront seat).
www.emanualpro.com
20-57
Seats
and Reassembly
FrontSeatDisassembly
CAUTION: When prying with a flat-tip screwdriver,wrap it with protsqtive tape to prevent damage.
NOTE:Takecarenot to scratchthe bodv or tear the seatcovers.
Driver's seat lmanually adiustablewith manual height adiustmentl:
>: Cliolocations removal:

barremoval:
Torsionbar
Torsion
HOOK
SEATCUSHION
10x 1.25mm
,17N.m (,1.8kgt m,
35 tbt.ft)
PIVOTNUT
8 x 1.25mm
22 N.n 12.2kgl.m,
16 rbI.ft)
10 x 1.25mm
47 N.m (4.8 kgf.m,
35 tbtfr)
HOOKS
10 x 1.25mm
47 N.m {,1.8kgl.m.
35 rbt.ft)
www.emanualpro.com
20-5 8
seat (manuallyadiustablel:
Passenger's
>: Clip locations

HOOK
HEADREST
SEAT.BACK
PIVOTWASHER
PIVOTNUT
8 x 1.25mm
22 N.m 12.2kgl..n,
16 tbt.ftl
SEATCUSHION
CENTERCOVER
BUSHING
1 0x 1 . 2 5m m '10x 1.25mm
,U N.m 14.8
35 rbt.ft) 47 N.m {4.8 kgf m,
35 rbl.ft)
UNDER-SEAT
TRAYGUIDE
1 0x 1 . 2 5m m
d 17 N.m {4.8kgl.m,
HOOKS 35 tbf.ft)
COVER
Reassembly
in the reverseorderof disassembly.
NOTE:
. Makesurethe bushingand pivotwasherare installedproperly.
. To preventwrinkleswhen installingthe seat-back
cover,makesurethe materialis stretchedevenlyover the pad.
. Greasethe movingportion.
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Seats
and Reassembly
FrontSeatLinkageDisassembly
CAUTION: Put on gloves to protect your hands.
RECUNEADJUSTER
8 x 1.25 mm
22 N.m 12.2kgl.m,
16 tbf.fi)
8 x 1.25mm
22 N.m 12.2kd-m,
16 tbtf0
CROSSBRACE
8 x 1.25mm
22 N.m 12.2kgl.m,
16 tbf.f0
INNERSLIDE
ADJUSTER
cRoss
BRACE
CONNECTING WIRE
To connect,twist 180".
OUTERSLIDE
AOJUSTER
8 x 1.25mm
22 N.rn l.2.2kgl-m,
16 rbr.ft)

Reassembly
NOTE:Greasethe moving portions.
www.emanualpro.com
20-6 0
FrontSeatArmrestReplacement FrontSeatCoverReplacement
NOTE:Takecare not to tear the seamsor damagethe CAUTION: Put on gloves to protect your hands.
seatcoverS.
NOTE:Take care not to tear the seamsor damagethe
>: Boltlocations.2 seatcovers.
6r1.0mm Seat-backcover:
9.8N,m ll.0 kgl.m,
7,2 tbf.ft) '1. Slide the front seatforward,and fold the
seat-back
forward.
2. Removethe armrestfrom the driver'sseat.
3. Release
the hook,and fold backthe seat-backcover.
SEAT-BACK
1 0x 1 . 2 5m m
47 N.m 1,1.8 kgf,m, 4. Releaseall insidesprings,then fold backthe seat-
35 tbt{t) backcover.and removethe clios.
WIRE
{Padsidei
(Seatback frame sjde) '00

cover on model)
(cont'd)
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20-61
Seats
FrontSeatCoverReplacement(cont'dl
Removethe headrestguide,then removethe seat- 3. Pull backthe edge of the seat cushioncover all the
Dacxcover. way around,then releasethe clips.and removethe
seatcushioncover.
COVER (padside)
6. is the reverseof the removalprocedure.

Installation lnstallationis the reverseof the removalprocedure.
NOTE: To preventwrinkleswhen installinga seat- NOTE:

backcover,makesure the materialis stretchedevenly . To preventwrinkleswhen installinga seatcush-
over the pad before securingthe hook and inside ion cover. make sure the material is stretched
springs. evenlyoverthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.
Seat cushion cover:
1. Removethe seatcushion(seepages20-58,59).
RINGPLIERS
UPHOLSTERY
available)
lCommercially
Removethe clipsfrom underthe seatcushion.then
loosenthe seatcushioncover.
CLIP
NEWCUP
SEAT FRAME
SEAT
CUSHION
COVER
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20-62
RearSeat Removaland lnstallation
CAUTION: When prying with a llat-tip screwdrivsr, with tilt:
wrap it with protectivetape to prevent damage.
NOTE:Beforeremovingthe rearseat,tilt it.
NOTE: Takecare not to scratchthe seatcoversand bodv.
l Removethe lower hinge covers,then remove the

bolts.
>: Boh locations.2
8 r 1.25mm
2 N.m 12.2kgl,n,
16 tbf ttl
LOWERHINGE
covERs LOWERHINGE
COVER
(cont'd)
www.emanualpro.com
20-63
Seats
RearSeat Removaland Installation(cont'dl
2. Foldthe seatcushionforward,and removethe base 5. removethe striker.
With tilt: lf necessary,
framecover,then removethe boltsand nut.
NOTE:The rear seat without tilt is shown,the rear

seatwith tilt is the same manner.
>i Boh screw locetions

A>, 1 B>, 4
8 x 1.25mm
22 N.m {2.2 kgf.rn,
16 rbtft) @ t
'l
a: Nut loc.iion,
8 x 1.25mm
22 N<n 12.2kglrn,
16 rbtftl
BASEFRAME
N O T E :M a k e s u r e t h e r e a r s e a t b e l t b u c k l e sa n d
centerbelttongueare routedproperly(withouttilt).
SEATBELTBUCKTES
(CENTERBELTTONGUEI
SEATCUSHION
? Removethe headrest.
4. Carefullyremovethe rear seatthrough the door open-

ing.
NOTE:An assistantis helptulwhen removingthe rear

seaI.
www.emanualpro.com
20-64
and Reassembly
RearSeat Disassembly
CAUTION: When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:Takecarenot to scratchthe body or tearthe seatcovers.
Without till:
SEAT-BACK
SEAT.AACK
RECLINEROD
PIVOT
COVER
PIVOTNUT
8 x 1.25mm
20 N.m 12.0kg{.m. WASHER
14 tbf.ftl
HOOKS
SEATCUSHION
LATCH
SEAT
CUSHION
5x1.0mm SEATLINKAGE
SEATCUSHION 9.8 N'm (1.0kgf.m,
STRAP 7.2 tbl.ltl
(cont'd)
Seats
RearSeat Disassembly (cont'd)
and Reassembly
with tilr:
SEAT-BACK
SEAT.BACK
RECLINEROO
PIVOTNUT
x 1.25mm
20 N{n (2.0kgt.m,
14 tbt-fr)
10 x 1.25mm
47 N.m {4.8kgfn, I-ATCH
35 tbtft) COVER
SEATCUSHION
LATCH
SEAT
CUSHION
SEATLINKAGE
6x1.0mm
9.8 N.m {1.0kgf.m, SEATCUSHION
T;LT CLIP 7.2 tbf.ftl STRAP
KNOB
Reassemble
NOTE:
. Makesurethe bushingand pivot washerare installedproperly.
. Greasethe moving portion.
20-66
www.emanualpro.com
and Reassembly
RearSeat LinkageDisassembly
CAUTION: Put on glovesto protect your hands'
Without tilt:
REABSEAT
FOOT
CENTER 6x1.0mm
9.8 N{n 11.0kgt'm,
COVER
7.2 tbt ftl
I
N
HINGE PIN
BASEFRAME E-CLIPS
Replace.
I
I
b
HINGEBRACKET
(cont'd)
Seats
RearSeat LinkageDisassemblyand Reassembly(cont'd)
with tilt:
NOTE:Referto section24 for the rearseatbelt bucklesand centerbelttongue removal
TILTCONTFOL
CABLE CENTEBARM
1 0x 1 . 2 5m m COVER
47 N.m {i1.8kgt.m,
35 tbf.ft)
6x1.0mm
9.8 N.m n.0 kgt.m,
n
7.2 tbt.tll /
8 r 1.25mm
16 N.m (1.6kgf.m,
12 tbt.ftl //-)
ASE FRAME
DAMPER
6x1.0mm
9.8 N.m 11.0kgtm,
7.2 tbttr)
TILTCONTROLROD
A SPRING
@ UPPERHINGE
TILT
CONTROL
CABLE
Replace.
BUSHING
H I N G EP I N
E.CLIP
Reptace.
Reassemble
NOTE:
. Greasethe moving ponion.
. lf necessary,
adjustthe tilt controlcable.
20-64
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RearSeatArmrestReplacement RearSeatCoverReplacement
NOTE:Take care not to tear the seamsor damagethe CAUTION: Put on gloves to protect your hands.
seat covers.
NOTE:Takecare not to tear the seamsor damagethe
sealcovers.
SEAT.BACK
Seal-backcover:
L Removethe seat-back{seepage20-65).
COLLAR
2. Remove:
a Armrest
. Headrest
reclinerod (seepage20-65)
. Seat-back
COLLAR
6x1.0mm Removethe seat cushionstrap bolt and strap bolt
9.8 N.m {1.0kgf.m, trim, then removethe seat-backmat.
7.2rbr.ft)
WASHER
NYLON
WASHER
VE ARMREST
WASHER "'---.' t.-r"t-- i,': "" '
ARMREST
PIVOTBOLT
6x1.0mm
9.8 N.m (1.0kgt.m,
7.2lbllll
4. Removeall the clips.

(cont'd)
Seats
RearSeatCoverReplacement(cont'dl
Removethe headrestguide and latch knob collar, Soat cushion cover:
then removethe seat-back
frame.
SEAT.BACK '1.
Removethe seatcushion(seepage20-65).
FRAME i
2. R e m o v et h e s e a t c u s h i o nl a t c h a n d s e a t c u s h i o n
strap(seepage20-66).
3. P u l l b a c kt h e e d g e o f t h e s e a tc u s h i o nm a t , t h e n
releaseall of the clips.
SEATCUSHION
MAT

--t)c/ t-t
t l
pio L]
l@
I HEADREST
GUroE
I
LATCHKNOB
COLLAR
Pull backthe edgeof the seat-back

coverall the way
around.releasethe clips,and removethe seat-back
cover.
CUSHION
COVER
Pull backthe edge of the seat cushioncover all the

way around,releasethe clips,and removethe seat
cushtoncover.
CLIPS
CLIPS WIRE
( L e a t h e rs e a t - b a c k (Padside,leatherseat,back
coveron '00model) coveron ,00model)
NOTE:
o To preventwrinkleswhen installinga seat_back
cover,makesure the materialis stretchedevenly
over the pad beforesecuringthe hook and clips.
COVER
20-70
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NOTE:
o To preventwrinkleswhen installinga seatcush-
i o n c o v e r ,m a k e s u r e t h e m a t e r i a li s s t r e t c h e d
evenlyover the pad beforesecuringthe clips.
UPHOLSTERY FING PUERS

(ComE|erciallY
available)
PAD
WIRE
(Padside)
Bumpers
FrontBumperRemovaland Installation
CAUTION: Put on gloves to protec,tyour hands.
NOTE:
. An assistantis helpfulwhen removingthe front bumper.
. Takecarenot to scratchthe front grille,lront bumperand body.
o Firstremovethe front grille (seepage20-77).
. lf necessary,
removethe front licenseplatebaseand front licenseplatelower bracket.
>: Boli screw locations >: Cliplocations,5

A>,3 B > ,4 C>,4
6x1.0mm 4 \ t . < \ l .r., I
9.8 N.m (1.0kgf.m,
7.2 tbt t0 S))PF
v
| ffi)m>l
Y./ I | w
w
l
FRONTGRILLE FRONTGRILLE
(seepage20-77) EMBLEMCOVER
(seepage20-77)
FENDER
tx\ -
\{_:
IB
FRONTBUMPER
20-72
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removethe front bumperbeam,front bumperupperbeamand guard bar.
lf necessary,
>: Bohlocations
A>,5 V.2 c>.6 D>,2 E>,6
10 x 1.25mm
Gfu @p;i,li',ll-"-' 38 N.rn {3.9 kgf.m,

28 rbl.ftl
>: Clip locations

A>, 5 B>.3 @,,2
n l n - n l z n Ir
dE6

I #\Er+
=.=r | ;lHl=|
t:Wl
TIE DOWN
HOOK
Yl-r
{to/ BEAM
TIE.DOWN
HOOK
v1
Installationis the reverseot the removalprocedure.
NOTE:
. M a k e s u r e t h e f r o n t b u m p e re n g a g e st h e f r o n t
bumperupperbeamsecurely.
. It necessary,adjust the front bumper upper beam
to obtainthe propergap. FRONTBUMPEB
. lf necessary, replaceany damagedclips.
Bumpers
RearBumperRemovaland Installation
CAUTION: Put on gloves to proteqt your hands.
NOTE:
. An assistantis helpfulwhen removingthe rearbumper.
. Takecarenot to scratchthe rearbumDerand bodv.
>: Boli,screwlocations >: Clip locelions, 7

a>,2 B>,4 c>, 10
.f-.' I
rgfi\\* ffi\\-. 3il;l-'lln*n,..,
WJ/* t.2tbtftl
Y)f 0f'"I trl
- l .
-
K
l
l
BEARBUMPER
STEP
SIOEMARKER
LIGHTCONNECTOF
Disconnect. REARSPLASH
GUARD
To body
To body
SIDE
MARKER
LIGHT
To body
To body
REARBUMPER
LIGHT
NOTE:
. lf necessary,
. Makesurethe side markerlight connectorsare pluggedin properly.
. Makesurethe rearbumperengagesthe sideclipson eachsidesecurely.
20-74
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Hood
Replacement
NOTE:
. An assistantis helpfulwhen removingand installingthe hood.
a Takecarenot to damagethe hood and body
. When removingthe clips,usea clip remover.
>: Bolt locations,4

6x1.0mm
9.8N.m {1.0kgt.m,
7.2tbtfr)
HOOD
WINDSHIELD
WASHERNOZZLES
(seepage20-100)
G
{
\
HOOD
WINDSHIELD HINGE
WASHER TUBE
(seepage20-100)
Installationis the reverseof the removalprocedure
NOTE:
. Makesurethe hood opensproperlyand lockssecurely.
. Adjustthe hood alignment.
. Adjustthe aim of the windshieldwashernozzles(seepage20-102)
Hood
Adjustment
NOTE: Beforeadjustingthe hood,looseneachbolt slightly.
Turnthe hood edgecushions,as necessary, to make Adjustthe hood right and left,as well as fore and aft,
the hood fit flushwith the bodv at front and sideedges. by usingthe elongatedholeson the hood hinge
f
sz
+
14-- HOODEDGE
CUSHION
-+ik-
HOODHINGE 6x1.0mm
9.8N.m (1.0kgtm,
7.2 tbt.ttl
HOODHINGE
Adiustthe hood latchto obtainthe properheightat the forwardedge'

Move the hood latchrightor left untilthe strikeris centeredin the hood latchas shown
HOOD
\ LATCH
?--
9.8N.m (1.0kgf m,
7.2 rbf.ftl HOODLATCH
20-76
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Front Grille
Replacement
CAUTION: When prying with a flat-tip screwdriver,
wrap it with protective tape, and apply protective tape
around the related parts to prevent damage.
NOTE:Takecare not to scratchthe front orille and front

oumper.
1. Removethe front grille emblem cover. Loosenand

removethe grille mountingscrews.and removethe
front grille by pullingit forward.
>: Screwlocations
a>,5 s>,2
@-l@,"l
N O T E : I n s e r t a P h i l l i p ss c r e w d r i v e rt h r o u g h t h e
holes in the front grille,then loosen the screws.
RearHatchGlass
Replacement
CAUTION: Harnosswiring locations:
. Put on glovesto protecl your hands.
. Use seal coversto avoid damaging any surfaces. REARWINDOWWIPER
. Do not damage the rear window delogger grid lines MOTORCONNECTOR
and terminals. Removethe rearwiper lower HARNESS'
cover(seepage20-99i. TRIM
NOTE:An assistantis helpful when removingthe rear
hatchglass.
a: Nul locations
Aa.4 Ba.4
@i!iff*-"-
REARSPOILER
.;=-
8 x 1.25mm
22 N-m l'2.2kgl.m,
'16tbt fr)
8 x 1.25mm
22N.m l.2.2*ql.m,
16 tbf.ft|
Installation is the reverse of the removal orocedure.
NOTE:
. Adjustthe rearhatchglassalignment.
. Makesurethe connector,terminalsand washertube are connectedproperly.
. Adjustthe aim of the rearwindow washernozzle(seepage20-103).
20-78
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Disassembly
and Reassembly
NOTE:
. Takecarenot to scratchthe rearhatchglass.
. lf necessary,
replaceany damagedspacersand seals.
. Referto page20-99fortherearwindowwiper motor removaland section23 for the high mount brakelight removal.
HINGESPACEN HINGEPLATE
('97- 99 models) ('00model)
HINGESPACERS
REARSPOILEB HARNESS
SPACER TRIM
{'99 00 models)
HARNESS
TRIM 6x1.0mm
9.8 N.m {1.0kgl.m,
7.2 tbt.ft)
WASHER STBIKER
REARSPOILER
SPACER
('97- 98 models)
s
RAFWINDOW
SEAL WIPERMOTOR
BASEPLATE
REARWINDOW
WIPERUPPER
CAUTION COVER
LABEL
MOTORBASE
PLATESEAL
/= PIVOTNUT
FEAR TIME 4WD
EMBLEM
GLASSPROTECTOR
{cont'd)
RearHatchGlass
Disassembly (cont'dl
and Reassembly
NOTE:Beforeinstallingthe rear spoilerspacer,harnesstrim. cautionlabel,real time 4WD emblem and glass protector,
cleanthe rearhatchglassbondingsurfacewith a spongedampenedin alcohol.
>: Alignment mark locatioos

A>
l r\,
ALIGNMENT
_\ |
w l :
MARK
f \
ALIGNMENT HARNESS
MARK TRIM
Center line
A
lnside:
REARSPOILERSPACER
Outside: Centorline
o o o O
REARSPOILER
SPACER
{'97 98 models)
SPOILER
REAR SPACEBS
SPACERS ('99 00 models)
{'99 00 models)
20- 8 0
www.emanualpro.com
Adjustment
NOTE:
. After adjustingthe tailgatedoor,adjustthe rearhatchglass.
. Loosenthe strikermountingboltsslightly.
. Removethe rearspoiler,and removethe supportstrutfrom body side.
1. Loosenthe rearhatchglassmountingnuts.
2. Adjustthe rearhatchglassso thereare equalgaps betweenthe rearhatchglass,the taillights,and the tailgatedoor.
NOTE:lf necessary,loosenthe rear hatchglasshinge mountingnuts and move the rear hatchglassbackwardor for-
ward to fit the rearweatherstripand tailgatedoor weatherstrip.
REARHATCI{
GLASSHINGES
REARHATCHGLASSHINGE
MOUNTINGNUT MOUNTINGNUT
6x1.0mm 6x1.0mm
9.8 N.m (1.0kgf.m, 9.8N.m 11.0kgtm,
7.2 tbt f 7.2 rbf.ftt
Removethe rearedge
otthe headliner
(seepage20-44).
Taillight side: Tailgate door side:
About
7mm
1o.27in.l
NOTE:Adjustfor equalgaps
betweenthe right and left. I
REARH ATCHGLASS
(cont'd)
www.emanualpro.com
20-81
RearHatchGlass
Adjustment(cont'dl
3 . After adjustingthe rearhatchglass,tightenthe rear hatchglassmountingnuts,and installthesupportstrut.
4 . Adjustthe strikeralignment.
NOTE:
. Move the strikerfore or aft to makethe rearhatchglassfit flush with the tailgatedoor'
. Move the strikerright or left until it's centeredin the rearhatchglasslatchas shown.
REARHATCH REARHATCHGLASS
GLASS LATCH
STRIKER
6x1.0mm
9.8 N.m (1.0kgt'm,
7.2tbl.ftl
NOTE:When equalizing the gap between

the tailgatedoor and rear hatch glass,do not
dglorm the rear hatch glass.
TAILGATEDOOR
5. Tightenthe strikermountingbolts.
6. Recheckthe rearhatchglassalignment.and makesurethe glassopensproperly,and lockssecurely.
7. Installtherearspoiler.and adjustit.
NOTE:Adjustthe rearspoilerso
thereare four equalgaps
betweenthe rearspoilerand REARSPOILER
the body.
REARHATCHGLASS
8. Checkfor water leaks.
NOTE: Do not squeezethe tip of the hose.
www.emanualpro.com
20-82
RearWeatherstripReplacement
W h e n i n s t a l l i n gt h e r e a rw e a t h e r s t r i pa,l i g n t h e a l i g n - '98 - 00 modols:
ment mark of the rear weatherstripto the body flange
notch.
NOTE:
. Makesurethereare no wrinklesin the weatherstrio.
. T h e s t e e l c o r e i n t h e r e a r w e a t h e r s t r i pc a n n o t b e
restoredto it originalshapeonce it is bend. Replace
the rearweatherstripwhen the steelcore is bent.
. Apply sealantto the areasindicatedby arrows.
. Checkfor water leaks.
Sealant: CemedineP/N 08712- 000i1,or equivalont
SEALANT
WEATHERSTRIP
'97 model:
area.
Sealing
Sealingarea.
BODY
FLANGE
REAR
WEATHERSTRIP
WEATHERSTRIP
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Moldings
RoofMoldingReplacement
CAUTION:
. Whn prying with a {lat-tip screwdriver,wrap it whh protective tape to prevent damage
NOTE:
. Takecarenot to scratchthe body.
. The steelcore in the roof moldingcannotbe restoredto it originalshapeonce it is bend.Replacethe roof moldingwhen
the steelcoreis bent.
. Startingat the front, carefullypry off the roof molding.
>: Clip locations

A>,2 B>,3
ROOFMOLDING
Installationis the reverseof the removalprocedure. STEELCORE
NOTE:
. Takecarenot to damagethe windshieldmolding.
. Makesurethe roof moldingis installedsecurely.
www.emanualpro.com
20-84
DoorMoldingsReplacement
CAUTION:
. Put on gloves to protect your hands.
. When prying with a flat-tip scrowdriver,wrap it with protstive tape to provent damag.
NOTE:
. Takecarenot to scratchthe body.
. Be carefulnot to damagethe front and reardoor moldings.
Adhesive aleas,
Adhesivearea. FRONTDOOR REARDOOB
MOLDING MOLDING
>: Clip locations,14 a: Plasticnut location, 1
(cont'd)
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20-85
Moldings
Door MoldingsReplacement(cont'd)
It the old molding is to be reinstalled: 7 . G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g sa s
snown,
The following materialsand tools are requiredto repair
t h em o l d i n g . N : Adlesivetapelocations
NOTE:Followthemanufacturer's
instructions. Forwerd L
Materials:(Reference) 25 mm {0.98in.l
8 2 0 m m 1 3 2 . 3i n . )
. Striperemover
3M 08907
. Stripeadhesiveremover 45 mm
( 1 . 8i n . l
3M 08908
. Adhesivetape FRONT 200 mm 125mm 30 mm
3M SuperAutomotiveAttachmentTape MOLDING {4.92in.) { 1 . 2i n . }
(7.87in.)
G l u eo n t h e r i b
area,
Tools: 26 mm (1.0in.) 440mm 117.3in.l
. Protectivetape . Film
. Knifeor Cutter . Plasticputty knife
. Spongeor Shoptowel . Alcohol
. Infrareddryer
35 mm 125mm
CAUTION: Put on gloves to protect your hands, {1.4in.) {4.92in.) REARDOOR
MOLDING
1. replaceany damagedclipson the mold-
lf necessary,
ang. (Front/rear end)
Width:5 mm
2. Apply the striperemoverevenlyto the bondingsur-
faceof the body and molding.
3. Coverthe bondingsurfaceof the body and molding

with a film, then heatto 104- 122"F(40- 50'C)for 5
- 10 minuteswith an infrareddryer.
NOTE: Use care when heatingto preventdeforma-

tion of the body and molding.
4. Carefullyscrape the adhesivetape with a plastic

putty knife.
For removalof adhesivetape residue,follow-upwith

stripe adhesiveremover,then scrapethe adhesive t'. Heatthe bonding surfaceof the door and molding
tape with a plastic putty knife. with an infrareddryer.
Door: 104- 140'F(40- 60'C)
Removethe protectivetape,then cleanthe bonding Molding:68 - 86'F (20- 30'C)
surfacewith a spongedampenedin alcohol.
NOTE:Use carewhen heatingto preventdeforma-
NOTE:Makesurethe bondingsurfaceis keptfree or tion of the molding.
water,oil and grease.
A l i g n t h e m o l d i n gw i t h t h e c l i p l o c a t i o n sa, n d s e t
the molding. Lightly push on the molding until its
edgeis fully seatedon the adhesivetape.
NOTE: Oo not spray water on the molding within

the first 24 hoursafterinstallation.
all removedparts.
1 0 . Reassemble
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Side Sill Panel
Replacement
NOTE:Takecarenot to scratchthe body.
>: Cliplocations >: Screwlocations,4

A>.7
NOTE: Loosenthe screw,

then removethe lowerclip Remove the side clips from the body
usinga clip remover, by turning them 45'
SIDE CLIP
NOTE:When removingthe side

sill panel,the sideclipswill
stay in the body.
S I O ES I L L P A N E L
Remove the lower clips,
then remove the side sill panel
by sliding it forwatd.
To installthe side sill panel,removethe sideclipsfrom the body,installthem on the side sill panel,then installthe sidesill
Danelon the vehicle.
NOTE:
. Takecarenot to twist the sidesill panel.
. lf necessary,
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20-47
SpareTire Gover
EmblemInstallation
Hard spare tire cover {for some models}:
Apply the emblemwhere shown.
NOTE:
. Beforeapplying,cleanthe sparetire coversurfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface
Attachment Point lRferencel:

U n i t :m m ( i n . )
Honda/CR-vemblem:
APPLICATION
TAPE HONDAEMBLEM
CR.VEMBLEM
SPARETIRECOVEB
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20-88
Fenderwell
FrontWheelwellProtector InnerFenderReplacement
Replacement
NOTE: Takecare not to scratchthe body.
NOTE:
a Take care not to scratchthe front wheelwell protector Removethe front wheelwell protector,
and body.
. Use a T30 Torx bit to remove the Torx screw. >: Screw locations,4 >: Clip locations,
>: Screwlocations
a >,3 B > ,1
A\
s))pp> ffi
)fl(
Y]
/ \ l l#
6'thp I sv.l/) D
,,-C\ 6x1.0mm
9.8Nm(1.0kgf.m, :rl
Y/ 7.2 tbf.ft)
>: Clip locations,

NOTE: Beforetemoving the
A I frontwheelwellProtector,
the screwfrom the front
remove
4t I bumperand lowerthe front
wt I
bumper.
a l
INNER FENDER
NOTE;lf necessary,
Installationis the reverseof the removalDrocedure.
NOTE:lf necessary,
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20-89
Fenderwell
RearWheelwellProtector FuelPipeProtectorReplacement
Replacement
NOTE: Take care not to scratchthe body.
NOTE:
. Take care not to scratch the rear wheelwell protector Removethe rearwheel (seesection18).
and body.
. Use a T30 Torx bit to remove the Torx screw. >: Cliplocations,3
/ll
>: Screw locations
a>,3
I ,.{\
B>,I
6x1.0mm
qK 1l
6him"
Y/
l FY-./),@ 9.8 N.m {1.0kgl.m.
7.2 rbtft)
>: Clip locations

A> , 5 B > ,1
YnTn | |
/'d)Ul | +['Tl+l
\=lHl | -_H_l removinsthe
tlrflJ
- | INoTE:Before
| lclip.remove
thescrew
from the rearbumperand
lowerthe rearbumper,
lnstallationis the reverseof the removalDrocedure.
NOTE:lf necessary.
NOTE:lf necessary,
20-90
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RearAir Outlet Replacement
NOTE:Takecarenot to scratchthe body.
Removethe rearbumper(seepage20-74).
>: Cliplocations,
4
Tt-
A\
-T[-r
Installation
is the reverseof the removalDrocedure.
www.emanualpro.com
20-91
Openers
FUELFILLOOORLATCH
page20'96
Replacement,
HOODRELEASEHANDLE
page20'95
Replacement,
HOODLATCH
page20'95
Replacement,
FUEL DOOROPENER
CABLE
Page20 94
Replacement,
HOODOPENERCABLE FUELFILLOOOROPENER
page20'93
Replacement, Page20_96
Replacement,
www.emanualpro.com
20-92
HoodOpenerCableReplacement
NOTE:
. Takecarenot to bendthe openercable.
Remove:
. Frontwheelwellprotectorand innerfender{leftside,seepage20 89}
. Frontgrille(seepage20-77)
. Kickpanel(leftside.seepage20-411
>: Clip locations,3
'.--)r I
@l
HOODLATCH
(seepage20-95)
t"
HOODRELEASE
HANDLE
(seepage20 95)
Routethe opener
cablethroughthe
hole in the body.
NOTE:
. lf necessary.
. Makesurethe hood openercableis routedand connectedproperly.
. Makesurethe hood opensproperly.
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Openers
FuelFillDoorOpenerCableReplacement
NOTE:
. Takecare not to bendthe openercable.
Removethe followingparts,then pull the carpetback,as necessary(seepage20-45),
a Kickpanel(leftside.see page20-41) Cargoareafloor and cargostoragebin (seepage 20-

Centerpillar lower trim panel (left side,see page 20- 43)
41) a Reartrim panel{seepage20-42)
Frontsidetrim (leftside,seepage20-41) Rearsidetrim panel(leftside,see page20-421
Rearseat(leftside,seepage20-63) a Rearsidetrim (leftside,see page20-41)
>: Clip locations

A>,6 B>,1 c>,1
@lRlg FUELFILLOOORLATCH
(seepage20-96)
FUELFILLDOOROPENER
{seepage 20-96)
NOTE:
. lf necessary,
r Makesurefuel fill door openercableis routedand connectedproperly.
. Makesurethe fuel fill dooropens properly.
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Hood ReleaseHandleReplacement HoodLatchReplacement
NOTE:Takecarenot to bendthe openercable. NOTE:Takecarenot to bendthe openercable.
Removethe left kickpanel(seepages20-41). Removethe front grille (seepage20-77).
>: Eoltlocations.2 >: Boltlocations,3
6x1.0mm 6x1.0mm
9.8 N.m {1.0kgl.m, 9.8 N.m {1.0kgf.m,
7.2 tbl.tll 7.2 tbt.ftl
HOODOPENER
CABLE
{seepage20-93)
HOOOLATCH
NOTE;
. Greaseeachlocationofthe hoodlatchas indicated
by the arrows.
. Makesurethe openercableis connectedproperly.
Installationis the reverseof the removalprocedure. . Makesurethe hood locksproperly.
. Adjust the hood latchalignment(seepage20-76).
NOTE:Makesurethe hood opensproperly.
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20-95
Openers
FuelFillDoorOpenerReplacement Fuel Fill Door Latch Reolacement
NOTE:Takecarenot to bendthe openercable. NOTE:Takecarenot to bendthe openercable.
Removethe leftfront sidetrim (seepage20-41). Removethe rear speakercover and rear speakerfrom
the left rearsidetrim panel(seepage20-42).
>: Boltlocstions.2
>: Boh locdions, 2
5x1.0mm
9.8N.m (1.0kgf.m, 6x1.0mm
7.2 tbt.ftl 9.8 N.m (1.0 kgf.m, FUELFILLDOORLATCH
7.2 tbf.ft)
FUELFILLDOOR
OPENERCABLE
(seepage 20-94)
FUELFILLDOOR
After installing,checkfor
a flushfit with the body.
FUEL DOOROPENER
CAELE
(seePage20,94)
FUEL FILL LATCH

Removethe fuel fill door latch
by turningit 90'
is the reverseof the removalprocedure.

Installation Installationis the reverseof the removalprocedure.
NOTE: NOTE:Make sure the fuel fill door opens properly

. Makesurethe openercableis connectedproperly. and lockssecurely.
. Makesurethe fuel fill door opensproperly,
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20-9 6
Wiper/Washer
REARWINDOWWIPER
ARM and MOTOR
WINOSHIELD WIPERARMS Replacement,page20 99
and LINKAGE Adiustment,page20 103
Adiustment,Page20-103
WASHERRESERVOIN
page20 99
Replacement, WASHERTUBE
page20-100
Replacement,
Wiper/Washer
WindshieldWiperArmsand LinkageReplacement
CAUTION: Put on gloves to protoct your hands. 3. Disconnectthe connector,remove the bolts, then
removethe windshieldwiper linkageassembly.
NOTE:Takecarenot to scratchthe hood and body.
>: Bohlocations,3
1. Removethe windshieldwiper arms. 6x1.0mm
9.8 N.m (1.0kglm,
2. Removethe clips,then removethe cowl cover. 7.2 tbt.fr)
>: Cliplocations
A>.9
a. Pryout the annerclip. b. Removethe clip.
INNERCLIP
/G
SHOP
TOWEL
"rr/ &
(Cowlcoverside) 4. S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d -
shieldwiper motor.
B>.8
NOTE:Scribea line acrossthe link and windshield
ql wiper linkageto show the originaladjustment.
>: Bohlocations,
3
NUT
6x1.0mm 10 x 1.25mm
8 N.m 10.8kgf.m, 18 N.m 11.8kgf.m,
5.8 lbf.ftl 13 tbf.ftl
SPRING
WINDSHIELD WASHER
WIPERARMS
NUTS
'10x 1.25mm
18 N.m 11.8kgf.m.
13 tbf.ftl s}@
1ffi,
/Y{
' L|NK
/
WINDSHIELD
WIPERLIN(AGE WIPERMOTOR
NOTE:
. Makesurethe connectoris connectedproperly.
. lf necessary. replaceany damagedclips.
. I n s t a l lt h e w i n d s h i e l dw i p e r a r m s a s d e s c r i b e d
on page20-103.
COVER . Checkthe windshieldwiper motor operation.
. Greasethe moving parts.
2 0- 9 8
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RearWindowWiperArm and WasherReservoirReplacement
Motor Replacement
GAUTION: Put on glovesto protect your hands.
CAUTION:Put on gloves to protect your hands.
1. Remove:
NOTE;Takecarenot to damagethe rear hatchglass. . Frontgrille (seepage20-771
. Front bumper (see page 20-721
1. Removethe rearwindow wiper arm. . Frontwheel{leftside,seesection18)
. Frontwheelwellprotector(leftside,see page20-
a: Nut loc.tion!, 3 >: Scaowlocationa,2 89)
. Innerfender(leftside,see page20-89)
6x1.0mm
. Headlight(leftside,seesection23)
9.8 N.m 11.0kgt'm,
7.2 tbf.ftl
@rrc
2. D i s c o n n e ctth e w a s h e rt u b e s a n d w a s h e r m o t o r
REARWIPER connectors.
COVER REARWINDOW
>: Boltlocations, 3
WIPERMOIOR
6x1.0mm
9,8 N.m 11.0kgt.m,
7.2 tbt.ftl
SPECIALNUT
18 x 1.0mm
9 N.m 10.9kgt m, Routethe washertubes
5.r tbt.ftl to the washerteservoir
WASHER
RESERVOIR
WINOSHIELO
WASHERMOTON
CONNECTORS
NUT HARNESS / t
REAR 6x 1.0mm cLrP C-(fu
9.8 N.m {1.0 kgt.m,
\ - S(ilq
WIPERARM
?.2 tbfftl
Removethe rearwiper lowercover. l' wrsHER

s{J
D i s c o n n e ctth e c o n n e c t o r t, h e n r e m o v et h e r e a r 3. Removethe bolts, then remove the washer reser-
window wiper motor. votr,
Installationis the reverseof the removalprocedure. 4. Installationis the reverseof the removalprocedure.
NOTE: NOTE:
. Makesurethe connectoris connectedproperly. a M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d
. Installthe rea. window wiper arm as described washertubes are connectedproperly.
on page20-103. . Checkthe washermotor operation.
. Checkthe rearwindow wiper motor operation.
. Greasethe movingparts.
Wiper/Washer
WindshieldWasherTubeReplacement
NOTE: '97
model:
. Takecarenot to scratchthe relatedpartsand body.
. When removingthe clips,use a clip remover.
'fr{-------
63
Removethe followingparts. ax---
\J
. Leftfront wheelwellprotector(seepage20-89)
. Left innerfender(seepage20-89) ,.&--
>: Clip locations \7
A >,2 B>,1 c>,1 D>,1
WINDSHIELO
WASHERNOZZLES Y-JOINT
Boutethe w6shertubes
to the washerreservoir
is the reverseof the removalprocedure.

lnstallation
NOTE:
. Takecare not to pinchthe washertubes.
. lf necessary,
. Afterinstalling, (seepage20-103).
adjustthe aim ofthe washernozzles
20-100
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RearWindow WasherTubeReplacement
NOTE:
. Takecarenot to scratchthe relatedpartsand body.
Removethe followingpartsfrom the left side of the vehicle,then pull the carpetbackas necessary(seepage20-45)
. Frontwheelwellprotector(seepage20-89) . Reartrim paneland rearsidetrim panel(seepage20-

. Innertender(seepage20-89) 42J
. Kickpanel(seepage20-4't) . Rearsidetrim (seepage20-41)
. Centerpillarlowertrim panel(seepage20-41) . Rear hatch glass support strut (body side, see page
. Frontsidetrim (seepage20-41) 20-7Al
. Rearseat(seepage20-63) . Ouarterpillartrim panel(seepage20-421
a Cargoareafloor and cargostoragebin (seepage20- o Cargoarealight (seesection23)
43) . Headliner(rearedge,seepage20-44)
>: Clip,harnesscu3hionlocation3
A > ,1 B > ,1 c>,3 D>,12 GROMMET
el4
@s_l GROMMET
Routethe washert!be
underthe wire harness
WINDSHIELD
WASHEBTUBE
Routethe washertubes
to the washerreservoir
wasnerno2zre.
WASHEB
RESERVOIR
wrNoow
TUBE
WASHER
REARWINDOW
WASHERMOTOR
(cont'd)
Wiper/Washer
RearWindow WasherTubeReplacement(cont'dl
REARWINDOW
WASHERNOZZLE GSOMMET
\
t
"'..--a
i;r.
REARWINDOW
WASHERTUBE
Routethe washertube
undorthe wire harness,
Installationis the reverseof the removalDrocedure.
NOTE;
. Takecarenot to pinchthe washertubes.
. lf necessary, replaceany damagedclips.
. After installing,adjustthe aim of the washernozzle(seepage20-103).
20-102
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WiperArms and WasherNozzlesAdiustmenl
Wind3hieldWipor/Washer: RearWindow wipor/Washer:
1, Adiust the wiper arms so that their park positions \ Distance

'_\ from center from black
matchthe illustration. ru"rrr."i. ltne ceramicedge
2 7 m m ( 1 . 1i n . ) 88 mm (3.5in.)
Viow from flont io roar
GLASS
Vi6w trom roar to lront

REAR
sPo[.-ER
C.nlar lino
L
Alignto the rearwindow

2. Insert a tack into the washer nozzles.and adjust defoggergrid line.
them so that they aim at positionsA, A', B, and B'
shown in the illustration.
\ Distance from center from black

^,J;-ll\ line ceramicedge
A and A' 3,$ mm (13.5in.) 287mm (11.3in.)
B and B' 122mm (4.80in.) 352mm (13.9in.)
Sub-frame
Sub-frameTo.que Sequence:
CAUTION: After loo3eningthe sub-framemounting bolts, be sure to replacethem with now ones.
REANCROSS
BEAM
10 r 1.25mm
49 N.m 15.0kg{.m, 12 x 1.25mm
36 tbt.ftl 74 N.m (7.5kgtm.
54 tbf.ft)
SNFFENER
BOLTS
1 l x 1 . 5m m
89 N.m 19,1kgt m,
66 tbt ftl
Replace.
20-104
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FrameRepairChart
Top view:
U n i t :m m ( i n . )
0: Innerdiameter
{4.021 t1.19}
lm 302
tr.rr!9$I
POtt{T
POINT'
POINT hl
SECTIONDD
20-106
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2&2 t111.11
I POINTn
258,1{10r.7}
32A7 1129.11
(cont'd)
FrameRepairChart
(cont'd)
Sideview:
U n i t :m m ( i n . )
0: Innerdiamete.
POINTd3
o15 {0.591For TrensmissionMount
z
d15 10.591
For Trrnsmi3don
Mount
POINTd1
t13 10.5'llFor Transmb3ion
Mount
POINTel
130 POINTh1
613 10.51)For Transmirsion
Mouni
t13 {0,511For Engin6 Mount
M10 x Pl.25
t13 10.51)For Uppcr Arm
.25
POINT
,1710.67)
Fof Re.r Beam
o16 10.631
LocateHole t5011.97| Locrt. Hol.
Damper POINT
Lower Bushing
o12 (0.,171
For Right Front Stop Point
POINTc1 t17 10.671
Fo. R..r
612 {0.47}For Left Front Stoo
b2
t12 {0.47}For Right Front Stop For Rcar Bo.m
r'17 10.671
POINTc2
r12 {0.47)For Left Front StoD
o11 (0.{31For EngineMount
20-108
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POlNTx.y / I
'sad
POINTm3, m4
FuelTank Strap Poinr
2700.5(106.32) SECTIONBB
RearDamoer Center
Upper Arm
M12 x P1.25
POINTn
I
FOINT
\-
.df
ql
ol
o2010.8|Locate Hole
rg (0.3)Fuel T
Strap Center
For RearCros3Beam
LocateHole
For ReerCross Beam
271,1(10,6.9)
POINTw
POINT 3, s1
ForTrailingAim
o14 {0.551
POINT v
Bear Damper Lower
Bushing Point
Heaterand Air Conditioning
Heater ...........21
NOTE:Section21 ("Heater")is includedin section22.
......'..'..
Air Conditioning '.'22'1
SYSTEM(SRS}
RESTRAINT
SUPPLEMENTAL
This model has an SRSwhich includesa driver'sairbagin the steeringwheel hub, a passenger's airbagin the dashboard
abovethe glove box ('97,00 models).and seat belt tensionersin the seat belt retractors('98- 00 models).Information
necessaryto safelyservicethe SRSis includedin this ServiceManual.ltems markedwith an asterisk(*) on the contents
pageinclude.or are locatednear,SRScomponents.Servicing,disassembling or replacingtheseitemswill requirespecial
precautionsand tools,and shouldonly be done by an authorizedHondadealer.
@
. To avoid rendering the SRS inoperative, which could lead to personal iniury or death in the event of 8 severe frontal
a collision, all SRSservicework must be performed by an authotized Honda dealer.
lmproper service procedures, including incorrect removal and installation of the SRS, could lead to personal iniury
causedby unintentional deployment of the airbags ('97 - 00 models),and seat belt tensioners 138 - 00 models).
Do not bump the SRS unit. Otherwise, the system may fail in case of a collision, or the airbags may deploy when the
ignitionswitch is ON {lll.
SRS eleqtricalwiring harnessesare identified by yellow color coding. Relatedcomponents are located in the steering
column, front console,dashboard,dashboardlower panel, and in the dashboard above the glove box. Do not use elec-
tricaltest equipment on thes cilcuils.
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Air Conditioning
Heater Control Panel

Reofacement ,.,...,,.,..,.,.,,22-46
Blower Unit
Replacement ..................
22-46
Overhaul...........,,,., .......-.22-17
Evaporalor
ReDlacement ...,.,.,..,......,22-4A
Overhaul................ .........22-19
A/C Filter
Replacement ..................22-50
*HeaterUnit
ReDfacement ..................22-50
Overhaul..,.,..,.,...,.. .........22-52
TemperatureControl
Adiustment ....................22-53
A/C ServiceTips and Precauiions............-....-....
22-54
A/C SystemTorqueSpecifications ....................
22-55
A/C System Service
Performance Test ......,...22-56
PressureTestChart .-.....22-5a
Recovery..............,. ...-.-...22-59
Evacuation -...........-........22-60
Charging................ .......-.22-61
LeakTest ........................22-61
Compressor
Repfacement ..........-.......22-62
flfustratedIndex .....,.......22-64
Cfutchfnspection .........,.22-65
CfutchOverhaul ............-
22-66
ThermafProtectorRep|acement................... 22-68
RefiefValveReplacement..............................
22-68
A/C ComoressorBelt
Adiustment ....................
22-69
Condenser
Repfacement .,.....,,.,..,.,..22-70
'Read SRSprecautionsbetore working in this area.
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SpecialTools
Rel. No. I Tool Number Description Oty I PageRelerence

.o 0 7 J G G- 0 0 1 0 1 0 A
BeltTensionGauge 1 22-69
6, 07sAz - 001000A BackprobeSet 2 22-33,36,37
@ 07947- 6340300 DriverAttachment 1 22-66
@ 07965- 6920500 Hub AssemblyGuideAttachment 1 22-61
* Includedin the BeltTensionGaugeSet,T/N 07TGG- 001000A
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22-2
ComponentLocation
lndex
EVAPORATOR
Replacement,page 22-48
Overhaul,page22-49
A/C PRESSURE SWTTCH
When the refrigorantpressureis below 200 kPa12.0kglc.r|r,
28 psi) or abov 3,200kPa(32 kgflcmr,455 psi),the AJCpressure
switch opensthe circuit to the Ay'Cswitch and stops the air
SERVICE
VALVE conditioningto protectthe compressor.
ILOW-PRESSURE
SIDE}
,
[\,
CONDENSER
-il
SERVICEVALVE
IHIGH-PRESSURE
SIDEI
Clutch Inspection,page 22-65
ClutchOverhaul,pago22-66
Thermal ProtectorReplacement,page 22-68
ReliefValve Replacemnt.page 22-68
(cont'd)
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ComponentLocation
lndex (cont'dl
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,and proceduresin the SRS
BLOWERUNIT
Ovethaul,page22 47
/alowenruoronl
page
\Test, 22-16 /
RECIRCULATION
EVAPORATOR CONTROLMOTOR
Feplacement,page22-48 page22 42
Replacement,
Overhaul,page22,49 lest, pag.e22 42
HEATERUNIT
page2250
Replacement,
page2252
Overhaul,
VALVECABLE A/C FILIER

Adjustment,page 22-53 Replacement.page 22-50
RECIRCULATION
CONTROLSWITCH
a/c swtTcH
REARWINDOW
DEFOGGER
MODE
MOTOR SwlTCH
page22-41 See section23
Replacement,
Test,page 22-41
MODECONTROL
DIAL
HEATERCONTROL
PANEL
CONTROL
Replacement,page 22 46
swtTcH
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22-4
SLOWERMOTORRELAY,
RADIATORFAN RELAY.
CONDENSER FAN REI-AY,
COMPRESSOR CLUTCHRELAY
(Locatedin the undeFhoodfuse/relay
box)
Test. page 22-45
CONDENSER
FAN 2P CONNECTOB
RADIATORFAN
2P CONNECTOR A/C PRESSURE
SWITCH
2P CONNECTOR
COMPARTMENT
WIREHARNESS
1PCONNECTOR
{cont'd)
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22-5
Component Location
Index(cont'dl
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
CONTROLMOTOR
BECIRCULATION
4P CONNECTOR
EVAPORATOR TEMPERATURE
SENSOR POWERTRANSISTOR
Tesl, page 22-44 3P CONNECTOR
AIR MIX CONTROLMOTOR

Replacement, page22-43
lest, page 22-13
BLOWERMOTOB
2P CONNECTOR
BLOWERMOTORHIGHRELAY
Test, page 22-45
HEATERSUB.HARNESS
7P CONNECTOR
DASHBOARDWIREHARNESS
HEATERCONTROLPANEL
8P AND 2OPCONNECYORS
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22-6
Description
The air conditionersystemremovesheatfrom the passengercompartmentby circulatingrefrigerantthroughthe system

as shown below.
High'temperature/ High-temperature/ High-temperature/

h i g h - p r e s s u rgea s h i g h - p r e s s u r lei q u i d h i g h - p r e s srue l i qu i d
r r a p so e o n s ,
and removes
Suction and compression Radiationof heat motsture
Il-
coMpREssoR coruoerusenl* necetve
Lessmoisturized More liquidified
low-pressurevapor row-pressurevapor
Absorption of heat
EVAPoRAToR
(-l EXPANSToN
vAL
EVAPORAYOR
SUCTIONLINE
tLow-PRESSURES|OEt
LIOUIDLINE
CONDENSER
DISCHARGELINE
IHIGH.PRESSURESIDEI
This vehicleusesHFC-I34a(R-l34a)refrigerantwhich does not containchlorofluorocarbons.

Pay attentionto the follow-
ing serviceitems:
. Do not mix refrigerantsCFC-12(R-12)and HFC-l34a(R-134a). They are not compatible.

. Use only the recommendedpolyalkyleneglycol (PAG)refrigerantoil (SP-10)designedfor the R-134acompressor.
Intermixingthe recommended(PAG)refrigerantoil with any other refrigerantoil will resultin compressorfailure.
. Afl Ay'Csystemparts(compressor, dischargeline.suctionline,evaporator,condenser.receiver/dryer, expansionvalve,
O-ringsfor joints)haveto be properfor refrigerantR-134a.Do not confusewith R-12parts.
. Usea halogengas leakdetectordesignedfor refrigerantR-134a.
. R-12and R-134arefrigerantservicingequipmentare not interchangeable. Use only a recovery/recycling/charging
station
that is U.L.iistedand is certifiedto meetthe requirementsof SAEJ2210to serviceR-134a air conditioning
system.
. Always recover the refrigerant R-134awith an approved recovery/recycling/charging station before disconnectingany
lVC fitting.
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22-7
CircuitDiagram
UNDER.DASH
UNDEB BOX
FUSE/RELAY
HOOD IGNITON SWITCH FUSEiRELAY
BOX
+
wHTBLK **f
/6'^'\ F;t"î I eLK/YEI
,o+trrffl- f
\_-./
COMPRESSOF
CLUTCH
RELAY
RED
BLK BLU'ryVHT
I,
m
I d I CoMPRESSOR
I I I CLUTCH
LIl
I
G401
G402
BLK/RED GRN WHT
IL^"^,Y**t,|
I,^,^,",
I CONDENSER
Btu/RED
,JC
PRESSURE
SWITCN
2 /:\
-{.-!}-
\,-/
1
Btu/yvHT
T*.'1
l l
Yl
MOTOR
r t l
BLK BLK BLK
l l l
G201
- -
G101
-
G202
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22-8
POWER
TRANSISTOR
ORNMHT
EVAPONATOR
TEMPERATURE
SENSOR
cnNj@_snN
Fg"{ GRY
PNK/BLK
NED/8LU
REO/YEL
s5v
AMD P
HOT
s coM
A I RM I X
CONTROL
MOTOB
BRN
"'"-
fi3'.Hfi|$l#i9D>
YEL/RED
GRN/YEL
VENT
B/L
I/lODE
8LU/8LK H CONT8OL
DASHLTGHTS_/4 l\r10T0R
EE|GHTNESS
< -! l_ RED YEL H/D
CONTROLLER M
YEL/BLU DEF
REAR 8RN/WHT
(l
fllf$!S,* aLurrL GRNI/VHT
RELAY
GRN/RED
8LK
O:8P coNNEcToR
n :20Pc0NNCToR
HEATER
CONTROL
PANEI- c401
c402
Troubleshooting
SymptomGhart
function (see next
system,reterto selt-diagnosjs
For electricalmalfunctionswhich are indicatedby the self-diagnostic
page).
Notetheseitemsbeforetroubleshooting a symptom.
. Checkthe enginecoolantlevel,and allow the engineto warm up beforetroubleshooting.
. Anv abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurementsneeded,use a digital multimeterwith an output of 1 mA or less at the 20 kO
rangewhen testing.
. Beforeperformingany troubleshooting procedurescheck:
- FusesNo. 47 17.5AJ,No. 55 (40A), No. 56 (20A), No. 57 (20A) in the under-hoodfuse/relaybox, and No. 17 {7.5A) in
fuse/relaybox.
the under-dash
._ GroundsNo. G101,G201,G202,G401,G4O2
- Cleanlinessand tightnessof all connectors
Symptom Sse pags
Mode controlmotor does not run, or one or more modesare inoperative.

