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Civic Service Manual PDF
Civic Service Manual PDF
Safety
Your safety,and the satetyof others,is very important.To help
you makeinformeddecisions,we have providedsafety
messages,and othersafetyinformationthroughoutthis manual.
Of course,it is not practicalor possibleto warn you aboutall the
hazardsassociated with servicingthis vehicle.You must use
your own good judgment.
Emissions
You will find impoftantsafetyinformationin a varietyof forms
including:
. SatetyLabels- on the vehicle.
. Satetv Messages preceded by a salety alert symbol A and
one of threesignalwords, DANGEF,WARNING,or CAUTION.
Thesesignalwords mean:
tmEnEErily;,:H,ll i":5*i5"?;rsERIousLYHuBrir
E$EEEE ys,: HURT
ir
f#,ff ,:hl:3,:JjERrousLY
tlGtltT]llilll YoucAN b€ HUBTif vou don'tfollow
. lnstructions
- howto service
thisvehiclecorrectlv
andsafelv.
*Restraints
GeneralInformation
Ghassisand PaintCodes
- 2 0 0 2M o d e l . . . . . . . . . . . . . 1. .-.2.
Chassisand PaintCodes
- 2 0 0 3M o d e l . . . . . . . . . . . . .1. .-.3.
ldentification
NumberLocations ........1-4
Warning/Caution
LabelLocations......1-5
Under-hoodEmission
ControlLabel ........... .... 1-7
)
L i f ta n dS u p p o r P
t o i n t s. . . . . . . . . , . . . . , . . .1. .-.8. , .
Towing ......1-9
PaftsMarkingLocations......................
1-10
GeneralInformation
Chassisand PaintCodes- 2OO2
Model
VehicleldentfficationNumber EngineNumber
[[tttrtF c d e f g h a
1-2
Chassisand PaintCodes- 2003Model
VehicleldentificationNumber EngineNumber
[--t-rlF c d e fg h a
I
VehicleldentificationNumber
and FederalMotor Vehicle
Saletv Standard Certif ication/
Color Label.
)_.
1-3
GeneralInformation
ldentificationNumber Locations (
0 I
EngineNumber
t)
1-4
, I warning/cautionLabelLocations
O
NOTE:FRONTPASSENGER AIRBAG WARNING TAG Steering Wheel:
(CHILD
SEAT)is installedon the glovebox on the U.S.
mooet. DRIVERMODULE
DANGER
Passenger's
Compartment: CABLEREEL
CAUTION
SRSINFORMATION
U.Sm
. odel
SRS WARNING
INFORMATION
FRONTPASSENGER
MODULE DANGER
MONITOR
NOTICE
,/
FRONT
SEATBELT
TENSIONER
CAUTION
SIDEMODULE SIDEAIRBAG CAUTION
DANGER Located on driver's
ano passen9ers
doorjamb(not shown)
..r'
(cont'd)
1-5
GeneralInformation
Warning/CautionLabelLocations(cont'dl
SERVICEINFORMATIONLABEL
(Undor-hood Emission Control
SRSWARNING Informationlab€l)and ENGINE
LABEL COOLANTINFORMATION
TIREINFORMATION
RADIATOR
CAPCAUTION
BATTERY
CAUTION c
1-6
Under-hoodEmissionControlLabel
EmissionGroupldentification Families:
Engineand Evaporative
Example:2002model EngineFamily:
ModelYear
2:2002
. P AT I E R2 B I N5
T H I SV E H I C LCEO N F O R MTSO U . S E 3: 2003
AND NLEV LEV REGULATIONS APPLICABLE TO 2002 ManulacturerSubcode
MODELYEARNEWPASSENGER CARSAND H N X :H O N D A
CALIFORNIA REGULATIONS APPLICABLE TO 2OO2 c. FamilyType
MODELYEARNEWLEVIi LEVPASSENGER CARS. V: LDV
d. Displacement
Example:2003model e. SequenceCharacters
V B P2: 0 0 2
X K C 2: 0 0 3
Evaporative Family:
1-7
GeneralInformation
Lift and Support Points
NOTE:If you are going to remove heavycomponents FloorJack
such as suspensionor the fuel tank from the rear of the
vehicle,first supportthe front ofthe vehiclewith tall 1. Set the parkingbrake.
safetystands.When substantialweightis removed
from the rear of the vehicle,the centerof gravity can 2. Blockthe wheels that are not being lifted.
changeand causethe vehicleto tip forward on the hoist.
3. When liftingthe rear of the vehicle.put the
FrameHoist gearshiftIever in reverse.
1. Positionthe hoist lift blocks(A),or safetystands, 4. Positionthe floor jack underthe front jacking
under the vehicle'sfront support points (B)and rear bracket(A) or rearjackingbracket(B),centerthe
support points (C). jacking bracketin the jack lift ptatform(C),and jack
up the vehiclehigh enoughto fit the safetystands
u n d e ri t .
J t
1- 8
Towing
lf the vehicleneedsto be towed, call a professional Wheel Lift Equipment The tow truck usestwo
towing service.Nevertow the vehiclebehind another pivoting arms that go underthe tires (front or rear)and
vehiclewith just a rope or chain.lt is very dangerous. lifts them off the ground.The other two wheels remain
on the ground.This is an acceptableway of towing the
EmergencyTowing vehicle.
T h e r ea r et h r e ep o p u l a rm e t h o d so f t o w i n g a v e h i c l e .
Sling-typeEquipment The tow truck uses metal
Flat-bedEquipment The operatorloadsthe vehicle c a b l e sw i t h h o o k so n t h e e n d s .T h e s eh o o k sg o a r o u n d
on the backof a truck.This is the bestway of parts of the frame or suspensionand the cableslift that
transportingthe vehicle. e n d o f t h e v e h i c l eo f f t h e g r o u n d .T h e v e h i c l e ' s
suspensioa n n d b o d y c a n b e s e r i o u s l yd a m a g e di f t h i s
To accommodateflat-bedequipment.the vehicleis method of towing is attemPted.
equippedwith towing hooks(A)and tie down hooks{B).
lf the vehiclecannot be transportedby flat-bed,it
The towing hook can be usedwith a winch to pull the should be towed with the front wheels off the ground lf
vehicleonto the truck, and the tie down hooks slotscan due to damage,the vehiclemust be towed with the
be used to securethe vehicleto truck. front wheels on the ground, do the following:
. Releasethe parkingbrake.
. s h i f t t h e t r a n s m i s s i o inn N e u t r a l .
. l m p r o p e rt o w i n g p r e p a r a t i ow
n i l l d a m a g et h e
transmission.Follow the above procedureexactly.lf
you cannot shift the transmission,the vehicle must
be transDortedon a flat-bed.
. Trying to lift or tow the vehicle by the bumperswill
c a u s es e r i o u sd a m a g e T , h e b u m p e r sa r e n o t
designedto supportthe vehicle'sweight.
1-9
GeneralInformation
PartsMarking
To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentificationnumber (VlN).Original
partshave self-adhesivelabels.Replacementbody parts have genericself-adhesivelabels.The originalengrneor
transmissionVIN plate is transferredlo a replacementengine or transmissionand attachedwith break-offbolts.
NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.
r a
1-10
ra
Specifications
L
Standardsand ServiceLimits
Enqine
ne Electrical
I
Item Measurement Oualification (
Standard or New Service Limit
lgnitioncoil Rated voltage 12V
F i r i n go r d e r 1 3-4 2
Sparkplug Type N G K t: Z F B 6 K 1 1
DENSO: SKJ20DR-M11
Gap 1 . 0 1 . 1 m m ( 0 . 0 3 90 . 0 4 3
in.) 1 . 3 m m ( O . OiSn 1. )
l g n i t i o nt i m i n g A t i d l e ( c h e c kr h e in neutral:8t2' ETDCat 650150rpm
Enqtne
Item Measurement Oualification Standard or New Service Limit
Compression Pressurecheckat 250rpm with wide Minimum 930kPa(9.5kgflcmr,135psi)
openthroftle. (SeeDesignSpecsfor Maximum 200kPa{2.0kgf/cm',28psi)
rato,
e_
vanatton
.l
2-2
a nder Head
Head
Item
Warpage
Height
Measur6ment Oualification
'103.95104.05
Standard or New
mm
Service Limit
0.05mm {0.002in.)
(4.093 4.096in.)
Camshaft Endplay 0.05 0.20mm (0.002 0.008in.) 0.4mm (0.02in.)
C a m s h a f tt o h o l d e r o i l c l e a r a n c e No.l journal 0.030 0.069mm 0 . 1 5m m { 0 . 0 0i6n . )
{0.001 0.003in.)
N o . 2 , 3 ,4 , 5 0.060 0.099mm 0.15mm (0.006in.)
journals (0.002-0.004in.)
Totalrunout 0.03mrn (0.001in.)max. 0.04mm {0.002in.)
Cam lobe height Intake,primary 33.925mm (1.3356 in.)
Intake, 8 m (l.1668
2 9 . 6 3m in.)
o
Exhaust
5.515 5.530mm 5.55mm (0.219in.)
L Valveguides LD. Intake
Exhaust
|.0.21710.21174n.1
5.515 5.530 mm 5 . 5 5m m { 0 . 2 1i9n . )
\0.2111 0.2177in.l
I n s t a l l e dh e i g h t lntaKe 1 5 . 2" 1 6 . 2m m ( 0 . 5 9 80 . 6 3 8 i n . )
Exhaust 15.5 16.5mm (0.610 0.650in.)
Rockerarms Arm-to-shaftclearance lntaKe 0.025 0.052mm 0.08mm (0.003in.)
(0.00'100.0020in.)
Exhaust 0.018 0.056mm 0.08mm (0.003in.)
(0.0007 0.0022in.)
v
lo
2-3
Standardsand ServiceLimits
Enqine
n q t n e Block
Block
Item
I Warpageof deck
Measurement Oualification Standardor New
0.07mm (0.003in.)max.
ServiceLimir
foro.. (ulur^^-"1
_ f
tsorediameter Aori 86.010 86.020mm 86.070mm (3.3886
in.)
(3.3862 3.3866in.)
Borll 86.000 86.010mm 86.070mm (3.3886
in.)
(3.3858 3.3862in.)
0 . 0 5m m ( 0 . 0 0 2I n . J
R e b o r i n gl r m i t
0 . 2 5m m ( 00 l i n . )
Piston SkirtO.D.at 11mm (0.4in.)from btt"' "' A 85.980 85.990mm (3.3850 3.3854in.) 85.930mm (3.383'l
F" in.)
bottom of skirt LetterB €s.980 r"i33846
l-il?0 85.920mm (3.3827 in.)
0.020 0.040mm (0 0008 0.0016in.) 0.05mm {0.002in.)
Top 1.220 1.230mm (0.0481 0.0484in.) 1.25mm 10.049 rn )
Second 1 . 2 2 0 1 . 2 3 0m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25mm 10.049 in.)
i 2.005 2.025mm (0.0789 0.0797in.) ?.09rrl9.091lt )
Pistonring ",";"* fo.o:s o.oto.rnlo.oorao.ooza i.'.f 0.13mm (0.005in )
lFis,.€-"'" EO3t 0 056rn. {OJ01rOOO2 i") 0 . 1 3m m ( 0 . 0 0i5n . )
L-
Ringend gap
Second(FEDEHAL 0.025 0.060mm (0.0010 0.0024in.) 0.13mm (0.005in )
I\4OGUL)
Top 0.20 0.35mm (0.008 0.014in.) 0.60mm (0.024in.)
Second 0.40 0.55mm {0.016 0.022in.) 0.70mm (0.028in.)
OiI(REKEN) 0.25 0.65mm (0.010 0.026in.) 0.75mm (0.030in.)
OiI(FEDERAL 0 20 0.70mm i0.008 0.028in.) 0.80mm 10.031in.)
I\4OGUL)
Pistonpin o.D. 21.961 21.965mm {0.8646 0.8648in.) 2 1 . 9 5 3m m l 0 8 6 4 3 i n
Pin'to-piston
clearance 0.005-*0.002 mm( 0.00020+ 0.005mm (0.0002 in.)
0.00008
c_
in.)
Connecting
rod Pin to-rod clearance 0.005 0.015mm (0.0002 0.0006in.) 0 . 0 2 m m l O 0 O O 8i n I
Small end bore diameler 21.970 21.976mm (0.8650 0.8652in.)
L a r g e - e n db o r e d i a m e t e r ( N o r m a l ) 4 8 . 0m m ( 1 . 8 9
in.)
Endplayinslalledon crankshaft 0.15 0.30mm (0.006 0.012in.) 0 . 4 0m m ( 0 . 0 1i6n . )
Crankshaft Main journal diameter No. l journal s4.e84 s5.008mm (2.1648=16illl
No.2 journal
N o .4 j o u r n a l
No.5 journal
No.3 journal 0 m ( 2 . 1 6 4 42 - 1 6 5 4 i n )
5 4 . 9 7 65 5 . 0 0 m
Rodjournal diameter 4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l
Rod/main 0.005mm 10.0002in.)max. 0.010mm (0.0004 in.)
Rod/mainiournalout of,round 0.005mm (0.0002
in.)max. 0.010mm (0.0004 in.)
E n dp l a y 0.10 0.35mm (0.004 0.0'14 in.) 0 . 4 5m m 1 0 . 0 1i 8
n.)
Runout 0.03mm (0.0012
in.)max. 0.04mm {0.0016
. . - ' . : - - ' + in.)
M a r n o e a r , n 9 - t o J o u r n ao
t t t c t e a r a n c e No. l journal m m ( 0 . 0 0 0 70 . 0 0 1i6n . )
0.017 0.041 0.050mm (0.0020 in.)
Deaflngs No.2 journal
No.4 journal
No.5
No.3 journa/ q0rr034, -rn {O'o010
0-o01r|"tl 0.055mm (0.0022in.)
Bodbearingclearance 0.021 0.049mm (0.0008 0.0019in.) 0.060mm (0.0024
in.)
2-4
o i nqlne
|tem
Engineoil
Lubrication
Capacity
Measurement Oualificalion Standerdor New
5.30 (5.6US qt)for engineoverhaul
ServiceLimil
a
No.2 journal,frontand 33.021 33.069mm (1.3000 1.3019 in.) 33.09mm {1.303in.)
L R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l
t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )
rearshaft
At idle
At 3,000rpm
7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .
300kPa{3.1ksf/cm',44psi)min.
8.0mm {0.31in.)min.
v a
2-5
Standardsand ServiceLimits
Fueland Emissions
Item Measulement Oualification
f
Standardor New ServiceLimit . \
Fuelpressure Pressurewith fuel pressuregauge 320-370kPa13.3-'3.8
kgtcm',47 52psi)
regulator connected
Fueltank Capacity 5 04 ( 1 3 . 2U Sg a l i
Engineidle ldlespeedwith headlights and radiator Neutral 750 50 rpm
fan off
F a s ti d l e Neutral 1,600150rpm
Clutch
Item Mea3urem€nl Oualification Slandardor New ServiceLimit
Clutchpedal Heightfromthe floor 193mm (7.60in.)
Stroke 1 3 0 1 4 0m m 1 5 . 1 5 . 5 i n . )
10 16mm (0.39 0.63in.)
D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r 1'15 mm (4.53 i n . )m i n .
Bunouton clutchmatingsurface 0.05mm 10.002 in.)max. 0.15mm (0.006in.)
Clutchdisc Bivetheaddepth 1.65 2.25mm (0.065 0.089in.) 0.7mm {0.03in.)
Ihickness 8.3 8.9mm (0.33 0.35in.) 6.0mm (0.24in.)
Pressureplate Warpage 0.03mm (0.001in.)max. 0 . 1 5m m ( 0 . 0 0i1n . )
Heightof diaphragm spring fingers Measured with 0.6mm (0.02in.)max. 0.8mm (0-03in.)
specialtooland
feelergauge
r a
\ < c
2-6
nualTransmissionand M/T Differential
O E Item
Transmission Capacity
M€asurement Oualification Standardor New
Forfluidchange:1.50 (1.6US qt)
Se.viceLimit
fluid U Sq t )
F o ro v e r h a u1l :. 70 1 1 . 8
' l - 0 . 1 7 ( 0 . 0 0 4 Adiust
Mainshaft Endplav 0.1 mm 0.007in.)
Diameterof bushingsurface 20.80 20.85mm {0.819 0.821in.) 20.75mm 10.817 in.)
D i a m e t e ro f d i s t a n c ec o l l a r 31.984-32.000 mm (1.2594 1.2598 in.) 3 m ( 1 . 2 5i7n . )
3 ' 1 . 9m
Diameter of ballbearingcontactarea 2 7 . 9 7 72 7 s 9 0m m \ 1 . 1 0 1 -51 . 1 0 2i0n . ) 27.92 m m ( 1 . 0 9i9n . )
(clutchhousingside)
'1.5354 38.93mm (1.5334n.)
Diameter of needlebearingcontact 38.984 39.000mm (1.5348 in.)
area
Diameterof ballbearingcontactarea 27.987 28.000mm (1.10'191.1024in.) 2 7 . 9 3m m { 1 . 1 0i0n . )
(transmission
housingside)
Runout 0.02mm (0.001in.)max. 0.05mm (0.002in.)
Mainshaft 3rd, t.D. 44.009 44.025mm 11.73261.7333 in.) 44.08mm (1.735in.)
4th and sth Endplay 0.06 0.16mm {0.002 0.006;n.) 0 . 2 5m m ( 0 . 0 1i0n . )
gears Thickness 23.92 23.97mm (0.94'10.944in.) 23.80mm (0.937in.)
Countershaft Diameterof needlebearingcontact 35.000-35.015mm (1.3780 '1.3785in.) 34.95mm (1.376in.)
area(clutchhousingside)
Diameterof distance
collarcontact 39.937 39 950mm (1.5723 1.512ain.| 39.88mm (1.570in.)
alea
D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a 3 3m ( 1 . 1 8 1 91- . 1 8 2i4n . )
30.020-30.0m m m ( 1 . 1 8i0n . )
29.97
( t r a n s m i s s i o nh o u s i n g s i d e )
Runout 0.02mm {0.001in.)max. 0.05mm (0.002in.)
innerrace
35 mm shim-to'bearing 0.04 0.10mm (0.0016 0.0039in.) Adjust
clearance
52.010 52.029mm (2.0476-2.0484 52.08mm (2.050in.)
a
Countershaft LD. in.i
0.06 0.16mm (0.002 0.006in.) 0 . 2 5m m 1 0 . 0 1i 0
n.)
L Countershaft
End play
Thickness
t.D.
22.92 22.91$m 10.902-0.904in.)
52.010 52.029mm (2.0476 2.0484in.)
22.87mm (0.900in.)
52.08mm {2.050in.}
2ndgear Endplay 0.06 0.16mm (0.002 0.006in.) 0.25mm 10.010 4n.)
Thickness 21.92 27.91mtn \1.099 1.101in.) 27.87mm 11.097 in.)
Countershaft LD. 39.95 39.96mm (1.572a 1.5132in.) 39.97mm (1.574in.)
'lst gear o.D. 46.989-47.000mm (1.8499-1.8504 in.) 46.94mm (l.848in.)
collar Length
distance 23.03 23.08mm (0.907-0.909 in.i
Countersha{l l . D . 39.95 39.96mm {1.5728'-1.5732in.l 39.97mm (1.574in.)
2ndgear o.o. 46.989 47.000mm (1.8499 1.8504 in.) 46.94mm (1.848in.)
distance
coliar L e n g t h 28.03 28.08mm (l.104 1.106in.)
v o
2-7
Standardsand ServiceLimits
Manual
anuatTransmission
I ransm ?
and Differentialcont'
Item Measutemenl Oualification Standardor New ServiccLimit
Nlainshaft4th LD. 32.00-32.01mm (1.2598 1.2602in.) 3 2 . 0 2m m ( 1 . 2 6i1n . )
and5thgears o.D. 38.989 39.000mm (1.5350 1.5354 in.) 38.94mm (1.533in.)
distance
collar L e n g t h 51.95 52.05mm (2.045 2.049in.)
B 24.03 24.08mm (0.946-0.947in.)
Selectlever
S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a
S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e
Fingerwidth
mm (0.665 0.669in.)
0.2 0.5mm (0.008 0.020in.)
14.85 '14.95
mm (0.585 0.589in.)
0 . 6 2m m ( 0 . 0 2i4n . ) L O
Shiftlever Shaft-to-selectleverclearance 0.05 0.25mm (0.002 0.010in.) 0.50mm (0.020in.)
Groove{to selectlever) 15.00 15.10mm {0.591 0.594in.)
Shaftto shiftarm clearance 0.013 0.07mm (0.0005 0.003in.) 0.1mm {0.004in.)
Mfi Pinionshaftcontactareal.D. 18.010 18.028mm (0.7091 0.7098in.)
differential C a r r i e r - t o - p i n i o ns h a f t c l e a r a n c e 0.027 0.057mm (0.0011 0.0022in.) 0.1mm (0.004in.l
carrier DriveshaftcontactareaLD. 28.025 28.045mm (1.1033 1.1041 in.)
Mfi Backlash 0.05 0.15mm {0.002 0.006in.)
differential t.D. 6 m ( 0 . 7 1 0 30 . 7 1 1 3 i n . )
1 8 . 0 4 21 8 . 0 6m
pinionqear P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e 0.059 0.095mm (0.0023 0.0037in.) 0.15mm (0.006in.)
80 mm shim 80 mm shim to-bearing
outerrace 0 0.10mm (0 0.0039in.) Adjust
clearance
in transmission
housing
2-8
o Rotational
olavmeasured
at outside 0 10mm (0 0.39in.)
Startingloadmeasured
at outside 2 9 N ( 3 . 0k g f . 6 . 6 l b s )
A n g l e o f r a c kg u i d e s c r e w l o o s e n e d
n
Item Measurement Oualitication Standardor New ServiceLimit
W h e e l a l i g n m e nCamber
t Front 0'00' 45'
Rear 0'45'- 45
Caster Front 1"33' 11"
TotalToe lrytt 0-3 mm(0::0.12 in.)
Rear lN 2 ' , mm (0.08"' ,, in.)
Frontwheelturningangle l n s i d ew h e e l 37'40'-2'
Outsidewheel 29'50'(Reference)
Aluminumwheelrunout Axial 0 0.7mm (0 0.03in.) 2.0mm (0.08in.)
Radial 0 - 0 . 7m m ( 0 0 . 0 3 i n . ) l.5mm{0.06in.)
Wheelbearing Endplay Front 0 0.05mm (0 0.002in.)
Rear 0 0.05mm (0 0.002in.)
Y a
2-9
Standardsand ServiceLimits
Brakes
Item
Parkingbrake
lever
Distance
M€asurement
traveledwhen leverpulled
with 196N (20kgf, 44 lbs) ol force
Oualification Standardor New
7 8 clicks
ServiceLimit
a
Brakepedal Pedalheight(carpetremoved) 1 8 4m m ( 7 4 / 1 6i n . )
Freeplay 0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8
in.)
Mastercylinder Piston-to-pushrod
clearance 0 0.4mm (0 0.02in.)
Erakedisc Thickness Front 2 1 . 0m m ( 0 . 8 3
in.) 19.0m 0 m (0.75 in.)
Rear 9.0mm {0.35in.) 8-0mm (0.31in.i
Runout Front 0.10mm (0.004in.)
Rear 0.10mm (0.004in.)
Parallelism Frontand rear 0.015mm (0.0006 in.)
Brakepads Thickness Front 10.0mm (0.39in.) 1 . 6m m ( 0 . 0 6
in.)
llear 9.0mm {0.35in.) 1 . 6m m ( 0 . 0 6
in.)
Air Gonditionin
Item Moasurement Oualilication Standard or New Service Limit
Refrige.ant Tvpe H F C1 3 4a ( B - 1 3a4)
Capacityof system 500 550g 117.6 19.4oz)
Refrigerant
oil Type S P1 O
(P/N38897-P13-A01AH or 38899-P13-A01
)
Capacity
ofcomponents Condenser 25 m0,15/6fl ozl
Evaporator 45 mA111/2fl ozt
Eachline and 10m0 (1/3fl or)
hose
Compressor 1 3 0 1 5 0m 0 1 41 / 3 5 f l o z )
Compressor Startercoil resistance At 68"F(20"C) 3.05 3.350
Drivebelt
Pulley-to-pressure plateclearance 0.35 0.6mm (0.014 0.024in.)
Autotensioner lneedsno adjustment) e-
2-10
DesignSpecifications
O |tem
DIMENSIONS Overalllength
Overallwidth
Measurement Oualification
4 , 2 1 0m m { 1 6 5 .i8n . )
1,695mm 166.7 in.)
Specilication
o
Normaloutput
L Nominalvoltage
Hourrating
Directionof rotation
12V
30 seconds
C l o c k w i s ea s v i e w e c lf r o m g e a r e n d
CLUTCH C l u t c ht v p e S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g
Clutchfrictionmaterialsurfacearea 1 7 4c m ' { 2 6 . 9s7q i n . )
I\,1AN
UAL Tvpe Svnchronized, s-speed forward,1 reverse
TRANSMISSIONPrimarvreduction D i r e c1t : 1
Gearratio lst 3.062
2nd 1.769
3rd 1.212
4th 0.921
5th 0.738
Reverse 3.583
Finalreduction Type Sinolehelicalgear
Gearratio 4.164
v o
2-11
DesignSpecifications
cont'
Item
STEERING Type
Measuremeni Oualification
Electric,
Powerassisted
Specilication
rackand pinion
C
Overallratio 15.1
Turns,lockto-lock
Steeringwheeldiameter 3 6 0m m ( 1 4 . 2
in)
SUSPENSION Type I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc. o i l s p r i n g
Rear D o u b l ew i s h b o n e
Shockabsorber Front Telescopic,
hydraulic.
nitrogengas-frlled
Rear Telescopic,
hydraulic,
nitrogengas,filled
WHEEL Camber Front 0"00'
ALIGNMENT Bear 0.45'
Caster Front 1'33'
Totaltoe Front 0 mm (0 in.)
Rear I n 2 m m ( 1 / 1 6i n . )
BRAKES Typeof servicebrake Front P o w e r a s s i s t e ds e l f - a d j u s l i n gv e n t i l a t e dd i s c
Bear Power-assisted self-adjusting soliddisc
Typeof parkingbrake Mechanical actuating, rearwheels
Padfriction surfacearea Front 4 5c m ' ( 7 . 0s q i n . ) x 2
Rear 2 8c m ' ( 4 . 3s q i n . )x 2
TIRES Sizeoffront and reartires Pl95/6081588V
Sizeo{ sparetire T125r0 D1595M
AIR Compressor Type Scroll
CONDITIONING Numberof
cylinders
Capacity 85.7m015.23 cu in.)/rev.
a
Maximumspeed 12,000rpm
Condenser
L u b r i c a n tc a p a c i t y
Lubricanttype
Type
130m0 {4 1/3floz)
SP-10(P/N38897'P13-A01AH
Corrugated fin
or38899-P13
A01) L
Evaporator Tvpe Corrugatedfin
Blower Type Siroccofan
Motor type 220 Wl12 V
Speed control 4 Speeo
M a x i m u m c a p a c i t y 480m" 116.900
cu ft)/h
T e m p e r a t u r ec o n t r o l Airmixtype
Compressor
clutch Tvpe Dry,singleplate,poly-Vbeltdrive
Electricalpower 42W maximumat 12V
cons!mptronat
68"F(20.C)
Refrigerant Type HFC134a(R-134a)
Capacity 500 550g (17.6 19.4oz)
../a
2-12
o Item
ELECTRICAL
RATINGS
Battery
Starter
Alternator
Measurement Oualilication
1 2 V 3 6A H / 5h o u r s
1 2V - . 1 . 1k W ,1 . 2k W
12V 95A,90A
Specitication
Fuses Under-hood
fuse 80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A
Under'dash
Iuse 3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5A
o
Spotlights 12V 5W
t Gauge lights
I n d i c a t o rl i g h t s
Sideturn signal
LED
12V 5W
light
v a
2-13
Body Specifications
Unit: mm {in.)
1.555{61.6)
1,i140(56.71
2-14
I
Maintenance
Lubricantsand Fluids
MaintenanceSchedulefor Normal
Conditions
Listed by Distance/Time
MaintenanceSchedulefor Severe
Gonditions
Listedby Distance/Time
t MaintenanceSchedule
Listedby Maintenance
ltemfor Normal
Conditions ...................
3-8
Listedby Maintenance
ltem for Severe
Conditions ...................3-9
\.4
Lubricantsand Fluids
For detailsof lubricationpoints and type of lubricantsto be applied,referto the illustratedindex and variouswork
ures{suchasAssem o v e r h a u l .l n s t a l l a t i o ne.t c . )c o n t a i n e di n e a c hs e c t i o n .
NO. LUBBICATION
POINTS LUBBICANT
1 Eng ine Honda Motor Oil (P/N08798-9023). The oil container
must disolavthe API Cenificationseal shown below.
M a k es u r ei t s a y s" F o r G a s o l i n eE n g i n e s . S
" AE
Viscositv:See chart below.
2 Transmission HondaMTF*'(P/N08798-9016)
3 Brakesvstem (includesABS line) HondaDOT 3 BrakeFluid*' (P/N08798-9008)
4 C l u t c hl i n e
5 Release f o r k ( m a n u a tl r a n s m i s s i o n l S u p e rH i g hT e m p U r e aG r e a s e{ P / N0 8 7 9 8 - 9 0 0 2 )
6 Throftlecableend (throttleIink)
7 Shift and selectcable ends (manual S i l i c o n eg r e a s e
transmission)
I Throttlecable end (dashboardlower panel hole)
9 Brakeboosterclevis grease
Multi-purpose
10 CIutchboosterclevis
11 Shift lever pivot
1' Pedalinkage
Batteryterminals
14 F u e lf i l l d o o r
H o o dh i n g e sa n d h o o d l a t c h
16 H a t c hh i n g e s
17 D o o rh i n o e s u , o D e ra n d l o w e r
18 Caliperpiston boot, caliperpins and boots HondaCaliDerGrease(P/N08C30-80234lvl)
19 A i r c o n d i t i o n i n cg o m p r e s s o r C o m p r e s s o r o iS
38899-P'13-A01)
l : P - 1 0( P / N3 8 8 9 7 - P 1 3 - A 0 1 A
o rH I
F o rr e f r i q e r a nH
t;FC'134 a ( R - 1 3 4a )
Recommond6dEngineOil
fanges
E n g i n eo i l v i s c o s i l yf o r a m b e n t t e m p e r a l u r e
* 1 : Always use HondaManualTransmissionFluid (MTF).Using motor oii can causestiffershifting becauseit does
not containthe Drooeradditives.
" 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of
the system.
3-2
t
o o o o o@@
o a9
3-3
MaintenanceSchedule
Listedby Distance/Timefor Normal Conditions
Thistwo pagel/lanitenance Scheduleoutlinesthe minimunrequiredmaintenance. Serviceat the indicated distance
or time,whichevercomes
first.use the lvlaintenance
Schedule
for Severeconditionsif the vehiclemeetsanyof the qualifiers
in the SevereConditions or if the
schedule
vehicleis normallydrivenin Canada.
(cold)(seepage6-321r
Inspectvalveclearance. 0.28 0.32mm (0.011 0.013in.)
0.21-0.25mm (0.008 0.010in.)Exhaust:
Intake:
Replace sparkplugs.UseIZFR6K'11(NGK)or SKJ20DR-M11 (DENSO).
1 . 0 1 . 1m m
120,000
mi/ 192,000km/6 years
I Replacetransmission fluid.UseHondaMTF(seepage13-3).
! Do items in A,B,alqq.,
/ / Y vcdrs
120,000
mil 192,000
Beplace coolant(seepage106).Capacity:
5.00 (5.3US qt).UseHondaAll SeasonAntifreeze/Coolant
Type2.
According to stateandlederalregulations,
tailureto do the maintenance
itemsmarkedwith an asterisk{*) will not voidthe customer's
emissions warranties,However,Hondarecommends thatall maintenance be doneat the recommended
services intervalto ensurelong-term I
reliability.
3-4
Dothe itemsin partsA, B, C, D, andE as requiredfor mileage/time
intervallisted.
A
Replace engineoillseepage8-5i. Capacity withoutlilterchange:4.0S (4.2US qt, 3.5lmp qt)
Rotatetires.Followthe patternshownin the Owner'sManual Checktireinformationandcondition.
B
Replace engineoil filterlseepage8-6). Capacity with filterchange:4.20(4.4US qt,3.7lmp qt)
Inspectfrontandrearbrakes(seepage19 3i.
. Checkpadsand djscsfor wear(thickness), damage,andcracks.
' Checkcalipers tor damage,leaks,andtjghtnessot mountbolts.
Checkparkingbrakeadjustment. ShouldbeIullyappliedwithin7 to I clicks.
Inspecttie rod ends,steeringgearbox,and boots{seepage17 5).
. Checkrackgreaseandsteeringlinkage.
. Checkbootsfor damageand leakinggrease
. Chackfluidline{or damageand leaks.
lnspectsuspensioncomponents.
. Chockboltsfor tightness.
. Checkconditionof balliointbootslor deterioration
and damage.
Inspectdriveshaftboots.Checkbootsfor cracksand boot bandsfor tightness(seepage16-3).
Insp€ctbrakehosesandlines{including ABS). Checkthemastercylinder, proponioning controlvalve,andABSmodulator{ordamage
andleakage.
add MTFlseepage13'3),engioecoolant,brakefluid,and
Checkall fluidlevelsandconditionot tluids;checkfor leaks.lf necessary,
windshield washerfluid.
L lnspectexhaust system*.Checkcatalytic converterheatshield, exhaustpipeand mufflerfordamage,leaks,andtightness{soepage9,8).
lnspect{uellinesandconnections*. Checkfor looseconnections, cracksand deterioration;
retightenlooseconnoctions
and replace
damagedparts(s€epage11 146).
l InsDect
andadiustdrivebelt.
. Lookfor cracksanddamage,andinspectautotensioner(needsno adjustment).
Replacethe dustandpollenlilter(seepage21 39).
. Replacethe dustandpollenfilterwheneverairflow lrom the heatingandcoolingsystemis lessthannormal.
D
air cleanerelementevery30,000miles(48,000
Replace km)(independent
of time).
E
brakefluidevery3 years(independent
i I Replace oI mileage).
Accordingto stateandfederalregulations,
failureto do the maintenance * ) will not voidcustomer's
itemsmarkedwith asterisk( emissions
warranties.
However,Hondarecommends thatall maintsnance servicebe doneat the recommendedintervalto ensurelongterm reliability.
3-5
MaintenanceSchedule
Listedby Distance/Timefor SevereConditions
Serviceat the indicated or time,whichevercomesfirst.Usethisscheduleif the vehicleis drivenMAINLYin Canadaor in anyof the
distance
tollowingconditions; il onlyOCCASIONALLY drivenin theseconditions,
usethe NormalConditions (seepage3-4).
schedule
SevereDrivingConditions
. Drivinglessthan5 miles{8 km) pertrip or, in freezingtemperatures,
drivinglessthan 10miles(16km)pertrip
. Drivingin extremelyhot (over90"F/32"C) conditions
. Extensive idl;ngor longperiodsof stopand go driving,suchasa taxior a commercial deliveryvehicle.
. Trailertowing,drivingwith a car-topcarrier,or drivingin mountainousconditions.
. Drivingon muddy,dusty,or de'icedroads
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .
km/ 6 years
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) .
3-6
Dothe itemsin partsA, B, C,D, E,F,and G as requiredfor mileage/time
intervallisted.
A
Feplaceengineoil(seepageS5). Capacity q (4.2US qt,3.5lmpqt)
withoutlilterchange:4.0
I
Replace engjneoil filter(seepageI 6). Capacity with filterchange:4.20 14.4US qt,3.7lmp qt)
Insoectfrontand rearbrakes,
. Checkpadsanddiscsforwearlthickness), damage,andcracks.
. Checkcalipers for damage,leaks,andtightnessof mountbolts.
Lubricatedoorlocks,latchesand hingeswith Hondawhitelithiumgrease.
Rotatetires,if the vehiclehasbeendriventhe distancelisted.Followthe patternshownin the Owner'sManual-Checktire inflaronaoo
condition,
Inspecttierod ends,steeringgearbox,and boots(seepage17,5).
. Checkrackgreaseandsteeringlinkage.
. Checkbootsfor damageand leakinggrease.
. Checklluidlinefordamageandleaks.
L Inspectsuspensron components
. Checkboltsfor tightness.
. Checkconditionof balljointbootsfor deteriorationanddamage.
Inspectdriveshaft boots.Checkbootsfor cracksand bootbandsfor tightness(seepage16-3).
D
InsDectand adiustdrive belt.
. Looktor cracksanddamage,and inspectautotensioner
{needsno adjustment).
Reolace dustand oollenfilter.
E
Replace
aircleanerelementevery15,000
miles124,000
km) in dustvcondition{independent
ol timei otherwiseuseNormalConditions
(seepage11-162).
scredule
F
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
brakefluidevery3 years(independent
Replace oJmileagei.
H
dustandpollenIilterevery15,000
Replacethe milesifvehicleis drivenmostlywhereair hashighconcentrationolsootfrom industryand
dieselpoweredvehiclesj
alsoreplacethe dustand pollenfilteranytimeaarflowis lessthanussal(seepags21-39).
A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,
3-7
MaintenanceSchedule
Listedby Maintenanceltem for NormalConditions
Followthe NormalSchedule if the severedrivingconditions in the lMaintenance
specified Schedule on the nextpagedo
for SevereConditions
c
not apply,and if onlyOCCASIONALLY drivenin severedrivingconditions.
Followthe SevereConditionsscheduleif the vehicleis drivenMAINLYin Canada.
months 12 24 3 48 60 12
engineoil
Replace o o o o a o o a a o O a
R o t a t et i r e s
{ C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )
engineoil filter
Replace o o a a a a
frontand rearbrakes
Inspect
C h e c kp a r k i n g b r a k e a d j u s t m e n t
Visuallyinspectthefollowingitems:
. Tie-rodends,steeringgearboxand boots
. Suspension components
. Driveshaftboots
. Brakehosesand lines(including ABSi
. Allfluidlevelsandconditionof{luids
. Exhaust system*
. Fuellinesandconnections*
Inspectandadjustdrivebelt a a a a
dustand pollenfilter
Replace
Reolace fluid
transmission a
Servicethefollowing items at the recommendedintervals
R e p l a c ea i r c l e a n e re l e m e n t Every miles(48,000
30,000 km)
sparkplugs
Replace Every miles(176,000
110,000 Lm)
Inspectvalveclearance Inspect
every110,000 km),otherwise
miles{176,000 onlyif noisy.
adiusl
I n s p e c ti d l e s p e e d * Every
160.000 km)or8 years
mres1256,000
R e p l a c ee n g i n e c o o l a n t miles(192,000
At 120,000 km)or 10years, miles(96,000
thenevery60,000 km)or5
brakefluid
Replace Every3 years
3-8
Listedby Maintenanceltem for SevereConditions
Usethisschedule if the vehicleis drivenMAINLYin Canadaor in anvof thefollowinaconditions. NOTE:it onlyOCCASIONALLY
drivenin these
conditions,usethe NormalConditions schedute.
SovereDrivingConditions
. Drivinglessthan5 miles(8 km)pertrip or, in lreezingtemperatures, drivinglessthan 10miles(16km)pertrip.
. Drivingin extremely hot over90 "F 132'C)conditions.
. Extensive idling,or longperiodsot stop-and-go-driving, suchas a taxior a commercialdeliveryvehicle.
. Trailertowing,drivingwith a cartop carrier,or drivingin mountainous conditions.
. Drivingon muddy,dusty,or de icedroads.
months 12 24 36 48 60 72
Replace
engineoil Replace
every
5,000
miies18,000
km)or6 months
Rotatetires a o a a o a a o a a a o
{Checktire intlationandconditionat leastonceper monthi
R e p l a c ee n g i n e o i l f i h e r
Inspectfrontand rearbrakes
L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s
Visuallyinspectthe followingitems:
. Tie rod ends,steeringgearboxand boots
. Suspension components
' Driveshaftboots
Checlparkingbraleadjuslment a a O a o a
Visuallyinspectthefollowingitems:
. Brakehosesand lines{including ABSi
. Allfluidlevelsandconditionoflluids
. Exhaust system*
. Fuellinesandconnections*
. Lightsandcontrols,vehicleunderbody
Inspectand adjustdrivebeh o a o a
R e p l a c ed u s t a n d p o l l e n f i l t e r " o ' t '
Replace
transmission
lluid a a
Servicethe following items atthe recommendedinteruals
Replace
aircleanerelement miies(24,000
Every15,000 km)in dustyconditions,
otheMiseusenormalschedule.
sparkplugs
Replace Every miles(176,000
110,000 km)
Replace
enginecoolant miles(192,000
At 120,000 km)of 10years,lhen
every miles(96,000
60,000 km)or5
Replace
brakefluid Every3 years
* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v .
N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0k m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s
o f s o o t i n t h e a i r f r o m i n d u s t r v a n d d i e s e l - D o w e r e dv e h i c l e s .
t,
3-9
EngineElectrical
EngineElectrical - +
SpecialTools 4-2
ENGINE
StartingSystem
Comoonent Location Index ............... 4-J
CircuitDiagram 4-4
StarterCircuit Troubleshooting 4-5
ClutchInterlockSwitchTest 4-6
StarterSolenoid Test .............. 4-7
StarterPerformance Test 4-8
StarterReolacement ............... 4-9
StarterOverhaul....................... 4-10
lgnition System
Component LocationIndex ............... 4-15
CircuitDiagram 4-16
lgnitionTimingInspection 4-17
lgnitionCoilRemoval/1nsta11ation .......................
4-18
SparkPlugInspection 4-19
ChargingSystem
Component LocationIndex ..................................
4-2O
CircuitDiagram ...........................
4-21
Charging CircuitTroubleshooting .......................
4-22
DriveBeltInspection ...................
4-26
DriveBeftReplacement ..............
4-26
DriveBeftAuto-tensioner Inspection.................. 4-27
DriveBeftAuto-tensioner Replacement ..............
4-28
AlternatorReolacement .............
4-29
AlternatorOverhaul ................ .... 4-30
CruiseControl
Component LocationIndex ..................................
4-36
CircuitDiagram ...........................
4-37
SymptomTroubleshooting Index .......................
4-38
CruiseControlUnitlnDutTest .............................
4-40
MainSwitchTesVReolacement ...........................
4-42
SeVResume/Cancel SwitchTesVReplacement .. 4-42
CruiseControlActuatorTest ......4-43
CruiseControlActuator/CableReplacement ......4-44
ActuatorCableAdjustment..................................
4-45
ClutchPedalPositionSwitchTest .......................
4-45
\.
EngineElectrical
SpecialTools \ C
Number Tool Number Description otv
o 07746-0010400 Attachment,52 x 55 mm 1
@ 07749-0010000 Driver 1
\(a
4-2
Starting System
ComponentLocationIndex
UNDER-DASH
FUSE/RELAYBOX
- l - -
-i
ar]]]ll I
-_-
-. rt_.1
_-- _. /
Itti:
: - l t . i t -i t! -t
!t:!|- CLUTCH INTERLOCKSWITCH
Test,page4-6
STARTERCUTRELAY
Test,page22-51
\ r \ ' l
\'\l I
\r\, l,
, . \ \ /
'....",r.v
\ \ /
\- \:,...)
\ /'\
t l \
STARTER
page4 5
StanerCircuitTroubleshoot,ng,
SolenoidTest,page 4-7
PerformanceTest,page4-8
Replacement,page 4-9
'10
Overhaul,page4
4-3
Starting System
CircuitDiagram
-
ilo.20lOA) :USAmotkl
No.2!l50A) : C.nid. model
UiIOENH@DfUSE/REI.IY
BOX
STHOTin STA8Tilll
UNDEiOASTI
FUST/ifLAY
80x
Y.
cLuTot
[{Tr8LocK
swtlcH
4-4
StarterCircuitTroubleshooting
NOTE: 4. Checkthe batterycondition.Checkelectrical
. Airtemperaturemust be between59'and 100'F(15' connectionsat the battery,the negativebaftery
and 38'C) during this procedure. cableto body, the engine ground cablesand the
. After this test, or any subsequentrepair,resetthe starterfor loosenessand corrosion.Then try
enginecontrolemodule (ECM)to clear any diagnostlc startingthe engine again.
trouble codes (DTCS){seepage 11-4).
. The batterymust be in good conditionand fully Did the statter crank the engine?
charged.
. lf you disconnectthe baftery,do the ECM idle learn YES Repairingthe looseconnectionfixed the
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . problem.The startingsystem is now OK.!
RecommendedProcedure: N O l f s t a r t e r w i l ln o t c r a n k t h e e n g i n ea t a l l ,g o t o
. Use a startersystemtester. step 5. lf it cranksthe engine erraticallyor too
. Connectand operatethe equipmentin accordance slowly, go to step 7. lf it won't disengagefrom the
with the manufacturer'sinstructions. flywheel ring gear when you releasethe key, check
for the following until you find the cause.
Alternate Procedure
. Solenoidplungerand switch malfunction
1. Hook up the following equipment: . Dirty drive gear or damagedoverrunningclutch
. Ammeter,0 400A
. Voltmeter,0 20 V (accuratewithin 0.1 volt) 5. Make sure the transmissionis in neutral,then
. Tachometer,0 1200rpm disconnectthe startersubharness1Pconnector(A)
'lP
from the enginewire harness connector(B).
Connecta jumper wire from the batterypositive
'l
terminalto the startersubharness P connector.
L
(cont'd)
4-5
StartingSystem
StarterCircuitTroubleshooting ClutchInterlockSwitch Test
(cont'dl
6. Checkthe following items in the order listeduntil
you find the open circuit.
1. Disconnect
the clutchinterlockswitch2Pconnector.
. Checkthe BLIVWHTwire and connectors
betweenthe under-dashfuse/relaybox and the
ignition switch,and betweenthe under-dash
fuse/relaybox and the starter.
. Checkthe ignition switch {seepage 22-53).
. Checkthe clutch interlockswitch and connector.
. Checkthe startercut relay (seepage 22-51).
. CheckLT GRNwire betweenthe startercut relayl
under-dashfuse/relaybox and the clutch
interlockswitch.
. Checkthe BLKwire betweenthe clutch interlock
switch and G501.
YES-Go to step8.
. Excessivelyworn starterbrushes
. Open circuit in commutator brushes
. Open circuit in starterarmaturecommutator
segments
. D i r t yo r d a m a g e dh e l i c asl p l i n e so r d r i v eg e a r
. Faultydrive gear clutch
4-6
StarterSolenoidTest
from thestarter
the S andlvlconnectors
1. Disconnect
solenoid.
4-7
StartingSystem
Starter PerformanceTest
1 , Disconnectthe wires from the S terminal and the M 5. Disconnectthe batteryfrom the starterbody. lfthe
termrnal. pinion retractsimmediately,it is working properly.
Specifications:
4-8
Starter Replacement
1. Make sure you havethe anti-theftcode for the radio. 5. Disconnectthe startercable (A)from the B terminal
then write down the frequenciesfor the radio's on the solenoid,then disconnectthe BLK,/WHT wire
presetbuttons. { B )f r o mt h eS t e r m i n a l .
10x 1.25mm
2. Disconnectthe negativecablefrom the batteryfirst, 44N.m{a.5kgf.m,33lblft)
then disconnectthe positivecable.
3. Disconnectthe knocksensorconnector.
A
6x1,0mm
12 N.m {1.2kgf.m,
8.7 tbt.ft)
8 x 1 . 2 5m m
9Nm
10.9kgf.m,7 lbl ft) 2
S'-12x12smm
6ilNm
{ 6 . 5k g l m , 4 7 l b f f t )
4-9
StartingSystem
Starter Overhaul f
Disassembly/Reassembly
STARTERSOLENOID
@
@
----_2<-
,--\
G
rw.h
; ,/ 1(-\
SOLENOIDLEVER
\:!@a - @-A
q -z\hsc6
b-.- ,"
OVERRUNNING
CLUTCHASSEMBLY
7:- o
o*"lu*. S#o
V*rN*
\#. A*@
\ c^)* -#""Jli[X:""
-v t^ fr/ /
a<-4 ffiA
9\:-/
,.. D lW
ffitr '!4/
END COVER t/
BRUSHHOLDER
\ r
4-10
\
(cont'd)
4-11
StartingSystem
StarterOverhaul(cont'dl
7. Checkthe mica depth (A).lf the mica is too high {B), 9. Placethe armature(A) on an armaturetester (B).
undercutthe mica with a hacksawbladeto the Hold a hacksawblade (C)on the armaturecore. lf
properdepth.Cut away allthe mica (C)between the blade is attractedto the core or vibrateswhile
the commutatorsegments.The undercutshould t h e c o r ei s t u r n e d ,t h e a r m a t u r ei s s h o n e d .R e p l a c e
not be too shallow,too narrow,or V-shaped(D). thearmature.
4-12
Starter Brush Inspection Starter Brush Holder Test
11. lvleasurethe brush length.lf it is not within the 14, Checkthat there is no continuitybetweenthe (+ )
servicelimit, replacethe brush holder assembly. b r u s hh o l d e r{ A )a n d ( ) b r u s hh o l d e r( B } .l f t h e r e
is continuity,replacethe brush holder assembly.
Brush Length
Standard{New): 14.0-14.5 mm (0.55-0.57 in.)
Service Limit: 9.0 mm {0.35 in.)
(cont'd)
4-13
StartingSystem
StarterOverhaul(cont'dl
Planetary Gear Inspection Starter Reassembly
OverrunningCluich Inspection
i.-
4-14
lgnition System
ComponentLocationIndex
SPARKPLUG
page4-'19
Inspection, IGNITION COIL
page4-17
lgnitionTimingInspection,
page4-18
Removal/lnstallation,
4-15
lgnition System
GircuitDiagram (
'No.20lOA)
:USAmo&l
UNDEBHOOD
FUST/8TIAY
M)( No.Al50A):Cmrda
model
lG1tioT in 0N {ll)
rd SIARIilll)
4-16
lgnition Timing Inspection
1 . Connectthe Honda PGM Testerto the data link 6. Pointthe light toward the pointer (A) on the cam
connector(DTC),and checkfor DTC'S.lf a DTCis c h a i nc a s e .C h e c kt h e i g n i t i o nt i m i n g u n d e rn o l o a d
present,diagnoseand repairthe causebefore conditions:headlights,blower fan. rearwindow
i n s p e c t i n tgh e i g n i t i o nt i m i n g . defogger,and air conditionerare not operaling.lf
the ignitiontiming differsfrom the specification,
Startthe engine.Holdthe engine at 3,000rpm with and there are no enginecontrol module {ECM)DTcs,
no load (in Neutral)until the radiatorfan comes on, r e p l a c et h e E C M( s e ep a g e1 1 - 4 )
then let it idle.
lgnition Timing:
C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . 8"+2" BTDC{REDmark {B))during idling in neutral
"SCS" menu A
4. Follow the tester'sprompts in the
{seethe testeroperator'smanual),
e o n d aP G MT e s t e ra n dt h e t i m i n g
D i s c o n n e c t t hH
light.
4-17
lgnition System
lgnitionCoilRemoval/lnstallation
1. Removethe ignition coil cover (A),then removethe
i g n i t i o nc o i l s( B ) .
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf ftl
---a
removal.
4-18
SparkPlug Inspection
1 . Inspectthe electrodesand ceramicinsulator. 3. Replacethe plug at the specifiedinterval,or if the
centerelectrodeis rounded{A). Use onlVthe spark
Burned or worn electrodes may be caused by: plugs listedbelow.
. Advancedignitiontiming
. Loosespark plug Spark Plugs: lZFR6Kl1(NGK)
. Plug heat rangetoo hot SKJ2ODR-M11(DENSO)
.Insufficientcooling
Worn or deformed
electrodes
f .lmpropergap
I J.Oil-touling
. Cs6on deposits
'r- 1I . Crackedcenter
\ electrodeinsulator 4 . Apply a small quantityof anti-seizecompoundto
the plug threads,and screwthe plugs into the
cylinder headfinger-tight.Then torque them to
1 8 N m ( 1 . 8k g f . m ,1 3 l b f f t ) .
L
Electrode Gap:
Standard(New): 1.0 1.1 mm
{0.039-0.0€ in.)
ServiceLimit: 1.3 mm {0.051in.l
4-19
GhargingSystem
ComponentLocationIndex
CHARGING SYSTEMINDICATOR
(ln the gaugeassembly)
q*o
BATTERY
Test,page22-50
ALTEBNATOR
page4-22
Troubleshooting,
DRIVEBELT page4-29
Replacement,
page4 26
Inspection, page4-30
Overhaul,
Replacement,page4 26
4-20
\ CircuitDiagram
'flo.
{l0Al :uSAhod.l
UNDTRXOOD
FUSI/RILAY
MX ilo.20l50Al:C.n.d.mod.l
+--,
I fmlil*t"t'
T-
+ilt
L = l
4-21
GhargingSystem
ChargingCircuitTroubleshooting
lf the chargingsystem indicatordoes not come on or 6. Measurethe voltageat the No. 3 terminal of the
does not go off, or the batteryis dead or low, test these e n g i n ew i r e h a r n e s s6 P c o n n e c t ow
r iththe ignition
items in the order listedbelow: s w i t c hO N {l l ) .
NO Go to step 3.
ls there battery voltage?
2. Startthe engine.
YES-Go to step 7.
Does the charging system indicator go off?
N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A )f u s e i n t h e
YES-Charging system indicatorcircuitis OK. Go under-dashfuse/relaybox. lf the fuse is OK, repair
to the Alternatorand RegulatorcircuitTest.t open in the wire betweenthe alternatorand the
under-dashfuse/relaybox.I ?
NO-Go to step 3.
7 . Turn the ignition switch OFF.
3. Turn the ignitionswitch OFF.
8 . Disconnectenginecontrol module (ECM)connector
4. Troubleshootthe multiplexcontrol system (see B (24P).
page 22 172).
9 . Checkcontinuitybetweenthe ECMconnector
ls the multiplex control system OK? t e r m i n a lB ' 1 0a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r
t e r m i n a lN o . 6 .
YES Go to step 5.
ECM CONNECTOB A (24P)
ls there continuity?
ls there continuity?
(cont'd)
4-23
GhargingSystem
(cont'd)
ChargingCircuitTroubleshooting
6. Startthe engine.Hold the engineat 3,000rpm with Alternator Control SystemTest
no load (in Neutral)until the radiatorfan comes on,
then let it idle. NOTE:After troubleshooting,performthe engine
control module (ECM)idle learn procedure(seepage
7. Raisethe engine speedto 2,000rpm, and hold it 11-139).
there.
1. Checkfor proper operationof the electricalload
8. Turn the headlights(high beam)on, and measure detector(ELD)by checkingthe malfunction
voltageat the under-hoodfuse/relaybox terminal. i n d i c a t o lra m p ( M l L ) ( s e ep a g e1l - 3 ) .l f a D T Ci s
present,diagnoseand repairthe causebefore
ls the voltagebetween 13.9and 15.1v? continuingwith this test.
YES-Alternator/regulatoroperationis OK.I
ENGINE
WIREHARNESS
6PCONNECTOR
Wiresideof femaleterminals
ls there 1 V or less?
YES Go to step 8.
N O - G o t o s t e p5 .
5 . T u r nt h e h e a d l i g h t a
s n d i g n i t i o ns w i t c hO F F .
6 . DisconnectECMconnectorB (24P).
\,
4-24
\
1 2 3 t 4t 5 6 1 1 2 3 1 4 l 5 l l6l 7
8 9 10 ,/1,/ 3 5 8 9 10 t.) 15
11o nt,/21 23 11o n
21 23
ACGC{WHT/GRN} ACGC(WHT/GRN)
o C (WHT/GRN)
o
2 3
5 6
Wire side ot femaleterminals
ENGINEWIREHARNESS6P CONNECTOR
Wire side oI lemale terminals
ls there continuity?
ls therc continuity?
YES-Repair short to ground in the wire between
the alternatorand the ECM.I YES Repairor replacethe startersubharnessor
the alternator(seepage 4-30).I
NO-Check that the terminalsare firmly seatedat
the ECMconnectorB. lf OK, substitutea known- NO Repairopen in the wire betweenthe
good ECM,and recheck(seepage 11-6). a l t e r n a t oar n d t h e E C M . I
lf prescribedvoltage is now available.replacethe
L o r i g i n aE
l CM,I
9 . DisconnectECMconnectorB (24P).
4-25
ChargingSystem
DriveBelt Inspection DriveBelt Replacement
indicator(A)is withinthe
Checkthatthe auto-tensioner 1, Move the auto-tensioner(A) to relievetensionfrom
standardrange (B)as shown.lf it is out of thestandard the drive belt (B).and removethe drive belt.
range,replacethedrivebelt(seepage4-26).
4-26
\
DriveBelt Auto-tensionerInspection
1 . Checkwhether there is a changein the positionof Removethe auto-tensioner(seepage 4-28).
the auto-tensionerindicatorbeforestartingthe
engineand after startingthe engine.lf there is a I n s t a ltlh e t e n s i o n e p
r ulley.
c h a n g ei n t h e p o s i t i o nr, e p l a c et h e a u t o - t e n s i o n e r .
7 . Clampthe auto-tensioner(A) by using two 8 mm
bolts (B)and a vise (C)as shown. Do not clamp the
auto-tensioneritself.
C h e c kf o r a b n o r m a n l o i s ef r o m t h e t e n s i o n e p r ulley.
lf abnorman l o i s ei s h e a r d ,r e p l a c et h e t e n s i o n e r
pulley.
4-27
ChargingSystem
DriveBelt Auto-tensionerReplacement
1. Removethe drive belt (seepage 4'26). 4. Removethe auto-tensioner,
2 . R e m o v et h e i d l e rp u l l e y .
6xl.0mm
9.8 N.m
(1,0kgl.m,
7.2 tbf.ft)
I
6x1,0mm
12 N.m
('1.2kgt.m.8.7lbt.ft)
x 1.25mm
22 N.m
{2.2 kgt m, 16 lbf ft}
\-a
4-28
l\- AlternatorReplacement
1. Make sure you havethe anti-theftcode for the radio, 9 . Removethe alternator.
then write down the frequenciesfor the radio's
preset buttons, 1 0 . Installthe alternatorand drive belt in the reverse
order of removal.
2. Disconnectthe negativecablefrom the batteryfirst,
then disconnectthe positivecable. 'I
1 . Connectthe positivecable and negativecableto
the battery.
3. Removethe front bumper (seepage 20-85).
tt. Enterthe anti-theftcode for the radio,then enter
4. Removethe right side headlight(seepage 22-79). the customer'sradio station presets.
6. Removethe drive belt (seepage 4-26). 1 4 . Performthe enginecontrol module {ECM)idle learn
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
7. Removethe three bolts securingthe alternator.
8 x 1 . 2 5m m
22 N.n 12.2kgl.m,
8 N.m
10.8kgf.m,6lbf.ft)
\
6
4-29
ChargingSystem
AlternatorOverhaul
ExplodedView
-
W|UF.,.oy." REARBEARING /
ROTOR
\ \ /
\ ,/ ./ FRoNrB
BEARING
@b.J.y{=RE+LN'"'
vVFko"-% \ I/
qtr*njlv
V ("rV) , PULLEY
BRUSH \11
-\\
/ PULLEY
BRUSH
HOLOER HOLDER LOCKNUT
TNSULATOR \ \l \ /
\ \ VOLTAGE
REGULATOR
}
(- /@
\-
@*F,-\:
\
v_re*^i \-a
\gP^@'I
TERMINAL
*ffilw9
INSULATOR
REARHOUSING
ASSEMBLY
INSULATOR
BUSHING
4-30
L
Special Tools Required 5 . R e m o v et h e e n d c o v e r( A )a n d d u s t s e a l{ B ) .
. Driver07749-0010000
. Attachment,52x 55 mm 07746-0010400
, (( , t tI
; r _l L t
L1i.21---^
tqLJ
1!q[-dr,:l
(cont'd)
4-31
ChargingSystem
AlternatorOverhaul(cont'dl
7. Removethe four screws,then removethe rectifier 9. lf you arenot replacing
the frontbearingand/or
( A )a n d f o u r i n s u l a t o r (sB ) . '16.
rearbearing,go to step Removethe rotorfrom
the statordriveendhousing.
f.r,e
4-32
\-
1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a
yvailable
tools 14. Supportthe stator housingin a vise, and drive out
shown, installa new rear bearingon the rotor shaft. the front bearingwith a brassdrift and hammer.
NOTE:Installthe bearingusing the inner race.
1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si ,n s t a l a
l new
front bearingin the stator housing.
13. Removethe front bearingretainerplate.
sH qE
6 e
u s 07749-0010000
f-\
\r-:1
\s---'^/
07746-0010400
( c o n t ' d)
4-33
ChargingSystem
AlternatorOverhaul(cont'd)
Rectitier Test Alternator Brush Inspection
/--:',t- -L . --
- -o \-- l'-=
\"
Rotor Slip Bing Test
P,
P.
P,
P.
4-34
Stator Test
'--l-- --i
4-35
GruiseControl
ComponentLocationIndex
CRUISECONTROLINDICATOR
(Builtinto gaug6assembly)
- l l
t.- _,- _
CRUISE CONTROL
ACTUATOR
Test,page4'43 ACTUATORCABLE
Replacement,page4-44 Adjustment,page4-45
\-a
4-36
CircuitDiagram
'
No.aloAl USAnod.l
No.20itoAl C.md! modrl
fUS'/iILAY IOX
UISEF NOOD
lcl H0Tii0llilll
mdSTARTlllll
1 Honilsffroi
2 6 1 1 1 3
uNtT
cnu6EcoNTnoL l0
CTuICIIPEDAL
P0sm0swtrct
4-37
CruiseControl
Symptom TroubleshootingIndex
NOTE:
' The numbersin the table showthetroubleshootingsequence.
. Beforetroubleshooting.
- checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dashfuse/relaybox. and the No. 7 (15A)
fuse in the
under-hoodfuse/relaybox,
- checkthat the horn sounds.
- checkthe tachometerto see if it works properly.
- checkthe speedometerlo see if it works properly.
4-38
svmptom Diagnosticprocedure Also check for
Set speeddoes not 1. Checkmain switch (seepage 4-42) Short to power in
cancelwhen main switch 2. Checkcruisecontrol unit (seepage 4-40) the LT GRNwire.
i s o u s h e dO F F
Set speeddoes not 1. CheckSET/RESU ME/CANCELswitch (seepage 4-42) Opencircuit,loose
c a n c ewl henCANCEL 2. Checkcruisecontrol unit (seepage 4-40) or disconnected
button is pushed terminals:
GRYiRED,
LTGRN/BLK
Set speedwill not 1. CheckSET/RESU ME/CANCELswitch (seepage 4-42) Open circuit,loose
r e s u m ew h e n R E S U M E 2. Checkcruisecontrol unit {seepage 4-40) or disconnected
button is pushed(with terminals:
main switch on, and set L TG R N / B L K
speedtemporarily
cancelledby pressingthe
brakeDedal)
4-39
CruiseGontrol
CruiseControl Unit Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
Wire sideof
femaleterminals
4-40
Cavity Wire Test condition Test:Desiredresult Possible cause il resultis notobtained
6 GRYiRED Setbuttonpushed Checkfor voltageto ground: B l o w nN o . 7 ( 1 5A ) f u s e i n t h e
Thereshould be battery under-hoodfuse/relaybox
voltage, Faultyhorn relay
W h e nt e s t i n gt e r m i n a lN o . 6 , Faultysevresume/cancel
there should be no voltageon swrtch
t e r m i n a lN o . 7 . Faultycable reel
7 LT GRN/ Resumebutton Checkfor voltageto ground: An open in the wire
BLK pusneo Thereshould be battery Shon to ground (horn sounds
voltage. when button is pressed)
W h e nt e s t i n gt e r m i n a lN o . 7 ,
there should be no voltageon
t e r m i n a lN o . 6 .
BRN Connectbattery Checkthe operationof the . Faultyactuator
11 BRNI/EL power to the BRN actuatormotor: You should . An open in the wire
t e r m i n a la n d g r o u n d be ableto hear the motor.
to the BRNIVEL
termrnal
10 BLUIVEL lgnitionswitch ON Attachto groundi Blown No. 10 (7.5A) fuse in
0r) C r u i s ei n d i c a t o lri g h ti n t h e the under-dashfuse/relaybox
g a u g ea s s e m b l ys h o u l dc o m e Blown cruise indicatorbulfl
on. F a u l t yg a u g ea s s e m b l y
An open in the wire
12 BLU/VVHT lgnitionswitch ON Checkfor voltage between FaultyVSS
(ll) and main switch thE BLU/VVHT (+) ANdBLK An openin thewire
ON; raisethe front of ( )terminals: Shortto ground
the vehicle,and T h e r e s h o u l d b e 05 V o r
rotateone wheel more repeatedly.
s l o w l yw h i l e h o l d i n g
the other wheel
13 LTGRN lgnitionswitchoN Checkfor voltageto ground: B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
{ l l )a n dm a i ns w i t c h Thereshouldbe battery under-dashfuse/relaybox
ON voltage. Faultymain switch
An oDenin the wire
14 LT BLU C l u t c hp e d a l Checkfor continuityto Faultyclutch pedal position
reteaseo grouno: swtlcn
T h e r es h o u l db e c o n t i n u i t y . P o o rg r o u n d( G 5 0 1 )
N O T E : T h e r se h o u l db e n o Incorrectclutchswitch
continuitywhen the clutch adjustment
oedal is Dressed. An open in the wire
lf any test indicatesa problem,find and correctthe cause,then recheckthe system.lf all the input tests prove OK,
the cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works
properly,replacethe cruisecontrol unit.
4-41
CruiseControl
Main Switch Test/Replacement Set/Resume/Cancel
Switch Test/
Replacement
1 . Removethe driver's dashboardlower cover (see
page 20-59).
1. Removethe two screws.then removethe switch.
Releasethe clips of the main switch and push the
main switch 1A)out of the panel,then disconnect
the 5P connector(B)from the main switch.
\-------11v1 1 4
\
;"itl*
Terminal
'\ 2
Position
sET(ONt CF --o
OFF (9 @ --o
RESUME
ION) o
ON o @ o \J o CANCEL{ON}
o
r\--
4-42
CruiseControlActuatorTest
1. Disconnectthe 4P connector(A) from the cruise 6. Checkthe operationof the actuatormotor in each
control actuator(B). output linkagepositionaccordingto the table.You
should be able to hear the motor.
OUTPUTLINKAGE
2. Removethe cover (A),and checkthe output linkage
(B)for smooth movement.
,to
FULLCLOSE
C h e c kf o r a c l i c k i n gs o u n df r o m t h e m a g n e t i cc l u t c h .
The output linkageshould be locked.
4-43
CruiseControl
CruiseControlActuator/CableReplacement
1 . Fully open the cruisecontrol link by hand,then 3 . Removethe actuatorcover (A),then removethe
removethe cruisecontrol cable{A) from link. actuatorcable (B)from the cruisecontrol actuator.
Loosenthe locknut(B),and removethe cablefrom
the bracket.
6x1,0mm
12 N.m (1.2kgf.m,8.7lbf.ft)
\rla
4-44
ActuatorCableAdiustment ClutchPedalPositionSwitch Test
1. Checkthat the actuatorcable{A) moves smoothly 1. Disconnectthe 2P connectorfrom the clutch pedal
with no binding or sticking. positionswitch (A),
SWITCH2PCONNECTOR
CLUTCHPEOALPOSITION
T e r m i n a l s i do
ef
m a l et e r m i n a l s
2. Startthe engine.
Terminal
Cl"t"h P"d"l I 1 2
PositionSwitch
PRESSED
RELEASED o o
4-45
EngineAssembly
EngineRemoval \,
5. Removethe intakemanifoldcover.
II
5-2
8. Removethe intakeair duct. 10. Fullv ooen the throttle link and cruisecontrol link
by hand,then removethe throttlecable (A) and
c r u i s ec o n t r o lc a b l e( B ) f r o mt h e l i n k s .L o o s e nt h e
locknuts{C),and removethe cablesfrom the
bracket.
1 1 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
1 2 . R e m o v et h ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) .
(cont'd)
5-3
EngineAssembly
EngineRemoval(cont'dl ..4,
1 4 . R e m o v et h e c l u t c hs l a v ec y l i n d e r{ A )a n d c l u t c h l i n e 16. Disconnectthe engine control module (ECM)
bracketmounting bolt (B). connectors(A) and main wire harnessconnector
(B).
't7. Remove
the harnessclamps (A) and grommet (B),
t h e n p u l l t h ee n g i n ew i r e h a r n e s st h r o u g ht h e
bulkhead.
\l,
5-4
1 8 .Removethe drive belt (seepage 4-26). 30. Disconnectthe air fuel ratio {4,/F)sensorconnector
(A) and secondaryheatedoxygen sensor
1 9 .R e m o v et h e l v C l i n e m o u n t i n gb o l t . (secondaryHO2S)connector(B),then removethe
three way catalyticconverter{TWC)assembly{C).
2 1 . R a i s et h e h o i s tt o f u l l h e i g h t .
o@
2 4 . L o o s e nt h e d r a i np l u g i n t h e r a d i a t o r t od r a i nt h e
enginecoolant(seepage 10-6).
2 5 . D r a i nt h e t r a n s m i s s i ofnl u i d ( s e ep a g e1 3 ' 3 ) .
t e s t a b i l i z el ri n k s( s e ep a g e1 8 - 1 8 ) .
2 7 . D i s c o n n e ct h
5-5
EngineAssembly
EngineRemoval(cont'd)
32. Lowerthe hoist. 36. Removethetransmission
mountbracketsupport
boltandnuts.
33. Removethe upperhose(A)andheaterhoses(B).
5-6
Make sure the hoist bracketsare positioned 41. Attachthe subframeadaptertofrontofthe
properly.Raisethe hoist to full height. subframe,thentightenthe knurledknob.
40. Removethefrontmountbracketmountinqbolt.
(cont'd)
5-7
EngineAssembly
EngineRemoval(cont'd)
43. Use a markerto make alignmentmarks on the 45. Disconnectthe compressorclutchconnector(A),
referencelines(A) that align with the centersof the then removethe Ay'Ccompressor(B)without
r e a rs u b f r a m em o u n t i n gb o l t s( B ) . disconnectingthe A'./Choses.
:r -
, !:_- _l.= -- ---.-','-
ffi4
ffit'"
4 7 . S l o w l yl o w e rt h e e n g i n ea b o u t1 5 0m m ( 6 i n . ) .
C h e c ko n c ea g a i nt h a t a l l h o s e sa n d w i r e sa r e
disconnectedtrom the engine/transmission.
5-8
Enginelnstallation
Special Tools Required
FrontsubframeadapterEOS02C00001
1
ENGINEMOUNTBRACKET
1 0x 1 . 2 5m m
il4 N.m {4.5kgf.m,33lbl.ft)
A/C COMPRESSOR
BRACKET
10 x 1,25mm
44 N.m {4.5kgf.m,33lbt.ft)
(cont'dl
5-9
EngineAssembly
EngineInstallation(cont'd)
Positionlhe engine under the vehicle.Attachthe 5. Installthe subframe(A).Alignthe reference marks
chain hoistto the engine,then lift the engine into (B)on the subframewiththe centerof the bolt
p o s i t i o ni n t h e v e h i c l e . h e a d st ,h e nt i g h t e nt h eb o l t s .
1 4 x 1 . 5m m
103Nm
{ 1 0 , 5k g f m .
6r" F 76 rbt.ftl
Replace.
I
6-_-'-
l 0 x 1 . 2 5m m
59 N.m (6.0 kgf.m, 4:] lbI.ft)
5- 10
7. Looselytightenthe front mount bracketmounting 10. Tightenthe transmissionmount bracketsupport
bolt. bolt and nuts.
1 2x 1 . 2 5m m
54 N m {5.5kgt m, 40 lbf.ft}
' t 2 . Tighten
the front engine mount bracketmounting
bolt.
12x 1.25rnrn
64 N.m{6.5kgf.m,
47 tbt.ftl
:l
1 4 . R e m o v et h e c h a i nh o i s tf r o m t h e e n g i n e .
'15.
I n s t a l l t h er a d i a t o r( s e ep a g e1 0 - 1 0 ) .
'16.
R a i s et h e h o i s tt o f u l l h e i g h t .
(cont'd)
5-11
EngineAssembly
EngineInstallation{cont'dl
1 8 . Connectthe suspensionlower arm ball joints (see 2 3 . I n s t a l l t h es p l a s hs h i e l d .
s t e p6 o n p a g e1 8 - 1 9 ) .
10x 1.25mm
33 N.m{3.i1kgf.m,
25 tbt.ftl
25. I n s t a l l t hder i v eb e l t .
26. InstalltheA,/Clinemountingbolt.
6 x '!.0mm
9.8 N.m (1.0kgf.m,
7.2 tbt.ftl
-d
,ry
6\
8 x 1.25mm
22N.m |.2.2kglm,
\ 16tbt.ft)
D
v a
5-12
27. lnstallthe upper radiatorhose {A) and heaterhoses 30. Connectthe ECI\4connectors(A) and main wire
(B). harnessconnector(B).
Pushthe enginecontrolmodule(ECM)connectors
throught h eb u l k h e a tdh, e ni n s t a l l t hger o m m e(tA ) .
2 9 . I n s t a l l t h eh a r n e s sc l a m p s( B ) .
3 4 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
(cont'd)
5-13
EngineAssembly
EngineInstallation{cont'dl \"
Installthe selectcable (A) and shift cable(B) using 37. Installthe batterycables(A) on the under-hood
the plasticwashers(C),washers(D),and new cotter fuse/relaybox, then installthe harnessclamp (B).
p i n s( E ) .
6x1.0mm
9.8N.m(1.0kgf.m, 6x1.0mm
7.2tbl.ftl 12Nm{1.2kgt.m,
8.7rbf.ft)
"-.----->)
"------'6
I n s t a l l t h eg r o u n dc a b l e( C ) .
3 9 . I n s t a l l t h ei n t a k ea i r d u c t .
6x1.0mm
12Nm{1.2kgf.m,
I n s t a ltlh e c l u t c hs l a v ec y l i n d e r( A )a n d c l u t c hl i n e 8.7 tbf.ft) \-
bracketmounting bolt (B).
6x1.0mm
8 x '1.25mm 9.8 N.m
24 N.m (2.4kgl.m, {1.0kgf.m,
7.2 tbt.ft)
a
5-14
4 0 . I n s t a ltlh e a i r c l e a n e rh o u s i n q . 4 3 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
6x1.0mm 6x1.0mm
12 N m (1.2kgf.m,8.7lbt.ft) 12Nm11.2kgf.m.
8.7 tbf.ft)
E Y
41. R e f i l l t h ee n g i n ew i t h e n g i n eo i l ( s e ep a g e8 - 5 ) .
n i t h f l u i d ( s e ep a g e1 3 - 3 ) .
48. R e f i l tl h e t r a n s m i s s i ow
5 0 . P e r f o r mt h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n
4 2 . I n s t a l l t h eb r e a t h e hr o s e( C )a n d v a c u u mh o s e1 D ) . p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
52. I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
5 3 . C h e c kt h e w h e e la l i g n m e n {t s e ep a g e1 8 - 4 ) .
5-15
\
EngineMechanical
CylinderHead
SpecialTools 6-2
Comoonent LocationIndex 6-3
EngineCompression Inspection b-t'
VTECRocker Arm Test ........... ............ 6-7
VTCActuatorInspection .................... 6-8
ValveClearance Adjustment ............. 6-9
Crankshaft PulleyRemovaland Installation.............. 6-11
C a mC h a i nR e m o v a l . . . . . . . . . . . . . . . . . . .6. -. 1
. .2. . . .
C a mC h a i nI n s t a l l a t i o n . . . . . . . . . . . . . . . .6. .-.1. .5. .
Auto-Tensioner Removal/1nsta11ation ......................... 6-19
ChainCaseOil SealInstallation ........6-21
CyfinderHeadCoverRemoval .......... 6-22
CylinderHeadRemoval ..................... 6-23
WC Actuator.ExhaustCamshaftSorocket
R e paf c e m e n t .........6-24
Cylinder Head Inspection for Warpage...................... 6-25
Rocker Arm AssemblyRemoval................................. 6-26
Rocker ArmsandShafts
Disassembly/Reassembly .............. 6-27
Rocker ArmsandShaftsInspection............................ 6-28
Camshaft Inspection .......................... 6-29
Valves,Springs,andValveSealsRemoval................ 6-31
ValveInsoection...................... ........... 6-32
ValveStem-to-Guide Clearance Insoection............... 6-32
ValveGuideReolacement ................. 6-33
ValveSeatReconditioning ................ 6-35
Valves,Springs, andValveSealsInstallation............ 6-37
Rocker Arm AssemblvInstallation .... 6-38
C v l i n d eHr e a dI n s t a l l a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 3
. .9. . . . . . . . . .
CylinderHeadCoverInstallation ......6-41
CylinderHead
SpecialTools a
Ref. No. Tool Number Description Oty
O OTAAJ.PNAA'IOO Air Pressure Regulator 1
.D OTHAH-PJ7O1OB V a l v eG u i d eR e a m e r5, . 5m m 1
o ozoa
I oz..rae-oot Socket,19 mm 1
@ 07JAB-0010204 H o l d e rH a n d l e 1
o 07NAB-0010404 HolderAttachment,50 mm 1
G) 07VAE-001010A Valve Spring CompressorAttachment 1
OTZAJ.PNAAlOO VTECAir Adapter 2
E] OTZAJ-PNAA2OO VTECAlr Stopper 1
Air Joint Adapter 1
O I 07ZAJ-PNAA300
tro 07742-0010100 V a l v eGu i d eD r i v e r , 5 . 5m m
I
@ 07746-001o4oo Attachment,52 x 55 mm
(D 07749-0010000 Driver
- -- -i
-- - l-:
'a- ti-- -
- 1jr-
r-
,.
',..)-)--'
@ o o
''
,- ,)
..'.,i2
a:-t'"
,.-/
Lq-,
r--\
.<:'':'v''
5'r'
o a l?
..#
..a:-"
/":
't'tY-,l
-- -'''
a,/'/'
@ OD @
6-2
ComponentLocationlndex
IGNITIONCOIL
COVER
CYLINDER HEAD
COVER
Removal, page6-22
page6-41
lnstallation,
CAM CHAIN
Bemoval,page6-'12
Installation,page6-15
CAM CHAINGUIDEA
"p
| ] t J,
VARIABLE VALVE
TIMINGCONTROL
twc) olL soLENotD
VALVE
CRANKSHAFT PULLEY
R e p l a c e m e npt a
, g e6 1 1
TENSIONER
ARM
AUTO.TENSIONER
page6-'lI
Replacement, O-RING
(cont'd)
6-3
CylinderHead
ComponentLocationIndex(cont'd)
CAMSHAFT
HOLDER
Fg
Y f\
R fr CAMCHAIN
GUIDEB
LI T
F]
EEI /
CAMSHAFTPOSITION -"-oowetew
ICMP}SENSOR g-----
TOPDEADCENTER
(TDC)SENSOR
EXHAUSTCAMSHAFT
SPROCKET
Removal,page6 24
page6-25
Installation,
EXHAUSTCAMSHAFT
ROCKER ARM
ASSEMBLY
Overhaul,page6 27
Inspection,page 6-28
6-4
.\
SPRING
RETAINER
ll"
>il( G\-r_
d:l.\
aFl
\ l gg
| | -/ TNTAKE
vALVE
EXHAUSTVALVE
T1 II ^-'-- 9E4L
--€.i
SEAL l l I I U- Replacement, Page6-31
l* I / uo.ur.r","o l l H e ,
H tl
Y
E-
I 1.-
U
_-/ |NTAKEVALVE
GUIDE
page6-33
Replacement,
,p
2bw
9)
\*""'RArNERcovER
wcsrRArNER
\
CYLINDER HEAD
Removal,page6'23
Inspection,page6-25
HEATSHIELD Installation,page6-39
EXHAUSTVALVE
Removal,page6-31
Installation,page6-37
INTAKEVALVE
Removal,page6 31
Installation,page6 37
CYLINDER
HEAD
GASKET
6-5
CylinderHead
EngineCompressionInspection \
\-
V,
6-6
WEC RockerArmsTest
Special Tools Required Repeatstep 3 on the remainingintakeprimary
. Air pressureregulator07AAJ-PNAA100 rockerarms with each piston at TDC.When all the
. VTECair adaoter07ZAJ-PNAA100 primary rockerarms passthe test, go to step 5.
. WEC air stoDoer07ZAJ-PNAA200
. Air joint adapter07ZAJ-PNAA300 Checkthat the air pressureon the shop air
compressorgauge indicatesover 400 kPa
1. Removethe cylinder headcover (seepage 6-22). (4 kgflcm',57 psi).
2. Set the No. 1 pistonat top dead center(TDC)(see 6 . Inspectthe valve clearance(seepage 6-9).
step 1 on page6-12).
7 . Removethe sealingbolt (A)from the relief hole,
3. Verify that the intakeprimary rockerarm (A) moves and installthe VTECair stopper(B).
independentlyof the intakesecondaryrockerarm
(B). D
OTAAJ.PNAAlOO OTZAJ-PNAA3OO
OTZAJ.PNAAlOO
(cont'd)
6-7
CylinderHead
WEC RockerArms Test (cont'dl VTGActuator Inspection
'10. '11.
Loosenthe valve on the regulator,and apply the Removethe cylinder headcover (seepage 6-22lr.
specifiedair pressure.
2. Removethe auto-tensioner(seepage6-19).
Specified air pressure:
290 kPa 13.0kgt/cm', 42 psi) 3. Loosenthe rockerarm adjustingscrewslsee step 2
on page6-26).
NOTE:lf the synchronizingpiston does not move
after applyingair pressure;move the primary or 4. Removethe camshaftholder (seestep 3 on page 6-
secondaryrockerarm up and down manuallyby 26t.
rotatingthe crankshaftclockwise.
5. Removethe intakecamshaft.
1 1 . W i t h t h e s p e c i f i e da i r p r e s s u r ea p p l i e d m
, o v et h e
i n t a k ep r i m a r yr o c k e ra r m ( A ) f o r t h e N o , 1 c y l i n d e r . 6, Checkthat the variablevalve timing control (VTC)
The primary rockerarm and secondaryrockerarm actuatoris lockedby turning the VTCactuator
( B )s h o u l dm o v e t o g e t h e r . clockwiseand counterclockwise. lf the VTC actuator
is not locked,replacethe VTCactuator.
lf the intakesecondaryrockerarm does not move,
removethe primary and secondaryrockerarms as 7 . S e a lt h e a d v a n c eh o l e s( A ) a n dr e t a r dh o l e s( B )i n
an assembly,and checkthat the pistonsin the the No. 1 camshaftjournal with tape.
primary and secondaryrockerarms move
smoothly.lf any rockerarm needsreplacing,
replacethe primary and secondaryrockerarms as
an assembly,and test.
1 2 .Removethe specialtools.
1 4 . T i g h t e nt h e s e a l i n gb o l t t o 2 0 N . m ( 2 . 0k g f . m ,
14 tbf.ft).
t5. I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
6-8
ValveGlearanceAdiustment
9. Apply air to the advancehole to releasethe lock. NOTE:Adjust the valvesonly when the cylinder head
temperatureis lessthan 100'F (38'C).
{cont'd)
6-9
GylinderHead
ValveClearanceAdjustment (cont'd) \. I
feelergaugefor the
3. Selectthe correctthickness 5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e
valvesyou'regoingto check. locknut(A),and turn the adjustingscrew {B) until
the drag on the feelergauge is correct..
Intake: 0.21 0.25mm (0.008-0.010 in.)
Exhaust; 0.28 0.32mm (0.011 0.013in.)
Adiustingscrew locations:
EXHAUST
No. 1 N o .2 No.3 N o .4
6-10
CrankshaftPulleyRemovaland
Installation
9. Rotatethe crankshaft180"clockwise(camshaft
pullevturns 90').
Special Tools Required
. Holder handle07JAB-001020A
. Holderattachment,50 mm 07NAB-001040A
. Socket,19 mm 07JAA-001020,4 or a commercially
a v a i l a b l e1 9 m m s o c k e t
Removal
1. Removefront tires/wheels.
3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e( A )a n d h o l d e r
attachment(B).
B
1 0 .Checkand, if necessary,adjustthe valve clearance 07NAB-001040A
on No.4 cylinder.
1 1 .Rotatethe crankshaft180"clockwise(camshaft
el / Srroo.oo,oroo
p u l l e yt u r n s9 0 " ) . (or
/ commercially
f available)
(cont'd)
6-11
CylinderHead
CrankshaftPulleyRemovaland CamChainRemoval a
Installation(cont'dl
NOTE:Keepthe cam chain away from magneticfields.
. .: Clean
O; Lubricate
ll
ll
t[] rL
-'....-----=a
(-, ,
5U-1J
It
t -
2 . Removethe front tires/wheels.
I n s t a l l t h ec r a n k s h a fpt u l l e y ,a n d h o l dt h e p u l l e y 3 . R e m o v et h e s p l a s hs h i e l d .
with holder handle(A) and holder attachment{B).
- , , - - . = . - - - - - _ _ - - _
B
07NAB-0010iroA
\
A
07JAB-001020A
Tightenthe bolt to 245 N.m (25.0kgf.m, 181 tbf.ft) 5. Removethe cylinder headcover (see page6-22).
with a torque wrench and 19 mm socket(C).Do not
use an impactwrench. 6 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .
I n s t a ltl h e s p l a s hs h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) .
\-
6-12
7. Disconnectthecrankshaftposition(CKP)sensor 1 1 . R e m o v et h e s i d ee n g i n em o u n tb r a c k e t .
connector{A) and variablevalvetiming control
{VTC)oil control solenoidvalve connector(B).
1 2 . R e m o v et h e c h a i nc a s e .
(cont'd)
6-13
CylinderHead
CamChainRemoval(cont'd) \ (
1 7 . R e m o v et h e c a m c h a i ng u i d eB .
gffi
llll
t5. Align the holes on the lock (A) and the auto-
t e n s i o n e (r B ) ,t h e n i n s e na 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft
clockwiseto securethe Din.
U U a
\-
6 -14
CamChainInstallation
1 8 . R e m o v et h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r NOTE:Keepthe cam chain away from magneticfields.
a r m( B ) .
1. Set the crankshaftto top dead center(TDC).Align
t./6. | \
,o the TDC mark {A) on the crankshaftsprocketwith
t h e p o i n t e r( B )o n t h e c y l i n d e rb l o c k .
{n$1J;
g"'-
(cont'd)
6-15
GylinderHead
CamChainInstallation(cont'dl \ {
6x1.0mm
1 2N . m
{1,2kgf.m,
8.7 tbf.ftt
'6I
8 x 1 . 2 5m m
22 N.m
Installthecam chain on the VTCactuatorand 12.2kgt.m,
exhaustcamshaftsprocketwith the punch marks 16tbf.ft)
(A) alignedwith the two colored pieces(B).
6. Installthe auto-tensi
B
6x1,0mm
12Nm
(1.2kgt.m,8.7 lbf ti)
a
6-16
7 , I n s t a ltlh e c a m c h a i ng u i d eB . 1 0 .Removeold liquid gasketfrom the chain case
mating surfaces,bolts,and bolt holes.
8 x 1.25mm
H4
\ilt
22 N.m
(2.2kgf.m,16lbt.ft) 1 1 .Cleanand dry the chain case mating surfaces.
H g
q
t o t h e i n n e rt h r e a d so f t h e h o l e s .
(cont'd)
6-17
GylinderHead
CamChainInstallation(cont'd) t {
'15.
Installthe new O-ring(A) on the chain case.Set the 1 6 . l n s t a l l t h es i d ee n g i n em o u n t . b r a c k e t .
edge of the chain case (B)to the edge of the oil pan
( C ) ,t h e n i n s t a ltl h e c h a i nc a s eo n t h e c v l i n d e rb l o c k
(D).
',.9
a
6x1.0mm
1 2N . m 6x1.0mm
(1.2kgt.m.8.7lbf.ft) 12Nm I
(1.2kgf.m,8.7lbf.ft) \
1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .
\-
6-18
Auto-TensionerRemovaU
lnstallation
1 9 . lnstallthe variablevalve timing control (VTC)oil
c o n t r o ls o l e n o i dv a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) .
Removal:
20. Connectthe crankshaftposition(CKP)sensor
connector{A) and VTC oil control solenoidvalve 1 . R e m o v et h e c h a i nc a s ec o v e r .
connector(B).
2 2 . I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
2 3 . I n s t a l l t h ed r i v eb e l t .
2 4 . I n s t a l l t h es p l a s hs h i e l d .
€D@
{cont'd)
6-19
GylinderHead
Auto-TensionerRemoval/lnstallation(cont'dl \
3. Align the holes on the lock (A) and the auto- Installation:
t e n s i o n e (r B ) ,t h e n i n s e r ta 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft 1. Installthe auto-tensioner.
clockwiseto securethe oin.
6x1.0mm
4. Removethe auto-tensioner. 12 N.m {1.2kgt.m,8.7 lbt.tt)
\ a
\-
6-20
ChainCaseOil SealInstallation
Removeold liquid gasketfrom the chain casecover SpecialToolsRequired
mating surfaces,bolts,and bolt holes. . Driver07749-0010000
. Attachment,52 x 55 mm 07746-0010400
4 . Cleanand dry the chain casecover mating surfaces.
1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l
Apply liquid gasket,P/N 08718-0009, evenlyto the squarelyinto the chain caseto the specified
chain case mating surfaceof the chain casecover i n s t a l l e dh e i g h t .
and to the innerthreadsof the holes.
6x1.0mm
1 2N . m
{1.2kgt.m,
8.7 tbf.ft)
33.0 33.7mm
{ 1 . 3 0 1 . 3 3i n . l
6-21
GylinderHead
CylinderHeadCoverRemoval \ (
V:t :;t 1
|,'.i/
\-
6-22
GylinderHeadRemoval
NOTE: 8. Removethe enginewire harnessconnectorsand
. Usefendercoversto avoiddamagingpainted wire harnessclampsfrom the cylinder head.
surfaces.
To avoid damage,unplug the wiring connectors . Enginecoolanttemperature(ECT)sensor
carefullywhlle holdingthe connectorportion. conneclor
To avoid damagingthe cylinderhead,wait until the . Camshaftposition(Cl\4P)(top dead center(TDC))
enginecoolanttemperaturedrops below 100'F(38"C) sensor B connector
betore looseningthe cylinder head bolts. . Camshaftposilion (CMP)sensorA connector
Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or 9. Removethe upper radiatorhose (A) and heater
hoses,or interferewith other parts. h o s e( B ) .
' 1 .Drainthe
enginecoolant(seepage 10-6).
'10.
Removethe harnessholder (A)from the bracket,
then removethe connectingpipe mounting boh {B)
and brakeboostervacuum line mounting bolts {C).
(cont'd)
6-23
CylinderHead
CylinderHeadRemoval(cont'd) VTCActuator,ExhaustCamshaft \
SprocketReplacement
Removethe rockerarm assembly(seepage 6-26).
1 4 . R e m o v et h e c y l i n d e rh e a d .
I
\ (
I
6-24
CylinderHeadInspectionfor
Warpage
Installation:
1. Installthe VTC actuatorand exhaustcamshaft 1 , Removethe cylinder head{see page 6-23).
sprocket.
Inspectthe camshaft(seepage 6-29).
2. Apply engineoil to the th readsof the VTC actuator
mounting bolt and exhaustcamshaftmounting bolt, Checkthe cylinder headfor warpage.Measure
then installthem. along the edges,and three ways acrossthe center.
4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .
6-25
CylinderHead
RockerArm AssemblyRemoval
'1. 4 . Removethe cam chain guide B, camshaftholders,
Removethe cam chain (seepage 6-12).
and camshafts.
2 . Loosenthe rockerarm adjustingscrews (A),
5 . Insertthe bolts (A) Into the rockershaft holder,then
A removethe rockerarm assembly(B).
CAMSHAFTHOLDERBOLTS LOOSENING
SEOUENCE:
\- {
6-26
RockerArms and ShaftsDisassembly/Reassembly
NOTE:
ldentifypartsas they are removedto ensurereinstallationin original location.
Inspectthe rockershaftsand rockerarms (seepage 6-28).
The rockerarms must be installedin the same positionsif reused.
When removing or installingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep
the holders,springsand rockerarms on the shaft.
Priorto reassembling,cleanall the parts in solvent,dry them, and apply lubricantto any contactpoints.
Bundlethe rockerarms with rubber bandsto keeDthem tooetheras a set.
EXHAUSTROCKER
SHAFT
EXHAUSTROCKER
ARM
rffin
,ffif-
wASHEB Yr rY Y V
\nl I ltnrllln
IJI_J;-L,JLI
[]1_L^|l]
'rl)
70) o
.;.
..1
t:l P
,q
'l
- l
,,_tl
o
INTAKE ROCKER
ARM ASSEMBLY
INTAKEROCKERSHAFT
6-27
CylinderHead
RockerArms and ShaftsInspection \
,,,@@
6-28
GamshaftInspection
NOTE:Do not rotatethe camshaftduring inspection. 3. Seatthe camshaftby pushing it away from the
camshafp t u l l e ye n d o f t h e c y l i n d e rh e a d .
1. Removethe rockerarm assembly(seepage 6-26).
and disassembleit (seepage6-27). 4. Zero the dial indicatoragainstthe end of the
camshaft,then push the camshaftbackand forth
2. Putthe rockershaft holders,camshaft,and and read the end play. lf the end play is beyondthe
camshaftholderson the cylinderhead,then tighten servicelimit, replacethe camshafthead and
the bolts to the specifiedtorque. recheck.lf it is still beyondthe servicelimit, replace
thecylinder.
Specified torque:
I mm bolis: CamshaftEnd Play:
22 N.m {2.2kgt m, 16lbf.ft} Standard{New}:0.05 0.20 mm
6 mm bolts: (0.002 0.008in.l
12 N.m {1.2kgf.m,8.7 tbf.ftl ServiceLimit: 0.4 mm (0.02in.)
6 mm bolts: @, €0, @
(cont'd)
6-29
CylinderHead
CamshaftInspection(cont'dl \ {
Unscrewthe camshaftholder boltstwo turns at a 10. Checkthe total runoutwith the camshaftsupported
time, in a crisscrosspattern.Then removethe on V-blocks,
camshaftholdersfrom the cylinder head.
. l f t h e t o t a l r u n o u to f t h e c a m s h a f its w i t h i nt h e
Lift the camshaftsout of the cylinder head,wipe servicelimit, replacethe cylinder head.
them clean.then inspectthe lift ramps.Replacethe . lf the total runout is beyondthe servicelimit,
camshaftif any lobes are pitted,scored,or replacethe camshaftand recheckthe camshaft-
excessivelyworn, to-holderoil clearance.lf the oil clearanceis still
beyondthe servicelimit, replacethe cylinder
1 . C l e a nt h e c a m s h a fjto u r n a ls u r f a c e si n t h e c y l i n d e r neao.
head,then set the camshaftsbackin place.Placea
plastigagestrip acrosseachjournal. Camshaft Total Runout:
Standard(New):0.03mm (0.001in.) max.
Installthe camshaftholders,then tighten the bolts ServiceLimit: 0.04mm {0.002in.)
to the specifiedtorque as shown in step 2.
\-
6-30
Valves,Springs,and ValveSealsRemoval
Special Tools Bequired 4 . I n s t a l l t h ev a l v eg u i d es e a lr e m o v e r .
Valvespring compressorattachment07VAE-001010A
5 . Removet h e v a l v es e a l .
6-31
GylinderHead
ValveInspection ValveStem-to-GuideClearance \
Inspection
1 . R e m o v et h e v a l v e s( s e ep a g e6 - 3 1 ) ,
4,. (
ExhaustValve Stem-to-GuideClearance:
Standard{Newl: 0.055 0.080mm
(0.0022-0.003rin.l
ServiceLimit: 0.11mm (0.004in.)
t- I
6-32
ValveGuideReplacement
SpecialToolsRequired Working from the camshaftside. usethe driver and
. Valveguidedriver,5.5mm 07742-0010100 an aarhammerto drive the guide about 2 mm (0.1
. Valveguidereamer,5.5mm 07HAH-PJ7o108 in.)towardsthe combustionchamber.This will
knockoff some of the carbon and make removal
1 . Inspectvalve stem-to-guideclearance(seepage 6- easier.Hold the air hammer directlyin line with the
32t. valve guide to preventdamagingthe driver.
As illustratedbelow, use a commerciallyavailable Turn lhe head over, and drive the guide out toward
air-impactvalve guide driver (A) modifiedto fit the the camshaftside of the head.
diameterof the valve guides.In most cases,the
same procedurecan be done usingthe specialtool
and a conventionalhammer.
-_|Jfillr-.-4fi'11., tT
-
10.8mm
{0.,|2in.)
(cont'd)
6-33
CylinderHead
ValveGuideReplacement(cont'dl \
Apply a thin coat of clean engineoil to the outside 1 0 .Coat both reamerand valve guide with cutting oil.
of the new valve guide. Installthe guide from the
camshaftside of the head;usethe specialtool to 1 1 .Rotatethe reamerclockwisethe full length of the
drive the guide in to the specifiedinstalledheight v a l v eg u i d eb o r e .
( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o ,
you may have to reheatthe head.
O7HAH.PJ7O1OB
Valve Guide Installed Height:
Intake: 15.2 16.2mm (0.598-0.638in.)
Exhaust: 15.5 16.5mm (0.610-0.650in.) ' - \
s i t h a v a l v e( s e ep a g e6 3 2 ) .
1 4 . C h e c kt h e c l e a r a n c ew
Verifythat a valve slidesin the intakeand exhaust
valve guideswithout exening pressure.
6-34
ValveSeat Reconditioning
1. Inspectvalve stem-to-guideclearance(seepage 6- 5. Make one more very light passwith the 45" cutter
32).lf the valve guidesare worn, replacethem (see to removeany possibleburrs causedby the other
page6-33)beforecuttingthe valve seats. cutters.
3 , C a r e f u l l yc u t a 4 5 ' s e a t ,r e m o v i n go n l y e n o u g h
materialto ensurea smooth and concentricseat.
N O T ET
: h e f i n a lc u t s h o u l da l w a y sb e m a d ew i t h
the 45'cutter.
(cont'd)
6-35
CylinderHead
ValveSeat Reconditioning(cont'dl \ (
\-
6-36
Valves,Springs,and Valve SealsInstallation
Special Tools Required l n s t a l l t h ev a l v es p r i n g .P l a c et h e e n d o f t h e v a l v e
Valve spring compressorattachment07VAE-00101
0A spring with closelywound coils toward the cylinder
ne a o .
1. Coatthe valve stemswith engine oil. lnstallthe
valves in the valve guides. 6 . Installthe valve retainer.
2. Checkthat the valves move up and down smoothly. 7 . Installthevalve spring compressor,Compressthe
spring, and installthe valve keepers.Removethe
Installthespring seatson the cylinder head. valve spring compressor.
6-37
CylinderHead
RockerArm AssemblyInstallation \
:,ean and dry the No. 5 rockershaft holder mating 5 . Removethe bolts from the rockershaft holder.
surfaces.
6 . M a k es u r et h e D U n c hm a r k so n t h e v a r i a b l ev a l v e
eeassemblethe rockerarm assembly(seepage 6- timing control (VTC)actuatorand exhaustcamshaft
2 1t . sprocketare facing up. then set the camshafts(A) in
the holder.
Apply liquid gasket,P/N 08718-0009,evenlyto the
:ylinder head mating surfaceofthe No. 5 rocker
shaft holder.
Specified torque:
8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft)
6 mm bolts: 12 N.m {1.2kgf.m,8.7 lbf.fil
6 mm bolts: @),@.@
6-38
CylinderHeadInstallation
Installthe cylinder head in the reverseorder of 5. Measurethe diameterof each cylinder head bolt at
removat: ooint A and DointB.
l f e i t h e rd i a m e t e ri s l e s st h a n 1 0 . 6m m { 0 . 4 2i n . ) ,
replacethe cvlinder head bolt.
( c o n td )
6-39
CylinderHead
CylinderHeadlnstallation(cont'd) \ {
7 . Apply engine oil to the bolt threadsand under the 10. Installthe rockerarm assembly{seepage6-38).
b o l t h e a d so f a l l t h e c y l i n d e rh e a db o l t s .
1 ' .t Installthe water bypasshose (A).
8 . Tightenthe cylinder head bolts in sequenceto 39
N.m {4.0 kgf.m,29 lbf.ft).Use a beam-typetorque
---l.-.
wrench.When using a preset-typetorque wrench,
be sure to tighten slowly and do not overtighten.lf
a bolt makesany noisewhile you are torquing it,
loosenthe bolt and retightenit from the first step.
B
6 x1.0mm
'r2N.m
c (1.2kgl.m,8.7lbf.ftl
6 x l . 0 m m
'12N,m(1.2kgt.m,8.7
lbf.ft)
9 . After torquing,tighten all cylinderhead bolts in two 1 2 .Tightenthe connectingpipe mounting bolt (B)and
steps(90" per step).lf you are using a new cylinder brakeboostervacuum line mounting bolts (C),then
head bolt,tighten the bolt an extra 90.. i n s t a l l t h eh a r n e s sh o l d e r( D )o n t h e b r a c k e t .
't3. Installthe
upper radiatorhose {A) and heaterhose
(B).
FIRSTSTEP
SECOND
STEP
6-40
GylinderHeadCoverlnstallation
1 4 . I n s t a l l t h ew a t e rb v p a s sh o s e . 1. Thoroughlycleanthe headcover gasketand the
groove.
1 5 . I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 6 . I n s t a l l t h ei n t a k em a n i f o l d( s e ep a g e9 - 5 ) .
2 2 . A f t e ri n s t a l l a t i o nc ,h e c k t h a t a ltl u b e s ,h o s e s a n d
connectorsare installedcorrectly.
2 3 . I n s p e c t f o r f u elle a k sT. u r nt h e i g n i t i o ns w i t c hO N
{ll) {do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel
line. Repeatthls operationtwo or three times, then
c h e c kf o r f u e l l e a k a g ea t a n y p o i n ti n t h e f u e l l i n e .
2 5 . I n s p e ctth e i d l es p e e d( s e ep a g e1 1 - ' 1 3 8 ) .
2 6 . I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
(cont'd)
6-41
GylinderHead
CylinderHeadGoverInstallation(cont'd)
Set the spark plug seals(A) on the spark plug tubes. 7. Tightenthe bolts in two or three steps.In the final
O n c et h e c y l i n d e rh e a dc o v e r( B )i s o n t h e c y l i n d e r s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 9 . 8 N . m ( 1 . 0
head,slide the cover slightly backand forth to seat kgf.m,7.2 lbf.ft).
the head cover gasket.
8 . I n s t a ltlh e d i p s t i c k( A )a n d b r e a t h e hr o s ei B ) .
\l
6-42
9 . Installthe four ignition coils (seepage 4-'18).
1 1 .lnstallthe intakemanifoldcover.
6 x 1 , 0m m
'12N.m{1.2kgf m.
8.7tbf.ftl
6-43
EngineMechanical
EngineBlock
S o e c i aTl o o l s . . . . . . . . . .7.-.2.
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .-.3. . . . . . . . . . .
Connecting RodandCrankshaft EndPlay
InsDection .............. 7-5
Crankshaft Main Bearing Replacement ...................... 7-6
Connecting RodBearingReplacement...................... 7-8
O i lP a nR e m o v a .l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .- 1 1
Crankshaft and Piston Removal ........7-12
Crankshaft Inspection ........................ 7-14
B l o c ka n dP i s t o nI n s o e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-. 1. .5. . . . . . . . .
C y f i n d eHr o n i n g. . . . . . . . . . . . . " . . . . . . . . . . . . .7. -. .' 1. .7. .
Piston,PinandConnecting RodReplacement .......... 7-18
PistonRingReplacement ................... 7 -21
Pistonlnstallation.................... ........... 7-23
Connecting Rod Bolt Inspection .......' 7 -24
Crankshaft lnstallation .....................'. 7-24
O i lP a nl n s t a l l a t i o .n. . . . . . . . . . . . . . . . . . . . . . . . . .7.-.2 7
Transmission EndCrankshaft Seal
lnstallation-ln Car ................... ........'7-28
EngineBlock
SpecialTools \ {
I o
\ {
7-2
ComponentLocationIndex
BAFFLEPLATE
LOWERBLOCK
fi E
fr
" 8
I
-4
FLYWHEEL
MAINBEARINGS
O i l c l e a r a n cpea,g e7 - 6
Selection, page7-6
CRANKSHAFT OILSEAL.
TRANSMISSION END
step21on page7-26
Installation,
THRUSTWASHERS
CRANKSHAFT
End play,page7-5
R u n o u t p, a g e7 - 1 4
Out-of-Round, page7-14
Removal,page7-12
lnstallation,page7-24
(cont'd)
7-3
EngineBlock
ComponentLocationIndex(cont'd)
/^., \
D->< | nrrucs
_,-ersroru
Benlacement. 7-21Page
Y1 l-"t
rkrej, I
ffil
rG\ AalQ
[=l
^oJ
\ PISTONPIN
Removal,page7-18
f,
PISTON I n s p e c t i o np ,a g e7 - 1 9
Removal,page7-'12 Installation,page7,20
Measurement,page7-15
CONNECTINGROD
End play, page7-5
Small end measurement,page7-19
6
\ (
ENGINEBLOCK
Cylinderbore inspection,page7-'15
Warpageinspection,page7-15
C y l i n d e br o r eh o n i n g ,p a g e1 - 1 1
Ridgeremovai,step 13 on page7-13
CONNECTINGROD
CONNECTINGROD BOLT
page7 24
lnspectaon,
7-4
ConnectingRod and CrankshaftEnd PlayInspection
the oil pump(seepage8-9).
1 . Remove 5. lnstalla dial indicatoras shown. Pushthe
crankshaftfirmly away from the dial indicator,and
Removethe baffleplates(seestep6 on page1 -12). zerothe dial againstthe end of the crankshaft.Then
pull the crankshaftfirmly backtoward the indicator;
3. Measurethe connectingrod end play with a feeler the dial readingshould not exceedthe servicelimit.
gauge betweenthe connectingrod and crankshaft.
Crankshaft End Plav
ConnectingRod End Play StandardlNew): 0.10-0.35 mm
Standard{New):0.15 0.30mm { 0 . 0 0 4 - 0 . 0 1 4i n . l
(0.006-0.012in.l ServiceLimit: 0.45mm {0.018in.)
ServiceLimit 0.40mm (0.016in.l
7-5
EngineBlock
CrankshaftMain BearingReplacement
MainBearingClearance
Inspection 6. lf the plastigagemeasurestoo wide or too narrow,
removethe crankshaft.and removethe upper half
1. To checkmain bearing-to-journaI oil clearance. ofthe bearing.Installa new, completebearingwith
removethe lower block and bearinghalves(see the same color code{s),and recheckthe clearance.
page 1 -12).. Do not file, shim, or scrapethe bearingsor the caps
to adjustclearance.
2 , C l e a ne a c hm a i nj o u r n a la n d b e a r i n gh a l fw i t h a
cleanshop towel. 7. lf the plastigageshows the clearanceis still
incorrect,try the next largeror smaller bearing(the
3. Placeone strip of plastigageacrosseach main color listedabove or below that one),and check
l o ur n a l . again.lf the proper clearancecannot be obtained
b y u s i n gt h e a p p r o p r i a t e
l a r g e ro r s m a l l e rb e a r i n g s ,
4. Reinstallthe b e a r i n g sa n d l o w e rb l o c k t, h e nt o r q u e replacethe crankshaftand start over.
the bolts to 29 N.m {3.0kgf.m,22 lbf.ft) + 56'.
5 . R e m o v et h e l o w e rb l o c ka n d b e a r i n g sa g a i n ,a n d
measurethe widest part of the plastigage.
\.
7-6
Main BearingSelection Main Journal Code Location
Crankshaft Bore Code Location 2. The main journal codesa{e stampedon the
cran kshaft.
1. Numbersor lettersor bars have been stampedon
the end of the block as a code for the sizeof each of
the five main journal bores.Write down the crank
bore codes.lf you can't readthe codes becauseof
accumulateddirt and dust, do not scrub them with
a wire brush or scraper.Cleanthem only with
solventor detergent.
(cont'd)
7-7
EngineBlock
CrankshaftMain Bearing ConnectingRodBearing \
Replacement(cont'd) Replacement
ConnectingRod Bearing-to-JournalOil
4 ffi#Tr,.*" i.,""*
Creen ; g=jiff;i Brown Black
'---l-'o"*, Clearance:
\-
Standard{Newl: 0.020 0.050mm
5
;;lT]*Brown Black 6il; (0.0008--0.0020in.l
ServiceLimit: 0.060mm (0.0024in.)
Brack !l;kr ar*
(Thicker)
7-8
8 . lf the plastigagemeasurestoo wide or too narrow, RodBearingSelection
removethe upper half of the bearing,installa new,
completebearingwith the same color code(s),and 1. Inspecteach connectingrod for cracksand heat
recheckthe clearance.Do not file. shim, or scrape damage.
the bearingsor the capsto adjustclearance.
Connecting Rod Big End Eore Code Locations
9 . lf the plastigageshows the clearanceis still
incorrect,try the next largeror smaller bearing(the 2 . E a c hr o d h a sa t o l e r a n c er a n g ef r o m 0 0 . 0 2 4m m
color listedabove or below that one),and check (0.0009in.),in 0.006mm (0.0002in.) increments,
clearanceagaln.lf the properclearancecannot be dependingon the sizeof its big end bore. lt's then
obtainedby usingthe appropriatelarger or smaller s t a m p e dw i t h a n u m b e ro r b a r ( 1 ,2 , 3 o r 4 / 1 l,l , l l l ,o l
bearing,replacethe crankshaftand stan over. t h e r a n g e .Y o u m a y f i n d a n y
l l l l )i n d i c a t i n g
c o m b i n a t i o no f n u m b e r sa n d b a r si n a n y e n g i n e .
( H a l ft h e n u m b e ro r b a r i s s t a m p e do n t h e b e a r i n g
cap,the other half on the rod.)
(cont'd)
7-9
EngineBlock
ConnectingRod BearingReplacement(cont'dl \ {
Connecting Rod Journal Code Location 4. Use the big end bore codes and rod journalcodes
to selectappropriatereplacementbearingsfrom
3. The connectingrod journalcodesare stampedon the followingtable.
the crankshaft.
NOTE:
Connecting Rod Journal Code Location (Letters or . Color code is on the edge of the bearing.
Bars) . When using bearinghalvesof differentcolors,it
does not matter which color is used in the top or
bottom.
\ {
(Thicker)
7-10
OilPanRemoval
1 . Drainthe engineoil (seepage8-5). 5 . C u tt h eo i l p a n s e abl y s t r i k i n g t h e s i d e o f t h e c u t t e r
to slidethecutteralongthe oil pan.
lf the engine is still in the vehicle,removethe
subframe.
7-11
EngineBlock
Crankshaftand PistonRemoval
1 . R e m o v et h e e n g i n ea s s e m b l y( s e ep a g e5 - 2 ) . 8. Removethe bearingcap bolts.To preventwarpage,
unscrewthe bolts in sequence1/3turn at a time:
2 . R e m o v et h e t r a n s m i s s i o (ns e ep a g e1 3 - 4 ) . repeatthe sequenceuntil all bolts are loosened.
3 . R e m o v et h e o i l p a n ( s e ep a g e7 - 11 ) .
7-12
1 0 .Removethe rod caps/bearings.Keepall caps/ 14. Use the wooden handleof a hammer (A)to drive
b e a r i n g si n o r d e r . out the pistons(B).
to. R e i n s t a l l t h ce o n n e c t i n gr o d b e a r i n g sa n d c a p s
after removingeach piston/connectingrod
assembly.
7-13
EngineBlock
Crankshaftlnspection \
1. Removethe crankshaftfrom the cylinder block(see 6. Placethe cylinder blockon the surfaceplate.
page7-121.
7 . C l e a na n d i n s t a l l t h eb e a r i g n so n t h e N o . 1a n d N o . 5
2. Cleanthe crankshaftoil passageswith pipe j o u r n a lo f t h e c y l i n d e rb l o c k .
c l e a n e r so r a s u i t a b l eb r u s h .
8. Lowerthe crankshaftinto the block.
3. Cleanthe keywayand threads.
9 . M e a s u r er u n o u to n a l l m a i nj o u r n a l sR
. o t a t et h e
4. Measureout-of round at the middle of each rod and crankshafttwo completerevolutlons.The
main journal in two places.The differencebetween differencebetweenmeasurementson eachjournal
measurementson each journal must not be more must not be more than the servicelimit.
than the serviceIimit.
Crankshaft Total Runout
Journal Out-ot-Round Standard(New):0.03mm 10.0012in.l max.
Standard(New):0.005mm (0.0002in.) max. ServiceLimit: 0.04mm (0.0016in.l
ServiceLimit; 0.010mm (0.0004in.)
(
L
I_JJ
fl
5. Measuretaper at the edgesof each rod and main
journal.The differencebetweenmeasurementson
eachjournal must not be more than the service
limit.
JournalTaper
StandardlNewl: 0.005mm (0.0002in.) max.
ServiceLimit: 0.010mm {0.0004in.)
