Honda ESM Accord 1998 PDF

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HONDA _.
:ACCORD: f- . .
2
' BODY REPAIR MANUAL 99 2333
2333
' TURBO DIESEL SUPPLEMENT 99 2463
2463
(I 2912
ACCORD 5 DOORIACCORD 5 DOOR TURBO DIESEL SUPPLEMENT 00 Ea
( ACCORD 415 DOOR SUPPLEMENT 00 3096
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(I. ACCORDJ'ACCORD 5 DOOR 01 3257
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::ACCORD
EngIne Electrical 94
151
MAINTENANCE REPAIR and CONSTRUCTION 99 391
414
3
3 “Steering
783
1159 @
Suspension 1201 55"".
"Brakes {Including ABSIIZZS
1228 @
1291
1453
1577
1869
INTRODUCTION
,);,
How to Use This
.
(
; Manual

General Info fl
.!
This manual is divided into 24 sections. Click on the chapter you want
4 !&*-!# 3
to look at from the opening screen, this is followed by 3 contents list of
!#
A!!3!
the chapter, click on the page you require The symbols printed at the
A!#
F 4! Specifications

top corner of each page can also be used as a quick reference system

! F #
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Each section includes:
! 9 ,
Maintenance
1.
- Atable of contents, or an exploded view index showing:
%!A/!&3/3
9
-
-
Parts disassembly sequence.
!F -
Bolt torques and thread sizes.
)!F H-
Engine Electrical El

!!
- Page references to descriptions in text.

/-
- Disassemn/assembly procedures and tools.
(!=! !- Engine

@F’TPP’N
+- Inspection.
-
*- Testing/troubleshooting.
4
= !
-
- Repair.
1- Cooling
!

- Adjustments.
%7 -
Fuel & Emmissions '6."
!J
Special Information

4/!
Transaxle
AWARNING F
!
* #
-

: Indicates a strong possibility of severe personal
injury or loss of life if instructions are not followed.
D#

(@
Steering

55.,
ACHUTION F
* #

D#

: Indicates a possibility of personal injury or Suspension *IIH]

equipment damage if instructions are not followed.
B !

(@
(including ABS) .ABS

Brakes ;!
%)<
)#
NOTICE F
: The purpose of these

messages is intended to help
!

prevent damage to the
-!
vehicle,
- other
:
property, or the

#:

Body
)
environment.
-
@ t
-
: Gives helpful
F - information.

@
Heating & Air Conditioning
6
J%

A CAUTION Body Electrical El
) !!
Detailed descriptions of standard workshop procedures,
(!3# A
safety principles and service operations are not included.
!&! -
Please note that this manual does contain warnings and
! !3

Restraints
1
cautions against some specific service methods which

&3
could cause PERSONAL INJURY, or could damage a
! 18%"?1CA !

vehicle or make it unsafe. Please understand that these
&!# -!
warnings and cautions cannot cover all conceivable ways in
3
&!!&!3
which service, whether or not recommend by HONDA,
3&A368(%A
might be done, or of the possible hazardous consequences

A!H F
of each conceivable way, nor could HONDA investigate all
&!3A !68(%&
!!
such ways. Anyone using service procedures or tools,
3-%
& !A
whether or not recommended by HONDA, must satisfy
368(%A
themselves thoroughly that neither personal safety nor
!&
!!
vehicle safety will be jeopardized.
&!3!!7H-
All information contained in this manual is based on the latest product
%!! !!
information available at the time of printing. We reserve the right to
&!!
-2&

make changes at any time without notice. No part of this publication
#
3 - !
may be reproduced, stored in retrieval system, or transmitted, in any
A&!AA
form by any means, electronic, mechanical, photocopying, recording,
A!A!A
A
A
or otherwise, without the prior written permission of the publisher.
3A3 3 !-
This includes text, figures and tables.
4! /A
!-
First Edition 9/98 2074 pages

5=5'0$*

HONDA MOTOR CO., LTD.
.,)@:&)@
All Rights Reserved
%!!1
1&
Service Publication Office
- '*

As sections with * include SRS components; special precautions

%3G! 1N!
are required when servicing.
F 3&
-
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

;''&%%,&%,>%/0
This Accord Sedan SRS includes a driver’s airbag located in the

-? *!

steering wheel
!( hub and a passenger’s airbag located in the
*!? *!

dashboard
above the
*
*
- glove box. Some types include seat belt
!
-*
@
# *
tensioner located in the

front seat belt retractors, and some

*
:

types include side airbags located in the
# *!
front seat-backs.

*6@
Information necessary to safely service the

#
#- SRS is included in

this Shop
Manual.

@
Items marked with 6/A0

6( an asterisk (*) on the contents page include,

! :
or are located near SRS components. Servicing, disassembling

@- !: * !
or replacing these
! items will require special precautions and

( B

tools, and should

:
therefore be done by an authorized

*
*# Honda

C.

@
O
' A WA NIN
To avoid rendering the SRS inoperative, which could lead to
4&
1&A3 !!
personal injury or death in the event of a severe frontal collision, all
!7 &&!!!A!!
SRS service work must be performed by an authorized Honda dealer.
1&3# H6!-
~ Improper service procedures, including incorrect removal and
& A!
&!
installation of the SRS, could lead to personal injury caused by
!!1A !!!7
unintentional deployment of the airbags, side airbags and seat belt
!!
A
!
tensioners.
-
‘ All SRS electrical wiring harnesses are indicated with yellow
%!!1!!3
3!!3
color. Related components are located in the steering column, front
!-1!!
! A
console, dashboard, dashboard lower panel, and in the dashboard
!AA!3!A
above the glove box, front seats and around the floor. Do not use
&
!&/A !-(
electrical test equipment on these circuits.
!!F -

General Information Index
General Information

Chassis and Engine Numbers

39
Identification Number Locations
42
Warning/Caution Label Locations
2
= ! 43
Lift and Support Points

Lift and Safety Stands
' 45
Floor Jack
!"# 5 46
Towing
43
0 47
Preparation of Work
2# 48
Abbreviations
%& ' 55
Wiring Diagrams
1 !) !

Specifications Index
Specifications

Standards and Service Limits
& 2-2
57
Design Specifications
(
2-19
5 76
Body Specifications
) 2-25
85
Wiring Diagrams
1 !) !
Maintenance Index

Maintenance

Lubrication Points + 86
, !
Maintenance Schedule +* 88
Wiring Diagrams
1 !) !
Enqine Electrical Index
%! %
Engine Electrical
%! %
Special Tools
!4! * 94
Starting System

Component Location Index
/ *+ 95
Circuit Diagram
(
** 96
Starter Test
4 * 97
Starter Solenoid Test
!4 *$ 99
Starter Replacement
1! *' 100
Starter Overhaul
8& ! *5 101
8rush Inspection
) 4-11
* 103
Overrunning Clutch Inspection
8&
! 4-11
* 103
103
Armature Inspection and Test
% 4 4-12
* 104
Field Winding Test (DENSO)
!2
4;( 8< 4-14
** 106
Starter 8rush Holder Test (DENSO)
) 6!4;( 8< 4-15
* 107
8rush Spring Test
)
4 4-15
* 107
107
Starter Reassembly
1! 4-16
* 108
Performance Test
4 4-16
* 108
Ignition System

/ 4-18
*' 110
Circuit Diagram
(
4-19
*5 111
Ignition Timing Inspection

4
4-21
* 113
Ignition Timing Setting (Except D1686 engine)

4

; /()
< 4-23
*+ 115
Distributor Replacement (Except D1686 engine)
( 1!; /()
< 4-24
** 116
Ignition Coil Replacement (D1686 engine)

!1!;()
< 4-25
* 117
117
Distributor Overhaul (Except D1686 engine)
( 8& !; /()
< 4-26
* 118
Ignition Control Module (ICM)

!, !;,<
Input Test (Except D16B6 engine)
4; /()
< 4-28
*' 120
120
Ignition Wire Inspection and Test

24 4-29
*5 121
121
Ignition Coil Test

!4 4-29
*5 121
121
Spark Plug Inspection
#!
4-31
*+ 123
123
Charging System

/ 4-33
*++ 125
125
Circuit Diagram
(
4-35
*+ 127
Troubleshooting
4 !
4-36
*+ 128
128
Alternator Replacement
%!1! 4-39
*+5 131
Alternator Overhaul
%!8& ! 4-41
** 133
Rectifier Test
14 4-43
**+ 135
135
Alternator Brush Inspection
%!) 4-44
*** 136
Rotor Slip Ring Test
1!1
4 4-44
*** 136
Stator Test (H22A7)
4;6%$< 4-45
** 137
Alternator Belt Adjustment (D16B6 engine)
%!)!%7 ;()
< 4-46
** 138
Alternator Belt Adjustment With A/C
%!)!%7 2%=
(Except D16B6 engine)
; /()
< 4-47
**$ 139
Alternator Belt Adjustment Without A/C
%!)!%7 2 %=
(Except D16B6 engine)
; /()
< 4-48
**' 140
Cruise Control
!
/ 4-49
**5 141
Circuit Diagram
(
4-50
*0 142
Control Unit Input Test
!? 4 4-51
* 144
Main Switch Test/Replacement
,34=1! 4-53
*+ 145
Set/Resume/ControI/Switch Test/Replacement
=1 =!=34=1! 4-54
** 146
Actuator Test
% 4 4-55
* 147
Actuator Cable Replacement
% !1! 4-56
* 148
Actuator Cable Adjustment
% !%7 4-57
*$ 149
Clutch Switch Test
! 34 4-58
*' 150
Brake Switch Test
)#34 4-58
*' 150
Wiring Diagrams
1 !) !
Engine Index
%!
Engine Removal/Installation
%!
-2
3
Special Tools
!4! 151
151

1&!=!!
Removal
1&! + 152
152
Installation
!! 164
164
Engine Mount Control System (A/T)

, !;%=4<
/ 5-23
+ 172
Circuit Diagram
(
5-24
* 173
173
Troubleshooting Flowchart
4 !
!3 5-25
174
174
Cylinder HeaderNalve Train
# .24- 6-1
5
D1636 engine
)5"5! 6-A-1
5
Special Tools
!4! 6-A-2
% 176
Valve Clearance
:!&!
Adjustment
%7 6-A-3
%+ 177
Crankshaft Pulley and Pulley Bolt
# !! !!)!
Replacement
1! 6-A-5
% 179
Timing Belt
4
)!
Illustrated Index
!! / 6-A-6
% 180
Inspection
6-A-7
%$ 181
Tension Adjustment
4%7 6-A-7
%$ 181
181
Removal
1&! 6-A-8
%' 182
Installation
!! 6-A-9
%5 183
CFK
Sensor
>
Replacement
1! 6-A-11
% 185
185
Cylinder Head
!6
Illustrated Index
!! / 6-A-1 2
% 186
Removal
1&! 6-A-14
%* 188
Warpage
2
6-A-24
%* 198
Installation
!! 6-A-29
%5 203
Rocker Arms
1#%
Removal
1&! 6-A-18
%' 192
Disassemn/Reassembly
(!=1! 6-A-19
%5 193
Rocker Arms and Shafts
1#%
Clearance Inspection
! 6-A-20
%0 194
Camshaft

Inspecflon
6-A-21
% 195
Valves, Valve Springs and Valve Seals
:!&A:!&
:!&!
Removal
1&! 6-A-23
%+ 197
Installation
!! 6-A-27
%$ 201
Valve Guides
:!&.
Valve Movement
:!&,& 6-A-24
%* 198
Replacement
1! 6-A-26
% 200
Reaming
1
6-A-26
% 200
Valve Seats
:!&
Reconditioning
1
6-A-25
% 199
Camshaft/Rocker Arms and Camshaft Seal/Pulley
=1#%!= !!
Installation
!! 6-A-28
%' 202
F1882, F18B3, F2036 Engines
+8":+8":+$"5%! 6-B-1
5"
Special Tools
!4! 6-B-2
) 206
Variable Valve Timing and Valve Lift
:!:!&4
:!&
Electronic Control (VTEC) Control System
!!;:4 <!
4 !
!3 )+ 207
VTEC Solenoid Valve
:4 !:!&
Inspecflon
)' 212
VTEC Rocker Arms
:4 1#%
Manual Inspection
, ! )5 213
Inspection Using Special Tools
?
!4! )5 213
Valve Clearance
:!&!
Adjustment
%7 ) 216
# !! !!)!
Replacement
1! )* 218
Timing Belt and Balancer Belt
4
)!)!)!
Illustrated Index
!! / ) 219
Timing Belt Inspection
4
)! ) 220
Balancer Belt Inspection
)!)! ) 220
Tension Adjustment
4%7 )$ 221
Removal
1&! )' 222
Installation
!! 0 224
CKP/TDC Sensors
>=4(
Replacement
1! )+ 227
Cylinder Head
!6
Illustrated Index
!! / )* 228
Removal
1&! ) 230
Warpage
2
)+5 243
Installation
!! )*+ 247
Cylinder Head Bolt
!6)!
Inspecflon
)+0 234
Rocker Arm Assembly
1#%%!
Removal
1&! )+0 234
Rocker Arms
1#%
(!=1! )+ 235
Inspecflon
)+ 236
1#%
! )++ 237
Camshaft

Inspecflon
6-B-34
)+* 238
:!&A:!&
:!&!
Removal
1&! 6-B-36
)+ 240
Installation
!! 6-B-41
)* 245
Valve Seats
:!&
Reconditioning
1
6-B-37
)+$ 241
Valve Guides
:!&.
Valve Movement
:!&,& 6-B-39
)+5 243
Replacement
1! 6-B-40
)*0 244
Reaming
1
6-B-40
)*0 244
Camshaft/Rocker Arms and Camshaft Seal/Pulley
=1#%!= !!
Installation
!! 6-B-42
)* 246
H22A7 engine
.7! 6-C-1
5
Special Tools
!4! 6-C-2
251
Variable Valve Timing and Valve Lift
:!:!&4
:!&
!!;:4 <!
4 !
!3 6-C-3
+ 252
VTEC Solenoid Valve
:4 !:!&
Inspecfion
6-C-6
255
VTEC Rocker Arms
:4 1#%
Manual Inspection
, ! 6-C-7
$ 256
Inspection Using Special Tools
?
!4! 6-C-7
$ 256
Valve Clearance
:!&!
Adjustment
%7 6-C-9
5 258
# !! !!)!
Replacement
1! 6-C-11
260
Timing Belt and Timing Balancer Belt
4
)!4
)!)!
Illustrated Index
!! / 6-C-12
261
Timing Belt Inspection
4
)! 6-C-13
+ 262
Timing Balancer Belt Inspection
4
)!)! 6-C-13
+ 262
Removal
1&! 6-C-14
* 263
Installation
!! 6-C-16
265
CKP/TDC Sensors
>=4(
Replacement
1! 6-C-21
270
Cylinder Head
!6
Illustrated Index
!! / 6-C-22
271
Removal
1&! 6-C-24
* 273
Warpage
2
6-C-39
+5 288
Installation
!! 6-C-43
*+ 292
Cylinder Head Bolts
!6)!
Inspecflon
6-C-29
5 278
1#%
Removal
1&! 6-C-30
+0 279
Disassembly/Reassembly
(!=1! 6-C-32
+ 281
! 6-C-33
++ 282
Rocker Arms
1#%
Inspecfion
6-C-34
+* 283
Installation
!! 6-C-42
* 291
Camshafts

Inspecfion
6-C-35
+ 284
:!&A:!&
:!&!
Removal
1&! 6-C-37
+$ 286
Installation
!! 6-C-41
* 290
Valve Seats
:!&
Reconditioning
1
6-C-38
+' 287
Valve Guides
:!&.
Valve Movement
:!&,& 6-C-39
+5 288
Replacement
1! 6-C-40
*0 289
Reaming
1
6-C-40
*0 289
Engine Block
%! "
6 7-1
7
D1636 engine
)5"5! 7-A-1
7
Special Tools
!4! 7-A-2
$% 296
Illustrated Index
!! / 7-A-3
$%+ 297
Flywheel
!3!
Replacement
1! 7-A-5
$% 299
Connecting Rod and Crankshaft

1#
End Play
! 7-A-6
$% 300
Main Bearings
,)

Clearance
! 7-A-7
$%$ 301
Selection
! 7-A-8
$%' 302
Connecting Rod Bearings

1)

Clearance
! 7-A-9
$%5 303
Selection
! 7-A-9
$%5 303
Pistons and Crankshaft
#
Removal
1&! 7-A-10
$%0 304
Crankshaft
#
Inspecfion
7-A-12
$% 306
Installation
!! 7-A-21
$% 315
Pistons

Inspecfion
7-A—1 3
$%+ 307
Installation
!! 7-A—21
$% 315
Cylinder Block
!)!#
Inspecfion
7-A-14
$%* 308
Bore Honing
)6
7-A—1 5
$% 309
Piston Pins

Removal
1&! 7-A—1 5
$% 309
Installation
!! 7-A—1 6
$% 310
Inspecfion
7-A-17
$%$ 311
Connection Rods
1
Selection
! 7-A-16
$% 310
Piston Rings
1

End Gap
. 7-A-18
$%' 312
Replacement
1! 7-A-18
$%' 312
Ring to Groove Clearance
1
.&! 7-A-19
$%5 313
Alignment
%!
7-A-19
$%5 313
Crankshaft Oil Seal
#8!!
!!
Installation 7-A-20
$%0 314
8!
Oil Pan
!!
Installation 7-A-24
$%* 318
F1832, F1833, F2036, H22A7 engines
+8":+8":+$"5:.7! 7-B-1
7"
Special Tools
!4! 7-B-2
$) 319
Illustrated Index
!! / 7-B-3
$)+ 320
Flywheel and Drive Plate
!3!(&!
Replacement
1! 7-B-8
$)' 325
Connecting Rod and Crankshaft

1#
End Play
! $)' 325
Main Bearings
,)

Clearance
! $)5 326
Selection
! $)0 327
Connecting Rod Bearings

1)

Clearance
! $) 328
Selection
! $) 329
#A)!
Crankshaft, Balancer Shafts and Pistons
Removal
1&! $)+ 330
Crankshaft
#
Inspecfion
$)$ 334
Pistons

Inspecfion
$)' 335
Installation
!! $)' 345
Cylinder Block
!)!#
Inspecfion
$)5 336
Bore Honing
)6
$)0 337
Piston Pins

Removal
1&! $)0 337
Installation
!! $)* 341
Inspecflon
$)+ 340
Connection Rods
1
Selection
! $) 338
Connecting Rod Bolts

1)!
Inspecflon
7-B-22
$) 339
Piston Rings
1

End Gap
. 7-B-25
$) 342
Replacement
1! 7-B-26
$) 343
Ring to Groove Clearance
1
.&! 7-B-26
$) 343
Alignment
%!
7-B-27
$)$ 344
Crankshaft Oil Seal
#8!!
Installation
!! 7-B-28
$)' 345
Crankshaft and Balancer Shafts
#)!
Installation
!! 7-B-30
$)+0 347
Balancer Shafts
)!
Inspecflon
7-B-35
$)+ 352
Balancer Shaft Bearings
)!)

Replacement
1! 7-B-38
$)+' 355
Engine Lubrication
%! &*
8-1
8
Special Tools
!4! 8-2
' 359
Illustrated Index
!! / 8-3
'+ 360
Engine Oil

8!
Inspecflon
8-6
' 363
Replacement
1! 8-7
'$ 364
Oil Filter
8! !
Replacement
1! 8-8
'' 365
Oil Pressure Switch
8! 3
Testing
4
' 368
Oil Pressure
8!
Testing
4
' 369
Oil Jet
8!"
Inspecflon
8-13
'+ 370
Oil Pump
8!
Overhaul
8& ! 8-14
'* 371
371
Removal
1&! 8-16
' 373
Inspecflon
8-17
'$ 374
Installation
!! 8-18
'' 375
Intake Manifold/Exhaust
6
2% System
# 9-1
9
Intake Manifold
#,!
Replacement
1! 9-2
5 380
Exhaust Manifold
/ ,!
Replacement
1! 9-5
5 383
Exhaust Pipe and Muffler
/ , !
Replacement
1! 9-9
55 387

!
Cooling Index
Cooflng

! 10-1
$
Radiator
1
Illustrated Index
!! / 10-2
0 397
Replacement
1! 10-6
0 395
Engine Coolant Refilling and Bleeding

!1!!
)!
10-7
0$ 396
Cap Testing
4
10-10
00 399
Testing
4
10-10
00 399
Thermostat
4
Replacement
1! 10-11
0 400
Testing
4
10-13
0+ 402
Water Pump
2
Illustrated Index
!! / 10-14
0* 403
Inspecflon
10-17
0$ 406
Replacement
1! 10-17
0$ 406
Fan Controls
!
/ 10-18
0' 407
Circuit Diagram
(
10-19
05 408
Module Input Test (F18B3
, ! 4; engine)
')+
< 10-21
0 410
Fan Motor Testing
,4
10-22
0 411
Radiator Fan
1 Switch Testing
34
10-22
0 411
Engine Coolant Temperature Gauge

!4 .

Gauge Testing
.
4
10-24
0* 413
Sending Unit Testing

?4
10-24
0* 413
Wiring Diagrams
1 !) !
+%

Fuel and Emissions Index
+$"5:.7%!
F2036, H22A7 Engine 11 -A-1

Special Tools
!4! 11-A-2
% 414
Component Locations

Index
/ 11-A-3
%+ 415
System Description
(
Vacuum Connections
: 11-A-8
%' 420
Electrical Connections
!! 11-A-12
% 424
Troubleshooting
4 !
Troubleshooting Procedures
4 !
11-A-15
% 427
Engine Control Module/Powertrain

!, !=3
Control Module Terminal
!, !4!
Arrangement
%
11-A-21
% 433
Diagnostic Trouble Code Chart
(
4 ! 11-A-26
% 442
PGM-FI System
'+#
System Description
( 11-A—30
%+0 446
How to Read Flowcharts
631 !3 11-A-33
%++ 449
Troubleshooting Flowcharts
4 !
!3

!, !=3
Control Module
!, ! 11 -A—34
%+* 450
Manifold Absolute Pressure Sensor
,!%! 11-A-39
%+5 455
Intake Air Temperature Sensor
#%4 11-A-42
%* 458
Engine Coolant Temperature Sensor

!4 11-A-44
%** 460
Throttle Position Sensor
4! 11-A-47
%*$ 463
Primary Heated Oxygen Sensor (Sensor 1)
68/
;< 11-A-50
%0 466
Secondary Heated Oxygen Sensor (Sensor 2)
68/
;< 11-A-59
%5 475
Heated Oxygen Sensor Heater
68/
6 11-A-62
% 478
Fuel Supply System
! ! 11-A-67
%$ 483
Random Misfire
1, 11 -A—69
%5 485
Misfire Detected in One Cylinder
,(8! 11-A-7O
%$0 486
Knock Sensor
># 11 -A—73
%$+ 489
Crankshaft Postion (CKP/TDC) Sensor
#;>=4(< 11-A-74
%$* 490
Vehicle Speed Sensor
:! 11-A-77
%$$ 493
Barometric Pressure Sensor
) 11-A-78
%$' 494
CYP Sensor
C 11-A-79
%$5 495
ECM/PCM Internal Circuit
,=,! 11-A—81
%' 497
Heated Oxygen Sensor
68/
11-A-82
%' 498
Idle Control System

#
System Description
( 11-A—83
%'+ 499
4 !
!3
Idle Air Control Valve
!%!:!& 11-A—84
%'* 500
Air Conditioning Signal
%

! 11-A-86
%' 502
Alternator
%! FR Signal
1
! 11 -A—88
%'' 504
Brake Switch Signal
)#3
! 11-A-90
%50 506
Starter Switch Signal
3
! 11-A-91
%5 507
Power Steering Pressure Switch Signal
3
3
! 11-A-92
%5 508
Idle Speed Inspection
! 11-A-94
%5* 510
Fuel Supply System
+##
Fuel Lines
! 11-A-95
%5 511
Fuel Tube/Ouick-Connect Fittings
!4 =D #
11-A-97
%5$ 513
System Description
( 11-A—100
%00 516
Fuel Pressure
! 11-A-100
%00 516
Fuel Injectors
!7 11-A-101
%0 517
Fuel Pressure Regulator
! 1
! 11-A-104
%0* 520
Fuel
! Filter
! 11-A-105
%0 521
Fuel Pump
! 11-A-106
%0 522
Fuel Gauge
!.
11-A-107
%0$ 523
Fuel Gauge Sending Unit
!.

? 11-A-108
%0' 524
Low Fuel
3 Indicator Light System
!
11-A-109
%05 525
Inertia Switch
3 11-A-11O
%0 526
PGM-F!E,1!
., Main Relay 11-A-111
% 527
FuelTank
!4# 11-A-115
% 531
531
Intake Air System
6 #
System Description
( 11-A-118
%' 534
Air Cleaner
%! 11-A-119
%5 535
Throttle Cable
4!! 11-A-120
%0 536
Throttle Body
4!) 11-A-122
% 538
Intake Air Bypass Control System
#%)! 11-A-125
% 541
Intake Control System (H22A7)
#!;6%$< 11-A-130
%+0 546
Fuel Injection Air Control System
!7%! 11-A-134
%+* 550
Emission Control System
%

#
System Description
( 11-A—136
%+ 552
Tailpipe Emission
4! 11-A-136
%+ 552
Three Way Catalytic Converter
42!& 11-A-136
%+ 552
Exhaust Gas Recirculation System
/ .1 ! 11-A—138
%+' 554
Positive Crankcase Ventilation System
&#:! 11-A-143
%*+ 559
Evaporative Emission Controls
&& ! 11-A-144
%** 560
Diagrams
(

Fuel-injected System Diagram (D16B6 engine: LHD)
!7(
;()
96(< 11-A-149
%*5 565
Fuel-injected System Connectors (D16B6 engine: LHD)
!7;()
96(< 11-A-150
%0 569
Fuel-injected System Diagram (D16B6 engine: RHD)
!7(
;()
916(< 11-A-151
% 573
Fuel-injected System Connectors (D16B6 engine: RHD)
!7;()
916(< 11-A-152
% 577
F1832, F1833 Engine
+8":+8"%! 11-B-1
"
Special Tools
!4! 11-A-2
% 414
Component Locations

Index
/ 11-B-2
) 581
System Description
(
Vacuum Connections
: 11 B-6
) 585
!! 11-B-1O
)0 589
Troubleshooting
4 !
4 !
11-B-
)+ 592
Troubleshooting Guide
4 !
. 11-B-16
) 595

!, !=3
Control Module Terminal
!, !4!
Arrangement
%
11-B-18
)' 597
(
4 ! 11-B-26
) 609
PGM-FI System
'+#
System Description
( 11-B-24
)* 607
631 !3 11-A-33
%++ 616
4 !
!3
Engine/Powertrain Control Module

=3!, ! 11-B-26
) 609
68/
11-B-31
)+ 614
,!%! 11-B-33
)++ 616
CKP/TDC Sensor
>=4( 11-B-36
)+ 619

!4 11-B-38
)+' 621
4! 11-B-4O
)*0 623
CYP Sensor
C 11-B-43
)*+ 626
#%4 11-B-45
)* 628
Idle Mixture Adjuster
!,/ %7 11-B-47
)*$ 630
Barometric Pressure Sensor
) 11-B-50
)0 633
:! 11-B-51
) 634
Knock Sensor
># 11-B-53
)+ 636
68/
6 11-B-55
) 638
Secondary Heated Oxygen Sensor
68/
11-B-58
)' 641
641
68/
11 B-6O
)0 643
Idle Control System

#
System Troubleshooting Guide
4 !
. 11-B-61
) 644
System Description
( 11-B-62
) 645
4 !
!3
!%!:!& 11-B-63
)+ 646
%

! 11-A-86
%' 502
Alternator FR
%! Signal
1
! 11-A-88
%'' 504
Brake Switch Signal
)#3
! 11-A-90
%50 506
Starter Switch Signal
3
! 11-A-91
%5 507
3
3
! 11-A-92
%5 508
! 11-B-65
) 648
Fuel Supply System
+##
4 !
. 11-B-66
) 649
Fuel Lines
! 11-A-95
%5 511
51 1
Fuel Tube/Quick-Connect Fittings
!4 =D #
11-A-97
%5$ 513
System Description
( 11-A-100
%00 516
Fuel Pressure
! 11-A-100
%00 516
Fuel Injectors
!7 11-B-67
)$ 650
! 1
! 11-A-104
%0* 520
Fuel
! Filter
! 11-A-105
%0 521
Fuel Pump
! 11-A-106
%0 522
Fuel Gauge
!.
11-A-107
%0$ 523
!.

? 11-A-108
%0' 524
Low Fuel
!
11-A-109
%05 525
Inertia Switch
3 11-A-11O
%0 526
PGM-F!E,1!
., Main Relay 11-A-111
% 527
FuelTank
!4# 11-A-115
% 531
Intake Air System
6 #
4 !
. 11-B-71
)$ 654
System Description
( 11-A-118
%' 534
Air Cleaner
%! 11-A-119
%5 535
Throttle Cable
4!! 11-A-120
%0 536
Throttle Body
4!) 11-B-72
)$ 655
Intake Air Bypass Control System
#%)! 11-A-125
% 541
Intake Control System
#! 11-A-130
%+0 546
Fuel Injection Air Control System
!7%! 11-A-134
%+* 550
%

#
4 !
. 11-B-74
)$* 657
System Description
( 11-B-75
)$ 658
Tailpipe Emission
4! 11-B-75
)$ 658
42!& 11-B-75
)$ 658
Exhaust Gas Recirculation System
/ .1 ! 11-B-76
)$ 659
&#:! 11-A—143
%*+ 559
&& ! 11-B-80
)'0 663
Diagrams
(

Fuel-injected System Diagram (D16B6 engine: LHD)
!7(
;()
96(< 11-B-85
)' 668
Fuel-injected System Connectors (D16B6 engine: LHD)
!7;()
96(< 11-B-86
)' 672
Fuel-injected System Diagram (D16B6 engine: RHD)
!7(
;()
916(< 11-B-87
)'$ 676
Fuel-injected System Connectors (D16B6 engine: RHD)
!7;()
916(< 11-B-88
)'' 680
D1636 Engine
)5"5%! 11-C-1

Special Tools
!4! 11-C-2
684
Component Locations

Index
/ 11-C-3
+ 685
System Description
(
Vacuum Connections
: 11 C-7
$ 689
!! 11-C-9
5 691
Troubleshooting
4 !
4 !
11-C-11
693
4 !
. 11-C-14
* 696
Engine Control Module Terminal

!, !4!
Arrangement
%
11-C-16
698
(
4 ! 11-C-18
' 702
PGM-FI System
'+#
System Description
( 11-C-19
5 703
631 !3 11-A-33
%++ 449
4 !
!3
Engine Control Module

!, ! 11-C-21
705
68/
11-C-26
710
,!%! 11-C-28
' 712
CKP Sensor
> 11-C-31
+ 715

!4 11-C-33
++ 717
4! 11-C-35
+ 719
#%4 11-C-38
+' 722
:! 11-C-40
*0 724
68/
6 11-C-42
* 726
68/
11 C-45
* 729
Idle Control System

#
4 !
. 11-C-46
* 730
System Description
( 11-C-47
*$ 731
4 !
!3
!%!:!& 11-C-48
*' 732
%

! 11-C-5O
0 734
Alternator FR
%! Signal
1
! 11-C-52
736
Brake Switch Signal
)#3
! 11-C-54
* 738
3
3
! 11-C-55
739
! 11-C-57
$ 741
Fuel Supply System
+##
4 !
. 11-C-58
' 742
Fuel Lines
! 11-C-59
5 743
!4 =D #
11-A-97
%5$ 513
System Description
( 11-C-61
745
Fuel Pressure
! 11-C-61
745
Fuel Injectors
!7 11-C-62
746
! 1
! 11-C-66
750
Fuel
! Filter
! 11-A-105
%0 521
Fuel Pump
! 11-A-106
%0 522
Fuel Gauge
!.
11-A-107
%0$ 523
!.

? 11-A-108
%0' 524
Low Fuel
!
11-A-109
%05 525
Inertia Switch
3 11-C-67
$ 751
PGM-F!E,1!
., Main Relay 11-C-68
' 752
FueITank
!4# 11-A-115
% 531
Intake Air System
6 #
4 !
. 11-C-72
$ 756
System Description
( 11-C-73
$+ 757
Air Cleaner
%! 11-A-119
%5 535
Throttle Cable
4!! 11-C-74
$* 758
Throttle Body
4!) 11-C-75
$ 759
%

#
4 !
. 11-C-77
$$ 761
System Description
( 11-C-78
$' 762
Tailpipe Emission
4! 11-C-78
$' 762
42!& 11-C-78
$' 762
&#:! 11-C-79
$5 763
&& ! 11-C-8O
'0 764
Diagrams
(

Fuel-injected System Diagram
!7(

;(F1882,
')A F1883,
')+A F2086, H22A7 engine: LHD)
0)A6%$
96(< 11-C-83
'+ 767
Fuel-injected System Connectors
!7
;(F1882,
')A F1883,
')+A F2086, H22A7 engine: LHD)
0)A6%$
96(< 11-C-84
'* 771
771
Fuel-injected System Diagram
!7(

;(F1882,
')A F1883,
')+A F2086, H22A7 engine: RHD)
0)A6%$
916(< 11-C-85
' 775
Fuel-injected System Connectors
!7
;(F1882,
')A F1883,
')+A F2086, H22A7 engine: RHD)
0)A6%$
916(< 11-C-86
' 779

Transaxle Index
Clutch
12-1

Special Tools
!4! 12-2
783
Illustrated Index
!! / 12-3
+ 784
Clutch Pedal
! !
Adjustment
%7 12-4
* 785
Clutch Master Cylinder
! ,!
Overhaul/Inspection
8& != 12-5
786
Replacement
1! 12-6
787
(!=1! 12-8
' 789
Slave Cylinder
!&!
Overhaul/Inspection
8& != 12-9
5 790
Replacement
1! 12-10
0 791
Pressure Plate
!
Removal/Installation
1&!=!! 12-11
792
Clutch Disc
! (
Removal/Inspection
1&!= 12-12
793
Flywheel
!3!
Inspection/Replacement
=1! 12-13
+ 794
Bearing Replacement
)
1! 12-14
* 795
! (A !
Clutch Disc, Pressure Plate
Installation
!! 12-15
796
Release Bearing
1!)
Replacement
1! 12-16
797
Manual Transmission

13-1

DH Model Manual Transmission
).

(D1636 engine model)
/)5"5!
0 13-1

Special Tools
!4! 13-2
+ 799
Maintenance
,
Transmission Fluid
4 ! 1 3-3
++ 800
Back-up Light Switch
)#
3
Test/Replacement
4=1! 13-3
++ 800
Troubleshooting
4 !
13-4
+* 801
Gearshift Mechanism
.,
Overhaul
8& ! 13-5
+ 802
Transmission Assembly
4%!
Removal
1&! 13-6
+ 803
Index
/ 13-12
+ 809
Transmission Housing
46
Removal
1&! 13-14
+* 811
Reverse Shift Holder
1&6!
! 13-15
+ 812
Reverse Idler Gear
1&!.
Removal
1&! 13-16
+ 813
,A A #
Mainshaft, Countershaft, Shift Fork
Disassembly
(! 13-16
+ 813
Mainshaft Assembly
,%!
Index
/ 13-17
+$ 814
! 13-18
+' 815
Disassembly
(! 13-19
+5 816
Inspecflon
13-20
+0 817
Reassembly
1! 13-21
+ 818
Countershaft Assembly
%!
Index
/ 13-22
+ 819
! 13-23
++ 820
Disassembly
(! 13-24
+* 821
821
Inspecflon
13-25
+ 822
Reassembly
1! 13-25
+ 822
Shift Fork
Assembly
#%!
Index
/ 13-27
+$ 824
! 13-28
+' 825
MBS Shift Piece Inspection
,) 13-29
+5 826
Synchro Sleeve, Synchro Hub
!&A6
Inspection/Installation
=!! 13-29
+5 826
Synchro Ring, Gear
1
A.
Inspecflon
13-30
++0 827
Shift Rod
1
Removal
1&! 13-31
++ 828
Differential
(!
Index
/ 13-32
++ 829
Backlash Inspection
)#! 13-32
++ 829
Bearing Replacement
)
1! 13-33
+++ 830
Final Driven Gear Replacement
!(&.1! 13-33
+++ 830
Thrust Shim Adjustment
4 %7 13-34
++* 831
831
Clutch Housing Bearing
! 6
)
Replacement
1! 13-36
++ 833
Mainshaft Thrust Clearance
,4 !
Adjustment
%7 13-38
++' 835
Transmission
4
Reassembly
1! 13-41
+* 838
Oil Seals
8!! 13-45
+* 842
4%!
Installation
!! 13-46
+* 843
U2J4/U2G5/UZQ7 Model Manual Transmission
;<2;32;=7

(F1832, F1833, F20B6, H22A7 engine models) 13-53
/+8":+8":+$"5:.7!
03
Special Tools
!4! 13-54
+* 849
Description
(
Limited Slip Differential (LSD)
!(!;(< 13-55
+ 850
Maintenance
,
Transmission Fluid
4 ! 13-57
+$ 852
Back-up Light Switch
)#
3
Test/Replacement
4=1! 13-57
+$ 852
Limited Slip Differential (LSD)
!(!;(<
Operational Check
8!# 13-58
+' 853
Rotating Torque Check
1
4F # 13-58
+' 853
4%!
Removal
1&! 13-59
+5 854
Index
/ 13-66
+ 861
861
Shift Arm Assembly
%%!
Index
/ 13-68
+' 863
(!=1! 13-69
+5 864
4%!
Disassembly
(! 13-71
+$ 866
Reverse Shift Fork
1& #
! 13-73
+$+ 868
Mainshaft Assembly
,%!
Index
/ 13-74
+$* 869
! 13-76
+$ 871
Disassembly
(! 13-78
+$' 873
Inspecfion
13-79
+$5 874
Reassembly
1! 13-80
+'0 875
%!?"*A?.4
Countershaft Assembly-U2J4, U2G5 Transmissions
Index
/ 13-81
+' 876
! 13-82
+' 877
Disassembly
(! 13-84
+'* 879
Inspecfion
13-85
+' 880
Reassembly
1! 13-85
+' 880
Countershaft Assembly-U207 Transmission
%!?D$4
Index
/ 13-87
+'$ 882
! 13-88
+'' 883
Disassembly
(! 13-90
+50 885
Inspecfion
13-91
+5 886
Reassembly
1! 13-92
+5 887
Shift Fork
Assembly
#%!
(!=1! 13-95
+5 890
! 13-96
+5 891
Synchro Sleeve, Synchro Hub
!&A6
Inspecfion
13-97
+5$ 892
Installation
!! 13-97
+5$ 892
Synchro Ring, Gear
1
A.
Inspecfion
13-98
+5' 893
Differential
(!
Index
/ 13-99
+55 894
)#!?"*A?.4
Backlash Inspection-U2J4, U2G5 Transmission 13-100
+00 895
!(&.1! 13-100
+00 895
Tapered Roller Bearing Replacement
41!!)
1! 13-101
+0 896
Oil Seal Replacement
8!!1! 13-101
+0 896
Bearing Outer Race Replacement
)
8 11! 13-102
+0 897
Tapered Roller Bearing Preload Adjustment
41!!)
!%7 13-103
+0+ 898
Mainshaft Bearing/Oil Seal
,)
=8!!
Replacement
1! 13-106
+0 901
Countershaft Bearing
)
Replacement
1! 13-107
+0$ 902
Mainshaft Thrust Bearing
,4 )
Adjustment
%7 13-108
+0' 903
4%!
Reassembly
1! 13-111
+ 906
Installation
!! 13-115
+ 910
Gearshift Mechanism
.,
Overhaul
8& ! 13-123
++ 918

Automatic Transmission 14-1

Special Tools
!4! 14-2
* 919
Description
( 14-3
*+ 920
Clutches
! 14-6
* 923
Power Flow
3 !3 14-8
*' 925
Electronic Control System
!! 14-15
* 932
Hydraulic Control
6 !! 14-20
*0 937
Hydraulic Flow
6 ! !3 14-24
** 941
Lock-up System
# 14-39
*+5 956
Shift Lever/Manual Mode Mechanism
&=, !,, 14-46
** 964
Shift Lever/Reverse Lock Mechanism
&=1&#, 14-47
**$ 965
Electrical System
% #
Component Locations
14-48
**' 966
PCM Circuit Diagram (A/T Control System)
, (
;%=4!< 14-50
*0 968
PCM Terminal Voltage/Measuring Conditions
,4!:!
=,

A./T Control System
%-=4! 14-52
* 970
4 !
14-56
* 974
Symptom-to-Component Chart

Electrical System
!! 14-59
*5 977
Electrical Troubleshooting
!!4 !
4 !
!3 14-62
* 980
Lock-up Control Solenoid Valve/
# !!:!&=
Shift Control Solenoid Valve A Assembly
!!:!&%%!
Test
4 14-111
* 1029
Replacement
1! 14-111
* 1029
Shift Control Solenoid Valve B/C
!!:!&)=
Test
4 14-112
* 1030
Replacement
1! 14-112
* 1030
A/T Clutch Pressure Control Solenoid
%=4! !!
Valve A/B Assembly
:!&%=)%!
Test
4 14-113
*+ 1031
Replacement
1! 14-114
** 1032
Mainshaft/Countershaft Speed Sensors
,=
Replacement
1! 14-114
** 1032
2nd Clutch Pressure Switch
! 3
Replacement
1! 14-115
* 1033
3rd Clutch Pressure Switch
+! 3
Replacement
1! 14-115
* 1033
Mode Switch
,3
Replacement
1! 14-116
* 1034
PCM (KE Model)
,;> ,!<
Replacement
1! 14-116
* 1034
A/T Gear Position Switch
%=4.3
Test
4 14-117
*$ 1035
Replacement
1! 14-118
*' 1036
A/T Gear Position Indicator
%=4.
Indicator Input Test
4 14-120
*0 1038
Interlock System
!#
!? 4 14-122
* 1040
1 040
Key Interlock Solenoid Test
>!#!4 14-124
** 1042
1 042
Shift Lock Solenoid Test
#!4 14-124
** 1042
1 042
Shift Lock Solenoid Replacement
#!1! 14-125
* 1043
1 043
Hydraulic System
.# #
Symptom to Component Chart

Hydraulic System
6 ! 14-126
* 1044
1 044
Road Test
14 14-130
*+0 1048
1 048
Stall Speed
!!
Test
4 14-132
*+ 1050
Fluid Level
! &!
Checking
#
14-133
*++ 1051
Changing

14-133
*++ 1051
Pressure Testing
4
14-134
*+* 1052
Transmission

Removal
1&! 14-136
*+ 1054
Illustrated Index
!! /
Right Side Cover
1
& 14-142
** 1059
TTansnfis§0n|4ou§ng
46
14-144
*** 1061
Torque Converter Housing/Valve Body
4F &6
=:!&) 14-146
** 1063
Right Side Cover
1
&
Removm
1&! 14-148
**' 1065
1065
WTansnflsflonlfioufing
46
Removm
1&! 14-150
*0 1067
1067
Torque Converter Housing/Valve Body
4F &6
=:!&)
Removm
1&! 14-152
* 1069
1069
Valve Body
:!&)
Repau
1 14-154
** 1071
1071
VaNe
:!&
Assembly
%! 14-155
* 1072
1072
Valve Caps
:!&
Descnpfion
( 14-156
* 1073
1073
ATFPump
%4
Inspecflon
14-157
*$ 1074
1074
Main Valve Body
,:!&)
Disassembly/Inspection/Reassembly
(!==1! 14-158
*' 1075
1075
Regulator Valve Body
1
!:!&)
(!==1! 14-160
*0 1077
1077
Accumulator Body
% !)
(!==1! 14-161
* 1078
1078
Servo Body
&)
(!==1! 14-162
* 1079
1079
Mamshafi
,
(!==1! 14-163
*+ 1080
1080
Inspecflon
14-164
** 1081
1081
Sealing Rings
!
1

Repbcement
1! 14-165
* 1082
1082
Countershaft

(!==1! 14-166
* 1083
1083
Disassembly
(! 14-167
*$ 1084
1084
Reassembly
1! 14-167
*$ 1084
1084
Beannglfiub
)
6
Bearing Replacement
)
1! 14-168
*' 1085
1085
Secondary Shaft

Disassembly/lnspection/Reassembly
(!==1! 14-169
*5 1086
1086
Inspecfion
14-170
*$0 1087
1087
Secondary Shaft Idler Gear
!.
Bearing Replacement
)
1! 14-172
*$ 1089
1089
Clutch
!
Illustrated Index
!! / 14-173
*$+ 1090
1090
Disassembly
(! 14-175
*$ 1092
1092
Reassembly
1! 14-177
*$$ 1094
1094
Differential
(!
Components
14-181
*' 1098
1098
BacMashlnspecfion
)#! 14-181
*' 1098
1098
Bearing Replacement
)
1! 14-182
*' 1099
1099
Differential Carrier Replacement
(!1! 14-182
*' 1099
1099
Tapered RoHerBeanng
41!!)
Preload Adjustment
!%7 14-183
*'+ 1100
1100
Tapered Roller Bearing Outer Race
41!!)
8 1
Repbcement
1! 14-186
*' 1103
1103
Oil Seals Replacement
8!!1! 14-187
*'$ 1104
1104
Torque Converter Housing Bearings
4F &6
)

Mainshaft Bearing/Oil Seal Replacement
,)
=8!!1! 14-188
*'' 1105
Countershaft Bearing Replacement
)
1! 14-189
*'5 1106
1106
Secondary Shaft Bearing Replacement
)
1! 14-189
*'5 1106
Transmission Housing Bearings
46
)

1&!=!! 14-190
*50 1107
Parking Brake Stop
#
)#
Inspection/Adjustment
=%7 14-191
*5 1108
Transmission
4
Reassembly
1! 14-192
*5 1109
Torque Converter/Drive Plate
4F &=(&! 14-203
*0+ 1120
Transmission
4
Installation
!! 14-204
*0* 1121
ATF !6
%4 Cooler Hoses
Connection
14-209
*05 1126
Shift Lever
&
Removal
1&! 14-210
*0 1127
Disassembly/Reassembly-LHD
(!=1!6( 14-211
* 1128
Disassembly/Reassembly-RHD
(!=1!16( 14-212
* 1129
Shift Lock/Reverse Lock Mechanism
#=1&#, 14-213
*+ 1130
Installation
!! 14-213
*+ 1130
Shift Cable
!
Replacement
1! 14-215
* 1132
Adjustment
%7 14-218
*' 1135
Differential
) 15-1
3
Driveshafts
) - 16-1
5
Special Tools
!4! 16-2
1137
Driveshafts
(&
Inspecfion
16-3
+ 1138
Removal
1&! 16-3
+ 1138
Disassembly
(! 16-6
1141
Reassembly
1! 16-9
5 1144
Installation
!! 16-17
$ 1152
Intermediate Shaft

Removal
1&! 16-19
5 1154
Disassembly
(! 16-20
0 1155
Reassembly
1! 16-21
1156
Installation
!! 16-23
+ 1158
!
Steering Index
Steering
! 17-1
7
Special Tools
!4! 17-2
$ 1159
Component Locations

Index
/ 17-3
$+ 1160
Troubleshooting
4 !
General Troubleshooting
.!4 !
17-4
$* 1161
Noise and Vibration
: 17-8
$' 1165
Fluid Leaks
! # 17-10
$0 1167
Inspection and Adjustment
%7
Steering Operation

8 17-12
$ 1169
Power Assist Check with Vehicle Parked
3%#3:!# 17-12
$ 1169
Steering Linkage and Gearbox

#
./ 17-13
$+ 1170
Pump Belt
)! 17-14
$* 1171
Rack Guide Adjustment
1#. %7 17-16
$ 1173
Fluid Replacement
! 1! 17-17
$$ 1174
Pump Pressure Check
# 17-18
$' 1175
*Steering Wheel
G
2!
Removal
1&! 17-19
$5 1176
(!=1! 17-20
$0 1177
Installation
!! 17-21
$ 1178
*Steering Column
G
!
1&!=!! 17-22
$ 1179
Inspection
17-24
$* 1181
1181
Steering Lock Replacement

#1! 17-25
$ 1182
3
6A
Power Steering Hoses, Lines
Fluid Leakage Inspection
! #
17-26
$ 1183
Replacement
1! 17-27
$$ 1184
Power Steering Pump
3

Replacement
1! 17-28
$' 1185
Disassembly
(! 17-30
$+0 1187
Inspection
17-33
$++ 1190
Reassembly
1! 17-35
$+ 1192
Power Steering Gearbox
3
./
Removal
1&! 17-38
$+' 1195
Installation
!! 17-40
$*0 1197
Ball Joint Boot Replacement
)!!")1! 17-43
$*+ 1200
Wiring Diagrams
1 !) !
;''&%%,&%,>%/0
This
Accord Sedan SRS includes a driver’s airbag located in the

-? *!
steering wheel
!( hub and a passenger’s airbag located in the
*!? *!

dashboard
above the
*
*
- glove box. Some types include seat belt tensioners located in the
!
-*
@
# *

front seat belt retractors and some

*

types include airbags located in the
# *!
front seat-backs.

*6@

#
#- SRS is included in this
Shop
Manual.

@

6( an asterisk (*) on the contents page include, or are located near, SRS components. Servicing,

! :

:

@- !:
disassembling or replacing these
* !
! items will require special precautions and tools, and should
( B

:
therefore be done by an

*
*#
authorized
Honda dealer.

C.
@
¢
A WARNING
To avoid rendering the

-
! SRS inoperative, which

-:( could lead to personal injury or death

D#
in the event
-
of a severe frontal collision, all SRS service work must be performed by an authorized
-

:- (
6*
*# Honda dealer.

C.
@
¢ Improper service procedures, including incorrect removal and installation of the

-
: !

-

SRS, could lead
:

to personal injury caused by unintentional deployment of the

D#*#

#
airbags, side airbags and seat belt
*!: *!*
tensioners.

@
¢ SRS electrical wiring harnesses
( ! are indicated with #
(

!@

( yellow colour coding. Related components are
located in the

steering column, front console, dashboard,
!
:

: dashboard
*
: lower panel, and in the
*

(: dashboard
*

above the
*
- glove box, front seats and around the
!
-*
:

floor. Do not use electrical test equipment on these

@)

B

circuits.
@

Suspension Index
Suspension

18-1
8
Special Tools
!4! 18-2
' 1201
Component Locations

Index
/ 18-3
'+ 1202
Wheel Alignment
2!%!

Service Information
& 18-4
'* 1203
1203
Camber
18-5
' 1204
1204
Caster
18-5
' 1204
1204
Front Toe Inspection/Adjustment
4=%7 18-6
' 1205
1205
Rear Toe Inspection/Adjustment
14=%7 18-7
'$ 1206
1206
Turning Angle Inspection
4
%
! 18-7
'$ 1206
1206
Wheel/Hub Inspection
2!=6
Bearing End Play
)
! 18-8
'' 1207
1207
Wheel Runout
2!1 18-8
'' 1207
1207
Front Suspension

Suspension/Arms
=%
Removal/Inspection
1&!= 18-9
'5 1208
Installation
!! 18-10
'0 1209
1209
Knuckle/Hub Replacement
> #!=6 1! 18-11
' 1210
1210
Ball Joint Boot Replacement
)!!")1! 18-16
' 1215
1215
Front Damper
(
Removal
1&! 18-17
'$ 1216
Disassembly/Inspection
(!= 18-17
'$ 1216
1216
Reassembly
1! 18-18
'' 1217
1217
Installation
!! 18-19
'5 1218
1218
Rear Suspension
1
Suspension Arms
%
Removal/Inspection
1&!= 18-20
'0 1219
1219
Installation
!! 18-21
' 1220
Hub Bearing Unit Replacement
6 )
?1! 18-22
' 1221
1221
Knuckle/Hub Replacement
> #!=6 1! 18-24
'* 1223
Rear Damper
1(
Removal
1&! 18-25
' 1224
1224
Disassembly/Inspection
(!= 18-26
' 1225
1225
Reassembly
1! 18-26
' 1225
Installation
!! 18-27
'$ 1226
Damper Disposal
((! 18-28
'' 1227
Wiring Diagrams
1 !) !
Brakes Index
"6
Conventional Brakes

-
"6 19-A-1
9
Special Tools
!4! 19-A-2
5% 1228
1228
Component Locations Index
/ 19-A-3
5%+ 1229
Inspection and Adjustment
%7
Brake System Rubber Parts and Brake Booster
)#1 )#) 19-A-4
5%* 1230
Brake Pedal
)#! 19-A-5
5% 1231
1231
Parking Brake
#
)# 19-A-6
5% 1232
Bleeding
)!
19-A-7
5%$ 1233
Brake System Indicator Circuit Diagram
)# (
19-A-8
5%' 1234
Parking Brake Switch Test
#
)#34 19-A-9
5%5 1235
Brake Fluid
)# Level Switch Test
! &!34 19-A-9
5%5 1235
Front Brake Pads
)#
Inspection and Replacement
1! 19-A-1O 1236
5%0
Front Brake Disc
)#(
Disc Runout Inspection
(1 19-A-14 1240
5%* 1240
Disc Thickness and Parallelism Inspection
(4#!!! 19-A-14 1240
5%*
Front Brake Calliper
)#!!
(!=1! 19-A-15 1241
5% 1241
Master Cylinder
,!
1&!=!! 19-A-18
5%' 1244
1244
Disassembly
(! 19-A-19
5%5 1245
Reassembly
1! 19-A-20
5%0 1246
1246
Pushrod Clearance Adjustment
!%7 19-A-22
5% 1248
1248
Brake Booster
)#)
Brake Booster Inspection
)#) 1 9-A-23 1249
5%+
1&!=!! 1 9-A-25 1251
5% 1251
Rear Brake Pads
1)#
1! 1 9-A—26
5% 1252
1252
Rear Brake Disc
1)#(
Disc Runout Inspection
(1 1 9-A-28
5%' 1254
1254
Disc Thickness and Parallelism Inspection
(4#!!! 1 9-A-28
5%' 1254
1254
Rear Brake Calliper
1)#!!
(!=1! 19-A—29
5%5 1255
1255
Rear Drum Brake
1( )#
Inspecflon
19-A-31
5%+ 1257
1257
Brake Shoes Replacement
)#1! 19-A-33
5%++ 1259
1259
Wheel Cylinder
2!!
Disassemn/Inspection
(!= 19-A-35
5%+ 1261
1261
Brake Hoses/Lines
)#6=
Inspection/Torque Specifications
=4F 5%+ 1262
1262
Brake Hose Replacement
)#61! 5%+$ 1263
1263
Parking Brake Cable
#
)#!
1! 5%+' 1264
1264
Anti-lock Brake System (ABS)

6"6#/"0 9"
Special Tools
!4! 5) 1266
1266
Component Locations
5) 1267
1267
Anti-lock Brake System (ABS)
%!#)#;%)<
Features/Construction
= 5)+ 1268
1268
Electronic Brake Distribution (EBD)
!)#( ; )(< 5) 1270
1270
Circuit Diagram
(
5) 1271
1271
Terminal Arrangement
4!%
5)' 1273
1273
Troubleshooting Precautions
4 !
5)5 1274
1274
Diagnostic Trouble Code (DTC)
(
4 !;(4<
DTC Indication
(4 5) 1276
1276
Troubleshooting Index
4 !
/ 5) 1277
1277
Troubleshooting
4 !
ABS Indicator Light Does Not G0 Off

%)
(.8 5)+ 1278
1278
ABS Indicator Light Does Not Come On
%)
(8 5)* 1279
1279
ABS Indicator Light Does Not G0 Off
%)
(.8 5) 1281
1281
DTC:11,12,13,14,15,16,17,18,21
(49AA+A*AAA$A'A 5)' 1283
1283
DTC: 31, 32, 33, 34, 35, 36, 37, 38, 51, 61, 81
(49+A+A++A+*A+A+A+$A+'AAA' 5)0 1285
1285
DTC: 52, 53
(49A+ 5) 1287
1287
DTC: 54
(49* 5) 1288
Modulator Assembly
, !%!
1&!=!! 5)+ 1289
1289
Pulsers/Wheel Sensors
!=2!
Inspecflon
5)* 1290
1290
Wheel Sensor Replacement
2!1! 5)* 1290
1290
Body Index
"
#
Body
"
# $
Special Tools
!4! 0 1291
1291
Doors
)

Component Locations Index
/ 0+ 1292
1292
Front Door Panel Removal and Installation
(!1&!!! 0$ 1296
1296
Front Door Outer Handle Replacement
(8 6!1! 05 1298
1298
Front Door Latch Replacement
(1! 0+ 1302
1302
Front Door Glass and Regulator Replacement
(.!1
!1! 0* 1303
1303
Label Replacement
!1! 0 1304
1304
Rear Door Panel Removal and Installation
1(!1&!!! 0 1305
1305
Rear Door Outer Handle Replacement
1(8 6!1! 0' 1307
1307
Rear Door Latch Replacement
1(1! 00 1309
1309
Rear Door Glass, Quarter Glass and
1(.!AD .!
Regulator Replacement
1
!1! 0* 1313
1313
Front and Rear Door Channel Tape
1(!4
Replacement
1! 0* 1313
1313
Sticker Replacement
#1! 0+0 1319
1319
Front and Rear Door Glass Adjustment
1(.!%7 20-30
0+0 1319
Front and Rear Door Position Adjustment
1(%7 20-32
0+ 1321
Front and Rear Door Striker Adjustment
1(#%7 20-33
0++ 1322
Mirrors

Con1ponentLocafionlndeX
/ 20-34
0+* 1323
Power Mirror Replacement
3,1! 20-35
0+ 1324
torHoMerRepbcement
,6!1! 2036
0+ 1325
Rearview Mirror Replacement
1&3,1! 20-36
0+ 1325
(Mass

/ 20-37
0+$ 1326
Parts/Tools
=4! 20-38
0+' 1327
Windshield Replacement
2!1! 20-39
0+5 1328
LabelRepbcement
!1! 2045
0* 1334
Rear Window Replacement
1231! 20-46
0* 1335
Sticker Replacement
#1! 20-51
0 1340
Sunroof

/ 20-52
0 1341
SynufioniTroubbshoofingIndex
4 !
/ 20-53
0+ 1342
Glass Height Adjustment
.!6
%7 20-54
0* 1343
Wind Deflector Replacement
2(!1! 20-54
0* 1343
Glass Replacement
.!1! 20-55
0 1344
Drain Channel Replacement
(!1! 20-56
0 1345
Sunshade Replacement
1! 20-57
0$ 1346
Motor Replacement
,1! 20-58
0' 1347
Frame and Drain Tube Replacement
(4 1! 20-59
05 1348
Drain Channel Slider and Cable
(!!!
Assembly Replacement
%!1! 20-61
0 1350
Switch Plate Adjustment
3!%7 20-63
0+ 1352
Closing Force
!
and Opening Drag Check
8
(
# 20-64
0* 1353
A*

Interior Trim
/ 20-65
0 1354
Trim Removal and Installation
41&!!! 20-66
0 1355
Headliner Removal and Installation
6!1&!!! 20-70
0$0 1359
Carpet Removal and Installation
1&!!! 20-72
0$ 1361
Consom

Center Console Removal and Installation
!1&!!! 20-74
0$* 1363
A* .

; :

; 2
;
Heater Control Unit, Climate Control Unit/Audio Unit
Unit Removal and Installation
?1&!!! 20-75
0$ 1364
A*Dashboard
) *

Instrument Panel Removal and Installation
!1&!!! 20-77
0$$ 1366
Navigation Unit Removal and Installation
&
?1&!!! 20-78
0$' 1367
Driver’s Dashboard Lower Cover
(&B(3&
Removal and Installation
1&!!! 20-78
0$' 1367
Passenger’s Dashboard Lower Cover

B(3&
1&!!! 20-79
0$5 1368
Glove Box Removal and Installation
.!&)/1&!!! 20-79
0$5 1368
Passenger’s Side Air Vent Removal and Installation 0'0

B%:1&!!! 20-80 1369
Passengefs Dashboard Panel

B(!
1&!!! 20-80
0'0 1369
Side Defogger Trim Removal and Installation
(
41&!!! 20-81

0' 1370
Dashboard Removal and Installation
(1&!!! 20-82
0' 1371
Steering Hanger Beam Replacement

6
)1! 20-87
0'$ 1376
A*
Seats
/ 20-92
05 1380
Front Seat Removal and Installation
1&!!! 20-93
05+ 1381
1381
Front Seat Disassembly and Reassembly
(!1! 20-95
05 1383
1383
Front Seat Torsion Bar Replacement
4)1! 20-107
00$ 1395
Front Seat Harness and Cable Wiring Locations
6!2
20-108
00' 1396
Front Seat Linkage Disassembly and Reassembly
#
(!1! 20-109
005 1397
Front Seat Cover Replacement
&1! 20-110
00 1398
Lumbar Support Replacement
1! 20-115
0 1403
1403
Rear Seat Removal and Installation
11&!!! 20-116
0 1404
Rear Seat Armrest Replacement
1%1! 20-118
0' 1406
1406
Rear Seat Back Latch Replacement
1)#1! 20-118
0' 1406
Rear Seat Cover Replacement
1&1! 20-119
05 1407
Bumpers
"
Front Bumper Removal and Installation
) 1&!!! 20-125
0 1413
Front Air Spoiler Replacement
%!1! 20-126
0 1414
1414
Rear Bumper Removal and Installation
1) 1&!!! 20-127
0$ 1415
Rear Lower Skirt Replacement
13#1! 20-129
05 1417
Hood
.

Replacement
1! 20-130
0+0 1418
1418
Adjustment
%7 20-131
0+ 1419
Hood Insulator Replacement
6 !1! 20-132
0+ 1420
1420
Hood Seal Rubber and Hood Molding Replacement
6!1 6,!
1! 20-133
0++ 1421
1421
Front Grille Replacement
.!!1! 20-133
0++ 1421
1421
Front Grille Disassembly and Reassembly
.!!(!1! 20-134
0+* 1417
1417
Trunk Lid
6&
Replacement
1! 20-135
0+ 1423
Adjustment
%7 20-138
0+' 1426
Trunk Lid Torsion Bar Replacement
4 #4)1! 20-139
0+5 1427
Trunk Spoiler Replacement
4 #!1! 20-140
0*0 1428
License Plate Trim Replacement
!41! 20-140
0*0 1428
License Plate Trim Disassembly and Reassembly
!4(!1! 20-141
0* 1429
1429
Trunk Lid Weatherstrip Replacement
4 #21! 20-141
0* 1429
1429
Emblem Replacement
!1! 20-142
0* 1430
Moldings

!
Roof Molding Replacement
1,!
1! 20-143
0*+ 1431
1431
Door and Side Moldings Replacement
(,!
1! 20-144
0** 1432
Side Sill Panel
'
Replacement
1! 20-145
0* 1433
Fenderwell
+(
Inner Fender
Replacement
1! 20-146
0* 1434
1434
Fenderwell Trim Replacement
3!!41! 20-146
0* 1434
Fuel Pipe Protector Replacement
!1! 20-147
0*$ 1435
Rear Air Outlet Replacement
1%8 !1! 20-147
0*$ 1435
A*
Openers
/ 20-148
0*' 1436
Hood Opener Cable Replacement
68!1! 20-149
0*5 1437
1437
Trunk Lid Opener/Fuel
4 #8= Lid Opener
!8
Cable Replacement
!1! 20-150
00 1438
Hood Release Handle Replacement
61!6!1! 20-154
0* 1442
Hood Latch Replacement
61! 20-154
0* 1442
Trunk Lid/Fuel
4 #= Lid Opener Replacement
!81! 20-156
0 1444
Fuel Lid Latch Replacement
!1! 20-156
0 1444
Trunk Lid Latch Replacement
4 #1! 20-157
0$ 1445
Trunk Lid Lock Cylinder Replacement
4 ##!1! 20-158
0' 1446
1446
Sub-frame
*
Replacement
1! 20-160
00 1447
A* +
Frame Repair Chart 20-162
0 1449
Wiring Diagrams
1 !) !
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintence is required)
;''&%%,&%,>%/0/ B 0
This

-? *!
steering wheel
!( hub, and a passenger’s airbag located in the
*:!? *!

dashboard
above the
*
*
- glove box, and some types include seat belt tensioners located in the
!
-*
:
# *

front seat belt retractors, and

*
:
some types include side airbags located in the

# *!
front seat-backs.

*6@

#
Shop
Manual.

@

6( an asterisk (*) on the contents page include, or located near, SRS components. Servicing, disassembling

! :

:

@- !: * !
or replacing these
( B

:

*
*# Honda

C.

dealer.
@
9
A WARNING

-


D#
in the event
-
of severe frontal collision, all SRS service work must be performed by an authorized

-

:- (
6*
*# Honda dealer.

C.
@
9 Improper service procedures, including incorrect removal and installation of the

-
: !

-

SRS, could lead
:


D#*#

#
*!: *!*
tensioners.

@
9 SRS electrical wiring harnesses
(

@

( yellow color. Related components are located
in the
!
:

: dashboard
*
: lower panel, in the
*

(: dashboard
above the
*
*
-
iglove box, front seats and around the
!
-*
:


@)

B
circuits.
@
.E

!
Heater & Air Conditioninq

;''&%%,&%,>%/0
This Accord Sedan SRS includes a driver’s airbag located in the

-? *!
steering wheel
!( hub, and a passenger’s airbag located in
*:!? *!

the dashboard
above the
*
*
!
-*
:
# *

front seat belt

*

#
Shop
Manual.

@

6( an asterisk (*) on the contents page include, or are located near, SRS components. Servicing,

! :

:

@- !:
disassembling or replacing these
* !
( B

:
therefore be done by an

*
*#
authorized
Honda dealer.

C.
@
0
A WARNING

-


D#
in the event
-

-

:- (
6*
*# Honda dealer.

C.
@

-
: !

-

SRS, could lead
:


D#*#

#
*!: *!*
tensioners.

@
‘ SRS electrical wiring harnesses
(

@

in the
!
:

: dashboard
*
*

(: dashboard
above the
*
*
-
glove box, front seats and around the
!
-*
:


@)

B
circuits.
@
Heater
. 21 -1

/ 21-2
1453
1453
Circuit Diagram
(
21-3
+ 1454
1454
Troubleshooting
4 !
Symptom Chart
21-4
* 1455
Flowcharts
!3
Blower Motor Speed
)!3, 21-5
1456
1456
Blower Motor
)!3, 21-7
$ 1458
Recirculation Control Motor
1 !!, 21-10
0 1461
1461
Heater Control Panel Input/Output Signals
6!! =8
! 21-12
1463
Heater Fan
6 Switch
3
Test
4 21-13
+ 1464
Relay
1!
Test
4 21-13
+ 1464
1 !!,
Test
4 21-14
* 1465
Replacement
1! 21-14
* 1465
Heater Control Panel
6!!
Replacement
1! 21-15
1466
Overhaul
8& ! 21-15
1466
*Blower Unit
G)!3?
Replacement
1! 21-16
1467
1467
Overhaul
8& ! 21-17
$ 1468
*Heater Unit/Core
G6?=
Replacement
1! 21-18
' 1469
Temperature Control
4 !
Adjustment
%7 21-20
0 1471
Mode Control
,!
Adjustment
%7 21-21
1472
*: Read SRS precautions before working in this
AF
*
(
6 ! area

Air Conditioning

! 22-1

Special Tools
!4! 22-2
1473
/ 22-3
+ 1474
Description
( 22-5
1476
Circuit Diagram
(

D16B6 engine models
()
! 22-6
1477
KY models
>C! 22-7
$ 1478
Except D16B6 engine and KY models
/()
>C! 22-8
' 1473
Troubleshooting
4 !
Symptom Chart
22-9
5 1480
Flowcharts
!3
Radiator Fan
1 22-10
0 1481
1481
Condenser Fan
22-13
+ 1484
Radiator Fan
1 Switch
3 22-16
1487
Both Fans
) 22-17
$ 1488
Compressor
22-21
1492
A/C System
%= 22-25
1496
Radiator Fan
1 Control Module
!, !
Input Tests
4 22-29
5 1500
A/C Thermostat
%=4
Test
4 22-30
+0 1501
1501
Relays
1!
Test
4 22-30
+0 1501
A/C Service Tips and Precautions
%=&4 22-31
+ 1502
A/C System Torque Specifications
%=4F 22-32
+ 1503
A/C System Service
%=&
Pressure Test Chart
4 22-33
++ 1504
Performance Test
4 22-34
+* 1506
Evaporator
&
Replacement
1! 22-36
+ 1508
Overhaul
8& ! 22-38
+' 1510
A/C Filter
%= !
Replacement
1! 22-39
+5 1511
Compressor (DENSO)
;( 8<
Replacement
1! 22-40
*0 1512
Illustrated Index
!! / 22-42
* 1514
Clutch Inspection
! 22-43
*+ 1515
Clutch Overhaul
! 8& ! 22-44
** 1516
Relief Valve Replacement
1!:!&1! 22-45
* 1517
Compressor (SANDEN)
;%( <
Replacement
1! 22-46
* 1518
Illustrated Index
!! / 22-48
*' 1520
Clutch Inspection
! 22-49
*5 1521
Clutch Overhaul
! 8& ! 22-50
0 1522
Thermal Protector Replacement
4!1! 22-52
1524
Relief Valve Replacement
1!:!&1! 22-52
1524
A/C Compressor Belt
%=)!
Adjustment (D16B6 engine model)
%7 ;()
!< 22-53
+ 1525
1525
Adjustment (Except D16B6 engine model)
%7 ; /()
!< 22-54
* 1526
1526
Condenser

Replacement
1! 22-55
1527
A/C System Service
%=&
Discharge
(
22-56
1528
Evacuation
& 22—57
$ 1529
Charging

22-58
' 1530
1530
Leak Test
#4 22—59
5 1531
Automatic Climate Control

22-62
5
Component Locations

Index
/ 22-62
1532
Circuit Diagram
(
22-64
* 1534
Troubleshooting
4 !
System Chart
22-66
1536
Self-diagnosis Function
!
22-67
$ 1537
Flowchart
!3
ln-car Temperature Sensor
4 22-68
' 1538
Outside Air Temperature Sensor
8 %4 22-71
$ 1541
Sunlight Sensor
!
22-74
$* 1544
Evaporator Temperature Sensor
&4 22-76
$ 1546
Air Mix Control Motor
%,/!, 22-79
$5 1549
1549
Mode Control Motor
,!, 22-84
'* 1554
Blower Motor
)!3, 22-88
'' 1558
1558
1 !!, 22-92
5 1562
Climate Control Unit
!!? 22-94
5* 1564
A/C System
%= 22-96
5 1566
Blower Motor Delays With Warm Engine
)!3,(!22
22-98
5' 1568
Climate Control Unit Input/
!!? =
Output Signals
8
! 22-99
55 1569
ln-Car Temperature Sensor
4
Replacement
1! 22-100
00 1570
Test
4 22-100
00 1570
1570
8 %4
Replacement
1! 22-101
0 1571
1571
Test
4 22-101
0 1571
1571
Sunlight Sensor
!

Replacement
1! 22-102
0 1572
Test
4 22-102
0 1572
Evaporator Temperature Sensor
&4
Test
4 22-103
0+ 1573
1573
Power Transistor
34
Test
4 22-103
0+ 1573
Mode Control Motor
,!,
Test
4 22-104
0* 1574
Replacement
1! 22-104
0* 1574
Air Mix Control Motor
%,/!,
Test
4 22-105
0 1575
1575
Replacement
1! 22-105
0 1575
1575
Climate Control Unit
!!?
Replacement
1! 22-106
0 1576
Electrical Index
%
Wiring Diagrams
1 !) !
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If electrical maintence is required)
;''&%%,&%,>%/0/ B 0
This

-? *!
steering wheel
!( hub, and a passenger’s airbag located in the
*:!? *!

dashboard
above the
*
*
!
-*
:
# *

front seat belt retractors, and

*
:
some types include side airbags located in the

# *!
front seat-backs.

*6@

#
Shop
Manual.

@

6( an asterisk (*) on the contents page include, or located near, SRS components. Servicing, disassembling

! :

:

@- !: * !
or replacing these
( B

:

*
*# Honda

C.

dealer.
@
9
A WARNING

-


D#
in the event
-

-

:- (
6*
*# Honda dealer.

C.
@

-
: !

-

SRS, could lead
:


D#*#

#
*!: *!*
tensioners.

@
9 SRS electrical wiring harnesses
(

@

in the
!
:

: dashboard
*
*

(: dashboard
above the
*
*
-
glove box, front seats and around the
!
-*
:


@)

B
circuits.
@
Schematic
symbols
#*

BATTERY GROUND i FUSE CDIL. SOLENOID CIGARETTE IJG HTER
an
' Component grOImd
a
GrOundtermiIIal
1
_LJ_
@—
THEHMISTOR
0 +1
RESISTOR VARIABLE RESISTOR IGNITION SWITCH HEATER
%
T I
, é
MOTOR PUMP ICE—cu” BREAKER HORN OIOOE' SPEAKER, Buzzee '
Q11? i
TRANSISTOR lTrI SWITCH [In normal puaifionl LIGHT EMITTING
Normally DFIEII'I Normally closed DIODE ILEDI
swuch
JJ
switch
’-f.. M
I I
RELAY (In normal positlonl CUN DENSER CONNECTION ' CONNECTOR _ " NEED SIN—HW—
Normally Open relay ‘ Normally closed .elav Input | Dutpul
IT
_—.*>__.
“ID-— I
fire--
--"UUCF"I- Vl——+]—
Wire Color Codes
1

The following abbreviations are used to identify wire colors in the circuit schematics :
4!!3
& 3! 9
WHT
264 White
2 PNK
> Pink
#
YEL
C Yellow
C!!3 BRN
)1 Brown
)3
BLK
)> Black
)!# GRY
.1C Grey
.
BLU
)? Blue
)! PUR
?1 Purple
!
GRN
.1 Green
. LT BLU
4)? Light Blue

)!
RED
1 ( Red
1 LT GRN
4.1 Light Green

.
ORN
81 Orange
8

The wire insulation has one color or one color with another color stripe. The second color is the stripe.
43 !!!3!-4!-
WHT! BLK
NOTE : Different wires with the same color in the same system have been given number suffixes to distinguish them (for
84 9(33!&
& /
;
example, YEL1 and YEL2 are not the same).
/!AC C <-
&

Locations
23-A-1
Relay and Control Unit Locations
1!!?
Engine Compartment

23—A-2
+% 1577
1577
Dashboard
( 23-A-3
+%+ 1578
Rear and Roof
11 23-A-6
+% 1581
1581
Floor and Rear
!1 23-A-7
+%$ 1582
Wire Harness and Ground Locations
26.
Engine Compartment

23-A-8
+%' 1583
1583
Dashboard
( 23—A-12
+% 1587
Dashboard and Floor
( ! 23—A-15
+% 1590
Floor
! 23-A-16
+% 1591
1591
Rear
1 23-A-1 8
+%' 1593
Roof
1 23-A-19
+%5 1594
Door
( 23-A-20
+%0 1595
Power and Ground Distributions
'
(
) *
23-B-1
"
Battery
)
Test
4 23-B-2
+) 1597
1597
Relays
1!
Power Relay Test
31!4 23-B-3
+)+ 1598
Ignition Switch

3
Test
4 23-B-6
+) 1601
1601
Electrical Switch Replacement
!!31! 23-B-6
+) 1604
1604
Under-dash Fuse/Relay
? Box
=1!)/
1&!=!! 23-B-7
+)$ 1602
Fuses

Under-hood Fuse/Relay
? Box
=1!)/ 23-B-8
+)' 1603
Driver's Under-dash Fuse/Relay
(&@? Box
=1!)/ 23-B-10
+)0 1605
1605
Passenger’s Under-dash Fuse/Relay

@? Box
=1!)/ 23-B-12
+) 1607
Power Distribution
3(
Circuit Identification (LHD Type)
;6(4< 23-B-14
+)* 1609
(RHD Type)
;16(4< 23—B-23
+)+ 1618
Ground Distribution
. (
Circuit Identification
23-B-32
+)+ 1627
(LHD Type)
;6(4< 23-B-33
+)++ 1628
(RHD Type)
;16(4< 23—B-41
+)* 1636
Gauges
! 23-C-1

Special Tools
!4! 23-C-2
+ 1644
1644
Gauge
.

/ 23-C-3
++ 1645
Gauge/Indicator/Terminal Location
.
==4!
Index
/ 23-C-4
+* 1646
1646
Bulb Locations
) ! 23-C-5
+ 1647
Circuit Diagram
(
23-C-6
+ 1648
1648
Replacement
1! 23-C-11
+ 1653
1653
Outside Air Temperature Indicator
8 %4 23-C-11
+ 1653
1653
Vehicle Speed Sensor Circuit
:!
Troubleshooting (A/T)
4 !
;%=4< 23-C-12
+ 1654
1654
Vehicle Speed Sensor Circuit
:!
Troubleshooting (M/T)
4 !
;,=4< 23-C-14
+* 1656
Vehicle Speed Sensor (VSS) (M/T)
:!;:<;,=4<
Replacement
1! 23-C-16
+ 1658
1658
Vehicle Speed Alarm System (KY model)
:!%!;>C!<
Vehicle Speed Alarm Unit Test
:!%!?4 23-C-17
+$ 1659
8 %4
Test
4 23c48
+' 1660
Lighting
& ! System
!# 2304
)
/ 2302
+( 1661
Circuit Diagram
(
2304
+(* 1663
1663
Combination Light Switch

3
Test/Replacement
4=1! 23-D-7
+($ 1666
1666
Headlights
6!

Adjustment
%7 23-D-9
+(5 1668
HID Bulb Removal
6() !1&! 23-D-1O
+(0 1669
1669
HID Lamp System Troubleshooting
6(4 !
23-D-12
+( 1671
1671
Replacement
1! 23-D-14
+(* 1673
1673
Headlights Adjuster
6!
%7
/ 23-D-15
+( 1674
1674
Description
( 23-D-16
+( 1675
1675
Circuit Diagram
(
23-D-17
+($ 1676
1676
Control Unit Input Test (With HID Lamp)
!? 4;26(< 23-D-19
+(5 1678
1678
Headlights Adjuster Levelling Motor
6!
%7 &!!
,
Input Test
4 23-D-21
+( 1680
Headlights Adjuster Levelling
6!
%7 &!!
Sensor Troubleshooting
4 !
(With HID Lamp)

;26(< 23022
+( 1681
1681
Headlights Adjuster Unit Input Test
6!
%7 ? 4
(Without HID Lamp)
;2 6(< 23024
+(* 1683
1683
Headlights Adjuster Levelling
6!
%7 &!!
Sensor Replacement (With HID Lamp)

1!;26(< 23025
+( 1684
Switch Test/Replacement
34=1!
(Without HID Lamp)
;2 6(< 23025
+( 1684
1684
Front
Fog Lights

Circuit Diagram
(
23026
+( 1685
Replacement
1! 23027
+($ 1686
1686
Switch Test
34 23027
+($ 1686
1686
Rear Fog
1 Light

Circuit Diagram
(
23028
+(' 1687
1687
Switch Test
34 23028
+(' 1687
!? 4 23029
+(5 1688
1688
License Plate Lights
!

Replacement
1! 23-D-30
+(+0 1689
1689
Brake Lights
)#

Circuit Diagram
(
23-D-30
+(+0 1689
High Mount Brake Light
6
, )#

Replacement
1! 23-D-31
+(+ 1690
Back-up Lights
)#

Circuit Diagram
(
23-D-32
+(+ 1691
Side Turn Signal Lights
4
!

Replacement
1! 23-D-33
+(++ 1692
Taillights
4!!

Replacement
1! 23-D-33
+(++ 1692
Turn Signal/Hazard Flasher
4
!=6H System
!
/ 23-D-34
+(+* 1693
Circuit Diagram
(
23-D-35
+(+ 1694
Turn Signal/Hazard Relay Input Test
4
!=6H1! 4 23-D-36
+(+ 1695
Hazard Warning Switch Test
6H2
34 23-D-37
+(+$ 1696
Interior Lights

/ 23-D-38
+(+' 1697
Circuit Diagram
(
23-D-39
+(+5 1698
Front Ceiling Light Test
!

4 23-D-40
+(*0 1699
Rear Ceiling Light Test
1!

4 23-D-41
+(* 1700
Glove Box Light Replacement
.!&)/
1! 23-D-41
+(* 1700
Trunk Light Test
4 #
4 23-D-42
+(* 1701
Trunk Latch Switch Test
4 #34
(Without Keyless Entry/Security Alarm System)
;2 >! = %!< 23-D-42
+(* 1701
Entry Light Control System

!
/ +(*+ 1702
Circuit Diagram
(
+(** 1703
!? 4 +(* 1705
Controls

%
Special Tools
!4! + 1708
Multiplex Control System
, !!/!
/ + + 1709
Circuit Diagram
(
+ * 1710
System Functions
+ 1711
Multiplex Communication System
, !!/ + 1711
4 !
. + 1712
Power and Ground Test
3. 4 + $ 1713
1713
!
(Mode 1)
;,< + 0 1716
Wake-up Function
2# Test
4 + 1717
Confirming the Function

+ 1718
Faulty Communication Line Symptoms
! + 1718
!
(Mode 2)
;,< + + 1719
1719
Power Door Locks
3(#
/ + * 1720
Circuit Diagram
(
+ 1722
Power Windows
323
/ + * 1730
Circuit Diagram
(
+ 1731
1731
Troubleshooting
4 !
+ 5 1735
!? 4 + +0 1736
Master Switch Replacement
,31! + ++ 1739
1739
Passenger's Window Switch Test/Replacement

@2334=1! + ++ 1739
Driver's Window Motor Test
(&@23,4 + + 1741
1741
Passenger's Window Motor Test

@23,4 + + 1742
1742
Lights-on, Key-in, Seat Belt Reminder System

A>A)!1
Circuit Diagram
(
+ +$ 1743
!? 4 + +' 1744
Ignition Key Light Test

>
4 + *0 1746
Ignition Key Switch Test

>34 + *0 1746
Instruments
+
Stereo Sound System

/ + 1747
Circuit Diagram (KY model)
(
;>C!< + + 1748
Circuit Diagram (With BOSE Sound System)
(
;2)8 < + * 1749
Audio Unit Removal
% ?1&! + 1751
Equalizer Unit Replacement
F !H?1! + ' 1753
Stereo Amplifier Replacement
%!1! + ' 1753
Audio Unit Connector Terminals Identification
% ?4! + 5 1754
Equalizer Unit Connector Terminals Identification
F !H?4! + 0 1756
Stereo Amplifier Connector Terminals Identification
%!4! + 1757
Power Antenna Motor Test/Replacement
3%,4=1! + 1758
Radio Remote Switch Test
1134 + + 1759
Speaker Replacement
#1! + * 1760
Clock (Without Automatic Climate Control)
!#;2 % !!<
Circuit Diagram
(
+ 1762
1 762
Replacement
1! + $ 1763
1 763
Cigarette Lighter

Circuit Diagram
(
+ ' 1764
1 764
Test/Replacement
4=1! + 5 1765
1765
Power Mirrors
3,
/ + 0 1766
Circuit Diagram
(
+ 1767
Function Test
4 + 1768
Power Mirror Switch Test
3,34 + + 1769
Power Mirror Actuator Test
3,% 4 + * 1770
Power Mirror Actuator Replacement
3,% 1! + 1771
Sunroof

/ + 1772
1 772
Circuit Diagram
(
+ $ 1773
1 773
34=1! + ' 1774
1 774
Motor Test
,4 + 5 1775
1 775
Limit Switch Test
34 + 5 1775
1 775
Rear Window Defogger
123(

/ + +0 1776
1 776
Circuit Diagram
(
+ + 1777
1 777
Function Test
4 + + 1778
1 778
Defogger Wire Repair
(
21 + + 1778

1 778
Driver's Power Seat
(&@3
/ + ++ 1779
1 779
Circuit Diagram (8-way Power Adjustable)
(
;'33%7 !< + +* 1780
1 780
34=1! + + 1781
1 781
Motor Test
,4 + + 1782
1 782
Wipers/Washers
2=2
/ + +$ 1783
Circuit Diagram
(
+ +' 1784
Circuit Diagram (With Headlight Washer)
(
;26!
2< + *0 1786
!? 4 + * 1787
Headlight Washer Control Unit Input Test
6!
2!? 4 + *+ 1789
Wiper/Washer Switch Test/Replacement
2=234=1! + ** 1790
Wiper Motor Test
2,4 + * 1791
Washer Motor Test
2,4 + * 1791
Windshield Wiper Motor Replacement
2!2,1! + * 1792
Washer Reservoir Replacement
21&1! + *$ 1793
Washer Tube Replacement
24 1! + *' 1794
Seat Heaters
6
/ + *5 1795
1 795
Circuit Diagram
(
+ 0 1796
1 796
Switch Test
34 + 1797
1797
Heater Test
64 + 1798
1 798
Relay Test
1!4 + 1798
1 798
Horns
6
/ + + 1799
1799
Circuit Diagram
(
+ * 1800
1800
Horn Test and Replacement
641! + * 1800
Switch Test
34 + 1801
1801
Security
#
Special Tools
!4! +. 1803
Immobilizer System
!H
/ +.+ 1804
Description
( +.* 1805
Circuit Diagram
(
+. 1806
1806
GOG)
Troubleshooting
4 !
+.$ 1808
Immobilizer Unit Replacement
!H?1! +.5 1810
Keyless Entry/Security Alarm System
>! = %!
/ +.0 1811
(DOC)
_\L\_\
000000
NNN
\INO
Circuit Diagram
(
+. 1813
1813
System Description
( +.$ 1818
Keyless Door Lock System
>!(#
Troubleshooting
4 !
+.' 1819
1819
CDCDCDCD
Nib—x—x
00000000
OOLOOO
NNNN
Keyless Receiver Unit Input Test

>!1&? 4 +.5 1820
!? 4 +.0 1821
1821
Transmitter Test
44 +. 1827
Keyless Transmitter Codes Input Procedure
>!4 23-G-27
+.$ 1828
1828
Super Locking Control Unit Input Test
#
!? 4 23-G-28
+.' 1829
Driver's Door Lock Knob Switch Test
(&@(#>34 23-G-30
+.+0 1831
Passenger's Door Lock Knob Switch Test

@(#>34 23-G-30
+.+0 1831
Door Key Cylinder Switch Test
(>!34 23-G-31
+.+ 1832
Trunk Key Cylinder Switch Test
4 #>!34 23-G-31
+.+ 1832
Trunk Latch Switch Test
4 #34 23-G-32
+.+ 1833
1833
Trunk Lock Actuator Test
4 ##% 4 23-G-32
+.+ 1833
1833
Security Horn Test
64 23-G-33
+.++ 1834
Hood Switch Test
634 23-G-33
+.++ 1834
N
Navigation System
,- !
# .
L
I
‘1"
Description
(
Overview
8&&3 +6 1835
1835
00000000000000000)
NNNNNNNNN
IIIIIIIIII
Navigation Function
&
+6+ 1836
1836
Circuit Diagram
(
+6' 1841
1841
Connector Locations
+60 1843
Terminal Arrangement
4!%
+6 1844
1844
Troubleshooting Precautions
4 !
+6* 1847
4 !
. +6$ 1850
Picture Diagnosis
(
+6' 1851
Troubleshooting
4 !
+6' 1861
1861
CD-ROM
(18,
Replacement
1! +6+ 1865
1865
Navigation Unit
&
?
1&!=!! +6++ 1866
1866
Display Unit/Audio Unit
(!?=% ?
1&!=!! +6+* 1867
1867
GPS Antenna
.%
1&!=!! +6+ 1868

Restraints Index
Seat Belts
" 24-1

/ 24-2
* 1869
Front Seat Belt Replacement
)!1! 24—3
*+ 1870
1870
Rear Seat Belt Replacement
1)!1! 24-6
* 1873
Inspection
24-8
*' 1875
Supplemental Restraint System (SRS)
#/0 24-11

Special Tools
!4! 24-12
* 1877
Component/Wiring Locations
=2

Index
/ 24-13
*+ 1878
Circuit Diagram
(
24-14
** 1879
Wiring Harness and Connectors
2
6 24-15
* 1880
Description
( 24-17
*$ 1882
Precautions/Procedures
=
General Procedures
.! 24-18
*' 1883
Airbag/Seat Belt Tensioner/Side Airbag
%
=)!4=%
Handling and Storage

6!

24-19
*5 1884
Backprobing Spring-Loaded Lock
)#

#
Connectors (Without waterproof type)
;2 3< 24-20
*0 1885
Seat with Side Airbag
3%
24-20
*0 1885
SRS Unit/Side Impact Sensor
1?=
Precautions
24-21
* 1886
Steering-related Precautions

! 24-21
* 1886
1886
Wiring Precautions
2
24-22
* 1887
1887
Precautions for Electrical Inspections
!! 24-22
* 1887
Spring-loaded Lock Connectors

!# 24-23
*+ 1888
1888
Disconnecting the Airbag Connectors,
(
%
A
Side Airbag Connectors and Seat
%

Belt Tensioner Connectors
)!4 24-24
** 1889
Troubleshooting
4 !
Self-diagnostic Precautions
!
24-26
* 1891
Reading the DTC
1
(4
(Diagnostic Trouble Code)
;(
4 !< 24-27
*$ 1892
Erasing the DTC Memory

(4, 24-29
*5 1894
1894
Troubleshooting Intermittent Failures
4 !
! 24-29
*5 1894
Diagnostic Trouble Code (DTC)
(
4 !;(4<
Chart
24-30
*+0 1895
Fuse Box and Connector Locations
)/ 24-33
*++ 1898
Flowcharts
!3 24-38
*+' 1903
Driver's Airbag
(&@%
Replacement
1! 24-73
*$+ 1938
Front Passenger's Airbag

@%
Replacement
1! 24-75
*$ 1940
Side Airbag
%
Replacement
1! 24-77
*$$ 1942
Seat Belt (With Seat Belt Tensioner)
)!;2)!4<
Replacement
1! 24-78
*$' 1943
Cable Reel
!1!
Replacement
1! 24-80
*'0 1945
SRS Unit
1?
Replacement
1! 24-83
*'+ 1948
Side Impact Sensor

Replacement
1! 24-84
*'* 1949
Scrapping

24-85
*' 1950
Wiring Diagrams
1 !) ! 1957
Wiring Diagrams
1 !) !
Air Conditioning
%
0 1957
Anti-lock Brake System
%!#)# $ 1661
Audio Unit
% ? 5 1965
1965
Battery‘l
) 1969
1969
Charging System

1973
Cigarette Lighter

5 1977
Clock
!# 1981
1981
Cruise Control
! 1985
ECM/PCM
,=, 1989
1989
ECM/PCM
,=, + 1993

! 1997
1997

! + 2001
Fan Controls
! ' 2005
Fan Controls
! 5 2009
Fan Controls
! 0 2013
Gauges
.
+ 2017
Gauges
.
* 2021
Headlights Adjuster
6!
%7 $ 2025
Headlight Washer
6!
2 2029
Horns
6 2033
Ignition Switch

3 2037 ?.
Ignition System

2041
2041
Immobilizer System
!H 2045
Immobilizer System
!H + 2049
Immobilizer System
!H * 2053
Immobilizer System
!H 2057
Indicators

ABS Indicator
%) + 2061
A/T Gear Position Indicator
%=4. * 2065
Cruise Indicator
+ 2069
Door Indicator
( + 2073
High Beam Indicator
6
) + 2077
Immobilizer Indicator
!H + 2081
2081
Low Engine Oil Pressure Indicator
3
8! + 2085
Low Fuel
3 Indicator
! * 2089
Malfunction Indicator Lamp (MIL)
,! ;,< + 2093
Seat Belt Reminder Indicator
)!1 + 2097
SRS Indicator
1 + 2101
Trunk Indicator
4 # + 2105
Turn Signal Indicator
4
! + 2109
Interlock System
!# 2113
>! = %! 2117
>! = %! + 2121
>! = %! * 2125
Lighting System

2129
Lighting System

2133
Lighting System

$ 2137
Lights Exterior

/
Back-up Lights
)#
' 2141
2141
Brake Lights
)#
' 2145
Front
Fog Light

$ 2149
OOVOUOWAOUOWCDUWOOCDUWN
Headlights
6!
2153
Headlights
6!
2157
High Mount Brake Light
6
, )#
' 2161
!
2165
!
2169
Parking Lights
#

2173 ,,2177
2177
Parking Lights
#

2181
Rear Fog
1 Light

+ 2185
Taillights
4!!
2189
Taillights
4!!
2193
Taillights
4!!
$ 2197
Turn Signal Lights
4
!
' 2201

A
Lights, Interior
Ceiling Light (Front)
!

; < $ 2205
Ceiling Light (Rear)
!

;1< $ 2209
Glove Box Light
.!&)/
$ 2213
Spotlights
!
$ 2217
Trunk Light
4 #
$ 2221
, !!/! 2225
, !!/! + 2229
, !!/! * 2233
Navigation System
&
2237
Power Door Locks
3(# 2241
Power Door Locks
3(# + 2245
Power Door Locks
3(# * 2249
Power Mirrors
3, 0 2253
Power Seats
3 2257
Power Windows
323 2261
Power Windows
323 + 2265
Power Windows
323 * 2269
Radiator Fan
1 Control Module
!, ! 5 2273
123(
' 2277
123(
5 2281
123(
0 2285
Seat Heaters
6 0 2289
Security Alarm System
%! 2293
%! + 2297
%! * 2301
Speed Alarm System (KY)
%!;>C< + 2305
Starting System

2309
Sunroof
2313
Supplementary Restraint System (SRS)
!1;1< 2317
Turn Signal/Hazard Flasher
4
!=6H System
! ' 2321
Vehicle Speed Sensor (VSS) (M/T)
:!;:<;,=4< * 2325
Wiper/Washer
2=2 2329
Chassis
and Enqine Numbers
%! ,* 1_2 Enqine Number/Transmission
%! ,*2

Vehicle
4 Identification Number (VIN)

,*/4,0
Number
,*
— Vehicle- Identification I'Iumbar [VIN] — — Engine Nu mt-ar
55.. I- Ln; '_. :-‘ I_I 3|; I_ I_I I_I_I]I_II

I I'gl' I'. 'n:
h‘-.—J' I_‘.'.L"J_1 r_‘l. Ia'=.-J-;~_- .51 IJ IIIIJIEU II'1IJI':
I'rpL-LI' 'u'd _
-‘.-| -| IL'X-ILFI. DI II I' |_.I‘i
HI '3 I III .|_' K
l'lllfl L'Ed
II
vs! Lh‘flJIl'l‘ '.-ni'.I.I.l..'. |.I:.|".I.v".
'L: z-J
I""'-'.I“.i' 1|_|I '

Lilac-[3| -l II.I.I|.I'.II-
. — Transmission Number
I'm. _ 0-}.-
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I :L‘Lll'f' flu-IL-
L' .I u'LIr. U “I...“ L.I"l.I2.-J'L".:Lh.1uq l'. I. H
IIIJIIJ "9.1:!
U : 1924': .u I IIJII-i I.1'-_.u'|.'
5 L1 irJ I'IIJ'IIZIPI .h“.-.n..-.I It! I-Ziti."‘..' wrun-
..|"J:'.u-'I.:‘.I'
“E ._1 I.-I ”LI'IISL‘I
%! ,*
Chassis and Enqine Numbers
Model/Applicable Area Code/VIN/Enqine
,!=%!!%=:=

1-3

=4
Number/Trgnsmission Number
O O| O O O VEHICLE
: 6 O O|
MODEL O| %%)
O ,8( APPLICABLE O GRADE
.1%( TRANSMISSION O
O 41%,8 IDENTIFICATION
( 4 %48 O ENGINE
. O| TRANSMISSION
41%,8
O O| %1 %8(
AREA CODE O NAME
%, O TYPE
4C O NUMBER
?,) 1 O NUMBER
?,) 1 O| NUMBER
?,) 1
Accord O
O % | KE
> O 1.6i S
- O 5MT
,4 O SHHCG7520YU000101~
66.$0C?0000Q O D1 BBS-E1 00001 ~
() 0000Q O| DH-1000001~
(600000Q
S E DAN O
O (% | O 1.6i LS
- O 5MT
,4 O SHHCG7540YU000101~
66.$*0C?0000Q O D1 BBS-E1 00001 ~
() 0000Q O| DH-1000001~
(600000Q
O O| O 1.8i S
-' O 5MT
,4 O SHHCG8520YU000101~
66.'0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i S
-' O 4AT
*%4 O SHHCG8620YU000101~
66.'0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 1.8i LS
-' O 5MT
,4 O SHHCG8540YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i LS
-' O 4AT
*%4 O SHHCG8640YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 1.8i ES
-' O 5MT
,4 O SHHCG8570YU000101~
66.'$0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i ES
-' O 5MT*1
,4G O SHHCG8580YU000101~
66.''0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i ES
-' O 4AT
*%4 O SHHCG8670YU000101~
66.'$0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 1.8i ES
-' O 4AT*1
*%4G O SHHCG8680YU000101~
66.''0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 2.0i LS
-0 O 5MT
,4 O SHHCG9540YU000101~
66.5*0C?0000Q O FZOB6-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 2.0i LS
-0 O 4AT
*%4 O SHHCG9640YU000101~
66.5*0C?0000Q O F2OBES-E100001~
0) 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 2.0i ES
-0 O 5MT
,4 O SHHCG9570YU000101~
66.5$0C?0000Q O F2OBES-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 2.0i ES
-0 O 5MT*1
,4G O SHHCG9580YU000101~
66.5'0C?0000Q O F2OBES-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 2.0i ES
-0 O 4AT
*%4 O SHHCG9670YU000101~
66.5$0C?0000Q O F2OBES-E100001~
0) 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 2.0i ES
-0 O 4AT*1
*%4G O SHHCG9680YU000101~
66.5'0C?0000Q O F2OBES-E100001~
0) 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 2.2 R
-1 O 5MT
,4 O SHHCH1590YU000101~
66650C?0000Q O H22A7-100001~
6%$0000Q O| uzo7-1000001~
?D$00000Q
O O| O 2.2 R
-1 O 5MT*5
,4G O SHHCH1580YU000101~
666'0C?0000Q O H22A7-100001~
6%$0000Q O| uzo7-1000001~
?D$00000Q
O O| O 2.0 TDi
-04( O 5MT
,4 O SHHCH2520YU000101~
6660C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000OOA~
5%00000%Q
O O| O 2.0TDi
-04( O 5MT
,4 O SHHCH2570YU000101~
666$0C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000001~
5%00000Q
O O| O 2.08Di
-0( O 5MT
,4 O SHHCH2580YU000101~
666'0C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000OO1~
5%00000Q
O O| KG
>. O 1.6i S
- O 5MT
,4 O SHHCG7520YU000101~
66.$0C?0000Q O D1 BBS-E1 00001 ~
() 0000Q O| DH-1000001~
(600000Q
O
O
O
I
O
O
O|
O
O
O
1.6i LS
-
1.6i LS
-
1.6i LS
-
O
O
O
5MT
,4
5MT*2
,4G
5MT*4
,4G*
O
O
O
SHHCG7530YU000101~
66.$+0C?0000Q
SHHCG7540YU000101~
66.$*0C?0000Q
SHHCG7550YU000101~
66.$0C?0000Q
O
O
O
D1 BBS-E1 00001 ~
() 0000Q
D1 BBS-E1 00001 ~
() 0000Q
D1BB7-E100001~
()$ 0000Q
O|
O|
O|
DH-1000001~
(600000Q
DH-1000001~
(600000Q
DH-1000001~
(600000Q
O O| O 1.8i S
-' O 5MT
,4 O SHHCG8520YU000101~
66.'0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i S
-' O 4AT
*%4 O SHHCG8620YU000101~
66.'0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 1.8i LS
-' O 5MT
,4 O SHHCG8530YU000101~
66.'+0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i LS
-' O 5MT*3
,4G+ O SHHCG8540YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i LS
-' O 5MT*4
,4G* O SHHCG8550YU000101~
66.'0C?0000Q O F18B4-E100001~
')* 0000Q O| uze5-1000001~
?.00000Q
O O| O 1.8i LS
-' O 4AT
*%4 O SHHCG8640YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 1.8i ES
-' O 5MT
,4 O SHHCG8570YU000101~
66.'$0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i ES
-' O 5MT*1
,4G O SHHCG8580YU000101~
66.''0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O| O 1.8i ES
-' O 5MT*4
,4G* O SHHCG8560YU000101~
66.'0C?0000Q O F18B4-E100001~
')* 0000Q O| uze5-1000001~
?.00000Q
O O| O 1.8i ES
-' O 4AT
*%4 O SHHCG8670YU000101~
66.'$0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O| O 1.8i ES
-' O 4AT*1
*%4G O SHHCG8680YU000101~
66.''0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
*1: with NAVI.

G93%:-
*2: with Auto Aircon.
G93% %-
*3: with NAVI and Leather seat
G+93%:
*4: 7PA
G*9$%
*5: with Trunk Spoiler
G934 #!
Chassis
and Enqine Numbers
%! ,*
Applicable Area CodeNlN/Engine
*
24,2%!
,*2
,*
Number/Transmission Number
O O O O O VEHICLE
: 6 O O|
MODEL O %%)
O ,8( APPLICABLE O GRADE
.1%( TRANSMISSION O
O 41%,8 IDENTIFICATION
( 4 %48 O ENGINE
. O| TRANSMISSION
41%,8
O AREA CODE O
O %1 %8( NAME
%, O TYPE
4C O NUMBER
?,) 1 O NUMBER
?,) 1 O| NUMBER
?,) 1
Accord O
O % KG
>. O 2.0i LS
-0 O 5MT
,4 O SHHCG9540YU000101~
66.5*0C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
S E DAN O
O (% O 2.0i LS
-0 O 5MT
,4 O SHHCG9550YU000101~
66.50C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i LS
-0 O 4AT
*%4 O SHHCG9640YU000101~
66.5*0C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1 000001~
,("%00000Q
O O O 2.0i LS
-0 O 4AT
*%4 O SHHCG9650YU000101~
66.50C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1 000001~
,("%00000Q
O O O 2.0i ES
-0 O 5MT
,4 O SHHCG9570YU000101~
66.5$0C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 5MT
,4 O SHHCG9590YU000101~
66.550C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 5MT
,4 O SHHCG9510YU000101~
66.50C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 5MT*1
,4G O SHHCG9580YU000101~
66.5'0C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 4AT
*%4 O SHHCG9670YU000101~
66.5$0C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1 000001~
,("%00000Q
O O O 2.0i ES
-0 O 4AT
*%4 O SHHCG9690YU000101~
66.550C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1 000001~
,("%00000Q
O O O 2.0i ES
-0 O 4AT
*%4 O SHHCG9610YU000101~
66.50C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1 000001~
,("%00000Q
O O O 2.0i ES
-0 O 4AT*1
*%4G O SHHCG9680YU000101~
66.5'0C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1 000001~
,("%00000Q
O O O 2.2 R
-1 O 5MT
,4 O SHHCH1590YU000101~
66650C?0000Q O H22A7-1000001~
6%$00000Q O| U2Q7-1000001~
?D$00000Q
O O O 2.0TDi
-04( O 5MT
,4 O SHHCH2520YU000101~
6660C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000001~
5%00000Q
O O O 2.0TDi
-04( O 5MT
,4 O SHHCH257OYU000101~
666$0C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000001~
5%00000Q
O O O 2.0TDi
-04( O 5MT
,4 O SHHCH254OYU000101~
666*0C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000001~
5%00000Q
O O O 2.08Di
-0( O 5MT
,4 O SHHCH2580YU000101~
666'0C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000001~
5%00000Q
O O KS
> O 1.6i S
- O 5MT
,4 O SHHCG7520YU000101~
66.$0C?0000Q O D1 BBS-E1 00001 ~
() 0000Q O| DH-1000001~
(600000Q
O O O 1.6i LS
- O 5MT
,4 O SHHCG7540YU000101~
66.$*0C?0000Q O D1 BBS-E1 00001 ~
() 0000Q O| DH-1000001~
(600000Q
O O O 1.8i S
-' O 5MT
,4 O SHHCG8520YU000101~
66.'0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O O 1.8i LS
-' O 5MT
,4 O SHHCG8540YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O O 1.8i LS
-' O 4AT
*%4 O SHHCG8640YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O O 2.0i LS
-0 O 5MT
,4 O SHHCG9540YU000101~
66.5*0C?0000Q O F2OBG-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 5MT
,4 O SHHCG9570YU000101~
66.5$0C?0000Q O F2OBG-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O KR
>1 O 1.6i S
- O 5MT
,4 O SHHCG7520YU000101~
66.$0C?0000Q O D1ESBE3-E100001~
() 0000Q O| DH-1000001~
(600000Q
O O O 1.6i LS
- O 5MT
,4 O SHHCG7540YU000101~
66.$*0C?0000Q O D1ESBE3-E100001~
() 0000Q O| DH-1000001~
(600000Q
O O O 1.8i S
-' O 5MT
,4 O SHHCG8520YU000101~
66.'0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O O 1.8i LS
-' O 5MT
,4 O SHHCG8540YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O O 1.8i LS
-' O 4AT
*%4 O SHHCG8640YU000101~
66.'*0C?0000Q O F18BZ-E100001~
') 0000Q O| MDJA—1000001~
,("%00000Q
O O O 1.8i ES
-' O 5MT
,4 O SHHCG8570YU000101~
66.'$0C?0000Q O F18BZ-E100001~
') 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i LS
-0 O 5MT
,4 O SHHCG9540YU000101~
66.5*0C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 5MT
,4 O SHHCG9570YU000101~
66.5$0C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 5MT*1
,4G O SHHCG9580YU000101~
66.5'0C?0000Q O F2086-E100001~
0) 0000Q O| U2J4-1000001~
?"*00000Q
O O O 2.0i ES
-0 O 4AT
*%4 O SHHCG9670YU000101~
66.5$0C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1000001~
,("%00000Q
O O O 2.0i ES
-0 O 4AT*1
*%4G O SHHCG9680YU000101~
66.5'0C?0000Q O F2086-E100001~
0) 0000Q O| MDJA—1000001~
,("%00000Q
O O O 2.2 R
-1 O 5MT
,4 O SHHCH1590YU000101~
66650C?0000Q O H22A7-1000001~
6%$00000Q O| U2Q7-1000OO1~
?D$00000Q
O O O 2.0TDi
-04( O 5MT
,4 O SHHCH2520YU000101~
6660C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000001~
5%00000Q
O O O 2.08Di
-0( O 5MT
,4 O SHHCH254OYU000101~
666*0C?0000Q O 20T2N-0000001~
04000000Q O| 9A—1000001~
5%00000Q
O O KY
>C O 1.8iS
-' O 5MT
,4 O SHHCG8527YU000001~
66.'$C?00000Q O F18BS-E100001~
')+ 0000Q O| U2J4-1000001~
?"*00000Q
O O O O 4AT
*%4 O SHHCG8627YU000001~
66.'$C?00000Q O F18B3-E100001~
')+ 0000Q O| MDJA—1 000001~
,("%00000Q
*1: with NAVI.

G93%:-
Identification Number Locations

,*&

1_5
3
Enginl, VIN Number
Plat: IEIocapt KY]
Vehltla Identification Numbar
'l i
li‘ 9‘ l \
P'l’q—‘liF
Him " 3:1)? .

I :-
-~ '
Elfin-:— ;;‘=jfm
,w
__ «is——
a ""—;3.—‘ fl“
Transmission Number
IMDJA Automatic]
“EM-Mission Mum bar Englne Numbar

iDH Manuali Transmission Number
IUZJl, U265. U211? Manual}
Eer‘tification Plate
{KY modal]
1 !2
&*&

Warninq/Caution Label Locations
5
SHE AIRBAG EAUTID N
fA
.aa
I l G 4‘ i'
a' I I
H‘~v
BATTERY CAUTION
fix
fifimgg I -.__ a. '
T"; fi-
J
“-1 m
'--.___‘--.h
-Lg
J—Vd—‘I
y‘EN
”a x, \
"x. ". “ "
AIR CONDITIONING
INFORMA'I'ION HADIATDH CAP
CAUTION
WEE INFORMATION
[Located on driver side donrjarnb]
NCITE: LHD mode-l is shown. FIHD
model is: symmetrical.
Warninq/Caution Label Locations
1 !2
&*&

1_7
7
(cont'd)
/
N0
NOTE: LHD model is shown; RHD model is similar.

84 96(!3N16(!!-
FRONT SEAT PASSENGER AIRBAG

DRIVER 5H3 AIRBAG CHILD SEAT CAUTION
5H3 AIRBAG CAUTION INFCIIRMATIDN
7 FRONT SEAT PASSENGER AIRBAG

I MODULE DANGERMARHIHG
SIDE AIRBAG CAUTION
STEERING COLUMN NOTICE
MONITOR NOTICE FHCI'NT SEAT BELT

TE NSIDNER CAUTION
DRIVER AIRBAG M DDULE

DANGERI'WAH MING
[JAE-LE HEEL CAUTION
FRONT SEAT PASSENGER

AIRBAG CHILD SEAT DANGER
SIDE AIRBAG CAUTION
&
'
1_8
8
Lift and Safety Stands
& #
1.
- Place the lift blocks as shown.
!!!#3-
2.
- Raise the hoist a few inches (centimeters), and rock the vehicle to be sure it is firmly supported.
13;<A#&! ! -
3.
+- Raise the hoist to full height, and inspect the lift points for solid support.
1 !!
A!! -
NOTE: Use the same support points to support the vehicle on safety stands.
84 9? &!-
“—
LIFT BLOCKS
FRONT SUPPORT POINT
REAR 5U PPDRT Pfll NT

&
'
1-9
9
+
<6
Floor Jack
- Set the parking brake and block the wheels that are not being lifted.
#
#!#3!
!-
.—‘
- When lifting the rear of the vehicle, put the gearshift lever in reverse (Automatic in El<-
2!
&!A
!&&;% position).
PW.”
+- Raise the vehicle high enough to insert the safety stands.

1&!

-
*- Adjust and place the safety stands so the vehicle will be approximately level, then lower the vehicle onto them.
%7 !&!3!!/!!&!A!3&!-
A WARNING
¢ Always use safety stands when working on or under any vehicle that is supported by only a jack.
%!3 33#
&! !7#-
¢ Never attempt to use a bumperjack for lifting or supporting the vehicle.
& 7#!

&!-
+
F
Front:
Canter the jack bracket

JACK UFT in the middle 01' the
PLATFDHM jack. lift platform.
F
Rear:
CH nlar the jack bracket

JACK LIFT in the middIE nf Ihe
PLATFORM jack lift platform.

( !
Towin
$
If the vehicle needs to be towed, call a professional towing
&!3A!!!3
+
F
service. Never tow the vehicle behind another vehicle with
&-&3&!&!3
just a rope or chain. It is very dangerous.
7 -&
-
Emergency Towing
%!#
( !
There are three popular methods of towing a vehicle.
4 !3
&!-
Flat-bed Equipment
+*%B
The operator loads the vehicle on the back of a truck. This is
4!&!# #-4
the best way of transporting the vehicle.
3
&!-
Wheel
1 Lift Equipment
& %B
The tow truck uses two pivoting arms that go under the tyres
43 # 3&

(front or rear) and lifts them off the ground. The other two
;<!
-43
wheels remain on the ground.
3!
-
Sling-type Equipment
!#%B
The tow truck uses metal cables with hooks on the ends.
43 # !!3#- TOWING HOOKS and
These hooks go around parts of the frame or suspension and
4#
TIE DOWN BRACKETS
the cables lift that end of the vehicle off the ground. The
!!&!
-4
vehicle’s suspension and body can be seriously damaged if
&!B !
F
Rear:
this method of towing is attempted.
3
-
If the vehicle cannot be transported by the flat-bed, it should
&!!A !
be towed with the front wheels off the ground. If due to
333!
-
damage, the vehicle must be towed with the front wheels on

A&! 333!
the ground, do the following.

A!!3
-
Manual Transmission

¢ Release the parking brake.
1!#
#-
¢ Shift the transmission to Neutral.
!-
Automatic Transmission

¢ Release the parking brake.
1!#
#-
¢ Start the engine.

-
¢ Shift to
position, then E-
A position.
¢ Turn off the engine.
4
-
Ri:
9
Remove the front air spoiler before towing so it does not get
1&!3

damaged.

-
A CAUTION
0 Improper towing preparation will damage the
3
3!!

transmission. Follow
- the above procedure exactly. If you
!!3& /!- TIE DOWN BRACKET
cannot shift the transmission or start the engine

(automatic transmission), the vehicle must be
; <A&!
transported on a flat-bed.
!-
0 It is best to tow the vehicle no farther than 50 miles
3&!0!
(80 km), and keep the speed below 35 mph (55 km/h).
;'0#<A#!3+;#=<-
0 Trying to lift or tow the vehicle by the bumpers will
4
!3&! 3!!
cause serious damage. The bumpers are not designed

-4

to support the vehicle’s weight.
&!B3
-
'

1
6
Pre aration of Work
1-11

A CAUTION
Mark or place all removed parts in order in a parts
,#!!!&
rack so they can be reassembled in their original
#!
!
Observe all safety precautions and notes while working.
8&!! 3!3#
- places.
!-
¢ Protect all painted surfaces and seats against dirt and
!!

scratches with a clean cloth or vinyl cover.
3!!&!&-
O Use the special tool when use of such a tool is

?!!3 !
specified.
-
¢ Work safely and give your work your undivided attention.

2#!
& 3# &-
When either the front or rear wheels are to be raised,
23!A
block the remaining wheels securely. Communicate as
!#
3! !-
frequently as possible when work involves two or more
F !!33#&!&3
workers. Do not run the engine unless the shop or
3#-(
!
working area is well ventilated.
3#
3!!&!-
O Parts must be assembled with the proper torque

!3F
according to the maintenance standards

established.
!-
0 When tightening a series of bolts or nuts, begin
2

! A

¢ Before removing or disassembling parts, they must be
)&
!
A
with the centre or large diameter bolts and tighten
3!
!

inspected carefully to isolate the cause for which service
!!! 3&
them in criss-cross pattern in two or more steps.
3-
is necessary. Observe all safety notes and precautions
-8&!!
and follow the proper procedures as described in this
!!3
manual.
!-
'

1
6
Preparation of Work
(cont’d)
/
?0
1-12

O Use new packing, gaskets, O-rings and cotter pins
?3#
A
#A8
Brake fluid and hydraulic components
)#! !
whenever reassembling.
3&!
- ¢ When replenishing the system, use extreme
2!
A /
9 Do not reuse parts that are required to be replaced.
( F !- care to prevent dust and dirt from entering the
&

Always replace them.
%!3!- system.
-
¢ Do not mix different brands of fluid as they
(/!
may not be compatible
!
¢ Do not reuse drained brake fluid.
( #! -
¢ Because brake fluid can cause damage to
) #!

painted and resin surfaces, care should be
A !
taken not to spill it on such surfaces. If spilled
#!! -!!
accidentally, quickly rinse it off with water or
!!AF #!33
warm water from all painted or resin surfaces.
33!! -
¢ After disconnecting brake hoses or pipes, be
%
#A
sure to plug the openings to prevent loss of
!

&!
Use genuine HONDA parts and lubricants or those
?
68(%! brake fluid.
#! -
equivalent. When parts are to be reused, they must be
F &!-2 A ¢ Clean all disassembled parts only in clean
!!!!!!
inspected carefully to make sure they are not damaged
!!#
BRAKE FLUID.
)1%> Blow open all holes and
?(-)!3!!!
or deteriorated and are in good usable condition.

!- passages with compressed air.

3-
Keep disassembled parts away from air-borne

>!3
Coat or fill parts with specified grease as specified (page
!!3
;
dust and abrasives.
&-
4-2). Clean all removed parts with solvent upon
*<-!!!&3!& ¢ Check that parts are clean before assembly.
#!!-
disassembly.
!- 0 Avoid oil or grease getting on rubber parts and
%&!

tubes, unless specified.
A !-
O Upon assembling, check every part for proper
?!
A#&
installation and operation.
!!-
'

1
6
Preparation of Work

%
*
!
Before Troubleshooting
"

*
! 0 Never try to disconnect connectors by pulling on

& !!

¢ Check applicable fuses in the appropriate fuse/relay box.
#!! =!/- their wires; pull on the connector halves instead.
3N !!!&-
¢ Check the battery for damage, state of charge, and
#
A
A 0 Always reinstall plastic covers.
%!3!!!&-
clean and tighten connections.
!
-
¢ Check the alternator belt tension.
#!!-
A CAUTION
0 Do not quick-charge a battery unless the battery ground
(F #
!

cable has been disconnected, otherwise you will damage the
!A3 3!!

alternator diodes.
!-
0 Do not attempt to crank the engine with the battery
(#
3
ground cable loosely connected or you will severely damage

!!! 3!!&!

the wiring.
3
- 0 Before connecting connectors, make sure the
)
A#
terminals are in place and not bent.
!!-
Handling Connectors
. !

¢ Make sure the connectors are clean and have no loose
,# !&!
wire terminals.
3!- BENT TERMINAL
¢ Make sure multiple cavity connectors are packed with
,# !!&#3
grease (except waterproof connectors).

;/3<-
¢ All connectors have push-down release type locks.
%!!& 3!!#-
LOCKING T113
0 #! !-

Check for loose retainer and rubber seals.
RUBBER SEAL HEI'AlMEH

RETAINER
LOCKING TAB
¢ Some connectors have a clip on their side used to

&!
attach them to a mount bracket on the body or on
#
another component. This clip has a pull type lock.
-4! !!!#-
¢ Some mounted connectors cannot be disconnected

0 The backs of some connectors are packed with
4##3
unless you first release the lock and remove the
! !!#&
grease. Add grease if necessary. If the grease is

-%
-

connector from its mount bracket.
#-
contaminated, replace it.
A!-
LOCKING
PAWL ON
OTHER Full ID
HALF 0F
CONNECTOR
disengage a“ BRACKET
'

1
6
Preparation of Work
%
* (cont’d)

!/
?0
1-14

u
¢ Insert the connector all the way and make sure it is
!!3# 0 Seat grommets in their grooves properly.

&!-
¢
securely locked.
!!#-
Position wires so that the open end of the cover faces
3&
A y m
down.
3-
_.
Face
open and
down
_- _ ”T?” .2
Testing and Repairs

!
0 Do not use wires or harnesses with broken
( 33#
insulation. Replace them or repair them by
!-1!
wrapping the break with electrical tape.
3
#3!!-
Handling Wires and Harnesses
. !1 . 0 After installing parts, make sure that no wires are
%!!
A# 3
¢ Secure wires and wire harnesses to the frame with their
333 pinched under them.
-
respective wire ties at the designated locations.
&3
!- 0 When using electrical test equipment, follow the
2
!!F A!!3
¢ Remove clips carefully; don’t damage their locks.
1&! !!NB
!#- manufacturer’s instructions and those described in
B
this manual.
!-
0 If possible, insert the probe of the tester from the
!A
wire side (except waterproof connector).
3;/3<-
EXPANSION
CLIP LOCKS
0 Use a probe with a sharp tester probe.

?3-
(:11:
Slip pliers under the clip base and through the hole at an
!! !
!
angle, then squeeze the expansion tabs to release the clip.

!AF H/!!-
SNAP-RING PLIERS
¢ After installing harness clips, make sure the harness

%!!
!A#
doesn’t interfere with any moving parts.
B3&
-
Keep wire harnesses away from exhaust pipes and
>33/
other hot parts, from sharp edges of brackets and holes,
A
#!A
and from exposed screws and bolts.
/3!-
'

1
6
Preparation of Work
%
* (cont’d)

!/
?0
1-15
3
.
(
+
(
Except SRS:
%F
A flowchart is designed to be used from start to final repair. It’s like a map showing you the shortest distance. But beware: if
%!3
!-B!#3
-) 39
you go off the "map” anywhere but a “stop” symbol, you can easily get lost.

KL3 KL!A !
!-
Describes the conditions or situation to start a troubleshooting flowchart.

( !
!3-
[bold type]
Asks you to do something; perform a test, set up a condition etc.
%#
NA -
Asks you about the result of an action, then sends you in the appropriate
%# !A
DEC: SIGN troubleshooting direction.
!
-
The end of a series of actions and decisions, describes a final repair action and
4A!
sometimes directs you to an earlier part of the flowchart to confirm your repair.
!!3 -
[bold type]
SRS:
F
SRS troubleshooting

* flowcharts

!
( are comprised of modules, each
(

: of which contains all actions necessary to reach

#
one
decision. Except of the

@%
steps you must perform, the
#

: modules also include standard specifications of a correctly

#
working system and test specifications. If the
(
6 !#
@ result of a test meets the

specification shown

in the

( module, the

:
conclusion from this

test is YES. If the
>%@ specification is not met, the

: conclusion is NO. If you do not exactly follow the

,@ #

#

(
procedure described in the

* module, you may get the

:#
#! wrong test result.
(
!@
l halal—Module
'_'_‘—‘—The item rested by this mndule
Test procedure
_._.——'—Standard specification
_.—-—-—-Test specification
H
C i '
_f_mr/’H°“CIUSIOH
I—VEE—-H—‘—-------———m..—
;-__'.-_ .._ '_T—....:— | f esut
-__ujf
ll":—
NOTE:
84 9
¢ The term “Intermittent Failure”
4K is used in these charts. It simply means a system may have had a failure, but it checks out
! L -!&! A #
OK at this time. If any indicator light on the dash does not come on, check for poor connections or loose wires at all
8>-!
A#!3!!
connectors related to the circuit that you are troubleshooting (see illustration below).
! !
;!! !3<-
¢ Most of the troubleshooting flowcharts have reset control module(s) or unit(s) and try to duplicate the Diagnostic Trouble
, !
!3&! !;< ;< !(
4 !
Code (DTC). If the problem is intermittent and you cannot duplicate the code, do not continue through the flowchart. To do
;(4<-! !A
!3-4
so will only result in confusion and, possibly, (a) needlessly replace control module(s) or unit(s).
3!!! ! A!A;<!!!! !;< ;<-
¢ “Open" and “Short” are common electrical terms. An open is a break in a wire at a connection. A short is an accidental
K8LKL!!-%#3-%!
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all.
3
3-!!A !!
3!!3#!!-
In complex electronics, this can sometimes mean something works, but not the way it is supposed to.
!/!A
3#A 3 -
TIGHT
'

1
6
Preparation of Work
%
* (cont’d)

!/
?0
1-16
5
Five-step Troubleshooting
+ -
*
! Wire Colour Codes

1

1. :4!
- Verify The Complaint The following abbreviations are used to identify wire
4!!3
& 3
Turn on all the components in the problem circuit to
4 !!! colours in the circuit schematics:
! 9
verify the customer complaint. Note the symptoms. Do
& !--( WHT
264 White
2
not begin disassembly or testing until you have narrowed

!
! &3 YEL
C Yellow
C!!3
down the problem area.
3!- BLK
)> Black
)!#
Analyze The Schematic
- %!H4 BLU
)? Blue
)!
Look up the schematic for the problem circuit.
# ! - GRN
.1 Green
.
Determine how the circuit is supposed to work by tracing
(3 3#
RED
1 ( Red
1
the current paths from the power feed through the circuit
3
ORN
81 Orange
8

components to ground. If several circuits fail at the same

-&! ! PNK
> Pink
#
time, the fuse or ground is a likely cause.
A
!#! - BRN
)1 Brown
)3
Based on the symptoms and your understanding of the
)
GRY
.1C Grey
.
circuit operation, identify one or more possible causes of
A! PUR
?1 Purple
!
the problem.
!- LT BLU
4)? Light Blue

)!
Isolate The Problem By Testing The Circuit
+- !4!)4
4 LT GRN
4.1 Light Green

.
Make circuit tests to check the diagnosis you made in
,# #

step 2. Keep in mind that a logical, simple procedure is
->!
!A! The wire insulation has one colour or one colour with
43 !! ! 3
the key to efficient troubleshooting. Test for the most
# !
-4 another colour stripe. The second colour is the stripe.
! -4! -
likely cause of failure first. Try to make tests at points
!#! ! -4# WHTJ'BLK
that are easily accessible.
!!-
*- Fix The Problem
/4!
Once the specific problem is identified, make the repair.
8!A#-
Be sure to use proper tools and safe procedures.
) ! -
Make Sure The Circuit Works
- ,# 4 2#
Turn on all components in the repaired circuit in all
4 !! !!
modes to make sure you have fixed the entire problem.
# &/!-
If the problem was a blown fuse, be sure to test all of the
!3!3 A !!
circuits on the fuse. Make sure no new problems turn up
-,# 3! NOTE:
84 9
and the original problem does not recur.

!! - Different wires with the same colour in the same system
(33!
have been given number suffixes to distinguish them
&
& /

(for example, YEL1 and YEL2 are not the same).
;/!AC C <-
Preparation of Work
'

1
6 1 -17
7
%
* (cont’d)

!/
?0
When checking any control module(s) or units(s) connector terminals, gently slide the sharp tester probe from the wire side into
2#
! !;< ;<!A
!!3
the connector until it comes in contact with the terminal end of the wire.
!3!3-
DIGITAL CIRCUIT TES'IER

{Commercially available] or
O?“ 1 -> 0020000
:
O Any CONTROL MODULE ar
UNIT
SHARP TESTER PROBE
A CAUTION
¢ Puncturing the insulation on a wire can cause poor or intermittent electrical connections.

!3 !!-
¢ For testing at connectors, bring the tester probe into contact with the terminal from the connector side

A
3!
of wire harness connectors in the engine compartment.
3
-
¢ For female connectors, just touch lightly with the tester probe and do not insert the probe.
!A7 !
!3-
RUBBER SEAL TESTER PROBE
autumn/1mm
UQCIIIOIIIIIIIIDIIH
f, .I-n-IYI’icIo-n — mlnauu
WIRE HARNESS
TERMINAL
**-

Abbreviations
1-18
8
List of automotive abbreviations, which may be used in shop
&&A3 F
Front

!-
manual. FIA
% Fuel Injection Air
!7%
ABS
%) Anti-lock Brake System
%!#)# FL Front Left

A/C
%= Air Conditioning, Air Conditioner
%
A% FP Fuel Pump
!
ACL
% Air Cleaner
%! FR1 Front Right
1

A/F
%= Air Fuel
% Ratio
!1 FSR
1 Fail Safe Relay
!1!
ALT
%4 Alternator
%! FWD
2( Front Wheel Drive
2!(&
AMP
%, Ampere (s)
%;<
ANT
%4 Antenna
% GAL
.% Gallon
.!!
API
% American Petroleum Institute
%! GND
.( Ground
.
APPROX.
%18R- Approximately
%/! GPS
. Global Positioning System
.!!

ASSY
%C Assembly
%!
A/T
%=4 Automatic Transmission
% 4 H/B
6=) Hatchback
6#
ATDC
%4( After Top Dead Center
%4( HC
6 Hydrocarbons
6
ATF
%4 Automatic Transmission Fluid
% 4 ! H028
60 Heated Oxygen Sensor
68/

ATT
%44 Attachment
%
ATTS
%44 Active Torque Transfer System
%&4F 4 IAB
!%) Intake Air Bypass
#%)
AUTO
%?48 Automatic
% |AC
!% Idle Air Control
!%!
AUX
%?R Auxiliary
% /! IAR
%1 Intake Air Resonator
#%1
IAT
%4 Intake Air Temperature
#%4
BARO
)%18 Barometric
) ICM
, Ignition Control Module

!, !
BAT
)%4 Battery
) ID
( Identification

BDC
)( Bottom Dead Center
)( (-(-
ID or ID. Inside Diameter
(
BTDC
)4( Before Top Dead Center
)4( ..
IG or IGN IgnMon

IMA
,% Idle Mixture Adjustment
!,/ %7
CARB
%1) Carburettor
IMMOBI.
,,8)- Immobilizer (Immobiliser)
!H;!<
CAT
%4 Catalytic Converter
!& IN
Intake
#
%4%
or CATA INJ
" Injection
7
CHG
6. Charge

INT
4 Intermittent

CKF
> Crankshaft Speed Fluctuation
# !
CKP
> Crankshaft Position
# KS
> >#
Knock Sensor
CO
8 Carbon Monoxide
,/
COMP
8, Complete
! L Left

CPB
) Clutch Pressure Back up
! )# L/C
= Lock-up Clutch
# !
CPC
Clutch Pressure Control
! ! LCD
( Liquid Crystal Display
F !(!
CPU
? Central Processing Unit
!
? LED
( Light Emitting Diode

(
CVT
:4 Continuously Variable Transmission
!:!4 LF Left Front

CYL
C Cylinder
! LH
6 Left Handle
6!
CYP
C Cylinder Position
! LHD
6( Left Handle Drive
6!(&
LR
1 Left Rear
1
DI
( Distributor Ignition
(
LSD
( Limited Slip Differential
!(!
DIFF
( Differential
(! * In-line Four
! Cylinder (engine)
!;
<
DLC
( Data Link Connector
(#
DOHC
(86 Double Overhead Camshaft
( !8&
DPI
( Dual Point Injection
( !7
DTC
(4 Diagnostic Trouble Code
(
4 !
ECM
, Engine Control Module

!, !
ECT
4 Engine Coolant Temperature

!4
EGR
.1 Exhaust Gas Recirculation
/ .1 !
ELD
( Electrical Load Detector
!!(
EPR
1 Evaporator Pressure Regulator
& 1
!
EPS
Electrical Power Steering
!!3
EVAP
:% Evaporative
&&
EX
R Exhaust
/
**-

Abbreviations
(cont’d)
/
?0
1-19
9
MAP
,% Manifold Absolute Pressure
,!%! 4 Torque
4F
MAX.
,%R- Maximum
,/ TB
4) Throttle Body
4!)
MBS
,) Mainshaft Brake System
,)# T/B
4=) Timing Belt
4
)!
MCK
,> Motor Check
,# TC
4 Torque Converter
4F &
MCU
,? Moment Control Unit
,!? TCM
4, Transmission Control Module
4!, !
MIL
, Malfunction Indicator Light
,!
TCS
4 Traction Control System
4!
MIN.
,- Minimum
, TDC
4( Top Dead Center
4(
MPI
, Multi Point Injection
, !7 TFT
4 4 Thin Film
4 Transistor
!4
M/S
,= Manual Steering
, !
T/N
4= Tool Number
4!
M/T
,=4 Manual Transmission
, !4 TP
4 Throttle Position
4!
TWC
42 Three Way Catalytic Converter
42!&
N
Neutral
!
NOx
8/ Oxides of Nitrogen
8/
VC
: Viscous Coupling
: !
VIN
: Vehicle Identification Number
:!
OBD
8)( On-board Diagnostic
8(
VSS
: Vehicle Speed Sensor
:!
028
0 Oxygen Sensor
8/
VTEC
:4 Variable Valve Timing & Valve Lift
:!:!&4
J:!&
8(8-(-
OD or 0D. Outside Diameter
8 ( Electronic Control
!!
VVIS
:: Variable Volume Intake System
:!:! #
P
Park
#
PAIR
%1 Pulsed Secondary Air Injection
!%7 2 With
2
PCM
, Powertrain Control Module
3!, ! 2=8 Without
2
PCV
: Positive Crankcase Ventilation
&#:! 284 Wide Open Throttle
284!
Proportioning Control Valve

!:!&
PGM-FI
., Programmed-fuel Injection

!7 2( Two Wheel Drive
432!(&
PGM-IG
.,. Programmed Ignition

*2( Four Wheel Drive
2!(&
PH
6 Pressure High
6
2 Two Wheel Steering
432!
PL
Pilot Light or Pressure Low
!
3 *2 Four Wheel Steering
2!
PMR
,1 Pump Motor Relay
,1! 4AT
*%4 4-speed Automatic Transmission
*% 4
P/N
= Part Number
5MT
,4 5-speed Manual Transmission
, !4
PRI
1 Primary
Park
#
P/S
= Power Steering
3
PSF
Power Steering Fluid
3
! Reverse
1&
PSP
Power Steering Pressure
3
Neutral
!
PSW
2 Pressure Switch
3 Drive (1st through 4th gear)
(&;
*
<
Drive (1st through 3rd gear)
(&;
+
<
Qty
D Quantity
D
Second

R
1 Right
1
First

REF
1 Reference
1
Drive
(&
RGB
1.) Red, Green, Black
1A.A)!#
RHD
16( Right Handle Drive
1
6!(& Second

RL
1 Rear Left
1 Low
3
RON
18 Research Octane Number
18 4 Low (gear)
3;
<
RR
11 Rear Right
11
( Second (gear)
;
<
+1( Third (gear)
4;
<
SAE
% Society of Automotive Engineers
% &
*46 Fourth (gear)
;
<
SCS
Service Check Signal
&#
! 46 Fifth (gear)
;
<
SEC
Second

Secondary

SOHC
86 Single Overhead Camshaft

!8&
SQL
D Solenoid
!
SPEC
Specification

S/R
=1 Sun Roof
1
SRS
1 Supplemental Restraint System
!!1
STD
4( Standard

SW
2 Switch
3
- & 2_2

%! %

Engine Electrical - Section 4
O O MEASUREMENT
%;%%, O| ,))/,%10 O
O Ignition coil

! O Rated voltage V
1&!
: O| O
O O Primary winding resistance at 20°C (68°F)<9
3
0P;'P ohms: O| O
O O Except H22A7 engine
/6%$
O| 0-*0- O
O O H22A7 engine
6%$
O| 0-+0-$$ O
O O Secondary winding resistance at 20°C (68°F)<#
3
0P;'P k O| O
O O ohms
O| O
O O D16B6 engine
()
O| -0*- O
O O F1882,
')A F1883,
')+A F2086 engine
0)
O| -*++- O
O O H22A7 engine
6%$
O| -'5- O
O Ignition wire

3 O Resistance at 20°C (68°F)<#9
10P;'P k ohms: O| /- O
O O Firing order

D1686 engine
()
O| *+ O
O O Except D1686 engine
/()
O| +* O
(”A
O O O| tandard (New)
/,(0 Service Limit
- & O
O Spark plug
#!
O Type
4 O| *
ee section 4 O
(I)
O O Gap
. Except H22A7 engine
/6%$
O| - .1 (0039-0043) -
-0-;0-0+50-0*+< O
O O H22A7 engine
6%$
O| 1 (0039-0043) -+;0-0<
-0-;0-0+50-0*+< 1.3 (0.051) O
O Ignition timing

O At idle
%! Except H22A7 engine
/6%$
M/T
,=4 O| (Neutral)
V; !< O
O O BTDC (Red)
)4(;1< A/T
%=4 O| N or P position)
V;,'< O
AA
O O H22A7 engine
6%$
O| Neutral)
V; !< O
O Alternator belt *1
%!!G O Deflection with 98 Nm (10 kgf, 22 Ibf) between
(!35';0#
A!<3 O| 0.5 (0.28-0.41) with used belt
$-00-;0-'0-*<3 ! O
O (D16B6 engine)
;()
< O pulleys
!! O| .0 (0.20-0.28) with new belt
-0$-0;0-00-'<33! O
O O O| O
%!!G O Belt tension N (kgf, Ibf)
)!;#
A!< O| 40-490 (35-50, 77-110) with used belt
+*0*50;+0A$$0<3 ! O
CDO)
O (Except D16B6 engine

; /()
O Measured with belt tension gauge
, 3!

O| 40-780 (65-80, 140-180) with new belt
*0$'0;'0A*0'0<33! O
O with A/C)
3%=< O O| O
(!35';0#
A!<3 O| 10.0-12.0 (0.39-0.47) with used belt
0-0-0;0-+50-*$<3 ! O
; /()
O pulleys
!! O| 5.5-7.5 (0.22-0.30) with new belt
-$-;0-0-+0<33! O
O with A/C)
3%=< O OI O
%!!G O Belt tension N (kgf, Ibf)
)!;#
A!< O| 390-540 (40-55, 88-120) with used belt
+50*0;*0A''0<3 ! O
; /()
O Measured with belt tension gauge
, 3!

O| 880-1,030 (90-105, 200-230)with new
''0A0+0;500A00+0<33 O
O without A/C)
3 %=< O O| ! O
(!35';0#
A!<3 O| 10.0-13.0 (0.39-0.51) with used belt
0-0+-0;0-+50-<3 ! O
; /()
O pulleys
!! O| 7.5-10.0 (0.30-0.39) with new belt
$-0-0;0-+00-+5<33! O
O without A/C)
3 %=< O O| O
O Alternator
%! O Belt tension N (kgf, Ibf)
)!;#
A!< O| 290-440 (30-45, 66-99) with used belt
50**0;+0*A55<3 ! O
O (Except H22A7 engine)
; /6%$
< O Measured with belt tension gauge
, 3!

O| 540-740 (55-75, 120-170) with new belt
*0$*0;$A0$0<33! O
O O O| O
O O O| Standard (New)
/,(0 Service Limit
- & O
O Alternator
%! O Output 13.5V at hot
8 +-: D16B6 engine
()
O| 85A
'% O
O (Except H22A7 engine)
; /6%$
< O Except D1686 engine
/()
O| 50% O
O O Coil resistance (rotor) ()

!;< D16B6 engine O| 2.6
- - O
O O at 20 °C (68°F)<
0P;'P ohms /()

Except D1686 engine O| 2.4
-* - O
O O Slip ring O.D.
!
8-(- O| 15.4 (0.61)
-*;0-< 14.15 (0.557)
*-;0-$< O
O O Brush length
) !
O| 13.2 (0.52)
+-;0-< 32. ;0-+<
+- (0.13) O
O O Brush spring tension N (kgf, Ibf)
)
;#
A!< O| 1.9 (0.19, 0.42)
-5;0-5A0-*< - O
/,(0 Service Limit
- & O
O Alternator
%! O Output 13.5V at hot
8 +-: O| 5% O
O (H22A7 engine)
;6%$
< O Coil resistance (rotor) at 20 °C (68°F)<
!;<0P;'P ohms O| -+-0 O
O O Slip ring O.D.
!
8-(- O| 14.4 (0.57)
*-*;0-$< 14.0 (0.55)
*-0;0-< O
O O Brush length
) !
O| 10.5 (0.41)
0-;0-*< 1.5 (0.06)
-;0-0< O
O O Brush spring tension N (kgf, Ibf)
)
;#
A!< O| 2.93.5 (0.30-0.36,
-5+-;0-+00-+A - O
O O O| 0.66-0.79)
0-0-$5< O
/,(0 Service Limit
- & O
O
Starter O ,
Manufacturer O| O
(Except H22A7 engine)
O ; /6%$
< O: 8
Output O| -0#2
1.0 kW O
O Commutator mica depth
O Ol 0-0-5;0-000-0+< 0.2 (0.08)
0.5 -0.9 (0020-0031) 0-;0-0'< O
O O|
Commutator runout Ol 0-0;0-000*</-
0.0 1 (0.0004) max. 0.015 (0.0006) O
0-0;0-000<
O O| ) !

Brush length Ol ';0-$<
18 (0.7) 5 (0.2)
;0-< O
O O| )
;#
A!<
Brush spring tension N (kg, Ibf) Ol -+5-;--5A
15.3-19.2 (1 .56—1.96, O
O O| O| +-***-+<
3.44-4.32) O
O
Starter
O
O|
O| ,
Manufacturer l Standard (New)
O /,(0
DENSO
O ( 8
Service Limit O
- &
O
l
(H22A7 engine)
O ;6%$
< Output
O 8 Oi -0#2
1 .0 kW O
O Commutator mica depth
O O 0-0-';0-000-0+< 0.2 (0.0008) O
0.5-0.8 (0020-0031) 0-;0-000'<
O O|
Commutator runout O| 0-0;0-000'</-
0.02 (0.0008) max. 0.05 (0.002) O
0-0;0-00<
O O| ) !

Brush length O| $-5'-0;-05'-0'<
27.9-28.0 (1 .098-1.108)27.0 (1.06)
$-0;-0< O
O O| )
;#
A!<
Brush spring tension N (kg, Ibf) O| *-0*-;0-0-$<
14.0-14.5(0.55-0.57) 5-0;0-+<
9.0 (0.35) O
O O| O| +-$$-$;-*-'<A
13.7-17.7(1.4-1.8), O
O O| O| +-05+-5$<
3.09-3.97) O
*1: 2
3!A7 !3&! -1
-17
G9 When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust
! !&! -
deflection or tension to used belt values.
- &

Cylinder HeadNalve Train (D16B6 engine)— Section
# .24- /)5"5! 0J

6
5
Unit of length: mm (in)

?!
9;<
O O| MEASUREMENT
%;%%, Ol STANDARD (NEW)
,))/,%10 SERVICE LIMIT
%4%& O
O Compression
O| 250 rpm (min-1)<
0; and !
Nominal Ol 1 ,270 (13.0, 185)
A$0;+-0A'< O
O O| wide open throttle
3! ,
Minimum Ol 9 30 (9.5, 135)
5+0;5-A+< O
O O| kPa (kgf/cmz, psi)
#;#
= A< Max. variation Ol
,/-& 2 00 (2.0, 28)
00;-0A'< O
O Cylinder head
! O| Warpage
2
Ol - 0.05 (0.002)
0-0;0-00< O
O O| Height
6
Ol 92.95-93.05 (3659-3663)
5-55+-0;+-5+-+< O
O Camshaft
O| End play
! Ol 0.05-0.15 (0002-0006)
0-00-;0-000-00< 0.5 (0.02)
0-;0-0< O
O O| Camshaft-to-holder oil clearance
!!! Ol 0050-0089 (00020-00075)
0-000-0'5;0-0000-00$< 0.15 (0.006)
0-;0-00< O
O O| Total runout
4! Ol 0.003 (0.001) max.
0-00+;0-00</- 0.04 (0.002)
0-0*;0-00< O
O O| Cam lobe height
!
Ol O
O O IN
Ol 35.019 (1 .3787)*1,A+*-$+*;-+$<G
+-05;-+$'$<G 34.734 (1 .3675)*2- O
O O EX
R Ol 37.904 (1.423)
+$-50*;-*+< O
O Valve
:!& O Valve clearance (cold)
:!&!;!< IN
O| 0.18-0.22 (0007-0009)
0-'0-;0-00$0-005< - O
O O EX
R Ol 0.23-0.27 (0009-0011)
0-+0-$;0-0050-0< - O
O O :!&8-(-
Valve stem O.D. IN
Ol 5.48-5.49 (02157-02161)
-*'-*5;0-$0-< 5.45 (0.2146)
-*;0-*< O
O O EX
R Ol 5.45-5.46 02146-02150)
-*-*;0-*0-0< 5.42 (0.2134)
-*;0-+*< O
AAAA
O O Stem-to-guide clearance

! IN
Ol 0.02-0.05 0.001-0.002)
0-00-0;0-000-00< 0.08 ( 0.003)
0-0';0-00+< O
O O EX
R Ol .05-0.08 0.002-0.003)
0-00-0';0-000-00+< 0.11 (0.004)
0-;0-00*< O
O :!&
Valve seat O 2
Width IN
Ol .85-1.15 0033-0045)
0-'-;0-0++0-0*< 1.6 (0.063)
-;0-0+< O
O O EX
R Ol .25-1.55 (0049-0061
--;0-0*50-0 2.0 (0.079)
-0;0-0$5< O
O O Stem installed height
!!
IN
Ol 3 .17-53.64 (2.093-2.112)
+-$+-*;-05+-< 53.69 (2.122)
+-'5;-< O
O O EX
R Ol 317-5364 (2093-2112)
+-$+-*;-05+-< 53.69 (2.122)
+-'5;-< O
O Valve spring
:!&
O F
ree length
!
R
IN and EX Ol 8.7 (2.31)
'-$;-+< O
O Valve guide
:!&
O |.D.
-(- IN
Ol 51553 (0217-0218)
--+;0-$0-'< 5.55 (0.219)
-;0-5< O
O O EX
R O| 5.51-5.53 (0217-0218)
--+;0-$0-'< 5.55 (0.219)
-;0-5< O
O O Installed height
!!
IN
O| 17.85-18.35 (0703072)
$-''-+;0-$0+0-$< O
O O EX
R O| 18.65-19.15 ( 0734-0754)
'-5-;0-$+*0-$*< O
O 1#
Rocker arm O %!
Arm-to-shaft clearance IN
O| 0017-0050 (00007-00020) 0-0';0-00+<
0-0$0-00;0-000$0-000< 0.08 (0.003) O
O O EX
R O| 0018-0054 ( 0.0007-0.0021)
0-0'0-0*;0-000$0-00< 0.08 (0.003)
0-0';0-00+< O
*1: 4
!
G9 Timing belt side
*2: (
G9 Distributor side
- &
Cylinder HeadNalve Train (F18B2, F1833, F20B6
# .24- /+8":+8":+$"5
2-4

engines)— Section 6
! 0J
5
O O| MEASUREMENT
%;%%, OI STANDARD (NEW)
%4%& O
O Compression
OI 250 rpm (min-1)
0; and
< !
Nominal OI 1 ,420 (14.5, 206)
A*0;*-A0< O
O OI wide open throttle
3! ,
Minimum OI 9 30 (9.5, 135)
5+0;5-A+< O
O O| kPa (kgf/cmZ,
#;#
= psi)
A< ,/-&
Max. variation OI 2 00 (2.0, 28)
00;-0A'< O
I
O Cylinder head
! OI Warpage
2
O 0.05 (0.002)
0-0;0-00< O
O O| Height
6
O 92.95-93.05 (3659-3663)
5-55+-0;+-5+-+< O
O
Camshaft O| End play
! O| 0.05-0.15 (0002-0006)
0-00-;0-000-00< 0.5 (0.02)
0-;0-0< O
O O| Camshaft-to-holder oil clearance
!!! O| 0050-0089 (00020-00075)
0-000-0'5;0-0000-00$< 0.15 (0.006)
0-;0-00< O
O O| Total runout
4! O| 0.003 (0.001) max.
0-00+;0-00</- 0.04 (0.002)
0-0*;0-00< O
O O| Cam lobe height
!
OI O
O OI F1882,
')A F1883 engines:
')+
9 OI O
O OI IN
Primary
OI 38.539 1.5173
+'-+5;-$+< O
AAAA
VVVV
O O Mid
, OI 39.223 1.5442
+5-+;-**< O
O O| Secondary
OI 33.913 1.3352
++-5+;-++< O
O O| EX
R OI 38.645 1.5215
+'-*;-< O
O O| F2OB6 engine:
0)
9 OI O
O O| IN
Primary
OI 38.539 (1.5173)
+'-+5;-$+< O
O O| Mid
, O| 39.725 (1.564)
+5-$;-*< O
O O| Secondary
O| 33.913 (1.3352)
++-5+;-++< O
O O| EX
R O| 38.645 (1.5215)
+'-*;-< O
O :!&
Valve O| Valve clearance (cold)
:!&!;!< IN
O1 0.24-0.28 (0009-0011)
0-*0-';0-0050-0< O
O O| EX
R O| 0.28-0.32 (0011-0013)
0-'0-+;0-00-0+< O
O O| :!&8-(-
Valve stem O.D. IN
O| 5485-5495 (02159-02163
-*'-*5;0-50-+< 5.455 (0.2148)
-*;0-*'< O
O| 5450-5460 (02146-02150
VVVV
O O| EX
R -*0-*0;0-*0-0< 5.420 (0.2134)
-*0;0-+*< O
O O| Stem-to-guide clearance

! IN
O| 0020-0045 (00008-00018
0-000-0*;0-000'0-00'< 0.08 (0.003)
0-0';0-00+< O
O O| EX
R O| 0.055-0.080 (00022-00031
0-00-0'0;0-000-00+< 0.12 (0.005)
0-;0-00< O
O :!&
Valve seat O| Width
2 IN
O1 1.25-1.55 (0.049-0.061)
--;0-0*50-0< 2.00 (0.079)
-00;0-0$5< O
O O| EX
R O| 125-155 (0049-0061
--;0-0*50-0 2.00 (0.079)
-00;0-0$5< O
O O| Stem installed height
!!
IN
O| 46.75-47.55 (1.841-1872)
*-$*$-;-'*-'$< 47.80 (1.882)
*$-'0;-''< O
O O| EX
R OI 46.68-47.48 (1 .838-1 .869)
*-'*$-*';-'+'-'5< 47.73 (1.879)
*$-$+;-'$5< O
O Valve spring
:!&
O| Free length
!
IN
O| 51.08 (2.0111)
-0';-0< O
O O| EX
R O| 55.58 (2.188)
-';-''< O
O Valve guide
:!&
O| .D.
-(- IN
O| 5.515-5530 (02171-02177)
--+0;0-$0-$$< 5.55 (0.219)
-;0-5< O
O
O
O
O|
O|
O|
Installed height
!!

EX
R
IN

EX
R
O|
O|
O|
E
5.515-5530 02171-02177)
--+0;0-$0-$$<
21.20-22.20 0.835-0874)
-0-0;0-'+0-'$*<
20.63-21.63 (0812-0854)
0-+-+;0-'0-'*<
5.55 (0.219)
-;0-5<

O
O
O
O 1#
Rocker arm O| Arm-to-shaft clearance
%! IN
O| 0026-0067 ( 0001-00026)
0-00-0$;0-000-00< 0.08 (0.003)
0-0';0-00+< O
O O| EX
R O| 0018-0054 (00007-00021)
0-0'0-0*;0-000$0-00< 0.08 (0.003)
0-0';0-00+< O
- & 3
Cylinder HeadNalve Train (H22A7 engine)— Section
# .24- /.7! 0J

6
5

?!
9;<
O O| MEASUREMENT
%;%%, O| STANDARD (NEW)
%4%& O
O Compression
O| 0;G<
250 rpm (min*1) and !
Nominal O| ,270 (13.0, 185)
A$0;+-0A'< O
O O| 3!
wide open throttle ,
Minimum O| 30 (9.5, 135)
5+0;5-A+< O
O O| #;#
=
kPa (kgf/cmz, psi)
A< ,/-&
Max. variation O| 00 (2.0, 28)
00;-0A'< O
O Cylinder head
! O| 2

Warpage O| 0.05 (0.002)
0-0;0-00< O
O O| 6

Height O| 14695-14705 (5785-5789)
*-5*$-0;-$'-$'5< O
O
Camshaft O| !
End play O| 0.05-0.15 (0.002-0.006)
0-00-;0-000-00< 0.5 (0.02)
0-;0-0< O
O O| !!!
Camshaft-to-holder oil clearance O| 0-000-0'5;0-0000-00$< 0.15 (0.006)
0.050-0.089 (00020-00075) 0-;0-00< O
O O| 4!
Total runout O| 0.003 (0.001) max.
0-00+;0-00</- 0.04 (0.002)
0-0*;0-00< O
O O| !

Cam lobe height O| O
O O| F1882,
')A F1883 engines:
')+
9 O| O
O O IN
Primary
O| 34.041 (1.3402
+*-0*;-+*0< O
VVVVVV
O O Mid
, O| 37.229 ( 1.4657
+$-5;-*$< O
O O Secondary
O| 34.071 (1.3414
+*-0$;-+**< O
O O EX
R Primary
OI 33.745 ( 1.3285
++-$*;-+'< O
O O Mid
, O 36.704 ( 1.4450
+-$0*;-**0< O
O O Secondary
O| 34.683 (1.3655
+*-'+;-+< O
0.15-0.19 (0.006-0.007) *1
I
O :!&
Valve Valve clearance (cold)
O :!&!;!< IN
O 0-0-5;0-000-00$<G O
O O EX
R O 0.17-0.21 (0.007-0.008) *1
0-$0-;0-00$0-00'<G O
O Valve stem O.D.
O :!&8-(- IN
O| 5.475-5.485 (02156-02159)
-*$-*';0-0-5< 5.455 (0.2144)
-*;0-**< O
O O EX
R O| 5.475-5.485 (02156-02159)
-*$-*';0-0-5< 5.420 (0.2144)
-*0;0-**< O
O Stem-to-guide clearance
O
! IN
O| 0025-0055 (00010-00022)
0-00-0;0-0000-00< 0.08 (0.003)
0-0';0-00+< O
O O EX
R O| 0050-0080 (00020-00031)
0-000-0'0;0-0000-00+< 0.11 (0.004)
0-;0-00*< O
O :!&
Valve seat Width
O 2 IN
O| 1 .30-1.50 (0051-0059)
-+0-0;0-00-05< 2.00 (0.079)
-00;0-0$5< O
O O EX
R O| 1 .25-1.55 (0.049—0.061
--;0-0*50-0 2.00 (0.079)
-00;0-0$5< O
O Stem installed height
O !!
IN
O| 4 2.5-42.7 (1673-1681)
*-*-$;-$+-'< 42.95 (1.691)
*-5;-5< O
O O EX
R O| 4 353-441 (1.728—1.736)
*+-5**-;-$'-$+< 44.35 (1.746)
**-+;-$*< O
O Valve spring
:!&
O Free length
!
IN
8
(Duter O| 44.10 (1.736)
**-0;-$+< O
O O
Inner O| 4 1.32 (1.627)
*-+;-$< O
O O EX
R 8
(Duter O| 4 4.92 (1.769)
**-5;-$5< O
O O
Inner O| 40.01 (1.575)
*0-0;-$< O
O Valve guide
:!&
|.D.
O -(- IN
O| 5510-5530 (02169-02177)
-0-+0;0-50-$$< 5.55 (0.219)
-;0-5< O
O
O
O
O
Installed height
O !!

O
EX
R
IN

EX
R
O|
O|
O|
I
5535-5555 02179-02187)
-+-;0-$50-'$<
14.55-15.05 0573-0593)
*--0;0-$+0-5+<
14.95-15.45 (0589-0608)
*-5-*;0-'50-0'<
5.60 (0.220)
-0;0-0<

O
O
O
O 1#
Rocker arm O %!
Arm-to-shaft clearance IN
O| 0025-0052 ( 00010-00020)
0-00-0;0-0000-000< 0.08 (0.003)
0-0';0-00+< O
O O EX
R O| 0025-0052 (00010-00020)
0-00-0;0-0000-000< 0.08 (0.003)
0-0';0-00+< O
*1: ,
3#
G9 Measuring point between camshaft and rocker arm
- &
Engine Block (D16B6 engine) — Section 7
%! "
6/)5"5! 0J
7
2-6
5
O O| MEASUREMENT
%;%%, Ol STANDARD (NEW)
%4%& O
O Cylinder block
!!# O| Warpage of deck surface
2
# Ol 0.07 (0.003) max
0-0$;0-00+</ 0.10 (0.004)
0-0;0-00*< O
O O| Bore diameter
) Ol 75.00-75.02 (2.953-2954)
$-00$-0;-5+-5*< 75.07 (2.958)
$-0$;-5< O
O O| Bore taper
) Ol - 0.05 (0.002)
0-0;0-00< O
O O| Reboring limit
1
! Ol - 0.5 (0.02)
0-;0-0< O
O
Piston O| Skirt O.D.
#8-(- At 5 mm (0.2 in)
%;0-< Ol 74980-74990 (29520-29524)
$*-5'0$*-550;-50-5*< 74.970 (2.9516)
$*-5$0;-5< O
O O| from bottom of skirt
# Ol O
O O| Clearance in cylinder
!! Ol 0.010-0.040 (00004-00016)
0-000-0*0;0-000*0-00< 0.05 (0.002)
0-0;0-00< O
O O| Groove width (for ring)
.&3;
< Ol O
O OI Top
4 Ol 1.020-1.030 (00404-00406)
-00-0+0;0-0*0*0-0*0< 1.05 (0.041)
-0;0-0*< O
O Ol Second
Ol 1.220-1.230 (00480-00484)
-0-+0;0-0*'00-0*'*< 1.25 (0.049)
-;0-0*5< O
O Ol Oil
8! Ol 2.805-2.820 (0.1104-0.1110)
-'0-'0;0-0*0-0< 2.85 (0.112)
-';0-< O
O Piston ring

O| Ring-to-groove clearance
1

&! Ol O
O O| Top
4 Ol 0. 030-0060 (0.0012-0.0024)
0-0+00-00;0-000-00*< 0.13 (0.005)
0-+;0-00< O
O O| Second
Oi 0 030-0055 (0.0012-00022)
0-0+00-0;0-000-00< 0.13 (0.005)
0-+;0-00< O
O O| Ring end gap
1

O O
O O| Top
4 O| 015-030 (0008-0012 )
0-0-+0;0-000-0< 0.70 (0.028)
0-$0;0-0'< O
O O| Second
O| 0.20-0.70 (0.008—0.028)
0-00-$0;0-00'0-0'< 0.80 (0.03)
0-'0;0-0+< O
O O| Oil
8! Ol 020-080 (0008-0031)
0-00-'0;0-00'0-0+< 0.90 (0.035)
0-50;0-0+< O
O Piston pin
O| 0D
8-( Ol 18994-19000 (07478-07480)
'-55*5-000;0-$*$'0-$*'0< - O
O O| Pin-to-piston clearance
! Ol 0.010-0.022 (00004-00009)
0-000-0;0-000*0-0005< - O
O Connecting rod

O| Pin-to-rod interference
Ol 0.014-0.040 (00008-00018)
0-0*0-0*0;0-0000-00< - O
O O| Small end bore diameter
!! Ol 18.98-18.98 (0.748-0.747)
'-5'-5';0-$*0-$*$< - O
O O| Large end bore diameter

Ol O
O O| Nominal
! Ol 48.0 (1.89)
*'-0;-'5< - O
O O| End play installed on crankshaft
!!!# Ol 0.15-0.30 (0.008-0012)
0-0-+0;0-000-0< 0.40 (0.018)
0-*0;0-0< O
O #
Crankshaft O| Main journal diameter
,7 ! Ol 54975-55000 (21644-21654)
*-5$-000;-**-*< - O
O O| Rod journal diameter
17 ! Ol 44976-45000 (1 .7707-1 .7717)
**-5$*-000;-$$0$-$$$< - O
O O| Taper
4 Ol 0.0025 (0.0001) max.
0-00;0-000</- 0.005 (0.0002)
0-00;0-000< O
O O| Out of Round
8 1 Ol 0.0025 (0.0001) max.
0-00;0-000</- 0.005 (0.0002)
0-00;0-000< O
O O| End play
! Ol 0.10-0.35 (0004-0014)
0-00-+;0-00*0-0*< 0.45 (0.018)
0-*;0-0'< O
O O| Total runout
4! Ol 0.03 (0.001) max.
0-0+;0-00</- 0.04 (0.002)
0-0*;0-00< O
O Beanng
)
O| Main bearing-to-journal oil clearance
,
7 !!! Ol O
O O| No. 1 and 5journals
-7 ! O| 0018-0036 (00007-00014)
0-0'0-0+;0-000$0-00*< 0.05 (0.002)
0-0;0-00< O
O O| No. 2, 3 and 4 journals
-A+*7 ! O| 0024-0042 (00009-00017)
0-0*0-0*;0-00050-00$< 0.05 (0.002)
0-0;0-00< O
O O| Rod bearing-to-journal oil clearance
1
7 !!! O| 0020-0038 (00008-00015)
0-000-0+';0-000'0-00< 0.05 (0.002)
0-0;0-00< O
- &
Engine Block (F18B2, F1833, F20B6 engines) —
%! "
6/+8":+8":+$"5! 0J
2-7
7
Section 7

7

?!
9;<
O O| MEASUREMENT
%;%%, O| ,))/,%10
STANDARD (NEW) SERVICE LIMIT
%4%& O
O Cylinder block
!!# O| Warpage of deck surface
2
# O| 0-0$;0-00+</-
0.07 (0.003) max. 0.10 (0.004)
0-0;0-00*< O
O O| Bore diameter
) %
Aorl O| '-00'-00;+-+*+-+*'<
85010-85020 (3.3465-33468) '-0$0;+-+*5<
85.070 (3.3492) O
O O| )
Borll O| '-000'-00;+-+*+-+*'<
85000-85010 (3.3465-33468) '-0$0;+-+*5<
85.070 (3.3492) O
O O| Bore taper
) O - 0.05 (0.002)
0-0;0-00< O
O O| Reboring limit
1
! O - 0.25 (0.010)
0-;0-00< O
O Piston
O| Skirt O.D.
#8-(- at 16 mm
!
No letter 4.980-84.990 (3.3457-33461) '*-5$0;+-++<
O '*-5'0'*-550;+-+*$+-+*< 84.970 (3.353) O
0000
O O (0.6 in) from
;0-< )
Letter B 4.970-84.980 (33453-33457) '*-50;+-+**5<
O '*-5$0'*-5'0;+-+*++-+*$< 84.960 (3.3449) O
O O (bottom of skirt)
;#< O O
O O Clearance in cylinder
!! 0.020-0.040 ( 008-00015)
O 0-000-0*0;0-00'0-00< 0
0-0;0-00< O
GOOD
O O Groove width (for ring)
.&3;
< 4
Top 1.220-1.230 ( .0480-0.0484)
O -0-+0;0-0*'00-0*'*< 1.
-;0-0*5< O
O O
Second 1.220-1.230 ( 0480-00484)
O -0-+0;0-0*'00-0*'*< 1
-;0-0*5< O
O O Oil
8! 2805-2825 ( .1104-0.1112)
O -'0-';0-0*0-< 2
-';0-< O
O Piston ring

O Ring-to-groove clearance
1

&! O O
O O 4
Top 0.035-0.060 (00014-00024)
O 0-0+0-00;0-00*0-00*< 0
0-+;0-00< O
O O
Second O| 0!0+00-0;0-000-00<
0|030-0.055 (00012-00022) 0.
0-+;0-00< O
O O Ring end gap
1

4
Top O| 0-00-+;0-00'0-0*<
0.20-0.35 (0008-0014) 0
0-0;0-0*< O
O O
Second O| 0-*00-;0-00-0<
0.40-0.55 (0016-0022) 0.
0-$0;0-0'< O
O O Oil
8! O| 0-00-$0;0-00'0-0'<
0.20-0.70 (0008-0028) 0.
0-'0;0-0+< O
O Piston pin
O O.D.
8-(- O| -5-5;0-'*0-'*'<
21.961-21.965 (0.8646-08648) -5+;0-'*+<
21.953 (0.8643) O
O O Pin-to-piston clearance
! -0.0050-+0.0020
O| 0-000V0-000 0.04 (0.0002)
0-0*;0-000< O
O O (-0.00020-+0.00008)
O| ;0-0000V0-0000'< O
O Connecting rod

O Pin-to-rod clearance
! 0.020 (0.0008)
0005-0015 (00002-00005) 0-00;0-000'<
O| 0-000-0;0-0000-000< O
O O Small end bore diameter
!! 21 .970-21 .976 (08650-08552) -
O| -5$0-5$;0-'00-'< O
O O Large end bore diameter

!
Nominal 48.0 (1.89)
O| *'-0;-'5< - O
O O End play installed on crankshaft
!!!# 0.15-0.30 (0006-0.012)040
O| 0-0-+0;0-000-0< (0.016)
0-*0;0-0< O
O Crankshaft
# O Main journal diameter
,7 ! O| O
O O No. 1, 2 and 4 journals
-A*7 ! 54980-55004 (21646-21555) -
O| *-5'0-00*;-*-< O
O O No. 3 journal
-+7 ! 54975-55000 (21644-2155) -
O| *-5$-000;-**-< O
O O No. 5 journal
-7 ! 54992-55016 (21650-21550) -
O| *-55-0;-0-0< O
O O| Rod journal diameter
17 ! 44975-45000 (17707-17717) -
O| **-5$*-000;-$$0$-$$$< O
O O| Taper
4 0.005 (0.0002) max.
O| 0-00;0-000</- 0.010 (0.0004)
0-00;0-000*< O
O O| Out-of-round
8 0.005 (0.0002) max.
O| 0-00;0-000</- 0.010 (0.0004)
0-00;0-000*< O
O O| End play
! 0.10-0.35 (00040014)
O| 0-00-+;0-00*0-0*< 0.45 (0.018)
0-*;0-0'< O
O O| Runout
1 0.02 (0.001) max.
O| 0-0;0-00</- 0.04 (0.002)
0-0*;0-00< O
O Beanngs
)
O| Main bearing-to-journal oil clearance
,
7 !!! Ol O
O O: No. 1 and 4journals
-*7 ! 0.050 ( 0.0020 )
0013-0037 ( 00005-00015 ) 0-00;0-000<
O| 0-0+0-0+$;0-0000-00< O
O O No. 2 journal
-7 ! 0021-0045 (00008-00018) 0-00;0-000<
O| 0-00-0*;0-000'0-00'< 0.050 ( 0.0020 ) O
O O| No. 3 journal
-+7 ! 0.055 (0.0022)
0025-0049 (00010-00019) 0-0;0-00<
O| 0-00-0*5;0-0000-005< O
O O| No. 5 journal
-7 ! 0009-0033 ( 00004-00013 )
O| 0-0050-0++;0-000*0-00+< 0.040 ( 0.0016 )
0-0*0;0-00< O
O O| Rod bearing-to-journal oil clearance
1
7 !!! 0015-0043 ( 0.0006-0.0017 )
O| 0-00-0*+;0-0000-00$< 0.050 ( 0.0020 )
0-00;0-000< O
O Balancer shaft
)! O| Journal diameter
" ! O| O
O O| No. 1 front journal
-7 ! 42.71 ( 1.6 81)
42722-42734 (16820-15824) *-$;-'<
O| *-$*-$+*;-'0-'*< O
O O| No. 1 rearjournal
-7 ! 42.71 ( 1.6 81)
20938-20950 (08243-08248) *-$;-'<
O| 0-5+'0-50;0-'*+0-'*'< O
O O| No. 2 front and rearjournals
-7 ! 38.70 ( 1.5 24)
38712-38724 (15241-15245) +'-$0;-*<
O| +'-$+'-$*;-*-*< O
-+7 ! 34.71 1.3 67)
34772-34734 (13670-13575) +*-$;-+$<
O| +*-$$+*-$+*;-+$0-+$< O
O O: Journal taper
" ! 0.005 (0.0002) max.
O| 0-00;0-000</- - O
O O End play
!
Front 0.10-0.40 (0004-0015)
O| 0-00-*0;0-00*0-0< - O
O O| 1
Rear 0.04-015(0002-0005)
O| 0-0*0-;0-000-00< - O
O O| 4!
Total runout 0.02 (0.001) max.
O| 0-0;0-00</- 0.03 (0.001)
0-0+;0-00< O
O O| Shaft-to-bearing oil clearance

!! O| O
O O| No. 1 front, No. 3 front and rear
-A-+ 0066-0098 (00026-00039)
O| 0-00-05';0-000-00+5< 0.12 (0.005)
0-;0-00< O
O O| journals
7 ! O| O
O O| No. 1 rearjournal
-7 ! 0.050-0.07 (0.0020-0.0030)
O| 0-000-0$;0-0000-00+0< 0.09 ( 0 .00 4)
0-05;0-00*< O
-7 ! 0076-0108 (00030-00043)
O| 0-0$0-0';0-00+00-00*+< 0.13 ( 0 .005)
0-+;0-00< O
O )!
Balancer shaft O| -(-
|.D. OI 42800-42820
*-'00*-'0;-'0-''< 42.8 3 ( 1.686)
(16850-16858) *-'+;-'< O
O bearing

O| No. 1 front journal
-7 ! 21.02 ( 0.828)
21.000-21013 (08268-08273) -0;0-''<
O| -000-0+;0-''0-'$+< O
O O| -7 !
No. 1 rearjournal 38.8 3 ( 1.529)
38800-38820 (15276-15283) +'-'+;-5<
O| +'-'00+'-'0;-$-'+< O
-7 ! O|34800-34820(13701-13709) 34.8 3 ( 1 .371 )
+*-'00+*-'0;-+$0-+$05< +*-'+;-+$< O
-+7 ! O O
- &
8
Engine Block (H22A7 engine) — Section 7
%! "
6/.7! 0J
7
O Ol MEASUREMENT
%4%& O
Cylinder block
O !!# O| 2
#
Warpage of deck surface O| 0.07 (0.003) max.
0-0$;0-00+</- 0.10 (0.004)
0-0;0-00*< O
O Ol )
Bore diameter A or |
% O| 87010-87020 (34256-34260)
'$-00'$-00;+-*+-*0< 87.070 (3.4279)
'$-0$0;+-*$5< O
O Ol B or II
) O| 87.000-87.010 (34252-34256)
'$-000'$-00;+-*+-*< 87.070 (3.4279)
'$-0$0;+-*$5< O
O Ol )
Bore taper O| - 0.05 (0.002)
0-0;0-00< O
O Ol 1
!
Reboring limit O| - 0.25 (0.010)
0-;0-00< O
O
Piston Ol #8-(-
Skirt O.D. at 15 mm
No letter
! O| 86993-87006 (34249-34254)
'-55+'$-00;+-**5+-**< 86.980 (3.4244)
'-5'0;+-***< O
O Ol (0.6 in) from
;0-< Letter B
) O| 86983-86996 (34245-34250)
'-5'+'-55;+-**+-*0< 86.980 (3.4240)
'-5'0;+-**0< O
O Ol (bottom of skirt)
;#< O| O
O Ol !!
Clearance in cylinder O| 0 .004-0027 (00002-00011)
0-00*0-0$;0-0000-00< 0.04 (0.002)
0-0*;0-00< O
O Ol .&3;
<
Groove width (for ring) Top
4 O| 1 2401.255 (00488-00494)
-*0-;0-0*''0-0*5*< 1.275 (0.0502)
-$;0-00< O
O Ol Second
O| 1 .230-1245 (00484-00490)
-+0-*;0-0*'*0-0*50< 1.265 (0.0498)
-;0-0*5'< O
O Ol Oil
8! Oi 2 .8 05-2825 ( 0.1104-0.1112)
-'0-';0-0*0-< 2.85 (0.112)
-';0-< O
Piston ring
O
Ol 1

&!
Ring-to-groove clearance O O
O Ol Top
4 O| 0.055-0.085 (00022-00033)
0-00-0';0-000-00++< 0.13 (0.005)
0-+;0-00< O
O Ol Second
O| 0.040-0.070 (00016-00028)
0-0*00-0$0;0-000-00'< 0.13 (0.005)
0-+;0-00< O
O Ol 1

Ring end gap Top
4 O| 0.25-0.35 (0010-0014)
0-0-+;0-000-0*< 0.60 (0.024)
0-0;0-0*< O
O Ol Second
O| 0.60-0.70 (0024-0028)
0-00-$0;0-0*0-0'< 0.90 (0.035)
0-50;0-0+< O
O Ol Oil
8! O| 0.20-0.70 (0.008-0.028)*1
0-00-$0;0-00'0-0'<G 0.80 (0.031) *1
0-'0;0-0+<G O
O Ol O| 0.20-0.50 ( 0.008-0.020)*2
0-00-0;0-00'0-00<G 0.60 (0.024)*2
0-0;0-0*<G O
Piston pin
O Ol 8-(-
O.D. O| 21 .961-21.965 (08646-08648)
-5-5;0-'*0-'*'< 21.953 (0.8643)
-5+;0-'*+< O
O Ol !
Pin-to-piston clearance O| -0.0030-+0.0060
0-00+0V0-000 0.009 (0.0004)
0-005;0-000*< O
O Ol O| (-0.00012-+0.00024)
;0-000V0-000*< O
Connecting rod
O
O| !
Pin-to-rod clearance O| 0.005-0.015 (00002-00006)
0-000-0;0-0000-000< 0.002 (0.0008)
0-00;0-000'< O
O Ol !!
Small end bore diameter O| 21970-21976 (08650-08652)
-5$0-5$;0-'00-'< - O
O Ol

Large end bore diameter Nominal
! O| 51.0 (2.01)
-0;-0< - O
O Ol !!!#
End play installed on crankshaft O| 0.15-0.30 (0006-0012)
0-0-+0;0-000-0< 0.40 (0.016)
0-*0;0-0< O
Crankshaft
O # O| ,7 !
Main journal diameter O| O
O Ol No. 1, 2 and 4 journals
-A*7 ! O| 54980-55004 (21646-21655
*-5'0-00*;-*-< O
vvvv
O Ol No. 3 journal
-+7 ! O| 54976-55000 (21644-21654
*-5$-000;-**-*< O
O Ol No. 5 journal
-7 ! O| 54992-55016 (21650-21660
*-55-0;-0-0< O
O Rod journal diameter
O 17 ! O| 47976-48000 (1 .8888-1 .8898
*$-5$*'-000;-''''-''5'< O
O Taper
O 4 O| 0.005 (0.0002) max.
0-00;0-000</- 0.006 (0.0002)
0-00;0-000< O
O Out-of—round
O 8 O| 0.004 (0.0002) max.
0-00*;0-000</- 0.006 (0.0002)
0-00;0-000< O
O End play
O ! O| 0.10-0.35 (0.004-0.014)
0-00-+;0-00*0-0*< 0.45 (0.0016)
0-*;0-00< O
O Runout
O 1 O| 0.03 (0.001) max.
0-0+;0-00</- 0.04 (0.002)
0-0*;0-00< O
Bearings
O )
Main bearing-to-journal oil clearance
O| ,
7 !!! O| O
O O No. 1 and 4journals
-*7 ! O| 0013-0037 (00005-00015)
0-0+0-0+$;0-0000-00< 0.050 (0.0020)
0-00;0-000< O
O O No. 2 journal
-7 ! O| 0021-0045 (0008-00018)
0-00-0*;0-00'0-00'< 0.050 (0.0020)
0-00;0-000< O
O O No. 3 journal
-+7 ! O| 0025-0049 (00010-00019)
0-00-0*5;0-0000-005< 0.055 (0.0022)
0-0;0-00< O
O O No. 5 journal
-7 ! O| 0009-0033 (0.0004-0.0013)
0-0050-0++;0-000*0-00+< 0.040 (0.0016)
0-0*0;0-00< O
O Rod bearing-to-journal oil clearance
O 1
7 !!! O| 0027-0055 (00011-00022)
0-0$0-0;0-000-00< 0.060 (0.0024)
0-00;0-00*< O
O )!
Balancer shaft Journal diameter
O " ! Ol O
O O No. 1 front journal
-7 ! O| 42722-42734 (1 .6820-1.6824
*-$*-$+*;-'0-'*< 4 2.1 7 1.681)
*-$;-'< O
VVVV
AAAA
O O No. 1 rearjournal
-7 ! O| 20938-20950 (08243-08248
0-5+'0-50;0-'*+0-'*'< 2 0.2 9 0.824)
0-5;0-'*< O
O O No. 2 front and rearjournals
-7 ! O| 38712-38724 (15241-15246
+'-$+'-$*;-*-*< 3 8.0 7 1.524)
+'-$0;-*< O
-+7 ! O| 34722-34734 (1 .3670-1 .3675
+*-$+*-$+*;-+$0-+$< 3 4.1 7 1.367)
+*-$;-+$< O
O Journal taper
O " ! O| 0.005 (0.0002) max.
0-00;0-000</- - O
O End play
O ! Front
O| 0.10-0.40 (0.004-0.016)
0-00-*0;0-00*0-0< - O
O O Rear
1 O| 0.04-0.15 (0002-0006)
0-0*0-;0-000-00< - O
O Total runout
O 4! O| 0.02 (0.001) max.
0-0;0-00</- - O
O Shaft-to-bearing oil clearance
O
!! O O
O O No. 1 front, No. 3 front and rear
-A-+ O 0.066-0.098 (00026-00039)
0-00-05';0-000-00+5< 0.12 (0.005)
0-;0-00< O
O O journals
7 ! O O
-7 ! O 0. 050-0075 (00020-00030)
0-000-0$;0-0000-00+0< 0.09 (0.004)
0-05;0-00*< O
-7 ! O 0076-0108 (00030-00043)
0-0$0-0';0-00+00-00*+< 0.13 (0.005)
0-+;0-00< O
Balancer shaft
O )! ID.
O -(- O 42800-42820 (1 .6850-1 .6858)
*-'00*-'0;-'0-''< 42.83 (1.686)
*-'+;-'< O
beanng
O
O No. 1 front journal
-7 ! O 21000-21013 (08268-08273)
-000-0+;0-''0-'$+< 21.02 (0.828)
-0;0-''< O
-7 ! O 38800-38820 (1 .5276-1 .5283)
+'-'00+'-'0;-$-'+< 38.83 (1.529)
+'-'+;-5< O
-7 ! O 34.800-34.820 (13701-13709)
+*-'00+*-'0;-+$0-+$05< 34.83 (1.371)
+*-'+;-+$< O
-+7 ! O O
*1: RIKEN manufactured piston ring
G91>
*2: TEIKOKU PISTON RING manufactured piston ring

G94 >8>?481.

- & 2_9
9
Engine Lubrication - Section 8/Cooling — Section 10
%! &*

82
!J
$
Engine Lubrication - Section 8

%! &*

8 Unit of length: mm (in)
?!
9;<
O O| MAINTENANCE
,%,,% O| STANDARD (NEW)
%4%& O
Engine oil
O
! O|
Capacity O| D1636 engine:
)5"5! F O
O O| ;?FAF<
/(US qt, Imp qt) O| 4.0 I (4.2US qt. 3.5 Imp qt.) for engine overhaul
*-0;*-?F-+-F-<
& ! O
O O| OI 3.6 I (3.8 US qt. 3.2 Imp qt.) for oil change, with filter
+-;+-'?F-+-F-<!
A3! O
O O| OI 3.3 I (3.5 US qt. 2.9 Imp qt.) for oil change, without
+-+;+-?F--5F-<!
A3 O
O O| OI filter
! O
O O| OI F1832, F1833, F2036 engines:
+8":+8":+$"5! F O
O O| OI 5.7 I (6.0US qt. 5.0 Imp qt.) for engine overhaul
-$;-0?F--0F-<
& ! O
*-*;*-?F-+-5F-<!
A3! O
O O| OI 4.1 [(4.3 US qt. 3.6 Imp qt.) for oil change, without
*-;*-+?F-+-F-<!
A3 O
O O| OI filter
! O
O O| OI H22A7 engine:
.7! F O
O O| OI 5.9 I (6.2US qt. 5.2 Imp qt.) for engine overhaul
-5;-?F--F-<
& ! O
*-';-?F-*-F-<!
A3! O
O O| O: 4.5 I (4.8 US qt. 4.0 Imp qt.) for oil change, without
*-;*-'?F-*-0F-<!
A3 O
O O| O filter
! O
Oil pump
O 8! O| !
Inner-to-outer rotor clearance O| 0.02-0.14 (0001-0006)
0-00-*;0-000-00< 0.20 (0.008)
0-0;0-00'< O
O O| D1636 engine
()
O| 0.02-0.16 (0001-0006)
0-00-;0-000-00< 0.20 (0.008)
0-0;0-00'< O
O O| Except D16B6 engine
/()
OI O
O O|
!
Pump housing-to-outer rotor clearance O| 0 .10 -0. 8 (0.004-0007)
0-00-';0-00*0-00$< 0.20 (0.008)
0-0;0-00'< O
_\_\
O O| D1636 engine
()
O| 0 .10 -0 9 (0.004-0007)
0-00-5;0-00*0-00$< 0.21 (0.008)
0-;0-00'< O
O O| Except D16B6 engine
/()
OI O
O O|
/!!
Pump housing-to-rotor axial clearance O| 0.03-0.08 (0001-0003)
0-0+0-0';0-000-00+< 0.15(0.006)
0-;0-00< O
O O| D1636 engine
()
O| 0 .02-0.07 (0.001-0.003)
0-00-0$;0-000-00+< 0.12 (0.005)
0-;0-00< O
O OO| | Except D16B6 engine
/()
OI O
Relief valve
O 1!&!& O|

!-'0P
Pressure setting at engine oil temp. 80°C OI O
O Oi ;$P
(176°F)<#;#
=A<
kPa (kgf/cm2, psi) OI O
O O at idle
! OI 70 (0.7, 10) min.
$0;0-$A0<- O
O O| at 3,000 rpm (min-1)
+A000;< O| 3 40 (3.5, 50) min.
+*0;+-A0<- O
Cooling - Section 10

!
$
O OI MAINTENANCE
,%,,% O| STANDARD (NEW)
,))/,%10 O
Radiator
O 1 O| !;?F-F-<
Coolant capacity I (US qt. Imp qt.) O| D1636 engine:
)5"5! F O
O O| ;!

AA!
!
(including engine, heater, cooling line and O| 4.6 I (4.9 US qt. 4.1 Imp qt.) for overhaul
*-;*-5?F-*-F-<& ! O
O O| &<
reservoir) O| 3.9 I (4.1 US qt. 3.4 Imp qt.) for coolant change
+-5;*-?F-+-*F-<!
O
O O| 1&0-;0-'?F-0-*'
Reservoir capacity 0.55 I (0.58 US qt. 0.48 OI F1832, F1833, F2036 engines:
+8":+8":+$"5! F O
O O| F-<
Imp qt) O| MIT
,=4 O
O OI OI 5.8 I (6.1US qt. 5.1 Imp qt.) for overhaul
-';-?F--F-<& ! O
O OI O: 4.2 I (4.4 US qt. 3.7 Imp qt.) for coolant change
*-;*-*?F-+-$F-<!
O
O OI O A/T
%=4 O
-$;-0?F--0F-<& ! O
O OI OI 4.1 [(4.3 US qt. 3.6 Imp qt.) for coolant change
*-;*-+?F-+-F-<!
O
O OI OI H22A7 engine:
.7! F O
-5;$-+?F--F-<& ! O
O OI OI 3.3 I (3.5 US qt. 2.9 Imp qt.) for coolant change
+-+;+-?F--5F-<!
O
Radiator cap
O 1 OI 8
#;#
=A<
Opening pressure kPa (kgf/cm2, psi) OI 93-123 (0.95-1.25, 14-18)
5++;0-5-A*'< O
Thermostat
O 4 Start to open °C ( °F)<
O| P;P OI 70-80 (169-176)
$0'0;5$< O
O O| Fully open °C (°F)<
!!P;P OI 90 (194)
50;5*< O
O Valve lift a fully open:
O| :!&! !!9 OI O
O OI except H22A7 engine
/6%$
O| 8 .0 (0.31) min.
'-0;0-+<- O
O O| H22A7 engine
6%$
O| 1 0.0 (0.39) min.
0-0;0-+5<- O
Cooling fan
O !
Thermostat “ON” temperature °C (°F)<
O| 4K8L P;P OI O
O O| except H22A7 engine
/6%$
O| 91-95 (196-203)
55;50+< O
O O| H22A7 engine
6%$
O| 92-98 (198-208)
55';5'0'< O
O temperature °C (°F)<
Thermostat “OFF”L P;P
O| 4K8 OI O
O O| except H22A7 engine
/6%$
O| Subtract 3-8 (5-15) from actual “ON” temperature
+';< !K8L O
O O| H22A7 engine
6%$
OI Subtract 2-7 (4-12) from actual “ON” temperature
$;*< !K8L O
O O| Fan timer “ON” temperature °C (°F)<
K8L P;P OI 103-109 (217-228)
0+05;$'< O
O O| Fan K8 temperature °C (°F)<
timer “OFF”L P;P O| Subtract 4-9 (7-16) from actual “ON” temperature
*5;$< !K8L O
- &
Fuel and Emissions - Section 11/Clutch
2
+%

2 - Section 12/
2-10
$
Manual Transmission (DH) —Section 13

/).0J

+%

Fuel and Emissions - Section 11
O OI MEASUREMENT
,))/,%10 O
Pressure regulator O| 3
!&
O
! Pressure with regulator vacuum hose O| D16B6 engine:
)5"5! F O
O O| #;#
=A<
disconnected kPa (kgf/cm2, psi) O| 290-300 (3.0-3.1, 43-44)
50+00;+-0+-A*+**< O
O O O| F1832, F18B3, F2036 engines:
+8":+8":+$"5! F O
O O OI 270-320 (2.8-3.3, 40-47)
$0+0;-'+-+A*0*$< O
O O O| H22A7 engine:
.7! F O
O O O| 270-370 (2.8-3.8, 40-54)
$0+$0;-'+-'A*0*< O
O Fuel tank
!# O| ;?
!-
!-<
Capacity / (US gal. Imp gal.) O| 65.0 (17.2, 14.3)
-0;$-A*-+< O
Engine
O
O| !3!
!

Idle speed with headlight and cooling fan O| D16B6 engine:
)5"5! F O
O O| ;<
off rpm (min-1) O| 750 i 50 (WT: neutral)
$0V0;,=49 !< O
O O| O| F1832, F18B3, F2036 engines:
+8":+8":+$"5! F O
O O| OI 750 i 50 (WT: neutral)
$0V0;,=49 !< O
O O| O| 730 i 50 (A/T: ,'<
$+0V0;%=49 N or P position) O
O O| OI H22A7 engine:
.7! F O
O O| OI 790 i 50 (WT: neutral)
$50V0;,=49 !< O
O O| !8W
Idle co % O| With TWC model: 0.1 max.
242!90-/-
O O| O| Without TWC model: 1.0 11.0
2 42!9-0V-0 O
Clutch

- Section 12
O O MEASUREMENT
%4%& O
Clutch pedal
O ! ! Pedal height
O !
!
to floor O| 177-187 (7.0-7.4)
$$'$;$-0$-*< - O
O O LHD
6( O| 201-211 (7.9-8.3)
0;$-5'-+< - O
O O RHD
16( O| 141-151 (5.55-5.94)
*;--5*< - O
O Stroke
O # O| 9-15 (0.4-0.6)
5;0-*0-< - O
O O Free play
! Ol 1.0-7.0 (004-028)
-0$-0;0-0*0-'< - O
O Pedal play
O !! Ol O
O Disengagement height
O (

!
to floor Ol 81
';+-<- O
O O LHD
6( Ol 10
0$;*-<- O
O
O Flywheel
!3!
Clutch disc
O !
O
C lutch surface runout
O !
Rivet head depth
O 1&
RHD
16(
U2J4, U2G5
?"*A?.
I
O
O
Ol
0 05 (0.002) max.
0-0;0-00</-
1 4 (0.06) min.
-*;0-0<-
0.15 (0.006)
0-;0-00<
0.2 (0.008)
0-;0-00'<
O
O
O
O O DH
(6 Ol 1 .3 (0.05) min.
-+;0-0<- (
0-;0-00'< O
O O U2Q7
?D$ Ol 1 .2-1.7 (0.05-0.07)
--$;0-00-0$< . (
0-;0-00'< O
O O
Surface runout Ol 0 6 (0.02) max.
0-;0-0</- 1.0 (0.04)
-0;0-0*< O
O O 4#
Thickness U2J4, U2G5
?"*A?. Ol 7 9-8.4 (0.31-0.33)
$-5'-*;0-+0-++< (
-0;0-*< O
O O DH
(6 Ol 7 7-8.2 (0.30-0.32)
$-$'-;0-+00-+< (
-0;0-*< O
O O U2Q7
?D$ Ol 8 33-90 (0.33-0.35)
'-+5-0;0-++0-+< 60 (0.24)
-0;0-*< O
Pressure plate
O ! O| 2

Warpage O 0 03 (0.001) max.
0-0+;0-00</- 0.15 (0.006)
0-;0-00< O
O O| (

!

Diaphragm spring finger alignment O| 0 6 (0.02) max.
0-;0-0</- 0.8 (0.03)
0-';0-0+< O
Manual Transmission (DH) - Section 13

/).0

O OI MEASUREMENT
%4%& O
Transmission oil
O 4! O| ;?F-F-<
Capacity / (US qt. Imp qt.) O| 1.8 (1.9, 1.6) at oil change
-';-5A-<!
O
O O O| 1.9 (2.0, 1.7) at overhaul
-5;-0A-$<& ! O
Mainshaft
O , O| !
End play O| 0.11-0.18 (0004-0007)
0-0-';0-00*0-00$< Adjust
%7 O
O O| (!!
%
Diameter of ball bearing contact area A O| 21 987-22000 (08656-08661)
-5'$-000;0-'0-'< 21.930 (0.8634)
-5+0;0-'+*< O
O O| ;4
<
(Transmission housing side) O| O
O O| (*A
)
Diameter of 4th, 5th gear contact area B O| 26980-26993 (10622-10627) -5+0;-00<
-5'0-55+;-0-0$< 26.930 (1.0602) O
O O| (+

Diameter of 3rd gear contact area C O| 33984-34000 (13380-13386) ++-5+0;-++'<
++-5'*+*-000;-++'0-++'< 33.930 (1.3358) O
O O| (!!
(
Diameter of ball bearing contact area D O| 25977-25990 (1 .0227-1.0232) -50;-00<
-5$$-550;-0$-0+< 25.920 (1.0205) O
O O| ;!
<
(Clutch housing side) O O
O O| 1
Runout O| 0.02 (0.001) max.
0-0;0-00</- 0.05 (0.002)
0-0;0-00< O
Mainshaft3rd and O| -(-
O ,+ ID. O| 39009-39025 (15358-15364)
+5-005+5-0;-+'-+*< 39.07 (1.5382)
+5-0$;-+'< O
4th gears
O *
O| !
End play 3rd
+ O| 0.06-0.21 (0002-0008)
0-00-;0-000-00'< 0.33 (0.013)
0-++;0-0+< O
O O| 4th
* O| 0.06-0.19 (0002-0007)
0-00-5;0-000-00$< 0.31 (0.012)
0-+;0-0< O
O O| 4#
Thickness 3rd
+ O| 30.22-30.27 (1 .190-1 .192)
+0-+0-$;-50-5< 30.15 (1.187)
+0-;-'$< O
O O| 4th
* O| 30.12-30.17 (1.186-1.188)
+0-+0-$;-'-''< 30.05 (1.183)
+0-0;-'+< O
Mainshaft5th gear O| -(-
O ,
ID. O| 37.009-37025 (1 457014577)
+$-005+$-0;-*$0-*$$< 37.07 (1.459)
+$-0$;-*5< O
O O| !
End play O| 0.06-0.19 (0002-0007)
0-00-5;0-000-00$< 0.31 (0.012)
0-+;0-0< O
O O| 4#
Thickness O| 28.42-28.47(1.119-1.121)
'-*'-*$;-5-< 28.35 (1.116)
'-+;-< O
O
Countershaft O| (!
%
Diameter of needle bearing contact area A O| 30000-30015 (1 .1811-1.1817)
+0-000+0-0;-'-'$< 29.95 (1.179)
5-5;-$5< O
O O| (
)
Diameter of 1st gear contact area B O| 35984-38000 (14187-14173)
+-5'*+-000;-*$-*$+< 35.93 (1.415)
+-5+;-*< O
O O| (!!

Diameter of ball bearing contact area C O| 24980-24993 (09835-09840)
*-5'0*-55+;0-5'+0-5'*0< 24.93 (0.982)
*-5+;0-5'< O
O O| 1
Runout O| 0.02 (0.001) max.
0-0;0-00</- 0.05(0.02)
0-0;0-0< O
- & 2_11

Manual Transmission (DH) — Section 13 (cont’d)

/).0J
/
?0

?!
9;<
O O| MEASUREMENT
%;%%, O| s TANDARD (NEW)
%4%& O
O Countershaft1st
O| -(-
ID. O| 41.009-41025 (16145-16152) *-0$;-$<
*-005*-0;-*-< 41.07 (1.617) O
O
O
O
gear

O| !;3

End play (when tightened by the specified
O| F <
torque)
O| 4#
Thickness
I 30.41-30.44 (1 .197-1 .198)
O
O
O|
0.03-0.10 (0001-0004)
0-0+0-0;0-000-00*<
+0-*+0-**;-5$-5'<
0.22 (0.009)
0-;0-005<
0.36 (1.195)
0-+;-5<
O
O
O
O Countershaft 2nd O| -(-
ID. O| 44009-44025 (17326-17333) **-0$;-$+<
**-005**-0;-$+-$+++< 44.07 (1.735) O
O gear

O| !;3

End play (when tightened by the specified O| 0.04-0.12 (0002-0005)
0-0*0-;0-000-00< 0.24 (0.009)
0-*;0-005< O
O O| F <
torque) O| O
O O| 4#
Thickness O| 31.91-31.96 (1.256-1258)
+-5+-5;--'< 31.85 ( 1
+-';-*< ) O
O Spacer collar
!! O| -(-
ID. O| 33000-33010 (12992-12996)
++-000++-00;-55-55< 33.04 ( 1
++-0*;-+0< ) O
E )
O (Countershaft 2nd O| 8-(-
; 0D. O| 38989-39000 (15350-15354)
+'-5'5+5-000;-+0-+*< 38.93 1
+'-5+;-++< O
O gear)

< O|

Length O| 32.03-32.06(1.261-1.262)
+-0++-0;--< 32.01 1
+-0;-0< ) O
O Spacer collar
!! O| -(-
ID. O| 27.002-27012(1.0631-10635)
$-00$-0;-0+-0+< 27.06( 1 .065 )
$-0;-0< O
O (Mainshaft4th and O| 8-(-
;,* 0D. 4th
* O| 33989-34000 (13381-13386)
++-5'5+*-000;-++'-++'< 33.93 ( 1.336)
++-5+;-++< O
O 5th gears)

< O| 5th
O| 31989-32000 (12594-12598)
+-5'5+-000;-5*-5'< 31.93 ( 1.257 )
+-5+;-$< O
O O|

Length 4th
* O| 22.83-22.86 (0899-0900)
-'+-';0-'550-500< 22.81 (0.896 )
-';0-'5'< O
O O| 5th
O| 23.53-23.56 (0926-0928)
+-++-;0-50-5'< 23.51 ( 0.926 )
+-;0-5< O
O Reverse idler gear Oi -(-
1&!
I . D. O| 15016-15043 (05912-05922)
-0-0*+;0-50-5< 15.08 (0.594 )
-0';0-5*< O
O Gear-to-reverse gear shaft clearance
O .&
! O| 0032-0077 (00013-00030)
0-0+0-0$$;0-00+0-00+0< 0.14 (0.006)
0-*;0-00< O
O Synchro ring

O| 1

!;

Ring-to-gear clearance (ring pushed O| 0.73-1.18 (0029-0046)
0-$+-';0-050-0*< 0.4 (0.016)
0-*;0-0< O
O O|

<
against gear) O| O
O Shift fork
# O| Finger thickness

# 1st, 2nd, 5th
AA O| 6.2-6.4 (0243-0253)
--*;0-*+0-+< - O
O O| 3rd, 4th
+A* O| 7.4-7.6 (0293-0300)
$-*$-;0-5+0-+00< - O
O O| Fork-to-synchro sleeve clearance
#!&! O| 0.35-0.65 (0.014-0.026)
0-+0-;0-0*0-0< - O
O Reverse shift fork O| Fork
1&# pawl groove width
#3!
&3 O| 127-130 (050-051)
-$+-0;0-00-< - O
O O| Fork-to-reverse idle gear clearance
#&!
! O| 0.5-1.1 (0023-0043)
0--;0-0+0-0*+< 1.8 (0.07)
-';0-0$< O
O O|
&3
L-groove width O| 7.05-7.25(0.278-0.285)
$-0$-;0-$'0-'< - O
O O| Fork-to-6th/reverse shift shaft piece pin
#=& O| 005-035 (0002-0014)
0-00-+;0-000-0*< 0.5 (0.02)
0-;0-0< O
O O| !
clearance O| O
I 13.05-13.13 (O.514-0.517)
O Shift arm A
% O| %
Inner diameter of shift arm A shaft contact O +-0+-+;0-*0-$< - O
O O|
point O 005-023 (0002-0009)
0-00-+;0-000-005< 0.35 (0.014)
0-+;0-0*< O
O O| %!
Shift arm A-to-shift arm C clearance O| O
O Shift arm B
) O| )
Inner diameter of shift arm B shaft contact O| 13.973-14.000(05501-05512) -
+-5$+*-000;0-00-< O
O O|
point O| O
O O| )!
Shift arm B-to-shaft clearance O| 0.013-0.070 (00005-00028)
0-0+0-0$0;0-0000-00'< 0.16 (0.006)
0-;0-00< O
O O| )!
Shiftarm B-to-shift piece clearance O| 02-05 (001-002)
0-0-;0-00-0< 0.6 (0.024)
0-;0-0*< O
O O| (#
Diameter of shift fork contact point O| 12908-13000 (05029-05118)
-50'+-000;0-050-'< 12.78 (0.503)
-$';0-0+< O
O O| #=
&3
Shift fork 1st-2nd/shift piece groove width O| 13.2-13.4 (0.52-0.53)
+-+-*;0-0-+< O
O MBS shift piece
,) O| (
Diameter of pin O| 6.9-7.1 (027-028)
-5$-;0-$0-'< 6.8 (0.27)
-';0-$< O
O Differential carrier O|
(! Pinion shaft bore diameter O| 18010-18028 (07091-07098)
'-00'-0';0-$050-$05'< - O
O O| !
Carrier-to-pinion shaft clearance O| 0023-0057 (00009-00022)
0-0+0-0$;0-00050-00< 0.095 (0.004)
0-05;0-00*< O
O O| (&
Driveshaft bore diameter O| 26025-26045 (10246-10254)
-0-0*;-0*-0*< - O
O O| &!
Carrier-to-driveshaft clearance O| 0045-0086 (00018-00034)
0-0*0-0';0-00'0-00+*< 0.14 (0.006)
0-*;0-00< O
O Differential pinion
(! O| )#!
Backlash O| 0.05-0.15(0.002-0.006)
0-00-;0-000-00< - O
O gear

O|

Pinion gear bore diameter O| 18042-18066 (07103-07113)
'-0*'-0;0-$0+0-$+< 0.095 (0.004)
0-05;0-00*< O
O O|
!
Pinion gear-to-pinion shaft clearance O| 0055-0095 (00022-00037)
0-00-05;0-000-00+$< 0.15 (0.006)
0-;0-00< O
O Set ring-to-bearing outer race

O| 0-0.1 (0-00.004)
00-;000-00*< Adjust
%7 O
- &
Manual Transmission (U2J2/UZGSIU2Q7)— Section

/;<2;32;=70J

2-12

13 (cont’d)
/
?0
O O| MEASUREMENT
%;%%, OI STANDARD (NEW)
%4%& O
O Transmission fluid O|
4! Capacity/(US qt. Imp. qt)
;?F--F< O| 1.9 (2.0, 1.7) at fluid change
-5;-0A-$<!
O
O O| O| 2 .0 (2.1, 1.18) at overhaul
-0;-A-'<& ! O
O ,
Mainshaft O| End play
! O| 0 .10-O.16 (0.004-0.006)
0-00-;0-00*0-00< Adjust
%7 O
O O| Diameter of ball bearing contact area C
(!!
OI 27977-27990 (11015-11020) $-5+;-00<
$-5$$$-550;-0-00< 27.93 (1.100) O
O O OI O
O O| Diameter of needle bearing contact area B
(!
) O| 37984-38000 (1 .4954-1 .4961) +$-5+;-*5+<
+$-5'*+'-000;-*5*-*5< 37.93 (1.493) O
O O O| O
O O| Diameter of ball bearing contact area A
(!!
% O| 27.987-28.000 (1.1018-1.1024) $-5*;-00<
$-5'$'-000;-0'-0*< 27.94 (1.100) O
O O O| O
O O| Diameter of 4th/5th contact area
(*= OI 30987-31000 (12200-12205)
+0-5'$+-000;-00-0< 30.93 (1.218)
+0-5+;-'< O
O O| Runout
1 O| 0.02 (0.001) max.
0-0;0-00</- 0.05 (0.002)
0-0;0-00< O
O Mainshaft3rd and O|
,+ ID.
-(- OI 43009-43025 (1 .6933-1 .6939)
*+-005*+-0;-5++-5+5< 43.080 (1.6961)
*+-0'0;-5< O
O 4th gears
*
O| End play
! O| 0.06-0.21 (0002-0008)
0-00-;0-000-00'< 0.30 (0.012)
0-+0;0-0< O
O O| Thickness
4# 3rd gear /?D$
+
Except U207 O| 32.42-32.47 (1276-1278)
+-*+-*$;-$-$'< 32.3 (1.27)
+-+;-$< O
O O| U2Q7
?D$ O| 34.92-34.97 (1 .375-1 .377)
+*-5+*-5$;-+$-+$$< 34.8 (1.37)
+*-';-+$< O
O O| 4th gear /?D$
*
Except U207 O| 30.92-30.97 (1217-1219)
+0-5+0-5$;-$-5< 30.8 (1.21)
+0-';-< O
O O| U2Q7
?D$ O| 31.42-31.47 (1237-1239)
+-*+-*$;-+$-+5< 31.3 (1.23)
+-+;-+< O
O Mainshaft 5th gear|O
,
ID.
-(- O| 43009-43025 (16933-16939)
*+-005*+-0;-5++-5+5< 43.080 (1.6961)
*+-0'0;-5< O
O O| End play
! O| 0.06-0.21 (0002-0008)
0-00-;0-000-00'< 0.30 (0.012)
0-+0;0-0< O
O O| Thickness
4# O| 30.92-30.97 (1217-1219)
+0-5+0-5$;-$-5< 30.8 (1.21)
+0-';-< O
O Countershaft
O| Diameter of needle bearing contact area A
(!
% O| 38000-38015 (1 .4961-1 .4967)
+'-000+'-0;-*5-*5$< 37.95 (1.494)
+$-5;-*5*< O
O O| O| O
O O| Diameter of ball bearing and needle
(!!
! O| 24987-25000 (09837-09843) *-5*;0-5'<
*-5'$-000;0-5'+$0-5'*+< 24.94 (0.982) O
O O| bearing contact area C

O| O
O O| Diameter of 1st gear contact area B
(
) O| 39984-40000 (15742-15748)
+5-5'**0-000;-$*-$*'< 39.93 (1.572)
+5-5+;-$< O
O O| Runout
1 O| 0.02 (0.001) max.
0-0;0-00</- 0.05 (0.002)
0-0;0-00< O
O Countershaft1st O|
ID.
-(- OI 46009-46025 (1.8114-1.8120)
*-005*-0;-'*-'0< 46.08 (1.814)
*-0';-'*< O
O gear

O| End play
! Except U2Q7
/?D$ O| 0.06-0.23 (0002-0009)
0-00-+;0-000-005< 0.23 (0.009)
0-+;0-005< O
O O| U2Q7
?D$ O| 0.06-0.18 (0002-0007)
0-00-';0-000-00$< 0.23 (0.009)
0-+;0-005< O
O O| Thickness
4# Except U2Q7
/?D$ O| 32.95-33.00 (1297-1299)
+-5++-00;-5$-55< - O
O O| U2Q7
?D$ O| 26.95-27.000 (1061-1063)
-5$-000;-0-0+< - O
O Countershaft 2nd O|
|.D.
-(- O| 47.009-47.025 (1.8507-1.8514)
*$-005*$-0;-'0$-'*< 47.08 (1.854)
*$-0';-'*< O
O gear

O| End play
! O| 0.10-0.15 (0004-0006)
0-00-;0-00*0-00< 0.18 (0.007)
0-';0-00$< O
O O| Thickness
4# O| 28.94-28.97 (1.139-1.141)
'-5*'-5$;-+5-*< - O
O Thrust washer
4 3 O| Thickness
4# O| 1.95-1.97 (0.077-0.078)
-5-5$;0-0$$0-0$'< - O
O (countershaft 1st O|
; OI O
I
O
<
gean O| O O
O Spacer collar
!! O| .D.
-(- O 36.48-36.49 (1 .436-1 .437)
+-*'+-*5;-*+-*+$< 36.50 (1.437)
+-0;-*+$< O
O (countershaft 2nd O|
; .D.
8-(- OI 41.989-42.000 (16531-1535)
*-5'5*-000;-+-+< 41.94 (1.651)
*-5*;-< O
'_O
I 31002-31012
O gean

< O| ength

O 29.07-29.09 (1 .144-1 .145)
5-0$5-05;-**-*< - O
O Spacer collar
!! O| .D.
-(- O (12205-12209) 31.06 (1.223)
+-00+-0;-0-05< +-0;-+< O
O (mainshaft 4th
;* O| .D.
8-(- OI37989-38000 (1 .4956-1 .4961) 37.94 (1.494)
+$-5'5+'-000;-*5-*5< +$-5*;-*5*< O
'_0
O
<
and 5th gears) O| ength

A
% OI 56.45-56.55 (2222-2226)
-*-;--< - O
O O| ) OI 26.03-26.08 (1025-1027)
-0+-0';-0-0$< 26.01 (1.024)
-0;-0*< O
IE4:
O O| OI O
I
O O| O O
O O| O O
O Reverse idler gear O|
1&!
-(- OI 20016-20043 (07880-07891)
0-00-0*+;0-$''00-$'5< 20.09 (0.7909)
0-05;0-$505< O
I
O O| Gear-to-reverse gear shaft clearance
.&
! O 0.036-0.084 (00014-00033)
0-0+0-0'*;0-00*0-00++< 0.160 (0.0063)
0-0;0-00+< O
O Synchro ring

O| ing-to-gear clearance (ring pushed
1

!;
O 0.85-1.10 (0033-00033)
0-'-0;0-0++0-00++< 0.40 (9.916)
0-*0;5-5< O
I
O O| against gear)

< O O
O Double cone
( ! O| Clearance (ring pushed against gear)
!;

< O O
O synchro
O| Outer synchro ring-to-synchro cone
8
OI 0.5-1.0 (0.02-0.04) min
0--0;0-00-0*< 0.3 (0.01)
0-+;0-0< O
O O| Inner synchro ring-to-gear

OI 0.5-1.0 (0.02-0.04) min
0--0;0-00-0*< 0.3 (0.01)
0-+;0-0< O
O O| Outer synchro ring-to-gear
8

OI 0.95-1.68 (0037-0066)
0-5-';0-0+$0-0< 0.6 (0.02)
0-;0-0< O
- &
Manual Transmission (U2J4lU265/UZQ7) - Section13

/;<2;32;=70

2-13

(cont’d)
/
?0

?!
9;<
O O| MEASUREMENT
%;%%, O| ,))/,%10
STANDARD (NEW) SERVICE LIMIT
%4%& O
Shift fork
O # O| Fingerthickness

# 1st,2nd,5th O| --*;0-*0-<
AA 6.2-6.4 (0.24-0.25) - O
O O| 3rd,4th
+A* O| $-*$-;0-50-+0<
7476 (0.29-0.30) - O
O O| Fork-to-synchro sleeve clearance
#!&! O| 0-+0-;0-0*0-0<
0.35-0.65 (0014-0026) 1.0 (0.04)
-0;0-0*< O
Reverse shift fork O|
O 1&# Pawl groove width
3!
&3 O| +-0+-+;0-0-<
13.0-13.3 (0.51-0.52) - O
O O| Fork-to-reverse idler gear clearance
#&!
! O| 0--;0-00-0*<
0.5-1.1 (0.02-0.04) 1.6 (0.07)
-';0-0$< O
I
O O Groove width *1
.&3G atA|O $-0$-;0-$'0-'<
% 7.05-7.25 (0.276-0265) - O
O O atB O| $-*$-$;0-50-+0<
) 7.4-7.7 (0.29-0.30) - O
O O| Fork-to-5th/reverse shift shaft
#=& at A'|O 0-00-+;0-000-0*<
%@ 0.05-0.35 (0002-0014) 0.5 (0.02)
0-;0-0< O
O O| Clearance*2
!G at B'|O 0-*0-';0-00-0+<
)@ 0.4-0.6 (002-003) 1.0 (0.04)
-0;0-0*< O
O
Shift arm O| ID.
-(- O| -5$+-000;0-'50-55<
15973-16000(06269-06299) - O
O O| Shift arm-to-shaft clearance
! O| 0-000-05;0-0000-00+<
0005-0059 (00002-00023) - O
O O| Shift fork diameter contact area
# O| -5+-0;0-0'0-<
12.9-13.0 (0506-0512) - O
O O| Shift arm-to-shift fork shaft clearance
#! O| 0-0-;0-00-0<
0205 (0.01-0.02) 0.6 (0.02)
0-;0-0< O
O !!&
Select lever O| Shaft outer diameter
O| -5*-5';0-$0-'$<
15.941-15966(06276-06267) - O
O O| Shift arm cover clearance
&! O| 0-0+0-0;0-00+0-00*0<
0032-0102 (00013-00040) O
O !&
Shift lever O| 0D.
8-(- O| -5*-5';0-$0-'$<
15.941-15966 (06276-06267) O
O O| Transmission housing clearance
4
! O| 0-00-*;0-000'0-00<
0021-0141 (00006-00056) O
O !#
Interlock O| Bore diameter
) O| -00-0;0-+00-+<
16.00-16.05(0.630-0.632) - O
O O| Shift arm clearance
! O| 0-0+0-05;0-00+0-00*+<
0032-0109 (00013-00043) O
Differential carrier O|
O (! Pinion shaft contact area
Except U207 O| '-000'-0';0-$0'$0-$05*<
/?D$ 18000-18018 (07087-07094) O
O O| ID.
-(- O| O
O O| Carrier-to-pinion shaft
0017-0047 (00007-00019) 0-0;0-00*<
Except U207 O| 0-0$0-0*$;0-000$0-005<
/?D$ 0.10 (0.004) O
O O| clearance
! O| O
I )
O O| Driveshaft contact area ID.
(&-(- 28005-28025 (1 .1026-1 .1033) -
O '-00'-0;-0-0++< O
O O| Carrier-to-driveshaft clearance
&! 0025-0066 (00010-00026)
1 O 0-00-0;0-0000-00< 0.12 (0.005
0-;0-00< O
O O| L O|0055-0091(00022-00036)
0-00-05;0-000-00+< 0.15(0.006)
0-;0-00< O
Differential pinion O|
O (! B acklash
)#! 0.05-0.15 (0002-0006)
O| 0-00-;0-000-00< - O
I
gear
O
O| |. D.
-(- 18042-18066 (07103-07113) -
O '-0*'-0;0-$0+0-$+< O
Except U2Q7
O /?D$ O| Pinion gear-to-pinion shaft clearance

! 0055-0095 (00022-00037)
O 0-00-05;0-000-00+$< 0.15 (0.006)
0-;0-00< O
Tapered roller
O 4!! O| Starting torque Nm (kgf/cm, lbf/in)

F ;#
=A!=< O| -*-;*A+<
1.4-2.5 (14-26, 12-23) Adjust
%7 O
bearing preload
O
! O| O| O
*1: Measuring points
G9,
*2: Measuring points
G9,

A.
- &

J

Automatic Transmission — Section 14
2-14

O O| MEASUREMENT
%;%%, O1 STANDARD (NEW)
%4%& O
O Transmission fluid O|
4! Capacity /(US qt, Imp qt)
;?FA!F< O| 6.1 (6.4, 5.4) at overhaul
-;-*A-*<& ! O
O O O| 2.5 (2.6, 2.2) at fluid change
-;-A-<!
O
O Hydraulic
6 ! O| Line pressure at 2,000 rmp (min-1) in N or O|
A000;<, 850-910
'050 800 (8.2, 120)
'00;'-A0< O
O pressure
O| P position
' O1 (8.7-9.3, 120-130)
;'-$5-+A0+0< O
O kPa (kgf/cm2, psi) O|
#;#
=A< O| O
O Hydraulic
6 ! O| 4th clutch pressure at 2,000 rpm (min-1) in O|
*! A000;< 840-920 (8.6-9.4, 120-130)
'*050;'-5-*A0+0< 790(8.1, 120)
$50;'-A0< O
O pressure
OI position
O O
O kPa (kgf/cm2, psi) OI
#;#
=A< 3rd clutch pressure at 2,000 rpm (min-1) O
+! A000;< O
O O O O
O O: in.
position O O
O OI 2nd clutch pressure at 2,000 rpm (min-1) O
! A000;< O
O O| in.
position O O
O O| 1st clutch pressure at 2,000 rpm (min-1)
! A000;< O O
O Ol in.
position O O
O Stall speed rpm (min-1) (Check with vehicle on level ground
!!;<;#3&!!&!
O O
O F20B6 engine
0)
O| A0
2,250 1,950-2,550
A50A0 O
O F18B2,
')A F18B3 engine
')+
O| A*0
2,450 2,150-2,750
A0A$0 O
O !
Clutch O ! !!
Clutch initial clearance 1st O| --+;0-0*0-0+<
1.15—1.35(0.045—0.053) O
O O 2nd O| 0-$0-5;0-0'0-0+<
0.7-0.9 (0.028-0.035) O
O O 3rd O| 0-0-';0-0*0-0+<
+ 0.6-0.8 (0024-0031) O
O O 4th O| 0-*0-;0-00-0*<
* 0.4-0.6 (0.016-0.024) O
O C lutch return spring free length
O !
!
1st,2nd O| *-$;-'0<
A 45.7 (1.80) 43.7 (1.72)
*+-$;-$< O
O O 3rd,4th O| ++-;-+<
+A* 33.5(1.32) 31.5 (1.24)
+-;-*< O
O Clutch disc thickness
O ! # O| -''-00;0-0$*0-0$5<
1.88-2.00 (0074-0079) Until grooves worn
?!
&3 O
O Clutch plate thickness
O ! !# 1st O|out
O
O O 2nd O| -5-0;0-0$$0-0'<
1.95-2.05(0.077-0.081 (!
Discoloration O
VVVV
O O 3rd O| --+;0-0'50-05+<
+ 225-235 (0089-0093 (!
Discoloration O
O O 4th O| --;0-000-0*<
* 255-265 (0100-0104 (!
Discoloration O
O O O| --+;0-0'50-05+<
225-235 (0089-0093 (!
Discoloration O
O !
Clutch Clutch end plate thickness
O ! !# Mark6 O| --0;0-000-0<
,# 255-260 (0100-0102 (!
Discoloration O
O 1st, 2nd clutches
O A! Mark7 O| --$0;0-0*0-0<
,#$ 265-270 (0104-0106 VVVVV (!
Discoloration O
O O Mark8 O| -$-'0;0-0'-0<
,#' 275-280 (0.108—1.110 (!
Discoloration O
O O Mark9 O| A'-50;0-0-*<
,#5 2,85-290 (0.112-0.114 (!
Discoloration O
O O MarkO O| -5+-00;0-0-'<
,#0 2.95-3.00 (0118-0118 (!
Discoloration O
O O Mark 1 O| +-0+-0;0-00-<
,# 3.05-3.10 (0120-0122 (!
Discoloration O
Mark2 O| +-+-0;0-*0-<
3.15-3.20 (0.124-0.126
VVVV
O O ,# (!
Discoloration O
O O Mark3 O| +-+-+0;0-'0-+0<
,#+ 3.25-3.30 (0.128-0.130 (!
Discoloration O
O O Mark4 O| +-++-*0;0-+0-+*<
,#* 3.35-3.40 (0132-0134 (!
Discoloration O
O !
Clutch Clutch end plate thickness
O ! !# ,# 2.05-2.10 (0.081-0.083
Mark 1 O| -0-0;0-0'0-0'+< (!
Discoloration O
2.15-2.20 (0085-0087
Mark2 O| --0;0-0'0-0'$<
VVVVVVV
O 3rd, 4th clutches

O +A*! ,# (!
Discoloration O
O O ,#+ 2.25-2.30 (0089-0091
Mark 3 O| --+0;0-0'50-05< (!
Discoloration O
O O ,#* 2.35-2.40 (0093-0094
Mark4 O| -+-*0;0-05+0-05*< (!
Discoloration O
O O ,# 2.45-2.50 (0096-0098
Mark 5 O| -*-0;0-050-05'< (!
Discoloration O
O O ,# 2.55-2.60 (0100-0102
Mark6 O| --0;0-000-0< (!
Discoloration O
O O ,#$ 2.65-2.70 (0.104-0.106
Mark7 O| --$0;0-0*0-0< (!
Discoloration O
O O ,#' 2.75-2.80 (0.108-0.110
Mark8 O| -$-'0;0-0'0-0< (!
Discoloration O
VV
O O ,#5 2.85-2.90 (0112-0114

Mae O1 -'-50;0-0-*< (!
Discoloration O
O Valve body
:!& Stator shaft needle bearing contact ID.
O !
-(- O| O
O Torque converter side
O 4F & 27000-27021 (1 .630-1.0638)
O| $-000$-0;-+0-0+'< Wear or damage
2
O
O O %4 pump side
ATF 29000-29021 (1.1417-1.1426)
O| 5-0005-0;-*$-*< - O
O O %4 pump gear thrust clearance
ATF
! 0.03-0.05 (0001-0002)
O| 0-0+0-0;0-000-00< 0.07 (0.003)
0-0$;0-00+< O
O ATF
!
O| %4 0210-0265 (00083-00104)
Drive O| 0-00-;0-00'+0-00*<
pump gear-to-body clearance (& - O
O O| Driven O| 0-0$00-;0-00'0-00*5<
(& 0070-0125 (00028-00049) - O
O pump driven gear ID.
ATF &
-(-
O| %4 14016-14034 (05518-05525)
O| *-0*-0+*;0-'0-< Wear or damage
2
O
O pump driven gear shaft 0D.
ATF &
8-(-
O| %4 13980-13990 (05504-05508)
O| +-5'0+-550;0-0*0-0'< Wear or damage
2
O
O Shifting device

& Reverse shift fork finger thickness
O| 1&#
# 5.90-6.00 (0232-0236)
O| -50-00;0-+0-+< 5.40 (0.213)
-*0;0-+< O
O #
# Parking brake pawl
and parking brake O| #
#3! O| - Wear or
2 O
O Parking gear
O| #

O| other defect
O
O Servo body
& Shift fork shaft bore ID.
O| #-(- 14000-14010 (05512-05516)
O| *-000*-00;0-0-< - O
O Shift fork shaft valve bore ID.
O| #&!&-(- 37000-37039 (1 .4567-1.4582)
O| +$-000+$-0+5;-*$-*'< 37.045 (1.4585)
+$-0*;-*'< O
O Regulator valve
1
!&!& Sealing ring contact ID.
O| !