Recirculationcontroldoor doesnot changebetweenFreshand Recirculate. 22-24
Radiatorfan does not run at all (but condenserfan runswith the AVCon).
Condenserfan does not run at all {but radiatorfan runswith the Ay'Con). 22-29
Bothfans (radiatorand condenser)do not run for enginecooling.but they both run with the A,/C
on.
Both fans do not run with the Ay'Con 22-33
Compressorclutchdoes not engage. 22-34
AJCsvstemdoes not come on (bothfans and compressor). 22-37
Both heaterand A/Cdo not work, 22-39
22-10
www.emanualpro.com
Self-diagnosis
Function
The heatercontrolpanelhasa self-diagnosis
function.
Runningthe Self-diagnosisFunction
'97 modl:
Turn the ignitionswitchON {ll),then set the mode controldial to the Vent position,and the recirculationcontrotswitchto
Recirculate{recirculation indicatorlightcomeson).Pressand holdthe recirculation controlswitchto Fresh(recirculation indi-
catorlight goes off).Continueto hold the switch;the recirculationindicatorlight will come on for two seconds.then it will
blink the DiagnosticTroubleCode(DTC)to indicatea iaulty component.lf no DTC'Sare found,the indicatorliqht will not
blinkatterthe initialtwo secondlight.
'98 - 00 models:
Set the mode controldial to the Vent position,and turn the ignitionswitchON (ll).Withinsix secondsafterturningthe igni-
tion switchon, pressthe recirculation controlswitchthe requirednumberof times dependingon the recirculation indicator
lightstatus:
. l f t h e i n d i c a t o r l i g h t i s O N , p r e s s t h e r e c i r c u l a t i o n c osnwt riot cl hf i v et i m e s .
. l f t h e i n d i c a t o r l i g h t i s O F F , p r e s s t h e r e c i r c u l a t i o n c osnwt irtoclhs i xI | m e s .
The recirculation indicatorlight will come on for two seconds,then blinkthe DiagnosticTroubleCode(DTC)to indicatea
faultycomponent.lf no DTC'Sarefound,the indicatorlightwill not blinkafterthe initialtwo secondliqht.
DTCIndicaiion Pattern{SeeDTC3}:
Rocirculation
indicator
light on
Recirculrtion
indicator
lighi off
'97 model: ,r*
/
P.essand hold th6 recircul.tion 1.5 aaa 0.3 aac
control switch
'98 - 00 modek: RECIRCULANON
Within six second3 atter the INDICATORLIGHT
ignition switch b turned ON (lll.
Prassthe rocirculationcontrol
switch the required number ol
times dependingon the r6circu-
lation indicator light striu3
MODECONTROLOIAL
Diagnostic
R6circulation
trouble Component with problsm Possiblo causc See page
indicator light
code {DTCI
'l
O n eb l i n k
Openor shortcircuit,obstructed
door,
Air mix control molor 22-12
faultymotor
2 Two blinks Elower motor Open or short circuit,faultv motor 22-14,16
Three blinks Evaporator
temperature
sensor Opon or short circuit,faulty sensor 22-20
In caseof multipleproblems,the recirculation

indicatorlight indicateonly one DTCthat is the leastnumberof blinks.
t
Resetiing the Solf.diagnosisFunqtion
Turningthe ignitionswitchOFFwill cancelthe self-diagnosis
function.After servicework, run the self-diaqnosis
function
onceagainto checkthat there is no other Droblem.
www.emanualpro.com
Troubleshooting
Air Mix ControlMotor
indicatorlight indicatesDiagnosticTroubleCode(DTC)1:A problemin the air mix controlmotor circuit.
Recirculation
The air mix controlmotor regulatesthe mixtureof cool/hotair accordingto outputsfrom the heatercontrolpanel.
Selt-diagnosiscircuit check indi-

cates a Droblem in the air mix
control motor circuil.
Chockthe air mix control moior:

1. Disconnect the air mix control
motor 5P connector,
2, Testthe air mix controlmotor
(seepage22-43).
Checkthe air mix control linkago

and doors:
1 . R e m o v et h e a i r m i x c o n t r o l
ls the air mix controlmotorOK? motor (seepage22'43).
2. Checkthe air mix controllink
age and doors for smooth
Do the air mix controllinkageand

doorsmovesmoothly?
Reolacelheair mix conlrol motor.
HEATERCONTROLPANEL2OPCONNECTOR
PNK/BLK
CheckIor a short in the wires:
1 - R e m o v et h e h e a t e rc o n t r o l
panel(seepage22-46).
body ground and the heater RED/BLU
control panel 20P connector
terminalsNo. 1, 6, 9, 17 and
18 individually.
Ropairany short in the wire(s)

betwoon th. heater co.rtrol panel
and the air mix conlrol motor.
To page22-13
www.emanualpro.com
Ftom page 22.12 HEATERCONTROLPANEL2OPCONNECTOR
Checktor a short to poweri

C h e c kt h e s a m e t e r m i n a l s f o r
voltage.
REO/8LU RED/YEL
Wire sideol femaleterminals
Repairshon lo power in the wi.e

between the heater control panel
and the air mix control motor,
(Thisdamagesthe heater control
Danel.l
Checktor an open in the wires:

Checkfor continuity between fol-
l o w i n g t e r m i n a l so f t h e h e a t e r
control panel20P connectorand
the air mix controlmotor 5P con-
nector,
zOPi 5P:
N o .1 - No.3
No.6 _ N o .4 RED/YEL
No.g _ No.2
N o .1 7 _ No.5
N o .1 8 _ N o .1

5P CONNECTOR
Repair any open in the wire{s) Wire sideof femaleterminals
betweon the heatercontrol panel
and air mix control motor.
Check toa loos wir63 or poor

connectionsrl the heater control
panel 20P connector and st the
air mix control motor 5P connsc-
tor. lJ the connections aro good,
substitute a known-good hoater
control panel, and rechock.I the
symptom/indication goes away,
..pl.ce the original heater con-
trol panel.
www.emanualpro.com
Troubleshooting
BlowerMotor Speed
indicatorlight indicatesDiagnosticTroubleCode(DTC)2: A problemin the blowermotor circuit
Recirculation
The speedof the blowermotor is controlledby signalssentfrom the heatercontrolpanel
Blower motol only runs on high NOTE: lf the blower motor does
spood position; h does not run in run at all,referto page22-16.
any othe. speodpositions.
3P CONNECTOR
POWERTRANSISTOR
Self-diagnosis circuitcheck indi-

c a t e sa p r o b l e mi n t h e b l o w e r 1
motor circuit,
2 ) 3
BLK
Chacklor.n open in the wire:

f
1. Disconnectthe power transis-
tor 3P connector.
2. Checkfor continuitybetween Wire side of femaleterminals
the No.3 terminaa l nd body
gro(1nd.
Chock for.n op.n in thc wiro

botween ihe powa. transistor
ls therecontinuity? rnd body ground, It tho wir. is
OK, check for poor ground at
G,O1 .nd G4o2.
JUMPER
WIRE
Chsckfor an opon in the wire:
'1. Connectthe No. 1 and No. 3
trminals of the power tran-
s i s t o r 3 P c o n n e c t o rw i t h a
jumperware.
2. Turn the ignitionswitch ON {ll).
Repairop6n in the wiro betwoon

tho Dower transi3tol and the
blowor motor.
HEATERCONIROLPANEL2OPCONNECTOR
Wire sideoI fgmaletrminals
Checktor an open in tho wire:
2. Disconnect the iumperwire.
3 . R e m o v et h e h e a t e rc o n t r o l 1 2 ,/1,/ 6 8 I 10
panel (seepage 22-46). 't1 12 1 3 1ia
't5 1 6 1 1 1 8 1 9 20
4. Check for continuity botween
the No. 20 terminal of the LI GRN/BLK
heatercontrolpanel20Pcon-
nectorand the No.2 terminal
o f t h e p o w e r t r a n s i s t o r3 P
connectof,
o
LT GBN/BLK
Rpairopon in tho wire betwoen
th6 oowor ttan3i3tor and th6
hoatar control oanel.
10 page22-15
22-14
www.emanualpro.com
From page22-14
Chockfor a short in the wire:

Checktor continuity between the HEATERCONTROLPANEL2OPCONNECTOR
No. 20 terminal of the heatercon'
trol panel20Pconnectorand body
ground,
2 ,/1,/l/ 6 8 9 10
11 12 1 3 1 a 1 5 1 6 1 7 1 8 1 9 20
LT GRN/BLK
R.p.ir short in the wire betwoen Wire sideof femaleterminals

th. herter control Denel snd the
oowor tranSastor.
Checkto. an open in the wire:

1. Turnthe ignitionswilchON (ll).
2. Measurethe voltage between HEATERCONTROLPANEL8P CONNECTOR
t h e N o . I t e r m i n a lo f t h e
heatercontrol panel 8P con-
nectorand body ground. 1
4 6 7 8
BLU/8LK
Repairopan in the wire betwaen

ls there batteryvoltage? tho heatsr cont.ol o.nel and the
blower motor.
Chockth6 power iransistor:

2. Reconnectthe heatercontrol
panel8P and 20Pconnectors.
3. Test the power transistor (see
page 22 44).
ls the power transistorOK?
Chec* for loo3e wires or Door oon-

neclions at the heater control
panel 8P and 20P connoctorsand
at lhe power tran3istor 3P connec-
tor. lf lhe connectiorc are good,
substituta , known-good hoater
contrcl pan6l, and rcheck.ll the
symptom/indication goes away.
replecgth6 originalheater control
oanel.
Troubleshooting
BlowerMotor
indicatorlight indicatesDiagnosticTroubleCode(DTC)2: A problemin the blowermotor circuit.
Recirculation
The speedof the blowermotor is controlledby signalssentfrom the heatercontrolpanel,
Blower motor do.3 not run at all.
Selt-diagnosis circuitcheck indi-

c a t e sa p r o b l e m i n t h e b l o w e r
motor circuit,
check rhe No. 55 (40 A) {use in

the under-hoodfuse/relaybox,
and the No. 17 (7.5A) fuse in the
under-dashfuse/relaybox.
Replaceth6 fuse(s),and rechalck.
BLOWERMOTOR 2P CONNECTOR
Check tho blowe. motor input
and output cilcuh:
1. Connectthe No. 2 terminalof
the blower motor 2P connec-
tor to body ground with a
jumperwrre.
2. Turnthe ignitionswitchON (ll). JUMPEF
w|RE
Wire side of lemale terminals

Doesthe blowermotor run? fo page 22-11
Chockthe blower moto.:

1 . D i s c o n n e ctth e j u m p e r w i r e
and the blowermotor 2P con-
nector.
the No. l terminal and body
ground.
Checktho blower motor rolay:

2 . R o m o v et h e b l o w e r m o t o r
relayfrom the under-hood
fuse/relaybox, and test it (see
page 22 45l'.
fo page 22-19
22-16
www.emanualpro.com
Frompage22-16
Check lhe blower motor high

telay:
1. Turn the ignitionswitchOFF,
and disconnecthe jumper
2 . R e m o v et h e b l o w e r m o t o r
h i g h r e l a y ,a n d t e s t i t { s e e
page22-45).
BLOWERMOTORHIGHBELAYitP CONNECTOR
BLU/BLKrF r
Checkfor rn opon in the wire: .--1 1 2 )
l. Connectthe No. 1 terminalof l | _ #
the blower motor high relay . r u u eI e l"3 1 i
4P connectorto body ground wrRE
with a iumperwire. I
Wire side of female terminals
R6pairopcn in the wire botwoen
Doesthe blowermotor run? the blower motor and the blower
motoi high relry.
Checktor an opon in the wire:

'1. Turn the ignitionswitch OFF,
and disconnect he iumper

3. Meas0rethe voltage between
t h e N o . 2 t e r m i n a lo f t h e
blower motor high relay 4P
connectorand body ground.
Repairopon in the wiro betweon

ls there batteryvoltage? the No. 17 fuse and tho blowel
motor high relay.
Checktor an open in the wire:

'1. Turnthe ignitionswitchOFF.
2. Checklor continuity between
t h e N o . 3 t e r m i n a lo t t h e
b l o w e r m o t o r h i g h r e l a y4 P
connectorand body ground.
Check for an open in the wire

between the blowar motor high
rel.y and body ground.lf the wiro
i3 OK, check fo. poor ground at
G{Ol .nd Gt|()2,
(cont'd)
To page22-18
www.emanualpro.com
Troubleshooting
BlowerMotor (cont'd)
Ftom page 22-17
BI-OWERMOTORI{IGHRELAY4P CONNECTOR
Checkfor an open in the wiro:
1 . F e m o v e t h e h e a t e rc o n t r o l
2. Checklor continuitybetween
t h e N o . 8 t e r m i n a lo I t h e
nectorand the No. 1 terminal
of the blower motor high
relay4P connector.
HEATERCONTROLPANEL8P CONNECTOR
Ropairop6n in th wira between Wiresideof femaleterminsls
tho heater control panol and tho
blowgr motor high relay.
Checklor an op6n in the wire: I{EATERCONTROLPANEL2OPCONNECTOR

Checklor continuity between the Wirc sideot femaleterminals
No. 8 terminaloI the heatercon
trol panel20Pconnectorand the
N o . 4 t e r m i n a lo f t h e b l o w e r
motor high relay4Pconnector.
Repairopen in the wire botweon

ls therecontinuhy? the heater control Daneland the
blowel motor high r6lay.
Check fo. looso wiles or oool

connoctionsat the haateacontrol
Danel8P .nd 20Pconnectorsand
at the blower motor high relay
4P connoctor. ll the connctions
are good, substitutg a known-
good h.at.r control panol, and
r.check. lf the symptom/indice-
tion goes away, replacethg origi-
nal heater contrcl panel.
www.emanualpro.com
Frcm page 22-16
Rcpbcc tho blower motor rolay.

BLOWERMOTORRELAY4P SOCKET
Ch.ck th. under-hoodtu.o/rolay

box:
Measur6the voltage betweenthe
No. 3 terminalofthe blowermotor
relay4P socketand body ground.
Chacktor an open in the wilo:

the No. 4 terminal of the
blower motor relav ,[P socket
and body ground.
Ropairopon in the wirs botwoon

ls thore batteryvoltage? th. No. 17 fu3o and th. blow6r
motol lolay.
Chacktor an opon in tho wilo:

2. Checkfor continuity between
the No. 2 terminal ot the
blower motor relay 4P socket
and body ground.
Chock tor !n opan in the wile

bstween tha blowar motor ralaY
.nd body ground. It tho wilc is
OK, chock fol poor ground at
G/Ol and G402.
Ropair opon in th. BLU/WHT

wira batwaan lho blowor motol
rohy and tho blowe. motor.
www.emanualpro.com
22-19
Troubleshooting
EvaporatorTemperatureSensor
Recirculationindicatorlight indicatesDiagnosticTroublecode (OTC)3: A problemin the evaporatortemperaturesensorcircuit.
The evaporatortemperaturesensor is a temperaturedependentresistor{thermistor}.The resistanceof the thermistor

decreases
as the evaporatoroutletair temperatureincreases.
Self-diagnosiscircuit check indi

cates a problem in the avapora-
tor tempeleture ssnsor circuit, EVAPORATOR
TEMPEMTURESENSOR
Terminalsideof malterminals
Chck the ev.porato. tempera-

ture sensor:
1. Disconnecthe evaporator
temperaturesensor 2P con-
RESISTANCE
2. Measure the resistance ko
betweenthe No. 1 and No. 2
t o r m i n a l so f t h e e v a p o r a t o r
temperature sensor.
86'F
30"c
ls the resistance
withinthe speci,
ficationsshownon the 9raph.
Checklor a short in the wire:

l R e m o v et h e h e a t e r c o n t r o l
the No.2 terminao l l the Wiresideof fema16
terminals
heatercontrolpanel20Pcon,
nectorand body ground.
Repai. short in the wir6 betwan

lhe hoater control Danoland the
evaporatoatampereturc senSoa.
fo page22.21
www.emanualpro.com
From page22-20
Chocktor an oDenin th wire:

Checkfor continuity betlveenthe
No. 2 terminalof the heatercon- 1 8 10
trol oanel 20P connector and the 11 1 2 1 3 1 a 1 5 1 6 't7 1 8 1 9 20
No.2 terminaloI the evaporator
temperaturesensor2P connoctor.
GIIN
Fopair open in the wiro between

tho heato. control penel and the
evaporatortempetatule sensor. EVAPORATOB TEMPERATURE SENSOR
2P CONNECTOR
Wire sideoI temaleterminals
1 2 ,/ l,/ 6 8 9 t0
'tl 1 2 1 3 l a t 1 5 1 6 '17 1 8 't9 20
Checkfor rn opsn in tha wiJe:

Checkfor continuity between the o
No. 9 terminalof the heatercon
trol oanel 20P connector and the +
No. 'l terminalot the evaporator
temperaturesensor2P connector, li-L:t
Ropairopen in tho wire betwegn

the heater control oanel and the
evaporatortgmpcrature sen3or.
Chgck fol loose wiros or pool

connectronsat the hoator control
oan6l 20P connector and at the
eveporator temperatura Sensol
2P connector. It the connections
are good, substitute a known-
good he.tel contlol panel, and
rechck. ll thg symptom/indica-
tion 90o3rwey, roplscethe origi-
nal heatercontrol oanel.
www.emanualpro.com
Troubleshooting
Mode ControlMotor
Mode control motol does not run.

or ono or more modesare inoDaa-
Checkthe No. 17 {7.5A) Iuse in

the under-dashfuse/relaybox.
Replacethe tus, snd iecheck.
MODECONTROLMOTOR7P CONNECTOR
Chocktor an open in th wi.6:

1. Disconnectthe mode control
motor 7P connector. 1 3 I 5
2. Turn the ignitionswitch ON (ll).
BLK/YEL
ground.
Repairopon in the wire betwoon
tho No. 17 luse and tho mode
control motor.
Checkthe mode control motor:

2. Test the mode control motor
Gee page 22 41')
.
Chock th mode cont.ol link.ge
and doors:
1 . R e m o v et h e m o d e c o n t r o l
ls lhe modecontrolmotor OK? motor (seepage22-41).
2. Checkthe modecontrollinkage
and doors for smooth move-
ment,
Do the mode control linkage

and doors move smoothly?
Replece the inod6 control motor.

Chockfor s shon in the wirs:

1 . R e m o v et h e h e a t e rc o n t r o l
2 l,/1,/ 8 I 10
panel(seepage22'46). 1 1 12 1 3 t a 1 5 1 6 1 7 r 8 1 3 20
2. Checkfor continuitybetween
BRN/WHT
the No. 12,13,14,15,16and 19
terminalsol the heater control
[E!r!
panel20Pconnectorand body YEL/RED
groundindividuaily.
ls therecontinuity?
To page22-23
NO
Repairany short in the wire(sl
between the mode control rnotoa
and the h6ater control Danel.
BLU
Ii
www.emanualpro.com
From page22-22
1 2
' V VL g l 8 9 10
Chgckfor a short to power:
Checkth6 same wires lor voltage.
't1 1 2 r s l r r l r s l 1r7e1 8 1 9 20
BRN/WHT
:L/BLU
Ropairlhort to powor in the wiio 8LU/BLX

betw6an tho mode comrol motor
end thc hoat.r cont.ol pan.l.
(ThisdamagF tha hator Gontrol
pancl.l
Wire sideot femaleterminals
Chackfor an opon in tha wiles:

2 ,/1,/l/ I I 10
Checklor continuity between the 1 1 1 2 1 3 t 1 4 t 1 51 5 1 1 1 8 1 9 20
followingterminalsoI the mode YEL/BLU BRN/WHT
control motor 7P connectorand
the heatercontrolpanol20Pcon- Kt I I
BLU/BL
nector. GRi|/YELI I
20Pt 7P. I
YEL/REDI
N o .1 2- N o .3
No. '13- No. 4
N o .1 4 - N o . 5 t -
N o .1 5- N o .6 YEL/BLUI q
No. t6 - No. 2
N o .1 9- N o .7
;f;T;T; BRN/WHT
YEL
BLU/BLK
GRN/ItEL
YI:L/FED
MODECONTROI-MOTOR7P CONNECTOR
Wire sideol temaleterminals
R.pair any opon in tho wilols)

betwaen th6 modg cortrol motor
and th. heatar control p.nsl.
Chock fo. loose wiret or pool

connections at the heat6r control
pancl 20P connector and tt the
modo control motor 7P connoc-
tor. lf tho connactions sre good,
substitute a known-good hortcr
control pan6l, and tech.ck. lf the
symptom/indication goes awayt
roplacotho original hcater @nttol
p3nel.
www.emanualpro.com
22-23
Troubleshooting
Recirculation
GontrolMotor
Rocirculation control door do6s

noi chango botwen Fresh and
Reci.culate.
Checkthe No. 17{7.5A)tuse in the

under-dashf use/relaybox.
Roplacethe fu36,and rechock.
REORCULATION
CONTROL
MOTOR
,rPCONNESTOR
Checkfor .n open in the wire: q?

1. Disconnectthe recirculation - T--- V-l
control motor 4P connector. l 1 l, r l / l 1 l
2. Turn the ignitionswitchON (ll). I BI.IUYEL
3. Measurethe voltage betlveen (v)
ground. +
Repairop6n in the wire bdtween
the No. 17 fuse and thc recircule-
tion control motor.
Check the rocirculation control

moior:
2. Test the recirculationcontrol
motor (seepage22-42).
Chock ths r.circulation control
linkag. end doori
1. Removethe recirculation con-
trol motor (see page 22,42).
2. Checkthe recirculationcontrol
linkageand door for smooth
YES
To page22-25
Do the recirculation
controllink Boprir the recirculrtion control
age and door move smoothly? linkag. or dooJ,
www.emanualpro.com
Ftom page22-24
Checktol a short in the wit6:

panel{seepage22-46)
the No.2 andNo.3terminals of
the heatercontrolpanel8Pcon
nectorand body ground indi-
vidually.
Reoaii short in tfte wir{s) birvn

the redrc{lstion conttol motor and
ihe hedter control panel.
Checkfor a shon to power:

Checkthe samewireslor voltage.
Repairshort to power in the wite

between the rocirculationcontrol
ls thereany voltage? motor and lh heator control
panel. (This demsges the heater
conlrolpanel.l
Chcktor an open in the wires:

Checkfor continuity betweenthe GRN/REO
---1
followingterminalsol the recircu'
lation control motor 4P connector
' l F I2 1 3
T
and the heatercontrol panel 8P i r l 5 1 6 I ;T;
8P: 4P:
N o . 2- N o . 4
No.3- No.2
Ropairopen in the wile(sl between ffi

1 I V I 4 I
the recirculalioncontrol motor
and the heeter cortrol Pan|. GRN/WHT
RECIRCULATION CONTROLMOTOR
,lP CONNECTOR
Check for loose wires or pool wire sideot femaleterminals
connections at the heatr control
Danel8P connoctor and .t the
rocirculation control motor 4P
connector.lf lhe connec{ionsare
good, substitule a known-good
hester control oanel, and rochock.
lI the symptom/indication goes
away, .eplace the otiginal heater
control pan|.
www.emanualpro.com
22-25
Troubleshooting
RadiatorFan
Radiator tan doos not run at sll

(but condonserfsn runs with the
A/C onl.
Checkrhe No.57 (20Alfuse in the

underhood fuse/relaybox, and
t h e N o . 1 7 1 7 . 5A ) l u s e i n t h e
0nder-dashfuserelay box.
R.pl.c. th. fur|.l, .nd r.chack.
Remove the radiator fan r6lay,

and test it {seepage22-45).
R.pllco tha r.diator frn rehy.
MDIATOR FAN RELAY4P SOCKET

Check the und.r-hood fus./r.l.y
box:
No. 2 terminalol the .adiatortan
relay 4P socketand body ground.
Chockthe radiatortan:
Connectthe No. 1 and No.2 tr
minals of the radiatorfan relay
4P socketwith a iumperwire.
Doesth6 radiatorfan run? fo page22-21
fo page22-28
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Ftom page22-26
RADIATORFAN REI-AY4P SOCKET

Ch6ckfor an open in the wire:
1. Disconnectthe jumperwire. BLK/RED
2. Disconnectthe radiatorfan 2P
3. Checkfor continuitybeNveen
the No. l terminalo{the radia-
tor fan relay 4P socketand the
N o . 2 t e r m i n a lo f t h e r a d i a '
tor fan 2P connector-
RADIATORFAN 2P CONNECTOR
Wire sideof lemaleterminals
Repai. open in the wira between

the radiatorfan .olay ,nd the radi'
atorfan.
Checklor an open in the wi.e:

Checkfor continuity betweenthe
No. 1 terminaloI the radiatorfan
2P connectorand body ground.
Check lor an open in the wir.

bturosn the radi.tor fan and body
ls therecontinuity? ground. lf ihe wire b OK, check fol
poor ground .t G2()l.
Replacethe radiator tan motor.
(cont'd)
www.emanualpro.com
Troubleshooting
Radiator Fan (cont'dl
From page 22-26
RADIATORFAN RELAY4P SOCKET

Chockfor an open in the wire:
'1. Disconnect jurnper
the wire.
2. Turn the ignitionswitchON (ll). 1
3. lleasure the voltage between 2
the No.4terrninalof the radia-
t o r f a n r e l a y 4 P s o c k e ta n d a
bodyground.
BLK/YEL
Rpairopen in th6 wire botwoon

ls there batteryvoltage? the No. 17 fuso and the radiatol
fan .elsy.
Rep.ir open in the GRN wire

botwen lhe radiator tan relay
and the PCM/ECM.
22-28
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Fan
Condenser
Condenserlan does not run at all

lbut radiator fan runs with the
A/C on).
Checkthe No. 56 (20A) fuse in the

under hoodfuse/relaybox, and the
No. 17 {7.5A) fuse in the under-
dashfuse/relaybox.
Replacethe luse(s),and .echeck.
Removethe condenserfan relay,

and test it (seepage22-45).
Replacethe condenserfan rlay. FAN RELAY4P SOCKET

CONDENSER
Checkthe under-hoodluso/relay
box:
No.2terminalof the condenserfan
relay4Psocketand body ground.
Checkthe condensff fan:

Connectthe No. 1 and No. 2 ter
minals of the condenserlan rclay
4Psocketwith a jumperwire.
Doesthe condenserfan run? page22-30
To page22 31
(cont'd)
www.emanualpro.com
22-29
Troubleshooting
CondenserFan{cont'd)
CONDENSER
FAN RELAY4P SOCKET
'1. Disconnect
the iumperwire.
2. Disconnect the condenserfan r---------t wHT
2P connector.
lr_f__l
1 2 | |
the No. 1 terminalof the con,
denserfan relay 4P socketand fT;.] |I
the No. 2 terminalof the con-
denserfan 2P connector. /Or
\j/
I
Ropairopen in the wire betwoen
G
ls therecontinuity? th condenserfan rslay and the
condensertan.
CONDENSER FAN 2P CONNECTOR
Wire sideol temaletorminals
Chechtor an open in the wire:
Checkfor continuitybetweenthe
No. I terminal of the condenser -r+-,.
1 2
fan 2P connector and body
ground. TBtK
@
Check for an open in thg wire
!
between the condenser fan and
body ground. lf the wiro is OK.
checktor poor ground .t G202.
Replacetho condensertan motor.
www.emanualpro.com
22-30
Ftorn page 22-29
FAN RELAY4P SOCKET
CONDENSER
Chockfor an open in the wiro:

1. Disconnect the iumperwire.
the No. 4 terminaloI the con-
denserfan relay 4P socketand
body ground.
Repairopcn in tho wire betwoon

the No. 17 tuse and the con-
denseafan relay,
R e p a i ro p e n i n t h e G R N w i r o
b6tw6en the cond.nser lan relay
and rhe PcM/EcM,
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22-31
Radiator Fan Switch
Both tans (radiatorand condenser)

do not run fo. enginecooling,but
they both run with the A/C on.
Checklor rn open in the wire: RADIATOBFAN SWITCH2P CONNECTOR

1 . D i s c o n n e ctth e r a d i a t o rf a n
switch2P connector.
2. Turnthe ignitionswitchON lll).
3, Measurethe voltage betlveen 1
the No.2 terminaa l nd body
ground. '.r
GRN
Repairopen in the wire between Wiresideof femaleterminals

ls there battery voltage? the radiator tan relay, the con-
densei lan .elay and the radiaior
tan swhch.

1. Turn the ignitionswitchOFF.
the No. 1 terminalof the radi-
ator fan switch 2P connector
and body ground.
Check for an open in the wire

ls therecontinuity? between the .adialor fan switch
and body glound. I ths wire is OF;
choc*tor poor g.ound at G'101.
ls the coolingsystemOK?
Replscethe radialor fan switch.
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Both Fans
Checkthe No. 17 (7.5 A) tuse in

the under-dash
fuse/relaybox.
Reolacethe tuse. and recheck.

RADIATORFAN RELAY'P SOCKET
1
Checkfor an opn in the wire: 2
1. Removethe radiatorfan relay.
2. TLrrnthe ignitionswitchON (ll). 1
the No.4 terminaloftheradia BLK/YEL
t o r f a n r e l a y 4 P s o c k e ta n d
bodyground.
Repairopen in the wire between

lhe No. 17 luse and the radiator PCMCONNECTOR
A I32PI
tan relay.
'9? model: 1 2 4 6 10 11
Checkfor an open in the wire: 12 t5 t6 17 18 r9 22 23 21
1. Make sure the A/C switch is
OFF.
GRN
2. Using a *BackprobeSet {T/N
0 7 S A Z- 0 0 1 0 0 0 A )m
, easure
the voltagebetweenthe No. 27
I20l terminalol the PCM/ECM
connectorA (32P)and body
groundwith the PCM/ECMcon-
nectorsconnected.
'98- 00 models Wire sideoI femaleterminals
[ ]:
A (32PI
PCM/ECMCONNECTOR
'98 - 0Omod6ls:
Repairopen in the wire btween

the.adiator fan ralav, the con-
denser tan rolay and the PCM/
ECM. Wire sideof femaleterminals
Checktor loosewires or poor con- * How to use the BackprobeSets

nodions at the PCM/ECMconnoc- Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multi
tor A (32P1.lf the connectionsarc meter.Usingthe wire insulationas a guide for the contouredtip of the backprobeadapter,
good, substitute a known-good gentlyslidethe tip into the connectorfrom the wire side until it comesin contactwith the ter
PCM/ECM,and recheck. It the minalend ofthe ware{seesectionl1).
symptom/indicalion goes away,
r.plrce the originalPCM/ECM.
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22-33
Troubleshooting
Checkthe No. 56 (20 A) fuse in the

underhood fuse/relaybox, and the
No. 17 (7.5A) fuse in the under
dashluso/rglaybox.
Replacethe fuso(sl,and r6check.
R e m o v et h e c o m p r e s s ocr l u t c h
relay,and test it (seepage 22 45).
Checkthe under-hoodfuse/relay
DOX:
No. 2 terminalof the compressor
clutch relay 4P socketand body
ground,
Chacklhe complessorclutch:
Connectthe No. 1 and No. 2 termi-
nalsofthe comoressorclutchrelav
4Psocketwith a jumper wire.
Doesthe comprossorclutchclick? To page22-35
To page22-36
22-34
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Ftom page 22-34
COMPRESSOR CLUTCHRELAY
ilP SOCKET
Checkfor an open in the wire:

1. Disconnect the jumperwire. -_-l RED
2 . D i s c o n n e ctth e c o m p r e s s o r tr-=--l I
clutch 1Pconnoctor. I
3. Checkfor continuity between
the No. 1 terminalof the com- I.TT
pressorclutch relay 4P socket
and the terminalol the com- @
pressorclutch1Pconnector.
I
$"f I
I
i 1 \ __---.1
1___J.RED
COMPRESSOR CLUYCHlP CONNECTOR
Wire sideof lemaleterminals
I Repairopen in the wire between

the comp.e3sor clutch relay and
the comprsssorclutch.
Inspect tha compreslor clutch
+
clearanco,the thormal protector,
and ths comDrg$or clutch tiold
coil lsee page 22-65).
I
I
.l- (cont'd)
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Troubleshooting
Compressor(cont'dl
Frcm page22-34
Ch6ckfor an open in the wire: COMPRESSORCLUTCHRELAY

1. Disconnect the jumperwire. 4P SOCKET
3, Measurethe voltage between
the No. 4 terminalot the com' 1
pressorclutchrelay4P socket 2
and body ground.
4 3
BLK/YEL
Repairop.n in the wire between
the No. l7 fu3e and the compres-
sor clutch ielay.
A I32P)
PCMCONNECTOB
Checkfor an opon in the wire:
1. Turn the ignitionswitch OFF,
then reinstallthe compressor
clutchrelay. '97 model: 1 2 6 I 10 11
2. Make sure the A"/Cswitch is '18 1 S
O F F ,t h e n t u r n t h e i g n i t i o n 12 15 1 6 1 7 22 23 21
switchON (ll).
3. Using a *BackprobeSet (T/N BLK/RED
07SAZ - 001000A),measure
the voltage betweenthe No.
17 terminal ol the PCM/ECM
connectorA (32P)and body
g r o u n d w i t h t h e P CM / E C M Wiresideof femaleterminals
connectors connected,
A {32P}
PCM/ECMCONNECTOR
38 - 00 models:
Wire sideof {em6leterminals
Repairopen in lhe wire betwoon

the compressor clutch r6lay and
the PCM/ECM.
Check tor loose wires or Door * How to use the BackDrobeSets

connections at the PCM,/ECM Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multi-
connecto. A {32P1.lf the connec- meter.Usingthe wire insulationas a guide for the contouredtip ot the backprobeadapter,
tions are good, sub3titute a gentlyslidethe tip into the connectortrom the wire sideuntil it comesin contactwith the teF
k n o w n - g o o d P C M / E C M ,a n d minalendo{the wire {seesectionl1).
rocheck. lf the symptom/indica-
tion goas away, replacthe origi-
nal PCM/ECM.
22-36
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A/C System
A/C aystem does not come on

{both fans and comDrossor).
A/C PRESSURE
SWITCH2P CONNECTOR
Ch6cklor .n open in the wire:

1. Disconnectthe A,/Cpressure
switch2P connector.
t h e N o . 2 t e r m i n a la n d b o d y
ground.
ls thereapprox.5 volts? fo page 22-38
C (31PI
PCMCONNECTOR
check tho PcM/EcM:

U s i n g a * B a c k p r o b eS e t ( T / N
07SAZ 0010004).measurethe '97 modol:
v o l t a g eb e t w e e nt h e N o . 5 t 2 7 l
terminalof the PCM/ECM connec,
t o r C ( 3 1 P )[ A 1 3 2 P )al n d b o d y
ground with the PCM/ECMcon-
nectorsconnected,
'98 - 00 models
I l:
PCM/ECMCONNECTOR
A I32P'
38 - 00 modeb:
Rop.ir open in th6 wire botweon

ls thereapprox.5volts? the A/C Dr*sure switch and the
PCM/ECM.
Check tor loo3e wires or Door * How to use the BackprobeSets

connections at the PCM/ECM Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multi-
connoctorC l3lPl lA (32Pll.It the meter.Usingthe wire insulationas a guide for the contouredtip ol the backprobeadapter,
connections arg good, 3ubdtitut gentlyslidethe tip into the connectorfrom the wire side until it comesin contactwith the ter.
a known-good PCM/ECM,and minalondolthe wire (seesection11).
recheck. ll the 3ymptom/indica-
tion go.. eway, rplaco thG origi-
nal PCM/ECM, (cont'd)
'98 -00 models
[ ]:
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22-37
Troubleshooting
A/G System {cont'd)
Frompage22-37
A/C PRESSURE
SWITCH
Checkth A/C pressureswitch:
2. Checklor continuitybgtween
t h e N o .1 a n dN o . 2 t e r m i n a l s
ofthe A,/Cpressureswitch.
Checkfor properAy'Csystempressure.
Roplecetha A/C prssureswitch.
Chocklor an opgn in thg wire:
1. Feconnectthe A/C pressure
switch 2P connector,
3. Turn the ignitionswitch ON llli.
t h e N o . 1 0 t e r m i n a lo f t h e
heatercontrolpanel20P con-
nectorand body ground.
Repairopen in the wir. botwcen

ls there approx. 5 volts? the A/C pres3urswitch and the
heater control oanel.
Check lor loos6 wiras or pool

connectionsat the heater control
Danel 20P connoctor and at the
A/C pr.ssule switch 2P connsc-
tor. lf the connectionsere good,
substitute a known-good heatar
co trol pangl, end recheck.lf the
symptom/indication goes away,
replacethe original heaterconlrol
panel.
22-38'
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Both heater and A/C do not work.
Checkthe No. 17(7.5A)fusein the

under-dashfuse/relaybox, and the
No. 47 (7.5A) fuse in the under-
hoodluse/relaybox.
nophcc ih. fur.l.l, .nd r.check.

Checktor rn open in the wiro:

panellseepage22 46).
the No. 1 terminal of the
nectorand body ground. Wiresideot femaleterminals
R.pair opan in lha wlra batw.cn

ls thero batteryvoltage? the No. 1? fuaa and tha h.ltcr
control panal.
Chgckfor an opan in th wirg:

I 2 A,/1,/ 5 8 9 10
t h e N o . l l t e r m i n a lo f t h o 1 t 1 2 1 3 1 a 1 5 1 5 1 7 1 8 1 9 20
heatercontrolpanel20Pcon-
noctorand body ground. WHT/BLU
Repsil opon in tha wi.a batwcan

ls there battery voltags? th. No. 47 tur. and tho hoitor Wiresideof femaleterminals
contlol panol.
Checkfor an opon in the wire:

Ch6cklor continuity betwoen the 2 3
No. 7 terminalof the heatercon-
trol panel8P connectorand body
{ 5 7 8
ground. BLK
Check for an opon in tho wira 0

b6{woon tho hoatar control p.nol
and body ground. It the wir. i3
OK, chsck for poor ground rt
GlOl lnd Glo2.
Check for loose wire3 or oooa

connection3at the haater control
prnol 8P and 20P connoctors. It
thc conncction3are good, substi-
tuta a known-good hater con-
trol prnol, and rechecft.lf the
symptom/indic.lion go.3 ewry,
repl.cg the original ha.ter con-
tlol oancl.
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Troubleshooting
HeaterControl PanelInput/OutputSignals
HEATERCONTROLPANELCONNECTORS
8P CONNECTOR 2OPCONNECTOR
8P CONNECTOR
Cavity lrvire colol Signal Cavity Wire colol Signal
'l DASHLIGHTSERIGHT-
BLK/TEL I G 2( P O W E R ) INPUT RED CUTPUT
NESSCONTROLLER
COMBINATIONLIGHT
2 GRN/RED RECIRCULATE INPUT RED/BLK SWITCH(ViaNo. 30 (7.5A) INPUT
fuse)
GRN/VVHT F R E S H INPUT 1 BLK GROUND OUTPUT
REARWINDOW
BLUI/EL CUTPUT 8 BLU/BLK BLOWERFEEDBACK INPUT
DEFOGGERRELAY
20PCONNECTOR
Cavity Wire color Signal Cavity Wire color Signal

'll
1 GRY AIR MIX POTENTIAL
+5V OUTPUT WHT/BLU BACKPU (POWER) INPUT
EVAPORATOR TEMPERA.
2 GRN OUTPUT 12 YEL MODEHEAT/DEF INPUT
T U R ES E N S O R
13 BLU/BLK MODEHEAT INPUT
14 GRN/YEL MODEHEAT/VENT INPUT
I C YEURED M O D EV E N T INPUT
6 PNI(BLK AIR MIX POTENTIAL INPUT to YEUBLU MODEDEF INPUT
7 17 RED/BLU A I RM I X C O O L OUTPUI
BLOWERMOTORHIGH
8 ORNrur'HT INPUT 18 RED/VEL AIR MIX HOT OUTPUI
RELAY
'19 BRNA/VHT IVIODE
MOTORGROUND INPUT
BRN SENSOR
GROUND INPUT
10 BLU,ryVHTA"/CPRESSURE
SWITCH INPUT 20 BASE CUTPUT
T GRN/BLKPOWERTRANSISTOR
22-40
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Mode ControlMotor
Replacement Test
1. Disconnect the 7P connectorfrom the mode control 1 . Disconnectthe 7P connectorfrom the mode control
motor. Removethe rod from the arm of the mode motor.
control motor, Remove the self-tapping screws and
the mode controlmotor. Connectbattery power to the No. 1 terminal, and
ground the No. 7 terminal.To avoid damagingthe
mode control motor, do not reverse power and
7P CONNECTOR
grouno.
MODECONTROLMOTOR
MODECONTROLMOTOR
2. Installin the reveGeorderof removal.After installa-

tion, make sure the mode control motor runs U s i n g a j u m p e r w i r e . c o n n e c tt h e N o . 7 t e r m i n a l
smoothlv. i n d i v i d u a l ltyo t h e N o , 2 , 3 , 4 , 5 a n d 6 t e r m i n a l si n
that order. Eachtime the connectionis made. the
mode controlmotor shouldrun smoothlyand stop.
lf the mode control motor does not run when jump-
ing the first terminal,jump that terminalagain after
j u m p i n g t h e o t h e r t e r m i n a l s .T h e m o d e c o n t r o l
motor is OK it it runs when jumping the first termi-
nal again.
lf the mode control motor does not run in step 3,

removeit, then checkthe mode control linkageand
doorsfor smoothmovement.lf they move smoothly,
reDlacethe mode control motor.
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RecirculationControl Motor
Replacement Test
1. Oisconnectthe 4P connectorand the wire harness 1 . Disconnectthe 4P connectorfrom the recirculation
clio from the recirculationcontrol motor. Remove controlmotor.
the self-tappingscrewsand the recirculationcontrol
motor, Connectbattery power to the No. 1 terminal, and
groundthe No. 2 and No. 4 terminals;the recircula-
tion control motor should run smoothly.To avoid
damaging the recirculationcontrol motor. do not
{P CONNECTOR
reversepower and ground.
CONTROLMOTOR
RECIRCULANON
lnstall in the reverseorder of removal.After installa-

tion, make sure the recirculation controlmotor runs Disconnect the No. 2 or No. 4 terminalsfrom ground;
smoothlv. the recirculationcontrol motor shouldstop at Fresh
or Recirculate.Don't cvcle the recirculationcontrol
motor for a long time.
4. lf the recirculationcontrol motor does not run in step

2, remove it, then checkthe recirculationcontrol link-
age and door for smooth movement.lf they move
smoothly, replacethe recirculationcontrol motor.
22-42
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Air Mix GontrolMotor
Replacement Test
1. Disconnectthe 5P connectorfrom the air mix con- 1. Disconnectthe 5P connectorfrom the air mix con-
trol motor. Remove the self-tapping screws, the air trol motor.
mix controlmotor and the flangecollar.
Connect battery power to the No. I terminal of the
air mix control moto., and ground the No, 5 termi-
5P CONNECTOR
nal; the air mix control moto. should run, and stop
at MAX HOT. lf it doesn't, reversethe connections;
the air mix control motor should run, and stoo at
MAX COOL.
lf the air mix controlmotor does not run, remove

i t , t h e n c h e c kt h e a i r m i x c o n t r o l l i n k a g ea n d
doors for smooth movement.
lf they move smoothly,replacethe air mix con-
trol motor.
AIR MIX
CONTROL
A
MOTOR
Installin the reverseorderof removal.After installa- Measurethe resistance betweenthe No. 2 and No. 3
tion. makesure the air mix control motor runs terminals.lt shouldbe approximately6 kOt 20%.
smoothlv.
4. Measurethe resistance betweenthe No. 2 and No, 4
terminals,lt shouldbe approximately
4.8kO:t 20%at
MAX HOT and approximately '1.2kO t 20% at lilAx
cooL.
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22-43
EvaporatorTemperature
Sensor Power Transistor
Test Test
Dip the sensorin ice water, and measurethe resistance 1 . Disconnectthe 3P connectorfrom the oower tran-
with a digital multimeter.Then pour hot water on the st$or.
sensor,and checklor changein resistance.
Carefullyreleasethe locktab on the No. 2 terminalin
Compare the resistancereading between the No. | 8nd the 3P connector,then removethe terminal and insu-
No. 2 terminals of the evaporatortemperaturesensor late it from body ground.
with the specificationsshown in the following graph;
resistanceshouldbe within the specifications.
1 2 V1 . 2 - 3 . 1 W
EVAPOBATOR
TEMPERATURE
SENSOB
No. 2 ILT GRN/BLK)
Terminalsideol maleterminals
RESISTANCE
ko
t0
50 68 86.F
10 20 30'c No.I IBLU/BLK)
Connecta 1.2- 3.4 W bulb betweenthe No, 1 and

the No,2 cavityon the 3P connectol
the 3Pconnectorto the powertransistor.

Reconnect
Turn the ignitionswitch ON (ll). and checkthat the

blowermotor runs.
a lf the blower motor runs at half soeed the oower
transistoris OK, replacethe heatercontrolpanel.
. lf ths blower motor does not run at half soeed,
reDlacathe Dowertransistor.
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22-44
Relays
Test
Thereshouldbe continuitybetweenthe No. 1 and No.3 Thereshould be continuitybetweenthe No. 1 and No. 2
terminalswhen power and ground are connectedto the terminalswhen power and ground are connectedto the
No. 2 and No. 4 terminals,and thereshouldbe no conti- No. 3 and No. 4 terminals,and there shouldbe no conti-
nuity when power is disconnected. nuitv when oower is disconnected.
,I I
t)
In P .I I
I
3
) tI r I
o Blowermotor relay
a Rsdiatorfan relay
Condenserfan relay
a Compressor
clutchrelay
. Blowermotor high relay F)'"

,2-4.._.
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22-45
HeaterControlPanel Blower Unit
'1. Removethe center panel togetherwith the heater 1 . Bemovethe evaporator (see page 22-48),
controlpaneland the audio unit (seesection20).
Disconnectthe connectors from the blower motor,
Removethe self-tappingscrewsand the heatercon- the blower motor high relay, the power transistor
trol panelfrom the centerpanel. and the recirculationcontrol motor. Remove the
w i r e h a r n e s sc l i o f r o m t h e r e c i r c u l a t i o nc o n t r o l
motor,and releasethe wire harnessfrom the clamp
on the blower unit. Removethe mountingbolts,the
mountingnut and the blower unit.
6x1.0mm
9.8 N.m (r,0 kgf.m, 7.2 lbl.ftl
6x1.0mm
9.EN.m 11.0kgf.m,7.2lbtftl
CENTERPANEL
lnstall in the reverseorder of removal. Make sure

that there is no air leakage.
3. lnstallin the reverseorderof removal.
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22-46
Overhaul
Notetheseitemswhen overhaulingthe blower unit.
. The recirculationcontfol motor. the power transistor,the blower motor high relay, and the blower motor can be
replacedwithout removingthe blowerunit.
. Betorereassembly, makesurethattherecirculation controldoorand linkagemove smoothlywithout binding.
o After reassembly,makesurethe recirculationcontrolmotor runs smoothly(sepage22-42).
o Makesurethat there is no air leakage.
RECIBCULATIONCONTBOLMOTOR
page22-42
Replacement.
m
POWEBTMNSISTOR
Test. page 22'44
BLOWER
Tost, page 22-45
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22-47
Evaporator
Replacement
1 . Recoverthe refrigerantwith a recovery/recycling/ 6. Disconnectthe connectorfrom the evaooratortem-
chargingstation(seepage22-59). oeraturesensor.and removethe wire harnessfrom
the evaporator.Removethe self-tappingscrews,the
Removethe battery. mounting bolt and the mounting nut. Disconnect
the drain hose,then removethe evaporator.
Removeeach bolt, then disconnectthe suctionand
receiverlinesfrom the evaporator.Plug or cap the
linesimmediatelyafter disconnecting
them to avoid 5xl,0mm
moistureand dust contamination, 9.8 N.m {1.0kgf.m, 7.2 lbf.ftl
II
I
RECEIVERLINE
I
o ,
-l: "
..
\
EVAPORATOR
6x1.0mm 6x1.0mm
9.8N'm(1.0kgfm, 9.8 N.m (1.0kgtm,7.2lbf.ftl
7.2 tbl.ttl
Removethe glove box (seesection20).
Removethe self-tappingscrewand the passenger's

dashboardlower cover,then removethe bolts and 7. Installin the reverseorder of removal,and note of
the glove box frametogetherwith the kneebolster. theseitems.
KNEE . lf you're installinga new evaporator,add refrig-

erantoil (SP.10)(seepage22-541.
Replacethe O-ringswith new ones at each fit-
t i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l
before installingthem. Be su.e to use the right
O-ringsfor HFC-134a (R-134altoavoid leakage.
a Apply sealantto the grommets.
a Makesurethat there is no air Ieakage.
a Charge the system (see page 22-6'll, and test its
performance(see page 22-56]-,
GLOVEBOX FRAME
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22-44
} -
Overhaul
1. Remove the filter lid. then pull out the A/C filter 6. Reassemblethe evaporatorin the reverseorder of
assembly. Makenoteof theseitems.
disassembly.
Pull out the evaporatortemperaturesensor from . Replace the O-ringswith new onesat eachfitting,
the evaporatorfins. and apply a thin coat of refrigerantoil before
installingthem. Be sure to use the right O-rings
R e m o v et h e s e l f - t a p p i n gs c r e w sa n d t h e c l a m p s for HFC-'134a (R-134a)to avoid leakage.
from the housings. . Installthe expansionvalve capillary tube with
the capillarytube in contactwith the outlet line
4. Carefullyseparatethe housings,then remove the directly,and wrap it with electricaltape.
evaporator. . Reinstallthe evaporatortemperaturesensor to
its originallocation.
lf necessary,remove the expansion valve When . Makesurethat there is no air leakage.
looseningthe nuts of the expansionvalve,use a sec-
ond wrench to hold the expansionvalve or the evapo-
rator line.Otherwise,they can be damaged.
ELECTRICAL TAPE
Replace.
Makesure there is no foreign matter stuck between
the capillarytube and outletline.
CAPILLARY
TUAE
;
EXPANSIONVALVE
,m
TEMPERATURE
SENSOR
lest, page 22-41
\!{
Y
FILTERLID I-OWERHOUSING
A/C FILTERASSEMBLY
A/C Filter HeaterUnit
1. Removethe glove box (seesection20). SRS componentsare located in this area. Reviewthe
SRS componentlocations,precautions,and procedures
Removethe glove box frame {see page 22-4A). in the SRSsection{24)beforeperformingrepairsor ser-
Releasethe wire harnessfrom the clamps on the

evaporator.Removethe filter lid, then pull out the 1. Disconnect
the negativecablefrom the battery.
,VCfilter assemblyfrom the evaporatorhousing.
2. Fromunderthe hood,openthe cableclamp,then dis-
connectthe heatervalve cable from the heatervalve
A/C FILTERASSEMELY arm. Turn the heatervalve arm to the fullv ooened
oositionasshown.
HEATERVALVE ARM
R e m o v et h e A / C f i l t e r f r o m t h e f i l t e r h o u s i n g .
Replacethe Ay'Cfilter accordingto the maintenance
schedulein the owner'smanual.
HEATER
VALVECABLE
When the engine is cool, drain the engine coolant

from the radiator(seesection10).
@ Do not remove the rldiator cap when

the engine is hot; the engine coolant is under pres-
sure and could sevo.ely scald you.
Installin the reverseorder of removal.Make sure

that there is no air leakage.
22-50
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4. Disconnectthe heater hosesfrom the heater unit. Removethe dashboard(seesection20).
Enginecoolantwill run out when the hosesare dis-
connected;drain in into a cleandrip pan. 7. Removethe evaporator(seepage22-48).
CAUTION:Enginocoolantwill damagep8int. Ouickly ll. Disconnectthe connectorsfrom the mode control

rinse any spilld engine coolant Itom painted sur- motor and the air mix control motor, and removethe
faces. wire harnessclips and wire harnessfrom the heater
unit. Remove the clip from the heater duct, then
removethe mountingnutsand the heaterunit
HEATERHOSE
IOUTLETSIDE)
6x1.0mm
9,8N.m (1.0kgt m,7.2lblft)
HEATER
UNIT
CLAMPS
Remove the mounting nut from the heater unit.