7- 14
Blockand PistonInspection
1 . Removethe crankshaftand pistons(see pageT -121. 4. Measurewear and taper in directionX and Y at
t h r e el e v e l si n e a c hc y l i n d e ra s s h o w n .l f
Checkthe pistonfor distortionor cracks, measurementsin any cylinder are beyondthe
oversizebore servicelimit. replacethe block.lf the
M e a s u r et h e p i s t o nd i a m e t e ra t a p o i n t I 1 m m { 0 . 4 block is to be rebored,referto step 7 after reboring.
in.)from the bottom of the skirt.There are two
standard-size pistons(No Letteror A, and B).The CylinderBore Size
letteris stampedon the top of the piston.Letters Standard(New):
are also stampedon the blockas cylinder bore A or l: 86.010 86.020mm
stzes. 13.3862 3.3866in.)
B or ll: 86.000 86.010mm
Piston Diameter: (3.3858 3.3862in.)
Standard(Newl: Service Limit: 86.070 mm (3.3886in.)
No Letter {or A): 85.980 85.990 mm
(3.3850 3.3854in.) Oversize:
B: 85.970-85.980mm O.25t 96.250 86.260 mm (3.3957 3.3961 in.)
(3.3846-3.3850in.)
Reboringlimit: 0.25mm (0.01in.l max.
Service Limit:
No Lefter lor A): 85.930mm (3.3831in.) Bore Taper:
B: 85.920mm 13.3827in.) Limit: (Differencebetween first and third
measurement)0.05mm (0.002in.)
6 mm {0.2in.}
First
Measurement
Second
Measutement
Third
Measurement
6 mm {0.2in.}
(cont'd)
7-15
EngineBlock
Blockand PistonInspection(cont'd) \
++ PISTON-TO-CYLINDER
CLEARANCE
PRECISION
STRAIGHT
EDGE
\
7-16
CylinderHoning
Only a scoredor scratchedcylinderbore should be
noneo.
'L
M e a s u r et h e c y l i n d e rb o r e s{ s e ep a g e7 - 1 5 ) .
lf the block is to be reused,hone the cylindersand
remeasurethe bores.
H o n et h e c y l i n d e rb o r e sw i t h h o n i n go i l a n d a f i n e
(400grit) stone in a 60 degreecross-hatchpattern
(A).Use only a rigid hone with 400 grit or finer
stone such as Sunnen,Ammco, or equivalent.Do
not use stonesthat are worn or broken.
3 . W h e n h o n i n gi s c o m p l e t et,h o r o u g h l yc l e a nt h e
engine blockof all metal particles.Wash the
cylinder boreswith hot soapywater,then dry and
oil them immediatelyto preventrusting.Never use
solvent,it will only redistributethe grit on the
c y l i n d e rw a l l s .
7-17
EngineBlock
Piston,Pin,and ConnectingRod Replacement
Disassembly 4 . Heatthe piston and connectingrod assemblyto
about 158'F(70"C),then removethe piston pin.
1. Removethe pistonfrom the cylinderblock (see
page7 -12).
2 . A p p l ye n g i n eo i l t o t h e p i s t o np i n s n a p r i n g s( A ) ,
and turn them in the ring grooves until the end
gaps are lined up with the cutoutsin the piston pin
b o r e s( B ) .
\ (
Removeboth snap rings (A).Start at the cutout in
t h e p i s t o np i n b o r e .R e m o v et h e s n a pr i n g s
carefullyso they do not go flying or get lost.Wear
eve protection.
\"
7-18
Inspection 3. Checkthe differencebetweenthe DistonDin
d i a m e t e ra n d p i s t o np i n h o l ed i a m e t e ri n t h e p i s t o n .
NOTE:Inspectthe piston,piston pin, and connecting
rod when they are at room temperature. Piston Pin-to-Piston Clearance
Standard(Newl: -0.005 to +0.002 mm
1. Measurethe diameterof the piston pin. (-0.00020 to +0.00008 in.)
ServiceLimit: 0.005mm (0.0002in.)
Piston Pin Diameter
Standard(New):21.961 21.965mm
(0.8646-0.8648in.)
ServiceLimit: 21.953mm 10.8643 in.l
v
(cont'd)
7-19
EngineBlock
(cont'd)
Piston,Pin,and ConnectingRodReplacement \
5 . I n s t a ltlh e r e m a i n i n gs n a pr i n g ( F ) .
6 . T u r nt h e s n a pr i n g si n t h e r i n gg r o o v e su n t i l t h e
end gaps are positionedat the bottom of the piston.
7 -20
PistonRing Replacement
1. Removethe piston{rom the cylinder block(see 4. Using a piston,push a new ring (A) into the
page 7 -121. c y l i n d e rb o r e 1 5 - 2 0 m m { 0 . 6 - 0 . 8 i n . )f r o m t h e
bottom.
2. Using a ring expander(A),removethe old piston
r i n g s( B ) .
SecondRing
Standard(New):0.40-0.55 mm
{0.016 0.022in.)
ServiceLimit: 0.70mm (0.028in.)
Oil Ring
REKENmanufacturedring
Standard(Newl: 0.25 0.65 mm
(0.010 0.026in.l
ServiceLimit: 0.75mm (0.030in.)
FEDERALMOGUL manufacturedrino
StandardlNew): 0.20 0.70mm
{0.008 0.028in.}
ServiceLimit: 0.80mm (0.031in.)
(cont'd)
7-21
EngineBlock
PistonRing Replacement(cont'd) \ {
6. Installthe top ring and secondring as shown.The 8. Positionthe ring end gaps as shown:
t o p r i n g ( A )h a sa 1 R m a r ko r n o m a r ka n dt h e
s e c o n dr i n g ( B )h a sa 2 R m a r ko r 2 N D m a r k .T h e
marks must be facing upward. About 90'
OIL RINGGAP SECONDRINGGAP
About 45"
7-22
PistonInstallation
lf the crankshaftis alreadyinstalled lf the crankshaftis not installed
1. Setthe crankshafttobottom dead center(BDC)for 1 . Removethe connectingrod caps.then installthe
e a c hc y l i n d e r . r i n g c o m p r e s s o ra, n d c h e c kt h a tt h e b e a r i n gi s
s e c u r e l yi n p l a c e .
2. Removethe connectingrod caps,then installthe
ring compressor,and checkthat the bearingis 2. P o s i t i o nt h e a r r o w( A ) f a c i n gt h e c a m c h a i ns i d eo f
securelyin place, Ineengrne.
\--lno
\ ^ un\-.--l. t
>-*/zi
wr
.,.'_\pf{
(( 'V,/:
Stop afterthe ring compressorpops free, and
checkthe connectingrod-to-crankjournal 4. Positionall pistonsattop dead center.
alignmentbeforepushingthe piston into place.
7-23
EngineBlock
ConnectingRod Bolt Inspection CrankshaftInstallation (
1 . I n s t a ltl h e c r a n k s h a fet n d b u s h i n gw i t h t h e s p e c i a l
tools when replacingthe crankshaft.Drive in the
c r a n k s h a fet n d b u s h i n gu n t i lt h e s p e c i atl o o l s
bottom aqainstthe crankshaft.
mm
07749-0010000
07746-00'l
Calculatethe differencein diameterbetweenpoint
A a n d p o i n tB .
Diflerence in Diameter: I (
\-
Specification:0 0.1 mm (0 0.004in.)
C h e c kt h e c o n n e c t i n gr o d b e a r i n gc l e a r a n c w
e ith
plastigage{seepage7-8).
e ith plastigage
C h e c kt h e m a i n b e a r i n gc l e a r a n c w
( s e ep a g e7 - 6 ) .
\- a
7-24
5 . I n s t a l l t h eb e a r i n gh a l v e si n t h e c y l i n d e rb l o c ka n d 12. Tightenthe connectingrod bolts to 20 N.m
conneclrngrods. (2.0kgf.m, 14 lbf.ft).
.\
,i,
\-1
(cont'd)
7-25
EngineBlock
CrankshaftInstallation(cont'd) {
'17
. Putthe lower blockon lhe cylinderblock. 2'1. Use the specialtoolsto drive a new oil seal
squarelyinto the blockto the specifiedinstalled
1 8 . Tightenthe bearingcap bolts in sequenceto height.
29 N.m (3.0kgf m, 22 lbf.ft).
07749-0010000
07zAo-PNAA100
7-26
OilPanlnstallation
23. Installthe baffle plates. 1 . Removeold liquid gasketfrom the oil pan mating
surfaces,bolts,and bolt holes.
6x1.0mm
1 2N . m
(1.2ksf m, 8.7lbf ft) 2 . Cleanand dry the oil pan mating surfaces.
2 4 . I n s t a l l t h eo i l p u m p ( s e ep a g e8 - 1 4 ) .
28. Installtheengine assembly(seepage 5-9). 5. Tightenthe bolts in two or three steps.In the final
s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 1 2 N . m ( 1 . 2
kgf m, 8.7 lbf.ft).
( } @
(cont'd)
7-27
EngineBlock
Oil PanInstallation(cont'dl TransmissionEndGrankshaftSeal
Installation- In Car
I
6 . l f t h e e n g i n ei s s t i l l i n t h e v e h i c l e i,n s t a l tl h e
subframe,
Special Tools Required
- 1 I n s t a l l t h es u b f r a m eA. l i g nt h e r e f e r e n c e
lines . Driver07749-0010000
on the subframewith the bolt head center,then . Oil seal driver attachment 96 07ZAD-PNAA100
tighten the bolts (seestep 5 on page 5-10).
-2 Tightenthe front mounting bolt (seestep 6 on '1.
D r y t h e c r a n k s h a fot i l s e a lh o u s i n g .
p a g e5 - 1 0 ) .
-3 Tightenthe rear mount mounting bolts (see 2. Use the specialtools to drive a new oil seal
s t e p7 o n p a g e5 - 1 1 ) . squarelyinto the blockto the specifiedinstalled
-4 Connectthe suspensionlower arm ball joints height.
(seestep 6 on page 18-19).
07749-0010000
7. After assembly,wait at least30 minutes before
/$rRfr4T
f i l l i n gt h e e n g i n ew i t h o i l .
tr*W(r
-]t fl\ OTZAD.PNAAlOO a
Measurethe distancebetweenthe crankshaft(A)
a n d o i l s e a l( B ) .
5.5 6.5 mm
l0.22- O.26in .l
7-28
EngineMechanical
t--l
r_::::-l
EngineLubrication
SpecialTools \
\-
8-2
ComponentLocationIndex
WASHER
DRAINBOLT
OILPAN
R e m o v apl ,a g e7 1 1
Installataon, page7-27
OILPUMP
page8-8
OverhaLrl,
HL]
BAFFLEPLATE
OILPUMP OILCONTROL
CHAINTENSIONER ORIFICE
--t
ksrarr
N\
lN-?
cKEr dczt$) OILFILTER
page8-6
Replacement,
# 1 OIL PRESSURESWITCH
SwitchTest,page8 4
\ Oil Pressuretest, page8'4
OIL PUMP R e p l a c e m e npt a, g e8 1 6
CHAINGUIDE
8-3
EngineLubrication
Oil PressureSwitch Test Oil PressureTest {
8-4
EngineOil Replacement
1 . Warm up the engine.
2 . R e m o v et h e d r a i nb o l t ( A ) ,a n d d r a i nt h e e n g i n eo i l .
n A
44 N.m {i1.5kgf.m,33lbf.ft)
Donotovertighten.
d i l ( s e ep a g e3 - 2 ) .
R e f i l l w i t ht h e r e c o m m e n d e o
Capacity
4.0 0 (4.2US qt) at oilchange.
4.2 014.4US qt) at oilchange includingfilter.
5.3 015.6US $) after engineoverhaul.
8-5
EngineLubrication
EngineOil FilterReplacement
Special Tool Fequired 5. lf 4 numbersor marks (1 to 4 or V to VVVV) are
Oil filter wrench 07HAA-PJ70100 printedaroundthe outsideof the filter, usethe
following procedureto tighten the filter.
EngineOil Filter(3/4-turntype)
. Spin the filter on until its seal lightly seatsagainst
1 . R e m o v et h e o i l f i l t e r w i t h t h e s D e c i at ol o l . t h e b l o c k ,a n d n o t ew h i c h n u m b e ro r m a r ki s a t
the bottom.
2. Inspectthe threads{A) and rubber seal (B)on the . Tightenthe filter by turning it clockwise3
new filter. Wipe off the seat on the engine block, numbersor marksfrom the one you noted.For
then apply a light coat of oil to the filter rubber seal. example,if number 2 is at the bottom when the
Use only filterswith a built-inbypasssystem. seal is seated,tightenthe filter until the number 1
comes around the bottom.
6 . A f t e ri n s t a l l a t i o nf i,l l t h e e n g i n e w i t ho i l u p t o t h e
specifiedlevel,run the enginefor more than 3
m i n u t e st,h e n c h e c kf o r o i l l e a k a g e .
07HAA-PJ70100
\,
8-6
Oil FilterFeedPipeReplacement
1 . Removethe oilfilter (seepage8-6).
3 . l n s t a l l t h e t w o 2 x0 1 . 5 m m n u t s ( Ao) n t o t h e n e w
oil filter feed pipe. Holdthe nut with a wrench,then
tighten the other nut.
4 . T i g h t e n t hoei lf i l t e r f e e p
d i p e t o t h eb l o c k t o4 9N .
m {5.0kgf.m,36 lbf ft),thenremovethe nutsfrom
the oil filterfeedoiDe.
8-7
EngineLubrication
OilPumpOverhaul
ExplodedView
6x1.0mm
BAFFLEPLATE 1 2N . m
{1.2kgfm,8.7lbf.ft)
x 1 . 2 5m m
27 N.m
6x1.0mm (2.8kst m, 20 lbt ft)
12 N.m A p p l ye n g i n o
eilto
11.2kgf.m,8.7 lbt ft) the boltthreads.
Ptr
P UI" I
EU
UPPERBALANCER
SHAFTHOLDER
$--."Dowetem
BALANCERSHAFT
BEARINGS
DOWELPIN
\
REAR
BALANCER
SHAFT
-
/=.---'n
FRONT
BALANCER
fs/ SHAFT
t w
LOWERBALANCER
SEALINGBOLT SHAFTHOLDER
39 N.m
{4.0kgf.m,29lbf.ftl
\-
8-8
Oil PumpRemoval 6. Removethe oil pump sprocket(A),then removethe
oil pump(B).
1. Setthe No. 1 piston attop deadcenter{TDC){see
s t e p1 o n p a g e6 - 1 2 ) .
2 . R e m o v et h e o i l p a n ( s e e p a g e T - 1 1 ) .
3 . R e m o v ea n d d i s c a r dt h e o i l p u m p c h a i n t e n s i o n e r .
(cont'd)
8-9
EngineLubrication
Oil PumpOverhaul{cont'dl {
1'[1e-\1.-,-2
'a -
1 :.: ,-'r'
\-
8- 10
BalancerShaft Inspection 3. Removethe baffle plate (A) and upper balancer
shaft holder {with bearings)(B),then removethe
1 . Seatthe balancershaft by pushingit away from the front balancershaft (C)and rear balancershaft (D).
o i l p u m p s p r o c k eet n d o f t h e o i l p u m p .
9 H . A
2 . Zero the dial indicatoragainstthe end of the ''/
.r L=] j/
balancershaft,then push the balancershaft back
and forth and readthe end olav. R
Rfl|]
Balancer Shaft End Play: 3B eI ]U U
Fronl Balancer Shaft: r
Standard{Newl: 0.070 0.135mm
+-
{0.0028 0.0053in.}
ServiceLimit: 0.15mm (0.006in.)
Rear Balancer Shaft:
Standard{New):0.070-0.135 mm
(0.0028 0.0053in.l
ServiceLimit: 0.15mm (0.006in.)
(cont'd)
8-11
EngineLubrication
Oil PumpOverhaul(cont'dl (
4. Measure the innerdiameterof the No. 1 bearingfor 5 . Measurethe diametersof the No. 1 journalson the
thefrontbalancershaftholeandthe rearbalancer front balancershaft and rear balancershaft.
shafthole.
NO.1Journal Diameter:
BearingInnerDiameier: Front:
Front: StandardlNew): 19.938 19.950mm
Standard(New):20.000-20.020mm (0.7850 0.7854in.)
(0.7874 0.7882in.) ServiceLimit: 19.92mm {0.784in.)
ServiceLimit; 20.03mm (0.789in.) Rear:
Rear: StandardlNewl: 23.938 23.950mm
Standard(New):24.000-24.020mm in.)
{0.9424-0.9/129
in.)
10.9/t49-0.9457 ServiceLimit: 23.92mm (0.942in.)
ServiceLimit: 24.03mm (0.946in.)
Front:
Front:
a
Rear:
8-12
6. Cleanboth balancershaft No. 2 journalsand 1 0 . A l i g nt h e p u n c hm a r ko n t h e r e a rb a l a n c esr h a f t
bearinghalveswith a cleanshop towel. with the centerof the two punch marks on the front
balancershaft,then install'thebalancershaftsin
7. Placeone strip of plastigageacrosseach No.2 the lower balancershaft holder
journal.
6 x1.0mm
'12N.m
(1.2kgt.m,8.7 lbt ft)
1 2 . I n s t a l l t h eu p p e rb a l a n c esr h a f th o l d e r( B )a n d
bafile plate (C).
(cont'd)
8-13
EngineLubrication
Oil PumpOverhaul(cont'd)
1 3 . l n s t a l l t h ep u m p h o u s i n g . Oil PumpInstallation
1. Make sure the No. 1 piston is at TDC (seestep 1 on
p a g e6 - 1 2 ) .
6x1,0mm
9%ttrc
1 2N . m
(1.2kgt.m,8.7lbf.ft) +:.:4.4 / t\ \
o/.-lY\
-rrdv :aa:'
f,o-;
8- 14
4. Apply engine oil to the threadsof the oil pump 8. Squeezethe new oil pump chain tensioner(A),then
sprocketmounting bolt (A). installthe set clip (B)on it as shown.
N O T ET
: h e s e tc l i p i s s u p p l i e dw i t h t h e o i l p u m p
chain tensioner.
A
10x 1.25mm
{4 N.m
(a.5kg{ m, B
I
33 rbf.ftl
9. Installthe oil DumD chain tensioner.
6x1.0mm
12N.m(1.2kgf.m,
8.7rbf.ft)
1 0 x1 . 2 5m m 8 x 1 , 2 5m m
,l,t N.m {4.5kgf.m, 22N m l2.2kot m.
33 tbt.ftl r6 tbt.fti
5 . L o o s e l yi n s t a l l t h eo i l p u m p( B ) t, h e ni n s t a l l t hoei l
pump sprocket(C).
(cont'd)
8-15
I
EngineLubrication
I
Oil PumpOverhaul(cont'dl Oif PressureSwitch Replacement (
8-16
r
EngineMechanical r-!i!1
IntakeManifoldand ExhaustSystem
lntakeManifoldRemovaland Installation.................
9-2
ExhaustManifoldRemovalandInstallation..............
9-7
ExhaustPipeand MufflerReplacement .....................
9-8
IntakeManifoldand ExhaustSystem
lntakeManifoldRemovaland Installation \
Exploded View:
8 x 1 , 2 5m m
22 N.m {2.2kgf.m, 16 lbf ft}
I
INTAKEMANIFOLD
Replaceif crackedor
if mating surfaceis GASKET
Replace.
k
'e)
w)
\ '! (
t9
INTAKE MANIFOLDPLATE
Replaceif crackedor
k
if matingsurfaceis \
damaged. 8 xx1.25
. 2 5mm
222 N' mm
2
12.2ksf
kgf.m, 1 6
6x1.0mm
1 2N . m
{1.2kgf.m,8.7lbf.ft)
8 x 1 . 2 5m m
22 N.m
(2.2kgf m. 16 lbt.ft)
\- (
9-2
Removal: 3. Disconnecttheintakeairtemperature(lAT)sensor
connector(A),and removethe breatherhose (B),
'1.
Removethe intakemanifoldcover. then removethe air cleanerhousingcover/intake
a i r d u c ta s s e m b l y( C ) .
2 . Removethe evaporativeemission(EVAP)canister
hose (A),brakeboostervacuum hose (B),and 4. Fully open the throttle link and cruisecontrol link
vacuum hoses{C). by hand,then removethe throttlecable (A) and
cruisecontrol cable(B)from the links.Loosenthe
locknuts{C).and removethe cablesfrom the
bracket.
(cont'd)
9-3
IntakeManifoldand ExhaustSystem
IntakeManifoldRemovaland Installation(cont'dl (
6 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - ' 1 4 4 ) .
7 . R e m o v et h e f u e l l i n e ( s e e p a g e l l - 1 4 9 ) .
8. Removethe positivecrankcaseventilation(PCV)
hose (A),harnessholder mounting bolt (B)and
h a r n e s sc l a m pm o u n t i n gb o l t ( C ) .
\-
9-4
4 . Installthe PCVhose {A), harnessholder mounting
b o l t ( B ) ,a n d h a r n e s sc l a m pm o u n t i n gb o l t( C ) .
1. Installthe intakemanifold (A)with a new gasket(B),
then installand tighten the two stud bolts (C).
w
e-li*h,r
*&
\
8 x 1.25mm
22 N.m
|.2.2k91.m.
16 tbt.ft)
8 x 1.25mm
22 N.rn
(2.2kgf m. 16 lbf.ttl
6x1.0mm
2. Tightenall intakemanifold mountlng bolts/nutsin a 12N.m(1.2kgf.m,8.7lbf.ft)
crisscrosspatternin two or three steps,beginning
with the inner bolt. 5 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
7 . I n s t a ltl h e t h r o t t l ec a b l e( s e ep a g e11 - 1 6 4 )t ,h e n
a d j u s t h e c a b l e( s e ep a g e1 1 - 1 6 3 ) .
8 x 1.25mm
22 N.m (2.2ksf m, 16lbf.ft)
8 . Installthe cruisecontrol cable (seepage 4-44).then
adjustthe cable (seepage 4-45).
(cont'd)
9-5
lntake Manifoldand ExhaustSystem
IntakeManifoldRemovaland Installation(cont'd)
9 . l n s t a l l t h ea i r c l e a n e rh o u s i n gc o v e r( A ) ,a n d 1 2 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
connectthe IAT sensorconnector(B).
6x1.0mm
1 2N . m
l.1.2k91.m,
8.7 tbf.ftl
B C
C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .
1 0 .Installthebreatherhose(C).
After installation,checkthat all tubes,hoses,and
1 1 .lnstalltheEVAPcanisterhose(A),brakebooster connectorsare installedcorrectly.
v a c u u mh o s e( B ) a
, n dv a c u u mh o s e s{ C ) .
Inspectfor fuel leaks.Turn the ignition switch ON
(ll) (do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel \-
line. Repeatthis operationtwo or three times,then
checkfor fuel leakageat any point in the fuel line.
9-6
ExhaustManifoldRemovaland Installation
1 . Removethe VTECsolenoidvalve (seepage 1'1-128).
SELF-LOCKING NUT
10x 1.25mm
44 N.m {4.5ksf.m, 33lbt.ftl
#'-.-
Beplace.
1 0x 1 . 2 5m m
44 N.m
(4.5kgt.m, 33 lbl ftl
Replace.
GASKET
Replace.
8 x 1-25mm
WASHEB 22 N.m (2.2kgI m, 16lbf.ft)
Replace.
Tightenthe boltsin steps,
10x 1.25mm alternating
sideto side.
14 N.m
{4.5kgl.rn, 33lbf.ft)
9-7
lntake Manifoldand ExhaustSystem
ExhaustPipeand Muffler Replacement \
8 x 1 . 2 5m m
22 N.m (2.2kst.m. 16lbf.ftl
Replace.
Tightenthe bolts in steps,
alternatingside'to side.
EXHAUSTPIPEB
HEATSHIELD
\,
6x1.0mm
9.8 N.m
{1.0kgt.m,7.2 lbf ft}
GASKET
Replace.
8 x 1.25mm
22 N.m {2.2kgf m, 16lbf.ft)
Replace. AIR FUELRATIO {A/F)
Tightenthe bolts in steps, SENSOR
alternatingside to-side. 44 N.m (it.s kgf.m, 33 lbf ftl
\-.
9-8
EngineCooling
CoolingSystem
Component Location Index ......................................... 10-2
Radiator CapTest ..................... .......... 10-3
RadiatorTest ............. 10-3
FanMotorTest ..........l0-4
Thermostat Test ...................... ........... 10-4
WaterPumpInspection ..................... 10-5
WaterPumpReplacement ................. 10-5
C o o l a nCt h e c k. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .0. .- .6. .
CoolantReplacement ......................... 10-6
Thermostat Replacement .................. 10-8
WaterPassage Installation ................ 10-9
WaterOutletInstallation .................... 10-9
Radiator andFanReplacement ................................... 10-10
FanControls
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .0. .-.1. .1. . . . . . .
SymptomTroubleshooting Index ............................... 10-12
CircuitDiagram .........10-13
Radiator FanCircuitTroubleshooting ........................ 10-14
Radiator FanSwitchCircuitTroubleshooting
( O p e n ). . . . . . . . . . . . . . . . . . .1. 0 - 1 6
Radiator FanSwitchCircuitTroubleshooting
( S h o r t ). . . . . . . . . . . . . . . . . . .1. 0 - 1 6
Radiator FanSwitchTest ................... 10-17
Radiator FanSwitchReolacement .............................. 10-17
CoolingSystem
ComponentLocationIndex \
WATER OUTLET,
I n s t a l l a t i opna,g e ' 1 0 - g
WATERPUMP
page10-5
Inspection,
Replacement.page10-5
\\f
PIPE
CONNECTING
RESERVE
TANK
WATERPASSAGE
page10-9
Installation,
THERMOSTAT
Test,page10 4
RADIATOR Replacement,page108
CAP
RADIATORFAN
ASSEMgLY
A/C CONDENSER R e p l a c e m e npta, g e1 0 - 1 0
FAN ASSEMBLY Fan MotorTest,page 10 4
Replacement,page 10'10-4
10
Fan Motor Test,page
\J
10-2
RadiatorCapTest RadiatorTest
1. Removethe radiatorcap {A),wet its sealwith 1 . Wait untilthe engine is cool, then carefullyremove
engine coolant,then installit on the pressuretester the radiatorcap and fill the radiatorwith engine
( B )( c o m m e r c i a l layv a i l a b l e ) . coolantto the top of the filler neck.
'123
Apply a pressureof 93 kPa{0.95 1.25
kgf/cm', l4 18 psi).
4 . I n s p e cfto r e n g i n ec o o l a n tl e a k sa n d a d r o p i n
pressure.
10-3
CoolingSystem
FanMotor Test ThermostatTest \ (
To test a closedthermostatl
STANDARDTHERMOSTAT
Lift height; above 8.0 mm (0.31in.)
Starts opening: 169 176"F(76 80"C)
Fullyopen: 194"F{90'Cl
10- 4
Water Pump Inspection Water Pump Replacement
1 . Removethe drive belt (seepage 4-26), 1. Removethe drive belt (seepage 4-26).
6x1.0mm
1 2 N m { 1 . 2k g t m ,
8.7 rbf.ft)
I n s t a l l t h ew a t e r p u m pw i t h n e w O r i n g si n t h e
reverseorder of removal.
7 . C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .
8 . I n s t a l l t h ec r a n k s h a fpt u l l e y( s e ep a g e6 - 1 2 ) .
L R e f i l tl h e r a d i a t o w
r i t h e n g i n ec o o l a n t a, n d b l e e d
air from the cooling system with the heatervalve
o p e n{ s e ep a g e1 0 - 6 } .
10-5
CoolingSystem
GoolantCheck CoolantReplacement \
1. Look at the coolantlevel in the reservetank. Make 1 . Startthe engine.Set the heatertemperaturecontrol
sure it is betweenthe MAX mark (A) and MIN mark dial to maximum heat.then turn off the ignition
(B), switch.Make surethe engine and radiatorare cool
to the touch.
Removethe radiatorcap.
\
Removethe reservetank drain cap (A),and drain
the coolant.
\-
10-6
After the coolanthas drained,tighten the radiator 8. Pour HondaAll SeasonAntifreeze/Coolant Type 2
drain plug securely.and installthe reservetank into the radiatorup to the baseof the filler neck.
drain cap securely.
NOTE:
1 . Fillthe reservetank to the MAX mark (A) with . Always use HondaAll SeasonAntifreeze/Coolant
HondaAll SeasonAntifreeze/Coolant Tvpe 2 Type 2 {P/N01999-9001).Using a non-Honda
(P/NO1999-9001). c o o l a n tc a n r e s u l ti n c o r r o s i o nc, a u s i n gt h e
cooling systemto malfunctionor fail.
. HondaAll SeasonAntifreeze/Coolant Type 2 is a
mixture of 50% antifreezeand 507owater. Pre-
m i x i n gi s n o t r e q u i r e d .
L I n s t a l l t h er a d i a t o cr a p l o o s e l y .
P u tt h e r a d i a t o cr a p o n t i g h t l y ,t h e n r u n t h e e n g i n e
a g a i na n d c h e c kf o r l e a k s .
10-7
GoolingSystem
ThermostatReplacement a
1 . D r a i nt h e e n g i n ec o o l a n t( s e ep a g e1 0 - 6 ) .
6 x 1 . 0m m
9.8N.m
( 1 . 0k g f . m , 7 . 2 l bf ft )
THERMOSTAT
i* -
LOWERHOSE
5 . I n s t a l l t h es p l a s hs h i e l d( s e es t e p2 2 o n p a g e5 - 1 2 ) .
6. Refillthe radiatorwith engine coolant,and bleed air from the cooling systemwith the heatervalve open (seepage
10_6).
\_
10-8
Water PassageInstallation Water Outlet lnstallation
1 . Cleanand dry the water passagemating surfaces. e a t e ro u t l e (t A ) w i t ha n e wO - r i n g{ B ) ,
I n s t a l l t hw
1 2 N m ( 1 . 2k g t m , 8 , 7 l b ff t )
3 . I n s t a l l t h ew a t e rp a s s a g e( A ) w i t ha n e w O - r i n g( B ) .
.t':.:
1 0x 1 . 2 5m m
44N m {4.5kgtm.33 lbf.ft}
10-9
CoolingSystem
Radiatorand FansReplacement {
3. Removethe bulkhead.
DRAINPLUG
O.RING RADIATOR
CAP
UPPERBADIATORHOSE
BADIATOB
BAOIATOAFAN
ASSEMBLY
\-
LOWERCUSHION
RADIATOR FAN
swtTcH
24Nm
{ 2 . 1kt g l m . 1 7 l b l h l
LOWERFADIATOR
HOSE
RESERVETANK
A/C CONDENSER
FANASSEMBLY
9 . 8N m { 1 . 0k g f m , 7 . 2l b ff t )
CONNECTORS
RADIATOBFANSWITCH
CONNECTOB
5. Disconnectthe fan motor connectorsand radiatorfan switch connector,then pull the radiatorup and out.
7 . I n s t a l l t h er a d i a t o ri n t h e r e v e r s eo r d e ro f r e m o v a l M
. a k es u r et h e u p p e ra n d l o w e rc u s h i o n sa r e s e t s e c u r e l V .
8 . I n s t a ltlh e b u l k h e a di n t h e r e v e r s eo r d e ro f r e m o v a l A
. p p l y b o d y p a i n tt o t h e b u l k h e a dm o u n t i n gb o l t s .
r i t h e n g i n ec o o l a n ta n d b l e e dt h e a i r ( s e ep a g e1 0 - 6 ) .
9 . F i l lt h e r a d i a t o w
\.
10-10
FanControls
ComponentLocationIndex
UNDER.HOOD
FUSE/RELAY
BOX
RADIATORFAN RELAY
10-11
FanControls
Symptom TroubleshootingIndex \ {
Beforeperformingany troubleshootingprocedurescheck:
. Fuses
. Grounds
. Cleanlinessand tightnessof all connectors
SYMPTOM PROCEDURE
Radiatorfan does not run for enginecooling, but it runs RadiatorFan Switch CircuitTroubleshooting(Open)
with A,/CON ( s e ep a g e1 0 - 1 6 ) .
\ , 4
\-
10-12
o CircuitDiagram
'
No.20loA): USA
modd
: Cm.de
No.20l50A) mod.l
UNDEN
DASX
UIIDEFHOOD BOX
FJSE/NILAY FUSE/RELAY
BOX
lG2H0TiiAClill,
0N{lllrndSTABI
llll)
10-13
FanGontrols
RadiatorFanCircuitTroubleshooting (
YES-Go to step 2.
NO Go to step 6.
RADIATORFAN RELAY4PSOCKET
Disconnectthe jumper, and turn the ignition switch
ON {ll}. Checkfor voltage betweenthe No. 3
terminal of the radiatorfan relay 4P socketand \-
b o d yg r o u n d .
BADIATOB
FANRELAY4PSOCKET
Terminalside of femaleterminals
ls therebatteryvoltage?
YES-Go to step 9.
\-
10-14
Disconnectthe radiatorfan motor 2P connector. 9 . Reinstallthe radiatorfan relay.
RAOIATOR
FANREI-AY
4PSOCKET RAOIATORFANSWITCH
2P CONNECTOR
Terminalsideof
femaleterminals 5\-'fl \ IJUMPER
f-; I wrRE
\r--
Wiresideof femaleterminals
RADIATORFAN MOTOR2P CONNECTOR
rftr
T-
Y
Wire side of femaleterminals
ls there battery voltage?
NO Checkfor an open in the wire between NO Repairopen in the wire betweenthe radiator
radiatorfan motor 2P connectorterminal No. 1 and fan switchterminal No. 2 and the under-hood
body ground. lf the wire is OK, checkfor a poor fuse/relaybox.l
g r o u n da t G 3 0 1 . 1
10-15
FanControls
RadiatorFanSwitch Circuit
Troubleshooting(Openl
RadiatorFanSwitch Circuit
Troubleshooting(Short)
\ I
1. Disconnectthe radiatorfan switch 2P connector. NOTE:After troubleshooting,perform the engine
c o n t r o lm o d u l e( E C M ) i d l el e a r np r o c e d u r e( s e ep a g e
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 11 , 1 3 9 ) .
3 . M e a s u r ev o l t a g eb e t w e e nt h e N o . 2 t e r m i n a lo f t h e 1 . R e m o v et h e r a d i a t o fra n r e l a yf r o m t h e u n d e r - h o o d
radiatorfan switch 2P connectorand body ground. fuse/relaybox, and test it (seepage 22-51).
RADIATORFAN SWITCH2P
ls the relay OK?
CONNECTOR
YES Go to step 2.
YES Go to step 3.
YES Replacethe radiatorfan switch.t YES Repairshort in the wire betweenthe radiator
f a n s w i t c h2 P c o n n e c t otre r m i n a lN o . 2 a n d u n d e r -
NO Checkfor an open in the wire betweenthe hood fuse/relaybox.l
radiatorfan switch 2P connectorterminal No. 1 and
body ground. lf the wire is OK, checkfor a poor NO Replacethe under-hoodfuse/relaybox.t
g r o u n da t G 3 0 1 . 1 \-
10-16
RadiatorFanSwitch Test RadiatorFanSwitch Replacement
NOTE:Bleedair from the cooling system after installing 1 . Disconnectthe radiatorfan switch connector,then
the radiatorfan switch (seepage 10-6). removethe radiatorfan switch (A).
2 . S u s p e n dt h e r a d i a t ofra n s w i t c h( A )i n a c o n t a i n e r
of water as shown.
\ Termina
1
Operation lTemperature
ON 196" 203'F
(91" gs"C)
swtTcH 5' 15'F {3' 8'C) lowel
OFF than the temoerature
when it goes on
10-17
Fueland Emissions
ffi a=:t=' (F
--1 /6\
l\r )l
W
I UtB
o
/'r';-:'-;--'
At-''
o
\-,/
\7
@
\- I
-'-,---=---1,-'.
ut/t ) i-==.€
'jt' *==-.2'l
o @ (i) -1,40-2, -3,@-4
*.'l€)
\\h
\\:
\\d
o @
\- a
11-2
GeneralTroubleshooting
Information
IntermittentFailures 2. lf the MIL stayson, connectthe HondaPGM Tester
(A) or an OBD ll scantool to the Data Link
The term "intermittentfailure" means a svstem mav Connector{DLC)(B) locatedunderthe driver'sside
have had a failure.but it checksOK now. lf the o f t h ed a s h b o a r d .
MalfunctionIndicatorLamp (MlL)on the dash does not
come on, checkfor Doorconnectionsor looseterminals
at all connectorsrelatedto the circuitthat Vou are
troubleshooting.
Opensand Shorts
"Ooen" and "Short" are common
electricalterms.An
open is a breakin a wire or at a connection.A short is
an accidentalconnectionof a wire to ground or to
anotherwire. In simple electronics,this usuallymeans
somethingwon't work at all. With complex electronics
( s u c ha s E C M s ) t h i sc a n s o m e t i m e sm e a ns o m e t h i n g
works, but not the way it's supposedto.
w:ix&K#
. Freezedata indicatesthe engineconditionswhen the
first malfunction,misfire,or fuel trim malfunction
was detected.
. The scantool and the Honda PGM Testercan readthe
DTC,freezedata,currentdata,and other Engine
Controll\4odule{EClvl)data.
. For specificoperations,referto the user's manual
that came with the scantool or HondaPGl\4Tester.
(cont'd)
11-3
Fueland EmissionsSystems
GeneralTroubleshootingInformation(cont'dl J
How to Resetthe ECM How to Removethe ECMfor Testing
You can resetthe ECM in eitherof two ways: 1. Removethe passenger'sdashboardlower cover
{seepage 20-63),the passenger'skick panel (see
. U s et h e O B Dl l s c a n t o o lo r H o n d aP G M T e s t e r t o page 20-63),and the glove box (seepage 20-63).
resetthe ECM memory.
Seethe OBD ll scantool or HondaPGI\4Testeruser's 2. Removethe ECM mounting bolts (B)and the ECM
manualsfor specificinstructions. (c),
' Turn the ignition switch OFF,and removethe No. 6
ECU{ECM}(15A)fuse (A)from the under-hoodfuse/
r e l a vb o x ( B l f o r 1 0 s e c o n d s .
9.8 N.m
{1.0kgf.m,7.2lbt.ft}
3 . R e m o v et h e E C M ( B ) .
How to Enda TroubleshootingSession
L
(requiredafterany troubleshootingl 4. Installthe ECM in the reverseorder of removal.
2 . D o t h e E C Mi d l e l e a r np r o c e d u r e( s e ep a g e1 1 - 1 3 9 )
\- ta
11-4
How to TroubleshootCircuitsat the ECM a s a g u i d ef o r t h e
2 . U s i n gt h e w i r e i n s u l a t i o n
contouredtip ofthe backprobeadapter,gently slide
Special Tools Required the tip into the connectorfrom the wire side until it
. DigitalMultimeterKS-AHM-32-003 (1) or a touchesthe end of the wire terminal.
commerciallyavailabledigital multimeter
. BackprobeSet 07SAZ-0010004 (2) 3. lf you cannot get to the wire side of the connector
or the wire side is sealed(A),disconnectthe
1. Connectthe backprobeadapters(A) to the stacking connectorand probe the terminals(B)from the
patchcords (B),and connectthe cords to a digital terminal side. Do not force the Drobeinto the
m u l t i m e t e (r C ) . connector.
07sAz-001000A
(cont'd)
11-5
Fueland EmissionsSystems
Information(cont'd)
GeneralTroubleshooting (
L I
EOS05A35570
\-
11-6
DTCTroubleshootingIndex
DTC Temporary
DTC Detection ltem Note
{MlLindication*)
P 0 0 1 (05 6 ) VariableValveTiming Control{VTC)Oil Control { s e ep a g e11 ' 11 8 )
S o l e n o i dV a l v eM a l f u n c t i o n
P 0 0 1 (15 6 ) P0011 VariableValveTiming Control(WC) System ( s e ep a g e1 1 -11 9 )
Malfunction
P 0 1 0 (73 ) (MAP)SensorCircuit
ManifoldAbsolutePressure ( s e ep a g e1 ' l - 5 2 1
LowVoltaqe
P 0 1 0 (83 ) (MAP)SensorCircuit
ManifoldAbsolutePressure ( s e ep a g e1 1 - 5 3 )
HiqhVoltaqe
P 0 1 1 2( 1 0 ) IntakeAir Temperature(lAT)SensorCircuitLow (seepage 11-55)
Voltaoe
(10)
P01r3 IntakeAir Temperature(lAT)SensorCircuitHigh (seepage '11-56)
Voltaoe
P 0 1 1 6{ 8 6 ) P0116 EnglneCoolantTemperature(ECT)Sensor Range/ { s e ep a g e1 1 - 5 7 )
PerformanceProblem
P0117
{6) (ECT)SensorCircuit
EngineCoolantTemperature ( s e ep a g e1 1 - 5 8 )
LowVoltaqe
P 0 1 1{86 ) EngineCoolantTemperature(ECT)SensorCircuit { s e ep a g e1 1 - 5 9 )
Hiqh Voltaqe
P 0 1 2 t27 \ Throttle Position(TP)SensorCircuitLow Voltaqe ( s e eD a q e1 1 - 6 0 )
P 0 1 2 {37 ) Throttle Posltion(TP)SensorCircuitHiqh Voltaoe ( s e ep a q e1 1 - 6 2 )
P 0 1 2 8( 8 7 ) P0128 CoolinqSVStemMalfunction ( s e eD a q e1 1 - 6 4 )
P 0 1 3 4( 4 1 ) Air Fuel Ratio(Ay'F) Sensor(Sensor1) No Activity ( s e ep a g e1 1 - 6 5 )
Detected
P 0 1 3 (76 3 ) P0137 SecondaryHeatedOxygen Sensor (SecondaryHO2S) ( s e ep a g e1 1 - 6 5 )
(Sensor2) CircuitLow Voltaqe
P 0 1 3 8( 6 3 ) P0138 SecondaryHeatedOxygen Sensor (SecondaryHO2S) ( s e ep a g e1 1 - 6 6 )
( S e n s o2
r ) C i r c u i tH i q hV o l t a q e
P 0 1 3 (96 3 ) P0139 SecondaryHeatedOxygen Sensor (SecondaryH02S) ( s e ep a g e1 1 - 6 7 )
( S e n s o2
r )SlowResDonse
P 0 1 4 1( 6 5 ) SecondaryHeatedOxygen Sensor(SecondaryH02S) ( s e ep a g e1 1 - 6 8 )
(Sensor2) HeaterCircuitMalfunction
P 0 1 7 1( 4 5 ) PO\11 FuelSvstemToo Lean ( s e ep a q e1 1 - 7 0 )
PO112l'45) PO\l2 FuelSystemToo Rich ( s e eo a o e1 1 - 7 0 )
P0300andany P0300andany R a n d o mM i s f i r e ( s e ep a g e1 1 - 7 1 )
of of
P 0 3 0 (17 1 ) P0301
PO302 (721 P0302
P0303(73) P0303
P0304(74) P0304
P0301(7'1) P0301 No. 1 Cyl n d e rM i s f i r e { s e ep a g e1 1 - 7 2 )
P0302(721 P0302 No.2 Cvl n d e rM i s f i r e { s e ep a q e11 - 7 2 )
P0303(73) P0303 N o . 3 C v l nder Misfire ( s e eo a q e1 1 - 7 2 )
P0304{74) P0304 N o . 4 C v l nder Misfire {seeDaqe11-72)
" ; T h e s e D T C sa r e i n d i c a t e db y a b l i n k i n gm a l f u n c t i o ni n d i c a t o lra m p ( M l L ) w h e nt h e S C Ss e r v i c es i g n a l i n e i s
jumped with the Honda PGM Tester.
{cont'd)
11-7
Fueland EmissionsSystems
DTCTroubleshootingIndex(cont'd) \ (
KnockSensorCircuitN4alfunction
CrankshaftPosition(CKP)SensorIntermittent ( s e ep a g e1 1 - 7 8 )
CamshaftPosition(CMP)SensorA No ( s e eo a q e1 1 - 1 2 1
CamshaftPosition(CMP)SensorA Intermiftent i s e ep a g e1 1 - 1 2 1 )
VelyeTiTing_controlll/T!)
Yetrgb-le Phqse
G s e eo a o e1 1 - 1 2 2
PO4i{ CqJalystSystemElficie-ncy Below Threshold s e eo a q e11 -1 6 7
P 0 4 5 1( 9 1 ) TU45I ( F T PS
F u e lT a n kP r e s s u r e ) e n s o rR a n g e / P e r f o r m a n c e( s e e p a g e l l 1 7 1 )
SeriaC
l o m m u n i c a t i o Ln i n kM a l f u n c t i o n Referto the l\4ultiplex
ControlSystem
T r o u b l e s h o o t i n{gs e e
P 1 1 0(61 3 ) Barometric
Pressure (BARO)
SensorRange/ ( s e ep a g e11 - 8 3 )
P 1 1 0(?1 3
P 11 0 8( t s '
PerformanP
BarometriP
c er o b l e m
( B A R OS
c ressure
BarometriP
) e n s o rC i r c u i tL o w
( B A R OS
c ressure ) e n s o rC i r c u i tH i g h
( s e ep a S e11 ' 8 3 )
{ s e ep a g e1 1 - 8 3 )
l\."
a
P112111) P't121 T h r o t t l eP o s i t i o n{ T P iS e n s o rS i g n a lL o w e rT h a n ( s e ep a g e1 1 - 6 3 )
-
P1122ll J Pl122 T h r o t t l eP o s i t i o n( T P )S e n s o rS i g n a lH i g h e rT h a n tsee page I r-oJ,
i j 1 1 2 8( 5 ) P11f,.8 (l\,4AP
M a n i { o l dA b s o l u t eP r e s s u r e S }e n s o rS i g n a l G;tp"s" 1154)
Loqer Than Expected
P 11 2 9( 5 ) ManifoldAbsolutePreisure (MAP)SeiiioiSgnul ( * " p a S e11 5 4 )
H i q h e rT h a nE x
P 1 1 5 7( 4 8 ) A i r F u e lR a t i o( A V FS) e n s o r( S e n s o r1 ) R a n g e / ( s e ep a g e1 1 - 8 4 )
R e r f o r m a n cP eroblem
Pr 158 (48) r ) A F S T e r m i n a l ( s e ep a g e11 - 8 5 )
A i r F u e lR a t i o { A " FS) e n s o r{ S e n s o 1
'l)
P 11 5 9( 4 8 ) A i r F u e lR a t i o1 A V FS)e n s o ri s e n s o r A F S+ T e r m i n a l ( s e ep a g e11 - 8 6 )
\.
11-8
DTC Temporary
DTC Detectionltem Page
{MlLindication*l
P1259t22J VTECSystem l\4alfunction ( s e eD a q e1 1 - 1 2 3 )
P1291t20\ ElectricalLoad Detector(ELD)CircuitLow Voltaqe ( s e eD a q el 1 - 9 2 )
P1298(20) ElectricalLoad Detector(ELD)CircuitHiqh Voltaqe ( s e eo a o e1 1 - 9 3 )
P 1 3 6 1( 8 ) CamshaftPosition(CMP)SensorB (Top DeadCenter ( s e ep a g e1 1 - 9 5 )
(TDC)Sensor)IntermittentSional InterruDtion
P 1 3 6 (28 ) CamshaftPosition(CMP)Sensor B (Top DeadCenter ( s e ep a g e1 1 - 9 5 )
( T D C )S e n s o r N
) o Siqnal
P'r456(90) P1456 EvaporativeEmissions(EVAP)ControlSystem ( s e ep a g e1 1 - 1 7 5 )
Leakaqe(FuelTank Svstem)
(90)
P14s7 P1457 EvaporativeEmissions(EVAP)ControlSystem ( s e ep a g e1 ' l - 1 8 0 )
Leakaqe(EVAPCanisterSvstem)
P 1 5 0 (51 0 9 ) P1505 PositiveCrankcaseVentilation(PCV)Air Leakaqe ( s e eo a q e1 1 - 1 6 8 1
P1519 (14) ldle Air Control(lAC)ValveCircuitMalfunction { s e ep a q e1 1 - 1 3 1 )
P 1 6 0 7( ) EnginC l o d u l e( E C MI)n t e r n aCl i r c u i t
e o n t r oM ( s e ep a g e11 - 9 6 )
Malfunction
" : TheseDTCSare indicatedby a blinking MIL when the SCSservicesignal line is jumped with the Honda PGM
Tester.
11-9
Fueland EmissionsSystems
Symptom TroubleshootingIndex \
When the vehiclehas one of these symptoms,checkthe diagnostictrouble code (DTC)with the scantool. lf there is no
DTC,do the diagnosticprocedurefor the symptom, in the sequencelisted,until you find the cause.
\-
11-10
Symptom Diagnosticprocedure Also checktor
Difficultto refuel 1 . T e s t t h e f u e lt a n kv a p o rc o n t r o lv a l v e { s e e p a g e1 ' l - M a l f u n c t i o n i ngga s
(MlL works OK. no DTCSset) 2. 1471. s t a t i o nf i l l i n gn o z z l e .
I n s p e ctth e f u e lt a n kv a p o rc o n t r o ls i g n a lt u b e
3. betweenthe fuel pipe and the fuel tank vapor
control valve.
4. Inspectthe fuel tank vapor vent tube betweenthe
EVAPcanisterand the fuel tank vapor control valve.
Checkthe EVAPcanister.
Fueloverflowsduring Replacethe fuel tank vapor control valve (seepage '11 Malfunctioninggas
refueling 189). stationfilling nozzle.
(No DTCSset)
11-11
Fueland EmissionsSystems
SystemDescriptions \ {
ElectronicControl System
The functionsof the fuel and emlssioncontrol systemsare managedby the enginecontrol module (ECM).
Fail-safeFunction
When an abnormalityoccursin the signalfrom a sensor,the ECI\4ignoresthat signaland assumesa pre-programmed
value for that sensorthat allowsthe enqineto continueto run.
Back-up Function
When an abnormalityoccursin the ECM,the injectorsare controlledby a back-upcircuitindependentof the systemto
p e r m i tm i n i m a ld r i v i n g .
Self-diagnosis
When an abnormalityoccursin the signalfrom a sensor,the ECM suppliesground for the malfunctionindicatorlamp
{MlL) and storesthe diagnostictrouble code {DTC)in erasablememory.When the ignition is first turned on, the EClvl
suppliesground to the l\4lLfor 15 to 20 secondsto checkthe M lL bulb condition.
\.
11-12
ECMData
You can retrievedata from the ECI\4by connectingthe OBD ll scantool or the Honda PGM Testerto the data link
connector(DLC).The items listedin the table below conform to SAE recommendedpractice.The HondaPGM Tester
also readsdata beyondthat recommendedby SAEto help you find the causesof intermittentproblems.
The "operatingvalues" listedare approximateand may vary dependingon the environmentand the individual
vehicle.
Unlessnoted otherwise,"at idle speed" means idling with the enginecompletelywarmed up in the neutralposition,
and the A,/Cand all
(cont'd)
11-13
Fueland EmissionsSystems
SystemDescriptions(cont'd) r a
ECMData(cont'd)
Data Description Opera'tingValue FreezeData
"open" or "closed". At idle speed:closed YES
FuelSystem Fuelsystem statusis indicatedas
Status Closed:Basedon the A,/FSensoroutput,the ECM
determinesthe airlfuel ratio and controlsthe amount of
injectedfuel.
Open: lgnoringAy'FSensoroutput,the ECM refersto
signalsfrom the throttle position{TP),manifoldabsolute
pressure(MAP),intakeair temperature(lAT),barometric
pressure(BARO),and enginecoolanttemperature(ECT))
sensorsto controlthe amount of iniectedfuel.
Short Term The airlfuel ratio correctioncoefficientfor correctingthe o.7 1.5 YES
FuelTrim amount of injectedfuel when the fuel system status
is "closed." When the ratio is leanerthan the
sloichiometricratio,the ECM increasesshort term fuel
trim gradually,and the amount of iniectedfuel increases.
The airlfuel ratio graduallygets richer,causinga lower
oxygen content in the exhaustgas. Consequently,the
short term fuel trim is lowered,and the ECM reducesthe
amount of injectedfuel.
This cvcle keepsthe airlfuelratio closeto the
stoichiometricratio when in closedloop status.
LongTerm Long term fuel trim is computedfrom short term fuel trim 0.8 1.2 YES
F u eT
l rim and indicateschangesoccurringin the fuel supply system
over a long period.
l f l o n gt e r m f u e lt r l m i s h i g h e rt h a n 1 . 0 0t,h e a m o u n lo f
w
injectedfuel must be increased.lf it is lower than 1.00,the
amount of injectedfuel must be reduced.
IntakeAir The IAT sensorconvertsintakeair temperatureinto W i t h c o l de n g i n e : YES
Temperature v o l t a g ea n d s i g n a l st h e E C M .W h e n i n t a k ea i r S a m ea s a m b i e n t
{IAT) temperatureis low, the internalresistanceofthe sensor temperature a n dE C T
increases,and the voltagesignal is higher.
Throttle Basedon the acceleratorpedal position,the opening At idle speed: YES
Position anole of the throttlevalve is indicated. a b o u t1 0%
lgnition lgnitiontiming is the ignition advanceangle set by the At idle speed:8" t 5" NO
Timing ECM.The ECM matchesignitiontiming to driving | ' t u L w n e nr n e > L )
conditions. s e r v i c es i g n a l i n e i s
jumped with the Honda
PGM Tester
Calculated cLV is the enoine load calculatedfrom IMAPdata. At idle speed: YES
L o a dV a l u e 12 34%
(cLV) At 2.500rpm with no
toao:
't4- 34%
\.,
11-14
J/-\
-1\_/
BEIAY2
A/C CLUTCHRELAY
I
) RAOIATOR
UNDER.HOOD
FUSE/RELAY BOX:
ONo. 19BATTERY (8oA)
ONo.6 ECU(ECM)(15A1
(3)No.20lG{40A1
{Canada:50A}
ONo.l4 OPTION {40A1
€)No.9 BACKuP (7.5A1
lo)No.7 HORN,STOP{15A}
UNDER.DASH
FUSE/RELAY BOX:
ONo. 17FUELPUMP
{15A}
@No.,t ACG{10A)
ONo.1 IGNCOIL(1sA)
q)No.10METER (7.5A)
0)No.14A/C CLUTCH
RELAY IlOA)
@No.2+B LAF(A/F)
HEATER (2OA)
(cont'd)
11-15
Fueland EmissionsSystems
SystemDescriptions(cont'dl \ a
ECMElectricalConnections
MAPSENSON
No. INJECTOR
No,2INJECTOR
TPSENSOR
No.3 INJEC]OB
No./tINJECTOF
IATSENSOR
ECTSENSOB
\'
CMP SENSORB
(TDCSENSOSJ
CKPSENSOR
F€VERSELOCK
SOLENOIDVAIVE
\-
11-16
A/FSENSOR
EVAPCANISTE6
PURGEVAIVE
EVAPCANISTER
VENTSHUTVATVE A/FSENSOR
(sENSOn 1)
sotENotovAtvE
CMP SENSOFA
wEcorl
PRESSUSESWTICH
N o . 2 l G N l l l O NC O I L
No. 3 IGNITIONCOIL
VTEC SOLENOID
No. a IGNITIONCOIL
{cont'd)
11-17
Fueland EmissionsSystems
SystemDescriptions(cont'd) \
ECMElectricalConnections
ARAKEPEDAL
POStTtONSWTTCH
GAUGEASSEMBLY
IMMOBILPENUN|T
EPSCONTROTUNIT
TERMINALLOCATIONS
\-
11-18
ECMInputsand Outputsat ConnectorA (31P)
1 2 3 6 1 I
AFS]TC ]GP2 IGPl ^:^ I -:, AFS+ CKP KS
'10
t1 12 15 T6 18 1 9 2A 21
SG2 ACV TPS AFS_ V S S IVAP vcc2 vccl
22 23 26
25 CMPB 27 28 29 30
HTC+ LG2 CMPA(rDc) tGPts,lrcPts3tGPts2GPLS1
NOTE:Standardbatteryvoltageis 12V.
(cont'd)
11-19
Fueland EmissionsSystems
SystemDescriptions{cont'd) \. il
ECMInputsand Outputsat ConnectorA (31P)
1 2 3 4 5 6 1 I
AFS]TC GP2 IGPl PG2 PG.1 AFS+ CKP KS
12 '15 1 6 18 1 9 20 21
10 11
SG2 sG1 IACV TPS AFS_ V S S IVAP vcc2 vccl
22 23 25 CMPB26 27 28 29 30
AFS LG2 IGPLS4
IGPLS3 IGPLS,I
IGPLS2
HTC+ Ct\.4PA
(rDc)
batteryvoltageis 12V.
NOTE:Standard
22
23
24
BRN?ryE
BRN?ryE
L
L
AFSHTC- (AIRFUEL
RATIO(A"iFiSENSOR
HEATER
LG2(LOGIC
1(L
CONTROL
GROUND
+ SIDE)
Detectsa,/Fsensorheater
voltage
Lessthan1.0V at alltimes
L e s st h a n
'1.0
V at alltimes
\. a
25 BLU,^/VHT CMPA (CAMSHAFT D e t e c t sC M P s e n s o r A Withenginerunning:pulses
POSITION SENSOR A) stonal
26 GRN CMPB CAMSHAFT Detects CMPsensor8 (TDc Withenginerunning:pulses
POSITION (CMP)SENSOB sensor)
B (TDC(TOPDEADCENTER
SENSORi)
27 BRN I G P L S 4{ N o .4 I G N I T I O N DrivesNo, 4 ignitioncoi WithignitionswitchON (ll)rabout0 v
COILPULSE) Withenginerunning:pulses
28 WHT/BLU I G P L S 3{ N o . 3 I G N I T I O N O r i v e s N o . 3 r g n i t i o nc o i
COILPULSE)
29 BLU/RED l G P L S 2 l N o .I 2
GNITION DrivesNo.2 ignitioncoil
COILPTJLSE)
30 YEUGRN IGPLSI(No.1 IGNITION DrivesNo. I ignitioncoil
co PlltsF)
\. a
11-20
Wire side o{ femaleterminals
NOTE:Standardbafteryvoltageis 12V.
(confd)
11-21
Fueland EmissionsSystems
SystemDescriptions(cont'dl L
ECMlnputsand Outputsat ConnectorE (31P}
1 2 3 4 6 8
iMo 1 I
sr-{]zsLG3 SG3 $1025 MRLY AFS
FPR HTC HTCR
14 15 16 18 20 21
FTP ELD EPS
LD ACC Z/VBS VSV
22 23 24 26 21 29 30 31
BKSWK-LINESEFMJ NEP rMo scs WEN MIL
CD
Wire side of femaleterminals
NOTE:Standardbatteryvoltageis '12V.
\-
11-22
ECMInputsand Outputsat ConnectorE (31P)
l
2 i 6 1 I 9
t M o $.c2s SFIO2S
IVRLY
AFS
tGl
FPR HTC HTCR
14 15 16 t8 20 21
FTP ELD EPS 2,4/BS VSV
LD
22 23 24 26 21 29 30 31
BKSWK LINESEFMJ NEP lvo scs WEN MIL
CD
Wire side of femaleterminals
NOTE:Standardbatteryvoltageis 12V.
(cont'd)
11-23
Fueland EmissionsSystems
SystemDescriptions(cont'dl !
VacuumHoseRouting
INTAKEAIR
BYPASSCONTROL
THERMALVALVE
\*
FRONTOF
VEHICLE
EVAPORATIVEEMISSION
{EVAP}CANISTERPURGEVALVE
\,
11-24
VacuumHoseRouting
(cont'd)
11-25
Fueland EmissionsSystems
SystemDescriptions(cont'd)
PGM-FISystem CamshaftPosition(CMPISensorB (TopDeadCenter
(TDCISensor)
The ProgrammedFuel Injection(PGM-Fl)system is a TheCMPsensorB (TDCsensor)detectsthe positionof
sequentialmultiport fuel injectionsystem. the No.1 cylinderasa reference
for sequential
fuel
injectionto eachcylinder.
Air Conditioning {A/C) Compressor Glutch Relay
When the ECfMreceivesa demandfor coolingfrom the
Ay'Csystem,it delaysthe compressorfrom being
energized,and enrichesthe mixture to assuresmooth
transitionto the AVCmode.
SENSOR
TERMINALS
ztRcoNta Crankshaft Position (CKPISensor
ELEMENT
The CKPsensordetectscrankshaftsoeedand
determinesignitiontiming and timing for fuel injection
of each cylinderas well as detectingengine misfire.
HEATER
HEATER
TERMINALS
\,
11-26
lgnition Timing Control MalfunctionIndicatorLamp lMlLl Indication{ln relation
The ECMcontainsthe memory for basicignitiontiming to ReadinessCodes)
"readinesscodes" that are part
at variousengine speedsand manifold absolute The vehiclehas certain
pressure.lt also adjuststhe timing accordingto engine of the on-boarddiagnosticsfor the emissionssystems.
coolanttemperature. lf the vehicle'sbafteryhas been disconnectedor gone
dead.if the DTCShave been cleared,or if the ECM has
Iniector Timing and Duration been reset.these codesare set to incomplete.In some
The ECM containsthe memory for basicdischarge states,part of the emissionstesting is to make sure
d u r a t i o na t v a r i o u se n g i n es p e e d sa n d m a n i f o l d these codes are set to comDlete.lf all of them are not
pressures.The basicdischargeduration,after being set to complete,the vehiclemay fail the test and the
read out from the memory, is further modified by test cannot be finished.
signalssent from varioussensorsto obtain the final
d i s c h a r g ed u r a t i o n . To checkif the readinesscodes are set to complete,
By monitoring long term fuel trim, the ECMdetectslong turn the ignition switch ON (ll). but do not startthe
term malfunctionsin the fuel systemand sets a e n g i n e . T h e M I L w ci lol m e o n f o r l S 2 0 s e c o n d sl f. i t
DiagnosticTrouble Code{DTC). then goes off, the readinesscodesare set to complete,
lf it blinksseveraltimes,one or more readinesscodes
Intake Air Temperature (lAT) Sensor are not set to comolete.To set each code, drive the
The IAT sensoris a temperaturedependentresistor v e h i c l eo r r u n t h e e n g i n ea s d e s c r i b e di n t h e
{thermistor).The resistanceof the thermistor decreases proceduresto set them in this section(seepage 11-46).
as the intakeair temDeratureincreases.
Manifold Absolute Pressure {MAP) Senso]
The MAP sensorconvertsmanifoldabsolutepressure
i n t oe l e c t r i c asl i g n a l st o t h e E C M .
SENSOR
UNIT
Knock Sensor
The knockcontrol system adjuststhe ignitiontiming to
minimizeknock.
PIEZO
CERAMIC
(cont'd)
11-27
Fueland EmissionsSystems
SystemDescriptions(cont'dl (
Secondary Heated Oxygen Sensor (Secondary HO2S) Vehicle Speed Sensor (VSS)
The secondaryHO2Sdetectsthe oxygen content in the The VSS is driven by the differential.lt generatesa
exhaustgas downstreamof the three way catalytic pulsedsignalfrom an input of 5 volts.The number of
converter(TWC)and sendssignalsto the ECMwhich pulsesper minute increases/decreases with the speed
checksthe efficiencyof the TWC.To stabilizeits output, of the vehicle.
the sensorhas an internalheater.The secondarvHO2S
i s i n s t a l l e di n t h e T W C .
BEARING
ztRcoNta SENSOR
ELEMENT TERMINALS
HEATER
TERMINALS
Starting Control
When the engine is started,the ECM providesa rich
mixture by increasinginjectorduration.
(
Throttle Position ITP)Sensor
The TP sensoris a potentiometerconnectedto the
throttlevalve shaft.As the throttle positionchanges,the
sensorvariesthe signalvoltageto the ECM.The TP
sensoris not replaceableapart from the throftle body.
ELEMENT BRUSHHOLDER
gRUSH
11-28
wEc/wc
The i-WEC has a VTC (VariableValveTiming Control)mechanismon the intakecamshaftin additionto the usual
VTEC.
This mechanismimprovesfuel efficiencyand reducesexhaustemissionsat all Ievelsof engine speed,vehiclespeed.
a n d e n g i n el o a d .
The VTECmechanismchangesthe valve lift and timing by using more than one cam profile.
The VTCchangesthe phaseof the intakecamshaftvia oil pressure.lt changesthe intakevalve timing continuously.
HIGH
LOW<- ENGINESPEED
{cont'd)
11-29
Fueland EmissionsSystems
SystemDescriptions(cont'dl (
VTC system
. The VTC system makescontinuousintakevalvetiming changesbasedon operatingconditions.
. Intakevalve timing is optimizedto allow the engineto producemaximum power.
'CamangleisadvancedtoobtaintheEGReffectandreducethepumpingloss.Theintakevalveisclosedquicklyto
reducethe entry of the airlfuel mixture into the intakeport and improvethe chargingeffect.
. Cam angle is reducedat idle to stabilizecombustionand reducesenginespeed.
' l f a m a l f u n c t i o n o c c u r s , t h e V T C s y s t e m c o n t r iosl d i s a b l e da n dt h e v a l v et i m i n g i s f i x e da t t h e f u l l y r e t a r d e dp o s i t i o n .
TDC
MAXIMUM VTCADVANCE50' MAXIMUM VTC ADVANCE50'
i l(-4 sHoRToVERLAP
'+-|l LoNGoVERLAP
VTEC system
' The VTECsystemchangesthe cam profileto correspondto enginespeed.lt maximizestorque at low enginespeed
and output at high engine speed.
. The low lift cam is used at low engine speeds,and the high lift cam is used at high enginespeeds.
LOWSPEEDVALVETIMING HIGHSPEEDVALVETIMING
11-30
System Diagram
CMPSENSORA
From No. il
ACC{10A)fuse
BLK
It
:5i.T,""
{cont'd}
11-31
Fueland EmissionsSystems
(
SystemDescriptions(cont'd)
ldle Control System FuelSupply System
When the engine is cold, the Ay'Ccompressoris on, the Fuel Cut-off Control
transmissionis in gear,the brakepedal is pressed.the Duringdecelerationwith the throttle valve closed,
power steeringload is high, or the alternatoris currentto the injectorsis cut off to improve fuel
charging,the ECIMcontrolscurrentto the ldle Air economy at enginespeedsover 1,030rpm. Fuelcut-off
Control(lAC)valveto maintainthe correctidle speed. actionalso occurswhen enginespeedexceeds
Referto the System Diagramto seethe functional 6,900rpm, regardlessof the positionof the throttle
layout of the system. valve,to protectthe enginefrom over-rewing. When
the vehicleis stopped.the ECMcuts the fuel at engine
Brake Pedal Position Switch speedsover 6,500rpm.
The brakepedal positionswitch signalsthe ECMwhen
the brakepedal is oressed. Fuel Pump Control
When the ignition is turned on, the ECMgroundsthe
Electrical Power Steering (EPS)Senser PGM-Flmain relay which feeds currentto the fuel pump
The EPSsensorsignalsthe ECMwhen the power for 2 secondsto pressurizethe fuel system,With the
s t e e r i n gl o a di s h i g h . e n g i n er u n n i n gt.h e E C Mg r o u n d st h e P G M - Fm
l ain
relay and feeds currentto the fuel pump. When the
ldle Air Control llACl Valve engine is not running and the ignition is on, the ECI\4
To maintainthe proper idle speed,the IACvalve cuts ground to the PGM-Flmain relaywhich cuts
changesthe amount of air bypassingthe throttle body currentto the fuel pump.
in responseto an electricalsignalfrom the ECM.
PGM-FIMain Relay1 and 2
From AIR To INTAKE
CLEANER MANIFOLD The PGM-Flmain relay consistsof two separaterelays.
Relay1 is energizedwheneverthe ignition switch is ON
(ll)to supply batteryvoltageto the ECM power to the
{
injectors,and power for relay,Relay2 is energizedto
supply power to the fuel pump for 2 secondswhen the
i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) ,a n d w h e n t h e e n g i n ei s
runnrng.
IAC VALVE
11-32
IntakeAir System Throttle Body
The throttle body is a single-barrelside draft type. lt
Referto the SystemDiagramto seethe functional housesthe TP senserand the IACvalve.The lower
layout of the system. portion of the IAC valve is heatedby enginecoolant
f r o m t h e c y l i n d e rh e a d .
Intake Air Bypass Control Thermal Valve
W h e nt h e e n g i n ei s r u n n i n g t, h e i n t a k ea i r b y p a s s
controlthermal valve sendsair to the iniectors,
IACVALVE
INJECTOR
{cont'd)
11-33
Fueland EmissionsSystems
SystemDescriptions(cont'dl {
THREEWAY
CATALYST
FRONTOF
VEHICLE BLOW-BY
:: VAPOR
€: FRESH
AIR
11-34
Emission(EVAPIControl
Evaporative EVAP Two Way Valve and EVAP Eyp8s Solenoid
System Valve
The EVAPtwo way valve is installedbetweenthe fuel
Referto the SystemDiagramto see the functional tank and the EVAPcanisterline.
layout of the system. The EVAPtwo way valve sendsfuel vapor to the EVAP
canistercorrespondingto the pressureinsidethe tuel
EVAPCanister tank. lt also relievesexcessvacuum in the tank by
The EVAPcanistertemporarilystoresfuel vapor from allowingfresh air to be drawn into the tank through the
the fuel tank until it can be purged back into the engine EVAPcanister.
a n db u r n e d . The EVAPbypasssolenoidvalve opensto bypassthe
two way valve during the EVAPleakcheck.
EVAP Canister Purge Valve
When the enginecoolanttemperature is below 149'F EVAP BYPASS
SOLENOID VALVE
(65'C),the ECMturns off the EVAPcanisterpurge valve
which cuts vacuum to the EVAPcanister.
SENSOR
UNIT
To FUELTANK
(cont'd)
11-35
Fueland EmissionsSystems
SystemDescriptions(cont'dl \ {
'Aftertheenginestarts,theIACvalveopensforacertainamountoftime.Theamountofairisincreasedtoraisethe
i d l es D e e d .
. When the engine coolanttemperatureis low, the IACvalve is openedto obtain the properfast idle speed.The
amount of bypassedair is controlledin relationto enginecoolanttemperature.
THROTTLEAODY
VARIOUS
SENSOnS
BLK
IntakeAir SystemDiagram
This systemsuppliesair for engine needs.A resonatorin the intakeair pipe providesadditionalsilencingas air is
drawn into the svstem.
THROTTLEAODY
VARIOUS
SENSORS
BLK
11-36
Emission(EVAPIControlDiagram
Evaporative
The EVAPcontrolsminimizethe amount of fuel vapor escapingto the atmosphere.Vapor from the fuel tanKrs
temporarilystoredin the EVAPcanisteruntil it can be purgedfrom the canisterinto the engine and burneo.
. The EVAPcanisteris purged by drawing fresh air through it and into a port on the intakemanifold.
The purgingvacuum is controlledby the EVAPcanisterpurge valve,which operateswheneverengine cootant
temperatureis above 149'F(65"C).
'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensan
regulatesthe flow of fuel vapor to the EVAPcanister.
' D u r i n g r e f u e l i n g , t h e f u e l t a n k v a p o r c o n t rvoal l v eo p e n sw i t h t h e p r e s s u r ei n t h e f u e lt a n k ,a n d f e e d st h e f u e lv a D o r
to the EVAPcanister.
FUELTANK
VAPOR
FUELTANK SIGNALTUBE
VAPOR
RECIRCULATION
VALVE BLU/RED
BLK
FUELFILLCAP EVAP +
CANISTER
VENTSHUT
FUELTANK FUELTANK VALVE
From
VAPOR BLK/YEL --<No. 4 Acc
RECIRCULATION { 1 0A } f u s e
TUBE
EVAP
CANISTER
EVAPTWOWAY
VALVE
(cont'd)
11-37
Fueland EmissionsSystems
SystemDescriptions(cont'd) I
ECM Circuit Diagram
CONNECTOi
mrrrrn
CMP SENSORB
(TDCSENSOn)
I-BRN/YEr-
\, a
11-38
wEc solENorD
_YEL/aLU __f
F=-1
-RED/aLK -----l
Hi I
|-GFN/YEL _l t_r I
I?SCNSOn
I
+
L!l
I ff:l_l
*'*"_-ll-t
I croz
-KnocK
l-
l
I SENSOn I
Y -l-
Ll]
wcoLcoNTnoL
SoLENO|OVAIVE
(cont'd)
11-39
Fueland EmissionsSystems
SystemDescriptions(cont'dl \
ECMCircuitDiagram{cont'd)
-{ffi]
---1t-|
IATSENSOR
-{El
------l
ECTSENSOS
T_""",,..
I-BFN/YEL
CMPSENSOAA
L- IJUNCTION
I CONNECTOR
-
ft^--l
, " , " . , J | t -' :
I REVERSE
I LocK
I soleloto
+ vaLvE
t!j]]
11-40
_1ffi1
----1 | |Fahdl
-'- |
G8N
t ,
I l -r l
'--r- '8r-K-L-| | T
l
BLU/
J.-
HcoNNEcroR
-l .lurcrroru
L9l
F
EVAPCANISTEB
ALK/YEL
WHT/ALU
WHT/NED
WHI/GRN
JUNCTION
CONNECTOR
rrrn
tcM PLUG
N o . 2 I G N I T I O NC O l t
PLUG
No.3IGNITION COIL
(cont'd)
11-41
Fueland EmissionsSystems
SystemDescriptions(cont'd) a
ECMCircuitDiagramlcont'dl
YEI/BLK
IGP2
VET/BLK
---rF-rl
-lF-forl
--JliD\l
--t-l
MAIN BETAV2
a
t_,", :t
l-,r'l r,
-,u-
I SENSOS
f-"'*'o""
tr
IMMOAIL|zERUNIT
a
11-42
SECONDAFY
H02S
(s€NsoR2l
m
tlil
TPS€NSOR
'--{=l
-{r I
CANISTERVEAIT
SHUTVALVE
t-_]
--lti l
EVAP EYPASS
solENorD
To€PS
CONTROLUNIT
CPU
GAUGE ASSEMBTY
(cont'd)
11-43
Fueland EmissionsSystems
SystemDescriptions(cont'dl L
ECMCircuitDiagram(cont'd)
UNDER.HOOD
!
FUSE/RELAY9OX
CONN€CTOF
CONNECTOi
WHI/NED
BLK/YET
lalLREllY_ _l
a
11-44
CONNECTOR
E
""rr"a*J
r''lHr/cnN
I
1
CONNECTOiK
IGNITIONSWITCH
lG2
' I
CONNECTOFJ
/GRN
TEST
TACHOMETER
CONNECTO8
UNDER.HOOD
UNDER.DASH
FUSE/FELAYBOX
UNDER.DASH
FUSE/RELAY BOX: POStTtONSWTTCH
4 ACG (1oAt ,or"-9J3{51
1 tGN CO|Lt15A)
2 A/F HEATER{2OA) re* _{F "_.rl
17 FUELPUMPI15A}
1OMETER{7.5AI Brake pedal pressed: closed
14 A/C CLUTCHRELAY{1OA} Brake pedal releasedropen
11-45
Fueland EmissionsSystems
How to Set ReadinessCodes L
MalfunctionlndicatorLamp(MlL)Indication CatalyticConverterMonitorand Readiness
(ln relationto Readiness
Codesl Code
The vehiclehas certain"readinesscodes" that are part NOTE:
of the on-boarddiagnosticsfor the emissionssystems. . Do not turn the ignition switch off during the
lf the vehicle'sbatteryhas beendisconnectedor gone procedure.
dead,if the DTCShave beencleared,or if the ECM has . All readinesscodes are clearedwhen the batteryis
been reset,these codesare set to incomplete.In some disconnectedor when the ECM is clearedwith the
states,part of the emissiontesting is to make sure these OBD ll scantool or HondaPGlvlTester.
codesare set to complete.lf all of them are not set to . Low ambienttemperaturesor excessiveslop-and-go
complete,the vehiclemay fail the emissiontest, or the traffic may increasethe drive time neededto switch
test cannot be finished. the readinesscode from incompleteto complete.
' The readinesscode will not switchto com Dleteuntil
To checkifthe readinesscodesare complete,turn the a l l t h e e n a b l ec r i t e r i aa r e m e t .
ignitionswitch ON (ll), but do not startthe engine.The . lf a fault in the secondaryHO2Ssystemcausedthe
MIL will come on for 15 20 seconds.lf it then goes off, MIL to come on. the readinesscode cannot be set to
the readinesscodesare complete.lf it blinksseveral comDleteuntil vou correctthe fault.
times, one or more readinesscodes are not complete.
To set readlnesscodesfrom incompleteto complete. EnableCriteria
do the procedurefor the appropriatecode. . E C Ta t 1 5 8 " F( 7 0 ' C )o r h i g h e r .
. I n t a k ea i r t e m p e r a t u r e
( l A T )a t 2 0 " F( - 7 ' C ) o r h i g h e r .
. Vehiclespeed is steady,and vehiclespeedsensor
( V S S )r e a d sm o r et h e n 2 5 m p h ( 1 3 k m / h ) .
Procedure
1 . C o n n e ctth e s c a nt o o l t o t h e v e h i c l e ' sd a t al i n k \
c o n n e c t o(rD L C i a, n d b r i n gu p t h e t o o l ' sg e n e r i c \"
O B Dl l m o d e .
2 . Startthe engine.
11-46
EvaporativeEmissions(EVAP)Control Air FuelRatio(A/FlSensorMonitorand
SystemMonitor and Readinesscode ReadinessCode
NOTE: NOTE:
All readinesscode are clearedwhen the batterVis . Do not turn the ignitionswitch off during the
disconnectedor when the ECM is clearedwith the orocedure.
OBD ll scantool or HondaPGM Tester. . All readinesscodesare clearedwhen the bafteryis
The enablecriteriamust be repeatedif the intakeair disconnectedor when the ECM is clearedwith the
temperature(lAT)drops lower than 36'F (20"C)from OBD ll scantool or Honda PGM Tester.
i t s v a l u ea t e n g i n e$ a n u p .
EnableCriteria
EnableCriteria ECTat 140'F(60"C)or higher.
At enginestart up, ECTand IAT are higherthan 32'F
(0"C), but lower than 95'F (35"C). Procedure
At enginestart up, the ECTand IAT are within 12'F 1. Connectthe scantoolto the vehicle'sdata link
(7'C)of each other. connector(DLC),and bring up the tool's generic
O B Dl l m o d e .
Procedure
1. Connectthe scantool to the vehicle'sdata link 2. Start the engine.
connector(DLC),and bring up the tool's generic
O B Dl l m o d e . 3. Test-drivethe vehicle under stop-and-goconditions
with short periodsof steadycruise.Duringthe
2. Startthe engine. drive, decelerate(wirh the throttlefully closed)for
5 seconds.After about 3.5 miles (2.2km).the
3. Test-drivethe vehicleunder stop-and-goconditions readinesscode should switch from incomDleteto
with short periodsof steadycruise.After about complete.
2 . 5m i l e s( 1 . 6k m ) ,t h e r e a d i n e scso d es h o u l d
switchf rom incompleteto complete. 4 . l f t h e r e a d i n e s s c o d e i s s t isl le tt o i n c o m p l e t ec,h e c k
for a temporary DTC.lfthere is no DTC,the enable
4. lf the readinesscodeisstill setto incomplete,check criteriawas probablynot meU repeatthe procedure.
for a temporaryDTC.lf there is no DTC,one or
more of the enablecriteriawere probably not met; Air/FuelRatio(A/FlSensorHeaterMonitor
repeatthe procedure. ReadinessCode
NOTE;All readinesscodes are clearedwhen the battery
is disconnectedor when the ECM is clearedwith the
OBD ll scantool or HondaPGM Tester,
Procedure
'1.
Connectthe scantool to the vehicle'sdata link
connector{DLC),and bring up the tool's generic
O B Dl l m o d e .
(cont'd)
11-47
Fueland EmissionsSystems
How to Set ReadinessCodes(cont'd) \-
MisfireMonitorand Readiness
Code
. This readinesscode is alwaysset to available
becausemisfiring is continuouslymonitored.
. l\4onitoringpauses,and the misfirecounterresets,if
the vehicleis driven over a rough road.
. Monitoringalso pauses,and the misfire counter
holds at its currentvalue.if the throttle position
changesmore than a predeterminedvalue,or if
driving conditionsfall outsidethe rangeof any
relatedenablecriteria,
FuelSystemMonitorand Readiness
Code
. This readinesscode is always setto available
becausethe fuel system is continuouslymonitored
during closedloop operation.
. Monitoringpauseswhen the catalyticconverter,
EVAPcontrol system,and Ay'Fsensor monitorsare
active.
. Monitoringalso pauseswhen any relatedenable
criteriaare not being met. Monitoring resumeswhen
lhe enablecriteriais again being met.
Readiness
Code
ComponentMonitorand
Comprehensive
a
11-48
PGM-FISystem
ComponentLocationIndex
CAMSHAFTPOS]TION{CMP)SENSORB
(TOPDEAD CENTER(TDC}
SENSORI
Troubleshootina.
oaoe 11-95
p;ge 1-1.1
Replacement, 14
ii'- r'1
ELECTRICAL LOAD
.I11---:,I DETECTOR {ELDI
''.!,i(..,.?:fir-J- Troubleshooting,
page1'l-92
.....,..:--.
INTAKEAIRTEMPERATURE
{IATISENSOR
Troubleshooting,
page'l'l-55
Replacement, page11-'l15
f - \
ENGINECOOLANTTEMPERATURE
r l (ECTISENSOR
Troubleshooting, page11-57
R e p l a c e m epnat ,g e1 11 1 4
MANIFOLD ABSOLUTEPRESSURE
(MAP)SENSOR
page11-52
Troubleshooting,
THROTTLEPOSITION
ITP}SENSOR
CRANKSHAFTPOSITION page11-60
Troubleshooting,
ICKPISENSOR KNOCKSENSOR
page'l1-78
Troubleshooting, Troubleshooting, page11-77
page 11-'l16
Beplacement, B e p l a c e m epnat ,g e1 11 1 5
AIR FUELRATIO{A/F)
SENSORISENSOR1}
page 11-84
Trorrbleshooting,
Replacement,page 11-113
{cont'd)
11-49
PGM-FlSystem
ComponentLocationIndex(cont'd) \
\.,
11-50
'}
DATALINKCONNECTOR IDLCI
Information,page 1l 3
GeneralTroubleshooting
PGM.FIMAINRELAY1
page11-97
Troubleshooting,
ENGINECONTROLMODULE
GeneralTroubleshooting Information,
p a g e1 1 3
page I 1-96
Troubleshooting,
11-51
PGM-FISystem
DTCTroubleshooting \ (
DTCP0107:
MAPSensorCircuitLowVoltage ls there about 5 V?
Wires de of femaleterminais
ls there about 5 V?
YES Go to step8.
ls therc continuity?
N O - G o t o s t e p7 .
YES-Repair short in the wire betweenthe ECM
1 . Measurevoltage betweenEClvlconnector ( A 1 9 )a n d t h e M A P s e n s o r . l
t e r m i n a l s4 1 1 a n d 4 2 ' 1 .
NO Updatethe ECM if it does not have the latest
ECM CONNECTOR
A 13'IP} software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
vccr o r i g i n aE
l CM.I
{YEL/BED)
sGr
{GRN/WHT}
11-52
DTCP0108:MAPSensorCircuitHighVoltage 9. MeasurevoltagebetweenMAPsensor3P
terminalsNo.1 andNo.3.
connector
'1.
Startthe engine.Holdthe engine at 3,000rpm with
no load (in neutral)until the radiatorfan comes on, MAP SENSOR3PCONNECTOF
then let it idle.
vccl
{ Y E L / Rl E
, lD
o) cl
2. Checkthe MAP with the scantool. l . l . r l
I lsct
le about 101kPa (780 nmHg, 30 in.Hg)ot highet, d) l{GRN/wHrr
or about2.9 V or higher indicated? Y i
Il
l l
YES Go to step 3.
W i r es i d eo f f e m a l el e r m i n a l s
NO-lntermittent failure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the MAP sensorand at the ECM.I ls there about 5 V?
A {31PI
ECMCONNECTOR
1 2 3
MAP
{GRN/REO} SG1(GRN/WHTI
JUMPER
WIRE
J U M P E RW I A E
Wiresideof femaleterminals
Wire side of fema e te.minals
11-53
PGM-FISystem
DTCTroubleshooting(cont'dl \
DTCPl128:MAPSensorSignalLowerThan DTCPl129:MAPSensorSignalHigherThan
Expected Expected
1. Turn the ignition switch ON (ll). 1. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on,
2. Checkthe MAP with the scantool. then Iet it idle.
\ a
11-54
IATSensorCircuitLowVoltage
DTCP0112: 8. Checkthe temperaturereadingon the scantool.
Be aware that if the engine is warm, the reading
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . w i l l b e h i g h e rt h a n a m b i e n t e m p e r a t u r el I. t h e
engine is cold, the IAT and ECTwill have the same
2. Checkthe IAT with the scantool. v al u e .
ls 302'F (150'C) or highet (or H-Limit in Honda ls the correct ambient temperatureindicated?
node of PGM Tester),ot 0 V indicated?
YES lntermittentfailure,system is OK at this time
VES-Go to step 3. Checkfor poor connectionsor looseterminalsat
t h e I A Ts e n s o ra n d a t t h e E C M . I
NO Go to step 8.
NO Replacethe IAT sensor.l
Disconnectthe IAT sensor2P connector.
YES-Go to step 5.
6 . DisconnectECMconnectorB (24P).
IAT SENSOR2PCONNECTOR
,^\
,
l r 2 l
t
-----Tr--- - l
IAT
_t{RED/YELI
II
W i r es i d eo f f e m a l et e r m i n a i s
ls there continuity?
11-55
PGM-FISystem
DTCTroubleshooting(cont'dl \ I
DTCP0113:
IATSensorCircuitHighVoltage 7. Checkthe IAT with the scantool.
IATSENSOR
2PCONNECTOR
:--- JUMPERWIRE
rJ-- \" {
l ' l L l
-'_-l--_----r--_
sG2 I rAT Wiresideof femaleterminals
{GRN/YEL) IRED/YEL)
I
L ] 1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
JUMPER WIRE
12. Checkthe IAT with the scantool.
Wiresideof femaleterminals
ls - 4"F ( 20"C) or less (or L-Limitin Honda
mode of PGM Tester) or 5 V indicated?
6 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
YES Updatethe ECMif it does not have the latest
software,or substitutea known-goodECI\4then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM.replacethe
originaE
l C M !.
(
\
11-56
DTCP0116:ECTSensorRange/Performance
Problem
NOTE:lf DTCP0117and/or P0118are storedat the
same time as DTCP0116,troubleshootthose DTCSfirst,
then recheckfor DTCP0116,
11-57
PGM-FISystem
DTCTroubleshooting(cont'dl \ (
YES Go to step 3.
ls 150'C (302"F)or higher (ot H-Limit in Honda YES-Repair short in the wire betweenthe ECM
mode ot PGM Tester) or 0 V indicated? ( B 8 )a n d t h e E C Ts e n s o r . l
6. DisconnectECMconnectorB (24P).
11-58
ECTSensorCircuitHighVoltage
DTCP0118: 1 . Checkthe ECTwith the scantool.
ECTSENSOR2P CONNECTOR
\ JUMPERWIRE
lt tt .l t l l
-I-l*,
Ecr Wiresideof femaleterminals
(RED/WHT) {GRN/YEL)
t l 1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
WIRE
JUMPER
1 2 . Checkthe ECTwith the scantool.
wire sideoI Iemaleterminals
ls 20"C ( 4"F) or less (or L-Limitin Honda
mode of PGM Tester) ot 5 V indicated?
6 . T u r nt h e l g n i t i o ns w i t c hO N ( l l ) .
YES- Updatethe ECM if it does not havethe latest
software,or substitutea known-goodECI\4,then
recheck(seepage 11-6).If the symptom/indication
goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
11-59
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCP0122:TP SensorCircuitLowVoltage 8. At the sensorside, measureresistancebetweenthe
TP sensor3P connectorterminalsNo. 1 and No. 2
1 . T u r nt h e i g n i t i o ns w i t c ho N ( 1 1 1 . with the throttlefully closed.
NO Go to step 3.
T e r m i n as li d eo f m a l et e r m i n a l s
3. Turn the ignition switch OFF,
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . YES Go to step 9.
TPSENSOR
3PCONNECTOB
ls thereabout5 V?
Terminalsideof maleterminals
YES-Go to step7.
r (31P).
1 0 . D i s c o n n e cEt C Mc o n n e c t oA
11-60
11. At thewire harnessside,checkfor continuity 13. At thewire harnessside,checkfor continuity
betweenTPsensor3Pconnector terminalNo,2 betweenTPsensor3Pconnector terminalNo.2
a n db o d yg r o u n d . a n db o d yg r o u n d .
11 2 1 3 1 2 3
'PS TPS
(RED/BLX}
REO/BLKI
ls there continuity?
ls thetecontinuity?
YES-Update the ECM if it does not have the latest
YES-Repairshortin the wire betweenthe ECM software,or substitutea known-goodECM,then
{ A 1 5a) n dt h eT Ps e n s o r . l l recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
N O - G o t o s t e p1 2 . originaE
l CM.I
12. ConnectECMconnector terminalA15to body NO- Repairopen in the wire betweenthe ECM
groundwith a jumperwire. ( A 1 5 )a n d t h e T P s e n s o r . l
A 131P)
ECMCONNECTOR 14. lvleasurevoltage betweenECMconnector
t e r m i n a l s4 1 0 a n d A 2 0 .
1 1 2 1 34 5 6 7 9 A 131P}
ECMCONNECTOB
10 1 1 1 1 2 t c 6 19
8 t2021
23124 28129130
wrne
,tf$,rr*, ];uueen
vcc2
(YEL/8LU)
Wire side oJ.femaleterminals
ls there about 5 V?
11-61
PGM-FISystem
DTCTroubleshooting(cont'd) (
DTCP0123:
TPSensorCircuitHighVoltage 7. Measurevoltage betweenECMconnector
terminalsA10 and A20.
1 . T u r nt h e i g n i t i o ns w i t c ho N ( l l )
ECMCONNECTOR
A 131PI
2. Checkthe throttle positionwith the scantool.
6. At the wire harnessside, measurevoltage between NO Updatethe ECMif it does not havethe latest
the TP sensor3P connectorterminalsNo. 1 and soflware,or substitutea known-goodECM,then
No.3. recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe (
TP SENSOR3P CONNECTOR o r i g i n aE
l CM.I
W;resideof femaleterminals
ls thete about 5 V?
NO Go to step 7.
11-62
DTCPl121:TPSensorSignalLowerThan SensorSignalHigherThan
DTCP1122:.fP
Expected Expected
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
2. Checkthe throttle positionwith the scantool. 2. Checkthe throttle positionwith the scantool.
ls 12.9'/.,0.6 V, or higher indicated when the ls 12.9%,0.6 V, or lessindicated when the throttle
throttle is tully opened? is f ully closed?
11-63
PGM-FISystem
(cont'dl
DTGTroubleshootang \ a
DTCP0128:CoolingSystemMalfunction 3. Checkthe radiatorfan.
NO Go to step 2.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d m a k es u r et h e
A,/Cis off.
11-64
DTCP0134:Ay'FSensor(Sensor1) No Activity DTCP0137: HO2S(Sensor
Secondary 2)
Detected CircuitLowVoltage
1. Checkthe attachmentstateof the A,/Fsensor 1 . R e s e t h e E C M( s e ep a g eI 1 - 4 )
( S e n s o r1 ) .
2. Start the engine.Holdthe engine at 3,000rpm wilh
ls it slacked f rom the exhaust pipe? no load (in neutral)until the radiatorfan comes on.
3 . S t a nt h e e n g i n e H
. o l dt h e e n g i n es p e e da t NO-lntermittent failure,system is OK at this time.
3,000rpmwith no load (in neutral)until the radiator Checkfor poor connectionsor looseterminalsat
fan comes on, then let it idle for 2 minute. the secondaryHO2S(Sensor2) and at the ECM.I
YES Go to step 8.
t h e s e c o n d a r yH O 2 S( S e n s o 2
NO Replace r ).1
r (31P).
9 . D i s c o n n e cEt C Mc o n n e c t oE
icont'd)
11-65
PGM-FISystem
DTCTroubleshooting(cont'dl a
10. Checkfor continuitybetweenthe secondaryHO2S DTCP0138: HO2S(Sensor
Secondary 2)
(Sensor2) 4P connectorterminal No. 2 and body CircuitHighVoltage
ground.
1 . R e s e t t h eE C M{ s e ep a g e ' 1 1 - 4 ) .
SECONDARY H02S
2) 4PCONNECTOR
ISENSOR
2. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on.
YES Go to step 4.
JUMPERWIRE
T e r m i n asl i d eo Jm a l et e r m i n a l s
11-66
8 . Checkthe secondaryH02S (Sensor2) output DTCP0139:SecondaryHO2S(Sensor2l Slow
voltagewith the scantool, Response
ls there 1.0 V ot mote? 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
Wiresideof femaleterminals
11-67
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCP0141: Secondary HO2S(Sensor
2l 6. Checkfor continuitybetweenbody ground and
HeaterCircuitMalfunction secondaryH02S (Sensor2) 4P connectorterminals
N o . 3 a n d N o .4 i n d i v i d u a l l y .
ls DTC P0141indicated?
YES-Go to step 3.
s02sHTc
{BLK/WHTI IG1(BLK/ORN}
Wire side ol lemale terminals
ls thereabout3.3 Q ?
T e r m i n asli d eo f m a l et e r m i n a l s
YES Goto step6.
YES Go to step 9.
NO Go to step 12.
1 0 . DisconnectECMconnectorE {31P)
11-68
11. Checkfor continuitybetweenECMconnector 1 3 .Turn the ignitionswitch OFF.
terminalE6andbodyground.
1 4 . Reconnectthe secondaryHO2S(Sensor2) 4P
ECM CONNECTORE {31PI connector.
1 7 . Measurevoltage betweenECMconnectorterminal
E 6a n d A 5 .
ECMCONNECTORS
ls therc continuity?
Y
I
Terminal
sideof maleterminals
N O - C h e c k t h e N o . 4 A C G ( 1 0 A )f u s ei n t h e u n d e r -
dash fuse/relaybox. lf the fuse is OK, repair open in
the wire betweenthe secondaryHO2S(Sensor2)
a n d N o . 4 A C G ( 1 0 A )f u s e . l
11-69
PGM-FISystem
DTCTroubleshooting(cont'dl
FuelSystemToo Lean
DTCP0171: 3. Turn the ignition switch OFF.
P 0 1 0 7P, 0 1 0 8P. 11 2 8 .P 11 2 9 :M a n i f o l da b s o l u t e
p r e s s u r e( M A P )s e n s o r
P1162.P1166,P 1167:4,,/Fsensor(Sensor1) heater
P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH O 2 S( S e n s o 2 r)
P014'l:SecondaryHO2S(Sensor2) heater
P1259:VTECsystem
1 . C h e c kt h e f u e l p r e s s u r e( s e ep a g e1 1 - ' 1 4 5 ) .
'
A973AX-041-XXXXX
ls luel pressure OK?
YES Go to step 2.
Does it hold vacuum?
NO Checkthese items:
YES-Check the enginevalve clearancesand adjust
. lf the pressureis too high, replacethe fuel if necessary,lf the valve clearancesare OK, replace
p r e s s u r er e g u l a t o(rs e ep a g e1 1 - 1 5 2 ) . 1 t h e i n j e c t o r s( s e ep a g e11 - 111 ) . 1
. l f t h e p r e s s u r ei s t o o l o w . c h e c k t h e f u epl u m p ,
the fuel feed pipe,the fuel filter, and replacethe NO-Replace the EVAPcanisterpurge valve.l
f u e l p r e s s u r er e g u l a t o (r s e ep a g e1 1 - 1 5 2 ) . I
11-70
DTCP0300:
RandomMisfireandAny Combination
of the Following:
DTCP0301:
No.1 CylinderMisfire
DTCP0302:No.2 CvlinderMisfire
DTCP0303:
No,3 CvlinderMisfire
DTCP0304:No. 4 CvlinderMisfire
NOTE:
. lfthe misfiring is frequentenoughto trigger detectionof increasedemissionsduring two consecutivedriving cycles.
the MIL will come on, and DTCP0300(and some comlrinationof P0301through P0304)will be stored.
. lf the misfiring is frequentenoughto damagethe catalyst,the MIL will blink wheneverthe misfiring occurs,and OTC
P0300(and some combinationof P0301through P0304)will be stored.When the misfirlng stops,the MIL will remain
on.
1. Troubleshootthe following DTCsfirst if any of them were stored along with the random misfire DTC(s):
P 0 ' 1 0 7P,0 1 0 8P, 1 1 2 8P , 1 1 2 9N r 4 a n i f o ladb s o l u t ep r e s s u r e( M A P )s e n s o r
P0111.P0'172t Fuelsvstem
P0335.P0336:Crankshaftposition(CKP)sensor
P0505:ldle control system
P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio (Ay'F) sensor
P1259:VTECsystem
P1361,P1362:Camshaftposition(CMP)sensorB {Top dead center(TDC)sensor)
P 1 5 1 9l:d l ea i r c o n t r o l( l A C )v a l v e
3. Findthesymptom inthechart below, and dothe relatedproceduresin the order listeduntil you find the cause.
11-71
PGM-FISystem
DTCTroubleshooting(cont'dl I
DTCP0301:
No.1 CylinderMisfire 1 . Determinewhich cylinder(s)had the misfire.
DTCP0302:No.2 CylinderMisfire Does the misf ire occur in the cylinder where the
ignition coil was exchanged?
DTCP0303:No.3 CylinderMisfire
YES Replacethe faulty ignitioncoil.!
DTCP0304:No. 4 CylinderMisfire
NO-Go to step 8.
11-72
1 6 .Test-drivethe vehiclefor severalminutesin the 22. Measurevoltage betweenignition coil 3P
rangeof the freezedata or under various connectorterminal No. 3 and body ground.
conditionsif there was no freezedata.
't7. IGNITIONCOIL3P CONNECTOR
Checkfor a DTCor a TemporaryDTCwith the scan
Tool.
ls there continuity?
DisconnectECMconnectorA {31P)
(cont'd)
11-73
PGM-FISystem
DTCTroubleshooting(cont'dl a
26. Checkfor continuitybetweenbody ground and 28. Checkfor continuitybetweenbody ground and
ECMconnectorterminal (seetable). ECMconnectorterminal (seetable).
ECMCONNECTOR
A {31PI ECMCONNECTOR
A {31P}
Wire s de of femaleterminals N O - R e p a i tr h e e n g i n e . l
3 0 . DisconnectECMconnectorB (24P).
PROBLEM DTC WIRECOLOR
CYLINDER T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
No.1 P0301 YEUGRN
N o .2 P0302 BLU/RED
N o .3 P0303 WHT/BLU
N o .4 P0304 BRN
11-74
voltagebetweenbodygroundandECM
32. fvleasure 36. Exchangethe injectorfrom the problemcylinder
terminal(seetable).
connector w i t h o n e f r o m a n o t h e rc y l i n d e r .
B (24P)
ECMCONNECTOR
3 7 . L e t t h ee n g i n ei d l ef o r 2 m i n u t e s .
33. Turn the ignitionswitch OFF,and removethe NO Updatethe ECM if it does not have the latest
engine cover. software,or substitutea known-goodECM.then
recheck(seepage 1'l-6).lf the symptom/indication
34. Disconnectthe injector2P connectorfrom the goes away with a known-goodEClvl,replacethe
p r o b l e mc y l i n d e r . originaE
l CM.I
4 4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )
l s t h e r e 1 0Q 13A?
t h e i n j e c t o r( s e ep a g e11 -1 1I ) .t
NO Replace
(cont'd)
11-75
PGM-FISystem
DTCTroubleshooting(cont'dl
45. Measure voltagebetweeninjector2Pconnector 48. Connectinjector2PconnectorterminalNo.2to
t e r m i n aNl o .1 a n db o d yg r o u n d . bodygroundwith a jumperwire {seetable).
INJECTOR
2P CONNECTOR INJECTOR2P CONNECTOR
tll-z]
-lt- tll-Z-l
-]_r-l_rNJ
,o,,"=rrrr*,
oI IJUMPER
IwrBE
Wiresideof femaleterminals
Wire side of {emaleterminals
B {24P)
ECMCONNECTOR
49. Checkfor continuitybetweenbody ground and
ECMconnectorterminal (seetable).
11-76
DTGP0325:Malfunctionin KnockSensor 7. Connectstanersubharness 6Pconnector terminal
Circuit N o .5 t o b o d yg r o u n dw i t ha j u m p e w
r ire.
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . STARTERSUAHARNESS
6P CONNECTOR
2. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on,
then let it idle. l1l213l
l._, / l 5 l 6 l
3. Holdthe engineat 3,000-4,000 rpm for at least KS IJUMPER
60 seconds. |RED/BLU)
IW|RE
I
ls DTC P0325 indicated?
Wiresideof femaleterminals
YES-Go to step 4.
6. Checkfor continuitybetweenECMconnector
terminalAg and body ground.
ECMCONNECTOR
A 131P)
ls there continuity?
YES-Go to step 9.
NO Goto step7. YES Updatethe ECM if it does not have the latest
software.or substitutea known-goodECM,then
recheck{seepage '11-6). lf the sym ptomlindication
goes away with a known good ECM,replacethe
originaE
l CM.I
NO Replace t h e o r i g i n a kl n o c ks e n s o ra n d / o r
starter subharness.l
11-77
PGM-FISystem
DTCTroubleshooting(cont'd)
DTCP0335:CKPSensorNo Signal 7. Measurevoltage betweenCKPsensor3P connector
t e r m i n a lN o , 1 a n d b o d y g r o u n d
DTCP0336:CKPSensorIntermittent
Interruption CKPSENSOR3P CONNECTOR
YES Go to step 3.
Wire side of female tefminals
NO Intermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
t h e C K Ps e n s o ra n d a t t h e E C M . I ls thereabout5 V?
CKPSENSOR3PCONNECTOF
CKPSENSOR3PCONNECTOR
,llYtL
L " l
a
IGP
(YEL/BLK} LGl
(
1 2 3 {BRN/YELI
W i r e s i d eo f f e m a l et e r m i n a l s
YES Go to step 9.
Is therebattery voltage?
NO Repairopen in the wire betweenthe CKP
YES- Goto step7. s e n s o ra n d G 1 0 1. I
NO Replace
t h e o r i g i n aC
l K Ps e n s o r . l
a
11-78
'10.l\4easure
voltagebetweenECMconnector
terminal
A7 andbodyground,
ECMCONNECTOR
A 13lPI
Wiresideot femaleterminals
ls there about 5 V?
N O - G o t o s t e p1 1 .
DisconnectECMconnectorA (31P)
1 3 . Checkfor continuitybetweenECMconnector
terminal 47 and body ground.
ECMCONNEfiORA (31P)
Wiresideof femaleterminals
ls there continuity?
11-79
PGM-FlSystem
DTCTroubleshooting(cont'dl
DTCP0500:VSSCircuitMalfunction 9. Turn the ignitionswitch OFF.
ls the correct speed indicated? 12. Blockthe right front wheel. and slowly rotatethe
left front wheel.
YES-lntermiftent failure,system is OK at this time.
'!3.
Checkfor poor connectionsor looseterminalsat lMeasurevoltage betweenECMconnector
t h e V S Sa n d a t t h e E C M . I t e r m i n a l sA 1 8 a n d A 2 4 .
NO Go to step 3. A I31PI
ECMCONNECTOR
A {31P)
YES Updatethe ECM if it does not have the latest
ECMCONNECTOR
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
origlnaE
l CM.I
NO Checkthese items:
NO Go to step 9.
11-80
DTCP0563:ECMPowerSourceCircuit 9 . Removethe glove box (seepage20-63).
Unexpected
Voltage
1 0 .Removethe PGM-FImain relay 1 (A7.
1 . R e s e t h e E C I \ {4s e ep a g el 1 - 4 } .
3. Wait 5 seconds.
4 . T u r nt h e i g n i t i o ns w i t c hO N { l l l .
YES Go to step 5.
8 . lvleasurevoltagebetweenECMconnectorterminal
E7 and body ground.
ECMCONNECTOR
E {31P}
MRLY
Wiresideof {emaleterminals
ls there continuity?
NO Go to step 9.
(conl'd)
11-81
PGM-FISystem
DTCTroubleshooting(cont'dl
14. Measurevoltage betweenECMconnectorterminal 1 8 .Removethe glove box (seepage 20-63).
E7 and body ground.
1 9 .Removethe PGM-FImain relay '1{A).
ECMCONNECTORE 13lPI
MRLY
IBEO/YEL)
W i r es i d eo f f e m a l et e r m i n a l s
NO-Update the ECM if it does not have the latest 20. Measure voltagebetween body ground and ECM
software,or substitutea known-goodEClvl,then connector terminals A3 and A2 individually.
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
ECMCONNECTOR
A {31PI
o r i g i n aE
l CM.I
IGP2 IGP1
(YEL/BLK) (YEL/BLK)
1 5 . DisconnectECI\4connectorA (31P).
to. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ECMCONNECTOR
A {3.IP)
W i r es i d eo f f e m a l el e r m i n a l s N O R e p l a c e t h eP G M F l m a i n r e l a y1 . !
11-82
DTGPl106:BAROSensorRange/Perfomance DTCPl107:BAROSensorCircuitLowVoltage
Problem
DTCPl108:BAROSensorCircuitHigh
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . Voltage
2. Startthe engine.Holdthe engineat 3,000rpm with 1 . R e s e t h e E C M{ s e ep a g e11 - 4 ) .
no load (in neutral)until the radiatorfan comes on,
then let it idle. 2. Turn the ignition switch ON (ll).
Acceleratefor 5 secondsusingwide open throttle. YES-Update the ECM if it does not havethe iatest
software,or substitutea known-goodECI\4,then
Checkfor a TemporaryDTCwith the scantool. recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
Is TemporaryDTC Pl106 indicated? originaE
l CI\4.I
YES-Update the ECM if it does not have the latest NO- Intermittentfailure,system is OK at this
software,or substitutea known-goodECM.then trme.l
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
o r i g i n aE
l C M !.
NO Intermittentfailure,system is OK at this
time.I
11-83
PGM-FISystem
DTGTroubleshooting(cont'dl L
Sensor(Sensor1)Range/
DTCPl157:Ay'F 6. Checkfor continuitybetweenECMconnector
Performance
Problem t e r m i n a l4s6 a n dA 1 6 .
1 . R e s e t t h eE C I M( s e ep a g e1 1 - 4 ) .
ECMCONNECTOR
A {3IP)
2. Startthe engine.
YES-Go to step 3.
JUMPERWIRE
11-84
8. Checkfor continuitybetweenECMconnector Sensor(Sensor1)AFS-
DTCPl158:Ay'F
terminals46 andbodyground. TerminalLowVoltage
A 131P}
ECMCONNECTOR 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.
YES Go to step 3.
NO Go to step 6.
' c o n td )
11-85
PGM-FISystem
DTCTroubleshooting(cont'd) (
YES Updatethe ECM if it does not have the latest 2. Start the engine.
software,or substitutea known-goodECM,then
recheck(seepage 11-6).if the symptom/indication ls DTC P1159 indicated?
goes away with a known-goodECM,replacethe
originaE
l CM.I YES-Go to step 3.
5. Checkfor continuitybetweenECMconnector
terminal 46 and body ground.
a
ECMCONNECTOR
A {31PI
ls therecontinuity?
NO Goto step6.
11-86
6. Substitutea known-goodAy'Fsensor(Sensor1i and
recnecK.
l s D T C P 1 1 5 9i n d i c a t e d ?
t h e A y ' Fs e n s o r( S e n s o r1 ) . 1
NO Replace
11-87
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCPl163:Ay'FSensor(Sensor1) Slow DTCPl164:A,/FSensor(Sensor1)Circuit
Response Range/Performance
Problem
NOTE:lf DTCP1162is storedat the same time as DTC ( s e ep a g e1 t - 4 ) .
1 . R e s e t t h eE C I \ 4
P1163.troubleshootDTCP1162first, then recheckfor
D T CP 1 1 6 3 . 2 . S t a r tt h e e n g i n e .H o l d t h e e n g i n e a t 3 , 0 0r0p m w i t h
no load (in neutral)until the radiatorfan comes on,
1 . R e s e t h e E C M( s e ep a g e11 - 4 ) .
3. Test-drivein 3rd gear.Startingat 1,600rpm,
2. Startthe engine.Hold the engine at 3,000rpm with accelerateusing wide open throttlefor at least
no load (in neutral)until the radiatorfan comes on. 5 seconds.Then deceleratefor at least5 seconds
with the throttle completelycloseduntil the A,/F
3. Test-driveunderthe following conditions: sensorreadinesscode is set to completeor
TemporaryDTCP1164comes on.
. 55 mph (89 km/h) steadyspeed
' Transmissionin sth gear 4. Checkfor a TemporaryDTCwith the scantool.
' Until the Ay'Fsensorreadinesscode or
TemporaryDTCPl163 comes on ls TemporaryDTC P1164indicated?
11-88
DTCPl166:Ay'FSensor(Sensor1)Heater Is therc battery voltage?
CircuitMalfunction
YES-Update the ECM if it does not have the latest
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) . soflware,or substitutea known-goodECM.then
recheck(seepage 11-6).lf the symptom/indication
2. Startthe engine. goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
ls DTC P1166indicated?
NO-Go to step 5.
YES-Go to step 3.
5. MeasurevoltagebetweenECMconnector
NO-lntermittent failure,system is OK at this lime. terminalsA22 and A24.
Checkfor poor connectionsor looseterminalsat
the Ay'Fsensorrelay,the A,/Fsensor(Sensor1),and A {31P}
ECMCONNECTOR
t h e E c M .!
4. MeasurevoltagebetweenECMconnector N O - G o t o s t e p1 0 .
terminalsA1 and A24. 30 secondsafter the ignition
s w i t c hi s t u r n e dO N ( l l ) . 6. Turnthe ignitionswitchOFF.
E (31P).
ECMconnector
7. Disconnect
A I31P)
ECMCONNECTOR
8 . T u r nt h ei g n i t i o n
s w i t c hO N{ l l ) .
W i r es r d eo f l e m a l et e r m i n a l s
(cont'd)
11-89
PGM-FISystem
DTCTroubleshooting(cont'dl
9. ConnectECMconnectorterminal EStobody ls there continuity?
ground with a jumper wire, then measurevoltage
betweenECMconnectorterminalsA1 and 424. YES Repairshort in the wire betweenthe A|/F
sensorrelay,A,/Fsensor{Sensor1) and ECM
ECMCONNECTORS
lA22J.a
NO Go to step 13.
1 4 . Measurevoltage betweenECMconnector
terminalsE8 and A24.
ECM CONNECTORS
E {31P)
Wire side of femaleterminals
1 0 .Turn the ignitionswitch OFF. YES-Repair open in the wire betweenthe ECM
(A22)and the IVF sensor(Sensor1).I
1 1 .Disconneclthe ECfMconnectorA (31P)and the Ay'F
sensor(Sensor1) 4P connector. N O - G o t o s t e p1 5 .
11-90
DTCPl167:Ay'FSensor(Sensor1)Heater 6. Checkfor continuitybetweenECMconnector
CircuitMalfunction t e r m i n a l s, 4 6a n d 4 1 6 .
1 . R e s e t t h eE C I \ (4s e ep a g e1 1 - 4 ) trTzTil,ilsl l t 9
t8 2C21
2. Startthe engine.Wait for at least80 seconds. l?rlzsIels
AFS IRED/YEL)
ls DTC P01167 indicated?
YES Go to step 3.
Wire side of lemale terminals
NO-lntermittent failure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the Ay'Fsensorrelay,at the Ay'Fsensor(Sensor1), ls thetecontinuity?
a n da t t h e E C M . I
h eA / Fs e n s o(rS e n s o1r ) . 1
Y E S - R e p l a ct e
? Turn the ignitionswitch OFF.
NO-Repairopenin thewire betweenthe Ay'F
Disconnectthe A,/Fsensor4P connectorand ECM s e n s o(rS e n s o1r) a n dt h eE C M( 4 6o r A 1 6 ) . I
connectorA (31P).
A/F SENSOR(SENSOR1)
4P CONNECTOR
JUMPERWIRE
Wire side of
f e m a l et e r m i n a l s
11-91
PGM-FISystem
DTCTroubleshooting(cont'dl I
DTCPl297:ELDCircuitLowVoltage 8. Turn the ignition switch OFF.
1 . R e s e t h e E C M{ s e ep a g e1 1 - 4 ) . 9. DisconnectECMconnectorE {31P).
YES Go to step 4. I l 2 l 34 5 6 1 7 8 I
to td / 12021
NO Intermittentfailure,system is OK at this time. ,2 2al2/ tA 31
Checkfor poor connectionsor looseterminalsat ELD
t h e E L Da n d a t t h e E C M . I (GRN/RED}
7\'
ELD{GRN/REDI
( E1 5 )a n d t h e E L D r.
ls thereabout5 V?
YES Replace
the ELD.t
N O - G o t o s t e p8 .
11-92
DTCPl298:ELDCircuitHighVoltage 8. T u r nt h e i g n i t i o ns w i t c hO F F .
5. DisconnecttheELD3P connector.
1 0 .DisconnectECMconnectorE (31P).
6. Turn the ignition switch ON (ll).
1 1 .Checkfor continuitybetweenbody ground and
7. Measurevoltagebetweenbody ground and ELD3P ECMconnectorterminal E15.
connectorterminal No. 1.
E 131PI
ECMCONNECTOR
ELD3PCONNECTOR
1 2 1 34 5 o t / I I
14 L C 6 l / 1 8 2C 21
IG1IBLK/ORNI
22123
24 21./ 2Q 30 J
ELD
i1' IGRN/RED)
(cont'd)
11-93
PGM-FISystem
DTCTroubleshooting(cont'dl
12, Checkfor continuitybetweenELD3P connector
t e r m i n a lN o . 2 a n d b o d y g r o u n d .
