INTRODUCTION ‘This supplement contains information for the 94 CIVIC COUPE. Refer to following shop manuals for service procedures and data not included in this supplement Description Code No. CIVIC MAINTENANCE, REPAIR and 62SR300A CONSTRUCTION 92 VOL.1 and VOL.2 CIVIC SUPPLEMENT 93, CIVIC SUPPLEMENT 94 62SR300B 628R320 628R321 ‘The first page of each section is marked with a black tab that lines ‘up with one of the thumb index tabs on this page. You can quickly find the first page of each section without looking through a full ta bie of contents. The symbols printed at the top corner of each page. ‘can also be used as a quick reference system. if instructions not followed, Indicates possibilty of personal injury or equipment @ if instructions are not followed. NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note ‘that this manual contains warnings and cautions against some specif- ie service methods which could cause PERSONAL INJURY, damage ‘a vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by HONDA, might be done, or of the possible hazardous consequences of every conceivable way, nor could HONDA investigate all such ways. Anyone using service procedures 6r tools. whether or not recommended by HONDA, must satisfy him- ‘self thoroughly that neither personal safety nor vehicle safety wi be jeopardized. All information contained in this manual is based on the latest product, information available at the time of printing. We reserve the right, to make changes at any time without notice. No part of this publica. tion may be reproduced, stored in retrieval system, of transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables, j- How to Use This Manual ——___ [Special Information, Indicates a strong possibilty of severe personal injury or loss of General Info Special Tools Specifications Maintenance Fuel and Emissions Transaxle Steering = | marked sections are not included in this manual First Edition 1/94 130 pages HONDA MOTOR CO.,LTD. Publication Office Al Rights Reserved Se ElectricalOut! ine of Model Changes irem DESCRIPTION ‘93 civic | 94 civic | 94 civic 3/4 DOOR| [3/4 DOOR, ‘COUPE REFERENCE | ‘SECTION General ‘Added + CIVIC COUPE for KG, KS, KE models ° 13,4 Engine PGM-CARB. Pomel Modifies + Rocker shaft collar for D1521 engine ° ‘Adopted D1522, D187 and D16Y1 engines for KO model + 01887 and 01629 engines for KB mode! Changed + Torque value of mount and bracket bolts and nuts + Recommended engine oil Changed + Wire harness color + Fuel feed pipe, fuel return pipe and fuel vapor pipe materials for 4WD (Except Europe) model ) ‘Adopted +_01522 engine for KO model Changed + Wire harness color + Fuel feed pipe, fuel return pipe and fuel vapor pipe materials for 4WD (Except Europe) modet Out of use + Fuel-sub pump for 4WD model Added + Jot pump for 4WD model ‘Added + 1587 and D16Y1 engines for KO model + 01587 and D1629 engines for KB model Modified + Electronic Control Unit (ECU) + Throttle body for B1GA2 engine Changed + Main wire harness + Main wire harness for B16A2 engine + Fuel pressure for D1582 engine + Throttle body ° ‘Added ” + 01587 engine for KG, KS, KE models + _D16z9 engine for KG model clutch ‘Changed + Torque value of clutch pipe for LHD model + Recommended grease " Manual Transmission ‘Changed + Recommended grease +_Method of shift fork spring pin installingrem DESCRIPTION 93 CIVIC '3/4 DOOR 94 civic 3/4 DOOR| 94 CIVIC ‘couPE [REFERENCE| ‘SECTION Manual Transmission Modified + Transmission mount, right front mountibracket and reat mountibracket, Changed + Torque value of transmission mounting bolts + Torque value of transmission mount bolt for S20 and 21 manual transmissions. + Transmission breather cap for S20 manual transmission + Shift fork for Y21 manual transmission + Superlow shaft, 2-4 select lever and transfer shaft for $22 manual transmission ‘Automatic ‘Transmission| Modified + Hydraulic circuit + Secondary