-(- 32000-32025 (1 .2598-12608)
O| +-000+-0;-5'-0'< 32.050 (1.2618)
+-00;-'< O
O body
O| O O
O % ! Sealing ring contact ID.
Accumulator body O| !

-(- 35000-35025 (1 .3780-1.3789)
O| +-000+-0;-+$'0-+$'5< 35.05 (1.3799)
+-0;-+$55< O
O Stator shaft
Sealing ring contact ID.
O1 !

-(- 29000-29021 (1.1417-1.1426)
O| 5-0005-0;-*$-*< 29.050 (1.1437)
5-00;-*+$< O
- &
Automatic Transmission — Section 14 (cont’d)

J
/
?0
2-15
3
?!
9;<
O OI MEASUREMENT
%4%& O
O Transmission
4 O| Mainshaft 3rd gear thrust shim, 41 x 72
,+
A*/$ O| 6.32-6.35 (02488-02500 )
-+-+;0-*''0-00< Wear or damage
2
O
l
O O| mm thickness
# O| 6.37-6.40 02508-02520
-+$-*0;0-0'0-0< Wear or damage
2
O
AAA/\AA
O O| O| 6.42-6.45 0.2528-02539
-*-*;0-'0-+5< Wear or damage
2
O
O Ol O| 6.47-6.50 02547-02559)
-*$-0;0-*$0-5< Wear or damage
2
O
O Ol O| 6.52-6.55 02567-02579 )
--;0-$0-$5< Wear or damage
2
O
O Ol O| 6.57-6.60 02587-02598 )
-$-0;0-'$0-5'< Wear or damage
2
O
O Transmission
4 Ol Mainshaft 4th gear thrust washer, 27 x 47 O|
,*
3A$/*$ 4.95-5.00 01949-01969 )
*-5-00;0-5*50-55< Wear or damage
2
O
O Ol mm thickness
# OI O
O Transmission
4 Ol Secondary shaft splined washer, 38 x 56.5 O|
!3A+'/- 6.82-6.85 0.269-0270)
-'-';0-50-$0< Wear or damage
2
O
AAA/\AAAAAAAA
O Ol mm thickness
# O| 6.87-6.90 0.270-0272)
-'$-50;0-$00-$< Wear or damage
2
O
O Ol O| 6.92-6.95 0.272-0274)
-5-5;0-$0-$*< Wear or damage
2
O
O Ol O| 6.97-7.00 0.274-0276)
-5$$-00;0-$*0-$< Wear or damage
2
O
O Ol O| 7.02-7.05 0.276-0278)
$-0$-0;0-$0-$'< Wear or damage
2
O
O Ol O| 7.07-7.10 0.278-0280)
$-0$$-0;0-$'0-'0< Wear or damage
2
O
O 4
Transmission Ol Secondary shaft thrust shim, 37 x 55 mm O|
A+$/ 4.87-4.90 0192-0193)
*-'$*-50;0-50-5+< Wear or damage
2
O
O Ol #
thickness O| 4.92-4.95 0194-0195)
*-5*-5;0-5*0-5< Wear or damage
2
O
O Ol O| 4.97-5.00 0196-0197)
*-5$-00;0-50-5$< Wear or damage
2
O
O Ol O| 5.02-5.05 0198-0199)
-0-0;0-5'0-55< Wear or damage
2
O
O Ol O| 5.07-5.10 0200-0201)
-0$-0;0-000-0< Wear or damage
2
O
O Ol O| 5.12-5.15 0202-0203)
--;0-00-0+< Wear or damage
2
O
O Ol O| 5.17-5.20 (0204-0205)
-$-0;0-0*0-0< Wear or damage
2
O
O 4
Transmission Ol Mainshaft 4th gear collar length
,*
!!!
O| 49.40-49.50 (1.945-1.949)
*5-*0*5-0;-5*-5*5< - O
O Ol Mainshaft 4th gear collar flange thickness O|
,*
!!!
# *-+*-0;0-$0-$$<
4.35-4.50 (0.171-O.177) 2

Wear or damage O
O Ol Countershaft distance collar length
!!!
O| 50.42-50.46 (1.985-1.987)
0-*0-*;-5'-5'$< - O
O Ol #
Cotter thickness O| 1.99-2.02(0.078-0.080)
-55-0;0-0$'0-0'0< - O
l
O O Secondary shaft sealing ring, 35 mm
!

A+ O| 1.890-1.950(0.074-0.077)
-'50-50;0-0$*0-0$$< 1.800 (0.071)
-'00;0-0$< O
O O #
thickness O| O
O O| Mainshaft sealing ring, 32 mm thickness
,!

A+# O| 1.850-1.950(0.073-0.077)
-'0-50;0-0$+0-0$$< 1.800 (0.071)
-'00;0-0$< O
O O| Mainshaft sealing ring, 29 mm thickness
,!

A5# O| 1.850-1.950(0.073-0.077)
-'0-50;0-0$+0-0$$< 1.800 (0.071)
-'00;0-0$< O
O O| Mainshaft sealing ring groove width
,!

&3 O| 2025-2060 (0080-0081)
-0-00;0-0'00-0'< 2.080 (0.082)
-0'0;0-0'< O
O O| Secondary shaft sealing ring groove width O|
!

&3 2025-2060 (0080-0081)
-0-00;0-0'00-0'< 2.080 (0.082)
-0'0;0-0'< O
O O| Mainshaft 4th clutch feed pipe 0D.
,*! 8-(- O| 11 .47-11.48 (04516-04520)
-*$-*';0-*0-*0< 11.45 (0.4508)
-*;0-*0'< O
O O| Mainshaft 3rd clutch feed pipe 0D.
,+! 8-(- O| 5.97-5.98 (02350-02354)
-5$-5';0-+00-+*< 5.95 (0.2343)
-5;0-+*+< O
O O| Secondary shaft feed pipe CD.
8-(- O| 7.97-7.98 (03138-03142)
$-5$$-5';0-++'0-+*< 7.95 (0.3130)
$-5;0-++0< O
O O| Mainshaft 4th clutch feed pipe bushing ID. O|
,*!
-(- 11 500-11518 (0.4528-O.4535)
-00-';0-*'0-*+< 11.530 (0.4539)
-+0;0-*+5< O
O O| Mainshaft 3rd clutch feed pipe bushing ID. O|
,+!
-(- 6018-6030 (02369-02374)
-0'-0+0;0-+50-+$*< 6.045 (0.2380)
-0*;0-+'0< O
O O| Secondary shaft bushing |.D.

-(- O| 8000-8015 (03150-03156)
'-000'-0;0-+00-+< 8.030 (0.3161)
'-0+0;0-+< O
O Ol Diameter of needle bearing contact area
(!
Ol O
O Ol On mainshaft of stator shaft
8 O| 22984-23000 09049-09055)
-5'*+-000;0-50*50-50< Wear or damage
2
O
AAA/\AAAAAAAA
O Ol On mainshaft of 3rd gear

8+
O| 55975-55991 22037-22044)
-5$-55;-0+$-0**< Wear or damage
2
O
O Ol On mainshaft of 4th gear collar
8*
!! O| 33975-33991 13376-13382)
++-5$++-55;-++$-++'< Wear or damage
2
O
O Ol On countershaft of 4th gear
8 *
OI 33975-33991 13376-13382)
++-5$++-55;-++$-++'< Wear or damage
2
O
O Ol On countershaft 2nd gear
8
O| 39979-40000 1 .5740-1.5748)
+5-5$5*0-000;-$*0-$*'< Wear or damage
2
O
O Ol On counter shaft of L side
8 OI 36005-36015 1 .4175-1.4179)
+-00+-0;-*$-*$5< Wear or damage
2
O
O Ol On parking gear
8#

O| 41964-41980 1.6521 -1 .6528)
*-5**-5'0;--'< Wear or damage
2
O
O Ol On secondary shaft of 1st gear
8
O| 37978-37993 1 .4952-1.4958
+$-5$'+$-55+;-*5-*5' Wear or damage
2
O
O Ol On secondary shaft of 2nd gear
8
O| 33986-33999 13380-13385)
++-5'++-555;-++'0-++'< Wear or damage
2
O
O Ol On secondary shaft of L side
8 OI 34000-34013 1 .3386-1.3391)
+*-000+*-0+;-++'-++5< Wear or damage
2
O
O Ol On reverse idler gear shaft
8&!
O| 14985-15000 05900-05906)
*-5'-000;0-5000-50< Wear or damage
2
O
O Ol Transmission housing of reverse idler gear O|
4
&!
14.800-14.819 05827-05834
*-'00*-'5;0-'$0-'+* - O
O Ol shaft contact area |.D.
-(- Ol O
O Ol Reverse idler gear shaft holder ID.
1&!
!-(- O| 14800-14824 (05827-05836) 2

*-'00*-'*;0-'$0-'+< Wear or damage O
O Ol Reverse selector hub CD.
1&! 8-(- O| 55.87-55.90 (21996-22008)
-'$-50;-55-00'< Wear or damage
2
O
O Ol Inside Diameter
( OI O
O Ol Mainshaft 3rd gear
,+
O| 61 DUO-61.019 (24016-24023
-000-05;-*0-*0+< Wear or damage
2
O
VVVVVVVV
l
O O Mainshaft 4th gear
,*
O| 40.000-40.016 (1 .5748-1 .5754
*0-000*0-0;-$*'-$*< Wear or damage
2
O
O O Countershaft 4th gear
*
O| 40.000-40.016 (1 .5748-1 .5754
*0-000*0-0;-$*'-$*< Wear or damage
2
O
O Ol Countershaft idler gear
!
O| 50.000-50.016 (19685-19691
0-0000-0;-5'-55< Wear or damage
2
O
O Ol Countershaft reverse gear
&
O| 46000-46016 (1.8110-1.8116
*-000*-0;-'0-'< Wear or damage
2
O
O Ol Reverse idler gear
1&!
O| 20.007-20.020 (07877-07882
0-00$0-00;0-$'$$0-$''< Wear or damage
2
O
O Ol Secondary shaft 1st gear

O| 44.000-44.016 (1 .7323-1 .7329
**-000**-0;-$++-$+5< Wear or damage
2
O
O Ol Secondary shaft 2nd gear

O| 40.000-40.016 (1 .5748-1 .5754
*0-000*0-0;-$*'-$*< Wear or damage
2
O
- &
Automatic Transmission (cont’d) Section 14

/
?0

2-16
5
O Ol MEASUREMENT
%;%%, STANDARD (NEW)
O ,))/,%10 SERVICE LIMIT
%4%& O
O Transmission
4 End play
Ol ! O O
O Mainshaft 3rd gear
Ol ,+
0.03-0.11 (0001-0004)
O 0-0+0-;0-000-00*< O
O Mainshaft 4th gear
Ol ,*
010-022 (0004-0009)
O 0-00-;0-00*0-005< O
O Countershaft 1st gear
Ol
0.00-0.33 (0000-0013)
O 0-000-++;0-0000-0+< O
O Countershaft 4th gear
Ol *
0.04- 0.28 (0.002-0911)
O 0-0*0-';0-000-5< O
O O| !

Countershaft idler gear 0015-0045 (00008-00018)
O 0-00-0*;0-0000-00'< O
O Countershaft reverse gear
O: &
0.10-0.25 (0004-0010)
O 0-00-;0-00*0-00< O
O Reverse idler gear
O 1&!
0.20-0.55 (0008-0022)
O 0-00-;0-00'0-0< O
O Secondary shaft 1st gear
Ol
0.07-0.15 (0003-0008)
O 0-0$0-;0-00+0-00< O
O Secondary shaft 2nd gear
Ol
O| 0-0*0-;0-000-00<
0.04-0.12 (0002-0005) O
O (! Pinion shaft contact area |.D.
Differential carrier O| -(- O| '-00'-0';0-$050-$0<
18.010-18.028 (0709-0710) O
O Carrier-to-pinion shaft clearance
Ol ! O| 0-0+0-0$;0-000-00<
0.023-0.057 (0.001-0.002) 0.1 (0.004)
0-;0-00*< O
O O| (&-(-
Driveshaft contact area ID. O| '-0'-0*;-0+-0*<
28025-28045 (1.103-1.104) O
O O| &!
Carrier-to-driveshaft clearance O| 0-0*0-0';0-000-00+<
0.045-0.086 (0.002-0.003) 0.12 (0.005)
0-;0-00< O
O Differential Pinion O| )#!
(! Backlash O| 0-000-0;0-000-00<
0.050-O.150 (0.002-0.006) O
O gear

O| -(-
ID. O| '-0*'-0;0-$00-$<
18042-18066 (0710-0711) O
O O|
!
Pinion gear-to-pinion shaft clearance O| 0-00-05;0-000-00*<
0.055-0.095 (0.002-0.004) 0.12 (0/005)
0-;0=00< O
O Differential tapered roller bearing preload
(!!!
! For new bearing
3
O| -$+-5;'*0A*+<
2.7-3.9 (28-40, 24-35) Adjust
%7 O
O Starting torque Nm (kgf/cm, lbf/in)

F ;#
=A!=< For used bearing O| -+-;+$A+<

2.5-3.6 (25-37, 22-32) Adjust
%7 O
O O| MEASUREMENT
%;%%, O STANDARD (NEW)
,))/,%10 O
O Ol O| 1 )
Wire Dia o.D.
@)@ Free Length
+&! No. of Coils O
,
@

O Spring

O| 1
!&!&
%
Regulator valve spring A O -5;0-0$< 14.7 (0.579) O $$-*;+-0*$<
O *-$;0-$5< 77.4 (3.047) O 15.2
- O
O O| 1
!&!&
)
Regulator valve spring B O -;0-0+< 9.2 (0.382) O **-0;-$+<
O 5-;0--+< 44.0 (1.732) O 12.5
- O
O O|
Stator reaction spring O *-;0-$$< 35.4 (1.394) O +0-+;-5+<

O +-*;-+5*< 30.3 (1.193) O 1.92
-5 O
O O| , !&!&
Modulator valve spring O -;0-0+< 10.4 (0.409) O ++-;-+5<

O 0-*;0-*05< 33.5 (1.319) O 9.8
5-' O
O O| 4F &#&!&
Torque converter check valve O -;0-0*+< O 38.2 (1.504) O
'-*;0-++< O +'-;-0*< 14.0
*-0 O
O O|spflng

O 0-5;0-0+< O 39.8 (1.567) O
-;0-0< O +5-';-$< 20.4
0-* O
O O| 1!&!&
Relief valve spring O 0-;0-0*< O 14.5 (0.571) O

-';0-'< O *-;0-$< 6.8
-' O
O O| !#&!&
Cooler check valve spring O 0-';0-0+< O 40.4 (1.591) O

$-;0-'0< O *0-*;-5< 16.9
-5 O
O O| &!&%
Shift valve A spring O 0-';0-0+< O 40.4 (1.591) O

$-;0-'0< O *0-*;-5< 16.9
-5 O
O O| &!&)
Shift valve B spring O 0-';0-0+< O 49.1 (1.933) O

-;0-0< O *5-;-5++< 21.7
-$ O
O O| &!&
Shift valve C spring O 0.7 (0.28)

0-$;0-'< O 32.2 (1.268) O
-;0-0< O +-;-'< 13.4
+-* O
O O| &!&
Shift valve E spring O 0.9 (0.035) O $-;0-55< O +-0;-*'0<

0-5;0-0+< 63.0 (2.480) O 22.4
-* O
O O| # &!&
Lock-up shift valve spring O 0.85 (0.028) O -;0-0< O +*-5;-+$0<

0-;0-0< 34.9 (1.370) O 15.6
- O
O O| #
&!&
Lock-up timing valve spring O ( .

0-$;0-0'< O 42.9 (1.689) O
-;0-0< O *-5;-'5< 14.2
*- O
O O| # !&!&
Lock-up control valve spring O 0.7 (0.028) O -;0-0< O +-$;-*0<

0-$;0-0'< 35.7 (1.406) O 17.2
$- O
O O| &!&(
Shift valve D spring O 0.7 (0.028) O -;0-0< O +-$;-*0<

0-$;0-0'< 35.7 (1.406) O 17.2
$- O
O O| &!&!&
Servo control valve spring O 0.7 (0.028) O -;0-*0< O $-';0-$0<

0-$;0-0'< 17.8 (0.701) O 7.9
$-5 O
O O| 1&&!&
Reverse CPC valve spring O 0.7 (0.028) O -;0-*0< O $-';0-$0<

0-$;0-0'< 17.8 (0.701 ) O 7.9
$-5 O
O O| &!&%
CPC valve A spring O 0.7 (0.028) O -;0-*0< O $-';0-$0<

0-$;0-0'< 17.8 (0.701 ) O 7.9
$-5 O
O O| &!&)
CPC valve B spring O 2.8 (0.102) O 5-;0-$$<

-;0-0< 19.8 (0.772) O 5-$;-$**<
69.7 (2.744) O 10.8
0-' O
O O| !
%
1st accumulator spring A O 2.5 (0.098) O -';0-0*<
-;0-05'< 12.8 (0.504) O *5-;-5*5<
49.5 (1.949) O 8.5
'- O
O O| !
)
1st accumulator spring B O 3.8 (0.150) O 5-;0-$$<
+-';0-0< 19.8 (0.772) O 5-';-+*<
59.8 (2.354) O 7.8
$-' O
O O| +% !
3rd Accumulator spring O 3.8 (0.150) O 5-;0-$$<

+-';0-0< 19.8 (0.772) O 5-';-+*<
59.8 (2.354) O 7.8
$-' O
O O| * !
4th accumulator spring O 2.8 (0.102) O -;0-'0<

-;0-0< 21.8 (0.850) O $+-;-''<
73.2 (2.882) O 10.0
0-0 O
O O| !
%
2nd accumulator spring A O (
-$;0-0< ) O 14.8 (0.583)
*-';0-'+< O 51.0 (2.008)
-0;-00'< O 9.6
5- O
O O| !
)
2nd accumulator spring B O O O O O
- & 2_17
7
Steering — Section 17/Suspension - Section 18
!J
72

8

?!
9;<
O O| MEASUREMENT
,))/,%10 O|
Steering wheel
O
3! O| 1!
3!
Rotation play at steering wheel O| 00;00-+5<
0-10 (0-0.39) O|
O O|
circumference O| O|
O O|
!
3!
Starting load at steering wheel O| O|
I
O O| ;#
A!<
circumference N (kgf, lbf)

Engine running O| +0;+-A-'<

30 (3.1, 6.8) O
Gearbox
O ./ O| %
!#
3!
Angle of rack-guide-screw loosened from O| P0P5°-10° O
O O| !#
locked position O| Oi
Pump
O O| 3 &!&!
Pump pressure with shut-off valve closed O| O
O O| #;#
=A<
kPa (kgf/cm2, psi) O| O|
O OI D1686 engine model
()
! O| A$00A*00;'A'050<
5,700-6,400 (58-65, 820-920) O|
O OI F1882,
')A F1883,
')+A F2086 engine models O| A$00$A*00;'$A5$0A0$0<
0)
! 6,700-7,400 (68-75, 970-1,070) O|
O
Power steering
O 3

fluid
O !
OI H22A7 engine model
6%$
!
OI 1!
Recommended fluid
OI Fluid capacity
!
O| A500$A00;$0$$AA000A050<
OI
OI
6,900-7,600 (70-77, 1,000-1,090)
I
O
O
O|
O OI ;?F-!F<
/ (US qt. Imp qt) For overhaul
& ! OI O|
O O| D1686 engine model
()
! .0-9)
O| -0;-A0-5< O|
O O| RHD (Except D1686 engine) O| -;-A-0<
16(; /()
< O|
O O| LHD (Except D1686 engine) O| -0;-A0-5<
6(; /()
< Oi
O O| For fluid change
!
O| 0-*;0-*A0-+< O
Power steering
O 3
O| (!35';0#
-!<
Deflection with 98 N (10 kgf. 22lbf) O| O|
belt*
O !G between pulleys
OI 3 !! OI O|
O OI D1686 engine model
()
! OI 0-*-0;0-*0-<3 !
10.5-14.0 (0.41-0.55) with used belt O|
O OI Except D1686 engine model OI $-0-0;0-+00-+5<33!
/()
! 7.5-10.0 (0.30-0.39) with new belt O|
O OI OI +-0-;0-0-<3 !
13.0-16.5 (0.51-0.65) with used belt O|
O OI OI '--0;0-++0-*+<33!
8.5-11.0 (0.33-0.43) with new belt Ol
Power steering
O 3
OI )!;#
A!<
Belt tension N (kgf, lbf) OI O
belt*
O !G OI , 3!

Measured with belt tension gauge OI O|
O Oi D1686 engine model
()
! O| +*0*50;+0A$$0<3 !
340-490 (35-50, 77-110) with used belt O|
O O O| *0$'0;'0A*+$<33!
640-780 (65-80, 143-176) with new belt O|
O OI Except D1686 engine model O| +50*0;*0A''<3 !
/()
! 390-540 (40-55, 88-121) with used belt O|
O OI 740-880 (75-90, 165-198) with new belt
O| $*0''0;$50A5'<33! O|
G9
*.
When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust
2
3!A7 !3&! -1
-17
deflection or tension to used belt values.
! !&! -
Suspension - Section 18

8
OI O| MEASUREMENT
,))/,%10 O
Wheel alignment O|
OI 2!!
Camber Front H22A7 engine model
6%$
! O| 0P@VP
-0°15' 11° O
OI O| Except H22A7 engine model|O 0PVPA0P0@VPG
/6%$
! 0° 11°, 0°10'11°*1 O
OI OI Rear H22A7 engine model
16%$
! O| P@V+0@
-1°15' 130' O
I
OI O Except H22A7 engine model|O P00@AV+0@A0P0@V+0@G
/6%$
! -1°00', 130', -0°50' 130'*1 O
OI Caster
O Front H22A7 engine model
6%$
! O| +0P00@VP
30°00' 11° O
OI O| Except H22A7 engine model|O P0@VPAP*@VPG
/6%$
! 2°50'11°, 2°45’ 11°*1 O
T
OI O| 4!
otal toe Front
O| 0V;0V0-0'<
0 12 (0 10.08) O
OI O| Rear
1 O| V;0-0'V0-0'<
IN 2 12 (0.08 10.08) O
OI O| Front wheel turning angle
3!

! O| O
OI O| Inward wheel
33! O| O
OI O| H22A7 engine model
6%$
! O| +P0@VP
36°06' 12° O
OI O| Except H22A7 engine model|O +5P0@VPA+5P$@VP
/6%$
! 39°10'12°, 39°27'12° O
OI O| Outward wheel
8 33! O| O
OI O| H22A7 engine model
6%$
! O| 5P@;1<
29°12' (Reference) O
OI O| Except H22A7 engine model|O +0P'@;1<A+P*@;1<G
/6%$
! 30°58' (Reference), 31°14' (Reference)*1 O
Wheel bearing
OI 2!
O| !
End play Front
O| 00-0;00-00<
0-0.05 (0-0.002) O
OI O| Rear
1 O| 00-0;00-00<
0-0.05 (0-0.002) O
OI O| 1
Rim runout %! 3!
Aluminium wheel %/!
Axial O| ,))/,%10
STANDARD (NEW) SERVICE L|M|T
%4%& O
OI 2!
Wheel O| Radial
1! O| 00-$;00-0+<
0-0.7 (0-0.03) 2.0 (0.08)
-0;0-0'< O
OI O| Steel wheel
!3! Axial
%/! O| O
OI O| Radial
1! O| 0-0;00-0*<
0-1.0 (0-0.04) 2.0 (0.08)
-0;0-0'< O
OI Ol 0-1.0 (0-0.04)
O| 0-0;00-0*< 1.5 (0.06)
-;0-0< O
*1: KY model
G9>C!
- &
Brakes - Section 19
"6
9
2-18
8
O O| M EASUREM ENT
,))/,%10 O
O Parking brake
#
# O| Play on stroke at 200 N (20 kgf, 44 Ibf)
!#00;0#
A**!< Ol To be locked when pulled 6-9 notches
4!#3 !!5 O
O lever
!& O| leverforce
!& Ol O
O Foot brake pedal
#! O| Pedal height (With floor mat removed)
!
;2!&< Ol O
O Ol M/T
,=4 Ol 168.5 (6.63)
'-;-+< O
O Ol A/T
%=4 Ol 173.5 (6.83)
$+-;-'+< O
O Ol F
ree play
! Ol 1 5 (0.04-0.20)
;0-0*0-0< O
O Master cylinder
,! Ol Piston-to-pushrod clearance
! Ol 0-0.4 (0-0.02)
00-*;00-0< O
O Ol Disc thickness
(# H22A7 engine model
6%$
! Ol STANDARD (NEW)
%4%& O
O (#
Disc brake Ol Except D1686, H22A7
/()A6%$ Ol 2 7.9-28.1 (1 .10-1 .11)
$-5'-;-0-< 26.0 (1.02)
-0;-0< O
O Ol engine model

! Ol 24.9-25.1 (0.98-0.99)
*-5-;0-5'0-55< 23.0 (0.91)
+-0;0-5< O
O Ol D1686 engine model
()
! Ol O
O Ol Rear
1 Ol 2 2.9-23.1 (0.90-0.91)
-5+-;0-500-5< 21.0 (0.83)
-0;0-'+< O
O Ol Disc runout
( Front
Ol 9 .9-10.1 (0390-0398)
5-50-;0-+500-+5'< 8.0 (0.31)
'-0;0-+< O
O Ol Rear
1 Ol - 0.10 (0.004)
0-0;0-00*< O
O Ol Disc parallelism Front
(!!! and rear
Ol - 0.10 (0.004)
0-0;0-00*< O
O Ol Pad thickness
# Front
Oi - 0.015 (0.0006)
0-0;0-000< O
O Ol Rear
1 O 10.5-11.5 (0.41-0.45)
0--;0-*0-*< 1.6 (0.06)
-;0-0< O
O Ol O| 8.5-9.5 (0.33-0.37)
'-5-;0-++0-+$< 1.6 (0.06)
-;0-0< O
O Drum brake
( # Ol Drum |.D.
( -(- Ol 2286-2287 (9000-9004)
'-'-$;5-0005-00*< 229.6 (9.039)
5-;5-0+5< O
O O|
Lining Ol 5.0 (0.20)

-0;0-0< 2.0 (0.08)
-0;0-0'< O
l
O Brake booster
)# O Characteristics at 98 N (10 kgf, 22 Ibf) and Ol
5';0#
A!< , !
Minimum line pressure O
O O 294 N (30 kgf, 66 Ibf) pedal force
5*;+0#
A!<! Ol ()
!
D1686 enqine model /()
!
Except D1686 enqine model O
O Ol Vacuum
: Ol O
O Ol kPa mm H . in H
#;6
-6
< Ol 98 (10, 22) N (kgf, Ibf)
5';0A<;#
A!< 98 (10, 22) N (kgf, Ibf)
5';0A<;#
A!< O
O Ol 0 (0.0)
0;0-0< Ol 0 (0,0) kPa (kgf/cm2, psi)0
0;0A0<#;#
=A< (0,0) kPa (kgf/cm2, psi)
0;0A0<#;#
=A< O
O Ol Ol 294 (30, 66) N (kgf, Ibf) 5*;+0A<;#
A!<
5*;+0A<;#
A!< 294 (30, 66) N (kgf, Ibf) O
O Ol Ol 1,470 (15, 213)
A*$0;A+< 1,275 (13, 185)
A$;+A'< O
O Ol Ol (kgf/cm2, psi)
;#
=A< (kgf/cm2, psi)
;#
=A< O
O Ol Ol 98 (10, 22) N (kgf, Ibf)
5';0A<;#
A!< 98 (10, 22) N (kgf, Ibf)
5';0A<;#
A!< O
O Ol 66.7 (500, 19.7)
-$;00A5-$< Ol 3,040 (31, 441)
+A0*0;+A**< 3,825 (39, 555)
+A';+5A< O
;#
=A< (kgf/cm2, psi)
;#
=A< O
O Ol Ol 294 (30, 66) N (kgf, Ibf) 5;+0A<;#
A!<
5*;+0A<;#
A!< 295 (30, 66) N (kgf, Ibf) O
O Ol Ol 6,860 (70, 995)
A'0;$0A55< 8,238 (84, 1, 194)
'A+';'*AA5*< O
;#
=A< (kgf/cm2, psi)
;#
=A< O
O Ol Ol O
Air Conditioning - Section 22

!

O O| M EASUREM ENT
%;%%, O STANDARD (NEW)
,))/,%10 O
Air conditioning
O %
O| 90;=
Lubricant type: SP-10 (P/N O O
system
O O| +''5$+00+A+''5'+00+
38897-P13-003, 38898-P13-003 or O O
SANDEN
O %( O| +''55+%0<-;
368899-P13-A01). (For Refrigerant:
1
9 O O
O O| 6
HFC-134a (R-134a))
+*;1+*<< O O
O O|
Lubricant capacity Condenser
O 2 5 (5/6, 0.9)
;=A0-5< O
O O| ;!HA!H<
ml (fl oz, lmp oz) Evaporator
& O 40(11/3, 1.4)
*0;=+A-*< O
O O|
Line or hose O 1 0 (1/3, 0.4)
0;=+A0-*< O
O O| 1&
Receiver O 10 (1/3,0.4)
0;=+A0-*< O
Air conditioning
O %
Lubricant type: ND-OIL8 (P/N
O| 9(8';= O O
l
system
O 38897-PR7-003, 38898-PR7-003 or
O +''5$1$00+A+''5'1$00+ O O
DENSO
O ( 8 38899-PR7-A01). (For
O +''551$%0<-; Refrigerant:
1
9 O O
O O| 6
HFC-134a (R-134a))
+*;1+*<< O O
O Lubricant capacity
O| Condenser
O 25 (5/6, 0.8)
;=A0-'< O
O ml (fl oz, lmp oz)
O| ;!HA!H< Evaporator
& O 40 (11/3, 1.4)
*0;=+A-*< O
O O| Line or hose
O 10 (1/3, 0.4)
0;=+A0-*< O
O O| Receiver
1& O 10 (1/3, 0.4)
0;=+A0-*< O
Compressor
O O| O O
SANDEN
O %( O| 90
Lubricant type: SP-1O O O
O O| ;!HA!H<
Lubricant capacity ml (fl oz, Imp 02) 130 (4 1/3, 4.6)
O +0;*=+A*-< O
O O| Field coil resistance at 20°C (68°F)<
!!0P;'P 3.05-3.35
ohms O +-0+-+ O
O O| !! !!
Pulley-to-pressure plate clearance 0.5 10.15 (0.02 10.006)
O 0-V0-;0-0V0-00< O
Compressor
O O| O O
DENSO
O ( 8 O| 9(8'
Lubricant type: ND-OIL8 O O
O O| ;!HA!H<
Lubricant capacity m/ (fl oz, Imp oz) 160 (5 1/3, 5.6)
O 0;=+A-< O
O O| !0P;'P
Stator coil resistance at 20°C (68°F)< 3.9-4.3
ohms O +-5*-+ O
O O| !! !!
Pulley-to-pressure plate clearance 0.5 10.15 (0.02 10.006)
O 0-V0-;0-0V0-00< O
Compressor belt O| (!35';0#
A!<
O ! Deflection with 98 N (10 kgf, 22 Ibf) O O
O O| 3 !!
between pulleys O O
O O| D16B6 engine model
()
! 7.5-9.5 (0.30-0.37) with used belt
O $-5-;0-+00-+$<3 ! O
O O| 5.0-6.5 (0.20-0.26) with new belt
O -0-;0-00-<33! O
O O| All except D16B6
%!!/() 10.0-12.0 (0.39-0.47) with used belt
O 0-0-0;0-+50-*$<3 ! O
O O| engine model

! 5.5-7.5 (0.22-0.30) with new belt
O -$-;0-0-+0<33! O
Compressor belt O| )!;#
A!<
O ! Belt tension N (kgf, lbf) O O
O O| , 3!

Measured with belt tension gauge O O
O O| D16B6 engine model
()
! O| +*0*50;+0A$$0<3 !
340-490 35-50, 77-110) with used belt O
AA
O O| O| 50'+0;$0'A050<33!
690-830 70-85, 150-190) with new belt O
O O| All except D16B6
%!!/() O| +50*0;*0A''0<3 !
390-540 (40-55, 88-120) with used belt O
O O| engine model

! O| ''0A0+0;500A00+<33!
8804.030 (90-105, 200-231) with new belt O
G9
*.
When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.
2
3!A7 !3&! -1
-
Readjust deflection or tension to used belt values.
17 ! !&! -
) !

Desiqn Specifications
9
O O| ITEM
% O METRIC
% O ENGLISH
%,&. O NOTES
,% O
<__________
O (
Dimensions O| Overall Length
8&!!
O 4,595 mm
*A5 O 180.9 in
'0-5 O O
O O| OverallWidth
8&!!2 O 1,750 mm
A$0 O 68.9 in
'-5 O O
O O| Overall Height
8&!!6
Except KY model
/>C! O 1,430 mm
A*+0 O 56.3 in
-+ O O
O Ol KY model
>C! O 1,445 mm
A** O 56.9 in
-5 O O
O O| Wheelbase
2! Except TYPE R
/4C 1 O 2,668 mm
A' O 105.0 in
0-0 O O
O O1 TYPE R
4C 1 O 2,670 mm
A$0 O 105.1 in
0- O O
O O| Track Front/Rear
4# =1 Except TYPE R
/4C 1 O 1,495/1,504 mm O
A*5=A0* 58.9/592 in
'-5=5- O O
O O1 TYPE R
4C 1 O 1,507/1,515 mm O
A0$=A 59.3/596 in
5-+=5- O O
O O| Wheel Arch Front/Rear
2!% =1 O 666/669 mm
=5 O 26.2/26.3 in
-=-+ EU
O ? O
O O| Seating Capacity

O Fi&e O O
O O| Curb Weight
2
O O O O
______________________________________________
O O| KE
> 1.6iS
- M/T
,=4 O 1,270 kg
A$0#
O 2,800 lbs
A'00! O O
O O| M/T with A/C, S/R
,=43%=A=1 O 1,301 kg
A+0#
O 2,868 lbs
A''! O O
O O| 1.6iLS
- M/T with A/C, S/R
,=43%=A=1 O 1,301 kg
A+0#
O 2,868 lbs
A''! O O
O O| 1.8iS
-' M/T
,=4 O 1,345 kg
A+*#
O 2,965 lbs
A5! O O
O O| A/T
%=4 O 1,370 kg
A+$0#
O 3,020 lbs
+A00! O O
O O| M/T with A/C
,=43%= O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
O O| A/T with A/C
%=43%= O 1,365 kg
A+'#
O 3,053 lbs
+A0+! O O
O O| M/T with S/R
,=43=1 O 1,361 kg
A+#
O 3,000 lbs
+A000! O O
O O| A/T with S/R
%=43=1 O 1,366 kg
A+'#
O 3,056 lbs
+A0! O O
O O| 1.8iLS
-' M/T with S/R
,=43=1 O 1,361 kg
A+#
O 3,000 lbs
+A000! O O
O O| A/T with S/R
%=43=1 O 1,366 kg
A+'#
O 3,056 lbs
+A0! O O
,=43%=A=1 O 1,376 kg
A+$#
O 3,034 lbs
+A0+*! O O
O O| A/T with A/C, S/R
%=43%=A=1 O 1,401 kg
A*0#
O 3,089 lbs
+A0'5! O O
O O| 1.8iES
-' M/T
,=4 O 1,406 kg
A*0#
O 3,100 lbs
+A00! O O
O O| A/T
%=4 O 1,431 kg
A*+#
O 3,155 lbs
+A! O O
O O| 2.0iLS
-0 M/T with S/R
,=43=1 O 1,361 kg
A+#
O 3,000 lbs
+A000! O O
O O| A/T with S/R
%=43=1 O 1,366 kg
A+'#
O 3,056 lbs
+A0! O O
,=43%=A=1 O 1,376 kg
A+$#
O 3,034 lbs
+A0+*! O O
%=43%=A=1 O 1,401 kg
A*0#
O 3,089 lbs
+A0'5! O O
O O| 2.0iES
-0 M/T
,=4 O 1,406 kg
A*0#
O 3,100 lbs
+A00! O O
O O| A/T
%=4 O 1,431 kg
A*+#
O 3,155 lbs
+A! O O
O O| TYPE R
4C 1 M/T
,=4 O 1,345 kg
A+*#
O 2,965 lbs
A5! O O
Weight
O 2
O| KG
>. 1.6iS
- M/T with A/C
,=43%= O 1,265 kg
A'#
O 2,833 lbs
A'++! O O
O
O
O
l
O
O
O|
1.6iLS
-
M/T with S/R
,=43=1
M/T with A/C
,=43%=
M/T with S/R
,=43=1
O
O
O
1,266 kg
A'#
1,265 kg
A'#
1,266 kg
A'#
O
O
O
2,935 lbs
A5+!
2,833 lbs
A'++!
2,835 lbs
A'+!
O
O
O
O
O
O
,=43%=A=1 O 1,301 kg
A+0#
O 2,868 lbs
A''! O O
O O| 1.8iS
-' M/T with A/C
,=43%= O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
O O| A/T with A/C
%=43%= O 1,365 kg
A+'#
O 3,053 lbs
+A0+! O O
O O| M/T with S/R
,=43=1 O 1,361 kg
A+#
O 3,000 lbs
+A000! O O
O O| 1.8iLS
-' M/T
,=4 O 1,345 kg
A+*#
O 2,965 lbs
A5! O O
O O| A/T
%=4 O 1,370 kg
A+$0#
O 3,020 lbs
+A00! O O
O O| M/T with A/C
,=43%= O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
O O| A/T with A/C
%=43%= O 1,365 kg
A+'#
O 3,053 lbs
+A0+! O O
O O| M/T with S/R
,=43=1 O 1,361 kg
A+#
O 3,000 lbs
+A000! O O
O O| A/T with S/R
%=43=1 O 1,366 kg
A+'#
O 3,056 lbs
+A0! O O
,=43%=A=1 O 1,376 kg
A+$#
O 3,034 lbs
+A0+*! O O
%=43%=A=1 O 1,401 kg
A*0#
O 3,089 lbs
+A0'5! O O
O O| 1.8iES
-' M/T
,=4 O 1,406 kg
A*0#
O 3,100 lbs
+A00! O O
O O| A/T
%=4 O 1,431 kg
A*+#
O 3,155 lbs
+A! O O
O O| 2.0iLS
-0 M/T
,=4 O 1,345 kg
A+*#
O 2,865 lbs
A'! O O
O
O
O
l
O
O
O|
A/T
%=4
M/T with A/C
,=43%=
A/T with A/C
%=43%=
O
O
O
1,370 kg
A+$0#
1,360 kg
A+0#
1,365 kg
A+#
O
O
O
3,020 lbs
+A00!
2,998 lbs
A55'!
3,053 lbs
+A0+!
O
O
O
O
O
O
O O| M/T with S/R
,=43=1 O 1,361 kg
A+#
O 3,000 lbs
+A000! O O
O O A/T with S/R
%=43=1 O 1,386 kg
A+'#
O 3,056 lbs
+A0! O O
O O M/T with A/C, S/R
,=43%=A=1 O 1,376 kg
A+$#
O 3,034 lbs
+A0+*! O O
O O A/T with A/C, S/R
%=43%=A=1 O 1,401 kg
A*0#
O 3,089 lbs
+A0'5! O O
O O 2.0iES
-0 M/T
,=4 O 1,406 kg
A*0#
O 3,100 lbs
+A00! O O
O O A/T
%=4 O 1,431 kg
A*+#
O 3,155 lbs
+A! O O
O O TYPE R
4C 1 M/T
,=4 O 1,345 kg
A+*#
O 2,965 lbs
A5! O O
O O KS
> 1.6iS
- M/T
,=4 O 1,270 kg
A$0#
O 2,800 lbs
A'00! O O
O O M/T with A/C
,=43%= O 1,285 kg
A'#
O 2,833 lbs
A'++! O O
O O 1.6iLS
- M/T with A/C
,=43%= O 1,285 kg
A'#
O 2,833 lbs
A'++! O O
O O 1.8iS
-' M/T with A/C
,=43%= O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
O O 1.8iLS
-' A/T
%=4 O 1,375 kg
A+$#
O 3,031 lbs
+A0+! O O
O O M/T with A/C
,=43%= O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
) !

$
/
?0
(cont’d)
O O ITEM
% O METRIC
% O ENGLISH
%,&. O NOTES
,% O
Weight
O 2
KS
O > 2.0iLS
-0 M/T
,=4 O 1,345 kg
A+*#
O 2,965 lbs
A5! O O
O O 2.0iES
-0 M/T with A/C
,=43%= O 1,390 kg
A+50#
O 3,064 lbs
+A0*! O O
O KR
O >1 1.6iS
- M/T
,=4 O 1,265 kg
A#
O 2,789 lbs
A$'5! O O
O O M/T with ABS
,=43%) O 1,270 kg
A$0#
O 2,800 lbs
A'00! O O
O O M/T with ABS, A/C O
,=43%)A%= 1,285 kg
A'#
O 2,833 lbs
A'++! O O
O O 1.6iLS
- M/T with A/C
,=43%= O 1,285 kg
A'#
O 2,833 lbs
A'++! O O
O O M/T with A/C, S/R O
,=43%=A=1 1,301 kg
A+0#
O 2,868 lbs
A''! O O
O O 1.8iS
-' M/T with A/C
,=43%= O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
O O 1.8iLS
-' M/T
,=4 O 1,345 kg
A+*#
O 2,965 lbs
A5! O O
O O A/T
%=4 O 1,370 kg
A+$0#
O 3,020 lbs
+A00! O O
O O M/T with A/C
,=43%= O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
O O A/T with A/C
%=43%= O 1,385 kg
A+'#
O 3,053 lbs
+A0+! O O
,=43%=A=1 1,376 kg
A+$#
O 3,034 lbs
+A0+*! O O
O O 1.8iES
-' M/T
,=4 O 1,375 kg
A+$#
O 3,031 lbs
+A0+! O O
O O 2.0LS
-0 M/T
,=4 O 1,360 kg
A+0#
O 2,998 lbs
A55'! O O
O O 2.0ES
-0 M/T
,=4 O 1,406 kg
A*0#
O 3,100 lbs
+A00! O O
O O A/T
%=4 O 1,431 kg
A*+#
O 3,155 lbs
+A! O O
O O TYPE R ,=4
4C 1 M/T O 1,345 kg
A+*#
O 2,965 lbs
A5! O O
O KY
O >C 1.8iS
-' M/T
,=4 O 1,340 kg
A+*0#
O 2,954 lbs
A5*! O O
O O A/T
%=4 O 1,365 kg
A+#
O 3,009 lbs
+A005! O O
Weight
O 2
Weight Distributions (Front/Rear)
O 2
( ; =1< O O O O
O KE
O > 1.6iS
- M/T
,=4 O 730/540 kg
$+0=*0#
O 1,610/1,190 lbs
A0=A50! O| O
,=43%=A=1 753/548 kg
$+=*'#
O 1.660/1,208 lbs
-0=A0'! O| O
O O 1.6iLS
- M/T with A/C, S/R O
,=43%=A=1 753/548 kg
$+=*'#
O 1,660/1,208 lbs
A0=A0'! O| O
O O 1.8iS
-' M/T
,=4 O 805/540 kg
'0=*0#
O 1,775/1,190 lbs
A$$=A50! O| O
O O A/T
%=4 O 830/540 kg
'+0=*0#
O 1,830/1,190 lbs
A'+0=A50! O| O
O O M/T with A/C
,=43%= O 820/540 kg
'0=*0#
O 1,808/1,190 lbs
A'0'=A50! O| O
O O A/T with A/C
%=43%= O 845/540 kg
'*=*0#
O 1,863/1,190 lbs
A'+=A50! O| O
O O M/T with S/R
,=43=1 O 813/548 kg
'+=*'#
O 1,792/1,208 lbs
A$5=A0'! O| O
O O A/T with S/R
%=43=1 O 838/548 kg
'+'=*'#
O 1,848/1,208 lbs
A'*'=A0'! O| O
O O 1.8iLS
-' M/T with S/R
,=43=1 O 813/548 kg
'+=*'#
O 1,792/1,208 lbs
A$5=A0'! O| O
O O A/T with S/R
%=43=1 O 838/548 kg
'+'=*'#
O 1,848/1,208 lbs
A'*'=A0'! O| O
,=43%=A=1 828/548 kg
''=*'#
O 1,826/1,208 lbs
A'=A0'! O| O
O O A/T with A/C, S/R O
%=43%=A=1 853/548 kg
'+=*'#
O 1,881/1,208 lbs
A''=A0'! O| O
O O 1.8iES
-' M/T
,=4 O 838/568 kg
'+'='#
O 1,848/1252 lbs
A'*'=! O| O
O O A/T
%=4 O 863/568 kg
'+='#
O 1,903/1,252 lbs
A50+=A! O| O
O O 2.0iLS
-0 M/T with S/R
,=43=1 O 823/538 kg
'+=+'#
O 1,814/1,846 lbs
A'*=A'*! O| O
O O A/T with S/R
%=43=1 O 848/538 kg
'*'=+'#
O 1,870/1,186 lbs
A'$0=A'! O| O
,=43%=A=1 838/538 kg
'+'=+'#
O 1,848/1,186 lbs
A'*'=A'! O| O
O O A/T with A/C, S/R O
%=43%=A=1 863/538 kg
'+=+'#
O 1,903/1,186 lbs
A50+=A'! O| O
O O 2.0iES
-0 M/T
,=4 O 848/558 kg
'*'='#
O 1,870/1,230 lbs
A'$0=A+0! O| O
O O A/T
%=4 O 873/558 kg
'$+='#
O 1,925/1,230 lbs
A5=A+0! O| O
O O TYPE R ,=4
4C 1 M/T O 820/525 kg
'0=#
O 1,808/1,157 lbs
A'0'=A$! O| O
O KG
O >. 1.6iS
- M/T with A/C
,=43%= O 745/540 kg
$*=*0#
O 1,643/1,190 lbs
A*+=A50! O| O
O O M/T with S/R
,=43=1 O 738/548 kg
$+'=*'#
O 1,627/1,208 lbs
A$=A0'! O| O
O O 1.6iLS
- M/T with A/C
,=43%= O 745/540 kg
$*=*0#
O 1,643/1,190 lbs
A*+=A50! O| O
O O M/T with S/R
,=43=1 O 738/548 kg
$+'=*'#
O 1,627/1,208 lbs
A$=A0'! O| O
,=43%=A=1 753/548 kg
$+=*'#
O 1,680/1,208 lbs
A'0=A0'! O| O
O O 1.8iS
-' M/T with A/C
,=43%= O 820/540 kg
'0=*0#
O 1,808/1,190 lbs
A'0'=A50! O| O
O O A/T with A/C
%=43%= O 845/540 kg
'*=*0#
O 1,863/1,190 lbs
A'+=A50! O| O
O O M/T with S/R
,=43=1 O 813/548 kg
'+=*'#
O 1,792/1,208 lbs
A$5=A0'! O| O
O O 1.8iLS
-' M/T
,=4 O 805/540 kg
'0=*0#
O 1,775/1,190 lbs
A$$=A50! O| O
O O A/T
%=4 O 830/540 kg
'+0=*0#
O 1,830/1,190 lbs
A'+0=A50! O| O
O O M/T with A/C
,=43%= O 820/540 kg
'0=*0#
O 1,808/1,190 lbs
A'0'=A50! O| O
O O A/T with A/C
%=43%= O 845/540 kg
'*=*0#
O 1,863/1,190 lbs
A'+=A50! O| O
O O M/T with S/R
,=43=1 O 813/548 kg
'+=*'#
O 1,792/1,208 lbs
A$5=A0'! O| O
O O A/T with S/R
%=43=1 O 838/548 kg
'+'=*'#
O 1,848/1,208 lbs
A'*'=A0'! O| O
,=43%=A=1 O 828/548 kg
''=*'#
O 1,826/1,208 lbs
A'=A0'! O| O
%=43%=A=1 O 853/548 kg
'+=*'#
O 1,881/1,208 lbs
A''=A0'! O| O
O O 1.8iES
-' M/T
,=4 O 838/568 kg
'+'='#
O 1,848/1,252 lbs
A'*'=A! O| O
O O A/T
%=4 O 863/568 kg
'+='#
O 1,903/1,252 lbs
A50+=A! O| O
O O 2.0iLS
-0 M/T
,=4 O 815/530 kg
'=+0#
O 1,797/1,168 lbs
A$5$=A'! O| O
O O A/T
%=4 O 640/530 kg
*0=+0#
O 1,852/1,168 lbs
A'=A'! O| O
O O M/T with A/C
,=43%= O 830/530 kg
'+0=+0#
O 1,830/1,168 lbs
A'+0=A'! O| O
O O A/T with A/C
%=43%= O 855/530 kg
'=+0#
O 1,885/1,168 lbs
A''=A'! O| O
O O M/T with S/R
,=43=1 O 823/538 kg
'+=+'#
O 1,814/1,186 lbs
A'*=A'! O| O
O O A/T with S/R
%=43=1 O 848/538 kg
'*'=+'#
O 1,870/1,186 lbs
A'$0=A'! O| O
,=43%=A=1 O 838/538 kg
'+'=+'#
O 1,848/1,186 lbs
A'*'=A'! O| O
%=43%=A=1 O| 863/538 kg
'+=+'#
O 1,903/1,186 lbs
A50+=A'! O| O
) !

/
?0
(cont’d)
2-21

O O ITEM
% O METRIC
% O ENGLISH
%,&. O NOTES
,% O
Weight
O 2
KG
O >. 2.0iES
-0 M/T
,=4 O 848/558 kg
'*'='#
O 1,870/1,230 lbs
A'$0=A+0! O| O
O O A/T
%=4 O 873/558 kg
'$+='#
O 1,925/1,230 lbs
A5=A+0! O| O
O O TYPE R ,=4
4C 1 M/T O 820/525 kg
'0=#
O 1,808/1,157 lbs
A'0'=A$! O| O
O KS
O > 1.6iS
- M/T
,=4 O 730/540 kg
$+0=*0#
O 1,610/1,190 lbs
A0=A50! O| O
O O M/T with A/C
,=43%= O 745/540 kg
$*=*0#
O 1,643/1,190 lbs
A*+=A50! O| O
O O 1.6iLS
- M/T with A/C
,=43%= O 745/540 kg
$*=*0#
O 1,643/1,190 lbs
A*+=A50! O| O
O O 1.8iS
-' M/T with A/C
,=43%= O 830/530 kg
'+0=+0#
O 1,830/1,168 lbs
A'+0=A'! O| O
O O 1.8iLS
-' A/T
%=4 O 815/560 kg
'=0#
O 1,797/1,234 lbs
A$5$=A+*! O| O
O O M/T with A/C
,=43%= O 820/540 kg
'0=*0#
O 1,808/1,180 lbs
A'0'=A'0! O| O
O O 2.0iLS
-0 M/T
,=4 O 815/530 kg
'=+0#
O 1,797/1,168 lbs
A$5$=A'! O| O
O O 2.0iES
-0 M/T with A/C
,=43%= O 840/550 kg
'*0=0#
O 1,852/1,212 lbs
A'=A! O| O
O KR
O >1 1.6iS
- M/T
,=4 O 725/540 kg
$=*0#
O 1,598/1,191 lbs
A5'=A5! O| O
O O M/T with ABS
,=43%) O 730/540 kg
$+0=*0#
O 1,610/1,190 lbs
A0=A50! O| O
O O M/T with ABS, A/C O
,=43%)A%= 745/540 kg
$*=*0#
O 1,643/1,190 lbs
A*+=A50! O| O
O O 1.6iLS
- M/T with A/C
,=43%= O 745/540 kg
$*=*0#
O 1,643/1,190 lbs
A*+=A50! O| O
,=43%=A=1 753/549 kg
$+=*5#
O 1,660/1,208 lbs
A0=A0'! O| O
O O 1.8iS
-' M/T with A/C
,=43%= O 820/540 kg
'0=*0#
O 1,808/1,190 lbs
A'0'=A50! O| O
O O 1.8iLS
-' M/T
,=4 O 805/540 kg
'0=*0#
O 1,775/1,190 lbs
A$$=A50! O| O
O O A/T
%=4 O 830/540 kg
'+0=*0#
O 1,830/1,190 lbs
A'+0=A50! O| O
O O M/T with A/C
,=43%= O 820/540 kg
'0=*0#
O 1,808/1,190 lbs
A'0'=A50! O| O
O O A/T with A/C
%=43%= O 845/540 kg
'*=*0#
O 1,883/1,190 lbs
A''+=A50! O| O
,=43%=A=1 828/548 kg
''=*'#
O 1,826/1,208 lbs
A'=A0'! O| O
O O 1.8iES
-' M/T
,=4 O 815/560 kg
'=0#
O 1,797/1,234 lbs
A$5$=A+*! O| O
O O 2.0LS
-0 M/T
,=4 O 830/530 kg
'+0=+0#
O 1,830/1,168 lbs
A'+0=A'! O| O
O O 2.0ES
-0 M/T
,=4 O 848/558 kg
'*'='#
O 1,870/1,230 lbs
A'$0=A+0! O| O
O O A/T
%=4 O 873/558 kg
'$+='#
O 1,925/1,230 lbs
A5=A+0! O| O
O O TYPE R ,=4
4C 1 M/T O 820/525 kg
'0=#
O 1,808/1,157 lbs
A'0'=A$! O| O
O KY
O >C 1.8iS
-' M/T
,=4 O 805/535 kg
'0=+#
O 1,775/1,179 lbs
A$$=A$5! O| O
O O A/T
%=4 O 830/535 kg
'+0=+#
O 1,830/1,179 lbs
A'+0=A$5! O| O
Weight
O 2
Max. Permissible Weight (EU)
O ,/-!2
; ?< O O O O
O O D1686 engine model
()
! O 1,740 kg
A$*0#
O 3,836 lbs
+A'+! O O
O O F18B2,
')A F18B3,
')+A F20B6 engine models O
0)
! 1,890 kg
A'50#
O 4,167 lbs
*A$! O O
O O H22A7 engine model
6%$
! O 1,820 kg
A'0#
O 4,012 lbs
*A0! O O
) !

(cont’d)
/
?0
2-22

O O ITEM
% O| METRIC
% O| ENGLISH
%,&. O| NOTES
,% O
ENGINE
O . O Type
4 D1686 engine
()
O| Water-cooled, 4-stroke SOHC
2!A*#86 O| O
O O O| gasoline engine

!
O| O
O O F1882,
')A F1883,
')+A F2086 engines
0)
O| Water-cooled, 4-stroke SOHC
2!A*#86 O| O
O O O| VTEC gasoline engine
:4
!
O| O
O O H22A7 engine
6%$
O| Water-cooled, 4-stroke DOHC
2!A*#(86 O| O
O O O| VTEC gasoline engine
:4
!
O| O
O O Cylinder Arrangement
!%
O| lnline 4-cylinder, transverse
!*!A& O| O
O O Bore and Stroke
)# O| 75.0 x 90.0 mm
$-0/50-0 O|
2.95 x 3.54 in
-5/+-* O
O O D1686 engine
()
O| 85.0 X 81.5 mm
'-0/'- O|
3.25 x 3.21 in
+-/+- O
O O F1882,
')A F1883 engines
')+
O| 85.0 X 88.0 mm
'-0/''-0 O|
3.25 x 3.46 in
+-/+-* O
O O F2086 engine
0)
O| 87.0 x 90.7 mm
'$-0/50-$ 3.43 x 3.57 in
O|
+-*+/+-$ O
O O H22A7 engine
6%$
O| O| O
O O Displacement
(! O| 1,590 cm3 (ml)
A50+;< 97.0 cu-in
5$-0 O| O
O O D1686 engine
()
O| 1,850 cm3 (ml)
A'0+;< 112.9 cu-in
-5 O| O
O O F1882,
')A F1883 engines
')+
O| 1,997 cm3 (ml)
A55$+; 121.9 cu-in
-5 O| O
O O F2086 engine
0)
O| 2,157 cm3 (ml)
A$+;< 131.6 cu-in
+- O| O
O O H22A7 engine
6%$
O| 9.6
5- O| O
O O Compression Ratio
1 O| 10.0
0-0 O| O
O O D1686 engine
()
O| 11.0
-0 O| O
O O F1882,
')A F1883,
')+A F2086 engines
0)
O| O| O
O O H22A7 engine
6%$
O| Belt Driven, SOHC
)!(&A86 O| O
O O Valve Train
:!&4 O| 4 valve per cylinder
*&!&! O| O
l l
O O D1686 engine
()
O 8e|t Driven, SOCH VTEC
)!(&A86:4 O O
O O O 4 valve per cylinder
*&!&! O O
O O F1882,
')A F1883,
')+A F2086 engines
0)
O| 8e|t Driven, DOHC VTEC
)!(&A(86:4 O| O
O O O| 4 valve per cylinder
*&!&! O| O
O O H22A7 engine
6%$
O| Forced and wet sump, trochoid pump O|
3 A O
O O O| O| O
O O Lubrication System
O| 354IQ74USqL311MmqD
+-*;+$-*?FA+-!F< O| O
O O Oil pump Displacement
8! (! O| 735lU77USqL647MmqD
$+-;$$-$?FA*-$!F< O| at 6,000 O
A000
O O D1686 engine
()
O| O| engine

O
/()
O| 125lU32USqL1flHmq
;+?FA0!F< O| rpm (min-1) O
;<
O O Water Pump Displacement
2 (! O| moumgusmn4nmpm)
0;5?FA*!F< O| at 6,000 O
A000
O O D1686 engine
()
O| O| engine rpm O

/()
O| Premium UNLEADED gasoline with a O|
? %( (
!3 (min-1)
;< O
O O Fuel Required
!1F O| Research Octane Number (RON) of 95 O|
18 ;18<5 O
O O D1686, F1882,
()A ')A F2086 engines
0)
O| or higher

O| O
O O O| LEADED gasoline with a Research O|
%( (
!31 O
O O O| Octane Number (RON) of 91 or
8 ;18<5 O| O
O O F1883 engine
')+
O| higher *1

G O| O
O O O| Super plus UNLEADED gasoline with a O|
! ? %( (
!3 O
O O O| Research Octane Number (RON) of 98 O|
18 ;18<5' O
O O H22A7 engine
6%$
O| or higher

O| O
O O O| O| O
O O O| O| O
O
Starter Ol TVpe
4 O| Gear reduction
. O| O
O O| Normal Output
!8 O| 1.0W
-02 O| O
O O| Normal Voltage
!:!
O| 12V
: O| O
O O| Hour Rating
6 1
O| 30 seconds
+0 O| O
O O| Direction of Rotation
(1 O| Clockwise as viewed from gear end O|
!#3&3
O
) !

(cont’d)
/
?0
2-23

O O| ITEM
% O| METRIC
% O| ENGLISH
%,&. O NOTES
,% O
O Clutch
! O| Type
4 M/T O|
,=4 Single plate dry, diaphragm spring

!!A

O O
O O| A/T|O
%=4 Torqu e converter
4F & O O
O O| Facing Area

% M/T O|
,=4 176 cm2
$ 27.3 sq in
$-+F O O
O Transmission O|
4 Type
4 M/T O|
,=4 Synchronized 5-speed fonNard, 1
H3A O O
O OI OI reverse
& O O
O OI A/T|O
%=4 Electronically controlled 4-speed
!!!!!* O O
O OI Primary Reduction
1 Type/Ratio O|
4=1 automatic, 1 reverse
A& O O
O OI O| Di rect/1 :1
(=9 O O
O 4
Transmission OI , !4
Manual Transmission O| DH
(6 U2J4
?"* U2G5
?. U2Q7
?D$ O O
O OI .1
Gear Ratio O| F1882
') O O
O OI
1 st O| D1686 F1883
() ')+ F18B2 H22A7
') 6%$ O O
O OI
2nd O| engine

F2086
0) ;$&<
(7cv) engine

O O
O OI 3rd
+ O|

engines

engine O O
O OI 4th
* O| 3,250
+A0 3,285
+A' 3,285
+A' 3,285
+A' O O
O OI 5th
O| 1,782
A$' 1,807
A'0$ 1,807
A'0$ 2,090
A050 O O
O OI Reverse O|
1& 1,250
A0 1,266
A 1,193
A5+ 1,481
A*' O O
O OI !1 .
Final Reduction Gear 1
Ratio O| 0.937
0-5+$ 0,966
0A5 0,843
0A'*+ 1,071
A0$ O O
O OI 4
Type O| 0,750
0A$0 0,787
0A$'$ 0,685
0A' 0,870
0A'$0 O O
O OI O| 3,153
+A+ 3,000
+A000 3,000
+A000 3,000
+A000 O O
O OI O| 4,437
*A*+$ 4,266
*A 4,062
*A0 4,266
*A O O
O OI O| Single helical gear

!!!
O O
O 4
Transmission OI % 4
Automatic Transmission O| O O
O OI .1
Gear Ratio
1st O| 2,528
A' O O
O OI
2nd O| 1,427
A*$ O O
O OI 3rd
+ O| 0.976
0-5$ O O
O OI 4th
* O| 0,653
0A+ O O
O OI Reverse O|
1& 1,863
A'+ O O
O OI !1 .
Final Reduction Gear 1
Ratio O| 4,466
*A* O O
O OI Type
4 Ol Single helical gear

!!!
O O
O Air Conditioning I
%
O Cooling Capacity
!
O 4,780 Kcal/h
*A$'0>!= O| 5A000)4?=
19,000 BTU/h O KY model
>C! O
O Ol O| 3,910 Kcal/h
+A50>!= O| A00)4?=
15,500 BTU/h O KR model
>1! O
O O| O| 3,740 Kcal/h
+A$*0>!= O| *A'00)4?=
14,800 BTU/h O KG, KE models
>.A> ! O
O Air Conditioning|
%
O Compressor:
9 O| O O
O O| SANDEN
%( Type
4 O| !!
Scroll O O
O O| Capacity
O| 85.7 cm3/rev
'-$+=& 5.22 cu-in/rev
- =& O O
O O| Max. Speed
,/- O| 10,000 rpm (min-1)
0A000;< O O
O O| Lubricant Type
4 O| SP-10
0 O O
O O| Lubricant Capacity O|
130 cm3
+0+ 4 1/3 fl oz,
*=+!HA O O
O Ol O| 4.6 Imp oz
*-!H O O
O Ol DENSO
( 8 Type
4 O| Swash-plate
3! O O
O Ol No of Cylinder
! O| 10
0 O O
O Ol Capacity
O| 188.0 cm3/rev
''-0+=& 11.47 cu-in/rev
-*$ =& O O
O Ol Max. Speed
,/- O| 7,600 rpm (min-1)
$A00;< O O
O Ol Lubricant Type
4 O| N D-OIL8
(8' O O
O Ol Lubricant Capacity O|
160 cm3
0+ 5 1/3 fl oz,
=+!HA O O
O O| O| 5.6 Imp oz
-!H O O
O Air Conditioning|
%
O Condenser
Type
4 O| Corrugated fin

O O
O O| O| O O
O Air Conditioning|
%
O Evaporator
& Type
4 O| Corrugated fin

O O
O O| O| O O
O Air Conditioning|
%
O Blower
)!3 Type
4 O| Sirocco fan
O O
O O| Motor Input
, O| 220 W/12 V max.
02=:/- O O
O O| Speed Control
! O| 4-speed*1/lnfinite variable*2
*G=&!G O *1: Manual A/C
G9, !%= O
O O| Max. Capacity
,/- O| 470 m3/h
*$0+= 16.600 cu-ft/h
-00 = O *2: AUTO A/C
G9%?48%= O
O Air Conditioning|
%
O Temp. Control
4-! Type
4 O| %,/
AHMR O O
O O O O O
O Air Conditioning|
%
O Compressor Clutch
! Type
4 O Dry, single plate, poly-V belt drive
(A
!!A!:!& O O
O O| Power Consumption O
3 O O
O O| SANDEN
%( O 40 W max/12 V
*02/=: O O
O O| DENSO
( 8 O 40 W max/12 V
*02/=: O O
O Air Conditioning|
%
O Refrigerant
1
Type
4 O HFC-134a(R-134a)
6 +*;1+*< O O
O O| Quantity
D O 500-550 g
000
18-19 oz
'5H O O
O Steering

O| TVpe
4 O Power assisted, rack and pinion
3A# O O
O System
O| Overall
8&!! Except H22A7 engine model
/6%$
! O 15.50
-0 O O
O O| Ratio
1 H22A7 engine model
6%$
! O 15.74
-$* O O
O O| Turns, Lock-to-Lock
4 A## O O O
O O| Except H22A7 engine model
/6%$
! O 3.02
+-0 O O
O O| H22A7 engine model
6%$
! O 2.88
-'' O O
O O| Steering Wheel Dia.

2!(- O 380 mm
+'0 15.0 in
-0 O O
) !

Design Specifications
/
?0
(cont’d)
2-24

O O ITEM
% O METRIC
% O| ENGLISH
%,&. O NOTES
,% O
O Suspension
O 4
Front O Independent double wishbone,
!3A O O
O O O coil spring with stabilizer
!
3!H O O
O O 1
Rear O Independent double wishbone,
!3A O O
O O #% 1
Front and Rear O coil spring with stabilizer
!
3!H O O
O O O Telescopic, hydraulic nitrogen
4!A !
O O
O O O gas-filled

!! O O
O Wheel
2! O| Camber
H22A7 engine model
6%$
! O -O°15'
0P@ O O
O Alignment
%!
O| Front
Except H22A7 engine model O
/6%$
! 0°00', 0°10'*1
0P00@A0P0@G O O
O O| Rear
1 H22A7 engine model
6%$
! O -1°15'
P@ O O
O OI Except H22A7 engine model O
/6%$
! -1°00', -0°50'*1
P00@A0P0@G O O
O O| Caster
O O O
O O| Front
H22A7 engine model
6%$
! O 3°00'
+P00@ O O
O OI Except H22A7 engine model O
/6%$
! 2°50', 2°45'*1
P0@AP*@G O O
O OI 4!4
Total Toe Front
O 0
0 mm 0
0 in O O
O OI Rear
1 O
In 2 mm 0-0'
In 0.08 in O O
O Brake System OI
)# 4
Type O
Front Power-assisted self-adjusting
3!7
O O
O OI O ventilated disc
&! O O
O OI 1
Rear O Power-assisted self-adjusting solid
3!7
! O O
O OI O disc*2. Power-assisted self-adjusting
G-3!7
O O
O OI O drum*3
G+ O O
O OI %
Pad Surface Area O
Front 53.2 cm2 x 2
+-/ 8.25 sq-in x 2
'-F/ O H22A7 engine
6%$
O
O OI O O model
! O
O OI O *$-/
47.6 cm2 x 2 7.38 sq-in x 2
$-+'F/ O Except H22A7,
/6%$A O
O OI O O D16B6 engine
()
O
O OI O O model
! O
O OI 1
Rear O *0-0/
40.0 cm2 x 2 6.20 sq-in x 2
-0F/ O D16B6 engine
()
O
O OI O O model
! O
O OI Lining Surface Area

% 1
Rear O -*/
25.4 cm2 x 2 3.94 sq-in x 2
+-5*F/ O Disk brake
(## O
O OI Parking Brake
#
)# O 86.8 cm2 x 2
'-'/ 13.45 sq-in x 2
+-*F/ O Drum brake
( # O
O OI 4
Type O Mechanical actuating, rear two wheel
,!
A33! O O
O OI O brakes
# O O
O 4
Tyre OI H
Size and Pressure O See tire label (see page 1-12)
!!;
< O O
O !!
Electrical O| Battery
) O *4 12 V-47 AH-20 HR
G*:*$%6061 O O
I
O O O *5 12 V-57 AH-20 HR
G:$%6061 O O
O O Under-hood fuse/relay box
? =!/ O 100A, 50 A, 40A, 30 A, 20A, 15 A,
00%A0%A*0%A+0%A0%A%A O O
O OI O 10 A, 7.5A
0%A$-% O O
O OI Driver's under-dash fuse/relay box
(&@ =!/ O 30 A, 15 A, 10 A, 7.5A
+0%A%A0%A$-% O O
O O| Passenger’s under-dash fuse/relay box

@ =!/ O 30 A, 20 A, 7.5A
+0%A0%A$-% O O
O O| Headlight high beam
6!

O 12 V-55W
:2 O O
O O| Headlight low beam
6!
!3 O *612 V-35W *712 V-55 W
G:+2G$:2 O O
O O| Front turn signal lights

!!
O 12 V-21 W
:2 O O
O O| Front parking lights
#
!
O 12 V-5W
:2 O O
O O| Front fog lights

!
O 12 V-55W
:2 O O
O O| Side turn signal lights

!!
O 12 V-5W
:2 O O
O O| Rear turn signal lights
1
!!
O 12 V-21 W
:2 O O
O O| Brake lights
)#!
O 12 V-21 W
:2 O O
O O| Tail lights
4!!
O 12 V-5W
:2 O O
O O| High mount brake light
6
#!
O 12 V-5W
:2 O O
O O| Back-up lights
)# !
O 12 V-21 W
:2 O O
O O| Rearfog light
1
!
O 12 V-21 W
:2 O O
O O| License plate lights
!!
O 12 V-5W
:2 O O
O O| Front ceiling light
!
!
O 12 V-5W
:2 O O
O O| Rear ceiling light
1!
!
O 12 V-5W
:2 O O
O O| Trunk light
4 #!
O 12 V-5W
:2 O O
O O| Glove box light
.!&/!
O 12 V-3.4W
:+-*2 O O
O O| Spotlights
!
O 12 V-5W
:2 O O
O O| Gauge lights
.
!
O 14 V-1.12 W, 1.4 W, 3.0 W,
*:-2A-*2A+-02A O O
O O O 9.5 V-1.1W
5-:-2 O O
O O| Indicator lights
!
O 12 V-LED, 14 V-0.84 W, 1.4 W
: (A*:0-'*2A-*2 O O
O O| Panel and pilot lights
!!!
O 14 V-0.84 W, 1.2W
*:0-'*2A-2 O O
: KY model
G9>C!
: Except B16B6 engine model
G9 /))
!
: B16B6 engine model
G+9))
!
: CG7 (Vehicle type)
G*9.$;:!<
: Except CG7 (Vehicle type)
G9 /.$;:!<
: With HID lamp
G926(!
: Without HID lamp
G$92 6(!
"
#

Body Specifications
2-25
3
Unit: mm (in)
?9;<
1,430 (5613)"
1,445 [559)"
1.5!]? 151$“
1,195 Isaak"
1.515 155.53“
1.504 [552!"
1,150 {63.91
- 669112633
EU only
2.668 "05.0! ‘3
2.610 "05.11"
4.595 HEELS]
666l262} ‘
L EU only
*1: Except KY model

G9 />C!
*2: KY model
G9>C!
*3: Except Type R
G+9 /41
*4: Type R
G*941
&*
'

Lubrication Points
3-2

For the details of lubrication points and type of lubricants to be applied, refer to the illustrated index and various work
!! ! !A!! /& 3#
procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
; %!=1!A1!A8& !A!!A-<-
O No.
,
@ O LUBRICATION POINTS
&;",', O LUBRICANT
&;", O
O 1 Engine
O
Always use a fuel-efficient oil that says "API
O %!3 !!Z% O
O O Service SG, SH or SJ."
O &.A6"-Z O
O O SAE Viscosity: See chart below).
O % :9!3<- O
O O 4
Transmission , !
Manual Genuine Honda MTF*1
O . 6,4 G O
O O %
Automatic Genuine Honda ATF 1 ,?,;%
O . 6%4 PREMIUM (Automatic O
O O Transmission Fluid-PREMIUM)
O 4 or DEXRONR II
! 1 ,?,<( R181 O
O O or III ATF
O %4 O
O + Brake line (includes Anti-lock brake line)
O )#!;! %!##!< O )#! (84+(84*G
Brake fluid DOT3 or DOT4*2 O
jswmwmmhw
O * O ! !
Clutch line O )#! (84+(84*G
Brake fluid DOT3 or DOT4*2 O
O Power steering gearbox
O 3

/ Steering grease P/N 08733-BO7OE
O

=0'$++)0$0 O
O Release fork (Manual transmission)
O 1!#;, !< Urea Grease UM264 (P/N 41211-PY5-305)
O ?.?,*;=*C+0< O
O $ Sift and select cable ends (Manual transmissions)
O !!;, !< Urea Grease UM264 (P/N 41211-PY5-305)
O ?.?,*;=*C+0< O
O ' Throttle cable end (Dashboard lower panel hole)
O 4!!;(!3!!< Silicone grease
O !
O
O 5 Throttle cable end (Throttle link)
O 4!!;4!!#< Multi-purpose grease
O , !
O
O 0 Brake master cylinder pushrod
O )#! Multi-purpose grease
O , !
O
O Clutch master cylinder pushrod
O ! ! Multi-purpose grease
O , !
O
O 12
Hood hinges and hood latch
O 6
! Multi-purpose grease
O , !
O
O 13
+ Battery terminals
O )! Multi-purpose grease
O , !
O
O 14
* O Fuel fill lid
!!!! Multi-purpose grease
O , !
O
O 15
Trunk hinges and latch
O 4 #
! Multi-purpose grease
O , !
O
O 16
Door hinges, upper and lower
O (
A !3 Multi-purpose grease
O , !
O
O 17
$ Door open detent
O ( Multi-purpose grease
O , !
O
O 18
' Rear brake shoe linkages
O 1#!#
Multi-purpose grease
O , !
O
O 19
5 Brake calipers
O )#! Silicone grease
O !
O
O 20
0 Power steering system
O 3
Genuine Honda Power Steering Fluid
O . 63
(V, II or S)
! ;:A< O
O 21
Air conditioning compressor
O %
Compressor oil:
O !9 O
O O SANDEN: SP-10 (P/N 38897—P13-003,
O %( 90;=+''5$+00+A O
O O 38898-P13-003 or 38899-P13-A01)
O +''5'+00++''55+%0< O
O O DENSO: ND OIL 8 (38897-PR7-003,
O ( 89(8';+''5$1$00+A O
O O 38898-PR7-003 or 38899-PR7-A)1)
O +''5'1$00++''551$%<< O
O O O ;(For Refrigerant: HFC-134a
1
96 (R-134a))
+*;1+*<< O
-30 -20 -1D 0 10 20 30 4G“:

I | I I I I
—20 '3 20 la 60 50 100"F
Recommended engine oil
1
!
Engine oil viscosity for ambient temperature ranges

!&

A CAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
?
! #!!3#!
-
Although this unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your
%!
!#! ! ! !!A!!&!
!3
hands with soap and water as soon as possible after handling used oil
33!!
!
G9 lf Honda MTF &!!A %&.A6"!3&% 02+0
*1: 6,4 is not available, you may use an AP1 service SG, SH or SJ-rated motor oil with viscosity of SAE 10W-30 or
10W-4O temporarily. Motor oil can cause increased transmission wear and higher shifting effort.
02*0!-,! 3

-
*2: 2. 6)#
G9 We recommend Genuine Honda Brake Fluid. ! -
&*
'

Lubrication Points

3-3
(cont’d)
;
?0

Maintenance Schedule
European Model - Normal Conditions
%

,

3-4

Follow the Normal Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance
!!3!, !&&
&,
Schedule on pages 3-6 and 3-7 do not apply.
!
++$!-
Service at the indicated krri3r1,|:|E|El 1 3|] EU 75 El 1051 SECTION
U'I
III
IJ
El
El
U1
F.)
'31
U1
U1
_x
_x
LIJ
41'-
distance ortime whichever miles 3: 1,IIIIIIEI 18 3E 45 5:1 53 NOTES and
‘HJ
"*4
l-J
M (D
'(fl
.cnm
comes first. months 24 48 Efl 84 PAGE
“HI
r'»_l
w.
_x
_t
_t
LU
I‘d
'15
0a
Li
0e
|
Replace engine oil and oil filter EH’ to El-1Ell
Replace air cleaner element 11—A—119
era—3
Inspect valve clearance Check. the valve clearance E-El-12
ELIE—9
Replace fuel filter 11—A—1EIE
Replace spark plugs Except Type R 4-31
Type R 4-32
Ei-A—B,
Replace timing belt, timing balancer belt and Check. vvater pump for signs of seal E-El-1El,
inspect water pump leakage E-CI 14,
10-1?)
4—45, 4—4?, we
Inspect and adjust drive belts - Check for cracks and damage. 17—14
- Check. deflection and tension. 22-52154
1 1 A34
Inspect idle speed 1 1-5—55
1 1- 0-5?
Replace engine coolant Check specific: gravitv fer freezing point. 1|}? to
1El-1U
Manual transmission: Genuine Honda I‘vITF 133,135?
Replace transmission fluid lve Automatic transmission: Genuine Honda
[0: Inspect] f—‘JF RREP-fllUlv’l [Automatic Transmission 14—132
AIT Fluid-F'REIlLIIv or DEKRDI‘J II or III .flTF
- Check the brake pad and disc 19—91-11, 'lEl-A—1El,
thickness. Check for damage or 18-A—12,19—A—14,
Inspect front and rear brakes cracks. 1 Stab—15, 1 9-A—17,
- Check the calipers fer damage, leaks, 19-.iK—2l3, 19-A—28,
and tightness. 1El-.fl.-3El, 19:11:31
Use only DOTS er DICJT4*3fiui. Check that 1 B-A-T
Replace brake fluid Everv 3 vears brake fluid level is betvveen the upper and
lower marks on the reservoir.
Check parking brake adjustment 'l'l l°l l'l l°l l'l Check the parking brake operation. 1 B-A-Ei
Replace pollen filter Everv 30,000 km (13,000 miles) or 12 months 22-39
Check lights alignment rZheck the position ofthe headlights 23- D-El
Test drive [:neise, stabilitv, dashboard Check fer read stabilitv, noise, vibrations
operations]. and dashboard operation
*1: *A000#;$A000!<=+A&*A000#;$A000!<=+!-
G9 Inspect at 45,000 km (27,000 miles)/36 months, and every 45,000 km (27,000 miles)/36 months after replacement.
*2: 2. 6)#

European Model - Normal Conditions (cont’d)
%

,

/
?0
3-5
3
Service at the indicated km ‘4' 1,EIEIEI 12U'_ SECTION
"'--l
L“
distance or time vvl'iicl'iever miles x '1 ,EIDEI ND TE E: and
c o m e s first months PAGE
£15 72' :31
(LI
l'\_'|
LEI
"*4
EEI 9E 1 DE:
r_'.-_.
_t
UJ
LiJ
l‘xJ
l’xJ
- Check for correct installation and
position, check for cracks,
‘v’isually inspect the following items: deterioration, rust and leaks.
- Check tightness ofscrevvs, nuts and
ioints, if necessary, retighten
° Check rack grease and steering
linkage.
Tie rod ends, steering gearbox, and boots - Check the boot for damage and
leaking grease
. Check the fluid line for damage and
leaks
° Check the bolts to r tightness lEl-Q,1El-1El,
- Check the all dust cover for lEl-11,'lEi—
deterioration and damage 2|], 18-21,
18-22
° Check boots and boot hand for lEi—3
Driveshafi boots cracks.
- Check rack grease.
Check the master cylinder, pro portioning
Eirake hoses and lines [including AEIE‘] control valve and ABS r'rujdulatort'or
damage and leakage
lCheck the catalytic converter heat shield,
Exhaust system exhaust pipe and mufflerfor damage,
leaks and tightness.
Check fuel lines for loose connections, 'I lat-LBS, 11-
cracks and deterioration. Retighten loose (3-59
Fuel lines and connections connections and replace any damaged
parts.
Tyre condition Check for pressure, punctures or cuts and
irregular thread vvear.

European Model - Severe Conditions
%

-

3-6
5
Service atthe indicated kmx1,888 ?.5 15 22.5 38 3?.5 45 52.5 88 825 T5 82.5 88 8?.5 .1125 128 SECTION and
distance ortime miles k1,IZIUIZI NOTES PAGES
hichevercomes first. months
4.5 13.5 18 22.5 2? 31.5 38 48.5 45 48.5 54 58.5 83 825 T2
18 24 38 38 42 48 54 88 88 T2 28 84 88 88
Replace engine oil and oil filter 8-?10 8-18
Clean (0) or replace (0) air cleaner 11—A—118
element
Use nonnal schedule except in
dustv conditions
Inspectvalve clearance ICtheckthe valve clearance Bah-3, 8-8-12, 8-0-8
Replace fuelfllter 11-A—185
Replace spark plugs ExceptTYPE R 4-31
TYPE 4-32
Ever—8, 8-8-18,
Replacetiming belt, timing balancer ICtheckvvater pump for signs ofseal leakage 8-0-14,
’t
belt and inspect vvaterpump 18—1?
+ ICtheckfor cracks and damage. 4-45, 4-41, 4-43

Inspect and adjust drive belts + Check deflection and tension. 13-14, 22—53, 22—54
Inspectidle speed 11-A—84,11—E|—85
11-0—5?
Replace engine coolant Check specific gravitv forfreezing point 18—? to
18-18
MIT Manual transmission: Genuine Honda MTF 13-3,13-5TI'
Automatic transmission: Genuine Honda ATF
PREMIUM (Automatic Transmission Fluid-
Replacetransmission fluid PREMIUM) or DEXRON II or III ATF.
14-132
+ ICtheckthe brake pad and disc thickness. 18-A—4, 18-91-18, 18-
Checkfordamage orcracks. A—12,18-A—14,18—A—
+ ICtheckthe calipers for damage, leaks and 15,18-A—1?,18-A—28,
Inspectfront and rear brakes tightness 18—A—28,18-A—38, 18—
991-31
Use onlv DO 2: or DOT4* fluid. Checkthat 1 Q-A-T
brake fluid level is betvveen the upper and
Replace brake fluid Everv 3 vears lower marks on the resenroir.
Check parking brake adjustment Checkthe parking brake operation. 1 Q-A-E
Replace pollen fllter Everv 30,000 km (18,000 miles) or 12 months 22—38
Checklights alignment 0 Checkthe position ofthe headlights. 23-D-Q
Test drive (noise, stabilitv, dashboard 0 Checkfor road stabilitv, noise, vibrations and
operations). dashboard operation.
*1
G These belts should normally be replaced at the intervals shown in the maintenance schedule. (Normal Conditions).
4! !!!!&!3 !-;!<-
Replace the timing belts at 75,000 km or 45,000 mile if the vehicle regularly is driven in one or more of these conditions:
1!
!$A000#*A000!&!
!!&9
9 In very high temperatures [43°C, (110°F)<&U-
&
T*+PA;0P above].
O In very low temperatures [-29°C, (-20°F)< U-
&!3 T5PA;0P under].
*2: 2. 6)#
3-7
7
European Models - Severe Conditions (cont’d)
%

-

/
?0
Service at the indicated km :u:1,EIIZIEI .75 15 22.5 :IU 3.7.5 45 52.5 5|] 5.7.5 .75 132.5 9|] 515105112513] SECTION
distance or time miles: m IUUIJ NOTES and
uvhichever comes: first. ”1,3t PAGES
31.5 35 4E|.5 45 49.5 54 58.5
LL'I
LT‘I
"--l
CF!
0']
“-J
-J
[NJ
\J
Cl'
51218 24 EU 42 4E 54 5|] 55 F2 .7'8 1
LL'I
LC!
0—!
0'!
J:-
Lu
(D
. Check for correct
installation and position,
check for cracks,
‘v’isually inspect the following items: deterioration. rust and
leaks.
Check: tightness of
t
screws. nuts and joints. if
necessary, retighten.
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 * Check rack grease and 1?-13,1I’-
steering linkage. 25
Check the boot for
o
Tie rod ends, steering gearbox and damage and leaking
boots grease.
Check the fluid line for
o
damage and leaks
* Check the bolts for 113—9n—
tightness. 1|],1El-11,
Suspension components . Check the all dust cover 113—25, 18—
for deterioration and 21, '8-22
damage
. Check: boots and boot 15-3
Dt'l'u'E:Eil'I:3fi lJEIiZItS hand for cracks.
. Check rack grease.
0 0 0 0 0 0 0 [0 Checkthe master cylinder, 'lEl-A—El,
Etrake hoses and lines [including ABS) proportioning control valve 19-42-35
and ABS modulator for
damage and leakage.
Check the catalytic 9-9
converter heat shield, to
Exhaust system exhaust pipe and muffler 9—1 2
for damage. leaks and
tightness.
Check fuel lines for loose 11-95-55
U‘I
connections, cracks and 11—[3—5
LCI
Fuel lines and connections deterioration. R'etighten
loose connections and
replace any damaged parts
Check. for pressure,
Tyre condition punctures or cuts and
irregular thread '-.-vear
Follow the Severe Maintenance Schedule if the customer’s vehicle is driven MAINLY under one or more of the following
!!3&, ! B&!&,%C !!3

conditions:
9
9 Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip.
(&
!'#;!<AH
A&
!#;0!<-
O Driving in extremely hot (over 32°C, (90°F)<-
(&
/!;&+PA;50P conditions.
O Extensive idling or long periods of stop-and-go driving.
/&!
!

&
-
O Trailer towing, driving with a car-top carrier, or driving in mountainous conditions.
4!3
A&
3A&
-
Driving on muddy, dusty or de-iced roads.
(&
A -
O
Note: If the customer’s vehicle is driven OCCASIONALLY under severe conditions, you should follow the Normal Conditions
9 B&!&8%8%C &A !!!3!
Maintenance Schedule on pages 3-4 and 3-5.
, !
+*+-

I>

KY Model
3-8
8
This Maintenance Schedule outlines the minimum required maintenance that you should perform to ensure the trouble-free
4, ! ! F ! !
operations of the customer’s vehicle. Due to regional and climatic differences, some additional servicing maybe required.
B&!-(
!!A!&
F -
Please consult the warranty handbook for a more detailed description.
! !3#!-
Service at the indicated km k 'I ,IIIUIII ED 40 El] EU 'IEIU 120 'I4EI 'IEEI 'IBIII EDI] SECTION
distance er time whichever miles a; IDIIID NOTES and
cemes first menths RAGE
'I M
2435 48 ED ?2 84 RE 108'
Cl
M [\J
'I 2435 48 ED 7‘1 h; 84 95 108'
M
III
Replace engine eil Every SDIIIEI km [3,000 miles] er 5 menths CI 7
U'I’
Replace engine eiI filter Every SDIIIEI km [EDEN] miles'] er 5 menths 8-8 lb 8- 'I U
Clean er replace air cleaner element Clean every 'IEIJIIIIID km [EDEN] miles] erE 'I 'I 435- 'I 'I 9
menths and replace every EDDEID km (12,000)
er 1'2 menths
Inspect valve clearance Check the valve clearance Ei—B—I 2
Replace fuel filter 11-A—IEI5
Replace spark plugs 4-31
Inspect distributer cap, reter and ignitien vviring 4—2591—214—
L39
Replace timing belt, timing balarnser belt and Check water pump fer signs ef seal Ieakat e
inspect water pump
III
I
. Check fer cracks and damage
Inspect and adjust drive belts - Check deflectien and tensien.
Inspect idle speed and idle CO

I'I—C—E?
Replace engine ceelant Check specific gravity ferfreezing peint. 1IJ-FtIII1IJ-ID
n
Inspect Pub“ valve Check the clicking seund ef rnetien frem the I 'I 41:143.
F' "‘v’ valve ef idling. I'I—C—?9
Inspect ignitien timing 4-21
~ Check the EVAF‘C] centrel canister ILA—144,
Inspect evaperative ernissien centrel system eperatien. 'I I—EI-E‘I,
- Check the hese fer bleckage, cracks er I'I-C-BI]
discennected.
Manual transmiss' n: Genuine Henda IvITF
Replace transmissien fluid Autematic Transn sien: Genuine Henda flaTF
F'REf-.-'IIUI-.4 [Autematic Transmissien Fluid-
F'REIvIILJIvI'I er DEE'JIRDI‘I II er III ATF.
- Check the brake pad and disc thickness. 1944.41, 19—A-
Inspect frent and rear brakes Every IEIIIJIZIIJ km ("LIEU miles] er 5 menths Cheek fer damage er cracks. 'IEI. 19-34-12.
. Check the calipers fer damage, leaks and 19-4314. 19-
tightness A—IS, 19-A-
17. IRA-'25,
19-45-28. 19-
A—EI]. IQ-A—SI

KY Model (cont’d)
I>
/
?0
3-9
9
Service at the indicated km x 1 .IIIDIII 4|] ED :3 1|:IIII '"' 1:10 1Ei|I| '1 EDD 3 E CT | O N
distance or time which ever miles i: 1.000 NOTES and
comes first months RAG E
35 :3 SE 108 ""'
hi:-
MtxJ
EIII :34 95 'lEIB '20
Use only EICJTEl or DOTW fluid. Check that 1 El—A— T"
Replace brake fluid 0 brake fluid level is bet'-.-'-.-'een the upper and
lower marks on the reservoir.
Check parking brake adiustment Check the parking brake operation. 1 l:l—.*'-"\- ti
Rotate tyres The suggested rotation method is shown in
[Check tyre inflation and condition at least one Rotate tyres every 1|].EIDEI km [EDIIID miles] the diagram ofthe Owner's Manual.
per mo nth‘i
+ Check for correct installation and position,
check for cracks. deterioration. rust and
Visually inspect the following items: leaks.
. Check tightness of screws. nuts andjoints.
lfnecessary. retighten
Tie rod ends. steering gearbox. and boots * Check rack grease and steering linkage. 1?-13.1?-25
+ Check the boot for damage and leaking
grease.
+ Check the fluid line for damage and leaks.
Every 1|'|.|'||‘|R km [H.I'II'II‘I miles) orE months

* Check the bolts fortightness. 1El-El.1B-1E|.
Suspension components * Check the all dust coverfor deterioration 18-11. 18-20.
and damage. 1321.132?
Driveshafi boots . Check boots and boot hand for cracks. 15—3
. Check rack grease.
Check the master cylinder. proportioning 19-A—3. 19-A-
Elrake hoses and lines [including ABS] control valve and ABS modulator for damac e 35
and leakage.
. Check all hoses for damage. leaks or 10—2. 10—11

Cooling system hoses and connection deterioration.
* Check all hose clamps. Retighten if
necessary.
Check the catalytic converter heat shield. 9-10
Ekhaust system ekhaust pipe and mufflert'or damage. leaks
and tightness
Check fuel lines for loose connections. cracks 1 1 4-K— 95
Fuel lines and connections and deterioration. Retighten loose connections 1 'l - Iii-553
and replace any damaged parts.
G92. 6)# ! -

*1: We recommend Genuine Honda Brake Fluid.
Sgecial Tools

4_2

O|RefNo.
1- O| Tool Number
4! O| Description
( |Qty
OD O| Remark
1#
O| 1 O| 0$"..00000
07JGG-OO101OO O| )!4.

BeltTension Gauge | 1
O O|
O| 2
O| 0$%I00000
07PAZ-OO101OO O| 1
SRS Short Connector | 1
O O|
Starting System
!# 4_3


&

DRIVER'S
LIN DEFI‘DASH
FUSEIRE LAY BED".
REAR SIDE
STARTER
CUT RE LAY
AIT GEAR POSITION

SWITCH MIT}
TEST, sectlnn 1-1 STARTER
Replacur'wr11.sucliun14 Teal, page 5—5
Solenoid Test. page. 41-?
PErfnrmanne T251. page 4-16
Replacement. pagu #- E
Ouclhaul. page 4-9
To go to the pages referenced on the diagram above,

4

&A
click on the following:
!#!!3
9
(See page 4-5)
;!*<
(See page 4-7)
;!*$<
(See page 4-16)
;!*<
( See page 4-8)
;!*'<
( See page 4-9)
;!*5<
!#
Starting System
) !
Circuit Diagram
4-4

UPCJEFI J-‘DDJ 35.. 5": 45H." ED)! Cih ITION SWlT-C-H

HIE—EH?
(D
I‘m: I11 NOEL-1| ND 42 [SIS-fl?
EA M NIL Wiil
Eu- (-‘M—T
STAQTEQ DRIVERS
CUT UNDE R-DhSH
RELAY FUE ErRELA'r' EDT.
EIL U-CIHN
V
- E'Ch'l-F‘CM
' FGM-F
MRIN ELLA"
EIL<-’WH'
,-" Extapl
|I HZEAF | [#233]
-. eng r13." | l?"gll'lfl.I IA-TI | lull-TI
P" WEE-
..I [J
Paw : k‘iJ .
WEI—f T
«b
M SOLENOID SULENCII:I PCT GEAR PCGITIDN
SWI'CH
{0‘4 [El awd E I'.
Mm.
z”
«a
poe'aninr .I
ELK
__—..._l
STAFITEH STARTER
{Partranmt magnal 1m; [Fifid winding 11W}
Starting System
!# 4_5
3
Starter Test

NOTE: The air temperature must be between 15 and 38°C

84 94 3+'H 3.
+- Check the battery, battery positive cable, ground,
#A&!A
A
(59 and 100°F)<
-
;500H before testing. starter cut relay and the wire connections for
!3
Recommended Procedure:

'
F looseness and corrosion. Test again.
!-4
-
¢ Use a starter system tester.
?- If the start still does not crank the engine, go to
!!#
A

¢ Connect and operate the equipment in accordance with
F 3 step 4.
*-
the manufacturer's instructions.
@ - 4.
*- Unplug the connector (BLK/WHT wire and solenoid
?!
;)>=2643!
¢ Test and troubleshoot as described.
4 !- terminal) from the starter.
!<-
Alternate Procedure:
'
F 5.
- Connect a jumper wire from the battery positive (+)
7 3&;V<
¢ Use the following equipment:
?!!3
F 9 terminal to the solenoid terminal.
!!!-
- Ammeter, 0 - 400 A.
%A0*00%- The starter should crank the engine.
4 !#
-
- Voltmeter, O - 20 V (accurate within 0.1 volt).
:!A00:; 30-&!<- Except H22A7 engine:
%.7! F
- Tachometer, O - 1,200 rpm (min.-1).
4A0A00;-<- SOLENOID
TERMINAL
¢ Hook up a voltmeter and ammeter as shown.
6# &!3-
“if“: ”If“
(D
<
O(D
‘3'
WlRE
6 x 1.0 mm
3.4 N-m (0.35 kgf-m.
2.5 lhf-fll
H22A7 engine:
.7! F
NEGATIVE
TERMINAL
NOTE: After this test, or any subsequent repair, reset the
84 9%A F A
ECM to clear any codes (see section 11).
,!;<-
Check
6the Starter Engagement:
%!!F
1.
- Remove the No.31 (15 A) fuse from the under-hood
1&-+;%<
fuse/relay box.
=!/-
2.
- Turn the ignition switch to START (III) with the shift lever
4
34%14;<3!&
in E
or El;%=4< !;,=4<-
position (NT) or neutral position (M/T).
The starter should crank the engine.
4 !#
-
If the starter does not crank the engine, go to step 3.
#
A
+- BLKIWHT ' .
If it cranks the engine erratically or too slowly, go to
#
!!!3!A
WlFlE I |
"Check for Wear and Damage" on the next page.
Z#2(
Z/
-
SOLENOID ,
TERMINAL ' "
¢ If the starter still does not crank the engine,
!!#
A
remove it, and diagnose its internal problem.
&A
!!-
¢ If the starter cranks the engine, go to step 6.
#
A
-
Starting System
!#
Starter Test (cont’d)
/
?0
4-6
5
- Check the ignition switch (see section 23).
#
3;+<- Check Cranking rpm
66 !
$0.00.“?
$- Check the starter cut relay (see section 23).

# !;+<- Engine speed during cranking should be above 100 rpm

#
!&00
'- Check the NT gear position switch (see section 14).
#%=4
3;*<- (min -1).
;<-
5- Check for an open in the wire between the ignition
#33
If speed is too low, check for:
!3A#9
switch and starter.
3- 0 loose battery or starter terminals.
!!-
10. #!H;+<-
0- Check the immobilizer system (see section 23). O excessively worn starter brushes.
/&!3 -
Check for Wear and Damage
6
1)! O open circuit in commutator segments.

-
The starter should crank the engine smoothly and steadily, if
4 !#
!!A O dirty or damaged helical spline or drive gear.

!!!&
-
the starter engages, but cranks the engine erratically, remove

A #
!!A& O defective drive gear overrunning clutch.
&&
&
! -
it, and inspect the starter drive gear and torque converter or
A&
F & Check Starter Disengagement
6) !!
flywheel ring gear for damage.
!3!

- With shift lever in E
2!& OI‘EI;%=4< !
position (NT) or neutral
¢ Check the drive gear overrunning clutch for binding or
#&
&
!
position (M/T), turn the ignition switch to START (Ill),
;,=4<A
34%14;<A
slipping when the armature is rotated with the drive gear
!
3 3&
and release to ON (II).
!8;<-
held.
!- The starter drive gear should disengage from the torque
4&
!

F
- If damaged, replace the gears.

A!
- converter or flywheel ring gear when you release the
&!3!

3 !
Check Cranking Voltage and Current Draw
66 !4
!)( key.
#-
Cranking voltage should be no less than 8.0 volts.
#
&!
!!'-0&!- If the drive gear hangs up on the torque converter or
&

F &
Current draw should be more than *1 amperes.
3 !G- flywheel ring gear, check for:
!3!

A#9
*1 :!9
G Valeo: 300
+00 0 solenoid plunger and switch malfunction.
!!
3! -
DENSO:
( 89 200
00 0 dirty drive gear assembly or damaged overrunning
&
!
&

If cranking voltage is too low, or current draw too high, check
#
&!
!3A 3
A# clutch.
! -
for:
9
¢ dead or low battery.
!3-
open circuit in starter armature commutator segments.

-
....
starter armature dragging.

-
shorted armature winding.
3
-
excessive drag in engine.
/&

-
!#
Starting System
7
_
Starter Solenoid Test

4 7
1.
- Check the hold-in coil for continuity between the S
#!! 3 2.
- Check the pull-in coil for continuity between the 8
# !!! 3
terminal and the armature housing (ground). The coil is
!
;
<-4! and M terminals. The coil is OK if there is
,!-4!8>
OK if there is continuity.
8> - continuity.
-
Except H22A7 engine:
%.7! F PULL-IN COIL HOLD-m BEHL
B x 1.0 mm B __‘ \ 5 | I"
s TERMINAL 3.4 N-m “3.35 kgf-rn. ',
2.5 Ihf—fii
c '1 l
M TERMINAL
B TERMINAL {/jfla—d—w—
z’ |-*’
3 film ill"! kgf-m. _.
5 Ibf-ft]
B x 1.25 mm
B N-m (0.9 kgf—m.
1F lbl-HI
H22A7 engine:
.7! F
5 TERMINAL
M TERMINAL X
B TE RMINAL
3 x 1.25 mm
9 N-m (0.9 kgi-un,
T lbf-ftl
!#
Starting System
Starter Replacement

4-8
8
1.
- Disconnect the battery negative cable, then disconnect
(
&!A H22A7 engine:
.7! F
the positive cable, and wait at least three minutes.
&!A3! - 11] 11: 1.25 111111
2.
- Remove the engine wire harness and radiator lower
1&
3!3 44 N-m i4.5 kgr-m.
hose from the bracket on the starter motor.
#- 33 lbf-fll
3.
+- Disconnect the starter cable from the B terminal on the
(!)!
solenoid, then disconnect the BLK/WHT wire from the 8
!A)>=2643
terminal wire.
!3-
%.7! F
COLLAR
1a a 1.25 mm aLKiWHT WIRE
u N-m (4.5 ltgf-m,
33 Ibf-f‘tl
BLKIWHT
WIRE
II) x 1.25 mm
M Nvm 14.5 kgf-m. 33 Ib'l-Hl
31:1.25mm
9 Mr“ [0.9 kgf-m, 'l' [bf-Hi STARTER
CABLE
4.
*- Remove the two bolts holding the starter, then
1&3!!
A
remove the starter.
&-
5.
- Install in the reverse order of removal.
!!&&!-
NOTE: When installing the starter cable, make
84 92!!
!A#
E x 1.25 mm sure that the crimped side of the ring terminal is

!
9 NM “1.9 kgf-m, facing out

T “1“.” 6 )1; 1.0 mm
3.4 N-m (0.35 kgt-m. Crimped side of ring
terminal
2.5 Ibl—f‘ll
NUT
STARTER 1D x 1.25 mm
CABLE AH N-m ”.5 REM“.
33 Ihf—fli
S.
- Connect the battery positive cable and negative to
&!
&
the battery.
-
Starting System
!# 4_9
9
Starter Overhaul
- (Valeo)
/4
0

%.7! F
STARTER
SOLENOID
Test, page 4-?
OVERHUNNING
CLUTCH
III:_.'pI_~I_;1iUI‘II page 4-11
.&
MDLVBDENUM
DISULFIDE
SOLENOID
LEVER
FRONT BEARING
.fiq
MOLYBOENUM
DISULFIDE
MOL‘I'BDENUM
’ _ msumne SPRING CU P
FIE-place.
"
Q). ,. GEAR Housm
G
GASKET
ARMATURE
HDUS-l MG
ARMATUHE
Inspection and Test. page 1—12
END COVER
BRUSH
SPRING
BRUSH
Inapuulifll‘u. page 1-11
4

&A
!#!!3
9
(See page 4-7)
;!*$<
(See page 4-11)
;!*<
(See page 4-12)
;!*<
Starting System
!# _
$
Starter Overhaul
- (DENSO) (cont’d)
/)%,0/
?0 4 10
H22A7 engine:
.7! F
SOLENOID
STARTER SOLE NDID
LEVER
___;. STARTER SOLENOID

Tf‘fil, page J T
OVERRUNNING
CLUTCH
WICIL‘II EDEN U M
DISULFIDE
BRUSH
OVERHUNNING
CLUTCH
Inspection. page 4 -11
SOLENOID LEVER
MOLYBDENUM
DISU LFIDE
SPRING CLIP
Re place.
BRUSH HOLDER
Test. page 4-15
GE MI HOUSING
AHMATUFIE HOUSING
AHMATUFIE
Inspection and lest. page LL12
Ea
END COVER
f . . MDL‘I’BDENUM
Inspection. paged-11

4

&A
!#!!3
9
(See page 4-7)
;!*$<
(See page 4-11)
;!*<
(See page 4-12)
;!*<
(See page 4-15)
;!*<
!#
Starting System
Brush

" Inspection
4-11
Overrunning Clutch

- ! Inspection
Measure the brush length. If not within the service limit,

, !
-3&!A - Slide the overrunning clutch along the shaft. Does
!&
! !
-(
replace the brush (or brush holder assembly).
! ; !!<- it move freely? If not, replace it.
&![A!-
Brush &!
" Length Rotate the overrunning clutch both ways. Does it
- 1&
! 3-(
Standard (NEW)
; 2< Service Limit
& lock in one direction and rotate smoothly in
!#!
Valeo
:! 18 mm (0.7 in)
';0-$< 5 mm (0.2 in)
;0-< reverse? If it does not lock in either direction or it
&[!#
DENSO
( 8 14.0 - 14.5 mm
*-0*- 9.0 mm
5-0 locks in both directions, replace it.
!#A!-
(0.55 - 0.57 in)
;0-0-$< (0.35 in)
;0-+< VALEO
4&%
-_— DVERHUNNING
CLUTCH
i
NOTE: To seat new brushes after installing them in their
84 943 !!

holders, slip a strip of #500 or #600 sandpaper, with the grit
!A!X00X00A3

side up, over the commutator and smoothly rotate the
A& !
armature. The contact surface of the brushes will be sanded
-4 3!!
to the same contour as the commutator.
-
DRIVE GEAR
DENSO:
)%,F
DRIVE GE AH
+- If the starter drive gear is worn or damaged,

&
3
A
replace the over-running clutch assembly; the gear
!&
! !N

is not available separately.
&!!!-
*- Check the condition of the flywheel or torque
#!3!F
converter ring gear if the starter drive gear teeth
&

&

are damaged.

-
!#
Starting System
Armature Inspection and Test

4-12

1.
- Inspect the armature for wear or damage, due to contact
3
A ¢ !3&
If commutator diameter is below the service
with the permanent magnet or field winding. If there is
3
!3
- limit, replace the armature.
!A! -
wear or damage, replace the armature.
3
A! - Commutator Diameter:

) F
Inspect to r damage. Standard (NEW)
; 2< &
Service Limit
DENSO
( 8 27.9 - 28.0 mm
$-5'-0 $-0
27.0 mm
(1.09 - 1.10 in)
;-05-0< (1.06 in)
;-0<
VERNIER
CALIPEH
2.
- # -
Check commutator surface and diameter.
0 If the surface is dirty or burnt, resurface with emery
A 3
cloth or a lathe within the following specifications, or
!!3!!3
A
recondition with #500 or #600 sandpaper.
3X00X00-
COMMUTATOH
SANDPAPEH
!#
Starting System
Armature Inspection and Test (cont’d)

/
?0
4-13

+-
3. , -
Measure the commutator runout. 4.
*- Check the mica depth. If necessary, undercut the
#-A
O If the commutator runout is within the service limit,
3&!A mica with a hacksaw blade to achieve proper
3#3!&
check the commutator for carbon dust or brass
# depth. If the service limit cannot be maintained,
-&!A
chips between the segments.
3
- replace the armature.
! -
Q If the commutator runout is not within the service
3& HIGH
limit, replace the armature.
!A! - MiCA NUT GOOD

F
Commutator Runout:
Standard (New)
;3< &
Service Limit
:!
Valeo 0 - 0.01 mm
00-0 0.015 mm
0-0
MICA DEPTH
(0 - 0.0004 in)
;00-000*< (0.0006 in)
;0-000<
DENSO
( 8 0 - 0.02 mm
00-0 0.05 mm
0-0
(0 - 0.0008 in)
;00-000'< (0.002 in)
;0-00<
VALEO:
4&%F
DIAL lNDlCATOR
Commutator Mica Depth:F

)
Standard (New)
;3< &
Service Limit
:!
Valeo 0.5 - 0.9 mm
0-0-5 0-
0.2 mm
(0.020 - 0.035 in)
;0-000-0+< (0.008 in)
;0-00'<
DENSO
( 8 0.5 - 0.8 mm
0-0-' 0.2 mm
0-
(0.020 - 0.031 in)
;0-000-0+< (0.008 in)
;0-00'<
5.
- Check for continuity between the segments of the
# 3

commutator. If an open circuit exists between any
- /3
segments, replace the armature.

A! -
COMMUTATDH
COMM UTATOH
DENSO:
)%,F
DIAL INDICATOR
COMMUTATOH
SEGMENT
COMMUTATDH
!#
Starting System
Armature Inspection and Test (cont’d)

/
?0
4-14
Field Winding Test (DENSO)
+ 1 !/)%,0
6.
- ! -6!
Place the armature on an armature tester. Hold a 1.
- Check for continuity between the brushes. If
# 3 -
#3! -
hacksaw blade on the armature core. there’s no continuity, replace the armature housing.
B A!
-
2.
- Check for continuity between each brush and the
# 3
armature housing (ground). If there is continuity,

;
<- A
HACKSAW BLADE replace the armature housing.
!
-
BRUSHES
AHMATU RE TESTER
AHMATUHE
If the blade is attracted to the core or vibrates while the
!&3!
core is turned, the armature is shorted. Replace the
A -1!
-
armature.
$- Check with an ohmmeter that no continuity exists
#3 /
between the commutator and armature coil core, and
3 !A
between the commutator and armature shaft. If
3 - AHMATURE
HOUSING
continuity exists, replace the armature.
/A! - [GROUNDI
SHAFT COMMUTATDH
COIL CORE
Starting System
!# 4_15
3
Brush .
/)%,0
" Holder Test (DENSO) Brush !
" Spring Test
1.
- Check that there is no continuity between the (+) brush
# 3;V< 1.
- Insert the brush into the brush holder, and bring
!A
holder and (-) brush holder. If there is continuity, replace

!;< !- A! the brush into contact with the commutator, then
3 A
the brush holder assembly.
!!- attach a spring scale to the spring. Measure the

!
-,
:1» BRUSH HDLDER :3 BRUSH HDLDEFt spring tension at the moment the spring lifts off the

!
-
brush.
1 ‘43-” SPRING SCALE
SPRING
BRUSH
-:3 BRUSH HOLDER :13 BRUSH HOLDER: Spring Tension:

!
F
Valeo
:! 15.25 - 19.25 N
-5-
(1.56 - 1.96 kgf, 3.44 - 4.32151)
;--5#
A+-***-+!<
DENSO +-$$-$
( 8 13.7 - 17.7 N
(1.4 - 1.8 kgf, 3.09 - 3.97151)
;-*-'#
A+-05+-5$!<
Starting System
!#
Starter Reassembly
*#
4-16
5 '

Performance Test
NOTE: Use the illustration as reference for reassembly (See

84 9?!! !; - Disconnect the wires from 8 terminal and M
(3!,
page 4-9) and (See page 4-10)
!*5<;!*0< terminal.
!-
1.
- Pry back each brush spring with a screwdriver, position
#
33&A - Make a connection as described below using as
,#!3

the brush about halfway out of its holder and release the
!3 !! heavy a wire as possible (preferably equivalent to
&3!;!F &!
spring to hold it there.

!- the wire used for the vehicle).
3 &!<-
VALEO:
4&%F +- Connect the battery as shown. If the starter pinion
3-
pops out, it is working properly. To avoid damaging
A3#
!-4&

the starter, do not leave the battery connected for

A!&
more than 10 seconds.
0-
(-B 9
12V
BATTERY
[G RDUNDi
)%,F
*- Disconnect the battery from the M terminal. If the

(,!-
pinion does not retract, the hold-in coil is working
A!!3#
properly. To avoid damaging the starter, do not

!-4&

A
leave the battery connected for more than 10
!&0
seconds.
-
@-
12V 9 ©
BATTERY 0
2.
- Install the armature in the housing. Next, pry back each
!!
-/A#
brush spring again, and push the brush down until it

A 3 !
seats against the commutator, then release the spring

A!
BODY
against the end of the brush.

- lGHOUND]
+-
3. !!& !-
Install the end cover on the brush holder.
Starting System
!# _
Performance Test (cont’d)
'
/
?0
7
4 1 7
5.
- Disconnect the battery also from the body. If the pinion
(!-
retracts immediately, it is working properly. To avoid
!A3#
!-4&
damaging the starter, do not leave the battery connected

A!&
for more then 10 seconds.
0-
Er) 6
12v
BATTE RY
IGRUUHD]
6
Clamp the starter firmly in a vice.
!!&-
7.
$- Connect the starter to the battery as described in the

diagram below, and confirm that the motor starts and

!3A
keeps rotating.
#
-
BATFEFW
12V
8.
'- If the electric current and motor speed meet the
!
specifications when the battery voltage is at 11.5 V, the
3&!
-:A
starter is working properly.
3#
!-
Specifications:

F
Maker
,# Electric current
! Motor speed
,
Valeo
:! 70A or less
$0%! 2,700 rpm (min-1) or more
A$00;<
DENSO
( 8 90A or less
50%! 3,000 rpm (min-1) or more
+A000;<
Ignition System
!
# 4-18
8

&

IGNITION TIMING CONTROL SYSTEM

,,,,&>%
Inspection (See Page 4-21)
;'!*<
IGNITION COIL
[01686 original
Testr page 4-29
IGNITION WIRES
Inspection and Test. page +29
DISTRIBUTOR
lEIcept ["536 engine]
Replacement. page d-Ed SPARK PLUG
Uuurhaul. page 41-25 Inspection. paged-31
Ignition Control MULIUIE I1ICM)
Input Test. page 4-23
Ignitinn lEmil Test. page +29

4

&A
!#!!3
9
(See page 4-29)
;!*5<
(See page 4-24)
;!**<
(See page 4-26)
;!*<
(See page 4-28)
;!*'<
(See page 4-29)
;!*5<
(See page 4-31)
;!*+<
Ignition System
!
#
Circuit Diagram
) !
4-19
9
D1636 engine:
)5"5! F
L. "iL‘IE F.-HCGD FUE-E. FIEJW EiC-X II3N|TIDNI E-'I‘I'ITC-
9
B-EI'I'I'EFI‘Ir
”3.41 (100A: \i:- 42 IEIOAI
m m
EILKJYEL
' No.5 DRIVE R'S

. [15A] JNDER-DASH
FUSE-PEN." B01
EILKJYEL
IISN TION COIL
CIMI'ICN WIRE IG NITDN I’I'IFIE
~r .—
2
LIL-L.-
cu: 1::
3%
V
Q 'm
(—1 )C'I
’66:» U
am ELCL
J
IGNITION WI RE IGNITION WIRE
WHY-(ERR
. Q
3:1 I \I:- 4 N53 1" N12

I“!
SPAR-C v SPARK SOARK SPhI-‘IK

PLUG PLUG PLUG j. PLUG
!
#
Ignition System
Circuit Diagram (cont’d)
) !/
?0
4-20
$
Except D1636 engine:

%)5"5! F
UNDER-#300 FUSE-RELAY my. PSMTICIN 5W TCH
No.41 Hum: N142 45w.)

m TX...» 'I'ul'hiT
\Dm
C]
ELK-”(EL
No.5 DH IV'EFI'S
:15“ UNDER-DASH GMIPCM
V
FUSE-Fl ELAY BO}:
ELK-TEL VEL'EHN
ZIISTFIIEILITGFI
EILKNEL
3
A IGNIT ICA COIL
Excepl HZEAF ergim . WH"-'5LK

HE‘EAT er‘gme: WriT-BLU 51};n YE_,‘GRN
|I'_':N| 1 HR. CON r HDI.

MCC'JLE -: ,M}
Has bult- n ".
amiss DcrIUe'Isar .J
\3—n
IGNITICN WIGES
YEL
SPARK
I”!
I“!
hi
F4
PLUG-3
Elam-5w.
3V? SENSOR '3 ‘der P:¢s1im 5H's-cr

!
#
Ignition System
Ignition Timing Inspection
!
!

4-21

- Check the idle speed, and adjust it if necessary (see
#!A7 ; H22A7 engine:
.7! F
section 11).
<- ¢ Remove the rubber plug from the "window" in
1& !
Z33Z
- Pull out the service check connector 2P (GRN/BLK and
!! &#;.1=)> the flywheel housing. While the engine idles,
!3!
-2!
!A
BRN wires) from the connector holder located under the
)13<!! point the timing light toward the pointer on the

!
3
dash on the front passenger side, then connect the 808

A flywheel.
!3!-
short connector (T/N 07PAZ-0010100) to it.
;4=0$%I00000<-
+- Start the engine. Hold the engine at 3,000 rpm (min.-1)

-6!
+A000;-<
with no load (A/T) in E
3!;%=4< or ElA,=4 !<
position, M/T in neutral)
until the radiator fan comes on, then let it idle
!A!!
*- Connect a timing light to the No. 1 ignition wire.

!
-
3-
%.7! F
0 Point the timing light toward the pointer on the

!
3
timing belt cover.

!&-
WINDGW TIMING LIGHT
TIMING LIGHT
!
#
Ignition System
Ignition Timing Inspection (cont’d)
!
!
/
?0
4-22

- Check the ignition timing in no load conditions:
#

!9 H22A7 engine:
.7! F
headlights, blower fan, rear window defogger, and air
!
A!3A33
A POINTER
conditioner are not operating.

- WHT MARK
Ignition Timing:
!
!F lTEICI
12L : 2“ BTDC {RED} during

Except Mfl' idling in neutral
H22A7 .
12: i 2'" BTDC [RED] during
engine i Afr
idling in E or [3! position
i
H22A7 153' L 2° BTDC [RED] during
engine idling in neutral
D1636 engine:
)5"5! F
POINTER
RED MARK
6.
- If the ignition timing is incorrect;

N
- the PCM in the D1636 engine should be
,()
!
replaced.
!-
- for engines except D1636 engine, ignition

/()
A

timing should be set (See Page 4-23).

!;'!*+<-
WHT MARK 7.
$- Disconnect the SOS short connector.
(-
[TDCI
RED MARK
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
POINTER
RED MARK
Ignition System
!
# 4-23

Ignition Timing Setting (Except D1636 engine))
!
! !/%)5"5! 00
- Inspect the ignition timing (See Page 4-21).

;'!*<-
_\
2.
- If necessary, adjust the ignition timing, as follows.
A7

A!!3-
Loosen the distributor mounting bolts, and turn the

!A
distributor ignition (DI) housing counterclockwise to

;(!<
!#3
advance the tim_ing,lor clockwise to retard the timing.
&
A!#3
-
_,l
MOUNTING BOLTS
22 M-m 12.2 lent-m, IB Ihr-m
3.
+- Tighten the distributor mounting bolts, and recheck the
4

!A#
ignition timing (See Page 4-21).

;'!*<-
Ignition System
!
# 4-24

Distributor Replacement (Except D1636 engine)
) *
/%)5"5! 0
Removal:

-F 4.
*- Connect the ignition wires to the distributor ignition

3

1.
- Disconnect the connector from the distributor.
( - (DI) cap as shown.
;(!<3-
2.
- Disconnect the ignition wires from the distributor ignition
(
3
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F
(DI) cap.
;(!<- No. 3 No. 4
3. 1&
!
+- Remove the mounting bolts from the distributor then
remove the distributor from the cylinder head.
& !-
{/GAMSHAFT END
,
|
.fl'
If:
1
No. 1
CYLINDER
MARK
D-FlING
No. 2
H22A7 engine:
.7! F
MOUNTING BOLTS No. 2
24 N-m 12.4 kgf-rn.
1? lbl-ftl
Installation:

F
NOTE: Before you install the distributor, bring the No.1 piston
84 9) !! A
-
to compression stroke TDC.
#4(- Na. 1
(W LIND ER
1.
- Coat a new O-ring with engine oil, then install it.
38
3
!A!!- MARK
2.
- Slip the distributor into position.
! -
NOTE: The lug on the end of the distributor and its
84 94!

mating grooves in the camshaft end are both offset to

&
eliminate the possibility of installing the distributor 180°
!!!!
'0P
out of time.
-
Install the mounting bolts, and tighten them lightly.
+- !!
!A
!
!-
ND. 3
- Connect the connector to the distributor.
-
- Set the ignition timing (See Page 4-23).

;'!*+<-
$- After setting the ignition timing, tighten the
%

A

mounting bolts.

!-
Ignition System
!
# 4-25
3
finition Coil Replacement (D1636 engine)
!

/)5"5! 0
IGNITION COIL
BRACKET
5 x I13 mm
B N-m 10.6 kgfum.
4 lhf'fll
S x 1.25 mm
24 Nvm [2.4 kgI-m.
17 Ibf-fll
3P CD MN ECTDH
IGNITION COIL
Teal, page 21-23
To go to the page referenced on the diagram above,

4

&A
!#!!3
9
(See page 4-29)
;!*5<
Ignition System
!
# 4-26
5
Distributor Overhaul
) *
- (Except D16B6 engine)
/%)5"5! 0
F1832, F1833, F2036 engines:

+8":+8":+$"5! F
DISTRIBUTOR IGNITION IDII CAP
Check fur cracks, wear,
CAP SEAL damage, and fouling.
Check for damage. Clean or replace.
DISTRIBUTOR IGNITION lDIl HOUSING

Check for cracks and damage.
— E IGNITION COIL
Test, pag E‘ d -29
YE U GHN
CYP SENSOR
TruuhlaEhuating,senlinn11 BLKWEL
DC:- I‘IIZIt disaasumblu.
WHTIELK DISTRIBUTOR
IGNITION IDII
ROTOR
IGNITIGN aTmL MODULE IICMI
Input Test, page 4-23
4

&A
!#!!3
9
(See page 4-28)
;!*'<
(See page 4-29)
;!*5<
Ignition System
!
# 4-27
7
Distributor Overhaul
) *
- (H22A7 engine)
/.7! 0
H22A7 engine:
.7! F
LEAK COVER
DISTRIBUTOR
IGNITION IDII
CAP SEAL
Chuck fur tlilrnugc. DISTRIBUTOR IGNITIIIJM
[DI] CAP
Check for macks. weal-r,
damage, and fouling.
Clean or replace.
IGNITION CONTROL
MODULE [ICMI
Input Test, page 4 28
YEUGHN
BLKIVEL
Fa
WHTIBLU
IGNITION COIL
Test, page d-ZQ
C‘I'P SE NSDR
, TIGtIIJICSI‘tLJuIing. auction H
{IT—T" Do not disassemble.
DISTRIBUTOR
IGNITION IDI)
HIDUSING
Check for ClflBkS
and damage

4

&A
!#!!3
9
(See page 4-28)
;!*'<
(See page 4-29)
;!*5<
Ignition System
!
# 4-28
8
Ignition Control Module (ICM) Input Test (Except
!

/0/%
D1636 engine)
)5"5! 0
NOTE:
84 9 +- Turn the ignition switch ON (ll). Check for voltage
4
38;<-#&!

¢ See section 11 when the malfunction indicator lamp
3! ! between the BLK/YEL wire and body ground.
3)>=C 3
-
(MIL) comes on.
;,<- There should be battery voltage.
4 !&!
-
¢ Perform an input test for the ignition control module

! ! ¢ If there is no battery voltage, check the
&!
A#
(ICM) after finishing the fundamental tests for the
;,<
! BLK/YEL wire between the ignition switch and
)>=C 33
3
ignition system and the fuel and emissions systems.

!- the ICM.
,-
¢ The tachometer should operate normally if the ICM is
4 !!!, ¢ If there is battery voltage, go to step 4.
&!
A
*-
OK.
8>- *- Turn the ignition switch ON (ll). Check for voltage
4
38;<-#&!

1.
- Remove the distributor ignition (DI) cap, the distributor
1&
;(!<A between the WHT/BLK [WHT/BLU] wire and body
3264=)>T264=)?U3
ignition (DI) rotor, and the leak cover.

;(!<A!#&- ground. There should be battery voltage.

-4 !&!
-
2.
- Disconnect the wires from the ICM.
(3,- [ ]: H22A7 engine
TU96%$

F1832, F1833, F2036 engines:
+8":+8":+$"5! F ¢ If there is no battery voltage, check:
&!
A#9
- ignition coil.

!-
- WHT/BLK [WHT/BLU] wire between the
264=)>T264=)?U33
ICM and ignition coil.
,
!-
¢ If there is battery voltage, go to step 5.
&!
A
-
- Disconnect the 25P connector from the ECM/PCM,
( ,=,A
and check for continuity on the YEL/GRN wire
# C =.13
between the ICM and ECM/PCM. There should be
3, ,=,-4 !
continuity.
-
- Check for continuity on the YEL/GRN wire to body
# C =.13
ground. There should be no continuity.

-4 ! -
$- If all the tests are normal, reconnect the ECM/PCM
!!!A ,=,
25P connector, and replace the ICM.
A!,-
WHTI’BLK WIRE
VELI'GHN WIRE
BLKIVEL WIRE
H22A7 engine:
.7! F
ICM
YELIG FIN WIRE
B LKI’ VE L WI FIE
WHTJ‘ BLU WI FIE
!
#
Ignition System
Ignition Wire Inspection and Test
!
1

4-29
9 Ignition Coil Test
!

- Carefully remove the ignition wires by pulling on the

!!&
3 !!
D16B6 engine:
)5"5! F
rubber boots. Do not bend the wires; you might break
-(3N
# 1.
- Turn the ignition switch OFF.-
4
38
them inside.
- 2.
- Disconnect the 3P connector and ignition wire.
(+
3-
- Check the condition of the ignition wire terminals. If any
#
3!-
terminal is corroded, clean it, and if it is broken or
!A!A#
distorted, replace the ignition wire.
A!
3-
SECONDARY SECUN DAHY

WINDING WINDING
TERMINALS TE RMINALS
Terminal Side
of I'T‘I-I-IIIE lml'r'lirlals
Check for broken,

corroded. and bent
terminals. 3.
+- Using an ohmmeter, measure resistance between
?
A 3
3.
+- Connect ohmmeter probes and measure resistance.
- the terminals. Replace the coil if the resistance is
!-1!!
Ignition Wire Resistance:
!
1 F not within specifications.
3-
25 k ohms
36
max. at 20°C (68°F)
@$H/58H+0 NOTE: Resistance will vary with the coil
84 913!!&3!
temperature; specifications are at 20°C (68°F).
N0P;'P <-
Primary Winding Resistance
' #1 !
(Between the
/"( No. 1 and No. 2 terminals, and the
,
@,
@ :
No. 3 and No. 2 terminals):
,
@,
@ 0F
0.45 - 0.55 ohms.
$@3$@33
@
Secondary Winding Resistance

#1 !
(Between the
/"( secondary winding terminals):

#( ! 0F
12.0-14.6k ohms.
@$@56
@
4.
*- If resistance exceeds 25 k ohms replace the ignition
/#!

wire.
3-
Ignition System
!
#
Ignition Coil Test (cont’d)
!

/
?0
4-30
$
%)5"5! F 3.
+- Using an ohmmeter, measure resistance between
?
A 3
1.
- Turn the ignition switch OFF,A&
4
38 and remove the distributor the terminals. Replace the coil if the resistance is
!-1!!
ignition (DI) cap.

;(<- not within specifications.
3-
2. ()>=C 264=)>;6%$
9
- Disconnect the BLK/YEL and WHT/BLK (H22A7 engine: NOTE: Resistance will vary with the coil
84 913!!&3!
WHT/BLU) wires from terminals (+) and (-) respectively.
264=)?<3!;V<;<&!- temperature: specifications are at 20°C (68°F).
90P;'P <-
TERMINAL A m F1832, F1833, F2036 engines:
+8":+8":+$"5! F
' #1 !
TERMINAL B i-I (Between the
/"( A and 3 terminals):
" 0F
9.. N.
l-I h
0.45 - 0.55 ohms.
$@3$@33
@
i Secondary Winding Resistance

#1 !
”It! (Between the
/"( A and secondary winding

#( !
terminals)
0
22.4 - 33.6k ohms.
@@56
@
H22A7 engine:
.7! F
' #1 !
(Between the
/"( A and 3 terminals):
" 0F
0.63 - 0.77 ohms.
$@5$@77
@
SECON DAR‘I’ Secondary Winding Resistance

#1 !
WINDING (Between the
/"( A and secondary Winding

#1 !
TERMINAL
Terminals):
0F
12.8 - 19.2 k ohms.
@89@6
@
.7! F
BLKIYEL WIRE
S ECUN BABY
WINDING
at?) TERMINAL
TERMINAL A l‘l
TERMINAL 3 I-l WHT.'BLU WIRE IGNITI UN CDIL
Ignition System
!
#
Spark Plug Inspection
6'!

4-31

%.7! F ¢ Replace the plug if the center electrode is
1!!
!
1.
- Inspect the electrodes and ceramic insulator for:
! !9 rounded as shown below:
3!39
ROUNDED
Wu rn DI daft: rmed
ELECTRODE
Electrodes - . Impruper gap
- Oil-fuulrng
: - Carbun deposits —_I
- Cracked tamer
Damaged I:|L-I;lrudu insululur
gasket
Cracked Spark Plugs

6'!
insulator Engine Type

4 Spark Plug Type
#!
4
D1686
() ZFR5F-11
I (NGK)
1 ;.><
ZFR5J-11
I (NGK)
1";.><
KJ1BCR-L11 (DENSO)
>"1;( 8<
F18B3
')+ ZFR5F-11
I (NGK)
1 ;.><
ZFR5J-11
I (NGK)
1";.><
KJ2OCR-L11 (DENSO)
>"01;( 8<
F1882
') ZFR6F-11
I (NGK)
1 ;.><
F2086
0) KJ2OCR-L11 (DENSO)
>"01;( 8<
Burned or worn electrodes may be caused by:
"
(

#**#F 3. %!!!F H
+- Apply a small quantity of anti-seize compound to
0 Advanced ignition timing
%&

the plug threads, and screw the plugs into the
!
A3!

0 Loose spark plug
#!
cylinder head finger-tight. Then torque them to 18
!

-4F '
0 Plug heat range too hot
!

Nm (1.8 kgf/m, 13 Ibf/ft).
;-'#
=A+!=<-
0 Insufficient cooling
!
Fouled plug may be caused by:

+
!#**#F
Retarded ignition timing
1

999999
Oil in combustion chamber

8!
Incorrect spark plug gap
#!

Plug heat range too cold
!

!
Excessive idling/low speed running
/&!
=!3
Clogged air cleaner element

!
!!
0 Deteriorated ignition coil or ignition wires
(
!
3
2.
- Check the electrode gap.
#!
-
0 Adjust the gap with a suitable gapping tool.
%7
3 !

!-
Electrode Gap
%

\Standard
1.1 - 8.1 mm (0.043 - 8.004 in)
-'-;0-0*+'-00*<
Ignition System
!
# _
Spark Plug Inspection (cont’d)
6'!
/
?0

4 32
H22A7 engine:
.7! F 2.
- Do not adjust the gap of platinum tip plugs; replace
(7
! !
N!
1.
- Inspect the electrodes and ceramic insulator for:
! !9 the spark plug if the gap is out of specification or if
#!

' the center electrode is rounded.
! -
Wurn or deformed ' Improper gap Electrode Gap:
%
F
eluctrudes ' Oil-fuming Standard 1.1 +0, -0.1 mm, (0.043 +0, -0.004 in)
-V0A0-A;0-0*+V0A0-00*<
—_ -| ' Curb-DH dE‘pEJfillS
I ' Cracked center
& 1.3 mm (0.051 in)
Service Limit -+;0-0<
Damaged
I electrode inaulamr
gasket | - f Platinum tip plug:
Du uul udpusl ”It'- gun:
i replace the speak plug if iha
gap is out of SPEElfIEEtlnr‘I m
lI
l
if the center electrode is

—"—‘"—5
&_______ rounded.
Cracked i—'_—_—;.
i—l
insulator
3.
+- Replace the plug at the specified interval, or if
1!!
&!A
center electrode is rounded as shown below:
! 3!39
ROUNDED ELECTRODE
NOTE: Use only the spark plugs listed below.

84 9?!#!
!!3-
Burned or worn electrodes may be caused by:
"
(

#**#F Spark Plugs: PZFR6F-11 (NGK)
6'!F'L+5+/,I0
0 Advanced ignition timing
%&

4.
*- Apply a small quantity of anti-seize compound to
%!!!F H
0 Loose spark plug
#!
the plug threads, and screw the plugs into the
!
A3!

0 Plug heat range too hot
!

cylinder head finger-tight. Then torque them to 18
!

-4F '
0 Insufficient cooling
!
Nm (1.8 kgf/m, 13lbf/ft).
;-'#
=A+=<-
Fouled plug may be caused by:
+
!#**#F
Retarded ignition timing
1

9999999
Oil in combustion chamber

8!
Incorrect spark plug gap
#!

Plug heat range too cold
!

!
Excessive idling/low speed running
/&!
=!3
Clogged air cleaner element

!
!!
Deteriorated ignition coil or ignition wires
(
!
3
Charging
System
! !# 4-33


&

D1636 engine:
)5"5! F
CHARGING SVSTEM LIGHT
lln the gauge assembly:
Test, section 23
BATrEI-w l"
Te 5t. section 23
ALTERNATOR
Troubleshooting. page -1-36
Replacement. page 41-39
ALTERNATOR BELT
Overhaul. page 4-41
Inspection and Adjustment. page 4 4B
Fla-miller Test. page 41-43

4

&A
!#!!3
9
(See page 4-36)
;!*+<
See page 4-39)
;!*+5<
AAAA
See page 4-41)

;!**<
See page 4-43)
;!**+<
See page 4-46)
;!**<
Charging
System
! !# 4_34

Component Location Index (cont’d)

&

/
?0

%)5"5! F
CHARGtNG SYSTEM LIGHT
Iiln the gauge assembly?
Tesl. section 23
BATTERY
Test. SEEIIDH 23
ALTERNATOR
Troubleshooting. page a BIB
Overhaul, pages 4-11. :2
Rectifier Test. page 4-43 ALTERNATOR BELT
Inspection and Adjustment, pages d-di‘, as

4

&A
!#!!3
9
(See page 4-36)
;!*+<
(See page 4-39)
;!*+5<
(See page 4-41)
;!**<
(See page 4-42)
;!**<
(See page 4-43)
;!**+<
(See page 4-47)
;!**$<
(See page 4-48)
;!**'<
! !#
Char in S stem
) !
Circuit Diagram
4-35
3
an'1=:v
G
2 :
|
D:|‘."E:| S
tJEi-DASI-
1—
F'_.SE-'F:E _A'1’ BO!
I EU; ".'EL
”‘fiWSNG
@ QYSTEW LIGHT
I -:'| LW]
.' H‘j-‘t I l
'.F‘.I'D;I|'1F!.- I
I BLK'B.
wH' : ELK "fEL 'uaaLLJ

F. 3L1
I
IG
"JDLTAEE EEGL -ATCFI 'v'CILTr'tGE :EGIJLA'UF: 'NHT-FiFF.’
..w?,--.
IVI |__| ._,-
: IELCI 'u'i' ME: '45. F E_C WINDING
HE 3" FIEH
H
I
' AL'EHNA'DR hLi EHNATOR
IExc-spl H2£hf an; 'iell |—i?FAT-' en; '.—'.|

Charging
System
! !# 4_36
5

*
!
Troubleshooting
If the charging system light does not come on or does not go off, or the battery is dead or low, test the following items in the

!

A!3A!!3

order listed below:
!!39
1.
- Battery (see section 23).
);+<-
2.
- Charging system light.

!
-
3.
+- Voltage.
:!
-
4.
*- Alternator/regulator.
%!=
!-
Charging
System Light
! !#& ! Test
Charging System Light Check-1:

Ignition switch ON lll].
Cheek tor a blown No. 6 :15 A]

. fuse and a blown charging ars-
// Does the charging system ND tern light bulb. H the fuse and
-'\_‘ light come on? bulb are OK, repair the open in
' the BLIU'I’EL, ELKIBLU and
YES WHTIBLU wira.
Charging System Light Check-2:

Start the engine.
j- Does the charging system Test and repair the alternator

light go off? components.
r
i ”O
r —————————————————————————————————————————————
I
—--- ___________________________________l.‘Z‘?.2.f't?f!19_i[‘£l
I
I
l
._ _ ALTERNATOR 4P CONNECTOR
I
Voltage Check:
l IG
I Measure the voltage at the NO. 'l (ELK/YELI
I
terminal of the alternator 4P con-
nector with the ignition switch I . .
E ON llll. Wire Sldeot
i 3 4 female-terminals
:
<
“\
I
I
I
I
J NO Repair the open in the wire
{ lsthere batteryI voltage? )2— between the alternator and
l under-dash fusefralay box.
I
I
I YES
I
I
I
[To next pagal

! !#
Charging

*
System
Troubleshooting (cont’d)

!/
?0
4-37
7
ALTERNATOR 2P CONNECTOR
{From previous page] (Except HZZAT engine-l
l—‘I
Wire side 0| .
1 2
female terminals
Cheek for an open in the L cir-
euit—l:
- 1. Turn the ignition switch OFF. L JUMPER WIRE
I 2. Disconnect the 2P [4P] can- lWHT/BLUl
I nectar from the alternator.
I 3. Connect the alternator 2P [4P]
connector terminal No. 1
[Nu 3| to body ground with a
iumperwire.
iii. Turn the ignition SWitch ON llll.
Turn the ignition switch OFF. and (H22A7 angina]
repair the open in the BLKHEL.
lightcome on?
BLKi‘BLU and WHTi'BLU wire.
YES Wire SldE of
female terminals
JUMPER WIRE
(WHTIBLUl
(Except H22A7 engine}
l““1
Wire side of
1 2 female 1erminals
L JUMPER WIRE
Check lor an open in the L cir- lWHTiBLU) __
cult-2:
Dieeoniiuul the ant-match 2P ldF’l
czijnnemni terminal No. 1 Wm. 3|
frrirr'. hotly ground with a jumper
wire.
1 _
ALTERNATOR 1!? CONNECTOR
Does the charging system YES ' Test and repair the alternator
(H22A7 engine)
light go tiff? ' l components.

Wire side of
NO female-terminals
JUMPER WIRE
Turn the ignition switch OFF. and
repair the short to ground in the L
5/
wnTieLu wire. __j (WHTIBLU)
1i-
I]:H1'€2if1\'ir engine
Char
in S stem
! !# 4_38
8
Troubleshooting

* (cont’d)

!/
?0
Alternator/Regulator Test

2!

A C UTION
Be careful during testing as the radiator and condenser fans come on suddenly while the engine is running.
) !

!3!

-
N CITE
Be sure to use an ammeter capable of measuring amperages higher than 120 A.
) !

0%-
Altarnaturlfiagulatur Tast:
‘l. Shift :0 IF] or :N] position lA-TI
or neutral lM,-'Tl, and start the
engine.
2. Hold the engine at 3.000 rpm
I'rnin"] with no load until the
radiator fan comes on, then let
it idle
3. Raise the engine speed to
2.000 rpm lmin-‘l, and hold rt
there.
4.. Turn the headlights (high CAUTION: As the headlights warm up
beam] on, and measure volt- considerably. do not sever them.
age at the battery terminals.
NO Test and repair the alternator

x”: Is the voltage between 13.9 '
and 15.1 V? components.
YES
Turn the blower motor and the

rear window defogger on, and
measure battery voltage.
a TERMINAL
__ _ WHT
/ . . . _ . . ... . NO ' "'—
. WIRE
" IS the battery volley... [Lbs " —"— Turn alsn hraite lights, etc. L‘Ill.
\__ than 13.5 V?
YES
Read the amperage. ‘
,r—————--- NO .
cf Is there more than 65 A? ., Test and repair the alternator
\ ' comp-enema.
YES
Alternatorfregulatur Operation is
UK. Test the alternator compo-
nents.
Charging
System
! !#
Alternator Replacement (D16B6 engine)

/)5"5! 0
4-39
9
D1636 engine:
)5"5! F 4.
*- Remove the lock bolt and mounting nut, then
1&!#!
A
1.
- Make sure you have the anti-theft code for the radio,
,# &A remove the alternator belt.
&!!-
then write down the frequencies for the radio’s preset.
33F B- 5.
- Pull out the through bolt, then remove the
!!
!A&
buttons.
- alternator from the transmission side.
!-
2.
- Disconnect the battery negative terminal first, then the
(
&!A ALTERNATOR THROUGH
positive terminal.
&!- BELT BOLT
3.
+- Disconnect the 2P connector. WHT wire and wire
(-26433
harness clamp.
!-
E J: 1.0 mm
iii-:11) mm 11 Nvm (1.1 kgfvm.
8 Mr“ (0.3 Raf-m, 8.0 lbfvl‘tl
Elhf-ft]
1WHT WIRE
.:::.
1'. LOCK BOLT
E N 1.25 mm
MOUNTING NUT 24 Mm [2.4 kgf-rn.
17 lhffl]
1n 1: 1.25 mm
44 iii-m [4.5 kgi—m.
33 lint-ft]
6.
- Install the alternator in the reverse order of removal.
!!!&&!-
7.
$- Adjust the alternator belt tension (See Page 4-46).
%7 !!;'!**<-
8.
'- Enter the anti-theft code for the radio, then enter
A
the customer’s radio station presets.
B-
2F CONNECTOR
Charging
System
! !# 4-40
$
Alternator Replacement (D16B6 engine) (cont’d)

/)5"5! 0/
?0

%)5"5! F 4.
*- Remove the adjusting bolt, locknut and mounting
1&7
!A!#
1. ,# &A

- Make sure you have the anti-theft code for the radio, bolt, then remove the alternator belt.
!A&!!-
then write down the frequencies for the radios preset
33F 5.
- Pull out the through bolt, then remove the
!!
!A&
buttons.
- alternator.
!-
Disconnect the battery negative terminal first, then the
- (
&!A F1832, F1833, F20B6 engines:
+8":+8":+$"5! F
positive terminal.
&!- MOUNTING BUILT
Disconnect the 2P/4P connector and WHT wire
+- (=*2643 10 x 1.25 mm
H N-m [4.5 Ital-m.
THROUGH 33 Ihf-ftl
BDLT
II‘ll'HT WIRE
LOCKNUT ALEHNAT'DH
8 en 10.3 kgi-m. ADJUSTING BELT
5 Iblrftl BULT 3 x 1.25 mm
2PHP
21 N-m 12.4 kgfvm.
CONNECTOR
17 Ibfvttl
H22A7 engine:
.7! F
MOUNTING BULT
THROUGH 10 x 1.25 mm
BOLT 44 N-m [4.5 kgfm,
33 Ibf~fll
ADJ USTING
BOLT
LOCKNUT
3 x 1.25 mm A TEHNATDH
24 Min {2.4 kgf-m. BELT
11 lbf-ftl
- Install the alternator in the reverse order of removal.
!!!&&!-
N97
$- Adjust the alternator belt tension (See Page 4-47)

%7 !!;'!**$<
and (See Page 4-48)
;'!**'<
8.
'- Enter the anti-theft code for the radio, then enter
A
the customer's radio station presets.
@-
Charging
System
! !# _

Alternator Overhaul

- (BOSH)
/".0 4 41

%.7! F
NOTE: It is necessary to separate the pulley, drive end housing and rotor only when the front bearing needs replacement.
84 9 !!A&
!3
!-
Loosen the locknut with wrenches to remove the pulley from the rotor. If necessary, use an impact wrench.
!# 33& !!-A 3-
24 mm 50::
WRENCH PULLEV
WRENCH
ROTOR
ASSEMBLY
Test, page 4-4-1 RETAINER
F'LATE FRONT
BEARING PRESSURE
RING
DRIVE END FRAME
ASSEMBLY
PULLEY
PULLEY LOCKN UT
54 Nvm [5.5 kgI-m.
47 lbl—fll
WASHER
REAR END
FRAME JDASSEMBL‘III
Rectifier test.
page #43
REG ULATOH
ASSEMBLY
BRUSH
Ins pact iun. page 41-44

4

&A
!#!!3
9
(See page 4-43)
;!**+<
(See page 4-44)
;!***<
Charging
System
! !# _

Alternator Overhaul

- (DENSO)
/)%,0 4 42
H22A7 engine:
.7! F
NOTE: Do not remove the pulley unless the front bearing needs replacement.
84 9(& !! !
!-
To loosen the pulley locknut, use 10 mm and 22 mm wrenches. If necessary, use an impact wrench.
4! !!!# A 03-A 3-
PULLEY
22 mm BOX
WRENCH
10 mm BOX WRENCH
PULLEY LDCKNUT
. kq
111 Mml113 . . 3 1.? Ihf-H I
REAR BEARING
SPACER RING ROTOR
lest, page 4-1111
BEARING
RETAINER smron
DRIVE-END HOUSING
'EL-'-" _ =:-.--._ FRONT BEARING Testoage 4-45
PULLEY LDCKNUT
111 Mm 111.3 kgf—m, 81.? lbI-I'II
CAUTION: Do not get grease

or oil on the slip rings.
STATOR THROUGH
BOLT
BRUSH HOLDER
INSU LATDR
VOLTAGE REG ULATOR

PU LLEV
REAR HOUSING
* fin
sac—2f % _ (‘3‘. I.
TERMINAL INSULATOR /
END COVER
BRUSH ASSEMBLY
Inspection, page 4-“.
DIODE [RECTIFIER] .rfilEISElll'lBL‘llr

Test, page 4-5.3

4

&A
!#!!3
9
(See page 4-43)
;!**+<
(See page 4-44)
;!***<
(See page 4-45)
;!**<
! !#
Charging System

Rectifier Test
4-43

%.7! F H22A7 engine:
.7! F
NOTE: The diodes are designed to allow current to pass in
84 94
!!3 NOTE: The diodes are designed to allow current to
84 94
!!3
one direction while blocking it in the opposite direction. Since
3!!#
- pass in one direction while blocking it in the opposite
3!!#

the alternator rectifier is made up of six diodes, each diode
! /A direction. Since the alternator rectifier is made up of
-!
must be tested for continuity in both directions with an
3 eight diodes (four pairs), each diode must be tested for

; <A
ohmmeter that has diode checking capability; a total of 12
#
!N! continuity in both directions with an ohmmeter that has
3
checks.
#- diode checking capability; a total of 16 checks.
#
!N!#-
1.
- Check for continuity in each direction between:
# 39 1.
- Check for continuity in each direction between:
# 39
- the B and P terminals.
)!- - )!-
the B and P terminals.
- E (ground) and the P terminals.
;
<!- - ;
<!-
E (ground) and P terminals.
All diodes should have continuity in only one direction.
%!! !& !- All diodes should have continuity in only one
%!! !& !
P: P': direction.
-
E [GRUUNDI
F:
P:
2.
- If any of the diodes fails, replace the rectifier
!A!
[Bod-f grnundl assembly. (Diodes are not available separately.)
!-;(&!!!-<
2.
- If any of the diodes fails, replace the rectifier assembly.
!A!!-
(Diodes are not available separately.)
;(&!!!-<
! !#
Charging System
Alternator Brush

" Inspection
4-44
Rotor Slip Ring Test

!
1.
- Remove the end cover, then take out the brush holder
1&&A# ! 1.
- Check the resistance between the slip rings. There
#3!
-4
by removing its two screws.
&
33- should be 1.8 - 3.0 ohms.
!-'+-0-
Measure the length of the brushes with a vernier caliper.
- , !
3&!- 1 If resistance meets the specification, go to
A

Alternator Brush &!

" Length:F step 2.
-
%.7! F 1 If resistance does not meet the specification,
A
Standard (new)
/(0 13.2 mm (0.52 in)
@/$@3 0 replace the alternator.
!!-
Service limit
- 3.2 mm (0.13 in)
@/$@ 0 Roma SHAFT
H22A7 engine:
.7! F
Standard (New):
/,(0F 10.5 mm (0.41 in)
$@3/$@ 0
Service Limit:
- & F 1.5 mm (0.06 in)
@3/$@$5 0
%.7! F
HER NIEFI
CALIPER
SLIP RINGS Roma

2.
- Check that there is no continuity between the slip
# 3!
rings and the rotor or rotor shaft.

-
3. ! #A!
+- If the rotor fails either continuity check, replace the
alternator.
!-
ALTERNATOR
BRUSHES
H22A7 engine:
.7! F
ALTERNATOR BR USHES
UEHNIEH CALIPER
3. !&!A!
+- If the brushes are less than the service limit, replace the
alternator brush assembly.
! !-
Charging
System
! !# _
3
Stator Test (H22A7 engine)

/.7! 0 4 45
1.
- Check that there is continuity between each pair of leads.
# 3!-
COIL CORE
2.
- Check that there is no continuity between each lead and
# 3!
the coil core.
!-
3.
+- If the coil fails either continuity check, replace the
!! #A!
alternator.
!-
Charging
System
! !# 4-46
5
Alternator Belt Adjustment (D16B6 engine)

"D/)5"5! 0
NOTE: When using a new belt, first adjust the deflection or

84 92
3!A7 ! Inspection with "
!!

( Belt tension gauge method

tension to the values for the new belt, then readjust the
&! 3!A7 1.
- Attach the belt tension gauge to the belt a measure
%!

!
deflection or tension to the values for the used belt after
!&! ! the tension. Follow
- the gauge manufacture’s
!!3

@
running engine for five minutes.

& - instructions. If the belt is worn or damaged, replace
-!3
A!
Inspection with )

( Deflection Method
it.
-
1.
- Apply a force of 98 N (10 kgf, 22 lbf), and measure the
%!5';0#
A!<A Tension:

F
deflection at the mid point between the alternator and
!3! Used Belt: $9$,/33$6! :77$* 0
;"F 340-490 N (35-50 kgf, 77-110 lbf)
crankshaft pulley. If the belt is worn or damaged, replace
# !!-!3
A! ,("F 640-780 N(65-80 kgf, 140-180 lbf)
New Belt: 5$78$,/538$6! :$8$* 0
it.
- LOCK BOLT
Deflection:
)
F 24 N-m i2.-I kgf'rn.
1? lbf-fli
Used Belt: 7@$$@3/$@8$@ 0
;"F 7.0 - 10.5 mm (0.28 - 0.41 in)
New Belt: 3@$7@$/$@9$@8 0
,("F 5.0 - 7.0 mm (0.19 - 0.28 in)
LUCK BOLT
Measure here. 24 N-m I24 kgf-m.
17 ibi-ni
MOUNTING
NUT
44 Tim “.5 kgf-m.
MOUNTING NUT
ALTERNATOR
44 NM 111.5 kgf-m,
BELT
33 lbf-ftl
CHAN [SHAFT
PULLE‘I’ TENSION GAUGE
ALTERNATOR WJGG — 001mm
Adjustment
D
ERA NKS HAFT BELT
PULLE‘I“ 1.
- Loosen the mounting nut and lock bolt

!#!
Adjustment
D 2.
- Move the alternator to obtain the proper belt
,&!!
1.
- Loosen the mounting nut and lock bolt

!#! tension, then retighten the lock bolt mounting nut.
A
!#!
-
2.
- Move the alternator obtain the proper belt tension, then
,&!!A 3.
+- Recheck the belt tension.
1#!-
retighten the lock bolt and mounting nut.

!#!
- NOTE:
84 9
3.
1#!- 0 For the power steering pump belt adjustment, refer
3
!7 A
NOTE:
84 9 to section 17.
$-
¢ For the power steering pump belt adjustment, refer to
3
!7 A 0 For the air conditioning compressor belt

!
section 17.
$- adjustment, refer to section 22.
7 A-
¢ For the air conditioning compressor belt adjustment,

!7 A
refer to section 22.
-
Charging
System
! !# 4-47
7
Alternator Belt Adjustment with 2/%)5"5

"D( A/C (Except D16B6
engine)
! 0

84 92
!!


&! 3!A7 1.
- Remove the three bolts from the left end of the
1&!!
!&! ! splash shield, and pull it back as needed.
!!A !!#-

& - 2. %!

!
- Attach the belt tension gauge to the belt and
Inspection with )

( Deflection Method
measure the tension. Follow
- the gauge
!!3

1.
%!5';0#
A!<A manufacturer’s instructions. If the belt is worn or
B -!3
!3! damaged, replace it.

A!-
# !!-!3
A! Tension:

F
it.
- Used Belt: 9$3$,/88$* 0
;"F 390 - 540 N (88 - 120 lbf)
Deflection:
)
F New Belt: 88$:$$,/9$$36! :$$* 0
,("F 880 - 1,030 N (90 - 105 kgf, 200 - 231 lbf)
Used Belt: $@$@$/$@9$@7 0
;"F 10.0 - 12.0 mm (0.39 - 0.47 in) MOUNTING BOLT
10 x 1.25 mm
New Belt: 3@37@3/$@$@$ 0
,("F 5.5 - 7.5 mm (0.22 - 0.30 in)
44 N-m (4.5 kgf-m, 33 IIJH'IJ
MOUNTING BDLT
10 x 1.25 mm
ADJUfiTING 44 NM [4.5 kgf-rn. 33 IbH'tl
BO LT ADJUSTING
BDLT
LCICKNUT
E:
B n 1.25 mm
22 N-m l2.2 RBI-"1. _|
16 Ibl-fil 5%?
LDCKNUT
B I 1.25 mm BELT TENSION GAUGE
22 N-m 42.2 kgf-m. 15 Ibf-Hl O‘NGG — 001mm
Adjustment
D
Adjustment
D
1.
- Loosen the mounting bolt and locknut.

!!# -
1.

!!# -
2.
- Turn the adjusting bolt to obtain the proper belt
4 7
!!
2.
- Turn the adjusting bolt to obtain the proper belt tension,
4 7
!!A
tension, then retighten the locknut and mounting
A
!#
then retighten the locknut and mounting bolt.

!#
!-
bolt.
!-
3.
1#!-
3.
1#!-
NOTE: For
84 9 the power steering pump belt adjustment, refer to
3
!7 A
NOTE: For
84 9 the power steering pump belt adjustment,
3
!7 A
section 17.
$-
refer to section 17.
$-
Charging
System
! !# 4-48
8
Alternator Belt Adjustment without

"D( A/C (Except

2/%
D16B6 engine)
)5"5! 0

84 92
!!


&! 3!A7 1.
- Attach the belt tension gauge to the belt and
%!

!
!&! ! measure the tension. Follow
- the gauge
!!3


& - manufacturer’s instructions. If the belt is worn or
B -!3
Inspection with )

( Deflection method
damaged, replace it.

A!-
1.
%!5';0#
A!<A Tension:

F
!3! Used Belt: 9$$,/$36! :5599* 0
;"F 290 - 440 N (30 - 45 kgf, 66 - 99 lbf)
# !!-!3
A! New Belt: 3$7$,/33736! :$7$* 0
,("F 540 - 740 N (55 - 75 kgf, 120 - 170 lbf)
it.
- MOUNTING BOLT
Deflection:
)
F 1D x 1.25 mm
I“ Nvm 11.5 kgf-m. 33lb1-f‘ll
Used Belt: $@$@$/$@9$@3 0
;"F 10.0 - 13.0 mm (0.39 - 0.51 in)
New Belt: 7@3$@$/$@$$@9 0
,("F 7.5 -10.0 mm (0.30 - 0.39 in)
MOUNTING BOLT
10 x 1.25 mm ADJUSTING
44 Min (4.5 kgf-rn. 33 “31-113 BOLT
LDCKNUT
3 x 1.25 mm -
2 him l2.2 kgf'm. “’J
1'5 lbf-ftl
ADJUSTING
BOLT
BELT TENSION GAUGE

DTJGG a 0010101
Adjustment
D
1.

!!# -
LGCKNUT 2.
- Turn the adjusting bolt to obtain the proper belt
4 7
!!
8 )t 1.25 mm
tension, then retighten the locknut and mounting
A
!#
22 N-m [2.2 kgf-m. 1s Ibf-ftl

bolt.
!-
Adjustment
D 3.
1#!-
1.

!!# - NOTE: For
84 9 the power steering pump belt adjustment,
3
!7 A
2.
- Turn the adjusting bolt to obtain the proper belt tension,
4 7
!!A refer to section 17.
$-
then retighten the locknut and mounting bolt.

!#
!-
3.
1#!-
NOTE: For
84 9 the power steering pump belt adjustment, refer to
3
!7 A
section 17.
$-
Cruise Control

4-49
9

&

CRUISE INDICATCIH LIGHT

MAIN SWITCH 1311”! into gauge assembly] SETIRESUMEICANCEL SWITCH
Test-'Fleplacement, page 4 53 Bulb Locations. section 23 T1331-"F'Ieplacement, page +54
CLUTCH SWITCH [MIT] BRAKE SWITCH CRUISE CONTROL UNIT

- Test, page 4-53 Test, page 4-58 Input Test, page 5-51
- Clutch Pedal Adjustment. Pedal Height Adjustment.
section 12 section 19
ACTU ATOR CABLE

Adjustment, page 41-5?
AIT GEAR POSITION ACTUATOR

SWITCH Test. page 4-55
Test, section 1d

4

&A
!#!!3
9
(See page 4-53)
;!*+<
(See page 4-54)
;!**<
(See page 4-58)
;!*'<
(See page 4-51)
;!*<
(See page 4-57)
;!*$<
(See page 4-55)
;!*<

Cruise Control
) !
Circuit Diagram
4-50
3$
:IFII‘I‘EFI'E
JNU EFI-UfiSH
UNDER-HOOD FUSE-RELAY BO): GM' Ch SWITCH FUSEIHELAV BOX
WIT—I EFIY
NOAH IIUCIAI- \ID 42 ISDAI INIS- 5' 17' 5h:
® D
EIAT
C; 'm
W
m m. WP I H-KI'F";L
Nil—Ir
NEAT? NICE
PEI-In] 115-5.}
HORN
RFL M"
r:- CLCNH'NATION
LIGI-‘T SWITCH
LT I3FIIN'FIEI3 V
Cr'uEILE
BLJ- PUFI' =EEL
ELK-VEL HEB-ELK.
FIE DBL K
43:” HIC: 3m. awn 3-4
INDICATOR
<9
LIGHT LGHT
SET In em:- IG a-JWJ
GD
RF E-._.|I.IE. MAW
CANE EL SWITCH
SWITCH
E. (5" EL BLK HEB-BM
LT GFIN
®
'JEH CLE SPE ED
SENSOR WSSI
FCM
BRAKE GAUGE U— BLK .— DIWING CIFIC'JIT
SWI'CFI RSSEMBLY PCM
I: CFIL:SE
REE INDICMOFI
{.51
LIGH'
DRIVER'S [1 2w;-
UNDER-DASH
FLISEJFIELAY EGX GAUGE
IXSSEMBLHr
'I'HT- ELK. LT GFIN ELK E-_L.-.-WHT
.'B.K
12
CFI-JISE CCINTFflL UNIT
{5
E-RN-W'TT
CH JISE I'm :A-T GEAR

CONT HG- I fisnmswnmi I
ACTL'J'ITG:
3.. agrarian-u I I
ION: Penal reieasedl.-'

|
r.
LT- 3132 -S1IJ'.{A-T:
[55:1 :wr'.
Cruise Control

_
3

; 4 51
SR8 components are located in this area. Review the SRS component locations, precautions, and procedures in the SR8
1!-1&31!A A 1
section (24) before performing repairs or service.
;*<
&-
-|. Remove the driver’s dashboard lower cover (see section 20).
1&&B!3&;0<-
2.
- Disconnect the MP connectorfrom the control unit.
(*! -
3.
+- Inspect the connector and socket terminals to be sure they are all making good contact.
#! !!#

-
If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system.
!A!AAA#-
If the terminals look OK, make the following input tests at the connector.
!!#8>A#!!3
-
- If any test indicates a problem, find and correct the cause, then recheck the system.
!A A#-
- If all the input tests prove OK, the control unit must be faulty; replace it.
!! &8>A! !N!-
”P CO NNECTD R
LT GRNIRED
BLKI‘I'EL
CRUISE comm l M WHTJ'BLK LT Gnu-t

UNIT +
BRNIWHT /
2 3 4 5 6 7
\
E 5 1D 11 12 13 H
BRN \ LT GHN
LT BLU
PU R BUM“lHT
PUHIWHT
BLU BLK
If Wile side Uffurilalc
terminals
Cruise Control

Control Unit Input Test (cont’d)

; /
?0
4-52
3
Cavity O
O - # 1
Wire O

Test condition O F)
Test: Desired result O '
*

Possible cause if result is not O
O O O O O
*
obtained O
O 1 BRN/WHT O 3
O )1=264 Connect battery power O #
Check the operation of the O ’ Faulty actuator
! O
O O O magnetic clutch: Clutch should
O
! 9! ! O ’
;.+0<
Poor ground (G302) O
O O O click and output link should be
O !# !# ! O ’ %3
An open in the wire O
O O O locked
O !# O O
O O GRY
.1C Ignition switch ON (ll), O #&!

9
O
38;<A Check for voltage to ground: O ’ Faulty brake switch
!#3 O
O O main switch ON and
O 38 There should be CV with the
O 4 !0:3 O ’ %3
O O brake pedal
O #! pedal depressed and battery
O ! O O
O O depressed, then
O A voltage with the pedal released O
O &!
3!! O
O O released
O ! O O O
O + O BLK
)> O ?!!
Under all conditions Check for continuity to ground:
O #
9 O ’
;.0<
Poor ground (G501) O
O O O There should be continuity
O 4 ! O ’ %3
O * BLK/YEL O
38;<
O )>=C Ignition switch ON (ll) O #&!

9
Check for voltage to ground: O ’ )!3-;%<
Blown No. 6 (15A) fuse in the O
O O O There should be battery voltage O &B =!/
O 4 !&!
driver’s under-dash fuse/relay box O
O O O O O ’ %3
O WHT/BLK O )#!
O 264=)> Brake pedal Check for voltage to ground:
O #&!

9 O ’ )!3-*$;%<
Blown No.47 (15A) fuse in the O
O O depressed, then
O A There should be battery voltage O =!/
O 4 !&!
under-hood fuse/relay box O
O O released
O ! with the pedal depressed, and
O 3!A O ’ Faulty brake switch
!#3 O
O O O 0V with the pedal released
O 0:3!! O ’ %3
O LT GRN/ O
O 4.1= Set button pushed Check for voltage to ground:
O #&!

9 O ’ )!3-*$;%<
O O RED
1 ( O There should be battery voltage O =!/
O 4 !&!
O O O O O Faulty horn relay
!! O
000..
O O O O O Faulty set/resume switch
!= 3 O
O O O O O Faulty cable reel
!!! O
O O O O An open in the wire
O %3 O
O $ LT GRN/ O 1
O 4.1= Resume button pushed O #&!

9
Check for voltage to ground: Blown No.47 (15A) fuse in the
O )!3-*$;%< O
O O BLK
)> O There should be battery voltage O =!/
O 4 !&!
O O O O O ’ Faulty horn relay
!! O
O O O O O Faulty
00.. set/resume switch
!= 3 O
O O O O O Faulty cable reel
!!! O
O %3 O
O ' O PUR
?1 Start the engine, main O #&!

9
O
A Check for voltage to ground: O Faulty cruise control unit
! ! O
O O switch ON and drive
O 38& There should be approx. 5V
O 4 !/-: O O
O O the vehicle to speed
O &! O O O
O O over 25 mph (40 km/h) O
O &;*0#=< O O
O O with the cruise control O
O 3 ! O O
O 5 O BRN
)1 Connect battery power O #
O 3 Check the operation of the O ’ Faulty actuator
! O
O O to the BRN terminal
O )1! actuator motor: You should be
O 9C ! O ’ %3
O O and ground to the
O
able to hear the motor.
O !- O O
O O PUR/WHT terminal.
O ?1=264!- O O O
O 1O O )?=)>
0 BLU/BLK O
38;<
Ignition switch ON (ll) O %
9
Attach to ground: O ’ )!3 !
Blown bulb O
O O O Cruise indicator light in the
O !
O ’ )!3-5;$-%<
Blown No. 9 (7.5A) fuse in the O
O O O gauge assembly should come on. O &B =!/
O

! !- driver’s under-dash fuse/relay box O
O O O O O ’ Faulty dimming circuit in the
!
O
O O O O gauge assembly
O

! O
O O O O O ’ %3
O 11 O ?1=264
PUR/WHT O 3
Connect battery power O #
Check the operation of the O ’ Faulty actuator
! O
O O to the BRN terminal
O )1! actuator motor: You should be
O 9C ! O ’ %3
O O and ground to the
O
able to hear the motor.
O !- O O
O O PUR/WHT terminal.
O ?1=264!- O O O
O 12 O )?=264
BLU/WHT O
38;< Check for voltage between the
Ignition switch ON (II) O #&!
3 O ’ Faulty vehicle speed sensor
!&! O
O O and main switch ON;
O 38N BLU/WHT (+) and BLK (-)
O )?=264;V<)>;< (VSS) (M/T)
O ;:<;,=4< O
O O raise the front of the
O terminals:
O !9 O 9 Faulty PCM (NT)
!,;%=4< O
O O O &!A There should be 0 - 5V or more O ’ %3
vehicle, and rotate one O 4 !0: An open in the wire O
O O wheel slowly while
O 3!!3!3! -0 - 5V or more repeatedly
O 0:! O O
O O holding the other wheel O
O !
3! O O
O 13 O 4.1
+ LT GRN O
38;<
Ignition switch ON (II) O #&!

N
Check for voltage to ground; O ¢ )!3-;%<
O O and mains switch ON O 4 !&!

O 38 There should be battery voltage O &B =!/
driver’s under-dash fuse/relay box O
O O O O O ¢ Faulty main switch
!3 O
O 9 %3 O
O 14 O
* 4)? A/T: Shift lever in -,A O #
9
LT BLU O %=49!& Check for continuity to ground: O ¢ Faulty A/T gear position switch
!%=4
3 O
O O O
or

There should be continuity.
O 4 ! - (A/T)
O ;%=4< O
O O O NOTE: There should be no
O 84 94 ! O ¢ Faulty or misadjusted clutch
!7 ! O
O O O M/T: Clutch pedal
,=49! ! O 3! ! switch (M/T)
continuity when the clutch pedal O 3;,=4< O
O O released
O ! is depressed or when the shift
O 3 O ¢
;.0A.0<
Poor ground (G101, G501) O
O O O lever is in other positions
O !& O ¢ %3
Cruise Control

Main Switch
( Test Replacement
4-53
3
- Carefully pry the switch out of the instrument panel.
!!3 !-
Terminal side of
male terminals
SWITCH
5P CDNNECTOR
2.
- Disconnect the 5P connector
(
3.
+- Check for continuity between the terminals in each
# 3!
switch position according to the table. If there is no
3
!-
continuity, replace the switch.
A!3-
kl. Terminal
%. 3 4 5 1 -2
Position '
OFF :3 1@ c}:@-_ {3
UN I I
5 :3——®——C:——C- O—~@~—u
Cruise Control

Set/ResumelCancel Switch 2
22( Test/Replacement
4-54
3
1.
,# &A 7.
$- Remove the steering column covers.
1&
! &-
then write down the frequencies for the radios preset
33F 8.
'- Disconnect the 16P connector between the
(3
buttons.
- combination switch harness and main wire harness.
33-
2.
- Disconnect the battery negative cable, then disconnect
(
&!A 9.
5- Check for continuity between the terminals as
# 3!
the positive cable, and wait at least three minutes.
&!A3! - shown:
39
3.
+- Disconnect the driver’s airbag and front passenger’s
(&B

B (El—5] __,__.____[4 5_6. Wire side of
airbag connectors (see section 24).

;*<- ;_ a . 9_1cl_1)112_13_14 15_1B_‘ female terminals
4.
*- Remove the dashboard lower cover and knee bolster.
1&!3&#!-
5.
- Disconnect the combination switch harness 4P
(3*
connector from the cable reel.
!!-
1."ilre
r' «.IldL-Uf
.—.' -, -
[—5—1 2.3.4
female {Dimirluls
¢
If there is no continuity, replace the
A!
combination switch harness.
3-
10. (*3
0- Disconnect the 24P connector between the
combination switch harness and left engine
3!

compartment wire harness.
3-
11. # 3!3-
- Check for continuity between terminals as shown.
[IITé-l-il-‘P‘ l'_l “5 T 3 9 “1 Terminal side of
{1112 131l15-il—]1Illlllfllzn 21 12 z: 21 male terminals
'- eu Side of
femalu Imminals
Terminal side of
male terminals i
6.
- Check for continuity between the terminals of the 4P
# 3!*
¢ If there is no continuity, replace the
A!
connector in each switch position according to the table.
3
!-
combination switch harness.
3-
l
"-.__ Terminal !
2
1
Position
__ .:'
SETlONl
_ 'nE'su ME 10m u:::~—----- ~62;
CANCEL [UN]
0 If there is continuity, and it matches the table, go to

A!A

step 7.
$-
0 If there is no continuity in one or both positions, go
A

to step 12.
-

Cruise Control

Actuator Test
4-55
33
12. 1&33A&3-
- Remove the two screws, then remove the switch. - Disconnect the 4P connector from the actuator.
(* -
@NT‘
SWITCH - Check the output linkage for smooth movement.
# !#
&-
+- Connect battery power to the No.2 terminal and
3-!
ground to the No.1 terminal.

-!-
*- Check for a clicking sound from the magnetic
#!#

clutch. The output linkage should be locked.
! -4 !#
!!#-
- If the output linkage is not locked, replace the
!#
!#A!
actuator assembly.
!-
Terminal side of
male terminals
SCREWS
Terminal side of male

terminals
13. # 3!3

+- Check for continuity between the terminals in switch
position according to the table.

!-
ar- ooNNECTon
. Terminal - Check the operation of the actuator motor in each
#
__ __ output linkage position according to the table.
!#

!-
Position
, .:-_;;. You should be able to hear the motor.
C !!-
SET iONl 5 ;;_;;__._._._i
RESUME tow-l— . Batteryr power
nol’sritiee
!
Output linkage position
CANCEL [DNJ
| —H———-- 6
FULL” :IMIDDLE FULL
CLOSE ,POSITION: OPEN
0 If there is continuity, and it matches the table,
A!A
replace the cable reel.
!!!- No _4 ' rid. 3'" The motor The motor The motor
Terminal Terminal runs. runs. 3 stops.
0 If there is no continuity in one or both positions,
A
replace the switch.
!3- Na .3 TNo.4 The motor I The motor i The motor
14.
*- If all tests prove OK, reconnect the cable reel and
!!&8>A!! Terminal Terminal stops. § runs. 5 runs.
combination switch harness connectors then reinstall the
3!!
steering column covers.

! &- OUTPUT
15.
- Reconnect the driver’s airbag and front passenger’s
1&B

B FULL LINKAGE
airbag connectors, and reinstall the access panel on the

A!!! OPEN ,1 ~ ._
steering wheel.

3!-
16.
- Reconnect the battery positive cable, then the negative
1&!A
&
cable.
!-
17.
$- After connecting the airbag connectors, confirm proper
%

A
system operation: Turn the ignition switch ON (II); the
94
38;<N MIDDLE
SR8 indicator light should come on for about six
1!
! / PO$ITION
seconds and then go off.

-
18.
'- Enter the anti-theft code for the radio, then enter the
A
customer's radio station presets.
@-
Cruise Control

Actuator and Cable Replacement

*
4-56
35
1.
- Loosen the locknut, then disconnect the actuator cable
!# A ! 4.
*- Remove the actuator cover, then remove the
1& &A&
from the throttle linkage.
!!#
- actuator cable from the actuator
!
ACTUATOR
COVER
LOCKNUT
ACTUATOR
CABLE
2.
- Disconnect the 4P connector from the actuator.
(* -
MOUNTING
BOLTS
6 r. 1.l.'l mm ACTU ATDH
11 Ill-m [1.1 kgf-rn. CABLE
In: lbf-fti 5.
- 1& #-
Remove the actuator from the bracket.
/ ACTURTCIH
BRACKET
LP CONNECTOR
3.
+- Remove the two mounting bolts, and remove the
1&3
!A& - Install the reverse order of removal, and adjust the
!!&&!A7
3#-
actuator with the bracket. free play at the throttle linkage after connecting the
!!!#

actuator cable.
!-
Cruise Control

_
37
Actuator Cable Adjustment

*D 4 57
1.
- Check that the actuator cable moves smoothly with no
# !&!3 5.
- Turn the adjusting nut until it is 3.75 i 0.5 mm
4 7
!+-$S0-
binding or sticking.

#
- (0.15 i 0.02 in) away from the bracket.
;0-S0-0<3#-
FREE PLAY 3.?5 i 0.5 mm (0.15 1 0.02 in!
‘
__-J,4—
. I
- -- CLOSED Posmou _I
LINKAGE ACTUATOR CABLE

2.
- Start the engine. Hold the engine at 3,000 min-1 (rpm)

-6!
+A000;< BRACKET ADJUSTING NUT
- !!!7

with no load (A/T) in E
3!;%=4< or ElA,=4 !<
position, M/T in neutral) 6' 5213:: cjnbcljiisfigfifigfijggfi?ng nut touches
#A
!# -
until the radiator fan comes on, then let it idle.
!A!!- LOCKNUT ’ g ADJUSTIHG'NUT
3.
+- Measure the amount of movement of the output linkage
, & !#

until the engine speed starts to increase. At first, the
!
-%A
output linkage should be located at the fully closed
!#
!! !!! »
position. The free play should be 3.75 i 0.5 mm (0.15 i
-4! !+-$S0-;0-S .
0.02 in). IEiCflIEIII
-
0-0<-
4.
*- If the free play is not within specs, move the cable to the
!3A&!
point where the engine speed starts to increase, and
3
A
tighten the locknut and adjusting nut.

!# 7
-
ADJUSTING NUT
W ,
LDEKNUT

Cruise Control
Clutch (
Switch
Test
4-58
38 Brake Switch
"6( Test
1.
- (+! 3-
Disconnect the 3P connector from the clutch switch. -
1. (*3-
Disconnect the 4P connector from the switch.
terminals

terminals
fly BRAKE SWITCH
CLUTCH SWITCH
2.
- Remove the clutch switch.
1&! 3- 2.
- Remove the brake switch.
1&#3-
3.
+- Check for continuity between the terminals according to
# 3!
3.
+- Check for continuity between the terminals
# 3!
!-
the table. according to the table.

!-
"it Terminal |
'-
x,‘ Terminal
. 2 . 3
Clutch Switch I Brake Switch I E
-—_lDE—PF-l-ESSED ___—_DEPHESSED .
RELEASED a": ' ——«.:- RELEASED ' c.7344:- |
4.
*- If necessary, replace the switch or adjust the pedal
A!37 ! 4.
*- If necessary, replace the switch or adjust the pedal
A!37 !
height (see section 12).

;<- height (see section 19).

;5<-
Sgecial Tools

5_2
3
O|RefNo.
1- O| Tool Number
4! O| Description
( |Qty
OD O| Remark
1#
O| 1 O| 0$>%>"*00
07KAK-SJ40101 O|
4!6

EngineTiltHangerSet | 1
|Except EU
O / ?
a m:
%!
-2

Enqine Removal/Installation

-
Removal
5-3
3
NOTE:
84 9 4.
*- Disconnect the intake air temperature (IAT) sensor
(# ;%4<
Use fender covers to avoid damaging painted surfaces.
?&&

- connector from intake air duct (D1686 engine).
# ;()
<-
To avoid damage, unplug the wiring connectors carefully
4&
A !
3
!! 5.
- Remove the intake air duct.
1&# -
while holding the connector portion.
3!!
- INTAKE AIFI
Mark all wiring and hoses to avoid misconnection. Also,
,#!!3
&-%!A DUCT
be sure that they do not contact other wiring or hoses, or
3
A
interfere with other parts
3
- Fix the hood in the vertical position by using a support
/&!

rod (P/N 74145-884-A00) as shown below.
;=$**'*%00<3!3-
SUPPORT
HUD
6.
- Disconnect the battery cables and connector from
(!
the under-hood fuse/relay box, then remove the
=!/A&
under-hood fuse/relay box.
=!/-
BATTERY
CABLES
CON NECTOR
UN D ER-HDCIID I
,# &A FUSE-FIE LAY "
then write down the frequencies for the radio’s preset
33F B BUN ‘
buttons.
-
+- Disconnect the battery negative terminal first, then the
(
&!A
positive terminal.
&!-
a x 1.0 mm
12 N-m 11.2 kgf-rn.
8.? lbf-f'tl
%!
-2

Removal (cont’d)

-/
?0
5-4
3
$- Remove the throttle cable and cruise control cable by
1&!! !! 9.
5- Relieve fuel pressure (see section 11).
1!& ! ;<-
loosening the locknuts then slip the cable ends out of
!
!# !! 10. 1& ! ! -
0- Remove the fuel feed hose and fuel return hose.
the accelerator linkage.
!!#
- H22A7 engine:
.7! F
NOTE:
84 9 2? N-m [2.8 kyl-m.
0 Take care not to bend the cable when removing it.
4#!3&
- FUE L FEE D 20 lbf-fll
HO$E
Always replace any kinked cable with a new one.
%!3!##!33-
0 Adjust the throttle cable when installing (see section
%7 !!3!!
;
11).
<-
0 Adjust the cruise control cable when installing (see
%7 !!3!!
;
section 4).
*<-
ADJUSTING
NUT LOCKNUT
THROTTLE
CABLE
WASHERS
Replace.
ADJUSTING FUEL RETURN

NUT HDEE
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F
CRUISE --
CDNmUL - ':
CABLE
FUEL FEED
LOCKN UT HOSE
8.
'- Disconnect the engine wire harness connectors from
(
3
under the under-hood fuse/relay box.
=!/-
ENGINE WIRE
HARNESS
CONNECTORS
2? NM 12.3 kgf-m,
20 Ibf-i‘t]
FUEL RETURN WASHERS

HflsE Replace.
%!
-2

Removal (cont’d)

-/
?0
5-5
33
D1636 engine
)5"5! F1832, F1833, F2036 engines
+8":+8":+$"5!
E )1: LI] mm 37 en [3.3 kgf-fn. BRAKE BODETER
ll N-I'n 11.1 kgf‘m, 27 lhf-fti VACUUM VACUUM HOSE
an lbf~fti HOSE
FUE L FEED
HOSE
VACUUM
EVAP CONTROL
FUEL RETURN HOSE
CANISTEH HOSE
HOSE
D16B6 engine
)5"5!
11. 1&#& A&&
- Remove the brake booster vacuum hose, evaporative
BRAKE HDDETEH
emission (EVAP) control canister hose.
; :%<!- VACUUM HDSE
H22A7 engine:
.7! F
BRAKE BOOSTER
VACUUM HOSE
EVAI‘ CONTROL
CAMISTER
HDSE
EVAF‘ CONTROL
CANISTEH HOSE
%!
-2

Removal (cont’d)

-/
?0
5-6
35
12. 1&3
;=<
- Remove the power steering (P/S) pump and air -3. 1&%=3
+- Remove the A/C compressor without
conditioning (A/C) compressor.

;%=<- disconnecting the A/C hoses.

%=-
%)5"5! F
-1. 1&
!A&=
- Remove the mounting bolts, then remove the P/S
pump belt and pump without disconnecting the P/S
! 3
=
hoses.
-
MOUNTING BOLT
B x 1.25 mm
22 Nvm [2.2 kg‘l—m.
16 lhf-fl]
.7! HS PUMP
' BE LT
AIC COMPRESSOR
B x 1.25 mm
22 film {2.2 Rain.
16 Ib’H‘tl
MOUNTING HOLT
B a: 1.25 mm
22 H-m 12.2 kgf-m.
1a Iti
-2.
- Loosen the alternator mounting bolt, locknut and
!
!A!#
adjusting bolt, then remove the alternator belt.
7
!A&!!-
MOUNhNG BOLT
10 x 1.25 mm
44 NW" [#5 Ital-m.
33 Ihf-ftl
ALTERNATOR
BELT
ADJUSTING LDCKNUT
BOLT B x 1.25 mm
22 Mai [2.2 Ital-m.
16 ibl-ftl
%!
-2

37
Removal (cont’d)

-/
?0
D1636 engine:
)5"5! F +- Remove the A/C compressor without
-3. 1&%=3
-1. 1&
!A&=
- Remove the mounting bolts, then remove the P/S disconnecting the A/C hoses.

%=-
pump belt and pump without disconnecting the P/S
! 3
=
hoses.
-
MOUNTING BOLT
8 x 1.25 mm
24 Mm {2.4 Ital-ml
1? lhf-fll
MC COMPRESSOR
24 N-rn 12.4 kgf‘m. 17 let)
LOCK BOLT
3 I 1.25 mm PIS PUMP
24 N-m 12.4 kgf-m. BELT
1T Ibi-it}
-2.
- Loosen the idler pulley center nut and adjusting
! !! 7

bolt, then remove the A/C compressor belt.
!A&%=!-
IDLER PULLE‘I" CENTER
ADJUSTING NUT
BOLT 10 11.25 mm
\ M NM [4.5 kgf—m, 33 Ibi-fll
AIC COMPRESSOR
BE LT
%!
-2

Removal (cont’d)

-/
?0
5-8
38
13. (
! !
+- Disconnect the engine control module 17. 1&!!!-4#
$- Remove the shift cable and select cable. Take
(ECM)/power—train control module (PCM) connectors
; ,<=3! !;,< care not to bend the cable when removing it.
!3&
-
from the ECM/PCM (see section 11).
,=,;<- Always replace any kinked cable with a new one
%!3!##!33
14. 1&

*- Remove the grommet mounting nuts from under the (Except D1686 engine with WT).
; /()
3,=4<-
under-hood fuse/relay box, then pull out the ECM/PCM
=!/A !! ,=, B I 1.25 mm
connectors.
- 22 Min 42.2 kgf-m. 15 Ibrl-ftl
GHDMME'I'
CUTTER FIN
Replace.
' Inspect [or

{wear and
damage.
coTTER PIN
Replace. w" .
_.-:>--- _ SELECT CABLE
STEEL PLASTIC
61: 1.0mm WASHER WASHER
12 film {12 uni-m. 3.? mm) lnSpect for
15. 1&!A3!
- Remove the starter cable, wire harness clamp and wear and
damage.
ground cable.

!-
16. (# !
3;,=4<-
- Disconnect the back up light switch connectors (M/T). 18. 1&! !&!!=
'- Remove the clutch slave cylinder and line/hose
BACK-UP LIGHT assembly (M/T).
!;,=4<-
SWITCH CONNECTORS NOTE:
84 9
B x 1.25 mm ¢ Do not disconnect the line/hose assembly.
(!=!-
9 N-m [0.9 Ital-n1. ¢ Do not operate the clutch pedal once the
(! !
7 t'tJ
slave cylinder has been removed.
!&!&-
¢ Take care not to bend the line.
4#!-
6 J: H} mm 3 x 1.25 mm
11Mml1.1 kgflrn, 24 Nm [2.4- kgf-m,
Ell Ib'l-fll 17 MM
WIRE HARNESS
CLAMP 12 M-m [1.2 Egrm.
3.? l‘tl
SLAVE
C‘I'LINDEFI
%!
-2

Removal (cont’d)

-/
?0
5-9
39
19. 1&
#
5- Remove the rear engine mount bracket mounting D16B6 engine:
)5"5! F
bolt-nut and rear stiffener.
! - BOLT
Except D1636 engine with 2F
%)5"5! ( WT: Haphca
BOLT
Repmcm
20. 1&

#
0- Remove the front engine mount bracket mounting

A/T:
2F bolts, and loosen the mount bolt.
!A! !-
MOUNHNG
BOLT
REA
SflFFENER
%!
-2

Removal (cont’d)

-/
?0
5-10
3$
-. Remove the radiator cap.
1&- 28. 3A&
'- Lower the hoist, then remove the upper radiator
-. Raise the hoist to full height.
1 !!
- hose, lower radiator hose and the heater hoses.
A!3-
+-. Remove the front tyres/wheels.
1&=3!- HEATER
*-. Remove the splash shield.
1&!!- HOSE
LOWER RADlfiTOR
UPPER RADIATOR
HOSE
5- cooler hoses, then plug the ATF
Remove the ATF !A!
%4
29. 1&%4
SPLASH cooler hoses and lines.
!!-
SHIELD
25. !
A

- Loosen the drain plug in the radiator, drain the engine
coolant (See Page 10-7).
!;'!0$<-
26 (!! -1!!
Drain the transmission oil or fluid. Reinstall the drain
plug using a new washer (see section 13 (WT) or
!

33;+;,=4<
section 14 (A/T)).
*;%=4<<-
27. (
!-1!!!
3
$- Drain the engine oil. Reinstall the drain bolt using a new
washer (See Page 8-7).
3;'!'$<-
ATF GDDLER
HDSES
%!
-2

Removal (cont’d)

-/
?0
5-11
3
30. 1 !!
-
+0- Raise the hoist to full height. 33. 1&!
!!A
++- Remove the bolts securing the shift cable holder,
31. (/
;68<
+- Disconnect the heated oxygen sensor (H028) then remove the shift cable cover. To prevent
&!&-4&
connector. (H22A7, F1832
-;6%$A engines.)
')
-< damage to the control leverjoint, be sure to

!!&7A
32. 1&/ %-
+- Remove exhaust pipe A. remove the bolts securing the shift cable holder
&!
!!
H22A7, F1832, F1833 engines:
.7:+8":+8"! F before removing the bolts securing the shift cable
&
!
!
SELF-LOCKING NUT cover (NT).
&;%=4<-
H025 CONNECTOR
I_H22.fi.'l'. F 1 F132 engines]
3 I: 1.2!) mm +*- Remove the lock bolt securing the control lever,
34. 1&!#!
!!&A
18 Nvm l1.B kgf-m. then remove the shift cable with control lever. Take
&!3!!&-4#
13 Ibl-fll
care not to bend the shift cable while removing it
!3!&

Replace.
(A/T).
;%=4<-
SHIFT CABLE 5 I ‘1“ mm
HOLDER 5.8 N-m 11.0 kgf-m,
12 IbH-ii
((53 A
'.l .
_
@II ”’3‘ Jam

{-._-F. J. Inf/5'- (315:.
___/_r: (n3 .5“n
l . ._.
' ';;::‘H-__ i . IEE—if

REPIHC—E.
—_ -:._'I.-'_- .
J"
'4
SELF-LOCKING NUT EXHAUST

“J I 1.25 mm PIPE A SELF-LOCKING NUT
10 x 1.25 mm
33 "41113-4 “9““ 10 x 1.25 mm 54 N11: [5.5 kgf-rn. LOCK WASHER
25 Iti as NM (3.9 lint-m. w lhf—fti Ruplacu.
ReplaCE- 213 lhfaftl Replace.
F2036, D1636 engines:
+$"5:)5"5! F LOCK BOLT
SELF-LOCKING NUT B x 1.0 mm
a I 1.25 mm 14 I'll-m {1.4 kgf'm. 1.
18 N~m l1.3 kgf-m. 10 lhf-fll B I 25 mm
_ 13lb'l-fll smr—‘r CABLE 25 Mr" [2-1 Ital-m.
COVER 20 lbf—fll
_ -' Replace.
35. 1&/;()
+- Remove the shift rod and extension rod (D1636
engine with WT).

3,=4<-
SHIFT HUD
GASKET RETAINER
Replace.
EXHAUST
PIPE A
GASKET
Replace.
SELF-LOCKING HUT
1011.25n1n1 3:12:51": f
an N-m 13.9 ugf-m. m . g m,
2H Ibf'fll 40 Ibf-fll
EXTENSION
Replace.
SELF-LOCKING NUT ROD
10 x 1.25 mm B): 1.25 mm 3 mm SPRING
33 N-m l“ kgf-m. 25 Ibf-fti 22 Nm 1.2.2 tut-m. 16 Ihf-l‘tl- P'”
Replace.
%!
-2

Removal (cont’d)

-/
?0
5-12
3
36. 1&#;'<-
+- Remove the damper fork (see section 18). D16B6 engine:
)5"5! F
37. ( !3!!7;
+$- Disconnect the suspension lower arm ball joints (see REAR MIDUNT
section 18).
'<- BRACKET
38. 1&&;<-!!
+'- Remove the driveshafts (see section 16). Coat all
precision finished parts with clean engine oil. Tie plastic
3!
!-4!
bags over the driveshaft ends.

&&-
39. 1& #-
+5- Remove the rear mount bracket.
%)5"5! ( WT:
HEAR MIDUNT
BRACKET
BOLTS
Flenlacu.
40. 1&!
!
;
*0- Remove flange bolts securing the radius rods (see
section 18).
'<-
41. ,#A
*- Mark on the front beam and rear beam, then
remove the front beam.
&-
BOLTS
Replace
A/T
2
HEAR MOUNT
BRACKET
BOLTS
BDLT$ Replace.
Replace.
BOLTS
Replace.
%!
-2

Removal (cont’d)

-/
?0
5-13
3
42. 3-
*- Lower the hoist. D16B6 engine:
)5"5! F
43. %
3-
*+- Attach the chain hoist to the engine as shown.
%)5"5! F
ENGINE TILT
HANGER SET
OTKAK — SJJIJEII1D1
iExcapt EU]
%!
-2

Removal (cont’d)

-/
?0
5-14
3
44. 1&
!A&
**- Remove the stopper and ground cable, then remove the 46. #
=!!
*- Check that the engine/transmission is completely
upper bracket.
#- free of vacuum hoses, fuel and coolant hoses, and
& A !!A
GHDU ND electrical wiring.
!!3
-
CABLE 47. !3!!3
/!0;
*$- Slowly lower the engine approximately 150 mm (6
in). Check once again that all hoses and wires are
<-#
!!3
UPPER disconnected from the engine/transmission.

=-
BRACKET 48. 3
!!3-1&
*'- Lower the engine all the way. Remove the chain
hoist from the engine.

-
49. 1&
&!-
*5- Remove the engine from under the vehicle.
*-
45. 1& #-
Remove the transmission mount bracket.
TRAN$MISBION MOUNT
BRACKET
%!
-2
33
5-15
Installation

Bracket Bolts/Nuts Torque Specification:

"6"
2,
B
F
H22A7 engine:
.7! F
PIS PUMP BRACKET 5 I 111'I mm
12 Iii-m [1.2 Raf-n1,
3.1 Ill-fl}
SIJE ENGINE MOUNT
_"'.'- BRACKET
1i- B x 1.25 mm
24 N-m l2.4 kgf-m.
ENGINE MOUNT 17 Ital-hi
"an“ E ENGIhE ~1q
BRACKET A
10 Jr. 1.25 mm
41 Nut {-13 kgf‘m.
I W"
35 Ibfd‘tl
10 I 1.25 mm
#9 III-n1 [5.0 kgf~m, 1|} II 1.25 mm
313 lt} 44 Mm 145 kgf‘m.
33 lbf-ftl
8 x 1.26 mm
24 Nm [2.1 lint-m, 1? lhf-fli
10 x 1.25 mm
4? film {4.8 Ital-m, 35 Ihf-fll
ALTERNATOR
BRACKET
STIFFENER
11] It 125 mm
49 "an IE.“ kgf-m, 36 Ibf-ft]
12 x 1.25 mm
64 H-m IE5 kgf-m.
I? It}
12 N-m [1.2 kgf-m. 8.? lh'lrft}

10 x 1.25 mm
44 Nm (4.5 ugh-n,
33 Ihf-ftl
%!
-2
5_16
35
Installation (cont’d)

/
?0

"6"
2,
B
F
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
P15 PUMP BRACKET
autumn“
‘2 ”'m “-2 “9““ SIDE ENGINE mourn
8.7 Ihf-I‘ti BRACKET
1|] 3: 1.25 mm
411 Mm 15.0 Him.
36 lbf-ftl
10 x 1.25 mm
«I? N-m [1.8 lint-m.
35 Ihf‘fll
STIFFENER ALTERNATOR
BRACKET
MC COMPRESSOR
BRACKET
12 x 125 mm
64 N-m 16.5 kgf-m.
4T Ibf-fti
1O 1: 1.25 mm
lul- N-m {II-.5 kgf‘m.
33 IhH‘tl 10 11.25 mm
49 Min l5.0 kgf-m.
36 Ibi-fti
10 x 1.25 mm ._
49 "m 15.0 hat-m.
3E lti
%!
-2
5_17
37
|nsta|lation(cont’d)

/
?0

"6"
2,
B
F
D1636 engine:
)5"5! F
PIS PUMP
BRACKET SIDE ENGINE
1n n 1.25 mm MOUNT BRACKET
49 N-rn [5.0 kgfrm.
35 Ihf—fti
REAR STIFFENER |
1D A 1.25 mm
54 film [5.5 kgfm.
IO lhf‘ftl
ALTERNATOR
BRACKET 1D x 1.25 mm
44 MRI ”.5 kgf-m.
33 Ibf-fti
E I 1.25 mm
213 Mm {2.4- kgi-m.
1T Ibf-fll
TD in: 1.25 mm
44 film [4..5 kgI-m, 33 Ibi-hi
FRONT MOUNT 1 1.25

BRACKET SUPPORT I 14.5
uu N-m "mugf-m.
33 lb'l-f‘li
AID
FRONT COMPRESSOR
STIFFENER BRACKET
III 1: 1.25 mm
38 N-m [3.9 Itg'I-mr
23 Ibffll
10 l: 1.25 mm
44 M11 14.5 kgf-rn.
10 I: 1.25 mm
33 Ihf-fli
44 film {1.5 inf-m.
B x 1.25 mm 33 lbf-fli
24 Min l2.4 kgf-m.
1T Ibi-iti
%!
-2


/
?0
5-18
38
Engine Installation:
%!
F D16B6 engine:
)5"5! F
Install the engine in the reverse order of removal.
!!
&&!- E x 1.0 mm
Reinstall the mount bolts/nuts in the following sequence.
1!! != !!3
F - 11 N-mlM kgi‘m.
Failure to follow this procedure may cause excessive noise
! !!3 /& 8.0 Ibf-ftl GROUND
and vibration, and reduce bushing life.
&A
!- CABLE
ii: 111 x 1.25 mm
1.
- Push the engine under the vehicle. Attach the chain

&!-% 52 N-m 15.3 kg’bm.
hoist to the engine, then lift the engine into position in

A!
33 Ibf-fll
the vehicle.
&!-
2.
- Install the upper bracket, then tighten the bolt and nuts
!! #A
!
in the numbered sequence shown.
F 3- 22 N-m [2.2 kgi—m.
3.
+- Install the stop.
!!- .- / 1s Ibi—ftl
%)5"5! F
5: 1.0 mm 112 12:125. mm
11 N-m 11.1 kgf-m. 52 N-m 15.3 kgf—rn.
3.0 Ibf-fll 3B Ib‘l-fl'l
GROUND : '_§_2:- 12 x 125 mm

CABLE 54 film
15.5 kgf-m.
3.12 I: 1.25 mm d0 Ib‘HtJ‘
52 N-m {5.3 kgf1m.
38 Ib‘l-ft]
UPPER
STOP
a x 1.25 mm
22 N-m [2.2 kgf-m.
15 Ib‘I-fii
STOP
1'22: 12 111.25 mm
54 N-m (5.5 high“.
40 lbf-fil
%!
-2


/
?0
5-19
39
4.
*- Install the transmission mount bracket, then tighten the
!! #A
D16B6 engine:
)5"5! F
bolt and nuts in the numbered sequence shown.
! F 3- :11 12 x 1.25 mm
%)5"5! ( WT: 54 NM (6.5 Min.
41 Inf-m
2 10 x 1.25 mm
38 N-m 13.9 kgf-m.
TRANSMISSION 23 “11-?“
MOUNT BRACKET
\L
5.1] 10 x 1.25 mm
1 12 x 1.25 mm ,---~-.--* 64 Min [6.5 hgf'm. TRANSMISSION
64 N-m [5.5 kgf'rn. I d 4? Ibmi MDUMT BRACKET
4? lbl—fll
5.
- Remove the chain hoist from the engine.
1&
-
NT:
2F 6.
- Raise the hoist to full height.
1 !!
-
)1" 12 x 1.25 mm 7.
$- Install the front beam. Align the marks on the rear
!!-%!
#
64 Mm {6.5 kyfim. beam and front beam, then tighten the bolts.
A
!-
41' lhf-ftl HEAR
BEAM MARK
'2. 10;: 1.25 mm
33 N-m [3.5 kgi-m,
23 lhI-ftl
12: 1.25 mm
6-1 N-rn [5.5 kgf-m.
TRANSMISSION I? lbfvft]
:2: 10 I 1.25 mm MOUNT BRACKET Replace.
3|] N-m 13.9 kgf‘m. 141: 1.5 mm
29 Ib'l-fll ma N-m 1113.5 kgf-m.
Tl'fi lbi-f‘ll
Replace.
%!
-2
5_20
3$

/
?0
8.
'- Tighten the flange bolts on the radius rods.
4
!
! - NT:
2F
14 :15 mm HEAR MOUNT
152 N-m 116.5 kgf-rn. 11B lbf-ft) BRACKET
12 II: 1.25 mm
RADIUS 64 N-m I6!) lief-m,
HDD 4? Ib'l-fl}
Install the rear mount bracket, then tighten the bolts.
9. !! #A
!-
5- D16B6 _ _ RED'WE-
WT: )5"5! F
engine.
%)5"5! (
HEAR MOUNT REAR MOUNT
BRACKET BRACKET
14 1-: L5 mm
12 :II 1.25 mm
83 Mm (3.5 Raf-m,
54 Ndm tfifi kgf-rn.
61 lhfdfll
41 Itl
Replace.
Replace.
%!
-2


/
?0
5-21
3
10. 3-
0- Lower the hoist. 12. 4
#
!
- Tighten the front mount bracket mounting bolts in
11. 4

!= A!!
- Tighten the rear mount mounting bolt/nut, then install the the numbered sequence shown.
F 3-
rear stiffener.
- ."_1_j: 1n 3: L25 mm
Except D16B6 engine with 2F
%)5"5! ( WT: 3:; Mm 13.9 kgfm.
zalbml
. {It--
12 x 125 mm
64 N-m 16.5 kgf-m.
H It}
Replace.
STIFFE "ER
1:: Ir. 1.25 mm
(2312 x 1.25 mm
33 N-m 13.9 kgfdm. 2B Ih’fdfll El. N-m 13.5 kgf-m. £1 lt)
Replace.
A/T:
2F
13. %7 # !!39
+- Adjust and make sure as follows:
1Dx1.25mm 1231.25 mm
33 N-n‘l [3.9 kgi-m, 54 Mm [5.5 kgi-m.
¢ Check that the set ring on the ends of the
#

23 lhf-ftl 4D lbf—fll driveshaft and intermediate shaft set rings into
&

place.
!-
¢ Adjust the throttle cable (see section 11 ).
%7 !!;<-
¢ Refill the engine with engine 0“ (See Page
1!!
3
!;'!
8-7).
'$<-
¢ Refill the transmission with oil or ATF ;
1!!3!%4 (see
section 13 or 14).
+*<-
¢ Refill the radiator with engine coolant, and
1!!3
!A
bleed air from the cooling system (See Page
!!
;'!
10-7).
0$<-
HEAR ¢ Clean the battery posts and cable terminals
!!!
ETIFFENEH with sandpaper, assemble them, then apply
3A!A!
D1636 engine:
)5"5! F grease to prevent corrosion.

&-
12 x 1.25 mm ¢ Inspect for fuel leakage (see section 11). After
!!#
;<-%
54 N-m 16.5 kgfam. assembling fuel line parts, turn ON (II) the
!
!!A 8;<
47 mm] ignition switch (do not operate the starter) so

3;<
that the fuel pump operates for approximately
! /!
two seconds and the fuel line pressurizes.
3 !! H-
Repeat this operation two or three times, and
13A
check for fuel leakage at any point in the fuel
# !!#
!
line.
!-
¢ Check the wheel alignment (see section 18).
#3!!
;'<-
¢ Enter the anti-theft code for the radio, then
A
33 Mm (3.5 kgf-m, enter the customer’s radio station presets.
B-
E1 Ibf-ft]
Replace.
%!
-2
5_22
3

/
?0
Mount and Bracket Bolts/Nuts Torque Value Specifications:

"6"
2,
B4
F
10 1: 1.25 mm
HEAR MDUNT 59 MM {5J5 kgf-m,
{Mm 43 mm:
10 x 1.25 mm "EAR MOUNT
55 N-m (6.0 kgf-m. mm
43 lbf-fll
———\_h\-_\-\.
fl—
TRANSMISSION
MOUNT .43
10 x 1.25 mm
4-4 N111 {ILE Rain.
33 lbf-ftl
12 x 1.25 mm
64 Film [5.5 kg‘l-m,
41' tHI
\I.
M12 x 1.25 mm
93 N‘m (9.5 kflf‘fl'h
'1 69 lbf-fll
SIDE ENGINE
MOUNT
FRONT MOUNT
Enqine Mount Control System (AIT)
%!

#/20 5-23
3

&

ENGINE MOUNT CGNTHOL

SOLENOID VALVE
Troubleshooting, page 5-25
POWEHTHAIN CDNTHI‘JL
MODULE lPCMi
HEAR MOUNT

4

&A
!#!!3
9
(See Page 5-25)
;'!<
%!

#/20
) !
Circuit Diagram
5-24
3
U-‘JEq-i-COU FUEE'REJW EEK
EM'TEFW
@— W
M 41 HODAI
NUJE £5291]
WHT
BAT IGNITION
lfii SWITCH
O
BLKI'YEL
No.6
“5“
DRIVERS
mosnmsn
FUSEIRELK'I‘ EDI
ELKI'YEL
ENGINE WUNT
CONTROL SQENDID
VALVE
HE D.'BLK
PCM
Gilli
%!

#/20

*
!+
(
Troubleshooting
Flowchart
5-25
33
NOTE:
84 9
t Check the vacuum hoses and pipes for damage and proper connections.
#&
-
t (See Page11-A—15 to11-A—20) before troubleshooting.
;'!%%0< !
-
— The engine vibrates excee-

eiwel'liI when Idling.
Checking Idle Speed:

1lI'll'iairrn up engine to normal operat-
ing temperature {the cooling fan
comes oni.
1 I.
‘\ Repair the idle control system
Is the idle speed [see pages 11- >NO [see pages 11—11-91 [except
A-Bd lexcept D1686 enginel. D1635 enginel. 11-3-85 {01656
11-B-E5 tDtfiBfi enginei]?
enginel]
YES
Checking the Engine Mount Con-

trol System:
1. Fully depress the brake pedal.
2. With the transmission in gear,
have an assistant connect and
disconnect the 2P connector
from the engine mount control .
solenoid valve. 1
\
Is there a noticeable change in
:: YES Reconnect the 2P connector to the
idle smoothness when the 2P
solenoid valve. The engine mount
connector is connected and
t disconnected? control system is OK.
‘L ENGINE MOUNT CONTROL
SOLENOID VALVE 2P CONNECTOR
NO
Testing the Engine Mount Con-

trol Solenoid Valve Wire:
1. Shift to E or E] position. lG'l
2 Disoonnect the 2P connector iBLKNEU
from the engine mount con-
r
trol solenoid valve. I
I
3. Measure voltage between the
engine mount control solenoid
valve 2P connector No. 1 termi-
nal and bodyI ground.
— Repair open in the wire
between the engine mount
A
"x5 N0
Is there battery voltage? /,>—- control solenoid valve and Wire side of female
No.6i15 Alfuee. terminals
YES — RepleoeNo.El15Alfme. .
Testing the Engine Mount Control

Solenoid Valve \Nire:
Meaeuro voltage between the MCS
engine mount control solenoid [HEDIBlJli
valve 2P connector No. 1 and N0. 2 IG‘I ‘
terminals lBLKIYELl
between Film “311] end the g
ND
A
Is there battery voltage? :3)— engine meurrt control solenoid

trdve.
— If the wire is OK, substitute a
YES
knewn-geo-d PCM end reehedc.
lTo page 5-26l

4

&A
!#!!3
9
(See Page 11-A-94)
;'!%5*<
(See Page 11-8-65)
;'!)<
%!

#/20
Troubleshooting

* Flowchart

!+
( (cont’d)
/
?0
5-26
35
lFrern page 5-25]

ENGlNE I'UI'DUNT DDNTRDL
SOLENOID VALVE 2P DONNEGTDFI
Testing the Engine Mount Con-

trol Solenoid Valve Wire: NICE
1. Raise the engine speed above IFIEDt ELI-l
1,000 rpm imin-‘l. K31
2. Measure voltage between the [MYELI
engine mount control solenoid
valve 2P connector No. 1 and
No. 2 terminals.
__®__ .
ground in the who between
< Is there battery- I.I-oltasgi e?

PCM (C11) and the engine
mount control solenoid valve.
— It the wire ls 0K. substitute a
Wire side of female
ND terminals
known-good PCM end recheck.
Testing the Engine- Mount and ENGINE MOUNT

Vacuum Hose: CONTROL SOLENOID
Disconnect the lower vacuum hose VALVE
[tom the engine mount control
solenoid valve. and connect a vac-
uum pumpr‘gauge to the hose.
fluently.I vacuum for 20 seconds.
<
— Replace the vacuum hose
between the engine mount
Does the engine mount hold NO
control solenoid valve and
vacuum?
the engine mount.
VACUUM PUMP!
— Replace the engine mount.
YES GAUGE
Testing the Engine Mount:

Release the vacuum, then apply i
uacu um again. i
v’ a
' Is there a noticeable change in
idle smoothness with and Replace the engine mount.
without vacuum applied? K
YES
ENGII’iE MDUNT
Testing the Engine Mount Con- CONTROL QDLENUID
trol Solenoid Valve: VALVE
Disconnect the lower vacuum hose
lfrorn the engine mount control
solenoid valve. and connect a vac-
uum pumptgeuge to the hose.
Is there manifold vacuum at

idling. and decrease the mani- NO Replace the engine mount con-
fold vacuum when raise the
! trol solenoid "We.
engine speed above 1,000
rpm ttnin'1lllI
YES
LOWER
Engine mount control system is VACUUM VACUUM PUMPJ’
OK at this time. HOSE GAUGE
Check the engine mount is nec.
mew.
Special Tools

6_A_2
5
O 1- O| Tool Number
4! O Description
( |Qty
OD O Remark
1#
O O| 07HAH - PJ70100
0$6%6"$000 O Valve Guide Reamer, 5.525 mm
:!&. 1A- O O
_\_\_\_\_\_\_\
O
O
O

+
*
i
O
O
O|
07JAA - 0010100
0$"%%00000
07JAB - 0010200
0$"%)00000
07JAB - 0010400
0$"%)000*00
O
O
O
Socket Wrench, 17 mm
#2A$
Handle
6!
Pulley Holder Attachment, HEX 50 mm
!!6!%A6 R0
O
O
O
O
O
O
O O| 07PAD - 0010000
0$%(000000 O Stem Seal Driver
!(& O O
O O| 07742 - 0010100
0$$*00000 O Valve Guide Driver, 5.5 mm
:!&. (&A- O O
O $ O| 07757 - 0010000
0$$$000000 O Valve Spring Compressor
:!&
O O
@
(5!
GI}
4-
Valve Clearance
Adjustment
D
6-A-3
5
NOTE:
84 9 5.
- Loosen locknut and turn adjustment screw until
!# 7 3 !
9 Valves should be adjusted only when the cylinder head
:!& !7 !3! feeler gauge slides back and forth with slight
!

!#3!

temperature is less than 38°C (100°F).
!+'P;00P <- amount of drag.

-
After adjusting, loosen the crankshaft pulley bolt, then
%7
A!# !!!A NOTE: Do not overtighten the locknuts, for the
84 9(&
!# A
retorque the crankshaft pulley bolt to 20 Nm (2.0 kgf/m,
F # !!!0;-0#
=A rocker arms are made of aluminium.
#! -
14 Ibf/ft) + 90°
*!=<V50P INTAKE and EXHAUST VALVE
Remove the cylinder head cover.
- 1&!&- LOCKNUTE
‘IE N-m {1.3 kgf'm. 13 lbf-fll
NOTE: When installing the cylinder head cover (see
84 92!!
!&;
page 6—A—30).
!%+0<-
Remove the upper cover (see page 6—A—8).
- 1& &;!%'<-
.00.“
Set the No. 1 piston at TDC. “UP” mark on the camshaft

+- -4(-K?L#
pulley should be at top, and TDC marks should align
!! !A4(# !!

with the cylinder head upper surface.
3! -
”UP" MARK
TDC MARKS
Adjusting screw location:

D !(

F
INTAKE
4.
*- Adjust valves on No.1 cylinder.
%7 &!&-!-
Intake:
6F 0.20 mm (0.008 in) 1 0.02 mm (0.008 in)
$@$/$@$$8 0O$@$/$@$$8 0
Exhaust:
% 0.25 mm (0.010 in) 1 0.02 mm (0.008 in)
F $@3/$@$$ 0O$@$/$@$$8 0
EXHAUST
Valve Clearance
4- _ _
Adjustment (cont’d)
D/
?0
5
6 A 4
6.
- Tighten the locknut, and check clearance again. Repeat
4
!# A#!
-1 8.
'- Rotate the crankshaft 180° counterclockwise to
1#'0P !#3
the adjustment if necessary.
7 - bring No. 4 piston to TDC. Both TDC grooves are

-*4(-)4(
&
FEELEH once again visible. Adjust valves on No. 4 cylinder.

&!-%7 &!&-*!-
GAUGE
$- Rotate the crankshaft 180° counterclockwise (camshaft

1#'0P !#3; ..UP.. MARK
!! 50P<-4K?L# !
pulley turns 90 )' The UP mark ShOUId be on the 9.
5- Rotate the crankshaft 180° counterclockwise to
1#'0P !#3
exhaust side.
/ - . .
Adjust valves on No. 3 cylinder. brIng No. 2 piston-to TDC. The .. UP ,, mark should

-4(-4K?L# !
%7 &!&-+!-
be on the Intake Side.
#-
”UP" MARK . .
Adjust valves on No. 2 cylinder.
%7 &!&-!-
"UP" MARK
6 '#'#"

Crankshaft
Replacement

Pullev and Pullev Bolt
6-A-5
53
1.
- Remove any oil from the pulleys, crankshaft, bolt and
1&! !!A#A! 3.
+- Use a felt tip pen to mark the pulley bolt head and
?!# !!!
washer. Clean and lubricate as shown below.
3-!! 3!3- washer.
3-
:3: Clean MARKING
x: Remove any oil
0: Lubricate
CBANKSHAFT TIMING BELT

PULLE‘lI DRIVE I’ULLE‘ir
PULLE‘I' BOLT CHANKSHAFT
MARKING
EMBOSSING MARKS
WASHER TIMING BELT 4.
*- Tighten the pulley bolt an additional 90°
4
!!!!50P
GUIDE PLATE
2.
- Tighten the pulley bolt to the specified torque.
4
!!!F - EMEDSSING MARK MARKING
Torque: 20 Nm (2.0 kgflm, 14 lbf/ft)

BF$,/@$6! 2:* 2 0
PULLEY HOLDER AWACHMENT.
HANDLE HEX 50 mm
UTJAB — 0010201] OTJAB — 0010400
SOCKET WRENCH. 17 mm
07JAA - W1D1EIID
MARKING
Timing Belt
!" 6_A_6
55

Illustrated Index
NOTE:
84 9
¢ For how to position the crankshaft and pulley before installing the belt (see page 6—A—9).
3# !!!!
!;!%5<-
Mark the direction of rotation on the belt before removing.
,#!&
-
....
Do not use the upper cover and lower cover for storing removed items.
( &!3&
&-
Clean the upper cover and lower cover before installing.
! &!3&!!
-
Replace the camshaft seals and crankshaft seals if there is oil leakage.
1!!#!!!#
-
6:1.flmm
/ 9.3 N-rn 11.0 kgf-m. 7.2 Imam
[:‘rLINDEH HEAD
EFF. WASHER cover:
Replace when damaged Refer .0 page fi-A-3U
-' ur deteriorated. when 1n5la||ing.
HEAD DOVER GAJSKET

Replace when leaking.
damaged or deteriorated
Apply liquid gasket at
the fdur carriers nfthe 8 “1'25 mm
recesses. 37 Nm (3.8 kgl-m. 27 lbf‘hl
Apply engine oil to the bolt
threads.
TIMING BELT
lnspeclinn. page 5-13. ?
Tension adjustment, page fi-A-T
Removal, page fi-A-B CRANKSHAFT SPEED FLUCTUATIDN
installation, page E-A-Ei [CKF] SENSOR
Replacement. page IB-A-11
UPPER COVER
6 x 1.0 mm
9.8 N-m i1.0 kgf-rn,
7.2 lbf-ftl
/ RUBBER SEhLS
WE) Replace when damaged
or deteriorated.
LOWER COVER
RUBBER
PLUG
CRANKSHAFT F'ULLEVr
Replacement, page B-A-S
PULLEY BOLT
14 x 1.25 mm
20 N41! [2.0 kgI-rn, 14 ItI a» 9D"
Install with concave
Replacement. page S-A-E
surface lacing in. Do not use an impact
wrench when installing.
TIMING BELT
DRIVE PULLEY
Replacement. page E-A-E O-HING \6: 1.0 mm
“9 PIHEE- 9.3 N-rn (1.0 kgr-m.
ADJUSTING BOLT E x 1.0 mm 7.2 Ibf-ftl
10 x 125 mm 11 N-m {1.1 Ital-m.
44 N-m 14.5 kgf-m. 33 l'ti 3.0 ltl
4

&A
!#!!3
9
(See Page 6—A-30)
;'!%+0<
(See Page 6—A-7)
;'!%$<
(See Page 6—A-8)
;'!%'<
(See Page 6—A-9)
;'!%5<
(See Page 6—A—11)
;'!%<
(See Page 6—A-5)
;'!%<
6-A-7
!" Tension Adjustment

D
Timing Belt
Inspection

57
1.
- Remove the cylinder head cover.
1&!&- NOTE:
84 9
0 When installing (see page 6—A—30).
2!!
;!%+0<- 0 Always adjust the timing belt tension with the
%!37
!3
2.
- Remove the upper cover (see page 6—A—8).
1& &;!%'<- engine cold.

!-
3.
+- Inspect the timing belt for cracks and oil or coolant

!#!! The tensioner is spring-loaded to apply tension to
4
!!
soaking.
#
- the belt automatically after making the following
! !!#
!!3

NOTE:
84 9 adjustment.
7 -
0 Replace the belt if oil or coolant soaked.
1!!!!#- Always rotate the crankshaft counterclockwise
%!3# !#3
0 Remove any oil or solvent that gets on the belt.
1&!!&
!- when viewed from the pulley side. Rotating it
3&3 !!-1

Inspect th is clockwise may result in improper adjustment of the
!#3 !7
area [or wea r. belt tension.
!-
Inspect the timing belt before adjusting the belt

!7
!
tension.
-
- 1&!&-
¢ Refer to page 6—A—30 when installing.
1
%+03!!
-
Remove the upper cover (see page 6—A—8).
- 1& &;!%'<-
Rotate the crankshaft five or six revolutions to set
+- 1#&/&!
the belt.
!-
Set the No.1 piston at TDC (see page 6—A—10).
*- -4(;!%0<-
Loosen the adjusting bolt 180°.
- 7
!'0P-
ADJUSTING EDLT
u N-m 14.5 kgfm.
33 Ib’l-fll
Rotate pulley
and inspect hell.
55-“ [Direction of
-- rotation.
4.
*- After inspecting, loosen the crankshaft pulley bolt, then
%
A!# !!!A
retorque the crankshaft pulley bolt to 20 Nm (2.0 kgf/m,
F # !!!0;-0#
=A
14 Ibf/ft) + 90°.
*!=<V50P-
- Rotate the crankshaft counterclockwise three teeth

1# !#3
on the camshaft pulley.
!!-
$- Tighten the adjusting bolt.
4
7
!-
'- After inspecting, loosen the crankshaft pulley bolt,
%
A!# !!!A
then retorque the crankshaft pulley bolt to 20 Nm
F # !!!0
(2.0 kgf/m, 14 |bf/ft)+ 90°.
;-0#
=A*!=<V50P-
!"
Timing Belt

-
Removal
6-A-8
58
NOTE:
84 9 5.
- Remove the dipstick, then remove upper cover and
1&#A& &
¢ Turn the crankshaft pulley so the No. 1 piston is at top
4 # !!- idler pulley bracket.
! !!#-
dead center (TDC) before removing the belt (see page
;4(<&
!;! NOTE: Do not use the upper cover for storing
84 9( &
6—A—10).
%0<- removed items.
&-
¢ Inspect the water pump before installing the timing belt
3 !!

! UPPER COVER
(see page 10-17)
;!0$<
Remove the splash shield (see page 5-10).
- 1&!!;!0<- E 1: LI] mm
N-x
9.8 N-rn 11.0 kgf-rn.