E L D 3 PC O N N E C T O R
W i r e s i d eo f f e m a l et e r m i n a l s
ls there continuity?
W i . e s i d eo f f e m a l et e r m i n a l s
NO Replace
the ELD.I
11-94
DTCPl361:CamshaftPosition(CMP)Sensor 7. l\4easure
voltage betweenCMP sensorB {TDC
B (TDCSensor)Intermittent
Interruption sensor)3P connectorterminal No. 1 and body
ground.
DTCPl362:CamshaftPosition(CMP)Sensor
B (TDCSensor)No Signal CMP S€NSOR 8 ITDCSENSOR)3P CONNECTOR
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.
B {TDCSENSOR)
CMPSENSOR 3PCONNECTOR
Wire s de olfema etefminals
IGP
{YEL/BLK}
1 2 3 ls there battery voltage?
Y E S - G o t o s t e p9 .
YES Go to step 7. YES Updatethe ECMif it does not have the latest
software,or substitutea known-goodECM,then
NO-Repair open in the wire betweenthe PGM-Fl recheck(seepage 11-6).lf the symptom/indication
m a i n r e l a y1 a n dt h e C M Ps e n s o rI ( T D Cs e n s o r ) . I goes away with a known-goodECM,replacethe
originaE
l CM.I
NO ReplacetheoriginaC
l MPsensorB(TDC
sensor).1
(cont'd)
11-95
PGM-FISystem
(cont'd)
DTCTroubleshooting
10. MeasurevoltagebetweenECI\4
connectorterminal DTCPl607:Malfunction
in ECMInternal
A26andbodyground. Circuit
A (31P)
ECMCONNECTOR 1. ResettheEC|\illsee page 11-4).
2 , T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r
1 2 3 4 5 6 1 7 I 40 seconds.
0 1 11 2 1 . / 61,/18 I 2C2l
2324 21m 30 ls DTC P 1607 indicated?
TDC {GRN}
YES Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11 6). lf the symptom/indication
goes away with a known-goodECM,replacethe
Wire side oI temaleterminals o r i g i n aE
l CM.I
N O - G o t o s t e p1 1 .
1 1 .Turnthe ignitionswitchOFF.
\
1 2 . Disconnect
ECIM A (31P)
connector
Checkfor continuitybetweenECMconnector
terminal426 andbodyground.
ECMCONNECTOR
A {31PI
Wiresideof femaleterminals
ls there continuity?
11-96
MIL CircuitTroubleshooting
1. Connectan OBD ll scantool/HondaPGM Tester . A l o o s eN o . 1 7 F U E LP U M P( 1 5 A ) f u s ei n t h e
( s e ep a g e1 1 - 3 ) . under-dashfuse/relaybox.
. A p o o rc o n n e c t i o n
a t E C Mt e r m i n a E
l 31.
2. Turn the ignition switch ON (ll) and readthe OBD ll . An intermittentopen in the GRN/ORNwire
scantool/HondaPGM Tester. b e t w e e nt h e E C M( E 3 1 a) n d t h e g a u g ea s s e m b l y .
. An intermittentshort in the wire betweenthe
Does the OBD ll scan tool/Honda PGM Tester ECM(A21)and the manifold absolutepressure
communicatewith the ECM? ( M A P )s e n s o r .
. An intermittentshort in the wire betweenthe
YES Go to step 3. ECI\4(A20)and the throttle posilion (TPisensor.
. An intermittentshort in the wire betweenthe
"
NO Go to troubleshooting DLCCircuit ECM (E5)and the fuel tank pressure(FTP)sensor.
T r o u b l e s h o o t i n g (" s e ep a g e1 1 - 1 0 9 ) .
6. Turn the ignition switch OFF.
3. Checkthe OBD ll scantool/HondaPGM Testerfor
DTCs. 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Are any DTCs indicated? ls the low oil pressure light on?
NO-Go to step 4. N O - G o t o s t e p8 .
Does the MIL come on and stay on for more than YES Go to step L
20 secondsaftet turning the ignition switch
oN (tr)? N O R e p a i rs h o n i n t h e w i r e b e t w e e nN o . 1 0
M E T E R( 7 . 5 A ) f u s e a n d t h e g a u g ea s s e m b l yA. l s o
YES lf the MIL alwayscomes on and stayson, go r e p l a c e t h eN o . 1 0 M E T E R{ 7 . 5 A f) u s e . l
to step 76. But if the lMlLsometimesworks
normally,first checkfor these problems. 9. Inspectthe No. 20 lG1 (40A)(Canada:50A)fuse in
the under-hoodfuse/relaybox.
. An intermittentshort in the wire betweenthe
E C I M( E 2 9 a
) n dt h e d a t al i n kc o n n e c t o(rD L C ) . ls the f use OK?
. An intermittentshort in the wire betweenthe
E C M( E 3 1 a ) n dt h e g a u g ea s s e m b l y . YES Repairopen in the wire betweenthe No. 20
l G ( 4 0 A ){ C a n a d a5r0 A ) f u s ea n d t h e g a u g e
NO lf the MIL is alwaysoff, go to step 6. But if the assembly.lf the wire is OK, test the ignition switch
lvllLsometimesworks normally,first checkfor {seepage 22 53).
these problems.
N O R e p a i rs h o r ti n t h e w i r e b e t w e e nN o . 2 0 l G
. A l o o s eN o . 1 0 M E T E R( 7 . 5 A f)u s ei n t h e u n d e r ( 4 0 A )l C a n a d a5: 0 A ) f u s ea n d t h e u n d e r ' d a s h
fusel
dash fuse/relaybox. r e l a yb o x .A l s o r e p l a c et h e N o . 2 0 l G ( 4 0 A i
. A l o o s eN o . 2 0 l G ( 4 0 A )( C a n a d a5: 0 A ) I u s ei n t h e ( C a n a d a5: 0 A )f u s e . I
under-hoodfuse/relaybox.
. A i o o s eN o . 6 E C U( E C M )( 1 5 A )f u s ei n t h e u n d e r -
hood fuse/relaybox.
(conr'd)
11-97
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
1 0 .Tryto startthe engine. to. Removethe blown No. 6 ECU{ECfU)(154)fuse
from the under-hoodfuse/relaybox.
Doesthe enginestart?
1 7 . Removethe glove box (seepage 20-63)and the
Y E S - G ot o s t e p1 1 . P G M ' F Im a i n r e l a y1 .
N O - G o t o s t e p1 4 .
1 1 .Turnthe ignitionswitchOFF.
ECMCONNECTOR
E 13lPI
l l 2 l 34 5 6 1 7 l1 8I
4 1 5161,/118 2( 2t
2' 23 24 z7l/ 129 31
1 8 . Checkfor continuitybetweenbody ground and
JUMPER MIL
(GRN/ORN}
WIRE P G M - Fm l a i n r e l a y1 4 P c o n n e c t otre r m i n a l sN o . 2
a n d N o .4 i n d i v i d u a l l v .
PGM-FIMAIN RELAY1
Wire side of femaleterminals 4P CONNECTOR
ls the M lL on?
f V (wHr/
B
v)
YES Updatethe ECM if it does not have the latest BLK)(
software,or substitutea known-goodECM,then IA
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECIM,replacethe
o r i g i n aE
l CM.I W r r es r d eo l l e m a l et e r m r n a l s
N O - G o t o s t e p1 6 .
11-98
19. Disconnecteach of the componentsor the 21. Checkfor continuitybetweenPGM-FImain relay 1
connectorsbelow, one at a time, and checkfor 4P connectortermlnal No. 1 and body ground.
continuitybetweenPGM-FImain relay 1 4P
PGM-FIMAIN RELAY1
connectorterminal No. 1 and body ground. 4P CONNECTOR
. PGfvl-Flmain relay 2
. ECMconnectorA (31P)
. Eachinjector2P connector
. ldle air control (lAC)valve3P connector
. CamshaftPosition(CMP)sensorB (Topdead
center(TDC)sensor)3P connector
. Crankshaftposition(CKP)sensor3P connector
PGM-FIMAIN RELAY1
4PCONNECTOR
Wire side of femaleterminals
ls there continuity?
l a i n r e l a y1 .A l s o r e p l a c e
N O - R e p l a c et h e P G M - Fm
t h e N o 6 E C U{ E C I M()1 5 A )f u s e .I
Wire side of femaleterminals
( 1 5 A ) f u s ei n t h e
22. I n s p e c t t h eN o . 1 7 F U E LP U I \ 4 P
ls thete continuity? under-dashf use/relaybox.
. P G M - Fm l a i n r e l a y2
. E C Mc o n n e c t oA r (31P)
. lnjectors
. l d l ea i r c o n t r o l( l A C ) v a l v e
. CamshaftPosition{CMP)sensorB (Top dead
center(TDC)sensor)
. Crankshaftposition(CKP)sensor
(conr'd)
11-99
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
25. Checkfor continuitybetweenECMconnector 27. Checkfor continuitybetweenECIVI
connector
terminal E9 and body ground. terminalEgandbodyground.
E (31P)
ECMCONNECTOR ECMCONNECTOR
E 131P)
11-100
31. Checkfor continuitybetweenfuel pump5P 33. Checkfor continuitybetweenfuel pump5P
connectorterminalNo.5 andbodyground. connectorterminalNo.5 andbodyground.
=
Wire side ol lemal€ rerminals
(cont'd)
11-101
PGM-FISystem
(cont'dl
MIL CircuitTroubleshooting
37. lvleasure voltagebetweenECM/PCM connector 40. lvleasurevoltage betweenPGN4-Fl main relay 1 4P
t e r m i n aEl 7a n db o d yg r o u n d . c o n n e c t otre r m i n a lN o . 4 a n d b o d vq r o u n d .
PGM-FIMAIN RELAY1
ECM CONNECTORE {31PI ilP CONNECTOR
MRLY
MRLY(RED/YEL)
ECMCONNECTOR
E 131PI
MRLY(RED/YEL)
ls there continuity?
11-102
42. ReconnectECI\4connectorE {31P). 48. MeasurevoltagebetweenPGM-FImainrelay1 4P
terminalNo.2 andbodyground.
connector
4 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
PGM.FIMAIN RELAY1
4PCONNECTOR
44. Measurevoltage betweenbody ground and ECM
connectorterminals42 and 43 individually.
ECMCONNECTOR
A {31PI
NO Go to step 45. 4 9 . T u r nt h e i g n i t i o ns w i t c hO F F .
IGPl (YEL/BLK)
W i r es i d eo f f e m a l et e r m i n a l s
4 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . ls there continuity?
YES Replace
t h e P G M - Fm
l a i n r e l a y1 . 1
{cont'd}
11-103
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
51. MeasurevoltagebetweenbodygroundandECM 53. Turn the ignitionswitch OFF.
terminals44, A5,423,and424
connector
individuallv. 54. Disconnectthe manifoldabsolutepressure(MAP)
sensor3P connector.
ECMCONNECTOR
A 131P)
PG2(BLK) PG1IBLKI 55. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ECMCONNECTOR
A {31P)
W i r es i d eo f f e m a l et e r m i n a l s
N O - R e p a i r o p e ni n t h e w i r e ( s )t h a t h a d m o r et h a n Wiresideof femaleterminals
1.0V betweenG 10'l and the ECM (A4,A5, A23,
A24l.a ls there about 5 V?
r (31P).
5 8 . D i s c o n n e cEt C Mc o n n e c t oA
Wiresideof femaleterminals
ls there about 5 V?
N O - G o t o s t e p5 3 .
11-104
59. Checkfor continuitvbetweenECIM connector t t, Turn the ignition switch OFF.
t e r m i n a4l 2 1a n db o d yg r o u n d .
o z , Disconnectthe throttle position(TP)sensor3P
ECM CONNECTORA {3,IPI connector.
6 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ECMCONNECTOR
A 131P)
ls there continuity?
ECMCONNECTOR
A {3TP} 65. Turn the ignition switch oFF.
W i r es i d eo t f e m a l tee r m i n a l s
ls there about 5 V?
N O - G o t o s t e p6 1 .
conlo
11-105
PGM-FISystem
MIL CircuitTroubleshooting(cont'd)
6 7 . Checkfor continuitybetweenECIM connector 68. Measurevoltage betweenbody ground and ECM
t e r m i n aAl 2 0a n db o d yg r o u n d . c o n n e c t otre r m i n a lE 5 .
A (31P)
ECMCONNECTOR
E (31PI
ECMCONNECTOR
r l 2 l 3 1 54 o t / 9
10 t1 121,/1,/ 1516 ta, 9 2A21
22 '3 241 12526 n
vcc2
{YEL/
o BLU}
YES Repairshon in the wire betweenthe ECN4 YES U pdatethe ECM if it does not have the latest
{A20)and the TP sensor,or repairshort in the wire software,or substitutea known-goodECM,then
betweenthe ECM (A8) and the knocksensor.t recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodEClvl,replacethe
NO Updatethe ECM if it does not have the latest o r i g i n aE
l CM.t
software.or substitutea known-goodECM,then
recheck(seepage l1-6).lf the symptom/indication NO-Go to step 69.
goes away with a known-goodECM,replacethe
originaE
l CM.t 6 9 . Turn the ignition switchOFF.
1 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
11-106
72. MeasurevoltagebetweenbodygroundandECM 7 6 . T u r nt h e i g n i t i o ns w i t c hO F F .
connector
terminalE5.
7 7 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ECMCONNECTOR
E 131P}
7 8 . Measurevoltage betweenECMconnectorterminal
E 2 9a n d b o d y g r o u n d .
E (31P)
ECMCONNECTOR
r l 2 l 3 1 4
5 6 1 8 9
,/1,/114
15 6 2A21
22 23 241 l,/ 2930
scstBRN)
Wire side of femaleterminals
ls there about 5 V?
Wiresideof femaleterminals
YES Replacethe FTPsensor.t
Is there continuity?
(cont'd)
11-107
PGM-FISystem
MIL GircuitTroubleshooting(cont'd)
81. Checkfor continuitybetweenECMconnector
t e r m i n a lE 2 9a n d b o d y g r o u n d .
ECMCONNECTOR
E 131P}
r l 2 l 34 5 8 I
14 t c 61,/118 2A21
22123124 271./ 3031
scs(BRN)
o
ls there continuity?
DisconnectECMconnectorE (31P).
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
11-108
DLCCircuitTroubleshooting
lf the ECMdoes not communicatewith the OBD ll scan 3. Measurevoltage betweenDLCterminalsNo. 5 and
tool, HondaPGfMTester,or l/M test equipment,do this No. 16.
troubleshootingprocedure.
DATALINKCONNECTOR
{DLC)
1. Measurevoltage betweenDLCterminal No. 16 and
body ground.
DATALINKCONNECTOR
{DLCI
(WHT/RED)
Terminalside of femaleterminals
T e r m i n asli d eo f l e m a l et e r m i n a l s
Terminalsideof Jemale
terminals ls there 8.5 V or more?
(cont'd)
11-109
PGM-FISystem
DLCCircuitTroubleshooting
{cont'dl
7. DisconnectEClvlconnectorE (31P).Make sure the ls there continuity?
O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s
disconnectedfrom the DLC. YES U pdatethe ECMif it does not have the latest
software,or substitutea known-goodECM,then
8. Checkfor continuitybetweenDLCterminal No. 7 recheck(seepage 11-6).lf the symptom/indication
a n d b o d yg r o u n d . goes away with a known-goodECM,replacethe
originaE
l CI\4.I
DATALINKCONNECTOR
IDLC)
NO Repairopen in the wire betweenDLCterminal
N o . 7 a n dt h e E C M{ E 2 3 )A. f t e rr e p a i r i n gt h e w i r e ,
checkthe DTCwith the OBD ll scantool/Honda
PGl\4Tester,and go to the DTCTroubleshooting
Index.l
1 0 .T u r nt h e i g n i t i o ns w i t c hO F F .
' I.
1 DisconnectECI\4connectorE (31P).l\4akesure the
O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s
Ierminal side of femaleterminals disconnectedfrom the DLC.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ls there continuity?
tJ. Measurevoltage betweenDLCterminalsNo. 5 and
YES-Repair short to ground in the wire between No.7.
DLCterminal No. 7 and the ECM {E23).After
r e p a i r i n gt h e w i r e ,c h e c kt h e D T Cw i t h t h e O B Dl l
scantool/HondaPGM Tester,and go to the DTC
DATALINKCONNECTOR
{DLC} t
Troubleshootingindex.I
NO Go to step 9.
ECMCONNECTOR
E {31PI
Terminalside of femaleterminals
K-LINE{LTBLU) Is there 0 V?
11-110
InjectorReplacement
(seepage1l-144).
fuel pressure
1 . Relieve
ffi\t\
*\
4 . R e m o v e t h e f u erl a i lm o u n t i n g n u t s ( Ef)r o m t h e f u e l r a i l( F ) t h e nr e m o v e t h e f u e rl a i la n d i n j e c t o r sa s a n a s s e m b l y .
(cont'd)
11-111
PGM-FISystem
InjectorReplacement(cont'd)
7 . C o a t t h e n e w o - r i n g s ( A ) w i t h c l e a n e n g i n e o l l , a n d i n s e r t t h e i n j e c t o risn(tBo)t h e f u e lr a i l( C ) .
8 , l n s t a ltl h e i n j e c t o cr l i p { D ) .
1 0 . I n s t a l l t h ei n j e c t o r si n t o t h e f u e lr a i l ,t h e n i n s t a l tl h e f u e l r a i li n t o t h e i n t a k e m a n i f o l d ( G ) .
1 4 . T u r n t h ei g n i t i o ns w i t c hO N ( l l ) ,b u t d o n o t o p e r a t e t h es t a r t e rA. f t e r t h e f u e lp u m p r u n sf o r a b o u t2 s e c o n d st,h e
fuel pressurein the fuel line rises.Repeatthis two or three times. then checkfor fuel leakage.
11-112
A/F SensorReplacement SecondaryHO2SReplacement
Special Tools Required Special Tools Fequired
O2 sensorwrench,Snap-onYA8875.SPTools 93750, 02 sensorwrench,Snap-onYA8875,SP Tools 93750,
o r e q u i v a l e n ct ,o m m e r c i a l l a
yvailabre o r e q u i v a l e n tc,o m m e r c i a l l a
Vv a i l a b l e
11-113
PGM-FlSystem
ECTSensorReplacement CMPSensorB (TDCSensorl
Replacement
'1.
R e m o v et h e a i r c l e a n e r{ s e ep a g e1 1 - 1 6 2 ) .
11-114
IAT SensorReplacement KnockSensorReplacement
1, Dlsconnectthe IAT sensor2P connector. 1. Removethe intakemanifold bracket(A).
24Nm
(2.4kgt.m,17lbt.ftl
3 . R e m o v et h e k n o c ks e n s o r( B ) .
11-115
PGM-FISystem
GKPSensorReplacement
the CKPsensor3Pconnector.
1. Disconnect
2. RemovetheCKPsensor{A).
12 N.m (1.2kgt m.
8.7 tbf.ftl
11-116
VTEC/VTC
ComponentLocationIndex
-gl
:1
ia i- r-:
@'-;'
-
--tl ;'l--i
lt i..,,
€)
'-
tt
,.. '--'- /
. -'
VTCOILCONTROL
SOLENOID VALVE CAMSHAFTPOSITION
page11-118
Troubleshooting, ICMPISENSORA
11-'l27
Test,page Troubleshooting,page 11-121
Pagel'!-128
Replacement,
VTCSOLENOID VALVE
page11-123
Troubleshooting,
page11-128
Removal/lnspection,
11-117
VTEC/VTC
DTGTroubleshooting
DTCP0010:WC Oil ControlSolenoidValve 8. MeasureresistancebetweenVTCoil control
Malfunction s o l e n o i dv a l v e2 Pt e r m i n a l sN o . 1 a n d N o . 2 .
W i r e s i d eo f 1 6 m a l et e . m i n a t s
Wiresideof femaleterminals
NO Go to step7.
11-118
11. Checkfor continuitybetweenECMconnector DTCP0011:VTCSystemMalfunction
t e r m i n a l sB 1 a n d B 2 3a n d b o d y g r o u n di n d i v i d u a l l y .
1. Resetthe EClvl(seepage 11-4).
2 . S t a r tt h e e n g i n e .H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h
n o l o a d ( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n .
1 3 .Checkfor continuitybetweenECMconnector N O - G o t o s t e p6 .
t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .
6 . Turn the ignition switch OFF.
vfc
(8LK/WHT)
W i r e s i d eo f f e m a l er e r m i n as
ls there continuity?
Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e E C M( B 1 ,
B23)and the VTCoil control solenoidvalve.l
(cont'd)
11-119
VTEC/VTC
DTCTroubleshooting(cont'dl
Removethe VTC strainer(A).Checkthe WC 13. ConnectECM connectorterminalsA3 and 81 witha
s t r a i n e fro r c l o g g i n g . j u m p e rw i r e m o m e n t a r i l y .
ECM CONNECTORS
NO-Clean the VTC strainer,then replacethe Did the engine stall or run rough?
e n g i n eo i l f i l t e ra n d t h e e n g i n eo i l . l
YES Test-driveat a steadyspeedbetween
9. Checkthe VTCoil control solenoidvalve{seepage 20 40 mph (30 60 km/h)for 10 minutes.
11-127
). lf temporaryDTCP00'l1 is indicated,updatethe
ECIVIif it does not have the latestsoftware,or \
ls the VTC oilcontrol solenoid valve OK? substitutea known-goodECM,then recheck(see
page 11-6).lf the symptom/indicationgoes away
YES Go to step 10. with a known-goodECM,replacethe original
E C M !.
NO Cleanthe ports of the WC oil control solenoid
valve,or replacethe VTCoil control solenoidvalve NO Go to step 14.
{seepage 11-127).a
1 4 . Checkthe VTC actuator(seepage6,8).
1 0 .InstalltheVTCoil control solenoidvalve.
ls the VTC actuatot OK?
1 1 .Startthe engine.Hold the engine at 700 1,000rpm.
YES Removethe auto-tensioner(see page 4-281,
1 2 . C o n n e cEt C Mc o n n e c t otre r m i n a lB 2 3 t o b o d v and clean or replacethe VTC oil strainer.Update
g r o u n dw i t h a j u m p e rw i r e . the ECI\4if it does not have the latestsoftware,or
substitutea known-goodECM,then recheck(see
ECMCONNECTOR
B {24PI
page 11-6).lf the symptom/indicationgoes away
with a known-goodECM,replacethe original ECM.
T
213415 6 7
8 e l1a,/1,/ 15 NO Replacethe VTC actuator.t
1 181./l l./ 21 23
vTc JUMPER
(BLK/WHT} WIRE
11-120
CMPSensorA No Signal
DTCP0340: 7. MeasurevoltagebetweenCMPsensorA 3P
terminalNo. 1 andbodyground.
connector
DTGP0344:CMPSensorA Intermittent
Interruption CMP SENSORA 3P CONNECTOR
'11-4).
1 . R e s e t h e E C M( s e ep a g e
2. Startthe engine.
YES-Go to step 3. W i r e s i d eo l f e m a l e t e r m i n as
;f-;-1 J ,o,,r.*,"r.,
CMPSENSORA 3P CONNECTOR I l1 l-t
,-or---T--I
{8RN/YEL)
ni-
tG1
(BLK/YEL}
1 2 3
YES Go to step 9.
Wiresideof femaleterminals
NO-Repair open in the wire betweenthe Cl\4P
s e n s oA
r a n dG 1 0 1 . 1
ls there battety voltage?
9. Substitutea known-goodCMPsensorA and
YES Go to step 7. recheck.
NO Replace l M Ps e n s o rA { s e ep a g e
t h e o r i g i n aC
11-128).t
(cont'd)
11-121
VTEC/VTC
DTCTroubleshooting(cont'd)
1 0 .Measurevoltage betweenECMconnectorterminal DTCP0341:WC PhaseGap
A25 and body ground.
1 . R e s e t t h eE C M{ s e ep a g e1 1 - 4 ) .
ECMCONNECTORA 131P)
2. Startthe engine.
ls DTC P0341indicated?
YES Go to step 3.
Wiresideof femalete.minals
3. Checkthe VTC oil control solenoidvalve (seepage
11_127]-.
ls there about 5 V?
Isthe VTC oil control solenoid valve OK?
YES-Repair open in the wire betweenthe ECM
( A 2 5 )a n d C M Ps e n s o rA . I YES-Go to step 4.
t h e c a m c h a i n( s e ep a g e6 - 1 2 ) . 1
NO Replace
11-122
DTCPl259:WEC SystemMalfunction 6. Disconnectthe VTECoil pressureswitch2P
connector.
SpecialToolsRequired
. Pressuregaugeadapter07NAJ P07010A 7. Checkfor continuitybetweenVTECoil pressure
. A/T low pressuregaugew/panel 07406-0070300 switch 2P connectorterminals No. 1 and No. 2
. A/T pressurehose 07406-0020201
. Av/Tpressurehose,2,210mm 07IMAJ-PY4o11A SWITCH
VTECOILPRESSURE
. l"/T pressureadapter07MAJ-PY40120 2PCONNECTOR
. Oil pressurehose 07ZAJ-S54,4200
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
2 . C h e c kt h e e n g i n eo i l l e v e l ,a n d r e f i l li f n e c e s s a r y .
Y E S G o t o s t e P1 4 .
(cont'd)
11-123
VTEC/VTC
DTCTroubleshooting(cont'd)
10. Measurevoltage betweenECMconnectorterminal 14. fMeasure voltagebetweenVTECoil pressure switch
89 and body ground. 2 Pc o n n e c t ot er r m i n a lN
s o .1 a n dN o .2 ,
B (24P)
ECMCONNECTOR
VTECOILPRESSURE
SWITCH
2P CONNECTOR
213415 o 1 VTPSW
8 I a t / t / n 3 15 (BLU/BLK)
(BRN/YELI
WPSW {BLU/BLK}
WiresideofIemale
terminals Wire side of Iemaleterminals
VTECSOLENOIDVALVE
2PCONNECTOR
2 3 415 6 7
I 9 ol./ ./ 13 15
VTPSW{BLU/BLK}
T e r m i n as li d eo f m a l et e r m i n a l s
ls there continuity?
11-124
1 8 . Removethe VTECoil pressureswitch (A) and 23. Turn the ignitionswitch OFF.
s s s h o w n ,t h e n r e i n s t a ltlh e
i n s t a l l t h es p e c i a l t o o l a
VTECoil pressureswitch. 24. Disconnectthe VTECsolenoidvalve 2P connector.
07406-0020201
ot 25. Aftachthe batterypositiveterminalto VTEC
07MAJ-PY,lo11A
and
07406-0070300 07MAJ-PY40120 s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 .
\lsl 26. Startthe engine,then connectthe batterynegative
t:={
t e r m i n a l t oV T E Cs o l e n o i dv a l v e2 P c o n n e c t o r
R A
22 N.m t e r m i n a lN o . 1 , a n d c h e c kt h e o i l p r e s s u r ea t a n
l2.2kgt.m, engine speedof 3,000rpm.
16rbf.ft)
07NAJ-P07010A ls the oil pressure above 390 kPa (4.0 kgt/crtf ,
57 psi)?
B {24P)
ECMCONNECTOR
2 1 . Startthe engine.Holdthe engine at 3,000rpm with
no load (in neutral)until the radiatorfan comes on.
(cont'd)
11-125
WEC/VTC
DTCTroubleshooting(cont'd)
30. DisconnectECMconnector B (24P) 32. ConnectVTECsolenoidvalve 2P connector
terminal No. 2 to body ground with a jumper wire.
Checkfor continuitybetweenECMconnector
t e r m i n a l8 1 5 a n d b o d y g r o u n d .
VTEC SOLENOIDVALVL
2P CONNECTOR
ECM CONNECTORB {24P)
r-.'-r.---.1
t 1 t 2 l
+
JUMPERI VtS
WIRE I IGRN/YEL)
I
Wiresideof femaleterminals
NO Goto step32.
Wiresideof femaleterminals
ls thete continuity?
11-126
WC OilControlSolenoidValveRemoval/Test
1 . R e m o v et h e W C o i l c o n t r o ls o l e n o i dv a l v e( A ) . Connectthe batterypositiveterminal to VTC oil
control solenoidvalve 2P connectorterminal No. 2.
NOTE:lnstallthe valve in the reverseorder of
removalwith a new o-ring (B),then checkthese VTCOILCONTROLSOLENOID
VALVE2PCONNECTOR
tlems:
BATTERY
11-127
VTEC/WC
CMPSensorA Replacement WEC SolenoidValveRemoval/
Inspection
1 . R e m o v et h e a i r c l e a n e r( s e ep a g e11 - 1 6 2 ) .
Resistance:14-30 Q
B-'-----'-l:,",14*
Installthe sensorin the reverseorder of removal
with a new o-ring (B).
6x1.0mm
9.8 N.m (1.0kgf.m, 7,2 lbf.ftl
11-128
ldleGontrolSystem
ComponentLocationIndex
TE'
IDLEAIRCONTROL{IAC)VALVE
page11-'131
Troubleshooting,
11-129
ldle ControlSystem
(
DTCTroubleshooting
DTCP0505:ldle ControlSystemMalfunction 7 . P u ty o u r f i n g e r so n t h e l o w e rp o n ( A )i n t h e t h r o t t l e
oooy.
NOTE:lf DTCP1519is storedatthe same time as DTC
P0505,troubleshootDTCP1519first, then recheckfor
DTCP0505.
3 . D i s c o n n e ct h
t e i d l e a i r c o n t r o l{ l A C )v a l v e 3 P NO With the throttlevalve completelyclosed,
connector. c h e c kf o r v a c u u ml e a k sa, n d r e p a i ra s n e c e s s a r y . l
NO- Replace
t h e I A Cv a l v e . I
11-130
DTCPl519:IACValveCircuitMalfunction 8, Checkfor continuitybetweenbody ground and IAC
v a l v e3 Pc o n n e c t otre r m i n a lN o . 1 .
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
IACVALVE3PCONNECTOR
2. Turn the ignition switch ON (ll)
ls DTC P 1519indicated? 1 2 3
YES Go to step 3. PG1{BLK}
r l 2 l 3 l 45 6 1 7 s
r0 1l 12./ / 115 6 ./118192C21
da 25126 l27ln2930
Wire side of femaleterminals IACV{BLK/RED}
1,)
ls therebattery voltage?
N O G o t o s t e p 11 .
LCOnIOl
11-131
ldle ControlSystem
(
DTCTroubleshooting(cont'd)
11. ConnectIACvalve3Pconnector terminalNo.3to 15. Measurevoltagebetweenbody ground and ECM
bodygroundwith a jumperwire. c o n n e c t otre r m i n a A
l 12.
IACVALVE3PCONN€CTOR
ECMCONNECTOR
A 131P}
r l 2 l 3 1 54 6 1 7 9
IACVIBLK/REO} t 0 1tl12l,/l/ tc 6 ,/ 118 2C21
22 231?4l|
12. zil28 30
JUMPERWIRE
IACVIBLK/RED)
N O - R e p l a c et h e I A Cv a l v e . I
!
ls therecontinuity?
1 3 .Reconnect
the IACvalve3Pconnector.
11-132
A/G SignalCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll). 6. Momentarilyconnectunder-hoodtuse/relaybox
14Pconnectorterminal No. 10 to body ground with
2 . MomentarilyconnectECMconnectorterminals424 a jumper wire severaltimes.
and E18with a jumper wire severaltimes.
UNDER.HOODFUSE/RELAY
BOX
I4P CONNECTOR
1 2 3 5 6
1 8 9 10 11 I J 14
ACC (RED)
JUMPERWIRE
Wiresideof femaleterminals
Wire side of femaleterminals
ls there a clicking noise f rom the NC compressor
ls there a clicking noise I rom the NC compressor clutch?
clutch?
YES- Repairopen in the wire betweenthe ECM
YES Go to step 3. (E'18)and the Ay'Cclutch relay.l
Y E S - T h e a i r c o n d i t i o n i n sg i g n a li s O K . I
11-133
ldle GontrolSystem
AlternatorFRSignalCircuitTroubleshooting
' t . Disconnectthe alternator4P '11.
connectorfrom the Connectalternator4P connector term inal No.4 to
alternalor. body ground with a jumper wire.
2. T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
ALTERNATOR4P CONNECTOR
3 . Measurevoltage betweenECMconnector
t e r m i n a l s4 2 4 a n d 8 1 3 . 1 2
ECM CONNECTORS ALTFIWHT/RED)
A l31Pl 3 4
1 2 1 3 4 5 6 1 1| 1 . , 'I JUMPERWIRE
10 1 1 1 1 2 , / 5 6 , / r8119l2C21
23124 28129130
L (BRN/Y EL)
ALTF
(WHT/REDI
Wiresideof femaleterminals
213 4t5 6 1
8 9ltal,/l/ 15 1 2 .Checkfor continuitybetweenbody ground and
EClvlconnectorterminal 813.
Wire side of femaleterminals
B (24PI
ECMCONNECTOB
ls there about 5 V?
YES Go to step 4.
\
N O - G o t o s t e p1 3 .
6. Slan the engine.Hold the engineat 3,000rpm with Wire side of femaleterminals
no load (in neutral)until the radiatorfan comes on,
then let it idle. ls there continuity?
9. DisconnectECMconnectorB (24P).
11-134
ElectricalPowerSteering(EPSI
SignalCircuitTroubleshooting
ls there continuity?
Wire side of femaleterminals
YES Repairshort in the wire betweenthe ECM
( 8 1 3 )a n dt h e a l t e r n a t o r . l ls there battery voltage?
5 . l\4easurevoltage betweenECMconnector
t e r m i n a l sA 2 4 a n d E 1 6 .
Y E S T h e E P Ss i g n a li s O K . t
N O G o t o s t e p1 0 .
6 . T u r nt h e i g n i t i o ns w i t c hO F F .
8 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
(cont'd)
11-135
ldle ControlSystem
ElectricalPowerSteering(EPSISignalCircuitTroubleshooting(cont'd)
'13.
9. Measure voltagebetweenEPScontrolunitterminal l\4easure voltagebetweenEPScontrol unitterminal
N o . l 7a n db o d yg r o u n d . N o . 1 7a n d t h e b o d y g r o u n d .
EPSCONTROLUNIT2OPCONNECTOR
EPSCONTROLUNIT2OPCONNECTOR
NO- Repairopen in the wire betweenthe ECM 1 4 . Turn the ignition switch OFF.
( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l
t5_ D i s c o n n e c t t hE
e C Mc o n n e c t oE
r {31P).
1 2 3 4 5 6 1 7 l1 89
5 6 . / 1 8 2A21
22 23 zi ./ 2930 o l
EPSLD
{LTGRN/BLK)
a,
Wiresideot Iemaleterminals
lsthere continuity?
11-136
BrakePedalPositionSwitch SignalCircuitTroubleshooting
1. Checkthe brakelights. , T O P( 1 5 A )f u s el n t h e
4 . I n s p e ctth e N o . 7 H O R N S
under-hoodfuse/relaybox.
Are the brake lights on without pressing the brake
pedal? ls the tuse OK?
YES-Go to step 3.
NO Go to step 4.
3. MeasurevoltagebetweenECMconnector
terminalsA24 and E22with the brakepedal
presseo.
11-137
ldle ControlSystem
ldle Speedlnspection
NOTE: 3 . Startthe engine.Holdthe engineat 3,000rpm with
' Leavethe idle air control (lAC)valve connecled. n o l o a d ( i n n e u t r a l u) n t i lt h e r a d i a t ofra n c o m e so n ,
. Beforecheckingthe idle speed,checkthese items: t h e nl e t i t i d l e .
- T h em a l f u n c t i o n i n d i c a t o lra m p ( M l L )h a s n o t b e e n
reportedon. 4 . Checkthe idle speedwith no-loadconditions;
- l g n i t i o nt i m i n g headlights,blower fan, radiatorfan, and air
- S p a r kp l u g s conditioneroff.
- Aircleaner
- PCVsystem ldle speedshould be: 750 t 50 rpm
. P u l l t h ep a r k i n gb r a k el e v e ru p . S t a r tt h e e n g i n e a
, nd
make sure the headlightsare off. 5 . Let the engine idle for 1 minute with the heaterfan
switch on Hl and air conditioneron, then checkthe
1. Disconnectthe evaporativeemission(EVAP) i d l es p e e d .
canisterpurge valve 2P connector.
ldle speedshould be: 750 t 50 rpm
2. Connecta tachometer(A)to the test tachometer
connector(B),or connectthe HondaPGM Tester(C) NOTE:lf the idle speed is not wilhin specification,
or an OBD ll scantool to the data link connector go to the Symptom TroubleshootingIndex,
(DLC)(D) locatedunder the driver'sside of the
dashboard. 6 . Reconnectthe EVAPcanisterpurgevalve 2P
connector.
11-138
ECMldle LearnProcedure
The idle learn proceduremust be done so the ECMcan
learnthe engine idle characteristics.
Procedure:
To completethe idle learn procedure,do this:
11-139
FuelSupplySystem
ComponentLocationIndex {
PUMP
T e s t ,p a g e1 1 - 1 4 1
Fleplacement, page 11'153
FUELFILTER
Replacement, page 11-152
FUELGAUGESENDINGUNIT
T e s t ,p a g e1 1 - 1 5 6
Replacement, page 11-153
FUELPRESSUN REGULATOR
Replacement, page'11-'152
FUELFILLCAP
FUELTANK
R e p l a c e m epnat ,g e '1l - 1 5 5
FUELTUBE/OUICK.CONNECT FITTINGS
Precautions, page 11-148
Removal, p a g e11-'149
Installation,page 11-'l50
FUELFEEDLINE FUELVAPORLINE
a
FUELPULSATIONDAMPER
page11'154
Replacement,
i . . /
PGM.FIMAIN RELAY1
PGM.FIMAINRELAY2
T r o u b l e s h o o t ipnagg, e ' l ' l - 1 4 1
11-140
FuelPumpCircuitTroubleshooting
lf you suspecta problemwith the fuel pump, checkthat 5. N4easure
voltage betweenPGM-Flmain relay 2 5P
the fuel pump actuallyruns;when it is on, you will hear connectorterminal No. 1 and body ground.
some noise if you listento the fuel fill port with the fuel
fill cap removed.The fuel pump should run for 2 PGM.FI MAIN RELAY2
5P CONNECTOR
secondswhen the ignition switch is first turned on. lf
the fuel pump does not make noise,checkas follows:
YES Go to step 6.
E
t 2 l
IGPl
(YEL/BLK}
Ftxm
7 -
z
IMOFPR ECMCONNECTOR
E 131P}
(GBN/
YEL)
Wiresideof femaleterminals
Wire side of femaleterminals
ls there battery voltage?
ls therecontinuity?
YES-Go to step 5.
YES-Go to step9.
NO Repairopen in the wire betweenthe PGM'Fl
m a i n r e l a y1 a n dt h e P G M - Fm
l a i n r e l a y2 . t NO-Repairopenin thewire betweenthe PGMFl
m a i nr e l a y2 a n dt h eE C M( E 1 ) . 1
(cont'd)
11-141
FuelSupplySystem
FuelPumpCircuitTroubleshooting(cont'dl (
L R e i n s t a l l t hP
e G M - Fm
l a i n r e l a y2 . ls there battery voltage?
N O - R e p l a c et h e P G M - Fm
l a i n r e l a y2 . 1
(
Turn the ignition switch OFF.
1 3 .ReconneclECMconnectorE (31P).
N O - G o t o s t e p1 9 .
20. R e m o v et h e P G M - Fm
l a i n r e l a y2 .
Wiresideof femaleterminals
11-142
21. ConnectPGM-Flmain relay 2 5P connector 25. Checkfor continuitybetweenfuel pump 5P
terminalsNo. 1 and No. 2 with a iumDerwire. connectorterminal No. 4 and body ground.
PGM.FIMAIN RELAY2
5P CONNECTOR FUELPUMP5P CONNECTOR
FUEL
PUMP
(YEL/
GRN) FNI E
JUMPER
WIRE tri
rcr fv
{YEL/BLK)
dffi
A
Wiresideol femaleterminals
Y E S R e p l a c e t h eP G M - Fm
l a i nr e l a y 2 . t
11-143
FuelSupplySystem
FuelPressureRelieving
Beforedisconnectingfuel lines or hoses,relieve 9. Placea rag or shop towel over the quick-connect
pressurefrom the system by disconnectingthe fuel fitting (A).
tube/quickconnectfitting in the enginecompartment.
1 . T u r nt h e i g n i t i o ns w i t c hO F F ,
l a i n r e l a y2 ( A ) .
2 . R e m o v et h e P G M - Fm
3 . S t a r t t h ee n g i n e a, n d l e t i t i d l e u n t i li t i s s t a l l s . NOTE:
. P r e v e ntth e r e m a i n i n gf u e l i n t h e f u e lf e e d l i n e o r
NOTE:The DTCSor TemporaryDTCSP0301.P0302, hosefrom flowing out with a rag or shop towel.
P0303,P0304may come on during this procedure. . Be carefulnotto damagethe line (E)or other
lf any DTCSare stored,ignorethem. parts.
. Do not use tools.
4 . Turn the ignitionswitch OFF. . l f t h e c o n n e c t o r d o e ns o t m o v e ,k e e p t h er e t a i n e r
tabs presseddown, and alternatelypull and push
Removethe fuel fill cap, and relievefuel pressure the connectoruntil it comes off easily.
inthefueltank. . Do not removethe retainerfrom the line; once
removed,the retainermust be replacedwith a
6 . Removethe enginecover. new one.
11-144
FuelPressureTest
Special Tools Required
. Fuel pressuregauge 07406-0040004
. Fuel pressuregaugesel 07ZAJ-S5A0100
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 ' 1 - 1 4 4 ) .
11-145
FuelSupply System
FuelLineInspection
Checkthe fuel system lines,hoses,and fuel filter for damage,leaks,and deterioration.Replaceany damagedparts.
Makesurethe connectionis
secureand the quick-connect
fitting cover is firmly lockedinto place.
11-146
Checkall clampsandretightenif necessary.
A: Do notdisconnect
the hosefromthe lineat theseioints.
Settheboltflange
T h e r es h o u l d b e n o
W.W Setthispart
C l a m pi n t h e m i d d l e .
C l a m pi n t h e m i d d l e .
t h e f u e l { i l lt u b e ,
a l i g nt h e m a r k s
on the tubeand
t h el i n e .
11-147
FuelSupply System
FuelLine/Ouick-Connect
FittingsPrecaution
The fuel tube/quick-connect fittings connectthe fuel rail
(A)to fuel feed hose (B),the fuel feed hose (B)to the
f u e l l i n e( C ) ,a n dt h e f u e l t u b e( D )t o t h e f u e l p u m p
a s s e m b l y( E ) .W h e n r e m o v i n go r i n s t a l l i n gt h ef u e l f e e d
hose,fuel pump assembly,or fuel tank, it is necessary
to disconnector connectthe quick-connectfittings.
Pay attentionto the following:
. T h e f u e lf e e dh o s e( B ) ,f u e lt u b e ( D ) ,a n d q u i c k -
connectfittings (F)are not heat-resistanU be careful
not to damagethem during welding or other heat-
generalrngproceoures.
. T h ef u e l f e e dh o s e( B ) ,f u e l t u b e( D )a n d q u i c k -
connectfittings (F)are not acid-proof;do not touch
them with a shop towel which was used for wiping
batteryelectrolyte.Replacethem if they came into
contactwith electrolyteor somethingsimilar.
11-148
FittingsRemoval
FuelLine/Ouick-Gonnect
1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e1 ' l - 1 4 4 ) . 4. Checkthe contactarea (A) of the line (B)for dirt and
d am a g e .
2 . Checkthe fuel quick-connectfiftingsfor din, and
clean if necessary. . lf the surfaceis dirty, clean it.
. if the surfaceis rusty or damaged,replacethe
Hold the connector(A) with one hand and squeeze f u e l p u m p ,f u e l f i l t e r f, u e l f e e dl i n e .
the retainertabs(B)with the other hand to release
them from the lockingpaws (C).Pullthe connector
off.
=k
NOTE:
. B e c a r e f u ln o t t o d a m a g et h e l i n ei D ) o r o t h e r
parts.Do not usetools.
. lf the connectordoesnot move, keepthe retainer
tabs presseddown, and alternatelypull and push
the connectoruntil it comes off easily.
. Do not removethe retainerfrom the line; once
removed,the retainermust be replacedwith a
new one.
NOTE:
. The retainercannot be reusedonce it has been
r e m o v e df r o m t h e l i n e .
Replacedthe retainerwhen
- replacing t h e f u e lr a i l .
- r e p l a c i n gt h e f u e lf e e dI i n e .
- r e p l a c i n gt h e f u e l p u m P .
- replacingthe fuel filter.
- replacing t h e f u e l g a u g es e n d i n gu n i t
- it has been removedfrom the line.
- it is damaged.
11-149
FuelSupply System
FuelLine/Ouick-Connect
Fittingslnstallation
1. Checkthe contacta rea (A) of the line (B)for dirt and 3. Beforeconnectinga new fueltube/quick-connect
damage,and clean if necessary. fitting assembly(A),removethe old retainerfrom
t h e m a t i n ol i n e ,
11-150
4. Align the quick-connectfittingswith the line (A). 5. lvlakesure the connectionis secureand that the
a n d a l i g nt h e r e t a i n e (r B )l o c k i n gp a w l sw i t h t h e p a w l sa r ef i r m l y l o c k e di n t o p l a c e c; h e c kv i s u a l l y
connector{C)grooves.Then pressthe quick- and by pullingthe connector.
connectfittings onto the line until both retainer
p a w l sl o c kw i t h a c l i c k i n gs o u n d .
N O T E ;l f i t i s h a r dt o c o n n e c tp, u t a s m a l la m o u n to f
n e w e n g i n eo i l o n t h e l i n ee n d .
11-151
FuelSupply System
FuelPressureRegulator FuelFilterReplacement \ {
Replacement
The fuel filter should be replacedwheneverthe fuel
pressuredrops belowthe specifiedvalue {270 320 kpa,
1 . R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 ) . 2.8 3.3 kgflcm', 40 47 psi),after makingsure that the
fuel pump and the fuel pressureregulatorare OK.
2 . Removethe fuel pressureregulator(A).
1 . R e m o v et h e f u e l p u m p ( s e e p a g e l l - ' 1 5 3 ) .
@-to
Re
IJ
e"^
^e
AR
...\
g s @n-)
s g
Installthe part in the reverseorder of removalwith
a n e w o - r i n g( B ) .
11-152
FuelPump/FuelGaugeSendingUnit Replacement
SpecialToolsRequired 8 . R e m o v et h e l o c k n u (t A )a n d t h e f u e lt a n k u n i t .
F u e ls e n d e rw r e n c h0 7 X A A - 0 0 1 0 1 0 A
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
9 . R e m o v et h e s t o p p e r{ O ) .R e l e a s e t h e h o o k ( P )a n d
r e m o v et h e f u e lf i l t e r( B ) ,t h e f u e l g a u g es e n d i n g
t e f u e l p u m p 5 Pc o n n e c t o(rB ) .
5 . D i s c o n n e ct h u n i t ( C ) .t h e c a s e( D ) ,t h e w i r e h a r n e s s( E ) ,a n d t h e
fuel pressureregulator(F).
Disconnectthe quick-connectfitting {C)from the
f u e lt a n ku n i t . 1 0 . W h e nc o n n e c t i n g t h e f u e lt a n k u n i t ,m a k es u r et h e
connection i s s e c u r ea n d t h e s u c t i o nf i l t e r( G )i s
7 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t t o t h e f u e lp u m p ( H ) .
f i r m l yc o n n e c t e d
locknut(A).
1 1 . I n s t a ltl h e f u e lt a n ku n i t i n t h e r e v e r s eo r d e ro f
r e m o v aw l i t h a n e w b a s eg a s k e t( l ) a n dn e w o - r i n g s
( J ) ,t h e nc h e c kt h e s ei t e m s :
. W h e nc o n n e c t i n tgh e w i r e h a r n e s sm , a k es u r e
t h e c o n n e c t i o ni s s e c u r ea n d t h e c o n n e c t o(rK )i s
f i r m l y l o c k e di n t ot h e p l a c e .
. W h e n i n s t a l l i n gt h e f u e l g a u g es e n d i n gu n i t ,
make sure the connectionis secureand the
c o n n e c t oirs f i r m l y l o c k e di n t o p l a c e .B e c a r e f u l
not to bend or twist the connectorexcessively.
. W h e ni n s t a l l i n g t h e f u e l t a n ku n i t ,a l i g nt h e m a r k s
93 N.m ( L )o n t h e f u e lt a n k( M ) a n d t h e f u e lt a n k u n i t( N i
19.5kgf.m,69 lbf.ftl
11-153
FuelSupply System
FuelPulsationDamperReplacement
1 . R e l i e v et h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 4 ) .
2. Removethe enginecover.
4 . R e m o v et h e g r o u n dc a b l e( G1 0 1 .
5 . R a i s et h e f u e l r a i l .
6 . P l a c ea w r e n c h( A )o n t h e f u e l r a i l( B ) .
7 . P l a c ea w r e n c h( C )o n t h e f u e l p u l s a t i o nd a m p e r( D ) .
8. Removethe pulsationdamper.
NOTE:
. Replaceall washerswhenever the fuel pulsation
damper is loosenedor removed,
. l f t h e d r a i nh o l e( A )o f t h e f u e l p u l s a t i o n d a m p e r
cover does not face bottom, reinstallit as shown.
11-154
FuelTank Replacement
1 . R e l i e v e t h e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
Removethe fuel pipe cover (A).Disconnectthe fuel vapor hose and quick-connectfittings.
Disconnectthe hoses.Slide backthe clamps (B),then twist the hosesas you pull to avoid damagingthem.
(}
\
A 38N.m
(3.9ksf.m,28lbfft)
6 . R e m o v e t h es t r a pb o l t s ,a n d l e t t h e s t r a p( C )h a n g f r e e .
7 . R e m o v et h e f u e lt a n k ( D ) .l f i t s t i c k s t o t h eu n d e r c o a t o ni t s m o u n t ,c a r e f u l l yp r y i t o f f t h e m o u n t
11-155
FuelSupply System
FuelGaugeSendingUnit Test
Special Tools Required 7. Measurevoltage betweenfuel pump 5P connector
Fuelsenderwrench 07XAA-001010A terminalsNo. 1 and No. 2 with the ignition switch
ON (ll).There should be batteryvoltage.
NOTE;For the fuel gauge system circuitdiagram,refer
to the GaugesCircuitDiagram(see page 22-58||. . lf the voltage is as specified,go to step 8.
. l f t h e v o l t a g ei s n o t a s s p e c i f i e d , c h e c k f o r :
1 . C h e c k t h eN o . 1 0 f U E T E R
{ 7 . 5 A ) f u s ei n t h e u n d e r -
dash fuse/relaybox beforetesting. - a n o p e n i n t h e Y E U B L Ko r B L Kw i r e .
- p o o r g r o u n d( G 5 5 1 ) .
2. Do the gauge drive circuitcheck(see page 22-56|l.
3 . T u r nt h e i g n i t i o ns w i t c hO F F .
FUELPUMP5P CONNECTOR
-VVV-
{Y
{YEL/BLK)
2 9 RESISTOR,
(elrt \
=-a \
//,
\ 4 5 /
11-156
1 0 . C h e c k t h a t t h ep o i n t e r o ft h e f u e lg a u g ei n d i c a t e s 1 5 . M e a s u r er e s i s t a n cbee t w e e nt h e N o . 1 a n d N o . 2
"F". 'l12
terminalswith the float at E (EN4PTY), \HALF
F U L L )a, n d F { F U L L p ) ositions.
. lf the pointerdoes not indicate"F", replacethe lf you do not get the following readings,replacethe
g au g e . f u e l g a u g es e n d i n gu n i t{ s e ep a g e1 ' 1 - 1 6 3 ) .
. lf the pointerindicates"F", inspectthe fuel
gauge sendingunit. Float F
'U2 LOW E
Position
NOTE:The pointerof the fuel gauge returns to the Resistance 1 1 68,5 114.4 130
bottom of the gaugedial when the ignition switch {0) to 13 to 74.5 to 126.6 to 132
is OFF,regardlessof the fuel level.-
NOTE:Removethe No. 9 BACKUP (7.5A)fuse from
11. Relievethe fuel pressure(seepage 11-144\. the under-hoodfuse/relaybox for at least 10
secondsafter completingtroubleshooting,
1 2 . R e m o v et h e f u e l f i l l c a p . otherwiseit may take up to 20 minutesfor the fuel
gaugeto indicatethe correctfuel level.
13. Disconnectthe quick-connectfittingsfrom the fuel
pump.
1 4 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t
locknut(A).
A
93Nm
{9.5ksf.m,69 lbf.ft}
11-157
FuelSupply System
Low FuelIndicatorTest
1 . Do the fuel gauge sendingunit test (seepage 11,
rcol.
. l f t h e l o w f u e li n d i c a t o r g o eo
s f f , t h es y s t e mi s O K .
. lf the low fuel indicatoris still on, referto the low
\,
fuel indicatorCircuitDiagram{seepage 22-58),
and checkthe circuit.
11-158
IntakeAir System
ComponentLocationIndex
i l .
11-159
IntakeAir System
Throttle BodyTest
NOTE:
. Do not adjustthe throttlestop screw. lt is presetat the
factory.
. lfthe malfunction i n d i c a t o lra m p ( M l L )h a sb e e n
reportedon, checkfor diagnostictrouble codes
( D L C S()s e ep a g e1 1 3 ) .
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
!
5 . Checkthe throttle positionwith the scantool. The
readingshould be about 10%when the throttle is
fully closedand about 90% when the throttle is fully
openeo.
11-160
Test
IntakeAir BypassGontrolThermalValve
Special Tools Required 5 . R a i s ea n d l o w e rt h e e n g i n es p e e d a
, n d m a k es u r e
Vacuum Pump/Gauge,0 30 in. Hg A973X-041-XXXXX the vacuum gauge readingdoes not changeas the
rpm cnanges.
1 . S t a nt h e e n g i n e T
. h e nl e t i t i d l € .
lf the vacuum readingchanges,checkfor these
NOTE:The enginecoolanttemperaturemust be proorems:
b e l o w1 4 9 ' F ( 6 5 ' C ) .
. l\4isrouted, leaking,broken,or cloggedintakeair
2 . R e m o v et h e v a c u u mh o s e( A ) f r o mt h e i n t a k ea i r bypasscontrol systemvacuum lines.
duct, and connecta vacuum pump/gaugeto the . A crackedor damagedintakeair bypasscontrol
nose. t h e r m a lv a l v e .
3 . R a i s ea n d l o w e r t h ee n g i n es p e e d a
. n d m a k es u r e
t h e v a c u u mg a u g er e a d i n gc h a n g e sa s t h e e n g i n e
speeocnanges.
. M i s r o u t e dl,e a k i n gb, r o k e n o, r c l o g g e di n t a k ea i r
bypasscontrol system vacuum lines.
. A crackedor damagedintakeair bypasscontrol
t h e r m a lv a l v e .
4 . H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h n o l o a d( i n
neutral)until the radiatorfan comes on, then let it
i dl e .
11-161
IntakeAir System
Air CleanerReplacement Air CleanerElementReplacement
1. Removethe nuts (A) and the stud (B). 1 . D i s c o n n e ct h
t e P C Vh o s e1 A ) .
{0.3kgf m,2lbf.ft)
2. Removethe air cleaner(C). 2 . O p e nt h e a i r c l e a n e rh o u s i n gc o v e r( B ) .
11-162
Throttle CableAdjustment
1 . Checkcablefree play at the throttle linkage.Cable
f r e e p fa v ( A )s h o u l db e 1 0 1 2 m m ( 3 / 8 1 / 2i n . ) .
11-163
IntakeAir System
Throttle CableRemoval/lnstallation
1. Fully open the throttlevalve,then removethe Installin the reverseorder of removal.
throttle cable (A)from the throttle link (B).
5 . After installing,startthe engine.Holdthe engine at
3,000rpm with no load (in neutral)untilthe radiator
fan comes on, then let it idle.
H o l dt h e c a b l e ,r e m o v i n ga l l s l a c kf r o m i t .
T h e s h o u l db e
no crearance.
(P/N08?98-9002)
2 . R e m o v et h e c a b l eh o u s i n g( C ) f r o mt h e c a b l e ('1.0kgf.m,
bracket(D). 7.2 tbf.ftl
SILICONEGREASE B
(P/N08798-9002)
11-164
Throttle Body Removal/lnstallation
NOTE:
' Do not adjustthe throttle stop screw.
. A f t e r r e a s s e m b l y , a d j u s t t h e t h r o t t l e c a b l e { s e e p a g e l l - 1a6n3d)t h e c r u i s ec o n t r o lc a b l e( s e ep a g e4 - 4 5 ) .
. The throttle position(TP)sensoris not removable.
THROTTLE
LEVER
Thereshould be
noclearance
THROTTLECABLE
MANIFOLD
ABSOLUTEPRESSURE
{MAP}SENSOR
22Nm
(2.2 kgt.m, 16 lbf.ft)
EVAPORATIVEEMISSION{EVAPI
CANISTERPURGEVALVE
IDLEAIR CONTROL
{IACI VALVE
11-165
IntakeAir System
Throttle Body Disassembly/Reassembly
2 N.m
{0.2 kgt m, 1 lbf.ft)
V MAPSENSOR
EMISSION
EVAPORATIVE {EVAP)
PURGE
CANISTER VALVE
TPSENSOR THROTTLEBODY
3.5 N.m
(0.35kgf m.2.5lbf ft)
11-166
CatalyticConverterSystem
DTCTroubleshooting
DTCP0420:CatalyticSystemEfficiency
BelowThreshold
NOTE:lf some of the DTCSlistedbelow are storedat
the same time as DTCP0420,troubleshootthose DTCS
first, then recheckfor DTCP0420.
P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH e a t e dO x y g e nS e n s o r
(secondaryHO2S)(Sensor2)
P 0 1 4 1S: e c o n d a r yH O 2 S( S e n s o 2 r )heater
1 . R e s e t h e E C M{ s e ep a g e1 ' l - 4 }t,h e nc o n t i n u et o
step 2 through 5 to resetthe readinesscode.
D r i v ef o r a b o u t l 0 m i n u t e sw i t h o u ts t o p p i n gY. o u r
speeocan vary.
N O C h e c kf o r r e a d i n e s cs o d ec o m p l e t i o nl.f t h e
readinessis complete,it was a interminentfailure,
and the system is OK at this time. lf the readiness
code is incomplete,repeatsteps2 through 5.1
11-167
PCVSystem
DTCTroubleshooting
DTCP1505:PCVAir Leakage
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
. PCVvalve
. PCVhose
. EVAPcanisterpurge valve
. Throttlebody
. Brakeboosterhose
NO - Intermittentfailure,system is OK at this
time.l
11-168
PCVValve Inspectionand Test PCVValve Replacement
1. Checkthe PCVvalve (A),hoses{B),and 'L
Disconnectthe PCVhose.
connectionsfor leaksor restrictions.
Removethe PCVvalve (A).
11-169
EVAPSystem
ComponentLocationIndex
EVAPORATIVEEMISSIONIEVAPI
CANISTERPURGEVALVE
Troubleshooting, 'l1-175,
step 3 on page
s t e p1 o n p a g e1 1 - 1 8 0
FUELTANK VAPORCONTROLVALVE
Test,page 11'187
R e p l a c e m e npt a, g e1 1 1 8 9
EVAPORATIVEEMISSION{EVAPI
CANISTER
step 28 on page 11'183
Troubleshooting,
page 11-189
Replacement,
FUELTANKPRESSURE SENSOR
T r o u b l e s h o o t ipnagg, e11 - 1 7 1
EVAPORATIVEEMISSION{EVAP}
BYPASSSOLENOIDVALVE
Troubleshooting,
s t e p1 p a g e' 1 1 ' 1 7 6 ,
' 120o n
s t e p o n p a g e1 1 1 8 1
EVAPORATIVEEMISSION{EVAP)
CANISTERVENT SHUT VALVE EVAPOBATIVEEMISSON{EVAP)
Troubleshooting, VALVE
TWO WAY 'l1-'186
step 23 on page 1'l 178, Test,page
s t e p1 go n p a g el 1 - 1 8 2
11-170
DTCTroubleshooting
DTCP0451:FTPSensorRange/Performa
nce 6. Connecta vacuum pump to the open end of the
Problem hose.
SpecialTools Required
Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX
1 . R e m o v et h e f u e lf i l l c a p .
ECMCONNECTOR
E 131P)
ECMCONNECTOR
E 13lPI
W i r es i d eo f f e m a l tee r m i n a l s
YES-Go to step 4.
NO Replacethe FTPsensor.I
NO Replacethe FTPsensor.!
11-171
EVAPSystem
DTCTroubleshooting(cont'd)
DTCP0452:FTPSensorCircuitLow Voltage 6. Turn the ignition switch OFF.
3 . R e m o v et h e f u e l f i l lc a p .
VCgl {YEL/BLU}
4. Turn the ignition switch ON (ll)
E 131PI
ECMCONNECTOR
Wiresideof femaleterminals
1 2 t 3 t 45 o / 8 9
././114 tc 61./18 2C 21 ls there about 5 V?
22123241 t 26 271/ 29 31 '1.
TP (LTGRN) YES Go to step 1
ls thete about2.5 V?
NO Go to step 6.
11-172
11. MeasurevoltagebetweenFTPsensor3P connector DTCP0453:FTPSensorCircuitHighVoltage
t e r m i n a l sN o . 2 a n d N o . 3 .
FUELTANKPRESSUBE
1. Checkthe vacuum lines at the FTPsensorfor
SENSOR3P CONNECTOR
misrouting,leakage,breakage,or clogging.
Y E S - G o t o s t e p2 .
N O R e p a i ro r r e p l a c ev a c u u ml i n e sa s
necessary.I
2 . R e s e t h e E C M{ s e ep a g e1 1 ' 4 ) .
W i r e s i d eo f f e m a l e t e r m i n a l s
1 4 .Checkfor continuitybetweenFTPsensor3P 1 1 2 1 34 5 6 7 I 9
connectorterminal No. 3 and body ground. 5 6 / t18 2C 21
24 2il./ 29 30 31
FTPSENSOR3P CONNECTOB TP {LTGRN}
{cont'd)
11-173
EVAPSystem
DTCTroubleshooting(cont'dl
6. Turn the ignitionswitch OFF. 11, Measurevoltage betweenFTPsensor3P connector
t e r m i n a lN
s o . 2 a n dN o . 3 .
7 . R e i n s t al h
l e f u e lf i l l c a p .
FTPSENSOR3P CONNECTOR
8. Disconnectthe FTPsensor3P connector.
9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
FTPILT GRN}
'10.
l\4easure voltage betweenFTPsensor3P connector
t e r m i n a l sN o . 1 a n d N o . 2 .
FTPSENSOR3P CONNECTOR
ls there about 5 V?
NO Go to step 12.
W i r es i d eo f f e m a l tee r m i n a l s
ls there about 5 V?
11-174
DTCPl456:EVAPControlSystemLeakage EVAP Canister Purge Valve Test
(FuelTankSvstem)
3. Disconnectthe vacuum hose from the EVAP
canisterpurge valve (A),and connecta vacuum
The fuel system is designedto allow specified oumo to the hose.
maximum vacuum and pressureconditions.Do not
deviatefrom the vacuum and pressuretests as
indicatedin these procedures.Excessivepressure/
vacuum would damagethe EVAPcomponentsor cause
eventualfuel tank failure.
YES Go to step 2.
YES- Replace
t h e f u e lf i l l c a p . I
N O T h e f u e l f i l lc a p i s O K .G o t o s t e p3 .
{cont'd)
11-175
EVAPSystem
DTCTroubleshooting(cont'd)
8. Checkfor continuitybetweenEVAPcanisterpurge EVAP Bypass Solenoid Valve Test
valve2Pconnenctor terminalNo.2 andbody
grouno. 11, Disconnectboth vacuum hosesfrom the EVAPtwo
way valve (A),and connecta vacuum pump to the
EVAP CANISTERPURGE canisterport on the EVAPtwo way valve.
VALVE 2P CONNECTOR
ls therecontinuity?
9 . Disconnect B (24P).
ECMconnector E 131P)
ECMCONNECTOR
1 0 . Checkfor continuitybetweenEVAPcanisterpurge
terminalNo.2 andbodyground.
valve2Pconnector 1 2 3 4 5 6 1 7 l1 8 9
4 5 6 / 118 2C21
EVAPCANISTERPURGE
2 2 t 2 ? 24 z7l./29
VALVE2PCONNECTOR 2WBS
(BLU/RED}
JUMPER
WIRE
1 2
PCS Wiresideof femaleterminals
{YEL/BLU)
'.\'
1 3 .Turn the ignitionswitch ON (ll).
11-176
1 5 . Turn the ignition switch OFF. '19.
Measurevoltage betweenEVAPbypasssolenoid
valve 2P connectorterminal No. 1 and body ground.
to. Disconnectthe EVAPbypasssolenoidvalve 2P
connecror. EVAPBYPASSSOLENOID
VALVE2PCONNECTOR
1 7 . Checkfor continuitybetweenEVAPbypass
solenoidvalve 2P connectorterminal No. 2 and
body ground.
2
tG'l
EVAP BYPASSSOLENOID {BLK/ORN)
VALVE 2P CONNECTOR
ls there continuity?
{cont'd)
11-177
EVAPSystem
(cont'dl
DTCTroubleshooting
2 0 . P l u gt h e f u e l t a n kp o r t ( A )o f t h e E V A P t w o w a y EVAP Canister Vent Shut Valve Test
valve,
22. Disconnectthe vacuum hosefrom the EVAP
canistervent filter (A),and connecta vacuum pump
to the hose.
25. T u r nt h e i g n i t i o ns w i t c hO F F .
2 1 . Checkfor continuitybetweenEVAPcanistervent
Does the voltagedtop to 1.5 V and hold fot at s h u tv a l v e2 Pc o n n e c t otre r m i n a lN o . 2 a n d b o d y
Ieast 20 seconds? ground.
N O R e p a i rt h e l e a kf r o m t h e E V A Pb y p a s s
solenoidvalve, EVAPtwo way valve.or
F T Ps e n s o r . l
{LTGRN/REOI
W i r es i d eo f f e m a l et e r m i n a l s
11-178
VacuumHosesand ConnectionsTest
Y E S - G o t o s t e p3 1 .
t h e f u e l t a n kv a p o rc o n t r o lv a l v e . l
NO Replace
EVAPCANISTERVENTSHUT
VALVE2PCONNECTOR
11-179
EVAPSystem
DTCTroubleshooting(cont'd)
DTCPl457:EVAPControlSystemLeakage 2. Turn the EVAPcanisterpurge valve on with the
(EVAPCanisterSystem) HondaPGM Tester,or connectECMconnector
terminal 821 to body ground with a jumper wire.
SpecialToolsRequired
Vacuum pump/gauge,0-30 in.HgA973X-041-XXXXX
W i r e s i d eo f l e m a l et e r m i n a l s
This is a two-trip code.Once cleared,it cannot be
reproducedin one trip. Also, certainspecificdriving
and ambientconditionsmust occur beforethe ECfMwill Turn the ignition switch ON (ll).
completethe system checks,Additionaltest drives may
still not meet the specificconditionsneededto 4 . Apply vacuum to the hose.
16^r^.1' '^6 rh6 ^^.16
ls therecontinuity?
YES-Goto step8.
4973X-041-XXXXX
NO Repairopenin thewire betweenthe EVAP
c a n i s t epru r g ev a l v ea n dt h eE C M / P C(M
821).I
s w i t c hO N( l l ) .
8 . T u r nt h ei g n i t i o n
11-180
9. MeasurevoltagebetweenEVAPcanisterpurge EVAP Bypass Solenoid Valve Test
terminalNo. 1 andbodyground.
valve2Pconnector
10. Disconnectboth vacuum hosesfrom the EVAPtwo
EVAPCANISTERPURGE way valve {A),and connecta vacuum pump to the
VALVE2PCONNECTOR canisterport on the two way valve.
ls thetebatteryvoltage?
the EVAPcanisterpurgevalve.l
YES- Replace
1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
NO Repairopenin thewire betweenthe EVAP
'It
canisterpurgevalveandthe No.4 ACG(10A) Apply vacuum to the hose.
fuse.I
Does the valve hold vacuum?
N O - G o t o s t e p1 3 .
1 4 . Disconnectthe EVAPbypasssolenoidvalve 2P
connector.
Checkfor continuitybetweenEVAPbypass
s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d
b o d yg r o u n d .
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
(cont'd)
11-181
EVAPSystem
DTCTroubleshooting(cont'd)
ls there continuity?
to. DisconnectECMconnectorE {31P). 19. Turn the EVAPcanistervent shut valve on with the
HondaPGM Tester,or connectECMconnector
't7.
Checkfor continuitybetweenEVAPbypass terminal E21to body ground with a jumper wire.
solenoidvalve 2P connectorterminal No. 2 and
body ground.
E (3TP)
ECMCONNECTOR
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
1 1 2 1 34 5 8 9 vsv(
{LTGBN/RED)
\ ,
1/ 1 5tal/la 2A21
lI l tl - 2l l z3lz4 zil./ m 31
2WBS JUMPER
WIRE
-[BLU/REo)
())
I
Wiresideol lemaleterminals
Wire side of femaleterminals
NO Updatethe ECI\4if it does not havethe latest YES-The EVAPcanistervent shut valve is OK. Go
software.or substitutea known-goodEClvl,then to step 27.
recheck(seepage 11-6).lf the symptom/indlcation
goes away with a known-goodECM,replacethe NO Go to step 22.
o r i g i n aE
l CM.I
2 2 . Turn the ignitionswitch OFF.
11-182
24. Checkfor continuitybetweenEVAPcanistervent Canister System Leak Test
Nlo . 2 a n d b o d y
s h u t v a l v e2 P c o n n e c t o r t e r m i n a
ground. 27. Turn the ignition switch oFF.
VATVE2P CONNECTOR
2 8 , C o n n e c t t w ot,h r e e - w a yT - f i t t i n g s( A )i n t o t h e h o s e
from the EVAPcanisterto the EVAPtwo way valve.
-4- Connectthe FTPsensorto one of the T-fittingsand
r 2l
l-T_*u t h e v a c u u mp u m p t o t h e o t h e l
ILTGFN/REDI
@
wn€ s de ol l€ma1e terminals
ls therc continuity?
25. T u r nt h e i g n i t i o ns w i t c ho N ( l l ) .
3 0 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
(cont'd)
11-183
EVAPSystem
DTCTroubleshooting(cont'dl I
31. While monitoring FTPsensorvoltagewith the 37. While monitoringFTPsensorvoltagewith the
Honda PGM Tester,or measuringvoltage between Honda PGM Tester,or measuringvoltage between
ECMconnectorterminalsE4 and E14,slowly pump E C Mc o n n e c t otre r m i n a l sE 4a n d E1 4 ,s l o w l yp u m p
the vacuum oumD. t h e v a c u u mp u m p .
ECMCONNECTOR
E 13lPI ECMCONNECTOR
E {31PI
32. Continueto pump vacuum until the voltagedrops 38. Continueto pump vacuum until the voltagedrops
to about 1.5V. Make sure the enginecoolant to about 1.5V.Make sure the enginecoolant
temperatureis still above 95'F 135.C)and your temperatureis still above95"F (35"C)and your
v a c u u mp u m p h a s n o l e a k . vacuum pump has no leak.
33. Monitor the voltagefor 20 seconds. 39. Monitor the voltagefor 20 seconds
Does the voltage drop 1.5V and hold for at least Does the voltage hold for at least 20 seconds?
20 seconds?
YES Inspeclthe fuel tank vapor control lineand
YES Inspectthe EVAPcanistervent shut valve connections.I
l i n ea n d c o n n e c t i o n s . l
NO Go to step 40.
NO-Go to step 34.
40. T u r nt h e i g n i t i o ns w i t c hO F F .
34. Turn the ignition switch OFF.
4 1 .Disconnectthe purge line hose {A) from the
35. Disconnectthe quick-connectfitting (A) fromthe c a n i s t e ar t t h e m e t a ll i n e a n d p l u gt h e h o s e( B ) .
EVAPcanister,and plug the canisterport {B).
4 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
3 6 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
11-184
43. While monitoringFTPsensorvoltagewith the
Honda PGM Tester,or measuringvoltage between
ECMconnectorterminalsE4 and E14,slowly pump
t h e v a c u u mp u m p .
ECMCONNECTOR
E {31P)
Wiresideof femaleterminals
11-185
EVAPSystem
EVAPTwo Way ValveTest
Special Tools Required 4. Move the vacuum pump hosefrom the vacuum
. V a c u u mp u m p / G a u g e , 0 - 3 0i n . H g fitting to the pressurefitting,and move the vacuum
A973X-041-XXXXX gauge hosefrom the vacuum side to the pressure
. Vacuum/Pressure cauge.0-4 in. Hg 07JAZ-0010008 side (A) as shown.
1 . R e m o v et h e f u e l f i l l c a p .
07JAZ-0010008
. lfthe pressuremomentarilystabilizes(valve
o p e n s )a b o v e1 . 0k P a( 8 m m H g , 0 . 3i n . H g )t,h e
Apply vacuum slowly and continuouslywhile v a l v ei s O K .
watchingthe gauge.The vacuum should stabilize . lf the pressurestabilizesbelow 1.0 kPa(8 mmHg,
m o m e n t a r i l ya t 0 . 8 2 . 1 k P a( 6 1 6 m m H g , 0.3 in.Hg),installa new valve and retest.
0 , 2 0 . 6i n . H g ) .
lf the vacuum stabilizes{valveopens)below 0.8 kpa
( 6 m m H g , 0 . 2i n . H g )o r a b o v e2 . 1k P a( 1 6m m H g ,
0.6 in.Hg),installa new valve and retest.
11-186
FuelTankVaporControlValveTest
SpecialToolsRequired ValveTest
VacuumPump/Gauge, 0-30 in. HgA973X-041-XXXXX
1 . N 4 a kseu r et h e f u e lt a n ki s l e s st h a n h a l ff u l l
FloatTest
2 . R e m o v et h e f u e l f i l l c a p .
1 . M a k es u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l .
3. Disconnectthe fuel tank vapor signaltube (A).
2. Removethe fuel fill cap to relievefuel tank
pressure,then reinstallthe cap.
A973X-041-XXXXX
P l u gt h e l i n e( B ) .
A973X-O41-XXXXX
6 . P u m pt h e v a c u u mp u m p 8 0 t i m e s .
. l f t h e v a c u u mh o l d s ,g o t o s t e P7 .
. l f t h e v a c u u md o e sn o 1h o l d ,g o t o s t e p 1 0 .
(cont'd)
11-187
EVAPSystem
FuelTankVaporControlValveTest (cont'd)
7. Connecta secondvacuum pump to the fuel tank Fill the fuel tank with fuel, then checkfor fuel in the
v a p o rs i g n a l t u b e( A ) . EVAPtwo way valve (A),and fuel tank vapor
recirculationhose (B).
11-188
EVAPCanisterReplacement FuelTankVapor ControlValve
Replacement
l. Removethe vacuum hoses(A).
1 . R e m o v et h e f u e lt a n k ( s e e p a g e l l - 1 5 5 ) .
2 . R e m o v et h e f u e l t a n kv a p o rc o n t r o lv a l v e ( A )f r o m
t h e f u e lt a n k( B ) .
11-189
Clutch
Tools
Special .........12-2
Comoonent L o c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . , .1. .2.-. 3
........
ClutchPedal,ClutchPedalPosition Switch,and
ClutchInterlock SwitchAdiustment.................... 12-4
CfutchMasterCylinderRep|acement ..................... 12-5
SlaveCylinderReplacement .'........ 12-7
ClutchReplacement ................... .....12-9
Clutch
SpecialTools a
Ref. No. Tool Number Description Oty
(1, OTJAF-PM7O11A C l u t c hA l i g n m e n tD i s c ,l
@ 07LAB-PV001
00 or 07924-PD20003 R i n gG e a rH o l d e r 1
o 07zAF-PR8A100 C l u t c hA l i g n m e n tS h a f t 1
@ 07936-3710100 R e m o v e rH a n d l e 1
l .
l _ l
'l-r
o o
.{\
.tt./
'\-'/
I
o
a
12-2
ComponentLocationIndex
CLUTCHINTERLOCKSWITCH
""*--/ page12-4
Adjustment,
\,L_.Ei
/i
(,'.' CLUTCH PEDAL
POSTTTON SWITCH
_,___-,-s\
RETAININGCLIP
A d j u s t m e npta, g e ' 1 2 - 4
Replace.
O-RING UTCHPEDAL
Replace. A d j u s t m e n tP, a g e1 2 4
CLUTCHMASTERCYLINDER
pagel2-5
Replacement,
CLUTCHDISC
Bemoval,page 12-9
I n s t a l l a t i op
na, ge'12-12
PRESSURE PLATE
Removal, page'12-9
l n s t a l l a t i opna,g e1 2 - 1 2
RELEASE BEARING
B e p l a c e m epnat ,g e1 2 - 1 3
FLYWHEEL
page'12-1
Inspection, 1
Replacement,page12-11
CLUTCHHOSE
CLIP
SLAVECYLINDER \".rr"*"o*
page 12-7
Replacement,
12-3
Clutch
ClutchPedal,ClutchPedalPositionSwitch, and ClutchInterlockSwitch
Adjustment
NOTE: 3. Tightenthe clutch push-rodlocknut(D).
. To checkthe clutch pedal positionswitch
(seepage 4-45). 4. With the clutch pedal released.turn the clutch
. To checkthe clutch interlockswitch (seepage 4-6). pedal positionswitch (B) in until it contactsthe
. Removethe driver's side floor mat beforeadjusting clutch pedal (C).
the clutch pedal.
. The clutch is self-adjustingto compensatefor wear. 5. Turn the clutch pedal positionswitch {B) in an
. lf there is no clearancebetweenthe mastercylinder additional3/4 to 1 turn.
pistonand push rod, the releasebearingwill be held
againstthe diaphragmspring.which can resultin 6. Tightenthe clutch pedal positionswitch locknut(A).
clutchslippageor other clutch problems.
7. Loosenlocknut(J)and the clutch interlockswitch
1. Loosenthe clutch pedal positionswitch locknut(A), (K).
and backoff the clutch pedal positionswitch (B)
until it no longertouchesthe clutch pedal (C). 8. Pressthe clutch pedalto the floor.
J
9.8 N.m 9 . R e l e a s teh e c l u t c hp e d a l1 0 ' l 6 m m ( 0 , 3 9 0 . 6 3 i n . )
(1.0kgf.m,7.2lbf.ft) from the fully pressedposition,and hold it there.
Adjust the positionof the clutchinterlockswitch (K)
so that the enginewill startwith the clutch pedal in
thls position.
A
9.8 N.m 10. Tightenthe clutch interlockswitch locknut(J).
11.0kgf.m,7.2 lbf.ft)
o
18 N.m
{1.8kgf.m,
13 tbf.ftl
12-4
ClutchMasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may 6. Disconnectthe reservoirhose (D)fromtheclutch
damagethe paint; if brakefluid does contactthe paint, mastercylinder reservoir.Plugthe end of the
wash it off immediatelVwith water. reservoirhose with a shop towel to preventbrake
fluid from coming out.
1 . P r yo u t t h e l o c kp i n ( A ) ,a n d p u l l t h e p e d a lp i n ( B )
out of the yoke. Removethe mastercylinder 7. Removethe O-ring(E)and the clutch master
mounting nuts (C). cylinderseal (F)from the mastercylinder.
UP
i
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
cleanerhousing (seestep 6 on page 5-2).
g-E
(cont'd)
12-5
Clutch
ClutchMasterCylinderReplacement(cont'd)
10. To preventthe retainingclip (A)from coming off,
pry open the tip of the retainingclip (B)with a
screwdriver,
: h e r e s e r v o ifri l l i n gi s c o v e r e di n t h e
N O T ET
bleedingprocedure.
I
l n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
12-6
SlaveCylinderReplacement
NOTE: 6. Removethe mounting bolts (A) andtheslave
. U s ef e n d e rc o v e r st o a v o i dd a m a g i n gp a i n t e d c y l i n d e r( B ) .
surfaces.
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i; t m a y d a m a g e
the paint; if brakefluid does contactthe paint,wash it
off immediatelywith water.
2. Removethe batterytray.
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
c l e a n e rh o u s i n g( s e es t e p6 o n p a g e5 - 2 ) .
(Brak6Assembly
Lube)
9 . P u l l t h eb o o t ( B )b a c k ,a n d a p p l yb r a k ea s s e m b l y
l u b et o t h e b o o ta n d s l a v ec y l i n d e r o d ( C ) .R e i n s t a l l
the boot.
(cont'd)
12-7
Clutch
SlaveCylinderReplacement(cont'd)
11. Bleedthe clutch hydraulicsystem.
L
12. Installthe intakeair duct (seestep 36 on page 5-14).
1 3 .I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 4 . Installthe batterytray.
12-8
ClutchReplacement
Spscial Tools Required 2 . I n s t a l l t h es p e c i atl o o l s .
. Clutchalignmentdisc 07JAF-PM7011A
. Ringgear holder07LAB-PV00100or A
07924-PD20003
. Clutchalignmentshaft 07ZAF-PR8A100
. Removerhandle07936-3710100 \-
PressurePlateand GlutchDiscRemoval
1 . C h e c kt h e d i a p h r a g ms p r i n gf i n g e r sf o r h e i g h t
using lhe speciallool and feelergauge.lf the height
is more than the servicelimit, replacethe pressure A-.- nl I
ptate. \ffim 9fra-I tP 07LAB-PV00100
or
StandardlNewl: 0.6 mm (0.02in.) max. |- 07924-PD20003
ServiceLimit: 0.8 mm {0.03in.)
To preventwarping,unscrewthe pressure plate
07zAF-PR8A100 mountingbolts(A)in a crisscross
patternin several
07936-3710100 plate(B).
OTJAF-PM7O11A steps,then removethe pressure
(cont'd)
12-9
Clutch
ClutchReplacement(cont'd)
6. Inspeclfor warpage using a straightedge (A) and 9. lvleasure th e clutchd isc th ickness.lfthethickness
feeler gauge (B).l\4easureacrossthe pressureplate is lessthan the servicelimit, replacethe clutchdisc.
(C).lf the warpage is more than the servicelimit,
replacethe pressureplate. StandardlNew): 8.3 8.9 mm
(0.33 0.35in.)
Standard{New): 0.03mm (0.001in.) max. ServiceLimit: 6.0 mm {0.24in.)
ServiceLimit: 0.15mm (0.006in.)
I n s p e c t t h el i n i n go f t h e c l u t c hd i s cf o r s i g n so f
s l i p p i n go r o i l . l f t h e c l u t c hd i s ci s b u r n e db l a c ko r
oil soaked.reolaceit.
12-10
FlywheelInspection FlywheelReplacement
1. Inspectthe ring gear teeth for wear and damage. 1 . I n s t a l l t h es p e c i atlo o l .
4 . I n s t a l l t h es p e c i a l t o o lt,h e nt o r q u et h e f l y w h e e l
mounting bolts in a crisscrosspatternin several
sreps.
1 2 x 1 . 0m m
103 N.m
(10,skst.m. 76 lbf ftl
(cont'd)
12-11
Glutch
ClutchReplacement(cont'dl
ClutchDiscand PressurePlateInstallation 5. Torquethe mountingboltsin a crisscrosspattern,
Tightenthe boltsin severalstepsto prevent
'L
T e m p o r a r i l yi n s t a ltl h e c l u t c hd i s co n t o t h e s p l i n e s warping t h ed i a p h r a g m
spring.
of the transmissionmainshaft,Make sure the clutch
disc slidesfreely on the mainshaft. PRESSURE PLATE MOUNTING BOLTTOROUE:
25 N.m{2.6kgt.m,19lbt.ft)
2 . l n s t a l l t h er i n g g e a rh o l d e r .
o
O?ZAF.PRSAIOO
\---,
/v
07936-3710100
{P/N08798-9002)
07LAB-PVo0'100
or
0792,1-PD20003
12-12
ReleaseBearingReplacement 4 . Apply super high temp urea grease{P/N08798-
9002)to the releasefork (A),the releasefork bolt
'L
Removethe releasefork boot (A)from the clutch ( B ) ,t h e r e l e a s eb e a r i n g( C ) ,a n d t h e r e l e a s eb e a r i n g
h o u s i n g( B ) . g ui d e ( D )i n t h e s h a d e da r e a s .
1 . 0 1 . 6g
10.04 0.06oz)
l-'..\
\\ \\
!ac
\ ) ) /
/-/
Xrl-Rl
It\'1
{re\
f-l\-._
0 . 4 1 . 0g
10.01 0.04o
I L!),l-*E
-A
" 0.t 1.09 (0.01 0.04oz)
2 . Removethe releasefork (C)from the clutch
h o u s i n g( B )b y s q u e e z i n tgh e r e l e a s ef o r k s e ts p r i n g With the releasefork slid betweenthe release
( D ) w i t hp l i e r s R
. e m o v et h e r e l e a s eb e a r i n g( E ) . b e a r i n gp a w l s .i n s t a l l t h er e l e a s eb e a r i n go n t h e
m a i n s h a fw t h i l e i n s e r t i n gt h e r e l e a s ef o r kt h r o u g h
3 . Checkthe releasebearingfor play and noise by t h e h o l ei n t h e c l u t c hh o u s i n g .
p l a yo r
s p i n n i n gi t b y h a n d .l f t h e r ei s e x c e s s i v e
n o i s e ,r e p l a c et h e r e l e a s eb e a r i n gw i t h a n e w o n e . 6 . Align the detentof the releasefork with the release
fork bolt,lhen pressthe releasefork over the
NOTE:The releasebearingis packedwith grease. r e l e a s ef o r k b o l ts q u a r e l yM. a k es u r et h e r e l e a s e
Do not wash it in solvent. f o r k s e t s p r i n g( F )i s p r o p e r l ys e t .
7 . I n s t a l l t h er e l e a s ef o r k b o o t{ E ) .M a k es u r et h e b o o t
s e a l sa r o u n dt h e r e l e a s ef o r k a n d c l u t c hh o u s i n g .
12-13
ManualTransmission
SpecialTools 13-2 SynchroRingandGear
Transmission FluidInspection Insoection .......13-39
a n dR e o 1 a c e m e. n. .t. . . . . . . . . . . .|.5-J
...-. Mainshaft BearingandOilSeal
Back-Up LightSwitchTest ..........t J - 5 R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.4, .1. .
Transmission Removal 13-4 Countershaft Bearing
Transmission Installation........... I J-at ReDlacement .. 13-42
Transmission Disassemblv........1 3 - 1 4 Mainshaft ThrustClearance
Reverse ShiftForkClearance Adiustment .....13-43
lnsoection 13-19 Transmission Reassemblv.........13-46
ChangeLeverClearance Gearshift Mechanism
lnsoection 13-19 R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.5. .1. .
ChangeLeverAssembly
Disassembly/Reassembly .......13-20 M/T Differential
ShiftForksClearance Comoonent LocationIndex ........13-52
Inspection 13-21 Backlash Inspection.....................
13-53
ShiftForks FinalDrivenGear/Carrier
Disassembly/Reassembly .......13-22 Replacement .. 13-53
Mainshaft Assemblv CarrierBearingsReplacement ... 13-54
Clearance Inspection 13-23 Oil SealReplacement 13-55
..................
Mainshaft Disassembly 't3-25 Differential
ThrustClearance
Mainshaft lnsoection 13-26 Adiustment .....13-56
Mainshaft Reassembly | 5-2.5
Countershaft Assemblv
Clearance Inspection 13-31
Countershaft Disassembly .........13-32
Countershaft Inspection............. 13-33
Countershaft Reassembly.......... 13-34
SynchroSleeveand Hub
Inspection andReassembly .... 13-39
ManualTransmission
SpecialTools
Ref.No. ToolNumber Description Oty
(!l vs802c000015 E n g i n eH a n g e rA d a p t e r ,2 . 0t o 2 . 4 L i t e r
ar\ vs802c000018 E n g i n eH a n g e r
ral
l
07GAJ-PG20' ]10 M a i n s h a fHt older
@ 07GAJ-PG20130 M a i n s h a fBt ase
07JAD-P190100 O i l S e a lD r i v e r
o 07NAD-P20A100 Oil Seal DriverAftachment
o 07736-A01000B AdjustableBearingPuller,20-40mm
,l
ri)
l
07746-0010300 Attachment,42 x 47 mm
@ 07746-0030100 Driver,40 mm LD.
@ 07746-0030300 Driver,30 mm LD.
@ 07749-0010000 Driver
of Mainshaft Inspection on T o o lS
Tool e t .0 7 G A J - P G 2 0 1 0 2 .
Set,
'16
M u s t b e u s e dw i t h c o m m e r c i a l lay v a i l a b l e3 / 8 " S l i d eH a m m e r .
Z-'
-4
U
@ o
I I
rS'D
A nDr f ;
\'---''
\".,i'i
IN
@ @
-4
-a ,/
Q)-''
o @
13-2
Transmission
FluidInspectionand Back-UpLight Switch Test
Replacement
1. Disconnecttheback-uplight switch (A) connector.
'1.
Parkthe vehicleon level ground,and turn the
e n g i n eO F F .
2 . R e m o v et h e o i l f i l l e rp l u g ( A )a n d w a s h e r( B ) ,c h e c k
the conditionof the fluid, and make sure the fluid is
at the proper level (C).
A
44 N.m{4.5kgt.m,
33rbr.ftl
R e i n s t a tl lh e d r a i np l u gw i t h a n e w w a s h e r ,a n d
refillthe transmissionfluid to the proper level.
Oil Capacity
1.50 (1.6US (F) at tluid change
1.70 {1.8US qt) at overhaul
5 . R e i n s t a tl lh e o i l f i l l e rp l u gw i t h a n e w w a s h e r .
13-3
ManualTransmission
Transmission
Removal
SpecialToolsRequired 8. Removethe cable bracket(A).then disconnectthe
. E n g i n eh a n g e ra d a p t e r . 2 . t0o 2 . 4l i t e rV S B 0 2 C 0 0 0 0 1 5 c a b l e s( B )f r o m t h e t o p o f t h e t r a n s m i s s i o h
nousing.
. E n g i n eh a n g e rV S B 0 2 C 0 0 0 0 1 8 Carefullyremove both cablesand the bracket
. Enginesupport hanger,A & RedsAAR'T 12566' togetherso as not to bend the cables.
. SubframeadaDterEOS02C000011 '
* A v a i l a b l et h r o u g ht h e H o n d aT o o l a n d E q u i p m e n t
Program888-424-6857 H A @
i l B
NOTE:Use fender coversto avoid damaging painted
surfaces.
R e m o v et h e a i r c l e a n e rh o u s i n g( s e ep a g e11 - 1 6 2 ) .
t e t r a n s m i s s i o gn r o u n dc a b l e( B ) .
D i s c o n n e ct h
13-4
10. Carefullyremovethe slavecylinderand clutchline 12. Attach the specialtool to the threaded hole in the
bracketso as not to bend the clutch line. Do not c y l i n d e rh e a d .
operatethe clutch pedalonce the slavecylinder has
been removed,
vsB02c00001s
tJ. I n s t a l l t h ee n g i n eh a n g e r( A ) a n d t h e e n g i n es u p p o r t
hanger {B) to the vehicle,then attachthe hook to the
1 1 .Removethe enginewire harnesscover (A) by
sDeciaitool.
lifting up on the locktab (B),then slidethe harness
f o r w a r do f f t h e a i r c l e a n e rh o u s i n gm o u n t i n g
bracket{C). vs802c000015
(cont'd)
13-5
ManualTransmission
Removal(cont'd)
Transmission
15. Removethe transmissionmount bracket(A) and 20. Removethe three way catalyticconverter(TWC)
n o u n t i n gb o l t ( B ) .
t r a n s m i s s i om assembly(seestep 30 on page 5-5)
to. R e m o v et h e a i r c l e a n e rb r a c k e {t C ) .
1 7 . R a i s et h e v e h i c l e a, n d m a k es u r ei t i s s e c u r e l y
supponed.
1 8 . D r a i nt h e t r a n s m i s s i o fnl u i d .R e i n s t a tl lh e d r a i nb o l t
w i t h a n e w w a s h e r( s e ep a g e1 3 - 3 ) .
db-
-qF
€Ds
1 3- 6
25. Supportthe subframewith the subframeadapter 27. Removethe clutchcover.
and a jack.
---
EOS02C000011
2 8 . R e m o v et h e f r o n t e n g i n em o u n t .
29. P l a c et h e t r a n s m i s s i oina c ku n d e rt h e t r a n s m i s s i o n ,
and removethe transmissionmounting bolts.
(cont'd)
13-7
ManualTransmission
TransmissionRemoval(cont'd) TransmissionInstallation \
30. Pullthe transmissionaway from the engine until Special Tools Required
the transmissionmainshaftclearsthe clutch . Enginehangeradapter,2.0to 2.4 liter VS802C000015
pressureplate,then lower the transmissionon the . En g i n eh a n g e rV S 8 0 2 C 0 0 0 0 1 8
transmissionjack. . Enginesupport hanger,A & RedsAAR-T-12566"
. subframe adaDterEoS02c000011
Removethe transmissionrear mount (A) and the * Availablethrough the HondaTool and Equipment
transmissionrear mount bracket{B). Program888-424-6857
1 . 0 ' 1 . 6g
{0.04 0.06oz)
3 . I n s t a l l t h et r a n s m i s s i o rne a rm o u n tb r a c k e (t A ) a n d
t h e t r a n s m i s s i o rne a rm o u n t( B ) .
't2x 1 . 2 5m m
64 N m {6.5kgf.m, 1 2 x 1 . 2 5m m
47
64 N.m
{6.5 ksf.m,
47 tbf.ft)
P l a c et h e t r a n s m i s s i o o
n n t h e t r a n s m i s s i o ina c k .
and raiseit to the engine level.
13-8
5 . I n s t a l lt h e t r a n s m i s s i o nm o u n t i n g bolts. 8. Supportthe subframewith the subframeadapter
a n da j a c k .
1 2 x 1 . 2 5m m
64 N.m 16.5kgf m.47 lbt ft)
1 2 x 1 . 2 5m m
64 N.m (6.5kgf.m,47 lbf.ft)
6 . I n s t a l l t h ef r o n t e n g i n e m o u n t .
9 . I n s t a l l t h ef r o n t s u s p e n s i o sn u b f r a m e( A )i n i t s
originap l o s i t i o nb y a l i g n i n gt h e m a r k s( B )y o u
made in the removal procedure,
12 x 1.25ftrn
64 N.m
(6.5 kgf m. 47 lbf.ft)
12x 1.25mm
64 N.m
(6.5kst.m,47 lbf ft)
7 . l n s t a l l t h e c l u t c hc o v e r .
1 4x 1 . 5m m
6x1.0mm
12 N.m {1.2kgI.m,9 lbf ftl
(cont'd)
13-9
ManualTransmission
Installation(cont'dl
Transmission
'10.
Installthethree rear mounting bolls for the 1 5 .Installthe transmissionmount bracket(A) and the
transmissionrear mount. transmissiom
n o u n t i n gb o l t{ B ) .
1 2 x 1 . 2 5m m
6x1.0mm 54 N.m {5.5ksf.m, 40lbf.ft)
12Nm
12x 1.25nn
54 N.m
(5.5kgf.m,
40 tbt.ft)
/t':::= 12 x 1.25 mm
-) 54 N.m
(5.5kgf.m,
40 tbf.ftl
12x 1.25mrn
64 N.m(6.5kgt.m,47lbf.ftl
12. Installthe intermediateshaft (seepage 16-24). 1 8 . R e m o v et h e e n g i n eh a n g e ra n d s p e c i atlo o l f r o m
engrne.
t5. Installthedrivershafts(seepage 16-17).
13-10
19. Tightenthe front engine mount bracketmounting 21. lnstallthe brakeboosterand EVAPline bracket
bolt. mounting bolts (A).and air cleanerhousing bracket
'12x 1.25mm m o u n t i n gb o l t ( B ) .T i g h t e nt h e a i r c l e a n e rh o u s i n g
64 N.m 16.5kgf.m, bracketmounting bolt (C),and installthe water
il7 lbf.ft) pipe mounting bolt (D).
A
9.8N.m
( 1 , 0k q f
22N.m
l2.2kglm,
2 0 . I n s t a ltl h e s p l a s hs h i e l d . 16rbt.ft)
%,
9.8Nm
(1.0kgf m.
'B 7.2tbl{rl
22Nm
{2.2kgf m, 16 lbf ft)
22. I n s t a l l t h ee n g i n eh a r n e s sc o v e r .
(cont'd)
13-11
ManualTransmission
Installation(cont'dl
Transmission
Applysuperhightemp ureagrease(P/N08798- 2 5 . I n s t a l l t h ec a b l eb r a c k e (t A )a n d c a b l e s( B ) .
9002)to the endof the slavecylinderrod.Installthe
slavecylinderandthe clutchlinebracket. Takecare
not to bend the clutch line.
8 x 1.25mm
BWZ[i:i'u'T!'*n'-'
6x1.0mm
22 N.m (2.2 kgf.m, 16 lbf ft) 9.8 N.m
(1.0kgf.m,
a^_
#._gEEa9En 7.2 tbt.ftl
(P/N08798-9002)
lPlN 08798-9002)
13-12
28. Connectthe transmissionground cable (A).
8 x 1.25mm
22 N.m (2.2kgf.m, 16lbf.ft)
B [---.-.---e
e
6x1,0mm
9.8 N.m
{1.0kgl m. 7 lbf ftl
8x125mm
22Nm
12.2kgt m, 16lbf ft)
I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 9 o n p a g e
5-15).
34. R e f l l l t h et r a n s m i s s i ofnl u i d ( s e ep a g e1 3 - 3 ) .
39. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
13-13
ManualTransmission
Transmission
Disassembly
ExplodedView-ClutchHousing
,.Y
:
' r'<__J'.@t / ,, tl
j=-X ri ,1.-6
'-==-Yh,_-9
n""
-'- R
,ot/u
v
,t- -1
A' i6 t3l
\?
q'/V^
t€4
13-14
Housing
ExplodedView-Transmission
tt-P
"=-@ @
'\b e
o,. @\ rai
\€:/
P \ B- o
z-W €: iq { " f / o
@------
dd
O=-rl
\ F,z
@
,-1 _\
(g/----------__-
"^\
\-/r*---------..-,
(cont'd)
13-15
ManualTransmission
TransmissionDisassembly(cont'd)
NOTE:Placethe clutch housingon two piecesof wood 3, Removethe interlockbolt (A),the changelever
thick enoughto keepthe mainshaftfrom hittingthe a s s e m b l y( B ) ,8 x 1 4 m m d o w e lp i n s( C ) ,a n d t h e
workbench. c l u t c hl i n ec l i p b r a c k e{t D ) .
R e m o v et h e d r a i np l u g( A ) ,f i l l e rp l u g( B ) ,a n d
1 0 m m f l a n g eb o l t ( C ) .
13-16
5. Removethe 8 mm flange bolts in a crisscross 10. Removethe reverselock cam.
Datternin severalsteos.
g
t.l Y
g
(,
^A
1 1 .Removethe reverseidler gear {A) and reversegear
6 . Removethe transmissionhangerA, and s h a f t{ B ) .
transmissiohn a n g e rB .
7 . R e m o v et h e 3 2 m m s e a l i n gc a p ( A ) .
E x p a n dt h e 7 2 m m s n a pr i n g ( B )o n t h e
countershaftball bearing,and remove it from the
groove using a pair of snap ring pliers.
n o u s i n g( C )a n d
L R e m o v et h e t r a n s m i s s i o h
1 4 x 2 0 m m d o w e l p i n s( D ) .
(cont'd)
13-17
ManualTransmission
TransmissionDisassembly(cont'd)
12. Removethe reverseshift fork. 15. Removethe differentialassembly(A) and magnet
( B) .
t7
t1
I
1 4 . R e m o v et h e 2 8 m m s p r i n gw a s h e r( E )a n d 2 8 m m
w a s h e r( F ) .
13-18
ReverseShift ForkClearance ChangeLeverClearanceInspection
Inspection
1 . Measurethe clearancebetweenchangelever (Al
and the selectlever (B)with a feelergauge (Cf.lf
1. Measurethe clearancebetweenthe reverseidler theclearance i s m o r et h a nt h e s e r v i c el i m i t ,g o r o
gear {A) and the reverseshift fork (B)with a feeler step 2.
gauge (C).lf the clearanceis more than the service
limit, go to step 2. Standard: 0.05 0.25 mm (0.002-0.010in.)
ServiceLimit: 0.50mm {0.020in.)
Standard: 0.20-0.59 mm (o.oo7 0.024 in.l
ServiceLimit: r.3 mm {0.051in.)
Measure the width of the reverseshift fork. . lf distanceis not within the standard,replacethe
c h a n g el e v e rw i t h a n e w o n e .
. l f d i s t a n c ei s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e t h e . l f d i s t a n c ei s w i t h i n t h es t a n d a r dr,e p l a c e t h e
reverseshift fork with a new one. selectlever with a new one.
. lf distanceis within the standard,replacethe
reversegear wrln a new one. Standard: 1 5 . 0 0 1 5 . 1 0m m ( 0 . 5 9 1 - 0 . 5 9 4i n . )
13-19
ManualTransmission
ChangeLeverAssemblyDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactsurface.
SELECT LEVER
@).1 I Becarefulnotto damagethedustseal
BREATHER CAP
Turnthe arrowtowardthe{ront
r rrl
l L l w h e ni n s t a l l i ni tg.
DUSTCOVEB
o{thevehicle,
andinstallit.
I a^^
7 Fr"irr6-rooa
SHIFTARM COVER
ROLLER
(P/N 08798-9002)
6x1.0mm
12 N.m
(1.2kgl.m,8.7 lbf.ft)
\op
WASHER
(g)'
\r' -, OILSEAL
'^ E-='- /-r,s
,/ ReDlace.
/
SELECTSTOP
PLATE
9.8Nm
{1.0kgf.m,7.2 lbf.ft)
REVERSELOCKCAM
STRIKER
13-20
Shift ForksGlearanceInspection
NOTE:The synchrosleeveand synchrohub should be 3. Measurethe clearancebetweenthe shift fork (A)
replacedas a set. and the shift arm (B).lf the clearanceexceedsthe
servicelimit, go to slep 4.
1. Measure the clearancebetweeneach shift fork (A)
and its matchingsynchrosleeve(B).lf the Standard: 0.2-0.5 mm (0.007 0.020in.)
clearanceexceedsthe servicelimit, go to step 2. ServiceLimit: 0.62mm (0.024in.)
. l f t h e w i d t h o f t h e s h i f t a r mi s n o t w i t h i n t h e
A standard,replacethe shift arm with a new one.
2 . l\4easurethe thicknessof the shift fork fingers. . l f t h e w i d t h o f t h e s h i f ta r m i s w i t h i n t h es t a n d a r d ,
replacethe shift fork and shift piecewith a new
. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s n o t one.
within the standard,replacethe shift fork with a
new one. Standard: 16.9-17.0 mm (0.665-0.669in.)
. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s w i t h i n
the standard,replacethe synchrosleevewith a
new one.
13-21
ManualTransmission
Shift ForksDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactparts.
sTH SHIFTFORK
PINDRIVER,
5 mm
13-22
MainshaftAssemblyClearanceInspection
NOTE:lf replacementis required,always replacethe 4. Measurethe clearancebetween4th gear (A) and
synchrosleeveand hub as a set. t h e d i s t a n c ec o l l a r( B )w i t h a d i a l i n d i c a t o (r C ) .
1. Supportthe bearinginner racewith an appropriate . lf the clearanceis more than the servicelimit, go
sizedsocket(A).and push down on the mainshaft to step 5.
(B). . lf the clearanceis within the servicelimit, go to
step 7.
. l f t h e c l e a r a n c ies m o r et h a nt h e s e r v i c el i m i t .g o
to step 3.
. lf the clearanceis within the servicelimit, go to
step 4.
MeasuredistanceO on the distanceco[ar.
Standard: 0.06 0.16mm
{0.002 0.006in.l . lf distance't is notwithin the standard,replace
ServiceLimit: 0.25 mm (0.010in.l the distancecollarwith a new one.
. lf distancee is within the standard,go to step 6.
Measurethe thicknessof 3rd gear.
Standard: 24.03 24.08mm
. lf thethickneso s f 3 r d g e a r i s l e s s t h a n t h es e r v i c e {0.946-0.9/uin.}
l i m i t ,r e p l a c e3 r d g e a r w i t ha n e w o n e .
. lf thethickneso s f 3 r dg e a r i s w i t h i n t h e s e r v i c e
limit, replacethe 3rd/4thsynchrohub with a new
one.
Standard: 23.92-23.97 mm
(0.941 0.944in.)
ServiceLimit: 23.80mm (0.937in.)
(cont'd)
13-23
ManualTransmission
MainshaftAssemblyClearanceInspection(cont'd)
6. Measurethe thlcknessof 4th gear. 8. MeasuredistanceO on the distancecollar.
. lf thethickneso s f 4 t h g e a ri s l e s s t h a n t h e s e r v i c e . l f d i s t a n c eO i s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e
limit, replace4th gear with a new one. the distancecollar with a new one.
. l f t h e t h i c k n e s s o4f t h g e a r i s w i t h i nt h e s e r v i c e ' l f d i s t a n c e Oi s w i t h i n t h es t a n d a r dg, o t o s t e p 9 .
limit. replacethe 3rd/4thsynchrohub with a new
one. Standard: 24.03 24.08mm
(0.946 0.947in.)
Standard: 23.92 23.97mm
(0.941 0.944in.)
ServiceLimit: 23.80mm (0.937in.)
. l f t h e t h i c k n e s s o5f t h g e a r i s l e s s t h a n t h e s e r v i c e
7. l\4easure the clearancebetweenthe distancecollar limit, replace5th gear with a new one.
( A )a n d s t h g e a r( B )w i t h a d i a l i n d i c a t o (r C ) .l f t h e . lf the thicknessof sth gear iswithin the service
clearanceis more than the servicelimit. go to step limit. replacethe 5th synchrohub with a new one.
8.lf theclearance i s w i t hi n t h e s e r v i c el i m i t ,g o t o
steD10. Standard: 23-92 23.97mm
10.9410.944in.l
Standard: 0.06 0.16mm Service Limit: 23.80mm (0.937in.l
(0.002-0.006in.)
ServiceLimit: 0.25 mm (0.010in.)
13-24
MainshaftDisassembly
1 . R e m o v et h e a n g u l a rb a l l b e a r i n g( A )a n d t h e
taperedcone ring using a commerciallyavailable
'10.
M e a s u r et h e t h i c k n e s so f t h e M B S d i s t a n c ec o l l a r . b e a r i n gs e p a r a t o{rB )a n d a c o m m e r c i a l l a yvailable
b e a r i n gp u l l e r{ C ) .B e s u r et h e b e a r i n gs e p a r a t oirs
. l f t h et h i c k n e so
s f M B S d i s t a n c ec o l l a ri s l e s s u n d e rt h e t a p e r e dc o n er i n g .
than the standard,replacethe MBS distance
c o l l a rw i t h a n e w o n e .
E-f
Support5th gear (A) on steel blocks,and pressthe
mainshaftout of the sth synchrohub (B).Use of a
jaw-typepuller can damagethe gear teeth.
(cont'd)
13-25
ManualTransmission
MainshaftDisassembly(cont'dl MainshaftInspection
3. Supportthe 3rd gear (A) on steel blocks,and press 1. Inspectthe gear surfaceand bearingsurfacefor
the mainshaftout of the 3rd/4thsynchrohub (B). w e a r a n d d a m a g et,h e n m e a s u r et h e m a i n s h a fat t
Use of a jaw-type puller can damagethe gear teeth. pointsA, B, C, D, and E. lf any part of the mainshaft
is lessthan the servicelimit, reDlaceit with a new
on e .
Standard:
A Ball bearingsurface(transmissionhousingside):
2 7 . 9 8 7 2 8 . 0 0 0m m ( 1 . 1 0 1 9 1 . 1 0 2 4 i n . )
B Distance collar surtace:
31.984 32.000mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000mm (1.53/t8 1.5354in.)
D Ball bearingsurface(clutchhousingside):
2 7. 9 7 7- 2 7 . 9 9 0m m ( 1 . 1 0 1 5 1 . 1 0 2 0 i n . )
E Bushing surface:
20.80 20.85mm (0.819 0.821in.)
ServiceLimit;
A : 2 7 . 9 3m m 1 1 . 1 0 i0n . l
B: 31.93 mm |.1.257in.l
C: 38.93mm 11.533in.l
Di 27.92mm {1.099in.l
E: 20.75mm 10.817in.l
13-26
2. Inspectthe runout by supponing both ends of the
mainshaft.Rotatethe mainshafttwo complete
revolutionswhen measuringthe runout. lf the
runout is more than the servicelimit. reolacethe
mainshaftwith a new one.
13-27
ManualTransmission
MainshaftReassembly
ExplodedView
A 3RD/4TH
SYNCHRO
SLEEVE
Note the directionof
installation.
QJ'
TAPEBEDCONERING
3RD/4TH
SYNCHROHUB MBS DISTANCECOLLAR
frfl
Y7
SYNCHRO
SPRING
SYNCHROSLEEVE
SYNCHRORING
NEEDLE BEARING
Checkfor wearandoperation.
MAINSHAFT NEEDLEBEARING (
Checkfor wear and operation. \
GEAR
4TH/5TH GEAB DISTANCECOLLAR
SYNCHRORING
SYNCHROSPRING
a
13-28
SpecialTools Required 6. Installthe3rd/4thsynchrosleeve(A) by aligning
. D r i v e r , 4 0m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0 the stops (B)with the 3rd/4thsynchrosleeveand
. Attachment,30mm l.D.07746-0030300 hub. After installing,checkthe operationof the 3rd/
4th synchrohub set.
NOTE:Referto the ExplodedView as neededduring
this procedure.
'1.
Cleanall the parts in solvent,dry them, and apply @--
lubricantto all contactsurfacesexceptthe 3rd/4th
and 5th synchrohubs.
2. I n s t a l l t h en e e d l eb e a r i n ga n d 3 r d g e a ro n t h e
mainshaft.
I n s t a l l t h es y n c h r or i n g a n dt h e s y n c h r os p r i n g .
4 . I n s t a l l t h e3 r d / 4 t hs y n c h r oh u b ( A ) b y a l i g n i n gt h e
synchroring fingers (B)with 3rd/4thsynchrohub
grooves(C).
7 . I n s t a l l t h es y n c h r os p r i n g( A ) .
-A
9 . I n s t a l l t h e4 t h g e a r ,n e e d l eb e a r i n gd, i s t a n c ec o l l a r ,
n e e d l eb e a r i n ga, n d s t h g e a r .
07746-0030100
(cont'd)
13-29
ManualTransmission
MainshaftReassembly(cont'dl \
1 0 . I n s t a l l t h es y n c h r or i n g a n d t h e s y n c h r os p r i n g . 1 4 . I n s t a l l t h es y n c h r os p r i n g( A ) .
'1.
1 I n s t a l l t h es t h s y n c h r oh u b ( A )b y a l i g n i n gt h e
synchrocone fingers (B)with sth synchrohub
grooves(C).
t5. I n s t a l l t h es y n c h r or i n g ( B )b y a l i g n i n gt h e s y n c h r o
cone fingers (C)with sth synchrohub grooves(D).
12. I n s t a l l t h e5 t h s y n c h r oh u b ( A )u s i n gt h e s p e c i a l 1 6 . I n s t a l l t h eM B S d i s t a n c ec o l l a ra n dt h e t a p e r e d
tools. c o n er i n g .
1 1 . I n s t a l l t h en e w b a l l b e a r i n g{ A ) u s i n gt h e s p e c i a l
t o o l sa n d a p r e s s( B ) .
U 1
07746-0030100
07746-0030100
07746-0030300
1 3 . I n s t a l l t h e5 t h s y n c h r os l e e v e .
\.
13-30
CountershaftAssemblyClearancelnspection
1 . Measurethe clearancebetweenthe 1st gear (A) 3. Measure the thicknessof the 1st oear.
a n dt h e d i s t a n c ec o l l a r( B ) w i t ha f e e l e rg a u g e( C ) .
. l f t h e t h i c k n e s s o lfs t g e a r i s l e s s t h a n t h es e r v i c e
. lftheclearance
i s m o r et h a nt h e s e r v i c el i m i t ,g o l i m i t ,r e p l a c el s t g e a r w i t h a n e w o n e .
to step 2. . lf the thicknessof '1stgear is within the service
. lftheclearance
i s w i t h i nt h e s e r v i c el i m i t .g o t o limit, replacethe lst/2nd synchro hub with a new
step 4. one.
Standard: 0.06 0.16mm 10.002 0.006in.l Standard: 22-92 22.97 mm 10.902 0.904 in.l
ServiceLimit: 0.25 mm (0.010in.l ServiceLimit; 22.87mm {0.900in.)
(cont'd)
13-31
ManualTransmission
CountershaftAssemblyClearance CountershaftDisassembly
Inspection(cont'd)
1 . Securelyclamp the countershaftassemblyin a
benchvlse with wood blocks.
5. Measurethe th icknessof the distancecollar.
. l f t h e t h i c k n e s si s n o t w i t h i nt h e s t a n d a r dr,e p l a c e
the distancecollar with a new one.
. l f t h e t h i c k n e s si s w i t h i n t h es t a n d a r dg, o t o
step 6.
. lf thethickneso s f 2 n d g e a r i s l e s s t h a nt h e
servicelimit, replace2nd gear with a new one.