valve body + Reverse idler gear Changed + Drain plug + Throttle pressure and governor pressure + Reverse selector hub on the countershaft Modified + Hydraulic circuit Changed Parking gear Reverse idler gear shaft and holder Oil guide cap of the sub-shaft Secondary valve body Serve body Countershatt Clutch assemblies Abolished + AWD disengagement mechanism | Added + Road test for CIVIC COUPE 14 Rear | Differentiat ‘Changed + Rear differential assembly Driveshatts ‘Changed +_ Rear driveshaft and propeller shaft for 4WD model Steering ‘Added + Rotary-valve-type power steering gearbox for LHD ‘model (POLTUGAL model oniy) v7 Brake Modified + Wire colors between solenoids and ABS control unit Modified + ABS for 4WD mode!Outline of Model Changes Body | Changed + Fastener and spacer for rear window + Limit switch position of sunroof motor unit Ades ; — + Some version emblems + Rear seat access cable Abolished + Shim for sunroof paneliglass height adjustment Added 5 20 + CIVIC COUPE model air Adopted a me Conditioning] + Refrigerant HFC-134a (R-134a) | Electrical | Changed + Wire color of ignition switch + Data link connector + Alternator brushes (Mitsuba type) + Terminal number of shift lock solenoid Modifies + Power supply circuit _ ° | Changed + Ignition system for KO model + Integrated Control Unit for KO and KB models + Seat heater for some KS model Added + Supplemental Restraint System (SRS) type Ill ‘Added + CIVIC COUPE mode! 23 °General Information Chassis and Engine Numbers . 1-2 Identification Number Locations £13 Warning/Caution Label Locations ..... 1-4 Lift and Support Points Lift .. 15 Floor Jack Safety Stands 1-6Chassis and Engine Numbers Vehicle Identification Number 1HGEV11310L300001 | ‘2 | | | | } \] | | lial | Manufacturer, Make and 1} Type of Vehicle — "HG: HONDA OF AMERICA | MFG., INC. | HONDA Passenger car | Line, Body and Engine Type Et: CIVIC Coupe/018z8 £2: CIVIC Coupa/D 1587 Body Type and Transmission Type — || 1: 2-door Coupe/5-speed Manual | 2; 2-do0r Coupe/a-speed Automatic | ||| Vehicle Grade (Series) —— — 2: BASIC (EJ2: KE, KG) 3: LSi (EJ2: KE, KG, KS) | || Si (EJ: KG) Fixed Code — | ‘Auxiiary Number —————— Factory Code — Li: Ohio Factory in U.S.A. (East Liverty) Engine Number | enjne rye ree Se Transmission Number Transmission Type M242: 4-speed Automatic, $20: 5-speed Manual Serial Number 24a: 3000001 ~ $20: 1000001 ~ 1-2Identification Number Locations i | 1-3Warning/Caution Label Locations ‘SERVICE INFORMATION (KS) ‘COOLANT INFORMATION (Except KS) | sarreny caution [csssesiasaets ‘AIR CLEANER, RECOMMENDED ENGINE Olt ‘and FILTER SERVICE SPARK PLUG INFORMATION Sanna ‘TIRE INFORMATION 1-4Lift and Support Points r Lift When heavy rear components such as suspension, fuel tank, spare ti {ational weight in tho luggage area before hoisting, When substantial weight Center of gravity may change and can cause the car to tip forward on the hoist snd hatch are to be removed, place removed from the rear of the car, the NOTE: Since each tire/wheel assembly weighs approximately 14 kg 130 lbs), placing the front wheels in the trunk can assist with the weight distribution, 1. Place the lift blocks as shown, 2. Raise the holst until the tyres are slightly off the ground and rock the car to be sure itis firmly supported. 3, Raise the hoist to full height and inspect lift points for solid support. FRONT SUPPORT POINT. urr Locks REAR SUPPORT POINTLift and Support Points r Floor Jack 1. Set the parking brake and block the wheels that are OTT not being lifted. © Always use safety stands when working on or un- der any vehicle that is supported by only a jack. 2. When lifting the rear of the car, put the gearshift © Nover attempt to use a bumper jack for lifting or lever in reverse (Automatic in [P] position), ‘supporting the car. 3. Raise the car high enough to insert the safety stands. 