Takecare not to damageor bend the fuel lines,the
brake lines.etc.
q
Installin the reverseorderof removal.Make note of
the followingitems.
a Apply sealantto the grommets.

a Do not interchangethe inlet and outlet heater
hoses.Makesurethat the clampsare secure.
Refill the cooling system with engine coolant
{seesection10).
a Adiustthe heatervalvecable(seepage22-53).
a Makesurethat there is no air leakage.
13 N.m 11.3kg{.m,9.4lbtftl
HeaterUnit
Overhaul
1. Removethe self-tappingscrews and the heater core Pull out the heate.core. Be carefulnot to bend the
cover. inletand outlet pipesduring heatercore removal.
Pullout the grommetfrom the heatercore pipes. Reassemble the heaterunit in the reverseorder of
disassemblv.
Removethe self-tappingscrewand the pipe clamp.
HEATERCORECOVER
HEATERCORE
22-52
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TemperatureControl
Adjustment
l. From under the hood, open the cable clamp, then 5. From underthe hood.turn the heatervalve arm to
disconnectthe heatervalve cable from the heater t h e f u l l v c l o s e d p o s i t i o na s s h o w n , a n d h o l d i t .
vatvearm. Attach the heater valve cable to the heater valve
arm, and gently pull on the heatervalvecablehous-
ing to takeup any slack,then installthe heate.valve
HEATERVALVE ARM cablehousinginto the cableclamp.
HEATERVALVE ARM
HEATERVALVECABLE
From under the dash, disconnectthe heatervalve VALVECABLE

HEATER
cablehousingfrom the cableclamp.and disconnect
the heatervalvecablefrom the air mix contlol arm
Setthe temperaturecontroldial on MAX COOLwith

the ignitionswitchON (ll).
Attachthe heatervalve cableto the air mix control

arm as shown above. Hold the end of the heater
valvecablehousingagainstthe stop,then snap the
heatervalvecablehousinginto the cableclamp.
A/C ServiceTips and Precautions
The air conditionersystemusesHFC-'134a (R-134a) refrigerantand polyalkyleneglycol

{PAG)refrigerantoil*, which are not
compatiblewith CFC-12 (R-12)
refrigerantand mineraloil. Do not use R-12refrigerantor mineraloil in this system,and do
not attempt to use R-12servicingequipmenudamageto the air conditionersystem or your servicingequipmentwill
resutr.
*KEIHINSP-10:
. P/N 38897- Pl3 - A01AH:120m{ (4 fl.oz,il.2 lmp.oz)
. P/N 38899- Pl3 - A01:40 mf 11113tl.oz,1.4 lmp.oz)
Use only serviceequipmentthat is U.L.-listedand is certifiedto meet the requirementsof SAE J2210to removeR-134a
from the air conditionersystem,
CAUTION: Exposureto air conditioner refrigerant and lubricant vapor or misl can irritats eyes, nose and throat. Avoid
breathingthe air conditionerrefrigerantand lubricantvaporor mist,
lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice.
R 134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed
air.
E@ Some mixtures of air and R-13,1ahave been shown to be combustible at elevatd pressuresand can result
in fire or explosion causing iniury or property damage. Never use complessed air to pressuretest R-l3,[a service equip-
ment or vehicle air conditioner systems.
Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers.
1. Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningparts.
2. Keepmoistureand dust out of the system.When disconnecting any lines,plug or cap the fittings immediately;don't
removethe capsor plugs untiljust beforeyou reconnecteachline.
3. Beforeconnectingany hoseor line.applya few dropsof refrigerantoilto the O-ring,
4. Whentighteningor looseninga fitting,usea secondwrenchto supportthe matchingfitting.
5. When dischargingthe system,use a R l34a refrigerantrecovery/recycling/charging station;don't releaserefrigerant
into the atmosphere.
6. Add refrigerantoil afterreplacingthe followingparts.
Notetheseitemswhen handlingrefrigerantoil:
o To avoidcontamination, do not returnthe oil to the containeroncedispensed,and nevermix it with other refriger-
a n to i l s .
. lmmediatelyafter usingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption.
. Do not spill the refrigerantoil on the vehicle;it may damagethe painu if the refrigerantoil contactsthe paint,wash
it off immediately.
Condenser . 25 ml (5/6 tl.oz, 0.9 lmp.oz)
Evaporator.,................................40
m/ 11113ll.oz,l.4lmp.ozl
Lineor hose........... 10 ml (1/3fl.oz,0.4 lmp.oz)
Receiver/Dryer....... 10 ml (1/3fl.oz,0.4 lmp.oz)
25 m/ (5/6ll.oz,0.9 lmp.oz)
Leakagerepair............................
Compressor.......,..., For compressor replacement,subtract the volumg ol oil drained from the removed
compressorfrom 130 m{ (4 113tl.oz, 1,6lmp.ozl, and drain the calculatsd volume of
oif from the now comprossor:130 ml (,1113tl,oz, 1.6lmp'ozl - Volume of removed
compressor= Volume to drain from new compressor.
NOTE:Evenif no oil is drainedtrom the removedcompressor,don't drain more than
5 0 m t 1 12 1 3 l l , o z , 1 .l m
8 p . o zf)r o m t h e n e w c o m p r e s s o r .
r.sr-o.o.t
rsom r rr:0.o.,
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22-54 I
A/C SystemTorqueSpecifications
EVAPORATOR
SUCTIONLINE
SUCTIONHOSE
RECEIVERLINE A
RECEIVENLINE B
RECEIVER/ORYER
O Dischargehos to the compressor{6 x 1.0 mml ....9.8 N.m 11.0kgrf.m.7.2lbtftl
@ Condenserline to the condenser(6 x 1.0 mm)

@ Condensorline to the receiver/dryer{6 x 1.0 mm) ........ 9.8 N.m {1.0 kgf.m, 7.2 lbt.ft)
(6
O Receiverline A to the receivor/dryer x 1.0 mm) .......... 9.8 N.m {1.0kgf.m.7.2lbf.ft}
...................
@ Receiver line B to th receive. line A
O Rceivertine C to the receivorline B
@ Recoiverline C to the evaporator (6 x 1'0 mml 9.8 N'm (1.0kgf.m,7.2lbtftl
O Sustion line to the evaporatot 16x 1.0 mml
@ Sustion line to the suction hose ......31 N.m (3.2kgl.m, 23 lbf.ft)
@ Sucion hose to the qompressor(6 x 1.0 mm) .....'...'9 8 N'm (1 0 kgt'm, 7'2 lbf'ftI
@ Compressorto the compressorbracket {8 x 1.25mm) . .. 24 N.m l2.il kgf'm, 17 lbf'ft}
(10 x 1.25 mm) ................ .........il,t N'm (4.5kgt'm, 33 lbf'ft)
@ Compressorbracket to the cylindsr block
pulley to the compressor bracket (10 x 1.25 mm) ,14N.m (/r.5kgf'm,33 lbf'ft)
.....................
@ ldler bracket
@ Lock nut of the sdiusting boh to the compressor bracket 24 N'm (2./tkgt'm, 17 lbf'ft)
.........................
@|d|erpu||eytotheid|orpu||eybracket.....'..........................'.....'.....'........'....44N.m(4.5kg'
@ compressorbracketto the left front mount (12x 1.25mml ................... ............................ 59 N'm (6.0kgt'm,/l:| lbf'ft1
A/G System Service
Performance
Test
The performancetest will helDdetermineif the air con-
ditionersystemis operatingwithin specifications.
Recovory/Recycling/chargingstation
Useonly serviceequipmentthat is U.L.-listed and is cer-
tified to meet the requirementsof SAEJ2210to remove
HFC-134a (R-134a) from the air conditionersvstem.
CAUTION: Exposure to air condiiioner rtrigerant and

lubricant vapor or mist can irritate yes, nose and
throat. Avoid bre8thing the air conditioner retrige.ant
and lubricant vapor or mist,
lf accidentalsystem dischargeoccurs.ventilate work

areabeforeresumingservice.
R-134aserviceequipmento. vehicleair conditionersys-

tems should not be pressuretested or leak tested with
comDressed air.
@ some mixturs ol air and R-134ahave becn

shown to be combuslible at olsvated pressuresand can
result in lire or explosion causing iniury or property
damage. Never use compressed air to prgssure test R-
13i[a service equipment or vehicle air conditioner sys. LOW.PRESSURE
tems. SIDE
Additional health and safety information may be obtained

from the refrigerantand lubricantmanufacturers.
1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n tr e c o v e r / r e c y c l i n g /
chargingstationto the vehicle,as shown.following
the equipmentmanufacturer's instructions,
2. Insen a thermometerin the centerair vent. Determine

the relativehumidityand airtemperature.
Testconditions:
. Avoid directsunlight.
o Openhood.
. open front doors.
. Set the temperaturecontrol dial on MAX COOL,
the mode controldial on VENTand the reci.cula-
tion controlswitchon RECIRCULATE.
. Turn the A,/Cswitch on and the fan switch on
MAX.
. Runthe engineat 1,500rpm.
. No driveror passengers in vehicle
After running the air conditioningfor 10 minutes

under the above test conditions,read the deliverv
temperaturefrom the thermometerin the dashvent
and the high and low systempressurefrom the Ay'C
gauges.
22-56
www.emanualpro.com
5. To comDletethe charts:
. Markthe deliverytemperaturealongthe verticalline'
. Markthe intaketemperature{ambientair temperature)alongthe bottom line'
. Drawa line straightup from the air temperatureto the humidity'
. Marka point 10%aboveand 10%belowthe humiditylevel'
a Fromeachpoint,draw a horizontalline acrossthe deliverytemperature'
. The delivervtemperatureshouldfall betweenthe two lines'
. Completethe low-sidepressuretest and high-sidepressuretest in the sameway'
. Anv measurements outsidethe line may indicatethe needfor furtherinspection
kPa
{kst/cm')
Ipsil
29r,0
t30t
l,a0l HUMIDITY
LEVEI-
2500
(251
t3601
2000 l
l20l I kp.
t28ol | {ksf/cmz}"F 80v.
lcsil Pcl
I
1s00'l ,l0oI 85 -l 80vo
{15} | (4} | (301
DELIVERY r21or
I t57lI I
HUMIOITY
PRESSURE LEVEL
980 j
t 3oo-.J
t "r1 l
I
rlol {31 I l25lI
r14ol r13l
I I HUMIDITY
-lL200 68 J
I LEVEL
t2) | (2otI
r28r
I I
I
-.1
100 ss l
(15r
TNTAKElli' I I
PRESSURE
] |
50 -l
,to,
DELIVERY
I
I
TEMPEBATURE.t
:.] _
rsl -ll
fl j7 95 104
6g *
l25l (30) (351 (ro) fct
t2o)
INTAKETEMPERATURE
A/C System Service
PressureTestChart
NOTE: PerformanceTest is on page 22-56.
Test results Relatadsymptoms Prcbablecaus Remody

Discharge(high) After stoppingcompressor,pressure Air in system Discharge, evacuate,
and recharge
pressure6bnormally dropsto about200 kPa12.0kgtlcm,, with specifiedamount.
hagh 28 psi)quickly,and then lalls gradualty. Evacuation: seepage22-60
Charging:seepage22-61
No bubblesin sightglasswhen Excessiverefrigerantin system Discharge, evacuate,
and recharge
condenseris cooledby water with speciliedamount.
Reducedor no air flow through . Cloggedcondenseror radia- Clean
condenser tor fins Checkvoltageand fan rpm.
. Condenser or radiatorfan Checkfan direction.
not wo.king properly
Line to condensoris excossivelvhot. Restrictedflow of relrigerantin Festrictedlines
sy$em
Dischargepressure Excessive bubblesin sightglass; Insufficientretrigerantin Checkfor leak.
abnormallylow condenseris not hot. Chargesystem.
Highand low pressures are balanced . Faultycompressordischarge Replacethe comprossor.
soon after stopping compressor.Low
sideis higherthan normal. . Faultycompressorseal
Outlet ot expansionvalve is not ' Faultyexpansionvalve . Replace
frosted, low-pressuregauge indicates . Moisture in system . Discharge,evacuate,and
rechargewith specifiedamount.
Suction {low) pros, Excessive
bubblesin sightglass; Insufficiontrelrigerantin Repairthe leaks.
sureabnormally condenseris not hot. Discharge,evacuate,and
rechargewith specifiedamount.
Chargeas rquired.
Expansionvalve is not frosted, and ' Frozenexpansionvalve . Discharge,evacuate,and
low-pressure lineis not cold.Low- lMoisture in system) rechargewith specitiedamount.
pressuregaugeindicates vacuum. . Faultyexpansionvalve . Replaceth expansionvalve.
Dischargetemperatureis low, and the Frozenevaporator Run the fan with compressoroff,
air llow trom vents is restricted. then checkevaporatortempera,
ture sensor.
Expansionvalve is frosted. Cloggedexpansionvalve Cleanor replace.
Feceiver/dryeroutlet is cool, and inlot Cloggedreceiver/dryer Replace
rsw6rm (shouldbe warm during
operation).
Suction pressure Low-pressurehose and checkjoint are . Expansionvalveopentoo long Repairor roplace.
abnormallyhigh coolerthan tho temperature around . Looseexpansioncapillary
evaporator. tube
Suction pressureis loworedwhen Excessiverefrigerantin system Discharge,
evacuate,
and recharge
condenseris cooledby water. wathspecifiedamount.
Highand low-pressure are equalized Faultygasket Replace
the compressor.
as soonas tho compressoris stopped, Faultyhigh-pressure
valve
and both gaugestluctuatewhile Foreignpaniclestuckin high-
running.
Slction and dis, Reducedair flow throughcondensr, . Cloggedcondenseror Clean
charge pressutes radiatortins Checkvoltageand fan rpm.
abnormallyhigh . Condenser or radiatorfan CheckIan direction.
not workingproperly
No bubblesin sightglasswhen Excessiverefrigerantjn system Discharge, evacuate,
and recharge
condenseris cooledby waler with specifiedamount.
Suctionand dis- Low-pressure hoseand motalend Cloggedor kinkedlow- Repairor replace.
chargepressure areasare cooterlhan evaporator. pressurehose pans
abnormallylow Temperature aroundexpansionvalve Cloggedhigh-pressureline Repairor replace.
rstoo low comparedwith that around
Refrigerant
leaks Compressor
clutchis diny. Compressorshaftsealleaking Replace the compressor.
Compressor
boltls)are dirty. Leakingaroundbolt(s) Tighton bolt{s)or replace
compressor.
gasketis wet with oil.
Compressor Gasketleaking Replacethe compressor,
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Recovery
Useonly serviceequipmentthat is U.L.-listed and is cer-
tifiedto meetthe requirementsof SAEJ2210to remove
HFC-134a (R-134a)from the air conditionersystem.
Station
Recovery/Recycling/Charging
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irritate eyes, nose and
throat. Avoid brqathing the air conditioner retrigerant
and lubricant vapor or mist.
systemdischargeoccurs,ventilatework area
lf accidental
beforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersys-

tems should not be pressuretested or leak testedwith
compressedarr.
@@ some mixtures of air and R-134ahave been

shown to be combustible at elevated plessures and can
result in fire or explosioncausinginiury or property dam-
age. Never use compressed air to pressure tect R-134a
serviceequipment or vehicleair conditionersystems.
Additionalhealthand safetyintormationmay be obtained

and lubricantmanufacturers.
from the refrigerant
' 1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n rt e c o v er y l r e c y c l i n g /
chargingstationto the vehicle,as shown,following
the equipmentmanufacturer's instructions
2. Measurethe amountof refrigerantoil removedtrom

the A,/Csystem after the recoveryprocessis com-
oleted.Be sure to installthe same amount of new
refrigerantoil backinto the AVCsystembeforecharg-
inq.
A/C System Service
Evacuation
Use only serviceequipmentthat is U.L.-listed and is cer-
tified to meet the requirementsof SAE J2210to remove
HFC-134a {R-134a)from the air conditionersystem.
Recovery/Recycling/Charging
Station
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irrhate eyes,noso and throat.
Avoid breathing the air condhioner retrigerant and lubri-
cant vapor or mist.
lf accidentalsystem dischargeoccu.s. ventilate work

areabeforeresumingservice.
R 134aserviceequipmentor vehicleair conditionersys-

tems should not be pressuretested or leaktested with
compressedarr.
!@ some mixtures of air and R-134ahsvo been

shown to be combustible at elevatedpressuresand can
result in tire or explosion causing iniury ot property
damage. Never use compressed air to pressure test R-
134a service equipment or vehicle air conditioner svs-
tems.
Additionalhealthand safetyinformationmay be obtained

from the refrigerant
and lubricantmanufacturers.
1, When an A,/CSystemhas beenopenedto the atmo-

sphere,such as during installationor repair,it must
be evacuatedusing a R-l34a refrigerantrecovery/
recycling/charging
station.{lf the system has been
open for severaldays,the receiver/dryer should be
replaced,and the system should be evacuatedfor
severalhours.)
Connect a R-134arefrigerant recovery/recyclin g/

chargingstationto the vehicle,as shown,following
t h e e q u i p m e n t m a n u f a c t u r e r ' si n s t r u c t i o n s .
Evacuatethe system,
lf the low-pressuredoes not reach more than 93.3

kPa (700 mmHg,27.6 in.Hg)in 15 minutes,there is
probablya leak in the system.partiallychargethe
system,and checkfor leaks(seeLeakTest).
22-60
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Charging LeakTest
Useonly serviceequipmentthat is U.L.-listed and is cer- Use only serviceequipmentthat is U.L.-listed and is cer-
tified to meetthe requirementsof SAEJ2210to remove tified to meetthe requirementsof SAE J2210to remove
HFC-134a (R-134a)from the air conditionersystem. HFC-134a (R-134a)from the air conditionersystem.
CAUTION:Exposureto air conditionerrefrigerantand CAUTION: Exposure to air conditionor refrigerant and

lubricant vapor or mist can irritate eyes, nose and lubricantvapor or mist can irritate eyes,nose and throat.
throat. Avoid breathingth air conditionerrefrigerant Avoid breathing the air conditioner retrigerantand lubri-
and lubricant vapor or mist. cant vapor or mist.
lf accidentalsystem dischargeoccurs,ventilate work lf accidentalsystem dischargeoccurs,ventilate work

a r e a b e f o r er e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t ha n d areabeforeresumingservice.
safetyinformationmay be obtainedfrom the relrigerant
and lubricantmanufacturers. R-134aserviceequipmentor vehicleajr conditionersys-
tems should not be pressuretested or leak testedwith
Connecta R-'134a refrigerantrecovery/recycling/charging compressedarr.
stationto the vehicle,as shown.followingthe equipment
manufacturer'sinstructions. !@ some mixturos of air and R-1348 have
been shown to be combustible at olovatod pres3uras
and can result in fire or explosion causing iniury or
Station
Rcovery/Recycling/Charging property damage.Never use comprelisedair to pressure
test R-13ilaservice equipment or vehicle air conditioner
systems.
Additionalhealthand safetyinformationmay be obtained

from the refrigerantand lubricantmanufacturers.
1 . Connect a R-134arefrigerant recoverylrecycling/

chargingstationto the vehicle,as shown in the pre-
vious column,followingthe equipmentmanufactur-
er's instructions.
2. Open the high-pressure valve to chargethe system

t o t h e s p e c i f i e dc a p a c i t y ,t h e n c l o s e t h e s u p p l y
valve,and removethe chargingsystemcouplers.
S e l e c tt h e a p p r o p r i a t eu n i t o f m e a s u r ef o r y o u r
chargingstation.
Refrigerantcapacity:700 to 750 g
0.70to 0.75kg
HIGH-PRESSURE
SIDE 1.5to 1.6lbs.
21.7 to 26.5 oz.
Add the same amount of new refrigerantoil to system
t h a t w a s r e m o v e d d u r i n g r e c o v e r y .U s e o n l y S P - ' 1 0 Checkthe systemfor leaksusing a R-134arefriger-
refrigerantoil. ant leak detectorwith an accuracyof 14 g (0.5 ozl
per year or better.
C h a r g et h e s y s t e m w i t h R e q u i r e da m o u n t o f R - 1 3 4 a
refrigerant.Do not overchargethe system;the compres- lf you find leaksthat requirethe systemto be opened
sor will be damaged. (to repair or replacehoses,fittings, etc.), recoverthe
system accordingto the RecoveryProcedureon page
S e l e c tt h e a p p r o p r i a t eu n i t o f m e a s u r ef o r y o u r
22-59.
chargingstation.
5. After checkingand repairing leaks,the system must
Refrigerantcapacity:700 to 750 g
ll- 0.70to 0.?5k9
1.5to 1.6lbs.
be evacuated(seeSystemEvacuationon page22-601.
21.7 to 26.5 oz.
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22-61
Compressor
Replacement
'L
lf the compressoris marginally operable.run the 5. Removeeach bolt, then disconnectthe suctionand
e n g i n e a t i d i e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r dischargelines from the compressor.Plug or cap
work for a few minutes.then shut the engineoff. the lines immediatelyafter disconnectingthem to
avoid moistureand dust contamination,
2. Disconnect
the negativecablefrom the battery.
6x1.0mm
Recoverthe refrigerantwith a recovery/recycling/ 9.8 N.m 11.0kgf.m,7.2 lbf.ft)
chargingstation(seepage22-59).
Disconnectthe condenserfan connector.Remove

the compressorclutch connectorand the wire har-
ness clip from the condenserfan shroud,then dis-
connectthe compressorclutch connector.Remove
the mountingbolts and the condenserfan shroud,
6x1.0mm
7 N.m 10.7kg{.m,5 lbl.ftl
CONDENSER
FAN
CONNECTOR
LINE LINE
DISCHARGE
6. Removethe power steeringpump belt (seesection

17t.
7. Loosenthe pivot bolt of the idler pulleybracketand

the adiusting bolt, then remove the Ay'Ccompressor
b e l t f r o m t h e p u l l e y s .l f n e c e s s a r y r, e m o v e t h e
mountingbolts from the left front mount,then
remove the A,/Ccompressorbelt through the gap
betweenthe bodv and the left front mount.
PIVOTBOLT
10 x 1.25mm
AIUUSTING 4,t N.m (4.5 kgf.m, 33 tbf.ftl tFT
FRONT
MOUltlT
10x 1.25mm COMPRESSOR

/t4 N.m (4.5kgl.m,33 lbtftl BELI
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8. Removethe mountingboltsand the compressor. 1 0 . C h e c kt h e i d l e r p u l l e yb e a r i n gf o r p l a y a n d d r a g ,
and replaceit with a new one if it's noisy or has
excessiveplay or drag.
IDLERPULLEY
kgtm,33lbfftl
+r N.m14.5
E x 1.25mm PIVOTBOLT
2aN.m(2.,1kgf.m,
l7 lbl.ft)
10x 1.25mm
ir4 N.m{4.5kgt m, 33 lbl'ft}
BBACKET
q
lf necessary,remove the compressor bracket as fol-
lows. 1 1 . lnstallin the reverseorderof removal.Make note of
the followingitems,
. Remove the nut and the washer from the left
front mount. When tighteningthe nut to the left . lf you'reinstallinga new compressor, drainall the
front mount,makesurethe washeris set proper- reJrigerantoil from the removed compressor,and
ly on the leftfront mount as shown. m e a s u r ei t s v o l u m e . S u b t r a c tt h e v o l u m e o f
drainedoil trom 130 m/ 14 U3 fl'o2,4.6lmp'oz);
. Removethe mountingbolts and the compressor the result is the amount of oil you should drain
bracket. 12 x 1.25mm lrom the new compressor(throughthe suctionfit-
59 N.m (6.0 kgt'm, trngl.
. Replacethe O-ringswith new ones at each fit-
t i n g , a n d a p p l y a t h i n c o a t o { r e f r i g e r a n to i l
before installingthem. Be sure to use the right
O-ringsfor HFC-134a (R-134a) to avoid leakage.
. Use refrigerantoil (SP-10) for R-134aKEIHINspi-
ral type compressorsonly.
. To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
. lmmediatelyafter using the oil, replacethe cap
on the container.and seal it to avoid moisture
aDsorprlon.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint; if the retrigerantoil con-
tacts the Daint,wash it off immediately.
. Adjust the Ay'Ccompr'essorblt (see psge 22-69)
and the power steeringpump belt {see section
10x 1,25mm 17t.
art N.m (4.5 kgf'm, 33 lbfftl . Chargethe system (seepage 22-611, and test its
performance(seepage 22-56]-.
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Gompressor
lllustratedIndex
CENTER
NUT
Replace.
ARMATUREPLATE
sHtM{s)
Replace.
SNAPRINGB
Replace.
ROTORPULLEY
Inspection.page 22-65
SNAPRINGA
Replace.
FIELDCOIL
THERMALPROTECTOR
Replace.
coMPRESSOR ----------------
(Donotdisassemble.)
O.RING
Roplace.
RELIEFVALVE
RELIEFVALVECOVER
('97modelonly.)
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22-64
ClutchInspection
Checkthe plated parts of the armature plate for color . Releasethe field coil connectorfrom the holder,then
changes,peelingor other damage.lf there is dam- disconnectit. Checkthe thermal protectorfor conti-
age,replacethe clutchset. nuity, lf there is no continuity, replacethe thermal
prorecror.
Checkthe rotor pulley bearing play and drag by rotat-
ing the rotor pulley by hand. Replacethe clutch set
with a new one if it is noisy or has excessiveplay/drag.
ROTOR
NOTE:The thermal protectorwill have no continuity

above 251.6to 262.4"F1122to 128"C).When the tem-
peraturedrops below 240.8to 219.8"F(116to 104'C),
Measurethe clearancebetweenthe rotor pulley and the thermalprotectorwill havecontinuity.
the armature plate all the way around. lf the clear-
anceis not within specifiedlimits,the armatureplate Checkresistance
of the field coil.
must be removed and shims added or removed as
required,following the procedureon page 22-66. Field Coil Resistance:3.2 i 0.15 ohms at 68"F {20'C)
Cloarance:0.5 t 0.15 mm {0.020t 0.q)6 in) lf resistanceis not within specifications,

replacethe
field coil.
NOTE:The shims are availablein four thicknesses:
0.1 mm. 0.2 mm. 0.4 mm and 0.5 mm
ABMATUBE
Compressor
GlutchOverhaul
1. Removethe centernut while holdingthe armature 3. Removethe snap ring B with snap ring pliers. Be
platewith the tool. careful not to d8mage the rotor pulley and com-
pressor.
CENTERNUT
17.6N.m ('1.8kgf.m, 13lbfft)
A,/CCLUTCHHOLOER Reolace.
lCommerciallY.vailable) \
Robinair:P/N 1020,0
Ked-Mooro: P/N J37872 i SNAPRINGB
R6place.
Remove the rotor pulley from the shaft with the

2. Removethe armatureplateby pullingit up by hand. tools.Be surethe clawsot the pullerare on the back
of the rotor pulley,not on the belt area;otherwise
ARMATUREPLATE the rotor pulleycan be damaged.
sHtMls)
Replace.
za:s
(i@,
22-66
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l-
5. Removethe bolt and holder,and screw and clamp. 6. Positionthe rotor pulleysquarelyover the field coil.
then disconnectthe field coil connector.Remove Pressthe rotor pulley onto the compressor boss
the snap ring A with snap ring pliers,then remove with the specialtool. lf the rotor pulley does not
the field coil. Be carefulnot to damagethe field coil press on straight, remove it, and check the rotor
and comoressor. pulleyand compressorbossfor burrsor damage.
CAUTION: Maximum pre3s load: 39,200 kPa

(400kgf/cm,, 5,690psi)
+
Press HUB ASSEMBLY
FIELDCOIL GUIDEATTACHMENT
07966 - 6920500
CLAMP
ROTOR
PULLEY
HOLDER
GROUND
TERMINAL
7,a N.m
10.75kgt'm,
5 tbt ftl
7. Reassemblethe comDressorclutch in the reverse

order of disassembly.Make note of the following
rrems.
Installthe field coil with the wire side facing down,

and alignthe bosson the tield coilwith the holein
the compressor.
C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g
surfaceswith non-oetroleum solvent.
a lnstallnew snap ringsA and B.
a Make sure the snap rings are fully seatedin the
groove.
Make sure that the rotor pulley turns smoothly
afterit's reassembled.
Routeand clamp the wires properlyor they can
be damagedby the rotor pulley.
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Compressor
ThermalProtectorReplacement ReliefValveReplacement
1. Removethe bolt,the groundterminaland the hold- l. Recoverthe refrigerant with a Recovery/Recycling/
er. Disconnectthe field coil connector.then remove ChargingSystem(seepage22-59).
the thermalDrotector.
Removethe reliefvalvecover ('97 model),the relief
7.4 N.m (0.75kgrf.m,5lbfftl valve and the O-ring.Plug the openingto keepfor-
eign matterfrom enteringthe systemand the com-
GROUND pressoroil from runningout.
TERMINAL
O.RING
Replace.
RELIEF
VALVE
9.8 N.m {1.0hgf.m,
7.2 rbr.ftl
Cleanthe matingsurfaces.
ReDlace the thermal protectorwith a new one, and Replace the O-ringwith a new one at the reliefvalve,
apply siliconesealantto the bottom of the thermal a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e
orotector, installingit.
Removethe plug. and installand tighten the relief

valve.
Put the cover on the relief valve so that the arrow

d i r e c t sd o w n w a r d s a s s h o w n i n t h e i l l u s t r a t i o n
above('97 model).
7. Chargethe system (see page 22-61),and test its

performance(seepage 22-561r.
SILICONESEALANT
3. lnstallin the reverseorderof removal.
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22-68
A/C CompressorBelt
Adjustment
Detlection Method Tension Gauge Method
1. Apply a force of 98 N (10 kgf, 22 lbfl, and measure 1. Attachthe specialtool to the Ay'Ccompressorbelt as
the deflectionbetweenthe A,/CcomDressorand the shown below,and measurethe tensionof the belt.
crankshaftpulley.
A/C ComoressorBelt
A/C CompressorEelt Used Belt; 390 - 540 N (40 - 55 kgf, 88 - 120 lbtl
UsedBeh:7.5- 10.5mm (0.30- 0.41inl New Belt: 740 - 880 N (75 - 90 kgf, 170- 200 lbt)
New Belt: 5.0 - 7.0 mm (0.20- 0.28 in)
Notetheseitemswhen adjustingbelttension:
Notetheseitemswhen adjustingbelttension: . F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n fso r t h e
. lf there are cracksor any damageevidenton the belttensiongauge.
belt,replaceit with a new one. . lf there are cracksor any damageevidenton the
. "Used belt" means a belt which has been used belt,replaceit with a new one.
for five minutesor more. . "Used belt" means a belt which has been used
. "New belt" means a belt which has been used for five minutesor more.
for lessthan five minutes. . "New belt" means a belt which has been used
for lessthan five minutes.
Loosenthe pivot bolt of the idler pulleybracketand

the locknutofthe adjustingbolt.
BELTTENSIONGAUGE
07JGG- 00't010A
Turn the adjustingbolt to get properbelttension,
Loosenthe pivot bolt of the idler pulley bracketand
Retightenthe pivot bolt of the idler pulley bracketand the locknutofthe adjustingbolt.
the locknutofthe adiustingbolt.
Turn the adjustingbolt to get properbelttension.
Recheckthe deflectionof the A,/Ccompressorbelt,
Retightenthe pivot bolt of the idler pulley bracketand
the locknutofthe adjustingbolt.
Recheck
the tensionof the A,/Ccompressorbelt.
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22-69
Gondenser
Replacement
't. Recoverthe refrigerantwith a recovery/recycling/ 6. Removethe mounting bolts,then removethe con-
chargingststion(seepage22-59) denserby lifting it up as shown. Be carefulnot to
d a m a g e t h e r a d i a t o r a n d c o n d e n s e rf i n s w h e n
Removethe front grille (seesection20). removingthe condenser.
Removethe coolant reservoii,but do not discon-

nect the reservoirhose Jrom the coolant reservoir
and the radiator.
Removethe bolts and the suction line bracketas

s h o w n . R e m o v et h e b o l t s a n d t h e u p p e r m o u n t
brscketsfrom the radiator.
6xl.0mm
9,8 N.m 11.0kgf'm' 7.2lbf'ft)
MOUNT
UPPER 1,0mm
BRACKETS
Remove each bolt, then disconnectthe discharge

and condenserlines from the condenser,Plug or
them
cap the lines immediatelyafter disconnecting
to avoid moistureand dust contamination. 7. Installin the reverseorderof removal.Make note of
the followingitems.
6x1.0mm
9.8 N.m 11,0kgf.m,7.2 lbfttl . lf you'reinstallinga new condenser,add refriger-
ant oil (sP-10)(see page 22-54]..
6x1.0mm o Replacethe O-ringswith new ones at each fit-
t\,
l/ t i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l
before installingthem. Be sure to use the right
O-ringsfor HFC-134a (R-134a) to avoid leakage.
a . Be careful not to damagethe radiatorand con-
it--:
denserfins when installingthe condenser.
. Be sure to install the lower mount cushionsof
i.. condensersecurelyinto the holes,
. Chargethe system(seepage 22-61),and test its
performance(seepage22-56).
LINE
DISCHARGE
CONDENSRLINE
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22-70
Body Electrical
SpeciafToofs ,...,..,.............-.23-2
Troubleshooting
Tips and Precautions......,.,..........,.................. 23-3
Five-stepTroubleshooting........,.,.,...,,.,......... 23-5
Wire ColorCodes ...,....,.. 23-5
Relay and Control Unit Locations
EngineCompartment..,.,......,......................... 23-6
Dashboard ,.,.,..............-.- 23-7
Door....................... .........23-10
Index to Cilcuits and Sysiems
AccessorySocket.. ,....,.,..,.,. 23-95
*Airbags................ .,....,.Sestion24
Air Conditioning ,.,.,....
Section22
Alternator ...................
Section4
Anti-lockBrakeSystem{ABSI ................... Section19
'A/T GearPositionIndicator....................... Section1,1
AutomaticTransmission System ...........,..
Section14
B a t t e r y. . . . . . . . . . . . . . . . . . . ..............23-50
BlowerControls .,...,.,,
Section22
ChargingSystem .......Seqtionil
Clock-'98 Model ................ 23-98
Connectorldentification and Wire Harness
R o u t i n g. . . . . . . . . . . . . . . . . . . . . . . . .2. .3 . 1 1
CruiseControl ............
Ssction4
DashLightsBrightnessContlo||er..................... 23-90
FanConlrols ...,......,....
Section10
FuelPump ,..,.,...,....,....
Section11
Fuses...................... .,,.,.,.,.,,.,23-40
*Gauges
CircuitDiagram ......-....-..23-58
FuelGauge .....,.,.....
Section11
Speedometer ..,..........,...
23-56
GroundDistribution ,....,.,...23-46
HatchGlsssODenor.........................,.,.,.,.,..,.,.,.,,.
23-121
HeaterControls .-........
Soction21
*Horns.,...,..,.,.,....... ................23"104
*fgnitionSwitch ,,.,.,..,.,.,,.,.,.,23-51
lgnitionKey Light System-'97 Mod6l .............. 23.88
- +
BODY
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SpecialTools
Ret. No. Tool Numbel Description Oty I PageReference
o OTLAJ PT3O2OA TestHarness 23-62,63
23-2
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Troubleshooting
Tips and Precautions
Before Troubleshooting N e v e r t r y t o d i s c o n n e c ct o n n e c t o r sb y p u l l i n g o n
. Checkapplicablefuses in the appropriatefuse/relay their wires;pull on the connectorhalvesinstead.
box. Alwavsreinstallolasticcovers.
. Checkthe batteryfor damage,state of charge,and
clean.and tight connections.
. Checkthe alternatorbelttension.
CAUTION:
. Do not quick-chargea battery unless the battery
ground cable has been disconnected,otherwise you
will damage the alternator diodes.
. Do not attempt to crank thc engins wilh the battery
ground cable loosely connected or you will severely
damagethe wiring.
Handling Connestors Beforeconnectingconnectors,make sure the termi-

. Makesurethe connectorsare cleanand haveno loose nalsare in placeand not bent.
wire terminals,
. N4ake sure multiplecavityconnectorsare packedwith
grease(exceptwater-tightconnectors).
. All connectorshavepush-downreleasetype locks.
LOCKINGTAB
. Checkfor looseretainersand rubberseals.

S o m e c o n n e c t o r sh a v e a c l i p o n t h e i r s i d e u s e d t o
attach them to a mount bracketon the body or on
anothercomponent.This clip hasa pull type lock.
RETAINER
Some mounted connectorscannot be disconnected
unlessyou first releasethe lock and removethe con-
nectorfrom its mount bracket.
T h e b a c k s o f s o m e c o n n e c t o r sa r e o a c k e d w i t h
grease.Add greaseif necessary. lf the greaseis con
taminated.reolaceit.
LOCKING
PAWLON
OTHER Pullto
HALFOF disengage BRACKET
CONNECTOR
{cont'd}
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23-3
Troubleshooting
Tips and Precautions(cont'dl
Insen the connectorall the way and make sure it is . Seatgrommetsin their groovesproperly.
securelyIocked.
Positionwires so that the open end of the coverfaces
down. NOT GOOD
Face
A -M/
V
openend
lr lr*
Tsting and Repairs
Handling Wires and Harnesges . Do not usewires or harnesses with brokeninsulation.
. Securewires and wire harnessesto the frame with Replacethem or repairthem by wrappingthe break
wire ties at the designatedlocations.
their respective with electricaltape.
. Removeclipscarefully;don't damagetheir locks. . A f t e r i n s t a l l i n gp a r t s ,m a k e s u r e t h a t n o w i r e s a r e
pinchedunderthem.
. W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. lf possible,insert the probe of the tester from the
wire side (exceptwaterproofconnector).
Slip pliers under the clip base and through the hole at
an angle,then squeezethe expansiontabs to releasethe . Usea probewith a taperedtip.
clrD.
After installingharnessclips, make sure the harness

doesn'tinterferewith any moving pans. Referto the instructionsin the HondaTerminalKit for
Keep wire harnessesaway from exhaustpipes and i d e n t i f i c a t i o an n d r e p l a c e m e not f c o n n e c t o rt e r m i -
other hot parts, trom sharp edges of bracketsand nals.
holes.and from exoosdscrewsand bolts.
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Five-stepTroubleshooting Wire ColorCodes
1. VerifyThe Complaint T h e f o l l o w i n ga b b r e v i a t i o nasr e u s e d t o i d e n t i f yw i r e
Turn on all the componentsin the problemcircuitto colorsin the circuitschematics:
verify the customercomplaint.Note the symptoms. W H T . . . . . . . . . . . . . . . . . . . .W . . .h. i. t. e. . .
Do not begin disassemblyor testinguntil you have Y E L , . . . . . . . . . . . . . . . . . . . .Y. .e. .l .l o
. .w ...
narroweddown the problemarea. B L K . . . . . . . . . . , . . . . . . . . . .B. .l.a. .c.k. . .
B L U . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . .
AnalyzeThe Schematic GRN.............................Green
L o o k u p t h e s c h e m a t i fco r t h e p r o b l e mc i r c u i t . R E D. . . . . . . . . . . . . . . . . . . . .R. .e. .d. . . . .
Determinehow the circuit is supposedto work by ORN.............................Oran9e
t r a c i n gt h e c u r r e n tp a t h sf r o m t h e p o w e r f e e d P N K . . . . . , . . . . . . . . . . . . . . .P. .i n. .k. . . . .
throughthe circuitcomponentsto ground.lf several B R N. . . . . . . . . . . . . . . . . . . . .B. .r.o. .w. .n. .
circuitsfail at the sametime, the fuse or ground is a G R Y. . . . . . . . . . . . . . . . . . . . .G . .r. a. .y. . . .
likelycause, P U R. . . . . . . . . , . . . . . . . . . . .P. .u. .r .p. l. e. .
L T B L U. . . . . . . . . . . . . . . . . .L, i.g. .h. .tB. l u e
Basedon the symptomsand your understandingof L T G R N . . . . . . . . . . . . . . . . .L. .i .g.h. .tG . reen
the circuitoperation,identifyone or more possible
causesof the problem. T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h
anothercolor stripe.The secondcolor is the stripe.
3. lsolateThe ProblemBy TestingThe Circuit
Make circuitteststo checkthe diagnosisyou made
in step 2. Keepjn mind that a logical,simple proce-
dure is the key to efficienttroubleshooting. Test for WHT/BLK
the most likely cause of failure first. Try to make
testsat pointsthat are easilyaccessible,
4. FixThe Problem
Once the specificproblem is identified,make the
repair.Be sure to use propertools and safe proce-
dures.
MakeSureThe CircuitWorks
Turn on all componentsin the repairedcircuitin all
modes to make sure you've fixed the entire prob-
lem. lf the problem was a blown fuse, be sure to
test all of the circuitson the fuse.lvlakesure no new
problemsturn up and the originalproblemdoes nol
recur.
O
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Relayand ControlUnit Locations
EngineCompartment
ELECTRICAL
LOADDETECTOR
IELDI
UNIT
UNDER.HOOD
FUSE/RELAY
BOX
t:
tr
tr ;
tr -
BLOWER
MOTOR
RELAY
A/C COMPRESSOR RADIATOR

CLUTCHRELAY FAN EELAY
UNDER.HOOD
ABS FUSE/RELAY
BOX
''r@
D
l--\ r rr r
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23-6
Dashboard
PGM.FIMAIN RELAY
BLOWER MOTORHIGHRELAY
lwir. colorc:BLK/YEL, I
LBLU/BLK, ORN/WHT,.ndBLKI
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23-7
Relayand GontrolUnit Locations
Dashboard(cont'd)
HEATERCONTROLPANEL
RELAY
REARWINDOWDEFOGGER
-rj,r1
/-\,r1
Iu lJ-JlJ r*t
WINDOWRELAY
CONTROLUNIT
INTEGRATEO TURNSIGNAL/HAZARDRELAY
23-8
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DAYTIMEBUNNINGLIGHTS
CONTROLUNIT (Canrda){'98 - (X)modok) OAYTIMERUNNINGLIGHTS
IGNITIONKEYLIGHT CONTROLUNIT lcanad!l l'97 modell
CONTROLUNIT l7 model)
CRUISECONTNOLUNIT
HORNBELAY137 modell
Iwiro color3:WHT/GRN, I
IWHT/GBN, GRY,andBLU/REDI
STARTERCUT RELAY{'98 - 00 modelsl
IWir6 color3:BLK/WHT,BLK^ UHT,I STARTEnCUTRELAYl7 modll
lGRY,.nd BLx/nED I lwire colors:BLK/WHT,BLK/WHY,l
IGRY,and BLK/RED I
HORNFELAYl'98 - 00 modcb)
lwire coloF: WHT/GRN, l
LWHT/GRN,GRY,and BLU/REDI
{cont'd)
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23-9
Relayand ControlUnit Locations
Dashboard(cont'd)and Door
REARACCESSORY SOCKETRELAY
I Wire colors:YEL/GRN, J
IWHT/BLK.BLK,.nd YEL/BLUl
REVERSE RELAY {A/TI

I WirecolonrYEI-/RED, I
IYEL/RED,YEL,.nd GRN/BLKI
REARWINDOWWIPER
CONTROLUNIT 137 mod.ll
INTERLOCX
CONTROLUNIT
KEYIISS/POWER
DOORL(rcK
CONTROLUNIT
23-10
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Gonnectorldentificationand Wire HarnessRouting
How to ldentity Connectors: "C" for connectors.

numbershavebeenassignedto all connectors,
ldentification The numberis precededby the letter
"G" for groundterminalsor "T" for non-groundterminals.
Location Others lFloor, Door,

EngineCompartmsnt Dashboard
Harness 8oof, Tailgate)
Startercable T 1 ,T 2 a n d@
Batterygroundcable G 1 a n dO
Enginegroundcable T3
groundcable
Transmission T4
G3
Enginewire harness C 1 0 1t h r o u g hC 1 3 7
T 1 0 1a n dT 1 0 2
G101
Enginecompartmentwareharness C201throughC218
G201and G202
Under-hoodABS fuse/relaybox t5ano9
wire harness
Main wire harness C301throughC309 C401throughC447
C351throughC361 G401and G402
Dashboardwire harness C501throughC524(C525)

G501
Leftsidewire harness C551throughC581
G551,G552and G553
Rightsidewire harness C601throughC605
lnteriorwire harness C701throughC703
Rearbumperwire harness C641throughC643
Heatersub-harness C731throughC740
Secondaryheatedoxygensensor C721through C722
sub-harness
Combinationswitchsub-harness C751throughC760
Driver'sdoor wire harness C661throughC667
Frontpassenger's
door wire harness C6Tl throughC676
Left reardoor wire harness C681throughC684
Rightreardoor wire harness C69'lthroughC694
Rearwire harness C611throughC520
Tailgatewire harness C631throughC634

G631
SRSmain harness C801throughC808

G801
High mount brakelight sub-harness C651throughC653
Fueltank oressuresensorsub-harness C645throughC647
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Connectorldentificationand Wire HarnessRouting
Starter Cables
Connoctoror Number of
Terminal Location Connectsto Notes
Cavities
T1 Rightside of enginecompartment Under-hoodfuse/relaybox
r2 Rightside of enginecompartment Starter motor
o Battery Batterypositiveterminal
Battery Ground Cable
Connoctoror Numberof
Terminal Location Conneqtslo Notes
Cavities
GI Rightfront shocktower Bodyground,via batteryground
cable
Battery Batterynegativeterminal
EngineGroundCable
Connectoror Numb6r ol
Terminal Location Connectsto Notes
Cavities
T3 Leftsideof engine Powersteeringpump bracket
Leftside of enginecompartment Bodyground.via engineground
caote
TransmissionGround Cable
Connsstor o. Number of
Location Connectsto Notes
Terminal Cavities
T4 Rightside of enginecompartment Transmission
Rightside of front frame Body ground,via transmission
groundcable
Under-hoodABS Fuse/RelayBox Wire Harnsss
Conn6storor Numberof
Terminal Location Connoctsto Notos
Cavities
tc Rightside of enginecompartment Under-hoodABS tuse/relavbox
@ Battery 88tterypositiveterminal
23-12
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STARTERCABLE
UNDER-HOODABS FUSE/RELAY
BOX WIREHARNESS
@
EATTERY
GROUND
CABLE
ENGINEGROUND
CABLE
TRANSMISSIONGROUND
CABLE
EnginoWire Harness
Connecto; or Number of
Location Conneqtsto Notos
Terminal Cavities
c101 10 Leftside of enginecompartment Main wire harness(C304)
c102 6 Leftside of enginecompartment Mainwire harness(C305):'97 - 98 models A/r
c103 Middleof engine No. 1 fuel injector
c104 Middleof engine Crankshaftspeedfluctuation(CKF)sensor
c105 Leftsideof enginecompartment Alternator USA
c105 Leftsideof enginecompartment Alternator Canada
c106 1 Middleof engine Engineoil pressureswitch
c 107 2 Middleof engine No.2 fuel injector
c 108 Middleof engine Evaporative emission(EVAP)purge
controlsolenoidvalve
c 109 Middleof engine No. 3 fuel injector
c]10 Middleof engine No. 4 fuel injector
c1l'l M i d d l eo f e n g i n e Primaryheatedoxygensensor
(PrimaryHO2S)(sensor1)
c112 Middleof engine Radiatorfan switch
c113 1 Middleof engine Coolanttemperaturesendingunit
c ' t1 4 Middleof engine Enginecoolanttemperature(ECT)sensor
Middleof engine Mainshaftspeedsensor Alr
cl16 2 Middleof engine Lock-upcontrolsolenoidvalve AlT
cl16 Middleof engine Back-uplight switch M/'r
c117 Middleof engine Shift controlsolenoidvalve Afi
c118 Middleof engine Linearsolenoidvalve
c119 Middleof engine Countershaftspeedsesnsor
c120 1 Rightsideof engine Startersolenoid
c121 10 Middleof engine Distributor
c't22 20 Behindright kickpanel Junctionconnector
c't23 Underright side of dash PCM '97 mooel
Underright side of dash ECIWPCM
c't25 31 Underright side of dash ECM/PCM
cl26 16 Underright sideof dash ECM/PCM
cl27 22 Underright sideof dash Main wire harness(C,|:}1)
cr28 l0 Rightsideof engine IVT gear positionswitch
cl29 Rightsideof engine Vehiclespeedsensor(VSS)
c130 Middleof engine Throttleposition(TP)sensor
c131 Middleof engine MAP sensor
c132 Middleof engine ldleair control(lAC)valve
c 133 Middleof engine lntakeair temperature(lAT)sensor
c134 l0 Middleof engine Junctionconnector '97 model
c134 '14 Middleof engine '98 - 00
Junctionconnector
mooets
c135 Leftsideof enginecompartment Powersteeringpressure(PSP)switch
c 136 14 Middleof engine Junctionconnector
1 Middleof engine Knocksensor(KS) '99 - 00
models
T101 Leftsideof en0inecompanment Alternator
r102 Rightsideof enginecompartment Under-hoodfuse/relaybox
G101 Middle of engine Engineground,via enginewire harness
23-14
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c1733
clsl gra,
c103
c137
T101
c104
c112
ENGINEWIREHARNESS cl13 cl' l1
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23-15
lrffiltEfinl,
EngineCompartment Wire Harness
Connectorol Number of
Terminal Cavities
c20'l 14 Leftside of enginecompartment Main wire harness(C307)
c202 Leftside of enginecompartment Cruiseactuator
c203 2 Behindfront bumper Rearwindow washermotor
c204 Behindright headlight Leftfront turn signal/sidemarkerlights
c205 2 Behindfront bumper Windshieldwashermotor
c206 Behindright headlight Leftfront parkinglight
c207 Leftsideof enginecompartment Condenserfan motor
c208 1 Leftsideof enginecompartment Frontfog lights Optional
c209 'l Leftsideof enginecompartment IVC compressorclutch
c210 Behindleft headlight Left headlight
Leftsideof enginecompartment IVC pressureswitch
c212 Behindfront bumper Left horn
c213 Behindfront bumper Righthorn
c2't4 2 Rightside of enginecompartment Radiatorfan motor
c215 Behindright headlight Rightheadlight
c216 Behindright headlight Rightfront turn signal/sidemarker
lights
c217 B e h i n dr i g h th e a d l i g h t Rightfront parkinglight
c21A Rightsideof enginecompartment Main wire harness1C357) '97 - 98
models
c218 10 Rightsideof enginecompadment Main wire harness(C357) '99 - 00
mooets
G201 Rightsideof enginecompanment Bodyground,via enginecompartment
wire harness
G202 Leftside of enginecompartment Bodyground,via enginecompartment
wire harness
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23-16
ENGINECOMPARTMENT
WIREHARNESS
c212
c211
Main Wire HarnesslEngine compartmont left and right branches)
Connectot ol Number ot
Terminal Location Conneqtsto Nots
Cavities
c301 5 Leftside of enginecompartment Windshieldwiper motor
Leftsideof enginecompartment Daytimerunninglightsresistor Canada
c303 2 Leftside of enginecompartment Test techometerconnector
c304 10 Leftside of enginecompanment Enginewire harness(C10])
c305 Leftside of enginecompartment Enginewire harness(C102):'97 - 98
models
c306 Leftside of enginecompartment Left front ABS wheel sensor ABS
c307 '14
Leftside of enginecompartment Enginecompartmentwire harness(C201)
c308 1 Leftsideof enginecompartment Brakefluid level switch {-)
c309 1 Leftside of enginecompartment Brakefluid levelswitch(+)
t1 Rightsideof enginecompartment Under-hoodfuse/relaybox (C908)
c352 Rightsideof enginecompartment Under-hoodfuse/relaybox (C906)
Rightsideof enginecompartment Under-hoodfuse/relaybox (C905)
c354 3 Rightsideof enginecompartment Under-hoodfuse/relaybox (C907) USA
10 Rightsideof enginecompartment ABS modulatorunit ABS
c356 Rightsideof enginecompartment ABS pump motor ABS
c357 8 Rightsideof enginecompartment Enginecompartmentwire harness(C218) '97 - 98
models
10 Rightside of enginecompartment Enginecompartmentwire harness(C218) '99 - 00
mooets
c358 Rightsideof enginecompartment Rightfront ABS wheelsensor ABS
c359 2 Rightsideof enginecompartment Under-hoodABS fuse/retaybox (C931) ABS
c360 Rightsideof enginecompartment Under-hoodABS fuse/relaybox (C9321 ABS
LJO I Rightsideof enginecompartment Evaporative emission(EVAP)contro '98 -
00
canistervent shutvalve mooets
G35l Rightside of enginecompartment Bodyground,via main wire harness ABS
23-18
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UNDEB.HOOD
FUSE/RELAY
BOX
MAIN WIREHARNESS
branch)
G351
MAIN WIREHARNESS
{left branch}
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23-19
Main Wire Harnss(left side of dash and floor branchesl{cont,dl
c401 5 Behindleft kickpanel Startercut relay

c402 Behindleft kickpanel Horn relay
c403 20 Behindleft kickpanel Leftsidewire harness(C558)
c404 20 Behindleft kickpanel Leftsidewire harness(C559) '97 model
c404 24 Behindleft kickpanel Leftsidewire harness(C559) '98 - 00
't4 mooets
c405 Underleft side of dash Cruisecontrolunit
c406 Underleft side of dash Daytimerunninglightscontrolunit Canada
c407 8 Underleft sideof dash Daytimerunninglightscontrolunit Canada
c408 5 Underleft side of dash lgnitionkey light controlunit '97 model
c409 Underleft side of dash Interiorwire harness{C701)
c410 3 Underleft side of dash Cablereel '97 model
c410 Underleft sideof dash Cablereel '98 -
00
models
c411 Underleft side of dash lgnitionkey switch
c412 Underleft side of dash lgnitionkey switch
c413 12 Underleft sideof dash Combinationswitchsub-harness {C753)
'97 -
98
models
c413 Underleft side of dash Combinationswitchsub-harness (C753) '99 - 00
moqets
c414 Underleft side of dash SRSmain harness(C803)
c415 Underleft side of dash Dashboardwire harness(C503)
c416 10 Underleft side of dash Dashboardwire harness(C501)
c416 '1
Underleft sideof dash Dashboardwire harness{C501)
c417 18 Underleft side of dash Under-dash fuse/relaybox (C922)
c418 20 Underleft side of dash Under-dash fuse/relaybox (C920)
c419 '18 '97 model
Underleft sideof dash Under-dash fuse/relaybox (C919)
c420 10 Underleft side of dash lntegratedcontrolunit '98 - 00
mooets
c420 15 Underleft side of dash Integratedcontrolunit Optional
c421 1 Underleft sideof dash Frontfog lightsswitch
c422 4 Underleft side of dash Brakeswitch
c423 8 Undermiddleof dash Interlockcontrolunit
c424 5 Undermiddleof dash Reverserelay
c425 5 Undermiddleof dash Rearaccessorysocketrelay
c42A Undermiddleof dash Rearaccessorysocketrelay
c426 Undermiddleof dash Rearheatedoxygensensorsub-
harness(C722) Optional
c437 22 Underleft side of dash Securitycontrolunit Optional
c438 Underleft side of dash Securitystarter cut relay (for security
alarmsystem)
c438 Underleft side of dash Junctionconnector(for interlocksystem) Optional
c439 Underleft side of dash Securitywire harness Optional
c440 Underleft sideof dash Securitywire harness '97 model
c441 Underleft sideof dash Rearwindow wiper controlunit
c442 Underleft side of dash Combinationswitchsub-harness(C760) '97 - 98
mooels
Underleft side of dash Combinationswitch sub-harness(C760) '99 - 00
models
Underleft side of dash Securltyindicator Optional
Underleft sideof dash Securityvalet switch Optional
Underleft side of dash Clutchinterlockswitch Mfi
Underleft side of dash Clutchswitch(forcruisecontrol) Mlr
Underleft side of dash Bodyground,via main wire harness
23-20
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MAIN WIREHARNESS
c115 cla6 c+to
"n,
dn' cntt
I -:-
--r F -'L-1al 1l}a] /l
a -n-rrr---rrr -
UNDER-DASH
FUSE/BELAYBOX
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Main Wire Harness{Right side of dash and floor branchesl{cont,dl
Connector or Number ol
Tsrminal Cavities Location Connectsto Notes
c427 25 Frontpassenger's
door Frontpassenger's door wire harness
(c671)
c428 6 Behindright kickpanel Rightsidewire harness{C601)
c429 Behindright kickpanel ABS controlunit ABS
c430 26 Behindright kickpanel ABS controlunit ABS
c431 22 Behindright kickpanel Enginewire harness(C127)
c432 7 Underright side of dash PGM-Flmain relay
c433 20 Under.ight side of dash JUnotronconnector
c434 Undermiddleof dash Tailgateopen relay Optional
c435 U n d e rm i d d l eo f d a s h Headlightsf lasherrelay Optional
c436 5 Undermiddleof dash Heatersub-harness (C731) '97 model
c436 7 Undermiddleof dash Heatersub-harness (C731) '98 -
00
models
c447 Behindright kickpanel ECM/PCM '98 -
00
mooets
G402 Underright side of dash Body ground,via main wire harness
23-22
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MAIN WIREHARNESS
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23-23
DashboardWire Harness
Connectorol Numbr of
Terminal Location Conngctsto Notes
Cavities
c501 10 Above under-dashfuse/relaybox Main wire harness(C416)
c501 1 Above under-dashfuse/relaybox Main wire harness(C416) Mir
c502 20 Above under-dashfusehelaybox Under-dashfuse/relaybox 1C912)
c503 Above under-dashfuse/relaybox Main wire harness(C415)
c504 Behinddashboardlower panel Hatchglassopenerswitch
c505 14 Above under-dashfuse/relaybox Left side wire harness(C556) '97 - 98
models
16 Above under-dashfuse/relaybox Leftsidewire harness(C556) '99 - 00
models
c506 Left side of steering wheel Dashlightsbrightnesscont.oller
c507 6 Left side of steering wheel Cruisemain switch
c508 20 Underleft side of dash Junctionconnector
c509 Behindgauges Gaugeassembly
c510 13 Behindgauges Gaugeassembly
c512 t6 Behindgauges Gaugeassembly
14 Behindgauges Gaugeassembly A/r
c514 10 Rightside of gauges Hazardwarningswitch
to Behindmiddleof dash Audio unit
Behindmiddleof dash Heatercontrol panel
20 Behindmiddleof dash Heatercontrol panel
c518 16 Undermiddleof dash Datalink connector
c519 Undermiddleof dash Servicecheckconnector
c520 2 Behindmiddleof dash Front accessorysocketconnector
c521 Behindmiddleof dash Ashtraylight
24 Behindmiddleof dash Heatersub-harness(C733)
2 Behindmiddleof dash Heatersub-harness {C740}
'97model
1 Behindmiddleof dash Heatersub-harness(C740) '98- 00
mooets
Uppermiddleof dash Clock '98- 00
models
G501 Behindmiddleof dash Bodyground,via dashboardwire har-
ness
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23-24
DASHBOARD
wlRE HART{ESS
Left Side Wire Harness
ConnectoroI Number of
Locaiion Connectsto Not6s
Terminal Cavities
c551 8 Behindunder-dash fuse/relay
box Under-dashfuse/relaybox (C921)
c552 16 Behindunder-dash fuse/relay
box Under-dashfuse/relaybox (C923)
10 Left side of steeringwheel Powermirror switch
c554 14 Left side of steeringwheel Powerwindow masterswitch
'I Left side of steeringwheel Powerwindow masterswitch
'97 - 98
c556 14 Above under-dashfuse/relaybox Dashboardwire harness{C505)
mooets
Dashboardwire harness1C505) '99 - 00
16 Above under-dashfuse/relaybox
models
Driver'sdoor Driver'sdoor wire harness(C661)
c558 20 Behindleftkickpanel Main wire harness(C403)
'97 model
'98 - 00
models
c560 ) Left side offloor Driver's seat belt switch
1 Leftquanerpanel Left rear door switch
c562 5 Fueltank F u e lu n i t
'97 model
c563 On left half of rearcrossbeam Left rearABS wheelsensor
'98 - 00
c563 On left half of rearcrossbeam Left rearABS wheelsensor
models
c564 1 Leftquarter panel Rearaccessorysocketconnector{+}
c565 1 Leftquarter panel Rearaccessorysocketconnector (-)
c566 Leftquarter panel Rearbumperwire harness1C641)
6 Leftquarter panel Trailerlightingconnector
c568 1 Leftquarter panel Tailgatedoor latchswitch
c569 Leftquarter panel Left rear speaker
c570 2 On left half of rearcrossbeam RightrearABS wheelsensor
14 Rightquarterpanel Rearwire harness(C611)
c572 1 Rightquarterpanel Rightrea. door switch
c573 Leftquarter pillar Lefttaillight
c574 1 Leftside of floor Parkingbrakeswitch
c575 6 Left B-piller Leftreardoor wire harness(C681)
c576 1 Left B-piller Driver's door switch
Behindleftkickpanel Selectunlockrelay(for securityalarm Optional
system)
6 Behindleftkickpanel Junctionconnector(for power door
locks)
c578 Underleftsideof dash SRSmain harness(C807) '98 - 00
mooets
'98 - 00
c579 LeftB-piller Driver'sseat belttensioner
models
Fueltank pressuresensorsub-harness '98 - 00
c580 Fueltank
(c645) mooets
'99 - 00
c581 Leftside of steeringwheel Power window master switch
mooets
G551 Behindleftkickpanel Bodyground,via left sidewire harness
Left side ot floor Bodyground,via left sidewire harness
G553 Leftquarterpiller Body ground,via left sidewire harness
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23-26
c553 c5:6 c5J5
C561 C565 C566