. l f t h e t h i c k n e s s o2f n d g e a r i s w i t h i n t h e s e r v i c e
limit, replacelhe 1sV2ndsynchro hub with a new
one.
4 . R e m o v et h e 3 5 m m s h i m a n d d i s t a n c ec o l l a r .
13-32
Countershaftlnspection
5. Support4thgear(A)on steelblocks,thenusea 1. Inspectthe gear surfaceand bearingsurfacefor
pressandan attachment(B)to pressthe w e a r a n d d a m a g e t, h e n m e a s u r et h e c o u n t e r s h a f t
(C)
countershaft out ofthe 5thgear. at pointsA, B, and C. lf any part of the countershaft
is lessthan the servicelimit, replaceit with a new
one.
Standard:
A Ballbearingsurfaceltransmissionhousingsidel:
3 0 . 0 2 0- 3 0 . 0 3 3m m { 1 . 1 8 1 9 1 . 1 8 2 4 i n . )
B Distancecollar surface;
39.937- 39.950mm 11.5723 1.572Ain.l
C Needlebearingsurface(clutchhousingside):
3 5 . 0 0 0 3 5 . 0 1 5m m { r . 3 7 8 0 - 1 . 3 7 8 5i n . )
Service Limit:
A : 2 9 . 9 7m m { 1 . 1 8 0i n . )
B: 39.88mm {1.570in.l
C: 34.95mm {1.376in.)
13-33
ManualTransmission
CountershaftReassembly
ExplodedView
SPECIAL BOLT
Eeplace.
1 1 8N . m 1 2k g fm ,8 7l b ff t )
(
BALL BEARING
Checkfor wear and
operation.
REVERSE
GEAR Note the directionof installation.
1ST/2ND
SYNCHRO
HUB 35 mm SHIM
NEEDLE BEARING
Checkfor wear
anoopera!on. Checkfor wear and
DISTANCECOLLAR operation.
DISTANCECOLLAR
FRICTIONDAMPER
Checkfor wear and damage.
(
COUNTERSHAFT TRIPLECONESYNCHRO
SYNCHROSPRING
13-34
SpecialToolsRequired 6 . I n s t a l l t h es y n c h r os p r i n g( A ) .
. Driver,40 mm l.D.07746-0030100
. Aftachment.30 mm 07746-0030300
I n s t a l l t h ed i s l a n c ec o l l a r ,n e e d l eb e a r i n ga, n d 1 s t
gear onto the countershaft.
'1st/2nd
Installthe s y n c h r oh u b ( A ) b y a l i g n i n gt h e
synchrocone fingers (B)with 1sV2ndsynchrohub
grooves(C).
5 . I n s t a l l t h er e v e r s eg e a r .
(cont'd)
13-35
ManualTransmission
CountershaftReassembly(cont'dl L,
9 . I n s t a ltl h e n e e d l eb e a r i n g . 1 2 . I n s t a ltlh e 4 t h g e a r( A )u s i n gt h e s p e c i a l t o oal n d a
press(B).Do not exceedthe maximum pressure.
1 0 .I n s t a l l t h e2 n d g e a r( A )b y a l i g n i n gt h e s y n c h r o
cone fingers (B)with znd gear grooves(C). B
14,700N {1,500 kgt,
3,307lbf) max.
07746-0030100
I n s t a l l t h e5 t h g e a r( A )u s i n gt h e s p e c i atl o o l a n d a
'l
1 . Supoortthe countershaft(A) on the steel blocks, press(B).Do not exceedthe maximum pressure.
t h e n i n s t a ltl h e 3 r d g e a r( B )u s i n gt h e s p e c i atlo o l
and a press(C).Do not exceedthe maximum 14,700N (1.500kgl,
Dressure. 3.307lbf) max.
07746-0030100
14,700N (1,500kgf,
3,307lbflmax. I
07746-0030100
13-36
1 4 . I n s t a ltlh e d i s t a n c ec o l l a r( A ) ,3 5 m m s h i m ,a n d o l d 16. lf the clearanceis more than the standard,selecta
ball bearing(B)using the specialtools and a press new shim from the following table. lf the clearance
(c). measuredin step 15 is within the standard,replace
o n l yt h e b a l lb e a r i n g .
35 mm Shim
PartNumber Thickness
23981-PPP-0000.87mm (0.0343n .
B 23981-PPP-9000 . 9 1m m { 0 . 0 3 5 8 n,
c 23982-PPP-0000 . 9 5m m ( 0 . 0 3 7 4 n.
D 23982-PPP-9000.99mm (0.0390n ,
E 23983-PPP-0001 . 0 3m m 1 0 . 0 4 0n6,
F 23983-PPP-9001 . 0 7m m ( 0 . 0 4 2 1n .
23984-PPP-0001 . 11 m m ( 0 . 0 4 3 7 n.
11 23984-PPP-9001 . 1 5m m ( 0 . 0 4 5 3 n.
J 23985-PPP-0001 . ' 1 9m m ( 0 . 0 4 6 9n .
K 23985-PPP-9001 . 2 3m m ( 0 . 0 4 8 4 n
L 23986-PPP-0001 . 2 7m m ( 0 . 0 5 0 0 n.
M 23986-PPP-9001 . 3 1m m ( 0 . 0 5 1 6i n .
N 23987-PPP-0001 . 3 5m m ( 0 . 0 5 3 1i n .
P 23987-PPP-9001 . 3 9m m ( 0 . 0 5 4 7n .
o 23988-PPP-0001 . 4 3m m ( 0 . 0 5 6 3i n .
R 23988-PPP-9001 . 4 7m m ( 0 . 0 5 7 9i n
t5. Measurethe clearancebetweenthe old bearing(A) 23989-PPP-000 1 . 5 1m m ( 0 . 0 5 9 4
in
a n dt h e 3 5 m m s h i m ( B )w i t h a f e e l e rg a u g e( C ) . T 23989-PPP-900 1 . 5 5m m ( 0 . 0 6 1 0
in
U 23990-PPP-0001 . 5 9m m { 0 . 0 6 2i6n .
Standard: 0.04 0.10mm 10.002 0.004in.) 23990-PPP-9001 . 6 3m m { 0 , 0 6 4i2n .
X 23991-PPP-0001 . 6 7m m ( 0 , 0 6 5 7i n
Y 23991-PPP-900 1 . 7 1m m { 0 . 0 6 7 3i n
z 23992-PPP-0001 . 7 5m m ( 0 . 0 6 8 9i n
23992-PPP-9001 . 7 9m m ( 0 . 0 7 0 5i n
AB 23993-PPP-0001 . 8 3m m ( 0 . 0 7 2i0n
AC 23993-PPP-9001 . 8 7m m ( 0 . 0 7 3 6i n
AD 23994-PPP-000' 1 . 9 1m m ( 0 . 0 7 5 2i n
AE 23994'PPP-900 1 . 9 5m m ( 0 . 0 7 6 8
in.
AF 23995PPP-000 1 . 9 9m m ( 0 . 0 7 8 3in.
{cont'd)
13-37
ManualTransmission
CountershaftReassembly(cont'd)
1 1 . Supportballbearing(A)on steelblocks(B),then 20. Tightenthe new specialbolt (A) (left-handthreads).
usea press(C)andan attachment (D)to pressthe
(E)out of the ballbearing.
countershaft
1 8 . l f n e c e s s a r yi n, s t a l l t h e3 5 m m s h i m s e l e c t e di n
step 16,then recheckthe clearance,
46-0030r00
13-38
SynchroSleeveand Hub Inspection SynchroRingand GearInspection
and Reassembly
1 . Inspectthe insideof each synchroring (A) for wear.
Inspectthe teeth (Bi on each synchro ring for wear
1. lnspectthegearteeth on ali synchro hubs and (roundedoff).
synchrosleevesfor roundedoff corners,which
indicatewear.
I / \
I l I
GOOD WORN
t l
GOOD WORN
\
(cont'd)
13-39
ManualTransmission
SynchroRing and GearInspection(cont'dl \ {
3. Inspectthe thrust surface{D)on each gear hub for 7. Measurethe clearancebetweeneach gear (A) and
wear. i t s s y n c h r or i n g ( B )a l l t h ew a y a r o u n d .H o l dt h e
synchroring againstthe gear evenlywhile
measuringthe clearance.lf the clearanceis less
than the servicelimit, replacethe synchro ring and
gear.
13-40
MainshaftBearingand Oil SealReplacement
Special Tools Required 4 . Drive the new oil seal in from the transmissionside
. O i l s e a ld r i v e r0 7 J A D - P 1 9 0 1 0 0 using the specialtools.
. A d j u s t a b l eb e a r i n gp u l l e r , 2 0 4 0 m m
07736-4010008
. Driver07749-0010000
. Attachment,42x 47 mm 07746-0010300 07749-0010000
. S l i d eh a m m e r ,c o m m e r c i a l l a yvailable
07746-0010300
1. Removethe differentialassembly,
2 . R e m o v et h e b a l l b e a r i n g( A ) f r o mt h e c l u t c h
h o u s i n g( B )u s i n gt h e s p e c i a l t o oal n d a
c o m m e r c i a l lay v a i l a b l e3 / 8 " - l 6 s l i d eh a m m e r( C ) .
13-41
ManualTransmission
CountershaftBearingReplacement
Special Tools Required 3. Positionthe oil guide plate C and new needle
. Adiustablebearingpuller,20-40 mm 07736-A0tOOOB bearing(A) in the bore of the clutchhousing(B).
. Oil seal driver 07JAD-AP190100
. S l i d eh a m m e r ,c o m m e r c i a l l a
yvailable
I n s t a l l t h en e e d l eb e a r i n gu s i n gt h e s p e c i a l t o o l .
B
Removethe needlebearing(A) usingthe special 6 x 1 . 0n n
12N.m{1.2kgt m,
tool and a commerciallyavailable3/8" - 16 slide 8.7 tbf.ft)
hammer (B),then removethe oil guide plate C.
(
07736-A010008
13-42
MainshaftThrust ClearanceAdiustment
Special Tools Required 5 . Measuredistance@ betweenthe end of the clutch
. Mainshaftbase07GAJ-PG20130 h o u s i n g( A )a n d t h e b e a r i n gi n n e rr a c e( B ) w i t ha
. M a i n s h a fht o l d e r0 7 G A J - P G 2 0 1 1 0 straightedge and depth gauge.Measureat three
locationsand averagethe readings.
1 . R e m o v et h e 7 2 m m s h i m ( A )a n d o i l g u i d ep l a t eM A
from the transmissionhousing(B).
,5---o
v/
( F o re x a m p l e )
2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 1 ) =1 . 5 6m m ( 0 . 0 6 1i n . )
2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 7 ) =1 . 5 0m m ( 0 . 0 5 9i n . )
T a k et h e m i d d l ev a l u eo f t h e m i n i m u mv a l u ea n d
t h e m a x i m u mv a l u e ,a n d s e l e c t h e 1 . 5 3m m
lnstallthe washer (H) on the mainshaft. ( 0 . 0 6 0i n . )s h i m .
{cont'd)
13-/li|
ManualTransmission
MainshaftThrust ClearanceAdjustment (cont'dl
72 mm Shim 7 . I n s t a l l t h e7 2 m m s h i m ( A )s e l e c t e da n d o i l g u i d e
PartNumber Thickness p l a t eM i n t h e t r a n s m i s s i o h
n o u s i n g( B ) .
2 3 9 3 1 - P 2 1 - 0 0 00 . 6 0m m { 0 . 0 2 3i6n . )
B 23932-P21-000 0.63mm (0.0248 in.
c 2 3 9 3 3 - P 2 1 - 0 0 00 . 6 6m m ( 0 . 0 2 6i0n .
,6,,-o
V
D 2 3 9 3 4 - P 2 1 - 0 0 00 . 6 9m m ( 0 . 0 2 7 1i n .
E 23935-P21-000 0 . 7 2m m ( 0 . 0 2 8i3n .
F 23936-P21-000 0 . 7 5m m ( 0 . 0 2 9i5n .
23931-P21-000 0 . 7 8m m ( 0 . 0 3 0i7n .
- 23938-P2'l-000 0 . 8 1m m ( 0 . 0 3 1i9n
23939-P21-000 0 . 8 4m m ( 0 . 0 3 3i1n
J 23940-P21-000 0 . 8 7m m { 0 . 0 3 4 3i n ,
23941-P21-000 0.90 mm (0.0354in.
L 23942.P21-000 0.93mm (0.0366in.
M 23943-P21-000 0 . 9 6m m ( 0 . 0 3 7i8n .
N 23944-P21.000 0 . 9 9m m ( 0 . 0 3 9i0n .
o 23945-P21-000 1 . 0 2m m ( 0 . 0 4 0i2n .
P 23946-P21-000 1 . 0 5m m ( 0 . 0 4 1 3i n . 8 . Thoroughlycleanthe spring washer (A) and
o 23941-P2't-000 'l.08mm (0.0425 in washer (B) before installingthem on the clutch
R 23948-P2'l-000 ' 1. 11 m m { 0 . 0 4 3i7n h o u s i n gs i d eb a l l b e a r i n g{ C ) .N o t et h e i n s t a l l a t i o n
23949-P21-000 ' 1 . 1 4m m ( 0 . 0 4 4 9i n directionof the spring washer.
T 23950-P21-000 1 . 1 7m m { 0 . 0 4 6 1n .
U 23951-P21-000 1.20mm 10.0472 n.
23952-P21-000 1.23mm (0.0484n .
23953-P21-000 1 . 2 6m m { 0 . 0 4 9 6 n.
X 23954-P21-000 1 . 2 9m m ( 0 . 0 5 0 8n .
23955-P21-000 1 . 3 2m m ( 0 . 0 5 2 0 n.
{
z 23956-P21,000 1 . 3 5m m ( 0 . 0 5 3i1n
23957-P21-000 1 . 3 8m m ( 0 . 0 5 4i3n
AB 23958-P21-000 1 . 4 1m m ( 0 . 0 5 5 5n
AC 23959-P21-000 1 . 4 4m m ( 0 . 0 5 6 7 n.
AD 23960-P21-000 1.47mm (0.0579n .
AE 2 3 9 6 1 - P 2 1 - 0 0 01 . 5 0m m ( 0 . 0 5 9 1n .
AF 23962-P21-OOO 1 . 5 3m m ( 0 . 0 6 0 2 n.
AG 23963-P21-000 1 5 6 m m ( 0 . 0 6 1 4n .
AH 23964-P21-000 1 . 5 9m m ( 0 . 0 6 2 6n .
AI 23965-P21-000 1 . 6 2m m ( 0 . 0 6 3 8i n 9 . l n s t a l l t h em a i n s h a fitn t h e c l u t c hh o u s i n g .
AJ 23966-P21-000 1 . 6 5m m ( 0 . 0 6 5i0n
AK 23967-P21-000 1 . 6 8m m ( 0 . 0 6 6i1n 1 0 .Placethe transmissionhousingover the mainshaft
AL 23968-P2r -000 1 . 7 1m m ( 0 . 0 6 7i3n . and onto the clutchhousing.
AM 23969-P21-000 1 . 7 4m m ( 0 . 0 6 8i5n .
AN 23970-P21-000 1 . 7 7m m ( 0 . 0 6 9i7n . 1 1 .Tightenthe clutchand transmissionhousingswith
AO 2 3 9 7 1 - P 2 ' t - O O O1 . 8 0m m ( 0 . 0 7 0 9
in. several8 mm bolts.
13-44
13. Attachthe specialtool to the mainshaftas follows: 1 6 . Z e r oa d i a l g a u g e{ A )o n t h e e n d o f t h e m a i n s h a f t .
. B a c k - o ut th e m a i n s h a fht o l d e rb o l t{ A )a n d l o o s e n
the two hex bolts (B).
. Fit the holderover the mainshaftso its lip is
towards the transmission.
. Align the mainshaftholder'slip aroundthe
groove at the insideof the mainshaftsplines,
then tightenthe hex bolts.
07GAJ-PG20130
13-45
ManualTransmission
Transmission
Reassembly \ (
n-",-o
l;-D
f.)
Installthe reverseidler gear (A) and reversegear
s h a f t( B )b y a l i g n i n gt h e m a r k{ C ) w i t ht h e r e v e r s e
g e a rs h a f th o l e( D ) .
13-46
6 , l n s t a l l t h er e v e r s el o c kc a m . 8. Removethe dirt and oil f rom the tramsmission
h o u s i n gs e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N
- 2 6 x 1 , 0m m 08718-0001) to the sealingsurface.Be sure to seai
z/ / 15 N.m
--' / {1 5 kgf m, the entirecircumferenceof the bolt holesto
€t I 11 tbf.ft) preventoil leakage.
Fl g NOTE:lf 5 minuteshave passedafter applying
E liquid gasket,reapplyit and assemblethe housings.
Allow it to cure at least20 minutesafter assembly
beforefilling the transmissionwith oil.
- - -Liquid gasket
{cont'd)
13-47
ManualTransmission
TransmissionReassembly(cont'dl (
\A
e./
./
8 x 1.25mm
27 N.m
(2.8kgf.m.
20 rbf.ft)
(t
13-48
16. Removethe dirt and oil from the shift iever cover 1 9 . I n s t a l l t h ed r a i np l u g( A ) ,f i l l e rp l u g ( B ) ,a n d 1 0 m m
s e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 - f l a n g eb o l t ( C )w i t h n e w w a s h e r s .
0001)to the sealingsurface.
/..l-.=,'-B
g ^ 44N.m
NOTE:lf 5 minuteshave passedafter applylng
liquid gasket.reapplyit and assemblethe housings.
@ Ut !?iJl'.'l,''
Allow it to cure at least20 minutesafter assembly
b e f o r ef i l l i n gt h e t r a n s m i s s i ow
n ithoil.
R\-: \
A
39Nm
(4.0 kgf m,
33 tbl.ft)
-.-t ?0,,.ru^
44 N m {4.5kgt m,33lbf.ft}
- - -Liquidgasket
1 7 . I n s t a l l t h e8 x 1 4 m m d o w e lp i n s( A ) .c l u t c hl i n ec l i p
b r a c k e (t B ) ,a n d c h a n g el e v e ra s s e m b l y( C ) .
{3.0kgf.m.22lbf.ft)
2 1 . A p p l y l i q u i dg a s k e t{ P / N0 8 7 1 8 - 0 0 0 1 } t oh e t h r e a d s
o i t h e b a c k - u pl i g h ts w i t c h( B ) ,a n d i n s t a l il t i n t h e
transmissioh nousing.
6x1.0mm
12N.m(1.2kgf.m,9lbtft)
1 8 . A p p l y l i q u i dg a s k e t( P iN 0 8 7 1 8 - 0 0 0 t1o) t h e t h r e a d s
of the interlockbolt (D),and installit on the
transmissioh nousing.
(cont'd)
13-49
ManualTransmission
TransmissionReassembly(cont'dl (
22. Installthevehiclespeedsensor(VSS){A)and
O - r i n g( B ) .
13-50
GearshiftMechanismReplacement
SHIFTLEVERHOUSING
{P/N 08798-9002}
SHIFTCABLECLIP
Replace.
r-LlRotatethe shift cable
t o w a r dt h e o p e n i n g .
6x1.0mm
9.8Nm
(1.0kgf.m,
7.2 tbf.fr)
COTTERPINS
qrBemovethe shift cable
{P/N 08798-9002) from the shift leverbracket.
13-51
M/T Differential
ComponentLocationIndex \ (
DRIVENGEAR
Beplacement,page 13-53
\ I
BacklashInsoection.oaoe 13-53
Feplacemeni,paoe I 3-5-3
13-52
Backlashlnspection FinalDrivenGear/Carrier
Replacement
1 . Placethe differentialassemblyon V-blocks(A),and
installboth axles.
1. Removethe bolts (left-handthreads)in a crisscross
patternin severalsteps,then removethe final
driven gear (A)from the differentialcarrier{B).
\tt x t . om m { t o )
1 2 1N m
(12.3kgf m,
89 rbt.ft)
o f b o t h p i n i o ng e a r s( B )w i t h
M e a s u r et h e b a c k l a s h
a dial indicator(C).lf the backlashis not within the
standard,replacethe differentialcarrier.
Installthe final driven gear with the chamferon the
Standard(New):0.05 0.15mm (0.002 0.006in.) i n s i d ed i a m e t e fra c i n gt h e c a r r i e rA
. l i g nt h e m a r k s
o n t h e f i n a ld r i v e ng e a ra n d t h e c a r r i e rT. i g h t e nt h e
bolts in a crisscrosspatternin severalsteps.
13-53
M/T Differential
CarrierBearingsReplacement \ {
077i16-0030100
6 07746-0030100
13-54
Oil SealReplacement
Special Tools Required 4 . I n s t a l l t h en e w o i l s e a li n t h e t r a n s m i s s i o hn o u s i n q
. Driver07749-0010000 with the specialtools.
. Oil seal driver attachment07NAD-P20A100
1. Removethe differentialassembly.
5 . I n s t a l l t h en e w o i l s e a li n t h e c l u t c hh o u s i n gw i t h
the specialtools.
3 . R e m o v e t h e o i sl e a l( A )f r o m t h e c l u t c hh o u s i n g( B ) .
13-55
M/T Differential
DifferentialThrust ClearanceAdjustment
SpecialToolRequired Installthe transmissionhousingonto the clutch
Driver.40 mm LD.07746-0030100 housing,then tightenthe 8 mm flange bolts in a
crisscrosspatternin severalsteps(seestep 15 on
1 . I n s t a lal n 8 0 m m s h i m t h a t ' st h e s a m es i z ea s t h e page 13-48).
one you removeo.
8 x 1 . 2 5m m
27 N m (2.8 kgf'm, 20 lbf.ft)
00746-0030100
-i.
w
.t ..1
-- -- :,- -=.
13-56
6. lf the clearanceis more than the standard,selecta
n e w s h i m f r o m t h e f o l l o w i n gt a b l e .l f t h e c l e a r a n c e
m e a s u r e di n s t e p5 i s w i t h i nt h e s t a n d a r dg, o t o
step 9.
80 mm Shim
Part Number Thickness
4 1 4 4 1P L 3 - 8 0 0 1 1 . 0m m ( 0 . 0 3 9 4 n.
B 41442-PL3-B001 1 mm (0.0433 n.
c 4 1 4 4 3 - P L 3 - 8 0 0 1 1 . 2m m ( 0 . 0 4 7 2
n.
D 4 1 4 4 4 - P L 3 - B 0 0 1 1 . 3m m { 0 . 0 5 1 2n .
E 4 1 4 4 5 - P L 3 - 8 10 0 1 . 4m m 1 0 . 0 5 5 1n .
F 4 1 4 4 6 - P L 3 - 8 0 0 1 1 . 5m m { 0 . 0 5 9 1n .
41447-PL3-8 1 0 0 1 . 6m m ( 0 . 0 6 3 0n .
rt 4 1 4 4 8 - P L 3 - B 0 0 1 1 . 7m m { 0 . 0 6 6 9n .
J 4 1 4 4 9 - P L 3 - 8 0 0 1 . 8m m ( 0 . 0 7 0 9n .
41450-PL3-80001. 0 5m m ( 0 . 0 4 1 3n . )
4 1 4 5 1 - P L 3 - 8 0 0 01. 1 5m m ( 0 . 0 4 5 3n . l
tvl 41452-PL3-80001 . 2 5m m ( 0 . 0 4 9 2n . l
N 41453-PL3-8000 1 . 3 5m m ( 0 . 0 5 3 ' ln . )
P 41454-PL3-80001. 4 5m m ( 0 . 0 5 7 1n . l
o 41455-PL3-80001 . 5 5m m ( 0 . 0 6 1 0n . )
R 41456-PL3-8000' 1 . 6m
5 m ( 0 . 0 6 5i0n . )
41457-PL3-8000 1 . 7 5m m ( 0 . 0 6 8 9i n . )
7 . R e m o v et h e b o l t sa n dt r a n s m i s s i o h
nousing.
9 . R e i n s t a tl h
l et r a n s m i s s i o n .
13-57
Driveline/Axle
SpecialTools .............
16-2
Driveshaft
Inspection .........................
16-3
Driveshafts
Removal ..........................
16-3
Driveshafts
Disassembly ...................
16-5
DynamicDamperReplacement ........16-8
Driveshafts
Reassembly ....................
16-9
Driveshafts
lnstallation ......................
16-17
lntermediate
ShaftRemoval ..............
16-19
Intermediate
ShaftDisassembly .................................
16-20
lntermediate
ShaftReassembly ..................................
16-22
lntermediate 16-24
Shaftlnstallation....................................
Driveline/Axle
SpecialTools L
Ref. No. ToolNumber DescriDtion Orv
n] 07GAD-PH70201 O i l S e a lD r i v e r 1
@ 07MAC-S100200 B a l l J o i n tR e m o v e r2, 8 m m 1
o 0 7N A F - S R 3 0 1 0 1 Half Shaft Base 1
@ 07xAc-001010A ThreadedAdapter,22 x 1.5mm 1
t9 07746-0010400 Attachment,52 x 55 mm 1
6) 07746-0030400 u f l v e r ,J 5 m m L U . 1
o 07749-0010000 Driver 1
(D 07947-S800100 O i l S e a lD r i v e r 1
o @
t g[] r\J ? ) \* a
,0)
16-2
DriveshaftInspection DriveshaftsRemoval
1. Checkthe inboardboot (A) andthe outboardboot Special Tool Required
(B)on the driveshaft(C)for cracks,damage,leaking B a l l j o i n tr e m o v e r 2, 8 m m 0 7 M A C - S 1 0 0 2 0 0
grease,and loose boot bands (D).lf any damageis
found, reDlacethe boot and boot bands. 1. Loosenthe wheel nuts slightly
H o l dt h e s t a b i l i z ebr a l l j o i n tp i n ( A )w i t h a h e x
wrench {B),and removethe flange nut (C).
Separatethe front stabilizerlink (D)from the lower
ar m .
(cont'd)
16-3
Driveline/Axle
DriveshaftsRemoval(cont'd) \
Left driveshaft:
t
07MAC-S100200 .."8
w^
'e
Separatethe ball joint from the lower arm (C)with
the specialtool (seestep 3 on page 18-19).
Be carefulnot to dislodgethe lower ball joint from
the knuckle. Right driveshaft:
16-4
Driveshafts
Disassembly
Special Tools Required
. T h r e a d e da d a D t e r . 2 x2 1 . 5m m 0 7 X A C - 0 0 1 0 1 0 A
. S l i d eh a m m e r ,c o m m e r c i a l l a
yvailable
. Boot band pincers,commerciallyavailable
Welded Type
(cont'd)
16-5
Driveline/Axle
DriveshaftsDisassembly{cont'd)
M a k ea m a r k( A )o n e a c hr o l l e r( B )a n d i n b o a r dj o i n t 8. Wrap the splineson the driveshaftwith vinyl tape
(C)to identifythe locationsof rollersand grooves (A)to preventdamageto the boot.
i n t h e i n b o a r dj o i n t .T h e n r e m o v et h e l n b o a r dj o i n t
on the shop towel (D).Be carefulnot to drop the
rollerswhen separatingthem from the inboard
Jornt.
9 . R e m o v et h e i n b o a r db o o t .B e c a r e f u n
l ottodamaoe
the boot.
R e m o v et h e c i r c l i p{ D ) .
7 . R e m o v et h e s p i d e r( C ) .
16-6
OutboardJoint Side: Wipe off the greaseto exposethe driveshaftand
t h e o u t b o a r dj o i n t i n n e rr a c e .
1 . R e m o v et h e b o o t b a n d s .B e c a r e f u n
l ottodamage
t h e b o o ta n d d y n a m i cd a m p e r . 4 . Make a mark (A) on the driveshaft(B) at the same
positionof the outboardjoint end {C).
. l f t h e b o o t b a n di s a n e a r c l a m p t y p e( A ) ,l i f t u p
the three tabs (B)with a screwdriver.
(cont'd)
16-7
Driveline/Axle
DriveshaftsDisassembly(cont'dl DynamicDamperReplacement
8. Removethe stopringtromthe driveshaft. 1 . R e m o v et h e i n b o a r dj o i n t ( s e ep a g e1 6 - 5 ) .
. l f t h e b o o l b a n di s a w e l d e d t y p e . c u t t h eb o o t
band.
. l f t h e b o o t b a n di s a d o u b l el o o p t y p e ,l i f t u p t h e
band bend, and push it into the clip.
. lfthe boot band is a low profiletype, pinch the
b o o t b a n du s i n ga c o m m e r c i a l l a y v a i l a b l eb o o t
band pincers.
6 . I n s t a l l t h ed y n a m i cd a m p e rb a n d( s e es t e pI o n
p a g e1 6 ' 1 2 ) .
7 . I n s t a ltlh e i n b o a r dj o i n t ( s e ep a g e1 6 - 11 ) .
16-8
DriveshaftsReassembly
ExplodedView
'02 model
SETRING
Replace.
/
0e //ROLLER
\)
6) /''"oH?"'
#'g!!a$il
/
YJ .?-- / Use the greaseIncluded
rr in the
// "\ ,I inboardboot
inboard boot set.
set
// /,/7\
II t,//>\ {\
\\1lg n --.-
r. .'(9
Usethe greaseincludedin the -<
inboardboot set.
- l>-
OOUBLELOOPBAND
/'..-:'\ Replace.
/ .-\
I .^-.1
I | //^\l r\
, \ V L/ A
.''
DYNAMTC
DAMPER
y
,/
//
DOUBLELOOPBAND STOPRING
Replace. Replace.
JOINT
OUTBOARD
(cont'd)
16-9
Driveline/Axle
DriveshaftsReassembly(cont'dl I
ExplodedView
'03 model
s l
E.
-"-,,, @(
Usethe greaseincluded
(^Y \ in the nboard boot set.
\_,/
>
LOWPROFILE
BAND
Beplace.
Usethe greaseincluded
in the inboardboot set. DOUBLELOOPBAND
Replace.
(Boot band replacementonly.)
DYNAMICDAMPER
OUTBOARDJOINT
at-
BOOTITPI
OUTBOARD
16-10
Special Tools Required 3. Installthe spider (A) onto the driveshaftby aligning
. Boot band tool, KD-3191or equivalent,commercially the marks (B)on the spider and the end of the
available driveshaft.
. Boot band pincers,Kent-MooreJ-359'10or equivalent,
commerclallyavailable
. Boot band pincers,commercially available
lnboardJoint Side:
1. Wrap the splineswith vinyl tape (A)to prevent
damageto the inboardboot.
5 Fit the rollers (A) onto the spider {B)with their high
shouldersfacing outward,and note these items:
(cont'd)
16-11
Driveline/Axle
DriveshaftsReassembly(cont'd) I
6 . Packthe inboardjointwith thejointgrease 8 . Make sure the ends of the boot are sealedin the
includedin the newdriveshaft
set. groovesin the driveshaftand joint, then installthe
boot bands.
Greasequantity
Inboardioint: 130 140g (4.6-4.9oz) . For the double loop type, go to step 12.
(Replacementboot bands only)
. For the low profiletype, go to step 9.
Usethe greaseincludedin the
inboardboot set. 9 . Installthe new low profile band {A) onto the boot
{B).then hook the tab (C)of the band,
16-12
Fit the boot ends onto the driveshaftand the 15. Threadthe free end ofthe band through the nose
inboardjoint, then installthe new double loop band sectionof the commerciallyavailableboot band
{A) onto the boot. tool KD-3191or equivalent(A),and into the slot on
t h e w i n d i n gm a n d r e l( B ) .
P u l lu p t h e s l a c ki n t h e b a n db y h a n d
M a r ka p o s i t i o n( A )o n t h e b a n d 1 0 - 1 4 m m ( 0 . 4 -
0 . 6i n . )f r o m t h e c l i p { B ) .
1 7 . L i f tu Dt h e b o o t b a n dt o o l t o b e n d t h e f r e e e n d o f
the band 90 degreesto the clip. Center-punchthe
c l i o ,t h e nf o l d o v e rt h e r e m a i n i n gt a i l o n t ot h e c l i p .
(cont'd)
16-13
Driveline/Axle
DriveshaftsReassembly(cont'dl {
18. Unwind the boot band tool, and cut off the excess 2 ' 1 .I n s t a l l t h en e w s e t r i n g .
free end of the bandto leavea 5- 10 mm (0.2-0.4
in.) tail protrudingfrom the clip
NOTE;
. Make sure the band and clip do not interferewith
anythingand the band does not move.
. Removeany greaseremainingon the
surroundingsurfaces
16-14
OutboardJoint Side: 4. Insertthe driveshaft(A) into the outboardjoint (B)
until the stop ring (C)is closeto the joint.
1. Wrap the splineswith vinyl tape (A) to prevent
damageto the outboardboot.
I n s t a l l t h en e w e a r c l a m pb a n d s( B )a n d o u t b o a r d
boot,then removethe vinyl tape. Be carefulnot to 5 . To completelyseatthe outboardjoint, pick up the
damagethe outboardboot. driveshaftand joint, and drop them from about 10
cm (4 in.) onto a hard surface.Do not use a
3 . Installthe new stop ring into the driveshaftgroove hammer as excessiveforce may damagethe
1 0c m
( 4i n . )
- ..,..,1;,t,:-,;
{cont'd)
16-15
Driveline/Axle
DriveshaftsReassembly(cont'd) {
Checkthe alignmentof the paint mark (A)with the 8. Adjust the length of the driveshaftsto the figure
o u t b o a r dj o i n t e n d ( B ) . below,then adjustthe boots to halfwaybetween
full compressionand full extension.Make sure the
ends of the boots seat in the groovesof the
driveshaftand joint.
t
-tTfi'.D.ilTD
Rightdriveshaft:475 480 mm {18.7 1 8 . 9i n . l
Grease quantity
Outboardioint: 105 115g (3.7 4.1 ozl 9 . Fit the boot (A) ends onto the driveshaft(B)and
/llt,)r
o u t b o a r dj o i n l ( C ) .
-*>
\{(
'.,o"o
:;,"0'A?g.fff
:l:f
16-16
DriveshaftsInstallataon
10. Closethe ear portion (A) of the band with a 1. Installa new set ring onto the set ring groove of the
commerciallyavailableboot band pincersKent- driveshaft{left driveshaft).
Moore J-35910or equivalent(B).
in.)MAX
6.0mm 10.24
12. R e p e ast t e p s1 0 a n d 1 1 f o r t h e b a n do n t h e o t h e r
end of the boot.
(cont'd)
16-17
Driveline/Axle
DriveshaftsInstallation(cont'd) {
"-'t-
I n s t a l l t h en e w l o c kp i n { D )i n t ot h e b a l l j o i n tp i n
hole from the insideto the outsideof the vehicle.
'10x 1.25mm
39 N.m
{4.0kgf.m,29 lbf.ft)
16-18
lntermediateShaft Removal
108N.m
(11.0kgf.m,
80 tbt.ft)
/
o
oo
e
3 . R e m o v et h e f l a n g eb o l t{ A )a n d t w o d o w e l b o l t s ( B ) .
22x 1.5 mm
1 8 1N . m
{18.5kgf.m,134lbt.ft) €.---2"
E J /
9. Cleanthe mating surfacesofthe brakedisc and the €
front wheel, then installthe front wheel with the
w
wheel nuts.
(cont'd)
16-19
Driveline/Axle
IntermediateShaft Removal IntermediateShaft Disassembly {
(cont'dl
4. Removethe intermediateshaft (A) from the Special Tools Required
differential.Hold the intermediateshaft horizontal . Oil seal driver 07947-5800100
until it is clear of the differentialto preventdamage . Half shaft base07NAF-SR30101
to the differentialoil seal (B).
1 . R e m o v e t h e s e rt i n g ( A ) ,o u t e r s e a (l B ) ,a n d e x t e r n a l
s n a pr i n g ( C ) .
PRESS L
16-20
3. Removethe internalsnap ring.
07947-s800100
07NAF-SR30101
16-21
Driveline/Axle
IntermediateShaft Reassembly
ExplodedView
FLANGEBOLT
INTERMEDIATE
SHAFTRING 10 x '1.25mm
39IVm
{4.0kgf.m,29lbt.ftl
\^
,tto", *,"o p
\--'+7\ E
BEARING
SUPPOBT
16-22
Special Tools Required 4. Pressthe intermediateshaft (A) intotheshaft
. Driver07749-0010000 b e a r i n g( B )u s i n gt h e s p e c i atl o o l a n d a p r e s s .
. Attachment,52x 55 mm 07746-0010400
. Attachment,35 mm 1.D.07746-0030400 PRESS
. Oil seal driver 07GAD-PH70201
I
1 . C l e a nt h e d i s a s s e m b l epda r t sw i t h s o l v e n t a, n d d r y
them with compressedair. Do not wash the rubber
partswith solvent.
PRES
I 07746-0030400
I n s t a l lt,h e n s e a tt h e e x t e r n asl n a pr i n g { A ) i n t ot h e
groove of the intermediateshaft (B).
07746-0010400
3 . I n s t a l lt,h e n s e a tt h e i n t e r n asl n a pr i n g i n t ot h e
groove ofthe bearingsupPort.
(cont'd)
16-23
Driveline/Axle
IntermediateShaft Reassembly IntermediateShaft Installation
(cont'd)
1 . U s es o l v e n to r b r a k ec l e a n e tr o t h o r o u g h l yc l e a n
the areaswhere the intermediateshaft {A) contacts
6 . l n s t a l l t h eo u t e rs e a l( A )i n t o t h e b e a r i n g s u p p o r t ( B ) the transmission(differential),and dry with
usingthe specialtool and a press. compressedair. Insertthe intermediateshaft
PRESS assemblyinto the differential.Hold the
intermediateshaft horizontalto preventdamageto
I the differentialoil seal (B).
Packthe interior
ofthe outer seal.
7 . I n s t a l l t h es e t r i n g .
2 . I n s t a l l t h el l a n g eb o l t( A )a n d t w o d o w e lb o l t s( B l .
A B
10 x 1.25mm l 0 x 1 . 2 5m m
39Nm 39 N.m (
(4.0kgf.m,29lbf.ft) (4.0kgf.m,
29 tbf.ftl
16-24
3. Installthe heat shield,and tightenthe three bolts.
8 x 1.25mm
22Nm
12.2
4 . I n s t a l l t h er i g h td r i v e s h a f(ts e ep a g e1 6 - 1 7 ) ,
16-25
Steering
Steering
S p e c i aTl o o l s . . . . . . . . . .1. .7.- 2
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .7. .-.3. . . . . . . . .
Steering WheelRotational PlayCheck.....................". 17-4
PowerAssistCheck.................. .......... 17-4
SteeringLinkage andGearboxInspection ................. 17-5
S t e e r i nW
g h e eR l e m o v a.l . . . . . . . . . . . . . . . . . . . . . . . . , . . . .1. .7. -. 6...........
Steering WheelDisassembly/Reassembly ................ 17-7
Steering WheelInstallation ............... 17-8
Steering ColumnRemovalandInstallation...........'... 17-9
Steering ColumnInspection .............. 17-11
SteeringLock Replacement .......................................'. 17-'12
R a c kG u i d eA d i u s t m e n t . . . . . " . . . . . . . . '1. .7' .- .1 3
ElectricalPowerSteering(EPS) 17-15
Steering
(
SpecialTools
Ref.No. Tool Number Description Oty
o 07MAA-S100200 LocknulWrench.43 mm
E
-.tt)-
---<,/
L\2 r
.V-
6Y
o
1 7-2
ComponentLocationIndex
DRIVER'S AIRBAG
ASSEMBLY
Removal/lnstallation,
p a g e2 3 - 1 1 3
STEERINGWHEEL
Removal,page 17-6
Disassembly/Reassembly,
page 17-7
Installation,page 17-8
STEERING COLUMN
SteeringColumnRemovaland Installation,
p a g e1 7 ' 9
SteeringColumn Inspection,
p a g e1 7 - 1 ' l
SteeringLockReplacement,
page 11-12
STEERINGGEARBOX
page'17-13
RackGuideAdjustment,
17-3
Steering
SteeringWheelRotationalPlay PowerAssistCheck \
Check
1 . Startthe engine,and let it idle.
1. Turn the front wheelsto the straightaheadposition. Attach a commerciallyavailablespring scaleto the
s t e e r i n gw h e e l .W i t h t h e e n g i n ei d l i n ga n d t h e
2. Measurehow far you can turn the steeringwheel v e h i c l eo n a c l e a n ,d r y f l o o r ,p u l lt h e s c a l ea s
left and right without moving the front wheels. shown, and read it as soon as the tires begin to turn.
3 . l f t h e s c a l er e a d sn o m o r e t h a n2 9 N ( 3 . 0k g f , 6 . 6l b f ) ,
the power assistis OK. lf it readsmore, checkthese
items:
. Fronttire pressure
. Steeringlinkage(seepage 17-5)
. Rackgulde adjustment(seepage 17-13)
. EPSsystem (seepage 17-18)
17-4
SteeringLinkageand GearboxInspection
BOOT
Inspect
Ior damageanddeterioration.
Checkfor looseness,
a n db i n d i n g . 12 mm BOLTS
Inspectfor looseness.
I STEERING COLUMN
Inspect
for loosecolumn
mountinghardware
STEERING JOINTS
TIE.RODLOCKNUTS Checkfor looseioint bolts,
Checkfor looseness. andlooseor bindingioints.
STEERING GEARBOX
Inspectfor loosemounting hardware.
GEARBOXMOUNTING CUSHIONS
Inspectfor deterioration.
TIE.RODENOBALLJOINT
lnsoect tor looseness,
b i n d i n ga,n dd a m a g e .
BALLJOINT BOOT
Inspect
for damageanddeterioration.
17-5
Steering
SteeringWheelRemoval {
1. Align the front wheels straightahead,then remove Note these items when removing the steering
the driver'sairbagfrom the steeringwheel (see wheel:
p a g e2 3 - 1 1 3 ) . . Do not tap on the steeringwheel orthesteering
column shaft when removingthe steeringwheel.
2. Disconnectthe cruisecontrol sevresumeswitch . l f y o u t h r e a dt h e p u l l e rb o l t s( D )i n t o t h e w h e e l
connector(A),and loosenthe steeringwheel nut hub more than 5 threads,the bolts will hit the
{B). cable reel and damageit. To preventthis, install
a p a i ro f j a m n u t s5 t h r e a d su p o n e a c hp u l l e rb o l t .
17-6
SteeringWheelDisassembly/Reassembly
WHEEL
STEERING
CONTACTPLATE ACCESSPANELA
CONNECTORHOLDERS 75*-=offi
,/*
MOOULESETBRACKET
ffi)Y
-f
b
/
WHEELREABCOVER
STEERING
accEss
PANEL
B
CRUISECONTROLSWITCH
17-7
Steering
SteeringWheelInstallation
1 . B e f o r ei n s t a l l i n g
t h e s t e e r i n gw h e e l ,m a k es u r et h e 3. Installthe steeringwheel nut (A),and tighten it to
front wheels are alignedstraightahead,then center the specifiedtorgue.
the cable reel (A).Do this by first rotatingthe cable
reel clockwiseuntil it stops.Then rotate it A _
39 N.m(4.0kgf m.29lbt ftl B
counterclockwiseabout two and a half turns.The
a r r o w m a r k( B )o n t h e c a b l er e e ll a b e ls h o u l dp o i n t
straightup.
lr,',,t
;. _,:!
'' '1i::..'.'l
17-8
SteeringColumnRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
Removal
2 . R e m o v e t h e d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 2 3 -a1n1d3t)h e s t e e r i n gw h e e l( s e ep a g e1 7 - 6 ) .
3 . R e m o v e t h ed r i v e r ' sd a s h b o a r dl o w e r c o v e r ( s e ep a g e2 0 - 5 9 a) n d u n d e r c o v e r ( s e e
p a g e2 0 - 6 0 ) .
I x 1.25mm
16 N.m (1.6kgf.m,
12 lbl.fr) b
5 . Disconnectthe wire harnessconnectorsfrom the combinationswitch assembly{B).
6 . Removethe combinationswitch assemblyfrom the steeringcolumn shaft by removingthe screw (C)on the top of
the combinationswitch.
7. Disconnectthe connectorsfrom the ignition switch,and releasethe wire harnessclips from the steeringcolumn.
\
(cont'd)
17-9
Steering
SteeringColumnRemovaland Installation(cont'd) {
lnstallation
1 . I n s t a ltl h e s t e e r i n gc o l u m n ,a n d m a k es u r et h e
wires are not caught or pinchedby any parts.
8 x 1 , 2 5m m
28 N.m
{2.9 kgf m,
21rbr.ft)
A
17-10
SteeringColumnInspection
. C h e c kt h e s t e e r i n gc o l u m nb a l l b e a r i n g ( A a) n d t h e s t e e r i n g j o i n t b e a r i n g s ( B ) f o r p l a y a n d p r o p e r m o v e m el fnatn. y
bearingis noisy or has excessiveplay, replacethe steeringcolumn as an assembly,
' C h e c k t h e a b s o r b i n g p l a t e s ( C ) , a b s o r b i n g p l a t e g u i d e s ( D ) , s t o p ( E ) , a n d c o a t i n g p l af o
t er sd(i F
s t)o r t i o na n d
breakage.lf there is distortionor breakage,replacethe steeringcolumn as an assembly.
17-11
Steering
SteeringLockReplacement
NOTE:Do not try to re-keya replacementsteeringlock. 7. Tightenthe shearbolts (A) untilthe hex heads(B)
lf necessary,re-keythe other locks. twist off.
1 . R e m o v et h e s t e e r i n gc o l u m n( s e ep a g e1 7 - 9 ) .
A
2. Centerpunch each ofthe two shear bolts (A),and
drill their headsoff with a 5 mm (3i16 in.) drill bit.
Be carefulnot to damagethe switch body when
I
removingthe shear bolts,
:..'-":'
17-12
RackGuideAdjustment
Special Tool Required 6. Tightenthe rackguidescrew(A)ro25 N.m (2.5
Locknutwrench, 43 mm 07MAA-S100200 kgf.m,18lbf.ft).thenloosenit.
9 . 8N . m ( r . 0 k g f . m , 7 . 2 l b t f t )
I 4il N.m
{a.5kgf.m,33lbt.ft)
3 . Removethe transmissionmount bracket(seestep
32 on page 13-8). 7 . Retightenthe rack guide screw to 6 N.m (0.6kgf m,
4 lbf.ft),then back it off to the specifiedangle.
Loosenthe rackguide screw locknut(A)with the
specialtool, then removethe rack guide screw (B). Specified Return Angle: 5' Max.
07MAA-S100200
Hold the rack guide screw stationarywith a wrench,
and tighten the locknutby hand until it's fully
seated.
9 . I n s t a l l t h es p e c i atl o o l o n t h e l o c k n u (t B ) ,a n d h o l d
the rackguide screw (A) stationarywith a wrench,
Tightenthe locknutan additional30" with the
specialtool.
17-13
ElectricalPowerSteering(EPSI
SpecialTools . . . . . . . . . .1. .7-. 1 6
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7. .-.1. .7. . . . . . .
General Troubleshooting Information....................... 17-18
DTCTroubleshooting Index .............. 17-22
SymptomTroubleshooting Index ............................... 17-23
SystemDescription................. ........... 17-24
CircuitDiagram .........17-26
DTCTroubleshooting ............... .......... 17-28
EPSlndicator CircuitTroubleshooting ....................... 17-47
MotorRemoval/lnstallation ............... 17-49
Steering GearboxRemoval ............... 17-51
Steering GearboxOverhaul ............... 17-55
Steering GearboxInstallation ........... 17-63
EPSControlUnitRemova l/lnsta llation....................... 17-67
Tie-rodBallJointBootReplacement .......................... 17-67
EPSComponents
SpecialTools \
-)
,.^G) C\
_---1t )
h5--d-'
u_r-.c_-
t t )
\L-,
a
17-16
ComponentLocationIndex
GAUGE
ASSEMBLY
UNDER.DASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
-,'/.,....
'.,i,
X \ ]
TOROUE
SENSOR
STEERINGGEARBOX
EPSCONTROL UNIT SteeringGearboxRemoval,page 17-51
EPSControlUnitRemoval/lnstallation, SteeringGearboxOverhaul,page 17-55
page17-67 SteeringGearboxInstallation,page 17-63
MOTOR
Removal/lnstallation,
page l7-49
17-17
EPSComponents
GeneralTroubleshooting
Information a
EPSIndicator . TheDTCS arememorized in theEEPRO|(non-volatile
memory)therefore the memorizedDTCScannotbe erased
Undernormalconditions, the EPSindicator
comeson when by disconnecting
the battery.
Perform
thespecified
the ignitlonswitchis turnedto theON(ll)position,
thengoes procedures
to clearDTCS.
off afterthe engineis started.
Thisindicates
thatthebulband
itscircuitareoperating correctly. Self-diagnosis
lf thereis anytroublein thesystemaftertheengineis started,
theEPSindicator will stayon,andthe powerassistis turned Self-diagnosiscan be classifiedinto two categories:
off. . I n i t i a l d i a g n o s i sp: e r f o r m e dr i g h ta f t e rt h e e n g i n e
startsand until the EPSindicatorgoes off.
WhenEPSindicator lightcomeson,thecontrolunit . Regulardiagnosis:performedright after the initial
memorizes the DTC.In thiscase,thecontrolunitwill not d i a g n o s i su n t i lt h e i g n i t i o ns w i t c hi s t u r n e dO F F .
the EPSsystemaftertheenginestartsagain,but it
activate
keepsthe EPSindicator on. The EPScontrol unit performsthe following functions
when a problem is detectedby self-diagnosis;
WhenDTC12,16,17,18or 67 is storedin thecontrolunit,the
'1.
EPSindicatorwill stayon untiltheDTCis erased.Whena T u r n so n t h e E P Si n d i c a t o r .
problemis detected andthe EPSindicator comeson,thereare 2. Memorizesthe DTC.
caseswhenthe indicator stayson untiltheignitionswitchis 3. Stops power assistand manual steeringoperation
turned0FF,andcaseswhenthe indicator goesoff begrns.
whenthesystemreturnsto normal.Eventhough
automatically
thesystemis operating normally, the EPSindicator
will come NOTE:
on underthefollowingconditions: . When DTC23 (a problemwith the circuitfor
enginespeedsignal)is detected,the power
'1:
Condition a s s i sw
t i l l r e t u r nt o n o r m a lw h e n t h e v e h i c l e
. Thevehiclewastraveling at least12.4mph(20km/h),then s p e e di s 0 . 6 2m p h ( 1 k m / h )o r a b o v e .
. A rapid changein vehiclespeedwas detected,then . Fot DfCs 22,23, 64, or 66 the EPSindicatorgoes
. Thevehicle(orthevehiclespeedsensorsignal)stoppedfor off automaticallywhen the system relurnsto
at least5 seconds n o r m a l .F o ra l l o t h e rc o d e s t, h e E P Si n d i c a t o r
. T h ee n g i n se p e e d 'l,640rpmorhigherforatleastS goes off when the system is OK afterthe ignition
w a ss t i l l
seconds switch is turned from OFFto ON (ll).
C o n d i t i o n2 : Restrictionon PowerAssistOperation
Afterthevehicle(orthevehiclespeedsensorsignal)has
stopped yettheenginespeedwasstill
for at least10seconds, Repeatedextremesteeringforce.such as turning the
1,640rpmor higherforat least20seconds. steeringwheel continuouslyback-and-forth with the
vehiclestopped,causesan increaseof power
C o n d i t i o n3 : consumptionin the EPSmotor. The increaseof electric
When theengine is280rpmor less,
speed andthevehicle
istraveling
at c u r r e n tc a u s e st h e m o t o rt o h e a tu p . B e c a u s e
t h i sh e a t
a speed of6,2mph(10km/h) or morefor3 seconds. adverselyaffectsthe system,the control unit monitors
the electriccurrent of the motor.
theactualcauseofthe problem,question
To determine the
customer duringwhichthe problem
abouttheconditions When the control unit detectsheat build-upin the motor,
takingtheaboveconditions
occured, intoconsideration. it reducesthe electriccurrentto the motor graduallyto
protectthe system,and it restrictsthe power assist
DiagnosticTroubleCode(DTCI o p e r a t i o nT. h e E P Si n d i c a t o dr o e sn o t c o m e o n d u r i n g
t h i sf u n c t i o n .
. lf theCPUcannotbeactivated,or itfails,theEPSindicator
comeson,butthe DTCis notmemorized. When steeringtorque is not appliedto the steering
. Thememorycanholdanynumberof DTCS. However, when wheel, or when the ignition is turned off, and the motor
thesameDTCis detected morethanonce,the mostrecent cools,the control unit will restorethe power assist
DTCis writtenoverthe priorDTC,therefore onlyone graduallyuntil it's fully restored(afterapproximately15
occurrence is memorized. m i n u t e sm a x i m u m ) .
. TheDTCS areindicatedrepeatedlyuntiltheignitionswitchis
turnedOFF.
. lf theDTCis not memorized,the
EPSindicator blinks.
17-18
How to TroubleshootEPSDTCs 2 . T u r nt h e i g n i t i o nO N ( l l ) ,a n d f o l l o wt h e p r o m p t so n
the PGM Testerto displaythe DTC(s)on the screen.
The troubleshootingflowchart proceduresassumethat After determiningthe DTC,referto the DTC
the causeof the problem is still presentand the EPS TroubleshootingIndex.
indicatoris still on, Followingthe flowchartwhen the
EPSindicatordoes not come on can result in incorrect NOTE:See the HondaPGM Testeruser's manual
diagnosis. for specificinstructions.
The connectoriliustrationsshow the female terminal
s i t h a s i n g l eo u t l i n ea n d t h e m a l et e r m i n a l
c o n n e c t o rw ServiceCheckSignalCircuit Method:
connectorswith a double outline.
1 . W i t h t h e i g n i t i o ns w i t c hO F F ,c o n n e c t h e H o n d a
1. Ouestionthe customeraboutthe conditionswhen P G MT e s t e r( A ) t o t h e 1 6 Pd a t al i n kc o n n e c t o(rD L C )
the problem occured,and try to reproducethe (B) locatedunderthe dash on the driver'sside of
same conditionsfor troubleshooting.Find out the vehicle.
when the EPSindicatorcame on, such as while
t u r n i n g .a f t e r t u r n i n gw, h e n t h e v e h i c l ew a s a t a
certain speed,etc.
How to RetrieveEPSDTCs
Honda PGM Tester Method: Short the SCScircuitto body ground using the
HondaPGN4Tester.
1, With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC) T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
(B) locatedunderthe dash on the driver'sside of
thevehicle. Recordthe DTC.
(cont'd)
17-19
EPSComponents
GeneralTroubleshootingInformation(cont'dl
5. The blinkingfrequencyindicatesthe DTC.DTCSare How to ClearEPSDTCs
indicatedby a seriesof long and short blinks.One
l o n g b l i n ke q u a l s1 0 s h o r tb l i n k s A
. d d t h e l o n ga n d Honda PGM Tesler Method:
short blinkstogetherto determinethe DTC.After
determiningthe DTC,referto the DTC 1. With the ignition switch OFF,connectthe Honda
TroubleshootingIndex. PGM Tester(A)to the 16Pdata link connector(DLC)
( B )l o c a t e du n d e rt h e d a s ho n t h e d r i v e r ' ss i d eo f
The system will not indicatethe DTCunlessthese the vehicle.
conditionsare met:
. Set the front wheels in the straightaheaddriving
position.
. The ignition switch is turned ON (ll).
. The engine is stopped.
. The SCScircuit is shortedto body ground before
the ignition switch is turned ON (ll).
Exampleof DTC23
17-20
Service Check Signal Circuit Method: 1 . Within 4 secondsafter the EPSindicatorgoes off,
returnthe steeringwheel to the straightahead
NOTE:Use this procedurewhen the PGM Tester driving positionagain and releasethe steering
softwaredoes not matchthe yearlmodelvehicleyou wheel.The EPSindicatorblinkstwice 4 seconds
are working on. after releasingthe steeringwheel, indicatingthat
the DTCwas erased.
1. With the ignitionswitch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector{DLC) NOTE:If the EPSindicatordoes not blinktwice, an
(B) locatedunderthe dash on the driver'sside of error was made in the procedureand the DTCwas
the vehicle. not erased.Turn the ignition switch OFF,and
repeatthe operationfrom step 3.
17-21
EPSComponents
DTCTroubleshootingIndex
D T C1: 6 A problemwith averageof voltagefor torque sensorVT3 and VT6 (seepage 17-29)
DTC:37 A problemwith the circuitfor input motor voltage in the EPScontrol unit (seepage 17-35)
DfC: 42 A problemwith the motor driven current (opencircuitor short to grounol (seepage '17-38)
DTC:45 A problemwith the motor driven current (opencircuitor short to grounol (seepage 17-38)
D T C :5 1 A problemwith EEPROM
in the EPScontrolunlt (seepage 17-43)
DTC:69 A p r o b l e mw i t h t h e i n t e r l o c kc i r c u i t( c u r r e n t ) ( s e ep a g e1 7 - 4 6 )
17-22
Symptom TroubleshootingIndex
EPSindicatordoes not stay 1. Checkthe motor wires betweenthe EPScontrol unit and the
on, no DTCis stored,and motor for a short to ground. Repairas needed.
there is no power assist 2. lf the motor wires are OK, replacethe steeringgearbox
{short in the motor).
17-23
EPSGomponents
SystemDescription
EPSGontrolUnit Inputsand Outputsat ConnectorA (2pl
EPSCONTROLUNITCONNECTOB
B {2P}
17-24
EPSGontrolUnit Inputsand Outputsat ConnestorC (20P1
C (2OP)
EPSCONTROLUNITCONNECTOR
17-25
EPSComponents
CircuitDiagram \ a
SPE€DSENSOR GAUGEASSEMBLY22PCONNECTON
3P CONNECTOR
GAUGEASSEMATY22PCONNECTOR TOFOUESENSOR
6P CONNECTOR
lli2l3F
r;T;T-I
(=J_:_LvJ
17-26
EPSCOI{IFOIUNIT OATA !IN( CONN€CTOA(T6P)
cou{EcToR A (2P)
F-l
A vTTrvaEvnrv
EPSCONTNOLUNIT
wwzna
co|lNEcTofi 8 {2P} MOTOF
CONNECTOR
17-27
EPSComponents
DTCTroubleshooting
DTC12: TorqueSensorT/SIG 1 . Turn the ignition switch ON (ll).
ls DTC12 indicated?
I s there battery v oltage?
YES Go to slep 5.
YES-Repair short to power in the + circuitwire
NO-Perform the appropriatetroubleshootingfor betweenthe torque sensorand EPScontrol unit.l
the code indicated.t
NO Go to step 9.
5 . Make sure the ignitionswitch is OFF,then
disconnectEPScontrol unit connectorC (20P)and
\
9 . Turn the ignition switch OFF.
the torque sensor6P connector.
1 0 . Checkfor continuitybetweenEPScontrol unit
Checkfor continuitybetweenEPScontrol unit connectorC (20P)terminal No. 15 and the torque
r ( 2 0 P ) t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .
c o n n e c t oC sensor6P connectorterminal No. 4.
EPSCONTROL C (2OPI
UNITCONNECTOR
EPSCONTROL
UNITCONNECTOR
C {2OP)
T/SIG W i r es i d eo f f e m a l et e r m i n a l s
(YEL/BLK)
TOROUE
SENSOR
6PCONNECTOR
T/SIG
(YEL/BLK)
Wire side of femaleterminals
Wire side ot femaleterminals
17-28
'I
1 . Substitutea known-goodEPScontrol unit, and DTC16:TorqueSensorVT3andW6
connectthe all disconnectedconnectors.
1 . C l e a rt h e D T C .
1 2 .Start the engine. 2. Startthe engine.
3 . W a i t a t l e a s t1 0 s e c o n d s .
Does the EPS indicator come on?
Does the EPS indicator come on?
YES Go to step 13.
YES Go to step 4.
NO Checkfor loose EPScontrol unitconnectors.lf
necessary,replacethe EPScontrol unit and NO Checkfor loosewires or poor connnections.lf
retest.l the connectionsare good,the system is OK at this
time.l
1 3 .Stop the engine,and verify the DTC.
4. Stop the engine,and verify the DTC.
ls DTCl2 indicated?
ls DTC16 indicated?
YES Checkfor loosetorque sensorconnectors.
lf necessary,substitutea known-goodsteering YES-Go to step 5.
gearboxand recheck.l
NO Performthe appropriatetroubleshootingfor
NO-Perform the appropriatetroubleshootingfor the code indicated.t
the code indicated.!
5. Make sure the ignition switch is OFF,then
disconnectEPScontrol unit connectorC (20P)and
the torque sensor6P connector.
Terminalname C
EPScontrolunitconnector
terminalNo.
Vccl 3
Vcc2 11
VT3 13
VT6 5
T/S GND 2
C (2OP)
EPSCONINOTUNITCONNECIOR
W re s d€ oltemalelermi.als
ls there continuity?
NO Go to step7.
{cont'd)
17-29
EPSComponents
DTCTroubleshooting(cont'd) I
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 9 . Turn the ignition switch OFF.
Vccz
(GRN/YELI
Wire side of
f e m a l et e r m i n a l s
VT6 {YEL/RED)
NO Go to step 9.
Wire side of femaleterminals
ls therecontinuty?
Y E S G ot o s t e p1 1 .
17-30
1 1 .Substitutea known-goodEPScontrol unit, and DTC17: TorqueSensorVccl
reconnectthe disconnectedconnectors.
DTC18:TorqueSensorVcc2
't2.
Start the engine.
1 . C l e a rt h e D T C .
Does the EPS indicator come on?
2 . S t a r tt h e e n g i n e .
YES Go to step 13.
3. Wait at least 10 seconds.
NO Checkfor looseor poor connectionsat the
EPScontrol unit and the torque sensorconneclors. Does the EPS indicator come on?
lf the connectionsare good, replacethe EPScontrol
u n i ta n d r e c h e c k . I YES Go to step 4.
1 3 .Stop the engine,and verify the DTC. NO Checkfor loosewires or poor connections.lf
the connectionsare good, the system is OK at this
ls DTC16 indicated? time.I
YES Replacethe steeringgearboxand recheck.l 4 . Stop the engine,and verify the DTC.
C (2OP)
UNITCONNECTOR
EPSCONTROL
Wiresideo{ femaleterminals
ls there continuity?
Y E S R e p a i rs h o n t o b o d y g r o u n di n t h e w i r e
betweenthe torque sensorand EPScontrol unit.I
NO Go to step 7.
(cont'd)
17-31
EPSComponents
DTCTroubleshooting(cont'dl \
Vcc2(GRN/YEL)
NO Repairopen in the wire betweenthe torque NO Repairopen in the wire betweenthe torque
s e n s o ra n d E P Sc o n t r o lu n i t . I sensorand EPScontrol unit.l
EPSCONTROL C (2OP)
UNITCONNECTOR 1 1 .Start the engine.
Wire side of femaleterminals 12. Stop the engine,and verity the DTC.
17-32
DTC22: VehicleSpeedSensorSignal 3 . Blockthe rearwheels and raisethe vehicle,and
make sure it is securelysupported.
DTC23: EngineSpeedSignal
4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
NOTE:
. lf the MIL indicatoris ON, troubleshootthe PGIVI-Fl 5 . Blockthe right front wheel, and slowly rotatethe
systemfirst. left front wheel, and measurethe voltage between
. Eventhough the system is operatingnormally,the r ( 2 0 P ) t e r m i n aNl o . 7
E P Sc o n t r o lu n i tc o n n e c t oC
EPSindicatorwill come on underthe following a n d b o d yg r o u n d .
conditions.
EPSCONTROL
UNITCONNECTOR
C {2OP)
- C o n d i t i o n1 :
. The vehiclewas travelingat least '12.4mph
(20 km/h),then
. A rapld changein vehiclespeedwas detected,
then
. T h e v e h i c l e( o rt h e v e h i c l es p e e ds e n s o rs i g n a l )
stoppedfor at least5 seconds,and
. The engine speedwas still 1,640rpm or higherfor
at least5 seconds
- Condition2:
After the vehicle(or the vehiclespeedsensor Wire side of femaleterminals
signal)has stoppedfor at least10 seconds,yetthe
e n g i n es p e e dw a s s t i l l 1 , 6 4 0r p m o r h i g h e rf o r a t
least20 seconds. Does the voltagepulse 0 V and 5 V?
- Condition3:
W h e nt h e v e h i c l es p e e di s 1 0 k m / h ( 6 . 2m p h )o r YES Go to step 6.
a b o v ea n d t h e e n g i n ei s r u n n i n ga t 2 8 0 r p m o r
below for 3 seconds. NO Repairopen in the wire betweenthe EPS
control unit and the VSS. lf the wire is OK,checkfor
1. Startthe engineand checkthe tachometer. a loose or poor connectionsat the EPScontrol unit.
lf necessary,substitutea known-goodEPScontrol
ls the tachometer working correctly? u n i t ,a n d r e c h e c k . l
YES- Go to step 2.
N O - G o t o s t e p9 .
YES Go to step 3.
(conr'd)
17-33
EPSGomponents
DTCTroubleshooting(cont'dl
Turn the ignition switch OFF,and disconnectEPS 11. Measurethe voltage betweenEPScontrol unit
control unit connectorC (20P). r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d b o d y g r o u n d .
c o n n e c t oC
EPSCONTROL
UNITCONNECTOR
C {2OP)
Wiresideof femaleterminals
17-34
'14.
Checkfor continultvbetweenEPScontrol unit DTC37: EPSControlUnitInternal Circuit
r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d E C M
c o n n e c t oC (lnputCircuitForMotorVoltage)
connectorE (31P)terminal No. 26.
1 . C l e a rt h e D T C .
ECMCONNECTOR
E {31PI
2. Startthe engine.
YES Go to step 4.
EPSCONTROL C (2OP}
UNITCONNECTOR
Wiresideof femaleterminals
ls there continuity?
Y E S R e p a i rs h o r t t ob o d y g r o u n di n t h e w i r e
betweenthe EPScontrol unit, the test tachometer
connector,the gaugeassembly,and the ECM.I
17-35
EPSComponents
DTCTroubleshooting(cont'dl .l
DTC41: VoltageForMotor 7. Checkfor continuitybetweenEPScontrol unit
r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .
c o n n e c t oB
1 . C l e a rt h e D T C .
EPSCONTROLUNITCONNECTOR
B I2P)
2 . S t a r tt h e e n g i n e .
-r
Does the EPS indicator come on?
o)
YES-Go to step 4. I
T
NO Checkfor loosewires or poor connections.lf
the connectionsare good,the system is OK at this Wiresideof femaleterminals
time.l
ls DTC 41 indicated? Y E S - R e p a i rs h o r tt o b o d y g r o u n di n t h e G R Nw i r e
betweenthe EPScontrol unit and the motor,l
YES Go to step 5.
NO Go to step 8.
NO Performthe appropriatetroubleshootingfor
t h e c o d ei n d i c a t e d . l Checkfor continuitybetweenEPScontrol unit
r ( 2 P ) t e r m i n aNl o . 1 a n d N o . 2 .
c o n n e c t oB
5. Make sure the ignition switch is OFF,then \
disconnectEPScontrol unit connectorB (2P)and EPSCONTROL B {2P)
UNITCONNECTOR
the motor 2P conneclor.
EPSCONTROLUNIT CONNECTOR
B {2P}
M2 (GRNI
M1 (RED}H
F---t||
Wiresideof femaleterminals
Itr
(f))
T
,L ls there continuity?
N O - G o t o s t e p7 .
17-36
9. Turn the ignition switch ON (ll),and measurethe 1 1 .T urn the ignition switch is OFF.
voltagebetweenEPScontrol unit connectorB (2P)
terminal No. 1 and body ground Substitutea known-goodEPScontrol unit, and
connectall the disconnectedconnectors.
B (2P)
EPSCONTROLUNITCONNECTOR
1 3 .Start the engine,and turn the steeringwheel from
lockto lock severaltimes.
1 4 . S t o pt h e e n g i n e a
, n d v e r i t yt h e D T C .
Is there battety voltage?
ls DTC 41 indicated?
YES Repairshort to power in the + circuitwire
betweenthe EPScontrol unit and the motor.I YES Replacethe steeringgearboxmotor and
recheck.l
N O - G o t o s t e p1 0 .
NO Performthe appropriatetroubleshootingfor
1 0 .Measurethe voltagebetweenEPScontrol unit t h e c o d ei n d i c a t e d . l
r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .
c o n n e c t oB
EPSCONTROL B (2P)
UNITCONNECTOR
razrcnrrrr
l{. I
l-t
I
(v)
Y
I
N O G o t o s t e p1 1 .
17-37
EPSComponents
DTCTroubleshooting(cont'd) {
EPSCONTROL
UNITCONNECTOR
B I2P)
M2 {GRN)
M1 IRED}H
I f2-l W i r es i d eo f f e m a l et e r m i n a l s
(C))
T
I ls there continuity?
N O - G o t o s t e p7 .
17-38
9. Turn the ignition switch ON (ll),and measurethe 11. Checkfor continuitybetweenEPScontrol unit
voltage betweenEPScontrol unit connectorB (2P) connectorB (2P)terminal No. 1 and the motor 2P
t e r m i n a lN o . I a n d b o d y g r o u n d . connectorterminal No. 2.
B (2PI
EPSCONTROLUNITCONNECTOR EPSCONTROLUNIT MOTORCONNECTOR
{2PI
B 12P)
CONNECTOR
M1{RED}H M1 IRED)
T-----l | |
lil
(v) M1 (RED}
I
I
EPSCONTROL B (2P}
UNITCONNECTOR
mzrcnrur
ll-l
A
(v)
Y
I
W i r es i d eo f f e m a l et e r m i n a l s
Y E S R e p a i rs h o r tt o p o w e ri n t h e + c i r c u i t w i r e
betweenthe EPScontrol unit and the motor.a
N O - G o t o s t e p1 1 .
(cont'd)
17-39
EPSGomponents
DTGTroubleshooting(cont'd) L (
12. Checkfor continuitybetweenEPScontrol unit 15. Stop the engine,and verify the DTC.
c o n n e c t oBr ( 2 P ) t e r m i n aNl o . 2 a n dt h e m o t o r2 P
c o n n e c t otre r m i n a lN o . 1 . ls DTC 42 or 45 indicated?
EPSCONTROLUNIT MOTORCONNECTOR
{2P) YES Replacethe steeringgearboxmotor and
CONNECTORB I2PI recheck.l
NO Performthe appropriatetroubleshootingfor
the code indicated.l
M2 IGRN)
ls there continuity?
Y E S - G o t o s t e p1 3 .
17-40
DTCtli|: MotorDrivenCurrentis Excessively 8. Measurethe voltagebetweenEPScontrol unit
Hish r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .
c o n n e c t oB
1 . C l e a rt h e D T C . EPSCONTROL
UNITCONNECTOR
B I2PI
2. Startthe engine.
Til
3. Turn the steeringwheel from lock-to-lockseveral M2tcRNl F-l
'10 f---1 z I
times, and wait secondsor more.
EPSCONTROLUNITCONNECTOR
B {2P}
M2 {GBN)
Itr
(v) ls there continuity?
T
-L
YES Repairshort betweenthe GRN and RED
wires in the motor circuitbetweenthe EPScontrol
Wiresideot Iemaleterminals u n i ta n d t h e m o t o r . l
N O G o t o s t e p1 1 .
ls therc battery voltage?
N O - G o t o s t e p8 . ( c o n td )
17-41
EPSComponents
DTCTroubleshooting(cont'dl (
1 3 .Stop the engine,and verity the DTC. 3. Stop the engine,and verify the DTC.
17-42
DTC50: EPSControlUnit InternalCircuit DTC51: EPSControlUnitInternalCircuit
(CPUor Microcomputer) (EEPROM)
1. Clearthe DTC. 1 . C l e a rt h e D T C .
Does the EPS indicator come on? Does the EPS indicatot come on?
3. Stop the engine,and verify the DTC. 3. Stop the engine,and verify the DTC.
YES-Check for looseor poor connectionsat the YES-Check for looseor poor connectionsat the
EPScontrol unit connections.lf the connectionsare EPScontrol unit connections.lf the connectionsare
good, substitutea known-goodEPScontrol unit. lf good. substitutea known-goodEPScontrol unit. lf
the symptom/indicationgoes away, replacethe the symptom/indicationgoes away, replacethe
original EPScontrol unit.l original EPScontrol unit.!
17-43
EPSComponents
(cont'dl
DTCTroubleshootang (
Does the EPS indicator come on? Does the EPS indicatot come on?
3. Stop the engine,and verify the DTC. 3. Stop the engine,and verify the DTC.
YES Go to step 5.
-Blwt{r/Bl.urH
l
\9
I
17-44
DTC66,68: EPSControlUnitlnternalCircuit DTC67: TorqueSensorl/FCircuit
1 . C l e a rt h e D T C . 1. Clearthe DTC.
Does the EPS indicator come on? Does the EPS indicator come on?
NO-Check for loosewires or poor connections.lf NO Checkfor loose wires or poor connections.lf the
the connectionsare good.the system is OK at this connectionsare good, the system is OK at this time. !
time.l
4. Stop the engine,and verify the DTC.
4. Stop the engine.and verify the DTC.
ls DTC 67 indicated?
ls DTC 66 or 68 indicated?
YES Checkfor looseor poor connectionsat the
YES-Check for looseor poor connectionsat the EPScontrol unit. lf the connectionsare good,
EPScontrol unit. lf the conneclionsare good, substitutea known-goodEPScontrol unit. lf the
substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe
symptom/indicationgoes away, replacethe original EPScontrol unit and recheck.!
original EPScontrol unit and recheck.I
NO-Perform the appropriatetroubleshootingfor
NO Performthe appropriatetroubleshootingfor the code indicated.I
the code indicated.t
17-45
EPSComponents
DTCTroubleshooting(cont'd)
DTC69: EPSControlUnit InternalCircuit
1 . C l e a rt h e D T C .
2. Startthe engine.
YES Go to step 4.
ls DTC 69 indicated?
17-46
EPSIndicatorCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll),startthe engine, 5. Turn the ignition switch OFF.
and watch the EPSindicator.
6. DisconnectEPScontrol u n it connectorC (20P).
Does the EPS indicator come on?
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
YES lf the EPSindicatorcomes on and goes off, it's
OK. lf the EPSindicatorstayson or blinks.go to 8. ConnectEPScontrol unit connectorC (20P)
s t e p1 2 . terminal No. 6 to body ground with a jumper wire.
YES-Go to step 3.
W i r e s d € o f l e m a l e 1 6 r m i n as
NO Repairopen in the indicatorpower source
circuit.l
. B l o w nN o . 1 0 ( 7 . 5 A ) f u s e . Does the EPS indicatot come on?
. Open in the wire betweenthe No. 10 (7.5A)fuse
and gaugeassembly. YES Go to step 9.
. Open circuitinsidethe under-dashfuse/relaybox,
. Faultygauge assembly. NO Repairopen in the wire betweenthe gauge
assemblyand the EPScontrol unit.l
3 . Turn the ignitionswitch OFF,
9 . Turn the ignitionswitch OFF.
4 . Connecta jumper wire betweenthe gauge
assembly22Pconnectorterminal No. 13 and body 1 0 .DisconnectEPScontrol unit connectorA (2P),
g r o u n d ,t h e nt u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
' l1 .
Checkfor continuitybetweenEPScontrol unit
(Blueconnector) connectorA terminal No. 2 and body ground.
GAUGEASSEMBLY
22PCONNECTOR
EPSCONTROL A I2PI
UNITCONNECTOA
w i r e s d e o f t e m a l et e r m i n a l s
Wiresideof femaleterminals
ls there continuity?
Does the EPS indicator come on?
YES Checkfor loose or poor connectionsat the
YES-Go to step 5. E P Sc o n t r o lu n i t .l f t h e c o n n e c t i o nasr e g o o d ,
substitutea known-goodEPScontrol unit. lf the
N O I n s p e ctth e E P Si n d i c a t o b r u l b ,i f t h e b u l b i s symptom/indicationgoes away, replacethe
O K , r e p l a c et h e b u l bc i r c u i tb o a r di n t h e g a u g e originaE l P Sc o n t r o lu n i ta n d r e c h e c k . I
assembly.l
N O R e p a i ro p e ni n t h e w i r e o r a b a d g r o u n da t
G151,t
(cont'd)
17-47
EPSComponents
EPSIndicatorCircuitTroubleshooting(cont'dl I
1 2 .Turn the ignitionswitch OFF. 16. Measurethe voltagebetweenEPScontrol unit
'1
connectorA (2P)terminalNo. and body ground.
1 3 .DisconnectEPScontrol unit connectorC (20P).
EPSCONTROL A (2P}
UNITCONNECTON
1 4 .Turn the ignitionswitch ON (ll).
EPSCONTROL
UNITCONNECTOR
C I2OP) YES-Go to step 17.
EPSCONTROL C (2OP)
UNITCONNECTOR
ls therebatteryvoltage?
Y E S - G ot o s t e p1 6 .
Wiresideof femaleterminals
ls therc about 10 V?
17-48
Motor Removal/lnstallation
Bemoval 4. Removethe connectorbracket(A) onthegearbox
housing,and disconnectthe motor 2P connector
1. Make sure you havethe anti-theftcode for the radio, (B).
then write down the frequenciesfor the preset
buttons. 9.8 N.m {1.0kgf.m,
(cont'd)
17-49
EPSComponents
(cont'dl
Motor RemovaUlnstallation (
17- 5 0
SteeringGearboxRemoval
Special Tool Required 8. Removethe cotter pin (A)from the tie-rod balljoint
Ball ioint remover,2Smm 0TlvlAC-S100200 nut {B),and loosenthe nut.
R e m o v et h e d r i v e r ' sa i r b a g ( s e e p a g e 2 3 - 1 1 3 ) .
7 . Removethe steeringjoint bolts (A),and disconnect 9 . Separatethe tie-rod balljoint and damper steering
the steeringjoint by moving the steeringjoint (B) arm usingthe specialtool (seepage 18-10).Repeat
toward the column. on the other side of the vehicle.
1 0 .G r a s pt h e r i g h ts i d et i e - r o d a, n d p u l lt h e r a c ka l l t h e
way to the passenger'sside,
' i l
(cont'd)
17-51
EPSComponents
SteeringGearboxRemoval(cont'd)
12. Disconnectthe EPSwire harness6Pconnector
(A), 1 4 . R e m o v et h e e n g i n ew i r e h a r n e s sc l a m p s{ A ) f r o m
andremovethe EPSwire harness(B)andmountino the three mounting brackets.
bracket(C).
-a--zi i F--_1
b-
H \ I
ry T,-.lt'^ \
'" \--
_ - 1 . . 1 . - '
17-52
17. Removethe bodv stiffener(A). 19. Removethe steeringstiffenerB from the right side
of the steeringgearbox.
i t1-:: .,
(cont'd)
17-53
EPSComponents
SteeringGearboxRemoval{cont'd)
22. Move the steeringgearboxand tie-rod ends as an
assemblyto the wheelwellopening on the
passenger'sside.
17-51
SteeringGearboxOverhaul
ExplodedView
I x '1.25
mm
20 N.m(2.0kgf.m,7.2lbt
ftl
O.RING
Replace.
CONNECTOR
PINION
SHAFT
GROMMET
RACKGUIDE
. -@ -sPRrNG
. DISCWASHEB @'---
g
L)-RACKGUIDE SCREW
6
' v---\
\.oc**u.
''
-'t
6^:,; v
BOOT BAND
Beplace.
'"''/
\ >-*\{i#r^i
--. i
. s(./t' J
-l
GUIDE \
SLTDER
\ \
{^il \ stot *,tttc
Renrace
\J" \
@ \ LocK
'162 scREw
N.m
II \
\
l t o . sr g f m , 1 1 9 l bfft )
SRACKET Beqtace.
BOOTBAND
LOCKWASHER - Replace.
Replace.
TIE.RODEND
rtE-ROD
54 N m {5.5kgf.m,40lbf ft)
(cont'd)
17-55
EPSComponents
SteeringGearboxOverhaul(cont'dl
Special Tools Required 4. Removethe stop plate (A).the 12 mm flange bolts
. Locknutwrench 07ZAA-S5A0100 (B),the O-rings(C),and the bracket(D)from the
. Pincers,Oetiker1098or equivalent,commercially
sleeringgearbox.
available.
NOTE:
. Referto the ExplodedView as neededduring this
procedure.
. Do not allow dust, dirt, or other foreign materialsto
enter into the steeringgearbox.
Eemoval
Disassembly
-,'i.
. -
- -.i::..:4,.-, -
:.--. '
1 7-56
6. Removethe two boot bands (A)from boot (B). 8. Installthespecialtool (A) on the lock screw (B)
Compressthe boot by hand,and apply vinyl tape securely.then loosenand removethe lock screw
(C)so the boot ends stay collapsedand pulled back from the steeringgearboxhousing.
07zAA-S5A0r00
(cont'd)
17-57
EPSComponents
SteeringGearboxOverhaul(cont'd)
'll.
Checkthe slider guide for damageand cracks. 15. Applymultipurpose greaseto the indicatedpart
Using verniercalipersto measurethe thicknessof part)
{shaded of the outersurfaceof the rack
the slider guide. lf the thicknessis lessthan service housing.Do not applyto the dentsandgrooves.
l i m i t ,r e p l a c et h e s l i d e rg u i d e ,
f
(fr--', -.----
Z,-----:-r-.--------.t.t'E-r
Il i l ( t t ,
/i\
,)))
I
i @ r |
25.3mm 25.3 mm
{0.925in.} {0.925in.l
12 Removeanddiscardthestopring{A)onthe
cylinderby expanding
it with snapringpliers.
Removeanddiscardthe lockscrew{B}.
1 4 . I n s t a l l t h en e w s t o p r i n g i n t h e g r o o v e( C ) o nt h e
cylinderby expandingit with a snap ring pliers.Be
carefulnot to scratchor damagethe housing
surfacewith the stop ring edges.
17-58
'19. Pushthe rack housing(A) into the steeringgearbox
16. Set the new boot bands (A) on the band installation
groovesof the boot (B) by aligningthe tabs (C)with housing(B) so the notch (C)is alignedwith the pin
the holes (D)of the band.Do not closethe ear of the (D)on the bottom of the gearboxhousinginside
boot band in this step.
(cont'd)
17-59
EPSComponents
SteeringGearboxOverhaul(cont'dl {
22. Apply multipurposegreaseto the sliding surface 25. Centerthesteeringrackwithin its stroke,and align
and circumferenceofthe rackguide (A),and install t h e s l i d e rg u i d e( A ) w i t ht h e h o t e s( B )i n t h e b o o t ( C ) .
it onto the gearboxhousing.Wipe the greaseoff Fit the slider guide to the boot by pressingaround
the threadedsectionofthe housrno. the edgesof the holessecurely
'1 - .- =-1,-
...'.
,. ,l
.j
E
25 N.m 12.5kgt.m,18tbt.ft)
2 3 . I n s t a l l t h ed i s cw a s h e r( B ) w i t hi t s c o n v e xs i d e
f a c i n gt h e r a c kg u i d e .I n s t a l l t h es p r i n g( C ) .A p p t y 26. Beforeinstallingthe bracket(D),cleanthe mating
sealantto the middle of the threadson the rack surfaceofthe 12 mm flange bolts (E)and the
guide screw (D),then installand tighten it to 25 bracket.Coatthe new O-rings{F)with multipurpose
N m (2.5kgf.m, 18 lbf.ft).Looselyinstatlrhetocknut g r e a s ea, n d i n s t a l l t h e mo n t h e ' 1 2m m f l a n g eb o l t s .
(E).
27. Looselyinstallthe bracketon the steeringrack by
24. Apply multipurposegreaseto the sliding surfaceof tighteningthe 12 mm flange boltsto 25 N.m (2.5
the slider guide (A).Keepgreaseoff of the rack-to- kgf.m, 18lbf.ft).
slider guide mating surfacesand the boot-to-slider
guide mating surfaces. 28. Hold the gearboxhousingusing a yoke,then install
Slidethe steeringrack all the way to left, and place the specialtoolon the lock screw (A).Retightenthe
t h e s l i d e rg u i d eo n t h e s t e e r i n gr a c kb y a l i g n i n gt h e lock screwto the specifiedtorque values.
bolt holes (B).
A
{ 1 6 . 5k g t . m , 1 1 9 l b f . f t }
17-60
30, Retightenthe 12 mm flange bolts (A) to the 3 4 . C l o s et h e e a r p o r t i o n( A )o f t h e b a n d s( B ) w i t h
soecifiedtoroue value. c o m m e r c i a l lav v a i l a b l ep i n c e r sO
, e t i k e r1 0 9 8o r
e q u i v a l e n(tC ) .
74 N.m (7.5kgf.m,5irlbf.ft)
. .,,";=-.
, . ,
*=,,',
(cont'd)
17-61
EPSComponents
SteeringGearboxOverhaul(cont'dl
36. Bendthe lock washer againstthe flat spots on the
bracketwitha Iarge pair of pliers.
17-62
SteeringGearboxInstallation
'1. 4. Insertthe pinion shaft up through the bulkhead,
Beforeinstallingthe steeringgearbox,slidethe
rack all the way to the passenger'sside (right then slip the right side of the steeringgearbox
direction). housing(A) over the mounting stud (C)on the
gearboxmounting bracket.
2 . Passthe right side of the steeringgearboxtogether
with the tie-rodsthrough the wheelwell openingon \- --' '.'', i
the passenger'sside.Continuemoving the steering
gearboxtoward the passenger'sside untilthe :-1
. . . .
driver'sside tie-rodend and gearboxclearsthe
mastercylinderand under-hoodfuse Ielay box.
Lower the steeringgearbox.and move it toward
t h e d r i v e r ' ss i d eu n t i l t h es t e e r i n gg e a r b o xi s l n
Dosition.
1 0x 1 . 2 5m m
6l N.m
(6.2 kgt.m, 45 lbt.ft)
3 . I n s t a l l t h ep i n i o ns h a f tg r o m m e t( A ) .
.: --.-{
.
( c o n t ' d)
17-63
EPSComponents
SteeringGearboxInstallation(cont'd)
7. Installthebodystiffener(A),andtorquethe 9. Reinstallthe heaterhose (A) on the hose bracket.
mountingboltsto the specifiedtorque.
8 x 1.25mm
29 N.m {3.0kgf.m,22lbf.ftl
L-t ,
:.i.t'
9.8N.m
(1.0kgf m,
7.2tbf.ftl
17-64
12. lnstalltheEPSwire harnessbracket(A)on the 1 4 . Centerthe steeringrackwithin its stroke.
gearboxhousing,andconnectthe 6Pconnector (B)
propefly. 1 5 . Wipe off any greasecontaminationfrom lhe ball
joint taperedsectionand threads.Then reconnect
9.8 N.m the tie-rod ends 1A)tothe damper steeringarms.
{1.0kgt m,7.2 lbt.ftl
lnstallthe ball joint nut (B) and tighten them.
,-', ''l
: 1 )
B
10x 1.25mm
i€ N.m
{4.4 kgf.m.
1 3 . I n s t a l l t h eh e a ts h i e l d( A ) . 32 tbt.ftl
,.!,..
''6 f
(cont'd)
17-65
EPSComponents
SteeringGearboxInstallation(cont'dl 4
1 7 . Installthe motor on the steeringgearbox(seepage 22. After installation,performthe following checks.
17-49).
. Performthe front toe inspection.
1 8 . lnstallthe steeringjoint (A).and reconnectthe . C h e c kt h e s t e e r i n gw h e e ls p o k e a n g l el.f s t e e r i n g
steeringshaft (B) and pinion shaft (C).Make sure spokeanglesto the right and left are not equal
the steeringjoint is connectedas follows: (steeringwheel and rackare not centered),
correctthe engagementof the joinvpinion shaft
. I n s e r t t h eu p p e r e n do f t h e s t e e r i n gj o i n t o n t o t h e serrations,then adjustthe front toe by turning
steeringshaft (line up the bolt hole (D)with the the tie-rods,if necessarv.
flat portion (E)on the shaft).
. Slip the lower end of the steeringjoint onto the
pinion shaft (line up the bolt hole with the groove
(F)around the shaft),and looselyinstallthe lower
joint bolt. Be sure that the lower joint bolt is
securelyin the groove in the pinion shaft.
. Pull on the steeringjoint to make surethat the
steeringjoint is fully seated.Then installthe
upper joint bolt, and tighten it to the specified
torque.Tightenthe lower joint bolt to the
specifiedtorque.
\
8 x '1.25mm
28 N.m
{2.9kgf.m,
21 tbt.ft)
17-66
EPSControlUnit Removal/ Tie-rodBallJoint Boot Replacement
Installation
Special Tool Required
Attachment,42 mm 07OAD-P0A0100
1. Removethe passenger'sunder panel.
l. Removethe boot from the tie-rod end, and wipe the
2. Turn up the floor carpel,removelhe EPScontrol old greaseoff the ball pin.
untr.
2 . P a c kt h e l o w e ra r e ao f t h e b a l l p i n ( A ) w i l h f r e s h
mulr purposegrease.
*-4
r/\-,
d______i.l+_D
-6rA
lnstallthe EPScontrol unit in the reverseorder of 3. Packthe interiorof the new boot (B) and lip (C)with
removal. fresh multipurposegrease.
E After installation,startthe engine,and let it idle. Note these items when installingnew grease;
Turn the steeringwheelfrom lock-to-lockseveral
times. Checkthat the EPSindicatordoes not come . Keepgreaseoffthe boot installationsection(D)
on. and the taperedsection(E)of the ball pin.
. Do not allow dust, dirt, or other foreign materials
to enterthe boot.
07(lAD-P0A0100
17-67
Suspension
Frontand RearSuspension
SpecialTools ............. 18-2
Component LocationIndex ......................................... 18-3
W h e eA l l i g n m e n .t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 8. - 4
WheelBearingEndPlayInspection............................ 18-8
WheelRunoutInspection .................. 18-9
B a l Jl o i n tR e m o v a l ... 18-10
FrontSuspension
Knuckle/Hu bAVheelBearingReplacement 18-1
BallJoint Boot Reolacement.................. 18-16
StabilizerBar Rep|acement.................... 18-17
StabilizerLink Removal/lnstallation 18-18
LowerArm Removal/lnstallation ............... 18-19
Damper/Spring Replacement 18-20
RearSuspension
H u bB e a r i n U
g n i tR e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . 18-26
KnuckleReolacement 18-28
Stabilizer BarReplacement .................... 18-30
Stabilizer Link Removal/lnstallation .......................... 18-31
UpperArm Removal/lnstallation ............... 18-32
TrailingArm Removal/lnstallation 18-33
Damper/Spring Replacement 18-34
Frontand RearSuspension
SpecialTools
Ref.No. Tool Number Description otv
o 07GAF-SE00100 Hub Dis/AssemblyTool
@ 07MAC-S100200 B a l lJ o i n t R e m o v e r2, 8 m m
07746-0010500 Attachment,62 x 68 mm
o 07749-0010000 Driver
07965-SA50500 Front Hub Dis/AssemblyTool
G) 07965-SD90100 Support Base
o o
[]
I
@ o a6,l
18-2
ComponentLocationIndex
FrontSuspension:
DAMPER/SPRING
page18-20
Replacement,
STABILIZER
BAR
page18-17
Replacement,
STABILIZER
LINK
page18 18
Removal/lnstallation,
KNUCKLE/HU8/WHEELBEARING
Replacement, page 18-11
Ball Joint Boot
Replacement, page'18-16
LOWEBARM
page 18 19
Removal/lnstallation,
RearSuspension:
STABILIZER
BAR
page18-30
Replacement.
UPPERARM
Removal/lnstallation,
page'18-32
DAMPER/SPRING
page'18-34
Replacement,
HUBBEARINGUNIT
page18'26
Replacement,
KNUCKLE
page18-28
Replacement,
TRAILINGARM
page 18 33
Removal/lnstallation,
18-3
Frontand RearSuspension
WheelAlignment
The suspensioncan be adjustedfor front camber,front Front Casterlnspection
toe, and reartoe. However,each of these adjustments
are interrelatedto each other. For example,when you U s ec o m m e r c i a l l a
vvailable c o m D u t e r i z ef do u rw h e e l
adjustthe toe, the camberchanges.Therefore,you a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
must adjustthe front wheel alignmentwheneveryou (caster,camber,toe, and turning angle).Follow the
adjustthe camberor toe. eouiomentmanufacturer'sinstructions.
Pre-Alignment
Checks Checkthe casterangle.lf the casterangle is not within
the specification,checkfor bent or damaged
For proper inspectionand adjustmentof the wheel susoensroncomoonents.
alignment,do these checks:
Front casterangle: 1'40't 1"
1. Releasethe parkingbraketo avoid an incorrect
measurement.
3 . C h e c kt h e t i r e s i z ea n d t i r e p r e s s u r e
Tire size:
Front/rear: 195/60R15
Tire pressure:
Front: 230 kPa {2.3kgf/cm',33 psil
Rear: 210 kPa |'2.1kgf/cm', 30 psi)
18-4
Front CamberInspection Front CamberAdjustment
Use commerciallyavailablecomputerizedfour wheel The front cambercan be adjustedby exchangingone or
alignmentequipmentto measurewheel alignment both of the damDerDinchbolts with the smaller
(caster,camber,toe, and turning angle).Follow the diameteradjustingbolt(s).The differencebetweenthe
equipmentmanufacturer'sinstructions. adjustingbolt diameterand the pinch bolt hole
d i a m e t e ra l l o w sa s m a l lr a n g eo f a d j u s t m e n t .
Checkthe camberangle.lf the camberangle is not
within the specification,adjustthe camber.
L o o s e nt h e d a m p e rp i n c h n u t sa n d b o l t s( A ) ,a n d
adjustthe camber by moving the bottom of the
d a m p e rw i t h i nt h e r a n g eo f t h e d a m p e rp i n c hb o l t
free play.
-+ +t A
1 6 x 1 . 5m m
157 N.m
(16.0kgf.m,
116 tbf.ftl
5 . C h e c kt h e c a m b e ra n g l e .l f i t i s w i t h i nt h e
specification,checkthe front toe. lf it is not within
the specification,go to step 6.
(cont'dl
18-5
Frontand RearSuspension
WheelAlignment (cont'd)
Raisethe front of the vehicle,and support it with RearCamberInspection
safetystandsin the proper location(seepage 1-8).
Removethe front wheels. Use commercially-available computerizedfour wheel
alignmentequipmentto measurewheel alignment
7 . Replacethe damper pinch boltswith the adjusting (caster,camber,toe, and turning angle).Followthe
bolts (A),and adjustthe camber angle. eouiDmentmanufacturer'sinstructions.
1 5 x 1 . 5m m
157N.m
{16.0kgt.m,
116tbf.ft)
'rntr
i,iY.a
.:r,//
18-6
Front Toe Inspection/Adjustment RearToe Inspection/Adiustment
Use commercially-available computerizedfour wheel Use commercially-available computerizedfour wheel
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster,camber,toe, and turning angle).Followthe (caster,camber,toe, and turning angle).Followthe
equipmentmanufacturer'sinstructions, equipmentmanufacturer'sinstructions.
2. Checkthetoe.lf it is not with in the specification,go 2. Checkthetoe. lf it is not within the specification.go
to step 3. to step 3.
( c o n t ' d)
18-7
Frontand RearSuspension
WheelAlignment (cont'dl WheelBearingEnd PlayInspec'tion
TurningAngleInspection 1. Raiselhe vehicle,and support it with safetystands
in the proper location(seepage 1-8).Removethe
Use commercially-available computerizedfour wheel wheels.
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster.camber,toe, and turning angle).Followthe 2. Installsuitable f lat washers (A) and wheel nuts,and
equiDmentmanufacturer'sinstructions. tighten the nuts to the specifiedtorque to hold the
b r a k ed i s cs e c u r e l ya g a i n s t h e h u b .
1 . T u r nt h e s t e e r i n gw h e e lf u l l y t o t h e r i g h t a n d l e f t
while applyingthe brake,and checkthe turning Front:
anglesof both front wheels, lf the turning angle is
not within the specificationor the inward turning
anglesdiffer betweenthe right and left side,go to
steD2.
Turning angle:
lnward: 34'00'+ 2'
Outward: 28'00' {reference)
108N.m
(11.0kgf.m,
80 rbf.ft)
Rear:
\
18-8
WheelRunoutInspection
1 . Raisethe vehicle,and supportit with safetystands 4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o ns h o w n ,a n d
in the proper location(seepage 1-5,. measurethe radial runout.
18-9
Frontand RearSuspension
BallJointRemoval
Special Tools Required 3. Loosenthe pressurebolt (A),and installthe special
Ball ioint remover.2Smm 07MAC-SL00200 tool as shown. Insen the jaws carefully,making
sure not to damagethe ball joint boot. Adjustthe
jaw spacingby turning the adjustingbolt (B).
Always use a ball joint removerto disconnecta ball
joint. Do not strikethe housingor any other part of 10 mm HEXNUT
the ball joint connectionto disconnectit.
'1,
I n s t a lal h e x n u t ( A )o n t o t h e t h r e a d s o f t h e b a l l j o i n t
{ B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n
end to preventdamageto the threadedend of the
b a l l i o i n to i n .
07MAC-S100200
18-10
FrontSuspension
Knuckle/Hub/WheelBearingReplacement
ExplodedView
WHEELBEARING
Replace.
SNAPRING
5 mm SCREWS
Replace.
FLATSCREWS
6x1.0mm
9.8Nm
(1.0kgf.m,7.2lbf.ft)
KNUCKLE
Checkfor delormation
a n oo a m a g e .
SPLASHGUARD
Checkfor corrosion.delormation.
and damage.
Replaceif rusted.
BRAKEDISC
SPINDLENUT
22 x 1.5mm
1 8 1N m
(18.5kgf.m, 134 lbt.ft)
Replace.
'--7.l
'tq
I
A p p ya s m a lal m o u not f e n g i n o
eil
to theseatingsurface.
lcont'd)
18-11
FrontSuspension
Knuckle/Hub/WheelBearingReplacement{cont'dl
Special Tools Required 5. Raisethe stake(A),and removethe spindle nut (B).
. Hub dis/assemblytool 07GAF-SE00100
. Balljoint remover,2Smm 0TlvlAC-S100200
. Attachment62 x 68 mm 07746-0010500
. Driver07749-0010000 - B
. SuDDortbase07965-5D90'100 ' 22x1.5mm
, 1 8 1N . m
1. Raisethe front of the vehicle,and support it with ('18.skgf.m,
134tbt.ft)
safetystandsin the proper location(seepage 1-8).
1 0 8N . m
(11.0kgf m,
80 rbf.ftl
B
12 x 1.25mm
108N.m
{11.0kgf.m,
80 rbf.ftl
7. Screwtwo 8 x 1.25mm bolts (B)into the discto
oush it awav from the hub. Turn each bolt two turns
at a time to preventcockingthe disc excessively,
4 . Removethe caliperbracketmounting bolts (B),and
removethe caliperassembly(C)from the knuckle.
To preventdamageto the caliperassemblyor
brakehose,use a short pieceof wire to hang the
caliperassemblyfrom the undercarriage.Do not
twist the brakehose with force.
18-12
8. Removethe flange bolt {A) andwheel sensor(B) 10. Removethe lock pin (A)from the lower arm ball
from the knuckle.Do not disconnectthe wheel joint, and removethe castlenut (B).
sensorconneclor.
NOTE:During installation,insertthe lock pin into
A
5x1.0mm t h e b a l l j o i n tp i n f r o m t h e l n s i d et o t h e o u t s i d eo f
9.8 N.m the vehicle.The closedend of the lock Din must be
(1.0kgl.m,
7.2 tbt.ftl
i n t h e r a n g es h o w n .
07MAC-SL00200
€--....-"
'R. 12x 1.25mm
59 69N m
(6.0 7.0 kgl m,
9 . Removethe flange nut (A) while holdingthe joint 43 -51 lbf tt)
pin (B)with a hex wrench (C),and disconnectthe
s t a b i l i z el ri n k{ D )f r o m t h e l o w e ra r m ( E ) . 1 1 .Disconnectthe lower arm from the knuckleusing
the specialtool (seepage l8-10).
10 x 1.25mm
39 N.m (,1.0kgf.m,29lbf.ft)
'13.Removethe driveshaftoutboardjoint
{C)fromthe
knuckle(D) by tappingthe driveshaftend (E)with a
plastichammer while drawing the knuckleoutward,
then removethe knuckle.
(cont'd)
18-13
FrontSuspension
Knuckle/Hub/Wheel (cont'd)
BearingReplacement
14. Separatethe hub (A)from the knuckle(B) usingthe 1 6 . R e m o v et h e s n a pr i n g ( A )a n dt h e s p l a s hg u a r d( B )
specialtool and a hydraulicpress.Be carefulnotto f r o m t h e k n u c k l e( C ) .
deform the splashguard. Hold onto the hub to keep
it from falling when pressedclear.
07GAF-SE00100
./ .-''- .|
a'\s
+
h u b ( B )u s i n gt h e s p e i i a l t o o l ,a c o m m e r c i a l l y Pross
a v a i l a b l eb e a r i n gs e p a r a t o(rC ) ,a n d a p r e s s .
07GAF-SE00100
\r
\ Press
\
18-14
1 8 . W a s ht h e k n u c k l ea n d h u b t h o r o u g h l yi n h l g hf l a s h 2 2 . P r e s sa n e w h u b b e a r i n gu n i t{ A )o n t o t h e h u b ( B )
point solventbefore reassembly. usingthe specialtools and a press.
"-t-_"*,,''
_,.' . . a-.)
../
..-. 23. I n s t a l l t h ek n u c k l e / h u b / h ubbe a r i n gu n i t i n t h e
reverseorder of removal,and notethese items:
. B ec a r e f u n l o t t o d a m a g e t h eb a l l j o i n tb o o t w h e n
2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yi n t h e k n u c k l e( B ) . installing the knuckle.
. Tightenall mounting hardwareto the specified
l O r q u ev a l u e s .
. Torquethe castlenut to the lower torque
specification,then tighten it only far enoughto
a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t
align the castlenut by looseningit.
. Installa new look pin on the castlenut after
torquing.
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
. B e f o r ei n s t a l l i n g
t h e s p i n d l en u t ,a p p l ya s m a l l
amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. B e f o r ei n s t a l l l n gt h e b r a k ed i s c ,c l e a nt h e m a t i n g
D surfaceof the front hub and the insideof the
6 N.m10.6kgf.m,4lbfft)
b r a k ed i s c .
lnstallthe splashguard (C),and tighten the screws . B e f o r ei n s t a l l i n gt h e w h e e l ,c l e a nt h e m a t i n g
(D)to the specifiedtorque. surfaceof the brakedisc and the insideof the
wneet.
. Checkthe front wheel alignment,and adjustit if
necessary(seepage 18-4).
18-15
FrontSuspension
BallJoint Boot Replacement
Special Tools Required Inst€llthe boot onto the ball joint pin, then squeeze
Front hub dis/assemblytool 07965-5450500 it gentlyto force out any air. Do not let dlrt or other
foreign materialsget into the boot.
1. Removethe boot.
Pressthe boot with the specialtool until the bottom
2. Packthe interiorand lip (A) of a new boot with fresh seatson the knuckle(A) evenly around.
grease.Keepthe greaseoff of the boot-to-knuckle
pross
mating surfaces(B).
07965-SA50500
-6r
rffi
€l
- - B
t
I
18-16
StabilizerBar Replacement
1 . Raisethe front of the vehicle,and support it with 4. lnstallthe stabilizerbar in the reverseorder of
safetystandsin the proper location(seepage 1-8). removal.and note these itemsl
Removethe front wheels.
. Use new self-lockingnuts on reassembly.
Removethe self-lockingnuts (A)while holdingthe . Note the right and left directionof the stabilizer
joint pin (B)with a hex wrench (C),and disconnect oar.
t h e s t a b i l i z el ri n k s( D ) f r o mt h e s t a b i l i z ebr a r ( E )o n . A l i g nt h e e n d so f t h e p a i n tm a r k s( A )o n t h e
the right and left. stabilizerbar with each end of the bushings(8).
. Note the forelaft directionofthe bushing holders.
D . Referto stabilizerLink Replacementto connect
''i] t h e s t a b i l i z ebr a r t o t h e l i n k s( s e ep a g e1 8 - 1 8 ) .
,.'i i
. i.',.:-l I
\'r'j--,r'r-'1
,' _: i :..
i'
i-ii::;i
;4-llt,-'j--;
1 0x 1 . 2 5m m
39Nm
(4.0 kgf m,
29 tbl,ft)
FORWARD
A
1 0x 1 . 2 5m m
39Nm
(4.0ksf.m, 29lbl.ftl
18-17
Front Suspension
StabilizerLink Removal/lnstallation
1 . Raisethe front of the vehicle,and support it with 4. Installthe self-lockingnut and flange nut, and
safetystandsin the proper location(seepage 1-8). lightlytighten them.
Removethe front wheels.
NOTE:Use a new self-lockingnut on reassembly.
Removethe self-lockingnut (A) and flange nut {B)
while holdingthe respectivejoint pin (C)with a hex 5. Placethe floor jack under the lower arm balljoint,
wrench (D),and removethe stabilizerlink (E). and raisethe suspensionto load it with the vehicle's
weaght.
mri-dEl
Do not placethe jack againstthe lower arm
balljoint.
A
10 x 1.25mm
38 N.m
(3.9kgf m,28 lbf.ft)
3 . l n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
and lower arm (C)with the joint pins (D)set at the
centerof their rangeof movement.
..,
B
10 x 1.25mm
39 N.m
{4.0kgf.m,29lbf.ft}
18-18
Lower Arm Removal/lnstallation
SpecialToolsRequired 5. Removethe flange bolts (A),and removethe lower
Balljoint remover,2Smm 07|MAC-S100200 arm {B}.
1 4x 1 . 5m m
83 N.m(8.5kgf.m,61lbf.ft)
oTMAc-sloo2oo
6--__
@a
1 2x 1 . 2 5m m
59 69Nm
16.0-7.0kgt-m,
43 51 lbf.ft)
18-19
Front Suspension
Damper/SpringReplacement
ExplodedView
./ SELF-LOCK|NGNUT
/.' 12 x 1.25inm
,,/ 44 N.m {4.5kgt.m,33lbf.ftl
,/ neDtace.
^a
ta
e9
-€.- - DAMPER MOUNTINGBASE
checkfor delormation
1, @-:'\--""'
lF \-:-./ - ,
E9-
DAMPERMOUNTING
BEARING
UPPER SPRINGMOUNTING
CUSHION
Checkfor deterioration
anooamage,
DAMPER SPRING
Checkfor lreelength.
DAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operatron.
18-20
SpecialToolsRequired 5. Removethe damper pinch bolts (A)while holding
Balljoint remover,28mm 07MAC-S100200 t h e n u t s( B ) .
Removal
1. Raisethe front of the vehicle,and supportit with
safetystandsin the proper location(seepage 1-8).
Removethe front wheels.
A 'l.25
10x mm
10 mm HEXNUT
07MAC-S1002000
q /.8
(cont'd)
18-21
FrontSuspension
Damper/Spring (cont'd)
Replacement
Disassembly/lnspection Reassembleall the pans, exceptfor the upper
s p r i n gs e a ta n d s p r i n g .
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 c o m m e r c i a l l y
availablestrut spring compressor(A) accordingto 4. Compressthe damper assemblyby hand,and
the manufacturer'sinstructions.then removethe checkfor smooth operationthrough a full stroke.
s e l f - l o c k i nngu t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t both compressionand extension.The damper
(C)with a hex wrench (D).Do not compressthe should extend smoothly and constantlywhen
spring more than necessaryto removethe nut, compressionis released.lf it does not, the gas is
leakingand the damper should be replaced.
C h e c kf o r o i l l e a k s a
, bnorman
l o i s e sa, n d b i n d i n g
during thesetests.
18-22
FrontSuspension
Damper/Spring (cont'dl
Replacement
Right side: Installation
1. Lower the lower arm, and positionthe damper
assemblyin the body, Turn the damper mounting
baseso the "AL" or "AR" mark (A)facestoward
the outsideof the vehicle.
B
10x 1.25mm
,14N.m
{4.5kgt.m,33lbf.ft)
9 . I n s t a l l t h e1 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) .
Hold the damper shaft with a hex wrench (C),and
tighten the 12 mm nut to the specifiedtorque.
,1,6
Looselyinstallthe flange nuts (A) onto the top of
the damper. L
1 0 .Removethe damperassembly
fromthe strutspring
compressor.
18-24
3 . P o s i t i o nt h e d a m p e ro n t h e k n u c k l ea, n d i n s t a l l t h e 8. Connectthe tie-rod end to the steeringarm, and
new damper pinch bolts (A) and nuts (B),and tightenthe nut (A)to the specifiedtorque. Install
lightlytighten the nuts. the cotterpin (B)after tightening,and bend lts end
asshown.
B
1 6 x 1 , 5m m
157N.m
(16.0kgt m,
116tbt.ftl
4 . P l a c et h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t ,
and raisethe suspensionto load it with the vehicle's
weight.
Do not placethe jack againstthe lower arm 9. Cleanthe mating surfaceofthe brakedisc and the
balljoint. insideof the wheel,then installthe front wheels.
18-25
RearSuspension
Hub BearingUnit Replacement
ExplodedView
SPLASHGUARD
Checkfor deformation.
x 1.0 mm
9.8 N.m (1.0kgf.m,?1 lbf ftl
KNUCKLE
un
Checkfor delormation.
HUBBEARING UNIT
Y
Checkfor faultymovement 6x1.0mm
andwear. 9,8 N.m HUB CAP
{1.0kgf.m,7 lbf.ft} Replace.
SPINDLENUT
22 x 1.5mm
181 N.m {18.5kgt.m, 134lbf.ft}
Beplace.
-A
T
Appy a small amount oI engineoil
to the seatingsurface.
18-26
1 . Raisethe rear of the vehicle,and support it with Releasethe parkingbrakelever.
'l-8).
safetystandsin the proper location(seepage
5 . Removethe brakehose mounting bolt (A).
Removethe wheel cap. wheel nuts, and rearwheel.
B
1 0x 1 . 2 5m m
55Nm
C {5.6kgf m.41lbf.ft}
108N.m(11.0kgf.m,80lbfftl
(2.2kgtm, 16lbt.ftl
Removethe hub cap (A), raisethe stake(B),and
r e m o v et h e s p i n d l en u t ( C ) .
Removethe caliperbracketmounting bolts (B),and
hang the caliper(C)to one side.To preventdamage
to the caliperor brakehose,use a short pieceof
w i r e t o h a n gt h e c a l i p e rf r o m t h e u n d e r c a r r i a g e .
O
\
A
ap
2 2 x 1 , 5m m
1 8 1N . m
(18.5kgf.m, 134lbf.ftl
t
\
I
A
6x1.0mm
9 . 8N . m
(1.0kgf.m,?.2lbf.ftl
(cont'd)
18-27
RearSuspension
Hub BearingUnit Replacement KnuckleReplacement
(cont'd)
1 . Raisethe rear of the vehicle,and suppon it with
safetystandsin the proper location(seepage 1-8).
9. Removethe hub bearingunit (A) from the spindle. Removethe rear wheels.
R e m o v et h e b r a k ed i s ca n d h u b b e a r i n gu n i t( s e e
s t e p 1 o n p a g e1 8 - 2 7 ) .
,=,,,
8 x 1.25mm
22 N.m
{2.2kgfm, 16lbf ftl
6x1.0mm
9.8 N,m
{I.0 kgt.m,7.2lbf ft)
18-28
5. Placethe floor jack underthe trailing arm {A),to 9 . I n s t a l l t h ek n u c k l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
support it. and note these items:
. F i r s ti n s t a l a
l l l t h e s u s p e n s i o cno m p o n e n t sa, n d
Do not placethe jack againstthe plate lightlytighten the bolts and nuls,then placea
sectionof the lower arm, Be carefulnot to floor jack under the lower a rm, and raisethe
damageany suspensioncomponents. suspensionto load it with the vehicle'sweight
beforefully tighteningthe bolts and nutsto the
specifiedtorque values.
. Align the cam positionsof the adjustingbolt (A)
and adjustingcam (B)with the markedpositions
w h e nt i g h t e n i n g .
. Use a new self-lockingnut on reassembly.
. T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e
specifiedtorque values.
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
12x 1.25mm . B e f o r ei n s t a l l i n g
59 N.m t h e s p i n d l en u t ,a p p l ya s m a l l
{6.0ksf.m.43lbf.ft) amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. Beforeinstallingthe brakedisc,cleanthe mating
surfaceof the hub and the insideof the brake
drsc.
. U s ea n e w h u b c a po n r e a s s e m b l y .
. Beforeinstallingthe wheel, cleanthe mating
Removethe flange bolt (B),and disconnectthe surfaceof the brakedisc and the insideof the
upper arm {C)from the knuckle. wheel.
. Checkthe wheel alignment,and adjust it if
1 . Mark the cam positionsof the adjustingbolt (A) and necessary{seepage 18-4).
adjustingcam (B),the removethe self-lockingnut
{C},adjustingcam, and adjustingbolt. Discardthe
self-lockingnut.
12x 1.25mm
59Nm(6.0kgf.m,
43 tbI.ftl
12x 1.25mm
59 N.m {6.0kgf m,43lbl.ft)
8. Remove the flange bolt (D), and remove the
k n u c k l e{ E ) .
18-29
RearSuspension
StabilizerBar Replacement
1 . Raisethe rear of the vehicle,and supportit with 4. Inslallthestabilizerbar in the reverseorder of
safetystandsin the proper location(seepage 1-8). removal,and notethese items:
Removethe rearwheels.
. Use new self-lockingnuts on reassembly.