4, Adjust and place the safety stands as shown on page 1-7 s0 the car will be approximately level, then low- fer the car onto them. Front Conter the jack bracket in tho mide fof the jack itt platform. ACK LIFT PLATFORM Rear - Gente the jack JACK LIFT PLATFORM, bracket in the miele fof the jack Ht platform. 1-6[- Safety Stands FRONT SUPPORT POINT RUBBER ATTACHMENTS, SAFETY STANDS REAR SUPPORT POINT 1-7Special Tools Individual too! lists ate located at the front of each section.Specifications Standards and Service Limits .. Design Specifications Body Specifications . 3-14 . 3-17Standards and Service Limits (— Cylinder Head/Valve Train — Section 6 ee MEASUREMENT STANDARD (NEW) SERVICE UMIT Compression 7250 min pm and wide open thrate Pa lkglem? psi, Nominal 1.300 120, 188) Minimum 95035, 135) EE Maximum variation | 200 (2.0, 28 Cylinder head | Warpage 0.05 (0002) Hight 1587 engine 94.95 - 95.05 (3738-3742) — pane Pe 1629 engine 92.95 9305 (3.659 - 3.663) — Comehatt | End ploy (0.05 0.15 (0.002 - 0.008) 05 (002) Camshattte-holder oil clearance (0.050 -0.089 (0.0020 0.0035) | 0.15 (0.008), Total runout 10.03 (0.001) max. 0.08 0.002) Cam lobe height D187 engine IN 36.087 (1.106) — x 36,196 (1.4251) — 1629 engine IN. Primary | 38.900 (14134) = } Mig ‘38107 (15003) — | | Secondary | 36.195 (7.4250) = _ ex $3e.008 (14968) = Valve | Valve clearance IN | 0.18 0.22 (0.007 - 0.008) = ex | 023-027 10009-0011) | votve stem 0.0. IN | 548-549 (02157-0216 5.45 0.2146) ex | 5.45 5.45 10.2146 0.2180) 5.42 (0.2138) Stem to-guide clearance IN | 0.02-0.05 0.001 - 00021 0.08 0.003) _| x | 0.05 ~ 0.08 0.002 - 0.003) 9.12 0.005) Valve seat Wath TN] 0.86 ~ 1.15 (0.033 — 0.045) 1610.06) EX | 1.25- 135 (0.049 -0.061) 20 (0.08) ‘Stem installed height D1se7 engine IN | 46985 ~47.455 18496 1.8683) | 47-705 (1.8781) ex | 48.965 — 49.435 (19278-19463) | 49.685 (1.9561), D16z9 engine IN 59.165 ~69.695 (2.0931 -2.1116) | 53.885 (2.1215) Ex | 59.165 ~ 53.695 2.0991 - 2.1116) _ | 93.865 2.1216), Valve spring Free feat DiSG7 engine IN | 51.90 2.083)"" = { 51.88 2.063)? = ex | 5528 2.176)" a 55.31 (2.178) — Diszaengine in | $187 (2:202) — eee - © | sa.41 2.300) = Valve guide iB IN | 851-583 (0217 -O216) 355 10218) | ex | 5515.53 0.217 0218) 5.55 (0.210) Installed height 01507 engine IN. | 1595 16.45 (0.628 - 0.642) —— ex | 16.95 — 1645 (0628 —0.648) = { D167 engine IN | 17:85 ~ 18.35 (0.703 0.722) —= EX | 18.65 19.15 0.738 0.754) Rocker arm ‘Aemto-shat clearance TN | 0.017 -0.050.0.0007 - 0.0020) | 0.08 (0.003) x | o.018-0.058:0.0007 0.0021) __| 0.08 (0.003) "3: NIHON HATSUJO manufactured valve spring *2; CHUO HATSUJO manufactured valve spring, 3-2(— Engine Block — Section 7 Unit of lath: en fin MEASUREMENT STANDARD WeWn senvce ur ‘Cylinder block | Warpage of deck surface ‘0.07 (0.003) max. 0.10 (0.008) | Bore sersner Soot a a0 eess—zessse | Sao anes sere ana Sos oie | Reborn i = Seine Fin Skit. af DIB sngine TBO mm Taaen Tawa aD ToRRH | TT ABET {er B16 ong .0 mm | (353 nV nooo at | craararee 2010-0040 0004-20016 | a0s 02 Sroovewa tna) Top S2a0.2ap\aoe ones) | 426|00001 Setond Vere vsswasse coc” | 138 bast sf [2is_Zee roar | Zeslorn Fianna fing taroove deannca Yop .090- 0.080 cotz—aoes) P0310. Boon Soso-oossier-ocen | atsloom Ring ond one Top 07-0.30(0006 ara oso os2e Eons vez engine | 820-020 nee aes) so ons Biser engine | 020-040 oeee test 0 fons ton Fn 3p. tasnt-Teooo 7076-700] — Pinte ston clearance Soro oor wer coo | —— Connecting] Pinteodieroronce = o040 6008 cots} — a Seals bor dente teee-teseoe on” | —— ingeendberedomst Nomina Ditzeengine | seta = Bisov ening | a 0(1091 — End la inated on rata O83 0.008-00%2 daowor8 Graniahat Wain journal dometer Dia oie | e978 8600012644766) | —— isovensne | eesve-sevootiqiey , 104 1d80x9 :Aju0 18 ‘saworsno ay) Aq yenueW 6 ssumo ay) 02 BUIPI098 AY {]epows SX 10} 1d80xa :Auo sesmyoeynueUs Aq PepUBWWOd “epOU SH 404 ce nue AG PepuOWWOIDA si [EALOIU! AIYRUOW "|oPOW S104 5, Hd AUOP 99 PINOYS (|8AB| 1UB}O0D PUB JL ‘HO auIbUB) a120 Aep OL AQ + ‘SuoNDaUUGD pus Sesoy “UolToun; BuuBaTS Jamo "31004 pue Xx0q 1888 "spua por-an ‘woRsuny Buudaig Biueusdwos wojsuadsns Dieigs Teay sateRUoD SNAPE ‘vonipudo pue Waishs 1sneyRa ‘S0uy) Pue SOS04 OG Bing OE one rad0 oye1q BUDHeg ‘Suu Ue S70p\ [m "Siunp 99 28 ‘UB SOsIp 3639 1UO14 a a 1 1 a u Tin 000°R Ane Boeider 1eFOu GH IO u a | u| [8 u sBnid eds uy a! ul u ue|009 euiBUZ 6 1 i T 1 i SoRDSUUOS pu FeSO Wishes BuyOeD Tl ct] dund 118m, = To 7 Ba | | , ; , ToRRoEUOS OY BaBRTE MOG TOTRUABIY) ‘svoipuoo pu uoteue eg T 7 7 7 i BOUERAR NA te ’ w we wos Te > ‘SRUOU ZI 50 (SAIL 00'S) WA O0'OI Alena Boejdoy > {10 pue yo auibua + 96 | v8 | 2 | 00 | ay | of | v2 ao 96 | ve | zz | oo | ab | se | vz | zt ‘smu QOO'L ‘sewoo Jeneyoiym ‘syauoW Jo JaquNU yeWA Oye [002 [oat arom tose fooc arta fae ae WHOOT'E X | 10 (Sow 40} wY OOO'L x parsy eaLoIU! aut e SOMES 4-4Saiuow @ 70 ay 900°9) WH OOO"! AAR] 1 Tass Gases Mea | + ae DE suUOW g 10 (8944 00'S) WA O00'OL A10Ng 1 ‘iedyeo pue soup oyeq wo | a 306av Spuow 21 10 ay 90071) WH O00'02 Mena | w wawae wueepiy | +a ee ‘suiuow ZL 40 (salu Q00'Z LI WH OOO'OZ Mena | uojssjuisuest | ye « . ~sipuous 9 10 (Sau 900"E) Wt 00'S Aleng | _y : yauy Wo pue yo eulbug | yee e av] yeareauy vvone1edo wot] soueuauieyy ‘wompuog ‘Aves5620u 4! soejdex 10 wedas ‘dn wy "snipe “uealo “Uoaadsul veyy “W9edsui=| soedeN=y sjeyayeU 21201109 1840 40 38S peos Bulsn seaie Ur Bu! ‘Sleasequ) aquEUaDLIEW eUdoLdde AYy 10} mojaq WeYO AUp sroyest @ Bumoy 24 ‘speod Appnus so/pue yBno: ul Bug :3 ‘oyIeeM pIo9 o19A95 UL Bu) ‘suomipuoa Aisnp 1 Buy Buraup souersip uoys poreedoy *y :apnjou! suonipuao Buiwyp axanag 0} sayy ‘suoIpuoa Bunup a1on9s Jepun pesn AjjeuoU S129 Uo Apuanbay} e10W pas!A1es oq snW swWeN) BUIMOHIO} GUL, IpUu0D Buy 0 janag BaInIag Kiane Taye Wade ‘18 BaypUey OOP "SOUS Jo SSaUTTETD —] 15 “2SION} BAND SOL (SuoneIedo pieoquseD yom Apoq pue seGewiep wuieg ‘SuRUOU ZT 30 (SER O00") WA GODOT AveAe 1o8dsuI ‘auou! 21 70 (89) 000°9) WH QO0'OL MAB YoedsUI ‘uesq 1ybypeNY pue UONeredO Sy (Gieds Bupniaul amnsseid pus 1eom "WORIBUGD FaIKL Uonipuos Aeneg 1 suWou gi 10 1 wt OODTOL Mans woadsUy so | 96 | a gy | ve | vz | zt gor | 96 | ba | zz | 09 | ee | oe | ve | ai oat | oat | ont | ozt | oot | 08 | 09 | o | oz 51976) PIF {Si seuoo JOnayoI\yas “sytuoW Jo JequinU ew Jaye 40 {Says 0) wy Q90"L X Parsi JeRIeIU) ay) 18 Bo!NI0g 45[ Fuel and Emissions System Description Electrical Connections .. Troubleshooting Self-diagnostic Procedures ... Fuel Supply System Fuel Injectors = D1587 engine has been added for KG, KS, KE model. Outline of Model Changes The Coupe model has been added, and changed following: 101628 engine has been added for KG model JSystem Description Electrical Connections IGNITION SWITCH “ey | a eae of “ ein ® iF 9 eiat je rE ieee ° i; . cI a | ety ||| | {festss BEroes covt senson| Laat eet | peeeed [enews + once ENGINE LIGHT }ai0 vsP | WARW ATS } szawer sme cows Boker BL ‘ess }—~ Te ne sen eaves [Tace a1 | over ri common cron 6th | for rom ase ager) [ar soot Soumar”| yess, Sines 7 ASSIS | (arr) ' | — | Sehocur as ae | suier posimion, | Consoue swircn 11-2 @ BATTERY (80 A)* O16 60 ae @ STOP. HORN (20 A)* @ cou (15 alr @ ACG (5) (15 A) © BACK-UP LIGHTS (10 A) © REAR DEFROSTER RELAY HEATER MOTOR RELAY COOLING FAN MOTOR RELAY (7.5 A) @ STARTER SIGNAL (7.5 A) © OPTION (50 A)* © INTERIOR LIGHT (7.5 A) *: UNDER-HOOD FUSE/RELAY BOX ‘SHIFT POSITION IMbICATORae 020 veo2: 22 662 Sewson v7 Pe ‘unomme: ANGLE: Sensor Diem Fee posvim [| viBaa ~ wer aouesoo 3 -} 02 aKew ‘Ta SENSOR _ meson we purge common SoLeNow vawve — ae HTONTE oo i407 QB + ‘Acar 09 $ ‘ALTERNATOR IkS mode! ent SO rN EGBG coceec cece ooo eloceccccclseeeae|ooe oo TERMINAL LOCATIONTroubleshooting [- Self-diagnostic Procedures | BASE MANUALS OR PAGE eranenoss, | SYSTEM INDICATED eee ee came” o peu — 3 3 pa OXYGEN SENSOR _ 3 3 [3 Tnurore ansoun aa 3 3 3 | waniro.o