Loosen the mounting bolt and lock bolt, then remove the
-
!!#!A&
7.2 Ibf-fll
power steering (P/S) pump belt and pump.
3
;=< ! -
MOUNTING BOLT
B u 1.25 mm
24 N-rn [2.4 kgl—m. 1? lbl-fil
III-"wll
K
3 K 1.25 mm
PIS PUMP IDLEFI PULLE'l" 21 N-rn [2.4 Raf-m. 1'! IbH-Ll
BELT BRACKET
6.
- Support the engine with the jack and wood under

37#3
the oil pan.
!-
7.
$- Remove the stop and ground cable, then remove
1&
!A&
LUCK BOLT
upper bracket (see page 6—A—17).
#;!%$<-
B I: 1.25 mm 8.
'- Remove the crankshaft pulley (see page 6—A—5).
1&# !!;!%<-
24 Iii-m 12.4 kgf-m. 17 lbf—fll 9.
5- Remove the lower cover and dipstick tube.
1&!3&# -
3.
+- Loosen the idler pulley center nut and adjusting bolt,
! !! 7
!A NOTE: Do not use the lower cover for storing
84 9( !3&
then remove the air conditioning (A/C) compressor belt

&
;%=<! removed items.
&-
(see page 5-7).
;!$<- DIPSTICK TUBE
4.
*- Loosen the mounting nut and lock bolt, then remove the

!#!A&
alternator belt.
!!-
LUCK BULT
B x 1.25 mm
21 I'll-m 12.4 nm.
1? IbH‘ll
ALTERNATOR
BELT
E x 1.0 mm
9.8 N-I‘I‘I [Ll] Ital-m.
D-RING 12 lbf-H]
MOUNTING HUT Fin-place.
'll} 1 1.25 mm
4: Min “.5 kgf‘m.
33 lbfrfll
!"
Timing Belt
Removal (cont’d)

-/
?0
6-A-9
59

Installation
10. 1&#! ;>

0- Remove the crankshaft speed fluctuation (CKF)<
sensor Install the timing belt in the reverse order of removal;
!!
!&&!N
from the oil pump.
! - Only key points are described here.
8!#-
1.
- Set the timing belt drive pulley so that the No. 1

!& !!-
piston is at top dead center (TDC). Align the
;4(<-%!

groove on the timing belt drive pulley to the pointer

&
!& !!
on the oil pump
!
TDC MARK POINTER
CKF SENSOR 51 1_u rnrn

11N-ml1.1kgf-m.
3.3 Ibi—Hl
11. 7
!'0P-
- Loosen the adjusting bolt 180°. Push the tensioner to
remove tension from the timing belt, then retighten the
&
!A

adjusting bolt.
7
!-
TIMING BELT KEY

DRIVE PULLE'r
Clean.
2.
- Set the camshaft pulley so that the No. 1 piston
!!-
TDC. Align the TDC marks on the camshaft pulley
4(-%!
4(# !!
with the cylinder head upper surface.
3! -
CAMSHAFT
PULLE‘lIr
"UP" MARK
UPPER S U RFACE
ADJUSTING BOLT
44 N-m [4.5 kgt-rrl.
33 lbf-l't]
12. 1&
!-
- Remove the timing belt.
TDC MARKS
!"
Timing Belt

/
?0
6-A-10
5$
+- Install the timing belt tightly in the sequence shown. (1)
!!
!
!F 3-;< 9.
5- Check that the crankshaft pulley and camshaft
## !!
to Timing belt drive pulley (crankshaft) to (2) Adjusting
4
!& !!;#<;<%7
pulley are both at TDC.
!!4(-
pulley to (3) Water pump pulley to (4) Camshaft pulley.
!!;+<2 !!;*< !!- CHANKEHAFI' PULLEY:
NOTE: Make sure the timing belt drive pulley and
84 9,#
!& !!
camshaft pulley are at TDC.
!!4(-
*- Loosen and retighten the adjusting bolt to tension the

7
!
timing belt.

!- TDC MARK
- Install the lower cover and upper cover.
!!!3& &- lWHITEl
NOTE: Clean the upper and lower covers before
84 9! !3&
installation.
!!-
- Install the crankshaft pulley, then tighten the pulley bolt
!!# !!A
!!! CAMSHAFT PU LLEY:
(see page 6—A—5).
;!%<-
$- Rotate the crankshaft pulley about five or six turns
1# !! &/ “UP” MARK
counterclockwise so that the timing belt positions on the
!#3
!
pulleys.
!!-
'- Adjust the timing belt tension (see page 6—A—7).
%7
!;!%$<-
Tue MARK
10. # !!
0- If the camshaft and crankshaft pulleys are not
positioned at TDC remove the timing belt, and
4(&
!A
adjust the position, following the procedure (see
7 A!!3
;
page 6-A—9), then reinstall the timing belt.
!%5<A!!
!-
11. %!!A7 !-
- After installation, adjust the tension of each belt.
¢ See section 4 for alternator belt tension
*!!
adjustment.
7 -
¢ See section 22 for NC compressor belt
%=!
tension adjustment.
7 -
¢ See section 17 for P/S pump belt tension
$= !
adjustment.
7 -
I+

CKF Sensor
Replacement

6-A-11
5
1&!&-
NOTE: Refer to page 6—A—30 when installing.
84 91
%+03!!
-
- Remove the crankshaft pulley (see page 6—A—5).
1&# !!;!%<-
+- Remove the upper cover and idler pulley bracket (see
1& &! !!#;
page 6—A—8).
!%'<-
*- Remove the dipstick tube, then remove lower cover (see
1&# A&!3&;
page 6—A—8).
!%'<-
- Disconnect the CKF A&
(> sensor connector, then remove the
>
CKF -
sensor.
CKF SENSOR
CON HECTOR
CKF SENSOR
\
6 x 1.0 mm
11 N-m (1.1 kgl-m,
8.0 lbw-t]
6.
- !!>
Install the CKF &&!-
sensor in reverse order of removal.
Cylinder Head
# . 6-A-12
5

Illustrated Index
NOTE:
84 9
¢ To avoid damage, wait until the engine coolant temperature drops below 38°C (100°F)<&
!-
4&
A3 !
! !3+'P;00P before removing the cylinder head.
¢ When handling a metal gasket, take care not to fold it or damage the contact surface.
2!
!
#A#!
-
¢ Use new O-rings and gaskets when reassembling.
?38

#3!
-
E a: 1.13 mm
9.5 Min “.0 kgf-rn. 1.2 Ehf-ftl
Apply snapsuds lp threads and cylinder head
WASHER contact surface when raplacing the rubber
Replace when damaged seal, than rerncwe any soapsuds after install-
or deteriorated. ing rubber seal.
RUBBER SEAL
Replace when damaged
or deterioralad.
CYLINDER HEAD
DOVER CYUNDEH HEAD BOLT
Refer to page fi-A-BD when 10 x 1.25 mm
installing cylinder head cover. 67 N-m "5.8 kgf-rn, IS t'tI
Tightening, page Sit—30
Apply engine oil to the lhraads.
HEAD COVER GASKET

Replace when leaking,
damaged or deteriorated.
Applyr liquid gasket at
the four corners of the
recesses.
E It 1.26 mm
2-!- Iil-rn {2.4 kgf-m.
1T IN-ftl
IGNITION COIL
See section 4. CYLNDEFI HEAD
GASKET
Replace.
CYLINDER
HEAD

4

&A
!#!!3
9
(See Page 6-A-30)
;'!%+0<
Cylinder Head
# . 6-A-13
Illustrated Index (cont’d)
/
?0
5
7%
&
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
!
A!!!!&AA!! -
3 x 1.25 mm
20 N-n'l (2.0 kgI-rn. 14 lhf-ftl
Apply engine oil to the
ROCKER ARM threads
ASSEMBLY
Removal, page E-A-IB
Inspection. page B-A-IEI
S x 1.0 mm
12 N-m I12 kgf-m. 3.? IbI-I‘ll
VALVE KEEPERS
CAMSHAFI' SPRING RETAINER

In spection, page 6-A-21
NTAKE VALVE
SPRING
OIL CONTROL
INTAKE VA LVE SEAL
ORIFICE
Replace.
Clean.
VALVE SPRING
D-RING
SEAT
Replace. INTAKE VALVE
GUIDE
VALVE KEEPERS
CAMSHAFT
PULLE‘Ir
SPRING RETAINER
EXHAUST VALVE
SPRING
EXHAUST VALVE
SEAL
Rep‘ace- 3:1.25mrn
37 film [3.8 kgI-m.
VALVE SPRING "w. 27 Ibfvl‘t]
SEAT fi Apply engine oil In
1he1hreaus.
OIL SEAL
EXHAUST VALVE Replace.
GUIDE
Inspectipn, page S-A-Zd
Replacement. page S-A 26
CYLINDER HEAD
Reaming, page 543.25
EXHAUST Rummy-ail, page fi-A-‘ld
VALUE Warpage. page B A 24
Vulve seal reconditioning.
INTAKE VALVE
page E-A-25
Removal, page 6 A 23 Installation, page fi-A-ZQ
Installation. page S-A-ET

4

&A
!#!!3
9
(See Page 6-A—18)
;'!%'<
(See Page 6-A—19)
;'!%5<
(See Page 6-A—21)
;'!%<
(See Page 6-A—24)
;'!%*<
(See Page 6-A—26)
;'!%<
(See Page 6-A—23)
;'!%+<
(See Page 6-A—27)
;'!%$<
(See Page 6-A—14)
;'!%*<
(See Page 6-A—25)
;'!%<
(See Page 6-A—29)
;'!%5<
# .
Cylinder Head

-
Removal
6-A-14
5
Engine Removal is not required in this procedure.

1&!F - 6.
- Remove the brake booster vacuum hose and
1&#&
NOTE:
84 9 evaporative emission (EVAP) control canister hose.
&&; :%<!-
¢ Use fender covers to avoid damaging painted surfaces.
?&&

- BRAKE BOOSTER
¢ To avoid damage, carefully unplug the wiring connectors
4&
A !! !
3
VAC UM HOSE
3!!
-
¢ To avoid damaging the cylinder head, wait until the
4&

!A3 !
engine coolant temperature drops below 38°C (IOO°F)<

! !3+'P;00P
before loosening the retaining bolts.
!

!-
¢ Mark all wiring and hoses to avoid misconnection. Also,
,#!!3
&-%!A
3
A
interfere with other parts.
3-
Secure the hood in the open position.
- -
N-x
Make sure you have the anti-theft code for the radio,
- ,# &A
33F B
buttons.
-
3.
(
&!A
positive terminal.
&!-
4.
*- Drain the engine coolant (see page 10-7).
(
!;!0$<-
5.
- Disconnect the intake air temperature (IAT) sensor
(# ;%4<
connector, then remove the intake air duct.
A&# -
INTAKE AIR
HOSE
EVAP EDNrHOL
CANISTEFI
HOSE
7.
$- Remove the breather hose and positive crankcase
1&&#
ventilation (PCV) hose.
&!;:<-
Pcv HusE
IAT SENSOR
CONNECTOR
BREATHER
HOSE
Cylinder Head
# .
Removal (cont’d)

-/
?0
6-A-15
53
8.
'- Remove the throttle cable by loosening the locknut, then
1&!!!
!# A 11. 1&
!!#!A
- Remove the mounting bolt and lock bolt, then
slip the cable ends out of the accelerator linkage. Take
!! !!#
-4# remove the power steering (P/S) pump belt and
&3
;=< !
care not to bend the cable when removing it. Always
!3&
-%!3 pump without disconnecting the P/S hoses.
3
=-
replace any kinked cable with a new one.
!##!33- MOUNTING BOLT
B x 1.25 mm
24 Min l2.d kgl-m.
/ 11 Ibf-fli
ADJUSTING
NUT
L KN T PIS PUMP
C": U THROTTLE BE LT
CABLE
9.
1!& ! ;<- LOCK BOLT
10. 1& ! ! -
0- Remove the fuel feed hose and fuel return hose. B x 1.25 mm
5 >1: LEI rnrn 2-1. Mm [2.4 kgf-m.

IlN-ml1.1kgf-m, 31' N-rn [3.8 kgfvn'l. 1T Ibf-ft]
8.0 Ibf-ftl 27 lbf-ftl - Loosen the idler pulley center nut and adjusting
12. ! !! 7
bolt, then remove the air conditioning (A/C)

!A&
;%=<
compressor belt.
!-
IDLER PULLEY CENTER
ADJU STING NUT
BOLT 10x 1.25 mm
M. N-m l4.5 kgf-m. 33 Ibf-ftl
FU E L FEE D
HOSE
AID COMPRE 550R

FLJ E L RETURN
BELT
HOSE
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-A-16
55
13.
!#!A&
+- Loosen the mounting nut and lock bolt, then remove the 15. 1& A
- Remove the upper radiator hose, heater hose and
alternator belt.
!!- water bypass hoses.
3-
ALTERNATOR LOCK ED LT WATER BYPASS
BELT 8 K 1.25 mm HDSE
24 N-m [2.1! kgl—m.
17 l‘t]
WATER BYPASS
MOUNTING NUT HOSE HEATER
10 x 1.25 mm HOSE UPPER RADIATOR
44 um [4.5 kgim, HOSE
33 Itl
16. 1&
3
- Remove the engine wire harness connectors and
14. 1&= #;!$<-
*- Remove the P/S pump bracket (see page 5-17). wire harness clamps from the cylinder head and
3!!
the intake manifold.
#!-
¢ Four injector connectors
7
Intake air control (IAC) valve connector
#!;%<&!&
....
Idle air control (IAC) valve connector

!!;%<&!&
Throttle position sensor connector
4!
Manifold absolute pressure (MAP) sensor
,!! ;,%<
connector

¢ Engine coolant temperature (ECT) sensor

! ; 4<
connector

¢ Radiator fan switch connector
13
¢ Coolant temperature gauge sending unit
!

connector

¢ Heated oxygen sensor (H028) connector
6/
;68<
17. 1&#!

!
$- Remove the spark plug caps and ignition coil from
the cylinder head.
!-
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-A-17
57
18.
37#3!#
'- Support the engine with the jack and wood block under 21. 1&
!;!%'<-
- Remove the timing belt (see page 6—A— 8).
the oil pan.
!- 22. 1& !!#&-
- Remove the camshaft pulley and back cover.
19. 1&
!A&
5- Remove the stop and ground cable, then remove the
CAMSHAFT
upper bracket.
#- PULLE‘I'
6 x 1.0 mm Clsan when installing.
11 N—ml1.1kgf-m. GROUND
B.nlb1-1'tl CABLE
1|} 1: 1.25 mm
52 Mm {5.3 Inf-m,
33 Ihf-HI I! x 1.25 mm
22 N-m 12.2 ital-m.
15 Ib‘lv‘h}
'-.
8 x 1.25 mm
6 x 1.0 mm 33' en [3.8 kgf-rn.
12 x 1.25 mm 21 IhFflJ
12 Mm 11.2 kgf-m. 8.? Ibf-ttl
541 Mm Apply engine Gil to the
{5.5 kgfvrn. bull threads.
4i] lbl-fil
23. 1&/ !#
+- Remove the exhaust manifold brackets and
self-locking nuts.
!!#
-
GASKET
Fla-place.
20. 1&!&-
0- Remove the cylinder head cover.
CYLINDER
HEAD COVER
EXHAUST
MANIFOLD
BRACKET
SELF-LOCKING NUT
1D x 1.25 mm
II] x 1.25 mm
44 Min “.5 kg‘I-m,
5-1- N-m l5.5 kgf-m.
41] Itl 33 Ib'l-fl}
Replace.
Cylinder Head
# .
Removal (cont’d)

-/
?0
6-A-18
58
6
Rocker Arms

-
Removal
24. 1&!!-4&3

A
*- Remove the cylinder head bolts. To prevent warpage, 1.
- Loosen the adjusting screws.
7
3-
unscrew the bolts in sequence 1/3 turn at a time; repeat
3!F =+ N ADJ U STING SCREWS
the sequence until all bolts are loosened.
F !!!!!-
CYLINDER HEAD BOLT LOOSING SEQUENCE:
>&,)%.%)"&&,%=;%,%F
if l
3 5 El 1' '|
Ll
ADJUSTING SCREWS
N
- Unscrew the camshaft holder bolts, then remove
?3!!A&
the rocker arm assembly.
#!-
25. 1&!-
- Remove the cylinder head. NOTE:
84 9
¢ Unscrew the camshaft holder bolts two turns
?3!!3
at a time, in a crisscross pattern, to prevent
AA&
damaging the valves or rocker arm assembly.

&!&#!-
¢ When removing the rocker arm assembly, do
2&
#!A
not remove the camshaft holder bolts. The
&!!-4
bolts will keep the camshaft holders, the
!3!!#!A
springs and the rocker arms on the shaft.

#-
CAMSHAFT HOLDER BOLTS LOOSENING
.+.&)%"&&%,,
SEQUENCE:
%=;%,%F
Rocker Arms

6 6_A_19
59
) *#2*#
NOTE:
84 9
9 Identify parts as they are removed to ensure reinstallation in original locations.
& !!
!!-
Inspect rocker shafts and rocker arms (see page 6-A—20).
##;!%0<-
.Q.
Rocker arms must be installed in the same position if reused.

1# !! -
When removing or installing rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the
2&
!!
#!A&!!-4!3!!#
holders, springs and rocker arms on the shaft.
!A
#-
INTAKE ROCKER INTAKE ROCKER
ARM 3
ARM A
H. pitl-I [4. places)
INTAKE ROCKER SHAFT
Letter "B" is stamped Letter "A" i5 stamped
on rocker arm. on rocker arm.
x...- u u
f” .;:r..1 -:'I[?- [am [:-r,: f
“.
SPRING nucn SHAH

14 places! COLLAR
[4 plans!
r [1% WM 7 {1] lllllljfij lllll r [l

i ; l
|._ i ..l_._ ,4 _. ! __ l
|
No. 4 CAMSHAF‘I' - No. 3 CAMSHAFT No. 2 CAMSHAFI' ]

_ @ HOLDER HOLDER HOLDER
g. . .
No. 5 CAMSHAFT ;
HOLDER '___‘ l—| I
ROCKER SHAFT
SPRING
M places]
Lelter ""EI" is stamped Letter "A" Is stamped

on rocker arm. on rocker arm.
EXHAUST ROCKER SHAFT
EXHAUST BECKER EXHAUST

ARM B ROCKER AFIM A
(4 pin-coal ll placui

6

6-A-20
5$
, ##/ #
Measure both the intake rocker shaft and exhaust rocker 3.
+- Measure inside diameter of rocker arm and check
, ##
-
shaft. for out-of-round condition.
-
-
1. , #!-
Measure the diameter of shaft at the first rocker location. Rocker Arm-to-Shaft

6
Clearance:
F
Surface should be smuuth. Standard (New):
/,(0F
Intake:
6F 0.017 - 0.050 mm
$@$7$@$3$
(0.0007 - 0.0020 in)
/$@$$$7$@$$$ 0
Exhaust:
% F 0.018 - 0.054 mm
$@$8$@$3
(0.0007 - 0.0021 in)
/$@$$$7$@$$ 0
Service Limit: $@$8/$@$$ 0
- & F 0.08 mm (0.003 in)
MICHOMETEFI
2.
- Zero the gauge to the shaft diameter.
I

-
MICRUMETER
Inspect rocker arm

face for wear.
4.
*- Repeat for all the rockers.
1!!#-
- If the clearance is over the service limit,
!&&!A
replace the rocker shaft and all over tolerance
!#!!&!
rocker arms.
#-
CY LlNDEH BORE
GAUGE

Camshaft
Inspection

6-A-21
5
NOTE:
84 9 - Seat the camshaft by pushing it toward the rear of

3
9 Do not rotate the camshaft during inspection.
(
- the cylinder head.
!-
O Remove the rocker arms and rocker shafts.
1&##- +- Zero the dial indicator against the end of the
I!

1. !
- Put the camshaft and the camshaft holders on the camshaft. Push the camshaft back and forth, and
- #A
cylinder head, then tighten the bolts to the specified
!A
! read the end play.
!-
torque.
F - Camshaft
End Play:
%'#F
Specified torque:

BF /,(0F 0.05 - 0.15 mm
Standard (New): $@$3$@3
8 mm bolts: 20 Nm (2.0 kgflm 14 lbf/ft)
8*
F$,/@$6! 2* 2 0 (0.002 - 0.006 in)
/$@$$$@$$5 0
#!

threads.
@ Service Limit:
- & F 0.5 mm (0.02 in)
$@3/$@$ 0
6 mm bolts: 12 Nm (1.2 kgflm 8.7 lbf/ft)
5*
F,/@6! 28@7* 2 0
5 mm bolts: :3}, {2: (iii, 13}:
iii.
'H
LID
.I'J
E e
g:
%
...
*- Remove the bolts, then remove the camshaft

1&!A&
holders from the cylinder head.
!!-
- Lift camshaft out of cylinder head, wipe clean,
!A3!A
then inspect lift ramps. Replace camshaft if
!-1!
lobes are pitted, scored, or excessively worn.
!AA/&!3-
- Clean the camshaft bearing surfaces in the
!

cylinder head, then set camshaft back in place.
!A#!-
- Insert plastigage strip across each journal.
!

7 !-
- Install the camshaft holders and tighten the bolts to
!!!
!
the specified torque.
F -
Camshaft
6_A_22
5
Inspection (cont’d)

/
?0
6.
- Remove the camshaft holders, then measure the widest
1&!A 3 8.
'- Check the cam lobe height wear.
#!
3-
portion of the plastigage on each journal.
!

7 !- Cam Lobe Height/,(0F
&
*. ! Standard (New):
Camshaft-to-Holder
Oil Clearance:

.
F Intake A: 35.019 mm (1.3787 in)
6F3@$9/@787 0
Standard (New): $@$3$$@$89
/,(0F 0.050 - 0.089 mm Intake B: 34.734 mm (1.3675 in)
6"F@7/@573 0
(0.002 - 0.004 in)
/$@$$$@$$ 0 Exhaust:
% 37.904 mm (1.4923 in)
F7@9$/@9 0
Service Limit:
- & F 0.15 mm (0.006 in)
$@3/$@$$5 0 Tm: Timing be"
. l IN: Intake, EX: Exhaust
7.
$- If the camshaft-to-holder oil clearance is out of
!!!
tolerance:
!9
- And the camshaft has already been replaced, you
%!!A
must replace the cylinder head.
!!-
- If the camshaft has not been replaced, first check
!A#
the total runout with the camshaft supported on
! 3 __,_.
V-blocks.
:!#-
Camshaft
Total Runout:

F
Standard (New): $@$/$@$$ 0@
/,(0F 0.03 mm (0.001 in) max.
Service Limit:
- & F 0.04 mm (0.002 in)
$@$/$@$$ 0
"I ”ca
#’n
\ Check this area for wear
Rotate calrlshaf‘i
while measuring.
-
o
If the total runout of the camshaft is within
! 3
tolerance, replace the cylinder head.
!A!!-
- If the total runout is out of tolerance, replace the
! !A!
camshaft and recheck. If the bearing clearance is
#-
!
still out of tolerance, replace the cylinder head.
!! !A!!-
4-:4- !4-
Valves, Valve Sprinqs and Valve Seals
6-A-23
5
:9

-
Removal
NOTE: Identify valves and valve springs as they are removed

84 9&!&&!&
&
so that each item can be reinstalled in its original position. _. B _.——._.
1‘
!!
!-
1.
- Using an appropriate-sized socket and plastic mallet,
?
H#!!!A
i
lightly tap the valve retainer to loosen the valve keepers
!
!&!&!&!&#
before installing the valve spring compressor.
!!
&!&
-
PLASTIC MALLET
L l
64-)

Intake Valve Dimensions
AStandard (New):
/,(0F 29.90 - 30.10 mm in)
9@9$$@$ 0
(1.177 - 1.185 in)
/@77@83 0
B Standard (New):
"/,(0F 117.42 - 117.72 mm
7@7@7
(4.623 - 4.635 in)
/@5@53 0
C Standard (New):
/,(0F 5.48 - 5.49 mm
3@83@9
(0.2157 - 0.2161 in)
/$@37$@5 0
C Service Limit:
- & F 5.45 mm (0.2146 in)
3@3/$@5 0
D Standard (New):
)/,(0F 0.75 - 1.25 mm
$@73@3
(0.030 - 0.049 in)
/$@$$$@$9 0
SOCKET D Service Limit:
)- & F 0.55 mm (0.022 in)
$@33/$@$ 0
% 4-)

Exhaust Valve Dimensions
2.
- Install the spring compressor. Compress the spring and
!!
-

remove the valve keeper.
&&!&#- AStandard (New):
/,(0F 25.90 - 26.10 mm
3@9$5@$
(1.020 - 1.028 in)
/@$$@$8 0
B Standard (New):
"/,(0F 114.60 - 114.90 mm
@5$@9$
(4.512 - 4.524 in)
/@3@3 0
C Standard (New):
/,(0F 5.45 - 5.46 mm
3@33@5
(0.2146 - 0.2150 in)
/$@5$@3$ 0
C Service Limit:
- & F 5.42 mm (0.2134 in)
3@/$@ 0
D Standard (New):
)/,(0F 0.95 - 1.45 mm
$@93@3
(0.037 - 0.057in)
/$@$7$@$37 0
D Service Limit:
)- & F 0.85 mm (0.033 in)
$@83/$@$ 0
VALVE SPRING
CDMPRE 550R
0775? — 0010000
4-
Valve Guides
4-
-
Valve Movement
6-A-24
5 # .
Cylinder Head
1!
Warpagg
Measure the guide-to-stem clearance with a dial indicator

,
!3! NOTE: If the camshaft-to-holder oil clearances (see
84 9!!!;
while rocking the stem in the direction of normal thrust
3!#
! page 6-A—21) are not within specification, the cylinder
!%<3A!
(wobble method).
;3!<- head cannot be resurfaced.
-
Intake Valve Stem-to-Guide Clearance:
64-
F If the camshaft-to-holder oil clearances are within
!!!3
Standard (New): $@$$@$
/,(0F 0.04 - 0.10 mm specifications, check the cylinder head for warpage.
A#!3
-
(0.002 - 0.004 in)
/$@$$$@$$ 0 I If warpage is less than 0.05 mm (0.002 in)
3
!0-0;0-00<
Service Limit:
- & F 0.16 mm (0.006 in)
$@5/$@$$5 0 cylinder head resurfacing is not required.
!
F -
Exhaust
% Valve Stem-to-Guide Clearance:
4-
F I If warpage is between 0.05 mm (0.002 in) and
3
30-0;0-00<
Standard (New): $@$$@5
/,(0F 0.10 - 0.16 mm 0.2 mm (0.008 in), resurface cylinder head.
0-;0-00'<A !-
0.004 - 0.006 in)
$@$$$@$$5 0 I Maximum resurface limit is 0.2 mm (0.008 in)
,/ !0-;0-00'<
Service Limit:
- & F 0.22 mm (0.009 in)
$@/$@$$9 0 based on a height of 93 mm (3.66 in).

5+;+-<-
Valve. amended 10 mm out from seat PRECISION STRAIGHT EDGE
“a.
Measure along edges, and three ways across
, !

A3
0 If measurement exceeds the service limit, recheck
/&!A# center.
-
using a new valve.

3&!&-
0 If measurement is now within the service limit,
33&!A
reassemble using a new valve.
!
3&!&-
0 If measurement still exceeds limit, recheck using
!!/!A#

alternate method below, then replace valve and
!!3A!&!&
guide, if necessary.

A-
NOTE: An alternate method of checking guide to stem
84 9%!#

__ -“-
clearance is to subtract the OD. of the valve stem,
! 8-(-&!&A
‘w may”:
-
measured with a micrometer, from the ID. of the valve
3A-(-&!&
guide, measured with an inside micrometer or ball

A 3!!
gauge. Take the measurements in three places along

-4# !!
Cylinder Head Height:
# .. ! F
the valve stem and three places inside the valve guide.
&!&!&!&
- Standard (New): 9@939@$3
/,(0F 92.95 - 93.05 mm
The difference between the largest guide measurement
43!

(3.659 - 3.663 in)
/@539@55 0
and the smallest stem measurement should not exceed
!! !/
the service limit.
&!-
64-
F
Standard (New): $@$$@$3
/,(0F 0.02 - 0.05 mm
(0.001 - 0.002 in)
/$@$$$@$$ 0
Service Limit:
- & F 0.08 mm (0.003 in)
$@$8/$@$$ 0
Exhaust
4-
F
Standard (New): $@$3$@$8
/,(0F 0.05 - 0.08 mm
(0.002 - 0.003 in)
/$@$$$@$$ 0
Service Limit:
- & F 0.11 mm (0.004 in)
$@/$@$$ 0
Valve Seats
4-
Reconditioning

! 6-A-25
53
1.
- Renew the valve seats in the cylinder head using a valve
13&!&!
&!& - After resurfacing the seat, inspect for even valve
%
A&&!&
seat cutter.
- seating: Apply Prussian Blue compound to the

9%! )!
NOTE: If the guides are worn (see page 6-A—24) replace
84 9
3;!%*<! valve face, and insert the valve in its original
&!&A&!&
!
them (see page 6-A—26) before cutting the valve seats.
;!%<
&!&- location in the head, then lift and snap it closed
!A!!
VhL'U'E SEAT against the seat several times.

&!-
CU‘I'I'EFI
iCor'n-me rciallv availaDIEI ACTUAL —- — —
-
SURFACE 7"- ——
VALVE
SEAT
PHUSSIAN BLUE COMPOUND i
6.
- The actual valve seating surface, as shown by the
4 !&!&
A3
2.
- Carefully cut a 45° seat, removing only enough material
!! *PA&
!
! blue compound, should be centered on the seat.
! A !-
to ensure a smooth and concentric seat.
- ¢ If it is too high (closer to the valve stem), you

;!&!&<A
3.
+- Bevel the upper edge of the seat with the 30° cutter and
)&!
3+0P must make a second cut with the 60° cutter to
# 30P
the lower edge of the seat with the 60° cutter. Check the
!3
30P -# move it down, then one more cut with the 45°
&3A 3*P
width of seat and adjust accordingly.
37
!- cutter to restore seat width.
3-
4.
*- Make one more very light pass with the 45° cutter to
,#&!
3*P ¢ If it is too low (closer to the valve edge), you
!3;!&!&
<A
remove any possible burrs caused by the other cutters.
&! - must make a second cut with the 30° cutter to
# 3+0P
Valve Seat Width:F
4-1 move it up, then one more out with the 45°
& A 3*P
Standard (New):
/,(0F cutter to restore seat width.
3-
Intake:
6F 0.85 - 1.15 mm (0.033 - 0.045 in)
$@83@3/$@$$@$3 0 NOTE: The final out should always be made
84 94! !!3
Exhaust:
% 1.25 - 1.55 mm (0.049 - 0.061 in)
F @3@33/$@$9$@$5 0 with the 45° cutter.
3*P -
Service Limit:
- & F $- Insert the intake and exhaust valves in the head
#/ &!&
Intake:
6F 1.6 mm (0.063 in)
@5/$@$5 0 and measure the valve stem installed height.
&!&!!
-
Exhaust:
% 2.0 mm (0.079 in)
F @$/$@$79 0 Intake, Exhaust
6:% Stem Installed Height:
. ! F
Standard (New): 3@73@5
/,(0F 53.17 - 53.64 mm
(2.093 - 2.112 in)
/@$9@ 0
Service Limit:
- & F 53.89 mm (2.122 in)
3@89/@ 0
'- If the valve stem installed height is over the service
&!&!!
&&
limit, replace the valve and recheck. If it is still over
!A!&!&#-!!&
the service limit, replace the cylinder head; the
&!A!!N
valve seat in the head is too deep.
&!&-
r-— raw”
VALVE STEM
INSTALLED HEIGHT
Valve Guides
4- 6_A_26
Replacement

55 Reaming
!
NOTE:
84 9 NOTE: For
84 9 new valve guides only.
3&!&
!-
¢ For best results, heat cylinder head to 150°C (300°F)<
!A!0P;+00P 1.
- Coat both the reamer and valve guide with cutting
&!&
3
before removing or installing guides.

&
!!

- oil.
!-
¢ It may be necessary to use an air hammer to remove
& 2.
- Rotate the reamer clockwise the full length of the
1!#3 !!!

some valve guides.
&!&
- valve guide bore.
&!&
-
1.
- Drive the valve guide out from the bottom of the cylinder
(&&!&
! 3.
+- Continue to rotate the reamer clockwise while
!#33!
head.
- removing it from the bore.
&
-
4.
*- Thoroughly wash the guide in detergent and water
4
!3

3
to remove any cutting residue.
&
-
5.
- Check the clearance with a valve (see page
#!3&!&;!
6—A—24).
%*<-
- Verify that the valve slides in the valve guide
:&!&!&!&

without exerting pressure.
3 /
-
Turn reamer in
clockwnsa direction
only.
HEAMEH
VfiLVE GUIDE DRIVER. HANDLE
5.5 mm
0111.2 — 0010100
9.: “1* vfl@§\

2.
- Drive in a new valve guide to the specified depth.
(&3&!&
-
VALVE GUIDE
DRIVER. 5.5 mm
01'7”»? - 0010100 VALVE GUIDE
FIEhMEH, 5.525 "101
Valve Guide Installed Height:
O?HAH - PJTD'IW
Intake: 17.85 -18.35 mm (0.703 - 0.?22 inl
Exhaust: 18.65 -19.15 mm (0.734 - 0.754 in}
VALVE GUIDE
1
Measure here
7/ ////'|'7////
CYLINDER HEAD
4-:4- !4-
Valves, Valve Springs and Valve Seats

Installation
6-A-27
57
- Insert the valves into the valve guides coat the valve
&!&&!&
&!& 4.
*- Install the valve spring and valve retainer, then
!!&!&
&!&A
stems with engine oil before inserting the valves.
3
!
&!&- install the valve spring compressor. Compress the
!!&!&
-
NOTE: Check the valves move up and down smoothly.
84 9#&!&& 3!- spring, and install the valve keepers.

A!!&!&#-
- Install the spring seats on the cylinder head.
!!
!- NOTE: Place the end of valve spring with closely
84 9!&!&
3!!
.00.“
+- Install the valve seals using the special tool.

!!&!&!
!!- wound coils toward the cylinder head.
3 !3!-
NOTE: Exhaust and intake valve seal are not
84 9 / #&!&!
interchangeable.

!-
WHITE BLACK
SEEING SPRING
INTAKE VALVE SEAL EXHAUST VALVE SEAL
STEM SEAL DRIVER,

(”PAD — 0010000
NOTE: Lise b b m-n 5nd“.
VALVE SPRING
COMPRESSOR
01151 — WWWD
5.
- Lightly tap the end of each valve stem two or three

!&!&3
times with a plastic mallet to ensure proper seating
3!!!
of valve and valve keepers.

&!&&!&#-
NOTE: Tap the valve stem only along its so you do
84 94&!&!!

not bend the stem.
-
PLASTIC
MALLET
/
UflLVE SEAL
Fl :4 p | 3;; r_'!
VALVE
STEMS
2
6
Camshaft/Rocker
2'#

Arms and Camshaft
6-A-28
58
Seal/Pulley

Installation
NOTE:
84 9 *- Apply liquid gasket (P/N 08070 - K0234M, 08070 -
%!!F
#;=0'$0>0+*,A0'$0
¢ Make sure that all rockers are in alignment with valves
,# !!#!
3&!& K0334M, or 08070 - X03318) to the head mating
>0++*,A0'$0R0++<
when torquing rocker assembly bolts.

3F
#!!- surfaces of the No. 1 and No. 5 camshaft holders.
--!-
¢ Valve locknuts should be loosened and adjusting screws
:!&!# !!7
3 NOTE: Clean and dry the cylinder head mating
84 9!!
backed off before installation.

#!!- surfaces before applying liquid gasket.
!
!F
#-
¢ To prevent rocker arm assembly from coming apart,
4&#!
A - Apply liquid gasket to the shaded areas.
%!!F
#-
leave camshaft holder bolts in the holes.
!&!!!-
1.
- After wiping down the camshaft, camshaft seal and
%3
3A!
journals in the cylinder head, lubricate both surfaces and
7 !!A! O“
install the camshaft.
!!-
2.
- Clean and install the oil control orifice with new O-ring.
!!!!!338
-
OIL CONTROL DRIFICE
CAMSHAFI' D-RJNG
Ke vwa v u p. Replace.
ND. 5 NO. 'I
- Set the rocker arm assembly in place and loosely

#!!!!
install the bolts.
!!!-
- Make sure that the rocker arms are properly
,# #!
positioned on the valve stems.
&!&-
Tighten each bolt two turns at a time in the
- 4
!3
sequence shown below to ensure that the rockers
F 3!3 #
do not bind on the valves.
&!&-
NOTE: Wipe off the excess of liquid gasket from
84 92/!F
#
No. 1 and No. 5 camshaft holders with a shop
--!3
towel.
3!-
Specified torque:

BF
8 mm bolts: 20 Nm (2.0 kgf/m, 14 lbf/ft)
8*
F$,/@$6! 2:* 2 0
#!

threads.
@
6 mm bolts: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)
5*
F,/@6! 2:8@7* 2 0
6 mm bolts: u’fl. 6'22. tilt. Iii}
__.':n'l
CAMSHAFT SEAL
Seal housing surface shou'd be dry.
Appiy a light coat of mi 10 camshaft
and Miner lip of seal.
3.
+- Turn the camshaft until its keyway is facing up (No. 1
4 !#3
;-
piston TDC).
4(<-
2
6
Camshaft/Rocker
2'#

Arms and Camshaft
6-A-29
59 Cylinder Head
# .
Installation

Seal/Pulley

/
?0
7.
$- Install the back cover, then install the camshaft pulley.
!!#&A!! !!- Install the cylinder head in the reverse order of removal:
!!!&&!9
CAMSHAFI' NOTE:
84 9
BACK PULLEY 0 Always use a new head gasket.
%!3 3
#-
COVER Clean wheninstalling. 0 Cylinder head and cylinder block surface must be
!!!#
clean.
!-
0 “UP” mark on camshaft pulley should be at the top.
K?L# !! !-
0 Turn the crankshaft so the No. 1 piston is at TDC
4 #-4(
(see page 6—A—9).
;!%5<-
0 Clean the oil control orifice before installing.
!!!!!
-
0 Do not use the upper cover and lower cover for
( &!3&
storing items disassembled.

!-
0 Clean the upper cover and lower cover before
! &!3&
installation.
!!-
1.
- Cylinder head dowel pins must be aligned.
!3! !
-
CYLINDER HEAD
B x 1.25 mrn
5 x 1.1] mm 37 Mm [3.8 kgf-m,
12 N111 (1.2 kgl-m, 3.7 Ibf‘fll 2? lbf-fl]
Apply engine oil to
the bolt threads.
# .
Cylinder Head

/
?0
6-A-30
5$
- Position the camshaft correctly (see page 6-A—9).
!;!%5<- - Install the timing belt (see page 6-A—9).
!!
!;!%5<-
N939"
.00.“
+- Tighten the cylinder head bolts sequentially in four steps.

4
!!F !! - - Adjust the valve clearance (see page 6-A—3).
%7 &!&!;!%+<-
1st step: (1) - (10) 20 Nm (2.0 kgf/m,14|bflft)
F/0/$0$,/@$6! 2:* 2 0 $- Install the head cover gasket in the groove of the
!!&
#
&
2nd step: (1) - (10) 49 Nm (5.0 kgf/m, 36 lbflft)
F/0/$09,/3@$6! 2:5* 2 0 cylinder head cover. Seat the recesses for the
!&-
3rd step: (1) - (10) 67 Nm (6.8 kgf/m, 49 lbflft)
F/0/$057,/5@86! 2:9* 2 0 camshaft first, then work it into the groove around
A3#
&
4th F/0:/057,/5@86! 2:9* 2 0
step: (1),(2) 67 Nm (6.8 kgf/m, 49 lbflft) the outside edges.

-
NOTE:
84 9 NOTE:
84 9
0 We recommend using a beam-type torque wrench.
2
F 3- ¢ Before installing the head cover gasket,
)!!
&
#A
When using a preset-type torque wrench, be sure
2
F 3A thoroughly clean the seal and the groove.

!!!
&-
to tighten slowly and not to overtighten.

!3!&
- ¢ When installing, make sure the head cover
2!!
A# &
0 If a bolt makes any noise while you are torquing it,
!#3! F
A gasket is seated securely in the corners of the

# !
loosen the bolt, and retighten it from the 1st step.
!!A
- recesses with no gap.
3
-
CYLINDER HEAD BOLT TORQUE SEQUENCE:
>&,)%.%)"&=;%%=;%,%F CORNERS OF
THE RECESS
.3. .1' '21." .1:_I-
HE AD DOVER GASKET
Clea n.
.,af :_,1 .1, . '1'

4.
*- Install the exhaust manifold bracket, then install the
!!/ !#A!!
exhaust pipe Aand the bracket, and then install the
/ %#A!!
coven
&- CORNERS DF CYLINDER HEAD
THE HEcEss COVE“
8.
'- Apply liquid gasket to the head cover gasket at the
%!!F
#&
#
four corners of the recesses.
-
NOTE:
84 9
¢ Use liquid gasket, Part No. 08070 - K0234M,
?!F
#A-0'$0>0+*,A
08070 - K0334M or 08070 - X03318.
0'$0>0++*,0'$0R0++-
¢ Check that the mating surfaces are clean and
#
!
dry before applying liquid gasket.
!
!F
#-
¢ Do not install the parts if five minutes or more
(!!&
have elapsed since applying liquid gasket.
&!!
!F
#-
Instead, reapply liquid gasket after removing
A!!F
#&

old residue.
! -
¢ After assembly, wait at least 30 minutes
%!A3!+0
before filling the engine with oil.
!!

3!-
Apply liquid gasket to

the shaded areas.
# .
Cylinder Head

/
?0
6-A-31
5
5- When installing the cylinder head cover, hold the head
2!!
!&A! 10. 4
3-!
0- Tighten the nuts in two or three steps. In the final
cover gasket in the groove by placing your fingers on the
&
#
&!

step, tighten all bolts, in sequence, to 9.8 Nm (1.0
A
!!!AF A5-';-0
camshaft holder contacting surfaces (top of the
!
; kgf/m, 7.2 Ibf/ft).
#
=A$-!=<-
semicircles).
!<- NOTE: After assembly, wait at least 30 minutes
84 9%!A3!+0
Set the spark plug seal on the spark plug pipe. Once the
#!
!#!
-8 before filling the engine with oil.
!!

3!-
cylinder head cover is on the cylinder head, slide the
!&!A!
cover slightly back and forth to seat the head cover
&!
!#&
gasket

#-
NOTE:
84 9
0 Before installing the cylinder head cover, clean the
)!!
!&A!
cylinder head contacting surfaces with a shop towel.
!
33!-
0 Do not touch the parts where liquid gasket was
( 3!F
#3
applied.
!-
0 Take care not to damage the spark plug seal when
4#
#!
!3
installing the cylinder head cover.
!!
!&-
0 Visually check the spark plug seal for damage.
: !!##!
!
-
0 Replace the washer when damaged or deteriorated.
1!33
-
6 I 1.0 mm
9.8 N-m (1.0 kgl-m. 12 lbf-fll
CYLINDER HEAD
COVER 11. %!!A#!! A
- After installation, check that all tubes, hoses and
connectors are installed correctly.
!!!-
12. A
- Enter the anti-theft code for the radio, then enter
the customer's radio station presets.
@-
SPARK PLUG
SEAL

Special Tools
6-B-2
5"
O 1- O| Tool Number
4! O Description
( |Qty
OD O Remark
1#
O O| 07HAH - PJ70100
:!&. 1A- |
O O
_\_\_\_\_\_\_\_\_\_\_\_\
LDOONO‘JU'l-D-OOMA
O O| 07JAA - 0010200
0$"%%00000 O Socket Wrench, 19 mm
#2A5 |
O O
O + O| 07JAB - 0010200
0$"%)00000 O Handle
6! |
O O
O
O
O
*

i
O
O
O|
07LAG - PT20100
0$%.4000
07LAJ - PR30101
0$%"1+00
07LAJ — PR30201
0$%"1+00
O
O
O
Balancer Shaft Lock Pin
)!#
Valve Inspection Set
:!&
Air Stopper
%
|
O
|
O
|
O
O
O
O
O $ O| 07MAB - PY30100
0$,%)C+000 O Pulley Holder Attachment, HEX 50mm
!!6!%A6 R0 |
O O
O ' O| 07NAJ - P070100
0$%"0$000 O Oil Pressure Gauge Attachment
8! .
% |
O O
O 5 O| 07PAD - 0010000
!(& |
O O
O 0 O| 07406.-.0070001
0$*0--00$000 O Low Pressure Gauge
3 .
|
O O
A AA
M ‘0
O O| 07742 - 0010100
:!&. (&A- |
O O
O O| 07757 - 0010000
:!&
|
O O
if!
N
IIII
if:
‘1.
lo
4 *4- !4-&
Variable Valve Timinq and Valve Lift
%

/4%0

#
6-B-3
5"
Troubleshooting

* Flowchart

!+
( (F1832, F1833 engines)
/+8":+8"! 0
\ I / \ I /
:fi: :-'
\ ,! ;,<(
4 !;(4<9%!:4
Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 21: A problem in the VTEC
!:!& -
Solenoid Valve circuit.
Before troubleshooting (See Page 11-A—15) to (See Page 11-A—20).
) !
;'!%<;'!%0<-
- The MIL has been reported on.
- With the 505 short connector
connected, code 21 is Indicated.
Check the VTECl-l Control System:

1- Do the er‘gire cortrol modL.|e
(ECl-al'p' pom-email“ oortrol ‘R oad ’e st:
modL.|e (POM) Reset ProoedLre Accelerate ir' 1st gearto ar‘ ergire speed overEnDDD rmp [mir-1].
(see sectior‘ 11 j}. l-old tt'at ergir‘e speed for at least two secords.
2- Start the er‘ gire. Iftt'e MILr'ot oome or' dL.rir‘g the first road test, repeat tt'istest
3- Wann L.p er‘gire to rormal two more times.
operatir‘g temperatLre looolir‘g
far comes or}.
4- Do tl‘e Road ’est.’
Inten'nittent failure, system is OK
at this time.
Is MIL or‘ ar‘d does it ir‘dicate \ NC
Check for poor connections or
code 21 ?
loose wires at VTEC solenoid
YES valve and ECIWPCM.
l—
VTEC SOLENOID VALVE 1P CONNECTOR
r—
Test the VTEC Solenoid Valve:
1. 'e tr e igr‘itior‘ switd‘ OFF. '1
2. Discorr‘ed the VTEC soler‘oid
valve oor‘r‘edor.
3. Cl" eck for cor‘tir‘ city betweer‘
VTEC soler‘cid valve 1 P I: ol‘ mil
correctortennir‘al No. '1 ar‘d
body groLr‘d.
'ermir‘al side of male termir‘al
NC
a: Is tl‘ ere 14 — 30 oi‘ms? :— Replace th e VTEC solen oid v alve.
YES
VTEC SOLEN OID E CMIPCM CONNECTOR

VALUE HARNESS a (25m
CONNECTOR ”"-
"Elm
L.» we
Test the VTEC Solenoid Valve [GRNNEL]
Wire:
Il‘ce"
Check for oortiroity betweer‘ 9”,...

9-
o:
VTEC soleroid valve 1P correotor

cr
JU '. u '..
tenniral No. 1 ard tl‘e ECMJ'PCM
oor'r ector termir al B12.
Wire side of female
tenniral s
NC Repair open in the wire between

Istl‘ere cortirLity? the ECWPGM [312) and VTEC
solenoid valve connector:
(To page 6-8-4]

4%

#
VTEC Control System
Troubleshooting

* Flowchart

!+
( (F1832, F1833 engines)
/+8":+8"! 0
6-B-4
5"
(cont’d)
/
?0
(From page 6-8-3}
VTE G SOLENOID VALVE CONNECTOR

l_|
Test the VTEC Solenoid
1
'i.i'alve Wire:
Cl‘eek for eor'tir'Lity betweer‘
VTEC soleroid valve oorrector
termir'al No. 1 ar'd body groLr‘d.
YES Repair short in the wire

ls tl‘ ere oortirLity? between the ECMIPCM [B12]:
andVTEc solenoid valve connector
Test the VTEC Solenoid Valve: Wire side of female termir' al

1. Correottl‘eV‘EC soler‘oid
valve oorr eotor.
2. Removetl‘e 10mm bolt. ar‘d
ir stall the special tools as LOW PRESSURE GAUGE
sl‘ owr. 07408-0070001 “~x
. Correct atael‘ometer.
LH-h-ILA
. Starttre ergir e.
. Warm L.p er gire to ronnal
operatirg temperatLre
[ooolirg far Domes or 1.
5. Cl‘eclt oil presee at er gir‘e
speeds of 1 .000. 2,000 ar‘d
4,000 rpm [mir —'1j:
NC'E: Keep measurir‘g time as sl‘ort
as possible because er‘gir‘e is re‘irg
witl‘ r‘o load Ijlesstl‘ ar‘ or‘e mir‘LIe}
NC
- ls presee below 49 kPa
[0.5 kgfi'onz. 7 psi}?
Ins pect the VTEC solenoid valve JH: L1
.' I
_.' '3 OIL PRESSURE GAUGE

»' .' ATTACHEMENT
Test the VTEC Solenoid Valve: DTNAJ -PD T01 00
1. 'e tl'e igritior switel‘ OFF.
2. Diseor'r' eet the VTEC soleroid
valve eor'reetor.
3. Attael' the battery positive
termir'al to tl‘e GRNNELtenniral.
VTEC SOLENOID VALUE
4. Start the ergire ard d‘edc oil
1 P CON N ECTOR
pressue at ergire speed of
3.000 rpm [mir '1 }. l_l
1 'ermir'al side
of
ls pressue above 250 kPa m ale termir'al
Inspect the VTEC solenoid valve
12.5 kgfi'emE. 36 psi]?
Substitute a known-good ECM!

PCM and recheck. ll’syn‘mtom!
{19:0
—
BATTERY
+
indication goes away, replace

the original ECIW POM.
VTEC Control System
4%

# 6_B_5
5"3
Troubleshooting

* Flowchart

!+
( (F20B6 engine)
/+$"5! 0
P1259
'39 The scan tool indicates Diagnostic Trouble Code (DTC) P1259: A problem in the VTEC Pressure
4!(
4 !;(4<59%!:4
Switch circuit or VTEC Solenoid Valve circuit.
3 :4 !:!& -
Before troubleshooting (See Page 11-A—15) to (See Page 11-A—20).
) !
;'!%<;'!%0<-
— The MIL has been reported on.
— DTC P125! is stored.
Check the VTEC Control System:

1 , Do the er gire cortrol l"i odLle
iECM}.-'po-w-eitrair cortrol
l‘TCdLIE (POM: Reset ProoedL. re 'R'Gfld ’331
(see sectior 11 j:. Accelerate ir' 1st gear to ar er gire speed over 5,000 rinp [Mir-1 ].
2, Start tl‘e ergire. l-old tl'at ergir‘e speed for at least two seoor ds.
3_ Warm Lp tre ergire to rormal If the D’C P1259 is r ot repeated dLrirg tre first road test,
operatir g teinperatLre repeat tl'is test two more times.
(coolirg far comes or].
4, Do the Road ’est.‘ lnternittent failure, system is OK
at this time.
Is D’C P1259 irdicated? NC Check for poor connections or
_ loose wires at VTEC pressure
YES switch, VTEC solenoid valve and
ECMI'P CM.
VTEC PRESSURE SWITCH 2P

OONNECTOR
Test the VTEC Pressure Switch: __
1. ’e tl‘e igriticr switd' OFF.
2. Discorrect the VTEC Pressure
Switch 2P corrector.
3. Check fir oortircity betweer‘
VTEC pressure switd‘ 2P
corrector teri‘tir‘al No. '1 ar‘d
No. 2.
lbhn‘]
'eri‘tir‘al side of male
teri‘tir‘ als
--..,_—— NC
< lstl‘ere CM Replace the 1iifTEII) pressure switch.
YE S
VTM
[BLUIBL K]:
Test the VTEC Pressure Switch

Wire:
1. 'e tre igritior switd‘ CN ill}.
2. Measue the voltage betweer'
VTEC presscre switcl‘ 2P
correctcr No. 2 ard bod y Wire side of female
groe. terlnir‘ als
Inspect for an open or shortto

ground in the wire between the
NC VTEC pressure switch and ECM!
ls trere battery voltage? Pm! [610).
If the wire is OK, substitute a
known-good ECWPCM and
(15 page 5343:: recheck.
VTEC Control System
4%

#
Troubleshooting

* Flowchart

!+
( (F20B6 engine) (cont’d)
/+$"5! 0/
?0
6-B-6
5"5
(From page 0-843}

VTEC PRESSURE SWITCH
2P CONNECTOR
Test the VTEC Pres sure

Switch Wire:
M east. re voltage across the VTEC
presee switch 2P corrector
FEW
Kai
Wire side of female termir als
- Repair open in the wire
NC between VTEC pressure
< Is there battery voltage? >— switch and G101.
- If the wire is OK, substitute a
YES known-good ECMIPCM and
recheck.
VTEC SOL EN OID VALUE
1 P CON N E CTOR
1. ’e the igritior switch ICFF.
2. Discorr ect the VTEC soleroid
valve 1P cor rector.
3. Check for cortirLitv betweer
the VTEC soleroid valve 1P
cor redor termiral No. 1 ard
body groe.
'ermi r al side of male termir al
NC
(2:; Is there 14- 30 ohms? l_>—| Replace VTEC solenoid valve
YES
LOW PRESSURE GAUGE
Test the VTEC Solenoid Valve: 07405-0070001 ‘
1. Remove the VTEC pressue
switd‘ ard irstall the special
tool as shown ther reirstall
the VTEC presee switch.
. Reoorr ect the VTEC soleroid
valve 1P corrector ardV‘EC
pressL re switch 2P corrector.
. Correct the tachometer
[see sectior11}.
. Startthe ergire.
. Wann Lp ergire to rormal
operatirg temperatLre
[coolirg far oomes or}. NOTE: Keep meaeirg time as short as
. Chedt oil presee at ergire possible because ergire is reirgwith ro I
speed of1.000. 2.000 ard load (less thar 1 mirLte]. :' OIL PRESSURE GAUGE
i
4000 rpm (mir J]. »' .' ATTACHMENT
DTNAJ-PTM DD
ls presee below 40 kPa NC lnspecttheVTEC solenoid
[0.5 kgfi'dnE. 7 psi} valve [see page 6-5-8).
YES
(To page Ei-B-T]

VTEC Control System
4%

# 6_B_7
5"7
Troubleshooting

* Flowchart

!+
( (F20B6 engine)
/+$"5! 0
(From page e—e-ej: VTEC SOLENOID VALVE

I 1P CONNECTOR
Test the VTEC Solenoid Valve: '_‘
1. _e tl'e igritior switol‘ OFF.
2. Disoor'r'ecttl‘e VTEC soleroid _ . .
valve 1P cor rector. ermlr'al Side Of
3. AttaCl' the battery positive male termir'al
termir'al to tie VTEC soleroid
valve tennir‘al. ,.
4. Start the er‘gire ard d“ eok T-éjwfl'j'
tl‘e pressue at ergire
speed of 3,000 rpm imir 4 i. _ BATTERY
I NC -
ls tl" e pressue above 250 kPa \ Inspect the VTEC solenoid valve
(2.5 kgfi'onQ. 36 psi j:? [see page 5-5-8}
ECMfPCM CONNECTOR
Test the VTEC Pressure Switch: C (31p) 'lr'TM
With the battery positive termir‘al [BLUIBLK]
Cor related to tie VTEC soler‘oid
valve meaSL. re voltage betweer‘
the ECMIPCM cor‘r‘eotor tennir‘al
C1D ard body nLPCI.
Wire side of female termir' al
ls tl" ere battery voltag e NC Replace the VTEC pressure

above 4,000 rpm imir‘ -1 1:? switch
YES WE SOLENOID EClWPCM CONNECTOR

vALvE HARNESS .----—. a (25p)
CWNECTOR [chm sll
Test the VTEC Solenoid ""'-—-"" VTS

‘ul'alve 'ee: ['1 [GRNJ’YE L)
1. 'e the igr‘itior‘ switch OFF.
2. Cl‘eok for cortiruity betweer _2 3 4 5 ? fl
tl‘eV‘EC soleroidvalve. '1P 9.0.. 121314 ‘5‘?‘a
oorreotortenniral ardtl‘e , .
ECMIPCM oorrectortennir‘al :23 13 2425
B12. 'INire side of female te nnir'als

Is were 00% the ECMIPGM "312} andVTEC
YES solenoid valve connector. VTEC SOLENOID
1—1 VALVE CONNECTOR
Test the VTEC Solenoid 1

1li'alve Wire:
Ci‘ eCk tl‘e cortiroit y betwee r' tl‘e
VTEC aoleroid valve 1P
Correctortenniral No. 1 ard ®
body groe.
Repair short in the wire betrveen
solenoid valve connector.
Substitute a known-good ECMI

POM and recheck. If syrnpton-I‘
the original ECIWPCM.
4

&A
!#!!3
9
(See Page 11-B-8)
;'!)'<
4%

4-
VTEC Solenoid Valve
5"8
6-3-8
Inspection

1.
- Disconnect the 1P connector from the VTEC solenoid
(:4 ! 4.
*- If the filter is not clogged, push the VTEC solenoid
!!
A :4 !

valve.
&!&- valve with your finger and check its movement. If
&!&3
#&-
2.
- Measure resistance between the terminal and body
, 3! the VTEC solenoid valve is normal, check the
:4 !&!&!A#
ground.

- engine oil pressure.

! -
R 't :14-309 fix1.Dmm
“I: an“ 12 N-m {1.2 kgI-m, 3.1 Ihmi
D-HING
Replace.
3.
+- If the resistance is within specifications, remove the
3A&
VTEC solenoid valve assembly from the cylinder head,
:4 !&!&!!A
and check the VTEC solenoid valve filter/O-ring for
#:4 !&!&!=8

clogging.
!

-
If there is clogging, replace the engine oil filter and the
!

A!
!!
engine oil.

!-
VTEC SOLENOID
VALUE ASSEMBLY
i)
VTEC SOLENOID
VALVE FlLTE HID-RING
Fl up lat: H.
5 11.1] mm
12 Mr” ”.2 Ital-m. 8.7 Ibf—f‘tl
4%
6
VTEC Rocker Arms
Manual Inspection

6-B-9
5"9 Inspection Using Special Tools

; !

- Set the No. 1 piston at TDC.

-4(- NOTE:
84 9
NA

1&!&- 0 Before using the Valve Inspection Tool, make sure
)
:!&4!A#
NOTE: When installing the cylinder head cover (See
84 92!!
!&; that the air pressure gauge on the air compressor

Page 6-8-45) and (See Page 6-8-46).
'!)*<;'!)*<- indicates over 400 kPa (4 kgf/cm2, 57 psi).
&*00#;*#
=A$<-
3.
+- Push the intake mid rocker arm on the No. 1 cylinder
##-! Inspect the valve clearance before rocker arm
&!&!#
manually.
!!- inspection.
-
4.
*- Check that the intake mid rocker arm moves
###& Cover the timing belt with a shop towel to protect
&
!33!
independently of the primary and secondary intake
!# the belt.
!-
rocker arms.
#- Check the intake primary rocker arm of each
###
Plilllitlilhl’l‘llII ROCKER MID RDCKEFI
cylinder at TDC.
!4(-
ARM ARM Remove the cylinder head cover.
- 1&!&-
NOTE: When installing the cylinder head cover
84 92!!
!&
(See Page 6-B-45) and (See Page 6-8-46).
;'!)*<;'!)*<-
Plug the relief hole with the special tool.
- !
!!3!!-
.-:-"‘-- H5“:-
RELIEF HOLE AIFI STDPPEFI

SECONDARY ROCKER ARM
DTLAJ — PH302U‘I
5.
- Check the intake mid rocker arm of each cylinder at
###!
TDC.
4(-
Q If the intake mid rocker arm does not move, remove
##&A&
the mid, primary and secondary intake rocker arms
A##
as an assembly, and check that the pistons in the
!A#
mid and primary rocker arms move smoothly.
#&!-
If any rocker arm needs replacing, replace the
#!
A!
primary, mid, and secondary rocker arms as an
AA#
assembly.
!-
4%
6
VTEC Rocker Arms
Inspection Using Special Tools (cont’d)

; !
/
?0
6-3-10
5"$
3.
+- Remove the sealing bolt from the inspection hole, and
1&!
!!A 5.
- With the specified air pressure applied, push up
2 !A
connect the special tool.
!!- the timing plate 2 - 3 mm (0.08 - 0.12 in) at plate

!+;0-0'0-<!
NOTE: Remove any oil from the bolt threads and
84 91&!! end; the synchronizing piston will pop out and
NH
3!!
camshaft holder threads before retightening the sealing
!

!
engage the intake mid, primary and secondary

#A
bolt.
!- rocker arms. Visually check the engagement of the
#-: !!#

10 1-: 1.0 mm synchronizing pistons A/B.
H
%=)-
SEALING BOLT NOTE:
84 9
20 N-m l2.0 kgf-m.1l|bf-ftl
¢ The synchronizing pistons can be seen in the
4H

gap between the mid, secondary and primary

3A
rocker arms.
#-
¢ With the timing plate engaged in the groove
2
!

&
on the timing piston, the piston is locked in the

A!#
pushed out position.
-
¢ Do not apply too much force when pushing up
(! 3

the timing plate.

!-
TIMING PLATE
VALUE INSPECTION AIR STOPPER

SET DTLAJ - PREDZU'I
(ITLAJ — PR30101
INSPECTION HOLE
PRIMARY
4.
*- Loosen the regulator valve on the valve inspection tool,

!&!&&!&!A
ROCKER ARM
and apply the specified air pressure to the rocker arm
! # SECONDARY
synchronizing pistons A/B.
H
%=)- ROCKER ARM
Specified Air Pressure:
'F
250 kPa (2.5 kgf/cm2, 36 psi)
3$6'/@36! 2:5 0 Pl-lll'li'llflfi‘lIr ROCKER MID ROCKER SECONDAR‘I”
ROCKER ARM
TIMING
FIST UM
TIMING STNCHRONIZING SYNCHRDMIZING

PLATE PISTON A PISTON E
VTEC Rocker Arms
4%
6 6_B_11

; !
/
?0
5"
6.
- Make sure that the intake primary and secondary rocker
,# ## 7.
$- Stop applying air pressure and push up the timing
!

arms are mechanically connected by the pistons, and

!!A plate; the synchronizing pistons will snap back to
!NH
3!!#
that the mid rocker arm does not move when pushed
#&3 their original positions.

!-
manually.
!!- Visually check the disengagement of the
: !!#

PRIMARY ROCKER MID ROCKER synchronizing pistons A/B.
H
%=)-
NOTE:
84 9
¢ When the timing plate is pushed up, it
2
! A
releases the timing piston, letting the return
!
A!

spring move the synchronizing pistons to their

&H

original positions.

!-
¢ Replace the intake rocker arms as an
1!##
assembly if either does not work correctly.
!3#!-
PRIMARY ROCKER MID ROCKER SECONDARY
ARM ARM ROCKER REM
_ SECONDARY ROCKER ARM .

0 If any Intake mId rocker arm moves Independently
##&! TIMING
of the primary and secondary rocker arms, replace
#A! PISTON
the rocker arms as a set.
#-
TIMING SYNCHRONIZING SVNCHRDNLZING

PLATE PlSTOhl A PISTON B
8.
'- Remove the speCIal tools.
1&!!-
9.
5- Check for smooth operation of each lost motion
#!
assembly. It is compressed slightly when the intake
!-!
!3#
mid rocker arm is lightly pushed and compressed
#!
!
deeply when the mid rocker arm is strongly pushed.
!3#
! -
¢ Replace the lost motion assembly if it does
1!!!
not move smoothly.
&!-
10. %A#,
0- After inspection, check that the MIL does not come
on.
-
4-
Valve Clearance
Adjustment
D
6-B-12
5"
NOTE:
84 9 Adjusting screw location:
D !(

F
9 Valves should be adjusted only when the cylinder head
:!& !7 !3! INTAKE
!+'P;00P <-
After adjusting, retorque the crankshaft pulley bolt to 245
%7
AF # !!!*
Nm (25.0 kgf/m, 181 Ibf/ft).
;-0#
=A'!=<-
- 1&!&-
84 92!!
!&;
Pages 6-8-45) and (See Pages 6-8-46).
'!)*<;'!)*<-
Set No. 1 piston at TDC. “UP” mark on the camshaft
- -4(-K?L#
pulley should be at top, and TDC grooves on the
!! !A4(
&
camshaft pulley should align with the cylinder head
!! !!
3!
surface.
-
Number 1 Piston at TDC:
,*'
)F
”UP" MARK
Nu.4 No.3 No.2 No.1
EXHAUST
5.
- Tighten the locknut and check clearance again.
4
!# #!
-
Repeat adjustment if necessary.
17 -
TDC MARK
+- Adjust valves on No. 1 cylinder.
%7 &!&-!-
Intake:
6F 0.26 mm (0.010 in) 1 0.02 mm (0.0008 in)
$@5/$@$$ 0O$@$/$@$$$8 0
Exhaust:
% 0.30 mm (0.012 in) 1 0.02 mm (0.0008 in)
F $@$/$@$ 0O$@$/$@$$$8 0
*- Loosen the locknut, and turn the adjusting screw until
!# A 7
3 !
the feeler gauge slides back and forth with a slight
!

!#3!

amount of drag.

-
LGCKNUT
'l’ x 0.75 l'l'llTl
2i) N-rn [2 l] Itgf-rn.
1i IbH'tJ
FEELER GAUGE
FEE LER GAUGE ADJUSTING

SCREW
Valve Clearance
4-
D/
?0
6-B-13
5"
6.
- Rotate crankshaft 180° counterclockwise (Camshaft
1#'0P !#3; 8.
'- Rotate crankshaft 180° counterclockwise to bring
1#'0P !#3
pulley turns 90°). The “UP” mark should be on the

!! 50P<-4K?L# ! No. 2 piston to TDC. The "UP” mark should be on
-4(-4K?L# !
exhaust side. Adjust valves on No. 3 cylinder.
/ -%7 &!&-+!- the intake side. Adjust valves on No. 2 cylinder.
#-%7 &!&-!-
,*'
)F Number 2 Piston at TDC:
,*'
)F
“UP" MARK "UP” MARK

7.
$- Rotate crankshaft 180° counterclockwise to bring No. 4
1#'0P !#3
-*
piston to TDC. Both TDC grooves are once again
4(-)4(
&

visible. Adjust valves on No. 4 cylinder.
&!-%7 &!&-*!-
,*'
)F
"LIP" MARK
Crankshaft
6 Pullev and Pullev Bolt
'#'#"
6-3-14
5"
Replacement

When installing and tightening the pulley, follow the procedure below.
2!!

!!A!!3 !3-
Clean, remove any oil and lubricate points shown below.
!A&!! 3!3-
0 9!
: Clean
x : Remove any oil
/91&!
¢ : Lubricate
9
CHANKSHAFI'
PULLEY TlMlNE BELT
DRIVE PULLEY
CRANKSHAFI'
WAS HER
XXXX
XXX
XXX
xxxxxxxxx
XX
XX
O
0
0
0'00
000
000
XXX
XXX
XXXX
XXXXXXXXXI—
XXX
XXX
PULLE‘Ir BOLT
BALANCER
BELT DRIVE F'ULLE\‘r
Crankshaft
6 pulley bolt size and torque valve:
#*
C
B--F
16 x 1.5 mm
5@3
245 Nm (25.0 kgf/m, 181 lbf/ft)
3,/3@$6! 2:8* 2 0
NOTE: Do not use an impact wrench when installing.
84 9( 33!!
-
HANDLE
umna — amazon
HOLDER ATTACHMENT.
HEX b0 rum
OTMAB — FY301OO
SOCKET WRENCH, 19 mm
[ITJAA — OD1DZIDID
!"""
Timinq Belt and Balancer Belt
5"3
6-3-15

Illustrated Index
NOTE:
84 9
How to position the crankshaft and pulley before installing the belt (See Page 6-8-20).
63# !!!!
!;'!)0<-
99999999
Mark the direction of rotation on the belt before removing it.

,#!&
-
Do not use the upper cover and lower cover for storing removed items.
( &!3&
&-
Clean the upper cover and lower cover before installing them.
! &!3&!!
-
Replace the camshaft seals and crankshaft seals if there is an oil leakage.
1!!#!!!#
-
Before installing the timing belt and balancer belt (See Page 6-8-14).
)!!

!!!;'!)*<-
Inspect the lower cover rubber seal for cracks and other damage before installing the lower cover.
!3& !#
!!
!3&-
If the rubber seal is coming off, apply liquid gasket to the lower cover and put the rubber seal back. Wipe off any liquid
!
A!!F
#!3& !#-2!F
gasket that is pressed out.

# -
When replacing rubber seal. clean the lower cover groove, cut the repair rubber seal to length, and put the rubber seal into
2!
!A!!3&
&A !!
A !
the groove evenly.

&&!-
E a 1.0 mrn
9.3 MM [1.0 kgl-m. 7.2 lbl-fll
WASHER ADPIV snapsuds to threads and cylinder head
Replace when damaged CUF‘IlEICl surface when replacing the rubber
or deterrgrated seal, then remove any soepeuds aher install-
ing the rubber seal.
C‘I'LINDEB HEAD RUBBER SEALS

COVER Replace when damaged
Refer to pages 5-3-15, 46 or deteriorated.
when installing.
UPPER COVER
HEN) COVER GASKET __ ..-" __ 5 I 1.0 mm
Fleplace when leaking. fl3= -_ ._ . I2 N-m 11.2 kgf—m, 8.? lbf-Hl
damaged or deteriorated. I . . '
Apply IIgUId gasket at l_.__ " k,
1hefeurcprners eithe ' "
”3633595-
Fleplace when damaged

or deteriorated.
10 x 1.25 mm
LDWEH CG'l-I'EB
59 ”m ”5.0 kgf-m.
43 lbf-fll RUBBER SEAL
Fittplace when damaged
g/nr dete- iorated.
CBANKS HAI-‘l‘ PULLE'lI'

1.", Replacement. page 5-13-14
\ PU LLEY eon
16 x 1.5 mm
12 N-m 41,2 Raff". 245 Mm {250' legf-m.
8.7 Ibf-hl 181 lbl—fll
Replacement. page 6 3-11
Do not use an impact
wrench when installing.
TIMING BE LT
ADJUSTING BOLT 6 a 1.0 mm
E? N-m 46.3 kgf-m. 12 N11: I12 lugf—n‘l,
49 lbf—fll 3.7 Ibr-hl
TIMING BELT 12 run (1,3 gym, ADJUSTING NUT
Inspection. page 6-3-16
8.? lbf-ftl 44 MW! 14.5 kgl-m,
Adjustment. page 5 B 1! 33 Ibl-fll
Removal, page 6-H-1S CKPITDC
Installetlon. page fi-E-ZD SENSORS BALANCEH
BELT
Inspection. page B-B-lB
Remtwal. page 6-5-18
ll'lSlullahgn, page G-B-E‘fl
To go to the pages referenced on the diagram above.

4

&A
!#!!3
9
(See Page 11-8-45)
;'!)*<
(See Page 11-8-46)
;'!)*<
(See Page 11-8-16)
;'!)<
(See Page 11-8-17)
;'!)$<
(See Page 11-8-18)
;'!)'<
(See Page 11-8-20)
;'!)0<
(See Page 11-8-14)
;'!)*<
!"
Timing Belt
Inspection

6-B-16
5"5 Balancer Belt
""
Inspection

,# &A 1.
- Make sure you have the anti-theft code for the
,# &
33F B radio, then write down the frequencies for the
A33F
buttons.
- radio’s preset buttons.
B -
(
&!A 2.
- Disconnect the battery negative terminal first, then
(
&!A
positive terminal.
&!- the positive terminal.
&!-
+- Disconnect the alternator terminal and the connector,
(!!A 3.
+- Disconnect the alternator terminal and the
(!!
then remove the engine wire harness from the cylinder
&
3! connector, then remove the engine wire harness
A&
3
head cover.
&- from the cylinder head cover.
!&-
*- Remove the cylinder head cover.
1&!&- 4.
1&!&-
0 When installing (See Page 6-B-45) and (See Page
2!!
;'!)*<;'! ¢ When installing (See Page 6-8-45) and (See
2!!
;'!)*<;
6-8-46).
)*<- Page 6-8-46).
'!)*<-
- Remove the upper cover.
1& &- - Remove the upper cover.
1& &-
$0.03.“.O‘S"
- Inspect the timing belt for cracks and oil or coolant

!#!! - Remove the crankshaft pulley.
1&# !!-
soaking.
#
- $- Remove the lower cover.
1&!3&-
NOTE:
84 9 '- Install the crankshaft pulley.
!!# !!-
0 Replace the belt if it is oil or coolant soaked.
1!!!!#- 5- Inspect the balancer belt for cracks and oil or
!!#!
1&!!&
!- coolant soaking.
!#
-
lI'ISpC-Ct ll‘1l5 are-a iru wunr.
NOTE:
84 9
¢ Replace the belt if it is oil or coolant soaked.
1!!!!#-
¢ Remove any oil or solvent that gets on the
1&!!&

belt.
!-
Inspem this area for wear,
Flume pulley iii?”

counterclockwise
and inspect bell.
$- After inspecting, retorque the crankshaft pulley bolt to
%
AF # !!! Rutate uh
I: Dun'lurclocl-cwise
245 Nm (25.0 kgf/m, 181 Ibf/ft).
*;-0#
=A'!=<-
and mane-ct belt.
A
10. %
AF # !!!
0- After inspecting, retorque the crankshaft pulley bolt
customer’s radio station presets.
B-
to 245 Nm (25.0 kgf/m, 181 Ibf/ft).
*;-0#
=A'!=<-
11. A
B-
M
!" 6-B-17
5"7
Tensioner Adjustment

D
NOTE:
84 9 7.
$- Loosen the adjusting nut 2/3 - 1 turn.
7
=+ -
¢ Always adjust timing belt tension with the engine cold.
%!37
!3
!- ADJUST'NG “UT fa]
¢ The tensioner is spring-loaded to apply proper tension to
4
!! “ ”m ”'5 “Bi-"1'33 Ibt-m l“
the belts automatically after making the following
! !!#
!!3

adjustment.
7 -
¢ Always rotate the crankshaft counterclockwise when
%!3# !#33
viewed from the pulley side. Rotating it clockwise may
&3 !!-1
!#3
result in improper adjustment of the belt tension.
!7 !-
¢ Inspect the balancer belt before adjusting the belt
!!7
!
tension.
-
¢ Do not loosen the adjusting nut-more than one full turn.
(!7
!! -
1.
,# &A
33F B
buttons.
-
2.
(
&!A
positive terminal.
&!-
3.
(!!A
&
3!
head cover.
&-
4.
*- Remove the cylinder head cover. (See Page 6-8-45)
1&!&-;'!)*< Direction of
(See Page 6-8-46).
;'!)*<- rotatifln- .
5. 1#&/&!
- Rotate the crankshaft five or six revolutions to set the '-
8- 1# !#3
Rotate the crankshaft counterclockWIse three teeth
belt.
!- on the camshaft pulley.
!!-
Set the No. 1 piston at TDC.
6. -4(-
- 5- Tighten the adjusting nut-
9- 4
7
-
10. %7
AF # !!!
0- After adjusting, retorque the crankshaft pulley bolt
to 245 Nm (25.0 kgf/m, 181 Ibf/ft).
*;-0#
=A'!=<-
11. A
B-
!"""

-
Removal
6-B-18
5"8
NOTE:
84 9 -
6. 1&!!-
Remove the alternator terminal and connector.
4 # !!-
dead center (TDC) before removing the belt (See Page
;4(<&
!;'!
6-8-21).
)<-
¢ Inspect the water pump (See Page 10-17).
3 ;'!0$<-
1.
,# &A
33F B
buttons.
-
Disconnect the battery negative terminal.
- (
&!-
PW.“
Remove the splash shield (See Page 5-10).

+- 1&!!;'!0<-
Remove the stop and ground cable, then remove the
*- 1&
!A&
upper bracket (See Page 6-8-28).
#;'!)'<-
NOTE:
84 9
0 Use a jack to support the engine before the upper
?7#

bracket is removed.
#&-
0 Make sure to place a cushion between the oil pan
,# ! 3!
and the jack.
7#-
5.
- Loosen the mounting bolts, then remove the power

!A&3 CONNECTOR 6 x 1.0 mm
steering (P/S) pump belt.

;=< !- 3 him 10.3 kgl-m.
MOUNTING BOLT 6mm
B a 1.25 mm $-
909°.“ Remove the alternator (see section 4).
1&!;*<-
22 film {2.2 kgfim. '- Remove the alternator bracket (See Page 5-16).
1&!#;'!<-
15 lbf-fll
5- Remove the dipstick and the tube.
1&# -
._ P15 PUMP DIPSTICKFI'UBE

- _ _ BELT
MOUNTING BOLT
8 I 1.25 mm
22 N-m 12.2 kgf-ml
16 lbl-fil
6 x 1.0 mm
12 N-m [1.2 ILgf-m,
8.7 lbf—Hl
Ill-RING
Replace.
!"""
Removal (cont’d)

-/
?0
6-B-19
5"9
10. 1&!&-
0- Remove the cylinder head cover. 14. 7
=+ -
*- Loosen the adjusting nut 2/3 - 1 turn. Push the
0 When installing (See Page 6-B-45) and (See Page
2!!
;'!)*<;'! tensioner to remove tension from the timing belt
&
!
6-8-46).
)*<- and balancer belt, then retighten the adjusting nut.
!!A
7
-
11. 1& !!!# !!;'!
- Remove the pulley bolt and crankshaft pulley (See Page
6-B-14).
)*<-
12. 1& &-
- Remove the upper cover.
NOTE: Do not use the upper cover for storing removed
84 9( &
&
-
E I Ll] mm
12 N-m l1 .2 kgl—m.
3.7 lbfvfl]
ADJUSTING NUT
+4 I’ll-m {4.5 Icy-Fm, 33 Ihf‘ftl
NOTE: When removing the balancer belt only:
84 92&
!!!9
¢ Lock the timing belt adjuster arm in place by
#
!7 !
installing one of the 6 x 1.0 mm bolts.
!!
/-0!-
¢ Loosen the adjusting nut 2/3 - 1 turn. Push the
7
=+ -
tensioner to remove tension from the balancer
&!
UPPER COVER
13. 1& !7
A&
+- Remove rubber seal from the adjusting nut, then remove belt, then retighten the adjusting nut.
!A
7
-
E I 1.0 mm BOLT
the lower cover.
!3&-
NOTE: Do not use the lower cover for storing removed
84 9( !3&
&
items.
-
LOWER
COVER
ADJUSTING NUT
u. N-m (4.5 kgf-I‘n.
33 Inf-m
15. 1&!!
!-
- Remove the balancer belt and timing belt.
6 H 1.0 mm
12 N-m [1.2 Icahn,
3.7 l‘ll
!"""
Timing Belt and Balance Belt

Installation
6-3-20
5"$
Install the timing belt and balancer belt in the reverse order of
!!
!!!& 3.
+- Set the camshaft pulley so that the No. 1 piston is
!!-
removal.
&!- at TDC. Align the TDC mark on the camshaft
4(-%!
4(#
Only key points are described here.
8!#- pulley with the back cover upper surface.
!!3#& -
9 When installing only the balancer belt, go to step 13.
2!!
!!!A
+- CAMEHAFI' FULLEY
Cit-tan
NOTE: Clean the upper and lower covers before installation.
84 9! !3&!!- "UP" MARK
1. 1&!!& !!;'!
- Remove the balancer belt drive pulley (See Page
6-B-15).
)<-
2.
!& !!-
- Set the timing belt drive pulley so that the No. 1 piston is
at top dead center (TDC). Align the dimple on the tooth
;4(<-%!
!
of the timing belt drive pulley with the V pointer on the oil

!& !!3:!
pump.
-
POINTER
TDC MARK
lDIMPLEl
TDC MARKS
4.
*- Install the timing belt tightly in the sequence shown.
!!
!
!F 3-
(1) Timing belt drive pulley (crankshaft) to (2)
;<4
!& !!;#<;<
Adjusting pulley to (3) Water pump pulley to (4)
%7
!!;+<2 !!;*<
Camshaft pulley.
!!-
84 9,#
!& !!
camshaft pulley are at TDC.
!!4(-
TIMlNG BELT KEY

DHI'LI'E PULLEV
Dean.
!"""

/
?0
6-B-21
5"
- Loosen and retighten the adjusting nut to tension the

7
11. # !!
- If the camshaft or crankshaft pulley is not
timing belt.

!- positioned at TDC, remove the timing belt and
4(A&
!
Install the balancer belt drive pulley and lower cover.
- !!!!& !!!3&- adjust the positioning following the procedure (See
7
!!3
;
NF”
Install the crankshaft pulley, then tighten the pulley bolt

$- !!# !!A
!!! Page 6-8-20), then reinstall the timing belt.
'!)0<A!!
!-
(See Page 6-8-14).
;'!)*<- 12. 1&# !!!3&-
- Remove the crankshaft pulley and lower cover.
Rotate the crankshaft pulley about five or six turns
'- 1# !! &/ 13.
!& !!-
+- Set the timing belt drive pulley so that the No. 1
!#3
! piston is at TDC.
4(-
pulleys.
!!- 14. #
!7 !
*- Lock the timing belt adjuster arm in place by
9. %7
!;'!)$<-
5- Adjust the timing belt tension (See Page 6-B-17). installing one of the 6 x 1.0 mm bolts.
!!
/-0!-
10. ,# # !! !!
0- Make sure the crankshaft pulley and camshaft pulley are 15. 7
=+ A&
- Loosen the adjusting nut 2/3 - 1 turn, and verify
at TDC.
4(- that the balancer belt adjuster moves freely.
!!7 &!-
16. &
- Push the tensioner to remove tension from the
balancer belt, then retighten the adjusting nut.
!!A
7
-
17. %!
! !!

$- Align the rear balancer shaft pulley by using a
special tool. Insert the special tool into the
!!-!!
maintenance hole to fix the rear balancer shaft.
!/!-
REAR BALANCEH BALANCER SHAFT
SHAFI' LOCK FIN
07 LAG - ”20100
TDC MARK
MAINTE NANCE
HOLE REAR BALANCEFI
SHAFT
‘UP' MARK
MMNTENANCE
HUI LE
WASHER fl'fi-
Replace. 6' _.x BALANCER SHAFT
LOCK PIN
DTLAG - PTZflIflflI
TDD MARKS 12 mm SEALING BOLT
29 Min I31] kgf m. 22 Ibf-Hl
!"""

/
?0
6-B-22
5"
18. %!

&! !!3
'- Align the groove on the front balancer shaft pulley with 24. #!3& !#
*- Check the lower cover rubber seal for cracks and
the pointer on the oil pump housing as shown.
!
3- other damage.

-
GROOVE NOTE:
84 9
¢ If the rubber seal is coming off, apply liquid
!
A!!F
gasket to the lower cover and put the rubber

#!3&
seal back. Wipe off any liquid gasket that is
!#-2!F
#
pressed out.
-
¢ When replacing rubber seal, clean the lower
2!
!A!!3
cover groove, cut the repair rubber seal to
&
&A !
length, and put the rubber seal into the groove
!
A !
&
evenly.
&!-
25. 1&# !!A!!
- Remove the crankshaft pulley, then install the
lower cover.
!3&-
26. !! ! 7
-
- Install the rubber seal around the adjusting nut.
NOTE: Do not loosen the adjusting nut.
84 9(!7
-
27. !!# !!A
!!
$- Install the crankshaft pulley, then tighten the pulley
bolt (See Page 6-B-14).
!;'!)*<-
28. %!!A7 !-
'- After installation, adjust the tension of each belt.
*!!
adjustment.
7 -
¢ See section 22 for air conditioning (A/C)

;%=<
POINTER compressor belt tension adjustment.
!7 -
$= !
adjustment.
7 -
29. A
5- Enter the anti-theft code for the radio, then enter
B-
GROOVE
19. !!!!-7
=+
5- Install the balancer belt. Loosen the adjusting nut 2/3 - 1
turn to tension the balancer belt.
!!-
20. 1&!!!A
0- Remove the special tool from the rear balancer shaft,
then install the 12 mm sealing bolt.
!!!
!-
21. !!# !!A
!!!
- Install the crankshaft pulley, then tighten the pulley bolt
(See Page 6-8-14).
;'!)*<-
22. 4 # !!
- Turn the crankshaft pulley about one turn
counterclockwise, then tighten the adjusting nut.
!#3A
7
-
23. 1&/-0!
!
+- Remove the 6 x 1.0 mm bolt from the timing belt
adjuster arm.
7 -
I'2)

CKP/TDC Sensors
Replacement

6-B-23
5"
- Removal the balancer belt (See Page 6-8-18).
1&!!!;'!)'<-
PONT‘
- Remove the balancer belt drive pulley.

1&!!& !!-
+- Disconnect the CKP/TDC sensors connector, then
(>=4(A
remove the CKP/TDC sensors.
&>=4(-
CKPJTDC SENSORS
CONNECTOR
CKPITDC SENSORS \/
5 x 1.0 mm
12 N-ml12 llgf-n'l.
3.: lbl-l‘ll
*- Install the CKP/TDC sensors in reverse order of removal.
!!>=4(&&!-
.0“?
- Install the balancer belt (See Page 6-8-20).

!!!!;'!)0<-
Cylinder Head
# . 6_B_24
5"

Illustrated Index
NOTE:
84 9
!-
4&
A3 !
2!
!
#A#!
-
?38

#3!
-
6 .I: 1.0 mm
5.5 N-ml1.0 kgf-rn. 12 IbH’tl
Apply snapsuds to threads and cylinder head contact
'JUIfElL'L! when ruplacing the rubber seal. then remove
any enapsude after installing the rubber seal.
CVUNDEH HEAD COVER

Refer to pages 6-8-45. 46 when
nnslalling. WASHER
or deteriorated.
HEAD COVER GASKET

Fleplaco when leaking. damaged
H RUBBER SEAL
Replace whe r1 damaged
or deteriorated.
Apply liquid gasket at the four
or deteriorated.
corners of the recesses, page 6-3-45
CV UNDER HEAD BOLT
Inspeclinn. page 6-5-30
Tightening, page fi-B—ld
S :1 1.26 mm
22 film (22 kgf-m.
16 Ibf-ft]
DISTRIBUTOR
S ee secti o n 4
O-RlNG
Replace. 10 x 1.25 mm
'.lr 44 N‘m “.5 kgf-m,
33 Ibl-l‘ll
JG
CYLINDER HEADM
GASKET %‘
22 N-rn [2.2 kgl-m.
16 lbf—fll
DowEL PIN "if: ' :2?“ \

DDWEL PIN

4

&A
!#!!3
9
(See Page 11-B-45)
;'!)*<
(See Page 11-8-46)
;'!)*<
(See Page 11-8-30)
;'!)+0<
(See Page 11-B-44)
;'!)**<
# .
Cylinder Head
/
?0
6-B-25
5"3
7%
&
!
A!!!!&AA!! -
3 at 1.25 mm
22 N-rl'l I21 Ital-m, 16 Ibf-HI
Apply- engine oil to
ROCKER ARM ASSEMBLV Ihe bnll threads.
Overhaul, page 6-8-31
lllfipuuiifll‘l. page E R 3?
6 :1 1.0 mm
LOCKNUT
12 NM (1.2 kg'I-m,B.'.llbI-I1I
Adjustlr1unl.pagu 5-3-12
OIL CGNTFIDL
OHIFICE VALVE KEEPERS
| 17‘1n—
DOWEL PIN SPRING RETAINER
7“"
\Wé _/ INTAKE VALVE SPfllNG
CAMSHAFT fl INTAKE VALVE SEAL
VALVE SPRING SEAT
1III'TE'C SOLENOID INTAKE VALVE GUIDE

VALVE
FILTER CAMSHAFT II'ULLEHr
Replace. Removal, page 6-3-29
Installation. page 6—8-43
LOST MOTION
ASSEMBLY
VALVE KEEP‘EHS \
SPRING RETAINER
EKHhUST VALVE
SPRING
ExHAUST VALVE SEAL

Replacement. page "IO-RING
E-B-EE Replace. CYLINDER ./7 611.0mrn
HEAD IIII'." 12 N-m [1.2 kgl-rn.
VALVE SPRING SEAT
5.7 lbf-ttl
BACK COVER
EXHAUST VALVE
GUIDE
EXHAUST VALVE
INTAKE VALVE
Removal. page 6-3-36
Installation. page E-El-M

4

&A
!#!!3
9
(See Page 11-B-12)
;'!)<
(See Page 11-8-36)
;'!)+<
(See Page 11-B-41)
;'!)*<
(See Page 11-8-29)
;'!)5<
(See Page 11-B-43)
;'!)*+<
# .
Cylinder Head

-
Removal
6-B-26
5"5
Engine Removal is not required in this procedure.

1&!F - 6.
- Remove the brake booster vacuum hose,
1&#& A
NOTE:
84 9 evaporative emission (EVAP) control canister hose
&&; :%<!
?&&

- and vacuum hoses.
& -
¢ To avoid damage, unplug the wiring connectors carefully
4&
A !
3
!! VACUUM BRAKEBUDSTEH
3!!
- HOSE VACUUNHHDSE
4&

!A3 !
engine coolant temperature drops below 38°C (100°F)<

! !3+'P;00P
!

!-
,#!!3
&-%!A
3
A
3-
- -
N-x
- ,# &A
33F B
buttons.
-
3.
(
&!A
positive terminal.
&!-
4.
*- Drain the engine coolant (See Page 10-7).
(
!;'!0$<-
5.
1&# -
INTAKEAm
EVAP CONTROL
DUCT
CANISTEFI HOSE . .
7.
$- Remove the breather hose and posmve crankcase
1&&#
&!;:<-
PCV HD$E
BHEATHEH
HOSE
Cylinder Head
# . 6-3-27
5"7
Removal (cont’d)

-/
?0
'- Remove the throttle cable and cruise control cable by

1&!! !! 11. 1&
!!#!A
- Remove the mounting bolt and lock bolt, then
loosening the locknuts then slip the cable ends out of
!
!# !! remove the power steering (P/S) pump belt and
&3
;=< !
the accelerator linkage. Take care not to bend the cable
!!#
-4#! pump without disconnecting the P/S hoses.
3
=-
when removing it. Always replace any kinked cable with
3&
-%!3!##!3 MOUNTING BOLT
3-
a new one. 3 x 1.25 mm
ADJUSTING 22 N-m l2.2 kgf-m,
NUT LOCKNUT 1B lbf‘fll
THROTTLE "3,. W5 PUMP

CABLE
ADJUSTING
NUT
s«raw-3 MOUNTING BOLT

CRUISE 3:1 1.25 mm
LDCKNUT CONTROL 22 I'll-m (2.2 kgf-m.
CABLE 115 lbf-fl)
9.
1!& ! ;<- 12. 1&!!-
- Remove the alternator terminal and connector.
0-
10. 1& ! ! -
Remove the fuel feed hose and fuel return hose.
FU EL FEED
HOSE
CONNECTOR 5 x 10 mm
FUEL RETURN WASHERS B N-m [0.5 kgf-m,
HOSE Replace. 2? N~m ‘23 “Him: 6 l-tl
20 lb'l-Hl
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-B-28
5"8
13. 1&!;*<-
+- Remove the alternator (see section 4). 17.
37#3!#
$- Support the engine with the jack and wood block
14. 1& A!3A
*- Remove the upper radiator hose, lower radiator hose, under the oil pan.
!-
heater hose and water bypass hoses.
3- 18. 1&
!A&
'- Remove the stop and ground cable, then remove
the upper bracket.
#-
6 x 1.0 mm 12 x 1.25 mm
11 Nm 11.1 kgf-m, 52 film [5.3 lint-m.
3.0 lbf-f‘ll \ 33 Ibivft]
GROUND
CA BLE
12 at 1.25 mm
52 N-m [5.3 kg'lrm.
38 Ibf-fl]
8 J: 1.25 mm
22 “Pm 12.2 kgl—m,
1E IbH‘rl
HEATER UPPER RADIATOR
HOSE HOSE
LOWER RADIATOR
HOSE
15. 1&
33
- Remove the engine wire harness connectors and wire
harness clamps from the cylinder head and the intake
!!#
manifold.
!-
Four injector connectors.
7-
99999
Intake air temperature (IAT) sensor connector.

# ;%4<- 12 x 1.25 mm STOP
54 um 15.5 kgf-m,
Idle air control (IAC) valve connector.
!!;%<&!&- 4o lbl-f'tl
Throttle position sensor connector.
4!- 19. 1&!&-
,!! ;,%< WASHER
connector.
- CYLlNDEH HEAD
0 Engine coolant temperature (ECT) sensor

! ; 4< COVER
connector.
-
Radiator fan switch A connector.
13%-
99999999
Radiator fan switch B connector

13)
Coolant temperature gauge sending unit connector.
!

-
Exhaust gas recirculation (EGR) connector.
/
!; .1<-
Heated oxygen sensor (H028) connector.
6/
;68<-
CKP/TDC sensor connector.
>=4(-
VTEC solenoid valve connector.
:4 !&!&-
VTEC oil pressure switch connector (F2086
:4 ! 3; 0)
engine).

<-
16. 1&#!

- Remove the spark plug caps and distributor from the
cylinder head.
!-
Cylinder Head
# .
Removal (cont’d)

-/
?0
6-B-29
5"9
20. 1&!!
!;'!
0- Remove the balancer belt and timing belt (See Page +- Remove the intake manifold bracket and
23. 1&#!#
6-8-18).
)'<- thermostat housing mounting bolts.

!-
21. 1& !!#&-
- Remove the camshaft pulley and back cover.
3 x 1.25 mm
BACK COVER 24 N-m l“ kg’lvm.
1? Ibl-Hl
O-FIING
E): 1.25 mm Replace.
CAMSHAFr 24 N-m 12.!- kgf-rn.
PULLEY 11 Ihr-ni
22. 1&/ !#!!#
- Remove the exhaust manifold brackets and self-locking 24. 1&!!-4&
*- Remove the cylinder head bolts. To prevent
nuts.
- warpage, unscrew the bolts in sequence 1/3 turn at
3
A 3!F =+
a time; repeat the sequence until all bolts are
NF !!!!
loosened.
!-
CYLINDER HEAD BOLT LOOSENING SEQUENCE:
>&,)%.%)"&&%,,%=;%,%F
.3" .7: .9. 5: ::.1i'-
EXHAUST
MANIFOLD
BRACKET
GASKETS
Replace.
t a 1'0 '5 '2

10 x 1.25 mm - Remove the cylinder head.
25. 1&!-
44 N«m (4.5 kghm. 33 lbl—Hl
SELF-LGCKING NUT
10 x 1.25 mm
54 Num l5.5 kgfum.
ID lbf-fli
Replace.
Cylinder Head Bolt
# ."
6_B_30 Rocker Arms Assembly

6*#
Inspection

5"$ Removal

-
1.
- Measure the diameter of each cylinder head bolt at point
, !! 1.
- Loosen the adjusting screws, then remove the
7
3A&
A and point B.
%)- bolts and the rocker arm assembly.
!#!-
3 NOTE:
84 9
70 mm ¢ Unscrew the camshaft holder bolts two turns
?3!!3
[2-5 W at a time, in a crisscross pattern, to prevent
AA&
“'—' *4 _ damaging the valves or rocker arm assembly.

&!&#!-
A ‘5 "12‘1““ ¢ When removing the rocker arm assembly, do
2&
#!A
not remove the camshaft holder bolts. The
&!!-4
bolts will keep the camshaft holders, the
!3!!#!A
LE ' —W
. MI 1 springs and the rocker arms on the shafts.

#-
_ .. , . _ I
| ADJUSTING SCREW
2.
- If either diameter is less than 11.3 mm (0.44 in), replace
!-+;0-**<A!
the cylinder head bolt.
!!-
ADJUSTING SCREW
CAMSHAFT HOLDER BOLT LOOSENING SEQUENCE:

Rocker Arms

6 6_B_31
5"
) *#2*#
NOTE:
84 9
O Identify parts as they are removed to ensure reinstallation in the original locations.
& !!
!!-
O Inspect rocker shafts and rocker arms (See Page 6-8-32).
##;'!)+<-
O Rocker arms must be installed in the same positions if reused.
1# !! -
9 When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the
2&
!!
#!A&!!-4!3!!#
holders, springs and rocker arms on the shaft.
!A
#-
”7%
&
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact points.
!
A!!!!&A!! -
Lurlr-ir "A” is stamped I «mm “H' is stamped

on rocker arm, l_:|l'l tucker Jrl‘r‘l,
EXHIfluUST ROCKER SHAFT

EXHAUST ROCKER EXHAUST ROCKER
ARM A ARM B
0—"— . ., D . -- 1—'—U
L
SPRING
ll ii, _ gill-ii “it, _.

No. 1 CAMSHAF‘I’ .. Oil 1 - - | -L-- -.,--" - a] No.5 CAMSHAFI'
HOLDER ELL} - r all HOLDER
i
- I
No.2 g No.3
CAMSHAFT . CAMSHAF‘I’
HOLDER | HOLDER
Tip—g J Lidiagfifi -.i_i1*- ’ ' .

SPRING
RU BBE Fl BA MD
TIMING n u r_‘.- " "-1

PLATE 9;. . . .
INTAKE ROCKER
ARM ASSEMBLY
INTfluKE ROCKER SHAFT
Rocker Arms

6 6_B_32
5"
Inspection

NOTE: When reassembling the primary rocker arm, carefully

84 92!
#A !!
apply air pressure to the oil passage of the rocker arm.
! !
#-
1.
- Inspect the rocker arm piston. Push it manually.
#- !!-
- If it does not move smoothly, replace the rocker
&!A!#
arm assembly.
!-
SVNCHHONIZING
PISTON B
SYNCHHUNIZING
PISTON A
TIMING
SPRING
TIMING
43
SECONDAR‘I’
ROCKER ARM
MID ROCKER
ARM
PRIMARY ROCKER
ARM
NOTE:
84 9
0 Apply oil to the pistons when reassembling.
%!!3!
-
0 Bundle the rocker arms with a rubber band to keep
) !#3 #
them together as a set.

-
NOTE: Set the timing plate and return spring as shown
84 9
!
3
below.
!3-
TIMING PLATE
RETURN SPRING
CAMSHAFT H0 LDE R

6

6-B-33
5"
, ##/ #-
Measure the intake rocker shaft and the exhaust rocker shaft. 3.
+- Measure the inside diameter of the rocker arm,
, #A
-
1. , #
Measure the diameter of the shaft at the first rocker and check it for an out-of-round condition.
# -
!-
location. Rocker Arm-to-Shaft

6
Clearance:
F
l1"_-ipl_‘l,': tucker .'1r|'|| Standard (New):
/,(0F
law: for wear Intake:
6F 0.026 - 0.067 mm
$@$5$@$57
(0.0010 - 0.0026 in)
/$@$$$$@$$5 0
Exhaust:
% F 0.018 - 0.054 mm
$@$8$@$3
(0.0007 - 0.0021 in)
/$@$$$7$@$$ 0
Service Limit:
- & F 0.08 mm (0.003 in)
$@$8/$@$$ 0
MICHOMETEH
2.
- Zero the gauge to the shaft diameter.
I

-
Inspect rocker arm
lama for wear.
Repeat for all rockers.
1!!#-
h“"m.
CYLINDER BORE
- If the clearance is over the limit, replace the
!&!A!
rocker shaft and all over tolerance rocker
#!!&!#
arms.
-
NOTE: If any intake rocker arm needs
84 9##
replacement, replace all three rocker arms in that
!A!!!#
set (primary, mid, and secondary).
;AA<-
MIC RUMETER

Camshaft
Inspection

6-B-34
5"
NOTE:
84 9 *- Remove the bolts, then remove the camshaft
1&!A&
¢ Do not rotate the camshaft during inspection.
(
- holders from the cylinder head.
!!-
¢ Remove the rocker arms and rocker shafts.
1&##- - Lift the camshaft out of the cylinder head,
!A
1.
- Put the camshaft and the camshaft holders on the
! wipe it clean, then inspect the lift ramps.
3!A!-
cylinder head, then tighten the bolts to the specified
!A
! Replace the camshaft if any lobes are pitted,
1!!A
torque.
F - scored, or excessively worn.
A/&!3-
Specified torque:

BF - Clean the camshaft bearing surfaces in the
!

8 mm bolts: 22 Nm (22 kgf/m 16 lbf/ft)
8*
F,/6! 25* 2 0 cylinder head, then set the camshaft back in
!A#
#!

bolt threads
*
place.
!-
6 mm bolts: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)
5*
F,/@6! 2:8@7* 2 0 - Place a plastigage strip across each journal.
!!

7 !-
6 mm bolts (11), (12), (13), (14)
5*
/0:/0:/0:/0 - Install the camshaft holders, then tighten the bolts
!!!A
!
to the specified torque as shown in the left column
F 3!!
of this page.

-
- Remove the camshaft holders. Measure the widest
1&!-, 3
portion of plastigage on each journal.
!

7 !-
Camshaft-to-Holder
Oil Clearance:

.
F
/,(0F 0.050 - 0.089 mm
(0.0020 - 0.0035 in)
/$@$$$$@$$3 0
Service Limit:
- & F 0.15 mm (0.006 in)
$@3/$@$$5 0
2.
- Seat the camshaft by pushing it toward the distributor

3
end of the cylinder head.
!-
3.
+- Zero the dial indicator against the end of the distributor
I!

drive, then push the camshaft back and forth and read
&A #
the end play.
!-
Camshaft
End Play:
%'#F
Standard (New): $@$3$@3
/,(0F 0.05 - 0.15 mm
(0.002 - 0.006 in)
/$@$$$@$$5 0
Service Limit:
- & F 0.5 mm (0.02 in)
$@3/$@$ 0

Camshaft

/
?0
6-3-35
5"3
7.
$- If camshaft-to-holder oil clearance is out of tolerance:
!!! !9 8.
'- Measure cam lobe height.
, !
-
- And the camshaft has already been replaced, you
%!!A Cam Lobe Height/,(0F
&
!!- Unit: mm (in)
?9;<
- If the camshaft has not been replaced, first check
!A# I III Tx'lIIIIIE EXHAUST
total runout with the camshaft supported on
! 3
FIEEIE, FRI 310535 I '1 5'1 WEI]
V-blocks.
:!#-
I.
Camshaft
Total Runout:

F F1 583 MID “.5442;
LU
.‘Lo
. -_ -—-—| ,—.—
/,(0F 0.03 mm (0.001 in) max. E n q i n E E: E: E III:
|'_i_'l |'_I_'|
I'_|I
Service Limit:
- & F 0.04 mm (0.002 in)
$@$/$@$$ 0 FEDEIE PHI 51??)
.
55' .ljj
a::.55403
'
engine MID 38.545I15215I
"'1'
I"- J
LU
_T
SEC 33.91 EI If 'I . EIEI 5'7"]
PRI: Primary ,(9,
19 MID: Mid SEC: Secondary
9
9#
IN: Intake R9 /
EX: Exhaust T/B: Timing Belt
4=)94
)!
PRI MID SEC _
Rotate camshaft
wh-Ie measuring
~— TIB
- If the total runout of the camshaft is within

! 3
!A!!-
! !A!
camshaft and recheck. If the oil clearance is still out
#-!!!!
of tolerance, replace the cylinder head.
!A!!-
III';;_:1_‘:,.',I,"II.*_'~.,'I'I=".". "”' '

4-:4- !4-

-
Removal
6-B-36
5"5
84 9&!&&!&
&
so that each item can be reinstalled in its original position.
!!
!-
1.
- Using an appropriate-sized socket and plastic mallet,
?
H#!!!A
lightly tap the valve retainer to loosen the valve keepers.
!
!&!&!&!&#-
h—u—q
PLASTIC MALLEI
F1832, F20B6 engines:

+8":+$"5! F
64-)

AStandard (New): @9$@$
/,(0F 33.90 - 34.10 mm
(1.335 - 1.343 in)
/@3@ 0
B Standard (New): @833@3
"/,(0F 114.85 - 115.15 mm
(4.522 - 4.533 in)
/@3@3 0
C Standard (New): 3@833@93
/,(0F 5.485 - 5.495 mm
(0.2159 - 0.2163 in)
/$@39$@5 0
C Service Limit:
- & F 5.455 mm (0.2148 in)
3@33/$@8 0
D Standard (New): $@73@3
)/,(0F 0.75 - 1.25 mm
(0.030 - 0.049 in)
/$@$$$@$9 0
D Service Limit:
)- & F 0.55 mm (0.022 in)
$@33/$@$ 0
2.
- Install the valve spring compressor. Compress the
!!&!&
-
spring and remove the valve keepers.

&&!&#-
% 4-)

Exhaust Valve Dimensions
AStandard (New): 8@839@3
/,(0F 28.85 - 29.15 mm
(1.136 - 1.148 in)
/@5@8 0
"/,(0F 112.85 - 113.15 mm
(4.443 - 4.455 in)
/@@33 0
C Standard (New): 3@3$3@5$
/,(0F 5.450 - 5.460 mm
(0.2146 - 0.2150 in)
/$@5$@3$ 0
C Service Limit:
- & F 5.420 mm (0.2134)
3@$/$@0
)/,(0F 0.95 - 1.45 mm
(0.037 - 0.057 in)
/$@$7$@$37 0
Service Limit:
- & F 0.85 mm (0.033 in)
$@83/$@$ 0
VALUE SPRING
COMPRESSOR
07757 — 0010000
4-:4- !4-
Valves, Valve Springs and Valve Seals 6-3-37 Valve Seats
4-
Removal (cont’d)

-/
?0
5"7 Reconditioning

!
F18B3 engine:
+8"! F - Renew the valve seats in the cylinder head using a
13&!&!

64-)
valve seat cutter.
&!& -
A Standard (New): @9$@$
/,(0F 33.90 - 34.10 mm NOTE: If the valve guides are worn (See Page
84 9&!&
3;'!
(1.335 - 1.343 in)
/@3@ 0 6-8-39) replace them, (See Page 6-8-40) before
)+5<!A;'!)*0<
"/,(0F 114.85 - 115.15 mm cutting the valve seats. .

&!&-
(4.522 - 4.533 in)
/@3@3 0
C Standard (New): 3@833@93
/,(0F 5.485 - 5.495 mm
(0.2159 - 0.2163 in)
/$@39$@5 0
C Service Limit:
- & F 5.455 mm (0.2148 in)
3@33/$@8 0
)/,(0F 0.75 - 1.25 mm
(0.030 - 0.049 in)
/$@$$$@$9 0
D Service Limit:
)- & F 0.55 mm (0.022 in)
$@33/$@$ 0
Exhaust
% Valve Dimensions
4-)

A Standard (New): 8@9$9@$
/,(0F 28.90 - 29.10 mm
(1.138 - 1.146 in)
/@8@5 0
"/,(0F 112.85 - 113.15 mm
(4.443 - 4.455 in)
/@@33 0
C Standard (New): 3@3$3@5$
/,(0F 5.450 - 5.460 mm
(0.2146 - 0.2150 in)
/$@5$@3$ 0
C Service Limit:
- & F 5.420 mm (0.2134 in)
3@$/$@ 0
D Standard (New): @33@83
)/,(0F 1.55 - 1.85 mm - Carefully cut a 45° seat, removing only enough
!! *PA&
!

(0.061 - 0.073 in)
/$@$5$@$7 0 material to ensure a smooth and concentric seat.
! -
D Service Limit:
)- & F 1.45 mm (0.057 in)
@3/$@$37 0 +- Bevel the upper edge of the seat with the 30°
)&!
3+0P
cutter and the lower edge of the seat with the 60°
!3
30P
cutter. Check the width of the seat and adjust
-#37
accordingly.

!-
*- Make one more very light pass with the 45° cutter
,#&!
3*P
to remove any possible burrs caused by the other
&!
cutter.
-
Valve Seat Width:F
4-1
Standard (New): @3@33
/,(0F 1.25 -1.55 mm
(0.049 - 0.061 in)
/$@$9$@$5 0
Service Limit:
- & F 2.00 mm (0.079 in)
@$$/$@$79 0
3‘30 D
f
SEAT WIDTH ——J."-— .-—— '
Valve Seats
4-
Reconditioning (cont’d)

!/
?0 6-B-38
5"8
- After resurfacing the seat, inspect for even valve
%
A&&!& $- Insert the intake and exhaust valves in the head
#/ &!&
seating: Apply Prussian Blue compound to the valve

9%! )! &!& and measure valve stem installed height.
&!&!!
-
face. Insert the valve in its original location in the head,
-&!&
!!A Intake Valve Stem Installed Height:
64-. ! F
then lift it and snap it closed against the seat several
!!
&! /,(0F 46.75 - 47.55 mm
Standard (New): 5@737@33
times.
- (1.841 - 1.872 in)
/@8@87 0
ACTUAL __ _ . Service Limit:
- & F 47.80 mm (1.882 in)
7@8$/@88 0
SEATING / Exhaust
% Valve Stem Installed Height:
4-. ! F
SURFACE Standard (New): 5@587@8
/,(0F 46.68 - 47.48 mm
(1.838 - 1.869 in)
/@88@859 0
l— Service Limit:
- & F 47.73 mm (1.879 in)
7@7/@879 0
7
”I"
VALVE
SEAT | VALVE STEM
INSTALLED HEIGHT
mussmm BLUE COMPOUND

- The actual valve seating surface, as shown by the blue
4 !&!&
A3!
compound, should be centered on the seat.
A !-
0 If it is too high (closer to the valve stem), you must

;!&!&<A
make a second cut with the 60° cutter to move it
# 30P &
down, then one more cut with the 45° cutter to
3A 3*P
restore seat width.
3-
0 If it is too low (closer to the valve edge), you must
!3;!&!&
<A
make a second cut with the 30° cutter to move it
# 3+0P & '- If valve stem installed height is over the service
&!&!!
&&
up, then one more cut with the 45° cutter to restore
A 3*P limit, replace the valve and recheck. If it is still over
!A!&!&#-!!&
seat width.
3- the service limit, replace the cylinder head; the
&!A!!N
NOTE: The final cut should always be made with the 45°
84 94! !!33*P valve seat in the head is too deep.
&!&-
cutter.
-
# .24- 6_B_39 Valve Guides
4-
Cylinder Head/Valve Guides
Warpage
1!
5"9 4-
-
Valve Movement
NOTE: If camshaft-to-holder oil clearances are not within

84 9!!!3 Measure the guide-to-stem clearance with a dial
,
!3!
specifications, (See Page 6-B-34), the cylinder head cannot
A;'!)+*<A! indicator while rocking the stem in the direction of
3!#

be resurfaced.
- normal thrust (wobble method).
! ;3!<-
If camshaft-to-holder oil clearances are within specifications,
!!!3A Intake Valve Stem-to-Guide Clearance:
64-
F
check the cylinder head for warpage.
#!3
- Standard (New):
/,(0F 0.04 - 0.09 mm
$@$$@$9
¢ If warpage is less than 0.05 mm (0.002 in) cylinder head
3
!0-0;0-00<! (0.002 - 0.004 in)
/$@$$$@$$ 0
resurfacing is not required.

F - Service Limit:
- & F 0.16 mm (0.006 in)
$@5/$@$$5 0
¢ If warpage is between 0.05 mm (0.002 in) and 0.2 mm
3
30-0;0-00<0- Exhaust
4-
F
(0.008 in), resurface the cylinder head.
;0-00'<A !- Standard (New):
/,(0F 0.11 - 0.16mm
$@$@5
¢ Maximum resurface limit is 0.2 mm (0.008 in) based on
,/ !0-;0-00'< (0.004 - 0.006 in)
/$@$$$@$$5 0
a height of 100 mm (3.94 in).

00;+-5*<- Service Limit:
- & F 0.24 mm (0.009 in)
$@/$@$$9 0
PRECISION STRAIGHT EDGE Valve extended 1:) mm out from seat.
w...
0 /&!A#

If measurement exceeds the service limit, recheck
using a new valve.

3&!&-
0 If measurement is now within the service limit,
33&!A
reassemble using a new valve.
!
3&!&-
0 If measurement still exceeds the limit, recheck
!!/!A#
using the alternate method below, then replace the

!!3A!
valve and guide, if necessary.
&!&
A-
84 9%!#

! 8-(-&!&A
3A-(-&!&

A 3!!
gauge.

-
Take the measurements in three places along the valve
4# !!
&!&
stem and three places inside the valve guide.
!&!&
-
The difference between the largest guide measurement
43!

and the smallest stem measurement should not exceed
!! !/
Measure along edges, and three ways across center.
, !

A3- the service limit.
&!-
# .. ! F Intake Valve Stem-to-Guide Clearance:
64-
F
Standard (New):
/,(0F 99.95 - 100.05 mm
99@93$$@$3 Standard (New):
/,(0F 0.020 - 0.045 mm
$@$$$@$3
(3.935 - 3.939 in)
/@93@99 0 (0.0008 - 0.0018 in)
/$@$$$8$@$$8 0
Service Limit:
- & F 0.08 mm (0.003 in)
$@$8/$@$$ 0
Exhaust
4-
F
Standard (New):
/,(0F 0.055 - 0.080 mm
$@$33$@$8$
(0.0022-0.0031 in)
/$@$$$@$$ 0
Service Limit:
- & F 0.12 mm (0.005 in)
$@/$@$$3 0
Valve Guides
4-
Replacement

6-B-40
5"$ Reaming
!
NOTE:
84 9 NOTE: For
3&!&
!-
!A!0P;+00P 1.
- Coat both reamer and valve guide with cutting oil.
&!&
3
!-
&
!!

- 2.
1!#3 !!!

¢ It may be necessary to use an air hammer to remove
& valve guide bore.
&!&
-
some valve guides.
&!&
- 3.
!#33!
A CAUTION 94 4.
*-
removing it from the bore.
&
-
Thoroughly wash the guide in detergent and water
4
!3

3
&
-
avoid burns, use heavy gloves when handling heated cylinder
& A &
!&3!
!
head.
- 5.
- Check the clearance with a valve (See Page
#!3&!&;'!
1.
(&&!&
! 6-B-39).
)+5<-
head.
- - Verify that the valve slides in the intake and
:&!&!#
VALVE GUIDE DRIVER. exhaust valve guides without exerting
/ &!&
3 /

5.5 mm pressure.
-
01142 - 0010100 VALUE lELIIDE REAMER. 5.525 mm HEAMEH HANDLE
1 [iiiI HAH — F‘J 1'01 DD
Tum rcarncl in
clockwise direction
'— l 61 {..' x I
-
2. (&3&!&
-
Drive in a new valve guide to the specified depth.
f
[ix
IIll --J
F. /
"‘kfi
IIII
[xx-
(”I—Rx.
115?
--:F_____.--“ ‘ L
lj—f -...‘FF—
mm
k"- g
..’":
VALVE GUIDE 0DRIVER. 5.5
077‘2—001010
A}, -._-_-_.__

4- . ! F
Intake:
6F 21.20 - 22.20 mm (0.835 - 0.874 in)
@$@$/$@83$@87 0
Exhaust:
% F 20.63 - 21.63 mm (0.812 - 0.852 in)
$@5@5/$@8$@83 0
i w
VALVE GUIDE—.._ Measure hem
7/ X/fff U/f/
Valves, Valve Sprinqs and Valve Seats
4-:4- !4- 6_B_41
5"

Installation
- Coat the valve stems with engine oil. Install the valves in
&!&3
!-!!&!& 4.
*- Install the valve spring and valve retainer, then
!!&!&
&!&A
the valve guides.
&!&
- install the valve spring compressor. Compress the
!!&!&
-
NOTE: Make sure the valves move up and down
84 9,# &!&& 3 spring and install the valve keepers.

!!&!&#-
smoothly.
!- NOTE: Place the end of the valve spring with
84 9!&!&
3
!!
!- closely wound coils toward the cylinder head.
!!3 !3!-
+- Install the valve seals using the valve guide seal installer.
!!&!&!
&!&
!!!-
NOTE: Exhaust and intake valve seals are not
84 9 / #&!&!
interchangeable.

!-
WHITE BLACK
SPRING SPRING
INTAKE VALVE SEAL EXHAUST VALVE SEAL
STEM SEAL DRIVER

VALVE SPRING
HTPAD - 0010000
COMPRESSOR
NOTE: Use 5.5 mm side. 01751 - 0010000
5.
- Lightly tap the end of each valve stem two or three

!&!&3
times with a plastic mallet to ensure proper seating
3!!!
of the valve and valve keepers.

&!&&!&#-
NOTE: Tap the valve stem only along its axis so
84 94&!&!!
/
you do not bend the stem.
-
PLASTIC
MALLET
VALVE SEAL
Heplace.
2
6
Camshaft/Rocker
Arms and Camshaft
6-B-42
5"
2'#
Seal/Pulley

Installation
1.
- After wiping down the camshaft and journals in the
%3
37 ! - Set the rocker arm assembly in place and loosely
#!!!!
cylinder head, lubricate both surfaces and install the
!A! !! install the bolts.
!!!-
camshaft and camshaft seal.
!- - Make sure that the rocker arms are properly
,# #!
2.
- Clean and install the oil control orifice with a new O-ring.
!!!!!338
- positioned on the valve stems.
&!&-
- Tighten each bolt two turns at a time in the
4
!3
,-
sequence shown below to ensure that the rockers
F 3!3 #
/z" I Ik“-.
OH CEONTR
DILIF‘IC nLfif E
L (WW_.-_
— '___ do not bind on the valves.
&!&-
Clean. Specified torque:

BF
D-RING 8 mm bolts: 22 Nm (2.2 kgf/m, 16 lbf/ft)
8*
F,/@6! 2:5* 2 0
Replace. Apply engine oil to the
#!

bolt threads.
*
@
CAMSHAFI’ 6 mm bolts: 12 Nm (1.2 kgf/m. 8.7 lbf/ft)
5*
F,/@6! 2@8@7* 2 0
KEYWEV up. 6 mm bolts: (11), (12), (13), (14)
5*
F/0:/0:/0:/0
g. ._a .- -._.2' £62: at; H
&
E !!-

Lubricate cam lobes after reassembly.
3.
+- Turn the camshaft until its keyway is facing up. (No. 1
4 !#3
-;-
piston TDC).
4(<-
4.
*- Apply liquid gasket to the head mating surfaces of the
%!!F
#

No. 1 and No. 5 camshaft holders.
--!-
- Apply liquid gasket to the shaded areas.
%!!F
#-
No. 5 No.1
2
6 6-3-43 Cylinder Head
# .
Camshaft/Rocker
2'#
Seal/Pulley
Arms and Camshaft
5"

Installation

/
?0
7.
$- Check the back cover rubber seal for cracks and other
##& !# Install the cylinder head in the reverse order of removal:
!!!&&!9
damage.

- NOTE:
84 9
NOTE:
84 9 O Always use a new head gasket.
%!3 3
#-
0 If the rubber seal is coming off, apply liquid gasket
!
A!!F
# O Cylinder head and cylinder block surface must be
!!!#
to the lower cover and put the rubber seal back.
!3& !#- clean.
!-
Wipe off any liquid gasket that is pressed out.
2!F
# - “UP” mark on the camshaft pulley should be at the
K?L# !! !
0 When replacing rubber seal, clean the lower cover
2!
!A!!3& top.
-
groove cut the repair rubber seal to length, and put

& !!
A Turn the crankshaft so the No. 1 piston is at TDC
4 #-4(
the rubber seal into the groove evenly.
!
&&!- (See Page 6-8-20).
;'!)0<-
0 After putting rubber seal check the jointing parts of
%
!#7
Do not use the upper cover and lower cover for
( &!3&
the rubber seal. Apply liquid gasket if there is any
!-%!!F
# storing removed items.

&-
gap or opening.

- Clean the upper cover and lower cover before
! &!3&
8.
'- Install the back cover.
!!#&- installation.
!!-
9.
5- Install the camshaft pulley onto the camshaft, then
!! !!A Cylinder head dowel pins must be aligned.
- !3! !
-
tighten the retaining bolt to the torque shown.

!F 3- CYLINDER HE AD
CAMS HAFT GASKET
PIE-place.
BACK COVER PULLEV
5 :I: 1.0 mm ‘ID I 1.25 mm

9.3 ”111 [1.0 kgi'm, 59 N-rrl I51] kgf-m.
12 it] HIM-HI
E x 1.0 mm
12 N-rn {1.2 inf-m. 3.7 Ibffll
# .
Cylinder Head

/
?0
6-3-44
5"
- Position the camshaft correctly (See Page 6-B-20).
!;'!)0<- 5.
- Mark the bolt head and the cylinder head as shown.
,#!!3-
.00.“
+- Apply clean engine oil to the threads of the cylinder head

%!!
!!
bolts.
!-
*- Tighten the cylinder head bolts is sequence to 29 Nm
4
!!F 5
(3.0 kgf/m, 22 Ibf/ft).
;+-0#
=A!=<-
NOTE:
84 9
0 We recommend using a beam-type torque wrench.
2
F 3-
When using a preset-type torque wrench, be sure
2
F 3A
to tighten slowly and not to overtighten.

!3!&
-
0 If a bolt makes any noise when you are torquing it,
!#3 F
A
loosen the bolt, and retighten it.
!!A
-
:.‘!_:.- 126.. '1. .14. ’0
HEAD
"._—
6.
- Tighten the cylinder head bolts until the mark on
4
!! !#
,__—
.—-—
|_.. ,._r
the bolt head align to the mark on the cylinder

!!
#!
|_
head (turn the bolt 90°) twice.

; !50P<3-
:
NOTE: If using a new cylinder head bolt, tighten

84 9
3!!A

the bolt 90° further.
!50P -
7.
$- Tighten the intake manifold bracket mounting bolt
4
#!#
!
and thermostat housing mounting bolts (See Page

!;'!
6-8-29).
)5<-
8.
'- Install the exhaust manifold bracket and the
!!/ !#
exhaust pipe A, then install the cover (See Page
/ %A!!&;'!
6-8-29).
)5<-
Cylinder Head
# . 6-3-45
5"3

/
?0
9.
5- Install the timing belt (See Page 6-8-20).
!!
!;'!)0<- 12. %!!F
#&
#
- Apply liquid gasket to the head cover gasket at the
Adjust the valve clearance (See Page 6-8-12).
10. %7 &!&!;'!)<-
0- four corners of the recesses.
-
Install the head cover gasket in the groove of the
11. !!&
#
&
- NOTE:
84 9
cylinder head cover. Seat the recesses for the camshaft
!&- ' Use liquid gasket, Part No. 08C70-K0234M,
?!F
#A-0'$0>0+*,A
first, then work it into the groove around the outside
A3#
& 08C70-K0334M, or 08070 -X0331S.
0'$0>0++*,A0'$0R0++-
edges.

- ' Check that the mating surfaces are clean and
#
!
NOTE:
84 9 dry before applying liquid gasket.
!
!F
#-
0 Before installing the head cover gasket, thoroughly
)!!
&
#A
! ' Do not install the parts if five minutes or more
(!!&
clean the seal and the groove.
!!
&- have elapsed since applying liquid gasket.
&!!
!F
#-
0 When installing, make sure the head cover gasket
2!!
A# &
# Instead, reapply liquid gasket after removing
A!!F
#&

is seated securely in the corners of the recesses
! old residue.
! -
with no gap.
3
- ' After assembly, wait at least 30 minutes
%!A3!+0
CORNERS 0F before filling the engine with oil.
!!

3!-
THE RECESS _ ..v:
HEAD COVER GAEKET
Clean.
Apply liquid gasket In

the shaded areas.
CO FINE H5 DF \
THE RECESS
CYLINDER HE AD
COVER
Cylinder Head
# . 6-3-46
5"5

/
?0
13. 2!!
!&A!
+- When installing the cylinder head cover, hold the head 14. 4
3-!
*- Tighten the nuts in two or three steps. In the final
&
#
&!

step, tighten all nuts, in sequence, to 9.8 Nm (1.0
A
!! AF A5-';-0
!
; kgf/m, 7.2 lbf/ft).
#
=A$-!=<-
semicircles).
84 9%!A3!+0
Set the spark plug seal on the spark plug pipe. Once the
#!
!#!
-8 before filling the engine with oil.
!!

3!-
cylinder head cover is on the cylinder head, slide the
!&!A! 5 -Ci'2:- 4
cover slightly back and forth to seat the head cover
&!
!#&
gasket

#-
NOTE:
84 9
)!!
!&A!
!
33!-
( 3!F
#3
applied.
!-
0 Take care not to damage the spark plug seal when
4#
#!
!3
installing the cylinder head cover.
!!
!&-
0 Visually check the spark plug seal for damage.
: !!##!
!
-
0 Replace the washer when damaged or deteriorated.
1!33
-
5:: LI] mm
9.3M- . It - . . - . .
CVUNDEH HEAD m” 0 mm ”Mm 15. %!!A#!! A
- After Installation, check thatall tubes, hoses and
!!!-
WASHER 16. A
B-
SPMK PLUG
SEAL
Special Tools

6_C_2
5
O 1- O| Tool Number
4! O Description
( |Qty
OD O Remark
1#
O O| 07HAH -PJ70100
:!&. 1A- |
O O
_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\
O O| 07JAA — 0010200
0$"%%00000 O Socket Wrench, 19 mm
#2A5 |
O O
O + O| 07JAB - 0010200
0$"%)00000 O Handle
6! |
O O
O * O| 07JAB - 0010400
0$"%)000*00 O Pulley Holder Attachment, HEX 50mm
!!6!%A6 R0 |
O O
O O| 07LAG- PT20100
0$%.4000 O Balancer Shaft Lock Pin
)!# |
O O
O Oi 07LAJ — PR30101
0$%"1+00 O Valve Inspection Set
:!& |
O O
O $ O 07LAJ — PR30201
0$%"1+00 O Air Stopper
% |
O O
O ' O| 07LAK - PR30100
0$%>1+000 O Oil Pressure Gauge Attachment
8! .
% |
O O
O 5 O| 07MAA- PR701OO
0$,%%1$000 O Tappet Adjuster Wrench Set
4%7 2 |
O O
O 0 O| 07NAG - P130100
0$%.+000 O Timing Belt Slider
4
)!! |
O O
O O| 07PAD - 0010000
!(& |
O O
O O| 07406 - 0070001
0$*000$000 O Low Pressure Gauge
3 .
|
O O
O + O| 07742 - 0010100
:!&. (&A- |
O O
O * O| 07757 — PJ10100
0$$$"000 O Valve Spring Compressor Attachment
:!&
% |
O O
O O| 07757 - 0010000
:!&
|
O O
[E] {I} :_'_§_"I ii} Ijjl

ll-‘i'l
I "I
g'
Vii:
I:
Variable Valve Timinq and Valve Lift
4 *4- !4-& 6_C_3
5
%

/4%0

#

*
!+
(
Troubleshooting
Flowchart
P1259
'39 The scan tool indicates Diagnostic Trouble Code (DTC) P1259: A problem in the VTEC Pressure
4!(
4 !;(4<59%!:4
Switch circuit or VTEC Solenoid Valve circuit.
3 :4 !:!& -
Before troubleshooting (See Page 11-A—15) to (See Page 11--A—20)
) !
;'!%<;'!%0<
- The l'lr'llL has been reported on.
- DTC P1259 is stored.
Check the 1tr'TEC Control System:

1. Do the engine control rrodule
[ECM] Reset ProoedLre (see - Road Test:
2 gamriutpeflelngine Accelerate ih 1st gearto ar ergire speed overEfllJlJ rpm [mir' -1].
3- Wanr up the engine to nonral l-old that Bl‘glr‘EqSPEBEl for at least two seoor‘ds.
operating terrperature I‘oooling Ifthe D C P1 24.. is hot repeated dLrIrg th e first road test,
fan oolr'es on}. ‘ repeat this test two more times.
4- DC' the Road 135“ lnten-nittent failure, system is OK

at this time.
Is D’C P1259 irdicated? NC Check for poor connections or
loose wrres atVTEC pressure
YES switch, VTEC solenoid valve and
ECM.
VTEC PRESSURE SWITCH 2P

CONNECTOR
Test the VTEC Pressure switch:
1. ’e the igritior switch OFF.
2. Dis ooh red th e VTEC Presee
switch oohredor.
3. Check for cortirLity betweer‘
VTEC pressure switch ooh hedor
termihal No. 'l ard No. 2. _____
{ohm}
'ermir‘ al side of male

termir‘als
'.— . . NC
{ is there om Replace the VTEC pressure switch.
YES
vrM
[BL ursL K]:

Wire:
1. 'e the igritior switch CN {ll}.
2. M eaee the voltage betweer
VTEC presee switch oohhector
No. 1 ar'd body groe.
Wire side of female

termir'als
Inspect for an open or short to
ground in the wire between the
: lstherebatteryvoltage'?’ > NC VTECpressureswitchandECM
' (C1D).
YES lfthe wire is OK, substitute a
known-good ECM and recheck.
(To page 6-0-4}
4%

#
VTEC Control System
Troubleshooting

* Flowchart

!+
( (cont’d)
/
?0
6-C-4
5
(From page 643-3] VTEC PRESSURE SWITCH

2P CONNECTOR.

Wire:
M eaSLre voltage across the V'EC
pressue switch 2P cohheotor.
@
Wire side of female
tennirals
Repair open in the wire
-
between VTEC pressure switch
.Q Is there battery voltage? _>—NC and G101 .
If the wire is OK, substitute a
YES
-
known-good ECM and recheck
VTEC SOLENOID VALUE
1P CONNECTOR
l_|
1. ’e the igr‘itior‘ switch OFF. 1
2. Disoorrect the V‘EC soleroid
valve 1P oor'r‘ector.
3. Check for OSPtiPLity bet'weer‘
the V’EC solehoid valve 1P
oorredortermir'al No. 1 ahd
bodv groLr‘d.
'ermir' al side of
male te rmi r' al
Nc
|sthere14 — 30 ohm? Re plaee VTEC solenoid valve. l
YE s LOW PRESSURE GAUGE

; _,.. 1,; 07406 _ 0070001
€512;

1. Removethe 10 mm bolt ahd
irstallthe special tool as
shown {'— g-i
. Reoorrect the V‘EC solehoid WAS HER
valve 1P corrector ahd V'EC a
Replace. \Kfid;
.r‘v
presee switch 2P oohhector.

. Correctthe tachometer [SEE “@-
sectior 11 1.
X . r
. Start the ergihe. OIL PRESSURE
(II-h-
. Warm L.p ergihe to hormal \ GAUGE ATTACHMENT

operatirg temp eratL. re I: ooolirg \ 07LAK-PR30100
far comes or}. SEALING BOLT
. Check oil pressure at ehgir'e 20 N.n1(2.0 kgf.m_. 14 mm)
III
speed of1.000. 2.000 ahd

5,000 rpm (mir-‘l j:. NC'E: Keep meaeirg time as
short as possible beoaLse
ergire is reirg with re
load [less thar ore mirLIe}.
ls presee below 49 kPa NO Ins peet the 1ii'TEIi: solenoid valve

(0.5 kgfi'cmE. T psi]? [see pa ge E-C-E}.
YES
(To page G-C-fi':

To go to the page referenced on the diagram above, click on the following:
4

&A!#!!3
9
(See Page 6—C-6)
;'!<
4%

#
VTEC Control System
Troubleshooting

* Flowchart

!+
( (cont’d)
/
?0
6-C-5
53
(Front page 0-0-4] VTEC SOL EN OID VALVE

1 P CONN E CTOR
Test the VTEC Solenoid Valve: |_|
1. Wm tl‘e ignition switd" OFF.
1
2. Disoornedtl'e VTEC sdenoid
_erlniral side of
valve 1P connector.
Inale tennir al
3. Armor tl‘e battery positive tenr'inal
totl'e VTEC solenoid
valve terir'inal.
4. Start its engine and Creek the —CJ CI
oil pressure at engine speed cf
12 v
5000 rpm“ (win-1].
BATTERY
Is the presee above 250 kPa Inspect the VTEC solenoid valve
[2.5 kgfi'onfl. 36 psi]? (see page 543—5).
YES EClWPCM CONNECTOR

Test the VTEC Pressure Switch: 0 (31m
Wrtl‘ tl‘e battery positive termir‘ a|
3-1
oorreoted to tie VTEC soler‘ oid VTM
valve. IneaSLre voltage betweer‘ [BL UIBL K]:
the ECM oorreo‘tortermir‘al C10
ar'd the body groe.
V
Wire side of
female termir‘al
Is Here battery voltage above Replace the VTEC pressure

5,000 rpm [Mir-1}? switch.
YES
V TE C SOLE NOID ECMI'P CM CON N ECTOR
VALVE HARNE SS _..-—-. _— B [2 5P}
Test the VTEC Solenoid Valve CONNECTOR —1' ohn‘
Wire: VTS
1. 'e tl‘e igritior switd" OFF. [GRNI‘I’ EL}
2. Cl‘ ed: for oortirLity betweer‘
the VTEC soleroid valve 1P
oorreotor termiral ard tl‘ e
ECM oorreotortermiral B12.
Wire side of fem ale

Repair open in thewire between terlnirals
< lstl'ere mm the ECM {312) and VTEC solenoid
valve oonneotor.
YES
VTEC 5 0L EN DID VALVE
1 P CON N ECTOR
Test the VTEC Solenoid Valve I_I
Wire:
cred: for oortirLity betweer the 1
VTEC soleroid valve 1P oorrector
tenniral No. 1 ard body
groL rd.
YES Repair short in the wire between

Is 0' ere oortirLit'y’? the ECM {B12} and VTEC solenoid
valve oonneotor. Wire side of female
NC
tennir al
Substitute a known-good ECM
and recheck. If symptom!
indication goes away, replace the
original ECM.
To go to the page referenced on the diagram above, click on the following:
4

&A!#!!3
9
(See Page 6—C-6)
;'!<
4%

4-
VTEC Solenoid Valve
Inspection

6-C-6
55
- Disconnect the 1P connector from the VTEC solenoid
(:4 ! 4.
*- If the filter is not clogged, push the VTEC solenoid
!!
A :4 !

valve.
&!&- valve with your finger and check its movement. If
&!&3
#&-
- Measure resistance between the terminal and body
, 3! the VTEC solenoid valve is normal, check the
:4 !&!&!A#
ground.

- engine oil pressure.

! -
Resistance: 14 - 30 ohms
F$
6 x 1.0 mm
12 film ”.2 kgf-m. IL? lbi-fli
CI—RI-NG
Replace.
C
£91
+- If the resistance is within specifications, remove the
3A&
VTEC solenoid valve assembly from the cylinder head,
:4 !&!&!!A
and check the VTEC solenoid valve filter for clogging.
#:4 !&!&!!

-
If there is clogging, replace the engine oil filter and the
!

A!
!!
VTEC PRESSURE
engine oil.

!- SWITCH
VTEC souanom VALVE 22 N-m [2.2 kgi-m.
ASSEMBLY 16 Ihl-HJ
1lul'TEll; SOLENOID VALVE

HLTER
Replace.
6 x 1.0 mm
12 N-m [1.2 kgfim. 3.? Ihf-f‘ll
4%
6
VTEC Rocker Arms
Manual Inspection

6-C-7
57 Inspection Using Special Tools

; !

A CAUTION
- Set the No. 1 piston at TDC.
-4(-
NA

1&!&-
84 92!!
!&; ¢ Before using the special tool (Valve Inspection
)
!!;:!&
Page 6-0-45) and (See Page 6-0-46).
'!*<;'!*<- Tool). make sure that the air pressure gauge on the air
4!<-#

+- Push the mid rocker arm on the No. 1 cylinder manually.
#-! !!- compressor indicates over 400 kPa (4 kgf/cm2, 57 psi).
&*00#;*#
=A$<-
*- Check that the mid rocker arm moves independently of
##&! Inspect the valve clearance before rocker arm
&!&!#
Q
the primary and secondary intake rocker arms.
##- inspection.
-
{INTAKE SIDE}
MID ROCKER ¢ Cover the timing belt with a shop towel to protect
&
!33!
ARM the belt from oil soaking.
!!#
-
SECONDARY ¢ Check the mid rocker arm of each piston at TDC.
##4(-
ROCKER ARM 1.
1&!&-
PRIMARY NOTE: When installing the cylinder head cover
84 92!!
!&
ROCKER ARM
(See Page 6-0-45) and (See Page 6-0-46).
;'!*<;'!*<-
2.
- Plug the relief hole with the special tool.
!
!!3!!-
RELIEF HOLE
AIR STDPPER
OTLA-J — PR30201
PRIMARY SECONDARY
ROCKER ARM ROCKER ARM
MID ROCKER
ARM
[EXHAUST SIDE!
5.
- Check the mid rocker arm of each cylinder at TDC.
##!4(-
0 If the mid rocker arm does not move, remove the
#&A&
mid, primary and secondary rocker arms as an
A#
assembly and check that the pistons in the mid and
!#
primary rocker arms move smoothly.
#&!-
0 If any rocker arm needs replacing, replace the
#!
A!
primary, mid, and secondary rocker arms as an
AA#
assembly.
!-
4%
6
VTEC Rocker Arms

; !
/
?0
6-C-8
58
3.
+- Remove the bolt and washer from the inspection hole
1&!3! 4.
*- Loosen the regulator valve on the valve inspection

!&!&&!&
and connect the special tool.
!!- set and apply the specified air pressure to the
!
REGULATOR VALVE rocker arm pistons.
#-
- Pull the lever and
Specified Air Pressure:
'F
turn tn adiusl.
250 kPa (2.5 kgf/cm2, 36 psi)
3$6'/@36! 2:5 0
5.
- Make sure that the intake primary and secondary
,# #
VALVE INSPECTION SET
INLAJ - PH3010‘I rocker arms are mechanically connected by the
#!!
pistons and that the mid rocker arms do not move
#&
when pushed manually.
3 !!-
MID ROCKER
ARM
SECONDAH‘I"
PRIMARY
ROCKER Mill“
ROCKER ARM
WASHER
Replace.
f INSPEcnou HOLE AIR STUPPER

07W - PRBBZM
III I 1.I.'I mm
2|] N-m 12.0 kgf-rn,
14 Ib'I-ftl
LOST MOTION
ASSEMBLY
¢ If any mid rocker arm moves independently of
#&!
the primary and secondary rocker arms,
#A
replace the rocker arms, as a set.
!#A-
6.
- Remove the tools.
1&!-
7.
$- Check for smooth operation of the lost motion
#!
assembly. It is compressed slightly when the mid
!-!
!3
rocker arm is lightly pushed and compressed
#!
!
deeply when the mid rocker arm is strongly pushed.
!3#
! -
¢ Replace the lost motion assembly if it does
1!!!
not move smoothly.
&!-
8.
'- After inspection, check that the check engine light
%A##
!

does not come on.
-
4-
Valve Clearance
59
_ _
Adjustment
D 6 C 9
NOTE:
84 9 3.
+- Adjust valves on No. 1 cylinder.
%7 &!&-!-
¢ Valves should be adjusted only when the cylinder head
:!& !7 !3! Valve Clearance:
4-F
!+'P;00P <- Intake:
6F 0.17 mm (0.007 in)
$@7/$@$$7 0
¢ After adjusting, retorque the crankshaft pulley bolt to 245
%7
AF # !!!* i 0.02 mm (0.0008 in)
O$@$/$@$$$8 0
Nm (25.0 kgf/m, 181 lbf/ft)-
;-0#
=A'!=<- Exhaust:
% 0.19 mm (0.007 in)
F $@9/$@$$7 0
1.
1&!&- 1 0.02 mm (0.0008 in)
O$@$/$@$$$8 0
NOTE: When installing the Cylinder head cover (599
84 92!!
!&; 4.
*- Loosen the locknut and turn the adjusting screw
!# 7
3
Page 6-0-45) and ($99 Page 6-045)-
'!*<;'!*<- until a feeler gauge slides back and forth with a
!!

!#3
- Set No. 1 piston at TDC. “
2. -4(-K ” marks on the pulleys
L# !! slight amount 01' drag.
!

-
should be at the top, and the TDC grooves on the
!A4(
& TAPPET ADJUSTER
pulleys should align with the cylinder head surface.
!! !!
3! - 33533350100
Number 1 piston at TDC:
,*
)F
"P‘MAHKS
LUCKNUT
20 I'd-m (2.0 kgf-rn. 14 MM”
TDC MARKS _ _ _
Align the marks Adjusting screw location:
D !(

F
an the pulleys Adjusting screw location:
INTAKE
EXHAUST
[cont‘dl
Valve Clearance
4- _ _
D/
?0
5$
6 C 10
5.
- Tighten the locknut, and check the clearance again.
4
!# A#!
- 7.
$- Rotate the crankshaft 180° counterclockwise to
1#'0P !#3
Repeat the adjustment if necessary.
17 - bring No. 4 piston to TDC. The TDC grooves are

-*4(-44(
&
FEELER GAUGE once again aligned. Adjust the valves on No. 4

!
-%7 &!&-*
cylinder.
!-
,*
)F
- 1#'0P !#3;

pulleys turn 90°). The “ f L# !
!! 50P<-4K ” marks should be on the I q. MARKS
exhaust-Side. AdJUSt the valves on NO- 3 cylinder.
/ -%7 &!&-+!- 8.
'- Rotate the crankshaft 180° counterclockwise to
1#'0P !#3
,*
)F
Number 3 Myer-fix: bring No. 2 piston to TDC. The “ f L# !

-4(-4K ” marks should
be on the intake side. Adjust the valves on No. 2
#-%7 &!&-
cylinder.
!-
,*
)F
“I“ MARKS
Crankshaft
6 Pullev and Pullev Bolt
'#'#"
6_C_11
5
Replacement

When installing and tightening the pulley, follow the procedure below.
2!!

!!A!!3 !3-
Clean, remove any oil and lubricate all the points shown below:
!A&!! !!3!39
0 9!
: Clean
x : Remove any oil
/91&!
¢ : Lubricate
9
GRAMKSHAFT
PULLE‘I'
TIMING BELT
lk DRIVE PULLEY
WASHER
CRANKSHAFI’
_ rY
xx_>_(__x xxxx
XKXXXXXK
K
PU LLEY EOLT
TIMING BELT
GUIDE PLATE
"MING Ell-LANCER
BELT DRIVE PULLEY
Crankshaft
6 pulley bolt size and torque value:
#*
C
B-F
16 x 1.5 mm
5@3
245 Nm (25.0 kgf/m, 181 lbf/ft)
3,/3@$6! 2:8* 2 0
NOTE: Do not use an impact wrench when installing.
84 9( 33!!
-
HANDLE
(”JAB - 0010200
PULLEV HOLDER AWACHME NT.

HEX 50 mm
MJAB - 0010400
SOCKET WRENCH. 19 mm
WJAA — 0010200
!""" 6_C_12
5

Illustrated Index
NOTE:
84 9
How to position the crankshaft and pulley before installing the belt (See Page 6-0-16).
63# !!!!
!;'!<-
.QQQQQ
Mark the direction of rotation on the belt before removing it.

,#!&
-
Do not use the middle cover and lower cover to store removed items.
( !&!3&&-
Clean the middle cover and lower cover before installing them.
!!&!3&!!
-
Replace the camshaft seals and crankshaft seals if there is oil leakage.
1!!#!!!#
-
Before installing the timing belt and timing balancer belt (See Page 6-0-11).
)!!

!
!!;'!<-
6 x 1.0 mm MIDDLE COVER

12 N-m [1.2 kg‘I-m.
SJIhf‘flI
HEAD COVER GASKET

Replace if its leaking,
damaged or deteriorated. WASHER Ex 1.0 mm
Apply liquid gasket at 12 him [12 lint-m. 3.? lbf-ftl
pr deterinrated.
the eight corners of the
recesses, page 6-13-15.
CYLINDER HEAD
COVER
Refer ICI pages BIS-:15. 46
when installing.
RUBBER SEALS
Fleplace when damaged
or deteriorated.
LOWER COVER
RUBBER SEAL
or deteriorated.
CAMSHAFI’
PU LLE‘I’S GRAN KSHAFI’ PULLEY
Replacement, page E-C—H
PULLEY BOLT
16 )r. 1.5 mm
245 Mm l25.0 kgf-m,
181 lbf-fll
Replacement, page 6-13-11
€11fi 5 x 1.0 mm Do not use an impact
Ell 12 N-ml1.2 Ital-m. 3‘7 Inf-ft] wrench whEn installing.
I he...
I. 10 x 1.25 mm
‘ 59 N-m I6.0 kgf'm, l3 lbf-ftl
l TIMING BELT
34 Inspection, page 643-13
_ J5; Removal. page 6-C--1#
Installation. page 6 (2-15
BALANCEH
BELT
Inspection, page fi-C 13
Removal, page B—C-‘Id
Installation, page 543—121
ADJUSTER
ADJUSTING BOLT
E? ".m {6.3 kgf-m, 49 l-rl
Apply liquid gasket
to the belt threads ADJUSTING NUT
installed in the u Mm [1.5 n‘m,
black side. 33 Ib’H‘tI
BALANCEFI
AUTO-TENSIONER TWICKP TIMING BELT BELT DRIVE
SENSORS DRWE PULLEY
Replacement. PULLEY
page ENE—21 CIEBI'I- Clea n.
E I 1.43 mm
12 H-m [1.2 lint-m. 3.? lbf-ftl
To go to the page referenced on the diagram above, click on the

4

&A!#
following:
!!3
9
( See Page 6-0-45)
;'!*<
( See Page 6-0-46)
;'!*<
( See Page 6-0-11)
;'!<
( See Page 6-0-13)
;'!+<
( See Page 6-0-14 )
;'!*<
( See Page 6-0-16 )
;'!<
( See Page 6-0-21 )
;'!<
!"
Timing Belt
Inspection

6-C-13
5 Balancer Belt
""
Inspection

,# &A - Make sure you have the anti-theft code for the
,# &
33F B radio, then write down the frequencies for the
A33F
buttons.
- radio’s preset buttons.
B -
(
&!A - Disconnect the battery negative terminal first, then
(
&!A
positive terminal.
&!- the positive terminal.
&!-
(!!A +- Disconnect the alternator terminal and the
(!!
&
3! connector, then remove the engine wire harness
A&
3
head cover.
&- from the cylinder head cover.
!&-
1&!&- *- Remove the cylinder head cover.
1&!&-
0 When installing (See Page 6-0-45) and (See Page
2!!
;'!*<;'! ¢ When installing (See Page 6-0-45) and (See
2!!
/'!*<;
6-0-46).
*<- Page 6-0-46).
'!*<-
- Remove the middle cover.
1&!&- - Remove the middle cover.
1&!&-
$0.03.“.O‘S"
- Inspect the timing belt for cracks and oil or coolant

!#!! - Remove the crankshaft pulley.
1&# !!-
soaking.
#
- $- Remove the lower cover.
1&!3&-
NOTE:
84 9 '- Install the crankshaft pulley.
!!# !!-
0 Replace the belt if oil or coolant soaked.
1!!!!#- 5- Inspect the timing balancer belt for cracks and oil

!!#!
1&!!&
!- or coolant soaking.
!#
-
Inspect this area for wear. NOTE:
84 9
¢ Replace the belt if oil or coolant soaked.
1!!!!#-
¢ Remove any oil or solvent that gets on the belt.
1&!!&
!-
Inspect this area for wear.
H mats pulley
and inspect belt.
Rotate pulley
and inspect belt.
10. %
AF # !!!
0- After inspecting, retorque the crankshaft pulley bolt
to 245 Nm (25.0 kgf/m, 181 Ibf/ft).
*;-0#
=A'!=<-
$- After inspecting, retorque the crankshaft pulley bolt to
%
AF # !!! 11. A
245 Nm (25.0 kgf/m, 181 Ibf/ft).
*;-0#
=A'!=<- the customer’s radio station presets.
B-
A
customer’s radio station presets.
B-
!"""
Timing Belt and Balancer Belt

-
Removal
6-C-14
5
NOTE:
84 9 6.
- Loosen the adjusting bolt, mounting bolt and
7
!A
!
4 # !!- locknut, then remove the alternator belt.
!# A&!!-
dead center (TDC) before removing the belt (See Page
;4(<&
!;'! MOUNTING BGLT
10 II: 1.25 mm
6—C-17).
$<- M Nm “.5 kgf-rn.
¢ Inspect the water pump after removing the timing belt
3 &

! 33 lb'l-fi}
(See Page 6—C-17).
;'!$<-
1.
,# &A
33F B
buttons.
-
2.
(
&!A
positive terminal.
&!-
3.
+- Remove the wheel well splash shield.
1&3!3!!!!-
4.
*- Loosen the adjusting bolt, locknut and mounting bolt,
7
!A!#
!A
then remove the power steering (P/S) pump belt.
&3
;=< !-
LDCKNUT ADJUSTING
B x 1.25 mm HOLT
ADJUSTING BOLT 22 Nvm 12.2 kgf-m, LOCKNUT ALTEHNJITOR
1B lblvfti a x 1.25 mm 55”
22 N-m l2.2 kgf-m, 16 Ihf-fli
7.
$- Remove the stop and ground cable, then remove
1&
!A&
the upper bracket (See Page 6—C-27).
#;'!$<-
NOTE:
84 9
¢ Use a jack to support the engine before the
?7#

upper bracket is removed.
#&-
¢ Make sure to place a cushion between the oil
,# ! 3!
pan and the jack.
7#-
8.
'- Remove the dipstick and tube.
1&# -
6 Jr. 1.0 mm
MOUNTING BOLT . 12 Mm {1.2 kgf—m.
PIS PUMP a x 125 mm If" 8.? lb‘f—fli
BELT 22 Mm [22 ugirm. 1a Ibf-Hl
5.
- Remove the alternator terminal and connector.
1&!!-
Replace.
9.
1&!&-
¢ When installing (See Page 6—C-45) and (See
2!!
;'!*<;
Page 6—C-46).
'!*<-
Pull up the
luck.
CDNNECTDR B ill-m till! kgf-m,

6 lbf-fl)
!"""
Removal (cont’d)

-/
?0
6-C-15
53
NOTE: The procedures in steps 9 and 10 are for reusing the
84 94 50
12. 1&!&-
- Remove the middle cover.
timing belt. For

!- replacing the timing belt, skip these
!

!A# NOTE: Do not use the middle cover to store
84 9( !&
procedures and go to step 12.

- removed items.
&-
10. ?3!
0- Use an open-end wrench to loosen the maintenance 13. 1& !!!# !!;
+- Remove the pulley bolt and crankshaft pulley (See
bolt. If it cannot be loosened with an open-end wrench, a
!-!33A Page 6—C-11).
'!<-
box wrench can be used after removing the lock pin.
/3 &
!#- 14. 1&!# !A
*- Remove the lock pin and rubber seals, then
NOTE: Use of a tool should be limited to initial loosening
84 9?! !!!!
remove the lower cover.
&!3&-
only.
!- NOTE: Do not use the lower cover to store
84 9( !3&
11. ?3! !-4
- Unscrew the maintenance bolt by hand until it stops. The removed items.
&-
auto-tensioner bracket is now fixed.
#3/- LOWER CDVEH
NOTE:
84 9
0 Never use a tool to unscrew the maintenance bolt
& ! 3!
after initial loosening it.
!!
-
0 If the auto-tensioner has been extended and the
/
timing belt cannot be installed, remove the

!!!A&
auto-tensioner, compress it and reinstall it (See
A!!;
Page 6—C-16).
'!<-
RUBBER
SEALS
6:1.0rnrn
12 MM [1.2 kgf-m. 8.? lbfvftl
15. 7
=+ -
- Loosen the adjusting nut 2/3-1 turn.
Push the tensioner to remove tension from the
&
timing balancer belt, then retighten the adjusting

!!A
7
nut.
-
MAINTENANCE
BOLT
Auto-tension er
fu nctlo nai:
ADJUSTER {L ADJUSTING NUT

44 N-m 14.5 mm.
Aumvta nsioner aw " 33 lbf-ftl
1:515 " ‘—
fixed in placa:
16. 1&
!!
!-
- Remove the timing balancer belt and timing belt.
!"""

Installation
6-C-16
55
NOTE: This procedure is to replace the timing belt. If you are
84 94 !
!- 4.
*- Remove the auto-tensioner.
1& -
reusing the timing belt, (See Page 6—C-19).

!A;'!5<- 5.
- Hold the auto-tensioner with the maintenance bolt
6! 3!
Install the timing belt and timing balancer belt in the reverse
!!
!
!!& pointing up. Loosen and remove the maintenance

-&
order of removal;
&!N bolt.
!-
8!#- NOTE: Handle the auto-tensioner carefully so the
84 96! !!
NOTE: Clean the middle and lower covers before installation.
84 9!!!3&!!- oil inside does not spill or leak.
!!!!#-
1.
- Remove the timing balancer belt drive pulley (See Page
1&
!!& !!;'! Replenish the auto-tensioner with oil if any spills or
1! 3!!!
(3-0-12).
<- leaks. The total capacity is 8 ml (1/4 fl oz).
!#-4!';=*!H<-
2.

!& !!- 6.
- Clamp the boss of the auto-tensioner in a vice.
! &-
at top dead center (TDC). Align the dimple on the teeth
;4(<-%!
! Use pieces of wood or a cloth to protect the boss.
?3!-
of the timing belt drive pulley with the V pointer on the oil

!& !!3:! NOTE: Do not grip the housing of the
84 9(

pump.
- auto-tensioner.
-
PDINTEH ON THE OIL PUMP HOUSING 7.
$- Insert a flat blade screwdriver into the maintenance
!!3&
hole. Place the stopper (P/N 14540-P13-003) on
!-!;=**0+00+<
the auto-tensioner while turning the screwdriver
3!
3&
clockwise to compress the bottom.
!#3-
NOTE: Take care not to damage the threads or the
84 94#

gasket contact surface with the screwdriver.

# 33&-
MAINTENANCE
FLAT BLADE v BOLT
SCREWDRIVER
GASKET
STOPPER Replace.
TDC KEY PIN 14540 - P13 -002_!
MARK
3.
+- The " T L# !! !
4K ” marks on the camshaft pulleys should be at
the top, and the TDC grooves on the pulleys should
A4(
& !! ! AUTO-TENSIDNEFI
align with the cylinder head surface.
!
3! -
"r“ MARKS
8.
'- Reinstall the maintenance bolt.
1!!!-
NOTE: Be sure to use a new gasket.
84 9) 3
#-
BOLT
/_“%\
MAINTENANCE \ GASKET
Replace.
-
a H-m 10.3 Raf-m.
5 mm}
TDC MAHK$
!"""

/
?0
6-C-17
57
9.
5- Make sure no oil is leaking around the maintenance bolt,
,# !!#
!A 11 . 1&-
- Remove the stopper.
then install the auto-tensioner.
!! - ADJUfiTER
STOPPER
pm 14540 — P13 —- nus
AUTO-TENSIONER PIN 14540 — P13 - 003
AUTO-TENSIONEH 12. !!

!!& !!
- Install the timing balancer belt drive pulley and
lower cover.
!3&-
13. !!# !!A
!!
+- Install the crankshaft pulley, then tighten the pulley
B x 1.25 mm bolt (See Page 6—C-11).
!;'!<-
22 N-m l2.2 Raf-m.
1a lbl—ft} 14. 1# !! &/
*- Rotate the crankshaft pulley about five or six turns
NOTE: Make sure the stopper stays in place.
84 9,# !- counterclockwise so that the timing belt positions
!#3
!
10. !!
!
!F 3-
0- Install the timing belt tightly in the sequence shown. on the pulleys.
!!-
1 Timing belt drive pulley (crankshaft) then 2 Adjusting
4
!& !!;#<%7
15. ,# # !!
- Make sure the crankshaft and camshaft pulleys are
pulley then 3 Water pump pulley then 4 Exhaust
!!2 !! / at TDC.
4(-
camshaft pulley then 5 Intake camshaft pulley.
!!3# !!- CRANKSHAFT:
,I.+F
84 9,#
!& !! POINTER
camshaft pulleys are at TDC.
!!4(-
FLYWHEEL TDC MARK

IWHITE]
CAMSHAFT PULLEYS:
.+';&&%>F
"t " MAHK$
TDC MARK$
Timinq Belt and Balance Belt
!"""

/
?0
6-C-18
58
16. # !!
- If either camshaft and crankshaft pulley is not positioned 22. %!

&!3
- Align the groove on the front balancer shaft with
at TDC, remove the timing belt and adjust the
4(A&
!7 the pointer on the oil pump housing as shown.
!
3-
positioning following the procedure on page 6—C—16, then

!!3

A FRONT BALANCER
reinstall the timing belt.
!!
!- SHAFT POINTER
17. # !!-
$- Set the crankshaft pulley so that the No. 1 piston is at
TDC.
4(-
18. 1&# !!!3&-
'- Remove the crankshaft pulley and lower cover.
19. 7
=+ &
5- Loosen the adjusting nut 2/3-1 turn and verify that the
timing balancer belt adjuster moves freely.

!!7 &!-
20. 1
7
-
0- Retighten the adjusting nut.
21. %!
! !!
!
- Align the rear balancer shaft pulley by using a special
tool. Insert the special tool into the maintenance hole to
!-!!!
the fix the rear balancer shaft.
/!-
HEAR BALANCEH BALANCEFI SHAFT
SHAFT LOCK PIN
INLAG PTEO'IOO
-
GROOVE
23. !!
!!-
+- Install the timing balancer belt. Loosen the
adjusting nut 2/3-1 turn to tension the timing
7
=+
balancer belt.
!!-
24. 1&!!A!!
*- Remove the special tool, then install the 12 mm
sealing bolt.
!
!-
25. !!!3&# !!A
- Install the lower cover and crankshaft pulley, then
tighten the pulley bolt (See Page 6—C-11).

!!!;'!<-
26. 4 # !!
HEAR BALANCER
counter-clockwise, then tighten the adjusting nut.
!#3A
7
-
27. !! ! 7
-
$- Install the rubber seal around the adjusting nut.
84 9(!7
-
28. %!!A7 !-
'- After installation, adjust the tension of each belt.
*!!
adjustment.
7 -
$= !
adjustment.
7 -
29. A
5- Enter the anti-theft code for the radio, then enter
B -
MAINTENANCE
HOLE
WASHER
“Splat!!- mm 5min
LOCK PIN
DTLAG - PT2U1|1IJ
12 mm SEALING BOLT
29 N-rn [3.0 kgf'rn, 22 Ihf-f'tl
Timinq Belt and Balance Belt
!"""

/
?0
6-C-19
59
NOTE: Use this procedure when reusing the timing belt.
84 9? 3

!- 5.
- Install the timing belt (See Page 6—C-17).
!!
!;'!$<-
Install the timing belt and timing balancer belt in the reverse
!!
!
!!& NOTE:
84 9
order of removal;
&!N ¢ If the auto-tensioner has extended and the
/
8!#- timing belt cannot be installed, remove and

!!!A&
84 9!!!3&!!-
NOTE: Clean the middle and lower covers before installation. compress the auto-tensioner (See Page
;'!
1.
- Remove the balancer belt drive pulley (See Page
1&!!& !!;'! 6—C-16).
<-
(3-0-12).
<- ¢ Take care not to damage the timing belt when
4#

!3
2.

!& !!- installing it.
!!
-
at TDC (See Page 6—C-16).
4(;'!<- ¢ Make sure the timing belt drive pulley and
,#
!& !!
3.
+- Set the camshaft pulleys so that the No. 1 piston is at
!!- camshaft pulleys are at TDC.
!!4(-
TDC (See Page 6—C-16).
4(;'!<-
4.
*- Install the special tool on the intake camshaft pulley.
!!!!# !!- a"? I
6.
- Remove the special tool.
1&!!-
7.
$- Tighten the maintenance bolt to make the
4
!#
auto-tensioner functional.
!-
TIMING BELT
SLIDEFI
DTNAG — P130100 Autu-tensinner Ill:
fixed in place: -
ADJUSTER
Auto—re nsioner
fu n mi 0 nal:
MAINTENANCE
BOLT
22 N-m [2.2 kgf‘rn, 1E lbf-ft]
!"""

/
?0
6-C-20
5$
'- Install the timing balancer belt drive pulley and lower
!!
!!& !!!3 24. %!!A7 !-
*- After installation, adjust the tension of each belt.
coven
&- ¢ See section 4 for alternator belt tension
*!!
5- Install the crankshaft pulley, then tighten the pulley bolt
!!# !!A
!!! adjustment.
7 -
(See Page 6-0-11).
;'!<- ¢ See section 17 for P/S pump belt tension
$= !
10.
0- Rotate the crankshaft pulley about five or six turns
1# !! &/ adjustment.
7 -
!#3
! 25. A
pulleys.
!!- the customer’s radio station presets.
B-
11.
- Make sure the crankshaft pulley and camshaft pulleys
,# # !! !!
are at TDC (See Page 6-0-17).
4(;'!$<-
12.
- If either camshaft and crankshaft pulley is not positioned
# !!
at TDC, remove the timing belt and adjust the
4(A&
!7
positioning following the procedure (See Page 6-0-16),

!!3
;'!<A
reinstall the timing belt.
!!
!-
13.
+- Set the crankshaft pulley so that the No. 1 piston is at
# !!-
TDC.
4(-
14.
*- Remove the crankshaft pulley and lower cover.
1&# !!!3&-
15.
- Loosen the adjusting nut 2/3-1 turn and verify that the
7
=+ &
timing balancer belt adjuster moves freely.

!!7 &!-
16.
- Retighten the adjusting nut.
1
7
-
17.
$- Align the rear balancer shaft pulley by using a special
%!
! !!
!
tool. Insert the special tool into the maintenance hole to
!-!!!
the fix the rear balancer shaft (See Page 6-0-18).
/!;'!'<-
18.
'- Align the groove on the front balancer shaft pulley with
%!

&! !!3
the pointer on the oil pump housing (See Page 6-0-18).
!
;'!'<-
19.
5- Install the timing balancer belt. Loosen the adjusting nut
!!
!!-7

2/3-1 turn to tension the timing balancer belt.
=+
!!-
20.
0- Remove the special tool, then install the 12 mm sealing
1&!!A!!!
bolt.
!-
21.
- Install the lower cover and crankshaft pulley, then
!!!3&# !!A
tighten the pulley bolt (See Page 6-0-11).

!!!;'!<-
22.
4 # !!
counterclockwise, then tighten the adjusting nut.
!#3A
7
-
23.
+- Install the rubber seal around the adjusting nut.
!! ! 7
-
84 9(!7
-
I'2)

CKP/TDC Sensors
Replacement

6-C-21
5
- Removal of the balancer belt (See Page 6—C-14).
1&!!!;'!*<-
PONT‘
- Remove the balancer belt drive pulley.

1&!!& !!-
+- Disconnect the CKP/TDC sensors connector, then
(>=4(A
remove the CKP/TDC sensors.
&>=4(-
CKPITDG SENSORS
CONNECTOR
CKPITDC SENSORS
E )1: 1.0 mm
12 N~m 11.2 kgf—m,
BJlbl-fil
*- !!>=4(&&!-
Install the CKP/TDC sensors in reverse order of removal.
.01?
- Install the balancer belt (See Page 6—C-16).

!!!!;'!<-
Cylinder Head
# . 6-C-22
5

Illustrated Index
NOTE:
84 9
!-
4&
A3 !
2!
!
#A#!
-
?38

#3!
-
E- at H] mm
IGNITION WIRE 9.3 N-n'I [Lu kgim. 1.2lbf-ftl
COVER
CLAMP
6 :II 1.1] mm H '
12 N-m (1.2 kgf-m. 3.1 lbI-hl ‘J
C‘r‘LINDER HEAD COVER
WASHER Refer to pages 5-0-15, I15 when
. .
Replace whun damaged '3 Ins-ta | | I I'Ig.
or deteriorated. R- .
HEAD COVER GASKET
Replace if its leaking. damaged
or deteriorated.
RUBBER SEAL Apply liquid gasket at the eight corners
Replace when damagedw '"-' - —- ' of the recesses. page 6—015
or deteriorated. VT- 3c“ '.-';'J- . ._.-l '_ --
-. 8 I: 1.25 mm
6 x. 1.0 mm 25 N-m12.5 Ital-m. 19lbf—fll
12 NM (1.2 kgf-m, 3.7 lbf-ftl
4'— 6 x 1.0 mm
RUBBER CAP
”:9 _ 3 12 N11: [1.2 kgf-m. a? lbl—i'tl
Replace when
damaged or
B 11.25 mm deteriorated.
22 film 12.2 kgf-m. 16 IbI-ftl 5%.”.l CAMSHAFT HOLDER
INTAKE CAMSHAFT
SEALS
KEYS
DISTRIBUTOR
/ 111x125 mm
I5 .1 1.0 mm 59 ”m [3.0 Raf-m, 43 Ib'l'ftl
12 Mm (1.2 kghn,
3.? lhf-fll PU LLE‘I’S
EXHAUST CAMSHJIFT
VTEC SOLENOID
VALVE D-RING
Replace.
WEC SOLENOID
VALVE FILTER OIL CONTROL ORIFIOE
Replace. Clean.

4

&A!#
following:
!!3
9
(See Page 6-0-45)
;'!*<
(See Page 6-0-46)
;'!*<
Cylinder Head
# . _ _
lllustratedlndex(cont’d)
/
?0
5
6 C 23
”7%
&
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts.
!
A!!!!&A!! -
c‘rumEH HEAD liens VALVE KEEPERs
Inspection. page 3-43-29
Tightening. page B-C-fl
EXHAUST VALVE - SPRING RETAIRER
SPRING INhER
INTAKE VALVE
EXHAUST VALVE SPRING "HER
SPRING OUTER
INTAKE VALVE
SPRING OUTER
20 mm SEALING BOLT
£9 N-II'I I53 kgf-m. 38 Ib‘M‘tl INTAKE VALVE SEAL
Replace.
WASHER
Replace. L: VALVE 3mm: SEAT
0 INTAKE VALVE GUIDE
o-ame
6M Replace.
INTAKE nocxsn
EXHAUST VALVE SEAL ' fix SHAFT 0mm:
Replacement. page |"' Clean.
542—3? cvunnan
Replace.
EXHAUST VALVE BACK COVER
GLIDE Clean.
LOST MOTION
ASSEMBLV
EXHAUST ROCKER
SHAFT ORIFICE
C108 I'l- EXHAUST VALVE
CYLINDER HEAD
GASKET
Replace. INTAKE VALVE
Removal, page 6—03?
Installation, page 6-041
10 a: 1.25 mm
44 Nm [4.5 Roi-m,
33 lbf-fll
B x 1.25 mm
24 N-m (2.4 kgf-m, 17 ItI
ENGINE MOUNT
BRACKET B

4

&A!#
following:
!!3
9
(See Page 6-0-29)
;'!5<
(See Page 6-0-43)
;'!*+<
(See Page 6-0-37)
;'!+$<
(See Page 6-0-41)
;'!*<
# .
Cylinder Head

-
Removal
6-C -24
5
Engine removal is not required in this procedure.

&!F - 6.
- 1&# -
Remove the intake air duct.
NOTE:
84 9
?&&

-
¢ To avoid damage, unplug the wiring connectors carefully
4&
A !
3
!!
3!!
-
4&

!A3 !
engine coolant temperature drops below 38°C (100°F)<

! !3+'P;00P
!

!-
,#!!3
&-%!A
3
A
3-
- -
N_\
- ,# &A
33F B
buttons.
-
Disconnect the battery negative terminal first, then the
+- (
&!A
positive terminal.
&!- INTAKE AIR
DUCT
Drain the engine coolant (See Page 10— 7).
*- (
!;'!0$<- $- Remove the brake booster vacuum hose and
1&#&
Remove the left strut brace.
- 1&! - evaporative emission (EVAP) control canister
&&; :%<!
B x 1.25 mm
hose.
-
Zil- N-I'n 12.4 nm.
BRAKE BOOSTER
17 Ibf-fll
VACUUM HOSE
EVAP CONTROL
CANISTER HOSE
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-C-25
53
8.
'- Remove the breather hose and positive crankcase
1&&# 10. 1!& ! ;<-
&!;:<- 11. 1& ! ! -
- Remove the fuel feed hose and fuel return hose.
Pcv Hose
FUEL FEED 27 MM [2-8 km'm.
HOSE 20 lbi-ftl
BHEATHER
HOSE WASHERS
Hen-lace.
5- Remove the throttle cable by loosening the locknut, then
1&!!!
!# A
FUEL HETUHN
slip the cable end out of the accelerator linkage. Take
!! !!#
-4# HOSE
care not to bend the cable when removing it. Always
!3&
-%!3
replace any kinked cable with a new one.
!##!33- 12. 1&7
!A

- Remove the adjusting bolt, mounting nut and
locknut, then remove the power steering (P/S)
!# A&3
;=<
pump belt and pump, without disconnecting the
! A3

P/S hoses.
=-
LDCKMUT MOUNTING NUT
B x 1.25 mm I! I 1.25 mm
22 N-m 12.2 Ital-m. 22 N-m [12 kgf-m.
1E Inf-ft] 16 lt}
LOCKNUT ADJUSTING
CABLE NUT
ADJUSTING
BDLT
PIS PUMP
BELT
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-C-26
55
+-
13. 1&!!-
Remove the alternator terminal and connector. - Remove the upper radiator hose, lower radiator
15. 1& A!3
hose, heater hose and water bypass hoses.
A3-
WATER BYPASS
HOSE
Pull up the
lock.
CONNECTOR
WATEH HEATER UPPER HADIATCIIFI
BYPASS HOSE HOSE
E x 1.9 mm HOSE
a N-m {0.3 hat-m. 16. 1&
3
- Remove the engine wire harness connectors and
5 Ibfvftl wire harness clamps from the cylinder head and
3!!
14.
!A!# 7
!A
*- Loosen the mounting bolt, locknut and adjusting bolt,
#!-
&!!-
then remove the alternator belt.
O Four injector connectors
7
MOUNTING BOLT Intake air temperature (IAT) sensor connector
# ;%4<
....
1D x 1.25 mm
Idle air control (IAC) valve connector
!!;%<&!&
441 him “.5 kgf-rn.
33 lbf-fll Throttle position sensor connector
4!
,!! ;,%<
connector

Engine coolant temperature (ECT) sensor

! ; 4<
connector

Radiator fan switch connector
13
Coolant temperature gauge sending unit
!

connector

Exhaust gas recirculation (EGR) connector
/
!; .1<
.....
Heated oxygen sensor (H028) connector

6/
;68<
CKP/TDC sensor connector
>=4(
VTEC solenoid valve connector
:4 !&!&
VTEC pressure switch connector
:4 3
ADJ U 51'] MG
BOLT 17. 1&#!

!
$- Remove the spark plug caps and ignition coil from
the cylinder head.
!-
LOCKNUT ALTERNATOR
B x 1.25 mm BELT
22 N-m (2.2 kgfvm. 16 lbf-ft)
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-C-27
57
18. 1&
!A&
'- Remove the ground cable, then remove the thermostat 21. 1&!&-
housing mounting bolts.

!- CY LINDEFI
til-RING -. -. - HEAD
Replace. COVER
THERMOS’TAT
CASE
5 x 1.0 mm
s x 1.25 mm 11 N-m 11.1 kgf-m.
3.0 Ibf-fil
22. 1&
!;'!*<-
- Remove the timing belt (See Page 6-C-14).
24 N-m l2.4 kgf-m.
23. 1& !!A

+- Remove the camshaft pulley, engine mount
1? mm:
bracket B and back cover.
#)#&-
19.
37#3!#
5- Support the engine with the jack and wood block under
the oil pan.
!-
20. 1&
!A&
0- Remove the stop and ground cable, then remove the CAMSHAFI'
PULLEY
upper bracket.
#-
61:11] mm 12 I: 1.25 mm
11 N-n‘l {1.1 kg‘l—m, 52 Nvm [5.3 Ital-mi
3.0 lhfffll 331mm
GROUND
CABLE
12 x 1.25 ITll'l'l W
52 en {5.3 kgf-m. in?
BB It]
BACK COVER ENGINE MDU NT

BRACKETS
12 1: 1.25 mm
5-: Mn [5.5 kgf-m. *"
m Ibf-ftl
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-C-28
58
24. 1&/ !#!!#
*- Remove the exhaust manifold brackets and self-locking 26. #7
3-
- Loosen the rocker arm adjusting screws.
-
nuts. ADJUSTiNG SCREWS
EX HAUST
MANIFOLD
BRACKET
ADJuaG SCREWS
27. 1&!!A
$- Remove the camshaft holder plates, camshaft
GASKETS holders and camshafts.
!-
Replace. CAMSHAFI' HOLDER
PLATE
1|] 1: 1.25 mm
1|] 1: 1.25 mm 44 N-m {4.5 Raf-m.
sa Mm 15.5 Him. «10 IbMt) 33 Iti
Replace.
25. 1&#!#-
- Remove the intake manifold bracket. CAMEHJIFI’
HOLDER
SEAL
Replace.
CAMSHAFTS
D-filNG
Replace.
8 R 1.25 mm
24 Mm [2.4 kgf-m.
1T Ibf-ft)
# .
Cylinder Head
Removal (cont’d)

-/
?0
6-C-29
59 # ."

Cylinder Head Bolt
Inspection

28. 1&!!-4&3

A
'- Remove the cylinder head bolts. To prevent warpage, 1.
- Measure the diameter of each cylinder head bolt at
, !!
unscrew the bolts in sequence 1/3 turn at a time; repeat
3!F =+ N point Aand point B.
%)-
the sequence until all bolts are loosened. B
9
F !!!!!-
$9?
70 mm
[2.8 inl
l‘mmm
' fl
A
E: M I llllllllllll l
1‘
a 0 {B
29. 1&!-
5- Remove the cylinder head.
2.
- If either diameter is less than 11.3 mm (0.44 in),
!-+;0-**<A
replace the cylinder head bolt.
!!!-

6 6_C_30
5$

-
Removal
1.
- Loosen the adjusting screws, then remove the camshaft
7
3A&
holder plate, camshaft holders and camshafts.
!!A!-
NOTE: Unscrew the camshaft holder bolts two turns at a
84 9?3!!3
time, in a crisscross pattern, to prevent damaging the
AA&

valves or rocker arm assembly.
&!&#!-
INTAKE
=15: (1:13 :i'r- is $3.- 6} (i:

“l“- ‘ ”°‘ 3 “‘1 2 ”9- 1 2.
- Remove the VTEC solenoid valve and 20 mm
1&:4 !&!&0
sealing bolt
!
!
EXHAUST
WASHER
Replace. 20 mm SEALING BOLT
419 Mm [5.0 inf-m.
36 ltl
VTEC SOLENOID
VALVE FILTER
“ep'm- VTEC SOLENOID
VALVE
5 n 1.0 mm
12 Min 11.2 kgl-rn.
BJ ltl

6
Removal (cont’d)

-/
?0
6-C-31
5
3.
+- Hold the rocker arms together with a rubber band to
6!#
3 5.
- Screw 12 mm bolts into the rocker arm shafts.
3!#-
prevent them from separating.
&
- Remove each rocker arm while slowly pulling out
1&#3!!3! !!

RUBBER BAND the intake and exhaust rocker arm shafts.
#/ #-
ROCKER ARMS
12 mm BOLTS
*- Remove the intake and exhaust rocker shaft orifices.

1&#/ #-
.h
NOTE: The shapes of the rocker shaft orifices of the

84 94# ROCKER SHAFT
intake and exhaust are different. Identify the parts as
#/ -
they are removed to ensure reinstallation in the original
& !!
!
locations.
!-
INTAKE HDBKEH
EIHAUET ROCKER
SHAFT ORIFIBE
EHRFT DRIFICE
Clea n_ (II-RINGS Clea n.
Replace.

6 _ _
) *#2*#
5
6 C 32
NOTE:
84 9
9 Identify parts as they are removed to ensure reinstallation in original locations.
& !!
!!-
Inspect rocker shafts and rocker arms (See Page 6-0-33).
##;'!++<-
....
Rocker arms must be installed in the same position if reused.

1# !! -
Clean the intake and exhaust rocker shaft orifices before installing.
!#/ #!!
-
After installing the rocker shaft orifices, try to turn the rocker shaft to make sure that the orifice has been inserted in the
%!!
#A ##
hole of the rocker shaft correctly. If the orifice is in place, it should not turn.
!#!-!A ! -
&
Prior to reinstalling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces.
!!
A!!!!&A!! -
INTAKE ROCKER ARM ASSEMBLIES
4k—l—’ C‘I'LINDEH NUMBER
l f l l
21} mm SEALING BOLT
49 N-rn [5.0 kgf-m, 3E Ibf-hl
INTAKE ROCKER %/INTAKE ROCKER
sHAFT
.
1 i I gagyoaICE
‘ |
I I I I I I'
I l I'
I . I"
I D NI IIHIIIII l l {- I'l lI O
o 0 I'l
O Q C OléI' O Ddoac g%
00
fi;
\
I'm 0 o . l
O O 6 0 L53 O 6‘ C) O O-MNGS
Haplaca.
(:1— 0' ‘35“ 5 OC.‘
cboO
Iaaarrl a,
My
O o
HOLE I ‘ [I
(OIL CONTROL II 1II
__
WASHER ORIFICE) ' I

EXHAUST ROCKER
Replace.
_I—-—
SHAFT ORIFICE
Clean.
EXHAUST ROCKER
SHAFT
RUBBER BMIID
| No. 2 No. 1
EH HAUST ROCKER ARM ASSEMBLIES

CYLINDER NUMBER

6

6-C-33
5
Measure both the intake rocker shaft and exhaust rocker
, ##/ # 3.
+- Measure inside diameter of rocker arm and check
, ##
shaft.
- for out-of round condition.
-
1.
- Measure diameter of shaft at first rocker location.
, #!- Rocker Arm-to-Shaft

6
Clearance:
F
Inspect rocker arm Intake and Exhaust
6%
face for wear.
/,(0F 0.025 - 0.052 mm
(0.0010 - 0.0020 in)
/$@$$$$@$$$ 0
Service Limit:
- & F 0.08 mm (0.003 in)
$@$8/$@$$ 0
MICROMETER
2.
- Zero gauge to shaft diameter.
I

-
Surface should be smooth.

CYLINDER BORE
Repeat for all rockers.
1!!#-
- If over limit, replace rocker shaft and all
&!A!#!!
overtolerance rocker arms.
&!#-
NOTE: If any rocker arm needs replacement,
84 9#!A
replace all three rocker arms in that set (primary,
!!!#;A
mid, and secondary).
A<-
MICHDMETEH

6
Inspection

6-C-34
5
NOTE: When reassembling the primary rocker arm, carefully
84 92!
#A !!
apply air pressure to the oil passage of the rocker arm.
! !
#-
1.
- Inspect the rocker arm piston. Push it manually.
#- !!-
- If it does not move smoothly, replace the rocker
&!A!#
arm assembly.
!-
PRIMARY ROCKER ARM
MID ROCKER ARM
SECONDAR‘I’
ROCKER ARM
Chuck piston movement

NOTE:
84 9
0 Apply oil to the pistons when reassembling.
%!!3!
-
0 Bundle the rocker arms with a rubber band to
) !#3
prevent them from separating.
&
-

Camshaft
Inspection

6-C-35
53
NOTE: Do not rotate the camshaft during inspection.
84 9(
- +- Seat the camshafts by pushing them toward the

3
1. 1&##-
- Remove the rocker arms and rocker shafts. distributor end of the cylinder head.
!-
NOTE: Rocker arms must be installed in the same
84 91# !! *- Zero the dial indicator against the end of the
I!

position if reused.
- camshaft, then push the camshaft back and forth.
A #-
Put the camshafts, camshaft holders and holder plates
- A!!! Read the end play.
1!-
on the cylinder head, then tighten the bolts to the
!A
! Camshaft
End Play:
%'#F
specified torque.
F - Standard (New): $@$3$@3
/,(0F 0.05 - 0.15 mm
Specified torque:

BF (0.002 - 0.006 in)
/$@$$$@$$5 <
1 to 20: 8@3

$F 8 x 1.25 mm Service Limit:
- & F 0.5 mm (0.02 in)
$@3/$@$ 0
25 Nm (2.6 kgf/m, 19 lbflft)
3,/@56! 2:9* 2 0
21 to 26: 5@$

5F 6 x 1.0 mm
12 Nm (1.2 gf/m, 8.7 lbflft)
,/@6! 2:8@7* 2 0
31$- 1'13" 12115 “3.? .? "11 {5' 21‘
- Remove the camshaft holders and holder plates

1&!!!
bolts from the cylinder head.
!!-
- Lift the camshaft out of the cylinder head, wipe it
!A3
clean, then inspect the lift ramps. Replace the
!A!-1!
camshaft if any lobes are pitted, scored, or
!AA
excessively worn.
/&!3-
$- Clean the camshaft holder surfaces in the cylinder
!! !
head, then set the camshaft back in place.
A#!-
'- Place a plastigage strip across each journal.
!!

7 !-
5- Install the camshaft holders and holder plates.
!!!!!-
Torque the bolts to the values and in the sequence
4F !&! F
shown in left column.
3!! -

Camshaft

/
?0
6-C-36
55
10. , 3!

0- Measure the widest portion of the plastigage on each Measure cam lobe height.
, !
-
journal.
7 !-
Camshaft-to-Holder
Oil Clearance

.

/,(0F 0.050-0.089 mm
(0.0020-0.0035 in)
/$@$$$$@$$3 0
Service Limit:
- & F 0.15 mm (0.006 in)
$@3/$@$$5 0
Inspect this area for wear.
INTAKE EXHAUST
SEC SEC MID PHI
l
PFII MID
11. !!! !9

- If camshaft-to-holder oil clearance is out of tolerance:
l
0 And the camshaft has already been replaced, you
%!!A TIE T/B
—.g_
!!-
0 If the camshaft has not been replaced, first check
!A# PHI: PRIMARY MID: MID SEC: SECONDARY
total runout with the camshaft supported on
! 3 T.i B: TIMING BELT
V-blocks.
:!#- &
Cam Lobe Height/,(0F
Camshaft
Total Runout:

F 6
Intake %
Exhaust
/,(0F 0.03 mm (0.001 in) max. Primary
+*A0*
34,041 mm ++A$*
33,745 mm
Service Limit:
- & F 0.04 mm (0.002 in)
$@$/$@$$ 0 (1,3402 in)
;A+*0< (1,3285 in)
;A+'<
Mid
, +$A5
37,229 mm +A$0*
36,704 mm
(1,4657 in)
;A*$< (14450 in)
;**0<
Secondary
+*A0$
34,071 mm +*A'+
34,683 mm
(1,3414 in)
;A+**< (1,3655 in)
;A+<
Rotate camshaft
while maa su ring
- If the total runout of the camshaft is within

! 3
!A!!-
! !A!
camshaft and recheck. If the bearing clearance is
#-
!
still out of tolerance, replace the cylinder head.
!! !A!!-
4-:4- !4-
Valves,

-
Removal
Valve Sprinqs and Valve Seals
6-C-37
57
84 9&!&&!&
& 4-)
F
Valve Dimensions:
so that each item can be reinstalled in its original position.
!!
!-
1.
- Using an appropriately sized socket and plastic mallet,
?
!H#!!!A
lightly tap the valve retainer to loosen the valve keepers
!
!&!&!&!&#
before installing the valve spring compressor.
!!
&!&
-
_.J|_,_D
PLASTIC MALLEI'
Intake Valve
64-
A Standard (New):
/,(0F 34.90 - 35.10 mm
@9$3@$
(1.374 - 1.382 in)
/@7@8 0
B Standard (New):
"/,(0F 105.40 - 105.70 mm
$3@$$3@7$
(4.150 - 4.161 in)
/@3$@5 0
C Standard (New):
/,(0F 5.475 - 5.485 mm
3@733@83
(0.2156 - 0.2159 in)
/$@35$@39 0
C Service Limit:
- & F 5.445 (0.2144 in)
3@3/$@ 0
D Standard (New):
)/,(0F 1.05 - 1.35 mm
@$3@3
(0.041 - 0.053 in)
/$@$$@$3 0
2.
- Install the spring compressor. Compress the spring and
!!
-
D Service Limit:
)- & F 0.85 mm (0.034 in)
$@83/$@$ 0
remove the valve keeper.
&&!&#- Exhaust
% Valve
4-
VALVE SPRING COMPRESSOR A Standard (New):
/,(0F 29.90 - 30.10 mm
9@9$$@$
01151 — 001000 (1.177 - 1.185 in)
/@77@83 0
B Standard (New):
"/,(0F 105.00 - 105.30 mm
$3@$$$3@$
(4.134 - 4.146 in)
/@@5 0
VALVE SPRING C Standard (New):
/,(0F 5.475 - 5.485 mm
3@733@83
COMPRESSOR
(0.2156 - 0.2159 in)
/$@35$@39 0
ATTACHMENT
01751 - “10100 C Service Limit:
- & F 5.445 (0.2144 in)
3@3/$@ 0
D Standard (New):
)/,(0F 1.65 - 1.95 mm
@53@93
(0.065 - 0.078 in)
/$@$53$@$78 0
D Service Limit:
)- & F 1.45 mm (0.057 in)
@3/$@$37 0
Valve Seats
4-
Reconditioning

! 6-C-38
58
1.
- Renew the valve seats in the cylinder head using a valve
13&!&!
&!& AG‘I'UAL
seat cutter.
- SEATING
5U RFAGE
Pnussmu BLUE COMPOUND l

6.
- The actual valve seating surface, as shown by the
4 !&!&
A3
blue compound, should be centered on the seat.
! A !-
1
;!&!&<A
If it is too high (closer to the valve stem), you
must make a second cut with the 60° cutter to
# 30P
move it down, then one more cut with the 45°
&3A 3*P
cutter to restore seat width.
3-
1 !3;!&!&
<A
If it is too low (close to the valve edge), you must
make a second cut with the 30° cutter to
# 3+0P
move it up, then one more out with the 45°
& A 3*P
NOTE: If guides are worn (See Page 6-C-39), replace
84 9
3;'!+5<A! cutter to restore seat width.
3-
them (See Page 6-C-40) before cutting the valve seats.
;'!*0<
&!&- NOTE: The final cut should always be made with
84 94! !!33
2.
- Carefully cut a 45° seat, removing only enough material
!! *PA&
!
! the 45° cutter.
*P -
to ensure a smooth and concentric seat.
- 7.
$- Insert the intake and exhaust valves in the head
#/ &!&
3.
+- Bevel the upper edge of the seat with the 30° cutter and
)&!
3+0P and measure valve stem installed height.
&!&!!
-
the lower edge of the seat with the 60° cutter. Check the
!3
30P -# Intake Valve Stem Installed Height:
64-. ! F
width of the seat and adjust accordingly.
37
!- Standard (New): @3@7
/,(0F 42.5 - 42.7 mm
4.
*- Make one more very light pass with the 45° cutter to
,#&!
3*P (1.673 - 1.681 in)
/@57@58 0
remove any possible burrs caused by the other cutters.
&! - Service Limit:
- & F 42.95 mm (1.691 in)
@93/@59 0
Valve Seat Width:F
4-1 Exhaust
% Valve Stem Installed Height:
4-. ! F
Standard (New):
/,(0F Standard (New): @9@
/,(0F 43.9 - 44.1 mm
Intake:
6F 1.30 - 1.50 mm 10.051 - 0.059 in)
@$@3$$@$3$@$39 0 (1.728 - 1.736 in)
/@78@75 0
Exhaust:
% F 1.25 - 1.55 mm (0.049 - 0.061 in)
@3@33/$@$9$@$5 0 Service Limit:
- & F 44.35 mm (1.746 in)
@3/@75 0
Service Limit:
- & F 2.00 mm (0.079 in)
@$$/$@$79 0
.1'
l.—
I
SEAT WIDTH ——l\—

l
,1
l "f":i‘“ :r
gl
“-4.. VALVE STEM
"~\{_ INSTALLED HEIGHT
\dfihmew...
5.
- After resurfacing the seat, inspect for even valve
%
A&&!&
seating: Apply Prussian Blue compound to the valve

9%! )! &!&
face, and insert the valve in the original location in the
A&!&
!!
head, then lift it and snap it closed against the seat
A!!
8.
'- If valve stem installed height is over the service
&!&!!
&&
several times.
&!- limit, replace the valve and recheck. If it is still over
!A!&!&#-!!&
the service limit, replace the cylinder head; the
&!A!!N
valve seat in the head is too deep.
&!&-
Cylinder Head
# .
Warpage
1!
6-C-39
59 4-
Valve Guides
4-
-
Valve Movement
NOTE: If camshaft-to-holder, oil clearances are not within

84 9!A!!3 Measure the guide-to-stem clearance with a dial
,
!3!
specification, the head cannot be resurfaced (See Page
A ;'! indicator while rocking the stem in the direction of
3!#

6-C-35).
+<- normal thrust (wobble method).
! ;3!<-
If camshaft-to-holder oil clearances are within specifications,
!!!3A Intake Valve Stem-to-Guide Clearance:
64-
F
check the head for warpage.
#3
- Standard (New): $@$3$@
/,(0F 0.05 - 0.11 mm
¢ If warpage is less than 0.05 mm (0.002 in), cylinder
3
!0-0;0-00<A! (0.002 - 0.004 in)
/$@$$$@$$ 0
head resurfacing is not required.

F - Service Limit:
- & F 0.16 mm (0.006 in)
$@5/$@$$5 0
¢ If warpage is between 0.05 mm (0.002 in) and 0.2 mm
3
30-0;0-00<0- Exhaust
4-
F
(0.008 in), resurface the cylinder head.
;0-00'<A !- Standard (New): $@$$@5
/,(0F 0.10 - 0.16 mm
¢ Maximum resurface limit is 0.2 mm (0.008 in) based on
,/ !0-;0-00'< (0.004 - 0.006 in)
/$@$$$@$$5 0
a height of 147 mm (5.79 in).

*$;-$5<- Service Limit:
- & F 0.22 mm (0.009 in)
$@/$@$$9 0
PRECISION STRAIGHT EDGE VIIVI ”Hind-d 10 mm out from “at.
0 If the measurement exceeds the service limit,

/&!A
recheck it using a new valve.
#
3&!&-
, !

A3- 0 If the measurement is now within the service limit,
33&!A
reassemble with the new valve.
!33&!&-
0 If the measurement still exceeds limit, recheck
!!/!A#
using the alternate method below, then replace the

!!3A!
valve and guide, if necessary.
&!&
A-
84 9%!#

! 8-(-&!&A
3A-(-&!&

A 3!!
gauge.

-
Take the measurement in three places along the valve
4# !!
&!&
stem and three places inside the valve guide.
!&!&
-
# .. ! F The difference between the largest guide measurement
43!

Standard (New): 5@937@$3
/,(0F 146.95 - 147.05 and the smallest stem measurement should not exceed
!! !/
(5.785 - 5.789 in)
/3@7833@789 0 the service limit.
&!-
64-
F
/,(0F 0.025 - 0.055 mm
(0.0010 - 0.0022 in)
/$@$$$$@$$ 0
Service Limit:
- & F 0.8 mm (0.003 in)
$@8/$@$$ 0
Exhaust
4-
F
Standard (New): $@$3$$@$8$
/,(0F 0.050 - 0.080 mm
(0.0020 - 0.0031 in)
/$@$$$$@$$ 0
Service Limit:
- & F 0.11 mm (0.004 in)
$@/$@$$ 0
Valve Guides
4-
Replacement

6-C -40
5$ Reaming
!
NOTE:
84 9 NOTE: For
3&!&
!-
!A!0P;+00P 1.
- Coat both reamer and valve guide with cutting oil.
&!&
3
!-
&
!!

- 2.
1!#3 !!!

¢ It may be necessary to use an air hammer to guides,

A valve guide bore.
&!&
-
remove some valve guides.
&&!&
- 3.
!#33!
1.
(&&!&
! removing it from the bore.
&
-
head.
- 4.
*- Thoroughly wash the guide in detergent and water
4
!3

3
&
-
5.
- Check the clearance with a valve (See Page
#!3&!&;'!
6—C-39).
+5<-
¢ Verify that the valve slides in the intake and
:&!&!#
exhaust valve guides without exerting
/ &!&
3 /

-
pressure.
REAMEFI HANDLE
Turn raamar in
clockwise direction
only.
VALVE GUIDE DRIVER,

5.5 mm
01742 - 0010100
2.
- Drive in a new valve guide to the specified depth.
(&3&!&
-
VALVE GUIDE DRIVER. .
5.5 mm
n‘nu — 0010100
VALVE GUIDE HEMEH.

5.525 mm
OTHAH - PJTO‘IW

4- . ! F
Standard (New):
/,(0F
Intake:
6F 14.55 - 15.05 mm (0.573 - 0.593 in)
@333@$3/$@37$@39 0
Exhaust:
% F 14.95 - 15.45 mm (0.589 - 0.608 in)
@933@3/$@389$@5$8 0
VALVE GUIDE 1
CVUNDEH
Measure here HEAD
«V XXX/T ////'/
4-:4- !4-
Valves, Valve Springs and Valve Seats

Installation
6-C-41
5
- Coat the valve stems with engine oil. Install the valves in
&!&3
!-!!&!& *- Install the valve spring and valve retainer, then
!!&!&
&!&A
the valve guides.
&!&
- install the valve spring compressor. Compress the
!!&!&
-
NOTE: Make sure the valves move up and down
84 9,# &!&& 3 spring and install the valve keepers.

!!&!&#-
smoothly.
!- NOTE: Place the end of the valve spring with
84 9!&!&
3
!!
!- closely wound coils toward the cylinder head.
!!3 !3!-
+- Install the valve seals using the valve guide seal installer.
!!&!&!
&!&
!!!- VALVE SPRING COMPRESSOR
NOTE: Exhaust and intake valve seals are not
84 9 / #&!&! 01151 — 0010000
interchangeable.

!-
W'I-IITE BLACK
SPRING SPRING VALVE SPRING
COMPRESSOR
ATTACHMENT
07757 - PJ1O1DID
INTEKE VALVE SEAL EXHAUST VALVE SEAL
STEM SEAL DRIVER

07PM) - 0010000
NOTE: User 5.5 mm side. - Lightly tap the end of each valve stem two or three

!&!&3
times with the wooden handle of a hammer to
33!
ensure proper seating of the valve and valve

&!&&!&
keepers.
#-
E VALVE SEAL
NOTE: Tap the valve stem only along its axis so
84 94&!&!!
/
4 fl Replace. you do not bend the stem.
-

6
Rocker Arms

Installation
6-C-42
5
- Install the lost motion assemblies.
!!!!- 4.
*- Install the VTEC solenoid valve and 20 mm sealing
!!:4 !&!&0!
NA
- Install the rocker arms while passing the rocker arm

!!#3!
# bolt.
!-
shaft through the cylinder head.

!- 20 mm SEALING BOLT
0 Valve adjusting locknuts should be loosened and
:!&7
!# !! 4'5 N-m [5.0 Ital-m.
WASHER 35 mm)
adjusting screw backed off before installation.
7
3#!!- Replace.
0 The component parts must be reinstalled in the
4 !!
original locations.

!!-
NOTE: Remove the rubber bands after installing the
84 91& !!

rocker arms.
#-
. . as
VTEC SOLENOID
+-
3. !!#-!#
Install the rocker shaft orifices. If the holes in the rocker VALVE FILTER
arm shaft and cylinder head are not in line with each
!!3 Replace.
other, thread a 12 mm bolt into the rocker arm shaft and
A!# VTEC SOLENOID
VALVE
rotate the shaft.
- E x 1.0 mm
NOTE:
84 9 12 N-m {1.2 kgt-m.
0 The shapes of the rocker shaft orifices for the
4# 3.? lblrl'ti
intake and exhaust are different. The orifices must
#/ -4
be installed in the original locations.
!!
!!-
0 Clean the rocker shaft orifices and install them with
!#!!3
new O-rings.
38
-
EXHAUST ROCKER
SHAFT CIRIFICE INTAKE ROCKER
Clea n. SHAFT OHIFIBE
O'RING Clean.
Replace.
# .
Cylinder Head

Installation 6-C -43
5
Install the cylinder head in the reverse order of removal:
!!!&&!9 - Apply clean engine oil to the threads of the cylinder
%!!
!!
NOTE:
84 9 head bolts.
!-
¢ Always use a new head gasket.
%!3 3
#- +- Tighten the cylinder head bolts is sequence to
4
!!F
¢ Cylinder head and cylinder block surface must be clean.
!!!# !- 29Nm (3.0 kgf/m, 22 Ibf/ft).
5;+-0#
=A!=<-
¢ Turn the crankshaft so the No. 1 piston is at TDC (See
4 #-4(; NOTE:
84 9
Page 6—C-16).
'!<- ¢ We recommend using a beam-type torque
2
F
¢ Do not use the middle cover and lower cover to store
( !&!3& wrench. When using a preset type torque
3-2
F
removed items.
&- wrench, he sure to tighten slowly and not to
3A
!3!
¢ Clean the middle cover and lower cover before
!!&!3& overtighten
&

installation.
!!- ¢ If a bolt makes any noise when you are
!#3
1
- Cylinder head dowel pins must be aligned.
!3! !
- torquing it. loosen the bolt, and retighten it.
F
-!!A
-
CYLINDER HEAD
GhSKET
Replace.
£93: '23] :21: :23; (I?

4. %#!!3
*- Attach the socket to the cylinder head bolt without
lash by turning the socket clockwise slightly, then
!
#!#3!
!A
mark the socket and the cylinder head as shown.
##!3-
CYLINDER
HEAD
- Tighten the cylinder head bolts until the mark on
4
!! !#
the bolt head align to the mark on the cylinder
!!
#!
head (turn the bolt 90°) twice.
; !50P<3-
NOTE: If using a new cylinder head bolt, tighten
84 9
3!!A

the bolt 90° further.
!50P -
# .
Cylinder Head

/
?0
6-C -44
5
- Tighten the intake manifold mounting bolt (See Page
4
#!
!;'! 10. %!!F
# A
0- Apply liquid gasket around the rubber cap, then
6—C-28).
'<- install the rubber cap.
!! -
$- Install the exhaust manifold bracket, and tighten the new
!!/ !#A
3 RUBBER CAP
self-locking nuts (See Page 6—C-28).
!!#
;'!'<-
'- Install the camshafts and camshaft oil seals.
!!!!-
NOTE:
84 9
0 Install the camshafts with the keyways facing up.
!!3#3
-
0 Install the oil seal with the spring side facing in.
!!!!3

-
0 The oil seal housing surface should be dry.
4!!
!-
5- Clean and install the oil control orifice with a new O-ring
!!!!!338
in the oil passage of the No. 3 camshaft holder.

!
-+!-
'\ f
O 00
O O
C)
11. %!!F

#

- Apply liquid gasket to the head mating surface of
the No. 1 and No. 5 camshaft holders on both the
--!
intake and exhaust side. Confirm that the camshaft
#/ -
keyways face up, then place those holders,
#3 A!!A
together with the No. 2, No. 3 and No.4 camshaft

3-A-+-*
OIL CON'I‘RDL
holders, on the cylinder head.
!A!-
ORIFICE
Clean. D'H'NG NOTE: The arrows marked on the camshaft
84 943#
Raplace. holders should point toward the timing belt.
! !3
!-
- %!!F
#-
Apply liquid gasket to the shaded areas.
No.5 No. 1
- EXHJIUQT
GO
# .
Cylinder Head

/
?0
6-C-45
53
12. 4
!F 3!3-
- Tighten the bolts in the sequence shown below. 14. !!
!;'!<-
*- Install the timing belt (See Page 6—C-16).
15. %7 &!&!;'!5<-
- Adjust the valve clearance (See Page 6-C-9).
16. !!&
#
&
- Install the head cover gasket in the groove of the
cylinder head cover. Seat the recesses for the
!&-
camshaft first, then work it into the groove around
A3#
&
the outside edges.

-
NOTE:
84 9
¢ Before installing the head cover gasket,
)!!
&
#A
thoroughly clean the seal and the groove.

!!!
&-
¢ When installing, make sure the head cover
2!!
A# &
gasket is seated securely in the corners of the

# !
recesses with no gap.
3
-
coRMERS DF
HEAD COVER GASKET THE RECESS
Clean.
lg; .33 {@113 .12: In: ,5; iii: a 33-11; @1

13. !!#&A !!

+- Install the back cover, camshaft pulleys and engine
mount bracket B.
#)-
CAMSHAFI' "EV
PULLEV
CYUNDEH HEAD
COVER
CORNERS OF
59 Min I61] kgf-m. THE RECESS
43 Ibf-fll
17. %!!F
#&
#
$- Apply liquid gasket to the head cover gasket at the
'II} x 1.25 mm eight corners of the recesses.

-
:4 Mm {4.5 Iig‘l-rn. NOTE:
84 9
33 Ibf-fll ¢ Use liquid gasket, Part No. O8C70-K0234M,
?!F
#A-0'$0>0+*,A
08C70-K0334M or 08C70-X0331S.
0'$0>0++*,0'$0R0++-
¢ Check that the mating surfaces are clean and
#
!
!
!F
#-
(!!&
&!!
!F
#-
A!!F
#&

BACK COVER B x 1.25 mm
old residue.
! -
ENGINE MOUNT 2‘ him :24 kgf'm.
BRACKET B 17 Ibl-ftl ¢ After assembly, wait at least 30 minutes
%!A3!+0
!!

3!-
Apply liquid gasket To

The shaded areas.
Cylinder Head
# . 6-C-46
55

/
?0
18. 2!!
!&A!
'- When installing the cylinder head cover, hold the head 19. 4
3-!
5- Tighten the nuts in two or three steps. In the final
&
#
&!

step, tighten all nuts, in sequence, to 12 Nm (1.2
A
!! AF A;-
!
; kgf/m, 8.7 lbf/ft).
#
=A'-$!=<-
semicircles).
84 9%!A3!+0
Once the cylinder head cover is on the cylinder head,
8!&!A before filling the engine with oil.
!!

3!-
slide the cover slightly back and forth to seat the head
!&!
!# LE: 133;. a-~.
cover gasket.
&
#-
NOTE:
84 9
)!!
!&A!
!
33!- -:. a
( 3!F
#3 7~ '1 {J
applied.
!- "\_,_<
0 Replace the washer when damaged or
1!33

deteriorated.
- : = .3
. |
E I 1.0 mm
12 film (1.2 kgf—m.
3.? Itl
\@ CYLINDER
WASHER \® HEAD COVER
(I?!) {S's C13 {3; It?)
20. %!!A#!! A
0- After installation, check that all tubes, hoses and
!!!-
21. A
B-

Sgecial Tools
7-A-2
7
Ref No.
O 1- O Tool Number
4! O Description
( Qty
OD O Remark
1#
O O 07LAB - PV00100
0$%):0000 Ring Gear Holder
1
.6! O1 O
LCDIPMA
O O 07PAF 000000
0$% - 0010000 Piston Pin Assembly Tool Set
%!4! O1 O
O O 07PAF 0000
0$% - 0010650 Piston Collar, 0D. 19 mm
!!A8-(-5 O1 O
_\
O + O 07749 - 0010000
0$$*5000000 Handle Driver
6!(& O1 O
O * O 07948 - SBOO101
0$5*')000 Driver Attachment, 96 mm
(&%A5 O1 O
Cit-1
133'

Illustrated Index
7-A-3
7
NOTE:
84 9
Apply liquid gasket to the mating surfaces of the right side cover and oil pump housing before installing them.
%!!F
#

&!
!!
-
Use liquid gasket part No. 08C70-K0234M, 08070-K0334M or, 08C70-X0331S.
?!F
#-0'$0>0+*,A0'$0>0++*,A0'$0R0++-
Clean the oil pan gasket mating surfaces before installing it.
!!
#
!!
-
&
Lubricate all internal parts with engine oil during reassembly.

!!!3
!
!-
DRAIN BIDLT Ii 11. 1.9 mm
411 Mm 11.5 Ital-m. 3:1 lhf-fll 12 N'm l1.2 kgt-m. FLYWHEEL COVER
8.? lbf-ftl
DIL PAM GASKET
6 1-1 1.0 mm
Fla place.
12 N11“ “.2 kgf‘m, 8.1 Ibt-fll
WAS HER
OIL PAN Ffeplace.
Flefer to page 7101-24
when installing. 12 x 1.0 mm
118 N-m
I121} kgf-m. B? Ibf-ft]
11 1: 1.5 mm Apply liquid gasket In

51 Ill-m these points.
15.2 kgf-m. 33 Ibfvftl
Apply engine oil to the bolt
threads.
NOTE: After torquing
each ca 1:. turn are nkshafl FLYWHEEL
to check for binding.
MAIN BEARING CAP - I - ‘1

MAIN BEARINGS \i’i
Selection, page ?-A-8 __
NOTE: New main bearings must " ' CHANKSHAFT lCiIL SEAL
be selected by matching crank Installation.
and block identification markings. page Y—A—Z‘D
Replace.
CHANKSHAFr-————_pi
Inspection. page T-A—1 2
6 x 1.0 mm 6 11 1.0 mm
11 N11! :1.1 kgf-m, 3.0 Ibr-MMr‘T M;- 11 N-m 11.1 kgf—m.
8.0 lb‘l-t‘tl
OIL SCREEN ———-'—"_’L "
6 x 1.0 mm /6I,-
11 Mm 11.1 kgfm, 8.01bf-ftl ' ' Apply liquid gasket
to mating surface.
GASKET
Replace. DOWEL PIN
lIZIIL PUMP
THFIUST WASHERS
Grooved sides face outward.
page 8-15.
NOTE: Thrust Washer thickness
is fixed and must not be changed
by grinding or shimming.
DOWEL PIN
BREATHING PORT COVER
CHANKSHAFI‘ SEAL Replace. MOUNT BOLTS
Installation, page 8-18 E 11: LII mm
Replace. 5111.0mn1 11 N-m l1.1 kgf-m, 8.1] Ibf'ftl
11 Min “.1 kgf—m. Apply llquid gasket to
3.0 Ibf-fl] the belt threads.

4

&A
!#!!3
9
(See Page 7-A-24)
;'!$%*<
See Page 7-A-8)
;'!$%'<
AAA/\AA
See Page 7-A-12)

;'!$%<
See Page 7-A-20)
;'!$%0<
See Page 8-14)
;'!'*<
See Page 8-16)
;'!'<
See Page 8-18)
;'!''<
Illustrated Index
7_A-4
7
(cont’d)
/
?0
NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft identification markings (see
84 93
!

!##
;
page 7-A-9).
!$%5<-
”7%
&

!!!3
!
!-
PISTON IN$TALLATI£IN DIRECTION:
EXHAUST
INTAKE
/
PISTON RINGS
‘_.___._,_..__—- Replacement. page lit-1e
Measurement. pages T-A-ts, 19
Alignment. page lie-1‘3
PISTON FIN
Rernuval. page T-AAIE PISTON
Installation, page EVA-16 \ Inspection, page "LA-13
Inspection. page T-A-I? @| NOTE: Before removing piston. inspect the
top of the cylinder bore for carbon build up or
ridge. Remove ridge it necessary. page Iii-11
CONNECTING HOD
ENGINE BLOCK
End play. page ‘f—A-G
Selection, page lit-16 Cylinder bore inspection, page f-A-‘I d.
Warpage inspection, page 3‘ A 14
Cylinder bore honing, page Tue—1.5
CON NECTING HUD

BEARINGS
Clearance, page T-A—B
Selection, page TIA-Q
Inspect tep- pf each cvtinder bore

for carbon build-Lip er ridge
before removing piston.
Remove ridge if necessary. page T-A-H
CDNNEETINE HOD BEARING CAP

Installation. page T-A-ZI
NOTE: Install caps se the Q" ' CONNECTING BUD CAP NUT
bearing recess is en the B x 0.15 mm
same side as the recess @FHH—HE 31 Film [3.2 kgf-rn,
in the red. 23 Ibfrfl]
Apply engine oil to the belt threads.
NCITE: After torquing each heating
cap. rntate crankshaft to check fur
binding.

4

&A (See Page 7-A—18)
;'!$%'<
!#!!3
9 (See Page 7-A—19)
;'!$%5<
(See Page 7-A-15)
;'!$%< (See Page 7-A—13)
;'!$%+<
(See Page 7-A-6)
;'!$%< (See Page 7-A—11)
;'!$%<
(See Page 7-A-16)
;'!$%< (See Page 7-A—14)
;'!$%*<
(See Page 7-A-9)
;'!$%5< (See Page 7-A—15)
;'!$%<
(See Page 7-A-21)
;'!$%<
Flmheel
+#( 7-A-5
73
Replacement

Remove the six flywheel bolts, then separate the flywheel

1&/!3!!A!3!
from the crankshaft flange. After installation, tighten the bolts
#!
-%!!A
!
in a crisscross pattern.
-
RING GEAR HOLDER
07LAB—PVOO‘I 00
ENGINE
BLOCK
RING GEAR
'“5933‘ ”"9 933' 12 x 1.0 mm
118 N-m
teeth for wear or
damage. {12.0 kgf-rn, a? Ibi-ft}
a RING GEAR HOLDER

OVLAB— PVOO‘I [IO

!
6
Connectinq Rod and Crankshaft
End Play
%'#
7-A-6
75
Connecting Rod End Play:

!
%'#F Push the crankshaft firmly away from the dial indicator,
#!3!A
Standard (New):
/,(0F 0.15 - 0.30 mm
$@3$@$ and zero the dial against the end of the crankshaft.
H!
#-
(0.006 - 0.012 in)
/$@$$5$@$ 0 Then pull the crankshaft firmly back toward the
4 !!#!#3
Service Limit:
- & F 0.40 mm (0.016 in)
$@$/$@$5 0 indicator; dial reading should not exceed service limit.
N!
!/&!-
Crankshaft
6 End Play:
%'#F
Standard (New):
/,(0F 0.10 - 0.35 mm
$@$$@3
If out-of-tolerance, install a new connecting rod.
!A!!3
- (0.004 - 0.014 in)
/$@$$$@$ 0
If still out-of-tolerance, replace the crankshaft (See Page
!! !A!#;'! Service Limit:
- & F 0.45 mm (0.018 in)
$@3/$@$8 0
7-A—10) and (See Page 7-A—21).
$%0<;'!$%<- 0 If end play is excessive, inspect the thrust washers
!/&A 3
and thrust surface on the crankshaft. Replace
#-1!
parts as necessary.
-
NOTE: Thrust washer thickness is fixed and must not
84 94 3#/
be changed either by grinding or shimming.

-
Thrust washers are installed with grooved sides facing
4 3!!3
&

outward.
3-
" !
Main Bearings

Clearance
7-A-7
77
- To check main bearing-to-journal oil clearance, remove
4#
7 !!!A& Main Bearing-to-Journal Oil Clearance:
" !
<
F
the main caps and bearing halves.

!&- Standard (New):
/,(0F
- Clean each main journal and bearing half with a clean
!7 !
!3! No. 1, 5 Journals:
,
@:3<
F
shop towel.
3!- 0.018 - 0.036 mm (0.0007 - 0.0014 in)
$@$8$@$5/$@$$$7$@$$ 0
+- Place one strip of plastigage across each main journal.
!!

7 !- No. 2, 3, 4 Journals:
,
@::<
F
NOTE: If the engine is still in the car when you bolt the
84 9
!!3 ! 0.024 - 0.042 mm (0.0009 - 0.0017 in)
$@$$@$/$@$$$9$@$$7 0
main cap down to check clearance, the weight of the
3#!A3
Service Limit: 0.05 mm (0.002 in)
- & F$@$3/$@$$ 0
crankshaft and flywheel will flatten the plastigage further
#!3!3!!!!

than just the torque on the cap bolt, and give you an
7 F !A
&
incorrect reading. For

- an accurate reading, support the

A
crank with a jack under the counterweights and check
#37# 3
#
only one bearing at a time.
!
-
*- Reinstall the bearings and caps, then torque the bolts.
1!!
AF !-
1st step:
F 25 Nm (2.5 kgf/m, 18 lbflft)
3,/@36! 2:8* 2 0
Final step: 3,/3@6! 2:8* 2 0
+ F 51 Nm (5.2 kgf/m, 38 lbflft)
NOTE: Do not rotate the crankshaft during inspection.
84 9(#
- 'VT
.__¢.(:
- Remove the cap and bearing again, and measure the
1&

A .. '.|;,.'Ii:l‘_$J/
. _"'H-._\__L_:.r/
widest part of the plastigage.
3!

-
6.
- If the plastigage measures too wide or too narrow,
!

33A
(remove the engine if it’s still in the car), remove
;&
B!!<A&
the crankshaft, and remove the upper half of the
#A& !
bearing. Install a new, complete bearing with the

-!!3A!
3
same color code (select the color as shown on the
!;!!3
next page), and recheck the clearance.
/
<A#!-
7.
$- If the plastigage shows the clearance is still
!

3!!!
incorrect, try the next larger or smaller bearing (the
A/!
!!
;
color listed above or below that one), and check
!!&!3<A#
again.

-
NOTE: If the proper clearance cannot be obtained
84 9!
by using the appropriate larger or smaller bearings,

!
!!
A
replace the crankshaft and start over.
!#&-
" !
Main Bearings
Selection

7-A-8
78
NOTE: If the codes are indecipherable because of an
84 9! Main Journal Code Location (Numbers)
<

&

/,*0
accumulation of dirt and dust, do not scrub them with a wire
! A 33
brush or scraper. Clean them only with solvent or detergent.
-!!3!&
-
6
Crankshaft "

&

Bore Code Location
Letters have been stamped on the end of the block as a code
&!#
for the size of each of the 5 main journal bores.
H7 !-
Use them, and the numbers stamped on the crankshaft
?A #
(codes for main journal size), to choose the correct bearings.
;7 !H<A
-
Bearing Identification
Color CULlL‘ IS Lurgur crank hurt.
on the
edge of |_A l B l C ' D ]
the bearing. '
—t~ Smaller hHHrIng Ithmknri
Hod l Pink l Yullnw Green ]

, .
am'ru—a
Pink i Yellow Green Brown
_..___
Yellow Green Brnwn I Black
L GrL-L‘n Brown | Black I EllLIE
Smaller Smaller
PULLE‘I’ END main bearing
(No. 1 JOURNAL! journal lthiCkErl
FLYWHEEL END
IMO. E JDURHALl
Connectinq Rod Bearinqs

!
" !

Clearance
7-A-9
79 Selection

- Remove the connecting rod cap and bearing half.

1&

!- NOTE: If the codes are indecipherable because of an
84 9!
NA
- Clean the crankshaft rod journal and bearing half with a

!#7 !
!3 accumulation of dirt and dust, do not scrub them with a
! A 3
clean shop towel.
!3!- wire brush or scraper. Clean them only with solvent or
3 -!!3!&
+- Place the plastigage across the rod journal.
!!

7 !- detergent.

-
*- Reinstall the bearing half and cap, and torque the nuts.
1!!
!AF - Connection Rod Code Location

&

Torque

B Numbers have been stamped on the side of each
&
,/@6! 2:* 2 0 connecting rod as a code for the size of the big end.

H
-
84 9(#
- Use them, and the letters stamped on the crankshaft
?A!#
- Remove the rod cap and bearing half and measure the
1&
! (codes for rod journal size), to choose the correct
;7 !H<A
3!

- bearings.

-
Connecting Rod Bearing-to-Journal Oil Clearance:

!
" !
<
F
Standard (New):
/,(0F 0.020 - 0.038 mm
$@$$$@$8 Half of number I5 0
(0.0008 - 0.0015 in)
/$@$$$8$@$$3 0 slamped on hearing
cap and the other
Service Limit:
- & F 0.05 mm (0.002 in)
$@$3/$@$$ 0 hall is stamped on
rod.
PLASTIGAGE STRIP
!

33A
remove the upper half of the bearing, install a new,
& !
A!!3A
Connecting Rod Journal Code Locations (Letters)
complete bearing with the same color code (select the
!
3!;!
color as shown in the right column), and recheck the
!3
! <A#
clearance.
!-
$- If the plastigage shows the clearance is still incorrect, try
!

3!!!A
the next larger or smaller bearing (the color listed above
/!
!!
;!!&
or below that one), and check clearance again.
!3<A#!
-
NOTE: If the proper clearance cannot be obtained by
84 9!
using the appropriate larger or smaller bearings, replace

!
!!
A!
the crankshaft and start over.
#&-
Bearing Identification
Cnlur [Lode Is an the
*——-—O~ Lurgur big and bun:
Edge. of
the bearing 1 I 2 I 3 4
A or | ———I-Sr'naller bearing (thicken

hurt-vii '-
Punk _ ”Yellow qn
C ur “I . . p _ ..
D or llll Yellow Green Brown
Green i Brown Black
Smaller Smaller
Brown Black 'Blue
rnd bearing
journal tttl-tcll
'
6 7_A_10
7$

-
Removal
1.
- Remove the oil pan assembly.
1&!!- 5.
- Remove the bolts. To prevent warpage, unscrew
1&!-4&3
A 3
2.
- Remove the right side cover.
1&
&- the bolts in sequence 1/3 turn at a time; repeat the
!F =+ N
RIGHT SIDE sequence until all bolts are loosened, then remove
F !!!!!A&
COVER the bearing cap.

-
MAIN BEARING CAP BOLTS LOOSENING
,"%,'"&&%,,
SEQUENCE
%=;%,%
E
DDWEL PIN
3.
+- Remove the oil screen.
1&!-
4.
*- Remove the oil pump.
1&! -
DIL SCREEN
GASKET
Replace. 6.
- Remove the rod caps/bearings and main
1&=

caps/bearings. Keep all caps/bearings in order.
=
->!!=
-
7.
$- Lift the crankshaft out of the engine, being careful
#
A
!
not to damage journals

7 !
OIL PUMP DDWEL PIN
O—RING
Replace.
CRANKSHAFT
'
6 7_A_11
7
Removal (cont’d)

-/
?0
8.
'- Remove the upper bearing halves from the connecting
1&
!&
rods and set them aside with their respective caps.