Removethe self-lockingnuts (A)while holdingthe . lMakesure the right and left ends of the stabilizer
joint pins (B)with a hex wrench (C),and disconnect bar are installedon their respectivesidesof the
t h e s t a b i l i z el ri n k s( D )f r o m t h e s t a b i l i z ebr a r { E )o n vehicle.
the right and left. . Align the ends of the paint marks (A) on the
s t a b i l i z ebr a r w i t h t h e b u s h i n g s( B ) .
A . Referto StabilizerLink ReDlacement
1 0 x 1 . 2 5m m to connect
38 N.m t h e s t a b i l i z ebr a rt o t h e l i n k s{ s e ep a g e1 8 - 3 1 ) .
(3.9 kgf.m,28 lbf.ft)
\....'..: .
Al
.----'';-r'--\---r-
-tt'.,'t),
18-30
StabilizerLink Removal/lnstallation
1. Raisethe rear of the vehicle,and support it with 4. lnstallthe self-lockingnut and flange nut, and
safetystandsin the proper location(seepage 1-8). lightlytighten them.
Removethe rearwheels.
NOTE:Use a new self-lockingnut on reassembly.
2. Removethe self-lockingnut (A) and flange nut (B)
while holdingthe respectivejoint pin {C)wilh a hex Placea jack under the trailing arm at the knuckle
wrench (D),and removethe stabilizerlink (E). side end. and raisethe suspensionlo load it with
the vehicle'sweight.
A
1 0 x 1 . 2 5m m
38 N.m 13.9kgf.m,28lbf.ftl
\,1 i
i'-r d
*l'',:
3 . I n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
a n dt r a i l i n ga r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e
centerof each moving range,
18-31
RearSuspension
UpperArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and supportlt with 5. Installthe upper arm in the reverseorder of
safetystandsin the proper location(seepage 1-8). renloval,and note these items:
Removethe rearwheels.
. F i r s ti n s t a l a
l l l t h e s u s p e n s i o cno m p o n e n t sa n d
P l a c ea f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d lightlytighten the bolts and nuts,then placea
supportthe suspensron. j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s et h e
suspensionto load it with the vehicle'sweight
Removethe flange bolt (A) and wheel sensor beforefully tighteningthe bolts and nuts to the
h a r n e s sb r a c k e (t B ) . specifiedtorque values.
. T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e
specifiedtorque values.
' B e f o r ei n s t a l l i n g t h e w h e e l ,c l e a nt h e m a t i n g
surfaceof the brakedisc and the insideof the
wheel.
. Checkthe wheel alignment,and adjustit if
necessary(seepage 18-4).
8 x 1 . 2 5m m
22 N.m(2.2kgf.m,
16rbf.ft)
1 2 x 1 . 2 5m m
59 N.m {6.0kgf.m,
ir3 lbf.ft)
1 2 x 1 . 2 5m m
59 N.m 16.0kgf m,
43 tbf.ft)
18-32
TrailingArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and suppon it with 7. Removethe trailing arm rear mounting bolt (A).
safetystandsin the proper location(seepage 1,8).
Removethe rearwheels.
Do not loosenthe specialbolts (B)on the
Removethe knuckle(seepage 18-28). t r a i l i n ga r m .
3 . P l a c et h e f l o o rj a c ku n d e rt h e t r a i l i n ga r m ( A )t o A
12 x 1.25mm
support it. 59 N.m
-----\':,'.ttg
'.,--1..-r.':1
B
1 0x 1 . 2 5m m
38Nm
(3.9kgl.m,
28 tbf.ftl
, ' a ' : -r
A
12 x 1.25Jnm
108N.m {11.0kgt.m,
80 tbf.ft)
18-33
RearSuspension
Replacement
Damper/Spring I
ExplodedView
9-----.---.-.
-=\
SELF-LoCK|NGNUT
I€tI
t=J 10 x 1.25mm
29 N m {3.0kgf.m,22 lbf.ft}
Replace.
DAMPERMOUNlING
COLLAR
DUSTCOVER
-t-
9...
r€)
qnJ/ \ \
E Z \
\
sroP PLArE
BUMP
n \
lt \
/t \ BUMPSTOP
tor weakness
Check
and damage.
DAMPERSPRING
Checkfor weakened
compressionand damage.
OAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operation,
18-34
Removal 5. Removethe damper assemblyfrom the body.
( c o n td )
18-35
RearSuspension
Damper/Spring (cont'dl
Replacement
Disassembly/lnspection Reassembly
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 c o m m e r c i a l l y 1 . I n s t a lal l l t h e p a r t s e x c e p t t h e
s e l f - l o c k i nngu t o n t o
availablestrut compressor(A) accordingto the the damper unit by referringto the ExplodedView.
manufacturer'sinstructions.then removethe self- Align the bottom of the spring {A} and the stepped
l o c k i n gn u t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t( C ) part of the lower spring seat (B),and align the
with a hex wrench (D).Do not compressthe spring d a m p e rm o u n t i n gb a s ea s s h o w n ,
more than necessarvto removethe nut.
10 x 1.25mm
29Nm
(3.0kgt m,22 lbt.ft)
18-36
Installation 3. Looselyinstallthe flange bolt (A) on the bottom of
thedamper.
1. Positionthe damper assemblyin the body. Note
the directionof the damper mounting base so that
the small hole dot on it is toward the front and
insideof the vehicle.
1 2 x1 . 2 5m m
61N m {6.2kgf.m.45lbf.ft)
D A
1 0 x 1 . 2 5m m
59 N.m
16.0kgt.m, ia lbt ft)
i n s i d eo f t h e w h e e l ,t h e n i n s t a ltl h e r e a rw h e e l .
18-37
Brakes
ConventionalBrakeComponents
Special Tools ........... l9-2
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .9. .-.3. . . . . . . . .
BrakeSystemInspectionand
Tests............... .......... 19-4
BrakePedaland BrakePedalPositionSwitch
Adjustment .............. 19-6
ParkingBrakeCheckand
Adjustment .............. 19-7
BrakeSystemBleeding ...................... 19-8
BrakeSystemIndicatorCircuit
Diagram . . . . . . . . . . . . . .1. 9. .-.9.
ParkingBrakeSwitchTest ................. 19-10
BrakeFluidLevelSwitchTest ...................................... 19-10
FrontBrakePadslnsoection and
Replacement ........... 19-11
FrontBrakeDiscInspection ............... 19-13
FrontBrakeCalioerOverhaul...................................... 19-14
MasterCylinderReplacement ........... 19-15
MasterCylinderInspection ................ 19-16
BrakeBooster
PushrodClearance Adjustment................................ 19-16
BrakeBoosterTest................... .......... 19-18
BrakeBoosterReolacement .............. 19-19
RearBrakePadsInspection and
Reolacement ........... 19-20
RearBrakeDiscInspection ................ 19-22
RearBrakeCaliperOverhaul....................................... 19-23
BrakeHosesand LinesInsoection .... 19-24
BrakeHoseReolacement ................... 19-25
ParkingBrakeCableReplacement .............................. 19-26
ABS (Anti-lockBrakeSystem)
Gomponents ... 19-29
ConventionalBrakeComponents
SpecialTools
Ref.No. Tool Number DescriDtion Qty
o 07JAG-SD40100 PushrodAdiustmentGauoe 1
19-2
ComponentLocationIndex
INDICATOR
BrakeSystemIndicatorCircuit
D i a g r a mp, a g e1 9 - 9
ParkingBrakeSwitch
Test,page 19 10
BrakeFluidLevelSwitch
Test,page 19-10
BRAKECABLE
P a r k i n gB r a k eC a b l e
Replacement,page 19 26
REARDISCBRAKE
RearBrakePads Inspectionand
Replacement,page l9-20
FRONTBRAKES RearBrakeDisc
FrontBrakePads,Inspectionand Inspection,page 19'22
Replacement, page 19-11 R e a rB r a k eC a l i p e O
r verhaul,
FrontBrakeDisc page 19'23
Inspection,page 19'13
FrontBrakeCaliper
O v e r h a u lp, a g e1 9 - 1 4 PARKING BRAKELEVER
BRAKEBOOSTER
Parkino
Brake
page19-7
CheckandAdjustment,
BrakeBooster
Test,page 19-18
BrakeEooster BRAKEPEDAL
Replacement, page 19 19 BrakePedalandErakePedalPosition
Switch
Adjustment,pagel9-6
BRAKEHOSESand LINES
BrakeHosesand Lines
Inspection,page 19 24
BrakeHoses
Replacement, page 19 25
MASTERCYLINDER
MasterCylinder
Fl6^1.^6m6nr ^2^o 1O-18
M a s t e rC y l i n d eIrn s p e c t i o np ,a g e1 9 - 1 6
BrakeBoosterPushrodClearance
A d j u s t m e n tp, a g e ' 1 9 - 1 6
BrakeSystemBleeding,page 19-8
19-3
BrakeComponents
Gonventional
BrakeSystemInspectionand Tests
BrakeSystemTest
Brake pedal sinks/fades when braking
2. Attacha 2-inchpieceof maskingtape along the bottom of the steeringwheel, and draw a horizontalreference
mark acrossit.
t-
3 . With the transmissionin Neutral,pressand hold the brakepedal lightly,then releasethe parkingbrake.
While still holdingthe brakepedal,hook the end of the tape measurebehind it. Then pull the tape up to the
steeringwheel, noting where the tape measurelines up with the referencemark you made on the maskingtape.
19-4
Rapid brake pad wear. Vehicle vibration {after a long 5. Loosenthe hydrauliclines at the mastercylinder,
drivel, or High, hard brake pedal then spin the wheelsto checkfor brakedrag.
YES-Go to step 4.
NO Replacethe brakebooster.I
YES Go to step 5,
19-5
ConventionalBrakeComponents
BrakePedalandBrakePedalPosition
SwitchAdjustment
PedalHeight PedalFreePlay
1 . Disconnectthe brakepedal positionswitch 4. With the engineoff, inspectthe play (A) on the
connector,turn the brakepedal positionswitch (A) p e d a lp a d ( B )b y p u s h i n gt h e p e d a lb y h a n d .
c o u n t e r c l o c k w i saen, d p u l l i t b a c ku n t i li t i s n o
l o n g e rt o u c h i n gt h e b r a k ep e d a l . F r e eP l a y :0 . 4 - 3 . 0 m m { 0 . 0 1 6 0 . ' l 1 8 i n . )
1 5N . m
(1.5kgl m. 11lbl ft) 7 . C h e c kt h e b r a k ep e d a lf r e e p l a ya s d e s c r i b e db e l o w .
19-6
ParkingBrakeCheckand Adiustment
Check Removethe rear console{seepage 20-57).
1. Pullthe parkingbrakelever {A) with 196 N (20 kgf, Pull the parkingbrakelever up one click,
44 lbf) of forceto fully apply the parkingbrake.The
parkingbrakelever should be lockedwithin the
specifiednumber of clicks(B).
Leverlockedclicks: 7-8
Make sure the parkingbrakearm (A) on the rear 8 . Releasethe parkingbrakelever fully, and check
brakecalipercontactsthe brakecaliperpin (B), that the parkingbrakesdo not drag when the rear
wheels are turned. Readjustif necessary.
NOTE:The parkingbrakearm will only contactthe
brakecaliperpin when the parkingbrakeadjusting 9 . Make surethe parkingbrakesare fully applied
nut is loosened. when the parkingbrakelever is pulled up fully.
19-7
ConventionalBrakeComponents
BrakeSystemBleeding
NOTE: 5. ReDeattheprocedurefor eachwheel in the
. Do not spill brakefluid on the vehicle;it may damage sequenceshown below until air bubblesno longer
the painUif brakefluid does contactthe paint.wash it a p p e a ri n t h e f l u i d .
off immediatelywith water.
. The reservoiron the mastercylindermust be at the BLEEDING
SEOUENCE:
MAX (upper)level mark at the start of the bleeding
procedureand checkedafter bleedingeach brake OFront Right ORe.r Right
c a l i p e rA
. d d f l u i da s r e q u i r e d .
. Do not reusethe drainedfluid.
. Always use Honda DOT3 brakefluid. Non-Honda
brakefluid can causecorrosionand shortenthe life of
the system.
. Make sure no din or other foreign matter is allowed
to contaminatethe brakefluid.
O Front Left ORoar Loft
1 . M a k es u r et h e b r a k ef l u i d l e v e li n t h e r e s e r v o i irs a t
t h e M A X ( u p p e r )l e v e ll i n e( A ) .
Refillthe mastercylinder reservoirto the MAX
{upper)level line.
FRONTBRAKE:
t-
19-8
BrakeSystemIndicatorCircuitDiagram
UNDER.OASH
FUSE/FELAYBOX
I GRN/ORN
A
Y
EBAK€FLUID
IEVELSwlICH ,tk ,o"","o ""o*.
(b, 3s1E8,.""",,"
oPEN,Leve,down
BtK I
I
+ -=:
csor
19-9
Conventional
BrakeComponents
ParkingBrakeSwitch Test BrakeFluidLevelSwitch Test
1. Removethe rear console,and disconnectthe Checkfor continuitybetweenthe terminals(A) with the
connector(A)from the switch (B). float in the down positionand the up position.
'dFu
\!E
!UF-
(B).With the float up, there should be no continuity.
19-10
Front BrakePadsInspectionand Replacement
Replacement
F r e q u e nitn h a l a t i o no f b r a k ep a d d u s t ,r e g a r d l e sos f 1 . R e m o v et h e b o l t( A ) ,a n d p i v o tt h e c a l i p e r( B )u p o u t
m a t e r i acl o m p o s i t i o nc,o u l db e h a z a r d o utso y o u r of the way. Checkthe hose and pin boots for
d a m a g ea n d d e t e r i o r a t i o n .
. Avoid breathingdust particles.
. N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k e
a s s e m b l i e sU. s ea n O S H A - a p p r o v evda c u u m
cleaner.
lnspection
1. Raisethe front of the vehicle,and support it with
safetystandsin the proper location{seepage 1'8).
Removethe front wheels.
Innerpad:
' . . '
, .a
Outer pad:
.^hv/
\v \ \."r------B
tJ I
lf the brakeDadthicknessis lessthan the service
l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t .
(cont'd)
19-11
ConventionalBrakeGomponents
Front BrakePadsInspectionand Replacement(cont'dl
3. Removethe pad retainers(A),and checkthe caliper 10. Push in the piston (A) so the caliperwill fitoverthe
pins for free movement. pads.Checkthe brakefluid level.The brakefluid
may overflow if the reservoiris too full. lvlakesure
the piston boot is in positionto preventdamagingit
when pivotingthe caliperdown
/:-."
t-.. 8x1.0mm
. .,.';- 34 N.m
i '1='
r 3.5 kgt m.
i.: r 25 tbf.ft)
..a.-
, a .).
19-12
Front BrakeDisclnspection
Runout Thicknessand Parallelism
1. Raisethe front of the vehicle,and support it with 1. Raisethe front of the vehicle,and supportit with
safetystandsin the proper location(seepage 1-8). safetystandsin the proper location(seepage 1-8).
Removethe front wheels. Removethe front wheels.
10 mm lo.itin.l
': . --'t-'"'-
t , .
BrakeDiscRunout:
ServiceLimit: 0.10mm (0.00ttin.l
19-13
ConventionalBrakeComponents
Front BrakeCaliperOverhaul {
Boors 3i,l'1.'"
-ffiFA / isli\ii ^ zswttt
BRAKEHOSE/ /8LEEO SCREW
/ / /eNm
/paq\
t l l l /
/
/
/
/ / (o.s
kgr'm.
| itbt.ftl
, 1
,\L,.'iE/ [ *fL-f
(}',
^ l^ /caLl
-ffi
-ffi
CALIPER
PINA
\:7
\--l "=;lGoX-
u";;;lqEty'
/ 3.4N.m >vr
\ / {3.5kef m, / ,,'
\ / 25 lbf ft) //'
t / SEAL|NG
)-
/) II ---=-?
.===? WASHEaS
WAStrtXS \
t9..-\ | #.'@ RepracF
- /7\
!s-
*d':ffi
(hA PADRETATNERS
\t/ \
19-14
MasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may 3 . R e m o v et h e c l u t c hr e s e r v o i (r B )a n d e n g i n e w i r e
damagethe paint;if brakefluid does contactthe paint, harnessclip (C)from the mastercylindermounting
wash it off immediatelywith water, b a s e( D ) .
r s s e m b l y( A ) .
1 , R e m o v et h e a i r c l e a n e a 4. Removethe reservoircap and brakefuid from the
reservoir.
19-15
ConventionalBrakeComponents
MasterCylinderInspection BrakeBoosterPushrodClearance
Adjustment
NOTE:
. Beforereassembling,checkthat alI partsare f ree of
dust and other foreign particles. SpecialToolsRequired
. D o n o t t r y t o d i s a s s e m b l e t hm
e astercylinder Pushrodadjustmentgauge07JAG-SD40100
assembly.Replacethe mastercylinder assemblywith
a new part if necessary. NOTE:Brakeboosterpushrod-to-piston clearancemust
. Do not allow dirt or foreign matterto contaminatethe be checkedand adjustmentsmade, if necessarV,before
b r a k ef l u i d . installingthe mastercylinder.
RESERVOIB CAP
I unecKIor otocKage 1 . S e t t h e s p e c i atlo o l ( A )o n t h e m a s t e r c y l i n d ebr o d v
of vent holes. (B),push in the centershaft (C)until the top of it
,--l RESERvOIRSEAL contactsthe end of the secondarypiston {D) by
Checklor damaoe t u r n i n gt h e a d j u s t i n gn u t ( E ) .
RESERVOIR and deterioration.
r ' , , . J \ + STRAINER
v Removeaccumulated
seotment.
RESERVOIR HOSES
Inspecthosesfor
damage,leaks,and
deterioration.
MASTER CYLINDER
Checkfor leaks,rust,anddamage
1 5N m { r . 5
11tbf.ftl
19-16
5. With a feelergauge (A),measurethe clearance 9 . C h e c kt h e p u s h r o dl e n g t h( A )a s s h o w n i f t h e
betweenthe gauge body and the adjustingnut (B) boosteris removed,lf the length is incorrect,
as snown, loosenthe pushrodlocknut(B),and turn the clevis
lf the clearancebetweenthe gauge body and the (C)in or out to adjust.
adjustingnut is 0.4 mm (0.02in.),the pushrod-to- A
pistonclearanceis 0 mm. However.if the clearance 1 1 6m m { 4 . 6i n . )
betweenthe gauge body and the adjustingnut is
0 mm, the pushrod-to-piston clearanceis 0 4 mm
{0.02in.) or more. Thereforeit must be adjusted
and rechecked.
1 0 x 1 . 0m m
1.5 N'm
11.5kgf.m,11 lbf.ftl
1 0 . I n s t a l l t h em a s t e rc y l i n d e r( s e ep a g el 9 - 1 5 )
07JAG-SO40100
19-17
Gonventional
BrakeComponents
BrakeBoosterTest I
FunctionalTest 3. Disconnectthe brakeboostervacuum hose (check
valve built-in)(A) at the boosterside.
1. With the enginestopped,pressthe brakepedal
severaltimes to depletethe vacuum reservoir,then
pressthe pedal hard, and hold itfor 15 seconds.lf
the pedalsinks,eitherthe mastercylinderis
bypassinginternally,or the brakesystem (master
c y l i n d e rl,i n e s .m o d u l a t o ro, r c a l i p e r si)s l e a k i n g .
19-18
BrakeBoosterReplacement
1 . R e m o v et h e m a s t e rc y l i n d e r( s e ep a g e1 9 - 1 5 ) . 5 . R e m o v et h e c l i p ( A )a n dt h e j o i n t p i n ( B ) .a n d
disconnecttheyoke from the brakepedal.
Removethe mastercylinder brakelines {A) from
t h e b r a k el i n ec l i p . .,.,....
alu
'..
i
' - / c
6x1.0mm {'l.3kgf.m,9lbf.ftl
9.8 N.m
(1.0kgf.m,
7.2 tbf.ft) Removethe brakeboostermounting nuts (C).
. Adjustthe pushrodclearancebeforeinstalling
the brakebooster(seepage 19-16).
. U s ea n e w c l i pw h e n e v e ri n s t a l l i n g .
. After installingthe brakeboosterand master
cylinder,fill the reservoirwith new brakefluid,
bleedthe brakesystem (seepage 19-8),and
adjustthe brakepedal height and free play (see
p a g e1 9 - 6 ) ,
19-19
Conventional
BrakeComponents
RearBrakePadsInspectionand Replacement
Replacement
Frequentinhalationof brakepad dust, regardlessof 1. Removethe bolt (A) and brakehose {B}from the
materialcomposition,could be hazardousto your mounting bracket.
h e ah h .
. Avoid breathingdust particles.
. Never use an air hose or brushto clean brake
assemblies,Use an OSHA-approvedvacuum
cleaner.
Inspection
'1.
Raisethe rear of the vehicle,and supportjt with
safetystandsin the proper location(seepage 1-8).
Removethe rearwheels,
Brakepad thickness:
Standard: 8.5 9.5 mm {0.33-0.37 in.} Removethe caliperbolts (C),and removethe
Servicelimit: 1.6 mm (0.06in.) caliper(D)from the caliperbracket.
3 . R e m o v et h e p a d s h i m s( A )a n d p a d s( B ) .
A
t {
\
-::--
B
r\
) )
\
19-20
4. Removethe pad retainers(A).and checkthe caliper 11. Rotatethe caliperpiston clockwiseinto the cylinder,
pins for free movement. then align the cutout (A) in the pistonwith the tab
:.i _ _l
{B) on the inner pad by turning the piston backso
t h e c a l i p e rc a n b e i n s t a l l e do n t h e p a d .L u b r i c a t e
the boot with rubbergreaseto avoid twisting the
Distonboot. lf the piston boot is twisted,back it out
so it is positionedproperly.
8 x 1 . 2 5m m
5. Cleanthe caliperthoroughly;remove any rust.and 22 N.m
checkfor groovesand cracks. l2.2kgt m,
16rbl.ttl
1 3 .I n s t a l l t h eb r a k eh o s e( E ) .
1 5 . C h e c kt h e p a r k i n gb r a k ea d j u s t m e n{ts e ep a g e1 9 - 7 ) .
1 0 . I n s t a l l t h eb r a k ep a d sa n d p a d s h i m sc o r r e c t l y .
I n s t a l l t h ep a d sw i r h t h e w e a r i n d i c a t o r {sC )o n t h e 1 6 . A f t e ri n s t a l l a t i o nc ,h e c kf o r l e a k sa t h o s ea n d l i n e
inside. joints or connections,and retightenif necessarY.
lf you are reusingthe pads,always reinstallthe
brakepads in their originalpositionsto preventa
momentaryloss of brakingefficiency.
19-21
Conventional
BrakeComponents
RearBrakeDiscInspection
Runout Thicknessand Parallelism
1. Raisethe rear of the vehicle,and support it with 1. Raisethe rear of the vehicle,and supportwith
safetystandsin the proper location(seepage 1-8). safetystandsin the proper location(seepage l-g).
Removethe rear wheels, Removethe rearwheels.
108N.m (11.0kgf.m,80lbf.ft)
19-22
RearBrakeCaliperOverhaul
BRAKEHOSE
t H\a \l / t,i*t'*" a ,/
i,,'IltE"
/ !!;,ff
?,,.t/*"^.,,.:,"",
l, /"V4# olT-J,.o"c. O.RING
Beplace.
CUP
Beplace.
.ARKING
NUr lii.'i rz.rrgr.. Gd ffi
2 7 N m { 2 . 8 k g ft .mm, ,
20 tbf.ftr PADSPRING
19-23
ConventionalBrakeComponents
BrakeHosesand LinesInspection {
1. Inspectthe brakehosesfordamage,deterioration,leaks,interference,andtwisting.
BRAKELINE-to-BRAKE
HOSE
15 N.m (1.5kgf.m, 11 lbf.ftl
BRAKEHOSE-to-CALIPER
lBANJOBOLTI
3il N.m {3.5kgf.m.25lbt'ft)
BLEEO SCREW
9 N.m{0.9kgf.m,7lbf.ftl
ABS MODULATORUNIT-Io-BRAKELINE
15N.m{1.5kgf m.11lbf.ftl
/,i'i'
t'' ,/ ,l
t t,.. -)
MASTERCYLINDEB-to-BRAKE LINE
15 N m {1.5kgt.m,ll lbf.ft)
BRAKEHOSE.tO-CALIPER
{BANJO BOLTI CONTROLVALVE-to-
34 N.m {3.5kgf.m,25 lbl.ft) BRAKELINE
15N.m11.5kgf m, 11lbf.ft)
BLEEDSCBEW
9 N.m BRAKELINE-Io-BRAKEHOSE
10.9kgf.m, 7 lbf ft) 15 N.m (1.5kgf.m,11lbf.ftl
19-24
BrakeHoseReplacement
NOTE: 6. Installthe brakehose bracket(A)on the damper
. Do not spill brakefluid on the vehicle;it may damage with the flange bolt (B)first, then connectthe brake
the paint;if brakefluid gets on the paint,wash it off hose (C)to the caliperwith the banjo bolt {D) and
immediatelywith water. n e w s e a l i n gw a s h e r s( E ) .
. To preventdripping,cover disconnectedline joints
with rags or shop towels.
. Beforereassembling,checkthat all parts are free of
dust and other foreign particles.
. Replacepartswith new ones wheneverspecifiedto
do so.
1 0 x 1 . 0m m
15 N.m
i (1.5kgf.m,
! 1t tbt.ftl
4. R e m o v ea n d d i s c a r dt h e h o s ec l i p ( B ) .
19-25
ConventionalBrakeComponents
ParkingBrakeCableReplacement 1
ExplodedView
ADJUSTING
NUT
PARKINGBRAKE
swtTcH
e
8 x 1.25
PARKING BRAKECABLE 22 N.m
for stiffness,
Check binding,anddamage. 12.2kgl
19-26
NOTE: 7 . l n s t a l l t h en e w c a b l ei n t h e r e v e r s eo r d e ro f
. The parkingbrakecablesmust not be bent or removal.and note these items:
distorted.This will leadto stiff operationand
prematurefailure. . Be careful not to bend or distortthe cable.
. Referto the ExplodedView as neededduring this . M a k es u r et h e p a r k i n gb r a k ec a b l ec l i p i s f u l l y
proceoure. seatedon the cable housing.
. Do the parkingbrakecable adjuslment(seepage
1 . R e l e a s teh e p a r k i n gb r a k el e v e rf u l l y . 1 9 - 7) .
19-27
Brakes
BrakeComponents................
Conventional 19-1
ABS (Anti-lockBrakeSystem)Components
C o m o o n e nLto c a t i olnn d e x . . . . . . . . . . . . . , . . . . . . . . . . . . . 1
. .9. .-.3. .0. . . . . . .
General Troubleshooting Information....................... 19-31
DTCTroubleshooting Index .............. 19-34
SymptomTroubleshooting Index ...,........................... 19-35
SystemDescription ................. ........... 19-36
CircuitDiagram .........19-42
DTCTroubleshooting ............... .......... 19-45
ABSIndicator CircuitTroubleshooting ......................19-52
BrakeSystemIndicator Circuit
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . . . . . . . . . . . . . .1. 9 - 5 5
ABSModulator-Control UnitRemovaland
lnstallation ............. 19-57
WheelSensorInsoection ...................19-59
WheelSensorReolacement .............. 19-59
ABSGomponents
ComponentLocationIndex (
RIGHT-REARWHEELSENSOR
page19-59
Inspection,
Replacement,page19-59
UNDER.OASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
\L
LEFT.REAR
WHEELSENSOR
Inspection,page 19-59
Replacement, page 19-59
DATA LINKCONNECTOR
I16PI
RIGHT.FRONT WHEELSENSOR
Inspection,page 19-59
Replacement, page 19-59
ABSMODULATOR.CONTROL UNIT
page19'57
andInstallation,
Removal LEFT-FRONTWHEELSENSOR
page19-59
Inspection,
Replacement,page1959
19-30
GeneralTroubleshootingInformation
ABS Indicator DiagnosticTroubleCode{DTCI
. lf the system is OK,theABS indicatorgoes off 2 . The memory can hold three DTCS.However,when
secondsafter turning the ignition switch ON (ll) the same DTCis detectedmore than once,the more
without startingthe engine,and then comes on again recentDTCis written over the earlierone.
and goes off 2 secondslater after startingthe engine. Therefore,when the same problem is detected
This occursbecausethe ABS control unitisturned repeatedly,it is memorizedas a single DTC.
on by the lG2 power source. . The DTCsare in the order they occurred,beginning
. The ABS indicatorcomes on when the ABS control with the most recent.
unit detectsa problem in the system.However,even . The DTCSare memorizedin the EEPROM(non-
though the system is operatingproperly,the indicator volatile memory).Therefore.the memorizedDTCs
will come on underthese conditions: are not clearedwhen the batteryis disconnected,the
- Only the drive wheels rotate ignition switch is turned off, or the system returnsto
- One drive wheel is stuck normal. Do the specifiedproceduresto clearthe
- The vehiclegoes into a spin DTCs.
- The ABS continuesto operatefor a long time.
- The vehicleis subjectedto an electricalsignal Self-diagnosis
disturbance
. Self-diagnosiscan be classifiedinto two categories:
To determinethe actualcauseof the problem,question - I n i t i ad
l iagnosis:
the customeraboutthe problem.taking the above Done right after the enginestarts and until the ABS
condilionsinto consideration. indicatorgoes off
- R e g u l ad r iagnosis:
. When a Droblemis detectedand lhe ABS indicator D o n er i g h t a f t e r t h ei n i t i a d
l i a g n o s i su n t i lt h e
comes on, there are caseswhen the indicatorstays ignition switch is turned OFF
on until the ignition switch is turned OFF,and cases . When a problem is detectedby self-diagnosis, the
when the indicatorgoes off automaticallywhen the system does the following:
sYstemreturnsto normal. - Turnsthe ABS indicatoron
- DTC61: The ABS indicatorgoes off automatically - Memorizesthe DTC
when the system returnsto normal. - StopsABS control
- D T C1 1 ,1 3 , 1 5 , 1 7, 3 1 , 3 2 , 3 3 ,3 4 ,3 5 ,3 6 ,3 7 ,3 8 ,5 4 ,
or 81: The ABS indicatorstayson until the ignition Kickback
switch is turned OFFwhether or not the system
returnsto normal. The pump motor operateswhen the ABS is functioning,
- D f C 1 2 ,1 4 ,1 6 ,1 a , 2 1 , 5 1 , 5 2o, r 5 3 ;T h e A B S and the fluid in the reservoiris forced out to the master
indicatorgoes off when the vehicleis driven again k t t h e b r a k ep e d a l .
c y l i n d e rc, a u s i n gk i c k b a c a
and the system is OK afterthe ignition switch is
t u r n e df r o m O F Ft o O N { l l } . PumpMotor
. The pump motor operateswhen the ABS is
functioning.
. The ABS control unit checksthe pump motor
operationwhen the vehicleis startedthe first time
after the ignition switch is turned ON (ll).You may
hearthe motor operateat this time, but it is normal.
(cont'd)
19-31
ABSComponents
GeneralTroubleshootingInformation(cont'd)
How to TroubleshootABS DTCs 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n df o l l o wt h e
prompts on the PGM Testerto displaythe DTC{S)
The troubleshootingflowchartproceduresassumethat on the screen.After determiningthe DTC,referto
the causeof the oroblem is still Dresentand the ABS the DTCTroubleshootingIndex.
indicatoris still on. Followingthe flowchartwhen the
ABS indicatordoes not come on can resultin incorrect NOTE:Seethe HondaPGM Testeruser'smanual
diagnosis. for specificinstructions.
The connectorillustrationsshow the female terminal
connectorswith a singleoutline and the male terminal Service Check Signal (SCS)Circuit Method:
connectorswith a double outline. 1. With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC)
1. Ouestionthe customeraboutthe conditionswhen (BI underthe driver'sside of the dashboard.
the problem occured,and try to reproducethe
same conditionsfor troubleshooting.Find out
when the ABS indicatorcame on, such as during
ABS control,after ABS control,when the vehicle
was at a certainspeed,etc.
19-32
4. The blinkingfrequencyindicatesthe DTC.DTCSare How to ClearABS DTCs
indicatedby a seriesof long and short blinks.One
l o n gb l i n ke q u a l s1 0 s h o n b l i n k s A
. d d t h e l o n ga n d Honda PGM Tester Method:
short blinkstogetherto determinethe DTC.After 1. With the ignition switch OFF,connectthe Honda
determiningthe DTC,referto the DTC P G MT e s t e r( A ) t o t h e l 6 P d a t a l i n kc o n n e c t o (r D L C )
T r o u b l e s h o o t i nI gn d e x . { B }u n d e rt h e d r i v e r ' ss i d eo f t h e d a s h b o a r d .
NOTE:
. lf the DTCis not memorized,the ABS indicator
will go off for 3.6 seconds,and then come back
on.
. lf the ABS indicatorstayson, troubleshootfor
"ABS indicator
does not go off" (seestep 1 on
page 19-53).
Example
ot DTC15
Short blinks T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c l e a r t h e
Long blink {five timesl DTC(s)by following the screenprompts on the
PGM Tester.
19-33
ABSGomponents
DTCTroubleshootingIndex
DTC Detection ltem Note
DTC:11 Rioht-frontwheel sensor{ooen/shortto bodv qround/shortto power) (seeoaoe 19-45)
DTC:12 Faultv riqht-frontwheel sensoroulse siqnal {seeoaoe 19-46)
DTC:13 Left-frontwheel sensor{oDen/shortto bodv qround/shortto power) (seeoaqe 19-45)
DTC:14 Faultvleft-frontwheel sensorDulsesrqnal (seepaqe 19-46)
DTC;15 Riqht-rearwheel sensor(oDen/shortto bodv qround/shortto power) (seeDaqe19-45)
DTC:16 F a u l t vr i q h t - r e awr h e e ls e n s o ro u l s es i q n a l (seepaqe 19-46)
DTC:17 Left-rearwheel sensor (open/shortto bodv qround/shortto power) (seeDaoe'19-45)
DTC:18 Faultvleft-rearwheel sensorDulsesiqnal (seeDaqe'19-46)
Drc:2l C o n t i n u o uo s D e r a t i o (nc h i o D e D
d ulser) (seepaqe 19-47)
DTC:3'l Solenoid (seeDaoe19-48)
DTC:32 Solenoid { s e eD a q e1 9 - 4 8 )
DTC:33 Solenoid {seeDaoe19'48)
DTC:34 Solenoid lsee oaqe 19-48)
DTC:35 Solenoid (seepaqe 19-48)
DTC;36 S ol en oi d (seeDaqe19-48)
DTC:37 S ol en o i d (seeDaqe19-48)
DTC:38 S o l en oi d (seeDaoe19-48)
DTC:51 lvlotor Iocked ( s e eD a q e1 9 - 4 8 )
DTC:52 lvlotor stuck off (seeDaoe19-49)
DTC:53 lMotorstuckon (seeDaoe19-50)
DTC:54 Main relav stuckoff ( s e ep a q e1 9 - 5 1
DTC:61 lG2 voltaqe { s e eo a q e1 9 - 5 ' l
DTC:81 cPU (CentralProcessinqUnit) {seepaqe 19-52)
19-34
Symptom Troubleshooting Index
Symptom Diagnostic procedure Also check for
ABS indicatordoes nol come on ABS IndicatorCircuitTroubleshooting(seepage
19-52)
ABS indicatordoes not go off and no ABS IndicatorCircuitTroubleshooting{seestep 1
ABS DTCis stored on Daqe19-53)
Brakesystem indicatordoes nol come BrakeSystem lndicatorCircuitTroubleshooting
on (seepaqe 19-55)
Brakesystem indicatordoes not go off BrakeSystemIndicatorCircuitTroubleshooting
and no ABS DTCis stored (seesteo1 on Daqe19-55)
19-35
ABS Gomponents
SystemDescription
ABSControlUnit Inputsand Outputsfor 31PConnector
1 2 4 5 6 7 B I 1112 1 41 5
20 ?1/t/t/l/t/
1 6 1 1 1B 1 9
19-36
Terminal Wire Terminalsign Description Measurement
number color Terminals Conditions {lgnition Voltage
switch oN lll))
14 WHT/ STOP Detectsbrake I 4 - GN D Brakepedal Pressed Eattery
BLK switchsiqnal Released voltaoe
t5 BLV rG2 Powersourcefor 15-GND Baftery
ORN activating
the voltage
svstem
16 BLK M-GND Groundforthe 16-GND Below
0.3V
0umD motor
WHT/ + B-MR Powersourcefor 17-GND Atalltimes Battery
RED the oumDmotor voltaoe
18 WHT/ + B-FSR ,18-GND
Powersourcefor Atalltimes Battery
GRN thevalverelav voltaoe
'19 BLK GND Groundfor the 19.GND Below
0.3V
modulator
assemDtv
20 BLU/ ABS DrivesABS 20-GND ABS ON A b o u t1 1V
RED indicator indicator OFF Below 1 V
BRN/ EBD Drivesbrake 2 1 - G N D Brakesystem OFF Below0.3V
YEL (Electronic
brake systemindicator indicator ONfor 8attery
distribution) bulb voltage
cnecK
( c o n t ' d)
19-37
ABS Gomponents
SystemDescription(cont'd)
Features
When the brakepedal is pressedduring driving,the wheels can lock beforethe vehiclecomesto a stop. In such an
event.the maneuverabilityof the vehicleis reducedif the front wheels are locked,and the stabilityof the vehicleis
reducedif the rearwheels are locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip
rate of the wheelsto ensuremaximum grip force from the tires,therebyensuringthe maneuverabilityand stabilityof
thevehicle.
The ABS calculatesthe slip rate of the wheels basedon the vehiclespeedand the wheel speed,then it controlsthe
brakefluid pressureto reachthe target slip rate.
TARGETSLIPRATE
OF
COEFFICIENT
FRICTION
SLIPRATE
19-38
ABSControlUnit
Main Control
The ABS control unit detectsthe wheel speed basedon the wheel sensorsignal it received,then it calculatesthe
vehiclespeed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring deceleration
basedon the rate of deceleration.
The ABS control unit calculatesthe slip rate of eachwheel and transmitsthe control signalto the modulatorunit
solenoidvalve when the slip rate is high.
T---
Self-diagnosisFunction
1 . T h e A B S c o n t r ou ln i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b - C P U . E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s .
2. The CPUScheckthe circuitof the system.
3 . T h e A B S c o n t r oul n i t t u r n so n t h e A B S i n di c a t o rw h e n t h e u n i t d e t e c t s ap r o b l e ma n d t h e u n i ts t o p st h e s y s t e m .
4. The self-diagnosiscan be classifiedinto thesetwo categories:
. l n i t i a ld i a g n o s i s
. R e g u l ad r iagnosis
On-boardDiagnosisFunction
The ABS can be diagnosedwith the Honda PGM Tester.
The ALB Checkercannot be usedwith this system.For air bleedingand checkingwheel sensorsignals.usethe Honda
PGM Tester.Seethe Honda PGMTesteruser's manualfor specificoperatinginstructions.
(cont'd)
19-39
ABSComponents
SystemDescription(cont'd)
ABSModulator
The ABS modulatorconsistsof the inlet solenoidvalves,outlet solenoidvalves,reservoir,pump, pump motor, and the
damping chamber.The modulator reducesthe caliperfluid pressuredirectly.lt is a circulating-typemodulator
b e c a u s e t h eb r a k e f l u i d c i r c u l a t e s t h r o u g h t h e c a l i p e r , r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r . T h e h y d r a u l i ch caos n t r o l
three modes:pressureintensifying,pressureretaining,and pressurereducing.The hydrauliccircuitis an independent
four-channeltype o ,n e c h a n n efl o r e a c hw h e e l .
19-40
t
WheelSensors
The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotate pastthe wheel sensor'smagnetic
coil, AC current is generated.The AC frequencychangesin accordancewith the wheel speed.The ABS control unit
detectsthe wheel sensorsignalfrequencyand therebydetectsthe wheel speed.
GEARPULSER
WHEELS€NSOR .r HIGXSPEED
!t LOW SPEED
VEJ!q!ESPEEq
8E!EEETqE
PRESSURE
OUTLET
VALVE 9p
OFF
INLET
VALVE oN
OFF
MoroR I
-,. l
t l
OFF
When the wheel speeddrops sharplybelow the vehiclespeed,the inlet valve closesand il necessary,the outlet valve
opens momentarilyto reducethe caliperfluid pressure.The pump motor startsat this time. As the wheel speed is
restored,and the outlet valve closes,the inlet valve opens momentarilyto increasethe caliperfluid pressure.
19-41
ABSGomponents
CircuitDiagram
"'-----
G50l
L "*'*" lJ5 Il
rI * *r +' tl ? l
I ^ lo+-sN
Gu csl LqF**,
19-42
*- :ffrre, *-
7--:::
19-43
ABSComponents
CircuitDiagram(cont'd)
UNDER-HOOD
FUSE/RELAY
BOXCONNECTORS BRAKEPEDALPOSITION
CONNECTOR
CONNECTOR
A {12P)
{12P) CONNECTOR
B {2P} SWITCH4PCONNECTOR
UNDER.DASH
FUSE/RELAY
BOXCONNECTORS MULTIPLEXCONTROL
CONNECTOR
I {5P) CONNECTOR
K I17P) UNIT13PCONNECTOR
1l2l3l,/15 1 2 3 4 5 67 1 2 3 ,/ ,/
8 1011121 31 415 1 1 6 7 8 9 10 11n213
GAUGEASSEMBLYCONNECTORS
CONNECTOR
A I22P) CONNECTOR
B I22PI
ABSCONTROL
UNIT3IP CONNECTOR q,
1 2 4 5 6 7 8 I 1112 1 415
20 21/1,/1,/vl,/l
16 1 1 1 8 1 9
/t,/t/t,/t/
Wire side of femaleterminals
tslTt?t /J 1T-1\
I tL | \t rlziJ
T e r m i n asl i d eo f m a l el e r m i n a l s
19-44
DTCTroubleshooting
DTC11,13,15,17:WheelSensor 5. Checkfor continuitybetweenthe appropriate
(Open/Short to Power)
to BodyGround/Short wheelsensor(+ ) circuitterminalandbodyground
{ s e et a b l e ) .
1. Disconnectthe ABS control unit 31Pconnector.
DTC Appropriate Terminal
2. Start the engine. 11 (Riqht-front) N o .5 : F R S( + )
13(Left-front) N o . 7 : F L S( * )
3. Measurethe voltagebetweenthe appropriate 1 5( R i o h t - r e a r ) No.2R : R S( * )
w h e e ls e n s o r( * ) c i r c u i t t e r m i n a lo f t h e A B S 17(Left-rear) N o . 9R L S( + l
control unit 31Pconnectorand body ground (see
table).
ABS CONTROLUNIT31PCONNECTOR
DTC ADpropriate Terminal
11(Rioht-front) N o . 5 :F R S( t )
13(Left-front) N o , 7 : F L S( * )
15 {Riqht-rear} N o .2 : R R S( * )
17 (Left-rear) N o . 9R t S( f )
F R S{ + I I G N R / B L K } F L SI + I ( B L U
R R S{ + )
(GNR/YEL)
s i d eof femaleterminals
W i r eside
Wire
\ ls therecontinuity?
NO-Go to step7.
Wiresideof femaleterminals
Disconnectthe harness2P connectorfrom the
ls thete battery voltage? appropriatewheel sensor,then checkfor continuity
b e t w e e nt h e 1 + ) a n d ( ) t e r m i n a l so f t h e h a r n e s s
YES Repairshort to power in the (+) circuitwire and body ground.
betweenthe ABS modulator-controlunit and the
appropriatewheel sensor.I ls there continuity?
NO Go to step 4. Y E S - R e p a i rs h o r t t o b o d y g r o u n di n t h e ( + ) o r { )
circuitwire betweenthe ABS modulator-control
4. Turn the ignition switch OFF. unit and the wheel sensor.l
(cont'd)
19-45
ABS Components
DTCTroubleshooting(cont'dl
7. Checkthe resistancebetweenthe appropriate DTC12,14,
16,18:WheelSensorPutse
w h e e ls e n s o r( + ) a n d ( ) c i r c u i t e r m i n a l s{ s e e Signal
ta ble).
NOTE:lf the ABS indicatorcomes on for the reasons
DTC Appropriate Terminal describedbelow,the indicatorgoes off when you test-
l+) Side *lSide d r i v et h e v e h i c l ea t 3 1 m p h ( 5 0k m / n l .
11 {Riqht-front) N o . 5 :F R S( * ) N o . 4 : F R1S- )
'13
{Left-front) N o .7 : F L S{ + i N o . 6F: L S( - . Only the drive wheel rotated
1 5( R i o h t - r e a r ) No.2:RBS {+) N o .1 : R B S (-) . T h e v e h i c l es p u n
17 (Left-rear) N o . 9 :R L S1 - N o . 8B : L S( - . Electricalnoise
1 . V i s u a l l yc h e c kf o r a p p r o p r i a t w
e h e e ls e n s o r a n d
ABS CONTROLUNIT31PCONNECTOR pulserinstallationand condition(seetable).
YES-Go to step 2,
Wire side of femaleterminals
NO Reinstallor replacethe appropriatewheel
s e n s o ro r p u l s e r , I \\|D
Is the rcsistance between 450 2,000 A ?
2. Disconnectthe ABS control unit 31Pconnector.
YES Checkfor a looseABS control unit3lP
connector.lf necessary.substitutea known-good 3 . Measurethe resistancebetweenthe appropriate
ABS modulator-controlunit, and recheck.l w h e e ls e n s o r( f ) a n d ( ) c i r c u i t e r m i n a l s( s e e
table).
NO Go to step 8.
DTC Appropriate Terminal
Disconnectthe harness2P connectorfrom the l*) Side ) Side
appropriatewheel sensor,and checkthe resistance 12 {Rioht-front) N o . 5 : F (B*S No.4:FBS
b e t w e e nt h e ( + ) a n d { ) t e r m i n a l s o ft h e w h e e l 14 (Left-front) N o . 7 ; F Ll *S No,6:FLS
sensor. 1 6( R i q h t . r e a r ) N o . 2R: R(S* N o1
. :BRS
18 (Left-read N o . 9B: L S1- No.8:RLS
ls the resistance between 450- 2,000 Q ?
Y E S - R e p a i ro p e ni n t h e ( + ) o r ( - ) c i r c u i tw i r e ,o r
short betweenthe (+) circuitwire and the { )
circuitwire betweenthe ABS modulator-control
u n i ta n d t h e w h e e ls e n s o r . l
NO Replace
t h e w h e e ls e n s o r . l
YES Go to step 1.
N O - G o t o s t e p4 .
19-46
4. Checkfor continuitybetweenthe appropriate DTC21:Continuous (Chipped
Operation
w h e e ls e n s o r( + ) c i r c u i t t e r m l n aal n d o t h e r w h e e l pulser)
s e n s o r( + ) c i r c u i t e r m i n a l s( s e et a b l e ) .
1. Clearthe DTC,then disconnectthe HondaPGM
DTC Appropiate Other Terminal tesler.
Terminal
12 No.5: No.7 No.2 No.9 2. Test-drivethe vehicleat 19 mph (30 km/h)or more.
F R W( * i
'14 No.5 No.2 No.9 Doesthe ABS indicator come on and is DTC 21
No.7:
FLWIT.) indicated?
to No.2; No.5 No.7 No.9
RRW(T-) YES Go to step 3.
18 No.9: No.5 N o .7 No.2
R L W( * ) NO The system is OK at this time.l
1g-47
ABSComponents
DTCTroubleshooting(cont'd)
DTC31,32.33,34,35,36,37,38:Solenoid DTC51:Motor Locked
1. Clearthe DTC,thendisconnect
the HondaPGN4 '1.
C h e c kt h e N o . 1 0 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d f u s e /
Tester. retayDox.
2. Test-drive
thevehicle. ls the tuse OK?
Doesthe ABSindicator comeon and are DTCs 31, YES-Reinstall the fuse, and go to step 2.
32, 33, 34, 35, 36, 37, 38 indicated?
NO- Replacethe fuse, and recheck.l
YES Replace
theABSmodulator-control
unit.t
2. Disconnectthe ABS control unit 31Pconnector.
NO Thesystemis OKat thistime.t
3. Measurethe voltagebetweenthe ABS control unit
3 1 Pc o n n e c t otre r m i n a lN o . 1 7a n d b o d y g r o u n d .
ABS CONTROLUNIT31PCONNECTOR
I
Wiresideof femaleterminals
YES Go to step 4.
19-48
4. Checkfor continuitybetweenthe ABS control unit DTG52:MotorStuckOFF
31P connectorterminal No. 16 and body ground.
1 . C h e c tkh eN o .1 0 ( 4 0 Af )u s ei n t h eu n d e r - h o o d
fuse/relay box.
ABS CONTROLUNIT31PCONNECTOR
ls thef useOK?
UNIT31PCONNECTOR
ABSCONTROL
ls there continuity?
YES-Go to step 5.
(cont'di
19-49
ABS Components
DTCTroubleshooting(cont'dl
4. Checkfor continuitvbetweenthe ABS control unit DTC53:MotorStuckON
3 1 Pc o n n e c t otre r m i n a lN o . 1 6 a n db o d y g r o u n d .
1 . C l e a rt h e D T C t, h e n d i s c o n n e ct th e H o n d ap GM
ABSCONTROL
UNIT31PCONNECTOR Tester.
2. Test-drivethe vehicle.
Wiresideof femaleterminals
ls therc continuity?
19-50
DTC54:MainRelayStuckOFF DTC61:lG2Voltage
1 . C h e c k t h eN o . 8 ( 2 0 A )f u s e i n t h e u n d e r - h o o fdu s e / : h e c kt h e N o . 1 1 ( 7 . 5 A f)u s e i n t h e u n d e r - d a s h
N O T EC
f u s ei f i t i s O K .
r e l a yb o x ,a n d r e i n s t a l l t h e fuse/relaybox beforetroubleshooting.
4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
UNIT31PCONNECTOR
ABSCONTROL
Wiresideof femaleterminals
19-51
ABSComponents
DTCTroubleshooting(cont'd) ABS IndicatorGircuit
Troubleshooting
DTC81:CPU(Central
Processing
Unit)
1. Clearthe DTC,then disconnectthe HondaPGM ABS indicator does not come on
Tester.
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a t c ht h e A B S
2. Test-drivethe vehicle. indicator.
Does the ABS indicator come on and is DTC 81 Does the ABS indicator come on?
indicated?
YES The system is OK at this time.I
YES Replacethe ABS modulator-controlunit.l
NO Go to step 2,
NO-The system is OK at this time. t
Pull up the parkingbrakelever.
YES Go to step 3.
5. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
NO Go to step 6.
19-52
8 . Disconnectthe gaugeassemblyconnectorA (22P). ABS indicator does not go off
9 . Checkfor continuitybetweengauge assembly 1. ChecktheNo.8 (20Alfusein the under-hood fuse/
connectorA {22P)terminal No, 12 and body ground. relaybox,andreinstallthefuseif it is OK.
NO-Replacethefuse,andrecheck. lf thefuseis
blown,checkfor a shonto bodygroundin thisfuse
circuit.ll thecircuitis OK,replacetheABS
modulator-control unit.I
YES- Repairshon to body ground in the wire NO Replacethe fuse, and recheck.If the fuse is
betweenthe gaugeassemblyand the ABS control blown, checkfor a shortto body ground in this fuse
unit.l circuit.lf the circuit is OK, replacethe ABS
modulator-controlunit.I
NO Go to step 10.
3 . Disconnectthe ABS control unit 31Pconnector.
'10.Disconnectthe gaugeassemblyconnectorB (22P).
Measurethe voltage betweenterminal No. l8 and
1 1 .Checkfor continuitybetweengauge assembly body ground.
connectorB (22P)terminal No. 12 and body ground.
UNIT3lP CONNECTOR
A8S CONTROL
GAUGEASSEMBLY B (22PI
CONNECTOR
(cont'd)
19-53
ABSComponents
ABS IndicatorCircuitTroubleshooting(cont'dl
5. Turn the ignitionswitch ON (ll). 10. Connectthe ABS control unit3lPconnector
t e r m i n a lN o . 2 0 a n d b o d y g r o u n dw i t h a j u m p e r
6 . Measurethe voltage betweenthe ABS control unit wire.
31PconnectorterminaI No. 15 and body ground.
ABSCONTROL
UNIT3IP CONNECTOR ABSCONTROLUNIT31PCONNECTOR
ABSCONTROL
UNIT31PCONNECTOB GAUGEASSEMBLY A (22P)
CONNECTOR
19-54
BrakeSystemIndicatorGircuitTroubleshooting
Brakesystem indicator does not come on Brakesystem indicatordoes not go off
'1. 1 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
Disconnectthe m ultiplexcontroI unit l3Pconnector
and the ABS control unit 31Pconnector.
t h e p a r k i n gb r a k e .
2. Release
2. Checkfor continuitybetweenthe ABS control unit
3 l P c o n n e c t otre r m i n a lN o , 2 1 a n d b o d y g r o u n d . Does the brake system indicatot go ofl after
several seconds?
ABS CONTROLUNIT31PCONNECTOR
YES The system is OK at this time.l
NO Go to step 3.
YES Go to step 4.
t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r .
6 . D i s c o n n e ct h
7 . C o n n e ctth e A B S c o n t r o lu n i t3 1 Pc o n n e c t o r
t e r m i n a lN o . 2 1 a n d b o d y g r o u n dw i t h a j u m p e r
ABS CONTROLUNIT31PCONNECTOR
W i r es r d eo f l e m a l el e r m i n a l s
(cont'd)
19-55
ABSComponents
BrakeSystemIndicatorGircuitTroubleshooting(cont'd)
8 . Turn the ignititonswitch ON (ll).
MULTIPLEX
CONTROL
UNIT13PCONNECTOR
JUMPER
WIRE
\
Wiresideof femaleterminals
NO Go to multiplexcontrol system
troubleshooting (seepage22-172).a
19-56
ABS Modulator-ControlUnit Removaland lnstallation
NOTE:
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n Ui f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f
immediatelywith water.
. Becarefulnot to damageor deform the brakelines during removal and installation.
. To preventthe brakefluid from flowing, plug and cover the hose ends and joints with a shop towel orequivalent
malenal.
Removal
'1.
Turn the ignitionswitch OFF.
2 . P u l lu p t h e l o c k ( A )o f t h e A B S c o n t r o u
l nit3lPconnector(B),thendisconnecttheconnector.
FLARENUT
l5 N.m (1.5kgt.m,11lbt.ftl
6)o
CI I mm NUT
8.8N.m {0.9kgl m.6.5lbfft)
\.
--/Q \,
\---'
6 mm BOLT
9.8N.m
11.0ksf.m,7.2lbf.ft)
(cont'd)
19-57
ABS Gomponents
ABS Modulator-ControlUnit Removaland Installation{cont'dl
3. Disconnectthesix brakelines.
Installation
'1.
I n s t a l l t h e A B Sm o d u l a t o r c o n t r oul n i t ,t h e nt i g h t e nt h e t w o 8 m m n u t s .
3 . P u s h i n t h e l o c k o f t h e A B S c o n t r oul n i t3 1 Pc o n n e c t o ur n t i ly o u h e a ri t c l i c ki n t o p l a c e t. h e nc o n n e c t h e c o n n e c t o r .
19-58
WheelSensorInspection WheelSensorReplacement
1 . Inspectthe front and rear pulsersfor chippedor NOTE:Inslallthe sensorscarefullyto avoid twisting the
damagedteeth. wtres.
Standard:
Front; 0.4- 1.0mm (0.02-0.04 in.)
Rear: 0.2 1.0mm (0.01 0.04 in.l
Front:
0.4 '1.0mm
10.02 0.0'l in.l
I
t 6 mm BOLT
9.8 N.m
{1.0kgf.m,7.2lbf.ftl WHEELSENSOR
Rear:
6 mmBOLT
9.8 N.m
11.0kgf.m,7.2lbf.ft)
6 mm BOLT
9.8 N.m
(1.0kgf'm,
7.2rbr.ft)
Bear:
0.2 1.0mm
{0.01 0.04in.}
19-59
Body
Doors Dashboard
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . 20-2 InstrumentPanelRemoval/lnstallation ........20-59
D o o rP a n eR l e m o v a l / l n s t a l l a t i o. .n. . . , . . . . . .20,4
.... Driver'sDashboardLowerCover
DoorOuterHandleReplacement 20-6 RemovatInstallation 20-59
DoorLatchReplacement 20-7 Driver'sDashboardUnderCover
DoorGlassand Regulator Removat Installation 20-60
Replacement 20-9 Oriver'sPocketRemoval/lnstallation ............ 20,60
D o o rS a s hT r i mR e p l a c e m e n. .t. . . . . . . . . . . . . . 2. .0. .t.0. . ShiftLeverTrim Removal/lnstallation ..........2 0 6 1
DoorGlassOuterWeatherstrip C e n t eP r a n eR
l e m o v a l / l n s t a l l a t i. o. .n. . . . . . . .20-62 ....
Replacement 20- 10 Passenger's DashboardLowerCover
DoorWeatherstrip Beplacement 20-11 Removal/lnstallation 20-63
D o o rG l a s sA d j u s t m e n t. . . . . . . . . . . . . . . . . . . . . . .20-11
.......... x GloveBox Removal/lnstallation 20-63
D o o rP o s i t i oAn d j u s t m e n .t . . . . . . . . . . . . . . . . . . .20-12
......... Dashboard SideVent
D o o rS t r i k eAr d i u s t m e n.t. . . . . . . . . . . . . . . . . . . . .2. .0. .1. 3. . . . . R e m o v a l / l n s t a l l a t i. o. .n. . . . . . . . . . . . . . . . . . . . 2
. .0. .-.6. .4. . . .
Mirrors BeverageHolderRemoval/lnstallation ........20-64
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20-14
........ Driver'sTrayRemoval/lnstallation ............... 20-65
P o w e rM i r r o rR e p l a c e m e n. .t . . . . . . . . . . . . . . . . .2. 0
. .-. 1. .5. . Passenger's Tray Removal/lnstallation ........20 65
M i r r o rH o l d e R
r e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-15
........ * DashboardRemoval/lnstallation .................. 20-66
Rearview M i r r o rR e p 1 a c e m e.n. t. . . . . . . . . . . . . .2. 0. .-.1. .6 S t e e r i"n H
q a n q eBr e a mR e o l a c e m e n. .t. . . . . . .2. 0. - 6 8
Glass Seats
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .2. 0
. .1
. .1. . . ComponentLocationIndex ........................... 20-10
W i n d s h i e lR
deplacement 20-19 * FrontSeatRemoval/lnstallation ................... 20-11
B e a rW i n d o wR e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . .20-25
........ * FrontSeatDisassembly/
r l a s sR e p l a c e m e n. .t . . . . . . . . . . . . . . . . 20-29
O u a r t eG ........ R e a s s e m b l y - D r i v e. .r .' s. . . . . . . . . . . . . . . . . . . . 2. .0. .-.7. .3. . . .
Moonroof * FrontSeatDisassembly/
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20,35 ........ R e a s s e m b l y - P a s s e n g. .e.r. '.s. . . . . . . . . . . . . .2. 0 . .-. 7. .4. .
SymptomTroubleshooting Index 20-36 * F r o n tS e a tC o v e rR e p l a c e m e n. .t . . . . . . . . . . . . .2. .O. .-.7. 5
G l a s sH e i g hA t d j u s t m e n.t. . . . . . . . . . . . . . . . . . . . 20-37
.......... R e a rS e a tR e m o v a l / 1 n s t a 1 1.a. t. i. o. .n. . . . . . . . .2. .0. -. .8.0
G l a s sR e p l a c e m e n t 20-31 RearSeat-back LatchReplacement.............. 20-81
W i n dD e fl e c t o r8 e p 1 a c e m e n. .t. . . . . . . . . . . . . . .20-38 ....... RearSeat-backStriker Replacement............ 20-81
D r a i nC h a n n eRl e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20 . . . .39
.... RearSeat-back CoverReplacement............. 20-82
S u n s h a dR e e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . . . .20-40
.......... R e a rS e a tC u s h i o n
C o v e rR e p l a c e m e n. .t . . . .2. 0 . 8 4
Motor Replacement 20-41 Bumpers
Frameand DrainTubeReplacement............ 20,42 F r o n tB u m p e R r e m o v a l / l n s t a l l a t .i o
. .n. . . . . . .20,85
...
D r a i nC h a n n eSl l i d e ar n dC a b l eA s s e m b l y R e a rB u m o e R r e m o v a l / l n s t a l l a t.i.o. .n. . . . . . .20-86
....
Replacement 20 44 Hood
L i m i tS w i t c hA d j u s t m e n .t . . . . . . . . . . . . . . . . . . . . 20-46
.......... Adjustment 20-47
ClosinoForceand ODeninaDraqCheck ......20,44 H o o dS e a lR e p l a c e m e n t 20,88
lnterioiTrim H o o dI n s u l a t oRr e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20,89
.......
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .20-49
........ Hatch
Trim Removal/lnstallation DoorArea .......... 20 50 Adjustment . . . . . . . . . . . . . .2. 0
. .-. 9. 0
Trim Removal/lnstallation H a t c hS u p p o nS t r u tR e p l a c e m e n. .t. . . . . . . . . .2. .0.-. 9 1
-RearSideArea 20-51 HatchWeatherstriD Reo1acement ................. 20-92
Trim Removal/lnstallation FuelFill Door
-CargoFloorArea 20-52 Adiustment . . . . . . . . . . . . . .2. 0
. .-. 9. 3
Trim Removal/lnstallation-Hatch Area .........20-53 ExteriorTrim
HeadlinerRemoval/lnstallation 20-54 F r o n tG r i l l eR e p l a c e m e n. .t. . . . . . . . . . . . 20-94
* C a r p eR
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . .20-55
............ CowlCoversReplac"rn""t .. . ..................... 20-95
Consoles A p i l l a rC o r n eTr r i mR e p l a c e m e n. .t. . . . . . . . . .20-96 ....
Frontand Rear
Consoles, R o o fl M o l d i nR g e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-97
........
Removal/lnstallation 20-57 RearLicenseTrim Replacement 20,98
FrontConsoleDisassembly/Reassembly
.....20-58 H a t c hS p o i l e8r e p 1 a c e m e .n.t. . . . . . . . . . . . . . . . .20-99
........
E m b l e mR e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . .2 0 - 1 0 0
Fenderwell
FrontInnerFenderReplacement 20-102
F r o n tF e n d eFr a i r i n gR e p l a c e m e n. .t . . . . . . . . .2. .0. .- 1 0 3
FuelPipeProtectorReplacement 20-104
R e a rA i r O u t l e R
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20-'to4
.......
Openers
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .2. .0. -. 1 . .0. .5
H o o dO p e n eC r a b l eR e p l a c e m e n. .t . . . . . . . . . .2. .0.-. 1 0 6
* FueF l i l lD o o rO p e n eC r able
Replacement 20 107
H o o dL a t c hR e p 1 a c e m e .n. t. . . . . . . . . . . . . . . . . . .2. 0 . .-.1. .0. .8.
FueF l i l lD o o rO p e n eR r e p l a c e m e n. .t. . . . . . . . .2.0. .- 1 0 9
H a t c hH a n d l eR e p l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .0. -. 1.1. .0.
H a t c hL a t c hR e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .2. .0.-. 1. .1. .0.
H a t c hL o c kC y l i n d eRr e p l a c e m e n. .t. . . . . . . . . .20-111 ....
Frame
SubframeReplacement.................................
20-112
FrameStiffener,Brace,and Gusset
Replacement .............
20-113
r Fremp RFnrir Chrrr . . . . . . . . . . . . . .2. 0
. -114
Doors
ComponentLocationIndex a
DOOROUTERTRIM
DOORSASHTRIM
page20-10
Replacement,
DOORGLASSOUTER
WEATHERSTRIP
page20-10
Replacement,
DOOR
Adiustment,
Position
page20-12
K-p
IJ A'A
dq
W2"'
Ya
\J aita.
DOORWEATHERSTRIP
page20-'l'l
Replacement,
POWERWINDOW
swtTcH
\
POWERDOORLOCKSWITCH
(Driver's)
20-2
GLASS
Replacement,page20-9
Adjustment,page20-11
IMMOBILIZER
LABEL
REGULATOR
page20-9
Replacement,
RETAINERCLIP
LOCK
CYLINDER
\
\
LOCKKNOB O
OUTERHANDLE
CYLINDERROO PROTECTOR
PROTECTOR ,-\
tt \
v4,,(,
E ) i l
- /6X@
W (
STRIKER
Adjustment,page20-13
LATCH
page20-7
Replacement,
POWERDOOR
LOCKACTUATOR
20-3
Doors
Door PanelRemoval/lnstallation
SpecialToolsRequired 3. Removethe armrestcover (A).Takecare not to
Trim pad remover,Snap-onA 177Aor equivalent, scratchthe door panel.
c o m m e r c i a l la
yvailable.
-1 Pry out the front edge of the cover to release
NOTE:When prying with a flat-tipscrewdriver,wrap it the hooks(B).
with protectivetape, and apply protectivetape around -2 Pry out the bottom and rear edge of the cover
the relatedparts.to preventdamage. to releasethe hooks(C).
-3 Pry out along the top to releasethe tabs (D).
1. Removethe mirror mount cover (seepage 20-15).
FastgngrLocations
A> : Screw,3 B > : Screw,5
20-4
5. Pull out the switch panel (A)to releasethe hook (B), 7. Disconnectthe inner handlecable {A) from the
then removethe panelfrom the door panel. i n n e rh a n d l e( B ) ,a n d d i s c o n n e c t t h p
e o w e rd o o r
Disconnectthe power window switch connector(C). lock switch connector(C){driver's).Takecare not to
bend the cable.
FastenerLocations
95 mm (3.74in.l
> : Clip,9
12 mm r q----------
i.0.17in.l r <_--'r-
ffi
EtA lmm
{0.04in.l
45 mm {1.77in.l 9 . Installthe door panel in the reverseorder of
removal,and note these items:
. Replaceany damagedclips.
. Make sure the cable is connectedsecurely,and
the connectoris plugged in properly.
. Checkthe window and power door lock
operatrons,
20-5
Doors
Door Outer HandleReplacement
NOTE:Puton glovesto protectyour hands. 4. Disconnectthe cylinder rod (A),and releasethe
retainerclip (B).then removethe lock cylinder(C).
1, Removetheseitems:
2 . R a i s et h e g l a s sf u l l y .
-l Removethe screw.
-2 Releasethe protectorfrom the latch protector
(B).
-3 Pullthe protectordown to releasethe hook (C)
from the door.
6x1.0mm
9.8 N.m
{1.0kgf.m,
7.2 tbt.ft')
20-6
Door LatchReplacement
7. Pull out the outer handle(A),then remove it. NOTE:Put on glovesto protectyour hands.
1. Removethese items:
Raisethe glassfully.
q
Installthe handlein the reverseorder of removal, FastenorLocation
and note these items: > : Bolt,1
. Make sure each rod is connectedsecurelv. IIilE
. Make sure the door locksand opens properly.
. W h e n i n s t a l l i n tgh e l o c kc y l i n d e rl.e a v e t h e o u t e r
door handlebolts looseso the inner protector
does not interferewith the lock cylinder
installation,then tighten the handle bolts.
. Installthe lockcylinder retainingclip on the
handle,then installthe lockcylinder.Be sure the
c l i p i s f u l l y s e a t e di n t h e s l o to n t h e l o c kc y l i n d e r .
. W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e
plasticcover is installedproperly,and is sealed
aroundthe coversDerimeter.
6x1.0mm
8 N.m
{0.8 kgf.m, 6 lbf.ftl
(cont'd)
20-7
Doors
Door LatchReplacement(cont'dl
5 . Disconnectthe cylinder rod (seestep 4 on page 20- 9. Installthe latch in the reverseorder of removal,and
6). notethese rtems:
FastenerLocations
) : Screw
U.#
6x1.0mm
5Nm
{0.5kgf.m,
4 tbf.ft)
20-8
Door Glassand RegulatorReplacement
NOTE:Put on glovesto protectyour hands. 3. Disconnectand detachthe connector(A) and
h a r n e s sc l i p ( B )f r o m t h e d o o r .
1. Removethese items:
FastonorLocations
. Door panel (seepage 20-4) C>: Bolt.1 D>: Bolt,5
. Plasticcover.as necessary(seepage 20-2)
2 . C a r e f u l l yr a i s et h e g l a s s( A )u n t i ly o u c a n s e e t h e
bolts,then removethem. Carefullypull the glass
out through the window slot.Takecare not to drop
the glass insidethe door.
6x1.0mm
8 N.m
FastenerLocations (0.8kgf.m,
6 rbf.ftl
):Boh,2
@
Removethe bolts(C),andloosenthe bolts(D),then
removethe regulator(E)throughthe holein the
door,
6x1.0mm
9.8 N m {1.0kgl.m, 7.2 lbf.ftl
. R o l l t h eg l a s su p a n d d o w n t o s e ei f i t m o v e s
freely without binding.
. Make sure that there is no clearancebetweenthe
g l a s sa n d g l a s sr u n c h a n n e w l h e n t h e g l a s si s
ctoseo.
. Adjust the positionof the glassas necessary(see
p a g e2 0 - 11 ) .
. Checkfor water leaks(seestep 7 on page20-121.
. Test-driveand checkfor wind noiseand rattles.
. W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e
plasticcover is installedproperlyand sealed
around its perimeter.
20-9
Doors
Door SashTrim Replacement Door GlassOuterWeatherstrip I
Replacement
NOTE:Takecare not to scratchthe door.
Fastener Locations
B>:Clip,s
20-10
Door WeatherstripReplacement Door GlassAdjustment
NOTE: NOTE:
. Takecare not to scratchthe door. . Checkthe weatherstripsand glassrun channelfor
. Use a clip removerto removethe clips. damageor deterioration,and replacethem if
necessary.
1. At the A-pillar,removethe door stop mounting bolt . Wipe the run channelcleanwith a shop towel.
(A). . Lubricatethe run channelwith Shin-Etsugrease
P/N 08798-9013.
FastenerLocations
A > : B o t t ,1 B>:Clip,1 C > : C l i p ,1 8 1. Placethe vehicleon a firm, level surface.
2. Removethese items:
'
14.----'
'r,
.,'o-,,tL' .
.rrt
B
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbf.ft)
Detachthe clips (8, C),then removethe door Checkthat the glassmoves smoothly.
weatherstrip(D).
. Replaceany damagedclips.
. Make sure the weatherstripis installedln the
h o l d e r( E )s e c u r e l y .
. A p p l y l i q u i dt h r e a dl o c kt o d o o r s t o p m o u n t i n g
bolt beforeinstallation.
. Checkfor water leaks(seestep 7 on page20-'121.
. Test-driveand checkfor wind noase.
(cont'd)
20-11
Doors
DoorGlassAdiustment{cont'd) Door PositionAdiustment \
6. Raisethe glassfully, and checkfor gaps.Checkthat NOTE;Checkfor equal gaps betweenthe front, rear,
the glass(A) contactsthe glass run channel(B) and bottom door edgesand the body. Checkthat the
evenrv. door and body edges are parallel.
. U s ea 1 2 m m ( 1 / 2i n . )d i a m e t e rh o s e( A ) .
. Adjust the rate of water flow as shown {B).
. Do not use a nozzle.
. H o l dt h e h o s ea b o u t3 0 0 m m ( 1 2i n . )a w a y f r o m
the door (C).
\
t, 8x1.25mm
29 N.m (3.0kgf.m,
12mm1112in,l ! 22 tbt.trl
\e
300mm {12in.l
20-12
Door StrikerAdjustment
3. Checkthat the door and body edges are parallel.lf M a k es u r et h e d o o r l a t c h e s e c u r e l yw i t h o u ts l a m m i n g
necessary,adjustthe door cushions(A)to make the it. lf necessary,adjustthe striker(A):The strikernuts
rear of the door flush with the bodv. a r ef i x e d ,b u t t h e s t r i k e rc a n b e a d j u s t e ds l i g h t l yu p o r
d o w n ,a n d i n o r o u t .
20-13
Mirrors
ComponentLocationIndex
POWERMIRRORACTUATOR
page22-1'18
Replacement,
.a\
|
b\.\
\ \-r<,,/
\.J
\.4
\\
1 \
TWEETER
\
TWEETER
MIRRORMOUNTCOVER
POWERMIRROR
page20-15
Replacement,
MIRRORHOLDER
Replacement,page20 '15
__.Q
-'-'
MOUNT
REARVIEWMIRROR
page20 16
Replacement,
20-14
PowerMirror Replacement Mirror HolderReplacement
1 . Lower the door glassfully. 1 . C a r e f u l l yp u l l o u t t h eb o t t o me d g eo f t h e m i r r o r
holder (A) by hand.Takecare not to scratchthe
2. Carefullypry out the mirror mount cover (A) by mrrror.
hand in the sequenceshown. Disconnectthe
tweeterconnector(B),and releasethe wire harness
(C)from the hook (D).
FastenerLocation
) : Clip,1
20-15
Mirrors
RearviewMirror Replacement
1. Turnthe mirrorbase(A)90.in eitherdirection. 4, Fit the mirror base over the mount, and securethe
mirror by turning the base90".
20-16
Glass
ComponentLocationIndex
FASTENER,2
PASSENGER'SAIRSAG glassside)
{Self-adhesive-type,
CAUTION LABEL
SIDERUBBERDAM
WINDSHIELDSIDETRIM
4 ',
m-_-==}lny'
S{|---..------'RErA'NER,6
f..N\
;\tJ
e
N8*?' CLIP,4
Blue
WINDSHIELD CLIP
page20-19
Beplacement,
LOWERRUBBER
DAM
UPPER DAM,4
RUBBER
SPOILER
FASTENER,2
(Selt-adhesive-type)
'9>
LOWERRUBBERDAM
(cont'd)
20-17
Glass
ComponentLocationIndex(cont'd)
\n iT- \
/nJ l"
l/ / Pll
vI - \
/ .--"..---.-_
LowERcLrp
(Self-adhesive-type)
b
I
-.,-
-''
LEVEMBLEM
('03model) OUARTERGLASS R €AR CLIP
page20-100
Replacement. page20-29
Beplacement, (Self-adhesive-type)
20-18
WindshieldReplacement
NOTE: Removethe cowl covers(seepage 20-95).
. Puton glovesto protectyour hands,
. Weareyeprotection whilecuttingthe glassadhesive 4. Removethe molding (A) from the upper edge of the
with pianowire. windshield(B).lf necessary,cut the molding with a
. Useseatcoversto avoiddamaging the seats. utility knife.
1. Removetheseitems:
. Rearview
mirror(seepage20-16)
. Windshield
wiperarms(seepage22-145)
the clips(B)from
2. Pullup the sidetrim (A)to release
the retainers(C),andpullthetrim rearwardto
releaseit fromthecliD(D)thenremovethetrim
from eachsideof thewindshield.
(cont'd)
20-19
Glass
WindshieldReplacement(cont'd)
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 ow i r e { A ) 10. With a knife,scrapethe old adhesivesmooth to a
backand forth in a sawing motion. Hold the piano thicknessof about 2 mm (0.08in.) on the bonding
wire as closeto the windshield(B)as possibleto surfacearoundthe entirewindshieldopening
preventdamageto the body and dashboard. flange:
Carefullycut through the rubber dam and adhesive
( C )a r o u n dt h e e n t i r ew i n d s h i e l d . . Do not scrapedown to the paintedsurfaceofthe
body; damagedpaint will interferewith proper
-A bonding.
\, ,.- . Removethe rubber dam and fastenersfrom the
oooy.
20-20
t5. Glue the side rubber dams (A) and lower rubber 1 4 . G l u et h e m o l d i n g( A ) w i t ha d h e s i v et a p e{ B )
dam (B)with adhesivetape (NITTO501M,or ( 3 M 4 2 1 2 ,o r e q u i v a l e n t ) t toh e u p p e re d g eo f t h e
equivalent).Glue the fasteners(C)with adhesive w i n d s h i e l d( C ) ;
tape (3M 4215,or equivalent)to the insideface of
t h e w i n d s h i e l d{ D )a s s h o w n : . B e s u r et h e a l i g n m e n m t a r k( D )o f t h e m o l d i n g
l i n e su p w i t h t h e a l i g n m e n mt a r k( E )o f t h e
. Be sure the rubber dams and fastenersline uD windshield.
withthealignmenm t a r k s( E ) . . Be carefulnot to touch the windshieldwhere
. Be carefulnot to touch the windshieldwhere a d h e s i v ew i l l b e a p p l i e d .
a d h e s i v ew i l l b e a o o l i e d .
FastenerLocations
A>:Fastener.2 B>:Retainer,2
q\
C > : R e t a i n e r , 6O> : C l i p , 2
(cont'd)
20-21
Glass
WindshieldReplacement(cont'dl
t o . Set the windshieldin the opening,and centerit. 18. With a sponge,apply a light coat of glassprimer
Make alignmentmarks (A) acrossthe windshield aroundthe edge of the windshield(A) betweenthe
and body with a greasepencilat the four points d a m s ( B )a n d m o l d i n g{ C )a s s h o w n ,t h e n l i g h t l y
shown. Be careful not to touch the windshield wipe it off with gauzeor cheesecloth:
w h e r ea d h e s i v ew i l l b e a p p l i e d .
. A p p l yg l a s sp r i m e rt o t h e m o l d i n g .
. Do not apply body primer to the windshield,and
do not get body and glassprimer spongesmixed
up.
. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
w i n d s h i e l dp r o p e r l yc. a u s i n ga l e a ka f t e r t h e
w i n d s h i e l di s i n s t a l l e d .
. Keepwater. dust, and abrasivematerialsaway
from the primed surface.
'l',,1r-
r Applyglassprimerhere.
) - '
1 7 . R e m o v et h e w i n d s h i e l d . G1)'r'
l l
ol
B
,,/ ll\
tl
-A
lnside
20-22
19. With a sponge,apply a light coat of body primer to 21. Packadhesiveinto the cartridgewithout air pockets
the originaladhesiveremainingaroundthe to ensurecontinuousdelivery.Putthe cartridgein a
windshieldopeningflange, Letthe body primer dry caulkinggun, and run a bead of adhesive(A)
for at least 10 minutes: aroundthe edge of the windshield(B) betweenthe
d a m s ( C )a n d m o l d i n g( D )a s s h o w n .A p p l yt h e
. Do not apply glassprimer to the body, and be adhesivewithin 30 minutesafter applyingthe glass
carefulnot to mix up glassand body primer primer. Make a slightlythickerbead at each corner.
sponges.
. Nevertouch the primed surfaceswith your hands.
. l\4askoff the dashboardbefore paintingthe
l'1fifr.,1:
?mm n
flange. in.l
10.28 ,..-
A..
20 mm )t
(0.79in.l
$?I.",x1"u.80.".,
trl
.,r []\"
Inside
- '
"V" c.. N
20. Beforefilling a cartridge,cut a in the end of the \F1
n o z z l e( A )a s s h o w n . 2 m m I 'Zn l
in.}I
{0.08 l
./"
A
12 mm (0.47in.)
U s es u c t i o nc u p st o h o l dt h e w i n d s h i e l do v e rt h e
o p e n i n ga, l i g ni t w i t h t h e a l i g n m e n m
t a r k sm a d ei n
step 16,and set it down on the adhesive.Lightly
p u s ho n t h e w i n d s h i e l du n t i li t s e d g e sa r ef u l l y
s e a t e do n t h e a d h e s i v ea l l t h e w a y a r o u n d .D o n o t
open or closethe doors until the adhesiveis dry.
7 mm {0.27in.)
(cont'd)
20-23
Glass
WindshieldReplacement(cont'd)
23. Scrapeor wipe the excessadhesiveoff with a putty 27. On both sidesofthe windshield,installthe side
knife or towel. To remove adhesivefrom a painted trim (Alto the clip (B),then set the bottom edge of
surfaceor the windshield,wipe with a soft shop the side trim over the cowl cover (C),and align the
towel dampensdwith alcohol. c l i p s( D ) w i t ht h e r e t a i n e r (sE ) ,a n d p u s ho n t h e c l i p
portionsof the trim until the trim is fully seatedon
24. Let the adhesivedry for at least t hour, then spray thewindshield.
water over the windshieldand checkfor leaks.
Mark Ieakingareas,and let the windshielddry, then
seal with sealant:
A: Grey 28. R e i n s t a al l l l r e m a i n i n gr e m o v e dp a r t s .I n s t a l l t h e
B :B l u e
rearviewmirror afterthe adhesivehas dried
thoroughly.
. S l a mt 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 du p .
. 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).
20-24
RearWindow Replacement
NOTE: 6. With a helperon the outside,pull the piano wire (A)
. Put on glovesto protectyour hands. backand Jorthin a sawing motion. Holdthe piano
. Wear eye protectionwhile cuttingthe glassadhesive wire as closeto the rearwindow (B)as possibleto
w i t h p i a n ow i r e . preventdamageto the hatch,and carefullycut
. Use seatcoversto avoid damagingany surfaces. t h r o u g ht h e a d h e s i v e{ C }a r o u n dt h e e n t i r er e a r
. Do not damagethe rearwindow defoggergrid lines
a n dt e r m i n a l s .
1 . Removethese items:
Removethese items:
Cutting positions:
(cont'd)
20-25
Glass
RearWindow Replacement(cont'd)
With a putty kniie. scrapethe old adhesivesmooth 1 1 . G l u et h e s i d eu p p e rf a s t e n e r s( A )a n d s i d e l o w e r
to a thicknessof about 2 mm (0.08in.) on the fasteners{B)with adhesivetape {3M 5312,or
bonding surfacearoundthe entire rear window ) . l u et h e u p p e rr u b b e rd a m s ( C ) w i t h
e q u i v a l e n tG
openingflange: adhesivetape (NITTO501fM,or equivalent)and
glue the lower rubberdam (D)with adhesivetape
. Do not scraDedown to the Daintedsurfaceof the (3M 4216,or equivalent)to the insideface of the
body; damagedpaint will interferewith proper rearwindow (E)as shown. Beforeinstallingthe
bonding lower rubber dam, apply primer (3M N-200,or
. Removethe fastenersfrom the tailqate. equivalent)to the areasbetweenthe alignment
marks {F),then glue the rubber dam on. lf
Cleanthe hatch bonding surfacewith a sponge necessary,glue the spoilerfasteners(G)with
dampenedin alcohol.After cleaning,keepoil, adhesivetape (3M 5671,or equivalent)to the
greaseand water from getting on the surface, outsideface of the rearwindow:
1 0 .lf the old rearwindow is to be reinstalled,use a . Be sure the side upper fasteners,and upper
putty knifeto scrapeoff all of the old adhesive,the r u b b e rd a m s l i n e u p w i t h a l i g n m e n m
t a r k s{ H ,l ) .
fastenersand the rubberdams from the rear . Be sure both ends of the lower rubber dam line
window. Cleanthe insideface and the edge oi the up with the edge of the glass,
rear window with alcoholwhere new adhesiveis to . Be sure the spoilerfastenersline up with
be applied.Make sure the bonding surfaceis kept a l i g n m e nmt a r k s{ J ) .
free of water, oil and grease. . Be carefulnot to touch the rearwindow where
a d h e s i v ew i l l b e a D o l i e d .
: Applyprimerhere.
1,1,.,1,'
E G
"6'J1r-,
20-26
12. Glue the side upperfasteners(A) andsidelower , p p l ya l i g h tc o a to f g l a s sp r i m e r
1 5 . W i t h a s p o n g ea
fasteners(B)with adhesivetape (3M 5312,or along the edge of the rear window (A),upper
equivalent)tothe hatch as shown. rubber dams (B),and lower rubberdam (C)as
shown, then lightly wipe it off with gauzeor
FastonerLocations
cheesecloth:
A>: Fastener,
2 B >: Fastener,
2
. With the printeddots (D) on the rearwindow as a
cl
T-8. ar\\
itf,
guide, apply the glassprimer to both side
portionsof the rearwindow.
. Do not apply body primer to the rearwindow,
and do not get hatchand glass primer sponges
m i x e du p .
. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the rear
window properly.causinga leak afterthe rear
w i n d o wi s i n s t a l l e d .
. Keepwater, dust, and abrasivematerialsaway
from the primed surface.
.. : Applyglasspiimer here.
1 4 . R e m o v et h e r e a rw i n d o w .
(cont'd)
20-27
Glass
RearWindow Replacement(cont'd) I
1 6 .With a sponge,apply a light coat of body primer to 18. Packadhesiveinto the cartridgewithout air pockets
t h e o r i g i n aa
l d h e s i v er e m a i n i n ga r o u n dt h e r e a r to ensurecontinuousdelivery.Putthe cartridgein a
window openingflange. Letthe body primer dry for caulkinggun, and run a bead of adhesive(A)
at least 10 minutes; aroundthe edge of the rearwindow (B)as shown.
With the glassprimer (C)you appliedin step 15 as
. Do not apply glassprimer to the body, and be a guide,apply the adhesiveto both side portionsof
carefulnot to mix up glassand body primer the rearwindow.
sponges. Apply the adhesivewithin 30 minutesafter
. Nevertouch the primed surfaceswith your hands. applyingthe glassprimer. fMakea slightlythicker
',,,,,': Applybodyprimerhe.e. bead at each corner.
12 mm r,
10.47in.) ,\
A
ii'-
(0.28in.l
20 mm
in.l
10.79
\
2mm
{0.08in.)
aru'.1{-----"
7 mm (0.27in.)
20-28
OuarterGlassReplacement
19. Use suctioncups to hold the rearwindow over the NOTE:
opening.align it with the alignmentmarks you . Put on glovesto protectyour hands.
'13, . Wear eye protectionwhile cuftingthe glassadhesive
made in step and set it down on the adhesive.
Lightlypush on the rearwindow until its edgesare with piano wire,
fully seatedon the adhesiveall the way around.Do . Use seatcoversto avoid damagingany surfaces.
not open or closethe doors until the adhesiveis dry.
1 . R e m o v et h e C - p i l l atrr i m ( s e ep a g e2 0 - 5 1 ) .
20. Scrapeor wipe the excessadhesiveoff with a putty lf necessary,removethe rear side trim panel (see
knife or towel. To removeadhesivefrom a painted page 20-51) and B-pillarupper trim (seepage 20-
surfaceor the rearwindow, use a soft shop towel 50).
dampenedwith alcohol.
2. Removethe front seal {A) from the front edge of the
21. Letthe adhesivedry for at least 'l hour,thenspray glass (B).lf necessary,cut the seal with a utility
water over the rear window and checkfor leaks. knife.
Mark the leakingareas,let the rear window dry,
then sealwith sealant.Let the vehiclestandfor at
least4 hours after rearwindow installation,lf the
vehiclehas to be used within the first 4 hours,it
must be driven slowly.
2 2 . R e i n s t a l l a lrle m a i n i n gr e m o v e dp a r t s .
. S l a mt 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 du p .
. 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).
(cont'd)
20-29
Glass
OuarterGlassReplacement(cont'dl
3 . Apply protectivetape to along the insideand 6 . With a putty knife,scrapethe old adhesivesmooth
outsideedgesof the body. Using an awl, make a to a thicknessof about 2 mm (0.08in.) on the
hole through the adhesivefrom insidethe vehicle. bonding surfacearoundthe entirequaner glass
Pusha pieceof piano wire through the hole, and o p e n i n gf l a n g e :
wrap each end around a pieceof wood.
. Do not scrapedown to the paintedsurfaceof the
With a helperon the outside,pull the piano wire (A) body; damagedpaint will interferewith proper
backand forth in a sawing motion. Holdthe piano bonding
wire as closeto the quarterglass(B) as possibleto . Removethe clips from the body.
preventdamageto the body, and carefullycut
through the adhesive(C)aroundthe entirequarter 7 . Cleanthe body bondingsurfacewith a sponge
grass. d a m p e n e di n a l c o h o lA
. f t e rc l e a n i n gk. e e po i l ,
greaseand water from getting on the surface.
Cuttingpositions:
5. Carefullyremovethe quarterglass.
20-30
9. Set the quarterglass(A) in the opening,and center 11 . A l i g nt h e u p p e rc l i p { A )a n d l o w e rc l i p ( B )w i t h t h e
i t . F r o mi n s i d et h e v e h i c l e m
, a k ea n a l i g n m e n mt ark edge of the quarter glass(C),then anachthem with
(B)to the quarterglasswhere the rear clip will be adhesivetape (NITTO571,or equivalent)to the
installedwith a greasepencil.Be careful not to insideface of the quarter glass,and align the center
l o u c ht h e g l a s sw h e r ea d h e s i v ew i l l b e a p p l i e d . of the rearclip (D)with the alignmentmark (E)you
made in step 9, and attach it with adhesivetape (3
M 4215,or equivalent)to the insideface of the
quarterglassas shown. Be carefulnot to touch the
glasswhere the adhesivetape will be applied.
25.5mm
{ 1 . 0i n . )
(cont'd)
20-31
Glass
OuarterGlassReplacement(cont'dl
Firstglue the front seal (A)with adhesivetape {31\4 '13.
With a sponge,apply a light coat of glassprimer
) .n d g l u et h e r u b b e rd a m ( B )
4 2 1 3 ,o r e q u i v a l e n t a along the edge of the rubber dam (A) and front seal
with adhesivetape (NITTO501M,or equivalent)to (B)as shown, then lightly wipe it off with gauzeor
the insldeface of the quarterglass(C)as shown. cheesecloth:
Beforeinstallingthe front seal and rubber dam,
a p p l yp r i m e r( 3 M N - 2 0 0 o, r e q u i v a l e n t ) t toh e i n s i d e With the printeddots (C)on the quarterglass(D)
tace of the glass.then glue the seal on: as a guide, apply the glass primer to the upper
and lower corner ponions of the quarterglass.
. Be sure the front seal lines upwiththe bottom Do not apply body primer to the quaner glass,
and front edgesof the glass. and do not get body and glassprimer sponges
. Be careful not to touch the glasswhere adhesive m r x e du p .
will beaoolied. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
.,1.,,/:/| Apply prlJnerhete.
quarterglassproperly,causinga leak afterthe
quarterglassis inslalled.
Keepwater, dust, and abrasivematerialsaway
30 mm from the primed surface.
-"-c 1 1 . 1i8n . l
50 mm I
{1.97in.1
/
\ t
nL
v - -
i--l
'100mm
{3.9i1in.)
45 mm
{ 1 . 7 7i n . }
6 mm (0.24in.) 3.5 mm
{0.r4 in.l
1 1m m
lo.i(} in.)
20-32
14, With a sponge.apply a light coat of body primer to 16. Packadhesiveinto the cartridgewithout air pockets
l d h e s i v er e m a i n i n ga r o u n dt h e q u a r t e r
t h e o r i g i n aa to ensurecontinuousdelivery.Putthe cartridgein a
glassopeningflange.Let the body primer dry for at caulkinggun, and run a bead of adhesive(A)
least 10 minutes: around the edge of the rubber dam (B) as shown.
W i t h t h e g l a s sp r i m e r( C ) y o ua p p l i e di n s t e p 1 3 o n
. Do not apply glass primer to the body, and be the quarterglass (D)as a guide. apply the adhesive
carefulnot to mix up glassand body primer to the upper and lower corner portionsof the
sponges. quarterglass.Apply the adhesivewithin 30
. Nevertouch the primed surfaceswith your hands. minutesafter applyingthe glass primer. lvlakea
slightlythickerbead at each corner.
)'/ii,/ii. I Apply bodv prime. here,
20 mm
mm
(0.08in.l
(0.79in.) l.:J611,
;\
2mm 7mm
{0.08in.) {0.28in.)
3mm
{ 0 . ' 1 2i n . }
I
A
20 mm
{0.79in.)
'10mm (0.39in.)
7 mm 10.27in.)
( c o n l ' d)
20-33
Glass
OuarterGlassReplacement(cont'd)
17. Use suctioncups (A)to hold the quarterglassover
the opening.align it with the clips (B)and set it
down on the adhesive.Lightly push on the quarter
glass until its edges are fully seatedon the
adhesiveall the way around.Do not open or close
the doors untilthe adhesiveis drv.
20-34
Moonroof
ComponentLocationIndex
GLASS
HeightAdjustment,page 20 37
Replacement, paqe 20-37
C l o s i n oF o r c ea n d O o e n i n" oD r a o
Check;page20-48
DRAINCHANNEL
page20-39
Replacement,
COVER
/,BR^CKEI
,5
_-""-\\q @?a<&,
..t'- ? LIMITSWITCH
@ (AUTO.STOPSWITCH)
-@c
.@
page20-46
Adjustment,
E R
I _a
WIND DEFLECTOR
page20-38
Replacement,
CABLETUBE
REARBRACKET
E
@
E STOP
.a'
CABLEASSEMBLY
Beplacement,page20-44
page20'41
Replacement,
gJ
-.- REARDRA'N TUBE
*\
MOONROOF
CONTROLUNIT
)
REARDRAIN VAI-VE
FRAME
page 20-42
Replacement,
20-35
Moonroof
Symptom TroubleshootingIndex
'1. Gl a s sh e i g h t
Water leaks Checkfor a cloggeddrain tube.
2. Checkfor a gap betweenthe glassweatherstripand the roof adJustment
panel.
3. Checkfor a defectiveor an improperlyinstalledglass
p r d r a i nc h a n n e l .
w e a t h e r s t r io
4. Checkfor a gap betweenthe drain seal and the roof panel.
20-36
GlassHeightAdjustment GlassReplacement
The roof panel (A) should be even with the glass 'L
C l o s et h e g l a s sf u l l y .
weatherstrip(B).to within 2*0.5/ 1 mm (0.08+0.02l
0.04 in.) all the way around.lf not, make the following S l i d et h e s u n s h a d ea l l t h e w a y b a c k .
adjustment:
Removethe screws (A),then remove both bracket
B covers (B).Removethe nuts (C)and shims {D)from
both glassbrackets(E).
2 + 0.5/ 1mm FastengrLocations
{0.08+ 0.02/-0.0i1in.}
A } : Screw, 2 c O ,Nut. il
@
E
\o
2. L o o s e nt h e n u t s{ A ) ,a n d i n s t a l l t h es h i m s( B )
betweenthe glassframe (C)and glass bracket(D)
on each side.
6x1.0mm
9 N.m {0.9kgf.m,7 lbf.ft}
Shim ihickness: Front and rear max. 2 mm 10.08in.l
4. Removethe glass{A) by lifting it up. Do not
B damagethe roof panel.
Forward
A
6x1.0mm
I N.m(0.9kgf.m,7lbt.ft)
20-37
Moonroof
Wind DeflectorReplacement
1 . O p e nt h e g l a s sf u l l y . 3. Installthedeflector(A) in the reverseorder of
removal,and checkthat lhe deflectorarm base (B)
2 . Removethe screws(A, B), and releasethe hooks and deflectorlink pivot base (C)line up with the
(C),then removethe wind deflector(D). s a m ea l i g n m e n lti n e s( D ) .l f n e c e s s a r ya,d j u s t h e m
forward or backwardso the edge of the deflector
Fastener Locations seal (E)touchesthe roof panel (F)evenly.Each
A>:Screw,2B>: Screw, 2 base must be moved the same amount for
adjustment.lf the deflectorseal and roof panel
make a rubbing sound, move the deflector
backwardas necessaryto positionit properly.
4il mm
( 1 . 7i n . )
_ - l
' a -- ' -
20-38
DrainChannelReplacement
1 . Removethe moonroof glass(seepage 20-37). 4 . R e m o v et h e d r a i nc h a n n e (l A ) .
FastenerLocations
) : Screw,2
I n s t a l l t h ec h a n n e il n t h e r e v e r s eo r d e ro f r e m o v a l ,
and notethese items:
P u s ht h e d r a i nc h a n n e o
l n t ot h e h o o k su n t i la
faint click is heard.
Checkthe glass height adjustment(seepage 20-
Releasethe drain channel(A)from both hooks{B) 31).
o f t h e d r a i nc h a n n e sl l i d e rb y p u l l i n gt h e d r a i n
channelforward, Checkfor water leaks.Letthe water run freely from
a hose without a nozzle.Do not use a high-pressure
spray.
20-39
Moonroof
SunshadeReplacement
1 . R e m o v et h e d r a i nc h a n n e l . 4. While liftingthe front portionofthe sunshade(A),
move the sunshadeforward until you can see both
Slidethe sunshade(A) until you can see both s u n s h a d er e a rh o o k s( B ) .D o n o t d a m a g et h e
s u n s h a d es l i d e rs p a c e r s( B ) . s u n s h a d ea n d h o o k s .
FastenerLocations FastenerLocations
> : Screw,4 ) : Screw,4
tF (F
3. Removethe screws,then remove both spacers. 5. Removethe screws,then remove both hooks.
20-40
Motor Replacement
6. Removethe sunshade(A), 1 . Removethe headliner(seepage 20-54).
..
{0.9kgf.m.
7 rbf.ftl
8 . I n s t a l l t h es u n s h a d ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
and checkthe glassheight adjustment(seepage
20-37).
20-41
Moonroof
Frameand DrainTubeReplacement
1 . Removethese items:
. Headliner(seepage 20-54)
. Moonroof glass(seepage20-37)
> : Bolt,10
{um
irl
/^
6x1.0mm
9.8N.m
(1.0kgf.m,7.2lbfft)
4 . With an assistantholdingthe frame (l). removethe bolts,startingat the rear,and releasethe rear hooks (J) by
moving the f rame forward,then removethe frame.
5 . With the help of an assistant,carefullyremovethe frame through the passenger'sdoor opening.Takecare not to
scratchthe interiortrim and body, or tear the seat covers.
20-42
6. To removea front drain valve (A)from the body, 8 . I n s t a l l t h ef r a m ea n d d r a i nt u b e i n t h e r e v e r s eo r d e r
removethe kick panel,left or right (seepage 20-50). of removal,and note these items:
Tie a string to the end of the drain tube, then pull
the front drain tube (B)down out of the front pillar. . B e f o r ei n s t a l l i n g
t h e f r a m e ,c l e a rt h e d r a i nt u b e s
and drain valves using compressedair.
. Checkthe frame seal.
. C l e a nt h e s u r f a c eo f t h e f r a m e .
. When installingthe frame, first attachthe rear
hooks into the body holes.
. Make sure the connectorsare plugged in
properly.
. When connectingthe drain tube, slide it overthe
f r a m en o z z l ea t l e a s t1 0 m m ( 0 . 3 9i n . ) .
.Installthetubeclip(A o )n t h e d r a i nt u b e( B )a s
shown.
20-43
Moonroof
DrainChannelSliderand CableAssemblyReplacement
1. Removethe frame (seepage 20-42). 5 . P i v o t t h eg l a s sb r a c k e (t A )d o w n b y s l i d i n gt h e l i n k
lifter (B) back,then slide both glassbracketsback
2. Removethese partsfrom the frame: with the link lifter.
. Sunshade(seepage 20-40)
. Moonroof motor (seepage 20-41)
FastenerLocations
A> rScrew.2 B): Screw,2 E > : B o l t , 2
@ @
r): Screw S l i d et h e c a b l ea s s e m b l y( A )a n d b o t hg l a s s
6\-'1 brackets(B) back,then removethem from the
f r a m e( C ) .
Position switch side:
6x1.0mm
A c g , aN . m
No switch sidel
o 6x1.0mm C
9.8 N.m
B 11.0kgf.m,7.2 lbf.ft)
V
20-44
7 . R e m o v et h e d r a i nc h a n n e sl l i d e r ( A )f r o m t h e g l a s s 8 . I n s t a l l t h es l i d e ra n d c a b l ea s s e m b l yi n t h e r e v e r s e
bracket(B). o r d e ro f r e m o v a l a, n d n o t et h e s ei t e m s ;
. D a m a g e dp a r t ss h o u l db e r e p l a c e d .
' Apply multipurposegreaseto the glassbracket
( A )a n d g u i d er a i lp o r t i o no f t h e f r a m e ( B )
indicatedby the arrows.
. Beforereinstallingthe motor, make sure both
l i n kl i f t e r sa r e p a r a l l e la, n d i n t h e f u l l y c l o s e d
position.
. Beforereinstallingthe motor, installtheframe
a n d g l a s s t, h e nc h e c kt h e o p e n i n gd r a g ( s e ep a g e
20-481.
B ---
\ -':rdrt'Irrt
\ fl u,t L-
----lll
a/J' I ll
l$=-r:-
20-45
Moonroof
Limit Switch Adjustment
1. Removethe headliner(seepage 20-54).
Fullyclosedpositionadiustment
2. With the moonroof wrench,closethe glass(A) fully:
5x0.8mm
5 N.m {0.5kgf.m,4lbf.ft)
3 . W i t h a n o p e n - e n dw r e n c h ,l o o s e nt h e l i m i ts w i t c hm o u n t i n gb o l t s( C ) .
' Move the switch plate (E)a little at a time, then secureit atthe positionwhere you hear a faint clickwhen
the
switch cam (F) pushesthe positionswitch (open/close).
. Checkthat the switch plate contactsthe switch bracket(G).
20-46
Auto-stop position adiustment
5. With the moonroofwrench.operatethe glass(A)to the auto-stopposition.
/--:.!Jtr+rtl
\_-_:_t+#1 <F
. / \
, / \
G i! .. I
. N 4 o v e t h se w i t c hp l a t e( E )a l i t t l e a t a t i m e , t h e n s e c u r e i t a t t h e p o s i t i o n w h e r e y o u h e a r a f a i n t c l i c k w h e n t h e
switch cam (F)pushesthe switch (auto-stop).
. Checkthat the switch platecontactsthe switch bracket(G).
8 . Checkthe operationof the glassby operatingthe moonroof switch:From the tilt-up positionto the fully closed
position,from the fully open positionto the auto-stopposition,from the auto-stoppositionto the fully closed
posltron.
L Checkfor water leaks.Letthe water run fleely from a hosewithout a nozzle.Do not use a high-pressurespray
20-41
Moonroof
ClosingForceand OpeningDragCheck
1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) . 4. Openingdrag check:Protectthe leadingedge of the
glasswith a shop towel (A).Measurethe effort
2. Closingforce check: requiredto open the glass using a spring scale(B)
as shown.
. With a shop towel {A) on the leadingedge of the
g l a s s( B ) ,a f t a c ha s p r i n gs c a l e( C )a s s h o w n .
. Havean assistanthold the switchto closethe
glasswhile you measurethe force requiredto
stop it.
. Readthe force as soon as the glassstops moving,
then immediatelyreleasethe switch and spring
scale.
20-48
InteriorTrim
ComponentLocationIndex
HATCHLOWERTRIM PANEL
oaoe20-53
HATCHSIDETRIM
page20 53
B.PILLARUPPEBTRIM
page20-50
TRIM
C-PILLAR
page20'51
DOOROPENINGTRIM
page20-50
A.PILLARTRIM
page20-50
R e m o v a l / l n s t a l l a t ipoang, e2 0 5 4
KICKPANEL
page20 50
Replacement,
page20-55
DOORSILLTRIM
page20-50
CARGOAREA FLOOR
page20-52
REARSIDESHELF
page20 5l
REARCENTERSHELF
page20-51
REARSIDETRIM PANEL CARGOFLOORMAT
page20-51 page20-52
REARTRIM PANEL
page 20-52
20-49
InteriorTrim
Trim Removal/lnstallation- Door Area
NOTE:
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Takecare not to bend or scratchthe trim and panels.
1 . R e m o v et h e t r i m a s s h o w n .T o r e m o v et h e d o o r s i l l t r i m a n d B - p i l l a ur p p e rt r i m , r e m o v et h e r e a rs i d et r i m p a n e l
as necessary(seepage 20-51).
. Replace a n y d a m a g e dc l i p s .
. Apply liquid thread lockto the anchor bolts before reinstallatior,.
. Beforeinstallingthe anchorbolts, make sure there are no twists or kinks in the belts.
FastenerLocations
A>: Clip,2 B > r C l i p , 3 C > : C l i p , ?
(Black) {White)
FRONTSEATBELT
2ffi ,"lF
\r{ UPPER ANCHORBOLT
Tl|t 7/16-20UNF
32 N m (3.3kgf m,24 lbf.ft)
A-PILLARTRIM
il-::7
KICKPANEL
ao----- LowERANcHoRcAP
/
FRONTSEAT BELTLOWER
ANCHORBOLT
7/16-20UNF
32 N.m (3.3kgt.m,24lbl.ftl
REARSIDETRIM PANEL
20-50
Trim Removal/lnstallation- RearSideArea
NOTE:
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Takecare not to bend or scratchthe trim and panels.
'1.
To removethe rear side trim panel,removethese items:
. Replace a n y d a m a g e dc l i p s .
. Make sure the cargo compartmentlight connectoris pluggedin properly.
. l f t h e t h r e a d s o n t h e r e a r s i d e t r i m p a n e lm o u n t i n gs e l f - t a p p i nEg Ts c r e w sa r ew o r n o u t , u s ea n o v e r s i z e sd e l f -
t a p p i n gE T s c r e w( P / N9 0 1 3 7 - S 1 A - E1o)1m a d es p e c i f i c a l lfyo r t h i s a p p l i c a t i o n .
. W h e ni n s t a l l i n g t h e r e a rs i d es h e l f ,s l i pt h e r e a rs e a tb e l tt h r o u g ht h e s l i t i n t h e t r i m .
' A p p l y i i q u i dt h r e a dl o c k t ot h e a n c h o rb o l t sb e f o r er e i n s t a l l a t i o n .
. Beforeinstallingthe anchorbolts,make sure there are no twists or kinks in the belt.
Fasten€r Locations
A>:Clip,11 B> rClip,2 c>rClap,l
-..:.:'
TRIM
S I D ES H E L F
REARSEATSELT
SIDETRIM PANEL
SEAT
STRIKERCAP
S I L LT R I M
SELF-TAI
scREws
5x0.8mm
{ 0 . 4k g f m , 3 l b f . f t )
.. F . -\ *: : :- . n: \
,/\ I FRONTSEAT AELT
\*J REARSEAT BELTLOWER \
LOWERANCHORBOLT
,/ ANCHOF BOLT
7/16-20UNF
\
\
7/16-20UNF
32 N.m
R E A RB U L K H E A O { 3 . 3k g f m , 2 4 l b t . t t )
COVER REARSPEAKERCOVER 32 N m (3.3 kgf m, 24 lbf ft, \
L O W E RANCHORCAP
20-51
lnteriorTrim
- CargoFloorArea
Trim Removal/lnstallation
NOTE:
. Put on glovesto protectyour hands.
. When jrying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage'
. Takecare notto bend or scratchthe trim and panels.
( s e ep a g e2 3 - 1 1 ) '
1 . T o r e m o v et h e r e a rt r i m p a n e l ,r e m o v et h e c h i l ds e a tt e t h e ra n c h o r
, n d r e p l a c ea n y d a m a g e dc l i p s '
3 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
Fastener Locations
A > :C l i p , 3 B > : C l i p . 4
j-=
E T r
\t
FLOORMAT
COVER
REARSEAT-BACK
-t
CARGOAREA FLO
7
To rearsade
trim panel.
To rearsidetrim
panel.
REARTBIM PANEL
20-52
Trim Removal/lnstallation- HatchArea
NOTE:
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Takecare not to bend or scratchthe trim and panels.
. Hatchuppertrim panel
. Left hatchside trim
. Righthatchside trim
. Hatchlower trim panel
, n d r e p l a c ea n y d a m a g e dc l i p s .
2 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
Fastener Locations
o>
A>;crip,a B>:crip,2 .>,l,l,Jil,l3 E>:crip.2
3il;1,
"-{q .1
\. n l f nl t
gg itr^
Y,]
O HATCHLowER TRrM
PANEL
HATCHLOWERTRIMPANEL
a- ,,) I
t7,
f.
) a =- -1 a ->
.D HATCHUPPERTRIM PANEL
HATCH UPPERTRIM PANEL
HATCHSIDETRIM
20-53
InteriorTrim
HeadlinerRemovaUlnstallation
NOTE: 3. From both rear passenger's,removethe caps (A),
. When prying with a flat-tip screwdriver,wrap itwith and removethe screws,then removethe grab
protectivetape to preventdamage. h a n d l e s( B ) .
. Takecare not to bend and scratchthe headliner.
. Be carefulnot to damagethe dashboardand other FastenerLocations
interiortrim. > : Screw,4
FastenerLocations
> : Screw,4
r(\'-r
\)*
5x0.8mm
5 N.m
{0.5kst m.4lbf ft}
20-54
CarpetReplacement
4. Removethe headliner. SRScomponentsare locatedin this area.Reviewthe
SRScomponentlocations(seepage 23-13)and the
-1 Removethe socketplug (A). precautionsand procedures(seepage23-14)in the SRS
- 2 R e m o v et h e r e m a i n i n gd o o r o p e n i n gt r i m { B } sectionbefore performingrepairsor service.
from each roof portion.
-3 Detachthe clips (C),and releasethe fasteners NOTE:
( D )b y p u l l i n gt h e f r o n t p o r t i o no f t h e h e a d l i n e r . Put on glovesto protectyour hands.
(E)down. . Takecare not to damage,wrinkle. or twist the carpet.
-4 With the help of an assislant,releasethe clips . Be carefulnot to damagethe dashboardor other
(F)of the headlinerfrom the moonroof frame interiortrim pieces.
( G ) ,a n d r e l e a s et h e h e a d l i n efrr o m t h e c l i p s( H )
by slidingthe headlinerforward, and lowering 1. Removethese items:
the headliner.
-5 Removethe headlinerthrough the passenger's . Frontseats,both sides(seepage 20-111
opening. . Driver'sdashboardunder cover (seepage 20-60)
. Passenger'sdashboardIower cover (seepage
FastenerLocations 20-631
C>:Clip,3 F>:Clip,2 H>:Clip,2 . Rearseatcushion(seepage 20-80)
. Kick panels,both sides(seepage 20-50)
a
o . Door silltrim, both sides(seepage 20-50)
. Consoles,front and rear (seepage20-57)
2 . R e m o v et h e n u t ( A ) ,a n d u s i n ga h e xw r e n c h ,
releasethe clip (B),then removethe footrest(C).
FastenerLocations
Aa:Nut,1 B):Clip,'l
--'1
I
--\ -JrL
tj=\-/I ;tt4f
l[il
A
6x1.0mm
9.8Nm
5 . Installthe headlinerin the reverseorder of removal, 11.0kgf m,7.2 lbf.ft)
and note these items:
-o
. 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
passenger'sdoor opening,be carefulnot to fold
or bend it, Also, be carefulnot to scratchthe
DOOy.
. C h e c kt h a t b o t hs i d e so f t h e h e a d l i n ear r e
securelyattachedto the trim.
. R e p l a c ea n y c l i p st h a t r e m a i ni n t h e r o o f d u r i n g
r e m o v a lR. e i n s t a l l t h cel i p sb a c ki n t h e h e a d l i n e r
before installation.
(cont'd)
20-55
InteriorTrim
CarpetReplacement(cont'dl
Using a utility knife,cut the carpet(A) underthe 5. Installthecarpetin the reverseorder of removal,
heaterareas(B),and cut out the parkingbrakelever and note these items:
area (C)as shown, then pull backthe carpet.
. T a k ec a r en o t t o d a m a g e w , r i n k l e ,o r t w i s t t h e
A B
carpeL
. Make sure the seat harnessesare routed
correctly.
. S l i pt h e c a r p e tu n d e rt h e r e a rs i d et r i m p a n e lo n
each side properly.
. Replace t h e c l i p i f i t ' sd a m a g e d .
. Reattachthe cut areasunder the heateraround
the parkingbrakelever with a wire tie.
. When installingnew carpet,cut the carpet(A)
underthe heaterareas(B),and around the
parkingbrakelever (C).After installingthe new
carpet,slip the carpetfrom the driver's and
passenger'sside through the spacebetweenthe
heaterunit and body, and reattachthe cut area
{C)around the parkingbrakeleverwith wire ties.
FastenerLocation
A >: Clip.1
tr
&z
20-56
Consoles
Console,Frontand RearRemoval/lnstallation
NOTE:Takecare not to scratchthe front seal, 2. Removethe front console(A).
dashboard,and relatedparts.
- 1 P u l lo u t t h e d a s h b o a r dc e n t e rl o w e rc o v e r{ B )
1 . R e m o v et h e r e a rc o n s o l e( A ) . to detachthe clips (C).
-2 Dlsconnectthe accessorypower socket
-1 Slidethe front seatforward fully on each side. c o n n e c t o(rD ) .
-2 Removethe screws{B)from the rear portionof 3 R e m o v et h e c o n s o l eb o x m a t ( E ) .
the rearconsole, - 4 R e m o v et h e b o l t s( F ) ,s c r e w s( G ) ,a n d c l i p s( H ) .
-3 Slidethe front seat rearwardfully on each side. -5 Gently pull out the front consoleto releasethe
- 4 P u l l t h ef r o n t p o r t i o no f t h e r e a rc o n s o l eu p t o h o o k s( l ) a n dp i n s ( J ) .
detachthe clips (C)and hooks (D),then release
the rearconsolefrom the front console(E). FastenerLocations
- 5 S t a r t i n ga t t h e r e a r ,p u l l t h e r e a rc o n s o l eu p , C > : C l i p , 3 F > i B o l t , 2 G > : S c r e w . 2H ) : C l i p , 2
then remove it.
*..4-
' * q ' 4!--
J - L } * fF-
J \ . / -,-('E9'/
d
FastenerLocations
B >:Screw,2 C >: Clip,2
6x1.0mm
98Nm
(1.0kgt.m,7.2lbf.ft)
. R e p l a c ea n y d a m a g e dc l i p s .
. Make sure the accessorypower socketconnector
i s p l u g g e di n p r o p e r l y .
. P u s ht h e c l i p si n t o p l a c es e c u r e l y .