aasowure pressure mar sensom) | ——2 | 3 4 (CRANK ANGLE (CRANK SENSOR) 1 1 5 coo ant TewPERATURE (Tw SENSORI 7 1 7 [THROTTLE Ange > eal 8 TDC POSITION (TDC SENSOR) - 1 1 [_ 8 | No. 1 CYLINDER POSITION (CYL SENSOR) | 1 1 10 INTAKE AIR TEMPERATURE (TA SENSOR) (ama 1 | i 3 13 ATMOSPHERIC PRESSURE (PA SENSOR) x SS mecet _|texopt KS mods ae aerate ain conTROL feACv) i 1 15 1GwmTiow OUTPUT siGNAL sa z “T a 7 11-5 (exoot KS model 7 ventete Sree sensor a a 19 [ AT LOCK-UP ConTHOL SOLENOID VALVE AB 2p 7 SPOOL SOLENOID VALVE 1 x a2 | vatve TING o1 pReSsURE SwrrcH x een [OXYGEN SENSOR HEATER aT 1 a3 | uet suer.y svsrew 3 3 1: Reter to Code No, 6258300 2: Refer to Code No. 62SR320 8: Refer to Code No. 62SR321 X: Not indicated ‘© I codes other than those listed above are indicated, verify the code. If the code indicated is not listed above, replace the ECU. ‘© Tho Check Engine Light may come on, indicating a system problem when, in fact, there is a poor or intermittent elec- trical connection. First, check the electrical connections, clean or repair connections if necessary. 11-4Fuel Supply System Ez [- Troubleshooting Flowchart — Fuel Injectors (D15B7 engine for KS model) 5 “GES. THE]. Set isanosis Check Engine Light indicates CODE 16: A problem in the Fuel Injector crcut. ‘The Fuel Injectors are a solenoid-actuated constant-stroke pintle type consisting of a solenoid, plunger needle valve and housing. When current is applied to the golenoid coll, the valve lifts up and pressurized fuel is injected. Because the nee- dle valve lift and the fuel pressure are constant, the injection quantity is determined by the length of time that the valve is open (i.e., the duration the current is supplied to the solenoid coill. The Fuel Injector is sealed by an O-ring and seal fing at the top and bottom. These seals also reduce operating noise. FUEL PIPE FILTER PLUNGER HOUSING custion. FUEL PPE RING — INSULATOR FUEL ‘ee INTAKE INJECTOR: ia ‘MANIFOLD = chock Engine Ligh has be ‘reported on — Wah sorvce check connector imped, CODE 16 sindeated Do the EGU Reset Procedure oo Stan the engine and allow i t0 NOTE: engine wi no str, may a ie “O-seconds of cranking to 36 the Gade Check for poor connect ee loose wires between fuel injectors ‘and ECU: | Sr Is the Check Engine Light on NO. a baad at {test drive may be YES ‘Start the engine and isten at each fue injector fora clicking sound ‘Turn the ignition switeh OFF. Disconnoct the 2P connector from the fuel injector that does not liek (cont'd (To page 11-6) 11-5Fuel Supply System -- Troubleshooting Flowchart — Fuel Injectors (D15B7 engine for KS model) (cont'd) 5 (rom poge 11-5) A ‘NO | lace the fuel injectorlinjectors: } << ttnen 10-13 a7 >MO_| aac the tinea ; Yes _ ‘Turn the ignition switch ON. — Measure voltage between YELI BLK (-+1 termina in the 2° con rector and body ground FUEL INJECTOR, ‘pen in the YELIBLK wire between the fue injector and the GNF main relay. Tur the ignition switch OFF. Reconnect the 2P connector to the fuel Injector Connect the test harness between the ECU and connectors, “Turn the ignition switch ON. I Measure voltage between A23 a3 (=F terminal and following (sean uncer terminal No. t fuel injector: far chfAs te) agi AT pp terminal bssasosoota] 55550800 [OBSERD] S00500G0SOO ela lea 1090000000000] 00900000 09000000000 +o, 3 ual ject: t AS (+) terminal. Az ith + No, 4 fuel injector: AD (+) torminal —_. \ no. ir open in the wire between | Is there battery voltage? > :CUIA1, AS, AB or A2) and Yes — =) — a Substitute @ known-good ECU and recheck. If symptomiindiew ton goes away. replace the origi nal ECU. 11-6Automatic Transmission Road Test ... Outline of Model Chanes + _The road tests have been added for civic coupe.Road Test NOTE: Warm up the engine to operating temperature. 