3&-
9.
5- Reinstall the main caps and bearings on the engine in
1!!

proper order.
-
10. !
!
0- If you can feel a ridge of metal or hard carbon around
the top of each cylinder, remove it with a ridge reamer.
!A&3
-
Follow the reamer manufacturer’s instructions. If the
!!3 B -
ridge is not removed, it may damage the pistons as they

&A

are pushed out.
-
RIDGE REAMEH
11. ?3!&

- Use the wooden handle of a hammer to drive the pistons
out.
-
HAMMEHHANDLE
PBTDN
12. 1!!

- Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
&
=
!-
13. ,#=
!3
+- Mark each piston/connecting rod assembly with its
cylinder number to avoid mixup on reassembly.
! &/ !-
NOTE: The existing number on the connecting rod does
84 94/

not indicate its position in the engine, it indicates the rod

A
bore size.
H-
6
Crankshaft
Inspection

7-A-12
7
¢ Clean the crankshaft oil passages with pipe cleaners or
!#!
3! Out-of-Round and Taper

a suitable brush.
! - 0 Measure out-of-round at the middle of each rod
, !
¢ Check the keyway and threads.
##3- and main journal in two places.
7 !3!-
Alignment
! 0 The difference between measurements on each
43
¢ Measure runout on all main journals to make sure the
, !!7 !# journal must not be more than the service limit.
7 ! &!-
crank is not bent.
#- Journal Out-of-Round:
<

F
¢ The difference between measurements on each journal
43 7 ! Standard (New):
/,(0F 0.0025 mm (0.0001 in) max.
$@$$3/$@$$$ 0@
must not be more than the service limit.
&!- Service Limit:
- & F 0.005 mm (0.0002 in)
$@$$3/$@$$$ 0
Crankshaft
6 Total Indicated Runout:

F
Standard (New):
/,(0F 0.03 mm (0.001 in) max.
$@$/$@$$ 0@
Service Limit:
- & F 0.04 mm (0.002 in)
$@$/$@$$ 0
DIAL INDICATOR
Rotate two complete
revolutions.
Measure our-Of-
rounri ill middle.
Measure Iaper
aI edges.
Support with lathe-

typa tool or V-blncks.
0 Measure the taper at edges of each rod and main

,

journal.
7 !-
0 The difference between measurements on each
43
journal must not be more than the service limit.
7 ! &!-
Journal Taper:
<
F
Standard (New):
/,(0F 0.0025 mm (0.0001 in) max.
$@$$3/$@$$$ 0@
Service Limit:
- & F 0.005 mm (0.0002 in)
$@$$3/$@$$$ 0
Pistons
'

Inspection

7-A-13
7
- Check the piston for distortion or cracks.
##- 3.
+- Calculate difference between cylinder bore
! !3!
NOTE: If cylinder is bored, an oversized piston must be
84 9!A&H diameter (see page 7-A—14) and piston diameter.
;!$%*<-
used.
- Piston to Cylinder Clearance
'

#
- Measure piston diameter at point Afrom bottom of skirt.
, %#- Standard (New):
/,(0F 0.010 - 0.040 mm
$@$$$@$$
A: 5 mm (0.2 in)
F3/$@ 0 (0.0004 - 0.0016 in)
/$@$$$$@$$5 0
Piston Diameter:
'
) F Service Limit:
- & F 0.05 mm (0.002 in)
$@$3/$@$$ 0
Standard (New):
/,(0F 74.980 - 74,990 mm
7@98$7:99$
(2.9520 - 2.9524 in)
/@93$@93 0 SERVICE LIMIl I
1] [lb l1|l1|{0.002 in) —-
Service Limit:
- & F 74.970 mm (2.9516 in)
7@97$/@935 0
L
SKIRT DIAMETER
r
If the clearance is near or exceeds the service
!/&
limit, inspect the piston and cylinder block for
!A!!#
excessive wear.
/&3-
Oversize Piston Diameter
- C'
)
0.25: 75.23 - 75.24 mm (2.9618 - 2.9622 in)
$@3F73@73@/@958@95 0
0.50: 75.48 - 75.49 mm (2.9716 - 2.9720 in)
$@3$F73@873@9/@975@97$ 0
# "
6
Cylinder Block
Inspection

7-A-14
7
1.
- Measure wear and taper in directions X and Y at three
, 3RC 0 If measurements in any cylinder are beyond
!
levels in each cylinder as shown.
!&!!3- Oversize Bore Service Limit, replace the block.
8&H)&A!!#-
0 If block is to be rebored, refer to Piston
!#A
Clearance Inspection (see page 7-A—13) after
!;!$%+<
reboring.

-
NOTE: Scored or scratched cylinder bores must be
84 9!
honed.
-
Reboring Limit: 0.50mm (0.02 in)
*
!& F$@3$/$@$ 0
2.
- Check the top of the block for warpage. Measure
#!#3
-,
along the edges and across the center as shown.
!

3-
SURFACES TCI BE MEASURED
Engine Block Warpage:

%! "
61!F
Standard (New):
/,(0F 0.07 mm (0.003 in) max.
$@$7/$@$$ 0@
Service Limit:
- & F 0.10 mm (0.004 in)
$@$/$@$$ 0
PRECISION STRAIGHT EDGE
/ _
H1
Cylinder Bore Size:
# "
CF
Standard (New):
/,(0F 75.00 - 75.02 mm
73@$$73@$
(2.953 - 2.954 in)
/@93@93 0
Service Limit:
- & F 75.07 mm (2.956 in)
73@$7/@935 0
Oversize
- C
0.25: 75.25 - 75.27 mm (2.9626 - 2.9634 in)
$@3F73@373@7/@955@95 0
0.50: 75.50 - 75.52 mm (2.9724 - 2.9732 in)
$@3$F73@3$73@3/@97@97 0
Bore Taper
"

Limit: /) *(
& F (Difference between first and third

measurement) 0.05 mm (0.002 in).
0$@$3/$@$$ 0@
# "
6
Cylinder Block
Bore Honing
"
.
!
7-A-15
73 '
'
Piston Pins

-
Removal
- Measure cylinder bores, (see page 7-A—14). If the block

, !A;!$%*<-!# NOTE:
84 9
is to be reused, hone the cylinders and remeasure the
A! 0 Use the piston pin assembly tool set (No.
?!!;-
bores.
- O7PAF-0010000)
0$% for removal of piston pins.
000000<&!-
- Hone cylinder bores with honing oil and a fine (400 grit)
6!3
!;*00
< 0 Be sure to use the pilot collar of correct No. as
) !!!-
stone in a 60 degree cross-hatch pattern.
0
- designated.

-
NOTE:
84 9 1.
- Set the special tools as shown.
!!3-
0 Use only a rigid hone with 400 grit or finer stone
?!
3*00
PILOT CELLAR,
such as Sunnen, Ammco, or equivalent.
A%AF &!- DD. 19 mm
0 Do not use stones that are worn or broken.
( 3#- UTPAF - 0010650
1?: Jae-:5;
. 3ft! _-
.
(50'2
Ain‘ot 1.0 w v
m’
t *1 It; N :‘I.I .00
I l i l-in? I; C u’
C
t 0.v o n
0 I
wt
't I"! 0
:6.
I «I
II
I
.‘I 0
1:0
I'
..
+- When honing is complete, thoroughly clean the engine

2
!A
!!

block of all metal particles. Wash the cylinder bores with
!#!!!!-2!3
hot soapy water, then dry and oil immediately to prevent
3A!!& 2.
- Place the piston on the special tools and press the
!!!
rusting.

- pin out using a hydraulic press.

!-
NOTE: Never use solvent, it will only redistribute the grit
84 9& !&A3!!!
Embossed mark lacing up.
on the cylinder walls.
!3!!-
*- If scoring or scratches are still present in cylinder bores

!!!
after honing to the service limit, rebore the cylinder block.

&!A!!#-
NOTE: Some light vertical scoring and scratching is
84 9!
&!

acceptable if it is not deep enough to catch your
!
PILOT COLLAR.
fingernail and does not run the full length of the bore.

! !!!
- 0.0. 19 mm
OTPAF - 00106-50
W CYLINDER BLOCK
CYLINDER NONE _l . ' ll
l H]. _ y
. l
J'fi _ _ . _._. 'i
I NOTE: Use a hydraulic press
1 When pressing pin in or out.
make sure that the recessed
NOTE:
84 9 | portion of the platun aligns
with the lips on the collar.
0 After honing, clean the cylinder thoroughly with
%
A!!
!3
soapy water.
3-
0 Only a scored or scratched cylinder bore must be
8!!
honed.
-

!
7'A'16 Piston Pins
'
'
Connecting Rods
Selection

75

Installation
Each rod falls into one of four tolerance ranges (from 0 to +

!! !
;0V NOTE:
84 9
0.024 mm (0 to + 0.0009 in), in 0.006 mm (0.0002 in)
0-0*;0V0-0005<A0-00;0-000< 0 Use the piston pin assembly tool set (No. 07PAF
?!!;-0$% -
increments) depending on the size of its big end bore. It’s
<
H
-B 0010000) with a hydraulic press.
000000<3 !-
then stamped with a number (1, 2, 3, or 4) indicating the
3 ;AA+A*<
0 Be sure to use the pilot collar of correct No. as
) !!!-
range.

- designated.

-
You may find any combination of 1, 2, 3, or 4 in any engine.
C AA+A*
- The arrow must face the
Normal Bore Size: 48.0 mm (1.89 in)
,
"
CF8@$/@89 0 timing belt EldE of the
engine and the connecting
NOTE:
84 9
rod uil hole must lace the
t Reference numbers are for big end bore size and do
1
H rtmt rJI tlw. trrtqpru!
NOT indicate the position of the rod in the engine.
84
-
t Inspect connecting rod for cracks and heat damage.

#
-
CONNECTING ROD BORE
REFERENCE NUMBER
Hall at number I5 stamped on
hearing cap, the mher half on
connecting rod.
CONNECTING HUD
DIL HOLE
1.
- Install the piston pin as shown.
!!3-
PILEIT cLAFt.
DD. 15 mm
MPAF - timoaac
Embossed mark
facing up.
Instruct balls
and nuts for
51."!55 cracks.
PISTON
I PIN
NOTE: Install the assembled piston and rod with the oil
84 9!!!3!
hole facing the intake manifold.
!
#!-
Piston Pins
'
'
Inspection

7-A-17
77
1.
- Measure the diameter of the piston pin.
, - +- Measure the piston pin-to-piston clearance.
, !-
Piston Pin Diameter:
'
' ) F NOTE: Check the piston for distortion or cracks.
84 9##-
Standard (New):
/,(0F 18.994 - 19.000 mm
8@999@$$$ If the piston pin clearance is greater than 0.024
!
0-0*
(0.7478 - 0.7480 in)
/$@778$@78$ 0 mm (0.0009 in), remeasure using an oversized
;0-0005<A
&H
Oversize:
- CF 18.997 - 19.003 mm
8@9979@$$ piston pin.
-
(0.7479 - 0.7481 in)
/$@779$@78 0 Piston Pin-to-Piston Clearance:
'
'
'
F
NOTE: All replacement piston pins are oversize.
84 9%!!!&H- Standard (New):
/,(0F 0.010 - 0.022 mm
$@$$$@$
(0.0004 - 0.0009 in)
/$@$$$$@$$$9 0
2.
- Zero the dial indicator to the piston pin diameter.
I!-
*- Check the difference between piston pin diameter

#3
and connecting rod small end diameter.

!!-
Piston Pin-to-Connecting Rod Interference:
'
'

!
F
Standard (New):
/,(0F 0.014 - 0.040 mm
$@$$@$$
(0.0006 - 0.0016 in)
/$@$$$5$@$$5 0
'
!
Piston Rings
End Gap
%
7-A-18
78 Replacement

1.
- Using a piston, push a new ring into the cylinder bore 15
?
A 3
! - Using a ring expander, remove the old piston rings.
?

/A&!
-
- 20 mm (0.6 - 0 8 in) from the bottom.
0;0-0'<- - Clean all ring grooves thoroughly.
!!!

&
!-
NOTE:
84 9
I ¢ Use a squared-off broken ring or ring groove
?F #

&
HJLJ) cleaner with blade to fit piston grooves.
!3!
&-
I _ $15-37 ' l Top ring groove is 1.0 mm (0.039 in) wide
4

&-0;0-0+5<3
.Q...
Second ring groove is 1.2 mm (0.047 in) wide

&-;0-0*$<3
Oil ring groove is 2.8 mm (0.11 in) wide.
8!

&-';0-<3-
File down blade if necessary.
!3!-
PISTON RING Do not use a wire brush to clean ring lands or
( 3 !
!
I 15_20 mm cut ring lands deeper with cleaning tool.

!3!
!-
(9.6—0.8 in] +- Install new rings in proper sequence and position
!!3
F
_. J. (see page 7-A—20).
;!$%0<-
END GAP "" NOTE:
84 9
¢ Do not reuse old piston rings.
( !
-
- Measure the piston ring end-gap with a feeler gauge:
,

3!

9
¢ If piston is to be separated from connecting

O If the gap is too small, check to see if you have the

!!A# &
rod, do not install new rings yet.
A!!3
-
proper rings for your engine.

-
RING EXPANDEH
If the gap is too large, recheck the cylinder bore

!
A#!
diameter against the wear limits, (see page

3!A;!
7-A—14). If the bore is over the service limit, the
$%*<-&&!A PISTON RING
cylinder block must be rebored.
!!# -
Piston Ring End-Gap:
'
!%F
Tap Ring
!
Standard (New):
/,(0F $@3$@$
0.15 - 0.30 mm
(0.006 - 0.012 in)
/$@$$5$@$ 0
Service Limit:
- & F 0.70 mm (0.028 in)
$@7$/$@$8 0
Second Ring

!
Standard (New):
/,(0F 0.20 - 0.70 mm
$@$$@7$
(0.008 - 0.028 in)
/$@$$8$@$8 0
Service Limit:
- & F 0.80 mm (0.031 in)
$@8$/$@$ 0
Oil Ring
!
Standard (New):
/,(0F 0.20 - 0.80 mm
$@$$@8$
(0.008 - 0.031 in)
/$@$$8$@$ 0
Service Limit:
- & F 0.90 mm (0.035 in)
$@9$/$@$3 0
'
! 7-A-19 Alignment
!
Piston Rings
Ring-to-Groove Clearance
!

-
79
After installing a new set of rings measure ring to-groove
%!!
3

& 1.
- Install the rings as shown.
!!
3-
clearance:
!9 NOTE: The manufacturing marks must be facing
84 94
#
Top Ring Clearance

! upward.
3-
Standard (New):
/,(0F 0.030 - 0.060 mm
$@$$$@$5$
TOP RING iChraI'nel
(0.0012 - 0.0024 in)
/$@$$$@$$ 0
Service Limit:
- & F 0.13 mm (0.005 in)
$@/$@$$3 0
Second Ring Clearance

!
Standard (New):
/,(0F 0.030 - 0.055 mm
$@$$$@$33
(0.0012 - 0.0022 in)
/$@$$$@$$ 0
Service Limit:
- & F 0.13 mm (0.005 in)
$@/$@$$3 0
FEELER GAUGE
SECOND RING lDarkI

|
Piston Ring Dimensions:
'
!)
F
__ ._ ___l
B
7
a. .-
Top Ring (Standard):

!/0F
A: 2.6 mm (0.10 in)
F@5/$@$ 0
B: 1.0mm (0.04 in)
"F@$/$@$ 0
Second Ring (Standard):

!/0F
A: 3.0 mm (0.12 in)
F@$/$@ 0
B: 1.2 mm (0.05 in)
"F@/$@$3 0
Piston Rings
'
!
Alignment (cont’d)
!/
?0
7-A-20
7$ 6
Crankshaft Oil Seal

Installation
2.
- Rotate the rings in their grooves to make sure they do
1

&#
&
not bind.
- E 4! !# !-
The seal surface on the block should be dry.
MARK Apply a light coat of oil to the crankshaft and to the tip of
%!!
!#
the seal.
!-
1.
- Drive in crankshaft oil seal against right side cover.
(&#!!

&-
NOTE: Drive the crankshaft oil seal in squarely.
84 9(&#!!F !-
HANDLE DRIVER
071'49 0010000
DIL RING
3.
+- Position the ring and gaps as shown:

39 FIIG HT SIDE
DO NOT posit-an any rung gab
COVER
SECOND RING GAP at piston thrust surface-s.
Approx 90
______y DRIVER ATTACHMENT: 96 mm
OTB-48 "5300101
Install seal wuh the
part numbflr SiOE!
1acing Out
2.
- Confirm that the clearance is equal all the way
!F !!!3
__ OILRING around with a feeler gauge.
3!

-
Approx ‘ 15 GAP Clearance: 0.5 - 0.8 mm (0.02 - 0.03 in)
F$@3$@8/$@$$@$ 0
so -
TOP RING GAP ’7 _ 15 __ __ RIGHT SIDE
'\
SPACER GAP
, "~/ can: an
DC:- ‘J-UT pas. tinn am.- rlrig gnu "\
m |i|‘.e-.'.'I1hthe pIL-zluri pm hma 0"- RING GAP
I1 l I ' ._ '“. " )

0.5-0.8 mm -——L,I— —- -
MADE—0.03 in]
RIGHT SIDE ‘i! CRANKSHAFT

COVER .i I OIL SEAL
NOTE: (See page 8-18) for installation of the oil

84 9;!''<!!!
pump side crankshaft oil seal.
#!!-
'

Pistons

Installation
7-A-21
7 6
Crankshaft

Installation
&
&
E )!!
A!
!
Before installing the piston, apply a coat of engine oil Before installing the piston, apply a coat of
E )!!
A!
to the ring grooves and cylinder bores.

&!- engine oil to the ring grooves and cylinder bores.

!

&!-
1.
- If the crankshaft is already installed:
#!!!9 1.
- Insert the thrust washers in the No.4 journal of the
3-*7 !
0 Set the crankshaft to BDC for each cylinder.
#)(!- cylinder block.
!!#-
0 Remove the connecting rod caps, and slip short
1&
A! 2.
- Insert bearing halves in the cylinder block and

!&!!#
sections of rubber hose over the threaded ends of
& connecting rods.

-
the connecting rod bolts.

!- 3.
+- Hold the crankshaft so rod journals for cylinders
6!#7 !!
0 Install the ring compressor, check that the bearing
!!
A#
No.2 and No.3 are straight down.
--+
3-
is securely in place, then position the piston in the
!!A 4.
*- Lower the crankshaft into the block, seating the rod
3#!#A

cylinder, and tap it in using the wooden handle of a
!A
3! journals, into connecting rods No.2 and No.3, and
7 !A
--+A
hammer.
- install the rod caps and nuts finger-tight.
!!

-
0 Stop after the ring compressor pops free, and

A
check the connecting rod-to-crank journal
#
#7 !
alignment before pushing piston into place.
!

!-
0 Install the rod caps with bearings, and torque the
!!3
AF
nuts to:
9
31 Nm (3.2 kgf/m, 23 lbf/ft)
,/@6! 2:* 2 0
#!

bolt threads.
*
@
2.
- If the crankshaft is not installed:
#!!9
0 Remove the rod caps and bearings, install the ring
1&
A!!
compressor, then position the piston in the cylinder,

A!A THl-‘IUST WASHERS
and tap it in using the wooden handle of a hammer.

3!- Grooved sndes lace
outward.
The arrow must face
the timing bell side 5.
- Rotate the crankshaft clockwise, seat journals into
1#!#3A7 !
of the engine. connecting rods No.1 and No.4, and install the rod

--*A!!
caps and nuts finger-tight.

-
NOTE: Install caps so the bearing recess is on the
84 9!!

same side as the recess in the rod.
-
CONNECTING ROD
lCOIL HOLE
RUBBER HDSES
0 Position all pistons at top dead center.
!!-
NOTE: Maintain downward force on the ring compressor
84 9,33

to prevent rings from expanding before entering the
&
/

cylinder bore.
!-
RING
j ,_ cumpnessnn
6
Crankshaft

/
?0
7-A-22
7
6.
- Check rod bearing clearance with plastigage (see page
#
!3!

;! '- Install the main bearing caps.
!!
-
909°
7-A—9), then torque the cap nuts.
$%5<AF - 5- Check clearance with plastigage (see page 7-A—7),
#!3!

;!$%$<A
,/@6! 2:* 2 0 tighten the bearing cap bolts in 2 steps.

!-
#!

bolt threads.
*
@ 1st step: 25 Nm (2.5 kgf/m, 18 lbflft)
F3,/@36! 2:8* 2 0
NOTE: Reference numbers on connecting rod are for
84 91
2nd step: 51 Nm (5.2 kgf/m, 38 lbflft)
F3,/3@6! 2:8* 2 0
big-end bore tolerance and do not indicate the position

! NOTE: Coat the thrust washer surfaces and bolt
84 9 3 !
of piston in the engine.

- threads with oil.
3!@
7.
$- Install the thrust washers on the No. 4 journal. Oil the
!! 3-*7 !-8! MAIN BEARING CAP BOLTS TIGHTENING
,"%,'"&.%,,
thrust washer surfaces.
3 - SEQUENCE
%=;%,%
E 0 El 0
Line up the mark when

installing connecting rod
can.
NOTE: Whenever any crankshaft or connecting

84 92&#

rod bearing is replaced, it is necessary after

!A
reassembly to run the engine at idling speed until it
!
!
!
reaches normal operating temperature, then
!
A
continue to run it for approximately 15 minutes.
/! -
6
Crankshaft

/
?0
7-A-23
7
NOTE:
84 9 11. %!!F
#!

- Apply liquid gasket to the oil pump mating surface
¢ Use liquid gasket, Part No. O8C70-K0234M,
?!F
#A-0'$0>0+*,A of the block, then install the oil pump on the
!#A!!!
08C70-K0334M or O8C70-X0331S.
0'$0>0++*,0'$0R0++- cylinder block.
!!#-
¢ Check that the mating surfaces are clean and dry before
#
! ¢ Apply grease to the lips of the oil seals. Then,
%!
!!!-4A
applying liquid gasket.
!
!F
#- install the oil pump while aligning the inner
!!! 3!!

¢ Apply liquid gasket evenly, being careful to cover all the
%!!F
#&!A
!&!! rotor with the crankshaft. When the pump is in
3#-2
mating surface.

- place, clean any excess grease off the
!A!/

¢ To prevent leakage of oil, apply liquid gasket to the inner
4&!#
!A!!F
# crankshaft, then check that the oil seal lips are
#A#!!!
threads of the bolt holes.
!!- not distorted.
-
¢ Do not install the parts if five minutes or more have
(!!& &
Apply liqmd gasket
elapsed since applying the liquid gasket. Instead,
!!
!F
#-A along the broken
reapply liquid gasket after removing the old residue.
!!F
#&
! -
¢ After assembly, wait at least 30 minutes before filling the
%!A3!+0 !!

engine with oil.

3!-
10. %!!F
#!#

0- Apply liquid gasket to the block mating surface of the
right side cover, then install it on the cylinder block.

&A!!!!#-
Apply liquid
gasket along the
broken line.
OIL PUMP HOUSING
RIGHT SIDE COVER 6: 1.0 mm

11 N-m l1.1 kgf-m,
8.0lbf-fil
6 11.0 mm
11 N-m [1.1 kgf-m.
Bl) lbf-ft] OIL SCREEN
RIGHT SlDE
COVER
GASKET
Replace. \
6 x 1.0 mm
11 Nvm l1.1 kgffll,
3’9, 8.0 IbH‘tl
DDW EL PIN
OIL PUMP D-DW'EL Pl”

6:: 1.11 mm
11 Mm O-HING
“-1 kgf-m. 3.0 lhf-m Replace.
6
Crankshaft

/
?0
7-A-24
7
NOTE:
84 9 2.
- Install the oil pan gasket and oil pan.
!!!
#!-
9 Use liquid gasket, part No. O8C70-K0234M, 08070-
?!F
#A-0'$0>0+*,A0'$0 NOTE:
84 9
K0334M or O8C70-X0331S.
>0++*,0'$0R0++- ¢ Use a new oil pan gasket.
?3!
#-
Check that the mating surfaces are clean and dry before
#
! ¢ Install oil pan no more than five minutes after
!!!&
applying liquid gasket.
!
!F
#- liquid gasket applied.
!F
#!-
Apply liquid gasket as an even bead, centered between
%!!F
#&A3 OIL PAH
the edges of the mating surface.

-
To prevent leakage of oil, apply liquid gasket to the inner
4&!#
!A!!F
#
threads of the bolt holes.
!!-
Do not install the parts if five minutes or more have
(!!& &
Apply liquid
!!
!F
#-A
____.+ gasket to
!!F
#&
! - these points.
After assembly, wait at least 30 minutes before filling the
%!A3!+0 !!

engine with oil.

3!-
Apply liquid gasket on the oil pump and right side cover
- %!!F
#!
&
mating areas as shown below.

3!3-
CYLINDER
BLOCK
Apply liquid gasket
to these points.
OIL PAN
Apply linuid gasket GAS-IE!"
to these points. Replace.
3.
+- Tighten bolts and nuts finger tight at six points as
4
!

/
shown below.
3!3-
llCIiIL PUMP
HlGHT SIDE
COVER
Apnlv liquid gasket
to these points.
4.
*- Tighten all bolts and nuts, starting from bolt 1, in a
4
!!! A
!A
clockwise direction.
!#3-
NOTE: Excessive tightening can cause distortion
84 9 /&

of oil pan gasket and oil leakage.
!
#!!#
-
Torque: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)

BF,/@6! 2:8@7* 2 0
Sgecial Tools

7-3-2
7"
Ref No.
O 1- O| Tool Number
4! O Description
( OD O Remark
1#
O O| 0$% - PT20100
07LAF 4000 O Bearing Replacement Tool Set
)
1!4! O O
LOOMA
O O| 07LAG - PT20100
)!# O O
O + O| 07749 - 0010000
0$$*5000000 O Handle Driver
6!(& O O
O * O| 07948 - 8800101
0$5*')000 O Driver Attachment, 96 mm
(&%A5 O O
3:
Illustrated Index
7-3-3
7"
&

E !!!3
!
!-
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
6 x 1.0 mm DIL FAN

Removal. page T-B-lEl
12 N 1.2 k - . 8.? IbH-t .
ml 91m J Installation. page 1' B 34
cm SCREEN in."
P
Ex'lflmrn L . _ " 6 a: 1.0 mm
11 Nm [1.1 kgi-m. «_-'_'.'--“ l?“ '1 12 N-m [1.2 kgl-m,
8.0 Ihf-fll " -—.~_ ". _ -'~“- 3.7 [bf-ft)
BEARING CAP
«U BRIDGE
GASKET -————_..+-‘—*F’
Replace. {5:3
DOWEL FIN
11 3: 15 mm
59 I'll-m [10 kgf-m, DRIVE PLATE IAITF
51 lhf-ftl
Apply- engine oil to the bolt 12 x 1.0 mm
threads. 74 N-m 17.5 kgl-m, 54 Ibirf‘tl
NOTE: After torquing each cap, : Torque sequence.
lurn crankshaft to check ”I : page T—B—B
for binding. _ "
MAIN BEARING ' x“ Cl

CAP
DOWEL PIN
FLYWHEEL {MIT}
12 x 1.0 mm
103 Mm {10.5 kgf-m, 76 Ihf-HJ
Torque sequence.
page LEI-8
C‘I'LINBER BLDCK
4

&A
!#!!3
9
(See Page 7-B-13)
;'!$)+<
(See Page 7-B-34)
;'!$)+*<
(See Page 7-8-8)
;'!$)'<
Illustrated Index
7-3-4
7"
(cont’d)
/
?0
&
E !!!3

!
!-
HA22A7 engine:
.7! F
1:“ I 1.0 mm
12 film [1.2 kgf-m. 3.? lbf-ftl
DIL PAN
Removal, page 7-3-13
Installation, page T-B-Ed-
E x 1.0 mm
11 N-m 11.1 kgf'm.
6 x11) mm
8.0 Ihf-ttl 11 N-m l1.1 Ital-m. 0.1] lbf-fll
BEARING CAP
BRIDGE
GASKET ..
Replace. _ ..--" '- 1;? ' (Tl-RING
11 J: 1.5 mm
159 MW: {10 kgf-m.
51 lbl—fll
Apply- ongine ml In the bolt
threads.
103 Mm I105 kgf-m.
NOTE:
TBIbf‘fl]
Aftertorquing each cap,
Torque sequence.
lurn crankshaft to check
page Iii—E
for binding.
MAIN BEARING
CAP
FLYWHEEL

4

&A
!#!!3
9
(See Page 7-B-13)
;'!$)+<
(See Page 7-B-34)
;'!$)+*<
(See Page 7-8-8)
;'!$)'<

Illustrated Index
(cont’d)
/
?0
7-B-5
7"3
NOTE:
84 9
O Apply liquid gasket to the mating surfaces of the right side cover and oil pump case before installing them.
%!!F
#

&! !!
-
9 Use liquid gasket, Part No. O8C70-K0234M, O8C70-K0334M, or O8C70-X0331S.
?!F
#A-0'$0>0+*,A0'$0>0++*,A0'$0R0++-
CHANKSHAFI'
End play, page T-H-H
Runout, Taper and
Out-nf-Flnund. page Y-El-l?
Installation, page T-B-ED
MAIN BEARINGS
Oil clearance. page 7-5-9
Selection, page T B 10
NOTE: New main bearings must
be selected by matching crank
and block identification markings
CRANKSHAFI' OIL SEAL

Installation, page 1-5-28
THRUST WASHERS
Grooved sides lace Uulward.
NOTE: Thrust washer thickness
BALANCEH is. fixed and must not be changed
GEAR CASE by grinding or shimming.
[II-RINGS
Replace.
B x 125 mm
25 MW: 12.5 kgf-m.
18 IbH‘tl
CRANKSHAFT OIL SEAL

Installation. page 8—20
Replace. RIGHT SIDE DOVER
THRUET WASHER block mating surf-ace.
BALANCER DRIVEN
GEAR
OIL PUMP
Overhaul. page 3-15
Apply liquid gasket
to block mating surface.
E 1-: 1.25 mm
25 Nam I25 film. BALANCER SHAFT OIL SEAL
It! Ibfhl Installation. page B-2fl
Replace.
I! 1-: 1.25 mm
25 N-m l3.0 kgf-m, BALANCIER BELT
22 l-tl DRIVEN F'IJLLEHr

4

&A
!#!!3
9
(See Page 7-8-9)
;'!$)5<
(See Page 7-B-10)
;'!$)0<
(See Page 7-8-8)
;'!$)'<
(See Page 7-8-1?)
;'!$)$<
(See Page 7-B-30)
;'!$)+0<
(See Page 7-B-28)
;'!$)'<
(See Page 7-B-20)
;'!$)0<
(See Page 7-B-15)
;'!$)<
Illustrated Index
7-3-6
7"5
(cont’ d)
/
?0
”7%
&

!!!3
!
!-
OIL JET
Handle the neule with
care. Do not damage or
deform.
Inspection, page 3-13
OIL JET BOLT

35 Mm {-1.0 kgf-rn. 25 Ibf-fll
HEAR BALANCEH SHAFT Inspection, page 8-13
End play. page 1-3-35
Hunuut. Taper and __ _ 6 I Ll) mm
H22“ angina; . .-
Out-of—Hound, pages 7—8—35, 36 11 N-m l1.1 kgf‘m.
Installation. page 7-6-32 Ell IbI-ft}
RETAINER
NOTE: Retainer thickness is fired
and must not be changed by
grinding or shimming.
RIGHT BHEATHEH
COVER
LEFI' BREATHER
COVER
E a: 1.0 mm BALANCER SHAFI'

211 Mm i215 kgf-m. BEARINGS
14 IbH-tl Inepection, page 1-8-3?
Replacement. page 3' 3-33
FRONT BALANCEH
SHAFT
4

&A
!#!!3
9
(See Page 7-B-35)
;'!$)+<
(See Page 7-8-36)
;'!$)+<
(See Page 7-B-32)
;'!$)+<
( See Page 7-B-13)
;'!$)+<
( See Page 7-8-3?)
;'!$)+$<
( See Page 7-B-38)
;'!$)+'<

Illustrated Index
(cont’d)
/
?0
7-B-7
7"7
NOTE: New rod bearings must be selected by matching connecting rod and crankshaft identification markings (see page
84 93
!

##
;!
7-3-11).
$)<-
PISTON INSTALLATION DIRECTION
EXHAU$T
PISTON RINGS
Replacement, page 18 26
INTAKE
Measurement, pages 13-25. 26
Alignment. page 7-3-2?
PISTON
Removal. page 7-3-13
Measurement, page T-B- 18
NOTE: To maintain proper clearance.
match the letter on the piston top with
the letter for each cylinder stamp-eel on
PISTON PIN the block.
Removal. page 1-8—20 On the piston top On the hie-cl:
Installation, page 18-2.: No letter q— A url
Inspection. page T-E-EB E q— Bnril
SNAP RING /Q CYLINDER BLOCK

Cylinder bore Inspection. page T-B-‘IQ
Warpage inspection, page 13-19
:ONNECTING REID Cylinder bore honing. page 13-20
End play, page T—B-fl Ridge removal, page 7-5—16
Emall end measurementr page 18-23
BUNNEC‘H NG HOD
BEARINGS
Clears nee, page T-B-tt
Selection. page F-BJ?
CYLINDER BORE SIZES

IA or I. B or I”
NOTE: To maintain proper piston
DDWEL PIN clearance. match these letters with
the letters on the pistons. The letters
CONNECTING R‘DD BEARING CAP on the black read from left tn right.
NIDTE: Install cap 54;: the bearing recess is en No. 1 through No. 11 evlinders.
the same side as the recess in the red. On the block On the platen top
A or I —-— Ne letter
B or II —h— B
No. 1 No. It
CONNECTING HUD BOLT

Inspection. page T-El-22
Tights ning, page T-B-BD

4

&A (See Page 7-8-8)
;'!$)'<
!#!!3
9 (See Page 7-8-11)
;'!$)<
(See Page 7-8-26)
;'!$)< (See Page 7-8-12)
;'!$)<
(See Page 7-8-25)
;'!$)< (See Page 7-8-22)
;'!$)<
(See Page 7-8-27)
;'!$)$< (See Page 7-8-30)
;'!$)+0<
(See Page 7-8-20)
;'!$)0< (See Page 7-8-13)
;'!$)+<
(See Page 7-8-24)
;'!$)*< (See Page 7-8-18)
;'!$)'<
(See Page 7-8-23)
;'!$)+< (See Page 7-8-19)
;'!$)5<
(See Page 7-8-16)
;'!$)<
+#( ) -'
Flywheel and Drive Plate
7-B-8
7"8
!

Connecting Rod and
Replacement
Crankshaft
6
End Play
%'#
Manual Transmission:

F Connecting Rod End Play:

!
%'#F
Remove the eight flywheel bolts, then separate the flywheel
1&
!3!!A!3! Standard (New):
/,(0F 0.15 - 0.30 mm
$@3$@$
from the crankshaft flange. After installation, tighten the bolts
#!
-%!!A
! (0.006 - 0.012 in)
/$@$$5$@$ 0
in the sequence shown.
F 3- Service Limit:
- & F 0.40 mm (0.016 in)
$@$/$@$5 0
RING GEAR HOLDER
CRANKSHAl-‘I'
ITEMS — PVDDIDD
CONNECTING HOD
.9:
RING GEAR HOLDER ENGINE
DTLAB - P1100100 BLOCK
0 If out-of—tolerance, install a new connecting rod.

!A!!3
-
0 If still out-of—tolerance, replace the crankshaft (see
!! !A!#;
page 7-B-13) and(see page 7-B-30).
!$)+<;!$)+0<-
Push the crankshaft firmly away from the dial indicator,
#!3!A
and zero the dial against the end of the crankshaft.
H!
#-
Then pull the crankshaft firmly back toward the
4 !!#!#3
indicator; dial reading should not exceed service limit.
N!
!/&!-
RING GEAR
12 x 1.0 mm
Inspect ring gear
103 Mm [10.5 kgf-I‘I‘i. TE lbf-H]
math for wear nr damage.
Automatic Transmission:

F
Remove the eight drive plate bolts, then separate the drive
1&
&!!A&
plate from the crankshaft flange. After installation, tighten the
!#!
-%!!A

bolts in the sequence shown.
!F 3-
SCREWDHWEH
Crankshaft
6 End Play:
%'#F
Standard (New):
/,(0F 0.10 - 0.35 mm
$@$$@3
(0.004 - 0.014 in)
/$@$$$@$ 0
Service Limit:
- & F 0.45 mm (0.018 in)
$@3/$@$8 0
0 If end play is excessive, inspect the thrust washers
!/&A 3
and thrust surface on the crankshaft. Replace
#-1!
12 x 1.0 mm parts as necessary.
-
. 74 ”-111 [1.5 kyf-m. NOTE: Thrust washer thickness is fixed and must not
84 94 3#/
"— ' 54 lint-ft]
be changed either by grinding or shimming.

-
Thrust washers are installed with the grooved sides
4 3!!3
&
facing outward.

3-
" !
Main Bearings

Clearance
7-B-9
7"9
- To check main bearing-to-journal oil clearance, remove
4#
7 !!!A& PLASTIGAGE STRIP
the main caps and bearing halves.

!&-
- Clean each main journal and bearing half with a clean
!7 !
!3!
shop towel.
3!-
+- Place one strip of plastigage across each main journal.
!!

7 !-
NOTE: If the engine is still in the car when you bolt the
84 9
!!3 !
main cap down to check clearance, the weight of the
3#!A3

crankshaft and flywheel will flatten the plastigage further
#!3!3!!!!

than just the torque on the cap bolt and give you an
7 F !
&
incorrect reading. For

- an accurate reading, support the

A
crank with a jack under the counterweights, and check
#37# 3
A#
only one bearing at a time.
!
-
*- Reinstall the bearings and caps, then torque the bolts
1!!
AF !
(see page 7-B-31).
;!$)+<-
84 9(#
- 6.
!

33A
- Remove the cap and bearings again, and measure the
1&

A (remove the engine if it’s still in the car), remove
;&
B!!<A&
3!

- the crankshaft, and remove the upper half of the
#A& !
Main Bearing-to-Journal Oil Clearance:
" !
<
F bearing. Install a new, complete bearing with the

-!!3A!
3
Standard (New):
/,(0F same color code (select the color as shown on the
!;!!3
No. 1 and 4
,
@ 0.013 - 0.037 mm
$@$$@$7 next page), and recheck the clearance.
/
<A#!-
(0.0005 - 0.0015 in)
/$@$$$3$@$$3 0 7.
!

3!!!
A/!
!!
;
Service Limit: $@$3$/$@$$$ 0
- & F 0.050 mm (0.0020 in)
color listed above or below that one), and check
!!&!3<A#
No.2
,
@ 0.021 - 0.045 mm
$@$$@$3
again.

-
(0.0008 - 0.0018 in)
/$@$$$8$@$$8 0
84 9!
Service Limit: $@$3$/$@$$$ 0
- & F 0.050 mm (0.0020 in)

!
!!
A
No. 3
,
@ 0.025 - 0.049 mm
$@$3$@$9 replace the crankshaft and start over.
!#&-
(0.0010 - 0.0019 in)
/$@$$$$@$$9 0
- & F 0.055 mm (0.0022 in)
No. 5
,
@3 0.009 - 0.033 mm
$@$$9$@$
(0.0004 - 0.0013 in)
/$@$$$$@$$ 0
Service Limit: $@$$/$@$$5 0
- & F 0.040 mm (0.0016 in)
Main Bearings
" ! 7_B_10
Selection

7"$
84 9! No. 1 and 4journals:
,
@D
F
! A 33 naming .mmimflion mLarge, crank bore
-!!3!&
-
crankshaft
6 Bore code Location
"

&

Cult)! CDC“?! is unlthe inrAcirl ?cirBor1I flanriil durEI-uriiil
Numbers or Letters or Bars have been stamped on the end

)& Edge ”f me “am“ —I- Smaller bearing iThickerl
of the block as a code for the size of each of the 5 main
!#H _
journal bores.
7 !- WI Yellow Yellow." Grm i Green!
Brown
Use them, and the numbers stamped on the crankshaft
?A # 5”” |
(codes for main journal size), to choose the correct bearings.
;7 !H<A
- 2 (it II
Mow.- Green
Gris-en." ‘ Brawn
Green Brown
{/- ‘H\ I. ._..I...a_._.. ._._._1
Brown;
I' I‘ 3 or III Green i Grnen- Brown
. Brown ' Black
Grecn.‘ Brnwni'
4orllil - Brown ' Bl-ick
Brown ' Black E
Brnwnl' Black."
5 or IIIII Brown Black
Black Bluvn
Brown-' Black;
5 n' llllll I it |
l' Black. B BC HIDE 8 us
'I '|
Smaller Smaller NOTE: When using bearing halves of

main bearing different colors. it does not matter
journal (Thicker) which color is used in the top or bottom.
No. 2, 3 and 5journals:
,
@:3D
F
No. 1 JOURNAL Ho. 5 JDUBHJIL . . .
tFULLEY END) lFtVWHEL END} Bearing Identification ——hLarger crank bore
593mm DONG“ Color C05“? is. on the t-rjrAnrl 2orBoril :torCnriii da‘Inriiil
UPPER edge of the hearing.
—I- Smaller bearing [Thickerl
. l
1 ml Pink Pink ‘r‘allnw Yell-9h.
Yellow = Green
PROJECTION
Pink: Yulluw.’
2 I'_l' l| Yellow _ Grnen
Yellow tween
COLOR
LOWER _ Yellow." Gleelv'
Ju' Iil Yellow Gratin
Green Brnwn
Yollmw' Green.“
-1 Cir I:Il GIL-en Blown
Green Brown
_, [3e Brnwr‘.‘
b or nut (green Brown
5 l uw'l Black
. Green? Brown?
!; nr till I ‘ Flrciwn Hlozlc
bio-«n Blac-
l t
Smaller Smaller NOTE: When using bearing halves of
main bearing different colors, it does not matter
journal [Thickerl which color is user! in the top or bottom.
" !
Main Bearings 7-3-11
7" Connecting Rod Bearings

!
" !
Selection (cont’d)

/
?0
Clearance
Main Journal Code Locations (Numbers or Bars)

<

&

/,*
"0 - Remove the connecting rod cap and bearing half.
1&

!-
The Main Journal Codes are stamped in one of the following
4," !!!3
- Clean the crankshaft rod journal and bearing half
!#7 !
!
locations.
!- with a clean shop towel.
3!3!-
%.7! F +- Place plastigage across the rod journal.
!!

7 !-
Main Journal Code Locations lNumb-urs or Bars) *- Reinstall the bearing half and cap, and torque the
1!!
!AF
bolts (see page 7-8-30).
!;!$)+0<-
NOTE: Do not rotate the crankshaft during
84 9(#
inspection.
-
- Remove the rod cap and bearing half and measure
1&
!
the widest part of the plastigage.
3!

-
Connecting Rod Bearing-to-Journal Oil

!
" !
<

Clearance:
F
Except H 22A7 engine:
%.7! F
Standard (New): $@$3$@$
/,(0F 0.015 - 0.043 mm
(0.0006 - 0.0017 in)
/$@$$$5$@$$7 0
Service Limit:
- & F 0.050 mm (0.0020 in)
$@$3$/$@$$$ 0
H22A7 engine:
.7! F
No. ‘l CRANK WEB
/,(0F 0.027 - 0.055
(0.0011 - 0.022 in)
/$@$$$@$ 0
Service Limit:
- & F 0.060mm (0.0024 in)
$@$5$/$@$$ 0
PLASTIGAGE STRIP
,4,
Arrows point to ND.1IT‘IBIU
and connecting rod journal
cuties.
H22A7 engine:
.7! F
Main Journal Coda Locations (Numbers ur Bars)

!

33A
remove the upper half of the bearing, install a new,
& !
A!!3A
complete bearing with the same color code (select
!
3!;!
the color as shown on the next page), and recheck
!3/
<A#
the clearance.
!-
!

3!!!
A/!
!!
;
color listed above or below that one), and recheck
!!&!3<A#
clearance again.
!
-
84 9!

!
!!
A
replace the crankshaft and start over.
!#&-

!
" !
Connectinq Rod Bearinqs
Selection

7-B-12
7"
84 9! Connecting Rod Journal Code Locations (Letters or

!
<

&

/&

! A 33 Bars)
"0
-!!3!&
- The Connecting Rod Journal Codes are stamped in one
4
1" !
Connecting Rod Journal Code Locations

!
<

&

if the following locations.
!!3
!-
Numbers or Bars have been stamped on the side of each
)& Except H22A7 engine:
%.7! F
connecting rod as a code for the size of the big end. Use

H
-? Connecting Find Journal Code Location: (Letter: or Earsl
them, and the letters or bars stamped on the crank (codes for
A!#;
rod journal size), to choose the correct bearings.
7 !H<A
-
Half of number or bar

is stamped on bearing can No. 1 CRANK WEB
and the other half is
stamped on rod
Bearing Design
" !) !
A
Arrows point to No.1mair1

and connecting rod iournal
codes.
H22A7 engine:
.7! F
PROJECTION Connecting Rod Journal Coda Locations [Letters ur Barsl
CDLDH
Bearing identification ——-—-— Larger big and burn

Color code is on the l
edge at the bearing. 1 ml 2 or u 3 gr III ! 4 nr nu
———rSmaller baaring (Thicker)
A or I Red Pink ! "r‘rtllnw Gris-3n
B 0r II Fi'lt Ynllnw I Green Brawn
C gr III Val Iuw Green Brown Black
I
D ur IIII Green Brown Blau ' BL”:
Smaller Smaller
rCI L1 bearin g
luurnal IThickerl
6 :"
Crankshaft.

-
Removal
'

Balancer Shafts and Pistons
7-B-13
7"
1.
- Remove the bolts securing the oil pan.
1&!
!- 4.
*- Remove the right side cover.
1&
&-
2.
- Hammer in an oil pan seal cutter between the oil pan
6!! 3!
and cylinder block.
!!#-
CYLINDER BLOCK
DL PAN
SEAL CUTYEFI
RIG HT SIDE COVER

OIL PAN 5.
- Remove the CKP/TDC sensors, then remove the
1&>=4(A&
3.
+- Cut the oil pan seal by striking the side of the cutter to
!!#
timing belt drive pulley (see section 6).

!& !!;<-
slide the cutter along the oil pan. Remove the oil pan.
! !
!-1&!- 6.
- Remove the balancer gear case.
1&!
-
DDWEL PIN
DIL PAN -.
SEAL nun-en - B 1: 1.25 mm
25 film 12.5 kgf-m. 18 Ibf-fll
Apply engine oil.

Replace.
BALANCEH DOWEL PIN

GEAR CASE
OIL PAN
6 :"
Crankshaft, '

Balancer Shafts and Pistons
7"
Removal (cont’d)

-/
?0
7.
$- Remove the front balancer driven pulley as shown.
1&!& !!3- 10. 1&!! -
0- Remove the oil screen and the oil pump.
HALANCER OIL SCREEN
DRIVEN PULLEY
MAINTENANCE HDLE GAS KET

Replace.
SCREWDRIVER
8.
'- Align the bolt hole and the balancer shaft hole, then
%!
!!!!A
insert a special tool to hold the rear balancer shaft.
!!!!-
9.
5- Remove the bolt and the balancer driven gear.
1&!!&
-
HEAR BALANCEH
SHAFI'
Replace.
DOWEL PIN
OIL PUMP
11. 1&!!;6%$
<-
- Remove the baffle plate (H22A7 engine)
BALANCEFI SHAFF
WASHER LOCK PIN
BALANCER Replace 07MB - PTZDW-D
DRIVEN GEAR
6 :"
Crankshaft, '

Balancer Shafts
Removal (cont’d)

-/
?0
and Pistons
7-B-15
7"3
12
Remove the bolts and the bearing cap bridge, then
1&!

A H22A7 engine:
.7! F
remove the bearing caps.
&
- -1. 1&!-
- Remove the 11 mm bolts.
A CAUTION
To prevent warpage, unscrew the bolts in sequence 1/3 turn
4&3
A 3!F =+
at a time; repeat the sequence until all bolts are loosened.
NF !!!!!-
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F
-1. 1&!-
- Remove the 6 mm bolts.
-' w.
'J
- 1&!

6 :"
Crankshaft, '

Balancer Shafts
Removal (cont’d)

-/
?0
and Pistons
7-B-16
7"5
13. 1&

-
+- Remove the bearing cap bridge and bearing caps. 18. !
!
'- If you can feel a ridge of metal or hard carbon
14. 4 #-+#
*- Turn the crankshaft so No. 2 and 3 crankpins are at the around the top of each cylinder, remove it with a
!A&3
top.
- ridge reamer. Follow

- the reamer manufacturer’s
!!3 B
15. 1&=
=
-
- Remove the rod caps/bearings and main caps/bearings. instructions.
-
Keep all caps/bearings in order.
>!!=
- RIDGE REAMEH
16. #
A
!
- Lift the crankshaft out of the engine, being careful not to (Commercially
damage the journals.

7 !- availablal
z'
19. ?3!&

5- Use the wooden handle of a hammer to drive the
CHANKSHAFr pistons out.
-
17. 1&!A&
$- Remove the bolts and the retainer, then remove the
HAMMER HANDLE
front balancer shaft and the rear balancer shaft.
!!-
HEAR BALANCER
SHAFT
\ FRONT BALANCER
SHAFT PISTON
20. 1!!

0- Reinstall the connecting rod bearings and caps
RETAINER
after removing each piston/connecting rod
&
=

assembly.
!-
21. 4&/ !A#
- To avoid mixup on reassembly, mark each
piston/connecting rod assembly with it's cylinder
=
!3@!
number.
-
NOTE: The existing number on the connecting rod
84 94/

does not indicate its position in the engine, it

A
indicates the rod bore size.
H-
6
Crankshaft
Inspection

7-B-17
7"7
0 Clean the crankshaft oil passages with pipe
!#!
3 Out-of-Round and Taper

cleaners or a suitable brush.
! ! - r Measure out-of-round at the middle and main
, !
0 Check the keyway and threads.
##3- journal in two places.
7 !3!-
Alignment
! r The difference between measurements on
43
0 Measure runout on all main journals to make sure
, !!7 !# each journal must not be more than the
7 !
the crank is not bent.
#- service limit.
&!-
0 The difference between measurements on each
43 Journal Out of-Round:
<

F
journal must not be more than the service limit.
7 ! &!- F1832, F1833, F2036 engines:
+8":+8":+$"5! F
Crankshaft
6 Total Indicated Runout:

F Standard (New):
/,(0F 0.005 mm (0.0002 in) max.
$@$$3/$@$$$ 0@
F1832, F1833, F2036 engines:
+8":+8":+$"5! F Service Limit:
- & F 0.010 mm (0.0004 in)
$@$$/$@$$$ 0
Standard (New):
/,(0F 0.02 mm (0.001 in) max
$@$/$@$$ 0 H22A7 engine:
.7! F
Service Limit:
- & F 0.04 mm (0.002 in)
$@$/$@$$ 0 Standard (New):
/,(0F 0.004 mm (0.0002 in) max.
$@$$/$@$$$ 0@
H22A7 engine:
.7! F Service Limit:
- & F 0.006 mm (0.0002 in)
$@$$5/$@$$$ 0
Standard (New):
/,(0F 0.03 mm (0.001 in) max.
$@$/$@$$ 0@
Service Limit:
- & F 0.04 mm (0.002 in)
$@$/$@$$ 0
DIAL INDICATOR
Finiatu crankshaft two
complete revolutions.
Measure in two
places at middle.
Measure taper
SUDDOH with lathe-

near edges.
.i l.
typa tool or V-bluc-ks.
7—?
r Measure taper at the edge of each rod and
,

main journal.
7 !-
r The difference between measurements on
43
each journal must not be more than the
7 !
service limit.
&!-
Journal Taper:
<
F
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
Standard (New):
/,(0F 0.005 mm (0.0002 in) max.
$@$$3/$@$$$ 0@
Service Limit:
- & F 0.010 mm (0.0004 in)
$@$$/$@$$$ 0
H22A7 engine:
.7! F
Standard (New):
/,(0F 0.005 mm (0.0002 in) max.
$@$$3/$@$$$ 0@
Service Limit:
- & F 0.006 mm (0.0002 in)
$@$$5/$@$$$ <
Pistons
'

Inspection

7-B-18
7"8
- Check the piston for distortion or cracks.
##- +- Calculate the difference between the cylinder bore
! !3!
NOTE: If the cylinder is bored, an oversized piston must
84 9!A&H diameter (see page 7-3-19) and piston diameter.
;!$)5<-
be used.
- Piston-to-Cylinder Clearance:
'

# F
- Measure the piston diameter at a point Afrom the
, % F1832, F1833, F2036 engines:
+8":+8":+$"5! F
bottom of the skirt.
#- Standard (New):
/,(0F 0.020 - 0.040 mm
$@$$$@$$
Point A:
'
F (0.0008 - 0.0016 in)
/$@$$$8$@$$5 0
F1832, F1833, F2036 engines: 5/$@5 0
+8":+8":+$"5! F 16 mm (0.6 in) Service Limit:
- & F 0.05 mm (0.002 in)
$@$3/$@$$ 0
H22A7 engine:
.7! F 15 mm (0.6 in)
3/$@5 0 H22A7 engine:
.7! F
NOTE: There are two standard-size pistons (No Letter
84 943H; Standard (New):
/,(0F 0.004 - 0.027 mm
$@$$$@$7
or A, and B). The letter is stamped on the top of the
%A)<-4! (0.0002 - 0.0011 in)
/$@$$$$@$$ 0
piston. Letters are also stamped on the block as cylinder
-!!#! Service Limit:
- & F 0.04 mm (0.002 in)
$@$/$@$$ 0
bore sizes.
H-
‘- PlSTON-TO-CYLINDER
Piston Diameter:
'
) F
CLEARANCE
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
Standard (New):
/,(0F
No Letter (A):
,
&/0F 84.980 - 84.990 mm
8@98$8@99$
(3.3457 - 3.3461 in)
/@37@5 0
3:
"F 84.970 - 84.980 mm
8@97$8@98$
(3.3453 - 3.3457 in)
/@3@37 0
Service Limit:
- & F
No Letter (A):
,
&/0F 84.970 mm (3.3453 in)
8@97$/@3 0
3:
"F 84.960 mm (3.3449 in)
8@95$/@9 0
H22A7 engine:
.7! F
Standard (New):
/,(0F
I.—
No Letter (A):
,
&/0F 86.993 - 87.006 mm
85@9987@$$5
(3.4249 - 3.4254 in)
/@9@3 0 If the clearance is near or exceeds the service
!/&
3:
"F 86.983 - 86.996 mm
85@9885@995 limit, inspect the piston and cylinder block for
!A!!#
(3.4245 - 3.4250 in)
/@3@3$ 0 excessive wear.
/&3-
Service Limit:
- & F Oversize Piston Diameter:
- C'
) F
No Letter (A):
,
&/0F 86.980 mm (3.4244 in)
85@98$/@ 0 F1832, F1833, F2036 engines:
+8":+8":+$"5! F
3:
"F 86.970 mm (3.4240)
85@97$/@$0 0.25: 85.230 - 85.240 mm (3.3555 - 3.3559 in)
$@3F83@$83@$/@333@339 0
H22A7 engine:
.7! F
mm 0.25: 87.233 - 87.246 mm (3.4344 - 3.4349 in)
$@3F87@87@5/@@9 0
PDINTA . DIAMETER _
# "
6
Cylinder Block
Inspection

7-3-19
7"9
1.
- Measure wear and taper in direction X and Y at three
, 3RC Bore Taper:
"
F
levels in each cylinder as shown.
!&!!3- Limit: (Difference between first and third
& F/) *(
5 mm i112 inl measurement) 0.05 mm (0.002 in)
0$@$3/$@$$ 0
¢ If measurements in any cylinder are beyond
!
First Oversize Bore Service Limit, replace the block.
8&H)&A!!#-
Malsurumant ¢ If the block is to be rebored, refer to Piston
!#A
Second
Mnuurumant
Clearance Inspection (see page 7-3-18) after
!;!$)'<
reboring.

-
Third
Measurement
NOTE: Scored or scratched cylinder bores must be
84 9!
6 mm [0.2 in)
honed.
-
Rebore Limit: 0.25 mm (0.01 in)
*
& F$@3/$@$ 0
2.
- Check the top of the block for warpage. Measure
#!#3
-,
along the edges and across the center as shown.
!

3-
SURFACES TO BE MEASURED
CYLINDER BORE SIZES

IA or I, B or III
Read the letters from left-to right
for No. I through No. 4 cylinders.
Cylinder Block Warpage:

# "
61!F
Standard (New): below 0.07 mm (0.003 in) max.
/,(0F*
($@$7/$@$$ 0@
Service Limit:
- & F 0.10 mm (0.004 in)
$@$/$@$$ 0
PRECISION STRAIGHT EDGE
Cylinder Bore Size:

# "
CF
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
Standard (New):
/,(0F
Aor |: 85.010 - 85.020 mm (3.3468 - 3.3472 in)

F83@$$83@$$/@58@7 0
B or II: 85.000 - 85.010 mm (3.3465 - 3.3468 in)
"
F83@$$$83@$$/@53@58 0
- & F83@$7$/@9 0
H22A7 engine:
.7! F
Standard (New):
/,(0F
Aor |: 87.010 - 87.020 mm (3.4256 - 3.4260 in)

F87@$$87@$$/@35@5$ 0
B or II: 87.000 - 87.010 mm (3.4252 - 3.4256 in)
"
F87@$$$87@$$/@3@35 0
- & F87@$7$/@79 0
Oversize:
- CF
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
0.25: 85.250 - 85.260 mm (3.3563 - 3.3567 in)
$@3F83@3$83@5$/@35@357 0
H22A7 engine:
.7! F
0.25: 87.250 - 87.260 mm (3.4350 - 3.4354 in)
$@3F87@3$87@5$/@3$@3 0
# "
6
Cylinder Block
Bore Honing
"
.
!
7-B-20
7"$ '
'
Piston Pins

-
Removal
1.
- Measure cylinder bores, (see page 7-B-19). If the block
, !A;!$)5<-!# - Apply engine oil to the piston pin snap rings and
%!
!

is to be reused, hone the cylinders and remeasure the
A! turn them in the ring grooves until the end gaps are

& !

bores.
- lined up with the cutouts in the piston pin bores.
! 3 -
- Hone cylinder bores with honing oil and a fine (400 grit)
6!3
!;*00
< NOTE: Take care not to damage the ring grooves.
84 94#

&-
stone in a 60 degree cross-hatch pattern.
0
-
NOTE:
84 9
0 Use only a rigid hone with 400 grit or finer stone
?!
3*00

such as Sunnen, Ammco, or equivalent.
A%AF &!-
TT
0 Do not use stones that are worn or broken.
( 3#-
9
¢
‘
II' i.l i 0.0.0.!”
""
i C". I I."..0 I
n
.II l 0 I O C n
l
.'
i . *t
'i IM
.C
SNAP RING Cutout m the

+- When honing is complete, thoroughly clean the engine
2
!A
!!
piston pin bore
block of all metal particles. Wash the cylinder bores with

!#!!!!-2!3 2.
- Remove both snap rings. Start at the cutout in the
1&
-
hot soapy water, then dry and oil immediately to prevent
3A!!& piston pin bore. Remove the snap rings carefully
-1&
!!
rusting.

- so they do not go flying or get lost. Wear eye

!

!-2
NOTE: Never use solvent, it will only redistribute the grit
84 9& !&A3!!!
protection.
-
on the cylinder walls.
!3!!- 5M1!" RING
*- If scoring or scratches are still present in cylinder bores

!!!
after honing to the service limit, rebore the cylinder block.

&!A!!#-
NOTE: Some light vertical scoring and scratching is
84 9!
&!

acceptable if it is not deep enough to catch your
!

fingernail and does not run the full length of the bore.

! !!!
-
CYLINDER BLOCK
if
cm moan HONE A
‘."r
NOTE:
84 9
0 After honing, clean the cylinder thoroughly with
%
A!!
!3
soapy water.
3-
0 Only a scored or scratched cylinder bore must be
8!!
honed.
-
'
'
Piston Pins
Removal (cont’d)

-/
?0
7-B-21
7"
!

Connecting Rods
Selection

3.
+- Heat the piston and connecting rod assembly to
6
! Each rod falls into one of four tolerance ranges (F18B2,
!! !
/+8":
approximately 70°C (158°F),
/!$0P;'P then remove the piston pin.
<A&- F18B3, F20B6 engines: from 0 to 0.024 mm (0.0009
+8":+$"5! F00-0*;0-0005
in), in 0.006 mm (0.0002 in) increments, H22A7
<A0-00;0-000<A.7
engines: from 0.008 mm (0.0003 in) to 0.032 mm
! F0-00';0-000+<0-0+
(0.0013 in), in 0.006 mm (0.0002 in) increments)
;0-00+<A0-00;0-000<<
depending on the size of its big end bore.

H
-
It is then stamped with a number (1, 2, 3, or 4/I, II,
3 ;AA+A*=A AIII,A
or
IIII)
indicating the range. You may find any combination
<

-C
of 1, 2, 3, or 4/|, II,
AA+A*=A AIII,A
or
”II
-
in any engine.
Normal Bore Size:
,
"
CF
F18B2, 18B3, F20B6 engines: 48.0 mm (1.89 in)
+8":8":+$"5! F8@$/@89 0
H22A7 engine: 51.0 mm (2.01 in)
.7! F3@$/@$ 0
NOTE:
84 9
0 Reference numbers or bars are for big end bore
1

size and do not indicate the position of the rod in
H
the engine.

-
NOTE: Inspect the piston, piston pin and connecting rod
84 9A
0 Inspect each connecting rod for cracks and heat

#
when they are at the room temperature.
3 - damage.

-
CONNECTING HOD BORE

REFERENCE NUMBER or BAH
Half of number is Stamped on
hearing cap. the other half on
connecting rod.
ll'lEiplL‘Li'l tmlts
and llUtfi for
stress cracks.
Connecting Rod Bolts

!
"
7-3-22
7"
Inspection

1.
- Measure the diameter of each connecting rod bolt at
,
!
point A and point B.
%)-
35 mm
£1.33 in! A
_-1—————--p-
20 mm
[0.79 in]
2.
- Calculate the difference in diameter between point A
! !3%
and point B.
)-
Point A - B = Difference in Diameter
'
"P) )
Difference in Diameter:
) ) F
Specification: 0 - 0.1 mm (0 - 0.004 in)

F$$@/$$@$$ 0
3.
+- If the difference in diameter is out of tolerance, replace
!A!
the connecting rod bolt.

!-
M
'
' 7"
7-3-23
Inspection

NOTE: Inspect the piston, piston pin and connecting rod

84 9A
3.
+- Check the difference between the piston pin
#3
when they are at room temperature.
3 - diameter and piston pin hole diameter on the
!
1.
- Measure the diameter of the piston pin.
, - piston.
-
Piston Pin Diameter:
'
' ) F Piston Pin-to-Piston Clearance F:
'
'
'

Standard (New):
/,(0F 21.961 - 21.965 mm
@95@953 F1832, F1833, F2036 engines:
+8":+8":+$"5! F
(0.8646 - 0.8648 in)
/$@855$@858 0 Standard (New):
/,(0F -0.0050 to +0.0020 mm
$@$$3$
O$@$$$
Service Limit:
- & F 21.953 mm (0.8643 in)
@93/$@85 0 (-0.00020 to+0.00008 in)
/$@$$$$
O$@$$$$8 0
Service Limit:
- & F 0.004 mm (0.0002 in)
$@$$/$@$$$ 0
H22A7 engine:
.7! F
Standard (New):
/,(0F -0.0030 to+0.0060 mm
$@$$$
O$@$$5$
(-0.00012 to+0.00024 in)
/$@$$$
O$@$$$ 0
Service Limit:
- & F 0.009 mm (0.0004 in)
$@$$9/$@$$$ 0
2.
- Zero the dial indicator to the piston pin diameter.
I!-
4.
*- Measure the piston pin-to-connecting rod
,

clearance.
!-
Piston Pin-to-Connecting Rod Clearance:
'
'

!
F
Standard (New):
/,(0F 0.005 - 0.015 mm
$@$$3$@$3
(0.0002 - 0.0006 in)
/$@$$$$@$$$5 0
Service Limit:
- & F 0.020 mm (0.0008 in)
$@$$/$@$$$8 0
'
'
Piston Pins
7"

Installation
1.
- Install a piston pin snap ring.
!!
- *- Install the piston pin. Assemble the piston and
!!-%!
sNAP RING connecting rod with the embossed marks on the

3#
same side.
-
EMBOSSED
MARK
- Coat the piston pin bore in the piston, the bore in the
A HSTON
connecting rod, and the piston pin with engine oil.

A3
!-
+- Heat the piston to approximately 70°C (158°F).
6/!$0P;'P <-
ROD
5.
- Install the remaining snap ring.
!!

-
'
!
Piston Rings
End Gap
%
7-B-25
7"3
1.
- Using a piston, push a new ring into the cylinder bore 15
?
A 3
!
- 20 mm (0.6 - 0.8 in) from the bottom.
0;0-0-'<-
2.
- Measure the piston ring end-gap with a feeler gauge:
,

3!

9
0 If the gap is too small, check to see if you have the

!!A# &
proper rings for your engine.

-
0 If the gap is too large, recheck the cylinder bore

!
A#!
diameter against the wear limits (see page 7-B-19).

3!;!$)5<-
If the bore is over the service limit, the cylinder
&&!A!
block must be rebored
!#
Piston Ring End-Gap:
'
!%F
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F
Top Ring

!
Standard (New):
/,(0F 0.20 - 0.35 mm
$@$$@3
(0.008 - 0.014 in)
/$@$$8$@$ 0
Service Limit:
- & F 0.60 mm (0.024 in)
$@5$/$@$ 0
Second Ring

! _ 5 —20 mm
Standard (New): -:';’:'l0.5- 0.0 ini
/,(0F 0.40 - 0.55 mm
$@$$@33
(0.016 - 0.022 in)
/$@$5$@$ 0
Service Limit:
- & F 0.70 mm (0.028 in)
$@7$/$@$8 0
Oil Ring
!
Standard (New):
/,(0F 0.20 - 0.70 mm
$@$$@7$
(0.008 - 0.028 in)
/$@$$8$@$8 0
Service Limit:
- & F 0.80 mm (0.031 in)
$@8$/$@$ 0
H22A7 engine:
.7! F
Top Ring

!
Standard (New):
/,(0F $@3$@3
0.25 - 0.35 mm
(0.010 - 0.014 in)
/$@$$$@$ 0
Service Limit:
- & F 0.60 mm (0.024 in)
$@5$/$@$ 0
Second Ring

!
Standard (New):
/,(0F 0.60 - 0.70 mm
$@5$$@7$
(0.024 - 0.028. in)
/$@$$@$8@ 0
Service Limit:
- & F 0.90 mm (0.035 in)
$@9$/$@$3 0
Oil Ring
!
Standard (New):
/,(0F 0.20 - 0.70 mm*1
$@$$@7$A
(0.008 - 0.028 in)
/$@$$8$@$8 0
0.20 - 0.50 mm*2
$@$$@3$A
(0.008 - 0.020 in)
/$@$$8$@$$ 0
Service Limit:
- & F 0.80 mm (0.031 in)*1
$@8$/$@$ 0A
0.60 mm (0.024 in)*2
$@5$/$@$ 0A
*1: RIKEN manufactured piston ring.
G91>
-
*2: TEIKOKU PISTON RING manufactured piston ring.
G94 >8>?481.
-
'
! !

-
Piston Rings
Replacement

7"5
7_B_26 Ring-to-Groove Clearance
- Using a ring expander, remove the old piston rings.

?

/A&!
- After installing a new set of rings, measure the
%!!
3
A
NA
- Clean all ring grooves thoroughly.

!!!

&
!- ring-to-groove clearances:

&!9
NOTE:
84 9 Top Ring Clearance

!
0 Use a squared-off broken ring or ring groove
?F #

& F1832, F1833, F2036 engines:
+8":+8":+$"5! F
cleaner with a blade to fit the piston grooves.
!3!
&- Standard (New):
/,(0F 0.035 - 0.060 mm
$@$3$@$5$
0 The top and 2nd ring grooves are 1.2 mm (0.05 in)
4

&-;0-0< (0.0014 - 0.0024 in)
/$@$$$@$$ 0
wide. The oil ring groove is 2.8 mm (0.11 in) wide.
3-4!

&-';0-<3- Service Limit:
- & F 0.13 mm (0.005 in)
$@/$@$$3 0
0 File down a blade if necessary.
!3!- H22A7 engine:
.7! F
0 Do not use a wire brush to clean the ring grooves,
( 3 !

&A Standard (New):
/,(0F 0.055 - 0.085 mm
$@$33$@$83
or cut the ring grooves deeper with cleaning tools.

&3!
!- (0.0022 - 0.0033 in)
/$@$$$@$$ 0
NOTE: If the piston is to be separated from the
84 9 Service Limit:
- & F 0.13 mm (0.005 in)
$@/$@$$3 0
connecting rod, do not install new rings yet.

A!!3
- Second Ring Clearance

!
Install new rings in the proper sequence and position
+- !!3
F
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
(see page 7-3-27).
;!$)$<-
Standard (New):
/,(0F 0.030 - 0.055 mm
$@$$$@$33
NOTE: Do not use old piston rings.
84 9( !
-
(0.0012 - 0.0022 in)
/$@$$$@$$ 0
PISTON RING
Service Limit:
- & F 0.13 mm (0.005 in)
$@/$@$$3 0
RING EXPANDER
H22A7 engine:
.7! F
(Cummerciallv availablel
Standard (New):
/,(0F 0.040 - 0.070 mm
$@$$$@$7$
(0.0016 - 0.0028 in)
/$@$$5$@$$8 0
Service Limit:
- & F 0.13 mm (0.005 in)
$@/$@$$3 0
'
!
Piston Rings
!
Alignment
7-3-27
7"7
1.
- Install the rings as shown.
!!
3- 2.
- Rotate the rings in their grooves to make sure they
1

&#
do not bind.
-
3.
+- Position the ring end gaps as shown:

39
TOP RING C3 DO ‘NJOT position any ring gap
SECOND RING GAP at prsmn Ihrusl surlaces.
*\
“3
Approx. 90
SECOND RING DIL RING

I
PEP
Approx, 15:. GAP
Piston Ring Dimensions:

'
!)
F TOP RING GAP SPRCER GAP
DU NUT Dos-lion any ring gap

in Ilne mm the match pin hole. OIL RING GAP
Top Ring (Standard):

!/0F
A: 3.1 mm (0.12 in)
F@/$@ 0
B: 1.2 mm (0.05 in)
"F@/$@$3 0
Second Ring (Standard):

!/0F
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F
A: 3.4 mm (0.13 in)
F@/$@ 0
B: 1.2 mm (0.05 in)
"F@/$@$3 0
H22A7 engine:
.7! F
A: 3.2 mm (0.13 in)
F@/$@ 0
B: 1.2 mm (0.05 in)
"F@/$@$3 0
NOTE: The manufacturing marks must be facing
84 94
#

upward.
3-
TOP RING MANN
SECOND RING
DIL RINGS
6
Crankshaft Oil Seal

Installation
7-B-28
7"8 '

Pistons

Installation
&
&
E 4! !# !-%!
The seal surface on the block should be dry. Apply a Before installing the piston, apply a coat of
E )!!
A!
light coat of oil to the crankshaft and to the lip of the seal.
!
!#!!- engine oil to the ring grooves and cylinder bores.

!

&!-
1.
- Drive in the crankshaft oil seal against the right side
(&#!!

If the
crankshaft
6 is already installed
#
coven
&- 1.
- Set the crankshaft to BDC for each cylinder.
#)(!-
NOTE: Drive the crankshaft oil seal in squarely.
84 9(&#!!F !- 2.
- Remove the connecting rod caps, then install the
1&
A!!
HANDLE DRIVER ring compressor, and check that the bearing is

A#

07749 - 0010000
securely in place.
!!-
3.
+- Position the arrow and the mark facing towards the
3#
3
timing belt side of the engine.

!
-
The arrnw must lace the

timing halt side of the
engine.
Installseal with the

part I'IUIT‘IIDETSILIB
Iacmg out. The mark must face —l—'I° '
the timing belt side krill
of the engine.
DRIVER ATTACHMENT. 05 mm
01940 r 5000101 4.
*- Position the piston in the cylinder, and tap it in
!A
2.
- Confirm that the clearance is equal all the way around
!F !!!3 using the wooden handle of a hammer.

3!-
with a feeler gauge.
3!

- NOTE: Maintain downward force on the ring
84 9,33
Clearance: 0.5 - 0.8 mm (0.02 - 0.03 in)

F$@3$@8/$@$$@$ 0 compressor to prevent the rings from expanding
&
/
before entering the cylinder bore.

!-
RIGHT SIDE
COVER RING
COMPRESSOR
Use-the wooden handle [Commelcifill‘f
0| a hammer to push or available]
tap the piston into the
cylinder bore.
0.5 -—- 0.3 mm 4- "4* ~ r )
”3.02 -—0.03 lnl a “37' f ;— __,
RIGHT SIDE CHANKSHAFT

COVER OIL SEAL
5.
- Stop after the ring compressor pops free, and

A
check the connecting rod-to-crank journal
#
#7 !
alignment before pushing the piston into place.
!

!-
NOTE: For
84 9 installation of oil pump side crankshaft oil
!!! #!
seal. (See page 8-20).
!-;!'0<-

Oil Seal

/
?0
7-B-29
7"9
- Check the connecting rod bearing clearance with
#

!3 If the
crankshaft
6 is not installed

plastigage (see page 7-B-11).
!

;!$)<- 1.
- Remove the connecting rod caps, then install the
1&
A!!
$- Apply engine oil to the bolt threads, then install the rod
%!
!!A!! ring compressor, and check that the bearing is

A#

caps with bearings, then torque the bolts.
3
AF !- securely in place.
!!-
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F 2.
- Position the arrow and the mark facing towards the
3#
3
$,/@$6! 2:* 2 0 timing belt side of the engine.

!
-
H22A7 engine:
.7! F
3,/@36! 2:8* 2 0 The arrow must fanema
'- Mark the connecting rod and bolt head as shown.
,#
!3- timing belt EldF! [ill
the engine.
BOLT HEAD
the timing bull Side

ufthc engine.
L H}
3.
+- Position the piston in the cylinder, and tap it in
!A
using the wooden handle of a hammer.

3!-
NOTE: Maintain downward force on the ring
84 9,33
compressor to prevent the rings from expanding

&
/
CONNECTING
ROD before entering the cylinder bore.

!-
RING
Use the. wooden handle COMPRESSOR
gt a hammer Tn push or “bk-1 (Commercially
tap the piston ;
I I availablel
intn 1he cylinder
5- Tighten the bolt until the mark on the bolt head lines up
4
! !#!! hnrr—i. l
with the mark on the connecting rod (Turn the bolt 90°).
3#
;4 !50P<- |
4.
*- Position all pistons at top dead center.
!!-
6 "
Crankshaft
and Balancer Shafts

Installation
7-B-30
7"$
“7% 6.
- Check the connecting rod bearing clearance with
#

!3
&
Before installing the crankshaft, apply a coat of engine

)!!
#A!
plastigage (see page 7-B-11).
!

;!$)<-
oil to the main bearings, rod bearings and balancer shaft
!
A
! 7.
$- Apply engine oil to the bolt threads, then install the
%!
!!A!!
bearings.

- rod caps with bearings, then torque the bolts.
3
AF !-
1. !!
!&!!#
- Install the bearing halves in the cylinder block and F1832, F1833, F2036 engines:
+8":+8":+$"5! F
connecting rods.

- 20 Nm (2.0 kgf/m, 14 lbf/ft)
$,/@$6! 2:* 2 0
2. 6!#7 !-7 !
- Hold the crankshaft so rod journal No. 2 and rod journal H22A7 engines:
.7! F
No. 3 are straight up.
-+
- 25 Nm (2.5 kgf/m, 18 lbf/ft)
3,/@36! 2:8* 2 0
3. !! 3-*7 !
+- Install the thrust washers in the No. 4 journal of the 8.
'- Mark the connecting rod and bolt head as shown.
,#
!3-
cylinder block.
!!#-
BO LT H EAD
CD NNECTING ROD CONNECTING ROD
No. 1 No. 3
CQNNECTING ROD THRUST WASHERS CONNECTING

No. 2 Grooved Side faulng HOD N0 4
outward
4.
*- Lower the crankshaft into the block, seating the rod
3#!#A

journals into connecting rod No. 1 and connecting rod
7 !
-
5- 4
! !#!
No. 4. Install the connecting rod caps and bolts finger
-*-!!
!
lines up with the mark on the connecting rod (Turn
! 3#
;4
tight.

- the bolt 90°).
!50P<-
- Rotate the crankshaft clockwise, seat the journals into
1#!#3A7 !
connecting rod No. 2 and connecting rod No. 3. Install

-
-+-!!
the connecting rod caps and bolts finger tight. Install

!

-!!
caps so the bearing recess is on the same side as the

recess in the rod.
-
6 "
Crankshaft
and Balancer Shafts

/
?0
7-B-31
7"
10. !!

-
0- Install the main bearing caps and bearing cap bridge. H22A7 engine:
.7! F
Coat the bolt threads with engine oil.
!3
!- -1. 4
!3-
- Tighten the 11 mm bolts in two steps. In the
11. #!3!

;!$)5<-
- Check clearance with plastigage (see page 7-B-9). first step. tighten all bolts in sequence to about
-
!!!F
12. 4

!-
- Tighten the bearing cap bolts. 29 Nm (3.0 kgf/m, 22 Ibf/ft) in the final step,
5;+-0#
=A!=<!A
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F tighten in same sequence, to 78 Nm (8.0

F A$';'-0
-1. 4
!3-
- Tighten the 11 mm bolts in two steps. In the first kgf/m, 58 Ibf/ft).
#
=A'!=<-
step, tighten all bolts in sequence to about 29 Nm
A
!!!F 5
(3.0 kgf/m, 22 Ibf/ft); in the final step, tighten in
;+-0#
=A!=<N!A

same sequence, to 78 Nm (8.0 kgf/m, 58 Ibf/ft).
F A$';'-0#
=A'!=<-
W 1.4.! 1- -.5.' t3}
NOTE: Whenever any crankshaft or connecting rod

84 92&#

bearing is replaced, it is necessary after reassembly to

!A!
run the engine at idling speed until it reaches normal

!
!!
operating temperature, then continue to run it for

A
approximately 15 minutes.
/! -
-2. 4
!F ;-
- Tighten the 6 mm bolts in sequence to 12 Nm (1.2
kgf/m, 8.7 Ibf/ft).
#
=A'-$!=<-
6 "
Crankshaft
and Balancer Shafts

/
?0
7-B-32
7"
NOTE:
84 9 14. !!#A
*- Insert the balancer shafts into the block, then
0 Use liquid gasket, Part No. 08C70-K0234M,
?!F
#A-0'$0>0+*,A install the retainer to the front balancer shaft and
!!!
08C70-K0334M or 08C70-X0331S.
0'$0>0++*,0'$0R0++- !#-
block.
Check that the mating surfaces are clean and dry
#
!
before applying liquid gasket.
!
!F
#-
Apply liquid gasket evenly, being careful to cover all
%!!F
#&!A
!&!!
the mating surface.

-
To prevent leakage of oil, apply liquid gasket to the
4&!#
!A!!F
#
inner threads of the bolt holes.
!!-
Do not install the parts if five minutes or more have
(!!& &
!!
!F
#-A
REAR BALANCEH
!!F
#&
! - SHAH
After assembly, wait at least 30 minutes before
%!A3!+0
filling the engine with oil.
!!

3!-
13. %!!F
#!#

+- Apply liquid gasket to the block mating surface of
the right side cover, then install it on the cylinder

&A!!!
block.
!#-
RIGHT SIDE COVER:
.)%4%F
RETAINER
E J: Hill mm
2'} ”m {2.0 kgf-m. 14 IbH'tl
15. %!!F
#!

- Apply liquid gasket to the oil pump mating surface
of the block, then install the oil pump on the
!#A!!!
cylinder block.
!!#-
Apply liquid gasket along ¢ Apply grease to the lips of the oil seals. Then,
%!
!!!-4A
the broken line. install the oil pump while aligning the inner
!!! 3!!

RIGHT SIDE ICEW'EH rotor with the crankshaft. When the pump is in
3#-2
Apply liquid gasket place, clean any excess grease off the
!A!/

in black mating surface. crankshaft and the balancer shaft, then check
#!A#
that the oil seal lips are not distorted.
!!!-
DDWEL I OIL PUMP:
&';'F
Apply linuid gasket along

fifixtflmm
11 N-m [1.1 kgf—m. 3.0 Ibf-ftl the broken line.
6 "
Crankshaft
and Balancer Shafts

/
?0
7-B-33
7"
5 x 1.0 mm 18. )!!
!&

'- Before installing the balancer driven gear and the
11 N-I‘l‘l (1.1 kgl-m. 8.0 Ibl-HI balancer gear case, apply molybdenum disulfide to
!
A!! !
the thrust surfaces of the balancer gears as shown.
!
3-
Appiv molybdenum
disulfide. BALANCER SHAFY
DRIVEN GE\AR
OIL PUMP
/ TH RUST
GASKET WASH EH
Replace.
Apply molybdenum
disulfide.
Applyr engine 01!

Replace.
EI'IJJITIIT'I
BALANCER BELT BALANCER DRIVE GEAR
11 N-m i1.1 kgl—m,
an l‘tI OIL PUMP ”ENE” PULL” BALANCER GEAR CASE
Apply liquid gasket AUDI? 'liITiUId 985k??? tu- 19.
5- Hold the rear balancer shaft with the special tool,
6!!3!!A
te the bolt threads. block "“3““9 5L"r““¢- then install the balancer driven gear.
!!!&
-
16. !!!-
- Install the oil screen. REAR BALANCER SHAFT:
%"&,%.+F
17. 6!!33&A
$- Hold the front balancer shaft with a screwdriver, then HEAR BALANCER
install the timing balancer belt driven pulley.
!!
!!& !!- \\_5HAFT BALANCER SHAFT
' LOCK FIN
FRONT BALANCER SHAFT:
+,"&,%.+F 07 LAG PT20100
-
TIMING BALANCER BELT
DRIVEN PULLEY
MAINTENANCE
HOLE
SCREWDRIVEH ' REAR BALANCER

DRIVEN GEAR . .___ SHAFT
MAINTE NANCE HOLE

8 I 1.25 mm
25 N-m 13.0 kgf-rn.
22 Ib'I-I'tl
' ‘ " BALANCE R SHAFT

MA NTENANCE r"" LOCK PIN
"OLE WASHER m LAG - Funny:

3 11.25 mm REP'BCE-
25 N-m :25 km-m. 12 mm SEALING BOLT
13 l‘tl 229 Mm (3.0 kgf-rn. 22 IbH'ti
6 "
Crankshaft
and Balancer Shafts

/
?0
7-B-34
7"
20. !!!
! -
0- Install the balancer gear case to the oil pump. 22. !!!#
-
- Clean and dry the cylinder block mating surfaces.
NOTE: Align the groove on the pulley edge to the pointer
84 9%!

& !!
23. %!!F
#A-0'$0>0++*,
+- Apply liquid gasket, Part No. 08C70-K0334M or
on the gear case while holding the rear balancer with the

3!!
!3 O8C70-X0331S, evenly to the cylinder block mating
0'$0R0++A&!!!#
special tool, then install the gear case.

!!A!!
- surface of the oil pan and to the inner threads of
!
DDWEL PIN the bolt holes. Install the oil pan.
!!-!!!-
NOTE:
84 9
9 Apply liquid gasket 4 mm wide.
%!!F
#*3-
9 Apply liquid gasket doubly to the jointing point
%!!F
# !7

of the liquid gasket.
!F
#-
."_é,_
E 11.25 mm I x’
25 film [2.5 kg-i-m.
13 Ihf-fll
Appl y engm 3 oil

Replace.
___...»-""'bALANCEn DOWEL PIN

$9 GEAR CASE
POINTER Apply liquid gasket

Align thL‘r QIHUVE along the hmlcnn Iina.
tn pointer
24. 4
!= 3-
*- Tighten the bolts/nuts in two or three steps. In the
final step, tighten all bolts/nuts, in sequence to 12
!A
!!!= AF
Nm (1.2 kgf/m, 8.7 Ibf/ft).
;-#
=A'-$!=<-
GROOVE
Check the alignment of the pointers after installing the
- #!
!!

-
gear case.
POINTER ON THE PULLEY
POINTER on
THE on. Pum-
Balancer Shafts
"
Inspection

7-B-35
7"3
NOTE: Inspect the balancer shaft before removing the right
84 9!&

- Remove the balancer shafts (see page 7-8-13).
1&!;!$)+<-
side cover and the balancer gear case (see page 7-8-13).
&!
;!$)+<- NOTE: Clean the balancer shafts.
84 9!!-
1.
- Push the balancer shaft firmly away from the dial
!!3! +- Inspect the surface of the balancer shaftjournal
!7 !
indicator. Zero the dial against the front end of the
-I!
and balancer bearing.
!
-
balancer shaft, then pull the balancer shaft firmly back
!A !!!!# *- Replace the bearing or balancer shaft if there is
1!
!
toward the indicator.
3- wear, damage or discoloration on the surface of
3A
!
Front Balancer Shaft
+
" End Play
%'# the bearing or the balancer shaft journal. When

!7 !-2
Standard (New):
/,(0F 0.10 - 0.40 mm
$@$$@$ replacing the rear No. 1 bearing, be sure to replace
!
-
A !
(0.004 - 0.016 in)
/$@$$$@$5 0 the oil pump housing with a new one.
!
33-
NOTE: A mirror-like surface is normal.
84 9%!# !-
- Measure taper at the edges of each journal.
,
7 !-
¢ The difference between measurements on
43
each journal must not exceed the standard.
7 ! /-
Journal Taper
<

Standard (New):
/,(0F 0.005 mm (0.0002 in) max.
$@$$3/$@$$$ 0@
-Iz.- _ __ ..
0 !/&A

If end play is excessive, inspect the retainer and thrust
surfaces on the balancer shaft.
!-
Rear Balancer Shaft
" End Play
%'#
Standard (New):
/,(0F 0.04 - 0.15 mm
$@$$@3
(0.002 - 0.006 in)
/$@$$$@$$5 0
0 If end play is excessive, inspect the thrust washer

!/&A 3
and thrust surfaces on the driven gear and oil pump
&
!
body
-
NOTE: The thickness of the retainer (front) and thrust
84 94#;<
washer (rear) are fixed and must not be changed either
3;</

by grinding or shimming.

-
Balancer Shafts
" 7_B_36

/
?0
7"5
6.
- Measure runout on the No. 2 journal of each balancer
, -7 !!
shaft to make sure the balancer shafts are not bent.
# !-
Balancer Shaft
" Total Indicated Runout

Standard (New):
/,(0F 0.02 mm (0.001 in) max.
$@$/$@$$ 0@
Service Limit:
- & F 0.03 mm (0.001 in)
$@$/$@$$ 0
DIAL INDEATGH
Rutaie two :nmplnfe
revolutions.
Journal Diameter
<
)
Standard (New):
/,(0F
No. 1 journal:
,
@D
F
Front:
+
F 42.722 - 42.734 mm
@7@7
(1.6820 - 1.6824 in)
/@58$@58 0
Rear:
F 20.938 - 20.950 mm
$@98$@93$
(0.8243 - 0.8248 in)
/$@8$@88 0
No. 2 journals front and rear:
,
@D

F
38.712 - 38.724 mm
8@78@7
(1.5241 - 1.5246 in)
/@3@35 0
Sumo” with lama Type No. 3 journals front and rear:
,
@D

F
tool or V-Dlocks. 34.722 - 34.734 mm
@7@7
7.
$- Measure the diameters of the balancer shaftjournals.
, !7 !- (1.3670 - 1.3675 in)
/@57$@573 0
MEASURING POINTS Service Limit-
- & F
No. 1 journal:
,
@D
F
Nu. BJDURNAL Front: @7/@58 0
+
F 42.71 mm (1.681 in)
Rear:
F 20.92 mm (0.824 in)
$@9/$@8 0
Nfl- 2 JOURNAL No. 2 journals front and rear:
,
@D

F
38.70 mm (1.524 in)
8@7$/@3 0
No. 1 JOURNAL
,
@D

F
34.71 mm (1.367 in)
@7/@57 0
8.
'- Remove the crankshaft, the pistons and the other
1&#A
parts from the block, then clean the balancer shaft
!#A!!
journal bearings in the block and the oil pump
7 !
!#!
housing with a clean shop towel.

3!3!-
9.
5- Check the surface of the bearings; if there is wear,
#
N3A
FRO NT BALANCE H damage or discoloration, replace the bearings or

!A!

SHAFT No. 3 JOUHNfliL
the oil pump housing.
!
-
Nu. 2JOURNAL
REAR BALANm-LH ”°- 1 JOURNAL

SHAFT
Balancer Shafts
" 7_B_37

/
?0
7"7
10. , !
0- Measure the inner diameters of the balancer shaft Bearing Inner Diameter
" !)
journal bearings.
7 !
- Standard (New):
/,(0F
MEASURE POINTS No_ 1 journals:
,
@D
F
~12 BEARING Front: @8$$@8$
+
F 42.800 - 42.820 mm
Na. 1 BEARING 'BLOCK‘ ND. 3 35mm; (1-5350 ' 1-6858 in)
/@583$@5838 0
tBLDCK] lBLOCKl Rear:
F 21.000 - 21.013 mm
@$$$@$
./—| (0.8268 - 0.8273 in)
/$@858$@87 0
x ' No. 2 journals front and rear:
,
@D

F
38.800 - 38.820 mm
8@8$$8@8$
. ”“3"” (1.5276 - 1.5283 in)
/@375@38 0
r._,.;_;;'::-_:;-_:\ - No. 3 journals front and rear:
,
@D

F
” 34.800 - 34.820 mm
@8$$@8$
(1.3701 - 1.3709 in)
/@7$@7$9 0
Service Limit:
- & F
No. 1 journals:
,
@D
F
REAR Front:
+
F 42.83 mm (1.686 in)
@8/@585 0
Rear:
F 21.02 mm (0.828 in)
@$/$@88 0
,
@D

F
38.83 mm (1.529 in)
8@8/@39 0
No.3 BEARING No. 3 journals front and rear:
,
@D

F
lBLDCKl 34.83 mm (1.371 in)
@8/@7 0
No. 2 BEARING - Calculate the shaft-to-bearings oil clearances.
11. ! !
!!-
laLOCKl BEARING |.D. - JOURNAL CD. = OIL
"%,@)@<;,&@)@P&
CLEARANCE
&%,%
Shaft-to-Bearings
Oil Clearances

" !
Standard (New):
/,(0F
No. 1 frontjournal, No. 3 front and rearjournals:
,
@
D
:,
@
D
F
0.066 - 0.098 mm (0.0026 - 0.0039 in)
$@$55$@$98/$@$$5$@$$9 0
No. 2 front and rearjournals:
,
@
D
F
0.076 - 0.108 mm (0.0030 - 0.0043 in)
$@$75$@$8/$@$$$$@$$ 0
No. 1 rearjournal:
,
@D
F
0.050 - 0.075 mm (0.0020 - 0.0030 in)
$@$3$$@$73/$@$$$$@$$$ 0
Service Limit:
- & F
No. 1 frontjournal, No. 3 front and rearjournals:
,
@
D
:,
@
D
F
0.12 mm (0.005 in)
$@/$@$$3 0
. No. 2 front and rearjournals:
,
@
D
F
DIAL GAUGE 0.13 mm (0.005 in)
$@/$@$$3 0
No. 1 rearjournal:
,
@D
F
Dim. GAUGE 0.09 mm (0.004 in)
$@$9/$@$$ 0
No. 1 REAR BEARING

lOIL PUMP HDUSiNCi-I
" " !
Balancer Shaft
Replacement

Bearings
7-B-38
7"8
The procedure shown below is used when using the bearing
4 3!3 3

1.
- Put the attachment with the side having larger
3&
!

replacement tool set (O7LAF-PT20100).
!!;0$% 4000<- diameter facing the bearing. Align the stopper pin

-%!

NOTE:
84 9 holes of the attachment and the shaft.
!-
¢ Remove all attachment parts from the cylinder block and
1&!!!!# Insert the stopper pin to fix the attachment.
/-
lay it with its oil pan side up.
!3! - FRONT No. I BEARING: ATTACHMENT A
¢ Remove or reinstall bearings one at a time.
1&!!
- No. 2 BEARINGS: ATTACHMENT B
No. 3 BEARINGS: ATTACHMENT C
¢ Remove bearings from the transmission side to the
1&

timing belt side and reinstall them in reverse sequence.

!!!&F -
Removal:

-F
NOTE:
84 9 STU PPEH PIN
¢ By changing the size and attachment point of the
)

H
attachment, all balancer bearings can be removed from
A!!!
&
the cylinder block in the same procedure.
!!# -
¢ The illustration shows the attachment points of each
4!! 3
special tool.
!!-
¢ When removing bearings successively, put the
2&

&!A
corresponding attachment through the shaft without

3
fixing them in advance.
/
&-
A:
SPECIAL TDDL SET LOCATION
ATTACHMENT B ATTACHMENT A
ATTACHMENT C \ \ THHUST BE AHlNG
GUIDE
We..\i _ \
SHAFT NUT
Align with the gtilde mark.
2.
- Hold the shaft end with a wrench and turn the nut
6!33
clockwise until the bearing comes off.
!#3 !
-
¢ Do not rotate the shaft.
(-
ATTACHMENT C J
ATTACHMENT 5
¢ Position of attachment fixing holes and guide marks on
/
!
# \ -'-.‘
the shaft.
- +- When removing bearings in succession, loosen the
2&

A!
9°
nut, remove the stopper pin from the pin hole you
A&!
A-IN C-RE B-IN B- HE C-IN A-RE
have finished and repeat above step 1 and 2 on
\\
&&
f f / the next bearing.
/
-
"E
.. l
A, / /
.231 biz-413' :--3 n41"
" " !
Balancer Shaft Bearinqs
Replacement (cont’d)
/
?0
7-B-39
7"9
Installation:

F 2.
- Install the shaft positioning pin.
!!
-
Front No. 1 bearing
+
,
@* ! END DISK
NOTE: Always use new bearings.
84 9%!3 3
-
1.
- Set the recess of the bearing to the detent of the

attachment.
-
FRONT
ND. 1 BEARING
ATTACHMENT A i"
.1
POSITIONING PIN
3.
+- Set the shaft so that the attachment pin is aligned
!

SB! ham.
with the positioning hole in the end disc.
3
!-
Attachment
%
Front No. 1 bearing: AttachmentA
-
9%% ATTACHMENT A
¢ The illustration shows the attachment points of the
4!! 3
special tools.
!!- BEARING
PIN
GUIDE SHAFT GUIDE ATTACHMENT A POSITIONING
HOLE /////
—_ .--
//¢
. "" _ "FT—"i r7 -
"""" __ __ 1.; _—- 1‘] —
i:>
J ,7
////;/
/,/’,./’
:i
»"f .-"’ x"); xx 2.2-:
o-—. _,
//"//:”,
:_ r __-a-+—._._ _.__ l
SHAFT DETENT
THHUST END DISK

BEARING
" " !
Balancer Shaft Bearinqs
/
?0
7-B-40
7"$
4.
*- Set the detent of the bearing to the groove of the

& Installation:

F
cylinder block.
!!#- No.2 and No.3 Bearings
,
@,
@" !
BEARING ATTACHMENT A 1.
- Set the recess of the bearing to the detent of the

attachment.
-
N0. 2 BEARINGS: ATTACHMENT 3-
ND. 3 BEARINGS: ATTACHMENT B
BEARING Set here.

¢ The illustration shows attachment points of
4!! 3
POSITIONING PIN DETENT
each special tool.
!!-
- Hold the end of the shaft with wrench and install the
6!33!! ¢ When installing bearings successively, set the
2!!

&!A
bearing by turning the nut clockwise.

!#3- bearings to the attachment and put them

0 Do not rotate the shaft.
(- through the shaft without fixing them in

3 /

advance.
&-
ATTACHMENT 6
THHUST BEARING
ATTACH ME NT B
NUT GUIDE
GUIDE SHAFT
i i
ATrACHMiENT c A'l'TACHMENT a
Balancer Shaft
" Bearinqs
" ! 7-3-41
7"
/
?0
2.
- Install the shaft positioning pin.
!!
- 4.
*- Set the detent of the bearing to the groove of the

&
END DISK cylinder block.
!!#-
GROOVE DETENT
POSITIONING PIN
3.
+- Align the attachment wit the guide mark. Applicable
%!
3
#-%!!
bearing No. is indicated at the guide mark. Align the pin

-
#-%!
BEAR'NG ATTACHMENT B urC
holes of the attachment and the shaft. Insert the stopper
!- 5.
- Hold the end of the shaft with wrench and install
6!33!!
pin to fix the attachment (for No. 2, and No. 3 bearings).
/;-A-+
<- the bearing by turning the nut clockwise.

!#3-
BEARING o (-
Do not rotate the shaft.
STOPPER PIN
ATTACHMENT B or C
Sgecial Tools

8_2
8
O 1- O| Tool Number
4! O Description
( |Qty
OD O Remark
1#
O O| 07LAG - PT20100
)!# | 1
O O
O O| 07406 - 0030000
0$*000+0000 O Oil Pressure Gauge Attachment
8! .
% | 1
O O
O + O| 07506 - 3000000
0$0+000000 O Oil Pressure Gauge
8! .
| 1
O O
O * O| 07746 - 0010300
0$$*000+00 O Driver Attachment, 42 x 47 mm
(&%A*/*$ | 1
O O
O O| 07746 - 0010400
0$$*000*00 O Driver Attachment, 52 x 55 mm
(&%A/ | 1
O O
O O| 07749 - 0010000
6!(& | 1
O O
O $ O| 07912 - 6110001
0$5000 O Oil Filter
8! Wrench
!2 | 1
O O

Illustrated Index
8
8-3
NOTE:
84 9
¢ Use new O-rings when reassembling.
?38
3!
-
¢ Apply oil to O-rings before installation.
%!!8
!!-
¢ Use liquid gasket, Part No. 08C70-K0234M, OSC70-K0334M or OSC70-XO331S.
?!F
#A-0'$0>0+*,A0'$0>0++*,0'$0R0++-
¢ Clean the oil pan gasket mating surfaces before installing.
!!
#
!!
-
D1636 engine:
)5"5! F
ENGINE OIL PRESSURE swrrcH
13 NM [1.3 lta, 13 Ihf-fll
we in. BSF'T [British
Standard Pipe Taperl
2E: threadalinch. Use
proper liquid sealant.
OIL PUMP OIL BREATHEH

O-RING
Overhaul. page 3-14 CHAMBER
Replace.
Inspection. page 3-1?
Apply liquid gasket 5 x 1 .1} mm
to the mating surface 11 N-m [1.1 kgf-m.
of the block. 8.0 Ihf'ftl
1““ , -. ' _ OIL FILTER

‘5 Replacement, page 8-3

E It 1.0 mm these points.
11 III-m [1.1 kgf-m,
3.0 lhf-HI
Apply liquid gasket
to the bolt threads_
OIL PAN
GASKET
GASKET Replace.
Replace,
OIL PAN
Refer to page 8-19
when installing.
E a: 1.0 mm
11 N-m 11.1 kgfvm.
3.1] Ib'lrf't]
6 a: 1.0 mm
6 J: 1.1] mm 12 N-rn [1.2 kgfvrn.8.71bf‘fil
11 NM 11.1 kgf-rn.
%\
Apply liquid gasket lo
31} lbf-ftl these points.
@
DRAIN BOLT
114 Mm [4.5 “Wm. 33 1131-111
WASHER
Dn nnl nvertighlcn.
Fleplace.

4

&A
!#!!3
9
(See Page 8-14)
;'!'*<
(See Page 8-17)
;'!'$<
(See Page 8-8)
;'!''<
(See Page 8-19)
;'!'5<
Illustrated Index
8-4
8
(cont’d)
/
?0
NOTE:
84 9
?38
3!
-
¢ Apply oil to O-rings for European models before installation.
%!!8
!!!-
o Use liquid gasket, Part No. 08C70-K0234M, OSC70-KO334M or OSC70-X0331S.
?!F
#A-0'$0>0+*,A0'$0>0++*,0'$0R0++-
F1832, F1833, F2036, H22A7 engines:
+8":+8":+$"5:.7! F
:3 x 1.25 mm BALANCES DRIVEN '3'" U
P MP
Dverhaul, page 3 15
25 N-m12.5 kgf-m, 1B|bH1l GEAR Inspection. Dane 8-1 :1.
FRONT Firing—iii,I liquid gasket to
BALANCER BELT block mating 5|,irf.3i:e.
DRIVEN PULLEV \
{II-RING
Enllfimm Replace.
25 N-m 13.0 km_ . - .:. J F1832. F1833.
22IbF-fll ' F2036 engines:
ENGINE OIL PRESSURE SWITCH
13 Nrm (1.8 kgf-rn,13lbf-ftl
BALANCE“ ms in. BSPT (British
GE RH CASE Standard Pipe Taper)
23thread5-'inch. Use
H22A7 angina:
KNOCK SENSOR
31 Nvm {3.2 kgI-m, 23 Ibf-f't]
8 x 1.25 mm
25 N-m [2.5 kgf-m. 1B lbf-ft]
0-HING
Replace.
ENGINE IDIL COOLER

[HZZM' angina!
DOWEL PIN
OIL FILTER
Replace. Replacement. page 8-8
é} OIL SCREEN ENGINE OIL COOLER

CENTER BOLT
{3737:
/u
14 film (7.5 kgf-m, 54 Ihf-ftl
6)»: 1.0 mm
A"! ' :
11N-ml1.1kgf-m 8.0lbf-ftl ”22
ENGINE9'19”":
OIL PRESSURE SWITCH
18 film 11.8 kgflm, 13 Ibl'vftl
1:8 in. BSPT “British
Standard Pipe Taper]
2E1 lhreads."inch. Use
DIL PAN
Refer to page 3-22
when installing
DRAIN BI‘JLT
61-: 1.0 mm WASHER 143-: 1.5 mm
12 N'm 11.2 kgf-m. 8.7 IbH‘ll Replace. “- Nam 14.5 kgf-rn. 33 Ib‘I-h‘l
Du nut avertighten.
4

&A
!#!!3
9
(See Page 8-15)
;'!'<
(See Page 8-17)
;'!'$<
(See Page 8-8)
;'!''<
(See Page 8-22)
;'!'<

Illustrated Index
83
_
(cont’d)
/
?0 8 5
H22A7 engine:
.7! F
1111.5 mrn 611.0 mm
'59 film ”.0 It I-m, | _
51 Ihf-f't] g BAFFLE PLATE 11 N m [1.1 kglm. 3.0 lhlil't]
Apply angina ml to the belt
threads.
NOTE:
After torquing each can,
turn crankshaft to chuck
for binding.
DIL JET BOLT
39 film [4.0 kgi-m, 29 Ibfifl)
OIL JET
Handle the nozzln with
care. Do not damage or
deform.
Replace. E i I "l __ ‘7 _ 5 x 1.0 mm

' ' " 11 M-m[1_1kgf-m,
3.0 Ihf-ftl
RIGHT BHEATHEH
MAIN BEARING COVE"
CAP
LEFI' BREATHEH
COVER
DUWEL PIN
CRANKSHAFT
MAIN BEARING
THRUST WASHERS
Grooved Sidu facet;
outta-3rd.
4

&A
!#!!3
9
(See Page 8-13)
;'!'+<
%!
Engine Oil
Inspection

8-6
85
- Park the vehicle on level ground, and turn off the engine.
#&!!&!
A
- Except D1636 engine:
%)5"5! F
Allow the oil a few minutes to drain back into the oil pan
%!!3!3 #! DIPSTICK
so the dipstick will show the actual level.
#3!!3 !!&!-
- Make certain that the oil level indicated on the dipstick is
,#!!&!#
between the upper and lower marks.
3 !3#-
D16B6 engine:
)5"5! F
___ DIPSTICK
UPPER
D LOWER
UPPER
LOWER
3.
+- If the level has dropped close to the lower mark,
!&!!!3#A
add oil until it reaches the upper mark.
! ! #-
%!
Engine Oil
87
Replacement

1.
- Warm up the engine.
2
- Engine Oil SAE Viscosity for Outside Temperature
%! %4
#

2.
- Drain the engine oil.
(
!- Ranges
!
WASHER
Replace.
DRAIN BOLT
1: Min [4.5 kyf-m, 33 liar-m 10 20 3!] WC
Do not overtighten. _ . i _ . _ |
3.
+- Reinstall the drain plug with a new washer, and refill with
1!!!
333A!!3
!-
the recommended oil.
ti in 40 so an 1IJII°F
Requirement
B Ambient tomparatura ranges
Always use a fuel efficient oil that says “API Service SG, SH
%!3 !!K%&.A6 4.
*- Fill the engine with oil up to the specified level, run
!!
3! !&!A
or SJ”.
"L- the engine for more than three minutes, then check

A#
SAE Viscosity; See chart in right hand column.
% :N
! - for oil leakage and oil level.
!!#
!!&!-
Capacity
#
D16B6 engine:
)5"5! F
3.3 I (3.5 US qt, 2.9 Imp qt) at oil change.
+-+;+-?FA-5F<!
-
3.6 I (3.8 US qt, 3.2 Imp qt) at oil change, including filter.
+-;+-'?FA+-F<!
A!
!-
4.0 I (4.2 US qt, 3.5 Imp qt) after engine overhaul.
*-0;*-?FA+-F<
& !-
F1832, F1833, F20B6 engines:
+8":+8":+$"5! F
4.1 [(4.3 US qt, 3.6 Imp qt) at oil change.
*-;*-+?FA+-F<!
-
*-*;*-?FA+-5F<!
A!
!-
-$;-0?FA-0F<
& !-
H22A7 engine:
.7! F
4.5 I (4.8 US qt, 4.0 Imp qt) at oil change.
*-;*-'?FA*-0F<!
-
*-';-?FA*-F<!
A!
!-
-5;-?FA-F<
& !-
Change
Interval
!-
European models:
!9
Every 10,000 km (6,000 miles) or 12 months (Normal
&0A000#;A000!<;!
condition).
<-
Every 5,000 km (3,000 miles) or 6 months (Severe
&A000#;+A000!<;&
conditions).
<-
Except European models:
/ !9
Every 5,000 km (3,000 miles) or 6 months.
&A000#;+A000!<-
Oil Filter
+ 8-8
88
Replacement

Atype oil Filter:

#
+ F 3.
+- Install the oil filter by hand.
!!!!-
Remove the oil filter with the special oil filter wrench.
1. 1&!!3!!!3-
- 4.
*- After the rubber seal seats, tighten the oil filter
% !A
!!
2.
- Inspect the threads and rubber seal on the new filter.
!3!- Clockwise with the special tool.
!#33!!-
Wipe off the seat on the engine block, then apply a light
2
!#A!!
Tighten:
! 7/8 turn clockwise.
F728
6( @
coat of oil to the filter rubber seal.
!! !- Tightening
! torque: 22 Nm (2.2 kgf/m, 16 lbf/ft)
!
BF,/@6! 2:5* 2 0
NOTE: Use only filters with a built-in bypass system.
84 9?!!3 !- OIL FILTER WRENCH
7a Applv oil to rubber seal 07912 — 6110001
before installing.
Inspect threads and

rubber snail surface.
ENGINE OIL COOLER

(HRH engine]
Oil Filter
+ 89
/
?0
Eight numbers (1 to 8) are printed on the surface of the filter.

;'< !- B type oil filter:
"#
F
The following explains the procedure for tightening filters
4!!3
/!

! 1.
- Remove the oil filter with the oil filter wrench.
1&!!3!!3-
using these numbers.

- 2.
- Inspect the threads and rubber seal on the new
!3
1.
- Make a mark on the cylinder block under the number
,##!!# filter. Wipe off seat on the engine block. Apply a
!-2
!#-%!
that shows at the bottom of the filter when the rubber
3!3 light coat of oil to the filter rubber seal.
!
!! !-
seal is seated.
!- NOTE: Use only filters with a built-in bypass
84 9?!!3 !
2.
- Tighten the filter by turning it clockwise seven numbers
4
!
!#3& system.
-
from the marked point. For
#- example, if a mark is made
/!A#
Apply oil to rubber seal
under the number 2 when the rubber seal is seated, the
3 !A before installing.
filter should be tightened until the number 1 comes up to
! !
!
the marked point.
#-
NB turn
clockwise.
MARK
Number when rubber Number afiartlghtaning.

seal is seated.
Inspect threads and
Number when rubber
3 1 2 +3 * 4 5 6 $
7 '
8 rubber seal surface.
seal is seated
!
Number aftertightening

8 1
' 2 + 3 * 4 5
6 $
7
5.
- After installation, fill the engine with oil up to the
%!!A!!
3!
specified level, run the engine for more than three
!&!A

minutes, then check for oil leakage.
A#!!#
-
Oil Filter
+
/
?0
8-10
8$
+- Install the oil filter by hand.
!!!!- Four numbers (1 to 4) are printed on the surface of the
;*<
*- After the rubber seal seats, tighten the oil filter clockwise
% !A
!!!#3 filter.
!-
with the tool.
3!- The following explains the procedure for tightening
4!!3
/!

Tighten:
! Fthree quarter turn clockwise.
B
6( @ filters using these numbers.
!
-
Tightening
! torque: 22 Nm (2.2 kgf/m, 16 lbf/ft)
!
BF,/@6! 2:5* 2 0 1.
- Make a mark on the engine oil cooler under the
,##
!!
number that shows at the bottom of the filter when
3!3
the rubber seal is seated.
!-
2.
- Tighten the filter by turning it clockwise three
4
!
!#3
numbers from the marked point. For
#- example, if a
/!A
mark is made under the number 2 when the rubber
# 3
seal is seated, the filter should be tightened until
!A! !
!
the number 1 comes up to the marked point.
#-
3,-‘4 turn
Clockwise.
LABINAL-Purflux 76
CDMMEHCIALLV-AVAILABLE
MARK MARK
Number when rubber Number after tlghlemng.

seal is seated.
3
Numberwhen rubber 1 2 +3 * 4
!
seal is seated
Numberaftertightening

*4 1 2 + 3
5.
- After installation, fill the engine with oil up to the
%!!A!!
3!
specified level, run the engine for more than three
!&!A

minutes, then check for oil leakage.
A#!!#
-
'(
Oil Pressure Switch
Testing
!
8-11
8
1.
- Remove the YEL/RED wire from the engine oil pressure
1&C =1 (3
! F1832, F1833, F2036 engines:
+8":+8":+$"5! F
switch.
3-
POSITIVE
2.
- Check for continuity between the positive terminal and
# 3&! E NGIN E DIL TERMINAL VEURED
the engine (ground).

;
<- PHESSUERE SWITCH WIRE
0 There should be continuity with the engine stopped.
4 ! 3
-
0 There should be no continuity with the engine
4 ! 3

running.

-
D1636 engine:
)5"5! F
VELI‘FIED WIHE
POSITIVE
TERMINAL
OIL FILTER
HA22A7 engine:
.7! F
VELIHED
ENGINE OIL \IVIFIE
PRESSURE
SWITCH
ENGINE OIL TERMINAL

PRESSURE SWITCH
3.
+- If the switch fails to operate, check the engine oil
3!A#
!
level. If the engine oil level is OK, check the engine
!&!-
!!&!8>A#

oil pressure.
! -
'
Oil Pressure
Testing
!
8-12
8
If the oil pressure warning light stays on with the engine
! 3
!
3
3.
+- Start the engine. Shut it off immediately if the

- !
running, check the engine oil level. If the oil level is correct:

A#
!!&!-!!&!9 gauge registers no oil pressure. Repair the

! -1
1.
- Connect a tachometer.
- problem before continuing.
!
-
2.
- Remove the engine oil pressure switch and install an oil
1&
! 3!!! *- Allow the engine to reach operating temperature
%!!3

pressure gauge.

- (fan comes on at least twice). The pressure should
;!3<-4 !
%.7! F be:
9
ENGINE OIL PRESSURE SWITCH Engine Oil Temperature: 80°C (176°F)
%! F8$P/75P+0
MOUNTING HOLE Engine Oil Pressure:
%! 'F
At Idle:
F 70 kPa (0.7 kgflcmZ, 10
7$6'/$@76! 2:$
psi) minimum
0
At 3,000 rpm (min-1): $6'/@36! 2:3$
:$$$/ 0F 340 kPa (3.5 kgf/cm2, 50
psi) minimum
0
¢ If oil pressure is NOT within specifications,
! 843A
inspect the oil pump (see page 8—17).
! ;!'$<-
OIL PRESSURE GAUGE

ATTACHMENT
Bil-‘06 — 0030000
OIL PRESSURE GAUGE
075m; — ammo
H22A7 engine:
.7! F
ENGINE OIL PRESSURE
RSWITCH
“a MOUNTING HOLE . r
OIL PRESSURE
GAUGE
07506 - 3000000
OIL PRESSURE GAUGE

ATTACHMENT
flTl-nfi — 0030000
Oil Jet
< 8_13
8
Inspection

1.
- Remove the oil jet (see page 8-5) and inspect it as
1&!7;!'<
follows.
!!3-
0 Make sure that a 1.1 mm (0.04 in) diameter drill will
,# -;0-0*<!!3!!
go through the nozzle hole (1.2 mm (0.05 in)

HH!!;-;0-0<
diameter).
<-
0 Insert the other end of the same 1.1 mm (0.04 in)
-;0-0*<
drill into the oil intake (1.2 mm (0.05 in) diameter).
!!!#;-;0-0<<-
Make sure the check ball moves smoothly and has
,# #!!&!
a stroke of approximately 4.0 mm (0.16 in).
#/!*-0;0-<-
0 Check the oil jet operation with an air nozzle. It
#!73HH!-
should take at least 200 kPa (2.0 kgf/cm2, 28 psi)
!#!00#;-0#
=A'<
to unseat the check ball.
#!!-
NOTE: Replace the oil jet assembly if the nozzle is
84 91!!7!HH!
damaged or bent.

-
‘— ‘- 1.2 mm
[0.05 in]
CH EC K BALL
2.
- Mounting torque is critical. Be very precise when
,
F !-)&3
installing.
!!
-
Torque: 39 Nm (4.0 kgf/m, 29 lbf/ft)

BF9,/@$6! 2:9* 2 0
Oil Pumg
' 8-14
8
-
Overhaul
NOTE:
84 9
?38
3!
-
¢ Apply oil to O-rings before installation.
%!!8
!!-
¢ Use liquid gasket, Part No. 08C70-K0234M, OSC70-K0334M or 08C7O -X0331S
?!F
#A-0'$0>0+*,A0'$0>0++*,0'$0R0++
¢ The rotors must be installed to the same direction.
4 !!-
¢ After reassembly, check that the rotors move without binding.
%!A#&3
-
D1636 engine:
)5"5! F
fixlflmm
PUMP HOUSING '.|' N-rrl Ill? kgf-rn. 5 IbH‘tl
Inspection. bag;- 8 1r
Apply qmd gasket
tn mating surface of
the cylinder block OUTER ROTOR
when installing. Inspection. page B H
DDWEL FIN INNER ROTOR
|nspec1iumpag¢ 8 1T
E 1 1.0 mm
11 N-rn (1.1 kgf-m, 8.0 l‘li
Appla- |iquid gasket
tnthe builthr'fiads.
PUM P COVE R
O-RING
l—luptace.
DOWEL PIN
DILSEAL
Installatlnn. page 5-18
Replace.
RELIEF VALVE
Valve must slide freely
in hum-3mg bole.
Replace if scored.
SPRING
@‘x‘ was HER

6 :1 1.0 mm
11 NM [1.1 kgf-m. 8.0 lbf—ftl
April? liquid gasket
[0- the bolt threads
SEALING BOLT
39 N-m HO kgf-m.
25 l'tl

4

&A
!#!!3
9
(See Page 8-17)
;'!'$<
(See Page 8-18)
;'!''<
'
Oil Pumg
Overhaul
- (cont’d)
/
?0
8-15
83

%)5"5! F
6 x 1.0 mm
6
7 N-m (IL? Ital-”1.5.1 Ihf—fll
PUMP HDUSING
Inspection, page 3-1? OUTER ROTOR
E I: III mm Apply liquid gasket Inspection. page 8—17
11 I‘ll-m 11.1 leaf-m, 3.0 Ib‘l-l‘t} to mating surface of
Ap ply liquid gasket the cylinder bleak
In the belt threads. when installing.
0-HING
Replace.
DOWEL PIN
PUMP COVER
INNER ROTOR
RELIEF VALVE
OIL SEALS Valve rrlust slide freely
Installation. page 3-20 in housing bore.
Replace. Replace if scored.
SPRING
$14 SEAUNG BOLT

as Nrm l-Lu kgf-m,
a lhl-ftl
4

&A
!#!!3
9
(See Page 8-17)
;'!'$<
(See Page 8-20)
;'!'0<
'
Oil Pump

-
Removal
8-16
85
D16B6 engine:
)5"5! F Except D1636 engine:
%)5"5! F
1. (
!-
- Drain the engine oil. 1. (
!-
- Drain the engine oil.
2. 4 #-
- Turn the crankshaft so that the No. 1 piston is at top 2. 4 #-
- Turn the crankshaft so that the No. 1 piston is at
dead center (see section 6).
;<- top dead center (see section 6).
;<-
3. 1&
!;<-
+- Remove the timing belt (see section 6). 3. 1&
!!!;
+- Remove the timing belt and the balancer belt (see
4. 1&!!-
*- Remove the oil pan and the oil screen. section 6).
<-
5
- Remove the mounting bolts and the oil pump assembly.
1&
!! !- Remove the timing belt tensioner and the balancer
*- 1&
!!
ill-RING belt tensioner.
!-
DflWEL PIN Replace. lOIL PUMP
Remove the CKP/TDC sensors, then remove the
- 1&>=4(A&
timing belt drive pulley (see section 6).

!& !!;<-
Remove the balancer belt driven pulley (see page
- 1&!!& !!;!
7-B-13).
$)+<-
Remove the balancer gear case and the balancer
$- 1&!
!
driven gear (see page 7-B-14).
&
;!$)*<-
Remove the oil pan and the oil screen.
'- 1&!!-
Remove the mounting bolts and the oil pump
5- 1&
!!
assembly.
!-
OIL PUMP
DDWEL PIN
GASKET
Replace.
OIL SCREEN
OIL SCREEN
'
Oil Pump
Inspection

8-17
87
1.
- Remove the screws from the pump housing, then
1&3
A 4.
*- Check the housing-to-outer rotor radial clearance.
#
!!-
separate the housing and cover.

&- If the housing-to-outer rotor radial clearance

!!
2.
- Check the inner-to-outer rotor radial clearance on the
# !! exceeds the service limit, replace the set of inner
/&!A!
pump rotor. If the inner-to-outer rotor clearance exceeds
- !/ and outer rotors and/or the pump housing.
=
-
the service limit, replace the inner and outer rotors.
&!A! - Housing-to-Outer Rotor Radial Clearance
.
!

Inner Rotor-to-Outer Rotor Radial Clearance

D1636 engine:
)5"5! F
D16B6 engine:
)5"5! F Standard (New):
/,(0F 0.10 - 0.18 mm
$@$$@8
Standard (New):
/,(0F 0.02 - 0.14 mm
$@$$@ (0.004 - 0.007 in)
/$@$$$@$$7 0
(0.001 - 0.006 in)
/$@$$$@$$5 0 Service Limit:
- & F 0.20 mm (0.008 in)
$@$/$@$$8 0
Service Limit:
- & F 0.20 mm (0.008 in)
$@$/$@$$8 0 Except D16B6 engine:
%)5"5! F
Except D16B6 engine:
%)5"5! F Standard (New):
/,(0F 0.10 - 0.19 mm
$@$$@9
Standard (New):
/,(0F 0.02 - 0.16 mm
$@$$@5 (0.004 - 0.007 in)
/$@$$$@$$7 0
(0.001 - 0.006 in)
/$@$$$@$$5 0 Service Limit:
- & F 0.21 mm (0.008 in)
$@/$@$$8 0
Service Limit:
- & F 0.20 mm (0.008 in)
$@$/$@$$8 0
INNER ROTOR OUTER RDTDFI

PUMP HOUSING
3.
+- Check the housing-to-rotor axial clearance on the pump
#
/!! 5.
- Inspect both rotors and the pump housing for

rotor. If the housing-to-rotor axial clearance exceeds the
-
/!!/ scoring or other damage. Replace parts if

-1!
service limit, replace the set of inner and outer rotors
&!A! necessary.
-
and/or the pump housing.
=
-
Housing-to-Rotor Axial Clearance
.
!

D16B6 engine:
)5"5! F
Standard (New):
/,(0F 0.03 - 0.08 mm
$@$$@$8
(0.001 - 0.003 in)
/$@$$$@$$ 0
Service Limit:
- & F 0.15 mm (0.006 in)
$@3/$@$$5 0
Except D16B6 engines:
%)5"5! F
Standard (New):
/,(0F 0.02 - 0.07 mm
$@$$@$7
(0.001 - 0.003 in)
/$@$$$@$$ 0
Service Limit:
- & F 0.12 mm (0.005 in)
$@/$@$$3 0
PUMP HOUSING OUTER ROTOR
'
Oil Pump

Installation
8-18
88
D1636 engine:
)5"5! F 7.
$- Apply liquid gasket to the oil pump and install it.
%!!F
#! !!-
1.
- Remove the old oil seal from the oil pump.
1&!!!! - NOTE:
84 9
2.
- Using the special tool, gently tap in the new oil seal until
?
!!A
!3!! ! ¢ Use liquid gasket, Part No. O8C70- K0234M,
?!F
#A-0'$0>0+*,A
the driver bottoms against the pump.
&
- 08C70- K0334M or O8C70-X0331S.
0'$0>0++*,0'$0R0++-
NOTE: The oil seal alone can be replaced without
84 94!!!!3 ¢ Check that the mating surfaces are clean and
#
!
removing the oil pump.
&
! - dry before applying liquid gasket.
!
!F
#-
HAN-OLE DRIVER ¢ Apply liquid gasket evenly, in a narrow bead
%!!F
#&!A3
077115 - flfllflflflfl centered on the mating surface.

-
¢ To prevent leakage of oil, apply liquid gasket
4&!#
!A!!F
#
to the inner threads of the bolt holes.
!!-
(!!&
&!!
!F
#-
A!!F
#&

the old residue.
! -
%!A3!+0
!!

3!-
¢ Apply grease to the lips of the crankshatt oil
%!
!#!
seal. Then, install the oil pump inner rotor
!-4A!!!
onto the crankshaft. Whenhe pump is in
#-2
' place, clean any excess grease off the
!A!/

DRIVER ATTACHMENT.
52 x 55 mm crankshaft, then check that the oil seal lips are
#A#!!!
uni-E - 0010400 not distorted.
-
3.
+- Reassemble the oil pump, applying thread lock to the
1!! A!
!# Apply IIqld gaskel
pump housing screws.

3- along the broken III'IE.
4.
*- Check that the oil pump turns freely.
#! !-
5.
- Apply a light coat of oil to the seal lip.
%!!
!!!-
6.
- Install the two dowel pins and new O-ring on the oil
!!33!38
!
pump.
-
PUMP HOUSING
'
Oil Pump

/
?0
8-19
89
fix 1.0 mm 10
0 Install the oil pan gasket and oil pan.
!!!
#!-
11 N-m [1.1 kgf-m. NOTE:
84 9
8.0 lbl-fl)
firmly- Iirqiiid gasmt
¢ Use a new oil pan gasket.
?3!
#-
DOWEL PIN tn: thetmlt thread-:2 ¢ Install oil pan no more than five minutes after
!!!&
liquid gasket applied.
!F
#!-
01L PAN
.L’} Apply liquid

“— DDWEL PIN
5? gasket to
“"‘* GASKET these points.
l'iup OED.
O—RING
Ruplace.
OIL SCREEN
E x 1.0 mm
E x 1.0 mm 11 N-m (1.1 kgt-m.
11 Num l1.1 kgf-m. 3.0 Ibf-ftl
3.0 Ibi—ftl OIL PAH
Apply liquid gasket GASKET
8.
'- Install the oil screen.
!!!-
to these points. FIE-place.
9.
5- Apply liquid gasket to the oil pump and right side cover
%!!F
#!
&
11. 4
!

/
- Tighten bolts and nuts finger tight at six points as
mating areas as shown below.

3!3-
shown below.
3!3-
CYLINDER
BLOCK
Apply liqunzl gasket
to these points.
TF—‘l .u‘
-r
. H01.
9 0
12. 4
!!! A
!;<A
- Tighten all bolts and nuts, starting from bolt (1),
clockwise direction.
!#3-
OIL PUMP
HlGHT SIDE
NOTE: Excessive tightening can cause distortion
84 9 /&

COVER of oil pan gasket and oil leakage.
!
#!!#
-
Apply liquid gasket Torque: 12 Nm (1.2 kgf/m, 8.7 lbf/ft)

BF,/@6! 2:8@7* 2 0
to those points.
'
Oil Pump

/
?0
8-20
8$
%)5"5! F +- Reassemble the oil pump, applying liquid thread
1!! A!
!F
1.
- Remove the old oil seals from the oil pump.
1&!!!! - lock to the pump housing screws.
!#
3-
2.
- Gently tap in the new oil seals until the special tool
.!3!! !!! *- Check that the oil pump turns freely.
#! !-
93.01:"
bottoms on the pump.
- - Install a dowel pin and the new O-ring on the pump.
!!3!38
-
NOTE: The oil seals alone can be replaced without
84 94!!!!3 - Apply liquid gasket to the oil pump and install it.
%!!F
#! !!-
removing the oil pump by using the special tools.
&
!
!!- NOTE:
84 9
¢ Use liquid gasket for European models, Part
?!F
# !A
HANDLE DRIVE“
No. 08070-K0234M, 08C70-K0334M or
-0'$0>0+*,A0'$0>0++*,
08C70-X0331S.
0'$0R0++-
5‘ ¢ Check that the mating surfaces are clean and
#
!
It.
!
!F
#-
¢ Apply liquid gasket evenly, in a narrow bead
%!!F
#&!A3
\ centered on the mating surface.
.

-
¢ To prevent leakage of oil, apply liquid gasket
4&!#
!A!!F
#
to the inner threads of the bolt holes.
!!-
(!!&
&!!
!F
#-
A!!F
#&

the old residue.
! -
%!A3!+0
!!

3!-
¢ Apply grease to the lips of the crankshaft oil
%!
!#!
DRIVER ATTACHMENT.
52 x 55 mm seal and the balancer shaft seal. Then, install
!!!-4A!!
07748 — 0010400 the oil pump inner rotor onto the crankshaft.
! #-
When the pump is in place, clean any excess
2 !A!/
grease off the crankshaft and the balancer

#!
shaft, then check that the oil seal lips are not
A#!!!
distorted.
-
HANDLE DRIVER -
urns - umoouu ., ' -- — r
ATTACHMENT, 42 x H mm
0774B — 0010300
Apply “Quid gasket

along the broken line.
'
Oil Pump

/
?0
8-21
8
9.
5- Before installing the balancer driven gear and the
)!!
!&

DIL PUMP
. . _
1.D
E'|1x N-rn mm
(1.1 kgl—m, balancer gear case, apply molybdenum disulfide to
!
A!! !
Apply liquid gasket tu
block r11a"inq-caurla-w= 8'0 lbf-fil
the thrust surfaces of the balancer gears as shown.
!
3-
‘ - ' .. Apply =q‘l gasket
\ {j m ihu Imll tincads. Apply malaria-d ennm BALANCER DRIVEN
disulfide.
...""l"‘\-».."’
GEAR
D-RING
Apply- engine ml.
Apply molybdenum
GASKET di en | tide.
Fireplace.
BALANCER DRIVE
6 x 1.0 mm
GEAR
11 N-m (1.1 kghm. 8.0 l'ri 0- Hold the rear balancer shaft with the special tool,
10. 6!!3!!A
then install the balancer driven gear.
!!!&
-
7.
$- Install the oil screen.
!!!-
8.
'- Hold the front balancer shaft with a screwdriver, then
6!!33&A REAR BALANCER SHAFT:
%"&,%.+F
install the timing balancer belt driven pulley.
!!
!!& !!- \ REAR BALANCER
SHAFT BALANCER SHAFT
FRONT BALANCER:
+,"&,%F .‘~—— —\ LOCK FIN
BALANCER BELT :17a — PTzomn
DRIVEN PULLE‘I’ MAINTENANCE HOLE
I. )/ _ MAINTENANCE
HOLE
, REAR EALANCEH
.- - SHAFT
\__
E x 1.25 mm
25 Mm ill) Ital-m. 22 lbf-Hl
MAINTENANCE .-»'- BALANCER SHAFT

’ LOCK PIN
“OLE WASHER arms - mmnn
3 l1.25 mm Replace.
2'5 N-m [2.5 Ital-n1. 12 mm SEALING BOLT
1E lhf-fll 29 N-I‘n l3.lJI kgfm. 22 lbffl]
'
Ofliflunp

/
?0
8-22
8
11. !!!
! -
- Install the balancer gear case on the oil pump. 13. %!!F
#A-0'$0>0++*,
+- Apply liquid gasket, Part No. 08070-K0334M or
NOTE: Align the groove on the pulley edge to the pointer
84 9%!

& !!
O8C70-X0331S, to the cylinder block mating
0'$0R0++A!!#
on the gear case while holding the rear balancer with the

3!!
!3 surface of the oil pan, then install the oil pan.
!A!!!-
special tool, then install the gear case.
!!A!!
- NOTE:
84 9
¢ Apply liquid gasket 4 mm wide.
%!!F
#*3-
¢ Apply liquid gasket doubly to the jointing point
%!!F
# !7

of the liquid gasket.
!F
#-
a 1: 1.25 mm
25 film [2.5 Ital-m,
13 Ihf-ftl
D-HING
Apply engine nil.
Replace
wucan DowEL PIN

GEAR CASE
POINTER GASKET Apply liquid gull“

Align the groove to Replace. along the bruit-n line.
pointer 14. 4
!= 3-
*- Tighten the bolts/nuts in two or three steps. In the
final step, tighten all bolts/nuts, in sequence to 12
!A
!!!= AF
Nm (1.2 kgf/m, 8.7 Ibf/ft).
;-#
=A'-$=<-
1'5 "31: {in :j_5 ,: :.,1 ,2- 13.2: a”: "fit
GROOVE
12. #!
!!

- Check the alignment of the pointers after installing the
gear case.

-
PDINTEH ON THE PULLEY
'H POINTER ON
' -' THE OIL PUMP
Intake Manifold
6
9_2
9
Replacement

Note: Use new O-rings and gaskets when reassembling.

9?38

#3!
-
D1636 engine:
)5"5! F
5 I: 1.0 mm
11 Nrm 11.1 kgf-m.
3.0 lbf—fl}
(II-RINGS
Fluplace.
3 J: 1.25 mm
23 Mm {2.3 kg'l-m.
1? lfl
THROTTLE BUD‘I"
See seciiun 11.
a x 125 mm Rep'ace'
22 N-m l2.2 kgf‘m.
1E Ibf-ft] 8 p: 1.25 mm
23 N-rn [2.3 kgi-m.
11 lbfvft)
GASKET
INTAKE MANIFOLD Replace.
Replace if cracked or if SPACER
mating surface are a x 1.25 mm
damaged. 24 N-m {2.1 kgf-m.
1? IbH-tl
Intake Manifold
6
9_3
9
/
?0
F1832, F1833, F2036 engines:

+8":+8":+$"5! F
6 I 1.0 mm
"N-ml'l.'l kgl-m, 6x111 mm
3.0 lbf-f‘ll 11 film (1.1 kgf-m,
EGH PORT 3.0 "3”.”
INTAKE AIR BYPASS PLATE
1MB! VALVE BODY GASKET
Ruplaca If cracked m if . Replace 3" 1-25 mm
mating Rur'frnjwi are; l '1. 2" ”11112.4 HQI-I‘n,
Lluulaguu. 17 IIJI-Hl
6 x 1.0 mm EXHAUST GAS

11 N-ml1.1kgf-m. RECIRCU LATION
8.0 lbf~ftl lEGHl VALUE
INTAKE MANIFOLD
CHAMBER PLATE
O~RING
Rec-lace GASKET
/ Replace.
INTAKE MANIFOLD
CHAMBER
Fluplacu if cracked or i.‘ INTAKE MANIFOLD
mating surface are Replace Ilcrackad nr i1
damaged. maling sutl'ace are
damaged.
O-RING _. - --
Fluplace. 'I , -_'I _ '. -. __ ‘ I};_.___.__——— O-FHNG
IDLE AIR ' -- 3 n —-/ Replace.
CONTROL
”#131 VALUE 3 x 1.25 mm
23 N-m |2.3 kgf-rn.
1T Ibl—fll
8 x 1.25 mm
24 film l2.4 kgf-m. . . .
1? "arm - 3;.._-_
GASKET 8 x 1.25 mm
Fl l ... 2-! l'1l-rn [2.4 kg'l-m.
E x 1.1:: mm W 3“ Rama“ 1711:v)
11 "m 11.1 kgf-m,
EH] Ibf-rt] THROTTLE EDDY INTAKE MANIFOLD
See section 11. a x 125 mm BRACKET
24 film [2-4 kaf'm' a )1: 1.25 mm
'1'! Ihffl] 2-1 N-m 12.41 kgf~m.
17 Ibf-H]
Intake Manifold
6
9-4
9
/
?0
NOTE:
84 9
?38

#3!
-
¢ Remove the wire harness clamp from the rear mount bracket before removing the intake manifold.
1&3! #&
#!-
H22A7 engine:
.7! F
6 1: 1.3 mm
11N-ml1.1 kgf-rn.
EGH PORT an lbf-fli a g 1.25 mm
PLATE 24 Wm 12.! kgf'rn,
I? Ibl—ltl
GASKET ecn VALVE

Replace.
E I 1.0 mm
11 N-m 11.1 kgflm. ———+"f_‘:‘.
an lbirl'tl {'1’
GASKET
Replace.
GASKET
O-RING Replace.
Replace.
INTAKE MhNIFDLD
IAC VALVE BRACKET
8 x 1.25 mm
24 N-m {2.4 kgf-m.
INTAKE MANIFOLD
Fleplace if cracked or if
mating surface are GASKET
damaged. Replace.
Exlflmm 3x125mm Bx1.25mm
11 film 11.1 kgf-m, 23 Nm [2.3 hgf-rn, THROTTLE BODY 24 film i2.4 ital-m.
3.0 Ibf‘fil 1? Ibf-fll See section 11. 11' lbf-Hl
%

Exhaust Manifold
93
9-5
Replacement

NOTE: Use new gaskets and self-locking nuts when reassembling.

84 9?3
#!!#
3!
-
D1636 engine:
)5"5! F
B I 1.25 mm
24 N-m 22.4 tum-m.
I? Ib'l-HI' CD‘IJ'EH
EXHAUST
MANIFOLD
{\- ;_. GASKET

{5
Q)". Fl an l ace .
SELF-LOCKING NUT
8 a 1.25 mm
31 Nvm [3.2 kg‘I-m.
HEATED OXYGEN W 23 lbfvft)
SENSOR (H0251 g Replace.
M N"! (-1.5 kgf-rn.
—'
33 mm:
10 I 1.25 mm EXHAUST MANIFOLD

:14 N-m 14.5 kgl-rn. BRACKET
33 IbH‘H
%

Exhaust Manifold
95
9-6
/
?0

84 9?3
#!!#
3!
-
F1832, F1833 engines:
+8":+8"! F
8 11: 1.25 mm
24 H-m {2.4 Raf-m.
1? lbf-ft] COVER
EXHAUST
MANIFDLD
GASKET
Re place.
SELF-LOCKING NUT
a x 1.25 mm
31 N-m [3.2 kgf-m.
23 lb‘I-ffl
Replace.
i
\ EXHAUST MANIFCILD
"" BRACKEr
1|] 1-: 1.25 mm

44 N-m “.5 Raf-m.
33 lhf-ftl
Exhaust
% Manifold

9_7
97
/
?0
F2036 engine:
+$"5! F
3 x 1.25 mm
24 N-rn [2.4 Raf-m, GASKET
1'! lhf-lfl Replace.
COVER EXHAUST
\ MANIFOLD
I'd— _
Ii 1: LI] mm
11 N-I‘n 11.1 kgf-m.
3.0 Ibi-‘M
COVER
SELF-LOCKING NUT
3 x 1.25 mm
'3 “I”; 31 N-m [3.2 kgI-m,
3-) 23 Ibf-ftl CG‘U‘EH
f1
PRIMARY HEATED w: 3 "' Replace
OXYGEN SENSOR ,4 .
(PRIMARY HozsI “—3
u Mm [4.5 kgI-rn.
33 Hum)
10:: 1.25 mm EXHAUST MANIFOLD
u N-rn [4.5 kgf-rn. BRACKET
33 IhI~HI
%

Exhaust Manifold
98
9-8
/
?0

84 9?3
#!!#
3!
-
H22A7 engine:
.7! F
EX HAUST GASKET
MANJFCILD Replace.
SELF-LOCKING NUT
B x 1.25 mm
31 film 13.2 kgf-m.
23 IbH-tl
Replace.
EXHAUST MANIFOLD
BRACKET
"J I 1.25 mm
44 N-m 14.5 kgfam.
33 lfl
% '
Replacement

9-9
99

84 9?3
#!!#
3!
-
D1636 engine:
)5"5! F
HEAT SHIELD MUFFLER
If] _]
6: 1.0 mm
11 N'm(1.1kg{'m. - GASKET
3.0 Ihf-ft] if Replace SELF-LOCKING NUT
1D x 1.25 mm
51 Nrrn [5.5 kgfrrn.
4D l‘t]
Replace.
SELF—LOCKING NUT “-- EXH A U 5T

E-E
1D x 1.25 mm "" If". fir; . PIPE B

33 N-m [3.4 kgi—m. 25 Ibf-ftl r -.
-
Raplace.
SELF-LOCKING NUT
8 x 1.25 mm
18 N-m (1.8 kgf-m,
13 [bf-ft]
Replace.
__ - GASKET
"—— Heplacu.
_"‘*- THREE wmr CATALYTIC

233:? CONVERTER (Twm
EXHAUST
PIPE A
GASKET
”.1: pl :1 L'|'..
SELFALDCKING NUT
10 a: 1.25 mm
54 Nrrn [5.5 kgfvm.
4n Ibf-ft]
Re plane.
SELF—LOCKING NUT TWC TIG HTE MING

1D x 1.25 mm SEQUENCE
33 film [3.4 kgf-rn. 25 Imam 1D x 1.25 mm
HEpIaCu. 33 N-m [3.5 kgI-m,
28 Half-fl]
% '
9$
9-10
/
?0

84 9?3
#!!#
3!
-
F1832, F1833 engines:
+8":+8"! F
HEAT SHIELD MUFFLER
H025
[F1832 engine MIT}
PRIMARY H025
(F1832 engine Ai'Tl
,.|____ GASKET
MN-ml4.5kgi-m,33lbf-ft1 in ". I ' ' Lie-x Huplacu.
SELF‘LOCKING NUT
10 x 1.25 mm
6 11.0 mm 54 N-m 15.5 kgf‘l'l'l.
11N-ml1.1 kgfum. 40 ll
HAHN-hi Replace.
SELF-LOCKING NUT
10 I 1.25 mm
33 “km 13.4 Raf-111,25 Ibfvh]
Replace.
SELF-LOCKING NUT
a 1: 1.25 mm
lam-n1 {1.8 kgf-m,
13 “film " .' .
' _\_
— _' H
_ IRISECONDAR‘I'
. HEATED
Replace. OXYGEN SENSOR
8 11: 1.25 mm lSECONDARY H0253
1F18B2 engine MT]
22 N-m 12.2 kgf-m.
44 N-m 14.5 Ital-m.
16 Ibl-ftl
33 lbl—hl
GASKET
Replace.
GASKETS Ar
Fleplace.
TWC
|F1882 angina]
EXHAUST
GASKET
PIPE A
Replace.
SELF-LOCKING NUT
II] x 1.25 mm
54 N-m 15.5 mm. GASKET
m IBM-n 10 x 1.25 mm FIE-place.
”Ema“- as N-m 13.9 kglvrn,
28 Itl
TWCIEXHEUST EHAM BER
SELF'LOCK‘NG NUT TIE HTENING SEDUE NICE EXHAUST
1') x 1.25 mm CHAMBER
33 N-rn [3.4 kgfrrn. 25 IbH't] GASKET lF'IBBS an girIvBl
Replace. Replace.
% '
9
9-11
/
?0
F2036 engine:
+$"5! F
HEAT SHIELD MUFFLER
GASKET
Replace.
SELF-LOCKING NUT
II} x 1.25 mm
5:1 Nlm 15.5 kgf-m.
40 lll
Replace.
E x 1.0 mm
11 film [1.1 kgl-m.
3'0 lbf-fl]
\
{I ‘- -
SELF-LOCKING NUT
1|] 3: 1.25 mm
33 Nam {31 kgf-m, 25 Ibf-fl)
Replace.
:iL‘f-zl-EfiflNG NUT SECONDARY HEATED

18 film (1.3 kgl—m, OXYGEN SENSOR
13 IbH‘tl (SECIZDIMIDfluFl‘!I HOZSl
_ 44 film [4.5 kgf-m,
Replace.
' - 33 Ibf-ft]
8 I 1.25 mm
22 N-m12.2 kgl-m,
IE Ibl-hl
. I'II‘"—_-—— GASKET
Replace.
k <5 D x'.” _ _ .7. .. ‘\

GASKET TWC
. _ rm - _. V - -. .
Replace.
E x HAUST a, /
PIPE A
SELF-LDCKING NUT xfl» ./ .
10 it 1.25 mm \ ..u—:\—____.-""'-'
54 Nrm [5.5 kgf-rn, 'g
no Ibf'ftl
Replace. 10:11.25mn1
23 mm] Rumm-
GASKET
SELF-LOCKING NUT
10 K 1.25 mm
33 N-m [3.4 kgf-m. 25 ”Elf-ft] TWC TIGHTENING
Replace. $EDUENCE
% '
9
9-12
/
?0

84 9?3
#!!#
3!
-
H22A7 engine:
.7! F
MUFFLE HS
GASKETS
Replace. \ ._ "Hz-1....
HEAT SHIELD
'! SELF-LOCKING NUTS
‘10 x 1.25 mm
54 N-m |5.5 ligf-m.
40 mm
Replace.
6 x 1.0 mm _,.--—-"
11 N-m (1.1 kgi-m,‘£:"\,ll ..
8.0 lhf-ftl "I ___
SELF-LOCKING NUT 1
10 x 1.25 mm W
33 Nm 13.4 kgf-m. 25 lbf-fll “‘
Replace.
33:11:23; ' -. __ -- " -. " SECONDARY was

33 [bf-ft] ‘ " " « Mm {4.5 kgr-m,
33 Ibf—ffl
SELF-LOCKING NUT
B at 1.25 mm
13 N-rn [1.3 kgf-rn.
13 mm:
Replace.
GASKETS
Replac e.
EXHAUST—"’4' ;
PIPE A
GASKET
Replace.
SELF-LGCKING NUT
" SELF-LOCKING NUT
W 1: 1.25 mm
III I 1.25 mm
54 Nm [5.5 kgfm. B x 1.25 mm
33 N-m 13.4 kgf‘m.
40 Ihffll 22 N-m [2.2 kgfam,
25 lM—H}
Raplace. 16 "3141)
Replace.
TWE TIGHTENIMG
3 I 1-25 "1'“ SEQUENCE
38 N'm (3.9 kgI-m.
28 IbH‘H
Radiator

10_2
$

Illustrated Index
Total Cooling System Capacity [Including heater and reservoir]

4!!
T!
&U
D1636 engine:
)5"5! F 4.6 I (4.9 US qt, 4.0 Imp qt)
@5/@9;B:@$B0
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
M/T:
2F 5.8 I (6.1 US qt, 5.1 Imp qt)
3@8/5@;B:3@B0
NT:
2F 5.7 I (6.0 US qt, 5.0 Imp qt)
3@7/5@$;B:3@$B0
H22A7 engine:
.7! F 6.9 [(7.3 US qt, 6.1 Imp qt)
5@9/7@;B:5@B0
Reservoir capacity:
-
#F 0.55 I (0.58 US qt, 0.48 Imp qt)
$@33/$@38;B:$@8B0
NOTE:
84 9
9 Check all cooling system hoses for damage, leaks or deterioration and replace if necessary.
#!!!

A!#!-
O Check all hose clamps and retighten if necessary.
#!!!
-
9 Use new O-rings when reassembling.
?38
3!
-
RADIATDH
Engine ceelant
Ftal'illing and bleeding. page 10-7
Laak last. page 10-10
Inspect soldered joints and
seams far lea ks.
Blow Out dirt {rum between
RADIATOR CAP
cora Fina wilh compressed air.
Pressure testing. page 1040
If insects, ate, are clngging
CONDENSER UPPER radiator. wash them oflwith
FAN SHRUUD RADIATOR low pressure water.
HOSE {N
61: 1.0 mm
9.8 N‘m I111 kgf'm, 5.4 Nvm [0.55 kgl—m. _
12 Ibf-ftl 4.0 Ibf-ft} "A‘. '-
CDOLANT
RESERVOIR
'- LOWER
CUSHION
a x 1.9 mm O-RIMG
? N-m [0.7 kgf'm. ~ Replace.
E lb‘I-i‘tl
ATF COOLER
RADIATOR ”055
FAN
when m“...
Rafar ta section H
hgggmmmfi
2.5 Mm. [112? kgf-m.
FAN MOTOR RADIATOR FAN
SHHOUD 2a Ibf HI

4

&A
!#!!3
9
(See Page 10-7)
;'!0$<
(See Page 10-10)
;'!00<
Radiator

10_3
$
/
?0
Engine Hose Connection:

%! .

F
D1636 engine:
)5"5! F
WATER BYPASS
HOSE
CONNECTING
PIPE
0-HING
Replace.
HEATER
THERMDSTAT HOSE
HOUSING
Replace.
HEATER HEATER
HIDSES VALVE
Radiator

10-4
$
/
?0
F1832, F1833, F2036 engines:

+8":+8":+$"5! F
WATER B'l" PASS
HG SE
lDLE AIR CONTROL

[IAC] VALVE
(II-RING
Replace.
8 x 1.25 mm
24 N-m (2.4 kgt-m.
I? Ibl-ftl
CON NECTING
PIPE
HEATER E x 1.25 mm HEATER THERMOSTAT

HDSES 24 N-m 12.4 kgf-m, VALVE HOUSING
‘l'l' lbl—fll
Radiator

10_5
/
?0
$3
H22A7 engine:
.7! F
u-HING WATER BYPASS
IAC VALVE REPIHEE- HGSE
CONNECTING
O-HING
Fleplace.
HEATER
HOSE
U—HING
Replace. I 8 x 1.25 mm
. I 2‘ N-n'l [2.4 kgf-m.
ENGINE OIL COOLER fly'l 17 Ibf-fl]
BYPASS HOSE
ENGINE OIL
COOLER THERMOSTAT
HOUSING
I
B x 1.25 mm HEATER
24 en [2.4 llgf-rn. VALUE
'1? Ibf-ffl
Radiator

$5
10-6
Replacement

1.
- Drain the engine coolant.
(
!- 5.
- Remove the fan shroud assemblies and other
1& !
- Remove the upper and lower radiator hoses, and ATF
1& !3A%4 parts from the radiator.
-
cooler hoses.
!- 6.
- Install the radiator in the reverse order of removal.
!!&&!-
3.
+- Disconnect the fan motor connectors.
(- Make sure the upper and lower cushions are set
,# !3
4.
*- Remove the radiator upper brackets, then pull up the
1& #A !! securely.
!-
radiator.
- 7.
$- Fill the radiator with engine coolant and bleed the
!!3
!!
air.
-
6 x 1,0 It‘ll‘r'l
9.3 N-m 11.0 kgI-I‘n.
RADIATOR 7'2 Ibl-fii
UPPER RADIATOR CAP
HOSE
UPPER BRACKET
q? .41.. AND CUSHION
CDNDENS ER FAN . |_ _. .. . _
SHROUD Ass EMBLV CODLANT
/ RESERVOIR
_ J _ ‘J. —
i
5 i 1.0 mm
9.8 ”rm :1 .0 kgf-m.
12 lbI-f‘ll
"if" . T741. .1 ; 1...._______ LOWER

"‘ I .'>..__: I . CUSHION
if I '
6 u 1.0 mm '1 "-—-' GRING
‘.' H-m (0.? kgf-m, Ru place.
5 Ibf-ft]
“JR LOWER RADIATOR

HOSE
5.4 MM £0.55 Ital-m,
4.0 IbfAft)
RADIATOR
. .__ FAN
ll. .- -.‘ :
FAN MOTOR 2.6 N-m 10.27 kgf-m. ' "
2.0 Ibf-H)
RADIATOR
FAN SHROUD
FAN MGTOR
CDNNECTDRS

Radiator
Engine Coolant Refilling and Bleeding
%!
!" !

10-7
$7
%.7! F 5.
- Apply liquid gasket to the drain bolt threads, then
%!!F
#!A
1.
- Start the engine. Set the heater temperature control dial

- !! reinstall the bolt with a new washer and tighten it
!!!333

to maximum heat, then turn off the engine. Make sure
/ A
-,# securely.
!-
the engine and radiator are cool to the touch.

! - - Tighten the radiator drain plug securely.
4
!
!-
N97
2.
- Remove the radiator cap.
1&- $- Remove, drain and reinstall the reservoir. Fill
1&A!!&- the
!!
3.
+- Loosen the drain plug, and drain the coolant.
!
A!- tank halfway to the MAX mark with water, then up
#!3,%R#33A
DRAIN PLUG to MAX mark with antifreeze.
,%R#3H-
MAX MARK
8.
'- Mix the recommended antifreeze with an equal
,/H3F !
4.
*- Remove the drain bolt from the rear side of the cylinder
1&!!
amount of water in a clean container.
3!-
!#-
block.
NOTE:
84 9
I -_— fl_- ¢ Use only genuine Honda antifreeze/coolant.
?!
6H=!-
¢ For best corrosion protection, the coolant
A!
concentration must be maintained year-round

at 50% minimum. Coolant concentrations less
0W -!!
than 50% may not provide sufficient protection
0W&
against corrosion or freezing.

H
-
¢ Coolant concentrations greater than 60% will
!
0W3!!
impair cooling efficiency and are not
!

recommended.
-
¢ Do not use additional rust inhibitors or
( !
anti-rust products; they may not be compatible
N!
with the coolant.
3!-
Engine Coolant Refill Capacity (including reservoir
%!
#/ !-

WASHER DRAIN BOLT 0.55 [(0.50 US qt, 0.48 Imp qt)):
$@33/$@3$;B:$@8B00F
Hernia-:9. 33 N-m IS 5 kgf-nn. B1 lint-ft] D16B6 engine:
)5"5! F 3.9 [(4.1 US qt, 3.4 Imp qt)
@9/@;B:@B0
F1832, F18B3, F2036 engine:
+8":+8":+$"5! F
MIT: 4.2 /@;B:@7B0
2F@ [(4.4 US qt, 3.7 Imp qt)
NT: 4.1 /@;B:@5B0
2F@ [(4.3 US qt, 3.6 Imp qt)

Radiator
Engine Coolant Refilling and Bleeding (cont’d)
%!
!" !/

?0
10-8
$8
9.
5- Pour coolant into the radiator up to the base of the filler
! !! H22A7 engine:
.7! F
neck.
#- 1.
- Start the engine. Set the heater temperature

-
control dial to maximum heat, then turn off the
!!/ A
engine. Make sure the engine and radiator are cool

-,#
!
to the touch.
-
2.
- Remove the radiator cap.
1&-
3.
+- Loosen the drain plug, and drain the coolant.
!
A!-
DRAIN PLUG
10.
! !3 ;
0- Start the engine and let it run until it warms up (the
radiator fan comes on at least twice).
!3<-
11. 4
-#!&!A
- Turn off the engine. Check the level in the radiator, add
coolant if needed.
!-
12.
!A

- Put the radiator cap on tightly, then run the engine again
and check for leaks.
#!#-
4.
*- Remove the drain bolt from the rear side of the
1&!
cylinder block.
!!#-
WASH EH
Ra place.
DRAIN BOLT
813 Mm 13.5 kgfm.
B1 IbH‘ll
Radiator

Engine Coolant Refilling and Bleeding (cont’d)
%!
!" !/

?0
10-9
$9
- After the coolant has drained, apply liquid gasket to the
%!A!!F
# 9.
5- Loosen the air bleed bolt in the thermostat
!!
drain bolt threads, then reinstall the bolt with a new
!A!!!33 housing, then pour coolant into the radiator to the

A !
washer and tighten it securely.
3
!- bottom of the filler neck. Do not let coolant spill on
!!#-(!!!!
- Tighten the radiator drain plug securely.
4
!
!- any electrical parts or the paint. If any coolant
!!-!
$- Remove, drain and reinstall the reservoir. Fill
1&A!!&- the tank
!!# spills, rinse it off immediately.
!!A!-
halfway to the MAX mark with water, then up to the MAX
!3,%R#33A ,%R BLEED BOLT
mark with antifreeze.
#3H- 5.3 Nrm 11.0 kgi-m, 1 lbf-ftl
'- Mix the recommended antifreeze with an equal amount
,/H3F !
of water in a clean container.
3!-
NOTE:
84 9
0 Always use Genuine Honda Antifreeze/Coolant.
%!3 . 6%H=!-
Using a non-Honda coolant can result in corrosion,
?
6! !A
causing the cooling system to malfunction or fail.

!
! !-
0 For best corrosion protection, the coolant
A!
concentration must be maintained year-round at

50% minimum. Coolant concentrations less than
0W -!!
50% may not provide sufficient protection against
0W&

corrosion or freezing. Coolant concentrations
H
-!
greater than 60% will impair cooling efficiency and

0W3!!!

are not recommended.
-
0 Do not use additional rust inhibitors or anti-rust
( !
products; they may not be compatible with the
N!3
coolant.
!-
Engine Coolant Refill Capacity [including reservoir
%!
#Q !-

10. 4
!!!
0- Tighten the bleed bolt as soon as coolant starts to
(0.55 [(0.58 US qt, 0.48 Imp qt))]:
/$@33/$@38;B:$@8B00RF run out in a steady stream.
-
3.3 [(3.5 US qt, 2.9 Imp qt)
@/@3;B:@9B0 - With the radiator cap off, start the engine and let it
11. 2A
!
run until warmed up (radiator fan comes on at least
!3 ;!
twice). Then, if necessary, add more coolant mix to
3<-4AA!/
bring the level back up to the bottom of the filler

!&!# !!
neck.
#-
12.
!A

- Put the radiator cap on tightly, then run the engine
again and check for leaks.

#!#-
Radiator

1 0_1 0 Testing
!
Cap Testing
!
$$
1.
- Remove the radiator cap, wet it‘s seal with engine
1&A3@!3
1.
- Wait until the engine is cool, then carefully remove
2 !
!A !!&
coolant, then install it on the pressure tester.
!A!! - the radiator cap and fill the radiator with engine
!!3

RADIATOR PRESSURE TESTER coolant to the top of the filter neck.
!!#-
{Commercially availablel 2.
- Attach the pressure tester to the radiator and apply
% !
RADIATOR
a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2,
5++#;0-5-#
=A
14 - 18 psi).
*'<-
RADIATDH PRESSURE
TESTER
SMALL ADAPTOR (Commercially availa hla]
iIliumrI'Imvenuaiiallwl.I available)
H-EOT‘lZl-IJB
SMALL ADAPTOR
[Commercially available?
H-901122-09
2.
- Apply a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2,
%! 5++#;0-5-#
=A
14 - 18 psi).
*'<-
3.
+- Check for a drop in pressure.
# -
4.
*- If the pressure drops, replace the cap.
A!-
3.
+- Inspect for engine coolant leaks and a drop in

!!#
pressure.
-
4.
*- Remove the tester and reinstall the radiator cap.
1&!!-
NOTE: Check for engine oil in the coolant and/or
84 9#
!!=
coolant in the engine oil.
!
!-
Thermos
tat

10_11
Replacement

$
NOTE: Use new O-ring when reassembling.
84 9?38
3!
-
D1636 engine:
)5"5! F
THEHMDSTAT
Install will: um “I:
RUBBER SEAL
Replace.
THEHMDSTAT
COVER
THE HMUSTAT
HDUSING
RADIATOR FAN
SWITCH
24 Mm {2.4 kgl-m. 1? Ibi-hlv RepIace. 6x11) mm
11 NM 11.1 hat-m. 5.0 lhf-I'fl
Thermostat

10_1 2
$
/
?0
NOTE: Use new O-ring when reassembling.

84 9?38
3!
-
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
‘5” d )
__
:1 PIN
g
*
r f
R U BBE Fl SEAL
RC pl Ll Lie
\;._--r-
6 x 1.0 mm
11 N-m[1.1|:gf-m,
8.0 lbl—fll
TH EH M USTAT
HOUSING
THERMOSTAT
Install with pin up.
THERMOSTAT COVER
H22A7 engine:
.7! F
Ell-RINGS
Replace.
BLEED BOLT
9.3 Nlm [Ll] kg‘l—m, 12 Ibf-f'tl
THERMOSTAT
THERMOSTAT HOUSING
COVER
RUBBER SEAL
Replace.
E at 1.0 mm THEHMDSTAT B x 1.25 mm
11 N-m l1.'l kgl-m. Infitall with pm up. 24 Mm [241 kgf-rn‘
ED lblrttl 1? lbf-ftl
Thermostat

Testing
!
10-13
$
Replace the thermostat if it is open at room temperature.
1! -
To test a closed thermostat:
4!9
1.
- Suspend the thermostat in a container of water as
3
shown.
3-
q——-——- — THERMGMETEH
TH ERMDSTAT
2.
- Heat the water, and check the temperature with a
63A# 3
thermometer. Check the temperature at which the
-# 3
thermostat first opens, and at which it is fully open.
A3 !!-
3.
+- Measure lift height of the thermostat when fully open.
, !
3 !!-
STANDARD THERMOSTAT
,)).%
Lift height:
& ! F
%.7! F
above 8.0 mm (0.31 in)
*
-8@$/$@ 0
H22A7 engine:
.7! F above 10.0 mm (0.39 in)
*
-$@$/$@9 0
Starts opening:

!F 76 - 80°C (169 -176°F)
758$P/5975H+0
Fully open:
+#
F 90°C (194°F)
9$H/9H+0
_
Water Pump
1'
Illustrated Index

$
1 0 1 4
NOTE: Use new O-rings when reassembling.

84 9?38
3!
-
D1636 engine:
)5"5! F
CGGLANT TEMPERATURE GAUGE
SENDING UNIT
9 N-m [0.9 ltgl-m,
'1‘ lbf-ft]
Apply liquid gasket )— 5 111.0 mm
to the threads. l/L\ 3b 11 III-m 11.1 high“,
. 8.0 lbf-f‘t]
. I
ENGINE C00 LANT

TEMPERATURE [ECTI 0.3"“;
ENSOH
153 Mm 11.3 kgf-m. Replace' WATER OUTLET
13 Ibf-fll COVER
Apply liquid gasket
ID mating surface.
O-RING
Replace.
041l RADIATOR FAN SWITCH
Replace. 24 ”m [2.4 kglvm,
17 lbl-I't]
WATER PUMP
Replacement, page 10—17
III-RING Ii 1: 1.0 mm
:1“!t- J1‘
‘15 .-
Replace
' . 11 N-m [1.1 II: 91-I1'IIr
.- - 8.0 Ibf-HI
'I CONNECTING
PIPE
(III-RING
Replace.
li :11 1.0 mm
11N-ml1.1k91-m.
3.0 IhrHtl 10 i: 1.25 mm
10 x 1.25 mm 4-4 N-m [1.5 kgi-m.
414 Mm [1.5 kyf-m. 3311:1111
33 lbf-ftl
4

&A
!#!!3
9
(See Page 10-17)
;'!0$<
Water Pump
1' 10_15
/
?0
$3
F1832, F1833, F2036 engines:

+8":+8":+$"5! F
RADIATOR FAN
SWITCH B
211 Mm 12.4 kgf—m.
-
‘1 ““"l ' :
F1833 “"9"“
Except HEB-3 engine:
OHHING _—_ I'D-RING D-HING
Replace/ “F _ D-HING Heplacn. ‘ - _ Replace.
Replace.
WATER OUTLET
COVER
WATER OUTLET
COVER
If. B x 1.25 mm
,- 2.1 N-rn [2.1 Raf-m,
/ 1': 111m:
____./’ :3.l
B x 1.25 mm
ENGINE COOLANT - -— He place.
24 N-m t2.4 kgt-m.
TEMPERArunE {Em} comm TEMPERATURE GAUGE
1? lbI-ttl
SENSOR SENDING UNIT
ENGINE mamm
TEMPERATURE IECT:
COOLANT TEMPERATURE GAUGE ‘3 NT“ ”-3 "Bl'm- "‘m “1-9 “9““
97 Ibf-ft]
SENS“
13 N-m {13 Ital-m SENDING UNIT
1a Ibf-ftl
13 mm: ' 9 "'m “’3 “Bf-m1 RADIATOR FAN
7 1111-111 sTcH A
24 N-m I24 kgf—m,
3 x 1.25 mm
24 I’d-m [2.1. kgl—m,
n lbf-fil
17 Ital-ft]
D-RING
[1/ Replace.
g SPRING
fl‘ PIN
WATER PUMP
Inspection,
page 10-1?
Replacement.
page 10-1 7'
THERMOSTAT
HOUSING
{II-RINGS
3' 1:". .'. Replace.
8 :1 1.25 mm
2-1 l'1l-rn [2.1 kgf-m,
1? Ihf-ftJ
U-HINGS CONNECTING
Replace. PIPE
11 N-m l1.1 Ital-m. 3.0 Ihf-ftl

4

&A
!#!!3
9
(See Page 10-17)
;'!0$<
Water Pump
1' 10_1 6
$5
/
?0
NOTE: Use new O-rings when reassembling.

84 9?38
3!
-
H22A7 engine:
.7! F
WATER 0U TLET
COVER
ENGINE CGULANT
TEMPERATURE [ECTl
SENSOR
13 film {1.3 kgf-m.
13 lbf-ft]
8 x 1.25 mm
24. Nvm (2.4 Ital-m. 1? Ibf-fi]
D-HING
Replace.
CODLANT - -
TEMPERATURE \____
G AU GE -.
SENDING UNIT
9 N11! [0.9 kgi-m, "“— ___"
7 Inf-m
BLEED BOLT
9.8 N-m 11.0 kn,
12 lbl-ftl
8 I 1.25 mm THERMOSTAT
24 N-m 12.4 kgf-m. HOUSING
1]" llJl-hl
O-RING
Ill—RING
Replace.
WATER PUMP Replace.
Inspection. \R‘
(p
pagelU-fi - ‘-
Replacement.
Dege 10-1?
RADIATOR FAN
SWITCH
24 Mm [2.4 kgi-m.
17 Ibfvl‘tl
O-RING
Replace.
8 x 1.25 mm
24 N-rn (2.4 kgfim.
17 lbf-Hl
C0 NNEC'HNG PIPE
6 J: 1.0 mm O-RINGS
11 Nm [1.1 kgf-m. 3.0Ibl-f1l Replace.
4

&A
!#!!3
9
(See Page 10-17)
;'!0$<
1'
Water Pump
Inspection

10-17
$7 Replacement

- Remove the timing belt (see section 6).

1&
!;<- 1.
- Remove the timing belt (see section 6).
1&
!;<-
NA
- Check that the water pump pulley turns

#3 !! - Remove the water pump by removing five bolts.
1&3 &
&!-
counterclockwise.
!#3- NOTE: Inspect, repair and clean the O-ring groove
84 9A!8

&
+- Check for signs of seal leakage.
#
!!#
- and mating surface with the cylinder block.

3!!#-
NOTE: Asmall amount of “weeping” from the bleed hole
84 9%!! K3
L!! D1636 engine:
)5"5! F
is normal.
!- WATER
D16B6 engine:
)5"5! F PUMP
D-BING
Replace.
11 um um kgi-m, 4;
EH] Ibf-ft] 6’
1D x 1.25 mm
1|] x 1.25 mm 14 Mai [4.5 kgi-m.
M N-rn {cl-.5 kgf-I‘n. 33 lint-Hi
33 Ibf-fll
Except D16B6 engine:
%)5"5! F
%)5"5! F
Replace.
WATER PUMP
E I 1.0 mm
11 N-m 11.1 kgf-m, 3.0 Ibf-f'tl
ELEED HUI LES 3.

+- Install the water pump in the reverse order of
!!3 &
removal.
&!-
NOTE:
84 9
¢ Keep the O-ring in position when installing.
>8
3!!
-
¢ Clean the spilled engine coolant.
!!!
!-
Fan Controls
+

10_1 8
$8

&

UNDEHvHDDD
FUS-EIFIELAY
BOX
GONDENSER FAN RELAY
Test, section 23
RADIATOR FAN RELAY

Test, section 23
RADIATOR FAN
DONTROL MODULE
Inpul Test, page 10-21
RADIATOR FAN RADIATOR FAN
SWITCH 3 SWITCH A
Test. page 10-22 Testr page 10-22
RADIATOR
FAN MOTOR
Test‘ page 10-22

4

&A
!#!!3
9
(See Page 10-21)
;'!0<
(See Page 10-22)
;'!0<
Fan Controls
+

10_1 9
$9
) !
Circuit Diagram
Except F1833 engine:

%+8"! F
DFWEFI'S
UNDER-FWD FUSE'RELAY BOX IGNITION UNDER-DASH
SWITCH FUSEIFIELAY EDI
BATI'EH‘I"
No.“ (100A) NM? [my am ”0-3 I15”
6) N N ma 0 YEL m
No.5? Ian] No.53 [2w
ELU-OFIN f BLUNJFIN
RADIATOR 0 CI CONDENSER
FAN —————————————— .1 FAN
new 0 ; d FIELJW swam :
AIR CONDITIONING
SYSTEM
BLU-‘B'JC GEN ELLl-‘r'EL
SRN GFIN
. ECM'PCM l
-_—_‘
FIAEIifiTCFI p 39““ , CONDENSEEI .'

FAN vac-Ton n SMTCH . FANIAOTOR
[ Exmpi H2257 9 m3 . '
1 Closed :At-m 9 ‘C [199%
v. man an ins:
[cased : A ss‘cljeua'r'l
(32m G101 . 520! :

GSUI 530‘ I
_ I_Wlm NED
+

Fan Controls
) !
Circuit Diagram
10-20
$$
F1833 engine:
+8"! F
JNDER-HDCC- FUSEJFIELAY 801
"SNITICIN
SWITCH
w
EAT—ERY
N: 41 LIMA: No.42 [sum
@— WHT
No.57- [ac-A] No 56 IEUAI

—C‘"\_A m
-
DRIVER'S
UNDER-DASH
FUSE-fl EUUI"
RADIATOR D CGNDENSE FI. EDI
misfw
FANI FAN
RELAY RELA'r
EILI'UYEL
ELUJBLK BLUNEL GRN VEL‘BLK YEL WHT SLKORN BLKIYEL BLKNEL
3 1 6' 2 T
u ‘—
RADIATOR FM CONTROL MODULE
r1
5 d
WHTIGRN
V
(ED
RADIATOR AIR
(IE)
RADIATOR
RADIATOR CONDENSER FAN SWITCH A FAN SWITCH B CONDITIONING
FAN MCI-TOR FAN MOTOR ['Clow: have ' [‘ Close: : Above ' SYSTEM
3; "5 I192?) _1-:6°C -:223°F]
ELK
G201 5202
Fan Controls
+

_
$
Module Input Test (F18B3 engine)

/+8"! 0 10 21
Perform the following tests with the radiator fan control module 8P connector connected, the ignition switch ON (II) and the A/C
!!3
3! !'A
38;<%=
switch OFF.-
38
If you find the cause of a problem, correct it before you continue.
!A -
BLKI'DFIN YEL/BLK
"I'EL BLK
Terminal side {5‘

male lurn'mifllF-
/" _"'\
SUV
- “a.
O| Wire colour O|
1

Test condition

O| )
Desired result O Possible cause if desired result is not
'
*
O|
O| O| O| O obtained

* O|
O| BLK
)> O| Check for voltage to body O|
#&!
There should be less
4 !! O 0 Poor ground (G202)

;.0< O|
O| O| ground.

- O| than one volt.
&!- O 0 An open in the wire
%3 O|
O| WHT
264 O| Check for battery voltage O|
#&!
There should be battery O
4 ! 0 Blown No. 58 (20A fuse in the
)!3-';0% O|
O| O| to body ground.

- O| voltage.
&!
- O under-hood fuse/relay box.
=!/- O|
O| O| O| O 0 An open in the wire
%3 O|
O| BLK/YEL O|
)>=C Check battery voltage to O|
#&!
4 ! 0 Blown No. 6 (15A) fuse in the
)!3-;%< O|
O| O| body ground: Ignition

9
O| voltage.
&!
- O under-dash driver’s fuse/relay box.
&B =!/- O|
O| O| switch-ON (II).
38;<- O| O 0 An open in the wire
%3 O|
O| BLK/ORN O|
)>=81 Check battery voltage to O|
#&!
4 ! 0 Blown No. 3 (7.5A) fuse in the
)!3-+;$-%< O|
Oi O| body ground: Ignition

9
O| voltage.
&!
- O under-dash driver’s fuse/relay box.
&B =!/- O|
O O| switch-ON (II).
38;<- O| O 0 An open in the wire
%3 O|
I
O| YEL/BLK O|
C =)> Check battery voltage to
#&!
O There should be battery O
4 ! 0 Faulty
radiator fan control module
!! ! O|

9
O voltage.
&!
- O %3
0 An open in the wire O|
38;<- O| O O|
O| YEL
C O| Check battery voltage to
#&!
O| There should be battery O
4 ! 0 Faulty
!! ! O|

9
O| voltage.
&!
- O 0 An open in the wire
%3 O|
38;<- O| O O|
O| GRN
.1 O| Connect to body ground: O|

9 1
Radiator fan and O 0 Blown No. 58 (20A) fuse or No. 57 (20A) O|
)!3-';0%< -$;0%<
O| O| Ignition switch-ON (II).

38;<- O| !
condenser fan should O fuse in the under-hood fuse/relay box.
=!/- O|
O| O| O| come on.
- O 0 Faulty
radiator fan relay or condenser
!! O|
O| O| O| O fan relay
! O|
O| O| O| O 0 An open in the wire
%3 O|
O| O| O| O 0 Faulty
!! ! O|
O| WHT/GRN O|
264=.1 Check for voltage: Engine O|
#&!
9
There should be approx. O
4 !/- 0 Faulty
radiator fan switch B
!3) O|
O| O| coolant temperature below O|
! !3 11 volts.
&!- O
O Faulty radiator fan control module
!! ! O|
O| O| 106°C (223°F).
0P;+P <- O| O O|
Fan Control
+

1 o_22
+( Testing
Radiator Fan Switch !
Fan Motor Testing
+

!
$
1.
- Disconnect the 2P connectors from the radiator fan
( Except F18B3 engine:
%+8"! F
motor and condenser fan motor.
- NOTE: Bleed air from the cooling system after installing
84 9)!!
!!

LOCK the radiator fan switch (See Page 10-7).
3;'!0$<-
1.
- Remove the radiator fan switch from the
1&3
thermostat cover (See Page 10-11) and (See
&;'!0<;
Turminalsidc of '!0<-
Page 10-12).
male lerminals 2.
- Suspend the radiator fan switch in a container of
3
water as shown.
33-
A
THERMOMETER .' >ll/
RADIATOR
FAN SWTCH
lI
_JL—'_' .1313!” I
4
f" ”I l WATER ___
"at. I] l 3.
+- Heat the water and check the temperature with a
63# 3
CONDENSER h, ] _| il‘nl thermometer. Do not let the thermometertouch the
-(!
FAN MOTOR "W“? ' r5115 bottom of hot container.
-
. J " cult-3;»,- 4.
*- Measure the continuity between the A and B
, 3%)
RADIATOR FAN MGTDF: terminal according to the table.
!
!-
2.
- Test the motor by connecting battery power to the B
4
3) a. Terminal i
terminal and ground to the Aterminal.
!
%!- "x —. A g 3
3.
+- If the motor fails to run or does not run smoothly, replace
! !A! Operation i Temperature ‘-
-
it. - - - I ON 91 _ 95 -=- C In“...
_ _
Except [196 _._203-F)
H22!” _ 3 — 8°C (5 —15°Fl lower

engine OFF than the temperature
when it goes on
92 —98cC 3 ,_
:ON l198—208‘"F l ‘T‘
HEZA? —-- -
engine 2—7c'Cl4—12‘F]
OFF lower than the tempera-
' turn when it goes on
Fan Control
+

10_23
$
Radiator Fan Switch !

+( Testing
F1833 engine:
+8"! F
NOTE: Bleed air from the cooling system after installing the
84 9)!!
!!

radiator fan switch (See Page 10-17).
3;'!0$<-
1.
- Remove the radiator fan switch Afrom the thermostat
1&3%
cover and radiator fan switch B from the water outlet
&3)3 !
cover (See Page 10-15).
&;'!0<-
2.
- Suspend the radiator fan switch in a container of water
33
as shown.
3-
THERMDMETER
RADIATOR FAN
SWITCH
WATER
3.
+- Heat the water and check the temperature with a
63# 3
thermometer. Do not let the thermometer touch the
-(!
bottom of hod container.
-
4.
*- Measure the continuity between the Aterminal and B
, 3%!)
terminal according to the table.
!
!-
Terminal
—-.I_ A El
Operation Temperalure
ON 91 — 95 'C L
I
HES — 20TH I
SWITCH - —— _.__ ..}, _. ..
A 3 — B'T'C i5 — 15"Fi lower

OFF than thetemperature
when it goes on
”v—i 103 — mart ______ . .. !
0” l21?—228"Fl ' ’
SWITCH ———————--
B d—S'Ci'i—16-Fl
OFF lowerthan the tempera-
ture when it goes on
%!
!

Enqine Coolant Temperature Gauqe
Gauge Testing
! !
10-24
$ Sending Unit Testing
!; !
- Check the No. 9 (7.5 A) fuse in the driver’s under-dash

#-5;$-%< &B -
1. (C =.13!
Disconnect the YEL/GRN wire from the coolant
fuse/relay box before testing.
=!/
- temperature gauge sending unit.

-
- Make sure the ignition switch is OFF,A
,#
38 then disconnect PDSITI'H'E TERMINAL
the YEL/GRN wire from the coolant temperature gauge
C =.13!

SENDING UNIT
sending unit, and ground it with a jumper wire.

A
37 3-
GAUGE SENDING UNIT
‘I'ELi'GHN WIRE
2.
- Using an ohmmeter, measure the change in
?
A

resistance between the positive terminal and the
3&!
engine (ground) with the engine cold and with the

;
<3
!3
TELJGRN WiFlE
engine at operating temperature.

-
3.
+- Turn the ignition switch ON (ll).
4
38;<-
Temperature
4 56°C (133°F)< '00P
P;++P 85 - 100°F
Check that the pointer of the coolant temperature gauge
#!

(85 - 212°C)
;'P<
starts moving toward the "H” mark. Turn the ignition
&
3K6L#-4

Resistance ohms
1 137
+$ 46 - 30
*+0
switch OFF K6L

38 before the pointer reaches “H” on the gauge
3.
+- If the obtained readings are substantially different

!!
dial. Failure
!- to do so may damage the gauge.
!

-
from the specifications above, replace the sending
&A!

0 If the pointer of the gauge does not move at all,

&!!A
unit.
-
check for an open in the YEL/GRN wire.
#C =.13-
If the wires are OK, replace the coolant
38>A!!
temperature gauge.

-
0 If the coolant temperature gauge works, test the
!

3#A
coolant temperature sending unit.
!
-

&

Component Locations

Index
11 -A-2

Ref No.
1- Tool Number
4! Description
( l Qty
D l Remark
1#
07PAZ - 0010100
0$%I00000 808 Short Connector
l 1
l
LOOOOMA
07VAJ - 0040100
0$:%"00*000 Fuel Pressure Gauge Attachment
! .
% l 1
l
+ 07406 - 0040002
0$*000*000 Fuel Pressure Gauge Set
! .
l 1
l
—1
+ 07406 - 0040202
0$*000*00 Fuel Pressure Hose Assembly
! 6%! l (1)
;< l Component Tools
4!
* 07WAA- 0010100
0$2%%00000 Adjustable Ring Nut Wrench
%7 !1
2 l 1
I
Component Locations

&

11 _A_3

Index (cont’d)
/
?0
F20B6 engine:
+$"5! F
EVAPORATIVE EMISSION INTAKE
IEVAPI PURGE CONTROL AIR
SO LENOID VALVE BYPASS IIAB]
IDLE AIR CONTROL IIACI VALVE Troubleshooting. page 11 A 145 CONTROL
TIIJLJC'IILZ-si‘i0i;111r'ii_';, paw} 11 Iii-E111 SOLENOID
MANIFOLD ABSOLUTE I / VALVE

PRESSURE [MAP] SENSOR I Troubleshooting,
Troubleshooting, page TWA-39 page ILA-126
THROTTLE POSITION ITFI SENSOR __, INTAKE AIR BYPASS [IABI

‘l'rn-.Jble5hooting,page H A.” x CONTROL DIAPHRAGM
. ”‘5‘. Iosting. pogo 11 JET-129
EXHAUST GAS RECIRCULATION -
IEGRI VALVE and LIFT sensor: a _ INTAKE AIR TEMPERATURE
Iroubleshooting. page ILA-139
’7‘ tom sensoe
Troubleshooting. pane ll—A-dz
|
CTLINDER POSITION [C‘I’PI

SENSOR I CRANKSHAFI' POSITIONI'TDF'
lBuild into the distributor! ' DEAD CENTER
Troubleshootingr page ll-A—TS I | ICKPITDCI SENSOR
- - _ lTroublhI‘JDIir‘ig, gage 11 A T4
1IIIEHIIIILE SPEED SENSOR . -

- - 'I ' .
[V551 11“”I
Troubleshooting. page li-A-‘H
POWER STEERING PRESSURE

ENGINE CDOLANT TEMPERATURE IPSP] SWITCH
IECT1 SENSOR -_""--—_ __ ______ _ _ _ _ —--""_-I-”- TrUUDIEHhUDIing. page ILA-'32
Troubleshooting. page ’I’I-A-da KNOCK SENSOR "(5} FNMA“
Troubleshooting pagL} 11.15....r3 HEATED DxYGEN SENSOR PRIMARY (H025)
ISENSOR 1)
Troubleshooting. page ll-A-M
Replacement, page ll-A-82
H22A7 engine:
.7! F
IDLE me coNTnoL iIACI VALVE
MANIFOLD ABSOLUTE Troublefihmtmg. page 11A 3‘ EVAPORATIVE EMISSION
PRESSURE [MAP] senson [EVAP] PURGE CONTROL
Troubleshooting. page 11-A-35' SOLENOID VALVE
Troubleshooting,oage11-A-145
THROTTLE POSITION ITPI SENSOR
Tloubloshooting. page 11 A 41‘ INTAKE AIR TEMPERATURE [IATI
SENSOR
lroubleshooting. page 11 A 11.2
EXHAUST GAS RECIRCULATI'ON
[EGRI VALVE and LIFT SENSOR
Troubleshooting. page 11-A—1 39'.“
:_ _ L POWER STEERING PRESSURE
" ' . I [PSPI SWITCH
-' ' 1 Troubleshooting. page 11 A 92
C‘I'LINDER POSITION IC‘I’PI

SENSOR
iEluildinto the distributor} 1
Troubleshooting. page It-A-TS ll
CRANKSHAFI' POSITION .I'TCIP
DEAD CENTER
[CKPITDCI SEN 50R
VEHICLE SPEED SENSOR Troubleshooting. page II-A-Td
WSSI
Troubleshooting. page ll-A-TT
ENGINE CODLANT TEMPERATURE INTAKE KNOCK SENSOR (K51

iECT] SENSOR CONTROL Troubleshooting, page 11 A .73
Troubleshooting. page 11-A-u SOLENOID
VALVE
Troubleshooting.
page ILA-131
To go to the pages referenced on the diagram above.

4

&A
!#!!3
9
(See Page 11-A-84)
;'!%'*< See Page 11-A—79 ;'!%*<
;'!%$5< (See Page 11-A—145) See Page 11-A-42)
;'!%*<
AAA/\AA
AAAA
vvvv
(See Page 11-A-39)

;'!%+5< See Page 11-A—77
;'!%$$< (See Page 11-A—126)
;'!%< See Page 11-A-74)
;'!%$*<
(See Page 11-A-47)
;'!%*$< See Page 11-A—44
;'!%**< (See Page 11-A—129)
;'!%5< See Page 11-A-92)
;'!%5<
(See Page 11-A—139)
;'!%+5< See Page 11-A—73
;'!%$+< See Page 11-A-54)
;'!%*<
See Page 11-A-82)
;'!%'<
See Page 11-A-131)
;'!%+<
Component Locations

&

11 -A-4

Index (cont’d)
/
?0
F2036 engine:
+$"5! F
THHCITrLE BODY 1TB)
THROTTLE CABLE Inspection. page PIA-122
infiper.1inn,-'Adjustment, pagu II A 121] Dmuaam'nblv. page. 'I 1311-12-1
Installation, page II-A 121
AIR CLEANER lACLl

Ruptacumcnt,
page 11 #119
FIE SUNATOH
POSITIVE CHANKCASE VENTILATION [PCW VALVE

Inapectlon. page ‘l‘l-A-‘lll-E
H22A7 engine:
.7! F
THHDTI'LE EDDY ITBI
Inspection, page 1 I-A-I22 THROTTLE CRBLE
Diaassambly, paga 1 1-A-124 Inspectionl'Adjustmam, page 11-A- 1 2|)
Installation. page 11-A-12'I
AIR CLEANER IACLI

Replacement.
paga11-A-119
RESONATOR
POSITIVE CFMNKCASE 1«I'EIIITILA‘I'IIZIIIII [P'C'U'I VALUE

lnspection,paga11-A-1d3

4

&A
!#!!3
9
;'!%0<
;'!%<
;'!%5<
;'!%<
;'!%*<
;'!%*+<
Component Locations

&

11 -A-5
3
Index (cont’d)
/
?0
PRIMAHV
SECONDARY HEATED OXYGEN SENSOR ISECONDAF“ll HOZSI ISENSOH 2i HEATED OXYGEN SENSOR PRIMARY IHO2SI iSENSOR II
Trauma-shooting, page 11 A 5‘3 1H22A7 engine)
Troubleshooting, page ILA-50
Replacen‘rer‘rl, L'mgL' H-A-B?
THREE WAY CATALYTIC

CONVERTER (TWCI
Troubleshooting, page Hurt-13‘.r
Inspection, page Hun-135
LHD:
&.)F
ENGINE CONTROL MODULE iECMII'
POWERTRAIN CONTROL MODULE (PCMI PGM-Fl MAIN RELAY INEHTIA SWITCH
Relay testing, page I I-A-‘I 11 Description, page
Rarrroval. page 11—A-17‘
Trmrhleshooling,paguII-A112 ii-A-HU
Troubleshooting Procedures, page 11 A16
Troubleshooting, page ‘l‘l-A-34
DATA LINK
CONNECTOR iDLC]
HEP]
eenvrce CHEER comweoron

Troubleshooting Procedures, page 'l'l-A-‘IS
RHD:
.)F
POM-Fl MAIN RELAY
SE RVICE CHECK CONNECTOR INEHTIA SWITCH Relay testing, page II-A—I 11
Troubleshooting Procedures. page 11-A-15 Description, page 11-A-11D Troubleshooting. page 114L112
ENGINE CONTROL MODULE lECMII

POWERTRAIN CONTROL MODULE (PCMI
Removal. page 11-A-1'r‘
[gm-A LINK Troubleshooting Procedures, page ILA-15
mmmfimgn ac] Troubleshooting. page 11-Av34
[15”

4

&A
!#!!3
9
(See page 11-A-50)
;'!%0< (See Page 11-A-17)
;'!%$<
(See page 11-A-82)
;'!%'< (See Page 11-A-15)
;'!%<
;'!%+$< (599 Page ll-A-34)
;'!%+*<
;'!%+< (See Page 11-A—1 11)
;'!%<
(See Page 11-A-112)
;'!%<
(See Page 11-A-110)
;'!%0<
Component Locations

&

11 _A_6
5
Index (cont’d)
/
?0

F2036 engine:
+$"5! F
LHD:
&.)F
FUEL PUMP
Testing. page 11 A105
FUEL Replacement, page 11-A-106
FULSATION FUEL GAUGE SENDING UNIT
DAMPER FUEL FEED PIPE Testing. page 1111-108
FUEL VAPOR PIPE

FUEL FILL CAP
EVAPORATIVE EMISSION (EVAPI
CO NTROL CANISTER
Troubleshooting, page i‘l-A-HE
FUEL TUBEIDUICK-WNNECT
FITTINGS
Precautions. page ILA-97
Disconnection, page 1 1-in-9?
Connection. page 11-A-QB
FUEL TANK
Replacement, page ILA-115
FUEL INJECTOHS FUEL FILTER

Description. page 11A 101 Fleplacen'tent, page 11 AIDS
Replacement, page 11 A402 FUEL RETURN PIPE
EVAPORATIVE EMISSION IEVAPI
FUEL RAIL FUEL PRESSURE REGULATOR TWO WAY VALVE
Testing. page 11 aft-1:14 Tagging. page 11_A.1¢g
Replacement. page 11 A 105
RHD:
.)F
FUEL PUMP
Testing, page 11 AIDE
FUEL PRESSURE REGULATOR FUEL FEED PIPE FUEL uaeoe PIPE Replacement. page 114-105
Testing, page i1-A-‘IO-i FUEL GAUGE SENDING UNIT
Replacement, page 11-A-‘IDB Testing. page 11-A-IDFS
FU E L FILL CAP
FUEL
PULSATION
DAMPER
FUEL TUBEIOUIL‘K—CDNN ECT

FITTINGS
Precautions. page 11 A 9?
Disconnection, page 1111-9?
Connection. page 11 iii-98
FUEL TANK
Replacement. page 11 A 1'15
FUEL HAIL ” FUEL FILTER

Replacement, page 11 A 105
EVAPORATIVE EMISSION [EVAP]

TWO WAY VALVE
FUEL INJECTUHS FUEL RETURN PIPE resting page “4443
Deecription. page 11-12-101
Replacement. page 11-A-102 EVAPORATIVE EMISSION IEVAP]
CONTROL CANISTEH
Troubleshooting. page Hue-145

4

&A
!#!!3
9
;'!%0<
;'!%0'<
;'!%*<
;'!%0<
;'!%0<
;'!%0*<
;'!%0<
(See Page 11-A-97)
;'!%5$<
(See Page 11-A-98)
;'!%5'<
;'!%<
;'!%*'<
Component Locations

&

11 -A-7
7
Index (cont’d)
/
?0
H22A7 engine:
.7! F
LHD:
&.)F
FUELPUMP
FUEL TANK Testing, page ILA-106
RepIacement. page II-A-IUS
FUEL GAUGE SENDING UNIT
FUEL VAPOR PIPE FUEL FEED PIPE Testing, page ILA-108
FUEL
PULSATION
DAMPER
EVAPORATIVE smussron IEVAPI FUEL ”'4 CAP

common. CANISTER
Troubleshooting. page ILA-145
FUEL TUBEIOUICK-CONNECT
FITTINGS
Precautions, page 11-A-S?
Disconnection. page tl-A-ST
Connection. page 111A~EIB
FUEL FILTER
Replacement. page ILA-115
FUEL INJECTDRS EVAPORATIVE EMISSION IEVAPI

Description. page 11-A-101 TWO WAY VALVE
Replacement. page 1 1 -A-1CI2 FUEL RETURN P'PE Testing. page ILA-148
FUEL RAIL FUEL PRESSURE REGULATOR

Testing. page 1I-A-104
RHD:
.)F
FUEL VAPOR PIPE FUEL PU MP
FUEL TANK Testing. page ILA-106
FUEL FEED PIPE Replacement. page ILA-115 Replacement. page 11-A-1CIE
Testing. page ILA-108
FUEL
PULSATIOI'II
DhMPER FUEL FILL CAP
FUEL TUBEIGUICK-OONNECT
FITTINGS
Precautions, page 11-A-9‘l‘
Disconnection. page tt-A-QT
Connection. page II-A-EIIB
FUEL HAIL FUEL FILTEFI

Replacement. page 11 A115
EVAPORATWE EMISSION IEVAFI

FUEL RETURN PIPE TWO WAY VALVE
FUELINJECTOFIS Testing. page 11-A—1dS
Description. page 11-A-1L‘J1
Replacement. page ILA-102 EVAPORATIVE EMISSION IEVAPI
CONTROL CANISTER
FUEL PRESSURE REGULATOR Troubleshooting. page 1 1-A-145
Testing. page 1 1-A-104
Replacement. page ILA-105

4

&A
!#!!3
9
;'!%0<
;'!%0'<
;'!%*<
;'!%0<
;'!%0<
;'!%0*<
;'!%0<
;'!%5$<
;'!%5'<
;'!%<
;'!%*'<
System Description
#)
11 _A_8
8
4

Vacuum Connections
F2036 engine:
+$"5! F
mm
EMISSION "flifli‘é
PRESEU FIE
Eggém iMAPi SEN Eur-1
CANISTEFI
K To EVAPORATIVE EMISSION [EVAP]

TWO WAY VALVE
IDLE AIR
Tn- ENGINE MOUNT ‘ - CONTROL IIAC]
CONTROL SOLENOID VALVE IAITI VALVE
7 EVAPORATI‘U'E EMISSION
i [EVAPJ CD NTFICIL
_J CANISTER
INTAKE AIR
BYPASS IIAB]
CHECK VALUE
EVAPORATIVE INTAKE
EMISSION AIR
[EVAPI B‘I’PASS IIAB]
PU FIGE CONTROL VACUUM
SOLENOID VALVE TANK
iNTAKE AIFI
BYPASS [IABI
CONTROL SOLENOID VALVE
INTAKE AIR
BYPASS IIAB)
CONTROL DIAPHRAGM VALVE
FRONT OF ' FUEL

VEHICLE PFI ESEUHE
FIE GU LATDFI
System Description
#)
11 _A_9
9
Vacuum Connections (cont’d)
4

/
?0
F2036 engine:
+$"5! F
1c. ENGINE I
" mum I
.._.J
Primary heated oxygen sensor (Primary HO2S) (Sensor 1)

1 /
;68<;< 19 #;%)<#&!&
5 Intake air bypass (IAB) check valve
Secondary Heated Oxygen Sensor (Secondary HO2S)
2 68/
;68< 20 #;%)<#&!&
(Sensor 2)
;<
+ ,!! ;,%< 21 #;%)<!!&!&
Intake air bypass (IAB) control solenoid valve
(OOONQO‘I-bw

*
! ; 4< 22 #;%)<!
&!&
Intake air bypass (IAB) control diaphragm valve
Intake air temperature (IAT) sensor
# ;%4< 23 /
!; .1<&!&!
+ Exhaust gas recirculation (EGR) valve and lift sensor
Crankshaft position (CKP) sensor
#;>< 24 &#&!;:<&!&
* Positive crankcase ventilation (PCV) valve
Top dead center (TDC) sensor
$ 4;4(< 25 43!&
Three way catalytic converter
Knock sensor (KS)
' >#;>< 26 &&; :%<!
Evaporative emission (EVAP) control canister
Idle air control (IAC) valve
5 !!;%<&!& 27 &&; :%<
!!
$ Evaporative emission (EVAP) purge control solenoid
valve
&!&
0 Throttle body (TB)
10 4!;4)< 28 &&; :%<33&!&
' Evaporative emission (EVAP) two way valve
11 Fuel
injector
!7 29 Fuel
5 tank evaporative emission (EVAP) valve
!#&&; :%<&!&
12 Fuel
pulsation damper
! ! 30
!!&!&
+0 Engine mount control solenoid valve
13 Fuel
+ filter
!!
14 Fuel
* pressure regulator
!
!
15 Fuel
pump (FP)
! ; <
16 Fuel
tank
!#
17 %!
$ Air cleaner
18 1
' Resonator
System Description
#)
$
- -
4

/
?0
Vacuum Connections (cont’d) 1 1 A 1 0
H22A7 engine:
.7! F
MANIFOLD
EVAPORATIVE EMISSION ABSOLUTE
iEVAPi CONTROL PRESSURE
CANISTER [MRPI SENSOR
LE To EVAPORATWE EMISSION iE‘U'AF‘]

TWO WAY VALVE
' “I EVAPORATWE
EMISSION
[EVAP]
,. ._ _.-- CONTROL
} ‘ CANISTEFI
IDLE AIR
CONTROL “AC?
INTAKE VALVE
CONTROL DIAPHRAGM VALVE I
I‘:":._.__——-— INTAKE
' '-“ CONTROL
CHECK VALVE
"_' -- HINTAKE
CONTROL
' VACUUM
TANK
EVAPORATIVE
EMISSON
[EVAP]
P'U ROE CONTROL
SOLENOID VALVE _ INTAKE
CONTROL SOLENOID VALUE
FRONT OF _ I FUEL
VEHICLE ‘“ PRESSURE
REGULATOR
System Description
#)
11 _A_11

4

/
?0
H22A7 engine:
.7! F
1 /
;68<;<
Primary heated oxygen sensor (Primary HO2S) (Sensor 1) 19 #!#&!&
5 Intake control check valve
2 68/
;68<
Secondary Heated Oxygen Sensor (Secondary HO2S) 20 #!& #
0 Intake control vacuum tank
(Sensor 2)
;<
+ ,!! ;,%< 21 #!!&!&
Intake control solenoid valve
(OOONQO‘I-bw

*
! ; 4< 22 #!
&!&
Intake control diaphragm valve
# ;%4< 23 /
!; .1<&!&!
#;>< 24 &#&!;:<&!&
$ 4;4(< 25 43!&
Knock sensor (KS)
' >#;>< 26 &&; :%<!
5 !!;%<&!& 27 &&; :%<
!!
$ Evaporative emission (EVAP) purge control solenoid
valve
&!&
10 4!;4)<
0 Throttle body (TB) 28 &&; :%<33&!&
' Evaporative emission (EVAP) two way valve
11 Fuel
injector
!7 29 Fuel
5 tank evaporative emission (EVAP) valve
!#&&; :%<&!&
12 Fuel
pulsation damper
! !
13 Fuel
+ filter
!!
14 Fuel
!
!
15 Fuel
pump (FP)
! ; <
16 Fuel
tank
!#
17 Air
$ cleaner
%!
18 1
' Resonator
S stem Descri tion
#)
11 _A-12

%

FEM-Fl HMN REL-0.1I

FUEL F'UHF
I’fl
._ —-Cllf_7— _..
.- ' 0‘ : own.-
:13: -.=-
aI">—. '-
':_1f' 11—:
J. F ": C-‘(P
ii .- BA'ITER'I' . . " . SEHEIDR
r- .
I
IAC VALVE
'-'-‘ TDC
_ SENSOR
- @D
T _:._¢-1r-~. ' IACV
[flat-.—
"; cnP
”1. sermon
P95 ._'_'-
o .::~"-_'T-—.::-- -- -—
EVAP P'UFlGE CONTROL
'-5-':1-“7' L1
SOLENOID VALVE
.
.. . __-_-;_-':.--4;. _ . . . ._ ucs
ENGINE "GUN? CONTROL
SOLENOID VALVE“
‘3
IIBSOL .-'_ :-.
I_l_1 Jr
IAE conrncu. _ 59 .-I._I
91-02 sure--
SOLENOID VALUE”
. o—c- JET-- -:_'

' mung CONTROL
SOLENOID VALVE“
HT:
.4:
l
. i 5E commun-
H025
I
T
t .‘N-t-
I
- SHOESHTC
.'-' :- scs _ stems

CHECK
o countcmn
A
-"I--. K-LINE
I 1
Ut
LINK
EON |'IIE ETEIR
1'. Q
ia'1——i
HIIF‘
I‘
___
5E HSDR
l
Fuses:
9
Battery (100) *A
);00<G%
—\—\LOOO\IO)O‘I-l>-OONA
Back-up, ACC (40A) *A

)# A%;*0%<G%
+ IG main (50A) *A
.;0%<G%
* AGCS (15A) *A
%.;%<G%
No 1 fuel pump (15A) *8
! ;%<G)
No 6 ECU (ECM/PCM) cruise control (15A) *8
?; ,=,< !;%<G)
$ No 9 Back-up light instrument light (7.5A) *8
5)# !
!
;$-%<G)
' No 13 Starter signal (7.5A) *8
+
!;$-%<G)
5 No 13 Clock back-up (7.5A) *0
+!## ;$-%<G
0 0 6;+0%<G%
Heated seat (30A) *A
1 %
No 6 LAF ;0%<G
heater (20A) *0
G* %9 =!/
A: in the under-hood fuse/relay box
G* )9&B =!/
B: in the driver’s under-dash fuse/relay box
G* 9
B =!/
C: in the passenger’s under-dash fuse/relay box
System Description
#)
11 _A_13

Electrical Connections (cont’d)
%

/
?0
. ._. _ ‘@___HUTII EH9 f "{ Fg—1§|Jfl_{ytfl"fi-.

“EC SOLENOID VALVE
pumsnmn“
m——— ___. _._..
Hi.
fE
0‘
r
. -1‘ measure + ‘3
I?!
To SPARK .
PLUGS
'E" Prinz: ‘1 ‘ ”1|”k
my:
IGNITION
cnlL r.- {3m mozh”
_ 21"3—1] E I 5 w_.
.r 1“___
:-. PHD-25:41:”
_ _
_|_ C BRAKE LIGHT
nap —ig fl vac:

E . .- l 3-; ‘rps IHRO‘HLE
nounusren :—.i.'. '+— —IFZ .3 9051mm
newsman 55 __,:l 55? _ i SENSOR
EGR VILVE
LIFT SENSOR
cmlss comma. K3
uur - .¢ EGR
VALVE
3? m
:; senson
_ P3151"
.. _, " . an
_IE seuson
.' mace -_- -

To _ '- ”--
I
muoBILIZEn ‘ I
UNI? moan {m1 . .
____. ._ "._. ._ .. '“QWF commas-son couozmeu momma

n ; CLutcu rm FAN
[magma -—. an.“ RELAY RELAY
INDICATOR . ¢ . _. _ . _.__
”“3“" couotnssn
1 FAN
. 1W ._-.
“35 . MDTDFI
G) FHDMTUFI
MC \ HM
BARCI PRESSUHE RADIATOR SWITCH
sanson rm
+ |_.-_.._.._._
IBM!" II'TIO SWITCH -' HOTDFI "' '
UII' [CH-IVE“? —
-- . --._____ _ m ' : CUM-"E

—___.- SWITCH
1 :1. .: _ CDNTHBL UNIT
J. ' "r5
I at
|
i
#)

System Description

%

/
?0
|
I
t ‘I'n GAUGE HAWSHAFI'
I “SEMBLY
”I; _ Np m:-
_(
SPEED SENSOR
I mun ASSIMELV
3
| E COUNTERSHM'T
SPEED SENSOR
If]
l L F .m- + GI NCSG-
| j‘Lc-1E-— - cam-~21 - ---—-— 1
| T
film-F5?!"
LOCK-UP contact. SOLENOID VALVE
4;. .-W-..:,_ . . . 4:
i
'
| - -1—
EMF! CONTROL SOLENOID VALVE A
| ! Lc_2_,fl__ -—~:>—'T.L"-C— --
+ J SHIFI' cuHTnOL souuocu VALVE B
| H;...._Di‘}. Quit; -_-- -::-> - —o
EHIFr CONTROL SOLENOID VALVE c
f
. . .I.
-' t— {517} -"“+ -:::- -":|:-'--;'_.» -- - - - T
' ' an aura PRESSURE CONTROL
SOLENOID VALVE A
r.‘
{LII-“- LS!
4
_ _|
m : If. «iii-1E:- 3.x.“ -..-_;. .
-£- GEAR POSIDON L'TCLUTCH FRESSII‘E CONTROL
_ SWIFCH SOLENOID VILVE B
SRIFT SWITCH :2 Tfl'
2ND CLUTCH PRESSURE SWITCH
.7_ __
To GAUGE 3RD CLUTCH PNEssunE min! f
ISEEMBLY
*l I “T
*2 3 WT
*3: FNBE engine
in! ‘. HZZAT engine
To INTEFltOCK UMT 4 *5 : W'flh CRUISE CONTROL
*6 1 With CLIMATE CONTROL
ECMJ'PCM CONNECTOR TERMINAL Locms

A (32F) a {Esp} c (3w) D (16F)
'551llanl1u 1111 2| :i4ls ' 1' a 5 “L234 [TI
I12I13114 1s 171a|15=u|21i22 n 24 _9_ "in 111213141515|11I1 r I 9l1011 12 l
IT M :12 19 2:1 1 a 2 1415 E
Troubleshootin

*
!g 11 -A-15
3

*
!'

How To Begin Troubleshooting

.
(
"!
*
!
When the Malfunction indicator Lamp (MIL) has been reported on, or there is a driveability problem, use the appropriate
2,! ;,<A&!!A
procedure below to diagnose and repair the problem.
!3
!-
A. 2,9
%- When the MIL has come on:
1.
- Connect the Honda PGM Tester or a scan tool to the 16P Data Link Connector (DLC) located on the passengers side
6.,4!(#;(<!

of the center console.
!-
2.
- Turn the ignition switch ON (II).
4
38;<-
3.
+- Check the Diagnostic trouble code C (DTC) and note it. Also check and note the freeze frame data.
#(
!;(4<-%!#H-
4.
*- Refer to the Diagnostic trouble Code Chart and begin troubleshooting.
1(
!
!
-
MALFU NCTIDN
'- IN DICATOH
NOTE:
84 9
0 See the scan tool or Honda PGM Tester user’s manuals for specific operating instructions.
!6.,4 B !
-
0 The scan tool or tester can read the diagnostic trouble codes (DTC), freeze frame data current data and other engine
4!
!;(4<AH

control module (ECM)/Powertrain control module (PCM) data.
! !; ,<=3! !;,<-
0 Freeze frame data indicates the engine conditions when the first malfunction, misfire, or fuel trim malfunction was
H
3! AA !! 3
detected. It can be useful information when troubleshooting.
- !3 !
-
B.
)- When the MIL has not come on, but there is a driveability problem, refer to the Symptom Chart (see page11-A—18).
2,A &!!A;!%'<-
C.
- DTCs are indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the SCS service connector connected.
(4!#
,! ;,<3&-
Connect the SOS short connector to Service Check Connector as shown (The 2P Service Check Connector is located).
4&#!<-
Turn the ignition switch ON (II).
4
38;<-
DATA LINK CONNECTOR (15m SERVICE CHECK
/ CONNECTUH IZPI
I, t3 TliEilluSLr'atiDn shows
SCAN TOOL or 5:5 SERVICE CONNECTD LHD will; FIHD twe .5
HONDA PGM TESTER [1]!t _ uu1o1flfl s-gr‘nmetrucal
Troubleshootin

*
!g 11 -A-16
5
Troubleshooting

* Procedures (cont’d)

!'
/
?0
Engine Control Module (ECM)/Powertrain Control Module (PCM) Reset Procedure

%!

/%02'
(

/'0'

Either of the following actions will reset the ECM/PCM.
!!3
3!! ,=,-
¢ Use the scan tool or Honda PGM Tester to clear the ECM's/PCM's memory.
?!6.,4! ,@=,@-
NOTE: See the scan tool or Honda PGM Tester user’s manuals for specific operating instructions.
84 9!6.,4 B !
-
¢ Turn the ignition switch OFF.-1&-+8>)%>?;$-%<
@3
4
38 Remove the No. 13 CLOCK BACK UP (7.5A) fuse from the passenger's wider-dash
fuse/relay box for 10 seconds.
=!/0-
No. 13 CLOCK
BACK UP
(7.5 A1 FUSE
PASSENGEH'S UNDER-DASH
FUSEIHELAV BOX 1 he Illustratiun Shows LHD WEE.
HHD type is symmetrical.
Final Procedure (this
+ '
/ procedure must be done after any troubleshooting)

*
#
*
!<
1.
- Remove the SCS short connector if it connected.
1&-
NOTE: If the SCS short connector is connected and there is on DTCs stored in the ECM/PCM, the MIL will stay on when
84 9(4 ,=,A,3!!3
the ignition switch is turned ON (II).

3 8;<-
2. ( ,=,1 -
- Do the ECM/PCM Reset Procedure.
3.
+- Turn the ignition switch OFF.-
4
38
4.
*- Disconnect the scan tool or Honda PGM Tester from the Data Link Connector. (16P).
(!6.,4(#-;<-
Known-Good ECM/PCM Substitution
I
(
%2'*

The ECM/PCM is part of the immobilise system. If you substitute a known-good ECM/PCM the ECM/PCM will have a different
4 ,=,!- #3
,=, ,=,3!!&
immobilise code. In order for the engine to start, you must rewrite the immobilise code with the Honda PGM Tester.
!-
A 3!36.,4-
Troubleshooting

*
! _ _
7
Troubleshooting


!'
/
?0 11 A 1 7
ECM/PCM Removal
%2'
-
Pull the carpet from the passenger’s side of the center console to expose the ECM/PCM. Remove the two bolts from the
!!
B!/ ,=,-1&3!
ECM/PCM. Check the system according to the procedure described for the appropriate DTC listed on the following pages.
,=,-#
(4!!!3

-
5.6 Mn!
11.“ kgf-m.
"L2 lbf-ftl ECM)’
_.f' {x The illustration shows LHD type.

FlHD type I5 symmetrical.
Checking
6 ! The ECM/PCM Connector Terminals
%2'

When checking the ECM/PCM connector terminals, gently slide the sharp tester probe from the wire side into the connector
2#
,=,!A
!!3
until it comes in contact with the terminal end of the wire.
!3!3-
DIG ITAL CIRCUIT TESTER
Corn mum's-lily availabla or
01'411 - M20913)
SHARP TESTER PROBE
The illustration shows LHEI type.


*
!
Troubleshooting
Troubleshooting


!'
/
?0
11 -A-18
8
Symptom Chart
#

Listed below are symptoms and probable causes for problems that DO NOT cause the Malfunction indicator Lamp (MIL) to
!3! !(884 ,! ;,<
come on. If the MIL was reported on, (see page 11-A—15). Troubleshoot each probable cause in the order listed (from left to
-,3A;!%<-4 !! !;!
right) until the symptom is eliminated. The probable cause and troubleshooting page reference can be found below.

< !!-4! !

!3-
Symptom
#
'
**
Probable Cause
Engine will not start

3!! 4, 2, 3, 5, 19, 13,1
*AA+AA5A+A
Hard starting
6
2,4,10,15,12,18
A*A0AAA'
!!!3
Cold fast idle too low 7, 6, 15
$AA
Cold fast idle too high
!!
7, 9, 10
$A5A0
Idle speed fluctuates
!! 7,9,8
$A5A'
Misfire or rough running
O ,

O Troubleshoot for misfire (see page
4 !;! O
O O 11-A—69,(see page11-A—70)
%5A;!%$0< O
Low power
O 33 O 2,8,9,11,16,15,17,19
A'A5AAAA$A5 O
Engine stalls

!! 2,4,10,7,19,5,14
A*A0A$A5AA*
Other Probable Causes for an engine that will not start:
8!
3!!9
Compression

Intake air leakage
#!#

Engine locked up

!#
Timing belt
4
!
Starting system

Overheating
8&
Battery
)
Immobilise system
!
Inertia switch
3
Pro bable Cause List (For the
'
**& /+
DTC Chart
) (see page 11-A—26))
;!%<0
Probable Cause O|
O '
** System
# O| Page
'! O|
O 1 Engine control module (ECM)/Powertrain control module (PCM)
OI
! !; ,<=3! !;,< O| ;!%+*<
(see page11-A—34) O|
O O| Fuel pressure
! O| ;!%0<
O + PGM-FI!
O| ., main relay O| ;!%<
01-w
O * Ignition system
O|
O| *
Section 4 O|
O Crankshaft position/top dead center/cylinder position sensor circuit
O| #==! O| ;!%$*<A
(see page11-A—74), O|
O O| O| and (see page
;! O|
O O| O| 11-A—79)
%$5< O|
O Intake air temperature (IAT) sensor circuit
O| # ;%4< O| ;!%*<
O $ Idle air control valve (IACV)
O| !!&!&;%:< O| ;!%'*<
O ' Throttle body
O| 4! O| ;!%<
O 5 O| 4!!
Throttle cable O| ;!%0<
O 0
10 O| ,!;4<
Manifold position (TP) sensor (see page11-A—39) O|
O| ;!%+5<
O Throttle position (TP) sensor
O| 4!;4< O| ;!%*$<
O Barometer pressure (Baro) sensor
O| ) ;)< O| ;!%$'<
O + A/T gear position signal
O| %=4

! O| *
Section 14 O|
O * Brake switch signal
O| )#3
! (see page11-A—90) O|
O| ;!%50<
O O| %!
Air cleaner (see page11-A—119 ) O|
O| ;!%5<
O Intake control system, intake air pipe
O| #!A# O| ;!%<A
(see page11-A—125), O|
O O| (see page11-A—130), O|
O| ;!%+0<A
O O| O| ;!%+*<
(see page11-A—134 ) O|
O 17
$ Three way catalytic converter (TWC)
O| 43!&;42< (see page11-A—136) O|
O| ;!%+<
O 18
' Evaporative emission (EVAP) control
O| &&; :%<! O| ;!%**<
O 5
19 O| !
Contaminated fuel O| O|
Troubleshootin

*
!g 11 -A-19
9
Troubleshooting


!'
/
?0
EXM/PCM Data
%G2')
You can retrieve data from the ECM/PCM by connecting the scan tool or the PGM Tester to the 16P data link connector (DLC).
C & ,=,
!.,4!#;(<-
The items listed in the table below can be indicated by both scan tool and Honda PGM tester. The Honda PGM Tester also
4!!!3!6.,-46.,4!
reads data beyond these items. Understanding this data may help you find the causes of intermittent problems.
-?
! !-
NOTE:
84 9
¢ The "operating values" listed are approximate and may very depending on the environment and the individual vehicle.
4Z
&! Z!/&
&& !&!-
¢ Unless noted otherwise, "at idle speed" means idling with the engine completely warmed up. A/T in park or neutral, M/T in
?!3AZ!Z!
3
!!3 -%=4# !A,=4
neutral, and the A/C and all accessories turned off.
!A%=!! -
O| Data
) O| Description
)
O| Operating Value
!4 Freeze Data Ol
O| +C)
Diagnostic Trouble
O| (
4 ! If the ECM/PCM detects a problem, it will store it
O| ,=,!A3!! If no problem is detected,
O| !A O| YES
C O|
Code (DTC)
O| ;(4< as a code consisting of one letter and four
O|
! there is no output
O| O| O|
O| numbers.
O| - O| O| O|
Engine Speed
O|
O| 4 ,=,
Nearly the same as
The ECM/PCM computes engine speed from the O| ! O| YES
C O|
O| O|
!#- tachometer indication.
signals sent from the Crankshaft Position sensor. O| - O| O|
O| O| At idle speed:
O| %!9 O| O|
O| This data is used for determining the time and
O| 4
O| F2086 engine:
0)
9 O| O|
O| amount of fuel injection.
O| !7- O| ,=49$0 i 50 rpm (min-1) O|
M/T: 750 V0;< O|
O| O| i 50 rpm (min-1) O|
NT: 730 V0;<
O| %=49$+0 O|
O| O| H22A7 engine:
O| 6%$
9 O| O|
O| OI 790 i 50 rpm (min-1)
O| $50V0;< O| O|
Vehicle Speed
O| :! The ECM/PCM converts pulse signals from the
O| 4 ,=,& !
! Nearly the same as
O| ! O| YES
C O|
O| O| :!;:<;,=4< speedometer indication
Vehicle Speed Sensor (VSS) (WT) or countershaft O| O| O|
O| speed sensor (A/T) into speed data.
O| ;%=4<- O| O| O|
Manifold Absolute
O| ,!%! The absolute pressure caused in the intake
O| 4! # With engine stopped:
O| 2
9 O| YES
C O|
Pressure (MAP)
O| ;,%< manifold by engine load and speed.
O| !
!- Nearly the same as
O| ! O| O|
O| O| atmospheric pressure.
O| - O| O|
O| O| At idle speed:
O| %!9 O| O|
O| O| 21-41kPa(160-310 mm
O| *#;0+0 O| O|
O| O| Hg, 6.3-122 in Hg)
O| 6
A-+-6
< O| O|
Engine Coolant
O|
! O| 4 4&! With cold engine:
The ECT sensor converts coolant temperature into O| 2!
9 O| YES
C O|
Temperature (ECT)
O| 4 ; 4< Same as ambient
voltage and signals the ECM/PCM. The sensor is O|
O| &!

! ,=,-4 O| O|
O| O| 3!

a thermistor whose internal resistance changes O| %4-
temperature and lAT. O| O|
O| O| 3! -4 ,=, With engine warmed up:
with coolant temperature. The ECM/PCM uses the O| 2
3 9 O| O|
O| O| &!

! 4 approx: 70-100°C
voltage signals from the ECT sensor to determine O| /9$000P O| O|
O| the amount ofinjected fuel.
O| 7 !- (158—212°F)<
O| ;'P O| O|
Heated Oxygen
O| 68/
The Heated Oxygen Sensor detects the oxygen
O| 468/
/
0.0-1.25V
O| 0-0-: O| YES
C O|
Sensor (HOZS)
O| ;68< content in the exhaust gas and sends voltage
O| /
&!
At idle speed:
O| %!9 O| (Primary, O|
;A
(Primary Sensor 1)
O| ;< O|
! ,=,-)
!A about 0.1-0.9V
signals to the ECM/PCM. Based on these signals, O| 0-0-5: O| Sensor 1
O|
O| ;< the ECM/PCM controls the air/fuel ratio. When the O|
(Secondary Sensor 2) O| ,=,!= !-2 O| only)
!< O|
O| oxygen content is high (that is, when the ratio is
O| /

;A3 O| O| O|
O| leaner than the stoichiometer ratio) the voltage
O| !<&!
O| O| O|
O| signal is lower. When the oxygen content is low
O|
!!3-2/
!3 O| O| O|
l
O| (that is, when the ration is richer than the
O| ;A3 O O| O|
O| stoichiometric ratio), the voltage signal is higher.
O| <A&!

!
- O O| O|
Heated Oxygen
O| 68/
The Heated Oxygen Sensor detects the oxygen
O| 468/
/
0.0-1.25V
O| 0-0-: O| NO
8 O|
Sensor (HOZS)
O| ;68< content in the exhaust gas and sends voltage
O| /
&!
At idle speed:
O| %!9 O| O|
(Primary Sensor 1)
O| ;< about 0.1-0.9V
signals to the ECM/PCM. Based on these signals, O| 0-0-5:
O|
! ,=,-)
!A O| O|
O| ;(F2086 engine)
0)
< the ECM/PCM controls the air/fuel ratio. When the O|
O| ,=,!= !-2 O| O|
O| oxygen content is high (that is, when the ration is O|
O| /

;A3 O| O|
O| leaner than the stoichiometer ration), the voltage
O| !<A&!
O| O| O|
O| signal is higher.
O|
!
- O| O| O|
O| The heated Oxygen Sensor signals are electrical O|
O| 48/

!!! O| O|
O| current that are indicated as voltage on the scan
O| &!
O| O| O|
O| tool.
O| !- O| O| O|

*
!
Troubleshooting
Troubleshooting


!'
/
?0
11 -A-20
$
O )
Data O| Description
)
O Operating Value
!4 O| +C)
Freeze Data O
O H028 Feedback
68 # O| Loop status is indicated as “open” or “closed”.
KLK!L- O At idle speed: closed
%!9! O| YES
C O
O Loop Status
O| Closed: Based on the H028 output, the
!9)68 A O O| O
O O| ECM/PCM determines the air/fuel ratio and
,=,= ! O O| O
O O| controls the amount of injected fuel.
! 7 !- O O| O
O O| Open: Ignoring H028 output, the ECM/PCM refers O
89

68 A ,=, O| O
O O| to signals from the TP, MAP and ECT sensors to O

!4A,% 4 O| O
O O| control the amount of injected fuel.
! 7 !- O O| O
O 4 Trim O|
!4
Short Term Fuel The air/fuel ratio correction coefficient for
4= ! O V0W O| YES
C O
O O| correcting the amount of injected fuel when H028 O

7 !368 O| O
O O| feedback is in the closed loop status. When the
#!! -2 O O| O
O O| signal from the H028 feedback is weak, short

!68#3#A O O| O
O O| term fuel trim gets higher and the ECM/PCM
!