20-57
Consoles
Front ConsoleDisassembly/Reassembly
NOTE;Takecare not to scratchthe consoleand relatedparts.
Fastener Locations
):Screw,8
C*
FRONTCONSOLE
\ a
BEVERAGE
HOLDER
ASSEMBLY
,/
',/
BOX
CONSOLE
20-58
Dashboard
InstrumentPanelRemoval/ Driver'sDashboardLower Cover
Installation Removal/lnstallation
FastenerLocations
B> : c l i p . 2 D D:,C l i p , 2
^*,
20-59
Dashboard
Driver'sDashboardUnderCover Driver'sPocketRemoval/
Removal/lnstallation lnstallation
20-60
Shift LeverTrim Removal/lnstallation
NOTE: 4. Pull outthe shift levertrim (A) by hand to release
. Takecare not to scratchthe dashboardand related t h e r e m a i n i n gc l l p s( 8 , C ) a n d h o o k s( D ) ,a n d
parts. disconnectthe hazardwarning switch connector(El,
. Put on glovesto protectyour hands. then removethe trim.
,,.;w,
1. Removethe glove box (seepage20-63). FastenerLocations
B >:Clip,1 C > : C l ; p1, D>: Hook,3
2. Removethe shift knob.
, ,
U s i n ga r a t c h ew
t r e n c ha n d a n 1 1 i n c he x t e n s i o n
(A)wrapped with a shop towel (B),carefullyinsert
the extensionthrough the glove box opening,and Installthe trim in the reverseorder of removal,and
push the shift levertrim (C)from underthe trim to note these rtems.
releasethe clips (D)and hooks (E)of the left side.
. Make sure the hazardwarning switch connectot
Fastener Locations is plugged in properly.
D>clip,2 E> H o o k , 2 . Pushthe clip and hook portionsinto place
.-a7 securely,
i:F \r-
t1
\V u
20-61
Dashboard
DashboardCenterPanelRemoval/lnstallation
NOTE: 4. Pull out the centerpanel (A)to releasethe clips (B)
. Put on glovesto protectyour hands. and hooks (C),and removethe harnessholder (D)
. When prying with a flat-tipscrewdriver,wrap it with from the bracket(E).Disconnectthe audio unit
protectivetape, and apply protectivetape around the connector(F),antennalead (G),heaterswitch
relatedparts,to preventdamage. connector(H)and heatercontrol unit connectors(l).
. Takecare not to scratchthe dashboardand related
parts. FastenerLocations
B ): Clip,8
1. Make sure you have the anti-theftcode for the radio, *4
the write down the frequenciesfor the preset
, F
buttons.
2 . Removethese items:
20-62
Passenger's
DashboardLower GloveBox Removal/lnstallation
CoverRemoval/lnstallation
SRScomponentsare locatedin this area.Reviewthe
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a) n dt h e
NOTE:Takecare not to scratchthe dashboardand p r e c a u t i o nasn d p r o c e d u r e (ss e ep a g e2 3 1 4 )i n t h e S R S
relatedparts. sectionbeforeperformingrepairsor service.
-1 Gently pull down the rear edge to releasethe 1. Removethe passenger'sdashboardlower cover.
c t i p s( B ) .
-2 Pullthe cover away to releasethe pins (C)from 2. While holding the glove box (A),removethe glove
t h e h o l d e r s( D ) . box stop (B)on each side.
FastenerLocations FastenerLocalions
B>: Clip,3 >Boh.2
.-6\
A
I jl
.-<,/fir-"b
{Ill
tJ
r-3t.oi,t-'
10.5kgf m,
4 tbf.ft)
Installthe under cover in the reverseorder of Removethe bolts,then removethe glove box.
removal,and push the clip ponions into place
securety. 4 . l n s t a l l t h eg l o v eb o x i n t h e r e v e r s eo r d e ro f
removal.
20-63
Dashboard
DashboardSide Vent RemovaU BeverageHolderRemoval/
Installation lnstallation
NOTE: NOTE:
. Takecare not to scratchthe dashboard. . Takecare not to scratchthe dashboard,
. Put on glovesto protectyour hands. . Put on glovesto protectyour hands.
FastenerLocations
3. Removethe screws,then removethe air duct (A)
f r o m t h e d a s h b o a r d( B ) . ):Screw.2
FastenerLocations
):Screw, 7
6hD
t
4 . Remove the screws, lhen remove the slde vent (A). 3 . Installthe beverageholder in the reverseorder of
removat.
Fastener Locations
):Screw,4
5 . l n s t a l l t h es i d ev e n t i n t h e r e v e r s eo r d e ro f r e m o v a l .
20-64
Driver'sTray Removal/lnstallation Passenger's Tray Removal/
Installation
NOTE:
. Takecare not to scratchthe dashboard.
. Put on glovesto protectyour hands. NOTE:
. Takecarenotto scratchthe dashboard.
1. Removethe dashboard(seepage 20-66). . Puton glovesto protectyourhands.
FastenerLocations
):Screw, 8
20-65
Dashboard
DashboardRemoval/lnstallation
SRScomponentsare locatedin this area.Reviewthe 4. From the centerpanelopening,removethe screws,
SRScomponentlocations(seepage23-13)and the then removethe centerbracket(A).
precautionsand procedures(seepage23-14)in the SRS
FastenerLocations
sectionbeforeperformingrepairsor service.
):Screw,2
NOTE:
. When prying with a flat-tipscrewdriver,wrap it with
protectivetape, and apply protectivetape aroundthe
relatedpartsto preventdamage.
. Havean assistanthelp you when removing and
installingthedashboa rd.
. Takecare not to scratchthe dashboard,body, and
other relatedparts.
. Put on glovesto protectyour hands.
20-66
Driver's side: Middle portion:
Passenger'sside:
1 0 . D e t a c ha l l o f t h e h a r n e s sa n d c o n n e c t ocr l i p s .
(cont'd)
20-67
Dashboard
DashboardRemoval/lnstallation SteeringHangerBeam
(cont'd) Replacement
11. From outsidethe driver'sdoor, removethe caps (A), NOTE:Put on glovesto protectyour hands.
then removethe bolts (8, C, D),and lift up on the
dashboard(E)to releaseit from the guide pins 1, Removethe dashboard(seepage 20-66).
(F.G) on the body.
2. Removethese items from the dashboard:
FastenerLocations
B>rBolt.3 C>: Bolt,2 D>: Bolt,2 . lnstrumentpanel (seepage 20-59)
. Driver'spocket(seepage20-60)
m6[-,,,,",",,-,F6't---''
v{/- ffi'!-- . G a u g ea s s e m b l y( s e ep a g e2 2 - 6 4 )
Kr* w- . Passenger'sairbag(seepage 23-'l14)
20-68
4. Removethe bolts (A) and screws(B)securingthe 5 . I n s t a l l t h eb e a mi n t h e r e v e r s eo r d e ro f r e m o v a l ,
d a s h b o a r d( C )a n d s t e e r i n gh a n g e rb e a m( D ) ,a n d and note these items:
disconnectthe power mirror switch connector(E)
and cruisecontrol main switchconnector(F). . N 4 a kseu r et h e d a s h b o a r dw i r e h a r n e s s( G ) i s n o t
S e p a r a t et h e d a s h b o a r da n d s t e e r i n gh a n g e rb e a m . pinched.
. Make sure the connectorsare plugged in
FaslenerLocations properly.
A>rBolt,4 B>:Screw,9
20-69
Seats
ComponentLocationIndex
REARSEAT
page20-80
Removal/lnstallation,
Seat-backLatchReplacement,
page20-81
Seat-backStrikerReplacement,
page20-81
Seat'backCoverReplacement,
page 20-82
SeatCushionCoverReplacement,
page20-84
FRONTSEAT
page20-i 1
Removal/lnstallation,
page20 73
Disassembly/Reassembly-Driver's,
page20-74
Disassembly/Reassembly-Passenger's,
SeatCoverReplacement,page20-75
20-70
Front Seat Removal/lnstallation
For some models:SRScomponentsare locatedin this 4. Removethe bolts securingthe front seat.
area.Reviewthe SRScomponentlocations(seepage
23-'13)and the precautionsand procedures(seepage FastenerLocations
23-14)in the SRSsectionbefore performingrepairsor > : Bolt,
service.
NOTE
. When prying with a flat-tipscrewdriver,wrap it with
@
protectivetape to preventdamage.
. Takecare not to scratchthe body or tear the seat
covers.
. Put on glovesto protectyour hands.
Outef:
1 0 x 1 . 2 5m m
lnner:
(cont'd)
20-71
Seats
(cont'dl
FrontSeatRemoval/lnstallation
Lift up the front seat,then detachthe harnessclip
(A).and disconnectthe seat belt switch connector
( B )a n d s e a tb e l tb u c k l et e n s i o n ecr o n n e c t o(rC ) .l f
e q u i p p e dw i t h a s i d ea i r b a g d, i s c o n n e ct th e s i d e
a i r b a gc o n n e c t o (r D ) ,a n d o n t h e p a s s e n g e r 'sse a t ,
d i s c o n n e ct th e O P D Su n i tc o n n e c t o(rE ) .T h e
p a s s e n g e r 'sse a ti s s h o w n ,t h e d r i v e r ' ss e a ti s
s i m i l a re x c e p ti t h a sn o O P D Su n i tc o n n e c t o r .
7 . I n s t a l l t h es e a ti n t h e r e v e r s eo r d e ro f r e m o v a l a
, nd
notethese rtems:
20-72
- Driver's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)
and the precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
NOTE:
. Takecare not to tear the seamsor damagethe seatcovers,
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver.wrap it with protectivetape to preventdamage.
' Apply multipurposegreasetothe moving portion of the seattrack.
. To preventwrinklesin the seat cushioncover,stretchthe materialevenlyoverthe pad.
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
SEAT-BACK
10 x 'l.25mm
47 N.m {4.8kgf.m,
35 rbt.ft)
WIRETIE
RECLINECOVER
RECLINEKNOB
20-73
Seats
- Passenger's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-'13)
and the precautionsand procedures(seepage 23-14)beforedoing repairsor service.
NOTE;
. Takecare not to tear the seamsor damagethe seatcovers
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage
. Apply multipurposegreaseto the moving portion of the seattrack
. To Dreventwrinklesin the seat cushioncover,stretchthe materialevenlyover the pad.
. lvlakesure the rear seat accesscable is connectedproperlyon each side
. Replaceany damagedclips,and replacethe wire ties with new ones
SIDEAIRBAG
SEAT"BACK HARNESS
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
10 x 1.25mm
47 N.m (4.8kgf.m,
3s rbf.ft)
HANGERSPRING
OPDSHARNESS
u
CENTEBCOVER
WIRETIE
SEATCUSHION
FRAME/SEAT
TRACKS
/
REARSEAT ,/CLIP
ACC€SSCABLE
v/
N
*r(".o,
ACCESSKNOB ,/
/- /
I
SLIDELEVER
/ H o o K
RECLINEKNOB
RECLINE
COVER
20-74
Front SeatCoverReplacement
For some models:SRScomponentsare locatedin this 3 . Foldthe seat-backforward.
area.Reviewthe SRScomponentlocations(seepage
23 13)and the precautionsand procedures(seepage t h e h o o k s( A ) ,a n d u n z i pt h e s e a t - b a c k
4. Release
23-'14)in the SRSsectionbeforeperforming repairsor c o v e r( B ) .
service,
NOTE:
. Takecare not to tear the seamsor damagethe seat
covers,
. On the passenger'sseatwith side airbag,do not
touch the OPDSsensorin the seat-backpad, and keep
it away from oil. Oil can corrodethe sensorcausingit
to fail.
. Puton glovesto protectyour hands.
Seat-backCover
'L
Removethe front seat isee page 20-71).
2. W i t h s i d ea i r b a g :F r o mu n d e rt h e s e a tc u s h i o n ,
detachthe side airbagconnectorclip (A),and on
the passenger'sseat,detachthe OPDSunit
c o n n e c t ocr l i p ( B ) .R e l e a s teh e h o o ks p r i n g s( C )
f r o m t h e s e a tc u s h i o nf r a m es p r i n g{ D ) ,t h e n p u l l
the guide cover (E)back,and removethe wire ties
(F).The passenger'sseat is shown, the driver'sseat
is svmmetricalexceptit has no OPDSunit
connector.
(cont'd)
20-75
8 . Using a flat-tipscrewdriverwrappedwith 9. Unzipthe headrestportionof the seat-backcover
protectivetape, insert it into the hook portions ( A ) ,t h e n r e m o v et h e z i p p e ri B ) ,a n d r e m o v et h e
( s e v e np l a c e so) f t h e h e a d r e srte a rt r i m i A ) f r o m t h e cover.
headrestfront trim side. Prv up the hooks (B)to
releasethe labs (C)of the headrestfront trim (Di
w h i l e p u l l i n gt h e h e a d r e sftr o n tt r i m f o r w a r d ,a n d
removethe tflm.
D
(cont'd)
20-77
Seats
Front Seat CoverReplacement{cont'd)
SeatCushionCover Outside:
20-78
6 . R e m o v et h e s e a tc u s h i o nc o v e r( A )w i t h t h e s e a t 8. Installthecover in the reverseorder of removal,
cushion pad from the seat cushionframe. and note these items;
r {, ]
: F + r
r * ?
20-79
Seats
RearSeat Removal/lnstallation
NOTE:Takecare not to scratchthe body or tear the seatcovers.
'1.
Removethe rear seat as shown.To removethe seat-back,removethe front portion of the cargofloor mar lsee
page 20-52).
'Beforeinstallingthecenteranchorboltsontheseat-backwiththecentershoulderbelt,makesurethereareno
twists or kinksin the belt.
. Make sure the seat-backslock securelv.
Fastener Locations
\'7
22 N.m CENTERHINGE
{2.2kgf.m, 16lbf.ftl
BUSHING
RIGHTSEAT-BACK LEFTSEAT.BACK
CENTERBELT
PIVOTBUSHING
PIVOT
BUSHING
CENTERANCHORBOLT
7/16-20UNF
32Nm
(3.3kgf m.24 lbt ftl
SEATBELTBUCKLE
6x1.0mm
9.8Nm
{1.0kgf.m,7.2lbf.ft)
HOOK
SEATCUSHION
20-80
I RearSeat-backLatchReplacement RearSeat-backStriker Replacement
1 . Removethe seat-back(seepage 20-80). NOTE:Takecare not to scratchthe interiortrim.
Removethe seat-backpad {A) from the seat-back 2. Removethe bolts,then removethe seat-back
frame (B).On right seat-backwith centershoulder striker(A).
belt,passthe centerbelt (C)through the hole in the
FastenerLocations
seat-backpad.
) : Bolt,2
F
,-;1
8 x 1.25mm
22 N m 12.2kgl rn,
16 tbf.ft)
3 . l n s t a l l t h es t r i k e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
Removethe bolts,then removethe seat-backlatch and move the striker(A) up or down until it is
(A)from the seat-backframe (B),and releasethe centeredin the seat-backlatch {B).
\ pivot pin {C)of the latch lever (D)from the seat'
backf rame.
FastenerLocations
20-81
Seats
RearSeat-backCoverReplacement
NOTE: 5. On right seat-backiUsing a Torx T30 bit, remove
. Takecare not to tear the seamsor damagethe seat the bolts,then removethe belt holdertrim (A),and
covers. removethe trim from the centerbelt (B).
. Put on glovesto protectyour hands.
FastenerLocations 6x1.0mm
'1. 9.8Nm
Removethe seat-back(seepage 20-80). ) : Bolt, (1.0kgf.m,7.2lbf.ft)
A*-
Removethe headrest. \./-
Fastener Locations
) : Clip,4
1W
Releasethe hook (A),and unzipthe seat-backcover
(B).The right seat-backis shown. the left seat-back
i ss i m i l a r .
\
4 . Pull up the outsideedge of the latch lever cover (A)
to releasethe clips, and releasethe cover from the
p i v o tp i n s( B )o f t h e l a t c hl e v e r{ C )w h i l e p u l l j n gt h e
latch lever.
Fastener Locations
D : Clip,2
i\r*
rJ
20-82
7. Pull backthe edge of the seat-backcover (A),and 9. Removethe seat-backcover (A)from the seat-back
r e l e a s et h e c l i p s{ B ) . pad (B).On right seat-backwith centershoulder
belt, passthe centerbelt (C)through the hole in the
seat-bacl(cover.
20-83
Seats
RearSeat CushionCoverReplacement
'1.
Removethe rear seat cushion (seepage 2O-80). 4. Installthecover in the reverseorder of removal,
and note these items;
Releaseall the clips (A)from under the seat
c u s h i o n a, n d f o l d b a c kt h e s e a tc u s h i o nc o v e r( B ) . . To preventwrinkles,make surethe materialis
stretchedevenlyover the pad beforesecuring
t h ec l i p s .
. Replaceany clips {A) you removedwith new
o n e s .I n s t a ltlh e m w i t h c o m m e r c i a l l a
yvailable
u p h o l s t e r yr i n g p l i e r s( B ) .
\
iw F 1., +. ts+'
1L
i l
1 r
l-,+ J ,+ l
l
20-84
Bumpers
Front BumperRemovaUlnstallation
NOTE:
. H a v ea n a s s i s t a nht e l py o u w h e n r e m o v i n ga n d i n s t a l l i n g
t h ef r o n tb u m p e r .
. Takecare not to scratchthe front bumper and body.
. Puton glovesto protectyour hands.
'L
Removethe front bumper as shown.
, n d n o t et h e s ei t e m s :
2 . I n s t a l l t h eb u m p e ri n t h e r e v e r s eo r d e ro f r e m o v a l a
FastenerLocations
A ) , Screw, 2 B >: Screw,2 C>:Bolt.4 D>:Clip,7 E>:Clip,2
f
{D[] k/- ' h
*S- 6
=$
4
t
ABSORBER
SIDESPACER
UPPERBEAM
LEFTFRONTSIDEMARKER
LIGHTCONNECTOR
' * D ;
e 3 INNER
FRONT
FENDER
BUMPER e
ti-\ FEONTBUMPER
A
C l E
I
FRONTAIR SPOILER
SPOILER
AIR SPOILER 6 x 1 . 0m m
PLATE PLATE 9.8 N.m (1.0kgt.m,7.2lbf.ft)
20-85
Bumpers
RearBumperRemovaUlnstallation
NOTE:
' Havean assistanthelp you when removingand installingthe rear bumper.
. Takecare not to scratchthe rear bumper and body.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Put on glovesto protectyour hands.
L R e m o v et h e r e a rb u m D e ra s s h o w n .
. Make sure both rear side marker light connectorsare pluggedin properly.
'Makesuretherearbumperengagesthehooksofthesidespacers,sidebrackets,andupperbracketsonboth
sidessecurely.
. Make sure the upper spacersof the rear bumper engagethe clips on the body securely.
. R e p l a c ea n y d a m a g e dc l i p s .
Fastener Locations
SIDEBRACKET
UPPERBRACKET
\
, 6 x 1 . 0m m
/ 9.eN.n
,/ 11.0kgl m,
./ 1.2tbt.ttl
SIDESPACER
a
\
'-
:r A
CAP
LEFTREARSIDEMARKER
LIGHTCONNECTOR
A
D
UPPERSPACER
REARBUMPER
20-86
Hood
Adjustment
'1.
Slightly looseneach hood hinge bolt,
. A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e al l s f o r w a r da n d r e a r w a r db, y u s i n gt h e e l o n g a t e dh o l e so n t h e h o o dh i n g e
(B).
. Turn the hood edge cushions(C),as necessary,to makethe hood iit flush with the body at the front and side
edges.
6x1.0mm
6x1.0mm 9.8 N.m
9.8 N.m {1.0kgf.m,7.2lbf.ft}
{1.0kgl.m,7.2 lbf.ftl
3 . Adjustthe hood latch (D)to obtainthe proper height at the forward edge,and move the hood latch right or left
until the striker(E)is centeredin the hood latch.
(contd)
20-87
Hood
Adjustment(cont'd) HoodSealReplacement
5. Checkthat the hood opens properlyand locks 1 . Using a clip remover,detachthe clips,then remove
securely. the hood seal (A).Takecare not to scratchthe hood.
I n s t a l l t h es e a li n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
note these items:
. R e p l a c ea n y d a m a g e dc l i p s .
. P u s ht h e c l i p si n t o p l a c es e c u r e l y .
. :I
20-88
HoodInsulatorReplacement
t e w i n d s h i e l dw a s h e rt u b e s( A ) .
1 . D i s c o n n e ct h
FastenerLocations
'10
) : Clip,
t*'-&
,2V..=-'
( \
I n s t a l l t h ei n s u l a t o irn t h e r e v e r s eo r d e ro f r e m o v a l ,
and note these items:
. R e p l a c ea n y d a m a g e dc l i p s .
. Pushthe clips into placesecurely.
20-89
Hatch
Adjustment
1. Removethe support strut from each side (seepage 20-91).
2 . R e m o v e t h e C - p i l l a r t r i m f r o m e a c h s i d e ( s e e p a g e 2 0 - 5 ' l ) ,daonw
dnp tuhl le r e a r p o n i o n o f t h e h e a d l i n e r ( s e e
page20-54).Takecare not to bend the headlinerexcessively.
5 . A d j u s t t h eh a t c h( A )a l i g n m e n it n t h e f o l l o w i n gs e q u e n c e .
. Adjustthe hatch hinges(B) right and left, as well as forward and rearward,using th e elongatedholes.
'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside
edges.
. Adjustthe fit betweenthe hatch and hatchopening by moving the striker(D).
8 x 1.25mm
22 N.m
{2.2kgf.m,16lbf.ft} \
8 x 1.25mm
18 N.m 11.8kgf.m, 13 lbf.ft)
20-90
HatchSupportStrut Replacement
Tighteneach bolt and nut securely. 1 . With the help of an assistant,use a flat-tip
screwdriver(A)to pry the supportstrut clips (B)
7 . Checkthat the hatchopens properlyand locks from each end of the supportstrut (C)at the hatch
securery. and body, then releasethe supportstrut from the
pivot bolts (D).Do not removethe clips from the
Reinstallthe supportstruts securely. supportstrut.
9 . R e i n s t a lal l l r e m a i n i n gr e m o v e dp a r t s .
D
8 x 1.25mm
22 N.m(2.2kgf.m,16lbf ft)
20-91
Hatch
HatchWeatherstripReplacement
1 . R e m o v et h e h a t c hw e a t h e r s t r i{pA ) b y p u l l i n g o u t
on it.
2 . L o c a t et h e p a i n t e da l i g n m e n mt a r k{ B )o n t h e h a t c h
weatherstrip.Allgn the paintedmark with the
alignmenttab in the the centerof the hatchopening,
a n d i n s t a l tl h e h a t c hw e a t h e r s t r i a
p l l t h ew a y
around in the directionshown. Make surethere are
no wrinklesin the weatherstrip.
20-92
FuelFill Door
Adjustment
1. Removethe nut (A),and removethe fuel fill door 7. Apply multipurposegreaseto each location
o p e ns p r i n g{ B ) . indicatedby the arrows.
>t=-
r'
2 . S l i g h t l yl o o s e nt h e h i n g em o u n t i n gb o l t s( A ) .
3 . A d j u s tt h e f u e lf i l l d o o r ( B )i n o r o u t u n t i li t ' sf l u s h
with the body, and up or down as necessaryto
a^rr.li7a tha n.nc
T i g h t e nt h e h i n g em o u n t i n gb o l t s .
5 . R e i n s t a l l t h feu e lf i l l d o o r s p r i n g .
20-93
ExteriorTrim
FrontGrille Replacement
1 . Removethe front bumper (seepage 20-85).
FastqnErLocations
C >:Screw.4 D ) : Clip, 4
ll
-S---: \
i")
F
3 . I n s t a l l t h eg r i l l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
a n d r e p l a c ea n y d a m a g e dc l i p s .
20-94
Cowl CoversReplacement
1 . R e m o v et h e w i n d s h i e l dw i p e r a r m s ( s e ep a g e2 2 - 1 4 5 ) .
3. Pullthe hood rear seal (A) away from the cowl covers,then remove it, and using a clip remover,detachthe clips
(B)from the cowl covers.Takecare not to scratchthe cowl covers.
FastenerLocations
B> rClip,3 C>:Clip,8
:- ::::
= - --::;-:
4 . Detachthe clips (C)by carefullypulling the passenger'scowl cover {D) upward,to releasethe hooks{E),and pull
out the cover forward to releasethe hooks(F),then removethe cover.Takecare not to scratchthe body,
Detachthe clips (C)by carefullypulling the driver'scowl cover (G) upward.and pull out the cover forward to
releasethe hooks(H),then removethe cover.Takecare not to scratchthe body.
. R e p l a c ea n y d a m a g e dc l i p s .
. Pushthe clip portionsinto placesecurely.
. Reinstallboth windshieldside trim properly(seestep 26 on page 20-24).
20-95
ExteriorTrim
A-PillarCornerTrim Replacement
1 . Open the door. 5 . R e p l a c ea n y d a m a g e dc l i p s .
FastenerLocation
FastenerLocations
20-96
RoofMolding Replacement
1 . Apply protectivetape to the body (A).Using a 4, Pull up and releasethe rear bracket(A)from the pin
flat-tipscrewdriverwrapped with protectivetape (B),then removethe roof molding (C).
(B),pry up on the roof molding (C).Takecare not to
scratchthe bodv.
..:.::.l.
g
. T a k ec a r en o t t o d a m a g et h e w i n d s h i e l dm o l d i n g .
. Make sure the roof molding is installedsecurely.
Pull up and slidethe roof molding to releasethe
front bracket(D)from the pin (E).
20-97
ExteriorTrim
RearLicenseTrim Replacement
NOTE:Put on glovesto protectyour hands. 3 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s( A , B ) w h i l e
h o l d i n gt h e r e a rl i c e n s et r i m ( C ) ,t h e n r e m o v el h e
1. Removethe hatch lower trim panel (seepage 20- trim, Takecare not to scratchthe hatch.
FastenerLocations
2. On insidethe hatch.removethe bolts securingthe A>:Clip,2 B>:Clip.2
r e a rl i c e n s et r i m ( A )a n d h a t c hl o c kc y l i n d e r( B ) . \ ! -
FastenerLocations
cHl €:t+
> : Bolt,2
-)
4 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
, nd
note these rtems:
. Replaceany damagedclips.
. Pushthe clip portionsinto placesecurely. \
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ftl
20-98
HatchSpoilerReplacement
NOTE:Put on glovesto protectyour hands. 4 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s ,w h i l e
p u l l i n gt h e h a t c hs p o i l e r( A )a w a y ,a n d r e l e a s et h e
'l.
Removethe hatch upper trim (seepage 20-53). fasteners(B),then removethe spoiler.Takecare
not to scratchthe body.
2. Removethe high mount brakelight (seepage22-
82). FastenerLocations
> : C l i p2.
3. From insidethe hatch,removethe bolts {A} and t
n u t s( B ) .
Fastener Locaiions
A>: Bolt,2 Bar Nut,
fi'f$t-- /,fl
uLt* v_/
$. A
5 . I n s t a l l t h es p o i l e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
and note these items:
5x1.0mm
9.8Nm
(1.0kgf.m.7.2lbf.ft) R e p l a c ea n y d a m a g e dc l i p s .
Replaceany damagedfasteners.Before
installingthe fastenerto the spoiler,cleanthe
spoilerbonding surfacewith a sponge
d a m p e n e di n a l c o h o l G
. l u et h e f a s t e n e wr ith
a d h e s i v et a p e( 3 M 5 6 7 1 ,o r e q u i v a l e n t ) t toh e
spoiler.
Pushthe clip and fastenerportions into place
securely.
20-99
ExteriorTrim
EmblemReplacement
NOTE:When removingthe emblem,take care not to scratchthe body.
"H" emblem and front type emblem, removethe front bumper (seepage 20-85)
1. To removethe front
3 . A p p l yt h e e m b l e m ,w h e r es h o w n .
. Wheninstalling t h e s i d ei - V T E Ce m b l e mo n t h e b o d y ,a l i g nt h e a p p l i c a t i otna p ew i t h t h e e d g eo f t h e w h e e la r c h ,
then pressthe emblem into place,and removethe applicationtape.
. ' 0 3 m o d e l :W h e n i n s t a l l i n g t h e L E Ve m b l e mo n t h e q u a r t e rg l a s s ,a l i g nt h e a p p l i c a t i o tna p ew i t h t h e e d g eo f t h e
b l a c kc e r a m i ca n d a l i g n m e n m t a r ko n t h e q u a r t e rg l a s s t, h e n p r e s st h e e m b l e mi n t o p l a c e a, n d r e m o v et h e
a p p l i c a t i o tna p e .
FRONTTYPEEMBLEM
FBONT"H" EMBLEM
FRONTSi EMBLEMPLATE
PUSHNUTS
PINS
FRONTGRILLE FRONTGRILLE
20-100
REARCIVICEMBLEM
LEVEMBLEM
(Leftsideonly)
('03model)
REARVERSIONEMBLEM
SIDE|-VTECEMBLEM
REAR"H" EMBLEM
Unit: mm {in.l
Adhesivetape: 3M 4213E,o. equivalent
Thickness:0.8mm (0.03in.)
LEVEMBLEM
Align. Ontoinsideface
of the guarterglass.
REARLICENSE
HATCHLINE TRIM REARSiR EMBLEM
REARsi EMBLEM (Canada)
34
11.3)
, ilg .,!!ll,'nt
(1.93) I (1.s31
=-t
50
{'!,9?)
CIVICEMBLEM E d g eo f t h e
hatch.
ADHESIVETAPE Edge of the
hatch.
SIDEi-VTECEMBLEM
Left Side: SIDEi.WEC Right Side: 63 (2.5)
EMBLEM
. 114(4.49)
F.l^6 ^l rh-
wheelarch.
.=4,
y'
Li.Est
112
(5'5s)
Edgeof the BODY BODY o"f,r,ao.o"
APPLICATION LINE
wheel arch. TAPE LINE TAPE
4. After installingthe front "H" enblem and front type emblem, reinstallthe front bumper.
20-101
Fenderwell
FrontInnerFenderReplacement
NOTE:Takecare not to scratchthe body.
FastenerLocations
B):Screw,4
0*€
E>:Clip,1
,ws
F > : C l i p ,1 G):Clip,8
. R e p l a c ea n y d a m a g e dc l i p s .
. P u s ht h e c l i p si n t o p l a c es e c u r e l y .
20-102
Front FenderFairingReplacement
1 . Removethe front inner fender as necessary(see 3. From the wheel arch, removethe clip (A),and
p a g e2 0 - 1 O 2 1 . releasethe clip (B),then removethe front fender
f a i r i n g( C ) .
Open the front door. From outsidethe door,
r e m o v et h e u p p e rc l i p ( A ) ,a n d f r o m i n s i d et h e d o o r , FastenerLocations
removethe lower clip (A) securingthe front fender A > : C l i p1, B > : C l i p1,
f a i r i n g( B )a n d f r o n tf e n d e r( C ) .
FastenerLocations J*.' -@
A>:Clip,2
J<a-'
o --____--
20-103
Fenderwell
(
FuelPipeProtectorReplacement RearAir Outlet Replacement
1 . R e m o v et h e c l i p s ,t h e n r e m o v et h e f u e l p i p e 1 . R e m o v et h e r e a rb u m p e r( s e ep a g e2 0 - 8 6 ) .
protector(A).Takecare not to scratchthe body.
r n e r e a ra t r
Fastener Locations the body.
> : Clip,4
I n s t a l l t h ea i r o u t l e t sb y p u s h i n go n t h e h o o k
I n s t a l l t h ep r o t e c t o irn t h e r e v e r s eo r d e ro f r e m o v a l , p o r t i o n su n t i l t h eh o o k ss n a pi n t o p l a c e .
and note these items:
. R e p l a c ea n y d a m a g e dc l i p s .
. P u s ht h e c l i p si n t o p l a c es e c u r e l v .
20-104
Openers
ComponentLocationIndex
HATCHLOCK
CYLINDER
page20-1'l1
Replacement,
HATCHHANDLE
Replacement,
p a g e2 0 - 1 1 0
HATCHLATCH
Replacement,page20'110
FUELFILLDOORLATCH
page20-107
FUELFILLDOOROPENEBCABLE
page 20-107
Replacement,
FUELFILLDOOROPENER
Replacement,page20-109
I{OOD RELEASEHANDLE
page20-'106
HOODOPENERCABLE
Replacement,page20-106
z)-105
Openers
Hood OpenerCableReplacement
NOTE:
. Put on glovesto protectyour hands.
. Takecare not to scratchthe body and relatedparts.
l. Removethese items:
2. Disconnectthe hood openercable(A) from the hood latch {B) (seepage20-108),and removethe bolts (C),then
removethe hood releasehandle(D)from the body.
FastenerLocations
6x1.0mm
C>:Bolt,2 E >:Clip,3 9,8 N.m
11.0kgl.m, 7.2 lbl.ft)
@m l,.t'.
W:"
Using a clip remover,detachthe clips (E),and removethe grommet (F)from the body, then removethe hood
openercablefrom the vehicle.Takecare not to bend the cable.
4 . I n s t a l l t h ec a b l ei n t h e r e v e r s eo r d e ro f r e m o v a l a
, n d r e p l a c ea n y d a m a g e dc l i p s .
20-106
FuelFill Door OpenerCableReplacement
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and the precautions
and procedures(seepage 23-14)in the SRSsectionbeforeperformingrepairsor service.
NOTE;
. Put on glovesto protectyour hands.
. Takecare notto scratchthe body and relatedparts.
. D o o rs i l l t r i m { s e ep a g e2 0 - 5 0 )
. R e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 )
5. Disconnectthe fuel fill door openercable (A)from the opener(B) (seestep 3 on page 20-109).
FastenerLocations
C > : C u s h i o n t a p e1, D > : C l i p 1, E > : Clip,2
4 . K C m o d e l :R e m o v e t h el e f tm i d d l ef l o o rc r o s s - m e m b egru s s e t( s e ep a g e2 0 - 1 1 3 ) .
5 . R e m o v et h e c u s h i o nt a p e{ C ) ,a n d r e l e a s et h e c a b l ef r o m t h e c l i p s( D ,E ) .
6 . R e m o v e t h e f u efli l l d o o r l a t c h( F ) f r o m t h eb o d y b y t u r n i n gi t 9 0 ' .
7. Removethe fuel fill door openercablefrom the vehicle.Takecare not to bend the cable
8 . I n s t a lt lh e o p e n e r c a b l e i n t h e r e v e r s e o r d e r o f r e m o v a l , r e p l a c e t h e c u s h i o n t a p e , a n d r e p l a c e t h e c l i p i f i t i s
oamageo.
20-107
Openers
Hood LatchReplacement
NOTE: Installthe hood latch in the reverseorder of
. Put on glovesto protectyour hands. removal,and note these items:
. Takecare not to scratchthe body.
. Apply multipurposegreaseto each locationof
1. Removethe bolts,then removethe hood latch (A) the hood latch indicatedby the arrows.
from the body. . Make sure the hood openercable is connected
properly.
FastenerLocations . Make sure the cableactuatesthe latch beforeyou
> i Bolt,3 closethe hood,
. Adjustthe hood latchalignment(seestep 3 on
page 20-87).
. M a k es u r et h e h o o do p e n sp r o p e r l ya n d l o c k s
securely.
--------------'
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ft)
20-108
FuelFillDoorOpenerReplacement
1 . Using a flat-tipscrewdriverwrapped with 4. Disconnectthe fuel fill door openercable (A),then
protectivetape, detachthe hooks(A) by prying the removethe openeriB). Takecare not to bend the
front side cap (B),then remove it from the left door c ao t e .
s i l l t r i m ( C ) ,a n d l o o s e nt h e b o l t ( D )s e c u r i n gt h e
f u e lf i l l d o o r o p e n e r .
6x1.0mm
9.8 N.m 5 . Installthe opener in the reverseorder of removal,
11.0kgf m,7.2 lbf.ft) and note these items:
2. Removethe left door sill trim (seepage 20-50i. lMakesure the openercable is connected
properly.
3 . R e m o v et h e o p e n e r( A l f r o m t h e b o l t{ B ) . lvlakesure the fuel fill door opens properlyand
lockssecurely.
20-109
Openers
HatchHandleReplacement HatchLatchReplacement
NOTE:Put on glovesto protectyour hands. NOTE:Put on glovesto protectyour hands.
()rI
a
,t.
R e m o v et h e b o l t s ,t h e n p u l l t h eh a t c hl a t c h( E )o u t ,
then remove it.
I n s t a l l t h el a t c hi n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
notethese items:
20-110
HatchLockCylinderReplacement
NOTE;Put on glovesto protectyour hands. 4. Installthe lock cylinder in the reverseorder of
removal,and note these items:
'1.
Removethese items:
. Make sure the rod is connectedproperly.
. Hatchlower trim panel (seepage 20-53). . Make sure the hatchopens properlyand locks
. Rearlicensetrim (seepage 20-98). securely.
- . .
Fastener Location
6 x 1 . 0m m
> : Bolt,1 9.8Nm
(1.0kgf m,7.2lbt.ftl
rS'l-.
u-ar
*/t
20-111
Frame
SubframeReplacement
SubframeTorque
NOTE:After looseningthe subframemounting bolts,be sureto replacethem with new ones.
Referenceholesalignment:
SUBFRAME
REFERENCE HOLE
( B o d yS i d e )
INSTALLATION
REFERENCEHOLE
(Subframe
side)
INSTALLATION
REFERENCE HOLE
FRONTSUSPENSION
SCREWDRIVER
or TAPEREDPUNCH INSTALLATION
To body. REFERENCE HOLE
To body.
I
n
E
SPECIAL
' 1 4x 1 . 5mBOLTS
m
103 N.m
(10.5kgf.m,75lbf.ft)
Replace.
20-112
FrameStiffener,Brace,and GussetReplacement
FrameStiffener,Brace,and GussetTorque
NOTE:When installingthe middle floor cross member braceor gussets,torque the mounting hardwarein the
following sequenceto avoid damageto the quarterpanel.
MIDDLE
FLOOR
CROSS-MEMgER
BRACE/GUSSET
SIDEFRAMESTIFFENER
8 x 1 . 2 5m m
29 N.m
(3.0kgf m,22 lbf ft)
To body.
U.S.model: model:
Canada
1 0x 1 . 2 5m m
38 N.m
(3.9kgf.m.28lbf.ftl
MIODLE
FLOOR MIDDLE
FLOOR
CROSS-MEMBER CROSS.MEMBER
BRACE GUSSET
__!:::-- 1 0 x 1 . 2 5m m
.. | - 38Nm
(3.9kgf.m,28 lbl.ftl
1 0 x 1 . 2 5m m
38 N m (3.9 kgt.m, 28 lbf.ftl
20-113
Frame
FrameRepairChart
Top view
VEFTICAL
UNE
20-114
K Locatinghole d25 (0.981 Fortrailingarm d13 (0.511
Fortrailing.rm rl3 10.51) For upper arm bracketcenterrl5 {0.59)
m Locatinghole o25 (0.981 t1, t2 Locatingholes13 (0.51)
n Locatinghole s20 (0.79) Foruppe.arm o13{0.511
Trailingarm center For rear lower arm cent€r
p Reardampercenter Locatingholes50 (1.97)
q Forupperarm o13 (0.51) x1 Locatinghole s20 (0.79)
x2 Locatinghole o25 (0.981
(cont'd)
20-115
Frame
FrameRepairChart(cont'dl I
Sideview
SECTIOiIAA
BASE
UNE
trr2xt.6 l
VERTICAI
LINE
20-116
Frame
FrameRepairChart(cont'dl I
Sideview
SECTIOiIAA
BASE
UNE
trr2xt.6 l
VERTICAI
LINE
20-116
Locatinghole o25 {0.98) Fortrailingarm s13 {0.51}
Fortrailingarm 613 {0.511 For upper arm bracketcenter o15 {0.591
m Locatinghole d25 {0.98} 11,t2 Locatingholeo13{0.51}
Locatinghole r20 {0.79) Forupperarm d13{0.51)
Trailingarm center For rear lower arm centei
p Reardamper centel Locatingholeo50{1.97}
q Forupperarm o13 (0.51) xl Locatinghole a20 {0.79}
x2 Locetinghole s25 (0.98)
20-117
HVAC(Heating,
Ventilation,
andAir Gonditioningl
HeatingandAir Conditioning DustandPollenFilter
SpecialTools 21-2 Reolacement ..21-39
Comoonent Location lndex ........z t-'5 BlowerUnitRemovaland
A/CService Tiosand lnstallation ......21-39
Precautions z t-o BlowerUnitComoonents
A,/CRefrigerant Oil R e D l a c e m e .n. t. . . . . . . . . . . . . . . . .2. .1. .- .4. 1. . .
ReDlacement z t-o Evaporator Core
General Troubleshooting Reolacement ..21-42
lnformation 21-8 *HeaterUnit/Core
DTCTroubleshooting Index .......21-9 ReDlacement ..21-43
SymptomTroubleshooting HeaterValveCable
1ndex.............. 21-10 Adjustment .....21-46
SystemDescription..................... 21-11 CompressorReplacement .......... 21-47
CircuitDiagram 21-14 Comoressor ClutchCheck .......... 21-48
D T CT r o u b l e s h o o t i n. .g. . . . . . . . . . .z. .t .- .t .o Comoressor ClutchOverhaul.....21-49
Recirculation ControlMotor Compressor ThermalProtector
CircuitTroubleshooting .......... 21-25 R e o 1 a c e m e.n. .t . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
HeaterControlPowerandGround Comoressor ReliefValve
Circuits Troubleshooting ........21-27 R e o l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
Condenser FanCircuit Condenser Reolacement............ 21-52
Troubleshooting ...................... 21-28 Refrigerant Recovery .................. 21-53
Radiator andCondenser Fans SystemEvacuation ...................... 21-54
CommonCircuit SystemCharginS......................... 21-55
Troubfeshooting ...................... 21-29 Refrigerant LeakTest.................. 21-56
Compressor ClutchCircuit A,/CSvstemTests ........................ 21-57
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . 2
. .1. .-.3. .0
A,/CPressureSwitchCircuit
Troubleshooting ...................... 21-32
Air Mix ControlMotor
TestandReolacement ............. 21-34
ModeControlMotor
TestandReplacement ............. 21-35
Recirculation ControlMotor
TestandReolacement ............. 21-36
Evaporator Temperature Sensor
Reolacement andTest ............. 21-31
PowerTransistor Test ................. 21-38
HeaterControlPaneland
PushSwitchAssemblv
RemovalandInstallation........21-38
HVAC{Heating,Ventilation,and Air Conditioning)
SpecialTools
Ret.No. Tool Number DescriDtion Otv
o 07sAz-001000A BackprobeSet 2
---2
att-,,- KCe
"-t--'
/'Tt
e^t"'
T
21-2
Heatingand Air Gonditioning
ComponentLocationIndex
EVAPORATOR CORE
VALVE
SERVICE (Built-in theheaterunit)
{LOW.PRESSUBE
SIDEI B e p l a c e m epnat ,g e2 1 4 2
SERVICE
VALVE
{HIGH-PRESSURE
SIDEI
RECEIVER/DRYER
COMPRESSOR
Beplacement,page21 47
ClutchCheck,page21-48 CONOENSEB
page 21-52
Replacement,
C l u t c hO v e r h a u lp, a g e2 1 - 4 9
ThermalProtectorCheck,page21-48
ThermalProtectorReplacement, page21 51
R e l i eVf a l v eR e p l a c e m e npta, g e2 1 5 1
Heatingand Air Conditioning
ComponentLocationIndex(cont'dl
RADIATORFAN RELAY
Test,page22-51
CLUTCHRELAY
Tesl, page 22-51
MOTORRELAY
Test, page 22-5I
'-t
t_]]l UNDER.HOOD BOX
FUSE/RELAY
/l I T I -
-::--
l- -l -
CONDENSERFAN
Test, page 22-51
.\\
... A/C PRESSURE
SWITCH
-
RADIATORFAN
CONOENSERFAN
21-4
BLOWENUNIT
HEATERUNIT/CORE Removal page21-39
andInstallation,
page21-43
Beplacement,
BLOWERUNITCOMPONENTS
page21-41
Replacement,
HEATERVALVECABLE
page21-46
Adjustment,
DUSTAND POLLEN
FILTER
page21'39
Replacement,
RECIRCULATION CONTROLMOTOR
Test,page21-36
page21-36
Replacement,
MODE CONTROLMOTOR
Test,page21-35
Replacement,page21-35
POWERTRANSISTOR
Test,page 21-38
21-5
HeatingandAir Conditioning
A/C ServiceTips and Precautions A/C Refrigerant
Oll Replacement
R e c o m m e n d eP
d A Go i l : K E I H I NS P 1 0 :
T h e a i r c o n d i t i o n i n sg y s t e mu s e sH F C - 1 3 4(aR - 1 3 4 a ) C o n d e n s e r. . . . . . . . . . . 2m5A\ 5 1 6t l . o z 0 , . 9l m p . o z )
'1.4
r e fr i g e r a n at n d p o l y a l k y l e n e g l y c(oPl A G )r e fr i g e r a n ot i l , . m0 (1113Il.oz, lmp.oz)
E v a p o r a t o r. . . . . . . . .4. 5
'10
w h i c ha r e n o t c o m p a t i b l e w i t h C F C ' 1 2( R - 1 2r)e f r i g e r a n t L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4l m p . o z )
'10
andminerao l i l .D o n o t u s eR - ' 1 2r e f r i g e r a not r m i n e r a l R e c e i v e r / D r y e.r. . . m 0 ( ' 1 1f3l . o z , 0 . 4l m p . o z )
oil in this system,and do not aftemptto use R 12 Leakagerepair ....25 m0,1516 Il oz,0.9 lmp.oz)
s e r v i c i n ge q u i p m e n td; a m a g et o t h e a i r c o n d i t i o n i n g C o m p r e s s o r. . . . . . . F . .o rc o m p r e s s orre p l a c e m e n l ,
s y s t e mo r y o u r s e r v i c i n ge q u i p m e nw t ill result. s u b t r a ctth e v o l u m eo f o i l d r a i n e d
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . - l i s t eadn d i s from the removedcompressorfrom \
certifiedto meet the requirementsof SAE J2210to 1 3 0m 0 ( 4 1 / 3 f l . o z4, . 6 l m p . o z )a, n d
r e m o v eR - 1 3 4 af r o m t h e a i r c o n d i t i o n i n sg y s t e m . d r a i nt h e c a l c u l a t e vdo l u m eo f o i l
'130
f rom the new compressor: m0
lf accidentalsystem dischargeoccurs,ventilatethe i . 4 1 1 f3l . o z , 4 . 6l m p . o z ) V o l u m eo f
w o r k a r e ab e f o r er e s u m i n gs e r v i c e . removedcompressor= Volume to
d r a i nf r o m n e w c o m p r e s s o r .
R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n g
systemsshould not be pressuretested or leaktested NOTE:Evenif no oil is drainedfrom
withcompressed air. the removedcompressor,don't
d rain more than 50 m0 \1 2/3 fl.oz,
' 1 . 8l m p
A d d i t i o n ahl e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e o z ) f r o mt h e n e w
obtainedfrom the refrigerantand lubricant compressor.
manufacturers.
21-6
RECEIVER
LINEA
RECEIVER/DRYER
CONDENSER
LINE
21-7
Heatingand Air Conditioning
GeneralTroubleshootingInformation
How to Retrievea DTC
The heatercontrol panel has a self-diagnosisfunction.To run the self-diagnosisfunction,do the following:
1 . T u r nt h e f a n s w i t c hO F F .
3 . T u r nt h e i g n i t i o ns w i t c ho N { l l i .
.lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty
circuil or comDonent.
. lf the system is OK, the recirculationindicatorstaysoff.
atc INOICATOR
BECIRCULATION REARWINDOW
INDICATOB OEFOGGERINDICATOR
/A\
-:@
RECIRCULATION
@r REARWINDOW
CONTROLSWITCH DEFOGGERSWITCH
DTC 7
Recirculation +
indicatot
Recirculation+
indicalor
go6s oft ----->
Turn the ignition switch OFFto cancelthe self-diagnosisfunction.After completingrepairwork, run the self-diagnosis
f u n c t i o na o a i nt o m a k es u r et h a t t h e r ea r e n o o t h e rm a l f u n c t i o n s .
21-8
DTCTroubleshootingIndex
DTC{Recirculation Detection ltem Page
IndicationBlinks)
7 A n o p e n i n t h e a i r m i x c o n t r o lm o t o rc i r c u i t ( s e ep a q e2 1 - 1 6 )
8 A short ln the air mix control motor circuit ( s e eD a o e2 1 - ' 1 6 )
9 A p r o b l e mi n t h e a i r m i x c o n t r o l i n k a q ed, o o r ,o r m o t o r ( s e ep a q e2 1 -1 7 )
10 An open or shon in the mode control motor circuit ( s e eo a q e2 1 - 1 8 )
11 A p r o b l e mi n t h e m o d ec o n t r o l i n k a g ed, o o r s ,o r m o t o r ( s e ep a q e2 1 1 9 1
12 A p r o b l e mi n t h e b l o w e rm o t o rc i r c u i t ( s e ep a q e2 1 - 2 0 )
13 A problem in the EEPROMin the heatercontrol panel; ( s e ep a g e2 1 - 3 8 )
the control oanel must be reolaced
14 An ooen in the evaDoratortemDeraturesensorcircuit (seepaqe 21-23)
A short in the evaDoralortemoeraturesensorcircuit ( s e eo a q e2 1 - 2 4 1
In case of multiple problems,the recirculationindicatorwill indicateonly the DTCwith the least number of blinks.
ln caseof an intermittentfailure,the heatercontrol panelwill storethe DTCuntil the ignition is turned off.
21-9
Heatingand Air Conditioning
SymptomTroubleshooting
Index \ {
! a
21-10
SystemDescription
HeaterControlPanelInputsandOutputs
HEATERCONTFOLPANELCONNECIORS
CONNECTOR
A {r/rP) CONNECTORB (22P)
CONNECTOR
Cavity Wire color Sional
_| \ln Y AIRMIXPOTENTIAL +5V OUTPUT
2 LT GRN S E N S OC
RO M M O N
GROUND INPUT
3 PNK/BLU AIR MIX HOT OUTPUT
BLU A,/CPRESSURE
SWITCH INPUT
5 GRNA/EL RECIRCULATE INPUT
6 GRNA/VHT FRESH INPUT
7 BLUI/EL POWER TRANSISTOR OUTPUT
8 BLU/RED BLOWERFEEDBACK INPUT
I GRN AIR MIX COOL OUTPUT
10 YEL/RED MODEDEF OUTPUT
11 . YEVBTU MODEVENT OUTPUT
YEL/BLK REARWINDOWDEFOGGERRELAY INPUT
BLK GROUND OUTPUT
14 BLK/YEL l G 2( P o w e r ) INPUT
CONNECTOR
B on
Cavity Wire color Siqnal --T
1
2
3 BLIVRED R E A RW I N D O WD E F O G G ES
RW I T C HL E D INPUT
4 LT GRN A./CSWITCHLED INPUT
5 L TG R N / B L K RECIRCULATIO CNONTROL S W I T C HL E D INPUT
6 PNVBLK AIR MIX POTENTIAL OUTPUT
7 BRN EVAPORATOR
TEIMPERATURE
SENSOR OUTPUT
8
9
10
11 RED GAUGE
ASSEMBLY al' 'TDr ri
RED/BLK TAILLIGHTSRELAY INPUT
14 BLU REARWINDOWDEFOGGER
SWITCH INPUT
ic LT GRN/RED A/C SWITCH INPUT
16 YEVRED RECIRCULATIO
CNONTROL
SWITCH INPUT
17 YEUGRN MODE4 OUTPUT
18 WHT/BLU MODE3 OUTPUT
19 RED/BLU M O D E2 OUTPUT
20 RED/YEL M O D E1 OUTPUT
BRN^,^/HT I G N( P o w e d OUTPUT
22 REDA/r'HT (Not used)
(cont'd)
21-11
Heatingand Air Gonditioning
SystemDescription(cont'dl
The air conditioningsystem removesheatfrom the passengercompartmentby circulatingrefrigerantthrough the
system as shown below.
BLOWER
FAN
\ \
\ r\,u /
EXPANSIONVALVE
(Metersthe required
amount of refrigerant
into the evaporator)
APOBATORTEMPERATURE
SENSOR
A/C COMPRESSOR
RECEIVER/DRYER (Suctionand comoression)
(Trapsdebris,and \-^
removesmorsturel
/- I vAPoR
HrcHPRESSURE
CONDENSER
(Radiationof heat) -:--l
[ '.... Low PREsSUBE
LrourD
21-12
HeatingandAir Conditioning
GircuitDiagram
+. C}F BLK/RED
\ rG2/
/
.I
\ IHEFMAI
I
PBorEcro8 I
Y I
lTl *n*,*,
| <l I CLUTCH
I
tf
_l n
I
.
G301
MUITIPLD(
CONTFOI
UNITI
A/CPnESSUEt
swTOt
-!10. irgF 8Ll t...iCF BLU
T T
I I
j
193"C) l
19S"F
B LX 8u(
I
G301
I I ilnthoundor dasiluse/lelay
box
21-14
- BU/YEL
-8lU/wH'I
EVAPORATOB
TEMPERATUNESENSOR
sn 4-Lrenil
m
::-:::: ., . a/c
YEUBLU
YEL/NED M DEF
MODEl
M00l
BED/YEI Mq)EI co TnoL
MOTOS
RED/8LU M00€2
M00t3 s
WHT/8LU MOOE3
YEL/GRN MOOEI
LTGRI'l
ffftH,,
F*u,*
GNNMHT 8U
GRN/YEL
8LK--..-...-l
(
f
coNNEcroFrir.Pt
mxr{EcroB
! {2P)
G5'1
I
G602
21-15
Heatingand Air Conditioning
DTCTroubleshooting
DTC7:An Openin theAir Mix ControlMotor DTC8:A Shortin theAir Mix ControlMotor
Circuit Circuit
1. Test the air mix control motor {seepage 2'l-341. 1. Testthe air mix control motor(see page 21-341.
ls the air mix control motor OK? ls the ait mix control motor OK?
YES-Go to step 2.
N O - R e p l a c et h e a i r m i x c o n t r o lm o t o r . l YES-Go to step 2.
2. Disconnectthe air mix control motor 5P connector. NO-Replace the air mix contorol motor.I
3. Disconnectheatercontrol panel connectorsA {14P) 2. Disconnectthe air mix control motor 5P connector.
a n dB ( 2 2 P ) .
3. Disconnectheatercontrol panelconnectorsA (14P)
4. Checkfor continuitybetweenthe following andB (22P).
terminalsof heatercontrol panel connectorsA
(14P)and B (22P)and the air mix control motor 5P 4. Checkfor continuitybetweenbody ground and
connector, heatercontrol panelconnectorA (14P)terminals
14P: 5P: No. 1, 2, 3, and 9 individually,and betweenbody
N o .1 No.5 ground and heatercontrol panelconnectorB (22P)
No.2 No.4 t e r m i n a lN o . 6 .
No.3 No.2
No.9 N o .1
HEATERCONTROL A {I4PI
PANELCONNECTOR
22P: 5P:
No.6 No.3
W i r e s i d eo f f e m a l et e r m i n a l s
ls there continuity?
YES-Check for loosewires or poor connectionsat
heatercontrol oanel connectorsA (14P)and B (22P)
and at the air mix control motor 5P connector.lf the W i r e s i d eo i l e m a e l e r m i n a l s
connectionsare good. substitutea known-goodair
mix control motor, and recheck,lf the symptom/
indicationgoes away, replacethe originalair mix ls therc continuity?
control motor. lf the symptom/indicationcontinues,
substitutea known-goodheatercontrol panel,and Y E S - R e p a i ra n y s h o r t t o b o d y g r o u n dl n t h e
recheck.lf the symptom/indicationgoes away, wire(s)betweenthe heatercontrol panel and the air
replacethe original heatercontrol panel.l mix control motor.l
N O R e p a i ra n y o p e n i n t h e w i r e ( s )k e t w e e n t h e
heatercontrol panel and the air mix control N O - G o t o s t e p5 .
motor.l
21-16
5. Turn the ignition switch ON (ll),and checkthe same DTC9: A Problemin the Air Mix Control
terminalsfor voltage. Linkage,Door,or Motor
HEATERCONTROLPANELCONNECTOR
A {14PI 1, Test the air mix control motor (seepage 21-34).
YES-Substitute a known-goodheatercontrol
panel,and recheck.lf the symptom/indicationgoes
away, replacethe original heatercontrol panel.l
HEATERCONTROLPANELCONNECTOR
B I22PI
Wiresideof femaleterminals
21-17
Heatingand Air Conditioning
DTCTroubleshooting.(cont'd)
DTC10:An Openor Shortin the Mode 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h e s a m e
ControlMotorCircuit t e r m i n a l sf o r v o l t a g e .
YES Go to step 2.
s (14P)
3 . D i s c o n n e cht e a t e rc o n t r o lp a n e lc o n n e c t o r A
and B \22P1. Wire side of femaleterminal
tl 12 15 T6 1 1 1 8 t 9 2A 21 22
HEATER
CONTROL
PANEL
CONNECTOR
A {14PI
RED/YEL
WHT
Wiresideof femaleterminals
NO- Go to step 6.
W i r e s i d e o f f e m a L el e r m i n a l s
ls there continuity?
Y E S R e p a i ra n y s h o r t t o b o d y g r o u n di n t h e
wire(s)betweenthe heatercontrol panel and the
mode control motor.l
NO Go to step 5.
21-18
Turn the ignition switch OFF,and checkfor DTC11:A Problemin the ModeControl
continuitybetweenthe following terminalsof Linkage,
Doors,or Motor
heatercontrol panel connectorsA (14P)and B (22P)
and the mode control motor 10Pconnector. 1. Testthe mode control motor (seepage 21-35).
14P: 10P:
'10
N o .2 No. ls the mode control motor OK?
No.10 No,1
N o .1 1 No.2 YES Substitutea known-goodheatercontrol
panel,and recheck.lf the symptom/indicationgoes
22P: 10P: away, replacethe original heatercontrol panel.l
N o .1 7 No.8
N o .1 8 No.6,9 NO Replacethe mode control motor, or repairthe
No.19 No.5 l i n k a g ea n d d o o r s . l
N o .2 0 N o .4 , 7
HEATER
CONTROL PANELCONNECTOR A (14PI
Wiresideof lemaleterminals
MODECONTROLMOTORlOPCONNECTOR
Wiresideof femaleterminals
HEATERCONTROLPANELCONNECTORB {22PI
Wire side of femaleterminals
ls there continuity?
21-19
HeatingandAir Gonditioning
DTCTroubleshooting{cont'd)
DTC12:A Problemin the BlowerMotor 7. Checkfor continuitybetweenthe No. 3 terminal of
Circuit the power transistor4P connectorand body ground.
'1.
C h e c kt h e N o . 1 2 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d POWERTRANSISTOR4P CONNECTOR
fuse/relaybox, and the No. 14 (10A)fuse in the
under-dashf use/relaybox.
2
Are the tuses OK?
3 4
YES-Go to step 2. BLK
o
NO Replacethe fuse(s),and recheck.l
BLOWERMOTOB2PCONNECTOR
ls there continuity?
YES-Go to step 8.
3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
YES Go to step 4,
NO Go to step 17.
Y E S - G o t o s t e p1 0 .
21-20
1a Disconnectheatercontrol panelconnectorA (14P). 1 5 . Reconnectheatercontrol panel connectorA (14P).
1 3 .Checkfor continuitybetweenthe No. 7 and No. 8 lo. Test the power transistor(seepage 21-38).
terminalsof heatercontrol panel connectorA (14P)
a n d b o d y g r o u n di n d i v i d u a l l y . ls the power transistorOK?
HEATER
CONTNOL
PANEL
CONNECTOR
A {14PI YES Checkfor loosewires or poor connectionsat
heatercontrol panel connectorA (14P)and at the
power transistor4P connector.lf the connections
are good, substitutea known-goodheatercontrol
panel,and recheck.lf the symptom/indicationgoes
away, replacethe original heatercontrol panel.l
) NO Go to step 20.
8LU/RED
20. Turn the ignitionswitch OFF.
21-21
Heatingand Air Conditioning
DTCTroubleshootinglcont'd)
22. Measurethe voltage betweenthe No. 3 terminal of 25. Turn the ignition switch OFF,
the blower motor relay 4P socketand body ground.
26. Checkfor continuitybetweenthe No. 1 terminal of
the blower motor relay 4P socketand body ground.
BLOWERMOTORRELAY4PSOCKET
BLOWERMOTORRELAY4PSOCKET
2 1
4 3
BLOWERMOTORRELAY4PSOCKET
ls therebattery voltage?
YES-Go to step25.
21-22
DTC14:An Openin the Evaporator 4. Checkfor continuitybetweenthe No. 7 terminal of
Temperature
SensorCircuit heatercontrol panelconnectorB (22P)and the
No. 1 terminal of the evaporalortemperature
1. Removethe evaporatortemperaturesensor(see s e n s o r2 P c o n n e c t o r .
p a g e2 1 - 3 7 ) .
HEATERCONTROLPANELCONNECTOR B {22P)
2. Measurethe resistancebetweenthe No. l and Wiresideof femaleterminals
No. 2 terminalsof the evaporatortemperature
sensor.
x D i pt h e s e n s o ri n i c ew a t e r ,a n d m e a s u r e
resistance.Then pour hot water on the sensor,and
c h e c kf o r c h a n g ei n r e s i s t a n c e .
TORTEMPERATURE
EVAPORA SENSOR
t-l
ll#l EVAPORATOR
TEMPERATURE SENSOR 2PCONNECTOR
Wiresideof femaleterminals
lI UT-TU
l , l , l l
---r---T--I
t ^
11c))-l ls there continuity?
\9/
50 68 86'F
10 20 30'c
TEMPERATURE
Y E S - G o t o s t e p3 .
NO Replacethe evaporatortemperature
sensor.I
(cont'd)
21-23
Heatingand Air Gonditioning
DTCTroubleshooting{cont'd)
6. Checkfor continuitybetweenthe No. 2 terminal of DTC15:A Shortin the Evaporator
heatercontrol panel connectorA (14P)and the Temperature
SensorCircuit
No, 2 terminal of the evaporalortemperature
sensor2P connector. 1. Removethe evaporatortemperaturesensor(see
p a g e2 1 - 3 7 ) .
HEATER
CONTROL PANELCONNECTOR A {14PI
Wiresideof femaleterminals 2. Testthe evaporatortemperaturesensor(seepage
LT GRN 21-37J.
YES Go to step 3.
NO Replacethe evaporatortemperature
sensor.!
EVAFORATOR
TEMPERATURE SENSOR 2PCONNECTOR
Wiresideof femaleterminals Disconnectheatercontrol panel connectorB l22Pl.
ls there continuity?
21-24
RecirculationControlMotor CircuitTroubleshooting
1 . C h e c kt h e N o . 1 4 ( ' 1 0 A ) f u sien t h e u n d e r - d a s h f u s e / 8. Checkfor continuitybetweenthe No. 5 and No. 6
relay box. terminalsof heatercontrol panelconnectorA (14P)
and body ground individually.
ls the f use OK?
HEATER
CONTROL A I14P)
PANELCONNECTOR
YES Go to step 2.
RECIRCULATIONCONTROLMOTOR
ls there continuity?
5P CONNECTOR
YES Repairany shortto body ground in the
wire(s)betweenthe heatercontrol panel and the
recirculationcontrol motor.l
NO-Go to step 9.
YES Go to step 5.
{cont d r
21-25
Heatingand Air Conditioning
RecirculationControl Motor CircuitTroubleshooting(cont'd!
10. Turn the ignition swirchOFF.
HEATER
CONTROL PANEL CONNECTOR A {14P}
Wiresideol temaleterminats
RECIRCULATION
CONTROL MOTOR5PCONNECTOR
Wiresideol lemaleterminals
ls there continuity?
21-26
HeaterControlPowerand GroundCircuitsTroubleshooting
1 . C h e c kt h e N o . 1 4( 1 0 A ) f u s ei n t h e u n d e r - d a s h 6. Checkfor continuitybetweenthe No. l3terminal of
fuse/relaybox. heatercontrol panelconnectorA (14P)and body
g round.
ls the f use OK?
A (1ilP)
CONTRoLPANELCONNEcToR
HEATER
YES-Go to step 2.
N O - R e p l a c et h e f u s e ,a n d r e c h e c k . l
1 2 3 4 5 6
HEATER
CONTROL A {14P}
PANELCONNECTOR
ls therc continuity?
YES-Go to step 5.
21-27
Heatingand Air Conditioning
CondenserFanCircuitTroubleshooting
NOTE:lf neitherthe condenserfan nor the radiatorfan 4 . C o n n e ctth e N o . l a n d N o . 2 t e r m i n a l s o f t h e
work, go to Radiatorand CondenserFansCommon condenserfan relay 4P socketwith a jumper wire.
CircuitTroubleshooting(seepage21-29).
CONDENSERFAN RELAYitP SOCKET
1. Checkthe No. 1 (20A)fuse in the under-hood
f u s e / r e l a yb o x ,a n d t h e N o . 1 4 ( 1 0 A ) f u s ei n t h e
under-dashf use/relaybox.
YES-Go to step 2.
CONDENSER
FAN FELAY4PSOCKET
r-,_-l
1 2 |
Flr
\----1--rl
IELK/YEL
d,
ls thete battery voltage? I
YES-Go to step 4.
ls there battery voltage?
NO-Replace the under-hoodfuse/relaybox.l
YES Replacethe under-hoodfuse/relaybox.t
N O - R e p a i r o p e ni n t h e w i r e b e t w e e nt h e N o . 1 4
fuse in the under-dashfuse/relaybox and the
c o n d e n s efra n r e l a y . l
21-28
Radiatorand CondenserFans
CommonCircuitTroubleshooting
9 . Disconnectthe condenserfan 2P connector,
1 0 .Checkfor continuitybetweenthe No. 1 terminal of NOTE;lf both fans and the Ay'Ccompressorclutchdo
the condenserfan relay 4P socketand the No. 2 not work when the Ay'Cswitch is on, go to Ay'CPressure
terminal of the condenserfan 2P connector. Switch CircuitTroubleshooting(seepage 21-32l,.
CONDENSER
FANRELAY4PSOCKET 1. Checkthe No. 1 {20A}and No. 4 (20A)fuses in the
under-hoodfuse/relaybox, and the No. 14 (10A)
fuse in the under-dashfuse/relaybox.
YES Go to steD2.
YES Go to step 5.
8 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
(cont'd)
21-29
HeatingandAir Conditioning
Radiatorand CondenserFans CompressorClutchCircuit
CommonCircuitTroubleshooting Troubleshooting
(cont'dl
1. Checkthe No. 1 (20A)fuse in the under-hood
9. Using a BackprobeSet, measurethe voltage f u s e / r e l a yb o x ,a n dt h e N o . 1 4 { 1 0 A ) f u s ei n t h e
betweenthe No. 6 terminal of ECN4
connectorB under-dashfuse/relaybox.
{24P)and body ground with the ECMconnectors
connecteo. Are the tuses OK?
ECMCONNECTOR
B {24P} YES Go to step 2.
YES UDdatethe ECM if it does not have the latest NO-Go to step 3.
so{tware,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication \
3. Removethe compressorclutchrelay from the
goes away with a known-goodECM,replacethe under-hoodfuse/relaybox, and test it (seepage 22-
originaE
l CM.I 5 1) .
COMPfiESSON
CLUTCHBELAY'P SOCKET
YES Go to step 5.
NO Replacethe under-hoodfuse/relaybox.I
21-30
5. Connectthe No. 1 and No. 2 terminalsof the L Turn the ignition switch OFF.
compressorclutch relay 4P socketwith a jumper
wire. 10. Reinstallthecompressorclutch relay.
COMPRESSORCLUTCHRELAY4P SOCKET
11. l\4akesure the Ay'Cswitch is OFF.
1 2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
ECMCONNECTOR
E 131P}
2 3 t 4 5 6 1 E 9
1 4 1 5 16 m 21
Does the compressor clutch click ? 22 23 24 26 27 29 31
RED
YES Go to step 6.
N O - G o t o s t e p1 4 .
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ls there battery voltage?
8. Measurethe voltagebetweenthe No. 3 terminal of
the compressorclutch relay 4P socketand body YES Updatethe ECM if it does not have the latest
ground. software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
CLUTCHRELAY4PSOCKET
COMPRESSOR goes away with a known-goodECIM,replacethe
o r i g i n aE
l CM.I
t e j u m p e rw i r e .
1 4 . D i s c o n n e ct h
YES-Go to step 9.
{cont'd)
21-31
Heatingand Air Conditioning
Compressor
ClutchCircuit A/C PressureSwitch Circuit
Troubleshooting(cont'dl Troubleshooting
YES Go to step 3.
YES Go to step 7.
N O - G o t o s t e p9 .
1 . S t a nt h e e n g i n e .
21-32
8. Connectthe No.4terminal ofheatercontrol 11. Checkfor continuitybetweenthe No. 2 terminal of
connectorA (14P)to body ground with a jumper the A,/Cpressureswitch 2P connectorand the No. 9
wire, terminal of under-dashfuse relav box connector
F t12Pt.
HEATER
CONTROLPANELCONNECTOR
A I14P} A/C PRESSURE SWITCH2PCONNECTOR
W i r e s i d eo f f e m a l et e r m i n a l s
BLU
2 3 4 5 6
7 8 I r 0 l x 11 12 l 3 t 4
JUMPER
WIBE
Wiresideoffemale
terminals UNDER.OASHFUSE/RELAYBOX CONNECTORF (12P)
W i r es i d eo f f e n a l e l e r r r i n a l '
2 5
6 1 B g l r ot l l2
BLU/WHT
JUMPER
WIRE
ls there continuity?
Does the NC system come on?
YES Repairopen in the wire betweenthe heater
YES Go to step 10. control panel and the A,/Cpressureswitch.l
21-33
HeatingandAir Conditioning
Air Mix ControlMotorTest Air Mix ControlMotor Replacement
1. Disconnectthe 5P connectorfrom the air mix 1 . Removethe under-dashfuse/relaybox (seepage
control motor. 22-491.
2. Connectbatterypowertothe No. l terminal ofthe Disconnectthe 5P connector{A) from the air mix
air mix control motor, and ground the No. 2 control motor (B).Removethe self-tappingscrews
t e r m i n a l t; h e a i r m i x c o n t r o lm o t o rs h o u l dr u n ,a n d and the air mix control motor from the heaterunit.
stop at Max Cool.lf it doesn't,reversethe R e m o v et h e r o d ( C )f r o m t h e a r m ( D )o f t h e a i r m i x
connections;theair mix control motor should run, controi motor.
and stop at Max Hot. lf the air mix control motor
does not run, remove it. then checkthe air mix ,.,:l'
control linkageand door for smooth movement.
AIRMIX CONTROLMOTOR
21-34
Mode ControlMotor Test Mode ControlMotor Replacement
'1.
Disconnectthe 10Pconnectorfrom the mode 1 . R e m o v et h e E C M( s e ep a g e 1 1 - 4 ) .
control motor.
2. Removethe relay mount bracketbolt, and move
Connectbatterypower to the No. 1 terminal of the the relaysout of the way.
mode control motor, and groundthe No. 2
terminal;the mode control motor should run 3 . Disconnectthe 10Pconnector{A) from the mode
smoothly and stop at Defrost.lf it doesn't,reverse control motor (B).Removethe self-tappingscrews
the connections;the mode control motor should and the mode control motor from the heaterunit.
run smoothly and stop at Vent.When the mode
control motor stops running,disconnectbattery
power immediately.
MODECONTROLMOTOR
21-35
HeatingandAir Conditioning
RecirculationControlMotor Test RecirculationControlMotor I
Replacement
1. Disconnectthe 5P connectorfrom the recirculation
control motor.
1 . R e m o v et h e E C M( s e ep a g e1 1 - 4 ) .
RECIRCULATION
CONTROL
MOTOR
21-36
EvaporatorTemperatureSensor EvaporatorTemperatureSensor
Replacement Test
1 . Removethe driver'sdashboardlower cover (see l. Dip the sensorin ice water, and measurethe
page 20-59)and the under cover (seepage 20-60). resistancebetweenits terminals
t0
32 50 68 86 'F
0 10 20 30'c
TEMPERATURE
21-37
HeatingandAir Gonditioning
PowerTransistorTest HeaterControlPaneland Push a
Switch AssemblyRemovaland
1. Disconnectthe 4P connectorfrom the power Installation
Iranslslor.
POWERTRANSISTOB
C a r e f u l l yr e l e a s et h e l o c kt a b o n t h e N o . 4 t e r m i n a l \
(BLUI/EL)(A) in the 4P connector,then removethe
terminaa l n d i n s u l a t ei t f r o m b o d y g r o u n d .
3 . lnstallthe control panel and push switch assembly
in the reverseorder of removal.After installation,
operatethe control panel controlsto see whether it
worKspropeny.
4 . Runthe self-diagnosis
functionto confirm that
there are no problemsin the system (seepage21-
8).
(To112 power
2V p o w e rssource on
o u r c eo n vvehicle)
ehicle)
S u p p l y1 2v o l t st o t h e N o . 4 c a v i t yw i t h a j u m p e r
wire.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
b l o w e rm o t o r r u n s .
21-38
Dustand PollenFilterReplacement BlowerUnit Removaland
lnstallation
The dust and pollenfilters should be replacedevery
3 0 , 0 0 0m i l e s( 4 8 . 0 0 0
k m ) o r 2 4 m o n t h sw h i c h e v e r
comes first. Replacethe filters more often if the air flow For some models:SRScomponentsare locatedin this
i s l e s st h a n u s u a l . area.Reviewthe SRScomponentlocations(seepage
23-13)and precautionsand procedures(seepage 23-14)
1. Openthe glove box. Removeboth glove box stops, in the SRSsectionbeforeperforming repairsor service.
then let the glove box hang down (seepage 20 63).
1. Make sure you havethe anti-theftcode for the radio,
2 . R e m o v et h e f i l t e rl i d ( A ) f r o mt h e b l o w e ru n i t ,t h e n then write down the frequenciesfor the preset
p u l l o u t t h e f i r s td u s ta n d p o l l e nf i l t e r( B ) .S l i d et h e buttons.
secondfilter to the left,and pull it out.
2. Disconnectthe batterynegativecable,and wait 3
minutesbefore beginningworK.
Cut heare.
{cont'd)
21-39
Heatingand Air Gonditioning
Blower Unit Removaland Installation{cont'd}
Removethe steeringhangerbeam bracketcover 10. Disconnecttheconnector{A) from the recirculation
from the right side of the glove box opening,then control motor, then removethe wire harnessclip
removethe bolts and the olove box frame. {B).Removethe mounting bolts,the mounting nuts
a n d t h e b l o w e ru n i t ( C ) .
21-40
Blower Unit ComponentsReplacement
Nole these items when overhaulingthe blower unit;
' The recirculationcontrol motor (A),the power transistor(B),the blower motor (C),and the dust and pollenfiltefs (D)
can be replacedwithout removingthe blower unit.
. Beforereassembly,make surethatthe recirculationcontrol linkageand doors move smoothly.
. After reassembly,make surethe recirculationcontrol motorruns smoothly (seepage 2j-36).
21-41
Heatingand Air Gonditioning
EvaporatorCoreReplacement a
1 . Recoverthe refrigerantwith a recovery/recycling/ 5. Carefullypull out the evaporatorcore without
chargingstation(seepage 21-53). bendingthe pipes.
21-42
HeaterUnit/CoreReplacement
SRScomponentsare locatedin this area.Reviewthe 6. Slidethe hose clamps (A) back,then d isconnectthe
SRScomponentlocations(seepage23'13),and inlet heaterhose (B)and the outlet heaterhose (C)
precautionsand procedures(seepage 23-14)in the SRS from the heatercore. Enginecoolantwill run out
sectionbefore performingrepairsor service. when the hosesare disconnected;drain it into a
clean drip pan. Be sure not to let coolantspill on
1. Make sure you have the anti-theftcode forthe radio, the electricalpartsor the paintedsurfaces.lf any
then write down the freouenciesfor the radio's coolantspills,rinse it off immediately.
Dresetbuttons.
W h e nt h e e n g i n ei s c o o l ,d r a i nt h e e n g i n ec o o l a n t
from the radiator(seepage 10-6).
8 x 1.25mm
12 N.m (1.2kgf.m,8.7lbf.ft)
(cont'd)
21-43
Heatingand Air Conditioning
HeaterUnit/CoreReplacement(cont'd)
8. Removethe dashboard{seepage 20-66). 1 1 . R e m o v et h e m o u n t i n gb o l t s ,t h e m o u n t i n gn u t s ,
and the heaterunit.
9. Disconnecttheconnectors(A) from the blower
motor, the recirculationcontrol motor, the mode
control motor, and the power transistor,then
removethe wire harnessclips (B)and the
connector(C).Removethe self-tappingscrewsand
the bracket(D).
7 t ,
5 x 1 . 0m m
9.8 N.m
11.0kgl m,
7.2 tbf.ftl
21-44
13. Installthe heatercore and the evaporatorcore in
the reverseorder of removal.
21-45
Heatingand Air Conditioning
HeaterValveCableAdjustment
1 . F r o mu n d e r t h eh o o d ,o p e nt h e c a b l ec l a m p{ A ) , 5, From under the hood,turn the heatervalve arm {C)
then disconnectthe heatervalve cable (B)from the to the fully closedpositionas shown, and hold it.
heatervalve arm {C). Attachthe heatervalve cable (B)to the heatervalve
a r m ,a n d g e n t l yp u l l o n t h e h e a t e rv a l v ec a b l e
housingto take up any slack,then installthe heater
v a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) .
.'.-:',,
- " l l
.....-
t.- l
,
21-46
CompressorReplacement
1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er,u n t h e 8. Removethe mounting bolts and the compressor.
engineat idle speed,and let the air conditioning
work for a few minutes,then shut the engine off.
u1/
and apply a thin coat of refrigerantoil before
installingthem. Be sure to use the correctO-rings
f o r H F C - 1 3 4{aR - 1 3 4 at o ) a v o i dl e a k a g e ,
. U s er e f r i g e r a not i l ( K E l H l NS P - ' 1 0f o ) r HFC-134a
K E I H I Ns p i r a lt y p e c o m p r e s s oor n l y .
. To avoid contaminatlon,do not returnthe oilto
( the containeronce dispensed,and never mix it
with other refrigerantoils.
o . l m m e d i a t e l ya f t e ru s i n gt h e o i l , r e i n s t a l l t h ec a p
on the container,and seal it to avoid moisture
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint. lf the refrlgerantoil
contactsthe paint,wash it off immediately.
. Chargethe system (seepage 21-55).
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 1 - ' 1 3 9 ) .
. Enterthe antitheft code for the radio,then enter
the customer'sradio station presets.
21-47
HeatingandAir Gonditioning
CompressorClutchCheck a
1 . Checkthe armatureplatefor discoloration,peeling, 4. Releasethe field coil connectorf rom the holder,
or other damage.lf there is damage,replacethe then disconnectit. Checkthe thermal protectorfor
clutch set (seepage 21-49), continuity.lf there is no continuity,replacethe
t h e r m a lp r o t e c t o (r s e ep a g e2 1 - 5 1 ) .
Checkthe rotor pulley bearingplay and drag by
rotatingthe rotor pulley by hand.Beplacethe NOTE:The thermal Drotectorwill have no
clutchset with a new one if it is noisy or has c o n t i n u i t ya b o v e2 5 2 t o 2 7 0 " F\ 1 2 2 l o 1 3 2 ' C )W
. hen
excessiveplay/drag(seepage 21-49). t h et e m p e r a t u r e d r o p sb e l o w2 4 1t o 2 1 9 ' F( 1 1 6t o
104'C),the thermal protectorwill have continuity.
,\.
Measurethe clearancebetweenthe rotor pulley (A)
and the armatureplate (B)all the way around.lf the Checkresistanceof the field coil. lf resistanceis not
clearanceis not within specifiedlimits, removethe within specifications,replacethe field coil
armatureplate (seepage 21-49)and add or remove ( s e ep a g e2 1 - 4 9 ) .
shims as neededto increaseor decreaseclearance.
FieldCoil Resistance: 3.05 3.35ohmsat68"F
Clearance: 0.510.15 mm {0.02010.006in.) t20"c)
N O T ET: h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s :
0 . 1m m . 0 . 2m m , 0 . 4m m , a n d0 . 5m m .
21-48
Compressor
ClutchOverhaul
Special Tool Required 3. lf you are replacingthe field coil, removethe snap
A,/Cclutch holder,Robinair10204.Kent-MooreJ37872, ring (A) with snap ring pliers,then removethe rotor
or HondaTool and EquipmentKMT-J33939, pulley (B).Be careful not to damagethe rotor pulley
c o m m e r c i a l la
yvailable or tne compressor.
1 . R e m o v et h e c e n t e rn u t ( A )w h i l e h o l d i n gt h e
armatureplatewith a commerciallyavailableA,/C
c l u t c hh o l d e r( B ) .
\ot
1 7 . 6N . m
{1.8kgf.m,
13 tbt.ft)
-@
/@h"
.ffi
4. Removethe bolt and holder (A).then disconnect
the field coil connector(B).Loosenthe clamp screw
(C)to iree the field coil wire. Removethe snap ring
{ D ) w i t hs n a pr i n g p l i e r s t, h e n r e m o v et h e f i e l dc o i l
Removethe armatureplate (A) and shim(s)(B), (E).Be careful not to damagethe field coil or the
taking care not to losethe shim(s).lf the clutch comoressor.
needsadjustment,increaseor decreasethe
number and thicknessof shims as necessary,then
reinstallthearmatureDlate,and recheckits
clearance(see page21-481.
N O T ET : h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s :
0 . 1 m m , 0 . 2 m m , 0 . 4 m m , a n d 0 . 5m m .
7.4 N.m
(0.75kgf m,
9-=-g 5 tbf.ft)
----------------
"\)
(cont'd)
21-49
HeatingandAir Gonditioning
CompressorClutchOverhaul(cont'd)
5. Reassemblethe clutch in the reverseorder of
disassembly,and note these items:
. I n s t a l l t h ef i e l dc o i lw i t h t h e w i r e s i d ef a c i n g
down, and align the boss on the field coil with the
h o l ei n t h e c o m p r e s s o r .
. Cleanthe rotor pulley and compressorsliding
surfaceswith contactcleaneror other
non-petroleumsolvent.
. I n s t a l l n e w s n a pr i n g s ,n o t et h e i n s t a l l a t i o n
direction,and make surethey are fully seatedin
the groove.
. Make sure that the rotor pulleyturns smoothly
after it's reassembled,
. R o u t ea n d c l a m pt h e w i r e sp r o p e r l yo r t h e y c a n
be damagedby the rotor pulley.
21-50
CompressorThermalProtector CompressorReliefValve
Replacement Replacement
A
9,8 N.m
(1.0kgf m,7.2lbf.ft)
Replacethe thermal protector(A)with a new one,
and apply siliconesealant(B)to the bottom of the Clean the mating surfaces.
thermal Drotector.
4 . Installa new O-ringon the reliefvalve, and apply a
thin coat of refrigerantoil to the O-ring.
21-51
Heatingand Air Conditioning
GondenserReplacement
1 . Recoverthe refrigerantwith a recovery/recycling/ 4, Removethe mounting bolts,then removethe
chargingstation(seepage 21-53). condenserby lifting it up. Be carefulnot to damage
the radiatoo
r r t h e c o n d e n s efri n s w h e n r e m o v i n o
Removethe front bumper {seepage 20-85). the condenser.
5 . l n s t a l l t h ec o n d e n s eirn t h e r e v e r s eo r d e ro f
removal,and note these items.
6x1.0mm
9.8 N.m ('1.0kgf.m,7.2lbf.ft) . l f y o u ' r ei n s t a l l i n ga n e w c o n d e n s e ra,d d
r e f r i g e r a not i l ( K E l H l NS P -1 0 )l s e ep a g e2 1 ' 6 ) .
. Replacethe O-ringswith new ones at eachfitting,
and apply a thin coat of refrigerantoil before
installingthem. Be sure to usethe correctO-rings
f o r H F C - 1 3 4(aR - ' 1 3 4 a ) a t ov o i dl e a k a g e .
. lmmediatelyafter using the oil, reinstallthecap
on the container,and seal it to avoid moisture
absorption.
. D o n o t s p i l l t h er e f r i g e r a not i l o n t h e v e h i c l e ; i t
,t\
may damagethe paint.lf the refrigerantoil
contactsthe paint,wash it off immediately.
. Be carefulnot to damagethe radiatoror the
condenserfins when installingthe condenser.
. Chargethe system (seepage 21-55).
6x1.0mm
9.8 N.m (1.0kgt.m.7.2lbf.ft)
21-52
RefrigerantRecovery
1. Connecta R-134arefrigerantrecovery/recycling/
chargingstation{A) to the high-pressureservice
Air conditioningrefrigerantor lubricantvapor port (B)and the low-pressureserviceport (C),as
can irritateyour eyes,nose.or throat. shown, following the equipmentmanufacturer's
Be carefulwhen connectingserviceequipment. instructions.
Do not breatherefrigerantor vapor
r: -:
1!l i t:
-'', - (
Use only serviceequipmentthat is U.L.-listedand is
certifiedto meet the requirementsof SAE J2210to
r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g '=i -
system.
lf accidentalsystemdischargeoccurs,ventilatethe
work area before resumingservice
r
Additionalhealthand safetyinformationmay be
obtainedfrom the refrigerantand lubricant
manufacturers.
21-53
Heatingand Air Conditioning
SystemEvacuation
2. Connecta R-134arefrigerantrecovery/recycling/
chargingstation(A)to the high-pressureservice
. Air conditioningrefrigerantor lubricantvapor pon (B)and the low-pressureserviceport (C),as
can irritateyour eyes,nose,or throat. shown,following the equipmentmanufacturer's
. Be carefulwhen connectingserviceequipment. instructions.Evacuatethe system.
. Do not breatherefrigerantor vapor.
lf accidentalsystem dischargeoccurs,ventilatethe
work area before resumingservice.
21-54
SystemCharging
2 . Evacuatethe system(seepage 21'54).
Air conditioningrefrigerantor lubricantvapor 3 . Add the same amount of new refrigerantoil to the
can irritateyour eyes,nose,or throat. systemthat was removedduring recovery.Use
Be carefulwhen connectingserviceequipment. only KEIHINSP-10refrigerantoil.
Do not breatherefrigerantor vapor,
4 . Chargethe system with the specifiedamount of
R-134arefrigerant.Do not overchargethe system;
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . ' l i s t e a
dn di s the compressorwill be damaged.
certifiedto meet the requirementsof SAEJ2210to
r e m o v eH F C - 1 3 4{aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g Selectthe appropriateunits of measurefor your
system. refrigerantchargingstation.
21-55
HeatingandAir Conditioning
RefrigerantLeakTest
Special Tool Required 1. Connecta R-134arefrigerantrecovery/recycling/
Leakdetector,HondaTool and EquipmentYGK-H-10PM chargingstation(A)to the high-pressureservice
c o m m e r c i a l la
vvailable port (B)and the low-pressureserviceport (C),as
shown, following the equipmentmanufacturer's
anstructions.
A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r
can irritateyour eyes,nose,or throat.
Be carefulwhen connectingserviceequipment.
Do not breatherefrigerantor vapor
lf accidentalsystem dischargeoccurs,ventilatethe
work area before resumingservice.
Open the high pressurevalve to chargethe system
R - 1 3 4 as e r v i c ee q u i p m e n o
t r v e h i c l ea i r c o n d i t i o n i n g to the specifiedcapacity,then closethe supply
systemsshould not be pressuretestedor leaktested valve,and removethe chargingsystem couplers.
with compressedair.
Selectthe appropriateunits of measurefor your
Additionalhealthand safety informationmay be refrigerantchargingstation.
obtainedfrom the refrigerantand lubricant
manufacturers. Refrigerant capacity:
500 to 550 g
0.50to 0.55kg
1 . 1 0t o 1 . 2 1l b s
17.6to 19.4oz
21-56
A/C SystemTests
Pressure
Test
Test results svmotom3 DGaUSe
Discharge (high) pressure
Afterstoppingcompressor, Air in system Recover,evacuate(seepage21-54),
pressure dropsquickly,andthencontinues
to and rechargewith specifiedamount
abnormallyhigh {seeoaoe21 55).
or no airflow through
Beduced Cloggedcondenser or radiator Clean
condenser fins Checkfan voltageand rpm.
Condenseror radiatorfan not Checkfan direction.
leaks
Fefrigerant clulchis dirtv.
:omoressor :omoressor shaftsealleakinq Reolacethe comDressor,
lomoressorbolt(s)aredirtv. no aroundbolt(s) Tiohtenbolt{s)ot reolacecomDressor,
; o m D r e s s o ro a s k e t i s w e t w i t h o i l . iet no acethe comoressor.
(cont'd)
21-57
Heatingand Air Conditioning
A/C SystemTests(cont'd)
PerformanceTest Open the glove box. Removeboth glove box stops,
then let the glove box hang down (seepage 20-63).
Test conditions:
The performancetest will help determineif the air
conditionersystem is operatingwithin specifications. . Avoid direct sunlight.
. Open the hood.
Use only serviceequipmentthat is U.L.-listedand is . Open the front doors.
cenified to meet the requirementsof SAE J2210to . Sel the temperaturecontrol dial on Max Cool,the
r e m o v eH F C - 1 3 4(aR - 1 3 4 a l f r o m
t h e a i rc o n d i t i o n i n g mode control dial on Vent,and the recirculation
system. control switch on Recirculate.
. Turn the A,/Cswitch on and the fan switch on Max.
lf accidentalsystem dischargeoccurs,ventilatethe . R u nt h e e n g i n ea t 7 5 0 r p m .
work area before resumingservice . N o d r i v e ro r p a s s e n g e risn v e h i c l e .
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r c o n d i t i o n i n g A f t e r r u n n i n gt h e a i r c o n d i t i o n i n fgo r I 0 m i n u t e s
systemsshould not be pressuretestedor leaktested underthe above test conditjons,read the delivery
with compressedair. temperaturefrom the thermometerin the center
vent, the intaketemperaturenear the blower unit,
Additionalhealthand safety informationmay be and the high and low system pressurefrom the Ay'C
obtainedfrom the refrigerantand lubricant g au g e s .
manufacturers.
1 . Connecta R-134arefrigerantrecover/recycling/
chargingstationto the high-pressureserviceport
and the low-pressureserviceport, following the
equipmentmanufacturer'sinstructions.
D e t e r m i n et h e r e l a t i v eh u m i d i t ya n d a i r
Iemperarure.
21-58
7. To completethe charts:
. r el o n gt h e v e r t i c a l i n e .
M a r k t h ed e l i v e r y t e m p e r a t u a
. Mark the intaketemperature(ambientair temperature)along the bottom line.
. Draw a line straightup from the air temperatureto the humidity.
. M a r ka p o i n t 1 0% a b o v ea n d 1 0% b e l o w t h eh u m i d i t yl e v e l .
. From each point. drawa horizontalline acrossthe deliverytemperature.
. The delivervtemperatureshould fall betweenthetwo lines
. Completethe low-sidepressuretest and high-sidepressuretest in the same way.
. Anv measurementsoutsidethe line may indicatethe needfor further inspection.
kPa
(ksl{cm') {kgflcm')
Lpsrl Lpsil
2500- 600
[25) _ {6t
360l tssl 80 yo
a0 0/"
2000 HUMIDITY
(201 LEVEL
1280
fcl 30 9o
1500-
{1s} 30%
,21o)
80%
1000-
(101
:1401
500 -
{5)
171l
DELIVERY
PRESSURE
100
{11
h4l
INTAKE
PRESSURE
OELIVERY
TEMPERATURE
I I I
.F
68 77 86 95 104
t20l t25l t30) (35) {40) {'cl
INTAKETEMPEBATURE
21-59
BodyElectrical \
Wipers/Washers
ComponentLocationIndex ....................... 22-134
C i r c u iD
t iagram
RearWindowWiperIntermiftent
C o n t r oU l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-138
........
Wiper/Washer Switch
TesVReplacement 22-140
C o n t r oUl n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . . . . .2.2. .-.1. .4. 1
..
WiperMotorTest 22-143
WasherMotorTest 22-144
WasherFluidLevelSwitchTesV
R e p l a c e m e(nCt a n a d a.l . . . . . . . . . . . . . . . . . .22-144 .......
WindshieldWiperMotor Replacement.... 22-145
RearWindowWiperMotor
Replacement 22-146
W a s h eR r e s e r v oR i r e p l a c e m e n. .t. . . . . . . . . .22-146 ....
W a s h eTr u b e sB e p l a c e m e n. .t. . . . . . . . . . . . . .22 . . . 147
...
lmmobilizerSystem
componentLocationIndex ........... 22-162
S y s t e mD e s c r i p t i o .n. . . . . . . . . . . . . . . :. . . : . . : . :22-163
...
CircuitDiagram 22-164
Troubleshooting
lmmobilizerControlUnit
- R e c e i v eRre p l a c e m e n. .t. . . . . . . . . . . . . . . . .22-167 ........
BodyElectrical
SpecialTools
Ref. No. Tool Number Description Otv
Q) 07wAz-001010A MPCSServiceConnector 1
o) O7LAJ-PT3O2OA Test Harness 1
o 07TAz-001020A BackProbeAdaotet 1
22-2
GeneralTroubleshootingInformation
Tipsand Precautions Some connectorshave a clip on their side used to
attachthem to a mount bracketon the body or on
Before Troubleshooting a n o t h e rc o m p o n e n tT. h i sc l i p h a sa p u l lt y p e l o c k .
1. Checkapplicablefuses in the appropriatefuse/relay Some mountedconnectorscannot be disconnected
oox. unlessyou first releasethe lock and removethe
connectorfrom its mount bracket(A).
2. Checkthe batteryfor damage.stateof charge,and
cleanand tight connections.
Handling Connectors
. Make surethe connectorsare clean and have no
l o o s ew i r e t e r m i n a l s .
. Make sure multiplecavity connectorsare packedwith
dielectricgrease(exceptwatertight connectors). Nevertry to disconnectconnectorsby pulling on their
. All connectorshave push-downreleasetype locks(A). wires; pull on the connectorhalvesinstead.
Alwavs reinstallDlasticcovers,
(cont'd)
22-3
BodyElectrical
GeneralTroubleshootingInformation(cont'd)
Checkfor looseretainer(A)andrubberseals(B). HandlingWires and Harnesses
. Securewires and wire harnessesto lhe frame with
their respectivewire ties at the designatedlocations.
. Removeclips carefully;don't damagetheir locks(A).
| . , ./ f
.ll t/
lwtl"//
----E;
'l/ F. \--------\
tflr'---'..-
I It
22-4
Testingand Repairs UsebackDrobeadaotor07TM-0010204.
. Do not usewires or harnesseswith brokeninsulation.
Replacethem or repairthem by wrappingthe break
withelectricaltape.
. After installingparts,make surethat no wires are
o i n c h e du n d e rt h e m .
. When using electricaltestequipment,followthe
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. l f p o s s i b l ei ,n s e r t t h ep r o b eo f t h e t e s t e r f r o m t h ew i r e
side (exceptwaterproofconnector).
( c o n td )
22-5
BodyElectrical
GeneralTroubleshootingInformation(cont'dl
Five-stepTroubleshooting Wire Color Codes
'1.
Verify The Complaint The following abbreviationsare usedto identifywire
T u r n o n a l l t h e c o m p o n e n t si n t h e p r o b l e mc i r c u i t colors in the circuitschematics:
to verify the customercomplaint.Note the w H T . . . . . . . . . . . . . . . . . . . . , . , . White ............
symptoms.Do not begin disassemblyor testing Y E L . . . . . . . . . . . . . . . . . . . . . . , , .Y. .e.l.l .o. w ,......
until you have narroweddown the problem area. B 1 K . . . . . . . . . . . . . . . . . . . . . . . . . . .B. .l.a. .c. k. . . . .
B L U. . . . , . . . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . .
2. AnalyzeThe Schematic G R N . . . . . . . . . . . . . . . . . . . . . . . .G . .r.e. .e.n. . . . . . .
Look up the schematicfor the problem circuit. R E D. . . . . . . . . . . . . . . . . . . . . . . . . . . .Red
........,
Determinehow the circuit is supposedto work by o R N . . . . . . . . . . . . . . . . . . . . . . . . Orange.............
tracingthe currentpathsfrom the power feed P N K . . . . . . . . . . . . . . . . . . . . . . . .P . .i,n. k. . . . . . . . .
through the circuitcomponentsto ground. lf B R N . . . . . . . . . . . . . . . . . . . . . . . .Brown .............
severalcircuitsfail at the same time, the fuse or G R Y . . . . . . . . . . . . . . . . . . . . . . . .Gray ............,
g r o u n di s a I i k e l yc a u s e . P U R . . . . . . . . . . . . . . . . . . . . . . . .P . .u. .r .p.l.e. . . . . .
1 T 8 1 U . . . . . . . . . . . . . . . . . . . . . Light . . . . . ,Blue
.....
Basedon the symptoms and your understandingof 1TGRN....................L . .i.g. h
. .G
t. ,r.e. .e n
the circuitoperation,identifyone or more possible
causesof the problem. The wire insulationhas one color or one color with
anothercolor stripe.The secondcolor is the stripe.
3. lsolateThe ProblemBy TestingThe Circuit
Make circuitteststo checkthe diagnosisyou made
i n s t e p2 . K e e pi n m i n d t h a t a l o g i c a ls, i m p l e
procedureis the key to efficienttroubleshooting.
Testfor the most likelycauseof failure first, Try to
make tests at pointsthat are easilyaccessible.
22-6
Relayand Control Unit Locations
EngineCompartment
BLOWERMOTORRELAY
RADIATORFAN
RELAY
HORNRELAY
CONDENSERFAN
RELAY
ELDUNIT
UNDER-HOOD
FUSE/RELAY
BOX
\...
,-:1-'...
22-7
Relayand GontrolUnit Locations
Dashboard
_DAYTIME RUNNINGLIGHTSEELAYlCanada)
lWirecolorsrRED,RED/YEL,I
LRED/BLKandRED/8LU I
_LOW BEAMCUTRELAYlcanada) _
lWire REDMHT,
colors: RED/BLK,I
LBEDA/ELandRED/BLU I
KEYLESSRECEIVER
UNIT
CRUISECONTROLUNIT
'
'-.:- ':
..? ;,
POWERWINOOW RELAY
TURN SIGNAL/HAZARDRELAY
TAILLIGHTRELAY UNDER.DASH
; .[:_- - FUSE/RELAY
BOX
-l:r --
MULTIPLEXCONTROLUNIT
22-8
(cont'd)
22-9
Relayand Control Unit Locations
Dashboard(cont'd) a
SRSUNIT
PGM.FIMAINRELAY1
EPSCONTROLUNIT lWirecolors:YEUBLK,
LWHT/BLK,WHT/BLKand RED/YEL
AIR/FUEL RATIOSENSORRELAY PGM.FIMAN RELAY2
[WirecolorsrWHT,WHT/RED, I fwirecolors:YEUBLK, I
OBNandBLK/ORN I YEUBLKand GRN/YELI
LYEUGRN,
22-10
Rearand Roof
MOONROOF OPENRELAY -
Wirecolors:GRNI/EL,GRN, I
LRED/YEL, BLKandYEL/GRNI
MOONROOF CLOSERELAY
fwire colors:GRN/BLK,
GRN, l
IGRN,AtVHT,BLKand YEL/GRNI
REARWINDOWWIPERINTERMITTENT
CONTBOLUNIT
22-11
Relayand ControlUnit Locations
Door and Seat
Driver'sDoor:
l\:
].\
POWERWINDOWMASTERSWITCH
lHasbuilt-incontrolunit)
Passenger's
Seat:
22-12
Gonnectors
and Harnesses
a GonnectorIndex
ldentification
numbershavebeenassigned to in-lineconnectors. by the letter"C" for connectors,
The numberis preceded "G" for ground
terminalsor "T" for non groundterminals.
Hamess Location
EngineCompartment Dashboard Others{Floor,Door, Not€s
Trunk.and Roo{l
Startersubharness C 1 0 2a n dC 1 0 3 (seepage22-15)
T1 andT2
T 1 0 1a n dT 1 0 2
Batterygroundcable T3 {seepage22-l!)
G'l and ( -
Enginegroundcable T4 {seepage22-14)
Enginewire harness C l 0 l t h r o u g hC 1 0 4 (seepage22 16)
G1 0 1
Enginecompartment
wire harness G201andG202 (seepage22 18)
{riohtbranchi
Enginecompartment
wire harness G301 (seepage22 18)
(leftbrench)
Enginecompartment
wire harness (seepage22-18)
(dashboard) c401
C451and C452
C501throughC503
c551
c851
G402
EPSsubharness C 1 5 1a n d C 1 5 2 \seepage22 241
G'151
Dashboard wire harness
A C504throughC510 (seepage22-26)
lleftbranch) G501andG503
L e f ts i d et u r n s i g n a l l i g h t c506 (seepage22-26)
22-13
and Harnesses
Connectors
Gonnectorto Harnesslndex
BatteryGroundCable
Connectoror Terminal Cavities Location Connectsto Notes
T3 Left side of enqinecompartment
Left side of enginecompartment Bodygroundviabattery
qroundcar)le
2 Batterv B a t t e r vn e o a t i v et e r m i n a l
EngineGround Cable
Connectoror Terminal Cavities focation Connec{sto Notes
r4 5 Riohtsideof enoine
4 Rightsideof enginecompartment Bodygroundviaengine
ENGINEGROUNDCABLE
BATTERYGROUNDCABLE
\.....
22-14
StarterSubharness
Connectoror Terminal Ret Cavities Location Connoc,ts
to Notes
Alternator 10 4 Right side of eng;necompartment
Knocksensor 8 1 Front of engine
Startersolenoid 5 1 Middle of enginecompartment
c102 7 6 Front of enginecompartment Enginewire harness(see
page22 16)
c103 6 1 F r o n t o f e n g a n ec o m p a r t m e n t Enginewire harness(see
o a a e2 2 - 1 6 )
T1 2 L€tt sideof enginecompartment Underhoodfuse/relay box
r2 4 Middleor enoinecomDanment Stanermotor
T101 1 Under-hood fuse/relay
box
r102 I Alternator
Batterv Battervpositiveterminal
STARTERSUB HARNESS
22-15
Connectorsand Harnesses
Connectorto HarnessIndex(cont'dl
EngineWireHarness
2 Transmission housing
Camshaft position(CMP)sensor 3 Leftsideof engine
Lllr sensor 3 Rightsideofengine
EC[,4connectorA Underglovebox
ECI/lconnectorB 24 Underglovebox
Enginecoolanttemperature (ECT) 2 Leftside of engine
sensor
Engineoil pressure switch 28 1 BightsideoI engine
EVAPcanisterpurgevalve 2 Leftside of intakemanifold
ldleair control(lAC)valve 18 3 Left sideof intakemanifold
lgnitioncoilNo. l 4 3 Middleof enginecompartment
lgnitioncoilNo.2 5 3 Middleof enginecompartment
lgnitioncoilNo.3 6 3 Middleof enginecompartment
lgnitioncoilNo.4 7 3 Middleof enginecompartment
IniectorNo. 1 25 2 Middleof enginecompartment
InlectorNo.2 24 2 Middleof enginecompartment
IniectorNo.3 20 2 Middleof enginecompartment
IniectorNo.4 19 2 Middleof enginecompanment
Intakeairtemperature {lAT)sensor 12 2
3 Leftsideof intakemanifold
TDCsensor 8 3 Leftsideof engine
Throttleposition(TP)sensor 11 Left side of intakemanifold
Vehiclespeedsensor(VSSI 10 3 Transmission housing
VTCoil controlsolenoidvalve 27 2 Rightsideo{ engine
VTECoil pressureswitch 29 2 Rightsideof engine
VTECsolenoidvalve 30 2 Rightsideof engine
c 101 3 20 Underrightsideof dash ECMwire harness{seepage
22-321
c102 22 Frontof enginecompanment (seepage
Startersubharness
22-15)
Frontof enginecompartment (seepage
Startersubharness
22 151
22-16
....-
10
11
13
14
22-17
Connectorsand Harnesses
Connectorto HarnessIndex{cont'dl
EngineCompartmentWire Harness(Rightbranch)
Connsctoror Terminal Cavitiss Location Connectsto Notes
ABSmodulator-control unit Bightsideo{ enginecompartment
Bearwasher motor 8 2 Behindrightsideof {rontbumper
RightfrontABSwheelsensor 12 2 Rightsideot enginecompartment
Rightfrontairbags€nsor 2 Behindrightsideof frontbumper
Bightfrontparkinglight 1 2 Behindrightheadlight
Rightfrontsidemarkerlight 10 2 Behindrightsideof Jrontbumper
Rightfrontturn signallight 11 2 Behindrightheadlight
Rightheadlight 2 Behindrightheadlight
Righthorn I Behindfrontbumper
wash€rfluidlevelswitch 7 2 Behindrightsideof trontbumper Canada
Windshield washermotor 2 Behindriohtsideof frontbumoer
G201 6 Behindrightsideof trontbumper Bodygroundvia€ngine
compartment
wtreharness
G202 Behindrightsideof Jrontbumper Bodygroundviaengine
.omnerhent wire harness
22-18
ENGINECOMPARTMENT
WIRE
HARNESS
(cont'd)
22-19
and Harnesses
Connectors
Connectorto HarnessIndex (cont'dl
EngineCompartmentWire Harness(Left branch)
24 l Frontof enginecompanment
22 2 Leftsideof enginecompartment
AirJuel(A,,/F)
ratiosensor 2 Leftsideof enginecompartment
Brakefluidlevelswitch 2 Leftsideo{ enginecompartment
Condenser fan motor 25 2 Frontof enginecompartment
Cruisecontrolactuator 1 4 Underrightsideof cowlcover
ELDunit 9 3 Under'hood f use/relay
box
Foglightconnector ,l Leftsideof enginecompartment
LeftfrontABSwheelsensor 12 2 Leftsideof enginecompanment
Leftfrontairbagsensor 2 Behindleftsideof frontbumper
Leftfrontparkinglight 17 2 Behindleftheadlight
Leftfrontsidemarkerlight 2 Behindleftsideof frontbumper
Leftlrontturnsignallight 13 2 Eehindleftheadlight
Leftheadlight 20 3 Behindleftheadlight
Lefthorn 21 l Behindfrontbumper
Radiatorfan motor 23 2 Leftsideof enginecompartment
Radiatorfan switch 2 Frontof enginecompartment
Secondary heatedoxygen(SHO2S) 3 4 Leftsideof enginecompartment
22-20
l' \-
ENGINECOMPARTMENTWIRE
HARNESS
(conr'd)
22-21
and Harnesses
Connectors
Connectorto HarnessIndex (cont'd)
EngineCompartmentWire Harness(Dashboard)lcont'dl
Connectoror Terminal Cavities Location Connectsto Notes
Foglightconnector 5 1 Undermaddle of dash Oplion
Under'dash fuse/relaybox 12 Underleftsideof dash
connectorF (seepage22-45)
Underdash fuse/relaybox 5 10 Underleftsideof dash
connectorG (seepage22-45)
Underdash fuse/relay
box 3 Underleftsideof dash
connectorH (seepage22'45)
Under-dash fuse/relay
box 2 5 Underleftsideof dash
connector| (seepage22'45)
Under-dash fuse/relay
box 3 8 Underleftsideol dash
connectorJ (seepage22-45)
c151 12 2 Underrightsideof dash EPSsubharness {seepage22-
24)
c401 1 Underrightsideot dash Dashboard wire harnessB
(seepage22-30)
c451 I Underrightsideot dash ECMwire harness(seepage
22-321
c452 9 UnderrightsideoJdash ECMwire harness(seopage
22 32)
c501 10 '10 UnderrightsideoI dash Dashboard wire harnessA
(seepage22-26)
c502 6 4 Underrightsideol dash Dashboard wire harnessA USA
lsee page 22-261
c502 6 8 UnderrightsideoJdash Dashboard wire harnessA Canada
(seepage22-26)
c503 5 UnderrightsideoJdash Dashboard wire harnessA
(seepage22-26)
10 Undermiddleof dash Floorwireharness(seepage
22-34l'
'14
c851 1 Underrightsideof dash ,VCwire harnesslsee page
22-43\
G402 1' I Eodygroundviaengine
..mdarlma.t w,rc harncss
22-22
BOX
FUSE/RELAY
UNDER-DASH
WIRE
ENGINECOMPARTMENT
D
' -
-.,.i ' 1_-1.:,
ifa.: ,, ..j
. - ,
-,,
-g'-.t ';.-a
22-23
Connectorsand Harnesses
Connectorto Harnesslndex (cont'dl
EPSSubharness
Connectoror Terminal Cavities Location Connectsto Notes
EPScontrolunitconnectorA 2 2 Underrightsideofdash
EPScontrolunitconnectorB ,l 2 Underrightsideof dash
EPScontrolunitconnector
C 3 20 Underrighrsideof dash
EPSmotor 1 2 Middleof enginecompanment
EPStorquesensor 6 Middleof enginecompartment
c151 6 2 Underrightsideof dash Enginecompartment wire
harness(seepage22-18)
c152 4 I Underrightsideof dash wire harness(seepage
ECI\,4
22-321
G151 5 aodygroundvia EPS
22-24
EPSSUB HARNESS
22-25
Connectorsand Harnesses
Connectorto HarnessIndex (cont'd)
DashboardWire HarnessA {Leftbranchl
Connectoror Terminal ffi
Accessorypower socket 22 2 Undermiddleof dash
Audioantenna 2 2 Underleftsideof dash
Brakepedalpositionswitch 26 4 ] Underleftsideof dash
Clutchinterlockswitch 2 ] Underleftsrdeof dash
Clutchpedalpoistionswitch 30 2 | Underleftsideof dash
Cruisecontrolunit 29 14 I Underleftsideof dash
Cruisemainswitch 6 5 Underleftsideof dash
Daytimer!nning lightscontrolunit 28 14 Underlettsideof dash Canada
Daytimerunninglightsrelay 4 Underlettsideof dash Canada
Gaugeassembly connectorA I 22 I Behindgaugeassembly
GaugeassemblyconnectorB 8 22 i Behindgaugeassembly
Hazardwarningswitch 20 10 Behindhazardwarnningswitch
Heatercontrol panelconnectorA 11 22 Behindheatercontrolpanel
Heatercontrol panelconnectorB 18 '14 Behindheatercontrolpanel
HVACpush switch assembly 19 10 ] BehindHVACswitchassembly
Keylessreceiverunit 10 5 I Undermiddleof dash
Low beamcut relay 5 5 lUnderleftsideofdash
Optionalsecurityconnector 3 16 Underlefrsideof dash
Powermirrorswitch 27 13 UnderleftsideoI dash
Under-dash fuse/relaybox 17 ln the under-dashfuse/relay
box
connectorK (seepage22-45)
Under'dashfuse/relaybox ,I4 l0 In the under-dash
fuse/relay
box
L {seepage22-45}
Underdashfuse/relay box 12 In the undeFdash
fuse/relay
box
connectorM lsee page22'45)
Under-dashfuse/relaybox In the underdashfuse/relay
box
connectorN (seepage22-45)
UndeFdash fuse/relaybox 12 Inthe under-dash
fuse/relay
box
connector
UndeFdash
O (seepage22-45)
fuse/relaybox
connectorY(seepage22 45)
11 In the under-dash
fuse/relay
box L
c504 Underleftsideof dash Driver'sdoorwire harness
(seepage22'40)
c505 Underleftsideot dash Driver'sdoorwire harness
(seepage22-40)
c506 34 Underleftsideof dash Leftsideturo signallight
suonarness
c507 1 Underleftsideof dash Roofwire harness(seepage
22 3Al
c508 Undermiddleof dash Floorwire harness{seepage
22-341
c509 24 Undermiddleof dash Floorwire harness(seepage
22 34J
c510 25 12 Undermiddleol dash Dashboard wire harnessB
(seeoaoe22-30)
G501 1 Undergaugeassembly Body ground via dashboard
22-26
WIRE
DASHBOARD
A
HARNESS
,./
-19
20
34 I
(cont'd)
22-27
Connectorsand Harnesses
Connectorto HarnessIndex (cont'd)
DashboardWire HarnessA (Rightbranch)
Connecloror Terminal Cavities Location Connectsto Notes
Audiounitconnector 20 Eehindaudiounit
c501 6 10 Underrightsideof dash Enginecompartment wire
harness(seepage22,18)
c502 5 4 Underrightsideof dash Enginecompanmentwire USA
harness(seepage22-18)
c502 5 8 Underrightsideof dash Enginecompartment wire Canada
harness(seepage22-18)
c503 4 5 tJnderrightsideof dash Enginecompartment wire
harness(seepage22-18)
c5' 11 Undermiddleof dash ECN4 wire harness(seepage
22-321
c512 12 8 Undermiddleof dash Floorwire harness{seepage
22-341
8 2 Underrightsideof dash Rightsideturn signallight
suonarness
c514 9 Underrightsideof dash Passenger's doorwire
harness(seepage22 4l)
10 6 Underrightsideof dash Passenger's doorwire
harness(seepage22 4'l)
ca52 2 21 Undermiddleofdash A,/Cwire harness(seepage
'l 22-43)
c853 3 Undermiddleof dash ly'Cwire harness(seepage
22-431
G502 Underrightsideof dash Eodygroundvia dashboard
22-28
WIBE
DASHBOARO
HARNESS
A
'---/...'