1. Apply parking brake and block the wheels. Start the engine, then move the selector lever to [Bi] position while depressing the brake pedal. Depress the accelerator pedal, and release it suddenly. Engine should not stall 2. Repeat same test in [Ba] position 3. Shift the selector lever to [Di] position and check that the shift points occur at approximate speeds shown. Also check for abnormal noise and clutch slippage. 1587: (Ds) or [Da] Position © upshit Throttle Opening Unit of peed [tat = ana Bnd = 5rd ard = ath Full-losed throttle [Km is 19 36 — 40 48-69 mph o-12 22-25 30 = 39 3/16 throttle Km/h 21-25 | 49-53 66 — 72 mph 13 ~ 16 T 30 — 33 41 — 45 | 6/16 throttie Kmih | 26 — 34 60-72 | 83-95 mph 16 — 21 37-47 52 —59 Full-opened throttle Kmih 49 — 54 91-99 143 — 153 mph [31 — 34 oy — 62 ao os | # Downshit Throtte Opening ath = oa Grd ~ 2nd Bnd = tet Ful-closed throttle a es et [_ | [ie Fullopened throne Ket 120 — 131 39-90 | 40 aa mph 75 — 81 52 — 56 25-27 | © Lock up Throttle Opening Unit of speed | [Bs] Position _ —— iockup ON | Lockup OFF | Lockup ON | Leckup OFF Fall-closea trove [kam 24-27 | 28-26 | 97-103 | 92-98 mph 15-17 | _14~16 | 60-68 | s7—61 e716 tows kmtr | 107-113 | 8793 | 107-113 | 92 — 98 mph 66 — 70 84-58 | 66-70 57 — 61 Fal-opened tote Kt] 441 — 147 | 196 — 142 | 132 — 136 | 126 — 192 | mph ce-91 | e5-68 | e2—s6 | 7-02 14-2Fro 1629: [Di] or [D3] Posi © Upsnite Throttle Opening Unit of speed | __Tet = 2nd 2nd = 3rd 3rd — 4th Full-closed throttle Kmvh 15 — 19 36 —40 49 —53 mph 9-12 22 — 25 30 — 33 3/16 throttle Kmih 22 — 26 52 — 56 67-73 mph 14-16 32-35 42-45 6/16 throttle ~ Km/h 27 — 35 65 — 77 86 — 98 mph 17 22 40 48 53-61 Furopaned throne Keni 35 60 104112 is 162 mph 3497 65-70 94 — 101 @ Downshitt Throttle Opening Unit of speod | ath ~ Sed 3rd = and 2nd = tet Full-closed throttle Kenih = _29— 33 9-13 mph — 18-21 6-8 Fulropened throto Kit 130 = 141 93 — 100 38 43 moh a1 87 58 — 62 24 — 27 © Lookup Throttle Opening Unit of speed [Bs] Position {Bs} Position _ Lockup ON | Lockup OFF | lockup ON | Lock-up OFF Fullclosed throttle Knih 24-27 | 23-26 | 97-103 | 9208 | ___mph 15 — 17 14 — 16 60-64 | 57-61 [6116 throtte kmh wo7—113 | 87-93 | 107-113 | 92-08 moh | 66-70 | s4—se | 66-70 | 5761 Fullopened trotte Kenih ist — 167 | 145-151 | 192-138 | 127— 198 mph 94-98 | 90-98 | e2-86 | 79-83 14-3Steering Special Tools .. 217-2 Component Location Index System Description Fluid Flow Diagram . Steering Pump .... Steering Gearbox . Troubleshooting General Troubleshooting Noise and Vibration Fluid Leaks Inspection and Adjustment Steering Operation . Power Assist Check ... Steering Linkage and Gearbox Rack Guide Adjustment 17-4 17-5 17-7 17-13 17-15 .. 17-17 17-17 17-18 17-19 Fluid Replacement ... 17-19 Fluid Leakage Inspection . 17-20 Power Steering Hoses, Pipes Replacement .... 17-21 Steering Gearbox Disassembly . .- 17-22 Reassembly .. c Outline of Model Changes 37 The rotary-velve-type power steering gearbox for LHD type has been added (POLTUGAL model only).Special Tools rettta. | _Toothamter Desspdon |. ow | Pane Retereee ‘07NAG - SR30200 Rack Remover loa 17-24, 32 Grroacoreree | Leeinuiench, 40mm 1 | ie ® @ @ | — — 8 uJ : ‘w ® ® o ® cS Oe ® 17-2Component Location Index LHD type, Power Steering: NoTE: Before removing the gearbox, remove the ignition key to keep the steering shaft from turning, After installing the gearbox, check the wheel alignment and adjust if necessary. ‘STEERING GEAREOX Rack Guide Adjustment, page 17-18 Diesen. page 122 ‘STEERING COLUMN, { SS) STEERING WHEEL POWER STEERING PUMP VALVE BODY UNIT Overhaul, page 17-25 ‘TIE-ROD END BALL JOINT 17-3System Description (- Fluid Flow Diagram The system is a compact rotary-valve-type power steering, connected to the steering gearbox. The fluid pressure is pro- vvided by 8 vane-type pump which is driven by the engine crank pulley. The amount of fluid and pressure is regulated by the flow contcol valve built into the pump. The fluid pressure from the pump is delivered to the valve unit around the