,=, O O| O
O O| increases the amount of injected fuel. The air/fuel O
7 !-4= ! O| O
O O| ratio gradually gets richer, causing a higher H028 O

!!
A

68 O| O
O O| output. Consequently, the short term fuel trim is
-F !A ! O O| O
O O| lowered, and the ECM/PCM reduces the amount O
!3A ,=, O| O
O O| of injected fuel. This cycle keeps the air/fuel ratio O
7 !-4!#= ! O| O
O O| close to the stoichiometric ratio when in closed
!3! O O| O
O O| loop status.
! - O O| O
O Long Term Fuel

4 Trim O|
!4 Long term fuel trim is computed from short term

! O V0W O| YES
C O
O O| fuel trim and indicates changes occurring in the
!

O O| O
O O| fuel supply system over a long period.
! !&!
- O O| O
O O| If long term fuel trim is higher than 1.00, the
!
!
-00A O O| O
O O| amount of injected fuel must be increased. If it is
7 ! - O O| O
O O| lower than 1.00, the amount of injected fuel must O
!3-00A 7 ! O| O
O O| be reduced.
- O O| O
O Intake Air
#% O| The IAT sensor converts intake air temperature
4%4&# O With cold engine:
2!
9 O| YES
C O
O Temperature (IAT)
4 ;%4< O| into voltage and signals the ECM/PCM. When
&!

! ,=,-2 O Same as ambient
O| O
O O| intake air temperature is low, the internal
# !3A! O temperature and ECT
4 O| O
O O| resistance of the sensor increases and the voltage O
&!
O| O
O O| signal is higher.

!
- O O| O
O 4!
Throttle Position O| Based on the accelerator pedal position, the
)!!A O| At idle speed:
%!9 O| YES
C O
O O| opening angle of the throttle valve is indicated.

!!&!&- O| approx. 10%
/-0W O| O
O Ignition Timing

4
O| Ignition timing is the ignition advance angle set by O|

&
! At idle speed:
%!9 O| NO
8 O
O O| the ECM/PCM. The ECM/PCM matches ignition
,=,-4 ,=,
O| F20B6 engine: 12° 1 2 °
0)
9PVP O| O
O O| timing to the driving conditions.

&
- O| H22A7 engine: 15 ° 1 2 °
6%$
9PVP O| O
O O O| BTDC with 8C8 service
)4(3& O| O
O O O| signal line isjumped with

!!7 3 O| O
O O O| the Honda PGM tester
6., O| O
O Calculated Load
! ! O| CLV is the engine load calculated from the MAP
:
!! !,% O| At idle speed:
%!9 O| NO
8 O
O Value (CLV)
:! ;:< O| data.
- O| 12-34%
+*W O| O

*
!
Troubleshooting
Engine/Powertrain Control Module Terminal
%! 2'
(

11 -A-21

!
Arrangement
ECM/PCM CONNECTOR A (32F)

%2',,%/'0
ECMFPCM CONNECTOR A IEZF'I
I 9 ‘0
.5 b
nus um. .Ln 3 "If? .5 a; 565
1) I) " 1.5 11' IB 1!} «1 22 :1 2.

D NEF' 2D'
I-- M 5-11“ _ swan Eli;
[MP EN IND
‘: PHL'JES
lM-l'} 25 TI
ma:
25
IuJ
_. HTCH“
to 5-H!”
PHOES
HTC”
2!!
Wire side female terminals
ECM CONNECTOR A (32P)
%,,%/'0
NOTE: Standard battery voltage is 12V.
84 9&!
:-
O| Terminal O|
Wire Colour O
1

,
Terminal Name O Description
)
O Signal
! O|
O| ,
@
No. O| O O O O|
O| 5*1
G O| PUR
?1 O CRS (Cruise control
1; ! O Down shift signal input
(3
! O When cruise control is used: pulses O|
2 ! 9 !
O| O| O signal)

!< O from cruise control
! O O|
O| 6*1
G O| BLU/YEL O
)?=C LED A
(% O Shift indicator light
!
O In manual mode:
!9 O|
O| O| O O control
! O 0 In 4th gear position: Battery
*
9) O|
O| O| O O O voltage
&!
O|
O| O| O O O 0 In 1st, 2nd and 3rd gear
A+
O|
O| O| O O O positions: 0V
90: O|
O| $ O| PUR
?1 O LED B
() O Shift indicator light
!
O In manual mode:
!9 O|
O| O| O O control
! O 0 In 2nd and 3rd gear positions:
+
9 O|
O| O| O O O Battery voltage
)&!
O|
O| O| O O O 0 In 1st, and 4th gear positions: 0V O|
A*
90:
O| ' O| BLK/WHT O
)>=264 SOZSHTC (Secondary O
864; Drives secondary heated O
(& With ignition ON (II): Battery voltage O|
2
8;<9)&!

O| O| O heated oxygen sensor O
/
oxygen sensor heater
/
O With fully warmed up engine
2 !!3
O|
O| O| O heater control)
!< O O running: 0V

90: O|
O| 9*1
5G O| BLU/WHT O
)?=264 VSSOUT (Vehicle
:8?4;:! O Vehicle speed signal
:!
! O Depending on vehicle speed: Pulses O|
(
&!9 !
O| O| O speed sensor output
O detected from
O O|
O| O| O signal)

!< O countershaft speed
O O|
O| O| O O sensor
O O|
O| 1O
0 O| BRN
)1 O 808 (Service check
;&# O Detect service check
(&# O 2!90:
With the terminal connected: 0V O|
O| O| O signal)

!< O connector signal (the

!; O With the terminal disconnected:
2!9 O|
O| O| O O signal causing a DTC

!
(4 O Battery voltage
)&!
Oi
O| O| O O indication)
< O O
O| 11 *1 O|
G BLU/BLK O
)?=)> LED C
( O Shift indicator light
!
O In manual mode:
!9 O|
O| O| O O control
! O 0 In 1st and 3rd gear positions:
+
9 O|
)&!
O|
O| O| O O O 0 In 2nd and 4th gear positions: 0V O|
*
90:
O| 12
O| PNK
> O IMOLMP (Immobiliser O
,8,;! Drives immobiliser
(&! O With immobiliser indicator light
2!!
O|
O| O| O indicator light)
!
< O indicator light
!
O turned ON: 0V
890: O|
O| O| O O O With immobiliser indicator light
2!!
O|
O| O| O O O 8 Battery voltage
turned OFF:9)&!
O|
O| 13
+ O| PNK/BLK O
>=)> IMOEN (Immobiliser
,8 ;! O Sends immobiliser
! O O|
O| O| O enable signal)
!
!< O enable signal
!
! O O|
O| 14*1 O|
*G GRN/BLK O
.1=)> D4IND (D4 indicator)
(*(;(*< O Drives D4 indicator light O
(&(*!
With D4 indicator light turned ON: OV O|
2(*!
890:
O| O| O O O With D4 indicator light turned OFF:9 O|
2(*!
8
)&!
O|
O| O| O O O O|
O| 15
O| GRN/YEL O
.1=C FLR (Immobiliser fuel O
1;! ! Drives fuel pump relay
(& ! ! O 0V for two seconds after turning
0:3
O|
O| O| O pump relay)
!< O O ignition switch ON (II), then battery O|

38;<A
O| O| O O O voltage
&!
O|
O| 17
$ O| RED
1 ( O ACC (A/C clutch relay) O
%;%=! !< Drives A/C clutch relay O
(&%=! ! With compressor ON:OV
2890: O|
O| O| O O O 28 Battery
With compressor OFF:9) O|
O O O O O voltage
&!
O
O 18
' O GRN/ORN
.1=81 O MIL (Malfunction
,;,! O (&,
Drives MIL O With MIL turned ON: 0V
2, 890: O
O O O indication light)
!
< O O With MIL turned OFF:9)
2, 8 Battery O
O O O O O voltage
&!
O
O 19
5 O BLU
)? O NEP (Engine speed
;
O Outputs engine speed
8
O With engine running: Pulses
2

9 ! O
O O O pulse)
!< O pulse
! O O
O 2O
0 O BLK./WHT
)>-=264 O PHOZSHTCR (Primary O
68641; Drives primary heated
(& O With ignition switch ON (II): Battery O
2
38;<9)
O O O heated oxygen sensor O
/
/
O voltage
&!
O
O O O heater control relay)
!!< O O With fully warmed up engine
2 !!3
O
O O O O O running: 0V

90: O
O 20 *3+ O
0G GRN/RED
.1=1 ( O PHOZSHTCR (Primary O
68641; Drives primary heated
(& O With ignition switch ON (II): 0V
2
38;<90: O
O O O heated oxygen sensor O
/
/
O O
O O O heater control relay)
!!< O relay
! O O
O 21
O GRY
.1C O >
K Line O Sends and receives
& O With ignition switch ON (II): Pulses O
2
38;<9 !
O O O O scan tool signal
!
! O O
*1: NT
G9%=4
*2: WT
G9,=4
*3: F2086
G+9 engine
0)

*4: H22A7 engine
G*96%$

Troubleshootin

*
!g 11 -A-22

%! 2'
(

Arrangement (cont’d)
!/
?0
ECMIPCM CONNECTOR A (32P)

%2',,%/'0
ECMIPCM CONNECTOR A l32Pl
5 I T _‘ _ '3‘. ._ 10 1|
CR5 tn: a LED 3 ‘1'”? my, 3:3:5 no r:
. .'. A . .5" . _ . . h . ._ _
11 1.1 'I- .5 I 11 1s '9 : 22 n 2*

.MI] MD I}! ‘ ._ -
LMP an inn fl" - MIC MIL MP . ' L'“ 5"“ "'35 srs ‘: PH025
' . . _.____.
:"L n. J.‘ 23
. .-
I: HTC R I‘.. I
I“: 5 UP A05 ILL! . w 11 985W F'HUE‘J
HTC“
IWire Sirle female terminals
%,,%/'0
84 9&!
:-
O
Terminal OI Wire Colour O
1

,
Terminal Name O| Description
)
O| Signal
! O
O ,
@
No. O| O O| O| O
O 22 *1
G O| ORN
81 O S-DN (Shift down)
(;3< O| Detects downshift switch O|
(33 In manual mode and shift lever
!!& O
O O| O O| signal

! O| pushed toward downshift position
33 O
O O| O O| O| (marked with “-“): 0V
;#3KK<90: O
O O| O O| O| In manual mode and shift lever in
!!& O
O O| O O| O| neutral position: Battery voltage
!9)&!
O
O 23
+ O| WHT
264 O SHOZS (Secondary
68; O| Detects secondary
( O| With throttle fully opened from idle
2! !!! O
O O| O heated oxygen sensor, O|
/
A heated oxygen sensor
/
O| with fully warmed up engine: Above O
3 !!3
9%&
O O| O sensor 2)
< O| (sensor 2) signal
;<
! O| 0.6V
0-: O
O O| O O| O| With throttle quickly closed: Below O
2!F #!!9)!3
O O| O O| O| 0.4V
0-*: O
O 24
* O| BLU/ORN O
)?=81 STS (Starter switch
4;3 O| Detects starter switch
(3 O| With starter switch ON (II): Battery O
238;<9)
O O| O signal)

!< O| signal

! O| voltage
&!
O
O O| O O| O| 238
With starter switch OFF:90:
0V O
O 25
O| RED
1 ( O IMOCD (Immobiliser
,8(;! O| Detects immobiliser
(! O| O
O O| O code)
< O| signal

! O| O
O 26 *1
G O| WHT/BLU O
264=)? S-UP (Shift up)
?; < O| Detects upshift switch
( 3 O| In manual mode and shift lever
!!& O
O
O
O
I
O
O
O|
O
O
O
O|
O|
O|
signal

! O|
O|
O|
pushed toward upshift position
3
(marked with “+”): 0V
;#3KVL<90:
In manual mode and shift lever in
!!&
O
O
O
O O| O O| O| neutral position: Battery voltage
!9)&!
O
O 27
$ O| BLU/RED O
)?=1 ( ACS (A/C switch signal) |
%;%=3
!<O Detects A/C switch signal O|
(%=3
! With A/C switch ON: 0V
2%=3890: O
O O| O O| O| With A/C switch OFF:9% :
2%=38 About 5V O
O 28 *1
'G O| 264=1 (
WHT/RED O ILU (Interlock control O|
?;!#! (&!#!
Drives interlock control O| With ignition switch ON (II) and
2
38;< O
O O| O unit)
< O|
unit O| brake pedal depressed: Battery
#!9) O
O O| O O| O| voltage
&!
O
O 31 *1
+G O| )1
BRN O S-MODE (Shift mode) O|
,8( ;< ( !
Detects manual mode O| In manual mode (shift lever is
!;!& O
O O| O O| switch signal
3
! O| positioned in manual mode): 0V
!<90: O
O O| O O| O| In other than manual mode: Battery O
!9)
O O| O O| O| voltage
&!
O
O 32
+ O| WHT/BLK O
264=)> BKSW (Brake switch) O|
)>2;)#3< Detects brake switch
(#3 O| With brake pedal released: 0V
2#!!90: O
O O| O O| signal

! O| With brake pedal depressed:
2#!9 O
O| O| O O| O| Battery voltage
)&!
O
*1: NT
G9%=4
*2: WT
G9,=4
Troubleshootin

*
!g 11 -A-23

%! 2'
(

!/
?0
ECM/PCM CONNECTOR B (25P)

%2',,%"/3'0
EGMIPCM CONNECTOR B lZfiPi
‘ 5‘ 3 a a ' l
'5" P61 nu: m1 IL! r mu .5!
I u 1§ 1E 11 13
I9 11 12 u
Kin-e K}: N.” w; Im 2(5),." 53L ['57: L51. [fl-
mg". in 21 22 2) (1;: 25
.1: [G1 vau LG: u»:'- 15w L53~

ECM CONNECTOR B (25P)
%,,%"/3'0
84 9&!
:-
O| Terminal O|
Wire Colour O|
1

,
)
OI Signal
! O|
O| ,
@
No. O| O| O O| O|
O| 1 O| C =)>
YEL/BLK O| |GP1 (Power source)
.;3 < O 3
Power source for the O| With ignition switch ON (II): Battery O|
2
38;<9)
O| O| O| O ECM/PCM control circuit
,=,! O| voltage
&!
O|
O| O| O| O O| 2
38 0V
With ignition switch OFF:90: O|
O| O| )>
BLK O| PG1 (Power ground)
.;3
< O .
Ground for the O| -0:!!
Less than 1.0V at all times O|
,=,! O| O|
O| + O| RED
1 ( O| |NJ2(No.2fue|
";- ! O Drives No. 2 fuel injector
(&- !7 O| With engine running: Pulses
2

9 ! O|
O| O| O| injection)
7< O O| O|
O| * O| BLU
)? O| |NJ3(No.3fue|
"+;-+ ! O Drives No. 3 fuel injector
(&-+ !7 O| With engine running: Pulses
2

9 ! O|
O| O| O| injection)
7< O O| O|
O| O| YEL
C O| |NJ4(No.4fue|
"*;-* ! O Drives No. 4 fuel injector
(&-* !7 O| With engine running: Pulses
2

9 ! O|
O| O| O| injection)
7< O O| O|
I
O| $ O| PNK
> O E-EGR
.1 O Drives EGR valve
(& .1&!& O| With EGR operation during driving O|
2 .1
&

O| O| O O O| with fully warmed up engine: Duty
3 !!3
9( O|
O| O| O| O O| controlled
!! O|
O| O| O| O O| With EGR not operating: 0V
2 .1
90: O|
O| 8 *1
'G O| WHT
264 O| LSA— (A/T Clutch
%;%=4! O NT clutch pressure
%=4! O| With ignition switch ON (II): Pulses O|
2
38;<9 !
O| O| O| pressure control
! O control solenoid valve A
!!&!&% O| O|
O| O| O| solenoid valve A - side) O
!&!&%< power supply negative
3 !
& O| O|
O| O| O| O electrode
! O| O|
O| 59 O| YEL/BLK O|
C =)> |GP2 (Power source)
.;3 < O Power source for the
3 O| With ignition switch ON (II): Battery O|
2
38;<9)
,=,! O| voltage
&!
O|
O| O| O| O O| 2
38 0V
With ignition switch OFF:90: O|
O| 0
1O O| )>
BLK O| PG2 (Power source)
.;3 < O .
Ground for the O| -0:!!
O| O| O ECM/PCM control circuit
,=,! O| O|
O| 11
O| BRN
)1 |NJ1 (No. 1 fuel
O ";- ! O Drives No. 1 fuel injector
2

9 ! O|
O| O| injection)
O 7< O O| O|
O|
12 O| .1=C
GRN/YEL VTS (VTEC solenoid
O :4;:4 ! O (&:4 !
Drives VTEC solenoid O| With engine at low rpm: 0V
2
!390: O|
O| O| valve)
O &!&< O &!&
valve O| With engine at high rpm: Battery
2

9) O|
O| O| O O O| voltage
&!
O|
O| 13
+ O| YEL/GRN
C =.1 ICM (Ignition control
O ,;
! O Sends ignition pulse

! O| With ignition switch ON (II): Battery O|
2
38;<9)
O| O| module)
O !< O O| voltage
&!
O|
O| O| O O O| With engine running: About 10V
2

9% 0: O|
O| O| O O O| (depending on engine speed)
;

< O|
O| 14 *1
*G O| BLU/BLK
)?=)> OPZSW (2nd Oil
O 82;8! O Detects 2nd oil pressure
(! O| With ignition switch ON (II): Pulses O|
2
38;<9 !
O| O| pressure switch)
O 3< O switch
3 O| O|
O| 15 *4 O|
G* RED/BLU
1 (=)? ICSOL (Intake control O
O 8;#! Drives intake control
(&#! O| With engine running, engine speed O|
2

A

O| O| solenoid valve)
O !&!&< O solenoid valve
!&!& O| below 3,950 rpm (min-1): Battery
!3+A50;<9) O|
O| O| O O O| voltage
&!
O|
O| O| O O O| With engine running, engine speed O|
2

A

O| O| O O O| above 3,950 rpm (min-1): 0V
&+A50;<90: O|
O| 16*3+ O
G RED/BLU
1 (=)? O IABSOL (Intake air
%)8;# O: (&%)!
Drives IAB control O With engine running, engine speed
2

A
O
O| O O bypass control
! O !&!&
solenoid valve O below 4,200 rpm (min-1): Battery
!3*A00;<9) O
O| O O solenoid valve)
!&!&< Ol O voltage
&!
O
O| O O Ol O With engine running, engine speed
2

A
O
O| O O Ol O above 4,200 rpm (min-1): 0V
&*A00;<90: O
O| 17*1 O
$G RED
1 ( O LSA+ (A/T clutch
%V;%=4! Ol A/T clutch pressure
%=4! O With ignition switch ON (ll): Pulses
2
38;<9 ! O
O| O O pressure control
! Ol control solenoid valve A
!!&!&% O O
O| O O solenoid valve A + side) Ol
!&!&%V< power supply positive
3 !& O O
O| O O Ol electrode
! O O
O| 18*1 O
'G GRN
.1 O LSB- (A/T clutch
);%=4! Ol A/T clutch pressure
%=4! O With ignition switch ON (ll): Pulses O
2
38;<9 !
! Ol control solenoid valve B
!!&!&) O O
O| O O solenoid valve B - side) Ol
!&!&)< power supply negative
3 !
& O O
O| O O Ol electrode
! O O
O| 19*3+ O
5G BLK/WHT
)>=264 O HO2SHTC (Primary
6864; Ol Drives primary heated
(& O With ignition switch ON (ll): Battery O
2
38;<9)
O| O O /

heated oxygen sensor O| oxygen sensor heater
/
O voltage
&!
O
l .
O| O O heater control)
!< O O With fully warmed up engine
2 !!3
O
O| O O O O running: Duty controlled

9( !! O
O| 2O
0 O BRN/BLK
)1=)> O LG1 (Logic ground)
.;

< Ol Ground for the O Less than 1.0V at all times
-0:!! O
O| O O Ol ECM/PCM control circuit
,=,! O O
O| 21
O WHT/BLU
264=)? O VBU (Voltage back up) Ol
:)?;:!
# < Power source for the
3 O Battery voltage at all times
)&!
!! O
,=,! O O
O| O O Ol Power source for the
3 O O
O| O O Ol DTC memory
(4 O O
O| 22
O BRN/BLK
.;

< Ol .
Ground for the O -0:!!
Less than 1.0V at all times O
,=,! O O
O| 23
+ O BLK/BLU
)>=)? O IACV (Idle air control
%:;!! Ol (&%&!&
Drives IAC valve O With engine running: Pulses
2

9 ! O
O| O O valve)
&!&< Ol O O
O| 24 *1 O
*G BLU/WHT
)?=264 O OPBSW (3rd oil
8+2;+! Ol Detects 3rd pressure
(+ O With ignition switch ON (ll): Battery O
2
38;<9)
O| O O pressure switch)
3< switch
3 O voltage
&!
O
O| 25*1 O
G ORN
81 O LSB+ (A/T clutch
)V;%=4! O| NT clutch pressure
2
38;<9 !
l
O O O pressure control
! O| control solenoid valve B
!!&!&) O O
O O O solenoid valve B + side)|O
!&!&)V< power supply positive
3 !& O O
O| O O O| electrode
! O O
*1: NT
G9%=4
*2: WT
G9,=4
*3: F2086
G+9 engine
0)

*4: H22A7 engine
G*96%$

*
!
Troubleshooting
%! 2'
(

11 -A-24

!/
?0
ECMIPCM CONNECTOR C (31 P)

%2',,%/'0
ECMIPCM CONNECTOR C (31F)
__...:___‘ _. . ..
5 ' 6 i 'J a ‘1 10
x5 ! ALTF_ ECEHLI
I
501 BMW CKPM V11“
l
11 I] | 11 1a v. w : ll]- 19 20 21 22
MCS («ms :
NTIZ.
rams.
.
910025 mums MAP 962 9031 rucp TDEI'I'I PCS
23 75 2r: 2: i 26 2*: JD 31
v55 ' IAT am IFS ; VCC: cP [:vm 5 W'

ECM CONNECTOR C (31 P)
%,,%/'0
84 9&!
:-
O|
Terminal O| Wire Colour O
1

,
)
O Signal
! O|
O| ,
@
No. O| O O| O O|
O| 3
+ O| RED/BLU O
1 (=)? KS (Knock sensor)
>;>#< O| Detects KS signal
(>
! O With engine knocking: Pulses
2
##
9 ! O|
O| 5
O| WHT/RED O
264=1 ( ALTF ;%!
%4 (Alternator FR
1 O| Detects alternator FR
(! 1 O With fully warmed up engine
2 !!3
O|
O| O| O signal)

!< O| signal

! O running: 0V - battery voltage

90:&!
O|
O| O| O O| O (depending on electrical load)
;
!!!< O|
O| O| WHT/BLK O
264=)> EGRL (EGR lift sensor) O|
.1; .1!< Detects EGR valve lift
( .1&!&! O %!9% -:
At idle: About 1.2V O|
O| O| O O| sensor signal

! O O|
O| $ O| GRN/WHT O
.1=264 8G1 (Sensor ground) O|
.;
< . ,%
Ground for MAP sensor O Less than 1.0V at all times
-0:!! O|
\l
O| ' O| BLU
)? O CKPP (CKP sensor P O|
>;> (>
Detects CKP sensor O With engine running: Pulses
2

9 ! O|
O| O| O side)
< O| O O|
O| 5 O| WHT
264 O CKPM (CKP sensor M O|
>,;>, . >
Ground for CKP sensor O O|
O| O| O side)
< O| O O|
O| 1O
0 O| BLU/BLK O
)?=)> VTM (VTEC pressure O|
:4,;:4 Detects VTEC pressure
(:4 O With engine at low engine speed: 0V O|
2
!3
90:
O| O| O switch signal)
3
!< O| switch signal
3
! O With engine at high engine speed:
2

9 O|
O| O| O O| O Battery voltage
)&!
O|
O| 11 *1
G O| RED/BLK O
1 (=)> MCS (Engine mount
,;
O| Drives engine mount
(&
O At idle: 0V
%!90: O|
O| O| control solenoid valve) O|
!!&!&< control solenoid valve
!!&!& O Above idle: Battery voltage
%&!9)&!
O|
O| 13*3+
+G O| WHT
264 O PHOZSHTC+ (Primary O|
6864V; Detects primary heated
( O 2
38;<9)
With ignition switch ON (ll): Battery O|
O| O| O heated oxygen sensor O|
/
/
O voltage
&!
O|
O| O| O heater control + side) O|
!V< voltage
&!
O O|
OI 14 *3+
*G O| RED
1 ( O 68V;
PHOZS+ (Primary O| Detects primary heated
( O With ignition switch ON (ll): Battery O|
2
38;<9)
Oi O: O heated oxygen sensor, O|
/
A oxygen sensor (sensor
/
; O voltage
&!
O|
O O O sensor 1 + side)
V< O| 1)
!
< signal O O|
O| 15*3+
G O| BLU
)? O PHOZS- (Primary
68; O| Detects primary heated
( O With ignition switch ON (ll): Battery O|
2
38;<9)
O| O| O heated oxygen sensor, O|
/
/
; O voltage
&!
O|
O| O| O sensor 1 + side)
V< O| 1)
!
< signal O O|
O| 16
O| WHT
264 O PHOZS (Primary
( O With throttle fully opened from idle
2! !!! O|
O| O| O heated oxygen sensor, O|
/
/
; O with fully warmed up engine: Above O|
3 !!3
9%&
O| O| O sensor 1)
< O| 1)
!
< signal O 0.6V
0-: O|
O| O| O O| O With throttle quickly closed: Below O|
2!F #!!9)!3
O| O| O O| O 0.4V
0-*: O|
O| 17
$ O| RED/GRN
1 (=.1 O MAP (Manifold
,%;,! O| Detects MAP sensor
(,% O With ignition switch ON (ll): About 3VO|
2
38;<9% +:
O| O| O absolute pressure
! O| signal

! O At idle: About 1.0V (depending on
%!9% -0:;
O|
O| O| O sensor)
< O| O
<
engine speed) O|
O| O| O O| O O|
O| 18
' O| GRN/BLK
.1=)> O 8G2 (Sensor ground) O|
.;
< Sensor ground

O -0:!!
O| 19
5 O| YEL/RED
C =1 ( O VCC1 (Sensor voltage) O|
:;&!
< 3 ,%
Power source to MAP O With ignition switch ON (ll): About 5V|O
2
38;<9% :
O| O| O O| sensor
O With ignition OFF:90:
2
8 0V O|
O| O| O O| O O|
O| 20
0 O| GRN
.1 O TDCP (TDC sensor P O|
4(;4( (4(
Detects TDC sensor O With engine running: Pulses
2

9 ! O|
O| O| O <
side) O| O O|
O| 21
O RED
1 ( O TDCM (TDC sensor M
4(,;4(, O| . 4(
Ground for TDC sensor O OI
O| O O side)
< O| O O|
O| 22
O RED/YEL
1 (=C O PCS (EVAP purge
; :%
O| Drives EVAP purge
(& :%
O With engine running, engine coolant O|
2

A
!
O| O O control solenoid valve)
!!&!&< O| control solenoid valve
!!&!& O below 35°C (131 °F)<G+AP
!3+P;+P *3, 65°C O|
O| O O O| O (149°F)<G*9)&!

;*5P *4: Battery voltage O|
O| O O O| O With engine running, engine coolant O|
2

A
!
O| O O O| O above 35°C (131°F)<G+AP
&+P;+P *3, 65°C O|
O| O O O| O (149°F)<G*90:
;*5P *4: 0V O|
O| 23 *2 O
+G BLU/WHT
)?=264 O VSS (Vehicle speed
:;:! O| Detects VSS signal
(:
! O With ignition switch ON (II) and front O|
2
38;<
O| O O sensor)
< O| O wheel rotating: Cycles 0V - about 5V O|
3!
9!0: :
O| O O O| O or battery voltage
&!
O|
O| 25
O RED/YEL
1 (=C O IAT (Intake air
%4;# O| Detects IAT sensor
(%4 O With ignition switch ON (ll): About
2
38;<9% O|
l
O| O O temperature sensor)
< O signal

! O 0.1 - 4.8V (depending on intake air O|
0-*-':;
#
O| O O O O temperature)
< O|
O| 26
O RED/WHY
1 (=26C O ECT (Engine coolant
4;
! O| Detects ECT sensor
( 4 O With ignition switch ON (ll): About
2
38;<9% O|
Oi O O temperature sensor)
< O| signal

! O 0.1 - 4.8V (depending on engine
0-*-':;

O|
O O O O| O coolant temperature)
! < O|
O| 27
$ O RED/BLK
1 (=)> O TPS (Throttle position
4;4! O| Detects TP sensor signal O
(4
! With throttle fully open: About 4.8V O|
2! !!9% *-':
O| O O sensor)
< O| O With throttle fully closed: About 0.5V O|
2! !!!9% 0-:
O| 28
' O YEL/BLU
C =)? O VCCZ (Sensor voltage)
:;&!
< O| Provides sensor voltage O
&&!
With ignition switch ON (ll): About 5V|O
2
38;<9% :
O| O O O| O With ignition switch OFF:90:
2
38 CV O|
O| O O O| O O|
O| 29
5 O YEL
C O CYPP (CYP sensor P
C;C O| (C
Detects CYP sensor O With engine running: Pulses
2

9 ! O|
O| O O side)
< O| O O|
O| 30
+0 O BLK
)> O CYPM (CYP sensor P
C,;C O| . C
Ground for CYP sensor O O|
O| O O side)
< O| O O|
O| 31
+ O GRN
.1 O PSPSW (P/S pressure
2;= O| Detects PSP switch
(3 O At idle with steering wheel in straight O|
%!3
3!

Oi O O switch signal)
3
!< O| signal

! O ahead position: 0V
90: O|
O O O O| O At idle with steering wheel at full
%!3
3! !! OI
O| O O O| O !#9)&!

lock: Battery voltage O|
*1: NT
G9%=4
*2: WT
G9,=4
*3: F2086
G+9 engine
0)

*4: H22A7 engine
G*96%$

Troubleshootin

*
!g 11 -A-25
3
%! 2'
(

!/
?0
%2',,%)/5'0/2
#0
ECM/PCM CONNECTOR D (16p) (A/T only)
F‘CM CONNECTOR D HEFI 1A” only)
1 2 3 4 -,
LC SHE SHE. AWN nan.
u . I at 1B 11 1;
[NPR 5N“ IIHI'JJ fi'lllut HG NM W9;
I] ‘l 1': 1%
aw?" A1") AIPI M55
Wire side female terminal-=5
ECM CONNECTOR D (16P) (AIT only)

%,,%)/5'0/2
#0
84 9&!
:-
O Terminal O
Wire Colour O
1

,
)
O Signal
! O
O No.
,
@ O O O O O
O 1 O YEL
C O LC (Lock-up control
;# ! O Drives lock-up control
(&!# ! O During half and full lock-up conditions, O
(
! !!!# A
O O O solenoid valve)
!&!&< O solenoid valve
!&!& O and during deceleration condition:

!9 O
O O O O O Battery voltage during no lock-up
)&!

!# O
O O O O O condition: 0V
90: O
O O GRN/WHT O
.1=264 SHB (Shift control
6);! O (&!
Drives shift control O Battery voltage in following positions:
)&!
!!3
9 O
O O O solenoid valve B)
!&!&)< O !&!&)
solenoid valve B O 0 1 and 2 positions
O
O O O O O 0 D4 and D3 positions in 1st and 2nd O
))
O O O O O gear

O
O O O O O 0 P, R and N positions
'A, O
O O O O O 0V in following positions:
0:!!3
9 O
O O O O O 0 D4 and D3 positions in 3rd gear
))+
O
O O O O O 0 D4 position in 4th gear
)*
O
O O O O O O
O + O .1
GRN O SHC (Shift control
6;! O (&!
)&!
!!3
9 O
O O O solenoid valve C)
!&!&< O !&!&
solenoid valve C O 0 1 position
O
O O O O O 0 D4 and D3 positions in 1st and 3rd
))+ O
O O O O O gear

O
0:!!3
9 O
O O O O O 0 2 position
O
O O O O O 0 D4 and D3 positions in 2nd gear
))
O
)*
O
'A, O
O O O O O O
O * O RED/BLK O
1 (=)> ATPNP (At gear
%4;%
O Detects A/T gear
(%=4
O In N position: 0V
,90: O
O O O position switch)
3< O position switch signal
3
! O In any other position: Battery voltage
9)&!
O
O O O O O O
O O BLK/YEL
)>=C O VBSOL (Battery
:)8;) O Power source of
3 O With ignition switch ON (II): Battery
2
38;<9) O
O O O voltage for solenoid
&!
! O !&!&
solenoid valve O voltage
&!
O
O O O valve)
&!&< O O With ignition switch OFF:90:
2
38 0V O
O O WHT
264 O ATPR (At gear position O
%41;%
Detects A/T gear
(%=4
O In R position: 0V
90: O
O O O switch)
3< O position switch signal
3
! O In any other position: Battery voltage
9)&!
O
O $ O BLU/YEL O
)?=C SHA (Shift control
6%;! O (&!
)&!
!!3
9 O
O O O solenoid valve A)
!&!&%< O !&!&%
solenoid valve A O 0 2 position
O
O O O O O 0 D4 and D3 positions in 2nd and 3rd O
))+
O O O O O gear

O
0:!!3
9 O
O
O O O O O 0 D4 and D3 positions in 1st gear
))
O
)*
O
'A, O
O O O O O O
O ' O PNK
> O ATPD3 (At gear
%4(+;%
O Detects A/T gear
(%=4
O In D3 position: 0V
)90: O
3< O position switch signal)
3
!< O In any other position: Battery voltage
9)&!
O
O O O O O O
O 5 O YEL
C O ATPD4 (At gear
%4(*;%
O Detects A/T gear
(%=4
)90: O
3
9)&!
O
O 1O
0 O PNK
> O NC (Countershaft
; O Detects countershaft
( O Depending on vehicle speed: Pulsing
(
&!9 !
O
O O O speed sensor)
< O speed sensor signal

! O signal

! O
O O O O O When vehicle is stopped: Approx 0V
2&!9%/0: O
O 11
O RED
1 ( O NM (Mainshaft speed
,;, O Detects mainshaft speed O
( Depending on vehicle speed: Pulsing
(
&!9 !
O
O O O sensor)
< O sensor
O signal

! O
O O O O O When vehicle is stopped: Approx 0V
2&!9%/0: O
O 12
O WHT
264 O NMSG (Mainshaft
,.;, O Ground mainshaft speed O
. O
O O O speed sensor ground)

< O sensor signals

! O O
O 13
+ O BLU/WHT
)?=264 O ATPPN (At gear
%4;%
O Detects A/T gear
(%=4
O In P or N positions: 0V
',90: O
3
9)&!
O
O 14
* O BLU
)? O ATP2 (At gear position
%4;%
O Detects A/T gear
(%=4
O In 2 position: 0V
90: O
O O O switch )
3
9)&!
O
O 15
O BRN
)1 O ATP1 (At gear position
%4;%
O Detects A/T gear
(%=4
O In 1 position: 0V
90: O
O O O switch)
3
9)&!
O
O 16
O GRN
.1 O NCSG (Countershaft
.; O Ground for countershaft O
. O
O O O speed sensor ground)

< O speed sensor
O O
Troubleshooting

*
! _ _
5
Diagnostic Trouble Code (DTC) Chart
) !

*
/)0 11 A 26
O DTC
) O| )

Detection Item O| '
**
Probable Cause OI '! OI
(MIL indication*) O|
O /&
A0 O| O| O|
O P0101 (3)
00;+< Manifold absolute
O| ,!! Open or short in MAP sensor circuit
O| 8,% O| (see
; O|
0999909099.9909909999090090090090
O Pressure circuit
O| MAP sensor
O| ,% Oi !%+5<
page11-A—39) O|
O Low input
O| 3 ECM/PCM
O| ,=, O O|
O P0108 (3)
00';+< Manifold absolute
O| ,!! Open in MAP sensor circuit
O| 8,% O| (see
; O|
O Pressure circuit
O| MAP sensor
O| ,% O| !%*<
page1 1 -A-41) O|
O High input
O| 6
ECM/PCM
O| ,=, O| O|
O P0112 (10) O| #
0;0< Intake air Short in IAT sensor circuit
O| %4 O| (see
; O|
O Temperature circuit
O| 4 IAT sensor
O| %4 O| !%*<
page11-A—42) O|
O Low input
O| 3 ECM/PCM
O| ,=, O| O|
O P0113 (10)
0+;0< Intake air
O| # Open in IAT sensor circuit
O| 8%4 O| (see
; O|
O| 4 IAT sensor
O| %4 O| !%*+<
page11-A—43) O|
O High input
O| 6
ECM/PCM
O| ,=, O| O|
O P0117 (6) O|
!
0$;< Engine coolant Short in ECT sensor circuit
O| 4 O| (see
; O|
O| 4 ECT sensor
O| 4 O| !%**<
page11-A—44) O|
O Low input
O| 3 ECM/PCM
O| ,=, O| O|
O P0118 (6)
0';< Engine coolant
O|
! Open in ECT sensor circuit
O| 8 4 O| (see
; O|
O| 4 ECT sensor
O| 4 O| !%*<
page11-A—46) O|
O O| 6

High input ECM/PCM
O| ,=, O| O|
l
O P0122 (7)
0;$< Throttle position
O| 4! Open or short in TP sensor circuit
O 84 O| (see
; O|
O Circuit
O| TP sensor
O 4 O| !%*$<
page11-A—47) O|
O Low input
O| 3 ECM/PCM
O| ,=, O| O|
O P0123 (7)
0+;$< Throttle position
O| 4! Open in TP sensor circuit
O| 84 O| (see
; O|
O Circuit
O| TP sensor
O| 4 O| !%*5<
page11-A—49) O|
O High input
O| 6
ECM/PCM
O| ,=, O| O|
O (1) O| /

P0131 *4*;<
0+G Primary heated oxygen sensor Short in Primary H028 (Sensor 1) circuit
O| 68;< O| (see
; O|
O O| !3&!

Circuit low voltage Primary H028 (Sensor 1)
O| 68;< O| !%0<
page11-A—50) O|
O (Sensor 1)
O| ;< O| Fuel supply system
! ! O| O|
O O| O| , O| O|
O 0+G * (1)
P0132 *4 ;< O| Primary heated oxygen sensor |
/
O Open in Primary H028 (Sensor 1) circuit
868;< O| (see
; O|
O Circuit high voltage
O|
&!
Primary H028 (Sensor 1)
O| 68;< O| !%<
page11-A—52) O|
O (Sensor 1)
O| ;< ECM
O| , O| O|
O 0++G (61) O| /

P0133 *4*;< Primary heated oxygen sensor Primary H028 (Sensor 1)
O| 68;< O| (see
; O|
O Slow response
O| !3 Exhaust system
O| / O| !%+<
page11-A—53) O|
O (Sensor 1)
O| ;< O| O| O|
O 0+G (41) O| /

P0135 *4*;*< Primary heated oxygen sensor 0 Open or short in Primary H028 (Sensor 1)
O| 868;< O| (see
; O|
O Circuit malfunction
O| ! heater circuit
O| O| !%<
page11-A—62) O|
O (Sensor 1)
O| ;< 0 ECM
O| , O| O|
O P0137 (63)
0+$;+< 0 Open or short in Secondary H028 (Sensor 2) O|
Secondary heated oxygen sensor|O 868;<
O| /
(see
; O|
O| ! heater circuit
O| O| !%5<
page11-A—59) O|
O (Sensor 2)
O| ;< 0 Secondary H028 sensor
O| 68 O| O|
O O| 0 ECM
O| , O| O|
O P0138 (63)
0+';+< O| /
0 Open or short in Secondary H028 (Sensor 2) O|
Secondary heated oxygen sensor|O 868;< (see
; O|
O| ! heater circuit
O| O| !%0<
page11-A—60) O|
O (Sensor 2)
O| ;< 0 Secondary H028 sensor
O| 68 O| O|
O O| 0 ECM
O| , O| O|
O P0139 (63)
0+5;+< O| /
0 Secondary H028 sensor
Secondary heated oxygen sensor|O 68 O| (see
; O|
O| ! O| O| !%<
page11-A—61) O|
O (Sensor 2)
O| ;< O| O O|
*: These DTCs are indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the 808 short connector connected.
G94(4!#
,! ;,<3-
**: The
GG94 indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.
!
,! ;,< ! !-
*1: NT
G9%=4
*2: WT
G9,=4
*3: F20B6
G+9 engine
0)

*4: H22A7 engine
G*96%$

Troubleshooting

*
! 11 -A-27
7
) !

*
/)0 (cont’d)
/
?0
O| DTC
) O| Detection Item
)
O| Probable Cause
'
** OI Page
'! O|
O| /&
A0
(MIL indication*) O| O| O| OI
O| P0141 (65)
0*;< O| /

Secondary heated oxygen sensor O| 868;<
0 Open or short in secondary HO2S (Sensor 2) O| (see
; OI
O| O| !
Circuit malfunction O|
heater circuit O| !%<
page11-A—62) OI
O| O| ;<
(Sensor 2) 0 ECM/PCM
O| ,=, O| O|
O| O| O| O| O|
O| P0171 (45) O| !
0$;*< System too lean O| Fuel supply system
! ! O| (see
; OI
09090090909099.909909090
O| O| O| 68;<
Primary HO2S (Sensor 1) O| !%$<
page11-A—67) OI
O| O| O| ,%
MAP sensor O| O|
O| O| O| !
Contaminated fuel O| O|
O| O| O| :!&!
Valve clearance O| O|
O| O| O| / !#

Exhaust leakage O| O|
O| P0172 (45) O|
0$;*< System too rich O| Fuel supply system
! ! O| (see
; OI
O| O| O| 68;<
Primary HO2S (Sensor 1) O| !%$<
page11-A—67) OI
O| O| O| ,%
MAP sensor O| O
O| O| O| !
Contaminated fuel O| O
O| O| O| :!&!
Valve clearance O| O
O| 0+00
P0300 and some O| 1
Random misfire O|

Ignition system O| ; O
O|
of O| O| Fuel supply system
! ! O| !%5< OI
O| P0301 (71
0+0;$< O| O| 68;<
Primary HO2S (Sensor 1) O| OI
VVVV
O| P0302 (72
0+0;$< O| O| ,%
MAP sensor O| OI
O| P0303 (73
0+0+;$+< O| O| .1
EGR system O| OI
O| P0304 (74
0+0*;$*< O| O| %&!&
IAC valve O| OI
O| O| O| !
Contaminated fuel O| OI
O| O| O| # !
Lack of fuel O| OI
O| P0301 (71
0+0;$< O| !
- Cylinder 1 O| Fuel injector
!7 O| (see
; OI
VVVV
O| P0302 (72 O| !

0+0;$< - Cylinder 2 O| Fuel injector circuit
!7 O| !%$0<
page11-A—70) OI
O| P0303 (73 O| !+
0+0+;$+< - Cylinder 3 O|

Ignition system O| OI
O| P0304 (74 O| !*
0+0*;$*< - Cylinder 4 O| 3
Low compression O| OI
O| O| ,
Misfire O| :!&!
Valve clearance O| OI
O| O| (
Detected O| O| OI
O| P0325 (23) O| >#;><
0+;+< Knock sensor (KS) circuit O| 8>#;><
Open to short in Knock sensor (KS) circuit O| (see
; OI
09999090
O| O| ,!
Malfunction O| >#;><
Knock sensor (KS) O| !%$+<
page11-A—73) OI
O| O| ECM/PCM
O| ,=, O| OI
O| P0335 (4) O| #
0++;*< Crankshaft position O| #
Crankshaft position sensor O| (see
; OI
O| O|
Sensor circuit O| #
Crankshaft position sensor circuit O| !%$*<
page11-A—74) OI
O| O| 3
Low input O| ,=,
ECM/PCM O| OI
O| P0336 (4) O| #
0++;*< Crankshaft position O| #
Crankshaft position sensor O| (see
; OI
O| O|
Sensor O| 4
!#
Timing belt skipped teeth O| !%$*<
page11-A—74) OI
O| O| 1
=
Range/performance O| O| OI
O| P0401 (80) O| /

0*0;'0< Exhaust gas O| .1&!&
0 EGRvalve O| (see
; OI
O| O| 1 !
Recirculation O| .1!
0 EGRIine O| !%+5<
page11-A—139) OI
O| O| !3
Insufficient flow despatched O| O| OI
O| P0420 (67)
0*0;$< O| !
Catalyst system O| 43!&
0 Three way catalytic converter O| (see
; OI
O| O| !3
Efficiency below O| 68;<
0 Secondary HO2S (Sensor 2) O| !%+$<
page11-A—137) OI
O| O| 4!
Threshold O| O| OI
O| P0443 (92)
0**+;5< O| &&; :%<
Evaporative emission (EVAP) O| 8&&; :%<
0 Open or short in evaporative emission (EVAP) O| (see
; OI
O| O|
!!&!&
Purge control solenoid valve O|
!!&!&
purge control solenoid valve circuit OI !%*<
page11-A—145) OI
O| O| !
Circuit malfunction O| &&; :%<
!
0 Evaporative emission (EVAP) purge control O| OI
O| O| O| !&!&
solenoid valve O| OI
O| O| 0 ECM/PCM
O| ,=, O| OI
*: These DTCs are indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the SOS short connector connected.
G94(4!#
,! ;,<3-
**: The
!
,! ;,< ! !-
*1: NT
G9%=4
*2: WT
G9,=4

*
!
Troubleshooting
) !

*
/)0 (cont’d)
/
?0
11 -A-28
8
O DTC
) O )

Detection Item O '
**
Probable Cause O Page
'! O
(MIL indication*) O
O /&
A0 O O O
O P0500 (17)*2 O :!
000;$<G Vehicle speed Vehicle speed sensor
O :! O (see
; O
O Sensor circuit
O Vehicle speed sensor circuit
O :! O !%$$<
page11-A—77) O
O Malfunction
O ,! ECM
O , O O
P0715 (70)*1** O %
O 0$;$0<GGG Automatic O O *
Section 14 O
P0720 (70)*1** O 4/!
O 0$0;$0<GGG Transaxle O O O
P0730 (70)*1** O
O 0$+0;$0<GGG O O O
P0753 (70)*1** O
O 0$+;$0<GGG O O O
P0758 (70)*1** O
O 0$';$0<GGG O O O
P0763 (70)*1** O
O 0$+;$0<GGG O O O
O P1107 (13) O )
0$;+< Barometric ECM/PCM (Baro sensor)
O ,=,;)< O (see
; O
O Pressure circuit
O O O !%$'<
page11-A—78) O
O Low input
O 3 O O O
O P1108 (13) O )
0';+< Barometric ECM/PCM (Baro sensor)
O ,=,;)< O (see
; O
O Pressure circuit
O O O !%$'<
page11-A—78) O
O High input
O 6
O O O
O P1149 *3+;<
*5G (61) O /

Primary heated oxygen sensor Primary H028 (Sensor 1)
O 68;< O (see
; O
O (Sensor 1)
O ;< ECM/PCM
O ,=, O !%*<
page11-A—54) O
O Circuit range/performance
O
= O O O
O problem
O ! O O O
O P1162*3+;*'<
G (48) O /

Primary heated oxygen sensor Open or short in Primary H028 (Sensor 1)
O 868;<
0 O (see
; O
O (Sensor 1)
O ;< O
circuit page11-A—55)
O !%< O
O ! Primary H028 (Sensor 1)
O 68;<
0 O O
O O ECM/PCM
O ,=,
O O O
O P1163*3+;<
+G (61) O /

O 68;<
O O (see
; O
O (Sensor 1)
O ;< ECM/PCM
O ,=,
9 O !%$<
page11-A—57) O
O Circuit slow response
O !3 O O O
O P1164*3 (61) O /

*G+;< Primary heated oxygen sensor Primary H028 (Sensor 1)
O 68;< O (see
; O
O (Sensor 1)
O ;< ECM/PCM
O ,=, page11-A—58)
O !%'< O
O Circuit/range/performance
O =
= O O O
O problem
O ! O O O
O P1165*3+;<
G (61) O /

O 68;< O (see
; O
O (Sensor 1)
O ;< ECM/PCM
O ,=, O !%*<
page11-A—54) O
O Circuit range/performance
O
= O O O
O problem
O ! O O O
O P1166*3+;*<
G (41) O /

O 868;<
0 O (see
; O
O (Sensor 1)
O ;< O
circuit O !%*<
page11-A—64) O
O Heater system electrical problem O 68;<
O 6!!! 9 Primary H028 (Sensor 1) O O
O O ECM/PCM
O ,=,
9 O O
O P1167*3+;*<
$G (41) O /

O 868;<
0 O (see
; O
O (Sensor 1)
O ;< O
circuit page11-A—66)
O !%< O
O Heater system malfunction
O 6! Primary H028 (Sensor 1)
O 68;< O O
9090990
O O ECM/PCM
O ,=, O O
O P1259 (22) O :4 !
5;< VTEC system malfunction VTEC Solenoid valve
O :4 !&!& O Section 6
O
O O Open or short in VTEC solenoid valve circuit
O 8:4 !&!& O O
O O VTEC pressure switch
O :4 3 O O
O O Open or short in VTEC pressure switch circuit O
O 8:4 3 O
O O ECM/PCM
O ,=, O O
*: These DTCs are indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the 808 short connector connected.
G94(4!#
,! ;,<3-
**: The
!
,! ;,< ! !-
*1: NT
G9%=4
*2: WT
G9,=4
*3: F20B6
G+9 engine
0)

*4: H22A7 engine
G*96%$

*
!
Troubleshooting
) !

*
/)0 (cont’d)
/
?0
11 -A-29
9
O DTC
) O )

Detection Item O '
**
Probable Cause O Page
'! O
(MIL indication*) O
O /&
A0 O O O
O P1359 (8) O #=
+5;'< Crankshaft position/top CKP/TDC sensor circuit
O >=4( O (see
; O
O Dead center sensor
O ( O O !%$<
page11-A—76) O
O Connector disconnection
O O O O
O P1381 (8) O 4
+;'< Top dead center O 4(
TDC sensor O (see
; O
O Sensor intermittent
O O O !%$*<
page11-A—74) O
O Interruption
O O O O
O P1382 (8) O 4
+;'< Top dead center O 4(
TDC sensor O (see
; O
O Sensor no signal
O
! O 4(
TDC sensor circuit O !%$*<
page11-A—74) O
O O ECM/PCM
O ,=, O
O P1381 (8) O !
+';'< Cylinder position sensor O C
CYP sensor O (see
; O|
O Intermittent interruption
O O page11-A—79) O|
O !%$5<
O O O O O|
O P1382 (9) O !
+';5< Cylinder position sensor O C
CYP sensor O (see
; O|
99099099090999.
O No signal
O
! O C
CYP sensor circuit page11-A—79) O|
O !%$5<
O O ECM/PCM
O ,=, O O|
O P1491 (12) O .1&!&
*5;< EGR valve EGR valve (with lift sensor)
O .1&!&;3!< O (see
; O|
O O
Lift insufficient EGR valve lift sensor circuit
O .1&!&! page11-A—140) O|
O !%*0<
O O (
Detected EGR valve circuit
O .1&!& O O|
O O EGR line
O .1! O O|
O O ECM/PCM
O ,=, O O|
O P1498 (12) O .1&!&
*5';< EGR valve EGR valve (with lift sensor)
O .1&!&;3!< O (see
; O|
O Lift sensor
O EGR valve lift sensor circuit
O .1&!&! page11-A—142) O|
O !%*<
O High voltage
O 6
&!
ECM/PCM
O ,=, O O|
O P1519 (14) O !!
5;*< Idle air control O %&!&
IAC valve O (see
; OI
l
O O :!&
Valve circuit O %&!&
IAC valve circuit O !%'*<
page11-A—84) O
O O Failure
! ECM
O , O O
O P1807 (-) O
!
0$;< Engine control ECM/PCM
O ,=, O (see
; O|
O Module/power control module
O , !=3! ! O page1 1 -A-81) O|
O !%'<
O internal
O ! O O O|
O Circuit failure A
O ! % O O O|
O P1750 (70)** O %
$0;$0<GG Automatic O O Section 14 O|
*
O P1708 (70)** O 4/!
$0;$0<GG Transaxle O O Ol
O P1738 (70)** O
$+';$0<GG O O O
O P1739 (70)** O
$+5;$0<GG O O O|
O P1753 (70)** O
$+;$0<GG O O O|
O P1788 (70)** O
$';$0<GG O O O|
O P1773 (70)** O
$$+;$0<GG O O O|
O P1791 (70)** O
$5;$0<GG O O O|
*: These DTCs are indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the SOS short connector connected.
G94(4!#
,! ;,<3-
**: The
!
,! ;,< ! !-
*1: NT
G9%=4
*2: WT
G9,=4
PGM-FI System
'+# 11 -A-30
$
System Description
#)
ENGINE CONTROL MODULE lECMIr'

POWERTRAIN CONTROL MODULE
INPUTS IPCMI OUTPUTS
: TDCi‘CKF’ Sensor
CYF‘ Sensor Fuel Injectors
MAP Sensor F'GM-FI Main Helav [Fur-2| Pump}
ECT Sensor MIL
IAT Sensor IAC Valve
TFI Sensor All: Compressor Clutch Fielay
EGR Valve Lift Sensor DLC

lFuel Injector Timing and Duration . -- — If
H023 Condenser Fan Relay
1 V5 5” ICM
Electronic Idle Control
BA R0 Sensor EVAP Purge Control Solenoid Valve
KS IOther Control Functions 3 H025 Heater
Starter Signal EGH valve
ALT FFi Signal Ignition Timing Control IAB Control Solenoid Valve”
Air Conditioning Signal Intake Control Solenoid Valve“
A‘T Gear Position Signal" ECM'PCM Back—up Functions Engine Mount Control Solenoid Valve"
Battery ll.i'oltalgie (IGN. 1i" VTEC Solenoid Valve
NT Control Function5 VSS Signel‘1
Brake Switch Signal
A
PSF' Switch Signal Lock-up Control Solenoid Valve“
Service Check Signal Shift Control Solenoid 'v’alve’1
CRS Signal‘1 AFI' Clutch Pressure Control Solenoid
Mainshaft Speed Sensor“ il'alve'1
Countershef‘t Speed Sensor" Dd indicator Light"

Encli'flrd Clutch Pressure Switch Tachometer Signal
Signal"
'1:A.'T '3: F2036 engine

'2: MIT *4: H22A7 engine
PGM-FI System
'+#
The PGM-Fl!F ! ! !7-
4., system on this model is a sequential multiport fuel injection system.
Fuel Injector Timing and Duration
+D
!)

The ECM/PCM contains memories for the basic discharge duration at various engine speeds and manifold pressures. The
4 ,=,
&
! -4
basic discharge duration, after being read out from the memory, is further modified by signals sent from various sensors to

A
A
!&
obtain the final discharge duration.
!
-

Idle Air Control
When the engine is cold, the A/C compressor is on, the transmission is in gear *1, the brake pedal is depressed, the P/S load
2
!A%=A
GA#!A=!
is high, or the alternator is charging, the ECM/PCM controls current to the IAC Valve to maintain the correct idle speed.

A!

A ,=,! %:!&!-
Ignition Timing Control
!
!

¢ The ECM/PCM contains memories for basic ignition timing at various engine speeds and manifold air flow rates. Ignition
4 ,=,

&
!!3-

timing is also adjusted for engine coolant temperature.

!7
! -
¢ A knock control system is also used. When detonation is detected by a knock sensor (K8), the ignition timing is retarded.
%##!! -2##;><A

-
PGM-Fl System
'+# 11 -A-31

System Description (cont’d)
#)
/
?0

+

Other Control Functions
1.
!
- Starting control
When the engine is started, the ECM provides a rich mixture by increasing fuel injector duration.
2
A ,&/
!7 -
2. Fuel
- Pump Control
! !
0 When the ignition switch is initially turned ON (II), the ECM/POM supplies ground to the PGM-Fl!
2
3!! 8;<A ,=, !
., main relay that
supplies current to the fuel pump for two seconds to pressurise the fuel system.
! ! 3 !-
0 When the engine is running, the ECM/PCM supplies ground to the PGM-Fl! ! !
2

A ,=, !
., main relay that supplies current to the fuel
pump.
-
0 When the engine is not running and the ignition is ON (II), the ECM/PCM cuts ground to the PGM-Fl!A
2

8;<A ,=,
., main relay,
which cuts current to the fuel pump.
3 ! -
+- Fuel Cut-off Control
! !
0 During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at
(
!3!&!&!A !7 & !
speeds over 1,100 rpm (min
&A00; '1).
<-
0 Fuel cut-off action also takes place when engine speed exceeds 6,500 rpm (min-1):
! !#!3
/A00; <9 F2086 engine, 7,700 rpm (min-1):
0)
A$A$00; <9
H22A7 engine, regardless of the position of the throttle valve to protect the engine from over-revving.
6%$
A
!!&!&
&&&
-
A/C Compressor Clutch Relay
*- %=! 1!
When the ECM/POM receives a demand for cooling from the air conditioning system, it delays the compressor from being
2 ,=,&!

A!
energised, and enriches the mixture to assure smooth transition to the A/C mode.

A/ %=-
Intake Control Solenoid Valve *4*
- #!!:!&G
When the engine speed is below 3,950 rpm (min-1),
2
!3+A50; the ECM supplies a ground to the intake control solenoid valve. This
<A , !
#!!&!&-4
opens the solenoid valve sending intake manifold vacuum to the intake control diaphragm.
!&!&
#!& #!
-
Intake Air Bypass (IAB) Control Solenoid Valve *3+
- #%);%)<!!:!&G
When the engine rpm is below 4,200 rpm (min-1), the IAB control solenoid valve is activated by a signal from the
2
!3*A00;<A%)!!&!&&
!
ECM/PCM, intake air flows through the long intake path, then high torque is delivered. At speeds higher than 4,200 rpm
,=,A#!3
!
#A
F !&-%
*A00
(min-1),
; the solenoid valve is deactivated by the ECM/PCM, and intake air flows through the short intake path in order to
<A!&!&& ,=,A#!3
#
reduce the resistance in airflow.
!3-
Evaporation Emission (EVAP) Purge Control Solenoid Valve
$- & ; :%<
!!:!&
When the engine coolant temperature is above 55°C (131 °F):
2
! &P;+P <9 F2OB6 engine, 65°C (149°F):
0)
AP;*5P H22A7 engine, the ECM/PCM
<96%$
A ,=,
supplies a ground to the EVAP purge control solenoid valve which controls vacuum to the EVAP purge control canister.
!
:%
!!&!&3!& :%
!-
Exhaust Gas Recirculation (EGR) Control Solenoid Valve
'- / .1 !; .1<!!:!&
When the EGR is required for control of oxides of nitrogen (NOx) emissions, the ECM/POM controls the EGR valve.
2 .1F !/
;8/<A ,=,! .1&!&-
PGM-Fl System
'+# 11 -A-32

#)
/
?0
ECM/PCM Fail-safe/Back-up Functions

%2'+ 2"6+

1. Fail
- safe Function
!
When an abnormally occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-programmed
2!!
!A ,=,

!

value for that sensor that allows the engine to continue to run.
&! !!3
-
Back-up Function
- )#
When an abnormally occurs in the ECM/PCM itself, the fuel injectors are controlled by a back-up circuit independent of the
2!! ,=,!A !7!!#
system in order to permit minimal driving.
!&
-
+- !
(Malfunction Indicator Lamp (MIL)
;,! ;,<
When an abnormally occurs in a signal from a sensor, the ECM/PCM supplies ground for the MIL and stores the code in
2!!
!A ,=, !
,
erasable memory. When the ignition is initially turned ON (II), the ECM/PCM supplies ground for the MIL for two seconds
!-2
!! 8;<A ,=, !
,3
to check the MIL bulb condition.
#, !-
Two Driving Cycle Detection Method
*- 43(&
!(,
To prevent false indications, the "two driving cycle detection method" is used for the EGR system and other self-diagnostic
4&!AZ3&
!Z .1!

functions. When an abnormally occurs, the ECM/PCM stores it in it‘s memory. When the same abnormally re-occurs after
-2!! A ,=,@-2!!
the ignition switch is turned OFF 8;<
A ,=,&
,-

3 8 and ON (ll) again, the ECM/PCM informs the driver by turning on the MIL.
PGM-Fl System
'+# 11 -A-33

.
(
+
(
A flowchart is designed to be used from start to final repair. It’s like a map showing you the shortest distance. But beware: if
%!3
!-B!#3
-) 39
you go off the "map” anywhere but a “stop” symbol, you can easily get lost.

KL3 KL!A !
!-
START Describes the conditions or situation to start a troubleshooting flowchart.
( !
!3-
[bold type]
Asks you to do something; perform a test, set up a condition etc.
%#
NA -
/—\ Asks you about the result of an action, then sends you in the appropriate
%# !A
EZIEIIZI EillCZIN troubleshooting direction.
!
-
The end of a series of actions and decisions, describes a final repair action and
4A!
[hold WW] sometimes directs you to an earlier part of the flowchart to confirm your repair.
!!3 -
NOTE:
84 9
¢ The term “Intermittent Failure”
4K is used in these charts. It simply means a system may have had a failure, but it checks out
! L -!&! A #
OK at this time. If any indicator light on the dash does not come on, check for poor connections or loose wires at all
8>-!
A#!3!!
connectors related to the circuit that you are troubleshooting (see illustration below).
! !
;!! !3<-
¢ Most of the troubleshooting flowcharts have reset control module(s) or unit(s) and try to duplicate the Diagnostic Trouble
, !
!3&! !;< ;< !(
4 !
Code (DTC). If the problem is intermittent and you cannot duplicate the code, do not continue through the flowchart. To do
;(4<-! !A
!3-4
so will only result in confusion and, possibly, (a) needlessly replace control module(s) or unit(s).
3!!! ! A!A;<!!!! !;< ;<-
¢ “Open" and “Short” are common electrical terms. An open is a break in a wire at a connection. A short is an accidental
K8LKL!!-%#3-%!
connection of a wire to ground or to another wire. In simple electronics, this usually means something will not work at all.
3
3-!!A !!
3!!3#!!-
In complex electronics, this can sometimes mean something works, but not the way it is supposed to.
!/!A
3#A 3 -
TlGHT
PGM-Fl System
'+#
Engine Control Module/Powertrain Control Module
%!

2'
(

11 -A-34

(ECM/PCM)
/%2'0
NOTE
I lfthis symptom is irtermittert, checkfor.
AlmseACGS l15AjlfLse irthe Lreer-hmefLsekelary box.
Noose No 9 BACK UP LIGHT INSTRUMENT LlGl-IT [ISA]
fL.se ir the criver's cer-cash fLSE.’TE|EIy tour
The Malfunction Indicator Lamp Almse No. 1 FUEL PUMP I115AjlfLse ir the eri'ueI‘s cer—eash
[MIL] never comes on (even for fLseI'reIay bur
two seconds} after ignition is Ar irtermittert shut ir the wire betweer the ECM"PCM [MB]
turned ON Ill}. :rcthe gauge assembly
Ar irtermittert short ir the wire betweer the ECM"PCM [I319],
arc the IMP sersor, cmnershaft speee sersor
Ar irtermlttert short ir the wire betweer the ECM'PCM [I323],
Check the inertia switch:
arc the TF' sersor, the EGR 'ua‘ue lift sersor, mairshd‘t speee sersor
1. Pressthe irertia switch bLttor.
PGMFI mair relay
2. ’e the igritior switch CN Ijll}.
Doesthe MIL come or for two

lnten-nittent failure, system is OK
secerds alter igr itior switch
at this time.
teecl CN ill}?
NO
IN ERTIA SWITCH 3P CONNECTOR
INERTIA
SWITCH l '1 2 3 | t
Check the inertia switch:
1 . Discerrnect the irertia sw'rtch
3P oer rector.
. Correct the irertia switd‘ 3P [REDJBLK) [REDJ'WHD
oerrectertermirals No. 1 ard
No. 3 with a e‘tperwire. JUMPER WIRE
’ermiral side of male termir als
Does the MIL Dome or for two
-. seccrds alter igritior switch Repla ce the inertia switch.
""-..___tL.rred ON I: ll}?
NC
— Repair short or open in the wire
between No.9 BACK UP LIGHT
NC INSTRUMENTLIGHT[7.5A)
Is the low oil pressue light or? fuse and gauge assembly
— Replace No.9 BACK UP LIGHT
YE 4"
\J INSTRUMENTLIGHTIIEA) Ibse.
ECMJPCM CON N ECTOR A [32F]
f 39 ‘U
Ill—“Br? 05 E‘-
E.“
.4._
Try to start the er gire. ‘9 2B 2‘ 22 23 241
25.: 2h 3‘ 32
Check for an open in the wire or MIL IGRNIORN]:

bulb I MIL line): JUMPER WIRE
—~\ YES 1. "'e the igritior switch OFF.
< Does the ergire start? _. — Wire side of few ale
2. Correct the ECIvll’PCM
correotor tenriral1‘x18to body tern‘ir als
NO 3 grourd with ajLIrperwire.
TL.rr the igritier switch ON [II].
NC
K. IstheMlLer'?
- Repair open in the wires

bemeen ECI'IIIPCM [A1 8} and
gauge assentlyt
[To page 11-A-35'; - Replace the MIL bulb.
YES
PCM and reoheok (see page 11 -A-1 E-
Ior immobilizer informaion]. ll'
symptomlindioation goes away.
replaoethe original ECMPCM.
PGM-Fl System
'+#
Engine Control Module /Powertrain Control Modu le
%!

2'
(

11 -A-35
3
(ECM/PCM) (cont’d)
/%2'0/
?0
(From page 11-13-34}
1, 'e' the igr‘itior‘ switch ICFF.

2, lr'speot AGES (15i fl.se ir the
Lhder-h ood iselrelay box.
- Repair short in the wire

between ACGS (15A) fuse
IsthefLse CK?
and PGM-Fl n1ain relay.
YES - Replace ACGS [1 5A) fuse.
lhspect No. 1 FUEL PUMP (15A;

fLse ir' the eer-dash fLselrelay
box.

between No.1 FUEL PUMP
—\.. NC (15A) fuse and PGM-Fl main
*2 lsthe fLse CK? ';—' relay
- Replace No.1 FUEL PUMP
YES
(15A) fuse.
IGP‘l ECMJPCM CONNECTOR B [25F]

(YELJBLK) 4
Check for an open in the wires 2 : J i H
L'"
.5. f‘
"GP lin es): 5 ‘U
L'"
2C
1-?
1_ Discorrect the fLel irjedor ar‘d ‘5 22 23 24 23
IAC valve correctors. P
.'| . [17'] IGP2
2_ 'Lrh the igr itior switch CN Ijll}. ' " " I‘I'ELJBLK}
uf—qfl
3_ l'uleaSLre voltage betweer‘

body groe ard ECMIPCM W1 re side of female terl‘tir‘ als
cohhectcr ten‘tirals B1 ar‘d BE!
ircl'r-xiclL. ally
- Repair open in the wirels)
between ECMIPCM [81, BS)
:w
and PGM-FI main relay.
Check for poor connections
Is there batteryvoltage?
or loose wires at the PGM-FI
YES main relay.
Test the PGM-FI main relay
(see page11-A-111).
check for an open in the wire
(PG, LG lines]: PG1 [am
1. Reocr'r'ecuhe fLEI irjeclcr
a"cl INC value ocrreclcrs. 3 4 t f
J .4 . n .fi .5 .5
2. MeaSLre voltage betweer bod;
goLr'cl arcl ECMIPCM oorreclor 2 22 23 24 2t
terrr'ir'als BE. B10. 520 arcl 322 ($9 t? Lo: [BRNIEL K]:
ir' dividl. ally.
L=G1 [Erwin
Repair open in the wirels}
between ECMIPCM and G101
NC
*2 Istherelessthar' 1.0 V? )— (located at the left side of the
intake manifold) that had more
YES than 1.0 V.
l'o page 1-13-36}

PGM-Fl System
'+#
%!

2'
(

11 -A-36
5
/%2'0/
?0
ECMIPGM CONNECTOR G [31H

Ll {ifii HE‘U
.3.4. ‘fi‘r"li‘§2[l 2.22
II."
Check for a short in the wires 23 2E; BE 2.!" EB 25 3E 3'
WCCLUCCZ lines):
MeaSLre voltage bet-seer body Check for a short in a sensor: vccz all. VICE-1
gree ard ECMIPCM corrector "M‘ile measuirg voltage betweer {YE LJE LU] WE URE D]
terl'tir'als C1 9 ard C28 irdiu‘idLally body grourd ard ECMJ'PCM
correct orte nnir‘als 0'19 ar d 028 Wire side of female terl'tir'als
ir‘ diu'idLally. discor‘r‘eot the 3P
NC corrector of ead‘ sersor ore at
4 Is tl‘ere approx. 5 V? :— a time.
- MAP ser‘sor
YES - ‘P sersor
- EGR valve
- Mair si‘alt speed ser‘sor life";
— Courtersi‘alt speed ser‘ sor IZN'}
—- NC
Is ti‘ere approx. 5V?
Substitute a known-good ECM! YES

PGI‘I'I and recheck [see page 11-11-16
for in‘rnohiliaer information). If
synnptomi'indication goes away, Replace the sensor that had
replace the original ECIWPIWI. approx. 5 V.
Repair short inthe wire between

MAP sensor. TP sensor. EGRvalue.
mainshaft speed sensor (N11.
countershaft speed sensor W11
and ECWPCM:C1B.C28].
PGM-Fl System
'+# 11 -A-37
7
%!

2'
(

/%2'0/
?0
The Malfunction Indicator Lamp

[MIL] stays on or comes on after
two seconds.
NOTE
I Vuher there is he ciagrcstic Trt‘Je Ccce tDTC] storec. the MIL will stay- cr' if
the SCS short correctcr is correctec arc the igriticr switch is ON [II].
Check the Diagnostic Trouble ' Ifthis symptcrrr i5 irterrn ittert, check for: .
Code [91-9,]: - Ar rrterrn rttert short rr the wire betweer the ECMrPCM [MD]
1. Current a scar‘ tcol cf Hor‘ca arc the service check ccrrector
PGM tester - Ar irterrn ittert short ir the wire betweer the ECM‘PCM [ME] arc the gage
2. TLIT‘ the igr'iticr' switch ON til}. assembly
3. Rear: the DTC with the scar tool 0 See the scar tool or Hcrca PGM Tester Lser's marLalsfcr specific
crHcrcaPGi'ttlteaen cperetir‘g ir‘strccticrs.
_ . _. . YES Gototroubleshootinqproeedures
“C We 6WD Cr® (see page11-A-15).
NC
Check the DTC by MLindieation:

1, IN the ighitior switch OFF.
2, Correct the 865 short
oohhectorto the service check
corhedor.
3_ 'e‘ the ighitioh switch CN fill}.
—|— - Repair open or short in wire
YES between the ECMPCM (A21)
-::_ Does the MIL ihcicate ar‘y DTC? :3.»— and Data Link Connector.
"'--"'—— - Go to troubleshooting procedure
NC (see page11-A-15)
_|"y' to start the er gire
Substitute a known-good ECMPCM

w and rech eck (see page11-A-1B
C DOES the ergire start? torimmobilizer information. If
—"' syrnptomlindicaticn goes away.
YES replace the origind ECMPCM.
Check for a short in the wire tcr-trPcr-t cow NEG [on ,1 (32m
[365 line}:
see (are N]
1. 'e' the igritior switch CFF
ar'cite' the igritior switch a e ‘c
p
E!
CNUII- '2'3 4'2 '.-"e'szc2‘22 23 24

2 Meascre voltage hem-ear body 2:,- 25 2; 23 3: 32
groLr'd ar tithe EClu'lr'PClu'l — ”——
correctortennir‘alr‘xtfl.
Wire side c11ert'ale1errt'rnels
NC Repa‘r shorttc body ground in

< Isthere new thewire between ECMPCM (A10)
and service check connector.
YES
t'o page 114x68}

4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+# 11 -A-38
8
%!

2'
(

/%2'0/
?0
(From page '1 '1 eta-3?}
Check for a short in the wire

[MIL line):
1. ’e‘ the ighitior‘ switch OFF.
2. Disoor‘r‘ectthe ECWPCM
ocrr' edcr A I: 32F j:.
3. ’e‘ the igr‘itior‘ switch CN [II].
H—I— YE" Repair short to body ground in

IStheMILCN? ' thewire between the ECMIPCM
(manna MIL.
NC
Substitute a knmn-good Emil!
PCM and recheck (see page 11-A-1E
1'cI-rin‘l'ncilailiaerinl'ermaiiem.I1r
symptemlindicatien goes away
replace the original ECMIPW.
4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+#
Manifold Absolute Pressure (MAP) Sensor

*
'/'0

11 -A-39
9
P0107
'$$7 The scan tool indicates Diagnostic Trouble Code (DTC) P0107: A low input (high vacuum)
4!(
4 !;(4<00$9%!3 ;
& <
problem in the Manifold Absolute Pressure (MAP) sensor.
!,!%! ;,%<-
The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECM/PCM.
4,%&!! !!
! ,=,-
SENSOR
0U TF' U T
VOLTAGE
l1 Ls __IIL 15_ {a 3‘5 .30 iii-HQIGAUGE

100 an :00 400 500 m m lmmHllREADIHG

- DTC P010? is stored.
Problem verification:
1. 'Lrh the igr‘iticr‘ switch [CN ill}.
2. Checkthe MAP with the scar
tccl.
lntem1ittent failure, system is OK

Is approx. 101 kPa|:TGUl‘1l‘11‘g,1-"'-., YES at this time. Cheek for poor
\ 30 ir.i—gj: irdicated? connections or loose wires at
MAP sensor and ECIWPCM.
NC
MAP SENSOR 3P CONNECTOR
(meek for an open in wire
N061 line):
1. 'e the igriticr switch OFF. vcc1
2. Disccrrectthe MAP ser‘scr (YEURED)
ccrhectcr.
3. 'e the igriticr switch CN ill}.
4. luleaaLre voltage betweeer‘ the
MAP aerscr correctcr No. '1 391
termir a| ahd Nc. Etermihal. [GRNJ'WHT]:
"NHL" SIDE 01 im‘ale lDIiT‘II'IE'lIS
NC Repair op en in the wire between

'1’ lathere approx. 5V? )—
EGI'II'IJ'PCM {-319} and MAP sens or.
YES
('0 page 11 -.A‘~.-4Uj:

PGM-Fl System
'+#
Manifold Absolute Pressure (MAP) Sensor (cont’d)

*
'/'0
/
?0
11 -A-40
$
(From page 11-A-C‘B]
Cheek for :1 open or short in the

MP sensor:
Check the MAP with the scar
tod.
Is approx. 2 kPa (15 mmHg,

Replace the MAP sensor.
0.5 ir.Hgl cr less ir‘cicaec?
YES
Cheek for: shortin thewire -._J:L~_ imp

{RE DJGRH]
[In
tl'i'lAP line]:
1_ TL.rr the igr‘itior‘ switch OFF.
2 Disccrrectthe ECMJP CM
corr actor C (31 P].
3. Checkfcr oor‘tiruiby betweer
the MAP serscr corrector No. 3
tennird arc bow gropr'c.
Repa'r short in 'Ihewire between

lathere cortirpity'?
ECMPCM m1 7] and MAP sensor.
Substitute: known-qoodECM
PCI'lll andreoheok (see page11-A-
1Bl'or immobilizer information).
Il'normd MAP isindieated.
replaoe the origind EC MPCM.
4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+#

*
'/'0
/
?0
11 -A-41

P0108
'$$8 The scan tool indicates Diagnostic Trouble Code (DTC) P0108: A high voltage (low vacuum)
4!(
4 !;(4<00'9%
&!
;!3& <
problem in the Manifold Absolute Pressure (MAP) sensor.
!,!%! ;,%<-
— The ML has been reported on.
— DTC Films is stored.
Problem verifioation:
1. Smrtthe er'gir'e. Help the
ergir‘e at 3,030 rpm (mir-‘I';
with re lea: lir‘ Park or FEL—
trd] Lrtjl the raciacrfar
enzmes anther let iticle.
Ch eek the MAP witlt tlte scar
tml.
Intermimntfa'lure. system is OK
ls1EI1 kPaTEICI mmHg. 30ir‘. Hg}. NO atthis time. Cheek for poor oon-
1.Ulu‘erhigherircimtec? neotions or loose wires at MAP
sensor and ECMPCM.
YES
MAP SENSOR 3P CONN ECTOR
Cheolr. for an open in the I'MP sensor:
1. TL.rr the igriticr switch OFF.
2 Discerrect the MAP sersor 3P
cerrectcr.
lrstall ajL. mperwire betweer‘
the MAP serscr 3P eerrector
termirzds No. 3 are No. 2
TL.rr the igr'm‘cr switch ON {ll}. SG‘l " mp
.Ulrh-
Ch eel: the MAP with the scar tcol. IGRNWHT] tREDlGRN]

JUNIPER WIRE
Wire siee ottemde tenttir'als
Is 101 kPa [YBZImmHg 33 ir‘. Hg}. NO
1.0 V or higher ireieatee?
YES vcc1__-_..-J:L.___
(YEURE D] "
Ch eel: tier :1 open in wire :361
line:
1. Remove the jL.m perwire.
2 Measue udtage betweer the
MAP serszur 3P ca‘rectortermirals
No. 1 are No 2
:eRNIWHT]
Repa’r open in thewire beMeen
Is there app ro'x. 5V? the ECMIPCM (CT) andthel'MP
sensor.
Ch eolu: for :1 open in the wire ECMPCM CONN ECTOR C IMF]

tltline]:
1. TL.rr' the ig ritiur switch CIFF. se1 (GRNJWHTJ [—
2. lr' stdl aip er wire or the
ECMJP CM curr ectcrs betweer 3 5 s T" e 1e
CT are C1 T. '11 13 14 1s 1s 1? 13 19 2021 22
Te' the igritiur switch CIN (ll). 23 2:3 25 d'r 23- 2933 31
Che ekthe MAP with the scar tod.
FMPtREDlGRN]
Repa'r open in thewires between JU MFE R W RE
ls1U1 kPa (TmmmHg. 33 ir. Hg}.
the ECM'PCM (C17) 2111 the MAP Wire siee site made terrnir'als
1.0Verhigherircicatec?
sensor.
YES
Substituteaknmn-good ECM
PCMmd reoheok lsee page 11 «A-
13 for immobilizer information].
If normal MAP is indioated.
replaoe the original ECMP CM.
PGM-FI System
'+# 11 -A-42

Intake Air Temperature (IAT) Sensor
6 /0
P0112
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0112: A low voltage (high
4!(
4 !;(4<09%!3&!
;

temperature) problem in the Intake Air Temperature (IAT) sensor circuit.
<!#%4 ;%4< -
The IAT sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intake air
4%4 ;<-4#
temperature increases as shown below:
3!39
RESISTANCE
ik DhI'I‘I}
— The NHL has been reported on.
— orc P0112 is stored. ID
— Or from Probable Cause list.
1. ’e the igr'iticr' switch CN ill}.
2. Shed: the lit—with the scar
THERMISTOR
H 1 JL ‘0 H IO 1“ I3":-
tool. I u a. I04 II .11: :ds I'rl
IN TAKE AIR TEMPERATURE
Is 150°C [3 02°F} or higher NO

[or l--Limit ih h-cr da mode of
PGM Tester} or 0 V ihclicated?
YES Is the correct ambier‘t

temperature ir'dimted‘?
YES
Inten'nittent failure, system 0K
atthis time. Check for poor
connections or loose wires at IAT
sensor and ECMIPCM.
IIlheclt for a short in the IAT
sensor:
'1. Disochhectthe If? ser‘scr 2P
ocrr ectcr. l Replace the IAT sensor.
2. Chede; the lA'with the scar
tool. v.
_ lfthe er‘gir‘e is warm, itwill be higher
thar‘ ambier‘t tempe ratL. re
Is 150°C [302°F} or higher

[or h-Limit ih l-crda mode of Repia ce the IAC sens or. I
PGM Tester} or W irdicated?
YES IAT SENSOR 2P CONNECTOR
Check for a short in the wire (IAT

Iin e}:
1, 'e the igriticr switch OFF.
2, Disecr'r'ect the ECMIPCM
ccr'r'ectcr C(31P}.
3. Check for ccrtih Lity betweer
the IAT serscr 2P ecrrectcr
termir' al No. 1 ahd body grccrd. Wire side of female termir' ale
YES Repair short in the wire bemeen

~71 Is there CGl‘Ill‘LlI'y’?
ECMIPCM (025) and [AT sensor.
NC
PCI'li'l and recheck [see page 11-A-
15 for immobilizer in formation).
If normal [AT is indicated, replace
the original ECMIPCM.
4

&A
!#!!3
9
;'!%<
PGM-FI System
'+# 11 -A-43

Intake Air Temperature (IAT) Sensor (cont’d)
6 /0
/
?0
P0113
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0113: A high voltage (low
4!(
4 !;(4<0+9%
&!
;!3
temperature) problem in the Intake Air Temperature (IAT) sensor circuit.
<!#%4 ;%4< -
— The MIL has been reported on
— DTC P0113-is stored.
1. Te the igritior switch ON ill}.
2. Cheekthe IATwith the scar
1nd.
Intermittentt'a'lure. system is OK
ls 20°C (44°F: or less (or Ltimit
atthis time Check torpccr ccn-
ir Hcrca mcce crfPGM Tester] or
neoti ons or loose wires at IAT
St! ircicatec?
sensor and ECIWPCM.
Check for at open in the lAT

sensor: lAT SENSOR 2P CONNECTOR
1, Disccrr eat the IAT se rsor 2P
cor rector. IAT
2, Correct the IAT sersor 2P ccrrector (REDlYEL) so:
termirds No. 1 are No. 2with a {cement}
jL. mperwire. JUMPER
3_ Ch eek the irtdce airte mpe ratt. re WIRE
with the sear tod. Wire sice offemde termirals
.__..-"'is 20°C (4°F} cr less (or L-Limit

.3: ir Hcrea mcce 0t PGM Tester} or bi! Replace the IAT sensor.
5V ireieatec?
YES
Check for at open in the wires
HAT. SC: lines): EC MPCM CONNECTOR C (31 P]
1. Te the igriticr switch OFF.
2, Correct ECMJPCM corrector
. 3 5 e r e s 10
termirds C18 arc C25with a ' 16 1.7 tats 20 21 22
jL mperwire. 2s 26 2rze 29 3:: 31
3, Te the igriticr switch ON ill}. IAT tn EDIYEL) so: (can lBLK]
4, Ch eck the IAT with the scar
JUMPER WIRE
tool.
Wire sice offernde ten‘nirals
ls 20°C (44°F) cr less (or L—Limit Repair open in the wires between
ir Hcrca mcce crfPGM Tester] or ECMPCM Kit 8. C25] and lAT
St! ireicztec? sensor.
YES
Bu bstitutte a known-good E CM
PCM atd recheck (see page 11-A-
13 for immobilizer information).
It' normd lAT is indicated. replace
the original ECMPCM
4

&A
!#!!3
9
;'!%<
PGM-FI System
'+#
Engine Coolant Temperature (ECT) Sensor
%!
/%0

11 -A-44

P0117
'$7 The scan tool indicates Diagnostic Trouble Code (DTC) P0117: A low voltage (high
4!(
4 !;(4<0$9%!3&!
;

temperature) problem in the Engine Coolant Temperature (ECT) sensor circuit.
<!
!4 ; 4< -
The ECT Sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the engine
4 4 ;<-4

coolant temperature increases as shown below:
! 3!39
RESISTANCE
[k ohm}
/
/
TH ERMISTOR n1
1‘ I: 20 13 I HI-J'lzn I'I:
J .13 hilt-I‘ll! lfifiJJ-Iil'fi
ENGINE COOLANT TEMPERATU RE
— The MIL has been reported on

— DTC P011? is stored.
Prohlem verification:
1. IN the igriticr switch CN (Hi.
2. Check the EC’ with the scar
tccl.
Intermittent failure. system is OK

[Isis 150°C [302°F} or higher
It: [or l"—Ll|"‘llt ih h'crda mode of
NC at this time. Ch eok for poor
connections or loose wires at ECT
""-._I_PGM 'ester} or 0 v ihdicated? sensor and ECMIPCM.
YES
Check for a short in the ECT sensor:

1. Disocrrectthe EC_serscr2P
ocr'r'ectcr.
2. Chad; the EC_Witl‘ the scar
tccl.
|3150°Ct302°F1cr higher
[or l--Limit ir l-crcla mode of Replace the ECT sensor.
PGM 'ester] or 0 V irdicated?
(To page 114x45}

PGM-Fl System
'+# 11 -A-45
3
Engine Coolant Temperature (ECT) Sensor (cont’d)
%!
/%0

/
?0
(From page 1145.44]
ECTSENSOR 2P CONNECTOR
l!.'.‘heclu: fora shortiri thewire
tECT line]:
1, Te' the igr‘iticr switch OFF.
2, Discerrect the ECMI'PCM .- ECT
CCIF‘FECICI' C (31 P}. “EMS! ‘REDMHU
3, Checkfor cortireity hetweer
the ECT ser‘sor 2P corrector termir‘al ?
No.1 ETC bocy grcu‘c. Wire sice 0‘ female termir‘ds
< Isthere cortir‘eity” ‘x YES Repair short in the wire heme-en

ECIWPGM 1:223] aid ECT sensor.
. . NO
[wrth climate
cor‘trol Ll" it}
Ch eck for Climate Con trol Unit

circuits:
1. Disea‘retCP corrector
from the Climate Cortrol Urit
2 Check for cu‘tiruity betweer
the ECT serscr 2P corrector
termiral No. 1 arc bocy grourc.
{ lethere corfiruity? YES Replaoe'lhe CIimateCchtrolUnit l
NO
Substitutea known-qccCM
PCM andrecheck (see paue11-A-
1cr immobilizer information).
Ifhcrmd ECTisindicated. replace
the original ECMP CM

4

&A
!#!!3
9
;'!%<
PGM-FI System
'+# 11 -A-46
5
Engine Coolant Temperature (ECT) Sensor (cont’d(
%!
/%0

/
?/
P0118
'$8 The scan tool indicates Diagnostic Trouble Code (DTC) P0118: A high voltage (low
4!(
4 !;(4<0'9%
&!
;!3
temperature) problem in the Engine Coolant Temperature (ECT) sensor circuit.
<!
!4 ; 4< -
— DTC Pottais stored.
1. Te the igritior switch ON til}.
2. Check the ECTwith the scar
tool.
Intermittentfailure. system is OK
Is 20°C Ij—4”Fj: or less tor L-Limit NO at this time. Ch eok for poor
ir Horca mcce crfPGM Tester} or
oonneotions or loose wires at E CT
:3 V ir cicatec?
sensor and ECMPCM
YES
Cheok for an open in the ECT
sensor:
1. Discorrect the ECT sersor 2P
ECT SENSOR 2P CONNECTOR
ccr rectcr.
2 Correctthe ECT sersor 2P ECT 1 2 so:
ccrrectcrtermirds No. 1 are (REDIWHT) I'- tGRNJBLK]
No. 2with ajcmperwire.
3. Ch eck the ECT with the scar
tcol. JU l‘aPER WIRE
Wire sice offemde ten‘nir'aIS
ls 20°C (41°F) or less [or L—Lirn'n

-i;__ ir Hcrca mc-ce crf PGM Tester} or L! Replaoe the ECT sensor. l
:3 ‘u' ir cicatec?
YES
EClWP CM CON N E CTOR G t31P]
Check for an open in thewires
(ECT. 362 lines):
1. Te the igritior switch OFF. 3 5 6 T B 9 1D
2 Correct ECMI'PCM corrector 11 1314 15 1T1319 2021 22
tennirals C18 arc C26with a ESE 2:3 27' 213 29 33 31
jL mperwire.
ECTlR DJWHT)|_ SGZtG-RNIBLK]
3 Te the igritior switch ON til}.
4. Ch eck‘ the ECT with the scar JUMPER WlRE
tcol.
Vui re sice offemde ten‘nirals
Is 20°C (41°F: or less Ijor L—Lirnit Repa'r open in thewires between

ir Hcrca mc-ce crfPGM Tester} Dr ECMPCM:C18.C2€]md ECT
:3 V ir cicatec? sensor.
YES
Substimeaknown-good ECMi
F'Cl'i'l and reoheok (seepaue11-A-
13 for immobilizer information ).
If normal ECT is in dioated.
replaoe the original ECMPCM
PGM-Fl System
'+#
Throttle
Position (TP) Sensor

'

/'0

11 -A-47
7
P0122
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0122: A low voltage problem in the
4!(
4 !;(4<09%!3&!
!
Throttle Position (TP) sensor circuit.
4!;4< -
The TP Sensor is a potentiometer. It is connected to the throttle valve shaft. As the throttle position changes, the throttle
44-!&!&-%!
A!
position sensor varies the voltage signal to the ECM/PCM.
&&!

! ,=,-
— The MIL has been reported on. BRUSH
— DTC P0122 is stored. HOLDER
0U TP‘U T VOLTAGE W}
ERUBH
1. Start the ergir‘e. h-oldthe
er'gir'e at 3,000 rpm Ijmih-‘I ';
'with r'o load (ir‘ Park or heLtraI}
L.r'ti| the radiator far' ,3 ' THROTTLE
Domes or'. ther' tL.rr' the igr‘itior‘ 1 - iossnmo
switch ICFF. u - —-————:
2. ’e‘ the igr'itior' switch CN ill}. IDLE FUL
3. Ch ed< the throttle positior‘ THROTTLE
'with the scar tool.
Is there approx. 10% 'wher‘ the Inten'nittent failure, system is OK

throttle is fLIIv dosed ar‘d YES at this time. Check for poor TP SEH3°R 3P CONNECTOR
app rox. 90% 'wh eh th e throttle connections or loose wires at TP
is fLIIv opehed? sensor and ECMIPCM.
NC
Check for an open or short in the
ECMIPCM CONNECTOR c (31F) “ U002
wire WCCZ line}: $62
1. Ir!“ the igritior switch OFF.
[GRNIBLK} [YEUBLU]
2. Disoohh ed th e 'P serscr 3P
so: [GRNIBLK)
och recto r. ' 3 r h. . s a .U 'u'u'ireside offen‘detenrinals
3. 'Lrh the igritior switch CN (H1. 's '4 r. ‘5 's a 2L: 2‘ 22
4. I'uleaSLre voltage bet'weer‘
the 'P sersor 3P correctcr
as 2s- 2s 2x as 29 21L: IJ‘
termihals No. '1 ard No. 3. vccz WELIBLU) ____
“Mre side of fem ale termir‘als
YES
Check for an open in wire NCCZ
line):
Measure voltage betweeh ECMJ'
PCM correctortennir'als 018 ar'd
C28.
Check for an open or short in TP
sensor: ‘ermir‘al side of male termir‘ als
1. 'e' the ighitior switch OFF.
2. At the sehsor side. I‘Teaee Is the re at: prox. 5 V? Y ES
resistar' oe betweer the 'P
ser' sor 3P oohreotor tennihals NC
No.1 ahd No. 2with thethrottle
fLIIy olo sed. Repair open in the wire between
ECMJPCM [628} and TP sensor.
[To page 11-.A-4S}

Substitute a known-good EClW
POM and recheck (see page 11-A-
If prescribed voltage is now
available, replace the original
ECMrPCM.
4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+#
Throttle
Position (TP) Sensor (cont’d)

'

/'0
/
?0
11 -A-48
8
(Frcrn page11-A—4T]
Isthere approx. 0.5 - 0.9 k ohms? Replaee the throttle body ‘
YES
TP SENSOR 3P CONNECTOR
Cheek for an open or shortin the

TP sensor:
Measue resismr‘ce betweer the
TP ser'sor 3P cor‘rectortermirds
No 2 are No. 3 with the thrmle
liy clcsec.
Isthere approx. 4.5k ohms? Replaeethe throttle-body ‘Termir'd siceofmaletermir'ds
YES
Cheek for an open in the ECM
PCM iTPS line]:
1. Remrredthe TP ser‘sor 3P
ca" reetcr.
2‘ Te the igr‘itjor‘ switch ON {H}.
3 Meaee uoltxe betweer‘ (318
tem'liral arc CZYtermir‘d or ECMIPCM CONNECTOR C {31 P]
the ECM'P CM ctrr‘ector.
3 6 r a 9 10
.1314 1:) 161MB 19 2021 22
'53 25 26 2? 23 29 :13 31
TPS (REDJBLK) 362 (GRNJBLU1
v E
Wire sice offernde ten‘nir'als
Substitute a knm-good ECM

Is there approx: 0.5 t er the ' FISH and reoh eolt isee page11-A-
throttle is fLIiy closec are YES 16 for immobilizer information].
approx. 4.5ter the thrcttle Ii'presorihedeoltageisnow
is fl..|l'5l cperec? available replace the original
NO ECMPCM
Repair short in the wire heween

ECMTPCM H.118] aid TP sensor.
PGM-Fl System
'+#
Throttle

'

/'0
/
?0
11 -A-49
9
P0123
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0123: A high voltage problem in the
4!(
4 !;(4<0+9%
&!
!
Throttle Position (TP) sensor circuit.
4!;4< -
— DTC P1112: is stored.
TF' SENSOR 3F OONN EOTOR
Problem verifioat'on:
1. Startthe er'pir'e.Hc|cthe
er gir'e at 3,030 rpm Ijmir-‘I';
with re lea: (ir‘ Park or reLtral'; so:
Lrtil the raciacr far‘ (GRNJBLK)
ccmes er. ther' tL.rr' the igr‘itior
switch OFF.
2. Te the igr'iticr' switch ON (II).
3. Check the thrcttle pceitior‘
with the sca‘tcd. 'u’uire sice d female termir‘as
Is there apprcar. 10%wher‘the Intermittent fa'lure. system is OK

thrcrtle isfelly ciceec arc YES atthistime. Check for poor
app rcx. 9cm. wher the throttle oonneotionsorloosevdresatTP
isIiy cperec? sensor and E CMPCM.
NO
ECMJ'P CM CON N E CTOR O :31P]
Cheek for an open in the TP
sensor: saucer-113m
1_ Te the igritjcr switch OFF.
3 5 B 7 E 910
2 Discorr ect the TP sersor SP
ccr re ctcr. _..--‘1314151e121e19 2a 21 22
3 TL.rr the igritjcr switch ON 1:11}. 23. 23 262? 2e 293331
4_ At the wire haress sice, measure vccz (YELJBLUJ
tdtage betweer the TP ser‘sor 3P f]
ccrrectcrtermirds No. 1 are No 3.
Wire siee :1 female termir‘ d3
Is there approx. 5V? Replace the throttle body
Check for an open in the wire

tSG-z line]:
Measere tdtage betweer ECM."
PClu'l corr‘ ectcr G (31 P} termiras
G13 are I323.
Repair open in thewire between

Is there app ro'x'. 5V?
ECMPCM (C18) and TP sensor
Substittte a know-good EClW

POM and rebheok isee page 11 «A-
1E. for immobilizer information ].
Ii' preseribed voltage is now
militle. replaee the original
ECIWP CM
*1 : NT
‘2. |'I.|'|.'T
PGM-FI System
'+# 11 -A-50
3$
Primary Heated Oxygen Sensor (Primary H028)
' #.#!
/' #.0
(Sensor 1) (H22A7 engine)
/
0/.7! 0
The Heated Oxygen Sensors (H028) detect the oxygen content in the exhaust gas and signals the ECM. In operation, the
468/
;68</
/

! ,-A
ECM receives the signals from the sensor and varies the duration during which fuel is injected. To stabilise the sensor's output,
,&
!&
3 !7-4!@ A
the sensor has an internal heater. The Primary H028 (Sensor 1) is installed in exhaust pipe A.
!-468;<!!/ %-
VDLTAGE [V] l STUICHDCIMETHIE
I AIR-FUEL RATIO
ZIRCOMIA SEN 50H
ELEMENT TERMINALS
RICH *' AIR- -' LEAN

FUEL
HEeTEe RATIO
HEATER TERMINALS
P0131
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0131: A low voltage problem in the
4!(
4 !;(4<0+9%!3&!
!
Primary Heated Oxygen Sensor (H028) (Sensor 1) circuit.
68/
;68<;< -
— DTc P0131 is stored.
1. Do the ECM Reset ProoedLre.
2. Start the er‘gire. h-old the
ergire at 3000 rpm [Mir-1]
with ho load (ih Park or FELIFQI]
Lrtil the radiator far‘
comes Cl".
3. Check the Primary PCES
(Sersor 1:: output voltage with
the scar tool dL.rir‘g acoeleratior'
Lsirg wide oper‘ throttle.
_l_
Does the voltage stay at 0.5 V NC
Inten'nitterlt failure, system is OK
at this time. Check for poor
connections or loose wires at
or less? /
Primary H028 (Sensor1) and
YES ECM.
Check the fLel pressure I: see page

11 -1 01 ].
( Is it i" orm al? )—|NG Repair fuel supply system.
YES
(To page 11-A-51}

PGM-Fl System
'+# 11 -A-51
3
' #.#!
/' #.0
(Sensor 1) (H22A7 engine) (cont’d)
/
0/.7! 0/
?0
(From page 11 A50}
Check for a short in the H 025:

1. TL.rr' the igriticr switch OFF.
2 Disccrr‘ect the Primary H025
(Ser'sor 1'; 4P ccrrector.
3 Sun the ergire arc letit iele.
4. Check the primary H023
IjSersor 1:: outputvoltxe with
scar tool.
Does it stag at 0.5 V or less? Replace the H023t8ensor1).
YES
PRIMARY H 023 {Sen scr1]
Check for: shortin ihewire 4P CONNECTOR
tPHOZS line]:
1. Te the igr‘itior switch OFF. was 1 2
2 Discorr‘ect the ECM (WHT)
eorr eetor C (31 P].
3. Checkfcr cor‘tiruity betweerthe
Primary H025 (Sersor 1 j: 4P I: I: h nj'll
correctcrtennird No.1 are

beet)- groc.
Wire sicE d female termir'als
Repir short in the wire between

Is there cortiruity? serum 6] and Primary H023
t3er13cr1].
NO
Substitute : knawn-qccd ECM

and recheck (see page 11-A-
16 for immobilizer infcrmaticn]. If
symptcmlindicaticn aces away.
replace the origin 1 ECM.

4

&A
!#!!3
9
;'!%<
PGM-FI System
'+# 11 -A-52
3
' #.#!
/' #.0
/
0/.7! 0/
?0
P0132
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0132: A high voltage problem in the
4!(
4 !;(4<0+9%
&!
!
68/
;68<;< -
— DTC P01 3.2 is stored.
1. Dothe ECM Reset PreceCLre.
2. Startthe ergire. Holc the
ergir‘e at 3.CUO rpm lmir-1 j:
with re Ioac: Ijir‘ Park or reLtra:
Lr'til the raciacr far comes or.
3. Check the Primary H023
(Ser'sor1j: cetpetydtage with
the scar‘tcol.
Intermittenti'a'lure. system is OK
:t'lhistime. Cheek forpoor
Doestheuoltmestayatfiv 5; NO
oonneoti one. or loose wires at
crmcre?
Primary HOZStSensor tlmd
ECM
YES
Cheek for an open in the Primary
H023: PRIMQRY H023 {Sensor 1]
1. Terr the igritior switch OFF. 4P CONNECTOR
2. Discorrect the Primary H028
[Serscr 1 j: ccrr'ector. JUMPER WlRE
3_ Currectthe Primary H023
[3 er scr 1 : 4P cor‘r‘ ectorte rmir‘als
PH 023 m
352
IGRNI
No. 1 are No. 2with a “NH" 1 2 ELK]
ipeee.
Te‘ the igr‘itior‘ switch ON ill}. 3 4
we
Check the Primary H023

[3 er set 1 : cctpctydtage with Wire sice (1 female termir‘ds
the scar‘ tool.
Is there 1.5 V or more?

NO
ReplaeethePrimry H023
YES
Cheek for an open in thewire ECMPCM CONN ECTOR C {31F}
tPHOES line]:
1. Te the igritior switch OFF. " 5 6 T B 9 1D
2. Correct ECM corrector
11 ...--"'131415161T1319 20 21 22
tennirals C16 arc C18with a
jL mperwire 23.x” 2:3 26 27'23 29 33 31
3. Te the igritior switch ON ill}. “1023 (WHT) 362 {GRHIBLM
4. Check the Primary H025
(Serscr 1 '; CLttydtage with JU NFER W1RE
the scar tcol. Wire sice offemde ten'nir'als
Repair open in thewire heween

ECMtC1B]md Primary
Hozstsensom ].
Buhsimeaknown-good ECM
and reoheokiseepaae 11-A-
13 for immobilizer information). If
symptomlindioation goes away
replaoe'lt're original ECM
PGM-Fl System
'+# _ _
3
' #.#!
/' #.0 11 A 53
/
0/.7! 0/
?0
P0133
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0133: A slow response problem in the
4!(
4 !;(4<0++9%!3!
68/
;68<;< -
Description
)

By controlling the air/fuel ratio with a Primary HO2S (Sensor 1) and a Secondary H025 (Sensor 2), the deterioration of the
)!!
= !368;<60;<A
Primary H025 (Sensor 1) can be evaluated by its feedback period. When the feedback period of the H025 exceeds a certain
60;<&! #-2#60/
value during stable driving conditions, the sensor will be judged as deteriorated.
&!
!&
A3!!7
-
When deterioration has been detected during two consecutive trips, the MIL comes on and DTC P0133 will be stored.
2
3 &A,(40++3!!-
NOTE: If DTC P0131, P0132 and/or P0135 are stored at the same time as DTC P0133, troubleshoot those DTCs first, then
84 9(40+A0+=0+(40++A !(4A
troubleshoot DTC P0133.
!(40++-
Possible Cause
'
*
¢ Primary H025 (Sensor 1) Deterioration
60;<(
¢ Primary H025 Heater (Sensor 1) Deterioration
606;<(
¢ Exhaust system leakage
/ !#

Troubleshooting

* Flowchart

!+
(
— DTC P01 33 is stored.
Problem Verification:
1, Dott‘e ECM Reset ProoedLre.
2, Correct the smrtool.
3, Stature ergir e. r-oldtre
ergire at 3. 000 rpm [VHF-1]
witr ro load Ijir Park or remral]
Lrtiltre radiator far
comes or.
4_ Correct the SCS st‘ort
correctcr
Test—drive eer followirg
.U“
corditiors.
— 89 kmt'l‘ (55 mpl‘} steady
speed
—trarsmissior ir fitl‘ gear
— Urtil readiress code comes
or.

Is D—c P0133irdicated? ”0 connections
f" ““3 "_""°- cm“ “i” W"
or loosewrls at
YES Primary H025 (Sensor 1) moi ECM
Replace the Primary H028

(Sensor1).
PGM-FI System
'+# 11 -A-54
3
' #.#!
/' #.0
(Sensor 1) (F2036 engine)
/
0/+$"5! 0
The Primary Heated Oxygen Sensor (Primary H028 (Sensor 1) operates over a wide air/fuel range. The Primary H028
468/
;68;<&3= !
-468
(Sensor 1) is installed in the exhaust manifold.
;<!!/ !-
sensor:
TERMINALS
ZIHCDNIA +3. :;_I ':
ELEMENT l 'l'
HEATER TERMINALS
P1149
'9 The scan tool indicates Diagnostic Trouble Code (DTC) P1149: A range/performance problem
4!(
4 !;(4<*59%
=!
in the Primary Heated Oxygen Sensor (Primary H028) (Sensor 1) circuit.
68/
;68<;< -
P1165
4!(
4 !;(4<9%
=!
68/
;68<;< -
NOTE: If some of the DTCs listed below are stored at the same time as DTC P1149 or P1165, troubleshoot those DTCs first,
84 9(4!!3(4*5A !(4A
then troubleshoot DTC P1149 or 1165.
!(4*5-
P0137, P0138: Secondary H028 (sensor 2)
0+$A8+'968;<
P0141: Secondary H028 (sensor 2) Heater
0*968;<6
Troubleshooting

* Flowchart

!+
(
— DTC P114! or P1165 is stored.
Problem‘uferi fication:
1. Dothe ECMI'PCM Reset
Procedure.
2. Startthe engine. Holdthe
engine at 3. 000 rpm (min-1::
with no load (in Park or neutral]
untilthe radiator fan
com es on.
3. Check the Temporary DTC
with the scan tool.
a‘._ Test-drive under following
conditions.
— BEI kmn'h (55 mph} steady
speed
—NT in-position (NUT in
5th gear;
I... ntil readiness code or
Temporary DTC P1149
(P1165} comes on
Intermittent failure, system is OK

< Is Temporary DTC P1140 (P1165]\, NC at this time. Check for poor
ir'dioated? connections or loose wires at Primary
— H023 (Sensor 1 )ancl ECMIP CM.
YES

(Se nsor1 ).
PGM-Fl System
'+#
' #.#!
/' #.0
11 -A-55
33
(Sensor 1) (F2036 engine) (cont’d)
/
0/+$"5! 0/
?0
P1162
'5 The scan tool indicates Diagnostic Trouble Code (DTC) P1162: A malfunction in the Primary
4!(
4 !;(4<9%!
Heated Oxygen Sensor (Primary H028) (Sensor 1) circuit.
68/
;68<;< -
Troubleshooting

* Flowchart

!+
(
— The I'lrIL has been reported on.
— DTC P1152 is stored.
1. Dethe ECMrPCM Reset PrcceCLre.
2. Starttlre ergir‘e ar'c wait at
least two mir' Ltes.
Intermimntfa'lure. system is OK
anhistime. Cheek forpoor
Is DTC P1152 ir'eicatec? oonneoionsorloosevnresat'fl're
Primary H023 (Sensor1ja'rd the
YES ECMPCM
Cheek for an open or short in the ECMJ'P CM CONNECTORS

wires (PH023+. PHOZS- lines]: :5 LI ." B I
1. Te the igriticr switch OFF. “L a !_‘r:i r'sl
2. Stat the ergir e.
.7. .,.U 2" 35 34 J.
3. Meaee voltage betweer‘ the LG1 (enigma
ECMI'P CM ea” remortermir'als
C14 are BEE] are betweer' C1 :3
are BEE]. '_.,j _.-
NO PHOZS- (BLU]
'—|{l'_'_j_-. (To p x e 1 1 —A—S 6::
-
Is there 2.5 — 3.0V?
YES
Wire sice (1 female termir'ds
Check for .11 open in thewires

(PH 025+. PHOZS- lin es]: PRIPMRY H028 (SENSOR11 4P CONNECTOR
1. TLFF' the igriticr switch OFF.
2. Diswr‘r‘ed the Primary H028 P H 023+ (R ED]
4P ca" r'e ctcr. arc the ECM" Termir'al sice d male termir' as
PCM ccrr‘ectcr C (31F).
ECMPCM CON NECTOR C (31F]
3. Checkfcr CUl‘til‘Li’t‘y betweer
the Primary H028 (Sersor 1:: 3 {J b' r'
0C
4P ca" r'e ctcrtermira N0. 2

PH 023+ ‘b' ‘."H‘!-.|
h
'2».
f:
are the ECM"PCM ourrector (RE D] :5 2.23

termir'a I314 are betweer
PHOIS-
Primin- H028 (Serscr1l4P
raw]
eor'r'eetcrtem'rira Na 1 are
EClrI'l-‘P CM ClT recturtermiral Wire siee d female termir' as
C15
Repa'r open in thewire between

Is there eer'tir Lily? Primary H023 (Sensor1]:1d
ECMPCM(C14or C15].
Replaoe the F'rimryI H023

(Sensor 1].
PGM-Fl System
'+# _ _
35
' #.#!
/' #.0 11 A 56
/
0/+$"5! 0/
?0
Check for a shon in 'Ihe wires

PRIMARY H028 SENSOR1 4P CONNECTOR
[PH 025+, PH 023- lines): ‘ }
1. ’Lrh the ighiticr switd‘ IOFF. PHOZS-
2. Discchhectthe Primaryi-CES [BLU] H PH025+ {RED}
4P 00hr vector ahcl the ECM;‘ 1 2
PCM mhhectcrc {SAP}. 3 4
3. Check for ocrtirL'rty betweer‘ .-" .
|LD|1IT‘ I [\ohn'
body guard arcl the Primary
I-*C2S[Serscr1} 4P ccr‘r‘ectcr I
Ill—i
tennihal NC. 2 ahd NC. 1.
'ermir‘al side of male tennir‘als
< lathere ccrtirLity? X: NC Replace the Primary H025

—f: [Sensor 1).
YES
Rep air sh on in 'Ihe wire between

Primary HEIRS [Sen ear 1) and
ECIWP CM [014 or (:15).
PGM-Fl System
'+# _ _
37
' #.#!
/' #.0 11 A 57
/
0/+$"5! 0/
?0
P1163
'5 The scan tool indicates Diagnostic Trouble Code (DTC) P1163: A slow response problem in the
4!(
4 !;(4<+9%!3!
Primary Heated Oxygen Sensor (Primary H028) (Sensor 1) circuit.
68/
;68<;< -
NOTE: If DTC P1162 is stored at the same time as DTC P1163, troubleshoot DTC P1162 first, then troubleshoot DTC P1163.
84 9(4(4+A !(4A !(4+-
Troubleshooting

* Flowchart

!+
(
Problem 1ttferi'lit:ation:
1. Do th e ECMIPCM Reset
ProcedL. re.
2. Check the Temporary D’C
with the scar tool.
3. Start the ehgihe. holdthe
eh gihe at 3000 rpm (mir‘ -1 j:
with ho load (ih Park or hectral]
Lhtil the radiator far
comes or.
4. 'est-dr'ru'e Lhder followir‘g
cor ditiohs.
— 89 ltmn'h (55 mph : steady
speed
t'ih- positior‘ (MF ir‘
5th gear}
— Uhtil readihess code or
Temporary DTC P1163
comes oh
In terni ttent failu re, system is OK

Is ‘emporary D‘C, P1163 \, NC at this time. Cheek for poor
ir'dicated? connections or loose wires at Primary
H023 (Sensor 1} and ECl'I'IIPCM.
YES
Replace the Primary HOES

(se nsor 1).
PGM-Fl System
'+# _ _
38
' #.#!
/' #.0 11 A 58
/
0/+$"5! 0/
?0
P1164
4!(
4 !;(4<*9%
=!
68/
;68<;< -
Troubleshooting

* Flowchart

!+
(
Problem Verification:
1, Do the ECM.-'PCM Reset
Proce dL.re.
2, Start the ergire. l-old the
ergire at 3,000 rpm (mih-‘l j:
with ro load Ijir Park or rectralj:
L.rtil the radiator far
oom es or.
3, Check the ’emporary D’C
with th e scar tool.
4_ ’est-driue ir positioh.
flartir g at 1,600 rpm (mir-1 1:,
amelerate Lsirg wide cper
throttle for at least fwe seocr‘ds.
'her decelerate for at
least five seoords with the
throttle complete closed.
Urtil readiress code or
Temporary D‘C P1164 comes
or.

ls Temporary D'C P1164 \ NC at this time. Cheek for poor
irdicated? connections or loose wires at Primary
—" H023 (Sensor 1) and ECl'I'Il'PCM.
YES
Rep laee th e Primary H DES

(Sensor1).
PGM-Fl System
'+# _ _
39
Secondary Heated Oxygen Sensor (Secondary

#.#!
/
# 1 1 A 59
H023) (Sensor 2)
.0/
0
P0137
'$7 The scan tool indicates Diagnostic Trouble Code (DTC) P0137: A low voltage problem in the
4!(
4 !;(4<0+$9%!3&!
!
Primary Heated Oxygen Sensor (Secondary H028) (Sensor 2) circuit.
68/
;68<;< -
- The l'lt'llL has been reported on.
- DTC P013? is stored.
Problem verifi cation:

1. Do the ECl-tll'F-‘Clul Reset
ProoedL. re.
2. Start the ergire. l-oldthe
ergire at 3,000 rpm (Mir-1 ';
'with ro load (ir' Park or reLtral';
Lrtil the radiator far
mines or.
3. Check the Seoordary H328
[Sersor 2:: oLtt voltage at
3.EIEICI rpm imir -1j: with the scar
tool.
lnten-nittent failure, system is OR

NC at this time. Check for poor
Does the voltage stay at 0.3 V connections or loose wires at
or less?
Secondary H028 (Sensor 2} and
YES ECMIPCM.
SECONDARY H025 (Sen sor 214P

Cheek for a short in the Secondary CONNECTOR SHOES
H025: —'—‘—
1. ’e the igritior switch CFF. ~1l—I2 MT}
2. Disoorred the Secordary j
hC2S (Sersor 2} 4P oor‘r‘edcr. 3 4 _ _
3. flan th e er gire. ['fihlfi,
4. Check th e Secor dary l-'C2S
I||—(
[Sersor 2:: oLtt with the scar
tool.
'ermir‘ al side of male ten'tir' als
Does the voltage stay at 0.3 v' ‘3 NC Replace the Secondary H025
or less? (Sensor 2).
YES
Cheek for a short in the wire

(SH DES Iin e}:
1, 'e the igritior switd‘ OFF.
2, Disoorrect the ECMIPCM
correctorf‘. (32P1.
3, Ch ed: for oortirLity hem-oer
th e Seoor dary l-C2S (Serscr
2] 4P oohrectortermir al No. 2
ard body groe.
Repair short in the wire between

< Is there cortirLity? YES ECMIPCM (A23) and Secondary
H 028 (Sensor 2).
NC
Substitute a known-good ECIW

PCl'lt'l and reeheek (see page 11-A-
15 for immobilizer in formation. If
symptoml‘indieation goes away,
replaee the original ECWPW.
PGM-Fl System
'+# _ _
5$

#.#!
/
# 1 1 A 60
H023) (Sensor 2) (cont’d)
.0/
0/
?0
P0138
'$8 The scan tool indicates Diagnostic Trouble Code (DTC) P0138: A high voltage problem in the
4!(
4 !;(4<0+'9%
&!
!
68/
;68<;< -
1. Do the ECMEPCl-a'l Reset
ProoedL. re.
2. Start the er'gir'e. h-olclthe
ergir‘e at 3,000 rpm (mih'1';
with ho load (ir' Park or heLtral';
Lrtilthe radiator far' comes oh.
3. Check the seoor‘darv H328
(Sersor 2:: oLtt voltage at
3.EIEICI rpm l:l"11r"1] with the scar
tool.
. NC at this time. Check for poor
36:23:: h oltage stay at 0‘6 V connections or loose wires at
U‘ SecondaryHOZS (Sensor2) and
YES ECMIPCM.
Chflk 1'" an OPEN in "1'3 SECONDARY H025 (Sensor 2}4P

Seeondary H025: CONNECTOR
1. ’e the igritior switch OFF.
2. Discorrect the Seocr clarv
JUMPER WIRE
l-*C2S (Sersor 2} 4P cor‘r‘ector.
3. Corred the Secondary l~C2S
(Sersor 2:: 4P correctcr
so:
tennirals No. 1 ahd No. 2 with
(GRNIBLK)
a jL.mp er wire.
4. 'Lrh the ighitioh switch CN (H1.
5. Chede; the Seoohdarv l~C2S
(Sehsor 2:: oLtt voltage with 'ermir‘ al side of male ten‘iir‘als.
the scar tool.
Replace the Secondary H025

lsth ere 0.6V or more?
(Sensor 2).
Giteek for an open in the wire

(SHOES line}:
1. 'e' the igr itior switch OFF.
2. Corr eot ECMIPCM oorhector
ECMJPCM CONN ECTORS
termir'ala A23 ard C18 with a
jL.mper wire. A (32P
'e' the igr itior switch CN (Ill. L--""--""l L. b. _,. ale 'u |
3. Cheokthe Seoordarvl—C2S l‘2i3‘4‘ lilglgguzllzz 23 | 24 |
II."
4. (Seraor 2] atom voltage 252w: 23 /'J'| _-.g

with the scar tool.
SHOES (WHT) JUMPER WIRE
Repair open in the wire bemeen

'3 there 0-5 V or mere? - ECMIPCM (A23) and Secondary
H 028 (Sensor 2).
so: (ERNIE! LE]: :3 :31 P}
Substitute aknown-good ECM! lr/ ifuiPrfifiifi
PCM and reeheek (see page 11-A- 23 at: use; 2a 25% a‘
15 for immobilizer in formation). If -. ._ _ _
symptoml‘indieation 9°“ away, hire Side of female ten'iir'als
replaee the original ECWFW.

4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+# _ _
5

#.#!
/
# 1 1 A 61
H023) (Sensor 2) (cont’d)
.0/
0/
?0
P0139
'$9 The scan tool indicates Diagnostic Trouble Code (DTC) P0139: A slow response problem in the
4!(
4 !;(4<0+59%!3!
68/
;68<;< -
— DTc P013! is stored.
1. Do the ECMIPCM Reset
Procedure.
2, Start th e ergir e. i~cld the
ehgihe at 3. 000 rpm (mir'1j:
with rc Icacl Ijir' Park or hectral]
Lhtilthe radiator far‘ comes cr‘.
3_ Check the Seccr‘dary l-‘CES
(Sehscr 2} CLtt at 3. 000 rpm
[lair—1:: with the scar tccl.

: . . ‘ NC at this time. Check for poor
33836231: flragfcsfiifiggg ":3: connecti ons or loose wires at
' _ ' —'..--" Secondary H025 (Sensor 2} and
YES ECMIPCM.
Replace the Secondary H023

(Sen sor 2}.
PGM-FI System
'+#
Heated Oxygen Sensor (H023) Heater (H22A7
.#!
/.0./.7
11 -A-62
5
engine)
! 0
P0135
'$3 The scan tool indicates Diagnostic Trouble Code (DTC) P0135: A problem in the Primary
4!(
4 !;(4<0+9%!
Heated Oxygen Sensor (Primary HO2S) (Sensor 1) heater circuit.
68/
;68<;< -
P0141
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0141: A problem in the Secondary
4!(
4 !;(4<0*9%!
Heated Oxygen Sensor (Secondary H028) (Sensor 2) heater circuit.
68/
;68<;< -
PRIMARY Hozs (Sensor 1} 4P CONNECTOR

— DTC P0135, andior P0141 are
stored.
|
1. D: the ELEM/POM Reset
ProcedLre. ’ermir al side of male tennir‘als
2. Start the er‘gire.
In ternittent failu re, system is OK
Is D’C P0135 cr P0141 connections or loose wires at
ir'clicated? Primary H025 [Sensor 1),
[Secondary H023 (Sensor 2)’ and
YES ECMI'P CM.
Check for an open or shortin the SECONDARY H023 (Sensor 2) 4P CONNECTOR‘
H025:
1. ’e the igr‘iticr‘ switch OFF.
2. Disccrrecttt‘e I~C2S (Primary 1 2
cr Seccr‘dary'j: (Ser‘scr 1 or
Serscr 2] 4P ocr‘ rector.
4
3. Attre H328 side. measure
resistarce betweer‘ the PC28 -. it‘ll
4P ccrrectcrten‘tir‘ais No. 3
Wire side c7- female termir‘als
arcl No. 4.
- ls ti" ere approx. 3.3 ct‘i‘t ('12 - NC Replace the H025 (Primary or
14.3 crmjr at 200C IIBSCF}? Secon vi:lar1_.lP }.
YES
Check for ocr‘tir‘LJty betweer‘
body grc‘d ar‘d tl‘e PCZS 4P
ocrr ectcr termir‘als No. 3 ar‘d
No. 4 ird'widually.
—-... YES
C Is ti‘ere ocrtircity? Replace the H025 (Primary or
Se con cl arr }.
NC PRIMARY HO2S(Sensor1)4P CONNECTOR
IG1 I l P02 SH TC
Check for an open or short in the (ELK! 1 2
wires [P02SHTC, SOZSHTC' YEL)
line}:
1. 'e ti‘e igriticr switd‘ CN ill}.
2. Meaee voltage betweer ti‘e
I-C2S 4P ccrrectcr termirals
No. 3 ard No. 4. Wire SldL" 01 terrain: tenrn'rals
SECONDARY H028 (Sensor 2MP CONNECTOR'
Is ti‘ ere battery v citag e?
NC SOESH TC (ORNIBLU) t (BLIUYEL)
('0 page 1142-63] (Tc page 1142-53]

{2.1.1
'ennirai side of male termir‘ als
“. P0141
PGM-Fl System
'+# _ _
5
Heated Oxygen Sensor (H023) Heater (H22A7
.#!
/.0./.7 1 1 A 63
engine) (cont’d)
! 0/
?0
(From page 11 -.é‘~.-62] PRIMARY H025 [Sensor 1MP

R i F CONNECTOR
Check for an open in the wires 1 2

[l line): 4
3
MeaSLre voltage betweeh the IG1
primarvl-CZES 4P cohheotor (ELK)
terl'tir'al No. 3 Ijsecohdary H325: YE L)
NC- 4] ar'cl bodv nL-rd- Repair open in tin ewire between
NC Prima‘yHOiSfSensor 1]. Seoonda'y
lsthere battery voltage? Homihnmrirandfflo. GECU . ,w x 1 1 x x , __
YES flECMF‘CM] CRUISE CONTROLHSA) u".HI. Sum. 011t all. l Illals
fuse
Check for an open in the wires SECONDARY H023 [Sensor 2MP CONNECTOR'
[POESHTQ SOESHTC' line):
1. ’Lrh the igr‘itior‘ switch OFF.
2. Reoorr eat the H328 4P
oorr ector.
3. Disoohhectthe EClvlr‘PCM
oohh eotorfx Ij32P].
l [BLKI‘I'EL]:
In“ the igr‘itior‘ switch CN ill}. Fry
rh-
5. Meascre voltage betweeh the E'

ECMEPCM oor‘r‘ectortermir' als _ . . .
BE ardAECI (BE ahd .a\8j:'. ermnral Slde ofmale tennlr‘als
YES Rep air op en in the wire between

{___ Is there 0_1 V or less? _____'.' ECMI'PCM [13120,AB') and H025
'- (Primary, Secondanf).
NC
Substitute a known-good EClW EClWPCM CONNECTORS

PCf'u'l and recheck (see page 11 -A- PG1 (ELK)
1B for immobilizer information). If
symptomrindication goes away, a (25F)
replace the original ECMIPCM.
(From page 114‘1-62] POZSHTC

? [BLKJ'WHT]
Check for a shortin the wires _ A (32")

[POESHTQ SOESHTC‘ line): l 1.. r.- u r a a ‘U “|
1. 'e the ighitioh switch OFF. | '2[Ll'4‘-';,..--"“.-‘H‘Eizuk‘zz 23 24|
2. Disoorrect the ECMiPCM .--— 23 262.“ 23 L‘ 32
oorreotorfx 1:32P]. “i .
3. Check for cortihuity betweeh - SOZSHTC
the ECMIPCM oohheczor (BLKJWHTT
termirals A20 (1“8'] ahd body Wire side of female termir‘als
grocl.
Is there cohtih Lit'y? ECMIPCM (AREA?) and H028
[Primam Secondary).
POZSHTC
ECIWPCM CONNECTOR [BLKJ'WHT]
Substitute a known-good ECMI A [32F]
PCM and recheck (see page 11-A-
”L!
[-1.
15 for in‘rnobiliaer information). if

E":
syn‘ptomfindication goes away, ‘2 ‘3 ‘4 ‘ ' ' 2C 2‘ 22 23 24

E
‘:-.
(l—
replace the original ECMIPCM. 2;. 2a 2,- za ;' 32
SOZSH TC :
[ELKJ'WHTT ”h”
“. P0141 Wire side of female termir‘ als :
4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+# _ _
5
Heated Oxygen Sensor (H023) Heater (F2036
.#!
/.0./+$"5 1 1 A 64
engine)
! 0
P1166
'55 The scan tool indicates Diagnostic Trouble Code (DTC) P1166: An electrical problem in the
4!(
4 !;(4<9%!!!
Primary Heated Oxygen Sensor (Primary H028) (Sensor 1) heater circuit.
68/
;68<;< -
1. Do tl‘e ECMI'PCM Reset
ProoeclLre.
2. Start the er‘gire.
IS D—C P1166 irdicated? connections or loose wires at
— Primary H025 [Sensor 1) and
YES ECMIPCM.
ECMIPCM CONNECTOR B [25F]
2 2.1 4 E: .r' H
Cheek for an open or short in the
9 ‘LI “‘2‘2.'l‘-¢‘£;‘Ei‘ii‘§
wire [PH OESH T0 line):
‘Ei 2C 2‘ 22 22.12425;
I'uleaSLre voltage bet'weer ECM:l
- Q
PCM correctcrterinlr‘ais B1 , ar‘d Lf LG1 [BRNIBLIQ
-
-
BEE]. 3E] seccr‘ds after igr‘ iticr‘ PHOZSHTC V .1
switd‘ isteed CN [II]. [BLWHD .___—f Wire side of female termir‘als
—\fl POM and reeheek [see page 11-A-
(,1. '3 1" ere battery voltage? 18 for immobilizer in formation). If
smpton‘rfindieation goes away;
NC replace the original ECMI PCM.
wire [PHOZSHTC + line):
MeaSLre vcltage bet'weer‘ ECW
PCM ccrrectcr termir‘als 013 ar‘d
BEE].
ls tl‘ ere battery voltage? [—9 page “1‘35” ECMIPCM CONNECTORS

B [25H
‘ 2 a 4 a Bl
Cheekforan openorshortin the s ‘u ":213‘4‘3'6‘Ifi‘9l
wire [PH OESH TC line): ‘9 3“ £_ 333'“ 3"
1. _e ti‘e igriticr switci‘ OFF.
2. Dismrreqtre ECWPCM “31 ‘BRN’BL'Q c (31 P)
ocrrectcr B 1:25P]. L--" 3 L. 5 ,- 3 Q .U
3. _e ti‘e igriticr switci‘ CN Ijll}. |' ‘3'4'2‘6‘ {-13's2u :1 22
4. Measue voltage bet'weer' -: . 2:,- 2u2,23 29 at. 3‘
ECiu'll'PCl'ul ccrrectcr I: V 5| PHOZSHTG+
termlrals B19 arcl B20 Wire side of female tennirals T". [WHT)
Rep air op en or short in the wire

Is ti‘ ere battery v citage? between Primary H023 [Sen sor 1)
and ECI'II'IIPCM [B1 '5}.

PGM and recheck [see page11-A- - 2 3 4
II."
15 for in‘Inobiliaer information). If g ‘3 .. '2 ‘3 '4 ‘9 ‘5 ‘s ‘s

symptomfindication goes away, -9 23 2‘ 22 2a 24 2:.-
replace the original ECMIPCM. Lfi
PHDESHTC -—-.J LG1 iBRNIBLKi
[BLKJ'WHT) 1;.
4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+#
.#!
/.0./+$"5
11 -A-65
53
engine) (cont’d)
! 0/
?0
(Frem page 11 -A-E4}
V
Cheek flora short in the wire
SECONDARY HOES [Sensor 1 } 4P CONNECTOR
[PHOESHTC + line): PH O2SH Tc+

1. 'e the igritier switch ICFF. IWHT}
2. Diseerreet the ECMEPCM
eerreetcr C (25F) ardthe
F-‘rimary h-C2S (Serscr 1'; 4P
ecr'r'ector.
3. Check for oortirLity bet'weer‘
the Primary h-C2S (Ser‘sor1 j:
’ermiral side of male termir als
4P oorrectcrtermir'al No. 4
ard body groe.
Repair short in the wire bemeen
Primary H023 relay; Primary
Is there eertirLity?
H023 (Sensor1) and ECMIPCM
(C13).
Cheek fora short in the wire

[PHO2S HTCR lin e}:
1. ’e the igritier switch CN {ll}.
2. Measure yeltage bet'weer'
EClull'P CM our radar termirals
A20 arcl BED.
YES Replace the Primary H028

Is there batteryyclta ge?
[Sensor 1)
NC
A [32p] EWIPCM CONNECTORS
1: E .I' H Ei ‘ [i
‘ ' EU 2‘ 22 21.1 241
Cheek for a short in the wire: 21: 2H 2." ' 1J2
Cheek th e follcwirg fLses:
— HFJt‘ED SFJF (20 A} fuse in
under—heed fusea'relay tutor.
— Ne.EECU[ECWPCM}CRUISE
CON—ROL l, 1511} fuse in driver‘s
under—clash fus e’relay but.
— Me. 6 UtF HFJFER (20A) in
passenger's underdash fuse:I LG (BRNIBLK) Wire side of fem ale termirals
relay but.
YES Repair short in the wire bemeen

Are ary cf the fLses blcwr? the primary H023 relay and the
fuses.
Cheek for an open in the wire:

Check for ecrtirLityir the wires
betweer the primary l-C2S relay
ard the fl. ses.

Is there eertirLity? the primary H023 relay and the
fuses.
YES
The wires are OK, replace the

primary H025 relay.
PGM-Fl System
'+# _ _
55
.#!
/.0./+$"5 1 1 A 66
engine) (cont’d)
! 0/
?0
P1167
'57 The scan tool indicates Diagnostic Trouble Code (DTC) P1167: A system malfunction in the
4!(
4 !;(4<$9%!
Primary Heated Oxygen Sensor (Primary HO2S) (Sensor 1) heater circuit.
68/
;68<;< -
NOTE: If DTC P1162 is stored at the same time as DTC P1167, troubleshoot DTC P1162 first, then troubleshoot DTC P1167.
84 9(4(4$A !(4A !(4$-
— DTC P1167i5 stored.
|
1. LIICI tl‘e LCMIPCM Reset
Procedure.
2 Stan tl‘e engine. 'Wafl lDr at
IL‘E'tS‘t 3U SGCDI‘IJS.
Intermittent fa‘lum. system isOK at
IS D'C Pttfjr'indcated?
thistimu. Chuck for poor connoctions
or loosen-true : Primary H028
(Sensor 1] and ECMFCM.
PRIMARY H028[SENSOR1)4P CONNECTOR

Check for an open in the wire PH025+ (RED)
iPHOZS+. PH 028- lines):
1. ' urntl‘e lgl'lfllOl'l svritct‘ Oi l . 'ermir‘al side of male termir‘als
2. Disconted tl‘e Pnn‘ary l lOZS
4P cannectcr andtl‘e LCM!
PCM eemecior (3 (31m
13. Cl‘eds tor L‘Ul'ltll'lulty between
tl‘e Pnn‘ary l IOZS (Sensor 1; ECMIPCM CONNECTOR C [31F]
4P connecto' tem‘inal No. 2
PHOES+ . 3 5 ,- e 9 .U
and We Lc Mi‘PC M coni‘ector PH 025'
‘r"H‘92U2‘22
p
tern‘lrral C14 and between [BLU]
I:
Prm‘ai‘y l IOZS (Sensor 1_: 4P _ 25 2f 23 29 UL: Lt‘
cmnedortern‘iml No. 1 and gui-
L‘L‘MIPCM come-dd tenrinal {PH -—-" PHOZS- [E‘rLU]I
L 15. fl)
Wire side of female ten‘fiir'als
NU Repairupen in mcwirebetween
( Is iron: mi'ninuny? >— Primary H 025 {Sensor 1) and
ECMrF-CM “:14 or 5151
YLS

:Seneer 11
PGM-Fl System
'+# _ _
Fuel Supply System
+##
57
11 A 67
P1171
'7 The scan tool indicates Diagnostic Trouble Code (DTC) P1171: The fuel system is too lean.
4!(
4 !;(4<$94 !!-
P1172
'7 The scan tool indicates Diagnostic Trouble Code (DTC) P1172: The fuel system is too rich
4!(
4 !;(4<$94 !
Description
)

By monitoring the Long Term Fuel
)

4 Trim, long term malfunctions in the fuel system will be detected. If a malfunction has been
!4A!
! !3!!-!
detected during two consecutive trips, the MIL will come on and DTC P0171 and/or P0172 will be stored.

3 &A,3!!(40$=0$3!!-
NOTE: If some of the DTCs listed below are stored at the same time as DTC P0171 and/or P0172, troubleshoot those DTCs
84 9(4!!3(40$=0$A !(4
first, then troubleshoot DTC P0171 and/or P0172.
A !(40$=0$-
P0107-8:
00$'9 MAP sensor.
,%-
P0135*1,P166*2,P1167*2:
0+G Primary H028 (Sensor 1) Heater.
AGA$G 9 68;<6-
P0137-8:
0+$'9 Secondary H028 (Sensor 2)
68;<
P0141:
0*9 Secondary H028 (Sensor 2) Heater
68;<6
P0401:
0*09 EGR Flow
.1 Insufficient
!3
P0443:
0**+9 EVAP purge control solenoid valve circuit.
:%
!!&!& -
P1259:
59 VTEC System.
:4 -
P1491:
*59 EGR Valve Lift Insufficient.
.1:!& -
P1498:
*5'9 EGR Valve Lift Sensor High Voltage.
.1:!&6
:!
-
*1 :H22A7 engine
G96%$

*2:F20B6
G9 engine
0)

Possible Cause
'
*
DTC P0171
)'$7 Fuel Pump insufficient flow/pressure
! !3=
.QQQQQQQQQQQQQQQQQQQ
System too lean

#
Fuel ! Feed Line clogged, leaking

!
A!#
Fuel Pressure Regulator stuck open

! 1
! #
Fuel ! Filter clogged
!!

Fuel Injector clogged, air inclusion
!7!
A!
Gasoline doesn’t meet Owner’s Manual spec.
.!B83B, !-
Primary H028 (Sensor 1) deteriorated
68;<
MAP Sensor range/performance
,%
=
EGR System malfunction (too much flow)
.1! ; !3<
Valve Clearance
:!&!
Exhaust leak
/ !#
DTC P0172
)'$7 Fuel Pressure Regulator clogged, stuck closed
! 1
!!
A #!
System too rich
#
Fuel Return Pipe clogged

!1 !

Fuel Injector leaking
!7!#
Gasoline doesn’t meet Owner’s Manual spec

.!B83B, !
Primary H028 (Sensor 1) deteriorated
68;<
MAP Sensor range/performance
,%
=
EGR insufficient flow
.1 !3
EVAP Purge Control Solenoid Valve leaking, stuck open
:%
!!:!&!#
A #
Valve clearance
:!&!
PGM-Fl System
'+# 58
Fuel Supply System (cont’d)
-
-
+##/
?0 11 A 68
Troubleshooting

* Flowchart

!+
(
— DTC P0111 andIor P0112 are
stored.
|
Cl‘ edr tl'e fl. el pressue.
l3 fLelpressue CK?
YES / Istl‘e fLeI pressuetcc l‘igl‘

or too low?
check the Primary H023: ~—
1, Start tl‘e ergir‘e. l-oldtl‘e LOW
ergire at 3.000 rpm (Mir-1:: Check the fuel pressure regulator
witl‘ ro load Ijir' Park or neural} and fuel return pipe.
Lrtiltre radiator far comes or‘.
2, Check the Primary l-C2S
Check the fuel pump, fuel feed
(Sersor 1:: oLtt witl‘ the
pipe, fuel filter, and fuel pressure
scar tool.
regulator:
Does it stayat lesstrar 0. 3V""--...;-

Replace the Primary H028.
or more that“ 0.6 V?
Check for a sticking or leaking

E'v'AP purge control solenoid
valve:
Witl‘ a trauma l‘ip. apply vamu‘t
to tie EVAP ege ccrtrcl soler‘oid
valve from tl"e irtake I‘tarifold side.
Does it hold vamu‘t’? NC Replace the EVAP purge control

solenoi d valve.
._ YES '-
Check the MAP sensor output:
1, ‘e tl‘e igriticr S'vtitd‘ CN {ll}
2, Cl‘ edt tl‘e MAP 'witl‘ tl‘ e scar
tool.
Does it ir dicate atmospheric:

press L re ?
NC Check the response of MAP
sensor:
1. Start tl‘e er‘gir‘e.
2. Checktre MAP w'tl‘ tl‘e scar
tool.
" Is a MAP of 400 kPa l300 n"n"Hg,

12.0 in] or less irdicated'mt'ir'
cre semrd alter starlirgtt'e
ergire?
YES
Check the valve clearances and

adjust if necessary If the valve
clearances are OK, replace the
fuel injectors.
PGM-Fl System
'+# 11 -A-69
59

Random Misfire
P0300 and
'$$$ The scan tool indicates Diagnostic Trouble Code (DTC) P0300 and some of P0301 - P0304:
4!(
4 !;(4<0+000+00+0*9
P0301 through
'$$
! Random misfire.
1-
P0304
'$$
Description
)

Misfire detection is accomplished by monitoring the crankshaft speed with the crankshaft position (CKP) sensor which is
,!
#3#;><3
attached to the crankshaft. If misfiring is strong enough to cause damage, the catalyst is detected, the MIL will blink during the
#-

A!A,3!!!#

time of its occurrence, and DTC P0300 and some of DTCs P0301 through P0304 will be stored. Then, after misfire has
A(40+00(40+0
0+0*3!!-4A
ceased, the MIL will come on. If misfiring increases, emissions are detected during two consecutive driving cycles, the MIL will
A,3!!-
A
3 &&
!A,3!!
come on, and DTC P0300 and some of DTCs P0301 through P0304 will be stored.
A(40+00(40+0
0+0*3!!-
NOTE: If some of the DTCs listed below are stored at the same time as a misfire DTC, troubleshoot those DTCs first, then
84 9(4!!3(4A !(4A
troubleshoot the misfire DTC.
!(4-
P0107, P0108:
00$A00'9 MAP Sensor
,%
P0171, P0172:
0$A0$9 Fuel metering
!
P0401, P1491, P1498: .1

0*0A*5A*5'9 EGR system
P1259:
59 VTEC System
:4
P1361, P1362:
+A+9 TDC sensor
4(
P1381, P1382:
+'A+'9 CYP sensor
C
P1519:
59 IAC valve
!%&!&
Possible Cause
'
*
¢ Fuel pump insufficient fuel pressure, amount of flow
! ! A !3
Fuel line clogging, blockage, leakage
!!!

A!#
A!#

.QQQQQQQQQQQ
Fuel filter clogging

!!!

Fuel pressure regulator stuck open

!
! #
EGR system malfunction
.1!
Distributor malfunction
( !
Ignition coil wire open, leakage

!3A!#

Ignition control module malfunction

! !!
MAP sensor range/performance, poor response
,%
=A
Valves carbon deposit
:!&
Compression low
!3
IAC valve malfunction
%&!&!
VTEC system malfunction
:4 !
¢ Fuel does not meet Owner’s Manual spec., lack of fuel
!83B, !-A!# !
Troubleshooting

*
!
By test-driving, determine the conditions during which misfire occurs. Depending on these conditions, test in the order
)&
A
3 -(
A
described in the table below.
!!3-
'55-.— Possible cause I Crankshaft
EGR MAP Fuel Distributor and Valve IAC
. ------------------- "--. ' position ICM
'- . s stern sensor ressure | nitionwires Clearance Valve
'\ F399 \ Y sensor p g .
______________________________________________________________
Condition 1'1-A-139 11-A—39 section 6 'I1-A-‘ifl'l section 4 ' section 4 section 6 1142-34
Only low rpm and 5:: st: '3
[on]
[El
['99]
..
load
Only accelerating 'IEI- Eli'- - !._1_.I

[n
Only high rpm and '_._.:

lead
Not specific 13.3. 3' 1’57- fl‘.‘ I23 .i . {5.1

a.)
NOTE: If the misfire doesn't recur, some possible causes are fuel that doesn't meet owner‘s manual spec, lack of fuel, carbon
84 9@ A! !@3@ !A!# !A
deposits on spark plug, etc.
#!
A-
4

&A
!#!!3
9
;'!%+5<
;'!%+5<
;'!%0<
;'!%'*<
PGM-Fl System
'+# _ _
7$
Misfire Detected in One Cylinder
) # 11 A 70
P0301
'$$ The scan tool indicates Diagnostic Trouble Code DTC) P0301: Cylinder 1 misfire detected.
4!(
4 !;(4<0+09!-
AAAA
P0302
4!(
4 !;(4<0+09!-
P0303
4!(
4 !;(4<0+0+9!+-
P0304
4!(
4 !;(4<0+0*9!*-
Description
)

Misfire detection is accomplished by monitoring the crankshaft speed with the crankshaft position (CKP) sensor, which
,!
#3#;><A3
attached to the crankshaft. If misfiring is strong enough to cause damage, the catalyst is detected, the MIL will blink during the
#-

A!A,3!!!#

time of its occurrence, and DTC P0301, P0302, P0303 or P0304 will be stored. Then, after the misfire has ceased, the Mll
A(40+0A0+0A0+0+0+0*3!!-4AA,
come on. If misfiring that increases emissions, is detected during two consecutive driving cycles, the MIL will come on and DTC
-
A
3 &&
!A,3!!(4
P0301, P0302, P0303 or P0304 will be stored.
0+0A0+0A0+0+0+0*3!!-
NOTE: If some of the DTCs listed below are stored at the same time as a misfire DTC, troubleshoot those DTCs first,
84 9(4!!3(4A !(4A
troubleshoot the misfire DTC.
!(4-
P0107, P0108:
00$A00'9 MAP sensor
,%
P0171, P0172:
0$A0$9 Fuel metering
!
P0401, P1491, P1498: .1

0*0A*5A*5'9 EGR system
P1259:
59 VTEC System
:4
P1361, P1362:
+A+9 TDC sensor
4(
P1381, P1382:
+'A+'9 CYP sensor
C
P1519:
59 IAC valve
%&!&
Possible Cause
'
*
¢ Fuel injector clogging, fuel leakage, air leakage.
!7!

A !!#
A!#
-
Fuel injector circuit open or shorted.
!7 -
.QQQQQ
Spark plug carbon deposits, fouling, malfunction.

#!
A !
A! -
Ignition wires open, leaking.

3A!#
-
Distributor malfunction.
( ! -
Compression low.
!3-
Valve clearance out of spec.
:!&! -
PGM-Fl System
'+# 7
Misfire Detected in One Cylinder (cont’d)
) # /
?0
Troubleshooting

* Flowchart

!+
(
— 'lhe MIL has been reported on.

— DTc P0301, P0302, P0303 or
P0304 is indicated.
Check the fuel injector function:

Startti'e ergir e. arcl lister for a
diokirg soe atti'e fL.e| irjector
ir ti'e problem cylirder.
E NC
< Does ItL/—‘
YES
Ci‘ ed; for ar oper or srort ir tre
rarress betweer ECM.I'PCM, ard
tre fLeI irjector.
A re tr e wires 0 K?
YES
Repair open or short in the wire.
— Replace the fuel injector.

— Substitute a known-good
ECMIPCM and recheck [see
page 11 -A-1 8 for in'mobilizer
information). If syptoml
the original ECMIPCM.
Problem ve rification:
1. After oredtirg the freeze data. NC‘E:
do tre ECMIPCM Reset e lftrere is ro freeze data of misfirirg.
ProoedLre.
just dear tre D'C.
2. Excrargetl‘e spark pn from
e lftrere is ro freeze data of misfirirg.
tre problem oy'lirder with ore
test times eer various oorditiors
of arotrer oyiirder.
3. Correottl‘e 808 short are r eoessary.
Corrector.
4. 'est-drive tre oar several times
ir tr e rar ge oftre freeze data.
('o page 11 -A-T2}

4

&A
!#!!3
9
;'!%<
PGM-FI System
'+# 11 -A-72
7
Misfire Detected in One Cylinder (cont’d)
) # /
?0
(From page 11 -A-T1 j:
Intermittent nisfire clue to spark

Is III—C P0301. P0302. P030300“-
plug fouling, etc. [no ntisfire at
or PE] 304 ir' dioated?
this time}.
YES
Does the Misfire oooL.r ir‘ the I YES

oth er oyiir'derwhose spark plug Replace the faulty spark plug.
was exoh ah ge d?
NC
Check for fuel injector malfunction:

1. Excharge the fL.e| ihjector
from the problem cylir‘der
with ore from ahoth er
oyiircler.
2. Let th e er gir e idle for two
InirLtes. Note: ifthere is r'o freeze data of
3. 'est—dr'ru'e the vehicle serve ral misfirir‘g test drives LhdervarioLs
times ir the rarge ofthe freeze oor‘ditior's are heoessar'y'.
data.
Intermittent misflre due to bad

IS D_C P0301. P0302. P0303. "
contactin the ei injector
or P0304 irdioated? " connector [no misflre at this time}.
YES
—K
Does the Misfire CCCLI'il" the
YES Replace the faulty fuel injector.
other oyiihder whose fLel ihjeotor “.1:
was exoh er ged?
NC
Check the following items:

— 1Li'altre clearance.
— Cylinderleak-down.
— Compression.
— Crankshaft Position (CKP)
sensor.
PGM-Fl System
'+#
Knock Sensor (KS)
I
6
/I0
11 -A-73
7
P0325
'$3 The scan tool indicates Diagnostic Trouble Code (DTC) P0325: A malfunction in the circuit of
4!(
4 !;(4<0+9%!
the Knock Sensor (KS).
>#;><-
PIEZO CERAMIC
— DTc P0325 is stored.
DIAPH RAGM
procedLre.
2. Start the er‘gihe. l-cld the
ehgihe at 3000 rpm lmir‘ "1::
with he load Ijir‘ Park or
heLtralj: L.hti| the radiator
far comes cr‘. th eh let it idle.
h-cldthe er‘ gir‘e at 3.000 -
4,000 rpm Ijmih'1j: for at least
E0 seccr‘ds. Inten'nittcnt failure, system is OK
at this time [test-drive may be
nece ssaryr}.
IS D—C P0325 ir‘dimted? Check for poor connections or
loose wires at knock sensor (KS)
and ECMIPCM.
Check for a short in the wire [KS
line}: ECIWPCM CONNECTOR C [31F]
1_ 'e the igr‘iticr‘ switch CFF.
2. Bisccrr‘ect the kr‘cck‘ ser‘scr K5 [REDIBLU]
'l P ocr hector.
3. Ch ends for ocrtihcity betweer'
ECMIPCM ocr‘r‘ectcr teri‘tir‘als luhn‘il
CG ard body grccr‘d.
"Mre side of female terl‘tir‘als
l 5 th ere oc htih L. ity? YES Repair short in the wire between

ECWPCM [63} and knock sensor.
NC
Check for an open in the wire (KS

line}:
Check for ccrtihcity betweeh
ECMIPCM ccrhectcr tennihal 03
ard krcck sehscr correctcr
terl'tiral No. 1. KNOCK SENSOR 1P
CONNECTOR
Rep air open in the wire between
Is there ccrtihmty'?
ECI'II'IIPCM [ca]: and knock sensor.
Wire side of fem ale
Ks terl‘tir‘als
SLbstitLte a kth-gccd khcck [RE DIBLU)
serscr ahd recheck.
|Iohn‘ |
KS
(REDIELU)
IS Ell—C P0325 ihdicated? Replaucthc original knock sensor. ECMIPGM CONNECTOR
C(31P‘}
YES
L- e r e s ‘c
Substitute a known-good ECMI .4. eu'w‘s acre:
II."
PGM and recheck (see page 11-A- 23 25.: 25 at 2:5 as an 3‘

15 for immobilizer information. If
symptomfinclication goes away, Wire 5i de cf fem ale te n‘tirals

4

&A
!#!!3
9
(See Page 11-A-16)
;'!%<
PGM-FI System
'+# 11 -A-74
7
Crankshaft
6 Position/Top Dead Center (CKP/TDC)
'

2
)/I'2)0
Sensor

P0335
'$3 The scan tool indicates Diagnostic Trouble Code (DTC) P0335: A malfunction in the Crankshaft
4!(
4 !;(4<0++9%! #
Position (CKP) sensor circuit.
;>< -
P0336
'$5 The scan tool indicates Diagnostic Trouble Code (DTC) P0336: A malfunction in the Crankshaft
4!(
4 !;(4<0++9%! #
Position (CKP) sensor circuit.
;>< -
P1361
'5 The scan tool indicates Diagnostic Trouble Code (DTC) P1361: Intermittent interruption in the
4!(
4 !;(4<+9
Top Dead Center (TDC) sensor circuit.
4(;4(< -
P1362
'5 The scan tool indicates Diagnostic Trouble Code (DTC) P1362: No signal in the Top Dead
4!(
4 !;(4<+9
!4(
Center (TDC) sensor circuit.
;4(< -
Description
)

The CKP Sensor determines timing for fuel injection and ignition of each cylinder and also detects engine speed. The TDC
4>
!7
!!
-44(
Sensor determines ignition timing at start-up (cranking) and when crank angle is abnormal.

;#
<3#
!!-
NOTE: If DTC P1359 is stored at the same time as DTC P0335, P0336, P1361 and/or P1362, troubleshoot DTC 1359 first,
84 9(4+5(40++A0++A+=+A !(4+5A
then troubleshoot those DTCs.
!(4-
fiKP SENSOR
@E: — 33W
A"?
Adi/f
51:51"
“N.
“‘R'rnc SENSOR
CKPITDC SENSOR 4P CONNECTOR

— DTC P0335, P0336, P1361 and!
TDCP
GE}
U TDCM
or P1352 are stored.
l—I
Prehlem verification:
1 2
1. Do tl‘e ECMIPCM Reset 3 4
Prc oedL. re. CKPP CKPM
2. Start tl‘e ergire. Iftre er‘gir‘e {Jhn‘i
._ .'
does not start, te the igr‘iticr‘

'ermir‘al side cf male tennir‘als
switcl‘ to start pcsiticr (II I}
fcr1|ZI seccr ds.
Is D_C P0335. P0336. P1361 . at this time. Check for poor
cr P1362 irdicated? oonneotions or loose wires at
CKPITDC Sensor and ECIWPCM.
YES
Cheek for an open in the CKP! SE NS CR DTC SENSOR ECM IPCM WIRE
TDC sensor: TERMINAL TERMI HAL COLOR
1. 'e tt'e igr iticr switd‘ OFF. 'DC P1361 1 C20 GRN
2. Disccrrect ti‘e CKPFDC
serscr4P ocrrectcr. P1 362 2 I321 RED
3. Meaee resistar CE: betweer
tt'e tennirals cftre irdicated
CKP P03 35 3 CE BLU
serscr [' see table] PD 336 4 I39
"NI"—
Istt'ere 2.010 - 2.510 ci‘m Replaee the CKPITDC sensor [see

at 20°C {68°F}. section 6).
(Tc page 1143-75}

PGM-FI System
'+# 11 -A-75
73
Crankshaft
'

2
)/I'2)0
Sensor(confd)

/
?0
CKPITDIC SENSOR 4P CONNECTOR

(From page 11 aft-.74]
TDCP 4F=:L TDGM
1
CKF‘P
3 CKPM
@ ®
Check for a short in the CKPI
TDc sensor: [Win
Check for mhtihuityto body
groLr'd or both termihals of the
inflated ser‘sor ihdividLally.
’e n‘tihal side of male terl‘tir‘als
Is there oortihLity? Replace the CKPITDC sensor.
Check for an open in the wires

[CKPI'IDC lines):
1. Recerrect the CKPI’DC ser'scr
4P cerrectcr.
2. Dismr‘r‘ect the ECMIPCM
cerrectcr C 1:31P].
3. MeaSLre resistahce betweer‘
the ten‘tir'als cfthe ir‘dicated
serscr or the ECMJ‘P CM
ccrrectcr If 'see tabl e]. ECIWPCM CONNECTOR C [31F]
5__________l__________1 CKPP CKPM

Isthere 2.010 — 2.510 ohms Repair open in the indicated (BLU) 4' ohn‘ .
Nil-IT}
'1 at2000(680F]? sensorwires rsee table)
YES
Check for a short in the wires
[CKPI'IDC lines): 2L1 25 26 .a ' JUL: 3‘
Check for ccrtihu'rty betweeh
be the grcd ahd ECMA‘PCM
TDCP TDCM
ccrrectcr termihals (33 ahdfor
[GRN] [HE D}
I32 irdividLally.
W re side of female termir‘als
Is there CChtihLity? Repair short in the indicated

sensor wires ['see table).

CKPP
POM and recheck (see page 11-A- l3LU}
15 for in‘rnobiliaer infon'nation).
lfsyn‘ptomlindication goes
away, replace the original ECMI
PCM.
PGM-Fl System
'+# _ _
75
Crankshaft
'

2
)/I'2)0 1 1 A 76
Sensor (cont’d)

/
?0
P1359
'39 The scan tool indicates Diagnostic Trouble Code (DTC) P1359: A problem Crankshaft
4!(
4 !;(4<+59%!#
Position/Top Dead Center (CKP/TDC) sensor circuit.
=4(;>=4(< -
— DTC P1 SEE is stored.
Problem ve rification:
1, Baths ECM.-'PCM Reset
ProcedLre.
2, Stature ergir‘ 3. mm er gire
does not start. te‘ the
igritior start switct‘ to pcsiticr‘
UH} for1 CI secor‘ds.

NC
{2: IS D'C P1359 ir‘dicated?
connections or loose wires at CKPI
YES TDC sensor and ECMIPCM.
Cl‘eck for poor ccr‘r‘ecticr‘s or

loose wires betweer tl‘e CKPJ‘
'DC serscr ard tl‘e ECMJ'PCM.
—\-.. NC
( Are the ccrrecticrs CK? "'r—l Repair as necessary
YES
Substitute a knmn-good ECM!

PCM ancl recheck (see page 11-A-
symptomfinclication goes away,
replace the original ECMfPCM.

4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+#
Vehicle
4 Speed Sensor (VSS) (MIT)

/40/20
11 -A-77
77
P0500
'$3$$ The scan tool indicates Diagnostic Trouble Code (DTC) P0500: A malfunction in the Vehicle
4!(
4 !;(4<0009%! :!
Speed Sensor (VSS) circuit.
;:< -
Make SLFE lifts. jadts ard safety
startle are placed properly (see
1. Test-drive tre vel‘ icle. sectior 1].
2. Check the vel‘ide speed witl‘
the scar tool.
lnternittent failure, system is OK

Is the correct tool ird icated? at this time. Check for poor
connections or loose wires atVSS
and ECM.
Check for an open in the ECM: ECM CONNECTORS

1. ’e tl‘e igriticr sw‘td‘ OFF.
3125i!)
2. Blooktre rear'wl‘eels ard set ‘ 2 a 4 .2 r a
the parki brake. a 'u "'2 ‘3‘4'o’fi r a
3. sack Lptl‘e frcr‘t oftre vet'iole ‘9 2c 2' 22 2:124 22
arcl SL. pport it witl‘ safety um [ERNIE-LIE} c [31 P)
stards.
’e tre igr‘iticr‘ sw‘td‘ CN ill}. :j L b .' a g . Li
I'd"?-
Blooktre right from 'wf'eel ard "31'4'55 Ei‘r"H ‘9 HUE‘ 22

slowly rotate the left from 23.1 25.: 25 2.7 23 £9 L“: :J‘
v.i" eel.
E. I'vleaSL. re voltage betweer the Vol vss lawman
ECM correctcrten‘tir'als B20
arcl C23. Wire side of female ten‘tir‘als
YES
Does the voltage pulse betweer:"'-.._I_.9— ancl recheck [see page 11A-16
0 V ard approx. 5 V or battery for immobilizer information). If
voltage? smpton‘tl‘indication goes away,
replace the original ECM.
NC
Check for a short in the ECM:

A
h.
D.
[a
1. ‘e tl‘e igriticr switcl‘ OFF.

2. Disoorreottl‘e ECM correctcr
C [31H
3. ‘e tre igritior switcl‘ CN ill}. LG1 [enmem
4. Bionic tl‘e rigrt frcrt wl‘eel
1::-
arcl slowlyrotate tl‘e lelt frcrt ' EU 2‘ 22

A
Di.
c5
U."
wi‘eel. ' -"'2-'; 252.’ 23 d9 3U Ll‘

Measue voltage betweer the
5J1
ECM corrector termirals B20 vss (BLUJ'WHT)

arcl C23.

Does the voltage pulse betweer ancl recheck [see page 11-A-16
0 V arcl approx. 5 V or battery for immobilizer information). If
vonage? smptoml‘inclication goes away,
NC
— Repair short in the wire

between ECM (023) and the
USS.
V53.
— lfwire is OK, test the V35
[see section 23).

4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+# 11 -A-78
78
Barometric Pressure (BARO) Sensor
"
'/"0
P1107
'$7 The scan tool indicates Diagnostic Trouble Code (DTC) P1107: A low voltage problem in the
4!(
4 !;(4<0$9%!3&!
!
Baro sensor circuit.
) -
P1108
'$8 The scan tool indicates Diagnostic Trouble Code (DTC) P1108: A high voltage problem in the
4!(
4 !;(4<0'9%
&!
!
Baro sensor circuit.
) -
— DTc P1107 or P1108 is stored.
1. Butte ECMJ‘PCM Reset
Procedure.
2. ’e the igr'iticr‘ switch ON {II}.
_l_
Is D'c P110? or P1108 imitated-“‘3‘ NC """'.'“i‘.‘°"‘ him"! “5"” is OK
at thls tlme.
YES

POM and recheck [see page 11-A-
If the syn‘ptomtindicalion goes
away, replace the original EGMJ‘
POM.
4

&A
!#!!3
9
;'!%<
PGM-Fl System
'+# _ _
79
Cylinder Position (CYP) Sensor
# '

/>'0
11 A 79
P1381
'8 The scan tool indicates Diagnostic Trouble Code (DTC) P1381: Intermittent interruption in the
4!(
4 !;(4<+'9
Cylinder Position (CYP) sensor circuit.
!;C< -
P1382
'8 The scan tool indicates Diagnostic Trouble Code (DTC) P1382: No signal in the Cylinder
4!(
4 !;(4<+'9
!!
Position (CYP) sensor circuit.
;C< -
Description
)

The CYP Sensor detects the position of No.1 cylinder for sequential fuel injection to each cylinder.
4C-!F ! !7!-
PICK-UP
. ” JESSE l'iELY
PICK-UP ..
AS-SE l'iELY

— DTC P1331 andror P1382 are
stored.
Prohlem verification:
1. Dc ti“ e ECMIPCM Reset
PrccedL. re.
2. Start ti‘e ergire.

—— NC . .
ls D‘C P1381 ardfc1382 \ atthls time. Check for poor
irdicated? oonn eoti on s or loose wires at 62%?
YES distributor and ECM‘PCM.
Check the ignition [spark plug)

wires:
Check for poor ccrrecticrs at the
igr'iticr' [spark pn} wires ard
tt'e ccr'diticr cfti‘e igriticr
wires [see secticr 4}.
Are “.3 wires CK? NC Reconnect or replace the ignition

(s park plug) wires.
YES
(Tc page 11 43-80}

PGM-Fl System
'+# _ _
8$
Cylinder Position (CYP) Sensor (cont’d)
# '

/>'0
/
?0 1 1 A 80
J‘
(From page” " -rs':- bismIBUToR-w CONNECTOR
I H22A7 cn gin c:
Check for an open in the CYP FEDBE cnginc: CYPP
sensor:
1. 'e' the ighitioh switch CFF. y—y—F—fl
2. Disoohhectthedistribctor 1 2 3 4 .
bohr'ecto r.
3. Meascre the resistahbe '3v '3v
betweer‘ the distribLtor 4P CYPM
bor'r'ectorterr‘tihals No. 3 art! — - . . . _ _
. ermir‘al Side of male tEfl‘ill‘aIS ’ermlhal SIdE‘ Cf male ten‘tlhals
No. 4 (No. 2 ahd No. 41'.
': h-EEAT er' gir‘e
NC Replace the distributor ignition
Is there 0.8 -1." k ohm?
J housing [see section 4).
YES
F2 DEE en gin e:
H22A7 engine:
it]
Check for a short in the CYP
CYPP
a»?
sensor: 1 2 3 4
Check for DSPtiPty betweer‘
body groe ar‘d the distributor CYPP CYPM
corrector termir‘als No. 3 ahd [/"a
No. 4 (No. 2 ar‘d No. 4::‘ir‘di'u'idLaIIy: °"'T mg)
/ Is there cohtih city? \Z YES Replace the distributor ignition

housing [see section 4).
NC
ECMIPCM CONNECTOR 0131?}
Check for an open in the wires 'd L- o r s g ‘c

[CYPline}: “ ‘d_'4'L~ rj‘r 3‘9 zuz‘zz
1. Reoorrect the distributor 2d,!" 29 2‘1 2-" 23 £9 'JU 3‘ CYPM
oohrector.
2. Disoorrectthe ECMiPCM CYPP
borr ector C 1:31P]. (YEL)
3. MeaSLre resistahce betweeh
ECMIPCM oohhector
termirals C29 ard 030. Wire side of female termir‘als
NC Rep air op en in the wire between

Is there 0.8 — 1.5 k ohm? — ECIWPGM [629, CEO) and the
distributor.
YES

[CYP lin e}:
Check for cortihcity betweeh body
II."
groLr‘d ard ECWPCM oohhedor . -' ' 3L- 3‘ 33

p
A
I...
Di.
'1"
I:
termihal .3251 23y" 2:.- 25 2.-' 23 as an 3‘

CYPP
YES Repair short in the wire between WEL}
'5 there OGFIif‘LiW? ECMIPCM [629} and the @
NC distributor.

symptontfinclication goes away.
'+#
PGM-Fl System
8
-
-
ECM/PCM Internal Circuit
%2' 11 A 81
P1607
'5$7 The scan tool indicates Diagnostic Trouble Code (DTC) P1607: A ECM/PCM Internal Circuit
4!(
4 !;(4<0$9% ,=,!
Problem.
!-
- DTc P160? is stored.
1. Dotre ECluii'PCM Reset
ProoeclLre.
2. ’e the igriticr switch CN ijll].
3. Wait ti" ree seccr‘ds
'
__l_
ls D‘C P1607 irdicated? NC Intermittent failure, system is OK
this time.
YES

PCM and recheck (see page 11-A-
16 for immobilizer in formation). If
symptomiindication goes away,
replace the original ECWPCM.

4

&A
!#!!3
9
;'!%<
.#!

Replacement

11 -A-82
8
1.
- Disconnect the H028 4P connector, then remove the
(68*A& Secondary H028:

#.F
H028.
68- SECONDARY H025
Primary HOZS:
' #.F #4 Wm ”.5 kgf-m,
33 lb‘f-fll H025 4P CONNECTOR
F2036 engine:
+$"5! F
H025 4P CON NEOTOR
O: SEN-SCH WRENCH
O: SENSOR Snap-an YABBTS or
WRENCH
FHJMAR‘I' H025 Snap-an
equivalent
u M-m “.5 kgf-m. YAESTB or
-
2. !!68&&!-
Install the H028 in reverse order of removal.
33 lbf-ft] equivalent
H22A7 engine:
.7! F
PRIMARY H025
:4 Mn [45 uni-m. 33 lt]
H025 4P CONNECTOR
Dz SENSOR
WRENCH
Snap-on YABBII'S or
equivalent
Idle Control System

# 11 -A-83
8
System Description
#)
The idle speed of the engine is controlled by the Idle Air Control (IAC) Valve. The valve changes the amount of air bypassing
4!
!!!%!;!%<:!&-4&!&

into the intake manifold in response to electric current controlled by the ECM/PCM. When the AC Valve is activated, the valve
#!! !! ,=,-2%:!&&A&!&
opens to maintain the proper idle speed.
!-
-' ENGINE
_i (:00a From
_ _ _ 1I'ELl‘__ _ _ PGM-FI
ELK '' MAIN
RELAY
_ VARIOUS
. _ _ _ gig—J SEW sensons
am
1.
- After the engine starts, the IAC valve opens for a certain time. The amount of air is increased to raise the idle speed about
%
A%&!&-4 !
150-300 rpm (min-1).
0+00;<-
2.
- When the coolant temperature is low, the IAC valve is opened to obtain the proper fast idle speed. The amount of
2! !3A%&!&!-4
bypassed air is thus controlled in relation to the engine coolant temperature.
!!!
! -
3.
+- When the idle speed is out of specification and the scan tool does not indicate Diagnostic Trouble Code (DTC) P1519,
2! !(
4 !;(4<5A
check the following items:
#!!3
9
Air conditioning signal (See Page11-A—86).
%

!;'!%'<-
9999999
ALT FR
%4 signal (See Page 11-A-88).
1
!;'!%''<-
Brake switch signal (See Page 11-A-90).
)#3
!;'!%50<-
Starter switch signal (See Page 11-A-91).
3
!;'!%5<-
A/T gear position signal (see section 14).
%=4

!;*<-
PSP switch signal (See Page 11-A-92).
3
!;'!%5<-
Hoses and connections
6
0 IAC valve and its mounting O-rings
!%&!&
8

4.
*- If the above items are normal (and the scan tool does not indicate DTC P1519), after AC valve replacement, substitute a
&!;!(45<A%&!&!A
known-good ECM/PCM and recheck. lf symptom goes away, replace the original ECM/PCM.
#3
,=,#-
3A!
! ,=,-
Idle Control System

# 11 -A-84
8
Idle Air Control (IAC) Valve

/04-
P1519
'39 The scan tool indicates Diagnostic Trouble Code (DTC) P1519: A problem in the Idle Control
4!(
4 !;(4<59%!!!
(IAC) valve circuit.
;%<&!& -
The IAC Valve changes the amount of air bypassing the throttle body in response to a duty signal from the ECM/PCM in order
4%:!&

!
! ,=,
to maintain the proper idle speed.
!-
FromAlR
4" CLEANER
- 'lhe MIL has been reported on.
- DTc P151! is stored.
‘ QMI... TolHTAKE
.:_‘-='
NIAHIFQD
Problem verification
1. Dcthe ECM-‘PCM Reset
ProcedLre.
2. ’e the igr'iticr' switch CN Ijll}.

atthis time. Check for poor
C IS D—C P1519 ir‘dicated? >—NC
connections or loose wires at IAC
YES valve and ECMIPCM.
Check for an open in the wire IAC VALVE 3P CONNECTOR

[IGP line]:
3|
1, IN the ighitich switch IOFF.
2, Discchh ect th e IAC valve 3P
|1 2
och hedc r. IGP WELIBLKIJN
3. in the ighitich switch CN {ll}. I:-
H€55.
4. At the wire harhess. meascre
voltage betweeh IAC valve 3P
ocr hedcrtermihal Nc. 2 ar‘d
bcdv nLr‘d. Wire side of female tennir‘als
Repair open in the wire between

Nc
if ls th ere battervvcltage? the IAC valve and PGM-Fl main
relay
YES

[PG line}:
49‘
1. 'e the ighitich switch OFF.

PG
2. At the wire harness. check for
"3q
ccr'tir'Litv betweer IAC valve
3P ecr'r ectcr termih al No. 1
ar' d bcdv grcLhd.
Repair open in the wires between

( Is there ccrtih Litv? )—NC ECMIPCM and G101 [located at
the thermostat housing).
YES
ECIWPCM CONNECTOR B [25F]

Check fora short in the wire
[IAC‘IJ' line}: 2 3 4 2 f 3
1 , Disccrrect the ECMEPCM E “U ...2.3a4
ccr‘r‘ectcr B (25P1.
2C 2‘ 22 23 24 22
2. Check for ecrtirLitv betweer
bcdv grcd ar'd ECMEPCM [AW
ccr‘r‘ectcrtermir'al B23. [ELIUBLLH
(Tc page 11-13-85} Wire side of female termir‘ ale

Idle Control System

# _ _
83
Idle Air Control (IAC) Valve (cont’d)

/04-/
?0 11 A 85
_ _ YES Repair short in the wire between

i '3 ”‘3“? DE— the [Ac valve and ECMIPCM
NC (323)
IAC VALVE 3P CONNECTOR
_
Wll'e Slde 01 tetraelermnas IACV lBLKJ'BLU}

ECIWPCM CONNECTOR B REP}
Check for an open in the wire 6;“ . 2 3 4 g ,- g

Hemline]: __.- g ‘u ...2.3.4.2.fi.{..3
Cl‘eek for oortirLity betweer‘ IAC ‘9 2c 2‘ 22 23242:.-
valve 3P oorrectortermir‘al No. 3
ar'cl EClull'PCl-al corrector tennir‘al IACV ‘8 LKIBLU}
323. Wm: 51t 01 lcn‘dclm'n‘ll'lds

ls tl" ere cortirLity? '3? the [AC valve and EClWPCM
(823).
YES
ECMJ'PCM CONNECTOR B [25F]
2 34:: " H
I1.‘.hel:lt the [AC valve:
1.Reecrrecttl‘e|ft0vawe3P 9 ‘U “ ‘3‘3'4"" ‘r' ‘H
E‘
c-t
ecrrector. ‘9 2c 2‘ 22 23 24 2:;
2. 'e tl'e igritior switch ON Ifll}. LAW
3. Measuevoltage betweer
body grc cl arcl ECMEPCM lBLIUBLU}
ecr'r'eetor termiral B2 3.
Wire side of female termir‘ale

ls tl'ere approx. 1E2 battery NC Replace the [AC valve.
velta ge?
YES

PCl'lll ancl recheck [see page 11-A-
15 for immobilizer in formation). If
symptontlindication goes away,

4

&A
!#!!3
9
;'!%<
Idle Control System

# 11 -A-86
85

! !
This signals the ECM/PCM when there is a demand for cooling from the air conditioning system.
4
! ,=,3!

-
In spe eticn cfAir Conditioning
Signal.
E CMIPCM CON N ECTORS
Li 5 s s ‘U “ |
i.“
-
Enigma? short -In the wrre 2! 2e 2’ It's'smz'zz
a_ 3‘ 23 24|
32
1. ’e' the igr' itior' switch IOFF. A03 (BLUIRED)

2, DiscorhecttheNC pressue B ”5"}
switch cor'r'ector. ‘ 2 3 4 L- 5 cl
3, ’e' the igr'itior' switch CN Ijll}. s ‘c “ ‘3's's‘s‘s‘ .“sl
4, luleaSLre voltage betweer‘ ‘5 2c 1" '-"- 35241:
EccM cor‘r‘ec‘tortennir‘als .--“~ LofiERI-JIBLK}
A2? ard B20. —t LL.
'W'ire side of female tennir‘als
Check for a shortin the wire

(Acs line):
NC 1. ’L.rr‘ the igr‘itior' switch OFF.
:4“ r 2. Disccr‘hedthe ECNl.v'PCM
Isthere approx. JV? 2— ccr‘r‘edon‘x {32’s}
3. Check for oortihuity betweer‘
YES body groL. r‘d ar‘d ECMJ'PCM
ocr‘r‘ edor termir‘ al A2?
r. E r' H Ei ‘U
H 2. .,. 23 241
l..— ACS {BLUIRED}

-:ohn"|
_..-'— —'-._'_ 15"
NC
the ECWPCM 1A2?1ancl the NC
check for an open in the wire pressure SWitl'l-
moo line}:
1, 'e' the ighitior switch CFF. - Substitute akncwn-gcccl
2, Recor'r'ecttheNC pressL. re ECMIPCM and recheck [see
switch cohhector. page114t-1crimmcbilizer
3, 'e' the ighitior switch CN {Ill}. infcrmaticn). If prescribed
4, lulomer'tarily correct EClull' voltage is ncw available. replace
POM correctortenniralsMT the criginal ECMPCM.
ar'cl BEUwithiperwire - See the :ir ccncliticning
several times. inspecticn {see secticn 22).
L..- '_. -1 L- s .-' s E ‘E “ |

_ _ «2 3'4” ' ”secure: as 24
(opagell-A-Sr} I i' 252:2; {:3 'J‘ i I
ACCIRED} ‘ 3 J
Zoo‘-
5 .U“ 2 rs‘s'r'su
'5 2c 1 2332's
JUMPERWIRE L611 RNIBLK}
4

&A
!#!!3
9
;'!%<
Idle Control System

# 11 -A-87
87
Air Conditioning Signal (cont’d)

! !/
?0
(From page 11 -.A‘~.-8Eij:

[A00 line]:
l3 tl'ere a dickirg roise from NC Momer‘tarilvoor‘r‘eo‘ttl‘e eer-
the NC compressor dud"? l'ood fLsea'relav box 1GP cor rector
termir‘al No. 11 to body grou‘d
YES
with a jL.mper v.-ire several times.
UNDER-HOOD FUSEIRELA‘I' BOX

1GP CONNECTOR
1 2 3 l—I 4
7 8 l -1 o -1 1 |12/|14 1e
Acc ( RED) iJUMPER WIRE
Wire side of
fema le termir‘als
ls tl' ere a olidcirg r oise fromfi' NC
tl‘ eNC compressor CILtct‘? /"'
YES
See air conditioner inspection
(see section 22).
Rep air open in the wire bemeen

the ECMIPCM 1A1?) and the NC
clutch relay
AISEP} ECMIPCM co NNECTORS

Check for the operation of the L— l 'r' HS'G
AJ'C: I‘ EI‘ ‘41 ‘9"L2'22 2L1 24]

ELZFJP.‘ RE;- -' d' :12
1. Start tl" e er‘gir‘e. a (25p)
2. '1. rr tl" e blower switch CN. A65 (BLUIRED) 2 i.
ht.“-
“A
Q ‘U“'
3. '1. rr tl" eNC switch CN. Ll‘ti‘ ‘3
‘Ei 2L: :33: '-
LG1 l B NIBLK}
Wire side of female tennirals
[Aco line]:
MeaSLre voltage betweer ECM."
POM oor'r'eotor tennir als £27
YES
ar'd BED.
—\_ N
C
C Is voltage lesstrar 1.0V?
YES
Air conditioning signal is OK.
the ECMIPCM 1A2?) and theme
switch.
EGMIPGM and recheck (see
page 11-11-16 for immobilizer
information}. If symptom!
the original ECWPCM.
— See the air conditioner
inspection [see section 22).

4

&A
!#!!3
9
;'!%<
Idle Control System

# 11 -A-88
88
Alternator (ALT) FR Signal

/&0+ !
This signals the ECM/PCM when the Alternator (ALT) is charging.

4
! ,=,3%!;%4<

-
ECMIP CM CONNECTORS
a (215i!)
5
2 3412 .r'
“U “'2'3'4‘2‘fi‘i
6|
43'
' Ei 2L: 2' 22 23 24 22
LG1 (BRNIBLK) c [31H

fl ALTF lWHTJ‘RED]:
é; |
I
I].
Li L ii HE‘U
.3.4. B‘fi‘ r ‘3‘ 5 2L 2‘ 22
Inspection ofALT FR Signal. . 2".
23 20 El 2H 29 Lilli Li‘
IL
Wire side of fem ale te nnirals
ALTF [WHTIRED]:
Check for a short in the wire (ALT
F line]:
E r' HQ‘U
1. Discohhect the 4P Ij2Pi'
‘r"H‘ 2L: 2‘ 22
cohhector from the AL’.
2. ’Lrh the igritioh switch CN til}. ' 2i 23 2Q HE J‘
3. luleaSLre voltage betweer‘ ': except l-22r\i" eh gire
ECMIPCM cohhector termir‘ als
320 ahd I35. Check for a shortin the wire (ALT
F line):
1. ’L.rr‘ the ighitior switch OFF.
2. Disocr‘r'ecz the regative battery
NC cable from the battery.
3. Disocr‘r‘ed the ECMJ'PCM
cchhectcr C 1:31P}.
YES 4. Check for cohtih Lity betweer'
body grocr‘d ah d ECMJ'PCM
ccr‘r‘ectorten‘tir‘al CS.
Is there ocr‘tir‘Lity?
Check the operation oftheALT:
1. 'Lrh the ighitioh switch OFF. NC
2. RecorrecttheAL'liPQPi‘
cor rectorto theAL‘.
3. Start the ergire. l-old the Repair short in the wire between
ergire at 3.000 rpm [l‘fiiF'1 j: the EClWPCM [CS]: and the ATL.
with ho load (ir Park orheLtralj:
L.r'til the radiator far
Substitute a know-good EClW
comes or. ther let it idle.
4. l'uleaSLre voltage betweeh
18 fcrimmobilizer information} If
ECMIP CM cor rectortermihals
820 ard I35. prescribed voltageis now
available. replace the original
ECMIPCM.
Does th e voltage decrease wh eh

headlights ard rear defcgger are ALT FR signal OK.
te ed or?
To pagell-A-SQ}
4

&A
!#!!3
9
;'!%<
Idle Control System

# _ _
89
Alternator (ALT) FR Signal (cont’d)

/&0+ !/
?0 1 1 A 89
(From pagell-A-SS]
ALT 4P CONNECTOR
I—I
1
Cheek for an open in the wire lALT 3

F line]: ALT F
1. ’e tl‘e igritier switd‘ ICFF. IWHD'
2. Discerremtre 4P Ij2P]' RED}
ccrrectcr from the AL’.
3. 'e tl‘e igriticr switd" CN ill}. Wire side of
4. M eaSL. re vclta ge betweer‘ the female termir‘als
AL' 4P ocrredcrtermir‘al No.
4 (No. 2::‘ ard body grc‘d. ‘: except l~22AT er‘gir‘e
ALT 2P CON N ECTOR'
Repair open wire between the
'5 were 3'39”“ 5 V? ECMIPCM (05) and the ALT.
YES
See the ALT inspection (see sec-

tion 4}.
Wire side of
female terlnir‘ ale
Idle Control System

# _ _
9$
Brake Switch !/I>
F20
"6( Signal (except KY model: MIT) 11 A 90
This signals the ECM/PCM when the brake pedal is depressed.

4
! ,=,3#!-
I Inspection of Brake Switch Signal. I
l fire the brake ligl‘ts or without YES Inspect the brake switch [scc
depressir‘g the brake pedal? section 1 9).
Depress tl"e brake pedal. I
, K5. NC Ir'specttt‘e S’CP [15111) mse ir‘

< Dotre brake I'QHS Dome or‘? / tl‘e eer-t‘ood hsev'relaybox.
YES
..— NC
/ Istre km?—
YES
_ Repair short in the wire

between the brake switch ancl
the STOP [15 A} fuse.
_ Replace the STOP [15 A} fuse.
Check for an open in the wire _ Repair open in the wire

"3s line}: between the brake switch and
1. Depress tl‘e brake pedal. the STOP [15 A) fuse,
2- Measuevoltage betweer . — Inspect the brake switch [see
ECMIPCM correctcrtennlrals section 19)
A32 arcl B20 witl‘ tl‘e
brake p eclal cle p ressed. A (329) ECIWPCM CONNECTORS
Li .' 3 9 ‘U
C."
-' ‘ 9 JG 2‘ 22 21.1 24
p
O:
2?; 2H 2." EH 3' L12
:3s IWHTIBLK]
B [25m
' 2 3 4 .I' H
II."
5 'U “‘2‘3‘4‘£;‘f_i‘.n"
'9 2L: 2‘ 22 232422
LG1 iBRNIBLK}
Wire side of female terlnir‘ als

< ls tl'ere battery voltage? 3’— lhl ECWPCM (A32) “Id the
brake switch.
YES
l Brake switch signal is OK. I

#
Idle Control System
Starter Switch !
( Signal
11 -A-91
9
This signals the ECM/PCM when the engine is cranking

4
! ,=,3
#
NIB—E:
In sp eetion of Starter Switeh
I An“: 'rarsmissior‘ II"- or-positior'.
Signal.
I MF: ir remral.
ECIWPCM CONNECTORS
A (329)
, Fj x a s 'u
i."
Cheek for an open or short in the '2'2'4'2 «y'a's2u 2' 22 2:1 24
wire [STS line}: 2.: 2r; 2.- 2s 2' :12
luleaee voltage betweer‘ ECM.‘I STS (BLUIORN)
PCl'ul oorr eotor termir‘als A24 BIEEP}
and BEE] or the ECMIPCM . 2 3 4 -
(a
Q ‘U 1112;314:21fi1ilal
oorreotors witl‘ tl‘e igritior‘ switd‘
.9 2L: 2‘ 22 22242::
ir the start Ijlllj: positior.
LG1 [BRNIBLK]:
Wire side of female termir‘ als
f,— Ir' speot the No. 13 S’AR’ER

a.-.i:_ ls tl‘ ere battery voltage? SIGNAL [T6 A} mse ir' the driver's
LPder-dasi‘ mselrela'y box.
YES
Starter switch signal is OK.

\ IS II“ 6 ft. 5 8 ok '? "-. NC _
YES

between the ECl'i'll'PcM [A24]
and the No. 13 STARTER
SIGNAL [15 A)1i.ise or the
PGM-FI main relay:
- Replace the ”Di. 13 STARTER
SIGNAL [15 A}1i.ise.

the EGMIPCM (A24) and the Ne.
13 STARTER SIGNAL [7.5 A} liise.
Idle Control System

# _ _
9
Power Steering Pressure (PSP) Switch !
'
( !'/''0( Signal 1 1 A 92
This signals the ECM/PCM when the power steering load is high.
4
! ,=,33
!
-
ECMtPcM CONNECTORS
c (31F
L. :J 5; Li .r H E ‘ L:
‘Ij'd‘L-“Li ‘ 5‘3 ‘EZUZ‘ 22
Inspection of PSP switch signal. ' 2!. 2H Zi' Eli 29 3G 3‘
PsP sw team a use}

J 3‘1 .I'H
II."
E ‘U “‘2‘3‘4‘2‘Ei‘r"fl
Cheukfer an 0 en in the wire {PSP ‘5 2c

SW ”M F L612‘ [ERNIE-LIE]:
22 23H 22
1, ’e the igr'iticr' switd‘ CN til}. Wire side of female termir‘als

2, luleaSLre voltage betweer‘
ECl-ali'F-‘CM ccr‘r‘ec‘tcrten‘iir‘als
.331 ar cl BEG. Check foran open in thewire (PSP
SW line):
1. ’e the igr‘itior‘ switch CFF. EEZNS‘EET‘S‘R"
2. Discor'r'ect the PSP switd‘ 2P
ccrhector. PSP SW [GEN]
— NC 3. ’L.rr‘ the igr‘ itior‘ switd‘ ON ill}.
~71 Is there less thar 1.0 V? '2—‘ 4, m the wire side, mrreatf‘e
YES PSP switch 2P corrector
termir‘als No. '1 ard No. 2with a
jumper wire. GND "El-K}
. Measure voltage betweer' Wire side of female
U1
ECMJ‘PCM cor‘r‘ecmr ten‘iir‘als termir‘als

031 ar‘d B20.
_ cf;- Is there lessthar‘ 1.0 V?

Nc
Check the operation of the PSP '--.—
switch: YE S
1. Start the er gire.
2. 'e steerirg wheel slowly. — REll‘li" OPEN in "It wire
3. MeaSLre voltage betweer between “1* ECWPCM P331}
ECMIPCM mrreetcrtermir ale and 1!“! P5P switch. _
I331 ar'cl 320. — Repair open In BLK wire
between the PSP switch and
ground [G301].
Replace the PSP switch.
< Is there battery '9' clta ge?
YES
[—5 page '1 '1 J‘s-93}

| Psp switch signal is OK.
Idle Control System

# 11 -A-93
9
'
( !'/''0( Signal
(cont’d)
/
?0
I: From page '1 '1 4k 32::
ECMIPCM CONNECTORS
c (31 P)
- H E ‘U
1-.
I:
-‘f_i‘.u'H‘EiZUZ‘ 22
1-.
2?.1_.--""IZU 262.123 29 EU 3‘
Check fora short in the PSP P8P sw B (ESP)

switch: (Gem
[1] 5 .U.2 ...2.3.4.3.fi...ul
a 4 - 5 el
:1.
1. ’e the igr'iticr' switch OFF.
2. Discorrectthe 2P oorr‘ector ‘ 5 2L: 2‘ 22 23 24 2::
from the PSP switch.
3. ’e the igriticr switch CN fill}.
L61 [ERNIE-L K]:
4. luleaSLre voltage betweer‘
EClull'P CM ocrr ectcr termir‘als Wire side of female termir‘ als
I331 arcl BED.
H Q U
2.
: j‘
PSP 3w :GRN}
[Elm-ii
Check forashcrtin thewirelPSP

I=
SW line):
1. 'e the igr‘ltior‘ switch I(EFF.
2. Disocr‘r‘edthe ECMJ'PCM
{I Is th are t: artery u cltag e? NC
\— ocr‘r‘ edOl'A II32P}.
YES 3. Cheds' for oortirbit'y betweer‘
body groL. rd ard ECM.I'PCM
oorr actor terl‘tir al 031.
Replace the PSP switch. I
_..--— , , YES
NC
the ECMJPCM [031) and the PSP
switch.
Substitute a kncwn-accd ECM

PCM and recheck (see page11-A-
16 for immobilizer infcrmaticn).
If prescribed vcltage is ncw
available replace the criginal
EClWPCM.

#
Idle Control System

11 -A-94
9
NOTE:
84 9 4.
*- Idle the engine for one minute with heater fan
!
3
9 Leave the AC valve connected.
&%&!&- switch at HI and air conditioner on, then check the
36A#
O Before inspecting the idle speed, check these items:
)
!A#9 idle speed.
!-
- The MIL has not been reported on.
4,- Idle speed should
be:

*F
- Ignition timing.

- F2036 engine:
+$"5! F
- Spark plugs.
#!
- M/T
,=4 750 i 50 rpm (min-1)
$0V0; <
- Air cleaner.
%!- A/T
%=4 730 i 50 rpm (min-1)
$+0V0; <
- PCV system.
:-
(in E
; or El<
position)
Connect a tachometer.
- -
H22A7 engine:
.7! F
TACHDMETEH
‘790 i 50 rpm (min-1)
$50V0; < ‘
TAG HOMETEFI NOTE: If the idle speed in not within specification
84 9!3
CD NNECTOH Refer to Symptom Chart (See Page 11-A—18).
1;'!%'<-
I .
- Start the engine. Hctld the engine at 3,000 rpm (min-1)

-6!
+A000;<
with no load in parking or neutral until the radiator fan
3!#
! !
comes on, then let it idle.
A!!-
Check the idle speed with no-load conditions:
+- #!3!9
headlights, blower fan, rear defogger, radiator fan, band
!
A!3A
AA
air conditioner are not operating.

-
Idle speed should
be:

*F
F2036 engine:
+$"5! F
M/T
,=4 750 i 50 rpm (min-1)
$0V0; <
A/T
%=4 730 i 50 rpm (min-1)
$+0V0; <
(in E
; or El<
position)
H22A7 engine:
.7! F
‘790i-50rpm
$50S0; (min-1)
<
Fuel Supply System
+## 11 _A_95
93
+&
Fuel Lines
NOTE: Check fuel system lines, hoses and fuel filter for damage, leaks or deterioration, and replace if necessary.
84 9# !!A !!
A!#A!-
The illustration shows LHD type:
4!! 36(9
(See Page 11-A—6) and (See Page 11-A—7) for RHD type
;'!%<;'!%$<16(
3? N-rn ms kgf-m.
21 lhf-ftl
22 I'll-m [2.2 kg’lrm,

16 Ihflfll
The illustratmn shows

LHD type.
Refer to 11-A—E, 7
page for FIHD type.
Fuel Supply System
+## 11 _A_96
95
Fuel Lines (continued)
+& /
0
NOTE: Check all hose clamps and retighten if necessary.

84 9#!!!
-
Black Triangle means do not disconnect the hose from the pipe
)!#4
!
FUEL TANK EVAPORATIVE
EMISSION lEVAP] FUEL PUMP
VALVE LUCK NUT FUEL PUMP
FUEL FUEL GAUGE SENDING UNIT
TANK BASE PACKING
FUEL TU BE! Replace.
OUICK-DONNECT ‘
FITTINGS
EUAPOHATIVE EMISSION
IEVAPI TWO WAY
VALVE
EVAPORATIVE
EMISSION IEVAP]
CONTROL
CANISTER
a .- --
To FUEL
PRESSURE
REG ULATOFI "—-
EVAPORATIVE
EMISSION {EVAPl
CONTROL
CANISTEFI
'1: F2085. HZZA? engine
'2: F1832, F1833 engine
Clamp in the middle
milks»! “Ms.
I
._ a -.r. III/1% II'L'IJ'IIH'J’I;
Clamp in the middle
1i] - 14 mm
10.39 — 0.55 inl
Fuel Su | S stem
+## 11 -A-97
97
+*2= 6
+ !
'

Precautions )

Disconnections
A WARNING A WARNING
Do not smoke while working on the fuel system. Keep open
(#3!3#
!-> Do not smoke while working on the fuel system. Keep
(#3!3#
!->
flame or sparks away from the work area.
!#33#- open flame or sparks away from the work area.
!#33#-
The fuel tube/quick-connect fittings assembly connects the
4 ! =F #
! 1. (
&!-
- Disconnect the battery negative cable.
in-tank fuel pump with the fuel filter and the fuel return pipe,
# ! 3 !! ! A 2. 1& !!!A!& !
- Remove the fuel fill cap, and relieve fuel pressure
the fuel filter with the fuel feed pipe. For
!!3 !- removing or installing
&
!!
in the tank
#
the fuel filter, the fuel pump and fuel tank, it is necessary to
!!A ! !#A 3. 1!& ! ;'!%00<-
+- Relieve fuel pressure (See Page 11-A—100).
disconnect or connect the quick-connect fittings.
F #
- Check the fuel quick-connect fittings for dirt, and
*- # !F #
A
Pay attention to following:
!!3
9 clean if necessary.
!-
¢ The fuel tube/quick-connect fitting assembly is not
4 ! =F #
! Hold the connector with one hand and press down
- 6!33
heat-resistant; be careful not to damage it during
N !

the retainer tabs with the other hand, then pull the
3A !!
welding or other heat-generating procedures.
3!

- connector off.
-
¢ The fuel tube/quick-connect fitting assembly is not
4 ! =F #
! NOTE:
84 9
acid-proof; do not touch it with a shop towel which was
N 33!33 ¢ Be careful not to damage the pipe or other
) !

used for wiping battery electrolyte. Replace the fuel
3
!!-1! ! parts Do not use tools.
( !-
tube/quick-connect fittings assembly if it came into
=F #
! ¢ If the connector does not move, keep the
&A#
contact with electrolyte or something similar.
3!!
!- retainer tabs pressed down, and alternately
3A!!
¢ When connecting or disconnecting the fuel
2

! pull and push the connector until it comes off
!! !
tube/quick-connect fittings assembly, be careful not to
=F #
!A ! easily.
!-
bend or twist it excessively. Replace it if damaged.
3/&!-1!
- ¢ Do not remove the retainer from the pipe; and
(&N
Adisconnected quick-connect fitting can be reconnected, but
%F #
A removed, the retainer must be replaced with
&A !3
the retainer on the mating pipe cannot be reused once it has

new one.
3-
been removed from the pipe. Replace the retainer when
&-1!3 LOCKING PAWL
- replacing the fuel pump.
!
! -
- replacing the fuel filter.
!
!!- RETAINER TAB
- replacing the fuel feed pipe.
!
!-
- it has been removed from the pipe.
&-
- it is damaged.

- PIPE
ACCESS PANEL
_; 1
Press down.
6.
- Check the contact area of the pipe for dirt and
#
damage.

-
- If the surface is dirty, clean it.
A!-
- If the surface is rusty or damaged, replace the

A!
fuel pump or fuel feed pipe.
! !-
CONTACT AREA
RETAINER
Fuel Supply System
+## 11 -A-98
98
Fuel Tube/Quick-Connect Fittings (cont’d)
+*2= 6
+ !/
?0
7.
$- To prevent damage and keep out foreign matter, cover
4&
#
A&

Connection
A WARNING
the disconnected connector and pipe end with plastic
3!
bags.

-
Do not smoke while working on the fuel system. Keep
(#3!3#
!->
open flame or sparks away from the work area.
!#33#-
1.
- Check the pipe contact area for dirt and damage,
#
A
and clean if necessary.
!-
CONTACT AREA
PLASTIC BAGS
NOTE:
84 9
¢ The retainer cannot be reused once it has been
4
removed from the pipe.
&-
Replace the retainer when
1!3
- replacing the fuel pump
!
!
!
!- 2.
- Insert a new retainer into the connector if the
3
- it has been removed from the pipe.
&- retainer is damaged, or after

A
- it is damaged.

- - replacing the fuel pump.
!
! -
!
!-
- removing the retainer from the pipe.
&
-
New RETAINER
Hus-3n into
CONNECTORS
Fuel Supply System
+## 11 -A-99
99
Fuel Tube/Quick-Connect Fittings (cont’d)
+*2= 6
+ !/
?0
Before connecting a new fuel tube/quick-connect fitting

)
3 ! =F #
*- Reconnect the quick-connect fittings checking their
1F #
#

assembly, remove the old retainer from the mating pipe.
!A&!
- arrows line up with the arrows on the fuel pump
3! 33 !
-2-n assembly.
!-
ARROWS FUEL
R
With the
PUMP
labs pulled
ASSEM BL‘I"
apart. pull QUICK—
the retainer A“ CONNECT
nfl FITTINGS
New FUEL TUBE!

QUICK-CONNECT
FITTING ASSEMBLY
- Make sure the connection is secure and that the
,#
pawls are firmly locked into place; check visually
3!!!#!N#& !!
and by pulling the connector.
!!
-
- Reconnect the battery negative cable, and turn the
1
&!A
ignition switch ON (II). The fuel pump will run for

38;<-4 ! 3!!
about two seconds, and fuel pressure will rise.
3A ! 3!!-
as; Repeat two or three times, and check that there is
13A#
+- Align the quick-connect fittings with the pipe, and align
%!
F #
3A!
no leakage in the fuel supply system.
!#
! !-
the retainer locking pawls with the connector grooves.
!#
3!3
&-
Then press the quick-connect fittings onto the pipe until
4F #
!
both retainer pawls lock with a clicking sound.
3!!#3!#
-
NOTE: If it is hard to connect, put a small amount of
84 9A !!
new engine oil on the pipe end.
3
!-
Connection with ( F

( new retainer:
CONNECTOH
CONNECTOR
RETAINER
RETAINER
‘(K PIPE
Ex“ hum
FREJ”a
HR
Connection to existing retainer:

! F
“HE—9
+## 11 -A-100 +'
Fuel Pressure
Fuel Supply System
System Description
#)

$$
The fuel supply system consists of a fuel tank, in-tank
4 ! ! !#A# Relieving
- !
high-pressure fuel pump, PGM-Fl!A !!A !

! A., main relay, fuel filter, fuel Before disconnecting fuel pipes or hoses, release
)
!A!
pressure regulator, fuel injectors, and fuel delivery and return

!A !7A !!& pressure from the system by loosening the fuel
!
!
lines. This system delivers pressure-regulated fuel to the fuel
!-4!&
! ! ! pulsation damper on top of the fuel rail.
! !!-
A WARNING
injectors and cuts the fuel delivery when the engine is not
7 !!&3

running.

-
Do not smoke while working on the fuel system. Keep
(#3!3#
!->
open flame or sparks away from the work area. Be sure
!#33#-)
to relieve fuel pressure while the ignition switch is off.
!& ! 3!
3-
1.
- Disconnect the battery negative cable from the
(
&!
battery negative terminal.

&!-
2.
- Remove the fuel fill cap.
1& !!!-
3.
+- Use a wrench on the fuel pulsation damper at the
?3 ! !
fuel rail.
!!-
4.
*- Place a rag or shop towel over the fuel pulsation
!
3!& ! !
damper

5.
- Slowly loosen the fuel pulsation damper one
!3!! ! !
complete turn.
! -
FUEL PU LSATIDN
DAMPER
H N-rn
l2.2 ligf1m. 15 Ibf—ft]
SHOP TOWEL
NOTE: Replace the washers whenever the fuel
84 91!33& !
pulsation damper is loosened or removed.
!!&-
+##
Fuel Supply System Fuel Injectors
11 _A_101 +D

Fuel Pressure (cont’d)
+'/
?0
$
Inspection

Description
)

1.
- Relieve fuel pressure (See Page 11-A—100).
1!& ! ;'!%00<- The fuel injectors are a solenoid-actuated constant
4 !7!
2.
- Remove the fuel pulsation damper from the fuel rail.
1& ! ! !!- stroke, pintle-type consisting of a solenoid, plunger
#A!
!A!

Attach the fuel pressure gauge attachment and fuel
% !

! needle valve and housing. When current is applied to
!&!&
-2 !
pressure gauge.

- the solenoid coil, the valve lifts up and pressurised fuel
!!A&!&! !
is injected. Because the needle valves lift and
7-) !&!&!
FUEL PRESSURE K? N) pressures are constant, the injection quantity is
A7F
GAUGEATTACHMENT H ,Ar” l determined by the length of time that the valve open
!
&!&
“TVAJ - 0040100
(that is the duration the current is supplied to the
; !
solenoid coil). The fuel injector is sealed by an O-ring
!!<-4 !7!8

,. GAUGE and seal ring at the top and bottom. These seals also
!
-4!!
E J 07405—0040002 reduce operating noise.

-
.I
i — - ' FILTER
PLUNGER HOUSING .- .I: '. -%
FUEL PRESSURE
REGULATOR
SOLENOID COIL
3.
+- Start the engine. Measure the fuel pressure with the

-, ! 3
engine idling and the vacuum hose of the fuel pressure

!
& !
regulator disconnected from the fuel pressure regulator

! !
! PLUNGER
and pinched. If the engine will not start, turn the ignition
-
3!!A

switch ON (ll), wait for two seconds, turn it off, then back
38;<A33A A#
on again and read the fuel pressure.

! -
Pressure should be:
!9 FU E L RAIL
F2036, F1832, F18B3 engine:
+$"5:+8":+8"! F
O-RING
280-330 kPa (2.9-3.4 kgf/cm2, 41-48 psi)
8$$6'/@9@6! 2:8 0
H2AA7 engine:
.7! F
330-380 kPa (3.4-3.9 kgf/cm2, 48-55 psi)
$8$6'/@@96! 2:833 0
If the fuel pressure is not as specified, first checks the
! A# INTAKE
fuel pump (See Page 11-A—106) if the fuel pump is OK,
! ;'!%0< ! 8>A MANIFOLD
check, the following:
#A!!3
9
0 If the fuel pressure is higher than specified, inspect
!
A
for:
9
- Pinched or clogged fuel return hose or line.
!
! !-

- Faulty fuel pressure regulator (See Page
! !
!;'! CUSHION
11-A—104).
%0*<- RING
0 If the fuel pressure is lower than specified, inspect
! !3A
for:
9 FUEL
INJECTOR
- Clogged fuel filter.
!
!!-
! !
!;'!
11-A—104).
%0*<-
- Leakage in the fuel line.
#
!!-
Fuel Su I s stem
+## 11-A-102
$
Fuel Injectors (cont’d)
+D
/
?0
Replacement

A WARNING
Do not smoke while working on the fuel system. Keep open flame or sparks away from the work area.
(#3!3#
!->!#33#-
- Relieve the fuel pressure (See Page 11-A—100).
1!& ! ;'!%00<-
9.00.”?
- Disconnect the connectors from the fuel injectors EGR valve (and EVAP purge control solenoid valve).
( !7 .1&!&; :%
!!&!&<-
+- Disconnect the vacuum hose from the EVAP purge control solenoid valve.
(& :%
!!&!&-
*- Disconnect the vacuum hoses and fuel return nose from the fuel pressure regulator.
(& ! !
!-
NOTE: Place a rag or shop towel over the hoses before disconnecting them.
84 9!
3!&
-
- Disconnect the fuel hose from the fuel rail.
( ! !!-
SOWNQ’S"
- Remove the retainer nuts from the fuel rail and harness holder.
1& !!!-
$- Disconnect the PCV valve.
(:&!&-
'- Disconnect the fuel rail.
( !!-
5- Remove the fuel injectors from the intake manifold.
1& !7#!-
FUEL
_ PULsmoN
F2935 engine: HZZA? engine: DAMPER
22 Mm
WASHER {2.2 Icyf-m.
HARNESS
HOLDER
12 N-m EVAP HARNESS FUEL Replace. 1e Ibf-ft]
”2 kgfmr PURGE HOLDER RAIL -
3.7 lbf-ftl 00a
EGR VALVE SOLENDID
VALVE
12 Mm
{1.2 kg‘f-m.
FUEL 3.? lbf-ft]
PU LSATIDN
DAMPER
22 N-m
[2.2 uni-m.
16 Ibf-fl]
PCV FUEL
. FUEL unw E K—" "
.o—RING “ PRESSURE
.w .
{Cl-RING ' pRESSURE
Replace. . ._ K" REGULATOR = Replace. REGULATOR
'P...
SEAL
RING
INJECTOR Replace.
x0
SEN-
RING
INJECTOR
D-RING
Replace.
cusmon Replace. EKJPEHID“

Replace.
RING
Re F' lace.
Replace.
10.
0- Slide new cushions rings onto the fuel injectors.
!3
!7-
11.
- Coat new O-rings with clean engine oil, and put them on the fuel injectors.
38
3!
!A !7-
12.
- Insert the fuel injectors into the fuel rail first.
!7 !!-
13.
+- Coat new seal rings with clean engine oil, and press them into the intake manifold.
3!
3!
!A#!-
W
+## $
11 -A-103
+D
/
?0
14. 4&

8
A!! !7 !!A!!#!-
*- To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in the intake manifold.
FUEL
HAIL
tECTOH
INTAKE
MANWOLD
15.
- Install and tighten the retainer nuts.
!!
-
16.
- Connect the fuel hose to the fuel rail with new washers.
! !!333-
17.
$- Connect the vacuum hoses and fuel return hose to the fuel pressure regulator.
& ! !
!-
18.
'- Connect the vacuum hose to the EVAP purge control solenoid valve.
& :%
!!&!&-
19.
5- Install the connectors on the fuel injectors, EGR valve and EVAP purge control solenoid.
!! !7A .1&!& :%
!!-
20.
0- Connect the PCV valve.
:&!&-
21.
- Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately two seconds, the
4
38;<A -% ! /!3A
fuel pressure in the fuel line rises. Repeat this two or three times, then check whether there is any fuel leakage.
! !!-13A#3 !!#
-
Fuel Supply System
+## 11 -A-104
$
+'!
Description
)
Testing
!
A WARNING
The fuel pressure regulator maintains a constant fuel
4 !
! !
pressure to the fuel injectors. When the difference between
!7-23
the fuel pressure and manifold pressure exceeds F2086,
! ! / 0)A Do not smoke while working on the fuel system. Keep
(#3!3#
!->
F1882,
')A F1883 engine:290 kPa (3.0 kgf/cm2, 43 psi), H22A7
')+
950#;+-0#
=A*+<A6%$ open flame or sparks away from the work area.
!#33#-
engine:340 kPa (3.5 kgf /cm2, 50psi), the diaphragm is

9+*0#;+-#
=A0<A
1.
- Attach the fuel pressure gauge attachment and
% !

pushed upward, and the excess fuel is fed back into the fuel
3A/ !# ! fuel pressure gauge (See Page 11-A—101). Start
!

;'!%0<-
tank through the return line.
#
!- the engine.

-
Closed:

F FUELPRESSUHE
TuINTAKE GAUGE ATTACHMENT
MAHFOLD nwAJ - 0040300 FUEL
PRESSURE
GAUGE
0T4DB—DOflMKE
IMAPHRAGH
F
FUELFHESSUHE
FlEGU LATDR
CLMHP
[NAPHRAGH Pressure should
' be:

*F
F2036, F1832, F1833 engine:
+$"5:+8":+8"! F
280-330 kPa (2.9-3.4 kgf/cm2, 41-48 psi)
8$$6'/@9@6! 2:8 0
H22A7 engine
.7!
330-380 kPa (3.4-3.9 kgf/cm2, 48-55 psi)
$8$6'/@@96! 2:833 0
2.
- Reconnect the vacuum hose to the fuel pressure
1& !
regulator.

!-
3.
+- Check that the fuel pressure rises when the
# ! 3
vacuum hose from the fuel pressure regulator is
& !
!
FUELINLET disconnected again.

-
¢ If the fuel pressure did not rise, replace the
! A!
fuel pressure regulator.
!
!-
Fuel Su | S stem
+## 11 _A_1 05 ++
$3 Fuel Filter
Fuel Pressure Regulator (cont’d)
+'!
/
?0
Replacement
Replacement

A WARNING A WARNING
(#3!3#
(#3!3#
!->
!#33#- open flame or sparks away from the work area. While
!#33#-2!
1. !3! !
!A
- Place a shop towel under the fuel pressure regulator, replacing the fuel filter, be careful to keep a safe
!
!!A !#
then relieve fuel pressure (See Page 11-A—100).
!& ! ;'!%00<- distance between battery terminals and any tools.
3!!-
2. (& ! -
- Disconnect the vacuum hose and fuel return hose. The fuel filter should be replaced whenever the fuel
4 !! !!3& !
3. 1&3!-
+- Remove the two 6 mm retainer bolts. pressure drops below the specified value
!3&!
12 N-rn T[F1OBS,F18BZ,F18B3 engine: 280-330 kPa (2.9-3.4
8)A ')A ')+
9'0++0#;-5+-*
(1.2 kgf-m, kgf/cm2, 41-48 psi), H22A7 engine: 330-380 kPa
#
=A**'<A6%$
9++0+'0#
3.? lbf-ft} (3.4-3.9 kgf/cm2, 48-55 psi) with the fuel pressure
;+-*+-5#
=A*'<3 !
regulator vacuum hose disconnected and pinched] after

!& U
making sure that the fuel pump and the fuel pressure
#
! !
regulator are OK.

!8>-
1.
(
&!
FUEL battery negative terminal.

&!-
PRESSURE 2.
- Relieve fuel pressure (See Page 11-A—100).
1!& ! ;'!%00<-
REGULATOR 3
+- Disconnect the hose and quick-connect fittings
(F #

_ O-RING ((See Page 11-A—97).
;;'!%5$<-
Replace. 4.
*- Remove the fuel filter.
1& !!-
FUEL FILTER
*- Apply clean engine oil to a new O-ring, and carefully

%!!
!38
A !!
install it into its proper position.
!!-
- Install the fuel pressure regulator and the 6 mm retainer
!! !
!
bolts
!
- Reconnect the vacuum hose and fuel hose.
1& !-
Fuel Su | S stem
+##
Fuel Pump
+'
11 -A-1 06
$5
Testing
! Replacement

A WARNING A WARNING
(#3!3#
(#3!3#
!->
!#33#- open flame or sparks away from the work area.
!#33#-
If you suspect a problem with the fuel pump, check that the
!3 ! A# 1. 1&!-
- Remove the spare tyre lid.
fuel pump actually runs; when it is ON (ll), you will hear some
! !! N38;<A 3!! 2. 1&!!-
- Remove the access panel from the floor.
noise if you hold your ear to the fuel filler port with the fuel
! !!!3 ! 3. 4
38
+- then disconnect the
Turn the ignition switch OFF,A
filler cap removed. The fuel pump should run for two seconds
!!&-4 ! ! 3 fuel pump 4P connector.
! *-
when ignition switch is first turned ON (II). If the fuel pump
3
3 8;<- ! Disconnect the quick-connect fittings from the fuel
*- (F #
!
does not make noise, check it as follows:
#A#!!39 pump.
-
1.
- Remove the spare tyre lid
1&! Attach the adjustable ring nut wrench, and remove
- %7 !
3A&
2.
- Remove the access panel from the floor.
1&!!- the fuel pump lock nut.
! !# -
3.
+- Turn the ignition switch OFF,A
4
38 then disconnect the 5P ADJUSTABLE RING NUT
connector from fuel pump.
! - WRENCH
OTWAA - 0010100
4.
*- Connect the PGM-Fl!$!
., main relay 7P connector terminal
No.4 and No.5 with a jumper wire.
-*-37 3-
PGM-FI MAIN
RELAY 7P CONNECTOR
F 2 3
4 s a 1
FUEL PUMP lG‘l lREDIWHTl

{BUCHELI lREDIBLKl'
JUMPER Wire side of
WIRE female terminals
‘: with inertia switch
5.
- Check that battery voltage is available between the fuel
#&!
&!!3 !
pump 4P connector terminal No. 1 and body ground
*!-

when the ignition switch is turned ON (Ill.
3
3 8;!!-
FUEL PUMP 4P CONNECTOR FUEL FUEL PUMP
LOCK NUT
43—.
FUEL PUMP 1 2 93 N~rn [9.5 kgf—m.
lBLKJ'YELl EB Itrf-ftl
3 4
V |
Wire side of
female terminals
0 If battery voltage is available, check the fuel pump
&!
&!!A# !
ground. If the ground is OK, replace the fuel pump.

-
8>A! ! -
0 If there is no voltage, check the wire harness (See
&!
A#3;
Page 11-A—112).
'!%<-
Fuel Supply System
+## 11 _A_1 07 +!
$7 Fuel Gauge
Fuel Pump (cont’d)
+'/
?0
6.
- Remove the fuel pump assembly.
1& ! !- Testing
!
FUEL PUMP NOTE: See section 23 for the fuel gauge system circuit
84 9+ !

Locx NUT diagram.

-
1. #-5)%>?.6441?, 4
- Check the No.9 BACK UP LIGHT INSTRUMENT
LIGHT (7.5 A) fuse in the driver’s under-dash
.64;$-%< &B
fuse/relay box before testing.
=!/
-
Remove the spare tyre lid.
- 1&!-
:59)!“
Remove the access panel from the floor.
+- 1&!!-
FUEL Turn the ignition switch OFF,A
*- 4
38 then disconnect the
PUMP
ASSEMBLY fuel pump 4P connector.
! *-
5.
- Measure voltage between the fuel pump 4P
, &!
3 ! *
connector terminals No.3 and No.4 with the ignition
!-+-*3

switch ON (II).
38;<-
There should be between 5 and 8 V.
4 !3':-
BASE PACKING FUEL PUMP 4F CONNECTOR
Replace. '._'
1 ', 2
I BLK I 3 4 lYELIBLUI
MAHKINGS JUMPER
WIRE
Wire side of female terminals

¢ If the voltage is as specified, go to step 6.
&!
A
-
¢ If the voltage is not as specified, check for:
&!
A#9
- An open in the YEL/BLU or BLK wire.
%C =)?)>3-
- Poor ground (LHD: G55l, RHD: G58l).

;6(9.A16(9.'<-
lICIUIIZIIL- 6.
- Turn the ignition switch OFF.-
4
38
CONNECT 7.
$- Connect the fuel pump 4P connector terminals
! *!
FITTINGS
No.3 and No.4 with a jumper wire, then turn the
-+-*37 3A
7.
$- Align the mark on the fuel pump assembly with mark on
%!
# ! !3#
ignition switch ON (ll).

38;<-
the fuel tank.
!#-
8.
'- Reconnect the quick-connect fittings checking their
1F #
#
FUEL PUMP 4P CGNNECTOR
arrows line up with the arrows on the fuel pump
3! 33 !
assembly.
!-
ARROWS (BLK! 4 lYELIBLU]
FUEL
PUMP
ASSEMB LY
JU MPEFI
QUICK- IWIFIE
CONNECT I .- -. 2!!
mcs If); x -.
9.
5- Install the part in the reverse order of removal with a
!!&&!3
new base gasket.
3
#-
Fuel Supply System
+## 11 -A-1 08 +! !;
$8 Fuel Gauge Sending Unit
Fuel Gauge(cont’d)
+!/
?0
8.
'- Check that the pointer of the fuel gauge starts moving
# !

&
- Remove the spare tyre lid.
1&!-
@NT‘
toward the “F”L#-
3K mark. - Remove the access panel from the floor.
1&!!-
0 If the pointer of the fuel gauge does not move at all,
!

&!!A +- Turn the ignition switch OFF,A
4
replace the gauge.
!

- fuel pump 4P connector.
! *-
0 If the gauge is OK, inspect the fuel gauge sending

8>A !

4.
*- Disconnect the quick-connect fittings from the fuel
(F #
!
unit.
- pump.
-
NOTE:
84 9 5.
- Remove the fuel pump assembly (See Page
1& ! !;'!
0 Turn the ignition switch OFF
4
38 before the pointer 11-A—106).
%0<-
reaches “F”L

!-
K on the gauge dial. Failure to do so may
! 6.
- Measure the resistance between the No.1 and
, 3-
damage the fuel gauge.

!

- No.2 terminals at E (EMPTY), 1/2 (HALF FULL)
-! ; ,4C<A=;6% ?<
0 The fuel gauge is a bobbin (cross-coil) type, hence
4 !

;!<A and F ;(FULL)
by moving the float.
?<&
!-
the fuel level is continuously indicated even when
!!&! !&3 Float Position
! E
1/2
= F
the ignition switch is OFF,A&

38 and the pointer moves Resistance(ohms) +0+
1;< 130-132 '-$*-
68.5-74.5 11-12

more slowly than that of a bimetal type.
!3!!-
Terminal side of
3 4 male terminals
1:2 i'
If you do not get the above readings, replace the fuel

&
A! !
gauge sending unit (See Page 11-A—109).

;'!%05<-
7.
$- Install the part in the reverse order of removal of
!!&&!
removal with a new base gasket (See Page
&!33
#;'!
11-A—106).
%0<-
Fuel Supply System
+## 11 'A-109 &
(+
& ! System
Low Fuel Indicator Light#
Fuel Gauge Sending Unit (cont’d)
+! !; /
?0
$9
Replacement
Indicator Light !

& ! Testing
1.
- Remove the fuel pump assembly (See Page 11-A-106).
1& ! !;'!%0<- NOTE: See section 23 for the low fuel indicator circuit
84 9+!3 !
2.
- Remove the fuel gauge sending unit from the fuel pump
1& !

! diagram

assembly.
!- 1. #-5)%>?.6441?, 4
- Check the No.9 BACK UP LIGHT INSTRUMENT
FU E L PUM P LIGHT (7.5 A) fuse in the driver’s under-dash
.64;$-%< &B
IASSEI'U'IBL"!r fuse/relay box before testing.
=!/
-
Park the vehicle on level ground.
- #&!!&!
-
Drain the fuel tank: Remove the fuel return line
+- ( !#91& ! !
from the fuel pressure regulator, and attach a
!
!A
suitable hose to the regulator fitting. Place the
!
!
-!
other end of the hose in a container suitable for
!
gasoline. Start the engine, and run it until the tank

!-
A !#
is empty (the engine stalls).
;
!!<-
Add less than 8.5 I 12.2 US. Gal, 1.8 Imp. Gal) of
*- %!'--?--.!A-'-.!<
fuel, and turn the ignition switch ON (II). The low
!A
38;<-4!3
fuel indicator light should come on within four
!!
!3
minutes.
-
LOW FUEL INDICATOR LIGHT

¢ !
3 A

If the light comes on within four minutes, go to
step 9.
5-
¢ !
3 A
If the light does not come on within four minutes,
go to step 5.

-
Remove the spare tyre lid.
- 1&!-
N979"
Remove the access panel from the floor.

- 1&!!-
Turn the ignition switch OFF,A
$- 4
FLl-E L GAUG E
fuel pump 4P connector.
! *-
SENDING UNIT
3.
+- Install the parts in the reverse order of removal.
!!&&!-
Fuel Supply System
+## 11 _A_11 0
$ Inertia Switch /I:I%:I:I
( (KG, KE, KS, KR
Low Fuel Indicator Light#/
?0
&
(+
& ! System (cont’d) models)

0
8.
'- Connect the fuel pump 4P, connector terminals No.3
! *A!-+ Description
)

and No.4 with a jumper wire.
-*37 3- The inertia switch is a safety device which automatically
43&3 !!
0 If the light comes on, replace the fuel gauge
!
A! !

cuts off the fuel supply in the event of a collision or
! !&!!
sending unit (See Page 11-A—109).

;'!%05<- sudden impact. The switch is located behind the glove
-43!
!&
0 If the light does not come on check for:
!
#9 box. After an impact, the switch must be reset by
/-%A3
- an open in the YEL/BLU wire between the fuel
C =)?33 ! pressing the button before the engine can be restarted.

-
gauge sending unit and fuel gauge assembly.

!

!- BDflT
- blown bulb.
!3 !-
- poor ground (LHD:G55|, RHD:G58I).