T
I
22-29
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
DashboardWire HarnessB
Collqctor or Terminal Cavities Locatiol| Connectsto Notes
C a b l e reel 2 5 In steeringcolumncover
Combination lightswitch 1 In steeringcolumncover
Driver'sairbaginflator 17 4 In steeringcolumncover
lgnitionkey switch 16 In steeringcolumncover
lgnitionswitch 't9
1 In steeringcolumncover
lmmobilizer controlunit receiver 18 1 In steeringcolumncover
Passenger's airbaginflator I 4 Undermiddleof dash
SRSunitconnector A 18 Undermiddleofdash
Wiper/washerswitch 3 14 In steeringcolumncover
Underdashfuse/relay box 5 5 Underleft sideof dash
connectorAlseepage22,45)
Under dashluse/relaybox 6 6 Underleftsideofdash
connectorB (seepage22-45)
Under'dash fuse/relaybox 14 Underleftsideof dash
connectorC (seepage22-45)
Under-dash fuse/relaybox 1 2 Underlettsideof dash
connector S lseepage22-45)
Under'dash fuse/relaybox 8 8 Under left sideof dash
connectorX(seepage22 45)
c401 10 Underrightsideof dash Enginecompartment wire
harness(seepage22-'18)
c402 12 10 Undermiddleof dash Floorwire harness(seepage
22-34J
c403 11 4 Undermiddleof dash Floorwire harness(seepage
22-341
G510 14 12 Undermiddlesideof dash Dashboard wire harnessA
(seeoaoe22-26)
G40l Undergaugeassembly Bodygroundviadashboard
22-30
WIRE
OASHBOARD
HARNESS
B
22-31
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
ECMWire Harness
Connectoror TerminiF I Re- lcavities L Location Connectsto Notes
Arrruert/vrl ralo sensorretay Eehindglovebox
Datalinkconnector Undermiddleof dash
EC[/lconnectorE 8 Behindglovebox
PGM-Flmainrelay1 7 4 Behindglovebox
PGM-Flmainrelay2 6 4 Behindglovebox
Under-dash fuse/relay
box 1 In the under-dash
fuse/relay
box
connector D (seepage22 45)
Underdashfuse/relay box 2 Inthe under-dash
fuse/relay
box
connectorE lsee page22-45)
under-dashfuse/relaybox 3 6 In the under-dash
fuse/relay
box
connectorR lsee page22-45)
c10'1 4 20 Underrlghtsideof dash Enginewire harness(see
page22'16)
c152 1' I 8 Underrightsideof dash EPSsubharness(seepage
22-24)
c451 I Underrightsideof dash Enginecompanment wire
harness{seepage22-18)
c452 10 4 Underrightsideot dash Enginecompartment wire
harness{seepage22-18)
c453 14 6 UndermiddleoI dash Floorwire harness(seepage
22-34)
c511 12 Undermiddleof dash Dashboard wire harnessA
{seeoaoe22-26)
G451 Undergaugeassembly Bodygroundvia ECMwire
harness
22-32
ECMWIREHARNESS
22-33
Connectorsand Harnesses
Connectorto Harnesslndex (cont'd)
FloorWire Harness(Frontsidel
Connec-tor or Terminal I Ref uavftres Location connects to Nol6s
Driver'sseatbeltswitch 11 3 I Underdriver'sseat
Driver'ssideairbaginflator l0 2 i Underdriver'sseat
Driver'ssideimpactsensor 13 2 I Leftside offloor
Leftside seatbelt buckletensioner 12 4 Underdriver'sseat
Memoryerasesignal(MES)connector 19 2 Underdashfuse/relaybox
Parkingbrakeswitch 9 1 1Middleoffloor
Passenger's seatbelt switch 5 3 Underpassenger's seat
Passenger's sideairbaginflator 3 2 Underpassenger's seat
Passenger's sideimpactsensor 7 2 Rightsideoffloor
Rightsideseatbeltbuckletensioner 4 4 Underpassenger's seat
SRSunitconnector B 20 18 I Undermiddleof dash
SRSunitconnector C 21 8 Undermiddleof dash
Under-dashfuse/relaybox 11 18 Underdashfuse/relaybox
connector P {seepage22-45)
Under-dash fuse/relaybox 'r8 8 Underdashfuse/relay
box
connectorO (seepage22,45) ]
c402 22 10 Undermiddleof dash Dashboard wire harnessB
I {seepage22 30)
c403 23 4 Undermiddleof dash Dashboard wire harnessB
(seepage22-30)
c453 6 Undermiddleof dash ECMwire harness(seepage
22-321
c508 2 4 Undermiddleof dash Dashboard wire harnessA
(seepage22-26)
c509 14 6 Undermiddleofdash Dashboard wire harnessA
\see page 22-26)
c512 1 8 Undermiddleof dash Dashboard wire harnessA
I {seepage22-26)
10 Undermiddleof dash Enginecompartment wire
harness(seepage22 18)
6 4 ] Unaermiddleof aasn OPDSunitharness(seepage
22-421
G551 I L,nderpassenger's
seat Bodygroundviafloorwire
22-34
- 10
11
FLOORWIREHARNESS
( c o n t ' d)
22-35
Gonnectors
and Harnesses
Connectorto HarnessIndex (cont'dl a
Floor Wire Harness {Rear side}(cont'dl
22-36
FLOORWIREHARNESS
22-37
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
RoofWire Harnsss
Connectoror Terminal Cavities tocation Connectsto Notes
Moonroofclose relay 6 5 Middleof roof
Moonrool control unit I 5 Middleof roof
Moonroofmotor 2 Middleof roof
Moonrootopenrelay 7 5 Middleof roof
Moonroofpositionsensor1 8 2 MiddleoI roof
N4oonroofpositionsensor2 5 4 Middleof roof
Moonroofswitch 1 5 Frontof roof
Rearceilinglight 3 N4iddleof roof
SpotlighVceiling
light 2 4 Frontof roof
c507 10 8 Underleftsideof dash Dashboardwire harnessA
(seeoaoe22-261
22-38
HatchWire Harness
Connectoror Torminal Cavities Location Connects to Notes
Hatchlatchswitch 7 2 Middleo{ hatch
Hatchlockactuator 2 Middleof hatch
Highmountbrakelight 8 2 Behindhighmountbrakelight
Licenseplatelight connectorA 2 Middleof hatch
Licenseplatelight connectorB I 2 Middleof hatch
Rearwindowde{ogger connector
A 3 1 RightC-pillar
Bearwindowdetoggerconnector
B 10 1 LeftC-pillar
( )
Bearwindowwipermoto. 6 4 Middleof hatch
c553 2 12 Rightquanerpanel Floorwire harness(seepage
22-341
c554 l 2 Rightquanerpanel Floorwire harness(seepage
)2-34\
22-39
and Harnesses
Connectors
Connectorto Harnesslndex (cont'd) \,
Driver'sDoorWire Harness
Connectoror Terminal ReI Cavities Location Connectsto Notes
Driver'sdoor lockactuator 9 2 Driver'sdoor
Driver'sdoorlockknobswitch 10 3 Driver'sdoor
Driver'sdoor lockswitch 1 3 Driver'sdoor
Driver'sdoorspeaker 7 2 Driver'sdooa
Driver'spowerwindow motor 2 Driver'sdoor
Left power mirror actuator 3 6 Driver'sdoor
Left tlveeter 2 Driver'sdoor
Powerwindow masterswitch 8 Driver'sdoor
c504 5 20 Underleftsideof dash Dashboard A
wire harness
't3 \seepage22-261
c505 6 Underleftsideof dash Dashboard A
wire harness
DRIVER'SOOORWIREHABNESS
22-40
Passenger'sDoor Wire Harness
Connectoror Terminal Rel Cavities Location Connectsto Notes
Passenger's
doorlockactuator 6 2 Passenger's
door
Passenger's
doorspeaker I 2 Passenger's
door
powerwindowmotor
Passenger's 5 2 Passenger's
door
powerwindowswitch
Passenger's 1 5 Passenger's
door
Rightpowermirroractuator 4 6 Passenger's
door
Righttweeter 3 2 Passenger's
door
c514 2 13 Underrightsideof dash Dashboard wire harnessA
(seepage22'26)
1 6 Underrightsideof dash Dashboard wire harnessA
lsee oeoe 22-26\
PASSENGER'S
DOORWIREHABNESS
22-41
and Harnesses
Gonnectors
Connectorto Harnesslndex {cont'dl
OPDSUnit Harness
ConnoctororTorminal Cavitios Location Connectsto Notes
OPDSunit 2 I In frontpassenger's
seat
1 Underfrontpassenger'sseat Floorwareharness(seepage
22-34)
FLOORWIBEHARNESS
22-42
A/C Wire Harness
Connoctoror Terminal Rel Cavities Location Connec'tsto Notes
Air mix controlmotor I 5 Undermaddle of dash
Blowermotor 2 2 Underrightsideof dash
Evaporator temperaturesensor 8 2 Undermiddleof dash
Modecontrol motor 3 10 Underrightsideof dash
Powertransistor 4 Underrightsideof dash
Recirculationcontrolmotor 1 5 Underrightsideof dash
c851 1 1 Undermiddleol dash Enginecompartment wire
harness(seepage22-18)
c852 6 21 Undermiddleofdash Dashboard wire harnessA
{seepage22 26i
c853 5 ,] Undermiddleo{ dash Dashboard wire harnessA
lsee oaoe 22-261
22-43
Fuse/Relay
Boxes
Connectorto Fuse/RelayBox Index
Under-hoodFuse/RelayBox
22-44
Under-dashFuse/RelayBox
W ( M e m o r ye r a s es i g n a l( M E S )
l5
to
17
l t
2
Optionalconnector
Floorwire harness(seepage22-34)
connector)
X 28 I {Plugsdirectly into the multiplexcontrol unat)
Y 13 ( P l u q sd i r e c t l vi n t ot h e m u l t i D l e cx o n t r o lunrl)
tn--rl
I U LI L.]L.J
h - - n -
UL]L]UL]
I] L] L] LI L]
!3 12
22-45
PowerDistribution
Fuseto Componentslndex
Under-hoodFuse/RelayBox
l l I
t
t t
t4 " t | lI
l l - - -
- E'l E,l E,l r--r r---rt__J i; i6'!/'
O: Sparefuse
22-46
Under-dashFuse/RelayBox
_ _ ^ :
Hr tl_l
f at-t
at\t I
r^,rl fl
!!;r -
!f 3 3 9: , i ; s ! ! s
Fnf |rnITf
22-47
GroundDistribution
Groundto ComponentsIndex
Ground Componentor circuit qrounded
Batterv,Transmissionhousinq
En g i n e
G1 0 1 ECM(PGis BLK;LGis BRN/YEL)
BLK:IACvalve,lgnitioncoils,Vehiclespeedsensor,VTECsolenoidvalve
BRNA/EL:Camshaft oosition(CMP)sensor.CKPsensor,TDCsensor.VTECoil pressure
switch
G 15' ] EPScontrolunit
G201 ELDunit. Multiplexcontrol inspectionconnector,Multiplexcontrol unit, Powerwindow relay,Rear
window washer motor, Rightfront parkinglight, Rightfront side marker light, Rightfront turn signal
light,Turn signal/hazardrelay,Washerfluid level sensor(Canada), Windshieldwasher motor,
WindshieldwiDer motor
G202 ABSmodulator-control
unit
G301 Blower motor relay,Brakefluid level switch,Condensorfan motor, Cruisecontrol actuator,Leftfront
parkinglight, Leftfront side marker light, Leftfront turn signallight, Radiatorfan motor, Radiatorfan
swrtcn
G401 Combinationliqht switch,lqnitlon kev srvitch,Wiper/wasfrersr,virch
G402 Left and riqht airbaqsensors,SRS unit
G4 5 1 Datalink connector(DLC)
G501 Clutchinterlockswitchm Clutchpedal positionswitch (for cruisecontrol),Cruisecontrol main switch,
Cruisecontrol unit, Daytimerunning lightscontrol unit (Canada),Driver'sdoor lock knob switch,
Driver'sdoor lockswitch,Driver'spower window motor, Heatercontrol panel,Left power mirror
defogger(Canada),left side turn signal light, Moonroof control unit, Monroof open and close relays,
'1,
Moonroof positionsensor Moonroof seitch,Power mirror switch,Powertransistor,Powerwindow
masterswitch.SDotliqhts
G502 Accessorypower socket,Gaugeassembly,Keylessreceiverunit, lvlultiplexcontrol unit, Right power
m i r r o rd e f o g g e {r C a n a d a )
G503 A u d i ou n i t
G551 Driver'sseat belt switch,Fuelgauge sendingunit, Fuelpump, Memory erasesignal(IMES)connector,
OPDSunit. Riohtseat belt switch
G552 High mount brakelight, Licenseplate lights,Rearwindow defogger,Rearwindow defoggernoise
condenser.Rearwindow wioer motor, Hatchlatch switch
Back-uplights,Brakelights,Rearside marker lights,Rearturn signal lights,Rearwindow wiper noise
condenser,Rearwindow wiper intermittentcontrol unit, Taillights
22-48
Under-dashFuse/RelayBox
Removaland Installation
SRScomponentsare locatedin this area.Reviewthe 5. Removethe mounting bolt, and slidethe under-
SRScomponentlocations{seepage 23-13)and dash fuse/relaybox (A) down from the bracket{B).
precautionsand procedures(seepage23-14)in the SRS
sectionbeforeperformingrepairsor service. 6. Disconnectthe backside from connectorsfrom the
back of the under-dashfuse/relaybox, and remove
Removal the fuse/relaybox.
1. Make sure you have the anti-theftcode for the radio, N O T E : T h eS R Sc o n n e c t o irs a s p r i n g - l o a d eldo c k
then write down the frequenciesfor the radio's type (seepage 23-11).
presetbuttons.
lnstallation
2. Disconnectthebatterynegativecable,then
disconnectthe positivecable,and wait at least 1. Installthe under-dashfuse/relaybox in the reverse
three minutes. order of removal and connectall connectorsto the
under-dashfuse/relaybox.
3. Removethe driver'sdashboardlower cover (see
page 20-59). 2 . I n s t a l l t h ed r i v e r ' sd a s h b o a r dl o w e rc o v e r .
4. Disconnectthe connectorsfrom the fuse side of the 3. Connectboth the negativecable and positivecable
under-dashfuse/relaybox. to the battery.
6 . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
22-49
Battery
Battery Test {
. l f t h e c a s ei s d a m a g e d r, e p l a c e t h eb a t t e r y . l
. lf the case looksOK, go to step 3.
3. Checkthe indicatorEYE.
. lf the EYEindicatesthebafteryischarged,goto
step 4.
. l f t h e E Y Ei n d i c a t e s al o w c h a r g e ,g o t o s t e p 7 .
6. Recordbatteryvoltage.
. l f v o l t a g ei s a b o v e 9 . 6 v o l t s , t h e
b a t t e r yi s O K . l
. l f v o l t a g ei s b e l o w 9 . 6 v o l t sg, o t o s t e p T .
7 . C h a r g et h e b a t t e r yo n H i g h( 4 0a m p s )u n t i lt h e E Y E
shows the batteryis charged,plus an additional30
minutes.lf the batterychargeis very low, it may be
necessaryto bypassthe charger'spolarity
protectioncircuitry.
. l f t h e E Y Ei n d i c a t e s t h eb a t t e r yi s c h a r g e d w i t h i n
3 hours,the batteryis OK.l
. lf the EYEindicatesthebatteryis notcharged
within 3 hours,replacethe battery.l
22-50
Relays
PowerRelayTest
Usethischanto identifythetypeof relay,thendo the type 1:
testlistedfor it.
relayinputtest(seepage22-
NOTE:Turnsignal/hazard
87).
Relay Test
A'lCcomoressor
clutchrelav Normally-open
Airlfuel ratio sensorrelav type A
Condenserfan relay
H e a d l i o hrte l a v1
H e a d l i q hrte l a v2
H o r nr e l a v
Powerwindow relay type 2:
R a d i a t oIra n r e l a y
Reverserelav
Startercut relav
T a i l l i q h rt e l a V
D a y t i m er u n n i n gl i g h t sr e l a y
{ C a n a d)a
P G M - FmI a i nr e l a v1
P G M - Fm
l a i n r e l a v2
Blower motor relav Normally-open
Rearwindow defoqoerrelav tvpe B
Moonroofclose relay F i v et e r m i n a l
Moonroof oDenrelav type
Low beam cut relav {Canada) PGM-FImain relay 1
PGM-FImain relay 2
Normally-open
type A: type 1:
type 2:
(cont'd)
22-51
Relays
PowerRelayTest (confdl
Normally-open
type B: Five-terminal
type
Checkfor continuitybetweenthe terminals. C h e c kf o r c o n t i n u i t yb e t w e e nt h e t e r m i n a l s .
tF-gr
tJ 1l
6:)
rc*V
.r{{
(n F, t )\ \
type2:
type 2;
22-52
lgnitionSwitch
Test
SRScomponentsare locatedin this area.Reviewthe
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a
) nd
precautionsand procedures{seepage 23-'l4)in the SRS
sectionbefore performingrepairsor service.
WHT/RED
Wiresideof
f e m a l tee r m i n a l s
BLK/WHT BLK/YEL
BLK/RED
22-53
Gauges
\-
ComponentLocationIndex
PARKINGBRAKESWITCH
p a g e1 9 - 1 0
FUELGAUGESENDING
p a g e1 1 - 1 5 6
SWITCH
ENGINEOILPRESSURE
page8-4
GAUGEASSEMBLY
Procedure,page22-56
SelJ-diaqnostic
Gauqedulb Replacement,page22 63
Rep6cement,page22-64
CoolantTemperatureGauge
page22'64
TroLrbleshooting,
BRAKEFLUIDLEVELSWITCH
p a g e1 9 - 1 0
VEHICLESPEEDSENSOR{VSS)
page22-65
Troubleshooting,
Beplacement,page22-67
22-54
CONNECTORA CONNECTOR B
(bluel lgreenJ
SPEEDOMETER
VehicleSpeedSignalCircuit
page22-65
Troubleshooting,
TACHOMETEB
\7
t----/ \
_ / \
i . . _ -
FUELGAUGE
ODO/TRIPMETER Test,page11-156
22-55
Gauges
Self-diagnosticProcedure v
The gaugeassemblyhas a self-diagnosisfunction.
. T h e B e e p e rD r i v eC i r c u i C
t heck
. The IndicatorDrive CircuitChecL
. The LCDSegmentsCheck
. The GaugesDrive CircuitCheck(Speedometer,Tachometer,Fuelgauge,Coolanttemperaturegauge)
. T h e C o m m u n i c a t i oLni n eC h e c k( t h ec o o l a n t t e m p e r a t u rsei g n a l i n e b e t w e e nt h e g a u g ea n d E C M )
Enteringthe self-diagnosis
f unction:
Beforedoing the self-diagnosisfunction,checkthe No. 9 (10A)fuse in the under-hoodfuse/relaybox and No. 10 {7.5A)
fuse in the under'dashfuse/relaybox.
NOTE:
. While in the self-diagnosismode, the dash lights brightnesscontrolleroperatesnormally.
'Whileintheself-diagnosismode,thetrip/resetbuttonisusedtostartthebeeperdrivecircuitcheckandthegauge
drive cicuit check.
. lf the vehiclespeedexceeds1.2 mph 12km/h)orthe ignition switch is tu rned OFF,the self,diagnosis mode ends.
oN flrl
lgnition
OFF
Switch
Lighting
Switch
Trip/Reset
5 sec. 5 sec.
The BeeperDriveCircuitCheck:
When enteringthe self-diagnosismode, the beepersoundsfive times
TheIndicatorDriveCircuitCheck:
When enteringthe self-diagnosismode,the following indicatorsblink.
Seatbelt indicator,Door/hatchindicator,Brakesystem,Lowfuel indicator,Maintenancerequiredindicator(USA),
W a s h e rf l u i d l e v e li n d i c a t o (r C a n a d a O
) , i l p r e s s u r el i g h t .
22-56
\
The LCDSegmentCheck:
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
i s o d e ,t h e o d o / t r i ps e g m e n tb l i n k sf i v et i m e s .
TheGaugeDriveCircuitCheck:
i s o d e ,t h e s p e e d o m e t e trh, e t a c h o m e t e rt ,h e f u e l g a u g e ,a n d t h e c o o l a n t
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
temperature g a u g en e e d l e ss w e e pf r o m t h e m i n i m u mp o s i t i o nt o m a x i m u mp o s i t i o nt,h e n r e t u r nt o t h e m i n i m u m
posrtron.
NOTE:After the beeperstops soundingand the needlesreturnto the minimum position,pushingthe trip/resetbutton
s t a r t st h e b e e p e rd r i v ec i r c u i tc h e c k( o n eb e e p )a n d t h e g a u g ed r i v ec i r c u i tc h e c ka g a i n .
T h e c h e c kc a n n o tb e s t a r t e du n t i l t h en e e d l e sr e t u r nt o t h e m i n i m u mp o s i t i o n .
Self-diagnosis ON
mode OFF
Trip/Reset
9l- r n =--llJL--
@,
switch oFF _---
Normal: Faulty:
iD ,-
:-l!:!!JlJ!J t l
i-
f l
O i -
t
--
i-
-
| | | t t f
,- r-
r-
i-
,
Endingthe self-diagnosisfunction:
T u r nt h e i g n i t i o ns w i t c hO F F .
N O T E lrf t h e v e h i c l es p e e de x c e e d s1 . 2m p h { 2 k m / h ) t, h e s e l f d i a g n o s i sf u n c t i o ne n d s .
22-57
Gauges
CircuitDiagram
'
UflOEN fiOOOFUSE/8ILAY
8OX N o 2 0 i o A: lU S A
ECM/PCM
V
I
-r'
r--l
l J , ii-ciorurnn
I coNNECron
I 8|
COOLANI
TEMPfNAIUFT
SPIEDOMEIENTACHOMEIIR FUTLGAUGI GAUGE
Norll0AlFUSE
8L(
-o-
22-58
ti) l To mxr I
MAi{IIiIANCE
ft0unlD
[{0tcaTo8
LIGH]
(LEDI
(cont'd)
22-59
Gauges
CircuitDiagram(cont'dl I
No2il5AlFUSE
ilnlh.undi hooq DASH
llu!./rcl.ybox r LGHTS
Yt Yl
t l
'- -t
WASHEF
Itut0
I!VEL
6t0tc ToR
UGHT
(tDl
J
ls?2
I
BLUIYEL
I
J
cSutsE
m n0L
a
22-60
'- --t
I DAYTIME I
./ ib-n'rnoL ! BUNN|NG ;
tNGniEorL UNIT i LIGHTS I
PRESSUBE I @NTROL
swtTcH I UNII
i
lCld.d Eisin.3topp.d
l I
iopd Ersin.runni.si L -.-..
icmadd
(cont'd)
22-61
Gauges
CircuitDiagram(cont'dl \"
GRNIfiED
I
\""'7
V
LEFTTUN
SIGI'IAL
II'{DICATOR
GAUGIASSEi|BLY LTCHTS
CoME|NAT|ON tMf,tOBtUZEn
LtctlTswtTclt @l\tTRoL
UN|I ftCtIVER
22-62
GaugeBulb Replacement
RIGHTTURNSIGNALINDICATOR
LIGHT{1.4WI
CRUISE ITORLIGHT{I.4W)
HIGHBEAMINOICATOR
LIGHT{1.4W) LEFTTURNSIGNALINDICATORLIGHTl1.il wl
GAUG€LIGHT{1.4WI
GAUGELIGHT{1.4W}
IMMOBILIZENINDICATOR
{1.4Wl
LTGHT
22-63
Gauges
GaugeAssemblyReplacement CoolantTemperature
Gauge
Troubleshooting
1 . Removethe instrumentpanel (seepage 20-59),
t h e n r e m o v et h e u p p e rc o l u m nc o v e r{ s e ep a g e1 7 -
Beforetesting,checkthe No. I { 10A)fuse in the under-
hood fuse/relaybox and the No. '10(7.5A)fuse in the
2. P l a c ea c l e a ns h o pt o w e l ( A )u n d e rt h e g a u g e under dash fuse/relaybox.
assemblyto preventscratchingthe steering
c o l u mn o r d a s hp a n e l . 1. Startthe engine,and checkthe malfunction
i n d i c a t o lra m p ( M l L ) .
3 . Removethe screwsfrom the gauge assembly(B).
Does the MIL come on?
ls a DTC indicated?
3 . D o t h e c o m m u n i c a t i o lni n ec h e c kw i t h t h e s e l f -
4. Disconnectthe connectors(C),and removethe diagnosisprocedure(seepage 22-56).
g a u g ea s s e m D r y .
ls the word "Error" indicated on the odo/ttip
I n s t a l l t h eg a u g ea s s e m b l yi n t h e r e v e r s eo r d e ro f d isplay ?
removal.
YES The gaugecannot receivethe signalfrom the
multiplexcontrol unit and the ECI\,4. Checkfor an
open in the WHT/GRNwire (gaugeconnector
t e r m i n a lB1 3 ) .l f n o o p e ni s f o u n d ,g o t o s t e p5 .
NO Go to step 4.
YES Go to step 5.
NO Replace t h e g a u g ea s s e m b l y . l
22-64
I VehicleSpeedSignalCircuitTroubleshooting
Special Tools Required: 5. Connectthe WHT test harnesscliD(B)to the
Test Harness07LAJ-PT3020A positiveprobe of a voltmeter,and connectthe RED
test harnessclip (C)to the negativeprobe.
Beforetesting,inspectthe No. 4 (10A)and No. 10 (7.5A)
fuses in the under-dashfuse/relaybox.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Y E S - G o t o s t e p7 .
Connectthe test harnessonly to the enginewire
harness. NO Repairopen in the BLK,/YEL wire betweenthe
VSS and the under-dashfuse/relaybox.l
3 . Connectthe REDtest harnessclip (B)to the positive
probe of an ohmmeter.Coverthe white (C)and 7 . Disconnectthe WHT test harnessclip (B).
green {D)test harnessleadswith protectivetape (E).
8 . C o n n e ctth e G R Nt e s th a r n e s sc l i p{ D )t o t h e
4 . Checkfor continuitybetweenthe REDtest harness positiveprobe of a voltmeter.
c l i p a n d b o d yg r o u n d ,
ls there continuity?
YES Go to step 5.
N O R e p a i ro p e ni n t h e B L Kw i r e b e t w e e nt h e V S S
a n dG1 0 1 . I
Is there 5 V or more?
YES- Go to step 9.
(cont'd)
22-65
Gauges
VehicleSpeedSignalCircuitTroubleshooting(cont'dl
9 . Turn the ignitionswitch OFF. 14. Disconnectthe 22Pconnector"8" from the gauge
assemDry.
1 0 .Connectthe other test harnessconnector(A)to the
V S S( B ) ,
GAUGE
ASSEMBLY B (22P)
CONNECTOR
'15.
Connectthe positiveprobe of a voltmeterto the
BLU/WHTwire and the negativeprobeto ground.
1 1 .R aisethe front of the vehicle,and make sure it is
securelysupported. '16.
Slowly rotateone wheel with the other wheel
blocked.
' t 2 .Put
the vehiclein neutralwith the ignitionswitch
o N { |)| , Does voltage pulse f rom 0 to about 5 V or more?
t5. Slowly rotateone wheel with the other wheel YES- Replacethe speedometerassembly.I
blocked.
NO Repairopen in the BLUMHTwiTe between
Does voltage pulse ttom 0 to about 5 V ot morc? the VSS and the speedometer.l
NO Replacethe VSS.I
22-66
I J VSS Replacement
1. Removethe intakeresonator.
22-67
ExteriorLights
GomponentLocationIndex
UNDER.HOOD
FUSE/RELAY
BOX
HEADLIGHT RELAY1
Test,page22-51
HEADLIGHT RELAY2
Test,page22-5'l
BRAKEPEDALPOSITION
swtTcH
Test,page22-84
Adjustment,page l9'6
0/
FRONTTURNSIGNAL
LIGHT
B u l bB e p l a c e m e npt a
, g e2 2 8 1
HEADLIGHTS PARKINGLIGHT
Replacement,page22 79 B u l bR e p l a c e m e npt a, g e2 2 - 8 1
Adjustment.page22-78
page22-81
Eulb Replacement, FRONTSIDEMARKERLIGHT
Bulb Replacement,page22 83
22-68
-a-.,_
z
HIGHMOUNTBRAKELIGHT
page22-82
Replacement,
LICENSE
PLATELIGHTS
page22-83
Replacement,
BACK.UPLIGHT
page22-82
Replacement,
TAILLIGHTSsnd BRAKELIGHTS
page22-82
Replacement,
REARSIDEMARKERLIGHT REARTURNSIGNALLIGHT
page22-83
Replacement, Beplacement,page22-82
(cont'd)
22-69
ExteriorLights
ComponentLocationIndex(cont'dl !
DAYTIMERUNNINGLIGHTSRELAY{Canadal
[Wirecolors:RED,REDryEL,
I
LRED/BLKandRED/BLU I
Test,page22-51
_LOW BEAMCUTRELAY {Canadal_
WirecolorsrREDMHT,RED/BLK,I
LREDryELandRED/BLU I
Test,page22-51
DASH LIGHTSBRIGHTNESS
CONTROLLER
. . i \
'
:' --,': -
' i,-'-'l
/ DRLINDICATOR
LIGHT{Canadal
I t- -
FUSE/
UNDER.DASH
RELAYBOX
22-70
LET] f,IGHT IETT I ucEr\6E
FBOIII TSONT NEANSIDE I PI.ATE
SIDE s]0E MAircN
MAiKEE
L.IGHT
MANXtF
IJGIIT
IIGHT |fiIli
I
8L.l(
_o
22-71
ExteriorLights
CircuitDiagram- Canada t J
UNOEN
HOOO
FUSE/8ELAY
BOX
N ol 9 l 8 0 A l
) to.o No.1'l
- i50Al loa)
IT WHT ED RED,I
N o . ! 0S( 7A lusE
r
d.3hl
/', t-\
I EAr \ rc|'/moN
. rcz/ swfrcH
'2
I- _ l
-- ,'orrro"
V \ vG2Horin0N{ll) .) INDICAIOF
-/ l'lcli;
'l'I
I
I
BU1
BED *01
I
I
=
.|
I RE
A DNL
) No12
i l7.5Al fifili{*1l,.H'
I DAYTIME
--t
BUNNINC
\y
II
TIGHT
luDl
II LIGHTS
EfLAY
t J
HT/BI tU RED/
BLU RE
In 12 , ll t0 t1
8
,{ oorr,",rr.,ro { r- SLU/BID
uctrrscournoLu,'r"
l
T
I I J l
!3 3
||MoS|UZEn
CONTNOL
SYSIIMUGHI UNIT RECEIVEB BI( BI BI G8N
VY 17
Y
I I
GNfl/FEO GRI\/NED
II
I
f'
r\ 88A(E F\ PANKNG
I FiUrD ; } BNAXE
( 2 , LTVEL +./ swrTcH
[./ SWITCH
'nddoM
I
I
i i
G301 cl.1
G501
\, J
22-72
J
DASH
LIGHTS
COMEINATION
LIGHT
SWIqI
BLI( BL]( I
!
t
l ! I
l
I
G301 G301 G552
22-73
ExteriorLights
CircuitDiagram- BrakeLights \
UiDENHOOD
FUSE/NEUYBOX
SATIISY
r!o7l15A)
I |
\ ,r-T-v--rrni'citr
22-74
CircuitDiagram- Back-upLights
UiDEN H@DFUSI/8EIAY
80)(
22-75
ExteriorLights
DaytimeRunningLightsControlUnit InputTest- Canada \
T h e D R Li n d i c a t o lri g h ti n t h e g a u g ea s s e m b l yw i l l c o m e o n w h e n y o u t u r n t h e i g n i t i o ns w i t c ht o O N ( l l )w i t h t h e
headlightswitch off and the parkingbrakese1.lt should go off when you turn on the headlightswitch and releasethe
parkingbrake.lf it comes on at any other time, do the control unit input test.
r i l l g l o w a t h a l fi t s n o r m a li n t e n s i t y .
: h e nt h e d a y t i m er u n n i n gl i g h t sa r e o n ,t h e h i g h b e a mi n d i c a t ow
N O T EW
RED/BLU
GNN/BLK
RED/BLU GRN/BLK
GRN/ORN
22-76
4. Makethese input tests at the connector,
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the input tests prove OK,the control unit must be faulty. Replaceit.
22-77
ExteriorLights
HeadlightAdjustment \
Beforeadiustingthe headlights:
. Parkthevehicleon a levelsurface.
. Makesurethetire pressures arecorrect.
. Thedriveror someonewho weighsthe sameshould
sit in the driver'sseat.
'1.
Cleanthe outer lens so that you can seethe center
of the headlights(A).
3 . O p e nt h e h o o d .
22-78
HeadlightReplacement
'1.
T u r nt h e l o w b e a m so n . Removethe front bumper (seepage 20-85).
22-79
ExteriorLights
CombinationLight Switch Test/Replacement
1. Removethe driver's dashboardlower cover (seepage 20-60).
3 , D i s c o n n e c t t hle6 P c o n n e c t o r ( Af)r o m t h e c o m b i n a t i o nl i g h ts w i t c h( B ) .
Light switch:
\ Telmint
4 5 12 13
Position
OFF
Headlight switch
LOW o--
HIGH o--
OFF
Passingswitch
ON
o-
Turn signalswitch:
\ Terminal
2 10 11
Position
LEFT ----o
NEUTRAL
RIGHT o--
22-80
Bulb Replacement
Headlight: FrontTurn SignalLight:
ParkingLight:
1. Disconnectthe 3P connector(A)from the headlight.
1 . R e m o v et h e i n n e rf e n d e r( s e ep a g e2 0 - 1 0 2 ) .
Headlight{high/low): 60/55 W
2. Disconnecttheconnectors(A) from the lights.
f-rI
-'-+l
A- )/
22-81
ExteriorLights
TaillightReplacement HighMount BrakeLight
Replacement
1 . Removethe rearbumper(seepage20-86).
2 . Openthetailgate,anddisconnect
the connectors 1. Open the hatch.
(A)fromthetaillight(B).
2. Removethe plastictrim.
Brako/Taillight; 2115W
TurnSignalLight: 21 W 3. Disconnectthe2P connectors(A)from the high
Back-upLight: 21W m o u n tb r a k el i g h t( B ) .
=\\
ili--- _\ \
, \ .
r B ---'a
\r t
\ Carefullyremovethe high mount brakelight.
Removethe mounting nuts and bolts,then remove 5 . lnstallthe light in the reverseorder of removal.
t h et a i l l i g h t .
'
22-82
LicensePlateLight Replacement Side Marker Light Replacement
1 . Removethe hatch lower trim panel (seepage20- 1. Carefullyprythe light(A)outofthe rearbumper,
anddisconnect the 2Pconnector (B)fromthe light.
Becarefulnotto damagethe rearbumper.
P u l l t h el i c e n s ep l a l el i g h ta s s e m b l yo u t . a n d
disconnectthe 2P connector(A) from the light. Side Marker Light: 5W
LicensePlateLight: 5Wx2
'[-J^
,^f , t lo \
+tiP'-
' f l ^
t \-J
"/
\==-^ 2 . Removethe bulbsocket(A)by turningit 45'
3 . S e p a r a t et h e l e n s( B )a n d h o u s i n g( C ) ,t h e n r e m o v e counterclockwise.
thenreolace the bulb.
the bulb.
4 . l n s t a l l t h el i g h ti n t h e r e v e r s eo r d e ro f r e m o v a l .
22-83
ExteriorLights
BrakePedalPositionSwitch Test SideTurn SignalLight Replacement
1. Disconnectthe4P connector(A) from the brake NOTE:Be careful nol to damagethe fender.
pedal positionswitch {B).
1 . P u s ht h e r e t a i n i n gs p r i n g( A ) .a n d r e m o v et h e s i d e
t u r n s i g n a l i g h t( B ) ,
T h e r es h o u l db e n o c o n t i n u i t yw h e n t h e b r a k e
pedal is pressed.
T h e r es h o u l db e c o n t i n u i t yw h e n t h e b r a k ep e d a l
is released.
22-84
TurnSignal/Hazard
Flasher
ComponentLocationIndex
COMBINATION LIGHT/TURN
SIGNALSWITCH
Test,page22-80
page22-80
Beplacement,
TURNSIGNALINDICATOR LIGHTS
(lnthegaugeassembly)
page22'63
BulbReplacement,
HAZARDWARNINGSWITCH
Test,page22-88
page22-88
Replacement,
TURNSIGNAL/HAZARDRELAY
InputTest,page22-87
FUSE/RELAY
UNDER.DASH BOX
22-85
TurnSignal/Hazard
Flasher
CircuitDiagram \
'No20lr0A
USA
DASH
Ut\toEB No.2{
l50A):Cmada
UNDff HOOD
FUSUftIIY8OX TUSVRILAY
8OX
fiIGHTT
INDICATON FBONT
IIGHT
11.1W)
22-86
RelayInputTest
TurnSignal/Hazard
1 . R e m o v e t h e t u r ns i g n a l / h a z a rrde l a y( A )f r o m t h e u n d e r - d a sfhu s e / r e l a yb o x ( B ) .
000i0!1000
00u!u0
Inspectthe relay and fuse/relaybox socketterminalsto be sure they are all makinggood contact
.lfanvtestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t sp r o v eO K , t h e t u r ns i g n a l / h a z a rrde l a ym u s t b e f a u l t y .R e p l a c ei t
Cavitv Tesl condition Test: Desired result Possiblecauseil resultis not obtained
1 U n d e ra l l c o n d i t i o n s Checkfor continuityto ground: . P o o rg r o u n d( G 2 0 1 )
Thereshould be continuiw. . An ooenin thewire
3 lgnitionswitch ON ll) ( Check for voltage to ground: ' Blown No. 19 (7.5A)fuse in the
Hazardwarning switch Thereshould be batteryvoltage. under-dashfuse/relaybox
OFF . Faultyhazardwarning switch
. A n o o e ni n t h e w i r e
Hazard warningswitch Checkfor voltageto ground: . Blown No. 5 {10A)fuse in the
ON There should be battery voltage. under-hoodfuse/relaybox
lgnitionswitchOFF . Faultyhazardwarning switch
. An ooen in the wire
2 (
l g n i t i o ns w i t c hO N l l ) C o n n e cN t o . 2 t e r m i n a l t oN o . 3 . P o o rg r o u n d( G 2 0 1G , 3 0 1 ,G 5 0 1 ,
and turn signal switch terminal: G502, G553)
in Rightor Left position R i g h to r l e f tt u r n s i g n a l i g h t s . Faultyturn signalswitch
s h o u l dc o m e o n . . A n o D e ni n t h e w i r e
lgnitionswitch OFF C o n n e cN t o . 2 t e r m i n a tl o N o . 3 . P o o rg r o u n d( G 2 0 1G , 3 0 1 ,G 5 0 1 ,
Hazardwarning switch t e r m r n a l : G502, G553)
ON H a z a r dw a r n i n gl i g h t ss h o u l d . Faultyhazardwarning switch
c o m eo n . . An open in lhe wire
22-87
TurnSignal/Hazard
Flasher
HazardWarningSwitch Test
1 . Removethe centerpanel (seepage 20-62).
\ Termin6l
1 2 4 7 10
;;;-_-\
OFF
ON @
22-88
Entry Light ControlSystem
ComponentLocationIndex
CEILINGLIGHT/SPOTLIGHTS
Test,page22-96
Replacement,page22-96
REARCEILING LIGHT
Test,page22-96
page22-96
Replacement,
FRONTPASSENGER'S
DOORSWITCH
IGNITIONKEYLIGHT
Test,page22-91
22-89
EntryLightControlSystem
CircuitDiagram t J
'No.20({0A)
USA
UiIOTf,HOOD
fUSE/8ELAY
BOX
EiIIpN
SMTqI
lGlHoTin0Nilll
nd STAnT0D CEILING
UGHT
Y
I
I
\ J
DtrVTN'S
DOOR
Locx
(NOB
ORIVEBS
DOOR
SWITCH
PASSTNGERS
DOOB
SWITCH
IGNIlx)N
KEY
SWtTCH
j
l'
s!t/tTc8 i9r"..d l
BU
I
G()t
22-90
\
lgnition KeySwitch Test lgnition Key Light Test
2. Disconnectthe 6P connector.
22-91
EntryLightControlSystem
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplex control system (seepage22-172).
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
K Il7PI
UNDEB-DASIJ
FUSE/RELAYBOX CONNECTOR
O {,I2PI
GRN/RED
UNDEB.DASH
FUSE/RELAY
BOXCONNECTOR
P {18PI
3 4 5 6),/18.
GRN LT GRN/REO
UNOER.DASHFUSE/REI"AY
BOX CONNECTOBX I8PI
1 ,/13 4 5 7 8
8ED/WHT WHT/BLK
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
Y {13PI
YEL/RED
4 . Inspectthe connectorand socketterminalsto be sure they are all making good contact.
22-92
I
maketheseinputtestsat theconnector'
stilldisconnected,
5. Withtheconnectors
. lf anvtestindicates a problem,find andcorrectthe cause,then recheck
the system
. lf allthe inpultestsproveOK,go to step6.
22-93
InteriorLights
ComponentLocationIndex u J
CEILINGLIGHT/SPOTLIGHTS
Test,page22-96
page22-96
Replacement,
REARCEILING LIGHT
Test,page22-96
page22-96
Replacement,
v J
HATCHLATCHSWITCH
Test,page22-97
CARGOAREALIGHT
fesl, page 22-97
Replacement, page22-97
$ J
22-94
CircuitDiagram
STAB
ctu[G
LIGHT
MUITIPLEX
c0NTlot
UIIIT
\ J
HATCH
LATClI
swtTcH
22-95
Interior Lights
CeilingLight/SpotlightsTest/ RearCeilingLight Test/
Replacement Replacement
2 . Carefullypry off the lens {A) wilh a small 2 . Carefullypry offthe lens (A) with a small
screwdnver, screwdriver.
CeilingLight: 5W CeilingLight: 8 W
Spotlight: 5Wx2
x 1-0 mm
5x1.0mm
\A
t e 4 Pc o n n e c t o(rC )f r o m t h e h o u s i n g .
4 . D i s c o n n e ct h 3. Removethe two mounting screws.
22-96
CargoArea Light Test/Replacement Hatch Latch Switch Test
'1.
1 . Open the hatch. Open the hatch.
Carefullypry out the cargo area light (A). Removethe hatch lower trim panel (seepage 20-
s3).
CargoArea Light: 5W
Disconnectthe 2P connector{A) from the hatch
l a t c h( B ) ,
Checkfor continuitybetweenthe No. 1 (+) and 4 . Checkfor continuitybetweenthe No. 1 and No. 2
N o . 2 ( ) t e r m i n a l sT. h e r es h o u l db e c o n t i n u i t y . terminals.
lf there is no continuitv,checkthe bulb. lf the bulb
is OK, replacethe cargo area light. . Thereshould be continuitywith the hatch open
. Thereshould be no continuitywith the hatch
ctoseo.
22-97
AudioSystem
ComponentLocationIndex
AUOIOUNIT
Removal/f
nstallation,
Daoe22-100
Connector
Terminals,pa-ge
22-101
RIGHTDOOBTWEETER
page22-102
Replacement,
ROOFANTENNA
page22-'1
Replacement, 03
DRIVER'SDOORSPEAKER
page22 102
Replacement,
LEFTREARSPEAKER
page22-102
Replacement,
RIGHTREARSPEAKER
page22-102
Replacement,
ANTENNA LEAD
22-98
t CircuitDiagram
'
No.20ioA)
:USA
/ 8AT \
--------F f!t- WHT/FED
\ ACC/
ACC
HoTinACC
lllmd0Nllll
AUDIO
UflIT
t - r a - r : - r a O e ? a
22-99
AudioSystem
Audio Unit Removal/lnstallation !\,
NOTE: Removethe heatercontrol panel (seepage 21 38).
. Put on glovesto protectyour hands.
. Takecare not to scratchthe dashboardand related R e m o v et h e f o u r m o u n t i n gb o l t sa n d t h e a u d i ou n i t
parts. from the radio brackets.
7 . I n s t a l l t h ea u d i ou n i ti n t h e r e v e r s eo r d e ro f
removal,and note these items:
\v
. Make sure the audio unit and A/C connectorsare
pluggedin properly,and the antennalead is
connectedproperly.
. Enterthe anti-theftcode for the radio,then enter
4 . Disconnectthe audio connector(B)and antenna the customer'sradio stationpresets.
lead (C),heatercontrol panelconnectors(D) and
HAVCpush switch assembly(E),then removethe
center panel.
22-100
Audio Unit ConnectorReplacement
Cavity Wire Connectsto
1 YEUGRN Roof antenna
2 YEURED ACC (Power)
3 Not used
4 Not used
5 PNK R i o h tr e a rs D e a k e(r+ I
6 BLU^/vHT (+)
LeftrearsDeaker
7 GRN/YEL Front oassenqer'sdoor sDeaker{+)/Riqht tweeter (+)
8 GRN/BLK Driver'sdoor speaker{ + )/Lefttweeter (+ )
9 RED/BLK Liqhts on siqnal
10 WHT/RED Constantpower
11 Not used
12 Not used
Not used
14 Notused
ta BLU/YEL R i o h tr e a rs o e a k e (r -
to BLU/BLK Left rear sDeaker(
11 GRY/RED Front passenqer'sdoor speaker( )/Riqhttweeter{
18 LT GRN Driver'sdoor sDeaker( )/Lefttweetr ( -
19 RED Dashliqhts briqhtnesscontroller
20 BLK Gr o u n d( G 5 0 3 )
AUDIOUNIT2OPCONNECTOR
22-101
AudioSystem
SpeakerReplacement
DoorSpeaker: Rear:
1 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) . 1 . Removethe speakercover (A).
2. Pullthe top of the speaker{A) straightout, just 2. Removethe three screws,then disconnectthe 2P
enoughto releasethe upper clip. lf you pull the connector(B)from the speaker(C).
speakerout too far, you will damagethe lower clips
(C).Then lifi the speakerstraightup to releasethe
lower clips.
Tweeter:
Carefullypry the tweeter (A) out of the mirror mount
cover,then disconnectthe 2P connector(B)from the
'-----d
tweeter.
22-102
RoofAntennaReplacement
1. Removethe rear part of headliner(seepage20-54).
22-103
RearWindow Defogger
ComponentLocationIndex t J
*:Rearwindow defoggerswitch is built into the heatercontrol panel.
REARWINDOWDEFOGGER
RELAY
UNDER.HOOD
FUSE/RELAY
BOX Test,page22-51
REARWINDOW
DEFOGGERSWITCH+
u I
NOISE
CONDENSER
page22 107
CapacityTest,
REARWINDOWDEFOGGEB
Test,page22 106
Function
DefoggerWire Repair,page22 106
22-104
J CircuitDiagram
T f,rAiwrxDow
,74 DEfOGGES
;Hl}lj.'fl,1fl1fi" BEATERcoNrf,oLpANrL(\iP\/ I SWrcfl
INDIATOR
t
L ILEDI
22-105
RearWindowDefogger
FunctionTest DefoggerWire Repair
NOTE: NOTE:To make an effectiverepair,the brokensection
. Be carefulnot to scratchor damagethe defogger m u s t b e n o l o n g e rt h a n o n e i n c h .
wires with the testerprobe.
. Beforetesting,checkthe No. 11 (30A)fuse in the 1. Lightly rub the area aroundthe brokensection(A)
'14('10A)
under-hoodfuse/relaybox and No. fuse in with fine steelwool, then clean it with alcohol.
the under-dashfuse/relaybox.
. lf there is no voltage.checkfor:
- faulty defoggerrelay.
- an open in the BLK,BLK,/YEL, or YEL/BLKwire.
- taulty heatercontrol panel.
. lf there is batteryvoltage,goto step 2.
6V
22-106
NoiseGondenserCapacityTest
1 . Removethe right rear side trim panel (seepage 20-
66).
Wiresideol femaleterminals
Use a commerciallyavailablecondensertester.
Connectthe condensertester probes,and the
measurecondensercapacity.
22-107
Moonroof
ComponentLocationIndex
MOONROOF SWITCH
f e $ , p a g e2 2 - 1 1 2
R e p l a c e m epnat ,g e2 2 - 1 2
T e s tp. a g e 2 2 - 1 1 2
Replacement, page20-41
MOONROOFLIMIT SWITCH
Test,page22-113
\|.
MOONROOF CONTROLUNIT
InputTest,page22-'l10
22-108
CircuitDiagram
-
No.20lOAl:US
UNDIR OAS8FUSE/NILAY
MX No.20150
) :Canda
BL|( 8LI
+
G50t
I
G5{1
22-109
Moonroof
MoonroofControlUnit Input Test I J
1 . R e m o vteh eh e a d l i n e( sr e ep a g e2 0 - 5 4 ) .
2 . Disconnect (A)fromthecontrolunit(B).
the 5Pconnector
GRN/WHT LT GRN
2 Wire sideof
1 3 4 5 f e m a l et e r m i n a l s
RED/YEL BLK
Inspectthe connectorand socketterminalsto be sure they are all making good contact. b J
. lf the terminalsare bent, looseor corroded,repairthem asnecessary.and recheckthesystem.
. lf the terminalslook OK, go to step 4.
$ J
22-110
4- Reconnect
the moonroolcontrolunit5Pconnector,
andmaketheseinputtestsattheconnector.
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,go to step5.
Disconnectthe
moonroofcontrolunit5Pconnector,
andmakethese;nputtests
at the connector
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,the controlunit mustbefaultv.Replace
it.
22-111
Moonroof
Switch Test/Replacement Motor Test \ J
'1 1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) .
. Carefullypry the moonroof switch (A) out of the
headlin
er.
2. Disconnectthe 2P connectorfrom the moonroof
motor.
\ Terminal
--\
OPEN \7 o
1 4 5
Pi.iti.. CLOSE (,
CLOSE FO
TILT lf the motor does not run. replaceit,
22-112
Limit Switch Test Auto-stopSwitch Test
l . Removethe headliner(seepage 20-54). 1 . Removethe headliner(seepage 20-54).
CLOSE BotwoenAUTO-STOP
andCLOSE
22-113
PowerMirrors
ComponentLocationIndex
POWERMIRRORS
FunctionTest,page22-116
Replacement, page20-15
ActuatorTest,page22-117
ActuatorReplacemenl,page22-118
q3:.[ ---\,--,-'/
j-' ',i. it .i/
-:,)
'\ \,
-,''
-lo'
t:
-o '
,.'7
POWERMIRRORand
MIRRORDEFOGGERSWITCH
lesl, page22-111
Replacement, page22-117
$r-
22-114
CircuitDiagram
'1
ih.a i|0At :Usa
UiD$ DASH
UiIDTSrcODR]SE/R€LAY
8OX rcilmoN
s1/vtTcH N'SUnIIAY8OX
t J
22-115
PowerMirrors
FunctionTest
1. Removethe driver's pocket(seepage 20-60). Left mirror
Right mirror
W i r es i d eo f
t e m a l et e r m i n a l s
8 . C o n n e ctth e N o . 2 t e r m i n a l t ot h e N o . 1 1t e r m i n a l ,
WHT/RED a n d t h e N o . 5 { o r N o . 1 3 )t e r m i n a tl o t h e N o . 6
terminaw l i t h j u m p e rw i r e s .T h e r i g h tm i r r o rs h o u l d
RED/BLK RED/YEL tilt down (or swing left)with the ignition switch ON
( ).
o n n e c t o(rB )f r o m t h e s w i t c h .
3 . D i s c o n n e c t t h e ' 1 3cP . lf the mirror does not tilt down (or does not swing
left),checkfor an open in the GRN/WHT(or WHT/
4. Choosethe appropriatetest basedon the R E D ) w i r eb e t w e e nt h e r i g h tm i r r o ra n d t h e 1 3 P
symptom: connector.
. Both mirrors don't work, go to step 5. lf the wire is OK, checkthe right mirror actuator.
. Left mirror doesn'twork, go to step 7. . l f t h e m i r r o r n e i t h e r t i l t s d o w n o r s w i n g sl e f t ,
. Rightmirror doesn'twork, go to step 8. repalrthe RED|YELwire.
. Defoggerdoesn'twork (Canada),go to step 9. ' l f t h e m i r r o r w o r k sp r o p e r l yc. h e c k t h em i r r o r
swrrcn.
Both mirrors
Defogger(Canada)
5. Checkfor voltage betweenthe No. 2 terminal and
b o d y g r o u n dw i t h t h e i g n i t l o ns w i t c hO N ( l l ) . 9 . C o n n e ctth e N o . 1 a n d N o . I t e r m i n a l sw i t h a
There should be batteryvoltage. jumper wire, and checkfor voltage betweenthe
. lf there is no batteryvoltage,checkfor: N o . 2 t e r m i n a lo f t h e m i r r o rc o n n e c t oar n d b o d y
- b l o w n N o . 1 4 ( 1 0 A )f u s e i n t h e u n d e r ' d a s h ground.Thereshould be batteryvoltageand both
fuse/relaybox. m i r r o r ss h o u l dw a r m u p w i t h t h e i g n i t i o ns w i t c h
- a n o p e ni n t h e B L K r y E L wire. oN t).
. lf there is batteryvoltage,goto step 6. . l f t h e r ei s n o v o l t a g eo r n e i t h e r w a r m su p , c h e c k
for:
6. Checkfor continuitybetweenthe No. 6 terminal - a n o p e n i n t h e B L K I / E Lo r o R N w i r e .
a n d b o d yg r o u n d . - b l o w n N o . 1 4 ( ' l 0 A ) f u s ei n t h e u n d e r - d a s h
T h e r es h o u l db e c o n t i n u i t y . fuse/relaybox.
. lf there is no continuity,checkfor: . l f o n l y o n e f a i l st o w a r m u p , c h e c k :
- a n o p e ni n t h e B L Kw i r e . - its defogger.
- p o o r g r o u n d( G 5 0 1 ) . - p o o r g r o u n d( G 5 0 1G , 502)
. lf there is continuity,checkboth mirrors . l f b o t hw a r m u p , c h e c k t h e d e f o g g e r s w i t c h .
i n d i v i d u a l la
y s d e s c r i b e di n t h e n e x tc o l u m n .
22-116
PowerMirror Switch Test Power Mirror ActuatorTest
1 . Removethe driver'spocket(seepage 20-60). 1 , Removethe door panel (seepage 20-4).
2 . Reachthrough the pocketopening,and push out 2 . Disconnectthe 6P connector(A) from the power
the power mirror switch (A). m i r r o ra c t u a t o r( B ) .
\.f9.-'"1L 2 5 6 10 11 12 13 \ Terminal
6 4
Position Position
--o
UP
CF
o- o
TILTUP o o
o- o
TILTDOWN o
G -c) SWINGLEFT o @
o- -o SWING RIGHT @
o- !
-o 4. lf the mirror fails to work properly,replacethe
RIGHT -o
o mtrror actuator.
UP
DefoggerTest {Canada);
"[T 5 . C h e c kf o r c o n t i n u i t yb e t w e e nt h e N o . 1 a n d N o . 2
terminalsof the 6P connector.Thereshould be
continuity.lf there is no continuity,checkfor an
open circuit.
RIGHT
Te.minal
\ tlf I 8
il;;;
ON o o
OFF
22-117
PowerMirrors
PowerMirror Actuator Replacement \ 4
'1.
Removethe power mirror (seepage 20-15). 8. Removethe three Torx screws,and separatelhe
actuator(A)from the mirror housing{B).
2 . Carefullyremovethe mirror holderfrom the mirror
. e n t l yp u l l i t o u t b y h a n d( s e ep a g e2 0 - 1 5 ) .
h o u s i n gG
3 . Disconnectthe connector.
\ J
22-118
10. lnsertthe terminalsinto the connectorin the
o r i g i n aa
l r r a n g e m e nat s s h o w nb e l o w .
LEFTMIRROR
CONNECTOR RIGHTMIRROR
CONNECTOR
Wiresideof femaleterminals
*:Canada
'l'1.
Reassemblein the reverseorder of disassembly.
Be carefulnot to breakthe mirror holderwhen
reinstallingit to the actuator.
1 2 .R e i n s t a l l t h m
e i r r o ra s s e m b l yo n t h e d o o r .
22-119
Horns
ComponentLocationIndex \
UNDER-HOOD
FUSE/RELAY
BOX
HORNRELAY
Test,page22-51
.-
:.."'
HORNSWITCH
fesl, page22-122
CABLEREEL
HORNS page23,119
Replacement,
Test,page22 122
B e p l a c e m e npt a
, g e2 2 1 2 2
*r
22-120
J GircuitDiagram
22-121
Horns
Horn Test/Replacement Horn Switch Test
1 . Removethe front bumper {seepage 20-85). 1 . Removethe steeringcolumn covers(seepage '17-
9).
Disconnectthe 1Pconnector(B),and removethe
horn (A). Disconneclthe dashboardwire harnessB 5P
connector(A) from the cable reel (B).
|. . . . : .../..
...,
22-122
I
4. Reconnect wire harnessB 5P
the dashboard 1 . Usinga jumperwire,connentthe steering
wheelto
connector{A),anddisconnectthe hornswitch b o d yg r o u n d .
positive1Pconnector(B).
8 . Closethecontactsbetweenthe hornplateandthe
contactplate.
. lf the hornssound,replacethesteeringcolumn.
. l f t h eh o r n s d on o t s o u n dr,e p l a c e t hheo r na n d
contactplate.
22-123
PowerWindows
ComponentLocationIndex I J
UNDER.DASH
FUSE/RELAY
BOX
FRONTPASSENGER'S
WINDOWMOTOR
Test,page22-132
t J
DRIVER'SWINDOWMOTOR
Test,page22-129
FRONTPASSENGER'SWINDOW SWITCH
t e s l ,p a q e2 2 - 1 3 0
I n D uT
f est, page 22-132
Beplacement,page22-133
\ J
22-124
CircuitDiagram
'No.20il0A)
: USA
UNOERHMO FUSI/8tLAY8OI tGt'TtoitswtTcfi
22-125
PowerWindows
MasterSwitch Input Test
NOTE:Thepowerwindowcontrolunitis builtintothe powerwindowmasterswitch,andit onlycontrolsthe driver's
windowoperations.
1. Removethe windowmasterswitch{A)(seepage22-133).
GRN/WHT
22-126
4. Withthe connectorstill disconnected,maketheseinputtests attheconnector.
.lfanytestindicatesaproblem,findandcorrectthecause.thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t sp r o v eO K ,g o t o s t e p5 .
'l'1 . Faultydriver'swindow
1 RED/YEL C o n n e ctth e N o . and Checkfor driver'swindow
N o . 7 t e r m i n a l sa, n d t h e molor operaflon: motor
RED/BLK N o , 4 a n d N o . 1 4t e r m i n a l s , I t s h o u l dr u n ( t h ed r i v e r ' s . An open in the wire
and turn the ignition switch w i n d o w m o v e sd o w n ) .
oN flr).
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the input tests prove OK, the control unit must be faulty. Replacethe power window masterswitch.
Cavity Wire Test condition Test: Desired result Possible cause if result is not
obtained
22-127
Driver'sWindow Motor Test
Motor Test: PulserTest:
1 . Removethe door panel (seepage 20-4). 1 . Reconnectthe 4P connectorto the driver'swindow
motor, and reconnectthe 20Pconnectorto the
Disconnectthe 4P connector(A)from the driver's power window masterswitch.
window motor.
Connectthe test leadsof a voltmeterto the No, 3
and No. 4 terminalsof the driver'swindow motor
4P connector.
Terminal
\
2
il;;'-\
UP e o
DOWN @ e
4 . lf the motor does not run or fails to run smoothly,
replacerL
22-129
PowerWindows
Passenger's
Window Switch Input Test
1 . Removethe switch panel (seepage 20-4).
'' "'"1.
o Wire side of femaleterminals
BLU/WHT GRN/BLK
Inputthe connectorand socketterminalsto be sure they are all making good contact.
4 . Reconnectthe connector,and using a back probe, makethese input tests at the connector.lf any test indicatesa
problem,find and correctthe cause,then recheckthe svstem,
22-130
5. Disconnect
the 5Pconnector,
andmaketheseinputtests.
Cavitv Wire Test condition Test: Desired result Possiblecauseil resultis not obtained
1 RED Connectthe No. 2 Checkfor passenger's Faultymaster'swindow switch
RED/BLU t e r m i n a tl o t h e N o . window motor operation:lf An open in the wire
, n dt h e should run (the passenger's
1 t e r m i n a la Faultypassenger'swindow
N o . 4 t e r m i n a tl o window moves down), moror.
t h e N o . 5 t e r m i n a l , There should be battery
a n dt u r n t h e voltage.
ignition switch ON
{ll),and pressthe
down button on
the power window
masterswitch for
the passenger's
window.
22-131
PowerWindows
Passenger's
Window Switch Test Passenger's
Window Motor Test
1 . Removethe switch panel (seepage 20-4). 1 . Removethe passenger'sdoor panel (seepage20-
4).
Removethe power window switch (A) from the
doorpanel. Disconnectthe 2P connector(A)from the
passenger'spower window motor.
Disconnectthe 5P connector(B)from the
passenger'spower window switch.
Terminalside of
m a l et e r m i n a l s
tfiTtTtT;Etl
l' '-r--r-,Jl
22-132
MasterSwitch Replacement Passenger's
Window Switch
'1.
Replacement
Removethe door grip (seepage 20-4).
2 . Removethe power window masterswitch (A)f rom 1 . Removethe door grip {seepage 20-4).
t h e d o o rp a n e l .
2 . Removethe power window switch (A) from the
o o o rp a n e r .
22-133
Wipers/Washers
ComponentLocationIndex
WIPER/WASHERSWITCH
Test,page22-140
Replacement,page22 140
WINDSHIELD WIPERMOTOR
Test,page22-'143
Replacement,page22-145 UNDER.DASH
FUSE/RELAY
BOX
INTERMITTENT WIPERCIRCUIT
l l nt h em u l t i p l ecxo n t r oul n i t )
InputTest,page22-138
22-134
WASHER TUBES
page22-147
Replacement,
WASHER RESERVOIB
page22'146
Replacement,
WASHERFLUIDLEVELSWITCH{Canada)
TesI,page22-144
Replacement,page22-144
CONDENSER
CapacityTest,page22 107
REARWINDOWWIPERINTERMITTENT
CONTROL UNIT
InputTest,page22'138
REARWINDOWWIPERMOTOR
f e$, page22-143
Replacement, page22 146
BEARWINDOWWIPERARM
page22 146
Replacement,
22-135
Wipers/Washers
CircuitDiagram- Windshield \ 1
UNOENHOOD
FL]SE/8ELAY
BOX IGNITIONSWITCN
'7{
F;^--il I
-':-;--u,Hr- 6\
U-I^-- o,f-''*""
MULTIPIIX
coiln0L
UNIT
L\'
\,!
22-136
CircuitDiagram- RearWindow
-
No2olaoAl
:USA
UI\IOIF H@OFUSE/RELAY
MX GNMOIIISW|ICH
-;i
BATTERYr---------------
l No'g,soA, ro2o. | /,^1\
(-;1_=l----_--_fww{"-' l
\+y
lErHorb0Ni||l
andsra8r
0
I
ffAn w$tDowwtPEE
INTE$'ITTEI'IT
C{)NNOL
UI'/IT
f--------------- li
22-137
Wipers/Washers
RearWindowWiperIntermittentGontrolUnit InputTest
the rightrearsidetrim panel{seepage20-51).
1 . Remove
LTGRN/REO WHT/RED
WHT/RED LT GRN
LT GRN/BLK
22-138
\
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
' lf all the input tests prove OK, the control unit must be faultv. Replaceit.
Cavitv Wire Tesl condition Test: Desired result Possiblecauseif resultis not obtained
GRN lgnitionswitch ON Checkfor voltageto ground: . B l o w nN o . 9( 1 0 A ) f u sien t h e
flr) Thereshould be battery under-dash fuse/relay box
voltaqe. . An openin thewire
10 BLK U n d e ra l l Checkfor continuity
to Poor ground (G553)
conditions grouno: A n o p e ni n t h e w i r e
Thereshouldbe continuitv.
6 WHT/RED lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
( l l )a n d r e a r Thereshould be battery under-dashfuse/relaybox
window washer vortage. Faultyrearwlndow wiper/
switch ON washer switch
4 LT GRN/ lgnition switch ON Attachto groundl A n o p e ni n t h e w i r e
RED ( l l )a n d r e a r The rearwindow wiper motor
window wiper s h o u l dr u n .
switch ON
LT GRN lgnition switch ON Attachto ground: B l o w nN o . 9 ( 1 0 A ) f u s ei n t h e
flr) The rear window wiper motor under-dashfuse/relaybox
s h o u l dr u n . Faultyrearwindow wiper motor
An open in the wire
20 LT GRN/ lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
BLK (ll) Thereshould be battery under-dashfuse/relaybox
voltage. Faultyrearwindow wiper motor
A n o D e ni n t h e w i r e
22-139
Wipers/Washers
Wiper/WasherSwitch Test/Replacement
lowercover{seepage20-60).
the driver'sdashboard
1 . Remove
Removethesteeringcolumncovers(seepage17-9).
Disconnecl (A)fromthewiper/washer
the 14Pconnector switch{B)
Terminal
6 4 14 l2 12 11
Position
OFF o- -{
tNl o-
LO o-
HI
Mist switchON r
Washor 3witch ON
22-140
ControlUnit InputTest
l . Beforetesting,troubleshootthe multiplexcontrol system lsee page22-jj2).
UNDER-DASH
FUSE/RELAY
BOX UNDER.DASH
FUSE/RELAY
BOX UNDER-DASHFUSE/RELAY
BOX
CONNECTORB I6PI CONNECTOR
G {1OP) CONNECTORJ {8PI
WHT/BLU
\
l-,1
€ l l
- l-rl l-,1 - llTtl
F_j-JF-#
lslrlzlol 1 4 1 5 1 76 l 8 l
\
BLU/RED BLU/WHT
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
X I8PI
BLU/BLK
(cont'd)
22-141
Wipers/Washers
ControlUnit Input Test (cont'dl \ J
5. Reconnectthe connectors,and make these input tests at the connector.
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t s p r o v e O K , t h e m u l t i p l e x c o n t r ou ln i tm u s t b e f a u l t y .R e p l a c e
t h e u n d e r - d a sfhu s e / r e l a yb o x
assembly.
L J
22-142
Wiper Motor Test
Windshield: RearWindow:
1. Open the hood,and carefullyremovethe cap nuts 1. Open the hatch,and removethe hatchtrim panel
and the wiper arms. Make surethey do not touch (seepage 20-53).
the hood.
2. Disconnectthe4P connector{A) from the motor {B).
2, Removethe hood seal andcowl cover.
3 . D i s c o n n e c t t h5eP c o n n e c t o(rA ) f r o mt h e m o t o r ( B ) .
Terminal
Connected @ o
1 2 4
P-"-,tion
LOWSPEED O O
HIGHSPEED o o 4 . Testthe wiper motor park switch by connectingan
a n a l o gv o l t m e t e rb e t w e e nt h e N o . 4 ( + ) t e r m i n a l
and ground, and run the motor. The voltmeter
5 . Testthe wiper motor park switch by connectingan should indicate12 V and 4 V or lessalternatelv.lf it
a n a l o gv o l t m e t e rb e t w e e nt h e N o , 5 ( + ) t e r m i n a l does not, reolacethe motor.
a n d g r o u n d ,a n d r u n t h e m o t o ra t l o w o r h i g hs p e e d .
T h ev o l t m e t e rs h o u l di n d i c a t e1 2V a n d 4 V o r l e s s
alternately.lf it does not, replacethe motor.
.l J
j 22-143
Wipers/Washers
WasherMotorTest WasherFluidLevelSwitch Test/
Replacement- Canada
1. Partiallyremovethe right inner fender (seepage
20-'t021.
1 . Partiallyremovethe right innerfender (seepage
2. Disconnectthe 2P connectors(A) from the washer 20-102).
motors (B).
Disconnectthe 2P connector{A) from the washer
level switch.
FLOATUP
FLOATDOWN o- ---o
lf the continuityis not as specified.replacethe
swtTcn.
22-144
WindshieldWiper Motor Replacement
1 . Open the hood. Removethe nuts (A) and the 5 . S c r i b ea l i n e ( A )a c r o s st h e l i n ka n d w l n d s h i e l d
w i n d s h i e l dw i p e ra r m s ( B ) . wiper linkageto show the original adjustment.
Separate t h e w i n d s h i e l dw i p e r l i n k a g e( B )f r o m t h e
w i p e r m o t o r( C ) .
N.m
(3.2ksf.m,23 lbt.ft)
R e m o v et h e b o l t s( C ) ,m o v ew i n d s h i e l dw i p e r
l i n k a g ea s s e m b l y{ D ) t o w a r dt h e p a s s e n g e r 'ssi d e
of the vehicle until it slidesoff of the pin (E),then
removethe assembly.
22-145
Wipers/Washers
RearWindow Wiper Motor WasherReservoirReplacement
Replacement
1 . Partiallyremovethe right inner fender.
1 . Open the hatch,and removethe hatchtrim panel Disconnectthe 2P connectors(A)irom the washer
(seepage 20-53). motors (B) and level switch (Canada).
A
9.8N.m {1.0kgf.m,
7.2rbf.ftl
B
8 N.m 10.8kgt.m,
6.0rbf.ft) 3 . Disconneclthe tubes (C)from the washer motors.
A
9.8 N.m
(1.0kgt.m,
B 7.2 tbf.tt)
9.8 N.m
{1.0kgt.m,7.2lbfftl
22-146
WasherTubesReplacement
1 . Removethe rightinnerfender{seepage20-102).
2 . Remove
the washernozzles
andclips,thenremovethetubes.
<=>
r"-----------='
--==':?-
L-!
(cont'd)
22-147
Wipers/Washers
WasherTubesReplacement(cont'dl
22-148
AccessoryPowerSocket
CircuitDiagram AccessoryPower Socket Test/
Replacement
. Thereshould be batteryvoltage.
. lf there is no baneryvoltage,checkfor:
- p o o r g r o u n d{ G 5 0 2 ) .
- an open in the wire.
- b l o w n N o . 1 8 ( 1 5 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
22-149
DoorLockSystem
Keyless/Power
ComponentLocationIndex
Test,page22-161
P r o g r a m m i n gp,a g e2 2 - 1 6 1
DRIVER'SDOORLOCKSWITCH
Test,page22-160
RECEIVER
UNIT
lnput Test,page22-153
IGNITIONKEYSWITCH
Test,page22-91
PASSENGER'S DOORLOCKACTUATOR
Test,page22 158
MUTIPLEXCONTROLUNIT
InputTest,page22-155
DRIVER'SDOORSWITCH HATCHLATCHSWITCH
Test,page22-97
HATCHLOOKACTUATOR
Test,page22 159
DRIVER'SDOORLOCK
ACTUATOR/KNOB SWTICH
Test,page22-158
Actuator PASSENGER'SDOORSWITCH
KnobSwitchTest,page22 160
22-150
\ J CircuitDiagram
UNOEE DASH
UiDENHooDFUSE/RETIY
8OX fUSE/SELAYBOX
/ 8Ar \
-) cl-
\ lG1,/
lG1HoTin0N(lllaidSTAfft(llll
l3
IT
I
BLK
I
UI'IDE8DASH
f USE/RETAY
80X G502
MULTIPUX
CONTNo!
Uflfi
I J
000R
Loc(KNOE
tl
\"2 PASSTNGtrS
xtY
0008100(
t'-F>
Li___J-
ACTUATOi
DBt!'t8'S
000R100(
ACTUATOB
t
(cont'd)
22-151
Keyless/PowerDoor LockSystem
CircuitDiagram(cont'dl \ J
HOOD
UNDEN FU8E/BELAY
MX
l\br t15a)FUSE
t"-
HORN
SWTCH
UNDEN
DAS}I
FUSE/8ELAY
8OX
t J
Y,,, mMErNAllofl
LIGHISWITCH
22-152
KeylessReceiverUnit Input Test
1. Removethe driver'sdashboardlower cover (seepage 20-59).
2 . R e m o v et h e a u d i ou n i t ( s e ep a g e2 2 - 1 0 0 ) .
WHT/RED
Wiresideof femaleterminals
e a kl li n gg o o dc o n t a c t .
4 . I n s p e c t t h e c o n n e c t o r a n d s o c k e t t e r m i n a l s t o b e s u r e t h e y a rm
t
(cont'd)
22-153
Keyless/PowerDoor LockSystem
KeylessReceiverUnit Input Test (cont'dl
With the connectorstill disconnecled,makethe input test at the connector.
.lftestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf the inputtest provesOK, goto step 6.
.lfanytestindicalesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtests prove OK, replacethekeylessreceiverunit.
22-154
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplexcontroI system (seepage 22-172).
FUSE/RELAY
UNDER.DASH BOX UNDER.DASH
FUSE/RELAY
BOX UNDER-OASH BOX
FUSE/RELAY
CONNECTOR
C {1itPl CONNECTOR
F I12P) CONNECTORJ {8PI
BLU BLU/RED
FUSE/RELAY
UNDER.DASH BOX UNDER.DASH
FUSE/RELAY
BOX FUSE/RELAY
UNDER.OASH BOX
CONNECTORK {17PI CONNECTOR
M Il2PI P I18PI
CONNECTOR
BLU/ORN
UNDER.DASH
FUSE/RELAY
BOX UNDER-DAsH
FUsE/neLeY
sbx FUSE/RELAY
UNDER.DASH BOX
O (8P)
CONNECTOR X (8P)
CONNECTOR Y {13P)
CONNECTOR
,/1,/ 3 4 5 6 8
4. Inspectthe connectorand socketterminalsto be sure they are all making good contact.
(cont'd)
22-155
Keyless/PowerDoor LockSystem
Control Unit Input Test (cont'dl
5. Reconnectall connections
to the underdashfuse/relay
box,and maketheseinputtestsat the appropriate
connectors
on the under-dash
fuse/relay
box.
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,goto step6.
22-156
6. Disconnect
the M, P,K andJ connectors
fromthe underdashfuse/relay
box,and maketheseinputtestsat the connectors.
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
.lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder-dashfuse/relayboxassembly.
Cavitv Wire Test condition Test:Desiredresult Pdsiblo c6useif resultis not obtain€d
K2 BLU/ORN Underall conditions Checkfor continuitybetween An openin the wire
the K2terminalandthe keyless
receiverunit5Pconnector
disconnected:
Thereshouldbe continuitv.
M7 YEUBLK ConnectJ7 terminalto [,47 Checkactuatoroperation: Faultydriver'sdoorlockactuator
M9 YEL lMgl terminal,and Mg Thedriver'sdoorlockactuator An openin the wire
lMTl terminaltoJ4 shouldlock lunlockl
22-157
I
Keyless/Power
DoorLockSystem
Door LockActuatorTest
Driver'sdoor: Passenger'sdoor:
1 . R e m o v et h e d r i v e r ' sd o o r p a n e l( s e e p a g e 2 0 - 4 ) . 1 . R e m o v et h e p a s s e n g e r 'dso o r p a n e l( s e e p a g e 2 0 -
4).
2. Disconnectthe 2P connectorfrom the actuator.
2. Disconnectthe 2P connectorfrom the actuator,
UNLOCK e e LOCK e e
UNLOCK e o
4 . lf the actuatordoes not operateas specified,
repracerr. lf the actuatordoes not operateas specified,
reprace[,
22-158
Hatch Lock Actuator Test
1. Open the hatch.
Terminalside of
m a l et e r m i n a l s
J
4. Checkactuatoroperationby connectingpower and
ground accordingto the table.To preventdamage
to the actuator,apply batteryvoltage only
momentaflty.
\Terminal 1
Po.irion\
LOCK @
UNLOCK o
22-159
Keyless/Power
DoorLockSystem
Door LockKnob Switch Test Door LockSwitch Test Tr
the driver'sdoorpanel(seepage20-4).
1 . Remove '1.
Removethe driver'sdoor panel (seepage 20-4). NO
I
. l
I
(
. 1
I
22-160
TransmitterTest TransmitterProgramming
NOTE: Storingtransmittercodes:
. l f t h e d o o r su n l o c k o r l o c k w i t h t h e t r a n s m i t t ebru, t The codes of up to three transmitterscan be storedin
the LEDon the transmitterdoes not come on, the LED the keylessreceiverunit memory. (lf a fourth code is
is faulty. Replacethe transmitter, stored.the code which was input first will be erased.)
. l f a n y d o o r i s o p e n ,y o u c a n n o t l o c k t h e d o o r w i t h t h e NOTE:lt is importantto maintainthe time limits
transmrtter. betweenthe steps.Make sure the doors and the hatch
. lf you unlockedthe doors with the transmitter,but do are closed.
not open any of the doors within 30 seconds,the 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .
doors relockautomatically.
. The doors do not lock or unlockwith the transmitterif 2. Within 1 to 4 sec.,push the transmitterlock or
the ignition key is insertedin the ignition switch. unlockbutton with the transmitteraimed at the
receiverin the multiplexcontrol unit behindthe
1. Pressthe lock or unlock buttonfive or six times to d r i v e r ' ss i d eo f t h e d a s h .
resetthe transmitter.
3. Within 1 to 4 sec.,turn the ignition switch OFF.
. lf the lockswork, the transmitteris OK.
. lf the locksdon't work, go to step 2. 4. Within 1 to 4 sec.,turn the ignition switch ON (ll).
1 1 . W i t h i n1 t o 4 s e c . ,p u s ht h e t r a n s m i t t elro c ko r
unlockbutton with the transmitteraimed at the
r e c e i v e irn t h e m u l t i p l e xc o n t r o lu n i t b e h i n dt h e
driver'sside of the dash.
1 2 . C o n f i r my o u c a n h e a r t h es o u n do f t h e d o o r l o c k
actuators.Within 1 to 4 sec.,push the transmitter
lock or unlockbutton again,
22-161
lmmobilizerSystem
ComponentLocationIndex
CONTROLUNIT.RECEIVER
IMMOBILIZER
page22-165
Troubleshooting,
page22-167
Replacement,
TRANSPONDER
(8uiltintothe ignitionkey)
22-162
SystemDescription
The vehicleis equippedwith an immobilizersystemthat will disablethe vehicleunlessthe proper ignition key is used.
This system consistsof a transponderlocatedin the ignition key, an immobilizercontrol unit-receiver,an indicator
l i g h t ,a n d t h e E C M .
When the key is insertedin the ignition switch and turned to the ON {ll) position,the immobilizercontrol unit-receiver
sendspower to the transponderin the ignition key.The transponderthen sendsa coded signal backto the immobilizer
control unit-receiverwhich then sendsa coded signalto the ECI\4.
IMMOBILIZER
CONTROLUNIT.RECEIVER
KEYCYLTNDER
iEl'JUiliii'tlun"oona"|.r
lf the proper key has been used,the immobilizerindicatorlight will come on for about 2 seconds,then go off.
lf the wrong key has been used or the code was not receivedor recognizedby the unit,the indicatorlight will come
on for about 2 seconds,then it will blink until the ignition switch is turned OFF.
lf the ignition switch is turned OFF,the indicatorwill blinkfor about 5 secondsto signalthat the unit has reset
correctly,then the indicatorwill go off.
lf the customerhas lost his key,and cannot startthe engine,contactHondaCustomerRelations.
IMMOBILIZER
INDICATOR
LIGHTBLINKING
PATTERN:
IGNITIONSWITCH ON
OFF
PROPER
KEY INDICATOR ON
INSERTED LIGHT
WRONGKEY INDICATOR ON
INSERTED LIGHT
OFF
(| i.,
22-163
)
lmmobilizerSystem
CircuitDiagram t J
'
No20(LAl r USA
UNDTRrcODFUSE/RELAY
8OX
rGNtTt0i/
swlrcH
lct HoTin0N{ll)
.ndSIAnTl|l)
F G N
8ELAY1
YEUBIJ(
t I
\ J
22-164
)
Troubleshooting
Beforetroubleshootingthe immobilizersystem, 5. Disconnectthe 7P connector(A)from the
troubleshootany EClvlDiagnosticTroubleCodes(DTCS) i m m o b i l i z ecr o n t r o lu n i t - r e c e i v e( B
r ),
( s e ep a g e1 1 - 3 )a, n d m a k es u r et h e E C Mh a s n o
malfunction.
l
(cont'd)
22-165
lmmobilizerSystem
Troubleshooting(cont'dl
8. Checkfor voltage betvveenthe immobilizercontrol Checkfor continuitybetweenthe immobilizer
unit-receiver7P connectorNo. 6 terminal and No. 1 control unit-receiver7P connectorNo. 2 terminal
rermlnat. a n d E C Mt e r m i n a lE 2 7 .
22-166
t lmmobilizerControl Unit-ReceiverReplacement
'L
Removethe driver'sdashboardlower cover (see
page20-59).
I J (c).
5 . Installthe immobilizercontrol unit-receiverin the
reverseorder of removal.
22-167
MultiplexControlSystem
ComponentLocationIndex lr, J
REARCEILINGLIGHT
Test,page22'96
LIGHT/SPOTLIGHTS
Test,page22-96
ASSEMBLY
GAUGE
IGNITIONKEYLIGHT
Test,page22'91
ECM
MULTIPLEXCONTROLUNIT
{Builtinto the under-dash
fus6/relav boxl
Troubleshooting,page22'172
InputTest,page22-175
22-168
I CircuitDiagram
'
I'10.20 :usA
{a0AJ
UNDEf,
DASH ib.a)l50A):C.nd.
UiIDM HOOD
IUSE/NEUY
BOX IGNITiON
SWITCH FUSE/NEUYBOX
/ BAI \
--_to oJ- BLI,'YEL
\ tcl ./
MULTIPLEX
c0NT80r
tNsPECTror!
CONNECIOF
HAICII
LATCH
SWITCH
G201
{cont'd)
22-169
MultiplexControlSystem
CircuitDiagram(cont'd) J
l'1o.3 tUSt
l7.5AJ
lln$.uidt hoodr
itutefd4bor I
V
I
wHTPLU
l0
t--t---
lrfl | I.l|MOBItEER
@NTIOL UIIIT
lE lnv*-
| > | ucHT
CIILINGLIGHT RECEIVEE
VI
lt A
Y l
l'*'
I' I
22-170
I SystemDescriptions
The MultiplexControlSystem hasfour internal MultiplexCommunication
functions:
. Multiplexing ( s e n dm u l t i p l es i g n a l so v e rs h a r e d To reducethe number of wire harnesses,digital signals
wtres) a r e s e n tv i a s h a r e dm u l t i p l e xc o m m u n i c a t i o lni n e s
. Wake up/sleep(runsat full power only on demandto r a t h e rt h a n s e n d i n gn o r m a le l e c t r i c asl i g n a l st h r o u g h
reducebatterydraw) i n d i v i d u awl i r e s .
. Fail-safe(fixesor ignoresfaulty signals) . The input signalsfrom each switch are convertedto
. Self-diagnosis(Mode 1 for the system,Mode 2 for digital signalsat the centralprocessingunit (CpU).
i n p u tl i n e s ) . T h e d i g i t a ls i g n a l s a r e s e n t f r o m t h e t r a n s m i t t i nu gn i t
t o t h e r e c e i v i n gu n i t a s s e r i a ls i g n a l s .
The systemcontrolsthe functionof these circuits: . The transmittedsignalis convertedto a switch signal
. E n t r yl i g h t c o n t r o(l i g n i t i o nk e y l i g h t a n d c e i t i n gl i g h t ) at the receivingunit, and it operatesthe related
. Wiper/washerintermittentwipe and park functions componentor monitors a swltch.
. Keyless/powerdoor lock . There are exclusivecommunicalionlines between
. Meter assembly,temperaturegauge,and indicator the ECM,the gauge assembly,and the under,dash
lights fuse/relaybox.
. HVAC(compressorand fan control)
. K e y - i nr e m i n d e r Wake-upand Sleep
. H e a d l i g hrte m i n d e r
. Seatbeltreminder The multiplexcontrol system has "wake-up" and
"sleep" functions
to decreaseparasiticdraw on the
batterywhen the ignitionswitch is OFF.
. ln the sleep mode,the multiplexcontrol unit stops
functioning(communicationand CPUcontrol)when it
is not necessaryfor the systemto operate.
I J . As soon as any operationis requested(for example,a
door is unlocked),the relatedcontrol unit in the sleep
mode immediatelywakes up and beginsto function.
. When the ignition switch is turned OFF,and the
driver'sor front passenger'sdoor is opened,then
closed,there is about a 10 seconddelay beforethe
control unit goes from the wake-upmode to the sleep
mode.
. lf any door is open,the sleep mode will not function.
. l f a k e y i s i n t h e i g n i t i o ns w i t c h ,t h e s l e e pm o d ew i l l
not function.
. When in sleep mode,the draw is reducedfrom
70 80 mA to lessthan 10 mA.
Fail-safe
To preventimproper operation,the multiplexcontrol
system has a fail-safefunction.In the fail-safemode,
the output signal js fixed when any part of the system
malfunctions(for examplea faulty control unit or
c o m m u n i c a t i o lni n e ) .
Eachcontrol unit has a hardwarefail-safefunctionthat
fixes the output signalwhen there is any CPU
malfunction,and a softwarefail-safefunctionthat
i g n o r e st h e s i g n a lf r o m t h e m a l f u n c t i o n i ncgo n t r o lu n i t
and allowsthe systemto operatenormally.
22-171
/ar
Multiplex ControlSystem
Troubleshooting
Mode 1 Tset 7. Checkfor continuitybetweenterminal 4ofthe
under-dashfuse/relaybox connectorJ and body
1. Removethe driver's dashboardlower cover {see ground.
page 20-59).
ls there continuity?
2. Checkthe No. 9 ( 10A)fuse in the under-hoodfuse/
relay box and the No. 10 (7.5A)fuse in the under- YES Replacethe under-dashfuse/relaybox.l
dash fuse/relaybox.
N O- R e p a i tr h e o p e n i n t h e w i r e . l ft h e w i r e i s o k ,
Are the fuses OK? r e p a i rG 3 0 1 . 1
Did the spotlight and ceiling light indicate mode . lf the DTC(s)isstill present.go to the next step
1? listedfor the DTC.
. lf the DTC(S)is no longer presentreplacethe
YES-Go to step 8. originap l art.
NO Go to step 7.
22-172
I
Individual DTCs
Multiplex Probable Cause Multiplex Probable Cause
DTC DTC
The multiplexcontrol unit cannot 1 , 2a n d3 Short to ground on one of the
receivesignalsfrom the gauge & communicationwires.
assemDty. ECMDTC Short to ground on the YELwire
'l
Faultypoweror groundto the P0600 betweenthe PCMterminal E24
gaugeassembly Simultane and the under-dashfuse/relay
2 . Faultygauge assemblv ously b o x t e r m i n a lE 1 0
3 . Faultyunder-dashf use/relay 2 . Short to ground on the WHT/
box GRNwire betweenthe Gauge
The multiplexcontrol unit cannot assemblyterminal A2 and
receivesignalsfrom the ECM under-dashfuse/relaybox
1 Faultypower or ground to the t e r m i n a lK 1 0
ECM 1 a n d 6 Open in the communicationwire
2 . F a u l t yE C M Simultane I Open in WHT/GRNwire
? Faultyunder-dash
fuse/relay o u sl y betweenthe under-dashfuse/
box relay box terminal K10 and the
J Internalfailure of the multiplex GauqeassemblVterminal 42
control unit 2 a n d 5 O p e ni n t h e c o m m u n i c a t i o w n ire
1 Faultyunder-dash fuse/relay S i m u l t a n e 1 Open in the YELwire between
box ously the under-dashfuse/relaybox
5 The gaugeassemblycannot receive t e r m i n a lE 1 0a n d E C Mt e r m i n a l
signalsfrom the multiplexcontrol
u n i ta n d t h e E C M
(cont'd)
22-173
I MultiplexControlUnit Input Test
1 . Removethe driver'sdashboardlower cover (seepage20-59).
CONNECTOR
C {14P} CONNECTOR
E I13P) CONNECTOR
F {12P} CONNECTOR
J {8PI
GRN/RED
{USAI WHT/RED
(Canada)
GRN/ORN
3 4 5 1 2 3
6 7 E 1 0) . / 12 4 5 6 1
CONNECTOR
K {17P) CONNECTOR
O I12P) P (18P)
coNNECTOR
1 2 4 5 7 3 5 6 7 I
8 10 /V ,/ l,/ ,/1,/l,/ 12 15 17
O (8P}
CONNECTOR CONNECTOR
X {8P) CONNECTORY {13P)
2 3 ,/1,/
6 1 8 r0 12
{cont'd)
22-175
MultiplexControlSystem
MultiplexControl Unit lnput Test (cont'd)
3. Inspect
the connector to be suretheyareall makinggoodcontact
andsocketterminals
.lftheterminalsarebent,looseorcorroded,repairthemasnecessary,andrecheckthesystem
. llthe terminalslookOK,go to step4.
H",=
P18 RED Checkfor voltageto ground: Faultyhatchlatchswrtch
Theresho0ldbe 1V or less- Poorground(G552)
An openin the wire
f-9*:li:'^:**:':s*:* F a u l t yh a t c h l a t c hs w i t c h
X5 l g n i r i o nk e y i n t h e C h e c kf o r v o l i a g e t o g t o u n d : . F a u l t yi g n i t i o n k e y s w i t c h
ignit on switch Thpre should be I V or lcss . Poorground (G401)
. An open in the wire
l g n r t r o nk e v o u r o { t h e C h e c kf o r v o l l a g e t o g r o u n d : **6
I : [11y.'::i':::1"'
22-176
I J
Cavitv Wire Test condition Test:Desiredresult Possible
causeif resukis notobtained
X8 WHT/BLK Underallconditions Attachto ground:Theignitionkey BlownNo.3 (7.5A)fuse in the under,hood
lightshouldcomeon.
BlownLED
An ooenin the wire
o7 GRN/RED Ceilinglightswitchin A t t a c h t o g r o u n d : T h e c e i l i n g l i g h t , ElownNo.3 (7.54)fusein the undeFhood
the middleposition, s p o t l i g h t ss h o u l d c o m e o n .
all doorsclosed Faultyceilinglight
An oDenin the wire
c]1 BLU Underall conditions Attachto ground:Dashlightsshould BlownNo.2 (15Aifusein the under-hood
fuse/relaybox
Faultytaillightrelay
An ooenin the wire
F8 GRN/RED Brakefluidreservoir C h e c kf o r v o l t a g et o g r o u n d : Faultybrakefluidlevelswitch
float in down T h e r e s h o u l d b e l e s st h a n I V . An openin thewire
position(brakefluid
K10 WHT/GRN Underall conditions Checkfor voltageto ground: An openor shortin the wire
Thereshouldbe batteryvoltagein
the sleepmodeand3 Tvoltswhen
I J
I J
22-177
I
Restraints
Restraints
SpecialTools .............
23-2
SeatBelts
Component LocationIndex .........................................
23-3
FrontSeatBeltReplacement .......................................
23-4
RearSeatBeltReplacement ........................................
23-6
Inspection ..................
23-8
ChildSeatTetherAnchorRemoval/lnstallation ........23-9
SRS(SupplementalRestraintSysteml
Component LocationIndex ......................................... 23-13
Precautions and Procedures ,,.,......... 23-14
General Troubleshooting Information....................... 23-23
I DTCTroubleshooting
SymptomTroubleshooting
Index ..............
Index...............................
23-28
23-30
SystemDescription................. ........... 23-31
CircuitDiagram .........23-34
DTCTroubleshooting ............... .......... 23-36
SRS Indicator CircuitTroubleshooting ....................... 23-105
ComponentReplacemen(/lnspection After
Deployment ..............23-112
Driver'sAirbagReplacement ............ 23-113
FrontPassenger's AirbagReplacement ..................... 23-114
SideAirbagReplacement .................. 23-115
A i r b a gD i s p o s a.l . . . . . . . . . . . . . . . . . . . . . . ........2 . .3. - 1 1 6
C a b l eR e eR l eplacement . . . . . . . . . . . . . .2. .3. .- .1. 1 9
SRSUnitRepfacement ....................... 23-122
SidefmpactSensorReplacement ..........,.................... 23-123
OPDSUnitReplacement .................... 23-124
FrontfmpactSensorReplacement .............................. 23-125
Restraints
SpecialTools \
o o
\ J
@ Gl
ro
L .
23-2
SeatBelts
I ComponentLocationIndex
REARCENTER BELTand
REARSEATBELTBUCKLES
step1 on page23-8
page23 9
Inspection,
SHOULDER
ANCHOR ADJUSTER
step8 on page23-4
FRONTSEATBELT
Replacement,page23-4
page23 9
Inspection,
I
CHILDSEATTETHER
ANCHORS
Removal/lnstallation,
page23-11
REARSEATBELT
Beplacement,page23.7
page23-9
Inspection,
FRONTSEAT
BELTBUCKLES
step1 on page23'6
23-3
SeatBelts
FrontSeat Belt Replacement
SRScomDonentsare locatedin this area.Reviewthe 6. Removethe upper anchorcover {A),and remove
SRScomponentlocations(seepage23-13)and the t h e u p p e ra n c h o rb o l t( B ) .
precautionsand procedures(seepage23-14)in the SRS
sectionbefore performingrepairsor service, B
7/16-20
UNF
32N m (3.3kgf.m,24lbt.ft)
NOTE:Checkthe front seat beltsfor damage,and
replacethem if necessary.Be careful not to damage
them during removaland installation.
6x1.0mm
3.4N m {0.35kgf.m,2.5lbf.ft)
7/16-20
UNF
5 . R e m o v et h e r e a rs i d et r i m p a n e l( s e e p a g e 2 0 - 5 1 ) . 32 N.m(3.3kgf m,2irlbf.ft)
qt
23-4
9 . Removethe B-pillaruppertrim {seepage20-50) Upperanchorbolt construction:
1 0 .Removethe shoulderanchoradjuster{A).
UPPERANCHOR UPPERANCHOR COLLAR
BOLT
BUSHING TOOTHED
LOCKWASHER
8 x 1.25mm
22 N.m(2.2kgf.m,16lbf.ftl WASHER
{cont'd)
23-5
Seat Belts
Front Seat Belt Replacement(cont'd)
SeatBelt Buckle 7. Installthe bucklein the reverseorder of removal,
and note these items:
1. Make sure you have the anti-theftcode for the radio,
then write down the frequenciesfor the preset . Assemblethe washerson the centeranchor bolt
buttons. as shown.
. Apply liquid thread lockto the centeranchor bolt
2. Disconnectthe negativecablefrom the battery, before reinstallation.
and wait at least3 minutesbefore beginningwork. . lf the seat belt tensionerhas been deployed,
replacethe front seatbelt protectorwith a new
3. Removethe front seat (seepage 20-7'1). one.
. Apply liquid thread lockto the seat mounting
4. Detachthe seat belt switch connectorclip (A),seat bolts before reinstallation
belt buckletensionerconnectorclip (B),and . Reconnectthe negativecableto the battery.
h a r n e s sc l i p ( C ) . . Enterthe anti-theftcode for the radio,then enter
the customer'sradio stationpresets.
. Resetthe clock.
. Do the ECMiPCMidle learn procedure(seepage
11 _ 1 3 9 ) .
.-..:.a--
7/16-20
UNF
32N m {3.3kgf m,24lbf.ft)
23-6
I RearSeat Belt Replacement
NOTE:Checkthe rear seat beltsfor damage,and 5. Installtheseat belt in the reverseorder of removal,
replacethem if necessary.Be carefulnot to damage and note these items:
t h e m d u r i n gr e m o v a a
l n di n s t a l l a t i o n .
. lf the threadson the retractormounting self-
RearSeatBelt tapping ET screw are worn out, use an oversized
self-tappingET screw (P/N90133-524-0030)
1 . R e m o v et h e r e a rs e a tc u s h i o n( s e ep a g e2 0 8 0 ) . m a d es p e c i f i c a l lfyo r t h i s a p p l i c a t i o n .
. Apply liquid thread lockto the anchorbolt before
2. Removethe lower anchor bolt {A}. reinstallation.
' Checkthat the retractorlockingmechanism
A functions{seepage 23-9).
7/16-20UNF
32 N.m (3.3kgf.m, . Beforeinstallingthe anchor bolt, make sure there
24 tbf.ftl are no twists or kinksin the rear seat belt.
l . \ J ,
I 3 , R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 ) .
B
7/16-20
UNF
N m {3.3kgf.m,2irlbf.ft)
A
6x1.0mm
3.4 N.m {0.35kgl m,2.5 lbf.ftl
(cont'd)
23-7
SeatBelts
RearSeat Belt Replacement{cont'd)
CenterBelt and Seat Belt Buckles 7. Removethe seat belt guide (A)from the pin (B),
and releasethe centerbelt (C)from the seat belt
1. Removethe seatcushion{seepage 20-80). g ui d e .
A
7/16-20 UNF
32N.m13.3kgf.m,
24 tbt.ft)
'.;r-
1-..i, ,
<i..
-"':''
'" "':
A
6x1.0mm 7/16-20UNF
3. Removethe right seat-back(seepage 20-80). 9.8 N.m (1.0kgf m, 32 N.m(3.3kgf m,
7.2 tbl.ttl 24 tbf.ftl
4. Removethe seat-backcover (seepage20-82).
FastenerLocation B
.:.',
t.)
23-8
I Inspec'tion
9. lnstallthe seat belt and bucklesin the reverseorder with seatbelttensioners.
Forfrontseatbeltretractors
of removal,and note these items: reviewtheSRScomponent locations(seepage23-13)
andthe precautionsandprocedures (seepsge23-14)in
. Checkthat the retractorlockingmechanism the SRSsectionbeforeperformingrepairsor service.
functions(seestep 1 on page 23-10).
. Assemblethe washerson the centeranchor bolt Retractor,Front and Rear
as shown (exceptcentershoulderbelt).
. Apply liquidthread lock to the anchor bolts 1. Beforeinstallingthe retractor,checkthat the seat
beforereinstallation. belt can be pulled out freely.
. Beforeinstallingthe centeranchor bolt, make
sure there are no twlsts or kinksin the centerbelt, 2. l\4akesure that the seat belt does not lockwhen the
retractor(A) is leanedslowly up to 15'from the
Canler anchor bolt construction: mounted position.The seat belt should lock when
the retractoris leanedover 40'. Do not attemDtto
disassemblethe retractor.
WASHER Front:
Forward lnside
Rear:
Forward Inside
(cont'd)
23-9
Seat Belts
Inspection(cont'd)
RetraEtor,RearCenter In-vehicle
1. Beforeinstallingthe retractor,checkthat the seat 1. Checkthat the seat belt is not twisted or caught on
belt can be pulled out freely. anything.
2, Make sure that the seat belt does not lockwhen the 2. After installingthe anchors.checkfor free
retractor(A) is leanedslowly up to 15' from the movementon the anchorbolts. lf necessary,
mounted position. removethe anchor bolts and checkthat the
washersand other partsare not damagedor
i m p r o p e r l yi n s t a l l e d .
3 , Leanthe retractorover 40', and make sure that the For rearcentershoulderbelt,checkthat the seat
seat belt does not lockwhen pulled out over 900 b e l tl o c k sw h e n p u l l e do u t o v e r 4 0 0m m ( 1 5 . 7i n . )
mm (35.4in.).Do not aftemptto disassemblethe with the seat-backfolded down.
retractor.
Make sure that the seat belt will retract
4 . Replacethe seat belt with a new assemblyif there automaticallywhen released.
is any abnormality.Do not disassembleany part of
the seat belt for any reason. 7 . For each passenger'sseat belt, checkthe seat belt
retractorlockingmechanismALR (automatic
lockingretractor).This function is for securingchild
seats.
- 1 P u l l t h es e a tb e l ta l l t h e w a y o u t t o e n g a g et h e
ALR.The seat belt should retractwith a
ratchetingsound, but not extend.This is
normal.
\,J
23-10
I ChildSeatTetherAnchorRemovaUlnstallation
Middle Side
1. Removethe child seattether anchorcover (A) in 1. Removethe rear bulkheadcoversfrom both sides
t h e r e a rt r i m p a n e l( B ) . ( s e ep a g e2 0 - 5 1 ) .
f-..- t"
.i..].-
,tltl
8 x 1.25mm
22 N m {2.2ksf.m, 16lbf.ft)
v\
2 . R e m o v et h e a n c h o rb o l t( C ) ,t h e n r e m o v et h e c h i l d A I 1
8 x 1 . 2 5m m
seattether anchor(D).Do not removethe toothed 22 N.m {2.2kgt m. 16lbfft)
washer (E)from the tether anchor.
l n s t a l l t h ea n c h o r si n t h e r e v e r s eo r d e ro f r e m o v a l .
3 . I n s t a l l t h ea n c h o ri n t h e r e v e r s eo r d e ro f r e m o v a l .
I J
23-11
sRs
ComponentLocationIndex
LEFTFRONTIMPACTSENSOB SRSINOICATOR
page23-105
Troubleshooting,
RIGHTFRONTIMPACTSENSOR
SIDEAIRBAG CUTOFFINDICATOR
AIRBAG
DRIVER'S
page23-113
Replacement,
page
Disposal, 23 1'16
FRONTPASSENGER'SAIRBAG
Replacement, page23-114
Disposap
l , a g e2 3 ' 1 1 6
SENSOR/
SEATBACK
Replacement,
page20-75
FRONTPASSENGER'S
SIDEAIRBAG
Replacement,
p a g e2 3 ' 1 ' 1 5
Disposal,
p a g e2 3 ' 1 1 6
FRONTPASSENGER'S
SEATBELT
CABLEREEL TENSIONER
Beplacement, Beplacement,
p a g e2 3 - 1 1 9 page23-4
Disposal,
page23-'116
OPDSUNIT
MEMORYERASE page23-27
Initialization,
(MES}
SIGNAL Replacement, page23-124
CONNECTOR
I2PI
SIOE
PASSENGER'S
IMPACTSENSOR
Replacement,
p a g e2 3 - 1 2 3
DATA LINK
CONNECTOR FRONTPASSENGER'SSEAT
(DLCI16P BELTBUCKLETENSIONER
DRIVER'SSEATBELTTENSIONER
Replacement, page23 4
D i s p o s a pl ,a g e2 3 - 1 1 6
23-13
sRs
Precautionsand Procedures
GeneralPrecautions Steering-related
Plecautions
Pleaseread the following precautionscarefullybefore CableReelAlignment
performingairbagsystem service.Observethe
instructionsdescribedin this manual.or the airbags . M i s a l i g n m e not f t h e c a b l er e e lc o u l dc a u s ea n o p e ni n
could accidentallydeploy and causedamageor injuries. t h e w i r i n g ,m a k i n gt h e S R Ss y s t e ma n d t h e h o r n s
inoperative.Centerthe cable reelwheneverthe
. Exceptwhen performingelectricalinspections. following is performed(seestep 6 on page23-121).
alwaysturn the ignition switch OFF,disconnectthe
negativecablefrom the battery,and wait at least3 - Installationof the steeringwheel
minutesbefore beginningwork. - Installationof the cable reel
NOTE:The memory is not erasedeven if the ignition - I n s t a l l a t i oonf t h e s t e e r i n gc o l u m n
switch is turned OFFor the batterycablesare - Other steering-related adjustmentor installation
disconnectedfrom the battery.
. Use replacementpans which are manufacturedto the . Do not disassemblethe cable reel.
same standardsand quality as the original parts.Do
not installused SRSpartsfrom anothervehicle.Use . Do not apply greaseto the cable reel.
only new pans when making SRS repairs.
. Carefullyinspectany SRS part beforeyou installit. . lf the cable reel shows any signs of damageor
Do not installany part that shows signs of being contamination.replaceit with a new one. For
droppedor improperlyhandled,such as dents,cracks, example,it does not rotatesmoothly.
or deformation.
23-14
AirbagHandlingand Storage . Storethe removedairbagon a secure,
flat surface
awayfrom any highheatsource(exceeding 200'Fi
Do not disassemblean airbag,lt has no serviceable
parts.Oncean airbag has been deployed,it cannot be
repairedor reused.
(cont'd)
23-15
sRs
Precautionsand Procedures{cont'dl .j
SRSUnit, Front lmpact Sensors,and Side . Do not disassemblethe SRS unit,front impactsensors,
lmpact Sensors or side impact sensors.
. Be careful not to bump or impactthe SRS unit, front . Turn the ignition switch OFF,disconnectthe battery
impact sensors,or side impactsensorswheneverthe negativecable,and wait at least3 minules before
ignition switch is ON (ll),or for at least3 minules after beginninginstallationor replacementof the SBS unit,
the ignition switch is turned OFF. or disconnectingthe connectorsfrom the SRSunit.
23-16
I
WiringPrecautions for ElectricalInspections
Precautions
Some of the SRSwiring can be identifiedby a special . When using electricaltestequipment,insertthe
yellow outer covering,and the SRSconnectorscan be probe of the tester into the wire side of the connector.
identifiedby their yellow color. Do not insertthe probe of the testerinto the terminal
Observethe instructionsdescribedin this section. side of the connector,and do not tamper with the
connector.
. Neverattemptto modify. splice,or repairSRSwiring.
l f t h e r ei s a n o p e no r d a m a g ei n S R Sw i r i n g ,r e p l a c e
the harness.
M a k es u r ea l l S R Sg r o u n dl o c a t i o n sa r e c l e a n ,a n d
groundsare securelyfastenedfor optimum metal-to-
metal contact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.
(cont'd)
23-17
sRs
Precautionsand Procedures(cont'dl
Spring-loaded
LockConnector Side Airbag Connector:
Connecting
Hold both connectorhalves,and pressthem firmly
Connecting togetheruntil the projection(C)of the sleeveside
1. To reconnect,hold the pawl-sideconnector,and
presson the backof the sleeve-sideconnectorin
connectorclicks. J
the directionshown. As the two connectorhalves
are pressedtogether,the sleeve(A) is pushedback
by the pawl (C).Do not touch the sleeve.
\ J
23-18
Backprobing
Spring-loaded
LockConnectors Seatswith SideAirbags
When checkingvoltageor resistanceon this type of "SIDEAIRBAG" label
Seatswith side airbagshave a on
connectorthe first time, you must removethe retainer the seat-back.Becausethe componentpans (seat-back
to insertthe tester orobe from the wire side. cover,cushion,etc.)of seatswith and without airbags
are different,make sure you installonly the correct
NOTE:lt is not necessaryto reinstallthe removed replacementparts.
retainer;theterminalswill stay lockedin the connector
housrno.
A W h e n c l e a n i n gd, o n o t s a t u r a t e t h es e a t w i t hl i q u i d ,
and do not sDravsteam on the seal
To removethe retainer(A),inserta flat-tipscrewdriver Do not reoalra torn or fraved seat-backcover.
(B) betweenthe connectorbody and the retainer,then ReDlacethe seat-backcover.
carefullypry out the retainer.Takecare not to breakthe A f t e ra c o l l i s i o ni n w h i c ht h e s i d ea i r b a gw a s
connector. deployed,replacethe side airbagwith new parts.lf
the seat-backcushion is split, it must be replaced.lf
the seat-backframe is deformed,it must be replaced.
Never put aftermarketaccessorieson the seat{covers,
pads,seat heaters,lights,etc.).
(cont'd)
23-19
sRs
Precautionsand Procedures(cont'dl
DisconnectingSystemConnectors
Beforeremoving a front airbag.side airbag,or other SRS relateddevices{the SRS unit,the cable reel,the front impact
sensors,the side impact sensors,the seat belt buckletensioners,and the seat belt tensionerconnector),disconnecting
connectorsfrom relateddevices,or removingthe dashboardor the steeringcolumn, disconnectthe airbagconnectors
or the side airbagconnectorsto preventaccidentaldeploVment.
Turn the ignition switch OFF,disconnectthe negativecablefrom the battery,and wait at least3 minutesbefore
beginningthe following procedures.
'BeforedisconnectingSRSunitconnectorA(1)fromtheSRSunit,disconnectthedriver'sairbag4Pconnector(3).
the front passenger'sairbag4P connector(4),the driver'sseat belt tensioner2P connector(6),and the front
passenger'sseatbelt tensioner2P connector(7).
. BeforedisconnectingSRS unit connectorB (8)from the SRS unit, disconnectboth side airbag2P connectors(11.'12),
and both seat belt buckletensioner4P connectors(9, 10).
. Beforedisconnectingthe cable reel 4P connector(2),disconnectthe driver'sairbag4P connector(3).
'Beforedisconnectingthefloorwireharness4Pconnector(5),disconnectbothseatbelttensioner2Pconnectors
(6.7).
\ .
23-20
1. Disconnectthe batterynegativecable,and wait at Side Airbag
least3 minutes.
4. Disconnectboth side airbag2P connectors(Alfrom
Driver's Airbag the floor wire harness.
Front Passenger'sAirbag
(cont'd)
23-21
sRs
Precautionsand Procedures(cont'd) 4
SeatBelt Tensioner SRS Unit
bothseatbelttensioner2Pconnectors
5. Disconnect 7. DisconnectSRS unit connectorA, SRS unit
(A)fromthefloorwire harness connectorB, and/or SRS unit connectorC from the
S R Su n i t .
\ J
23-22
GeneralTroubleshooting
Information
DTC(Diagnostic
TroubleCodesl Readingthe DTC
The self-diagnostic function of the SRSsystem allows it When the SRSindicatoris on, read the DTCusing either
to locatethe causesof system problemsand then store of the following methods:
this informationin memory. For easiertroubleshooting,
this data can be retrievedvia a data link circuit. PGM Tester "SRS" Menu Method:
Connectthe Honda PGM Tester{A)to the 16Pdata link
. W h e ny o u t u r n t h e i g n i t i o ns w i t c hO N ( l l ) ,t h e S R S connector{DLC)(B), and follow the Tester'sDromptsin
indicatorwill come on. lf it goes off after 6 seconds, "SRS"
the menu.
the system is normal. lf the Testerindicatesno DTC,no communication.DTC
. lf there is an abnormality,the svstem locatesand 3-6 to 3-'10,DTC4-6 to 4-10,DTC9-1,or DTC9-2,
definesthe problem,storesthis informationin double-checkby usingthe "SCS" menu method.
memory, and turns the SRS indicatoron. The data
w i l l r e m a i ni n t h e m e m o r ye v e nw h e n t h e i g n i t i o n
switch is turned off or if the batteryis disconnected.
. When you connectthe HondaPGlMTesterto the 16P
d a t al i n kc o n n e c t o(rD L C ) t os h o r tt h e S C St e r m i n a l ,
a n d t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .t h e S R Si n d i c a t o r
will indicatethe diagnostictrouble code (DTC)by the
n u m b e ro f b l i n k s .
. When you connectthe HondaPGM Testerto the 16P
data link Connector(DLC),you can retrievethe DTCin
t h e H o n d aS y s t e m s" S R S " m e n u .
. After readingand recordingthe DTC,proceedwith
the troubleshootingprocedurefor th is code.
Precautions
. U s eo n l y a d i g i t a lm u l t i m e t etro c h e c kt h e s y s t e m .l f
it's not a Hondamultimeter,make sure its output is
1 0 m A ( 0 . 0 1 Ao) r l e s sw h e n s w i t c h e dt o t h e s m a l l e s t
v a l u ei n t h e o h m m e t e rr a n g e A , t e s t e rw i t h a h i g h e r
o u t p u tc o u l dd a m a g et h e a i r b a gc i r c u i to r c a u s e
a c c i d e n t aal i r b a gd e p l o y m e nat n d p o s s i b l ei n j u r y .
. Wheneverthe ignition switch is ON (ll),or has been
turned OFFfor lessthan 3 minutes,be careful not to
b u m pt h e S R Su n i Ut h e a i r b a g sc o u l da c c i d e n t a l l y
d e p l o ya n d c a u s ed a m a g eo r i n j u r i e s .
. Beforeyou removethe SRSharness,disconnectthe
driver's airbagconnector.the front passenger's
airbagconnector,both side airbagconnectors,both
seat belt buckletensionerconnectors,and both seat
b e l tt e n s i o n ecr o n n e c t o r s .
. Make sure the batteryis sufficientlycharged.lf the
batteryis dead or low, measuringvalueswon't be
correct.
. Do not touch a tester probe to the terminalsin the
SRSunit or harnessconnectors,and do not connect
t h e t e r m i n a l sw i t h a j u m p e rw i r e . U s eo n l y t h e
backprobeset and the HondaPGM Tester.Backprobe
spring loadedlocktype connectorscorrectly.
(cont'd)
23-23
sRs
GeneralTroubleshootingInformation(cont'd) L 4
PGM Tester "SCS" Menu Method {retrieving the flash Readingthe main code:
codes):
I nc a s eo f 1 - 1 0
Countthe numberof blinks.
The SRSindicator(A) indicatesthe DTCby lhe number
Examplo:
of blinkswhen the Honda PGM Tester(B) is connected 1 . 2S r . 2S 1 . 2S 1 . 2S 1 . 2S
to the DLC(datalink connector)( 16P)(1). *t**t*l*l
""_f]_flfl
'1.
Make sure the ionition switch is OFF.
""ffi
Main code= 10 I =12
l n c a s eo f 2 0 o r m o r e
3 . Make sure the SCS line is grounded,then turn the
T w o s e t s o f f o u r f a s t b l i n k sc o u n t a s 2 0 .
ignitionswitch ON (ll).The SRS indicatorcomes on A d d a n y f u n h e r b l i n k s t o g e t h e ra s s h o w n .
for about 6 seconds,and then goes off. Then it will
Examplo:
blinkto indicatethe DTC(seethe table below).
0 . 1s 0.1s
4. Readthe DTC.
12s12s
,y'fl\,,. /[N *l-
5 . Turn the ignition switch OFF,and wait for 10 *FtftffN*+fH-t-ff
seconds.