LEFTSIDEWIREHARNESS
Right Side Wire Harness
Connec{oror Numberof Conneststo Notes

Location
Tsrminal Cavities
c601 6 Behindright kickpanel Main wire harness(C428)
'1 Frontpassenger'sdoor switch
c602 RightB-piller
c603 Rightreardoor Rightreardoor wire harness(C691)
'98 - 00
c604 2 Undermiddleof dash SRSmain harness{C808)
mooets
'98 - 00
2 R i g h tB - p i l l e r Frontpassenger's
seatbelttensioner
models
Rear Bumper Wire Harness
Connectorol Number ot Notes

Location Connoctsto
Terminal Cavities
c641 4 Leftquarterpanel Leftsidewire harness(C566)
c642 2 Behindrearbumper Leftrearside markerlight
c643 2 Behindrearbumper Rightrearside markerlight
'98 Model
FuelTank PressureSensor Sub-harness-
Connectoror Number ot Not63

Location Connectsto
Terminal Cavities
c645 Fueltank Leftsidewire harness(C580)
c646 ? Leftside of fuel tank Fueltank pressuresensor
c647 2 Leftside of fuel tank Evaporativeemission(EVAP)bypass
solenoidvalve
High Mount Brake Light Sub-harnoss
Conneslor or Number of Connec-tsto Notes

Location
Terminal Cavities
c651 2 Top of hatchglass High mount brakelight
c652 1 Top of hatchglass Rearwire harness(C617)
c653 1 Top of hatchglass Rearwire harness(C618)
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23-28
HIGHMOUNT BRAKELIGHT
SUB-HARNESS
RIGHTSIDEWIBEHARNESS
FULTANK PRESSURE
SENSORSUB.HARNESS
REARBUMPERWIREHANNESS
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23-29
RearWiro Harness
Connectoror Number of Notes

Location Connectsto
Terminal Cavities
c61l 14 R i g h tq u a r t e p
r anel Leftsidewire harness(C57'l)
c612 2 R i g h tq u a r t e p
r anel Rightrearspeaker
c613 R i g h tq u a r t e p
r anel Tailgatewire harness(C631)
c614 6 R i g h tq u a n e rp i l l e r Rightaillight
1 Rightside of hatchglass Rearwindow defogger(+)
Middleof hatchglass Rearwindow wiper motor
c617 1 Top of hatchglass High mount brakelight sub-harness
(c652)
'I Top of hatchglass Hjgh mount brakelight sub-harness
c618
{c653)
c619 1 Leftside of hatchglass Rearwindow defogger(-)
c620 Roofarea R e a rc e i l i n gl i g h t
G611 R i g h tq u a r t e p
r iller Bodyground,via rearwire harness
Tailgate wire Harness
Connestoror Numberof Noles

Location Connectsto
Terminal Cavities
Rightquarterpanel Rearwire harness(C613)
2 Middleof tailgatedoor Hatchglassopenersolenoid
c633 2 Leftsideof tailgatedoor Licenseplatelight
c634 1 Middleof tailgatedoor Hatchglasslatchswitch
I/iddle of tailgatedoor Body ground,via tailgatewire harness
23-30
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TAILGATEWIREHARNESS
Drivsr's Door Wire Harness
Connectoror Number of
Location Connoctsto Notes
Terminal Cavities
25 Driver'sdoor Leftsidewire harness{C557)
Driver'sdoor Left front speaker
4 Driver's door Driver'spowerwindow motor
c664 Driver's door Driver's door lock actuator
Driver's door Driver's door lock switch
at Driver's door Driver's power mirror actuator
c667 18 Driver's door Keyless/power door lockcontroluni
Front Pa$enger's Door Wire Harnsss
Connectoror Number ot
T6rminal Cavities
c671 2^ Frontpassenger's
door Main wire harness(C4271
c612 Frontpassenger's
door Rightfront door speaker
Frontpassenger's
door Front passenger'spower window motor
door Frontpassenger's door lockactuator
door Front passenger'spower window switch
I Frontpassenger's
door Front passenger'spower mirror actuator
DBIVEB'SDOORWIRE
HARNESS
6tt inliiioint""
23-32
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o,- Left Rear Door Wile Harness
Conneclor or Numbor of
Location Connectsto Notos
Trminal Cavities
c681 Left rear door Leftsidewire harness{C575)
c6a2 2 Leftreardoor Leftrearoowerwindow motor
c683 Left rear door Left rear door lock actuator
c684 5 Left rear door Left rear oower window switch
Right Real Door Wire Harness
Connectoror Number of
Locstion Conneststo Notos
Terminal Cavitios
c691 Rightreardoor Rightsidewire harness(C603)
c692 Rightreardoor Rightrearpowerwindow motor
Rightreardoor Rightreardoor lockactuator
c694 Rightreardoor Rightrearpowerwindow switch
LEFTREARDOOR
WIRE HARNESS
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lntglior Wire Harness
Connectoror Numbr of
Notes
Location Connoct3lo
Terminal Cavities
c701 Underleft sideof dash Main wire harness(C409)
c702 Roofarea Frontceilinglight
c703 Roofarea Spotlights
SocondaryHeatedOxygen Sensor Sub-harflss
Connoqto. ol Numbor ot
Location Connectsto Notos
Tarminal Cavities
c721 Undermiddleof dash Secondaryheatedoxygensensor
{SecondaryH02S)(Sensor2)
c722 Undermiddleof dash Main wire harness(C426)
23-34
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OXYGENSENSOR
SUE.HARNESS
Hoat6rSub-harness
Connectoror Numbsrot
Localion Connectsto Notes
Tgrminal Cavities
'97 model
c73'] 5 Undermiddleof dash Main wire harness{C436)
'98 - 00
c731 7 Undermiddleof dash Main wire harness(C436)
modsls
c732 7 Behindmiddleof dash Modecontrolmotor
c733 24 Behindmiddleof dash Dashboardwire harness(C522)
c734 Behindglove box Air mix controlmotor
c735 Behindglove box Evaporatortemperaturesensor
c736 Behindglove box Blowermotor high relay
c737 Behindglove box Blower motor
c738 Behindglove box Powertransistor
'97 model
c739 Behindglove box Recirculationcontrolmotor
'98- 00
c740 Behindmiddleof dash Dashboardwire harness(C523)
mooels
c740 1 Behindmiddleof dash Dashboardwire harness(C523)
Combination Switch Sub-harness
Conneqtor ol Number of
Location Conneststo Notos
Terminal Cavities
c751 6 Above under-dashfuse/relaybox Under-dash fuse/relaybox (C914)
7 Above under-dashfuse/relaybox Under-dash fuse/relaybox {C915)
Main wire harness(C413) '97 - 98
c753 12 Underleft side of dash
mod6ls
'99 - 00
10 Underleft sideof dash Main wire harness(C413)
models
c754 2 Behindsteeringcolumn Shift locksolenoid
c755 Behindsteeringcolumn Parkingpin switch
c756 Behindsteeringcolumn Combinationlight switch
c757 7 Behindsteeringcolumn Combinationlight switch
c758 6 Behindsteeringcolumn Wiper/washerswitch
8 Behindsteeringcolumn Wiper/washerswitch
'97 - 98
c760 Underleft side of dash Main wire harness(C442)
models
Main wire harness(C442) '99 - 00
c760 5 Underleft side of dash
models
23-36
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Ol-
I
f-
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SRS Main Haln93s
ConnGtoro1 Numbor of
Terminal Cavities
c801 t Leftside of under-dash fuse/relaybox (C911)
Under-dash
fuse/relaybox
c802 Top of under-dashfuse/relay Memoryerasesignal{MES)connector
box
c803 Underleft sideof dash Main wire harness{C414)
c804 Underleft sideof dash Cablereel
c805 Behindglove box Frontpassenger'sairbag
c806 18 Middleof floor SRSunit
c807 Underleft sideof dash Leftsidewire harness(C578) '98 - 00
mooets
Rightsidewire harness(C604) '98 - 00
c808 Undermiddleof dash
mooets
G801 Middleof floor Bodyground,via SRSmain harness
23-38
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SRSMAINHARNESS
D\
n
ll-
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23-39
/
Fuses
Under-hoodFuse/RelayBox
ALTERNATOR
BATTERY
lTo engine wire harness{T102)l
lTo slarter cableslTlll
DEn r-'l
IJ
tr 11
IJ
tr r'1
51
LI
tr r-'l
56
IJ
r-'l
57
LJ
cro1
lTo condensrtan .slayl lTo blower motor releyl
c903
.: Not used lTo radiator ten relavl
NOTE:View from the backsideof the under-hoodfuse/relaybox.
c306
fTo main wiro hamose(C352ll
c305
lTo mainwiie harnes lc353ll
lTo main wirc harness1C354)l lTo main wire harnesslC351ll
23-40
www.emanualpro.com
Under-dashFuse/RelayBox
c912
wire harness{C502ll
lTo dashboard
c914
lTo switchsub-harness
{C751ll
c911
c915
lToSRSmainharness{C801)l lTo combinatioo
switchsub-harness
1C752)l
r'=G@6
T"r r-1 T't r't r-l r-r r't r;l Fl T1 r-l r-l
G
23 21 25 26 21 28 29 30 31 32 33
rr Ll tJ tJ LJ Ll lJ LJ t-J LJ u Ll
- r-l n rT n Tl r-l ri n Fl r-'l r-l
12 13 1a t5 16 11 1a 19 20 21 22
L-] [J LI LI I.J I.J tJ tJ TJ LI LI IJ c9r6
- Fn Fl F1 r-'l T1 r;l r-l r-t r;l |-] r-l [Topowe.windowrelay]
| 2 3 1 5 6 7 a 9 1 0 r l
a; Canada LI I.J LI LJ tJ LJ IJ LI I.J IJ IJ tJ
i -': C927loption {ACCll

141: C928lOption (lG2)l
lTo rear window defoggerrelayl
NOTEr View from the backside of the under-dash tuse/relay box.
c922 c924
lTomainwireharness
1C417)l lTo integraledconttolunitl
c919
(css1)l lTo mainwire herness1C419)l
c920
lTo main wire harness1C418)l
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Fuses
Under-hoodABS Fuse/RelayBox
lTo under-hoodABS fus6/r6lay box wire harnessl
c931 c933
lTo main wire harness1C359)l lTo ABS pump moto. relayl
c932
lTo main wire harness(C360)l
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23-42
PowerDistribution
Index(numericalsequence)
Fuse-to-Gomponent(sl
Under-hood Fuse/RolayBox:
Fuse Capacity wiro Color Circuit(s)Protcted
'100A A
41
40A WHT/BLK lgnitionswitch(BAT)
43 7 . 5A WHT/RED lntegratedcontrolunit
Ceilinglights
Spotlights
44 1 5A WHT/BLK PGM-Flmain relay
Not used
46 40A WHT/BLU No. 7, 8, 10,11fuse in the under-dashfuse/relaybox
47 7 . 5A WHT/BLU A u d i ou n i t
Clock{'98- 00 models)
Datalinkconnector('98- 00 models)
ECM(VBU){'98- 00 models:M/T)
Heatercontrolpanel
PCM (VBU)(A./T)
48 30A WHT Combinationlight switch(via under-dashfuse/relaybox)
No. 20,33 fuse in the under-dashfuss/relaybox
49 Not used
50 204 WHT/GRN Rearwindow defogger(viarelay)
204 WHT/GRN Door lockcontrolunit
Hatchglassopenersolenoid
Keylessdoor lockcontrolunit ('98- 00 models)
52 1 5A WHT/GRN Horn relay
Horns(via relay)
via brakeswitch:
ABS controlunit
Brakelights
Cruisecontrolunit
ECM ('98 - 00 models: M/T)
Highmount brakeiight
PCM(4./T)
Trailerlightingconnector
53 10A WHT/BLK Turn signal/hazard relay(viaswitch)
54 40A WHT/RED Optionconnector(+B)
No. 6 fuse in the under-dashfuse/relaybox
40A BLU/WHT Blowermotor (viarelay)
50 204 WHT Condenserfan motor (viarelay)
RED Ay'Ccompressorclutch (via relay)
20A BLK/RED Radiatorfan motor (viarelay)
Under-hoodABS Fuss/nehy Box:
Fusg Capacity Wire Color Circuitls) Protoct
61 40A WHT ABS pump motor {via relay}

204 WHT/GRN ABS controlunit
7 . 5A BRN/YEL ABS controlunit
{cont'd)
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23-43
PowerDistribution
Index(numericalsequencel(cont'dl
Fuse-to-Component(sl
Under-dashFuse/RelayBox:
Fuse Capacity Wire Color Circuit{s)Protected
1 Not used
Not used
3 1 0A "^ Rearwindow washermotor (viaswitch)
Rearwindow wiper controlunit ('97 model)
Rearwindow wiper motor
1 0A RED/B
LU Daytimerunningrightsresister{Canada)
R i g h th e a d l i g h{tH i g hb e a m }
5 1 0A RED/GRN Daytimerunningrights resister(Canada)
High beam indjcatorlight
Left headlight(Highbeam)
6 1 0A WHT/BLK Rearaccessorysocket(viarelay)
7 20A RED/VVHT Left rearpowerwindow motor (viaswitch)
I 204 YEUBLK Rightrear powerwindow motor (viaswitch)
9 15A RED Distributor(ignitioncontrolmodule)
10 204 GRN/BLK Frontpassenger's powerwindow motor (viaswitch)
11 204 BLU/BLK Driver'spowerwindow motor {viaswitch)
Powerwindow masterswitch(powerwindow controlunit)
12 7 . 5A YEVBLK Turn signal/hazard relay(viaswitch)
13 '15A
YEUGRN PGM-FImain relay
RED SRSunit (VA)
14 7 . 5A BLK/YEL Cruisecontrolunit (viaswitch)
Cruisemain switchindicatorlight
7 . 5A BLK/VVHT Alternator
Chargingsystemlight
E L Du n i t( U S A )
EVAPbypasssolenoidvalve('98- 00 models)
EVAPcontrolcanistervent shutvalve('98- 00 models)
EVAPpurgecontrolsolenoidvalve
PrimaryHO2S
SecondaryH02S
VSS
7 . 5A BLVBLU ABS controlunit
17 7 . 5A Optionconnector(lG2)
BLKA/EL Ay'Ccompressorclutch relay
Blowermotor high relay
Blowermotor relay
Condenserfan relay
Heatercontrolpanel
Left power mirroractuators(viaswitch)
Mode controlmotor
Radiatorfan relay
Recirculation controlmotor
Rightpower mirror actuators(viaswitch)
18 7.54 YEUBLK Daytimerunninglightscontrolunit (Canada)
19 7.54 YEVRED Back-uplights
Reverserelay (A"/T)
20 BLKAr'YHT Daytimerunninglightscontrolunit (Canada)
l0A RED/VHT R i g h th e a d l i g h(tL o wb e a m )
22 1 0A RED/YEL Left headlight(Low beam)
23-44
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under-dash Fuse/RelayBox:
Fuse Capacity wir6 Color Circuit(sl Protocted
1 0A PNK SRSunit (VB)

7 . 5A Powerwindow relay
25 7 . 5A IntegratedControlUnit
; ABS indicatorlight
A/T gear positionindicatorlight
Clock('98- 00 models)
Cruiseindicatorlight
Gaugeassembly
Interlockcontrolunit (A,/T)
Powerdoor lockcontrolunit
Shift locksolenoid(lVT)
SRSindicatorlight
204 Integratedcontrolunit ('98- 00 models)
GRN/BLK Integratedcontrolunit (viawindshieldwiper switch)
Windshieldwashermotor (viaswitch)
Windshieldwiper motor
10A YEUGRN Front accessorysocket
Rearaccessorysocket relay
28 10A Optionconnector(ACC)
YEURED Audio unit
29 Not used
30 7.5A Optionconnector(dashlights)
Integratedcontrolunit
a, olrL" Ashtraylight
A,/Tgear positionindicatorlight
Audio univclock('97model)
Audio unit ('98- 00 models)
Cruiseindicatorlight
Cruisemain switchlight
Dashlightsbrightnesscontrolunit
Gaugelights
Hazardwarningswitchlight
Heatercontrolpanel
Powerwindow masterswitchlight ('99- 00 models)
7 . 5A Integratedcontrolunit
BLU,ryVHT ECM('98- 00 models:M/T)
PCM (4./T)
PGM-Flmain relay
7 . 5A RED/GRN Leftfront pa.kinglight
Leftfront side markerlight
Left rearside markerlight
Lefttaillight
Licenseplatelight
Rightfront parkinglight
Rightfront side markerlight
Rightrearside markerlight
Rightaillight
7 . 5A WHT/GRN lgnitionkey light
lgnitionkey light controlunit ('97model)
Interlockcontrolunit (via ignitionswitch)
Key interlocksolenoid
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23-45
GroundDistribution
Ground-to-Component(sl
Index
Ground Wire Color Component or Circuits Grounded
BLIVRED Battery
G2 BRN ValveCover
G3 BLK Transmissionhousing
G1 0 ' l BLK A,/Tgear position switch
ECM(PG1,PG2)('98- 00 models:M/T)
PCM(PG1,PG2l(Avrr)
PGM-FImain relay
Powersteeringpressure(PSP)switch
Radiatorfan switch
VSS
BRN/BLK Datalinkconnector
ECM(1G1,LG2)('98- 00 models:M/T)
PCM(LGI, LG2)(IVT)
Shielding:
between ECM ('98 - 00 models: M/T) or PCM (Ay'T)and CKFsensor
betweenECM{'98- 00 modets:M/T}or pCM (Ay'T) and CKpsensor
between ECM ('98 - 00 models: M/T) or PCM (rVT)and CYPsensor
betweenECM ('98 - 00 models: M/T) or PCM (Ay'T)and TDC sensor
between ECM {'98 - 00 models: M/T) or PCM (ly'T)and countershaftspeed sensor (Ay'T)
between ECM ('98 - 00 models: M/T) or PCM{A,,/T)and mainshaftsped sensor {!VT)
between ECM ('98 - 00 models: M/T) or PCM(A,/T)and primary HO2S
between ECM ('98 - 00 models: M/T) or PCM(Ay'T)and secondaryHO2S
G201 BLK H o r n( H i g h )
Horn {Low}
Radiatorfan motor
R i g h th e a d l i g h t
Rightfront parkinglight
Rightfront side markerlight
Rightfront turn signallight
G202 BLK Condenserfan motor
Cruiseactuator
Leftfront parkinglight
Leftfront side markerlight
Leftfront turn signallight
Leftheadlight
Rearwindow washermotor
Windshieldwashermotor
G351 BLK ABS pump motor
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23-46
Ground Wir Color Component or Circuits Grounded
G401 BLK ABS indicatorcircuit

ABS controlunit
Ashtraylight
A/T gear positionindicatordimmingcircuit
Brakefluid levelswitch
Clutchinrerlockswitch(M/T)
Clutchswitch(Mff)
Cruisemain switch
Cruiseindicatorcircuit
Cruisecontrolunit
Dashlightsbrightnesscontroller
Dataiink connector
Daytimerunningrightscontrolunit (Canada)
Front accessarysocket
Gaugeand indicators
Heatercontrolpanel
lgnitionkey light controlunit ('97model)
lgnitionkey switch
Integratedcontrolunit
Interlockcontrol unit (Ay'T)
Parkingpin switch{A,/T)
Powerwindow relay
Rearaccessary socketrelay
Bearwindow defoggerrelay
Rearwindow wiper controlunit ('97model)
Servicecheckconnector
Spotlights
SRSindicatorcircuit
Turn signal/hazard relay
Windshieldwiper motor
Windshieldwiper/washerswitch
- plus everythinggroundedthrough G402
G402 BLK ABS controlunit
Blowermotor relay
Blowermotor high relay
E L Du n i t( U S A )
Powertransistor
- plus everythinggroundedthroughG401
{cont'd)
www.emanualpro.com
23-47
GroundDistribution
Index(cont'dl
Ground-to-Component(sl
Ground Wire Color Component or Circuits Grounded
G501 BLK Audio unit

BLK Driver'sdoor lockactuator(doorlockknob switch)
Driver'sdoor lockswitch
Driver'spowerwindow motor
Powerdoor lockcontrolunit
Powermirror switch
Powerwindow masterswitch
G552 BLK Driver's seat belt switch
F u e lg a u g es e n d i n gu n i t
BLK Fuelpump (FP)
Leftrearside markerlight
Lefttaillight
Rearaccessary socket
Rightrearside markerlight
BLK High mount brakelight
Rearwindow defogger
Rearwindow wiper motor
Rjghtaillight
- plus eveMhing groundedthroughG631
BLK Hatchglassopenersolenoid
Licenseplatelight
- plus eveMhing groundedthroughG6l1
G801 BLK SRSunit
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23-48
Box
Fuse/Relay
Under-dash
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e Installation:
SRS componentlocations,precautions,and procedures
in the SRSsection(241beforeperformingrepairsor ser- 1. C o n n e c t h e c o n n e c t o r st o t h e u n d e r - d a s hf u s e /
vice. relay box (seesection24 for the SRSmain harness
connector),then install the under-dashlusehelay
I Removal:
1. Makesureyou havethe anti-theftcode for the radio,

then write down the frequenciesfor the radio'spre-
2.
box in the reverseorderof removal.
lnstallthe knee bolsterand the driver'sdashboard

lower cover(seesection20).
set buttons(with anti-theftfeature).
3. Connectthe batterypositivecable,then connectthe
2. Disconnectthe batterynegativecable,then discon- negativecable.
nectthe positivecable,and wait at leastthree min-
utes. 4. Enterthe anti-theftcodefor the radio,then enterthe
customer'sradiostationpresets(with anti-thettfea-
3. Removethe driver'sdashboardlower cover and the ture).
kneebolster(seesection20).
5. Confirmthat all systemswork properly
4. Removethe two mountingnuts,and pull the under-
dashfuse/relaybox out from underthe dash
D i s c o n n e ctth e c o n n e c t o r sf r o m t h e u n d e r - d a s h
fuse/relaybox (seesection24 for the SRSmain har-
nessconnector),and take out the under-dashfuse/
relayoox.
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23-49
Battery
Test
@M
. Battery fluid (eleqtrolyte)contains sulturic acid. lt may couse sevore burns if it gets on your skin or in your eyes. Wear
protective clothing and a fac6 shield.
- lf elestrolyte gets on your skin o. clothos, rinse it otf with wator immdiately.
- lf leqtrolyte gets in your eyes.tlush it out by splashing water in your syes for at least 15 minutes;
call a physician
immediately.
. A battery gives off hydrogon gas. lf ignited, the hydrogen will xplode and could crack the battery case and splattr
acid on you. Kgop sparks.flamss, and cigarettesaway from the battry,
. Overchargingwill raise the tomperatute of the electrolyte.This may torcs electrolyto to spray out of the battEry vents,
Follow the charger manutacturer'sinstructions, and chargethe battery at a proper ral,
Use eithera JCI or BearARBSTtester,and follow the manufacturer's procedures.lf you don't have one of tnesecomput-
erizedtesters,follow this conventionaltest procedure:
To get accurateresults,the temperatureofthe electrolytemust be between70.F(21.c)and loo"F (38"c).
lf the caseis crackedor the terminalsare roose.

replacethe batterv.
CheckIndicatorEYEColor
lf the indicatorshows low electrolyte,
add distilled
water if possible.
EYEIndicatesOK
Test LoadCapacity(#1)
. Apply 300amp load for 15 secondsto removesurface
charge.
. Allow 15 secondsrecoveryperiod.
. Apply test load (seeTest LoadChart).
. Recordvoltageat the end of 15 seconos.
Voltagestaysabove9.6
volts;batteryis OK.
www.emanualpro.com
23- 5 0
(},
Chargeon High Setting(40amps)

Chargeuntil EYEshowschargeis OK,plus an additional30 minutesto
assureJullcharge.
NOTE:lf the batterychargeis very low, it may be necessaryto bypass
the charger'spolarityprotectioncircuitry.
lf the EYEdoes not show chargeis OK within three hours,the batteryis
no-good;replaceit. Writedown how long the batterywas charged.
Test Load Capacity(#2)

. Apply 300amp load for 15 secondsto removesurfacecharge.
. Allow 15 Secondsrecoveryperiod,
. Applytest load (seeTest LoadChart).
. Recordvoltageat the end ot 15 seconds.
Voltagestaysabove9.6volts; Voltagedropsbelow9.6volts;
battery is OK. batteryis no-good,
J-
TESTLOAD CHART
Usethe test load or use 1/2the cold crankingamps (CCA)printedon
the labelon the top of the battery.lf neitheris indicated.usethe infor-
mationbelow:
BATTERY COLDCRANKING TESTLOAD
CODE AMPS (CCA) {amps)
55 410 200
BATTERYCODE
i
5582{LtS)-MF
J
J
PowerRelays
RelayTest
NOTE:See page23-86for turn signal/hazard
relay input . Blowermotor relay
IESI. . Rearwindow defoggerrelay
Normally-opontype: type 1:
'1.
Checkfor continuitybetweenthe terminats.
. Thereshouldbe continuitybetweenthe No. I and
No. 3 terminalswhen power and groundare con-
nectedto the No. 2 and No. 4 terminals.
. Thereshouldbe no continuitybetweenthe No. 1
and No. 3 terminalswhen power is disconnected.
H
\ Terminal
l 3
t"""r f*r t*i__\
Disconnected
Connected o
type 2i
a Blowermotor high relay

a Rearaccessorysocketrelay(M/T)
a l 2 \
Itrrz-Hl
llHrrUll
Y:F,
' , 3 a l
ffi
23-52
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Normally-opentype: Normally-opentype:
1. Checkfor continuitybetweenthe terminals. 1. Checkfor continuitybetweenthe terminals.

. Thereshouldbe continuitybetweenthe No. 1 and . Thereshouldbe continuitybetweenthe No. 4 and
No. 2 terminalswhen power and groundare con No.3 terminalswhen power and groundare con-
nectedto the No.3 and No. 4 terminals nectedto the No. 1 and No. 2 terminals.
. Thereshouldbe no continuitvbetweenthe No. 1 . Thereshouldbe no continuitybetweenthe No. 4
and No. 2 terminalswhen power is disconnected. and No. 3 terminalswhen power is disconnected.
Terminal
\ Terminal
1 2
\ -_\ 3
t.*", ^"- t*f \ tl**^-*
Drsconnected Disconnected
Connected o o Connected o- ---o
a Powerwindow relay
a Radiatorfan relay
a Condenserfan relay . ABS pump motor relay
a A,/Ccompressorclutchrelay
a Reverserelay (A/f)
Horn relay
Rearaccessorysocketrelay {A,/T)
a Startercut relay
\K,
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lgnition Switch
Test ElectricalSwitch Replacement
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e SRS componentsare located in this area. Review the
SRScomponentlocations,precautions,and procedures SRScomponentlocations,precautions,and procedures
in the SRSsection{24}beforeperformingrepairsor ser in the SRSsection{24)beforeperformingrepairsor ser-
vtce. vice.
L l M a k es u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e 1. M a k e s u r e y o u h a v e t h e a n t i - t h e t tc o d e f o r t h e
radio'spresetbuttons(wilh anti-theftfeature). r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
2. Disconnect the batterynegativecable. radio'spresetbuttons(with anti-theftfeature).
3. Removethe driver'sdashboardlower coverand the
kneebolster{seesection20). 2. Disconnect
the batterynegativecable.
4. Disconnectthe 5P connectorfrom the under-dash
fuse/relaybox and the 3P connectorfrom the main 3. Removethe driver'sdashboardlower coverand the
wtre narness, kneebolster(seesection20).
3P CONNECTOR
4. Disconnectthe 5P connectorfrom the under,dash
tuse/relaybox and the 3P connectorf.om the main
wire harness{seeleft column).
R e m o v et h e s t e e r i n gc o l u m n c o v e r s( s e es e c t i o n
'17
t.
Insertthe ignitionkey,and turn it to "0".
7. Removethe two screws and the electricalswitch

from the steeringlock,
5P CONNECTOR
Wiresideof
temaleterminals
Checktor continuitybetweenthe terminalsin each

switchpositionaccordingto the table.
\ rernrnal I I3l 5 3 I1l

(ACC) {BAT} flG1) 0G2i lsrl swrTcH LOCKCYLINDER
ros[ron \
0 (LocK)
r(Accl o- -o
fl (oN) G _o
III(START) o- -.o
{ I | 3Pconnector
lf the continuitychecksdo not agreewith the table, lnstallin the reverseorderof removal.
replacethe electricalswitch.
7. After reconnectingthe battery,enter the anti-theft 9. After reconnectingthe battery,enter the anti-theft
code for the radio,then enter the customer'sradio code for the radio,then enter the customer'sradio
stationpresets(with anti-theftfeature). stationpresets(with antj-theftfeature).
www.emanualpro.com
23-54
GaugeAssembly
section{24}beforeperformingrepairsor service.
I x 1.25mm
24 N.m {2.4
VEHICLESPEEDSENSOF{VSS'
page23-62
Troubleshooting,
GAUGEASSEMBLY
Gauge/lndicator/Terminal
LocationIndex,page 23-56
BulbLocations,page23-57
Removal,page23-61
FUELGAUGESENDINGUNIT
Seesection1l
J-
PARKINGBRAKESWITCH
GAUGE
COOLANTTEMPERATURE BRAKEFLUIDLEVELSWITCH
SENDINGUNIT
SWITCH
ENGINEOIL PRESSURE
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GaugeAssembly
Gauge/lndicator/TerminalLocationIndex
CONNECTOR "A"
{A/T GEABPOSITIONINDICATOR)
a1___-__-____>816 cl--------->cl3
JilililIJililil1
JililtHililL
.. """^
,
o o u e o u
t)1- --->t)5 E1- - -->E5 Fl---->F5
CONNECTOR "D- CONNECTOR "E" CONNECTOR "F"

{ABS INDICATOR) {CBUISEINDICATOR' {SRSINDICATOR}
SPEEDOMETER:
Indicates
60 km/hat 637 rpm or
60 mph at 1,026rpm ofthe
vehiclespeedsensor(VSS).
oo/ \oo
TACHOMETER:
lndicates100rpm at
200pulsesper minute
of the ignitioncontrol
module(lCM).
www.emanualpro.com
23- 5 6
l- Bulb Locations
TAILGATEINDICATOR
LIGHT(,I.4W) SYSTEMLIGHT(1.4WI
CHARGING
GAUGELIGHT{1.4WI GAUGELIGHTI1,4WI
BRAKESYSTEM
LTGHT
11.4Wl LOW ENGINEOIL PRESSURE
SEATBELT HIGHBEAM INDICATORLIGHT{1./rW}
REMINDERLIGHT{1.' W' INDICATORLIGHT
{ 1 . 4W l MALFUNCTION
LOW FUELINOICATOB INOICATOR
LIGHT13WI LAMP {MIL)
BULBI1.4WI
RIGHTTURNSIGNAL LEFTTURN SIGNAL

INDICATORLIGHTI1.' WI INDICATORLIGHT{1,4W}
GAUGELIGHT
t3wl
1,.
f-=\ F -
A/T GEARPOSITION GAUGELIGHTS13WI SRSINDICATOR('1./tW)

INDICATOR {1.12x 7} (Onthe printedcircuitboard)
(Onthe printed GAUGELIGHT{3.' W}
circuitboard)
ABSINDICATOR (1,4W) cRutsEtNDtcAToR w)
11.r2
lOn the printedcircuitboard) (On the printed circuit board)
GaugeAssembly
CircuitDiagram
U N O E R . I I O OFDU S E / R E L8AOYX UNOER_DASH
BATTERY FUSEiNELAY
BOX
N o . 4 1( 1 0 0 A ) N o . 4 2( 4 0 A )
@*"
YEL
E5 ASSEMSLY
GAUGE
'''
l-
| 0l
|
I I
RED 8LK BLU/RED
J
ALTERNATOR
-I
DASHLIGHTS
BRIGHTNESS
CONTROLLER
CRUISE
CONTROL
UNIT
ABS
-I
CONTROL
UNIT
J
SRSUNIT
G401
G4A2
23-58
www.emanualpro.com
(}-.
tI -, I
rJr--------11-.----..1'\-J
I T
BLK/YEL
I BLUMHT
BLKMHTJ 'i- | g
l t Y
YEL_
TURN
SIGNAU
HAZARD
WARNING IGNITION
swrTcH CONTROL
No.si10A) .--......_ I/lODULE
FUSE LEFT RIGHT IcM)
Y Y Y f7
I
BLU
1.,
MALFUNCTION
INDICATOR
tA[rP([,{tL)
{1.4W1
l.,
CRN/ORN
I
PCM
COOLANT
TEII,4PERATURE
SENDING
UNIT
BLK
G401
T
G552
G402
(cont'd)
www.emanualpro.com
23-59
GaugeAssembly
CircuitDiagram(cont'd)
GAUGE
ASSEMBLY
PREVIOUS
PAGE
SEAT
BRAKE BELT TAILGATE
SYSTEM REMINDER INDICATOR
LIGHT LIGHT LIGHT
l1.4Wl (1.4W) {1.4W}
\ a1 \ / '
./ \J 7 \
\
B6
Gnru;neo I f7 | BED'BLU
I INTEGRATED REAR
I i oo,,#, i
R U I \ N | N0GG H T S
I coNTRoL
I UN|T
CEILING
LIGHT
l v
| | I
I L__c_o!l!g_yI'__l
rcanada)
I
l t\ It tI
-l I r-
REDIBLU
A
I Jl
TAILGATE
ABS I SRAKEFLUIO LATCH
CONTROL I LEVET
SWITCH swtTcH
UNIT . Floaldown)
I fCLOSED rTailsate
openI
. Floal
up J fCLoSED
I Glass
rCLOSED open I I0PEN iTailsateclosed.J
lLoPEN toPEN : Glass
closed
I
+
BLK BLK
G401
T
G552
tlsA)-
G402
23-60
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Removal
'1. Remove
the two screwsfrom the instrumentpanel.
2. Removethe instrumentpanelcarefullyto avoiddamagingthe clips.
3. Tilt the steeringwheeldown with the tilt adjustmentlever.
4, Spreada protectivecloth over the steeringcolumn.
5. Removethe four mountingscrewsfrom the gaugeassembly.
6. Pullthegaugeassemblyout, and disconnectall connectorsfrom it.
7, Removethe gaugeassembly.
GAUGEASSEMELY
INSTRUMENT
PANEL
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23-61
VehicleSpeedSensor(VSSI
Troubleshooting
Beforetesting,inspectthe No. 15 (7.5A) fuse in the underdashfuse/relaybox.
T6st tho BLK wirei TESTHARNESS

1. Disconnectthe 3P connector OTLAJ- PT3O2OA
from the vehiclespeedsensor
{VSS). REDTESTHARNESS
2. Connect the test harness
{07LAJ- PT3020A)only to the
enginewire harness.
3. Connectthe FEDtest harness
clip to the positiveprobe of an
ohmmeter,
the REDtest harnessclip and PROTECTIVE
body ground. TAPE
Repairopen in the BLK wire

betwGonthe vSS .nd G101.
GRNTESTHARNESS
CLIP
T.st the BLK/YELwire:
1. Connectthe WHT test harness
clip to the positive probe of a TESTHARNESS
vohmeter,and connectthe RED OTLAJ- PT3O2OA
test harnessclip to the negative
probe.
REO HARNESS
CLIP
WHT TESTHARNESSCLIP
Rep.ir op.n in th. BLK/YELwire

ls there batteryvoltage? betwaen the VSS rnd the und6r-
dash fuse/.6lav box.
Test the BLU/WHTwi.s:

C o n n e c t h e G R Nt e s t h a r n e s s
c l i p t o t h e p o s i l i v ep r o b e o f a
voltmeter.and connectthe RED
test harnessclip to the negative TAPE
probe.
ls thereabout5 V or more? Repairopen in the BLU/WHTwiro

bstweon the VSS and PCM.
(To next page)
23-62
www.emanualpro.com
o-. (Frompreviouspage)
WHT TESTHARNESS
CLIP
TESTHARNESS
T6st the VSS: OTLAJ_ PT3O2OA
1. Turn the ignition switch OFF. BEDTESTHARNESS
2 , C o n n e c tt h e o t h e r t e s t h a r - GRNTESTHARNESS ct-tP
nessconnectorto the VSS,
3. Raisethe front and rearof the
vehiclea , n d s u p p o r tj t w i t h PROTECTIVE
safety stands. TAPE
4. Put the transmissionin neu-
t r a l w i t h t h e i g n i t i o ns w i t c h
oN r).
5. Slowly rotateone wheel with
the otherwheelblocked.
Doesvoltage pulse from 0 to

approx,5 V or more?
'B-
GAUGEASSEMBLY16PCONNECTOR
Spoodom6torT6st:
1, Disconnect the 16Pconnector
" B " f r o m t h e g a u g ea s s e m
2. Toucha probeto the BLUMHT

wire. and connect it to body Wire sideof
groundthrougha voltmeter. femaletermin6ls
3. Slowly rotate one wheel with BLU/WHT
the otherwheel blocked.
I
(v)
R.p.ir opon in the BLU/WHTwire
It
Doesthe meter indicatepuls-
ing voltage? betwen the VSS and the 3oeedo-
mgter.
Integrated Gontrol Unit
CircuitDiagram-'97 Model
UNDER.HOOD
FUSEiRELAY8OX SWlCrl
tGNITtON
BATTEFY
I N o . 4 {' ' 0 0 4 ) \0.d2'40A) |
cr*" w_T+!v_T
ELK
l__*l;;T H-uTr.r--i=r-
I
BLKryEL
G F NBi L K
WINDSHIELD
WIPER/
WASHEF
9WTTCH, lo
,,.h\ WINDSHIELD
OFF/INT INT ( il) WASHEB
SWITCH
V V Y a
g
WHTiBLK YEL
tt l
l I 3
t
t
l
l l-I V
BEMINDEB
LIGHT
WHT]BLKWINDSHIELD (r 4w)
I WASHER
I MOTOB
KEY.IN/SEAT
BELT
NTERMITTENT
WIPERRELAYCIRCUlT andLIGHTS-ON
BEMINDERCIRCUIT
RED/BLU
BLUMHT BLK
DRIVER'S
SEAT
BELT
V
WINDSHIELD
swtTcH
f CLOSED
r Unbuckled
)
(OPEN :Buckled -.1
WIPER
MOTOR BL(
(As) I
-tr
-l
G401 G552
23-64
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< - ELK/WHT
COMBINATON
LIGHTSWITCH
S'TARTEB
\-/ CUT
RELAY
I
RED/GRN
A,/rGEAR
POSrr0NSWTTCH
(CLOSED:lnpostion
Eor N)
1,,,,,"
Yilei'r
GRN/RED
I
.l- . BNAKEFLUIO
LEVELSWITCH
. P A R K I NE
(usA)
swrTcH
GR A K E
NTEGRATED
CONTROLUNIT A8
KEY.IN]SEAT BELTandLIGHTS'ON BULB

BRAKE
R E M I N D ECRR C UT CHECKCIFCUT
B1o
I PowER POWER
BLU/RED DOOR
LOCK DOOR
LOCK
I UNT
CONTFOL CONTROL
UNIT
I J
Y
F r,r'tro
RED
BLUi LTGRN/RED LTGRN/RED LT
t l
"l\
u/ /rh d[)
!s-l
v
I FFONT I LEFT
no*
llon. I PASSENGEBS
I DOOR
I
|
REAB
00OR
155,1'*
I a C L O S E DK e y l n s e d e d
oDen) lSwlTcH
dosedJ J f C-OSED
I
: oootooer ) |
SWITCH
: Door
f CLOSED opel
\oPEN Keyrcmoved ( ooE\ Dootdosed,r \oPEN Doo'closed
| | |
8LK
t l
4 _L
:
-._
-
G40r
IntegratedControlUnit
CircuitDiagram-'98 - 00 Models
FUSE/BELAY
UNOER,HOOD 8OX
EATTERY
N0.41(100A) N0.42(40A)
@*" -....+
WHT/BLK WHT
WHT/RED
IJNDERDASHFUSEiBELAYBOX
WINDSH
ELDWPER/ GRN/BLK
REAS
gsHERlIrTcH
. lo WINDOW
/.Fn WINDSHIELDWIPER
OFF/NT INT ( il) WASHEF MOTOR
SWITCH
f7 f7 Y f7
WHT/BLK
tt l
l
t l -9
t
BLU/BLKYEUBLU
l I
LTGRN WHT/BLK
WINDSHIELD
WASHEF
MOTOR
INTEGFATED
coNTsoLUNIT I 85 I 83 t,,
INTERIT,IITTENT
WIPERRELAY
CIRCUIT NEAFWINDOWINTERMITTENT
WIPERRELAY
CIRCUIT
8LK
G401
G402
23-6 6
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COMBlNATION
LIGHTSWIlCH
\-7
I
REO/GFN GRY
GRN
I
I
rql)
Y4-orot
POSTT1ON (A/T)
I SWTTCH
I . (cLosEDInposrlionEor NI
-"'-},,,,," I CLUTCN
I INTERLOCK
YEL I swrTcH(M,T)
I /CLOSED :Clulch
Dedal\
SEATEELT \lullydeprsssed I
REMNDER |
LIGHT
(1.4W)
Y l1eff
E II
6 g
v**JT"
' BFAKEFLUID
8LK
{
Gl01(A,T)
f;iillrvrr
LEVELSWITCH
'PARKINBGR A K E
(usA)
swrTcH
A6 INTEGRATED
CONTROL
UNIT A8
\-
i
KEY]N/SEAT
BELTandLIGHTS.ON
REMINDERCLRCUIT
I
:
*,
,,,[:ltrh::ffIxl,,'.l'"
KEYLESS/POWER
DOOB
LOCK
CONTROL
UNlT
q
/BLU RED/BLU
RED/BLU
FEO/BLU
l*,*,J I
B L UB/ E D I
V
GFN/nED+-]
LTGRN/RD LTGRN/RED
dF)
Y*
I
DRIVER'S
A
Y
A
Y*,u,.,
t
d['\
\s.i
4P'\
l
lsE SEAT
I cvro\ | Bft_oi|l
EF's l*'n IFFÎ'
13frBELT
swrTcH (3!?i". 13fft"Doo'open) l39P*
l(3 sl:$P)l
rcLosED
(OPEN
lHfi.#' )
Hrtrff"%
l
:Door
oper) | fCLOSED.
. Door
dosd, \oPE\
| fCLO#D.Door
ooe.)
. 000'closed, \oPE\ Door
ciosed,
BtK
4 T
: l
I I
l--
|
l --
G40t
G402
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IntegratedGontrol Unit
Input Test -'97 Model
section{24)beforeperformingrepairsor service.
'1. Removethe driver'sdashboardlowercoverand

the kneebolster(seesection20).
2. the 'l0Pconnectorfrom the inteoratedcontrolunit.

Disconnect
3. Removethe integratedcontrolunit from the under-dashfuse/relaybox.
4. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
. lf the terminalsare bent,looseor corroded,repairthem as necessary, and recheckthe system.

.lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
INTEGRATEO
CONTROLUNIT
rOPCONNECTOR
femaleterminals
23-6 8
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All Systems:
Cavity Wire Test condition Test: Desiredrsult Possiblecauseif result is not obtained
Underall conditions Checkfor continuityto ground: . P o o rg r o u n d( G 4 0 1G
, 402)
414 . An open in the wire
Thereshouldbe continuity.
Under all conditions Checkfor voltageto ground: . Blown No. 43 (7.5A) fuse in the
A9 Thereshouldbe batteryvoltage. under-hoodfuse/relaybox
. An open in the wire
lgnitionswitchON (ll) Checkfor voltageto ground: . Blown No. 25 (7.5A)fuse in the
A6 Thereshouldbe batteryvoltage. underdashfuse/relaybox
Intermittent Wipol System:
Cavity Wire Tost condition Test: Desiredresult Possiblecauss if result is not obtained
lgnitionswitchON (ll), Checkfor voltageto ground: Elown No. 26 (20A)fuse in the
and windshieldwiper Thereshouldbe batteryvoltage. under-dashfuse/relaybox
B1 BLU/BLK switchat OFF/lNT Faultywindshieldwiper switch
Faultywindshieldwiper motor
An open in the wire
lgnitionswitchON (ll) Checkfor voltageto ground: Blown No.26 (20A) fuse in the
Thereshouldbe batteryvoltage. under-dashfuse/relaybox
82 BLUrur'HT Faultywindshieldwiper motor
Anopeninthewire
lgnitionswitchON (ll), Checkfor voltageto ground: Blown No. 26 (20A) tuse in the
and windshieldwipe. Thereshould be battery voltage. under-dashfuselrefaybox
B3 YEVBLU
switch at INT Faultywindshieldwiper switch
An open in the wire
lgnitionswitchON (ll), Checkfor voltageto ground: Blown No. 26 (20A) fuse in the
and windshieldwasher Thereshouldbe batteryvoltage. under-dashfuse/relaybox
B4 WHT/BLK
switchON Faultywindshieldwasherswitch
An open in the wire
(cont'd)
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23-69
lntegratedControlUnit
InputTest-'97 Model(cont'd)
At----------+A7
Key-in/SeatBelt Reminder,Lights-on RemindorSystem:
Cavity Wire Test condition Test: Desiredrosult Possiblecause if re3ult is nol obtainod
C o m b i n a t i olni g h t Checkfor voltageto ground: B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e
switchON Thereshouldbe batteryvoltage. under-dashfuse/relaybox
A8
Faultycombinationlight switch
An open in the wire
lgnitionswitchON {lll. Checkfor voltageto ground: Poorground (G552)
and driver'sseatbelt Thereshouldbe 1 V or less. Faulty seat belt switch
switchunbuckled Blownseatbelt reminderlight
B7 RED/BLU bulb
lgnitionswitchON (ll), Checkfor voltageto groundl
and driver'sseatbelt Thereshouldbe 4 V or more. An open in the wire
switchbuckled
Driver'sdoor open Checkior voltageto ground: . Faultydriver'sdoor switch
Thereshouldbe 1 V or less. . An open in the wire
B9 GRN
Driver'sdoor closed Checkfor voltageto ground:
Thereshouldbe 4 V or more.
lgnitionkey insened Checkfor voltageto ground; Poorground(G401,G,[02)
into the ignitionkey Thereshouldbe 1 V or less. Faultyignitionkey switch
switch An open in the wire
8 1 0 BLU/RED
lgnitionkey removed Checkfor voltageto ground:
trom the ignitionkey Thereshouldbe 4 V or more.
swrtch
Bulb CheckSystem (BrakeSystem Light):
Cavity Wire Test condition T6st: DGsirgd rosult Possiblecause if resuh is not obtainod
lgnitionswitchON {ll), Connectto ground:Brakesystem Blown No. 25 (7.5A) iuse in the
brakefluid reservoir l i g h ts h o u l dc o m eo n . under-dashfuse/relaybox
A4
full, and parkingbrake Blown brakesystemlight bulb
teveroown An open in the wire
lgnitionswitchat Checkfor voltageto ground: Blown No.31 (7.5A) fuse in the
START(lll),and Thereshouldbe batteryvoltage. under-dashfuse/relaybox
A/T gear position Faultystartercut relay
A13
switchE or E FaultyA/f gear positionswitch
P o o rg r o u n d( G 1 0 1 )
An open in the wire
23-70
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InputTest-'98 - 00 Models
L Removethe driver'sdashboardlower coverand the kneebolster(seesection20).
Disconnect 'l5P
2. the connectorfrom the inteqratedcontrolunit.
3. Removethe integratedcontrolunit from the under-dashfuse/relaybox.
. lf the terminalsare bent,looseor corroded.repairthem as necessary, and recheckthe system.

.lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket.
lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.
UNDER-DASH
FUSE/RELAY
BOX
A8<------A14
INTEGRATED
CONTROLUNIT
YEL/BLU LT GRN WHT/BLK
15PCONNECTOR
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www.emanualpro.com
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IntegratedControl Unit
InputTest-'98 - 00 Models(cont'dl
YEL/BLU LT GRN WHT/BLK

A 1- - - - - - - - > A7 GRN/BLK LT GRN/REO
Wiresideof
femaleterminals
A8------->A14
WHT/BLK BLU/RED
Key-in/Se8t Beft Reminder,Lights-on Remindol System:
Cavity Wire Test condition Test: Desiredresult Possiblecaus it result is not obtained
Combinationlight Checkfor voltageto ground: Blown No. 30 (7.5A) fuse in the
switch ON Thereshouldbe batteryvoltage. under-dashfuse/relaybox
A8
An open in the wire
lgnitionswitchON (ll), Checkfor voltageto ground: Poorground{G552)
and driver'sseatbelt Thereshouldbe 1 V or less. Faulty seat belt switch
switchunbuckled Blownseatbelt reminderlight
RED/BLU
lgnitionswitchON (ll), Checkfor voltageto ground: b ul b
and driver'sseat belt Thereshouldbe 4 V or more. An open in the wire
switchbuckled
Driver'sdoor open Checkfor continuityto ground: . Faultydriver'sdoor switch
Thereshouldbe continuity, . An open in the wire
814 GRN
Driver'sdoor closed Checkfor continuityto ground:
Thereshouldbe no continuity.
lgnitionkey inserted Checkfor voltageto ground: Poorground(G401,G402)
into the ignitionkey Thereshouldbe 'l V or less. Faultyignitionkey switch
swrtch An open in the wire
B8 BLU/RED
lgnitionkey removed Checkfor voltageto ground:
from the ignitionkey Thereshouldbe 4 V or more.
switch
Bulb CheckSystem lBrake System Lightl:
Cavity Wire Test condition Test: Desiredresult Possiblecaus if result is not obtained
lgnitionswitchON (ll), Connectto ground:Brakesystem Blown No. 25 (7.5A) fuse in the
brakefluid reservoir l i g h ts h o u l dc o m eo n . under-dashfuse/relaybox
A4
full, and parkingbrake Blown brakesystemlight bulb
leverdown An open in the wire
lgnitionswitchat Checkfor voltageto ground: Blown No. 31 {7.5A) fuse in the
START(lll),and Thereshouldbe batteryvoltage. under-dashfuse/relaybox
A,/Tgear position Faultystarter cut relay
switchE or E FaultyA,/Tgear positionswitch(A,/T)
A13
Faultyclutchinterlockswitch(M/T)
Poorground{G101:AfI. G401and
G402:M/T)
An open in the wire
23-74
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LightingSystem
l-. ComponentLocationIndex
I{IGHBEAM INOICATORI-IGHT
DAYNMERUNNINGLIGHTS
REslsToi lCan!drl
Test,page23-80
COMBINATIONLIGHTSWTCH
Test,page 23-78
DAYTIMERUNNINGLIGHTS
CONTROLUNIT lCanadal
Input Test, page23-79
FRONTTURNSIGNALLIGHT/
Replacment,Page23-80 FRONTSIDEMARKERLIGHT
Adjustment,Page23-81 page23-80
Replacemont,
HIGHMOUNT BRAKELIGHT
BRAKE/PARKING LIGHT
BACK.UPLIGHT
LightingSystem
CircuitDiagram(USAI
UNOER_HOOD
FUSE/RELAY
8OX
BATTERY
@**'
rrf JLo -,.9,;,, Td
UNDER-DASH
FUSEiREIAY
BOX
I f l I
No.5
i,"dii No.4
I
tl0Al Zt'"olli {10A)
N0.30
17.5A)
li':,.î
I I I
RED/BLU RED'BLK
lt l
l
t l
HIGHSEAI\4 J J
INDICATOR
LIGHT
V
' DASHLIGHTS
V
, PARKINGLIGHTS
. DASHLIGHTS . SIDEMARKRLIGHTS
BRIGHTNESS,TAILLIGHTS
COIVTROLLER . LICENSE
PLATETIGHT
BLK BLK
I
G40l
G4a2
.&
-
G202
23-76
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O,- CircuitDiagram(Canada)
UNDERHOOD 80X
FUSEiRELAY
BATTEBY
@*" +WHT
WHT/BLK
UGHTSWITCH
c0t\48rNATroN
l = o ), : . , o F F
RED
- A S HF U S E / R E L8AO
U N D E RD YX
BBAXESYSTEM
LIGHT
ABSCONTROL
UNIT
. DASHLIGHTS ' PARKING

, DASHLIGHTS ' SIDEMAHKER
LIGHTS
LIGHTS
I
I
E R I G H T N E S.ST A I L L I G H T S GRN/RED
C O N T H O L L E. RL I C E N SPEL A T
LIGHT
NEO/CRN
I
T,
8LK
HIGHBEAM
INOICATOR
LIGHT
BLK BLK 8LK 8LK
I I
G401
c402
G202
I
G20
-L
-::
G40l
G402
d
--
G401
G402
LightingSystem
CombinationLight Switch Test
'1. Remove
the driver'sdashboardlower coverand the kneebolster(seesection20).
2. Removethe steeringcolumncovers(seesection'17).
3. Disconnect
the 4Pand 7P connectorfrom the switch.
4. Removethe screws,and slidethe switchtowardthe driver,sdoor,
4P CONNECTOR
2 3 I
5 6
Terminal
1 2 3 5 6
Position
OFF
Headlightswitch
:m: o_ ----o
=D
L0w o-- ----o o- ----o
HIGH o_ ----o o- _--_o_----o
OFF
Passingswitch
r : Canada
ON o_ ---o
23-78
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DaytimeRunningLightsControlUnit Input Test (Canadal
DAYTIMERUNNINGLIGHTS
1. Removethe driver's dashboard lower cover and the CONTBOLUNIT
knee bolstet (seesection 20).
Disconnectthe connectorsfrom the daytime run-

ning lightscontrolunit.
Inspectthe connectorand socket terminals to be

surethey are all makinggood contact.
8P CONNECTOR
lf the terminalsare bent,looseor corroded,repair
them as necessary,and recheckthe system.
l f t h e t e r m i n a l sl o o k O K , m a k e t h e t o l l o w i n g IP
inout testsat the connector' CONNECTOR
YEL/BLK
- lf anv test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input tests prove OK, the control unrt GRN/RED
must be faulty; replaceit. BLK/WHT
RED/GRN
Cavity Tst condition Tost: Desiredresult Possiblecauseii r$uh is not obtained
Checkfor continuityto ground: . Poorground(G401,G402)

Underall conditions
B1 BLK Thereshouldbe continuity. . An open in the wire
Underall conditions Checktor voltageto ground: Blown No. 20 (7.5A) luse in the
A2 BLK,4iVHT There should be battery voltage. under-dashfuse/relaybox
An open in the wire
lgnitionswitchoN (ll) Checkfor voltageto ground: Blown No. 18 (7.5A) fuse in the
Thereshouldbe batteryvoltage. under-dashtuse/relaybox
82 YEUBLK Faultyignitionswitch
An open in the wire
Combinationlight Checkfor voltageto ground: Blown No.,tg (30A) fuse in the

" " There should be battery voltage. under-hoodfuse/relaybox
switchin =D Posi-
A4 RED Faultycombinationlight switch
uon
An open in the wire
Combinationlight Headlights(highbeam)should Poorground (G201.G202,G401,

switchOFF;connecta come on, (andhigh beam G402)
jumperwire between indicatorshouldcome on). Blown headlightbulbs
A1 WHT/RED Faultydaytimerunninglights
the 82 and 41 termi-
nals,then turn the igni- resrslor
tion switchON (ll) An open in the wire
lgnitionswitchON (ll), Connectto ground:The brake Blown No. 25 (7.5A) fuse in the
brakefluid reservoir systemlight shouldcome on. under-dashfuse/relaY box
R'I GRN/RED Blown brake system light
full. and parkingbrake
leverdown An open in the wire
Checkfor continuityto ground: . Faulty parking brake switch
Parkingbrakeleverup
B6 8EDlGRN Thereshouldbe continuity . An open in the wire
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LightingSystem Headlights
Dafime RunningLightsResistor Replacement
Test (Canada)
CAUTION: Halogen headlights bGcomevery hot in use;
CAUTION: The d.ytime running lights resistor becomes do not touch them or the attaching hardware immedi-
very hot when the daytime running lights are on; do not ately after they have been turned oft.
touch it or the attaching hardware immediatelyaller
the lighls have been turned off. 1. Removethe front bumper(seesection2O).
1. Disconnect
the 3P connectorfrom the resistor. 2. Removethe mountingbolts.
3. Disconnecteach connector,then removethe head-

light assembly.
HEADLIGHTASSEMELY
Measurethe resistancebetweenthe resistortermi- HEADLIGHT:60/55 W

nal No. 1 (or No. 2) and the powerterminalNo. 3. TURN SIGNAL/SIDEMARKERLIGHT:
2118W {37 model}
1.0- 2.0 O
Resistance: 2718W ('98 - 00 modelsl
PARKINGLIGHT:5W l'97 modell
Replacethe resistorwith a new one if any of the 3CP{'98 - 00 modelsl
resistances
are beyondspecification.
23-80
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Adjustment
"0" mark as
Bstore adiusting the headlights: 5. lf eitherindicatoris not alignedwith its
. Parkthe vehicleon levelground describedleft column,an adjustmentcan be made
. Makesurethe fuel tank is tull by usinga Phillipsscrewdriver.
. The driver or someonewho weighsthe same should
sit in the driver'sseat. Adjustthe headlightsto localrequirementsby turn-
. Loadthe trunk with the itemsyou usuallycarry' ing the adjusters.
. Push down on the front and rear bumpers several
timesto makesurethe vehicleis sittingnormally' NOTE:
. As the outer lensesare made of an acrylicoated,
polycarbonated material,do not cover the head-
CAUTION: Halogen headlights become very hot in use;
do not touch them or the atiaching hardware immedi- lightswhen they areturnedon
. When making horizontaladiustments,slide the
ately after they have been turned off.
horizontalindicatorgear rearward.
1. ODenthe hood. After horizontaladjustment,put back the hori-
zontalindicatorgear.
2. Removethe left innerfender{seesection20).
3. Checkthehorizontal adjustmentindicator. HORIZONTAL

The "0" markon the indicatorgear should
horizontal INDICATOR
GEAR
be alignedwith the mark.
"0" MARK
Checkthe verticaladjustmentindicator.The bubble

should be centeredunderneaththe longest scribe
markon the gauge.
VERTICALINDICATOR:
ol-
www.emanualpro.com 23-A1
)
RearSide MarkerLights/
LicensePlateLight Taillights
RearSide Marke. Light: 1. Openthe hatchglass.
1. Removethe retainingspring, and removethe rear 2. Disconnect

the 6P connectorfrom the taillight.
side markerlight from the rearbumper.
3. Removethe three screws,then pull out the outer
2. Disconnect
the 2P connectorfrom the light. taillight.
RETAINING
HOUSING
Brak/Plrking light 2115W

LicensPlate Light: Back-uplight: 21CP(18 W)
Turn signll light 21 W
1. Removethe two screwsfrom the licenseplate light,
and pull the light out part of the way. Inspect the gasket; replace it if it is distorted or
$ays compressed.
2. Disconnect
the 2Pconnectorfrom the light,
Installthe taillight, and run water over it to make
sure it does not leak.
LIGHT(8 WI
23-A2
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Back-upLights
CircuitDiagram
FUSE/RELAY
UNDEN-HOOD BOX
_*,,@_ "*"
*"_,,.
]__ _..'
-r- iu.Er.w
(M/r)
I
I
BACK,UP
LIGHT
swtTcH
/0n1he \
I lransmisson J
\no!s{ /
lolosed : Inposilion
Rl
GRN/BLK
I LEFI
BACK,UP
LIGHT
2 1 C P( 1 8 W )
RIGHT
BACK,UP
LGHT
2 1 C P0 8 W )
A,/IGEAR
Posrl0N
swtTcH
/Back'up \
\lhl swilch ,/
ICLOSED : Inposilion
[8ll
TBLK 8LK
I I
G101
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BrakeLights
GircuitDiagram High Mount BrakeLight
Replacement
UNDER.HOOD
FUSE/RELAY
BOX 1. P u s ht h e c l i p s , a n d r e m o v e t h e c o v e r f r o m t h e
BATTENY housing.
No.s2
{15A) |
\Y*-I=f*-'o*T*'no"l
/,i\ |
HOUSING
I V
HORNSYSTEM
T:,^-,
*",*"",
i.t53l|
I
GRNA,VHT
-.1
GBNMHT
I
I
. ABSCONTFOL
UNIT
' ECM/PCM
. CRUISE
CONTROL
UNIT
2. Disconnect
the connectors.
Removethe two nuts and the housing.
GRNAVHT GRNWH
l l
t l
LEFI
BFAKE
LIGHT
(2rw)
A[$^Jlr
A RIGHT
EFAKE
LIGHT
(21w)
Yi,?'il
Y
BLK
t
BLK
l
BLK
lr ll
I
BLK
I
d
I
G553 oi,,
23-84
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Turn SignallHazardFlasherSystem
O -. CircuitDiagram
UNDER.OASH
HOOD
UNDEF BOX
FUSE/NELAY IGNT]ONSWITCH FUSE/RELAY
BOX
BATTEFY No12(7.sA)
@**'
N0.30(7.54)
FUSE
YEUBLK
V
WHTiELK
I
REO/BLK
l,
\ l----r-l-----i-F-- --------_ \
HAZARD
WARNING
swtTcH
10 3
tI '
GRN/ORN GRNAVHT FqD
_ GRN/ORN
q- .+
DASHLIGHTS
BSIGHTNESS
CONTROLLER
INDICATOR INDICATOR
(1.4W)
TFAILER
LIGHTING
CONNECTOR
BLK
BtK
:i1r'97model
G553 G401 *2 :'98-00models
G402
Turn SignallHazardFlasherSystem
Turn Signal/HazardRelayInput Test
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponent/ocations,precautions,ano proceoures
vice.
1. Removethe turn signal/hazard

relayfrom the under-
dashfuse/relaybox.
Inspectthe relay and luselrelaybox socketterminals

to be surethey are all makinggood contact.
l f t h e t e r m i n a l sa r e b e n t , l o o s e o r c o r r o d e d ,
reparrthem as necessary, and recheckthe system.
l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
input testsat the fuse/relaybox socket.
- lf any test indicatesa problem,find and cor- ' 1
rectthe cause,then recheckthe system.
- lf all the input tests proveOK, the turn signal/
IF\_-'l
hazardrelaymust be faulty;replaceit. - ] l
/ll
$ o{+-
ll
FUSE/RCLAY
BOX
SOCKET
Cavity Test condition Tesl: Desiredresults Possiblecause if result is not obtained

Underall conditions Checkfor continuityto ground: . P o o rg r o u n d( G 4 0 1G
, 402)
2
Thereshouldbe continuity. . An open in the wjre
l g n i t i o ns w i t c h O N ( l l l Connectfor voltageto ground: Blown No. 12 (7.5A) fuse in the
Thereshouldbe batteryvoltage. under-dashfuse/relaybox
Faultyhazardwarningswitch
An open in the wire
3
HazardwarningswitchON Connectfor voltageto ground: Blown No. 53 (10A) fuse in the under-
Thereshouldbe batteryvoltage. hood fuse/relaybox
Faultyhazardwarningswitch
An open in the wire
Hazardwarningswitch Hazardlightsshouldcome on. Poorground(G201.c202, c401,
ON;connectthe No. 1 G 4 0 2G
, 5 5 3G
, 6 1 1 c, 6 3 1 )
terminalto the No. 3 Faultyhazardwarningswitch
terminal. An open in the wire
1 l g n i t i o ns w i t c hO N ( l l )a n d R i g h to r l e f t t u r n s i g n a ll i g h t ss h o u l d . Faultyturn signalswitch
t u r n s i g n a sl w i t c hi n r i g h t come on.
or left;connectthe No. 'l
t e r m i n atlo t h e N o . 3
terminal.
23-86
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Turn SignalSwitch Test HazardWarningSwitch Test
1 . Removethe driver'sdashboardlower coverand the 1. Removethe centerpanel{seesection20).
2. Removethe two screws,then remove the switch
Removethe steering column covers {see section from the centerair vent.
17]-.
D i s c o n n e c t h e 4 P a n d 7 P c o n n e c t o r sf r o m t h e
switch.
4. Removethe screws,and slidethe switchtowardthe

driver'sdoor.
lNol usd)
HAZARD
swtTcH
Checkfor continuitvbetweenthe terminalsin each
Checkfor continuitybetweenthe terminalsin each

switchpositionaccordingto the table. \ Terminal
2 3 5 7 8 10
t**--\
Terminal
1 2 OFF (9 U (_)
Position
RIGHT o-
Neutral
ON o @o o o o
o- --o
tl-
LEFT
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23-87
lgnition Key Light System-'97 Model
CircuitDiagram
IJNDER-HOOD
FUSE/HELAY
BOX
BATEBY
l-Noj',roo{ l;;f
tF*-'--ff::f-*"-l
.l-----
| ; )"tli|illsx"r
I
WHT/CRN
I
,k ,0r,,o,u
( P I KEYLGHT
{14w)
Y
I
WHT/BLK WNT/GRN
ORVER'S
000R
9!rl9rl^
^
ULU5EU:UOOrOpen
I I
(OPEN :DoordosedJ
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ControlUnit Input Test
l. Bemovethe driver'sdashboardlowercoverand the kneebolster(seesection20).
the 5P connectorfrom the controlunit.

2, Disconnect
. lf the terminalsare bent,looseorcorroded,repairthemas necessary, and recheckthe system.

. lf the terminalslook OK, makethe followinginput testsat the connector.
- lf any test indicatesa problem,find and correctthe cause.then recheckthe system.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
IGNITIONKEYLIGHT
CONTROLUNIT
5P CONNECTOR
))
Cavity Wire Test condition Test: Desiredresult Possiblecauseif rsult is not obtained
Underall conditions Checkfor continuityto ground: . Poorground{G401,G402}

BLK . An open in the wire
lgnitionswitchON (ll) Checkfor voltageto ground: . Blown No. 33 (7.5A) fuse in the
'I Thereshouldbe batteryvoltage. under-dashfuse/relaybox
WHT/GRN
Driver'sdoor open Checkfor voltageto ground: . Faultydriver'sdoor switch
Thereshouldbe 1 V or less. . An open in the wire
GRN
Driver'sdoor closed Checkfor voltageto ground:
Thereshouldbe 4 V or more.
Underall conditions Connectto ground:lgnitionkey Blown No. 33 (7.5A) fuse in the
light shouldcome on. under-dashfuse/relaybox
WHT/BLK
Blown ignitionkey light bulb
An open in the wire
DashLightsBrightnessController
CircuitDiagram
G401
23-9 0
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ControllerInput test
NOTE:The controlunit is built into the dashlightsbright-
nesscontroller.
1. Carefullypry the controllerout of the dashboard.
the 3P connectortrom the controller,

Disconnect
Inspectthe connectorterminalsto be sure they are

all makinggood contact.
. lf the terminalsare bent,loose,or corroded,repair

them as necessary, and recheckthe system.
. lf the terminalslook OK, makethe followinginput
tests at the connector.
- lf any test indicatesa problem,find and cor-
rect the cause.then recheckthe system.
- lf all the input tests prove OK, the controller OASHLIGHTS
BRIGHTNESS
must be taulty;replaceit. CONTROLLER
Wire sideof
lemaleterminals
Csvity Wire Tst condhion Tsst: Desiredresuli Possible cause if result is not obi8inod
Combinationlight Checkfor voltageto ground: Blown No. 30 (7.5A) fusein the

switch ON Thereshouldbe batteryvoltage. under-dashfuse/relaybox
1 RED/BLK
An open in the wire
Underall conditions Checkfor continuityto ground: . Poorground(G401,G402)
2 BLK . An open in the wire
Thereshouldbe continuitv.
Combinationlight Connectto ground: . An open in the wire
5 RED switchON Dashlightsshouldcome on full
bright.
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23-91
InteriorLights
FRONTCEILINGLIGHT
Test,page 23-94
SPOTLIGHTS FRONTPASSENGER'S
Test, page DOORSWITCH
REARCCILINGLIGI{T
Test, page 23-94
RIGHTREAR
swtTcH
DRIVER'SDOORSWITCH
HATCHGLASS
LATCHSWITCH
LEFTREAR
oooRswtTcH
TAILGATE
LATCHSwlTCH
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23-92
CircuitDiagram
I J
FUSERELIY
UNOER.I]OOO BOX
BA--FqY
[t..*;;;;l
\:/-*-.........-='_Fn-'.,,
o-,
INDCATOF
!ICH'I
f7
I
II
BLU/EL(
I
I
rJ----r
I| Y| l^,,o.orro
| coNthoL
I F#l*'
FI
LTG
t_* d,*^*
"r**I
r"$$i,,,,,*,,
I
/f\
\9/
I FRoNT
I PASSENGEF'S
| 0@R
) | swrlcN
J lTcLosED D@'
( I
.-"
Iuffi**
I Iii{il'' l!oPEN:D@'
l J l t I
I
InteriorLights
CeilingLaghtTest SpotlightTest
Front and rgar: 1. Turn the spotlightswitchOFF.
1. Turn the light switchOFF. 2. Pry off the lens.
2. Pry off the lens. 3. Removethe two screwsand the housing.
3. Removethe two mountingnuts and the housing. 4. Disconnect

the 3P connectorfrom the housing.
4. the 3P connectorfrom the housing.

Disconnect
1 1' 3' 2'
aULB(5Wx2l

switchpositionaccordingto the table,
Checkfor continuitybetweenthe terminalsin each \ Terminal 2

switchpositionaccordingto the table. 1 ol 3
t"",rr" \ 2'
trmtnar 1
ON o- /-\
\:./ --o
\ or R
2' 3' 3
Position \ 1' OFF o @ o
OFF o- Pd'l -o
MIDDLE o- /=\ -o ON o- /a
\:./ --o
L
ON o- /a\
\:/ -o OFF o- (9 --o
23-94
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AccessorySocket
o-. Circuit Diagram
UNDER_HOOO
FUSE/RELAY
8OX IGNITIONSWITCH
txt
Fffi^-.rr-.rrl wHT'BrK 6\
+*HT-137F wHr
BLK
t-'**1*fffiT
| -*T]
I
REO/GRN
( I I UNDER-DASH
) No.6
i ll%ti i l9:,'3FUSE/RELAY
BOX
i{10A) I T
Y E LGRN
I
/BLK YEL/GRN YEL,
YEL/GflN RED/BLK
l-
J-i,_,
''l '"*'
l t
t l
l ft- l333iEi.''
I
,*1.I
ir*?:r"$
t l t l
| $Ni*"
t-*r-
BLK
t 8LK
l t
8LK 8LK
l
l J
tl t l lt l l
- l
-:a -:
G553 G40t G401 G40t
G4A2 G4A2 G4A2
AccessorySocket
AccessorySocketTest/Replacement
Front AccessorySocket: 5. If all the tests proveOK, replacethe front accessory
socket.
1. Removethe centerdashboardlower cover (seesec-
t i o n2 0 ) .
2. the 2Pconnectorfrom the front accessory

Disconnect
socket.
Inspectthe connectorterminalsto be sure they are

lf the terminalsare bent,looseor corroded,repair

them as necessary, and recheckthe system.
l f t h et e r m i n a l sl o o kO K ,g o t o s t e p4 .
PBOTECTOB
FACEPANEL
ACCESSORY
SOCKET
Turn the ignition switch to ACC (l), and checkfor

voltagebetweenthe No. 1 and No. 2 terminals.
. Thereshouldbe batteryvoltage.
. lf there is no batteryvoltage,checkfor:
- b l o w n N o . 2 7 ( 1 0A ) f u s e i n t h e u n d e r - d a s h
fuse/relaybox.
- p o o rg r o u n d( G 4 0 1G , 402).
- a n o p e ni n t h e w i r e .
23-96
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RearAccessorySocket: 5. Removethe thermofusehousingand thermal pro
tector,then removethe socketand cover.
'1. Removethe left rear side trim panel
{see section
20t.
2. Disconnect
the connectors.
COVER
THEEMAL
3. lnspectthe connectorterminalsto be sure they are PROTECTOR
l f t h e t e r m i n a l sa r e b e n t ,l o o s eo r c o r r o d e d ,
repairthem as necessary,and recheckthe sys
tem.
T$
. l f t h e t e r m i n a l lso o kO K ,g o t o s t e p4 .
ACCESSORY THERMOFUSE
SOCKET HOUSING
SOCKET
A (YEL/8LUI
ry
\ J
I IBLK}
4. Turnthe ignitionswitchto ACC(l),and checktor volt

agebetweenthe A and B terminals.
o Thereshouldbe batteryvoltage.
. lf there is no batteryvoltage,checkfor:
- b l o w nN o . 6 ( ' 1 0A ) a n d N o . 2 7 ( 1 0A ) f u s e si n
the under dashfuse/relaybox.
- faulty rear accessorysocketrelay (test,page
23-53).
- poor ground (G401,G402,G553).
J - a n o p e ni n t h e w i r e .
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23-97
Glock-'98 - 00 Models
CircuitDiagram
UNDEE,HOOD
FUSE/RELAY
BOX IGNTIONSWlTCH
BATTERY
@-*" -l
No.41(1004) N0.42140A)
N0.47(7.54)
UNOEN.DASH
FUSgFELAY
8ox
G40t
G402
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23-9 8
Removal Terminals
1. Removethe centerair vent (seesection20).
2, the 4Pconnector.
Disconnect
3. Removethe two screws.
CLOCK
Connectsto
Constantpower (time
I WHT/BLU
memory)
YEL lG1 (mainclockpowersupply)
RED/BLK Lights-onsignal
4 BLK G r o u n d{ G 4 0 1G
, 402}
CENTERAIR
VENT
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t
I
I
23-99
StereoSoundSystem
AUDIOUNIT
AI{TENNA MAST page23-'102
Replacement.
Replacement,page 23'103 page23-102
Terminals,
SUB ANTENNALEAD
FROI'ITSPEAKERS
page23-103
Replacement,
REAR
Beplacement,pago 23-103
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23-100
E
t J CircuitDiagram
-T
UNOEB,DASH
FUSE/FELAY
UNDER.HOOO BOX IGNITIONSWITCH FIJSE/RELAY
BOX
l-^*"-l
T'5
WHT,tsLK
1
I
(7.5A)
No.30
II
II
FUSE
I
a,-, YEURED
AUOIO
UNIT
o o o o
1 sl 1 6 l |7 [ 6 1 s tr4 | 1l7l
GHY,ryVHT BRN/BLK
LEFTREAR RIGHTBEAR LEFI FRONT RIGHTFBONT

SPEAKER SPEAKER D O O FS P E A K E R DOOBSPEAKER
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23-101
StereoSound System
Audio Unit Removal AudioUnit Terminals
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio's presetbuttons (with anti-theftfeature).
Removethe centerpanel(seesection201,
Removethe four mountingbolts,and pull the audio

unit out.
D i s c o n n e c t h e ' l 6 P c o n n e c t o ra n d s u b a n t e n n a
lead,then removethe audio unit.
AUDIOUNIT
CENTEBPANEL
Cavrty Wire Connoct3 to

1{7) RED/GRN Right front door speaker@
Installin the reverseorderof removal. 2 {8} BLU Left front door speaker@
3 {9) RED/BLK Lights-onsignal
After installingthe audio unit, enter the anti-theft
Constantpower (tuning
code for the radio. then enter the customer's radio 4 (10) WHT/BLU
memory)
station presets(with anti-theftfeature).
ACC (main sterso power
5 (2) YEURED
supplyl
7 (6) BLU/YEL Left rear soeaker@
8 (s) RED/VEL Rightrearspeaker@
9 (17) BRN/BLK Riqht f.ont door speakerO
1 0( 1 8 ) GRY/BLK Left front door soeakerO
Dashlightsbrightnesscon-
1 2( 1 9 ) RED
troller
14 (20) BLK G r o u n d( G 5 0 1 )
1 5( 1 6 ) GRYMHT Left rear speakerO
1 6( 1 5 ) BRN^ll/HT Rightresr speakerO
T e r m i n aN l o . 6 , 1 1 ,a n d 1 3 :N o t u s e d
( T e r m i n aNl o . 1 , 3 ,4 , ' 1 1 , 1 21, 3 ,a n d ' 1 4N o t u s 6 d )
{ ): '99 - 00 models
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23-102
SpeakerReplacement Mast AntennaReplacement
1. Removethe speakercover. NOTE:To remove the antennalead, it is necessaryto
removethe dashboard(seesection20).
2. Removethe threescrewsfrom the speaker.
1. the antennaleadfrom the audio unit.
Disconnect
3. Disconnectthe 2P connector,and removethe door
speaker. 2. Removethe two mountingscrews,then removethe
mast antenna.
Front speaker:
MOUNTINGSCREWS
FRONTSPEAKER
Rearspeaker:
/a--=-
2P CONNECTOR
SPEAKER
COVER
ll-
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23-103
Horns
SRScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions,
HORN
Test,page23-105
HORNSW|TCHES
Test,page 23-106
m
/\
HORNRELAY CAELEREEL
Test. page23-53 R e p l a c e m e n t ,s e c t i o n 2 4
23-104
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CircuitDiagram HornTest
1. Removethe front bumper(seesection20).
2. the 2P connectorfrom the horn

Disconnect
3, Removethe horn.
HORN
2P CONNECTOR
} - BLU/FED
I
fl"'
KEYLESSi
POWEF
DOORLOCK
B L UFi E O
I
BLU/RED
I
4. Test the horn by connectingbatterypower to one
terminaland groundingthe other.The horn should
sound.
CONTROL
UNIT g)iirrN I LOW
HORN
t
BLK BLK
l
l l
I
BLK
I
I
I
G201
5. lf the horn failsto sound,replaceit
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23-105
Horns
Switch Test
1 . Disconnectthe batterynegativecable,then disconnect 6. Removethe driver's airbag (see section 241,then
the positivecable,and wait at ieastthreeminutes. disconnectthe horn connectorfrom the steerinq
wneet.
Disconnect
the driver'sairbagand front passenger's
airbagconnectors(seesection24). 7 . Checkfor continuity betweenthe No. 2 or No. 3 ter-
minal of the cable reel sub-harness3P or 6P con-
Removethe drive.'sdashboardlower coverand the nectorand horn Dositiveterminal.
Disconnectthe cablereel sub-harness

3P or 6P con-
nectorfrom the main wire harness.
MAIN WIRE CABI.I REEL

HARNESS SUB.HARNESS
3P o. 6P 3P or 6P
CONNECTOR CONNECTOR
HORNCONNECTOR
lf there is no continuity,replacethe cable reel

37 modol ,98- 0Omodots (seesection 24).
Terminal
sideof lf there is continuity.repair or replacethe horn
maleterminals switch.
8. lf sll tests prove OK, reinstall the driver's airbag

(seesection24), and reconnectthe cable reel sub-
Checkfor continuitybetweenthe No. 2 or No. 3 ter- harnessconnector.
m i n a l o f t h e c a b l er e e l s u b - h a r n e s a
snd body
groundwith the horn switchpressed. 9 . Reconnectthe driver'sand front passenger's
airbag
'97 model: '98 - (X)modols: connectors,and reinstallthe accesspanel on the
steeringwheel.
1 0 . Reconnectthe batterypositivecable,then the negative

cable.
1 1 . After installing the airbags, confirm proper system

operatron:
Terminalsideof Terminalsideof . Turn the ignitionswitch ON (ll);the SRS indica-

tor light should come on for about six seconds
. lf there is continuity.the horn switchis OK. and then go off.
. lf there is no continuity,go to step 6. . Makesure both horn buttonswork.
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23-106
PowerMirrors
CircuitDiagram
FUSURELAY
UNDER.HOOD BOX IGNITION
SWITCH
N0.41(100A) N0.42(40A) lBAI \

- l
@"*' +WHT
WHT/8LK
\
.Y^rc2l
YEL
I
-t----t UNDER,DASH
I lu.'xI FUSE/RELAY
B0x
I
BLKIryEL
POWEN
MIRRON
SWTCH
3 5
YEURED BLUMHT BLK
+l
vHT
GRN
l,- -:
G551
'9&00rnodels
[ ]:
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23-107
PowerMirrors
FunctionTest
1. Pry the switch out of the dashboard.Be carefulnot Left mirror inoperative:
to damagethe mirror switchor the dashboarddriv-
er's lowercoverwhen pryingthe switchout. 6. Connectthe No. 2 {BLKI/EL)terminal of the ,l0p
, Disconnect the 10Pconnectorfrom the switch. connectorto the No. 3 (YEUREDIterminal and the
Choosethe appropriatetest dasedon the symptom: N o . 5 ( o r N o . 6 ) t e r m i n a lt o b o d y g r o u n d w i t h
. Both mirrorsdon't work, go to step 4. jumper wires. The left mirror should tilt down (or
. Left mirror doesn't work, go to step 6. swing left) when the ignition switch is turned ON
. Rightmirror doesn'twork,go to step 7. t).
lf the mirror doei not tilt down (or does not swing
left),removethe left door panel,and checkfor an
open in the BLUMHT (or BLU/BLK)wire between
the left power mirror and the switch. lf the wire is
OK,checkthe left power mirror actuator,
lf the mirror neithertilts down nor swings left,
repairthe YEUREDwire.
lf the mirror operatesproperly,checkthe mirror
switch.
Right mirror inoperaiiva:
7. Connectthe No. 2 {BLVYEL)terminat of the 1Opcon-

nectorto the No. 3 (YEURED) terminaland the No. 9
(or No. 8) terminal to body ground with jumper wires.
The right mirror should tilt down (or swing left) when
the ignitionswitchis turnedON l).
. lf the mirror does not tilt down (or does not

swing left), remove the right door panel, and
checkfor an open in the GRN,4TVHT (or yEUBLK)
w i r e b e t w e e nt h e r i g h t p o w e r m i r r o r a n d t h e
switch. lf the wire is OK, checkthe right power
mtrror actuator.
. lf the mirror neithertilts down nor swings left.
repairthe YEUREDwire.
-.t-..------'-
. lf the mirror operatesproperly,checkthe mirror
switch.
Both inoperative:
4. Checkfor voltage between the No. 2 (BLVYEL)ter-

minal and body groundwith the ignitionswitch ON
flr).
Thereshouldbe bafteryvoltage,
. lf there is no voltage,checkfor:
- blown No. 17 (7.5 A) fuse in the under-dash
fuse/relaybox.
- an open in the BLK,/YEL wire.
. lf there is battery voltage, go to step 2.
5. Checkfor continuitybetweenthe No. 4 {BLK)termi-
nal and body ground.
lf there is no continuity,checkfor;
. an open in the BLKwire.
. poor ground (c551).
23-108
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Switch Test Actuator Test
1. Removethe switch as describedin FunctionTest 1. Prv out the mirror mount cover (seesection20).
{seepage23-108).
2. the 8P connectorfrom the power mirror.
Disconnect
2. CheckJor continuitybetweenthe terminalsin each
switchpositionaccordingto the table. MIRRORMOUtrlT
COVER
\ Teminal
2 3 4 5 b 8 I
t*t* \
UP o ooo
DOWN oo oo
L
LEFT o .o o o
RIGHT o oo o
UP o oo o
DOWN oo o o
R
oo o o
J- RIGHT o oo o
Checkactuator operation by connecting power and
groundaccordingto the table.
\ Terminal
-\ 1 8
;;,i".
TILTUP @
TILTDOWN @
SWINGLEFT o @
SWINGRIGHT @ o
POWERMIRROR
swtTcH
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23-109
RearWindow Defogger
GomponentLocationIndex
rr^ja} aia\ al I rl
!
REABWINDOWDEFOGGER SWTTCH
InputTest,p89e23-113
FUSE/RELAY
BOX
REARWINDOW DEFOGGER
FunctionTest.page23-112
DetoggerWreRepair,page23-112
23-110
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EI
a- CircuitDiagram
BOX
FUSE/REI-AY
UNDER-HOOD
IGNITION
SWTCH
BATTERY
N 0 . 4 2( 4 0 4 )
N 0 . 4 1{ 1 0 0 A )
-f
@-*" +WHT
WHT/8LK
"r?h
\_--,' I
I
II
l- REAsWINDOW
B1 {iniheheater
DEFOGGER
SWITCH
panel)
control
l"
8LK
I J G401
G402
RearWindow Defogger
FunctionTest DefoggerWire Repair
1. Checkfor voltagebetweenthe positiveterminaland NOTE:To make an effectiverepair,the brokensection
body ground with the ignitionswitch and defogger m u s tb e n o l o n g e rt h a no n e i n c h .
switchON.
Thereshouldbe batteryvoltage. 1. Lightlyrub the areaaroundthe brokensectionwith
fine steelwool, then cleanit with alcohol.
. lf there is no voltage.checkfor:
- faultydefoggerrelay. 2. Carefullymaskaboveand belowthe brokenportion
- faultydefoggerswitch. of the defoggerwire with cellophanetape.
- an open ,n the BLK/BLU,WHT/GRN,BLU/YEL,
or BLKwire.
. lf there is batteryvoltage,go to step 2. OPEN
POSITIVETERMINAL
CELLOPHANE
TAPE
Mix the conductivepaint thoroughly.Using a small

brush, apply a heavy coat of the conductivepaint
extending about 1/8" on both sides of the break.
Allow 30 minutesto dry.
Checkfor continuitybetweenthe negativeterminal

and body ground.
l f t h e r e i s n o c o n t i n u i t yc, h e c kf o r a n o p e n i n t h e
defoggergroundwire.
Touch the voltmeter positiveprobe to the halfway

point of eachdefoggerwire, and the negativeprobe
to the negativeterminal.Be carefulnot to scratchor
damagethe defoggerwireswith the testerprobe.
Thereshouldbe approximately6 V with the ignition
switchand the defoggerswitchON.
. lf the voltageis as specified,the defoggerwire is

oK.
. lf the voltageis not as specified,repairthe defog-
ger wire.
- lf it is more than 6 V, there is a breakin the
negativehalf of the wire.
- l f i t i s l e s st h a n 6 V , t h e r e i s a b r e a ki n t h e
positivehalf of the wire.
Checkfor continuityin the repairedwire.
5, Apply a secondcoat of paint in the sameway. Let it

dry three hoursbeforeremovingthe tape.
23-112
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Switch Input Test
NOTE:Beforetesting, check for blown No. 17 (7.5 A)
fuse in the under-dashfuse/relaybox.
1. Removethe centerpanel{seesection20).
REARWINOOWDEFOGGER SWITCH
lin the heatercontroloanel) CENTERPANEL
Checkfor voltagebetweenthe 84 and 87 terminals

in each switch positionwhen batterypower is con-
nectedto the B l terminal.
OFF lessthan 0.4V

ON baftery voltage
Ol-
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I 23-113
Wipers/Washers
SRScomponentsare locatedin this area.Reviewthe SRs componentlocations,precautions,and procedures
in the s6s
REABWINDOWWIPERMOTOB
Tst,page23-120
WPSR/WASHER SWITCH
Test.page 23-l't9
REARWINDOW WIPER
CONTROL UNlT137mod.ll
Inputtest.page23-118
WINDSHIELD WIPERMOTOR
Tost,page23-119
n
t ff
INTERMITTENT W|PENRELAY
CIBCUIT,REARWINDOWINTERMTNENT
wlPER RELAYCIBCUITl'98 - 0Omod.t.l
UNDER.DASHFUSE/RELA BOX (ln the integratedcontrol unit)
Input test, page 23-68
23-114
www.emanualpro.com
-
l - CircuitDiagram{Windshieldl
UNDEB,DASH
BOX
FUSE/NELAY
UNDEB.HOOD IGNITONSWITCH BOX
FUSENELAY
N0.41(1004) N0.42{40A)
@*"
BLUiBLK
INTEGEATED
CONTFOL
YEUBLU UNIT
/ Hasbui[-in
\
WHTiBLK I inlermiltenl
I
\ wiperrelay/
l-
BLK 8LK BLK
II
I
_L
I
G401 G401 G401
G402 G402 G402
Wipers/Washers
CircuitDiagram(RearWindow)-'97 Model
UNDER.HOOD
FUSE/RELAY
BOX
N0.41(100A) N0.42(40A)
@**' WHT/BLK
+WHT
, 7 ! i s - - - - - - -- - - -
JiJ frT
BLK
t'
8LK
d-l
G401
G4A2
I
G202
I
G611
G631
23-116
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CircuitDiagram(RearWindowl-'98 - 00 Models
FUSEi
UNDER.HOOD 80X
RELAY
BATTERY
N 0 . 4 (11 0 0 A ) N 0 . 4 (24 0 A )
GNITON
@*,' +WHT
WHT/BLK SWTCH
UNDEF-DASH
FTJSE/RELAY
BOX
REAR
WINDOW
WPERMOTOR
J D L
I OFF
GRN/BLK
I
INTEGRATED CONTROLUNT
/Has boll-inre wndow\
w perrelay ]
A n',$s".,,,
t nlermillenl
vil8t8E
BLK
I
BLK BLK
I
n- n_
Ot- .L
-
G202
-:
G611
G40l
G402 G631
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I
23-117
Wipers/Washers
RearWindow WiperGontrolUnit lnput Test-'97 Model
1 . Removethe driver'sdashboardlower cover and the
kneebolster{seesection20).
Disconnect
the 8P connectorfrom the controlunit. 8P CONNECTOF
Inspectthe connectorand socketterminalsto be sure

they are all makinggood contact.
a lf the terminalsare bent,loose,or corroded,repair

them as necessary.and recheckthe system.
. lf the terminalslook OK, makethe following input
tests at the connector.
- lf any test indicatesa problem,find and correct LT GRN/BLK
the cause,then recheckthe system. T GRN/RED\ LT
- lf all the input tests are OK, replacethe control
UNII.
1 2
1 6
GRN/BLK
Cavity Test condhion Test Desirdr93uh Possiblecause il rasuh is not obtained

Underall conditions Checkfor continuityto ground: . Poorground(G401,c402)
4 BLK
Thereshouldbe continuity. . An open in the wire
lgnitionswitchON (lll Checkfor voltageto ground; Blown No. 3 (10A) fuse in the
GRN There should be battery voltage. under-dashfuse/relaybox
An open in the wire
lgnitionswitchON (ll), Checkfor voltageto ground: Blown No. 3 (10A) fuse in the
and rearwindow There should be battery voltage. under-dashfuse/relaybox
'l LT GRN/
wiper/washerswitch Faultyrearwindow wiper/washer
RED
ON switch
An open in the wire
lgnitionswitchON (lll Checkfor voltageto ground; Blown No. 3 {10A) fuse in the
LT GRN/ Thereshouldbe batteryvoltage. under-dashfuse/relaybox
BLK Faultyrearwindow wiper motor
An open in the wire
lgnitionswitchON (ll) Checkfor voltageto ground: B l o w nN o . 3 { 1 0A ) f u s ei n t h e
LT GRN Thereshouldbe batteryvoltage. under-dashfuse/relaybox
Faultyrgarwindow wiper motor
An open in the wire
lgnitionswitchON lll), Checkfor voltageto ground: B l o w nN o . 3 ( 1 0A ) f u s ei n t h e
and rearwindow Thereshouldbe batteryvoltage. under-dashfuse/relaybox
5 GRN/BLK wiper/washerswitch at Faultyrearwindow wiper/washer
washerposition switch
An open in the wire
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23-118
Wiper/WasherSwitch Test WindshieldWiperMotor Test
Windshield/ReErWindow Wiper/WasherSwitch: 1. Open the hood, removethe cap nuts, and caretully
remove the wiper arms so that they do not touch
1. Removethe driver'sdashboardlower coverand the the hood.
Removethe cowl cover(seesection201.
2. Removethe steeringcolumncovers{seesection17)
Disconnectthe 5P connectortrom the windshield
3. D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e wiper motor.
switch, remove the two screws, and pull out the
switch.
\ lind3hi.ld:
tilt-rltl
IEZIA
RaarWindow:
1 12 3
I t-7 al
J- Checkfor continuitybetlveenthe termlnalsin each

switchpositionaccordingto the tables.
Windshield Wiper/WasherSwitch:
\ Terminal
---__\ 4 3 2 1 7 5
P*t-
OFF o o
Test the motor by connectingbattery power and
INT oo o o groundaccordingto the table.
LO o o
HI o o \ -l
Terminal
4
;fi;"
Mistswhch
"0N"
o o LOW SPEED @
Washerswitch"0N" o o H I G HS P E E D @
RearWindow Wipsr/Washer Switch
lf the motor does not tun or fails to run smoothly,
\ ---\Teminal 1 2 3 4 6 replaceit.
ti'"
Washer switch'0N'
G -o G -o Connectan analogvoltmeterbetweenthe No. 5 (+)
(wiperswitchoFFl and No. 3 (-) terminals,and run the motor at low or
high speed.
OFF G -o
The voltmeter should alternatelyindicate0 V 8nd
ON G o 4 V or less.
ll - Washer
switch
(Wiper
"ON'
"0N"1 G -o G -o
switch
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23-11 9
Wipers/Washers
RearWindow WiperMotor Test WasherMotor Test
1 . Removethe tailgatetrim panel(seesection20), 1. Removethe front bumper(seesection20).
Disconnectthe 4P connectorfrom the wiper motor D i s c o n n e c t h e 2 P c o n n e c t o r sf r o m t h e w a s h e r

assembly. molors,
REARWINDOW
WASHERMOTOR
4P CONNECTOR
WIPEB
LOWERCOVEn
Pushtab
to release,
Test the motor by connecting battery power to the Test the washer motor by connecting battery power
No. I terminal,and groundto the No. 3 terminal. and groundaccordingto the table.
lf the motor does not run or fails to run smoothly,

replaceit. L_Iq'.r91 ,l
Battery
4. Reconnect
the 4P connectorto the wiper motor. Disconnected
Connected @
5. Connectan analogvoltmeterbetweenthe No. 4 (+)
and No. 2 (-) terminals.
a lf the motor fails to run smoothly, replaceit.
a lf the motor runs smoothly, but little or no washer
Run the motor by turning the wiper/washerswitch
f l u i d i s p u m p e d ,c h e c kf o r a d i s c o n n e c t e do r
oN. blockedwasherhose,or a cloggedpump outletin
the motor.
The voltmeter should alternatelyindicate0 V and
1 1V o r l e s s .
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23-120
HatchGlassOpener
CircuitDiagram Switch Test
1. Remove the dashboard lower cover (see section
FUSE/RELAY
UNDER.H@D BOX 20).
BATTEFY
|-*;rr^!...',r,*;l
.......1<\o<\r+l 2. Disconnect
the 2Pconnectorfrom the switch.
@*" I R e m o v et h e s w i t c h f r o m t h e d a s h b o a r d l o w e r
3.
I cover.
I
WHT/GRN
DASHBOAND
LOWER COVER
WHT/GRN WHT/GBN
II
rt
KEYLESSi
POWEF
DOOB LOCK
CONTROL
UNIT
V
II
HATCHGLASS
I OPENERSWITCH
YEL
J HATCH
GLASS
OPENER
soLENOr0
TBLK
Checkfor continuitybetweenthe No. 1 and No. 2
terminals.
.
There should be continuity when the switch is
pushed.
Thereshouldbe no continuitywhen the switchis
I released.
out,
Ot- G631
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23-121
HatchGlassOpener
Solenoid Test SolenoidReplacement
1. Open the tailgateand removethe tailgatetrim (see 't. Removethe tailgatetrim (seesection20).
section20).
2. Disconnect
the 2P connector.
2. Disconnect
the 2Pconnectorfrom the solenoid.
SOLENOID
Terminalsade
of
maletermtnals
Removethe rod from the key cylinder.
Connectpowerto the No. 1 terminaland groundto 4. Removethe three mountingbolts,then removethe

t h e N o . 2 t e r m i n a l sm o m e n t a r i l vT. h e s o l e n o i d solenoid.
shouldooerate.
Installthe replacement
solenoidin the reverseoader
of removal.
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23-122
Power Door Locks
ComponentLocationlndex
TRANSMITTER
Test, page23-130
Cod6 Input Procedure,
DRIVER'SDOORL(rcK SWITCH page23-131
Test,page23-129
LOCKBUTTON
HATCHGLASS BUTTON
PA rc AUTTO]II
RIGT{TREARDOORLOCK
ACTUATOR
Test,page 23-129 HATCHGLASSOPENERSOLENOIO
Replacement,section20 fesl, page 23-122
Replacemnt.pago 23-122
FRONTPASSENGER'S
DOORLOCKACTUATOR
Test, page 23-129
R6Dlacement, soction20
LEFTBEARDOORLOCK
ACTUATOB
Tesr,page23-129
Beplacement,
section20
. DRIVEB'SDOORLOCK
KNOB SW|TCH
Tesr,pag623-128
. DRIVER'SDOORLOCK
ACTUATOR
T6st,psge 23-128
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23-123
Power Door Locks
CircuitDiagram(With KeylessEntrySystem)
UNDERDASH
FUSE/FELAY
UNDER.HOOD BOX GNTIONSWTCH FUSE/RELAY
BOX
EATTEFY
@*n'
YEL
WHT/GFN
UNLOCK
ITEYLES--l
nrrenu@
I TRANSMIT]ER
I
Lr--------
HORN
RELAY
f7
LOCK
II- GRY @
HATCH
FRONT
OPENER CEILING KEYLESS
swlTcH LGHT DOOsLOCK
C O N T R OULN I T
f7
Y_o*,,.,,,0-
I
. PASSENGENS
DOORSWITCHES
. ]NTEGRATED
CONTROL
UNIT
5
INTEGRATED I
CoNTROL
UNT I
YEL ,Y, I
F",'*-{
.,ufrro I
fIl
L
t L
l
HATCH
rthg#,i."J
+
l B l GLASS
OPENER
DRIVER'S
DOOFLOCK
SOLENOD
8!?i"'[:lll',fffi) swrTcH
BL(
T
BLK BLK 8LK
I
G61l
G63l
I
I--
G401
G402
I
G551
I
G551
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23-124
CircuitDiagram{WithoutKeylessEntrySystem)
UNDER-DASH
UNDER.HOOD
FUSEi
RELAY
8OX IGNTIONSWITCH FUSE/RELAYBOX
BATTEBY
+wqr-t_t- 6\ tr.*;l vEL
@**' wrr3-K BLKYEL
ffr
l-J'; KNOB
HORN
t
|
I
oBtvERs
DOOnLOCK
ACTUATOR
r
RELAY
V
(Nolused)
LOCK
HATCH
GLASS FRONT
o
OPENER CEILING POWER
SWTCH TIGHT DOOR
LOCK
CONTROL
UNIT
f7 V
l_
I
r-
INTEGRATED EIGHT
REAR
CONTROL
UNIT 00oRLocK
ACTUATOR
V
YEL
I
BLU/RED
I 8Lr YEURED
l-
I
BLU/RED GRNORN -Tq. s l-lLocx^l
l,
II GRNWHT +
, |
-=tGJ--
I
t / |Iupl ,#. L?Vno' I Locx I
tFl ::iii^ ( li: ) swrTcH
YAil''"',4,.'{yrcLosED
DRIVER'S
D00RLOC(
SWITCN
?
tottt
l'
BLK
I
BLK BLK
I
G6l1
II
I':
G()1
G402
II
I:
G551
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'tl
23-125
PowerDoor Locks
GontrolUnit Input Test
1. Removethe driver'sdoor panel(seesection20).
2. Disconnect
the 18Pconnectorfrom the controlunit.
3. lnspectthe connectorand socketterminalsto be surethey are all markinggood contact.
. lf the terminalsare bent,looseorcorroded,repairthemas necessary, and recheckthe system.

- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.
18PCONNECTON
BLU
GRN/BED GRY YEL WHT/REO\ WHT/GRN
7 2 3 ,/ 5 8
10 1t 1 21 1 3 14 16 17 1E
GRN/WHT I LT
femaleterminals
www.emanualpro.com
23-126
Disconnocithe 18Pconnestor from the powr door lock control unit.
Cavity Wire Test condition Tost: Dcsiredresult Po$ible csuse il result is not obtainod
Underall conditions Checkfor continuityto ground: . Poorground(G55'l)
11 8LK Thershouldbe continuity. . An openin the wire
Connectthe No. 7 termi' Checkdoor lock operation: Faultyactuator
nalto the No. 8 terminal, Driver'sdoor shouldunlock. Faultyjunctionconnector(C577)
7 BLU and the No.6 terminalto An openin the wire
the No. 17terminal BlownNo. 51 (20Al{use in the under-
momentarily. hoodfuse/relay box
Underall conditions Connectto ground: BlownNo.52 (15A)tuso in the under-
Hornshouldsound, hood fuse/relaybox
GRY Faultyhorn
Faultyhorn relay
An openin tho wire
Connectthe No. 'l8 termi- Checkdoor lock operation: Faultyactuator
nalto the No. 8 terminal, Passenger'sdoors should unlock. An openin the wire
YEURED and the No.6 terminalto BlownNo.51 (20A)fuse in the under-
the No. 17terminal hood fuse/relaybox
momentarily.
Connectthe No.6termi- Checkdoor lockoperationl Faultyactuator
nalto th6 No.I terminal, All doorsshouldlock. An openin the wire
WHT/RED and the No. 18terminalto BlownNo. 51 {20A) fusein ihe under-
the No. 17terminal hood fuse/relaybox
momentarily.
Connectan ohmmeter Checkfor conlinuity: ' Faultydriver's door lock actualor
betweenthe No. 9 termi- Thereshouldbe continuity. . An openin the wire
9 BLU/RED nal and the No. l7 termi-
nal.Driver'sdoor lock
knobin UNLOCK
*: With keylessentry system
NOTE:To preventdamageto the motor,apply batteryvoltageonly momentarily.
Feconnoctthe 18Pconneqtorto the power door lock control unit,
Cavity Wir6 Test condition Tost: Dsirodresult Possiblecauseif result is not obtaind
Underall conditions Checkfor voltageto ground: BlownNo. 51 (20Alfuse in the under-
WHT/GRN There should be batteryvoltage. hood tuse/relaybox
An openin the wire
Driver'sdoor lockknob in Checktor voltageto ground: Faultydriver'sdoor lockactuator
10 BLUAVHT LOCK Thereshouldbe 1 V or less. Poorground(G551)
An openin the wire
lgnitionkeyis in the igni- Checktor voltageto ground: Faultyignitionkeyswitch
13 BLU/RED tion switch Thereshouldb 1 V or less. Poorground(G401,G402)
An openin the wire
lgnitionswitchON (ll) Checkfor voltage to ground: BlownNo. 25 (7.5A) fusein the under-
YEL There should be battery voltage. dashfuse/relay box
An openin the wire
Connectthe No. 5 Checkhatchglass lock operation: . Faulty hatch glass opener solenoid
5 YEL terminalto the No.I ter- Hatchglassshouldunlock. . An opon in the wire
minalmomentarily
LT Passengor's
door open Checkfor continuityto ground: . F a ( l l t yd o o r s w i t c h
14 . An open in the wire
GRN,NED Thereshouldb continuity.
Front ceiling light Checktor voltageto ground: Faultylront ceilinglight
2 GRN/RD "MlDDLE" position An openin the wire
There should be battery voltage.
Driver'sdoor lock switch Checklor voltageto ground: Faultydriver's door lock switch
12 GRNAr'VHT in LOCK Poorground{G551)
Thereshouldbe 1V or less.
- An openin the wire
' GRN/ORN
Driver'sdoor lock switch
in UNLOCK
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23-127
Power Door Locks
Driver'sDoorLockKnobSwitchTest Driver'sDoorLockActuatorTest
1. Removethe driver'sdoor panel(seesection20). 1, Removethe driver'sdoor panel(seesection20).
2. Disconnectthe 6P connectorfrom the actuator. 2. the 6P connectorfrom the actuator.