;6(9.A16(9.'<-
HE SET
FUEL PUMP 4P CONNECTOR BUTTON
SPRING
2
iBLKl IVE Lf BLUi
JU MPEH WIRE

9.
5- Add 4 loffuel (1.1 U.S. Gal, 0.9 Imp. Gal). The light
%* !;-?--.!A0-5-.!<-4!

should go off within four minutes.
!
3 - MOVING
CONTACT
MAGNET
W
+##
11-A-111
PGM-Fl Main Relay
'+ #
Description
)
Relay Testing
# !
4., main relay actually contains two individual
The PGM-Fl! !!3& ! NOTE: If the car starts and continues to run, the
84 9 A
relays. This relay is located at the driver side of the cowl. One
!-4!!&3!-8 PGM-Fl!8>-
., main relay is OK.
relay is energised whenever the ignition is on, which supplies
!
3&
A3 ! 1. 1&.,
- main relay
Remove the PGM-Fl!
the battery voltage to the ECM/PCM, power to the fuel
&!
,=,A3 ! 2. %&!-
- Attach the battery positive terminal to the No. 2
injectors, and power for the second relay. The second relay is
7A3!-4! terminal and the battery negative terminal to the
!
&!
energised for two seconds when the ignition is switched on,

33
3A No. 1 terminal of the PGM-Fl!-4
-!., main relay. Then
and when the engine is running, to supply power to the fuel
3

A !3 ! check for continuity between the No. 5 terminal
# 3-!
pump.
- and No. 4 terminal of the PGM-Fl!-
-*!., main relay.
PGMrFI ¢ If there is continuity, go on to step 3.
A
+-
MAIN RELAY ¢ If there is no continuity, replace the PGM-Fl
A!.,
main relay and retest.
!-
Na. 2
INJECTOR
FU EL PU MP
To ECMIPCM
CONNECTOR
TERMINAL
B1 and 39
lIGF}
Tu ECMIP‘CM
CONNECTOR - I%T F EL
TERMINALE15 a U PUMP
iFLH] "W model: A15]
3.
+- Attach the battery positive terminal to the No. 5
%&!-
terminal and the battery negative terminal to the
!
&!
No. 3 terminal of the PGM-Fl!-4
-+!., main relay. Then
check that there is continuity between the No. 7
# 3-$
terminal and No. 6 terminal of the PGM-Fl
!-!., main
relay.
!-
¢ If there is continuity, go on to step 4.
A
*-
¢ If there is no continuity, replace the PGM-Fl
A!.,
!-
*- Attach the battery positive terminal to the No. 6
%&!-
!
&!
No. 1 terminal of the PGM-Fl!-4
check that there is continuity between the No. 5
# 3-
terminal and No. 4 terminal of the PGM-Fl
!-*!., main
relay.
!-
¢ If there is continuity, the PGM-F1!
A., main relay is
OK.
8>-
¢ If there is no continuity, replace the PGM-F1
A!.,
!-
Fuel Supply System
+## 11-A-112

PGM-Fl Main Relay (cont’d)
'+ #/
?0
Troubleshooting

*
!
Engine will not start.
PGM-FI MMN RELAYTF' CONNECTOR
Inspection of PGM-Fl n1ain
relay and rela y ha mess. on o
12—? {ELK}
.7
[GND line):
1. ’e the ighitioh switch OFF.
Wire sice offe made ten‘nir‘als
2. Discor'rect the PGM-Fl mair
rela v cohhector.
3. Check for CCf‘til‘ty betweer
the PGM-FI maih relay
TF‘ oor'rector
termihal No. 3 ahd body groLr‘d.
BAT
Repair open in the wire between ? :WH wean]
Isthere oohtir‘city?
the PGM-Fl main relay and G101.

wire [Bat line):
lvleaSLre voltage betweeh the
PGI'ul-FI mair‘ relay 7P ooh hector
termiral No. 7 ahd body grour‘d. 3
i—UIN
— Repla ee the A065 [1EA) fuse
in the under-hood fuseJrelay
5 I"
NO box. |G1
Is there battery voltage?
— Repair open or short in the '-.__ :REDJWHT]
Ili—l l<
YES wire between the PGM-Fl main {RE DJBLK]'
relay and the A665 (15A) fu se.
wire [IG1 line): ‘: w ith ir‘e rtia 3w itch
1_ 'Lrh the igr‘itior‘ switch CN ill}.
2. Meaee the voltage betweer‘ INE RTIA SWITCH 3P
the PGM—Fl maih relay TP CONNECTOR
oorr eotor termih al No. 5 ahd body
Cheek the inertia switch:
groe.
1. ‘e' the igritior switch CN ill]. INERTIA
2. Disoor'r'eotthe 3P oohhector SWITCH
NO from the ir'ertia switch. (RED!
Is there battery voltage? v—l—
3. 'e' the igr'itior switch CN ill]. BLK)
YES i 4. Measue voltage betweeh the ‘en‘fiir‘al side of male
i ir'ertia switch 3P corrector termir‘ als
i termir‘als No. 1 ard No. 3.
i
i
i
s: Is there battery voltage? _‘
NC
l YES
— Replace the No.1 FUEL PUMP
! {15A)fuse in thedriver's
| under-h ood fuselrelay box.
i — Repair open or shortin the
wire between the PGM-FI ma'n
i relay and the No. 1 FUEL
i PUMP (15A) fuse.
i
('o page 11-A-113]
i
i Re place the inertia switeh.
i
Fuel Supply System
+## 11-A-113

'+ #/
?0
(From page 11 -.A-11 2]
Check for an open or shortin the PGM-FI MAIN RELAY 7P CONNECTOR

wire [8TB line):
1. 'e‘ the ighitioh switch to the STS EUIORN]
S'AR'UII] positioh.
NC—E: Mi" ih FELIl'al. N’ ll"
3
T
or Elpositioh. B I
2. M eaSLre the voltage betweer‘

the PGM-Fl l‘iail‘ relay TP
oor'r'eotor terr‘tihal No. 2 ah :1 body
groLr' cl. Wire sice offem ale te rrnirals
— Replaue the Ho. 13 STARTER

SIGNAL {15 A} fuse in the
:fl
driv er's under-hood fuselrelay
Is there battery voltage? box.
— Repa'r open or short in the
YES wire between the PGM-Fl main
relay and the Ho. 13 STARTER
SIGHAL {15 A} fuse.
Cheek for an open in the wire

[ F LR lin e}:
1. ’e the igr‘itior‘ switch OFF.
2. Dis ooh red th e ECMJ‘P CM EcmPCM CONNECTOR
oohredorA 1:32P]. A (32p)
3. Check for CCPtiPty betweer‘ . [l u
CC:
the PGM—Fl i‘tair‘ relay TP .4. 2U 23 241
I
oohrectorteri‘tir‘al No. 1 ar‘d
211s 2.7 32
ECMIPCM oor‘r‘ectorteri‘tir‘al
mommy FLR (GRNIYEL)
F LR [G RNI‘I'EL }'
Wire sice offern de te n‘nir'als

N0 Repair open in the wire between
< Is there CCFtil‘Lity? :— the ECIWPCM {A15.A18')
and the PGI'II'l-Fl main relay.
YES ECMIPCM CONNECTOR
Cheek for an open in the wires

IGP1 (YEUBLK)
[IGPL IGP2 lines):
e (zap)
IGP2
1.Recorrect the ECMi‘PClvl [YELIBLKJ 2 d 4 5.:
‘U .. 1.34.2:
E El
corrector B i25P].
2. Recorrect the PGM-FI flair
relay 7P corrector. CE] 2U 2' 22
PG1 (ELK)
3. 'e the ighitioh switch CN ill}.
4. Measue voltage betweeh
ECl'u'li'PClul cohhector tennihals Wire also 0‘ female termirds
BED. B1 ard BEL
— Repa'r open in the wire

NO between the ECM‘PCM
Is there battery voltage? {31. EB]: and the PGM-FI
main relay.
— Replaue the PGM-Fl main
relay.
('o page 1143-114]
“. KY model
Fuel Supply System
+## 11-A-114

'+ #/
?0
(From page 1143-11 3';
ECMIPCM CONNECTOR
FLR [GRNJYELT
Stir" l5 B‘U“
41 r. 6 ,r H B" 2. 22.124
2!" 21‘ 2.12
2.-
P61 (ELK) REF}

2
5 ‘U
Check for an open in the EClW 2..
‘5 2U
PG“:
'1. 'Lrh the igritior switch OFF. Wire sice (1 female termir‘ds
2. Measure voltage betweer‘
ECMJ'PCM ocrrectcrtermir‘als
A15 (ME? arcl 82 wher the
igh itich switch is first teed
ON [II] for two semrds.

PCM and recheck {see page11-A-
( |sthere1.0Vcrless? >—NO 18 forimmebilizer information).
”prescribed veltageis now
YES available. replace the original
ECMPCM.
Cheek the PGM-Fl main relay
{see page114k-111}.
“. KY model
4

&A
!#!!3
9
;'!%<
+##
Fuel Su
+6
FuelTank
| S stem
11-A-115
3
A WARNING
9.
5- Disconnect the hose and quick-connect fittings
(F #

(See Page 11-A—97).
;'!%5$<-
(#3!3#
!-> QUICK-CONNECT
!#33#- FITTINGS
Removal

-
1.
1!& ! ;'!%00<-
2.
1& !!!-
3.
+- Drain the fuel tank: Remove the fuel return line from the
( !#91& ! !
fuel pressure regulator, and attach a suitable hose to the
!
!A !
regulator fitting. Place the other end of hose in a

!
-!
container suitable for gasoline. Start the engine, and run
!
!-
A
it until the tank is empty (the engine stalls).
!#;
!!<-
4.
*- Remove the spare tyre lid (see section 20), and the
1&!;0<A
access panel from the floor. Disconnect the fuel tank 4P
!!-( !#*
connector.
-
HOSE
10. (%)3!A
0- Disconnect the ABS wheel sensor 2P connector,
and headlight adjuster levelling sensor 3P
!
7 !&!!
+
connector if equipped
F
HEADLIGHT ADJUSTER LEVELING RENEDR 3P
ICON NECTDH
4P CONNECTOR
5.
- Loosen the rear wheel nuts slightly, then raise the
3! !
!A
vehicle and make sure it is securely supported. Remove
&!# ! -1&
the rear wheels.
3!-
6.
- Release the parking brake lever fully.
1!#
#!& !!- ABS WHEEL SENSOR 2P
7.
$- Remove the TWC (see section 9).
1&42;5<- CONNECTOR
8.
'- Remove the fuel cover and disconnect the fuel fill neck
1& !& !!!# 11. 1&!A!
- Remove the stabiliser bar, the heat shield and
tube and the breather tube from the fuel fill pipes.
!!!- parking brake cable bracket.
#
#!#-
FUEL smaluzan HEAT
SHIELD
PIPE
FUEL FILL
NECK TUBE
_ . _; _ 22 MM
_ ____ _,r_..
_ . __ [2.2 hut-m.
ff—..£}/islb i-hi
-
-
FILL PIPES
PARKING BRAKE
CABLE BRACKETS
Fuel Supply System
+## 11-A-116
5
Fuel Tank (cont’d)
+6/
?0
12. 1&#9

- Remove the rear brakes: -2. 1&# #-
- Remove the brake drum and brake shoe.
With *6
1 rear disc brakes Remove the parking brake cable from the
1&#
#!
-1. 1&!!#
#!-
- Remove the cable clip and parking brake cable. backing plate using a 12 mm offset wrench.
#
!
3-
Remove the two caliper bolts, caliper body
1&3!!A!
assembly. Remove the brake hose bracket.
!-1&##-
55 H-m -—-—-—-'* =3"
45.5 kgf-rn,
41 Int-m EM
if". 12 mm
OFFSET
PARKING BRAKE CABLE

_. ...y I BBAKEHOSE
., J/:_. BRACKET 13. 1&!
!-
+- Remove the flange bolt.
59 Min I613 kgt—m. 43 Mrfll
1% 11’9““ CABLE cup
-2. 6!!!
- Hold the caliper body assembly to the damper
spnng.

-
DAMPER
_ spams
__1.;,4:”_I,-L..—————CAUPEH
*.
.m
' -' Bomr A
53'5”“
14. !7#A A
*- Place the jack, or support, under the rear
suspension sub frame. Remove the mounting
-1&
bolts, and the rear suspension sub frame.

!A -
1
With *6
rear drum brakes
-1. (#!3!!-
- Disconnect the brake line from the wheel cylinder.
BRAKE LINK
16 N-n‘l {1.6 kgf-m. 12 lbf-Hl
Remix
103 "I” suspensmu
no.5 kg‘l-rn. sun
15.9 Ibfit] FRAME
Fuel Supply System
+## 11-A-117
7
Fuel Tank (cont’d)
+6/
?0
15. 1&!A !#-

- Remove the bolts, and the fuel tank straps. Installation

BDLT$ 1. !! !#A
!-
- Install the fuel tank straps, and tighten the bolts.
FUEL TANK
STRAPS
FUELTANK
STRAPS
BOLTS
33 Nm
I15 kgf-m, 2!! Hum}
- Place the jack, or support, under the rear
!7#A A
suspension sub frame. Install the rear suspension
-!!
sub frame, installing the boss with the holes in the
A!!
3!
rear suspension sub frame.
-
BOSS
+- Install the remaining parts in the reverse order of
!!
&
removal.
&!-
*- If equipped with drum brakes, after installing the
F 3 #A!!

brake hose, bleed the brake system (see section
#A!#;
19). If not go to step 5.
5<-
-
- After installing, adjust the wheel alignment (see
%!!
A7 3!!
;
section 18).
'<-
Intake Air System
6 # 11 -A-118
8
System Description
#)
The system supplies air for all the engine needs. It consists of the intake air pipe, Air Cleaner (ACL), intake air duct, Throttle
4 !!!
-#A%!;%<A# A4!
Body (TB), Idle Air Control (IAC) Valve and intake manifold. A resonator in the intake air pipe provides additional silencing as
);4)<A!%!;%<:!&#!-%#&!!

air is drawn into the system.
3-
“TAKE THROTTLE
aonr
MANIFOLD Am-
AIR INTAKE
_n_ ————~—=ENBWE RESONATOR

”l CUQLAHT
__ _ BLK
‘I'E U
VARIOUS
__ LE ____BLKI .. ECM’ SENSDRS
BLU " POM
ELK
Intake Air System
6 # _ _
Air Cleaner (ACL)
/&0
9
11 A 119
ACL Element Replacement

&%
Remove the air intake duct and AOL housing cover.
1&# %
&-
AIH lNTAKE ACL HOUSING
DUCT COVER
ACL ELEMENT
Maintenance Schedule, 99:: section 3
AOL
HOUSING
Intake Air System
6 # _ _
le Cable

*
Thrott
$
11 A 120

2D H22A7 engine
.7!
1.
- Start the engine. Hold the engine at 3,000 rpm (min-1)

-6!
+A000;< ADJUSTING
with no load (in park or neutral) until the radiator fan
3!;# !< ! LDCKNUT ”UT
comes on then let it idle.
!!- "
2.
- Hold the throttle link to the throttle; there should be no
6!!!#!N ! . .
clearance (with cruise control).
!;3 !<- ._ _-‘ "1'3
THFtclTrLE LINK
DEFLECTION CABLE
10—12mm BRACKET
lam —1/2inl
4.
*- If deflection is not within specs, loosen the lock nut,
!3A!!# A
turn the adjusting nut until the deflection as
7
!!
Them Would be specified, then retighten the lock nut.
A
!# -
m clmanca 5.
- With the cable properly adjusted, check the throttle
2!!7 A#!
3.
+- Check cable free play at the throttle linkage. Cable
#!!!!#
-! valve to make sure it opens fully when you push
&!&# !!3
deflection should be 10-12 mm (3/8—1/2 in).
! !0;+='=<- the accelerator pedal to the floor. Also check the
!!!-%!#
F2036, F1832, F1833 engine:
+$"5:+8":+8"! F throttle valve to make sure it returns to the idle
!&!&# !
ADJUSTING “HUT position whenever you release the accelerator
3& !!
LDC pedal.
!-
CABLE DEFLECTION
BRACKET 10 — 12 mm
l3ffl - 11'2 in]
Intake Air System
6 # 11 -A-121

Throttle
Cable (cont’d)

*/
?0
Installation

+- Hold the cable sheath, removing all slack from the
6!!A&
!!!#
1.
- Fully open the throttle valve, then install the throttle
!!!&!&A!!! cable.
!-
cable in the throttle link and install the cable housing in
!!!#!!!
Turn the adjusting nut until it is 3 mm (0.12 in.)
*- 4 7
!+;0--<
the cable bracket.
!#- away from the cable bracket.
3!#-
Start the engine. Hold the engine at 3,000 rpm (min-1)
-
-6!
+A000;< Tighten the lock nut. The cable deflection should
- 4
!# -4!! !
3!;# !< ! now be 10-12 mm (3/8—1/2 in). If not, see
30;+='=<-A
comes on then let it idle
!! Inspection/Adjustment.
=%7 -
F2036, F1832, F1833 engine:
+$"5:+8":+8"! F F2036, F1832, F1833 engine:
+$"5:+8":+8"! F
ADJUSTING LOCKNUT LUCK NUT
INNER CABLE 3 mm (1/8 in) 9.3 Mn:
ADJUSTING NUT -
:11: kgf-rn,
12 lbf-I‘tl
.—-—-_1:-:I "n
CABLE BRACKET
H22A7 engine:
.7! F
3 mm {“8 in)
LDCKNLFT ADJUSTING NUT
9.3 N-m
CAB-LE [Ll] kg‘I-m.
_:___
.l
BRACKET
-I
I
1.2 lhf-ftl . _. 44—4‘ -—
H22A7 engine:
.7! F
TH HDTTLE LIN K
CABLE BRACKET
ADJUSTING
LOCKNUT "”T
INNER CABLE
Intake Air System
6 #
Throttle
Body

"
#
11 -A-122

Description
)
Inspection

The throttle body is a single-barrel side-draft type. The lower
4!
!!-4!3 Check that the throttle cable operates smoothly without
#!!!3
portion of the throttle valve is heated by engine coolant from
!&!&
! binding or sticking.

#
-
the cylinder head.
!- If there are any abnormalities, check for:
!A#9
THROTTLE 0 Excessive wear or play in the throttle valve shaft.
/&3!!&!&-
Pnsmom 0 Sticky or binding throttle stop screw and throttle
#
!3!
iTPl link at the fully closed position.
!# !!!-
SENSOR
0 Clearance between throttle stop screw and the
!3!3
throttle link at the fully closed position.
!!# !!!-
F2036 engine:
+$"5! F
There shtnuld be
THROTTLE LINK no clearance.
..——-' '. " —J

THHGTTLE THROTTLE
THROTTLE STOP SCREW
VALVE STOP
(Do not adiustl
SCREW
(Do not adjusLi H22A7 engine:
.7! F
THROTTLE Them should be
LINK no clearance.
THROTTLE STOP SCREW

(Do not adjust}:
Replace the throttle-body if there is excessive play in

1!!/&!
the throttle valve shaft or if the shaft is binding or
!&!&

sticking.
#
-
Intake Air System
6 # _ _
Throttle
Body (cont’d)

"
#/
?0

1 1 A 1 23
Removal

-
F2036 engine:
+$"5! F
MAP SENEDR
TP SENSOR
22 N11!
[2.2 ltgl-m_
1a lbf-fl] -
CRUISE CONTROL
CABLE
H22A7 engine:
.7! F
MAP 5E NSOFI GASKET
Replace.
TP SENSOR
22 film
[2.2 kgf-m,
1a Ham]
THROTTLE
CABLE
NOTE:
84 9
¢ Do not adjust the throttle stop screw.
(7 !3-
¢ After reassembly, adjust the cruise control cable (see section 4), the throttle cable (See Page 11-A—120).
%!A7 !!;*<A!!;'!%0<-
¢ The TP sensor is not removable.
44&!-
Intake Air System
6 # 11 -A-124

Throttle
Body (cont’d)

"
#/
?0
Disassembly
) *#
F2036 engine:
+$"5! F
2.1 N-n1
“1.21 Raf-m. 1.5 lbf—fi)
MAP
SENSOR
Truu t1 IE 3h outing
pa gr: 1 1- A- 39
Replace.
TP
SE NSDH
Truubleshoming
p 3 BE 1 l-A- d. 3
H22A7 engine:
.7! F
2.1 MM
W21 kgf-m. 1.5 lhf-fll
99
«:ad
I
MAP
SENSOR
Troubleshooting
O-RING page 11-A-39
H 8 place \f2—
: |
Troubleshooting
page li-A-N

4

&A
!#!!3
9
;'!%*$<
;'!%+5<
Intake Air S stem
6 # _ _
3
11 A 1 25
'"take Air Bypass (IAB) Control System (F2036,
6 "#/"0

#/+$"5:
F1832, F1833 engines)
+8":+8"! 0
Description
)

Two air intake paths are provided in the intake manifold to allow the selection of the intake path most favourable for a given
43#&#!!!3!#& !
&
engine speed. Satisfactory power performance is achieved by closing and opening the Intake Air Bypass (IAB) valves. High

-3&!

#%);%)<&!&-6

torque at low rpm is achieved when the IAB valves are closed, whereas high power at high rpm is achieved when the IAB
F !3&3%)&!&!A3
3
&3%)
valves are opened.
&!&-
”“3
CONTROL
From Me. 6 ECU
BLKI [ECMJPCM]
SOLENO'D | ' ' ' "s ——_""'”"‘ cnunsE oonmm
VALVE (15 Al FUSE
LAB VACUU lil'l TANK
=3 /
:‘ . (:4
r. l‘ VARIOUS
LAB CONTROL HE or , ECW SENSORS
DLAPHRAGM
.gg'j _: BLU ' PCM
I l
J ma
k CHECK
: IAB [CONTROL SOLENOIDIVALVEOFF I

it
ENGINE RPM IS ABOVEI3,906r m "main
4.200 1%", m'n" '1
*‘l: F1332, F1883 engine

‘2: F2086 Engine
Intake Air S stem
6 # _ _
Intake Air Bypass (IAB) Control System (F2036,
6 "#/"0

#/+$"5:
5
1 1 A 1 26
F1832, F1833 engines) (cont’d)
+8":+8"! 0/
?0
Troubleshooting

*
!
'7 Inspeutien oflAB Control System.
Cheek fer vauuum at idle:

1. Start the engine and allcw it
to idle.
2. Removettevacwm tcsefrom
the MB ccntrcl dapl'ragm
and connect vacuum gaugeto :-
tt'e l‘ose. a I... .-
Cheek forvauuum atlABvanuum

tank:
- %'~"ri-fi=
.
L‘ y..r"
' |
vacuum
PUMPI
GAUGE
| t a NO Remove vacuum rose fromtt‘e ' ”1.3
St ere vacuum. IAB control diapt‘rag'r, tt‘en creck CONTROL
YES for vacuum at the IAB vacuum DIAPHRAGM
tank.
/ —\N0_
Is tt‘ ere vacuum ?
YES
Repa'r the blockage or vacuum
ledt between theIABvauuum
tank and 'll'teintakemmii'old.
, , IAB CONTROL SOLENOID

Cheek for an open In here VALVE 2P CONNECTOR
(IAB SOL line):
1. 'urntt‘e ignition switct‘ OFF. |G1
2. Discomed tt‘e IAB control
solenoid valve comedor.
3. 'urntt‘e ignition switct‘ ON ill}.
4. Measure voltage between the
IRS control solenoidvalve 2P
connectortem‘inals No. 1 and
No. 2
IAS 50L
{RE DI
SLU]:
Wire side of female ten'rinals
<1": Is there battery voltage?
NO YES
Replace the IAB control solenoid

valve.
Check for :1 open in thewire '51

{IG1):
Measure voltage between body
gromd andtl‘e Ir'tEl control
sderoidvave 2P connectcr
terminal No. 2.
W
('0 page 11-A-127} [—0 page Hit-12.7}
Intake Air System
6 # 11 -A-127
7
Intake Air Bypass (IAB) Control System (F2036,
6 "#/"0

#/+$"5:
+8":+8"! 0/
?0
(Frorh page 11-Ft-126f: [Frorr' page 11-A-126]
i7
Check for vacuum at4.DDL‘r1
Is there batten.- voltage”?
YES
filinitll‘llr2 rpm {min-1):
1. Raise engine speed to above Repair open in thewire between
4,000” (4.503}? rpn" [Win-1}. the IAB control solenoid valve
2. Check forvacturh atthe connector and No. 3 ECU (ECMJFGM
vacuum" hose. CRUISE CONTROLHBA] fusein the
driv er's under-dash fuselrelay box.
Check for an open in the wire ECMPCM CONNECTOR B {25H

{IAB SOL line]:
1. Stop the engine and turn the Li c ."
a
ignition switch ON ill}. 2..
n'
,9
2. Cornect ECluli'PClul connector
ten'r'inals B15 and BEG with a L61 IAE
ju'r‘perwire. saw
{BLKHUWER WIRE SOL
(RED!
BL Ll]:
./ Does the soleroidvave click NO Wire side d
\ 'whenthejurr'peris ccnnected?I /' fen‘detern'inds
YES
Repair open in thewire between
ECMPCM (B18) and 'IheIAB
control solen oid vave connector.
Substitute a know-good EClW

ROM and recheck {see page 11 -A-
symptomlinclicalion goes away.
replace the original ECIWPCM.
YE U Discomed the IAB control

Is there v acum‘ ?
sderoidvalve cornedor.
NO
YES
< Is therevacuur? :3
NO '—|
I Replace the IAB control solenoid valve.
IAB CONTROL SOLENOID

Check for short in thew-ire
VALVE 2P CONNECTOR
{LAB 30L line]:
1.TL.rr the ig ritior switch OFF. [AB eoL
2. Disco" rectthe ECM‘PCM corrector {REDJ'ELU}
B [ESP].
3. Check for cortirLity- betweer bocv
grmr‘c arc the IAB ccrtrd solerdc
vave 2P correctcrtermira No 2
Wire side offerr'ale
«1 Is there ccntimity ? YES
:3r—I tem‘inals
NO
Repair short to ground at thewire
between ECMPCM (B1B) andthe
lAB con trol solenoid vdve connector.
Substitute a known-good EClWP CM

and recheck tsee page 1141-16 for
irnrnobilizer information]. If symptom
goes away. replace the original ECM
(To page 11-A-128': PCM.
4

&A
!#!!3
9
;'!%<
Intake Air S stem
6 # _ _
8
11 A 1 28
'"take Air Bypass (IAB) Control System (F2036,
6 "#/"0

#/+$"5:
+8":+8"! 0/
?0
(From page 1141-12. j:

VACUUM
PU MPIGAU GE
CHECK FOR IAB annual diaphragm:
1. Ramona 'uEICLLm hose from
me IAB cortrd ciaphragm f. FU L L -CL 05E
arc ccrrectuacum mp to .
- " SCREW
1116 hose. .
53. flppl‘y 'uEICLLfl‘I.
3. Checktha-zfijmme IAB cortrd
waive isir close cwtactwi‘m me
ll—clcee screw.
Cheek thevaouum line for proper

(1 INCH connection ordamage.|fOK.gu
—/ to the lAB nonwol valve tuning
YES (see page11-A-129].
IAB mntrol syswn is OK.

4

&A
!#!!3
9
;'!%5<
Intake Air 3 stem
6 # 11 A429
9
Intake Air Bypass (IAB) Control Valve Testing
6 "#/"0

4- !
A CAUTION
Do not adjust the IAB control valve full-close screw. It was
(7 %)!&!& !!!3-3
preset at the factory.
-
1.
- Check the IAB control valve shaft for binding or sticking.
#%)!&!&
#
-
2.
- Check the IAB control valve for smooth movement.
#%)!&!&&-
3.
+- Check that (A) of the IAB control valve is in close
#;%<%)!&!&!
contact with the stopper when the vacuum hose is
33&
disconnected from the IAB control diaphragm.
%)!
-
STOPPEH
4.
*- Check. that (B) of the IAB control valve is in close
#;)<%)!&!&!
contact with the full-close screw when you apply 51 kPa
3 !!!33 !#
(380 mm Hg, 15 in Hg) of vacuum to the IAB control
;+'06
A6
<& %)!
diaphragm.

-
FULL-CLOSE
SCREW
I\Tfic—%\Tflnfl
r If any fault is found, clean the linkage and shafts with

! A!!#
3
carburettor cleaner
!
- If the problem still exists after cleaning, disassemble the
!!!/!
A!
intake manifold and check the IAB valve body assembly
#!#%)&!&!
(see section 9).
;5<-
Intake Air System
6 # _ _
Intake Control System (H22A7 engine)
6

#/.7! 0
$
1 1 A 1 30
Description
)

When the engine speed is below 3,950 rpm (min-1), the ECM supplies a ground to the intake control solenoid valve. This
2
!3+A50;<A , !
#!!&!&-4
opens the solenoid valve sending intake manifold vacuum to the intake control diaphragm.
!&!&
#!& #!
-
INTAKE
CONTROL Tu No. 5 Ecu
SOLENOID _ ELK)I fl. {ECM}
VALVE VEL CRUISE DoNTHc-L
[15 A] FUSE
_ ___.
'i '— 1
INTAKE 2- RED; __ ECM VARI
SE N331:
CONTROL - "3.5. ; _. BLU ' ' —'
CHECK
VALVE 1
LL: ! 1
"I— *‘—'-—I NTAKE ELK
1 CONTROL
l
VACUUM
TANK
” ~41-1.4,...“ ____
I
_ J L- INTAKE
- - T‘Wcomnm
: CONTROL
T" ‘ DIAPHRAGM
Intake Air System
6 # 11 -A-131

Intake Control System (H22A7 engine) (cont’d)
6

#/.7! 0/
?0
Troubleshooting

*
!
Ins pee tion of intake eon trol
system. INTAKE
CONTROL _
SOLENOID .-
Check for vacuum at idle.
1. Sun the er‘gire arc allow it
to iele.
VACUUM PUMP!
2. Remove the uao.L.m hose
GAUGE
from the Make cortrol ciaphragm
are correct avaceem gauge to the
hose.
YES Diseor‘r‘ eetthe irmke cortrol

( Is there vaCLLm?
sole roie value corr ector.
NO
Y ES
< Is there vaCLLm? I. -
no—/—‘
Replace the in H1: control
solenoid valve.
Ch eol: for a short in the wire “C

IAB CONTROL SOLENOID
SOL line]:
VALVE 2P CONNECTOR
1. TL.rr' the igr'itior switch OFF.
2. Disecrr'ectthe ECM corrector B 1 Ic SOL
[ESP]. 1—1 {REDIBLU}
3. Cheekfor CITfiI‘LlI‘y betweer‘
boo; grown: are 1he IAR
1;. 2 -*_1_
ccflrd soler'cio waive 2P
" ' fine}
correctorten‘niral No. 2 I
Wire side offewale
tern‘inals
< Is there cm
NO
Repair short to ground at thewire
between ECM (315] and theinuke
oontrol solenoidvdveoonneetor.
Cheek for vaouum above (DOD Substitute a known good ECM

rmp lmin-1]. and reoh eel: tsee page11-A-16
1. Raise ergire speec to some for immobilizer in formation]. It
4.030m1p (mir-‘l j}. symptom goes away. replaoe the
2. ChfldifUUaCLLm athevaCLLrn origin 1 ECM.
hose.
(To page 114L132]

6 #
Intake Air System
Intake Control System (H22A7 engine) (cont’d)
6

#/.7! 0/
?0
11 -A-132

(Frcrn page11A—131]
Cheolt l'or vaouu in at intite
oontrol vaouurn tank:
Is there uaceem? Re move lower'uaeLLm hose
from the IAR eertrd soler tic
YES value, ther cheek for-umLLm.
T. NO
Isthereum
YES Repa‘r the blookane or vaouum

leak between the intake oontrol
vaouum tank. intake oontrol solenoid
vdve and the intdtemmil'old.
Cheek for an open in the wire (IC INTAKE CONTROL SOLENOID

SOL line}: VALVE 2P CONNECTOR
1. TLIT‘ the igritior switch OFF. '51
2. Disco" reetthe irmke cortrol {BLKIYE L}
sole r'oie value corr ector.
3. Stanthe er'gire arc raise
er' gir'e sp eee to 4,003 rpm Ijmir'-1 :1.
4. Measereudwge betweer‘the
ir'take ecrtrd solero‘cudue IC SOL
2P correctortermirals No. 1 {REDJ‘BLU}
are No. 2. _ _
WIFE} Side of female
_.—I— YES -
tenrlnals
\: Is there batteryvoltage? :/—|
NO Replace theintake oonlrol solenoid

valve.
Check for an open in the wire ____J:]

"G1 line}: III-1"l |G1
Measere voltage betweer bCICy }—l {3t
grown: are 1he irtalte eor‘trol sder‘oic . 2 ___.-" YE L}
'udue 2P correctutermird No. 1. """‘—"' (VT.
IIH
lstl‘ere batteryvoltage?
YES Repa’r open in 'lhewire between

theintdte control solenoid valve
connector and No. 3 ECU {ECM}
CRUISE CONTROL {151%} fusein the
driver's under-dash fuselrel ay box.
Cheek foran open in 'lhewire ECM CO'NNECTOR B ‘25P}

to some]: ‘. f. ...'~.* .".".,..."..
mo:
1. Tetheigritior switch OFF F. ,E .531 41“.:

arete the igrificr switch Ol'llljlll 9 JL A as ”a d”-
2 Correct ECM eorrectcrtennirds. LG1 “3
.— - - -
El1aareBZUlw-rthajempe . -
rmre. BRNI JUMPERWIRE
(ELK) tsRiL-DI
Does the solereie 'ud'ue dick NO Wiresieleof ELL-'1'

wher the i per is oorr eotec? ,-"' fen" ale tern‘inals
YES Repair open in 1h ewire between

ECM (B15) and the intdte oontrol
solen old vdve oonneotor.
Substitute :ltnmn-goodECM and

reoheolt tsee page11-A-1Gl'or
immobilizerinl'orrnation]. ”symptom!
(Topage11-A-133] indioati on goes may. replaoe 1h e
ori ind ECM
4

&A
!#!!3
9
;'!%<
Intake Air System
6 # _ _
Intake Control System (H22A7 engine) (con
t’d)
6

#/.7! 0/
?0

1 1 A 1 33
VACUUM
FUNFIGAUGE
(From page 1141-132}

tn
Cheek the-intake annual dimhragm:
1. Correct an 'UEUZLLm mp to
the imdce ctrtrd ciaphragm.
INTAKE
Cheek thevaouum linefor proper (INTRO.
:Does it holcfiuamm’? NO oonneofions or damage. DMPHRAGM
_. IfOK. replaceme intdtewn trel
YES diaphragm.
I In tire control system is OK.

Intake Air S stem
6 # _ _
Fuel Injection Air (FIA) Control System
+D
/+0

#

11 A 1 34
Description
)

When the engine running, the IAC valve sends intake air to the fuel injectors.
2

A%&!&# !7-
/ FIA LINE
Bu“ ; VARIOUS
— ECMI ENSURE
—— BLU ' " PCM ' S
BLK
6 #
Intake Air System
Fuel Injection Air (FIA) Control System (cont’d)
+D
/+0

#/
?0
11 -A-135
3
To EVAF' FURGE
CONTROL OANISTER
Tn ENGINE MOUNT
CONTROL SOLENOID --— —~..
Inspeetien of the Fuel Injeetion Air
VALVE (NT)
tFIA] eon trol system.
Cheek ferAirAssist line:

1. Stat the ergire. Hdc the
ergire at 3030 rpm Ijmir-T: VACUU M
with ro loot: Ijir Park or r‘eetrdj: PUNPIGAU GE
Lrtil the raziatorfar
comes or. ther let it icle.
2. Remoue the ‘uaCLLm hose
from the IN: naive are correct
EI'UEICLLm gaegetothe hose.
Is there uaeLLm?
NO Repair the blockage or vacuum
ledt beMe-en the IAC vdve and
YES
Check the IAC valve:

1. Te the igritior switch OFF.
2 Remove the ‘uaCLLm gaLge.
are co" rect a 34m;- ju‘rt arc
'UEICLLITI gauge as sh cwr.
3 Disccrr'ectthe UtCudue SP
cor'r' ectot
4. Stmthe ergire are check
the mm Lm.
< ISIhEI‘E'uaCLLITI Cher—40km YES

[303 ITIITIHQ. 11-3 ir.Hg}? RENEW the IAC valve.
NO
Fuel Injeetien AirtFlA] control

system is OK.
%

# 11 _A_1 36 Way Catalytic Converter
1##
-
System Description
#)
5 Three
(TWC)
/10
The emission control system includes a Three Way Catalytic

4!! 42! Description
)

Converter (TWC), Exhaust Gas Recirculation (EGR) system,
&;42<A / .1 !; .1<A The
Three
Way Catalytic Converter (TWC):
1##
-/10F
Positive Crankcase Ventilation (PCV) system and
&#:!;:< The Three Way Catalytic Converter (TWC) is used to
442!&;42<
Evaporative Emission (EVAP) Control system.
&& ; :%<!- convert hydrocarbons (HC), carbon monoxide (CO),
&;6<A/;8<A
Tailpipe Emission
%
and oxides of nitrogen (NO x) in the exhaust gas to
/
;8/</

Inspection

carbon dioxide (CO 2), dinitrogen (N 2) and water
/;0<A
;<3
A WARNING
vapour
& -

-2

(#3!3#
!-> (see section 9)
;5<
!#33#- SECONDAH‘I"
1.

-6!
+A000;< HEATED
0X ‘I'GEN SENSD H
3!;# !< ! ISECONDAR‘I' HD25I
A!!-
- -
PW.“
HOUSING
Check the idle speed (See Page 11-A—94).
+- #!;'!%5*<-
Warm up and calibrate the CO meter according to the
*- 2 !8

meter manufacturer’s instructions.
B -
5.
- Check idle CO with the headlights, heater blower, rear
#!83!
A!3A
window defogger, cooling fan, and air conditioner off.
33
A!
A-
C0 meter should
indicate 0.1% maximum.

$@S @
|
FRONT OF TH REE WAY
VEHICLE CATALYSTS
Inspection

If excessive exhaust system back-pressure is
/&/ #
suspected, remove the TWC from the car. Using a
A&42-?

flashlight, make a visual check for plugging, melting or
!!
A#& !#!

A!

cracking of the catalyst. Replace the TWC if any of the
#
!-1!42
visible area is damaged or plugged.
&!
!
-
FLASH LIGHT
%

#
Three
Way Catalytic Converter (TWC) (cont’d)
1##
-/10/
?0 7
1 1 A 1 37
P0420
'$$ The scan tool indicates Diagnostic Trouble Code (DTC) P0420: Catalyst system efficiency
4!(
4 !;(4<0*09!
below threshold.
!3!-
Description
)

This system evaluates the catalysts capacity by means of the H028 (Primary and Secondary) output during stable driving
4&! !B68;<
!&

conditions. If deterioration has been detected during three consecutive driving cycles, the MIL comes on and DTC P0420 will
-
&&
!A,(40*03!!
be stored.
-
NOTE: If some of the DTCs listed below are stored at the same time as DTC P0420, troubleshoot those DTCs first, then
84 9(4!!3(40*0A !(4A
troubleshoot DTC P0420.
!(40*0-
P0137, P0138:
0+$A0+'9 Secondary H028 (Sensor 2)
60;<
P0141:
0*9 Secondary H028 (Sensor 2) Heater
60;<6
Possible Cause
'
*
¢ TWC Deterioration
42(
¢ Exhaust system leakage
/ !#

Troubleshooting

* Flowchart

!+
(
- DTC P0420 is stored.
Problem verification:
1. Baths ECMI'P CM Reset Proeee Lre.
2 Startthe ergire. Hdcthe ergire
at 3.030 rpm (mir-1 j: with re loo:
Ijir Park or neutral] L.r'ti| the raziator
far com as or.
3 Correctthe SCS short corrector.
4. Tester'rue 64 - 88 k'h (40 - :35
mph} for acpror. two mir Lte s.
Ther cecelerate for at least 3
seem" as with the throttle completely
clcsec. Ther‘ reCLce the vehicle
sp eec to 56 km'h
(Emmi. ar‘ctry to hole it
Lrtil the reaciress coce
comes or.
. . NO Intermittentfa'lure. system isOK

IsDTC P0420Ircneatec.7 atthistime.
YES
Cheek th e TWO (see page 11 «it-133].

If nooeosary. replaoe the TWO.

4

&A
!#!!3
9
(See Page 11-A-136)
;'!%+<
%

# _ _
8
Exhaust
% Gas Recirculation (EGR) System

/%0# 1 1 A 1 38
Description
)

The EGR system reduces oxides of nitrogen (NOX) emissions by recirculating exhaust gas through the EGR valve and the
4 .1 /
;8/< !
/

.1&!&
intake manifold into the combustion chambers. The ECM/PCM memory includes the ideal EGR valve lift for varying operating
#! -4 ,=,! ! .1&!&!&

conditions.
-
The EGR valve lift sensor detects the amount of EGR valve lift and sends it to the ECM/PCM. The ECM/PCM then compares it
4 .1&!&! .1&!&! ,=,-4 ,=,
with the ideal lift in its memory (based on signals sent from other sensors). If there is any difference between the two, the
3!!;
!<-33A
ECM/PCM cuts current to the EGR valve.
,=, .1&!&-
WHTf _
ELK ‘
VELf ‘_
BLU
EGR VALVE —i VARIOUS
urr sermon __ __ __ GEM EcMIPCM _ -semsons
\ ' ""3“
PNK I
‘_ l‘ -
INTAKE
MANIFOLD
%

# _ _
9
Exhaust
% Gas Recirculation (EGR) System (cont’d)

/%0#/
?0 1 1 A 1 39
P0401
'$$ The scan tool indicates Diagnostic Trouble Code (DTC) P0401: Insufficient flow in the Exhaust
4!(
4 !;(4<0*09 !3 /
Gas Recirculation (EGR) system.
.1 !; .1<-
Description
)

Deterioration (clogging, leakage, etc.) in the EGR line or EGR valve is detected by means of the changes in MAP before and
(;!

A!#
A-< .1! .1&!&
,%
after the operation of the EGR valve. If deterioration has been detected during two consecutive driving cycles, the MIL will
.1&!&-
3 &&
!A,3!!
come on and DTC P0401 will be stored.
(40*03!!-
Possible Causes
'
*
¢ Clogging, leakage in the EGR line
!

A!#
.1!
¢ Faulty EGR valve
! .1&!&
Troubleshooting

* Flowchart

!+
(
— The MLL has been reported on.
1. Dctre ECMIPClul Reset
ProcedLre.
2. Corredtre SCS sl‘crt
ccrrectcr.
3. ’est-clr'we eertre fcllcwir‘g
ccr cliticrs:
_ W'rtl" CLt ar‘y electrical Icad.
— Deoelerate from 89 kl‘ll'l‘
[55 mph: for at least 5
seccr ds.
NC Intermittent failure, system is OK

< ls D—c P0401 irdicated? "'33:; at this time.
YES
— lClean theintakemmii'old EGR

portwith orb ureter elem er.
— lSloan the passage inside the
EGR valvewith orburetor
ulemer or replane the valve.
%

# _ _
$
Exhaust

/%0#/
?0 1 1 A 1 40
P1491
'9 The scan tool indicates Diagnostic Trouble Code (DTC) P1491: A malfunction in the Exhaust
4!(
4 !;(4<*59%! /
.1 !; .1<-
1. Do tre ELEM/POM Reset
ProoedLre.
2. Correct tre SOS srort
corrector.
3. Stature ergire. l-oldtre
ergire at 3000 rpm lmir-‘l j:
witl‘ ro load Ijir Park or
reLtral] L.rti| tre radiator far
comes or.
4. Drive tre vel‘icle or tre road
for approx. 10 mirutes. ’ry to
keep the ergire speed ir tre
1.?00 - 2.500 rpm (VHF-1]
EGR VALVE SP CONNECTOR
rar ge.
-
Intermittent failure system is OK .1 2 2'
/ ls D’C P1491 irdicated? \___ NC at this time Check for poor 4 6
connections or loose wires at EGR -
YES vdve and ECMI'PCM. “56R L G101
(PNK) —-.. [ELK]
Cheek for a malfunction in the [12
EGR valve:
"Mre side of female termirals
1_ Start the ergire ard let it idle.
2_ I'uleaSLre voltage betweer tre
EGR valve 6P corrector
termirals No 4 ard No. S. EGR VALVE SP CONNECTOR
lstl‘ ere batteryvoltage? ., Cheek the EGR valve:

NC 1, ‘e tre igritior svtitd‘ OFF. 1 2 3
/ 2. Disoorreottl‘e EGR valve 6P 4 6
YES DGr'r'ec‘tGr.
3. Correct tre battery positive
tenniral to EGR valve 6P
Substitute a known-good ECMI Dorreotor termiral No. 6.
POM and recheck (see page 11.A- 4. Starttre ergire ard let it idle. 9
15 for immobilizer information). ”'3? EFFF'ECI Fl"? battery BATTERY
“r svrnptomlin dication goes regatrve termlral to EGR valve 12 'v'
away; replace the original ECMI EP eor rector termlral No. 4
Wire side of female termirals
PCM.
Doestre ergire stall or NO

rLr roLgr?
YES
Replace the EGR valve.
['o page 11-A-1 41';

4

&A
!#!!3
9
;'!%<
%

# _ _
Exhaust

/%0#/
?0

1 1 A 1 41
(From page 11-A-14D]
EGR VALVE 6P CONNECTOR
1 2 3 Wiresideof
E'EGR female terlnir‘ ale
[P NK) 4 6
Check for an open in the wire (E-
EGR line]: I'lll-V-W
1. —U|TI the ignition SMtCl" OFF. "-:.-" ECWPCM WNNEc B ‘25P}
2. Disconred the EC M'PCM [ E-EGR
conredor B ESP} from the ECM;‘ [pun].
PClul.
3, Ch ed»: for continu‘ty between ‘ 2 J 4 .I' H
II."
EClul mmedortenrinal BF 9 ‘L' “ ‘2 ‘3 ‘4‘;- ‘Ei ‘ ,r ‘ H
and the EGR valve 6P connector ‘5 2L: 2‘ 22 2d 24 2;-
tenrind No. 4.
Wire side of female tennir‘als
Is there ccrtihLit ,9 NC Repair open in the wire between

y. the EGR valve and the ECM [37}.
YES

[GND line}: 1 2 3
Cheda‘ for ocrtirLitybem-eer the
EGR val-re 6P ccrrectcr termiral 4 E
No. 6 ar'd bodygrcd.
G101
_ _ _ [ELK]:
. . 7 Repalropenlnthewuebetwccn

PCM and recheck [see page 11-A-
1 E for in‘rnobiliaer information).
If symptoml‘indication goes
away, replace the original ECIW
POM.
4

&A
!#!!3
9
;'!%<
%

#
Exhaust

/%0#/
?0
11 -A-142

P1498
'98 The scan tool indicates Diagnostic Trouble Code (DTC) P1498: A high voltage problem in the
4!(
4 !;(4<*5'9%
&!
!
Exhaust Gas Recirculation (EGR) valve lift sensor circuit.
/ .1 !; .1<&!&! -
— The l'li'llL has been reported on.
1. Do the ECMEPCl-al Reset
ProcedL. re.
2. Start the er gire.
lrtermittert failLre, system is OK

ls D'C P1498 ir‘clica‘ted?
oorr ecti ors or loose wires
betweer EGR valve ard ECMJ'PCM.
Check for an open in the EGR EGR VALVE SENSOR SP CONNECTOR

valve lift sensor:
1, ’e the igritior switch ICFF.
862 vccz
2, Disoorrectthe EGR valve lift
ser sor EP corrector.
loan: [YELI
3, ’e the igritior switch CN {ll}.
BLK) BLU}
4, l'uleaSLre voltage betweer the
EGR valve lilt sersor 6P
1
corredorten‘tirals No. 3 ar‘d 4
No. 2.
Wire side of female termir' als
Is there approx. 5 V? Replace the EGR valve.
NC
Check for an open in the wire {362

line}:
l'uleaSLre voltage betweer ECM!
POM eorrectortermirals I318 ard
I328.
Repair open in the wire bemeen

Is there approx. 5 V? ECM [018) and EGR valve lift
sensor.
NC
EClWPCM CONNECTOR C [31H
PCl'li'l and recheck [see page 11-A- sczicamsLK}
If smptoml‘indication goes
away, replace the original ECM! HE‘S
PGM. ‘5 EUE‘ 22
d5 3'3 3‘
vcczrVEusLui

4

&A
!#!!3
9
;'!%<
%

# 11 -A-143

Positive Crankcase Ventilation (PCV) System
'
-64
/'40#
Description
)
H22A7 engine:
.7! F
The Positive Crankcase Ventilation (PCV) system is
4&#:!;:<
designed to prevent blow-by gas from escaping to the

&!3

atmosphere. The PCV valve contains a spring-loaded
-4:&!&
!
plunger. When the engine starts, the plunger in the PCV
!
-2
A!
:
valve is lifted in proportion to the intake manifold vacuum,
&!&!#!& A
and the blow-by gas is drawn directly into the intake manifold.
!3
3!#!-
W BHEATHEH
PWE
BREATHER
PIPE
2.
- At idle, make sure there is a clicking sound from
%!A# !#

the PCV valve when the hose between PCV valve
:&!&33:&!&
and intake manifold in lightly pinched with your
#!!
!3
fingers or pliers. If there is no clicking sound, check

!-!#
A#
the PCV valve grommet for cracks or damage. If
:&!&
#
-
-I-: BLEID'll'll-Bllr VAPDR the grommet is OK, replace the PCV valve and

8>A!:&!&
: FRESH AIR recheck.
#-
Inspection

1.
- Check the PCV hoses and connections for leaks and
#:!#
clogging.
!

-
F2036, F1832, F1833 engines:
+$"5:+8":+8"! F
PCV
HOSE
(”I Gently pinch here.
BREATHER VALVE
PWE
%

# 11 _A_144

Evaporative Emission (EVAP) Controls
%-
-%
/%4'0

Description
)

The evaporative emission controls are designed to minimise the amount of fuel vapour escaping to the atmosphere. The
4&&!
!&
-4
system consists of the following components:
!!3
9
A. %-
-%
/%4'0

@ Evaporative Emission (EVAP) Control Canister
An EVAP control canister is used for the temporary storage of fuel vapour until the fuel vapour can be purged from the
% :%!
!& ! !&

EVAP control canister into the engine and burned.
:%!
-
B. 4
'!

#
"@ Vapour Purge Control System
EVAP control canister purging is accomplished by drawing fresh air through the EVAP control canister and into a port on
:%!

!3

:%!
the throttle body. The purging vacuum is controlled by the EVAP purge control canister and the EVAP purge control
!-4

& !! :%
! :%
!
solenoid valve.
!&!&-
j E‘u'x-‘IP FLIFIGE CONTROL DIAPHRAGM VALvE OPEN AFTER STARTING ENGINE
! EVAP PURGE CONTROL SOLENOID VALVE DUTY CONTROLLED
A
l ENGINE COOLANT TEMPERATURE ABOVE 55'C1131"Fl:FZDBB engine, I35- T:
j IIAEI'FI: H22AT engine
C.
@ Fuel Tank Vapour Control System
+64

#
When fuel vapour pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens and
2 !& !#
&! :%33&!&A&!&
regulates the flow vapour to the EVAP control canister.

!!3& :%!-
.H':
.-
_.J.r :- ..
:--H-—_: "Ti“
‘] .': |__
. ,F'__,——.1rl
EVAP
EVAP PURGE
F rom No.6 Ecu IECMIFGMI
TWO W” . CONTROL BLK
4‘ CRUISE CONTROL
”LEE SOLENO'D
'' VALVE
VELE
(15 A] FUSE
FUEL
TANK
EVAP VALVE _. _
VARIOUS
/ FUEL TANK _ HEDI ECMI‘ - ENSOHS
VEL PCM ._ 5
FILL ' _ -
cm;- ....... ll.— Tr» SID: FRAME ELK
1' EVAP
a CONTROL —
Ch MISTER
%

# 11 -A-145
3
Evaporative Emission (EVAP) Controls (cont’d)
%-
-%
/%4'0

/
?0
P0443
'$ The scan tool indicates Diagnostic Trouble Code (DTC) P0443: An electrical problem in the
4!(
4 !;(4<0**+9%!!!
EVAP Purge Control Solenoid Valve circuit.
:%
!!:!& -
— DTC P044: is stored.
|
Prooedu re.
2. 'urr' the ighitioh switch CN ill}.
Intermittent failure system is OK
at this time. Ititheolt for poor
IS D—C P0443 irdicated? oon heotions or loose wires
between the EVAP Purge Control
Solenoid 1tl'alve and the EClWPCM.
Check the EVAP purge control
solenoid valve:
1. ’urr' the igr‘itior‘ switch OFF.
2. Disoohh ect the 2P oohhector
from the EVAP purge oor'trol
EVAP
solehoid valve.
3. Disoohh ect the vacuum hose
PURGE CONTROL ._
from the EVAP purge oor'trol CANISTER
car ister ar‘d correct a vacuum
gaugetothe hose.
4. Start the ehgihe ahd allow it to
idle.

EVAP PU RGE CONTROL
YES SOLE NOlD
Is there vacuum? __ [PCS lin e}:
1. 'urr' the ighitioh switch OFF.
VALVE 2P CONNECTOR
NC 2. Check for oohtihuitv bet'weer‘
the EVAP pu rge cor‘trol
soler'oid valve 2P oor‘r‘edor PCS
ten'tir'al No. 2 ahd body (REUYEL)
grou r'd.
Irohn‘ 1|
""’-_1;‘AI'ire side of
cf: Is there ooh tihuitv? — female
te n‘tir‘als
Replace the EVAP purge control
solenoid valve.
Check for a short in the EClW

PCM:
1, Diseor'r' eat the ECMIPCM
ooh rector C(31P}.
2, Check for oohtiruitv betweeh
the EVAP purge cohtrol
soler‘oid valve 2P cohhector
termir'al No. 2 ar d body
grour‘d.
Is there oohtiruitv?
. YES
NC
the EVAP purge control solenoid
valve and the EClWPCM [622}.

(To page 1143-146]
FISH and retest [see page 11-A-16
for immobilizer information). If
svn‘mtoml‘indication goes away,
4

&A
!#!!3
9
;'!%<
%

# 11 -A-146
5
%-
-%
/%4'0

/
?0
(From page 11-.A-1 45]
Check the EVAP purge control

valve:
1. 'e the igritior switch OFF. EVAP PURGE CONTROL SOLENOID
2. ’e the igritior switch CN ill}. VALV E 2P CONNECTOR
3. Atthe harr‘ess side. measue
voltage betweer the EVAP
ege oor‘trol soler oid valve 2P
oor'r'ectorten‘iiral No. 1 ard IG1(BLKIYEL) . Vii
.
bodv groL.r‘d.
3.1
Wire side of
female
termir‘ als

— \ NC EVAP purge control solenoid
Is there battery voltage? - valve and the No. 6 ECU (ECM!
PCM} CRUISE OONTROL (1 EA
YES fuse}.
ECMIPCM CONNECTORS
[PCS line}:
PG1 (ELK)
'1. 'Lrh the igr‘itior‘ switch OFF.
2. Recohhect the 2P oor‘r‘edorto
the EVAP purge cor‘trol a [25m 9
soleh oid valve. '9
3. 'Lrh the igr‘itior‘ switch CN ill}.
4. Measue voltage betweer‘
ECMIPCM corrector tennii‘als
022 ahd B2.
o [31m ..
Pcs
[RE DI‘I'EL]:

the EUAP purge control solenoid
< Istherebatteryvoltage? '>—NC - valve and the ECMIPCM (022). If
wire is OK, replace EVAP purge
YES control solenoid valve.

PCl'li'l and retest (see page 11 A-
15 for immobilizer in forma tion).
If symptontlindiea tion goes
away; replace the original ECMI
POM.
4

&A
!#!!3
9
;'!%<
%

# 11 -A-147
7
%-
-%
/%4'0

/
?0
Inspection

Inspection ovaporative
Emission Controls
E'll'AF'
|
PU RGE CON TROL
Check the vacuum when cold:
GAHNISTER VACU UM
1, Discorrect Ire vao. L.l"i rose
from Ire EVAP purge cortrcl PUl'lFl
[arister ard correct a GAUGE
vaCLLIn gaLge to tre rose.
2, Start Ire ergire ard allow it to
idle:
NC’E: Ergire coolart
teinperatLre must be below
55°C I}131°F]: BEOBS ergire,
55°C Ij14Q°Fiz l-22J‘~.T ergire.
YES Inspect vacuum hose routing.

Is there vacu. r'i? If 0K, replace the EVAP purge
control solenoid valve.
NC
Check the vacuum when hot:

l~c|d tre er gire at 3000 rpm
[Mir-1} witr ro load ijir Park
or reLtraI} L.rti| tre radiator
far Domes or. tr er raise the
ergire speed to 3,500 rpm
[Mir-1}.
Check forvamum at Ire
vamun rose.
sa—I— YE“ Inspect vacuum hose routing.

Is there vacm. in? If 0K, replace the EVAP purge
NC
Check the EVAP control canister:

1. 'e tl‘e igriticr switcr OFF.
2. Reecrrecttre VGCLLP'l rose
to the EVAP ege cortrol
earister.
3. Reincvetre fL.e| fill Gap.
4. Correct a vamurt gauge to
carister ege air rose.
Starttre ergire ard raise
5J1
speed to 3.500 rpm ir'iir-'l i.
PURGE AIR CON TROL
Does vacmr'I appear or NO Replace the EVAP control

gaL. ge witrir 1 r'iirLIe? canister.
l YES
See EVAP two-way valve test to
complete.
Evaporative emission controls
are OK.
%

# 11 -A-148
8
%-
-%
/%4'0

/
?0
Evaporative Emission (EVAP) Two Way Valve Testing

%-
-%
/%4'0(
1#4- ! - Slowly pressurize the vapour line while watching
!3! H& !3!3
1.
1& !!!- the gauge.

-
2.
- Remove vapour line from the two way valve on the fuel
1&& !33&!& ! Pressure should stabilise at 1.3-4.7 kPa (10-35
!!-+*-$#;0+
tank and connect to T-fitting from vacuum gauge and
#4
&

mm Hg, 0.4-1.4 in. Hg).
6
A0-*-*-6
<-
vacuum pump as shown.
& 3- ¢ |f pressure momentarily stabilises (valve
!!;&!&
[3% -' —'-'
opens) at 1.3-4.7 kPa (10-35 mm Hg, 0.4-1.4
<-+*-$#;0+6
A0-*-*
. ‘ - ] VACUUM! in. Hg), the valve is OK.
-6
<A&!&8>-
‘. .' mssuna GAUGE ¢ |f pressure stabilises below 1.3 kPa (10 mm
!!3-+#;0
' I, 0 - 100 mmHg
I)! l0—4in.Hgl Hg, 0.4 in. Hg) or above 4.7 kPa (35 mm Hg,
6
A0-*-6
<&*-$#;+6
A
: ll 1.4 in. Hg), install a new valve and retest.
-*-6
<A!!3&!&-
VACUUM
PUHPIGAUGE
T-FITI'ING
3.
+- Apply vacuum slowly and continuously while watching
%!& !3! !3!3
the gauge.

-
Vacuum should stabilise momentarily at 0.7-2.0 kPa
: !!!0-$-0#
(5-15 mm Hg, 0.2-0.6 in. Hg)
;6
A0-0--6
<
0 If vacuum stabilises (valve opens) below 0.7 kPa (5
& !;&!&<!30-$#;
mm Hg, 0.2 in. Hg) or above 2.0 kPa (15 mm Hg,
6
A0--6
<&-0#;6
A
0.6 in. Hg) install a new valve and retest.
0--6
<!!3&!&-
4.
*- Move vacuum pump hose from vacuum to pressure
,&& &
fitting, and move vacuum gauge hose from vacuum to

A&&

&
pressure side as shown.
3-
*‘T _ .T 'T
PRESSURE
SIDE
_ _
Diagrams
) ! 9
Fuel-injected System Diagram (F18B2, F18B3,
+ D#) !/+8":+8": 11 A 149
F2036, H22A7 engine: LHD)
+$"5:.7! F&.)0
;._..._..__..... .
—-—--—-+
_.......__....__.....
. -
.
UNDER MCI-ICED I'UEILJHLLf-‘r' B'LJJ'C
-:'.:_'-
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g.‘ \J‘W PUR'. ‘H"

c115'1 T L' GRN 2 —
II— Q '.\H'.'a_x‘ . . L
I_ U. NH'AH' .l —
c1263
( BLKhEL
3 I'd H".'I5LU
Q] 'M-Q'JHED?
C‘l
ORH'HED c312
rm—
m— a
W
NI
LB” [‘3
g9
'8 1
‘—
] 53'v _.
i
'i
0209 '
(:13: RP.—
c120 [*3—
u'_
cm-s
[01—
[we Rumm—
m—
cm“
[4_
c2327
cm
c122 1‘ 0142'“
_ ,
Igswm
C 4 21
E6 —
din-BL» @[BLNI'EL
[0)- RFL‘JBIU‘ | '.\H"T CEM'FED
[u] BLU’VFL' .
Eumrr' I3 PEE‘BLU
C123 c143'5- 3 {I} am‘n. Glam-7‘
—
m— r41 Penn-H-
c124 6622
[-0] x Bl |
C12;
[|_
,1 uni—-
5 c123 c1 27
[ll]—
ral— €631
PU FIN-(T
O‘E . Df'cmr. Mru Mfum- 55m: cnbr hm.- been g» :n .1 "mt“ an 1c cumulmmcrr m narrat-
VEL'ELK‘ nnc vasmx‘ me nmztnmm
D Rename Fuel nncEn-mnm agar
Q Counccm an n'ahtcmwah [double cullnm Vim ‘tcnflcrn'molim
Canntcm min 'cn'ar :ermnnh mrclc omlnc'i VIM ‘Icn‘ mm: 5m.-
Component Locations

&

11 .B.2
"

Index
INTAKE
AIR
BYPASS [IABI
CONTROL
EVAPORATIVE EMISSION SOLENOID
MANIFOLD ABSOLUTE IEVAF} FURGE CONTROL VALVE
PRESSURE (MAN SENSOR SOLENDID VALVE I‘Nith lW‘I; model] Troublefihflflting.
Troubleshooting. page 11-3-33 Truuhlaahuutlng. page 11-3-82 page ILA-126
IDLE AIR CONTRDL IIACI VALVE
Troubleshooting. page 11-3-63
THROTTLE POSITION ITPI SENSOR INTAKE AIR BYPASS (IAB)
Troubleshooting. page 11-8-40 CONTROL DIAPHRAGM
EXHAUST GAS RECIRCULATION “a. INTAKE AIR TEMPERATURE HAT]

IEGH] VALVE and LIFI' SENSOR a SENSOR
'. TIL‘lUIJICEShCIDfing' page 11 B 45
lwilh 'I'WC modell a. '
Troubleshooting page 11-3-40 .-
CHANKSHAFT POSITION!
C‘IILINDEFI POSITION IC‘I'PI TOP DEAD CENTER
SENSOR "
lCKPfTDCI SENSOR
[Build into the distribl.ltr'.1rlI Troubleshooting. page 11 3-35
Truublushoming. page 11-3-43
VEHICLE SPEED SENSOR

(USSI (MITJ KNOCK SENSOR [KSI
Troubleshooting. page ‘I‘I—El-Sl Troubleshooting. page 11-3-53
ENGINE CODLANT TEMPERATURE

lECTl SENSOR
POWER STEERING PRESSURE
EPSPII SWITCH
To go to the pages referenced on the diagram above, click on the following:
4

&A!#!!3
9
(See Page 11-8-33)
;'!)++<
(See Page 11-B-40)
;'!)*0<
(See Page 11-B-43)
;'!)*+<
(See Page 11-B-51)
;'!)<
(See Page 11-8-38)
;'!)+'<
(See Page 11-8-63)
;'!)+<
(See Page 11-8-53)
;'!)+<
( See Page 11-8-82)
;'!)'<
( See Page 11-A—126)
;'!%<
;'!%5<
( See Page 11-B-45)
;'!)*<
( See Page 11-8-36)
;'!)+<
( See Page 11-8-92)
;'!)5<
Component Locations

&

11 .B.3
"
Index (cont’d)
/
?0
SECONDARY HEATED OXYGEN SENSDR lSECI'.)I'IIIIIIII5.R\'l HUZSi lWith TWC model: NT?
Truuhlashnuting. page 11—3-53
PRIMARY
HEATED OXYGEN SENSOR [PI-ili'ln'iilitR‘l‘r HGESi
(With TWC modeli
Troubleshooting. page 11—3-31
Replacement. page 1 l-B-EI}
THREE WAY CATALYTIC

CONVERTER ITWCJ
Inspection. page ll-B-?5
THROTTLE BODY lTBl THROTTLE CABLE

Inspection, page 11—8-72 lnspection.-'Adiuslmenl. page 11-A—120
Disassembly, page 11-B‘i'3 Installation, page 114-121
AIR CLEANER {ACLI

Replacement,
page 1 1 43.419
RESONATOR
POSITIVE CRANKCASE VENTILATION IPL‘VI VALVE

Inspection page ILA-143

4

&A!#!!3
9
(See Page 11-B-58)
;'!)'<
(See Page 11-B-31)
;'!)+<
(See Page 11-8-60)
;'!)0<
(See Page 11-B-75)
;'!)$<
(See Page 11-B-119)
;'!)5<
(See Page 11-B-72)
;'!)$<
(See Page 11-B-73)
;'!)$+<
;'!%0<
;'!%<
;'!%*+<
;'!%5<
Component Locations

&

11 .B.4
"
Index (cont’d)
/
?0
LHD:
&.)F
ENGINE CONTROL MODULE IElII'J'II'IIJf
PDWEFITHAIN CONTROL MODULE IP‘CM]
Rcmuvel. page 11-3-15
Troubleshooting F'rpcedures. page 11-3-13
INEHTIA SWITCH
Trpuhleehapting, page 17-3-26
Description, page 11 A 11:]
DATA UNI. SERVICE CHECK CONNECTOR FEM-Fl MAIN P‘tM‘Ir

CONNECTOR [DLC] Self-diagnostic Procedurue, page 11-8-13 Relay [tr-sling. page 11-A-11‘]
IEPI TrUUbICShC-pting, page 1 1-A-112
RHD:
.)F
PGM-FI MAIN RELAY
Relay testing, page 11-A-111 INEHTIA SWITCH
Troubleshooting, page 11-A-‘I 12 Dcacriptior‘l, page 11-A-11U
IDLE MIXTURE ADJUSTER IIMAI

[Without TWC madall
Troubleshooting. page11-B-d?
4

&A!#!!3
9
(See Page 11-B-15)
;'!)<
(See Page 11-B-13)
;'!)+<
(See Page 11-8-26)
;'!)<
;'!%<
;'!%<
;'!%0<
(See Page 11-B-47)
;'!)*$<
Component Locations

&

11 .B.5
"3
Index (cont’d)
/
?0
FUEL PUMP
Testingr page ILA-1116
LHD: Replacement. page 'l'l-A-IDE
FUEL GAUGE SEWING UNIT
FUEL FEED PIPE Testing. page ILA-10:3
FUEL
PULSATIEIN
FUEL VAPOR PIPE DAMPER
FUEL FILL CAP
EVAPORATWE EMISSION IEVAP}
CONTROL CANIS‘I’ER
Testing. page II-B-EH FUEL TUBEffllflcn-WHHEET
FITTINGS
Precautions. page 11-A-3T
Disconnection, page “-1137
Connection, page ILA-EB
FUEL TANK
Replacement, page 11-A-115
FUEL FILTER
EVAPORATIVE EMISSION IEVAPI

TWO wA‘f VALVE
FUEL INJECTDFtS
Testing. page 11 -A-'H-8
Testing. page 11-8—6?
Replacement. page 11-8-6 FUEL RAIL FUEL RETURN PIPE
FUEL PRESSURE REGULATOR

Testing. page ILA-”104
Replacement. page ll—A-IOS FUEL PUMP
HHD:
Replacement. page ll—A-‘IUS
FUEL FEED PIPE Testing, page IIvAVIDB
FUEL VAPOR PIPE
FUEL PRESSURE REG ULATDR FUEL Fll-l- Ch?
Testing. page 11-A-104
Replacement. page ILA—105
FUEL
PULSATIDN
DAMPER
FUEL HAIL
.- FUEL TUBEIOUICK-CDNNEUT
FITHNGB
Precautions. page 1 I-A-ET
Disconnection. page 11—A-B?
Connection, page 1145.35
FUEL INJECTDRS FUEL TANK
Testing. page 11-B-EITI‘ Replacement, page ILA-115
Replacement, pa ge 1143-55
FUEL FILTER
FUEL RETURN Pip-E Replacement. page 11-A-105
EVAPCIRATIVE EMISSION iEVAPI EVAPORATWE EMI$5IDN IEVAPI

CONTROL CANISTEH TWO Wfl‘l' VALVE
Troubleshooting. page 1143-82 Testing. page 11 int-143
52::223211332;
To go to the pages referenced on the diagram above. click on the following:
4

&A!#!!3
9
;'!)'<
;'!%5$<
;'!)'*<
(See Page 11-B-67) (see Page 11'A'98)
;'!)$<
;'!%5'<
(See Page 11-B-69) ;'!%<
;'!)5<
(See Page 11-A-106) (see Page 11'A'105)
;'!%0<
;'!%0<
(See Page 11-A-108) (see Page 11'A'148)
;'!%0'<
;'!%*'<
;'!%0*<
(See Page 11-A-75)
;'!%$<
System Description
#)
11 _B_6
"5
4

Vacuum Connections
With 1W6 modal:
MANIFOLD
meow“;
PRESSURE
[MAPI sanson
EVAPORATNE r ..............
EMISSION : ‘l
IEVAPI
comm
CANISTEFI L; To EVAPOHA‘I'IVE EMISSION IEVAF‘I
\' TWO WAY VALVE
I
Tn ENGINE MOUNT ,— ..... _ _......__ ‘
‘\ ______‘__/ _ IJ
CONTROL SOLENOID VALVE IAITI ..... ..._ .
. IDLE AIR '

i
'\ CONTROL (IACI I I
-. VALVE I
i
.i
EVAPORATWE EMISSION
IEVAPI CONTROL
CANISTER
INTAKE AIR
BYPASS [IABI
CHECK VALVE
INTAKE
AIR
BYPASS IIABJ
EVAPORATIVE VACUUM
EMISSION TANK
IEVAPI
PURGE CONTROL
SOLENOID VALVE
INTAKE AIR
BYPASS IIABI
INTAKE AIR
BYPASS IIABI
FUEL
PRESSURE
REGULATOR
FRONT OF
“E HICLE
System Description
#)
11 _B_7
"7
4

/
?0
With 1W0 model:
1 /
;68<;<
Primary heated oxygen sensor (Primary HO2S) (Sensor 1) 19 #;%)<#&!&
2 68/
;68<
Secondary Heated Oxygen Sensor (Secondary HO2S) 20 #;%)<#&!&
(Sensor 2)
;<
+ ,!! ;,%< 21 #;%)<!!&!&
Intake air bypass (IAB) control solenoid valve
(OOONQO‘I-bw

*
! ; 4< 22 #;%)<!
&!&
Intake air bypass (IAB) control diaphragm valve
# ;%4< 23 /
!; .1<&!&!
#;>< 24 &#&!;:<&!&
$ 4;4(< 25 43!&
Knock sensor (KS)
' >#;>< 26 &&; :%<!
5 !!;%<&!& 27 &&; :%<
!
$ Evaporative emission (EVAP) purge control
diaphragm valve

&!&
10 4!;4)<
0 Throttle body (TB) 28 &&; :%<
!!
' Evaporative emission (EVAP) purge control solenoid
valve
&!&
11 Fuel
injector
!7 29 &&; :%<33&!&
5 Evaporative emission (EVAP) two way valve
12 Fuel
pulsation damper
! ! 30 Fuel
+0 tank evaporative emission (EVAP) valve
!#&&; :%<&!&
13 Fuel
+ filter
!! 31
!!&!&
+ Engine mount control solenoid valve
14 Fuel
!
!
15 Fuel
pump (FP)
! ; <
16 Fuel
tank
!#
17 %!
$ Air cleaner
18 1
' Resonator
#)

System Description
4

/
?0
11 -B-8
"8
Without TWO modal:
EVAPORATIVE
EMISSION
IEVAPI
CONTROL
OANISTER
5. Tu EVAPORATIVE EMISSION IEVAPI

TWO WAY VALVE
MANIFOLD
ABSOLUTE
To ENGINE MOUNT PRESSURE
CONTROL SOLENOID VALVE IAITI :3 I: _.. IMAPI SENSOR
IDLE AIR
CONTROL (IACI
VALVE
INTAKE AIR
BYPASS [IABI
CHECK VALVE
INTAKE
AIR
BVPASS IIAB]
VACUUM
TANK
INTAKE AIR
BYPASS [IABI
INTAKE AIH
BYPASS (IABI
FUEL
PRESSURE
REGULATOR
FRONT OF
VEHICLE
System Description
#)
11 _B_9
"9
4

/
?0
Without TWO modal:

,!! ;,%< 17 #!;%)<#&!&
$ Intake control (IAB) check valve
\IQO‘I-PQJN—‘I

! ; 4< 18 #!;%)<& #
' Intake control (IAB) vacuum tank
+ Intake air temperature (IAT) sensor
# ;%4< 19 #;%)<!!&!&
5 Intake air bypass (IAB) control solenoid valve
* Crankshaft position (CKP) sensor
#;>< 20 #;%)<!
&!&
0 Intake air bypass (IAB) control diaphragm valve
4;4(< 21 &#&!;:<&!&
Positive crankcase ventilation (PCV) valve
Knock sensor (KS)
>#;>< 22 &&; :%<!
$ Idle air control (IAC) valve
!!;%<&!& 23 &&; :%<
!!
+ Evaporative emission (EVAP) purge control solenoid
valve
&!&
8
' Throttle body (TB)
4!;4)< 24 &&; :%<33&!&
* Evaporative emission (EVAP) two way valve
9
5 Fuel injector
!7 25 Fuel
tank evaporative emission (EVAP) valve
!#&&; :%<&!&
10
0 Fuel pulsation damper
! ! 26
!!&!&
Engine mount control solenoid valve
11
Fuel filter
!!
12
Fuel pressure regulator
!
!
13
+ Fuel pump (FP)
! ; <
14
* Fuel tank
!#
15
Air cleaner
%!
16
Resonator
1
#)

System Descrigtion
%

11-B-10
"$
.4,-
.' _\
FEM-Fl MAIN FlE LA'I"
FUEL PUMP
IGNITIDN
SWITCH INERTHL I: " -4
$2.35? T #71
.swrrcn
[ _.____“%'_J*_.I r ! ‘:::'
J: _. Ex 9- CH
yayrilw l‘ : {132;
. mm} 1 ‘f ,I, mm
1. __ -
515 ~r
“—9334”. +-
:1.
FUEL INJECTOR!
vau x35.
. . __..__1E-EI
—!+- Id
13--"!-‘7'-O "“1 ’ H'- {PIE} 'FL
. .3
" , CYP
sausan
MC VALVE 1
_ rue
5E Ham
on
, sense-n
---, _.w_ ,-. ..—-.

EVAP P‘URGE CONTROL
SOLENOID VALVE‘3
..
?.. $13 ‘5 2_,_

:ZP'TI‘E'H.
.V.,
.."
ENGINE MOUNY CONTROL

FF"
SOLENOID VALVE“
.3. -"a'n"- 1:. 1A§§9Lg IE
MB CONYHOL
SOLENOID VALVE
A LT
3:.
'7,
SECONDARY “ 5
rim 5
J)“
Tn SPEEDOMETER
l EAL
’ ‘M' :
SERVICE
‘
_ __. —G CH EEK
-—C: CONNECTOR
v55 *3
DATA
um:
DONNEC‘T'UH
HAP
SEHSGR
Fuses:
9
Battery (100) *A
);00<G%
Back-up, ACC (40A) *A
)# A%;*0%<G%
+ IG main (50A) *A
.;0%<G%
* AGCS (15A) *A
%.;%<G%
! ;%<G)
?; ,=,< !;%<G)
5)# !
!
;$-%<G)
+
!;$-%<G)
5 No 13 Clock back-up (7.5A) *0
+!## ;$-%<G
0 6;+0%<G%
No 6 LAF ;0%<G
% heater (20A) *0
*A: in the under-hood fuse/relay box
G%9 =!/
*8: in the driver’s under-dash fuse/relay box
G)9&B =!/
*0: in the passenger’s under-dash fuse/relay box
G9
B =!/
#)

System Description
"
%

/
?0
1
- O-“D‘J'” C-
'I'TEC SOLENOID VALVE
THROTTLE
FOSITDN
SENSOR
IEIMTIflH
COIL
IMA"
aHAKE sw'iroi-I
i . BRAKE LIGHT
D—_. ”5.? " ..

TECHOHETEFI *3
CONNECTOR EEG“; son ”we 1
LIFT se~son‘-‘
._
Hi 71'?
E051
VALVE "
3
CRUISE CONTROL
UNIT
P535”
I 1- RADIATOR
: FAN comnoL
1
To MODULE -
IMHOBIUZEH K. 1—.-
UMT
I_._.
COMPRESSOR CONDENSER
CLUTCH FAN
IMMOBJLIZEFI fiELA'r RELAY
INDICATOR
LIGHT
B-M’io RADIATOR
EE NEDFI FAN
{Built Into MOTOR
m- Ec-cui
CLIMATE
CONTHI'JL UNIT
#)

System Description
%

/
?0
11-3-12
"
*-
| IaiJ I" '—

I A
VBSOL 3.
|
|
Tu GAUGE VSEDUT
——-—Iit"9: —\ a .'—5 MAINSHAFT
ASSEMBLY ‘- SPEED EEHSCIH
| 5;. III-1
GALFGE ASSEMBL'F up
I
DIIIND -‘ '
Jul
El
I
-9 CDLIN'I'EREHM-‘I'
W“. 2:
SPEED SENSOR
I
I ATPPN {Eli
:1.
I
5' M o I—m—o .
D’W"—CI .. _ _.
I ATPFI N A
J
LOCK-UP CONTROL SOLENOID VALV
I
(a -ur--.::,
SHIFT CONTROL SOLENOID VALVE A
I 4:,_fct"_{}—._.. _ ._.__.
I
T M‘
SHIFT CONTROL SOLENOID VALVE E
suc__ - _.__LDJ-Eru;
I
’. ‘\ .__ _ ___ _. _._. . I
Ewes—é.
_.IJ.—
SHIFT CONTROL SOLENOID VALVE C
I
HW- ¢'
arm—(LEM _-._rI:I:'-.r;__ . ._
I
'1. ,
AJ'TCLIJTCH PRESSURE CONTROL
SDLENEID VALVE A
I
I
I _
NT
GEAR POSI110N
LEB‘
::.—"-_'uj"~<:-—
NT CLUTCH PRESSURE CONTROL I I
l SWITCH SOLENOID VALVE B I
I
I
.. 1-)—
SHIFT SWITCH
| 2ND CLUTCH PRESSURE SWITCH

kiw-
I - opzsw
l To GAUGE massun: swncn .5—

2
.—+
3RD CLUT
ASSEMBL'I'
I C?
UFSSW
I
I
I
: *1: NT
I *2: MIT
I
: *3: with TWC modal
| ans-1: Without TWC modal
I
TU INTEHLDCK UNIT 1 - *5: NT with TWC modal
I *6 1 Except MIT without TWO model
at? I With CRUISE CONTROL
_ ......................................... _j *5 : With CLIMATE CONTROL
ECWPCM CONNECTDFI TERMINAL LOCATIONS

A (32P) El (25F) C(31P)
56? alaiwIII 1 flll/I I'SIBI'T'I 8 l 9
lab}
IIZ'IEI Mini 15 171519 20 2122 23 24 9 10 11' 3'," ’ ’Islfllmliu «14122

ESE 27 M31 Iii 2|] 3. 2 #2723 93D 31
Troubleshootin

*
!g 11 -B-13
"

*
!'

How to Begin Troubleshooting

.
(
"!
*
!
When the Malfunction Indicator Lamp (MIL) has been reported on, check the Diagnostic Trouble Code (DTC) as following:
2,! ;,<A#(
4 !;(4<!!3
9
NOTE: This operation can also be carried out with Honda PGM Tester connected to data link connector (5P).
84 94! 36.,4!#;<-
1.
- Connect the 808 short connector to Service Check Connector as shown (The 2P Service Check Connector is located
4&#!
under the dash on the driver side of the car. Turn the ignition switch ON (II).
&-4
38;<-
SERVICE CH EEK
CONNECTDH lZPl
DATA LINK
CONNECTOR
(SP)
scs SERVICE CONNECTOR .

WPAz—uuwwu
The illustration shows LHD type. RHD type is
svrnmelrical.
2.
- Note the Diagnostic Trouble Code (DTC): The MIL indicates a code by the length and number of blinks. The MIL can
(
4 !;(4<94,!
!#-4,
indicate multiple problems by blinking separate codes, one after another. Codes 1 through 9 are indicated by individual
!!!!#
A-
5& !
short blinks. Codes 10 through 65 are indicated by a series of long and short blinks. The number of long blinks equals the
!#-0
!
!#-4 !
!#F !
first digit, the number of short blinks equals the second digit. Sometimes the first blink is difficult to see; always count the

A !#F !
-!# !N!3
blinks at least twice to verify the code.
!#!3&-
MALFUNC‘HDN ,x’m...
INDICATOR
LAMP
{MILI .
Separate Problems:
Short
_PL_J‘1__JL _. -_._ = Soc 0161

mmqm =SeeDTCIl
‘l. I'CIJ"‘—' ”“1 =ScoDTc13
Long short
Multiple Problems:
_n_rL'TL._._rL_nl—J‘l_ = 5'“ DTC" "“5 3
Ill—iri— mm =SHDTC3 and4
_ru—n__J—rfl"l!'l— = s... cm: 3 Ind u
Troubleshooting

*
! _ _
"
Troubleshooting


!'
/
?0 11 B 14
Engine/Powertrain Control Module (ECM/PCM) Reset Procedure

%! 2'
(

/%2'0'

NOTE: This operation can also be carried out with Honda PGM Tester.
84 94! 36.,4-
1.
- Turn the ignition switch off.
4
3-
2.
- Remove the No.13 CLOCK BACK UP (7.5 a) fuse from the passenger's under-dash fuse/relay box for 10 seconds to reset
1&-+8>)%>?;$-<
@ =!/0
the ECM/PCM.
,=,-
No. 13 CLOCK
BACK UP
i725 Al FUSE
PASfiENGEH'S UNDER-DASH The illustration shows LHD type.

FUSEIRELAY BOX HHD type is symmetrical.

+ '
/ procedure must be done after any troubleshooting)

*
#
*
!0
1.
- Remove the SOS Short Connector.
1&-
NOTE: If the 808 short connector is connected and there are no DTCs stored in the ECM/PCM, the MIL will stay on when
84 9(4 ,=,A,3!!3
the ignition switch is turned ON (II).

3 8;<-
2. ( ,=,1 -
- Do the ECM/PCM Reset Procedure.
Known-Good ECM/PCM Substitution (KG, KE, KS, KR models)
I
(
%2'*
/I:I%:I:I
0
The ECM/PCM is part of the immobilizer system. If you substitute a known-good ECM/PCM, the ECM/PCM will have a different
4 ,=,!H- #3
,=,A ,=,3!!&
immobilizer code. In order for the engine to start, you must rewrite the immobilizer code with the Honda PGM Tester.
!H-
A 3!H36.,4-
Troubleshooting

*
! _ _
"3
Troubleshooting


!'
/
?0 11 B 15
ECM/PCM Removal
%2'
-
Pull the carpet from the passenger's side of the center console to expose the ECM/PCM. Remove the two bolts from the
!!
@!/ ,=,-1&3!
ECM/PCM. Check the system according to the procedure described for the appropriate DTC listed on the following pages.
,=,-#
(4!!!3

-
5.6 N-m
{LII Ital-m,
12 IBM”
/"
The illustration shows LHIIII type.
Checking
6 !the ECM/PCM Connector Terminals
%2'

When checking the ECM/PCM connector terminals, gently slide the sharp tester probe from the wire side into the connector
2#
,=,!A
!!3
until it comes in contact with the terminal end of the wire.
!3!3-
DIGITAL CIRCUIT TESTER
Commercially IVIIIIhII or
W411 - 002mm
SHARP TESTER PRDSE
The illustration shows LHDtype.

RHD type is svrnrnetrical.

*
!
Troubleshooting

*
!
Troubleshooting Guides
11-B-16
"5
NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the order they should be
84 9%3A ! # !
inspected starting with (1). Find

3;<- the symptom in the left column, read across to the most likely source, then refer to the page
!! A!#! A

listed at the top of that column. If inspection shows the system is OK, try the next most likely system (2) etc.
!! -38>A/!#!;<-
PAGE SYSTEM POM-Fl
ENGINE.-' i TOP DEAD CE Ni- ENGINE
' MANIFOLD INTAKE AIR BARO-
POWEFI- HEATED TEHICFIAN Ksi—mrr COOL-CWT THROTTI I'- IDLI:
ABSOLUTE TEMPERA- METRIC
TRAIN OXYGEN POSI TION,-'C'r'LIN-i TEMPERA- POSITION MIXTLI FIE
PFI ES SURE TURE PFIE SSUHE
CONTROL SE NSOFI' ‘ DER POSITION TUFIE SENSOR ADJ USTEFI '3
SE NSOFI SENSOFI SENSOR
MODULE SE msun ' SENSOH
em:- :
SYM PTOM 11-3-26 11-8-33 11-5-35. 43 -
I .
11-3-33 11-8-40 'I'I-B-Ilb 1131? 11.550”
MALFUNCTIDN mail"
m
| .- | x
“TOR LAMP {MIL}
TUH us an
LT] 0’ jI—_. . :Efl;
'
z l
2m]:
MfiLFUNCTIDN |'\|EI.‘--
ELIJE
:-"_IJE<:Ir-:I_I ._-
CfiITOR LAMP IMILi
u-rZ-L‘ I?
Em:
BLIN ICE
ENGINE WON‘T START ®

OIFFICULT TO START
W—‘N
ENGINE WHEN COLD
WHEN COLD
FflST IDLE
OUT OF SPEC I
RC! U GH IDLE
IRREGULAR
IDLING WHEN 'WAPIM
' ENGINE SPEED
T30 HIGH
VI'HEN I'd-”TM
Eh CINE SPEED
TOD LC‘K'I'
'I'HII. F.
'll'i'J‘FI WING UP
I' “LC U [NT
STALL I‘ll:-
AFTER
'u'i'AHMING UP
I.IIISI‘II'N‘I-L OH
HO LIE-I
RUNNiNG
PODS FAILS
FE HF URI-1 EMISSION
AMEE TE ST
u
}
I i <2"
LOSS OF
i
Eu
'-._ L:
POWER
r
G* If codes other than those listed above are indicated, count the number of blinks again. If the MIL is in fact blinking these
!&A !#
-,!#

codes, replace the ECM/PCM.
A! ,=,-
BU ,3!

A&#
)? If the MIL is on while the engine is running, connect the 808 short connector to the service check connector if no code is
displayed (MIL stays on steady), the back up system is in operation.
!;,<A# -
Substitute a known-good ECM/PCM and recheck if the indication goes away, replace the original ECM/PCM.
#3
,=,#
3A!
! ,=,-
*1: with TWC model
G9342!
*2: without TWC model
G93 42!
*3: WT
G+9,=4
*4: with TWC model (A/T)
G*9342!;%=4<

*
!
Troubleshooting
Troubleshooting

* Guides (cont’d)

! /
?0
11-B-17
"7
FEM-Fl IDLE CONTROL FUEL EU FPLY EMISSION CDNTHEIL
VTEC EXHAUST 5A5

'III'EHICLE SPEED OTHER INTAKE AIR [TH-ER EME-
IDLE NH CUN- OTHER IDLE FUEL HECIHCULATHJN
SOLENOID FUEL SION DDNTFbDL
SENSOR" THDL VALVE CONTROLS INJECTOR IEGFIII WNTHDL
VALUE' SUPPLY S'I'ETEH
S‘Y'STEM"
2-;
l'l-E-S‘l 6-3-3 11-B-fi1 'nB-a? I I 45-56 115-71 1143-16 11-E-T4
—I—
--.. .-'
.- l a.
3-3
N. l
,EH
i®®®®®
(-3
@I
Troubleshootin

*
!g 11 -B-18
"8
%! 2'
(

Arrangement
!

%,,%/'0
ECMJPCM CONNECTOR A [32 Pl
. (I / .- f 5 6 7 r.) . 11
x"! .-“/ / f“.- CRB
sum . 93
LED A LED B Hré‘ gill; LEDC
11 13
IMG- m
32: "LSD 16 n 13 ‘8 P“, 2: :2 2:: 2i
Ll'll' EN ma run we MIL REP "7c mc S-DN sHazs STE
_._ _ .,. J, ,
25 21' 2a n l 3! :2
age
sup ms nu m 15.94005 :15»!

x"

%,,%/'0
84 9&!
:-
O Terminal O
Wire Colour O
1

,
Terminal Name OI Description
O
)
Signal
! OI
O No.
,
@ O O OI O OI
O 5 *1
G O PUR
?1 O CRS (Cruise control
1; ! OI Down shift signal input
(3
! O When cruise control is used: Pulses OI
2 ! 9 !
O O O signal)

!< OI from cruise control
! O OI
O 6 *1
G O BLU/YEL O
)?=C LED A
(% OI Shift indicator light
!
O In manual mode:
!9 OI
O O O OI !
control O 0 In 4th gear position: Battery
*
9) OI
O O O OI O voltage
&!
OI
O O O OI O 0 In 1st, 2nd and 3rd gear
A+
OI
O O O OI O positions: 0V
90: OI
O $G O PUR
?1 O LED B
() OI Shift indicator light
!
O In manual mode:
!9 OI
O O O OI !
control O 0 In 2nd and 3rd gear positions:
+
9 OI
O O O OI O Battery voltage
)&!
OI
O O O OI O 0 In 1st, and 4th gear positions: 0V OI
A*
90:
O 'G O BLK/WHT O
)>=264 SOZSHTC (Secondary OI
864; Drives secondary heated O
(& With ignition ON (II): Battery voltage OI
2
8;<9)&!

O O O heated oxygen sensor OI
/
/
O With fully warmed up engine
2 !!3
OI
O O O heater control)
!< OI O running: Duty controlled

9( !! OI
O 5G O BLU/WHT O
)?=264 VSSOUT (Vehicle
:8?4;:! OI Vehicle speed signal
:!
! O Depending on vehicle speed: Pulses OI
(
&!9 !
O O O speed sensor output
OI detected from
O OI
O O O signal)

!< OI countershaft speed
O OI
O O O OI sensor
O OI
O 1O
0 O BRN
)1 O 808 (Service check
;&# OI Detect service check
(&# O 2!90:
With the terminal connected: 0V OI
O O O
!<
signal) O|
!;
connector signal (the O With the terminal disconnected:
2!9 O|
O O O OI signal causing a DTC

!
(4 O Battery voltage
)&!
Oi
O O O OI indication)
< O O
O 11 *1 O
G BLU/BLK O
)?=)> LED C
( OI Shift indicator light
!
O In manual mode:
!9 OI
O O O OI !
control O 0 In 1st and 3rd gear positions:
+
9 OI
)&!
OI
O O O OI O 0 In 2nd and 4th gear positions: 0V OI
*
90:
O 12 *3 O
G+ PNK
> O IMOLMP (Immobiliser OI
,8,;! Drives immobiliser
(&! O With immobiliser indicator light
2!!
OI
O O O indicator light)
!
< OI indicator light
!
O turned ON: 0V
890: OI
O O O OI O With immobiliser indicator light
2!!
OI
O O O OI O turned OFF:9)&!

8 Battery voltage OI
O 13 *3+
+G O PNK/BLK
>=)> O IMOEN (Immobiliser
,8 ;! OI Sends immobiliser
! O OI
O O O enable signal)
!
!< OI enable signal
!
! O OI
O 14 *1
*G O GRN/BLK O
.1=)> D4IND (D4 indicator)
(*(;(*< OI Drives D4 indicator light O
(&(*!
With D4 indicator light turned ON: OV OI
2(*!
890:
O O O OI O With D4 indicator light turned OFF:9 OI
2(*!
8
)&!
OI
O O O OI O OI
O 15 *3+ O
G GRN/YEL O
.1=C IMOFLR
,8 (Immobiliser OI
1;! Drives fuel pump relay
(& ! ! O 0V for two seconds after turning
0:3
OI
O O O fuel pump relay)
! !< OI O ignition switch ON (II), then battery OI

38;<A
O O O OI O voltage
&!
OI
O 16 *4* O
G GRN/YEL O
.1=C 1;(Fuel
FLR pump relay) OI
! !< Drives fuel pump relay O
(& ! ! 0V for two seconds after turning
0:3
OI
O O O OI O ignition switch ON (II), then battery O|

38;<A
O O O| O O voltage
&!
O
O 17
$ O RED
1 ( ACC (A/C clutch relay) O
O| %;%=! !< Drives A/C clutch relay
(&%=! ! O With compressor ON: 0V
2890: O
O O O| O O With compressor OFF:9)
28 Battery O
O O O| O O voltage
&!
O
O 18
' O GRN/ORN O| ,;,!
.1=81 MIL (Malfunction O (&,
Drives MIL O With MIL turned ON: 0V
2, 890: O
O O indication light)
O| !
< O O With MIL turned OFF:9)
2, 8 Battery O
O O O| O O voltage
&!
O
O 19
5 O )?
BLU O| ;

NEP (Engine speed O Outputs engine speed
8
O With engine running: Pulses
2

9 ! O
O O pulse)
O| !< O pulse
! O O
O 20 *3+ O
0G BLK./WHT O| 68641;
)>-=264 PHOZSHTCR (Primary O Drives primary heated
(& O With ignition switch ON (ll): Battery O
2
38;<9)
O O heated oxygen sensor O
O| /
/
O voltage
&!
O
O O heater control relay)
O| !!< O O With fully warmed up engine
2 !!3
O
O O O| O O running: Duty controlled

9( !! O
O 21
O GRY
.1C DLC (TxD/RXD)
O| (;4/(=1/(< O Sends and receives
& O With ignition switch ON (ll): Pulses O
2
38;<9 !
O O O| O scan tool signal
!
! O O
: A/T model
G9%=4!
*2: WT model
G9,=4!
*3: with TWC model
G+9342!
G*93 42!
*5: A/T with TWC model
G9%=4342!
*6: Except M/T without TWC model
G9 /,=43 42!
Troubleshootin

*
!g 11 -B-19
"9
%! 2'
(

!/
?0
ECMIPCM CONNECTOR A (32P)

%2',,%/'0
ECMIPCM CONNECTOR A 132 PI
./ / -/" _, i _ - .-' 5 _' E 1 1

g.” 5 s
V 55 1O 11
X/ x" CR5 _LED.§ twa H"; our 5:; LEE”:
...
,2: "Lin. 5“ “L5,: is n _ In 19 : ”10°23 21 22 23 2:
LMP m .m m; rut mac IA NEP‘ . inc OLC S-DN SHozs 5 rs
:1. 25 27 a __.-"'i an it 32
3;] sur AC5 ILU , E. M.- s-uoos axsw
Wire Side femaleterminals

%,,%/'0
84 9&!
:-
Terminal O| 1

O Wire Colour O Terminal Name
, O| O|
Description
)
Signal
! O|
O No.
,
@ O O O| O| O|
O 22 *1 O
G ORN
81 S-DN (Shift down)
O (;3< O| Detects downshift switch O|
(33 In manual mode and shift lever
!!& O|
O O O O| signal

! O| pushed toward downshift position
33 O|
O O O O| O| (marked with “-“): 0V
;#3KK<90: O|
O O O O| O| In manual mode and shift lever in
!!& O|
O O O O| O| neutral position: Battery voltage
!9)&!
O|
O 23 *5 O
+G WHT
264 SHOZS (Secondary
O 68; O| Detects secondary
2! !!! O|
O O heated oxygen sensor, O|
O /
A heated oxygen sensor
/
O| with fully warmed up engine: Above O|
3 !!3
9%&
O O sensor 2)
O < O| (sensor 2) signal
;<
! O| 0.6V
0-: O|
O O O O| O| With throttle quickly closed: Below O|
2!F #!!9)!3
O O O O| O| 0.4V
0-*: O|
O 24
* O BLU/ORN O 4;3
)?=81 STS (Starter switch O| Detects starter switch
(3 O| With starter switch ON (II): Battery O|
238;<9)
O O signal)
O
!< O| signal

! O| voltage
&!
O|
O O O O| O| With starter switch OFF:90:
238 0V O|
O 25 *3+ O
G RED
1 ( IMOCD (Immobiliser
O ,8(;! O| Detects immobiliser
(! O| O|
O O code)
O < O| signal

! O| O|
O 26 *1 O
G 264=)? S-UP (Shift up)
WHT/BLU O ?; < O| Detects upshift switch
( 3 O| In manual mode and shift lever
!!& O|
O O O O| signal

! O| pushed toward upshift position
3 O|
O O O O| O| (marked with “+”): 0V
;#3KVL<90: O|
O O O O| O| In manual mode and shift lever in
!!& O|
O O O O| O| neutral position: Battery voltage
!9)&!
O|
O 27
$ O BLU/RED O %;%=3
!<O
)?=1 ( ACS (A/C switch signal) | Detects A/C switch signa ||O
(%=3
! With A/C switch ON: 0V
2%=3890: O|
O O O O| O| With A/C switch OFF:9% :
2%=38 About 5V O|
O 28 *1 O
'G 264=1 ( ILU (Interlock control O|
WHT/RED O ?;!#! (&!#!
Drives interlock control O| With ignition switch ON (II) and
2
38;< O|
O O unit)
O < O|
unit O| brake pedal depressed: Battery
#!9) O|
O O O O| O| voltage
&!
O|
O 30 *4* O
+0G .1=1 ( IMA (Idle mixture
GRN/RED O ,%;!/ O| Detects IMA signal
(,%
! O| With ignition ON (II): About 0.5-4.5V O|
2
8;<9% 0-*-:
O O adjuster)
O 7 < O| O| (depending on idle mixture)
;
!/ < O|
O 31 *1
+G O BRN
)1 O S-MODE (Shift mode)
,8( ;< O| Detects manual mode
( ! O| In manual mode (shift lever is
!;!& O|
O O O O| switch signal
3
! O| positioned in manual mode): 0V
!<90: O|
O O O O| O| In other than manual mode: Battery O|
!9)
O O O O| O| voltage
&!
O|
O 32 *6 O
+G 264=)> BKSW (Brake switch) O|
WHT/BLK O )>2;)#3< Detects brake switch
2#!!90: O|
O O O O| signal

2#!9 O|
O O O O| O| Battery voltage
)&!
O|
*1: NT model
G9%=4!
*2: WT model
G9,=4!
*3: with TWC model
G+9342!
G*93 42!
*5: NT with TWC model
G9%=4342!
*6: Except M/T without TWC model
G9 /,=43 42!

*
!
Troubleshooting
%! 2'
(

11 -B-20
"$
!/
?0
ECM/PCM CONNECTOR B (25P)

%2',,%"/3'0
ECMIPEM DONNECTUH B {25”
1 3' 3 A l 5 J I
"3P1 P61 mu INJ: ! lt E EC." LEI.
g 10 n ' u i u u
m, IE
1?
v15 I on 25w
ms 18
'3’? PG! "I." 501 ‘3‘” Lil-
'21] 21 | :2 2; 5:, 25
”31 nu ma Law In. I L554

ECM CONNECTOR B (25P)
%,,%"/3'0
84 9&!
:-
O| Terminal O
Wire Colour O
1

,
)
O Signal
! OI
O| ,
@
No. O O O O O|
O| 1 O YEL/BLK O
.;3 < O 3
Power source forth e O With ignition switch ON (II): Battery O|
2
38;<9)
O| O O O ECM/POM control circuit
,=,! O voltage
&!
O|
O| O O O O With ignition switch OFF:90:
2
38 0V O|
O| O BLK
)> O PG1 (Power ground)
.;3
< O .
,=,! O O|
O| + O RED
1 ( O |NJ2 (No. 2 fuel
";- ! O Drives No. 2 fuel inj ector
(&- !7 O With engine running: Pulses
2

9 ! O|
O| O O injection)
7< O O O|
O| * O BLU
)? O |NJ3 (No. 3 fuel
"+;-+ ! O Drives No. 3 fuel inj ector
(&-+ !7 O With engine running: Pulses
2

9 ! O|
O| O O injection)
7< O O O|
O| O YEL
C O |NJ4 (No. 4 fuel
"*;-* ! O Drives No. 4 fuel inj ector
(&-* !7 O With engine running: Pulses
2

9 ! O|
O| O O injection)
7< O O O|
O| $G+ O PNK
> O E-EGR
.1 O (& .1&!&
Drives EGR valve O With EGR operation during driving O|
2 .1
&

O| O O O O with fully warmed up engine: Duty
3 !!3
9( O|
O| O O O O controlled
!! O|
O| O O O O With EGR not operating: 0V
2 .1
90: O|
O| 'G O WHT
264 O LSA— (A/T clutch
%;%=4! O A/T clutch pressure
%=4! O With ignition switch ON (II): Pulses O|
2
38;<9 !
! O !!&!&%
control solenoid valve A O O|
O| O O solenoid valve A - side) O
!&!&%< power supply negat ive
3 !
& O O|
O| O O O !
electrode O O|
O| 59 O YEL/BLK O
.;3 < O 3
Power source forth e O 2
38;<9)
With ignition switch ON (II): Battery O|
Oj O O O ECM/POM control circuit
,=,! O voltage
&!
O|
O O O O O With ignition switch OFF:90:
2
38 0V O|
O| 1O
0 O BLK
)> O PG2 (Power source)
.;3 < O .
,=,! O O|
O| 11
O BRN
)1 O |NJ1 (No. 1 fuel
";- ! O Drives No. 1 fuel inj ector
(&- !7 O With engine running: Pulses
2

9 ! O|
O| O O injection)
7< O O O|
O| 12
O GRN/YEL O
.1=C VTS (VTEC solenoid
:4;:4 ! O (&:4 !
Drives VTEC solenoid O With engine at low rpm: 0V
2
!390: O|
O| O O valve)
&!&< O &!&
valve O With engine at high rpm: Battery
2

9) O|
O| O O O O voltage
&!
O|
O| 13
+ O YEL/GRN O
C =.1 ICM (Ignition control
,;
! O Sends ignition pulse

! O With ignition switch ON (II): Battery O|
2
38;<9)
O| O O module)
!< O O voltage
&!
O|
O| O O O O With engine running: About 10V
2

9% 0: O|
O| O O O O (depending on engine speed)
;

< O|
O| 14*1 O
*G BLU/BLK O
)?=)> OPZSW (2nd Oil
82;8! O Detects 2nd oil pressure
(! O With ignition switch ON (II): Pulses O|
2
38;<9 !
O| O O pressure switch)
3< O 3
switch O O|
O| 16
O RED/BLU O
1 (=)? IABSOL (Intake air
%)8;# O (&%)!
Drives IAB control O With engine running, engine speed O|
2

A

O| O O bypass control
! O !&!&
solenoid valve O below 3,900 rpm (min-1): Battery
!3+A500;<9) O|
O| O O solenoid valve)
!&!&< O O voltage
&!
O|
O| O O O O With engine running, engine speed O|
2

A

O| O O O O above 3,900 rpm (min-1): 0V
&+A500;<90: O|
O| O RED
1 ( O LSA+ (A/T clutch
%V;%=4! O A/T clutch pressure
%=4! O With ignition switch ON (II): Pulses O|
2
38;<9 !
! O control solenoid valve A
!!&!&% O O
O O O solenoid valve A + side) O
!&!&%V< power supply positive
3 !& O O
O O O O electrode
! O O
O 18*1
'G O GRN
.1 O LSB- (A/T clutch
);%=4! O A/T clutch pressure
2
38;<9 !
! O control solenoid valve B
!!&!&) O O
O O O solenoid valve B - side) O
!&!&)< power supply negative
3 !
& O O
O O O O electrode
! O O
O 2O
0 O BRN/BLK
.;

< O .
O O O O ECM/PCM control circuit
,=,! O O
O 21
O WHT/BLU
264=)? O VBU (Voltage back up) O
:)?;:!
3 O Battery voltage at all times
)&!
!! O
,=,! O O
O O O O Power source for the
3 O O
O O O O DTC memory
(4 O O
O 22
O BRN/BLK
.;

< O .
,=,! O O
O 23
+ O BLK/BLU
)>=)? O IACV (Idle air control
%:;!! O (&%&!&
Drives IAC valve O With engine running: Pulses
2

9 ! O
O O O valve)
&!&< O O O
O 24 *1 O
*G BLU/WHT
)?=264 O OPBSW (3rd oil
8+2;+! O Detects 3rd pressure
(+ O With ignition switch ON (ll): Battery O
2
38;<9)
O O O pressure switch)
3< O switch
3 O voltage
&!
O
O 25 *1 O
G ORN
81 O LSB+ (A/T clutch
)V;%=4! O A/T clutch pressure
2
38;<9 !
! O control solenoid valve B O
!!&!&) O
O O O solenoid valve B + side) O
!&!&)V< power supply positive
3 !& O O
O O O O electrode
! O O
*1: NT model
G9%=4!
*2: WT model
G9,=4!
*3: with TWC model
G+9342!
G*93 42!
Troubleshootin

*
!g 11 -B-21
"
%! 2'
(

!/
?0
ECM/PCM CONNECTOR C (31 P)

%2',,%/'0
ECMFPCM CONNECTOR C i31Pi
b n a a n
ALTF . [ML 5G1 CKW“ CKPM
. g ,
IE . 11 5 1! 13 an :21 22
7.1025 MAP 552 ‘I'CEI TDCP I [DEM P135
’3 25 as l 11 2! a an 3‘
v55 I“ £61|TPS me: cP Iz'rm 5w
Win:- side female terminals.

ECM CONNECTOR C (31 P)
%,,%/'0
84 9&!
:-
O
Terminal O| Wire Colour O
1

,
)
O| Signal
! O
O ,
@
No. O| O O| O| O
O 3
+ O| RED/BLU O
1 (=)? KS (Knock sensor)
>;>#< O| Detects KS signal
(>
! O| With engine knocking: Pulses
2
##
9 ! O
O 5
O| WHT/RED O
264=1 ( ALTF ;%!
%4 (Alternator FR
1 O| Detects alternator FR
(! 1 O| With fully warmed up engine
2 !!3
O
O O| O signal)

!< O| signal

! O| running: 0V - battery voltage

90:&!
O
O O| O O| O| (depending on electrical load)
;
!!!< O
O 6 *3+
G O| WHT/BLK O
264=)> EGRL (EGR lift sensor)
.1; .1!< O| Detects EGR valve lift
( .1&!&! O| At idle: About 1.2V
%!9% -: O
O O| O O| sensor signal

! O| O
O 7
$ O| GRN/WHT O
.1=264 SG1 (Sensor ground)
.;
< O| Ground for MAP sensor
. ,% O| Less than 1.0V at all times
-0:!! O
O 8
' O| BLU
)? O CKPP (CKP sensor P
>;> O| (>
Detects CKP sensor O| With engine running: Pulses
2

9 ! O
O O| O side)
< O| O| O
O 5
9 O| 264
WHT O CKPM (CKP sensor M
>,;>, O| . >
Ground for CKP sensor O| O
O O| O side)
< O| O| O
O 11 *1
G O| RED/BLK O
1 (=)> MCS (Engine mount
,;
O| Drives engine mount
(&
O| At idle: 0V
%!90: O
O O| O control solenoid valve)
!!&!&< O| control solenoid valve
!!&!& O| Above idle: Battery voltage
%&!9)&!
O
O 16 *3+
G O| WHT
264 O PHOZS (Primary
2! !!! O
O O| O heated oxygen sensor,
/
A O| oxygen sensor (sensor
/
; O| with fully warmed up engine: Above O
3 !!3
9%&
O O| O sensor 1)
< O| 1)
!
< signal O| 0.6V
0-: O
O O| O O| O| With throttle quickly closed: Below O
2!F #!!9)!3
O O| O O| O| 0.4V
0-*: O
O 17
$ O| RED/GRN O
1 (=.1 MAP (Manifold
,%;,! O| Detects MAP sensor
(,% O| With ignition switch ON (ll): About 3VO
2
38;<9% +:
O O| O absolute pressure
! O| signal

! O| At idle: About 1.0V (depending on
%!9% -0:;
O
O O| O sensor)
< O| O| engine speed)

< O
O O| O O| O| O
O 18
' O| GRN/BLK O
.1=)> SG2 (Sensor ground)
.;
< O| Sensor ground

O| Less than 1.0V at all times
-0:!! O|
O 19
5 O| YEL/RED O
C =1 ( VCC1 (Sensor voltage)
:;&!
< O| Power source to MAP
3 ,% O| With ignition switch ON (ll): About 5V|O
2
38;<9% :
O O| O O| sensor
O| With ignition OFF:90:
2
8 0V O
O O| O O| O| O
O 20
0 O| GRN
.1 O TDCP (TDC sensor P
4(;4( O| Detects TDC sensor
(4( O| With engine running: Pulses
2

9 ! O
O O| O side)
< O| O| O
O
21 O| 1 (
RED O TDCM (TDC sensor M
4(,;4(, O| . 4(
Ground for TDC sensor O| O
O O| O side)
< O| O| O
O 22 *3+
G O| RED/YEL O
1 (=C PCS (EVAP purge
; :%
O| Drives EVAP purge
(& :%
O| With engine running, engine coolant O|
2

A
!
O O| O control solenoid valve)
!!&!&< O| !!&!&
control solenoid valve O| below 65°C (149°F):
!3P;*5P Battery voltage O|
<9)&!

O O| O O| O| With engine running, engine coolant O|
2

A
!
O O| O O| O| above 65°C (149°F):
&P;*5P 0V
<90: O|
O 23 *2
+G O| BLU/WHT O
)?=264 VSS (Vehicle speed
:;:! O| Detects VSS signal
(:
! O| With ignition switch ON (II) and front O|
2
38;<
O OI O sensor)
< O| O| wheel rotating: Cycles 0V - about 5V O|
3!
9!0: :
O O O| O| or battery voltage
&!
O|
O 25
O RED/YEL O
1 (=C IAT (Intake air
%4;# O| Detects IAT sensor
(%4 O| With ignition switch ON (ll): About
2
38;<9% O|
O O O temperature sensor)
< O| signal

! O| 0.1 - 4.8V (depending on intake air O|
0-*-':;
#
O O O O| O| temperature)
< O|
O 26
O RED/WHY O
1 (=26C ECT (Engine coolant
4;
! O| Detects ECT sensor
( 4 OI With ignition switch ON (ll): About
2
38;<9% O|
O| O O temperature sensor)
< O| signal

! O 0.1 - 4.8V (depending on engine
0-*-':;

O|
O| O O O| O coolant temperature)
! < O|
O| 27
$ O RED/BLK
1 (=)> O TPS (Throttle position
4;4! O| Detects TP sensor signal O
(4
2! !!9% *-':
O| O O sensor)
< O| O With throttle fully closed: About 0.5V O|
2! !!!9% 0-:
O| 28
' O YEL/BLU
C =)? O VCCZ (Sensor voltage)
:;&!
< O| Provides sensor voltage O
&&!
With ignition switch ON (ll): About 5V|O
2
38;<9% :
O| O O O| O With ignition switch OFF:90:
2
38 CV O|
O| O O O| O O|
O| 29
5 O YEL
C O CYPP (CYP sensor P
C;C O| (C
Detects CYP sensor O With engine running: Pulses
2

9 ! O|
O| O O side)
< O| O O|
O| 30
+0 O BLK
)> O CYPM (CYP sensor P
C,;C O| . C
Ground for CYP sensor O O|
O| O O side)
< O| O O|
O| 31
+ O GRN/YEL
.1=C O PSPSW (P/S pressure
2;= O| Detects PSP switch
(3 O At idle with steering wheel in straight O|
%!3
3!

i
O
O
O|
O
O
O
O
O
O
switch signal)
3
!< O|
O|
O|
signal

! O
O
O
ahead position: 0V
90:
At idle with steering wheel at full
%!3
3! !!
!#9)&!

lock: Battery voltage
O|
OI
O|
*1: NT model
G9%=4!
*2: WT model
G9,=4!
*3: with TWC model
G+9342!
G*93 42!

*
!
Troubleshooting
%! 2'
(

11 -B-22
"
!/
?0
ECM/PCM CONNECTOR D (1GP)

%2',,%)/5'0
PCM CONNECTOR D (16H
2’
sun SHC ATPR VSHUl
l
6 ' 1 S 10 11 1?
ATP“ SHA liPfli AYPD‘ NC M“ Fllsfi
11 \l 15 16
11'?" All! AYh NESG

ECM CONNECTOR D (16P)
%,,%)/5'0
84 9&!
:-
O Terminal O
Wire Colour O
1

,
)
O Signal
! O|
O No.
,
@ O O O O O|
O 1 O YEL
C O LC (Lock-up control
;# ! O Drives lock-up control
(&!# ! O During half and full lock-up
(
! !!!# O|
O O O solenoid valve)
!&!&< O solenoid valve
!&!& O conditions, and during deceleration O|
A
!
O O O O O condition: Battery voltage during no O|
9)&!

O O O O O lock-up condition: 0V
!# 90: O|
O O GRN/WHT O
.1=264 SHB (Shift control
6);! O (&!
Drives shift control O Battery voltage in following positions: O|
)&!
!!3
9
O O O solenoid valve B)
!&!&)< O !&!&)
solenoid valve B O 0 1 and 2 positions
O|
O O O O O 0 D4 and D3 positions in 1st and
)) O|
O O O O O 2nd gear

O|
'A, O|
0:!!3
9 O|
O O O O O 0 D4 and D3 positions in 3rd gear O|
))+

)*
O|
O O O O O O|
O + O GRN
.1 O SHC (Shift control
6;! O (&!
Drives shift control O Battery voltage in following positions: O|
)&!
!!3
9
O O O solenoid valve C)
!&!&< O !&!&
solenoid valve C O 0 1 position
O|
O O O O O 0 D4 and D3 positions in 1st and
)) O|
O O O O O 3rd gear
+
O|
0:!!3
9 O|
O|
O O O O O D4 and D3 positions in 2nd gear OI
))

0

)*
O|
'A, O|
O O O O O O|
O * O RED/BLK O
1 (=)> ATPNP (At gear
%4;%
O Detects A/T gear
(%=4
O In N position: 0V
,90: O|
3< O| position switch signal
3
! O In any other position: Battery voltage O|
9)&!

O O BLK/YEL O
)>=C VBSOL (Battery
:)8;) O| Power source of
3 O With ignition switch ON (II): Battery O|
2
38;<9)
O O O voltage for solenoid
&!
! O| solenoid valve
!&!& O voltage
&!
O|
O O O valve)
&!&< O O With ignition switch OFF:90:
2
38 0V O|
O O WHT
264 O ATPR (At gear position O|
%41;%
Detects A/T gear
(%=4
O In R position: 0V
90: O|
O O O switch)
3< O| position switch signal
3
! O In any other position: Battery voltage O|
9)&!

O $ O BLU/YEL O
)?=C SHA (Shift control
6%;! O| Drives shift control
(&! O Battery voltage in following positions: O|
)&!
!!3
9
O O O solenoid valve A)
!&!&%< O| solenoid valve A
!&!&% O 0 2 position
O|
O O O O O 0 D4 and D3 positions in 2nd and O|
))
O O O O O 3rd gear
+
O|
0:!!3
9 O|
O|
O O O O O 0 D4 and D3 positions in 1st gear O|
))

)*
O|
'A, O|
O O O O O O|
O ' O PNK
> O ATPD3 (At gear
%4(+;%
O Detects A/T gear
(%=4
)90: O|
3
!< O In any other position: Battery voltage OI
9)&!

O 5 O YEL
C O ATPD4 (At gear
%4(*;%
O| Detects A/T gear
(%=4
O| In D4 position: CV
)90: O|
3< O| position switch signal)
3
!< O| In any other position: Battery voltage
9)&!
OI
O 1O
0 O PNK
> O NC (Countershaft
; O| Detects countershaft
( O| Depending on vehicle speed:
(
&!9 O|
O O O speed sensor)
< O| speed sensor signal

! O| Pulsing signal
!

! O|
O O O O| O| When vehicle is stopped: Approx 0V
2&!9%/0: O|
O 11
O RED
1 ( O NM (Mainshaft speed
,;, O| Detects mainshaft speed O|
( Depending on vehicle speed:
(
&!9 O|
O O O sensor)
< O| sensor
O Pulsing signal
!

! O|
O O O O| O When vehicle is stopped: Approx 0V
2&!9%/0: O|
O 12
O WHT
264 O NMSG (Mainshaft
,.;, O| Ground mainshaft speed O
. O|
O O O
<
speed sensor ground) O| sensor signals

! O O|
l
O 13
+ O BLU/WHT
)?=264 O ATPPN (At gear
%4;%
O Detects A/T gear
(%=4
O In P or N positions: CV
',90: O|
3
!< O In any other position: Battery voltage O|
9)&!

O 14
* O BLU
)? O ATP2 (At gear position
%4;%
O| Detects A/T gear
(%=4
O In 2 position: 0V
90: O|
O O O switch )
3
9)&!

O 15
O BRN
)1 O ATP1 (At gear position
%4;%
O| Detects A/T gear
(%=4
O In 1 position: 0V
90: O|
O O O switch)
3
9)&!

O 16
O GRN
.1 O NCSG (Countershaft
.; O| Ground for countershaft O
. O|
O O O
<
speed sensor ground) O| speed sensor
O O|
Troubleshooting

*
! _ _
"
) !

*
/)0 11 B 23
Ol Diagnostic
) !
O System Indicated
# Ol Page
'! O
Ol Trouble Code

*
O Ol O
Ol (DTC)
/)0 O Ol O
Ol O
0 O Engine/powertrain control module (ECM/PCM)

=3! !; ,=,< Ol (See Page
;'! O
Ol O Ol 11-B-26)
)< O
Ol 1 O Primary heated oxygen sensor (primary H028) *1
/
;68<G Ol (See Page
;'! O
Ol O Ol 11-3-31)
)+< O
Ol 3
+ O Manifold absolute pressure (MAP) sensor
,!! ;,%< Ol (See Page
;'! O
Ol O Ol 11-B-33)
)++< O
Ol * O Crankshaft position (CKP) sensor
#;>< Ol (See Page
;'! O
Ol O Ol 11-B-36)
)+< O
Ol O Engine coolant temperature (ECT) sensor

! ; 4< Ol (See Page
;'! O
Ol O Ol 11-B-38)
)+'< O
Ol $ O Throttle position (TP) sensor
4!;4< Ol (See Page
;'! O
Ol O Ol 11-B-40)
)*0< O
Ol ' O Top dead center position (TDC) sensor
4;4(< Ol (See Page
;'! O
Ol O Ol 11-B-36)
)+< O
Ol 5 O N0. 1 cylinder position (CYP) sensor
-!;C< Ol (See Page
;'! O
Ol O Ol 11-B-43)
)*+< O
Ol 10
0 O Intake air temperature (IAT) sensor
# ;%4< Ol (See Page
;'! O
Ol O Ol 11-B-45)
)*< O
O| 11
O Idle mixture adjuster (IMA) *2
!/ 7 ;,%<G O| (See Page
;'! O
OI O Ol 11-3-47)
)*$< O
Ol 12
O Exhaust gas recirculation (EGR) valve lift sensor *1
/
!; .1<&!&!G Ol (See Page
;'! O
Ol O Ol 11-B-76)
)$< O
Ol 13
+ O Barometer pressure (Baro) sensor
) ;)< Ol (See Page
;'! O
Ol O Ol 11-B-50)
)0< O
Ol 14
* O Idle air control (IAC) valve
!!;%<&!& Ol (See Page
;'! O
Ol O Ol 11-B-63)
)+< O
Ol 17
$ O Vehicle speed sensor (V88) *3
:!;:<G+ Ol (See Page
;'! O
Ol O Ol 11-3-51)
)< O
Ol 21
O VTEC solenoid valve
:4 !&!& Ol (See Page
;'! O
Ol O Ol 11-B-3)
)+< O
Ol 23
+ O Knock sensor
># Ol (See Page
;'! O
Ol O Ol 11-B-53)
)+< O
Ol 41
* O Primary heated oxygen sensor (primary H028) heater *1
/
;68<G Ol (See Page
;'! O
Ol O Ol 11-B-55)
)< O
Ol 63*4*
+G O Secondary heated oxygen sensor (secondary H028) *4
/
;68<G* Ol (See Page
;'! O
Ol O Ol 11-B-58)
)'< O
Ol 65*%
GW O Secondary heated oxygen sensor (secondary H028) heater *4
/
;68<G* Ol (See Page
;'! O
Ol O Ol 11-B-55)
)< O
Ol 70 *4*
$0G O Automatic Transmission
% 4 Ol Section 14
* O
*1: with TWC model
G9342!
G93 42!
*3: WT
G+9,=4
*4: NT
G*9%=4
*5: NT with TWC model
G9%=4342!
1 If codes other than those listed above are indicated, verify the code. If the code indicated is not listed above, replace the
!&A&-!&A!
ECM/PCM (for immobilizer information) (See Page 11-B-14).
,=,;!H<;'!)*<-
1 The MIL may come on, indicating a system problem when, in fact, there is a poor or intermittent electrical connection.
4,A
!3AA!!-
First, check the electrical connections, clean or repair connections if necessary.
A#!!A!-
PGM-Fl System
'+# 11 -B-24
"
System Description
#)
ENGINE CDNTHDL MDDLILE IECMH

PDWEHTHAIN CONTROL MODULE
ENF'L'TS IPCMII OUTPUTS
TDQ‘CKF‘ Sensor ; ___ '
WP Sensor !
MAP Sensor Fuel Injectors
ECT Sensor PGM-Fl Main Relay lFuel Pump)
IAT Sensor MIL
TP Sensor _"_—_:.J" I7 It. IAC Valve
EGH Value Lift Sensor" \} NC Compressor Clutch Relay
H02 S" I
! Fuel Injector Timing and Duration] 1"! DLC
USS" Condenser Fan Flelev i
RAPID Sensor Electronic Idle Control ICM
KS EVAP Purge Control Solenoid Valve"
Starter Signal H028 Heater-1
ALT FR Signal @l EGFI valve" I
Air Conditioning Signal 9 g D O IAB Control Solenoid Valve
NT Gear Poeition Signal“ : ECMIPCM Back-up Functions Engine Mount Control Solenoid Valve“
Battery Voltage IIGN. 1]" i VTEC Solenoid Valve
Brake Switch Signal'5 : Arr Cantrm Funcligng VSS Signal“
F'SFl Switch Signal Lock—up Control Solenoid Valve"
new2 ' Shift Cantrol Solenoid Valve“
Service Choc-k Signal NT Clutch Pressure Control Solenoid
CFIS Signal“ 5 Valve"
Mainsheft Speed Sensor" : D-‘l Indicator Light“
Countershal‘t Speed Sensor“ -': Tachometer Signal
2ndl3rd Clutch Pressure Switch
Signal“ I
'1: with TWC model
'2: without WC model
*3: MT
*4: AFT
*5: except MIT without TWC model
PGM-Fl System
'+#
The PGM-FI!F ! ! !7-
+D
!)

The ECM/PCM contains memories for the basic discharge duration at various engine speeds and manifold pressures. The
4 ,=,
&
! -4

A
A
!&
!
-
Idle Air Control

When the engine is cold, the A/C compressor is on, the transmission is in gear *4, the brake pedal is depressed *5, the P/S
2
!A%=A
G*A#!GA=
load is high, or the alternator is charging, the ECM/PCM controls current to the IAC Valve to maintain the correct idle speed.
!
A!

A ,=,! %:!&!-
!
!

r The ECM/PCM contains memories for basic ignition timing at various engine speeds and manifold air flow rates. Ignition
4 ,=,

&
!!3-

timing is also adjusted for engine coolant temperature.

!7
! -
r A knock control system is also used. When detonation is detected by a knock sensor (K8), the ignition timing is retarded.
%##!! -2##;><A

-
PGM-Fl System
'+# 11 -B-25
"3
#)
/
?0

+

Other Control Functions
1.
!
- Starting control
2
A ,&/
!7 -
2. Fuel
- Pump Control
! !
0 When the ignition switch is initially turned ON (II), the ECM/PCM supplies ground to the PGM-FI!
2
3!! 8;<A ,=, !
., main relay that
supplies current to the fuel pump for two seconds to pressurise the fuel system.
! ! 3 !-
0 When the engine is running, the ECM/PCM supplies ground to the PGM-FI! ! !
2

A ,=, !
pump.
-
0 When the engine is not running and the ignition is ON (II), the ECM/PCM cuts ground to the PGM-FI!3
2

8;<A ,=,
., main relay which
cuts current to the fuel pump.
! -
! !
(
!3!&!&!A !7 & !
speeds over 1,100 rpm (min -1).
&A00;<-
0 Fuel cut-off action also takes place when engine speed exceeds 6,900 rpm (min-1), regardless of the position of the
! !#!3
/A500;<A
!
throttle valve to protect the engine from over-revving.
!&!&
&&&
-
A/C Compressor Clutch Relay
*- %=! 1!
When the ECM/PCM receives a demand for cooling from the air conditioning system, it delays the compressor from being
2 ,=,&!

A!

A/ %=-
Intake Air Bypass (IAB) Control Solenoid Valve
- #%);%)<!!:!&
When the engine rpm is below 3,900 rpm (min-1), the IAB control solenoid valve is activated by a signal from the
2
!3+A500;<A%)!!&!&&
!
ECM/PCM, intake air flows through the long intake path, then high torque is delivered. At speeds higher than 3,900 rmp
,=,A#!3
!
#A
F !&-%
+A500
(min-1), the solenoid valve is deactivated by the ECM/PCM, and intake air flows through the short intake path in order to
;<A!&!&& ,=,A#!3
#
reduce the resistance in airflow.
!3-
Evaporation Emission (EVAP) Purge Control Solenoid Valve*1
- & ; :%<
!!:!&G
When the engine coolant temperature is below 65°C (149°F),
2
! !3P;*5P the ECM/PCM supplies a ground to the EVAP purge control
<A ,=, !
:%
!
solenoid valve which cuts vacuum to the EVAP purge control canister.
!&!&3 & :%
!-
7. / .1 !; .1<!!:!&G
$- Exhaust Gas Recirculation (EGR) Control Solenoid Valve *1
When the EGR is required for control of oxides of nitrogen (NOx) emissions, the ECM/PCM controls the EGR valve.
2 .1F !/
;8/<A ,=,! .1&!&-
ECM/PCM Fail-safe/Back-up Functions
%2'+ 2"6+

1. Fail
- safe Function
!
When an abnormally occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-programmed
2!!
!A ,=,

!

value for that sensor that allows the engine to continue to run.
&! !!3
-
Back-up Function
- )#
When an abnormally occurs in the ECM/PCM itself, the fuel injectors are controlled by a back-up circuit independent of the
2!! ,=,!A !7!!#
system in order to permit minimal driving.
!&
-
+- !
;,! ;,<
When an abnormally occurs in a signal from a sensor, the ECM/PCM supplies ground for the MIL and stores the code in
2!!
!A ,=, !
,
erasable memory. When the ignition is initially turned ON (II), the ECM/PCM supplies ground for the MIL for two seconds
!-2
!! 8;<A ,=, !
,3
to check the MIL bulb condition.
#, !-
Two Driving Cycle Detection Method
*- 43(&
!(,
To prevent false indications, the "two driving cycle detection method" is used for the EGR system and other
4&!AZ3&
!Z .1
self--diagnostic functions. When an abnormally occurs, the ECM/PCM stores it in it‘s memory. When the same abnormally
!
-2!! A ,=,@-2!!
re-occurs after the ignition switch is turned OFF 8;<
A ,=,&
,-

3 8 and ON (II) again, the ECM/PCM informs the driver by turning on the MIL.
PGM-FI System
'+# 11 -B-26
"5
%!

2'
(

(ECM/PCM)
/%2'0
NOTE:
84 9
0 If this symptom is intermittent, check for:
A#9
- A loose ACGS (15A) fuse in the under-hood fuse/relay box.
%!%.;%< =!/-
- A loose No. 9 BACK UP LIGHT INSTRUMENT LIGHT (7.5A) fuse in the driver’s under-dash fuse/relay box.
%!-5)%>?.6441?, 4.64;$-%< &B =!/-
- A loose No. 1 FUELPUMP
%!- fuse (15A) in the driver’s under-dash fuse/relay box.
? ?, ;%<&B =!/-
- An intermittent short in the wire between the ECM/PCM (A18) and the gauge assembly.
%33 ,=,;%'<

!-
- An intermittent short in the wire between the ECM/PCM (C19), the MAP sensor and/or Countershaft Speed sensor.
%33 ,=,;5<A,%= -
- An intermittent short in the wire between the ECM/PCM (028), the TP sensor, Mainshaft Speed sensor, the EGR
%33 ,=,;'<A4A,A .1
valve lift sensor (with TWC model engine) and/or IMA (without TWC model).
&!&!;342!
<=,%;3 42!<-
- PGM-FI!-
., main relay.
NOTE
I If this symptom is ir'ten'nittert. check for.
— Aloese ACGS (1 Shlfese ir the cerhooefeser'relary box.
— Aloese No SHACK UP LIGHT INSTRUMENT LlGl-IT item
fLse ir the criuer‘s cemash fL.se."relay box
The Malmncfim Indicator Lamp — Aloese No 1 FUEL PUMP fI..se USA] irthe eri'uer’s Lreereash
fLSE'JI'EiEIy tor
Egggfl5°33, $14:s' — Ar irtermitlJer't short ir the wire betweer the Ecrw'rcrur we j:
turned ON illl- arethe gage assembly . . . | _
— Ar rrtermrttert short rr the wrre betweer the ECM’PCM $19},
(KG. Kl; KS, KR rrodels} the MAP serscr arcr'cr Coertershdt Speeesersor
i'- ''''''''''''' — ''''''''''''''' j — Ar irtermittert short ir the wire betweer the ECM‘PCM [(323],
i Check the inertia switch: | the TP serscr. Mdrshdt Speec sersor, the EGR value lift
1. Press the ir ertia switch better. i sersor rfwith TWO mccel ergire] arcr'or IMA rfwithmt T‘Ir'u'C mceel]
i 2. 'e the igr'rtior sw'tch CN till}. i — PGM-FI mair relay
i i _________________________________________
'_..-""'Does the MIL come or fortwo
i 4:: seoords alter igritior switch '.
lntem1ittent failure, system is OK
at this time.
! teecl CN ill}?
| NO — INERTIA SUVITCH 3P CONNECTOR
! Checktheinertia switch: INER'flA
I 1. Disoorrect the irer‘tia switd" SWITCH 1 2 3 i "31
| 3P corrector.
i 2. Correct the irertia switch 3P
oor rector termirals No. '1 ard
iREUBLK} (REDJWHT)
i No. 3 with a jemper wire. JUMPER WIRE

i Tenniral side of male termir als
i Does the MIL come or for two
i secorcls after igr itior switch Replace the inertia switch.
i teeel CN {ll}?
i
between No. El BACK UP LIGHT
NC INSTRUMENT LIGHT (LEA)
< Is the low oil presee light or? >— fuse and gauge assentlyr.
— Replace Not 9 BACK UP LIGHT
YES INSTRUMENT LIGHT (715 A) fuse.
ECMIPCM CONNECTORAISEP}
tr r' e s ‘e
Check the engine starting: '2 '2 '4 . - . .3 '9 2e 2‘ 22 2:1 24
l-\
t':‘
’ryto start the ergire. 2r.- 2rj2r' 2d ___..-'.Je J‘ :12

_ 3 MIL [GRNIORN]
Check the MIL. JUMPER WIRE
f#—xa YES 1. Terr the igr'rtior switch Ol'l'.
Does the ergire start? 2. Correct the ECMr‘PCM 'IA'ire side of ferrale
--.— - oorredor terrr‘ir al A18 to body tenrirals
NO groe.
3. 'e the igritior switch ON ill].
NC
< Isthe MIL or? J—‘
— Replace the MIL bulb.

— Repair open wire between the
ECMIPCM [A18}anrl the
('0 page 11-l3-2Tj: gauge assembly.
YES
Substitute a hnmn good ECMI
PCM and reoheok tsee page11-B-14
for immobilizer information]. If
synptomiinclioation goes away.
replace the original ECMPCM.

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-FI System
'+# 11 -B-27
"7
%!

2'
(

/%2'0/
?0
(From page 11-8-26]
Cheek the fuse:

1. 'e tre igritior switol‘ OFF.
2. IrspeotACGS (1 51“.] f1.se ir
tl'e eer-l‘ood mselrela'y
box

NC between the A063 (15 A)
< Istl‘efLse CK? fuse and the PGM-Fl main
relay.
YES - Replaee A063 (15 A) fuse.
Cheek the fuse:

Irspeottre No.1 FUEL PUMP [15
A} fL. se ir tl‘e driver‘s L.r der—dasl‘
fLsen'relavbox.

between the No.1 FUEL
NC PUMP [15A}fuse and the
< Istl‘e fL. se CK? PGM-Fl main relay:
- Replaee No.1 FUEL PUMP
YES
[15A}fuae.
EClWPCM CONNECTOR B [25F]

IGP1
[‘I'EUBLK)
7

"6P1, IGP2 line a): 2 :3 4 e r e
1. Discorr‘ect tl‘e fLeI ir‘jectors 9 'u .2 .3 .4 ‘Fj ‘r' ‘H
ard IAC valve correctors. _--" 2U 2‘ 22 21.1 24 21:

2. 'e tl‘e igritior switcl‘ CN ill}.
3" Ki]- Ion
Ia:
3. MeaSL. re voltage betweer‘ W1 re side of

bodv groL. rd ard ECWHPCM = (YELIBLK)
female terl‘fiir‘als
oorreotortermir als B1. 89
irdividLallv.
— Repair open in the wirels)
between ECIWPIWI (B1, BS)
NC
and PGM-Fl rnairl relay
< Is there battery voltage?
— Cheek for poor eonn ections
YES or loose wires at the PGM-Fl
main relay.
PG1 (ELK)
fPG, LG lines):
2 L141: {‘3
1. Recorrect all He fLEI irjector . ‘2‘3‘4/‘fi‘i‘3
ard IAC valve correctors.
2. lvleaSLre voltage bet'weer' body
2l=
. . L .1 (i) LGZIBRNIBLK]:
r! 22 id 2‘1 £1:
groe ard ECMA‘F’Clvl oorreotor

PGZ NH?-
termirals BE. B1 0. BED ar'd
(BLK)"'-_I
B22 irdi'vidLallv. LG1 [—BRNJBLK}
NC Repair open in the wirels)
< Istrere lesstl‘ar 1.0V? bemeen the ECIWPCM (BE, B1 0,
BED, BEE]: and G101.
| YES
('o page 11-8-28]

PGM-Fl System
'+# 11 -B-28
"8
Engine Control Module /Powertrain Control Module
%!

2'
(

/%2'0/
?0
ECIWPCM CONNECTOR G [31 P}

(Frol‘tpage11-B-2T] a 4 3 e ,-
‘F.i “B '5 2C 2‘ 22
2:1 22 2e 2.-' 23 25 3c 3‘
V002 V001
Check for a short in the wires t
ELIBLU him Dhl EURED
W001, V002 line s; W )
'I“ W 1'
MeaSLre voltage betweer body =
groe ard ECM/PCM oer rector Wire side of female termirals
terl‘tirals I319 ar‘d (328 ll‘dl'u'ldLaH'y’.
I:.‘.heclr fora short in a sensor.

While IneaSLrirg voltage betweer‘
body grew d ard ECM/PCM
oer'r'ecter termirals C19 ar‘d (328
ir'dividLally. disocrr‘ecttt'e SP
NO ocr'r'ecter efeacl‘ serscr ore at
1i.__ Is there approx. 5 V? a time:
0 MAP serscr
YES 0 ‘P serscr
. EGR valve (with ‘WC model]
I I'ulair'sl‘afi speed ser‘scr (AF:
I CoLrtersl‘ all speed ser‘scr [N']
0 India ['mitl‘cm "NC model]

—-.-. NC
PCM and recheck (see page 11 8-14 ( Is there approx. 5 v? _::.~—-
for immobilizer in formation).
If symptomtindication goes YES
away, replace the original ECMI _ _ _
Pcm_ Repair short In the Wire bemeen
MAP sensor, TP sensor, EGR
valve (with TWO model), Mainshatt
speed sensor (N11. Countershaft
speed sensor (N11. IMA [without
TWO model) and EGMJPCM
(C19, (:28).
Replace the sensor that had

ap p re: . E V.
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-FI System
'+# 11 -B-29
"9
%!

2'
(

/%2'0/
?0
NOTE:
84 9
When there is no Diagnostic Trouble Code (DTC) stored, the MIL will stay on if the SOS short connector is connected and
2(
4 !;(4<A,3!!
the ignition switch is ON (II).

38;<-
If this symptom is intermittent, check for:
A#9
- An intermittent short in the wire between the ECM/PCM (A10) and the service check connector.
%33 ,=,;%0<&#-
- An intermittent short in the wire between the ECM/PCM (A18) and the gauge assembly.
%33 ,=,;%'<

!--
The Malflrnction Indicator Lan'p
{MIL} stays on or comes on after
NOTE:
two seconds.
I Wher‘ there is he Diagr‘ cstic Trestle Cece ID TC} store 1:. the MIL wi|| stag.-
or if the 363 short eor'r'eetcr is correctec: arc the igritier switch is ON [II].
I If this symptom is ir'termitter‘t. check for.
— Ar ir'termit‘ber't short ir' the wire betweer the ECMI‘PCM [A10] are the
seruiee eh eek ecr rector.
Check the DTC by MIL indication: — Ar ir'termitter'tshcrt ir'thewire betweer‘the ECMJF'CM [A13] zrethe
1. ’e the ighiticr switch OFF. gage assem Lily.
2. Cor heat the 808 short ccrrecter
to the service cheds' cchh enter.
3. ’e the igr‘itioh switch ON III}.
YES Go to troubleshooting procedures

< Does the MIL ir‘dicate ar‘y D’C? [see page 11-5-13).
NC
Check the engine starting:

1. Remcvethe 808 short ocr‘r‘ectcr
from the sewice check ocr‘r‘edcr.
2. 'ry to start the er‘gir‘e.

PGI'i'I and recheck (see page 11 -B-
NC 14 for immobilizer information).
Does the er‘gir‘e start?
If smptomi‘indication goes
away, replace the original ECIW
YES
PGI'II'I.
Check fora short in the wire ECMIPCM CONN ECTOR A {32?}

[508 line):
1. 'e‘ the igr'rticr switch CFF scsrBRN}
and te the igr‘iticr‘ switch
t: 6 8 a 1D 11
CN {ll}.
12131415161r'1815320 2122 23 24
2. M easue voltage betweer‘
body groe ahd the ECMr’ 2t: 26 2.-' 2a 30 31 32
POM ecr‘r‘ectcrtermir‘al A10.
'INII'C‘ SldL" OI IIL‘IT‘E'IIIL‘ IIZ‘IIT‘II'IEIIS
Repair short to body ground in
< Is there battery 1; cltage?

N0 the wire between ECIWPCM
[A10] and service check
YES connector.
('6 page 11-8-30]

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# 11 -B-30
"$
%!

2'
(

/%2'0/
?0
(From page 1'1 43-29]
Check for a short in the wire [MIL

line}:
1. ’Lrh the ighitioh switch OFF.
2. Dismr‘r‘ ect the ECNl.v'PCM
oer hector A (329:.
3. ’e the ighitior‘ switch CN {II}.
YES Repair short to body ground in

‘\ IstheMILCN? the wire between the ECMIPCM
[1118) and MIL.
NC
POM and recheck (see page 11-3-
14 for immobilizer information}.
If symptoniindication goes
away, replace the original EGMJ‘
POM.
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-FI System
'+# 11-B-31
"
Heated Oxygen Sensor (H028) (with 1
0
.#!
/.0/( TWC model)
\ | / \ | /

IE, /-\ 4,! ;,<(
4 !;(4<9%!6
The Malfunction Indicator Lamp (MIL) Indicates Diagnostic Trouble Code (DTC) 1: A problem in the Heated
Oxygen Sensor (H028) circuit.
8/
;68< -
The Heated Oxygen Sensor (H028) detects the oxygen content in the exhaust gas and signals the ECM/PCM in operation, the
468/
;68</
/

! ,=,A
ECM receives the signals from the sensor and varies the duration during which fuel is injected. To stabilize the sensor's output,
,&
!&
3 !7-4!H@ A
the sensor has an internal heater. The H028 is installed in the exhaust pipe A.
!-468!!/ %-
lIRCONIA SEN 30R VQTAGE (V) STOI CHIOI‘IE TRIC
ELEMENT TERMHALB ‘ I T‘“-- AIR-FUEL RATIO
|
Ir
|
I
/; -T‘:l\.
elite... gaffe
'— —' uIi-l- L
1 53min [
1-:
\u‘. --')
r};
HEATER it] RICH - AIR - LEAN
HEATER FUEL
TERMHALS RATIO
— With the 303 short connector
connected (see page11-B—13),
code 1 is indicated.
Check the fuel pressure:

lrspect fLeI pressure Ij see page
11 elk-1 01 i.
NC Go to page 11-3-86 Fuel Supply

Is it r‘orI‘taI ?
System.
YES
1. Do the ECMI'PCM Reset
ProoedLre (see page '1 '1 5—1 4}.
2. Starttl‘e ergire. lsold tl‘e
ergir e at 3.000 rpm IjI‘tir-l j:
with ro load IjiI‘ Park or I‘ELtl'aI}
Lrtil tl‘e radiator far
comes or. tl‘ er let it idle for at
least ore Inircte before test—
drivirg.
'estdrive eer followirg
- oor clitio rs.
N— ir positior IjlvlF ir 4tf'
gear}.
r‘toselerate Lsirg wide oper‘
tl‘rottle for at least five seccrds.
tl‘er decelerate for at
least five secords witi‘ tl‘e
tl‘ rottle completely d ose d.
<
lntcn'nittcnt failure, system is OK
Is He MIL or ard does it >£ at this time. Check for poor

connections or loose wires between
ir clicate code 1'?
the PrimaryHOES and the ECM!
YES POM.
(To page 11-8-32]

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+#
Heated Oxygen Sensor (H028) (with 1
0
.#!
/.0/( TWC model)
1 1-B-32
"
(cont’d)
/
?0
(From page 11-8-31}
Ch eek the ECMfPCM voltage:

1, Stanthe ergir e. h-oldthe E CMIPCM CONNECTORS
ergire at 3. 000 rpm Ijmir-l'; B (25F) c [31m
with ro load (ir Park or reLtral'; E5 —.
2 SJ 4 3 5 r |a 9
(a
DC
Lrtilthe radiator far comes or. 9 ‘U .. ,2.3.4-_____. 'fi‘i‘fi 11 1617 18 19120 2122
ther let it idle for at least ore
2L! 2' 22 22.1 24 2E; 23 25 26 27' 2E |29 30 31
mirLte before te st-drivirg.
, luleaSLre voltage betweer
U31 PHozs [WI-IT} Wire side of
ECMIPCM oorrectorten‘tirals
(BRNIBLKI‘ (E female termir als
K?“
820 ard I316.
, IGper the th rottle wide oper.
ther qLioklvrelease it.

Is the voltage above 0.6 V at
POM and recheck (see page 11 -B-
wide oper throttle to 4.500 rpm YES 14 for immobilizer information).
Ijmir-l j: ard below 0.4 V wh er
If symptomtindication goes
the throttle is qLicklv released
away, replace the original ECMJ
from 4.500 rmp Ijmir-l l?
PCM.
NC
PRIMARY
H028 4P CONNECTOR
Cheek the Primary H023:

'l. 'e the igritior switch OFF.
2. Disoorreot the 4P oohrector PHOZS 5G2
from the Primary PC2S.
3. At the Primary l-CZS han‘ess
side. correct the battery positive
ten'tiral to termir al No. 3
ard batterv regative ten‘tiral
to termiral No. 4.
. Startthe ergire. IG1 PH OZSH TC
U1 «h-
. fitter two mirLtes. meaSLre

voltage betweer Primary
h-GES 4P oorrectortermirals
No.1 ard No. 2.
'ermir als side of male termirals
Is the voltage above 0.6V at

wide oper throttle to 4,500 rpm NC Replace the Pri mary H028 [see
[mir-‘|] ard below 0.4V wher page 11 -B-60).
the throttle is ciLidtlv released
from 4. 500 rpm (mir-‘l }.
YES
Repair open or short in the wire

ECMIPCM [016} and the Primary
HEIRS.
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
(See Page 11-8-60)
;'!)0<
PGM-FI System
'+# 11 -B-33
"

*
'/'0
-@—-I
\
/ I
| /
\ / 1
\ |
+
/
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 3: An electrical problem in the
\ 4,! ;,<(
4 !;(4<+9%!!!
Manifold Absolute Pressure (MAP) Sensor circuit.

,!%! ;,%< -
The MAP sensor converts manifold absolute pressure into electrical signals and inputs ECM/PCM.
4,%&!! !!
! ,=,-
The MIL has been reported on.
OUTP UT
With the SOS shortconnector
VOLTAGE
connected (see page 11-3-13),
1. Do the ECMI'PCM Reset ‘1 I 10 1! III Hal GAUGE
ProcedL. re (see page 11-8-1 4}. IM 2“ lum- Hal READING
2. Start er‘gir‘e ard allow it
to idle.
<
Isthe MIL or‘ ar‘d doesitir‘dicate No nece ssaryr}. Ch eck for poor
code 3. connections or loose wires between
YES the MAP sensor and the ECMIPCM.
ECIWPCM CONNECTOR C [31P}

Check the ECIWPCM outputvolt-
age W001 line): souGmHn
1. ’e the igr‘itior‘ sw‘td" OFF. 3 b [5 ." 8 S3
2. ’e the igr‘itior‘ switch ON ill}.
3. M eaSLre voltage betweer‘
11 115 1; 1819 2D 2122
ECMI'PCM corrector termirals
CT ard C19
23 2t: 26 21' 28 29 3D 31
L
Iii :1 mm
Substitute a known-good ECIW [ [YELIRED]
NC POM and recheck (see page 11 -B-
Wire side of female
Is there approx. 5 V? 14 for immobilizer information).
termir‘ als
If smptomi‘indication goes away,
YES
SG1 (GRNJ'WHT)
J b 6 89'
CE)
Check the ECIWPCM output voltage
[MAP line}: 11 16 1! 1819 2D 2122
M eaSL re voita ge betweer ECMI’ 2t! 26 21' 28 2S 3L]
PCM oorreotortennirals CT ard
C1 T.
MAP (REDIGRN)
PGM and recheck (see page 11-8-
<
YES
ls ti‘ere approx. 3 V? 14} for immobilizer information).
If smptomi‘indication goes away,
NC replace the original ECIWPCM.
(To page 11-8-34]

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+#

*
'/'0
/
?0
11 -B-34
"
MAP SENSOR 3F CONN ECTOR

(From page 11-8-33}
Wire side
Check for an open in the wire [561 offer'iale
line): ten‘rnr'als
1. 'e ti‘e igritior switei' ICFF.
YES 2. Disoor rec: 3P oorr enter from
< Isti'ere approx. 5V? ti‘e MAP sersor. VCGi
3. ’e ti‘e igritior switei' CN [II].
NC 4. MBaSLFE: voltage betweer‘ MAP
sersor 3P eorreetor teri‘iirais
No. 1 ard No. 2. 5‘31
NC
Is there approx. 5 V?
YES

the ECMJPCM {CT} and the MAP
sensor.

[MAP line):
M eaSL. re voltage betweer' MAP
ser‘sor 3 P oor‘ rector teri‘iir‘als
No.2 ar‘d No. 3.
Is there approx. 5 V? lREDIGRH]
YES h‘
Rep air op en in the wire betw een

the ECMJPCM [01?) and the MAP
sensor.
ECMIPCM CONNECTOR c [31H

Cheek the MAP sensor:
3G1 (GRNJ'WHT) '—
1. 'e ti‘e igritior switd‘ OFF.
2. Diseorreetti‘e 3P oorrector
from ti‘e MAP sersor.
3 / ‘3 r5 a a
3. 'e ti‘e igritior switd‘ CN ill}. ,.-" 151! 18 19m 2122 GD
4. M eaSLre voltage betweer 23 2t~ 25 2; 2a 2a 30 31
ECiuli'PCi-ai eorreetor termirals
CT ar'd I317. MAP [REDIGRN]
Wire side of female termir‘als
<
YES
Is ti‘ere approx. 5 V? Replace the MAP sensor.
NC
('o pageii-BGE}
PGM-Fl System
'+#

*
'/'0
/
?0
11 -B-35
"3
HAP SENSOR 3P CONNECTOR

[Lrom page 11-H-34]
'.+ f:
Cheek foran open in the wire
[V001 linen: VCC1 . —
Measure we tage between MAD [YELIREDl LE} Wire side :f
' female te'rr'ina 5
serieer 3P connector terrnina No.
1 and Body greurid.
_, NQ Repair open in the wire between

<__ 5 there apnrex. 5 V? the ECMIPCM [C19i and the MAP
YES
ECMJPCM CONNECTOR C [31F]
Check for a short in the wire "a 5 ' .-" a e

[MhF' line]: _ "1515155120 2122
1 lure the ignition 5w tis't OH- 93,. 75 95?? 98 :19 3331
? III sconnect l-CMHJCM connecto'
(3 [313-1] t'orn 1'16- l-[ll't n'i-‘Cl'ui
MAP [REDJG RN]
3 Iii-tech: for con'. nuity between _
“1/ W re Side of fernele
I—C tutti-Hillel connector terrrlna _ terminals
(31? ans body ground

H. Is Here cenununy r «‘—
— . - fl .“"\_ Y ES
the ECMIPCM (C17) and the MAP
/
NO
Substitute a known-good ECMJ'

PCM and recheck {see page 11-3-14
for irnrnulailizer infurmation). If
51ml ptu mlindieation goes away.
replace the original ECMI'FCM.
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# _ _
CKP/TDC Sensor
I'2)

"5
11 B 36
*
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft
, . \ / i \ 4,! ;,<(
4 !;(4<*9%!#
Position (CII(P) Sensor circuit.
;>< -
'
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead
IE, /-\ 4,! ;,<(
4 !;(4<'9%!4(
Center (TDC) Sensor circuit.
;4(< -
The CKP Sensor determines timing for fuel injection and ignition of each cylinder and also detects engine speed. The TDC
4>
!7
!!
-44(
Sensor determines ignition timing at start-up (cranking) and when crank angle is abnormal.

;#
<3#
!!-
CKP SENSOR
“w r f“
{WW 43
‘94.!"
_ The MIL has been reported on. t; \i :11“

connected [see page 11 -B-1 3), .5/
code 4 andIor 8 are indicated. TDC SEN 30R
CKPITDO
SE N 50R 4 P
CON N E CTOR
Problem verification: @
1. Dctre ECMI‘PCM Reset TDCP TDCM
ProoeclLre (see page 11-8-14}.
2. Start the ergire.
CKPP CKPM
'm'n‘ll‘nl Side 01 Iran:

Icm‘n‘lals

at this time (test-drive may be
Is the full L or ard does it ir‘dicate NC necessary).
'\cc 4 ardI'cr 8? Check for poor connections or
" loose wires between the CKP!
YES TDC sensor and the ECIWPCM.
til-lock the sensor resistance:

1. 'e tl‘e igriticr switch OFF.
2. Diaocrrecttre CKPFDC ':
ser'scr4P ccrrectcr. _ SENSOR ECMIPCM WIRE
3. MeaaLre reaiatarce hem-ear SENSCR D C TERMINAL TERMINAL COLOR
termir‘ als cftre ir dicated CKP 4 3 CB 'BLU_
serscr. 11 002% $1
see table DC 3 2 .321 RED
< IS II'EFE 2010 _ 2‘51 0 Cl‘l‘i? NC Replace the CKPITDC sensor.
YES
(To page 11-8-37}

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+#
CKP/TDC Sensor (cont’d)
I'2)
/
?0
11 -B-37
"7
CKPITDC
(From page 11-8-36] SE NSOR 4P
CONNECTOR
Check the sensor for a short: TDCP TDCM

Check for cortiruity to body CKPM
greLr‘d or all tennirals
irdh‘idLally.
'see table
puni'] ’ermir‘al side of
I male tennir‘ als
<
YE
ls tl‘ere ccrtirL. ity? Replace the CKPI'IDC sensor.
NC
Check for an open in the wire ECIWPCM CONNECTOR

[CKPI‘IDC line): C(31P)
CKPP CKPM
1. Remrr‘ecttl‘e 4P corrector. (BLU) W‘I'HT}
2. Dismrr‘ect ECMJ‘PCM corremor
C [31l from the ECWPCM.
3. Measue resistarce betweer‘
ECMIPCM ocrredcr termir‘als 11 1819 ’ 22
cftre ir‘dicrated serscr. 23 2t: 28 31
LB
‘see table
W1 re side of TDCP TDCM
female termir‘ als (GRN) _a:'ohl '
[RED]
NC Rep air ope n or a hort in 1h e

lstrere 2,010 — 2,510 or P1?
in dica ted sen aor wires. ' see table
YE S
CKPP
[Bl-U}

[CKPI'IDC line):
Check for ocrtiruity betweer‘
body grcL. rd ard ECWPCM
mrrectcr termir als CB ardt'or C2D
ir' dividLally.
<
YES Repair short to body ground in
Is there osrtirLity'? the indicated sensor wires, 'see
table
NC

PCl'lll and recheck (see page 11-3-14
for immobilizer in formation). If
symptomfindication goes away.
PGM-Fl System
'+# 11 -B-38
"8
%!
/%0

IE, E] 4,! ;,<(
4 !;(4<9%!

The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 6: A problem in the Engine
Coolant Temperature (ECT) Sensor circuit.
!4 ; 4< -
The ECT sensor is temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine
4 4 ;<-4

coolant temperature increases as shown below.
! 3!3-
RESISTAN CE {it ohm]
- The NHL has been reported on.
connected [see page 11-3-13).
Problem verification: THERMSTOR .3 .. QT... ., H. mm in

1. Dothe ECM.-'PCM Reset - .# l-m w m mIW-‘J
PFGCECILFE (533 page 11-3-1 41- ENGINE COOLANT TEMPERATURE
2. ’Lrh the igr'itior' switch CN Ijll}.
NO necessary). Check for poor
Isthe MILOF ahd does it ir‘dicate [Eh-u
connections or loose wires bemeen
code 5?
the ECT sensor, the EOMIPCM
and the climate control unit
YES
(with climate control unit model}.
Check the sensor resistance:
1. Start the ehgih e. l~old the
etgite at 3.000 mm limit"1 I: ECT SENSOR 2P comuscron
with ro load Ijir park or heLtralj:
Lrtilthe radiator far comes oh.
ther let it idle.
2. 'Lrh the ighitior switch OFF.
3. Dis ooh red th e 2P cor‘r‘ectcr
from the EC' sersor.
4. l'uleaSLre resistahce betweer‘
the 2ten‘1ihals or the EC' . . "' .
sehsor ennlr‘al Side ofmaletermlr‘ als
-
NC
"\\ l3 “‘5'“? 2'30 - 4'30 CH‘TS? _}— Replace the ECT sensor.
YES
Check the ECIWPCM oumut ECT SENSOR 2P CONNECTOR
I.roltage [ECT lin e}: ECT
1. 'e' the igritior switch CN til}.
2. At the ehgire h arr ess side. RED!
meaSLre voltage betweeh the WT}
ECT sehsor 2P cor rector
Wire side of
tennir‘al No. 1 ard bodygrochd.
female tennir‘ als
| =
YES
lathere approx. 5V? f'
NC
{—0 WEE 11-3-39} [—0 page 11-8-39}

4

&A
!#!!3
9
(See Page 11-8-13)
;'!)+<
(See Page 11-8-14)
;'!)*<
PGM-FI System
'+# 11 -B-39
"9
%!
/%0

/
?0
[From page 11-8-38]
V
Check for an open in the wire [5132
line):
MEaSLI'B voltage betweer' the
EC' sersor 2P oor'r'ectortermir'als
No. '1 ard No. 2.

Is there approx. 5V? the ECMIPCM [018} and ECT
sensor.
, rom page 11 -B-38'l_
I'F YES ECT SENSOR 2P CONNECTOR
Substitute a known-good ECMI'

so:
PCM ancl recheck [see page 11 -B- [GRNIBLK]:
14 for immobilizer information}. If
Wire side of
[with climate syrmtoniindication goes away.
female termir' als
replace the original ECMI'PCM.
oortrol Lrit]
Check for Climate Control Unit

circuits: ECT SENSOR 2P CONNECTOR
1. ’e the igr‘itior‘ switch OFF. ECT (RED!
2. Disoohhect 20F corrector
from the Climate Cortrol Ur'it.
3. ’e the ighitior switch CN Ijll}.
4_ At th e er‘gir‘e harr‘ess side,
<
measue voltage betweer‘ the
Il—l' Fl
EC' ser‘ sor 2P cor‘r‘ector Wire side of
termir‘ al No. 'l ar‘d body groLr‘d. female te n‘tir‘als
YES
ls th ere approx. 5V? _"I—‘ Replace the Climate Control Unit. I
NC ECMIPCM CONNECTOR C [31 P

l—l
Check for an open in thewire [ECT

3 [5 s 7 a 9 x"
line):
',..----'"|1s17 13|19 2o2122
MeaSLre voltage betweeh ECMJ'PCM
23.. 25 [ZGZFZBI 293cm
oorr eotor termir al C26 ahd body ECT (RE DJ'WH T)
groe.
.5! "Wire side of female
I'IJ termir'als
|
<
YES Repair open in the wire between
Is there approx. 5V? the ECI'II'IIPCM (GEE) and ECT
SEHSDL
INC
Check fora short in the wire (ECT
line]:
1. 'e the ighitioh switch OFF. 16T1319
2. Disoohhect ECMIPCM correotor 2 TB
I3 (31F; from the ECMIPCM.
3. Check the CCl‘til‘t'y' betweer' ECTlREDl'WH
EClu'li'PClu'l oohhector termir'al
C26 ahd body groLr'd.
<
. . YES Repair short in the wire between
Isthere oohtlr‘uty? the ECl'i'lI'PCM [026) and ECT
SEHSDL
|Nc
PCM and recheck (see page 11-3-
14 for in'rnobiliaer information}. If
symptoniinclication goes away.
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# _ _
"$
Throttle

'

/'0
1 1 B 40
_ __ 7
$ ,
IE, /-\ 4,! ;,<(
4 !;(4<$9%!4!
The Malfunction Indicator (MIL) indicates Diagnostic Trouble Code (DTC) 7: A problem in the Throttle Position
(TP) Sensor circuit.
;4< -
The TP sensor is potentiometer. It is connected to the throttle valve shaft. As the throttle position changes, the throttle position
44-!&!&-%!
A!
sensor varies the voltage signal to the ECM/PCM.
&&!

! ,=,-
BRUSH
OUTPUT VOLTAGE w} LH OLDER
- The MIL has been reported on. _ F I 1 k,___ . ___._ _,.--BRU3H
. . "_ll
u—LNu-hm
'1 -- - fiESlSTOR
-
connected (see page11-B-13}.
code 1' is indicated.
|
|
Problem verification: _ THROTTLE
1. Do the Ecmpcm Reset OPENING . 1
ProcedLreljseepage11-3-14}. IDLE FULL INNER l T. -L
2. Start th e er‘gihe. THROTTLE BUSH
I Inten'nittent failure. system is OK t .. _'_'J

. . . : NC at this time [test-drive may be
<Isthe_l-1|L or‘ ar‘d does It Irdlcate necessary}. Check forpoor
code " ' connections or loose wires between

l YES the TP sensor and the ECMfPCM.
Ch eck the sensor output voltage:

1- ’e the igr‘itior‘ switch OFF.
2- ’e the igr‘itior‘ switch ON ill}.
3- Meaee voltage betweer‘
ECMEPCM oor‘r‘ector termirals
C18 ahd C27.
I
XIs the voltage approx. 0.5V at it. ||
H Suhstitute a known-good ECMi
CICSE throttle, ahd approx. 45V at YES POM and recheck [see page 11 -B-14
1.-' fL.|| :3 i3I er throttle? ".I— forlmmoblllzerlnformatlon).
- -' ' ' If
NC‘E: ‘h ere shoL.|d be a smooth swtorflindicafion goes away.
trahsrtloh 53 the throttle '3 replace the original EClWPCM.
'-..Idep res sed. .-
NC EClWPCM CONNECTOR C [31F]

' 3 5 6 7 B 9
- 1s 17 1a 19 202122
23 25 26 27 2 29 I30 31
TPS (RE Draw—(5G2 [GRwBLK].
Check the TP circuit:
1. _e the igritioh switch OFF.
_
2. Discorrect 3P correctcr from
the ‘P sersor.
3. _LIT the igritior switch CN ill}. TP SENSOR 3P CONNECTOR
4. At the ergire harress side.
in eaSLre voltage betweeh the was:\
_P sersorSP cohhector
tennihal No. 3 ahd body groLr'd.
I 1 2 3 tree:
NC [YELJ'BLLI]:
< Is there approx. 5V? \,
YES -H“'—J®
'INI'I: SIIJI.‘ 01
inhale lL‘I'IT‘II'Ifl-S
‘3'
(To page 11-8-41] (To page 11-8-41]
4

&A
!#!!3
9
(See Page 11-8-13)
;'!)+<
(See Page 11-8-14)
;'!)*<
PGM-Fl System
'+# _ _
"
Throttle

'

/'0
/
?0 1 1 B 41
(From page 11-13-40] [From page 11-13-40}
V
Check for an open in the wire (3G2 Cheek ff" an 9P“ i“ ““3 wire
lin e}: W062 line}:
fit the er'gire i‘arress side. ["1 8351.“? M 333W? voltage betweer ECW
voltage betweer the -p 53,15” 3p POM Opr'r'ectcrtermir‘al 028 ard
correctcrten'firalsNo. 1 ard NO. 3. bodygred.
|
< Is tl‘ere approx. 51!?
YES

the ECMIPCM (028} TP sensor.
NC

PCM and reeheek [see page 11-3-
14 for immobilizer in forma tion) It
smptomfindieation goes away,
replace the original EClWPCM.
NC Repair open in the wire beMeen

<2: Is there approx. 5 V? the ECMI‘PCM [018) and TP
sensor.
YES
EClWPCM CONNECTOR C [31 P}
a 6 8 a
_ 16 1.." 18 153 20 21 22
23 213 262:“ 28 253 3031
vccz (YEUBLUJILW
TP SENSOR 3P CONNECTOR '%)
- Wire side Offemale
5G2 / \ terlnlr‘als
[GRNIBLK]:
Check for a shortin the wire (1P5 vccz

“Ml: . .. . V [YELIBLU]
1. Hr ti‘e Igrrtlcr swvtci‘ CFF. —
2. Dismrrect 3P correctcr from Wire side Cf
ti‘e ‘p gersor. female tennir ale
3. Dismrrect ECMIPCM correctdr
1.75" 33
C(31P} from ti‘e ECMJPCM. _ , ' J J J
4. Ci‘edt for cortiruity berweer' 11 " 1b 1" 18 13 2021 2
ECl-a'li'PCl'u'i ccrrector termir‘ al 3-73 ' 25 2-" 23 2'5 3U 31
C27 ard body nLr‘d.
I @ TPS [REDIBL K}
. . YES Repair short in the wire between
< '5 The“? WWL'W? in: EOMIPOM [can and TP sensor.
NC
('6 page 11-13-42:

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+#
Throttle

'

/'0
/
?0
11 -B-42
"
(From page 11-13-41]
TP‘ SENSOR 3P CONNECTOR
ECMIPCM CONNECTOR 0131p}
3 5 E .7 8 Si
Check for an open in the wire " -"""1E|1T181Q 202122
[TPS line):
2T 28 29 30 31
Check for cor‘tir‘uity betweer‘ TPS [REDJ'
ECMIPCM cor‘r‘ecmr termir‘al C2? BLK} TPS [RED‘BLK]
or cl the ’P ser scr 3P ccr‘r‘ector
Wire side of
tenniral No. 2. "Nire side of
fem ale termir‘als
< IS li‘crc- mmlnuiy’? Replace the throttle body
NC

the ECWPCM (027) and TP
3e risor.
'+#
PGM-Fl System
"
_ _
CYP Sensor
>'
11 B 43
\ | / \ | /
5
C@: 2E: 4,! ;,<(
4 !;(4<59%!!
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder
Position (CYP) Sensor circuit.
;C< -
The CYP Sensor detects the position of No. 1 cylinder for sequential fuel injection to each cylinder. The CYP Sensor is built into
4C-!F ! !7!-4C !
the distributor.
-
PMKUP
- The NHL has been reported on. ASSEMBLY
connected [see page 11-3-13),
1. Dctl‘e ECMIPCM Reset
ProcedLre (see page 11 -B-1 4}.
2. Stature er'gir'e.

at this time (test-drive maybe
Is tl‘e MI L or arcl does it NC
. . necessary). Check for poor
connections or loose wires between
-
-
< 'Fd'cat" code 9? /
the distributor and the ECMIPCM.
YES
Check for poor ocrcliticrs at

igriticr wires:
NC
-.:_': Are ti" :5 wires C K? Correct as necessary
YES
Check the ignition wires:

Cl‘ eck ti‘ 8 Der cliticr cftl‘e igriticr
wires [see secticr 4}.
NC
< Are the wires CK? Replace the ignition wires.
YES DISTRIBUTOR 4P
CONNECTOR
. l—I
Check the sensor reslsta nce: _
2. Disocr' rect tl‘ e distribLtcr 4P
ocr'r'ectcr. CYP” C'I'PP
3. MeaSLre resistarce betweer
tf'e distribLtcr 4P ocrrectcr
terinir‘als No. 3 and No. 4. 'ermir'al Side ofl‘tale
te nnir'als
< Istf'ere 800 _1 500 chin”? NC Replace the distributor ignition

' ' housing (see section 4}.
YES
(To page 11-8-44}

4

&A
!#!!3
9
(See Page 11-8-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# _ _
CYP Sensor (cont’d)
>'
/
?0
"
11 B 44
DISTRIBUTOR
(From page11-B-43} 4P CONNECTOR
l—I
Check the sensor for a short:

Cl" ed: for oortirLityto body @w
groL. rd or the distribLtor 4P CYPP CYPM
oorrectortermirals No. 3 ard - -
No. 4 irdiu'idLally. ’erl‘tir al side of In ale
terl‘tirals
< IS trere mrtirLity’P YES Replace the distributor ignition

' housing (see section 4}.
NC
ECI'WPCM CONNECTOR C [31F]
Check for an open in the wire:

1. Recurrent tre 4P ccrrector. I18 192021 22 mp”
2. Disocrrect ECMIPCM oorredcr ’ 2a {ELK}
C- (31?: fI'Cl‘1 the ECMJ’PCM. CYPP
3. MeaSLre resistarce betweer EL
ECMIPCM correctcrten‘tirals Wire side of female W }
C29 ar d 030. termir als

NC between ECMJPCM [029} and
\ Is there 800 —1 .500 ohm? _'_'.'»— —
:YP W‘s":
epalr open In
_
the wlre
YES between ECMIPCM [030} and
CYP sensor.
Gl'leck fora short in the wire

[CYP line]: 3 b 5 8 ‘3
Ct'edt for ocrtirLity betweer 11 151-"13 192D 21 22
body grc :1 ard EClu'li'PCl'u‘l 23 25 2t 2.-' 25 253 EU 31
onrreotcr termiral C29. CYPP
l‘I'EL}
< . . YES Repair short in the wire between *
'5 ti‘ere mm“? ECMIPCM (029) and CYP sensor.
NC
POM and recheck [see page 11-3-
symptontl‘indication goes away,

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# _ _
"3
6 /0
1 1 B 45
/
_ — — 0
10
IE, /-\ 4,! ;,<(
4 !;(4<09%!#%
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 10: A problem in the Intake Air
Temperature (IAT) Sensor circuit.
4 ;%4< -
The IAT sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the air
4%4 ;<-4
temperature increases as shown below.
3!3-
- The MIL has been reported on. RESISTANCElk Ohm]
- With the SOS shortconnector 33
connected (see page 11-B-1 a},
1. Do the EcMiPCM Reset r"
ProcedL. re (see page 11-8-1 4}. THERMSTCR Q1 1 1' r .
-20 0 33 40 EU 30 10:! 131m)
2. ’e‘ the ighitioh switch ON ill}. at 12 GB 1&1 116 211 3'e
IN TAKE AIR
Inten'nittent failure, system is OK TEMPE MTU RE
<|s the MILor‘ ar‘d does it irdicene NC '1 "“5 in“ "“1““ m" be
necessary}. Check for poor
code 10? connections or loose wires between
the IAT sensor and the EClWPCM.
YES
Check the sensor resistance: IAT SENSOR 2P CONNECTOR

1. In“ the igr‘itior‘ switch OFF.
2. Discorhect 2P cor‘r‘ector from
the If? seh scr.
3. MeaSLre resistahoe betweer‘
the 2termir‘als Cl" the In—
serson
'ermi l" al side of male termir‘ al 3

NC
‘3; Is there 0.4 — 4.0 oh In? Replace the IAT sensor.
YES
Check the ECIWPCM oufilut IATSENSOR 2P CONNECTOR
voltage [IAT line):

1. ‘e the ighitioh switch CN ill}.
2. fit the Hair wire han‘ ess side.
meaSLre voltage betweeh IA—
sersor 2P correct ortennihal
No. 1 ahd body grocr‘d. Li W”? 3'09 '31
iL-n‘alu: tent‘lnals
' Y ES
Is there approx. 5V?
NC
s7
(To page11-B-46] (To page11-B-46]
4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# _ _
"5
6 /0
/
?0 1 1 B 46
(From page 11-8-45} lFrom page 11-8-45}
V
Check for an open in the wire (IAT Check for an open in the wire
line}: [5 G2 line):
l'u'leaSLre voltage betweer Exit-ll;I MeaSLre voltage betweer‘ tl‘e IA—
PCl'ui oor'r ector termir‘al C25 ard sersor 2P oorreetor tenniral No. [AT SENSOR 2"
bodygroLr‘d. 1 ard No. 2. CONNECTOR
[AT so:
[RE D'YEL} ionmem
NC Wire side of femal

- - approx. rJV.1:
lstt'ere .
tennlr‘als
YES

the ECMJPCM [c1 8} and [AT
sensor.
Substitute a known-good ECMJ

PCM and recheck [se page 11-3-14
for immobilizer information} If
symptomiindication goes away;

(I; lsttere approx. 5V? the ECMIPCM [025) and lAT
sensor.
NC
Check for a short in the wire (IAT ECWPCM CONNECTOR 0 mp}

“Mi: 3 b e a a
1. 'e ti‘e igritior switch OFF. 11 151; 1819A] 2122
2. Disoorreet ECMIPCM corrector ,, , , _ , .. , _ _
clan P] from tl‘e ECWPCM. 25 b 2b 2" 28 29*“ 51
3. Ct‘edt ti‘e oortir Lity betweer [AT (RE MEL}
ECMIPCM oorrector termir al
C25 ard body groe. Wire side of female termir‘ale
_ _ YES Repair short in the wire between

< '5 “‘EFE CGFTIFLW? the ECMIPCM (625) and [AT
sensor.
NC
POM and recheck [see page 11-3-14 ‘I‘I
for in‘rnobiliaer information). If 23
symptoml‘indication goes away,
replace the original ECIWP CM. [AT (REDWEL)

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-FI System
'+# 11 -B-47
"7
Idle Mixture Adjuster (IMA) (without
D/0/( TWC model)

1
0
:fi; ;-*
\ | / x | /

\ ,! ;,<(
4 !;(4<9%!!,/
Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 11: A problem in the Idle Mixture
Adjuster (IMA) circuit.
%7 ;,%< -
The Idle Mixture Adjuster (IMA) is selected resistance device used to control idle mixture.
4!,/ %7 ;,%<!& !!/ -
connected [see page 11 -B-1 3),
1. Do the EDMI'PCM Reset
ProoedLre (see page 11 -B-1 4'}.
2. ’e the igr'itior' switch CN Ijll '1.

<Isthe MIL or' ar'd does it ir‘dicate \ NC
necessary). Check for poor ECIIIIJ'PCM
oode11?
connections or loose wires between CONNECTOR
the IMA and the ECMIPCM. [ 31 P}
YES
Check the ECM output voltage 862 I GRNIBL K}

WOO: line}:
11 1e 1; 1B 2L1 2122
2. ’e the igritior switch CN {II}.
3. MeaSLre voltage bet'weer'
2:3 2': 2B 21' 28 2B 31
ECMIIP CM ooh redortermir‘als VCC2 (YE UBL U}
C18 arcl (328.
Substitute a known-good ECIW Wire side of female
NC PCM and recheck [see page 11-3-14 termir‘als
<2: Is there approx. 5 V? for immobilizer information). If
symptomlindication goes away;
YES replace the original ECIWPCM.
Check the ECMIPCM outputvoltage

[IMA lin e}:
M eaSL. re voita ge betweer ECIWPCM
corrector termir als £30 ar‘d C18.

YES PCM and recheck [see page 11-3-14
< Isthere approx. 0.5 —4.5 V? for immobilizer information} If
symptomlindication goes away,
NC replace the original EWJPCM.
<
YES
Is there approx. 5 V? ECIWPCM CONNECTORS
A (32?)
NC 8 53 1E] 11
1213 141th 1E1.v'18 15320 21 22 23 24
2th 25 2f 28 3E] 31 32
IMA
[GRNIRE D]:
c (311)}
:3 5 L1 .' 8 E3
11 15 1:r 181B 21
23 2t! 26 2." 28 2333
Wire side of female tennir‘als so: ioRmeLx}

W
(_o page 11-8-48} (To page 11-8-48]

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-FI System
'+# 11 -B-48
"8
D/0/( TWC model)

1
0
(cont’d)
/
?0
(From page 11-8-4?) [From page 11-13-47]
W IMA 3P CONNECTOR
Cheek for an open in the wire {5G2
line]: l123|
1. 'e' the igr'itior‘ switch OFF. vccz as:
2. Diseorrect 3P oor‘hector from
the Ilulfxser'sor. "E” [GRN
3. ’e‘ the igr'itior‘ switch CN [H j:. 5”” IBLK]:
4. MeaSLre voltage betweeh IMA Wire side
3P eor‘reotor termir‘als No. 1 of female
and No. 3. ten-air ale
< Isthere approx. 5V?

NC
YES
the ECMIPCM (c1 8} and the IMA.
Cheek for an open in the wire (IMA

line}:
MeaSLre voltage betweeh IMA 3P
Check the IMA: oohr'edortermirals No. 2 ar‘d
1. 'e the igr‘itior‘ switch OFF. No. 3.
2. Disoorr‘ed the 3P cor‘r‘eotor l NO
from the IMA.
Isthere approx. 5 V?
3. 'e the igr‘itior‘ switch CN Ijll}.
4. MeaSLre voltage betweer‘ ECM! | YES
PCM oor‘r‘ector termir‘ als A30
ard C1 8. Replace the IMA.
<
YES
NC the ECMIP CM (A30) and the IMA.
til-leek for an open in the wire
W062 line): Replace the IMA.
MeaSLre voltage betweeh IMA 3P
eorrectortermiral No. 1 ar'd
bodv g I'GLl" d.
| 1 23'
<
|
NC
IMA
[GRNI
RED)
[(91 so:
[GRNIBLK]:
YES
EClWPCM CONNECTORS A [32F]
551' 89 1U 11
the ECMIPCM [028} and the IMA.
12131415 161.-'1815320 2122 ZS 24
2b .26 2." 28 30 31 32
IMA (GRNIRED)
vccz
[YELJ‘BLLI]: "1:51:1819 202122
23 2b 26 22' 28 253 30 31
('o page 11-13-49] Wm: Slim: :31 terrale tenhlnals so: [GRNJ‘BLK]:
PGM-Fl System
'+# _ _
"9
D/0/( TWC model)

1
0 11 B 49
(cont’d)
/
?0
From a 31143-48" E CMJPGM CON N EGTOR

( p Q J A (32F)
‘Jfif 8531B
Check for: short in the wire 1213 141:: 1E1.-'18 19 20 212.2 23
"MA line]: 2:. 25 2; 25 EU 31 32
1. ’e tl‘e igritior switch ICFF.
2. Dismrrect ECMIPCM IMA
mrrecterfx (32?: from tl‘e ECLM;l @ [GRNIRED]
PCM. _
3. Check for ocrtirLity betweer _
ECMIPCM ocrr edcr termir‘ al
ABE] ar (1 body groe.
< | tr t' 't YES Repair short in the wire between

5 are a" W 3’? the ECMIPCM (A30) and the IMA.
NC
Substitute : known-good ECIW

PCM and recheck [see page 11-3-14
smtem‘indication goes away,

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# 11 -B-50
"3$
Barometric Pressure (BARO) Sensor
"
'/"0
_‘ ' 1'3 :
:3 +
IE, /-\ 4,! ;,<(
4 !;(4<+9%!
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 13: A problem in the
Barometric Pressure (BARO) Sensor.
) ;)%18<-
4)%18 ! ,=,-
The BARO Sensor is built into the ECM/PCM.
connected (see page 11 3-13}.
1, Do the ECM i‘ PCM Reset
PrcoedL. re (see page '1'1-B-1 4}.
2. ’Lrh the ighiticr‘ switch CN {II}.
Isthe MIL or the ahd does it NC lnten'nittent failure, system is OK

irdicate code 13? at this time [test-drive may be
< necessary).
YES

Pm! and recheck [see page 11-3-14
for immobilizer information} If
symptomfindication goes away.

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# "3
-
-
Vehicle
4 Speed Sensor (VSS) (MIT)

/40/20 1 1 B 51
_‘ ' :3 $
1'7
IE, /-\ 4,! ;,<(
4 !;(4<$9%!:!
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the Vehicle
Sensor (VSS) circuit.
;:< -
The VSS generates a pulsing signal when the front wheels turn.
4:
!

!33! -
- The l'li'llL has been reported on.
connected [see page 11-3-13).
code 1? is indicated.
|
1. Do the ECM Reset Procedure
(see page 11 43-14}.
2. Test-driu'etrar'smissior‘ ir‘
reLtral. accelerate to 4,000 rpm
lmir-1 1:. th er' clecelerate to
1.5EIEI rpm Ijmir-1j: with throttle
lly dosed for at least 5
seoorcls
I lnten-nittent failure, system is OK

Is the lullL oh ahcl does it ir‘dicate NC atthis time. Check for poor
oode1'r'? connections or loose wires bemeen
the V88, the ECM.
YES
Ch eck the ECM input voltage: ‘I’A’T‘RNING

1. IN the ighitioh switch CFF. Make sure lifts, jacks ar'd safety
2. Block rearwheels ard setthe star‘ds are placed properly [see
parkihg brake. sack L.p the froht sectior' 1}.
ofthe car ahcl sport with
ECM CONNECTORS
safety star ds. B [2 SP)
3. 'Lrh the ighitioh switch Ctll}.
013w)
4. Block the right from wheel ar‘d 2 3 4 "
slowly rotate lelt fror‘t wheel IU .. I 2 I 3 I
EL'I
-
ard measue voltage betweer‘ — 2C 2‘ 22 23 24 23
' dd 2H 2.“ EB 29 3U Ll‘
ECl'ul cohhector tennir‘al [320 L61 [BRNJ'BLK] 23 -'
ard c123. V S lBLl-IJ‘WHT}
Lg}
"Mre side of female termir' als
Substitute a known-good ECMJ

PCM and recheck [see page11-B-14
Does voltage lse W ard approx. YES
for immobilizer information}. If
5V? symptomlindieation goes away,
replace the original EClWPCM.
NC
(To page 11-8-52}

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# 11 -B-52
"3
Vehicle
4 Speed Sensor (VSS) (M/T) (cont’d)

/40/20/
?0
(From page 11-8-51]

ECM CON N ECTORS
B [25F]
1 2 3.15 S
“-1
S 1U 11 121314 161T1S
Check the circuit was line): 20 2122 232425
LG1 [anmauq c (3“,)
2. Disoor‘r‘ect ECM ooh hector C
1:31P] from the ECM. SST
3. In“ the igr‘itior‘ switch CN ill}. 11 1E 17 1819 21 22
4. Block the right fror‘twheel ard 25 2627'28 30 31
slowly rotate left froht wheel
arcl measure voltage betweer'
—.f3':1—| vss (BLUJ'WH T}
ECM cor‘r‘ector termir‘als B20
Wire side of fem ale terl‘tir‘als
ard 023.
_ Repair short in the wire
hetwe en the ECM (023).
NC _ Repair open in the wire
Does voltage pulse 0 V ahd approg'f‘e"
5 V?
USS.
YES _ lfwire is OK, test the VSS (see
section 23}.

and recheck (see page11-B-14
for immobilizer information). If

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# 11 -B-53
"3
Knock Sensor
I
6
_‘ ' :3 +
2'3
IE, /-\ 4,! ;,<(
4 !;(4<+9%!>#
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 23: A problem in the Knock
Sensor (KS) circuit.
;>< -
A knock control system was adopted which sets the ideal ignition timing for the octane number of the gasoline used.
%##!33!

! -
— The MIL has been reported on. PIEZO

— With the SOS short connector CERAMC
connected (see page11-B-13},
DIAPHRAGM
ProblemVerifica tion
1. Do the ECM/PCM Reset
ProoedL. re (see page 11-8-1 4}.
2. Start the er‘gir‘e. l-oldthe
ehgihe at 3.000 rpm imir‘-'l j:
with ho load Ijir‘ Park or heLtralj:
Lhtil the radiator far com es or,
theh let it idle.
3. hold er‘gir‘e at 3.000 - 4.000
rpm Ijmir‘-'| j: for 10 secor‘ ds N—
ih orEl positior‘. Mi" ir'
heLtral.
lntem‘littent failure, system is OK

Is the MIL or‘ ar‘d does it
nece ssaryr}. Check for poor
ihdicate code 23?
connections or loose wires
YES between the KS and the ECMIPCM.
Check to a a shortin the wire [KS

line}: ECMIPCM CONNECTOR C [31F]
1. ‘e the igritior switch OFF.
2. Discorrect the KS cohr‘ector.
3. Discorrect the ECMJ‘PCM cor—
KS [REDIBLU}
rector C i31P]. a s
s 6 x
4. Chedc for oortihuity bet'we er'
16 1x 18 19 20 21 Z:
ECMIPCM oohhector termir‘ al
I33 ahd body nLF‘d.
"2:3 26 2; 28 29 30 31
"Mre side of female termir'als
< Is there OGHiPty? YES Repair short in the wire between

ECWPCM (CS) and KS.
NC
KNOCK SENSOR 1P
CONNECTOR
Check for an open in the wire Wire side of female
[KS line):
KS tennir' als
Check for COPIiFLit'y' bet'weer'
(REDIBLU)
ECMIPCM cohhector termir‘ al 03 KS
ar'd the KS 1P cohhector termir'al [REDIBLW
No.1. X”, 3 b 5 I a El
11 15 1 .' 1a 19 20 21 22
(To page 11 43-54] 23 2b 25 2! 25 29 30 31
4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
PGM-FI System
'+# 11 -B-54
"3
Knock Sensor (cont’d)
I
6
/
?0
(From page 11-8433]

< Is there CGl‘tlr‘t'y'?
ECMIPCM (03) and Ks.
YES
Check the KS:

1. SLbS‘tltLte a khcmvh-gocd KS.
2. Start the ehgihe. holdthe
er gihe at 3000 rpm hair -'I j:
with he load Ijir' Park or FELIFQI}
L.rtil the radiator far‘ Domes or,
ther let it idle.
3. hold er‘gir‘e at 3,000 — 4,000
rpm I‘l‘tih-‘l ': for '10 semr‘ds N'
ir or E] positior‘, Mf'ir'
rearal.
Is the MIL or ahd does it >£ Replace the KS.

ir clicate code 23?
YES


4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# _ _
"33
Heated Oxygen Sensor (H028) Heater (with 1
.#!
/.0./( TWO 1 1 B 55
model)

0
_‘ ' ”.3 *
4'1
/
IE] /-\ 4,! ;,<(

4 !;(4<*9%!
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 41: A problem in the Primary
Heated Oxygen Sensor (PHOZS) Heater circuit.
68/
;68<6 -
_‘ 6'5 ,
1:
IE, /-\ 4,! ;,<(
4 !;(4<9%!
Secondary Oxygen Sensor (SHOZS) Heater circuit (A/T model).
8/
;68<6 ;%=4!<-
— The NHL has been on.
connected [see page 11 -B-1 3),
code 41 , andIor 65 are indicated.
1. Dctl‘e ECM.-'PCM Reset
ProcedLre (see page 11 -B-1 4'}.
2. Stantl‘e er'gir' e.

< Istl‘e MILor‘ ar'd does it ir‘dicate\. NC at “"5 time. Check f" FD”
d 41 51-? connections or loose wires between
on e or J the Primary H028, Secondary
YES H023 and the ECIWPOM.

H025: PRIMARY H028 SECONDARY
1. 'e‘tl‘eigriticr switch CFF. 4’” CONNECTOR H0254? CONNECTOR'
2. Disocrrecttre FCES (Primary 4:0 .—|
or Seccrdary'j: 4P ocrredcr. 1 2 1 2
3. At ti“ e l-*C2S side. meascre I61 3 4 pH 02q TC I61 . SHOE TC
reSIstarce betweer tl‘e I~C2S 3 4
4P ccrrectcr tennir als No. 3 LF—e.
ard NC. 4. .-"-_. :EII'II'E'
iohli‘j ' '
'ermir‘al side of male 'en‘tir‘al side of female

tennir‘als termir‘als
Is there approx. 3.3 cl‘m at NC Replace the H025 [Primary or

20°C {68°F}. Secondary) (see page 11-3-60).
YES
Greek for ccrtirLity betweer body '51 PHOZSHTC I61 3 4 SHOIHTC

grc'd ar' d tl‘e I-C2S 4P ccrrectcr L g
termir‘ als No. 3 ard No. 4
ir' diu'idLally. I
'53l.".‘I I ‘
if) @ fl
< Is tl‘ere ccrtirLity? YES Replace the H028 [Primary or

Secondary) (see page 11-3-60}.
NC
(To page 11-8-56}

“. code 55

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
(See Page 11-8-60)
;'!)0<
PGM-FI System
'+# 11 -B-56
"35
.#!
/.0./( TWC
model) (cont’d)

0/
?0
(From page 11-8-55}
PRIMARY HOES PRIMARY H023

Check for an open or shortin the 4P CONNECTOR 4P CONNECTOR
wires (PHOESHTC, SH OZHTC‘ I61 1—. PHOESHTC
line): [Butt 1 2 [BLIU SH 02 SH Tc I61
1. 'e Ire igritior switol‘ CN ill}. YEL}
3 4
WH'D (BLKJWH r) [BL KJ'YE L]:
2. Meaee voltage betweer‘ the
#028 4P correotor termirals
No. 3 ard No.4.
Wire side of female Wire side of 1‘1 ale

termir‘als termirals
< ls tt' ere battery voltage?

YES
I61
(ELK!
1
.
2 I61
NC [BL KJ'YEL}
YEL) 5 4
Check for an open in the wires [’o page 11-8-5l
[IG1 line):
Measure voltage betweer‘ body
grocl ar‘d tt‘e l~C2S 4P oor‘r‘eotor
termir al No. 3 Ijseoor‘ Clary:
No. 4}.
Rep air op en in the wire between

NC H025 and No. 8 ECU (ECMIPCM)
if ls tl‘ ere t: attery v oltag e? CRUISE CONTROL (15 A) fuse in
the driver's under-dash fuse!
YES relay box.
ECMIPCM CON N ECTORS

Check for an open in the wires P61 {ELK} a (25 P)
[PHOZSHTQ SHOZSH TC‘ line):
l l
1. ‘e tl‘e igritior switd‘ OFF. 2 a 4 I.' 'd
g ,0 ,, 1-3 '4..--"'u .Iud
E.‘
2. Reoorrect tl‘e l~C2S correotor.

3 Disoorrect tl‘e ECMJ‘PCM EU 2' 22 23 24 23'
correotorfx 1:32P]. PHOZHTC SH oznrc
4. 'e tl‘e igritior switd‘ CN ill}. I..-‘~..I(BLKNVHD iawnn
5. M easue voltage betweer é!
ECMIPCM corrector termirals
BE arcl E120 1:82 al‘d.t‘18]'. C: Li. B Ei ‘U
‘2'3'4'3'6'."H‘9 EU 2. 22 23 24
as as 3.
2: 28 :30 L12
Wire side of female termir‘als
< lstl‘ere 0.1V or less?

/’
ECI‘III'PCM [A20, A8’) and H028.
NC

14 for immobilizer information}. If
synmtomfindication goes away.
“. Ell—C Efi
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# 11 -B-57
"37
.#!
/.0./( TWC
model) (cont’d)

0/
?0
(From page 11-8-56}
ECMIPCM CONNECTOR A [32F]

PH 02H Tc SHOEH Tc
Check for a short in the wires [BLKJ'WHU
[PHOESHTQ SHOESHTC’ line):
1. —LIT tl‘e igritior switd‘ ICFF.
2. Discer‘r‘eet tl‘e ECMIPCM 55.!
cerrecterfujflP}. [5.1.731 121 1

I
15161.:181
3. Check forcortirLity betweer 2E 28
body groe ard ECMIPCM
corrector termir al A 20 (A8} '. — Wire side of female termir‘als T

< ls tl‘ere oortirLity? YES
ECMIPCM (1120,1181 and H025.
NC

PCM and recheck [see page 11-3-
14 for in‘rnobiliaer information). If
sympton‘n'indication goes away,
': [II—C Efi
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
PGM-Fl System
'+# _ _
"38
Secondary Heated Oxygen Sensor (H028) Heater

#.#!
/.0. 1 1 B 58
(with 1
F20
/( TWC model: A/T)
+
, . \ / l : 4,! ;,<(
4 !;(4<+9%!
Secondary Heated Oxygen Sensor (Secondary H028) circuit.
68/
;68< -
- With the SOS shortconnector
connected (see page 11-B-1 a},
code 63 (Secondary our ygen
sensor) is indicated.
1. Do the PCM Reset ProoedLre
(see page 11 -B-1 4].
2. Start the er‘gire. l-oldtl‘e ergir‘e
at 3,000 rpm lmir'1 j: 'witl‘ ro load
lir‘ Pads or r‘eL.tralj: L.rti| tl‘e
radiator far‘ oomes or. tf‘er‘ let
it idle for at least ore mir'me
before test-dn'virg.

< Doestl‘eMlLblir‘kard X: No atthistirne. Cheokforpoor
does 't ‘rd'cate code 63? connections or loose wires between
I I I the Secondary H028 and the
YES POM
Check the fLel pressure:

lrsped fLel pressure [see page
11-A-101 1.
No Go topage11-B-66 Fuel Supply

Is it r‘ormal ? System.
YES
PCM CONNECTOR
Check the PCM input voltage: A (32")
1. Start tl‘e ergir e. l~old tl‘ e t: 6 8 9 1U 11
ergireat3.000 rpm |:l"lll‘"1} 1213 1411-116 1.-'18153 20 2122 23 24
witl‘ ro load lir Park or reLtral} 2t: "6 2', 28 . 3U 31 32 33
Lrtiltre radiator far comes or, '
trer let it idle for at least ore V :33?
mirLte before test—dri'u'irg. .: — j
2. Measue voltage betweer‘ F’CM 5'32
oorrectortennirals .l‘x 23 C (31") lGRNIBLK}
ard 018. 3 {3 r5 5 g
3. Cper tl‘etl‘rottlewide oper‘ 11 ' 15 1', 18 19 2D 21 2:
tier qLickly release it. 23 '25 " 35 2". 28 29 3D 31
“All re side of female termir'als
lstl‘evoltage aboveDfiVat EUPHVJ‘EikNMN-QOOCIPCM

wide oper tl‘rottle to 4.500 rpm YES and recheck [see Page 11-B-14
(flip -1} ard below 0.4 V wl‘er‘ for in‘rnobiliaer information). If
He tl‘rottle is qLicltly released SWPW'WiNPiHiON 9°“ 3W“.
from 4.500 rpm (Hip-1]? replace the original POM.
NO
(To page 1143-59]

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
;'!%0<
(See Page 11-B-66)
;'!)<
PGM-Fl System
'+#
Secondary Heated Oxygen Sensor (H028) Heater

#.#!
/.0.
11 -B-59
"39
(with 1
F20/
?0
/( TWC model: A/T) (cont’d)
(From page 11-8-58}
SECONDARY
Ch eek the Secon da ry H 023:
H025 4P CONNECTOR
1. ’e the ighitioh switch OFF. ""0
2. Disoor‘r‘ect the 4P bohredor
from the Seoohdary H328. 3H0 562
3. At the Seoor‘dary l-C2S harress
side. oor‘r‘ ect the battery positive
tennihal to termihal No. 3 ar‘ d
battery hegat'we termir‘al to
tennihal No. 4.
Start the ehgihe. IGI S H 025 HTC
I'd"?
Alter two mir‘ LIBS. m easr. re

voltage betweer‘ Secor‘dar'y if] [I]
h'C2S 4P oor‘r‘edor teri‘tir‘als
No. 'l ar‘d No. 2. BATTERY
'en‘tir‘al side of female termir‘als
Is the voltage above 0.6 V at ".l

wide opeh throttle to 4.500 rpm
NC Replace the SeeondaryHOZS [see
[Mir—1} ahd below 0.4 V 'wher' I"
pap e, 11 3-60}.
theth rottle is quickly released
from 4.500 rpm lmir"1 l?
YES

POM [1123) and the Secondary
HEIRS.
4

&A
!#!!3
9
(See Page 11-8-60)
;'!)0<
.#!

Replacement

11 -B-60
"5$
1.
(68*A&
H028.
68-
p rimary HOZS:
' #.F
fl: $EN5DH
WRENCH
Snap-on
PHlMAR‘I' H025 VA 3315 or
14 ”-111 {4.5 Raf-m, 33 lbf-ftl equivalent
H023 4P CONNECTOR
S econdary HOZS:

#.F
SECONDARY H025
44 ”rm “.5 lint-m.
33 mm: H025 4P CONNECTOR
0: SENSOR WRENCH
Snap-on VA 8875 Or
muivnlnnt
2.
- !!68&&!-
Install the H028 in reverse order of removal.

#
Idle Control System
System Troubleshooting
#
* Guide

!
11-B-61
"5
NOTE:
84 9
Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should be
%3A ! # !
inspected, starting with (1). Find
A
3;<- the symptom in the left column, read across to the most likely source, then refer to the
!! A!#! A
page listed at the top of that column. If inspection shows the system is OK, try the next system (2) etc.

!! -38>A/;<-
If the idle speed is out of specification and the Malfunction Indicator Lamp (MIL) does not blink Diagnostic Trouble Code
! ,! ;,<!#(
4 !
(DTC) 14, go to inspection (See Page 11-8-61).
;(4<*A
;'!)<-
PAGF SLB-S‘I’Slthl PIfiiIU‘uE Fl AU i-L'IMA'IC

A H | HDSFF‘I
IU'LI: All-i 'dHA H; STARTEF' TRANS-11m F
CCNIEIITICJN "LTEPNATOH : ANC-
IICINTRDL IN” PH E'u'r'ITE'I E'a‘a' TCll BEAR
U II-L'JNNEL'.
'.'.|1L '.'l.-‘ FIE Nell-L SIGNAL” 5K?NA| ’05 T": H
:zlu NI‘I-L " TIONS
3 Lil“ -'-IL "
SYMPTOM 11 5-63 1145.85 'l'I-PrBE '1 I-n-s-z Iii-EUIIZII'I 1d
DIF F ICU LT TC! START

E NGI NI: WH tN CU LB
{WHEN IICILEI FAST lDLE OUT

art!
."_"\
UF SPtC l LED: - 2,500 mm

I'HII'I ‘l'l
'5’)
ROUGH lfllE
WHEN WARP-l tNUINE SPEED

III—I“-
FD-CJ HIGH
1|dle 5mmd is balmv

if?
spat-find rprn Inn

._.
I,—
Injadl
Idle speed does not

:1.
Increase afiar I"- Itxal '

_‘
f—
start up.
Cln mndclr: win

M|
autmr-utiu Hummus
(fl.
|\_2
'I‘II'HEh
son. the Mir: speed
twin M arc-I35 In gear
H PM ___————~—————————fl
10:: Law "1“ 5mm ”"0“
I'\M_J l
whnn air Ins-1c.—

"fl
tiunnr in ON
:lIJlu strand drops

M.‘
/ "a.
when Steaming
whnnl -s turning
ILlII: 5pm fluctu-

,
all
a?)
ate: with nlncll'um

\
l/
WHILE 'I‘I‘AHMING
FFlF UF'
DUENT
SIN-LNG AFTER WARMING
up
FAILS EMISSION rtST
*1: m
'2: except MI'T with cut TWC model

4

&A
!#!!3
9
(See Page 11-8-63)
;'!)+<
See Page 11-A-86)
;'!%'<
,—\
See Page 11-A-88)

;'!%''<
,—\
See Page 11-A-90)

;'!%50<
,—\
See Page 11-A-92)

;'!%5<
,—\
Idle Control System

# 11 -B-62
"5
System Description
#)
4!
!!!%!;%<:!&-4&!&

into the intake manifold in response to electric current controlled by the ECM/PCM. When the IAC Valve is activated, the valve
#!! !! ,=,-2%:!&&A&!&
opens to maintain the proper idle speed.
!-
From
< PGM-FI
! MAIN
5cm vnnlous
:tfi’ . . . POM \\ \
ssnsons
1.
- After the engine starts, the IAC valve opens for a certain time. The amount of air is increased to raise the idle speed about
%
A%&!&-4 !
150-300 rpm (min-1).
0+00;<-
2.
2! !3A%&!&!-4
!!!
! -
3.
+- When the idle speed is out of specification and the Malfunction Indicator Lamp (MIL) does not indicate Diagnostic Trouble
2! ,! ;,<(
4 !
Code (DTC) 14, check the following items:
;(4<*A#!!3
9
0 Air conditioning signal (See Page 11-A—86)
%

!;'!%'<
ALT FR
%4 signal (See Page 11-A—88)
1
!;'!%''<
999999
Brake switch signal (See Page 11-A 90)

)#3
!;'!%50<
Start switch signal (See Page 11-A—91)
3
!;'!%5<
A/T gear position signal (see section 14)
%=4

!;*<
PSP switch signal (See Page 11-A—92)
3
!;'!%5<
Hoses and connections
6
0 IAC valve and its mounting O-rings
%&!&
8

4.
*- If the above items are normal (and the MIL does not indicate DTC 14) after IAC valve replacement, substitute a
&!;,(4*<%&!&!A
known-good ECM/PCM and recheck. lf symptom goes away, replace the original ECM/PCM.
#3
,=,#-
3A!
! ,=,-
Idle Control System

# _ _
"5

/04- 11 B 63
_‘ ' 1'4 :
:3 *
IE, /-\ 4,! ;,<(
4 !;(4<*9%!!%
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 14: A problem in the Idle Air
Control (IAC) Valve circuit.
!;%<:!& -
The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM/PCM in
4%:!&

!
! ,=,
order to maintain the proper idle speed.
!-

— With the 505 short connector From AIR
connected (see page11-B-13}, CLEAN ER
‘ToINTAKE
Problem verifica tion: I ..___E MNIFOLD
ProoedLre (see page 11 43-1 4}.
2. Start the ergire

lstl‘eMlLor ard doesit NC atthistime,Check forpoor
ir'dicate code 1 4? connections or loose wires between
YES the IAC value and ECIWPW.

"GP line): —
1. ’e tl‘e igr‘itior‘ switd" OFF. | 1 2 :3 |
2. Discor'r'ecttf'e IAC 'u'al'u'e 3P IGP (YEUBLKJJW
corrector.
3. ’e tl‘e igriticr switch CN ill}. E“.
‘J
4. At the wire ramess. measure
voltage betweer‘ IAC 'u'aiv'e 3P -
corrector termir‘al NO 2 ar‘ d "All re side of female termir‘als
body groLr‘d.

«;jf ls tl" e re b attery 'v‘ olt age ?1T;_L the [AC I.ralire and PGM-Fl main
YES relay.

[PG line): — _
1. ‘e tl‘e igritior switd‘ CFF. PG I 1 2 J I
2. fxttl‘e wire ran‘ess. check for (BLKJA
cortirLity betweer IAC 'v'alu'e
3P oorrector termiral No. 1 film
ard body grocrd.
Repair open in the wires between

- -. NC
< 'Stfere CCFWW? \ EcmrPcm and G101 (located at
YE S the th en'nos tat housing).
Check for a short in the wire ECWPCM CONNECTOR B ‘25P}

[IACV line): , . .
1. Disoorrecttl‘e ECWPCM 1 2 3 A: b _ ', a
oorrector B 1:25P]. 9 10 11 121314 1e1.- 1a
2. Cl‘edt for cortircity betweer' 2U 21 22 23 24 23
body groe ard ECWPCM [AW [BLIUBLUé:j
oor' r' ector termi ral B 23.

(To page 11-8-64]
4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
(See Page 11-B-14)
;'!)*<
Idle Control System

# _ _
"5

/04-/
?0 11 B 64
(From page 11-3-63}
I __ I. -.._YES R. palrs
- h Dnll‘l
<
| “1
3 EFECGF'FL'W 'm CW":
‘brw
E ten
thelACUalveand ECIWPCM [323}
no
[AC VALVE 3P CONNECTOR
[MW]: IAOV [BLKJBLM
Cl‘eok for oortirLity betweer‘ IAC ECIWPCM CONNECTOR B [25F]
val-re 3P oorreotor termir‘al No. 3 - .- _,
arcl ECMIPCl-al oorr ector termir‘ al 1 2 3 '1 5 ’ 3
B23. 9 10 11 121314 161T18
20 21 22 23 24 25
[AW [BLKJBLm |
Wire side of female termir‘a S

ls ti“ ere cortir‘uity‘?
the IAC valve and ECWPG‘H [I323].
YES
Check the [AC valve:

1. Reoorreottl‘e IACvah/e 3P corrector. 1 2 3 4 5
m m
"-.l "-.l
2. ‘e tl‘e igritior switch CN Ifll}. 9 10 11 121314 161
_L
3. MeaSLre voltage betweer body grourd
U1
ar'd ECMfF-‘CM oorrectortenniral B23. 20 2122 23 2'1 2
mcv [BLIUBLU]:
'5 “'3“? approx. “2 battery “1L Replace the IAC valve.

voltage?
YES
Substitute a known-good ECWPCM

and recheck [see page11-B-14 for
immobilizer in formation). Its ympton'i
indication goes away, replace the
original ECIW POM.

#
Idle Control System

11 -B-65
"53
NOTE:
84 9 4.
*- Idle the engine for one minute with heater switch at
!
33
9 Leave the IAG valve connected.
&%.&!&- HI and air conditioner on, then check the idle
6A#!
9 Before inspect the idle speed, check these items:
)!A#9 speed.
-
4,- Idle speed should be:
- Ignition timing

KG, KE. K5, KFI modal:
- Spark plugs
#!

- Air cleaner
%! Mfr 750 : 50 rpm [min ‘I
- PCV system
: 730 : 50 rpm [min ‘I
l"[
- - A IinWI orlfl position}
TACHDMETER
KY model:
TACH CIMETER
CONN ECTDR
M-‘T i 750 L 50 rpm ir‘riiri ‘II
750 -' 50 rpm [min ‘i
WT
(in -E or El position)
Nb-fE: If the idle speed in not within specification Refer
84 9!31
to Symptom Chart (See Page 11-8-61).
;'!)<-
j' 5:1,
2.

-6!
+A000;<
with no load (M/T: in park or neutral) until the radiator
3!;,=49# !< !
fan comes on, then let it idle.
A!!-
3.
+- Check the idle speed with no-Ioad conditions:
#!3!9
headlights, blower fan, rear defogger, radiator fan, and
!
A!3A
AA

-
ldlo spud should he:
KG, ICE. KS. KR modal:
NW 750 t 50 rpm (midi)

NT 730 L 50 rpm (min ‘)
{in [E or IE] position)
KY modal:
M-‘T 3'50 i 50 rpm Imin ‘I

MT 750 _i 50 rpm (min ‘I
lin IE or [g] positionl
Idle Control System

# 11 _B-66
"55
#
* Guide

!
NOTE: Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should
84 9%3A ! # !
be inspected starting with (1). Find

!! A!#! A

listed at the top of that column. If inspection shows the system is OK, try the next most likely system (2), etc.
!! -38>A/!#!;<A-
PAGE LSUB-SYETEM FUEL I [_UtL FUEL FUEL FUEL PI: l'.'l-Fl l column."-
M A IN , HATED
""PH.“ ss . [NJFCTQR PnEssunE
_ Hum-1 Pump
“--—.._ FIELULATDR RELAY , FUEL
-'
.'
'
J
J _ _ ___ . _
—i-
SVWTDM
—._ .
—““-—- __
—J
11 A 95 11-3-6!
___
11am ‘ll-A-HJS i'l-A 105 914-111 i —
I . .. __
FNGII‘LE wow-r sum @I :3: (1) ; ®

DIFFIEULT TCI STAR'I'
ENIGINE WHEN CCILEI CIR HDT I31) ®
RU UGH IDLE I (T) I
MISFIHE OH I ‘
HUUGH I' 1:"
RUNNING
_
POUR PEFIFUFI- FAILS
EMISSION (in I
MAN'CE - \— ' ' i
TEST
L055 0F rm,
POWER 3 I '-.__2,1
WAH MING '5‘] ..I I

FRED LIE m 'J P
STALLIhG 3.5.5}?—
WAR MING . I
UF -
4

&A
!#!!3
9
;'!%5<
(See Page 11-8-67)
;'!)$<
;'!%0*<
;'!%0<
;'!%0<
;'!%<
+##
Fuel Supply System
Fuel Injectors
+D

11-B-67
"57
Description
)
Testing
!
The fuel injectors are a solenoid-actuated constant stroke,
4 !7! #A NOTE: Check the following items before testing: idle
84 9#!!3

9!
pintle-type consisting of a solenoid, plunger needle valve and
!
!A!
!&!& speed, ignition timing and idle 00%.
A

!8W-
housing. When current is applied to the solenoid coil, the

-2 !!!A If the
engine runs:
! F
valve lifts up and pressurized fuel is injected. Because the
&!&! H !7-) 1. 2
!
A !7
- With the engine idling, disconnect each fuel inject
needle valve lift and the fuel pressure are constant, the
!&!&! ! A connector individually and inspect the change in
& !!

injection quantity is determined by the length of time that the
7F !
the idle speed.
!-
valve is open (that is the duration the current is supplied to
&!&; ! ¢ If the idle speed drop is almost the same for
!!
the solenoid coil). The fuel injector is sealed by an O-ring and
!!<-4 !7!8
each cylinder, the fuel injectors are normal.
!A !7!-
seal ring at the top and bottom. These seals also reduce
!
-4!! ¢ If the idle speed or quality remains the same
!F !
operating noise.

- when you disconnect a particular fuel injector
3 ! !7
FILTEFI replace the fuel injector and retest.
! !7-
Check the clicking sound of each fuel injector
- #!#
!7
PLUNGER HOUSING means of a stethoscope when the engine is idling.
3
!
-
SOLENOID ODIL
¢ If any fuel injector fails to make the typical

!7!#!
clicking sound, check the sound again after
!#
A#

FLU NGEH replacing the fuel injector.
!
!7-
¢ If clicking sound is still absent, check the
!#
!!A#
FUEL RAIL following.
!!3
-
0 Whether there is any short-circuiting, wire
2
A3
O-RING
breakage or poor connection in the
#

YEL/BLK wire between the PGM-Fl
C =)>33., main
relay and junction connector.
!7 -
0 Whether the junction connector is open
27
or corroded.
-
INTAKE 0 Whether there is any short-circuiting, wire
2
A3
MhNIFOID breakage or poor connection in the
#

YEL/BLK wire between the junction
C =)>337
connector and the fuel injector.
!7-
CUSHION 0 Whether there is any short-circuiting, wire
2
A3
RING breakage or poor connection in the wire
#
3
between the fuel injector and the
3 !7
ECM/PCM.
,=,-
If all is OK, check the ECM/PCM (See
!!8>A# ,=,;
Page11-B-26) and PGM-Fl!;
'!)<., main relay (See
Page11-A—111).
'!%<-
D-HING
Fuel Supply System
+## 11 _B_68
"58
+D
/
?0
If the
engine cannot be started:
!
*F
1.
- Remove the connector of the fuel injector, and measure
1& !7A
the resistance between the 2 terminals of the, fuel
3!A !
injector.
7-
Resistance should
be: 10-20 ohms

*F$$

FUEL
INJECTOR
0 If the resistance is not as specified, replace the fuel
A! !
injector.
7-
0 If the resistance is as specified, check the fuel
A# !
pressure (See Page 11-A—101).
;'!%0<-
- If the fuel pressure is as specified, check the
! A#
following:
!!3
9
¢ Whether there is any short-circuiting, wire
2
A3
breakage or poor connection in the YEL/BLK
#
C =)>
wire between the PGM-Fl!
33., main relay and the
junction connector.
7 -
¢ Whether the junction connector is open or
27
corroded.
-
2
A3
breakage, or poor connection in the YEL/BLK
#
AC =)>
wire between the junction connector and the
337
fuel injector.
!7-
2
A3
breakage or poor connection in the wire
#
3
between the fuel injector and the ECM/PCM.
3 !7 ,=,-
If all is OK, check the EGM/PCM (See Page
!!8>A# .,=,;'!
11-8-26).
)<-
Fuel Su | S stem
+## 11_B_69
"59
+D
/
?0
Replacement

A WARNING
(#3!3#
!->!#33#-
1!& ! ;'!%00<-
9.00.”?
- Disconnect the connectors from the fuel injectors, EGR valve (and EVAP purge control solenoid valve*).
( !7A .1&!&; :%
!!&!&G<-
+- Disconnect the vacuum hose from the EVAP purge control solenoid valve*.
(& :%
!!&!&G-
*- Disconnect the vacuum hoses and fuel return hose from the fuel pressure regulator.
(& ! !
!-
84 9!
3!&
-
- Disconnect the fuel hose from the fuel rail.
( ! !!-
$0.00.“.O’9‘
- Remove the retainer nuts from the fuel rail and harness holder.
1& !!!-
$- Disconnect the PCV valve.
(:&!&-
'- Disconnect the fuel rail.
( !!-
5- Remove the fuel injectors from the intake manifold.
1& !7#!-
': With TWC model
HARNESS
HOLDER
12 N‘m
. -. EGR VALUE ”-2 kgf-m.
.- FUEL 8.7 Ibf-f‘l)
RAIL
EVAP
PURGE
CONTROL
SOLENOID
VALVE
FUEL
PU LSATIDN
P'fl‘lllr VALVE
DAMPER
22 film
12.2 kgf—m.
16 Ibl-ftl
WASHER
Replace.
FUEL
PRESSURE
REGULATOR
{/- OAHING
Replace.
SEAL (II-RING
RING
Replace. I
CUSHION “99'3“-
RING
FUEL Replace.
INJECTOR
10.
0- Slide new cushion rings onto the fuel injectors.
!3
!7-
11.
- Coat new O-rings with clean engine oil, and put them on the fuel injectors.
38
3!
!A !7-
12.
- Insert the fuel injectors into the fuel rail first.
!7 !!-
13.
+- Coat new seal rings with clean engine oil, and press them into the intake manifold.
3!
3!
!A#!-
Fuel Su | S stem
+## _ _
+D
/
?0
"7$
11 B 70
14. 4&

8
A!! !7 !!A!!#!-
*- To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in the intake manifold.
FUEL
RAIL
i ‘3 \
FUEL
INJECTOR
INTAKE
MANIFOLD
15.
!!
-
16.
- Connect the fuel hose to the fuel rail with new washers.
! !!333-
17.
$- Connect the vacuum hoses and fuel return hose to the fuel pressure regulator.
& ! !
!-
18.
'- Connect the vacuum hose to the EVAP purge control solenoid valve*.
& :%
!!&!&G-
19.
5- Install the connectors on the fuel injectors, EGR valve and EVAP purge control solenoid valve*.
!! !7A .1&!& :%
!!&!&G-
20.
0- Connect the PCV valve
:&!&
21.
- Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately two seconds, the
4
38;<A -% ! /!3A
! !!-13A#3 !!#
-
*: with TWC model
G9342!
Intake Air System
6 # _ _
"7
#
* Guide

! 11 B 71
84 9%3A ! # !

!! A!#! A

listed at the top of that column. If inspection shows the system is OK, try the next system (2), etc.
!! -38>A/;<A-
| PAGE [SUB-SYSTEM
- . AIR
. m. ANDCLEANER
INTAKE THROTTLE THROTTLE INTAKE ma
_ - ._E BYPASS
“H AIR DUCT CABLE - BODY CONTROL
SYMPTOM 11-A-119 '11~A‘12o ' 11—8-12 11-A-125

'w
WHEN COLD FAST IDLE OUT
[H]
OF SPEC
WH E N WAR M | D LE 3 PE E D ‘ IQ. ill-T

TO U H | G H - -__J .___
LOSS OF POWER ['22: r" [3' Kit

4

&A
!#!!3
9
;'!%5<
;'!%0<
(See Page 11-8-72)
;'!)$<
;'!%<
Intake Air System
6 # 11 -B-72
"7
Throttle
Body

"
#
Description
)
3.
+- Allow the engine to idle, and check that the gauge
%!!3
!A#

4!
!!-4!3 indicates no vacuum.
& -
!&!&
! If there is vacuum, check the throttle cable (See
& A#!!;
the cylinder head. The Evaporative Emission (EVAP) Control
!-4 && ; :%<! Page 11-A—120).
'!%0<-
Canister port is located on the top of the throttle body.
!!- 4.
*- Check that vacuum is indicated on the gauge when
#&

3
THHI‘JTTLE the throttle is opened slightly from idle.
!!
!!-
msmow If the gauge indicates no vacuum, check the

& A#
lTPl
SENSOR throttle body port. If the throttle body port is
!-!
clogged, clean it with carburettor cleaner.
!
A!3 !-

5.
- Stop the engine, and check that the throttle cable

A#!!
operates smoothly without binding or sticking.
!3
#
-
If there are any abnormalities in the above steps,
!&A
check for.
#-
¢ Excessive wear or play in the throttle valve
/&3!!&!&
shaft.
-
¢ Sticky or binding throttle at full close position.
#
! !!!-
¢ Clearance between throttle stop screw and
!3!3
throttle link at the fully closed position
!!# !!!
There should be
THROTTLE
VALVE
THROTTLE
STOP
SCREW
[Do not ad|ust.l
Inspection

1.

-6!
+A000;<
3!;# !< !
A!!-
VACUUM
PUMFIGAUGE
THROTTLE STOP SCREW

[Do not adjust.)
Replace the throttle body if there is excessive play in
1!!/&!
!&!&

sticking.
#
-
2.
- Disconnect the vacuum hose (to the EVAP control
(& ; :%!
canister) from the top of the throttle body, connect a
<!A
vacuum gauge to the throttle body.
&

!-
Intake Air System
6 # _ _
Throttle
Body (cont’d)

"
#/
?0
"7
11 B 73

-
Removal
GASKET
Replace.
TP SENSOR
MAP SENSDR
22N-m
‘22 kgf-m,
15 Ib‘H‘H
THHD'I'I'LE
CRUISE CONTROL
CABLE
NOTE:
84 9
(7 !3-
¢ After reassembly, adjust the cruise control cable (see section 4), the throttle cable (See Page 11-A—120).
%!A7 !!;*<A!!;'!%0<-
¢ The TP sensor is not removable.
44&!-
Disassembly
) *#
2.1 N-m
[0.21 kgf-m. 1.5lb1-m
gg %/ EENSDR
Troubleshooting
pa ge 1 1-3-33
TP
SENSOR
Troubleshooting
pa ge ’I’I—B-lfl

4

&A
!#!!3
9
(See Page 11-8-33)
;'!)++<
;'!%*0<
%

#
System Troubleshoo
#
* ting Guide

! "7
11 'B'74
NOTE: Across each row in the chart, the sub-system that could be sources of a symptom are ranked in the order they should
84 9%3A ! # !

3;<- the symptom in the left column, read across the most likely source, then refer to the page
!! A!#! A

!! -38>A/;<A-
PAGE SUEi‘SYSTEM POSITIVE

THREE WAY EXHAUST GAS CRANKCASE EVAPORATWE
CATALYTIC RECIHCULATION - EMISSION
CONVERTER“ SYSTEM” VEQJ'SfiTnlqON . CONTROLS
SYMPTOM 1 1-335 11—B-T6 1 1-A-143 11-13-30
ROUGH IDLE (13' "'2'\_
FHEflUENT I AFTER WARMING . 1-,l .