pin. ion of the steering gearbox. The valve inside the valve unit controls the hydraulic pressure and changes the direction of, the flow. The fluid then flows to the power cylinder, where rack thrust is generated. Fluid returning from the power cylin: der flows beck to the reservoir, where the fluid is “filtered” and supplied to the pump again. VALVE UNIT vate a \ “ | pl & FLOW CONTROL VALVE STEERING GEARBOX POWER CYLINDER 17-4[- Steering Pump Construction ‘The pump is 9 vane-type incorporating a flow control valve (with an integrated relief valvel and is driven by @ V-belt from the crank pulley. The pump features 10 vanes. Each vane performs two intake/discharge operations for every rotation of the rotor. This means that the hydraulic fluid pressure pulse becomes extremely small during discharge. INLET PORT ROTOR ‘CAM RING FLOW CONTROL VALVE rive SHarT VANE Operation ‘The belt-driven pulley rotates the rotor through the drive shaft. As the rotor rotates, the hydraulic pressure is applied to the vane chamber of the rotor and the vanes will rotate while being pushed onto the inner circumference of the cam ring. ‘The inner circumference of the cam ring has an extended portion with respect to the center of the shaft, so the rollers ‘move downward in the axial direction as the carrier rotates. As a result of this roller movement, the internal volume of the vane chamber will change, resulting in fluid intake and discharge, START OF FLUID INTAKE: FLUID INTAKE: FLUID MOVEMENT: FLUID DISCHARGE: DISCHARGE PORT The vanes are pushed onto The volume ofthe vane cham: The sucked-in fluid moves As the vanes return to the the inner circumference of the ber increases so that fluid Is toward the discharge port. thei original position on the eam ring sucked in inner side, the volume of the vane chamber decreases 30 the fluid is discharged trom the discharge port (cont'd) 17-5System Description [- Steering Pump (cont?) $$$ Flow Control FLow CURVE “The flow contro! valve in the pump performs the follow. ing steps @ through @ to contral the flow of fluid, i. to increase the discharge volume when engine speed is low and to decrease it when the engine speed increases, ‘The assistance thrust of the steering gearbox changes in compliance with the change in the discharge volume. FLOW OF FLUID ® When the engine starts, fluid discharged from the discharge port starts to run through the metering ‘orifice in the pump. The discharge volume increases as the engine speed increases. PUMP PM. @® As the flow has already boon regulated by the metering orifice when the engine speed is at or near the idle speed, a constant and regulated amount of fluid is discharged until the engine speed reaches the middle speed range. As the engine speed increases, the pressure difference between the ends of the metering orifice increases. A pressure differ- tence is created between the top and bottom ends of the flow contro! valve, to0, pushing the flow control valve to open the by-pass passage. This allows the excess fluid to return to the inlet port preventing merenae pressure at the discharge port from rising oxces- ORIFICE Bal FF now conrron VALVE ‘As the engine speed continues to increase, the flow control valve is pushed back further. When the (PD ‘engine speed reaches a given speed, the return pas. ‘sage outside the metering orifice is connected to the inlet port, ond the opening to the inlet port © pe widens in proportion to the increase in engine i spo0d. This makes port ofthe fluid ragulated by the METERING DISCHARGE PORT @ metering orifice return to the inlet port of the pump; oer there by discharged fluid from the pump is decreased slowly by this amount, ® The orifice in the return passage regulates and r maintains the flow of fluid discharged from the t c burp aa glven level ui te engine speed reach DG pevonn pabzioe 8 the high speed range. Pressure Relief Pressure outside of the metering orifice is directed to the bottom of the flow control valve. When the pressure builds up, the relief valve in the flow control valve opens to relieve the pressure. As the flow control valve is pushed back by the pressure difference this time, the flow of fluid in the bypass passage increases, controlling the pressure outside the metering orifice. The above operations are repeated to provide constant discharge pressure from the pump. ‘DAMPING ORIFICE (Decreases excessive vibration in the valve.) 