Disconnect
6P CONNECTOR 6P CONNECTOR
Terminalsideot Terminalsideof
maleterfiinals maleterminals
Checkfor continuitybetweenthe terminalsin each Checkactuatoroperationby connectingpower and

switch position accordingto the table. ground accordingto the table.To preventdamsge
to the actuator. apply battery voltage only momen-
rsrmrnal tarilv,
\ ? 6
Position \ Terminal
\ __l
LOCK o- -o F*'',1."
UNLOCK o- --o LOCK @ o
UNLOCK @
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23-128
DoorLockActuatorTest
Passenger's Driver'sDoor LockSwitch Test
door panel(seesection20).
1 . Removethe passenger's L Removethe innerhandle{seesection20).
Disconnect
the 2P connectorfrom the actuator. Disconnectthe 3P connector.then removethe two
mountingscrewsand driver'sdoor lockswitch.
NOTE: The left rear door lock actuator is shown;
the front passenger's
and right reardoor lockactua-
tors are similar.
2P CONNECTOR

\ lermlnal
1 2 3
Position \
LOCK o- --o
OFF
Terminal
sideof UNLOCK o- -_o
maleterminals
Checkactuatoroperationby connectingpower and

ground accordingto the table.To preventdamage
to the actuator, apply battery voltage only momen-
raflry.
\ Terminal ,l
;;il;--r
LOCK @
UNLOCK @
4. lf the actuatordoes not work properly, replaceit.
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23-129
PowerDoor Locks
TransmitterTest (With KeylessEntrySysteml
NOTE:
. The ceilinglight (in middleposition)comeson within 30 secondswhen you unlockthe doorswith the transmitter.
. The doorsdo not lockor unlockwith the transmitterif the ignitionkey is in the ignitionswitch.
. lf any door is open,you cannotlockthe doorswith thetransmitter.
o lf you unlockthe doorswith the transmitter,but do not open any of the doorswithin 30 seconds,the doors relockauto-
matically.
. For hatchglassbuttonoperation,hold the buttonfor morethan two seconds.
. lf you pressthe PANICbuttonfor more than two seconds,the horn soundsfor about 30 seconds,and the transmitter
LEDcomeson. (The panic mode will not be activatedif the ignition key is in the ignitionswitch.)The panic mode is
cancelledby pressingany of the transmitterbuftons.
. The horn soundsonly the first time you press a transmitterbutton,(Pressingrepeatedlydoes not activatethe horn
again.)
Doors cannot bo locked or

unlockedwhh lhe transmitter.
BATTERY
{cR20251
R e w r i t et h e t r a n s m i t t e rc o d e ,
then try to locldunlockthe doors
{seepage23-131}.
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23-130
TransmitterProgramming
Storingtransmittercodes:
The codesof up to three transmitterscan be read into
the kevlessreceiverunit memory (lf a fourth code is
stored.the codewhich was inDUtfirstwill be erased.)
N O T E : l t i s i m p o r t a n tt o m a i n t a i nt h e t i m e l i m i t s
betweenthe steps.
1 . Turn the ignitionswitchON (ll).
Within 1 to 4 sec.,push the transmitterlock or unlock

buttonwith the transmitteraimed at the vehicle.
Within 1 to 4 sec.,turn the ignitionswitchOFF.
Within 1 to 4 sec.,turn the ignitionswitchON (ll).
W i t h i n 1 t o 4 s e c . . p u s h t h e t r a n s m i t t e rl o c k o r
u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e
vehicle.
o. Within 1 to 4 sec.,turn the ignitionswitchOFF.
1 . Within 4 sec.,turn the ignitionswitchON {ll).
W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r
- u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e
vehicle.
9 . Within 1 to 4 sec.,turn the ignitionswitchOFF,
1 0 . Within 4 sec.,turn the ignitionswitchON (ll).
1 1 . W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o f
u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e
vehicle.
1 2 . Confirm you can hear the sound of the door lock

aduators.
1 3 .W i t h i n 8 s e c . ,a i m t h e t r a n s m i t t e r s( u p t o t h r e e )
whose codes you want to store at the receiver,and
pressthe transmitterlockor unlockbuttons.
Confirm that you can hear the sound of the door
lock actuatorsafter each transmitter code is stored.
1 4 . Turn the ignitionswitchOFF,and pull out the key.
1 5 . Confirmproperoperationwith the new code{sl.
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23-131
PowerWindows
t t
L--JIJJ'JJL J 1J 15-
- ------------
--) ------------
t_.1
FRONTPASSCNGER'S
WINDOWMOTOR
Test,page23-137
POWERWINDOWMASTER
SWITCH FBOI{TPASSENGER'S
(Hasbuilt in controlunit) WI{DOW SWTTCH
Input Test,page 23-'134 Test,page23-138
Test,page 23-135 LEFTREANWWDOW
SwlTCH
Test,page23-137
LEFTREARWINDOW
MOTOR
Test,page23-'t38
--.-\-.--t
DRIVER'SWINDOW
MOTOR \-
Test, page 23-137
RIGHTREARWINDOW
MOTOB
Test. page 23-138
RIGHT wtNDowswTcH
T6sr,page23-137
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23-132
GircuitDiagram
L]NDEFH@O FISETRELAY
BOX
rblr (r0oA) rlo42t40A)

@-*'
V
I
PASSENGEAS
FFONTPASSENGEFS
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23-133
Power Windows
MasterSwitch Input Test
NOTE:The controlunit is built into the powerwindow masterswitchand only controlsdriver'sdoor window operations.
1. Removethe masterswitch,and disconnectthe 14P,2?and 1Pconnectorsfrom the masterswitch.
. lf the terminals are bent, loose or corroded, repair them as necessary,and recheckthe system,
- lf a test indicatesa problem, find and correctthe cause,then recheckthe system.
- lf all the input tests prove OK, the power window maser switch must be faulty; replaceit.
lirP CONNECTOR
1P CONNECTOR
BLU/ORN RED/BLU YEL/BLK GRN/YEL
BLU/YEL \ RED/YEL GRN
WiresideoI
femaleterminals
GRN/BLK aLu/BLK BLK RED/WHTYEL/GRN YEL
Wire side of
femaleterminals
POWERWINDOWMASTEBSWITCH
RED/BLK
www.emanualpro.com
23-134
Cavity Wi1 Test condition Tesi: Dssiredrosult Po$ible causeif 183uhis not obtained
Underall conditions Checkfor continuityto ground: . Poorground(G551)
A11 Thereshouldbe continuity. . An open in the wire
BLK
B1
lgnitionswitchON (ll) Checkfor voltageto ground: Blown No. 7, 8, 10 or l1 (20A)
A 1 0 BLU/BLK Thereshouldbe batteryvoltage. fuse in the under-dashfuse/relay
box
A9 GRN/BLK Faultypowerwindow relay
An open in the wire
A6 YEUBLK
412 RED/WHT
Connectthe A10 termi- Checkthe driver'swindow motor: . Faultydriver'swindow motor

A4 RED/BLU nalto the 43 terminal, It shouldrun (thewindow moves . An open in the wire
and the A4 terminalto down).
the A11 terminal,then
A3 RED/YEL turn the ignitionswitch
oN flr).
Connectthe A9 termi- Checkthe front Passenger's Faultyfront passenger'swindow
A1 BLUI/EL nalto the A2 terminal, window motor: motor
and the Al terminalto It shouldrun (thewindow moves Faultyfront passenger'swindow
t h e 4 1 1 t e r m i n a lt,h e n down). switch
- A2 BLU/ORN turn the ignitionswitch An open in the wire
oN flr).
Connectthe 46 termi- Checkthe right rearmotor: Faultyright rearwindow motor
A14 YEL nalto the A13terminal, It shouldrun (thewindow moves Faultyrightwindow switch
and the 414 terminal oown). An open in the wire
to the A11terminal,
YEUGRN then turn the ignition
switchON (ll).
Connectthe A12 termi- Check the leftrearmotor: Faultyleft rearwindowmotor
A8 GBN/YEL nalto the A7 terminat, ,t shouldrun {thewindowmoves Faulty,eftrearwindowsrrvitch
and the A8 terminalto down), An openin thewire
the A11terminal.then
GRN turn the ignitionswitch
oN flr).
Connectthe A10te.mi- Checkfor voltage betweenthe A5 Faultypulser
nalto the 43 terminal, and Al l terminals: Faultydriver'swindow motor
and the A11 terminal ADorox.6V shouldbe indicatedas An open in the wire
A5 BLU
to the 44 terminal. the driver'swindow motor runs.
then turn the ignition
switchON (ll).
Combinationlight Checkfo. voltageto ground: Blown No.30 (7.5A) fuse in the
*cl switch ON Thereshouldbe batteryvoltage. under-dashfuse/relaybox
RED/BLK Faultycombinationlight switch
An open in the wire
Combinationlight Connectto ground: ' An open in the wire
RED switch ON Dashlightsshouldcome on full
bright.
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PowerWindows
MasterSwitch Test
1 . Removethe switch (seesection 20). F.ont Passongsr'sSwitch:
rermrnal
Disconnectthe 14P,2P and 1P connectorsfrom the \ A2 A9 B1
power window masterswitch. '**[ffi A1
ON o- -_o
o- --o
OFF
switchpositionaccordingto the tables.
DRIVER'S
FRONT
PASSENGER'S ON G- --o
swrTcH swncH UP
OFF o- C
ON o- --o
DOWN
OFF o- --o
Right RearSwitch:
B \\N \ Terminal
'".'*l-$j[\ A14 413 A6 B1
7-.i::,,, ON o- --o
o* --o
OFF
OFF
\\'. )),, ON o- --o
UP
OFF o- --o
ON o-- --o
o- --o
DOWN
OFF
Left R.ar Switch:
t - _ _ _ _ _ r - _ _ Terminal
I F---T-----r-----r----r-----T---------T-----'r I \ A12 A8 A7 B1
l l a l l A 2l A 3 l A { l A 5l A 6 l A 7l a B l l e*Li*l$[\
l Fa # l
ll el A 1 0 l l A 1 1 l A 1 2 llt-t___Jl
I r________r_____J
A13lal.ll ON o- o --o
OFF
OFF o- --o
fr---r-l r---- -------r
I t--------
-ll l ON o-- --o
ll 'lr 8 1 ll ll l l c 1 |I c 2 ll lr
o- --o
UP
OFF
L--:J
ON o- -_o
DOWN
OFF o- --o
Dliver's Switch: Swhch Light: '99 - 00 modls
The driver'sswitchis combinedwith the control unit so \ Terminal

you cannot isolatethe switchto test it. Instad,run th6 ti.*----_\
masterswitchinputtest procedureson page23-134.
lf the tests are normal.the drive/s switch is faulty. Underallconditions o- -o
ILED)
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23-136
Window Switch Test
Passenger's Driver'sWindow Motor Test
1 . Removethe inner handle(seesection20). Motor Test:
Disconnectthe 5P connectorthen removethe two 1. Removethe driver'sdoor panel,and disconnectall

mounting screwsfrom the passenger'sswitch. connectors(seesection201.
2. Disconnectthe 4Pconnectorfrom the window motor.
Terminalsideof
maleterminals
Testthe motor in eachdirectionby connectingbat-

t e r y p o w e r a n d g r o u n d a c c o r d i n gt o t h e t a b l e .
Whenthe motor stopsrunning.disconnectone lead
immediately.
switchpositionaccordingto the table \ Terminal
-\
;;b"
\ Terminal
__\ UP o (!r
1 2 3 5
;"rL- DOWN @ o
UP o- -o
OFF
-o o- -o 4. lf the motor doesnot run at all or doesnot run
smoothly.rePlaceit.
DOWN o- -o
PulserTest:
5. Connectthe test leadsof an analogohmmeterto the

No, 3 and No. 4 terminals.
6. Run the motor by connectingpower and groundto

the No. 1 and No. 2 terminals.The ohmmeterneedle
shquldmove backand forth alternately.
PowerWindows
Passenger's
Window Motor Test
Front: 3. Checkwindow motor operation by connectingpower
and ground accordingto the table.When the motor
l. Removethe passenger'sdoor panel,and disconnect stops running, disconnectohe lead immediatelv.
allthe connectors(seesection20).
Front:
2. Disconnectthe 2Pconnectorfrom the window motor.
\ Terminal
.l\
;."b"
UP @
DOWN o @
Rar:
I Terminal
-l\
;*r*
UP o @
DOWN @ o
lf the motor doesnot run at all or does not run

smoothly,replaceit.
Rear:
1. Removethe passenger's doo. panel,and disconnect

allthe connectors(seesection20).
2. Disconnectthe2Pconnectorfromthe window motor.
23-138
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I J
Restraints
SeatBelts .....24-1
SupplementalRestraintSYstem
(sRSl......'.'. ""'.""".""""24-13
SeatBelts
ComponentLocationIndex.'."..'..'-'.' 24'2
FrontSeatBeltReplacement '......"'..24-3
RearSeatBeltReplacement '.' 24-6
......'.".
lnspection .....""""""""' 24-9
f, -
ChildSeatTetherAnchor
lnstallation-'97 - 99 Models."'."24-10
ChildSeatTetherAnchor
-'00 Model ....'......'.'....'.'.."-'-'."'
24'11
l -
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Seat Belts
SRScomponentsare locatedin the partsareasmarkedwith an asterisk{*). Reviewthe SRScomponentlocauons,precau-
tions,and proceduresin this section(24)beforeperformingrepairsor service(,98_ 00 models).
CHILDSEATTETHENANCHOR
-'97
lnstallation 99 models,page24-10
- '00 model,page24-11
CHILDSEATTETHER
ANCHORCOVER('00 modtl
REARSEATBELTBUCKLE/
CENTERBELTTONGUE
.FRONTSEATBELT (seepage24-7)
Replacement,page24 3
page24-9
Inspection,
BELTEUCKLES
(seepage24 5)
24-2
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FrontSeat Belt RePlacement
J
SRScomponentsare locatedin this area.Reviewthe SRS o. Disconnectthe seat belt tensiongr connector.
componentlocations,precautions, and proceduresin this
section (24) before performing repairs or service('98 - 00 @ To avoid accidontal deployment and
models). possibteinlury, always disconnectthe soat bsh ton-
sionr connoctor bofore rsmoving th6 retractor l'98
- 00 modsls, se page 21-231.
CAUTION: Check the front seat bslts for damago. and
replacothom if necessary.Be careful not to damage
them during removal and in3tallation' 7 . R e m o v et h e u D D e ra n d l o w e r a n c h o r b o i t s , t h e
retractor bolt, the retractor mounting bolt, and
Front scat bolt: remove the front seat belt and retractor.
1. M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e 8. Removethe centerpillaruppertrim (seesection20).

radio,then write down the frequenciesfor the pre-
set buttons. 9 . Removethe shoulderanchoradjuster.
2. Disconnectthe negativebatterycable,and wait at
leastthree minutesbeforebeginningwork.
3. Slidethe front seatforwardfully.
4. Bemove(seesection20):
. Centerpillarlowertrim Pane
. Kickoanel
. Frontsidetrim
5. '97 model:Removethe upper anchorcover and the
lower anchorcaP. I x 1.25mm
'98 - oO models: Removethe upper anchor cover
23 N.m 12.3kgt.m,
and pull the lower anchorcoverback. 1? tbf.ft)
UPPENANCHORBOLT SHOULDER
7/1&20UNF ANCHOR
32 N.m (3.3kgt'm. ADJUSTER
24 tbf.ft)
Applyliquidthread
lock. SHOULDER
ANCHOR
ADJUSTER
SEATBELT
UPPER
COVER
TENSIONER 10. lnstallationisthe reverseof the removalprocedure.
{'98 - 0o modols)
NOTE:
RETRACTOR
MOUNTINGBOLTZ,, REARSIDE Checkthat the retractorlockingmechanismfunc-
Gx1.0mm ./ tions as describedon Page24-9.
9.8N.m (1.0kgt.m, Assemblethe washers,collarand bushingon the
?.2 tbtft) uooerand lower anchorboltsas shown.
Eeforeinstallingthe anchor bolts, make sure there
are no twists or kinksin the front seat belt.
ANCHOR Make sure the seat belt tensionerconnectorls
COVER connectedsecurelv.
l'98- 00models) Enterthe anti-theftcode for the radio,then enter
the customer's radio station presets
RETRACTORBOLT
7/1&20UNF ANCHOR
32 N.m 13.3kgt m, CAP
24 tbt.ft) ('97 modell
LOWERANCHORBOLT
?,/1&20UNF
32 N.m {3.3 kgf.m,2,1lbf.ftl
(cont'd)
Seat Belts
FrontSeat Belt Replacement
{cont'dl
Uppgr anchorboh construqtion: Rtractorbolt construqtion:
UPPEBAI{CHOR
aolT
Apply liquidthread RETNACTOR
tock.
T(X)THED
LOCI(WASHCR BOLT
bwd
RETBACTOR
Lower anchor bolt construction:
'97 modol:
LOWERANCHOR
24-4
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Ssat belt buckle: Csntor anchor bolt construstion:
1. Slidethe front seatforwardfully

TOOTHED WAVE CENTER
ANCHOR
Removethe centercover(seesection20). LOCKWASHER WASHER BOLT
2.
3. Driver's: Disconnectthe seat belt switch connector,

and detachthe harnessclips from the seatcushion
frame.
>: Cliplocations
SPRING WASHER CENTER

WASHER ANCHOR
5. lnstallationis the reverseof the removalprocedure.
NOTE:Assemblethe washerson the centeranchor

bolt as shown.
To seat belt
buckle.
SEATBELT
swlTcH
CONNECTOR
4. Removethe centeranchorbolt,then removethe seat
belt buckle. Pull out the seat belt switch harness
(with seat belt switchl.
SEATBELT
BUCKLE
CENTERANCHORBOLT
7/1&20UNF SEATBLT
32 N.m {3.3kg{ m, 24 lbf ftl SwlTCH
HARNESS
Seat Belts
RearSeat Belt Replacement
CAUTION:Checkthe rear sat belts for damage,and 6. Installationis the reverseof the removalprocedure.
replacelhem if necessa.y.Be caretul not to damage
them during temoval and installation. NOTE:
. Checkthat the retractorlockingmechanismfunc-
Rearseat belt: tions as describedon page24-9.
. Assemblethe washers,collarand bushingon the
1, Removethe rearseat{seesection20}. lower anchorbolt as shown.
. Beforeinstallingthe anchorbolt, makesurethere
2. Carefullypull on the upper anchorcover and lower are no twistsor kinksin the rearseatbelt.
anchorcoverto removethem.
Upper anchot bolt construction:
UPPERANCHORBOLT
7/16-20UNF
32 N.m 13.3kg{.m,
24 tbt.ft) UPPERANCHOR
TOOTHEO
LOCKWASHER
/
A
\tt
REARSEAT
BELT
UPPER RETRACTOR ANCHOR

ANCHOR COLLAF
COVER
LOWER
ANCHOR
COVER Lowel anchor bolt construqtion:
LOWERANCHOR
BOLT SPRING
WASHEB
RETRACTOB TOOTHED
MOUNTINGBOLT LOCI(WASHER
6x1.0mm
9.8N.m (1.0kgt.m.
7.2 rbf.ftl
RETRACIOREOLT
7/16-20UNF
32 N.m {3,3kgf.m,
24 rbr.ft)
LOWERANCHOFBOLT
7/1S20UNF
32 N.m 13.3kgl.m, 2/r lbf.ftl
BUSHING
3. Removethe lower anchorbolt. WASHERS COLLAR
LOWERANCHOR
4. Remove(seesection20):
. Cargoareafloor and cargostoragebin Rgtractor boll construction:
. Reartrim paneland rearsidetrim panel
/\ r>--->.
Removethe upper anchor bolt, the retractorbolt. f/F\-. (t--nnnllH \
the retractormounting bolt, and remove the rear
seatbelt and retractor.
/
P \v*\ \ \
T(X)THED RETRACTOR RETMCTOR
LOCKWASHER BOLT
24-6
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) J
Seat belt buckles/Centerbelt tongue: with tilt:
without tilt: 1. forward.and tilt the rearseatup

Foldthe seat-back
1. Removethe rearseaton eachslde. 2. While holdingthe trunk floor extensionup, remove

the centeranchorbolts
2. Raisethe trunk floor extensions,removethe cenler
anchorbolts,then removethe seat belt bucklesand SEAT.BACK CENTERBELTYONGUE
centerbelttongue.
CENTFRANCHORBOLTS
7/16-20UNF
32 N.m (3.3kgf.m,
2a rbtftt
CEiITER AT{CHORBOLTS
7/1e20 UNF SEATBELT
32 N.m {3.3kgt m, BUCKLE
2r bf.frl
and returnthe seatto its origi-

Raisethe seat-back,
) nal position.
Removethe center anchor bolts, then remove the

center belt tongue and seat belt buckle.
SEATBELT
BUCKITS
\\
NOTE:When reinstallingthe rear seats.make sure

there are no twists or kinksin the centerbelt tongue
and seatbelt buckle.
) (cont'd)
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Seat Belts
RearSeat Belt Replacement(cont'dl
5. Installationis the reverseof the removalDrocedure.
NOTE:Makesurethere are no twists or kinksin the

centerbelttongueand seatbelt buckle.
Cenler anchor bolt construction:
\
TOOTHED
LOCKWASHER
ANCHOR
24-8
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Inspection
SRS componentsale located in this area. Reviewthe Rear:
SRScomponentlocations,precautions,and procedures
in this section(24)beforepreformingrepairsor service
('98- 00 models).
40.
!!!@ To avoid accidontaldeployment and possi- /A *1ix

6i6-'rnpry. att"ays aisconnsct th seat beh tensioner con-
\|
nctor belore removing tho retrastor {.98 - 00 modols, seo _t-. \ /
page2+231.
L =
ls
Rgtlastor Insgection
RETRACTOR
1. Beforeinstallingthe retactor,checkthat the seatbelt Forwerd
Forwerd lnsida
can be pulledout freely
2. Make sure that the seat belt does not lock when the
retractoris leanedslowlyup to 15'from the mounted 3. Beplacethe seatbeltwith a new assemblyif thereis
Dosition.The seat belt should lock when the retractor any abnormality.Do not disassembleany part of
is leanedover 40". the seatbeltfor any reason.
CAUTION: Do not attsmpt to dbassemble ths relrac' In-vehicleS68t Belt InsPestion

tor.
1. Chckthat the seat belt is not twistedor caughton
Front: anything.
'97 modol: .: Mounted Position After installingthe anchors,checkfor free move-

ment on the anchorbolts lf necessary,removethe
anchorbolts,and checkthat the washersand other
partsare not damagedor improperlyinstalled.
Checkthe seatbeltsfor damageor discoloration.

Cleanwith a shop towel if necessary.
CAUTION: Uso only soap and wator to clean.
NOTE:Dirt build-upin the metal loopsof the upper

anchorscan causethe seat belts to retractslowly
RETRACTOR Wipe the insideof the loopswith a cleanclothdamP
Forward - lnside
enedin isopropylalcohol.
'98 - 00 modcls: Checkthat the seat belt does not lock when pulled
out slowlv. The seat belt is designedto lock only
duringa suddenstop or impact.
Makesurethat the seatbeltwill retractautomatically

when released.
For each passenger'sseat belt, make sure that the

locking mechanism in the seat belt retractorwill
engagewhen the seatbelt is pulledall the way out.
'1.
Replacethe seatbeltwith a new assemblyif there is
RETRACTOR any abnormality.Do not disassembleany part of
Forward - the seatbeltfor any reason.
)
Seat Belts
ChifdSeat TetherAnchor Installation-,97 - 99 Models
Canadamodel: NOTE:
. Do not removethe toothedwasherfrom the childseat
Attachmentpointsare providedfor a rear searmounted tether anchor.Use the seat anchorwith the toothed
childrestraintsystemwhich usesa top tether.The attach_ washerattachedto it.
ment pointsare locatedon both rearcornersof the head_ . When installinga child seat on the rear seat,follow
liner,just behindthe rear seat-back. When using a child the instructionsof the manufacturer
of the childseat.
seatwith a top tether,installthe child seattetheranchor . Additionalanchorsare available.
securelv.
NOTE:To installa child seat on the rearseat,selectthe

attachmentpoint you want to use,and removethe plug
coverfrom the attachmentpoint of the headliner.Install
the child seattetheranchorsecurely.
ATTACHMENT
POINTS
PLUGCOVERS
CHILOSEAT
TETHER TOOTHEDWASHER
ANCHOR
24-10
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-'00
l r Child Seat TetherAnchor Removal/lnstallation Model
AttachmentDointsare providedfor a rear seat mountedchild restraintsystemwhich usesa top tether'The attachment
pointsare locatedon both rear cornersof the headliner,just behindthe rear seat-backThe child seattether anchorsare
installedinto eachattachmentpoint.Eachchild seattetheranchoris coveredwith a childseattetheranchorcover.
NOTE:
. Do not removethe toothedwasherfrom the child seattetheranchor.Usethe anchorwith the toothedwasherattached
to it.
. When installinga childseaton the rearseat,follow the instructionsof the manufacturerof the childseat.
U n i t im m ( i n . )
HEADLINER
TOOTHEOWASHEB
CHILDSEAT
TETHERANCHOR
I x '1.25mm
22 N.m (2.2kgf m,
16 rbf.ft)
)
SupplementalRestraintSystem (SRS)
SpecialTools .."....."" 24-14 Troubleshooting
Component/Wring Location Self-diagnosticProcedures............. 24-26
lndex- '97 '....."""24-15
model ..........'.." .....".."'24'26
Readingthe DTC ..................
Component/WiringLocation Erasingthe DTCMemory ................24-28
lndex - '98 - 00 models ..............."
24-16 Troubleshooting lntermittent
Description .'.........."'.24'17 Faifures "'...........24'24
CircuitDiagram .........24'14 DiagnosticTroubleGode {DTC}
Precautions/Procedures Chart-'97 model ....""....... "......24-29
24-19
GeneralPrecautions......".."'........... DiagnosticTroubleGode (DTCI
Airbag/SeatBelt Tensioner Chart-'98 - 00 models ............. 24-31
24-19
Handlingand Stolage ....''........... SRSIndicatorLight Wire
24-20
...............'...... Connections ','," 24'33
SRSUnit Precautions
Ffowcharts ....-........24'34
\ lnspeciionAfter Deployment .......'.24'20
) <D Driver's Airbag
WiringPrecautions.............'............24-21
Repfacement ..'......21'87
SpringJoadedLockConnector
with Built-inShort Contact '...'....24-21 Front Passenger'sAirbag
Spring-loadedLock Connectors.."' 24-22 Repfacement .....'.',24'AS
BackProbingSPring-loadedLock GableReel
Conneetors ,.......24-22 Replacement .......'.24-91
Disconnectingthe Airbag Connectors and SRSUnit
the Seat Beh Tensioner Replacement .........24-95
Connectors ....'....24-23
Airbag/SeatBelt Tensioner
Steering-lelatedPrecautions..........24-25
Disposaf .................24'97
) - e
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SpecialTools
Ref. No. Tool Number Description Oty PageReference

I
o"' 07HAz- SG00500 DeploymentTool 1 24-91
@-, 07PM- 0010100 SCSServiceConnector 1 24-21
/a\ 07sAz- TB40114 SRSInflatorSimulator '1
24-50
@ 07TAZ- SZ50114 SRSSimulatorLeadC I 24-50
rA*, o7TAZ - OO1O20A BackprobeAdapter,l7 mm 2 24-43
* 1: Includedin SRSTool Set 07MAZ- SM5000B
*2: Use with the stacking patch cords from T/N 07SAZ-
0010004,BackprobeSet.
o @
/n
o
24-14
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Component/WiringLocationsIndex-'97 model
SRSINDICATOR LIGHT(ln the gaugeassembly)

page24-27
Troubleshooting,
Gaugeassembly,section23
To CRUISECONTROL
SET
DRIVER'SAIBMG To DRIVERSAnBAG
Replacement,
DASHBOABDw|RE HARNESS page 21-87
LIGHTin
to SBS INDICATOR Disposal,page 24-97
GAUGEASSEMBLY
5P FRONTPASSEITGER'SAIRBAG
Replacement,pago 24{9
MAIN WIREHABNESS Disposal,page 24-97 sBsitAr[ ] nNEss
to DASHBOABDwlRE HARNESS to FROI|T PASSEiIGEB.S
21P ANBAG
2P
GOf$ECrOn PPI
SRSMAIN HABNESS lBLr( 8R t
to UNOEB-DASH
FUSE/BELAYBOX
2P CONNECTOR
SRSMAIN HARNESS
to MAIN
WIRE HARNESS sns ut{fT
3P OONNECTOR GROUND
SES MAIN HAR]GSS

MEMORYERASESIGNAL tosnsU n
IMES) CONNECTORI2PI ItP OOIIITECTOR
[GRY. GRYI or twHT, BLr.l
www.emanualpro.com
24-15
Gomponent/WiringLocationsIndex-'98 - 00 models
SRSINDICAIORLIcHT (ln the gauge assembty) CABLEREEL

page24 27
Troubleshooting, Replacement,
Gaugeassembly.section23 page24-91
To HORNSWITCH
To CRUISECONTROL
SET/RESUMESWTCH
To DRIVER'SAIRBAG
FRONTPASSENGER'S AIRBAG
DASHBOARDWIREHARNESS Replacement,page24-89
ORIVER'SAIRBAG Disposal,page24 97
to SRS INDICATORLIGHf in Replacement,
GAUGEASSEMBLY page 24-87
5P CONNECTOR SRSMAIN HARNESS
Disposal,page 24-97 to FROI{TPASSENGER,S
AIRBAG
SRSMAIN HARNESS 2P CONiIECTOR
ro CABLEREEL
2PCONNECTOR
RIGHTSIDEWIREHARNESSto
MAIN VYIREHARNESS SEAI BELTTENSIONER
to DASHBOARDWIREHARNESS SRSUNIT 2P CONNECTOR
24PCONNECTOR (lncludingsafingsensor
and impactsensor)
SRSMAIN HARNESSto
SRSMAIN HARNESSto
RIGHTSIDEWIREHARNESS
LEFTSIDEWIREHARNESS
2P CONNECTOR
2P CONNECTOR
SRSMAIN HARNESS
to MAIN WIREHARNESS SERVICECHECK
3P CONNECTOB CONNECTOR I2PI
IBLK BRNI
SRSMAIN
to UNDER-DASH
BOX
FUSE/RELAY SEATBELTTENSIONER
2PCONNECTOR Replacement,page24 3
Disposal,page 24-97
MEMORYERASESIGNAL ORIVER'SSEATBELT
(MES)CONNECTOR I2PI
IGRN,GRNIor IWHT,BLKI Replacement,page 24-3
page24-97
Disposal,
LEFTSIDEWIREHARNESSto
SEATBELTTENSIONER
2P CONNECTOR
www.emanualpro.com
24-16
Description
) J
The SRSis a safetydevicewhich,when used in conjunctionwith the seat belt,is designedto help protectthe driver and
front passengerin a frontalimpactexceedinga certainset limit.The systemconsistsof the SRSunit (includingsafingsen-
sor and impactsensor),the cablereel,the driver'sairbagand front passenger's
airbag.
Seat Bolt Tensioner {'98 - 00 models}

The seatbelt tensioneris linkedwith the SRSairbagsto further increasethe effectiveness of the seat belt. In a front-end
collision,the tensionerinstantlyretractsthe belt firmly to securethe in
occupants their seats
DRIVER'SAIRBAG FRONTPASSENGER'S
AIREAG
FRONTPASSENGER'S
SEATBELTTENSIONER
{'98 - 00 modelsl
SRSUNIT
DRIVER'SSEATBELT
TENSIONERl'98 - 0Omodeb)
Operation
The main circuitin the SRSunit sensesand judgesthe forceof impactand, if necessary, ignitesthe intlatorcharges.lf bat
tery voltageis too low or power is disconnecteddue to the impact,the voltage regulatorand the back-uppower circuit
) respectivelywill keepvoltageat a constantlevel.
For the SRSto operate:

(1) The impactsensormust activate,and sendelectricsignalsto the microprocessor.
(2) The microprocessor must computethe signals,and sendthem to the airbaginflators(andseatbelttensioners).
(3) The inflatorsmust igniteand deploythe airbags(andactivatethe tensioners).
---__-l
TENSTO1En
I
I
_-___J
1 9 8- 00 N4odes)
Selt-diagnosisSystem
A self-diagnosis circuitis built into the SRSuniUwhen the ignitionswitchis turned ON (ll),the SRSindicatorIight comes
on and goesoff afteraboutsix secondsif the systemis operatingnormally.
lf the light does not come on, does not go off aftersix seconds,or it comeson while driving,it indicatesan abnormalityin
the system.The systemmust be inspectedand repairedas soon as possible.
the memorywill storethe causeof the malfunction,and the data link circuitpasseson the infor
For batteryserviceability,
mationfrom the memoryto the data link connector(DLC).This informationcan be readwith the HondaPGMTestercon-
nectedto the DLC{16P).
www.emanualpro.com
24-17
CircuitDiagram
NOTE:The SRSmain harnessusesall GRY('97model)or GRN('98- 00 models)wires.

UNDEF,HOOD
FUSE/RELAY
BOX IGNITIONSWITCH
-'-
WHT/BLK WHT
UNDER.DASH
FUSE/RELAY
BOX
+
SFS INDICATOR CIRCUIT
YEUGRN
(lnlhegaugeassembly)
SRS NDICATOR
L G H T{ r . 4 W )
Shillloc*soenoid P G MF I
mamrelay
FRONT
PASSENGER'S DRIVEB'S
ALRBAG AIRBAG
INFLAlOR NFLATOR
A BLU
#+
tl . /t t lI
BLK
t l
GRY
(GFN)
GFY
(GRN)
GRY GRY
(GRN) (GRN)
d
GR\
1 0 1 4 1 1 3
5 12 4 11 | 16 17 15 I 18 I
GRN GFY GRY GNY GRY

(BLU/PNK) lcFNt (GlN)
? ?
H
I
LTBLU
r-?
BRN BRN
t t t
r ? F ? F
G401
FRONT
PASSENGERS
SEATBELT
TENSIONEF
DRIVER'S
SEATEELT
TENSIONER
('98- 00M o d e l s )
U DATA
V
CONNECTOR
(Drc)(r6P)
CHECK
V
LINX PCM/ECMSERVICE MEMORY
CONNECTOB
ERASE
S GNAL(MES)
CONNECTOR
(2P)
V
S8S UNT TERMINALS
3 5 6 7 I
10 11 14 15 17 18
T e r m i n a sl i d eo f m a l et e r m i n a l s
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24-18
Precautions/Procedures
) GeneralPrecautions Airbag/SeatBeltTensioner
Handlingand Storage
Carefullyinspectany SRS part beforeyou install it.
Do not installany partthat showssignsof beingdrop- Do not try to disassemblean airbag or a seat belt ten-
ped or improperlyhandled,such as dents,cracksor sioner.They have no serviceableparts.Once an airbag
deformation: or a seatbelttensionerhavebeendeployed.they cannot
be repairedor reused.
- Airbags
- Cablereel For temporarystorageof an airbag or a seat belt ten-
- SRSunit sioner during service,pleaseobservethe following pre-
- Seatbelttensioners cautons:
. Store the removed airbag with the pad surface up.

N The driver's/frontpassenger'sairbagconnectorsand
seat belt tensionerconnectorshave a built-in short
contact (see page 24-211.
@ r th airb.g is impropcrty stord face down,

accidental deployment could propel the unit with enough
forcto caus6serious iniury,
Use only a digital multimeterto checkthe system,lf

it's not a Honda multimeter,make sure its output is
10 mA (0,01A) or lesswhen switchedto the smallest
value in the ohmmeterrange.A testerwith a higher
outputcould damagethe airbagcircuitor causeacci-
) - dentaldeploymentand possibleinjury.
Do not install used SRS Dansfrom anothervehicle,

When makingSRSrepairs,useonly new pans.
E x c e p tw h e n p e r f o r m i n g e l e c t r i c a li n s p e c t i o n s ,
alwaysdisconnectboth the negativecable and posi-
tive cable from the batterv.and wait at least three
minutesbeforebeginningwork.
R e p l a c e m e not f t h e c o m b i n a t i o nl i g h t a n d w i p e r /
w a s h e rs w i t c h e sa n d c r u i s ec o n t r o ls w i t c h c a n b e
donewithout removingthe steeringwheel:
- Combinationlight and wiper/washerswitch replace- AIRBAGCONNECTORS

ment{seesection231.
- Cruisecontrolsevresumeswitchreplacement(see
section41. Store the removed on a secureflat surfaceawav from
a n y h i g h h e a t s o u r c e( e x c e e d i n g
2 1 2 " F / 1 0 0 ' Ca)n d
Wheneverthe ignition switch is ON {ll}, or has been free of any oil, grease.detergentor water.
turnedOFFfor lessthan three minutes,be carefulnot
to bump the SRSunit; the airbagscould accidentally lmproperhandlingor storagecan internallydamage
deployand causedamageor injuries. the airbagand seatbelttensioner.makingthem inop-
erative.
Wheneverthe airbaghas been activated,replacethe lf you suspectthe airbagand seatbelt tensionerhave
SRSunit. b e e n d a m a g e d ,i n s t a l l n e w u n i t s a n d r e f e r t o t h e
Deploymenvoisposal Procedures for disposingof the
The original radio has a coded theft protectioncircuit. damaoedunits.
) Be sure to get the customer'scode number before dis-
connectingthe batterycables.
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SRSUnit Precautions InspectionAfter Deployment
Takeextracarewhen paintingor doing body work in After a collision in which the airbags were deployed.
the area belowthe dashboard.Avoid directexposure replacethe SRSunit,and inspectthe following:
of the SRS unit or wiring to heat guns, welding, or
sprayingequipment. 1. Inspectall the SRS wire harnesses.Replace,don't
repair,any damagedharnesses
Disconnectthe driver's/frontpassenger'sairbagcon-
nectors and seat belt tensioner connectorsbefore 2. Inspectthe cablereelfor heatdamage,lf thereis any
working belowthe dashboardnearthe SRSunit. damage.replacethe cablereel.
After any degreeof frontal body damage,or after a 3. After the vehicle is completely repaired,turn the
collisionwithout airbagdeployment,inspectthe SRS ignitionswitch on. lf the SRS indicatorlight comes
unit for physicaldamage.lf it is dented,cracked,or on for about six secondsand then goesoff, the SRS
detormed,reolaceit, systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting.
Be surethe SRSunit is installedsecurelv.
Do not disassemble
the SRSunit.
S t o r e t h e S R S u n i t i n a c o o l { l e s st h a n a b o u t
1 0 4 " F / 4 0 " Ca)n d d r y { l e s st h a n 8 0 o / o
h u m i d i t y .n o
moisture)place.Do not spill water or oil on the SRS
unit,and keepit awavfrom dust.
During installationor replacement,be carefulnot to

bump (impactwrench,hammer,etc.)the areaa[ound
the SRS unit, The airbagscould accidentallydeploy
and causedamageor injury.
rD
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24-20
J Wiring Precautions Spring-loadedLock Connestorwith
Built-in Short Gontact
. Neverattemptto modify,spliceor repairSRSwiring.
The driver's airbag/frontpassenger'sairbag and seat
NOTE:SRSwiring can be identifiedby specialyellow belttensionershave a spring-loaded lockconnectorwith
outercoveflng. a built-inshort contact.When this connectoris discon-
nected,the power terminal and the ground terminal in
the airbagconnectorare automatically shorted.
Conngctorhalvcs diSconnested:
GROUNDTERMINAL
Be sureto installthe harnesswiresso that they are

pinchedor interferingwith otherparts.
ACT
SHORTCONTACT
CABIf REELCONNECTOR
Connector halves connected;

GROUNDTERMINAL
M a k e s u r e a l l S R Sg r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-to-
metalcontact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.
CONTACT
CONTACT
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24-21
Spring-loadedLockConnectors BackprobingSpring-loadedLock
Connectors
SomeSRSsystemconnectorshavea spring-loaded
lock.
. When checkingvoltageor resistanceon this type of
Disconnecting connectorthe first time, it is necessary
to removethe
To releasethe lock,pull the spring-loaded sleevetoward retainerto insertthe testerprobefrom the wire side.
the stop while holdingthe oppositehalt of the connector. It is not necessaryto reinstallthe removed retainer;
Then pull the connectorhalvesapart.Be sure to pull on the terminalswill stay lockedin the connectorhous-
the sleeveand not on the connectorhalf. inq.
SPRING-LOADED
SLEEVE
RETAINER
*Discardafter removal.
Connecting
1. Hold the pawl-sideconnector hall and press on the To removethe retainer,insert a tlat-tip screwdriver
backof the sleeve-sideconnectorhalf in the direction betweenthe connectorbody and the retainer.then
shown. As the two connector halves are Dressed carefullypry out the retainer.Takecare not to break
together,the sleeve is pushed back by the pawl. Do the connector.
not touch the sleeve.
RETAINEN
When the connec-torhalvesare completelyconnected,

the pawl is released.and the spring-loadedsleeve
locksthe connector. RETAINER
SPRING.LOAI'ED
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24-22
andthe SeatBeltTensionerConnectors
the AirbagGonnectors
Disconnecting
) 1 ,
Beforeremovingthe airbagor SRSrelateddevices(the SRSunit,the cablereeland the seatbelttensionerconnector),dis-
connectingconnectorsfrom relateddevices,or removingthe dashboardor the steeringcolumn, disconnectthe airbag
connectorsand seatbelttensionerconnectorsto Dreventaccidentaldeployment
@ Turn the ignition switch oFF and disconnect ths nogative cable from the battery, and wait at least ihree
minutes before beginning the tollowing proceduresA and B. lprocedure B follows the procedureA.l
Beforedisconnecting the SRSmain harnessfrom the SRSunit,disconnectboth airbags(C,D) and both seatbelttensioners
(F,H) {'98- 00 models).
the cablereel2P connector(B),disconnectthe driver'sairbagconnector(C).

Beforedisconnecting
Beforedisconnecting the left side wire harness2P connector(E).disconnectthe driver'sseat belt tensioner2P connector
(F)('98- 00 models).
Beforedisconnecting the right side wire harness2P connector(G),disconnectthe tront passenger's

seatbelttensioner2P
connector(H) ('98- 00 models).
SRSMA1NHARNESS
----l
i--- E t
i Jl Jl l*",r* I I
LEFTSIDE
WIREHARNESS
)
{cont'd)
the AirbagConnectorsand the Seat BeltTensioner
Disconneeting
Connectors(cont'd)
1. Disconnectthe batterynegativecable,then discon- Seat Bslt Tensioner(38 - 00 modebl:
nectthe positivecablefrom the battery.and wait at . Removethe left and (or) right centerpillar lower
leastthree minutes. trim panels(seesection20).
. Disconnectthe seat belt tensioner 2P connectors
D i s c o n n e ctth e a i r b a g a n d t e n s i o n e rc o n n e c t o r s from the left sidewire harness(driver'sside)and
lsee page 24-22). (or)the right sidewire harness(frontpassenger's
side).When disconnected. the seatbelttensioner
Driver's Airbag: is automatically shorted.
. R e m o v et h e a c c e s sp a n e l f r o m t h e s t e e r i n g
w h e e l , t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r
betweenthe driver'sairbagand cablereel.When
disconnected, the airbag connectoris automati-
callvshorted. CLIPS
ACCESSPANEL
DRIVER'S
AIRBAG
2PCONNECTOR
Front Passsng/sAirtag:
. Disconnectthe 2P connectorbetweenthe front
passenger'sairbagand SRSmain harness.When
disconnected. the airbagconnectoris automati-
callYshorted.
DRIVER'SSIDE:LEFTSloE WIREHARNESS
FRONTPASSENGER'S SIDE:RIGHTSIDEWIRE
HARNESS
24-24
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Steering-related
Precautions
)
Stooring Whel and Csble Re6lAlignmnt NOTE:
T o a v o i d m i s a l i g n m e n to f t h e s t e e r i n gw h e e l o n . Whenthe airbagand cabler6elare disconnected, and
reassembly,make sure the wheels are turned straight the batteryis reconnectedand the ignition switch is
aheadbeJoreremovingthe steeringwheel. turned ON (ll),the SRSunit will storethis as an open
in the driver'sairbag inflator,and the SRS indicator
light will come on, In such a case,makesure to con-
firm the DTC,then clearthe SRSunit memory.
. For disconnectingthe spring-loadedlock type con-
nector, refer to page24-22.
'97
model:
SRSMAIN HARNESS CABLEREEL
To centerthe cable reel,rotatethe cable reel clockwise

(approxi-
until it stops,Then rotate it counterclockwise
matelytwo and a halfturns) until the arrow mark on the
cablereel labelpointsstraightup.
'98 - 00 models:
LABEL
UNDER-DASH
Steering Column Bemoval FUSE/RELAY
BOX
CAUTION: Before removing the stosring column, tirsi Do not replacethe originalsteeringwheelwith any other
disconneqt tha connsctor between tho cabls roel and d e s i g nb e c a u s ei t w i l l m a k e i t i m p o s s i b l et o p r o p e r l y
the SRSmain harness. installthe airbag(use only genuineHondareplacement
lf the steering column is going to be removed without partsl.
dismounting the steering wheel, lock the sieering by
turning the ignition key to o-LOCKposition, or remove After reassemblv,confirm the wheels are still turned
the key trom the ignition so that the steering wheel will straightaheadand that the steeringwheel spokeangle
not turn. is correct.lf minor spokeangleadjustmentis necessary,
do so only by adjustingthe tie-rods,not by removing
and repositioning the steeringwhee .
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24-25
Troubleshooting
Self-diagnostic
Procedures
The self-diagnosticfunction of the SRSsystem allows it to locatethe causesof system problems and to store this informa-
tion in memory,For easiertroubleshooting, this datacan be retrievedvia a data linkcircuit.
. When you turn the ignitionswitchON (ll).the SRSindicatorwill come on. lf it goes off aftersix seconds,the systemis
normal.
. lf there is 8n abnormality,the system locatesand definesthe problem.storesthis informationin memory,and turns
the SRSindicatorlight on. The datawill remainin the memoryevenwhen the ignitionswitchis turned off or if the bat-
terv is disconnected.
. When you connectthe SCSserviceconnectorto the servicecheckconnector(2P),and turn the ignitionswitchON (ll),
the SRSindicatorlight will indicatethe diagnostictroublecode (DTC)by the numberof blinks.
. After readingand recordingthe DTC,proceedwith the troubleshooting forthis code.
Precsutions
. Useonly a digitalmultimeterto checkthe system.lf it's not a Hondamultimeter.makesure its outputis 10 mA (0.01A)
or lesswhen switchedto the smallestvalue in the ohmmeterrange.A testerwith a higheroutput could damagethe
airbagcircuitor causeaccidentalairbagdeploymentand possibleinjury.
. Wheneverthe ignitionswitchisON (ll).or has beenturnedOFFfor lessthan three minutes,be carefulnottobumpthe
SRSunit;the airbagscouldaccidentally deployand causedamageor injuries.
. Beforeyou removethe SRSmain harness,disconnectthe airbagand tensionerconnectors(seepage24-23).
. Make sure the battery is sufficiently charged (see section 23). lf the battery is dead or low, measuringvalues won't be
correct.
. Do not touch a testerprobeto the terminalsin the SRSunit or harnessconnectors,and do not connectthe terminals
with a jumperwire. Use only the backprobeset and the SCSserviceconnector.
For backprobingspring-loadedlock type connectors,.efet to page 24-22.
Readingthe DTC
Whenthe SRSindicatorlight is on, readthe DTCusingone of thesemethods;
A. Connectthe HondaPGM Testerto the 16PData Link Connector{DLC),and follow the tester'sprompts.lf the tester
indicatesno DTC,DTC9-1 and DTC9-2,double-checkby jumping the servicecheckconnector(2P)and watchingthe
SRSindicatorlight (seenext page).
DATA LINKCONNECIOR{DLCI{16P)
HONDAPGM TESTER
24-26
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)
B . The SRSindicatorlight can also indicatethe DTCby the numberoJ blinkswhen the SCSserviceconnectoris connecr-
ed to the servicecheckconnector(2P).
1 . Turn the ignitionswitchOFF,and wait for ten seconds.Then connectthe SCSserviceconnectorto the servicecheck
connector{2P).lf you do not wait ten seconds.the SRSunit will not be completelyresetand will not outputDTCS.
SEBVICECHECKCONNECTOR
I2PI
IALK,BRNI
SEBVICECONNECTOR
07PAZ- 0010100
2. Turn the ignitionswitchON (ll).The SRSindicatorlight comeson for aboutsix secondsand then goesoff. Then it will
indicatethe DTC:
- The DTCconsistsof a main code and a sub-code.
- Includingthe most recentproblem,up to threedifferentmalfunctionscan be indicated.
- In caseof a continuousfailure.the DTCwill be indicatedrepeatedly(seeexample1 below).
- In caseof an intermittent
failure,the SRSindicatorlightwill indicatethe DTCone time,then it will stayon (seeexarn-
)
pte2 below).
- lf both a continuousand an intermittentfailureoccur,both DTCSwill be indicatedas continuousfailures.
- In casethe systemis normal {no DTC),the SRSindicatorlight will stay on (seeexample3).
3. Readthe DTC.
4. Turn the ignitionswitchOFF.and wait for ten seconds.Then disconnectthe SCSserviceconnectorJromthe service
checkconnector(2P).
Examplesof DTCIndications:
1. Continuousfailure,SRSIndicatorLight is:
0.3s 0.3s 0.35 0.3s
, s--l f.-, s--.l --l fl-!
--1 M.h@de
r-
-r f- l i - r -l F --l F
Main code (1) Sub-code (2) M.a^ code (rt Sub-cod6ltl
.............v_
DTC21 D T Cr . 2 otc I r
Mo6t r.@nl p.oblem Third.mGr .oconl
2. Intermittentfailure,SRSIndicatorLight is:
Light srayson in cas ol
DTC5,1
3. Normal(no failure),SRSIndicatorLight is:

)
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24-27
Troubleshooting
Erasingthe DTCMemory TroubleshootingIntermittent
Failures
To erase the DTC{S)from the SRS unit, use a Honda
P G M T e s t e r( s e et h e H o n d aP G M T e s t e rS R SV e h i c l e lf there was a malfunction.but it doesn'trecur,it will be
SystemSupplement)or the followingprocedure. storedin the memory as an intermittentfailure,and the
SRSindicatorlight comeson.
1. Makesurethe ignitionswitchis OFF.
2. Connectthe SCSserviceconnectorto the MES con, After checkingthe DTC,troubleshoot as follows:
nector(2P).Do not use a jumperwire.
1. Readthe DTC(see"Readingthe DTC").
E r a s et h e D T C m e m o r y ( s e e " E r a s i n g t h e D T C
Memory").
3. With the shift leverin neutral,turn the ignitionswitch

ON (ll),and let the engineidle.
4 . The SRSindicatorljght comeson for about six sec-

onds and then goesoff.
MEMORYERASE
SIGNAL(MES}CONNECTOR I2PI
IGRY,GRYIor IGRN,GRNI
SCSSERVICE CONNECTOR ON
t*F
07PAZ- 0010100 l t
--- _l
3. Turn the ignitionswitchON (ll),
4. The SRS indicatorlight comeson for aboutsix sec-
onds and then goes off. Removethe SCSservjcecon
nectorfrom the MES connector{2P)within four sec-
onds afterthe SRSindicatorlight went otf.
5. The SRSindicatorlight comeson again.Reconnect Shakethe wire harnessand the connector, takea test
the SCS service connectorto the MES connector drive (quickacceleration, quick braking,cornering),
(2P)within four secondsafterthe SRSindicatorlioht and turn the steeringwheel fully left and right,and
comeson, hold it there for five to ten secondsto find the cause
6. The SRS indicatorlight goes otf. Removethe SCS of the intermittent failure.
s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o r( 2 P ) lf the problem recurs,the SRS indicatorlight will
within four seconds. stayon.
7. The SRSindicatorlight indicatesthat the memoryis
erasedby blinkingtwo times.
L Turn the ignition switch OFF,and wait for ten sec
-+t 6!.c
onos. l.-
,l sec or less
Problemrecurs,light stayson.
SRSindicator
liqtfi
OFF
MES 6. lf you can't duplicatethe intermiftent

tailure,the sys-
connac'lol CONNECTED
tem is OK at thistime.
terminals
OISCONNECTEO
:-
24-28
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I j DiagnosticTroubleCode(DTG)Ghart-'97 model
SRS indicator light DTC Pos3iblscause Corroctiveaction Slc pago
doesn'tcome on none
(doesn't FaultySRSindicatorlight circuit Troubleshooting 24-34
come on)
none*'
(doesn't FaultySRSindicatorlight circuit,internal 24-37
Troubleshooting
tailureof SRSunit,faultySBS powersupply
go off)
Openin the driver'sairbaginflator 24-50
in the driver'sairbag
Increasedresistance 24-50
inflator
Shortto anotherwire in the driver'sairbag Troubleshooting 24-52

inflatoror decreasedresistance
Shortto power in the driver'sairbaginflator 24-54
doesn't go off Shortto groundin the driver'sairbaginflator 24-56
Open in the passenger's

airbaginflator 24-58
Increasedresistancein the passenger's

airbag
24-54
inflator
Shon to anotherwire in the passenger's 24-60

Troubleshooting
airbag inflator or decreasedresistance
Shortto power in the passenger's

airbag
24-62
2-4
inflator
Shon to ground in the passengar's

airbag
24-64
2-5
inflator
) r ,
(cont'd)
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24-29
Troubleshooting
DiagnosticTroubleCode(DTC)Chart-'97 model (cont'dl
SRS indicator light DTC Possiblecause Correstiveaction See page
SRSunit replace-
5-3 Internalfailureof the SRSunit 24-96
ment
5-4
5-5
o-l
6-2 SRSunit replace-