STALLING UP L2 I
- FAILS EMISSION -- i
I TEST ®
POOR
PERFORMANCE i ___ ___ _ ___ __ __._.. . _________
5 LOSS OF
POWER
'1: with TWC model

4

&A
!#!!3
9
(See Page 11-8-75)
;'!)$<
(See Page 11-8-76)
;'!)$<
;'!%*+<
(See Page 11-8-80)
;'!)'0<
%

#
System Description
#)
11 -B-75
"73 Three
Way Catalytic Converter
1##
-
(TWC) (with 1
0
/10/( TWC model)
The emission control system includes a Three-Way Catalytic

4!! 42! Description
)

Converter (TWC)*1, Exhaust Gas Recirculation (EGR)*1,
&;42<GA / .1 !; .1<GA The Three Way Catalytic Converter (TWC) is used to
442!&;42<
Positive Crankcase Ventilation (PCV) system and
&#:!;:< convert hydrocarbons (HC), carbon monoxide (CO),
&;6<A/;8<A
Evaporative Emission (EVAP) Control system.
&& ; :%<!- and oxides of nitrogen (NOx) in the exhaust gas, to
/
;8/</
A
*1: with TWC model
G9342! carbon dioxide (COz,
/;8 dinitrogen (N2)
A
; and water vapour.
<3& -
Tailpipe Emission
%
Removal/Installation (see section 9)

-2
/
90
Inspection

SECONDARY
A WARNING
HEATED
OXYGEN SENSOR
Do not smoke during this procedure. Keep open flame or
(#
->! [SECONDARY H025:
-;A.‘Ti
sparks away from the work area.
#33#-
1.
- HQUSiNG
2.

-6!
+A000;<
3!;# !< !
A!!-
3.
+- Check the idle speed (See Page 11-8-65).
#!;'!)<-
4.
*- Warm up and calibrate the CO meter according to the
2 !8

meter manufacturer's instructions.
@ -
5.
- Check idle CO with the headlights heater blower, rear
#!83!
!3A I. .
33
A!
A- F Fit 3 N 1 OF ,_- -:j’_'_'_'-,
'5" E H 1C L E _ . '-
Specified CO:
F
For cars with 1
F$@S
+
( TWC model: 0.1% maximum
For cars without
+
( TWC model: 1.0 i 1.0%

1
F@$O@$S
0 If unable to obtain this reading:
!
9
Without TWC model, adjust by turning the adjusting
2 42!A7
7
1
screw of the IMA.

3,%- THHFE W'A 'r‘
CATALYEYS
With TWC model, see ECM/PCM troubleshooting
242!A ,=, !

guide (See Page 11-8-26).

;'!)<- Inspection

ADJUSTING |f excessive exhaust system back-pressure is
/&/ #
suspected, remove the TWC from the vehicle.
A&42&!-
Using a flashlight, make a visual check for plugging,
?
!!
A#& !#!

A
melting or cracking of the catalyst.
!
#
!-
Replace the TWC if any of the visible area is damaged
1!42&!

or plugged.
!
-
- If unable to obtain a CO reading of specified %

!8
W
by this procedure, check the engine tune-up
A#

condition.
-
FLASHLIGHT
%

# 11 _B_76
"75
Exhaust
% Gas Recirculation (EGR) System (with 1

/%0#/( TWC
model)

0

IE] /-\ 4,! ;,<(
4 !;(4<9%! /
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 12: A problem in the Exhaust
.1 !; .1<-
The EGR system is designed to reduce oxides of nitrogen emissions (NOX) by recirculating exhaust gas through the EGR
4 .1
/
;8/< !
/

.1
valve and the intake manifold into the combustion chambers. It is composed of the EGR valve, ECM/PCM and various sensors.
&!&#! - .1&!&A ,=,& -
The EGR valve lift sensor detects the amount of EGR valve lift and sends the information to the ECM/PCM. The ECM/PCM
4 .1&!&! .1&!&! ,=,-4 ,=,
then compares it with the ideal EGR valve lift, which is determined, by signals sent from the other sensors. If there is any
3! .1&!&!A3A
!-
difference between the two, the ECM/PCM reduces current to the EGR valve to reduce EGR valve.
33A ,=, .1&!& .1&!&-
WHTJ'
sen VALVE
LlFl' semen V
__ rm
aLu
__ .T‘
_
J
GENE EGMIPCM VARIOUS
‘auc — x __ smsons
L,—
INTAKE
MANIFOLD
%

# 11 -B-77
"77
Exhaust

/%0#/( TWC
model) (cont’d)

0/
?0
— The ML has been reported

en.
— Wi'fl'r the acts sherteenneetbr
ebnneeted lsee paue11-B-13).
nude 12 is indicated.
Preblem verifieation:
1, DI: the ECM‘P CM Reset
Pmceccre rjsee page 1143-14].
2 Correctthe SCS service check
cer'r' ecter rjsee page 1143-13].
3. Test-criue r‘ecessary: Start
ergir‘e. Hclc the ergire at
3,030 rpm (mic-1 j: with re
Icac rjir Park or r‘ectrdj: Ll‘lll
the raciatorfa‘ comes or.
ther let it icle. Driue the vehicle
or the rcac for approx. 10
mirLtes. Try to keep the
ergire speec ir‘ the 1.?00 -
2,500 rpm (mic-1:: rar‘g e.

Does the MIL blir'k' arc :tthistime. Cheek for peer
. cues it ir cicate cope 12’? connections or lease wires bet-wan
the EGR valve and EGlIrlfPCM.
YES
EGR VALVE SP CONNECTOR
L
Cheek the ECMPCM oumut SGZ vccz
voltage WCCE line]: (GRNIBLK) l‘fELIBLU}
1. Te the igr‘itior‘ switch OFF.
1 2
2 Disccrrectthe EGR valve 6P
currector.
3. Te the igr‘itior‘ switch ON
[ll]. .r v.
4. At the ha'r‘ess sice. me ascre
"Alire side of female termir‘ als
udtage betweer the EGR
vam- EF' correctortenhir‘ds
ND. 2 are No. 3
Cheek for an open in 'll'rewire
NO (362 line]:
< Is there app rcrx'. 5V? 15'— Me 26L. re voltage betweer' the
EGR value 6P ctrr'ecturtermir‘al vcc
YES N0. 3ar'c busy grams. [YELJ‘BLU]:
YES
NO
Repa‘r open in thewire between
the EGR valve and the ECMFCM
H.118].
(TI: page 11 -B-T ': [Te pa e 11 -El-i-'El]

4

&A
!#!!3
9
(See Page 11-B-13)
;'!)+<
%

# 11 _B_78
"78
Exhaust

/%0#/( TWC
model) (cont’d)

0/
?0

(Fra‘r page 11-El-TT] [Frorr' page 11-El-TT] VCC2
— ELIBLLI
1 2 3 W }
4.x”e
Check for an open in the wire . . I .
WCC2 line}: ‘Nre SIdE offemaleterlnlr‘ale
k2,!
, ’Lrnthei I'itilzn switch OFF.
5;
12 Disccnnegt the ECMI‘FCM ECIWPCM CONNECTOR c [31 HI:
col'nector I3 [31 F]. /- - - H 9
('‘-
to:
3 Check for COl'lil'ILli‘t‘y between ..
I:
ECM-‘P CM conl'uectortennina 2 2; 2:5 25 an 3'
2:3
I:
028 and the EGR vab'e 6P
con'lectortermil'al No. 3. \(IYiEfBLU)
NO Wire side of female tennir‘als

Is there COl'ltiIIIi‘t'y?
YES
Repa‘r open in the wire between
the EGR valve and the ECM’PCM
{C28}.
[EGRL line):
1, ’e the igr‘itior‘ switch OFF. EGRL
Substitute : known-good ECM
2, Disoorrecttl‘e ECMIPCM (WHTJBLK)1 -—
oorr ector C 1:31P]. POM md reoheok {see page 11 -B-
3. Check for oor‘tir‘uity betweer' 14]. for immobilizer information].
ECMIPCM oor‘r‘edor termir‘al It symptomiindiolion goes
CE ard the EGR valve 6P away. replaoethe original ECM
oorr edor termir‘al No. 1 . POM.
Repir open in the wire between

{12:- Is tl" ere oor‘tir‘mty? No the EGR valve and the ECMPCM
{CS}
YES
EGRL
Cheek fora short in the wire
flNHUBLK) -—
[EGRL line): r 123
Greek for cortirpity betweer the
EGR valve 6P oorrectcrtermir‘al [Er 6:1 4 5
No. 1 ard body gourd.
YES Repa'r short in the wire between

<1 Is there oortiruity? 51"»— 1he EGR valve and the ECMPCM
NC
{CE-l

{GNU line}.
Check fcr continuity betweentre
EGR valve 6P oomectortern‘inal PG1
No. 5 and body ground. [ELK]
Repair op en in the wire between

Is there oortirLity?
the EGR Hive and the G101.
('0 page 11-3-79]

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
%

#
Exhaust

/%0#/( TWC
11 -B-79
"79
model) (cont’d)

0/
?0

E-EGR 1 2 3
lPNKi 4 5
(Frcm page11-B-i'8';
Wire side of female termir‘ ale
Cheek l'er :1 open in thewire (re-a

U
iE-EGR line]: E-EGR
1. Disecrrectthe EClu‘liF‘CM ECMIPCM CONNECTOR B {ESP} lPNK}
eor‘r‘ eetor B {ESP}. 12 345 B
2 Cheekfcr cor'tirLity betweer‘ 9 10 11 121314 161T18
EClLI'lI'P Clul cor rectortermir‘d
20 21 22 23 2:1 25
B? are the EGRualue 6P
eorr ectortenniral N0. 4. Wire side of female termir‘als
Repair open in th ewire between

Is there cortir Lil‘y? the EGRvdve rid the ECMPCM
(37].
E-EGR
Cheek fer a short in thewire [PNKJ
iE -EGR line].
Ch eel: fcr eortir Lil‘y betw ear the
EGR value 6P ewreetortermir‘al
No. stare hoe,- grmre.
'Il—i 3., _.
1-r-.
Repair short in thewire between
YES
lsth ere ecrleity? the EGRvdve an d the ECMPCM
(37].
NO
Cited: the EGR Hive: EGR VALVE EP CONNECTOR
‘ . Recerlnectthe ECM"PCM
cennecterB {ESP} and C (3‘ P]. 123
2. Cdnnectthe battery positive
tenninalte EGRualue 6P
46
eennecterterminal he. 4.
3. Start the engine and letit idle. E-EGR PG1
then ednneetthe battery negative
tenninalto EIC-Rualue 5P
emneetterminal he. 6.
‘ermir‘al side of male ten'tir'ale
Isthe engine stall or n.In rough? Replace the EGR v alve.
YES
Bu hetitute a kn mm geed ECIW

F'Cl'lil and reeheek lsee page 11 -B-
14 l'er immobilizer information].
If swptemfindeatim gees
away. replaeethe erigin al ECIW
F'CI'lIl.
4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
%

# 11 _B_80
"8$
%-
-%
/%4'0

Description
)

The evaporative emission controls are designed to minimize the amount Of fuel vapor escaping to
4&&!
H !&

the atmosphere. The system consists Of the following components:
-4!!3
9
A
Evaporative Emission (EVAP) Control Canister
%-
-%
/%4'0

An EVAP control canister is used for the temporary storage Of fuel vapor until the fuel vapor can be purged from the EVAP
% :%!
!& ! !&
:%
control canister into the engine and burned.
!
-
B
" Vapor Purge Control System
4
'!

#
:%!

!3

:%!
the throttle body. The purging vacuum is controlled by the EVAP purge control diaphragm valve and the EVAP purge
!-4

& !! :%
!
&!& :%

control solenoid valve (with TWC model).
!!&!&;342!<-
EVAP PURGE CONTROL DIAPHRAGM VALVE OPEN AFTER STARTING ENGINE
EVAP PURGE CONTROL SOLENOID VALVE OFF
I ENGINE COOLANT TEMPERATURE ABOVE BET 1149"F]
C
Fuel Tank Vapor Control System
+64

#
When fuel vapor pressure in the fuel tank is higher than the set value Of the EVAP two way valve, the valve opens and
2 !& !#
&! :%33&!&A&!&
regulates the flow Of fuel vapor to the EVAP control canister.

!!3 !& :%!-
With 1
F
1 TWC model:
From No.5 ECU

._..__.. __4 IECMIP'CMl
CHUlSE CONTHGL
FUEL 115 A} FUSE
TANK -
EVAPVALVE mn-m4;___
EVAP ”* |
PURGE
CONTROL
smLNOpNHT‘HL
VALVE ' =33 ‘1 ECMJ’
VARIOUS
SENSORS
PCM
_m FUELTQNEH
CONTROL _ BLK
CANmTER T EVAP
PUFIGE
FRESH AIR CGHTHUL
DIAPHRAGM
VALUE
%

# 11 _B_81
"8
%-
-%
/%4'0

/
?0
1
1
F
Without TWC model:
EVAF'
TWO WAY
VALVE
FUEL TANK
FUEL FILL CAP l‘ EUAP VALVE
FUEL TANK _ :i
EVAP CONTROL "'_—. — ___..'
CANI$TEH
EVAP PURGE
T comnm
FRESH nun DIAPHRAGM
VALVE
%

# 11 -B-82
"8
%-
-%
/%4'0

/
?0
Troubleshooting

* (with 1
0

!/( TWC model)

EVAF"
PU RGE CON TRCIL
DIAPH RAG-M Wt LVE
In sp ection ovaporative
Emission Controls
Check the vacuumwhen cold: VACUUM

1. Biseorreettl'e vac. um rose PU l'lFJCAUCE
from tl'e EVAP purge oortrol
carister ard correct a vao..um
EVAF‘ PURGE CONTROL
gauge to tl'e rose. SCLENClD
2. Start tre ergire ard allow it VALVE 2P CCN HECTOR
to idle.
Check the EVAP purge control PCS
NC’E: Ergire ooolart
valve:
temperature must be below
1. ’urr tre igritior switol‘ ICFF.
55°C {149%}. 2. Disoor‘rect tre 2P oorrector
from the EVAP purge oortrol
<
YES
Is tr ere vao. um? sol er ol d valve.
3. Stan tre er gire.
4. At tre rarress side, measure
NC voltage betweer tre EVAP Wire side of female
purge oortrol soleroid valve termir als
2P oorreaortenniral No.1
ard No. 2.
I YES
Is the re battery voltage?
7
Inspect vacuum hose routing.
IfOK, replace EVAP purge
NC _..--J:L._ |G1
1 "'v. :a LKI't'EL}
[IG1 line):
fxttl‘e l‘an‘ ess side. measure voltage
betweer tre EVAP purge oortrol
soleroid valve 2P oor rector
termiral No. 2 ard body grou rd.

EVAP purge control solenoid
< lstr ere batteryvoltage?
valve and the No. 6 ECU lECl'lflI
I YES PCM} CRUISE CONTROL 115 A]:
fuse.
(PCS line):
1. _urr tre igritior switd‘ OFF.
E crwvcm CONNECTORS
0 (MP)
2. Recorrect tre 2P oorreotor PCS
to tre EVAP purge oortrol lRE D}
soleroid valve.
3. _urr tre igritior switd‘ CN [H].
4. Measure voltage betweer
ECMIPCM correotortennirals
E
C22 ar cl B2. 3 [25F]
{-
W 2
'u
2 4
.. .2 3
r.
'r
H
E ‘H
(_o page 11-8-83} (_o page 11-8-83] 2c 2‘ 22 2' 2 '
%

#
%-
-%
/%4'0

/
?0
11 -B-83
"8
(From page 11-8-82] [From page 11-8-82}
Is there batteryvolta ge?

Check the vacuum when hot
1. Start the er‘gihe. i-old the YES Repair open in the wire between
ergir‘e at 3,000 rpm [VHF-1}
valve and the ECMIPCM [022}.
with r'o load Ijih Park or l‘ELtl’al}
L.r'ti| the radiator fah
Domes or‘. theh let it idle. Substitute a known -good ECIW EVAP PURGE CONTROL
Check for vao..L.m at the PCM and retest tsee page 11 5-14 SOLENOID
sacrum hose after startihg for immobilizer informaion]. If VALVE 2P CONNECTOR
th e er' gir e. symptomiindioation goes away.
replabetne original ECMPCM.
Check the EUAP purge control

:—\£ Is there vaCLLm?
solenoid valve:
Bisoor'r'eot the 2P oohrector from
the ege oohtrol solehoid valve.
YES Wire side offemale
YES terminals
lnspeetvacuum hose routing.

IfOK, replace the EVAP purge
NC
[PCS line}:
1. 'e' 1he igr'itior switch OFF.
2. Discor'r'eel ECMI'PCM
oohr'edor C {Sip}.
3. Check for oohtirLity betweer‘
the EVAP ege oohtrol
soler'o'd valve 2P cohrector
ten'hir'al No. 1 ahd body groLr‘d
Is there oohtirLity?

Cheek the EVAP control canister:
1. Reeorrect the vaCLLm hose
NC valve and the EClWPCM [622}.
to the EWxP ege cohtrol
earister.
Remove fLel fill Gap.
PCM and recheck [see page
Corr eat a vacuum gauge to
11-3-14 for immobilizer
earister ege air hose.
in formation}. lfsmtoni
Start the ergihe ahd raise
indication goes away, VACUUMPR ESSU RE
speed to 3.500 rpm imir"1 i.
replace the original ECIWPCM. GAUGE. 0-100 mmHg t0-4in.Hg]
D035 WELL” appear '3'" Elm-DEW Replace the EVAP control oanisw. I
withir 1 mirLte?
YES
See EVAP two way valve test to

complete. (4:. J _..-F '-~-.. .
PURGE
Evaporative enission controls
are OK.
AIR HOSE

4

&A
!#!!3
9
(See Page 11-B-14)
;'!)*<
%

#
%-
-%
/%4'0

/
?0
11-3-84
"8
Testing (without
!/( TWC model)

1
0 6.
- Raise engine speed to 3,500 rpm (min-1) Vacuum
1
+A00;<:
1. 1& !!!-
- Remove the fuel fill cap. should appear on gauge within 1 minute.
!

3 -
2.
!!3!-
- Start the engine and allow it to idle. ¢ If vacuum appears on the gauge in 1 minute,
&

A
3. (& :%
!
+- Disconnect vacuum hose at the EVAP purge control remove gauge, test is complete.
&

A!-
diaphragm valve (on the EVAP control canister) and

&!&; :%!< ¢ If no vacuum, disconnect vacuum gauge and
& A&

connect a vacuum gauge to the hose.
&

- reinstall fuel fill cap.
!! !!!-
EVAP 7.
$- Remove EVAP control canister and check for signs
1& :%!#

PURGE CONTROL of damage or defects.

-
DIAPHRAGM VALVE
¢ If defective, replace EVAP control canister.
&A! :%!-
8.
'- Stop engine. Disconnect upper vacuum hose from

-( &
EVAP purge control diaphragm valve. Connect a
:%
!
&!&-
vacuum pump to lower vacuum as shown, and
& !3& 3A
apply vacuum.
!& -
Vacuum should
4 remain steady

#
" VACUUM PU MPIGAUGE
0 If there is no vacuum, check vacuum hose for

& A#&
blockage, cracks or disconnected hose, as well as
!#
A#A3!!
vacuum port for blockage.
& !#
-
4.
*- Disconnect the vacuum gauge and reconnect the hose.
(&

-
5.
- Connect a vacuum gauge to EVAP control canister
&

:%!
purge air hose.

- VACUUM PUMPIGAUGE
VACUUMIPHESSUHE ¢ If vacuum drops, replace the EVAP control
& A! :%!
GAUGE. O - 100 mra [l1 — 4 in.Hgi canister and retest.
-
9.
5- Restart engine. Reconnect upper vacuum hose
1
-1 &
EVAP purge control diaphragm valve. Vacuum
:%
!
&!&-:
(lower vacuum hose side) should drop 1 zero.
;!3& < !H-
¢ If vacuum does not drop to zero, replace the
& HA!
EVAP control canister and retest.
:%!-
PURGE AIR
HOSE
Diagrams
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1- Tool Number
4! | Description
( |
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07PAZ - 0010100
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|
|
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0$*000*000 | Fuel Pressure Gauge Set
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|
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Component Locations

&

11 _C_3

Index
MANIFOLD ABSOLUTE
PRESSURE IMAF'I SENSOR
T' I ' - -
'“b “MOW“ page 11 C 2'3 IDLE AIR CONTROL IIAC] VALVE
Troubleshooting. page 11-043
THROTTLE POSITION [TP] SENSOR
TI'OLIDICSI‘IOOIII‘IQ, Dfiflfi 11-C-35 EVAPORATIVE EMISSION
lEVAPl PURGE CONTROL
INTAKE AIR TEMPERATURE IIATI SENSOR SOLENOID VALVE
Troubleshooting, page 1142-38 Troubleshooting. page 1143-31
CRANKSHAFI' POSITION
1II'EHIIILE SPEED SENSOR
ICKP} SENSOR
WSSI TrOu bieshooling.
page 11-C-31
ENGINE COOLANT TEMPERATURE HEATED OXYGEN SENSOR POWER STEERING PRESSURE

IECTI SENSOR IHDZS] (P5P) SWITCH
Troubleshooting. page 1‘I-C-33 Troubleshooting. page 11-13-25 Troubleshooting. page 11-055
Replacement. page 11-12-45

4

&A!#!!3
9
(See Page 11-0-28)
;'!'<
(See Page 11-0-35)
;'!+<
(See Page 11-0-38)
;'!+'<
(See Page 11-C-40)
;'!*0<
(See Page 11-0-33)
;'!++<
(See Page 11-C-48)
;'!*'<
(See Page 11-0-81)
;'!'<
(See Page 11-0-31)
;'!+<
(See Page 11-0-55)
;'!<
(See Page 11-0-26)
;'!<
(See Page 11-C-45)
;'!*<

&

Component Locations

Index (cont’d)
/
?0 1 1 -C -4
THRDTI'LE CABLE THRGTI'LE EDDY FI'BI

Inspection.-'Adjustr'r1cnt, page it-C-Td Inspection. page H-C-TB
ln5lallation. page 1143-74 Disassemblv. page II-C-TG
." __ _ "'5
AIR CLEANEHMCLI . -- - - - -
Replacement. ‘ '
page11—A-119
RESONATOR
PGSITIVE CRANKCAS-E VENTiLATIDN IPCW VALVE
Inspection. page 11-079

4

&A!#!!3
9
( See Page 11-C-74)
;'!$*<
;'!%5<
(See Page 11-0-75)
;'!$<
(See Page 11-0-76)
;'!$<
(See Page 11-0-79)
;'!$5<
Component Locations

&

11 _C_5
3
Index (cont’d)
/
?0
LHD:
&.)F
INERTIA SWITCH
ENGINE coNTRoL MODULE lEc
Descriptiol'l. page 11-C-Fji‘
Removal. page I] C 13 PGM-FI MAIN RELAY
Troubleshooting Procedure-5. page ‘I‘I-C-ll Helen,I testing, page ‘1 1 (3-68
Troubleshooting, page ll-C-21 Iroubleshootil‘ng.pagfi11-C-69
SERVICE CHECK CONNECTOR DATA LINK

Self-diagnostic Procedures. page 11-C—13 CONNECTOR IDLE:
(EPJ
RHD:
.)F
ENGINE CONTROL MODULE IECMJ
Henwval. page 11-013 INERTIA SWITCH
Troubleshoot-fig Procedures, page 11-C-‘I'I Description. page ‘I‘I-C-ST
Trouhleshnotmg, page ‘l‘l-C-ZI
PGM-Fl MAIN RELAY

DATA LINK SERVICE CHECK CONNECTOR Halal,lle51:rlg,.uugo'|'| C 53
CGNNECTDR IDLC) Self-diagnostic Procedures, page 11 E 13
IEPI

4

&A!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-11)
;'!<
(See Page 11-0-21)
;'!<
(See Page 11-0-13)
;'!+<
(See Page 11-0-68)
;'!'<
(See Page 11-0-69)
;'!5<
(See Page 11-0-67)
;'!$<
Component Locations

&

11 _C_6
5
Index (cont’d)
/
?0
LHD:
&.)F
FUEL PUMP
Heplacement.page11-A-1fl5
FUEL
FIP. TANK
lacement, [am-2 ILA-115
FUEL_ GAUGE SENDING UNIT
p F “ Tcstmg, page 11—A-1US
FUE L FEED PIPE
FUEL VAPOR PIPE‘ FUEL FILL CAP
EUAPflRATWE EMISSION (EVAPI

CONTROL CANISTEFI
FUEL TUBEIDUICK‘CCIN NECT

FITTINGS
Precautions. page ILA-‘3!
Disconnection, page “ILA-93'
Connection, page ILA-QB
FUEL FILTER
FUEL INJECTORS Replacement, page ILA-105
Testing. page 11-063
Replacement. page TLC-641 EVAPORATIVE EMISSION IEVAPI
TWO WA‘I’ VALVE
FUEL RAIL Testing. page 11-A-143
FUEL PRESSURE REGULATOR
Testing, page 11-066 FUEL RETURN ”PE
Replacement. nape 11-C-E7
RHD:
.)F
HJI:L IJLJH'F’
l-UI:L IANK lee-.Ing. page "-e-‘Ub
Replaceelent cage ll-Fn-l‘: Replacement ' :é ll-F-IL'E
HJI:L UAUUI: SENDING UNI'I
leszmg. page ' ' ._;-..' :JB
I'UI:L H:I:D F'II‘I:
HJI:L VAI'URI’IF’I: HJI:L HLLCFl-F I
tUflI’URflIWI: EMISSIUN ItVAI’] COX 1 RDL

ERNIE [EH
l'pe p eahee'. "g. page I‘ —2_'.-‘r_H
l-Ul:L rUBtluUIUK-UONNECI
l-IrllNLis
i- rant 2-12. page ‘ ' -'
Ipn. page "
Lprlrleitlpn. page] I-e-ga
I-UI:L I-ILIER
Replaieetent figs “-3- IE;-
HJI:L INJtUIUHS
Te51|ng. page 1142-63
Replacement. 'lI-C-fid tVflI'URflIIVI: EMISSIUN ItVflI']
. . _ I‘Il'I'U Il'I'flY VALVE:
HJI:L PRESSURE: HEDULIUDR [E's-1mg. page . . -F-.-' .15
HJI:L RAIL lestlng. page " «36
'a'eplacewlent 2 _
I'UI:L Ht] URN I'IF'I':

4

&A!#!!3
9

;'!%0< (See Page 11-0-81)
;'!'<
;'!%0'< (See Page 11-0-63)
;'!+<
;'!%< (See Page 11-0-64)
;'!*<
;'!%0< (See Page 11-066)
;'!<
;'!%*'< (See Page 11-0-67)
;'!$<
(See Page 11-A-97)
;'!%5$<
(See Page 11-A-98)
;'!%5'<
System Description
#)
11 -C-7
7
Vacuum Connections
4

EVAPORATWE
EMI$$IDN
{EVAN
CONTROL
CANISTEH .:—._-a
To EVAPORATIVE EMISSION LEVAF‘]

TWO WAY VALVE
MANIFOLD
ABSOLUTE
PRESSURE
[MAN SENSOR
EMISSION
[E‘U'AF‘I'
PURSE CONTROL
SOLE NOID VALVE
'I
FUEL
PRESSU HE
REG ULATDR
FRONT OF
VEHICLE
#)

System Description
8
11 _C_8
4

/
?0
r3. .
(E:
Heated oxygen sensor (H028)

6/
;68< 13
+ Air cleaner
%!
COOONQO‘I-PLON—‘I

,!! ;,%< 14
* Resonator
1
+ Engine coolant temperature (ECT) sensor

! ; 4< 15
Positive crankcase ventilation (PCV) valve
&#&!;:<&!&
* Intake air temperature (IAT) sensor
# ;%4< 16
43!&
#;>< 17
$ Evaporative emission (EVAP) control canister
&&; :%<!
!!;%<&!& 18
' Evaporative emission (EVAP) purge control solenoid valve
&&; :%<
!!&!&
$ Throttle body (TB)
4!;4)< 19
5 Evaporative emission (EVAP) two way valve
&&; :%<33&!&
' Fuel injector
!7 20
0 Fuel tank evaporative emission (EVAP) valve
!#&&; :%<&!&
5 Fuel filter
!!
10
0 Fuel pressure regulator
!
!
11
Fuel pump (FP)
! ; <
12
Fuel tank
!#
#)

System Description
9
%

_. '
x].- E
FUELINJECTDFIE 1H.” 2 K .‘II

3' BATTER! '*—f—'17"’5'5"9' k3).
I—GE- utP
_~r:: sermon
ILTF r'
K, n lawman
' can.
E
F»-'Tju_1"—:.—m.’_ ‘
EVA? WHBE cnmnnL ‘
SOLENOID VALVE
"7 l E . iii—5:3 -C- EEFI'I'IGE

lillL ' _ ____ .5. CHECK
i conmcmrt
I?
Fuses:
9
Battery (100) *A
);00<G%
LOOOVCDOW-PCDNA

6;+0%<G%
+ IG main (50A) *A
.;0%<G%
* AGCS (15A) *A
%.;%<G%
! ;%<G)
?; ,=,< !;%<G)
5)# !
!
;$-%<G)
+
!;$-%<G)
5 No 6 H-ECU (ECM) VBU (7.5A) *0
6 ?; ,<:)?;$-%<G
10 )# A%;*0%<G%
0 Back up, ACC (40A) *A
11 +!## ;$-%<G
No 13 Clock back up(7.5A) *C
*A: in the under-hood fuse/relay box
G%9 =!/
*8: in the driver’s under-dash fuse/relay box
G)9&B =!/
*0: in the passenger’s under-dash fuse/relay box
G9
B =!/
#)

System Description
$
%

/
?0
NAP
BENSON
_ _.*!°?§."'_‘F_.-
_nJ.
.l
THROTTLE
POSTDON
SENSOR
«53—. . _ __
BRAKE sun—iron
_.'_ . BRAKE LIGHT IIT

SENSOR
TACHOME‘I’EH EC'I'
CONNECTOR SENSOR
_. U—T: PSPSW ."1

PSF SW‘TCH
.1"—
"--.l A C E
comnnesson CONDENSER BADMTOH
CLUTCH FAN
RELAY RELAY
'9‘} FiNC
TD .
IMMOBJLIZER -'
STD
UNIT
-" RADIATOR
C: FINSWITCH
CDNDENSE HADMTORE
FAN FAN
MOTOR .~. MOTOR
IMOLMP I?)
a A cs_
IMHOEIUZEH E i
.-‘
INDICATOR
LIGHT NC
PRESSURE
SWITCH
AN:
5W1TCH
_|_i_
/ J55 /f i.» Len-i .- 51

ECM CONNECTOR TERMINAL LOCATIONS
la: 79 75 71/175 «fr: :2 #1 ff'laa "-/rx"]59 saL/
\
I55 “2” 52i sol 43 as. £43 42 fl£53736
_3 ’34:.r.-"-"”132: 31 K39
Izalflzslzsl -" KIM/1 ”Mal/”fliswulia'ui'n], flé'i'a'T/V’I'E '1?” 4 ' a "2 . 1
Troubleshootin

*
!g 11 -C-11

*
!'

How to Begin Troubleshooting

.
(
"!
*
!
When the Malfunction Indicator Lamp (MIL) has been reported on, check the Diagnostic Trouble Code (DTC) as following:
2,! ;,<A#(
4 !;(4<!!3
9
NOTE: This operation can also be carried out with Honda PGM Tester connected to data link connector (5P).
84 94! 36.,4!#;<-
1.
- Connect the 808 short connector to Service Check Connector as shown (The 2P Service Check Connector is located
4&#!
under the dash on the driver side of the car). Turn the ignition switch ON (II).
&<-4
38;<-
SERVICE CHECK
CONNECTOR IZPl
DATA LINK
CONNECTOR
ESP)
scs SERVICE CONNECTOR

UTFM - 0010100 'I The. illustration shows LHL'! type. FIHD typu is
symmetrical.
2.
- Note the Diagnostic Trouble Code (DTC): The MIL indicates a code by the length and number of blinks. The MIL can
(
4 !;(4<94,!
!#-4,
indicate multiple problems by blinking separate codes, one after another. Codes 1 through 9 are indicated by individual
!!!!#
A-
5& !
short blinks. Codes 10 through 41 are indicated by a series of long and short blinks. The number of long blinks equals the
!#-0
*!
!#-4 !
!#F !
first digit, the number of short blinks equals the second digit. Sometimes the first blink is difficult to see; always count the

A !#F !
-!# !N!3
blinks at least twice to verify the code.
!#!3&-
MALFUNCTION
INDICATOR
Separate Problems:
Short
'
.—. ——H M =5“ m1
' :i' " =SooD‘I'03
1.3“” flmn— 2 See me 14
Long short '3
l". Baum see i -'
Multiple Problems:
J"_I'Ll‘-."___II__..'JIIE =SeaDTC1and3
rim F..".l_ll‘l._l"|.|'L—_JT_—L|"L = see me 3 and a
E. a
Lfim—J—UU U 'L' 3— = sac DTC a and 1‘

Troubleshooting

*
! _ _

Troubleshooting


!'
/
?0 11 C 12
Engine Control Module (ECM) Reset Procedure

%!

/%0'

NOTE: This operation can also be carried out with Honda PGM Tester.
84 94! 36.,4-
1.
- Turn the ignition switch off.
4
3-
2.
- Remove the No.6 H-ECU (ECM) VBU (7.5A) fuse from the passenger’s under-dash fuse/relay box for 10 seconds to reset
1&-6 ?; ,<:)?;$-%<
B =!/0
the ECM.
,-
No. 6 H-ECU lECMi

VBU [7.5 All FUSE
PASSENEEH'S UNDER-DASH
FUSEII'RELA‘I' BOX The illustration shows LHD typ-u.
RHD type is Symmetrical.
+ '
/ procedure must be done after any troubleshooting

*
#
*
!
1.
- Remove the SOS Short Connector.
1&-
NOTE: If the 808 short connector is connected and there are no DTCs stored in the ECM the MIL will stay on when the
84 9(4 ,,3!!3
ignition switch is turned ON (II)

3 8;<
2.
- Do the ECM Reset Procedure.
( ,1 -
Known-Good ECM Substitute
I
(
%*
The ECM is part of the immobilizer system. If you substitute a known-good ECM the ECM will have a different immobilizer
4 ,!H- #3
, ,3!!&!H
code. In order for the engine to start, you must rewrite the immobilizer code with the Honda PGM Tester.
-
A 3!H36.,4-
Troubleshooting

*
! _ _

Troubleshooting


!'
/
?0 11 C 13
%
-
ECM Removal
Pull the carpet from the passenger’s side of the center console to expose the ECM. Unbolt the ECM cover. Remove the four
!!
B!/ ,-?! ,&-1&
bolts from the ECM.
! ,-
a I'll-m 10.8 kgI-m,

6 lhf-fl]
9.6 Mm
[1.0 Ital-m.
7.2 lhI-ftl
ECM .-
BRACKET The illustration shows LHD type.
RHD type is symmetrical.
Checking
6 !the ECM Connector Terminals
%

When checking the ECM connector terminals, connect the ECM test harness and test pin box. Check the system according to
2#
,!A ,/-#

the procedure described for the appropriate DTC listed on the following pages.
(4!!!3

-
ECM
TEST
HARNESS
07m - 31131.03!!!)
DIGITAL CIRCUIT TESTER

Camntercially available or
m 411 — 0020000
TEST . .
PIN Box lPIN BOX 130 SEEMI _ ' The Illustration shows LHD time.
nil-CAI _ 0010100 - FlHD type Is Symmetrical.

*
!
Troubleshooting

*
!
11-C-14

NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the order they should be
84 9%3A ! # !
inspected starting with (1). Find

!! A!#! A

listed at the top of that column. If inspection shows the system is OK, try the next most likely system (2) etc.
!! -38>A/!#!;<-
PAGE I SYSTEM PGM-FI
I
MANIFOLD ENGINE
ENGINE EHANKSHAFT THROTTLE INTAKE AIR
HEATED OXY- ABSOLUTE COG LANT 1.‘EHltlLE SPEED
CONTROL POSITION POSITION TEMPE FEATURE
IGEN SENSDFI" PFIE $$U RE TEMPERATURE SENSOR
MODULE SENSOR SENSOR SENSOR
SENSDR SENSOR
SYM PTOM 11-C-21 11-C-26, d2 1142-23 TLC-31 IVE-33 1142-35 11-C-35 'H-C-l-EI
m} —-—
MALFUNCTIDN INDI- "H N. ' -" ‘i-I. l .-" H_I /
EAIOH LAMP lMlLl E
TURNS cm .-’ .r I a, ,-' E. 'x .a- J 5,
MALFUNCTIDN INDI-
CATOR LAMP IMILl
BLINKS
ii]: 06E];
'I-u.
.x El
I .-'
N. —I—
x.
.x
I /
a. E.”
/.-~.
2-:
ENGINE WON'T START G)

DIFFICU LT TO START
ENGINE WHEN COLD ®
IWHEN cow
' FAST IDLE
OUT OF SPEC
®
...._,,__
' ROUGH IDLE;
IRREGULAR
IDLING WHEN WARM
ENGINE SPEED
TOO HIGH
lI'III'HEN WARM
ENGINE SPEED
TOO LOW
WHILE
WARMING UP
FREDUENT
STALLIN'G
AFTER
WARMING UP
MISFIHE UH
ROUGH
HUN MING
C3) ®
POOH FAILS
PEHFDHM- EMISSION
ANCE TEST
LOSS OF
POWER ® ®
G* |f codes other than those listed above are indicated, count the number of blinks again, If the MIL is in fact blinking these
!&A !#
A,!#

codes, replace the ECM.
A! ,-
4

&A
!#!!3
9
(See Page 11-C-21)
;'!<
(See Page 11-C-26)
;'!<
(See Page 11-C-42)
;'!*<
(See Page 11-C-28)
;'!'<
(See Page 11-C-31)
;'!+<
(See Page 11-C-35)
;'!+<
(See Page 11-C-38)
;'!+'<
(See Page 11-C-40)
;'!*0<
Troubleshooting

*
! 11-C-15
3
Troubleshooting

* Guide (cont’d)

! /
?0
IDLE CONTROL FLI EL SLI FPL'Y'
I EMISSION CONTROL
IDLE AIR INTAKE AIR
CONTROL VALVE OTHER IDLE CONTROLS FUEL INJECTOR OTH EH FUEL SUPPLY SYSTEM
ram
1 1 Cut-El I'l-C-IG lit-72 'l'l-C-TT
l 1.
H. ' /
x-l x.
(“396996)
@@®®@
@
E)
E)
®
4

&A
!#!!3
9
(See Page 11-C-46)
;'!*<
(See Page 11-C-62)
;'!<
(See Page 11-C-58)
;'!'<
(See Page 11-C-72)
;'!$<
(See Page 11-C-77)
;'!$$<
Troubleshootin

*
!g 11 -C-16
5
%!

!
Engine Control Module Terminal Arrangement
/ f' 1
95
"if“ -/ 3/“ l--/ .x /_/ ___..m “3?:
I‘ s; __...x .M 5-2 ./
w -' .,-- .
m1 ____- law—~22 f #LTF -
_.__ __._i____.___.: .__. .-'. . . . .. T. . . .x‘ . . .
23 _.--“‘ t6 :5 ! x” I!" fell, / l ‘9 E ./ / “ l
1:; ____. .z“ vau IUPL'i'I :
Eff .--"'" . {___ . scs /_ / cum / II

2!!
84 9&!
:-
O Terminal O
Wire Colour O
1

,
)
O| Signal
! O|
O ,
@
No. O O O O| O|
O 1 O GRN/YEL O
.1=C 1;(Fuel
FLR pump relay) O
! !< Drives fuel pump relay
(& ! ! O| 0V for two seconds after turning
0:3
O|
O O O O O| ignition switch ON (ll), then battery O|

38;<A
O O O O O| voltage
&!
O|
O O ORN
81 O IACV N (Idle air control O
%:;!! Drives IAC valve N side
(&%&!& O| With engine running: Pulses
2

9 ! O|
O O O valve N side)
&!&< O coil
! O| O|
O + O BRN
)1 O |NJ1 (No. 1 fuel
";- ! O Drives No. 1 fuel injector
2

9 ! O|
O O O injection)
7< O O| O|
O * O BLU
)? O |NJ3 (No. 3 fuel
"+;-+ ! O Drives No. 3 fuel injector
(&-+ !7 O| With engine running: Pulses
2

9 ! O|
O O O injection)
7< O O| O|
l l
O O BLK
)> O PG ((INJ) (Power
.;;"<;3 O Ground for the injector
. 7 O Less than 1.0V at all times
-0:!! O
O O O ground)

< O circuit
O O
O ' O GRN/ORN O
.1=81 MIL (Malfunction
,;,! O (&,
Drives MIL O| With MIL turned ON: CV
2, 890: O|
!
< O O| 2, 8 Battery
With MIL turned OFF:9) O|
O O O O O| voltage
&!
O|
O 5 O GRN
.1 O FANC (Radiator fan
%;1 O Drives radiator fan relay
(&! O| With radiator fan running: CV
2
90: O|
O O O control)
!< O O| With radiator fan stopped: Battery
29) O|
O O O O O| voltage
&!
O|
O 11
O GRN/BLK O
.1=)> 8G2 (Sensor ground) O
.;
< Ground for H028
. 68 O| Less than 1.0V at all times
-0:!! O|
O 12
O WHT
264 O HOZS (Heated oxygen O
68;6/
Detects heated oxygen
(/
O| With throttle fully opened from idle
2! !!! O|
O O O sensor)
< O sensor signal

! O| with fully, warmed up engine: Above O|
3 !!A3
9%&
O O O O O| 0.6V
0-: O|
O O O O O| With throttle quickly closed: Below O|
2!F #!!9)!3
O O O O O| 0.4V
0-*: O|
O 13
+ O GRN/WHT O
.1=264 BKSW (Brake switch) O
)>2;)#3< Detects brake switch
2#!!90: O|
O O O O signal

2#!9 O|
O O O O O| Battery voltage
)&!
O|
O 14
* O GRN/WHT O
.1=264 SG1 (Sensor ground) O
.;
< . ,%
Ground for MAP sensor O| Less than 1.0V at all times
-0:!! O|
O 16
O WHT
264 O CKPM (CKP Sensor M O
>,;>, . >
Ground for CKP sensor O| O|
O O O side)
< O O| O|
O 5
19 O )1
BRN O 808 (Service check
;&# O Detects service check
(&# O| 2!90:
With the terminal connected: 0V O|
O O O signal)

!< O connector signal (the

!; O| 2!9
With the terminal disconnected: O|
O O O O signal causing a DTC

!
(4 O| Battery voltage
)&!
O|
O O O O indication)
< O| O|
O 25
O WHT
264 O lGPLS1 (Ignition pulse) O
.;
!< Sends ignition pulse to

! O| With engine running: Pulses
2

9 ! O|
O O O O ignition coil N0. 1 and

!- O| O|
O O O O No. 4
-* O| O|
O 26
O WHT/BLU O
264=)? VBU (Voltage back-up) O
:)?;:!
3 O| Battery voltage at all times
)&!
!! O|
O O O O ECM control circuit
,! O| O|
O O O O Power source for the
3 O| O|
O O O O DTC memory
(4 O| O|
O 28
' O BRN/BLK O
)1=)> LG (Logic ground)
.;

< O Ground for the ECM
. , O| Less than 1.0V at all times
-0:!! O|
O O O O control circuit
! O| O|
O 29
5 O BLK/BLU
)>=)? O IACV P (Idle air control O
%:;!! Drives IAC valve P side
(&%&!& O| With engine running: Pulses
2

9 ! O|
O O O valve P side)
&!&< O coil
! O| O|
O 31
+ O RED
1 ( O INJ2 (No. 2 fuel
";- ! O Drives No. 2 fuel injector O|
(&- !7 With engine running: Pulses
2

9 ! O|
O O O injector)
7< O O Ol
O 32
+ O YEL
C O INJ4 (No. 4 fuel
"*;-* ! O Drives No. 4 fuel injector O|
(&-* !7 With ignition switch ON (ll): Battery Ol
2
38;<9)
O O O injector)
7< O O voltage
&!
Ol
O O O O O Ol
O 34
+* O BLK
)> O PG (Power ground)
.;3
< O . ,
Ground for the ECM O -0:!!
Less than 1.0V at all times Ol
O O O O !
control circuit O O|
O 36
+ O RED/YEL
1 (=C O PCS (EVAP purge
; :%
O Drives EVAP purge
(& :%
O 2

A

With engine running, engine O|
O O O control solenoid valve) O
!!&!&< control solenoid valve
!!&!& O coolant, below 39°C (102°F):
!A!3+5P;0P Battery Ol
<9)
O O O O O voltage
&!
Ol
O O O O O With engine running, engine coolant Ol
2

A
!
O O O O O above duty controlled
& !! Ol
O 37
+$ O BLK/WHT
)>=264 O HO2SHTC (Heated
6864;6 O Drives heated oxygen
(&/
O With ignition switch ON (ll): Battery Ol
2
38;<9)
O O O oxygen sensor heater O
/
sensor heater
O voltage
&!
Ol
O O O control)
!< O O With fully warmed up engine
2 !!3
Ol
O O O O O
90:
running: CV O|

*
!
Troubleshooting
Engine Control Module Terminal Arrangement
%!

!
11-C-17
7
(cont’d)
/
?0
; 53 w
: vcm nap: ___.»’
:1 I __-"'__.-
um m3”
2!!

84 9&!
:-
I
O Terminal O
Wire Colour O
1

,
)
OI Signal
! O
O ,
@
No. O O O O| O
O 38
+' O BLU
)? O NEP (Engine speed
;
O Outputs engine speed
8
O| With engine running: Pulses
2

9 ! O|
O O O pulse)
!< O pulse
! O| O|
O 42
* O BLU/WHT O
)?=264 VSS (Vehicle speed
:;:! O Detects VSS signal
(:
! O| With ignition switch ON (II) and front O|
2
38;<
O O O sensor)
< O O| wheel rotating: Cycles 0V — 5V
3!
9!0:\: O|
O 43 O
*+ BLU
)? O CKPP (CKP sensor P O
>;> (>
Detects CKP sensor O| With engine running: Pulses
2

9 ! O|
O O O side)
< O O| O|
O 46
* O YEL/BLU O
C =)? VCCZ (Sensor voltage) O
:;&!
< Provides sensor voltage O|
&&!
With ignition switch ON (ll): About 5VO|
2
38;<9% :
O O O O O| With ignition switch OFF:9)
2
38 Battery O|
O O O O O| voltage
&!
O|
O O O O O| O|
O 48
*' O RED
1 ( O ACC (A/C clutch relay)
%;%=! !< O Drives A/C clutch relay |
(&%=! ! O With compressor ON: 0V
2890: O|
O O O O O| With compressor OFF:9)
28 Battery O|
O O O O O| voltage
&!
O|
O 50
0 O WHT/RED O
264=1 ( ALTF ;%!
%4 (Alternator FR
1 O Detects alternator FR
(! 1 O| With fully warmed up engine
2 !!3
O|
O O O signal)

!< O signal

! O| running: 0V — battery voltage

90:\&!
O|
O O O O O| (depending on electrical load)
;
!!!< O|
O 52
O WHT/GRN O
264=.1 IGPLSZ (Ignition pulse) O
.;
!< Sends ignition pulse to

! O| With engine running: Pulses
2

9 ! O|
O O O O ignition coil N0. 2 and

!- O| O|
O O O O No. 3
-+ O| O|
O 54 O
* YEL/BLK O
C =)> IGP1 (Power source)
.;3 < O 3
Power source for the O| With ignition switch ON (ll): Battery O|
2
38;<9)
O O O O ECM control circuit
,! O| voltage
&!
O|
O O O O O| With ignition switch OFF:90:
2
38 0V O|
O 55
O BLK
)> O PG (IGN) (Power
.;.<;3 O Ground for the ignition
.
O| -0:!!
O O O ground)

< O system
O| O|
O 58
' O YEL/BLK O
C =)> IGP2 (Power source)
.;3 < O 3
Power source for the O| With ignition switch ON (ll): Battery O|
2
38;<9)
O O O O ,!
ECM control circuit O| voltage
&!
O|
O O O O O| With ignition switch OFF:90:
2
38 0V O|
O 59
5 O YEL/RED O
C =1 ( VCC11 (Sensor
:; O 3 ,%
Power source to MAP O| With ignition switch ON (ll): About 5VO|
2
38;<9% :
O O O voltage)
&!
< O sensor
O| With ignition switch OFF:90:
2
38 0V O|
O O O O O| O|
O 63
+ O PNK
> O IMOLMP (Immobilizer O
,8,;!H Drives immobilizer
(&!H O| With immobilizer indicator light
2!H!
O|
!
< O indicator light
!
O| turned ON (ll): 0V
8;<90: O|
O O O O O| With immobilizer indicator light
2!H!
O|
O O O O O| turned OFF:9)&!

8 Battery voltage O|
O 71
$ O GRN/BLK O
.1=)> 8G3 (Sensor ground) O
.+;
< Sensor ground

O| -0:!!
O 72
$ O GRN
.1 O PSPSW (P/S pressure O
2;= Detects PSP switch
(3 O| At idle with steering wheel in straight O|
%!3
3!

O O O switch signal)
3
!< O signal

! O| ahead position: 0V
90: O|
O O O O O| At idle with steering wheel at full
%!3
3! !! O|
O O O O O| lock: Battery voltage
!#9)&!
O|
O 73
$+ O RED/BLK O
1 (=)> TPS (Throttle position O
4;4! Detects TP sensor signa | O|
(4
2! !!9% *-':
O O O sensor)
< O O| With throttle fully closed: About 0.5V O|
2! !!!9% 0-:
O 75
$ O BLU/RED O
)?=1 ( ACS (A/C switch signal)
%;%=3
!<O Detects A/C switch
(%=3 O| With A/C switch ON: 0V
2%=3890: O|
O O O O signal)

!< O 2%=38
With A/C switch OFF:9% :
About 5V O
O 77
$$ O RED/YEL
1 (=C O IAT (Intake air
%4;# O Detects IAT sensor
(%4 O With ignition switch ON (ll): About
2
38;<9% O
< O signal

! O 0.1-4.8V (depending on air intake
0-*-':;
# O
O O O O O temperature)
< O
O 78
$' O RED/WHT
1 (=264 O ECT (Engine coolant
4;
! O Detects ECT sensor
( 4 O With ignition switch ON (ll): About
2
38;<9% O
< O signal

! O 0.1-4.8V (depending on air intake
0-*-':;
# O
O O O O O temperature)
< O
O 79
$5 O BLU/GRN
)?=.1 O IMOCD (Immobilizer
,8(;!H O Detects immobilizer
(!H O O
O O O code)
< O signal

! O O
O 80
'0 O RED/GRN
1 (=.1 O MAP (Manifold
,%;,! O Detects MAP sensor
(,% O With ignition switch ON (ll): About 3VO
2
38;<9% +:
O O O absolute pressure
! O signal

! O At idle: About 1.0V (depending on
%!9% -0:;
O
O O O sensor)
< O O engine speed)

< O
O O O O O O
O 81
' O ORN/BLU
81=)? O IMOEN (Immobilizer
,8 ;!H O Sends immobilizer
!H O O
O O O enable signal)
!
!< O enable signal
!
! O O
O 88
'' O LT BLU
4)? O DLC (TxD/RXD)
(;4/(=1/(< O Sends and receives
& O With ignition switch ON (ll): Pulses O
2
38;<9 !
O O O O scan tool signal
!
! O O
Troubleshooting

*
! _ _
8
) !

*
/)0 11 C 18
Ol Diagnostic
) !
Ol System Indicated
# Ol Page
'! O
Ol Trouble Code

*
Ol Ol O
Ol (DTC)
/)0 Ol Ol O
O| O
0 O|
! !; ,<
Engine control module (ECM) O| ;'!
(See Page O|
O| O| O| 11-C-21) O|
<
O| 1 O| 6/
;68<
Heated oxygen sensor (H028) O| ;'!
(See Page O|
O| O| O| 11-0-26) O|
<
O| 3
+ O| ,!! ;,%<
Manifold absolute pressure (MAP) sensor O| ;'!
(See Page O|
O| O| O| 11-0-28) O|
'<
O| * O| #;><
Crankshaft position (CKP) sensor O| ;'!
(See Page O|
O| O| O| 11-0-31) O|
+<
O| 6
O|
! ; 4<
Engine coolant temperature (ECT) sensor O| ;'!
(See Page O|
Ol Ol Ol 11-0-33) O|
++<
Ol $ Ol 4!;4<
Throttle position (TP) sensor Ol ;'!
(See Page O|
Ol Ol Ol 11-0-35) O|
+<
Ol 10
0 Ol # ;%4<
Intake air temperature (IAT) sensor Ol ;'!
(See Page O|
Ol Ol Ol 11-0-38) O|
+'<
Ol 14
* Ol !!;%<&!&
Idle air control (IAC) valve Ol ;'!
(See Page O|
Ol Ol Ol 11-C-48) O|
*'<
Ol 17
$ O Vehicle speed sensor (VSS) *3
l :!;:<G + Ol (See Page O|
;'!
*0<
Ol 41
* Ol 6/
;68<
Heated oxygen sensor (H028) Ol ;'!
(See Page O|
*<
¢ If codes other than those listed above are indicated, verify the code. If the code indicated is not listed above, replace the
!&A&-!&A!
ECM (See Page 11-C-12) for immobilizer information.
,;'!<!H-
¢ The MIL may come on, indicating a system problem when, in fact, there is a poor or intermittent electrical connection. First
4,A
!3AA!!-
check the electrical connections, clean or repair connections if necessary.
#!!A!-
PGM-Fl System
'+# 11 _c-19
9
System Description
#)
INPUTS ENGINE CONTROL MODULE [ECM] OUTPUTS

CKP Sensor l i Fllel-Iniectors
MAP Sensor . i PGM Fl Main Relay iFuel Pumpl
ECT Sensor - I I Fuel Injector Timing and Duration I
i MIL
IAT Sensor I ! IAC Valve
TP Sensor _J Electronic: Idle Cuntrul |_ NC Compressor CIU'Ch HBIEV
H025 :l Radiawr Fan Relay
.-’|
V55 ,x' Diner Control Functions —L.-‘ i Condenser Fan Relay
ALT FR Signal _ ______ _ ; [CM
Air Conditioning Signal . lgniinn Timing Control EVAP Purge Control Solenoid Valve
! Elrake Switch Signal H025 Heater
F'SF‘ Switch Signal .L
PGM-FI System
'+#
The PGM-FI!F ! ! !7-
+D
!)

The ECM/POM contains memories for the basic discharge duration at various engine speeds and manifold pressures. The
4 ,=,
&
! -4

A
A
!&
!
-
Idle Air Control

Idle Air Control Valve (IAC Valve)

4-/4-0
When the engine is cold, the A/C compressor is on, the brake pedal is depressed, the P/S load is high, or the alternator is
2
!A%=A#!A=!
A!
charging, the ECM controls current to the IAC Valve to maintain the correct idle speed.

A ,! %:!&!-
!
!

¢ The ECM contains memories for basic ignition timing at various engine speeds and manifold air flow rates. Ignition timing
4 ,

&
!!3-

is also adjusted for engine coolant temperature.
!7
! -
Other
Control Functions

+

1.
- Starting control

!
2
A ,&/
!7 -
2.
- Fuel Pump Control
! !
0 When the engine is running, the ECM supplies ground to the PGM-FI! ! !
2

A , !
pump.
-
0 When the engine is not running and the ignition is ON (II), the ECM cuts ground to the PGM-FI!3
2

8;<A ,
., main relay which cuts
current to the fuel pump.
! -
PGM-Fl System
'+# 11 _c_20
$
#)
/
?0
3.
! !
(
!3!&!&!A !7 & !
speeds over 1,160 rpm (min -1).
&A0;<-
0 Fuel cut-off action also takes place when engine speed exceeds 6,780 rpm (min-1),
! !#!3
/A$'0; regardless of the position of the
<A
!
throttle valve to protect the engine from over-revving.
!&!&
&&&
-
*- A/C Compressor Clutch Relay
%=! 1!
When the ECM receives a demand for cooling from the air conditioning system, it delays the compressor from being
2 ,&!

A!

A/ %=-
- Evaporation Emission (EVAP) Purge Control Solenoid Valve
& ; :%<
!!:!&
When the engine coolant temperature is below 38°C (102°F),
2
! !3+'P;0P the ECM supplies a ground to the EVAP purge control
<A , !
:%
!
solenoid valve which cuts vacuum to the EVAP purge control canister.
!&!&3 & :%
!-
ECM/PCM Fail-safe/SeIf-diagnosis Functions
%2'+ 2 !
+

1. Fail
- safe Function
!
When an abnormally occurs in a signal from a sensor, the ECM ignores that signal and assumes a pre-programmed value
2!!
!A ,

!
&!
for that sensor that allows the engine to continue to run.
!!3
-
- !
;,! ;,<
When an abnormality occurs in a signal from a sensor, the ECM supplies ground for the MIL and stores the code in
2!
!A , !
,
erasable memory. When the ignition is initially turned on, the ECM supplies ground for the MIL for two seconds to check
!-2
!! A , !
,3#
the MIL bulb condition.
, !-
'+#
PGM-Fl System

-
-
%!

/%0
Engine Control Module (ECM) 11 C 21
The Malfunction lnclicator Lamp

{MIL} never comes on [even for NOTE
1WD SEW“) ififl' ifilflitififi I Ifthis symptom is irterrnitter't. checkfor.
'5 turnecl 0“ (“l- - A loose ACES [1M]fi.se ir' the Lhcer-hocc fLseI'relay to:
- A loose No 9 BACK UP LIGHT INSTRUMENT LIGHT [TEA] fLse ir' the
criuer's cer-hozuc fLSE.‘TEIa‘y box
A loose No 1 FUEL PUMPfLse USA} ihthe cn'vei‘s cereash fLSEL'TEIIEIy tor
- Ar' ir'tem'iitter't short ir the wire betweeh the ECM {8} are the gauge assembly-
Check the inertia switch: - Ar ir'tem'iitter't short ir the wire betweeh the ECM 1:59} are the MAP ser'scr
1. Press the ir‘ertia switch but oh. - Ar ir'ten‘nit‘ber't short ir the wire betweeh the ECM 1:46;, the TP sersor
2. ’e the igr‘itioh switch CN Ill}. - PGMFI ma'r' relay
Does the MIL come or for two

seccrds after ighitioh switch
at this ti me.
is tuned CN i‘ll'i?
NC
INERTIA SWITCH 3P CONNECTOR
Check the inertia switch: _ I
1- Disocrrectthe ir‘ertia switch
3P ccrrector.
INF-RT“
SWITCH III 1
2- Correct the ihertia switch 3P {REDIBLM t
ccrrectcrtenhir‘als No. 1 ard lREDWT}
No. 3 with a jumper wire. JUMPER WIRE
’en‘tir‘al side of male termir‘ als
Does the MIL come or‘ for two YES

seocrds alter igr‘itior‘ switch REM?“ “1B inertia SWiEI'I-
is turned ON (I I}?
NC
' Reparshcrtin thewire
between Ho. BBACPHJP LIGHT
____.--..___—— NC INSTRUMENT LIGHT REA]
r-Z'._____ls th e low oil pres sure light cr‘?____.31 fuge at d gau a; assembly.
' YES ' ' Replace lilo. I BACKUP
LIGHTIHSTRUNEHT LIGHT
£7,511] fuse.
Try to start the ergire. Check the MIL:
1- _LII'IT the igi‘iticn switch OFF.
2- Coi‘nectthe ECM test han'less
—-.., YES atclthetest pin but between
‘3 Does the ergire start? 11'"? EM 5116‘ cmnector
[see page1143—13].
NC 3- IComeetthetest pin box tennind
No. B to body ground
4- Tom the ignition switch ON ill}.
IstheMlL or?
YES
- Replace the MIL bulb.
- Repair open wire between the
ECM (8) and the gauge
assembly
Subfiitute a known-good ECM

and recheck isee page11-C-12 for
(To page 11 -C-22] immobilizer informaicn].
Il' syrri ptcmlindicaicn goes airmailI
4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-12)
;'!<
PGM-FI System
'+# 11 -C-22

Engine Control Module (ECM) (cont’d)
%!

/%0/
?0
(From page 1'1 43-21]
Check the fuse:

1._urn the ignition switch OFF.
2. Inspect the ACE-S x: 15ft} fuse in
the underhoodfuse.v're|ay box.
' Repair shortin thewire

NC between theACGS {15Mfuse
( Isthe fL.se CK? )— and the PGMJ’I main relay.
' Replace ACGS {15A}fuse.
YES
Glteek the fuse:

Irspect the No.1 FUEL PUMP
t1fii:fL.seihthe dr'wer's eer-
clash fLsen‘relay box.
- Repair short in thewire between

NC the No 1 FUEL PUMa {15A} fuse
Isthe fLSB CK? and the POM-Fl main relay.
- Replace No. 1 FUEL PUMP
118A] fuse
Check the fuse:
Inspedthe No. 6 H-ECU IZECM}
VEi-U (7.5M fuse in the passenger's
underdash fuseihelay box.
— Reptir short in the wire between

NC theNo. GH-ECU (ECM]VBU
1:: Is the fist: CK? 1T.6A]fuse and the ECU {26].
— ReplaoeNo.8 H-ECU lECM]
YES VBU 17.5 A] fuse.

WBU line):
1. Connect the ECM test hamess
and the test pin bot between
the ECM and comector
[see page 11—C—1 3].
2. lu'leaSLre voltage between body
gromd andthe test pin box No 26
NC Repair open in the wirefs)

( Is there battery 'v' olt age? >— beMeen ECM (26) and No. 6
H-ECU (ECMWBU [7.5m fuse.
YES
('6 page 11 -C-23}

4

&A
!#!!3
9
(See Page 11-C-13)
;'!+<
PGM-Fl System
'+#
%!

/%0/
?0
11 -C-23

(From page 11-0-22]

[IGP1,IGP2lines):
1. Diseor heat the fi..e| ihjectors
ar'cl IAC valve oohheotors.
2. Correct the ECM test harr ess
ar'cl th e test pih box betweer
the ECM ahd oohheotor (see
page 11-0-13].
3. ’L.rr' the igr‘itioh ON fill].
4. MeaSLre voltage betweer‘
bodv groL.r‘d ahd the test pih
box terr‘tir‘als No. 54. No. 58
ird'rviclLallv.
Repair open in the wirels)
-
between EOM [54, EB) and
% NC PGM-Fl main relay.
< Is there battery voltage?
check for poor connections
-
YES or loose wires at the PGM-Fl
main relay.
(PG, LG lines):
1. Reoorrect allthe fLeI ir‘jedors
arcl IAC valve cohheotors.
2. MeaSLre voltage betweer‘ body
groe ar‘dthe test pir‘ box
terr‘tirals No.6, No. 34, No. 55
ard No. 28 ir‘dividually.
_. _|_ No Repair open in the wirels)

Is there less thar‘ '1 .0 V? between the ECM [6, 34, 55, 28)
and (32021030212
' YES '
'ZRFD
W001, V002 lines):
MeaSLre voltage betweeh body
grocl ardtest pih box termihals
Check for a short in a sen sor.
No. 59 arcl No. 46 if“ diu'idLally
While measuir‘g voltage betweeh
bodv groLr'cl ar'dthetest pir box
ten‘tir'las No. 59 arcl No. 46
NC
< Is there approx. 5 V? ihdividLallv disoorreotthe 3P
oor'r'eotor of each sersor ore at a
YES time:
I MAP eeheor
I 'P seheor
—.\
NO
C Is there approx. 5 V? 322:.
YES
Rep air short in the wire between
MAP sensor, TP sensor and EOI'lr'l
and recheck (see page 11 -0-1 2 (59. 45).
for immobilizer information). if
symptontfinclication goes away, Replace the sen sor that had
replace the original ECM. ap prox . E U.

4

&A
!#!!3
9
(See Page 11-C-13)
;'!+<
(See Page 11-C-12)
;'!<
PGM-Fl System
'+#
%!

/%0/
?0
11 -C-24

Tl're Malfunction Indicator Light NC'E:

{NHL} stays on or comes on after :- “Alher there is re Diagrcstic'rccble Ccde [D'C] stcreci, the MILwiII
two seconds. stay or ifthe SCS shcrt ccrrectcr is corrected arcithe igriticr switch
is ON rill].
e Ifthis symptom is irten‘tittert, check for:
- .e irterrtittert sh crt ir thewire betweer the ECM [1Q] arcithe
Checkthe DTC by ML indication: service ch eck ccrr ectcr.
1. ’e the igritior switch IOFF. - Ar irterr‘tittert sh crt ir thewire betweer the ECM [8] ardthe
2. Correct the 808 short gauge assembly.
ccrrectcr to the service
check ccrrector.
3. ’e the igriticr switch CN fill}.
< . . _ \ YES Gototroubleshooting

Does the MIeclrcate aryD C? procedures(see page 11-0-11}.
NC

1. Remove the 505 short
ccrrectcr from the sewice
check ccrrectcr.
2. 'ry' to start the ergire.
Substitute a know-good ECM
NC and recheck {see page11-C-12
Does the ergire start? for immobilizer information).
If symptomlindication goes may
YES replace the origin: ECM.

[5C5 line}:
1. 'e the igr iticr switd‘ OFF.
2. Ccrr ect the ECM test harress
arci thetest pir tics betweer
the ECM arci ccrrectcr
[see page 11-0-13}.
3. 'e the igr iticr switch CN {ll}.
4. Meascrevcltage betweer
bcciygrccrci arcithetest pir
bcx terr'rir al No. 1 9.
NC Repair short to body ground in

< Is th ere battery-voltage? )— the wire bemeen ECM (19} and
service check connector.
YES
('c page 11 -C-25}

4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-Fl System
'+# 11 _c_25
3
%!

/%0/
?0
(From page '1 '1 43-24}
Check for a short in the wire MIL

line]:
1. ’e the igr‘itioh switch OFF.
2. Dismr‘r‘ect the ECM
oerrector.
3. ’e the ighitioh switch CN {II}.
Repair short to body ground in

YES
<\ Isthe MIL ON? the wire between the ECM [8}
and MIL.
NC

and recheck (see page11-c-12
symptomlindieation goes away,
replace the original EOM.

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
PGM-Fl System
'+#
Heated Oxygen Sensor (H028)
.#!
/.0
11 -C-26
5
-@—-I
\
/
|
I
/
\ /
x
(
|

/
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 1: A problem in the Heated
\ 4,! ;,<(
4 !;(4<9%!6
Oxygen Sensor (H028) circuit.

8/
;68< -
The Heated Oxygen Sensor (H028) detects the oxygen content in the exhaust gas and signals the ECM operation, the ECM
468/
;68</
/

! ,A ,
receives the signals from the sensor and varies the duration during which fuel is injected. To stabilize the sensor 5 output, the
&
!&
3 !7-4!H A
!-468!!/ !-
sensor has an internal heater. The H028 is installed in the exhaust manifold.
IIRGOHIR :EEIQI'IT‘IEHRALS I STOICHIOMETRIG
ELEMENT
VOLTAGE (V) "--__ RIR-FUELRATICI
r”
: flair-‘44J-fii‘. 1. ,. I as i
:1
I '-s'-
.I—I'I‘
sENsOR
TERMINALS RICH— AIR 4 LEAH
FUEL
RATIO
_ The MIL has been reported on.

_ With the 505 short connector
connected (see page11-C-11),
code1 is indicated.
Check the fuel pressure:

lr'spect fLeI presscre (see page
11-0-12}.
NC Go to page 11-0-58 Fuel Supply

-:j:__ Is it Formal? "j;
System.
YES
1. Do tl‘e ECM Reset ProoedLre
[s ee page 11 —C—1 2}.
2. Starttl‘e ergire. l-olcltl‘e
ergire at 3000 rpm (mir‘| j:
with r'o load (trarsmissior ir
reLtral] Lrtil tl‘ e radiator far
comes or. trer let it idle forat
least ore mirLte before
test—dri-xirg.
3. Test-drive cler tre followirg
corditiors:
- 'rar smissior ir 4th gear.
- Accelerate Lsirg wide oper
tf'rottle for a least five
secorcls. tl‘er decelerate
for at least five secords
witf' tl‘etl‘rottle complete
dosed.
lntern'ittentfailure, system is OK
Is the MIL or ard does it irdicate NC at this time. Check for poor
codet? connections or loose wires
between the H023 and the ECM.
YES
(To page 11-0-27}

4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-FI System
'+# 11 -C-27
7
Heated Oxygen Sensor (H028) (cont’d)
.#!
/.0/
?0
(From page 11-0-26}
Ch eek the ECM input voltage:

1. 'e the igritior switch CFF.
2. Correct the ECM test harr ess
ardthe test pir box betweer
the ECl'ul ard oorrectorisee
page 11-6-13].
Start the ergire. hold the
ergire at 3,000 rpm (Mir-1';
with ro load Iftrarsmissior ir
reLtral} L.rtil the radiator far
comes or. ther let it idle for at
least ore l‘1ir‘LtE before
test-drivir g.
luleaee voltage bet'weer‘ ECM
oorrectortermirals No. 11 ard
No. 12.
Cp er the throttle wide oper.
!'_,"I
ther qt. ioklv release it.
Is the voltage above 0.6V at Substitute a known-good ECM

wide oper throttle to 4.500 rpm YES and recheck [see page 11 4:42
[Mir -'| j: ard below 0.4 V wheh II?— for in-rnobiliaer intern-nation}. If
the throttle is gLidtlv released sympton‘tlindicaiion goes away,
from 4,500 rpm [lair-1}? replace the original ECM.
NC
H 025 4P CON N ECTDR

Ch eek the H028: I [E]
1. ‘e the igritior switch CFF.
2. Disoorr eot th e 4P oohrector
from the l-C28.
3. fit the l-C2S sersor side. H 025 H TC IG1
ooh rest the battery positive
termiral to termiral No. 2 ard
batterv regative termiral to 5G2 H025
termiral No. 1.
Start the ergire.
5-“ :h
fitter two mirLtes. measue

‘v"
voltage betweer l-CES 4P
ooh reotortermirals No. 3 ard
No. 4. _B|'|"1l|"alS side of P1 ale te n‘fiirals
Is the voltage above 0.6V at

wide oper throttle to 4,500 rpm it NC
/.
Replace the H028 [see page
[Mir-Hard below 0.4ter .- 11 £45).
th e throttle is ciLickIv released
from 4.500 l'pl“'l (Mir-1}?
YES

ECM [12} and the HEIRS.

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
(See Page 11-C-45)
;'!*<
PGM-Fl System
'+# _ _
8

*
'/'0
11 C 28
\ | / \ | /
_ __ 3
+ ,
IE, /-\ 4,! ;,<(
4 !;(4<+9%!!!
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 3: An electrical problem in the
Manifold Absolute Pressure (MAP) Sensor circuit.
,!%! ;,%< -
The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECM.
4,%&!! !!
! ,-
SENSOR
UNIT x.
— The MIL has been reported on. \.
connected (see page 11-0-11),
1. Do the ECM Rest procedLre
(see page 11 -C-1 2].
2. ’e‘ the igr‘itioh switch ON ill}.
. . _ NC at this time [test-drive may be
Is th e MIL or‘ ar‘d does It Ir‘dloat necessary}. Check for poor
05:“? 3? connections or loose wires
between the MAP sensor and
YES the ECM.
Check the ECM output voltage
W001 line):
1. In“ the ighitioh switch OFF.
2. Correct the ECM test hamess
ahclthe test pih box betweer'
the ECM ahd cor‘r‘ectorljsee
page 11-0-13].
3. Ir!" the igr‘itior‘ switch CN III}.
4. Measue voltage betweer‘ the
test pir‘ box termir‘als No. 59
ahd No. 14.
and recheck [see page 11-0-12
Is th ere approx. 5 V? for in‘rnobilizer information). If
symptoml'indication goes away,
YES replace the original ECM.
Check the ECM output voltage

MAP line):
MeaSLre voltage betweer‘ the
test pih boxtermihals No. 80 ar'd
No. 14.
NC and recheck [see page 11-0-12
< Is there approx. 3 V? >— for in‘rnobilieer information). If
smptomrindication goes away,
YES replace the original ECM.
(To page 11 -C-29]

4

&A
!#!!3
9
(See Page 11-C-13)
;'!+<
(See Page 11-C-12)
;'!<
(See Page 11-C-11)
;'!<
PGM-Fl System
'+# _ _
9

*
'/'0
/
?0 1 1 C 29
(From page 11-0-28]

Cheek feran epen in thewirelSG-1 MAP SENSOR 3"
line: CONNECTOR
1. 'e the igr'rtior switch CFF. Wire S'de
YES 2. Diseor‘r‘eet 3P eorrector from Cf felnale 1 3
M
< Is th ere approx. 5 V? the MHP sereor. tennlhals
3. ’e the igr'rtior switch CN fill]. 351
NC 4. MEflSL re volt age betweer MAP [G RN!
ser'sor 3P oorr'ectortermirals WHT}
NC. 2 and NC. 3. v0.31
[YELI
NC RED]:
YES
the ECM {14) and the MAP sensor.
Cheek for an open in the wire '1 2 3

[I'I'IAP line}:
MeaSL. re volta ge betweer‘ MAP MAP 561
ser'sor 3P oohredortermir‘als (RED! [G RNI
No.1 ar'd No. 2. GRN) WHT}
/ Is there approx. 5 V?
YES
Repair open inthewire between

Check the MAP 5°" 5°" the ECM (an) and the MAP sensor.
1. 'e the igr'rtioh switch OFF.
2. Diseorrect the 3P corrector
from the MAP sersor.
3. 'e the igr'rtioh switch CN Ijll}.
4. luleaSLre voltage betweeh the
test pir box tennirals No. 80
ard No. 14.
Is there approx. 5 V? Replace the MAP sensor.
('o page 11-0-30]

PGM-Fl System
'+#

*
'/'0
/
?0
11 -C-30
$
(From page 11 -C-2E|';

WG-31 line}:
MeaSLre voltage betweer MAP
ser‘ sor 3P cor'r'ector termir‘ al No.
3 ar'd body groLr'cl.
—\
C Is th ere approx. 5 V? -,—Nc
the ECM [59) and the MAP sensor.
YES
MAP SENSOR 3P CONNECTOR
V001
WELIRED}
[2"
Wire side of
MAP Iin e}:
fem ale terl‘fiir‘als
1. 'e' the igritior sw‘td‘ OFF.
2. Diseor'rect ECM corrector
from the ECM.
3. Ch ed: for eortirLity betweer
the test pir box termiral No.
BU ar'd body groe.
Repair short in thewire between

Is there oortirLity?
the ECM (an) no theMAP sensor.
NC
and reoheolt lsee paue11-C-1211'or
immobilizer information]. If
symptornfindioation goes away.
replaoe the original ECM.

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
PGM-Fl System
'+# _ _
CKP/TDC Sensor
I'2)

11 C 31
\ l / \ l /
_ __ 4
* _
IE] /-\ 4,! ;,<(
4 !;(4<*9%!#
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft
Position (CKP) Sensor circuit.
;>< -
The CKP Sensor determines timing for fuel injection and ignition of each cylinder and also detects engine speed.
4>
!7
!!
-
CKP SENSOR

connected (see page11-c-11}, CKP
code 4 is indicated. SE NSOR 3P
CONNECTOR
is ee page 11-0-12].
2. —l"y' to start tire er‘gir‘e.
’ermir'al side of male

termir‘ als
In tern‘l'ttent failu re, system is OK

NC at this time [test-drive may be
”is tl‘ 8 MIL cr ard does it irdicaté»... necessary}-
/\ code 4? / Check for poor connections or
G loose wires between the CKP
YE ‘J sensor and the ECM.

2. Diaocrrecttl‘e CKP ser'scr 3P
ccrrectcr.
3. Measure resistarce betweer'
tf'e CKP ser scr 3P ccrrectcr
termir als No. 1 ard No. 3.
NC
< Is there 1.850 -2.450 ci‘m? )— Replace the CKP sensor.
YES
(To page 11-6-32]

4

&A
!#!!3
9
(See Page 11-0-11)
;'!<
(See Page 11-C-12)
;'!<
PGM-Fl System
'+#
- -
CKP/TDC Sensor (cont’d)
I'2)
/
?0 11 C 32
(From page 11 -C-31 j:
Cheek the sensor for a short:

Greek for cortiruity betweer
body grc'd ard tre CKP sersor
3Pteri‘1ir‘als No. 1 ard No.3
ir' dividLally.
Y ES
Is there oortirLity? >—| Replace the OK!" sensor.
NC CKP
SE NSOR 3P
[CKP line}:
CONNECTOR
1. Recorreottt‘e 3P correotor.
2. Correct the ECM test harness
ardtretest pir‘ box totr‘e
wire harness or‘ly. r‘ot totre
ECM [see page 11-0-13].
3. Measue resistarce betweer'
ECM oorrector termir‘als No.
1 and No. 3.
'en'tir'al side of
male termir‘ als

Is there 1.850 -2450 cm? between ECM [43, 16) and CKP
sens or.
YES
(El-leek for a short in the wire

[GKP line}:
Ct' 3:14 for oortirLity betweer'
bodygrcd ardti‘e test pir box
ten'tiral No. 43.
Rep air sh on to body ground in

Istrere cortirbity? '>_YES the wire between ECM (4a) and
GKP sensor.
NC

11d reuhenk tseepaue11-C-12 for
immobilizer information). If
sympton'tiindioation goes away.
replane the origind ECM.
4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-C-12)
;'!<
PGM-FI System
'+#
%!
/%0

11 -C-33

-@—-E
\
/ I
| /
\ /
\ |

/
l : 4,! ;,<(

4 !;(4<9%!

The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 6: A problem in the Engine
Coolant Temperature (ECT) Sensor circuit.
!4 ; 4< -
The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine
4 4 ;<-4

coolant temperature increases as shown below.
! 3!3-
RESISTANCE
(K ohm)
code 6 indicated.
Problem uerific ation: THERMISTOR

“L . . V .
'Jl'I n :1. .1 m nun-n.3, I'U'
- u; 1I_II.1JI_-I.|t ’I_' .In F“
1. Do tl‘e ECM Reset ProcedLre
[see page 11 43-12]. ENGINE COOLANT TEMPERATURE
2. ’e tl‘e igr'itior' switd‘ CN Ijll}.
lstl‘e lullL or ard does it ir‘dicate necessary). Check for poor
code 5? connections or loose wires
beween the ECT sensor and
the ECM.
1. Start tl‘e ergire. l~oldtl‘e
ergire at 3000 rpm Ijmir-l j:
with ro load lirarsinissior ir
PELTFQI} Lrtil ti“ e radiator far
comes or. trer let it idle.
'e tl‘e igritior switcl‘ CFF.
Disoorr ed the 2P oorr‘edor
from He ECT ser sor.
l'uleaSLre resistar ce betweer‘
tl‘e 2ten‘1irals or ti" e ECT
sersor 'ermir‘al side of male tennir‘als
NC
lstl‘ere 200—400 ol‘m? :3— Repla ce the E CT sens or.
YES
Check the ECM output voltage ECT SENSOR 2P CONNECTOR
[ECT Iin e}:
1. 'e' tt'e igritior switch ON til}.
ECT
2. At the ergire l‘ arr ess side. [REDI
meaSLre voltage betweer tl‘e WH T]:
ECT sersor 2P cor rector
tennir‘al No.2 ard bodygrocrd.
Wire side of _
lstt'ere approx. 5V?
NC
(To page 11-6-34} l'o page '1 '1 4334}

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-FI System
'+# 11 -C-34

%!
/%0

/
?0

(From page 11-0-33] [From page 11 {233]
sea EGT
W (GRNI [REDJ'Wl-IT}
ELK)
Ch eok for at open in the wire 13G:
line]:
M east. re voltage betweer the
EC’sersorEP mrrector Wire side of
tennirals No.1 ard No. 2. fem ale terlnirals

the ECM (71) and ECT sensor.

and reoheok {see page 11-C-1Efor
immobilizerinformation}. If
symptomlindioation goes away.
replaoetheoriginal ECM.
Cheek for an open in thewire (ECT

line}:
1. ’e the igr‘ itior‘ switch CFF.
2. Corr ed the ECM test harress
ard the test pir‘ box betweer‘
the ECM ar‘d oor‘r‘ector {see
page 11—0—1 3].
'e the igr‘ itior‘ switch CN Ijll}.
MeaSLre voltage betweer‘ the
test pir box ten‘tir‘al No. .78
ard body nLJ‘CI.

Isthere approx. 5 V?
the EGMWB} and the ECT sensor.
Cheek for a short in the wire (ECT

line}:
1. 'e the igr itioh switch CFF.
2. Disccrrect ECM corrector
from the ECM.
3. Check the osrtihuity betweer
the test pir box termihal No.
TB ard body nLr‘d.
Is there osrtihLity'? YES Repair short in 'Ihewire between

the ECM {TB} and the ECT sensor.
NO

and recheck (see page 11-0-12
symptoniindioation goes away,

4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-Fl System
'+# _ _
3
Throttle

'

/'0
1 1 C 35
$
, . \ / I \ 4,! ;,<(
4 !;(4<$9%!4!
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 7: A problem in the Throttle
Position (TP) Sensor circuit.
;4< -
The TP sensor is a potentiometer. It is connected to the throttle valve shaft. As the throttle position changes, the throttle
44-!&!&-%!
A!
position sensor varies the voltage signal to the ECM.
&&!

! ,-
— The MIL has been report on.

— With the 5G5 short oonneotor
oon neoted {see page 11-C-11).
oode 'I' is indicated.
I
1. Do tI' e ECM Reset Procedure
(see page 11-0-12]. RESISTOR
2. Start the er‘gir‘e.
No a thistime {test-drive may be
Istre MIL or‘ ar‘d does it irdicate necessary]. Cheek for poor
code 7"? ' oonneotions or Ioosewires
YES beween the TF sensor and the ECM
Cheek the sensor output voltage:
1. ’e tI‘e igr‘itior‘ sw‘td‘ OFF.
2. Correct tI‘e ECM test f‘arr‘ess
ardtretest pir‘ box betweer'
the ECM ard oor redor I: see
page 11 -C-1 3}.
3. ’e the igritior sw‘td' CN III}.
4. I'uleaSL. re voltage betweer‘ the
test pir box termir‘als No. T3
and No 71
”the ”wage approx- 0-5 V :1 IL“ Sabstitute a known-flood ECM

closed ti‘rd‘tle. it'd approx. 4'3 V at YES md reuheuk tsee Pine 11 -C-12 for
I" n" qsuen ti‘rd‘tle. '— immobilizer ini'brmation]. li'
NOTE: There shotld be a smodh symp tomfindiuation goes away.
transifim as theti‘rcttle is replace the origini ECM.
depressed.
NC
Cheek the 1P circuit:

1. 'e ti‘e igritior OFF.
2. Discorrect 3P cor rector from
the 'P sersor.
3. 'e ti‘e igritior switch CN III}. TP SENSOR 3P CONNECTOR
4. r‘xtti‘e ergire I‘arress side. —
I‘TEESLI'E! voltage betweer' tI‘e 1 3 V662
M
'P sersor 3P corrector [YELIBLLI]

termir aI No.3 ard body groLr'd.
NC
YES
"Mre side of
female tennir‘als
W
('o page 11 -C-3Ei] [To page 11-066}

4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-Fl System
'+#
Throttle

'

/'0
/
?0
11 -C-36
5
(Front page 11-0-35} IjFroln page 1'1 43-35}
V
Cheok for an open in thewire 1562
"3.3,?
.,I.-"

line]: (V002 line):
At the engine hamess side. measure MEaSLFE voltage betweer tl‘e test
voltage betweenthe’F sensor 13F pir box tenniral No. 46 ard body
cenl'ecterterwirals No 3 and No. 2. groe.
_/ Is trere approx. 5V?

YES
. NO

the ECM [48} TP sensor.

and recheck (see page11-C-12 tor
immobilizerinformation). If
sym ptomiindioation goes away.
rmlaoe the original ECM

the ECM [71) TP sensor.
YES
TP SENSOR 3P CONNECTOR
Cheek for a short in the wire (“’8

Iin e}: 5G2 vccz
1. 'e ti'e igritior switch CFF. [GRNJBLIU i‘I'ELIBL U]:
2. Disoor'reet ECM oorrector
from the ECM.
3. Check for oortirLity betweer Wire side of
the test pir box teri‘tiral No. female tennir‘ als
T3 ar'd body groe.
Isti‘ere ml‘tll‘LlI'y‘? Repair short in the wire hemeen

the ECM (73) and TP sensor.
('o page 11-0-37}

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
PGM-Fl System
'+#
Throttle

'

/'0
/
?0
11 -C-37
7
(From page 11-0-36}
TP SENSOR 3P CONNECTOR TES T PIN BOX

TERMINAL
[TPS lin e}: —
Cl‘edt for oortirLity betweer‘ the
Wire side of
test pir box termir al No. 73 ar‘d ‘ .
female terl'tir' als
the ’P sersor 3P correctcr Wire 5'“ Cf
tenniral No. -1_ female termir‘als
TPS [REDI
ELK)
. . YES Replace the TP sensor [see page

< Isti‘ere ccrtIrLrty? >—
11-0-76).
NC

the ECM {7'3} and TP sensor.

4

&A
!#!!3
9
(See Page 11-0-76)
;'!$<
PGM-FI System
'+#
6 /0

11 -C-38
8
\ I / \ I /
:fi: :-
0
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTG) 10: A problem in the Intake Air
\ 4,! ;,<(
4 !;(4.<09%!#%
Temperature (IAT) Sensor circuit.
4 ;%4< -
The AT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor
4%4 ;<-4
decreases as the air temperature increases as shown below.
3!3-
RESISTANCE (k ohm)

— With the SSS shortconnector
connected (see page11-c-11},
TH ERMISTOR
-mlmln-.'}" .".,_...._.l
Problem verification: l ‘V- '5‘ “II 2'1.“e
1. Do the ECM Reset PrccedLre IN TAKE AIR TEM PERATU RE
(see page 11 -C-1 2::
2. ’e‘ the igr‘iticr switch CN ill}.

at this time {test-drive may be
lsthe MIL cr‘ ar‘d does it ir‘dioate
necessary]. Check for poor
code 10?
connections or loose wires
YES between the IAT sensor and the ECM.
Check the sensor resistance: IAT SENSOR 2P CONNECTOR

1. ’Lrh the igr‘iticr‘ switch CFF.
2. Discchhect 2P ccrhectcr from
the If? sehscr.
3. MeaSL. re resistahoe betweeh
the 2teri‘1ir‘als or the LAT .-' '-.
o h n‘ I
serscn I.___ ___.
'erinir‘ al side of male tennir‘als

Nc
lsthere 0.4—4.0Kchi‘1? ' Replace the [AT sensor.
YES
lAT SENSOR 2P CONNECTOR
I1.‘.hecll{ the ECM outputvoitage
[IAT Line}: IAT
1. _L.l'l‘ the igriticr switd‘ CN ill}. [REDI‘I'E L]:
2. fit the Hair wire harress side.
ineaSLre voltage betweeh IA—
sehscr 2P ocrhectcr terinir‘ al
No. 2 ard body grocr‘d.
W1 re side of —
female termir‘als
[Tc page 11-0-39: Tc page 11-0-39}

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-Fl System
'+# _ _
9
6 /0
/
?0 1 1 C 39
(From page 11-0-38] [From page 11-038}
3’7
Check for an open in the wire (IAT
V
line]: [8132 line}:
1_ 'e tl'e igritior switol‘ CFF. luleaSLre voltage betweer tl‘e IA-
2_ Correct the ECM test l“ arress ser'sor 2P eor'r'eetortenniral No.
ar'dtl'e test pir box betweer 1 ar'd Nil 2-
tl‘e ECM ar‘d oorreotor lsee
page 11-0-1 3'1.
3. ’e‘ tl'e igr‘itior switol‘ CN ill}. —-.. NC
4. Meascre voltage betweer‘ ECM C Is tl' ere approx. 5 V? :2:-
oor'r' ector termiral No. T? ard —
body groLr‘d. YES

the ECM (71) and IAT sensor.

ancl recheck [see page 11-0-12
for immobilizer in formation} It
smptomrinclication goes away.
[AT SENSOR 2P CONNECTOR
—2 IAT
“3“” I. [REDI‘I'EL]
BLK)
Wire side of female tennir‘als
lstl‘ ere approx. 5 V? Rep air open in the wire between

the ECM finand [AT sensor.
Check for a short in the wire (IAT

line}:
1. 'e tl‘e igritior switch OFF.
2. Diseorrect ECM oorrector
from tl‘e ECM.
3. Cl‘edt for oortiruity betweer'
the test pir box tenhir‘al No.
T? ard body groe.
Rep air short in the wire between

the ECM if?) and [AT sensor.
Eu bstitutc a known-good ECM

ancl recheck {see page 11 -C-1 2 for
symptomlinclication goes away.

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-Fl System
'+# $
-
-
Vehicle
4 Speed Sensor (V88)

/40 11 C 40
_‘ ' 1'7 :
:3 $
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the vehicle
IE, /-\ 4,! ;,<(
4 !;(4<$9%!&!
speed sensor VSS circuit.
: -
The VSS generates a pulsing signal when the front wheels turn.
4:
!

!33! -
—With the 505 short connector
connected (see page11-c-11),
code 1? is indicated.
l
(see page 11 -C-1 2}.
2. ’est-clr'ru'etrarsmissior ir
r'eutral. accelerate to 4,000 rpm
(Mir-1}. ther decelerate to
1,500 rpm (Mir-'1 j: with throttle
fully dosed for at least 5
secor‘ds.
Isthe Mcr and does it atthistime. Check for poor
irclicate ccde1i“? oonn cations or loose wires between
the V33. the ECM.
YES
Check the ECM input voltage:

1. ’urr the igr‘iticr‘ switch OFF.
2. Block rearwheels ahd set the Make SUB “RS. JGCKS ar'd SGTEW
parkirg brake. -ack up the from STEFCIS are placed properly [333
ofthe car ahd support with SECTiCP 1 l-
safety star‘ds.
3. Correct the ECM test hawess
ard the test pir‘ box betweer'
the ECM ar‘d oor‘r‘ectorlsee
page 11-0—13].
. 'urr the igr‘iticr‘ switch ON ill}.
4:. .
5. Bloch; the right from 'wh eel ar‘ d

slowly rotate left from wheel
arcl measure voltage betweer'
the test pir box ten‘tir‘al No.
42 arcl No. 28.
Does voltage pulse 0V ar'd and recheck {see page 11 -C-12 for
approx. 5V? immobilizerlindieation goes away.
replauethe original ECM.
NC
('6 page 11 -C-41 i

4

&A
!#!!3
9
(See Page 11-C-13)
;'!+<
(See Page 11-C-12)
;'!<
(See Page 11-C-11)
;'!<
'+#
PGM-Fl System

-
-
Vehicle
4 Speed Sensor (VSS) (cont’d)

/40/
?0 1 1 C 41
(From page 11 -C-4D}
Ch eck the circuit was line}:

1. ’e' the ighitioh switch ICFF.
2. Disoor‘r‘eot ECM oohheotor
from the ECM.
3. ’Lrh the igr‘itioh switch CN ill}.
4. Block the right from wheel ar'd
slowly rotate left from wheel
arcl meaSL. re voltage betweer'
the test pih box termir‘als No.
42 ahd No. 28.
— Repair shortin the wire
between the ECM (42].
" — Repair open in the wire
Doesthe voltage pulse 0 V NC
< ar cl approx . rJ V? / V35.
YES — Ifthewire isOK. testtheVSS {see
section 25'].
Substitute a knmn-good ECM

and recheck (see page11-c-12
for immobilizer information}. If
symptemlindicatien goes away.
4

&A
!#!!3
9
(See Page 11-C-12)
;'!<
PGM-Fl System
'+# _ _

Heated Oxygen Sensor (H028) Heater
.#!
/.0. 1 1 C 42
_‘ ' 4'1 :
:3 *
IE, /-\ 4,! ;,<(
4 !;(4<*9%!6
The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 41: A problem in the Heated
Oxygen Sensor (H028) Heater circuit.
8/
;68<6 -
1. Dctt‘e ECM Reset ProoedLre
is ee page 11-0-1 2].
2. Start tl‘e er' gir'e.

Is tl‘e I'ulIL or ard does it ir‘dicate\ NC at this time. Check for poor
code 41? / connections or loose wire
beween the H028 and the ECM.
YES
H028 4P CONNECTOR
H025:
1. ’e tl‘e igriticr switch CFF. H028HTC '61
2. Disocrredtre l-'C2S 4P
ocrr ectcr.
3. At the H325 side. measue
resistarce betweer the hC2S
4P ccrrectcrten‘tirals No. 1 1
ard No. 2. '. _
'en‘tir‘al side of male

termir‘als
\ NC Replace the H025 (see page 11-

< Is tl‘ ere 2 _ 20 Gl‘l‘iS 7- C 5).
YES
H02 SH TC
Attf'e H328 side. deck for
ecr'tir'Lity betweer body groe ard
tf'e l-C2S 4 P ccrrectcr terinirals
[15.1a No. 2 irdi-xidLally.
fl
. ., )— Replace the H023 (see page 11-

Ietl‘ere CGPIIFLfly‘.7 0 I5).
Fe page 11-0-43}
4

&A
!#!!3
9
(See Page 11-C-45)
;'!*<
(See Page 11-0-12)
;'!<
(See Page 11-0-11)
;'!<
PGM-Fl System
'+# _ _

Heated Oxygen Sensor (H028) Heater (cont’d)
.#!
/.0./
?0 1 1 C 43
[From page 11-13412: H028 4P oONNEcToR

l HosTc IG1
Check for an open or short in the {SH-:5; 1—. 15;?
wires [H OESH T0 line):
1. Start tl‘e er gir'e. 3 4
2. fitti‘e l‘arr'ess side. measue
voltage betweer tl'e FCES 4P
oorrectortermir' als No. 1 ard
No. 2.
Wire side of female
termir als
< ls tl‘ ere battery voltage?
NC
“IA [BLKJ'
"V." 1—1 YEL]:
l’o page '1 '1 43-44:: 1 2
Cheek for an open in the wires 3 4
[IG1 line]:
luleaSLre voltage betweer body
grocl ardtre FCES 4P
oor'r' ector termir al No. 2

H028 and No. 8 ECU (EM)
ls tl‘ere battervvoltage? CRUISE CONTROL [15A] fuse in
the driver‘s under-dash fuse!
YES relay box.

[H OESH TC lin e):
1. ‘e tl‘e igritior switch OFF.
2. Reoorrecttl‘e l-CES oorrector.
3. Correottl‘e ECM test l‘an‘ess
ardtl‘etest pir box betweer
the ECM arcl oorreotortsee
page 1143—13}.
Start the er gir e.
.4“
5. MeaSLre voltage betweer tl‘e

test pir box termir als No. 37
arcl No. 34.
YES Re palr
- open -In theWIre
- beMeen
{ ls tl'ere 1.0V orless? ECM (37);“ H028.
NC

and recheck [see page 11-0-12 for
smtom‘indieation goes away,
4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-12)
;'!<
PGM-FI System
'+# 11 -C-44

Heated Oxygen Sensor (H028) Heater (cont’d)
.#!
/.0./
?0
(From page 1'1 43-43]

all“. ,."'

[HOZSHTC line):
1. ’e tl‘e igr‘itior switd‘ OFF.
2. Correcttl‘e ECMtestl‘arr‘ess
ardtl'etest pir‘ box totl'e
wire harness cr‘ly. rottotl'e
ECM Ijsee page 1'1 -C-'13::.
3. Cl" eds for oor‘tir‘Ljny betweer'
body groLr‘d ar‘dtl‘etest pir‘
bcxtermir‘al No. 3.7.

ls tl‘ere cortir Lity?
ECM (3?) and H025.
NC

and recheck {see page11-C-12 for
swptornlindioation goes away.
replaee the original ECM.
4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
(See Page 11-0-12)
;'!<
.#!
11 _C -45
3
Replacement

1.
(68*A&
H028.
68-
o: SENSOR
WRENCH
Snap—on
vmvs or
equivalent H023 4F CONNECTOR
HEATED
OXYGEN
SENSOR [H025l
u Mm (4.5 kg‘I-m.
33 Ibf-f't]
-
2. !!68&&!-
Install the H028 in reverse order or removal.

#
Idle Control System
#
* Guide

!
11 -C-46
5
NOTE:
84 9
Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should be
%3A ! # !
inspected, starting with 1. Find
A
3- the symptom in the left column, read across to the most likely source, then refer to the
!! A!#! A
page listed at the top of that column. If inspection shows the system is OK, try the next system 2. etc.

!! -38>A/--
If the idle speed is out of specification and the Malfunction Indicator Lamp (MIL) does not blink Diagnostic Trouble Code
! ,! ;,<!#(
4 !
(DTC) 14, go to inspection (See Page11-C-47).
;(4<*A
;'!*$<-
PAGE SUB-SYSTE M POWE Fl
IDLE NFI AIH BRAKE STE [FINE HOSEE
.I'1|_FLftN.I‘I.1|§_IIH I-Ft :
CONT REM CONDITIONING SW1 [CH I-‘Hl-‘SBIJHF AND
SIGNAL
VALVE SIGNAL SIGNAL SWITCH CUNNECTIUNS
SIGMA-L
“a K'----.,__
SVMP‘TUM HM. . 11cm 11C5D 11-E-‘52 11-66: H 1142-55-
DIFFICULT IO SIP-HT
EKGJNE WHEN CU LO
9 l
WHEN COLD FAST iDLE OUT OF

SPEC ILWU - 2.001:- rom IITlin-‘ll
E)
FICIU EH IDLE
@6369
WHEN WARM ENGINE SPEED TOO

HIGH
5 Idlvu speed is below

specified rpm lino land:-
@ 9
increase after lflfllflI start

up.
.
WHEN
Idle amen-{ls drops when
WARM RPM
air candnionar in ON
TDD LOW
@ I
Idle speed drops when

figuring whwl is turning
' lull:- speed fluctuates

®;@
m1h electrical load
WHILE WARMING UP
FREQUENT
STALLING
AFTER WARMING UF
{-9
FA] L5 EMISSION TEST

4

&A
!#!!3
9
(See Page 11-C-48)
;'!*'<
(See Page 11-0-50)
;'!0<
(See Page 11-0-52)
;'!<
(See Page 11-C-54)
;'!*<
(See Page 11-0-55)
;'!<
Idle Control System

# 11 -C-47
7
System Description
#)
4!
!!!%!;%<:!&-4&!&

into the intake manifold in response to electric current controlled by the ECM. When the IAC Valve is activated, the valve opens
#!! !! ,-2%:!&&A&!&
to maintain the proper idle speed.
!-
Frurn
YELJ’ "‘ PG M-FI
Bur. MAIN
FIE LAY
URN
""- VARIOUS
aLKa‘ ; SENSORS
BLU
IAC
/ VALVE
INTAKE
MANIFOLD
1.
2! !3A%&!&!-4
!!!
! -
- When the idle speed is out of specification and the Malfunction Indicator Lamp (MIL) does not indicate Diagnostic Trouble
2! ,! ;,<(
4 !
Code (DTC) 14, check the following items:
;(4<*A#!!3
9
- Air conditioning signal (See Page 11-0-50).
%

!;'!0<-
- ALT FR
%4 signal (See Page 11-0-52).
1
!;'!<-
- Brake switch signal (See Page 11-C-54).
)#3
!;'!*<-
- PSP switch signal (See Page 11-0-55).
3
!;'!<-
- Hoses and connections.
6-
- IAC valve and its mounting gasket.
%&!&

#-
+- If the above items are normal (and the MIL does not indicate DTC 14), after IAC valve replacement, substitute a
&!;,(4*<A%&!&!A
known-good ECM and recheck. lf symptom goes away, replace the original ECM.
#3
,#-
3A!
! ,-
Idle Control System

# 11 -C-48
8

/04-
\ I / \ I /
:fi: :-'
*
\ 4,! ;,<(
4 !;(4<*9%!!%!
The Malfunction Indicator Lamp (MIL) Diagnostic Trouble Code (DTC) 14: A problem in the Idle Air Control
(IAC) Valve.
;%<:!&-
The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in order to
4%:!&

!
! ,
maintain the proper idle speed.
!-
SHAFT
— The l'li'llL has been reported on.
— With the 803 short connector To INTAKE . ..._
connected [see page 11-0-11), MANIFOLD .
-FromAlR
CLEANER
1. Do the ECM Reset ProcedLre mu E
[see page 11-0-12].
2. ’e the igritior switch CN Ijll j:.
lntenn ittent failure. system is OK

Does the lullLblirkard NC atthistime. Check for poor
does it irdicate code 14? connections or loosewires between
the IAC valve and the ECM
YES
Check the ECM input voltage:
2. Correct the ECM test hamess
ardthe test pir box betweer
the ECM ard corrector (see
page 11-0-13}.
3. 'e the igritior switch CN til}.
4. l'uleaSLre voltage betweer 'ermi ral side of male IAC VALVE 3P CONNECTOR
': IACV N lire
bodv groe ard th e test pir termirals
box tennirals No. 29. No. 2'
Check the IAC Valve:
irdividLallv. 1. 'e the igritior switch OFF.
2. Disoorred the IAC Valve 3P I... 1 -"
NC corrector.
s:j'___ Is there battery voltage?
.. 3. Measure resistarce betweer
IAC Valve 3P corrector
IGP [YELIBL Ki
YES
teri‘tirals No. 2 ard No. 1, No. 3
irdiu'idcally. Wire side of female termirals

Is th ere '10 — 22 ohms? NC
,—
[1GP line}:
1. 'e the igr itior switch OFF. YES
2. Discorrect the IAC Valve 3P
I Replace the IAC Valve.
corrector.
3. 'e the igr itior switch CN {ll}.
4. At the wire harress. measL. re Substitute a known-good ECM
voltage betweer IAC Valve 3P and recheck [see page 11-c-12
correctortermiral No. 2 ard for immobilizer information). If
bo dv groe. symptomlindication goes away,

NC
the IAC Valve and PGM-FI main
relay.
YES
(To page 11-0-49}

4

&A
!#!!3
9
(See Page 11-C-11)
;'!<
(See Page 11-0-12)
;'!<
(See Page 11-0-13)
;'!+<
Idle Control System

# 11 -C-49
9

/04-/
?0
(From page 11 43-48} [AG VALVE 3P GONNEGTOR
Check for an open in the wire IACV P

[IACV P, [AW N' line): (BLKJBLU)
1. 'e tl‘e igr‘itior‘ switch ICFF.
2. Dismr rec: tl' e ECM corrector.
3. Cl‘eck for cortirLity betweer‘
IAC Val-re 3P corrector
termir al No. 1 ardtl‘etest pir‘
box termir‘al No. 29 (IAC Valve
3P corrector tennir‘al No. 3 ar‘d
the test pir‘ box tenniral No. TEST PIN BOX
2':.' TERMINALS
': IACV N lire
<
—/—
ls tr ere cortir Lity?
"
the [Ac Valve and ECM [29, 2'}.
YES

[IACV P, lACV N' line):
Cl‘eck for cortirLity betweer
body groe ard tl"e test pir‘ box
termirals re. 29, No. 2'
ir'd'ru'idL. ally:

Is there ocrtirLit 3:?
the [AC Valve and ECM [29, 2'}
YES
Check the [AC Valve:

1. Disenr'r'ecttl‘e IAC Valve 3P
ecr'r' actor.
2. Mature resistarce betweer
IAC Val-re 3P correctcr
termir‘als No. 2 arcl No.1. No.3
'ermir' al side of l“1 ale
ir' dividL ally.
termir‘als
NC
lstl'ere10 - 22 ol‘ms? Replace the [AC Valve.
YES

ancl recheck [see page 11-0-12
symptoml‘indication goes away,

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
Idle Control System

# 11 -C-50
3$
Air Conditioning System

!#
This signals the ECM when there is a demand for cooling from the air conditioning system.
4
! ,3!

-
In sp eotion ofAir Conditioning
Signal
Gheok for a short in the wire

[ACE line}:
1. ’e the igritior switch IOFF.
2. Correct the ECM test harress
ard the test pir box betweer
the ECM ar cl the corrector (see
page 11-0-13}.
Discorrect the NC pressue
switch corrector.
’e the igritior switch CN Ijll}.
I'd"?-
luleasL. re voltage betweer the

test pir box termirals No. 75
ard No. 34.
Check for a short in the wire [AC3

line):
1_ 'e the igritior switch OFF.
lsthere approx. 5V? 2_ Disoorredthe ECM corrector.
3_ Check for cortirL. ity betweer
YES body grocrd ard ECM
corredortenniral No. T5.
YE S
NC
the ECMiTE} and the NC
pressure switoh.
check for an open in the wire — Substitute aknown-good ECM

moo line}: and reoheok {see page11-C-12
1. 'e the igritior switch CFF. for immobilizer information}. If
2. Recorrect theJ‘w'C presee presoribed voltage is now
switch corrector. available replaoe the original
s. 'e the igritior switch CN {ll}. ECM.
4. Momertaril'y' correct the test — See the air oonditioner
pir box tennirals No. 48 ard inspeotion {see seotion 22}.
No. 34 with a jLInper wire
several times.
['o page 11 43-51}

4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
(See Page 11-0-13)
;'!+<
Idle Control System

# 11 -C-51
3
Air Conditioning System (cont’d)

!#/
?0
(From page 11-6-50]

moo lin e}:
lethereaclidtirg roise from NO Momertarily correct the eer
the NC compressor soh? hood fLeeI'relay box 1GP corrector
termir ale No. 11 to bodygrourd
YES
with a jLInperwire several times.
Is there a diekir g raise from NO

theNC Dom pure as or clLtch?
—/'
YES
See air conditioner inspection

(s ee section 22}
Rep air op en in the wire between

the ECM [48} and theAIC clutch
relay:
ISheclt for the operation of the UNDER-HOOD FUSEJRELA‘I' BOX

AIS: 1GP CONNECTOR
1. Start the ergire.
2. 'e the blower switch CN. 1 3|—|4
3. 'e the NC switch CN. I8 1'10 11 I12 fl1 4 1E
ACCIRED) J: JUMPERWIRE
'INire side of
Check for an open in the wire female tennirals
— NC [AGO line}:
Does the NC operate? '2—' Meast. re voltage betweer the
test pir box tennirals No. 75 ard
YES No. 34.
NO
( l3 voltage lees thar 1 .0 V?
Air conditioning signal is OK.
YES
the ECM (75) and theme switch.
EGl'lll ancl recheck (see page
11-6-12 for immobilizer
in formation}. If symptom!
the original ECM.
— See the air conditioner
inspection [see section 22).

4

&A
!#!!3
9
(See Page 11-C-12)
;'!<
Idle Control System

# 11 -C-52
3
Alternator (ALT) FR Signal

/&0+ !
This signals the ECM when the Alternator (ALT) is charging

4
! ,3%!;%4<

-
lnspeetion ofALT FR Signal.
Cheek for a short in the wire (ALT

F line}:
1. Cor'r' eat the ECM test harhess
ar'I:l the test pih box betweer‘
the ECM ar‘d oohheotor (see
page 11-0-1 3}.
2. Disoor‘r‘eot the 2P oohheotor
from the AL’.
3. ’e the igr‘ itioh switch CN ill}.
4. MeaSLre voltage betweeh the
test pih box tennihals No. 50
ahcl No. 34. Che ek for a short in the wire (ALT
F line}:
1. ’e' the ighitioh switch CFF.
——————————\ NC 2 Bisoor'heot the hegat'ru'e
< Is there approx. 5 V? battery cable from the battery.
3. Bisoor'heot the ECM oor‘r‘ector.
YES 4_ Ch eok for oohtihLity betwe eh
body groLh cl ahcl the test pih
Cheek the operation of theALT: boxtermihal No. 50.
1. ’Lrh the ighitioh switch OFF.
2. Recohheot theAL' 2P YES
cohhetor to the AL'. Is there cohtir‘ Lity?
3. Stanthe er‘gir‘e. holdthe
NC
ehgihe at 3.00 rpm [Mir-1}
with ho load :ftrar‘smissior‘ ir‘
heLtral} L.r‘til the radiator far‘ Repair short in the wire between
comes or‘. ther‘ let it idle. the ECM [50) and theALT.
4. l'uleaSLre voltage betweer‘ the
test pih boxtermir‘als No. 50
arcl No. 34.
and res heuk (see page 11-6-1 2 for
prescribed 1.Ibltage is now arailzhle.
Does th e v olta 9e decrease 'w'heF‘"'- _ _

headlights ard rear defogger are ALT FR 3'9"" IS 0K-
teecl or?
('o page 1143-53]

To go to the pages referenced on the diagram above
4

&A
!#!!3
9
(See Page 11-0-12)
;'!<
(See Page 11-0-13)
;'!+<
Idle Control System

# 11 -C-53
3
Alternator (ALT) FR Signal (cont’d)

/&0+ !/
?0
(From page 11-0-52]
ALT 2P CONNECTOR
Cheek for an open in the wire (ALT ALT F

F line}: qwn 11m; D}
1. In“ the ighiticr switch OFF.
2. Disochhed the 2P ocr‘r‘edor
from the AL'.
3. 'Lrh the igr‘iticr‘ switch CN ill}. "Mre side of
4. Measue voltage bet'weer‘ the female terlnir' als
AL‘ 2P correctcr termir‘al
No. 2 ahd body groL. hd.
Is there approx. 5 V? Repair open wire between the

Ecru [ED]: and theALT.
See the ALT in spec ion [a ee

3e e'liorl 4).
Idle Control S stem

# _ _
Signal
Brake Switch !
"6(
3
11 C 54
This signals the ECM when the brake pedal is depressed.

4
! ,3#!-
I Inspection of Brake Switch Signal.I
fire the brake ligl‘ts or without YES Inspect the brake switch [see
depressir‘g the brake pedal? section 19).
NC
I Depress tl"e brake pedal. I
—-..
. ’J NC Ir‘speo: tl‘e S’CP 1"1. 5 N.l use ir‘
< Dotre brakes ligl‘ts come or‘. the eer-rood fLsev'relaybox.
YES
/—
Istl‘e mse CK?
no
YES
— Repir short in thewire

between the brake switch and
the STOP {15A} i'use.
— Replace the STOP {151%.} l'use.
. . — Repa’r open in lhewire

I1.‘.heclt for an open In the wlre .
[1BKSW line}: between the brake switch and
Depress tl‘e brake pedal. h e STOP ‘15“ fuse:
2 Connect the ECM test ramess — Inspect the brake switch (see
andtl‘e test pin box between “Mm" 18)
the ECM and connector (see
page 1143-13}.
3. Mess Lre voltage between ire
test pin box terrrinals No. 13
and No. 34 witl‘ ire brake
pedal depress ed.
NC Repair open in the wire heween

4 Is tl'ere m— the ECM (1 a) and the brake
switch.
YES
I Brake switch signal is OK. I

4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
Idle Control System

# _ _
33
'
( !'/''0( Signal 1 1 C 55
This signals the ECM when the power steering load is high.
4
! ,33
!
-
PSP swncH 2P CONNECTOR
Inspection of PSP switch signal.
PSPSWIGRN]:
JUMPER
WIRE .-
ICtheolt for an open in thewire {PSP
5W line]:
1. Correct tl'e ECM test l‘arress
GND LK
ardtretest pir box betweer [B 1'
Eggi'i’flggda'icrremor lsee Wire side of female terlnirals
2. ’e tre igritior switcl‘ CN (ll).

3. luleaSLre voltage betweer tl‘e
test plr box terinlrals NC' "'2 Ch eok for :1 open in the wire (PSP
arcl No. 34. S'Wline):
1. ’Lrntreigrition switd‘ OFF.
2. Disconnect the PSP switcr 2P
connector.
i — NC 3. ’un tre igr‘ition switd" ON ill}.
'5 there IBSSH‘ ar 1‘01"? / 4. Attrewireside, oonrecttl'e
YES PSP's'Mtd' 2P connector _
terirlnals No. 1 and No. Emir a
juirper 'M' re.
Measure voltage betweentl'e
.(‘h
test pin box tern‘inals No. T2

and No. 34.
NC
ls trere less tl‘ar 1.0 V?
Check the operation ofthe PSP
switch: YES
1. Starttl‘e ergir e. . . .
2. 'e steerirgwl‘ eel slowly. _ 5:3;Lzfifi: Eéxfiflfind
3. l'uleaSLre voltage betweer the the PSP switch.
test pir boxterrtirals No. 72 _ Repair open in BLK wire
arcl NC- 34- between the PSP switch and
ground [G301 }.
< ls tr ere battery '9' olt age?
YES
PSP switch signal is OK. [—5 page 11-6-56}

4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
Idle Control System

# 11 -C-56
35
'
( !'/''0( Signal
(cont’d)
/
?0
IjFrcr'l page '1 '1 413-55}
Check for: short in the PSP

switch:
1. ’e the igr'iticr' switd‘ OFF.
2. Disccrr‘ect the 2P oorr‘ector
from the PSP switch.
3. ’e the igriticr switd‘ CN Ijll}.
4. M eaSL. re volta ge betweer‘ the
test pir box termirals No. .72
arcl Ne. 34.
Check for a short in the wire [PSP

SW line):
NC 1. 'L.n" the igr‘itior‘ switch IGFF.
Is there battery voltage? -..__:: 2. Disccrr‘ect the ECM oor‘r‘ector.
3. Check for cortirLit'y betweer'
YES body grourd ardthetest pir'
box termir al No. .72.

— YES
NC

the ECM [72} and the PSP switch.
Substitute a kncwn-gccd ECM

and recheck {see page11-C-12
fcrimmcbilizerinfcnnaticn). If
prescribed vcltaaeis new
available. replace the criginal ECM.
4

&A
!#!!3
9
(See Page 11-0-12)
;'!<

#
Idle Control System

11 -C-57
37
NOTE:
84 9 4
* Idle the engine for one minute with heater fan
!
3
¢ Leave the IAC valve connected.
&%&!&- switch at HI and air conditioner on, then check the
36A#
¢ Before inspect the idle speed, check these items:
)!A#9 idle speed.
!-
4,- Idle speed should
be:

*F
- Ignition timing.

- 810 1 50 rpm (min-1)
8$O3$/ 0
- Spark plugs.
#!
- NOTE:
84 9
- Air cleaner.
%!- If the idle speed is not within specification, refer to
!3A
- PCV system.
:- Symptom Chart (See Page 11-C-46).
;'!*<-
1.
-
TACHOMETEFI
TACHDMETEH
CONNECTCIR
2.

-6!
+A000; <
with no load (transmission in neutral) until the radiator
3!; !< !
A!!-
3.
+- Check the idle speed with no-load conditions:
#!3!9
headlights, blower fan, rear defogger, radiator fan, and
!
A!3A
AA

-
Idle speed should
be:

*F
750 i 50 rpm (min-1)
73$O3$/ 0
Fuel Su | S stem
+## 11_C_58
38
#
* Guide

!
84 9%3A ! # !

!! A!#! A

listed at the top of that column. If inspection shows the system is OK, try the next most likely system (2), etc.
!! -38>A/!#!;<A-
F‘AGE @S‘I‘STEM FIJEL FUEL ' FUEL FUEL. FUtL PG M FI CONTAMI-

PRF SURE MAN“: NFITI'JJ
"a. LINES INJEC10H 5' FllTFFl PUMP
—H“'\-\.._\_\_ “-5.55 1 REGULATOR RELAY FUE'L
a.._
_—
S‘P'MPTDM “a--..,_~ 11 1:59 11-1152 11-E-EEi 1141.405 ii-A-‘IGG 1143-53
———l— __.____
EN GI NE WU N‘T START ® {33' CD ®
mmcu LT TCI START (D @J
Ens-NE WHEN com on H01 :
..
@ @
9
FI'EIUGH IDLE
._,,__
MISFIRE DR
_
HUUGH
('9
® (“3.6
RUNNING
FAILS
POUR PERFOR-
EMISSION
MANC‘E
TEST
_ ._. ' _ _._ . --—
LOSS OF
POWER
WHILE
WARMING - (D
FREDLIE NT UF' __ _
STALLING mg i i
WARMING ' CD I
UP |
4

&A
!#!!3
9
(See Page 11-0-59)
;'!5<
(See Page 11-0-62)
;'!<
(See Page 11-0-66)
;'!<
;'!%0<
;'!%0<
(See Page 11-0-68)
;'!'<
Fuel Supply System
+## 11 -C-59
+&
Fuel Lines
39
NOTE: Check fuel system lines, hoses and fuel filter for damage, leaks or deterioration, and replace if necessary.
84 9# !!A !!
A!#A!-
33 Mm (335 kgl-rn, 27 mm)
15 Nm (1.5 kgf-m,
11 Ibf-‘l'll
Theillustrauon shows
LHD type.
Refer to 'll-C-E
page for RHD type.
+##
Fuel Supply System
Fuel Lines (cont’d)
+& /
?0
11 -C-60
5$
NOTE: Check all hose clamps and retighten if necessary.

84 9#!!!
-
P (-
Do not disconnect the hose from the pipe.
FUEL PUMP
LOCK NUT
FUEL PUMP
FUEL TANK EVAPORATIVE FUEL GAUGE SENDING UNIT
EMISSIDN IEVAPI BASE PACKING
VALVE Replacu.
t).—
FUELTUBEI .
QUICK-CO NNECTH*==_—_'_—__—
HTnNGs . _:—
——
l.
EUAPOFIATWE FUEL
EMISSION lEVAPl FILTER
CONTROL
(MINISTER
; EVAPORA‘I'WE EMISSION
IEVAPJ TWO WAY
To FUEL
PRESSURE q—.. -__
REGULATOR
.u “av .19 -.- .-.v .u w flu. ‘ “‘- n1 .u luv-v .u .-
Clarvp in the middle
1D — 14 mm
[0.39 -0.55 in)
Fuel Supply System
+## 11 -C-61 Fuel Pressure
+'
System Description
#)

5
The fuel supply system consists of a fuel tank, in-tank
4 ! ! !#A# Before disconnecting fuel pipes or hoses, release
)
!A!
high-pressure fuel pump, PGM-Fl!A !!A !

! A., main relay, fuel filter, fuel pressure from the system by loosening the service bolt
!
&!
pressure regulator, fuel injectors, and fuel delivery and return

!A !7A !!& on the fuel feed pipe.
!-
A WARNING
lines. This system delivers pressure-regulated fuel to the fuel
!-4!&
! ! !
injectors and cuts the fuel delivery when the engine is not
7 !!&3

running.

- Do not smoke while working on the fuel system. Keep
(#3!3#
!->
open flame or sparks away from the work area. Be sure
!#33#-)
to relieve fuel pressure while the ignition switch is off.
!& ! 3!
3-
1.
(
&!
battery negative terminal.

&!-
2.
1& !!!-
3.
+- Use a wrench on the service bolt at the fuel feed
?3&! !
pipe.
-
4.
*- Place a rag or shop towel over the service bolt.
!
3!&&!-
5.
- Slowly loosen the service bolt one complete turn.
!3!!&!! -
SERVICE BOLT
15 Nlm (1.5 kgf—m. ‘I'I Ib'H‘ll
SHDP TOWEL
NOTE: Replace the washers whenever the service bolt
84 91!33&&!
is loosened or removed.
!&-
+##
Fuel Supply System
Fuel Pressure (cont’d)
+'/
?0
11 -C-62
5 Fuel Injectors
+D

Inspection

Description
)

1.
- Relieve fuel pressure (See Page 11-C-61).
1!& ! ;'!<- The fuel injectors are a solenoid-actuated constant
4 !7!
2.
- Remove the service bolt from the fuel feed pipe Attach
1&&! !% stroke, pintle-type consisting of a solenoid, plunger
#A!
!A!

the fuel pressure gauge.
!

- needle valve and housing. When current is applied to
!&!&
-2 !
FUEL the solenoid coil, the valve lifts up and pressurized fuel
!!A&!&! H !
PRESSURE is injected. Because the needle valve lift and the fuel
7-) !&!&! !
GAUGE
07406 — 0040002 CLAMP pressure are constant, the injection quantity is
A7F
determined by the length of time that the valve is open
!
&!&
(that is the duration the current is supplied to the
; !
solenoid coil). The fuel injector is sealed by an O-ring at
!!<-4 !7!8

the top and bottom. These seals also reduce operating
-4!!

n0|se.
-
D-RING FUEL HAIL
FUEL
INJECTOR
INTAKE
MANIFOLD
FUEL PRESSURE
REGULATOR
3.
+- Start the engine. Measure the fuel pressure with the

-, ! 3
engine idling and the vacuum hose of the fuel pressure

!
& !
regulator disconnected from the fuel pressure regulator

! !
!
and pinched. If the engine will not start, turn the ignition
-
3!!A

switch ON (ll), wait for two seconds, turn it off, then back
38;<A33A A#
on again and read the fuel pressure.

! -
Pressure should
' be:

*F
280-330 kPa (2.9-3.4 kgf/cm2, 41-48 psi)
8$$6'/@9@6! 2:8 0
If the fuel pressure is not as specified, first check the
! A#
fuel pump (See Page11-A-107). If the fuel pump is OK,
! ;'!%0$<- ! 8>A
check the following:
#!!3
9
0 If the fuel pressure is higher than specified, inspect
!
A
for:
9
- Pinched or clogged fuel return hose or line.
!
! !-

! !
!;'!
11-C-66).
<-
0 If the fuel pressure is lower than specified, inspect
! !3A
for:
9
- Clogged fuel filter.
!
!!-
! !
!;'!
11-C-66).
<-
- Leakage in the fuel line.
#
!!-
+##
Fuel Supply System
+D
/
?0
11 -C-63
5
Testing
! If the
engine cannot be started
!
*
NOTE: Check the following items before testing: idle speed,
84 9#!!3

9!A 1.
- Remove the connector of the fuel injector, and
1& !7A
ignition timing and idle 00%.

!8W- measure the resistance between the 2 terminals of
3!
If the
engine runs:
! F the fuel injector.
!7-
1. 2
!
A !7
- With the engine idling, disconnect each fuel injector Resistance should
be: 13.8-15.3 ohms

*F@83@
at 20°C
$P
connector individually and inspect the change in the idle
& !!
! (68°F)
/58P+0
speed.
-
0 If the idle speed drop is almost the same for each
!!
cylinder, the fuel injectors are normal.
!A !7!-
0 If the idle speed or quality remains the same when
!F !3
you disconnect a particularfuel injector, replace the
! !7A!
fuel injector and retest.
!7-
Check the clicking sound of each fuel injector by means
- #!#
!7
of a stethoscope when the engine is idling.
3
!
-
FUEL
INJECTOR
0 If the resistance is not as specified, replace the
A!
fuel injector.
!7-
0 If the resistance is as specified, check the fuel
A# !
pressure (See Page 11-0-62).
;'!<-
0 If any fuel injector fails to make the typical clicking
!7!#!!#
- If the fuel pressure is as specified, check the
! A#
sound, check the sound again after replacing the
A#
!
following:
!!3
9
fuel injector.
!7- ¢ Whether there is any short-circuiting, wire
2
A3
- If clicking sound is still absent, check the following.
!#
!!A#!!3
- breakage or poor connection in the YEL/BLK
#
C =)>
2
A3 wire between the PGM-FI!
33., main relay and the
#
C =)> junction connector.
7 -
wire between the PGM-FI!
33., main relay and the ¢ Whether the junction connector is open or
27
junction connector.
7 - corroded.
-
¢ Whether the junction connector is open or
27 ¢ Whether there is any short-circuiting, wire
2
A3
corroded.
- breakage, or poor connection in the YEL/BLK
#
AC =)>
2
A3 wire between the junction connector and the
337
#
C =)> ECM.
,-
wire between the junction connector and the
337 If all is OK, check the ECM (See Page 11-0-21).
!!8>A# ,;'!<-
fuel injector.
!7-
Whether there is any short-circuiting, wire
2
A3
breakage or poor connection in the wire
#
3
between the fuel injector and the ECM.
3 !7 ,-
If all is OK, check the ECM (See Page 11-C-21) and
!!8>A# ,;'!<
PGM-F1!;'!'<-
., main relay (See Page 11-0-68).
Fuel Su | S stem
+## 11_C_64
5
+D
/
?0
Replacement:
F
A WARNING
(#3!3#
!->!#33#-
- Relieve the fuel pressure (See Page 11-0-61).
1!& ! ;'!<-
PONT‘
- Disconnect the connectors from the fuel injectors.

( !7-
+- Disconnect the vacuum hoses and fuel return hose from the fuel pressure regulator.
(& ! !
!-
84 9!
3!&
-
4.
*- Remove the retainer nuts from the fuel rail.
1& !!-
5.
- Disconnect the fuel rail.
( !!-
6.
- Remove the fuel injectors from the intake manifold.
1& !7#!-
FUEL FEED HOSE
12 Mr“ NOTE:
(1.2 kgf—m. If JCmOVD the fuel
3.?Ibt-l1l feed hose from the
fuel rail, replace the
fuel lead hose
assembly.
FUEL
PRESSURE
REGULATOR
[II-RING
Replace\
FUEL
INJECTOR
"$3.5
O-FIING a
7.
$- Slide new cushions rings onto the fuel injectors.
!3
!7-
8.
'- Coat new O-rings with clean engine oil, and put them on the fuel injectors.
38
3!
!A !7-
9.
5- Insert the fuel injectors into the fuel rail first.
!7 !!-
Fuel Supply System
+## 11 _C_65
53
+D
/
?0
10.
0- To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in the intake manifold.
4&
8
A!! !7 !!A!!#!-
FUEL RAIL
FUEL lNJECTOH
11. !!
-
12. & ! !
!-
- Connect the vacuum hoses and fuel return hose to the fuel pressure regulator.
13. 4
38;<A -% ! /!3A
+- Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for approximately two seconds, the
! !!-13A#3 !!#
-
+##
Fuel Supply System
+'!

11-C-66
55
Description
)
Testing
!
A WARNING
The fuel pressure regulator maintains a constant fuel
4 !
! !
pressure to the fuel injectors. When the difference between
!7-23
the fuel pressure and manifold pressure exceeds 300 kPa,
! ! /+00#A Do not smoke while working on the fuel system. Keep
(#3!3#
!->
3.1 kgf/cm2,
+-#
= 44 psi, the diaphragm is pushed upward, and
A**A
3A open flame or sparks away from the work area.
!#33#-
the excess fuel is fed back into the return line.
/ !# !- 1.
- Attach the fuel pressure gauge (See Page
% !

;'!
To INTAKE 11-C-62) Start engine.
<
-
MANIFOLD FUEL
PRESSURE
GAUGE CLAMP
011.05 — 0040002
DIAPHRAGM
FUEL PRESSURE
REGULATOR
!9
Pressure should be:
280-330 kPa (2.9-3.4 kgf/cm2, 41-48 psi)
8$$6'/@9@6! 2:8 0
T (with the
/( fuel pressure regulator vacuum hose
!
-
disconnected and pinched).

0@

i
FUEL INLET FUEL lNLET
2.
-
3.
+-
Reconnect the vacuum hose to the fuel pressure
1& !
regulator.

!-
Check that the fuel pressure rises when the
# ! 3
vacuum hose from the fuel pressure regulator is
& !
!
disconnected again.

-
¢ If the fuel pressure did not rise, replace the
! A!
fuel pressure regulator.
!
!-
FUEL
RETURN
Fuel Su l S stem
+## 11 _C _67 Inertia Switch
(
Fuel Pressure Regulator (cont’d)
+'!
/
?0
57
Replacement
Description
)
A WARNING
The inertia switch is a safety device which automatically
43&3 !!
cuts off the fuel supply in the event of a collision or
! !&!!
(#3!3#
!-> sudden impact.
-
!#33#- The switch is located behind the glove box. After an
43!
!&/-%
1.
- Place a shop towel under the fuel pressure regulator,
!3! !
!A impact, the switch must be reset by pressing the button
A3

then relieve fuel pressure (See Page 11-0-61).
!& ! ;'!<- before the engine can be restarted.

-
2.
- Disconnect the vacuum hose.
(& - sour
3.
+- Remove the clip from fuel pressure regulator.
1&! !
!-
FUEL O-HING VACUUM
RESET __ __ _/
PRESSURE
REGULATOR
Replace HOSE
BUTTON- "- . -.
CLIP SPRING
TERMINALS
STEEL
BALI.
MOVING
CONTACT
MAGNET
4.
*- Apply clean engine oil to a new O-ring, and carefully
%!!
!38
A !!
install it into its proper position.
!!-
5.
- Install the fuel pressure regulator and clip.
!! !
!!-
6.
- Reconnect the vacuum hose.
1& -
Fuel Supply System
+## 11 _C_68
58
PGM-Fl Main Relay
'+ #
Description
)
Relay Testing
# !
The PGM-Fl! !!3& !
4., main relay actually contains two individual NOTE: If the car starts and continues to run, the 1 main
84 9 A
relays. This relay is located at the driver side of the cowl. One
!-4!!&3!-8 relay is OK.
!8>-
relay is energized whenever the ignition is on which supplies
!
H3&
3 ! 1.
- Remove the PGM-Fl!-
1&., main relay.
the battery voltage to the ECM, power to the fuel injectors,
&!
,A3 !7A 2.
- Attach the battery positive terminal to the No.2
%&!-
and power for the second relay. The second relay is
3!-4! terminal and the battery negative terminal to the
!
&!
energized for two seconds when the ignition is switched on,

H33
3A No.1 terminal of the PGM-Fl!-4
and when the engine is running, to supply power to the fuel
3

A !3 ! check for the continuity between the No.5 terminal
# 3-!
pump.
- and No.4 terminal of the PGM-Fl!-
-*!., main relay.
PGM-Fl ¢ If there is continuity, go on to step 3.
A
+-
MAIN RELAY ¢ If there is no continuity, replace the PGM-Fl
A!.,
!-
[1:53.235 r
No. 2
i
INJECTOR -
FUEL PUMP
_;
l
l
.1
To IGN. 1 L5 7 To BAT (Ell
|
. To ECM
To GROUND .3 CONNECTOR
TERMINAL
No. 54 and No. 53
“SH
To ST. swiTCI-i L:
I
To EEM i L. '_ .I
CUNNECTDH 1 To FUEL PUMP
TERMINAL . _ . _ .
No. 1 lFLRl
3.
+- Attach the battery positive terminal to the No.5
%&!-
!
&!
No.3 terminal of the PGM-Fl!-4
-+!., main relay. Then
check there is continuity between the No.7 and the
# 3-$
No. 6 terminal of the PGM-Fl!-
-!., main relay.
¢ If there is continuity, go on to step 4.
A
*-
A!.,
!-
4.
*- Attach the battery positive terminal to the No.6
%&!-
!
&!
No.1 terminal of the PGM-Fl!-4
check there is continuity between the No.5 and the
# 3-
No.4 terminal of the PGM-Fl!-
-*!., main relay.
¢ If there is continuity, the PGM-Fl!
A., main relay is
OK.
8>-
A!.,
!-
Fuel Su | S stem
+## 59
'+ #/
?0 ' '
11 C 69
— Engine will not start.

— lnspeetion of PGM-Fl n1ain PGM-Fl MAIN RELAY 7P CONNECTOR
relay and relay harness 13m)
{ELK}
1 2 _T
Cheek for an open in the wire 4 5 E I ®
[GND line):
1. ’e tl'e igr‘itior switd‘ OFF.
2. Disoor‘r‘ecttl‘e PGM-Fl mair :
relay oor‘r‘ector.
W1 re side of female terl‘tir‘als
3. Check for cortiruity betweer
tl‘e PGM-Fl mair relay TP
oor'r'eo‘tortermiral No. 3 ard
body groL.r‘d.
-1 2 THAT
Rep air op en in th e wire between 4 5 e I [WHTIGRN]:
'5 tl‘ere cort'my' the PGM-Fl main relay and G101.
' I 7
YES

wire [BAT line):
lul eaSLre voltage betweer‘ tl‘ e
Pll-Fl mair‘ relay 7P correct or
tenniral No. 7 ard body grour'd.
. ml
M
— ReplaoetheACGS 116A] fuse 4 I3
Lh
in the under-hood fl.|se.lrelayI
box. _ IG1
Il—
Is there battery voltage? — Repair open or short in the |.__1___.| lREWBLK}
YES—: wire between the PGM-Fl main _
Ill-l
relay and theACGS 116A] fuse.

wire [IG1 line):
1. _LIT tl‘e igritior switd‘ CN ill}.
2. M eaSLre tl‘e voltage betweer'
tl‘ e PGMFI Hair relay .II-P INERTlA SWITCH
oorreotortermlral No. a ard
bodygroe. _ _ _ 3P CONNECTOR
Check the Inertla swneh:
1. _e tl'e igr'itior switd‘ OFF.
2. Disoor‘r‘eot the 3P . oorrector
— NC . .
letl‘ere batte "olta e? frolntl'e Ir'ertla SWltd‘.
CM 3. _e'tl'eigr'itiormitd‘ owl]. 'NERW‘
YES 4. M eaSL. re voltage betweer tl‘ e SWITCH
ir'ertia switol' 3P oorrector (RED;
tennir‘als No.1 arcl No. 3. ELK)
. NC
Is It ere battery voltage? a—l
YES
_ Replaoe theNo. 1 FUEL PUl'IP
(15A) fuse in the driver's
under-hood fuselrelay box.
— Repair open or short in the
wire heme-en the PCNl-Fl rnain
relay and theNo. 1 FUEL PUMP
(_o page 11-070] (15A) fuse.
Replaee the inertia switeh.

Fuel Su | S stem
+## 7$
'+ #/
?0 ' '
11 C 70
(From page 11-6-69]

PGM-FI MAIN RELAY 7P CONNECTOR
are [BLUIORN]:
LI-‘Il
wire [8T5 line):
UIM
1. 'e the ighitioh switch to the E
'-|
I Hi:
S’f’ Ijlll'; positioh. '1.
NC’E: trar‘smissioh ih
reLtraI.
2. Measue the voltage betweer‘
the PGM-FI maih relay 7p Wire side of female terl‘tir‘als.
cor'r'ector teri‘tih al No. 2 ahd
body groL.r‘d. — Replaee thehle. 1SS'I'ARTER
SIGNAL {7.5 A} firse in the
driver's under-heed Msehelay
bet.
Is there battery voltage?
— Repair epeh or short in the
YES wire between the PGM-FI main
relay and the Ne. 13 STARTER
SIGNAL {15 A} 'llise.

[FLR line):
1. In“ the ighitioh switoh OFF.
2. Cor red the ECM test harhess
ahcltest pih box to the wire
harhess or‘lv, hot to the ECM
[see page 11-0-13].
3. Check for OSPIIPLIIV betweer‘
th e PGM-FI i‘tair‘ relay TP
cohhector teri‘tir‘al No. 1 ar‘d
th e test pir‘ box termir‘ al No. 1 .
—— NC Repair open in the wire between

C ISTI‘EFB Cw theECMtHand theF'GM-FI main
relay.
YES

flGP1, IGP2 line a):
1. Cohheotthe ECM oohhector.
2. Reoohhect the PGM-FI mail"
relav 7P cohhector.
3. 'e the ighitioh switch CN ill}.
4. Meaee voltage betweeh the
test pih boxten‘tihals No. 54,
No. 58 ahd No. 34.
— Repair epen in thewire

NC between the ECM {54. 58)ahd
< Isthere ban@ the PeM-FI main relay.
— Replaee the PGM-Flmaih
YES relay.
('o page 11 -C-.T1 2:

4

&A
!#!!3
9
(See Page 11-0-13)
;'!+<
Fuel Supply System
+## 11-C-71
7
'+ #/
?0
(From page 1'1 Ail-TD]
Cheek for an open in the ECM:

2. Measere voltage bet'weer' the
test pir‘ box teri‘iir‘als No. '1
ahd No. 34wher‘ the igr‘itior‘
switch is first tL.l'l"ed ON ill} for
two seoor‘ds.
Substitute a known-good ECI'I'I

and recheck [see page 11-c-12
NC for immobilizer information}. If
C |sthere1.UVorless? >—.
prescribed voltage is now
available, replace the original
YES ECM
Check the PGM-Fl main relay

[see page 1143-68).

4

&A
!#!!3
9
(See Page 11-C-12)
;'!<
(See Page 11-C-68)
;'!'<
Intake Air System
6 # 11 -C-72
7
#
* Guide

!
84 9%3A ! # !

!! A!#! A

listed at the top of the column. If inspection shows the system is OK, try the next system (2), etc.
!! -38>A/;<A-
PAGE l SUB-SYSTEM AIR CLEANER
fi__ I AND INTAKE THCFEELELE THEODSLE
“--..__~ “a3“ ' AIFI DUCT
SYMPTOM — ' 11-A-1'IS ' ' ' ' 11-c-74' 11-015
WHEN COLD FAST IDLE OUT OF SPEC ®
WHEN WARM IDLE SPEED T00 HIGH ® (D
LOSS DF POWER ® ®
I
i

4

&A
!#!!3
9
;'!%5<
(See Page 11-C-74)
;'!$*<
(See Page 11-0-75)
;'!$<
Intake Air System
6 # 11 _C-73
7
System Description
#)
The system supplies air for all engine needs. It consists of the intake air pipes, Air Cleaner (ACL), intake air duct, Throttle Body
4 !!!
-#A%!;%<A# A4!)
(TB), Idle Air Control (IAC) valve and intake manifold. A resonator in the intake air pipe provides additional silencing as air is
;4)<A!%!;%<&!&#!-%#&!!

drawn into the system.
3-
From
YELI PGM-Fl
ELK “ MAIN
RELA'r
[—
_..._... ——-—-ORN- ._ ___.
BL“. If I. ECMI {_..-

—' 'IVAHIDUS
ELU .. PCM . _ semsnns
IAC
VALVE
11
-n m
I --- .1—
' r _.
‘ 't‘
.' I. _-
J .15....
..
|
. DUCT
'—'U r=f-'
INTAKE THFID'ITLE ACL RESONATOR

MANIFOLD EICIIDV'
6 #
Intake Air System

*
Throttle Cable
11 -C-74
7

2D Installation

1.
-6!
+A000;<
- Start the engine. Hold the engine at 3,000 rpm (min-1) 1.
- Fully open the throttle valve, then install the
!!!&!&A!!
with no load neutral) until the radiator fan comes on,
3! !< !A throttle/cable in the throttle link and install the cable
!=!!!#!!!
then let it idle.
!!- housing in the cable bracket

!#
Check cable free play at the throttle link Cable deflection
#!!!!#!! 2.
- Start the engine. Hold the engine at 3,000 rpm

-6!
+A000
should be 10 - 12 mm (3/8 -1/2 in.).
!0;+='=-<- (min-1)
; with no load (transmission in neutral) until
<3!; !< !
ADJUSTING the radiator fan comes on, then let it idle.
A!!-
LIABLE
BRACKET THROTTLE LIN K
CABLE DEFLECTIDN
BRACKET 1D — 12 mm
(3MB - ”2 inl ADJUSTING LDCKNUT lNNEH CABLE
If deflection is not within specs, loosen the locknut, turn the
!3A!!# A NUT
adjusting nut until the deflection is as specified. Then
7
!!-4 3.
+- Hold the cable sheath, removing all slack from the
6!!A&
!!!#
retighten the locknut.

!# - cable.
!-
With the cable properly adjusted, check the throttle valve to
2!!7 A#!&!& 4.
*- Turn the adjusting nut until it is 3 mm (1/8 in) away
4 7
!+;='<3
be sure it opens fully when you push the accelerator pedal to
!!3 !! from the cable bracket.
!#-
the floor. Also check the throttle valve to be sure it returns to
!-%!#!&!& 5.
- Tighten the locknut. The cable deflection should
4
!# -4!! !
the idle position whenever you release the accelerator pedal.
!3& !!!- now be 10 - 12 mm (3/8 -1/2 in). If not, see
30;+='=<-A
=%7
ADJUSTING NUT
3mml1fainl
LDCKNUT
9.3 N-m
i1.o kgf-m.
7.2 lb‘I-ftl
CABLE BRACKET
Intake Air System
6 # 11 -C -75
73
Throttle
Body

"
#
Description
)
Inspection

4!
!!-4!3 Check that the throttle cable operates smoothly without
#!!!3
!&!&
! binding or sticking.

#
-
the cylinder head.
!- If there are any abnormalities, check for:
!A#9
THROTTLE 0 Excessive wear or play in the throttle valve shaft.
/&3!!&!&-
POSITION iTPl 0 Sticky or binding throttle lever at the fully closed
#
!!& !!!
SENSOR
position.
-
0 Clearance between throttle stop screw and throttle
!3!3!
lever at the fully closed position.
!& !!!-
There should be
THROTTLE THROTTLE
VALVE STOP
THROTTLE STDP SCREW
SCREW
“3:: not adjustJ ”30 not adjust.)
Replace the throttle body if there is excessive play in
1!!/&!
!&!&

sticking.
#
-
Intake Air System
6 # _ _
Throttle
Body (cont’d)

"
#/
?0
75
11 C 76

-
Removal
MAP SENSOR
TP SENSOR
22 N-m
[2.2 kgf-m.
1E Itl
O-RING
Replace.
THROTTLE
CABLE
NOTE:
84 9
(7 !3-
¢ After reassembly, adjust the cruise control cable (see section 4), the throttle cable (See Page 11-0-74).
%!A7 !!;*<A!!;'!$*<-
Disassembly
) *#
4.5 N-m (0.45 kgfvrn.
3.5 Ibf-f‘tl SENSOR
Troubleshooting
..-- page 11-028
GASKET Q
Replace. 3—“ O-RING
Replace.
IDLE AIR CONTROL llACl VALVE

If N-m (0.3" kgi-m. 2 him

5 lbf-f‘tl (0.2 kgf-m. TP
1 ”3"” SENSOR U-RING
Troubleshunling Replane.
page 11 C 35

4

&A
!#!!3
9
(See Page 11-0-28)
;'!'<
(See Page 11-C-48)
;'!*'<
(See Page 11-0-35)
;'!+<
%

#
#
* Guide

! 77
11 -C -77
NOTE: Across each row in the chart, the sub-system that could be sources of a symptom are ranked in the order they should
84 9%3A ! # !

3;<- the symptom in the left column, read across the most likely source, then refer to the page
!! A!#! A

!! -38>A/;<A-
. PAGE l SUB SYSTEM THREE WAY nfiggii EVAPORATIVE

CATALYTIC EMISSION
CONVERTER VENTILAT‘ON CONTROLS
I SYMPTOM SYSTEM _ __ _ _
" ll—C-?B 11.079 1142.30
ROUG H IDLE .; _']:'_;.
FAILS EMISSION m, (.23

TEST k
POOH _ , __
PERFORMANCE .' I I
: LOSS OF :l
POWER J”)

4

&A
!#!!3
9
(See Page 11-0-78)
;'!$'<
(See Page 11-0-79)
;'!$5<
(See Page 11-0-80)
;'!'0<
%

#
System Description
#)
11 -C-78
78 Three
Way
1
(TWC)
/10
Catalytic Converter
##
-
The emission control system includes a Three-Way Catalytic

4!! 42! Description
)

Converter (TWC), Positive Crankcase Ventilation (PCV)
&;42<A&#:!;:< The Three Way Catalytic Converter (TWC) is used to
442!&;42<
system and Evaporative Emission (EVAP) Control system.
&& ; :%<!- convert hydrocarbons (HC), carbon monoxide (CO),
&;6<A/;8<A
Tailpipe Emission
%
and oxides of nitrogen (NOX) in the exhaust gas, to
/
;8/</
A
Inspection

carbon dioxide (COz,
/;8 dinitrogen (N2)
A
; and water vapor.
<3&-
A WARNING
Removal/Installation (see section 9)

-2
/
90
HOUSING
Do not smoke during this procedure. Keep open flame or
(#
->!
sparks away from the work area.
#33#-
1. -
2.
-6!
+A000;<
with no load (transmission in neutral) until the radiator
3!; !< !
A!!-
Check the idle speed and adjust the idle speed. If
+- #!7 !-
necessary (See Page 11-C-57).
;'!$<-
Warm up and calibrate the CO meter according to the
*- 2 !8

meter manufacturer's instructions.
@ -
Check idle CO with the headlights heater blower, rear
- #!83!
B!3A THREE WA?
33
A!
A- CATALYSTS
Specified CO%: 0.1% maximum
SF$@S
FRONT OF
VEHICLE
Inspection

If excessive exhaust system back-pressure is
/&/ #
suspected, remove the TWC from the vehicle.
A&42&!-
Using a flashlight, make a visual check for plugging,
?
!!
A#& !#!

A
melting or cracking of the catalyst.
!
#
!-
Replace the TWC if any of the visible area is damaged
1!42&!

or plugged.
!
-
FLASHLIG HT
%

# 11 _C_79
79
Positive Crankcase Ventilation (PCV) System
'
-64
/'40#
Description
)
1.
- Check the PCV hoses and connections for leaks
#:!#
The Positive Crankcase Ventilation (PCV) system is
4&#:!;:< and clogging.
!

-
designed to prevent blow-by gas from escaping to the

&!3

BREATHEH
atmosphere. The PCV valve contains a spring-loaded
-4:&!&
! PlFE
plunger. When the engine starts, the plunger in the PCV
!
-2
A!
:
valve is lifted in proportion to intake manifold vacuum and the
&!&!#!&
blow-by gas is drawn directly into the intake manifold.
!3
3!#!-
BHEATHER
P1PE
PCV
VALUE
- H055
.-: BLOW-BY VAPOR 2.
- At idle, make sure there is a clicking sound from
%!A# !#

: FRESH AIR the PCV valve when the hose between PCV valve
:&!&33:&!&
and intake manifold in lightly pinched with your
#!!
!3
fingers or pliers. If there is no clicking sound, check

!-!#
A#
the PCV valve grommet for cracks or damage. If
:&!&
#
-
the grommet is OK, replace the PCV valve and

8>A!:&!&
recheck.
#-
i Gently pinch liflrfl.

%

# 11 _C_80
8$
%-
-%
/%4'0

Description
)

The evaporative emission controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The system
4&&!
H !&
-4
consists of the following components:
!!3
9
A
Evaporative Emission (EVAP) Control Canister
%-
-%
/%4'0

An EVAP control canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the EVAP
% :%!
!& ! !&
:%
control canister into the engine and burned.
!
-
B
" Vapor Purge Control System
4
'!

#
:%!

!3

:%!
the throttle body. The purging vacuum is controlled by the EVAP purge control canister and the EVAP purge control
!-4

& !! :%
! :%
!
solenoid valve.
!&!&-
| EVAP FUROE CONTROL SOLENOID VALVE DUTY CONTROLLED AFTER
. STARTING ENGINE
l—ENGINE COOLANT TEMPERATURE ABOVE 39-1: IIoz'FI

C
Fuel Tank Vapor Control System
+64

#
When fuel vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve, the valve opens and
2 !& !#
&! :%33&!&A&!&
regulates the flow of fuel vapor to the EVAP control canister.

!!3 !& :%!-
u -.‘TL .
K_
r
TL.
L:
:‘
I—
[—7
l
"
J
.I—fi
LC?
I_
EVAP
JL
" l_l ._I-
PURGE —-
r-
CONTROL From No.6 ECU

BLKI‘ ‘ lECMl
— 'L.‘
SOLENOID
EVAP
|
VALVE YEL CRUlSE CONTROL
TWO WAY :' E‘smnm us AI FUSE
VALVE
CANISTER
FUEL _ _
FlL -Efl —; VARIOUS
CAP FUEL I“ SENSORS
TANK
EVA PV ALVE T‘ RED!
FRESH AIR YEL
\ ifill ELK
FUEL TANK
%

# 11 _C_81
8
%-
-%
/%4'0

/
?0
Inspection of Evaporative
Emission Controls
|
EVAP
PURGE
CONTROL
w
{a .
9:13
Check the vacuum when cold: CANISTER
1, Discorr ect tre vacuum rose
from tre EVAP purge cortrol
car ister ard correct a vacuum VACUUM
gauge to tie rose. J PU MPJ‘
2, Start tre ergire ard allow it to / GAUGE
Id|e_ _ EVAP PU RGE
NC E: Ergrre coolart CONTROL SOLENOID
tempermre I‘m st be belcw Check the lamp purge control VALVE 2P (:0qc
39°C I}102°F}. solenoid valve:
Quickly raise tre ergire speed 1. Discorrect tl‘e 2P CCFFBCTCF
to 3000 Film Ijmir'1 -: from the EfP purge cortrol
soleroid valve. Pcs [RED
ls trere vacuum?
YES 2, Ouicklyraisetl‘e er‘gire speed NEL}
- to 3. 000 rpm Ijmir' 1.
Wire side of
NC
ls tl‘ ere vacuum? . female
tennir als
Inspect vacuum hose routing.

If OK, replace the EVAP purge
NC control solenoid valve.

[PCS lin e}:
1. 'Lrnthe ignition switch OFF.
2. Discmnect ECM cornector.
3. Check for co‘rtinLity between
the EUAF ege control sol enoid
valve 2F comectcr tem‘inal
No. 2 and body ground.
Check the vacuum when hot:
1. Start the ergire. l~old tre
ls tr ere oor tiruity?
ergire at 3,000 rpm |:l‘1ll""1 ::
witl" ro load rjir Park or NO
reutral] urtil tre radiator far Repair short in the wire between
comes or. trer let it idle. the EVAP purge control solenoid
2. Cl‘eck for vacuum at tre valve and the ECM [36}.
vacuum r ose after startirg
tre ergire. Substitute a known-good ECM
3. Quickly raisetre ergire speed and recheck [see page 11 -C-12 for
to 3.000 rpm Ijmir'1 j:. immobilizer in formation). If
smptoml'indication goes away,

valve:
1. 'urr tf'e igritior switcr OFF.
IG1 (BLKI‘I'EL)
2. Discorrecttl‘e 2P corrector
from tf'e EVAP purge cortrol
NC soleroidvalve.
”like"? “304““? 3. 'urr tl'e igritior switcr CN ill].
4. Attf'e rarress side. measure
YES voltage betweer tre EVAP
purge cortrol soleroid v alve
2P correctortenniral No. 1
ard ho d'y' grourd.
W
('o page 11-6-82] ['o page 11 -C-82}

4

&A
!#!!3
9
(See Page 11-C-12)
;'!<
%

# 11 _C_82
8
%-
-%
/%4'0

/
?0
(From page 11 -C-81 j: [From page 11-0-81 ';

W
".3: NC
ls tr ere hart ery voltage?

EVAF" purge control solenoid vave
and the No. 3 ECU (ECM) CRUISE
CONTROL (15A).
Cheek for an open in thewire (PCS

line]:
1, ’e tre igritior switch OFF.
2, Reoorrect tre 2P correotor
to tie EfP ege cortrol
soler oid va lve.
3, Correottre ECM test t‘arress
ard tr e test pir box betweer
tre EClul arcl oorrector (see
page 11-0-13}.
luleaSLre voltage betweer tt‘e
5b" .4“
test pir boxtermirals No. 36

arcl No. 34.
NC
R" Is there batteryvoltage?
YES
"—I
valve and the ECM [35}.

solenoid valve:
'1 . 'e tre igr'rtior switch OFF.
2. Correct the test pir box
termirals No. 36 ard No. 34
witl' ajLI'tper wire.
3. flarttre er gire ard check for
vaoLLI‘w at tl‘e vaoLLIa l‘ cse.
NC
< Is there a USELLI‘T?
Gheek the EVAP control canister: YES

"—I
Ins pectvae uum hose routing.
1, Reoorrect the vacuum rose lfok, replace EVAP purge
to tl‘e EVAP purge oortrol
carister.
2, Removetl‘e fLel fill cap.
3- Correct a VECLLP'l gaugeto Substltute a known-good ECM
cariater ege air rose and retest [see page 11-6-12 for
4, Start the er gire ard raise immobilizer information). If
speed to 3500 rpm “VHF-1}. smton‘flndleatlon goes away,
' ' replace the original ECM.
NC
Does vaoLLr'I appear or gauge Replace the EVAP control
witl‘ir 1 l‘1ll‘LIe? canister.
YES
- — -?;__I__. VACUUM
PUMPI
GAUGE
See EVAP two way valve test to . "’ a “1.“ ~ -- w 3*
complete.
Evaporative emission controls PURGE AIR HOSE "
are OK.

4

&A
!#!!3
9
(See Page 11-C-12)
;'!<
(See Page 11-0-13)
;'!+<
Diagrams
) ! 11 _C_83
8
Fuel-injected System Diagram (D1636 engine: LHD)
+ D#) !/)5"5! F&.)0
.+ .-'.+.--'.. _. . .
I:
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Diagrams
) !
Fuel-injected System Connectors (D1636 engine:
+ D#

/)5"5! F
11 -C-84
8
LHD)
&.)0
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Illustrated Index
12-3

NOTE:
84 9
0 Whenever the transmission is removed, clean and grease the release bearing sliding surface.
2&&A!
!
!
-
0 If the parts marked * are removed, the clutch hydraulic system must be bled (See Page 12-9)
!#G&A! ! !;'!5<
0 Inspect the hoses for damage, leaks, interference, and twisting.

A!#AA3
-
O LHD type is shown. RHD type is similar.
6(3-16(!-
*1. )5"5!

A@ D16B6 engine model
*2. %)5"5!

A@ Except D1636 engine model
6 x 1.0 mm
9.3 N-m [1.0 kgfvm. I2 IbH‘Il
LOCK PIN 'RESEFWDIPI

Replace.
I
\.
- 'HESEFWCIIFI HDSE
RETAINING CLIP
1"”- Replace.
PEDAL PIN
H O-BING
Replace.
CLUTCH PEDAL ———+_ -' " ‘CLUTCH MASTER CYLINDER

Adjustment, page 12-4 Dverhaulflnspectiun, page 12-5
8 x 1.25 mm
13 N-m l1.3 kgf-m.
Disassemblw‘Heassembly, page 12-?
9.4 ItI
'1; 118 Mm [12.0 kgf-m. 86.8 IbI-t‘tl

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'2: 103 Nm [10.5 kgf-m. 16 Ibl-ftl
9.8 N-ml1.0 kgf-m, 7.2 lblvttl
4" PRESSURE PLATE

Removal-Inspection, page 12-10
“CLUTCH PIPE
Installatlun,page12-13
FIE LEASE BEARING

Replacement. page 12-1-1
. ___."'“ FLYWHEEL
' |nspecllor‘wficplacement. page 12-12
\R“ DOWEL PIN

CLUTCH DISC
Run'uuwalstnspectinn, paigu 12 H]
Installation. page 12-13
TRANSMISSION/
/\
. D-FIING
See page 13-1 RELEASE FORK 8 I 1.25 mm
25 N'm IZB kglvm. 13 Ibf-f‘tl
B x 1.25 mm
22 N-m {2.2 kg‘f-m.
15 Ibf-f'tl HULL PIN
'SLAVE CYLINDER
12 3
OVC'hBUIIIHSDECIia, page
Hflolacement, plug“ 12 9
4

&A!#!!3
9
(See page 12-5)
;!<
(See page 12-6)
;!<
(See page 12-7)
;!$<
(See page 12-4)
;!*<
(See page 12-14)
;!*<
(See page 13-2)
;!+<
(See Page 12-10)
;'!0<
(See page 12-13)
;!+<
(See page 12-12)
;!<
(See page 12-8)
;!'<
(See page 12-9)
;!5<
Pedal
Clutch '
_
Adjustment
D

12 4
NOTE:
84 9 2.
- Loosen locknut B, and turn the push rod in or out
!# )A
¢ To check the clutch switch, see section 23.
4#! 3A+- to get the specified stroke (A) and height (C) at the

#;%<
;<
¢ The clutch is self-adjusting to compensate for wear.
4! !7
3- clutch pedal.
! !-
3.
+- Tighten locknut B.
4
!# )-
A CAUTION 4.
*- Turn the clutch switch (or adjusting bolt) in until it
4 ! 3;7
!< !
If there is no clearance between the clutch master cylinder
!3! ! contacts the clutch pedal.
! !-
piston and push rod the release bearing is held against the
!
!
5.
- Turn the clutch switch (or adjusting bolt) in an
4 ! 3;7
!<
diaphragm spring, which can result in clutch slippage or

A3 !! !
additional 3/4 to 1 full turn.
!+=* !! -
other clutch problems.
! !- 6.
- Tighten locknut A.
4
!# %-
1.
- Loosen locknut A, and back off the clutch switch (or
!# %A#! 3;
adjusting bolt) until it no longer touches the clutch pedal.
7
!< !!
! !-
ffil ASSIST SPRING
PUSH ROD
CLUTCH MASTER CYLINDER
.35
/__/+.___ CLUTCH SWITCH
lnr ADJUSTING BOLTl
LOCKNUT A
9.8 N‘m (1.0 kgf-m, 7.2 lint-l1]
__‘ l
mm [0.7 kgt-m. Sim-It] ' A __
_ \A
6 ~ 90
'. I;_r%\:
\ ‘2.
a . .q,_-:I—-u-I-I,I-,-.-I41:-.:-. -. - -I-,—.—.—.—.-
"-' " ' ' 'A-_r.'-.-.-..h. -_'-_'-_h_-.
(A) (STROKE at PEDAL):

;%<;418> (%<9 141-151 mm 5.55-5.94 in)
*--5*<
(B) (TOTAL CLUTCH PEDAL FREE
;)<;484%?46 (% PLAY):
1 %C<9 9-15 mm (0.4-0.6 in) includes the pedal play 1.0-7.0 mm (0.04-0.28
5;0-*0-<! !!-0$-0;0-0*0-'
in)
<
(C) (CLUTCH PEDAL HEIGHT):
;<;?46 (%6 .64<9 LHD: 177-187 mm (6.97-7.36 in) to the floor
6(9$$'$;-5$$-+<!
RHD: 201-211 mm (7.91-8.31 in) to the floor
16(90;$-5'-+<!
(D) (CLUTCH PEDAL DISENGAGEMENT HEIGHT): 6(9';+-5< !
;(<;?46 (%( .%. , 46 .64<9 LHD: 81 mm (3.19 in) minimum to the floor
RHD 107 mm (4.21 in) minimum to the floor
16(0$;*-< !
Clutch #
Master Cylinder 12-5
3
Overhaul/Inspection
- 2
A CAUTION
¢ Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it
(!!#! N
N#! A3
off immediately with water.
!33-
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
!!!#! N!3 !!
3-
.Q...
Before reassembling, check that all parts are free of dust and other foreign particles.
)!
A#!!
!-
Replace parts with new ones whenever specified to do so.
1!333&-
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
,#
!!3#! -
Do not mix different brands of brake fluid as they may not be compatible.
(/#! !-
¢ Do not reuse the drained fluid. Use only Genuine Honda Brake Fluid
( ! -?!. 6)# or an equivalent DOT 3 or DOT 4
! F &!(84+(84*
brake fluid.
#! -
NOTE: LHD type is shown. RHD type is similar.
84 96(3-16(!-
M 9)#%! F &!

-
: Brake Assembly Lube or equivalent rubber grease.
611.0 mm ,. .. , .
5.3 N-m l‘l.flI kgf-m. 12 lbf-ftl '_ '
RESERVOIR
8 x 1.25 mm '.I
RESERVOIR HOSE
13 N-m (1.3 kgf-rn. 9.4 Ibf-ftl Inspection for damage. leaks.
Interference. and twisting.
LOCK PIN
Ruplac e.
PEDAL PIN
YOKE
1 rum. in? kgf-m. 5 Ibf-ftl
DUST SEAL
MASTER CYLINDER BODY
ClHCLlP Check the cylinder wall
far scoring and wear.
funim u
Check for wear
{Brake A55m'r‘l blv and damage.
Lube}

Clutch #
Master Cylinder
Replacement

12-6
5
A CAUTION
4.
*- Pry out the cotter pin, and pull the pedal pin out of
A !!!
the yoke. Remove the nuts.
#-1& -
0 Do not spill brake fluid on the vehicle may damage the
(!!#! &!
NUT
paint; if brake fluid does contact the paint, wash it off
N#! A3 13 Mr“ ”.3 kgf-m.
'Elul lbf-l'tl
immediately with water
!33
0 Plug the end of the clutch line reservoir hose with a shop
!
! !&3
towel to prevent brake fluid from coming out.
3!&#!
- . PEDAL PIN
LHD type:
&.)#F
1.
- Remove the brake fluid from the clutch master cylinder
1&#! ! !
reservoir with a syringe.
&3
-
2.
- Disconnect the reservoir hose from the clutch master
(&!
cylinder reservoir.
!&-
6x 1.0mm
9.8 N-m l1.l.'l Ital-n1. 7.2 Ihl‘fll LOCK PIN
CLUTCH MASTER Replace.
CYLINDER RESERVOIR a
HESEFWOR NUT
HOSE . 13 MM [1.3 kgf-l‘rllr
a, _ 9.4 lbf-l'tl
5.
- Remove the retaining clip. Disconnect the clutch
1&
!-(!
POWER RELA‘I'
line, and remove the O-ring.
!A&8
-
RESEmrc-in CLUTCH
HOSE LINE
3.
+- Remove the clutch master'cylinder reservoir and power
1&! !&3
Replace.
relay.
!-
CLUTCH MASTER
“UNDER RETAINING cur
Replace.
6.
- Remove the clutch master cylinder, then remove
1&! !A&
the reservoir hose from the clutch master cylinder.
&! !-
7.
$- Install the clutch master cylinder in the reverse
!!! !&
order of removal.
&!-
8.
'- Bleed the clutch hydraulic system (See Page
)!! !;'!
12-10)
0<
Clutch #
Master Cylinder 12-7
7
/
?0
RHD type:
.)#F 5.
- Pry out the lock pin, and pull the pedal pin out of
!#A !!!
Remove the brake fluid from the clutch master cylinder
1. 1&#! ! !
- the yoke. Remove the nuts.
#-1& -
reservoir with a syringe.
&3
- NUT
- Disconnect the reservoir hose from the clutch master
2. (&! 51.33%? “gi'm'
cylinder reservoir.
!&- .
cLUTcH LINE .3-a " x".
Replace. H '5 _
LOCI: PIN
fl?f I
Replace. I
RESERVOIR RETAINING
HOSE CLUTCH cur:- 13 film ".3 Ital-m,
MASTEFI Replace. 9.1 mm:
CYLINEIIEH . I I
3.
+- Remove the retaining clip. Disconnect the clutch line,
1&
!-(! !A
6.
- Remove the clutch master cylinder.
1&! !-
and remove the O-ring.
&8
-
4.
*- Disconnect the connector, then remove the mode
(A& CLUTCH a
control motor.
!- MASTER Q
- - '- ‘~.. C‘I'LINDEH Q I
I. fl _ —d3 ":45?
;;..»“
if” 7P CONNECTOR
MODE CONTROL 7.
$- Install the clutch master cylinder in the reverse
!!! !&
MOTOR order of removal.
&!-
8.
'- Bleed the clutch hydraulic system (See Page
)!! !;'!
12-10)
0<

Clutch #
Master Cylinder
) *#2*#
12-8
8
A CAUTION
3.
+- Remove the piston assembly and gasket from the
1&!
#
master cylinder body.
!-
0 Do not spill brake fluid on the car; it may damage the
(!!#! N
GASKET
N#! A3
immediately with water.
!33-
0 Before reassembling, check that all parts are free of
)!
A#!!
dust and other foreign particles.

!-
0 Replace parts with new ones whenever specified to do
1!333&
so.
-
0 Make sure not dirt or other foreign matter is allowed to
,#
!!3
contaminate the brake fluid.
#! -
0 Do not mix different brands of brake fluid as they may
(/#!
not be compatible.
!-
0 Do not reuse the drained fluid. Use only Genuine Honda
( ! -?!. 6
Brake Fluid
)# or an equivalent DOT 3 or DOT 4 brake fluid.
! F &!(84+(84*#! -
1.
- Remove the dust seal from the clutch master cylinder.
1& !! !-
E'lfiTflM
A33EMBL‘I'
4.
*- Turn and remove the bracket and gasket from the
4 &#
#
master cylinder body.
!-
CLUTCH WE
[NUMBER GASKET
2.
- Pry the circlip off the clutch master cylinder.
!! !-
-
5. !!&&!-
Install in the reverse order of removal.
Slave Cylinder
-# 12_9
9
Overhaul/Inspection
- 2
A CAUTION
¢ Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it
(!!#! N
N#! A3
off immediately with water.
!33-
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
!!!#! N!3 !!
3-
Before reassembling, check that all parts are free of dust and other foreign particles.
)!
A#!!
!-
Replace parts with new ones whenever specified to do so.
1!333&-
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
,#
!!3#! -
Do not mix different brands of brake fluid as they may not be compatible.
(/#! !-
Do not reuse the drained fluid. Use only Genuine Honda Brake Fluid
( ! -?!. 6)# or an equivalent DOT 3 or DOT 4
! F &!(84+(84*
brake fluid.
#! -
968(%. ?.?,*;=*C+0<-
: Brake Assembly Lube or equivalent rubber grease.

9)#%! F &!
-
BOOT
Check that it is fitted secure
ever cylinder bod-g.
LHD: HHD:
PUSH HOD BLEEDER SCREW
2 N-m IOZ kgf-m‘ 'l Ibflftl
Urea Greas- UM264

19m 41211 — v - 3051
SLAVE CYLINDER BUD"!r

Check the cylinder Wall for
scoring and wear.
SLAVE CYLINDER SPRING

Install with small end
facing piston.
PISTON CUP
SLAVE CYLINDER PISTON Replace.
Check for wear and damage. ,_._-.——--
,5: [Finis]
lBrake Assembly
L u bel
-#
Slave Cylinder
Replacement

12-10
$
3.
A CAUTION
+- Remove the slave cylinder and O-ring.
1&!&!8
-
NOTE: Use only Honda Genuine Urea Grease UM
84 9?!6. ?.?,
0 Do not spill brake fluid on the car; it may damage the
(!!#! N
264 (P/N 41211 - PY5 - 305).
*;=*C+0<-
N#! A3
immediately with water.
!33-
0 Plug the end of the clutch line a shop towel to prevent
!
! !3!&
brake fluid from coming out.
#!
-
1.
- Remove the mounting bolts, the slave cylinder, and
1&
!A!&!A DI-FIINE
clutch line mounting bolt.
! !
!- / Replace.
CLUTCH
Eaton-m
s3 M-m £1.11 kufim- 1-2 ”it? a x 1.215 mm
22 film I22 kgf‘m. 15 Ihfifil
IFIN #1211 - W5 - 305i

4.
*- Install the slave cylinder in the reverse order of
!!!&!&
removal.
&!-
5.
- Bleed the clutch hydraulic system.
)!! !-
NOTE: Be careful not to damage the slave cylinder
84 9) !
!&!
body with over tighten the bleeder screw.
3&
!3-
¢ Remove front engine stopper bracket (D1686
1&
#;()
engine only), then attach a hose to the

!<A
bleeder screw, and suspend the hose in a
!3A
container of brake fluid.
#! -
¢ Make sure there is an adequate supply of
,# F !
C'l’LlNDEFl fluid at the clutch master cylinder, then slowly
! ! !A!3!
2.
- Remove the roll pin.
1&!!- pump the clutch pedal until no more bubbles
! ! ! !
ROLL appear at the bleeder hose.
!-
¢ Refill the clutch master cylinder with fluid
1!!! !3!
when done.
3-
¢ Use only genuine Honda super Duty DOT 3
?!
6 ( (84+
brake fluid or an equivalent DOT 3 or DOT 4
#! F &!(84+(84*
brake fluid.
#! -
¢ Confirm clutch operation, and check for
! A#
leaking fluid.
!#
! -
BLEEDEFl SCREW
2 him no.2 kgf-m,
11 lt}
Pressure Plate
''
Removal/Inspection

-2

12-11

1.
- Check the diaphragm spring fingers for height using the
#

4.
*- Inspect the fingers of the diaphragm spring for

dial indicator.
!- wear at the release bearing contact area.
3!
-
Standard (New): 0-;0-0</-
;3<9 0.6 mm (0.02 in) max. DIAPHRAGM SPRING
Service Limit:
&9 0.8 mm (0.03 in)
0-';0-0+<
Standard (Now): 0.6 mm (0.02 in} max.
Service Limit: 0.8 mm “1.03 it‘ll
PRESSURE PLATE
5.
- Inspect the pressure plate surface for wear,
! 3A
cracks, and burning.
#A
-
6.
- Inspect for warpage using a straight edge and
3

feeler gauge. Measure across the pressure plate.
!

-, !-
DIAL Standard (New): 0.03 mm (0.001 in) max.
/,(0F$@$/$@$$ 0@
INDICATOR
Service Limit:
- & F 0.15 mm (0.006 in)
$@3/$@$$5 0
PFlE * : UHE PLATE
If the height is more than the service limit, replace the

&!A!
pressure plate.
!-
2.
- Install the special tools as shown.
!!!!3-
PRESSURE CLUTCH ALIGNMENT TGOL BET
PLATE UTPAF - 0020000
FEEtEFl GAUGE STRAVGHI'

EflGE
If the warpage is more than the service limit,
3
&!A
replace the pressure plate.
! !-
RING GEAR HOLDER

WLAB — WMIOO or
01524 - Puma-n3
3.
+- To prevent warping, unscrew the pressure plate
4&3
A 3 !
mounting bolts in a crisscross pattern in several steps,

!&!A
then remove the pressure plate.
& !-

Clutch )
Disc
Removal/Inspection

-2

12-12

1.
- Remove the clutch disc and special tools.
1&! !!- 4.
*- Measure the rivet depth from the lining surface to
, &!

CLUTCH Disc the rivets, on both sides.
&A-
Standard (New)
/,(0
D1636 engine:
)5"5! F 1.3 mm (0.051 in)
@/$@$3 0
F1832, F1833, F2036 engines:
+8":+8":+$"5! F
1.4 mm (0.055 in)
@/$@$33 0
H22A7 engine:
.7! F 1.2-1.7 mm (0.047-0.067 in)
@@7/$@$7$@$57 0
Service Limit:
- & F 0.2 mm (0.008 in)
$@/$@$$8 0
CLUTCH DI$C
- Inspect the lining of the clutch disc for signs of slipping

!
!
!
or oil. If the clutch disc is burned black or oil soaked,

!-! !#!#A
replace it.
!-
+- Measure the clutch disc thickness.
, ! #-
Standard (New)
/,(0
D1636 engine:
)5"5! F 7.7-8.2 mm (0.30-0.32 in)
7@78@/$@$$@ 0
F1832, F1833, F2036 engines:
+8":+8":+$"5! F LINING SURFACE
7.9-8.4 mm (0.31-0.33 in)
7@98@/$@$@ 0 HIVET
H22A7 engine:
.7! F 8.3-9.0 mm (0.33-0.35 in)
8@9@$/$@$@3 0
Service Limit:
- & F 6.0 mm (0.24 in)
5@$/$@ 0
CLUTCH Disc
If the rivet depth is less than the service limit,

&!&!A
replace the clutch disc.
!! -
If the thickness is less than the service limit, replace the

#!&!A!
clutch disc.
! -
Flmheel
+#( 12_1 3

Inspection/Replacement

2
- Inspect the ring gear teeth for wear and damage.

3
- 4.
*- Install the special tool as shown.
!!!!3-
NA
- Inspect the clutch disc mating surface on the flywheel for

!
!3! FLYWHEEL
wear, cracks, and burning.
3A#A
-
3.
+- Measure the flywheel runout using a dial indicator
, !3!
!
through at least two full turns. Push against the flywheel

!3 !! -
!3!
each time you turn it to take up the crankshaft thrust
# #
washer clearance.
3!-
NOTE: The runout can be measured with the engine
84 94 3

installed.
!!-
Standard (New): $@$3/$@$$ 0@
/,(0F 0.05 mm (0.002 in) max.
Service Limit: $@3/$@$$5 0
- & F 0.15 mm (0.006 in)
DIM.
INDICATOR
RING GEAR HOLDER

WLAB - PUDMM or
[”524 - 992mm
5.
- Install the flywheel mounting bolts in a crisscross
!!!3!
!
pattern in several steps as shown, then remove the
&!3A&
special tool and the flywheel.
!!!3!-
Torque

B
D16B6 engine model:
)5"5!
F
118 Nm (12.0 kgf/m, 86.8 lbf/ft)
8,/@$6! 2:85@8* 2 0
Except D16B6 engine model:
%)5"5!
F
103 Nm (10.5 kgf/m, 76 lbf/ft)
$,/$@36! 2:75* 2 0
HWI-IEEL 6.
- Align the hole in the flywheel with the crankshaft
%!
!!3!3#
If the runout is more than the service limit, replace the
&!A! dowel pin, and install the flywheel. Install the
3!A!!!3!-!!
flywheel and recheck the runout.
!3!# - mounting bolts finger-tight.

!

-
7.
$- Install the special tool, then torque the flywheel
!!!!AF !3!
mounting bolts in a crisscross pattern in several

!&!
steps.
-
Flmheel
+#(
Bearing Replacement (D16B6 engine)
" !/)5"5! 0
12-14

- Install the special tool as shown.
!!!!3- 4.
*- Drive the new bearing into the flywheel using the
(&3
!3!

NA
- Remove the flywheel mounting bolts in a crisscross

1&!3!
! special tools as shown.
!!3-
pattern in several steps, and remove the flywheel.
&!A&!3!- HANDLE DRIVER
FLYWHEEL CHI-'49 —0010000
ATTACHMENT.
32 I 35 mm
0T?45 0010100
FLYWHEEL
A
__,..-- --..._\_|_
MOUNTING
5.
- Align the hole in the flywheel with the crankshaft
%!
!!3!3#
BOLTS
dowel pin, and install the flywheel. Install the
3!A!!!3!-!!
RING GEAR HOLDER mounting bolts finger-tight.

!

-
07LAB -— Pvnow-D 6.
- Install the special tool, then torque the flywheel
!!!!AF !3!
Or mounting bolts in a crisscross pattern in several

!&!
07924—PD20IJD3 steps as shown.
3-
3.
+- Remove the ball bearing from the flywheel.
1&!!
!3!-
MOUNTING
BOLTS
12 It 1.0 mm .
11B N-m 112.0 kgf-m. .
35.3 lbw-Li .
DRIFT
PUNCH ‘\
“I
RING GEAR HOLDER '. "I'.L._.
MLAB—oomo
or iii,"
07924 — P020003 FLVWHEEL
FLYWHEEL
BEARING

Clutch ) ''
Disc Pressure Plate

Installation
12-15
3
1.
- Install the ring gear holder.
!!

!- *- Torque the mounting bolts in a crisscross pattern
4F
!
CLUTCH ALIGNMENT TOOL SET as shown. Tighten the bolts in several steps to
3-4
!&!
DTPAF - 0020000 prevent warping the diaphragm spring.
&3

-
CLUTCH DISC Torque:

BF
8 x 1.25mm
8@3
3,@56! 2@9* 2
[PIN 41211 — PYS— 305i

RING GEAR HOLDER
DTLAB - Woman or
03924 — P0210003
2.
- Apply grease to the splines of the clutch disc, then install
%!
!! A!!
the clutch disc using the special tools as shown.
!
!!3-
NOTE: Use only HONDA Genuine Urea Grease UM264
84 9?!68(%. ?.?,*
(P/N 41211-PY5-305).
;=*C+0<-
3.
+- Install the pressure plate and the mounting bolts
!! !
!
finger-tight.

-
PHESEURE PLATE
5.
- Remove the special tools.
1&!!-
6.
- Check the diaphragm spring fingers for height (See
#

;
Page 12-11)
'!<
" !
Release Bearing
Replacement
12-16
5
1.
- Remove the release fork boot from the clutch housing.
1&!#!
- 4.
*- Apply grease to the release fork the release fork
%!
!#!#
bolt, the release bearing, and the release bearing
!A!
A!
RELEASE guide in the shaded areas.

-
BEARtNG NOTE: Use only HONDA Genuine Urea Grease
84 9?!68(%. ?.
UM264 (P/N 41211-PY5-305).
?,*;=*C+0<-
D16B6 engine:
)5"5! F
A: Fill up
F+
B : 0.3-0.9 g (0.01-0.03 oz)
"F$@$@9!/$@$$@$
C0
C : 0.5-1.1 g (0.02-0.04 oz)
F$@3@!/$@$$@$
C0
%)5"5! F
A: 0.4-1.0 g (0.01-0.04 oz)
F$@@$!/$@$$@$
C0
B :1.0-1.6 g (0.04-0.06 oz)
"F@$@5!/$@$$@$5
C0
C : 0.4-1.0 g (0.01 0.04 oz)
F$@@$!/$@$$@$
C0
RELEASE
RELEASE FORK BEARING
BOLT GUIDE
RELEASE FORK
SET SPRING
RELEASE
RELEASE FORK FORK
BOOT
2.
- Remove the release fork from the clutch housing by
1&!#!

RELEASE
squeezing the release fork set spring with pliers.
F H
!#
3!- FDFIK
Remove the release bearing.
1&!
- 300T
3.
+- Check the release bearing for play by spinning it by
#!
!

hand. If there is excessive play, replace the release
-/&!A!!
bearing with a new one.

33-
NOTE: The release bearing is packed with grease. Do
84 94!
#3
-(
not wash it in solvent.
3!&-
5.
- Install the release bearing set spring on the release
!!!

!
fork, with the release fork s|id between the release
#A3!#!3!
bearing pawls.

3!-
6.
- Install the release bearing on the mainshaft while
!!!
3!
inserting the release fork through the hole in the

!#
!
clutch housing.
!
-
7.
$- Align the detent of the release fork with the release
%!
!#3!
fork bolt, then press the release fork over the
#!A!#&
release fork bolt squarely.
!#!F !-
8.
'- Install the release fork boot, make sure the boot
!!!#A#
seals around the release fork and clutch housing.
! !#!
-
Release Bearing
" ! _
/
?0 7
12 1 7
9.
5- Move the release fork right and left to make sure that it
,&!#
!#
fits properly against the release bearing, and that the
!
!
A
release bearing slides smoothly. Wipe off overflowed
!
!!-2&!3
grease.

-
HELEAEE
RELEASE FORK BEARING

Special Tools
13-2

O 1- O Tool Number
4! O Description
( OD O Remark
1#
O O 07GAD - PG20100
0$.%(.000 O Pin Driver, 5.0 mm
(&A-0 O O
_\_\_\_\_\_\_\_\_\_\_\_\VVV—\VVV—\—\
LDOONO‘JU'l-D-OOCIJOOOOOMMMMA
O O 07GAJ - PG20102
0$.%".00 O Mainshaft Clearance Inspection Tool Set
,!4! O O
O O 07GAJ - PG20110
0$.%".00 O Mainshaft Holder
,6! O;< Component Tools
O4!
mi'\)'—\
O O 07GAJ - PG20120

0$.%".00 O Collar
!! O;< Component Tools
O4!
O + O 07GAJ - PG20130
0$.%".0+0 O Mainshaft Base
,) O;< Component Tools
O4!
O + O 07JAC - PH80000
0$"%6'0000 O Adjustable Bearing Remover Set
%7 !)
1& O O
O + O 07JAC - PH80100
0$"%6'000 O Bearing Remover Attachment
)
1&% O;< Component Tools
O4!
(9N4
O + O 07JAC - PH80200

0$"%6'000 O Remover Handle Assembly
1&6!%! O;< Component Tools
O4!
O ++ O 07741 - 0010201
0$$*0000 O Remover Weight
1&2
O;< Component Tools
O4!
O * O 07JAD- PH80101
0$"%(6'00 O Seal Driver Attachment
!(&% O O
O O 07JAD - PH80200
0$"%(6'000 O Pilot, 26 X 30 mm
!A/+0 O O
O O 07LGC - 0010100
0$.00000 O Snap Ring Pliers
1
! O O
O $ O 07744 - 0010600
0$$**00000 O Pin Driver, 8.0 mm
(&A'-0 O O
O ' O 07746 - 0010300
(&%A*/*$ O O
O 5 O 07746 - 0010400
(&%A/ O O
O 0 O 07746 - 0030100
0$$*00+000 O Driver, 40 mm
(&A*0 O O
O O 07746 - 0030400
0$$*00+0*00 O Driver, 35 mm
(&A+ O O
O O 07746 - 0030300
0$$*00+0+00 O Driver, 30 mm
(&A+0 O O
O + O 07749 - 0010000
6!(& O O
O * O 07947 - SD90200
0$5*$(5000 O Seal Drive Attachment
!(&% O O
O O 07947 - 6110501 or
0$5*$00 O Seal Driver Attachment
!(&% O O
O O 07947 - 6110500
0$5*$000 O O O
O O 07979 - PJ40001
0$5$5"*000 O Magnet Stand Base
,
) O O
_\
1: 1133'
Maintenance
13-3
Back-up Light(
"6& ! Switch

+
Transmission Fluid Test/Replacement
2
NOTE: Check the fluid with the engine OFF !&!
84 9#! 3
8 and car on level 1.
- (3-
Disconnect the connectors from the switch.
ground.
-
1.
- Remove the filler plug, then check the level and
1&!!!
A#!&!
pl Terminal side of
condition of the fluid.
! -
\I' 12. I male ierr'ninals
FILLER PLUG
M N-m (4.5 hgf-m. 33 flit-ft}
Proper Laval
WASHER
Replace.
2.
- The oil level must be up to the filler hole. If it is below the
4!!&! !!!-!3 BACK-UP LIGHT SWITCH
hole, add fluid until it runs out, then reinstall the filler
!A! ! A!!!! 25 N-n‘l [2.5 kgf-rn. 18 Ibf-ftl
plug with a new washer.

!
333-
3.
+- If the transmission fluid is dirty, remove the drain plug
! A&!
and drain the fluid.

! -
4
* Reinstall the drain plug with a new washer, and refill the
1!!!
333A!! WASHER
Hernia-CE.
transmission fluid to the proper level.
! !&!-
NOTE: The drain plug washer should be replaced at
84 94!
3 !! 2.
- Check for continuity between the No. 1 and No. 2
# 3--
every fluid change.
&!
- terminals.
!-
5.
- Reinstall the filler plug with a new washer.
1!!!!!
333- ¢ There should be continuity when the shift
4 ! 3
Fluid Capacity
+ # lever moves into reverse.
!&&&-
1.8! (1.9 US qt, 1.6 Imp qt) at fluid change
@8/@9;B:@5B0 ! ¢ There should be no continuity when the shift
4 ! 3
1.9! (2.0 US qt, 1.7 Imp qt) at overhaul
@9/@$;B:@7B0
- lever is in any position except reverse.
!&/&-
Always use genuine Honda manual transmission fluid
%!3
6 !! 3.
+- If necessary, replace the switch.
A!3-
(MTF).
;,4 If it is not available, you may use an API service
<-&!!A %&
8G or SH grade motor oil with a viscosity of SAE
.6
!3&%
10W-30 or 10W-40 as a temporary replacement.
02+002*0!-
FILLER PLUG
44 H-m 14.5 light“. 33 lb’I-fti
WASHER
Replace.
WASH ER
. Replace.
III._ "-._ 'II.’

“ . ,2
DRAIN PLUG
39 N-i'n [4.0 kgf-rn. 29 IIJI-ftll
Troublesho

* oting

! 13-4

Reverse Gear Noise Reduction System
-,

#
After the clutch pedal was depressed to shift into Reverse, the mainshaft continues to rotate because of its inertia. The
%! !31&A -4
resulting speed difference between mainshaft and reverse idler gear produces gear noise.
!
3&!

-
The reverse gear noise reduction system employs a cam plate, which was added to the reverse shift holder. When shifting into
4&
!!A33&!-2

Reverse, the 5th/reverse shift piece-connected to the shift lever-rotates the cam plate. This causes the 5th synchro set to stop
1&A=&!&!-4
the rotating mainshaft. As there is no speed difference between mainshaft and reverse idler gear, there will be less gear noise.

-%3&!
A3!!!
-
NOTE: This system is not a fully-synchronized gear noise reduction system.
84 94 !!H
-
Therefore, you may hear gear noise when
4A
3
1) 1&3!!-
< you shift into Reverse with the car not yet completely stopped.
2) !
!
-
< you shift speedily during fast idling.
Gearneisewhen shifting into
reverse after the enginewas
flirted
Cheek dun'ng dn'uing ifthe

gear neise disappears when
YES Replaee the 5th syn eh re hub and
sleeve as a set.
shifting into :3th gear.
Measure 1he clearance between

5th shiftferk and 5111 synchro
sleeve [see page ' 3-26}.
__I_
mm (0.04 in] NO Replaoetheath shimukorsth
Is the dearance'.0
or less? syn oh ro sleeve
YES '
Measure the M38 shift piece pin
[see page ‘ 329}.
lsitfifl mm (0.2? in} ormore? :::;Li Replaeethe MES shift piece.
Replaeethe reverse shill helder.

4

&A
!#!!3
9
(See page 13-26)
;!+<
(See page 13-29)
;!+5<

Gearshift
Mechanism 3
13-5
-
Overhaul
NOTE:
84 9
¢ Inspect rubber parts for wear and damage when disassembling, replace any worn or damaged parts.
3
3!
A!3
-
¢ Install the clip as shown.
!!!3-
¢ Turn the boot so the hole is facing down as shown.
4 !
33-
¢ Make sure the boot is installed on the shift rod.
,# !!-
CHANGE LEVER KNOB

1".8 N-m “3.3 light“, 5.8 lbl-hl
3 x 1.25 mm
22 film I22 kgf-m, 16 Ihl-ltl
CHANGE "I i
DUST SEALA I ll emmsmn
j EITE MSIDM HUD
H‘EXTENSION
_ _ ____-——— END nuanzn
CHANGE
LEVER \H—J
55'” w q
'
" 1 . 25 "'m
8
22 ”m lit-2 kgf-m. 16mm:
spams_ PIN
. . RBDIBLI:
'17-"
CHANGE E‘Z'J j /
CLIP
6: 1.0mm
(fj/ 9,3 MI!) 11.0 kghn, 7.2 Ihf-ftl
M i:
SHIFT ROD
SELF-LOCKING NU?
Replace
E x 125 mm
"'. '-, 22 him :12 kgI-m. 1s lhl-Itl
HEAR JOINT mi | AR
I - .——- ,
THRUST "I I'm-“#1”—
WASHER
HEAR JOINT BUSH
SPRING FIN
Replace.

*#

-
Removal
13-6
5
A WARNING
3.
+- Carefully remove the slave cylinder and clutch line
!!&!&!! !
clamp so as not bend the clutch line.
!! !-
A CAUTION
0 Make sure jacks and safety stands are placed properly
,# 7#!!
(see section 1).
;<-
0 Apply parking brake and block rear wheels so vehicle
%!#
#!#3!&! 0 Do not operate the clutch pedal once the slave
(! !!&
will not roll off stands and fall on you while working under it.
3!!!!!! 3!3#
- cylinder has been removed.
!&-
0 Take care not to bend the clutch pipe
4#!
A CAUTION CLUTCH LINE CLAMP
Use fender covers to avoid damaging painted surfaces

?&&

1.
- Disconnect the negative (-) cable first, then the positive
(
&;<!A&
(+) cable from the battery.
;V<!-
2.
- Remove the intake air duct
1&#
INTAKE AIFI D UCT
CLUTCH
LINE
SLAVE
CYLINDER
*-
4. (!-
Disconnect the starter motor cables.
STARTER MDTOH CABLES-

*#
Removal (cont’d)

-/
?0
13-7
7
5.
- Disconnect the back-up light switch connector and
(# !
3 $- Remove the three upper transmission mounting
1&
transmission ground wire.

3- bolts and the lower starter mounting bolt.
!!3
!-
TRANSMISSION
GROUND m BACK-LIP LIGHT STARTER
SWITCH CONNECTOR MUU NTING
BOLT
6.
- Disconnect the vehicle speed sensor (VSS) connector.
(&!;:<-
TRANSMISSION
MOUNTING BOLTS
V53 CONNECTOR
8.
'- Remove the front engine stopper bracket and front
1&
#
engine support bracket.

#-
FRONT ENGINE
STOPPEH BRACKET
FRONT ENGINE
SUPPORT BRACKET

*#
Removal (cont’d)

-/
?0
13-8
8
9.
5- Drain transmission fluid with a shop towel covering the
(! 33!&
13. 1&&!;
+- Remove the driveshafts from the differential (see
front and rear beams to catch any spilled fluid (see page
!!! ;! section 16). Coat all the precision finished surfaces
<-!!
13-3).
++<- with clean engine oil grease. Tie bags over the
3!
!
-4
&
10. 1&!!-
0- Remove the splash shield. driveshaft ends.
&-
DRIVESHAFI'
SET RING
Flaplana.
SPLASH SHIELD
11. 1&A!! A

- Remove the cotter pins, and loosen the castle nuts, then *- 1&/ %-
separate the ball joints and lower arms on both sides
!!7!3
(see section 18).
;'<-
'' - Liz,» GASKET

‘Q'ZI _ ' . Replace.
_ EXHAUST
PIPE A
LOWER ARM
GASKET
Ha place.
Replace
COWEFI PIN 5M
Replace D FEB
‘ FORK
12. 1&#-
- Remove both damper forks.
SELF-LOCKING NUT
Renlace.

*#
Transmission Assemblv
Removal (cont’d)

-/
?0
13-9
9
-
15. 1&/-
Remove the shift rod and extension rod. 18. 1&
!
'- Remove both radius rods mounting bolts from the
lower arm.
!3-
SHIFT HOD
“- / CLIP
.H\
ER. - .
I! I 20 mm
SPRING PIN
Replace.
RADIUS ROD
EXTENSlON ROD
19. 1&3
!
5- Remove the power steering cooler pipe from the
front beam.
-
PIN DRIVER. 3.0 mm
OTIII-d — DOTDEDD POWER STEERING
COOLER PIPE
16. 1&
-
- Remove the front and rear engine stiffeners.
FRONT BEAM
FRONT ENGINE
STIFFENER
RERR ENGINE
STIFFE HER
$-
17. 1&! &-
Remove the clutch cover.

*#
Removal (cont’d)

-/
?0
13-10
$
20. ,##A
0- Make reference marks on the rear and front beam, then 23. !!7# A
+- Place a floor jack under the transmission, and
&-
remove the front beam. raise the transmission just enough to take the
7
#
weight off of the mounts.
3
-
FIE FEHENBE
MARK 24. 1& #
*- Remove the transmission mount bracket and
transmission mount rubber assembly.
!-
TRANSMISSJDN MOUNT
RU BEER ASSEMBLY
(9?, TRANSMISSION
6:39“ MOUNT BRACKET
FRONT BEN'II'I
FRONT BEAM
-
21. 1& -
Remove the distributor. - Remove the rear engine mount bracket bolts and
25. 1&
#!
22. %
A!

- Attach the chain hoist to the engine, then lift the engine transmission mounting bolts.

!-
slightly.
!
!- SPECIAL BDLTS
Replace.
CHAlN HOIST
3 :1 1.25 mm BOLT
SPECIAL BOLT
RE place.

*# 13-11

Removal (cont’d)

-/
?0
26. !!3

!!
- Pull the transmission away from the engine until it clears
the mainshaft, then lower it on the transmission jack.
A!37#-
Take care not to bend the clutch line.
4#! !-
27. 1&!&!#
$- Remove the slave cylinder bracket from the
transmission.
-
SLAVE
CYLINDER
BRACKET

*# 13-12

Index

Refer to the drawing below for transmission disassembly/reassembly.

13
!3!=!-
Clean all the parts thoroughly in solvent and dry with compressed air.
!!!
!!&3-
”7%
&
Lubricate all the parts with oil before reassembly.

!!3!!-
NOTE:
84 9
¢ This transmission uses no gaskets between the major housings; use liquid gasket (P/N 08070-K0234M).
4
#37
N !F
#;=0'$0>0+*,<-
¢ Always clean the magnet (66) whenever the transmission housing is disassembled.
%!3!
;<3&
!-
¢ Inspect all the bearings for wear and operation.
!!
3-

*#
Index (cont’d)
/
?0
13-13

Torque Value
4F :!
A- 15 Nm (1.5 kgf/m, 11 lbf/ft)
%;-#
=A!=<
B - 27 Nm (2.8 kgf/m, 20 lbf/ft)
)$;-'#
=A0!=<
C - 31 Nm (3.2 kgf/m, 23 lbf/ft)
+;+-#
=A+!=<
1 Ball bearing
)!!
36 =1&#
+ 5th/Reverse shift fork 69 '04
5 80 mm Thrust shim
Selection (see page 13-34)
!;!++*<
2
5th Synchro hub
37
+$ 52 mm Snap ring 70 (!!

$0 Differential assembly
(see page 13-31)
;!++<
3
+ 5th Synchro sleeve
!& 38 $04
+' 70 mm Thrust shim 71 *//$-8!!-
$ 14 x 25 x 17.5 mm Oil seal.
Selection (see page 13-39)
!;!++5< Replace
1!
4
* Synchro spring

39 8!
!
+5 Oil guide plate 72 +/'8!!-
$ 35 x 55 8 mm Oil seal.
Replace
1!
Synchro ring

40 2-!
*0 Washer. replace 73
$+ Shift rod
GDO‘I
5th gear

41 )# !
3;-
* Back-up light switch 25 Nm (2.5 74 )
$* Boot
kgf/m, 18 lbf/ft)
#
=A'!=<
7
$ 32 x 37 x 23.5 mm Needle bearing
+/+$/+-!
42 3;-#
=A!=<
* Set screw 22 Nm (2.2 kgf/m, 16 lbf/ft) 75 8!
!
$ Oil guide plate
8
' Spacer collar
!! 43 2-1!
*+ Washer. Replace 76 +0//!
$ 30 x 55 x 21 mm Needle bearing
9
5 34 X 39 x 23 mm Needle bearing
+*/+5/+!
44
--0;-0<
** Spring L. 26.0 mm (1.02 in) 77
$$ Countershaft
10
0 4th gear
*
45 !!!;=<
* Steel ball (5/16 in)
11
Synchro ring

46 )# !
3
* Back-up light switch harness stay 78 +/*/-!
$' 36 x 41 x 25.5 mm Needle bearing

Check for wear and operation
#3
12
Synchro spring 47 4

*$ Transmission hanger 79

$5 1st gear
13 +=*!&
+ 3rd/4th synchro sleeve 48 +!
!;-
*' 32 mm sealing bolt 25 Nm (2.5 80 Friction
'0 damper

kgf/m, 18 lbf/ft)
#
=A'!=<
14 +=*
* 3rd/4th synchro hub 49 +//'!!
*5 35 x 62 x 8 mm oil seal 81
' Synchro ring

Replace
1!
15 +

3rd gear 50 8!!
+5;*-0#
=A5
0 Oil drain plug 39 Nm (4.0 kgf/m, 29 82
' Synchro spring

lbf/ft)
!=<
16 +*/+5/$-!
34 x 39 x 27.5 mm Needle bearing 51 2-1!

Washer. Replace 83
'+ 1st/2nd synchro hub
=
17 ,
$ Mainshaft 52 Filler
plug 44 Nm (4.5 kgf/m, 33 lbf/ft)
!!!
**;*-#
=A++!=< 84
'* Reverse gear
1&

18 2
' Washer 53 2-1!
+ Washer. Replace 85
' Synchro spring

19
3
5 Spring washer 54 4
* Transmission housing 86
' Synchro ring

20 )!!
0 Ball bearing 55 )

Breather cap 87
'$ Friction damper

Check for wear and operation
#3
21 /*/$8!!
26 x 42 x 7 mm Oil seal 56 8!
!
Oil gutter plate 88
'' Spacer
Replace
1!
22 '!
!
28 mm Plug bolt 57 1&!#
$ Reverse lock cam 89 +5/**/$!
'5 39 x 44 x 27 mm Needle bearing

23 =!
-+-
+ 1st/2nd select spring L. 36.26 mm 58 1&!
-+-*
' Reverse select spring L. 63.4 mm 90

50 2nd gear
(1.428 in)
;-*'< (2.496 in)
;-*5<
24
* Shift arm shaft 59 1&!
5 Reverse select retainer 91 +

5 3rd gear
25 !
Clutch housing 60

0 Shift arm C 92 *

5 4th gear
26 !#
!+5;*-0
Interlock guide bolt 39 Nm (4.0 61 )
Shift arm B 93

5+ 5th gear
kgf/m, 29 lbf/ft)
#
=A5!=<
27 1&!
$ Reverse shift holder 62
Interlock
!# 94 !
5* Needle bearing
28 1&!

' Reverse idler gear 63
+ Collar
!! 95 )!!
5 Ball bearing
29 1&!

5 Reverse idler gear shaft 64
* Shift arm A
% 96
3
5 Spring washer
30 /

+0 5 x 22 mm Spring pin 65
Spring washer

3 97 # -1!
5$ Locknut. Replace
Replace
1! 108 to 0 to 108 Nm
0'00'
(11.0 to 0 to 11.0 kgf/m, 79.6 to 0 to
;-00-0#
=A$5-0
79.6 lbf/ft)
$5-!=<
31 +=*
+ 3rd/4th Shift piece 66 ,

Mag net
32 =&
+ 5th/reverse shift piece 67 !!
!;-#
=A
$ Set ball spring bolt 22Nm (2.2kgf/m,
16 lbf/ft)
!=<
33 ,)
++ MBS shift piece 68 */0(3!
' 14 x 20 mm Dowel pin
34 =#
+* 1st/2nd Shift fork
35 +=*#
+ 3rd/4th Shift fork

.
!
Transmission Housing

-
Removal
13-14

NOTE: Place the clutch housing on two pieces of wood thick
84 9!!
33# 4.
*- Loosen the transmission housing attaching bolts in

!
enough to keep the mainshaft from hitting the workbench.

#
3#- a crisscross pattern in several steps, then remove
&!A&
1.
- Remove the back-up light switch.
1&# !
3- them.
-
2.
- Remove transmission hanger.
1&
- - Remove the 32 mm sealing bolt.
1&+!
!-
.039"
I HANSMISSIUN - Expand the snap ring on the countershaft ball
/
!!
HANGER bearing, and remove it from the groove using a

A&
&

pair of snap ring pliers.

!-
32 mm StALING UULI
SNAP RING PLIEHS

0?LGC - 0010100
WAS HEB
Hepl ace.
O
(r,-
BACK-UP
LIGHT SWITCH
3.
+- Remove the setting screws, washers, springs, and steel
1&
3A3A
A! SNAP RING
balls.
!!-
7.
$- Separate the transmission housing from the clutch

!
housing, and wipe it clean of the sealant.

A3!!-
8.
'- Remove the thrust shim, oil guide plate, and oil
1& A!
!A!
gutter plate from the transmission housing.

!
-
DIL BUTTER
THHUST SHIM OIL GUIDE PLATE PLATE
in I' II I -
STEEL BALLS
\ D. 5:15 in
SPRING
‘W I... 26.0 mm [1.02 inI
SETTING SCREW
TRANSMISSION HOUSING
Reverse Shift
- Holder
.
13-15
3

- Measure the clearance between the reverse shift fork

, !3&# 3.
+- Measure the clearance between the reverse idler
, !3&!
and 5th/reverse shift piece pin.
=&- gear and the reverse shift fork.

&#-
Standard:
F 0.05-0.35 mm (0.002-0.014 in)
$@$3$@3/$@$$$@$ 0 Standard:
F 0.5-1.1mm (0.02-0.04 in)
$@3@/$@$$@$ 0
Service Limit: $@3$@$ 0
- & F 0.5 mm 10.02 in) Service Limit: @8/$@$7 0
- & F 1.8 mm (0.07 in)
STHIREVERSE SHIFT PIECE PIN REVERSE IDLEH GEAR
REVERSE
SHIFT FORK
REVERSE SHIFT FORK
4.
*- If the clearance is more than the service limit,
!&!A
2.
- If the clearances are more than the service limit,
!&!A measure the width of the reverse shift fork.
3&#-
measure the widths of the groove in the reverse shift
3
&& Standard:
F 12.7-13.0 mm (0.500-0.512 in)
@7@$/$@3$$$@3 0
fork.
#-
Standard:
F 7.05-7.25 mm (0278-0285 in)
7@$37@3/$@78$@83 0
REVERSE SHIFT FORK
REVERSE SHIFT FOHK
REVERSE SHIFT HOLDER

REVERSE SHIFT HOLDER
0 If the widths of the grooves are not within the
3
&3
standard, replace the reverse shift holder with a
A!&!3 _ _ , _
new one.
3- ¢ , Within the
If the Width is not _ standard, replace
33A!
0 If the width of the grooves are within the standard,
3
&3A &!33-
the reverse-shift holder mm a new one.
replace the 5th/reverse shift piece with a new one.
!=&33- ¢ If the Width is Within _the standard, replace the
33A!
,
reverse idler gear With a new one.
&!
33-
-
Reverse Idler Gear

-
Removal
13-16
5 Mainshaft,

Shift
Fork
+
6
Countershaft,
:
:
Disassembly
) *#
-
1. 1&&!-
Remove the reverse shift holder. 1.
- Remove the interlock guide bolt from under the
1&!#
!
clutch housing.
!
-
REVERSE SHIFT 2.
- Remove the shift arm B attaching bolt.
1&)
!-
HOLDER
fiHll—l ARM 3
ATTACHING BOLT
SPRING
WASHER
2.
- Remove the reverse idler gear shaft and reverse idler
1&&!
&!
CLUTCH ' -
gear

- HOUSING
REVEREE IDLER
GEAR SHAFT
INTERLDCK GUIDE BDLT
3.
+- Remove the mainshaft and countershaft
1&
assemblies with the shift fork from the clutch
!3#!
housing.

-
NOTE: Before removing the mainshaft and
84 9)&

countershaft assemblies, tape the mainshaft spline
!A!
to protect it.
-
MAINSHAFT and
CDUNTEHSHAFT
ASSEMBLIES
REVERSE IDLER
GEAR
Tape the main shaft

HDU SING spline.
WASHER
SPRING
WASHER
Mainshaft
Assembl
*# 13-17
7

Index
NOTE: The 3rd/4th and 5th synchro hubs are installed with a press.
84 94+=* !!3-
”7%
&
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 3rd/4th
!
A!!!!&A!! -4+=*
and 5th synchro hubs, however, should be installed with a press before lubricating them.
A3&A !!!3!
-
3HDHTH SYNCHRO SLEEVE

BAL L BEARING
Arr/Check for wear
and operation.
49“"
5TH SYNCH R0 HUB
3RDI4TH 5TH SYNCHRO

SYNCH RC! HUB SLEEVE
SYNCHRD SPRING [SYNCHRD SPRING

SYNCHRO RING .
Inspection. ._.-n-- SYNCHRD RING
page 13—30
5TH GEAR
Inspection. page 13—19
32 x 3? x 23.5 mm
NEEDLE BEARING
Check for wear and
3RD GEAR
CHAMFER i operation.
SPACER COLLAR
34 .1 39 x 2?.5 mm / Inspection, page 13-18
NEEDLE BEARING 34 x 39 I 23 mm
Check for wear NEEDLE BEARING
and operation. Ilium] .' Check for wear
and opurfllion.
MAINSHAFI' #TH GEAR

'iiifin'i' Inspection. page 13-13
Inspection, page 13-21] SYNCHRD RING
an I“
inspection. page 13-31]
Rsvucnno SPRING

4

&A
!#!!3
9
(See page 13-29)
;!+5<
(See page 13-30)
;!++0<
(See page 13-18)
;!+'<
(See page 13-20)
;!+0<
(See page 13-19)
;!+5<
*#
Mainshaft Assembly

13-18
8
NOTE: If replacement is required, always replace the synchro
84 9!F A!3! +- Measure the clearance between 4th gear and the
, !3*

sleeve and hub as a set.
!& - spacer collar.
!!-
1.
- Measure the clearance between 2nd and 3rd gears.
, !3+
- Standard:
F 0.06-0.19 mm (0.002-0.007 in)
$@$5$@9/$@$$$@$$7 0
Standard:
F 0.06-0.21 mm (0.002-0.008 in)
$@$5$@/$@$$$@$$8 0 Service Limit: $@/$@$ 0
- & F 0.31 mm (0.012 in)
Service Limit:
- & F 0.33 mm (0.013 in)
$@/$@$ 0
4TH GEAR
DIAL
2ND GEAR
3RD GEAR

!&!A
measure distance A on the spacer collar.
%!!-
2.
- If the clearance is more than the service limit, measure
!&!A Standard:
F 22.83-22.86 mm
@8@85
the thickness of 3rd gear.
#+
-
(0.898-0.900 in)
/$@898$@9$$ 0
Standard:
F 30.22-30.27 mm
$@$@7
Service Limit: @8$@898 0
- & F 22.81 mm 0.898 in)
(11.190-1.192 in)
/@9$@9 0
Service Limit:
- & F 30.15 mm (1.187 in)
$@3/@87 0
I H 4TH GEAR
33D GEAR SIDE
'2!
SPACER
H COLLAR
- If distance A is less than the service limit, replace

%!&!A!
the spacer collar with a new one.
!!33-
If distance A is within the service limit, measure the
%3&!A
thickness of 4th gear.
#*
-
0 If the thickness of 3rd gear is less than the service
#+
!& Standard:
F 30.12-30.17 mm
$@$@7
limit, replace 3rd gear with a new one.
!A!+
33- (1.186-1.188 in)
/@85@88 0
0 If the thickness of 3rd gear is within the service
#+
3& Service Limit: $@$3/@8 0
- & F 30.05 mm (1.183 in)
limit, replace the 3rd/4th synchro hub with a new
!A!+=* 33 4TH GEAR
one.
-
¢ If the thickness of 4th gear is less than the

#*
!
service limit, replace 4th gear with a new one.
&!A!*
33-
¢ If the thickness of 4th gear is within the
#*
3
service limit, replace the 3rd/4th synchro hub
&!A!+=*
with a new one.
33-
*#
Mainshaft Assembly
Clearance Inspection (cont’d)

/
?0
13-19
9 Disassembly
) *#
6.
- Measure the clearance between the spacer collar and
, !3!! 1.
- Remove the ball bearing using a bearing puller as
1&!!

!!
5th gear.

- shown.
3-
Standard:
F 0.06-0.19 mm (0.002-0.007 in)
$@$5$@9/$@$$$@$$7 0 BEAHI N G P'U LLEH
Service Limit:
- & F 0.31 mm (0.012 in)
$@/$@$ 0
0
BALL
BEARING
:2] 4TH GEAR
DIAL
IN DICATDR
tea]:
'5—"""'.‘
{a {It
[ J 5TH GEAR
7.
$- If the clearance is more than the service limit, measure
!&!A
distance B on the spacer collar.
"!!-
Standard:
F 23.53-23.56 mm
@3@35
(0.926-0.928 in)
/$@95$@98 0
Service Limit:
- & F 23.51 mm (0.926 in)
@3/$@95 0
SPACER
COLLAR
[ I
5TH GEAR -||-

SIDE
III: CAUTION
Remove the synchro hubs using a press and steel blocks
1&
!!#
as shown. Use of a jaw-type puller can cause damage to
3-?73 !!

8.
'- If distance B is less than service limit, replace the
"!&!A! the gear teeth.

-
spacer collar with a new one.
!!33- 2.
- Support 4th gear on steel blocks, and press the
*
!!#A
If distance B is within the service limit, measure
"3&!A mainshaft out of the 5th synchro hub as shown.
3-
thickness of 5th gear.
#
-
Standard:
F 28.42-28.47 mm
8@8@7 PH E55
(1.119-1.121 in)
/@9@ 0 5TH SYNCHRO H UB
Service Limit:
- & F 28.35 mm (1.116 in)
8@3/@5 0
5TH GEAR ATTA B HMENT
0 If the thickness of 5th gear is less than the service

#
!&
limit, replace 5th gear with a new one.
!A!
33-
0 If the thickness of 5th gear is within the service
#
3&
limit, replace the 5th synchro hub with a new one.
!A! 33-
*# 13_20 Inspection

Mainshaft Assembly
Disassembly (cont’d)
) *#/
?0
$
3.
+- Support the 3rd gear on steel blocks, and press the
+
!!#A 1.
- Inspect the gear surface and the bearing surface

mainshaft out of the 3rd/4th synchro hub as shown.
+=* 3- for wear and damage, then measure the mainshaft
3
A
at points A, B, C, and D.
%A)AA(-
Standard:
F A: @987@$$$
F 21.987-22.000 mm
(0.8656-0.8661 in)
/$@8535$@855 0
B: 5@98$5@99
"F 26.980-26.993 mm
(1.0622-1.0627 in)
/@$5@$57 0
C: @98@$$$
F 33.984-34.000 mm
(1 .3380-1 .3386 in)
/@8$@85 0
D: 3@9773@99$
)F 25.977-25.990 mm
(1.0227-1.0232 in)
/@$7@$ 0
Service Limit: F
- & F A: @9$/$@85 0
21.930 mm (0.8634 in)
B: 5@9$/@$5$ 0
"F 26.930 mm (1.0602 in)
C' @9$/@38 0
F 33.930 mm (1.3358 in)
D 3@9$/@$$3 0
)F 25.920 mm (1.0205 in)
3RD GEAR
Check for wear

and damage.
Check oil passages

for clogging.
Check for wear and damage.
¢ If any part of the mainshaft is less than the
!
service limit, replace it with a new one.
&!A!33-
2.
- Inspect for runout.
-
Standard:
F 0.02 mm (0.001 in) max.
$@$/$@$$ 0@
- & F 0.05 mm (0.002 in)
NOTE: Support the mainshaft at both ends as
84 9
shown.
3-
Rotate two complete

revolutions.
¢ If the runout is more than the service limit,

&!A
replace the mainshaft with a new one.
!33-
Mainshaft
Assembl
*# 13-21

Reassembly
*#
A CAUTION
3.
+- Install the 5th synchro hub using the special tools
!!
!!
and a press as shown.
3-
When installing the 3rd/4th and 5th synchro hubs, support
2!!
+=* A
the shaft on steel blocks, and install the synchro hubs using
!!#A!!

PRESS
a press.
- DRIVER. 40 mm LE].
NOTE: For
84 9 reassembly sequence (see page 13-17).
!F ;!+$<- 0? 746 —003010IJ
1.
- Support 2nd gear on steel blocks, then install the 3rd/4th

!!#A!!+=*
synchro hub using the special tools and a press as

!! ATTACHMENT.
shown.
3- 3:] mm ID.
0'? T46 — 0030300
5TH SYNCHRD HUB
PRESS
DRIVER. 40 mm ID
.\\
\Q‘QR»,v“
01746— 0030100
" :‘Ifl-IjI'I'“ .'

ATTACHMENT,
35 mm ID.
DT?4E—0030400
3RDJ'4TH
SY N CH“ 0 H UE
4.
*- Install the ball bearing using the special tools and a
!!!!

!!
press as shown.
3-
NOTE: Install the ball bearing with the tapered end
84 9!!!!
3
2ND GEAR facing down.

3-
PRESS
DRIVE", 40 mm ”3!.
2.
- Install the 3rd/4th synchro sleeve by aligning the
!!+=*!&!

07746 — 0030100
stoppers of the 3rd/4th synchro sleeve and hub.
+=*!& -
NOTE: After installing, Check the operation of the
84 9%!!
A# ATTACHMENT, 30 mm LU.
3rd/4th synchro hub set.
+=* - 0??46 0030300
Luna-3“
34545,. .
N.
3HDi4TH BALL BEARING
SYNCH HG 5L EE VE
" .I\\\ I. _.
- '\\\ \s‘rf'
' -"';---.x ,
I’Mfi‘i“
' '\\‘\\‘
Countershaft

Assembly
*# 13-22

Index

NOTE: The 3rd, 4th, and 5th gears are installed with a press.
84 94+A*A
!!3-
&
E !

A!!!!&A!! -4+A*A
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 3rd, 4th,
and 5th gears., however, should be installed with a press before lubricating them.

-A3&A !!!3!
-
LOCKNUT Replace.
103—!)«103 N-m
11_O-0-11 .0 kgf-m
79.6—-O-79.6 lbl-h
'"IE‘I
SPRING WASHER
BALL BEARING
Check for wear and
operation.
NEEDLE BEARING
SYNCHRO SPRING Check for wear
and operation.
.r/l/I
SYNCHRD RING U
Inspection, page 1340 a 5TH GEAR
::l 4m GEAR
FRICTION DAMPER ”JV/MW
3RD GEAR
1ST GEAR l 2ND GEAR
Inspection, pages 13—23. 30 "j I I .
- ( Inspection. pages 13-23, 31)
(ZZZ/ll, 39 II 44 II 2‘! mm
.2“ "x; NEEDLE BEARING
(eM"; Check for wear and
“mum” operation.
'9; SPACER COLLAR
% InspectI'On, page 13-23
-- FRICTION DAMPER
SYNCHRD RING
36 x 41 x 255 mm Inspection, paga13-3fl
NEEDLE BEARING
Check for wear and DpErEIIICIr'I. SYNCHRD SPRlNG
COUNTERSHAl-‘l'
Inspection, page 13—25 REVEREE GEAR
Inspoctinn, page 13-29
9
1 STI'ZHD SYNCHHO HUB

4

&A
!#!!3
9
(See page 13-30)
;!++0<
(See page 13-23)
;!++<
(See page 13-25)
;!+<
(See page 13-29)
;!+5<

*#
Countershaft Assembly

13-23

84 9!F A!3! 3.
+- Measure clearance between 2nd and 3rd gears.
, !3+
-
!& -
sleeve and hub as a set. Standard:
F 0.04-0.12 mm (0.002-0.005 in)
$@$$@/$@$$$@$$3 0
1.
- Measure the clearance between the countershaft and
, !3 Service Limit: $@/$@$$9 0
- & F 0.24 mm (0.009 in)
1st gear.

-
Standard:
F 0.03-0.10 mm
$@$$@$ 3RD GEAR
(0.001-0.004 in)
/$@$$$@$$ 0
Service Limit: $@/$@$$9 0
- & F 0.22 mm (0.009 in)
‘lST GEAR i-i‘é’Jl
SPACER 2ND GEAR

COLLAR
4.
!&!A
measure the thickness of the spacer collar.
#!!-
Standard:
F 32.03-32.06 mm (1.261-1.262 in)
@$@$5/@5@5 0
Service Limit: @$/@5$ 0
- & F 32.01 mm (1.260 in)
2.
- If the clearance is more than the service limit, measure
!&!A
the thickness of 1st gear.
#
-
SPACER _ l"
Standard:
F 30.41 -30.44 mm
$@$@ COLLAR “a.“
(1.197-1.198 in)
/@97@98 0
Service Limit: $@5/@93 0
- & F 30.36 mm (1.195 in)
155T GEAR [/—
.-_ ‘r — '-_
" 1— . J."
5.
- If the thickness is less than the service limit,
#!&!A
:2-5’?- Fig":=1 replace the spacer collar with a new one.
!!!33-
2 '2: I H ~. 4|
If the thickness is within the service limit, measure
#3&!A
Let—q" --.. m the thickness of 2nd gear.
#
-
Standard:
F 31.91-31.96mm (1.256-1.258 in)
@9@95/@35@38 0
0 If the thickness of 1st gear is less than the service
#
!& Service Limit: @83/@3 0
- & F 31.85 mm (1.254 in)
limit, replace 1st gear with a new one.
!A!
33- 2ND GEAR
0 If the thickness of 1st gear is within the service
#
3&
limit, replace the 1st/2nd synchro hub with a new
!A!= 33
one.
-
¢ If the thickness of 2nd gear is less than the

#
!
service limit, replace 2nd gear with a new one.
&!A!
33-
¢ If the thickness of 2nd gear is within the
#
3
service limit, replace the 1st/2nd synchro hub
&!A!=
with a new one.
33-

*#
Countershaft
Disassembly
) *#
Assembly
13-24

A CAUTION
4.
*- Support 4th gear on steel blocks, and press the
*
!!#A
countershaft out of 5th and 4th gears as shown.
*
3-
Remove the gears using a press and steel blocks as shown.
1&

!!#3-
PRESS
Use of a jaw-type puller can damage the gear teeth.
?73 !!

-
1.
- Securely clamp the countershaft assembly in a bench
!! !
" 5TH GEAR
vice with wood blocks.
&33!#-
2.
- Raise the locknut tab from the groove of the
1!#
&
countershaft, then remove the locknut and the spring
A&!#
4TH GEAR
washer.
3-
CHISEL
TAB
0,.
LOCKNUT 5.
- Support 1st gear on steel blocks, and press the

!!#A
Replace.
countershaft out of 3rd gear as shown.
+
3-
WOOD BLOCKS
3.
+- Remove the bearings using a bearing puller as shown.
1&

!!3-
BEARING PULLEH
J! 'I'
III-f
(Illlfl
l":- ., .. :fi

*#
Countershaft
Inspection

Assembly
13-25
3 Reassembly
*#
A CAUTION
1.
- Inspect the gear surfaces and bearing surfaces for wear

3
and damage, then measure the countershaft at points A,

A %A
B, and C.
)A- 0 Press the 3rd, 4th, and 5th gears on the
+A*A

Standard:
F A: $@$$$$@$3
F 30.000-30.015 mm countershaft without lubrication.
3 ! -
(1.1811-1.1817 in)
/@8@87 0 0 When installing the 3rd, 4th, and 5th gears, support
2!!
+A*A
A
B: 3@985@$$$
"F 35.984-36.000mm the shaft on steel blocks and install the gears using a
!!#!!