17-6S) “The rack-and-pinion type steering gearbox has a valve unit incorporated with the pinion to control the steering fluid pres: sure. Steering fluid from the pump is regulated by a rotary vaive in the valve unit and is sent through the cylinder pipe to the power cylinder, where hydraulic pressure is applied. The steering fluid in the other side of the power cylinder returns ‘through the cylinder pipe and valve unit to the reservoir. [- Steering Gearbox VALVE UNIT CYLINDER PIPE POWER CYLINDER Valve Unit Inside the vaive unit is the valve, which is coaxial with the pinion shaft, and controls the steering fluid pressure. The valve housing is connected with the fluid pipe from the pump, return pipe to the pump, and the two cylinder pipes from the respective power cylinder. The pinion shaft is double - structured with the input shaft connected to the pinion gear, both of which are interconnected with the torsion bar, ‘The pin inserted in the valve and the pinion shaft groove engage; this allows the pinion shaft to rotate together with the valve. Because of this construction, the difference in angle in the circumferential direction between the input shaft and the valve becomes larger according to the torsional strength of the pinion or steering resistance. However, maximum torsion ‘between the shafts is regulated by the engaged splines of the shafts at the pin engagement section to hold the torsion bar within the set value This allows the steering system to function as an ordinary rack-and-pinion type steering ifthe steering fluid is not pressur- ied because of a faulty pump. npur SHAFT Hh VALVE HOUSING VALVE Se Difference in angle between the input shaft and pinion shaft “input SHAFT

Put over the pipe until the hose stops ot the stopper 25-55 mm (001-022 in) RETURN PIPE 201m (29 kg-m, 21 Ib) FEED PIPE [38 Neem (3.8 kg-m, 27 If) RETURN HOSE 17-21Steering Gearbox rp Disassembly Stooring Rack Disassembly Nore: © LHD type is shown, © Before disassembling the gearbox, wash it off with solvent and a brush, ‘© Do not dip seals and O-rings in solvent. 1. Remove the steering gearbox. 2. Remove the air hose and clips. 3. Remove the tie-rod end and locknut. AIR HOSE STEERING GEARBOX cur 4. Remove the boot bands and tube clamps. Pull the boots away from the ends of the gearbox. ‘Tus cAMP 007 BAND 5. Hold the steering rack with a wrench and unscrew the rack end with a wrench, Replace. 6. Loosen the locknut and remove the rack guide 7. Remove the spring and rack guide from the gear housing RACK GUIDE SCREW ‘SPRING Lockiiur RACK GUIDE 17-22@ 8, Remove the cylinder pipe A and B from the gear- box. 98. Drain the fluid from the cylinder fitings by moving the steering rack back and forth. CYLINDER PIPE 8 CYLINDER PIPE A 10. Remove the two flange bolts, then remove the valve body unit from the gearbox. (See page 17-25 for valve body unit disassembly.) VALVE oy UNIT FLANGE BOLT o-nING Replace. sHIMS 11. Drill a3 mm (0.12 in) diameter hole approximately 2.5 ~ 3.5 mm (0.10 - 0.14 in} in depth in the staked point on the cylinder. NOTE: Do not allow metal shavings to enter the cylinder housing, STAKED POINT Depth: 25 -3.0 mm (0.100.120) CYLINDER END 12. Install a puller yoke to the steering gearbox. Clamp the puller yoke in a vise with soft jaws as shown, then loosen and remove the cylinder end. PULLER YOKE: Commercially Avai Snap-On T/N C31 orce TIN 7372 (cont'd) 17-23