Internalfailureof the SRSunit 24-96
ment
6-4
SRSunit replace-
7-2 lnternalfailureof the SRSunit 24-96
doesn'tgo off ment
7-3
8-1
SRSunit replace-
a-2 Internalfailureof the SBS unit 24-96
menr
8-5
Internalfailureof the SRSunit or two failures
8-6 Troubleshooting 24-82
at a time
SRSunit replace-
9-2
Internalfailureof the SRSunit
FaultySRSpowersupply(VBline)
menr
Troubleshooting
24-96
24-84
l*
'10- SRSairbagsdeployed(SRSunit must be SRSunit replace-
1 24-96
replaced) ment
*1: In caseof an intermittentfailureDTC9-1,it meanstherewas an internalfailure
of the SRSunit or a faultv SRSindica-
tor light circuit.Do the troubleshooting
for intermittentfailures{seepage24-28),
*2: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.
NOTE: Before troubleshooting DTCS5-1 through 8-5, check battery/systemvoltage. lf voltage is low. repair the charging
systembeforetroubleshooting the SRSsystem.
24-30
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) ; TroubleCode(DTCIChart-'98 - 00 models
Diagnostic
SRSindicator light DTC Possiblscause Correctivaagtion See page
doesnt come on none

(doesn't FaultySRSindicatorlight circuit Troubleshooting 24-34
come on)
none*3 FaultySRSindicatorlight circuit.internal
{doesn't failureof SRSunit,faulty SRSpower supply Troubleshooting 24-42
go off) ( V Bl i n e )
No DTC
(lightcomes 24-47
FaultySRSpower supply(VA line) Troubleshooting
on afterself-
diagnosis)
1-1 Open in the driver'sairbaginflator 24-50
in the driver'sairbag
lncreasedresistance 24-50
inflator
Shortto anotherwire in the driver'sairbag Troubleshooting
1-3 24-52
inflatoror decreasedreslstance
1-4 Shortto power in the driver'sairbaginflator 24-54
1-5 Shortto groundin the driver'sairbaginflator 24-56
2-1 Open in the passenger'sairbaginflator 24-54

in the passenger's
Increasedresistance airbag 24-58
inflator
Shon to anotherwire in the passenger's 24-60
airbaginflatoror decreasedresistance Troubleshooting
doesn't go off Shortto power in the passenger's

airbag 24-62
2,4
inflator
Shortto ground in the passenger's
arrbag 24-64
inflator
3-1 Openin the driver'sseatbelttensioner 24-66
lncreasedresistancein the driver'sseatbelt 24-66

3-2
tensroner
Shon to anotherwire in the driver'sseatbelt Troubleshooting 24-64
tensroner
3-4 Short to power in the driver'sseat belt tensioner 24-10
Shortto ground in the driver'sseatbelttensloner 24-72
4-1 Open in the passenger's seatbelttensioner 24-14
Increasedresistance in the passenger'sseat 24-74

belttensioner
Shortto anotherwire in the passenger's seat 24-76
4-3 Troubleshooting
belttensioner
Short to power in the passenger'sseat belt ten- 24-74
4-4
sroner
Shon to groundin the passenger's seatbelt 24-AO
4-5
tensroner
) -
(cont'd)
Troubleshooting
DiagnosticTroubleCode(DTC)Chart-'98 - 00 modets(cont,dl
l*-
SRSindicator light DTC Po$ibla cause Corroctivelction Sec pag
5-l
Internalfailureof the SRSunit SRSunit replace-
24-96
ment
5-4
6-1
lnternalfailureof the SRSunit SRSunit replace-

24-96
6-3 ment
6-4
Internalfailureof the SRSunit SRSunit replace-

24-96
ment
doesn'tgo off
8-1
8-2
8-3 Internalfailureof the SRSunit SRSunit replace-
24-96
ment
8-4
8-6
Internalfailureof the SRSunit SRSunit.eplace-

24-96
9_2*2*3 ment
SRSunit replacementcode (SRSunit must not
10-1
be usedany longer)
SRSunit replace-
ment
24-96
1,.-
NOTE:
*1: In caseof an intermittentfailureDTCg-1,
it meanstherewas an internalfailureof the SRSunit or a faulw SRSindica-
tor light circuit.Do the troubleshooting for intermittentfailures(seepage2,+_2g),
*2: In caseof an intermiuentfairureDTc
9-2, it meansthere was an internarfairureof the power suppry(vB rine).Do the
troubleshooting for intermittentfailures(seepage24-29).
*3: DTCcannotbe readwith a HondaPGM
Tester;checkby jumpingthe SCSservicconnector.
NOTE: Before troubleshooting DTCS5-1 through g-6. check battery/systemvoltage. lf voltage is low, repair the charg_
ing systembeforetroubleshootingthe SRSsystem.
\f ..
24-32
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SRSIndicatorLightWireConnections
SRS Indicator Light Power Circuit

WIREHARNESS
DASHBOARD
YEL
BLK
To UNDER-DASH + To GAUGE
FUSE/RELAYBOX <_ csog assEMBLy
20PCONNECTOR
SRS Indicator Light Control Circuit
SRSMAIN HARNESS
) -
MAIN WIREHARNESS
V A I V B
I
t
To UNDER-DASH
FUSE/BELAYBOX
2P CONNECTOR
c414 MAIN WIREHARNESS3P CONNECTOR Terminalside of msle trminals

c415 MAIN wlRE HARNESS24PCONNECTOR Terminalaide of male terminals
c502 WIREHARNESS2OPCONNECTOR
DASHBOARD Wire side of lemslo terminsls
c503 WIREHARNESS24PCONNECTOR
OASHBOARD Wire side of female trminal3
c509 DASHBOABDWIREHARNESS5P CONNECTOR Wire sid ot lemale te.minals
) c801 SRSMAIN HARNESS2P CONNECTOR wire side ol f.male terminals

c803 SRSMAIN HARNESS3P CONNECTOR Wire side ol female terminals
c806 SRSMAIN HARNESST8PCONNECTOR Wire side of lomrle terminals
Troubleshooting
The SRSIndicatorLight Doesn'tComeOn
lr-
CAUTION:Wheneverthe ignition switch is ON D, or
has been turned OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
Ch6ckthe power supply (fuse):

Turnthe ignitionswitchON {ll),and checkwhetherthe other
indicatorlightscomeon (brakesystem,e(c.r.
Do the other indicator liglrts com6 on?
Checkthe No. 25 (7.5A) fuse in the under-dash

tuse/relay
DOX.
ls the tus oK?
YES NO
Checkthe bulb:
Replacethe No.25 (7.5 A) fuse, and checkthat the
SRSindicatorlightcomeson.
Doesthe SRSindicator liqht come on?
YES NO
END
Checkthe wire h.rnesi kwen fus.nd gauge .3sembly:

Checkfor an open in the wire harnessbetween fuse
lu
No. 25 (7.5Al and the gaugeassembly,and repair.Check
that lhe SRSindicato.lighi
Doesthe SRSindic.tor liqht com6 on?
YES NO
END
Checkthe SRSindicator light bulb:

2. Removethe gaugeassembly.
3. Checklor blown SRSindicatortightbulb.
ls the SRSindicator tight bulb OK?
YES NO
Checkthe SRSindicator light circuit:

Replacethe bulb, and reconnectthe gauge assembly
conneclors.
Thenturn the ignitionswitchON {ll).
Doesthe SRSindicator light come on?
I YEs No
:ND
(A)To page24-35 (B)To page24 35
24-34
www.emanualpro.com
) Jt
Frompage24 34 From page 24-34 DASHBOARDWIREHARNESS
(A) (8) 5P CONNECTOR
Chockth6 SRSindic.lor light circuit:

1. Disconnectthe dashboardwire harness5P connector
from the gaugeassembly.
2. Connecta voltmeterbetweenthe No l terminal (+) o{
the 5P connectorand grouncl.
3. Turn the ignitionswitchON {ll),and measurevoltage
ls thero 8.5 V or lats for 3ix second! aflsr the ignition
switch ha3 bon turnod ON (ll)7
YES NO
DASHBOARDWIREHARI{ESS
5P CONI{ECTOR
Fdulty SRS indicator light cilctlit in ths gauge sssomblY;
replaco tho SRS printod circuit board in the gauge c509
aasombly,
Wire side ol female

terminals
MAIN WIREHARNESS
) _
Chockth6 wire harn.$ of the SRSindicstor light circuh (11:
2. Disconnectthe main wire harness24Pconnectorfrom
the dashboardwire harness-
3. Connecta voltmeterbetweenthe No 5 terminal (+) of
the ma;nwire harness24Pconneciorand ground
4. Turnthe ignitionON {ll),and measurevoltage.
ls there 8,5 V or lr3 tor six scond3efter the ignilion
switch has bssn turnod ON llll?
YES NO
DASHBOAROWIRE
HARNESS24P
CONNECfOR
Short to powor in the BLU wire of tho dashbosrd wire MAIN WIREHARI{ESS2/tP COI{ ECTOR
harne3s;Epait the harne3.s.
Terminalsideof maleterminals
To page 24-36
(cont'd)
www.emanualpro.com
24-35
Troubleshooting
The SRSIndicatorLight Doesn'tComeOn (cont,dl
J
From page 24-35 '97 modol:
Checklhe wire harnessotthe SRSindicator light circuit l2l:

L Turnthe ignitjonswitchOFF. MAIN WIREHARNESS
2. Disconnect the SRSmain harness3p connectorfrom the 3P CONNECTOR
mainwire harness.
3. Connecta voltmeterbetweenthe No. I terminal (+) of
the SRSmain harness3P connectorand qround.
4. Turnthe ignitionswitchON (ll),and measurevoltaqe.
UNDER.DASH SRSMAIN HARNSS
ls there 8.5 V o. less tor six seconds atter the ignition FUSE/RELAY
BOX 3P CONNECTOR
switch has beenturned ON
'98 -
00 models:
MAIN WIREHARNESS
3P CONNECTOR
Short to power in th BLU wire of the main wiro halno3s;
SRSMAIN HARNESS
3P CONNECTOR FUSE/RELAY
BOX
SRSMAIN HARNESS
3P COI{NECTOB
c803
Checkth wire hahess of th6 SRSindicator ci.cuit {31:

2. Disconnectthe battery negative cable, then the positive
cable,and wait threeminutes.
3. Disconnectthe driver's and front passenger,sairbag con-
nectors{anddisconnectthe seatbelt tensionerconnectors}
(seepage24-23).
4. Disconnectthe SRS main harness18p connectorfrom
5. Reconnectthe battery positive cable, then reconnectthe

negativecable.
6. Connecta voltmeterbetweenthe No. 6 terminal (+) of
the SRSmain harness'l8Pconnectorand ground.
7. Turnthe ignitionswitchON (ll),and measurevoltage.There
shouldbe 0.5V or less.
SRSMAIN HARNESS
18PCONNECTOR
Short to power in the BLU wire oI the SRS main harngas;
24-36
www.emanualpro.com
The SRSIndicatorLight Doesn'tGo Off -'97 model
CAUTION:Wheneverth ignilion switch i3 ON (lll, ol
has been turnd OFF for less than three minutes, be
accideniallydeploy and causedamag or iniuries.
Try to reproducethe sRs indicator light:

1. ErasetheDTCmemory(seepage24 28)
2. Turn the ignitionswitchON {ll),and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then
goes off.
Doe3 the SRS indicator light slay on?
YES NO
Intermiftent ftilure, system is OK at this time. So Troubl_

shootingIntermittentFailuteson p.ge 24_28.
Checkthe No. 13 (15 Al fuse:

'L Turn the ignition switch OFF.
2. Checkfor blown No. 13 (15 A) fuse in the under dash
fuse/relaybox.
ls lhe tuse OK? No. 13 115Al FUSE UNOER.DASH
FUSE/RELAYBOX
YES NO
Replacethe luse, and err3e the memory
' 1 . R e p l a cteh e N o .1 3 ( 1 5 A ) f u s e
2. Erasethe DTc memory(seepage24-28).
) 3. Turnthe ignitionswitchON (ll).
ioes the SRS indicatol light go off after 3ix s6conds? SRSUNIT
YES NO
ENO
Confirm tho OTC,and continuettouble3hooting.
Checkfor an open in the SRSmain hatnss{VA lins}:

1. Disconnectthe batterYnegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnect the driver'sand front passenger's
airbagcon
nectors(seepage24-23). SRSMAIN HARNESS
3. Disconnectthe SRS main harness18Pconnectorfrom r8P CONNECTOR
the sRs unit.
negativecable.
5. Connecta voltmeterbetweenthe No. 7 terminal (+) ot SRSMAIN HARNESS18P CONNECTOR
the SRSmain harnessl8P connectorand 9rouncl
6. Turnthe ignilionswitchON {ll).
ls there battory voltage?
YES NO
Ooen in the SRS main harness{VA line); replacethe

natnoss.
(cont'd)
(A)
To page24 38
www.emanualpro.com
24-37
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off - '97 model (cont,d)
J
Frompage24 37
(A)
Checkthe SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo.
6 and No.7 with a jumperwire and backprobe
Faulty SRSunit or poo. contact at the SRSmain ha.ness

18Pconnectoi; checkthe connector.
lfthe conneqtoris OK, replacethe SRSunit.
Oidtuse No. 13 (15Al blow? SRSMAIN HARNESS18PCONNECTOR
JUMPERWIRE
(B)
To page24'39
Check for a short to ground in the SRS indicator tight cir- Wlresidoot tomaleterminsls
cutl:
1. Turnthe ignitlonswitchoFF. )
2, Disconnectthe dashboardwire harness5p connector DASHBOARDWIREHARNESS
from the gaugeassembly. 5P CONNECTOR
3. Checkresistance betweenthe No. 1 terminalofthe dash
board wire harness5P connectorand ground. There
shouldbe 1 MOor more.
(c)
To page 24-40
Shon to ground in th6 gaugo assembly;replacothe gau96
DASHBOANDWIRE HARI{ESS
5P CONNECTOR
c509
Wire side ol female

terminals
T
243a
www.emanualpro.com
Frompage24-38 DASHBOARDWIREHARNESS
{B) 5P CONNECTOR
Checklhe SRSindicalor circuit:

1. Turnthe ignitionswitchOFF
2 . R e m o v et h e g a u g e a s s e m b l y D o n o t d i s c o n n e ctth e
dashboardwire harness5P connectorfrom the gauge
assemoly.
3. Turn the ignition switch ON (ll).
4. Connecttie dashboardwire harness5P connectortermi-
nalsNo. I and No 5 with a iumperwire.
Doesthe SRSindicator light 90 otn
Faulty SRS indicator light circuit in the 9aug6 a$embly; 5P CONI{ECTOR
reolace the SRS printod circuit boa.d in th' gauge
Y;yfivvcsos
ffi
BLU
I IYEL
Wir6.sideof female
Checktor rn open in the SRSindicator light circuit: JUMPERWIRE lormrna|s
1. Turnthe ignitionswitchOFF
2. Disconnectthe dashboardwire harness5P connector
from the gaugeassemblY.
3. Checkres]sta-nce between the No. 6 terminal ol the SRS SRSMAI HAN ESS
) main harness18Pconnectorand No l terminal ol the t8P CO I{ECTOR
dashboardwire harness5P connector;there should be
Wire side oI fsmale terminals
{D) 1E)
To page24-41 To page24-41 DASHBOARDWIREHARNESS
5P COI{NECTOR
)
(cont'd)
Troubleshooting
The SRSIndicatorLight Doesnt Go Off -'97 model {cont'dl
i,
Frompage24-38 MAIN WIRE

1C) HARNESS24PCONNECTOR
Checkfor a short to ground in tho main wire ha.n.3s:

1. Disconnectthe dashboardwire harngss24p connector
from the main wire harness,
2. Checkresistancebetweenthe No. 5 terminal of the dash_
shouldbe 1 M0 or more.
OASHBOARDWIRE
Short to ground in tho deshbosrd wire harne.r; raD.ir
HARNESS
the dashboardwiro harness.
24PCONNECTOR
DASHBOARDWIREHAff{ESS
24P COi{NECTOR BLU
Wire side of female

t6rminals
MAIN wlRE HARNESS

3P CONNECTOB
Checktor a short to ground in tho SRSmain hfina3!:

1. Disconnectthe SBS main harness3p connectorfrom the SRSMAIN HARNESS
maanwire harness. 3P CONNECTOR
2. Checkresistancebetween the No. 1 terminal of the SRS
main harness3P connectorand ground.Thereshouldbe UNDER.OASH
1 MO or more. FUSE/RELAYBOX
SRSMAII{ HARI{ESS
3P CONNECTOR
cao3
Short to ground in tho main wire harnesr; ,opair th6
main wire hamoss.
Short to ground in the SRS main hsrn6sa;.oplac. thc SRS

main harn6ss.
) r
24-40
www.emanualpro.com
)
DASHBOARDwlRE hARNESS
From page24-39
(D) 5P CONNECTON
Checkthe SRSindicator circuit input voltage:

1. Reconnect the SRS main harness18Pconnectorto the
SRSunit
2. Connecta voltmeterbetweenthe No 1 terminal (+) of
the dashboard5Pconnectorand ground.
3. Turn the ignition switch ON (ll), wait for six seconds,
then measurevoltage
fs there 8.5 V or more? -
YES NO
The oroblem hts disappoareddue to disconnoctingand

connecting the connectors. Be 3ure all terminals make
good contact, and rocheckthe system {see Trouble'
DASHBOAROWIREHARI{ESS
shooting Intermittent Failur6 on pagg2'l-281'
5P CONI{EC'OR
c509
Pool contacl at the SRS main harness18Pconnector;check
the connector.
. lf the connoctor is OK. aubstituta a known-good SRS unit,
and recheck.
. ll the problem is still present, replaco the SRS main h'r-
ness.
Frompage24-39
) iE)
Checkfor an oPen in the dashboardwire hatn8s:

1. Disconnectthe main wire harness24P connectorIrom
the dashboardwire harness
2. Check resistancebetween the No. 6 terminal of the SRS
mainhamess18Pconnector and No 5 terminalotthe main
wire harness24Pconnector;thereshouldbe 0- 1 0 O
15the resistance.s specified?
YES NO
Terminalsideof malelerminals
ODen in the BLU wire ot the dashboard wit6 harness;
rep.ir the dashboaldwite harness.
Checkfor an open in the main wirc harness:

'1. Disconnectthe SRSmain harness3P connectorfrom the
mainwire harness,
2. Checkresistancebetweenthe No. 6 terminal of the SRS
mainharness18Pconnector and No 1 terminalofthe SRS
main harness3Pconnector;there shouldbe 0 - 1 0 u
|3 lhe re3istanceas sPecifiod?
YES NO
SRSMAIN HABNSS
3P CONNECTOR
Oon in the BLU wire ol the main wire harness; rcpair
tha main wire harness
) Opn in the SRS main harn4s; replacethe SRS msin har'

no3s.
Troubleshooting
The SRSIndicatorLight Doesnt Go Off - ,99- 00 models
CAUTION:Wheneverthe ignition switch is ON {lll, or
tl-
has been turnod OFF for less than three minutes, be
T.y to reproducethe SRSindicator tight:

1. Erasethe DTCmemory(seepage24-28).
2. Turn the ignitionswitchON { }, and checkthat the SRS
goes off.
Doesthe SRSindicator tight stey on?
YES NO
Intermittent failure, system b OK at this time. 56 Trouble-

shootingInle.mittent Failureson page24-2g.
Checkthe No. 23 (10Alfuse:

2. Checkfor blown No. 23 flO A) fuse in the under dash
luse/relaybox.
ls the fuse OK?
No. 23 110Al FUSE
YES NO
Repl.ce the tuse, and erasethe memory FUSE/RELAY
BOX
1. Beplacethe No. 23 (10Ai fuse.
3. Turnthe ignitionswitchON flt).
Doesthe SRSindicator light go ott after six secondt
YES NO
I
END
Conti.m tha DTC,and continue troubl*hooting.
Chockfor an open in the SRS main harness(Vg line):

1. Disconnectthe batterynegativecable,then disconnect
2. Disconnectthe driver,sand front passenger,sairbag con_
nectors,and discoonectthe seat belt tensionerconnectors
(seepage 24-23).
the sRs unit.
4. Reconnect the bafterypositivecable,then reconnectthe
negativecable.
5. Connecta voltmeterbetweenthe No. 3 terminal (+) of
the SRSmain harness18pconnectorand oround.
6. Turnthe ignitionswitchON 0l). SRSMAIN HARNESS18PCONNECTOR
ls there battery voltage?
YES NO
Open in the SRS main harness(VB line); replacothe

natness,
| \
(A)
To page24 43
24-42
www.emanualpro.com
)
Ftom page 24-42

(A)
SRSUNIT
SRSMAIN HARNESS
Checkthe SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo.
3 and No.6 with a iumperwire and backprobe
Doesthe SRSindicator light go otf?
Faulty SRSunit or poor contact at the SRSmain harness

18Pconnedor; checkthe connector.
lf the connoctoris OK, replacethe SRSunit
SRSMAIN HARNESS18PCONNECTOR
Did tuseNo. 23 {10A} blow?

JUMPERWIRE
1B)
fo page24-44 Wiresideof lemalelerminals
Check for a short to ground in the SRS indicator light cir-
) curl: DASHBOAEDWIREHARNESS
1. Turnthe ignitionswitchOFF. 5P CONNECTOR
2, Disconnectthe dashboardwire harness5P connector
from the gaugeassembly,
3. Checkresistance betweenthe No l terminalofthedash-
r n d g r o u n d .T h e r e
b o a r dw i r e h a r n e s s5 P c o n n e c t o a
shouldbe 1 Mo or more.
(c)
To page24-45
Short to ground in the gauge assembly;replacethe gauge
DASHEOARDWIREHARNESS
5P CONNECTOR
c509
)
(cont'd)
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -'99 - 00 models(cont,d)
J
Frompage24,43
(B) DASHBOARDWIREHARNESS
5P CONNECTOR
Checkthe SRSindicator circuit:

2 . R e m o v et h e g a u g e a s s e m b l y D
. o n o t d i s c o n n e ctth e
dashboardwire harness5p connectortrom the gauge
assemDty.
3. Turnthe ignitionswitchON 0l).
4. Connectthe dashboardwire hamess5p connectortermi
nalsNo. 1 and No. 5 with a iumoerwire.
Dooslhe SRSindic.tor light go offl
YES NO
Fauhy SRS indic.tor light circuit in lho gruge a3samblv;

replaco the SRS print6d circuit bo.rd in the g.uge DASHBOARDWIREHANNESS
assombly. 5P CONNECTOR
liTv;Tv;1c5i0s
#
Checkfor an opeo in the SRSindicaior light circuit: lsru lYEr
1. Turnthe ignitionswirchOFF. Wiresadeol lernale
2. Disconnectthe dashboardwire harness5p connector JUMPERw|RE rerminats
from the gaugeassembly.
3. Checkresistance betweenthe No. 6 terminalof the SRS
main haroess18Pconnectorand the No. 1 terminal ot
the dashboardwire harness5P connector;there should
be0-1.0O. SRSMAIN HARNESS
I
18PCONNECTOR
|3 the rosbtance a3 sDecified?
YES NO
Wirsideot lemaleieminals
(D) (E)
To page24-46 To page24-46
5P CONNECTOR
J
24-44
www.emanualpro.com
J
From page 24-43 MAIN WIRE
1C) HABNESS2,lP CONNECTOR
Chockfo. a short to glound in tho main wire harn63:

1. Disconnecttho dashboardwire harnoss24P connector
from the mainwire harness.
2. Checkresistance betweenthe No 5terminaloIthedash-
shouldbs 1 Mo or more.
OASHBOARD WIRE
HARNESS
Short to ground in tho dashboatd wilo harnots; repair 2,rP CONNECTOR
OASHBOARDWIREHARI{ESS
24P CONNECTOR BLU
MAIN WIRE
3P CONNECTOR
Chcckfor a short to ground in the SRSmain harnoss:
1. Disconnectthe SRS main hart\ess3P connector{rom the
main wire harness,
2. Checkresistancebetween the No. 1 terminal of the SRS cToR BOX
FUSE/RELAY
main harness3P connectorand ground.Thereshouldbe
1 MOor more.
SRSMAIN HARNESS
3P CONIIECTOR
c803
Short to ground in the mlin wire harnoss; .epair lh

mlin wira harness.
Short to ground in thc SRS mtin hemess; replacetho SRS
)
(cont'd)
www.emanualpro.com
24-45
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -,99 - 00 models(cont,d)
J)
Frcm page 24-44

{D) DASHBOARDWIREHARNESS
Chckthe SRSindicator circuit input voltage:

1. Reconnectthe SRS main harness18p connectorto the
SRSunit.
2. Connecta voltmeterbetweenthe No. 1 terminal {+) of
the dashboard5P connectorand ground.
3. Turn the ignition switch ON {ll}, wait for six seconds,
then measurevoltage.
ls there 8.5 V or more?
YES NO
The problem has disappareddue to disconnectingand

connecting tho connectors. Be sure all terminals make
good contact, and .echeck the system {seo Troublo_
shooting Intermiftent Failureson page2it-2E).
DASHEOARDWFE HARNESS
5P CONNECTOR
Poo. contact at the SRS main harn8s 18p connector;check
the connector. c5ott
. lf the connoctor is OK, aubstitute a known-good SRS unit,
end recheck.
. lf the problem is still present, .6place tho SRS m.in har-
ne33. Wiresideof lemale
terminals
Ftom lage24-44
(E) J
Checkfor an open in the dashboa.dwire harnessi
1. Disconnectthe main wire harness24p connectorfrom
the dashboardwire harness.
main harness18Pconnectorand No. S te.minalof the main
wire harness24Pconnector;thereshouldbe 0 - 1.00.
ls th resistancers speciliedT
YES NO
Open in the 8LU wi.o ol the dashboard wire hrmess:

repair the dashboardwire ha.ness. Torminalsideol maletermtnal
Checkfo. an open in the m.in wire hamess:

1. Disconnect the SRSrnainharness3p connectorfrom the SRSMAIN HARNESS
main wire harness, 18PCONNECTOR
2. Check resistancebetweenthe No. 6 terminal of the SRS
rnain harness18Pconnectorand No. 1 terminalof the SRS c806
main harness3Pconnector;there shouldbe 0 1.0O.
b the rGbtanco as sDecified?
YES NO
ca03
SRSMAIN HARNESS
Open in the BLU wir6 of th6 main wire hernos3;reori.
3P CONNECTOR
the main wire hamess,
Open in the SRS main harness;rplacethe SRS main ha.-

noss.
24-46
www.emanualpro.com
No DTC
CAUTION:Wheneverthe ignition switch is ON {lll, ol
has been tulned OFF for less than three minutes, bs
accideniallydeploy and causedamago or iniuries.
Chckthe fuse:
2. Checkfor blown No. 13 ('15A) fuse in the under-dash
Iuse/relay
box.
b th fuse OK?
YEs NO
1A)To page24 48
Replacethe fuse.Turn the ignitionswitchON {ll),and check

that the luse doesn'tblow.
ls the fuse OK? No. 13(r5 Al FUSE UNDER-DASH
FUSE/RELAYBOX
YES NO
The problm has disappeared.Ted{rive the vhicle and

see TroubfeshootingIntermittont Failureaon page21-28.
Check Ior short to ground between tho underdash tuse/

relay box and the SRSunil.
the positivecable, and wait for threeminutes.
3. Disconnectthe driver's and front passenger'sairbag con-
nectors,and disconnectthe seat belt tensionerconnectors
(seepage24-23).
4. Disconnectthe SRS main harnessl8P connectorfrom
the sRs unit.
main harness18Pconnectorand ground. SBSMAIN HARNESS
Thereshouldbe 1 M0 or more. 18PCONNECTOR
ls the .esistancoas soecified?
YES NO
Faulty SRSunit; replacelhe SRSunit {seepage 24-951.
) (cont'd)
(B)
To page24-48
Troubleshooting
No DTC(cont'dl
1
ltofi page 24-47
(B)
Chockfor short to ground in the SRSmain harne3s:

1. Disconnect the SRSmain harness2P connectorlrom the
underdashfuse/relay box.
2. Checkresrstance betwoenthe No.7 terminalof the SRS
main harness18Pconnectorand ground.There should
be 1.0M0 or more.
k the ro3irtancc as specifid?
YES NO
Short to ground in tho under-da3hlus6/rolay box;

replacethe under-dashfuse/relav box,
Short to glound in the SRS m.in hernoss;roplacetho SRS

main hatnei3. FUSE/RELAYBOX
J
(A)Frompage24-47
Checktor an opn in the SRSmain harness:

the positivecable.and wait for threeminutes.
3. Disconnectthe driver's and front passenge/sairbag con,
nectors,and disconnectthe seat belt tensionrconnectors
{seepage 24-23}.
4. Disconnectthe SRS main harness18Pconnectorfrom
the SRSunit.
negativecable.
6. Connecta voltmeterbetweenthe No. 7 terminaloI the
SRSmain harness18Pconnectorand ground.
7. Turnthe ignitionswitchON (lll , and measurevoltage.
Poor conlact .t the SRS main harness l8P connesto.:

checkth6 connector,
. It the connector is OK, substitute a known-good SRS
unit, and rgcheck.
. It lhe problem ii still p.es6nt, rcplace the SRS mlin
hamess.
To page24-49
J 3
24-48
www.emanualpro.com
)
Frompage24-48
Checktor an open in the SRSmain harne$:

2. Disconnectthe SRSmain harness2P connectorlrom the
undeFdashfuse/relaybox.
main harness2P connectorand the No. 7 terminalof the
SRSmain harnessl8P connector.
Thereshouldbe 0 - 0.5O.
ls the re3istancas soecitiod?
YES NO
Poor contact at iho SRS main harnoss2P connoctor;

checkthg connocior. UNDER-DASH
. lf the connector is OK. substitute a known-good under- BOX
FUSE/RELAY
da3hfuse/rolav box, and .echeck.
'lf tho problm is still present. replace tho SRS main
harne3s.
SRSMAIN HARNESSlEP CONNECTOR
Opon in the SRS main ha.ness;replacethe SRS main har

ness.
)
c801
SRSMAIN HARNESS
2P CONNECTOR
Troubleshooting
DTC1-1and DTC1-2
J
DRIVEF'SAIRBAG
CAUTION:Wheneverthe ignition switch is ON {ll}, or 2P CONNECTOR
accidentallydeploy and causedamage o1 iniuries.
Try to reproducethe SRSindicator light:

2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson tor about six secondsand then CABLEREEL
ooes off.
2P CONNECTOR
Doesthe SRSindicator liqht stav on?
YES NO
Intermiltent failure, svstem is OK at this time. See

Trouble3hootingIntermittent Failureson page 24-28. SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
Checktor an open in the driver's airbag inflatori t2 0 JACKI
1. Turn the ignitionswitchOFF- 07saz - TB40r1A
3. Disconnectthe driver's airbag 2P connectorfrom the
cable reel 2P connector-Do not disconnectthe passen
ger'sairbagconnector.
4. Connectthe specialtool(2 O)to the cablereel2P connec
tor.
5. Reconnect the battervpositivecable,then reconnectthe
negativecable,
6. Erasethe DTCmemory(seepage24-28). '97 modol: '98 - 00 models:
7. Readthe DTC{see page 24-261. CABLEREEL
ls DTC 1-1or DTC 1-2 indicsted? 2P CONNECTOR
YES NO
SRSMAIN
HARNESS2P
CONNECTOR
Open or increasedresistancein the driver'sairbaginflato.;

replacethed.ive.'s airbag (s6epage24-871.
Checkfoi an ooen in the cable reel:

the positivecable,and waatfor threeminutes. SRSSIMULATOR
2. Disconnect the specialtool (2 Oi from the cable reel 2P LEADC
07TAZ- SZ5011A
3. Removethe dashboardlower cover,and disconnectthe and SRSINFLATOR
cablereel2P connectorfrom the SRSmain harness. SIMULATOR
4. Connectthe specialtool (2 0) to the SBSmain harness2P 120 JACKI
connector, (cont'd) 07sAz - TB4011A
To page24'51
J
24-50
www.emanualpro.com
)
Frompage24 50
Checkfor an opon in the cabl rel (cont'd):

5. Reconnect the battervpositivecable,then reconnectthe
negativecable,
7. Readthe DTC(seepage24-2d.
ls DTC 1-1or DTC 1-2 indic.ted?
YES NO
Open or increased resistance in the cable reel; replace

the cable reel (seepaqe 24-91J.
Checkfor an open in the SRSmain harne$:

the positivecable,and wait lor threeminutes.
2- Disconnect the front passenger's airbagconnectorland
disconnect both seatbelttensionerconnectors),
) 3, Disconnectthe SRS main harness18Pconnectorfrom
the SRS unit. Do not disconnectthe specialtool 12 O)
from the SRSmain harness.
4. Checkresistance betweenterminalsNo. 1 and No. 13 of SRSMAIN HARNESS
the SRSmain harness18Pconnector. 18PCONNECTOR
Thereshouldbe aoorox.2.0 3.0 0.
ls the rcsistancas soecified?
YES NO
Poor contact at the SRS main harnoss 18P connctor;

check the connector.
. It the connecior is OK, substitute a lnown-good SRS
unit, and recheck.
.lf the problem is still present,.eplacethe SRS main
harness,
Opon or inc.oasedrc3istancein the SRS main harnoss;

roDlacetho ha]nss.3.
www.emanualpro.com
24-51
Troubleshooting
DTC1-3
J
CAUTION: Whonovor the ignition switch is ON (ll), or
has been turnod OFF for less thsn three minutss. be
caroful not to bump the SRS unit; tha ailbags could
accidentallydoploy and cau3odamage or iniuries.
Try to r.produce the SRSindicator light:

indicatorlight comeson for about six sacondsand then
goes off. 2P CONNECTOR
Do.s the SRSindic.tor light stay on?
YES NO
Intermittenl failuro. sy3tom i3 OK at this time. Soo

Trouble3hootingIntormittenl Failure3on prqo 24-28.
SRSSIMULATOR
tfAD c
0?TAZ- SZ5olrA
and SRSINFLATOR
Chockfor a short to enother wirG in the driver's sirbag inf,artor: /SIMULATOR
1. Tlrn tho ignitionswitchOFF. / Q a JACKI
2. Disconnectthe battery negativecable,then disconnect /' 07s,A-TB411A
the positivecable,and wait for three minutes.
3. Disconnctthe driver's airbag 2P connectorfrom the
cablo rel 2P connector,Do not disconnectthe oassen-
ger'sairbagconnctor.
4. Connectthe specialtool(2 Olto the cablereel2P connec-
ffi
tor.
5. Reconnectthe baftery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory (seepage 24-28). '97 model: ,98 - 00 models:
7. Readthe DTC(see page24-261.
b DTC1-3 indicatod? CABLE
REEL
2PCONNECTOR
YES NO
Sho.t in the driv6r's airb.g intletor; replacethe d vr's

.irb.g l3oo pag6 247).
Ch6cklor a short in the cablc reol:

'1. Disconnectthe
battery negativecable,then disconnect
2. Disconnectthe specialtool {2 O) lrom the cable reel 2P
conneclor.
3. Removethe dashboardlower cover,and disconnectthe SRSSIMULATOR
cablereel2P connectorfrom the SRSmain harness. LEADC
4. Connectthe specialtool (2 O) to the SRS main harness 07TAZ- SZ50114
2P connector. {cont'd} and SnS INFLATOR
SIMULATOR
{2 0 JACK}
07sAz - TB{011A
To pago 24-53
24-52
www.emanualpro.com
Frompage24-52
Chockfor a shon in th6 cablo recl {cont'dl:

5. Reconnectthe battery oositive cable,then reconnecttha
negativecable.
6. Erssethe DTCmemory (seepage 24-28).
7. Readthe DTC(see page24-26l'.
ls DTC'l-3 indic{tod?
YES NO
SRSUNIT
Short in the csble reel; replacetha cabls rcol lsao paga
24-911.
Chockfor a short in th SRSmain ha.nors:

1. Disconnectthe batterynegativecable,thn disconnect
the Dositivecable,and wait for three minutes.
2. Disconncttho lront passengor'sairbag connector (and
disconnectboth seat belt tensionerconnectors).
the SRS {rnit.Do not disconnectthe specialtool (2 0)
from the SRSmain harness2Pconnector.
4. Checkthe resistancebetweenterminals No. 1 and No. 13
of SRSmain harness18Pconnector.
Thereshouldbe aDorox.2.0- 3.00.
) b th rsciitlnce a3 sDecifi6d? SRSMAIN HABNESS
18PCONNECTOR
YES NO
( . ,L z l3 l l 6 3 c806
Faulty SRSunit; rspl.c. th6 SRSunit l.co p.sc 2a-95,, 15 18
Wiresideot
tormrnats
Shori in the SRS m.in h.rn.e!; ropbce the SRS main htr-
ne33.
Troubleshooting
DTC1-4
ial
CAUTION: Whonover the ignition switch is ON (ll), or

has boen turned OFF for less than throe minutos, bs
carelul nol to bump tho SRS unit; the airbags could
accidentallydeploy and causedamago or iniuri63.
Try to rop.oducotho SRSindicator light:

1. Erasethe DTCmomory(soepage24-28).
2. Turn the ignitionswitchON {ll},and checkthat the SRS
indicatorlight comeson for aboutsix secondsand then REEL
goes off. 2P CONNECTOR
Doe3th6 SRSindicltor light 3tay on?
YES NO
Intormittent tailure, rystem is OK rt this timo. See

Troubl$hooting Intermittent Failurcson pago 2G28.
SIMULATOR
LEAD C
07TAZ- SZ5011A
.rd SRSINFIATOR
Chacklor a 3hort to powor in ths driyar's airbag inflrtor: /SIMULATOR
1. Turnthe ignitionswilchOFF. ./ ea JA0KI
2. Disconnectthe batterynegativecable,thn disconnect 1( otstz-terore
3. Disconnectthe driver's airbag 2P connector{rom the
cable reel 2P connector.Do not disconnectthe passen-
4. Connectthe specialtool (2 0) to the cablereel2P conn6c-
ffi
tor,
5. Reconnctthe battery positive cable.then reconnectthe
ltl
negativecable.
6. Erasethe DTCmemory (seepage 24-28).
7. Readthe DTC{see page 24-261. '97 model: '98 - 00 models:
ls DTC 1-4 indicatod? CABLE
REEL
YES NO
Short to powe. in the driv.r's rirbrg inflator; replacethe

ddver's airbeq (!o D.qa 2447).
Chckfor. short to powe. in tho cabl6.ool:

the oositivecable,and wait lor three minutes.
2. Disconnect the specialtool (2 O) from the cable reel 2P SIMULATOR
connefior, I-EADC
3- Removethe dashboardlower cover,and disconnect the 07TAZ- SZ5011A
cablereel2Pconnectorlrom the SRSmain harness. and SRSINFLATOR
4. Connectthe specialtool (2 0) to the SRS ma;n harnss SIMULATOR
2P connoctor. (cont'dl (2 0 JACKT
07sAz - lB4011A
To page 24-55
24-54
www.emanualpro.com
Ftom page24-54
Checkfor 6 short power in the cable r6el {cont'd):

negativecable.
7. Readthe DTC(see page 24-261.
b DTC1-4 indicarodz
YES NO
Short to power in lhe cablo roel; replace th cabl ieel

{seepago24-91).
Checktor a short to power in th. SRSmain harn$s:

1.Disconnectthe batterynegativecable,then disconnect
the positivecable, and wait for three minutes.
2. Disconnectthe front passenger's airbagconnector{and
disconnect both seatbelttensionerconnectors).
3. Rernovethe specialtool (2 O)from the SRSmain harness
2P connector.
the SRSunit.
5. Beconnectthe batterv positive cable, then reconnectthe
negativecable. SRSMAIN HARNESS
6. Connecta voltmeterbetweenthe No. 1 {+) terminalol 18PCONNECTOR
the SRSmain harness18Pconnectorand body ground.
7. Turn the ignition switch ON (ll), and measurevoltage.
Thereshouldbe 0.5V or less.
9. Connecta voitmeterbetweenthe No. 13 {+i terminalof
the SRSmain harness18Pconnectorand body ground.
10.Turnthe ignitionswitch ON lll), and measurevoltage.
Are voltagesas specified?
YES NO
Faulty SRSunit; replacoth SRSunit lsoo pas6 24-95).
Short to power in th SRS main hamoss; roplecethe SRS

main haanass.
www.emanualpro.com
24-55
Troubleshooting
DTCl-s
CAUTION: Whenever tho igniiion switch is ON {ll), or
DRIVER'SAIRBAG
O'-
2P CONNECTOR
has been lurned OFF for loss lhan thrse minules, be
caretul not to bump the SRS unit; the airbags could

2. Turn the ignitionswitchON lll), and checkthat the SRS
goes off.
CAALEREEL
Doostho SRSindicator liqht stav on? 2P CONNECTOR
YES NO
Inte.mittent tailure,3y3tem is OK at this timo. 506

TroubleshoolingIntermittent Failureson Daq24-28.
Checktor a short to ground in the driver's ai.bag intlator:

2. Disconnectthe battery negativecable,then disconnect
the positivecable,and wa:l for threeminutes.
3. Disconnectthe driver's airbag 2P connectorfrom the
ar
h /
SRSSIMULATOR
LEADC
07TAZ- SZ50r1A
.nd SRSINFLATOR
SIMULATOR
{2 0 JACK)
07sAz - TBaolrA
ffi
cable reel 2P connector,Do not disconnectthe passen,
4. Connectthe specialtool {2 O}to the cablereel2Pconnec-
tor.
5. Reconnectthe battery positive cable. then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24 28).
7. Readthe DTClsee page 24-261.
ls DTC1-5 indicated?
'97 model: '98 - 0Omodels:
YES NO
CABLE
REEL
2PCONNECTOR
Short to ground in the driver's airbag inflator;replacethe

driver's airbag (s6epage 24-871.
Chockfor a short to ground in the cablo reel:

1. Disconnectthe battery negativecable,then disconnect
2. Disconnect the specialtool i2 O) from the cable reel 2P
3. Removethe dashboardlower cover,and disconnect the

cablereel2P connectorfrom the SRSmain harness. SRSSIMULATOR
4. Connectthe specialtool {2 O) to the SRS main harness LEAOC
2P connector. (cont'd) 07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
t2 0 JACKI
07sAz - TB{01rA
To page24-57
J..
24-56
www.emanualpro.com
)
Frompage24 56
Check{or a short to ground in the cable reel (cont'd):

5. Reconnectthe batterv positive cable, then reconnectthe
negativecable.
6. Eraselhe DTCmemoty lsee page 24-28).
7. Readthe DTClsee page24 26).
ls OTC1-5 indicated?
YES NO
Short lo ground in the cable reel; replacethe cable reel

{seeoaoe 2,1-91}.
Checkfor a short to ground in the SRSmain harness:

'1. Disconnect the batterynegativecable,the disconnect
the
positivecable,and wait for threeminutes.
2. Disconnectthe tront passenger'sairbag 2P connector
(6nddisconnect both seatbelttensionerconnectors).
3. Removethe specialtool 12{))fromthe SRSmain harness
2P connector. SRSMAIN HARNESS
4- Disconnectthe SRS main harness18Pconnectorfrom 18PCONNECTOR
) the sRs unit.
5. Checkresistance betweenthe No. l terminalo{theSRS
main harness18Pconnectorand ground,and between
the No. 13terminalof the SRSmain harness18Pconnec-
tor and ground.
Thereshouldbe I M0 or more.
ls lhe resistanceas soecitiod?
YES NO
Faulw SRSunit reDlacethe SRSunit lsee paqe 24-951.
Short to ground in the SRS main harness;replacethe SRS

main hamss,
www.emanualpro.com
24-57
Troubleshooting
DTC2-1 and DTC2-2
!a
CAUTION:Wheneverthe ignition switch is ON lll), or SRSMAIN HARNESS

has been turned OFF tor less than throe minutes, be

indacator light comeson for aboutsaxsecondsand then
Doesthe SRSindicator lioht stav on?
Intermittent tailure, svstem is OK ai lhis time. See

Troubl*hooting Intermittent Failureson paqe24-28.
Chockfor an open in the passongor'sairbag inflator:

1. Turnthe ignitionswitchOFF. SIMULATOR
2. Disconnectthe batterynegativecable,then disconnect I-EADC
the positivecable,and wait for threeminutes. 07TAZ- SZ5tt11A
3- Disconnect the front passenger's airbagconnectorlrom and SRSINFLATOR
the SRSmain harness(seepage24-2:,,.
4. Connectthe specialtool (2 0) to the SRS main harness /StMULATOR
2P connector.Do not disconnect the driver'sairbagcon, / Q A JACKI
y' 07slz-TA411A
nector.
negativecable.
7. Readthe DTC(seepage 24 26!'.
ls DTC2-1 or DTC2-2 indicated?
ffi
Open or incrcased resistance in tho passenger'sairbag
To page 24'59
24-58
www.emanualpro.com
)
Frompage24 58
Checkfo. an oD6nin the SRSmain harness: sRsUNIT

2. Disconnectthedriver'sairbag2P connectorland disconnect
both seatbelttensionerconnectors) (seepage24 23).
the SRS unit. Do not disconnectthe soecialtool (2 Oi
from the SRSmain harness.
4. Checkresistance betweenthe No. 10terminaland No. 14
terminalof the SRS main harness18Pconnector.There
shouldbe aoorox.2.0- 3.0g.
ls the .osistancas soecified?
YES NO
Poor contacl ai the SRS main harness 18P conneclori

checklhe connector, 18PCONNECTOR
.lf the conneclor is OK, substitute a known-good SRS
unit, and recheck.
.lf the problem is still present,replacethe SRS main
hatnesli,
Open or increasedresistancein the SRS main harness;

replacethe harness.
www.emanualpro.com
24-59
Troubleshooting
DTC2-3
{J
CAUTION: Whenevor the ignition switch is ON { }, or SRSMAIN HARNESS
careful not to bump the SRS unit; lhe airbags could
accidentallydeploy and causodamage or iniuries.

1- Erasethe DTCmemory{seepage24 28).
goes off.
Doesthe SRSindicator light stay on?
YES NO
Intermittont failur, syslem is OK at this time. 560

T.oubloshootinglntormittent Failur6 on page 24-28.
Checkfor a short to another wiro or decreasedresbtanc in

the pa$nger's airbag inflator: SIMULATOR
1. Turnthe ignitionswitchOFF. LEAD C
2. Disconnectthe batterynegativecable,then disconnect 07TAZ- SZ50I1A
the positivecable,and wait for threeminutes. and SRSINFLATOR
3. Disconnectthe front passenger'sairbag 2P connector /STMULATOR
from the SRSmain harness(seepage24-23). / I2n JACKI
4. Connectthe specialtool (2 O) to the SRS main harness y' 07sAz-fB1011A
2P connector.Do not disconnectthe driver,sairbagcon-
nector.
negativecable.
6. Erasethe DTCmemory(seepage24 28i.
ffi
7. Readthe DTC(seepage 24-26).
YES NO
Short to another wir6 or decaea3draktance in the oas-

senger's airbag intlatoi; replac the passenger'sairbag
{see pago 24-8t1.
To page24 61
24-60
www.emanualpro.com
)
Frompage24 60
Ch6cktor a short to another wire or decreasodaGsistance in

lh SRSmain harness:
2. Disconnectthe driver'sairbag2P connector(anddisconnect
both seatbelttensionerconnectors).
'18Pconnectorfrom
3. Disconnectthe SRS main harness
the SRSunit.Do not disconnect the specialtool (2 O).
4. Checkresistance betweenthe No. 10terminaland No. 14
terminalof the SRS main harness18Pconnector.There
shouldbe aoorox.2.0- 3.00.
ls the rosistanc6 as specified?
YES NO
Faultv SRSunit; replacelhe SRSunit lsee page 24-95).
SRSMAIN HARNESS
18PCONNECTOR
Short to anothor wire or decre.sed re3i3t.nce in the SRS
main harness;replacthe SRSmain harn*s.
www.emanualpro.com
24-61
Troubleshooting
DTC2-4
Ot-
GAUTION: Whnever tho ignition switch is ON 0t). or SRSMAIN HARNESS
has been turned OFF for less than threo minutes, bo
accidentallydeploy and causedamaga or iniuriss.