\ J
23-24
Includingthe most recentproblem,up to three differentDTCScan be indicated(seeexample 1 below).
ln case of a continuousfailure,the DTCwill be indicatedrepeatedly{seeexample 1 below).
In caseof an intermittentfailure,the SRS indicatorwill indicatethe DTCSone time, then it will stay on (seeexample
2 below).
lf both a continuousand an intermittentfailure occur,both DTCSwill be indicatedas continuousfailures.
When the system is normal (no DTCS),the SRS indicatorwill stay on (seeexample3).
lf the SRSindicatorcomes on continuouslywithout a DTC,there mav be a problemwith the svstem.
lf the SRSindicatordoes not come on as indicatedabove,alwayscheckfor an open or a short to ground in the SCS
circuitbeforetroubleshootingthe system.
1. Continuousfailure,SRSIndic6torblink$likethis: S: Second
1 . 2S 1 , 2S 0.3s 0.3s
0.3s
ON
OFF
Bulb check Maincode(21 Subcode
l1) Main code l1l Subcode(3) Main code {11 Subcode{'l) Indications
period are lepeated
DTC2-l DTC1-3 DTC1-1 tn cese ot
Most recentp.oblem Sscond-mostrecent Third-mostrocent continuous
2. Intermittent failure, SRS lndicator blinks like this: problem problem failure.
ON
OFF
Bulb chock No DTC,systom is normal, the indicator
period stays on.
(cont'd)
23-25
sRs
GeneralTroubleshootingInformation(cont'dl
Erasingthe DTGMemory Troubleshootinglntermittent Failures
Specisl Tool Required lf there was a malfunction,but it doesn't recur.it will be
SCSserviceconnector07PAz-0010100 storedin the memory as an intermittentfailure,and the
SRS indicatorwill come on.
To erasethe DTC(S)fromthe SRSunit, use a Honda
PGMTester{seelhe HondaPGfMTesterSRSVehicle After checkingthe DTC,troubleshootas follows:
SystemSupplement)or the following procedure.
1. Readthe DTC(see"Readingthe DTC").
1. Make sure the ignition switch is OFF.
"Erasingthe DTC
2. Erasethe DTCmemory (see
2. Connectthe SCSserviceconnector{A) to the MES Memory").
2P connector(B).Do not use a jumper wire.
3. With the shift lever in neutral,startthe engine,and
letit idle.
3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
r i l l b l l n kt w o t i m e s i n d i c a t i n g
7 . T h e S R Si n d i c a t ow
that the memory has beenerased.
'10
8. Turn the ignition switch OFF,and wait for
seconds.
. h e S R Sj s
9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )a g a i n T
OK if the SRSindicatorcomes on for 6 secondsand
then goes off.
\ J
23-26
I
Initializingthe OPDS{OccupantPositionDetectionSystem}Unit
Special Tool Required
SCSserviceconnector07PAz-00'1
0100
c
07PAZ-00r0100
4 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
5. The SRS indicatorcomes on for about 6 secondsand goes off. Removethe SCSserviceconnectorfrom the MES
connectorwithin 4 secondsafterthe SRSindicatorwent off.
6. The SRSindicatorcomes on again.Reconnectthe SCSserviceconnectorto the MES connectorwithin 4 seconds
afterthe SRS indicatorcomes on.
7. The SRSindicatorgoes off. Removethe SCSserviceconnectorfrom the MES connectorwithln 4 seconds.
8. Watch the sRS indicator.
'lftheindicatorblinkstwotimesandthenstayson,theOPDSisinitialized.buttheDTCSneedtobeerased.
step 9, then erasethe DTCS.
.lftheindicatorblinkstwotimesandthengoesoff,theOPDSunitisinitialized.Gotostep9.
' lf the indicatorstayson without first blinking.theOPDSis not initialized.Readthe DTC.lf DTC 15-'lis indicated,
repeatthe initializationprocedure.lf anotherDTCis indicated,go to the appropriatepage in the DTC
TroubleshootingIndex.
9. Turn the ignition switch off, and disconnectthe PGM Tester.
SBS indic.ror
MES
I J DISCONNECTED
23-27
sRs
DTCTroubleshootingIndex t .
DTC Detection ltem Notes
t- | O D e ni n d r i v e r ' sa i r b a qi n f l a t o r (seeDaqe23-36)
Increasedresistancein driver'sairbaq inflator (seeDaoe23-36
t-5 Shon to anotherwire or decreasedresistancein driver's airbag (seepage23-37)
inflator
1-4 Shortto Dowerin driver'sairbao inflator (seepaqe23-39
t-5 Shortto qround in driver'sairbaq inflator {seepaqe23-40
2-1 Open in front Dassenqer's airbaq inflator {seeoaoe23-42
2-2 I n c r e a s e rde s i s t a n cien f r o n tp a s s e n q e r 'asi r b a qi n t l a t o r (seeoaqe 23-42
2-3 Short to anotherwire or decreasedresistancein front passenger's (seepage23-43)
airbao inflator
2-4 Short to oower in front oassenoer'sairbaq inflator (seepaqe23-45
2-5 Short to qround in front passenqer'sairbaq inflator (seepaqe 23-46
3-1 ODenin driver'sseat belttensioner (seepage 23-48
3-2 lncreasedresistancein driver's seat belt tensioner (seepaqe 23-48
3-3 Short to anotherwire or decreasedresistancein driver'sseat belt (seepage 23-49)
tensioner
3-4 Short to oower in driver'sseat belt tensioner (seeDaqe23-51
3-5 Short to oround in driver'sseat belt tensioner (seeoaoe 23-52
21-1 ODenor increasedresistancein driver'sseat belt buckletensioner (seepaqe 23-54
Short to anotherwire or decreasedresistancein driver'sseat belt (seepage23-55)
buckletensioner
2't-4 Short to Dowerin driver'sseat belt buckletensioner (seepaqe 23-56)
2't-5 Shon to oround in driver'sseat belt buckletensioner (seeoaqe23'57
4-'l ODenin front oassenoer'sseat belt tensioner {seepage23-58)
{seepaqe23-58)
4-2
4-3
lncreasedresistancein front oassenqer'sseat belttensioner
Short to anotherwire or decreasedresistancein front passenger's {seepage23-60) t J
seat belt tensioner
4-4 Shon to Dowerin front Dassenqer's seat belt tensioner lsee oaqe23-61
4-5 Short to qround in front oassenoer'sseat belt tensioner (seeDaqe23-63
Open or increasedresislancein front passenger'sseat belt buckle (seepage 23-64)
tensioner
22-3 Short to anotherwire or decreasedresistancein front passenger's (seepage 23-65)
seat belt buckletensioner
22-4 Short to oower in front oassenqer'sseat belt buckletensioner (seepaqe 23-66
22-5 Short to oround in front oassenoer'sseatbelt buckletensioner (seepaqe 23-68
5-1 lnternalfailure of SRSunit (seepage23-69)
5-2 NOTE:
5-4 BeforetroubleshootingDTCS5-1 through 8-6,checkbattery/system
5-8 voltage.lf the voltage is low, repairthe charging system before
6-3 troubleshootinothe SRS.
6-4
6-7
6-8
1-)
7-3
8-1
a-2
8-4
8-5
8-6
\ J
23-28
I J
DTC Detection ltem Notes
9-1 Internalfailure of the SRS unit. lf intermittent,it could mean internal (seepage23-69)
failure of the unit or a faulty indicatorcircuit.Referto
TroubleshootingIntermittentFailures(seepage 23-26).
NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system
voltage.lf the voltage is low, repairthe chargingsystem before
t r o u b l e s h o o t i nt gh e S R S .
9-2 Internalfailure of the SRSunit. lf intermittent,it could mean internal
failure of the power supply (VB line).Referto Troubleshooting
IntermittentFailures(seepage 23-26).
NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system
voltage.lf the voltage is low, repairthe chargingsystem or replace
the b€tterybeforetroubleshootingthe SRS.
9-3 Faultydriver'sseat belt buckleswitch (seeDaqe23-71)
9-4 FaultLtglt passenger's
seatbeltbuckleswitch lgqgfage 23-74)
9-6 FaultyIeft front imDactsensor {see Daqe23-77)
9-7 Faultyright front impact sensor (seepaqe 23-79)
10-1 Seat belt and seat belt buckletensioners(and airbag(s))deployed (seepage23-69)
10-2 D r i v e r ' ss i d ea i r b a gd e p l o y e d
r0-3 Seat belt and seat belt buckletensioners(and airbag(s))and driver's
s i d ea i r b a gd e p l o y e d
'10-4
Frontpassenqer'sside airbaodeDloved
'10-5
Seat belt and seat belt buckletensioners(and airbag(s))and front
passenqer'sside airbaq deDloved
10-6 Driver'sand front passenqer'sside al
l r 10-7
11-1
Seat belt and seat belt buckletensioners(and airbag(s))and driver's
and front passenger'sside airbagsdeployed
Open or increasedresistancein driver's side airbao inflator ( s e ep a q e2 3 - 8 1 )
Short to anotherwire or decreasedresistancein driver'sside airbao (seepage23-82)
inflator
11-4 Short to power in driver'sside airbaq inflator (seeoaqe 23-83)
I t-5 Short to ground in driver's side airbaq inflator {seepaqe 23-85)
Open or increasedresistancein front passenger'sside airbag (seepage 23-86)
inflator
Short to anotherwire or decreasedresistancein front passenger's (seepage 23-87)
side airbag inflator
12-4 Short to power in front passenqer'sside airbaq inflator {seeDaqezJ-uu}
Iz-5 S h o r tt o g r o u n di n f r o n t p a s s e n g e r 'ssi d ea i r b a qi n f l a t o r (seeoaqe 23-90)
13-1 Internalfailure of the driver's side impactsensor (seepage 23-70)
N o s i g n a lf r o m t h e d r i v e r ' ss i d ei m p a c ts e n s o r ( s e ep a q e2 3 - 9 1 )
13-4 Faultypowersupplyto the df,rglllug t Opacts9I99L (seepage23-92)
- 7 i i
14-1 , Internalfailureofthe frontpassenger's
sideimpactsensor (seepage23-70)
I J
23-29
SRS
Symptom TroubleshootingIndex \ 4
Symptom Diagnosticprocedure Also check for
SRSindicatordoesn'tcome on S R SI n d i c a t oTr r o u b l e s h o o t i n(gs e e
p a o e2 3 - 1 0 5 )
SRSindicatorstayson when in SRSIndicatorTroubleshooting(see Inabilityto retrieveDTCswith the
"SCS" menu method step 1 on page 23-107) PGM Tester.Retrievethe flash
codes usingthe SCSmenu method
(seepage 23-24).
Slde airbagcutoff indicatorstays . M a k es u r en o t h i n gi s o n t h e f r o n l DTC 15-2troubleshooting
o n a f t e rb u l bc h e c k( l f t h e passenger'sseat.
indicatorstayson, it does not set . lf the side airbagcutoff indicator
a DTC).Side airbagcutoff stayson after the ignition switch
indicatoris flashing i s t u r n e dO N ( l l ) ,i n i t i a l i z teh e
OPDSunit (see page23-271.
- lf the side airbagcutoff
i n d i c a t o or p e r a t e sn o r m a l l Yt,h e
system is OK.
- lf the side airbagcutoff
indicatorstayson, replacethe
u F U 5 S e n S O{ rS e eS e C r O Z nUl.
The sensor is part of the seat-
back Dad.
t r J
\ J
23-30
I SystemDescription
SRSComponents
Airbags
The SRSis a safetydevicewhich, when used with the seat belt, is designedto help protectthe driver and front
passengerin a frontal impact exceedinga certainset limit. The system consistsofthe SRS unit, includingsafing
sensorand impactsensor(A),the cable reel (B),the driver's airbag(C),the front passenger,sairbag (D).seat belt
tensioners(l),seat belt buckletensioners(J), and front impactsensors(K).
Sincethe driver'sand front passenger'sairbagsusethe same sensors,both normally inflateat the same ttme.
However,it is possiblefor only one airbagto inflate.This can occurwhen the severityof a collision is at the margin,or
threshold,that determineswhether or not the airbagswill deploy.In such cases,the seat belt will provide sufficient
protection,and the supplementalprotectionofferedby the airbagwould be mininal.
Side Airbags
The side airbags(E)are in eachfront seat-back.They help protectthe upper torso of the driver or front seat passenger
during a moderateto severeside impact.Side impact sensors(F) in each door sill and in the SRS unit detectsuch an
impactand instantlyinflatethe driver'sor the passenger'sside airbag.Only one side airbagwill deploy during a side
impacl. lf the impact is on the passenger'sside,the passenger'sside airbagwill deploy even if there is no passenger.
OPDS
The side airbagsystemalso includesan occupantpositiondetectionsystem (OpDS).This systemconsistsof sensors
(cont'd)
23-31
sRs
SystemDescription(cont'dl !J
SRSOperation
The main circuit in the SRS unit sensesand judgesthe force of impact and, if necessary.ignitesthe inflatorcharges.lf
batteryvoltage is too low or power is disconnecteddue to the impact,the voltage regulatorand the back-uppower
circuit,respectively,will keepvoltageat a constantlevel.
Side Airbaglsl
( 1)A side impact sensormust activate,and send electricsignalsto the microprocessor.
(2)The microprocessormust computethe signalsand send them to the side airbag inflator(s).However,the
microprocessorcuts off the signalsto the front passenger'sside airbag if the OPDSunit determinesthat the tront
passenger'shead is in the deploymentpath of the side airbag.
(3)The inflatorthat receivedthe signal must ignite and deploythe side airbag.
lw$ad..n sl
T' n0m
P gsfrlctR
S oXrVEr
S I
J
9oEAiA$ SOtlr&G I sEctto
f'**)r !
\ J
23-32
Self-diagnosis System
A self-diagnosiscircuitis built into the SRS uniUwhen the ignition switch is turned ON (ll),the SRS indicatorcomes on
and goes off after about 6 secondsif the SRS is operatingnormally.
lf the indicatordoes not come on, or does not go off after 6 seconds.or if il comes on while driving, it indicatesan
abnormalityin the SRS.The SRSmust be inspectedand repairedas soon as possible.
For betterserviceability,the SRSunit memory storesa DTCthat relatesto the causeof the malfunction,and the unit is
connectedto the data link circuit.This informationcan be read with the Honda PGM Testerwhen it is connectedto the
data link connector(DLc) (seepage 23-23).
23-33
SRS
CircuitDiagram J
rrssf c s
srarsftr
rrl$0[n
r-----Tr-i
i___':--_:"1
\ J
23-34
I J
tr ozr"*
tr ul"ar
1i
NJfl |-(tzl
t l
I J
I J
23-35
sRs
DTCTroubleshooting J
2. Turn the ignition switch ON {ll),and checkthat the NO Open or increasedresistancein the driver's
SRSindicatorcomes on for aboul 6 secondsand airbag inflator;replacethe driver'sairbag (seepage
then goes off. 23-113).t
Does the SBS indicator stay on? 9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait ior 3 minutes.
YES-Go to step 3.
10. Disconnectthe front passenger'sairbag4P
NO Intermittentfailure,system is OK at this time. connectorfrom dashboardwire harnessB (seestep
Go to TroubleshootingIntermittentFailures(see 3 o n p a g e2 3 - 2 1 ) .
page 23-26).
11. Disconnectboth seat belt tensioners2P connectors
3. Turn the ignition switch OFF.Disconnectthe from the floor wire harness(seestep 5 on page23-
batterynegativecable,and wait for 3 minutes. 22t.
07sAz-TB4011A
07xaz-s230100
23-36
'16
13. Checkresistancebetweenthe No. 7 and the No. DTC1-3:Shortto AnotherWire or Decreased
t e r m i n a l sa n d b e t w e e nt h e N o . 6 a n d t h e N o . 1 5 in Driver'sAirbagInflator
Resistance
t e r m i n a l so f S R Su n i tc o n n e c t oAr ( 1 8 P )T. h e r e
s h o u l db e 2 . 0 3 . 0 0 . SpecialToolsRequired
. SRS inflatorsimulator07SAZ-T8401
1A
. SRSsimulatorlead F 07XAZ-S230100
SRSUNITCONNECTOR
A I18P)
YES-Go to step 3.
Wiresideof femaleterminals
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
ls the resistance as specilied? page 23-261.
YES-Faulty SRS unit or poor contactat SRSunit Turn the ignition switch OFF.Disconnectthe
connectorA (18P)and the SRSunit, checkthe batterynegativecable,and wait for 3 minutes,
connectionbetweenthe connectorand the SRS
unit. lf the connectionis OK, replacethe SRSunit Disconnectthe driver'sairbag 4P connector(A)
( s e ep a g e2 3 - 1 2 2 ) . 1 from the cable reel.
07sAz-T84011A
07xAz-s230100
ConnecttheSRSinflatorsimulator{2 0
connectors)and the simulatorlead F to the cable
reel.
Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
(cont'd)
23-37
sRs
DTCTroubleshooting{cont'd)
8. Readthe DTC. 14. Checkresistancebetweenthe No. 7 and the No. 16
t e r m i n a l sa n d b e t w e e nt h e N o . 6 a n dt h e N o . 1 5
Is DTC 1-3indicated? t e r m i n a l so f S R Su n i tc o n n e c t o r A( 1 8 P )T. h e r e
should be an open circuit,or at least 1 M Q .
YES Go to step 9.
SRSUNITCONNECTOR
A {18P)
NO Short in the driver'sairbag;replacethe
driver's airbag (seepage 23-'l13).1
GRN/WHT GRN/RED
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
N O - R e p l a c ed a s h b o a r dw i r e h a r n e s sB . l
IJ
23-38
DTC1-4:Shortto Powerin Driver'sAirbag Readthe DTC.
Inflator
ls DTC 1-4indicated?
SpecialToolsBequired
. sRS inflatorsimulator07SAZ-T84011A YES-Go to step 9.
. SRSsimulatorlead F 07XAZ-S230100
NO-Short to power in the driver's airbag;replace
1. Erasethe DTCmemory (seepage 23-26). t h e d r i v e r ' sa i r b a g( s e ep a g e2 3 - 11 3 ) . 1
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e 9 . T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h
te
SRS indicatorcomes on for about 6 secondsand batterynegativecable,and wait for 3 minutes.
then goes off.
1 0 .Disconnectthe front passenger'sairbag4P
Does the SRS indicator stay on? connectorfrom dashboardwire harnessB (seestep
3 o n p a g e2 3 ' 2 1 ) .
YES Go to step 3.
1 1 .Disconnectboth seat belt tensioner2P connectors
NO Intermittentfailure,system is OK at this time. from the floor wire harness(seestep 5 on page 23-
Go to TroubleshootingIntermittentFailures(see 221.
page 23-26).
r ( 1 8 P ) f r o mt h e
1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oA
3. Turn the ignition switch OFF.Disconnectthe SRSunit (see step 7 on page 23-22).
batterynegativecable,and wait for 3 minutes.
Disconnectthe specialtool from the cable reel.
07sAz-T84011A
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
connectors)and the simulatorlead F to the cable
reel.
6 . Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
(cont'd)
23-39
SRS
DTCTroubleshooting(cont'd) L
Turn the ignition switch ON {ll). DTC1-5:Shortto Groundin Driver's
Airbag
lnflator
1 6 . Checkfor voltage betweenthe No. 7 terminal of
S R Su n i tc o n n e c t oA r ( 1 8 Pa ) n d b o d y g r o u n d ,t h e Special Tools Required
l n d b o d y g r o u n d ,t h e N o . 6
N o . 1 6t e r m i n a a . SRS inflatorsimulator07SM-TB4011A
t e r m i n a la n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l . SRSsimulatorlead F 07XM-S230100
and body ground.Thereshould be 0.5 V or less.
1. Erasethe DTCmemory (seepage 23-26).
SRSUNITCONNECTOR
A {18P)
2. Turn the ignition switch ON (ll),and checkthatthe
SRS indicatorcomes on for about 6 secondsand
then goes oIf.
YES Go to step 3.
NO Go to step 17.
4. Disconnectthe driver'sairbag 4P connector(A)
from the cable reel. a
1 1 . Turn the ignition switch OFF.
IJ
23-40
8. Readthe DTC. 14. Checkresistancebetweenthe No.7 terminal of
SRS unit connectorA {18P)and body ground,the
ls DTC 1-5 indicated? N o . 1 6t e r m i n a la n d b o d y g r o u n d ,t h e N o . 6
t e r m i n a la n d b o d y g r o u n d .a n d t h e N o . 1 5t e r m i n a l
YES-Go to step 9. and body ground.There should be an open circuit,
o r a t l e a s t1 M Q .
NO Short to ground in the driver's airbaginflator;
replacethe driver's airbag(seepage 23-113).I A I18PI
SRSUNITCONNECTOR
N O - G o t o s t e p1 5 .
t h e c a b l er e e l . I
YES Replace
NO Replacedashboardwire harnessB.l
23-41
sRs
DTCTroubleshooting(cont'dl {
07sAz-T84011A
07xAz-s230100
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
! J
23-42
\
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) , a n d c h e c k t h a t t h e
SRS indicatorcomes on for about 6 secondsand
then goes off.
07sAz-T84011A
07xAz-s230100
C o n n e ctth e S R Sl n f l a t o rs i m u l a t o r( 2 0
c o n n e c t o r sa)n d t h e s i m u l a t o rl e a dF t o d a s h b o a r d
w i r e h a r n e s sB .
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
T J
(cont'd)
23-43
sRs
qJ
DTGTroubleshooting(cont'd)
Readthe DTC. '12.
DisconnectSRS unit connectorA (18P)from the
SRS u nit (see step 7 on page 23-22l..
ls DTC 2-3 indicated?
13. Disconnectthespecialtool from dashboardwire
YES Go to step9. h a r n e s sB .
NO-Short in the front passenger'sairbag inflator; 14. Checkresistancebetweenthe No. 4 and No. 13
replacethe front passenger'sairbag (seepage 23- t e r m i n a l sa n d b e t w e e nt h e N o . 5 a n d N o . 1 4
1 1 4 )t . t e r m i n a l so f S R Su n i tc o n n e c t oA r ( 1 8 P )T. h e r e
s h o u l db e a n o p e nc i r c u i t o, r a t l e a s t1 M Q .
9 . Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
SRSUNIT CONNECTOR
A I18P)
BLU/BLK
Wiresideof femaleterminals
N O - S h o n i n d a s h b o a r dw i r e h a r n e s sB ; r e p l a c e
d a s h b o a r dw i r e h a r n e s sB . l
T J
23-44
DTC2-4:Shortto Powerin FrontPassenger's 8. Readthe DTC.
AirbagInflator
ls DTC 2-4 indicated?
Special Tools Required
. SRSinflatorsimulator07SAZ-TB4011A YES-Go to step 9.
. SRSsimulatorlead F 07XAZ-S230100
NO-Short to power in the front passenger'sairbag
1. Erasethe DTCmemory (seepage 23-26). inflator;replacethe front passenger'sairbag (see
p a g e2 3 - 1 1 4 ) . I
2. Turn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand 9. Turn the ignitionswitch OFF.Disconnectthe
then goes off, batterynegativecable,and wait for 3 minutes.
Does the SRS indicatot stay on? 10. Disconnectthe driver's airbag4P connectorfrom
the cable reel (seestep 2 on page 23-21).
YES-Go to step 3.
11. Disconnectboth seatbelttensioner2P connectors
NO Intermittentfailure,system is OK at this time. from the floor wire harness(seestep 5 on page 23-
Go to TroubleshootinglntermittentFailures(see 22).
page23-26).
07sAz-T84011A
07xAz-s230100
Connectthe SRSinflatorsimulator(2 Q
connectors)and the simulatorlead F to dashboard
w i r e h a r n e s sB .
6 . Reconnectthe batterynegativecable.
{cont'd)
23-45
sRs
DTCTroubleshooting(cont'd) {
the SRSunit(see
YES FaultySRSuniureplace
page23-1221
.a
07xAz-s230100
5 . Connectthe SRSinflatorsimulator(2 Q
connectors)and the simulatorlead F to dashboard
wire harnessB.
\ J
23-46
I
Reconnectthe batterynegativecable. 12. DisconnectSRS unit connectorA (18P)from the
SRS unit (seestep7 on page 23-221.
7 . Erasethe DTCmemory.
1 3 .Disconnectthespecialtool from dashboardwire
Readthe DTC. h a r n e s sB .
't4.
ls DTC 2-5 indicated? Checkresistancebetweenthe No. 4 terminal of
SRS unit connectorA (18P)and body ground,the
YES-Go to step 9. No. 13 terminal and body ground.the No. 5
terminaa l n d b o d y g r o u n d ,a n d t h e N o . 1 4t e r m i n a l
NO-Shon to ground in the front passenger's and body ground.Thereshould be an open circuit,
airbaginflator;replacethe front passenger'sairbag o r a t l e a s tl M Q .
( s e ep a g e2 3 - 11 4 ) . 1
A {18P}
SRSUNITCONNECTOR
9 . Turn the ignitionswitch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes. BLU/RED BLU/YEL
I
I Wire side ol temaleterminals
23-47
sRs
DTCTroubleshooting(cont'dl
DTC3-1:Openin Driver'sSeatBeltTensioner 6. Reconnectthe batterynegativecable.
DTC3-2:Increased
Resistancein Driver's
SeatBeltTensioner 7. Erasethe DTCmemory.
1 1 .Connectthe SRSinflatorsimulator(2 Q
connectors)and simulatorlead F to dashboardwire
harnessB.
07sAz-T84011A
1 2 . Reconnectthe batterynegativecable.
Erasethe DTCmemory.
07TAZ-52501'lA
1 4 .Readthe DTC.
5. ConnecttheSRSinflatorsimulator(2 0 connector)
and simulatorlead C to the floor wire harness. ls DTC 3-1 or DTC 3-2 indicated?
23-48
I
to. Oisconnectthe driver's airbagconnector(seestep DTC3-3:Shortto AnotherWire or Decreased
2 on page 23-21),f ront passenger'sairbag in Driver'sSeatBeltTensioner
Resistance
connector(seestep 3 on page 23-21),andfront
passenger'sseat belt tensionerconnector(seestep SpecialToolsRequired
5 on page 23-22). . SRS inflatorsimulator07SAZ-T8401'1A
. SRSsimulatorlead C 07TM-S25011A
1 7 . DisconnectSRSunit connectorA (18P)from the . SRSsimulatorlead F 07XAZ-S230100
SRSunit (seestep 7 on page 23-22).Do not
disconnectthe specialtool from dashboardwire 1. Erasethe DTCmemory (seepage 23-26).
harnessB.
2. Turn the ignition switch ON (ll),and checkthatthe
1 8 . Checkresistancebetweenthe No.8 terminal and SRS indicatorcomes on for about 6 secondsand
t h e N o . 1 7t e r m i n a o r (18P).
l f S R Su n i tc o n n e c t oA then goes off.
T h e r es h o u l db e 2 . 0 - 3 . 0 Q.
Does the SRS indicator stay on?
A (18P)
SRSUNITCONNECTOR
YES Go to step 3.
RED/WHT
NO-lntermittent failure,system is OK at this time,
Go to TroubleshootingIntermittentFailures{see
i-4
2 3 5 6 1 \lel a; page 23-26).
10 1 l 1Z t 3 t 5 16
E a Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
I RED/BLU
] Disconnectthe driver'sseat belt tensioner2P
Wiresideof femaleterminals connector(A) from the floor wire harness.
07TAZ-S25011A
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r )
a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .
I
(cont'd)
23-49
sRs
DTCTroubleshooting(cont'd)
6. Reconnectthebatterynegativecable. 16. Disconnectthe driver'sairbagconnector(seestep
2 on page23-211,lrontpassenger'sairbag
7. Erasethe DTCmemory. connector(seestep 3 on page 23-21),and front
passenger'sseat belt tensionerconnector(seestep
8. Readthe DTC. 5 on page 23-22).
RED/WHT
07sAz-TB4or
1A
RED/BLU
L J
W i r es i d eo f f e m a l e
terminals
1 3 .Erasethe DTCmemory.
1 4 .Readthe DTC.
t J
23-50
I J
DTC3-4:Shortto Powerin Driver'sSeatBelt 6. Reconnectthe batterynegativecable.
Tensioner
7. Erasethe DTCmemory.
SpecialToolsBequired
. SRSlnflatorsimulator07SAZ-TB4011A 8. Readthe DTC.
. S R Ss i m u l a t o lre a dC 0 7 T M - S 2 5 0 1 1 A
. SRSsimulatorlead F 07XAZ-S230100 Is DTC 3-4 indicated?
2. Turn the ignition switch ON (ll),and checkthat the NO-Short to power in the driver'sseat belt
SRSindicatorcomes on for about 6 secondsand tensioner;replacethe driver'sseat belt
then goes off. ( s e ep a g e2 3 - 4 ) . 1
Does the SRS indicatot stay on? L Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
YES- Go to step 3.
10. Disconnectfloor wire harness4P connectorC403
NO Intermittentfailure,system is OK at this time. (A) from dashboardwire harnessB.
Go to TroubleshootingIntermittentFailures(see
page 23-261.
1 1 .C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
connectors)and simlator lead F to dashboardwire
07sAz-T84011A h a r n e s sB .
' t 2 .Reconnectthe batterynegativecable.
Erasethe DTCmemory.
N O - S h o n t o p o w e ri n t h e f l o o rw i r e h a r n e s s ;
r e p l a c et h e f l o o rw i r e h a r n e s s . I
T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h
te
(cont'd)
23-51
sRs
DTCTroubleshooting(cont'dl
16. Disconneclthe driver'sairbagconnector(seestep DTC3-5:Shortto Groundin Driver'sSeatBelt
2 on page23-21l,Irontpassenger'sairbag Tensioner
connector(seestep 3 on page 23-2'l),and front
passenger'sseat belt tensionerconnector(seestep Special Tools Required
5 on page 23-221. . sRS inflalor simularor07sAz-TB4011A
. SRSsimulatorlead C 07TAZ-S25011A
17. DisconnectSRSunit connectorA (l8P)from the . SRSsimulatorlead F 07XAZ-S230100
SRS unit (see step 7 on page 23-22).
1. Erasethe DTCmemory {seepage23-26).
18. Disconnectthe specialtoolfrom dashboardwire
h a r n e s sB . 2. Turn the ignition switch ON (ll),and checkthat the
SRS indicatorcomes on for about 6 secondsand
19. Reconnectthe batterynegativecable. then goes off.
20. Turn the ignition switch ON (ll), Does the SRS indicator stay on?
YES-FaultySRSunit;replace
the SRSunit{see
page23-122],
.a
L J
23-52
t
6. Reconnectthe batterynegativecable. 16. Disconnectthedriver'sairbagconnector(seestep
2 on page23-211,lrontpassenger'sairbag
7. Erasethe DTCmemory. connector(seestep 3 on page 23-21),and front
passenger'sseat belt tensionerconnector(seestep
8. Readthe DTC. 5 on page 23-22).
)
07sAz-T84011A
Y E S - F a u l t yS R Su n i u r e p l a c et h e S R Su n i t{ s e e
'11.
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q page 23-122l,.a
connectors)and simulatorlead F to dashboardwire
h a r n e s sB . NO Short to ground in dashboardwire harnessB;
r e p l a c ed a s h b o a r dw i r e h a r n e s sB . l
Reconnectthe batterynegativecable.
Erasethe DTCmemory.
1 4 . Readthe DTC.
23-53
sRs
DTCTroubleshooting{cont'd)
DTC21-1:Openor Increased Resistance
in 8. Readthe DTC.
Driver'sSeatBeltBuckleTensioner
l s D T C 2 1 - 1i n d i c a t e d ?
SpecialTools Required
. SRSinflatorsimulator07SAZ-TB4011A YES Go to step 9.
. SRSsimulatorlead F 07XAZ-S230100
NO Open or increasedresistancein the driver's
1. ErasetheDTCmemory (seepage 23-261. seat belt buckletensioner;replacethe driver'sseat
b e l tb u c k l e . I
2. Turn the ignition switch ON (ll),and checkthat the
SRS indicatorcomes on for about 6 secondsand 9. Turn the ignition switch OFF.Disconnectthe
then goes off. batterynegativecable.and wait for 3 minutes.
Does the SBS indicatot stay on? 10. Disconnectboth side airbag2P connectors(see
step 4 on page 23-2lland the front passenger's
YES Go to step3. seat belt buckletensioner4P connector(seestep 6
on page 23-22).
NO-lntermittent failure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see r ( 1 8 P ) f r o mt h e
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t o B
page 23-261. SRSunit (seestep 7 on page 23'22).Do not
disconnectthe specialtool from the floor wire
3. Turn the ignition switch OFF.Disconnectthe narness.
batterynegativecable,and wait for 3 minutes.
12. Checkresistancebetweenthe No. 1 and No. 10
4. Disconnectthe driver's seat belt buckletensioner r ( 1 8 P )T. h e r e
t e r m i n a l so f S R Su n i tc o n n e c t oB
4P connector(A) from the floor wire harness. s h o u l db e 2 . 0- 3 . 0 O .
b /
SRSUNITCONNECTOR
B Il8PI
GRN/YEL
l t ' '
A\ I' ? 3 6 1 6 s
Y l r 0t l 1 5 t 6 17 t6
] TI
GRN/BLK
W i r es i d eo f f e m a l tee r m i n a l s
L J
23-54
I
DTC21-3:Shortto AnotherWireor 8. Readthe DTC.
DecreasedResistance
in Driver'sSeatBelt
EuckleTensioner ls DTC 21-3 indicated?
GRN/YEL
GRN/BLK
Wiresideof femaleterminals
23-55
sRs
(cont'dl
DTCTroubleshootang
DTG21-4:Shortto Powerin Driver'sSeatBelt Readthe DTC.
BuckleTensioner
ls DTC 21-4 indicated?
SpecialToolsRequired
. SRSinflatorsimulator07SAZ-TB4011A YES Go to step 9.
. SRSsimulatorlead F 07XM-S230100
NO Shon to power in the driver'sseat belt buckle
1. Erasethe DTCmemory (seepage23-26). tensioner;replacethe driver's seatbelt buckle.l
2. Turn the ignition switch ON (ll),and checkthat the L Turn the ignition switch OFF.Disconnectthe
SRSindicatorcomes on for about 6 secondsand batterynegativecable,and wait for 3 minutes.
then goes off.
1 0 .Disconnectboth side airbag2P connectors(see
Does the SRS indicatot stay on? step 4 on page 23-21)and the front passenger's
seat belt buckletensioner4P connector(seestep 6
YES-Go to step 3. on page 23-22).
5 . ConnecttheSRSinflatorsimulator{2 0
connectors)and the simulatorlead F to the f loor
wireharness.
Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
\, .J
23-56
1 1 .DisconnectSRS unit connectorB (18P)from the DTC21-5:Shortto Groundin Driver'sSeat
SRSunit (seestep 7 on page 23-22). BeltBuckleTensioner
1 2 . Disconnectthe specialtool from the floor wire Special Tools Required
harness. . SRS inflatorsimulator07SAZ-TB4011A
. SRSsimulatorlead F 07XAZ-S230100
Reconnectthe batterynegativecable.
1. Erasethe DTCmemory {seepage 23-26}.
1 4 . Turn the ignitionswitch ON (ll).
2. Turn the ignition switch ON (ll),and checkthat the
Checkfor voltage betweenthe No. 1 lerminal of SRSindicatorcomes on for about 6 secondsand
SRSunit connectorB {18P)and body ground, and then goes off.
t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d
be 0.5 V or less. Does the SBS indicator stay on?
SRSUNITCONNECTOR
B I18PI YES-Go to step 3.
the SRSunit(see
YES FaultySRSunit;replace
page23-1221
.f
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q
connectors)and simulatorlead F to the floor wire
n ar n e s s .
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
(cont'd)
23-57
sRs
DTCTroubleshooting(cont'dl
Readthe DTC. DTC4-1:Openin FrontPassenger'sSeatBelt
renstoner
ls DTC 21-5 indicated? DTC4-2:lncreasedResistance
in Front
Passenger's
SeatBeltTensioner
YES Go to step 9.
Special Tools Required
NO Short to ground in the driver's seat belt . SRS inflatorsimulator07SM-T84011A
buckletensioner;replacethe driver's seat belt . SRSsimulatorlead C 07TAZ-S25011A
buckle.l . SRSsimulatorlead F 07XAZ-S230100
'L
9 . Turn the ignitionswitch OFF.Disconnectthe Erasethe DTCmemory (seepage23-26).
batterynegativecable,and wait for 3 minutes.
Turn the ignition switch ON {ll),and checkthat the
1 0 .Disconnectboth side airbag2P connectors(see SRS indicatorcomes on for about 6 secondsand
step 4 on page 23-21)andthe front passenger's then goes off.
seat belt buckletensioner4P connector(seestep 6
on page 23-221. Does the SBS indicator stay on?
'1
1 3 .Checkresistancebetweenthe No. terminal of Turn the ignition switch OFF.Disconnectthe
SRS unit connectorB (18P)and body ground,and batterynegativecable,and wait for 3 minutes.
t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d
, r a t l e a s t1 M Q .
b e a n o p e nc i r c u i t o Disconnectthe front passenger'sseat belt
tensioner2P connector(A) from the floor wire
SRSUNITCONNECTOR
B {18PI harness.
07TAZ-525011A
ls the tesistanceas specilied?
the SRSunit(see
YES FaultySRSuniureplace 5. Connectthe SRS inflatorsimulator(2 0 connector)
page23-122)
.a a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .
N O - S h o r t o g r o u n di n t h ef l o o rw i r eh a r n e s s ;
replace thefloorwire harness.l
\ J
23-58
)
L Turn the ignition switch OFF.Disconnectthe 18. Checkresistancebetweenthe No. 9 terminal and
'18
batterynegativecable,and wait for 3 minutes. the No. terminal of SRS unit connectorA (18P).
T h e r es h o u l db e 2 . 0 - 3 . 0 Q .
10, Disconnectthe floor wire harness4P connector
C403(A)from dashboardwire harnessB.
SRS UNIT CONNECTORA {18P}
RED/YEL
1 2 3 4 5 7 8
{ l
l 6
1 0 11 12 15 1 7 r8l \t
)
07sAz-T840't
1A
r l
RED/BLK
I
23-59
sRs
DTCTroubleshooting(cont'dl
DTC4-3:Shortto AnotherWire or Decreased 8. Readthe DTC.
Resistance
in FrontPassenger'sSeatBelt
Tensioner ls DTC 4-3 indicated?
YES-Go to step 3.
1 1 .C onnectthe SRSinflatorsimulator(2 0
connectors)and simulatorlead F to dashboardwire
harnessB.
Reconnectthe batterynegativecable.
1 3 .Erasethe DTCmemory.
1 4 .Readthe DTC.
\ J
23-60
16. Disconnectthedriver'sairbagconnector(seestep DTC4-4:Shortto Powerin FrontPassenger's
2 on page23-211, front passenger'sairbag SeatBeltTensioner
connector(seestep 3 on page 23-21),and driver,s
seat belt tensionerconnector(seestep 5 on page Special Tools Required
23-221. . SRS inflatorsimulator07SAZ-T84011A
. S R Ss i m u l a t o rl e a dC 0 7 T A Z - S 2 5 0 1 1 A
17. DisconnectSRSunit connectorA (18p)from the . SRSsimulatorlead F 07XAZ-S230100
SRS unit (see step 7 on page 23-22).
1. Erasethe DTCmemory (seepage 23-26).
18. Disconnectthe specialtool from dashboardwire
harnessB. 2. Turn the ignition switch ON {ll),and checkthat the
SRS indicatorcomes on for about 6 secondsand
19. Checkresistancebetweenthe No. 9 terminal and then goes off.
t h e N o . 1 8t e r m i n a o
l f S R Su n i tc o n n e c t oA r (18p).
T h e r es h o u l db e a n o p e nc i r c u i t o
, r a t l e a s t1 M e . Does the SRS indicator stay on?
SRSUNITCONNECTOR
A I18P} YES Go to step 3.
2 3 4 5 6 8
It 6] page 23-261.
I
T batterynegativecable,and wait for 3 minutes.
YES-FaultySRSunit;replace
the SRSunit(see
page23-1221
.f
07TAZ-S2501'lA
{cont'd)
23-61
sRs
DTCTroubleshooting(cont'd)
6. Reconnectthe batterynegativecable. 1 5 .Turn the ignitionswitch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
7. Erasethe DTCmemory.
t o . Disconnectthe driver's airbagconnector(seestep
8. Readthe DTC. 2 on page23-211,tront passenger'sairbag
connector(seestep 3 on page 23-21),and drivefs
ls DTC 4-4 indicated? seatbelt tensionerconnector(seestep 5 on page
23-22t.
YES Go to step 9.
1 1 . DisconnectSRS unit connectorA ('l8P)trom the
NO-Short to power in the front passenger'sseat SRS unit (seestep 7 on page 23-22).
belt tensioner;replacethe front passenger'sseat
b e l t( s e ep a g e2 3 - 4 ) . I 1 8 . Disconnectthe specialtool from dashboardwire
h a r n e s sB .
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable.and wait for 3 minutes. 1 9 . Reconnectthe batterynegativecable.
A (18PI
SRSUNITCONNECTOR
t' J
07sAz-TB4o11A
1 1 .Connectthe SRSinflatorsimulator(2 0
connectors)and simulatorlead F to dashboardwire terminals
WiresideoJJemale
h a r n e s sB .
Y E S - G o t o s t e p1 5 .
23-62
I
DTC4-5:Shortto Groundin FrontPassenger's 8. Readthe DTC.
SeatBeltTensioner
ls DTC 4-5 indicated?
Special Tools Required
. SRSinflatorsimulator07SAZ-TB40'11A YES-Go to step 9.
. SRSsimulatorlead C 07TAZ-S25011A
. SRSsimulatorlead F 07XAZ-S230100 NO Short to ground in the front passenger'sseat
belt tensioner;replacethe front passenger'sseat
1. ErasetheDTCmemory (seepage 23-26]|. b e l t( s e ep a g e2 3 - 4 ) . I
Y E S - G o t o s r e p3 .
1 2 . Reconnectthe batterynegativecable.
Erasethe DTCmemory.
1 4 . Readthe DTC.
(cont'd)
23-63
sRs
DTCTroubleshooting(cont'dl
16. Disconnectthe driver's airbagconnector(seestep DTC22-1:Openor Increased in
Resistance
2 on page 23-21),front passenger'sairbag SeatBeltBuckleTensioner
FrontPassenger's
connector(seestep 3 on page 23-21).and driver's
seat belt tensionerconnector(seestep 5 on page SpecialTools Required
23-22). . SRSinflatorsimulator07SAZ-T84011A
. SRSsimulatorlead F 07XAZ-S230100
r ( 1 8 P ) f r o mt h e
1 7 . D i s c o n n e cSt R Su n i tc o n n e c t oA
SRSunit (seestep 7 on page 23-221. 1. Erasethe DTC memory (see page 23-261.
18. Disconnectthe specialtoolfrom dashboardwire 2. Turn the ignition switch ON (ll),and checkthat the
harnessB. SRSindicatorcomes on for about 6 secondsand
then goes otf.
19. Checkresistancebetweenthe No.9 terminal of
S R Su n i tc o n n e c t oA r ( 1 8 Pa ) n d b o d y g r o u n d ,a n d Does the SRS indicator stay on?
t h e N o . l 8 t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d
. r a t l e a s t1 M Q .
b e a n o p e nc i r c u i t o YES-Go to step 3.
w i r e s i d eo f l e m a l et e r m i n a l s
Y E S F a u l t yS R Su n i Ur e p l a c et h e S R Su n i t ( s e e
page 23-1221.1
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q
connectors)and the simulatorlead F to the floor
w t r eh a r n e s s .
23-64
t
6. Reconnectthe bafterynegativecable. DTC22-3:Shortto AnotherWire or
DecreasedResistance
in FrontPassenger's
7. Erasethe DTCmemory. SeatBeltBuckleTensioner
8. Readthe DTC. SpecialToolsRequired
. SRS inflatorsimulator07SAZ-TB4011A
ls DTC 22-1 indicated? . SRSsimulator lead F 07XAZ,S230100
NO Open or increasedresistancein the front 2. Turn the ignition switch ON fll), and checkthat the
passenger'sseat belt buckletensioner;replacethe SRSindicatorcomes on for about 6 secondsand
front passenger'sseat belt buckle.l then goes off.
9. Turn the ignitionswitch OFF.Disconnectthe Does the SRS indicator stay on?
batterynegativecable,and wait for 3 minutes.
YES Go to step 3.
10. Disconnectboth side airbag2P connectors(see
step 4 on page23-21)and the driver's seat belt NO Intermiftentfailure,system is OK at this time.
buckletensioner4P connector(seestep 6 on page Go to TroubleshootingIntermittentFailures(see
23-22). page 23-26),.
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB
r ( 1 8 P ) f r o mt h e 3. Turn the ignition switch OFF.Disconnectthe
SRSunit (seestep 7 on page 23-22).Do not batterynegativecable,and wait for 3 minutes.
disconnectthe specialtool from the floor wire
I harness.
1 2 . C h e c kr e s i s t a n cbee t w e e nt h e N o . 2 a n d N o . 1 1
4. Disconnectthe front passenger'sseat belt buckle
tensioner4P connector(A) from the floor wire
harness.
terminalsof SRS unit connectorB ('l8P).There
s h o u l db e 2 . 0 3 . 0 0 .
SRSUNITCONNECTOR
B I,I8PI
)m 3 6 7 8
r5 r6 1T 1 8
9
W i r es i d eo f f e m a l tee r m i n a l s
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 Q
connectors)and the simulatorlead F to the floor
ls the resistance as specified? w t r eh a r n e s s .
{cont'd)
23-65
sRs
DTCTroubleshooting(cont'dl
8. Readthe DTC. DTC22-4:Shortto Powerin FrontPassenger's
SeatBeltBuckleTensioner
ls DTC 22-3 indicated?
SpecialToolsRequired
YES Go to slep 9. . S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-TB4011A
. S R Ss i m u l a t o rl e a dF 0 7 X A z5 2 3 0 1 0 0
NO-Short in the front passenger'sseat belt buckle
tensioner;replacethe front passenger'sseat belt 1. Erasethe DTCmemory (seep age23-26).
buckle.l
2 . T u r nt h e i g n i t i o ns w i t c hO N { l l } ,a n d c h e c kt h a tt h e
9. Turn the ignition switch OFF.Disconnectthe S R Si n d i c a t ocr o m e so n f o r a b o u t6 s e c o n d sa n d
batterynegativecable,and wait for 3 minutes. then goes off.
10. Disconnectboth side airbag2P connectors(see Does the SHS indicator stay on?
s t e p4 o n p a g e2 3 - 2 1 ) a n dt h e d r i v e r ' ss e a tb e l t
buckletensioner4P connector(seestep 6 on page YES Go to step 3.
23-22).
N O I n l e r m i t t e n t f a i l u r e , s y s t ei smO K a t t h i s t i m e .
'11. Go to TroubleshootingIntermittentFailures(see
D i s c o n n e cSt R Su n i tc o n n e c t oB
r { 1 8 P ) f r o mt h e
SRS unit (seestep 7 on page23-221. page 23-261.
12. Disconnectthe specialtool from the floor wire 3. Turn the ignition switch OFF.Disconnectthe
ha r n e s s . batterynegativecable,and wait for 3 minutes.
GRN/RED
GRN
WiresideoI femaleterminals
\ J
23-66
t
6. Reconnectthe batterynegativecable. 1 0 .Disconnectboth side airbag2P connectors(see
s t e p4 o n p a g e2 3 - 2 1 ) a n dt h e d r i v e r ' ss e a tb e l t
7. Erasethe DTCmemory. buckletensioner4P connector(seestep 6 on page
,1_r'>\
8. Readthe DTC.
1 1 .DisconnectSRS unit connectorB (18P)from the
ls DTC 22-4 indicated? SRS unit (seestep 7 on page 23-221.
SRSUNITCONNECTOR
B I18P)
Y E S - F a u l t yS R Su n i t ;r e p l a c et h e S R Su n i t ( s e e
page 23-1221.l
23-67
sRs
DTCTroubleshooting(cont'dl
DTC22-5:Shortto Groundin Front 8. Readthe DTC.
SeatBeltBuckleTensioner
Passenger's
ls DTC 22-5 indicated?
SpecialTools Required
. SRSinflatorsimulator07SAZ-T84011A YES-Go to step 9.
. SRSsimulatorlead F 07XAZ-S230100
NO Short to ground in the front passenger'sseat
1. Erasethe DTCmemory (seepage 23-26). belt buckletensioner;replacethe front passenger's
s e a tb e l tb u c k l e . l
2. Turn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand 9. Turn the ignition switch OFF.Disconnectthe
then goes off. batterynegativecable,and wait for 3 minutes.
Does the SRS indicator stay on? 10. Disconnectboth side airbag2P connectors(see
step 4 on page 23-21)and the driver'sseat belt
YES-Go to step 3. buckletensioner4P connector(seestep 6 on page
23-22t.
NO - Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see r ( 1 8 P l f r o mt h e
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB
page 23-26). SRS unit (see 7
step on page 23-221.
3. Turn the ignition switch OFF.Disconnectthe 12. Disconnectthe specialtool from the floor wire
batterynegativecable,and wait for 3 minutes. harness,
g {18PI
SRSUNITCONNECTOR
5 . Connectthe SRSinflatorsimulator(2 Q
connectors)and simulatorlead F to the floor wire ls the resistance as specified?
narness.
YES-Faulty SRSunit; replacethe SRS unit (see
6 . Reconnectthe batterynegativecable. page 23-1221.a
!U
23-68
I
DTCs-1,5-2,5-4,s-8,6-3,6-4,6-7,6-8,7-1, DTC10-1,10-2,10-3,10-4,10-s,10-6,10-7:
7-2,7-3,A-1,4-2,8-3,8-4,8-5,8-6,9-1,9-2: Airbags,SideAirbags,and/orSeatBeltand
InternalFailureof the SRSUnit SeatBeltBuckleTensionersDeployed
NOTE:Beforetroubleshootingany of these DTCs,check The SRS unit must be replacedafter any airbagsand/or
the battery/systemvoltage.lf the voltage is low, repair tensionershave deployed(seepage 23-122).!
the chargingsystem or replacethe batterybefore
troubleshootingthe SRS.lf the battery/systemvoltage
is now OK, ask the customerif the batteryever went
oeao,
t h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1
YES Replace
23-69
SRS
DTCTroubleshooting(cont'd)
DTC13-1,13-2:InternalFailureof the Driver's DTC14-1,14-2:InternalFailureofthe Front
SidelmpactSensor Passenger's
SidelmpactSensor
1. Erasethe DTCmemory (seepage 23-26). 1. Erasethe DTCmemory (seepage23-26).
2. Turn the ignition switch ON (ll),and checkthat the 2. Turn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand SRSindicatorcomes on for about 6 secondsand
then goes off. then goes off.
Does the SRS indicatot stay on? Does the SRS indicator stay on?
YES Replacethe driver's side impact sensor(see YES-Replace the front passenger'sside impact
page 23-123).a sensor (see page 23-123],.1
I J
23-70
I
DTC9-3:Faulty Driver'sSeatBeltBuckle 6. Bucklethe driver's seat belt.
Switch
Checkresistancebetweenthe No. 1 and No.3
1. Erasethe DTCmemory (seepage 23 26). terminalsofthe driver's seat belt buckleswitch 3P
c o n n e c l o rT. h e r es h o u l db e 0 1 ( J .
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,t h e n b u c k l ea n d
u n b u c k l et h e d r i v e r ' ss e a tb e l ts e v e r atl i m e s . Checkresistancebetweenthe No. 1 and No.2
terminalsof the same connector.Thereshould be
3. Readthe DTC. , r a t l e a s t1 M Q .
a n o p e nc i r c u i t o
YES Go to step 4.
t
T e r m i n as li d eo f m a l et e r m i n a l s
Ate the resistancereadings as specified?
YES- Go to step 7.
I
(cont'd)
23-71
sRs
(cont'dl
DTCTroubleshooting
7, Unbucklethe driver'sseat belt. 8. Checkresistancebetweenthe No. 1 terminal ofthe
floor wire harness3P connectorand bodv oround.
Checkresistancebetweenthe No. 1 and No.2 '1
T h e r es h o u l db e 0 0.
terminalsofthe driver'sseat belt buckleswitch 3P
c o n n e c t o rT. h e r es h o u l db e 0 1 Q . FLOORWIREHARNESS3P CONNECTOR
DRIVER'S
SEATBELT
BUCKLESWITCH3PCONNECTOR
Wiresideof femaleterminals
T e r m i n asl i d eo f m a l et e r m i n a l s
ls the resistanceas specified?
N O O p e ni n t h e f l o o rw i r e h a r n e s so r p o o r g r o u n d
T e r m i n as li d eo I m a l et e r m i n a l s connection a t G 5 5 1 .l f G 5 5 ' 1i s O K , r e p l a c et h e f l o o r
w r r eh a r n e s s . l
ls the rcsistance as specified?
9 . Disconnectthe negativecablefrom the battery.
YES Go to step 8.
1 0 . DisconnectSRS unit connectorC (8P)from the SRS
NO-Replace the driver'sseat belt buckleassembly, unit {seestep 7 on page 23-22).
then clearthe DTC.I
\ J
23-72
I
11. Checkresistancebetweenthe No. 2 terminal of the 13. Checkresistancebetweenthe No. 8 terminal of
floor wire harness3P connectorand body ground. SRS unit connectorC (8P)and the No. 3 terminal of
Thereshould be an open circuit.or at least 1 fvlQ , the floor wire harness3P connector.There should
be0 1Q.
FLOORWIRE HARNESS3P CONNECTOR
HARNESS SRSUNITCONNECTORC
FLOORWIRE I8P}
3PCONNECTOB
NO Short to ground in the floor wire harnessor NO Open in the floor wire harness;replacethe
multiplexcontrol unit. Replacethe faulty harnessor floor wire harness.l
3 part.I
] g 1 4 . Checkresistancebetweenthe No. 4 terminal of
1 2 .Checkresistancebetweenthe No. 3 terminal of the r ( 8 P )a n d t h e N o . 2 t e r m i n a o
S R Su n i tc o n n e c t oC l f
floor wire harness3P connectorand body ground. the floor wire harness 3P connector.There should
T h e r es h o u l db e a n o p e nc i r c u i to, r a t l e a s t1 M Q . be0-1 0.
LT GRN
23-73
SRS
DTCTroubleshooting(cont'dl J
DTC9-4:FaultyFrontPassenger's
SeatBelt 6. Bucklethe front passenger'sseat belt.
BuckleSwitch
Checkresistancebetweenthe No. 1 and No.3
1. Erasethe DTCmemory {seepage 23-26). terminalsof the front passenger'sseat belt buckle
switch 3P connector.Thereshould be 0- 1 Q.
2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) ,t h e n b u c k l ea n d
unbucklethe front passenger'sseat belt several Checkresistancebetweenthe No. 1 and No.2
times. terminalsof the same connector.Thereshould be
a n o o e nc i r c u i t o
, r a t l e a s t1 M Q .
3. Readthe DTC.
FRONT
PASSENGER'S
SEATBELT
BUCKLE
SWITCH
3PCONNECTOR
ls DTC 9-4 indicated?
YES-Go to step 7.
23-74
7. Unbucklethe front passenger'sseat belt. 8. Checkresistancebetweenthe No. 1 terminal ofthe
floor wire harness3P connectorand body ground.
Checkresistancebetweenthe No. 1 and No. 2 T h e r es h o u l db e 0 1 Q .
terminalsof the front passenger'sseat belt buckle
s w i t c h3 Pc o n n e c t o rT. h e r es h o u l db e 0 1 ! ) . FLOORWIRE HARNESS3P CONNECTOR
FRONTPASSENGER'S
SEATBELT
BUCKLESWITCH3PCONNECTOR
Wiresideof femaleterminals
Terminalside of maleterminals
ls the tesistance as specified?
YES Go to step 9.
(cont'd)
23-75
sRs
DTCTroubleshooting(cont'dl
1 1 . C h e c kr e s i s t a n c be e t w e e nt h e N o . 2 t e r m i n a o
l fthe 13. Checkresistancebetweenthe No. 7 terminal of
floor wire harness3P connectorand body ground. S R Su n i tc o n n e c t oC r ( 8 P )a n d t h e N o . 3 t e r m i n a lo f
There should be an open circuit,or at least 1 M 0 . the floor wire harness3P connector.
T h e r es h o u l db e 0 - 1 Q .
FLOORWIREHARNESS
3PCONNECTOR
FLOORWIRE C (8P)
HARNESS SRSUNITCONNECTOR
3PCONNECTOR
Wiresideof femaleterminals
Wiresideof temaleterminals
N O O p e nl n t h e f l o o rw l r e h a r n e s sr;e p l a c e t h e
f l o o rw i r e h a r n e s s . l
\ J
23-76
DTC9-6:FaultyLeftFrontlmpactSensor 8. Disconnect
the enginecompartment wire harness
2Pconnector{A)fromthe leftfrontimpactsensor.
Special Tools Required
. SRSinflatorsimulator07SAZ-TB4011A
. SRSsimulatorlead H 07YM-S3AA100
YES-Go to step 3.
{cont'd}
23-77
sRs
DTCTroubleshooting(cont'dl
13. Checkvoltagebetweenthe No. 10terminalof SRS 16. Checkresistancebetweenthe No. 10 and No. 11
A (18P)andbodyground.There
unitconnector terminalsof SRS unit connectorA (18P).There
'l
shouidbe V or less. s h o u l db e 1 0 o r l e s s .
1 2 3 7 8 I
10 11 12 l 3 t 4 15 1 6 1 1 t6
RED
07YAZ-S3AA100
07SAZ-TB,O11A
\."r1
23-78
)
2 . T u r nl h e i g n i t i o ns w i t c hO N { l l ) ,a n d c h e c k t h a t t h e
SRSindicatorcomes on for about 6 secondsand
then goes off.
YES-Go to step 3.
YES-Go to step 4. I
F!-
t 1 t 2 ) l 5 6 I 6
NO Repairthe poor connectionsand retest.lf DTC I r o l r l r13 1 6 1 7 18
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
I
(cont'd)
23-79
sRs
DTCTroubleshooting(cont'd)
13. Checkvoltagebetweenthe No.1terminalofSRS 16. Checkresistancebetweenthe No. 1 and No. '12
unitconnector A (18P)andbodyground.There terminalsof SRS unit connectorA (18P).There
shouldbe 1 V or less. s h o u l db e 1 O o r l e s s .
SRSUNIT CONNECTOR
A I18P} SRSUNITCONNECTOR
A {18P)
GRN
J_
l r 1 2 l r 5 6 7 8 9
tE.]I t 3 1 1 r5 16 1 1 t6
/A BLK
07YAZ-S3AA100
23-80
I
DTC11-1:Openor Increased Resistance
in 6. Reconnectthe batterynegativecable.
Driver'sSideAirbagInflator
7. Erasethe DTCmemory.
SpecialToolsRequired
. S R Si n f l a t o rs i m u l a t o 0
r 7SM-TB4011A 8. Readthe DTC.
. SRSsimulatorlead E 07XM-S140200
ls DTC 11-1indicated?
1. Erasethe DTCmemory (seepage 23-26),
YES Go to step 9.
2. Tu rn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand NO-Open or increasedresistancein the driver's
then goes off. side airbag inflator;replacethe driver's side
a i r b a g( s e ep a g e2 3 - 1 ' 1 5 ) . 1
Does the SBS indicatot stay on?
9. Turn the ignitionswitch OFF.Disconnectthe
YES Go to step 3. batterynegativecable,and wait for 3 minutes.
07sAz-T84011A
I
{cont'd)
23-81
sRs
DTCTroubleshooting(cont'dl
' It . D i s c o n n e c t
r ( 1 8 P ) f r o mt h e
S R Su n i tc o n n e c t oB DTC11-3:Shortto AnotherWireor
SRS unit (seestep 7 on page 23-22).Do not DecreasedResistance
in Driver'sSideAirbag
disconnectthe specialtool from the floor wire lnflator
harness2P connector.
SpecialToolsRequired
12 Checkresistancebetweenthe No.6 and No. 17 ' S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A
r ( 1 8 P )T. h e r e
t e r m i n a l so f S R Su n i tc o n n e c t oB . SRSsimulatorlead E o7XAZ-S140200
s h o u l db e 2 . 0- 3 . 0 Q .
1. Erasethe DTCmemory (seepage 23 26).
SRSUNITCONNECTOR
B I18PI
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
SRS indicatorcomes on for about 6 secondsand
WHT/BLU then goes off.
YES-Faulty SRS unit or poor contactat SRS unit Disconnectthe floor wire harness2P connector(A)
r ( 1 8 Pa
c o n n e c t oB ) n d t h e S R Su n i t .C h e c kt h e f r o m t h e d r i v e r ' ss i d ea i r b a g .
connection;if the connectionis OK, replacethe
SRS unit (seepage 23'1221.a
07sAz-T84011A
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r )
a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
23-82
I
8. Readthe DTC. DTG11-4:Shortto Powerin Driver'sSide
AirbagInflator
ls DTC 11-3indicated?
Special Tools Required
YES-Go to step9. . SRS inflatorsimulator07SAZ-T84011A
. SRSsimulatorlead E o7XAZ-S140200
NO*Shon to anotherwire in the driver's side
airbag inflator;replacethe driver'sside airbag (see 1. Erasethe DTCmemory {seepage 23-261.
p a g e2 3 - 1 1 5 ) . I
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e
9. Turn the ignition switch OFF.Disconnectthe SRS indicatorcomes on for about 6 secondsand
batterynegativecable.and wait for 3 minutes. then goes off.
10. Disconnectthefront passenger'sside airbag2P Does the SBS indicator stay on?
connector(seestep 4 on page 23-21)and both seat
belt buckletensioner4P connectors(seestep 6 on YES Go to step 3.
page 23-22l,.
NO Intermittentfailure,system is OK at this time.
11. Disconnectthe specialtool from the floor wire Go to TroubleshootingIntermittentFailures(see
harness2P connector. page 23-26l,.
1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oB
r { 1 8 P ) f r o mt h e 3. Turn the ignition switch OFF.Disconnectthe
SRSunit {seestep 7 on page23-221. batterynegativecable,and wait for 3 minutes.
SRSUNITCONNECTOR
B {18PI
WHT/BLU
07sAz-TB4011A
WHT/BLK
Wiresideof femaleterminals
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 0 c o n n e c t o r )
ls the resistance as specified? a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
N O S h o n t o a n o t h e rw i r e i n t h e f l o o rw i r e
harness;replacethe floor wire harness.I
(cont'd)
23-83
sRs
(cont'd)
DTCTroubleshooting
6. Reconnect
the batterynegative
cable. 1 1 .DisconnectSRS unit connectorB (18P)from the
SRSunit (seestep 7 on page 23-22l,.
7. Erasethe DTCmemory,
' t 2 .T u r n
t h e i g n l t i o ns w i t c hO N ( l l ) .
8. Readthe DTC.
1 3 .Checkfor voltage betweenthe No. 6 terminal of
Is DTC 11-4indicated? SRS unit connectorB (18P)and body ground,and
betweenthe No. 17 terminal and body ground.
YES-Go to step9. Thereshould be 0.5 V or less.
\.J
23-84
I
DTC11-5:Shortto Groundin Driver'sSide 8. Readthe DTC.
AirbagInflator
ls DTC 11-5indicated?
Special Tools Required
. S R Si n f l a t o rs i m u l a t o 0
r 7SM-T84011A YES Go to step 9.
' SRSsimulatorlead E o7XAZ-S140200
NO Short to ground in the driver'sside airbag
'1.
Erasethe DTCmemory {seepage 23-26). inflator;replacethe driver'sside airbag (seepage
23-115).t
2. Turn the ignitionswitch ON {ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand 9. Turn the ignition switch OFF.Disconnectthe
then goes off. batterynegativecable,and wait for 3 minutes.
Does the SRS indicator stay on? 10. Disconnectthe front passenger'sside airbag2P
connector(seestep 4 on page 23-21)andboth seat
YES Go to step 3. belt buckletensioner4P connectors(seestep 6 on
page 23-221.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see 1 1 . D i s c o n n e c t S RuSn i t c o n n e c t o r B( 1 8 P ) f r o m t h e
page 23-261. SRS unit (seestep 7 on page 23-22).
SRSUNIT CONNECTOR
B I18P)
WHT/BLK
07saz-TB,r011A
Wiresideof femaleterminals
Connectthe SRSinflatorsimulator(2 Q connector)
and simulatorlead E to the floor wire harness. ls the resistance as specified?
I
23-85
sRs
DTCTroubleshooting(cont'd)
DTG12-1:Openor Increased
Resistancein Reconnectthe batterynegativecable.
SideAirbagInflator
FrontPassenger's
7 . Erasethe DTCmemory.
SpecialToolsRequired
. S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A Readthe DTC.
. SRSsimulatorlead E o7XAZ-S140200
ls DTC 12-l indicated?
1. Erasethe DTCmemory (seepage 23-26).
YES Go to step L
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
SRSindicatorcomes on for about 6 secondsand NO-Open or increasedresistancein the front
then goes off. passenger'sside airbag inflator;replacethe front
p a s s e n g e r 'ssi d ea i r b a g( s e ep a g e2 3 - 11 5 ) . 1
Does the SBS indicator stay on?
9 . Turn the ignition switch OFF.Disconnectthe
YES Go to step 3. batterynegativecable.and wait for 3 minutes.
'10. Disconnectthe driver'sside airbag2P connector
NO - Intermittentfailure, system is OK at this time.
Go to TroubleshootinglntermittentFailures(see {seestep 4 on page 23-21)andboth seat belt buckle
page23-26). tensioner4P connectors(seestep 6 on page 23-22).
07xAz-s1A0200
I J
23-86
I
1't. DisconnectSRS unit connectorB ('l8P)from the DTC12-3:Shortto AnotherWireor
SRSunit (seestep 7 on page 23-22).Do not DecreasedResistancein FrontPassenger's
disconnectthe specialtool from the floor wire SideAirbagInflator
h a r n e s s2 P c o n n e c t o r .
SpecialToolsRequired
1 2 .Checkresistancebetweenthe No.7 and No. 18 . S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A
t e r m i n a l so f S R S u n i t c o n n e c t oBr ( 1 8 P )T. h e r e . SRSsimulatorlead E o7XAZ-S140200
s h o u l db e 2 . 0 3 . 0 ( J .
1. Erasethe DTCmemory (seep age 23-261.
SRSUNITCONNECTOR
B {18P)
2. Tu rn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand
WHT/RED then goes off.
YES Go to step 3.
07xAz-s1A0200
(cont'd)
23-87
sRs
DTCTroubleshooting(cont'dl
6. Reconnectthe batterynegativecable. DTC12-4:Shortto Powerin FrontPassenger's
SideAirbagInflator
7, Erasethe DTCmemory.
Special Tools Required
8. Readthe DTC. . sRS inflatorsimulator07sAz-TB4011A
. SRSsimulatorlead E 07XM-S140200
ls DTC 12-3indicated?
1. Erasethe DTCmemory (seepage 23-26).
YES-Go to step I
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e
NO Short to anotherwire in the front passenger's SRS indicatorcomes on for about 6 secondsand
side airbag inflator;replacethe front passenger's then goes off.
s i d ea i r b a g( s e ep a g e2 3 - l l 5 ) . 1
Does the SRS indicator stay on?
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes. YES-Go to step 3.
10. Disconnectthe driver's side airbag2P connector NO- Intermittentfailure,system is OK at this time.
(seestep 4 on page 23-21)and both seat belt buckle Go to TroubleshootingIntermittentFailures{see
tensioner4P connectors(seestep 6 on page 23-22). page 23-26).
12. DisconnectSRS unit connectorB ('lSPlfromthe 4. Disconnectthe floor wire harness2P connector(A)
SRS unit {see step 7 on page 23-221. from the front passenger'sside airbag.
B I18P)
SRSUNITCONNECTOR
WHT/RED
-r-'r-Jl
2 3 ' 8lel
6 n
10 l l 15
-T
i['tl,Bl S
07xAz-s1A0200
WHT/GRN
5. Connectthe SRS inflatorsimulator(2 Q connector)
Wiresideof {emaleterminals a n d s i m ul a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
Y E S F a u l t yS R Su n i t ;r e p l a c et h e S R Su n i t{ s e e
page 23-1221.a
N O S h o r tt o a n o l h e rw i r e i n t h e f l o o rw i r e
harness;replacethe floor wire harness.I
\.J
23-88
\
23-89
sRs
DTCTroubleshooting(cont'dl .t
4. Disconnectthe floor wire harness2P connector(A) 12. Checkresistancebetweenthe No. 15 and No. 18
from the front passenger'sside airbag. r ( 1 8 Pa
t e r m i n a l so f S R Su n i tc o n n e c t oB ) nd
betweenthe No. 16 and No. 18 terminals.Then {
checkresistancebetweenthe No. 18 terminal and
body ground.Thereshould be an open circuit,or at
l e a s t1 M Q .
B {18PI
SRSUNITCONNECTOR
2 3 6 7 8
1 0 11 t6 1 7 1E
LTGRN/REDd WHT/GRN
i 116\l 9 Y 9
07xAz-s1A0200 GRY/RED
o
5. Connectthe SRS inflatorsimulator(2 Q connector)
and simulatorlead E to the floor wire harness. Wire side of femaleterminals
N O - S h o r t t o g r o u n di n t h e f l o o rw i r e h a r n e s s ;
r e p l a c et h e f l o o rw i r e h a r n e s s . l
23-90
)
YES- Go to step 3.
ls the connectionOK?
YES Go to step 5.
)
(cont'd)
23-91
sRs
DTCTroubleshooting{cont'd)
8. DisconnectSRSunitconnector B (18P)fromthe DTC13-4:FaultyPowerSupplyto the Driver's
SRSunit (seestep7 on page23-221. SidelmpactSensor
9. Checkresistance betweenthe No.8 andNo.15 1. Erasethe DTCmemory {seepage 23-261.
terminalsof sRSunitconnector B ('l8P).There
s h o u l db e0 1 . 0Q . 2. Turn the ignition switchON (ll),and checkthat the
SRSlndicatorcomes on for about 6 secondsand
B I18P)
SRSUNITCONNECTOR then goes off.
3
I
:fr;f;l n
YES Go to step 3.
N O O p e ni n t h e f l o o rw i r e h a r n e s sr;e p l a c et h e
floor wire harness.l
23-92
t
5. Disconnect (A)
thefloorwire harness2Pconnector 8. Checkresistancebetweenlhe No.8 and No. l5
fromthedriver'ssideimpactsensor. terminalsof SRSunil connectorB (18P).There
should be an open circuit,or at least 1 M 0 .
SRSUNIT CONNECTOR
B {18P'
BRN/YEL
I
2 3 flliT;l n
10 11 1tr6l1tf;l \
LT GRN/RED
I SRSUNITCONNECTOR
B {18PI
BRN/YEL
NO- Short in the floor wire harness;replacethe
f l o o rw i r e h a r n e s s . I
YES-Go to step8.
23-93
sRs
DTCTroubleshooting(cont'dl
DTC14-3:No Signalfromthe Front 5 . Disconnectthedriver'sside airbagand front
SidelmpactSensor
Passenger's passenger'sside airbag2P connectors(seestep 4
on page 23-21).Also disconnectboth seat belt
SpecialToolsRequired buckletensioner4P connectors(seestep 6 on page
. SRSinflatorsimulator07SAZ-TB401'lA 23-22t.
. SRSsimulatorlead H 07YAZ'S3AA100
Disconnectthe floor wire harness2P connector{A)
1. ErasetheDTCmemory (seepage 23-26). from the front passenger'sside impact sensor.
YES Go to step 3.
Is the connectionOK?
YES-Go to step 5.
23-94
)
t- YES-Go to step 3.
2 3 0 l-u5l n
1 0 t1 t5 iFf;l \ NO-lntermittent failure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-261.
GRY/RED
3. Turn the ignition switch OFF.Disconnectthe
Wiresideol lemaleterminals batterynegativecable,and wait for 3 minutes.
"-;s.\
\f r l/ \--)
\ l
j
1
- F.,=
I
(cont'd)
23-95
sRs
DTGTroubleshooting(cont'd)
7. Checkresistancebetweenthe No. 9 terminal of DTC15-1:FaultyOPDSUnit
SRS unit connectorB (18P)and body ground.There
should be an ooen circuit,or at least 1 N4Q. NOTE:
. An incorrectOPDSunit can causeDTC 15-1.
. A n e w ( u n i n i t i a l i z eOd )P D Su n i t i n s t a l l e d
witha faulty
B {18PI
SRSUNIT CONNECTOR
O P D Ss e n s o rc a nc a u s eD T C 1 5 - 1 .
. lf you installa new OPDSunit and a new SRSunit at
PNK/BLU t h e s a m et i m e , i n i t i a l i z teh e O P D Sm a n u a l l y( s e e
page 23-27),do not usethe HondaPGM Tester.
Is DTC 15-1indicated?
ls the tesistance as specilied?
YES Go to step 5.
YES Go to step 8.
NO Intermittentfailure,system is OK at this time.
NO-Short to ground in the floor wire harness; Go to TroubleshootingIntermittentFailures(see
replacethe floor wire harness.l page23-26).
PNK/BLU
_-r
NO Go to step 9.
GRY/RED
Wiresideot femaleterminals
23-96
)
C h e c kt h e N o . 9 ( 1 0 A )f u s e .
ls there battery voltage?
ls the f use OK?
YES-Go to step 16.
YES Short to ground in the OPDSunit; replacethe
NO Open in the floor wire harnessor OPDSunit OPDSunit (seepage 23-1241.1
harness;replacethe faulty harness.I
NO-Short to ground in the No. 9 (10A)fuse circuit
9. Replace t h e N o . 9 ( 1 0 A ) f u s ei n t h e u n d e r - d a s h (floor harness,or OPDSharness);replacethe
) fuse/relaybox. affectedharness.I
1 0 .Turn the ignitionswitch ON (ll) for 30 seconds,then to. Turn the ignition switch OFF.
turn it off.
1 1 . Checkresistancebetweenthe No.8 terminal of
1 1 .C h e c kt h e N o . 9 ( 1 0 A ) f u s e . OPDSunit harness8P connectorand body ground.
'1.0
Thereshould be 0 Q.
ls the tuse OK?
OPDSUNIT HARNESSsPCONNECTOR
YES lntermittentfailure,system is OK at this time.
Go to TroubleshootingIntermiftentFailures(see
page 23-26). l4V-'l^l
TVjEl
#
NO Go to step 12. BLK
23-97
sRs
DTCTroubleshooting(cont'dl
1 8 . Turn the ignition switch OFF.Disconnectthe 22. Checkresistancebetweenthe No. 3 terminal of
batterynegativecable.and wait for 3 minutes. SRSunit connectorB (18P)and the No. 7 terminal
of OPDSunit harness8P connector.Thereshould
1 9 . Disconnectboth side airbagconnectors(seestep 4 be0 1.0Q.
o n p a g e2 3 - 2 1 ) a n db o t hs e a tb e l tb u c k l e t e n s i o n e r
4P connectors(seestep 6 on page23-22). B (18PI
SRSUNITCONNECTOR
GRN/ORN
20. DisconnectSRSunit connectorB (18P)from the
SRS unit (see step 7 on page 23-221.
SRSUNITCONNECTOR
B I18PI
BLU
GRN/ORN Wire side of femaleterminals
YES Go to step23.
23-98
25. Checkfor voltagebetweenthe No. 3 terminal of DTC15-2:FaultySideAirbagCutoffIndicator
SRS unit connectorB (18P)and body ground.There Circuit
s h o u l db e 0 . 5V o r l e s s .
1. Make sure nothing is on the front passenger'sseat.
B (18P)
SRSUNITCONNECTOR
2. Erasethe DTCmemory (seepage 23-26]-.
PNK 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) , a n d c h e c k t h a t t h e
SRSindicatorcomes on for about 6 secondsand
then goes off.
Wiresideof temaleterminals
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
ls the voltageas specilied? page 23-26).
initializethe system (seepage 23-27). Does the side airbag cutoft indicator come on?
t h e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1
YES Replace Make sure the side airbagcutoff indicatorgoes off
after 5 seconds.
NO The system is OK.l
Does the side airbag cutoff indicator go otf after 5
seconds?
NO Go to step 32.
{cont'd)
23-99
sRs
DTCTroubleshooting(cont'd)
7. Checkthe No. 10 (7.5A)fusein the under-dash 1 1 .Turn the ignltion switch OFF.
fuse/relaybox.
12. Disconnectthe dashboardwire harness17P
ls the f use OK? connectorK from the under-dashfuse/relaybox,
YES Go to step 8.
OPDSUNITHABNESS
8PCONNECTOR
9 . Turn the ignitionswitch ON (ll).
YES-FaultyOPDSunit;replacethe OPDSunit(see
W i r es i d eo f f e m a l et e r m i n a l s page23-124)
.a
NO-Go to step15.
ls there battety voltage?
Y E S G o t o s t e p1 1 .
NO Go to step 23.
23-100
)
t5. Turn the ignitionswitch OFF. 1 9 . Turn the ignition switch OFF.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
1 7 . Turn the ignition switch ON (ll).
22. Checkfor voltage betweenthe No. 3 terminal of the
1 8 . Checkfor voltagebetweenthe No. 3 terminal of the OPDSunit harness8P connectorand body ground.
OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less.
Thereshould be 0.5 V or less.
A
) \t OPDSUNITHARNESS
8PCONNECTOB
OPOSUNITHARNESS
8PCONNECTOR
I \,
(cont'd)
23-101
sRs
(cont'dl
DTCTroubleshooting
23. Turn the ignitionswitch OFF. 2 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i
NO Go to step 31.
T e r m i n as li d eo f m a l et e r m i n a l s
23-102
Checkfor voltagebetweenthe No. 2 terminal of 32. Turn the ignitionswitch OFF.
r ( 2 2 Pa
g a u g ea s s e m b l yc o n n e c t o B ) ndbody
ground.Thereshould be batteryvoltage. 33. Disconnectthe OPDSunit harness8P connector(A)
f r o m t h e O P D Su n i t ( s e ep a g e2 3 -1 2 4 ) .
ASSEMBLY
GAUGE CONNECTOR
B {22P)
YEL
1 2 3 4 5 X 6 8 9 10
1t 12 IJ
,/1,/1,/)1 1 21 22
Wiresideof femaleterminals
\,
(cont'd)
23-103
sRs
DTGTroubleshooting(cont'dl J
37. Checkresistancebetweenthe No. 15 terminal of DTC15-3:FaultyOPDSSensor
gauge assemblyconnectorA (22P)and body
ground.Thereshould be an open circuit,or at least 1. Erasethe DTCmemory {seepage 23-261.
1M0.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
GAUGEASSEMBLY A I22PI
CONNECTOR SRS indicatorcomes on for about 6 secondsand
then goes off.
YES-Go to step 3.
NOTE:Aftermarketdevices(fluorescentlights,
Wire side of femaleterminals
laptop computers,etc.)used near the front
passenger'sseat-backcan interferewith the seat-
ls the resistance as specified? backsensorsand causea false DTC15-3.lf one of
these deviceswas used,erasethe DTC,operatethe
YES-Short to ground in the side airbagcutoff devicenearthe seat-back,and recheckfor DTCs.lf
indicatorcircuit;replacethe gaugeassembly.l DTC15-3is reset,eraseit, and do not usethe
devicenearthe seat-back.
NO Short to ground in the dashboardwire
harnessA, floor wire harness,or OPDSunit 3 . Checkthe connectionat the OPDSsensorharness
harness;replacethe faulty harness.l connectorand the OPDSunit connector. {
YES-Go to step 4.
NO Reconnectthe OPDSsensorharness
connector,and clearthe DTC.I
foam (seepage
4 . Replacethe OPDSsensor/seat-back
20-141,and initializethe OPDS(seepage 23-27).
ls DTC 15-3indicated?
23-104
I SRSIndicatorCircuitTroubleshooting
TheSRSIndicatorDoesn'tComeOn 4. Checkfor voltage betweenthe No. l4terminal of
gauge assemblyconnectorA (22P)and body
1. Turn the ignition switch ON (ll),and see if the other ground within the first 6 secondsafter turning the
indicatorscome on {brakesystem,etc). ignition switch ON (ll).Thereshould be 8.5 V or less.
YES Go to step 2.
N O - G o t o s t e p8 .
Wiresideof femaleterminats
Y E S - F a u l t yS R Si n d i c a t o cr l r c u i ti n t h e g a u g e
assembly;replacethe gauge assembly.I
I \9
d N O - G o t o s t e p5 .
GAUGE
ASSEMBLY
CONNECTOR
B I22PI
1 2 3 4 5 X 6 8 9 10
11 12 l 3
BLK
/)x 1 1 1B 21 22
o.
Wiresideof femaleterminals
YES Go to step 4.
N O O p e ni n t h e B L Kw i r e o f d a s h b o a r d wire
l{, h a r n e s sA o r f a u l t yb o d y g r o u n dt e r m i n a l( G 5 0 1 )l.f
t h e b o d y g r o u n dt e r m i n a li s O K ,r e p l a c ed a s h b o a r d
w i r e h a r n e s sA . I
(cont'd)
23-105
sRs
SRSIndicatorCircuitTroubleshooting(cont'dl J
6 . DisconnectSRSunit connectorC (8P)from the SRS 9. Connecta voltmeterbetweenthe No.2 terminal of
unit {see step 7 on page 23-22). gauge assemblyconnectorB (22P)and body
g r o u n d .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d
7 . DisconnectgaugeassemblyconnectorA (22P). measurethe voltage.There should be battery
Connecta voltmeter betweenthe No, l4terminal of voltaqe.
gauge assemblyconnectorA (22P)and body
g r o u n d .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d GAUGEASSEMBLY B (22P}
CONNECTOR
measurevoltage.There should be 0.5 V or less.
YEL
GAUGEASSEMBLY A {22P)
CONNECTOR
1 2 3 4 5 X 6 8 9 10
ll 12 ,/ ,/ ,/x 11 o 21 22
L Turn the ignition switch OFF.Checkthe No. 10 1 0 . Replacethe No. 10 (7.5A)fuse,then checkto see if
{7.5A)fusein the under-dashfuse/relaybox. the indicatorscomes on.
NO Go to step 9. N O R e p a i tr h e s h o r tt o g r o u n di n t h e u n d e r - d a s h
f u s e / r e l a yb o x N o . 1 0 ( 7 . 5 A ) f u s ce i r c u i t . l
23-106
I J
TheSRSlndicatorStaysOn Whenln "SCS" t h e N o . 1 3 ( 1 0 A )f u s e .
6. Replace
MenuMethod
7. Turn the ignition switch OFF.Disconnectthe
NOTE: batterynegativecable,and wait for 3 minutes.
. lf you cannot retrieveDTCSwiththe PGM Tester
usingthe SRSmenu method.retrievethe flash codes 8. Disconnectthe driver'sairbag 4P connector(see
with the Testerin SCS mode {seepage 23-24|,. step 2 on page 23-21).
. A new SRS unit must sensethe entire system is OK
beforecompletingits initialself-test.The most 9. Disconnectthe front passenger'sairbag4P
common causeof an incompleteself-testis the connector(seestep 3 on page 23,21).
failureto replaceall deployedpartsafter a collision,
in particular,seat belt tensionersand seat belt buckle 10. Disconnectboth seatbelt tensioner2P connectors
tenstoners. (seestep 5 on page 23-221.
. An incompleteself-testpreventsthe PGM Testerfrom
retrievingDTCS,althoughflash codesare availablein '11.
D i s c o n n e c t S RuSn i t c o n n e c t o r A { 1 8 P ) f r o m t h e
the Tester'sSCSmode. SRS unit (see step 7 on page 23-22],.
I NO Go to step 2.
ls the f use OK?
Y E S - S h o r t t o g r o u n di n t h e S R Su n i t ;r e p l a c et h e
Checkthe No. '13{ 10A)fuse in the under-dash SRS unit (seepage 23-122).a
fuse/relaybox.
N O G o t o s t e p1 5 .
l s t h e f u s eO K ?
t h e N o . 1 3 ( 1 0 A )f u s e .
15. Replace
YES--Goto step 19.
NO Go to step 3.
3 . R e p l a c e t h eN o . 1 3 ( 1 0 A )f u s e .
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 3 0
seconds.Then turn the ignitionswitch OFF.
C h e c kr h e N o . 1 3 ( 1 0 A )f u s e .
Y E S T h e s y s t e mi s O K a t t h i st i m e . I
NO Go to step 6.
I
{cont'd)
23-107
sRs
SRSIndicatorCircuitTroubleshooting(cont'd)
'16. 24. Beconnectthe batterynegativecable.
Disconnectdashboardwire harnessB connectorS
from the under-dashfuse/relavbor.
Connecta voltmeterbetweenthe No. 3 terminal of
SRS unit connectorA (18P)and body ground.Turn
the ignition switch ON (ll),and measurethe voltage.
Thereshould be bafteryvoltage.
A (18PI
SRSUNITCONNECTOR
PNK
1 8 . C h e c kt h e N o . 1 3 ( 1 0 A )f u s e .
ls there battery voltage?
ls the f use OK?
YES Go to step 29.
YES Short to ground in dashboardwire harness
B; replacedashboardwire harnessB.I NO Go to step 26.
NO-Short to ground in the under-dashfuse/relay 26. Turn the ignition switch OFF.
box; replacethe under-dashfuse/relaybox.l
2 7 . Disconnectdashboardwire harnessB connectorS
1 9 . Turn the ignition switch OFF.Disconnectthe from the under-dashfuse/relavbox.
batterynegativecable,and wait for 3 minutes.
23-108
I
28. Checkresistancebetweenthe No. 3 terminal of 3 1 . C o n n e ctth e N o . 3 t e r m i n a lo f S R S u n i t c o n n e c t o r A
SRSunit connectorA (18P)and the No. 2 terminal (18P)and the No. 5 terminal of SRSunit connector
of dashboardwire harnessB connectorS. There C ( 8 P ) w i t ha j u m p e rw i r e .
s h o u l db e 0 1 . 0 0 .
l 2
l 2 3 5 7 8 I
1 0 11 12 l 3 1 4 1 5 16 1 1 l 8
29. Turn the ignitionswitch OFF. 34. Turn the ignition switch OFF.
30. DisconnectSRSunit connectorC {8P)from the SRS 35. Disconnectthe jumper wire betweenthe No. 3
unit (see step 7 on page 23-22],. terminal of SRSunit connectorA (18P)and the
No. 5 terminal of SRSunit connectorC (8P).
3 6 . C h e c kt h e N o . 1 3 ( 1 0 A ) f u s ei n t h e u n d e r , d a s h
fuse/relaybox.
NO Go to step 37.
37. Replace
t h e N o . 1 3{ 1 0 A ) f u s e .
I (cont'd)
23-109
sRs
SRSlndicatorGircuitTroubleshooting(cont'dl
38. Removethe gauge assembly(seepage 22-64),then 40. Removethe gauge assembly(seepage 22-64),then
disconnectgauge assemblyconnectorA from the disconnectgauge assemblyconnectorA from the
g a u g ea s s e m D l y , g a u g ea s s e m b l y .
GAUGEASSEMBLYCONNECTOR
A I22P)
Wiresideof lemaleterminals
23-110
42. Turn the ignition switch OFF. 47. Checkresistance betweenthe No.6 terminalof
SRSunitconnector C (8P)andbodyground.There
43. lf necessary,removethe SCSserviceconnector shoulbd e0 - 1 . 0 Q .
from the l\4ESconnector.
SRS UNIT CONNECTORC I8P)
4 4 . T u r nt h e i g n i t i o ns w i t c hO N { l l } .
r ( 8 P )f r o m t h e S R S
4 5 . D i s c o n n e cSt R Su n i tc o n n e c t oC
unit (see step 7 on page 23-221. Wiresideof femaleterminals
,l
I
IL,
23-111
sRs
After Deployment
ComponentReplacement/lnspection
NOTE:Beforedoing any SRS repairs.use the PGM
TesterSRSmenu method to checkfor DTCS;referto the
DTCTroubleshootingIndexfor the lessobvious
deployedparts (seatbeit tensioners,front sensors,side
airbagsensors,etc.)
\|J
23-112
Driver's Airbag Replacement
Removal Installation
1. Disconnectthebatterynegativecable,and wait at 1. Connectlhe horn switch connector(1P)to the
least3 minutes beforebeginningwork. driver'sairbag.
2. Removethe accesspanel (A)from the steering 2. Placethe new driver'sairbag (A) inthesteering
wheel, then disconnectthe driver's airbag 4p wheel, and secureit with new Torx bohs (B),and
connector(B)from the cable reel. installthe maintenancecover (C).
a
9.8 N.m {1.0kgf.m,7.2 lbt.ft)
. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ;t h e S R Si n d i c a t o r
should come on for about 6 secondsand then go
off.
. Make sure the horn works.
lfc
23-113
sRs
AirbagReplacement
FrontPassenger's
Removal Installation
1. Disconnectthebatterynegativecable,and wait at 1. Placethe new front passenger'sairbag(A) into the
least3 minutes before beginningwork, dashboard.Tightenthe front passenger'sairbag
m o u n t i n gn u t s( B ) .
2. Removethe glove box stops,and lower the glove
box.
thefrontpassenger's
3. Disconnect airbag4P
(A)from dashboard
connector wire harnessB.
9.8N m {1.0kgf.m,7.2lbfft}
N O T E : T h ea i r b a gl i d h a sp a w l so n i t s s i d ew h i c h
aftachit to the dashboard.
4 . Reconnectthe batterynegativecable.
trr
23-114
) SideAirbag Replacement
NOTE:Reviewthe seatreplacementpro6edure in the Installation
Bodysectionbeforepertormingrepairsor service.
NOTE:
Removal . l f t h e s i d ea i r b a gl i d i s s e c u r e db y a t a p e , r e m o v e l h e
rape.
1. Disconnectthebatterynegative
cable,andwait at . Do not open the lid of the side airbagcover.
least3 minutesbeforebeginningwork. . Use new mounting nuts tightenedto the specified
torque.
2. Disconnect
thesideairbagharness2P . Make sure that the seat-backcover is installed
connector
{A). properly,lmproper installationmay preventproper
deployment.
. Be sure to installthe harnesswires so that they are
not pinchedor interferingwith other parts.
3 . Removethe seatassembly(seepage20-71)and
) seat-backcover (seepage 20-75).
5. Reconnectthe batterynegativecable.
l,o
23-115
sRs
Airbag Disposal
Special Tool Required Driver's Airbag:
Deploymenttool 07HAz-SG00500
4. Removethe accesspanelf rom the steeringwheel,
Beforescrappingany airbags,side airbags,seat belt then disconnectthe driver'sairbag4P connector
tensioners,or seat belt buckletensioners(including from the cable reel (seestep 2 on page 23-21).
those in a whole vehicleto be scrapped),the airbags,
side airbags,seat belt tensioners,or seat belt buckle Front Passenger'sAirbag:
tensionersmust be deployed.lf the vehicleis still within
the warranty period,the HondaDistrictService 5. Lowerthe glove box,then disconnectthefront
Managermust give approvaland/orspecialinstruction passenger'sairbag 4P connectorfrom dashboard
beforedeployingthe airbags,side airbags,seat belt wire harnessB (seestep 3 on page 23-211.
tensioners,or seatbelt buckletensioners.Only afterthe
airbags,side airbags,seat belt tensioners,or seat belt Side Airbag:
buckletensionershave been deployed(asthe resultof
vehiclecollision,for example),can they be scrapped. 6. Disconnectthe side airbag2P connectorsfrom the
floor wire harness(seestep 4 on page23-211.
lf the airbags,side airbags,seat belt tensioners,and
seat belt buckletensionersappearintact(not deployed), Seat belt tensioner:
treat them with extremecaution.Follow this Drocedure.
7. Disconnectthe seat belt tensioner2P connectors
DeployingAirbagsin the Vehicle from the floor wire harness{seestep 5 on page 23-
22).Pullthe seat belt out all the way, and cut it off.
lf an SRSequippedvehicleis to be entirelyscrapped,its
airbags,side airbags.seat belt tensioners.and seat belt Seat belt buckle tensioner:
buckletensionersshould be deolovedwhile still in the
vehicle.The airbags,side airbags,seat belttensioners, 8, Disconnectthe seat belt buckletensioner4P
and seat belt buckletensionersshould not be connectorsfrom the floor wire harness(seestep 6
consideredas salvageablepartsand should never be on page 23-221.
installedin anothervehicle.
$ J
23-116
)
9. Cut off each connector,strip the ends of the wires, 10. Connecta 12 volt batteryto the tool.
and connectthe deploymenttool alligatorclips (A)
to the wires. Placethe deploymenttool at least30 . lf the green light on the tool comes on, the igniter
feet (10 meters)away from the vehicle. circuit is defectiveand cannot deDlovthe
component.Go to Disposalof Damaged
NOTE:The driver'sairbagand the front passenger's ComDonents.
airbageach have four wires,two yellow and two . lf the red light on the tool comes on, the
red. Twist each Dairof unlikecoloredwires componentis readyto be deployed.
together,and connectan alligatorclip to each pair.
1 1 . P u s ht h e t o o l ' sd e p l o y m e nst w i t c h T . h e a i r b a g sa n d
tensionersshould deploy (deploymentis both
h i g h l ya u d i b l ea n d v i s i b l e a
: l o u d n o i s ea n d r a p i d
inflationof the bag,followed by slow deflation).
/ :
i'..-':
!
(cont'd)
23-117
sRs
Airbag Disposal(cont'dl J
DeployingComponentsOut of the Vehicle DeploymentTool Check
lf an intactairbagor tensionerhas been removedfrom 1. Connectthe yellowclipsto bothswitchprotector
a scrappedvehicle,or has beenfound defectiveor handleson thetool;connectthetoolto a battery.
damagedduring transit,storage,or service,it should be
deolovedas follows: 2. Pushthe operationswitch:greenmeansthetool is
OK;redmeansthetool is faulty
batteryandthe yellowclips.
3. Disconnectthe
Contactyour HondaDistrictServiceManagerfor
how and where to return it for disposal.
I|J
23-118
) CableReelReplacement
Removal 6. Removethe dashboardlower cover (Ai.
1 . M a k es u r et h e f r o n tw h e e l sa r e a l i g n e ds t r a i g h t
ahead.
I,
(cont'd)
23-119
sRs
CableReelReplacement(cont'd) J
Disconnectthe dashboardwire harness4P Installation
connector(A)from the cable reel,then disconnect
the dashboardwire harness5P connector{B}from 1. Beforeinstallingthe steeringwheel. align the front
the cable reel. wheels straightahead.
9 . R e l e a s teh e t a b ( B ) ,t h e n p u l l o f f t h e c a b l er e e l( A ) .
23-120
)
-
A gn the projectionson the cable reel with the
noleson the steeringwheel, and installthe steering
Ai\eelwith a new steeringwheel bolt (A).
) c
23-121
sRs
SRSUnit Replacement
Removal lnstallation
'1.
Disconnectthe batterynegativecable,and wait at 1 , I n s t a l l t h en e w S R Su n i t ( A ) w i t hT o r x b o l t s( B ) ,t h e n
least3 minutesbefore beginningwork. connectthe connectors{C)to the SRSuniu push
them into positionuntil they clicks.
2. Disconnectthe driver'sand front passenger's
airbagconnectors(seepage 23-21). NOTE:When tighteningthe Torx boltsto the
specifiedtorque, be carefulto turn them in so that
3. Disconnecttheside airbagconnectors(seepage their headsrest squarelyon the brackets.
23-211.
9.8 N.m (1.0kgf m, 7.2 lbf ft)
4 . Disconnectboth seat belt tensionerconnectors(see
page 23-22)and both seat belt buckletensioner
connectors {see page 23-221.
23-122
)
Side lmpact SensorReplacement
Removal lnstallation
1. Disconnectthe batterynegativecable,and wait at 1 . I n s t a ltlh e n e w s i d ei m p a c ts e n s o rw i t h a n e w T o r x
least3 minutesbefore beginningwork. bolt (A),then connectthe floor wire harness2P
connector{B)to the side impact sensor{C).
2. Disconnectthe appropriateside airbag2P
connector(seestep 4 on page 23-21).
4 . R e m o v et h e f r o n t d o o r s i l l t r i m a n d t h e B - p i l l a r
lower trim panel (seepage 20-50).
2. Reconnectthe negativebatterycable.
23-123
sRs
OPDSUnit Replacement
NOTE:Reviewthe seat replacementproceduresin the Installation
body sectionbeforeperformingrepairsor service.
1. Placethe new OPDSunit (A) on the seat-backframe.
Removal Tightenthe two screws(B),and connectthe OPDS
unit harness8P and sensorconnectors(C)to the
1. Disconnectthe batterynegativecable.and wait at OPDSunit. Reinstallthecover (D).
least3 minutesbefore beginningwork.
4. Reconnectthe batterynegativecable.
23-124
)
Front lmpact SensorReplacement
Removal Installation
1 . Disconnectthe batterynegativecable.and wait at 1. Installthe new front impact sensorwith new Torx
least3 minutesbefore beginningwork. bolts (A),then connectthe engine compartmentwire
harness2P connector(B)to the front impactsensor
2 . Disconnectthe driver'sairbag4P connectorlsee {c).
step 2 on page23-21),the front passenger'sairbag
4P connector(seestep 3 on page 23-21),both seat A
9.8N.m
belttensioner2P connectors(seestep 5 on page (1.0kgf.m,7.2lbf.ftl
23-221,and both seat belt buckle4P connectors(see
step 6 on page23-22).
Reconnectthe batterynegativecable.
23-125
ServiceManuallndex
) s
NOTE:Refertothe lollowing listto look up A/C PressureSwitch Circuit
DTCS, symptoms, fuses,connectors, wire Troubleshooting
.........
...-.-....-...-.-.-....-..21-32
B
harnesses,specifications,
maintenance
schedules,andgeneralservice A/C SignalCircuit
inlormation: Troubleshooting.........................-......
11-'133 Back-upLightSwitch
Test.........................................................
13'3
DTCTroubleshootingIndexes A/F lAir FuelRatiol Sensor
ABS/TCSComponents ........................
19-34 Replacement .......................................
11-113 Back-upLi9ht3
EPSComponents '17-22
................................. CircuitDiagram 22-75
FuelandEmissions 11-i A-Dillar CornerTrim
Heating/Ventilation
................................
21-9 Replacement ...............-.....-..............-....
20,96 BallJoint Boots
s R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 2
. .8. . . . . . . . . . . . . . . . . . Replacement ...... 1 81 6
ABS IndicatorCircuit
SymptomTroubleshootingIndexes Troubleshooting ... 19-52 BallJoints
ABS/TCSComponents........................ 1935 R e m o v a 1 . . . . . . . . . . . . . - . . ................ . . . 1 8 - 1 0
CruiseControlSystem..........................4 38 ABSModulator-contml Unit
EPSComponents ................................. 17-23 Bemoval/lnstallation ............................
19-57 Betterv
FanControls 10,12 . . . . . . . 2520
Fueland Emissions.............................. 11-10 ABS/TCSComoonents
Heating/Ventilation..............................21 10 Component LocationIndex................. 19-30 Beverage Holder
) s A/C Condenser
Replacement,.,
A/C CondenserFanCircuit
Troubleshooting
...................
. . . . . .....21-28
.....25 12
(cont'd)
ServiceManualIndex
(cont'dl
BrakeSystemIndicatorCircuit CombinationLight Swilch CylinderHeadAssembly
CircuitDiagram TesVReplacement ..............................22 80 Component LocationIndex..................... 6-3
Conventional
BrakeComponents..... 19-9 Inspection................................................. 66
Troubleshooting ConnectingRod Bearings Removal.......... &23
ABS/TCS ......19-55
Components........... R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .-.. . . . 7 - 8 I n s t a 1 1 a l .i .o. n. . . . . . . . . . . . . . . . . . . . . . . . . .6. .3. 9. . . . . . . . . . . . . .
Bumper,Rear ConventionalBrakeComponent3 D
R e m o v a l / l n s t a l l a t i o.n. . . . . . . . . . 2 0 . 8 6 ComponentLocationIndex................... 19'3
Troub1eshootin9 .....................................
19-4
R e p a i.r. . . . . . . . . . . . . . . . . 19-8 Dampers.Front
R e p l a c e m e n t . . . . . . . . .. .. .. .. .. .. .. .. . . . . . . 1
. .8. 2
. .0. .
c Coolant
Inspectio . .n. . . . . . . . . . . . ........ . . .1 0 6 Oampers,Rear
R e p l a c e m e n t . . . . . . . . . . . . ....... . . . .1 06 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . .1 . .8. .-.3. .4. . . . . . . . . . . . .
CableReel
Replacement....................................... 23-119 CoolantTemperatureGat|ge DashVents
T r o u b 1 e s h o o t i n 9 . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . Bemoval/lnstallation
...... .-.......................... 20-64
Camshaft
Inspection.......................-...-................... 6-29 CoolingSyslem Dashboard
Component LocationIndex................... 10-2 Bemoval/1nsta11ation ............................ 20-66
CargoArea Light
TesVRep1acement ................................ 22-97 CountershaftBearings OashboardCenterPanel
R e p l a c e m e n t . . . . . . . .. . . . . . . . . . . . . . 1 . .3. .-.4. .2 Removal/1nstaf 1ation............................ 20 62
Carpet
R e p l a c e m e n t . . . . . - . . ..-. . . . .... . . . . - . 2 0 - 5 5
CeilingLight
Cowl Cover
R e p l a c e m e n t . . . . . . . . . . . ........ . . . . . 2 0 - 9 5
DashboardLower Cover
Removal/lnstallation ...................... 20-59,63 3
-estrReplacement ................................ 22.96 Crankshaft DashboardUnderCover
R e m o v a. l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .- .1. 2. . . . . . .Removal/lnstallation
........ ............................ 20 60
ChargingSystem Inspec(on,,,,, ........14
Component LocationIndex................... 4-20 l n s t a l l a t i o n . . . . . . . . . ... . . . . . . . . . . . . . 1 - 2 4 DifferentialCarrierBearings,M/T
C i r c u iDt i a g r a m. . . . . . . . . . . . . . . . . . . . . . . .4. .-.2. .1. . . . . . . . . Rep1acement,,......,...,...,.,.,,,.,.,,,........,.,. 13-54
Troubleshooting . . . . . . . 4 - 2 2 CrankshaltMain Bearings
R e p l a c e m e n t . . . . . . . . - . - . . . . . . . . . . . . .7. .-.6. . . . . . .Ditferential
. . . . . . . . . . . Oil Seals,M/T
ChildSeatTetherAnchor 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3.-. 5 . .5. . . . . . . . . . . . .
R e m o v a l / l n sl at at ;fo n. .. . . . . . . . . . . . . . . .2. .3. .1.1. . . CrankshaftOilSeal,TransmissionEnd
1nstanation .............................................. 7 28 DifferentialPinionGears,M/T
CKP(CrankshaftPosition)Sonsor I n s p e c t i o. n, . . . . - , . , , , . , . . , . - , . , . . . . . .1. .3.5, .3, . , , ,
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1.1. .-.1. .1. 6. . . . . . Crankshafl
..... Pulley
Removal/lnstallation -..................-.......... 6-11 OLCCircuit
Clutch Troubleshooting ................................ 11-109
ComponentLocation 1ndex................... 12-3 CruiseControlActuator
R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . . . .1. .2. -. 9 . . . . . . .Test
.......... ...................... 4-43 Door Glass
RepIacement.......................4 . .-. 4. .4. . . . . . R
. . e. .p. .1. a. .c e m e n t . , . , , , , , , , , , , , . , , , , , , , 2 , ,0, .-,9. , . , . , . , , , , , , . , ,
ClutchInteYlockSwitch Adjustment. .. .....................20-11
T e s t . . . . . - . . . . . . . . - . . . - .......-.-.-. .. -. . . . . . . . 4 - 6 CruiseControlActuatorCable
Adjustment............................................. 4 45 Door GlassWeathelstrips
ClutchMasterCylinder R e p l a c e m e. n . .t. . . . . . . . . . -. .. .. . . . . . . . . - . . . 1
. .0. 2 0
Replacement.......................1 . .2. .5. . . . . . . Cruise
. . . . . . . .Control
. Main Switch
TesVRep1acement .................................. 4 42 Door Latches
clutch Pedal Replacement ..........-.-.............................. 20-7
Adjustment............................................. 12 4 CruiseControlSet/Resume/Cancel Switch
TesVRep1acement .................................. 4 42 Door LockActuators
ClutchPedalPositionSwitch Test...................................................... 22-154
T e s t . , . , , , , , . , , , . , . , , , , , , . , . ,.,.,.,.,.,.,4, ,4. 5, , , , , . . CruiseControlSystom
Component LocalionInde\................... 4-36 Door LockKnob Switches
Clutch Slave Cylindor C i r c u iDt i a g r a m. . . . - . . . . . . . . . . . . . . . . . . .4. .3. 7 . . . . . . . .Test
. . . -......... . . . - . . . . . . . . ......22-160
Beplacemeit... 12-1
CruiseControl Unit Door LockSwitches
CMP{CamshaftPositionlSenso] I n p u t T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. ., 4 0 T e s t. . . . . . . ........ . . . . . . . . . . . . . ..................2...2. .-. 1 6 0
R e p l a c e m e n t . . . . - . . . - . . . . . . . . . . . .1.1. .- .1. 2 . .8. . . . . . . . . . .
Door Outer Handles
CMP(TDC)Sensors Rep1acemen1 ........................................... 20-6
R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . .1.1. .1. 1. .4. . . . . . . . . . . .
)
HeaterValveCable lmmobilizerSystem
G A d j u s t m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .?. .1. -. .4.6. Component LocationIndex .............. 22-162
Description
High Mount BrakeLight C i r c u i t D i a g r a.m
..........................22-164
GaugeA3sembly 8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2
. .2. .8. 2. . . . . . . .Troubleshooting
...... ............................ 22,165
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . . . . . . . .
Hood InnerFender,Fronl
Gaug€s Adjuslment Repfacemenl....................................... 20-102
Component LocationIndex..........-...... 22 54
H o w - t ol n f o r m a t i o n
. . . . . . . . . . . . . . . . . . . . . . . . 2 2 - 5Hood 6 lnsulator InsideRearviewMirror
CircuitDiagram 22-54 Replacement......................................... 20-89 R e p l a c e m e n t . . . . . . . . . . - . . . . . . . . . . .2. .0. 1. .6. . . . . . . . . . . . . .
GenoralInformation Hood Latch InstrumentPanel
(Seeseclion 1) R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1
20 8 Removal/1nsta11ation.................
.......20-59
GloveBox HoodOpenerCable IntakeAir BypassControlThermalValve
Removal/1nsta11ation
.......................-....
20-63 ComponentLocation Index ..............20 105 T e s r . . . . . . . . . . . . . . . . . . . ........... . .....1. .1. - 1 6 1
R e p l a c e m e. n
. .t. . . . . . . . . . ...... . . . . . . . . . 2 01 0 6
Grille IntakeAir System
Replacement...........-.............................
20-94 Hood Seal ComponentLocationIndex...-.-........ 11-159
Beplacement.-...........................-...........
20-88
IntakeManitold
Horn Removal/1nsta11ation ................................ I 2
H TesVReplacement . . ................
......22-122
lntermediateShaft Assembly
Horn Switch R e m o v a. 1. . . . . . . . . . . . . . . - . - . . . - . . . . . . .1. 6. .-.1. .9. . . . . . . . . . . .
Test ............-........ 22-122 D i s a s s e m b | y . . . . . . . . . . . . . . . . . . . . . - .1. 6. ., 2 0
Adiustment....... R e s a s s e m b. |. y. . . . . . . . . . . . . . . . . . . . . . .1. .6. 2. .2. . . . . . . . . .
Horns Installation .........-...-.............................. 16-24
HatchHandle Component LocationIndex. . . . . . . . . . . . . . 2 2 - 1 2 0
Replacement 20-110 Circ!itDiagram 22 121
Hubs
. . . 1. 11 1 3
KeylessEntry Transmitter
$
Test R e p l a c e m e n. .t.. . . . . . . . . . . . . . . . . . . . . . 1. .A.2. .6. . . . . . . Repair............... 22-161
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .6.1. . . . . . . . . . . . . .
H.tch Lock Actuator
Test 22-159 KeylessEntry/SecurityAlarm System
ComponenlLocationIndex.............. 22 150
HatchLockCylinder C i r c u iDl i a g r a m. . . . . . . . . . . . . . . . . . . . . 2
. .2. .1. 5 1
R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .0. ,. 1. .1. .1. . . . . . . . . .
IAT {lntakeAir Temperature}Sensor KeylessReceiverUnit
HatchSpoiler Replacement.,.........-... '11
115 lnputTest ............................................ 22-153
Replacement
ldle ControlSystem KnockSensor
HatchSupport Struts ComponentLocation Index .............. 11-129 R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .1.1. .1. .1. 5
............
Beplacement..... 20-91 I n s p e c t i o n , . , . . . . . . . . . - . . . . . . . , . , . ,1,',l,1, 3, .8, , , . , . , . . . . .
Knuckles
HatchWeatherstrio lgnition Coillsl Replacement
Replacement.... 20-92 Bemoval/lnstallation ...............-.............. 4 18 F r o nS
t u s p e n s r o. .n. . . . . . . . . . . . . . . . .1. 8. .-.1. . . . . .
RearSuspension ........ .................-... 18-28
HazardWarningSwitch lgnition Key Light
test .................... 22_88 T e s t , , . , , , , . , . . . , . . . . . . -.......................
. 22-91
MuhiplexControlSystem
. .e. .n. .t....... . . . .1. 3. .- 3
Parking Erake
Inspection A d j u s t m e n t. . . . . . . . . . . . . . . . . . 1
. .9. .- 7
Disassembly ......................................... 1325 ComponentLocation lndex ..............22 168
Resassembly ........................................ 13 28 CircuitDiagram.................................. 22-169 Parking Brake Cable
Adjustment........................................... 13-43 0escription......................................... 22-171 Rep1acement.........................1 . .9. .-.2. .6. . . . . . . . .
Troubleshooting ................................ 22-17 2
M/T ReverseShift Fork ParkingErakeSwitch
I n s p e c t i o. n. . . . . . . . . . . ................ . . . . . . . .l .3. .1. 9 . . . . Muliiplex ControlUnit, Under-dash Test................. . . . .1. 9 - 1 0
InputTest
M/T Shift Level EntryLightControlSysiem............. 22-92 Passenger's TraV
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3. .- .5. 1. . . . . . . . .Keyless .... Entry/Security Alarm Removal/lnstallation ............................ 20-65
Systern.-....................................... 22-155
MainshaftBearings MultiplexControl System.............22 115 PCVValve
R e p l a c e m e n t . . . . , . . . . . . . . . . . . . . . . .1. .3.4. .1. . . . . . . . . Wiper/Washer.................................
..... 22'141 B e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .'.1. 6 . .9. . . . . . . . . .
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l. 1. . 1. .6. .9. . . . . . .
Mairtenance
lSeesection3) PistonRings
N 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .7. .- .2. 1. . . . . - . - . .
MIL
How to Informatron ............................. 11.46 Pistons
NoiseReductionCondenser R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . - . . .7. .-.1. .8. . . . . . . . . .
MIL Circuit Test,, . . . . . . . . . . . . .1. 0 21 2 1 n s t a | 1 a t.i .o. n ..........................1 . .-.2. .3. . . .
Troubleshooting .......... .- . . . . ......... 1197
PowerR€lay
Mirrors Test...............-.-...................................... 22-51
ComponentLocation Index................. 20'14 o PowerWindow Motor, Driver's
Mode ControlMotor t e s l . . . . . , ,.,,,. , , , . . . . . . . . . . . .
Replacement . . . . . . . . . 2 1 , 3 5 Oil Filte]
T e s t . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 2 1 3 5 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. -. 6. . . . . . . . Power . . . . . . Window Motors, Passenger's
MoonroofDreinChannel
22-110
lnputTest ............................................
Oil Pan T e s r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .2. 4. . . . . . . . . .
R e m o v a l. . . . . . . . . . . . . , . , , , , , , , , , , , , . , . , , , .7. .1. .1. . . . - . . .Replacement.......................................
....
l n s t a l l a t i o .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. .- .2. 7
...........
22-133
t s Timing/CamChain
lnstallation ...........6
...612
. . .1. 5
.
VTECSolenoidValve
Femoval/lnspection....-......................11-128
Timing/CamChainCaseOilSeal
Installation......................-......................6,21 WasherFluidLevelSwitch
TesVReplacement .............................. 22 144
TrailingArms
Removal/lnstallation .............. . . . . .....1833 WasherFluidReservoir
Replacement ....................................... 22-146
tnm
Component Locationlndex................- 20 49 WasherMotor,Windshield
R e m o v a l / l n s t a l l a. t. i-o. .n. . . . .5200, 5 1 , 5 2 , 5 3 T e s t- . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . .1. .4. 4. . 2 2
Troubleshooting WasherTube,Windshield
{Seefirstpageot thisIndex) Replacement......-...-............................
22 147
WheelBearings
I n s p e c | i o n. . . . . . . . . . . . . . . . . . . . . . . . . . ............1...8. 8. . . .
U
Wheel Speed Sensors
],s
I n s p e c t i o n . . - . . , . , . , , . , , , , , . , . , , , . . . . . . . . . . . .1. .9.-. 5
. .9. . . .
UndeFdashFuse/R€layBox R e p l a c € m e n. t. . . . . . . - . . . ..... . . . . . - . . . 1 . 9-59
Removal/lnstaf
lation............................
22-49
WheelsandTires
UpperArms Inspect|on
R e m o v a l / | n s t a 1 1 a t i o n . . . . . . . .. .. ..1. .8. -. .3. 2.