(1.4167-1.4173 in)
/@57@7 0 press.
-
9
24.980-24.993 mm
F @98$@99 NOTE: For
84 9 reassembly sequence (see page 13-22).
!F ;!+<-
(0.9835-0.9840 in)
/$@983$@98$ 0 1.
- Install the needle bearing on the countershaft.
!!!
-
Service Limit: F 9@93$/@79 0
- & F 29.950 mm (1.1791 in)
99:"?
I 36 x 41 x 25.5 mm
35.930 mm (1.4146 in)
"F 3@9$/@5 0 NEEDLE BEARING
24.930 mm (0.9815 in)
F @9$/$@983 0
COUNTEHSHAFT
Check ail passages

tor ciogging.
2.
- Assemble the parts below as shown.
%!!33-
NOTE: Check that the fingers of the friction
84 9#

Check for wear damper are securely set in the grooves of the
!
&
and damage. 1st/2nd synchro hub.
= -
0 If any part of the countershaft is less than the
! :3.
service limit, replace it with a new one.
&!A!33-
CU -— 2ND GEAR
2.
-
{Oz/l
Standard:
F 0.02 mm (0.001 in) max.
$@$/$@$$ 0@
39 I 44 I 2? mm
- & F 0.05 mm (0.002 in)
Service Limit: $@$3/$@$$ 0 NEEDLE BEARING
Support with SPACER come

Hut—Blocks. £9-=+—— FRIC'HOH DAMPER
. a 4—— SYNCHHO mm
W svncnno spams
I. ‘—
13.”:"0 I REVERSE GEAR
SVHCHRO HUB
13TJZND
SYHCHRD HUB
SVMCHHO SPRING
Rotate two complete SYNCHRD RING
revolution.
0 If the runout is more than the service limit, replace
&!A! " L. FRICTION DAMPER
the countershaft with a new one.
33- 3* 157 GEM
3.
+- Install the parts on the countershaft.
!! -
Countershaft

Assembly
*#
Reassembly (cont’d)
*#/
?0
13-26
5
4.
*- Support the countershaft on a steel block as shown and
!!#3 7.
$- Install the bearings using the special tools and a
!!

!!
install 3rd gear using the special tools and a press as
!!+

!! press as shown.
3-
shown.
3- DRNER. 40 mm LD.
3'21) fl??4fl—00301OO
PRESS
I"H-—-PRE$5
DRIVER. 40 mm ID.
OTT4fi—0030100
3RD GEAR BEARING
ATTACHMENT.
35 mm I.D.
mus—0030400 ETTACH MENT.
3|] mm ID.
DT?4B—0030300
5.
- Install 4th gear using the special tools and a press as
!!*

!!
shown.
3-
PRESS
8.
'- Securely clamp the countershaft assembly in a
!! !
DRIVER, 40 mm I.D bench vice with wood blocks.
&33!#-
DTTH—DDSOQDO
9.
5- Install the spring washer, tighten the Iocknut, then
!!
3A
!# A
ATTACHMENT. stake the Iocknut tab into groove.
#!#
&-
35 mm LD. LOCKNUT
8>?4
anu-oomoo
108 to 0 to 108 Nm
0'00'
(11.0 to 0 to11.0 kgf-m, 79.6 to 0 to 79.6 lbf-ft)
;-00-0#
A$5-0$5-<
LOCKNUT
Raplaca.
6.
- Install 5th gear using the special tools and a press as
!!

!!
3-
shown.
DRIVER. 40 mm ID. PRESS

III? 146 — 0030300
ATTACHMENT.
30 mm I.I:l.
GIT-15 —0030300 5TH GEM:
WOOD BLOCKS
Shift
Fork Assembl
+
6*# 13_27
7

Index
7%
&
!
A!!!!&AA!! -
52
BHDMTH SHIFT FORK
stmnavenss
SHIFT FORK \
ISTIZND SHIFT FORK

(3
‘—(
M85 SHIFT
PIECE
5 x 22 mm
SPRING PIN
Replace.
J 5TH (REVER SE
\
SHIFT PIECE
anmaTH 5 x 22 mm
SHIFT PIECE SPR'NG PIN
Replace.
PIN DRIVER, 5.0 mm '
DTGAD— P620100
“f3
+
6*#
Shift Fork Assembly

13-28
8
NOTE: The synchro sleeve and the synchro hub should be
84 94!& ! 3.
+- Measure the clearance between the shift piece or
, !3
replaced as a set.
!- shift fork and the shift arm B.
#)-
1.
- Measure the clearance between each shift fork and its
, !3# Standard:
F 0.2-0.5 mm (0.008-0.02 in)
$@$@3/$@$$8$@$ 0
matching synchro sleeve.

!&- Service Limit: $@5/$@$ 0
- & F 0.6 mm (0.024 in)
Standard:
F 0.35-0.65 mm (0.014-0.026 in)
$@3$@53/$@$$@$5 0
Service Limit: @$/$@$ 0
- & F 1.0 mm (0.04 in)
SYNCHHD 5L EEVE
SHIFT FORK _ . . _ SHIFT ARM B SHIFT FORK

2.
- If the clearance IS more than the serVIce limit, measure
!&!A 4.
!&!A
the thickness of the shift fork fingers.
##
- measure the groove of the shift piece or shift fork.

&#-
Standard:
F Standard:
F 13.2-13.4 mm (0.520-0.528 in)
@@/$@3$$@38 0
3rd/4th:F
2 7.4-7.6 mm (0291-0299 in)
7@7@5/$@9$@99 0
lst/2nd, 5th:F
2:3 6.2-6.4 mm (0244-0252 in)
5@5@/$@$@3 0 $HIFT PIECE
SHIFT FORK
0 If the thickness of the shift fork fingers is not within

##
3 ¢ If the groove of the shift piece or shift fork. is

&#-
the standard, replace the shift fork with a new one.
A!#33- not within the standard, replace the shift piece
3A!
0 If the thickness of the shift fork fingers is within the
##
3 or shift fork with a new one.
#33-
standard, replace the synchro sleeve with a new
A!!&33 ¢ If the groove of the shift piece or shift fork is

&#
one.
- within the standard, replace the shift arm B
3A!)
with a new one.
33-
Shift
Fork Assembly
+
6*# 13-29
9 Svnchro
# Sleeve, Svnchro

-:#
MBS Shift
" Piece Inspection
'
.*
Hub
Inspection/Installation

2
1.
- Measure the width of the MBS shift piece.
, 3,)- 1.
- Inspect gear teeth on all synchro hubs and synchro

!!
Standard:
F 6.9-7.1 mm (0.27-0.28 in)
5@97@/$@7$@8 0 sleeves for rounded off corners, which indicate
!& A3
wear.
3-
MES SHIFI' PIECE 2.
- Install each synchro hub in its mating synchro
!!

sleeve, and check for freedom of movement.
!&A#&-
NOTE: If replacement is required, always replace
84 9!F A!3!
the synchro sleeve and synchro hub as a set.
!& -
svncnno
SlEE'U'E
0 If the width of the MBS shift piece is not within the

3,)3
standard, replace the MBS shift piece.
A!,)-
3.
+- When assembling the synchro sleeve and synchro
2!
!&
hub, be sure to match the three sets of longer
A !

teeth (120 degrees apart) on the synchro sleeve
;0
<!&
with the three sets of deeper grooves in the
3
&
synchro hub.
-
A CAUTION
Do not install the synchro sleeve with its longer teeth in
(!!!&3!

the synchro hub slots because it will damage the spring
! 3!!

ring.

-
SVMCHRD LONGER TEETH
HUB
SVNEHRU
SLEEVE
Synchro
# RingI Gear

!: 13_30
$
Inspection

- Inspect the synchro ring and gear.

-
A:
3-
%9 Inspect the inside of the synchro ring for wear.
B: !&
)9 Inspect the synchro sleeve teeth and matching

teeth on the synchro ring for wear (rounded off).

3; <-
CI Q
GOOD WORN
C:
9 Inspect the synchro sleeve teeth and matching
!&

teeth on the gear for wear (rounded off).

3; <-
CI Q
GOOD won"
D.
3-
(9 Inspect the gear hub thrust surface for wear.
E: 3
-
9 Inspect the cone surface for wear and roughness.
F'9 !!
&3A
Inspect the teeth on all gears for uneven wear,
scoring, galling, and cracks.

A
!!
A#-
2.
- Coat the cone surface of the gear with oil, and place the

3!A!
synchro ring on the matching gear. Rotate the synchro

-1
ring, making sure that it does not slip.

A#
!-
Measure the clearance between the synchro ring and
, !3

gear all the way around.

!!3 -
NOTE: Hold the synchro ring against the gear evenly
84 96!

&!
while measuring the clearance.
3!
!-
Synchro
# Ring-to-Gear Clearance

!

Standard:
F 0.73-1.18 mm (0.029-0.046 in)
$@7@8/$@$9$@$5 0
Service Limit:
- & F 0.4mm (0.016 in)
$@/$@$5 0
If the clearance is less than the service limit, replace the
!!&!A!
synchro ring and synchro cone.

-
Shift
Rod

13_31

-
Removal
NOTE: The steel balls are all of the same size (5/16 in).
84 94!!!!!H;=<- 6.
- Remove shift arms C and B, and the interlock, then
1&)A!#A
1.
- Remove the differential assembly.
1&!!- remove the reverse select spring and retainer.
&&!
-
2.
- Remove the 28 mm plug bolt and |1st/2nd select spring.
1&'!
!!=!
- 7.
$- Remove the shift arm Aattaching bolt, the set ball
1&%
!A!!
3.
+- Remove the shift arm C attaching bolt.
1&
!- spring bolt, set spring, and steel ball.

!A
A!!!-
4
*- Remove the shift arm shaft.
1&- Remove the shift rod, then remove the shift arm A.
'- 1&A&%-
—‘$°.°°
NOTE: Be careful not to lose the steel ball.
84 9) !!!!!- Remove the reverse lock cam.
5- 1&&!#-
5.
- Remove the steel ball, spring, and collar.
1&!!!A
A!!- 0 1&
-
0 Remove the magnet.
REVERSE LOCK CAM
SHIFT ARM C
REVERSE SELECT RETAINER
REVERSE SELECT SPF-“NE

L. 63.4 mm l2.5O in!
SHIFT ARM 5 \
INTERLOCK E
SPRING L. 21.4 mm-
l0.843 lnl
SHIFT ARM A
DOWEL PIN
CLUTCH
HOUSING
DIFFERENTIAL ASSEMBLY
\ SHIFT ARM SHAFT
15mm SELECT spams

$3353
/
SHiFT Run
\
L. 36.26 mm l1.428inl
23 mm PLUG BOLT BOOT
)
Differential

Index
13-32
"6 Inspection
Backlash
THHUST SHIM - Place differential assembly on V-blocks and install

!!!:!#!!
/ Selective part both driveshafts.
&-
- Measure the backlash of both pinion gears.
, #!
-
Standard (NEW): 0.05-0.15 mm (0.002-0.006 in)
/,%10F$@$3$@3/$@$$$@$$5 0
BALL BEARING
Check for wear and damage". DIAL
{‘3‘- ' - . IN DICATDR
PINIDN GEARS
DIFFERENTIAL CARRIER
Check for cracks.
SPE EDOMETER
DRIVE BEAR
FiHAL DRIVEN GEAR

Check for wear and damage.
BALL BEARING
Check for wear and damage. 3.
+- If the backlash is not within the standard, replace
#!3A!
the differential carrier.
!-
10 x 1.0 mm
101 NM (10.3 kgf-m. 14.5 lbhft]
Left-hand threads
Differential
)
Bearing Replacement
" !
13-33
+ ) -
NOTE: Check bearings for wear and rough rotation. If

84 9#
3
- 1.
- Remove the bolts in a crisscross pattern in several
1&!&!
bearings are OK, removal is not necessary.

8>A&!- steps, then remove the final driven gear from the
A&!&

1.
- Remove ball bearings using a bearing puller as shown.
1&!!

!!3- differential carrier.
!-
NOTE: The final driven gear bolts have left-hand
84 94!&
!&!
BEARING PU LLER threads.
-
FINAL DRIVEN GEAR

Chamfar on inside diameter of
final driven gear laces carrier.
2.
- Install new ball bearings using the special tool as shown.
!!3!!

!!3-
NOTE: Drive the bearings squarely until they bottom
84 9(&
F ! !
against the carrier.

-
DRIVER, 40 mm I.D.
077'45 —DDED1DD
10 x 1.0 mm BOLT DIFFERENTIAL

‘il.'l1 H+n1 {10.3 lint-m. 74.5 Ibf-ft] CARRIER
Left-hand threads.
2.
- Install the final driven gear by tightening the bolts in
!!!&

!
a crisscross pattern in several steps.
&!-
BALL BEARING
Differential
) 13_34
Thrust
Shim
Adjustment
D

1.
- Install the differential assembly, making sure it bottoms
!!!!A#
3.
+- Install the transmission housing (see page 13-43).
!!
;!+*+<-
in the clutch housing, using the special tool as shown.
!
A
!!3- NOTE: Do not apply liquid gasket to the mating
84 9(!!F
#
surface of the clutch housing.

!
-
DRWER' 40 mm In 4.
*- Tighten the transmISSIon housmg attaching bolts
4

!
07745—0030100 (See page 13-44)-
;!+**<-
8 x 1.25mm
8@3
27 Nm (2.8 kgf/m, 20 lbf/ft)
7,/@86! 2:$* 2 0
5.
- Use the special tool to bottom differential assembly
?!!!!
in the clutch housing.
!
-
DRIVER. 40 mm LD.
OTTflfl—DOSDIOO
IIIIII
CLUTCH
HOUSING
-
2. !! -
Install the thrust shim.
84 9!!H 3
NOTE: Install the same size thrust shim that was
&-
removed.
THRUST
SHIM
6.
- Measure clearance between thrust shim and
, !3
bearing outer race in transmission housing.

-
TRANSMISSION
HDU$ING
Differential
) 13-35
3
Thrust
Shim
D/
?0
7.
$- If the clearance is more than the standard, select a new
!A!3
thrust shim from the following table.
!!3
!-
NOTE: If the clearance measured in step 6 is within the
84 9! 3
standard, go to step 10.
A
0-
Standard:
F 0-0.10 mm (0-0.004 in)
$$@$/$$@$$ 0
80 mm THRUST SHIM
8$.;.
',*
Part Number Thickness
6
41441 -PL3-BOO
***+)00 1.0 mm (0.394 in)
-0;0-+5*<
41442-PL3-BOO
***+)00 1.1 mm (0.0433 in)
-;0-0*++<
41443-PL3-BOO
***++)00 1.2 mm (0,0472 in)
-;0A0*$<
41444-PL3-BOO
****+)00 1.3 mm (0.0512 in)
-+;0-0<
41445-PL3-BOO
***+)00 1.4 mm (0.0551 in)
-*;0-0<
41446-PL3-BOO
***+)00 1.5 mm (0.0591 in)
-;0-05<
41447-PL3-BOO
***$+)00 1.6 mm (0.0630 in)
-;0-0+0<
41448—PL3-BOO
***'+)00 1.7 mm (0.0669 in)
-$;0-05<
41449-PL3-BOO
***5+)00 1.8 mm (0.0709 in)
-';0-0$05<
41450-PL3-BOO
**0+)00 1.05 mm (0.0413 in )
-0;0-0*+<
l
41451 -PL3-BOO
**+)00 1.15 mm (0.0453 in
-;0-0*+<
41452-PL3-BOO
**+)00 1.25 mm (0.0492 in
-;0-0*5<
41453-PL3-BOO
**++)00 1.35 mm (0.0532 in)
-+;0-0+<
41454-PL3-BOO
***+)00 1.45 mm (0.0571 in )
-*;0-0$<
41455-PL3-BOO
**+)00 1.55 mm (0.0510 in )
-;0-00<
41456-PL3-BOO
**+)00 1.65 mm (0.0650 in )
-;0-00<
41457-PL3-BOO
**$+)00 1.75 mm (0.0689 in )
-$;0-0'5<
8.
'- Remove the bolts and transmission housing.
1&!
-
9.
5- Replace the thrust shim selected in step 7, then recheck
1! !$A#
the clearance.
!-
10. 1&!
-%!!F
0- Remove the bolts and transmission housing. Apply liquid
gasket to the surface of the transmission housing and

#

reassemble.
!-

Clutch .
!" !
Housing Bearing
Replacement

13-36
5
Mainshaft
3.
+- Drive the new oil seal into the clutch housing using
(&3!!!

1.
- Remove the ball bearing using the special tool as shown.
1&!!

!!3- the special tools as shown.
!!3-
ADJUSTABLE BEARING fl.
REMOVER SET
OTJAC — P1430000
ATTACHMENT. 42 I 47 mm
UTFTII-fi —Ofl10300 DRIVER
07?49—0010000
CLUTCH
HOUSING
\‘
OIL SEAL
(—k‘ fl Replace.
2.
- Remove the oil seal from the clutch housing.
1&!!!
-
CLUTBH 4.
*- Drive the ball bearing into the clutch housing using
(&!!
!

the special tools as shown.

!!3-
ATTACHMENT. 52 x 55 mm DRIVER
DTT4-B—UO1D4OO 07749—0010000
DIL SEAL
\
Flsplace.
CLUTCH
HOUSING E
BALL BEA RING
side down.
Clutch .
!" !
Housing Bearing
/
?0
13-37
7
N
Countershaft

- Install the oil guide plate, then drive the needle
!!!
!A&!
1.
- Remove the needle bearing using the special tool as
1&!

!! bearing into the clutch housing using the special

!

!
shown, then remove the oil guide plate.
3A&!
!- tools as shown.
!3-
ADJUSTABLE BEARING
HEMOVEH SET
o7JAC— PHEUDDO
CLUTCH
HUU SING
N EEDLE BEAHIN G
OIL GUIDE PLATE
ATTACHMENT. 52 in: 55 mm
OTTd-fl—DO‘I D400
DRIVER
D1749 —DD1ODDU
CLUTCH
IT /HDU SIHG
L
NEEDLE BEARING
DIL GUIDE PLATE

Mainshaft
Thrust Clearance
8
13-38
Adjustment
D
1.
- Remove the thrust shim and oil guide plate from the
1& !
! 4.
*- Measure the distance (C) between the surfaces of
, ;<3
transmission housing.

- the clutch housing and bearing inner race.
!

-
THHUST SHIM NOTE:
84 9
¢ Use a straight edge and depth gauge.
?

-
¢ Measure at three locations and average the
, !&

readings.

-
I©
OIL GUIDE END OF CLUTCH HOUSING
PLATE
TRANSMISSION ”I \ j — I {I __ _ ( T
HDUSING — —— _,. -J
2.
- Install the 3rd/4th synchro hub, spacer collar, 5th
!!+=* A!!A
synchro hub, ball bearing, and thrust washer on the
A!!
A 3
mainshaft. Install the assembly in the transmission
-!!!
housing

- INNER RAGE OF BALL BEARING
(B) 3HDI4TH S‘I‘ NGHRD HUB
5.
- Select the proper shim on the basis of the following
!!!3
calculations:
! !9
THH UST WASHER NOTE: Use only one thrust shim.
84 9?! -
(Basic Formula)
;) !<
SPACER COLLAR (B) + (C) - 0.95 = shim thickness
;)<V;<0-5Y#
Example of calculation:
/!! !9
Distance (B) (2.00 mm) + Distance (C) (0.09 mm)
(;)<;-00<V(;<;0-05<
5TH SYNCHHO HUB
= 2.09 mm
Y-05
subtract the spring washer height (0.95 mm) = the

3
;0-5<Y
“LL BEARING required thrust shim (1.14 mm)
F ;-*<
3.
+- Measure the distance (B) between the end of the
, ;)<3
transmission housing and thrust washer.

3-
NOTE:
84 9
0 Use a straight edge and vernier calliper.
?

&!!-
0 Measure at three locations and average the
, !&

readings.

-

Mainshaft
Thrust Clearance
D/
?0
13-39
9
70 mm THRUST SHIM
7$.;. 6.
- Install the oil guide plate and selected thrust shim
!!!
!!

Part Number 4#
Thickness in the transmission housing.

-
% 23931 -PL3-B00
+5++)00 0.60 mm (0.0236 in)
0-0;0-0+< NOTE:
84 9
iN-<><E<C—ICDED'Uozgl—XL_IOTIITIUOCU>
) 23932-PL3-B00
+5++)00 0.63 mm (0.0248 in)
0-+;0-0*'< ¢ Clean the thrust washer, spring washer and
! 3A
3
23933-PL3-B00
+5+++)00 0.66 mm (0.0260 in)
0-;0-00< thrust shim thoroughly before installation.

!!!-
( 23934-PL3-B00
+5+*+)00 0.69 mm (0.0272 in)
0-5;0-0$< ¢ Install the thrust washer, spring washer and
!! 3A
3
23935-PL3-B00
+5++)00 0.72 mm (0.0283 in)
0-$;0-0'+< thrust shim properly.
!-
23936-PL3-B00
+5++)00 0.75 mm (0.0295 in)
0-$;0-05<
. 23937-PL3-B00
+5+$+)00 0.78 mm (0.0307 in)
0-$';0-0+0$< THRUST SHIM
6 23938-PL3-B00
+5+'+)00 0.81 mm (0.0319 in)
0-';0-0+5<
23939-PL3-B00
+5+5+)00 0.84 mm (0.0331 in)
0-'*;0-0++< OIL GUIDE
" 23940-PL3-B00
+5*0+)00 0.87 mm (0.0343 in)
0-'$;0-0+*+< PLATE
> 23941 -PL3-B00
+5*+)00 0.90 mm (0.0354 in)
0-50;0-0+*<
23942-PL3-B00
+5*+)00 0.93 mm (0.0366 in)
0-5+;0-0+< TRANSMISSION
, 23943-PL3-B00
+5*++)00 0.96 mm (0.0378in)
0-5;0-0+$'< HOUSING
23944-PL3-B00
+5**+)00 0.99 mm (0.0390 in)
0-55;0-0+50<
8 23945-PL3-B00
+5*+)00 0.02 mm (0.0402 in)
0-0;0-0*0< 7.
$- Install the thrust washer and spring washer in the
!! 3
3
23946-PL3-B00
+5*+)00 1.05 mm (0.0413in)
-0;0-0*+< mainshaft

D 23947-PL3-B00
+5*$+)00 1.08 mm (0.0425 in)
-0';0-0*<
1 23948-PL3-B00
+5*'+)00 1.11mm (0.0437 in)
-;0-0*+$<
MAINSHAFT
23949-PL3-B00
+5*5+)00 1.14mm (0.0449 in)
-*;0-0**5<
4 23950-PL3-B00
+50+)00 1.17mm 10.0461 in)
-$0-0*< THRUST WflSHEFI
? 23951 -PL3-B00
+5+)00 1.20 mm (0.0472 in)
-0;0-0*$<
SPRING WASHER
: 23952-PL3-B00
+5+)00 1.23 mm (0.0484 in)
-+;0-0*'*<
2 23953-PL3-B00
+5++)00 1.26 mm (0.0496 in)
-;0-0*5<
R 23954-PL3-B00
+5*+)00 1.29 mm (0.0508 in)
-5;0-00'<
8.
'- Install the mainshaft in the clutch housing.
!!!
-
C 23955-PL3-B00
+5+)00 1.32 mm (0.0520 in)
-+;0-00<
9.
5- Place the transmission housing over the mainshaft
!
&
I 23956-PL3-B00
+5+)00 1.35 mm (0.0531 in)
-+;0-0+<
and onto the clutch housing
!
23957-PL3-B00
%% +5$+)00 1.38 mm (0.0543 in)
-+';0-0*+<
10. 4
!
3
0- Tighten the clutch and transmission housings with
23958-PL3-B00
%) +5'+)00 1.41 mm (0.0555 in)
-*;0-0<
IO'I'II'I'IUOUJ
several 8 mm bolts.
>>>>>>Jj>>>>>>>
&!'!-
23959-PL3-B00
% +55+)00 1.44 mm (0.0567 in)
-**;0-0$<
NOTE: It is not necessary to use sealing agent
84 9 !

23960-PL3-B00
%( +50+)00 1.47 mm (0.0579 in)
-*$;0-0$5<
between the housings.
3
-
23961 -PL3-B00
% +5+)00 1.50 mm (0.0591 in)
-0;0-05<
8 x 1.25mm
8@3
% 23962-PL3-B00
+5+)00 1.53 mm (0.0602 in)
-+;0-00<
23963-PL3-B00
%. +5++)00 1.56 mm (0.0614 in)
-;0-0*< 27 Nm 12.8 kgf/m. 20 lbf/ft
7,@86! 2@$* 2
23964-PL3-B00
%6 +5*+)00 1.59 mm (0.0626 in)
-5;0-0< 11. 43!-
- Tap the mainshaft with a plastic hammer.
%! 23965-PL3-B00
+5+)00 1.62 mm (0.0638 in)
-;0-0+'<
%" 23966-PL3-B00
+5+)00 1.65 mm (0.0650 in)
-;0-00<
OZZVXL
23967-PL3-B00
%> +5$+)00 1.68 mm (0.0661 in)
-';0-0<
% 23968-PL3-B00
+5'+)00 1.71 mm (0.0673 in)
-$;0-0$+<
23969-PL3-B00
%, +55+)00 1.74 mm (0.0685 in)
-$*;0-0'<
23970-PL3-B00
% +5$0+)00 1.77 mm (0.0697 in)
-$$;0-05$<
23971 -PL3-B00
%8 +5$+)00 1.80 mm (0.0709 in)
-'0;0-0$05<

Mainshaft
Adjustment

Thrust Clearance
(cont’d)
D/
?0
13-40
$
-
12. # !
Check the thrust clearance in the manner described e.
- Zero a dial gauge on the end of the mainshaft.
I!

-
!3-
below.
A CAUTION DIAL GAUGE
Measurement should be made at room temperature.

, ! -
-
a. !!!&
Slide the mainshaft base and the collar over the
-
mainshaft.
"—F/III CLUTCH
MAINSHAFT l‘ V5.1. HOUSING
{f ”HE.
__'-._ MAINSHAFT BASE MAINSHAFT HOLDER

' 07GAJ—P62013fl WGAJ- P620110
COLLAR f.
- Turn the mainshaft holder bolt clockwise; stop
4 !!!#3N
OTGAJ — P6201 20 turning when the dial gauge has reached its

3!

b.
- Attach the mainshaft holder to the mainshaft as
%! maximum movement. The reading on the dial
/ &-4
!
follows:
!!39 gauge is the amount of mainshaft end play.

!-
NOTE:
84 9
0 Back-out the mainshaft holder bolt and loosen the
)# !!! A CAUTION
two hex bolts.
3/!- Turning the mainshaft holder bolt more than 60
4
!!0
0 Fit the holder over the mainshaft so its lip is
!&! degrees after the needle of the dial gauge stops moving

!!

&

towards the transmission,
3A may damage the transmission.

-
0 Align the mainshaft holder’s lip around the groove
%!
!B!
& 9.

- If the reading is within the standard, the

3A
at the inside of the mainshaft splines, then tighten
!A
clearance is correct.
!-
the hex bolts.
/!- If the reading is not within the standard,

3A
recheck the shim thickness.
##-
MAINSHAFT HOLDER Standard: 0.11-0.18mm (0.004-0.007 in)
F$@$@8/$@$$$@$$7 0
BOLT
HEN
{1&3 \S MAINSHAFT
1251/ _ l’. éfifi‘imw
'fl
0.
- Seat the mainshaft fully by tapping its end with a
!!
3
plastic hammer.
!-
d.
- Thread the mainshaft holder bolt in until itjust
4!! !7
contacts the wide surface of the mainshaft base.
3 -
Transmission

Reassembly
*#
13-41

NOTE: The steel balls are all of the same size (5/16 in).
84 94!!!!!H;=<- - Insert shift arm shaft in the clutch housing.
!
-
N97
1.
- Install the magnet and reverse lock cam.
!!
&!#- $- Install the collar, spring, and steel ball into the
!!!!A
A!!!
2.
- Set shift arm Aon the clutch housing, then install the
%!
A!! case. Compress the ball and insert the shift arm
-!!
shift rod.
- shaft.
-
3. !!
3%
!-
+- Install the spring washer and shift arm Aattaching bolt. Install shift arm C in shift arm A, then insert the
'- !!%A
4. !!!!!A
A!!
!-
*- Install the steel ball, spring, and set ball spring bolt. shift arm shaft.
-
5
- Install shift arm B in the interlock, then set it on the
!!)!#A Install the reverse select retainer and reverse
5- !!&!&
clutch housing.
!
- select spring onto shift arm shaft.
!
-
Install the differential assembly.
0- !!!!-
am 11.5 kgfvm, 'I'l lbfvftl

A: E n 1 0 mm SHIFT ill-RM C
\
“f
31 N-m (3.2 kgf-m, 23 inf-m
/ REVERSE LOCK CAM
/ {REVERSE SELECT RETAINER

l Iii '.
4. ".132
SHIFT ARM B a
., n.
/ ”H REVERSE SELECT SPRING
Q'W L. 53.4 mm 12.50 in]
INTERLUCK
II] -- ak‘ MAGNET
SPHING “a.
I... 21A mm
(0.843 in] K
,. SET BALL spams BOLT
SHIFT ARM A -—__ 22 N-m 12.2 kgfom. 16 Ibf‘fti
14 x 20 mm .._.——
DOWEL PIN
fau.—-+ fifii SPRING
L. 25.6 mm 11.01 in]
CLUTCH
HOUSING\‘5 .._/" '-
DIFFERENTIAL
ASSEMBLY
OIL SFAL
Hizplacx.
SHIFT ARM SHAFT
SHIFT ROD
BOOT
Transmission

13_42
*#/
?0

11. +
33-
- Set the 36mm spring washer and washer. 15. !!&!
&!

- Install the reverse idler gear and reverse idler gear
12. !!A A#
- Install the mainshaft, countershaft, and shift fork shaft.
-
assemblies.
!- REVERSE IDLER
NOTE: Align the finger of the interlock with the groove in
84 9%!

!#3
& GEAR SHAFT
the shift fork shaft.
#-
MAINSHAFTICDUNTEHS HAFT
SHIFT FORK ASSEMBLIES
Tape the mamshaft

splines.
RE‘III EHSE IDLER

GEAR
-
16. !!&!-
Install the reverse shift holder.
REVERSE SHIFT
HDLDEH
.-'_' '- - “I I
13. !!
3'
!-
+- Install the spring washer and shift arm 8 attaching bolt.
14. !!=!
A'!
!A
*- Install the 1st/2nd select spring, 28 mm plug bolt, and
interlock guide bolt.
!#
!-
NOTE: Apply liquid gasket P/N 08C70-K0234M to the
84 9%!!F
#=0'$0>0+*,
threads of the 28 mm plug bolt and interlock guide bolt.
'!
!!#
!-
8 x 1.0 mm
31 N-m (3.2 kg’i-m. 23 Ihf-m
15TI2ND SELECT SPRING SPRING
L. 36.26 mm {1.423 in! WASHER
15 N-m (1.5 kgf'm,

11 Ibf-f‘tl
28 mm PLUG BOLT
54 Nim 15.5 kgfrrn.
40 Ihf-fll INTEFILOCK GUIDE BOLT
39 N-n‘l [4.0 kQFm. 29 Ibi-ftl
Transmission

*#/
?0
13-43

17. !!!
!-
$- Install the oil gutter plate. 20. !!3!
-
0- Install the dowel pins and the transmission housing.
18. !!!
!
'- Install the oil guide plate and thrust shim on the 21. 3
3
- Lower the transmission housing with the snap ring


- pliers, and set the snap ring into the groove of the
!A

&
OIL BUTTER PLATE countershaft bearing.

-
THRLI$T SHIM NOTE: Check that the snap ring is securely seated
84 9#
!
OIL GUIDE
in the groove of the countershaft bearing.

&
-
22. !!+!
!-
- Install the 32 mm sealing bolt.
NOTE: Apply liquid gasket P/N 08C70-K0234M to
84 9%!!F
#=0'$0>0+*,
the threads.
@
32 mm SEALING BOLT
25 N~rn l2.5 kgf‘m. 18 Ibf~ft|
SNAP RING PLIERS

OTLGC - DD‘ID‘IDD
TRANSMISSION HOUSING
19. %!!F
#
5- Apply liquid gasket to the surface of the transmission
housing mating with the clutch housing as shown.

3!
3-
NOTE:
84 9
0 Use liquid gasket P/N 08C70-K0234M.
?!F
#=0'$0>0+*,-
0 Remove the dirty oil from the sealing surface.
1&!!
-
O If 20 minutes have passed after applying liquid
0 &!
!F
gasket, reapply it and assemble the housings.

#A!!
-
Allow it to cure at least 20 minutes after assembly
%!!3 !0 !
SNAP RING
before filling the transmission with oil.
!!
3!-
4.6—8.3 mm
[0.18 (1.33 in]
Transmission

*#/
?0
1 3-44

23. 4

!
+- Tighten the transmission housing attaching bolts in the 25. !!# !
3
- Install the back-up light switch and transmission
numbered sequence in several steps shown below.
F &!3!3- hangen

-
8 x 1.25 mm
8@3 B x 1.25 mm
2? Mn! [2.3 kgI—n‘l.
Torque: 27 Nm (2.8 kgflm 20 Ibf/ft)

BF7,/@86! 2$* 2 0 201mm
TRANSMISSION
B x 1.25 mm
HANGER
Torque: 27 N-m {2.3 kgfvm 2O lbI-ft]
WASHER
BACK-UP LIGHT SWITCH Replace.
HARNESS STAY
BACK-UP LIGHT
SWITCH
25 N-m I15 Raf-n1. 1E IhI-I‘tI
*- !!!!!A

A3-
WASHER _ S
\STEEL BALL
D. 5I1Bm
Replace. \fi
9
§
5*
SPRING
L. 25.0 mm {1.02 ini
SETTING SCREW
22 N‘m I21 kgf'm. 16 Ibf-ITI
Oil Seals

Replacement

13-45
3
Transmission Housing:

.
!F Clutch .
!F
Housing:
1.
- Remove the oil seal from the transmission housing.
1&!!
- 1.
- Remove the oil seal from the clutch housing.
1&!!!
-
CLUTCH
HOUSING
OIL SEAL
Replace.
TRANSMISSION
HOUSING OIL SEAL
Rapla ce.
2.
- Install the oil seal into the transmission housing using
!!!!

the special tools as shown.

!!3- 2.
- Install the oil seal into the clutch housing using the
!!!!!

special tools as shown.
!!3-
DRIVER
DRIVER SEAL DRIVER 01'149 ~OD1000U DRIVER ATTACHMENT
UTTQQ — 001 0000 I ' ATTACHMENT OTJAD— PH801'D1
\! 07947—5110501 or
. 07947—51 10500
OIL SEAL
I [—-J , ’-/. mL SEAL B 5/ Replace.
I
TE
. . : ' ‘/Huplacu.
“' ‘53 PILDT, 26 x 30 mm

on AD — PHBOZDD PILOT. 25 I 30 mm
D7JAD- “13020“

*#

Installation
13-46
5
1.
- Check the two dowel pins are installed in the clutch
#33!!!! 5.
- Place the transmission on the transmission jack,
!7#A
housing.

- and raise it to the engine level.

!&!-
2.
- Install the slave cylinder bracket to the transmission
!!!&!# 6.
- Install the transmission mounting bolts and rear
!!
!
assembly.
!- mount bracket bolts.
#!-
SLAVE SPECIAL BOLTS
CYLINDER
Replace.
BRACKET 12 I 1.25 mm
14 x 1.5 mm
54 N-m 15.5 kgf—m. #7 Ibf-HI
84 NM [8.5 Ital-m. 51 IbfflI
B x 1.25 mm
22 N-m lunar-m,
ialbfiti
3.
+- Apply HONDA Genuine Urea Grease UM264 (P/N
%!68(%. ?.?,*;=
41211-PY5-305) to the release fork, the release fork
*C+0<!#A!#
bolt, the release bearing, and the release bearing guide
!A!
A!

-
in the shaded areas. WASHERS
RELEASE FORK BOLT
12 I 1.25 mm REAR
IPIN 41211 —P‘I’5—3051
29 "am [3.0 kgf-rn, SPECIAL BOLT MOUNT
BRACKET
22 Ibf-ftl RELEASE
BEARING Replace.
H x 1.5 mm
a: N-m 18.5 kgf-m. a1 lhf-l‘tl
RELEASE
7.
$- Install the three upper transmission mounting bolts
!!
!
FD RR and lower starter motor mounting bolt.
!3
!-
{PIN 41211 —P"I"5—3051

_\
RELEASE
FORK
.@ ®
II J“ (Pm 41211 —PY5—:mfii
0.3—0.9 g
tum—0.03 ozl
4.
*- Install the release bearing, release fork, and boot on the
!!!
A!#A 1i] 3: 1.25 mm
transmission.
- H N-m 14.5 kgf‘m,
3:! Ibf-ftl
12 n 1.25 mm
at him [5.5 hull-m, 47 lb'Ht]

*#

/
?0
13-47
7
8.
'- Raise the transmission, then install the transmission
1A!! 10. !!!

#-
0- Install the front beam by aligning the marks.
mount rubber assembly and transmission mount bracket.
! #- MARK
0 Torque the mounting bolts and nut in the sequence
4F
! F
shown.
3-
Make sure the bushings are not twisted or offset.
,#
3-
Awm—xo
: 12 x 1.25 mm 64Nm (6.5kgf/m,47|bf/ft)

9/-*;-#
=A*$!=<
: Temporarytightening
94

:12 x1.25 mm 64 Nm 6.5 kgf/m, 47lbf/ft)

+9/-*;-#
=A*$!=<
AA
:10x1.25 mm 64 Nm 6.5 kgf/m, 47lbf/ft)

*90/-*;-#
=A*$!=<
|1_'I
TRANSMISSION
MOUNT RUBBER RH ' a.
12 x 1.25 mm
M I 1.5 mm 64 en [5.5 kgfim.
103 Mm 110.5 kgf-m. 47 lhfvfli
15.9 lbf-fll
11. !!3
!
- Install the power steering cooler pipe in the pipe
clamps.
!-
x TRANSMISSION E I 1.0 mm
MOUNT BRACKET 9.3 N-m 11.0 kg‘l—m, 7.2 Ihf-fli
5-
9. 1&-
Remove the chain hoist. PIPE CLAMP
POWER STEERING

*#

/
?0
13-48
8
12. !! 33
!
- Install both radius rods with new mounting bolts on the 15. !!A
A!3-
- Install the shift rod, spring pin, and clip as shown.
lower arm.
!3- NOTE:
84 9
1!- x 1.5 mm ¢ Turn the boot so the hole is facing down.
4 !
3-
179 N-I'I'I “3.3 kgfvm. 132 Ib'Ht} ¢ ,# !!
Make sure the boot is installed on the shift
-
rod.
SHIFI' ROD
B x 29 mm
SPRING PIN
Replace.
RADIUS nun
13. !!! &-
+- Install the clutch cover.
14. !!
-
*- Install the front and rear engine stiffeners.
FRONT ENGINE
STIFFENER
EXTENSION ROI}
8 x 1.25 mm
22 "m {2.2 “mm, H" ”MR, 3.0 mm
W mm] 0914.4 — comma
B l 1.25 mm -
16. !!/-
- Install the extension rod.
24 N-rn 12.4 kgf-m.
1? Ibf-f‘ll $- Install the exhaust pipe A.
17. !!/ %-
SELF-LflcKlm HUT
Replace.
8 x 1.25 mm
_. _I_1_l:lN-ml1.al_rgf-m, 13 lhf-ftl
6 x 1.0 mm
12 film [1.2 kgf-m.
3.7 lbf—fll
12 I: 1.25 mm
5? N-m 15.8 kg‘I-m. B x 1.25 mm
42 lbf‘h’l 21 Mm 124! kg'l-rn,
11' lbf-I‘t]
In x 1.25 mm
44 I'll-m ”.5 kgfnrn. GASKET
33 lbf'fl) HEAR ENGINE
' 61)
Replace.
& SELF-Lam NUT

Replace.
In a: 1.25 mm SELHOCKING I“UT 10 x 1.25 mm
an I'll-n1 13.5 kyl-m, Rep'm- 55 N111 {5.5 ham.
2:: Int-m 1" I 125 mm 40 Hm
33 N-m 13.4 Icahn,
25 lbl-l‘tl

*#

/
?0
13-49
9
18. !!&33
;<-
'- Install the driveshafts with new set rings (see section 16). 21. !!!!-
- Install the splash shield.
10 x 1.25 mm
33 N-m {3.9 kgi-m. FRONT ENGINE
SUPPORT BRACKET
DRIVESHAFI'
FRGNT ENGINE
STOPPER BRACKET
1D I: 1.25 mm
36 film l3 9 kgf-m.
23 lbl-hi
10 x 1.2!: mm
33 N-rn [3.9 kgI-m,
2i! lbt-fl]
SET RING
19. !!#33!# ;
5- Install both the damper forks with new locknuts (see [-4 N-rn (6.5 kgi n1. 4? lhf-f‘tl
section 19).
5<- - Install the front engine stopper bracket and front
22. !!
#
20. !!!!7!3A!!
0- Install the ball joint onto the lower arms, then install the engine support bracket.

#-
10 x 1.25 mm
castle nuts and new cotter pins (see section 18).
! 3;'<-
10 :1 1.25 mm
33 NH! 13.9 kgi-m. FRONT ENGINE
28I «Hi SUPPORT BRACKET
43 N-m iu kgf-rn.
32 lb‘H'lI
FRONT ENGINE <39
STOPPER BRACKET
10 x 1.25 mm
313 Mm [3.9 hgf- \/
28 lb'l-fil
_-__ '-F"1.—3"""-- 10 it 1.25 mm

_.__ 38 N-m 13.9 kgf-m,
25 Ibffil
LOWER ARM
12 :1 1.25 mm
BALL JOINT 54 N-m 16.5 Him. 41 Ihfafil
CUTTER PIN
Fireplace. Replace.
12 x 1.25 mm 12 I 1.25 mm
49 — 55 N~m 64 N-m Iii-.5 kgl—m.
l5.D - 6.0 Ital-m. 47 lb'l-fll
36 - 4-3 lhf-ftl

*#

/
?0
13-50
3$
23. &!;:<-
+- Connect the vehicle speed sensor (VSS) connector. 26. !-,#
- Connect the starter motor cables. Make sure the
V55 COHHECTUH crimped side of the ring terminals is facing out.

!
-
E I 1.0 mm
3.4 H-m (0.35 ugh-n.
2.5 Ibf-ftl
24. # !

3-
*- Connect the back-up light switch connector. a x 1.25 mm STARTER MOTOR
9 Mn 10.9 kgf-m. CABLES
6 1: LI] mm 1 lbffll
9.3 N-m l'l .l‘l kgl-m. $- Apply HONDA Genuine Urea Grease UM 264
27. %!68(%. ?.?,*
1.2 lbl'ft]
(P/N41211-PY5-305) to the end of the slave
;=*C+0<!&
cylinder rod. Install the slave cylinder and clutch
!-!!!&!!
line clamp so as not to bend the clutch line.
!!! !-
{ii-(1.0mm 811.25 mm
5.3 Mm {1.0 kgl-m. 22 N-m {2.2 kgf‘m.
12 Ital-h] 16 t‘tl
CLUTCH UNE
CLAMP
TRANSMISSION
3:33:10 BACK-UP LIGHT swimn
CONNECTOR
25. !!
-
- Install the transmission ground.
fl SLAVE
CVIJHDER
(PIN M211 - PY5 - 305i

*#

/
?0
13-51
3
'-
28. !!# -
Install the intake air duct. 30. !! A#

+0- Install the distributor, then check the ignition timing

(see section 23).
;+<-
INTAKEAHIDUCT 31. &;V<!A
+- Connect the positive (+) cable first, then the
negative (-) cable to the battery.

&;<!-
32. 1!!! ;!++<-
+- Refill the transmission fluid (see page 13-3).
33. ##
++- Check the transmission and check for smooth
operation.
-
34. #! -
+*- Check the clutch operation.
35. #3!!
;'<-
+- Check the front wheel alignment (see section 18).
36.
!
+- Loosen the three mounting bolts on the front
engine stopper bracket, then torque the three

#AF
mounting bolts in step 21. Make sure the bushings

!-,#

are not twisted or offset.
3-
29. 4 K

5- Turn the breather cap so that the “F”L#3
mark points toward
the front of the vehicle.
&!-
FHONTEHDE
BREATHER
CAP
Special Tools

13_54
3
O 1- O| Tool Number
4! O Description
( OD O Remark
1#
T2 _\_\_\_\_\_\_\_\_\_\_\_\_\_\VVV_\_\VV_\_\_\<
O O| 07GAD - PG20100
0$.%(.000 O Pin Driver, 5.0 mm
(&A-0 |
O O
LDOONO‘JUTUTCIJTU'l-D-OOOOOOMA
O O| 07GAD - PG40100
0$.%(.*000 O Driver Attachment
(&% |
O O
O + O| 07GAJ - PG20102
0$.%".00 O Mainshaft Clearance Inspection Tool Set
,!4! |
O O
O + O| 07GAJ - PG20110
0$.%".00 O Mainshaft Holder
,6! O;< O
I“);
O + O| 07GAJ - PG20130

0$.%".0+0 O Mainshaft Base
,) O;< O
O * O| 07HAJ - PK40201
0$6%">*00 O Preload Inspection Tool
!4! |
O O
O O| 07JAC - PH80000
0$"%6'0000 O Adjustable Bearing Remover Set
%7 !)
1& |
O O
O O| 07JAC - PH80100
0$"%6'000 O Bearing Remover Attachment
)
1&% |(1
O;< O
mll\)—\
O O| 07JAC - PH80200

0$"%6'000 O Remover Handle Assembly
1&6!%! |(1
O;< O
O
O
O
+

$
I
O
O
O|
07741 - 0010201
0$$*0000
07JAD - PH80101
0$"%(6'00
07JAD - PH80400
0$"%(6'0*00
O
O
O
Remover Weight
1&2

Driver Attachment
(&%
Pilot, 28 X 30 mm
!A'/+0
|(1
O;<
|
O
|
O
O
O
O
O ' O| 07LAD - PW50601
0$%(200 O Bearing Attachment
)
% |
O O
O 5 O| 07LGC - 0010100
0$.00000 O Snap Ring Pliers
1
! |
O O
O 0 O| 07TAJ - ST70100
0$4%"4$000 O Preload Inspection Tool
!4! |
O O
O O| 07746 - 0010300
(&%A*/*$ |
O O
O O| 07746 - 0010400
(&%A/ |
O O
O + O| 07746 - 0010500
0$$*00000 O Driver Attachment, 62 x 68 mm
(&%A/' |
O O
O * O| 07746 - 0010600
0$$*00000 O Driver Attachment, 72 x 75 mm
(&%A$/$ |
O O
O O| 07746 - 0030100
0$$*00+000 O Driver, 40 mm ID.
(&A*0-(- |
O O
O O| 07746 - 0030400
0$$*00+0*00 O Attachment, 35 mm ID.
%A+-(- |
O O
O $ O| 07749 - 0010000
6!(& |
O O
O ' O| 07947 - 6890100
0$5*$'5000 O Oil Seal Driver
8!!(& |
O O
O 5 O| 07979 - PJ40001
0$5$5"*000 O Magnet Stand Base
,
) |
O O
I
“i
r_.|
.5-
-: _-l
"an
J-l'l
3-3,
_.
z'
Description
)
_
33
Limited Slip Differential (LSD) (HA22A7 engine
& ) /&)0/.7! 13 55
model)

0
Funcfion
+

Operation of the helical type limited slip differential (LSD) is dependent upon the eight pinion gears that are in mesh with the
8!!!!!;(<

3
two side gears. They transfer the driving power to the driving axles as well as permit the outside wheel to turn more times than
3
-4&
3&
/!3!! 3!
the inside wheel when the vehicle goes around a turn. All gears are helically cut so that this differential action is limited by the
3!3&!
-%!!
!!! !!
friction created between each gear and differential carrier when either wheel slips.
3
!33!!-
Construction

The unit consists of the two side gears, four short pinion gears, four long pinion gears, two thrust washers, a center washer,
4 3
A
A !

A3 3A3A
and a carrier that houses the gears and washers. One short and one long pinion gear are in mesh with each other and are

3-8!

3
allowed to walk around the side gears.
!!33!#
-
-; _'1_::- (if:
(!
Differential carrier
‘OVCDOW-bcpNA
Thrust washer
4 3
+ Left side gear

* Center washer
3
Right side gear
1

Pinion gear (long)

;!
<
$ Pinion gear (short)

;<
peration

Straight-load driving

!&
The differential carrier and gears rotate together as a unit when both wheels rotates at the same speed. Turning effort
4!

33!-4

from the final driven gears are directly transmitted to both wheels.
!&
!3!-
Description
)
_
35
Limited Slip Differential (LSD) (HA22A7 engine
& ) /&)0/.7! 13 56
model) (cont’d)

0/
?0
¢ When rounding a curve

2
&
When the vehicle rounds a curve, the differential allows the outer wheel to rotate a little faster than the inner wheel. When
2&! &A!!!3 3!!!3!-2
this takes place, the short and long pinion gears rotate, and walk around the side gears in the directions shown. If, for
#!A!

A3!#
3-A
example, the right shaft is rotated in a counterclockwise direction with the differential carrier held stationary, the force is
/!A
!#33!!A
transmitted through the right side gear, short pinion gears and long pinion gears to the left side gear, causing the left shaft

A
!

!
A
!
to rotate in a clockwise direction. This allows the outer wheel to turn more times than the inner wheel when the vehicle
!#3-4!!3 3! 3!3&!
goes around a turn.

-
PINION GEAR PINIDN GEAR
lLONGl ISHORN
DIFFERENTIAL CARRIE R
LEFT SHAFT
RIGHT SHAFT
LEFT SIDE
GEAR
RIGHT SIDE GEAR

¢ When limiting differential action
2!
!
The limited slip differential (LSD) acts to limit the differential action when either wheel slips on ice or snow or on turn. This
4!!!;(<!!33!!3 -4
is done by using the friction created between each gear and differential case:

3
!9
(1) 4
!!! 3
;< The pinions are forced against the differential carrier by the force as they are rotated and repelled outward in
engagement.

-
(2) 4
!!
! !!!
;< The ends of the pinion gears are held firmly against the differential carrier due to the side thrust from the helically cut
gears.

-
l‘ll iZi
PINION GEARS
, PINIDN
GE ARE \_____
\4
"K.
“x DIFFERENTIAL
CARRIER
With the pinion gears locked, the torque applied to the slipping wheel is reduced and the torque delivered to the other
2
!#AF !!
3! F !&
wheel is increased.
3!-

Maintenance

+
Transmission Fluid
13-57
37 Back-up Light(
"6& ! Switch
Test/Replacement
2
NOTE: Check the fluid with the engine OFF &!
84 9#! 3
8 and vehicle on -
1. (3-
Disconnect the connectors from the switch.
level ground.
!&!
- No. 1 TERMINAL
BACK-LIP LIGHT SWITCH
1.
- Remove the filler plug, then check the level and
1&!!!
A#!&! 25 N-m :25 I: 9' -m. 13 mm ’
! -
condition of the fluid. no. 2 TERMINAL
HLLEH PLUG
44 Min «.5 leaf-m. 33 mm:
/
Proper Level
l
WASHER
Replace.
2.
- The fluid level must be up to the filler hole. If it is below
4! !&! !!!-!3
the hole, add fluid until it runs out, then reinstall the filler
!A! ! A!!!!
plug with a new washer.
!
333-
3.
+- If the transmission fluid is dirty, remove the drain plug
! A&!
and drain the fluid. Cover the front and rear beams with
! -&3
a shop towel to catch any spilled fluid.
3!!!! -
4.
*- Reinstall the drain plug with a new washer, and refill the
1!!!
333A!!
WASHER
transmission fluid to the proper level.
! !&!- Replace.
NOTE: The drain plug washer should be replaced at
84 94!
3 !!
every fluid change.
&!
- 2.
- Check for continuity between the No. 1 and No. 2
# 3--
5.
- Reinstall the filler plug with a new washer.
1!!!!!
333- terminals.
!-
Fluid Capacity
+ # ¢ 4 ! 3!&
There should be continuity when the shift lever
1.9 [(2.0 US qt, 1.7 Imp qt) at fluid change
@9/@$;B:@7B0 ! into reverse.
&-
¢ 4 ! 3!&
There should be no continuity when the shift lever
2.0 [(2.1 US qt, 1.8 Imp qt) at overhaul
@$/@;B:@8B0
-
in position except reverse.
/&-
Always use genuine Honda Manual Transmission fluid
%!3
6, !4!
3.
+- If necessary, replace the switch.
A!3-
(MTF).
;,4 If it is not available, you may use an API service
<-&!!A %&
8G or SH grade motor oil with a viscosity of SAE 10
.6
!3&% 0
W-30 or 10 W-4O as a temporary replacement.
2+002*0!-
FILLEFI PLUG
u I'll-m {1.5 Ital-m. _ -.
33 Ihr-n:
WASHERS
Replace.
DRAIN PLUG
35 N-m 14.0 kgf-m. 29 Itl
Limited Slip Differential (LSD) (HA22A7
& ) /&)0/.7
en ine model
!
0
13-58
38 Rotating Torque Check

!
B 6
Operational Check

6
A CAUTION
- Setting parking brake and block the rear wheels.

#
#!#3!-
- Raise the front of the vehicle, and support it with
1&!A 3
The helical type limited slip differential (LSD) distributes
4!!!!!;(< safety stands in proper locations (see section 1).
!;<-
optimum power between the two driving axles according to
333&
/!
+- With the engine off, shift the transmission into
2
A
difference in torque as demanded by the driving wheels.
F &
3!- Neutral.
!-
Under no circumstances should the engine be started with
? !
3 *- Measure the rotating torque with a beam-type
,
F 3
either wheel raised off the ground, such as when adjusting
3!
A 37
torque wrench in the direction shown. Rotate the
F 33-1
wheel balance with an on-the-vehicle wheel balancer or
3!!3&!3!! torque wrench more than two complete turns and
F 33!
when transporting the vehicle in the event of accident.
3
&!&- take the maximum reading.
#/
-
1.
- Set the parking brake and block the rear wheels.
#
#!#3!-
2.
- Raise the front of the vehicle, and support it with safety
1&!A 3
stands in the proper locations (see section 1).
!;<-
3.
+- With the engine off, shift the transmission into 1st gear.
2
A
-
4.
*- Rotate either front wheel by hand and check that the
13!#
other wheel rotates in the opposite direction.
3!-
5.
- If the opposite front wheel does not rotate, or if you
3!A
cannot spin the front wheels at all, the limited slip
3!!!A!!
differential is faulty and should be replaced.
! ! !!-
- Shift the transmission into 1st gear and measure

the rotating torque again.

F
-
- Calculate the rotating torque:
! !
F 9
Service Limit:
&9
Measurement from step 5 >2.5
, ]-
Measurement from step 4
, *
$- Repeat step 3 through 6 for the other wheel.
1+
3!-
9°.“
'- Replace the limited slip differential assembly if the

1!!!!!
rotating torque is lower than the service limit.

F !3&!-

*# 13-59
39

-
Removal
A WARNING
4.
*- Remove the engine wire harness clamp.
1&
3!-
' Make sure jacks and safety stands are placed properly
,# 7#!!
(see section 1). . ENGINE WIRE
;<- , mass cum '
0 Apply parking brake and block rear wheels so vehicle
%!#
#!#3!&! \ _
will not roll off stands and fall on you while working under it.
3!!!!!! 3!3#
- ' '
Use fender covers to avoid damaging painted surfaces.

?&&

- " _
1. (
&;<!A&
- Disconnect the negative (-) cable first, then the positive
(+) cable from the battery. Remove the battery.
;V<!-1&-
2.
1&# -
lNl'AKE AIR DUCT
5.
- Carefully remove the slave cylinder and clutch line
!!&!&!! !
clamp so as not bend the clutch line.
!! !-
Do not operate the clutch pedal once the slave

(! !!&
cylinder has been removed.
!&-
CLUTCH
UNE
CLAMP
"V“.
3.
+- Remove the battery tray.
1&-
BATTERY THA'r

*#
Removal (cont’d)

-/
?0
13-60
5$
-
6. (!A&
Disconnect the starter motor cables, then remove the 9.
5- First remove the cable bracket, then disconnect
&!#A
-
starter motor. the cables from the top of the transmission
!
STARTER housing. Carefully remove both cables and the

- !!&!
MOTOR bracket together so as not to bend cables.
#
!-
EDTIER PINS
Replace.
CABLES
CABLES
7.
$- Disconnect the back-up light switch connectors.
(# !
3-
BACK-UP LIGHT SWITCH
CONNECTORS
STARTER
CABLE 10. (&!;:<
0- Disconnect the vehicle speed sensor (VSS)
CLAMP
connector.
-
V55 (:DI'IEETCIR
TRANSMISSION
GROUND GAB-LE
8.
'- Remove the transmission ground cable and starter
1&
!

*#
Removal (cont’d)

-/
?0
13-61
5
11. 1&
#-
- Remove the rear engine mount bracket brace. 13. 1&
#B
+- Remove the front engine stopper bracket’s three
mounting bolts.

!-
FRONT ENGINE
MOUNT BRACKET
14. 1&!# !
*- Raise vehicle and make sure it is securely
MOUNT BRACKET supponed.
-
BHAEE 15. (! A33!&
- Drain transmission fluid, with a shop towel covering

12. 1&3
!-
- Remove the two upper transmission mounting bolts. the front and rear beams to catch any spilled fluid
!!!
ENGINE (see page 13-57).
;!+$<-
WIRE
HARNESS 16. 1&!!-
- Remove the splash shield.
UPPER TRANSMISSION
MDUNHNG BOLTS
SPLASH SHIELD

*# 13-62
5
Removal (cont’d)

-/
?0
17. 1&A!! A

$- Remove the cotter pins, and loosen the castle nuts, then 20. 1&-!!
0- Remove the intermediate shaft. Coat all the
separate the ball joints and lower arms on both sides
!!7!3 precision finished surfaces with clean engine oil
3!
!
(see section 18).
;'<- grease. Tie bags over the shaft end.

-4
&-
INTERMEDIATE
LOWER ARM
CASTLE surf-w
Fireplace.
CUTTER PIN DAMPER
RH place. FDRK
18. 1&#-
'- Remove both the damper forks.
19. 1&&
5- Remove the driveshafts from the intermediate shaft and
differential (see section 16). Coat all the precision
!;<-!! - 1&
-
finished surfaces with clean engine oil grease. Tie bags
3!
!
-4

&&-
over the driveshaft ends.
DRIVE$HAFr
SET RING
Replace.
ENGINE STIFFENER

*#
Removal (cont’d)

-/
?0
13-63
5
22. 1&
!
- Remove both the radius rods mounting bolts from the 24. ,##A
*- Make reference marks on the rear and front beam,
lower arm.
!3- then remove the front beam.
&-
REFERENCE
MARK
REAR BEAM
RADIUS ROD
23. 1&3
!
+- Remove the power steering cooler pipe from the front FRONT BEAM
beam.
-
POWER STEEHlNG
COOLER PIPE
FREINT BEAM
25. %

'/
- Attach the chain hoist to the engine using the 8 x
-! 3-
1.25 mm bolts and nut as shown.
CHAIN HDIST
FRONT BEAM

*#
Removal (cont’d)

-/
?0
1 3-64
5
26. !!7# A
- Place a floorjack under the transmission, and raise the 30. 1&3
#
+0- Remove the two rear engine mount bracket
transmission just enough to take weight off of the
7
#3
mounting bolts.

!-
-
mounts.
HEAR SIDE
27. 1& #
$- Remove the transmission mount bracket and TRANSMISSION REAR ENGINE
transmission mount rubber.
- MOUNTING BOLT MOUNT BRACKET
MOUNTING BOLTS
TRANSMISSION
MOUNT
TRANSMISSION
MOUNT BRACKET
31. 1&

!-
+- Remove the rear side transmission mounting bolt.
32. 1&
!-
+- Remove the front side transmission mounting bolt.
STUD BOLT
FRONT SIDE TRANSMISSION
MOUNTING BOLT
28. 1& !

'- Remove the transmission mount stud bolt on the

-
29. 1&#!#-
5- Remove the intake manifold bracket.
INTAKE MANIFOLD
BRACKET

*# 13-65
53
Removal (cont’d)

-/
?0
33. !!3

!!
++- Pull the transmission away from the engine until it clears
the mainshaft, then lower it on the transmission jack.
A!37#-
Take care not to bend the clutch line.
4#! !-
34. 1&!&!#
+*- Remove the slave cylinder bracket from the
transmission.
-
SLAVE
CYLINDER
BRACKET
35. 1&A!#A!

+- Remove the boot, the release fork, and the release
bearing from the transmission.

-
RELEASE
BEARING
RELEASE
FORK

*# 13-66
55

Index
Refer to the drawing below for the transmission disassembly/reassembly. Clean all the parts thoroughly in solvent, and dry with
13
!3!=!-!!!
!!&A3
compressed air.
-
”7%
&
Lubricate all the parts with oil before reassembly.

!!3!!-
NOTE:
84 9
¢ This transmission uses no gaskets between the major housings; use liquid gasket P/N 08C70-K0234M (see page 13-70)
4
#37
N !F
#=0'$0>0+*,;!+$0<
and (see page 13-113)
;!++<
¢ Always clean the magnet (7) whenever the transmission housing is disassembled.
%!3!
;$<3&
!-
¢ Inspect all the bearings for wear and operation.
!!
3-
Clutch housing
!
8
' Reverse idler gear shaft
1&!
15 #!
Shift fork assembly
AWN—x
Oil seal. Replace

8!!-1! 9
5 Reverse idler gear
1&!
(See page 13-95)
;!+5<
+- 14 x 20 mm Dowel pin
*/0(3! 10
0 Oil seal. Replace
8!!-1! 16 ,!
Mainshaft assembly
* Oil guide plate
8!
! 11
Ball bearing
)!!
(See page 13-74) (See page
;!+$*<;!
13-75)
+$<
5
Needle bearing
!
12
3
Spring washer 17 !
$ Countershaft assembly
Index (See page 13-81) (See
/;!+'<;
page 13-87)
!+'$<
Retaining plate
1
! 13 2
+ Washer 18 (!!
' Differential assembly
N03
$ Magnet
,
14 1&#
* Reverse shift fork Index (See page 13-99)
/;!+55<

*#
57
Index (cont’d)
/
?0
23 !
+ Shift arm assembly 30
+0 Washer. Replace
2-1! 38
+' Drain plug
(!
Index (See page 13-68)

/;!+'< 31
+ Spring L.26 mm (1.02 in)

-;-0< 39
+5 Washer. Replace
2-1!
24 8!
!
* Oil gutter plate 32
+ Steel ball D.5/16 in
!!!(-= 4O
*0 Filler plug
!!!
25 $'
78 mm Shim 33
++ Transmission hangerA
4
% 41
* Washer. replace
2-!
Selection (See page 13-109)
!;!+05< 34
+* 32 mm sealing bolt
+!
! 42
* Transmission hanger B
4
)
26 8!
!
Oil guide plate 35
+ Washer. Replace
2-1! 43
*+ Transmission housing
4
27 2-1!

$ Washer. Replace 36
+ Reverse idler gear shaft bolt
1&!
!
28 )# !
3
' Back-up light switch 37
+$ Oil seal. Replace
8!!-1!
29
3
5 Setting screw
*#
Shift

Index
Arm Assembly
13-68
58
NOTE:
84 9
O The shift arm cover can be removed and installed with the transmission in the vehicle.
4&&!!3&!-
Lubricate all moving and sliding surfaces with the specified grease.
!!&
!
3
-
.Q.
Turn the shift lever boot so the hole is facing down.

4 !&!
3-
Use only HONDA Genuine Urea Grease UM264 (P/N41211-PY5-305).
?!68(%. ?.?,*;=*C+0<-
SELECT LEVER
IPIN 41211— PYE —305}

E 11.11 mm
12 N-ml kyl-
16): 23 I 5 mm
Eltrf-ftl
lIL'IIL SEAL
Replace.
SHIFI' ARM
5H1” MM COVER - Inspection, page 13 96
8 I 1.1} mm
28 Mr“ 12.9 inf-m,
LOCK WASHER
Replace.
_ INTEHLOCK
51H!REVERSE INTERLDCK son (I
SELECT SPRING as III-"'- «.0 Ital-m. 29 mm:
SELECT
RETURN SPRING O'L 55“
Replace.
SELECT ARM f?
5 x 22 mm
,6: SPRING PIN
{PM 41231 — m — 3051 “99'3“-
'fil Bxllmm
11"!” $1211 — PYE - 305} DOWEL PINS
SHIFT LEVER

4

&A
!#!!3
9
(See page 13-96)
;!+5<
*#
Shift Arm Assembly
) *#2*#
13-69
59
NOTE:
84 9 +-
3. 1&&!#-
Remove the reverse lock cam.
¢ During reassembly, grease all sliding parts.
(
!A
!!!
- E 11.0 mm
¢ Use only HONDA Genuine Urea Grease UM264 (P/N
?!68(%. ?.?,*;= 15 N-m [1.5 kgtm. 11 Itl
1.
-
41211-PY5-305).
*C+0<-
Remove the shift arm cover assembly.
1&&!-
/
SHIFI' ARM C(WEFI
Ii a: 1.0 mm ? MEMBW
12 N-m 11.2 ugh-:1, 9 Ibi-hl REVERSE LOCK CAM
/
SHIFT ARM COVER
*-
4. 1&!!-
Remove the oil seal.
H:____/ GIL SEAL
2.
- Remove the spring pin, then remove the select lever,
1&
A&!!&A Replace.
select arm and springs.
!
- fl
SELECT ARM (Fm #1211 - PY5 — 305)
5 x 22 mm
SPRING PIN
Replace}.
SELECT RETURN SPRING
5TH]REVERSE
SELECT SPRING
SHIFT ARM
COVER
SHIFT ARM COVER
SELECT LEVER
Shift
Arm Assembly
*# 13_70
7$
Disassembly/Reassembly (cont’d)
) *#2*#/
?0
5.
- Raise the tab of the lock washer, then remove the bolt.
1!#3A&!- 8.
'- Install the shift arm assembly in the reverse order
!!!&
6.
- Remove the interlock bolt.
1&!#!- of removal.
&!-
NOTE: Apply liquid gasket (P/N 08070-K0234M) to the
84 9%!!F
#;=0'$0>0+*,< NOTE:
84 9
threads before reassembly.
!- o Use liquid gasket (P/N 08C70-KO234M).
?!F
#;=0'$0>0+*,<-
B in: 1.0 mm ¢ Remove the dirty fluid from the sealing surface
1&! !

INTERLDGK BOLT 23 N-m 12.9 kgf-m. ¢ Seal the entire circumference of the bolt holes
! !!
35 Mm 143 t-in, 29 ItI 21 IbI-I‘II to prevent fluid leakage.
&! !#
-
¢ If 20 minutes have passed after applying
0 &!

liquid gasket, reapply it and assemble the
!F
#A!!
housings. Allow it to cure at least 20 minutes

-%!!3 !0
after assembly before filling the transmission
!!!

with fluid.
3! -
LOCK WASHER
__ Replace.
TAB
7.
$- Remove the shift lever, shift arm, and interlock.
1&!&AA!#-
NOTE: Turn the shift lever boot so the hole is facing
84 94 !&!
down.
3-
SHIFT ARM
INTERLDCK
Turn the chamfer

in this direction.
SHIFT LEVER .
SHIFT '-.
OIL SEAL
Replace.
mm “211 _ v - 305:

*#
Disassembly
) *#
13-71
7
NOTE:
84 9 6.
- Remove the 32 mm sealing bolt.
1&+!
!-
¢ If the transmission housing or clutch housing are

!
7.
$- Expand the snap ring on the countershaft ball
/
!!
replaced, the bearing preload must be adjusted.
!A
! 7 - bearing, and remove it from the groove using a

A&
&

¢ Place the clutch housing on two pieces of wood thick
!!
33# pair of snap ring pliers.

!-
enough to keep the mainshaft from hitting the

#
8.
'- Separate the transmission housing from the clutch

!
workbench.
3#- housing, and wipe it clean of the sealant.

A3!!-
1.
- Remove the shift arm cover assembly (see page
1&&!;! $NAP MG PLEHS
13-69).
+5<- DILGC — WI 01 III
SNAP RING
2.
- Remove the reverse idler gear shaft bolt.
1&&!
!- 32 mm
3.
+- Remove the setting screws, then remove the washers,
1&
3A&3A SEALING BOLTH
springs, and steel balls.

A!!!-
STEEL BALLS 0. EMS in
; ‘. ‘7" I l :
SPHIME L 25 mm ".02 in] ,
CLUTCH HflUSING
9.
5- Remove the 78 mm shim and oil guide plate, then
1&$'!
!A
remove the oil gutter plate.
&!
!-
OIL GUTI'EH PLATE
TB mm SHIM
WASHER __ . _ x
' "_': REFINE—H .41; ' | '. '\ I'll 7%?
' I}; REVERSE mLER GEAR l l

SHAFT BOLT
4.
*- Remove the back-up light switch.
1&# !
3-
5.
- Remove the 10 mm bolts and 8 mm bolts in a
1&0!'! on. GUIDE —-———...
criss-cross pattern in several steps.
&!- PLATE
TRANSMISSION fi mfigigs ION

HANGER A “L TRANSMISSiDN
HOUSING \ _.
‘J 't
Li-Tri-fi
kg!
_’ “LY: . 13"";-
-
’..-
- ' : .-" .' III)“. 12/
BACK-UP LIGHT g .,.

SWITCH
r- '4
ti51,641.-
.3”?- I 'I
' ” WASHER
FleplutZIP.

*#
Disassembly (cont’d)
) *#/
?0
13-72
7
0-
10. 1&&#-) !!
Remove the reverse shift fork. Be careful not to loose 12. 1&
- Remove the mainshaft and countershaft
!!!-
the steel ball. assemblies with the shift forks from the clutch
!3#!
REVERSE sun-T FDHK housing.

-
NOTE: Before removing the mainshaft and
84 9)&

counter shaft assemblies, tape the mainshaft
!A
spline to protect it.
!-
MAINSHAFr ASSEMBLV
CDUNTEHSHAFT
ASSEMBLY
@"fi
“In
l
I STEEL BALL
in. EMS inl
[WI/l,” ;
11. 1&&!
&
- Remove the reverse idler gear shaft and the reverse
idler gear.
!
- '41!.l'
REVERSE IJLEFI 65 Ta pa Iha main- WhSHER

GEAR shaft splines.
‘ ' SPHERE WASHER
REVERSE IDLER
GEAR SHAFT
GLUl'Gl-l
w a;
~. _._J"
2") ‘--. L“
.5“ " r"
,2
_ l
HOUSING
13. 1&!!-
+- Remove the differential assembly.
DIFFERENTIAL ABSEMBL'I'
- +
6
Reverse Shift Fork

13-73
7
1.
- Measure the clearances between the reverse shift fork
, !3&# 3.
+- Measure the clearance between the reverse idler
, !3&!
and 5th/reverse shift piece pin.
=&- gear and reverse shift fork.

&#-
0 If the clearances are more than the service limit, go
!&!A
If the clearance is more than the service limit, go to
!&!A

to step 2.
- step 4.
*-
0 If the clearances are within the service limit, go to
!3&!A
Standard:
F 0.5-1.1 mm (0.02-0.04 in)
$@3@/$@$$@$ 0
step 3.
+- Service Limit: @8/$@$7 0
- & F 1.8 mm (0.07 in)
Standard:
F A: 0.05-0.35 mm (0.002-0.014 in)
F$@$3$@3/$@$$$@$ 0 REVEREE Sl-lllz'l' IFOBK
B: 0.4-0.8 mm (0.02-0.03 in)
"F$@$@8/$@$$@$ 0
REVERSE IDLEH
Service Limit: F$@3/$@$ 0
- & F A: 0.5 mm (0.02 in) GEAR
B:1.0 mm (0.04 in)
"F@$/$@$ 0
N I (ETHIREVERSE SHIFT
REVERSE SHIFT 'Fonx'PIFCE SIN Lfi I
* - 1.4-“ I -
. 'I .
4.
*- Measure the width of the reverse shift fork.
, 3&#-
0 If the width is not within the standard, replace
33A!
the reverse shift fork with a new one.
&#33-
0 If the width is within the standard, replace the
33A!
reverse idler gear with a new one.
&!
33-
Standard:
F 13.0-13.3 mm (0.51-0.52 in)
@$@/$@3$@3 0
- Measure the widths of the groove in the reverse shift
, 3
&&
fork.
#- REVERSE SHIFI' FORK
0 If the widths of the grooves are not within the
3
&3
standard, replace the reverse shift fork with a new
A!&#33
one.
-
0 If the widths of the grooves are within the standard,
3
&3A
replace the 5th/reverse shift piece with a new one.
!=&33-
Standard:
F A: 7.05-7.25 mm (0278-0285 in)
F7@$37@3/$@78$@83 0
B: 7.4-7.7 mm (0.29-0.30 in)
"F7@7@7/$@9$@$ 0
REVERSE SHIFT FORK
Mainshaft
Assembl
*# 13-74
7

Index
NOTE: The 3rd/4th and 5th synchro hubs, and the ball bearing are installed with a press.
84 94+=* A!!
!!3-
”7%
&
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the
!
A!!!!&AA!! !! /
3rd/4th and 5th synchro hubs.
+=* -
U2J4, U265 Transmissions:
;<:;3
F
BALL BEARING
Check for wear and operation.
SYNCHRD RING
Inspectionr page 13-93
TAPEFIED CONE RING
3RDHTH STNCHRO SLE EVE

Inspection. page 13-95, 97"
3RDMTH SYHCHRO HUB

SYNCHRO RING
Inspection, page 1333
SYNCHRO SPRING
SYNCHRO
5TH SYNCHRO HUB
spams
Inspection, page 13-93r
SYNCHHO 5TH SYNCHRO SLEEVE

RING Inspection, page 13-96, 9?
Inspection.
page 13—93 SYNCHRO SPRING
SYNCHHO RING
3RD GEAR
Inspection.
page 13-?5. SH
5TH GEAR
38 x 43 x 25 mm Inspection, page “Ia—T1 QB
NEEDLE BEARING
Check for INear and operation.
SPACER COLLAR
Inspection, page 13-?6. 3'?
38 It l3 x 26 mm
NEEDLE BEARING
ATH GEAR
Inspection, page 13-?1 53
'-" MAINSHAFT
In] Inspection, page 13-?5

4

&A
!#!!3
9
(See page 13-98)
;!+5'<
(See page 13-96)
;!+5<
(See page 13-97)
;!+5$<
(See page 13-76)
;!+$<
(See page 13-79)
;!+$5<
(See page 13-77)
;!+$$<
Mainshaft
Assembly
*# 13-75
73
Index (cont’d)
/
?0
U2Q7 Transmission:
;=7
F
SYNEHRD RING BALL BEARING
IITSIJHE'HDI'I- Page 13 93 / Check for wear and operation.
SYNCHHO STOPPER RING

SPRING
TAPERED RING
3HDMTH SYNCHHO HUB
Inspeclion. page 13-97
37 x 42 It 15 mm
NEEDLE BEARING
SBDMTH SVNCHRO SLE EVE _
Inspection, page 13-95. 9?
SPACER COLLAR
SYNCHHO
SPRING smcnno RING
SYNCHRO Inspection. page 13-98
RING
SYNCHRO SPRING
Inspection,
page 13—98
5TH SYNCHRO HUB
Ins action, a 313 9?
380 GEAR p p 9
Inspection.
page 13% 95 am svncneo SLEEVE
Inspection, page 13—96. 91"
38 x 1-3 x 25 mm
SYNCHRD RING
NEEDLE BEARING
Inspection, page 13—98
Check for wear
and operation.
" 1““e GEAR
Ins ection, a e13—??,EIIB
MAINSHAFI' p p 9
SPACER COLLAR
lnspection,page13-?5.?T
38 x 43 x 26 mm
NEEDLE BEARING 4TH GEAR
Inspection, page til-T}, 98

4

&A
!#!!3
9
See page 13-98)
;!+5'<
AAAAAA
See page 13-96)

;!+5<
See page 13-97)
;!+5$<
See page 13-76)
;!+$<
See page 13-79)
;!+$5<
See page 13-77)
;!+$$<
*#
Mainshaft Assembly

13-76
75
84 9!F A!3! 4.
*- Measure the clearance between 4th gear and the
, !3*

!& - spacer collar with a dial indicator.
!!3!-
1.
- Support the bearing inner race with a socket, and push

3#A If the clearance is more than the service limit, go to
!&!A

down on the mainshaft.
3- step 5.
-
2.
- Measure the clearance between 2nd and 3rd gears with
, !3+
3 Standard:
F 0.06-0.21 mm (0.002-0.008 in)
$@$5$@/$@$$$@$$8 0
a feeler gauge.
!

- Service Limit: $@$/$@$ 0
- & F 0.30 mm (0.012 in)
0 If the clearance is more than the service limit, go to
!&!A
PRESS
step 3.
I
+-
0 If the clearance is within the service limit, go to step
!3&!A

4
*- m/ MAIHSHAFr
Standard:
F 0.06-0.21 mm (0.002-0.008 in)
$@$5$@/$@$$$@$$8 0
Service Limit: $@//$@$ 0
- & F 0.3(mm (0.012 in) 4TH GEAR
PRESS
DIAL
iHDICATOFI
5.
- Measure distance (1) on the spacer collar.
, ;<!!-
¢ If distance (1) is less than the service limit,
;<!&!A
replace the spacer collar with a new one.
!!!33-
¢ If distance (1) is within the service limit, go to
;<3&!A

step 6.
-
3RD GEAR Standard:
F 26.03-26.08 mm (1.025-1.027 in)
5@$5@$8/@$3@$7 0
3.
+- Measure the thickness of 3rd gear.
, #+
- Service Limit: 5@$/@$ 0
- & F 26.01 mm (1.024 in)
0 If the thickness of 3rd gear is less than the service
#+
!&
limit, replace 3rd gear with a new one.
!A!+
33- 4TH GEAR
0 If the thickness of 3rd gear is within the service
#+
3& 37' L{TEA *- SIDE
!A!+=* 33
Transmission Type
44 U2Q7
?D$ U2J4, U2G5
?"*A?. SPACER COLLAR
Standard
34.92-34.97 mm +-*+-*$
+*-5+*-5$ 32.42-32.47 mm
(1 .375-1.377 in)
;-+$-+$$< (1276-1278 in)
;-$-$'<
&
Service Limit 34.8 mm
+*-' 32.3 mm
+-+
(1.37 in)
;-+$< 1.27 in)
-$<
3RD GEAR
*#
Mainshaft Assembly

/
?0
13-77
77
6.
- Measure the thickness of 4th gear.
, #*
- 8.
'- Measure distance (2) on the spacer collar.
, ;<!!-
0 If the thickness of 4th gear is less than the service
#*
!& ¢ If distance (2) is less than the service limit,
;<!&!A
limit, replace 4th gear with a new one.
!A!*
33- replace the spacer collar with a new one.
!!!33-
0 If the thickness of 4th gear is within the service
#*
3& ¢ If distance (2) is within the service limit, go to
;<3&!A

!A!+=* 33 step 9.
5-
one.
- Standard:
F 26.03-26.08 mm (1.025-1.027 in)
5@$5@$8/@$3@$7 0
Transmission Type
44 U2Q7
?D$ U2J4, U2G5
?"*A?. Service Limit: 5@$/@$ 0
- & F 26.01 mm (1.024 in)
Standard
31 .42-31 .47 mm +0-5+0-5$
+-*+-*$ 30.92-30.97 mm
(1 237-1234 in)
;-+$-+*< (1217-1219 in)
;-$-5< _,_-
I,» SPACER
A" COLLAR
&
Service Limit 31.3 mm
+-+ 30.8 mm
+0-'
(1.23 in)
;-+< 1.21 in)
-< L 1.-
__ 4TH GEAR
{lo/I 5TH BEAR ' 1 2'
! “A SIDE
9.
5- Measure the thickness of 5th gear.
, #
-
¢ If the thickness of 5th gear is less than the
#
!
7
$ Measure the clearance between 5th gear and the spacer
, !3
service limit, replace 5th gear with a new one.
&!A!
33-
collar with a dial indicator.
!!3!- ¢ If the thickness of 5th gear is within the
#
3
If the clearance is more than the service limit, go to step
!&!A
service limit, replace the 5th gear synchro hub
&!A!

8.
'- with a new one.
33-
Standard:
F 30.92-30.97 mm (1217-1219 in)
$@9$@97/@7@9 0
EH ___ EX
Standard:
F 0.06-0.21 mm (0.002-0.008 in)
$@$5$@/$@$$$@$$8 0
Service Limit: $@$/$@ 0
- & F 0.30 mm (0.12 in) Service Limit: $@8/@ 0
- & F 30.8 mm (1.21 in)
PRESS 5TH GEAR
L
MAINSHAFI’ |
SPACER COLLAR
a ( : 1 3
/
DIAL
INDICATOR
. “gig/\t/ 5TH GEAR
SOCKET
*#
Mainshaft Assembl
78
Disassembly
) *#
A CAUTION
- Remove the spacer collar, tapered ring, and
1&!!A
A
synchro ring.

-
Remove the synchro hubs using a press and steel blocks as
1&
!!# 3.
+- Support 5th gear on steel blocks, and press the

!!#A
shown. Use of a jaw-type puller can cause damage to the
3-?73 !!
mainshaft out of the 5th synchro hub, as shown.
A3-
gear teeth.
-
1.
- Remove the ball bearing and tapered cone ring or
1&!!

PRESS
stopper ring using a bearing puller as shown.

!!3-
ATTACHMENT
5TH SYNCHRO HUB
' _ — BEARING FULLER ’/ 5m GEAR
2"- EH ‘ZflfiiCommamally
available}
BALL BEARING
STEEL $52.
BLOCKS
*- In the same manner as above, support the 3rd

&A +
gear on steel blocks, and press the mainshaft out

!!#A
of the 3rd/4th synchro hub, as shown.
+=* A3-
'-

;<:;3
F
BALL
BEARING
TAPEHED
CONE
SPACER COLLAR
L '
3 15:4; .1: ML ,-..L.
l.—.-.-.-r-
——. I,
.
smcnno RING
MAINSHAFT ———--
U2Q7 Transmission:
;=7
F
STOPPER SPACER CELLAR

RING
TAPEHED
E ‘sv mcnno RING
F
RING
MAINSHAFT
Mainshaft
Assembly
*# 13-79
79
Inspection

1.
- Inspect the gear surface and bearing surface for wear

3 - Inspect the runout by supporting both ends of the

and damage, then measure the mainshaft at points A, B,

A %A)A mainshaft. Rotate the mainshaft two complete
-13!
and C.
- revolutions when measuring the runout.
&! 3
-
If any part of the mainshaft is less than the service limit,
!&!A If the runout is more than the service limit, replace
&!A!
replace it with a new one.
!33- the mainshaft with a new one.
33-
Standard:
F Standard:
F 0.02 mm (0.001 in) max.
$@$/$@$$ 0@
A (Ball bearing surface):
/"* ! 0F 27.987-28.000 mm
7@9878@$$$ Service Limit: $@$3/$@$$ 0
- & F 0.05 mm (0.002 in)
(1.1018-1.1024 in)
/@$8@$ 0
B (Needle bearing surface): 7@988@$$$
"/,* ! 0F 37.984-38.000 mm
(1.4954-1.4961 in)
/@93@95 0
C (Ball bearing surface):
/"* ! 0F 27.977-27.990 mm
7@9777@99$
(1.1015-1.1020 in)
/@$3@$$ 0
Service Limit: F7@9/@$$ 0
- & F A: 27.94 mm (1.100 in)
B: 37.93 mm (1.493 in)
"F7@9/@9 0
C: 27.93 mm (1.100 in)
F7@9/@$$ 0
A inspect for wear

and damage.
n |
. I. {I},
Inspect for wear
and damage. -
Inspect oil passages for clogging.

*#
Mainshaft
Reassembly
*#
Assembl
13-80
8$
A CAUTION
2.
- Install the 5th synchro hub using the special and a
!!
!
press as shown.
3-
When installing the 3rd/4th and 5th synchro hubs support the
2!!
+=*
DRIVER. 40 mm ID. *./ PRESS
shaft on steel blocks, and install the synchro hubs using a
!!#A!!
0??“ - 0030100 li-I
press.
-
NOTE: For
84 9 reassembly sequence (see page 13-74) and (see
!F ;!+$*<;
page 13-75).
!+$<-
ATTACHMENT-r I
1.
- Support 2nd gear on steel blocks as shown, then install

!!#3A!! 35 mm I.D. .
the 3rd/4th synchro hub using the special tools and a
+=*
!! 01115 — 0030400
press as shown.
3-
NOTE: After installing, inspect the operation of the 3rd/4th
84 9%!!
A+=*
synchro hub set.
- " . r 5111 smcuno ma
;<:;3
F
PRES-‘3
AWACHM ENT. DRIVER. 40 mm LU.
35 mm LD. 01716 — 0030100
mus — 0030400
3.
+- Install the ball bearing with the thin-edge outer race
!!!!
3

facing down. Use the special tools and a press as

3-?!!
*5?“- ‘/ 3RDMTH shown.
3-
" -K S‘I'NCHRD HUB
HANDLE DRIVER
0??!5 — 0010000
U2Q7 Transmission:
;=7
F
DRIVER. 40 mm LEI.
““555 urns - mama DRIVER BALL BEARING
30.13““!
SYHCHHO HUB ATTACHMENT.
‘2 x 4'! mm
0??“ - 0010300
AWACHMENT.
35 mm ID.
07'145 - 0000400
2ND GEAR
Countershaft

Assemblv - U2J4. U265
*#;<:;3 13-81
8

Transmissions

Index
7%
&
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
!
A!!!!&AA!! -
.2”, LOEKNUT HBUIEICE
fax, -_.-:_-_-- 127* 0* 127 Nm
REVERSE GEAR / 13—- n —- 1a kgtmi
. Inggcctiofi' page 13.93.51;- (H 34-! 0"“ EMILIf-I't _.
1swznn amen-mo Hus RE _ J/ 1" a.

_
I1spection,
//
/— KR
page 13 El? >\ ,4' BALL BEARING
G 'i Check forwua' and operation
( L5 " ,l‘x‘ 25 x 56.4 x 19 I11“?

FRICTION DAMFEH
{t—FW, £5" ,3 NEEDLI: BtAHIl'nllzi
Check lor wear and calt'lags.'\ "heck f0" WEE“ 3”:
operaticn.
m
.4 b? NLHHU SPRING // a 5TH GEAR
f/ I: x,
_.p SYNCHRO RING (\ :39 J IlTH GFAR
n5 D ectinn, I ta u p. 11PM] \V /
‘N. ‘-..,
'ISI BLAH
Insgccticrn, page 13-82, 98
40 A 46 I 25.3 mm 2?": GEAR

NEEDLE BEILRING Inspection pagc ‘3 83. 93
Deck forwear and :upM-jtian.
42 x :17 x 24 mm
\
x 'I'H RU ST WASHER NEEDLE BEARING
inS'JectiDn, rag
.- e 13—8.!' If, __ \ Chczl: for wear and (animation.
f, \ '1" SPACER
( 6]
‘l
4 Selectionpnga 13-92
“a CDUNTEFISHAFI " 'fig“FRBTION DAMPER

|ns30ctiompagy 13—85\\
"" ‘l Checkforwearmd damage.
J,
DOUBLE EDIE
SVNGHHO
Ins-pertinn, nag-11R FIR

4

&A
!#!!3
9
(See page 13-98)
;!+5'<
(See page 13-96)
;!+5<
(See page 13-97)
;!+5$<
(See page 13-82)
;!+'<
(See page 13-85)
;!+'<
(See page 13-83)
;!+'+<
Countershaft

Assembly - U2J4, UZG5
*#;<:;3
Transmissions

13-82
8

NOTE: If replacement us required, always replace the

84 9! F A!3! 3.
+- Measure the thickness of the 1st gear.
, #
-
synchro sleeve and hub as a set.
!& - ¢ If the thickness of 1st gear is less than the
#
!
1.
- Measure the clearance between the 1st gear and the
, !3
standard, replace tst gear with a new one.
A!
33-
thrust washer with a feeler gauge.
33!

- ¢ If the thickness of 1st gear is within the
#
3
!&!A
standard replace tst/2nd synchro hub with a
!= 3
2.
- new one.
3-
Standard:
F 0.06-0.23 mm (0.002-0.009 in)
$@$5$@/$@$$$@$$9 0 Standard:
F 32.95-33.00 mm (1297-1299 in)
@93@$$/@97@99 0
- & F 0.23 mm (0.009 in)
‘IST GEAR
THHUET WASHER
2.
- Measure the thickness of the thrust washer.
, # 3-
0 If the thickness is less than the standard, replace
#!A!
the thrust washer with a new one.
333-
0 If the thickness is within the standard, go to step 3.
#3A
+-
Standard:
F 1.95-1.97 mm (0.077-0.078 in)
@93@97/$@$77$@$78 0

*#;<:;3
Countershaft
Transmissions

Assemblv - U2J4, U265
13-83
8

/
?0
4.
*- Measure the clearance between the 2nd gear and 3rd
, !3
+ 6.
- Measure the thickness of the 2nd gear.
, #
-
gear with a feeler gauge.

3!

- 0 If the thickness of 2nd gear is less than the
#
!
!&!A
standard, replace 2nd gear with a new one.
A!
33-
5.
- 0 If the thickness of lst gear is within the
#
3
Standard:
F 0.10-0.15 mm (0.004-0.006 in)
$@$$@3/$@$$$@$$5 0 standard, replace 1st/2nd synchro hub with a
A!= 3
- & F 0.18 mm (0.007 in) new one.
3-
Standard: 28.94-28.97 mm (1.1394-1.141 in)
F8@98@97/@9@ 0
3RD GEAR
2ND GEAR
SPACER
5.
- Measure the thickness of the spacer.
, #-
#!A!
the spacer with a new one.
33-
#3A
-
Standard:
F 29.07-29.09 mm (1.144-1.145 in)
9@$79@$9/@@3 0
_ . 53352.
33. _
’+
Countershaft

Assembly - U2J4, U265
*#;<:;3 13-84
8
Transmissions

Disassembly
) *#
A CAUTION
4.
*- Remove the friction damper from the spacer using
1&
a press and a socket as shown.

#3-
Remove the gears using a press and steel blocks as shown.
1&

!!#3- PRESS
Use of a jaw-type puller can damage the gear teeth.
?73 !!

- ‘
1.
!! !
&33!#-
2.
- Raise the locknut tab from the groove in the
1!#
&
A&!#
washer.
3-
LOCKNUT
Replace.
SPRING WASHER
BENCH
VISE
w
FRICTlOH DAMPER
Inspect for wear and damage.
WOOD BLOCKS
3.
+- Remove the ball bearing using a press as shown.
1&!!

3-
PRESS
BALL BEARING
5TH GEAR
STEEL "'--‘.___
BLOCKS

*#;<:;3
Countershaft
Transmissions

Assembly - U2J4, U2G5
13-85
83 Reassembly
*#
Inspection


3 NOTE: For
84 9 reassembly sequence (See page 13-81).
!F ;!+'<-

A %A 1.
- Install the thrust shim, needle bearing, tst gear,
!! A!
A
A
B, and C.
)A- friction damper, synchro ring, and synchro spring.
A
A
-
If any part of the countershaft is less than the service
!& NOTE: Reassemble the 1st gear and friction
84 91!

limit, replace it with a new one.
!A!33- damper before installation.
!!-
Standard:
F A: 8@$$$8@$3
F 38.000-38.015 mm
"_,',+-- -— SYNCHRO SPRING
(1.4961-1.4967 in)
/@95@957 0
B: 9@98$@$$$
"F 39.984-40.000 mm 4—-— SVNCHRO RING
(1.5742-1.5748 in)
/@37@378 0
F: @9873@$$$
24.987-25.000 mm
0
(0.9837-0.9843 in)
/$@987$@98 0
Service Limit: F
- & F A: 7@93/@9 0
37.95 mm (1.494 in)
B: 9@9/@37 0
"F 39.93 mm (1.572 in)
C: @9/$98 0
F 24.94 mm (0 982 in)
Inspect for wear and darn-age.

-
If the runout exceeds the service limit, replace the
/&!A!
countershaft with a new one.
33-
Standard:
F 0.02 mm (0.001 in) max.
$@$/$@$$ 0@
- & F 0.05 mm (0.002 in) 2.
- Install the 1st/2nd synchro hub by aligning the
!!= !

NOTE: Support the countershaft at both ends as shown.
84 9 3- friction damper fingers with 1st/2nd synchro hub

3=
Rotate two complete revolutions.
13!&! -
&-
grooves.
15TI2ND
SYNCHHO HUB
.hll l l . .
FRICTION
DAMPER

*#;<:;3
Countershaft
Transmissions

Assemblv- U2J4, U2G5
13-86
85
*#/
?0
3.
+- Install the friction damper on the spacer using the
!!
5.
- Install the needle bearing and the ball bearing
!!!
!!
special tools and a press as shown.

!!3- using the special tool and a press as shown;

!!3N
PRESS PRESS
I-1rn
[Alum
HANDLE DRIVER
01149 - 0010000 OIL SEAL DRIVER
DRIVER
‘ / 01941 - 689-0100
ll
ATTACHMENT.
42 x 4? mm
07746 - 0010300
SPACER
FRICTION DAM?EH H BALL BEARING

. If! Inspect for wear and
9'-"-"- .- -.-'.- '--' - -' - -."." darn-390.
4.
*- Install the 2nd gear by aligning the synchro cone fingers
!!
!

" :\ NEEDLE HEARING
with 2nd gear grooves.
3

&-
2ND GEAR 6.
- Securely clamp the countershaft assembly in a
!! !
bench vice with wood blocks.
&33!#-
7.
$- Install the spring washer.
!!
3-
8.
'- Tighten the new locknut to the specified-value,
4
3!# &! A
then stake the locknut tab into the groove.
#!#
&-
Tr.:r.::,|.na~:12'll -r (I 4127 Mm [13 —" 0 *13 kgf-I‘n.
94 o -* 94 [bf-m
-
LUCK NUT
Replace.
SPRING
WASHER
WOOD BLOCKS
Countershaft

Assembly - U207
*#;=7 13-87
87

Transmission

Index
NOTE: The 4th and 5th gears are installed with a press.
84 94*
!!3-
&
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4th and
E !
A!!!!&A!! -4*
5th gears, however, should be installed with a press before lubricating them.

A3&A !!!3!
-
LOCKNUT Replace.
12? -F D #12? N|m
REVERSE GEAR I13 —. o —. 13 “91.,“
Inspection, page 13-35, 93' I 94 _. o _. 94 “31.11;
BALL BEARING
15173.43 SYNCHHD HUB Check for waar and nnnratiur
25 It 55 x 4 mm
NEEDLE BEARING
Check forwear and
-.'r\ {)[JHIHTIDI‘L
_ y*-—-—-— FRICTION DAMPER

"' Check lnr wear and damage.
I,” — 5TH GEAR
{H smcn no SPRING
- 4TH GEAR
DOUBLE CONE
SYNCHRO
Inspection. page 13-93 f_.- 3RD GEAR
, 15T GEAR ' -'i .

Ins action, a F! 13—88, 98 J- 2ND GEAR
p p g " . J 4ILA/Inspection, page 13-89. 95
Wkflbi‘fig w x #6 x 22 mm w; .
we”
’,42x 47 x 2‘ mm
tum ,
Eran—7 NEEDLE BEARlNG “1c
._ tau,
——-""' NEEDLE BEARING
id Eff? Check for were" and upurullun. fL--_-Jlfl“: Chuck lor wear and nperalinr
4' ' ., "“1 2‘: Vii—J Selection, page 13-39

__ ____\" RTHRUST WASHER
.' lint—— FRICTION DAMPER
'- ‘1 inspectinn, page 13-83 Check for wear and damage.
DOUBLE CONE
'S‘I'NCHRO
3 .._—-—-90UNTEHEHAFr ' --_.— ._ w; 4.

“Spam“ Page 13'9” 1i \HEX-fa;
,. SYNCHRD SPRING
//

4

&A
!#!!3
9
(See page 13-98)
;!+5'<
(See page 13-96)
;!+5<
(See page 13-97)
;!+5$<
(See page 13-88)
;!+''<
(See page 13-91)
;!+5<
(See page 13-89)
;!+'5<

*#;=7
Countershaft
Transmission

Assembly - U207
13-88
88


84 9!F A!3! 3.
+- Measure the thickness of the 1st gear.
, #
-
!& - ¢ If the thickness of 1st gear is less than the
#
!
1.
- Measure the clearance between the 1st gear and the
, !3
standard, replace 1st gear with a new one.
A!
33-
thrust washer with a feeler gauge.
33!

#
3
!&!A
standard replace ist/2nd synchro hub with a
!= 3
2.
- new one.
3-
Standard:
F 0.06-0.18 mm (0.002-0.007 in)
$@$5$@8/$@$$$@$$7 0 Standard:
F 26.95-27.00 mm (1.061-1.063)
5@937@$$/@$5@$50
- & F 0.23 mm (0.009 in)
THHUST WASH EH
U FEELEH
GAUGE
2.
- Measure the thickness of the thrust washer.
, # 3-
#!A!
the thrust washer with a new one.
333-
#3A
+-
Standard:
F 1.95-1.97 mm (0.077-0.078 in)
@93@97/$@$77$@$78 0
9/
Countershaft

Assembly - U207
*#;=7 13-89
89
Transmission


/
?0
4.
*- Measure the clearance between the 2nd gear and 3rd
, !3
+ 6.
- Measure the thickness of the 2nd gear.
, #
-
gear with a feeler gauge.

3!

- ¢ If the thickness of 2nd gear is less than the
#
!
!&!A
standard, replace 2nd gear with a new one.
A!
33-
5.
#
3
Standard:
F 0.10-0.15 mm (0.004-0.006 in)
$@$$@3/$@$$$@$$5 0 standard, replace 1st/2nd synchro hub with a
A!= 3
0.18 mm (0.007 in)
- & F new one.
3-
33:, GEAR Standard: 8@98@97/@9@$3 0
F 28.94-28.97 mm (1.1394-1.1405 in)
SPACER
5.
- Measure the thickness of the spacer.
, #-
#!A!
the spacer with a new one.
33-
#3A
-
Standard:
F 29.07-29.09 mm (1.144-1.145 in)
9@$79@$9/@@3 0
Countershaft

Assembly - U207
*#;=7 13-90
9$
Transmission

Disassembly
) *#
A CAUTION 4.
*- Support 1st gear on steel blocks, and press the

!!#A
countershaft out of 3rd gear.
+
-
Remove the gears using a press and the steel blocks as
1&

!!# was
shown. Use of a jaw-type puller can cause damage to the
3-?73 !!
',
gear teeth.
- L...l

1.
!! ! -'
&33!#-
2.
- Raise the locknut tab from the groove in the
1!#
&
A&!#
3RDGEAH
washer.
3-
1STGEAH
5.
- Remove the needle bearing and thrust washer
1&!
3
from the countershaft.
-
WflODBLDCKS
3.
+- Support 4th gear on steel blocks, and press the
*
!!#A
countershaft out of ball bearing, needle bearing, 5th
!!
A!
A
gear, and 4th gear.

A*
-
PRESS
4THGEAH

*#;=7
Countershaft

Transmission
Assembly - U207
13-91
9
Inspection

1.

3 - Inspect for runout.
-

A %A If the runout exceeds the service limit, replace the
/&!A!
B, and C.
)A- countershaft with a new one.
33-
If any part of the countershaft is less than the service
!& Standard:
F 0.02 mm (0.001 in) max.
$@$/$@$$ 0@
limit, replace it wit h a new one.
!A!33- Service Limit: $@$3/$@$$ 0
- & F 0.05 mm (0.002 in)
Standard:
F A. 8@$$$8@$3
F 38.000-38.015 mm NOTE: Support the countershaft at both ends as
84 9
(1.4961-1.4967 in)
/@95@957 0 shown.
3-
B: 9@98$@$$$
"F 39.984-40.000 mm Ftutala two complete revolutions.
(1.5742-1.5748 in)
/@37@378 0
F: @9873@$$$
24.987-25.000 mm
0
(0.9837-0.9843 in)
/$@987$@98 0
Service Limit: F: 7@93/@9 0
- & F 37.95 mm (1.494 in)
"F: 9@9/@37 0
39.93 mm (1.572 in)
F: @9/$@98 0
24.94 mm (0.982 in)
'2

*#;=7
Countershaft

Transmission
Assembly- U207
13-92
9
Reassembly
*#
A CAUTION
2.
- Install the double cone synchro and synchro spring
!! !
as shown.
3-
0 Press 3rd and 4th gears on the countershaft without
+*
3
lubrication.
! - "'--r:::;--...-~H SYNCHHD
SPRING
0 When installing 3rd and 4th gears, support the shaft on
2!!
+*
A
steel blocks, and install the gears using a press.
!!#A!!

-
NOTE: For
84 9 reassembly sequence (See page 13-87).
!F ;!+'$<-
1.
- Install the thrust washer, needle bearing, 1st gear, and
!! 3A!
A
A {ti-:0; ALI qJ-i
friction damper on the countershaft.
- " '. DOUBLE
CON E
SYNCHHG
TION DAMPER
€535? FRIC
l.
3.
+- Install-the 1st/2nd synchro hub as shown.
!!= 3-
15TI2ND
SYNCHHO HUB
#— COUNTEHSHAFT
DAMPER

*#;=7
Countershaft
Transmission

Assembly - U2Q7
13-93
9
*#/
?0
4.
*- Install the reverse gear, synchro spring, and double
!!&
A
A ! 6.
- Install the distance collar and needle bearing.
!!!!!!
-
cone synchro as shown.
3- 7.
$- Install the 2nd gear by aligning the synchro cone
!!
!

fingers with 2nd gear grooves.

3

&-
2ND lGEAR
DOUBLE CONE
SYNCH RD
SVHCHRO
/ SPRING
-. REVERSE
.M GEAR
FINGER
“flag;
-
5' InSta” the tion press
fricand on the spacer using the
!!

damper
!!3- 8.
'- Support the countershaft on a steel block, and
!!#A
PRESS install 3rd gear using the special tools and a press,
!!+

!!A
3-
as shown.
PRESS
HANDLE DRIVER
0'7?“ - 0010000 DRIVER
i
[.5 _.
ATTACHMENT,
42 x 4? mm
07748 - 0010300
DRIVER, 40 mm 1.0.
0??“ -— 0030100
SPACER ll
3RD GEAR
cnom DAMPER
_ . /|nswm forwearand
”JV—fir? dame.“
Countershaft

Assembly - U207
*#;=7 13-94
9
Transmission

*#/
?0
9.
5- Support the countershaft on a steel block, and install 4th
!!#A!!* 13. !!#A
+- Support the countershaft on a steel block, and
gear using the special tools and a press, as shown.

!!A3- install ball bearing using the special tools and a
!!!!

!!
press, as shown.
A3-
PRESS
PRESS
DRIVER, 40 mm H). _- :—_'i -,

mus-0030100 \{ '
DRIVER. 40 mm H].
OTT-ui - 0030100 \
I BALL BEARING
ATTACHMENT, 30 mm ID. \i. - / "H BEA"
01140 - 0030300 £1,315; ATTACHMENT. 25 mm ID.
UTHG - 0030200
10. !!

-
0- Install the 5th gear.
11. !!#A!!
- Support the countershaft on a steel block, and install
needle bearing using the special tools and a press, as
!

!!A
14. !! !
*- Securely clamp the countershaft assembly in a
shown.
3-
PRESS
bench vice with wood blocks.
&33!#-
i 15. !!
3-
- Install the spring washer.
16. 4
3!# &!
- Tighten the new locknut to the specified value then
I J stake the locknut tab into the groove.
#!#
&-
.fl' '-
Torque:

BF 127 to 0 to 127 Nm
7
$
7,
aan. 40 mm ID. I
Irma - 0030100 \ | (13 to 0 to 13 kgf/m,
/
$
6! 2:
|
94 to 0 to 94 lbf/ft)
9
$
9* 2 0
AWACHMENT. 25 mm ID. : '1, NEEDLE HEARING LDGKNUT
07140 - 0030200 \yW Replace.
BENCH 1lal'ISE
12. !!!

-
- Install the needle bearing outer race.
WDDD BLOCKS
Shift
Fork Assembl
+
6*# 13_95
93
) *#2*#
7%
&
!
A!!!!&AA!! -
PIN DRIVER 5.0 mm

MEAD - P6201011]
f/
5TH SHIFT FORK - —"'
3HDHTH SHIFT FORK

O
ETHIREVEHSE f4"
SHIFT PIECE
15mm: SHIFT FORK
5 I: 22 mm
SPRING PIN
Replace.
+
6*#
Shift Fork Assembly
Clearance/Inspection
2

13-96
95
NOTE: The synchro sleeve and synchro hub should be
84 94!& ! 3.
+- Measure the clearance between the shift fork and
, !3#
replaced as a set.
!- the shift arm.
-
1. , !3#
- Measure the clearance between each shift fork and its If the clearance exceeds the service limit, go to
!/&!A

matching synchro sleeve.

!&- step 4
*
If the clearance exceeds the service limit, go to step 2.
!/&!A
- Standard:
F 0.2 - 0.5 mm (0.008-0.020 in)
$@$@3/$@$$8$@$$ 0
Standard:
F 0.35-0.65 mm (0.014-0.026 in)
$@3$@53/$@$$@$5 0 Service Limit: $@5/$@$ 0
- & F 0.6 mm (0.024 in)
Service Limit: @$$/$@$9 0
- & F 1.00 mm (0.039 in) ETHIREVEHSE I 1STJ'2HID
SVNCHHCI SLEEVE SHIFT PIECE SHIFT FDRK
3HDHTH
SHIFT FORK
5HlFf ARM
SHIFI' FORK 4.
*- Measure the width of the shift arm.
, 3-
2.
- Measure the thickness of the shift fork fingers.
, ##
- ¢ If the width of the shift arm is less than the
3!
0 If the thickness of the shift fork finger is less than
##
! standard, replace the shift arm with a new one.
A!33-
the standard, replace the shift fork with a new one.
A!#33- ¢ If the width of the shift arm is within the
33
0 If the thickness of the shift fork finger is within the
##
3 standard, replace the shift fork or shift piece
A!#
standard, replace the synchro sleeve with a new
A!!&33 with a new ones.
33-
one.
- Standard:
F 12.9-13.0 mm (0.508-0.512 in)
@9@$/$@3$8$@3 0
Standard:
F SHIFT ARM
3rd/4th shift fork
+=*# $-*$-
7.4-7.6 mm
(0.29-0.30 in)
;0-50-+0<
lst/2nd shift fork
=# 6.2-6.4 mm
--*
#
5th shift fork (0.24-0.25 in)
;0-*0-<
SHIFI' FORK
#
-:#
Synchro
.*
Sleeve, Synchro Hub
97
1 3-97 Installation

Inspection

1.
- Inspect gear teeth on all synchro hubs and synchro

!! When assembling the synchro sleeve and synchro hub,
2!
!& A
sleeves for rounded off corners, which indicate wear.
!& A33- be sure to match the three sets of longer teeth (120
!
;0
2.
- Install each synchro hub in its mating synchro sleeve,
!!
!&A degrees apart) on the synchro sleeve with the three

<!&3
and check for freedom of movement.
#&- sets of deeper grooves in the synchro hub.

& -
A CAUTION
NOTE: If replacement is required, always replace the
84 9!F A!3!
synchro sleeve and synchro hub as a set.
!& -
SYNCHHD Do not install the synchro sleeve with its longer teeth in
(!!!&3!

SLEEVE the synchro hub slots because it will damage the spring
! 3!!

ring.

-
SYNCHRO LONGERTEETH
HUB
SYNEHHD
HUESLOT
DEEPER
GROOVES
SVHCHHG
HUB
SYNCHRO
SLEEVE
Synchro
# Ring, Gear

!: 13_98
Inspection

98
1.
- Inspect the synchro ring and gear.

-
A:
3-
%9 Inspect the inside of the synchro ring for wear. SYNCHRD SPRING -
B: !&
)9 Inspect the synchro sleeve teeth and matching

teeth on the synchro ring for wear (rounded off).

3; <-
GOOD “0“" smut-mo RING

C:
9 Inspect the synchro sleeve teeth and matching
!&

teeth on the gear for wear (rounded off).

3; <-
GOOD won"
D:
3-
(9 Inspect the gear hub thrust surface for wear.
E: 3
-
9 Inspect the cone surface for wear and roughness.
F:9 !!
&3A
Inspect the teeth on all gears for uneven wear,
scoring, galling, and cracks.

A
!!
A#-
2.
- Coat the cone surface of the gear with oil, and place the

3!A!
synchro ring on the matching gear. Rotate the synchro

-1
ring, making sure that it does not slip.

A#
!-
Measure the clearance between the synchro ring and
, !3

gear all the way around.

!!3 -
NOTE: Hold the synchro ring against the gear evenly
84 96!

&!
while measuring the clearance.
3!
!-
Synchro Ring-to-Gear Clearance
1
.!
Standard:
F 0.85-1.10 mm (0.033-0.043 in)
$@83@$/$@$$@$ 0
Service Limit: $@$/$@$5 0
- & F 0.40 mm (0.016 in)
Double Cone Synchro-to-Gear
)
*
# Clearance

Standard:
F
(A): /#
/0F (Outer Synchro Ring to Synchro

!
# Cone)

0
0.5-1.0 mm (0.02-0.04 in)
$@3@$/$@$$@$ 0
(B): /#
/"0F (Synchro Cone to Gear)

0
0.5-1.0 mm (0.02-0.04 in)
$@3@$/$@$$@$ 0
(C): /#
/0F (Outer Synchro Ring to Gear)

!
0
0.95 @58/$@$7$@$55 0
$@93 -1.68 mm (0.037-0.066 in)
Service Limit:
- & F
(A): $@/$@$ 0
/0F 0.3 mm (0.01 in)
(B): $@/$@$ 0
/"0F 0.3 mm (0.01 in)
(C): $@5/$@$ 0
/0F 0.6 mm (0.02 in)
If the clearance is less than the service limit, replace the
!!&!A!
synchro ring and synchro cone.

-
SYNCHROIHNG
GEAR
Differential
) 13-99
99

Index
NOTE:
84 9
¢ lf parts marked with an asterisk(*) were replaced, the tapered roller bearing preload must be adjusted (see page 13-103).
#3#;G<3!A!!
! 7 ;!+0+<-
¢ The limited slip differential assembly is non-rebuildable, replace it if it is damaged.
4!!!! !!A!
-
*THRUET EI-Ilnl'l
Adiustmerrt. page 13-10:!
*BEARING OUTER RAGE

Inspect for wear and damage. @
*TAPEHED ROLLER
BEARING _
Hem-cement, page 13-101 '
LIMITED SLIP DIFFERENTIAL ILROT THANSMISSDH}
Impact for wear and damage.
Inspect for damage.
'DIFFEHENTIAL CARRIER
“.12t U266 TRANSMISSIONS]
Backlash inspection, page 13-100
Imp-act for cracks.
ML “WEN GEAR
inspect for wear and damage.
10 at 1.0 mm
101 Mm {103 kgfm. 14 Ibf-ftl
Left-hand threads
'TAPERED ROLLER BEARING

'EEAHING OUTER RACE

Replacemem. page 13-102
inspect for Wear and damage.
‘75 mm EHIM

4

&A
!#!!3
9
( See page 13-103)
;!+0+<
( See page 13-102)
;!+0<
( See page 13-101)
;!+0<
( See page 13-100)
;!+00<
Differential
)
Backlash
;<:;3

"6 Inspection - U2J4, U265 Transmissions
13-100
$$ Final Driven Gear Replacement
+ ) -
- Place the differential assembly on V-blocks and install

!!!:!#!! 1.
- Remove the bolts in a crisscross pattern in several
1&!&!
both axles.
/!- steps, and remove the final driven gear from the
A&!&

2.
- Measure the backlash of both pinion gears. If the
, #!
- differential carrier.
!-
backlash is not within the standard, replace the
#!3A! NOTE: The final driven gear bolts have left-hand
84 94!&
!&!
differential carrier.
!- -
threads.
10 I 1.!) mm
Standard (New): 0.05-0.15 mm (0.002-0.006 in)
/,(0F$@$3$@3/$@$$$@$$5 0
101 N-m ”0.3 kfif‘m, Tl [hf-I‘ll
PINIOH GEARS Loft-hand thruads
DIAL INDICATE!“
FINAL DRIVEN GEAR

Chan-liar on inside diameter
of final driven gear faces carrier.
SIDE GEARS
V—EILDCK
DIFFERENHAL
Milan
2.
- Install the final driven gear with the chamfer on the
!!!&
3
III-BLOCK
inside diameter facing the carrier. Tightening the

-4

bolts in a crisscross pattern in several steps.
!&!-
Differential
)
Tapered Roller Bearing Replacement

" !
13-101
$ Oil Seal Replacement

NOTE:
84 9 1.
- Remove the oil seal from the transmission housing.
1&!!
-
¢ The tapered roller bearing and bearing outer race should
4!!

! ID x 68 I 22 mm
be replaced as a set.
!- OIL SEAL
FIE-place.
¢ Inspect and adjust the tapered roller bearing preload
7 !!
!
whenever the tapered roller bearing is replaced.
3&!!
!-
¢ Check the tapered roller bearings for wear and rough
#!!
3

rotation. If the tapered roller bearings are OK, removal is
-!!
8>A&!
not necessary.
-
1.
- Remove the tapered roller bearings using a bearing
1&!!

puller and a bearing separator as shown.

!!
3-
BEARING
FULLER
BEARING
SEPARATDH
lCEII'I'Ir‘I'IErClall'If
available:
_ TRANSMISSION Housing
-
2. !!3!!
Install the new 0I| seal Into the transmISSIon
housing using the special tools as shown.

!!3-
TAPERED
ROLLER
BEARING
2.
- Install new tapered roller bearings using the special tool
!!3!!

!!
as shown.
3-
NOTE: Drive the tapered roller bearings on until they
84 9(&!!
!
bottom against the differential carrier.

!-
- “i BEARING ATTACHMENT
‘—“ ovum - Pwsoeoi
TAPERED
ROLLER V'v HANDLE DRIVER
BEARING fa" 01149 - ammo
DRIVER A‘I'I'flCl-IIIEN'I'
[HEAD - P8110100
OIL SEAL H“:-
Raplaca. .
I HLOT. 23 x 3::- mm
- MJAD - Pm
Differential
)
Oil Seal Replacement (cont’d)
/
?0
13-102
$ Bearing Outer Race
" !
Replacement

Clutch .
!F
Housing: NOTE:
84 9
1.
- Remove the 0” seal from the clutch housing.
1&!!!
- 0 The bearing outer race and tapered roller bearing
4
!!

CLUTCH HOUSING should be replaced as a set.
!!-
Inspect and adjust the tapered roller bearing
7 !!

preload whenever the tapered roller bearing is
!3&!!

replaced.
!-
Remove the oil seals from the transmission
- 1&!!
housing and clutch housing (see page 13-101).

!
;!+0<-
Drive the bearing outer race and thrust shim out of
- (&

the transmission housing, or remove the bearing

A&
outer race and 75 mm shim from the clutch

$!
housing by heating the clutch housing to about

!

212°F ;00P<3
-
P (100°C) with a heat gun.
A CAUTION
( 3
Do not reuse the thrust shim if the outer race was
& -
driven out.
TRANSMISSION HOUSING:
,,.;,F
l-IAMJLE DRIVER
35 in: 56 x 8 mm III-"NB - M10000
OIL SEAL
Replace.
2.
- Install the new oil seal into the clutch housing using the
!!3!!!

!!3-
CLUTCH
HOUSING DRIVER
ATTACHMENT,
52 l 55 mm
01145 - 0010400
THHUST SHIM
BEARING ““41: '

OUTER RAGE
CLUTCH HOUSING:
&;..;,F
HANDLE DRIVER
0774-9 - 0010000
DRIVER ATTACHMENT
OIL SEAL D'IJAD - PHflfl'lfl'l
Replace.
.n""'| PILOT. 2: x :11} mm

_ ‘ | UTJAD - PHBIJM
15 mm SHIM
Differential
)
Bearing Outer Race Replacement (cont’d)
" !/
?0
13-103
$ Tapered Roller Bearing Preload

" !'

Adjustment
D
3.
+- Install the thrust shim or 75 mm shim and the bearing
!! $
NOTE: If any of the items listed below were replaced,
84 9!!33!A
outer race in the transmission housing and clutch

! the tapered roller bearing preload must be adjusted.
!!
! 7 -
housing using the special tools as shown.

!!3- 0 Transmission housing
4
NOTE:
84 9 Clutch housing
!
A0000.
0 Install the bearing outer race squarely.
!!
F !- Differential carrier
(!
0 Check that there is no clearance between the
#!3 Tapered roller bearing and bearing outer race
4!!

bearing outer race, thrust shim or 75 mm shim and

A $ Thrust shim
4
housing

75 mm shim
$
TRANSMISSION HOUSING:
,,.;,F Remove the bearing outer race and thrust shim
- 1&

HANDLE DRIVER from the transmission housing (see page 13-102).

;!+0<-
0774.9 — 0010000 NOTE: Install the thrust shim only on the
84 9!! !
transmission housing side.

-
DRIVER A CAUTION
ATTACHMENT. Do not reuse the thrust shim if the bearing outer race
(

I52 1 63 mm
was driven out.
3& -
01146 - 0010500
NOTE: Before adjusting the tapered roller bearing
84 9)7
!!

preload, let the transmission cool to room temperature if
!A!!
the bearing outer race was removed by heating the

3&

clutch housing.
!
-
2.
- First try the same size thrust shim that was
H 3
removed
&
A CAUTION
Use only one thrust shim.
?! -
THRUST sum F...- TI-IRUET SHH
CLUTCH HOUSING:
&;..;,F
HANDLE DRIVER
INTI-9 — 0010000
DRIVER
ATMCHMEHT.
3'2 3! 15 mm
0??“ - 0010600
7'5 mm SH“
4.
*- Install the oil seal (see page 13-48)
!!!!;!+*'<
Differential
)
Tapered Roller Bearing Preload Adjustment (cont’d)

" !'
D/
?0
13-104
$
3.
+- After installing the thrust shim install the bearing outer
%!!
!!
5.
- Rotate the differential assembly in both directions
1!!
race in the transmission housing (see page 13-102).

;!+0<- to seat the tapered roller bearings.
!!
-
NOTE:
84 9 6.
- Measure the starting torque of the differential
,
F !
0 Install the bearing outer race squarely.
!!
F !- assembly with the special tool and a torque wrench.
!3!!F 3-
0 Check that there is no clearance between the
#!3 NOTE:
84 9
bearing outer race, thrust shim and transmission

A ¢ Measure the tapered roller bearing preload at
, !!
!
housing.

- normal room temperature.
! -
4.
*- With the mainshaft and countershaft removed, install the
2 &A!! ¢ Measure the tapered roller bearing preload in
, !!
!
differential assembly, and torque the clutch housing and
!!AF !
both directions.
-

- ,))F 1.4-2.5 Nm
STANDARD: @@3,
NOTE: It is not necessary to use sealing agent between
84 9 !

3 (14-26 kgf/cm, 12-23 lbf/in)
/56! 2:* 2 0
the housings.

- U2J4, 265 Transmission:
;<:3
F
8 x 1.25 mm bolts: 27 Nm 12.8 kgf/m 20 lbf/ft)
8@3*
F7,@86! 2$* 2 0
10 x1.25 mm bolts: 7 Nm 14.8 kgf/m, 35 lbf/ft)
$@3*
F7,@86! 2:3* 2 0
TRANSMISSION {-.._ -""n.,
HANGER a ‘
10 mm BOLTS "“1
PRELOAD INSPECTION TOOL

WHAJ - PK40201
U207 Transmission:
;=7
F
flnzaxwmmboiu HANGERA Praluad Inspection Tool
Dth'r: B 1 ID mm hm ETTA-J — STTDIDIJ
)
Differential
Tapered Roller Bearing Preload Adjustment (cont’d)

" !'
D/
?0
13-105
$3
7.
$- If the tapered roller bearing preload is not within the
!!
!3 5-
9. 63! 9
How to select the correct thrust shim:
standard, select the thrust shim which will give the
A! 33!!
& -1)
<
correct tapered roller bearing preload from the following
!!
!!!3
Compare the tapered roller bearing preload
!!
!
!-
table. you get with the thrust shim that was

3 3
NOTE: Changing the thrust shim to the next size will
84 9

/H3!! removed, with the specified preload of 1.4-2.5
&A3!-*-
increase or decrease tapered roller bearing preload
!!
! Nm (14-26 kgf/cm, 12-23 Ibf/in).
;*#
=A+!=<-
about 0.3-0.4 Nm (3-4 kgf/cm, 2.6-3.5 |bf/in).
0-+0-*;+*#
=A-+-!=<- <
THRUST SHIM
.;. If your measured tapered roller bearing
!!

Part Number 4#
Thickness preload is less than specified, subtract yours
!!A
% 41381-PX5-000
*+'R000 1.90 mm (0.0748 in)
-50;0-0$*'< from the specified.
-
po—lC/JWO'UOZEVXL_IO'HITIUOCU>
) 41382-PX5-000
*+'R000 1.93 mm (0.0760 in)
-5+;0-0$0< If yours is more than specified, subtract the
A
41383-PX5-000
*+'+R000 1.96 mm (0.0772 in)
-5;0-0$$< specified from your measurement.
-
41384-PX5-000
( *+'*R000 1.99 mm (0.0783 in)
-55;0-0$'+< For example with a 2.17 mm (0.0854 in)
/!3-$;0-0'*<
41385-PX5-000
*+'R000 2.02 mm (0.0795 in)
-0;0-0$5< thrust shim:
9
41386-PX5-000
*+'R000 2.05 mm (0.0807 in)
-0;0-0'0$< (A) specified
;%< 2.5 Nm (26 kgf/cm, 23 lbf/in)
-;#
=A+!=<
41387-PX5-000
. *+'$R000 2.08 mm (0.0819 in)
-0';0-0'5< - you measure 0-#
=A!=<
0.6 Nm 16 kqf/cm, 5 Ibf/in)
41388-PX5-000
6 *+''R000 2.11 mm (0.0831 in)
-;0-0'+< 1.9 Nm (20 kgf/cm. 18 Ibf/in)
-5;0#
=-'!=<
41389-PX5-000
*+'5R000 2.14 mm (0.0843 in)
-*;0-0'*+< less
!
" 41390-PX5-000
*+50R000 2.17 mm (0.0854 in)
-$;0-0'*< (B) you measure 3.3 Nm (34 kgf/cm, 30 lbf/in)
;)< +-+;+*#
=A+0!=<
> 41391-PX5-000
*+5R000 2.20 mm (0.0866 in)
-0;0-0'< - specified
2.5 Nm (26 kqf/cm. 23 lbf/in)
-;#
=-+!=<
41392-PX5-000
*+5R000 2.23 mm (0.0878 in)
-+;0-0'$'< 0.8 Nm (8 kgf/cm, 7 Ibf/in)
0-';'#
=A$!=<
41393-PX5-000
, *+5+R000 2.26 mm (0.0890 in)
-;0-0'50< more

41394-PX5-000
*+5*R000 2.29 mm (0.0902 in)
-5;0-050< Each shim size up or down from standard
+< H 3
41395-PX5-000
8 *+5R000 2.32 mm (0.0913 in)
-+;0-05+< makes about 0.3-0.4 Nm (3-4 kgf/cm, 2.6-3.5
# 0-+0-*;+*#
=A-+-
41396-PX5-000
*+5R000 2.35 mm (0.0925 in)
-+;0-05< Ibf/in) difference in tapered roller bearing
!=<!!

41397-PX5-000
D *+5$R000 2.38 mm (0.0937 in)
-+';0-05+$< preload.
!-
41398-PX5-000
1 *+5'R000 2.41 mm (0.0949 in)
-*;0-05*5< 0 In example (A) your measured tapered
/!;%<
41399-PX5-000
*+55R000 2.44 mm (0.0961 in)
-**;0-05< roller bearing preload was 1.9 Nm (20
!!
!3-5;0
4 41400-PX5-000
**00R000 2.47 mm (0.0972 in)
-*$;0-05$< kgf/cm, 18 lbf/in) less than standard so
#
=A'!=<!
Recheck the tapered roller bearing preload.
'- 1#!!
!- you need a thrust shim five sizes thicker
&H#
than standard (try the 2.32 mm (0.0913
;-+;0-05+
in) thrust shim, and recheck).
< A#<-
0 In example (B) your measurement was
/!;)< 3
0.8 Nm (8 kgf/cm, 7 lbf/in) more than
0-';'#
=A$=<
standard, so you need a thrust shim two
A 3
sizes thinner (try the 2.11 mm (0.083 1
H;-;0-0'+
in) thrust shim, and recheck).
< A#<-
10. %7
!!
!A
0- After adjusting the tapered roller bearing preload,
assemble the transmission and install the
!!!
transmission housing (see page 13-57).

;!+$<-
TORQUE:
=;%F
10 x 1.25 mm: 47 Nm (4.8 kgf/m 35 lbf/ft)
$@3F7,/@86! 23* 2 0
8 X125 mm: 27 Nm (2.8 kgf/m. 20 lbf/ft)
8@3F7,/@86! 2@$* 2 0
11. 1!!
- Rotate the differential assembly in both directions
to seat the tapered roller bearings.
!!
-
" !2
Main Bearing/Oil Seal
Replacement

13-106
$5
1.
- Remove the differential assembly.
1&!!- 4.
*- Drive the new oil seal in from the transmission side
(&3!!
2.
- Remove the ball bearing using the special tool as shown.
1&!!

!!3- using the special tools as shown.

!!3-
3.
+- Remove the oil seal from the clutch side.
1&!!! -
HANDLE DRIVER
DTTIB - 0010000
DRIVER
ATTACHMENT.
42 a: I" mm
ADJUSTABLE BEARING 0??“ - 0010300
REMOVEH SET
DTJAC — PHEDflDfi
_ CLUTCH CLUTCH
- HOUSING HOUSING
| l OILSEAL
_ /'-w. I Replace.
BALL BEAHlNG
5.
- Drive the new ball bearing in from the transmission
(&3!!

side using the special tools as shown.

!!3-
BALL BEARING
DRIVER
ATTACHMENT.
"lI. 62 x 68 mm
07746 — 0010500
28 x 41 x 7 mm
OIL SEAL
Replace. CLUTCH
HOUSING
{31] [1,.- BALL BEARING

'. . “I 7;.
Countershaft

Bearinq
" !
Replacement

13-107
$7
1.
- Remove the retaining plate from the clutch housing.
1&
!!
- 3.
+- Position the oil guide plate and new needle bearing
!
!3!
Replace. in the bore of the clutch housing.

!
-
NOTE: Position the needle bearing with the 0” hole
84 9!
3!!
facing up.

-
CLUTCH HOUSING OIL HDLE$
NEEDII SEARING
OIL GUIDE PLATE
Li, /’R\\ \ RETAINING PLATE
hi3 \
|
2.
- Remove the needle bearing using the special tool, then
1&!

!!A
remove the 0” guide plate.
&!
!- 4.
*- Drive the needle bearing using the special tools as
(&!

!!
3-
shown.
HANDLE DRIVER
07749 - 0010000
DRIVER
ATTACHMENT,
52 l. 63 mm
01146 — 0010500
ADJUSTABLE BEARING
REMOVER SET
O7JAC -— PHSDOOO
CLUTCH
, —_( HOUSING
I : CLUTCH
i iLL
5—] HOUSING
II 11:..- [ ‘f i:']|"—II—!' NEEDLE BEARING
NEEDLE BEARING
OIL GUIDE PLATE

Countershaft

Bearinq
" ! 13_1 08
$8 Mainshaft
Thrust

/
?0
Clearance
Adjustment
D
5.
- Install the retaining plate, and stake the bolt heads into
!!
!A#! 1.
- Remove the 78 mm shim and 0” guide plate from
1&$'!
!
the groove in the retaining plate.

&
!- the transmission housing.

-
6 J: 1.0 mm Tl'fl mm
12 Mm {1.2 kg‘f-n‘l, 3.1 lb‘l-ftl
Replace.
TRANSMISSION
HOUSING
RETAINING PLATE
.- -._ .2"
2.
- Install the 3rd/4th synchro hub, spacer collar, 5th
!!+=* A!!A
synchro hub, spacer, and ball bearing on the
AA!!

mainshaft, then install the assembled mainshaft in
A!!!
the transmission housing.

-
3.
+- Install the washer on the mainshaft.
!!3-
4.
*- Measure distance (B) between the end of the
, ;)<3
transmission housing and washer

3
NOTE:
84 9
¢ Use a straight edge and vernier calliper.
?

&!!-
¢ Measure at three locations and average the
, !&

reading.

-
END ul'
TRANSMISSION
_II HOUSING
3RDMTH SYNCHHO HUB

{1/
SPACER COLLAR
5TH SYNCHHO HUB
spAcELn “'54-
BALL BEARING '- '—- '- -'
TRANSMISSION /
HOUSING

Mainshaft
Thrust Clearance
D/
?0
13-109
$9
5.
- Measure distance (C) between the end of the clutch
, ;<3! 78 mm SHIM
78.
housing and bearing inner race.

- ',*
Part Number 6
Thickness
NOTE:
84 9 23941 -P1 6-000
% +5*000 1.20 mm (0.0472 in)
-0;0-0*$<
;N<><E<C—lU);UD'UOZ§l_X"—_IG)THTIUOUJJ>
0 Use a straight edge and depth gauge.
?

- 23942-P16-000
) +5*000 1.23 mm (0.0484 in)
-+;0-0*'*<
0 Measure at three locations and average the
, !&
23943-P16-000
+5*+000 1.26 mm (0.0496 in)
-;0-0*5<
readings.

- 23944-P16-000
( +5**000 1.29 mm (0.0508 in)
-5;0-00'<
END of CLUTCH HOUSING 23945-P16-000
+5*000 1.32 mm (0.0520 in)
-+;0-00<
Z 23946-P16-000
+5*000
23947-P16-000
. +5*$000
23948-P16-000
6 +5*'000
1.35 mm (0.0531 in)
-+;0-0+<
1.38 mm (0.0543 in)
-+';0-0*+<
1.41 mm (0.0555 in)
-*;0-0<
23949-P16-000
+5*5000 1.44 mm (0.0567 in)
-**;0-0$<
" 23950-P16-000
+50000 1.47 mm (0.0579 in)
-*$;0-0$5<
23951 -P1 6-000
> +5000 1.50 mm (0.0591 in)
-0;0-05<
23952-P16-000
+5000 1.53 mm (0.0602 in)
-+;0-00<
23953-P16-000
, +5+000 1.56 mm (0.0614 in)
-;0-0*<
23954-P16-000
+5*000 1.59 mm (0.0626 in)
-5;0-0<
INNER RACE 01 HALL BEARING 23955-P16-000
8 +5000 1.62 mm (0.0638 in)
-;0-0+'<
23956-P16-000
+5000 1.65 mm (0.0650 in)
-;0-00<
23957-P16-000
D +5$000 1.68 mm (0.0661 in)
-';0-0<
- Select the proper 78 mm shim from the chart by using
!$'
23958-P16-000
1 +5'000 1.71 mm (0.0673 in)
-$;0-0$+<
the formula below.
!!3- 23959-P16-000
+55000 1.74 mm (0.0685 in)
-$*;0-0'<
Shim
Selection Formula:

+
9 23960-P16-000
4 +50000 1.77 mm (0.0697 in)
-$$;0-05$<
From the measurements you made in steps 4 and 5:
*9 23961 -P1 6-000
? +5000 1.80 mm (0.0709 in)
-'0;0-0$05<
-1. %;<;<;)<;*<-
- Add distance (C) (step 5) to distance (B) (step 4). 23962-P16-000
: +5000 1.83 mm (0.0720 in)
-'+;0-0$0<
-2. From
- this number, subtract 0.93 (which is the
A 0-5+;3 23963-P16-000
2 +5+000 1.86 mm (0.0732 in)
-';0-0$+<
midpoint of the flex range of the clutch housing
!/
!
23964-P16-000
R +5*000 1.89 mm (0.0744 in)
-'5;0-0$**<
bearing spring washer).

3<- 23965-P16-000
C +5000 1.92 mm (0.0756 in)
-5;0-0$<
-3. 4# &!!
+- Take this number and compare it to the available 23966-P16-000
I +5000 1.95 mm (0.0768 in)
-5;0-0$'<
shim sizes in the chart.
H- 23967-P16-000
%% +5$000 1.98 mm (0.0780 in)
-5';0-0$'0<
(for example)
;/!< 23968-P16-000
%) +5'000 2.01 mm (0.0791 in)
-0;0-0$5<
B: -+5
)9 2.39 - 23969-P16-000
% +55000 2.04 mm (0.0803 in)
-0*;0-0'0+<
+ 9
V C: 0-
0.22 0-5+ 23970-P16-000
%( +5$0000 2.07 mm (0.0815 in)
-0$;0-0'<
Y 2.61
- Y -' 23971 -P1 6-000
% +5$000 2.10 mm (0.0827 in)
-0;0-0'$<
‘H
Try the 1.68 mm (0.0661 in) shim.

4-';0-0<- 23972-P16-000
+5$000 2.13 mm (0.0839 in)
-+;0-0'+5<
23973-P15-000
%. +5$+000 2.16 mm (0.0850 in)
-;0-0'0<
23974-P16-000
%6 +5$*000 2.19 mm (0.0862 in)
-5;0-0'<
23975-P16-000
% +5$000 2.22 mm (0.0874 in)
-;0-0'$*<
23976-P16-000
%" +5$000 2.25 mm (0.0885 in)
-;0-0''<
23977-P16-000
%> +5$$000 2.28 mm (0.0898 in)
-';0-0'5'<
23978-P16-000
% +5$'000 2.31 mm (0.0909 in)
-+;0-0505<
23979-P16-000
%, +5$5000 2.34 mm (0.0921 in)
-+*;0-05<
23980-P16-000
% +5'0000 2.37 mm (0.0933 in)
-+$;0-05++<

Mainshaft
Thrust Clearance
D/
?0
13-110
$
NOTE: Measurement should be made at normal room
84 9, !! +-
13. !&-
Slide the mainshaft base over the mainshaft.
temperature.
- MAIlilsi-IAFr
$- Install the 78 mm shim selected and oil guide plate the
!!$'!!
!

- 3. CLUTCH
TRANSMISSION
1'3 mm ——n-1 I. ‘E‘i HOUSING
\;i::-_.-_.;'.‘-;’)
lilIllL GUIDE
/
PLATE
MAINSHAFI' BASE
076M — P620130
*-
14. %!
Attach the mainshaft holderto the mainshaft as
follows:
!!39
'- Thoroughly clean the -spring washer and washer before
4
!!
33
NOTE:
84 9
installing them on the ball bearing. Note the installation
!!
!!
-!!
¢ Back-out the mainshaft holder bolt and loosen
)# !!!
direction of the spring washer.

3-
WASHER the two hex bolts.
3/!-
¢ Fit the holder over the mainshaft so its lip is
!&!
towards the transmission.
3-
¢ Align the mainshaft holder’s lip around the
%!
!B!
groove at the inside of the mainshaft splines,

&!A
then tighten the hex bolts.

/!-
5- !!!
- MAIN$HAFT HOLDER
0-. !
&
Place the transmission housing over the mainshaft and BOLT
onto the clutch housing.
!
-
Tighten the clutch and transmission housings with
- 4
!
3
several 8 mm and 10 mm bolts.
&!'0!-
NOTE: It is not necessary to use sealing agent between
84 9 !

3
the housings.

-
12. 43!-
- Tap the mainshaft with a plastic hammer.
MAINSHAFT
HOLDER
076M - PGZD'I 'Il]
MAINSHAFr BASE
OTGAJ — P620130
15. !!
3
- Seat the mainshaft fully by tapping its end with a
plastic hammer.
!-
16. 4!! !7
- Thread the mainshaft holder bolt in until itjust
contacts the wide surface of the mainshaft base.
3 -
17. I!

-
$- Zero a dial gauge on the end of the mainshaft.

Mainshaft
Thrust Clearance
D/
?0
13-111

*#
Reassembly
*#
18. 4 !!!#3N
'- Turn the mainshaft holder bolt clockwise; stop turning 1.

- Install the differential assembly in the clutch
!!!!!
when the dial gauge has reached its maximum
3!

/ housing.

-
movement. The reading on the dial gauge is the amount
&-4
!

DIFFERENTIAL HSEMBL‘I“
of mainshaft end play.
!-
A CAUTION
Turning the mainshaft holder bolt more than 60 degrees after
4
!!0

the needle of the dial gauge stops moving may damage the
!!

&

transmission.
-
MAGNET STAND BASE
01919 — ”M1 DIAL GAUGE
CLUTCH HOUSING
2.
- Install the spring washer and washer over the ball
!!
33&!!
MGM - P920110 bearing. Note the installation direction of the spring

-!!
5- If the reading is within the standard, the clearance is

19.
3A! washer.
3-
correct.
- 3.
+- Tape the splines of the mainshaft with vinyl tape to
4!3&!
If the reading is not within the standard, recheck the

3A# protect the seal.
!-
shim thickness.
#- Insert the mainshaft and countershaft into the shift

Standard: 0.10-0.16 mm (0.004-0.006 in)
F$@$$@5/$@$$$@$$5 0 forks, and install them as an assembly.
#A!!!-
xi OOUHTERSHAFT
'7' ASSEMBL‘I'
{WI/#3:,-
Ill/I”
Tape the mainshaft

splines.
SPRING
WASHER
[C Draft”

*#
*#/
?0
13-112

4.
*- Install the reverse idler gear and reverse idler gearshaft
!!&!
&!
6.
- Install the oil gutter plate in the transmission
!!!
!
in the clutch housing.
!
- housing.

-
REVERSE IDLER OIL GUTI'EFI
GEAR PLATE
REVERSE IDLER GEAR

SHAH TRANSMISSION
HOUSING
'IZJ‘-
Fixflf-
flUTCH HOUSING L afar? \._./_"\
-
5. Install the reverse shift fork in the clutch housing with the
!!&#!
3
5th/reverse shift piece pin positioned in the slot of the
=&!
.__~__.r'~—""
HQ I "-..._; ."
reverse shift fork.
&#-
NOTE: Check that the steel ball is in the proper position.
84 9#!!!- 7.
$- Select the proper size 78 mm shim according to
!H$'

5 x 1.0 mm the measurements made during the Mainshaft

,
REVERSE SHIFT FORK 15 Nm {1.5 mm. 11 IbH‘tI Thrust Clearance Adjustment, (see page 13-108).
4 !%7 A;!+0'<-
8.
'- Install the oil guide plate and 78 mm shim into the
!!!
!$'

-
- - -Q mmsmssiun
.« HDU5|NG
I STEEL BALL
D. 5! 16 In

*#
*#/
?0
13-113

9.
5- Remove the dirt and oil from the transmission housing
1&!
U2Q7 TRANSMISSIONS:
;=7,,F
sealing surface. Apply liquid gasket to the sealing
!
-%!!F
#!
5TH SHIFT FORK
surface of the transmission housing as shown.

3-
NOTE:
84 9
0 Use liquid gasket P/N 08C70-K0234M.
?!F
#=0'$0>0+*,-
0 Remove the dirty oil from the sealing surface.
1&!!
-
0 Seal the entire circumference of the bolt holes to
! !!
prevent oil leakage.
&!!#
-
0 If 20 minutes have passed after applying liquid
0 &!
!F
gasket, reapply it and assemble the housings. Allow

#A!!
-%!!3
it to cure at least 20 minutes after assembly before
!0 !
filling the transmission with oil.
!!
3!-
STOPPER RING
12. 3
3
- Lower the transmission housing with the snap ring

----- : Liquid gasket
pliers, and set the snap ring into the groove of the
!A

&
countershaft bearing.

-
SNAP RING PLIEFIS
SNAP FiING 07LGC - 0010100
TRANSMISSION
HOUSING
10. !!*/03!-
0- Install the 14 x 20 mm dowel pins.
11.

3-
- Set the tapered cone ring or stopper ring as shown.
Place the transmission housing over the clutch housing,
!
&!
A
being careful to line up the shafts.

!! -
U2J4 U265 TRANSMISSIONS:
;<;3,,F
5TH SHIFT
FORK
TAPEHED CGNE RING


*#
*#/
?0
13-114

13. #
!
+- Check that the snap ring is securely seated in the 16. !!&!
!-
- Install the reverse idler gear shaft bolt.
groove of the countershaft bearing.

&
- 17. !!!!!A
A3
$- Install the steel balls, springs, washers and setting

Dimension Aas installed:
)
F 3.6 - 6.3 mm
@55@ screws.
3-
(0.142-0.248 in)
/$@$@8 0 STEEL BALL D. 5116 In
14. !!+!
!
*- Install the 32 mm sealing bolt
WASHER
NOTE: Apply liquid gasket P/N 08C70-K0234M to the
84 9%!!F
#=0'$0>0+*, Replace.
threads.
- SETTING SCREW
32 mm SEALING BOLT 22 N-m [2.2 kg‘f-m. 16 Ibf-fti
25 Hm {2.5 kgf-m, 1a lM-fl) SNAP RING
SPRING L. 26 mm ’
”_-P_ZL"I_ _ A
— _.--- .1;
Firm-T- WASHE
|
4*,
'Cr" .' Replace.
15. !!
%)A

- Install transmission hangers Aand B, then tighten the REVERSE IDLER GEAR SHAFT BOLT
u N-rn [4.5 lint-n1. 33 lb'l-HI
bolts in a crisscross pattern in several steps as shown.
!&!3-
18. !!&!;!
'- Install the shift arm cover assembly (see page
8 x 1.25 mm bolts: 27 Nm (2.8 kgf/m, 20 lbf/ft)
8@3*
F7,/@86! 2:$* 2 0
13-69).
+5<-
10 x1.25 mm bolts: 47 Nm (4.8 kgf/m, 35 lbf/ft)
$@3*
F7,/@86! 2:3* 2 0 19.
!!

5- Shift the transmission through all the gears before
mmsmsslon ,A— —-"“~.. _ installing it.
!!
-
HANGER R 10 mm BOLTS
A
- TRANSMISSION
'9 a: a x 50 mm bolts HANGER A
Other: B A 40 mm both

Transmission

Installation
13-115
3
- Check the dowel pins are installed in the clutch housing.
#3!!!!
- 5.
- Place the transmission on the transmission jack,
!7#A
2.
- Install the slave cylinder bracket to the transmission
!!!&!# and raise it to the engine level.

!&!-
assembly.
!- 6.
- Install the front side transmission mounting bolt.
!!
!-
SLAVE 12 n 1.25 mm
CYLINDER 64 Hum IE5 Ital-m.
BRACKET 47 lbf-fi}
22 N-m [2.2 kgf‘m.

1a IbMt}
3.
+- Apply HONDA Genuine Urea Grease UM264 (P/N
%!68(%. ?.?,*;= 7.
$- Install the rear side transmission mounting bolt
!!
!
41211-PY5-305) to the release fork, the release fork
*C+0<!#A!# 8.
'- Install the two engine mount bracket new mounting
!!3
#3
bolt, the release bearing, and the release bearing guide

!A!
A!

bolts.
!-
-
in the shaded areas. 12 a: 125 mm
54 H-I'ri [6.5 tut-m, 12 1: 1.25 mm
RELEASE RELEASE BEARING
IT lbI-fl} 64 MW: l6.5 Ital-m.
FORK BOLT GUIDE
47 Ihf—fll
BEARING
I‘.
0.4 — 1.0 g
10.01 - um oz}
BOOT
1.0 — 1.6 g
[0.04 - 0.06 nzl
4.
*- Install the release bearing, release fork, and boot on the
!!!
A!#A
-
transmission.
Transmission


/
?0
13-116
5
9.
5- Install the two upper transmission mounting bolts.
!!3
!- 11. 1A!!
- Raise the transmission, then install the
transmission mount rubber assembly and
!
transmission mount bracket
#
¢ Torque mounting bolts and nut in the
4F
!
sequence shown.
F 3-
¢ Make sure the bushings are not twisted or
,#
3
offset

1):12 x 1.25 mm *;-#
=A*$!=<
;<9/- 64 Nm (6.5 kgf/m, 47 Ibf/ft)
AAAA
2):Temporary tightening
;<94

3):10 x1.25 mm +';+-5#

=A'=<
;+<90/- 38 Nm (3.9 kgf/m, 28 Ibf/ft)
4):12 x1.25 mm *;-#
=A*$!=<
;*<9/- 64 Nm (6.5 kgf/m, 47 Ibf/ft)
TRANSMISSION
MOUNT
12 11.25 mm
64 M11 {3.5 kgi-m.
u lb'i-ftl
0-
10. !! !
Install the transmission mount stud bolt on the

-
STUD BOLT
. ;‘_:n:3' TRANSMISSION
MOUNT anncxn
50 mm
11.9? In]
- 1&-

Transmission


/
?0
13-117
7
13. !!!

#-
+- Install the front beam by aligning the marks. 15. !! 33
!
- Install both radius rods with new mounting bolts on
MARK the lower arm.
!3-
11 x 1.5 mm
/\
179 Mm (18.3 kgfwn, 132 "Bf-HI
LDWEFI
ARM
RADIUS REID
64 N-m 16.5 kgf‘m. 16. !!
-
- Install the engine stiffener.
47 Ibf-fil 12 x 1.25 mm
1!- x 1.5 mm 6-1. Mm
103 Mar-110.5 kgi—m. 16.5 kgI-m.
75.9 lbf—HI 47 Ihf—fll
14. !!3
!!-
*- Install the power steering cooler pipe in the pipe clamps.
E at 1.0 mm
9.3 Nrm 11.0 kgf-m. "1.2 lbf‘fll
/ PIPE CLAMP
ENGINE 10 :n: 1.25 mm

POWER STEERING STIFFENEH 44 N-m 14.5 kgi—m. 33 mm
COOLER PIPE
Transmission


/
?0
13-118
8
$-
17. !!#!#-
Install the intake manifold bracket. 5- Install the driveshafts with new set rings (see
19. !!&33
;
section 16).
<-
DRNESHAFT
Ix”?
SET RING
INTAKE B 11.25 mm Replace.
MANIFOLD 22 MM [2.2 kgl-m. 20. !!#33!#
0- Install both the damper forks with new locknuts
BRACKET 16 Ihf-ftl (see section 18).
;'<-
'- Install the intermediate shaft (see section 16).
18. !!;<- 10 x 1.25 mm
1D I 1.25 mm 4:! Min HA kgf—m.
35 N-m l4.0 lint-m. 32 IhrH-tl
23 Ibf-fll
% E INTERMEDIATE
LOWER ARM
BALL JOINT
/%~h
CUTTER PIN
Replace. Replace.
1211.25mm 1231.25 mm
49 - 59 H-m 64 Mm 16.5 Hahn.
(5.0 - 6.0 hut-m. 41 lbf-fll
as - 4.3 lhf-ftl
21. !!!!7!3A!!
- Install the ball joint onto the lower arms, then install
the castle nuts and new cotter pins (see section
! 3;
18).
'<-
Transmission


/
?0
13-119
9
22. !!!!-
- Install the splash shield. 24. !! #-
*- Install the rear mount bracket brace.
REAR ENGINE ¢::—:_-r—-._
,x:
MGUNT BRACKET
BRRCE
SPLASH sI-IIELD 1D x 1.25 mm

33 Hm I19 Itg‘I-m.
23. !!3
#
+- Install the washer and front engine bracket mounting

21' lat-HI
bolts.
!- 25. &!;:<-
- Connect the vehicle speed sensor (VSS) connector.
10 x 1.25 mm V55 CONNECTOR
38 N-rn {3.9 kgf—m.
27 Ibf-ftl
WASHER
Transmission


/
?0
13-120
$
26. !!!!&A!!!
- Install the cables to the levers, then install the cable 29. !!A!-
5- Install the starter motor, then connect the cables.
bracket. Turn the shift lever boot so the hole is facing
#-4 !&!
Make sure the crimped side of the ring terminals is
,#
!
down.
3- facing out.

-
3 I 1.25 mm 1L1 x 1.25 mm
27' Ndm (2.8 lint-n1. 33 M-m [3.5 kg‘f-rn. STARTER
20 lbf-ftl 21 Ibf-i‘tl MOTOR
CUTTER PINS 2
Replace.
‘3’
_ _'
CABLE
BRACKET
.64
IF!" 4121 I — P"I"5 — 305} ' '- , MN-mlfiEkgf—m,
/ STARTER In Ibfdftl
a x 1.25 mm CABLES
9 N-rn 10.9 kql—m. 6.5 Ibf-ftl
30. %!68(%. ?.?,*;=
+0- Apply HONDA Genuine Urea Grease UM 264 (P/N
41211-PY5-305) to the end of the slave cylinder
*C+0<!&!
rod. Install the slave cylinder and clutch line clamp.
-!!!&!! !!-
27. !!
!!
$- Install the transmission grodnd cable and starter cables Take care not to bend the clutch line.
4#! !-
5 x 1.1] mm
clamp.
!- 9.3 N-m 11.0 kgf-m. a u 1.25 mm
BACK-UP LIGHT SWITCH 3.2 Ibf-l't] 22 mm 12.2 kgf-m.
CONNECTORS
\ CLUTCH 16 Ihi-fll
LINE \
TRANSMISSION
GRUU ND
CABLE
SLAVE
I _ _? CYLINDER
3TAFITER IFIN 41211— PY5 — 305)

E x 1.0 mm
CABLE
5.3 N-m 11.9 kgf-I'I'I.
CLAMP
7.2 Ib‘l-fll
28. # !
3-
'- Connect the back-up light switch connectors.
Transmission


/
?0
13-121

31. !!
3!-
+- Install the engine wire harness clamp. ++-
33. !!# -
Install the intake air duct.
5 x 1.0 mm
INTAKE AIR
9.3 Hm [Ll] Ital-m,
DUCT
7.2 Inf-fl]
ENGINE WIRE
HARNESS CLAMP
32. !!#-

+- Install the battery bracket. 34. 4 Z
+*- Turn the breather cap so that the "F"Z#
mark points
3 x 1.25 I'I1ITI
3&!-
toward the front of the vehicle.
22 ”m [2.2 kgi-m.
BHEATHEH CAP
1E Ihf-fi]
BA‘I'I'ERY
BRACKET
6x1.0mm
9.8 N-m II .D nm,
12 lbI-fil
Transmission

13-122


/
?0
35. &;V<!A

&;<
+- Connect the positive (+) cable first, then the negative (-)
cable to the battery.
!-
36. 1!!! ;!+$<-
+- Refill the transmission fluid (see page 13-57).
37. ##-
+$- Check the transmission and check for smooth operation.
38. #! -
+'- Check the clutch operation.
39. #3!!
;'<-
+5- Check the front wheel alignment (see section 18).
40.
!

*0- Loosen the three mounting bolts on the front engine
stopper bracket, then torque the three mounting bolts in
#AF
!
step 21. Make sure the bushings are not twisted or
-,#
3
offset.
-
Gearsh
ift Mechan ism

13-123
-
Overhaul
NOTE:
84 9
9 Inspect rubber parts for wear and damage when disassembling.
3
3!
-
O Check that the new cotter pin is seated firmly.
#3!-
9 Be careful not to damage the guide pipe when removing the cables.
) !

3&
!-
{ES-l Remove the shift cable from the
change Ie'IIIer bracket.
CUTTER PIN
Replace.
STE Rotate the shift

cable toward the CHANGE CABLE PLATES
opening. Replace.
.fii
En: 1.0mm [PlN41211-P‘I’5-3051
9.3 MM [1.0 kgfm.
CHAN-GE LEVER KNOB 7'2 mm

B III-m [0.8 kg‘l—m,
5.3 IbI-m corrEn PIN
Replace. SELECT CABLE
CHANGE LEVER I'. GUIDE
E I: 1.25 mm \ GUIDE PIPE

22 film l2.2 kgf-rn. STEEL WASHER
1E lbi—fll
SHlFf CABLE
t9fl\ PLAsnc WASHER
CHANGE CABLE PLATE
Replace. CUTTER PIN
' 1' .' - Replace.
FLOATING/1,_~.-;_a-- ' , SELF-LOCKING NUT
COLLAR —--.__ SELECT LINK PIN Hlace.
E 1: LI] mm
1|] N-m 11.1 kgf-m, 8 lbf-f‘tl
FLOATING RUBBER W!“ 41211 - P‘I'5 - 395i

DAMPER
Inspect for wear
[I d .
3" “age EHANGE LEVER BRACKET

Special Tools
14-2

O 1- O 4!
Tool Number O Description
( OD O 1#
Remark
if? "<
O 07GAZ - SD40101
O 0$.%I(*00 O Driver Attachment, 78 x 90 mm
(&%A$'/50 O O
_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\
O 07HAC - PK40101
O 0$6%>*00 O Housing Puller
6
!! O O
O + 07HAJ - PK40201
O 0$6%">*00 O Preload Inspection Tool
!4! O O
O * 07JAC - PH80000
O 0$"%6'0000 O Adjustable Bearing Remover Set
%7 !)
1& O O
O 07JAC - PH80100
* O 0$"%6'000 O Bearing Remover Attachment
)
1&% O O
cub—x
O 07JAC - PH80200
* O 0$"%6'000 O Remover Handle Assembly
1&6!%! O O
O 07741 - 0010201
*+ O 0$$*0000 O Remover Weight
1&2
O O
O 07JAD - PH80101
O 0$"%(6'00 O Driver Attachment, 58 mm
(&%A' O O
O 07JAD - PH80400
O 0$"%(6'0*00 O Pilot, 28 x 30 mm
!A'/+0 O O
O $ 07JAD - SH30100
O 0$"%(6+000 O Driver Attachment, 65 x 65 mm
(&%A/ O O
O ' 07LAD - PW50601
O 0$%(200 O Attachment, 40 x 50 mm
%A*0/0 O O
O 5 07LAE - PX40000
O 0$% R*0000 O Clutch Spring Compressor Set
!
O O
O 07GAE - PG40200
5 O 0$.% .*000 O Clutch Spring Compressor Bolt Assembly
!
)!%! O O
O 07HAE - PL50100
5 O 0$6% 000 O Clutch Spring Compressor Attachment
!
% O O
O 5+ 07LAE - PX40100
-3 O 0$% R*000 O Clutch Spring Compressor Attachment
!
% O O
O 0 07LGC - 0010100
O 0$.00000 O Snap Ring Pliers
1
! O O
O 07PAB - 0010000
O 0$%)000000 O Mainshaft Holder Set
,6! O O
O 07PAZ - 001 O1 00
O 0$%I00000 O SCS Short Connector
O O
O + 07406 - 0020004
O 0$*000000* O A/T Oil Pressure Gauge Set
%=48! .
O O
O * 07746 - 0010100
O 0$$*00000 O Driver Attachment, 32 x 35 mm
(&%A+/+ O O
O 07746 - 0010300
O 0$$*000+00 O Driver Attachment, 42 x 47 mm
(&%A*/*$ O O
O 07746 - 0010500
(&%A/' O O
O $ 07746 - 0010600
(&%A$/$ O O
O ' 07746 - 0030100
O 0$$*00+000 O Driver, 40 mm ID.
(&A*0-(- O O
O 5 07749 - 0010000
O 0$$*5000000 O Handle Driver
6!(& O O
‘ .ui
1-1 15 16 11' 'IB

Description
)
14_3

The automatic transmission is a combination of a 3-element torque converter and triple-shaft electronically controlled automatic
4 +!F &!!!!!!
transmission which provides 4 speeds forward and 1 reverse. The entire unit is positioned in line with the engine.
3&*3&-4 !3
-
Torque Converter, Gears and Clutches

B
-:
The torque converter consists of a pump, turbine and stator assembly in a single unit. They are connected to the engine
4F & A !
! -4

crankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter is a ring gear which
#

-% F &

3
meshes with the starter pinion when the engine is being started. The entire torque converter assembly serves as a flywheel
33

-4F &!&!3!
while transmitting power to the transmission mainshaft. The transmission has three parallel shafts: the main-shaft, the
3!
3-4!!!9A
countershaft, and the secondary shaft. The mainshaft is in line with the engine crankshaft. The mainshaft includes the 3rd and
A-4!3
#-4! +
4th clutches, and gears for 3rd, 4th, reverse and idler (reverse gear is integral with the 4th gear). The countershaft includes the
*! A
+A*A&!;&

!3*
<-4 !
final drive, lst, 3rd, 4th, reverse, 2nd, parking and idler gears (the final drive gear is integral with the countershaft). The
!&AA+A*A&AA#
!
;!&

!3 <-4
secondary shaft includes the 1st and 2nd clutches, and gears for 1st, 2nd and idler. The counter-shaft 4th gear and the
! ! A
A!-4 *

countershaft reverse gear can be locked to the countershaft at its center, providing 4th gear or reverse, depending with which
&
!# A&
*
&A
33
way the selector moved. The gears on the mainshaft and the secondary shaft are in constant mesh with those on the
3!&-4
3
countershaft. When certain combinations of gears in the transmission are engaged by the clutches, power is transmitted from
-2

! A3
the mainshaft and the secondary shaft to the countershaft to provide -,A -,A -,A
& and El-
positions.
Electronic Control
%

The electronic control system consists of the Powertrain Control Module (PCM), sensors, and six solenoid valves. Shifting and
4!!3!, !;,<AA/!&!&-

lock-up are electronically controlled for comfortable driving under all conditions. The PCM is located below the dash-board,
!# !!!!!!&
!!-4,!!3A
under the front lower panel behind the center console.
!3!!-
Hydraulic Control
.#

The valve bodies include the main valve body, the regulator valve body, the servo body and the accumulator body. They are
4&!&! &!&A
!&!&A& !-4
bolted to the torque converter housing. The main valve body contains the manual valve, the modulator valve, the shift valve C,
!F &
-4&!& !&!&A !&!&A&!&A
the shift valve D, the shift valve E, the servo control valve, the torque converter check valve, the reverse CPC valve, the lock-up
&!&(A&!& A&!&!&AF &#&!&A&&!&A!#
shift valve, the lock-up control valve, the cooler check valve and the ATF
-4
!&!&
&!&A!# !&!&A!#&!&%4 pump gears. The regulator valve body contains the
regulator valve, the lock-up timing valve and the relief valve. The servo body contains the servo valve, the shift valve A, the shift

!&!&A!#
&!&!&!&-4&&&!&A&!&%A
valve B, the CPC valves Aand B, the 3rd and 4th accumulators. The accumulator body contains the 1st and 2nd accumulators
&!&)A&!&%)A+* !-4 ! !
and the lubrication check valve. Fluid
! #&!&- from the regulator passes through the manual valve to the various control valves. The
!
!
!&!&& !&!&-4
1st, 3rd and 4th clutches receive fluid from their respective feed pipes, and the 2nd clutch receives fluid from the internal
A+*! &! &A! &! !
hydraulic circuit.
! -
Shift
Control Mechanism

The PCM controls the shift control solenoid valves A, B and C, and the NT clutch pressure control solenoid valves Aand B
4,!!!&!&%A)A%=4! !!&!&%)
while receiving input signal from various sensors located throughout the vehicle. The shift control solenoid valves shift the
3!&

!& !
&!-4!!&!&
positions of the shift valves to switch the port leading the hydraulic pressure to the clutch. The A/T clutch pressure control
&!&3!
! ! -4%=4! !
solenoid valves A and B control the CPC valves A and B to shift smoothly between lower gear and higher gear. This
!&!&%)!&!&%)!3!3

-4
pressurises a line to one of the clutches, engaging the clutch and its corresponding gear.
!! A

!

-
Lock-up Mechanism
&
6
In -,AAA+*A
position, in 2nd, 3rd and 4th, and -,A+A H! #F &
position in 3rd, pressurized fluid is drained from the back of the torque converter
through a fluid passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the

!
A
!# !
F &&-%#!A
mainshaft rotates at the same speed as the engine crankshaft. Together with hydraulic control, the PCM optimises the timing of

#-4
3 !!A,

the lock-up mechanism. When lock-up control solenoid valve activates, modulator pressure changes to switch lockup on and
!# -2!# !!&!&&A !
3!#
off. The lock-up control valve and the lock-up timing valve control the range of lock-up according to the NT clutch pressure
-4!# !&!&!#
&!&!
!#
%=4!
control solenoid valves Aand B. The lock-up control solenoid valve is mounted on the torque converter housing and the NT
!!&!&%)-4!# !!&!& F &
%=4
clutch pressure control solenoid valves Aand B are mounted on the transmission housing. They are controlled by the PCM.
! !!&!&%)
-4!!,-
Description
)
14_4

(cont’d)
/
?0
Gear Selection

The shift lever has eight positions: E,A%1>A
4!&
9 PARK, E1 : 1 A
REVERSE, lEl ?41%A
NEUTRAL, 1st through 4th gear ranges,

*

A 1st

through 3rd gear ranges,

+

A 2nd gear and

1st gear. Also manual mode has been adopted in

-%! ! position.
-
O| Position
'

O| Description
)
O
O E%1> PARK O| Front wheels locked; parking brake pawl engaged with the
3!!#N#
#3!

3 O
O O| parking gear on the countershaft. All clutches released.
#

-%!!! !- O
O O| O
O O| Reverse; reverse selector engaged with countershaft reverse
1&N&!

3 & O
O El1 : 1
REVERSE O| gear and 4th clutch engaged.

*!

- O
O O| O
O O| %!!! !-
All clutches released. O
O E ?41%
NEUTRAL O| O
O O| General driving; starts off in 1st, shifts automatically to 2nd, 3rd, O
.!&
NA !!A+A
O DRIVE
(1: O| then 4th, depending on vehicle speed and throttle position.
*A
&!!- O
O (tst through 4th; automatic shifting)
;
*N
< O| Downshift through 3rd, 2nd and 1st on deceleration to stop. The O
(3
+A!-4
O O| lock-up mechanism operates in 2nd, 3rd and 4th gear.
!# A+*
- O
O O| O
O O| Manual shifting driving; shift gears between 1st and 4th with the O
, !
&
N
3*3
O (tst through 4th; manual shifting)
;
*N !
< O: shift lever operation, much like a manual transmission. The
!&A !# !-4 O
O O transmission will automatically downshift from 4th to 3rd gear to O
3!! !!3*+

or or
or (1:
DRIVE
O O| get more power when climbing or to provide engine braking

33!
&
#
O
O O| when going down a steep hill. When the vehicle decelerates to O
3

3!!-2&!!
O O| a stop, the transmission shifts to tst gear automatically. The
A
!!-4 O
O O| lock-up mechanism comes into operation in 2nd, 3rd and 4th
!# A+* O
O O| gear

- O
O DRIVE
(1: O| O
O (18’! through 3rd)
;
+< O| For rapid acceleration at highway speeds and general driving; O
!
3
!&
N
O O| up-hill and down-hill driving; starts off in tst, shifts automatically O
!!3!!&
NA !!
O O| to 2nd, then 3rd, depending on vehicle speed and throttle
A+A
&!! O
O O| position. Downshifts through 2nd to tst on deceleration to a
-(3
! O
O O| stop. The lock-up mechanism operates in 2nd and 3rd gear.
-4!# +
- O
O SECOND
8( O| O
O O| Driving in 2nd gear; stays in 2nd gear, does not shift up and
(&

N
A O
O O| down. For
3- engine braking or better traction starting off on loose O

#

!
O O| slippery surface.
! - O
O O| O
14
O FIRST O| Driving in tst gear, stays in 1st gear, does not shift up. For
(&

A
A - O
O O| engine braking.

#
- O
Starting is possible only in El

!! and E
!A !3-
positions through use of a slide-type, neutral-safety switch.
Automatic Transaxle (AIT) Gear Position Indicator

/20'

A/T gear position indicator in the instrument panel shows what gear has been selected without looking down at the console.
%=4
!33
!3 !#
3!-
With the shift lever in the ,
2!&A position manual shifting mode, the indicator light next to the
!
A!
/ indicator light in the instrument
!

panel will display the gear selected.
!3!!!
!-
Description
)
14-5
(cont’d)
/
?0
3
Egg: ESPWEHTEFI LOCK-UP CONTROL SDLENQID

VALVEISHIFI' CONTROL SOLENOID
VALVE A. ASSEMBLY
2ND CLU TCH
PRESSURE SWITCH
1ST CLUTCH
SHIFT CONTROL
SOLENOID VALUE E
SHIFT CD MTFDL
SOLENOID VALVE C
3RD CLUTCH
DIFFERENTIAL
ASSEMBLY 4TH CLUTCH
2ND CLUTCH
AIT CLUTCH PRESSURE

CONTROL SOLENOID
VALVE AI'B ASSEMEL‘I’
SECONDARY SHAFT
MAINSHAFI' SPEED
SENSOR
NT G EAR PDSITII’JN MAINSHAFT

SWITCH
can NTEFIQ HAF‘I'
Description
)
14_6
5
Clutches

The four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gear.
4 !!! !

-
When hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This presses the friction discs and steel
2 ! ! A! &-4!
plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch pack to it hub-mounted
!
A!#
@!-3

! #
gear. Likewise, when the hydraulic pressure is bled from the clutch pack, the piston releases the friction disc: and the steel
-#3A3 ! !! #A!9!
plates, and they are free to slide past each other. This allows the gear to spin independently on its shaft transmitting no power.
!A!-4!!3
!
3-
1st Clutch

The 1st clutch engages/disengages ist gear, and is located at the middle of the secondary shaft. The 1st clutch is joined
4!

=

A!!-4! 7
back-to-back to the 2nd clutch. The 1st clutch is supplied hydraulic pressure by its ATF 3
##! -4! ! ! %4 feed pipe within the secondary shaft
2nd Clutch

The 2nd clutch engages/disengages 2nd gear, and is located at the middle of the secondary shaft. The 2nd clutch is joined
4!

=

A!!-4! 7
back-to-back to the 1st clutch. The 2nd clutch is supplied hydraulic pressure through the secondary shaft by a circuit connected
##! -4! ! !

to the internal hydraulic circuit.
! ! -
3rd Clutch

The 3rd clutch engages/disengages 3rd gear, and is located at the middle of the mainshaft. The 3rd clutch is joined
4+!

=

+
A!!-4+! 7
back-to-back to the 4th clutch. The 3rd clutch is supplied hydraulic pressure by its ATF 3-
##*! -4+! ! ! %4 feed pipe within the mainshaft.
4th
Clutch
The 4th clutch engages/disengages 4th gear, as well as reverse gear, and is located at the middle of the mainshaft. The 4th
4*!

=

*
A3!!&
A!!-4*
clutch is joined back-to-back to the 3rd clutch. The 4th clutch is supplied hydraulic pressure by its ATF 3
! 7##+! -4*! ! ! %4 feed pipe within the
mainshaft.
-
Description
)
14_7
7
Clutches
(cont’d)
/
?0
ATF PUMP MAINS HAFI'

MAINSHAFI'
DRIVEN GEAR 3RD GE A R
4TH GEAR
RING GEAR
3RD CLUTCH COUNTERSHAFI'
4TH GEAR
TGRDUE CONVERTER 4TH CLUTCH
MAINSHA FT
REVERSE G EAR
LOCK- U P PISTON
MAINSHAFT IDLER GEAR
PITOT FLANGE
LUBRICATIDN
PITOT PIPE
MAIN SHAFT
PITOT PIPE
REVERSE
SELECTOR
.I! II
REVERSE
DRIVE PLATE-FF”; 1.? " SELECTOR HUB
COUNTERSHAT-‘l'
' _—fi‘\ CDUNTERSHAFI'
FINAL DRIVE
In. ;. 71, _ IDLER GEAR
GEAR
PARKING GEAR
CUUNTERSHAFT CO U NTERS HAFI'
3RD GEAR 2ND GEAR
COUNTERS HAF'I'
CDUNTERSHAFT
REVERSE GEAR
IST GEAR
SECONDARY SHAFT
SECONDARY SHAFT
IDLER GEAR
SECONDAR'Vr SHAFT
2ND GEAR
2ND CLUTCH
IST CLUTCH
SEED NDAR Y 5H A FT
‘IST GEAR
DIFFERENTIAL
ASSEMBLV FINAL DRIVEN
GEAR
Description
)
14_8
8
'
(+
(
Power Flow
Rx PART TORQUE TSTGEAH 2ND GEAR 3RD GEAR 4TH REVERSE PARKING
POSITION CONVERTER 1ST CLUTCH 2ND CLUTCH 3RD CLUTCH GEAR . CLUTCH GEAR GEAR
{j- x x x x I x x D
SEE
x x C:- C- x
(“I
”£3- x x x r. 'x: x 3:.
2ND C? x: CI >: x X x. x
3R D I: 3' N-r. 1. LT)- :x: .v >r. ; x
4TH {3: )1 x x C: Ch )1 ' x.

19;; 1ST C} CI: 3:. x x x: x —--v——-- x _ - -- -
2ND -:I_II- x: {LI 2: x x x 5-:
3R D C3 x .X [3' x :z: x . x
[1] L'i- I x I {'3 - x xI V: I I .. >6. 1 x
:j_j:- If) 'x x x x. x 'x
CI: Operates
KI Doesn't operate
Gear Operation

Gears on the mainshaft:
.9
¢ The 3rd gear is engaged/disengaged with the mainshaft by the 3rd clutch.
4+

=

3+! -
¢ The 4th gear is engaged/disengaged with the mainshaft by the 4th clutch.
4*

=

3*! -
¢ The reverse gear is engaged/disengaged with the mainshaft by the 4th clutch.
4&

=

3*! -
¢ The idler gear is splined with the mainshaft and rotates with the mainshaft.
4!
!33-
Gears on the countershaft:
. 9
¢ The final drive gear is integral with the countershaft.
4!&

!3 -
¢ The 1st gear, 3rd gear, 2nd gear and parking gear are splined with the countershaft, and rotate with the countershaft.
4
A+
A
#

!3 A3 -
¢ The 4th gear and reverse gear rotate freely from the countershaft. The reverse selector engages the 4th gear or the
4*
&
! -4&!

*

reverse gear with the reverse selector hub. The reverse selector hub is splined with the countershaft so that the 4th gear
&
3&! -4&! !3 *

or reverse gear engage with the countershaft.
&

3 -
¢ The idler gear rotates freely from the countershaft.
4!
! -
Gears on the secondary shaft:
.9
¢ The 1st gear is engaged/disengaged with the secondary shaft by the 1st clutch.
4

=

3! -
¢ The 2nd gear is engaged/disengaged with the secondary shaft by the 2nd clutch.
4

=

3! -
¢ The idler gear is splined with the secondary shaft and rotates with the secondary shaft.
4!
!33-
Description
)
14_9
9
Power Flow (cont’d)
'
(+
(/
?0
El'

Position
Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft is locked by
6 ! !! -3 -4 !#
the parking brake pawl interlocking the parking gear.
#
#3!!#
#

-
E'

Position
Engine power transmitted from the torque converter drives the mainshaft idler gear and the secondary shaft idler gear, but

3F &&!
!
A
hydraulic pressure is not applied to the clutches. power is not transmitted to the countershaft. the countershaft 4th gear is
! !! -3 - *

engaged with the reverse selector hub and the countershaft by the reverse selector when the shift lever is shifted in E

3&! &!3!&
position from
position. The countershaft reverse gear is engaged when shifted from El-
-4 &

3 position.
TDRDUE CONVERTER
3RD CLUTCH 4TH CLUTCH
MAIHSHAFT IDLER GEAR
. MAINSHAFI'
J! ' _-‘
' COUNTERSHAFI'
IDLER GEAR
COUNTERSHAFT
SECONDARY SHAFT
SECONDARY SHAFT
IDLER GEAR
, . " l
[ J 2ND CLUTCH
'] IST CLUTCH
“a
L
EEHNAL DRIVEN GEAR
Description
)
14_1 0
$
'
(+
(/
?0
In
or
position, the optimum gear is automatically selected from the ist, 2nd, 3rd and 4th gears, according to
A
!!!AA+*
A

conditions such as the balance between the throttle opening (engine loading) and vehicle speed.
!3!
;
!
<&!-
or

Position in 1st gear and
'

! Position
'

1.
- Hydraulic pressure is applied to the 1st clutch, then the ist clutch engages the secondary shaft 1st gear with the
6 ! !! A!

3
secondary shaft.
-
2.
- The mainshaft idler gear drives the secondary shaft via the countershaft idler gear and secondary shaft idler gear.
4!
&& !
!
-
3.
+- The secondary shaft 1st gear drives the countershaft 1st gear and the countershaft.
4
&
-
4
*- Power is transmitted to the final drive gear, which in turn drives the final driven gear.
3!&
A3 &!&
-
TORQUE CONVERTER
CDUNTERSHAFI' MAINSHAFT IDLER GEAR
‘IST GEAR
MAINSHAFT
COUNTERSHAFI’
IDLER GEAR
COUNTE RSHAFI'
SECONDM‘I’ SHAFT
SECONDARY SHAFT
FINAL DRIVE GEAR IDLER GEhR
1ST CLUTCH
SECONDARY SHAFT
'IST GEAR
FINAL DRIVEN G EAR

Description
)
14_11

'
(+
(/
?0
or

Position in 2nd gear and
'

! Position
'

1.
- Hydraulic pressure is applied to the 2nd clutch, then the 2nd clutch engages the secondary shaft 2nd gear with the
6 ! !! A!

3
secondary shaft.
-
2.
- The mainshaft idler gear drives the secondary shaft via the countershaft idler gear and secondary shaft idler gear.
4!
&& !
!
-
3.
+- The secondary shaft 2nd gear drives the countershaft 2nd gear and the countershaft.
4
&
-
4
3!&
A3 &!&
-
TDREIUE CONVERTER
COUNTERS-RAFT MAINSHAFI' IDLER GEAR

AK 2ND GEAR
\
‘3‘".
‘! l
I MAINSHAFT
COUNTERSHAFI'
IDLER GEAR
COUNTERSHAFT
SECONDARY SHAFT
FINAL DRIVE GEAR
J1 _ _ .. - -
—r_ J "J aasacononnv SHAFT
IDLER GEAR
—A RI; SECONDARY SHAFT

2ND GEAR
2ND CLUTCH
FINAL DRIVEN GEAR

Description
)
14_1 2

'
(+
(/
?0
or

Position in 3rd gear
'

!
1.
- Hydraulic pressure is applied to the 3rd clutch, then the 3rd clutch engages the mainshaft 3rd gear with the mainshaft.
6 ! !+! A+!

+
3-
2.
- The mainshaft 3rd gear drives the countershaft 3rd gear and the countershaft.
4+
& +
-
3.
+- Power is transmitted to the final drive gear, which in turn drives the final driven gear.
3!&
A3 &!&
-
TOHDUE CONVERTER
MAIHSHAFT 3RD CLUTCH
3RD GEAR
xg [fig—2E j MAINSHAFT
—* _
c l
CDUNTERSHAFT
Lk
yd
»§
‘
I SECONDARV SHAH
FINAL DRIVE GEAR L-r—l

f—E_
l—l
‘
rr‘
.. _'__
WM t
3
CDU NTEHSHAF‘I’
3RD GEAR
FlNAL DRIVEN GE AH
Description
)
14_1 3

'
(+
(/
?0
Position in 4th !

'

gear
1.
- Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft 4th gear while the
6 ! !&&!&

&!3 *
3!
shift lever is in the forward range -,A -,A
!&3
and
position).
<-
2.
- Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft 4th gear with the mainshaft.
6 ! !!*! A*!

*
3-
3.
+- The mainshaft 4th gear drives the countershaft 4th gear, which drives the reverse selector hub and the countershaft.
4*
& *
A3&&! -
4
3!&
A3 &!&
-
TORQUE CONVERTER
4TH CLUTCH
MAINSHAFr
4TH GEAR
L__
;- --- _ MAINSHAFI'
CDUNTERSHAFT
-—-> IDLEB GEAR
COUNTERSHAFT
SECONDARV SHAFT
IDLE R GE an
r" ' t , seconnnnv SHAFT
FINAL DRlV-I'E GEAR

:‘fll
REVERSE SELE CTOR HUB
REVERSE
SELECTOR
COUNTERSHAFI'
‘TH GEAR
FINAL DRIVEN GEAR

Description
)
14-14

'
(+
(/
?0
Position
El
1.
- Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft reverse gear while
6 ! !&&!&

&!3 &
3!
the shift lever is in the El-
!& position.
2.
- Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft reverse gear with the
6 ! !!*! A*!

&
3
mainshaft.
-
+- The mainshaft reverse gear drives the countershaft reverse gear via the reverse idler gear.
4&
& &
&&!
-
919.00
*- The rotation direction of the countershaft reverse gear is changed via the reverse idler gear.
4 &

&&!
-
- Power is transmitted to the final drive gear, which in turn drives the final driven gear.
3!&
A3 &!&
-
TORQUE CONVERTER
MMNSHAFI'
4TH CLUTCH
REVERSE GE AR
MMNSHAFT
CDUNTERSHAFT
iDLER GEAR
COUNTERSHAFT
Detailed View of Rum. Gun
MAINSHAl-‘l'
REVERSE GEAR
REVERSE
IDLER GEAR
REVERSE
SELECTOR HUB
I | REVERSE SELECTOR
i COUNTERSHAI-T
FINAL DRIVEN GEAR :—-’
. ".— J
‘\ REVERSE GEAR
SERVE! VhLVE SHIFT FORK

Description
)
3
14-15
Electronic Control System
%

#
Electronic Control
%

The electronic control system consists of the Powertrain Control Module (PCM), sensors and six solenoid valves. Shifting and
4!!3!, !;,<A/!&!&-

lock-up are electronically controlled for comfortable driving under all conditions. The PCM is located below the dashboard,
!# !!!!!!&
!!-4,!!3A
under the front lower panel behind the center console.
!3!!-
PCM
Throttle Position Sen sor

Signal .__._.. PGM.F} Data Link Connector
Control System
AIT
Engine Coolant Tern paraturo Control System
Sensor Signal Sen-lice Cheek Connector
Manifold Absolute Pressure

Sensor Signal Bra ko Switch Signal
Interlock Control Signal - I Shit-t Control

Solenoid Valve A
Shift Control
Solenoid Valve B
MU LTIPLEX
CONTROL
\f
UNIT Fl Shift Control

iDRlVER'Sl Solenoid Valve '3
Shift comm. . Automatic Transaxle Clutch

r Pressure Control Solenoid
Valve A
: "i- + stun
£1 mmcnron D4 - Automatic Transaxle Clutch
-
w
Manual Mode Pressure Control Solenoid

Valve 8
03
2nd Clutch Pressure
\J
\J
Switch
3rd Clutch Pressu re

N...)
\J
Switch
Mode Switch 5 Lock-up Control Lock-up Control

. Solenoid Valve
Shift Switch i+i-] Mainshaft Speed Sensor

Signal
Countetshai't Speed
D- indicator Light
Sensor Sig nal
Self-Diagnosis Signal 5°”‘9ia9m‘i5 CRUISE coNTRoL UNIT

Functlon
Description
)
14_1 6
5
Electronic Control System (cont’d)
%

#/
?0
Shift Control
!
Shifting is related to engine torque through the NT clutch pressure control solenoids which are controlled by the PCM. The

!
F
%=4! !!3!!,-4
PCM instantly determines which gear should be selected by various signals sent from sensors, and actuates the shift control
,!3
!!&
!A !
solenoid valves A, B and C to control shifting. Also, a Grade Logic Control System has been adopted to control shifting in
!&!&%A)!
-%!A.
!!

and
while the vehicle is ascending or descending a slope, or reducing speed.
3!&!

!A
-
The combination of driving signals to shift control solenoid valves A, B and C is shown in the table below.
4&

!!!&!&%A)3!!3-
O Position
'

O| Gear position

OI Shift
control solenoid valves

-- O
O O O A O "B O c O
O .1 A O Shifting from iEi

position O ON
8 O ON
8 O 8 ON O
O O O O O O
O
O
-, A O
O
Stays in 1st
O
O
OFF
8 O
O
ON
8 O
O
ON
8 O
O
O
O
-, A
O
Shifting gears between lst and 2nd
O

3 O
O
ON
8 O
O
ON
8 O
O
ON
8 O
O
O
O
-, A
O
Stays in 2nd
O O
O
ON
8 O
O
ON
8 O
O
OFF
8 O
O
O
O
-, A
O
Shifting gears between 2nd and 3rd
O

3+ O
O
ON
8 O
O
OFF
8 O
O
OFF
8 O
O
O
O
-, A
O
Stays in 3rd
O + O
O
ON
8 O
O
OFF
8 O
O
ON
8 O
O
O Shifting gears between 3rd and 4th
O

3+* O OFF
8 O OFF
8 O ON
8 O
EEEEIHEE
O O O O O O
O Stays in 4th
O * O OFF
8 O OFF
8 O OFF
8 O
O O O O O O
O 2nd
O O ON
8 O ON
8 O OFF
8 O
O O O O O O
O 1 ist
O O OFF
8 O ON
8 O ON
8 O
O O O O O O
O O

Shifting from iii
and iii
position O OFF
8 O ON
8 O ON
8 O
O O O O O O
O Stays in reverse
O & O OFF
8 O ON
8 O OFF
8 O
O O O O O O
O Parking
O #
O OFF
8 O ON
8 O OFF
8 O
O O O O O O
O O !
Neutral O 8
OFF O 8
ON O 8
OFF O
O O O O O O

Manual mode
In
position with sliding the shift lever to the manual mode position, the driver can use the shift lever to shift gears up and
3!
!& !A& !&

down; much like a manual transmission.
3N !# !-
¢ Pushing the shift lever toward the "+" mark: Transmission upshifts to the next higher gear.

!&3ZVZ#94 /

-
¢ Pulling the shift lever toward the "-" mark: Transmission downshifts.
!!
!&3ZZ#943-
The number of the selected gear is displayed in the shift indicator next to the
4 !
!/ indicator.
-
The transmission does not automatically upshift and downshift, and remains in the selected gear position (4th, 3rd 2nd and
4 !! 3A!
;*A+
1st). However, the transmission will automatically downshift as follows:
<-63&A3!! !!3!!39
¢ Downshift from 4th gear to 3rd gear to get more power when climbing or to provide engine braking when going down a
(3*
+

33!
&
#
3

3
steep hill.
!!-
¢ Downshift to 1st gear when the vehicle comes to stop.
(3
3&!-
To prevent engine over-revving, the transmission has 4-3, 3-2 and 2—1 downshift allowable speeds. When the vehicle is
4&
&&&
A*+A+3!!3!-2&!
coasting over the 4-3 downshift allowable speed, 3-2 downshift allowable speed and 2—1 downshift allowable speed, the PCM

&*+3!!3!A+3!!3!3!!3!A,
does not input the downshift signal from the shift switch, and the transmission does not downshift. When the vehicle is coasting
3
!3A3-2&!

over the 4-3 downshift allowable speed in 4th gear, and the 3-2 downshift allowable speed in 3rd gear, the PCM inputs the
&*+3!!3!*
A+3!!3!+
A,
signal to wait until it reaches the downshift allowable speed, then the shift indicator blinks to indicate the lower gear position

!3 !3!!3!A!#!3

several times.
&!-
Description
)
14_17
7
%

#/
?0
Lock-up Control
&
6

The lock-up control solenoid valve controls the modulator pressure to switch the lock-up shift valve and lock-up ON and OFF.-
4!# !!&!&! ! 3!# &!&!# 88
The PCM controls the lock-up control solenoid valve and the NT clutch pressure control solenoid valves Aand B. When the
4,!!# !!&!&%=4! !!&!&%)-2
lock-up control solenoid valve is turned ON, the condition of lock-up starts. The A/T clutch pressure control solenoid valves A
!# !!&!& 8A!# -4%=4! !!&!&%
and B regulate the NT clutch pressure control solenoid pressure, and apply pressure to the lock-up control valve and the
)
!%=4! !! A! !# !&!&
lock-up timing valve. The lock-up control mechanism operates in 2nd, 3rd and 4th gear
!#
&!&-4!# !A+*
position, and in 3rd gear, in
A+
A
position.
-
Grade Logic Control System

&
!

#
How it works:
.
( (
6F
The PCM compares actual driving conditions with memorized driving conditions, based on the input from the vehicle speed
4, !&
3H&
A &!
signal, the throttle position sensor, the engine coolant temperature sensor, the brake switch signal, and the shift lever position

!A!A
! A#3
!A!&
signal, to control shifting while the vehicle is ascending or descending a slope, or reducing speed.

!A!
3!&!

!A
-
SENISDHS SIGNALS DETEETED PCM
Cou ntershaft Speed

Sensor
J Judgement of Controlling Area
aottlc Position
Driving Resistance
Sensor
Driving Co ndifian 5
Calculation Demmmn M Calculation

standard
of actual accelwatim of decelera-
acceleratlon (in Mummfl tlnn
Engine Coolant
Co Dial M Tempe-stare
Temperature Sensor
Calculation of gradient
AH Gear Position
:00: or .03. Position l
SWItcr
I Selection of Slllling Muuu
l
- Normal Mode [Flat rnnrl mndel

- Asculdillg Mudu
- Gradual ascending mode
- Medium ascending mode
- Semi-steep ascending made
- Steep ascending mode
. Descending Mode
. Gradual descending mode
- Steep descending mode
- Domination Mode
Ammuatie 4 Spends
Description
)
14_1 8
8
%

#/
?0
Ascending Control
!

When the PCM determines that the vehicle is climbing a hill in
2,&!!
!! and
positions, the system extends the engagement
A/

area of 2nd gear and 3rd gear to prevent the transmission from frequently shifting between 2nd and 3rd gears, and between

+
&F !
3+
A3
3rd and 4th gears, so the vehicle can run smooth and have more power when needed.
+*
A&! &33-
NOTE:
84 9
¢ Shift schedules stored in the PCM between 2nd and 3rd gears, and between 3rd and 4th gears, enable the PCM’s fuzzy
!,3+
A3+*
A!,B HH
logic to automatically select the most suitable gear according to the magnitude of a gradient.
!
!!! !

-
¢ Fuzzy logic is a form of artificial intelligence that lets computers respond to changing conditions much like a human
HH!
!!!
!

!#
1mm-
4TI-l ASCENDING MODE: Upshifl Schedule
Throttle opening
— : FLAT ROAD MODE

--------- : GRADUAL ASCEMDING MODE
:
an
— — — - :SEMI-S‘I'EEP ASCENDING MODE

: STEEP ASCENDING MODE
: 2ND-3RD SHIFTING CHARACTERISTICS
HE
CONTROL AREA
: 3RD-4TH SHIFTING CHARACTERISTICS
DONTROL AREA
62 I'I'Ilph Vehicle spud

“00 kmlhl
Descending Control
) !

When the PCM determines that the vehicle is going down a hill in
2,&!

3!! and
positions, the shift-up speed from 3rd to 4th
A +*
gear and from 2nd to 3rd (when the throttle is closed) becomes faster than the set speed for flat road driving to widen the 3rd
+;3!!<!&
3+
gear and 2nd gear driving areas. This, in combination with engine braking from the deceleration lock-up, achieves smooth

&
-4A3
#
!!# A&
driving when the vehicle is descending. There are three descending modes with different 3rd gear driving areas and 2nd gear
&
3&!
-4
3+
&

driving areas according to the magnitude of a gradient stored in the PCM. When the vehicle is in 4th gear, and you are
&

,-2&!*
A
decelerating when you are applying the brakes on a steep hill, the transmission will downshift to 3rd gear. When you
!
3 !
#!!A3!!3+
-2
accelerate, the transmission will then return to higher gear.
!A3!!

-
DESCENDING MODE: Downshifi Schedule
: FLAT ROAD MODE

Throttle opening
--------- : GRADUAL DESCENDING MODE

- — —- - : STEEP DESCENDING MODE
T52 rn-ph Vehicle speed

(100 kmfhl
Deceleration Control
)

When the vehicle goes around a corner, and needs to decelerate first and then accelerate, the PCM sets the data for
2&!
A!!A,
deceleration control to reduce the number of times the transmission shifts. When the vehicle is decelerating from speeds
!! -2&!!

above 27 mph (43 km/h), the PCM shifts the transmission from 4th to 2nd earlier than normal to cope with upcoming
&$;*+#=<A,*!!3

!-
acceleration.
)

Description
%

#/
?0
14-19
9
PCM Circuit Diagram and Terminal Locations
' ) ! &

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Description
)
14_20
$
Hydraulic Control
.#

Hydraulic Control
.#

The valve body includes the main valve body, the regulator valve body, the servo body and the accumulator body. The ATF
4&!&! &!&A
!&!&A& !-4%4
pump is driven by splines on the right end of the torque converter which is attached to the engine. Fluid
&!
F &3
- flows through the
! !3

regulator valve to maintain specified pressure through the main valve body, to the manual valve directing pressure to each of

!&!&
&!&A !&!&

the clutches. The shift control solenoid valves B and C mounted on the outside of the torque converter housing. The shift
! -4!!&!&) F &
-4
control solenoid valve Aand the lock-up control solenoid valve are mounted on the torque converter housing as an assembly.
!!&!&%!# !!&!& F &
!-
The A/T clutch pressure control solenoid valves Aand B are mounted on the transmission housing.
4%=4! !!&!&%)
-
MT CLUTCH PRESSURE CONTROL 3RD CLUTCH
SOLENOID VALVE AIB PRESSURE SWITCH
ASSEMBLY
SERVO BUD‘I’
REGULATOR VALVE BODY
MAIN VALVE BDD‘I"
SHlFT CONTROL SOLENOID

VALVE C
SHIFI' CONTROL SOLENOID

VALVE B
ACCUMULATOR BODY
2ND CLUTCH
LOCK-UP CONTROL $OLENOID PRESSURE $WITCH
VALVEISHIFI' CONTROL $DLENDID
VALVE A ASSEMBLY
Description
)
_

Hydraulic Control (cont’d)
.#

/
?0 14 21
Main Valve Body

4-"
#
The main valve body contains the manual valve, the modulator valve, the shift valve C, the shift valve D, the shift valve E, the
4&!& !&!&A !&!&A&!&A&!&(A&!& A
servo control valve, the torque converter check valve, the reverse CPC valve, the lock-up shift valve, the lock-up control valve,
&!&!&AF &#&!&A&&!&A!# &!&A!# !&!&A
the cooler check valve, and the ATF
-4 &!&3!
!#&!&A%4 pump gears. The primary function of the main valve body is to switch fluid pressure on and
off to control hydraulic pressure going to the hydraulic control system.
! !

!!-
SHIFT VALVE E SHIFT VALVE D MODULATOR VALVE
TORQUE CONVERTER
CHECK VALVE sun—1 VALVE c
LOCK-UP SHIFT VALVE

REVERSE CFC VALVE
MAIN VALVE BODY
LOCK-UP CONTROL VALVE
COOLER CHECK VALVE

SERVO DONTHOL VALVE MANUAL VALVE
Regulator Valve Body
!
4-"
#
The regulator valve body is located on the main valve body. The regulator valve body contains the regulator valve, the lock-up
4
!&!&!&!&-4
!&!&
!&!&A!#
timing valve and the relief valve.

&!&!&!&-
REGULATOR VALVE
RELIEF VALVE
REGULATOR VALVE BODY
LOCK-UP TIMING VALVE

Description
)
_

.#

/
?0 14 22
Regulator Valve
!
4-
The regulator valve maintains a constant hydraulic pressure from the ATF !!A3!!
4
!&!& ! %4 pump to the hydraulic control system, while also
furnishing fluid to the lubricating system and torque converter. The fluid from the ATF !3
))@-

! !
F &-4! %4 pump flows through B and B'. Fluid
!
entering from B flows through the valve orifice to the A cavity. This pressure of the A cavity pushes the regulator valve to the

)!3
&!&%&-4 %&
!&!&
right side, and this movement of the regulator valve uncovers the fluid port to the torque converter and the relief valve. The fluid

A&
!&!& &! F &!&!&-4!
flows out to the torque converter and the relief valve, and the regulator valve moves to the left side. According to the level of the
!3 F &!&!&A
!&!&&!-%
!&!
hydraulic pressure through B, the position of the regulator valve changes, and the amount of fluid from B' through torque
!
)A
!&!&
A ! )@
F
converter also changes. This operation is continued, maintaining the line pressure.
&!
-4 A
! -
NOTE: When used, "left" or "right" indicates direction on the illustration below.
84 92 AZ!ZZ
Z!! !3-
From ATF PUMP
To TORDUE CONVERTER 1 To LUBHICATI'DN
l
'III'ALVE
OHIFICE
REGULATOR VALVE
Stator Reaction Hydraulic Pressure Control

.# '

Increases in hydraulic pressure according to torque are performed by the regulator valve using stator torque reaction. The
!
F
!&!&
F -4
stator shaft is splined with the stator in the torque converter, and its arm end contacts the regulator spring cap. When the
!3F &A
!
-2
vehicle is accelerating or climbing (Torque Converter Range), stator torque reaction acts on the stator shaft, and the stator arm
&!!
!
;4F &1
<AF A
pushes the regulator spring cap in the direction of the arrow in proportion to the reaction. The stator reaction spring

!
3-4

compresses, and the regulator valve moves to increase the line pressure which is regulated by the regulator valve. The line
A
!&!&&! 3
!
!&!&-4!
pressure reaches its maximum when the stator torque reaction reaches its maximum.
/ 3F / -
TORQUE EDNVERTER STATUE
REGULATOR VALVE EDDY
REGULATOR VALVE
STATOR SHAFT ARM
REGULATOR SPRING CAP
STATUE SHAFT
Description
)
_

.#

/
?0 14 23
Servo Body
-
"
#
The servo body is on the main valve body. it contains the servo valve, the shift valve A, the shift valve B, the CPC valves A and
4&&!&-&&!&A&!&%A&!&)A&!&%
B, the 3rd and 4th accumulators.
)A+* !-
Accumulator Body

"
#
The accumulator body is on the torque converter housing, next to the main valve body. It contains the 1st and 2nd
4 !F &
A/&!&-
accumulators and the lubrication check valve.
!! #&!&-
CFC VALVE A
SERVO BODY CFC VALVE B
SHIFT VALVE B
SERVO VALVE
SHIFT VALVE A
(TH ACCUMULATOR PISTON

3H0 ACCUMULATOR PISTON
ACCUMULATOH BODY SERVO BUD‘I’
LU BRICATION CHECK VALVE
1ST AOCUMULATDH PISTON

)

Description
Hydraulic Flow
.# +
(
14-24

Hydraulic Flow
.# +
(
As the engine turns, the ATF -% ! ;%4
%
A%4 pump starts to operate. Automatic transmission fluid (ATF)<3
%4
is drawn through the ATF
strainer
(filter) and discharged into the hydraulic circuit. Then, ATF !3
%4
;!<
! -4A%4 flowing from the ATF ! @
!
pump becomes line pressure that's regulated
by the regulator valve. Torque converter pressure from the regulator valve enters the torque converter through the lock-up shift

!&!&-4F &
!&!&F &
!#
valve, and it is discharged from the torque converter. The torque converter check valve prevents torque converter pressure
&!&A
F &-4F &#&!&&F &
from rising.

-
The PCM controls the shift control solenoid valves ON and OFF,A!!&!&!!
4,!!!&!&88 and the shift control solenoid valves apply shift control
solenoid pressure to the shift valves. Applying shift control solenoid pressure to the shift valves moves the position of the shift
! &!&-%!
!! &!&&
valve, and switches the port of hydraulic pressure. The PCM also controls A/T clutch pressure control solenoid valves Aand B.
&!&A3 ! -4,!!%=4! !!&!&%)-
The A/T clutch pressure control solenoid valves regulate A/T clutch pressure control solenoid pressure and apply A/T clutch
4%=4! !!&!&
!%=4! !! !%=4!
pressure control solenoid pressure to CPC valves Aand B.
!! &!&%)-
When shifting between upper gear and lower gear, the clutch is engaged by pressure from the CPC pressure mode. The PCM
2
3
!3
A!

-4,
controls one of the shift control solenoid valves to move the position of the shift valve. This movement switches the port of the
!!!&!&&&!&-4&3
CPC and line pressure. Line pressure is then applied to the clutch, and CPC pressure is intercepted. Engaging the clutch with
! - !! A -

! 3
line pressure happens when shifting is completed.
! 3
!-
Hydraulic pressure at the ports are as follows:
6 ! !!39
PORT NO. DESCRIPTION OF PRESSURE IFORT NO.’ DESCRIPTION OF PRESSURE PORT NO. DESCRIPTION OF PRESSURE
1 LINE 5H I CFC El nr'L'I'NE" ' ER
iSJ I CFC Bur LINE ' LS A 0: LS B
TOROUE CONVERTER
l
5K P CFC B Or LINE
5K' CFC B or LINE ' TOROUE CONVERTER
LC!
C!
5- I .___— __.
TORQUE CONVERTER
SA . TOROLIE FofiVis—RT—E? '
TORQUE CONVERTER
IA'_I' CFC A ATF COOLER
43 _I CFCB I TORQUE CONVERTER
CFC A ' LINE LUBRICATION
CFC a _ ._ “1—5? CLO TCH A LUERICATION
53 ‘ CFC ROI-LINE” 20 ' 2ND CLUTCH ‘ TOROUE CONVERTER
CFC A or LINE 25 I LINE _ ' ' TORQUE CONVERTER—m
CFC A or LINE—mm 30 ' 3RD CLOTCIJ' I SUCTION ' __
5F‘ CFC A CII’ LINE A0 E ATHmCLUTCH' x DRAIN
CFC ElCr LINE A1 HX ' HIGH FOSITION ORI—Afiw
CFC a or LINE 55 iLSA Ax AIR DRAIN __
NOTE:
84 9
’ CPC: Clutch Pressure Control pressure
9! !
69!!
SH: Shift Control Solenoid pressure
.QO
LS: A/T Clutch Pressure Control solenoid pressure

9%=4! !!
LC: Lock-up Control Solenoid pressure
9# !!
Description
)
_
Hydraulic Flow (cont’d)
.# +
(/
?0
3
14 25
E'

Position
The PCM controls the shift control solenoid valves. The conditions of the shift control solenoid valve and positions of the shift
4,!!!&!&-4!!&!&
valve are as follows:
&!&!!39
¢ Shift control solenoid valve A is turned OFF,A&!&%&!-
!!&!&% 8 and the shift valve A is moved to the left side.
¢ Shift control solenoid valve B is turned ON, and the shift valve B remains in the right side.
!!&!&) 8A&!&)
-
¢ Shift control solenoid valve C is turned OFF,A&!&!-
!!&!& 8 and the shift valve C remains in the left side.
Line pressure (1) passes through the manual valve and stops at the shift valve D. Line pressure (1) also flows to the modulator
;<
!&!&&!&(- ;<!!3 !
valve, and becomes modulator pressure (6). Modulator pressure (6) flows to the shift control solenoid valves and the NT clutch
&!&A ! ;<-, ! ;<!3!!&!&%=4!
pressure control solenoid valves. Under this condition, hydraulic pressure is not applied to the clutches.
!!&!&-?A ! !! -
NOTE: When used, “left" or "right” indicates direction on the hydraulic circuit.
84 92 AK!LK
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14 26
'

Position
1.
- lst gear at shifting from E

position
The PCM turns shift control solenoid valves Aand C ON when shifting to
4, !!&!&%83

position from E!!&!&)
Shift control solenoid valve B
remains ON. Shift control solenoid valve C is turned ON, and SH C pressure (SC) in the right side of shift valve C is released,
8-!!&!& 8A6 ;<
&!&!A
then shift valve C is moved to the right side. Shift control solenoid valve A is turned ON, and SH A pressure (SA) in the left side
&!&&
-!!&!&% 8A6% ;%<!
of shift valve A is released, then shift valve A is moved to the right side. The A/T clutch pressure control solenoid valve A
&!&%!A&!&%&
-4%=4! !!&!&%
regulates LS A pressure (56), and applies it to the CPC valve A. Line pressure (1) becomes line pressure (4) at the manual

!% ;<A!&!&%- ;<! ;*< !
valve, and flows to the shift valve C and the CPC valve A. Line pressure (4A) becomes CPC A pressure (4A) and passes
&!&A!3&!&&!&%- ;*%<% ;*%<
through the shift valve C, Aand B, then CPC A pressure (4A) becomes lst clutch pressure (10) at shift valve B. lst clutch

&!&A%)A% ;*%<! ;0<&!&)-!
pressure (10) is applied to the 1st clutch, then the 1st clutch is engaged with pressure of the CPC pressure mode. Line
;0<!! A!

3 -
pressure (4) passes through shift valve Aand B, and stops at shift valve B.
;*<
&!&%)A&!&)-
84 92 AK!LK
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Description
)
_
.# +
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7
14 27
2.
- Driving in 1st gear
(&

The PCM turns shift control solenoid valve A OFF,A !!&!&)8-6% ;%<
4, !!&!&%8 but shift control solenoid valves B and C remain ON. SH A pressure (SA) is
applied to the left side of shift valve A, then shift valve A is moved to the left side. This movement switches the port of line
!!&!&%A&!&%&!-4&3!
pressure and CPC pressure on shift valve A. The 1st clutch pressure is changed to line pressure mode, and the 1st clutch is
&!&%-4!
! A!
engaged securely. The CPC A pressure (5E) stops at shift valve B.

!-4% ; <&!&)-
84 92 AK!LK
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Description
)
_
.# +
(/
?0
8
14 28
3.
+- Shifting between ist gear and 2nd gear

3

As the speed of the vehicle reaches the prescribed value, the PCM turns shift control solenoid valve A ON. Shift control
%&!&! A, !!&!&%8-!
solenoid valves B and C remain ON. Shift control solenoid valve A is turned ON, and SH A pressure (SA) in the left side of the
!&!&)8-!!&!&% 8A6% ;%<!
shift valve A is released. Then shift valve A is moved to the right side to switch the port of line pressure and CPC pressure. The
&!&%!-4&!&%&
3! -4
PCM also controls the NT clutch pressure control solenoid valves. The A/T clutch pressure control solenoid valves Aand B
,!!%=4! !!&!&-4%=4! !!&!&%)
apply their pressure to the CPC valves Aand B. Line pressure (4) becomes CPC B pressure (48) at the CPC valve B, and
! &!&%)- ;*<) ;*)<&!&)A
CPC B pressure passes through shift valves C, B, and A, to become 2nd clutch pressure. The 1st and 2nd clutches are
)
&!&A)A%A! -4!
engaged with the CPC pressure mode.

3 -
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l."':l|;|CH PI: 55.“:

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' wumu In”; mnmiruwmue
PENN-KIWI
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5mm \ill U5
unmou—
Description
)
_
.# +
(/
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9
14 29
4.
*- Driving in 2nd gear
(&

The PCM turns shift control solenoid valve C OFF,A!%=4! !!&!&%!%
4, !!&!&8 and controls A/T clutch pressure control solenoid valve Ato release LS A
pressure (56). The shift control solenoid valves Aand B remain ON. Releasing LS A pressure in the CPC valve A releases
;<-4!!&!&%)8-1!
% &!&%!
CPC A pressure in the 1st clutch pressure circuit. Shift control solenoid valve C is turned OFF,A6 ;<
% ! -!!&!& 8 and SH C pressure (SC) is
applied to the right side of it. Then shift valve C is moved to the left side to switch the port of line pressure and CPC pressure.
!
-4&!&&!3! -
The 2nd clutch pressure is changed to line pressure mode, and the 2nd clutch is engaged securely. The CPC B pressure (5D)
4!
! A!

!-4) ;(<
stops at shift valve B.
&!&)-
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LI'i-ur :cflrkj.
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ll
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Description
)
14_30
$
.# +
(/
?0
5.
- Shifting between 2nd gear and 3rd gear

3
+

As the speed of the vehicle reaches the prescribed value, the PCM turns shift control solenoid valve B OFF.-4,!
%&!&! A, !!&!&)8 The PCM also
controls A/T clutch pressure control solenoid valve Ato apply LS A pressure (56) to the CPC valve A. Shift control solenoid
!%=4! !!&!&%!% ;<&!&%-!!
valve A remains ON, and C remains OFF.-!!&!&) 8
&!&%8A8 Shift control solenoid valve B is turned OFF,A6) ;)<!
and SH B pressure (SB) is applied to
the right side of shift valve B. Then shift valve B is moved to the left side to switch the port of line pressure and CPC pressure.

&!&)-4&!&)&!3! -
Line pressure (4) becomes CPC A pressure (4A) at the CPC valve A. The CPC A pressure (4A) becomes 3rd clutch pressure
;*<% ;*%<&!&%-4% ;*%<+!
(30) at shift valve B, and flows to the 3rd clutch. The 2nd clutch pressure is changed to CPC pressure mode by switching the
;+0<&!&)A!3+! -4!
3

position of shift valve B.
&!&)-
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4' _.., L-II‘-:cm-._-a.

J1. ' m.;m‘:1:p-.-A..~:.-
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I'.-.'|M'u.'|. sum [nut-In
'.-I._~1 a
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mum: um h
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I
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Description
)
_
.# +
(/
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14 31
6.
- Driving in 3rd gear
(&
+

The PCM turns shift control solenoid valve C ON, and controls A/T clutch pressure control solenoid valve B to release LS B
4, !!&!&8A!%=4! !!&!&)!)
pressure (67). Shift control solenoid valve A remains ON, and B remains OFF.-1!
) &!&)
;$<-!!&!&%8A)8 Releasing LS B pressure in the CPC valve B
releases CPC B pressure in the 2nd clutch pressure circuit. Shift control solenoid valve C is turned ON, and SH C pressure
!) ! -!!&!& 8A6
(SC) in the right side of shift valve C is released. Then shift valve C is moved to the right side to switch the port of line pressure
;<
&!&!-4&!&&
3!
and CPC pressure. 3rd clutch pressure is changed to line pressure mode, and the 3rd clutch is engaged securely. The CPC A
-+!
! A+!

!-4%
pressure (4A) stops at shift valve E.
;*%<&!& -
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-
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! l._: l1'—'I' nun w... -J} 4— umnrau wu -.-r I
mr- cljnllnk
D" ' canal) 'iH-lln't I:
lL't: LP mu'nzlt __ _ mun-1mm

9.1.1564: Hun-r ' 1 "" macro -'u.'-I- I-
{—1 . I'.c- L9 T mini:

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'I'IIJIII
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sun WM u'f I:-
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Description
)
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(/
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14 32
7.
$- Shifting between 3rd gear and 4th gear

3+
*

As the speed of the vehicle reaches the prescribed value, the PCM turns shift control solenoid valve A OFF.-4,!
%&!&! A, !!&!&%8 The PCM also
controls A/T clutch pressure control solenoid valve B to apply LS B pressure (57) to CPC valve B. Shift control solenoid valve B
!%=4! !!&!&)!) ;$<&!&)-!!&!&)
8 and SH A pressure (SA) is applied to the left
and C remains ON. Shift control solenoid valve A is turned OFF,A6% ;%<!!
remains OFF,A8-!!&!&% 8
side of shift valve A. Then shift valve A is moved to the left side to switch the port of line pressure and CPC pressure. Line
&!&%-4&!&%&!3! -
pressure (4) becomes CPC B pressure (48) at CPC valve B. The CPC B pressure (48) becomes 4th clutch pressure (41) at
;*<) ;*)<&!&)-4) ;*)<*! ;*<
shift valve D, and flows to the 4th clutch via the manual valve. The 3rd clutch pressure is changed to CPC pressure mode by
&!&(A!3*! & !&!&-4+!

switching the position of shift valve A.
3
&!&%-
NOTE: When used, "left" or “right” indicates direction on the hydraulic circuit.
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uh. 5n"! I.".|H1rl=.=l

immune ..u-.-r r.
nu-n_.r:_1w-w_|.
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In: Isms". .I a
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A-1:'J.I_Ir:'1- HI 55L“:
raw—mu saith-.11:
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-¢_ .
Description
)
_
.# +
(/
?0

14 33
8.
'- Driving in 4th gear
(&
*

The PCM turns shift control solenoid valve C OFF,A!%=4! !!&!&%!%
4, !!&!&8 and controls A/T clutch pressure control solenoid valve Ato release LS A
pressure (56). Shift control solenoid valves Aand B remain OFF.-1!
% ;<!%
;<-!!&!&%)8 Releasing LS A pressure (56) releases CPC A pressure in
the 3rd clutch pressure circuit. Shift control solenoid valve C is turned OFF,A6 ;<!

+! -!!&!& 8 and SH C pressure (SC) is applied to the right side
of shift valve C. Then shift valve C is moved to the left side to switch the port of line pressure and CPC pressure. The CPC B
&!&-4&!&&!3! -4)
pressure (5B) changes to line pressure (58) at shift valve C, and flows to the 4th clutch via shift valve C, shift valve B, shift
;)<
! ;)<&!&A!3*! &&!&A&!&)A
valve D, and the manual valve. The 4th clutch pressure is changed to line pressure mode by switching the position of shift
&!&(A !&!&-4*!
! 3

valve A, shift valve C, and 4th clutch is engaged securely. The CPC B pressure (5D) stops at shift valve A.
&!&%A&!&A*!

!-4) ;(<&!&%-
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Description
)
_
.# +
(/
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14 34
'

Position
The PCM controls the shift control solenoid valves and the NT clutch pressure control solenoid valves. The conditions of the
4,!!!&!&%=4! !!&!&-4
shift control solenoid valves and the positions of the shift valves are as follows:
!!&!&&!&!!39
¢ Shift control solenoid valve A is turned ON, and shift valve A is in the right side.
!!&!&% 8A&!&%
-
¢ Shift control solenoid valve B is turned ON, and shift valve B is in the right side.
!!&!&) 8A&!&)
-
¢ Shift control solenoid valve C is turned OFF,A&!&&!-
!!&!& 8 and shift valve C is moved to the left side.
The PCM also controls A/T clutch pressure control solenoid valve B to apply LS B pressure (57) to CPC valve B. Line pressure
4,!!%=4! !!&!&)!) ;$<&!&)-
(4) from the manual valve becomes line pressure (5C) at shift valve C. Line pressure (50) flows to shift valve A via shift valve B,
;*< !&!&! ;<&!&- ;0<!3&!&%&&!&)A
and becomes 2nd clutch pressure (20). The 2nd clutch pressure is applied to the 2nd clutch, and 2nd clutch is engaged
! ;0<-4! !! A!

securely.
!-
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EH |—_
“”|'_‘ «is
—— "TT.—
Description
)

.# +
(/
?0
14-35
3
'

Position
The PCM controls the shift control solenoid valves and the NT clutch pressure control solenoid valves. The conditions of the
4,!!!&!&%=4! !!&!&-4
shift control solenoid valves and the positions of the shift valves are as follows:
!!&!&&!&!!39
¢ Shift control solenoid valve A is turned OFF,A&!&%&!-
!!&!&% 8 and shift valve A is moved to the left side.
¢ Shift control solenoid valve B is turned ON, and shift valve B is in the right side.
!!&!&) 8A&!&)
-
¢ Shift control solenoid valve C is turned ON, and shift valve C is in the right side.
!!&!& 8A&!&
-
Line pressure (4) becomes line pressure (58) at shift valve C. Line pressure (5C) flows to shift valve B via shift valve A, and
;*<! ;)<&!&- ;<!3&!&)&&!&%A
becomes 1st clutch pressure (10). lst clutch pressure (10) is applied to the 1st clutch, and 1st clutch is engaged securely.
! ;0<-! ;0<!! A!

!-
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Description
)
_
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(/
?0
5
14 36
El'

Position
1.
-
position from El
Shifting to El position
or E
Line pressure (1) becomes line pressure (3) at the manual valve, and flows to the reverse CPC valve. Line pressure (3) is
;<! ;+< !&!&A!3&&!&- ;+<
regulated by the reverse CPC valve and becomes line pressure (3’). Line pressure (3’) pushes the servo valve to the reverse

!&&!&!

Honda ESM Accord 1998 PDF

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(E

MAINTENANCE REPAIR and CONSTRUCTION 99 391

(including ABS)  .ABS

First Edition 9/98 2074 pages

As sections with * include SRS components; special precautions

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

 ! items will require special precautions and

ABS Indicator Light Does Not G0 Off

41 &!!! 20-81

. E 

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

(With HID Lamp)

Sensor Replacement (With HID Lamp)

2 1  + + 1778

Keyless Receiver Unit Input Test

Handling and Storage

— Vehicle- Identification I'Iumbar [VIN] — — Engine Nu mt-ar

55.. I- Ln; '_. :-‘ I_I 3|; I_ I_I I_I_I]I_II

I""'-'.I“.i' 1|_|I '

*1: with NAVI.

*1: with NAVI.

Him " 3:1)? .

“EM-Mission Mum bar Englne Numbar

"x. ". “ "

NOTE: LHD model is shown; RHD model is similar.

FRONT SEAT PASSENGER AIRBAG

7 FRONT SEAT PASSENGER AIRBAG

SIDE AIRBAG CAUTION

STEERING COLUMN NOTICE

MONITOR NOTICE FHCI'NT SEAT BELT

DRIVER AIRBAG M DDULE

FRONT SEAT PASSENGER

REAR 5U PPDRT Pﬂl NT

+- Raise the vehicle high enough to insert the safety stands.

Canter the jack bracket

CH nlar the jack bracket

O Use the special tool when use of such a tool is

¢ Work safely and give your work your undivided attention.

O Parts must be assembled with the proper torque

Keep disassembled parts away from air-borne

! 0 Never try to disconnect connectors by pulling on

0 #!      !-

RUBBER SEAL HEI'AlMEH

¢ Some connectors have a clip on their side used to

Testing and Repairs

0 Use a probe with a sharp tester probe.

¢ After installing harness clips, make sure the harness

Describes the conditions or situation to start a troubleshooting flowchart.

! Wire Colour Codes

DIGITAL CIRCUIT TES'IER

SHARP TESTER PROBE

RUBBER SEAL TESTER PROBE

O (Except D16B6 engine

Unit of length: mm (in)

Unit of length: mm (in)

Unit of length: mm (in)

*2: TEIKOKU PISTON RING manufactured piston ring

Standards and Service Limits

Engine Lubrication - Section 8

Unit of length: mm (in)

Unit of length: mm (in)

O 3rd, 4th clutches

O O ,#5 2.85-2.90 (0112-0114

(including ABS) .ABS

! items will require special precautions and

41&!!! 20-81

.E

21 + + 1778

0 #! !-

O O ,#5 2.85-2.90 (0112-0114

Stator reaction spring O *-;0-$$< 35.4 (1.394) O +0-+;-5+<

Modulator valve spring O -;0-0+< 10.4 (0.409) O ++-;-+5<

Relief valve spring O 0-;0-0*< O 14.5 (0.571) O

Cooler check valve spring O 0-';0-0+< O 40.4 (1.591) O

Shift valve A spring O 0-';0-0+< O 40.4 (1.591) O

Shift valve B spring O 0-';0-0+< O 49.1 (1.933) O

Shift valve E spring O 0.9 (0.035) O $-;0-55< O +-0;-*'0<

Lock-up shift valve spring O 0.85 (0.028) O -;0-0< O +*-5;-+$0<

Lock-up control valve spring O 0.7 (0.028) O -;0-0< O +-$;-*0<

Shift valve D spring O 0.7 (0.028) O -;0-0< O +-$;-*0<

Servo control valve spring O 0.7 (0.028) O -;0-*0< O $-';0-$0<

Reverse CPC valve spring O 0.7 (0.028) O -;0-*0< O $-';0-$0<

CPC valve A spring O 0.7 (0.028) O -;0-*0< O $-';0-$0<

CPC valve B spring O 2.8 (0.102) O 5-;0-$$<

3rd Accumulator spring O 3.8 (0.150) O 5-;0-$$<

4th accumulator spring O 2.8 (0.102) O -;0-'0<

Engine running O| +0;+-A-'<

G92. 6)# ! -

- Inspect the ignition timing (See Page 4-21).

- Carefully remove the ignition wires by pulling on the