1. Erasethe DTCmemory(seepage24-28i.
2. Turn the ignitionswitchON (lli, and checkthat the SRS
indicatorlight comeson tor about six secondsand then
goes off.
Dosthe SRSindicator light stay on?
YES NO
Inlermittent tailure, system is OK at this tim. Sce

Troubleshooting Intermitt.f Failureson page 2+28.
Checkfor a short to power in the passengar,sai.bag infla-

tor:
1. Turnthe ignitionswitchOFF. SIMULAYOR
2. Disconnectthe bafterynegativecable,then disconnect LEAD C
the positivecable,and wait for threeminutes. 07TAZ- SZ5011A
3. Disconnectthe front passenger'sairbag 2P connector .nd SRSINFLATOR
Irom the SRSmain harnesslseepage24-23). /stMU|_ATOR
4. Connectthe specialtool (2 O) to the SRS main harness / t2 tr JAoKI
2P connector.Do not disconnect the driver,sairbagcon, olsAz-Tsn11A
//
ffi
nector,
negativecable.
7. Readthe DTC(see page 24-26|'.
ls DTC2-4 indicsted?
YES NO
Sho.t power in the passenger's airbag infator; rsplece tho

paisonge/i airbag {se pag 2il-89).
To page24-63
24-62
www.emanualpro.com
Frcm page24-62
Checklor a short to power in the SRSmain harness:

2. Disconnectthe drive/s airbag2P connector(anddisconnect
both seatbelttensionerconnectors).
3. Disconnectthe SRS main harness18Pconnectortrom
the SRSunit.
4. Removethe specialtool(2 0) from the SRSmain harness
2P connector,
5. Reconnectthe batterv positive cable,then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 10 (+) terminalof
SRSmain harness18Pconnectorand ground.
7. Turn the ignition switch ON (ll). and measurevoltage
8. Connecta voltmeterbetweenthe No. 141+)terminalof
the SRS main harness18Pconnectorand ground,and sRs
.I8PCONNECTOR
measurevoltage.Thereshouldbe 0.5V or less.
Are voltages .3 specifiedT
YES NO
FaultySRSunit; replacethe SRSunit (sce page 24'95).
Short to powor in the SRS main ha.ne3s; replace the SRS

main hdrness.
www.emanualpro.com
24-63
Troubleshooting
DTC2-5
tl
CAUTION:Wheneverthe igniiion switch is ON {ll}, or
has ben turnd OFF for less than three minutes, be
careful nol to bump the SRS unit; the sirbags could
accidentallydoploy and causo damage or iniuries.
Try to rep.oducethe SRSindicstor tight:

2. Turn the ignitionswitchON 0l), and checkthat the SRS
goes off.
ooes th6 SRSindicaror light st.y on?
YES NO
Inte.mitt.nt failure, system is OK at thi3 time. Se

Troubl6hooting Intermittem Failur6 on page2+28.
Checkfor a short to gaound in th6 prsenger,i airbag inlla-

tor: SIMULATOR
1. Turnthe ignitionswitchOFF. LEAOC
2. Disconnectthe batterynogativecable,then disconnect 07TAZ- SZ5011A
the positivecable,and wait for threeminutes. .nd SRSINFLATOR
3. Disconnectthe front passenger,sairbag 2p connector /StMULATOR
from the SRSmain harness{seepage24-23). / t2 a JACKI
4. Connectthe specialtool (2 0) to the SRS main harness 07saz-fB&11^
/
ffi
2P connector.Do not disconnectthe driver,sairbagcon,
nector.
negativecable.
7. Readthe DTClsee page2[-261.
YES NO
Short to ground in the pasngert airbeg inflator; ,cplace

the passenge/s airbag (se page 2+991.
To page24 65
24-64
www.emanualpro.com
) J
Frompage24'64
Checkfor a short to ground in the SRSmain harnessl

the posilivecable.and wait for threeminutes.
2. Disconnect the driver'sairbag2P connector(anddiscon-
nectboth seatbelttensionerconnectors),
3. Disconnectthe SBS main harness18Pconnectorfrom
the sRs unit.
4. Removethe specialtool (2 O)from the SRSmain harness
2Pconnector,
5. Checkresistance betweenthe No. 10terminalof the SRS
main harness18Pconnectorand ground,and between
the No. 14terminalof the SRSmain harness18Pconnec
tor and ground.Thereshouldbe 1 M0 or more.
ls the resistanceas sDcitied?
YES NO
sRs
Faultv SRSuniu replacethe SRSunit {seepaqe 24-951. 18PCONNECTOF
Short to ground in the SRS main harnss;replacihe SRS

main harness.
www.emanualpro.com
24-65
Troubleshooting
DTC3-1and DTC3-2
-
CAUTION:Wheneverthe ignition switch is ON flll, or
has been turned OFF for less than three minutes, b DRIVER'S LEFTSIOEWIRE
careful not to bump th SRS unit; the airbags could SEATBELTTENSIONER HARNESS
accidenlallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicatoi light:

2. Turn the ignitionswitch ON 1 ), and checkthat the SRS
goesoff.
Doesthe SRSindicaior lighr stay on?
YES NO
Intermittent failure, system is OK at this time. See

Troubleshootinglfiermittent Failu.6son page24-28.
Checktor an open in the driver's seat b6lt tensioner:

1. Disconnect the negativebatterycable,and wait lor three
minutes.
2. Disconnect the drave/sseat belt tensioner2p connector
from the left side wire harness2P connector(see page
24-23).Do not disconnect SRSSIMULA
the lront passenger,s seatbelt LEADC
tensioner2P connector.
3. Connectthe specialtool {2 O) to the left side wire harness
07TAZ- SZ501rA
2P connector,
andSRSINFLATOR
4. Reconnect
STMULAToR I
the negativebafterycable
5. Erasethe DTCmemory{seepage24,28). t2 0JACKI I
6. Readthe DTC(see page 24-26).
oTsaz- TB4otlA t \
ls OTC3-1or DTC3-2 indicatedT
YES NO
Open or increasedresistancein the d.iver's seat belt ten-

sioner; replacethe driver's seat belt {seepage 2il-91).
To page24 67
www.emanualpro.com
24-66
)
Frompage24-66
Checkfor an oFn in thc aide wir6 harne$:

1. Disconnect the left sidewire harness2P connectorfrom
the SRSmain harness2P connector.
2. Connectthe specialtool (2 o) to the SRS main harness LEFTSIDEWIRE
2Pconnector. HARNESS
3. Erasethe DTCmemory. 2P CONNECTOR
4. Readthe DTC.
ls DTC3-l or DTC3-2 indicated?
SRSMAIN
YES NO HARNESS
2P CONNECTOR
Ooen or incrersd reeidance in the lelt side wire hame3s;

rDlacathe hamess. C
00
SRSSIMULATOR
LEADC
Checkfor an open in the SRSmain harness: 07TAZ- SZ5011A
1. Disconnect the negativebatterycable,and wait for three and SRSINFLATOR
minutes.
2. Disconnectthe driver'sand front passenger'sairbags, {2 0 JACKI
and front passenger'sseatbelttensionerconnectors(see 07sAz - T84011A
page24-231.
the SRS unit. Do not disconnectthe specialtool (2 O)
from the SRSmain harness2P connector.
) art 4. Checkresistance betweenthe No. 4 and No. 11terminals
of the SRSmain harness18Pconnector. Thereshouldbe
2.0- 3.0 0.
13lhe resistance as soecified?
YES NO
Faulty SFS unil or poor contad at the SRS main h.mss sRsUNIT
18P connector and th SRS unit. check the connection
between the SRS main harn$s 18P connector and the
SRS unit. lf the connector i3 OK. rDlacoihe SRS unit
(s66pas6 24-951.
ODen or incaoasedresistancein the SRS msin harness;

reolacethe SRSmain harnss.
SRSMAIN HARNESS
.I8PCONNECTOR
)
terminals
www.emanualpro.com
24-67
Troubleshooting
DTC3-3
ra
CAUTION; Whenever the ignition switch is ON llll, or

has bon turned OFF for l6ss than three minutes, be ORIVER'S LEFTSIDEWIRE
SEATEELTTENSIONER HARNESS
carelul not to bump the SRS unit; the airbags could 2P CONNECTOR 2P CONNECTOB
accidontallydeploy and causedamage or iniuries.
Try to rproducethe SRSindicator light:

2. Turn the ignitionswitchON (lll, and checkthat the SRS
indicatorlight comeson for about six secondsand then
goes off.
Doesthe SRSindicator lighl stay on?
YES NO
Intarmittent failure, system is OK at this time. 506

TroublshootingIntormittantFailureson paqe24-28.
Checktor a 3hort to anothr wire or decreasedresistancein

ihe driver's seat bolt tan3ioneri
1. Disconnect the negativebatterycable,and wait for three
minutes,
2. Disconnectthe driver's seat belt tensioner 2P connector SRSSIMULATOR
from the left side wire harness2P connector(see page LEAOC
24-23).Do not disconnect the front passenger's seat belt 07TAZ-525011A
tensioner2P connector, and SRSINFLATOR
3. Connectthe specialtool (2 O) to the left side wire harness srMULAroR I
s
2P connector. t2 0 JACK| t
4. Reconnectthe negativebattery cable ozsAz- ls{orra !
6. Readthe DTC(seepage 24.26l'.
YES NO
Short to another wire or decreased.esistancein the

driver's s6at beh tcnsioner; replacthe diive.'s seat bolt
{seprge 24-911.
To page 24 69
24-64
www.emanualpro.com
\.p
Frompage24-68
Checklor a short to another wire or decreasedreaistancein

the side wire harnoss:
1. Disconnect the left side wire harness2P connectortrom
the SRSmain harness2P connector. LEFTSIDEWIRE
2. Connectthe specialtool (2 0) to the SRS main harness HARNESS
2P connector. 2P CONNECTOR
3. Erasethe DTCmemory.
4. Readthe DTC.
ls OTC3-3 indicated? SRSMAIN
HANNESS
YES NO 2P CONNECTOR
C
Short to another wire or decrcased resbtance in the le-h
side wire harness;reglacethe harneas.
0a
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
Checklor a 3hort to another wire or dec.easedresistancein and SRSINFLAToR
the SRSmain ha.ne$: SIMULATOR
1. Disconnect the negativebatterycable,and wait for three {2 0 JACK}
minutes, 07sAz - TB4011A
2. Disconnectthe driver's and front passenger'sairbags,
and front passenger's (see
I J
seatbelttensionerconnectors
page24 23l'.
the SRSunit.
4. Disconnectthe specialtool (2 O)from the SRSmain harness
2P connector.
5. Checkresistancebetweenthe No. 4 and No. 11terminalsof
the SRS main harness18Pconnector.There should be
1 M0 or more.
ls the resistancas soocified?
YES NO SRSUNIT
Faulty SRSunit; replacethe SRSunit lso paqe 24-95).
Short to another wire or decrasodrosistanco in the SBS

main harness;replacethe SRSmain harness.
SRSMAIN HARNESS
18PCONNECTOR
I J
lerminals.
www.emanualpro.com
24-69
Troubleshooting
DTC3-4
{
CAUTION: Whenever the ignition switch is ON (lll, ol
has been turned OFF for l6ss than thr6e minutes, b
careful not to bump the SRS unit; lho airbags could DRIVER'S LEFTSIDEWIRE
accidentallydeploy and causdamage or iniuries. SEATBELTTENSIONER HARNESS
2P CONNECTOR 2P CONNECIOR
Try lo reproducoth6 SRSindicator light:
1. ErasetheDTCmemory(seepage24-28).
ooes off,
Doe3the SRSindicator liqht stav on?
YES NO
Intcrmitt.nt f.ilur., iystem is OK at this time. Soe

Troubla3hooting Intermittent Failurca on Dage24-28.
Checklor a shortlo Dowar in the driver'33at beh tonsioncr:

1. Disconnoctthe negativebattery cable, and wait for three
minutes.
2. Disconnect the driver'sseat belt tensioner2P connector
from the left side wire harness2P connector(see page
24 23).Do not disconnect the front passenger's seat belt
tensioner2P connector, SRSSIMULATOR
3. Connectthe specialtool {2 0) to the left side wire harness LEADC
2P connector. 07TAZ- SZ5011A
4. Reconnectthe negativebattery cable. and SRSINFLATOR
5. Erasethe DTCmemory {see page24-28). SIMULATOR I
6. Readthe DTC(see page 24-26). {2 o JACK} I
ls DTC3-4 indicsted? ozsaz- tamrrl i
YES NO
Short to powar in the d.iver's seat belt tensioner;

replacethe d.iver's seat belt tensione. {3eepago 2il-31.
To page24'71
24-70
www.emanualpro.com
)
Frompage24-70
Chocktor a short lo power in the sid wi.e harness:
h
1. Disconnect the left sidewire harness2P connectorfrom
2. Connectthe sDecialtool {2 O) to the SRS maanharness LEFTSIDEWIRE
2P connector, HARNESS
3. Erasothe DTCmemory. 2P CONNECTOR
4. Readthe DTC.
b DTC3-4 indiclted?
SRSMAIN (
YES NO HARNESS
2P CONNECTOR
Short to power in the left side wire ha.n6ss;replecethe

narness. C
00
SRSSIMULATOR
Checkfor a short to power in the SRSmein harness: LEAOC
1. Disconnect the negativebatterycable,and wait for three 07TAZ- SZ5011A
mrnutes. and SRSINFLATOR
2. Disconnectthe driver'sand lront passenger'sairbags,
and front passenger'sseatbelttensionerconnectors(see (2 0 JACKI
page 24-231. 07SAZ- TB/t011A
3. Disconnectthe SRS main harness18Pconnectortrom
the SRSunit.
4. Disconnectthe specialtool(2
0)fromthe SRSmainharness
) 2Pconnector,then reconnectthenegativebatterycable.
5. Turn the ignitionswitchON (lll.
6. Checklor voltage betweenthe No. 4 terminal ol the SFS
main harness'18Pconnectorand body ground. There
shouldbe 0.5 V or less.Checkfor voltagebetweenthe No.
11terminalsol the SRSmain harness18Pconnector.There
shouldbe 0.5V or less.
ls tho voltage as specffied?
YES NO
Faulty SRSunit; replacetho SRSunit lsee paqe 24-95).
Short to power in the SRS m.in harness;.eplace the SRS

main hame3a.
SRSMAIN HARNESS
18PCONNECTOR
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24-71
Troubleshooting
DTC3-5
*r
CAUTION: Whonover tho ignition switch is ON (ll), or
has been turned OFF for less than thres minutes, b DRIVER'S
careful not to bump the SRS unit; the airbags could SEATBELTTENSIONER
accidontallydeploy and causedamsgo or iniurirs.
Try to reproducothe SRSindioto. light:

1. Erasethe DTCmemory (s66 pag624-28).
indicatorlightcomoson Ior aboutsix seconds,and then
goes off.
Do. the SRSindicsto. light 3tav on?
YES NO
lnto.mitlont hilure, ryltom is OK at thia timc. Ses

T.oubleshootinqIntermittont Failuroson page 2+28.
Chck for a short to ground in the djivoi's soat b6h tonsioner:

1. Disconnectthe negativebattery cable, and wait tor three
mtnutes.
2. Disconnoctthe driver's seat belt tensioner 2P connector
Irom the lft side wire harness 2P connector (see page SRSSIMULATOR
24-23).Do not disconnectthe front passenger'sseat belt LEADC
tensioner2P connector. 07TAZ-S25011A
3. Connectthe specialtool (2 0) to the left side wire harness and SRSINFLATOR
2P connector, SIMULATOR \
4. Rgconnectthe negativebattery cable. (2 0 JACK' I
5. Erasethe DTCmemory (seepage 24-28). ozsnz-teronl t
6. Readthe DTC(see page21-26).
YES NO
Short to ground in the driver's soai belt tensioner;

repllce the driver'3 seat belt lse Daq624-31.
To page2a-73
24-72
www.emanualpro.com
)
Frcm page24-12
Checklor . short to ground in lhe lido wire hrrnassi
\r
1. Disconnect the llt sidewiro hamess2P connectorfrom
2. Connectthe specialtool (2 0) to the SRS main harness LEFTSIDEwlRE
2P connoctor. HARNESS
3. Erasethe DTCmemory. 2P CONNECTOR
4. Readthe DTC.
SRSMAIN (
HARNESS
2P CONNECTOR
C
Short to ground in the lolt side wi.e harno3s;.eplscethe 00
hamer3.
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
Checkfor a short to ground in tho SRSmain harna+t: / (2 o JACK)
1. Disconnecttho negativebattery cable, and wait for three 07sAz - TB4o11A
/
mtnutes. I
2. Disconnectthe drive/s and front passenger'sairbags,
and front passenger'sseat bolt tensioner 2P connectors
) (seepage24-231.
3. Disconnectthe SRS main harnessl8P connectorfrom
the SRSunit.
4. Removethe spacialtool {2 0) from the SRSmain hamess
2P connector,
m a i n h a r n e s s1 8 Pc o n n e c t o ra n d b o d y g r o u n d ,a n d
betweenthe No. ll terminalsofthe SRS main harness
18Pconnectorand body ground.Thereshouldbe 1 M0
or more.
Short to ground in the SRS m.in hrrnar3; roplacotho SRS

mein hamoSs.
SRSMAIN HABNESS
18PCONNECTOR
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24-73
Troubleshooting
DTC4-1and DTC4-2
!|
CAUTION: Whenever tho ignition 3witch is ON (ll), ot FRONT

has boen turnd OFF for less than thro6 minutos, bo RIGH1SIDEWIRE
HARNESS PASSENGER'S
carful not to bump ihe SRS unit; the airbags could
2P CONNECTOR
accidentallydeploy and causodamage or iniurios,
Try to roproducathe SRSindicator light:

1. Erasethe DTCmomory(seepage24'28i.
2. Turn the ignitionswitchON (ll).and checkthat the SRS
indicatorlight comeson for aboutsix seconds.and then
ooes off,
Doesthe SRSindicator lisht stay on?
YES NO
Intermittent failure, syatem i3 OK at this tim6. Soo

Trouble3hootingInta.mittent Failuroson page24-28.
Ched( for an open in the front p.ssongo/s 3eat bolt teruiona.:

mrnutes.
2. Disconnectthe front passenger's seat belt tensioner2P SRSSIMULATOR
connectorfrom the right side wire harnss2P conneclor LEADC
(see page 24-23).Do not disconnectthe driver's seat belt 07TAZ- SZ5n11A
tensioner2Pconnector. andSRsINFLATOR
o
3. Connectthe specialtool (2 O)to the right sido wire har- SIMULATOR
ness2P connector. /izo.ncri
-
4. Reconnectthe negativebatterycable. ozsAz T8.011A
5. Erasethe DTCmemory lsee page 24 28). f
6. Readthe DTC(seepage 24'26).
k DTC4-1 or DTC4-2 indicatodT
YES NO
Open or increaaad resistance in lhe tront pa$enger's

seat belt tensioner; roplace the front p.s3engar's 3eat
belt lsee p.ge 24-31.
fo page24-75
24-74
www.emanualpro.com
)
Ftom page 2!-7a
Checklor .n oo.n in the side wire hsrness:

1. Disconnect the rightsidewire harness2P connectorfrom RIGHTSIDEWIRE
the SRSmain harness2Pconnector. HARNESS
2. Connectthe specialtool (2 Oi to the SRS main harness 2P CONNECTOR
2Pconnector.
4. Beadthe DTC.
ls DTC4-1 or DTC4-2 indicated?
YES NO
Open or inc.oasedresistancein th right side wire har- SRSMAIN HARNESS

2P CONNECTOR
ness;replacethe harness.
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
Checktor an open in the SRSmain harness: .nd SRSINFLATOR
1. Disconnect the negativebatterycable,and wait for three SIMULATOR
mtnutes. (2 0 JACK)
2. Disconnectthe driver'sand front passenger'sairbags, 07sAz - TB4011A
and driver'sseatbelt tensionerconnectors(seepage24-
23\.
the SRS unit. Do not disconnectthe specialtool (2 0)
) "r$ from the SRSmain harness2P connector.
4- Checkresistance betweenthe No. 5 and No. 12 terminals
of the SRSmain harness18Pconnector. Theresho!ld be
2.0- 3.00.
ls the resistancaas soecified?
YES NO
Faulty SRSunit or poor contact at the SRSmain harne3s

18P conneclor and the SRS unit, check the connestion
btween the SRS main harness 18P connctor and th6
SRS unit. lf the connector is OK, reDlacethe SRS unit
{seepage 24-951.
Open or increesedresistancoin the SRS main h.rnes3;

replacethe SRSmain harness.
SRSMAIN HABNESS
18PCONNECTOR
)
le.minals.
www.emanualpro.com
24-75
Troubleshooting
DTC4-3
{
CAUTION: Whonev.r ths ignition switch is ON (ll), or
has been turned OFF tor less than throe minutes, b RIGHTSIDEWIRE FRONT
careful not to bump tho SRS unit; the airbags could HARNESS PASSENGER'S
accidentallydeploy and csuse damage or iniuries. 2P CONNECTOR
Try lo reproducothc SRSindicator light:

'1. Erase
the DTCmemory (seepage 2{-28).
2. Turn the ignitionswitchON {ll},and checkthat the SRS
indicatorlight comeson for aboutsix seconds,and then
goes off.
Doosthe SRSindicstor light stay on?
YES NO
Intermittent failure, rystgm ia OK rt this timo. S6c

TroubloshootingIntermittont Failu.oson pago 2+28.
Chock to. a short to .nothor wira or decre8od ro3btance in

the froni pa3sengor'3aoat belt ten3ioner:
mrnutes.
2. Disconnectthe front passenger's seat belt tensioner2P SRSSIMULATOR
connectorfrom the right side wire hamess 2P connector LEADC
(see page 24-23).Do not disconnectthe driver's seat belt 07TM - SZ5011A
tensioner2P connector. and SRSINFLATOR
3. Connectthe specialtool (2 O)to the right side wire har- SIMULATOR
ness2P connoctor. /2 o JACKI
4. Reconnectthe negativebattgrycable. l07sAz - TB4011A
5. Erasethe DTCmemory (see page 24-28).
6. Readthe DTClsee page 24-261. tt2s>,-ar'
na
|3 DTCG3 indicatod? --\>
YES NO
Short to .noth6r wire o. dc6e.rd raktanco in the front

passenger'3sat boh teniioner; roplaccthe lront pass6n-
g6r's aeat belt (sepsge 2a-31.
To page24-77
24-76
www.emanualpro.com
Frompage24-76
Chockto. a aho.l to lnothcr wire or dcreslod rosbtanco in

th. side wiro harn.$: RIGHTSIOEWIRE
1. Disconnoct the rightsidewire harness2Pconnectorlrom HARNESS
the SRSmain harness2P connector. 2P CONNECTOR
2. Connoctthe specialtool (2 O) to the SRS main harness
2P connector.
4. Readtho DTC.
13DIC +3 indicated?
YES NO
SRSMAIN
2P CONNECTOR
Short to .noth6r wiro or doc.oasod r.sistanco in thG
dght sida wiro ha]ne3s;rapl.ce the hamcas.
SRSSIMULATOR
LEADC
07TAZ- SZ50114
and SRSINFLATOR
Chackloi a short to anothor wire o. docreasdrGbtancc in SIMULATOR
tho SRSmain h.]n$: {2 0 JACK)
1. Disconnectthe negativebattery cable, and wait for three 07saz - Ta1ol1A
mtnutes,
2. Disconnectth6 driver's and front passenger'sairbags,
and driver's seat belt tensionerconnectors(see page 24-

) the SRSunit.
4. Disconnectthe specialtool (2 0) from the SRS main har-
ness2P connctor.
5. Checkresistancebetweenthe No. 5 and No. '12terminals
of the SRSmain harness18Pconnector. Thereshouldbe
1 MO or more.
b the raaistanco aa soscifiedT
YES NO
F.ulty SRSunit; roplactho SRSunit lseo pase 24-951.
Short to enothor wi.o or decree3odr*istance in the SRS

main harnoit rophco the SRSmain ha.nsss.
SBSMAIN HARNESS
18PCONNECTOR
6 c806
\
15
l; iid of {6male
terminals,
www.emanualpro.com
24-77
I
Troubleshooting
DTC4-4
CAUTION:Wheneverthe ignition switch is ON (ll), or RIGHTSIDEWIRE FRONT
has been turned OFF tor less than thlee minutes. be HARNESS PASSENGER'S
careful nol to bump the SRS unit; the airbags could 2P
accidontallydeploy and causedamage or iniuries.

1. Erasethe DTCmemory{seepage24-28).
goes off.
Doosthe SRSindicator light 3t.y on?
vEs NO
Intermittent f!ilure, system is OK at this time. See

T.oubleshootingIntermittent F.ilures on page 24-28.
Checktor a 3horl lo power in the frolt passnge.'ssat belt

tensaoneri
'1. Disconnectthe negativebatterycable,and wait for three SRSSIMULATOR
mrnutes. LEADC
2. Disconnect the front passenger's seat belt tensioner2P 07TAZ- SZ5011A
connectorfrom the right sidewire harness2P connector and SRSINFLATOR
{seepage24-23}.Do not disconnect the driver'sseatbelt
tensioner2P connector. ,StMULATOR
3. Connectthe specialtool (2 O) to the right sidewire har- /(2 o JACK)
-
ness2P connector. t _07SAZTBiro11A
4. Reconnectthe negaiivebafterycable.
6. Readthe DTClseepage24-261.
ls DTC4-,1indicated?
YES NO
Short to power in the front passong6r'3seat belt ten-

sioner; replacethe front passongar'3sat beh {see page
21-31.
To page24'79
24-78.
www.emanualpro.com
)
Ftom page24 78
Checkfor a short to power in the side wire harn6s:

1. Disconnect the rightsidewire harness2P connectorfrom RIGHTSIDEWIRE
the SRSmain harness2Pconnector, HARNESS
2- Connectthe specialtool (2 0) to the SRS main harness 2P CONNECTOR
2Pconnector.
4. Readthe DTC.
ls DTC4-{ indicated?
YES NO
SRSMAIN
Short to power in the right side wire harness; replace 2P CONNECTOR
the harness.
SBSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR \
Checktor a short to oow6r in the SRSmain harness: (2 0 JACK)
1. Disconnect the negativebatterycable,and wait for three \
07sAz-T84011A
mtnutes, \
2. Disconnectthe driver'sand front passenger'sairbags, \
) J
and driver'sseatbelttensionerconnectors(seepage24-
23).
the sRS unit.
4. Disconnect the specialtool i2 0) from the SRSmain har
@
ness2P connector,then reconnectthe negativebattery
caore.
6. Checkfor voltagebetweenthe No. 5 terminalof the SRS
m a i n h a r n e s s1 8 Pc o n n e c t o ar n d b o d y g r o u n d .T h e r e
should be 0.5 V or less.Checkfor voltagebetweenthe
No. 12 terminalsof the SRSmain harness18Pconnector.
ls the voltage as specified?
YES NO
Faulty SRSunit; replacethe SRSunit (seepase 24-95).
Short to power in the SRS main harness;replacethe SRS

main harness.
SRSMAIN HARNESS
18PCONNECTOR
www.emanualpro.com
24-79
Troubleshooting
DTC4-5
\
GAUTION: Whonever the ignition switch is ON fll). ol
has be6n turned OFF for less than thrso minuter. be RIGXTSIOEWIRE FRONT
careful not to bump the SRS unit; the airbags could HARNESS PASSENGR'S
accidontallydeploy and causodamage or iniurias. 2P
Try to roproducoth. SRSindicrtor tighi:

goes off.
Doe3the SRSindicator light stay on?
YES NO
Intrmittent t.ilurG, syst.m is OK at thi! timo. So

TroubleshootingInte.miftnt Failure3on psqa 2+28.
Chcck Ior a shon to ground in the trodt parsnge/s lert beh

tensionea:
mrnutes.
2. Disconnectthe front passenger's SRSSIMULATOR
seat belt tensioner2p LEADC
connectortrom the right sidewire harness2p connector
(see page 24-23).Do not disconnectthe driver's seat bek 07lAz - s25011A
and SRSINFLATOR
tensioner2P connector.
3. Connectthe specialtool (2 0) to the right sidewire har- SIMULATOR
ness 2P connector, t2 0 JACKT
4. Reconnectthe negativebatterycable. o?saz- Taaol1A
5. Erasethe DTCmemory lsee page 24-28).
6. Readthe DTC(seopage 24-26!-.
k DIC G5 indicated?
YES NO
Short to ground in the Lont passengc.'33rt boh ton-

sioner; replacetho from p.rlenger's sort beh lsa page
21-3t.
To page24-81
24-80
www.emanualpro.com
Frompage24'80
Checklor a short to ground in the sido wir harness:

RIGHTSIDEWIRE
1. Disconnectthe rightsidewireharness2P connectorfrom
HARNESS
2. Connectthe specialtool {2 O) to the SRS main harness 2P CONNECTOR
2P connector.
3. Erasethe DTCmemorv.
4. Readthe DTC.
b DTC4-5 indicrtad?
YES NO
SRSMAIN HARNESS
2P CONNECTOR
Short to ground in the right side wire harness; replac.
the harne3!.
SRSSIMULATOR
LEADC
07TAz- SZ5011A
and SRSINFLATOR
SIMULATOR \
{2 0 JACK} \
Checktor a short io ground in the SRSmain ha.nessi 07SAZ-TB,O114
\
1. Disconnect the negativebatterycable,and wait for three I
ffi
minotes,
2. Disconnectthe driver's and front passenger'sairbags,
and driver's seat belt tonsionerconnectors(see page 24-
231.
) 3. Disconnectthe SRS main harness18Pconnectorfrom
4. Disconnect the specialtool (2 0) from the SRSmain har-

ness2Pconnector.
5. Checkresistancebetweenthe No. 5 terminal oI the SRS
m a i n h a r n e s s1 8 Pc o n n e c t o ra n d b o d y g r o u n d ,a n d
betweenthe No. 12 terminalof the SRS main harness
18Pconnectorand body ground.Thereshouldbe 1 M0
or more,
b th re3i3tance as specified?
YES NO
Faulty SRSunit replacethe SRSunit {seepace 2a-951.
Short to ground in the SRS main harness;replacethe SRS

main harnoss.
SRSMAIN HANNESS
18PCONNECTOR
www.emanualpro.com
24-81
Troubleshooting
DTC8-6 -'97 model
\
CAUTION: Whonever th ignition switch is ON fll). ol
has ben turned OFF for les3 than thro minutes, be
caretul not to bump the SRS unit; tho airbags could
accidentallydeploy and causedamage or iniurios.
Besidesindicatingan abnormalityin the SRS unit, DTC

8-6 may also indicatethat two problemsequivalentto
DTC1-1 and 2-4, 'l-4 and 2-1,or 1-4and 2-4 occurredat
the sametime. Proceedin the ordershown below.
Chockthe SBS main harnGs:

2. Disconnectthe driver's airbag and front passenger,s
afrDagconnectors{see page 24-23).
3. Disconnectthe SRS main harnesst8p connectorfrom
the sRs unit.
4. Reconnect the batteryposative cable,then reconnectthe
negativecable.
5. Turnthe ignitionswitchON 0t).
18PCONNECTOR
6. Connecta voltmeterand measurevoltagebetweenthe
No. 10 terminalot the SRSmain harnessl8p connector
and ground,and betweenthe No. 14terminaland qround.
Thereshouldbe aDorox.0-0.5V.
Are voltagesas specitied?
YES NO
Shon to power in tho SRSmain harness;reglacethe SRS

main harn63.
Chockthe SRSmein harnels and the cable rel:

Connecta voltmeterand measurevoltagebetweenthe No. 1
t e r m i n a l o f t h e S R S m a i n h a r n e s sl 8 p c o o n e c t o ra n d
ground,and betweenthe No. 13terminaland ground.There
shouldbe approx.0 0.5V.
Are voltagesas specifiod?
YES NO
Faulty SRSunit; replacethe SRSunit {saepago 24-951.
To page 24-83(A)
24-82
www.emanualpro.com
)
Frompage24-82iA)
Checkthe cable reeli

2. Disconnectthe cable reel 2P connectorfrom the SRS
main harness,
3. Turnthe ignitionswitchON lli).
4. Connect a voltmeter and fieasute voltage beNveenthe
No. 'l terminaloI the SRS main harness18Pconnector
a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d
ground.Thereshouldbe approx.0 - 0.5V.
Are voltagcs as specifiod?
YES NO
Short to powor in the cable reel; replace the cable reel

{soooaqa 24-921.
Short to powe. in ths SRS main harn633;replaco tho SRS

main harness.
www.emanualpro.com
24-83
Troubleshooting
DTC9-2-'97 model
\
CAUTION: Whenever the ignition switch is ON flll, or
has been turned OFF tor loss than thrse minute3, bs
careful not to bump the SRS unit; lhe airbags could
accidentallydoploy and causodamage or iniuriss.
Ch6ckthe tuso:
2. Checktor blown No. 23 (10 A) fuse in the !nder-dash
Iuse/relaybox.
(A)To page24-85
Replacethe fuse.Turn the ignitionswitchON {ll},and chck

thatthe fusedoesnt blow.
No. 23 110Al FUSE
FUSE/RELAYBOX
Tho problem has dilappeared. T6t-drive the vohid and

see Troubl6hogting Intermittedt Failur6 on prgc 2il-2g.
Check for shon to ground botween the undor-darh fu36,/

relay box and tho SRSunit.
3. Disconnect the driver'sand front passenger,s
airbagcon-
nectors{seepage 24,23).
5. Checkresistancebetween the No. 3 terminal of the SFS

main harness18Pconnectorand grouncl.
Thereshouldbe 1 M0 or more.
sRs
18PCONNECTOR
FauftySRSunit; replacoth6 SRSunit {3epage 2t-951.
To page 24-85
24-84
www.emanualpro.com
from page 24'84
(B)
Ch6ckfo. short io ground in the SRSmain harnes!:

1. Disconnectthe SRSmain harness2P connectorlrom the
under-dash fuse/relaybox.
main harness18Pconnectorand ground.There should
be 1.0MO or more.
ls the resbtancoas soecitied?
YES NO
Short to ground in the undor-dalh fuse/relay box;

rplacoth under-da3hfuse/relav box.
Short to ground in the SRS main harneas;replacothe SRS

main harneas.
FUSE/RELAY
BOX
(A) From page 24-84

SRSMAIN HARNESS
18P CONI{ECTOR
Chckfor an open in the SRSmain harnes:
the positivecable, and wait tor threeminutes.
3. Disconnect the driver'sand front passenger'sairbagcon-
nectors{see page2il 23).
the sRs unit.
5. Reconnectthe baftery positive cabie, then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 3 terminalof the
SRSmain harness18Pconnectorand oround.
7. Turnthe ignitionswitchON (ll), and measure
SBS MAIN HARNESS

18P COI{l{ECTOR
Poor contrct at the SRS main harnss 18P connector;

checkthe connectoa.
. lf the connsctor is OK, substitute a known-good SRS
unit, and rccheck.
. lf the problom is still present. replaco the SRS main
harness,
To page 24'86 (cont'd)
www.emanualpro.com
24-85
Troubleshooting
DTC9-2-'97 model lcont'dl
Frompage24-85
Checkfor an open in the SRSmain harness:

2. Disconnect the SRSmain harness2p connectorfrom the
under-dashfuse/relaybox.
main harness2P connectorand the No. 3 terminalof the
SRSmain harness18Pconnector.
Thereshouldbe 0-0.5 0.
ls th6 resistanceas soecified?
YES NO
Poor contact at the SRS main harness2p connector;

checktho connector, UNDER.OASH
. lf the connectori3 OK, substituto a known-good undr-
FUSE/RELAY
BOX
dash fuse/relaybox, and recheck.
. lf the problem is still present, roplace the SRS main
natness,
Open in the SRS main harn$s;.eplace the SRS main har-

ness.
SRSMAII{ HARI{ESS
2P CONNECTOR
24-86
www.emanualpro.com
Driver'sAirbag
Replacement
After a collisionin which the airbagswere deployed,the 3. Removethe two Torx bolts from the steering whsel,
airbags,the seat belt tensioners(if so equipped),and and disconnectthe horn connector. Remove the
the SRSunit must be replaced. driver'sairbag,
@ Store a removed airbag with the pad su.-

tacs up, lf th airbag is improperly stored face down.
DRIVER'S
accidental deployment could propal the unit with
enough forc io causgseriouginiury.
CAUTION:
. Always disconnoct the drivor's airbag connector
when the SRSmain harnessis disconnactod.
. Do not disassembleor tamper with ihe airbag.
NOTE:
Do not install used SRSparts from anothervehicle,
When repairing,useonly new SRSparts.
Carefullyinspectthe airbag beforeyou install it. Do
not install an airbag that shows signs of being
droppedor improperlyhandled,suchas dents,cracks
or deformation.
1 . Disconnectthe batterynegativecable,then discon-

nect the positive cable from the battery, and wait at
leastthree minutes.
Remove the access panel from the steering wheel.

then disconnectthe 2P connector between the driv-
er'6 airbag and cable reel.When disconnected.the
airbagconnectoris automaticallyshorted.
ACCESSPANEL
2P CONNECTON
(cont'd)
www.emanualpro.com
24-87
Driver'sAirbag
Replacementlcont'd)
CAUTION: 8. sure to instattthe SRSwiring so that it is 5. C o n n e c tt h e d r i v e r ' sa i r b s g 2 p c o n n e c t o rt o t h e
not plnched or inlerfsring with other parts. c a b l e r e e l 2 P c o n n e c t o r ,t h e n i n s t a l l t h e a c c e s s
panelon the steeringwheel.
4. P l a c et h e n e w d r i v e r ' s a i r b a g i n t o t h e s t e e r i n g
wheel, and secure it with new Torx bolts.
TORXEOLTS
9.8N,m11.0kgl.m,7.2tbf,ftl
Feplace.
2PCONNECTOR
Connectthe battery positive cable.then connectthe

negativecable.
7. After installingthe airbagassembly,confirm proper

systemoperation:
. Turn the ignitionswitch ON llt); the SRS indica-
and then go off.
. Mske sure both horn buttons work.
o Takea test-drive,and make sure the cruisecon-
trol switcheswork.
24-88,
www.emanualpro.com
Airbag
Front Passenger's
Replacement
After a collisionin which the airbagswere deployed,the Removethe three mountingnuts from the bracket.
airbags,the seat belt tensioners(if so equipped),and
the SRSunit must be reolaced. 5. Lift the front passsnger'sairbag out of the dash-
DOaro.
@ store a rsmovod airbag with lhe pad sur-
face up, It the airbag is improporly stor6d face down, NOTE:The airbag lid has pawls on its side which
accidental doploymnl could propsl ths unit with attach it to the dashboard.To remove the airbag,
gnough forco to causeserious iniury. cover the lid and dashboardwith a cloth, and pry
carefullvwith a flat tip screwdriver.
CAUTION:
. Always disconnsqt the front pa3s6ng6r'3airbag con-
noctor when tho SRSmain harnessis disconnocted,
. Do not disassambl6or tamper with tho airbag, FRONTPASSENGER'S
NOTE:
. Do not install us6d SRSparts from anothervehicle.
When repairing,useonly new SRSparts.
. Carefullyinspectthe airbag beforeyou install it. Do
not install an airbag that shows signs of being
droppedor improperlyhandled,suchas dents,cracks
or deformation.
1. Disconnectthe battery negative cable, then discon-

nect the positive cable from the battery. and wait at
leastthree minutes.
Removethe glove box (seesection 20).
Disconnectthe 2P connectorbetweenthe front Das-

senger'sairbag and SRS main harness,When dis-
connected,the airbag connector is automatically
shorted.
FRONT
PASSENGER'S
FRONTPASSENGER'S
AIRBAG
MOUNNNG NUTS
(cont'd)
www.emanualpro.com
24-49
Front Passenger's
Airbag
Replacement(cont'd)
GAUTION: Be sure to installthe SRSwiring so that it is 7. Attachthe airbagconnectorto the connectorhold_
not pinched or interfering with olher parts. er, then reinstallthe glove box.
6. P l a c et h e n e w f r o n t p a s s e n g e r ' sa i r b a g i n t o t h e
d a s h b o a r dT. i g h t e nt h e f r o n t p a s s e n g e r ,as i r b a g
mountrngnuts.
FRONTPASSENGER'S
FRONTPASSENGER'S
FRONTPASSENGER'S
AIRBAGMOUNTINGNUTS
9.8 N.m {1.0kgJ.m,7.2lbf ft)
Replace.
Connectthe b8tterypositivecable,then connectthe

negativecable.
After installingthe airbag.confirm proper sysrem

ooerauon:
Turn the ignition switch ON ( ); the SRS indicator
l i g h t s h o u l d c o m e o n f o r a b o u t s i x s e c o n d sa n d
then go off.
24-90
www.emanualpro.com
CableReel
)
Replacement
@ stors a removed airbag with the pad sur- Makesurethe wheelsare alignedstraightahead.
tace up. lf th airbag is improperly stored face down,
a c c i d e n t a ld 6 p l o y m e n t c o u l d p r o p e l t h e u n i t w i t h Removethe two Torx bolts from the steering wheel,
gnough force to causeserious iniuty. a n d d i s c o n n e ctth e h o r n c o n n e c t o r R
, e m o v et h e
driver'sairbag,
CAUTION:
. Always disconnect the airbag connector whgn the TORXBOLTS
SRS msin harnessis disconnoctod. Use a Torx T30 bit.
. Do not disassembloor tamper with the airbag.
NOTE:Carefullyinspectthe airbag before installingit.

Do not installan airbagthat shows signs of being
droppedor improperlyhandled,suchas dents,cracksor
deformation,
'1.
Disconnectthe batterynegativecable,then discon-
nectthe positivecablefrom the battery, and wait at
leastthree minutes.
Removethe accesspanelfrom the steeringwheel,

then disconnectthe 2P connectorbetweenthe driv-
er's airbagand cablereel.
DRIVER'S
DRIVER'SDASHBOARDLOWERCOVER
5. Removethe driver's dashboard lower cover (and

the knee bolster).
*f (cont'd)
www.emanualpro.com
24-91
GableReel
Replacement(cont'dl
6, Disconnect the connectorsfrom the horn and cruise 8. Removethe columncovers,
control sevresumeswitches.
cRursE
coNtRoL
SET/RESUME
SWITCHCONNECTOR
2P CONNECTOR
COVER
1. Loosenthe steeringwheel bolt, then install a steering Disconnectthe 3P [6P] connector betweenthe main
wheel puller on the steeringwheel and remove it. wire harnessand cable reel sub-harness,and the 2p
connectorbetweenthe cable reel and SRS main har-
Note these items when removing the stee.ingwheel: ness.
. Do not tap on the steering wheel or the steering
columnshaftwhen removingthe steeringwheel,
. lf you threadthe puller bolts into the wheel hub
more than five threads,the boltswill hit the cable
reel and damageit. To preventthis. installa pair
of jam nutsfive threadsup on eachpullerbolt.
STEERINGWHEEL STEERINGWHEELBOLT
39 N.m 14.0kgf.m.29 lbf.ftl
CAALEREELSU8
HARNESS
STEERING 3P l6PlCONNECTOR
[ ]:,98_00modets
10. Remove the cable reelfrom the cotumn,
24-92
www.emanualpro.com
)o NOTE: 1 3 . Installthe steeringcolumncovers.
. Before installing the steering wheel, the front
wheelsshouldbe alignedstraightahead. 1 4 . lf necessary,center the cable reel. {New replace-
. Be sure to installthe harnesswires so that they ment cable reels come centered,lDo this by first
are not pinchedor interfering with other parts. rotating the csble reel clockwise until it stops, Then
. After reassemblv,confirm that the wheels are rotate it counterclockwise(approximatelytwo and a
still turned straightaheadand that the steering half turns) until the arrow mark on the cable reel
wheel spokeangle is correct(roadtest).lf minor labelpointsstraightup.
spokeangleadjustmentis necessary, do so only
by adjustingthe tie-rods,not by removing and
repositioning the steeringwheel,
11. Set the cancel sleeve so that the projectionsare

alignedas shown.
VERIC AL
t PR(NECNONS
)...0
t5. Installthe steeringwheel on to the steeringcolumn

shaft,makingsurethe steeringwheelshaftengages
the cable reel and cancelingsleve.Do not tap on
the steeringwheel or steeringcolumn shaft when
installingthe steeringwheel.
CABLEREEL
I l: 38 - 00 models
't2. Carefullyinstallthe cable reel on the steeringcol-

umn shaft. Then connectthe 3P t6Pl connectorto
the cablereel sub harness,and connectthe 2P con-
nectorto the SRSmain harness.
(cont'd)
www.emanualpro.com
24-93
CableReel
(cont'dl
Replacement
1 6 . T i g h t e nt h e s t e e r i n gw h e e l b o l t t o t h e s p e c i f i e d Reconnectthe driver's airbag 2P connectorto the
torque,and connectthe horn connectorto the steer cable reel 2P connector,and reinstall the access
ing wheel.Then installthe driver'sairbag. panelon the steeringwheel.
TORXBOLTS 1 9 . Reconnect the batterypositivecable,then the nega-

9.8N.m(1.0kgd.m,7.2
lbnftl
Replace. tive cable.
DRIVER'S
20. After installingthe cable reel,confirm proper sys-
tem operation:
. Turn the ignitionswitch ON (ll);the SRS indica-

and then go off.
a Makesure both horn buttonswork.
. Go for a test drive.and makesurethe cruisecon-
trol switcheswork.
STEERING WHEELBOLT
38 N.m (3.9kgl.m,28lbf.ftl
Replace.
1 1 . Attach the cable reel 2P connectorto the connector

holder.Theninstall(thekneebolsterand)thedriver,s
dashboardlower cover.
CABLEREEL
BOLSTER
l'98 - 00 modalsl
DRIVER'SDASHEOARDLOWERCOVER
24-94
www.emanualpro.com
SRSUnit
).0 Replacement
CAUTION: 3. Removethe right sidecoverfrom the SRSunit.
. Before disconnecting any part of the SRS wire har-
nesg,disconnectthe airbag connoctors (and soat beh SRSUNIT
tensioner connectorsl.
. During installation or replacament,do not bump
(impact wrench, hammer etc.) the area near the SRS
unit.
Do not damage the SFS unit terminalg or connsc-
lors.
Do not disassemblethe SRS unit it has no saryice-
able parts,
a Store the SRS unit in a clean,dry area. TORX
a Do not use any SRS unit which has been subiected AOLTS
to water damage or shows signs ot being dropped or Use a Torx
improperly handlgd, such as dents, cracks or defor- T30 bir.
mation.
'1.
Disconnectthe batterynegativecable,then discon-
nectthe positivecablefrom the battery, andwaitat
leastthree minutes.
2. Disconnect the airbagconnectors(andseatbeltten-

sionerconnectors). (Whendisconnected, the airbag
and seat belt tensionerconnectorsare automatical-
COVER
ly shorted.)
Removethe left slde cover from the SRSunit. then
) Driver's Side: d i s c o n n e ctth e S R S m a i n h a r n e s s1 8 Pc o n n e c t o r
. R e m o v e t h e a c c e s sp a n e l f r o m t h e s t e e r i n g from the SRSunit.
w h e e l , t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r
betweenthe driver's airbag and cable reel (see
page 24-231.
Front Passenger'sSide:
. Disconnectthe 2P connectorbetweenthe front
passenger'sairbag and SRS main harness(see
page 24-231.
Soat Beh Tensionor('98 - 00 modelsr:

. Removethe left and right centerpillar lowertrim
sRs
HARNESS
panels(seesection20). 18PCONNECTOR
. Disconnect the seat belt tensioner2P connectors
from the left sidewire harness(driver'sside)and
the right wire harness(front passenger'sside)
(seepage24'231.
TORX
BOLTS
Us a Torx
T30 bir.
stoE
COVER
) o Removethe four Torx boltsfrom the SRSunit.then

oull out the SRSunit from the driver'sside.
(cont'd)
www.emanualpro.com
24-95
SRSUnit
(cont'dl
Replacement
6. l n s t a l lt h e n e w S R S u n i t . l f t h e T o r x b o l t s y o u 9. Reconnectthe driver's aibag 2P connectorto the
r e m o v e di n t h e p r e v i o u ss t e p h a v e r e d t h r e a d s , cable reel 2P connector,then reinstallthe access
replacethe Torx bolts. panelon the steeringwheel.
1 0 . Reconnectthe front passenger'sairbag connector

to the SRSmain harness.
1 ' t . Reconnectthe left side wire harness2P connector

to the driver'sseat belt tensionerand the right side
wire harness 2P connector to the front passenger's
seatbelttensioner('98- 00 models).
12. Reinstallthe centerpillar lowertrim panels{'98- 99

modelsl.
1 3 . Reconnectthe battery positive cable,then the nega-

tive cable.
1 4 . After installing the SRS unit, confirm proper system

operation:Turn the ignitionswitch ON (ll);the SRS
TORXBOLTS indicatorlight shouldcome on for aboutsix seconds
9.8 N.m {1.0 kgf.m,?.2 and then go off,
Use . Torx T30 bh,
SRSUNIT
TORXBOLTS
9.8N.m11.0kgf.m,7.2
lbtft)
Usoa TorxT30bit.
7. Connectthe SRSmain harnessl8P connectorto the

SRSuniu push it into positionuntil it clicks.
8. Install the SRS unit covers (right and left). Make

surethe coverssnaptogetherin the middle.
24-96
www.emanualpro.com
-
)
Disposal
Beforescrappingany airbags{and seat belt tansioners) 6. Cut off the airbag(and seatbelt tensioner)connectors.
(includingthose in a whole vehicleto be scrappedl.the Strip the ends of the airbag (and seat belt tensioner)
airbags(and seat belt tensioners)must be deployed.lf wires. and connectthe deploymenttool alligatorclips
the vehicleis still within the warrantvoeriodthe Honda to the airbag (and seat belt tensioner).Placethe
District ServiceManager must give approval and/or spe- deploymenttool at least thirty feet (10 meters)away
beforeyou deploythe airbags(andseat
cial instructions, from the airbao(and seatbelttensioner),
belttensioners).Only afterthe airbags{andseat beltten-
sioners)havebeendeployed(asthe resultof vehiclecol-
lision,for example),canthey be scrapped. DRIVER'S FRONTPASSENGER'S
lf the airbags (and seat belt tensioners)appear intact AIBBAG AIRBAG
(not deployed),treatthem with extremecaution.
Followthis procedure:
Doployingtho Airbags (and Soat B6li Ten3ione6):

ln-vehicle
lf an SRSvehicleis to be entirelyscrapped,its airbags

(and seat belt tensioners)should be deployedwhile still AI.IIGATOR
in the vehicle.The airbags (and seat belt tensioners) cuPs
lY6llowl
s h o u l d n o t b e c o n s i d e r e da s s a l v a g e a b l ep a r t s a n d
shouldneverbe installedin anothervehicle.
@ confirm that each airbag {and seat belt

tonsiongr) i3 ggcurely mountod; othgrwise, severe per-
sonal iniury could result from d6ploym6nt,
At lcast
thirty feot
) 1. Disconnectthe batterynegativecable,then discon-
110motersl
nectthe oositivecable.
Confirmthat the specialtool is functioningproperly

by following the checkprocedureon the tool label
or on page24-98.
Removethe accesspanel,then disconnectthe 2P

connector betweenthe driver's airbag and the cable
reel(seepage24-23).
Removethe glove box, then disconnectthe 2P con-

nector between the front passenger'sairbag and
SRSmain harness(seepage24-23).
Removethe centerpillar lower trim panel,then dis-

connect the 2P connector betweenthe seat belt ten-
sionerand side wire harness('98- 00 models)(see
page 24-231.
(cont'd)
www.emanualpro.com
24-97
Disposal(cont'dl I
1. Connecta 12 volt batteryto the tool' Deploying tho Airbag: Out-ot.vohicle
. It the green light on the tool comes on, the air- lf an intact airbag has been removedfrom a scrapped
bag ignitercircuitis defectiveand cannotdeploy vehicle,or has beenfound defectiveor damagsdduring
t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l transit.storageor seryice,it should be deployedas fol-
Procedure. lows:
. l f t h e r e d l i g h t o n t h e t o o lc o m e so n ,t h ea i r b a gi s
readyto be deployed.
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h e a i r b a g
should deploy (deploymentis both highly audible
and visible;a loud noise and rapid inflationof the
bag,followedby slow deflation).
. lf the airbagsdeploy and the green light on the

tool comeson, continuewith this procedure.
. lf an airbag doesn't deploy,yet the green light
comes ON, its igniter is defective.Go to Dam-
agedAirbagSpecialProcedure.
. During deployment,the airbag can become hot
enough to burn you, Wait thirty minutes after 'L Confirmthat the specialtool is functioningproperly
deploymentbeforetouchingthe airbag. by followingthe checkprocedureon this pageor on
the tool label.
Disposeof the completeairbag.No part of it can be 2. Positionthe airbagface up, outdoorson flat ground
reused.Placeit in a sturdy plasticbag, and seal it at leastthirty feet (10 m) from any obstaclesor peo-
securety.
CAUTION:
. Wear a faco shield and gloves when handling a
3.
Dte,
Followsteps6, 7, 8. and 9 of the in-vehicledeploy-
ment proceoure.
t
deployedairbag. Dlmaged Airbsg {or Seat Beh Ten3ion6r}Sp6cial
. Wash your hands and rinse them well with Procgdure
water after handling a deployed airbag.
!@ r an airbag {or seat Beh rensioner} cannol
be doployod,it should not be treated as normal scrap; it
should still be considereda potntially explosive device
lhat can causeserious iniury.
1. lf installedin a vehicle.follow the removal proce-

dure on page24-3and 24-87through90.
2. In all cases,makea shortcircuitby twistingtogether
the two airbag inflator wires.
3. Packagethe airbag in exactlythe same packaging
that the new reDlacement Dartcame in.
4. Mark the outside of the box "DAMAGEDAIRBAG
{ o r T E N S I O N E RN) O T D E P L O Y E Ds"o i t d o e s n o t
get confusedwith your parts stock.
5. Contactyour Honda District Service Manager for
how and whereto returnit for disposal.
DeploymentTool: CheckProcedure
l. Connectthe yellow clips to both switch protector

handleson the tool; connectthe tool to a battery.
Pushthe operationswitch:green meansthe tool is
OK: red meansthe tool is faultv.
Disconnectthe bafteryand the yellow clips.
www.emanualpro.com
24-98

Manual Honda 2 Desmontaje

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1 .

7. Removethe one bolt securingthe regulatorvalve

8. Removethe stator shaft and stop shaft.

9. Removethe detentspringfrom the detentarm, then

10. Removethe detentarm and detentarm shaft from

13. Removethe main separatorplate with two dowel

4. Roll up half a sheet of ATF-soaked #600 paper and

1. Removethe valve.and thoroughlyclean it and the

Installthe valve,spring,and cap in the valve body.

C a p sw i t h o n e p r o j e c t e dt i p a n d a h o l l o w e n d a r e Capswith flat ends and a groovearoundthe cap are

TOWARD OUTSID OF VALVE BOOY TOWARDOUTSIOOFVAIVE BODY

3. Removethe ATF pump driven gear shaft Measure

MAIN VALVE AOOY ATF Pumo Drive/DrivenGearThrust (AxiallClearance:

MAIN VALVEBODY CHECKEALL

t*-1 2.3 SHIFTVALVE

2. is the reverseorderof disassembly.

o RegulatorvalvespringA 1 . 8( 0 . 0 7 1 ) 14.7(0.579) 87.8(3.457)

O Lockup shiftvalvespring 0.9(0.035) 7.6 (0.299) 73.1 t2.902), 32.0

MAINSI{AFT lST GEAR

2. Assemblethe mainshaftparts,but do not installthe

29 N.m (3.Okst.m, 22 lbt.frl

THRUST WASHER Hold 2nd gear againstthe 2nd clutch,then measure

GEAR COLLAR 3RD GEAR 2'{D GEAR

NOTE:Apply ATFto all partsduringassembly.

1. For a better fit, squeezethe sealing ring together

Selectand install a new washer,then recheckthe

No. Part Number Thickness

2NO GEAR TRANSn SSTON

3RO CLUTCH ASSEMBLY

1. Removethe countershaftbearing from the trans-

2. Assemblethe countershaftparts using the special

4. Tightenthe locknutto 29 N.m (3.0 kgf.m,22 lbf.ft). NOTE:Takemeasurementsin at leastthree places,

0.10- 0.18mm (0.004- 0.007in)

7. Selectand installa new distancecollar,then recheck.

No. Part Number widrh

8. After selectinga new distancecollar. recheckthe

4. After the parts are assembled, hold countershaft lst

Installnew O-ringson the sub-shaft.

NOTE:Wrap the shaft splineswith tape to prevent

7. After installingthe ball bearingverifythe fottowing:

. The snap ring is seatedin the bearingand hous-

Do not s6t h6re. SPRIlIG RETAINER

Wrap a shop rag aroundthe clutchdrum, and apply

4. Installthe return spring, and spring retainer,then

9, Installthe discspring in the directionshown.

1ST,2ND, 4TH, lST-HOLDCLUTCH:

CLUTCH CLUTCHEI{D PLATE

12. Installthe snap ring.

ServiceLimit 10 22s60- P56 N00 3 . 0m m ( 0 . 1 1 8i n )

SNAPRING 3RDCLUTCHEND PLATES

Mark Part Number Thiclness

1 4 . lf the clearanceis not within the servicelimits,select

Checkthe backlashof both piniongears. PULLER

Removethe 5 x 15 mm roller (4WD)or 5 x 10 mm

R e m o v et h e o i l s e a l f r o m t h e t o r q u e c o n v e r t e r 4. Installthe oil seal in the torque converterhousing

DBIVERilo m.n LO.

SET RING,80 mrn

Measurethe clearancsbetweenthe 80 mm set ring

Installthe differentialassemblyin the torque con- STANDARD:0 - 0.15 mm (0 - 0.006inl

7. Selectand instslla new 80 mm set ring.

Part Numbor Thicknoss

ATTACHMENT 4. After installingthe bearings,verifythe following:

After installingthe bearing,verifythe following: