ACUrj|A

INTEGFIF|
Service Manual 1994
 INTRODUCTION

How to Use This Manual

This manualis dividedinto 23 sections.The first pageof each sec-
tion is markedwith a blacktab that linesup with its corresponding
thumb indextab on this page and the back cover. You can quickly
tind the tirst pageof each sectionwithout lookingthrougha full ta-
ble of contents.The svmbolsprintedat the top cornerof each page
can also be used as a quick referencesystem.
Specifications trtl:{lt'
Each section includes:
1. A table of contents.or an explodedview index showing:
a Partsdisassemblvsequence.
a Bolt toroues and thread sizes.
a Pagereferencesto descriptionsin text.
2. Disassemblv/assembly proceduresand tools.
M a i n te n a n c e 4Pi
3. InsDection.
4. Testing/troubleshooting.
5. Repair. H
6. Adiustments. Engine I-""
SpecialInformation
@ lnai""tes a strong possibility of sevor€ pelsonal iniury
01 loss of life it instructions al€ not tollowed.

CAUTION: Indicates a possibility ot personal inlury or oquipmont

damage if instructions ale not followed.
Fueland Emissions
Za
NOTE: Gives helpful information.

CAUTfON: Detaifeddoscriptionsot standad workshop procedures,

salety principlosand servicaopelationsare not included Pleasonote
that this manual conlains warnings and cautions against somo spocif-
*Transaxle
ic sgrvice methods which could cause PERSONALINJURY, damage
a vehicle or make it unsafe. Pleasounderstandthat those warnings
cannot cover all conceivablcwaYs in which service, whetheaor not
recommended bv HONDA, might be done, or of the possibla r-\
hazardous consequences of svery conceivable way, nor could
* Ste e ri n g l D l
HONDA investigateall such ways. Anyone using seryice plocedures \.t/
or toofa, whethor 01 not recomondedby HONDA, ,nust sttisfY him-
sett thoroughly that neither personal saf€ty nor v€hicle safety will
be jaopaldized.

All informationcontainedin this manualis basedon the latest product

informationavailableat the time of printing.We reservethe right

o
to makechangesat any time without notice.No part of this publica-
tion mav be reproduced,storedin retrievalsystem, or transmitted, * Brakes
in any Jorm by any means,electronic,mechanical,photocopying,
recording,or otherwise,without the priorwritten permissionof the (lncludins
!TEg)
publisher.This includestest. figures and tables.

First Edition7/93 1448 pages HONDA MOTORCO.,LTD,

All Rights Reserved Service Publication ottice
Specifications Apply to U.S.A. and Canada

*Electrical J--*
As sections with r includ€ SRS components.
special precautions are lequiled when servicing.
(lncludins
ISBE)
, ,

SUPPLEMENTAL SYSTEM(SRS}
RESTRAINT
The IntegraSRSincludesa driver's airbag,locatedin the steeringwheel hub. ln addition,all mod€lsexcepi
tna
Rs modelfor canada have a front passenger'sairbsglocatedin the dashboardabovethe glove box, InformaUon
necessaryto safely servicethe SRSis includedin this servica Manual.ltems markedwith an sstorisk(r)
on thr
contents page include,or are locatednear, SRScomponents.Servicing.disassemblingor roplacingthea6
ltems
will requirespecialprecautionsand tools, and shouldthoreiore be done by an authorhed Acura dealer.

' To avoid ronderingths sRS inoporativo,which could lard to porronll Injury or darth In thc
cvant ot. r.yr.
trontal collision, all sRs sorvico work must be pcrformcd by !n ruthorizcd Acu.! daerrr,
' lmpTopor3orvica proceduroa,including inco.roct r.movd r d Installation of tha SRS,could
Lld to pc[onc Inlu-
ry caussd by unintsntionalactivationot tho airbags.
' All sRs oloctrical wiring harnoa$! aro coverod with yallow In3ulatlon, Rcbtcd componcnts
arc bcrtad In tha
stoeringGolumn,front console,dsrhboa.d,and darhboardlowor plnol, lnd in thc d$hbolrd abovc tha gaov!
bor. Do not uas oloctdcalte$ oquipmonton thaaa citcuhs.

NoTE: The originalradiohas a codedthett protectioncircuit. Be sureto get the customer'scode numb6r
* disconnecting b€lore
the battery.
- removingthe No. 32 (7.S A) fuse Jromthe undsr-hood
fuse/relaybox.
- removingthe radio.
After service,reconnectpowerto the radioandturn it on. Whenthe word ,,CODE,,is displayed,
enterthe cus_
tomer's 5-digit code to restoreradio oDerauon.
GeneralInformation
Chassisand PaintCodes 1-2
ldentificationNumberLocations 1-4
Warning/CautionLabelLocations 1-5
Lift and SupportPoints
Lift 1-9
FloorJack 1-10
Safety Stands 1 - 11
Towing 1-12
I Chassisand PaintCodes
U.S.Model

VehicleldentificationNumber EngineNumber
JH4DB754*RSOOOOO
1 8 l 8 B r ------T-----
r300@l
Manutactulol, Make and Engine Typ6
Typ€ of Vshicle 81881: 1.8 f DOHCSequentiat Muhi-pori
J H 4 : H O N D AM O T O RC O . ,L T D . Fuel-injectedengine
ACURAPsssenger car B l8Cl : 1.8 | DOHCVTECSequ€nrial
Line, Body and EnginoType Multi-port Fu€l-iniected€ngin€
DB7:INTEGRA 4-door/B1881 Se al Numbel
DB8:INTEGRA 4-door/818Cl
DC2:INTEGRA 3-door/B18C1
DC4:INTEGRA 3-door/B18Bj
BodyType and Trsnsmission Type Transmission
Numbsr
3: 2-doorHatchbackS-speedManual
4: 2-doot Hatchback4-speed Y80- 1000@ I
Automatic
5; 4-doorSedans-speedManual Transmission
Type
6: 4-doorSedan4-speedAutomatic Y80: Manual
Vehicle Glado (Seriesl MPTA:Automatic
4: RS Serial Numbel
5: LS
8; GS-R
Check Digit Paint Code
Model Yaal
R: 1994
Factory Code COLOR
S: SuzukaFactoryin Japan
Serial Numb€l
BG.33P

Vehicleld€ntification
Numberand PaintCode
FederalMotor VehicleSafety StandardCertification
PaintCode Color
3DOOR 4DOOR
BG.33P ParadiseBlue-g.€enPeErl
G-71P LausanneGr6enPead
NH-5O3P GrsnadaBlack Pea.l
NH-538 Frost White
NH-575M ThunderGrav Metallic
R-72P Torino Red Pearl
R-81 MilanoRed
RP.24P Stealth Gray Pearl
YR.5O3M RosewoodBrown M€tallic

1-2
CanadaModel

VehicleldentificationNumbel EngineNumber
JH4DB753.RS800001 8 1 8 8 1 - 17 0 0 0 0 1

Manutacturer,Makeand Engin€Type
81881: 1.8 I DOHCSequential Multi-port
Type of v€hicle
JH4: HONDAMOTORCO., LTD. Fuel-injectedengine
ACURAPassenger car B 1 8 C 1 :1 . 8 I D O H CV T E CS e q u e n t i a l
Multi-DortFuel-iniected engrne
Lino. Body and EngineTYPo
D87: INTEGRA 4-doot/Bl881 SerialNumber
DC2:INTEGRA3-dootBl 8C1
DC4:INTEGRA 3-dooriB18B1
Body Type and TransmissionTYPo Number
Transmission
3: 2-doorHatchback5-speedManual
4'. 2-doorHatchback4-speed Y80-1000001
Automatic
5: 4-doorSedans-speedManual Type
Transmission
6: 4-doorSedan4-speedAutomatic Y80: Manual
VehicleGrade{Sedes} MPTA:Automatic
3: RS without passengerSRSairbag SerialNumbel
4: RS with passengetSRSaitbag

8: GS-R
Check Digit
Paint Code
Model Yeat
R: 1994 COLOR
FactoryCode
S: SuzukaFactoryin Japan BG.33P
Serial Numbel

Numberand
Vehicleldentification Paint Code
CanadianMotor Vehicle Safety Standard Certification PaintCode Color
3DOOR 4DOOR BG.33P Pearl
ParadiseBlue-green
G-71P LausanneGreenPearl
NH-5O3P GranadaElackPearl
NH-538 Frost White
NH-575M ThunderGrayMetallic
R-72P TorinoRedPearl
R-81 MilanoRed
RP-24P StealthGrayPearl
YR-503M RosewoodBrown Metallic

1-3
II
I
ldentificationNumberLocations

Vehicle ldontification v.hiclo ldontificalion

NumberlvlNl Numb€rlVlNl

Transmbsion Numbor
lAuromatic)

Transmissioh l\lumbor
lManuall

1-4
 LabelLocations
Warning/Caution

MODULEDANG€R
E: DRIVER
A: CABLEREALCAUTIONA
A DANGER
EXPLOSIVE/FLAMMABLE
MANUALFORDETAII'fDINSTRUCTION
SERVICE
BEFERTO- CONTACTWITHACID,WATERORHEAVYMETALSSUCH
AS COPPER, LEADOR MERCURY MAY PRODUCEHARM.
B: CABLEBEALCAUTIONB FUL AND IRFITATINGGASES OR EXPLOSIVECOM.
POUNDS.
STORAGET€MPERATURES MUST NOT EXCEED2OOOF
SERVICEMAI{UAL FOROETAILEDINSTRUCTION
REFERTO- (1OOOCI.FORPROPER HANDLING.STORAGEAND DIS-
POSALPROCEDURES REFERTO THE SERVICEMANUAL,
SRSSUPPLEMEf{T.
WHEEL OTICE
C: STEERII{G POTSON
CONTAINS POISONOUSSODIUMAZIDEANDPOTASSIUM
]{OT|CE I{ITRATE.
IMPROPEB STEERII{G ORINSTALLATION
WIIEELREMOVAL FIRSTAID
DAMAGESRSCOMPONENT. IF CONTENTSARESWALLOWED,INDUCEVOMITING.
FOLLOWSERVICE MANUALINSTRUCTION CAREFULLY. FOR EYE CONTACT, FLUSH EYES WITH U'ATER 15
MINUTES.IF GASESIFROMACIDORWATERCONTACT}
D: DRIVERINFLATORWAR[{|NGTAG ARE INHALED.SEEKFRESHAIR. IN EVERYCASE, GET
PROMPTMEDICALATTENTION.
WARNII{G KEEPOUT OF REACHOF CHILDREN
AND POSSIBLE
D€PLOYMENT
TO PflEVE T ACCIDE]TTAL
INJURY: F: DRIVERMODULEWARNING
SHORTCOI{NECTOR
ALWAYSII{STALLTHEPNOTECTIVE
O THEINFLATOR WHENTHEHARNESS
COI{I{ECTOR IS
A, WABNING
DISCONNECTED. THEAIRBAGINFLATORIS EXPLOSIVEAND' IF ACCIDEN-
TALLYDEPIOYED,CAN SERIOUSLYI{URTOR KILLYOU.
. DO NOTUSEELECTRICALTESTEOUIPMEI'IT ORPROB-
ING DEVICES.
THEYCAN CAUSEACCIOENTAL OEPLOYMENT.
. NO SERVICEABLEPARTS INSIOE,DO NOT DISAS.
SEMALE.
. PLACEAIRBAGUPRIGXTWHENREMOVED'
. FOLLOW SERVICEMANUAL II{STRUCTIONS
CAREFULLY.
(cont'd)

1-5
 Warning/CautionLabel Locations
(cont'd)

G: DBIVEBTNFORMATTON
{SUNV|SORt

G: DBIVEBINFORMATTON
{SUNvtSORt.

ALWAYS WEARYOUNSCIT EELT

C.Ai IS EOUIPPEDWITH A DRIVERAIRBAG ANO
A_FRo_NTSEAT pASSENGERnrnslc nNo e raoNi
SEATPASSENGER AIRBAGAS A SUPPIEMENTALBES.
TRAINT SYSTEM {SBSI rThis vo.3ion
ot tho lsb€l i! us6d in csrs wtth a,ront soat
ro suppLEMENr
rHEsEArBEt-r. paas€ngor'sairbag.
.: BEFoRE
Lr_ll^gls_lglls
oRrvrNG,ReeoL.qsetmsiDrrxE GLovEBox.

1-6
J: GLOVEBOX INFORMATIOf{ M: AIRBAGLABEL
AIRBAG
AIBBAGINFORMANO
SUPPLEMENTAL RESTiAINTSYSTEM(SRS) HOODI
N: SRSWARNINGIENGINE
. THE SRSMUST BE INSPECTED TEN YEARSAFTERIT
IS SHOWN
TI{EDATEOFINSTALLATION
IS INSTALLED. SUPPLEMENTAL RESTRAINTSYSTEM(SBSI
ON THE CERTTFICATION PLATE,LOCATEDON THE THISVEHICLEIS EOUIPPEDWITH DRIVERSIDEAIRBAG.
DRIVER'S DOORJAMB. ALL SRS ELECTRICALWIRINGAND CONNECTORS ARE
. DIAGNOSTICCHECKSAND REPLACEMENT OF SNS COLORED YELLOW.
COMPONENTS MUST BE DONEBY AN AUTHORIZED TAMPERING WITH,DISCONNECTING ORUSINGELECTRI-
DEALER CAL TESTEOUIPMENT ON TI{E SRSWIRINGCAN MAKE
. SEEYOUROWNER'SMANUALFORAODITIONALSRS THESYSTEMINOPERATIVE OB CAUSEACCIOENTAL FIR'
INFORMATION. ING OF THE INFLATOR.
A. WANING
INFLATORWARNINGTAG
K: FRONTSEATPASSENGER AND, IF ACCIDEN-
THEAIRBAGINFLATORIS EXPLOSIVE
HURTYOU'
CAf{ SERIOUSLY
TALLY DEPLOYED,
A WARNING FOLLOWSERVICEMANUALINSTRUCTIONS CAREFULLY.
ACCIDENTALAIRBAG DEPLOYMENTCAN SERIOUSLY
HURTOR KILLYOU. HOODIi
N: SRSWARNINGIENGINE
CONNECTOR
INSTALLTHE REDSERVICE WHENTHE IN-
FLATORHARNESSIS DISCONNECTED SUPPLEMENTAL RESTRAINT SYSTEM{SRSI
THIS VEI{ICLEIS EOUIPPED WITH DRIVERANO FRONT
MODULEDANGER
L: FRONTSEATPASSENGER SEATPASSENGER AIRBAGS.
ALL SRS ELECTRICAL WIRINGAND CONNECTORS ARE
A DANGER COLORED YELLOW.
EXPLOSIVE/FLAMMABLE TAMPENING WITI{, DISCONNECTINGORUSI G ELECTRI'
CONTACTWITHACID,WATERORHEAVYMETALSSUCH CAL TESTEOUIPMENT ON THESRSWIRINGCAN MAKE
AS COPPER. LEADOR MERCURY MAY PRODUCEHARM' THESYSTEMINOPERATIVE ORCAUSEACCIDENTAL FIB'
FUL AND IRRITATINGGASES OR EXPLOSIVECOM. ING OF THE INFLATOB.
POUNDS. A WABNING
STORGETEMPERATURES MUST NOT EXCEED2OOOF AI{O, IF ACCIDEN-
THEAIRBAGINFLATORIS EXPLOSIVE
tlOO"CI.FOBPROPER HANDLIING,STORAG€ AND DIS- CAN SEBIOUSLYHURTYOU'
TALI-YDEPLOYED,
POSALPROCEDURES REF€BTO THESERVICEMANUAL, MANUALINSTRUCTIONS CAREFULLY.
FOLLOWSERVTCE
SBS SUPPLEMENT.
POTSON 'This vorsionol tho labolis u36din cs.t with a front soat
CONTAI'\'SPOISONOUSSODIUMAZIOEAND POTASSIUM
NITRATE. passonger'sairbag.
FIRSTAID
IF CONTENTSARESWALLOWED, INDUCEVOMITING.
FOREYECONTACT,FLUSHEYESWITH WATERFOR15
MINUTES.
IF GASES(FROMACID OR WATERCONTACT)ARE IN.
HALED,SEEKFRESHAIR. IN EVERYCASE.GETPROMPT
MEDICAL ATTENTION.
KEEPOUT OF REACI.IOF CHILDREN.
A' WARNING
THEAIRBAGINFLATOR IS EXPLOSIVE AND. IF ACCIDEN-
TALLYDEPLOYEO, CAN SERIOUSLY HURTOR KILLYOU.
. DO NOTUSEELECTRICAL TESTEOUIPMENT ORPROB.
INGDEVICES.
THEYCAN CAUSEACCIOENTAL DEPLOYMENT.
. NO SERVICEAALE PABTS INSIDE.OO NOT OISAS-
SEMBLE.
. PLACEAIRBAGUPFIGHTWHENREMOVED.
. F O L L O W S E R V I C EM A N U A L I N S T R U C T I O N S
CAREFULLY.

{cont'd)

1-7
_
fi{lHfiFe*%
Warning/Caution
LabelLocations
(cont'd)

SERVICEINFORMATION

C)
SPARKPtUG
BATTERY
CAUTION II{FORMATION

AIR CLEAI{€R,
RECOM-
MENDEO OILand
FILTERSERVICE
RADIATORCAP
CAUTIOI{

TIREINFORMATION TIREINFORMATIOII
{300()R) t4DOOR)

1-8
Lift and SupportPoints
Lift
plac6
Wh€n heavy16arcompon€ntssuch aa susponsion,luel tank, spale tile and hatch ale to b€ removod,
il]iii6iliieigltt in the tuggageareabsforehoisting.Whensubstantialwoightis lemovedfrom ths l€ar ol th€ car, ths
cantor of gravity may chango and can cause the cal to tip folward on the hoist'
can assist
NOTE: Sinceeachtire/wheelassemblyweighsapproximately14 kg (30 lbs),placingthe front wheelsin trunk
with the weight distribution.

1. Placethe lift blocksas shown

and rock the car to be sure it is firmly supported.

2. Raisethe hoista lew inches(centimeters)

3. Raisethe hoistto full heightand inspectlift pointsfor solidsupport.

POINT
FRONTSUPPORT LIFTBLOCKS POINT
BEARSUPPORT

1-9
Lift and Support Points
FIoor Jack
1 . Set the parkingbrakeandblockthe wheelsthat are
not beinglifted. Always uss satety standswhen working oo 01un-
der any vehiclethat is supponedby only a jack.
2 . When
when lifting
tritrngthe rear o
off the car, put the gearshift a Naverattompt to use a bumporiack fo. lifting or sup-
lever in reverse(Automatictransmissionin
@ po- porting tho car,
sition).

3 . Raisethe car highenoughto insenthe safetystands.

4 . Adjustandplacethe safetystandsas shownon page

1-11 so the car will be approximately
level,then low-
er the car onto them.

Front

Centerthe jsck
bracketin the middle
ot the jack lift platform.
JACK LIFTPLATFORM

Rear

Centerthe jack
JACK LIFTPLATFORM bracketin the middle
of the jack Iift platform.

1-10
Safety Stands

ATTACHMENTS
RUBBER

t$
\F

SAFETYSTANDS REARSUPPORT
POINT
FROI{TSUPFORTPOII{T

1-11
 Towing

It the car needsto be towed, call a professionaltowing Front:

service.Nevertow the car behindanothercar with just
a rope or chain. lt is very dange.ous.

Emergency Towing
There are three popularmethodsof towing a car:

Flat-bedEquipmont-The operatorloadsthe car on the

back of a truck. This is the best way of transportingthe
car.

Whsol Lift Equipment-The tow truck uses two oivot-

ing arms that go under the tires (front or rear)and lifts
them otf the ground. The other two wheels remainon
the ground.

Sling-type Equipmont-The tow truck uses metal cables

with hooks on the ends. These hooks go around parts
rl of the frame or suspensionand the cableslift that end
of the car off the ground.The car's suspensionand bodv
can be seriouslydamagedif this methodof towing is at-
tempted.

It the car cannotbe transponedby flat-bed,it shouldbe

towed with the tfont wheels oft the ground. lf due to
damage.the car must be towed with the front wheels TOWING HOOKS
on the ground, do the tollowing:

ManualTransmission
a Releasethe parkingbrake,
a Shift the transmissionto Neutral. Real:
Automatic Transmission
a Releasethe parkingbrake.
a Start the engine.
a Shift to @ oosition,then to S position.
a Turn off the engine.

NOTICE:lmpropertowing preparationwill damagethe

transmission. Followthe aboveprocedureexactly.lf you
cannot shift the transmissionor stan the engine(auto-
matic transmission), your car must be transDortedon a
flat-bed.
a lt is best to tow the car no tartherthan SOmileslgo
km). and keep the speedbelow 3b mph (bE km/h).

NOTICE:Trying to litt or tow your car by the bumpers

will causeseriousdamage.The bumpersare not designed
to supportthe car's weight.
SpecialTools
lndividual tool lists are located at the front of each section
Specifications
Standardsand ServiceLimits .'-.'.'."-'-' 3-2
3-17
....'.'.'...."....."......
DesignSpecifications
BodySpecifications 3-20
'.....'.'.
Standardsand ServiceLimits
Train(B188tenginel- Secti
CylinderHead/Valve Declron 6
MEASUREMENT STANDARD '
{NEWI SERVICE
LIMIT
Compression 250rpmandwideopenth.ottl€ Nominal 1,370(14.0,199)
kPa(kgflcm?,
psi) Minimum 930(9.5,140)
Maximumvariation 200t2.0,2a)
Cylinderh.ad W6rpage 0.05(0.002)
Height r 3 1 . 9 5 -1 3 2 . 0(55 . 1 9-5 5 . 1 9 9 )
Camshaft Endplay 0.05- 0.15(0.002 - 0.0061 0.5(0.02)
Camshaft-to-holder
oil clearance 0.030- 0.06910.0012 - 0.0027) 0.1s{0.006)
Totalrunout 0.03(0.001) max. 0.04(0.002)
Camlobeheight tN 33.71611.327 1l
EX 33.528 (1.3200)
(Cold)*
Valveclearance lN 0.08- 0.12{0.003 - 0.005)
EX 0.'r6 - 0.20(0.006- 0.008)
ValvestemO.D. tN 6.580- 6.590(0.2591 - 0.2594) 6.s5(0.258)
EX 6.550- 6.s60(0.2579 - 0.2583) 6.52(0.257)
Stem-to-guide
clearance lN 0.02- 0.0s(0.001- 0.002) 0.0810.003)
EX 0.05- 0.08(0.002- 0.003) 0.11(0.004)
width tN r.25- 1.55(0.049 - 0.061) 2.0t0.08)
EX 1.25- 1.55{0.049 - 0.061) 2.0(0.08)
Steminstslled
height tN 40.765 - 41.235 (1.6049 - 1.6234) 41.485 (1.6333)
EX 12.763- 43.235t1,6a37 - 1.7022) 43.485 (1.7120)
Valvespring Freelength{Reference} lN 42.36(1.668) 41.s6{1.636)
EX NH 47.09{1.854} 46.27tl.A22l
CH 47.08(1.854) 46.21l1.a22l
Valv6guide Lu. lN 6.61- 6.63(0.260 - 0.261) 6.65(0.262)
EX 6.61- 6.6s(0.260-0.261) 6.6510.2621
Installed
height lN 13.75 - 14.25{0.541 - 0.561}
r5.75- 16.2510.620 - 0.640)
*: Measuredbetweenthe camshaftand rockerarm.
NH:NIHONHATSUJO manufactur€dvalvespring
CH:CHUOHATSUJO manufacturod valvesDrino

3-2
 Unitof length:mm {in}
k (81881
EngineBlock s cti 7
{Bl6E1 englnel- sectlon
MEASUNEMENT STANDARD (NEWI LIMIT
SERVICE
Warpageot decksLrrface 0.0710.003)max. 0.10(0.004)
Cylinderblock - 3.190)
Borediameter 81.00- 81.02{3.189 81.07(3.192)
BoretaPer 0.05(0.002)
Reboringlimit 0.25(0.010)
80.98- 80.99(3.188 - 3.189) 80.9713.188)
Piston SkirtO.D.at 15 mm (0.6in)Irom bottom of skirt
Clearancein cylinder 0.01- 0.04(0.0004 - 0.0016) 0.05(0.002)
Groovewidth (Forring) Top 1.030 - r.010(0.04060.0409) 1.0610.042)
Second 1.230 - 1.210(0.0484 - 0.0488) 1.26(0.050)
oil 2 . 8 0 -5 2 . 8 2 (00 . 1 1 0 40 . 1 1 1 0 ) 2.8410.112\
--
clearance top 0.045- 0.070{0.0018 - 0.0028} 0.13{0.00s)
Pistonring Ringto-groove
Second R 0.040- 0.065(0.0016 - 0.0026) 0.13(0.00s)
T 0.045- 0.070(0.0018 - 0.0028) 0.13(0.005)
'....=-
lop
;
0.20- 0.35(0.008 - 0.014) 0.60{0.024)
Ringendgap
T 0.20 0.30(0.008 - 0.012) 0.6010.024)
Second 0.40- 0.5s(0.0r6 - 0.022) 0.70(0.028)
oit R 0.20- 0.s0(0.008 - 0.020) 0.70(0.028)
T 0.20- 0.45(0.008 - 0.0181 0.70(0.028)
20.994 - 21.000 (0.8265 - 0.8268)
rrstonrln o.D. - 0.0009)
Pin-to-pistonclearance 0.0r0- 0.022(0.0004
0.013- 0.032(0.0005 - 0.0013)
rod
Connecting Pin-to-rodinterference
Smallendborediameter 20.968- 20.981(0.825s- 0.8260)
Largeendborediameter Nominal 48.0(1.89)
0.1s- 0.30(0.006 - 0.012)
Endplayinstalled on crankshatt
Crankshaft Mainjournaldiameter
N o .1 ,2 , 4 a n d5 j o u r n a l s 54.976- 55.000(2.1644- 2.1654)
No.3 iournal 54.970- 54.994(2.1642- 2.1651)
44.S76- 45.000{1.7707- 1.7717}
Rodiournaldiameter
Taper 0.00510.0002)max. 0.010(0.0004)
Out-ofround 0.005(0.0002)max. 0.010(0.0004)
Endplay 0.10- 0.35(0.004- 0.014) 0.45(0.018)
Runout 0.03(0.001)max. 0.04{0.002)
Bearing Mainbearing-to-iournal oil clearance
No.1,2, 4 and5 journals - 0.0017)
0.024 0.042{0.0009 0.05010.0020)
No.3 journal - 0.0019}
0.030 0.048{0.0012 0.060(0.0024)
Rodbearingto-iournal oil clearance - 0.0015)
0.020 0.038(0.0008 0.050(0.0020)

Pistonring
Ri RIKENmanutacture
T:TEIKOKUPISTON pistonring
RINGmanufacture

3-3
Standardsand ServiceLimits
Cylander Train(B18Clenginel Section6
Head/Valve
MEASUBEMENT STA]TDARD
INEWI SERV|C€
UM|T
Compr€6sion 250rpm and wideop€nthrottle Nomin6l 1,860(19.0,
270)
kPalkgl/cmr,psi) Minimum 930(9.s,140)
Maximumvariation 200t2.o,2a)
Cylind6rhoad Warpage 0.05{0.002)
H6ight 'r41.95- 1C2.05
(5.s89 - 5.593)
C.mshsft Endplay 0.05- 0.1s(0.002- 0.006) 0.5(0.02)
Camshaft-to-holdsr
oil clearance 0.050- 0.089(0.0020 - 0.0035) 0.15{0.006)
Totalrunout 0.015(0.0006)max. 0.03(0.001)
Camloboheight lN Primery 33.411{1.3154)
Mid 36.377tl.13221
Socondary 34.547 (1.3601)
EX Primary 33.1110.3036)
Mid 35.72011.4063)
Secondary 34.381 {1.3536)
Valvoclorrancelcoldl* lN 0.15- 0.19{0.006- 0.007}
EX 0.17- 0.21(0.007- 0.008)
ValvestemO.D. lN 5.475- 5.48s(0.2156- 0.21591 5.11510.21441
EX 5.450- 5.460(0.2146- 0.21s0' s.420{0.2134)
Stom-to-guid6
clerrsnco lN 0.025- 0.055{0.00'10
- 0.0022} 0.0810.003)
EX 0.050- 0.080(0.0020- 0.0031) 0.11{0.(x)4)
Valvoseat Width tN 1.25- 't.5s(0.049
- 0.06't) 2.0(0.08)
EX '1.25
- 1.s5{0.049- 0.061) 2.0(0.08)
Sr6minstalledh€ight lN 37.465- 37.935('1.4750
- 1.4935) 38.185(1.5033)
EX 37.16s- 37.635t1.4632- 1.4817) 37.885(1.491s)
Valv€Bpring Fre6length(Roferenca) lN Outer 41.05(r.6161 40.26(1.585)
Inner NH 36.'16 {1.4241 35.30(1.390)
CH 36.19t1.425) 35.30(1.390)
EX NH 41.96(1.652) 40.95(1.612)
CH 4 1 . 9 {41 . 6 5 1 ) 40.95(1.612)
Valveguido l.D. tN 5.51- 5.53(0.217 - 0.218) 5.55(0.219)
EX 5.5r- 5.53{0.2r7- 0.218) 5.5s{0.219}
Instslledhoight lN 12.55 - r3.0s(0.494 - 0.514)
EX 12.55 - 13.05(0.494 - 0.s14t
Rock€rerm Arm-to-shaft
clearance lN 0.025- 0.0s2{0.0010 - 0.0020) 0.08(0.003)
EX 0.025- 0.0s2(0.0010 - 0.0020) 0.08(0.003)
': M€asuredbetwoonthe camshattand rcc(ersrm.
NH:NIHONHATSUJOmanufacture v6lvespring
CH:CHUOHATSUJO manufscturov6lvespring

3-4
 Unit of length:mm (in)
(818C1englnel- Section7
BI k (ltluur
Engrne]'ocK
MEASUREMENT STANDARD (NEWI SERVIC€ LIMIT
Cyiinderblock warpageof decksurlace 0.05(0.002)max. 0.08(0.003)
Borediameter - 3.190)
81.00- 81.02{3.189 81.0713.192)
BoretaPer 0.05(0.002)
limit
Reboring 0.25(0.010)
Piston SkinO.D.ar 15mm (0.6in) {rom bottomot skirt 80.98- 80.9913.188 - 3.189) 80.97(3.188)
in cylinder
Clearance 0.0r- 0.04{0.0004 - 0.0016} 0.05(0.002)
Groovewidth (Forring) ToP 1.030- 1.0,r0{0.0406- 0.0409) 1.060(0.0417)
Socond 1.230- 1.240(0.0484 - 0.0488) 1.260(0.0496)
oil 2.805- 2.820(0.1104 - 0.11101 2 . 8 4 0( 0 . 1 1 1 8 )
Pistonring Ring-to-pistongrooveclearance Top 0.045- 0.070{0.0018 - 0.0028} 0.13(0.005)
Second 0.010- 0.065(0.0016 - 0.0026) 0.13(0.005)
Ringendgap I oP 0.20- 0.35{0.008- 0.014) 0.60(0.024)
Socond 0.40- 0,55(0.016 - 0.022) 0.70(0.028)
oil 0.20- 0.s0{0.008- 0.020} 0.7010.0281
20.994- 21.000(0.8265 - 0.8268)
rrstonrtn o.D. - 0.0009)
clearance
Pin-to-piston 0.010- 0.022{0.0004
rod Pinto-rodint€rference 0.017- 0.035(0.0007 - 0.0014)
Connecting
Smallendborediameter 20.964- 20.997(0.8254- 0.8267)
Largeendborediameter Nominal €.0 (1.89)
Endplay installedon crankshaft 0.15- 0.30(0.006 - 0.012)
crankshatt Msinjournaldiameter
N o .1 , 2 , 4a n d5 i o u r n a l s 54.976- 55.000(2.1644 - 2.16541
No.3 journal 54.974- 54.998(2.'|643- 2.1553)
Rodiournaldiameter 44.976- 45.000{1.7707 -' I.7717)
Taper 0.005{0.0002}max. -t-oou
Out'olround 0.004{0.0002)max. lo.ooort
Endplay 0.10- 0.35{0.00{- 0.014)
Runout 0.020(0.0008)max.
Eearing Mainbsaring-to-journal oil clearance
No.1,2, 4 and5 journals - 0.0017)
0.024- 0.042(0.0009 0.050(0.0020)
No 3 journal - 0.0019)
0.030- 0.048(0.0012 0.060{0.0024)
Rodbearing-to-journal oil clearanc€ - 0.0020)
0.032- 0.050(0.0013 0.060(0.0024)

3-5
 Standardsand ServiceLimits
- Section
EngineLubrication eclton g
u _
MEASUREMENT STANDARD
INEW} SERVICELIMTT
Engineoil Capacity etaet engine 4.6{4.9,4.0}torengineoverhaul
f (USqt, lmp qt) 3.8(4.0,3.3)for oil change,inctudin
g talter
3.513.7,3.11for oil change,withouttiher
818C1
engine 4.8{5.1,4.2)for engineoverhaul
4.0(4.2,3.5)lor oit change,includin
g filter
3.7 i3.9 3 3l fdr ^il .hi
O i lp u m p Inner-to-outer
rotorclearance 0.04- 0.16(0.002- 0.006) 0.20(0.008)
Pumphorising-to-outerrotorclearance 0.10- 0.19(0.004_ 0.007)
Pumphousing-to,rotor 0.21(0.008)
axialclearance 0.02- 0.07(0.001, 0.003) 0.1s(0.006)
Reliefvalve rressuresettingat engineoil temp.176.F{gO.Ct
kPalkgtcm,,psi) At idte 70 (0.7,10)min.
At 3,000rpm 3{0 {3.5,50)min.

Cooling- Sectiont0
MEASUBEMENT STANDARD INEWI
Radialor Coolantcapacity I {USqt, lmpq 0 8 1 8 8 1e n g i n e M/T:6.4(6.8,5.6)toroverhaul
I Includingengine,heater,I 4.4(4.6.3.9)f6r s66lsn1gh66q.*
I coolinglineandreservoirI A,rf:6.7{7.1,5.9)for overhaul
Reservoircapacity: 4.7{5.0,4.1)for coolantchanoe*
0.61(0.63USqt,0.53tmpqt) 818C1engine M/T:6.7 {7.1,5.9}for overhaul
4.7{5.0,4.1)for coolantchanoe*
Radiatorcap Openingpressure kPa(kgf/cm?,psi) -
,3 - 113toss- trs, r3=Jt&
Thermostst start to open oF(.C) 1 6 9- 1 7 6{76 80}
Fullyopen .F (.C) 194(90,
Valvelift at fully open 8.0(0.31)
Coolingfan lhermoswitch"ON" temperature .F {oC) 196- 203(91- 95)
"OFF"
Thermoswitch temporature "F (.C) Subtract5 - 14 (3 - 8) from actuat-ON', temperature
ng the coolantin the reservoirandthat remainingin the engine.

3-6
 Unit ot length: mm {in)
Fuel and Emissions Section 11
MEASUREMENT sTAt{ItAno(Newl SERVICEUMIT
.u.l pump Disolacoment in l2 V, 10seconds 81881engine 22217.5,7 -81min. | 12011.1'1'21
m, (fl oz,lmp oz) 818C1engins 364(12.3,12.8)min. I too (:.1, g.st
F aa3urorggulator Pressurewith regulatorvacuum hose disconnected
kPa (kgflcm',psi) Bl8Bl engine 275- 32a 12.8 -3.9,39.6 - 46.9)
Bl8Cl engin€ 329 - 378 (3.35- 3.85,47.6- 5.47)
tualt6nk Caprcity , {US gal,lmp gal) 50(13.2,
11.01
En9in6 ldle sDeed with headlight and cooling fan ofi rpm 7501 50 (M/T:neut..ll
750I 50 {A/T:E or E position}
Fast idle rpm 1,600i 2(x'lM/T:nsurr6l)
l,eooI 200(A/T:E or E po6itioo)
ldl6 CO % 0.1 max.

Clutch Section 12
MEASUREMENT STAM'Ad' IiEWI SERVICEUMIT

clutch padsl P6d6lheight to lloor 164(6.46)

Siroke 130- 140(5.12- 5.51)
Pedalplay 12 - 21 (0.47- 0.83)
Disengagementheight to floor 83 (3.27)min.
Clutchsudace runout max,
0.0510.002) 0.'15(0.006t
clutch disc Riv€t h€ad depth 1.3(0.05)min. 0.2(0.011
Thickness 8.4- 9.1 (0.3 - 0.36) 6.0(0.24)
Pr6sur6 plat€ Warpage 0.03(0.001)
mrx. 0.15(0.006)
Oiaphragmspringlingeralignment 0-6(0.02)ma* 0.8(0.03)

3-7
{n+
ll
Standardsand ServiceLimits
ManualTransmission Section 13
MEASUREMENT STANDARD{NEWI SERVICEUMIT
Transmission
oil Capacityf {US qt, lmp q0 2.2{2.3,1.9}loroilchange
2.3(2.4,2.0)lor assembly
Mainshaft End play 0.11- 0.18{0,004- 0.007) Adjust
Diameterot ball bearingcontactarea 27.977- 27s90 l.1.101- 1.1021 2 7 . 9 3( 1 . 1 0 )
(clutchhousingside)
Diameterof 3rd gear contactarea 37.984- 38.000{1.495- 1.495} 37.93{1.493)
Diameterof ball besring contactarea 27.987- 28.000{r.1018- 1.1024} 21.94 /.1.10!'
(transmission housingside)
Runo!t 0.02 (0.0008)max. 0.05 (0.002)
Mainshafi t.D. 43.009- 43.02511.6933, 1.6939) 43.08t 1.696)
3rd and Endplay 0.06- 0.21(0.0024 0.0083) 0.3(0.012)
4lh gears Thickness 3rd 34.92- 31.97 - 1.3768)
(1.3748 34.8(1.370)
4th 31.12- 31.1711.2370
- 1.23SOl 31.3 (1.2321
Mainshaft t.D. 43.009- 43.025(1.6933 - 1.6939) 43.08{1.696)
5th gear Endplay 0.06- 0.21 (0.0024- 0.0083) 0.3 (0.012)
Thickness 31.42- 31.47t1.237-1.2391 3 1 . 3( 1 . 2 3 2 )
Countershaft Diameterof needlebearingconlact area 33.000- 33.015(1.299- 1.300) 32.95\1.297)
Diameterof ball boaringcontactarea 24.980- 24.993{0.9835- 0.9840) 24.94(0.982)
Diameterof 1st gear contactarea 36.984- 37.000(1.4561 - 1.4567) 36.93{1.454)
Bunout 0.02 10.0008)max. 0.05 t0.002)
Countershaft t.D. 42.009- 42.02511.6539 - 1.6545) 42.08(1.657)
lst gear Endplay 0.04- 0.12(0.0016 - 0.0047) Adjust
Countershaft LD. 47.009- {7.02511.8507 - 1.85r4) 47.0811.854)
2nd gear Endplay 0.05- 0.12(0.0020 - 0.0047) Adjust
Thickness 81881engino 34.62- 34.67(1.3630 - 1.3650) 3{.5 (1.358)
818C16ngine 28.92- 28.97(1.1386 - 1.1405) 28.8(1.134)
Spacercollar t.D. 36.48- 36.49(1.4352 - 1.4366) 36.5(1.437)
(Countershaft o.D. 41.989- 42.00011.6531 - 1.6535) 4 1 . 9 4( 1 . 6 5 1 )
2nd gear) Length 29.02- 29.04(1.r42s- 1.1433)
B 29.07- 29.09(1.1444 - 1.1453)
Spacercollar t.D. -
31.002 31.012 (1.2205 - '1.2209) 31.06('1.223)
{l'rainshaft o.D. 37.989- 38.000(1.4956 - 1.4951) 37.94(1.494)
4th and Length 56.45- 56.5512.2224 - 2.22641
sth gears) B 26.03- 26.08(1.0248 - 1.0268)

3-8
 Unit of length:mm (in)
ManualTransmission Section 13
MEASUREMENI STANDARDINEW) SERVICELIMIT
Reverseidler LD. 20.016- 20.043(0.7880- 0.7891) 20.09(0.7909)
gear'1 gear shaft clearance
Gear-to-reverse 0.036- 0.084(0.0014- 0.0033) 0.16(0.006)
Synchroring Ring-to-gear
clearance (ringpushedagainst99ar) 0.85- 1.10(0.033- 0.043) 0.4(0.0't6)
O o u b l ec o n e Clearance {rin9pushedagainstgear)
synchro ring *2 Outersynchroring-to-gear 0.95r 1.68(0.037- 0.066) 0.6(0.024)
lnnersynchroring-to-gear 0.5- 1.0(0.02- 0.04) 0 . 3( 0 . 0 1 )
Outer synchro ring-to-synchrocone 0.5- 1.0{0.02-0.04) 0.3 (0.01)
Shitt fork Shifttork fingerthickness 7.4,7.6 (0.291- 0.299)
Fork-tosynchro sleeveclearance 0.35- 0.65(0.014- 0.026) 1.0(0.039)
qeverseshift Shift fork pawl groove width - 0.524)
13.0- 13.3(0.512
Fork-to-reverseidler gear clearance - 0.043)
0.5- 1.110.020 13907)
"1" groovewidth at sth gearside -0.303)
7.40- 7.70(0.291
at reversegear side - 0.28s)
7.05- 7.25(0.278
Fork-to-5th/reverse shift piece pin clearance
at 5th gear side 0.4- 0.9{0.016
- 0.03s)
at reversegear side - 0.018)
0.05- 0.45(0.0020
Shift arm Groovewidth of change piece contact area 11.8- 12.0(0.4646-0.4724)
Changepiece-to-shift arm clearance 0.05- 0.35(0.002- 0.014) 0.8010.031)
Shift piece Groovewidth of shift arm contactarea 7.9- 8.0 (0.311-0.315)
Shift piece'to-shiftarm clearance 0.10- 0.30(0.004- 0.012) 0.60(0.024)
LD. 14.000- 14.068{0.551- 0.554)
Shift piece-to-shaftclearance 0.011-0.092(0.0004 - 0.0036, 0.150(0.0059)
Diameterof shift Iork cont6ctarea 1'1.90- 12.00(0.469- 0.472)
Shift piece-to-shiftfork shaft clearance 0.20- 0.50 (0.008- 0.020i osoto.oart
Selector Diameterof changepiececontactarea 11.90- ' t2.00(0.469- 0.472)
Arm-to-changepiececlearance 0.05- 0.35{0.002- 0.014) 0.50(0.020)
Groovewidlh of interlockcontactarea 10.05- 10.15{0.3957 - 0.3996}
Arm-to-interlock clearance 0.05- 0.2s(0.002- 0.010) 0.50(0.020)
' 1 : 8 1 8 8 1e n g i n e
'2 818C1engine

- Automatic Transmission- oSection

Eutrlrrl 14
rr

MEASUREMENT STANDARD{NEWI SERVICELIMIT

Transmission Capacity I (USqt, lmp qt) 5.916.2,5.2)foroverhaul
lluid 2.7 (2.9,2.4)for lluid change
Hydraulic Line pressureat 2,000rpm 830 - 880 (8.5- 9.0, 120- 130) 780{8.0,110)
pressure (E or E position)
I kPalkgflcm', psi) 2nd clutch pressureat 2,000rpm 460 - 14.7,67) 4 1 0{ 4 . 2 . 6 0 )
(DJ position) throttleIully closed throttle fully closed
3rd clutch pressureat 2,000rpm II I
780{8.0,110)
(lqr posirion)
830- 880(8.5- 9.0,120- 130) throttle more than
4th clutch pressureat 2,000rPm throttlemorethan3/16opened 3/16opened
{E position)
2nd clutchpressureat 2,000rPm 830- 880{8.s- 9.0.120 130) 780(8.0,110)
(Elposition)
1st clutch pressureat 2,000rpm 830- 880(8.5- 9.0,120- 130) 780(8.0,110)
([O or E position)
'lst'holdclutchpressureat 2,000rpm 830- 880{8.5- 9.0,120- 130} 780(8.0,110)
(Elposition)
Throttle pressureB Throttle fully closed 0 - 1 s{ 0 - 0 . 1 5 , 02-1 )
Throtlle Iully opened 830- 880(8.5- 9.0,120- 130) 78018.0,110)
Stallspeedrpm (Checkwith car on levelground) 2,200- 2,600 Below 2,200,
above 2,600
(cont'd)

3-9
Standardsand ServiceLimits
AutomaticTransmis3ion(cont'dl- Sostion14
MEASUFEME'YT STANDARD
{NEWI SEBVICE
UM]T
Clutch Clutch initialcl6aranco lst, 2nd 0.65- 0.85 (0.026- 0.0331
3rd, 4th 0.40- 0.60(0.016- 0.024)
lst-hold 0.5- 0.8(0.020- 0.031)
Clutch rdtu.n spring troe length lst, 3rd, 4th 3 1 . 0{ r . 2 2 } 29.0(1.14)
2nd 33.2{1.31) 31.211.231
lst-hold 34.6 ('t.36) 32.6(1.28)
'1.8- 2.0
Clutchdisc thicknosg {0.071- 0.079) Untilgroov€6wornout
Clulch plale thickn$3 1.95- 2.05(0.077- 0.08r) Discoloration
Clutchond platothictnoss MARK 1 2.05- 2.10 (0.08'1- 0.083) Discoloration
('l8t) MARK 2 2.1s- 2.20{0.085- 0.087)
MARK3 2.25- 2.30(0.089- 0.091)
MARK4 2.3s- 2.40{0.093- 0.091)
MARK5 2.45- 2.50 (0.096- 0.098)
MARK6 2.55- 2.60(0.100- 0.102)
MABK7 2.65- 2.70(0.104- 0.106)
MABK8 2.75- 2.80(0.108- 0.110)
MARK9 2.85- 2.90(0.112- 0.111)
MARK10 2.95- 3.00(0.116- 0.118)
MAFK 1,I 3.05- 3.'r0{0.120- 0.122}
MARK12 3.15- 3.20(0.124- 0.126)
MARK13 3.25- 3.30(0.128- 0.130)
MAEK14 3.35- 3.40(0.132- 0.1341 Discoloration
Clutch ond plato thickn$s MARK 1 2.05- 2.10(0.081- 0.083) Oiscoloration
(2nd,3rd,ath) 2.15- 2.20{0.085- 0.087)
MARK2
MARK3
MARK 4
MARK 5
2.25- 2.30(0.089- 0.091)
2.35- 2.40{0.093- 0.094)
2.45- 2.50{0.096- 0.098}
II
MARK6 2.55- 2.60{0.100- 0.102} I
MARK7
MARK8
MARK9
MARK10
2.65- 2.70(0.104- 0.106)
2.75- 2.80{0.108- 0.r10)
2.85- 2.90{0.112- 0.1r4)
2.95- 3.0010.116 - 0.1r8)
I
Discoloration
Clutchond pl.t6 thicknoss MARK 1 2.05- 2.10{0.081- 0.083) Discoloration
(lst-hold) MARK2
MARK3
MARK 4
2.15-
2.25-
2.35-
2.20(0.085- 0.087)
2.30{0.089- 0.091}
2.40(0.093- 0.0941
tI
2.45- 2.50(0.096- 0.098)
NO MARK
MARK6 2.55- 2.6010.100- 0.102) I
MARK7 2.65- 2.70(0.101-0.106) Oiscolor6tion
 Unitol length:mm (in)
- a t c u a r r u r r 14
AutomaticTransmission- Section r.t

MEASUREMENT SIANDARD {NEW} SERVICELIMIT

iransmission Diameterof needlebearingcontactarea
On mainshattand stator shaft 22.980- 22.993(0.9047 - 0.9052) Wearor damage
On mainshaft2nd gear 35.975- 35.9910.4163- 1.4169)
On mainshaft4th gearcollar 31.975- 31.99r(1.2589 - 1.2595)
On mainshaftlst gesrcollar 30.975- 30.991t1.2195- 1.22011
On countershaft (leftside) 36.004- 36.017{r.4r7s- 1.4' l80)
On countershatt 3rd gear 35.980- 35.996(1.4165 - 1.4172)
On countershaft 4th gear 2 7 . 9 8-0 2 7 . 9 9 {31 . 1 0 1-61 . 1 0 2 1 )
On countershaftreversegear collar 3 1 . 9 7 5 - 3 1 . 9 9( 1 . 2 5 8-91 . 2 5 9 5 )
On countershaft lst gearcollar 31.975-31.991(1.2589 - 1.2595)
on sub'shaft(leftside) 25.991- 26.000(1.0233 1.0236)
On sub-shaft4th gearcollar 2 7 . 9 8 -0 2 7 . 9 9 (31 . 1 0 1-61 . 1 0 2 1 )
On reverseidler gear shaft 13.990 11.000(0.5508 - 0.5512) Wearor damage
Insidediameterof needlebearingconlactarea
On mainshaftlst gear 35.000- 35.016(1.3780 - 1.3786)
On mainshaft2nd gear 4 1 . 0 0-0 4 1 . 0 1 {61 . 6 1 4-2r . 6 1 4 8 }
On mainshalt 4th gear 38.000- 38.016(1.4961 - 1.49671
On countershaftlst gear 38.000- 38.0161' ].4961 - 1.4967)
On countershaft3rd gear 4 1 . 0 0 -0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 )
On countershaft4th gear 33.000- 33.016(1.2992 - 1.2998)
On countershaftreversegear 38.000- 38.0160.4961- 1.4967)
On sub-shatt4th gear 32.000- 32.016fl.2598 1.2605)
On reverseidlergear 18.007,18.020{0.7089 0.7094)
On statorshaft(rightside) 2 9 . 0 0-0 2 9 . 0 1 (31 . 1 4 r -7 1 . 1 4 2 2 )
On stator shaft {statorside) 27.000- 21.021(1.0630 - ' j.1638)
Reverseidlergearshaftholderl.D. 14.416- 14.43410.5676 - 0.5683) Wearor damage
Endplay
Mainshaft1stgear 0.08- 0.24(0.003- 0.009)
Mainshaft2nd gear 0.05- 0.13(0.002- 0.005)
Mainshatt4th gear 0.045- 0.140(0.002- 0.006)
Countershaft 1stgear 0.1- 0.5 (0.004 0.020)
Countershaft 3rd gear 0.04- 0.15(0.002- 0.006)
Countershaft 4th gear 0.05- 0.13(0.002- 0.005)
Sub-shaft4th gear 0.05- 0.17(0.002- 0.007)
Reverseidler gear 0.05- 0.r8 (0.002- 0.007)
Countershaftreversegear 0.10- 0.2510.004 - 0.010)
Selectorhub O.D. 51.87- 51.90(2.042- 2.043) *rd"-"g"
Mainshaft4th gearcollarlength 49.00- 49.05(1.929- 1.931)
' |.069)
Mainshatt'lstgearcollarlength 27.00- 27.15(1.063-
Ist g€arcollarflangethickness
lvlainshaft 2.5 - 2.6 \2.098- 2.102) Wearor damage
C o u n t e r s h a f td i s t a n c e c o l l a r l e n g t h 38.97- 39.00 1.534 1.535)
39.02- 39.05 'r.536- 1.537)
39.07- 39.10 1.538- 1.539)
39.12- 39.r5 1 . 5 4 -0 1 . 5 4 1 )
39.17- 39.20 r.542- 1.543)
39.22- 39.25 1.544 1.545)
39.27- 39.30 1.546- 1.547)
38.87- 38.90 1 . 5 3 0- 1.53r)
'1.532 - 1.533)
38.92- 38.95
Countershaftreversegearcollarlength 14.5- 14.610.57r 0.575)
Countershaftreversegearcollarflange
thickness 2.4- 2.6(0.094- 0.102) Wearor damage
'14.5 - 14.6(0.57'-l 0.575)
Countershaft1stgearcollarlength
'1st 2.4- 2.6(0.094 0.102) Wearor damage
Countershaft gearcollarflangethickness
Sub-shaft4th gearcollarlength 24.0, 24.1{0.945- 0.949} Wearor damage
Sub-shaft4th gearcollarflangethickness 3 . 0 0- 3 . 1 5{ 0 . 1 1 8 0 . r 2 4 ) Wearor damage
(cont'd)

3-11
 Standardsand ServiceLimits
Automatic Transmission (cont'dl - Section 14
MEASUREMENT STANDARD{NEW} SERVICE
t_tMtT
Transmission Mainshaft2nd gear thrust washer thickngss 3.97- 4.00{0.156- 0.'t57} Wear or damage
(contdl 4.02- 4.05(0.158-

II
0.159)
4.07- 4.10(0.r60- 0.1611
4.12- 4.'15(0.162- 0.163)
4.17- 4.20(0.164- 0.' t65)
4.22- 4.25(0.166- 0.167)
4.27-
4.32-
4.37-
4.30{0.168-
1.35{0.170-
4.40(0.172-
0.169)
0.17r)
0.173)
I
Wearor damage
Thrust washerthickness
Mainshaftball bearing left side 3.45- 3.55(0.136- 0.140) Wearlordamase
Mainshaft 1st gear left side 1.45- 1.50(0.057- 0.059)
Mainshatt1stgearrightside 3.43- 3.50(0.135- 0.138) Woaror damage
Sub-shaft4th gearthrustwasherthickness 2.93- 3.00(0.115- 0.1181
One-wayclutch contactarea l.D. t -
Countershaftlst gear 83.339- 83.365(3.2810 - 3.2821)
t
Parkinggear 66.685- 66.69812.6254- 2.6259) Wearor damage
Mainshaftfeedpip€A, O.D.{at 15mm trom end} 8.97- 8.98 {0.353- 0.354) 8.95{0.352t
Mainshaftleed piDeB, O.O.{at30 mm from end) 5.97- 5.98(0.23s0- 0.2354f 5.95(0.2341
Countershaftleed pipeO.D.(at l5 mm from end) 7.97- 7.98(0.3138 - 0.3142) 7.95(0.313)
Sub-shaftfeed pip€ O.D.(at 15 mm trom end) 7.97- 7.98{0.3138 - 0.3142) 7.9s(0.313)
Mainshaftsealingringthickness 1.980- 1.995(0.0780- 0.07851 1.80{0.071)
{29mm and 35 mm)
MainshaftbushingLO. 6,018- 6.030(0.2359- 0.2374) 6.045(0.2380)
MainshaftbushingLD. 9.000- 9.015(0.3s43- 0.3549) 9.03(0.356)
CountershaftbushingLD. 8.000- 8.01s(0.31s0- 0.3156) 8.03(0.3r6)
Sub-shaftbushingl.D. 8.000- 8.015(0.3150- 0.3156) 8.03(0.3161
Mainshattsealingring goovewidlh 2.025- 2.060(0.0797- 0.0811) 2.08(0.0821
Regulator Sealing ring contact area LD. 35.000 35.025{1.3780- 1.3782)
- 35.050(1.3799)

Shiftingdeviceand Reverseshift fork tinger thickness 5.90- 6.00 {0.232- 0.236) 5 . 4 O{ 0 . 2 1 3 )

parking brakecon- Parkingbrako ratchetpawl
trol Parkinggoar
Throftlo cam slopper heighl
Servo body Shift fork shaft bore Lo.
Shift fork shaft v6lve bore LO.
Oil pump Oil pump gearsideclearanc€
Oil pump gear-to-bodycl€6rance
Oil pump driveng6arI.D.
Oil pump shaftO.D.
lWear or other
t_'--'
27.0- 27.r (1.063-1.067)
14.000- 14.010(0.5512 - 0.5516)
37.000- 37.039(1.{567- 1.4582) 37.045{1:4585}
0.03- 0.05 (0.001- 0.002) 0.07 (0.003)
Drive 0.210- 0.265{0.0083 - 0.0104)
Driv€n 0.070- 0.125(0.0028- 0.0049)
14.016- 1{.034(0.5518 - 0.5525) W6aror damage
13.980- r3.990{0.5504- 0.5508) Wearor damage

3-12
L
 Unit of length: mm (in)
- Automatic Transmission
[t!'tttltttt tt - Section 14
STANDAND
INEWI
MEASUREMENT Wir. Di.. o.D. Fr.. L.ngth t{o. of Colh

Springs Regulatorvalve spring A 1.8{0.071} 14.7(0.579) 88.6 (3.488) 16.5

Regulatorvalve spring I 1.8(0.071) 9.6 (0.378) 11.011.7321
Stator r€actionspring 5.5(0.217) 26.4(1.039) 30.3(1.193) 2.1
Modulator valv€ body 1.3{0.0s1) 9.4 {0.370} 37.3{1.469) 12.1
't2,5
Torque convortercheckvalve 1.1{0.043} 8.4 (0.331) 33.8(1.331)
Cooierch€ckvalve sprang 1.1{0.043) 8.4(0.3:]t) 33.8(1.331) 12.5
Reliefv6lvospring 1.r (0.043) 8.6 (0.3l9) 37.1(1.461t 13.4
2-3 orifice control valvo spring 0.9(0.035) 6.6 (0.2601 33.0(1.299) 14.9
Throttle valve B adiustingsPring 0.7(0.0281 6.2 (0.244) 34.0 fi.339)
Throttle valve B spring 1.4(0.055) 8.5 (0.335) 41.5(1.634) 10.5
Throttle valvo B 6pring 1.4(0.055) 8.5 (0.335) 41.5(1.63i1) 11.2
Throttle valve I spring 1.1(0.055) 8.5 (0.335) 41.6{1.638} 12.1
1-2 shift valve sprang 0.9(0.0351 8.6 (0.339) 40.4(1.591) 14.5
2-3 shift valve spring 0.9(0.0351 7.6 (0.299) 57,0 12.2111
3-4 shift valve spring 0.9{0.035) 7.6 (0.2991 52.0(2.047) 26.8
'lst-holdaccumulator spring 4.0{0.157) 21.5(0.846t 71.1Q.A23l E.3
't05.4(4.150) 16 + 8.6
1st accumulatorsprang 2.5(0.098) 16.3(0.642)
2nd accumulalorspdng 3.6(0.142) 22.0 (0.866) 108.9(4.287) 15.2
3rd accumulatorspring 2.8(0.1r0) 17.5(0.689) 105.2(4.'142) 19.'l
4th accumulatorsPrang 2.6(0.102) 16.3(0.642) 103.3{4.067) 21.2
Lock-upshift valve spring 0.9(0.035t 7.6 {0.299) 73.7 12.9021 32.0
Lock-uptiming B valve spring 0.8(0.0311 6.6 {0.260} 60.8 (2.394) 22.1
Lock-upcontrol valve spring 0.8(0.031) 6.6 (0.260) 39.5(1.5s5) 25.O
CPCvalve spring 1.3(0.051) 9.4 (0.370) 35.3(1.390) 12.1
Kick-downvalvo spring 1.0(0.039t 6.6 (0.260) 2a.5(.1221 11.7
3-2 kick-downvalvo spring 1.3(0.051) 8.6 (0.339) 45.6(1.795t 17.0
Servo control valve spring 0.9{0.035) 6.4 (0.252) 34.1{1.343) 11.5
4th exhaustv6lve spring 1.0(0.039) 7.1(0.280) 60.3(2.374) 18.5
Servo orifice controlvalve spring 0.8(0.031) 6.6 (0.260) 48.2{1.898} 33.0

3-13
Standardsand ServiceLimits
Differential(Manualtransmissionl Section 15
M€ASUREMENT STANDARDINEW) SERVICELIMIT
Differential PinionshaftcontactareaLD. 81881engine 18.000- 18.016(0.7087 - 0.7093)
8 1 8 C 1e n g i n e 18.000 18.018(0.7087 - 0.7094)
Carrier'to-pinionclearance 81881engine 0.0r3 0.045(0.0005 - 0.0018) o.t aron,
B18Ct engine 0.0'13 - 0.047(0.0005 0.0019) 0.1{0.006}
Driveshafvintermediate shaft contactarea LD.
8 1 8 8 1e n g i n e 28.000- 28.021\1.1024-1.10321
818C1engine 28.005- 28.025(1.1026 1.'1033)
Carrierto driveshaftclearance 81881engine 0.020- 0.062(0.0008 0.0024)
BlSC'lengine 0.045, 0.086{0.0018 - 0.0034)
Carrier-to-intermediate
shatt clearance
B188l engine 0.050- 0.087(0.0020 0.0034)
818C1engine 0.075- 0.111(0.0030 - 0.0044)
Differential Eacklash 0.05 0.15 (0.002 0.006) Adjust
prnrongear t .D . '18.042
- 18.066(0.7103 0.7113)
PiniongeaFto-pinion shaftclearance 0.055- 0.095(0.0022 0.0037) 0.15{0.006)
Sel ring-to-bearing outerraceclearance 81881engin€ 0 - 0.10(0 0.004) Adjust
Differentialtaper roller bearing preload
StartingtorqueN.m {kgfcm,lbf.in) Bl8Cl engine 2.1r- 3.04{21.5 - 3 r.0,13.0-18.7) Adjust

Differential (Automatic transmissionl Section 15

MEASUREMENT STANDAROINEWI SERVICELIM]T
Difterential Pinionshatt contactarea l.D. 18.000- 18.018{0.7087- 0.7094)
carfl€r Carrier-to-oinion
clearance 0.016- 0.052{0.0006- 0.0020) 0.1{0.004)
Driveshafvintermediateshaft contactare l.D. 28.00s 28.025{1.1026 - 1.1033)
Carrier-to-driveshatt
clearance 0.025- 0.066(0.0010- 0.0026) 0.12(0.005)
Differential Backlash 0.05- 0.15(0.002- 0.006) Adjust
prnrongear t.D. 18.042- 18.066(0.7r03- 0.7113)
Piniongear-to-pinion
shaftclearance 0.059- 0.095(0.0023- 0.0037) 0.15(0.006)
Set ring-to-bearing
outerraceclearance 0 - 0.r5(0- 0.006) Adjust

Steering - Section 17
MEASUREMENT STANDARDINEWI
Steeringwheel Rotational play at steeringwheelcircumference 0 - 10 {0 - 0.39)
Staninglosd at steeringwheelcircumference
N {kgf,lbfl Enginerunning 3 4\ 3 . 5 , 7 . 7 1
Gearbox Angle of rack-guide-screwloosenedfrom locked 20" i 5'
position
Purnp Pumppressurewith shut-offvalveclosed 6,400 7.400165 75.920- 1.r00)
kPa(kgtlcm,,psi)
Powersteering Recommended fluid Hondapowersteeringfluid V
tluid Fluidcapacity For overhaul 1 . 0 6( 1 . 1 2 , 0 . 9 8 )
f (USqt, lmp q0 Forfluid change 0.79(0.83,0.70)
Power steering with 98 N (1okgt,22lhfl
Deflection 11.5- 13.5(0.45 0.53)withusedbelt
belt* betweenpulleys 8.0- 10.010.310.39)withnew belt
BelttensionN lkgf,lbl) 390 - 540 (40- 55, 88 - 120)with used belt
Measuredwith belttensiongauge 740 880175 90. 170 200)with new belt
' When usinga new belt,adjustdetlectionor tensionto new values.Runthe enginelor 5 minutesthen turn it off.
Readiustdetlectionor tensionto usedbeltvalues.
 Unitof length:mm {in)
Suspension Sestion 18
MEASUFEMENT STANDARD
I]{EWI
Camber Front -0. 10'1 1.
a gnment Rgar -0' 15' l$igl
Caster Front 1. 10' rt"
Totaltoe Front 0i2(010.081
Rear rN3:i(0.121ff)
Frontwhe€lturningangle Inwardwhe€l 36'0o'r 2'
Outwsrd wh€el 30. 30'
A1lc€lbearing Endplay Front 0 - 0.05(0- 0.002)
Roaa 0 - 0.05{0- 0.002}
STANDARD INEWI UMIT
SEBVICE
Rim runout(Aluminumwheel) Axial 0 - 0.7{0- 0.03) 2.0(0.08)
Radial 0 - 0.7(0- 0.03) 1.5(0.06)
Rim runoutisteelwhgel) Axial 0 - 1.0{0- 0.0{) 2.0(0.081
Radisl 0 - 1.0(0- 0.04) r.5(0.061

Brake Section 19
MEASUREMENT STANDARD
{NEWI
trrling brake Play in strok€at 200 N {20 kgf, 44 lbt) To b€ lockodwhen pulled 6 -10
lever lorce nolchsa
; oot brake Pedalheighl lwith floor mat removod) M/T 160(6.30)
,adal 155(6.50)
Freeplay 1-5(0.04-0.20)
Vastercylinder Piston-to-oushrodclearance 0 - 0.4(0- 0.2)
STANDARD INEWI SERVICELIM]T
f,,s4brake Oiscthickness Front 20.9- 21.1t0.82- 0.83t 19.0(0.75)
Re6r 8.9- 9.1{0.35- 0.36) 8.0 (0.31)
Disc runout Front 0.10 (0.004)
R6ar 0.r0(0.00a)
Disc parallolism Front and rear 0.015(0.0006t
Padlhickness Front 9.5- 10.5{0.37- 0.41} r.6(0.06)
Roar 7.0- 8.0{0.27- 0.31) 1.6(0.06)

Air Conditioning Scction22

MEASUREMENT STANDABOIT{EWI
Ar conditioning Lubricantcapacitymf (ll oz) Cond€nser 25(5/6)
Evaporator 40t1 1/3)
Lineor hose 1 0( l B t
Receiver 10(1/31
Lubricanttype: NO-OlL8{P/N38899- PR7- A0l)
Compressor Lubricantcapacitym{ (ll oz} 140';u(4-23';")
Lubricanttvge: ND-O|L8(P/N38899- PR7- A01)
Stator coil resistanceat 68'F (20'C)0 3.4-3.8
Pulley-to-pressure plate clearance 0.5r 0.15{0.02r 0.006)
7.5- 9.5 {0.30- 0.37)with used b€lt*'
Compressor Detlectionwith 98 N (10 kgf, 22 lbf)
8.5- 10.5{0.33- 0.41}witht/sodbelt'3
b€h'r betlveenpulleys
5.0 - 7.0 {0.20- 0.28)with new belt
Belt t€nsion N (kgf, lbl) 390 - 540 {r0 - 55, 88 - 120}with used beh*'
Measuredwith beltlensiongauge 340- 490 {35 - 50, 77 - 110}with used belt*3
740 - 880 {75 - 90, 170- 200)with new belt
.1: Whenusinga new bek,adjustdellectionor tensionto new values.Runthe enginetor 5 minulesihen turn it ott.
Readiustdetlectionor tension to lsed beh values.
'2: 81881engine
'3: 818C1engine

3-15
 Standardsand ServiceLimits
Electrical Section23
MEASUREMENT STANDARD
{NEWI
lgnilioncoil Rat€dvoltago V
Primarywinding resistanceat 58'F (20'C)O 0.6- 0.8
Secondarywinding resistance6t 68'F (20"C)kO 12.4- 19.2
lgnition wire Resistancear 68"F(20'C)k0 25 max.
STANDARDINEW} SEN$CE UM]T
Sparkplug Tvpe See Section23
Gap B18Blengine 1.0- 1.1{0.039- 0.043}
ll B18Clengine 1.3{0.051)rl

il lgnition timing

Alternatorb€lt'2
At idling
" BTDC(Red)- rpm
Deflecrionwilh 98 N {10 kgf,22lbll
M/T 16"r 2. -750r 50(Neurra0
16"t 2"-750r 50|!]or L?.lposition)
9.0- 11.0(0.35- 0.43)with us6db6li
betweenpulleys 6.0 - 8.0 {0.24- 0.31}with new b6lt
Eelt t€nsion N (kgf, lbf) 340 - 490 {35 - 50, 77 - 110)with used bolt
Measured with belt tension gsuge 690 - 880 {70 - 90, 154- 198}with now boh
STANDARDINEWI SENUCEUMTT
Alternator Ourput l3.5 V at hot A 90
Coil resistance(rotor)at 68"F{20"C}0 2.9
Slip ring O.D. 14.4t0.57) tnnro.rrr
Brush length r0.5(0.41) 1.5(0.06t
Erushspring tonsion N (kgt, lbf) 3.210.33,
0.73)
Staner Output
Mica depth 0.5- 0.8(0.02- 0.03) 0.2(0.0081
Commulatot runout 0 - 0.02(0- 0.0008) 0.05t0.@2)
CommutatorO.D. 29.9- 30.0(1.177- 1.r81) 29.0(1.142)
Brushlength 15.0- 15.5(0.s9- 0.61) 10.0(0.39)
Brush spring tension (new) N lkgt, lbf) 17.7- 23.5fi.8- 2.4,4.0- 5.3)
*1: Do not adiust the gap, replacespark plug it it is out of spec.
*2r When using a new belt, adjust d€tl€ctionor tension to new valu€s.Run tho enginelor 5 minutesthon turn it off.
Readiustde{lection or tensionto usodbeltvalues.
DesignSpecifications
]TEM METRIC ENGLISH NOIES
:' vENSTONS Overalllength 3 DOOR 4.380mm 172.1in
4 DOOR 4.525mm 178.1in
'1,710
mm 67.3in
Ov€rallWidth
OverallHeight 3 DOOR 1,335mm 52.6in
4 DOOR 1,370mm
Wheelbase 3 DOOR 2,570mm 101.2in
4 DOOR 2,620mm 103.1in
't,475/1,470
mm 5|8.1/57.9 in
TrackF/R
GroundClearance 150mm
SeatingCapacity Four(3 DOOR)Five (4 DOOR)
,rerght(usA) WeightRating{GVWR)
crossV€hicle 3,680lbs
'le,ght {CANADA) GrossVehiclsWeightRating{GVWR) 1,670kg
:\GINE Type 8 1 8 8 1e n g i n e Water-cooled, 4-strokeDOHC
gasoline engine
818C1engine Watercooled,4-strokeDOHC
VTECgasoline engine
CylinderArrangement Inline4-cylinder, transverse
BoreandStroke 8 1 8 8 1engrne 81.0x 89.0mm 3.19x 3.50in
818C1engane 81.0x 87.2mm 3.19x 3.43in
Displacement 8 1 8 8 1engrne 1,834 cm3(mf) 112cu-in
B18CI engine 1,797 cm3(m{) 110cu-in
Ratio
Compression 8 1 8 8 1engine 9.2:1
B18C1engine 10.0: 1
8 1 8 8 1engine Eeltdriven,OOHC4 valvepercylinder
8 1 8 C 1engine Beltdriven,DOHCVTEC
4 valvepercylinder
L!bricationSystom Forcedandwet sump,trochoidpump
OilPumpDisplacement 8 1 8 8 1engrne 50, {53USqt, 44lmpqt)/minute'l
B18C1 engrne 71 f {75USqt, 62 lmp qt)/minute"
WsterPumpDisplacement 8 1 8 8 1engine 140f (148USqt, 123lmpqt)/minute*!
B18C1engine 140f (148USqt. 123lmpqt)/minute*'
FuelRequired 9 1 8 8 1engine UNLEADED gasoline with86 Pump
OctaneNumb€ror higher
818C1engine Premium UNLEADED gasoline wilh
91 PumpOctaneNumberor higher
STARTER Typo Gearreduction
NormalOutput 1 . 4k W
NominalVoltage 12V
HourRating 30 seconds
Directionof Rotation Clockwiseasviewedlrom g6arend
Weight 3.7k9 | 8.3lbs
CLUTCH ClutchType M/T Singleplatedry,diaphragm spring
Torq!e converter
Area
ClutchFacing 203cm' I 31 sq-in
TRANSMISSION Transmission
Type M/T Synchronized 5-speedforward,1 reverse
Electronically controlled
4-speedautomatic.1 rcverse
PrimaryReduction Diract1 : 1
'1: At 6,000enginerpm (cont'd)
'2: At 7,600enginerpm

3-17
DesignSpecifications
{cont'd}
lTEM M E T R I C I € i I G L I S H I N O T E S
TRANSMISSION Type Manual transmission
Enginetypo 81881 | 818C1
G6arRatio 1st 3.230 3.230
2nd 1.900 r.9(X)
3rd 1.269 1.360
4th 0.966 1.034
5th o.711 0.'t87
Rov€rs€ 3.000 3.000
Fin6l Reduction Geartype Singlehelicalge.r
Gear ratio 4.266 4.400
Type Automatictransmission
GearRatio 'l6t 2.722
znd 1.464
3rd 0.97s
4th 0.638
Revelse 1.954
FinalR€duction Goartypo Singlehelic6lgoar
Gear ratio 4.357
AIR Cooling Capacity 3,570Kcal/h 14,166BTU/I
CONDITIONING Compr6ssor Type/Make swash-plare/NIPPoNDENSO
No. ol Cylinder 10
CaPtcity 150ml /rcv | 9.15cu-in/r€v
Max. Spsed 7,600rpm
LubricantC6pacity 140mf | 1-2Blloz
I l.;3 tmpoz
Lubricrnt Type ND-O|L8 (P/N38899- PR7- A01)
Cond6ns€r Type Corrugatedfin
Evaporator Type Corrugatodtin
Blower Type Siroccotan
Motor Input 200w12 v
SpeedContro 4-speed
Max. Capachy 450 m3/h | 15,900cu lvh
TemperatureControl Airmix type
CompressorClutch Type Dry, singlo plate, poly-V-b€ltdriv6
PoworConsumption 40 W max./12V at 68"F{20'C)
Refrigerant Type HFC-134a (R-134a)
Ou.ntity zoo-Ss I 24.7-l.aoe
STEERING Type Power assisted,rackand pinion
SYSTEM OverallRatio 16.1
Turns, Lock-to-Lock 2.98
SreeringWheel Dia. 380 mm | 15.0in
SUSPENSION Type Front Independentdouble wishbono,
coil spring with st6bilizer
Roar Independontdouble wishbong.
coil spring with stabilizer
ShockAbsorb€r,Front and Rear Telescopic,hydraulic nitrogen gas-tilled

3-18
 ITEM M E T R I C I E N G L I S H I M ) T E S
WHEEL Camber Front -0.10'
ALIGNMENT Rear -0.45'
Caster Front 1'1o'
TotalToe Front omm | oin
Rear In 2 mm I ln 0.08in
BRAKESYSTEM Type Front Power-assistedselt-adiusting
ventilateddisc
Rear PoweFassistedself-adjustingsolid disc
PadSurfaceArea Front io.u cm. x z | /,/5 so tn x z
Rear 21.0cm, x2 | 3.26sq in x 2
ParkingBrake Type Mechanicalactuating,reartwo wheel brakes
TIRE Size Front and r€ar P195/60R14 858*1
P195/55R15 84V*2
SpareTire T115t0D14*3
T135/70O15.4
ELECTRICAL 8attery I2V-36AH6HR
'12V -'1.4 kW
Starter
Alternator 12V-90A
Fuses
In Under-dashFuse/RelayBox 7.5A, 10A, 15A, 20 A, 30 A
In Under-hoodFuse/RelayBox 7.5 A, 10 A. 15 A, 20 A, 30 A, 40 A
50 A, 100A
In Under-hoodABS Fuso/RolayBox 1 0 A ,1 5 A , 2 0 A , 4 0 A
Headlights High 12V-6sW{HB3}
12V-55W(HB4)
FrontSideMarkerLights 12V-3CP sAE 168
FrontTurn SignauParkingLights 12V -32n CP sAE1157
RearTurn SignalLighls 12V -32 CP sAE 1't55
Stop/Taillights 12V -32n CP sAE1157
High Mount BrakeLight'5 12V-21W sAE7440
FearSideMarkerLights 12V-3CP sAE 168
Back-upLights 12V -32 CP sA€ 1156
LiconsePlateLights 12V-8W
CeilingLights 12V-5W
CargoArea Lights (3 DOOR) 12v-3.4W
TrunkLightsl4 DOOR) 12V-3.4W
Spotlights 12V-5W
GloveBox Light 12V-3.4W
GaugeLights 12V-3.4W
IndicatorLights v - 0.84w, 0.91w, 1.12W, 1.r W, 3 W
llluminationand PilotLights 12 V - 0.84W. 0.91W, 1.4W. LEO
HeaterllluminationLights 12V-1.4W
*1: RS,LS
*2: GS-R
*3: RS
*1: LS,GS-R
*5: Excepthigh mount brakelight installedin rcar spoiler.

3-19
Il Body Specifications

I
il
3 DOOf,: Unit:mm (in)
. DOOR: Unit mm {inl

3-21
Maintenance
Points
Lubrication .........4-2
MaintenanceSchedule ." 4'4
LubricationPoints

For the detailsol lubricationpoints and type of lubricantsto be spplied,reter to the illustratedindex and variouswork
procedure(such as Assembly/Reassembly, Replacement,Overhaul,Instatlation,etc.) containedin each section.

No. LUBRICATIONPOII\ITS LUBRICAI\IT

I Engine API ServiceGrade:Use SG or SH "Energy Conserving
II" grade oil.
The oil containermay also displaythe API Certification
s€al shown below. Make sure it says'For Gasoline
Engines.'
SAE Viscosity;See chan below.
Transmission Manual API Service Grades: SF or SG
SAE Viscosity: 1O W-3O or 1O W-4O
Automatic Honda Premium Formula or DEXRON@II
Automatic transmissionfluid
3 Brakeline (lncludesAnti-lockbrake linel Brakefluid DOT3 or DOT4
4 Clutch line Bfake tluid DOT3 or DOT4
Power steeringgearbox SteoringgreaseP/N 08733-BO7OE
Releasefork (Manualtransmission) Supe. High Temp Urea Grease(P/N O8798*9OO2)
Throttle wire end {Dashboardlower Danelholel
8 C.uisecont.ol actuatot wire end Siliconegrease
{Dashboardlower Danelholel
I Throttle cable end (Throttlelinkl
1 0 Cruisecontrol actuatorcable end lActuator link)
'I 'l
BrakemastercvlinderDushrod
12 Clutch mastercylinderpushrod
13 Enginehood hingesand enginehood latch
14 Batte.v terminals .Multi-purposegrease
15 Fuel fill lid
to Hatch hingesor trunk hinges
17 Door hinges.upper and lowet
18 Door oDendetent
19 Rear brakecalioers Rust-p,eventive
agant
20 Power steering system Honda power steering tluid-V
21 Air conditioningcompressor Retrigerantoit ND-otL8 |PlN 38899-pR7-A01)
(For Relrigerant:HFC-134a(R-134a))

-20 0 20 r}() 60 ao loooF

-30 -20 -'to o 10 20 30 40"c

API CERTIFICATIONSEAL Recolnmendodengine oil

Engine oil viscosity tor
ambient tgmpelalure rangos
 @
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\.___
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4-3
 MaintenanceSchedule
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4-5
 MaintenanceSchedule

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4-6
Engine
E n g i n eR e m o v a l / l n s t a l l a t i o. .n. ' ' . . . . . . . .5 - 1
C y l i n d e rH e a d / V a l v eT r a i n . . ' . . . . . . . . . . . .6 - 1
EngineBlock.... ......7-1
EngineLubrication .........8-1
System ...... 9-1
IntakeManifold/Exhaust
Cooling .......1O-1
EngineRemoval/lnstallation
S p e c i aTl o o l s . . . . . . . . .".....5-2
EngineRemoval/lnstallation ..."........ 5-3
Mount/BracketTorque ..' 5-16
 SpecialTools

ru Rst. No.

o
I Tool Numbor
07MAC-SLOO200
Dascription
Ball Joint Remover,28 mm
Oty Pag€ R€terenco

il
EngineRemoval/lnstallation

2. Removethe strut brace

@
a Make surejacks and safety stands aro placed ploper-
ly and hoisl brackots arg attachod to the correct po- 8 x 1.25mm
24 N.m (2.4 kgf.m,
sitions on tho engine (se€ ssction 1). 17 rbt.ft)
a Mak€ sure tho car willnot roll off stands and tallwhile
you are wotking under it'

CAUTION:
a Use fendet covals to avoid damaging painted
sudaces.
r Unspecified itsms alo common
a Unplug tho widng connectots carefully while holding
the couplor and tha connector portion to avoid
oamage.
a Mark all wiring and hoses to avoid misconnection.
Also, be sulo that thsy do not contact other wiring
or hoses, or interfere with oth€l parts.
STRUTERACE
NOTE: Anti-theft radioshave a coded theft ptotection
circuit. Be sure to get the customer'scode numberbeJore
- Disconnectingthe batterY.
- Removingthe No. 32 (7.5 A) fuse from the under-
hood tuse/relaybox.
- Removingthe radio
Disconnectthe batterynegativeterminallirst. then
Atter service,reconnectpower to the radio and turn it
"CODE" is displayed,enterthe cus- the positiveterminal.
on. Whenthe word
tomer's 5-digit code to restoreradio operataon.
Disconnectthe batterycablesfrom the undel-hood
fuse/relaybox and under-hoodABS fuse/relaybox.
1. Removethe hood (seesection 2O).

BATTERYCABLES

6 x l.O mm
9.8 N.m (1 .O kgf'm,
7.2 rbl.ftl

{cont'd)

5-3
 EngineRemoval/lnstallation
(cont'd)

Removethe intakeair duct, air cleanerhousingas- 7. Removethe enginewire harnessconnectoEon the

semblv and the bracket. right side of enginecompartment.

6 x 1 . Om m
9.4 N.m {l.O ksf.m, 7.2 tbf,ftl 6 x'l.Omm

m
9.8 N-m ll.0 kgt.m.

8. Relievefuel pressureby looseningthe servicebolt

on the tuel filter about one turn {see section 1 1).

@ oo not amoke whito working on tho

Removethe evaporativeemission(EVAp) control
canisterhose and vacuum hose.
VACUUM HOSE
fuel system. Keepopen flame away trom wo.k arsa.
Drain fuel only into an approved container.
CAUTION:
a Beforedisconnoctingany fu€l line. reliovothe tuol
pressule as doscribed above.
a Placea shop towel ov61the fu6l filter to prevont
prossurizedtuel from spraying ovel tho aogine.

9. Removethe fuel feed hose.

SERVICE BOLT
15 N.m (1.5 kgt.m,11 tbt.ftl

BAITJO EOLT
33 N.m 13.4 kgt.m,
THROTTI.EBODY 25 tbt.ftt
 ' t 2 . Removethe enginewire harnessconnectors,termi-
1O. Removethe brake boostervacuum hose and fuel
return hose. nal and clamps on the left side ot engine com-
oartment.
6 x 1 . Om m ENGINEWIRE
11 N.m {1.1kgl'm, BRAKEBOOSTER
VACUUMHOSE 6 x 1.0 mm HABNESS
8.O rbt.ltl 9.8 N.m {1 .O kgf.m,
7.2 tbt.ftl

BETURNHOSE

' t1 . Removethe throttlecableby looseningthe locknut.

linkage.
then slipthe cableendout of the accelerator
13. Removethe cruisecontrol actualor.
NOTE:
a Take care not to bendthe cablewhen removing
it. Always replaceany kinkedcable with a new 8 x 1.25mm
one, CRUISECONTROL
24 N.m (2,4 kgl.m,
a Adjust the throttle cable when installing(seesec- ACTUATOR
17 lbf.Irl
t i o n 11 ) .

LOCKNUT

AOJUSTINGNUT

5-5
EngineRemoval/lnstallation
(cont'd)

1 4 . Removethe engineground cable at the body end. 17. (Manusl transmission)Remove the clutch slave
cylinder and pipe/hose assembly.
Removethe adiustingbolt and mountingbolt, then a Do not disconnectthe pipe/hoseassembly.
remove the power steering (P/Sl belt and pump.
a Do not disconnect the P/S hoses. 6 x 1.Orl|m
ll N.m { 1.1 kgt.m, SLAVE CYLINDER
8.0

8 r 1 . 2 5m m
24 N.m (2.4 kgf.m. 17 lbl.ftl 8 x 1.25mm
24 N.m {2.4 kgl.m,
17 lbt.ftl

6. Loosenthe idlerpulleybolt and adjustingbolt, then 18. Removethe transmissionground cable and hose
removethe air conditioning(A/C)compresso.belt. cramp.

6 x 1 . Om m
1l N.m 11,1 kgt.m,
I tbt.ftl

IDLERPULLEYBOLT
10 x 1.25mm
44 N.m 14.5 kgt.m, 33 lbl.ftl
A/C COMPRESSORBELT

5-6
19. Removethe radiatorcap. 25. Removethe upperand lower radiatorhosesand the
heater hoses.
@@ u"" care whan removing the ladiatol
cap to avoid scaldingby hot enginecoolant ol ateam.
UPPERRADIATOR

20. Raisethe hoist to full height.

21. Removethe front tires/wheelsandthe splashshield.

LOWERRADIATOR
HOSE

6 x 1 . Om m
9.8 N.m (1.0 kgf'm'
7.2 tbf.ft) 26. (Automatictransmission)Removethe ATF cooler
hoses.

2 2 . Drainthe enginecoolant (see page 1O-5).

a Loosenthe drain plug in the radaator.

Drainthe transmissionoil or fluid. Reinstallthe dtain

plug using a new washer.

2 4 . Drainthe engineoil. Reinstallthe drain plug using

a new wasner.

CAUTION: Do not overtighten tho drain plug.

HOSE

{cont'd)

5-7
*l EngineRemoval/lnstallation
(cont'dl
27. Removethe radiatorassembly{see page 1O-4), 8188l engine:

28. Removethe A/C compressor.

a Do not disconnectA/C hoses.
8 x 1.25mm
24 N.m 12.4 kgf.m,
17 tbt.trl

GASKET
Replace.

GASKET
Replace.

SELF.LOCKINGNUT
I x 1.25mm
16 N.m (1.6kgt.m,
12 tbf.ft)
Replace.
10 x 1.25mm
54 N.m (5.5 kgl.m,
40 tbt.ttl
Replace.
8 x '1.25mm
24 N.m t2.4 kgf.m,17 lbl.ftl

29. Disconnectthe heatedoxygensensor(HO2Slcon- 30. Removethe shift rod and extensionrod {M/T).
nector, then removeexhaust pipe A.

B'l8Cl engine: Ho2s

CONNECTOR
I x 1.25mm SHIFTROD
22 N-m 12.2 kgf.m, '16 lbf.ftl

I x 1.25mm
24 N.m (2.4 kgf.m,
17 rbt.ftt

Replace.

SELF-LOCKING NUT
8 x 1.25mm
1 6 N . m 1 1 . 6k g f . m , EXHAUST
12 tbl.ftl PIPEA
Replace. SELF
1 0 x 1 . 2 5m m
54 N.m (5.5 ksf.m.4O lbf'ltl
Replace.

5-8
31. Remove the shift cable ( A / T ) . 34. Removethe driveshatls.

CAUTION:
a Do not pull on tho ddv$halt, tho CV ioint mav
I x 1.25mm
22 f.m 12.2 kgl'rn' SHIFT CABLE como apan.
16 tbl.ftl a Uso caro whsn prying out tho assombly.
Pult it slraight to avoid damaging th6 differantial
oil soal or intormodiato shaft dust seal.

NOTE: Coat all precisiontinished surfaces with

cleanengineoil or grease.Tie plasticbags over the
driveshaftends.
CONTROL
LEVER

SHIFT CAALE
covER locx usiea 6 x 1.0 mm
Replace. 14 N.m t1.4 kgf.m, 10 lbl'ftl

32. Removethe dampertork.

3 3 . Disconnectthe suspensionlower arm balljointsus-

ing the specialtool. Referto section 18 tor the proper
procedure.

NOTE: Adjust the tool so the iaws are parallelto

each other.

12 x 1.25mm REMOVER28 mm (cont'd)

oTMAC-S100200

5-9
 I EngineRemoval/lnstallation
(cont'd)

35. Lower the hoist.

I
I
36. Attach the chain hoist to the engine.

I
I
I
37, Removethe left and right front mounts and brackets. 39. Removethe side enginemounr.

1 0 r 1 . 2 5m m WASHERS
Replace.
Replace.
SIDE ENGIITE

MOUNTBOLT

LEFT FRONT
MOUNT
12 t 1.25nn
59 N.m {6.0 kgt.m,
43 lbf.trl
Replace.

40. Removethe transmissionmount

TRA SM|SS|OI{
MOUNT

MOUNT/BRACKET

38. Removethe rear mount bracket,

1 2 r 1 . 2 5m m
59 N.m (6.0 43 rbf.ftl
Replace.
12 r 1.25m|n 41. Checkthat the engineis completelyfree of vacuum
REARMOUNT 59 N.m {6.0 kgt.m, hoses, fuel and engine coolant hoses, and electrical
43 tbt.frl wi.ing.
Replace.
42. Slowly raisethe engineapproximately150 mm (6
in), Check once againthat all hosesand wires are
disconnected from the engine

43. Raisethe engineall the w8y and removeit trom the

car.

14 x 1.5 mm
118 t{.m (12.O kgt.m,86.8 lbl.ft}
R6place. (cont'dl

5-11
EngineRemoval/lnstallation

SIDE ENGITIE
MOUNT

5-12
Engine Installation Install the engine side mount, then tighten the
Installthe enginein the reverseorder of removal. bolt/nutson the engineside. Leavethe mount bolt
Reinstallthe mountbolts/nutsin the followingsequence. loose.
Failureto tollow theseproceduresmay causeexcessive
noise and vibration,and reducebushinglife. 10 x 1.25mm
52 N.m {5.3 kgf.m,
38 rbf.Itl
1. Install the transmissionmount, then tighten the Replace.
side.Leavethe mount
bolt/nutson the transmission
bolt loose.

A/T:
12 x 1.25mm
64 N.m (6.5 kgt.m,
47 rbf.ft)

3. Tightenthe mount bolt on the transmissionmount.

A/T:

M/T:
1 2 x 1 . 2 5m m
64 N.m 16.5 kgl.m,
47 tbt.frl
1 2 x 1. 2 5 n n
74 N.m (7.5 kgl.m,
54 rbf'ftt
M/T:

1 2 x 1 . 2 5m m
74 N.m (7.5 kgt.m,
54 tbt.ftl

{cont'd)

5-13
 EngineRemoval/lnstallation
(cont'dl

4. Tightenthe mount bolt on the side enginemount. 6. Installthe right front mount/bracket,then tighten the
bolts in the numberedsequenceas shown (O-@).

A/T: ' 1 . 2 5m m

m'
.tE @ 10 x
44 N.m (4.5 kgt'm,
33 tbt.fr)

12 x 1.25mm
74 N.m (7.5 kgf.m,
54 lbt.ttl

O 12 x 1.25mm
64 N.m 16.5 kgt.m,47 lbf.ftl
Replace.

5. Installthe rearmount bracket,then tightenthe bolts

in the numberedsequenceas shown {@ @).
M/T:
' 1 0x 1 . 2 5 m m
@
44 N-m (4.5 kgf.m,

@ 12 x 1.25mm
59 N.m {6.0 kgf'm, 43 lbl'It)
Replace.

12 r 1.25mm
59 .m 16.0 kgl.m,
O 1 2 x 1 . 2 5m m
83 N'm (8.5 kgf.m,61 lbt.frl
 Insrallthe left front mount,then tightenthe bolts in a Check that the sp.ing clip on the end of each
the numberedsequenceas shown (O-@), driveshaftclicks into place.

GAUTION: Uso oow spring clips.

a Bleedair trom the coolingsystem at the bleedbolt

O 12 x 1.25 ]n]n with the heatervalve open (see page 10-5).
83 N.m 18.5kst.m,61 lbt.ftl a Adjust the th.ottle cable (see section 1 1).
Replace. a Check the clutch pedaltree play lsee section 12).
a Check that the transmission shifts into gear
smoothlv,
a Adiust the tension of the following drive belts.
@ 1 2 r 1 . 2 5m m Alternatorbelt {s€e section 23).
59 N.m {6.0 kgl.n, P/S pump belt {see section 17).
43 tb{.ftl
Replace. A/C comoressorbelt (seesection 22).
a Inspecttor fuel leakage(see section 1 1).
. After assemblingfuel line parts, turn on the ig-
nition switch (do not operate th€ starter) so
that the Juelpump operatesfor approximat€-
lV two secondsand the tuel line pressurizes.
Repeatthis operation two or three times and
check for fuel leakageat any point in the fuel
line.
@ 1 0 r 1 . 2 5m m
44 N.m (4.5 kgf.m, 33 lbt.ftl

(cont'd)

5-15
k-
 Mount/BracketTorque

Mount and BracketEolts/NutsTorque Valve Specification:

il
TRANSMISSION
MOUNT:

I
I
 SIDEENGINE
MOUNT: Torqus Spocifications:
A : 1 0 x 1 . 2 5m m
59 N.m (6.O kgf.m, 43 lbf.ft)
B: 12 x 1.25 mm
59 N.m {6.0 kgt.m. 43 lbt.ft}
Reolace.
C: 14 x 1.5mm
1 1 8 N . m { 1 2 . Ok g t . m , 8 6 . 8 l b t . t t }
Replace.
D: 12 x 1.25 mm
74 N.m {7.5 kgf.m, 54 lbf.tt}
E : 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m, 47 lbf.ftl
F: 10 x 1.25 mm
52 N.m {5.3 kgl.m, 38 lbt.ft}
Replace.
G : 1 0 x 1 . 2 5m m
rt4 N.m (4.5 kgf.m, 33 lbf.ft)
H : 1 2 x 1 . 2 5m m
83 N.m (8.5 kgt.m. 61 lbl.ft)
l r 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m, 38 lbf.tt)
Reolace.

LEFTFRONTMOUNT:

/>
{cont'd)

5-17
Mount/BracketTorque
(cont'd)

REARSTIFFENER ALTERNATORBRACKET

10 x 1.25mm

'1.25mm
M/T: 12 x
57 N.m 15.8 kgf'm, 8x1.25mm
42 rbf.ft) 24 N.m 12.4 kgf'm, SIDEENGINEMOUNT
A/T: 10 x 1.25mm 17 tbt.ftt BRACKET
/14 N.m {4.5 kgf.m,
32 tbt.ftl

lO r 1.25mm
54 N'm (5.5 kgl.m,
40 tbf.ft)

P/S PUMP BRACKET

1 0 x 1 . 2 5m m
44 N.m (4.5 kgf'm, 33 lbf'ft|

FRONTSTIFFENER
(B18Cl engin€onlyl
t-*i; HEAT
INSULATOR
f--^,c*;"*".*- -
(818C1

l q Ghinein"onvt
I -4M ddv
'12 x 1 .25 mm ' 1 1N . m ( 1 . 1 k g l ' m , 8 O l b f ' t t )

57 N.m 15.8 kgt.m,

42 tbf.fr)

8 x 1.25mm
10 x 1.25mm 10 x 1.25mnl
24 N.m (2.4 kgf.m,
44 N.m {4.5 kgf.m, 44 N.m (4.5 kgf.m,
17 tbf.ft)
33 rbr.ftt 33 rbr.tt)

5-18
CylinderHead/ValveTrain
8 1 8 8 1e ngine

SpeciafTools .............6-2
Valve Clearance
Adiustment ............6-3
ValveSeals
Replacement(cylinderhead
removalnot required) .....................
6-5
Reconditioning ......6-27
Timing gelt
lllustratedIndex ...............................
6-7
Inspection ..............
6-9
TensionAdiustment ........................
6-9
Removal .................6-10
Installation .............6-12
CrankshaftPulleyBolt
Replacement .........6-8
 SpecialTools
-

t
Ref.No. I Tool Numbrr Ocacription Oty I Prgc R.terencc

o 07GAD- PH70100 ValveGuidelnstaller 1

o 07JAB- 001020A HolderHandle 1 6-8
OTMAB_ PY3O1OA PulleyHolderAttachment,HEX50 mm,
Offset 1 6-8
o 07757- PJ10toA ValveSpringCompressorAttachment 1 6-22
@ 07947- 6570100 ValveGuideDriver,6.6 mm 1 6-25,26
@ 07984- 657010C ValveGuideReamer,6,6 mm 1 6-26

I
o @

e:=-4-b4altltgt r-l-:ff:-b

@
ValveClearance
Adjustment
NOTE:
. Valves should be adjustedcold; at a cylinder head
temperatureof lessthan 100'F(38"C).
Adjustmentis the same for both intakeand exhaust
valves.
. After adjusting,retorquethe crankshaftpulleybolt to
177N.m (18.0kgim, 130lbf.ft).
2. Set the No. 1 piston at top dead center(TDC)(see
p a g e6 - 1 2 ) ." U P " m a r k o n t h e p u l l e ys h o u l db e a t
the top, and the TDC grooveson the pulley should
align with the TDC groove on timing belt back
cover.TDC mark (paintedwhite) on the crankshaft
pulley should align with pointeron the timing belt
towercover.

1. Removecylinderheadcover. Number 1 Diston at TDC:

ADJUSTINGSCREWLOCATIONS: "UP" MARKS

INTAKE

TDCGROOVES

EXHAUST

TDCMARKS
lPeintedwhitel

CRANKSHAFT
PULLEY

6-3
ValveClearance
Adjustmentlcont'dl
a on No. 1 cylinder.
Adjustvalveclearances 7. R o t a t et h e c r a n k s h a f t1 8 0 ' c o u n t e r c l o c k w i s €t o
bring No. 4 piston to TDC.The'UP" mark should
lntlkc: 0.08- o.l2 mm (o.(Xxl- 0.qr5 in) be pointing straight down. Adjust valves on No. 4
Exhru3t 0.16- 0.20 mm {0.0,05- 0.008in} cylinder.

4. Loosen lhe locknut and turn the adjusting screw Numb€r il piston at TDC:
until feelergaugeslidesbackand fonh with a slight
amountof drag.

LOCKNUT9x0.?5mm
25 N.m 12,5kgf.m, 18lbt'ft|

"UP'MARKS

Tightenthe locknutand recheckclearanceagain.
Repeatadjustment if necessary.
6. Rotate ths crankshaft 180" counte.clockwise
(camshaftpulleyturns 90'). The "UP" mark should
be on the exhaustside.Adjustvalveson No. 3 cylin-
der.
8. Rotate the crankshaft 180' cou nie rclockwise to
bring No. 2 piston to TDC.The "UP" mark should
be on the intakeside.Adjust valveson No. 2 cylin-
oer.
Numbor 2 pirton !t TDC:

I{umbcr 3 pidon !t TDC: -UP" MARKS

.UP' MANKS

EXHAUST CAITISHAFT INTAKECAMSHAFT NOTE:Referto page6-31when installingcylindorhEEd

PULI,IY PULLEY cover.
ValveSeals
(cylinderheadremovalnot requiredl
Replacement
NOTE: Cylinder head removal is not required in this Select the 7E in. diameter long compressor attach-
procedure. ment and fasten the attachmentto the No. 4 hole of
the leverarm with the speedpin supplied.
The procodureshown below applieswhen usingthe in-
c a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h Positionthe pistonat TDCand insertan air adaptor
Y AAA$-2A 718"attachment). into th€ spark plug hole. Pump air into the cylinder
to keepthe valv€closedwhile cgmpressingsprings
whcn u3ing this tool, a: with any tool, and removing the valve keepers.
@@
always u!€ agproved cyr Protcction. Using th.
right tool for cach iob hclps incraa3. produstivity Position the lever arm under the cross shaft so the
whilo 3ltrgu8rding tool!, cquipmcnt lnd the u3c1' lever is psrpendicularto the shEft and ths compres-
sor attachment rests on toD of the rstainer for th€
1. Turn the crankshaftso that the No. I and the No' 4 spring being compressed.Use the rear position slot
pistons are at top d€ad center (TDC). on the leveras shown.

2. Removethe cylinderheadcover. NOTE: Put shop towels over the oil passag€sto
preventthe valve keepersfrom falling into the cylin-
3. Removethe distributor. der h€ad.

4. Loosen and disconnectthe timing belt from the

c8mshaft pulleys. OIL PASSAGE

5. Removethe camshaft holde, bolts, then r€move the

camshaft holder,the camshaftand rocksr arms.

lntakc V!lv6 Sclls

6. Usingthe 6 mm bolts suppliedwith the tool, mount
the two up.ights to the cylinder head 8t the end
camshaftholde.s.The uprightsfit as shown.

7. Insortthe cross shaft through the bottom hole ot

the two up.ights.

OIL PASSAGES

(cont'd)

6-5
 ValveSeals
Replacement(cylinderhead removal not required) (cont'dl
'11.
Using a downward motion on the lever arm. com- 21. Positionthe lever arm unde. the crossshaft so the
pressthe valvespringand removethe keepersfrom lever is perpendicular
to the shaftand the compres-
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e sor attachmentrests on top of the retainerfor the
spring. spring beingcompressed.Usethe rear positionslot
on the leveras shown.
- Repeatstep l1 for the othervalvein that cylinder.
N O T E :P u t s h o p t o w e l s o v e r t h e o i l p a s s a g e st o
Removethe valveseals(seepage6-22). preventthe valvekeepersfrom fallinginto the cylin-
der head.
'14. Installthevalve
seals(seepage6-23).
OIL PASSAGE
Installthe springs,the retainersand the keepersin
reverseorder of removal.

16. Repeatsteps9 to l5 for the otherthreecylinders.

ExhaGt Valvs Soals

17. Usingthe 6 mm bolts suppliedwith the tool, mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
camshaftholders.The uprightsfit as shown.

18. Insert the cross shaft through the bottom hole of

the two uprights.

Using a downward motion on the lever arm, com-

pressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.

Repeatstep22 for the othervalvein that cylinder.

1 9 . Selectthe 7/8 in. diameter short compressorattach-
ment and fastenthe attachmentto the No. 4 hole of Removethe valveseals(seepage6-22).
the leverarm with the speedpin supplied.
Installthe valveseals(seepage6-23).
20. Positionthe pistonat TDCand insertan air adaptor
into the spark plug hole. Pump air into the cylinder Installthe springs,the retainersand the keepersin
to keepthe valveclosedwhile compressingsprings reverseorderof removal.
and removingthe valvekeepers.
27. Repeatsteps20 to 26 on the otherthreecylinders.

NOTE:Relerto page 6-31when installingcylinder

neaocover.
Timing Belt
lllustratedIndex
NOTE:
. Referto page6-12for positioningcrankshaftand pulleybeforeinstallingbelt.
. Mark the direction of rotation on the belt before removing.
. Replacethe rubbersealstor oil leakag€betweenthe cylinderheadand cover.
a Do not uss the middle cover and lower cover for storing itsms disassembled.
. Cleanthe middlecoverand lowercover beforeinstallation.

CAPNUT
6xl.0mm
9.8N'm (1.0kgf.m,7.2lbtft) WASHER
Replacowhen damaged
\o or deteriorated.
CYLINDERHEADCOVER
Referto pago6-31when
installing.
RUBBERSEALS
Replacewhen damaged
or deleriorsled.

8 x 1.25mm
37 N.m 13.8kgl.m,27 lbf'ft)

BACK OOVER
AD.'USTINGBOLT
10x t.25mm
5/rN.m15.5kgl.m,,o lbtft)
Foradjustrnent
only,
do not r€move,

COVER

6x1.0mm
9.8 N'm (1.0kg{.m.t.2 lbf.tt}
6x1.0mm
9.8 N,m 11.0kg{.m,
7.2 lbl.frl

TIMIMi BELT ALTERNATOR

Inspection,page 6-9 BELT
Adlustment,pago 6-9 lnstallwithconcave Adjustm6nt,
Replacement, page6"10 surfacefacing in. Soction23
Clean.

CRANKSHAFT
LOWEn PULI"EY
TIMINGBELT COVER Romov6any oil
DBIVEPULLEY and clgaaon thg
Removeany oil timing bolt guide
and clean, lnstall with concave plato side.
surfacefacing out,
Removeany oil
ano ctean.

BOLT
NOTE:When installinga new crankshaftand/ornew bolt: '14x 1,25mm
O tightenthe crankshaftpulleybolt to 196N'm (20.0kgf'm,145lbf'ft), lt7 t{.m 118.0kgl.m, 130lbtftl
O loosenbolt, Replacsmenl,page 6-8
O retightenit to 177N.m (18.0kgt.m,130lbf'ftl.

6-7
 CrankshaftPulleyBolt
Replacement

It NOTE:
. Crankshaftpulleybolt sizeand torquevalue:
1 4x 1 . 2 5m m
177N.m (18.0kgt.m.130lbf.ft)
. When installinga new crankshaftand/or new pulley
When installingthe bolt, lubricatethe threads and
flang€with engin€oil, but don't lubricatethe washe.
and pulley.

bolt:

Q tiglten the pulleybolt to 196 N.m (20.0kgf.m,145

tbnft).
O loosenthe bolt,
O retightenit to 177N.m (18.0kgf'm.130lbf.ft).

Don't lubricat€washer.

HOI-DERHANDII
o'JAB -oo1020A

PULI.TY HOI.I'€R ATTACHi'ENT,

HEX50 mm. OFFSET
- PY3010A

19 mm
SOCrETWRENCH,
AVAILABI.I
COMMERCI,ALLY
Timing Belt
Inspection TensionAdjustment

Removethe cylinderheadcover.
. Relerto page6-3'lwhen installing.
Inspectthe timing belt for cracksand oil or coolant
soaking.
NOTE:
. Replacethe belt if oil or coolantsoaked.
. Rsmove any oil or solvent that gets on the belt.
CAUTION: Always Ediust timing belt tonsion with tho
cngin. cold.
NOTE:
. The tensionetis spring-loadedto apply proper ten-
sion to the belt automaticallvaftermakingthe follow-
ing adjustment.
. Always rotate the crankshaftcounterclockwisewhen
viewed trom the pulley side Rotating it clockwise
may result in improper adjustmentot the belt ten-
sion.

R e m o v et h e c y l i n d e rh e a d c o v e r . ( R e f e rt o p a g e
6-31when installing.)

Setthe No. 1 pistonat TDC(seepage6-12).

3. Rotatethe c.ankshaft5 - 6 revolutionsto set the

bslt.

4. Setthe No. I pistonat TDC.

ADJUSNNGBOLT
54 N.m (5.5kqf.m,
a0 rbr.ftl
Foradiustmentonly,
do not remove,

Rotatepulley Directionol
and inspscrbell. rolatlon.

5. Loosenthe adiustingbolt 1/2turn (180')onlv

6. 3-teethon
Rotatethe crankshaftcounterclockwise
the camshaftpulley.
After inspecting,retorque the crankshaftpulley bolt
to 177N'm ('18.0kgf'm,130lbt'ft). 7. Tightenthe adjustingbolt to the specifiedtorque.

8. After adjusting,retorquethe crankshaftpulley bolt

to 177N.m (18.0kgl.m.130lbf.ft).

6-9
 Timing Belt
Removal
NOTE: 4, Loosenthe adjusting nut and mounting nut, then
. Turn the crankshaftpulley so the No. 1 piston is at removethe alt€rnatorbelt.
top d6ad center (TDC)before removing the belt (see
page&12). ADJUSNNGNUT
8 x 1.25mrr
a Inspectthe water pump when removed the timing 2a N.m l2.a lef.m,
bolt {see page 10-9}. 17 rbl.ftl

1. Removethawhe€lwellsplashshield(seepage6-18).

2. Loosen ths adjusting bolt and mounting bolts, then

remove the power steering {P/S)pump belt.

AA,USNNG

MOUNTINGNUT
10x 1.25mm EELT
a,lN.m{4.5kgl.m,33lbfftl
MOUivNNGBOLTS
8 x 1.25mm
2aN.m12.4kgf.m,17 lbtfrl Removethe cruisecontrolactuator(seepage6-18).

Loosenthe adjustingbolt and idler pulley bracket Removethe sid6snginemount.

bolt, then remove the air conditioning(A,/C)com- 10x 1.25mm
oressorbelt. 52N.m{5.3kgr'm,38lbtft}
Replace.

I ADJUSTING

IDLERPUI.IEYBRACKET
BOLT
l0 r 1.25mm
a/aN.m{1.5kgf.m.33lbf'ft}

12 x 1.25mm
74 N.m 17.5kgt m,
s4 tb{.ftl
1. Removethe cylinderheadcover. 10. Loosenthe adjustingbolt 180'.
. Referto page6-31when installing. 1'1. Pushthe tensionerto removetensionfrom the tim-
8. Removethe Dulleybolt and crankshaftpulley (see ing belt,then retightenthe bolt.
page6-8). 12. Removethe timing beltfrom the pulleys.
Removethe middlecoverand the lower cover.
NOTE:
. Do not usethe middlecover and lower coverfor NOTE:Pushthe tensionerpulleyto
storingitemsdisassembled. loosenthe belt.
. Cleanthe middle cover and lower cover before
installation.

CAPNUT 6 x 1.0 mm
9.8N.m 11.0 7.2rbl.ftl
WASHER CYLINDEFHEAD
when damaged
Replace COVER
Reterto page 6-31when
or
installing.
ADJUSTINGBOLT
10 x 1.25mm
54 N.m 15.5kg{.m,
/r0 lbf.ftl
Foradjustmentonly,

TIMINGBELT
Adiustment,Page6I

MIDOLECOVER

6x1.0mm
9.8 N.m 11.0kgJm, 7.2 lblftl

KE

6x1.0mm
9.8 N.m ('1.0kgt.m,7.2 lbl fr)
RemoveanYoiland clean
LOWEB@VER
NMING BELT
GUIOEPLATE
lnstallwithconcave
surfacefacingout.
CRANKSHAFT PULLEY
and clean.
Removeany oil
and cleanon ihe
6x1.0mm timing beltguide
9.8N.m (1.0kgtm,7.2lbt'ftl platesido.

6-11
Timing Belt
Installation
Installthe timing belt in the revorceorderof removal;
Only key points are describedhere,

NOTE:Cl€anthe middle cover and lower cover before

installation.

L Position the crankshaftand th€ camshaft pulleys as

shownbeforeinstallingthe timing belt.

A. Set the crankshaftso that the No. 1 oiston is at

top dead center (TDC).Align the g.oovo on the
t€eth side of the timing belt d.ive pulleyto the O
pointeron the oil pump.

L Align the TDC marks on intakeand exhaustpul-

tevs,
NOTE: To set the camshafts at TDC position for
No. 1 piston, align the holes in the camshafts
with the holes in No. l camshaft holders and
insert5,0 mm pin punchesin the holes.
2. lnstall the timing belt tightly in the sequence
snown.
O t i m i n g b e l t d r i v e p u l l e y { c r a n k s h a f t )+ @
A d j u s t i n gp u l l e y * @ W a t e r p u m p p u l l e y - @
Exhaustcamshaftpulley+ @ Intakecamshaftpul-
lev.

PIN PUNCHES,5.0 mm

TDCmark align6d with the

pointer on backcover, TDC MARK

6-12
CylinderHead
lllustratedlndex
CAUTION: To avoid damaging the cylind6r hoad, waii until ongin€ coolant temporature drop3 below lOO"F(38"C)b€fore
rsmoving it.

NOTE:Use new O ringsand gasketswhen reassembling.

CAPNUT 6 x 1.0mtn
9.8 N.m 11.0kgtm,7.2lbtftl
e
et
CYLINDERHEAD
COVER
Referto page6-31when
installang.

I x 1.25mm
22 N.m 12.2kgt.m, RUBBER SEAL
16 rbf.ft) Replacewhendamaged
or doteriorated.

I x 1.25mm INTAKECAMSHAFTHOI.DER
24 N.m12.4kgf.m,-.\ Seesection
17rbt.tr) --_r,_ 6x1.0mm
__.|._ O-RING 9.8 N.m {1.0kgl.m,7.2lbf.ft)
Roplace.

EXHAUSTCAMSHAFT
HOI.DER INTAKECAMSHAFT
Inspection,page5-21
RUBBERCAP
Replacefor oil SEAL
leakage. page6-30
Installation,
- Replace.
6tal --,
ffi;r
EXHAUST
CAMSHAFT KEY

LOCKNUT / . /
SEAL
Replace.
'@
25 N.m {2.5kgf.m,
18 tbtfiJ " t
@6 I x 1.25mm
37 N.m (3.8kgt.m,
ROCKERARM 27 rbtftt

CAMSHAFTPULLEYS
Removal,page6 19
page6,30
Installation,

8 x 1.25mm
37 N.m 13.8kg{.m,27 lbfftl
CAUTION: In h.ndling r m.t!l gr3kct, trko clrc not to fold it or dlmaga tho contact surfacr ol thr gaskat.

CYUNDEBHEAD
VAIVE XEEPERS BOLT
&t N.m 18,5kgl'm, VALVEKEEPERS
61 tbf.ftl I
Applyengineoilto
SPRING \n
\.\...i6
RETAINER the threads.
JI SPf,ING RETAINEB

r*#:-3
--../
ENDPIVOTBOLT ED..-
6:tN.ml6.akst'm, nrAxE vaLvESPRING
--------ig ,16lbl.ftl $----
STEMSEAL twtAKEvALvESTEMSEAL
S----
VALVE SPRING €.---- sEAT
valvE SPRING
SEAT INTAKE VAI-VE GUIT'E
Insp€ction,pago S24
EXHAUSTVALVE R6placom6nt,pago 6-25
GUII'E Reaming,pag€6-26

CYUNDERHEAD
Warpage,page6-28

TX)WELPIN DOWELPIN

CYLINDERHEAD GASKET
{3 LAYERSOF METALI
Reolac6. INTAKE VALVE
Replacement,Page6_22

O.RING
Replac€.
OIL CONTROL
EXHAUSTVALVE ORIFICE
Clean.

6-15
 GylinderHead
Removal
Engineremovalis not requiredfor this procedure. 5, Removethe intakeair duct.

CAUTION: To avoid damaging tho cylinder head, wait

I until tho ongino coolant temporature drops bolow 100"F

t {38"C)beforo loo36ningthe rotainin0 bolts.

NOTE:
. Inspectthe timing belt before removingthe cylinder
neao.
. Turn the crankshaftpulleyso that the No. 1 piston is
at top deadcenter(TDCI(page6-12).
. Markall emissionshosesbeforedisconnecting them.
. Anti-theftradioshavea codedtheft protectioncircuit.
Be sureto get the customer'scode numberbefore.
- Disconnectingthe battery.
- Removingthe No. 32 (7.5A) fuse irom the under-
hood fuse/relaybox.
- Removingthe radio.
After service,reconnectoowerto the radioand turn it
on.
When the word "CODE"is displayed,enter the cus-
tomer's5-digitcodeto restoreradiooperation.

1. Disconnect
the negativeterminalfromthe battery.

2. Drainthe enginecoolant(seepage 10-5).

Removethe breatherhose,water bypasshose and
. Removethe radiatorcapto speeddraining. evaporativeemission(EVAP)controlcanisterhose.

3. Relievefuel pressure(seeSection11).

@ Do not smoke whils working on tusl

systom, keep opon flame or spark away trom work
area.Drain fuol only inlo an approvod containsr.

4. Disconnect
the fuel feed hose.

SERVIC€
BOLT
WASHERS
Replace.
Removethe fuel returnhoseand positivecrankcase 9 . Removethe throttlecable.
ventilation(PCV)hose.
1 0 . Removethe throttlecontrolcable (automatictrans-
missiononly).

NOTE:
. Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one.
. Adjust the throttlecableand throttlecontrol
cablewhen installing(seesection11 and 14).

CONTROL
THROTTLE
CABLE

HOSE

R e m o v et h e b r a k e b o o s t e rv a c u u m h o s e , w a t e r
bypasshoseand vacuumhose. ATI'USTING

ERAKEBOOSTER 1 1 . R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r sa n d
VACUUM HOSE VACUUM HOSE wire harnessclampstrom the cylinderheadand the
intakemanifold.

a Fourfuel injectorconnectors
a Intakeair temperature(lAT)sensorconnector
a Engine coolant temperature(ECT)sensor con-
necror
TDC/CKP/CYP sensor connector
a lgnitioncoil connector
a ECTgaugesendingunit connector
a Throttleposition(TP)sensorconnector
a Manifold absolute Dressure(MAP) sensor con-
nector
a ldle air control(lAC)valveconnector
a EVAPpurgecontrolsolenoidvalveconnector

HOSE

(cont'dl

6-17
I CylinderHead
Removal(cont'dl
12. R€movethe spark plug caps and distributorfrom 15. Removethe enginegroundcable.
the cvlinderhead. Removethe adjustingbolt and mountingbolts,then
remove the power steering (P/S)pump belt 8nd P/S
Removethe upper radiatorhose, heaterhose and pump.
water bypass hose.
. Do not disconnectthe P/Shoses.
6x1.0mm
ADJUSTING 9.8 N.m 11.0tgfm,
BOLT 7.2 tbf.ftl
WATER BYPASS UPPERRAI'IAYOR

8 x 1.25mm P/S PUMP

24 .m (2.akstm, 17lbf.ftl

Remov€ the air conditioning (Ay'Clcompressor belt

14. Removeth6 solashshield. (seepags 6-10).

1 7 . R€movethe alternatorbelt (seepage6-10).

t 8 Ramovethe cruisecontrolactuator.
8 x 1.25mm
2a N.m 12.4kgt m,

9.8 N.m {1.0 kgt m. sHtEut

t.2 tbr.frt
ACTUATOR
19. Removethe sideenginemount. Removethe timing belt (seepage6-10).
10 x 1.25mm WASHERS
52 N.m (5.3 kgt'm, 38 lbf'ft) Removethe camshaftpulleysand backcover.

SIDEENGINE
MOUNT

12 x 1.25mm
74 N.m {7.5kgf.m, BACKCOVER
5{ rbtftl
20. Removethe cylinderheadcover.

23. Removethe exhaustmanifold.

CYLINDEBHEAD
NUT
SELF.LOOKING
8 x 1.25mm

BRACKET
(cont'd)

6-19
CylinderHead
Removal(cont'dl
2,0. Removethe intakemsnifold. Removethe camshaft holder bolts, then remove the
camshaftholde.s.camshaftsand rockerarms.

GASXET

IMTAXEMANIFOLD

25. Loosenthe locknutsand adiusting screws. 27. Removethe cylinder head bolts. then remove the
cvlindsrhead.

CAUTION: To preyant warpago. unlcr.w thc bolt3

in laquoncc 1/3 turn at I tim6; .apeat the $qurnca
until sll boltr arc loosrncd.
ADJUSNNG SCNEWLOCATN)NS:

CYLINOER
HEADBOLTSLOOSENINGSEOUENCE
 Camshafts
Inspection
1. Loosenthe adjustingscrews. 1 0 . Removethe camshaftholders.Measurethe widest
ponion of plastigageon eachjourna..
! 2. Removethe camshaftholdersand the rockerarms
Camshaft-toHolder Oil Clearance:
NOTE: Mark the rockerarms before removing Standard lNewl: 0.039- 0.069mm
them. (0.0015- 0.0027in)
SarvicoLimit 0.15 mm {0.006inl
R e i n s t a ltl h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e
PLASTIGAGE
camshaftholderbolts in a crisscrosspattern,begin-
ningwith the innerbolts.
9.8 N.m (1.0kgf.m,7.2lbf.ft)

Seatthe camshaftsby pushingthem towardthe dis-

tributorend of the headwith a screwdriver.

Z e r o t h e d i a l i n d i c a t o ra g a i n s tt h e e n d o f t h e
camshaft. push the camshaft back and forth and
readthe end play.
Camshalt End Play:
St.ndard lNow):0.05- 0.15mm
(0.002- 0.006inl
Seivice Limit: 0.5 mm {0,02in)

11. lf camshaft-to-holderoil clearanceis out of toler

ance:
. And the camshaft has already been replaced,
vou must replacethe cylinderhead.
. lf the camshafthas not beenreplaced,first check
total runout with the camshaftsupportedon V-
blocks.

Clmshaft Total Runout:

StEndard{New): 0.03 mm (0.001inl max'
ServicoLimit: o.Oilmm {0.002inl

Removethe camshaftholderboltsfrom the cylinder

head.

N O T E : U n s c r e wt h e c a m s h a f th o l d e r b o l t s t w o
turns at a time, in a crisscrosspattern.

Lift the camshaftsout ot the cylinder head. wipe

them clean,then inspectthe lift ramps.Replacethe
camshaftif any lobes are pitted, scored,or exces-
srvelyworm

Cleanthe camshaftjournal surfacesin the cylinder

head,then set the camshaftback in place.Inserta
plastigagestrip acrosseachiournal.
- lf the total runout of the camshaftsis within tol-
Installthe camshaftholdersand torquethe boltsto erance,replacethe cylinderhead.
the valuesand in the sequenceshownon page6-30.
- lf the total runout is out of tolerance,replacethe
NOTE:Do not rotatecamshaftsduring inspection. camshaftsand recheck.lf the oil clearanceis still
out of tolerance.replacethe cylinderhead.

6-21
Valves,Valve Springs and Valve Seals
Removal

N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e
removedso that eachitem can be reinstalledin its oriqi-
nal Dosition.

1. Tap eachvalve stem with a plasticmalletto loosen

valve keepersbeforeinstallingthe spring compres-
sor.

2. lnstallthe springcompressor.Compressspring and

removevatveKeeper.
VALVESPRINGCOMPRESSOR
xo No.3tB. whh r35 JAW o.

07757- PJ10r0A

Installthe special tool as shown.

Remove the valve seal.

lntaks Valvo Dimonsions
A Standard(New): 30.90- 31.10mm
- 1.221inl
|.1.217
COMMERCIALLY AVAILABLE
VALVEGUIDESEALREMOVER I Standard (Nowl: 103.80- 10'1.10mm
LISLEP/N 5t9d) or KO3350 {4.087- 4.098inl
SEAL C Standard lNow): 6.580- 6.590mm
REMOVER {0.2591- 0.259/rin}
C ServicoLimit 6.55 mm (0.258inl
D Standlrd (N€w): 1.35- 1.65mm
10.053- 0.065inl
D SsrviceLimit: 1.15mm (0.045in)

Exhau3tValve Dim6nsions
A Standard {New): 27.90- 28.10mm
11.098- 1.106inl
B Standard (Newl: 104.00- 104.30mm
(4.094- 4.106inl
C St.ndard (New): 6.550- 6.500mm
10.2579- 0.2583inl
C ServicoLimit 6.52 mm (0.257in)
D Standard{New): 1.65- 1.95mm
10.065- 0.077inl
D ServiceLimit: 1.,[5mm (0.057in)
 InstallationSequence
NOTE:Exhaustand intakevalvesealsate NOTinterchangeable.

@/.-uo.**.r..",
NOTE: Placeth€ 6nd oI valve
springwith closelYwoundcoils
towrrd th€ cylinder head.
SPRNG NETAINER

EXHAUSTVALVESEAL
{8LACKSPRING}
Replace.

@*_-.tt*
NOTE:Installth€v6lvosprings€ats
beforo instsllingthe valv6 sesls.

PLASTICMALIIT

6-23
.tIF"F-
Valves,ValveSpringsand
ValveSeals ValveGuides
Valvelnstallation ValveMovement
W h e n i n s t a l i i n gv a l v e s i n t h e c y l i n d e r h e a d ,c o a t Measurethe guide-to-stem clearancewith a dial indica-
valve stemswith oil beforeinseningthem into valve tor while rocking the stem in the direction of normal
guides, and make sure valves move up and down thrust (wobblemethod).
smoothlv.
lntake Valve Stsm-to-GuideClearance:
When valvesand springsare in place,lightlytap the Strndlrd (Newl:0.0i1-0.10mm
end of each valve stem two or three times to snsure (0.002- 0.004in)
properseatingof valvesand valve keepsrs(use plas- Ssrvicc Limit: 0.16 mm {0.006in)
tic mallet).
Exhsust Valye Stom-to-GuideClearance:
NOTE:Tap the valvestem only along its axis so you Standard{N€w):0.10- 0.16mm
do not bendthe stem. {0.0O'l- 0.006in)
Slrvica Limit: 0.22 mm {0.000in)
Valveextended10 mm out from seat

PLASNC MALI.IT

lf measurementexceedsthe service limit, recheck

usinga new valve.
l f m e a s u r e m e n ti s n o w w i t h i n t h e s e r v i c e l i m i t ,
reassembleusinga n€w valve.
l f m e a s u r e m e n st t i l l e x c e e d sl i m i t , r e c h e c ku s i n g
a l t e r n a t em e t h o d b e l o w . t h e n r e p l a c ev a l v e a n d
guide, if necessary.

?ur NOTE:An alternatemethod of checkingguide to stem

clearanceis to subtractthe O.D.of the valvestem, mea-
s u r e d w i t h a m i c r o m e t e r .f r o m t h e l . D . o f t h e v a l v e
g u i d e , m e a s u r e dw i t h a n i n s i d e m i c r o m e t e ro r b a l l
gauge.
Takethe measurementsin three placesalong the valve
stem and three placesinsidethe valveguide.
The diiferencebetweenthe largestguide measurement
and the smalleststem measurementshould not exceed
the servicelimit

lntake Valve Stom-to-GuideClearance:

Standard (Newl: 0.02- 0.05 mm
(0.001-0.002in)
ServiceLimit 0.08 mm (0.003in)

ExhaustValve Stom.to.Guid€ Clearanco:

Standard (Newl: 0.05- 0.08 mm
(0.002- 0.003inl
Srrvico Limit 0.ll mm 10.00'tinl

6-24
Replacement
1. As illustrated in the removal steps of this proce- 4. Working from the camshaft side. use the driver and
dure, use a commercially-available air-impactdriv- an air hammerto drive the guide about 2 mm {0.1
er attachmentmodified to fit the diameter of the i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l
valve guides. In most cases.tho same procedure knock oft some of the carbon and make removal
c a n b e d o n e u s i n g t h e V a l v e G u i d e D r i v e ra n d a eaSrer.
conventionalhammer.
GAUTIOiI:
o Alwrys woar safety goggles or a face shiold
COMMERCIALLYAVAILABI,I wh6n using tho Eir hammer.
VALVEGUIDEDRIVER . Hold ths air hammsr directly in lins with the
vrlvr guidc to prsvont damaging tho drivor.

Turn the head over and drive the guide out towatd
-----T_- the camshaftside of head.

sz-- l r l
f | 12.21i^l 11.3mm
lf a valveguide still won't move,drill it out with a 8
lo.il,l in) mm (5/16in) bit,then try again.

RGmov.lrnd In3tlllation CAUTION: Drill guid$ only in oxtremo cases:You

VALVEGUIDEDRIVER, 6.6mm could drmrgo tho cylinder hosd if ths guido br"akr.
0?942- 6570100

S e l e c tt h e p r o p e r r e p l a c e m e n tg u i d e s a n d c h i l l
t h e m i n t h e f r e e z e rs e c t i o no f a r e f r i g e r a t o rf o r
aboutan hour.

Use a hot plate or oven to evenly heat the cylinder

headto 300'F(150'Cl.Monitorthe temperaturewith
a cookingthermometer.

VALVEGUIDEDRIVER,6.6mm
07942 - 65701q)

",
CAUTION: OO
O (V /rl -1-- ) o
. Do not use a torch; it may warP the hgad.
. Do not get ths head hottq than 3OO'F1150"C);
excessivehgat may loos€n thGvalvs soat3.
. To avoid burns, usa hoavy glov93whon handling
the heated cylinder hoad.
Removethe new guide{s}from the refrigerator,
one
at a time, as you needthem.
{cont'd)

6-25
Valve Guides
Replacement
{cont'd} Reaming

7. SliDa 6.5 mm {0.25in) stselwashorand the correct NOTE:For new valveguidesonly.

driver attachmentover the end of the driver {The
washer will absorb some of the impact and extend Coatboth reamerand valveguidewith cuttingoil.
the life of the driver).
Rotatethe reamer clockwisethe full length of the

.,F-q-re
t t - T -
valveguide bore.

C o n t i n u et o r o t a t e t h e r e a m e t c l o c k w i s ew h i l e
It I removingit from the bore.
t l
DRVEn 6,5mm t0.25in) ATTACHMENT
Thoroughlywash the guide in detergentand water
WASHER
to removeany cuttingresidue.
8, Installthe new guide(s)from the camshaftside of
the head; drive each one in until the attachment Checkclearancewith a valve(seepage6-24).
bottomson the head.lf you have 8ll sixteenguides
to do, vou may have to reheat the head one or two . V e r i f y t h a t t h e v a l v e s l i d e s i n t h e i n t a k e8 n d
moreI|mes. exhaustvalveguideswithout ex€rtingpressure.

REAMERHANDLE

VALVEGUII'E REAMER,6.6 MM
079E4- 667ot0c

Valv6 Guida Instsllod Hcight:

lntaks: 13.75- 14.25mm
(o.sal - 0.561inl
Exhru3t: 15.75- 16.25mm
{0.620- 0.640in}
Valve Seats
Reconditioning

1. Renewthe valve seatsin the cylinderhead using a The actualvalve seatingsurface,as shown by the
valveseatcutter. bluecompound,shouldbe centeredon the seat.

NOTE: lf guides are worn (see page 6-24),replace
them (seepage6-251beforecuttingthe valveseats,
2. C a r e f u l l yc u t a 4 5 ' s e a t , r e m o v i n go n l y e n o u g h
materialto ensurea smoothand concentricseat.
3. Bevelthe upper edge of the seatwith the 30ocutter
and the lower edgeof the seatwith the 60' cutter.
Checkwidth of seatand adjustaccordingly.
4. Makeone more very light passwith the 45"cutterto
removeany possibleburrs causedby the other cut-
ters.
. lf it is too high (closerto the valve stem), you
must make a second cut with the 60" cutter to
move it down, then one more cut with the 45'
cutterto restoreseatwidth.
. l f i t i s t o o l o w ( c l o s e rt o t h e v a l v e e d g e l ,y o u
must make a second cut with the 30' cutter to
move it up, then one more cut with the 45"cutter
to restoreseat width.
NOTE:The final cut shouldalwaysbe madewith
the 45' cutter.
7. Insert intake and exhaust valves in the head and
measurevalvestem installedheight

Valvo Seat Width llntake and Exhaustl: Intako Valve Stem Install€d Height:
Standard: 1.25- 1.55mm {0.049- 0.061inl Standard (New): /$.765 - '11.235mm
Servics Limit:2.0 mm 10.08inl {1.604It- 1.6234in}
ServiceLimit: ill.il85 mm (1.6:133 inl
ExhaustValvo Stem lnstalled Height:
Standard {Newl: ,12.765- i|:|.235mm
11.6a37- 1.1022in1
ServiceLimit /B.il85 mm (1.7120inl
SEAT
WIDTH

After resurfacingthe seat, inspect for even valve

seating:Apply PrussianBluecompoundto the valve
f a c e , a n d i n s e r t v a l v e i n o r i g i n a l l o c a t i o ni n t h e
head,then lift it and snap it closedagainstthe seat
severaltimes.
8. lf valve stem installed height is over the service
limit, reDlacevalveand recheck.lf still over the ser-
vice limit, replacecylinder head;the valve seat in
the headis too deeo.

ACTUAL
SEATING
SUBFACE

VALVE
SEAT

PRUSSIAN

6-27
 GylinderHead
Installation

t NOTE:lf camshaft-to-holder oil clearances(seepage 6- Installthecylinderheadin the reverseorderof removal:

2 1 ) a r e n o t w i t h i n s p e c i t i c a t i o nt,h e h e a d c a n n o t b e NOTE:
resurfaced. . Always use a new head gasket.
. C y l i n d e rh e a d a n d c y l i n d e rb l o c ks u r f a c em u s t b e
oil clearancesare within specifica-
lf camshaft'to-holder ctean.
tions,checkthe headfor warpage. . "UP" markon the timing belt pulleysshouldbe at the
top.
lf warpage is less than 0.05 mm (0.002in) cylinder . Do not usethe middlecoverand lowercoverfor stor-
headresurtacingis not required. ing itemsdisassembled.
lf warpageis between0.05mm (0.002in) and 0.2 mm . Cleanthe middlecoverand lower coverbeforeinstal-
(0.008in), resurfacecylinderhead. lation.
Maximum resurfacelimit is 0.2 mm (0.008in) based . Replacethe washerwhen damagedor deteriorated.
'1. Cylinderhead dowel pins and the oil control orifice
on a heightof 132.0mm (5.20in).
must be aligned,
PRECISION
STRAIGHTEOGE NOTE:
. When handling a metal gasket,care should be
takennot to told it or damagethe contactsurface
of the gasket.
. Cleanthe oil controlorificewhen installing.
CYLINDERHEADGASKET
{3 LAYERSOF METALI
Replace.

OOWELPINS orl coNtnol

ORIFICE
Clean.

O.RING
Replace.

Measurealongedges,and 3 ways acrosscenter.

Tightenthe cylinderhead bolts in two steps.In the
Jirststep tighten all bolts,in sequence,to about 29
N.m {3.0kgf.m,22 lbl.ltJ;in the final step,tighten in
the samesequenceto 83 N.m (8.5kgf.m,61 lbf'ft).
NOTE:
. Apply engine oil to the cylinder head bolts and
the washers.
. Usethe longerbolts at positionsNo. 1 and No. 2
as shown.
CYLINDERHEADBOLTSTOROUESEOUENCE

@ o @ @ @

Cylinder Hoad Height:

Standard(New):131.95- 132.05mm
{5.195- 5.191t
in}

Put longer bolts here.

 Installthe intakemanifoldand tightenthe nuls in a CAUTION:
c.isscrosspatternin 2 or 3 steps,beginningwith the . Mlka 3uro thrt thc k.ywlyr on tho c.mthlttr lrc
inner nuts. facing up .nd No. I pi3ton i3 8t top d.rd clnt.r
(TDCt.
CAUTION: Check to. fold3 or 3cratchc! on ihc aur- . Rcphct th! rocksr armr in thsir o.iginal potltlom.
taco ol tho ga3kot. Roplscs with a nlw gaeket if
damagod. 6, Placethe rocker arms on the oivot bolts and ths
valve stems.
4. Tightenthe intakemanifoldbracketbolts.
GASXET
Replace.

7. lnstallthscamshafts,then installth€camshaftsosls
with ths open side (spring)facingin.

8. A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e r c a p , t h e n
installtherubbercao.

E x 1.25mm 8 x 1,25mm
2irN.ml2.itkg{.m, 23 N.m12.3kgf.m.
17tbf.ftl 17tbl.frt

5. Install the exhaust manifold and tighten the new

self-lockingnuts in a crisscrosspattern in 2 or 3
steps,beginningwith the inner nuts.
. Use new self-lockiflgnuts.
SELF.LOCKING NUT
8 x 1.25mm 8 x 1.25mm
24 N.m (2,akgf.m, EXHAUST 31 N.m (3.2 kgt m,23lbfftl
11 Replace.
GASKEI
Replace.

m l0 x 1.25mm 8 x 1.25mm
a,t N.m 14.5kgf.m, 2il N.m 12.4kg{.m,
33 tbt.ft) 17 rbtftl
(cont'd)

6-29
CylinderHead
Installation(cont'dl
9. Apply liquid gasketto the head mating surtacesof 11. Tighten each bolt in two steps to ensure that the
the No. 1 and No. 6 camshaftholders,then install rockers do not bind on the valves.
t h e m ,a l o n gw i t h N o .2 , 3 , 4 , a n d5 .

NOTE: 6r1.0mm
o "1" or "E" marks are stamoedon the camshaft 9.8 N.m 11.0kgf.m,7.2lbtft)
holders.
. Do not apply oil to the holder mating surfaceof
camshaftseals.
. Apply liquidgasketto the shadedareas.
. T h e a r r o w s m a r k e do n t h e c a m s h a t th o l d e r s
shouldpoint to the timing belt.

INTAKECAMSHAFTHOLDERS

Installkeysinto camshaftgrooves.
No.6 No.5 No.2 N o .1
NOTE:To set the camshaftsat TDCpositionfor No.
1 piston,align the holes in the camshaftswith the
holes in No. 1 camshaftholdersand insert5.0 mm
pin punchesin the holes.

KEYS

10. Tightenthe camshaftholderstemporarily.

. M a k e s u r e t h a t t h e r o c k e ra r m s a r e p r o p e r l y
positionedon the valvestems.

I r 1.25mm
37 N.m {3.8 kgf.m,27 lbf.ttl

6x1.0mm
9.8N.m(1.0kgf.m,
7.2tbtft)

1 3 . Pushcamshaftpulleysonto camshafts,then tighten

the retainingboltsto the torquespecified.
1 4 . Installthetiming belt {seepage6-12).
Adjustthe valveclea.ance(seepage6-31.
1 6 . Installthe rubberseal in the grooveof the cylinder
head cover. Seat the seal in the recessesfor thg
camshaftfirst, th€n work it into the groove around
the outside edges,
NOTE:
. B e f o r ei n s t a l l i n gt h e r u b b e r s e a l , t h o r o u g h l y
cleanthe sealand the groove.
. When installing, make sure the seal is seated
securelyin the cornersof the recass€swith no
gap.
1 7 . Apply liquid gask€t to the rubber seal at the eight
corners of the recesses.
NOTE:
. Use liquidgaskst,PartNo. 08718- 0001.
. Checkthat the mating surfacesare cl€an and dry
beforeapplyingliquidgasket.
. Do not install the parts if 20 minutes or mor6
h a v s e l a p s o ds i n c o a p p l y i n g l i q u i d g a s k e t .
Instead,reapply liquid gasket after removing old
reaidue.
. After assembly, wait at lsast 20 minutes before
fillingthe enginewith oil.

RUBAER
SEAL

Apply liquid g.sket to

the shadedareas.

CYUNDERHEAD
COVER

(cont'd)

6-31
GylinderHead
lnstallation(cont'dl
18. When installingthe cylinder head cover, hold the Tightenthe nuts in 2 or 3 steps.In the final step,
rubbersealin the grooveby placingyour fingerson tighten all nuts, in sequence,to 9.8 N'm (1 0 kgf'm,
the camshaftcontactingsurfaces(top of the semi- 7.2 tbf.ft).
circles).
O n c e t h e c v l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head,slidethe cover slightlybackand forth to seat
the rubberseal.

NOTE:
. Beforeinstallingthe cylinder head cover, clean
the cylinder head contacting surfacesusing a
shoptowel.
. Do not touch the pans where liquid gasketwas
aDplied.

6x1.0mm
9.8 N.m 11.0kgt'm,
7.2 tbf.trl

20. After installing,checkthat all tubes,hosesand con-

nectorsare installedcorrectlY.

6-32
'lllllllllmlmti'""
CylinderHead/ValveTrain
818C1engine
SpecialTools .............
6-34 Rocker Arms
wEc Removal .................
6-60
Troubleshooting Flowchart Location .................
6-61
WEC SolenoidValve................... 6-36 lnspection ..............
6-62
VTECPressureSwitch ................. 6-38 Arm-to-ShaftG|earance.................. 6-63
VTECSolenoidValve Inspection....6-41 Installation .............
5-64
RockerArms Camshafts
ManualInspection.....,................. 6-42 Inspection ..............
6-65
InspectionUsingSpecial Valve Guides
Tools ....................................,.....,..
6-/|i| ValveMovement..............................
6-70
ValveGlearance Replacement .........6-71
Adiustment ............
6-44 Reaming .................
6-72
Timing Belt Valve Seals
lllustrated1ndex...............................
6-46 Reconditioning ......6-73
Inspection ..............
6-48 Valves. Valve Springs and Valve Seals
TensionAdiustment........................ 6-48 Removal .................
6-67
Removal .................
6-4{l lnstallationSequence..........,.......,...
6-69
lnstallation .............
6-51 Valvelnstallation.............................
6-70
Crankshaft Pulley Bolt
Replacement .........6-47
CylinderHead
lllustratedIndex ...............................
6-53
Removal .................6-55
Warpage ................6-74
lnstallation .............
6-75
SpecialTools

ToolNumbar Dctcription Plea Rctllanca

o 07HAH- PJ7010Aor
_ PJTOIOB
ValveGuideReamer,5.5 mm 6-72
OTHAH
07JAB- 001020A HolderHandle 6-17
@ &45
@ 07LAA- PR30100 TappetAdiusterWrench
OTLAJ_ PR3O2OA Air Stoppet 6-43
@
/.\ 07MAB. PY3OlOA HEX50 mm,
PulleyHolderAttachment,
Offset 6-11
o OTMAF_ PRgO'IOA Valv€SpringCompressorAttachment
Extension 6-67
o 07742- 0010100 ValveGuideDriver,5.5mm
ValveSpringCompressorAttachment
6-71,72
6-67
@ 07757- PJ1010A

o @

@ o @

@ o @

6-34
VTEC

Ref€rto page11-32thru I l-39 beforotroubleshooting.

(MlL)
indicates
Disenostic code(Drc)2r:Aproblem
rrouble inthewEc
-g: -mi !5*3ij'i:,*o:",,XTl.Lamp
\,__-:-/ \.---l-l

Iel- -l 2,1l-

MIL h.. b..n Fport d on.

Wrth aaavica chack connac,tot
iomp.d, Codc 2l i. indic.t.d.

O o t h o o n g i n oc o n t r o lm o d u l e
(ECM)Rg3otProcgduro.

w6rrn up engine to normal op€r-

ating tsmporature (the cooling
fan comogon). ' RoadTest:
Acceleratein 1st gear to 6n engino spoodovor 6000rpm.
Hold thst engine sp€edtor at leasttwo seconds.
lflhe MIL do6s not coms on during th€ first road tost,
Do th€ RoadTest.' reoeatthis test two more tim95.

lmormitt.m t ilur., .yrtom i. OK

ls MIL on and does it indi- !t thi.tim..
Chacl tor poor connactiont ot
catocod€21?
loo.. wircr !l VTEC .ol.noid
v.lv. lnd ECM.

Turn tho ignition switch OFF.

O i s c o n n e c tt h o 1 P c o n n s c t o r
lrom the VTECsolenoidvalvo.

Chockfor continuity betw66n 1P

c o n n 6 c l o rt e r m i n a l a n d b o d y
9rcUnO.

ls there '14- 30 07 R.pl.c. th. VTEC rolonoid v.lvr,

YES
(To pago G37l

6-36
 {From pag6 636} ooooooooooooo ooooooooooo
ooooooooooooo ooooooooooo

'lP
Ch6ckfor continuity botw6en
connectort€rminal and A4 termi-
nal.

B.9.lr op.n in th. GRI{/YELwirc

b.tw..n ECM{Aa} .od vTEc
aolanoidvalvaconnac'tor.

Ch6ckfor continuity botwoon 1P

connectorterminal (harnessside)
and body ground.

ContinuityT

Ro.ir .hon i|r th. GRN/VELwirc

b.iw..n ECM (A4l .nd VTEC
aoldroid valv. Gonnac'tor.

Sub.titut! . krown-good ECM

|r|d r.ch!ck. lt .ytnptom/indic!-
tion gor3 away rrplact tha origi-
n.l Ecttl,

6-37
wEc
TroubleshootingFlowchart- VTECPressureSwitch
Referto page11-32thru11-39beJoretroubleshooting'
-.+- -r";-r- (DTC)22:A problemin the VTEC
IndicatorLamp (MlL)indicatesOiagnosticTroublesCode
- l{{?l- zizr: Malfunction
pressur€Switchcircuit.
;l

- l r @ l - | 2 21 -

- MIL har bagn.oportcd on.

- With t.rvic. chack connactor
iump.d, cod€ 22 it indic.t.d.

D o t h e e n g i n ec o n t r o lm o d u l e
(ECM)Reset Procedure.

Warm !p engineto normaloper-

ating temperstur€ (cooling fan
* RoadTest:
comeson).
Accoleratoin lst gear to an engine speedover 6000rpm
Hold that engine speedfor at leasttwo seconos'
lf the MIL does not come on during the first road test'
Do the Boad T€st.' reoeatthis test two more limes.

Intc.mift.nt failu.o, ry3tom ia OK

at thi. tim..
ls MIL on and doesit indi' Chack for pool connaction3ol
cate code 22? loo!. rvirat at VTEC Ptasturo
3whch and ECM.

Turn lhe ignition switch OFF

D i s c o n n e c tt h e 2 P c o n n e c t o r
lrom the VTECPressureswitch.

C h e c kI o r c o n t i n u i t y b e t w e e n
BLKterminaland body ground.

Rcpair opcn in BLKwit. botwcon

2P connectorrnd body ground
tG101l.

C h e c kf o r c o n t i n u i t y b e t w e e n
8LU/8LKterminaland D6 termi'
nal.

(To page6 39)

6-38
 (Frompage6-38)

Ropairop€n in BLU/BLK$,iro be
tween ECM lD6) and 2P conn.c-
tor,

o oooooo ooo ooo I oooooooo trt!*Hffi Oooooo ooooo

Checkfor continuity between D6
o oooo ooooo ooo I oo oooo oo o o o o o oo o o o o
terminaland body ground.
D6
R6pri. short in BLU/BLKwir. bc-
tweon ECM (D6l .nd 2P connec-
toa,

GAUGEJOINT ADAPTER
I Coitlnuity?

Remove10 mm sealingbolt and Y AVAILAEII

SNAPON MT2&17 GAUGE
OILPRESSURE
connectorl pressuregauge. 10 x 1.0mm
. lJse new washerwhen
installingthe sealingbolt.
Connecta tachometer{soe sec-
t i o n1 1 ) .

Startthe engineand warm it up

\n
to normal operatrngtemperature. \-

C h e c ko i l p r e s s u r ea t e n g i n e
]L
speeds of 1,000,3,000 and 5,000 NOTE:
rpm, Keep mgasuringtime as short as possiblebocaus€engine is
runningwith no load(lessthan one minute).

ls pressurebolow 50 kPa
(0.5kgflcm', 7 psi)? Inrpoct tho VTEC aolanoid v.lv..
vtEc sot-€NotD

Turn off the engine.

Checklor continuity betweenthe
2 terminals on the VTECpressure
switch.

YES
(To page 6-40)

Conlinuity?

(cont'd)

6-39
VTEC
Flowchart VTECPressureSwitch (cont'dl
Troubleshooting
u
lFrom pag6 6-39)

OOMMERCIALLYAVAILABII
D i s c o n n s c tl h e 1 P c o n n e c t o r OIL PRESSURE
GAUGE
trom the VTECsol6noidvalve.

Attach the battery positivo tormi

nal to the GRN/WHTterminal.

Startthe engineand chgckoil

pressureat 5,000rpm (lor VTEC
oil pr€ssure
test).

GAUGE JOIMf ADAPIOR

SNAPON MT2S1'
1 0 x 1 . 0m m
. Use new washer when
installingth6 soalingbolt.
NOTE:
Keep moasuringtim6 as shon 6s possi-
ble becauseenginei5 runningwith no
load lless than ono minuto).

ls pressureabove 400 kPa

(4kgt/cm,,60 psi)? In.p.ct th. VIEC .olrnoid v.lv..

Checktor continuity betwe6n the

2 terminsls on th€ VTECprsssure
switch !nder above condition.

Sub.titut. . klown-eood ECM

and rachack.|f aymplom/indica-
tion goaa away rrplaca th. o?igi-
n.l ECM.
WEC SolenoidValveInspection
Disconnectthe 1P connector trom the VTEC 4. lf th6 filter is not clogged, push the VTEC solenoid
solenoidvalve. valv€ with your finger and check its movement.

M€asurs resistancebetween th€ terminal 8nd body . l f V T E Cs o l s n o i d v a l v e i s n o r m a l , c h e c k t h e

grouno. enginsoil pr€ssure.

R.3bt!nc!: 1l - 30 O

6x1.0mm

lf the resistanceis within specificstions,romove the

WEC sol€noid valve from the cvlindor hsad, and
checkthe VTECsolenoidvalvefilterfor clogging.

. lf there is clogging,replacsthe engin€ oil filter

and the engineoil.

VTECSOT.CNOTD

12 tTln 11.2kg[.m,8.7 lbttt]

6-41
VTEC
Arms -
Rockerrtrrrri'
nlrungf rYrorrtrcr rrrDPEUtrl,rl

1. Set rh6 No. I Distonat TDC. 4. Removethe cylinderheadcover.

2. Removethe ignitionwire coverand the wires. Pushthe mid rockerarm on the No. 1 cylinderman-
ually.
3. Removethe ignitionclampswhile pullingup on the
lock. Checkthat the mid rockerarm moves independent-
ly of the primaryand secondaryrockerarms.

6 x 1.0.nm
9.8 N.m 11.0lgfm, 7.2 lbf.ftl
SECONDARY
ROCKERARM

w 7. Checkthe mid rockerarm of eachcvlinderat TDC.

. lf the mid rockerarm does not move,removethe

mid, primary and secondaryrockerarms as an
assemblyand checkthat the pistonsin the mid
and primaryrockerarms move smoothly.
. lf any rocker arm needs replacing,replacethe
primary,mid, and secondaryrockerarms as an
assemblv.

NOTE:Referto page6-78when installingcylinderhead

cover.
RockerArms - InspectionUsingSpecialTools
CAUTION: Apply specified air pressure to the rocker arm pis-
. Boforo using tho valvo inspoctiontool. make 3uro tons after looseningthe regulatorvalveon the valve
that th6 air prsssure gaugs on th6 air comprossol inspectiontool.
indicatG over 250 kPa {2.5 kgf/cm', 36 psi}
. Inspectthe valvs clearancobefors rockel lrm insPoc- SpecifiedAir Presrure:
tion. 250 kPa (2.5 kgt/cm', 36 psi)
. Covor the timing belt with a shop towsl to pl€vent - 500 kPa 15.0kgf/cm'. 71 Psi)
qotting oil on lhe b6lt.
. Checkths mid rocker srm of oach cylindor at TDC. Make sure that the primary and secondaryrocker
a r m s a r e m e c h a n i c a l l cy o n n e c t e db y t h e p i s t o n s
1. Removethe cylinderheadcover. and that the mid rocker arms do not move when
pushedmanuallv.
2. P l u g t h e r e l i e f h o l e w i i h t h e s p e c i a lt o o l ( A i r
Stopper).

RELIEFHOLE

PfiIMARY
LOST MOTION
ROCKERARM
ASSEMALY

o lf any mid rockerarm moves independentlyof

3. Removethe bolt and washer from the inspection tho primaryand secondaryrockerarms, replace
holeand connectthe valveinspectiontool the rocker arms as a set.

AIR STOPPEB 6. Removethe tools.

OTLA' - PR3O2OA

REGULATOR VALVE 7. Checkthe oDerationof the lost motion assembly by

. Pullthsleverand p u s h i n go n t h e m i d r o c k e ra r m . T h e l o s t m o t i o n
turn to adjust. INSPECTION a s s e m b l vs h o u l d c o m p r e s sf u l l y a n d o p e r a t e
HOtt
smoothlythrough its full stroke.Replacethe assem-
bly if it does not work smoothlY.

WASHER 8. A f t e r i n s o e c t i o n ,c h e c k t h a t t h e M a l f u n c t i o n
Replace.
IndicatorLamD(MlL)does not come on

NOTE:Referto page6-78when installingcylinderhead

cover.

10 x 1.0mm
20 N.m 12.0kgf.m,
1a tbt'ft|

TOOL
AVAILABLE}
ICOMMERCIALLY

6-43
ValveClearance
Adiustment
NOTE:
. Valves should be adjustedcold; at a cylinder head
temperatureof lessthan 100"F(38'C).
. Adjustmsnt is the same for intakeand exhaust
vatves. FOI{IER Ot{
o After adjusting, retorque the crankshaftpulloy bolt to LOWEFCOVER TDCMANK
lP.int d whit.t
177 N.m ( 18.0kgf.m, 130 lbf.ft).

1. Removecylinderheadcove..
BOLTLOCANONS:
ADJUSTING
IMTAKE
No. 4 No.3 No. 2 No. 1

Diroctionof
aotation.

3. Adjust valv6 clearanc6on No. 1 cylinder.

Intlkc: 0.15- 0.19 mm (0.006- 0.0,07inl

Exh.u3t 0.17- 0.21 mm (0.007- 0.m8 inl
No.4 No.3 No.2 N o .1
EXHAUST
4. Looson lh6 locknut and turn the adjusting screw
until feeler gaugo slides back and fonh with a slight
amountof drag.
Set No. 1 piston at TDC. "UP" mark on the pulley
should be at top, and TDC grooves on the pulley
should align with the pointer on back cover. TDC
g r o o v e s ( w h i t e p a i n t ) o n t h e c r a n k s h a t tp u l l e y FEEENGAUGE
should align with pointer on the timing belt lower
cover.
TAPPETAI\,USTEN WREI{CI{
O'LAA - PRIOIq'
Numbr. 1 pirton .t TDC:

7 x 0.75 mrn
20 f+|n (2.0kgf'm.14lbtftl

6-44
 Tightsn the locknut and recheckclearanceagain. 7.
Rep6atsdjustm6nt if necossary.
Rotatocrankshaft180' countsrclockwiseto bring
"UP" mark shouldbo
N o . 4 p i s t o n t o T D C .T h e
pointing straight down. Adjust valves on No. 4
cylinder.

FEEI.IRGAUGE Numb.r 4 pidon .t Tt C:

Rotsts tha crankshaft 180' counterclockwiss 8, Rotatecrankshaft180" counterclockwis€to bring

"UP" marks should be on
(c8mshaftpulleyturns 90'). The "UP" mark should No. 2 piston to TDC.The
be on th€ sxhaust 8id6, Adiust vslves on No. 3 cylin- the intaks sid6. Adjust valves on No. 2 cylinder.
oer,

Nurrb.r3tittondTDC: Nonb.r 2 pirton .l TltC:

.UP' MANKS

NOTE: Referto page 6-78 when installing cylinder head

cover.

6-45
TimingBelt
lllustrated lndex

NOTE:
. ReJertopage6-51for positioningcrankshaftand pulleybeforeinstallingbelt.
. Markthe directionof rotationon the belt beforeremoving.
. Replacethe rubbersealsfor oil leakagebetweenthe cylinderheadand cover.
. Do not usethe middlecoverand lower coverfor storingitemsdisassembled.
. Cleanthe middlecoverand lowercoverbeforeinstallation.

WASHER
Replacewhen CAP NUT
or deteriorated.
x 1,0mm
9.8 N.m 11.0kgf.m,7,2lbttrl

CYLINDER
HEAOCOVER
Reterto page 6'78
when installing.

RUBBERSEALS
Replace
whendamaged

3-E or deteriorated,

TIMINGBELT
page 6-48
Insp€ctaon,
Adjustment.page 6-48
R€placement.page 6'49

MIDDLECOVER

5xl,0mm
9.8 N.m (1.0kgt m,
7.2 rbtftt

8 x 1.25mm
56 N.m 15.7kgt m,
41 tbtftl
6x1.0mm
9.8N.m (1.0kgt.m,7.2lbfftl 6x1.0mm
9.8 N.m {1.0 kgl.m,
7.2lbf.ftl

10 x 1.25mm
Installwithconcave 5a N.m 15.5kgl.m.
surfacelacingin. (} tbf.ftl
Clean. Foradiustmentonly
do not remove.
TIMINGSEL Installwithconcave
DRIVEPULLEY surfacetacing out. BOLT
R e m o v e a n y o i l a n d c l e a n . Removeany oiland clesn. COVER 1il x 1.25mm
177N.m 118,0kgtm, 130lbtft)
PULLEY Replacement,page 6-47
Removeany oil and clean
on the timing beltguide
NOTE:When installinga new crankshaftand/ornew bolt: plateside.
O tightenthe crankshaftpulleybolrto 196N.m (20.0kgf.m.145lbf.ft),
@ loosenbolt,
@ retightenit to 177N.m fl8.0 kgf.m,130lbnft).

6-46
GrankshaftPulleyBolt
Replacement
NOTE: . When reinstallingthe bolt, lubricatethe thresds8nd
. Crankshaftpull€y bolt size and torqus value: flangewith engineoil, but don't lubricatethe washer
1,0x 1.25mm and pulley.
177 N.m (18.0kgt.m, 130 lbf'ft) Lubricetowith engine oil hers.
. When instslling a new crankshaft 8nd/or now pulley
bolt:

O tight6nthe pulleybolt to 196N'm (20.0kgf'm, 145

tbf.ft).
@ loosonthe bolt,
@ r6tighten it to 177 N.m (18.0kgf'm, 130 lbf'ft).

PULITYHOLDEB ATTACHMEUT,
HEXslt mm, OFFSET
OTMAB - PY3O1OA

SOCKETWRENCH,19 mm
COi'MEBCI,ALLYAVAILABT.E

6-47
TimingBelt
lnspection
Removethe cylinderheadcover.
. Referto page6-78when installing.
Inspectthe timing belt for cracksand oil or coolant
soaking.
NOTE:
. Replacethe belt if oil or coolantsoaked.
. Removeany oil or solventthat gets onthe b€lt.
TensionAdjustment
CAUTION: Always adlust timing bslt tsnsion with th6
engine cold.
NOTE:
. The tensioneris spring-loadedto apply proper ten-
sion to the belt automaticallyaftermakingthe follow-
ing adjustment.
a Alwavs rotate the crankshaftcounterclockwisewhen
viewed trom the pulley side. Rotating it clockwise
may result in improper adjustmentof the belt ten-
sion.

Removethe cylinderhead cover. (Referto page 6-

78 when installing.)

Setthe No. 1 pistonat TDC(seepage6-51).

Rotatethe crankshaft5-6 revolutionsto setthe belt.

4. Set the No. 1 pistonat TDC.

AINUSTINGAOLT
5/aN.m 15.5kg{.m,to lbtftl
For adjustmentonly,

A
\v-/
\ .//

Direction
rotat|on,
Rotatepulley
and inspectb6lt.
5. Loosenthe adjustingbolt 1/2turn (180')only.

Rotatethe crankshaftcounterclockwise
3 teeth on
the camshaftpulley.

7. Tightenthe adjustingbolr.

After inspecting.retorquethe crankshaftpulleybolt 8. After adjusting,retorquethe crankshaftpulley bolt

to 177N.m (18.0kgf.m,130lbf.ft). to 177N.m (18.0kgf.m,130lbf'ft).

6-48
Removal

NOTE: 4. Loosenthe adiusting nut and mounting nut, then

. Turn the crankshaftpulley so the No. 1 piston is at removethe alternatorbelt.
top dead center {TDC)before removing the belt (see NUT
page6-51). I x 1.25mm
. Inspectthe water pump when removed the timing 24 N.m {2.algf.rn,
17 tbf.ftl
belt {seepage10-9).

Removethe wheel well splashshield (see page 6-

57).

Loosenthe adiustingbolt and mountingbolts,then

remove the power steering (P/S)pump belt.

AOJUSTING

MOUNTINGNUT
10 x 1.25mm
4,t N.m lia.5 kgl.m,
33 tbt ftl

Removethe cruisecontrolactuator(seepageG58).

I x 1.25mm Bemovethe side enginemount.

2aN.ml2.akgt.m,17lbt ttl

Loosenthe adjustingbolt and idler pulley bracket 10x 1.25mm

bolt, then remove the air conditioning(Ay'C)
com- 52N.m15.3kgtm, 38lbtftl
oresso. belt.

ADJUSNNG

CNGINC
MOUNT

D1IN
BOLT
10 x 1.25mm
ira N.m (4.5 kgf.m, 33 lbf'ttl BELT
12 x 1.25mm
74 N.m (7.5kgt m,
s4 lbf.trl

(cont'd)

6-49
Timing Belt
Removal lcont'd)

1. Removethe cylinderheadcover. 1 0 . Loosenthe adjustingboh 180'.

. Referto page6-78when installing. 1 1 . Pushthe tensionerto r€movetensionfrom the tim-

ing belt,then retightenthe bolt.
8. Removethe pulley bolt and crankshaftpulley (see
page6-47). 1 2 . Removethe timing beltfrom the pulleys.

a Removethe middlecoverand the lowercover.

NOTE:
. Do not uss the middlecover and lower coverfor
storingitemsdisassembled.
a Cleanthe middle cover and lower cover before
installation.
6x1.0mm
9.8 N.m 11,0kgf'm, 7.2 lbl'ftl
WASHER
Replacewhen
or deteriorated.

CYLINDER
OOVER NMING BELT
Rel€rto pago 6-78 Adjustment,page 6-48
when inslalling.

MIDDLE
COVER
RUABERSEALS @^R
v@
R e p l a c 6w h e n
or deteriorated.

6x1.0mm
9.8 N.m {1.0 kgf.m,
7.2 rbnftl

LOWERCOVER

6r1.0mm
9.8N.m 11.0kgf.m,7.2lbtftl

CRANKSHAFT PULl"EY
Removeany oil and
cleanon the timing belt
guideplat6side.

TIMINGBELT
GUIDEPLATE
lnstallwithconcave
surfacefacing out.
BELT Removeany oil
TENSIONER and clean.
PULI.TYBOLT
17?N m {18.0kgf.m,130lbtftl
ADJUSNI{G BOLT
10 x 1,25mm
5,t N.m 15.5kgf.m,
.(l rbf.ftt
For adjustm€ntonly,
TimingBelt
lnstallation
Installthe timing belt in the feverseorderof removal;
Only key pointsare describedthere.

NOTE:Cleanthe middle cover and lower cover before

installation.

1. Positionthe crankshaftand the camshaftpulleysas

shown betoreinstallingthe timing belt.

A. Set the crankshaftso that the No. 1 piston is at

top dead center {TDC).Align the groove on the
teethside of the timing belt drive pulleyto the V
pointeron the oil pump.

B. Align the TDC marks on intakeand exhaustpul-

leys.

2. I n s t a l lt h e t i m i n g b e l t t i g h t l y i n t h e s e q u e n c e
shown.
O T i m i n g b e l t d r i v e p u l l e y ( c r a n k s h a t t*) @
A d j u s t i n gp u l l e y * @ w a t e r p u m p p u l l e y * @
Exhaustcamshaftpulley* @ Intakecamshaftpul-
lev,

(cont'd)

6-51
Timing Belt
Installation(cont'dl
1 Loosen and retighten the adjusting bolt to tsnsion 1. l f a c a m s h a f t p u l l e y i s n o t p o s i t i o n e da t T D C .
thB belt. .emove the timing belt and adiust the positioning
following the procedureon page 6-51,th6n r6install
4. Rotatethe crankshaftabout 4 or 6 turns countsr- rhe riming belt.
clockwiseso that the belt positions on the pulleys.
NOTE: Refsrto page 6,19 for timing b€lt removal.
5. Adjust ths timing bolt tension (see pags &48).
Aft€r installation,adiust the tension of each b€lt.
b. Ch€ckths crankshaftpullsy and the camshaftpul- o See section 23 for alternator belt tension adiust-
lsys at TDC. menr.
. See section 22 tot NC compr€ssor b6lt tension
CRANKSHAFTPULLEY: adjustm€nt.
. See section 17 for P/S pump b6lt t€nsion adiust-
menL

CAMSHAFT PULI..EY:

"UP- MANKS

6-52
Cylinder Head
lllustratedIndex
CAUTION: To svoid dsmaging the cylindor h.ad, wsit until tho engino coollnt tomper.turo drop3 bolow 100'F (38'C)
bofore romoving it.

NOTE:
r Use new O-ringsand gasketswhen reassembling.
. Use liquidgasket,Pan No. 08718- 0001.
. Replacethe rubbersealsfor oil leakagebetweenthe cylinderheadandcover.

cleanallthe partsin solvent,

,o reassembling, to anycontactparts.
drythem,andapplylubricant
fterw

6x1.0mm
9.8 N.m (1.0 kgt'm,
8 x 1.25mm 7.2tblftl
27 N.m 12.8kgt m, 6xl.0mm
20 rbt ft) 9.8 N.m {1.0 kgl m, 7.2 lbf.ftl

f,
f 4qi CYLINDERHEAD
s COVER
Referto psge 6-78
when instglling.

CAMSHAFT

liquidgasket
to thos€ points.
6 x 1.25mm INTAKE
2it t*m 12.4kg[.m, CAMSHAFT
17 rbf.ftl SEAL
Replace.
Replacewhen damaged
or det€riorated,

r 1.25mm
56 N.m 15.7kg{.m,
ial lbf.ft)

Replace.

6-53
 NOTE:Cleanthe headoil controlorificeand the rockershaftorificeswhen installino.

ROCKEBARM ASSEMBLY

CYLINDERHEAD
BOLTS
1 1x 1 . 5m m INTAKEVALVESPRINGINNER
81 N m (8.3ks{ m, 60
Apply clean engine oil
to threads and washer
contact surface. SPRINGRETAINER

INTAKEVALVESPRINGOUTER

VALVE SPRINGSEAT VALVESEAL

Replace.

SPRINGSEAT
VALVEGUIDE
SPRINGRETAINER
MOTION
EXI{AUSTVAL ASSEMBLY INTAKEVALVE
SPRING
VALVESEAL
Replace.
INTAKE ROCKER
VALVE ORIFICE
Clean.
LOSTMOTION
ASSEMBLY

ROCKERSHAFT
DOWEL
EXHAUSTVAL PIN -,
ROCKER
OOWEL SHAFTORIFICE
PIN

CYLINDERHEAO
GASKET
13LAYEBSOF MET
Replace.
SEALINGBOLTS,20 mm
64 N.m 16.5kgf.m,47 lbtftl
Cylinder Head
Removal

Engineremovalis not requiredor this procedure. 5. Removeth€ strut brace,

CAUTION: To avoid damaging tho cylinder head, wail

u[tilths.nginc coolant tsmperaturo drops bolow 100"F
(38'Cl bafore loos6ningtho retaining bolts.
8 x 1.25mm
24 N.m (2.1kg[.m, 17 lbtftl
NOTE;
. Inspectthe timing belt before removingthe cylinder
head.
Turn the crankshaftpulleyso that the No. 1 piston is
at top deadcenter(TDc){page6-51).
a Markall emissionshosesbetoredisconnecting them.
a Anti-theft radios have a coded theft protection circuit.
Be sure to get the customer's code number before
- Disconnectingthe battery.
- Removingthe No.32 (7.5A) fuse trom the under-
hood fuse/relaybox.
- Removingthe radio.
After service,reconnectpower to the radio 8nd turn it
on.
When the word "CODE"is displaved.enter the cus-
tomer's5-digitcodeto restoreradiooperation,

'1. Disconnect
the negativeterminalfrom the battery.

Drainthe enginecoolant(seepage10-5).

. Removethe radiatorcapto speeddraining. 6. Removethe intakeair duct.

Relievefuel pressure(seesection111.

l@ Do not 3moke whilo working on fuel

systgm. ko6p opon tlamo ot Sparkaway trom work
aroa. Drain fugl only into an approved containsr, INTAKE AIR

4. Disconnectthe fuel feed hose.

SERVIC€BOLT
15 N.m (1.5 kgtm, rl bf.tt)
WASHERS
Replace.

BANJOBOLT

(cont'd)

6-55
CylinderHead
Removal (cont'd)

7. Removethe vacuum hose and €vaoorativsemis- 9. Removeths brake boostervacuum hose and fu€l
sion (EVAP)controlcanisterhose. return hose,

BRAKEBOOSTER
VACUUMHOSE

6x1.0mm
12N.m11.2kgf.n,8.t lbf.trl
EVAPCONTROL
CANISTERHOSE 10. R€mov6tho thronlo cable.

NOTE:
o Taks care not to bsnd the cabl6 when removing
it. Always replaceany kinkedcable with a new
Remove the water bypass hose and positive on6.
crankcase
ventilation{PCV)hose. o Adiust the th.ottle cable when installing (sees6c-
tion1l).

WATERBYPAss
PCV HOSE HOS€

AD.'USTING THROTTI,"E
NUT CABI.T
l l . Removethe engine wire harnessconnectorsand 14. Removethe sDlashshield.
wi.e ha.nessclampsfrom the cylinderheadand the
intakemanitold.

a Four fuel injector connectors

o Intakeair tempe.ature {lAT) sensor connector
a Engine coolant temperature(ECT)sensor con-
nector
o TDC/CKP/CYP sensor connector
a lgnition coil conn€ctor
a ECTgaugesendingunit connector
a Throttle position (TP)sensor connector
a VTECsolenoidvalveconnector
a VTECDressureswitch connector
a Manifold absolute pressure(MAP) sensor con-
nector
a ldle air control{lAC)sensorconnector
a EVAPpurgecontrolsol€noidvalvoconnector
a Intake air bypass {lABl control solenoid valve
conneclor
6r1.0mm
12. Removethe spsrk plug caps and distributorfrom 9.8 N.m (1.0kgt m,
the cylinderhead. 1.2 tbtftl

1 3 . Removethe upper radiatorhose, heat€rhose and

water bypass hose.
1 5 . Removethe enginegroundcable.
Romovothe adjustingbolt and mountingbolts,then
remove the power steering (P/S)pump belt and P/S
WATER BYPASS pump.
. Do not disconnectthe P/S hoses.

6x1.0mm
9.8 N.m 11.0kgl.m,
7.2 tbt.ttl

HOSE

(cont'dl

6-57
, l
Cylinder Head
Removal(cont'dl
1 6 . Removethe heat shield from the P/S bracket(see 21. Removethe cylinderheadcover.
p a g e5 - 1 8 ) .
22. Removethe timing belt (seepage6-49).
1 7 . Removethe air conditioning(Ay'Clcompressorbelt
(seepage6-49). 23. Removethe camshaftpulleysand backcover.

'18. Remove
the alternatorbelt {s€epage6-49).
'19.
Removethe cruise control actuato..

8 x 1.25mm
N.m 12.4kgf.m, 17 lbtftl

ACTUATOR

20. Removethe sideenginemount. 24. Removethe exhaustmanifold.

10x 1.25mm SELF.LOCKING NUT

8 x 1.25 mm
31 N.m {3.2 kgt m, 23 lbf.ftl
Replace.

SIDEENGINE

12 x 1.25mrn
7a N.m 17.5kgl.m,
5a rbtftl

6 -5 8
'ilffi{
25. Removethe intakemanifold. 21. Remove the camshaft holder plates, camshaft hold-
ers, and camshafts.

GASKET

CAMSHAFT

28. Removethe cylinder head bolts, then removethe

cylinderhead.
26. Loosenthe adjustingscrews.
CAUTION: To prsvent warpage, unscrew th€ bolts
in sequencel/3 turn at a time; repeat until all bolts
aro loosoned.

CYLINDERHEADBOLTLOOSENINGSEOUENCE
INTAKE
No.4 No.3 No.2 No. 1

No. 4 No.3 N o .2 No. 1

EXHAUST

6-59
RockerArms
Removal

Holdthe rockerarmstogetherwith a rubberbandto 3. Screw 12 mm bolts into the rockerarm shafts.

oreventthem from seParating. Removeeach rocker arm set while slowly pulling
out intakeand exhaustrockerarm shafts.

BAND
RUBBER

Removethe intake and exhaust rocker shaft orifices,

then removethe VTECsolenoidvalve and the seal-
ing bolts. ROCKERSHAFTS

NOTE:The shapesof the rockershaftorificesof the

intakeand exhaustare different.ldentify the parts
as they are removedto ensurereinstallationin the
originallocations.

INTAKE ROCKER
EXHAUSTROCKER
SHAFTOBIFICE
SHAFTORIFICE Clean.
Clean.
O-RING
O.RING Replace.
Replace.
 Locations
tho orifice ls corrccdY
GAUTION: Aftcr in3tlllino th! roCk.r shrft o.ifice, trY to tum ihc tock r .hatt to makr luta thlt
in3artcd in the holc of tho lockor shrft. It the oritice b in placc' it should not turn'

NOTE:
o ldentifypartsastheyareremovedto ensurereinstallation in originallocdtions'
. lnsoect rockershafts and rockerarms (see pages 6-62and 63)'
o Rocke.arms must be installed in the same position it reused'
. Cleanthe rockershaft orifices when installing.

erio, to ,einstalling,clesn all the parts in solvent, dry them and spply lubricantto any contact surfacos'
I

ARII,IASSEi/IBUES
NTAKEBOCXER

RUBBERBA D
sEALlMi BoLTS,20 m|tr INTAKEROCXER
64 N.m 16.5ksf.]n,4.7lbf.ftl SHAFT

I
Cl6an.

&
tu ry o-nrM;s
R6placo.

ryHOII
TROCIGRSHAFT
oRrFrcEsl
-%
t

EXHAUSTROC(ER
BOCXER
SHAFT RUASERBA'{D

EXHAUSTB(rcKERARMASSEMBLIES

6-61
RockerArms
lnspection

N O T E :W h e n r e a s s e m b l i n gt h e) p r i m a r y r o c k e ra r m , Removethe lost motion assemblyfrom the cylinder

c a r e f u l l ya p p l y a i r p r e s s u r et o the
t oil passageof the head and inspectit. Test it by pushjngthe plunger
rockerarm. with your finger.
- l f t h e l o s t m o t i o n a s s e m b l yd o e s n o t m o v e
smoothlv,reDlaceit.

ROCKERARM Push
SECONDARY
t LOSTMOTIONASSEMBLY

PISTONS

Inspectthe rockerarm piston.

ciston.Pushit manually.
- lf it does not move smoothly,
smoot replacethe rocker
arm assembly.

\ xva
V/\'
Checkpistonmovement

. Apply oilto the pistonswhen whe reassembling.

. w i a rubber band to
B u n d l et h e r o c k e ra r mss with
keepthem togetheras a set.

6-62
Arm-to-Shaft Clearance

Measureboth the intake rocker shaft and exhaust rocker Measureinside diameterof rockerarm and chgck
shaft. for out-of-roundcondition.

1. Measurediameterof shaftat first rockerlocation, Rock6rA.m-iq.Shaft Clearance:

lntak. and Exhaust
Standald (Now): 0.025- 0.052mm
(0.0010- 0.0020in)
S.rvicc Limit: 0.08 mm {0.003in}

Surfacoshouldbe smooth.

2. Zerogaugeto shaftdiameter. Inspectrockerarm

facetor wear.

Repestfor all rockers.

- lf over limit. replace rocker shaft and all over
tolerancerockerarms.
MICROMETER
N O T E : l f a n y r o c k e ra r m n e e d s r e p l a c e m e n t ,
replaceall three rocker arms in that set (primary,
mid, and secondary).

6,63
RockerArms
Installation
1. I n s t a l l t h e r o c k e r a r m s i n t h e r e v e r s eo r d e r o f 4. Clean and install the rocker shaft orifices with new
removal: O - r i n g s .l f t h e h o l e s i n t h e r o c k e ra r m s h a f t a n d
. Valveadjustinglocknutsshould be loosenedand cylinderhead are not in line with each other,screw
adjusting screw backedoff before installation. a 12 mm bolt into the rocker arm shaft and rotate
. The componentparts must be reinstaltedin the the shaft.
originallocations.
NOTE:The shapesof the rockershaft orificesfor
2. Installthelost motionassemblies. the intake and €xhaust are different.The orifices
must be installedin the originallocations.
3. Install the rocker arms while insening the rocker
arm shaft into the cvlinderhead

NOTE:Removethe rubber band after installingthe

rocKerarms.
INTAKEROCKER
SHAFTORIFICE
EXHAUSTROCKER Clean.
SHAFTORIFICE
Cl6an.

O.RING
Beplace.

Beplace.
'/'/

12 mm EOLT

6-64
Camshafts
Inspection
NOTE:
. Do not rotatethe camshaftduringinspection.
. Removethe rockerarms and rockershafts.

1. P u t t h e c a m s h a f t sa n d c a m s h a f th o l d e r so n t h e
c y l i n d e rh e a d ,a n d t h e n t i g h t e n t h e b o l t s t o t h e
soecifiedtorque.

SpecifiedTorque:
O - @: 8 mm bolts 26 N.m {2.7 kgl.m,20 lbt'ftl
(D -(D:6 mm bolts 9.8 N.m {1.0kgt.m,7.2 lbf'ftl

4, Removethe bolts,then removethe camshafthold-

ers from the cvlinderhead.
o o o o @ N O T E : U n s c r e wt h e c a m s h a f th o l d e r b o l t s t w o
turns at a time, in a crisscrosspattern.

5. Lift camshaftout of cylinderhead.wipe clean,then

inspectlift ramps.Replacecamshaftif lobesare pit-
ted, scored,or excessivelyworn.

Cleanthe camshaftbearingsurfacesin the cylinder

head.then set camshaftbackin place.

1. Placea plastigagestrip acrosseachjournal.

Installthe camshaft holders,and then tighten the

bolts to the specifiedtorque as shown in the left
columnon this page.

NOTE:Do not rotatecamshaftsduring inspection.

Seateachcamshaftby pushingit toward distributor
end of the cylinderhead. 9. Removethe camshaftholders.Measurewidest Dor-
tion of plastigagestrip on eachjournal.
Z e r o t h e d i a l i n d i c a t o ra g a i n s te n d o f d i s t r i b u t o r
drive, then push the camshaftback and forth and Camshaft-to-HolderOil Clearance:
readthe end play. Standard {New): 0.050- 0.089mm
{0.002- o.Ooilin)
Camshaft End Play: Sswice Limit: 0.15mm (0.006in)
Standard (New): 0.05- 0.15 mm
10.002- 0.006inl
Sawics Limit: 0.5 mm (0.02inl

(cont'dl
Gamshafts
Inspection(cont'd)
10, lf camshaft-to-holderoil clearanceis out of loler- 11. Checkcam lobewear.
ance:
Clm Lobs Hcight Standard (N.w):
- And camshaft has already been replaced,you
must replacethe cylinderhead. IiITAKE EXHAUST
33.i{'l1 mm 3 3 . 1 1 1m m
- lf camshaft has not been replaced,first check PRIMARY ( 1 . 3 1 5 4i n l (1.3036in)
total runout with the camshaftsupportedon V-
36.377mm 35.720mm
blocks. MID
l't.4322inl (1.4063inl
CamehaftTotal Runout: 34.547mm 34.381mm
SECONDARY ( 1 . 3 6 0 i1n ) (1.3536in)
Sisndard (New): 0.015mm (0.0006inl
ServiceLimit: 0.03 mm (0.0012in)

Rotat€camshsft
while measuring

Checkthis are6tor wsar.

Crm Porition

- lf the total runout of the camshaftis within toler-

ance,replacethe cylinderhead. INTAKE CXHAUST
- lf the total runout is out of tolerance,r€Dlacethe
Mto sEc SEC MID PRI
camshaftand recheck.lf the oil clearanceis still
out of tolerance.replacethe cylinderhead. fTt-]--Tt-Tt-l
\ l l i l i l | /
\ t t t t l
LIL__H___}{-}U
ftB ftB

T/B: nMING BELT

PRI: PRIMAFY
MID:MID
SEC:SECONDARY

6-66
Valves,Valve Springs and Valve Seals
Removal
N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e I n s t a l ls p r i n g c o m p r e s s o rC
. o m p r e s ss p r i n g a n d
removedso that eachitem can be reinstalledin its orioi- remove valve keeper.
nal position.

1. Using an appropriate-sized socketand plasticmal-

let. lightlytap the valve retainerto loosenthe valve
keepersbeforeinstallingthe valve spring compres- VALVESpRtNG VALVESPRING
sor. COMPRESSoR COMPRESSoRATTACHMENT
ATTACHMENT EXTENSION

Snap-onCFrll

(cont'd)

6-67
Valves,ValveSpringsand ValveSeals
Removal(cont'dl
3. Installthespecialtoolas shown Valve Dimensions

COMMERCIALLY AVAILABLE
VALVEGUIDESEALREMOVER
Lrst"EP/N s79(x'OR KD3350

lntrko ValYo
A Standsrd (N.wl: ilil.go - *t.10 mm
(1.295- 1.303inl
B Standard (Newl: 101.00- 101.30mm
(3.976- 3.988inl
C Standard (N.w): 5.a75- 5.185mm
(0.2156- 0.2159inl
C Sorvicc Limit 5.i!15(0.21.lt in)
D Standard (Ncw): 1.05- 1.35mm
4. Removethe valveguide seal. (0.04i - 0.05:tin)
D Sorvicc Limh: 0.85 mm (0.033inl

Exhau3tValve
A Stand.rd (Ncwl 27.90- 28.10mm
11.098- 1.106inl
B Standard (Ncwl: 1qr.6lt- loo.glt mm
(3.961- 3.972inl
C St.nd.rd (Now| 5./L51,
- 5.460mm
(0.2146- 0.215|,inl
C ServicoLimit: 5.a20(0.2134inl
D Standsrd lNewl: 1.65- 1.95mm
{0.065- 0.077inl
D Sorvicc Limit 1.45mm (0.057inl

6-68
InstallationSequence
NOTE:Exhaustand intakevalvesealsare NOT interchangeable.

VAIVE IGEPGNS

/ v^LvEsP'ittNG
*nt
/^no,n
INTAKEVALVESPAING /'=\/
\y
VALVE SPRING

@--'**
EXHAUSTVALVESEAL
9-** NOE: Placethe end ofv.lv€
spring with closelywound coilg
(BLACKSPRINGI
loward the cvlinder h€ad.
Replace.

SPRINGSEAT
NOTE: lnstallthe valvo spring se6t6
bsfore installingthe valv6 so6ls,

VALVE GUIDE SEAL II{STALITR

KD-2EgS
NOTE:UsosmalllD
ond oftool.

VALVE SEAL
R€place.
P.%
6-69
Valves,Valve Springsand
ValveSeals Valve Guides
Valvelnstallation ValveMovement
When installingvalves in cylinder head, coat valve Measurethe guide-to-stem clearancewith a dial indica-
stemswith oil beforeinsertinginto valveguides,and t o r w h i l e r o c k i n gt h e s t e m i n t h e d i r e c t i o no f n o r m a l
makesurevalvesmove up and down smoothly. thrust(wobblemethod).

When valvesand springsare in place,lightlytap the lntaks Valvr Stom-to-GuideClearance:

end of each valve stem two or three times to ensure Standard(Newl: 0.05- 0.11mm
proper seatingof valve and valve keepers(use ham- {0.002- 0.OO'lin)
m e rh a n d l e ) . Ssrvice Limit: 0.16 mm (0.006in)

NOTE:Tap the valve stem only along its axis so you ExhaugtVdve Stem-to-GuideClsarancg:
do not bendthe stem. StandaldlNowl: 0.10- 0.16mm
(0.00'l- 0.006in)
Sorvics Limit: 0.22 {0.0m in)

Valveextended10 mm out from seat.

. l f m e a s u r e m e n te x c e e d st h e s e r v i c e l i m i t .
recheckusinga new valve.
. lf measurementis now within the servicelimit,
reassembleusinga new valve.
. lf measurementstill exceedslimit, recheckusing
alternatemethod below,then replacevalve and
guide,if necessary.

NOTE: An alternatemethod ot checkingguide to

stem clearanceis to subtractthe O.D.of the valve
stem. measuredwith a micrometer,from the l.D.ot
the valve guide,measuredwith an insidemicrome-
ter or ball gauge.
Take the measurementsin three placesalong the
valvestem and three placesinsidethe valveguide.
The differencebetweenthe largestguide measure'
ment and the smalleststem measurementshould
not exceedthe servicelimit.

lntafte Valvs Stom-to-GuidaClearance:

Stardard (Nowl: 0.025- 0.055mm
(0.0010- 0.0022inl
ServiceLimit: 0.08 mm (0,003in)

ExhaustValvo Stem-to-GuideClearance:
Standard lNew): 0.050- 0.080mm
10.0020- 0.0031in)
S€rvics Limit: 0.11 mm {0.0oilinl

6-70
1 . As illustratedin the removal steps ot this proce- Workingfrom the camshaftside, usethe driverand
d u r e . u s e a c o m m e r c i a l l y- a v a i l a b l ea i r - i m p a c t an air hammerto drive the guide about 2 mm (0.1
driverattachmentmodifiedto fit the diameterof the i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l
valve guides. In most cases,the same procedure knock off some of the carbon and make removal
c a n b e d o n e u s i n g t h e V a l v eG u i d e D r i v e ra n d a easier.
conventionalhammer,
CAUTION:
. Always wear ssfcty gogglos 01 a taca rhiold
COMMCRCIALLY.AVAILABLE whcn using thc air hrmmcr,
VALVEGUIDEDRIVER . Hold tho.ir hammer diroctly in line with tho
5.3mm
(0.21inl v6lvo goido to prov.nt drmaging tho driv6r.
I
_{l
Turn the head over and drive the guide out toward

azmm +- szmm tfr the camshaftsideof head.

{3.43inl I tz.zt in) 10.8mm lf a valve guide still won't move, drill it out with a
10.42inl 8.0 mm (5/16in) bit,then try again.
R.mov.l andIn3trll.tion
VALVEGUIDEDRIVER. CAUTION; Drill guid6 only in oxtromc cs3os:you
5.5mm could dlmsgo tho cylinder hoad if tho guidc brcakr.
07742- q)101tt0

S e l e c tt h e p r o p e r r e p l a c e m e n g
t uidesand chill
them in the freezer section of a refrigerator for
aboutan hour.

Use a hot plate or oven to evenly heatthe cylinder

headto 300'F(150"c).Monitorthe temperaturewith
a cookingthermometer.

VALVEGUIDEDBIVER.
5.5mm
07742- 0010100

-_ -\
lo
CAUTION: i oc)
. Do not us9 a iorch; it may warp ths hsad.
. Do not get ths head hottor than 300"F (150"C);
excsssivohgat may loogenthe valvo soaG.
. To avoid burns, use hsaw glovo3whon handling
the heated cylindor h€ad. 6. Removethe new guide(s)from the refrigerator,
one
at a time, as vou needthem.
(cont'd)
Valve Guides
(cont'dl
Replacement Reaming
7. Slip a 6 mm {0.2 in) steel washer and the correct NOTE:For new valveguidesonly.
driver attachmentover the end of the driver (The
washerwill absorbsome of the imDactand extend 1. Coatboth reamerand valveguidewith cuttingoil.
the life of the driver).
2, Rotatethe reamer clockwisethe full length of the
valveguide bore.

:=:-/--P
DRIVER 6 mm 10.2int
WASHER
ATTACHMENT
3.

4.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore.

Thoroughlywash the guide in detergentand water

to removeany cuttingresidue.

Installthe new guide(s)from the camshaftside of 5. Checkclearancewith a valve(seepage6-70).

t h e h e a d ;d r i v e e a c h o n e i n u n t i l t h e a t t a c h m e n t
bottomson the head.lf you have all sixteenguides . Verifythat the valve slidesin the intakeand ex-
to do, Vou may haveto reheatthe head one or two haustvalveguideswithout exertingpressure.
more times.

REAMERHANDLE

Turn reamerin
clockwisedirection
onry.

C'

a
-'{
)

Valve Guide Installed Height:

Intake: 12.55- 13.05mm {0.49it- 0.51itinl
Exhaust 12.55- 13.05mm {0.494- 0.514inl

VALVEGUIDE

6-72
ValveSeats
Reconditioning
Renewthe valve seats in the cylinder head using After resurfacingthe seat, inspect for even valve
valve seat cutters. s e a t i n g :A p p l y P r u s s i a nB l u e C o m p o u n dt o t h e
valve face, and insen valve in original location in
NOTE: lf guides are worn, replacethem before cut- thc hea.l.then lift it and snap it closedagainstthe
ting the valveseats. seat severaltimes.

ACTUALSEATING
SURFACE

VALVE
SEAT
PRUSSIANBLUE

The actualvalve seatingsurface,as shown by the

bluecompound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve steml, you
must make a second cut with the 60' cutter to
move it down, then one more cut with the 45'
cutter to restoreseat width.
. lf it is too low (closer to the valve edge), you
must make a secondcut with the 30'cutter to
move it up, then one more cut with the 45" cutter
to restoreseat width.

NOTE; The final cut should alwavs be made with

C a r e f u l l yc u t a 4 5 os e a t , r e m o v i n go n l y e n o u g h the 45'cuttef.
materialtoensurea smoothand concentricseat.
1. lnsert intake and exhaust valves in the head and
Bevelthe upperedge of the seatwith the 30' cutter measurevalvestem installedheight.
and the lower edge of the seat with the 60'cutter'
Checkwidth of seatand adjustaccordingly. Intake Vllve St€m ln3tslled Hsighl:
Stsndard (Now): 37.'155- 37.935mm
Make one more very light pass with the 45ocutter to (1.4750- f .il935in)
removeanv possibleburrs causedby the other cut- SorvicoLimit: 38.185mm 11.5033in)
ters. ExhaustValvo Stom In3talledHoight:
Standard (Now): 37.165- 37.6:15mm
Valve Seat Width: 11.4{X}2- 1.,1817 inr
Stlndard: 1.25- 1.55mm {0.0,19- 0.061in) Sewico Limit: 37.885 (1.i1915 in)
Ssrvico Limit 2.0 mm 10.08in)

SEAI wlDTH
VALVE STEM
INSTALLEDHEIGHT

8. lJ valve stem installed height is over the service

limit, replacevalve and recheck.lf still over the ser-
vice limit. replacecylinder head;the valve seat in
the headis too deeD.

6-73
GylinderHead
Warpage
NOTE: lf camshaft-to-holderoil clearances(see page Measurealongedges.and 3 ways acrosscenter.
6-65)are not within specification.the head cannot be
.esurfaced.

lf camshaft-to-holder
oil clearancesare within sDecifica-
tions,checkthe headfor warpage.

lf warpage is less than 0.05 mm {0.002in) cylinder

headresurfacingis not required.
lf warpageis between0.05mm {0,002in) and 0.2 mm
{0.008in), resurfacecvlinderhead.
Maximum resurfacelimit is 0.2 mm {0.008in) based
on a heightof 142mm (5.59in).

PRECISION
STRAIGHTEDGE

Cylindsr Hssd Height:

Standard lNsw): 1i11.95- 1,f2.05mm
15.s89- 5.593inl

6-74
 lnstallation
Installthecylinderheadin the reverseorderof removal: 2. Tightencylinderhead bolts in two steps.In the first
step, tighten all bolts in sequenceto about 29 N'm
NOTE: ( 3 . 0 k g f . m . 2 2 l b f ' f t ) .I n t h e f i n a l s t e p ,t i g h t e n i n
. Alwaysusea new headand manifoldgasket. samesequenceto 81 N.m (8.3kgnm.60lbf'ft).
. The cylinderheadgasketis a metal gasket Takecare
not to bend it. NOTE: Apply clean engine oil to the bolt threads
. Rotatethe crankshaft,set the No. 1 piston at TDC and underthe bolt head.
(page6-51).
. D o n o t u s e t h e m i d d l ec o v e r a n d l o w e r c o v e rf o r CYLINDERHEADBOLTTOROUESEOUENCE
storingitemsdisassembled.
. Cleanthe middlecoverand lowercover beforeinstal-
1 1x 1 . 5m m
lation. 81 N.m{8.3kgf.m,60lbfft)
a Replacethe washerwhen damagedor deteriorated

1. tnstallthe cylinderhead gasket.dowel pins and the

headoil controlorificeon the cylinderhead

NOTE:Cleanthe oil controlorificewhen installing.

O.RING
Replace.

Installthe intakemanifoldand tightenthe nuts in a

crisscrosspatternin two or three steps,beginning
with the inner nuts.
HEAD GASKET
OIL CONTROL RePlace
ORIFICE
Cloan.

8 x 1.25mm
23 N.m 12.3kgl.m.
17 tbf.ftt

8 x 1.25mm
kgf m,
24 N,m 12.,4
17 tbf.ft)
(cont'd)

6-75
CylinderHead
Installation{cont'd)
4. Install the exhaust manifold and tighten the new 5. Installthe camshafts,camshaftoil sealsand rubber
selJ-lockingnuts in a crisscrosspattern in two or cap.
threesteps,beginningwith the inner nuts.
NOTE:
. Usenew self-lockingnuts. . Installthe camshaftswith keyway facing up.
o Installtheoil sealwith the springsidefacingin.
. The oil sealhousingsurfaceshouldbe dry,
. Set the O-ringand dowel pin in the oil passage
of th€ No. 3 camshaftholder

8 r 1.25mm SELF.LOCKING NUT O-RING{ReDlace.)

2aN..n12.4lgtm, 8 x 1.25mm
r 7 tbf.ftl 31 N.m 13.2kgf'm, 23 lbtltl
Replace.

EXHAUST
GASKET
Replsco.

&,x Kgywayis lacingup.

A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e rc a p , t h e n
installthe rubbercap.

a.l N.m 14.5kgt m,

33 tbr.trl
8 x 1.25mm
24 N.m (2.4 kgt m,
rt tbfft)

6-76
7. Apply liquid gasket to the hesd mating surface of 9. Tightenthe bolts in the sequenceshown below.
th€ No. 1 and No. 5 camshaft holders on both the
intako and exhaust side. Confirm that the camshaft
koywEysface up, then place those holders,together
with th€ No.2, No. 3 and No.4 camshaftholders,
on th€ cylind6r head.

NOTE: The arrows msrked on the camshaft holders

shouldpoint to the timing belt.
CAIISHAFTHOIDERS INTAKE
lrlo.6 Ho.a No.3 1to.2
t /
r l l bl
d t t t o 0 o o o o o

ffi
ro888rfl?x \trt
I
Applyliquidgaskot
to lh6 3had€daroas.
EXHAUST

(D - @: 8 x 1.25mm 27 N.m {2.8 kgf.m,20 lbt ttl

Temporarilytightonthe bolts of tho camshafthold- (D - (D: 6 x 1.0 mm 9.8 N.m (1.0 kgrl.m,7.2 lbf'ft}
6rs and thE camshaftholderplates,
10. Installthe backcoverand camshaftpulleys.

CAMSHAFT
CAMSHAFT HOI,I'ER

10x 1.25mm
56 N.ln l5.t kgf.m,
4r lbl.trl
6x1.0mm
9.8 N.m 11.0kgtm, t.2lbf'ft)

(cont'd)

6-77
CylinderHead
Installation lcont'd)

1 1 . lnstallthetiming belt lsee page6-51).
12. Adjustthe valveclearance(seepage6-44).
1 3 . Installthe rubberseal in the grooveof the cylinder
head cover. Seat the seal in the recessesfor the
camshaftfirst, then work it into the groove around
the outsideedges.
NOTE:
. B e f o r e i n s t a l l i n gt h e r u b b e r s e a l .t h o r o u g h l y
cleanthe sealand the groove.
. W h e n i n s t a l l i n gm , a k es u r e t h e s e a l i s s e a t e d
securelyin the cornersof the recesseswith no
gap.
14. Apply liquid gasketto the rubbe. seal at the eight
corne.s of the recesses.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
a Do not install the parts if 20 minutes or more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t .
Instead,.eapplyliquid gasketafter removingold
residue.
r After assembly, wait at least 20 minutes before
filling the enginewith oil.

Apply liquidgasketto
the shadedareas.

COVER

6-78
When installingthe cylinder head cover. hold the Tighten the nuts in 2 or 3 steps. In the final step'
rubbersealin the grooveby placingyour fingerson tighten all nuts, in sequence,to 9.8 N'm (1.0kgf'm,
the camshaftcontactingsurfaces(top of the semi- 7.2 tbf.ft).
circles).
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head,slidethe cover slightlybackand forth to seat
the rubberseal.

NOTE:
Before installingthe cylinder head cover, clean
t h e c y l i n d e rh e a d c o n t a c t i n gs u r f a c e su s i n g a
shop towel.
Do not touch the pans where liquid gasketwas
applied.

6x1.0mm
9,8 N.m 11.0kgt'm,
7.2 tffirl

1 7 . After installing,checkthat all tubes,hosesand con-

nectors are installedcorrectly.

6-79
EngineBlock
SpeciafTools .............7'2 PistonRings
7-3
lllustratedIndex ................................... Replacement .........7-16
Flywheel and Drive Plate EndGap .................7-17
Repfacement .........7-7 Ring-To-Groove 7 -17
C|earance,,,,.,,,......
Main Bearings Alignment ..............7-18
Clearance 7-8
,.............. Piston Pins
Selection 7-8
................ Removal ........,........7-18
Connecting Rod Bearings Installation(818B1engine) .............
7-19
Clearance ...............
7-9 fnstaffation(818C1enginel .............
7-20
Selection 7-9
................ fnspection ..............7-2O
Crankshaft Connecting Rods
Removal .................7-10 End Play .................7-21
EndPlay .................7-12 Sefeetion ..........,,,,,,7-22
lnspection ........,,,.,,7-12 Oil Seal
fnstallation .............7'22 fnstaffation .............7-25
CylinderBlock Installation
..............7-13 (engineremoval not requiredl.........7-26
Inspeetion
BoreHoning .....,.,,.7'14
Pistons
Inspaction ..............7-15
Installation .............7-16
 SpecialTools

Raf.No. I Tool Numbcr Dcacription Oty I Pago Rotcrenc.

o 07GAF- PF60300 Piston Pin Easelnsert 1 7-14,19,20
@ 07HAF- P120102 Piston BaseHead I 1-18,19,20
@ OTLAD _ PR4O1OA Seal Oriver 1
- 'I
@ 07LAF PR30100 PilotCollar 7-19,20
o 07LAB- PV00100 or RingGearHolder 1 7-1
07924- PD20003or
01924 - PD20002
@ 07948- S800101 Driver Attachment 1 7-25,26
o 07749- 0010000 Driver 1

I
@ 07973- PE00310 Piston Pin Driver Shaft 1 7-19,20
o 07973- PE00320 Piston Pin Driver Head 1 1-19.20
@ 07973- 5570500 Piston Base 1 1 - 1 8 ,1 9 ,2 0
o 07973- 6570600 PistonBaseSpring 1 1-18

Eg
o @ ,a\

o @

@ @

7-2
lllustrated Index

NOTE: Lubricateall internalpartswith engineoil during

. Apply liquidgasketto the matingsurfacesof the right reassemory.
s i d e c o v e r a n d o i l p u m p h o u s i n gb e f o r ei n s t a l l i n g
them.
- 0001.
. U s el i q u i dg a s k e tP, a n N o . 0 8 7 1 8 6x1.0mm
. C l e a nt h e o i l p a n g a s k e t m a t i n g s u r f a c e sb e f o r e 12 N.m (1.2kgf.m,I lbf.ftl
installingit. OIL PAN

Bl8Bl engine: wAsHEF

DRAINPLUG
44 N.m {4.5kgf.m, 6x1.0mm
33 tbtfr) 11 N.m (1.1kgf.m,8lbtft)

GASKET
Replace.

6x1.0mm OIL SCREEN

1'l N.m {1.1kgt.m, I lbtft)

12 x 1.0mm
103N.m (10.5kgf.m,?6lbf ft)
11 x 1.25mm
76 N.m
17.8kgl.m, 56 lbf ftl
MANUAL Applyengineoilto the bolt
FLYWHEEL threadsand the washers.
NOTE: After torquing
'12x 1.0mm GASKET each cap, turn crankshaft
Replace. to checklor binding.
74 N.m {7.5kgt m,54lbf.ftl WASHER
Torquesequence, page7 7
BEARINGCAP CRANKSHAFT
End play,page7-12
Runout,Taper,and
AUTOMATICTRANSMISSION Out-of-Round, pages7 12,13
DRIVE PLATE page7 22
Instsllation,
Checkfor cracks,
MAIN BEARING
6x1.0mm Radialclearance,page7-8
Apply liquidgasket 11 N.m {1.1kgl.m, page7-8
Sel€ction,
to blockmatingsurface. 8 tbf.frt NOTE:New main bearings
must be selectedby matching
OIL SEAL crankand blockidentification
page7-25,
Installation, markrngs.

RIGHT
SIDECOVER
DOWELPINS
OIL PUMP
THRUSTWASHERS Overhaul,page 8-9
Groovedsidesfaceoutward.
NOTE:Thrustwasherthickness
is tixedand must not be changed
by grindingor shamming.

8 x 1.25 mm
2,1N.m {2.4kgt m,
17 tbt.ft)
O.RING OIL SEAL
Applyengrne page8-11
Installation,
orl.
Replace.
6x1.0mm
Apply liquidgasket '11N.m {1.1kgf'm, 8 lbl ft)
to blockmating (conr'dl

7-3
lllustratedIndex
(cont'd)

NOTE: Lubricateall internalpartswith engineoil during

. Apply liquidgasketto the matingsurfacesof the right reassemblv.
side cover and oil pump housing before installing
thsm.
. Useliquidgask6t,PartNo. 08718- 0001.
. C l e a nt h e o i l p a n g a s k e t m a t i n g s u r t a c € sb e f o r e
innallingit.

Bl8Cl !ngin.:
DBAINPLUG
4,aN.mla.stgl.m.
33 rbr.ftt

6x1.0mm
11 N.m (1.1kgt m,
E |bfitl

OIL PAN

6x1.0mm
ti l*m 11.lkgf m, GASKET
12x t.0 mln I tbf.ftl Replace.
lo:t N.|n110.510f'm,
tG lbffrl
Torquesoquonce. page7-7

BAFFLEPLATE

6xl.0mm
ll N.m (1.1kgt m.
8 tbt frl
O|L SCAEEN
6 x 1.0 rim
11 N.m (1.1 kgf.m,
8 tbt ft)

FLWYHEEL

7-4
 No. a 3, /aCAP BOLTS
l l x 1 . 5m m
64 N.m {6.5 kgt m,
49 tbf.ftl
Applyengineoilto tho bolt
BEARING threads and the washers.
CAPBRIDGE NOTE:Aftertorquing
each cap, turn crankshaft
to checkfor binding.

No. 1,5 CAP BOI-TS

11x 1.5mm
73 N.m {7.4 kgf.m,
56 tbt'ft|
CRANKSHAFT Apply engineoil.
Endplay,page7-12
Runout,Taper,and
Out-of-Round, pages7'12.13 BEARINGCAP
page7-22
Installation,

YHRUSTWASHERS
Groovedsideslace outward.
NOTE: Thrust washerthickness MAIN BEARING
is fixedand must not be chano€d Radialclearance. page7 8
S6l€ction,page7-8
NOTE:New main bearings
OIL SEAL must be selectedby matching
Installation, crank and block identification
pages7-25,26 marxrngs.
Replace.

OIL JEI BOLY

16 N.m 11.6kg{'m,12lbtftl
Be caretul not to damage.

OIL JET OIL PUMP

Inspection, Overhaul,page8-9
6r1.0mm page 8-8 Apply liquidgasket
11 N.m 11.1kgt m, to block mating
8 lbf ftl surface.
RIGHTSIDE
6x1.0mm
COVER
11 N.m {1.1kSf.ft,
Applyliquidgasket
to block mating 8 rbf.ftl
surface.

DOWELPIN

DOWELPIN
OIL SEAL
Instellelion,
O.RING. page8-11
Apply engine Replace. 8 x 1.25mm
orl. 24 N.m {2.4 kgt m,
Replace. 17 tbtft)

(cont'd)

7-5
lllustratedIndex F
(cont'd)

NOTE: New rod bearingsmust be selectedby matching Lubricateall internalpartswith engineoil during
connectingrod and crankshaftidentificationm a r K r n g s reassemorv.
( s e ep a g e s7 - 8 , 9 )

PISTONINSTALLATIONDIRECTION

PISTONRINGS
Replacement,
Measurement.
page7'16
page7-17
Alignment,page7 18
-1@
r@ EXHAUST

PISTONPIN
Removal,page7-18
pages7 19,20
lnstallation,
Inspection,page7'20 INTAKE

Removal,page7'11
Measurement,page7 15 Inspecttop of each cylinder bore
for carbonbuild-upor ridgo
betore removing piston.
CONNECTING ROO Removeridgeit necessary, page7'11
Endplay,page7-21
page7-22
Selection,
page7-21
Smallend measurement.

CONNECTING ROD
EEARINGS
Clearance,page7-9
Selection,page7-9

BLOCX
page7 13
Cylinderboreinspection,
page7'14
Warpageinspection,
CONNECTING RODNUT Cylinderborehoning,page7-14
818B1ongine
8 x 0 . 7 5m m
31 N.m {3.2 kgf.m,23 lbf ftl
818C1engine
9 x 0.75mm
a,aN.m (4.5kgt m, 33 lbf.ft| CONNECTING RODBEARINGCAP
Aftertorquingeachbearang page7'23
Installation,
cap, rotate crankshaftto NOTE:Installcapsso the bearingrecessis
checkfor binding. on the samesideas the recessin the rod.

r-(,
Flywheel and Drive Plate
Replacement

ManualTransmission: AutomaticTransmission:
Removethe eight flywheel bolts,then separatethe lly- Removeth€ eight drive plate bolts, then separatethe
w h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n , drive plate from the crankshaftflange, After installation,
tightenthe boltsin the sequenceshown. tightenthe bolts in the sequenceshown.

RINGGEARHOLOER
o?LAB- PV00100,
07924 - PO2IX)03or
07924 - PD20/m2
\
n
.t=?4
fut!!-+-r / AK{:{AAo
t=tz-21
- +
I lvaz'Z
ENGINE
BLOCK
rs#*ffi_9
r t.0 mm
t,l N.m
(7.5 kg{.m,54 lbf.ft}

-o.r
o \
/ oo^t,
\..?bi

r10.5kgi.m,76lbt.ftl

7-7
Main Bearings
Clearance Selection

T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e , CAUTION: lf ths codes are indeciphorable becau3o ot

removethe main capsand bearinghalves. an lccumulation ol dirt and dust, do not gcrub thgm
C l e a ne a c h m a i n j o u r n a la n d b e a r i n gh a l f w i t h a with a wirs brush or gcrapsr.Clean them only with 3ol-
cleanshop towel. vont or doisrggnt.
Placeone strip of plastigageacrosseach main iour-
nal. Crankshaft Bore Code Location
NOTE:lf the engineis still in the car when you bolt
the main caD down to checkclearance,the weight Letters have been stamped on the end of the block as a
of the crankshaftand flywheelwill flattenthe plasti- codefor the sizeof eachof the 5 main journalbores
gage further than just the torque on the cap bolt, U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e
and give you an incorrectreading.Fot an accurate crank(codesfor main journalsize),to choosethe correct
reading, support the crank with a iack under the bearings.
counterweightsand check only one bearing at a
trme.
Reinstallthe bearing caps and cap bridge (818C1
engineonly)then torquethe bolts.
81881engine:77N'm (7.8kgf'm,56lbl'ft)
818C1engine:
No. 1,5 cap bolts 73 N'm (7.'lkgt'm,56lbf'ftl
No. 2, 3, 4 cap bolts 6a N'm (6.5 kgf'm, 49 lbf'ftl
NOTE:Do not rotatethe crankshaftduring inspec-
tron,
Removethe cap bridge (818C1engine only), caps
and bearingsagain,and measurethe widest part oJ
the plastigage.
Main Bearing-to-JournalOil Cl€arance:
Standard (Newl:
No. 1, 2, 4, 5: 0.024- 0.042mm
10.0009 - 0.0017inl
ServiceLimit: 0.050mm {0.0020inl
No. 3: 0.030- 0.0,18mm
(0.0012 - 0.0019inl Mlin Joumal CodGLocttion3 (Numborsor
gaBl
Ssrvice Limit: 0.060mm {0.0024inl
STNIP
PLASTIGAGE

B..ring ld.ntificrtion
lf the plastigagemeasurestoo wide or too narrow, Colorcodeis
(removethe engineif it's still in the car),removethe on the edge ot Largercrank Dore
crankshaft.and removethe upper half of the bear- the bearang.
ing. Installa new. completebearingwith the same I c D
color code (selectthe color as shown in the right -------.r> smaller bearing(thicker)
column),and recheckthe clearance.
CAUTION: Do not file, shim, or scrapoihe bo.rings tr;;lIl G'een

or the caps to adiust clearance.

lf the plastigageshows the clearanceis still incor-
rect,try the next largeror smallerbearing(thecolor
IlE;tl
t r -I tt l Green
Gre€^

Blacr

listedaboveor belowthat one),and checkagain. l H l t Blue

NOTE: lf the Droperclearancecannot be obtained I L o . " " lLiGreen Elack

by usingthe appropriatelargeror smallerbearings, Smaller Smaller

reolacethe crankshaftand startover. msin bearing
journal (thicker)

7-8
ConnectingRod Bearings
Clearance Selection
1. Removethe connectingrod cap and bearinghalf. CAUTION: lf the codss are indeciphsrable bocause of
an accumulation of dirt and dust. do not scrub tham
2. Cleanthe crankshaftrod journal and bea.ing half with a wiro brush or scraper.Clean them only with sol-
with a cleanshootowel. vont or dotetgenl.

3. Placethe plastigageacrossthe rod journal. Connecting Rod Code Location

4. Reinstallthe bearing half and cap, and torque the
nuts.
81881 sngino: 31 N'm 13.2kgf.m,23 lbt'ft)
818C1sngine: 4,1N.m 14.5kgf.m. 33 lbf'ft}
A number has been stampedon the side of each con-
nectingrod as a code for the sizeof the big end. Use it,
and the lettersstampedon the crank(codesfor rod jour-
nal size),to choosethe correctbearings.

NOTE:Do not rotatethe crankshaftduring inspec-

tion.

ConnectingRod B€aring-to-JournalOil Clcalancr: Halfof numberis

8l88l ongine: stampedon bearing
Standard (New): 0.020- 0.038mm cap and the other
{0.0008- 0.0015in) half is stampedon
rod.
ServicaLimit: 0.050mm (0.0020inl
818C1engin€:
Standard (New): 0.032- 0.050mm
(0.0013- 0.(XP0inl
ServiceLimit: 0.060mm (0.0024in)
STRIP
PLASTIGAGE

Conn.cting Rod Joumsl Codc LocatioN lLotteE or B.trl

ll the plastigagemeasurestoo wide or too narrow,

removethe upper half of the bearing.installa new,
completebearingwith the same color code (select Berring ldcntification
t h e c o l o r a s s h o w n i n t h e r i g h t c o l u m n ) ,a n d Colorcodeis
recheckthe clearance. on the edgeof Largerbig end bore
the bearing.
t 2 3
CAUTION: Do not file, shim, or scrape lhe bearing
or the capgtq adiust clgaranca. Smallerbearing{thicker)

1. lf the plastigageshows the clearanceis still incor- tF;l

l - l f
It Red Gr€€n

rect,try the next la.geror smallerbearing{the color

l i B o r ' r lI l
listed above or below that one), and check clear-
anceagain. lEalllt Elack

NOTE: lf the proper clearancecannot be obtained

I 1 o . , , ,L' l l Bla€k Blue

Smaller Smaller
by usingthe appropriatelargeror smallerbearings, rod bearing
reolacethe crankshaftand stan over. journal (thicker|
Crankshaft
Removal
NOTE:End play for th€ connectingrods and crankshaft 5, Removethe bearingcap bolts,
shouldbe inspectedbetoreremovingthe crankshaft.
CAUTION: To prevent warPag€, unscrew ths bohr
1. Removethe oil Dan,oil screenand the oil pump. in 3equoncg1/3 turn at a tim€; rspeat ihe sgquanco
until all bolts are loos€ned.

OIL PAN o @ @

R e m o v et h e c a p b r i d g e { 8 1 8 C 1e n g i n eo n l y } a n d
main caps/bearings. Keepall caps/bearings in order.

Removethe baffleplate.

Turn the crankshaftso No.2 and 3 crankpinsar€ at

the bottom.

Removethe right side cover.

7 -1 0
 7 . Removethe rod caps/bearings.
Keepall caps/bear- 12. Use the wooden handleof a hammer to drive the
ings in order. prslonsouI.

8 . Lift the crankshaftout of the engine,being careful CAUTION:

not to damagejournals. a Take care not to damage the contact surfaco ot
the metal gasket.
. When removing the piston/connecting rod, taks
caronot to hit the oil iot {818C1snginsonlyl.
. It tho oil iet nozzlo is damag6d or bont, replaco
the oil ist assembly (818C1engine only, page 8-
8).

CRANKSHAFT

9 . Removethe upper bearinghalvesfrom connecting

rodsand setthem asidewith their resDective
caDs.

1 0 . Reinstallmain caps and bearingson the engine in

oroDerorder.

1 1 .l f y o u c a n f e e l a r i d g e o f m e t a l o r h a r d c a r b o n
around the top of each cylinder, remove it with a
ndge reamer.
Followthe reamermanufacturer's instructions.

CAUTION: It the ridge is not removed, it may dam- 1 3 . Reinstallthe rod bearingsand caps after removing
age the pistons as they are pushed oul. eachpiston/connecting rod assembly.

1 4 . Mark each piston/connecting

rod assemblywith its
RIDGEREAMER cylindernumberto avoid mixup on reassembly.

NOTE:The existingnumber on the connectingrod

does not indicateits positionin the engine,it indi-
catesthe rod bore size.

7-11
Crankshaft
End Play lnspection

NOTE;End play should be inspectedbefore removing

crankshaft. . Cleanthe crankshattoil passageswith pipe cleaners
or a suitablebrush.
Pushthe crankfirmly awav from the dial indicator,and . Checkthe keywayand threads.
zerothe dial againstthe end of the crank.Then pull the
c r a n k f i r m l y b a c k t o w a r d t h e i n d i c a t o r ;d i a l r e a d i n g Alignment
shouldnot exceedservicelimit.
Measurerunouton all main journalsto makesurethe
crankis not bent.

The differ€nce between measurementson each jour-

nal must not be more than the servicelimit.

Crank3haftTotal lndicatod Runout:

Bl8Bl engins:
Sisndod {Nsw): 0.03 mm {0.001in) max.
SorviceLimit: 0.05 mm {0.002inl
818C1engin€:
Standard {Nsw): 0.020mm (0.0008in} mar.
SGrviceLimits: 0.030mm 10.0012in)

OIALINDICATOR
Rotatetlvo complete
revolutions.

CrankshaftEnd Play:
Standard(New):0.10- 0.35mm
(0.04- 0.01i|inl
S€rvic€Limit 0.i15mm (0.018inl

. lf end play is excessive,inspectthe thrust wash€rs

Replacepans as
and thrust surfaceon the crankshaft.
necessary.

NOTE:
Thrust washer thickness is fixed and must not be
changedeitherby grindingor shimming.
Support with lathe-
Thrustwashersare installedwith groovedsidesfac-
ing outward.

7-12
 GylinderBlock
Inspection
Out-ot-Roundand Taper 1. Measure wear and taDer in dirsction X and Y at
three levelsin eachcvlindsras shown.
. Measureout-of-roundat the middle of each rod and
main journalin two places.
6mm
frrgt
. The differencebetween msasurementson each jour- Y Meaauremonl
nal must not be more than the se.vicelimit. Second
Moa6urgmont
Journal Oul-of-Round: Thi.d
M063uremgnt
Bt8Bi.ngine:
Strndrrd (Now): 0.(x15mm (0.0002inl m!x.
Scrvicr Limit 0.010mm (o.fixx inl
G mm {0.24in}
Bl8Cl cngins:
Strnd.rd {Nowl: 0.004mm (0.(XD16inl m!x.
Sorvicc Limit 0.qt6 mm {0.qx!2,1 in} BOREGAUGE
CYUNDER

Cyllndor Borr Siz.:

Standard (Ncwl: 81.q!- 81.02mm
(3.18, - 3.190inl
Scrvicr Limh: 81.07(3.192in)
Ovar3izc:
near edggs. .t + O.25t81.25- 81.27mm (3.199- 3.200inl
Borc Tlpor:
(Ditfcrcncc bctw!.n firtt tnd third
Scrvice Limit
moasurcm.ntl 0.115 mm (0.002in)

. l f m o a s u r € m e n t si n a n y c y l i n d s r a r e b e y o n d
OversizeBore ServiceLimit, rsglacethe block.
. lf the block is to be rebored, refer to Piston
Measuretaper at the edges of each rod and main ClearanceInspection(see page 7-151after rebor-
journal. ing.
The difference between measurementson each jour-
nal must not be more than the servicelimit. NOTE: Scored or scratchedcylinder bores must be
honed.
Journal Tapor: Rcboring Limil: 0.25 mm (0.01inl
8l8Bl angino:
Standard (Newl: 0.q)5 mm l0.0(Xl2inl m.x.
SorvicoLimit 0.010mm (0.0004inl
BlSCl ongino:
Standrrd (Now): 0.005mm (0.0002inl m8x.
Scrvic€ Limit

(cont'd)

7-13
CylinderBlock
Inspection(cont'dl
2. Checkthe top of the blockfor warpage. Measurecylinderboresas shownon page7-13.
Measurealong the edgesand acrossthe centeras lf the block is to be reused,hone the cylindersand
snown. remeasurethe bores.

SURFACES
TO BE MEASURED Honecylinderboreswith honing oil and a fine (400
pattern.
grit) stonein a 60 degreecross-hatch

NOTE:
. Use only a rigid honewith 400grit or finer stone
suchas Sunnen,Ammco,or equivalent.
a Do not usestonesthat are worn or broken.

Engine Block Warpsgc:

81881ongine:
Standard lNewl: 0.07 mm {0.003inl max.
ServiceLimil: 0.10mm {0.00,1inl W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
B18Cl engine: cylinderblockof all metal panicles.Wash the cylin-
Standard (New): 0.05 mm 10.002inl max. der bores with hot soapy water, then dry and oil
ServiceLimit 0.08 mm {0.003inl immediatelyto preventrusting.

NOTE: Never use solvent, it will only redistribute

the grit on the cylinderwalls.

lf scoring or scralchesare still presentin cylinder

bores after honing to the service limit, reborethe
engineblock.

NOTErSome light venicalscoringand scratchingis

acceptableif it is not deepenoughto catchyour fin-
gernailand does not run the full lengthof the bore.

CYLINDERHONE

. After honing,cleanthe cylinderthoroughlywith

soapywater.
. Only scoredor scratchedcylinderboresmust be
noneo.

7-14
Pistons
Inspection
1. Checkthe oiston for distortion or cracks. 3, C a l c u l a t et h e d i f f e r e n c eb e t w € o nc v l i n d e r b o r e
diameteron (seepage7-13)and pistondiametsr.
NOTE:lf the cylinderis bored,an oversizedpiston
must be used, Pbton-io"Cy'indorClea18nco:
Stsndard (Nrwl: 0.010- 0.0/O mm
2. M o a s u r €t h e p i s t o n d i a m e t e ra t a p o i n t l 5 m m {o.ofira- 0.0016in}
(0.6in) from the bottomof the skin. S.rvic. Limit: 0.05 mm {0.002in)

Pbion Diamat6r:
Standard lNowl: 80.S - 80.99mm
(3.188- 3.189inl
SorvicaLimit 80.97mm (3.188in)

rKI

lf the clearanceis near or €xc€edsthe servicelimit,

inspect the piston and cylinder block for excessive
wear.

Ov.rsizc Pilton Diamcter:

O.25t81,23- 81.21|rnm{3.1980- 3.198'lin)

7-1
Piston PistonRings
lnstallation Replacement

Beforeinstallingthe piston,applya coat of 1 . Usinga ring expander,removeold pistonrings.

engineoil to the ring groovesand cylinderbores.
'1. lf the crankshaftis alreadyinstalled: Cleanall ring g.oovesthoroughly.
. Removethe connectingrod caps and slip short
NOTE:
sectionsof rubber hose ove. the threadedends . Use a squared-oJfbroken ring or ring groove
of the connectingrod bolts. cleanerwith bladeto fit pistongrooves.
a Installthe ring compressor,checkthat the bear' . Top ring groove is 1.0 mm (0.039in) wide, sec-
ing is securelyin place,then positionthe piston
ond groove is 1.2 mm (0.047in) wide. and oil
i n t h e c y l i n d e ra n d t a p i t i n u s i n gt h e w o o d e n
ring grooveis 2.8 mm (0.110in) wide.
handleof a hammer. . Filedown bladeif necessary.
Stop after the ring compressor pops free and
checkthe connectingrod-to-crankjournal align-
CAUTION: Do not use a wire brush to cloan thr
ment beforetappingpistoninto place. ring lands, or cut ring lands dsopo. with cl€aning
. Installthe rod caps with bearings,then torque
tool.
the nuts,
81881 ongino: 31 N.m {3.2 kgf.m, 23 lbf.ftl
NOTE: lf the piston is to be separatedfrom the con-
818C1cngino: 44 N'm 1,t.5kgf.m, 33 lbf.ftl
nectingrod, do not installnew ringsyet.
lf the crankshaftis not installed:
o Removethe rod caps and bearings.install the
Installnew rings in the prope. sequenceand posi-
ring compressor,then positionthe piston in the
tion (seepage7-18).
cylinderand tap it in usingthe woodenhandleof
a nammer. NOTE:Do not useold pistonrings.
. Positionall Distonsat toD deadcenter.

The arrow must face CONNECTING ROD

the timing beltside OIL HOI-E(Br8Bl onginel
of the engine.The
connectingrod oil hole
must lace the intak€
manifold{81881€ngine).

NOTE:Maintaindownwardforce on the ring com-

pressor to prevent rings from expanding before
enteringthe cylinderbore,

Usethe woodenhandle
BINGCOMPRESSOR of a hammerto pushor
tap the pistonintothe
cylinderbore.
I

'1.
Using a piston, push a new ring into the cylinder After installinga new set of rings, measurethe ring-to-
bore 15- 20 mm (0.6 0.8 in) from the boftom. gfoove clearances:

M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l e r Top Ring Cl€arance:

gauge: Standard lNewl: 0.045- 0.070mm
10.0018- 0.0028in)
lf the gap is too small.checkto see if you have ServiceLimit: 0.13mm {0.005inl
the properringsfor your engine.
SecondRing Clearance:
lf the gap is too large,recheckthe cylinderbore Standard {Newl: 0.040- 0.065mm
diameteragainstthe wear limits on page7-13. (0.0015- 0.0026inl'1
ll the bore is over the servicelimit, the cylinder 0.0i15- 0.070mm
blockmust be rebored. (0.0018 - 0.0028in)',
ServiceLimit: 0.13 mm (0.005inl
Piston Ring End-cap:
Top Ring
Standard (New): 0.20- 0.35 mm
(0.008- 0.01'linl'1
0.20- 0.30 mm
10.008- 0.012inl''
ServicaLimit: 0.60 mm (0.024in)
Second Ring
Standard (Now): 0.40- 0.55 mm
10.016- 0.022in)
ServiceLimit: 0.70 mm (0.028in)
Oil Ring
Standard (New): 0.20- 0.50 mm
(0.008- 0.020in)'1
0.20- 0.,15mm
{0.008- 0.018inl',
ServicaLimit: 0.70 mm 10.028in)

iliiii
.--r.llli.j---.-
PISTONNING

ioi
---'z ll
ENDGAP-11--
RIKENmanufactured pistonring RIKENmanufacturedpistonring
T E I K O K UP I S T O NR I N Gm a n u f a c t u r e do i s t o n r i n q T E I K O K UP I S T O NR I N Gm a n u f a c t u r e dD i s t o nr i n o
{ 8 1 8 8 1e n g i n eo n l y ) ( B ' 1 8 8e1n g i n eo n l y )

7-17
PistonRings PistonPins
Alignment Removal
1. Installtheringsas shown. 1. Assemblethe PistonPin Toolsas shown.

ldentifytop and secondrings by the chamferon the PISTON BASE HEAD

edge.Makesurethey are in their propergrooveson
the prston. PISTO]TPIN BASE INSEN|T
--r otGAF- PH6{t1,0
NOTE: The manufacturingmarks must be facing
upwaro.

TOPBING

--l

PISTON BASE SP '{G

07973 - 65r06{X'

SECONDRING

Rotatethe rings in their grooves to make sure they

do not bind.
MARK

OIL RING SPACER

3. Positionthe ring end gapsas shown:

-.- position ' ring
' gap
sEcoNo
----'-- R|NG
_- GAp
- - :': :.-"' : -any
DO NOT
{ at prston
thrustsurfaces.

App.ox. 90"

OIL RING
ls" GAP
TOP BINGGAP SPACERGAP
DO NOTpositionany ring gap
in linewith the pistonpin hole. OIL RINGGAP

7 -1 8 ,
 Installation(B18Bl engine)

2. Adjustthe lengthA of the pistonpin driver. 1. Usea hvdraulicoressfor installation.

A:81881 engine:49.70mm {1.957inl When pressingthe pin in or out, be sureto posi-

Bl8Cl €ngin€:51.70mm {2.035inl tion the recessedflat on the piston againstthe
lugs on the baseattachment.
PISTONPIN DRIVERHEAD
07973 - PE00320

PISTONPIN DRIVERSHAFT
07973- PE00310
The arrowmustfacethe
timing beltsideo{ the
PILOI COLLAR
engineand the connecting
07LAF- PR30100 rod oil hole mustfacethe
Embossedmarkfacingup.
rearsideof the engine,

otl Hols
2. AdjustthelengthB of the pistonpindriver.

B:49.70mm (1.957
inl
NOTE:Usea hydraulicpress.
When pressingpin in or out, PISTONPIN DRIVERHEAD
makesurethat the recessed 07973- PEfl)320
portionof the pistonaligns
with the lipson the collar.

Placethe piston on the piston base and pressthe

pin out with a hydraulicpress.
PISTONPIN DR|VENSHAFT
079?3- PE|X)310

Embossedmark
ffi*.r,"ror","l
PILOTCOLLAN
07LAF- PF301(x)

PISTONPIN BASEINSERT
07GAF- PH603oO

PISTONBASEHEAD
07HAF- PL20t02

PISTONBASE
079?3- 6570500

NOTE: lnstall the assembledpiston and rod with

the oil holefacingthe intakemanifold.

7-19
PistonPins
lB18C1enginel
Installation Inspection
1. Usea hydraulicpressfor installation. Measurethe diameter of the piston pin.

. When pressingpin in or out, be sure you posi- Pi3ton Pin Dirmltlr:

tion the recessedflst on the piston againstthe Standard lN.wl: 20.994- 21.dlo mm
lugs on the baseattachment, (0.8265- 0.8:168inl
Ovo.3ize: 20.907- 21.(xxtmm
(0.8267- 0.&16S in)
Th€ arrow must tace
timing beltsid€of rhe
engino. NOTE: All replacementpiston pins are oversize.

Tho mork must tace

the timing belt side
ot the engine.

Adjust the l€ngth B of piston pin driver.

Br 51.70mm (2.035inl

PISTONPIN
fl--.l DRr\rERHEAD
j 07e73- PEm32o
I
-T- ll t PlsroNPtN
\J ---..'' DRtvERsHAFr
- PEoo3lo
07s73 2. Zerothe dial indicatorto the pistonoin diamater.
; tl i-
- ,rH ,l l -4
ilil r
Embossedm.rk ll ll-- PISTONPIN
facins up. l!-lJ
\
t PILOTCOLLAR
o?LAF-PR3o1n'
I =)ffi
ri _-r -_t, -l l l'll,llltllrl ll ll li l i l l
L-lt|lllltlll
_- PrsroNPINBASEINSERT
O?GAF- PH6O3q)

PISTONBASEHEAD
07HAF- P120102

PISTONBASE
07973 - 65705U)

7-20
 ConnectingRods
End Play
3. Measurothe piston pin-to-pistonclearance. NOTE:End play should bs insp€ctedbefore removing
the crankshaft.
NOTE: Checkthe Distonfor distonion or cracks.
Connrcting Rod End Pl.y:
It the piston pin clearanceis greater than 0.022 mm Stlndrrd (Nrwl: 0.15- o.3o mm
(0,0009in), remeasureusing an ovorsizepiston pin. (0.(xt6- 0.012inl
Scrvict Limit o./tomm (0.016inl
Pbton Pin-to-PLton Cloeranco:
StlndErd (Ncwl: 0.010- 0.022mm
- o.(Xxlg
(0.(xto4 inl

a lf out-of-tolerance,install a new connscting rod.

a lf still out-of-to16rance, replacethe crankshaft
pages7-10and 7-22)

4. Check the difference betwsen piston pin diameter

and connectingrod smallend diam€ter.

Pbton Pin-to4onnocting Rod Inlcdaranca:

Strndlrd {Ncw}:
Bl8Bl ongino:0.013- 0.G12mm
(0.fiX15- 0.0013inl
Bl8Cl cngin.: 0.017- 0.036mm
IO.ON1- O.|,o11int

7-21
ConnectingRods Crankshaft
Selection lnstallation

Eachrod falls into one of four toleranceranges(from 0 Before installing the crankshaft.apply a coat of
to + 0.024mm (0 to + 0.0009inl, in 0.006mm {0.0002in) engineoil to the main bearingsand rod bearings.
increments)dependingon the size ot its big end bore.
It's then stampedwith a number(1,2,3, or 4) indicating 1. Installthe thrustwashersin the No. 4 iournslof the
cvlinderblock.
the range.
You may find any combinationol 1, 2, 3, or 4 in any
engane.

Normsl Boro Sizoi ,18.0mm 11.89inl

NOTE:
a Referencenumbersare Jor big end bore sizeand do
NOTindicatethe positionof the rod in the engine.
. Inspectconnectingrod for cracksand heatdamage.

CONNECNNGRODBORE
REFERENCE NUMBER
HalfoI numberis stampedon
bearingcap.th€ otherhalfon
connectingrod.
Groovedsidetacing
o!tward

Insertbearinghalvesin the engine block and con-

nectingrods.

Holdthe crankshaftso rod journalsfor cylindersNo.

2 and No.3 are straightup.

Lower the crankshaftinto the block. putting the rod

journalsinto connectingrods No.2 and No.3.
Installthe rod capsand nuts finger-tight,

CONNECNNGROD

7 -22
 Rotatethe crankshaftclockwise,put journals into 8. Checkclearsncewith plastigsge(see page 7-8).then
connecting rods No. 1 and No. 4, and install the rod tighten bearingcap bolts in 2 steps.
caps and nuts finge.-tight.
13t st.p: 29 N.m (3.0 kgf.m, 22 lbt.ftl
NOTE:lnstallcaps so the bearingrecessis on the 2nd 3tsp:
samgsideas the .ecessin the rod. 81881 .ngin.: 76 N.m (7.8 kgt.m,56 lbf,ft)
Bl8Ct engine:
Check rod bearing clsarancewith plastigage(see No. 1, 5 cap bol$: 73 N.m (7./rkgf'm, 56 lbf,ftl
page 7-9),then tighten the capnuts in 2 steps. No. 2, 3, a clp bolbr 6{ N.m (6.5 kgf'm, /r9 lbf,ftl

l3t 3t.p: 20 N.m (2.0 kgf.m, rl btfil BEARINGCAP BOLTSTOROUESEOUENCE

2nd 3tep:
81881 cnginc: 31 N.m (3.2 kgf.m, 23 lbf.ft) Bl88l cngino:
818C1.ngin!: ,14N.m (4.5 kgt.m,33 lbf.ft)

NOTE: Referencenumbers on connectingrod are

for big-endbore toloranceand do NOT indicatethe
positiooof pistonin the engine.

I n s t a l l t h e m a i n b e a r i n g s / c a p sa n d c a p b . i d g e
(818C1engineonlyl.

NOTE:Coatthe bolt threadswith oil.

CAPBRIDGE
lBlSCl .noin. onlyl

Bl8Cl ongino:

EEARIlTG

CAUTION: Whenever any crsnkehaft or connocting rod

b.aring is rlphccd. it i5 ncccrsrry aftor rclssombly to
run tho ongino ai idling 3p6ad until it re.chei normrl
opcrating tcmporature, thon continuo to run it fol
spp.oximltoly f 5 minula3.

(cont'd)

7-23
Grankshaft
Installation(cont'd)
9. Apply non-hardening liquidgasketto the blockmat- 10. Apply non-hardening liquidgasketto the blockmat-
ing surfaceof the right side cover,and installit on ing surface of the oil pump, and install it on the
the cylinderblock, cvlinderblock.

NOTE: OILPUMP:
. Use liquidgasket,PartNo. 08718- 0001.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
. Apply liquid gasket as an even bead, centered
betweenthe edges of the mating surface.
. To preventleakageof oil, apply liquid gasketto
the innerthreadsof the bolt holes.
. Do not install the parts if 20 minutes or more
have elapsedsince applying the liquid gasket.
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly, wait at least 20 minutes before
fillingthe enginewith oil.

RIGHTSIDECOVER:

6x1,0mm
tl N.m {1.1kgr'm.
8 tbf.ftl

RIGHTSIDE

6x1.0mm
11 N.m {1.1tgl.m,

DOWELPIN

O.RING

R6plac€. 8 x 1.25mm
2il l$m l2.iakg[.m.
OIL PUMP 1t rbf.ftl
DOWELPINS

7-24
 Oil Seal
lnstallation

1 1 . lnstalltheoil screen. The sealsurfaceon the blockshouldbe dry.

Apply a light cost of oil to the crankshaftand to
Installtheoil pan. the liDof the seal.

NOTE:Cleanthe oil pan gasketmatingsurfaces. Drivein flywheelend sealagainstright sidecover.

1' I Tightenthe boltsas shown below. NOTE:Drivethe end sealin squarely.

Torque: 12 N.m {1.2 kgf.m, 9 lbf'ft) DRIVER

07t,49- (xll(xtoo

NOTE: Tighten the bolts and nuts in two steps and

toroue the bolts in a crisscrosspattern
lnstallsealwiththe
part numberside
tacing out.

2. Confirmthat clearanceis equal all the way around

with a fe€lergauge.

Cler.6nce: 0.5 - 0.8 mm (0.02- 0.03 inl

RIGHTSIDE
COVER

NOTE:Reterto right column and 8-10lor installa-

tion of the oil pump side oil seal.

7-25
Oil Seal
Installation(engineremovalnot
required)
The sealsurfaceon the blockshouldb€ dry.
Apply a light coat of greaseto the crankshaftand
to the lio of seal.

Using the specialtool, drive in the timing pullsy-

end seal until the driver bottoms against the oil
pump.
When the seal is in place,clean any excessgrease
off lhe crankshaftand checkthat the oil seal tiD is
not distoned.

S€ALDRIVEB
07LAD- PRimroA
lnstallse6lwith
tho
Pan number
tacing out.

Usingthe specialtool, drive in the flywheel-endseal

until the driverbottomsagainstblock.

NOTE:Align the hole in the drivsr attachmentwith

the Dinon the crankshaft.

7-26
EngineLubrication

S p e c i aTf o o l s . . . . . . . . ........8-2
l l l u s t r a t e dI n d e x . . . . . . . . ."' 8-3
EngineOil
Inspection . . . . . . . . . . . " ' . . .8' - 5
R e p l a c e m e n. t. . . . . . . . . . . . .".". . . . . . . . ' . ' .8 - 5
Oil Filter
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . ." . . . . . . . 8 - 6
Oil Pressure
Testing ....' 8-8
Oil Jet
I n s p e c t i o n{ 8 1 8 C 1 e n g i n eo n l y } . . . . . 8 - 8
Oil Pump
Overhaul ... 8-9
Removal/lnspection/lnstallation. . ' . . . 8- 1O
SpecialTools

Rel. No. I Tool Numbel Descrlption Oty I Pago Roferenco

o OTLAD_ PR4OlOA Seal Driver 8-11
@ o 7 9 12 - 6 1 1 0 0 0 1 Oil Filter Wrench 8-7

8-2
lllustrated Index

CAUTIOIiI: Do not ovortighten the drain plug. NOTE;

o Use new O-ringswhen reassembling.
81881 sngine: a Apply oil to O-ringsbetore installation,
. Use liquid gasket, Part No. O8718-OOO1.
a Cleanthe oil pan gasket mating surtacesbefore in-
stallingit.
WASHER
Replace. 6 x'l.omm
12 N.m {1.2 kgt.m,9 lbt.tt)
DRATTPIUG \
44 .m (4.5 tgf.m, 33 lbf'ftl\ \
Do not ovgr tightgn.
\
-@5 \

OILPAI{

GASKET
R6placs,

6 r l.O mtn
121{.m11.2kol.m,
I lbl.ttl 6 x 1.0 mm
OIL SCREEN '11 N.m 11.1 kgt'm,8lbt.ftl
O|L BNEATHER 6 x 1 . Om m
TAIIK ll N.m {1.1kgf'm,
I tbt.ftl

GASKET
Replace.

BAFFLEPTATE

eq
nU2o@
\\
uI

#-'
OIL FIL
Repl.cemont, p6gs 8-6 I x 1.25mm
A 24 N.m 12.4 kgf..n,
17 rbr.ftl
ENGINEOIL PRESSURE
,F
swlTcH 6 x 1 . Om m
18 .m 11.8 kgl.m, 13lbl.ftl 11 N-m(1.1kgt.m,8lbf.ft)
'l/8 in. BSP lgritish Standard OIL PUMP
HEAD OIL Overhaul,page 8-9
Pioo Taporl 28 Threads/inch. lnspectionpage, 8-1O
Use propgr laquid56alant. CONTROLORIFICE
CIean. Apply liquid gasket to
block mating surlace. (cont'dl

8-3
lllustrated Index
(cont'dl

CAUTION: Do not overtighten rhe dlain ptug. NOTE:

a Use new O-ringswhen reassembling.
818C1 engine: a Apply oil to O rings before installation.
. U s e l i q u i dg a s k e t .P a r tN o . 0 8 7 1 8 - O O O 1 .
DRAINPLUG a Cleanthe oil pan gasket mating surfacesbefore in-
44 N.m (4.5 kgf.m, 33 lbt.ftl stallingit.
Do not overtighten.

OIL PAN

6 x 1.0mm
12 N.m 11.2 kgl.m, 9 lbf.ftl

6 x 1.0 mm
1 1 N . m 1 1 . 1k g t . m ,
S lbf.fil
OIL JET BOLT
16 N.m {'1.6kgf.m, '13 lbf.ft}
Replace.
OIL JET
Be careful not to damage.
Inspection,page 8-8
EAFFLEPLATE
O-RING
Replace.
6xl.0mm
11 N.m (1.1 kgt.m, I lbt.ft)

OIL SCREEN

GASKET
Replace.
Il
,--)e
6V

ENGINEOIL COOLER
6 r ' 1 . 0m m
ENGINEOIL FILTER l 1 N . m ( 1 . 1 K9-m,
page 8-6
Replacement, 8 rb-trl

O-RING
Replace.

OIL COOLER
CE TER BOLT HEAD OIL CONTROL 8 x 1.25mm
74 N.m (7,5 kgf.m, 54 lbf.ft) ENGINEOIL PR€SSURE ORIFICE 24 N.m (2.4 kg-m, 17 lb-ft)
swtTcH Clean.
OIL PUMP
1A N.m {1.8 kgf.m, 13 lbf.ft) Overhaul,page 8-9
1/8 in. BSP {BritishStandard Removal/lnspection/lnstallation,
page 8-10
PipeTaperl 28 threads/inch. Apply liquidgasketto mating
Use properliquidgasket. surfaceot the engineblock.

8-4
EngineOil
lnspection Replacement

Check engine oil with the engine off and ths cal CAUTION: Remova tho drain plug cal€fully whilo the
parked on level ground, ongine is hot; the hot oil may cause scalding.

Make cenain that the oil levelindicatedon the dip- 1. Warm up the engine.
stick is between the upper and lower marks.
2, Drainthe engineoil.
3 . lf the l€vel has droppedclose to the lower mark, add
oil until it reachesthe upper mark.

CAUTION: Inssrt lho dipstick carotully to avoid

bending it.

3. Reinslallthedrainplugwith a new washer,and refill

with the recommendedoil.

CAUTION: Do not ovortighton tho drain plug.

"Energy
Requirement API ServiceGrade:Use
Conservingll" SG or SH grade oil.
SAE 5W-3O Drefered.

Capacity B 1 8 B 1e n g i n e :
3.51 (3.7 US qt, 3.1 lmpqtl
at oil change.
3.8 t (4.0 US qt, 3.3 lmp qt)
at change.includingfilter.
4.6 I 14.9US qt. 4.0 lmp qt)
after engineoverhaul.
B18Cl engine:
3.7 f (3.9 US qt, 3.3 lmp qt)
at oil change.
4.O t 14.2US qt, 3.5 lmp qt)
at change,includingfilter.
4.a I (5.1 US qt, 4.2 lmp qt)
after engineoverhaul.
Change Every 7,5OOmiles (12,OOokm) or
6 months

(cont'd)

8-5
EnglneOil Oil Filter
Replacement{cont'd) Replacement

CAUTION: Aftar the ongine has boan run. tho oxhaust

pipos will bo hot; b€ caretul when wo.king around tho
erhaust manitold,

Removethe oil tilter with the specialoil filter wrench.

Inspectthe threadsand rubbe.sealonthe new lilter.

Wipe off seat on engineblock.then apply a light coat
of oil to the tilter rubberseal,

NOTE: Useonly filrerswith a built-inbypasssystem.

ElrclltEs
Inspectthreadsand
rubbersealsurface-
ENGINEOIL COOLER
(8'l8Cl ongino onlyl

APICERTIFICATION
SEAL

The numbersin the middleof the API Servicelabeltell

you the oil's SAE viscosityor weight. Selectthe oil for
your car accordingto this chart:

Ambient TomDo?aturo

Apply oil to rubber seal

An oil with a viscosity of 5W-3Ois preferredfor improved betore anstalling.
fuel economyand year-roundprotectionin the car.
You may use a l OW-3Ooil it the climatein your areais
limited to the tempe.aturerange shown on the chart.

4. Fillthe enginewith oil up to the specifiedlevel,.un

the enginefor morethan three minutes.then check
lor oil leakageand oil level.

8-6
 Installthe oil tilter by hand. Eightnumbers{'l to 8) are printedon the surfaceof
rhe filter.
4. After the rubbersesl seats,tighten the oil filter clock-
wise with the specialtool. The followingexplainsthe procedurefor tightening
filters using these numbers.
Tighten: 7/8 turn clockwise.
Tightening torque: 22 N.m (2.2 kgf'm, 16 lbf'ft) 1) Makea markon the cvlinderblockunderthe num-
ber that shows al the bottom of the filter when
CAUTION: Installationother than the abova ploce- the rubber seal is seated.
dure could r6suh in serious engine damag€ due to
oil leakage. 2) Tightenthe tilter by turning it clockwiseseven
numbersfrom the markedpoint. For example,if
a markis madeunderthe number2 when the tub-
ber seal is seated.the filter shouldbe tightened
OILFILTEBWRENCH 'l
until the number comes up to the markedpoint.
07912-6110001

MARK

Number when rubber Numberafter tightening.

seal is seated.

Numberwhen rubber 4 6 I
seal is seated

Numberafter tightening 8 ? o 7

5. After installation,till the enginewith oil up to the

specified level, run the engine for more than 3
minutes,then check for oil leakageand oil level.

8-7
_l- .4
Oil Pressure Oil Jet
Testing Inspection(B18C1 engineonly|
lf the oil pressurewarninglight stayson with the engine Removethe oil jet (seepage 8-4) and inspectit as
running, check the engine oil level. lf the oil level is follows.
correct:
a Make surethat a I .l mm (O.04in) diameterdrill
1. Connecta tachometer. will go throughthe nozzlehole{1.2 mm {O.OSin)
diameterl.
2. Removethe oil pressureswitch and installan oil pres- a Insertthe other end of the same 1.1 mm (O.O4
sure gauge. in) drill into the oil intake {1.2 rnm {0.05 in}
diameter).
3. Stan the engine.Shut it off immediatelyif the gauge Make surethe check ball movessmoothlv and has
registersno oil pressure.Repairthe problembefore a stroke of approximately4.0 mm {O.16 in).
continuing. a Checkthe oil jet operationwith an air nozzle.lt
should take at least 2OOkPa (2.O kgf/cmr,28
4. Allow the engineto reachoperatingtemperatu,e{fan Dsi)10 unseatthe check ball.
comes on at least twice). The Dressureshouldbe:
NOTE: Replacethe oiljet assemblyif the nozzle
Engine Oil Pressure: is damagedor bent.

At ldle: 70 kPa (0.7 kgf/cmr, 10 psi)

minimum 1 . 2 m m 1 0 . 0 5i n )
At 3,OOOlpm: 340 kPa {3.5 kgf/cmz, 50 psi}
minimum

a lJ oil pressureis within speciJications,replacethe

engineoil pressureswitch and recheck.

a lf oil pressureis NOT within specifications,in-

spect the oil pump (see page 8-1O).

OILPRESSUREGAUGE
COMMERCIALLY
AVAILABI.E

'16 N.m (1.6 kgt.m, l2lbt.ftl

2. Mountingtorqueis critical.Be very precisewhen in-

stalling.

Torque: 16 N.m (1.6 kgt.m, 12lbf.ftl

8-8
Oil Pump
Overhaul
NOTE:
a Use new O-ringswhen reassembling.
a Apply oil to O-ringsbefore installation.
. U s e l i q u i dg a s k e t ,P a r tN o . 0 8 7 1 8 - O O 0 1 .
a After reassembly,check that the rotors move without binding.

6 x 1.0 mm
6 N.m 10.6 kgl.m, 4 lbt'ttl

OUTERROTOR O.RING
pagesI 10, 11
Inspection, Replace.

6 x 1 . Om m
11 N.m (1.1kgf.m,

DOWEL PIN 0 8 tbf.frl

PUMPCOVER
Inspection,page 8-10

8 x 1.25mm
INNERROTOR 24 N.m (2.4 kgf.m,
Inspect|on, t7 tbt'ft)
page 8-1 1

OIL SEAL
Installation,Page8-1 1
Replace.
RELIEFVALVE
Valve must slide treely
in housingbore.
PUMP HOUSING Replacewhen scored.
\
lnspection,pages8-10, 11 SPRING
Apply liquidgasket
to matingsufaceoI
the cylinderblock
when installing.
*\

8 x 1.25mm SEALINGBOLT
24 N.m (2.4 kgl.m, 39 N'm 14.0 kgf.m,
17 lbl.Irl 29 tbt.ttt
Oil Pump
Removal/lnspection/lnstallation

Drainthe engineoil. 1O. Removethe screws trom the pump housing,thsn

separate the housing and coveJ.
Turn the crankshatt and align the white groove on
the crankshaltpulleywith the pointeron the lower 1 1. Check the inner-toouter roto. radialclearanceon the
cover. pumP rotor.

5. Remove the cylinder head cover and middle cover. Innor Rotol-to-Outor Rotor Radial Cloaranco
StandErd(Newl: O.O4-O.16 mm
4. Removethe power steeringpump belt, air condition- (0.O02-0.006 in)
er belt and the alternator belt. Service Limit: O.2O mm (0.008 inl

Removethe crankshaft pulley and remove the low-

er cover.

6. Remov€the timing belt.

7. R€movethe drive pulley.

8. Remov€the oil pan and oil screen.

9. Remove the oil pump.

OILPUMP

1 2 . Check the housing-to-rotor axial clearance on the

pump rotor.

Housing-to-Botor Axial Claalanc€

Standard(Nowl: O.O2-O.O7 mm
(O.OO1 -O.OO3 inl
ServiceLimit: O.15 mm (0.006 in)

HOUSING
OIL PAN

8-10
t5. rotor radialclearance.
Check the housing-to-outer 1'l the oil pump,applyingthreadlockto the
Reassemble
pump housingscrews.
Housing-to-Outer Rotol Radial Clearance:
Standard{Newl: O.1O-O.19 mm 1 8 . Check that the oil pump turns freely.
(O.oO4-O.OO7in)
Servic€Limit: O.2Omm {O,OO8in) 1 9 . Apply a light coat of oil to the seal lip.

20. Installthe two dowel pinsand new O-ringon the oil

pump.

Apply liquidgasketto the cylinderblockmatingsur-

face of the oil pump.

NOTE:
. U s e l i q u i dg a s k e t ,P a r tN o . 0 8 7 1 8 - O O O 1 .
a Checkthat the matingsurfacesarecleanand dry
betore applyingliquidgasket.
a Apply liquidgasketevenly,in a narrowbeadcen-
tered on the mating surface.
a To preventleakageof oil, apply liquidgasketto
the innerthreadsot the bolt holes.

1 4 . Inspect both rotors and pump housingfor scoring or

other damage.Replaceparts il necessary.

1 5 . Removethe old oil seal trom the oil pump.

to- Gently tap in the new oil seal until the specialtool
bottoms on the PumP.

NOTE: The oil seal alone can be replacedwithout

removingthe oil pump.

Do not installthe parts if 20 minutesor more have

elapsed since applying liquid gasket. Instead.
reapply liquid gasket aftet removing the old
restclue.
After assembly,wait at least 20 minutesbefore
filling the enginewith oil.

OIL PUMP

(cont'd)

8-11
Oil Pump
Removal/lnspection/lnstallation
(cont'd)
22. Installthe oil pump on the cylinderblock.
a Apply greaseto the lip of the oil pump seal.
Then, installthe oil pump onto the crankshaft.
When the pump is in place, clean any excess
greaseoll the crankshaftand checkthat the oil
seal lip is not distorted.

23. Installthe oil screen.

24. Installthe oil pan.

NOTE: Cleanthe oil pan gasket mating surtaces.

8 x 1 . 2 5m m
24 N.m (2.4 kgl.m,
17 tbt.ftl
6 r 1 . Om m
1'l N.m {1.1kgf.m,
8 rbf.fr)
OIL PUMP
Apply liquidgasketto
cylinderblock mating
sudace.
O-RING
Apply engineoil

DOWEL PINS

GASKET
Replace. OIL SCREEN

6 x 1 . Om m
11 N.m ('l .1 kgf.m,
8 tbf.trl

OIL PAN

6 x 1 . Om m
12 N.m {1.2 kgf.m, 9 lbf.ft}

8-12
lntake Manifold/Exhaust
System
Intake Manifold
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 2 ..
Exhaust Manifold
R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 4 ..
Exhaust Pipe and Muffler
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . 9. .-. 5. .
Intake Manifold
Replacement

NOTE: Use new O-ringsand gasketswhen reassembling.

CAUTION: Check for tolds or scratches on the aurface ot the gasket. Roplacewith a now gasket it damagod,

81881 engine:

5r0.8mm
6 N'm {0.6 kgl.m.
4 rbr.ftl INTAKEAIR
TEMPERATURE 5xO.8mm IiITAKE MANIFOLD
IIATI SENSOR 6 .m (0.6 kg{.m. ReplaceiI cracked or
4 tbf.ftl it mating s!rtaces aro
'*o*ot'u""'""N damag€o.

PURGECONTROL O-RING
SOLENOIDVALVE Replace.

8 x 1.25mm
22 N.r 12.2 kgl.m,
'16 tbt.ftt

GASKETS
Replace.

I x 1 . 2 5m m
20 N.m (2.0 kgt.m.
14 rbf.ftl

O.RING
IDLE AIR Replace.
{IACI VALVE
Be careful not
to damage. THROTTLE
BODY
O-RINGS
8 x 1.25mm 8 x 1.25 mm Beplace.
24 N.m (2.4 kgf'm, 23 N.m (2.3 kgl.m,
17 rbf.ft) 17 lbf.frl

"o
BRACKET aYc
g
8 x 1.25mm
24 N.m (2.4 kgl'm. /
17 tbr.ftl
THERMO
VALVE
8e careful not to
damage.

8 x 1.25mm
24 N.m (2.4 kgl'm,
1 7 rbf'ft1

9-2
NOTE: Use new O-ringsand gasketswhen reassembling.
CAUTION: Chock for folds 01 scratches on th6 surfac6 of tho gaskot. Replace wilh a new gasket if damaged.

818C1 engino:

5 x O.8 rnm
INTAKE MANIFOLD 6 N.m 10.6 kgl.m,
Replaceil cracked or 4 tbt.ttl
il mating surfaces are EVAP PURGECONTROL
damageo. l
I
VALVE

IAT SENSOR { , /

5xO.8mm
? , / GASKETS
Replace.
6 N.m 10.6 kgf.m,
4 tbf.ftl O.BI G
Replace.

INTAKE AIR
BYPASSVALVE
BODY

INTAKEMANIFOLD
CHAMBER

IAC VALVE
Be carelul not
lo oamage.

8 x 1.25mm
23 N.rn 12.3 kgt'm,
17 tbf.frl

O.RINGS BRACKET
Replace.
I x 1.25 mm 8 r 1.25mm
22 N.m 12.2 kgl.ft, 24 N.m {2.4 kgf.h,
t6 tbt.tt) t7 rbr.ftl
8 x t.25 mfi
24 N.m (2.4 lgf.m. I r 1.25 lnm
17 tbt.ft) 24 N.m 12.4 kgt.m,
17 tbt.ftl
HEATERBYPASS
8 x 1.25mm
THROTTLE PIPE
20 .m (2.0 kgt.m,
AODY
14 tbf.ftl

o-Rt Gs
Replace. FAST IDL€ THERMO VALVE
Be carelul not to damage.

I x 1.25mm
24 N.m (2.4 kgl.m, 17lbf'ft|

9-3
Exhaust Manifold
Replacement
NOTE: Use new gasketsand seltiocking nuts when teassembling.

GASKET
Replace.

€XHAUST MAt{IFOLD

I r 1.25 mm
24 N.ln (2.4 kgf.m, l7 lbt.ft)

Ss
Z \
i...1%\
R
A\
/ \\-i
tr l'A
| 1tr.
/ \
t \
I
I
8 x 1.25mm
24 N.m {2.4 kgf.m,
8 x '1.25mm
3l N.m {3.2 kgf.m. 23 lbf.ltl
Replace.
1 7 tbf.ftl

10 x 1.25mm
44 .m {4.5 kgl.rh. 33 lbf.ft}
ExhaustPipe and Muffler
Replacement

NOTE: Use new gasketsand selflocking nuts when reassembling.

Bl88l engine:

HEAT SHIELDS

MUFFLER
6 x 1.0 mm
9.8 N.m l1.O kgf.m, 7.2 lbf.ftl
EXHAUSTPIPE TIP

,
I
^1
e
e
HEAT SHI€LD
,@\
8 x 1.25mm
22 N.m 12.2 kgt.m, 16 lbf.ftl
Replace.
Tightenthe bolts in steps,
alternatingside-to-side.

SELF-LOCKIIIGNUT
1 0 x 1 . 2 5m m
33 N.m (3.4 kgt.m,
25 tbf.ftt
Replace. COVER
HEATEOOXYGEN
SENSOR(HO2Sl
44 N.m 14.5 kgt.m,
33 rbf.ftl
I x 1.25mm
24 N.m 12.4 kgf.m,
17 tbl.frl

BRACKET

GASKETS
Replace. GASKET
Replace.

THREEWAY
CATALYTIC
CONVERTER

COVER

6 x 1.0 mm
SELF-LOCKINGNUTS SELF-LOCKING NUT 9.8 N.m l1.O kgf.m, 7.2 lbl.ttl
10 x 1,25mm 8 x 1.25mm I x 1.25mm
54 N'm 15.5 kgf'm, 16 N.m {1.6kgf.m, 22 N.m (2.2 kgl.m, r6lbt.ftl
40 tbf.ftl r2 tbt.frl Replace.
(cont'd)
Replace. Replace. Tighten the flange nuts in steps,
alternating side-to-side.
ExhaustPipe and Muffler
Replacement(cont'dl

NOTE: Use new gasketsand selt-lockingnuts when reassembling.

818C1 engine:

HEAT SHIELOS MUFFLER

EXHAUST PIPETIP

I
h€
6 x 1.0 mm
9.8 N'm {1.O kgt.m, 7.2 lbf.ft)

HEAT SHIELD

EXHAUSTPIPEB

8 x 1.25mm
22 N.m 12.2 kgf.m, 16 lbf'ftl
Replace.
Tighten the bolts in steps,
GASKET alternating side'to-side.
Replace.

SELF,LOCKING NUT
10 x 1.25mm
33 N.m {3.4 kgf.m,
25 tbf.frl
Replace.
COVER
HO25
44 N.m {4.5 kgf.m,
33 tbf.fr)

I r 1.25mm
24 N.m 12.4 kgf.m,
17 lbf.ftl

BRACKET

GASKETS GASKET
Replace. Replace.
EXHAUST PIPEA

COVER

6 x 1 . Om m
SELF.LOCKINGNUTS 9.8 N.m (1.0 kgf.m, 7.2 lbt'ft|
10 x 1.25mm 8 x 1.25mm SELF-LOCKINGNUT
54 N.m 15.5 kgl.m, 22 N.m 12.2 kgf.m, 16 lbl.ftl 8 x 1.25mm
40 lbf.frl Repiace. 1 6 N . m 1 1 . 6k g f . m ,
Replace. Tighlenrhe flangenuts in sreps, 12lbf.ftl
alternatingside-to-side. Replace.
Cooling
lllustrated Index 10-2
Radiator
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1
. .O. .-.4.
Engine Goolant Refilling and
Bleeding 10-5
C a pT e s t i n g . . . . . . . . . . . . .1. .0 - 6
Pressure Testing .........10-6
Thermostat
R e p | a c e m e.n. t. . . . . . . . . . . . . . . . . . . . . . . 1. .O. .-.7.
Testing .....1O'7
Water Pump
lllustrated Index......... . 10-8
Inspection .10-9
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1
. .O. .-.9.
lllustrated Index

@ sy"t". is under high plessurewhen engine CAUTION: lf any engine coolant spills on paint€d por-
is hot. To avoid dsnger of relsssing scalding engine tions ot the body, rinse it ofl immediately.
coolant. remove cap only when engine is cool.
NOTE:
Total Cooling System Capacity (lncluding heater and a Checkall coolingsystem hosesfor damage.leaksor
r€servoirl deteriorationand replaceif necessary.
Bl8Bl engine: a Check all hose clamps and retightenif necessary.
Mfl: 6.4 | {6.8 US qt, 5.6 lmp qt} a Use new O-ringswhen reassembling.
AlTt 6.7 | {7.1 US qt, 5.9 lmp qt}
Bl8Cl engine:
Mfi: 6.7 t {7.1 US qt, 5.9 lmp qt} RADIATOR
Enginecoolant refillingand bleeding,
page 10-5
'l0-6
Leaktest, page
Inspectsolderedjoints and
seamsfor leaks.
Elow out dirt from between
core fins with compressedair.
lf insects,etc., are clogging
.adiator,wash them off with
low pressurewater,
CONDENSER
FAN SHROUD
{soe soction 221

\*
S! COOLANT
*) P RESERVOIR
ATF COOLER
HOSES
{81881 6ngine)
R
U

6 x 1 . Om m
7 N.m (O.7 kgt.m. 5 lbf.ftl

5x0.8mm
4.4 N.m (O.45kgf.m,
3.3 lbl.fr)

FAN SHROUD

M/T: Manual t.anamiaaion

A/T: Automatic t.ansmiasion
ATF: Automatic t.ansmission fluid

10-2
ENGINECOMPARTMENTHOSECONNECTIONS:

Bl88l engine: FAST IDLE

THERMOVALVE

THERMOSTAT
HOUSIITG
IDLEAIR CONTROL
IIAC} VALVE

O'RING BREATHERPIPE
Replace.

O-RING
Replace.

HEATERHOSES

818C1 engine:
ENGINEOIL
COOLER BREATHERPIPE

IAC VALVE

HEATERBYPASS
PIPE

THERMOSTAT
FASTIDLE HOUSING
THERMOVALVE

HEATEBHOSES

10-3
Radiator
Replacement

1. Drainthe enginecoolant. 5. Removethe fan shroudassembliesand other parts

from radiato..
Removethe upperand lower radiatorhoses,and ATF
cooternoses. lnstallthe radiatorin the reverseorder of removal:

Disconnectthe fan motor connectors. NOTE:

a Set the upper and lower cushionssecurely.
4. Removethe radiatorupper brackets,then pull up the a Fill the radiatorand bleed the air.
radiator.

UPPERBRACKET
AND CUSHTOl{
RADIATOR
CAP 6 x l . O m m
9.8 N.m (1.O kgt.m,
7.2 rbf.ft)

6 x 1.0 mm
9.8 il.m 11.Okgt'm,
7.2 lbr.ftl
t
e

FAN MOTOR

CUSHION

SHROUD O-RING
Replace.
6 x 1.0 mm
9.8 N.m ('l.O kgl.m, DRAIN PLUG
7.2 tbl.ttl
LOWERRADIATOR
HOSE
 EngineCoolantRefillingand Bleeding
@ ne-oving the radiatorcap while the engine
is hot can cause the engine coolant to splay out, seri-
ously scalding you. Always let the engine and radiatol
cool down betore removing the radiator cap.
CAUTION: When poudngenginecoolant,be sure to shut
the relay box lid and not to let coolant spill on the elec-
tlical pans or the paint. ll any coolant spills, rinse it otf
immediately.
1. Slidethe heatertemperaturecontrol leverto maxi-
mum heat.
Make sure the engineand radiatorare cool to the
touch.
2. Removethe radiatorcao.
3. Loosenthe drainplug on the bottom of the radiator,
and removethe drainbolt from the enoineblock.Let
the coolant drain out.
ENGINEDRAIN BOLT
78 N.m {8,O kgt.m, 58 lbt.ftl
Apply liquidgaskerto
bolt thread when installing.
WASHER
Replace.
Removethe reservoirfrom its holder by pullingit
straightup. Drainthe coolant,then put the reservoir
back in its holder.
5 . Whenthe coolantstopsdraining,applyliquidgasket
to the drainbolt threads,then reinstallthebolt with
a new washer. Tighten it securely
6. Tightenthe radiatordrain plug securely.
7. Mix the recommendedantifreeze/coolant with an
equal amount of water in a clean container.
NOTE:
. Use only HONDA-RECOMMENOED
antifreeze/
coolant.
a For best corrosionprotection,the enginecoolant
concentrationsmust be maintainedyear-roundat
50% MINIMUM.Coolantconcentrations lessthan
50% may not provide sufficient protection
againstcorrosionor freezing.
CAUTION:
a Do not mix ditterent blands ot anti-freeze/
coolants.
a Do not use additional rust inhibitois or anti-rust
products; they may not bs compatibl€ with the
recommgndsd engins coolant.
Engin€ Coolant Retill Capacity: including reservoir
{0.6 t (0.6 US qt, 0.5 lmp qt)).
81881 engine:
MlTt 4.4 | (4.6 US qt, 3.9 lmp qr)
A f f t 4 . 7 [ ( 5 . OU S q t , 4 . 1 l m p q t ]
Bl8Cl engine:
Mnt 4.7 | (5.0 US qt.4.1 lmp qt)
8. Pourcoolantinto the radiatorup to the baseof the
filler neck.
9. Loosenthe bleedbolt on top of the engine.Tighten
it againwhen coolantcomesout in a steadystream
with no bubbles.
BLEEDBOLT
9.8 N.m (1.O kgl.m, 7.2 lbf.ftl
1O. Refillthe radiatorto the base of the tiller neck. Put
the cap on the radiator.and tighten it only to the tirst
stop, Stan the engineand let it run until it warms
up (theradiatorcoolingfan comeson at leasttwice).
11. Turn oft the engine.Checkthe levelin the radiator,
and add coolant it needed.Installthe radiatorcaD,
and tighten it fully.
'12. Fillthereservoirtothe MAX mark. lnstallthereser-
voir cap.
10-5
Radiator
Cap Testing

1 . Removethe radiatorcap, wet its seal with engine

coolant,then installit on the pressuretester.

2 . Apply a pressureol:
9 3 - 1 2 3k P a
( O . 9 5 - 1 . 2 5 k g J / c m ' ,1 3 . 5 - 1 7 . 8 p s i )

3 . Check for a drop in pressure.

PRESSURE
TESTER

PressureTesting
1 . Wait until the engineis cool, then carefullyremove
the radiatorcap and fill the radiator with engine
coolant to the top of the filler neck.

Attach the pressuretesterto the radiatorand apply

a pressureof:
93- 123 kPa
( O . 9 5 - 1 . 2 5 k g f / c m , .1 3 . 5 - 1 7 . 8 p s i )

Inspect for engine coolant leaks and a dfop in

pressure,

Removethe tester and reinstallthe radiatorcap.

NOTE:
a Checkfor engineoil in the enginecoolantand/or
coolant in the engineoil.
a Check for ATF in the engine coolant and/or
coolant in the ATF (A/T).

10-6
Thermostat
Replacement

NOTE:Use new gaskets and O-rings when reas-

sembling,

6 x 1 . Om m
1 1 N . m 1 1 . 1k g t . m , 8 . Ol b t . f t l

THERMOSTAT l
MOUIITINGRUBBER
Replace. ECT SWITCH
22-25 N.m 12.2-2.6 ksl.m, 'l6-'19 lbl.ttl

Testing

Replacethermostatif it is open at room temperature.

To test a closed th€rmostat:

SusDendthe thermostatin a containerof water as THERMOMETER

shown.

Heat the water and check the temperaturewith a

thermometer.Checkthe temperatureat which the
thermostatfirst opens and at full lift.

CAUTION: Do not let the thelmometer touch the

bottom of the hot container.

Measurethe lift heightof the thermostatwhen it's THERMOSTAT

fullv oDen.

STANDARDTHERMOSTAT
Lift height: above 8.O mm (O.31 inl
Starts opening:169 - 176"F {76-8OoCl
Fully open: 194oF (90oCl

10-7
Water Pump
lllustratedIndex
NOTE: Bl8Bl cngln :
a Usenew O-ringsandnew specialboltswhenreassembling.
a Useliquidgasket,PartNo. O8718-0OO1.
ECT SEI{SOR
ENGI E COOLAI{T 3;iil3 onsino:
B18c1
TEMPERATURE IECTI SENSOR
t8 N.m 11.8kot.m,13lbt'ttl

ECTGAUGESEDINGU]{IT
I N.m (0.9 tgf.n, 7 lbf'tt)
Apply liquid gaskot
to tho threads.

6 r 1 . 0m m
11 N.m l1.l kgl.m,8.O lbl.ftl
6r1.Omm
1l t{.m ll.1 tgl.m. OUTIET
BLEEDBOLT
8.O tbt.ftl
9.8 N.m (l.O rg[.m. 7.2 lbt'ft|

WATER OUTLET
KNOCK SEI{SOR COVER
3l N.m {3.2 kgf.m. Apply liquid gasket
23 tbf.ftl to mating sudace.
(8l8Cl .ngin€ onlyl

ECTSIY]TCH
WATERPUMP 22-26 .m 12.2-2.C )l{/l'nt.
Inspectaon, 16-19 tbr.ftl
pagelO-9
o-itltc
o-Rtt{G Roplrco.
Roplaco.

8r1.Orxtr
12 .|n ll.2 lgt.m,
8.7 n{.ftt

6xt.Omm
12 N'ft (1.2 kgf..n.8.7 lbt.ft)

10-8
 Inspection Replacement
Removethe timing belt (81881 engine:see page Removethe timing belt (818B1 engine:see page
6 - 1 O ,B 1 8 C 1e n g i n e :s e e p a g e6 - 4 9 ) . 6 - 1 0 , 8 1 8 C 1 e n g i n e :s e e p a g e6 - 4 9 ) .

Check that the water pump pulley turns counter- 2 . Removethe camshaft pulleysand the back cover
clockwise, ( 8 1 8 8 1e n g i n e s: e ep a g e6 - 1 9 . B 1 8 C 1e n g i n e s: e e
page 6-581.
J. Check for signs ol seal leakage.
J. Removethe water pump by removingfive bolts,
NOTE: A small amount ot "weeping" from the
bleed holo is normal, NOTE: Inspect,repairand cleanthe O-ringgroove
and mating su.lace with the cylinderblock.

BLEEDHOLE DOWELPIN

6 r 1.O rnm
12 N.m {1.2 kgf.m,
BI-EEDHOI-E 4.7 bf.ftl

4. lnstall the water pump in the reverse order

removat.

NOTE:
a Keepthe O-ring in positionwhen installing.
a Cleanthe spilledenginecoolant.

10-9
Fueland Emissions
S p o c i aTl o o l s . . . . . . . . . . . . . . .1. 1 - 2 Fuel Supply System
Compon€nt Location Systam TloubloshootingGuid. ..................1 1-97
l n d e x. . . . . . . . . . . . . . . . . . . . . . .1 1 - 3 F u o lL i n o s . . . . . . . . . . . . . . . . . . . .1. '.l- 9 8
System Description System Description ........ 11-100
V a c u u mC o n n e c t i o n.a. . . . . . , . . . . . . . . . . . . . . . . .1.1. .- 8 F u o lP r a s s u r e . . . . . . . . . . . . . . . .1. 1 - 1 0 0
E f e c t r i c aCl o n n e c t i o n.s. . . , . , . , . . . . . . , . . . , , . . . . . , ' 1 1 - 1 2 F u 6 lI n i 6 c t o r s . . . . . . . . . . . . . . . .1. 1 - 1 0 2
S y s t € mC o n n e c t o r s. . . , . . . , . . . . . . . . . . . . . . . . . -1. -1- -. 2 O Fuel PressureRagulato. .,. 11-106
T.oubloshooting F u e lF i l t e r . . . . . . . . . . . . . . . . . . . .1. 1. -108
T r o u b l e s h o o t i nGgu i d o . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 3 2 F u a lP u m p . . . . . . . . . . . . . . . . . . .1. .1 - 1 0 9
Self-diagnosticProcedures.,..,...............1 1-34 P G M - FM l a i nF 6 l a y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. .".11 1
H o w t o R o a dF l o w c h a r t s. . . . . . . . . . . . . . . . . . . , .1.1. - 3 9 F u e lT a n k . . . . . . . . . . . . . . . . . . . .t. 1. - 1 1 4
PGM-Fl System
S y s t o mD e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . 1. .l.-.4 O Intake Air System
Troubleshooting Flowcharts System TroubloshootingGuido ..................1 1-1 1 5
E n g i n eC o n t r o lM o d u l s. . . . . . . . . . . . ...... . . . . . . . .1 1 - 4 2 Systom Dascription ........ 11-116
H e a t e dO x y g o nS e n s o r . . . . . . , . . . . . . . . . . . . . . .1. .1. - 4 6 Air Clean€r . . . . . . . . . . . . . . . . . .1. .1 - 1 1 7
HeatedOxyg€n Sonsol Heatel .....,.........1 1-47 T h r o t t l sC a b l e ................'11-118
F u e lS u p p l yS y s t e m. . . . . . . . . . . . . . - . . . . . . . . . . .1. .1. -. 5 0 T h r o t t l 8B o d y . . . . . . . . . . . . . . .1. 1 - 1 2 0
Manitold Absolute Pressure lntake Air Bypass Cont.ol Systsm
S s n s o r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. .- .5. 2
.... [B18Cl enginal . , . . . . . . . . .1 1 - 1 2 3
Top D6ad Cente./Crankshatr Intake Manilold [B1881 onginol ................. 11-128
Position/Cylindor Positionsonsor ........ 1 1-56
EngineCoolantTempsratureSonsor ....... 11-58 Emission Control System
T h r o t t l oP o s i t i o nS o n s o r. . . . . . . . , . . , , . . . . . . . . 1. .1. - 6 0 Systsm TroubleshootingGuido ..................1 1-129
Intake Air TemperatursSensor...............11-62 Systam Doscription ........ 11-130
B a r o m e tc P r s s s u r o S e n s o r. . . . . . , . . . , . . . , . .1, .1 - 6 4 TailpipsEmission ........... 11-130
l g n i t i o nO u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .1. 1 . .- 6 6 ThraeWay CatalyticConvortor ...,...,.........,11-131
V e h i c l eS p e € dS e n s o r. . . . . . . . . . . . . . . . . . . . . . . .1. 1 . .- 6 8 PositivaCrankcaEoV6ntilationSystcm .,....., 11-134
E l e c t d c aLl o a dD o t e c t o r. . . . , . . . , . . . . . . . . . . , . 1. .1. - 7 O EvaporativoEmissionContro|,..,..,.,.,,.,,..,..,1 1-135
K n o c kS e n s o r[ 8 1 8 C 1e n g i n e ]. . . . . . . . . . . . . .1. 1 - 7 4
A / T F l S i g n a lA / B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.7 6

ldle Contlol System

System TroubleshootingGuide ..................1 1-78
Systom Description ........ 11-79
Troubloshooting Flowchans
l d l €A i l C o n t r o Vl a l v e . . . . . . . . . . . . . . . . . . . . . . . .1. 1 . .- 8 2
A i l C o n d i t i o n i nSg i g n a l . . . . . . . . . . . . . . . . . . . . . .1. .1.- 8 4
A l t e m a t o rF R S i g n a l . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .1. -. 8 6
Automatic Transaxle (A/T) Gear
PositionSignal ......... 11-88
B r a k eS w i t c h S i g n a l . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. -. 9 O
S t a r t e lS w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .- 9 2
Power Steering PressureSwitch Signal ... 11-93
F a s tl d l e T h e r m oV a l v e . . . . . . . . . . . . . . . . . . . , . . . . . 1 . .1. -. 9 4
l d l s S p e e dS € t t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1.-. 9
.5
SpecialTools

Ref. No I Tool Numb€r Description I OtV I Page Reference.

o A973X_041*XXXXX Vacuum Pump/Gauge ,l
1't-'t20, 124, ' 1 3 7 ,
140
@ oTJAZ-O010008 Vacuum/Pressure Gauge0-4 in. Hg 1 1 1 - 1 3 91,4 0
OTLAJ_PT3O1OA 't 1-37
@ Test Harness 1
oTPAZ-0010100 'l
@ SCS Short Connector I t -J.+

@ o7406-OO40001 Fuel PressureGauge 1 1 1 - t 0 11

, 06

\t

1 1 -2
Component Locations
lndex

81881 sngin6:

IOLEAIR CONTROLOACI VALVE

T page '11-82

ABSOLUTE
MANIFOLD
{MAP}SENSOR
PRESSURE EVAP
Troubleshooting, PURGECONTROL
SOLENOID VALVE
Troubleshooting,
THROTTLEPOSITIOIII{TP) SENSOR 11-137
Troubleshooting, page 1 1-60 THROTTLECABLE
Inspection/Adiustment, page 1 1-118
Installation,page 11-1 18
TOP DEAD CENTER/CRATIIKSHAFT
POSITIOf{/CYLINDERPOSITION
(TDC/CKP/CYP}SENSOR INTAKE AIR TEMP€RATUREIIAT) SEI{SOR
page 1 1-56
Troubleshooting, Troubl€shooting, page 1 1-62

POWERSTEERINGPRESSURE(PSP)
swtTcH
ELECTRICAL page 11-93
Troubleshooting.
LOAD
OETECTOR
IELD}
Troubleshooting.
page,l l-70

IGNITION MODULE{ICMI
Troubleshooting, page 1 1-66
sq IDLETHERMOVALVE
Inspection,page 11-94

ENGINECOOLANT TEMPERA (ECTISENSOR HEATEO SENSORlHO2S}

page I 1-58 pages 11-46, 47
Troubleshooting.
Troubleshooting,

11-3
Component Locations
lndex
B18Cl ongino:

EVAP
PURGECONTROL
SOLEiIOIDVALVE
Troubleshooting,
p a g e1 1 - 1 3 7

MANIFOLD AESOLUTE
PRESSURE (MAPISENSOR INTAKE AIR TEMPERATURE
page 11-52
Troubleshooting, IIAT) SENSOR
p a g e1 1 - 6 2
THROTTLE
(TP}
POSITION
THROTTLECABLE
SENSOR Inspection/Adiustment, page 'l 1-119
Troubleshooting, page 1 1-119
page 1 1-6O lnstallation,

IOLE AIF CONTROL(IACI VALVE

TOP DEAD CENTER/CRANKSHAFT Troubleshooting. page 1 1 -82
POSITION/CYLINDER POSITION
{TDC/CKP/CYPISEI{SOR POWERSTEERINGPRESSURE(PS'I
Troubl€shooting. Page 1 1-56 swtTcH
page 1 1-93
Troubleshooting,
ELECTRICAL
LOAD
DETECTOR
IELD}
Troubleshooting,
page.11-70

IGNITIONCONTNOLMODULE OCMI
Troubleshooting, Psge 1'l-66
sElrlsoRtKsl
ENGIT{ECOOLANTTEMPERA Troubfeshooting, page 1 1-7 4
{ECT}SEI{SOR
Pag€11-58
Troubleshooting, HEATED OXYGEN SENSOR(HO2S}
pages 11-46, 47
Troubleshooting,
FAST IDLE VALVE
'l
Inspection, page 1 -94

11-4
 THROTTLE BODY(T8I
page11-120
Inspsction, THROTTLE CABLE
Disassembfy,page11'122 pages1l-'l 18, 119
InsDection/Adjustment,
AIR CLEAI{ERIACL)
Replacoment, 11-117 pages1 1-118, 119
Inslallation,

INTAKE
AIR
BYPASS (IABI
co TROL
OIAPHRAGM
{Bl8C1 ongino onlyl
Troubleshooting,
page 11-124

INTAKE
AIR
EYPASS IIABI
co TnoL
I
SOLENOID
POSITIVECRA KCASE VALVE (B18Cl .ngino onlyl
RESONATOR vEt{TtLATtOt{(PcVl VALVE Troubl6shooting,
psgo1 l-134
Inspection, p a g e1 1 - 1 2 4

ENGI]TECONTROL MODULE{ECM)
page11-34
Procedures,
Selt-diagnostic
page11-42
Troubfeshooting,

MAIN RELAY
RelayTesting,page 1 1-111
SERVICECHECX CONNECTOR(2PI pag€ 1 1-112
Troubleshooting,
page'l 1-34
56ll.diagnosticProcedures,
11-5
SystemDescription
Index

FUELGAUGESE]IIDINGU]{IT
Tgsting,s€ction23
FUEL PUMP
T€sting.page 11-1 10
FUELFILTER Roplscam€nt.page 11-l 10
page 11-l OB
Replacement,

FUELFEEDPIPE
FUELFIIL CAP

FUEL II{JECTORS
page 1 1-102
Troubleshooting,
Replacemont,page 1 1-105

FUELTA K
R6placomont,
p a g el 1 - 1 1 4

EVAFORATIVE EMISSION
IEVAP}TWO WAY VALVE
Testing,pag€11-140

EVAPORATIVE
EMTSStOt{ FU€L
{EVAP}PURGE PNESSURE REGUIATOR
CONTROLDIAPHNAGM Testing,page11-106
VALVE Roplac€m€nt,page11-107
page'l 1-137
Troubleshooting,

FUEL RAIL FUELVAFONAPE

EVAFORATIVCEMISSION
(EVAPI COI{TROLCANISTER
Troubl6shooting. pag6 1 1-'l 37

11-6
System Description
Vacuum Connections

81881 engin€:

EVAPORATIVEEMISSIOT{
(EVAPI
PURGECONTROL
SOLENOIDVALVE

EVAPORATIVEEMISSION
(EVAP}PURGECONTROL
To
DIAPHRAGMVALVE EVAPORATIVE
EMtSSTON
{EVAP}
TWO WAY
VALVE

EVAPORATIVEEMISSION
IEVAP) CONTROI-CANISTER

FRONTOF
VEHICLE

11-8
 ENGINE
COOLANT
|l
U]

HEATEDOXYGEI{SEI{SOF(HO2S} @ FUELTAI{K EVAPORATIVEEMISSION(EVAP}VALVE

MANIFOI.DABSOLUTEPRESSURE (MAP)SEI{SON G) FUELPULSATIONDAMPER
ENGINECOOLANTTEMPERATURE IECT}SENSOR @ AIR CLEANER
INTAKEAIRTEMPERATURE IIAT} SEI'ISOR @)RESONATOR
IIAC)VALVE
IDLEAIR CONTROL @ THREEWAY CATALYTICCONVEnTER (TWC)
FASTIDLETHERMOVALVE o POS|TIVECRANKCASE IPCV)VALVE
VEITITILAT|ON
FUELII{JECTOR @ EVAPOBATIVE IEVAP)COI{TROL
EMISSION CANISIER
FUELFILTER @ EvApoRATrvEEMrssroNIEVAP)PURGEcoNTRoL
FUELPRESSUREREGULATON SOLENOIDVALVE
FUELPUMPIFP) @ EVAPORATTVE EMISSION(EVAP)PURGE CONTROL
FUELTAI{K DIAPHRAGM VALVE
(iDEVAPORATIVEEMISSION(EVAPITWOWAY VALVE

11-9
System Description
Vacuum Connections

818C1 engine:

INTAKEAIR
SYPASSIIAB}
CONTROLDIAPHRAGMVAI-VE
to
EVAPORATIVE
EMISStON
MANIFOLOABSOLUTE IEVAPI
PRESSURE{MAP) SENSOR TWO WAY
VALVE
EVAPORATIVEEMISSION
{EVAP) PURGECONTROL
DIAPHRAGMVALVE

INTAKE
AIR
BYPASS IIAB}
VACUUM
TANK

EVAPORATIVEEMISSION
IEVAPI CONTROLCANISTER

INTAKEAIR
BYPASS IIABI
CONTROLSOLENOIDVALVE

PURGECONTROL
SOLENOIDVALVE

11-10
c) HEATEDOXYGENSENSOR lHO2Sl G) FUELPUI-SATION DAMPER
€) MANIFOLDABSOLUTE PRESSURE IMAPISENSOB @ AIR CLEANER
O EI{GINECOOLANTTEMPERATURE {ECT}SENSOR (D RESONATOR
€) INTAKEAIR TEMPERATURE {IAT)SENSOR 6 imrlre arR Bypass (tAB)coNTRoL DIAPHRAGM
@ KNOCKSENSOR tKSl VALVE
VALVE
@ IDLEalR coNTRoL llAcl vALvE (D)IITITP IIN BYPASS{IAB)COTROLSOLENOID
O FASTIDLETHERMOVALVE ds)INTIXT AIR EYPASSTIABIVACUUMTANK
@ FUELINJECTOR rio'lrnrarg ltn BYPASS(lABl cHEcK vALvE
@ FUELFILTER 6 rsnee wav cATALYTtccoNvERTERlrwc)
@ FUELPRESSURE REGULATOR 6 posrnve cRAf{KcAsEvENTILATIoN{Pcv) vALVE
O) FUELPUMP(FPI 6 evlponlrtve EMtsstot{ tEvAPlcoNTBoL cANlsrER
@)FUELTANK 6 evlponltvE EMtssloN{EvAP}PURGE coNTRoL
@ FUELTANK EVAPORATIVE EMISSIONIEVAPIVALVE SOLENOID VALVE
6i EVAPORATIV€ EMISSION (EVAPIPURGECONTROL
DIAPHRAGM VALVE
6o ivlpoalrtve Eutsstof{ IEVAPIrwo wAY vALvE

11-11
SystemDescription
ElectricalConnections
PGM.FI MAII{ RELAY

fUEL
PUMP
- rc2lL

IllL
i i \|
r--ri l {a/Tl
.i

FUELINJ€CTORS

DATA To BAOIATORFAt!
LIIIK RETAY,CONDENSER
co t{EcToR FAI{ RELAY
To A/C SWITCH

A/C CLUTCH RELAY

FUSES
O BATTERY I1OOAI*
@ oPTroNt50 alr
o rG {50 A).
@ sroP. HoBN{2OAl*
@ BACKUP(7.5 Al*
@ No. 3 INTERIOR LIGHT{7.5 A)
O Ecu (EcMt(1s A)'
@)No. 24 ACG (ALTI0Gl
{15 A: 81881sngin6,
2OA:818C16n9ine)
@ No. 15 BAcK-uPLlcHTsllo Al
@ No. 13 REARDEFROSTER RELAY
A/T GEAR HEATERMOTORRELAY
COOLING FAN MOTORRELAYI7.5 A}
O No. l8 STARTER SIGNAL 17.5A)
*: UNDER-HOOD BOX
FUSE/RELAY
11-12
 ITIAP
sEl{SOR

TP SEI{SOR

..!L1.99'!.elsrl
VTEC SOLE]{O|O

EVAP
PURGECOT{TROL
SOLEI{OIOVALVE

|AA CO TROL SOLEI{OID

VAI.VE

ECT SEI{SOR

ALT C 416

IUSA or yl

TERMINALLOCATIONS

ooooooooooooo oooooooo ooooooooooo

ooooooooooooo oooooooo ooooooooooo

(cont'd)

11-13
System Description
ElectricalConnections(cont'd)

rHriRED,
fl--fwl
I
Jftfi:]ff*-,
cl13 HO2S

181881cngr|.l tBl8cl .nerEt Flll---------------

YEURED - YEr/wI{ri | |
- YvHrnEr-l | i|APsEIrsoFI
-cn AvHrr
ll_l

cl11

ECTSEI{SOR

c120
, REDI'EL
GRI{/BLU {E IAT SET{SOR

cl15
YEL/BLU
RED/8U(
GR]I/BLU
1E
cl19
wt{T/GRl{ WHT/GRT{
wL?/nEor ALTERI{ATOF
WHT/REDr

cl to
tclrl

c131
".rro*.fl..Fl
- ll PnEssunE I
- atK' swrcH I
1l

(To psge 1 l -15)

11-14
D14 :wHT/nED'
-'-'--''''-''-'

TDC/CYP/CKPSENSOR

:j:on 2-"''''-' '- -----

811
812 :-WHT--------'-''''-''''
813 :ji oRNi sLU =::::i-:jjjjjjj
814 :ji WHT/ALU jjji-::-:-:::i:jj
815
816

KS

t{o. 1 FUEI
II{JECTOR

c122
t{o. 2 FUEL
II{JECTOR

c123
No. 3 FUEL
NJECTOR

c124
YEL/ALX t{o. 4 FUEL
YELI II{JECTOR

YEL/BLK EVAP PURGE

- RED2 cot{TRoL
soLE{otD
VAIVE

(cont'd)

11-15
System Description
ElectricalConnections (cont'dl

BLI(/YEL BTKiYEL-JT---l
oRI{r oR 1 ----l I vss I
BLK' {l I

c't 16
v:r-,sr-*-J l-----]
'o"
".*,".u uo.u.
{l I

lA18a1ongine,

lB18C1 6ngin€)

il
tl
".t t
enn__JlF-----l
ll r Brx_LlswrcH I
c423 ! caor -L
es-ot

c405
eaurvxrJ SERVICECHECK
r BLK -l COIIIIECTOR
1 -
G401 :--
c40a
BRN/BLKf
DATA LINK
LT BLUI
corrttIEcToR
WHT/RED{

11-16
 lBl lcl
I T
t Il
] neonr-x
RED/WXT

GAUGE ASSEMALY

c449 - C553 {!L rNDrcAToR

F- GR[{/OR]{

["'

To RADIATORFAt{
RELAY, COI{D€I{SER
FAI{ RELAY

To A/C COTT|PfiESSOR
CLUTCH RELAY

To A/C SWITCH

(cont'd)

11-17
System Description
ElectricalConnections(cont'dl

160Al fioo Al
wnrneo
J
,*rr"a* -l
c216
wHr/8ru
T
I
YEL/WHT--L
c214 sToP. HORI{t20 Al
wHvem {
auryet{
oR nED-l
-alx {
If_ "rti'
c218
G20r

I{o. 3 lttTERlOR LIGHT

wxrneo
{
"a*,"ao {
o. la STARTER
c44t) stGI{At- t7.5 Al
*utwxr
{
wHriRED--l
l|5^.llll.n'i'20r!|.c1q*,
or-rrv:r-
{ No. 15 8ACK-UP LIGHIS
c551
t10 al
-{

nft C4. Af,:Ca13 f

- -l
8rr(/nED
- surwxr -{
el3t
F
w{T/GRr{_-]
cR ^i|Hrl
1

{Toptg€ 11-19,

11 - 1 8
{Frompago 1 1-'l8l

PGM-FI lrtAtt{
REL,AY

t
I=
G502

11-19
System Description
SystemConnectorsIEngineCompartmentl

ENGINE
WIRE HARNESS

{818C1 onginol

o
t3

c132
c131

UNDER,
HOOO
FUSE/RELAY
aox

MAllrl
WIRE ct 04
HARI{ESS c102
c220 c222

11-20
cl10 c111 c112 cl1

6 r'ft] r+
lrl2l
trtr
E:I

I if,l.)
\:-/

-
lI-FErwHr l-l l IOTBLF------l l;TYra-"wrrr. I
1olGuNlert la lsLx/YEL l]l I le llel/nEo I
fo lanlr I€ TcRNrwHrtl
I ,ITwHr^rJl I

o
c117 c 13 t c 132 c214

tr
lB18C1engine)

/ r \
ffi
\^y
---l
IETYEL/€Lh---l
----,, ldlcRr/vEr
lohED'

c215 c216 c221

^Jl
r'fr] FFIN
ffi
- lll
fi'Twtl-rirllrlerrrltlerl-l
fr-Twrr
I@ LWHTTREO I

ohN/BLK l |/BL!

ALU/YEL

NOTE: a Different wires with the same color have been given a number suffix to distinguishthem (for example,
YEL/BLK1and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSystem.
a - Connectorof male terminals:View from terminalside
- Connectorof temaleterminals:View from wire side (cont'd)

11-21
System Description
SystemConnectors[EngineCompartment](cont'd)

c 120
{81881sngino}

(B18Cl onginol

11-22
 c117 ct 20 cr20
cl16 lBl88l 6nginol c119 l8lSBt.nglnrl (Bl8Cl .ngln l
FI
/
EI
/ t \
A ET F,-f.

\2 t z t
RP \?
--'l
|@|iaf,-'6trlaltrlaru----1 |6-I!EUBLK 16lwHiffiN----f l6TciN-6LU----- l6-ltR,iEit----
toltEUB'.f---- lO lhEo' I l@lwHrnco' I loliEo/YEi----. l@ IiEp/YcL I
| 3 l a L & Y E r --- I
frlwHrEru

c121 c122 c 123 24 cr33

fr ffi ffi ffi .2

A

---------l
l6'lau,-r, --.-.1I
|o lhEo/8llJ
IO IYEL/8LX I I-T-

ct 34 c3t I
,8.
\^y O
f6-IPilK/BLu---l
IO IYEUBL( I tsF

NOTE: a Different wires with the same color have been given a numbe. suffix to distinguish them (for example
YEL/BLK1and YEL/BLK,are not the same).
O: Related to Fuel and EmissionsSystem.
a - Connector of male terminals: View from terminal sid6
- Connectorof female terminals:Viow from wire side

11-23
System Description
System Connectors [Dash and Floor]

ENGINE
COMPARTMENT
WIRE

PGM-FIMAIN
RELAY
DASHBOAROWIRE
HARNESS

REAR
WIRE MAIN
HARNESS WIRE
HARI{ESS

C1I44 UNDEN-OASH
FUSE/REALY
BOX

11-24
c4't9

2 3 4 5 7 8 e nc

5 t6| -

a ALUfYEL YEL'

c431 c431
c423 (wlthout lwlth
crui!a cruit€
control) coniroll

|' l r l
-t
t t I

12 t3 lslnl
3 13 ----'l
l6'TwHr/cnN----l fitr G-Fil------
5 BLU/YEL 1ol cRN^vHr lo ln/Hr/68n I
6 lo lciN,r/vHr I
l-IcRY------l
a 1a

20

c432 c439
c44il
rfltrrn
ffi I'VCT,1 riTLF-I
ffi
14l51617l
lETWrr;eo---f
-- YEL/BLK' lO lGRt/8LU I
frlwHr. 2 Ht/alu Titfgruffir-----l
l3l8rK I iEO/YIL ktlBrKr--
I t lBLx,REo I 15 I o lYcL/Gnir I
t 5 | 5 16 lao laLx./YEL I
't7
I 6 G R N / B L X-- I I "] IYEUBL( --- I
f?-TFEpcFN ktlterwirr
a
BL&"/EL 20
YEL

c444

ffir
trtr]
-l
I6TLK^//Hr
L' l!!g!!r l
l o l s L k r F E D l]l I
|;TBLU'BLi

NOTE: a Ditterent wires with the same color have been given a number suttix to distinguishthem (fot example
YEL/BLKrand YEL/BLK,are not the samel.
O: Relatedto Fuel and EmissionsSystem.
a - Connectorof male terminals:View from terminalside
- Connectorof femaleterminals:View from wire side (cont'd)

11-25
System Description
System Connectors [Dash and Floor] {cont'd}

DASHBOARD
HARNESS

MAIN
UNDER-DASH WIRE
FUSE/RELAY HARNESS
BOX

11-26
 1 2 3 4 6 7
I r0l1 11121131
114115116

gL&YEL BLK/YEL 6 REO/6LU

2 12 2 8RN/8LK
BLK GFN 3 BLU
GFN,YEL YEL LT GRII/SL( 9 GRN/BLII 12 BLUf/€L
5 15 5 YEL/RED 13
6
YEL 16 BLU
YEL/6LK t6
I

a DiJterentwires with the same color have been given a number sutfix to distinguishthem (for example
YEL/BLK1and YEL/BLK'are not the same).
O: Relatedto Fuel and EmissionsSystem.
a - Connectorot male terminals:View from terminalside
- Connectorof female terminals:View from wire side

{cont'd)

11-27
System Description
SystemConnectors[Dashand Floorl (cont'd)

c/ro5
SERVICE
CHECK
CONI{ECTOR

11-28
 c405 c406 c410 tEGM-Al

fr r'tr--Jl

-----l
ffi I6TBRN/B,L(-__-l
l€, lwHr/uED l_l
l6TLr BN---
YEL'
tt4
| (jt ALK/AED

SLU 1a
ALK t(9 YEL
| 0o)

ALK'
ALK'
YEL/BLK
GRN/oRr l@ BLK

c408 {ECM-Bl
3 9 1 t3tl5
2 4 8 1C l 2 4

BLK
2
YEL

I ALU/REO 5
6 6

ALU/YEL

a Different wires with the same color have been given a number suffix to distinguishthem (for example
YEL/BLK1and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSystem.
a - Connectorof male terminals:View from terminalside
Connectorof femaleterminals:View from wire side

11-29
System Description
SystemConnectors[FuelPumpl

REARWIRE
HAFNESS

11-30
c510

NOTE: a Ditferent wiros with tho samo color hava been given a numb€r sutfix to distinguish them {for example
YEL/BLKI and YEL/BLK, are not th€ same).
O: R€lated to Fuel and EmissionsSystom.
a - Connoctor ol malo tarminals: Vi6w from terminal side
- Connector ol f6msl€ tarminals: Vi€w from wire sid€

11-31
Troubleshooting
TroubleshootingGuide

NOTE: Across each row in the chart. the systems that could be sourcesof a symptom are ranked in the order they should
be inspectedstaning with O. Find the symptom in the left column, read acrossto the most likely source.then refer
to the pagelistedat the top of that column.lf inspectionshows the systemis OK, try the next mosr likelysystemO, etc,

PGM.FI

TOPDEADCINTTR/ ENGINE
MANIFOLO INfAKE AIR BARO.
ENGINE HEATEO CRANKSHAFT COOLANT THROTTTE IGNITION vEHtct-E
AESOLUTE TEMP€RA. METRIC
CONTROL OXYGEN POSTT|ON/ TEMPfRA. POStTtON OUTPUT SPfED
PRESSURE TURE PRESSURE
MOOULE S E N S O R
SENSOR
CYLINDER TURT SENSOR sar,rs0RSENSOR SIGNAL SENSOR
POSITION
SENSOR SENSOR
SYMPTOM 11.42 4 6 ,4 7 , 5 0 11-56 l1-58 1l-60 11-62 11-64 1t-66 1r-68

lrmr: - -r:+r-
MALFUNCTION INOICATOR 1 l o r : t : ] :
L A M P( M I U " T U R N S
ON
i;:i'
-tK3t- 16l- 16l
' - \
-16l
/-----\ -{"Pr: -o_ -16l-.z-\
r6t
/_-\
\ --l-l \.--r--l
MALFUNCTION INOICATOR
L A M P( M I L ) ' ' B L I N K S :O. or-8.
-D:o.:@.
l 3 l .E-o.:O: or tr]- - i-i-\! l 7 -l
r 0I
| t - /----\ | 1 3| r5 -t
I t - /-]-\1 7t -
o, O' /__-\ / /__-\ z_---\ /.---\

ENGINEWON'T STAffT o @ @
DIFFICULT
ENGIN€
TO START
WHENCOLO @ @ (9) o
WHENCOTD
FASTIDLE
ouT0f sPtc
@ @

IRREGULAR
IDLING
ROUGHIDLE @ o
RPMTOO
HIGH
@ @
RPMTOO
LOW
@
WHILE
FREOUENT
@ @
STALLING
AFTER
@
MISFIREOR
ROUGH
RUNNING
@ @ @
POOn
PERFOEM. FAITS
ANCE EMISSION
TEST
@ @ @
Loss0F
POWER @ @ @
* lf codes other then those listedabove are indicated,count the numberof blinksagain.It the MIL is in fact blinking
^ these codes, replacethe ECM.
qy, lf the MIL is on while the engineis running.connectthe SCS shon connectorto the servicecheck connector.It no
code is displayed{MlL stays on steady),the back-upsystem is in operation.
Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM.

USA: CANADA:
MALFUNCTION \ ----l CHECK
INDICATOR -ltGl- ENGTNE - { -1t-
- | -
LAMP {MIL) LTGHT

* * *: 818C1engine

1-32
 PGM-FI I O L EC O N T R O L FUELSUPPLY

VARIAEIEVALVEVARIABLEVALVE
TIMINC& VALVE TIMING& VATVE IOLEAIR OTHER OTHER
INTAKE €MtsstoN
ELECTRICALLIFTELECTRONICI-IFTILECTRONIC KNOCK FI FI FUEL AIR CONTROLS
LOAO coNTRO|- cottTR0t stNsoR SIGNAL SIGNAT
c0NTR0r- IOLE
INJECTOR
FUEL
DETECTOR CONTROLS SUPPTY
SOLENOID PffESSURE

| 1"70 s38 11.74 r 1-76 t 1-76 11-82 11-78 | 1-102 r 1-97 t 1 - 11 5 l l 129

E r6t-
- --- --- -16l-
/-----.. E fl -o_ ,.''\
\.-r-l \-!-/ \.--r-z \.---l
-t l0 t-
---i-\
t 2 tI
/ --i-\ /--
l 2j--\2 l t 2 3l - -t
/--.i-\
30 t 3 rt - /----\
,--T-\ l- /-.--\ [|- I 1 6t\ -
/ _-i-

o @

o @ @

o Q)

@ a, @ @

o @ @

@ o
o
(JJ

@ @ @ o @

11-3
Troubleshooting
Procedures
Self-diagnostic
When the MalfunctionIndicatorLamp {MlL) has been reportedon, do the following:
'1.
Connect the SCS short connecto. to Service Check Connector as shown. (The 2P Service Check Connector is
locatedunder the dash on the passengerside of the car.) Turn the ignitionswitch on.

DATA LII{K
CONNECTOR (3PI
NOTE:
Do not attach
jumperwire.

2. Note the DiagnosticTroubleCode (DTC):The MIL indicatesI code by the length8nd numbsrot blinks.The MIL
can indicatemultiplecomponentproblemsby blinkingseparatecodes,one after another.Codes 1 through Igre
indicatedby individualshon blinks.Codes 1Othrough 43 are indicatedby a seriesof long and shon blinks.Th€
numberof long blinksequalsthe first digit, the numberot short blinks equalsthe seconddigit. Sometimesthe
firsr blink is difficult to see; always count the blinks at least twice to verify the code.

MALFUNCTIOI{ CANADA:
INDICATOR CHECK
LAMP ENGINE
IMIL} LIGHT

Sgprrate Prcbaomr:
shT
-n-----n-=n- = s.o DTc1
+!+1].TL;I!!=- "
= s.. Drc 3
-L '" " = Sce DTC 13
,JU
Long .hon
Multiplr Probl.ln.:
J-l_tx-TL-n-ffu-r- = S€. DTC 1 lnd 3
-J.rrU-L-r]tltlr'l- __-tnrua = Sce DTC 3 and 4
Jll-lrl-t-----Tt/'tnj]_ = S.. DTC 3 lnd 14

11-34
Engine Control Modute {ECM) Reset procedure

1. Turn the ignition switch otJ.

2' Removeth€ BACK UP (7.5 A) fuse trom the unde.-hoodfuse/relaybox for lo secondsto reset
the EcM.

BACKUP I7.5 AI FUSE

UNDER-HOOO
FUSE/RELAY
BOX

Final Procedurelthis procedure must be done after any troubleshooting)

1. Removethe SCS Short Connector.

NOTE: lf the SCS short connectoris connectedand there are no DTCSsto.ed in the ECM,the MIL will stav on.

2. Do the ECM Reset Procedure.

11-35
Troubleshooting
Self-diagnosticProcedures(cont'dl

DIAGNOSTIC
TROUBLE SYSTEMINDICATED Psge
CODE(DTCI
o ENGINE
C O N T R O LM O D U L EI E C M ) 11-42
,l
H E A T E DO X Y G E NS E N S O RI H O 2 5 ) 11 - 4 6
a MANIFOLDABSOLUTEPRESSURE{MAP SENSOR) 11-52
4 CRANKSHAFTPOSITION(CKPSENSOR) 11 - 5 6
o ENGINE
COOLANT (ECTSENSOR)
TEMPERATURE 11-58
THROTTLEPOSITION(TP SENSOR} 11-60
I TOP DEADCENTERPOSITION(TDC SENSORI 11 - 5 6
9 No. 1 CYLINDERPOSITION(CYPSENSOR) 11 - 5 6
10 (IAT SENSOR)
INTAKEAIR TEMPERATURE 11-62
13 BAROMETRIC (BAROSENSOR}
PRESSURE 1|-64
14 IDLEAIR CONTROL(IAC VALVE} 11-42
t c IGNITIONOUTPUTSIGNAL 11-66
to FUELINJECTOR 1't-102
17 VEHICLESPEEDSENSOR{VSSI 11-68
20 LOAD DETECTOR(ELD)
ELECTRICAT 't 1-70
VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC
CONTROLSOLENOID
21 6-36
VALVE{VTECSOLENOID VALVE)'
VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC
CONTROLPRESSURE
22 6-38
SWITCH(VTECPRESSURE SWITCHI-
23 K N O C KS E N S O R{ K S } - 1 1 - 74
30 A/T FI SIGNALA 11-76
3'r A/T FI SIGNALB 11 - 7 6
4'l HEATEDOXYGENSENSOR(HO25} HEATER 11-47
43 FUELSUPPLY
SYSTEM 11 - 5 0
':818C1 engine

a lf codes other than those listed above are indicated, verifv the code. lf the code indicated is not listed above, replace
rhe ECM.
a The MIL may come on, indicatinga systemproblemwhen, in fact, there is a poor or intermittentelectricalconnection.
First, check the electricalconnections,clean or repairconnectionsit necessary.
o The MIL and @ indicatorlight may light simultaneously when the DiagnosticTroubleCode (DTC)6, 7 or 17. Check
the PGM-Flsystem according to the PGM-Flsystem troubleshooting, then recheck the l!! indicator light. ll it lights,
s e e p a g e 1 4 - 5 O ,5 1 .
a The MIL does not come on when there is a malfunctionin the A/T Fl signalor ElectricalLoadDetector(ELDIcircuits.
However, it will indicate the codes when the Service Check Connector is shorted.

11-36
It the inspectionfor a particularcode requiresthe test harness.removethe right door sill moldingand kick panel. Pull
the carpet back to exposethe ECM, Unbottthe ECM cover. Turn the ignitionswitch off and connectthe test harness
Check the system accordingto the proceduredescribedfor the appropriatecode(s)listed on the following pages.

KICK
PANEL

TEST
HARNESS
OTLAJ_PT3OlOA

DIGITAL MULTIMETER
Commarciallyovribbla or
KS-AHM-32-OO3

NOT USED
o oooooooooooo oooooooo ooooooooooo
ooooooooooooo oooooooo ooooooooooo

TERMINAL LOCATIONS (cont'd)

11-37
Troubleshooting
Self-diagnosticProcedures(cont'dl

a Punctudng th6 inruLtion on r wirc cln cruaa poo? or Int!finltttri aLctrlcC connac,tlom.
a For tosting at connoctofs othor thsn tho taat hrmara, bdng thc tartar probc Into contact whh tha tarnilnal trom thr
connector ride of wilo hamclr conn.ctora In thc cnglnc comprnrnam. Foi t.|nab connactorr,lurt touch llgl ly whh
tha tostor probo and do not Inlcrt tho prcbc.

TES'EB PNOBE

TERflt]IAI

11-38
 How to ReadFlowcharts
A flowchrrt is dasignedto be us€d fiom start to final repair. lt's like a map showing you the shortest distanco. But be-
"map" anywhere but a "stop" symbol, you can easily get lost
ware: if you go off tho

l6rffil Desclibas the conditions or situation to start a troubleshooting flowchart.

(bold tyDo)

|TeTiONl Asks you to do something; pedorm a test, set up a condition etc'

<:6Eei6io-fr\> Asks you about the result of an action, then sends you in the appropriste troubleshooting direction.

I-SJTFI The snd of a series ot actions and decisions, describes I tinal repair action and aomotimea diracts
(bold typel you to 8n garlier part of the tlowchart to confirm your repair'

NOTE:
a Tha tarm ,,lntormittgnt Failure" is used in these chans. lt simply means a system may have had a failur6, but it chocks
out OK !t this time. lf th6 Msltunction Indicator Lamp (MlL) on ihe dash does not come on, check for poor connections
or loose wires at all connectors rolated to the cilcuit that you are troubleshooting (see illustration b6low).
a Most ot tho troublashootingflowchans have you reset the EngineControl Module (ECM)and try to duplicate the Disg-
nostic Troubls Cod6 (DTC). lf the problem is intermittent and you c8n't duplicat€ the cod6, do not continus through
the flowchart, To do so will only rosult in confusion and, possibly, a ne€dlessly replaced ECM
a ,,opon,'and ,,short,, are common electricalterms. An open is a break in a wir6 or at a conn€ction.A short is an
accidontalconnaction ot a wir€ to ground or to another wire. In simple electronics,this usually means som€thingwon't
work at all. In complex electronics (like ECM's), this can sometimes mean something wolks, but not the way it's sup-
poSadto,
a il th6 olectricsl readingsare not as specified when using the test harness, check the test harnessconnoctions bsfore
procooding.

LOOSE

11-39
PGM-FISystem
System Description

ENGINECONTROLMODULE(ECMI OUTPUTS
TDC/CKP/CYPSensor Fuel-lnjectors
MAP Senso. PGM-FIMain Relay(FuelPump)
ECT Sensor MIL
IAT Sensor IAC Valve
TP Sensor A/C CompressorClutch Relay
lFuettnjectorTimingandDuration]
HO2S Radiator Fan Relav
vss I Electr..l"ldle Contr;il CondenserFan Relav
BAROSensor ALT
ELD rcM
Fit'e' contr; Funcrfit
Starter Signal EVAP PurgeControlSolenoid
ALT FR Signal Ttntrlg c..trol
l6tio;
Air ConditioningSignal HO2S Heater
A/T Gear Position Signal VTEC SolenoidValve'
tEcM aack-,rpFunctiorlsl
BatteryVoltage{lcN. 1) IAB Control Solenoid Valve*
BrakeSwitch Signal
PSPSwitch Signal
Knock Sensor'
VTEC PressureSwitchr
': 818C 1 €ngine

PGM-Fl System
The PGM-Flsystem on this model is a sequentialmultipon fuel injectionsystem,

Fuol Iniector Timing and Duration

The ECM containsmemoriestor the basic dischargedurationsat variousenginespeedsand manifoldpressures.The
basicdischargeduration,after beingreadout from the memory,is turther modiliedby signalssent from vanoussensofs
to obtain the final dischargeduration.

ldle Air Control

ldle Air ControlValve (lAC Vatve)
When the engineis cold, the A/C compressoris on, the transmissionis in gear (A/T only) the brakepedalis depressed,
the P/Sloadis high,or the alternaloris charging,the ECMcontrolscurrentto the IAC Valveto maintaincorrectidlesoeed.

lgnition Timing Control

a The ECMcontainsmamoriesfor basicignitiontiming at variousenginespeedsand manifoldpressures.lgnitiontiming
is also adjustedfor enginecoolanttemperature.
a A KnockControlSystemis alsoused.when detonationis detectedby the knocksensof.the ignitiontiming is retarded
(B18Cl engine).

Other Control Functions

1. StartingControl
When the engineis started.the ECM providesa rich mixture by increasingfuel injectorduration.
2. Fuel Pump Control
a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-Flmain relaythat supplies
currentto the fuel pump tor two secondsto pressurizethe tuel system.
a When the engineis running,the ECMsuppliesgfound to the PGM-Flmain relaythat suppliescurrentto the fuel pump.
a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FImain relavwhich cuts
current to the fuel pump.

11-40
3. Fuel Cut-oft Control
a During decelerationwith the throttle valve closed, current to the {uel injectors is cut otJ to improve fuel economy
at speeds over tollowing rpm:
. 8188l engine:91O tpm (Canadamodel: 1,O50 rpm)
. 818C1 engine:95O tpm (Canadamodel: l,O5O rpm)

a Fuelcut-olf actionalsotakes placewhen enginespeedexceeds,7,O0Orpm {818B1 engine),8,1O0 rpm (B18Cl

engine), regardlessoI the position of the throttle valve, to protect the engine from ovet-revving.

4. A/C CompressorClutch Relay

When the ECM receivesa domand for cooling trom the air conditioning system, it del8ys the compressorfrom being
enetgized,and enriches the mixture to assure smooth transition to the A/C mode.

EvaporativeEmission(EVAP)PurgeControlSolenoidValve
Whenthe enginecoolanttemperstureis below 163oF {73"C), the ECMsuppliesa groundto the EVAPpu.gecontrol
solenoid valve which cuts vacuum to the EVAP purge control diaphragm valve.

6 . Intake Air Bypsss (lAB) Control Sol€noid Valve

When the enginerpm is below 5,750 rpm, the IAB control solenoidvalve is activatedby a signalfrom the ECM,
intske air flows through the long intake path, then high torque is delivered. At spaeds highe. than 5,750 rpm, the
solenoid valve is deactivated by the ECM, and intake air flows through the short intake path in order to reduce the
resistancein airflow.

ECM fail-safe/bEck-upFunctions
1. Fail-sateFunction
When an abnormalityoccursin a signalfrom a sensor,the ECM ignoresthat signaland assumesa pre-progtammed
value tor that sensorthat allows the engineto continueto run.

Back-uDFunction
When an abnormalitv occurs in the ECM itself, the fuel iniectors are controlled by a back-up citcuit independentof
the system in order to permit minimaldriving.

2 Self-diagnosisFunctionIMaltunctionIndicatorLamp {MlL)1
Wh6n an abnormalityoccurs in a signalfrom a sensor,the ECM suppliesground for the MIL and stores the code
in erasablememory.When the ignitionis initiallyturned on, the ECM suppliesgroundtor the MIL tor two seconds
to check the MIL bulb condition.

4. Two Trio Detection Method

To prevent tals€ indications, th€ Two Trip Dstection Method is used for the HO2S and fuel metering-relatedself-
diagnostictunctions.When an abnormslityoccurs,the ECM stores it in its memo.y. Wh€n the ssme sbnormality
recursalter the ignitionswitch is turned OFF and ON ag8in,the ECM informs the driver by lightingthe MlL.
However, to ease troubleshooting, this function is canc€ll€d when you short the service check connector. The MIL
will then blink immedistelvwhen an abnormalityoccurs.

11-41
PGM-FISystem
EngineControlModule(ECM)
NOTE: lf this svmptom is intermittent.check for a loosefuse No. 15 (BACK
The Malfunction Indicator Lamp UP LIGHT,1OA)in the under-dashJuse/relaybox, a poor connectionat ECM
(MlL) n6v6. com6s on lovon fol terminalA13, or an intermittentopen in the GRN/ORNwire betweenthe ECM
lwo socondal aftor ignition is (A13) and the gauge assembly.
tumed on.

lurn the ignitionswitch ON.

InspectNo. 15 {BACK-UPLIGHT}
ls the low oil pressurelight on? l1O A) luse in the underdash
tuse/relay box.
- R€placo No. 'l5
IBACK-UP LIGHT)
Turn lhe ignition switch OFF.
llo Al fuso.
- Ropair short in
ls the fuse OK? YEL wiro botwoon
No. 15 (BACK-UP
Conneclthe test harnessbetween LIGHT){10 A) fuso
the ECM and connectors (see ano gauge 6$om-
p a g €1 1 - 3 7 ) .
Repairopon in YEL wiio botw6on blv.
No.'15IBACK-UPLIGHTI110 A)
luso and gaug6 assombly.

I A13
I| | o o o o o o o o o o o o o I o o o o o o o o I o o o o o o l o o o o o o o o o o o I
Turn the ignitionswitch ON.

- RsDlacotho MIL bulb.

- Ropairopon in GRN/ORNwi.e
l s t h e M I Lo n ?
betwoen ECM {A13} and
gaug€ a$6mbly.

lB18B1 onginoonlyl

Measure voltage between body

Oroundand the tollowingtermi-
nafs individuallv:423, 424.

Ropah op6n in BLK wirolsl bo-

tw6en ECM and GlOl llocatod at
ls there less than 1.O V?
thormostat housing) that had
moro than 1.0 V.
G 10'l

Substituto a known-good ECM

and rochgck, lf symptom/indica-
tion go€s away, roplacotho origi-
nal ECM.

11-42

Th. ll.lfunction Indicltor Lamp
lMlll at!y3 on o. cornaaon alt6l
two aacond!.
Connectthe SCS short connector
to th6 sorvice check connector
(see page 11-34).
Turn the ignition switch ON.
Doesthe MIL indicateanv Oi-
agnostic Trouble Code (DTC)?
Romoveth€ SCS shon connector
lrom the service ch€ck connector.
Try to start the engine.
InsDoctECU{ECM)115A) tuse in
th6 undeFhood luse/relav box.
ls the luss OK?
'NOTE: After repair,disconnectthe SCS Short
Connsctor,test drivethe car, and rechecktheMIL
lor a code.
(To page 1 'l -44)
NOTE:
a Whenthere is no code stored,the MIL willstay on if the servicecheckcon-
nector is shorted.
a tf this svmotom is intermittent,check for:
- A loose ECM fuse (15A) in the under-hoodtuse/relaybox
- A looseNo. 24 fuse (ACG)(ALT)( 1 5A: B18B1 engine,2OA: B18C1 en-
gine) in the under-dashfuse/relaybox
- An intermittentshort in the BRN/WHTwire betweenthe ECM (D4) and
the servicecheck connector
- An intermittentoDenin the BLK wire betweenthe servicecheck con-
nector and G4O1
- An intermittentshon in the GRN/ORNwire betweenthe ECM(A 13) and
the gauge assembly.
- An intermittentshort in the YELMHT wire betweenthe ECM (D19)and
the MAP sensor
- An intermittentshort in the YEL/BLUwire betweenthe ECM (D20) and
the TP sensor
Go to iolfdiagnostic Proceduros
(se€ pago 11-34).
o o o o o o o o o o o o o l o o o o o o o o l i i i : $ A $ . P s ,ol o o o o o o o o o o
ooooooooooooo I oooooooo oooooooooo
D 4( + ) D22 t-l
Turn the ignition switch OFF.
uu,l
l"oo,o'.
Connectthe test harnessbetween
the ECM and connectors (see
p a g e1 1 - 3 7 ) .
Turn the ignitionswitch ON.
Measurevoltage botween D4 (+ )
terminaland D22 { - ) terminal.
connect the SCS shon
ls thereapprox.5 V? connector to servlce
check connector.
Ropair shon to body g.ound in
BRN/WHT wire betwoon th6 ECM Measure voltage be_
lD4) end sorvlco chock connocto?. tween D4 {+} terminal
and body ground.
- R6pairopen in BRN/WHTwito
botwoon EcM lD4) and s6rv-
ice chock connactor.
- Repoir opon in BLK wiro bo- ls thereapprox.5 V?
twoon 36rvi@ chock connectoa
and G4Ol.
- RsolacoECU{ECM}(15 Allus€. Removethe scs short
- R6pairshon in YEL/WHT wilo Connector from the
botw6on ECU lEcMl 115 A) service check con-
fuso and PGM-FI main rolay. nector.
(cont'd)
lTo page 1 1-44)
11-43
PGM-FISystem
EngineControl Module (ECMI (cont'dl
(Frompage 1 1-43) (Frompage 11-43)

Inspectthe No. 24ACG {ALT)(lG)

(15 A: 81881 engine, 2OA:
818C1 enginelfuse in the under-
dash fuse/relav box.
- R.pllr .hon in BLK|rEL wlr6 Disconnect"A" con-
batr.v€qr undariair luro/Fby nector from the ECM.
ls the fuse OK? box lnd FGM-FI m.in .obv.
- noebco lto. 24 ACG {lG) nLT)
(15 A: 81881 ongin., 2OA:
Bl8Cl onein.l tu!6.
Turn the ignition switch ON.

Subrtltute r knowngood ECM

.nd rochock. ll lymptom/indics- ls the MIL ON?
Disconnect the 3P connector ot tlon g@a rw!y, rephco tho origi-
each sensor one al a time: n.l ECM.
. MAP sensor
. TP sensor
Ropair short to body
giound in GRN/ORN
wir6 botwoon tho ECM
lA131 6nd MlL.

Rcplaoo thg lgnlor that caur6d

Doesthe MIL remainON? th. llght to Oo out.

Turn the ignition switch OFF.

Dt9
I

connect the test harness. I o o o o o o o o o oo o o I o o o o o o o o I o m o o o l o o o o o o o o o o o | |

Disconnect the "D" connector I o o o o o o o o o o o o o I o o o o o o o o 1 o ( ' o e ( l oI o o o o o o o o o o o | |
from th€ ECMonly, not the main - l

wire harness(see page 11-37). D2O I

\-.J
Continuity?
Check tor continuity between
body ground and D19, O2Oter-
minals,
- Bapai?rhod ro body g.ound in
YEL/WHT wi.e boiwoon ECM
(Dl9) .nd MAP ..n3or.
- R.p!k shon to body ground in
YEL/BLU wire b.lwo6n ECM
(O2Ol .nd TP 3on!or.
Reconnect all tho sensor con-
necrors,
Reconnectthe "D" connector to
rhe ECM.

Turn the ignitionswitch ON.

{ T o p a g e1 1 - 4 5 }

11-44
 (Frompage 1l-44)

Measure voltage between 426

{- ) andthe following:B'1(+ } and
A25 {+t.

BATTERY
VOLTAGET

- Ropsir opon in YEL/BLK wiro

ls there battery voltage?
botwoon ECM (425, 81l and
PGM-FIm6in relay.
- Chock PGM-FImain rclay and
wiring connectors at PIGM-FI
main.olay(soepsg6 11-1121.

Measurevoltage between body

ground and the tollowingtermi-
A23. A24, A26,
nalsindividually:
42.

- noprir opon in BLK wit. b6-

ls there less then 1.0 V?
Substitut6 r known{ood ECM
and r6chock. lf symptom/indica-
tion goos away, roplacotho origi-
nal ECM.
twson ECM 1A23, A24l and
G'101 {locatod al th6.mostat
housingl.
Repair opon in BRN/BLKwite
botweon ECM (A26, B2l and
Gl0r.

ooooooooooo oooooooo ooooooooooo

ooooooooooo ooooooo ooooooooooo

L€ssthan 1.0 V?

11-45
PGM-FISystem
HeatedOxygenSensorlHO2Sl
-fi-l:
-t6l-
:

--.-
t z
The Malfunction Indicator Lamp (MlL) indicates Diagnostic Troubls Code (DTC) 1: A problsm in
/ \ /?\ the HeatedOxygen Sonsor(HO2S| circuit.

The Heated Oxygen Sensor IHO2S) det€cts th6 oxygon contont in th6 exhaust gas and signals th6 ECM. In operation,
the ECM receiv€s th6 signals trom the sensor and vari€s the duration during which tu6l is iniocted. To stabilize thd sen-
aor's output, tho sensor has 8n intarnal heater and the sensor olemant is coatod with a catslyst. The HO2S is installod
in TWC housing(B18Cl engine)or exhaustpipe B (Bl8Bl €ngine).
sEl{SOR
TERMII{ALS
ztRcot{lA VOLTAGE(V} sTotcHtoltETnc
ELEiIE'{T AIR-FUEL
BANO

HEATER
- --.'!- - -__- HEATEB
TEBMIT{ALS
l r P l _ l! l - RICH - AN.
FUEL
- LEAI{

RATIO
- Th! mll h.. bo.n raportad on.
- Wlth thr SCS rhon coon cto.
connoctad lr.. p!9. 1t-341,
cod. t l. Indlcltrd.

Oo th€ ECM Res€t Procodure {soo

pag€ 11-35).

Stan the 6ngine. Hold th6 engine

A3,qgq rpm with no load {A/T in
Lrylor lll position, M/T in nourrall
until the radiator lan com6s on.
then lot it idle lor ot least on6
minutg beforo road t€6tin0.

Connoctths SCSshort connoctor

to th6 sorvic€ check connector
lsoo p.g6 1 1-34).

Rood t€st witlthe automatic

transmissionin L?l position (M/T:
4th gear).
Stsrting st l,600 rpm, acc6lorate
u6ing wide open throttlo for at
lesgt 5 seconds.Thsn dgcol€rste
for at lorst 5 s€conds with th€
throttlo completoly closed.

Intarmittd[ t llurc, lyri.m b Of

Ooes the MIL blink and doos it !l thla tlmc. Ch.ck lor poor con-
indic6t6 cod6 1? nacdona o? loota wlrat |l C223
(loc.trd at right $ock towo.l,
Cr 13 (HO2S| lnd ECM.

Go to plga and partonn tad fot

cod. 43 lr.a p.go l1-501.

1 1-4 6
mll )ffltl Lamp(MlL)indicates
Indicator
TheMalfunction TroubleCode(DTCI41: A problemin
Diagnostic
Y- -:- the HeatedOxygenSensor{HO2S)Heatercircuit.

-.----r- \- l-l
tt(gt- -t
- r - - - 7 r tt I

- Th6 MIL has boenroponod on.

- With the SCS rhort connoc-
to. connociod (aoe pago
11-341. codo 41 is indic.tod.

Do the ECM ResetProcedure{see

p a g e1 1 - 3 5 1 .

Intoamittont tdl||.g, ryr-

ls the MIL on and does it indi-
cste code 41?
Turn the ignition switch OFF.
t m i3 OK at thi! timo
(tost driv6 lnay bg ns-
cearatYl.
Chock tor poor conn6c-
tions or looro wires at
C223 llocatod at right
shod( row..l, C3O5 {lo-
cated 6t loft ahock low-
or), C424, C113
(HO2S) and ECM.

t€rminal side

Measurc tasistance betwgen ter-

minals3 snd 4 on the HO2S.

ls thero 1O-4O 0?

DIGITALMULTIMETEB
Commorciallyavailabloor
KS-AHM-32-OO3

(cont'd)

(To page 1 1-481

PGM-FISystem
HeatedOxygenSensorHeater(cont'd)
11-471

Check for continuity to body

groundon terminals3 and 4of the
HO2S.
YEL/BLK
I+I (-I
ORI{/BLK

Checkfor continuity betweenter wire side

minal4 and terminals1 and 2 in-
dividually.

Turn the ignitionswitch ON.

At the HO2S harness. measure

voltagebetweenYEL/BLK1f lteF
minal and ORN/BLK l-) ter- HO2S
mrnal. 44 N.m
{4.5 kgt.m, 33 lbf.ft}

YES
Turn the ignitionswitch OFF.

Disconnectthe "A" connector

Measure voltage between YEL/ from the ECM.
BLK l+) terminal and body
ground.

Turn the ignitionswitch ON.

At HO25 harness,measurevol-
tage between YEL/8LK(+) termi-
nal and ORN/BLK{-) terminal.

RoDair short in ORN/

ls there baftery voltage? BLK wir6 b6tw6on ECM
(A6l and HO2S.

Ropai.opon in YEL/BLK
wire botwoan HO2S
.nd PGM-FImain relav.

Turn the ignitionswitch OFF. Turn the ignitionswitch OFF.

{ T o p a g e1 1 - 4 9 )
{ T o p a g e1 1 - 4 9 }

11-48
 "A"
Connect the test harness
connector to the main wire har
ness only, not the ECM (seepage
11 - 3 7 1 .

Connectan ammetetbetweenter-
minalsA6 {+ ) and 426 (- )

* Monitor over a 5 minute Deriodunl6ss Turn the ignitionswitch ON.

the current drops below O.1A im-
mediatelv.

ls the current less than

0.1A?.

Subrtitulo s known-good ECM

.nd r.ch6ck. lf symptom/indica-
tion goes away. roplacotho origi-
n.l ECM.

Connoct the test harn€ss "A"

connector to the main wire har-
n6ss only. not th€ €CM {seopage BATTERY o o o o o o o o o o o o o I o o o o o o o o ooooooooooo
't't-37).
VOLTAGE?o o Q o o o o o o o o o o I o o o o o o o o ooooooooooo

Turn the ignition switch ON.

L-E;
Measwe vohage bstween A6 {+ }
tg.minaland A23 {-)terminal.

Ropsii op6n in ORN/BLKwiro bo-

tw..n ECM {A6l and tho HO2S.

Subrtiluto s known{ood ECM

lnd Echock. ll .ympiom/indic{-
tirn god !way, '.pLc! f|e origl-
h.l ECM.

11-49
PGM-FISystem
Fuel Supply System

rj-t T,-n The MaltunctionIndicatorLamp (MlL) indicaresDiagnosticTroubleCode (DTC)43: A problemin

- - t - . - L:!-i - the HeatedOxygen Sensor(HO2S)circuit. or a probtemin the Fuel Supply System.

-+-
l- t @"-t - -- t--i--
1 3|
'

- Tho MIL h.s boenreportodon. From codr I troebl.-

- With rhe SCS short con- lhoorlng lprgo 1146).
noctor connocted (soo paga
1l-34), codo 43 b indlcat.d,

ls the code 43 accompanied by Go to Fuol Supply .y.t.m (|ec

the MIL and poor driveability? pag6 1t-971.

Do the ECM Resetftocedure lsee

p a g e1 1 - 3 5 ) .

Connectthe SCSshort connector

to the service check connector
'l1-34).
{see page

Start the engine. Hold the engine

at 3,00O rDm with no load {A/T in
@or@ position,M/T in neutral)
until the radiator Ian comes on,
then let it idle for at least one
manute,

Intonnitl.nt t llure, tydom lr OK

Raisethe enginespeedto 3,000
rpm and hold that throttle position
tor at least one minute.
Do not vary the throttle position
even if the rpm drops.
at thi. tim. lto.t drlv. mly b.
nocaararyr.
Chock lor poo? connactlona ot
loots wiro at C223 lloc.t.d at
rlghl lhock towo.]. Cl13lHO2Sl
and ECM,

Ooesthe MIL blink and does it

indicatecode 43?

NOTE:
. UseDIGITAL MULTIMETER.
Turn the ignitionswilch OFF. . U6e2 Volt rang6.

Connectthe test harnessbetween o oooooo oooooo I oo oooooo ooooooooooo

the ECM and conneclors {see ooQooooo ooooo I oooo oooo ooooooooooo
p a g e1 1 - 3 7 1 . 426
JUMPERWIRE
With the ignitionswitch OFF,wait
for at least two minutes. o ooooo oooo ooo I oo oooooo Isdtcllodsl ooo oooooooo
o oooo ooo oo ooo I oooo oooo ooooooooooo
lnstalla jumper wire on the test 426 t-l vohrgo rhould rl.n.t D 1 4{ + l
harnessbetween A6 and A26. |.- 0.4-0.5 V wh.n th.
ignirioo .wilch i! fird
I
t|rtrod o.r, Itd docr!6a
1Topage 1 1-5'll to b.low O.1 V in L..
th6n two minutaa.

11-50
 {Frompage I 1-5O)

Turn the ignition switch ON.

Measure voltage between o14

(+ l terminaland A26 (- I termi-
nal as soon as the ignition switch Msasuro voltage between D14
is turned on. (+) le.minal snd 426 l-) ter-

ls there O.1 V or less when the

igniiion switch is first tu.ned ls ther€ more than O.1 V?
on?

Turn the ignition switch OFF.

Disconnect the "D" connoctor

from the main wire h6rness.

Turn th€ ignition switch ON.

Measure volt6ge betwesn D14

l+) terminal and A26 (-) ter-
minal.

Measure voltage al th€ ongino

wire harnsss sid€ ol the HO2S R.pri. rhort in WHT/
conngctor botween WHT/RED ls there more than O.1 V? REDwire betwo€n ECM
{+)and GRN/BLU (- ). (Dl41 rnd lho HO2S.

Subdlht. . known{ood ECM

.nd r..firck. ll rymptom/indic!-
tion goaa !w!y, .aphca rha otigl-
nll ECM.

ls thero moro than O.1 V?

(+)
WHT/RED (-I
GRI{/BLU
Ch.ck for oDcn in WHT/RED wir.
brrworn ECM (D141 .nd lh.
HO2S. It wl]o l. OK, .oprir op€n
iD GRil/8LU rvlr. b.tw..n ECM
lD22l lnd thc HO2S. wire side

DIGITALMULIIMETER
avallabloo.
Commarcially
KS-AHM-32-OO3 HO25
44 N.m (4.5 kgl.m, 33 lbf.ftl

11 - 5 1
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor

fxai - lfil1 The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 3: An electrical

-:- -?- problemin the ManifoldAbsolutePressure(MAPI Sensorcircuit.

The MAP sbnsorconvertsmanitoldabsolutepressureinto electricalsignalsand inputs the ECM.

SENSOR OUTPUT
VOLTAGE

1.5

(in. Hsl GAUGE

600 700 READIIIO
{mft Hg)
- Tho MIL has boon roportod on.
- Wirh tho SCS rhort connoctor
connectod lsoo pags 11-34),
codo 3 b indicatsd.

Do the ECM ResetProcedure{soe

p a g e1 1 - 3 5 ) .

Intormittont tailuro, lystom ir Ol(

at thls timo {tort drivo may bs
nocessary).
ls the MIL on and does it indi-
Chack to? Door connocllon oi
cate code 3? loosa wiroa 6t C223 {locltod at
right shock tow6rl, C'l 14 (MAP YEL/REDlBlSBl onginc)
sonaorl and ECM. YEL^YHTlBlaCl .ngin.l | + I

Turn the ignitionswitch OFF.

{+l

Disconnectthe 3P connectortrom
the MAP sensor,

Turn the ignitionswitch ON.

{ T o p a g e1 1 - 5 3 )

11 -5 2
 11,52)

Measurevoltage between YEL/

WHT {818C1 engine),YEL/RED
(B188'1engine){+ ) terminaland
bodv ground.

Measure voltage between YEL/

WHT (818C1 engine),YEL/RED
ls there approx. 5 V?
{B1881engine)(+ } terminaland
GRN/WHT(- ) terminal.

Turn the ionitionswitch OFF. Repair opon in GRN/

WHT wir6 botweon
ls there approi. 5 V?
ECM lD2l l and tho
MAP sonsor,
Connect the test harness "D"
connectorto the ECMonly, notto
the main wire harness {see page
11,37).

Turn the ignitionswitch ON.

Measurevoltage betweon wHT/

Measurevoltage between D19 YEL (+ ) terminaland GRN/WHT
{+} terminaland D21 {-} {- } terminal.
termrnat,

ls there approx. 5 V?

Bepairopen in YEL/WHTwi.e be-

tw€6n ECM lD19) and tho MAP
aon30t.

ls there approx. 5 V?
Substitule s known-good ECM
and rechock. ll symptom/indica'
tion goes away, replac€tho oiigi'
nal ECM. Turn the ignitionswitch OFF.

Reconnecl the 3P connector to

the MAP sensor.

Connectthe test harnessbetween

the ECMand connector(seepage
11 - 3 7 1 .

Turn the ignitionswitch ON.

(cont'd)
{ T o p a g e1 1 - 5 4 } lTo page I l-54)
PGM-FISystem
ManifoldAbsolutePressure{MAPISensor(cont'd)
l F r o mp a g e1 1 - 5 3 ) (Frompaqe 1 1-53)

M6asure voltage between D17

{+) terminaland 021 (-}
terminal.

Turn the ignitionswitch OFF.

Connect the test harness "D"

connectorto the ECMonly. not to
the main wire harness lsee page ls there approx.3 V?
11-37).

Substituto 6 known{ood ECM

Turn the ignitionswitch ON. .nd rach.ck. It symptom/indica-
tion gooa away, Eplaco tho orlgi-
nrl €CM.

Measurevoltage botwson Dl7

approx.3 v?
( + ) t e r m i n a la n d D 2 1 { - } -
terminal. D 1 7t i l D 2 1( - l
ooooooooooooo I oooooooo l l 5 o i E € t d lo o o o o o o
o oooooooooooo ! oooooooo ooooooooooo

R.p.lr opon or ahort in WHT|rEL

ls there approx. 5 V? wi?obotw.on ECM {O17) and tho
MAP senso..
NO

Substitute a known{ood ECM

and rochsck. It prdcribed voltrgo
b now availablo, rophce trie origi-
nal ECM.

11-54
' . - - - . - '
PGM-FISystem
TDC/CKP/CYP
Sensor
_f'=l_ fi_l The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)4: A problemin
t:- the CrankshaftPosition(CKP)Sensorcircuir.

l'6]- ftl
- The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 8: A problemin
-i-
the ToD Dead Center ITDC) Sensorcircuit.

-flG]l- The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)9: A problemin

- ft-]
, - the CvlinderPositionICYP)Sensorcircuit.

The CKP Sensordeterminestiming tor fuel injectionand ignitionof each cylinderand also detects enginespeed.The
TDC Sensordeterminesignitiontiming at start-up(cranking)and when crank angleis abnormal.The CYPSensordetects
the positionof No. 1 cylindertor sequentialfudl injectionto each cylinder.

- \.--r-l - -__l_-
tPJ:;LlJ:lEl--;?
l ,:
- Tho MIL hos beonroponod on.
- With rho SCS short connoctor
conneclod lsso pago I l-341,
code 4, 8 and/or 9 ar6 in-
dicated.

Do the ECM Resetprocedure(see

p a g e1 1 - 3 5 ) .

Intohittent failuro, syst€m is OK

ls the MiL on and does it in-
dicate code 4, 8 and/or 9?
at thia tima {t6st drivo may be
noceaSaayr.
Chock for poo. connections or
looss wires at C222 (located at
right shock towerl, C110
(TOC/CKP/CYP Sonsorland ECM.

Turn the ignitionswitch OFF.

Disconnectthe 8P connectorfrom
the TDC/CKP/CYP sensor.

{To page 1 1-57)

11-56
 { F r o mp a g e 1 1 - 5 6 )

SENSOR ECM
Measureresistancebetween ter- SEIiSOF DTC
TENMINAI COLOR
minalsof the indicatedsensor. 2 815 ATU/GFN
'see table
6 816 BTUTVEI
813 ORN/BTU
TDC a
814
R.olac6 th. distributor
ls there 35O-7O0 0? housing (8oo aoction 9
B1t ORN
231. a s12

Check for continuity to body

ground on both terminalsot the
indicatedsensor,

Rgplace tho di.tributor

housing llo€ loction
23t.

Connect the test harness to the

main wire harnessonly, notto the
ECM (see page 1 1-371.

Measureresistancebetween ter- o oooooo oo ooo o I oooooooo l6coocl o oo ooo ooooo

minalsof the indicatedsensoron o oooo ooooo ooo I oooo oooo lo{nofioo't oooooooo ooo
test harness.
'see table

812
350-7000?

Roprir opon in tho indi-

ls there 350 70O 0? cated senaoawirea.
*soo tablo

Check for continuity to body

groundon 815. 813 and/orB'l 1
terminals.

Repair short to body

ground in tho indicrl.d
ls there continuity?
t€naor wiroa.
i s€e tabla
NO

Substituto a known-good ECM

and rechock. lf symptom/indica-
tion goes away. roplacotho origi-
n.l ECM.

11-57
PGM-FISystem
Engine Coolant Temperature(ECT) Sensor
- ,-!-- \ ---1- -
-l 6
t@l- - | - The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)6: A problemin
the EngineCoolantTemperature(ECT)Sensorcircuit.
The ECT Sensoris a temperaturedependantresistor(thermistor).The resistanceoI the thermistordecreasesas th€ en-
gine coolant tempe.atureincreasesas shown below. RESISTANCE
{k0l

-
JrsG-11 - -\.--r-l
t 5| j 3 2 6 8 l O r rl a 0 t 7 6 2 t 2 2 a 8( . F l
-2tt 0 20 rto ao D r@ t20 (,cl
\ /--i- \
ENGII{ECOOLAI{TTCMPERATURE
- Th€ MIL has boon roDortodon.
- Wlth tho SCS shon connoctor
connoctod {s66 pag6 '11-34},
code 6 is indicatod.

Do the ECM ResetProcedu.elsee

page 1 1-35).

Turn the ignitionswitch ON.

Intoimittont failur6. ryatom is OK
el this lime ltosl d.ive may bo
ls the MIL on and does it indi- nocassaryl.
cate code 6? Chock for poor connsctiona or
looso wiros al C223 {locatod at
tight shock lowor, C111 (ECT
sonsorl,C419 {TCMI and ECM.
Start the engine. Hold the engine
at 3,O0Orom with no load {Afi in
N or lF]position,M/T in neutral)
until the radiatorlan comes on,
then lot it idle.

Turn the ignitionswirch OFF.

Disconnectthe 2P conneclorlrom
the ECT sensor.

Measure resistancebetween the

2 terminalson the ECT sensor.

ls there 2OO-4OOO?

(To page 1 1-59)

11-58
--
 ECT SENSOR

Turn the ignitionswitch ON.

Measure voltage betweon RED/

WHT and body ground.

Measure voltage between RED/

ls there approx. 5 V? WHT {+}terminal and GRN/8LU
(- ) terminal.

GRN/BLU
{-}

ls there approx. 5 V? Ropai. opon in GRN/

BLU wiro botwoon ECM
Turn the ignitionswitch OFF. (D221 and tho ECT
36n3('r.
Sub3tituto a known-good €CM
and rochock. lf 3ymptom/indica-
tion go6s away, roplacothe odgi-
nal ECM.
A/T only

Oisconnectthe 22P connector

trom the Transmission Control
Module (TCM).

Turn the ignitionswitch ON.

ls there approx. 5 V7

Turn the ignitionswitch OFFand

reconnect the connector to the
I
TCM.
_i

Connect the test harn€ss "D"

connectorto the ECMonly. not to
the main wire harness {see page
11-37).

Turn the ignitionswitch ON.

Measurevoltage between D13

(+) terminal and D22 (-l ter-
mlnal.

Repair opoa or shon in

REO/WHTwiro botwoen ECM
ls the.e approx. 5 V? lDl3l and th6 ECT sonsor.
R6pairshon in REO/WHTYYi..
b6tw66n ECM{D131andTCM.

Substiluto a known-good ECM

and rochock. ll lymptom/indica-
tion goea6wsy, replacotho o.igi-
n6l ECM,

11-59
PGM-FISystem
ThrottlePosition(TPl Sensor
.:-\.----
-ll@l--l The MalfunctionIndicatorLamp(MtL)indicateeDiagnosticTroubleCod€(DTC)7: A problcmin
t l-
rhe ThronlePosition(TPl Sonsorcircuit.
TheTPSensoris a potsntiometer,lt is connectedto the throttlevalveshaft.A8 the throttlopositionchan96, the throttlo
positaonsensorvariesthe voltagesignalto the ECM.
BBUSH
HOLDER OUTPUTVOLTAGEIV)
BNUSH I
a
t
RESISTOF
t
I
o.| IXNOTTII
o
TERMIIIAL ;0rr- of€ no
THNOTTIE
)ran1 )ril
-Y- -?..
- Th. MIL h.. baln rlport d on.
- With th. SCS thort conn.ciol
conn.c-ted (rco pngc 11-341.
codo 7 i. indlc.t d.

Do the ECM Resethocedure (se€

page l 'l-35).

l. ..mrtt nt fClur., lyrt m la OX

ls the MIL on and do€s it
indicats codo 7?
Turn th€ ignition switch OFF.
.t thb dm. ll.at drlv. rn.y br
ncoaataryl.
Chack lor poo? connactlo|ra ot
loora wlr.r !t C223 lloc.t d !t
dgtn drod( tow..t, Cl15 ITP ...t-
rorl, C419 (TCMI .nd ECM.
YEL/aLUl+l TP SEITSOR
RED/BLK
{-I

Disconnecttho 3P connectorlrom cnn/BLuI - l

th€ TP sensor.

Turn the ignition switch ON.

Meosu.o voltage betwoon YEL/

BLU (i ) terminaland GRN/BLU
I -, torminal.

Measurs voltagG betw66n YEU

ls there approx. 5 V? BLU (+l terminal and body
giound.

(To page 1 1-6'l)

(To page 1 1-611

11-60
,,,----
 (From 1 1-60) {From page 1 1-60)

Repsir op.n in GRN/

8LU wii6 botwoon ECM
Turn the ignitionswitch OFF. ls there approx. 5 V ?
lD22l snd tho TP
aenaot.

Turn the ignition switch OFF.

Connectthe test hamessbetween

Connectthe test harnessbetween the ECMand connector{seepage
the ECM and connectors (see 11-37).
page 11-37l-.

Turn the ignitionswitch ON.

Turn the ignilion switch ON.

Measure voltage between D2O
{ + ) t e r m i n sal n d D 2 2 { - }
termtnal,
Ropoi. open in YEL/BLU
wire bgtween ECM
ls there approx. 5 V 7
{D20} and rho TP
30naot.

-ReDai. ahort in YEL/BLU wiro

borwoonECM (D2Oland tho TP
son30t.
-Sub3tituto a known-good ECM
Measure 6nd rochock. It prcacribodvol-
voltagebetweenD11 {+ )
t6go is now availablo, roplaco
terminaland 022 (- I terminal.
th6 original ECM.

Fr. o.5 v n tua .b drdn ?

A/T only

Turn the ignitionswitch OFF.

ls voltageapprox.O.5 V at lull
close throtlle. and approx. 4 v Disconnect the 22P connector
at full open throttle? from the Transmission Control
NOTE:Thereshouldbe a
Module (TCM).
smooth transition as the throt-
tle is depressed.

lurn the ignitionswitch ON.

Substitute a known-good ECM
and roch6ck. ll symptom/indica-
tion 9063 away, roplacoth6 origi- ls voltageapprox.0.5 V ar full - Replaco tho TP
nal ECM. close throttle, and approx. 4 V aonsoa,
at tull open throttle? - Repai. opon or ahon
NOTE:There shouldbe a in RED/BLKwir. b€-
smooth transition as the throt' twoon ECM lDl1l,
tle is deprossod. TCM 6nd TP sonsor.

11-61
PGM-FISystem
IntakeAir Temperature(lAT) Sensor
\ ----:-- z \ ---L /
-h6l-
/ I- t0 l-\ The MalfunctionIndicatorLamp (MlL) indicstesDiagnosticTroubleCod6 (DTC) 1O: A problemin
| \ / the Intake Air TemDerature(lAT) Sensorcircuit,
The IAT Sensor is a temperature dependant resistor (the.mistor). The resistanc€ of the thermistor d6creases8s the
intake air temDeratura incroases as shown below.

RESTSTAXCE
tmt

THERMISTOR -a a2 aa roa .t7a 212 a t |l

-20 o 20 rto ao I t6 rro t.cl

I TAKE AIR TEiiIPTFATURE

)1611:till
---l- ---i-\
/ \ z

- Th! *llL hs b!!n Egortad on.

- \|\rrdrdra SCS rhon connrcto.
conn.ct.d lt . psg. 1l-341. Bl8Bl onglnc:
cod. 10 l. hdlclt.d.

Do the ECM Resot kocoduro {se€ wi.a sido

pago 11-35).

Turn the ignition switch ON.

Into.n{tlont failuro. rys-
r.m ir OK .t thi. iim.
(toat drlvc m6y b6
arooa!!1ryt.
ls the MIL on and doos it
Ched( tor poor clnncc-
indicate code 10 ?
lioiE or loote wlrar 6t
C223 lloc.tod right
lhock toworl, C12O
(lAT renrcrl and ECM.
Turn the ignition swiich OFF.

Oisconnoct tho 2P connector from

the IAT sensor.

818C1 .nglnc: IAT SEI{SOR

Meosu.eresistonc€ betweenthe
2 torminalson the IAT aengor.

ls thero 0.4-4.0 k0? Rlobco tho IAT aonsor.

(To pago 1'l-63)

RED/YELI+ )

11-62
 {Frompag6 l1-62}

Turn the ignition switch ON.

Messuro voltage b€tw€6n RED/

YEL (+) terminal and body
ground.

M€asurs voltage between RED/

ls thore approx. 5 V ? YEL {+) rerminaland GRN/BLU
{ - I terminal,

Rsp.lr op.n in GBt{/

Turn the ignition switch OFF.
Connsct lhg t€st hamess "D"
connoctorto the ECMonly. not to
th6 main wire harness lsse page
11-371.
8LU wir bctwo.r ECM
ls thero a99rox. 5 V ?
lD22l snd tho IAT
aanaor.
Sub.lhul. a tnown{ood ECM
lnd rachack. It rymptom/lndlc!-
don gort arv.y, t pl.c. dr! oilgl-
n.l ECM.

Turn tho ignition switch ON.

Mgasur€ voltag€ bstwgon D15

(+) terminal and D22 l-l
tgrminal.

Rap.lr opon or rhon In REDfYEL

ls th€re spprox. 5 V ? wh. b.tw..n ECM lDl5l rnd th.
lAf tcrrao.-

S0brlitrrt. . lnown{ood ECM

'|d '.<hoc-l, tl p.slcribad voltlec
ta now lvarlblc, rlplaca tha origi-
nal ECM.

11 - 6 3
PGM-FISystem
BarometricPressure(BAROISensor

fAl- f;ff: The MaltuncrionIndicatorLamp (MtL) indicatesDiagnosticTroubteCode (DTCI 13: A probtemin

L--:g the BarometricPressure{BARO)Sensor.

The BARO Sensoris built into the ECM.

-.+.-- \--r- /
/
t ( g t - t 1 3t -
' \ / _ i - \

- Tho MIL has booo reponod on.

with th6 scs Short COnnOCtO.
connoctod (aeo psgo 11-34),
cod€ 13 is indicatod.

Do the ECM ResetProcedurc(see

p a g e1 ' l - 3 5 ) .

Turn the ignitionswitch ON.

Intormitt€nt trluro, sys-

ls the MIL on and doesit indicate tem is OK !l this timo
c o d e1 3 ? {le!t driv6 msy bo
necoSaaiy).

Substituto . knorvn-good ECM

and reck6ck. lt symptom/indicr-
tion goes away, roplacoth6 origi-
nal ECM.

11 -6 4
 PGM-FISystem
lgnition Output Signal

i16;11 :ffi1 The MalfunctionIndicatorLamp(MlLl indic8tesDiagnosticTroubleCode(DTC)15: A probl€min

'--=-- . -r- t the lgnitionOutput Signslcircuir.

- Th. MIL hsr b..n roport.d od.

- Widr ths SCS .hon cohnecto.
connoct€d {..o plgo 11-341,
codg |5 i! indicatrd.

Do the ECM Reset ftocedure (see

page 'l'l-351.

NOTE| ll the onoine won't stan. it

may take 20 seconds ot cranking to
5€t th€ COde.

Intarmltt nt hllur.. ryltam i. OK

!t drlr dm. (t |l drlva mly bo
ls th€ MIL on and do€s it indicate naoaaalry).
code 15 ? Chack tor Door cmnactiona or
loo|. rYlrar !t C223 llocltld !t
rlghr .hoct tow.rl, Cl10 (lCMl
.nd ECM.
Turn the ignition swirch OFF.
I

D|STNIBUTOB

Turn the ignitionswitch ON.

Measure voltage betwoon BLK/ wir6 sido

YEL (+) terminal snd body
grouno.

R.p.ir op.n In BLK/YELwlr. bo-

ls the.e battory voltage ? ftvarn th. 2P conn.cior lnd ioni-
tion rwitch.

(To page 11-67)

11-66
 Turn tho ignition 3witch OFF.

TTERYVOLTAGE4
421 (+l
ooooooooooooo
Connoct th€ toat hamess bgtwe,sn
the ECM and conn€ctors {see oooooooooooo
pago 11-371.

Turn th6 ignition switch ON.

Measurc voltags betwe€n A21

{+) te.minaland A26 {-}
t6rminal.
- R.pl.c. th! lC (trr..ctlo[
23t.
ls th6re bottory vollsge 7 - napllr op.n or .ho?t In
YEL/GB'{wlrc b.tw.cn ICM
..d Eciil lA21l.

NoTEr lf rhe YEL/GRNwke was shortsd,

tho ICM may bo damaged.
Sub.thut. ! known{ood ECM
.nd r.ck ck. ]t .ymptom/lndlc.-
don go.. !w!y, ..pbc. lha odgl-
n.l ECM.

11-67
PGM-FISystem
Vehicle Speed Sensor (VSS)
- _-_f_-., \-=1_ -
It6l- IndicatorLamp(MtL)indicateE Diagnostic Trouble Code IDTC) 17: A problem in
-l tl' l- The Maltuncrion
ths VehicloSD6sd(VSS)circuit.
The VSS generates a pulsing signal when the front wheels turn.

- Tha mll hs b..n ltgortld o.r.

* Yvlrh th. Sc]S $o.r coi[cto.
connast.d l... ploa I l -341,
cod! 17 i. Indlc.i.d.

Do the ECM Basot Procodur6 16€€

pag€ I I -351.

Roadrosr whh A/T in13 positaon

{M/T: in 2nd O6ar),accol6rat6to
4,OOO rpm, thon d6c6l6,ate to
1,5OO .pm with th.ottlo fully
closod tor at loast 5 s6conds.

Int rmltllrt t llur., .yrtam b O|(

.t drlr drr.
ls th6 MIL on and doos it indic.t6
'l7 Chcct lor poor conicctlon! oa
code ? lootc wl... !t C3O50ocrtad rt
Ltt rhod. torr.l, eA24. C112
IVSA).nd ECil.

Block roar whe€19 and 5st th6 @4""r

parking brsko. Jsck up th€ f.ont r.r whadr b.lor.
of the c6. and support with saf€- l.d.lnC up tront ol
iy standa. cat,

Turn the ignition Bwitch OFF.

Connect tho t€st hamos3 b€tw€€n

tho ECM ond connoctora {as€
p a g 61 1 - 3 7 ) .

Tu.n th€ ignitioh switch ON.

Block the .ight lront whoel and a 2 5{ - t atol+l

alowly rctato loft tront wh6ol and
m6asur6 voltago b€twoon BlO 0- 10V ?
{+) torminal and A26 l-}
terminal. in llj positionlA/Tl.
NOTE:Transmission

Doss voltago puleo O V and

10 v? Tu.n th€ ignition switch OFF.

Sub|tllul. ! knosn{ood ECM

lnd r!ch.ck. lt .Vmgiom/lndlc.-
tlon g@.. .w.y, r.pLca di. orlgl-
n.l ECM.
lTo p6ge 1 1-691

11-68
 (Frompage 1 1-68)

Disconnect the "B" connector

from the ECM only, not the main
wile hatness.

Turn the ignitionswitch ON.

Block tho right front who€l and

slowlv rotate l6ft front wheel and
m€asure voltage between 8'l O
l+) terminaland A26 (-) - Roo.ir lhort in ORt{
terminal.
wire belween ECM
18101tnd rhs VSS
or cruia6 control
unit.
Doos voltage pulso O V and -
'tov? ncp.i. op€n in ORI{
wira botwoan ECM
(8101and the vSS.
- It wir. i! OK, tott
tho vSS. lsoc aec-
SubrtituL . known-good ECil lnd
tion 231
Ech.ck. fi lynptom/ndcltbn gp..
rw!y, .rpleco lh. originalECM.

11 - 6 9
PGM-FISystem
ElectricalLoad Detector (ELDI
tft;-]/ The Maltunction Indicaror Lamp (MlL) indicatss Diagnostic Trouble Code IDTC) 20: A probtem in
-Li!- tne ElectricalLoad Detecror{ELD}circuit.

With lho SCS lhon connectol

connoctod {ree pago 11-34}, cod.
20 is indicatod.

Do the ECM B6setProcedurs{see

page 1 'l-35).

Start engine and keep engin€

speed at idle.
Turn on headlights.
lntennlna tlllure, lyrtom lt Ol(
!t irl. dm. (lgtt driv. mly bo
Ooes the MIL indicato code 20? na@raaryl.
Chrck for Door connactlona oa
loota wiro. rt C218 IELD, lnd
Ectrt.

View trom
wire side

B L K( - )
Romove the undgr-hood fusg/
relay box and remove the tus6/
relav box lowet cover.
GRn/iEDI - |

BLK/YELI + I

Turn lhe ignition switch ON.

Measure voltage betw€on BLK/

YEL (+l terminal and BLK (-)
terminal.

Msasuro voltag€ b€tweon BLK/

ls there bartory voltagel Y€L {+) terminal snd bodv
ground.

Rcpir oo.n in BLK wir.

batwaan lha 3P connrc-
tor lnd G2Ol {loc.t.d
troit ot angh|. comprn-
m.r dghl .ld.l,

B.p.lr op.n in BLKrYEL wlrr b.-

tw..n o.24ACG (ALn flcl115
A: Bl88l .ngln!, 20 A:818C1
cnginol fu!. In thr und.r{..h
tu.o/r.lly bor lnd tho 3P con-
rcclo?.

( T o p a g e1 1 - 7 ' l )

11 -7 0
 (Frompog6 1 1-7Ol

Meaauro voltage betweon GBN/

RED ierminal and body ground.

Boplir opon 01lhort in GR /RED

wir. batworn ECM (DlOl and tho
13the.e approx, 5 V? 3P connoctor.
1l wir. i! OK, .ubrtituta. known-
good ECM .nd rochock.

wire side

B L K{ _ I

GR /NEDI-I
Turn tho ignition switch OFF.
BLKIEL { + }

connect tho loat hamasa botweon

tho ECM and connectors (soa
pag€ 11-37),

(To page 11-72)

11-71
PGM-FISystem
ElectricalLoad Detector (ELD) (cont'd)

While measuringvoltagebetween
D l O 1 + ) t e r m i n a al n d 4 2 6 l - )
terminal,turn the headlighrswitch
to the secondposition(a) {low).
425t-t D 1 0l + )
, DoosVolrago Orop?----------------J

Does the voltage drop when

the headlightsare turned on?

Subrtitute . known-good ECM

and rochock. lt 3ymptom/indic€-
tion goos away, ioplaco th6 origi-
nal ECM.

11-7 2
PGM-FISystem
Knock Sensor(KS) tB18C1 enginel

ml- nl: IndicatorLamp(MlL)indicatesDiagnostic

The Malfunction TroubteCode(DTC)23: A probtemin
the KnockSensor(KS)circuit.

a6l--fzt
.i--1/.---r+\

- The MIL h6s boon r6port6d

on.
- With th6 SCS ahort connec-
tor connoctod (soe pago
11-341,codo 23 is in-
dicrtod.

Oo the ECM ResetProceduro(see

p a g e1 1 - 3 5 ) .

Startthe engine.Holdthe engine

g!-3,Opqrpm with no load {A/T in
LrylorlPlposirion,M/T in neurra
until the radiatorfan comes on,
then let it idle.

Holdthe engineat 3,0O0-4,000

rpm for 10 seconds.
Intomittor failure, ay5-
t.m is OK at this tim6
(teat drivo mav bo
nec€saary,.
Chock tor Door connec-
tion3 or loo3o wlaos et
C222 {locatod 6r ghr
shock tow6r), Cl33
(KSl and ECM.
Turn the ignitionswirch OFF.

Connect the test harness to the

main wire harnessonly, not to the
ECM (seepage 1 1-37).

ware sido

oooooo ooo ooo o loooooooo

o oooo ooo oo ooo I oooo oooo

Check for continuity between D3

terminaland body ground.

Ropdr short in RED/BLU

wiro b€tweon ECM {D3l
and ths Ks.

( T op a g e1 1 - 7 5 )

11-7 4
 (Frompage 1 1-74)

Chock tor continuitv on REO/8LU

wirs botween D3 tormin6l8nd 2P
conn6ctor.

Rop.ir op.n in RED/BLUwir. b.-

twcen ECM (D3l and th. KS.

Stsrt the engine. Hold th€ engine

st 3,000 rDmwith no load (A/T in
@ or@ position,(lvt/t in neutratl
until the r6diator l6n comoa on,
then l6t it idl€.

Holdthe engin€at 3,000-4,OOo

rDmlor 10 seconds.

Subrtitutr r known{ood ECM

.nd 6ch.ck. lt tymptoh/indic!-
liarn goar away. raplaca lha otigi- KS
nd ECM. 32 N.m (3.2

wire side

11-75
PGM-FISystem
A/T Fl Signal A/B (A/T only)
\[l0l- The MaltunctionIndicarorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 30: A problemIn
-L=\ the A/T Fl SignatA circuit between TransmissionControlModule (TCMI and ECM.
tItil- The MalfuncrionIndicarorLamp {MlL) indicatesDiagnosticTroubleCode {DTCI 31: A problemIn
-Li!- the A/T Fl SignalB circuit between TransmissionControtModule (TCM) and ECM.

\.__r_/ \.__r_/
- l 3 0l - o ' - l 3 t l -
-----\ /----\

Wlth tho SCS ahon connocrol

coni|ocd {!o. p.g. 'l 1-341, codo
3O and/or 31 ars indicltod.

Oo ths ECMResotProceduro{see
pag€ 'l 1-35).

Test drive necessary.

Drive the car lor severalmiles so
that the transmissionuDshiftsand
downshilts several times.

Intormittant tsilu.o, sy3tem iB OK

Doesthe MIL indicarecode at thir tima,
30 and/or 31? Chack lor poor connactions ot
l.ro!€ wiror at C419 (TCM] and
ECM.

Turn the ignition switch OFF.

Connect the test harness to th€

main harnessonly, not to the ECM
(see p8go l'l-37).

Disconnect the 22P connector

from the TCM.
84'

ulty?
+
Continuity?
Check lor continuity between B3
andlor 84' terminal and body
grouno.
r: code 31 1A/TFl signal Bl

Ropairlhon in GRN/8LUor GRY'

wiro b6twoon ECM (83 or 84'l
and tho TCM.

( T op a g e1 1 - 7 7 )

11 -7 6
 (Frompage 1 'l-76)

Check for continuity on GRN/BLU

or GRY'wire between83 or 84'
and 22P connectorof the TCM.

Ropairopen in GRN/BLUor GRY'

wiro botwoon ECM lB3 or B4'l
and the TCM,

Substituts a known-good ECM

and rochock. ll symptom/indica-
tion goos 6way, roplacatho origi-
nal ECM.

11-77
ldle Gontrol System
Guide
SystemTroubleshooting
NOTE:
a Acrosa each row in the chan, the sub-systemsthat could be sourcesof a symptom are ranked in the order they should
be inspected, starting with O. Find the symptom in the left column, read across to the most likely source, then reler
to the page listsd at ths top ot that column. It inspection showa the system is OK, try the next system @, etc.
a lf the idle speed is out of sp€cification and th€ Malfunction Indicator Lamp {MlL) does not blink Diagnostic Trouble
Code (DTC) 14, 9o to inspectiondescrib€don pags 1 1-81.

PAGE AUTOMATIC POWER

AIR HOSES
IDTI IDLEAIR coN0f ALTER. IRAI{SA(LE ERAK€ STARTER STEERII'IGFASTIOLE
ANO
OJUSTIi c0NTROt-
TtoNtitc NAION FN GtAR swrTcH swtTcH PffESSURE THERMO
CONNEC.
SCREW SIGNAL P0sm0 SIGNAL SIGNAT swncH TIONS
SIGNAL stGIAt SIGNAL
SYMPTOM 11-95 11-42 11-84 11 - 8 6 11-88 11-90 11-92 I 1-93 11-94

DIFFICULTTO START
ENGINEWHEN COLD
@ o
WHEN COLD FAST IDLE OUT OF
SPECl1,0OO- 2,0OO rpm|
o @ o

ROUGH IDLE o
WHEN WARM RPM TOO HIGH o o o
ldl6 3p6od b b€low
specitisd rpm (no loadl @ o
ldla 5p66d doos nol
incraas€alter initial o
On mod6l3 with auto-
WHEN
matic transmBsion,ths o
idlo sp€ed drops in 963r

TOOLOW ldl6 sp€eds drops when

8ir condilioner in ON
o o
ldls spo6d drops when
6ts6iing wh66l i6 turninC @ o
ldla spoed lluctust63
with alactrical load
o

WHILE WARMING UP @ o
FREOUENT
STALLING
AFTERWARMING UP o @

FAILS EMISSIONTEST o

1 1 -7 8
 SystemDescription
The idle speed ot lhe engineis controlledby the ldle Air Control {lAC) Valve.
The valve changes the amount ot air bypassing into the intake manifold in responseto electric current controlled by the
ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle speed.

#l' ----r
To FGM-FI
MAIN
RELAY

VARIOUS
SENSORS

FAST
IDLE
IAC VALVE THERMO
BLK

r
VALVE

INTAKE MAI{IFOLD

(cont'd)

11-79
ldle Control System
System Description (cont'd)

1. Atter the engineslarts.the IAC valveopensfor a censin time, The amountot air is increasedto raisethe idle soeed
about 15O-3OO rom.

2. When the coolanttemperatureis low, the IAC valve is openedto obtain the properfast idle speed.The amount of
bypassedair is thus controlledin relationto the enginecoolanttemperature.

IDI-ESPEED
lrpm)

ENGINE
COOLANTTEMPERATURE
176
t"Fl
80 (oct

11-80
1. when the idls speedis out of specificationand the MalfunctionIndicatorLamp(MlLldoesnot blink DiagnosticTrou-
ble Code (DTC) 14, check the tollowing items:
. Adiust the idle speed {see page I1-95)
. Air conditioningsignal (see page l1-84)
. ALT FR signal (seepage '11-86)
A/T gea, positionsignal(see page 11-88)
Erakeswitch signal (see page 1 1-90)
Starter switch signal(see page 1l-921
PSPswitch signal(see page 1 1-93)
Fast idl6 thormo valve (see page l1-94)
Hoses and connsctions
IAC valve and its mountingO-rings

2. lf the above items are normal,substitutea known-goodIAC vslv€ and readjustthe idle speed (see page 11-95)'

. It the idle speed srill cannot be adjusted to speciJication(and the MIL does not blink code 14) after IAC valve
roplacement, substitute a known-good ECM and recheck. It symptom goes away, replsce the original ECM.

11 - 8 1
ldle Control System
ldle Air Control(lACl Valve

lt6l- -l lf l- The MaltunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode {DTC} 14: A problemin

' '- the ldle Air Control llAC) Valve circuit.
The IAC Valve changes the amount of air bypasEingthe throttle body in respons€ to a current signal from the ECM in
order to maintainthe properidle speed.

/ ffi:| \ r;611
/--T-\

- The MIL h.3 beenreport don,

- With tho SCS shon connoctol
connoctod (soo pago 'l 'l -341,
cod6 14 is indicatod.

Do the ECMResetProcedure(see
p a g e1 1 - 3 5 ) .

With the engine running snd the

ls the MIL on and does it indicate
code 14?
Disconnectthe 2P connectorfrom
the IAC valve.
accelerator pedal releas€d, dis-
conn€ct th€ 2P connector frort
tho IAC valvo. htarmitlaot frlu]., aya-
t.m i. OK !t thir tlft.
ll.rl drlv. mly ba nac-
aaaaryl.
Chack tor Doo. conn€c-
tlonr oi loora wirca at
C3O5 (loc.t.d .t |.ft
lhock tow.tl, C424,
Cl tB (lAC v.lvol .nd
Sub.iituto . known{ood IAC ECM.
vdva lnd iotolt.

{ T o p a g e1 1 - 8 3 }

11-82
 (From page 'l 1-82)

Measure voltago between the

YEL/BLKwire and bodv ground.

R.pair op.n In YEL/8LK who b.-

ls th€rs battery voltage? twoon IAC vCvc dd PGM-FImdn
relay.

Turn th€ ignition swirch ott and IAC VALVE BLK/BLU{ _ }

reconnectthg 2P cohnectorto the
IAC valve.

Conn€ct the test hs.ness "A"

connector to the main wirs hrr-
n6ss only, not the ECM lsee page
t 1-37).

Tu.n tho ignition switch ON.

Momentarilyconnect Ag torminal
to 423 terminol seveaaltim€s.

Sub.titutr ! known{ood ECM

.nd ral..t. lt .ymptom/hdlcatioo
Does th6 IAC valve click? goa! awsy. rophca tia origlnal
ECM.

Raplir op.n or rhort in 8LK/BLU

wl]. b.tw.cn IAC v!lv..nd ECM
(A91, It th. wlro L OK, r.Dhc.lhe
IAC v.lv.. JUMPERWIRE
A9 l+) A23{-l

1 1-83
ldle Gontrol System
Air ConditioningSignal

This signals the ECM when there is a demand for cooling from the air conditioning system.

Connectthe t€st harnessbetween

the ECM and connectors.Discon-
nect "B" connectorfrom the main
wire harnessonlv, not the ECM
{see page 11-37}.

Turn the ignition switch ON.

.pprox. 5 V?

Measurevoltagebetween851+ ) 426 (- )
lerminaland A26 l- I terrninal.

Sub.litut ! known{ood €CM

ls there approx. 5 V? rnd r6<tEck. ll p.lrcib.d vottrgo
i! now avalhbla, iaplaco tho o,ig-
in.l ECM.

Turn th€ ignition switch OFF.

Reconnect"8" connector to the

main wire harness.
ooooooooooooo oooooooo ooooooooooo
Cllcklng?
oooooooooooo oooooooo ooooooooooo
Turn the ignilionswitch ON.

MomentarilvconnectA15 termi-
nalto A26 terminsl severaltimes.

Momsntarilv connect the 8LK/

ls there a clicking noise from REDt€rminal of the 4P connector
the A/C comDressorclutch? on the A/C clutch rel6v to body
ground sevsral times.

ls there a clicking nois€ lrom 3o6 rlr condhlohar in-

th€ A/C comoressor clutch? rDactlon llaa lac{ion
221.

Rop.ir opon in BLK/BEDwiro be-

two.n ECM {A15} and A/C clurch
rally.
lTo page

11-84
-
 r-Less than 1.0 V?-----------.1
(Frompage 11-84) I 85{+l
|----------------
I| | ooooooooooooe loooooooo 1t)6i}66i)l ooooooooooo I
l-_---_-------l-
I 426t_t

Measurevoltage between 85 {+ )
Does A/C operate?
terminaland A26 (-) terminal.

R€pairopoi in BLU/RED
ls voltagelessthan 1.O V? wiro b€trYaen ECM lBSl
and A/C awilch.

Aii coiditiodlng slgnal i! OK. Substituto a known-good ECM

and rochock, lf 3ymptom/indica-
tion goos 6way, r€placoth6 orig-
inal ECM.

11-85
ldle Control System
Alternator (ALTI FR Signal

This signalsthe ECM when the Alternator(ALT) ascharging.

Inspection ot ALT FR Sign.l.

Connectthe tost harnessbetween

the ECM and connectors.Discon-
nect "D" connector from the
main wire harnoss only, not the
ECM lsee page 11-37).

Turn the ignitionswitch ON.

ooo oo oooooo
ooooooooooo

Measurevoltage between D9 (+ )
terminaland A26 {-}terminal.

Sub{inno s known-good ECM

ls there approx. 5 V? and redrack. It pro.ctibod volt go
la now availablg, ropllco tha orlg-
inal ECM.

Turn the ignitionswitch OFF.

Reconnect"D" connectorto the

main wire harness,

Start tho engino. Hold the engine

!L3,099 rpm with no load (A/T in
LN]or El position, M/T in neutral)
until the radiator tan comes on,
rhen let it idle.
Voh.go?
D 9l + )

Measurovoltage between Dg (fl ooooooooooo

terminaland 426 (- I terminal. ooooooooooo

Does the voltage decrease

when headlightsand .ear Turn ths ignitionswitch OFF.
delogger are turned on?

ALT FR rignal is OK.

(To page 1 1-87)

11 - 8 6
 (Frompage 1 1-86)

Disconnect "D" connector lrom

ECM only, not the main wire
harnesa,

Disconnect tho nsgstive baftery

cable from the baftery.

Check for continuity betwe€n D9

terminal and body ground.

Continuity?

Check for continuity betwoan D9

te.minal and body ground.

soe AIT Inrpactlon

(... r.ctlon 231.
Check lor continuity between D9
t€rminsl snd body ground.

Rop.lt C|on in WHT/RED wi.. b.-

tw.on ECM lDgl rnd ALT.

Ropair op€o in WHT/RED wito b6-

tween ECM {D9} .nd .ltomrtor.
Sao ALT inapaction
lres .lctlon 231.

11-87
ldle Control System
Automatic Transaxle {A/Tl Gear Position Signal {A/T onlyl

This signalsthe ECM when the transmissionis in @ or @ position.

Turn the ignition switch ON.

obsorve the A/T shift indicator

a n d se i e c l e a c h p o s i t i o n
separately.

Soo A/T goa. position indicator in-

spoqtion ls6o lection 141.

Turn the ignitionswitch OFF.

Connectthe test hamessbetween

the ECM and connectors.Discon-
nect "B" connoclorlrom the main
wire harnessonly, not the ECM
(seepage 11-37).
appror. 5 V?
87l+)
ooooooooooooo
Turn the ignitionswitch ON.
oooooooooooo
A26 {-}
Measurevoltage between 87 (+ I
terminaland 426 1- ) terminal.

Subslituto . known-good ECM

ls there approx. 5 V? 6nd .ech6ck. lf pr63cribod voltage
ia now availablo,rcplacoths o.ig-
inel ECM.

Turn the ignitionswitch OFF.

Reconnect"8" connectorlo lhe

maanwire harness.

( T op a g e1 1 - 8 9 )

1 1 -8 8
-.
 {Frompage 11-88)
Measurevoltagebetween87l+)
terminal and A26 (-) teJqrinal
with the transmission in Lryl po-
sataon.
ls there lessthan 1.0 V?
Measurevoltage between 87 (+ I
terminal and A26 (-) reJqrinal
with the transmissionin lPl po-
sition.
ls there less than 1.0 V?
MeasurevoltagebetweenB7l+)
terminal and A26 l-) terminal
with the transmission in gear.
ls there battery voltage ?
A/T goat position signal b OK.
L63r than 1,0 V? -
87 l+)
ooooooooooooo
oooooooooooo
426 (- )
Ropair open in LT GRN/BLK
wir. botwoon ECM lB7) and
gaugo as!€mbly.
- Rspalr opon in GR wito b.-
twoon tho gaug6 a$ombly lnd
A/T goar position .witch.
Lo.s rhln 1.0 v? --ii t+t
o o o o o o o o o o o o o I o o o o o o o o I O O n P s O lo o o o o o o o o o o
ooooo ooooo ooo I oooooooo lQcosito I ooooooooooo
A26 (- )
Reprir open in GRNMHT wi.r bg-
twoon gaugo ssrombly and A/T
goar poritlon 3witch.
BATTERYVOLTAGE? --;;
{+ I
A26 t- )
R6oai. short in LT Git{/BLK wire
botwo6n ECM (B7l and gaugoar-
aombly.
11-89
ldle Control System
Brake Switch Signal

This signalsthe ECM when the brake pedal is depressed.

Inlp.ction ot Brd(. Switcfi Siignal.

Are the brake lights on without ltuoacl ths braka .wilch {!.a !ac-
depressinOthe brake pedal? don 191,

InspectSTOP,HORN(20 Alluse
Oo the brake lights come on?
in the undeFhoodfuse/relavbox.
R.pl!c. S T OP ,
HOR {2O A) tu...
R.pdr dbrt In WtlT/
ls the luse OK.? GBI wlrr batu..n
b?!ka .wltch a.rd
sToP, HOR[{ (20 A}
lura.

Connect tho t€st harness to the
main wire hamessonly, not to the
ECM {seepage 11-37).
- Ropalropon In WHT/GRNwiro
batwoan b'lka lwltch and
STOP, HORTI{20 Al lu!o.
- InlDect tho braka awitch la6a
.6cdon 19).

( T o p a g e' l 1 - 9 1 )

11-90
 (Frompage 11-9Ol

426 {-) D 2( + l
I-- BATTERY
VOLTAGE?
Measurcvohage between D2 (+ l
terminal and A25 (-) terminal
with the brake oedal deoressed.

Repair opon in GRI{/WHT wiro bo-

twoen th6 b..ko rwitch .nd ECM
{D2}.

Brako lwitch signal ir OK,

11 - 9 1
ldle Gontrol System
Startel Switch Signal

This signalsthe ECM when the engineis cranking.

BATTERY
VOLTAGE?

ooooooooooooo
oooooooooooo
Connectthe lest harnessbotween
the ECMand connector(seepage A 2 6{ - }
11,37).
NOTE:
a M/T: Clutch pedal must be
oeprgsseo.
Measurevoltage between 89 (+) a A/T: Trsnsmission in lll or LIJ position.
terminal and 426 (-) terminal
with the ignition switch in the
start position.

InspectNo. 18 STARTERSIGNAL
ls there batterv voltage? {7.5 A) fuse in the under-dash
fuse/relav box.

- Roplac. No. 18
STARTER SIG AL
(7.5 A) lurc,
- Rrpsir lhort In BLU/
WHT wir. batwccn
ECM (89) .nd No.
18 STARTER SIG.
t{AL {7.5 Al 1u..,
PiGM-Fl fi.ln rol.y.

R.palr opon in BLU/WHT wir6 b6-

tw€.n ECM lB9l and t{o, 18
STARTERSIGNAL 17.5 Al lu.o.
Startor .witch .ign.l is OK.

11-92
 Power Steering Pressure(PSP)Switch Signal
This signalsthe ECM when the power steeringload i s h i g h .
-;"nection.*."------'.ill]
- -
;;;;;;;l (see
connecrors
;:"r"tffa;i'
Turn the ignitionswitch ON.
Measurevoltagebetween88 {+ )
terminaland A26 {-) terminal.
ls there lessthan 1.0 V?
Turn steeringwheel slowly.
Measurevoltage between B8 (+)
terminal and 426 (-) termanal
while steeringwheel is turning.
PSP switch signal is OK.
w o ooooo oooo ooo I oo ooo oo o l.Do€d(iltl ooooooooooo
o oooo ooo ooooQ I oooQ oo oo $aG$ast.l oooooooo oo
A 2 6l - ) B gl + l
L6s! thsn l.O V?
Turn the ignitionswitch OFF.
Disconnectthe 2P connectortrom
the PSPswitch.
Tu.n the ignitionswitch ON.
ls there less than 1.O V?
Ropair opon in GRN wire betwssn
ECM {88} and PSPsrYilch ot BLK wire side
wi.o botw6cn PSP switch and
G301 (locatodat loft ongin6com- GRN
partm6ntr.
Disconnectthe 2P connectorlrom
the PSPswitch.
PSP SWITCH
Repairshort in GRNwi.e botwoon
ECM {881 and PSP switch.
ll wiro i3 OK, substitute a known-
good ECM and.ocheck. lI
proscribod vollage is now avail
able, replaco tho original ECM.
11-93
ldle Control System
Fast ldle ThermoValve
DEscliptlon Inspaction
To prevent erratic running when the engine is warming
up, it is n€cessaryto raise the idle speed. The fast idle NOTE: The tast idle thermo valve is factory adiustsd;
thermo valve is controlledby a thermowax plunger,When it should not be disassombl€d.
the engineis cold. the enginecoolant su.roundingthe
thermowax contracts the plunger,allowing additionalair 1. Remove the intake air duct from the throttlg body.
to be bypassed into the intake manifold so that the en-
gine idlss taster. When the enginereachesoperatingtem- 2. Stan the engine.
peratur€, the valve closss, reducing the amount of air
bypassing into the manifold. 3. Put your finger over ths lower port in throttle body
and make sure that there is 8ir flow with tho engine
cold (engine coolant temperatute below 86oF,
300c).

a lf not, leplace the fast idle thermo valvs and

retest.
FASTIDLETHERMO
VALVE o-Rr{Gs
Replace

AIN EYPASSVALVE

llo kgf.m, 7 lbt.trl

4. Start the engine. Hold the sngine at 3.0OOrpm with
no load (A/T in I or @ position, M/T in neutral]
until the radiator fan comes on, then let it idl6.

Checkthst valve is completelyclosed. lt not, air suc-

tion can be telt at the lower Don in the throttle body,
a It any suction is felt, the valve is leaking Check
engine coolant level and for air in tho engine
coolant system (see section 1O). ll OK, rsplace
the fast idle thermo valve and rechock.

11-94
- ldle Speed Setting

Inspoction/Adiustment

NOTE:
a When the idle speedset, checkthe followingitems:
- The MIL has not been reported on.
- lgnitiontiming
- Sparkplugs
- Air cleaner
- PCV svstem
a (Canada)Pulltheparkingbrakeleverup. Stan the en-
gine, then check that the headlightsare off.

1 Start the engine. Hold the engine at 3,000 rpm with

no load (A/T in S or @ position, M/T in neutral)
until the radiatortan comes on, then let it idle.

2. Connecta tachometer.

3. Disconnectthe 2P connectottrom the ldle Air Con- Turn the ignitionswitch OFF.
trol {lAC) valve.
Reconnectthe 2P connectoron the IAC valve,then
removethe BACKUP (7.5 A) fuse in the under-hood
tuse/relavbox for 1O secondsto reset the ECM.

e Restart8nd idlethe enginewith no-loadconditions

for one minute, then check the idle speed.

NOTE: (Canada)Pull the parking brake lever up.

Startthe engine,then checkthat the headlightsate
off.

ldlo speed should be;

4. Start the engine with the sccelerator pedal slightly 81881 ongino:
depressed.Stabilizethe rpm at 1,OOO,then slowly
release the pedal until the engine idles. MTf 75O ! 50 rpm
75O t 50 rpm
Checkidlingin no-loadconditions:headlights,blower AIT (in[]or@positionl
fan, reardefogger,radiatorfan, and ai. conditioner
are not operatrng.
818C1 engine:750 1 50 rpm
ldl€ spood should bo;

81881 ongino:

MlT 48O ! 50 rym

48O I 50 rpm
An
lin@or@oosition)

818C7 engine:48O ! 50 rym

Adjust the idle speed, if necessary, by turnmg the

idle adiustingscrew.

NOTE: After adiustthe idle speedin this step, check

(cont'd)
the ignitiontiming (see section 231.
lf it is out ot spec. go back to step 4.

11-95
ldle Control System
ldle Speed Setting (cont'd)

9. ldle the enginefor one minute with headlights{Low}

ON and check the idle sDeed.

ldla sp6od should bo;

81881 engine:

M/T 750 i 50 rpm

75O t 50 rpm
An
{in $ or p] positionl

818C1 engine:75O 1 50 rpm

1 0 .Turn the headlightsoff.

ldle the enginefor one minute with heatertan switch
at Hl and air conditioneron, then check the idle
speeo.

ldls spood should bo;

81881 ongino:

M/T 82O 1 50 rpm

840 1 50 rpm
AN (in [N] or lll position)

818C1 engino:85O t 50 nm

NOTE: lf the idle speedis not within specitication,

see SystemTroubleshooting Guideon page 1 1-78.

11-96
Fuel Supply System
System TroubleshootingGuide

NOTE: Across each row in the chart, the sub-systemsthat could be sources of a symptom ara tanked in tho order they
should be inspected starting with O. Find the symptom in the left column, read across to the most liksly source, then
refer to the page listed at the top of that column. lf inspection shows the system is OK, try the next most liksly system
@, etc.

PAGE FUEL PGM-FI CONTAM'

FUEL FUEL FUEL FUEL
PRESSURE MAIN INATEO
LINES INJECTOR FILTER PUMP
REGULATOR RELAY FUEI

SYI\4
PTOM 11-98 11-102 11 , 1 0 6 l1-toa 11-109 t'l 'nl

ENGINE
WON'TSTART @ o @

DIFFICULT
TO START
ENGINEWHENCOLDOR HOT
o \4

ROUGHIDLE o @
MISFIRE
OR
ROUGH
RUNNING
o @ @
FAILS
POORPER.
FORMANCE
EMtSSION @ o
LOSS OF
POWER
@ @ o
WHILE

FREOUENT
WARMING
UP
o
STALLING
AFTER
WARMING
UP
o

11-97
FuelSupplySystem
Fuel

NOTE:Check all fuel system lines and hoses for damage, leaks or deterioration, and replaco if n€cessery.

11-98
NOTE: Chock 8ll hoso clamps and r€tighton if necossary.

Sot th€ centgr

l2 mm
(0.47 inl

12-15 mm
to.47-o.59 hl

t2 mm
{0.47 in}

11-99
FuelSupplySystem
SystemDescription FuelPressure
The fusl supply system consists ot a fuel tank, in-tank
high presssurefu6l pump, PGM-FImain relay, fuel filter,
tuel pressure regulatot, fuel inioctors, fusl pulsation
damper and fuol delivery and return linss. This system a Do not smok6 while working on the fuol syst6m,
deliverspressure-regulatoredfu6l to the fu6l injectorsand Keep open flames or spalks away tlom your work
cuts the fuel delivory wh6n the engine is not running. aroa.
a 8e sure to raliavofuol p.essur6while th6 6n9in6is off.

NOTE: Eeforedisconnectingfuel pipes or hoses, release

pressure from the system by loosening the 6 mm se.-
vice bolt on top of the fuel filter.

1. Disconnectthe batterynegativecablefrom the bat-

tery negativeterminal.

NOTE: The LS and GS-Rmodel radio may have a

coded theft protectioncircuit. Be sure to get the cus-
tomer's code number betore disconnectingthe
batterv,
After service, reconnect Dowe. to the radio and turn
it on. When the word "CODE" is displayed.enter
the customer's s-digit code to restore radio
ooeration.

2. Removethe fuel fill cap.

3. Use a box end wrench on the 6 mm servicebolt at

the fuel tilter, while holdingthe specialbanjo bolt
with anotherwrench.

4. Placea rag or shop towel over the 6 mm servicebolt.

5. Slowly loosenthe 6 mm servicebolt one complete

turn.

SERVICEBOLT
15 N.m
(1.5 kgf.m,
11 rbr.ftl

FUELFILTER
NOTE:
a A fuel pressu.egaugecan be attachedat the 6
mm seryicebolt hole.
a Alwavs replacethe washerbetweenthe service
bolt and the specialbanio bolt. wheneverthe ser-
vice bolt is loosened.
a Replace all washers whenever the bolts are
removeo.

11 - 1 0 0
Insp6ction a lf the fuel pressureis not as specified, first check the
fuel pump (seepage 1 l - 1 1O).lf the fuel pump is oK,
1. Relievefuel pressure(see page 11-1OO) check the following:

2. Removethe servicebolt on the tueltilter while hold-
ing the banjobolt with anotherwrench. Attach the
specialtool
3. Siart the engine.* Measurethe {uel pressur€with
the engineidlingand vacuumhoseof the fuel pres-
sure regulatordisconnectedfrom the tuel pressure
regulatorand pinched.
- lf the fuel pressurois higherthan specified,inspectfor:
. Pinched or clogged tuel return hose or line.
. Faultyfuel pressureregulator(see page 11-106)
- It the fuel p.essu.eis lower than specitied,inspect fo.:
. Clogged fuel tilter.
. Faultyfuel pressureregulator(seepage '11-106).
. Leakagein the fuel line.

Pressureshould b€;
818B1 engins:
275-324 kPa (2.8-3.3 kgl/cm2,40-47 psil

818C1 ongine:
329-37a kPa (3.35-3.85 kgf/cmz,48-55 pei)

4. Reconnect vacuum hose to the tuel plessure

regulator.

Prossuroshould b€;
Bl8Bl ongino:
216-245 kPa (2.2-2.5 kgf/cm' , 31 -36 psil

B18Cl on9in6:
27O-319 kPa 12.75-3.25 kgt/cm', 39-46 psi)

FUEL PRESSUREGAUGE
07406 - OO4000 1 CLAMP

lf the enginewill not stan, turn the ignitionswitch

on. wait for two seconds,turn it off, then back on
again and read the fuel pressure.

11 - 1 0 1
Fuel Supply System
Fuel Injectors
- --l- - \-l-l
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) l6: A problemin
1 1 6 l - /- l---i-
/---r-\
tc l-
\ the Fuel lniectorcircuit.

The Fuel Injectors a.e a solenoid-actuatedconstant-stroke pintle type consisting of a solenoid, plungel n€edlevalvs and
housing. When cur.ent is appliedto the solsnoid coil, the vslve litts up and pressurizedfuel is injected. Becausethe nee-
dle valve litt and the luel pressureare constant, the iniection quantity is determined by the length of time that the valv€
is open (i.e.,the durationthe cu.rent is suppliedto the solenoidcoill. The Fu€l Iniectoris sealedby an O-ringand seal
ring at the top and bottom. These seals also reduce operating nois6.

FILTER
O.RII{G FUEL RAIL

PTUNGER

-_-- - ___L-

- I| r.G
- -l -- :l t_o- l -

- Tho MIL has boen roportod on.

- Wilh tho SCS .hon connocto.
conoctod (soo pago 11-34),
code 16 is indicalod.

Do the ECM Besel Procedure(see

page l l -351.

NOTE:lf enginewillnot start, it may tak6

lO secondsol cranking to sgt th6 code.

Intermittant tailura, aystam ir OK

ls the MIL on and does it
indicatecode l6?
at thir tim. (t..1 drivo m.y b.
nocaar!ry1.
Ch.ck lor poor connactiona ot
100!6 wir6!.t C221 (loortod rt
right .hock low.rl, C121,C122,
Cl23, Cl24 llu6l InFctorrl, lnd
ECM.

{To page 1 1-1O31

11-1 0 2
 lFrompsge11-1021

St6n the enoin€8nd listgnat oach

fuol inioctor fo. a clicking sound.

Turn the ignition switch OFF.

Disconnoct tho 2P cohnector from

th6 lu€l iniocto. th6l does not
click.

Mossur€ rggistancebatwson th€

2 terminalEol fuol injocto..

FUEL
II{JECTOR

R.phce tho fuol ini.ctor/lni.ctor!

ls thoro 1O- 13 07 that ar€ not 10- 13 O.

T!.n tho ignition switch ON.

Moaaur€ voltage b€tweon

YEL/BLK { + I terminsl in ths 2P
connoctor and body ground.

B.prh op.n In tho YEL/BLK wlt6

ls thore battory volt6g€7 botwaan tha luol inioctor aad lha
PGM- Fl main r.lsy.

(To p6ge I l-1O41

(cont'd)

11-103
Fuel Supply System
Fuel Injectors (cont'd)

(Frompage 'l1-103)

Turn lhe ignitionswitch OFF.

Reconnect the 2P connector to

the tuel injector.

Connectthe test harnessbetween

rhe ECM and connectors {seo
page'11-371.

Turn the ignitionswitch ON.

Measure voltage between A23

{-) terminal and following
terminal:
. No. 1 tuel injector:
A1 (+ ) terminal.
. No. 2 fuel injector:
A3 {+ I terminal.
. No. 3 fuel injector:
A5 {+ ) terminal.
. No. 4 fuel injector:
A3{+)
A2 {+ ) terminal.

oooooooooo oooooooo ooooooooooo

oooooooooooo oooooooo ooooooooooo
A2{+}

Ropairopon in the wi.o betw6on

th6 ECM(A1, A3, A5 or A2l and
th6 tuel iniector.

Sub3titute a known-good ECM

and r6chock. lf symptom/indica-
tion goes away, .eplsco tho origi-
nal ECM.

11-1 0 4
Rapl!c!ment 7 . Slide new cushionrings onto the luel iniectors.
oo not smoko during tho work. Keep open
@ t'. Coat new O-ringswith cleanengineoil and put them
fllma3 lway from your wolk aloa. on the fuel injectors.
1. Retievetuel pressure{see page 1 1-10O). 9 . Insen the injectors into the tuel rail tirst.

2. Disconnect the connectors trom the fuel iniectors.
3. Disconnect the vacuum hose and fuel return hosa
from the fuel pressure regulatol.
NOTE: Placea r8g or shop towel over the hoses be-
for6 disconnecting them.
4. Loosenthe retainer nuts on the Juel rail and harness
holder.
1 0 . Coat new sealringswith cleanengineoil and press
them into the intake manifold.
1 1 .Installthe Jueliniectorsand fuel railassemblyin the
intake manilold.
CAUTION: To plovont damage to th€ O-dngs, instsll
tho fuol inioctors in tho fuol r8il first, thon install th€m
in the intaks mEnitold.

5 . Disconnectthe tuel 18il.

6. Removethe fuel injectors from the intake manifold.

cusHloN
RING
Replace.

12. Alignthe centerlineon the connectorwith the mark

on the fuel rail.

FUEI.RAIL

FUEL

MABKI'{GS

1 3 .Install and tighten the retainer nuts

1 4 .Conn€ct the vacuum hose and tuel retuln hose to

the fuel pressure regulator.

lnstall the connecto.s on the fuel injectors.

1 6 . Turn the ignition switch ON, but do not operate the

starte.. After the tuel pump runs for approximately
two seconds,the tuel pressurein the fuelline rises.
ReDeatthis two or threetimes,then checkwhether
there is any fuel leakage

11-105
Fuel Supply System
FuelPressureRegulator
Description
The fuel pressure.egulatormaintainsa constant Juel
pressureto the tuel injectors. When the difference be-
tween the fuel pressureand manitoldpressur€exceeds
3.O kgf/cm' 1294 kPa, 43 psi) tB18C1 engine: 3.5
kgt/cm, (343 kPa, 50 psi)], the diaphragmis pushed up-
ward, and the excessfuel is fed back into the fuel tank
through the retufn line,
CLOSE:
Te6ting
@ oo not smoko during the t€st. Ko6p opon
flames away from your work area,
1. Attach a fuel pressuregaugeto the se.viceport of
t h e l u e l f i l t e r{ s e ep a g e 1 1 - 1 0 1 ) .
Prossuroshould be;
Bl88l ongin€:
275-324 kPa (2.8-3.3 kgf/cm', 40-47 psil
B18Cl €ngino:
329-378 kPa (3.35-3.85 kgf/cm' .48-55 pEi)
(with tho tuol pressurersgulator vacuum hoso dls-
connoctod and pinched)

FUELPRESSURE GAUGE
07406 - oO/IOOO
1

DIAPHRAGM

\r__l FUELINLET

INTAKE
MA'{IFOLD Reconnectthe vacuum hose to the fuel pressure
VACUUM
regulator.

DIAPHNAGM Checkthat the tuel pressurerises when the vacu-

um hosefrom the fuel pressureregulatoris discon-
nected again.

a lf the fuel pressuredid not rise, replacethe fuel

pressure regulatot.

/1-
\J FUELINLET

FUEL
RETURI{

11-106
Raplacoment

@ oo not amoko whil6 working on fuel sys-

tam. Koop open flamo away tlom your work atea'

1. Placea shop towel under the fuel pressureregula-

tor, then reliev€tuel pressure(seepage 1l-10O).

2. Disconnectthe vacuum hose and fuel returnhose.

3. Remove the two 6 mm retainer bolts.

12 N.m
{1.2 kgl.m,
9 rbf.ft)

Rsplace.

NOTE:
a Replacothe O-ring.
a When assemblingthe fuel pressureregulator,ap-
ply clean engineoil to the O-ringand assemble
it into its proper position, taking care not to
damagethe O-dng.

11-107
Fuel Supply System
Fuel Filter

a Do not smoko while wo*ing on tusl system.

Keop open tlame away ftom your wotk area. SERVICEBOLT
SPECIAL 15 N.m ll.5 kgt.m,
a While replaclng th6 tusl liher, be caletul to koop a safo BOLT 1 I rbr.ftl
distanc6 betweon battery torminals and any tool3. 33 N.m
(3.4 kgt.h,
25 rbf.ft) WASHER
The Juelfilter should b€ replacedevery 4 years or 60,0O0 Replace
miles(96,OOO km), whichevercomesf irst.or whenever
the fuel pressure drops below the specilied value
1275 - 324 kPa, 2.8 - 3. 3 kgJ/cmr,40-47 psi (Bl 8C 1
e n g i n e :3 2 9 - 3 7 8 k P a , 3 . 3 5 - 3 . 8 5 k g f / c m r ,4 8 - 5 5
psi) with the fuel pressure regulator vacuum hose dis-
connectedl afte. making sure that the tuel pump and the
fuel pressureregulatorare OK.
1Ottl.m
1, Disconnectthe batterynegativecabletrom the bat- (1.Okgf.m,
tery negativeterminal. 7 tbt.ftl

NOTE; The LS and GS-Rmodel radio may have a

coded theft protectioncircuit, Be sureto get the cus-
tomer's code number before disconnectingthe
batterv.
After service, reconnect power to the tadio and turn
it on. When the word "CODE" is displaved,enter
the customer's 5-digit code to restore radio
operation.

2. Placea shop towel underand aroundthe fueltilter.

3. Relievefuel pressure(see page 11-100).

4. Removethe specialbanio bolt and the fuel feed pipe

from the fuel tilter.

Removethe fuel filter clamp and tuel Jilter.

When assembling,use new washers,as shown,

NOTE: Cleanthe llared joint ot high pressurehoses

thoroughlybefore reconnectingthem,

11 - 1 0 8
[":::,::-'
Eecauseof its compactimpellerdesign,the fuel pump is installedinsidethe fueltank, therebysavingspaceand simplify-
ng the fuel line system.

FUELPUMP

FUEL FILTER
FUEL PUMP BRACKET

FUEL PUMP CROSSSECTIONlsido vi6rvl N lTop vi6w)

FUEL PUMP ASSEMBLY CROSSSECTION

D|SCHARGEFORT ^ . tNLEr P
PORT

PUMPCOVER

IMPELLERS

CHECK VALVE PUMP CASING GROOVES

IMPELLER

The fuel oumo consistsof a DC motor, a circumferenceflow pump, a reliefvalve for ptotectingthe fuel line
lir systems,
a check valve for retainingresidualpressure,an inlet port, and a dischargeport. The fuel pump assembly
emblyconsistsof
the impellers(drivenby the motor),the fuel pump casing{whichforms the pumpingchsmber),and the fuel pump
p cover.

OPERATION
(1) When the engineis started.the PGi/t-Flmain relay actuatesthe fuel pump, and the motor turns together
togeth with the
impellers.
Differentialpressureis generatedby the numerousgroovesaroundthe impellers.
(2) Fuelenteringthe inlet porr flows insidethe motor from the pumpingchambe.and is forced through th discha.ge
rgh the
port via the check valve.
ss the fuel to the
lf tuel flow is obstructedat the dischargeside of the tuel line, the relief valve will open to bypass
inlet port and prevent excessive fuel pressure.
(3) When the enginestops,the tuel pump stops automatically.However,a checkvalve closesby gravity avitv to
t retainthe
residualpressurein the line, helpingthe engineto aestanmore easily.

(cont'd)

11-109
Fuel Supply System
FuelPump(cont'dl
Tc.ting Roplacomont

@E o" not smoko during tho tesr. Koop open @ oo not smoks whilo worklng on fuel syr-
flrmo away fiom your work area. tem. Kaop opon llamos away from your wolk araa.

lf you susp€ct a problem with the tuel pump, check that 1. Removethe rear ssats {soe section 2O).
the lusl pump actuallyruns;when it is ON, you will hear
some noise if you hold your ear to the luel lill oon with 2. Removethe accessoanel.
the fuel fill cap remov6d. The fuel pumD should run for
two seconds, when ignition switch is first turned on. ll 3. Disconnectthe 2P connectorfrom the fuel pump.
the fuel pump does not make noiss, check as tollows;
4. Removethe fuel pump mountingnuts.
1. Removothe rear seat (see section 2O).
-'2. 5. Removethe fuel pump trom the luel tank.
Removethe accesspanel.
6. Installa new washeron the banio bolt, then install
3. Disconnect the 2P connector from the fuel pump. Darts in the revers€ order of removal.

CAUTION: 86 lure to tum th6 ignition switch OFF

botor6 disconnoctlng th€ wilos,

4. Connect the BLK|yEL@ wire 8nd YEL/GRN@ wire

with a iumpe. wire 8t the PGM-FI main relav con-
nectot.
l.t, .--/ re -Fl 6 N.m
.\ . MAll{ RELAY lO.6 kgl.m,.
4 tbt.ftl

27 .m
BL& (2.4 kgt.m,
Jumper YEL 21 tbt.ftl

Check that battery voltage is available at the tuel

pump connectorwhen the ignitionswitch is turned
ON (positive probe to the YEL/GRNwire, negative
probe to ths BLK/WHT wire).

ACCESS
PANEL

side
YEL/
GRN

a lf battery voltage is available, replace the fuel

pump.
a It there is no voltage, check the tusl pump ground
and wire harness{see page I 1-1 l2).

11-110
 PGM-FlMain Relay

Doscription Relay Testing

The PGM-Flmain relavactuallvcontainstwo individual NOTE: lf the car stans and continuesto run,
r the PGM-
rerays. Fl main relay is OK.
This relay is locatedat the lett side of the cowl.
Onerelayis energizedwheneverthe ignitionis on which 1. Removethe PGM-Flmain relay.
suppliesthe battery voltageto the ECM, power to the
fuel injectors,and power for the secondrelay. 2. Attach the batterypositiveterminalto
nalto the No. 2 ter-
The secondrelay is energizedfor 2 secondswhen the minal and the battery negativeterminal
termir to the No.
ignitionis switchedon, and when the engineis running, 1 terminalof the PGM-FImain relay.
lay. Then
T checkfor
to supply power to the fuel pump. continuity between the No. 5 terminal
minaland No. 4 ter-
minal of the PGM-FImain relay.

a lf there is continuity,go on 10
to step
ste 3.
a lt thereis no continuity,replace
ce the PGM-Flmain
PGM-FI
MAIN RELAY
relay and retest.
No.2

FUEL PUMP To lGN. I 8Ar C)

To GROUND
ECM {425, 81)

To ST. SWITCH

To ECM {47} J To FUELPUMP

Attach the battery positive terminalto

inalto the No. 5 ter-
minal and the battery negative termil to the No.
terminsl
3 terminalof rhe PGM-Flmain .elav.
ay. Then
Tl checkthat
there is continuitybetweenthe No. 7 ; terminaland
No.6 terminalof the PGM-Flmain ain relay.
re

a lf there is continuity,go on to step

st€ 4.
ce the
a lf there is no continuity, replace th€ PGM-Flmain
relay and retest.

Anach the batterypositiveterminalto

inalto the No. 6 ter-
termil to the No.
minal and the battery negativeterminal
ay, Then
1 terminalofthe PGM-Flmainrelay, Tl checkthat
there is continuitybetweenthe No. 5: terminaland
No. 4 te.minalof the PGM-Flmain
nainrelay.
r

-Flmain
a It there is continuitv, the PGM-FI mi relayis OK.
a lf there is no continuity, replace th( PGM-Flmain
ce the
relav and retest.
(cont'd)

11-111
Fuel Supply System
PGM-FlMain Relay(cont'dl
Tloubloshooting
- Engino will not sran.
- Inspection oI PGM-FImain re-
lay and rolay ha.n6!a.
Checklor continuitvbetweenBLK
terminal@ and body ground.
Measure the voltage between
YELMHT terminal@ and body
ground.
ls there battery voltage?
Turn the ignitionswitch ON.
Measure the voltage between
BLK/YELterminal @ and body
ground.
Turn the ignition switch to the
STARTposition.
Measure the voltage between
BLUMHT terminsl@ and body
ground.
{ T o p a g e1 1 1 1 3 }
11-112
Rapairopen in BLK wire botwoon
PGM-FImain.el6yand GIO'l llo-
catod at thormostot housingl.
- Roplacoth. ECUIECMI(15Al
lus6 in tho under-hoodfu!o/r6-
lay box.
- Ropair opan or short in the
YEL/WHT wil6 botwosn the
PGM-FImain rolayand the ECU
{EcMl 115 A} luso.
- Reolac. ths No. 24 ACG {ALT}
{ l c l { 1 5 A : 8 1 8 8 1 6 n g i n o2, 0
A: Bl8Cl engin6)tuse in tho
undor-dashfuso/rolaYbox.
- Ropaii op6n or rhon in tho
BLK/YEL wiro botwoen tho
PGM-FImain ielay and th€ No.
24 ACG {ALT) flG} {'15 A:
818Bi ongine,20 A: 818Ci
onginol fuso.
BLU/
BLU wHt
NOTE:
. M/T: Clutch pedal must Bt-x
be depressed.
. A/T: Transmission in
N or E] position.
- Replacothe l\lo. 18 STARTER BLK/ YEL/
SIGNAL {7.5 A} fuso in tho YEL BLK
undor-dashfuaa/rolay box.
- R6pai. open or short in tho
BLU/WHT wire botweon ths
PGM-FImain relay and tho No.
1A STARTERSIGNALI7.5 AI
luse.
 ( F r o mp a g e ' l ' l - 1 1 2 1

Turn the ignitionswitch off.

Connectthe test harnossb€tween

the EcM and conneclors.
Oisconnect "A" connector trom
the ECMonlv. not the main wire
harness(see page 1'1-37).

Check for continuity between

GRN/BLUterminal O and A7
lermrnal.

Roplir op.n in GRI{/BLUwirc bo-

tw..n ECM lATl lnd PGM-FI
main rolay.
YES

Reconn€ct"4" connector to the

ECM.
Bstt.ry vohago?
r-----r_-l
A 2 3 ( - l A 2 5B l

Turn the ignition switch ON.

Measure the voltag€ between

A23l- ) t€rminaland the tollow-
ing t€rminals;A25 (+ ) Bl (+ ).
- Ropair opon in rh. YEL/BLK
wir. @ b€twoon the ECM
1A25, 8tl .nd PGM-FI mrin
raLy.
- Roplsc. ttro PGM+I min ru4.y.

Turn the ignition switch OFF.

Brttaiy voftago?
a7 (+l A23(-)
M€asurethe voltage betw€en A7
(+)torminal and A23 { - } t€rmi-
nal when the ignition switch is
first turned ON for two soconds.

Subrlitutc . known{ood ECM

.nd 6chock. lf p..crib.d volt.g.
ls there 1.O V or l€ss? ir now avallablo, rodaco lha otlgi-
nsl ECM.

Chod. th6 FGM-FI fioin relay {3o.

p 6 g 61 1 - 1 1 1 1 .

11-113
Fuel Supply System
Fuel Tank

Replacement

@ oo not smoke while working on fusl syltem. Koep opon flame rway from your wort ar6a.

1. Relievethe fuel pressure{see page 11-1OO).

2. Jack up the car and support with jackstands.
3. Removethe drsin bolt and drain the fuel into an approvedcontainer.
4. Removethe rear seat, accessDanelsand disconnectthe 2P and 3P connectors.
5- Remove the EVAP two way valve cover and tuel hose protector.
6. Disconnectthe hoses.
CAUTION:
a Whan disconnacling tho hosos, slide back tho clampr, th6n twist horos as you pull, to lvold drmlglng thcm.
a Clean the tlarod roint ot high plossulo hosos thoroughly brforc roconnccling thsm.
7. Place a jack. or other support, under the tank.
8. Remove the strao nuts and let the straDs tall free.
9. Removethe Jueltank.
NOTE: The tank may stick on the undercoat applied to its mount. To remove, caretully pry it off tho mount,
1O. Installa new washer on the dlain bolt, then installpsns in the raverseordgr ot rsmoval.

FUEL
PUMP

EVAP FUEL
TWO WAY VALVE TANK

38 l{.m
(3.9 kgt'm,
28 rbl.ftl

EVAP
TWO WAY FUELTAI{K
VALVE STRAPS
COVER
tO t{.m
ll.O kgt'm,
7 lbl.frl

11-114
Intake Air System
System TroubleshootingGuide

NOTE: Across 6ach row in the chart, the sub-systems that could be sources of a symtom are ranked in the order they
should be inspected st8rting with O. Find the symptom in the left column, read across to the most likely source, then
ret€r to the page listod at the top of that column. tf inspection shows the system is OK, try the next system @, etc.

181881onglnol

't
11-118 1-117

WHENCOLD FAST IOLEOUT OF SPEC

WHENWARM IDLESPEEDTOO HIGH

lB18Cl cngin.l

PAGE I sue-svsreu THROTTLE THROTTLE

INTAKEAIR
BYPASS(IAB)
AIR CLEANER
AND INTAKE
_\.-..\ CABLE BODY
AIR DUCT
CONTROL
sYMPToM \---...- 1 11 1 9 1't-120 11-124 1 l 117

WHENCOLDFAST IDLEOUT OF SPEC o

WHENWARM IDLESPEEDTOO HIGH o o

LOSSOF POWER o @ @

11-115
Intake Air System
SystemDescription
The system supplies air for allengine needs. lt consists of the intake air pipe, Air Cleaner(ACL), intake air duct, Throttle
Body (TB), ldle Air Control {lAC) Valve, tast idle thermo valve, and intake manifold.
A resonatorin the intake air pipe providesadditionalsilencingas air is drawn into the system.

na
cot{TRoL
To

ffi -------------+
SOLENOID
VALVE
i'"ii'i''
RELAY

VARIOUS
SENSORS

IAB
-BLK
CONTROL --L EI{GINE
DIAPHRAGM - cooLnnt
VALVE
t FAST
IDLE
U THERMO
VALVE INTAKE
AIR PIPE

INTAKE
AIR
DUCT

11-116
 Air CleanerIACL)

ACL Element Rsplacoment

ACL HOUSING
COVER

ACL ELEMENT
Clean air cleaner element everv
15,OOOmiles (24,OOOkm) or 'l2 mon-
ths and reDlaceeverv 3O,OOOmiles
(48,00Okm) or 24 months underdus-
ty conditions,rough or muddy roads.

AKE AIR OUCT

11-117
Intake Air System
Throttle cable [81881 enginel

Inspection/Adiustment Installation
'I .
Startthe engine.Holdthe engineat 3,000 rpm with 1. Fullyopen the throttle valve.then installthe throt-
no load (A/T in $ or@ oosition,M/T in neutral)until tle cablein the throttle linkageand installthe cable
the radiatorfan comes on, then let it idle. housingin the cable bracket.

2. Checkthat the throttle cableoperatessmoothly with 2. Start the engine.Holdthe engineat 3,OOOrpm with
no bindingor sticking.Repairas necessary. no load (A/T in S or @ position,M/T in neutralluntil
the radiatortan comes on, then let it idle.
3. Checkcablefree play at the throttle linkage.Cable
d e f l e c t i o ns h o u l db e 1 O - 1 2 m m ( O . 3 9 - O . 4 7i n . )
CABLE
THBOTTLELII{K ARACKET

-l-r
,)
j i;
ITINERCABLE
LOCKNUT

DEFLECTION 5. Hold the cablesheath,removingall slack from the

1O-12 mm cable.
1O.39-0.47 in.l
Turn the adjustingnut until it is 3 mm (O.12 in.) away
trom the cable bracket.
4. lf deflectionis not within specs,loosenthe locknut
and turn the adjustingnut until the deflectionis as Tightenthe locknut. The cabledeflectionshouldnow
specifled. be 10- 12 mm (O.39-O.47 in.). lf not, see Inspec-
tion/Adjustment.
With the cableproperlyadjusted.checkthe throttle
valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe throt-
tle valve to be sure it returnsto the idle oosition 3 mm {0.12 in)
wheneveryou releasethe acceleratorpedal.

LOCKNUT
1ON.m
{1.O kgl.m,
7 tbt.ft)

1 1 - 11 8
 Throttlecable [B18C1enginel
Inspection/Adiustment lnstallation
1. Start the engine. Hold the engine at 3,O0Olpm with 1. Fullv open the throttle valve, then install the throt-
no load in neutraluntil the radiatorfan comes on, tle cable in the throttle linkage and install th€ cable
then let it idle. housingin the cable bracket.

2. Checkthat the throttl€ cableoperatessmoothly with 2. Stan the engine. Hold the engine at 3,OOOrpm with
no bindingor sticking.Repairas necessary. no load in neutraluntil the radiatorfan comes on,
then let it idle.
3. Check csble free play at the throttle linkage, Cable
d e f l e c t i o ns h o u l db e 1 0 - 1 2 m m ( O . 3 9 - O . 4 7i n . ) THROTTLELI K

CABLEBBACKET

I{UT
ADJUSTING

5. With part A of the cabl€ bracket, support the cable

sheath so that there is no inner wire free play. Turn
DEFLECTIOI{ the adjusting nut until it touches part A, leaving a
10-12 mm gap between the locknut and adiusting nul.
(O.39-O.47in.l
4. Move the cable sheath to psrt B of the cable brack-
et that so the bracket slides into the gap between
the locknut and adiusting nut. Tighten the locknul.

lf deflectionis not within sDecs,loosenthe locknut

and turn the adjusting nut until the deflection is as LOCKT{UT
specitied. lO t{.m (t.O kgl.m, pARTB
7 lbt.ftl NUT
ADJUSTING
With the cable properly adjusted, check the throttle {Locked by bracket)
valve to be sure it opens fully when you push the
acceleratorDedalto the tloor. Also checkthe throt-
tle valve to be sure it retums to the idle position
whenever vou release the accel€rator pedal.
PABT A

NO GAP
LOCKNUT
AIUUSTING
NUT

5, The cable deflectionshould now be 10-12 mm

{O.39-O.47 in.). lf not, see Inspection/Adiustmsnt

11-119
lntake Air System
Throttle Body

Description
The throttle body is ot the single-barrel
side-draft1ype.
The lower portionof the throttle valve is heatedby en-
gine coolantfrom the cylinderhead.The idle adjusting
screw which increases/dec.eases bvDassair and the
EvaporativeEmission(EVAP)ControlCanisterport are
locatedon the top of the throttle body.
Insoection
CAUTION: Do not adiust the thlottle stop screw. lt is
preset at the lactory.
1. Startthe engine.Holdthe engineat 3,OOOrpm with
no load (A/T in S or E position,M/T in neutral)until
the radiatorfan comes on, then let it idle.

2. Disconnectthe vacuum hose (to the EVAPcontrol

canister)from the top of the throttle body; connect
IOLEAOJUSTING a vacuum, gaugeto the throttle body.

VACUUM PUMP
GAUGE
A973X-O41-XXXXX

THROTTLE
STOP SCREW
(Non-adiustsb16l 3. Allow the engineto idle and check that the gauge
indicatesno vacuum.

a li there is vacuum,checkthe throttle cable (see

p a g e1 1 - ' l1 8 , 1 1 9 ) .

Checkthat vacuumis indicatedon the gaugewhen

the throttle is openedslightlyfrom idle.

a lf the gaugeindicatesno vacuum,check the throt-

tle body port. lf the throttlebody port is clogged.
clean it with carburetorcleaner.

5 . Stop the engineand check that the throttle cable

operatessmoothly without bindingor sticking.

a lf thereare any abnormalities

in the abovesteps,
check for:

- Excessive wear or Dlavin the throttlevalveshaft.

Sticky or bindingthrottle lever at full close po-
srtron.
Clearance betweenthrottlestop screwand throt-
tle lever at tull close Dosition.

11-120
818B1 engino:

There should be
no clearance.

THROTTLESTOP SCREW
(Non-adiustablel

818Cl engine:

THROTTLELINK

(Non-adjusrablel

Replacethe throttle body if there is excessiveplay in the

throttlevalve shalt or if the shaft is bindingor sticking.

11-121
IntakeAir System
Throttle Body (cont'dl
Dirarssmbly

GAUTION:
a Ths throttlo stop scrow is non-adrustablo.
a Aftar reassombly, adiust rhr throttlo Gablo(pago 11-118, 1 19). and A/T throttlo contlol cabl6 (section 14) for c!r8
rYith A/T.
a Tho TP sonaor ir not lomovablo

MAP
SENSOR
Troubleshooting
p a g e1 1 - 5 2

O.BING

TP
SETSOR
I
d^'%
IDLEADJUSTING
SCREW
Troubleshooting
poge1l-60

o-RtftG
Replace.

FASTIDLE
THERMO
VALVE
page11-94
Inspection,

1ON.m
11.Okgl.m.
7 tbf.ftl

11-122
 IntakeAir Bypass(lABl ControlSystem tBl8C1 enginel
Osscription
Two air intakepaths are providedin the intake manifoldto allow the selectionof the intak€ path most
t favorabl€
favc for a
given enginespeed.
Satisfactorypower peformanc€ is achievedby closingand openingthe intakeair bypass(lAB)controlvslves.
valve! Hightor-
que at low RPMis acheivedwhen the valvesare closed,whereashigh power at high RPMis achievedby when the valves
8re oDeneo.

IAB CONTROL
VALVES

To PGM-FI
MAIN RELAY
RELi

IAB
CHECK VALVE

(cont'dl

11-123
IntakeAir System
IntakeAir Bypass(lAB) ControlSystemtBl8C1 enginel(cont'dl
Troublcahooting

Insp€ction of IAB Conltol Sytt.m

tA8 COI{TROL
DIAPHRAGM
Start engino and allow to idle.
VACUUIIPUMP/GAUG€
A973X-041-XXXXX
R€move# 13 vacuumhosetrom
the IAB control diaph.agm and
connect vacuum gauge to the
hose.

R€move # 12 vacuum hose from

th€ IAB vacuum tank, then check
tor vaccum at the IAB vacuum
tank.

Rcplir lh. block.g. ot

vacuufi laak boiwaao
tha IAB vacuum tank
lnd th. intlk m!ni-
fold.

Disconnect the 2P conn€ctor lrom

the IAB control solenoid valve.

Measure voltage between

YEL/BLK(+l torminal and
PNK/8LUl-) terminsl.

IAB CONTBOL
SOLENOIDVALVE from
wiro haana
sid€

PI{K/
B L UI - I

YEI/
a L Kl + l
ls thoro battery voltage?

Measure voltage b€tween

BLK^|/EL(+) torminal and body
ground.
 (Frompage 1 1-124) {Frompago 1 1-124}

Raise engine speed to above
6,000 rpm.
Repsirop6n in YEL/BLK
wiro botwoon tho 2P
ls there battery voltage?
connector and FGM-FI
main relaY.

Turn the ignitionswirch OFF.

Checklor vacuumat #'l3 vacu-
um hose.
Connectlhe test harnessbetween
the ECM and connectors lsee
p a g e1 1 - 3 7 ) .

Turn the ignitionswitch ON and

connect a lumper wke between
ECM (A17) terminal and ECM
{A26) terminal.

Ooes the solenoid valve click
when the jumper is con-
nected?
RopaiioponinP K/BLU
wiao botwoen ECM
lAl7l and tho 2P con-
nectot.

Sub3titute a known-good ECM

and rechock. lf symptom/indica-
tion goos away, r6placetho origi-
nal ECM.

Disconnectthe 2P connectortrom
the IAB control solenoidvalve.

Turn the ignitionswitch OFF.

Checkfor continuity to ground on

the PNK/BLUwire.
ls there continuity to ground?
Ropairshort to g.ound
at PNK/BLU wiro bo-
two6n ECM {A17) and
tho 2P connector.

IAB control syst6m is OK. Substituto a known-good ECM

and racheck. It symptom goos
swsy, roplace tho original ECM.

11-125
a

Intake Air System

IntakeAir Bypass(lABl ControlValve IB18C1 enginel
Trlting

GAUTIOI{; Do not rdlust lho IAB control valvo tull-close screw. lt is prosot at th. t.ctoty.

1. Chsck the IAB control valve shsft for binding or sticking.

2. Check th6 IAB control valve for smooth movement.

3. With the engine at idle, check that @ot the IAB control valve is in close contact with the stoppsr when vacuum
hose is disconnected.

With th€ ongine at idl6, check that @of the IAB control valve is in close contact with the full-closo acrew whsn
the vacuum hose is connectad.

a lf 8ny fault is lound, clean the linkage and shatts with carburetor claaner'

- lf the oroblam still exists after cleaning, disassemblethe intake manifold and check the IAB valvE body sss8mbly.

11-126
Dls!$.muy:

ITTAKE
MANIFOLD
23 N.m
12.3kgt.m.
17 tbt.ftl

GASXET
6 Rgplace.
a a
|AA VALVEAODY

I]{TAKE MANIFOLD 24 N.m

CHAMBER (2.4 kgf.m,
t7 tbf.ftl

11-127
Intake Air System
IntakeManifoldIB18B1enginel
Disassembly:

{ uuu
24 N.m
12.4 kgf.m,
t7 tbt.ftl 23 N'm
(2.3 kgt.m,
17 tbf.ftl

11-128
EmissionControl System
System TroubleshootingGuide

NOTE: Acrosseach row in the chart,the sub-systemsthat could be sourcesof a symptomare lanked in the ord€rthey
should be inspected starting with O. Find the symptom in the lett column, read across to the most likely source, then
reJerto the page list€d at the top of that column. lf inspection shows the system is OK, try the next most likely system
@, etc.

PAGE SUB.SYSTEM POSITIVE

THREEWAY EVAPORATIVE
CRANKCASE
CATALYTIC EMtSSTON
VENTILATION
CONVERTER CONTROLS
SYSTEM

SYMPTOM 1 1 - 1 3 21, 3 3 1 1 -1 3 4 1 1 tJo

ROUGHIDLE o
FAILS
EMISStON o @
TEST
POORPERFORMANCE
LOSSOF
POWER
o

11-129
EmissionControlSystem
SystemDescription
The emissioncontrol system includesa ThreeWay Cata-
lytic Convener (TWC), Positive Crankcase Ventilation
(PCV)system and EvaporstiveEmission{EVAP)Contfol
syst€m. The emissioncontrol system is designedto meet
federsl and stats emissionstandards.
11-130
Tailpipe Emission
Inspection
f!fifil oo nor amoro ou]rngrnr! Foacqurr. ^!op
any open flame away from yout wotk atca.
Start the engine. Hold the engine at 3,OOOrpm with
no load (A/T in @ or@ position,M/T in neutral)until
the radiatorfan comes on, then let it idle,
Connect a tachometer.
Check and adiust the idle speed, if necessary (sss
p a g e11 - 9 5 ) .
Warm up and calibrate the CO meter according to
the meter manutacturer'sinst.uctions.
Check idle CO with the headlights, hester blower,
rearwindow defogger,coolingfan, and air condition-
er otf.
NOTE: (Canada)Pull the parking br8ke lever up.
Stan the engine,then checkthat the headlightsare
off.
CO meter should indicate0.1 maximum.
 ThreeWay GatalyticConverterITWC)
Dr!criplion

Th6 Three Way Cstalytic Converter (TWC) is used to convert hydrocarbons (HCl, carbon monoxide (CO), and oxides
ot nitrogen{NOx) in the exhaustgas, to carbondioxide (COr},dinitrogen(N2land water vapo..

The illustrationshows the TWC tor the 818C1 engine.

THREEWAY
CATALYSTS

FBONTOF
VEHICLE

11-131
EmissionControl System
ThreeWay CatalyticConverter(TWC)(cont'dl
Inspection

lf sxcessive oxhaust system back-pressureis suspected. remove the TWC trom the car and make a visual check for plug-
ging, meltingor crackingof ths catalyst. Replacethe TWC if any of the visiblearea is damagedor plugged.

81881 ongino:

T SHIELO

TI{REEWAY
CATALYTIC
CONVERTER{TWCI
Removsl/installation,see section 9
Inspecthousingfor cracksor
other damage.
Inspect element tor clogging
by lookingthroughthe inside.

HEAT SHIELD

11-132
818Cl engine:

HEAT SHIELO

THREEWAY
CATALYTIC
r
COI{VEBTEB{TWCI
R€moval/installation.sso s€ction 9
Inspoct housing tor cracks or
othor damage.
Inspect elemont for clogging
by looking through the inside.

HEAT SHIELD

11-133
EmissionControlSystem
PositiveCrankcaseVentilation(PCVISystem
Description Insp€cdon

The Positive Crankcase Ventilation (PCV) system is 1. Check th€ PCV hos6sand connectionstor lsaks and
designed to prevent blow-by gas {rom escaping to the clogging.
atmosphsre. The PCV valve contains a spring-loadsd SREATHER
plunger. When the Bnginestarts, the plunger in the PCV
valve is lifted in proportion to intake manifold vacuum
and the blow-by gas is drawn directly into th€ intak€
manifold.

FCV VALVE

.F: ILOW-BYVAFOR
er FRESHAIR
2 . At idle, mak6 sur€ th6fe is a clicking sound from th6
PCV valve when the hose between rcV valve and
intake manifold in lightly pinched with your fingors
or oli€rs.

Gontly pinch hero.

a lf thera is no clicking sound, ch6ck the PCV valve

grommet for cracks or damage. ll the grommet
is OK, reolace the PCV valve and recheck.

11-134
 EvaporativeEmission(EVAPIControls
Da.cdptlon

Thg avaporstive omission controls are designed to minimize the smount of fusl vapor escaping to the atmosphero. The
system conaists ot the following compon€nts:

A . Evlporttly. Emlttbn (EVAPI Control Caniltot

An EVAP control canistor is used lor the temporary storage ot fuel vapor until the fuel vapor can be purged lrom
th€ EVAP control canister into the engin€ and burned.

vlpor hr]gG Cmt]ol Syst m

€VAp control canistgr puroing is accomplished by drawing fresh air through tho EVAP control canister and into a
pon on th6 throttl€ body. Th€ purging vacuum is controllsd by the EVAP purge control diaphragm valve end the
EVAP purge control solenoid valve.

C. Ft|.l Tmk Vlpor Control Systom

When fuel vapor prassurein the fuel tank is higher than the set v8lue of the EVAP two way v8lv6, th€ valve opens
and regulates the flow ol fuel vapor to the EVAP control canister.

(cont'd)

11-135
EmissionGontrol System
EvaporativeEmission(EVAPIControl(cont'd)

EVAP
PURGE
EVAP CONTROL
TWO WAY VALVE SOLENOID
VALVE
FUELTANK
EVAP VALVE
FUEL
FILLCAP VARIOUS
sEt{soRs

BLK
5

EVAP CONTROL
CANISTEB

FRESH
AIR

11-136
 #7 VACUUM HOSE

Troublclhooting

VACUUM PUMP/
GAUGE
A973X-O41-XXXXX
Disconn€ct #7 vacuum hose
trom the EVAP putgo control di' COI{TROL
EVAPPTJBGE
aph.agmvalve lon the EVAPcon- DIAPHRAGMVALVE
t.ol canistor) and connoct a
vacuum gauge to tho hose.

Stsrt the €ngine and allow it to

idls.
NOTE: Engine coolant tempera-
ture must be b€low 163oF (73ocl

EVAP
Oisconnectthe 2P connegtortrom PUBGECONTROL
the EVAP purge control solenoid VALVE
YEL/
Bl8Bl .noin.: B L K( + I
YEL/
B L KI + I

(-t

wirg aide

--\

EVAP M e as u r o v o l t a g o b e t w € e n
R'RGECOI{TROL YEL/BLK{+) terminsl 6nd RED
VALVE
SOLENOID l-) terminal.
Inapactvacuum hoa€
ror.ring.
ls ther6 battery voltage? l| OK, toolrc. EVAP
purgo conttol solenoid

Moasule voltage botween

YEL/BLK {+) terminal bodY
ground.

(To page 1 'l-139)

(To pa96 1 1-138)

(cont'd)

11-137
EmissionGontrolSystem
EvaporativeEmission(EVAP)Gontrols(cont'd)
(Frompage 1 1-137)
Start the engine. Hold the engine
at 3,OOOrom with no load lA/T in
E orE position,M/T in neutrsl)
unlil lhe radiator tan comes on.
then let it idle.
Checklor vacuum at # 7 vacuum
hose alter starting the engine.
lTo page 1 1-'l39)
11-138
{ F r o mp a g e 1 1 - 1 3 7 }
Ropair opon in YEL/BLK
wirc b.tw..n EVAP
ls there baftery voltage? purgo control rolanoid
vrlvo and th. xiM-Fl
mlin r6lay.
Inspoct RED wirc for 6n opon to
trody g.ound botween ECM lA20)
and th6 conn6ctor.
It wir. b OK, substiluto a known-
good ECM and rochock, It sym-
ptom 9o6s away, roplaco tho
original ECM,
Oisconnectthe 2P connoctorfrom
the EVAP purge control solenoid
Intpoct vacuum hoaa
rcuting.
ls there manifoldvacuum? It OK, reolrco tr|c EVAP
Purge contlol lolanoid
Inrpoct for a short i|t REDwire bo-
lwoen ECM {A2Ol and th6 con-
noclor.
ll wiro la OK, substituto a known-
good ECM 6nd .echock. lf symp-
tom goes away, loplacetho origi-
nal ECM.
 (F.om pdge 1l-138)

VACUUMPRESSURE
GAUGEO-4 In.Hg
oTJAZ-OOIOOOB

Connoct a vlcuum gaugo to

caniator purg! lir ho!o.

Stsn tho onginc lnd rai!. spo€d

to 3,50O rpm.

PURGEAIR HOSE

Do€avocuum opp€aron gougo Connect a vacuum gauge to the

within 'l minuto? csnister puag6hos6 and raisethe
sngin€ spe€d to 3,500 rpm.

Saa EVAP tso {ay vdv. t.!t io Inapoct tha purga hoso
conrDbta. and drronl. body potl
Evapoardva ambdon coartaoL|.| for pinch or blocklga.
ox.

(cont'd)

11-139
EmissionControl System
EvaporativeEmissionControls
(cont'dl
Evaporativ€ Emission {EVAPI Two Way Valvo Tasting

l. Removethe tuel fill cao.

2. Removevapor line trom the two way valve on the

fuel tank and connect to T-fitting trom vacuum
gauge ano vacuum pump as snown.

VACUUM/
PRESSUREGAUGE
oTJAZ-OOIOOOa

A973X-041-XXXXX

f T-FITTING

Apply vacuum slowly and continuouslywhile watch-

ing the gauge.

Vacuum should stabilize momentarilv at 5-15

m m H g ( 0 . 2 - 0 . 6 i n .H g ) .
a It vacuumstabilizes(valveopenslbelow5mmHg
(O.2in.Hg)or above I 5 mmHg (O.6in.Hg),install
a new valve and retest.

4. Move vacuumpump hosefrom vacuumto pressure

titting, and move vacuumgaugehosetrom vacuum
to oressureside as shown.

J-. . -,-/asr^:
fF
,T 4?e
Slowly pressurize
the vaporlinewhile watchingthe
gauge.

Pressure shouldstabilizeat 1O-35 mmHg(0.4- 1.4

i n .H g ) .
a lf p.essuremomentarilystabilizes{valveopensl
a t 1 O - 3 5 m m H g ( O . 4 - 1 . 4 i n . H g ) t, h e v a l v ei s
oK.
a lf pressurestabilizesbelow 10 mmHg {O.4in.Hg)
or above35 mmHg(1.4 in.Hgl,installa new valve
and retest.

11 -1 4 0
Transaxle
Clutch 12-1
M a n u aTl r a n s m i s s i o. .n. . . . . . . . . . . . . . . . 1
. .3. .- 1
A u t o m a t iT
c r a n s m i s s i o. .n. . . . . . . . . . . . . 14-1
...
Differential
ManualTransmission
81881 engine 15-1
818C1engine 15-9
AutomaticTransmission ............... 15-19
Driveshafts 16-1
Glutch

S p e c i aTf o o l s . . . . . . . . . . . . . . . .1 2 - 2
f f f u s t r a t e Idn d e x . . . . . . . . .... 12-3
Clutch Pedal
Adjustment ................12-4
Clutch Master Cylinder
Removal/lnstallation .... 12-5
Slave Gylinder
Removal/lnstallation .... 12-6
PressurePlate
Removal/lnspection ..... 12'7
Clutch Disc
lnspection/Removal ..... 12-8
Flywheel, Flywheel Bearing
fnspection . 12-9
R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .1.2. .-.9
Clutch Disc, PressurePlate
Installation 12-10
ReleaseBearing
Removal/lnspection 12-11
 SpecialTools

Ref. No, I Tool Number Description Oty Page Reference

o
/^
OTJAF_PM7011A Clutch AlignmentDisc
'I
12,7
OTLABPVOO1 OOor Ring Gear Holder 1 1 2 - 1 ,8 , 9 , 1 0
o7 924-PD20003
ri) 07NAF-PR30100 Clutch AlignmentShaft I 1 2 - 7, 8 , 1 0
@ 07746-0010100 Attachment, 32 x 35 mm 1 12-10
07749-OO10000 Driver I 12-10
@ 07936-3710100 Handle I 1 2 - 1, 8 , 1 0

12-2
lllustrated Index

NOTE:
a Wheneverthe transmissionis removed,clean and greasethe releasebearingslidingsudace.
a It the pans marked r are removed.the clutch hydraulicsystem must be bled (see page 12-6).
a Inspectthe hoseslor damage,leaks,interterence,and twisting.

*RESERVOIR
HOSE
ASSISI SPRING
COTTER
Beplace.
I
N
n Il
6 x 1,0 mm
9.8 N.m ll.0 ksf.m, 7 lbf.tt)

9 t
PEDAL PIN v-_fl 1 5 N . m 1 1 . 5k g l . m ,
11 tbt.ftl
TCLUTCHMASTER CYLINDER
page 12-5
Removal/lnstallation,

.CLUTCH PIPE
CLUTCH PEDAL
Adjustment,
page 12-4 15 N.m {1.5kgl.m,
1 1 rbf.ft)
JOtt{T
8 x 1.25mm
25 N.m (2.6 kgl.m,
19 lbt.ttl
19 N.m ll.9 kgt.m,
14 lbf.ftl FLYWHEEL
RELEASEBEARING Inspection.page 12-9
Romovaf/lnspection, page 1 2-1 1 Replacement, page 12-9
lnstaffation,page 12- 12
CLUTCH DISC
Removal/lnspection. page'12-8
TRANSMISSION
Romoval. see Installation,page 12-10
section 13 12 x 1.0 mm
103 N.m llO.5 kgt.m,
ICLUTCH PIPE 76 rbf.ftl
PRESSUREPLATE
Removal/lnspection. page 12-7
Installation,page 12,10

8 x 1.25mm
22 N.m (2.2 kgf.m.
16 lbl.rr)

TSLAVE CYLINDER
Removaf/lnstallation. page 12-6
32 N.m {3.3 kgf'm,
24 tbf.ftl

ICLUTCH 15 N. m {1.5kgf.m,
'| I tbf.ftl

12-3
ctutch
Clutch Pedat
Pedal I
Adjustment

[-],ll'"-""
NOTE:
a To check the clutch interlock switch and clutch
sb''''""
Turn the clutch switch (or adjustingbolt) in 3/4 to
1 full turn further.
f
| :;i:'":fff*tr#:?iff:".,*::,::".
| .#::J:::
switch, see seclion 23.
a The clutch is selt-adjusting

"orr,O",
CAUTION: It there
to compensatefor wear.

there is no clearanco
clearancobetween
between the master
mastel
6 . Tighten locknurA.

7. aoo""n
,. Loosenlocknut B and the clutch intertoct
interlockswitch.
switcl.
| |
| | | |
cylinder piston and push lod. the releasoboaringis held | | I
againsl the diaphragm
against diaphragm spring,
spring, which
which can result
result in clutch
clutch | the clearancebetweenthe tloor
8. Measuretne floor boardand I I
slippage 01 othel
slippage clutch problems.
othel clutch problems. clutch pedalwith the clutch pedaltully deeressed.
depressed.
I I I
1 . Loosenlocknut A, and back otf the clutch switch
1. | 9. R
9. Release
e l e a s the c l u t c hpedal
teh e clutch p e d a l15-2O m m {(O.59-O.79
1 5 - 2 0 mm O.59-O.79 I I
{or adiustingbolt) until it no longertouchesthe clutch
adjustingboltl I in) trom
int the fully depressedpositionand hold it there. I
from ttre I
pedal. Adiustthe positionof the clutch interlockswitch so
that the enginewill start with the clutchpedalin this
,2 . ::":""
Loosenrocknut
locknut c,
C, and rurn
and turn the push
the push rod
rod in
in or
or out
out | iliiiliffi:l1l:J"'1"-:H"l:tJ:i"i#fT:I
oosition. I

::***r**'' '-"'"'';*1,,0*
to get the specifiedstroke(@)and height(O) at the
clutch pedal.

.,".,u"**;
10. Turnclutchinterlockswitch 3/4 to 1 tull turn funher.
I tf

|
. il*:*j':"'-(@)andheisht(olatthe
Tighten locknut C. ,:.;:,nterrockswitch3/4torrurrturnturtner.
1 1 . T i g h t e nl o c k n u tB .

Turn the clutch switch (or adjustingbolt) until it con-

|

, II
tacts the clutch pedal.

ASSIST SPRING LOCKNUTB

9.8 N.m (1.0 kgf.m,7 lbf.ftl
-6ll
CLUTCH INTERLOCK
PUSH ROD swtrcH
CLUTCH MASTER CYLINDER

CLUTCH SWITCH
{or AOJUSTING BOLTI

LOCKNUTA
9.8 {N.ml (1.0 kgl.m, 7 lbt.ftl
LOCKNUTC
l3 N.m l'l.3 kgf.m, 9

(STROKEat PEDALI:130-140 mm 15.12-5.51 in)

{TOTALCLUTCHPEDALFREEPLAY):12-21 mm 10.47-0.83 inl includingtho p.dal play I -lO mm 10.04-0.39 inl
{CLUTCHPEDAL HEIGHTI: 164 mm (6.46 in} to tho lloot
{CLUTCHPEDAL DISENGAGEMENTHEIGHTI: 83 mm 13.27 inl minimum to tho lloo.
Clutch Master Cylinder
Removal/lnstallation

CAUTION: Removethe clutch mastercylinder.

a Do not sgill b.ake lluid on the car; it may damags the
painl; it biake fluid does contact tha paint. wash it NOTE: Do not spillbrakefluid on the clutch master
otf immediately with water. cylinderdamper.
a Pluglhe end ot the clutch pips and r€servoilhose with
a shop towel to prsvent blake fluid ttom coming out.

1. Remove the brake fluid from the clutch master

cylinde.reservoirwith a syringe.

2. Disconnectthe clutch oioe and reservoirhosefrom

the clutch master cvlinder.

CLUICH PIPE
15 N'm {1.5kgl.m,
1 1 tbf.ftl

OAMPER
CLUTCH
CLU
MASTER
M AI
cYL
CYLINDER
!l rn
Installthe clutch mastercylinder in Ine reverseor-
der of removal.

NOTE: Bleedthe clutchhydraulic

c system
s\ (seepage
CLUTCH 12-61.
MASTER
CYLINDER

Pry out the cotter pin. and pull the pedal pin out ot
the yoke. Remove the nuts.

NUTS
13 N.m {1.3 kgf.m,
9 lbt.frl

12-5
Slave Cylinder
Removal/lnstallation

CAUTION: Install the slave cylinder in the reverseorder ol

a Do not spill brake tluid on the car. it may damago tho removat.
paint; it brake tluid doos conlacl tho paint, wash it
off immediately with watei. NOTE: Make surethe boot is installedon the slave
a Plug tho €nd of the clutch pipe with a shop lowsl to cylinder.
plevcnt b.ake fluid from coming out.

-61, Super High Temp Urea Grease {P/N

08798-9002).
: BrakeAssemblyLubeor equivalentrubber CLUTCH PIPE
15 N.m (1.5 kgf.m, 11 lbf'ftl
grease.
'1.
Disconnectthe clutch pipe from the slavecylinder.
SLAVE CYLINOER
Removethe slavecylinderfrom the clutch housing.

-Cl
tP/N08798-90021

8 x 1.25mm
22 N.m 12.2 kgl'm,
16 rbt'ft)

...::
:^.
Gil^lt i
(BrakeA$embry
Lubol
4. Bleedthe clutch hydraulicsystem.

a Attach a hose 1o the bleederscrew, and suspend

BOOT the hose in a containeroJ brakefluid.
Remove and check for signs ol leaking and deterioration. a Make surethere is an adequatesupplyof tluid at
the clutch mastercylinder.then slowly pumpthe
clutch pedaluntil no more bubblesappearat the
bleederhose.
a Refillthe clutch mastercylinderwith fluid when
done.
a Use only DOT 3 or 4 braketluid.

12-6
PressurePlate
Removal/lnspection

Check the diaphragmspring fingers for height us- 4. Inspectthe pressureplateI surfacefor wear, cracks,
ing the specialtools and a feeler gauge. and burning.

StandardlNew): 0.6 mm (0.02 inl Max. diaphrag springfor wear

Inspectthe fingers of the diaphragm
ServiceLimit: O.8 mm {O.O3in} at the releasebearingcontact
nracr area.
ar

FEELER
GAUGE
CLUTCHALIGNMENTOISC DIAPHRAGM
SPRING
OTJAF_PM7011A
PRESSUREPLAT€

07NAF-PR30100 07936-3710100 6. Inspectfor warpageusinga straight

stru edge and feef
er gauge.
. lf the heightis morethanthe servicelimit,replace
the pressureplate. NOTE: Measureacrossthe pressure
prer plate at three
pornls.
2. Installthe specialtools.
Standard(Newl: 0.03 mm (0.0
0.001 in) Max.
3. To prevent warping, unscrew the pressureplate SorviceLimit:0.15 mm (0.0O6
)O6 inl
mounting bolts in a crisscrosspattern in several
steps, then removethe pressureplate.
STRAIGHTEOGE

CLUTCH ALIGNMENTSHAFT
07NAF-PR30100
HANDLE
07936-3710'l OO

FEELERGAUGE
RINGGEARHOLDER PI
07LAB-PVOOlOOor
07924-PD20003 PRESSUREPLATE lf the warpage is more than
replace the pressure plate.

12-7
ctutch Disc

'.#fu;;
Glutch Disc I

l
Removal/lnspection
'1. Measure the depth trom the lining surface to the
Removethe clutch disc and specialtools.
rivets, on both sides.
Inspectthe liningof the clutchdiscJorsignsoJ slip-
pingo. oil. lf it is bu.nedblackor oil soaked,replace Standard(Now): 1.3 mm (O.05 inl Min.
''
it. ""-*":'-- inr
{o'oo8
Se.viceLimit: O.2 mm {O.OO8inl

=-.--']!
; i , n-\ ll
"LUrcH
CLUTCH Drsc
DISC
| CLUTCHDISC I I

W@*-l
@
slbir":ix:l#
Ii!fr..;*'::l;'"o^"
\t'=f
CLUTCHALIGNMEI{T
07NAF-PR30100
HAt{DLE
07936-3710t0O
SHAFT

3.
|
Measu.ethe clutch disc thic
thickness.

Standard{Now}: 8.4-9.1 mm (o.33*0.36 inl

Sarvica Limit: 6.0 mm (O.24 in)
LINING SURFACE
II
CLUTCH DISC

It the rivet deDth is less than the service limit,

reolacethe clutch disc.

lf the thickness is less than the service limit,

reolacethe clutch disc,
Flywheel, Flywheel Bearing
Inspection Replacement
Inspect the ring gear teeth for wear and damage. Install the special tool.

Inspect the clutch disc mating surface on the Remov€the flywhe€l mounting bolts in a criascross
flywheel fo. wear, cracks, and burning. pattern in severalsteps 8s shown, then remove the
tlywheel.
Measurethe flywheel runout using a dial indicator
through at least two full tu.ns. Push against the FLYWHEEL
Ilywheel each time you turn it to take up the crank-
shaft thrust washe. clearance.

NOTE; The runoutcan be measu.edwith enginein-

stalled.

Standard (ttlervl: O.O5 mm (O.002 inl Max.

Service Limit: 0.15 mm 10.006 inl

RING GEAB FLYWHEEL

MOUI{TII{G BOLTS

3. Remov€ the flywheel bsaring from th€ tlywheel.

DIALII{DICATOR
It the runout is more than the servicelimit, leplace
the flvwheel.

Turn the inner race of the flywheel bearingwith your

finger. The bearingshould turn smoothly and quiet-
ly, Checkthat the bearingouter race fits tightly in
the flvwheel.

FLYWHEEL
BEARING

It the racedoes not turn smoothly,quietly,or fit

tight in the flywheel, replacethe flywheel bearing. (cont'd)

12-9
 Clutch Disc,
Flywheel,FlywheelBearing PressurePlate
Replacement(cont'd) Installation

4. Drivethe new flywheelbearingintothe flywheelus- l. Installthe ring gear holder.

ing rhe specialtools as shown.
t Apply greaseto the splineof the clutch disc, then
install the clutch disc using the specialtools as
DRIVER
07749-O010000 snown.

NOTE: Useonly SuperHighTemp UreaGrease(P/N

08798-9OO2).

CLUTCH DISC

ATTACHMENT.
32x35mm
07746-OOlO100

FLYWHEEL

FLYWHEELBEARING

5 . Align the hole in the flywheel with the crankshaft RINGGEARHOLDER CLUTCH ALIGNMENTSHAFT
dowel pin and installtheflywheel.Installthemount- OTLAB-PVOOI
O0ot 07NAF-PR30100
07924-PD20003 HANDLE
ing bolts finger-tight. 07936-3710100

o. Installthe specialtool as shown, then torque the 3. Instalithe pressureplate.

flywheel mounting bolts in a crisscrosspattern in
severalsteDsas shown.
CLUTCH ALIGNMENTSHAFT
oTNAF-PR30100
FLYWHEEL HANDLE
07936-3710100

PRESSUREPLATE

MOUNTINGBOLTS
12 x 1.0mm
1 0 3 N . m 1 1 0 . 5k g f . m ,
76 tbf.fr)

12-10
t
\_
 ReleaseBearing
Removal/lnspection

4. Torquethe mountingbolts in a crisscrosspatternas 1 . R e m o v et h e release fork boot trom the clutch

shown.Tightenthe boltsin severalstepsto prevent housing.
warping the diaphragmspring.
2. Removethe releasetork trom the clutchhousingby
squeezingthe releasefork set springwith pliers.Re-
move the releasebearing.

CLUTCHHOUSING

8 x 1.25mm
25 N.m 12.6 kgt'm,
19 tbt.ftl

RELEASEFORK

Checkthe releasebearingfor play by spinningit by

hand.

CAUTION: The release boaring i6 packed with

grease. Do not wash it in solvent.

Removethe specialtools.

Recheckthe diaphragmspring fingers tor height (see

page 12-7]..

-24/--2,t'.2424?'

IJ
l{ there is excessiveplaY,rep)acethe rdease\Ear-
ing with a new one.

,F=:=
ReleaseBearing
Installation
1 . With the releasetork slid betweenthe releasebear-
ing pawls, installthe releasebearingon the main-
shaft while insertingthe releasefo.k through the hole
in the clutch housing.

2 . Alignthe detentot the releasefork with the release

tork bolt, then pressthe releasefork over the release
fork bolt.

NOTE; Use only Super High Temp Urea G.ease(P/N

08798- 9002).

-611
lPlN 08798-

-6
{P/N0879a- 9002)

Move the releasefork right and left to make surethat

the fork tits properlyagainstthe releasebearing,and
that the releasebearingslidessmoothly.

4. lnstallthe releasefork boot.

12-12
ManualTransmission
SpecialToofs .............
13-2 MainshaftAssembly
Maintenance Index ................ ......13-21
Transmission Oi1,...,........,........,.,.....
13-3 Clearancefnspection .......................
13-22
Back-upLight Switch Disassembly ..........13-25
Replacement .........13-3 Inspection ..............13-26
TransmissionAssembly Reassembly ...........13-21
Removal ..,.......,......
13-4 Countershaft Assembly
lllustratedIndex ...................................
13-8 Index ................ ......13-28
TransmissionHousing ClearanceInspection .......................
13-29
Removal ...........,.....
13-10 Disassembly ..........13-30
ReverseChangeHolder,Reverseldler Gear Inspection ..............
13-31
Glearance lnspestion.......................
13-11 Reassembly ...........
13-32
Removaf .................
13-12 SynchroSleeve,SynchroHub
ChangeHolderAssembly Inspection ..............
13-34
Clearance Inspection.......................
13-13 Installation .............
13-34
Removal .................
13-15 SynchroRing,Gear
Disassembly/Reassembly ...............
13-16 lnspection ..............
13-35
Mainshaft, Gountershaft,Shift Fork Clutch HousingBearing
Removal ...,.............
13-17 Replacement .........13-36
Shift Rod Mainshaft Thrust Clearance
Removal 13-18
................. Adiustment ............
13-38
Shift Fork Assembly Transmission
Index ................ ......13-19 Reassembly ...........
13-tl1
Clearance Inspection.......................
13-20 TransmissionAssembly
lnstallation .............13-46
Gearshift Mechanism
Overhaul ................
13-50
 SpecialTools

Rsf. No. I Tool Numbrr D!3cription Oty Prgc R.{.rcnc.

o 07GAJ- PG20110
o 07GAJ- PG20130
o .07736 - A010004
o 07746- 0010300
@ 07746- 0010400
@ 07746- 0030r00
07746- 0030300
@ 07746- 0030400
@ 07745- 0041100
@ 07749- 0010000
* Must be usedwith commerciallvavailable3/ 8"- 16 SlideHammer.
I
'13- 40
MainshaftHolder 1
MainshaftBas€ 1 13-40
AdjustableBearingPuller,25 - 40 mm 1 13- 36,37
Attachment,42 x 47 mm 1 13-36
Attachment,52 x 55 mm 1 13- 36,37
Oriver,40 mm l.D. 1 1 3- 2 7 , 3 3
Attachment,30 mm l.D. 1 1 3- 2 7 , 3 3
Attachment,35 mm l.D, 1 1 3- 2 7 , 3 3
Pilot,28 mm 1 13-36
Driver 1 13- 36,37

o @

ll
@ @ @

o @ @

13-2
Maintenance Back-upLightSwitch
- TransmissionOil Replacement

NOTE:Checkthe oil with the engineOFF,and the car on /itch, see section 23.
NOTE:To checkthe back-uplight switch,
levelground.
1. Disconnect the connector,then remove
rem( the back-up
1. Removethe oil filler plug, then checkthe level and light switchconnectortrom the conn
]onnectorclamp.
condition of the oil.
2. Removethe back-uplight switch.
OIL FILLERPLUG
44 N.m lia.5kgf.m, ProperLevel
33tbtftl

Replace.

2 . T h e o i l l e v e lm u s t b e u p t o t h e f i l l e r h o l e .l f i t i s
below the hole. add oil until it runs out, then rein-
stallrhe oil filler plug.

3. l f t h e t r a n s m i s s i o no i l i s d i r t y , r e m o v et h e d r a i n
p l u ga n dd r a i nt h e o i l .

4. R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r ,a n d BACX-UPLIGHTSWITCH
25 N.m 12.5kg[.m, 18 lbf.ftl Replace.
refillthetransmissionoil to the properlevel.

NOTE:The drain plug washershouldbe replacedat -up light switch.

lnstallthe new washerand the back-
everyoil change.
Checkthe transmissionoil level(see
) page13-3).
5 Reinstallthe oil filler plug with a new washer.

OilCapacity
2.2 ( ''2.3US.qt,1.9 lmp.qt) at oil chang€.
2-3I l2.1Us.ql,2.0lmp.qtlat oyerhaul.
'10W - 40, API Service
Use only SAE 10 w - 30 or
SF or SG grade.

OILFILLERPLUG
a4N.ml{.5 kgf.m,33 lbf.ftl

ORAINPLUG
$ N.m 14.0kgf.m.
29 lbf.fr)

13-3
TransmissionAssembly
Removal
4. Disconnectthe back-up light switch connoctor and
Mskc aurs iack! and safoty Etandsaro placod proper- the transmissiongroundwir€.
ly lsl8 saqtion 1|.
Apply parking brake tnd block rear whccl! to car 5, Remove the lower radiator hose clamp trom ths
will not roll ofl stand3 and f.ll on you while wotking transmissionhangerB.
undrr it.
BACK.UPLGHT
CAUTION: Use tondcr coyar3.to avoid drmlging suTcH cot{t{EcToR
plintsd 3qrfaca3,

Disconn€ctthe negative {-) cable from the battery,

then the positive(+)cable.

Drain the transmissionoil, then reinstallthe drain

plug with a new washer(seepage 13-3),

Removethe intakeair duct and the air cleanerhous-

ing assembly,

AIR CITANER
HOUSING
lnaNsMttistoN tnaNsi ssloN
GROUND WIRE HANGEBB

o. R€movethe wire harnessclamPs.

1. Disconnectthe stsrt€r motor cables and the vahicla

soeed sensor (VSS)connector.

VSS OONNECTOR

13-4
Removotho clutch pip€ bracketand th€ slave cylin- 10. Removethe enginesplashshield.
oer.

NOTE: Do not operate the clutch pedal once th€

slavg cvlinder has been r€moved.

R€move the three uppor transmission mounting 11. Disconnectthe heatedoxygen sensor(HO2S)con-
bolts 8nd lower staner motor mounting bolt. nector,lhsn rsmove the exhaust pipe A, and the
threeway catalyticconverter(B18ClEngine).

HO2S
co NEctoR
SELF.LOCKIIUT
Ropl.ce.

EXHAUST
STARTEB PIPEA
MOTOB MOUNNNG
MOUNNNG BOLTS
BOLT THBEEWAY SELF.LOCKNUT
CATALYTIC Replace.
CONVEEIER
engin6)
1818C1

13-5
19. Removethe clutchcover. 21. Placea transmissioniack under the transmission
and a jackstandunderthe engine.

Removethe transmissionmount.

TRANSMISSIONMOUNT

23. Removethe rear mount bracketbolts and the trans-

missionmountingbolts.

MOUNT/BRACKET
BRACKET

24. Pull the transmissionaway from the engine until it

clearsthe mainshaft,then lower it on the transmis-
sion iack.

13-7
lllustratedIndex

Referto the drawingbelowfor the transmissiondisassembly/reassembly.

Cleanall the partsthoroughlyin solventand dry with compressedair.

ruurlcateattthe partswith oil beforereassembly.

I
NOTE:
usesno gaskets
. Thistransmission useliquidgasket(P/N08718-0001)
the majorhousings;
between
{seepage13-43).
a Alwavscleanthe magnet@ wheneverthe transmissionhousingis disassembled.
a Inspectall the bearingsfor wear and operation.

o
*N
@
o
@
@
@

@ @
(3 @
(, @
@
@
@ t q q l
a n l ^ ' 1 u
lt I Ej
@ n l
11-4fi
(9
@
,\|j Uh
@
B

t
g
Y

o
@
@
@
[@.--oa
F5i,--@
:7

13-8
 ,
Bolt Size
6x1.0mm 1 2 N . m( 1 . 2k g i m , 9 l b n f t )
B 6x1.0mm 15 N.m (1.5kgnm,11 lbf.ft)
c I x 1 . 0m m 15 N.m (1.5kgf.m,11 lbf.ft)
D 8 x 1 . 2 5m m 24 N.m (2.4kgf.m,17 lbf'ft)
E 8 x 1 . 2 5m m 27 N.m (2.8kgnm,20lbnft)
F 8 x 1 . 0m m 30 N.m (3.1kgf.m,22 lbf'ft)

i) BALLBEARING @ WASHERBeplace.
e sroPPER R|NG @ TRANSMISSIONHOUSING
9 TAPERRING 6980 mm SHIM(*1)
A NEEDLEEEARING 79.5mm SHIM{*21
O SPACER @ THRUSTSHIM{*2I
.d SYNCHRORING T. 2.0 mm (0.079in)
t sYNcHRo SPR|NG @ BEARINGOUTERRACE{*2}
!) 5TH/REVEFSEsYNcHRo SLEEVE @ SHIFTPIECESHAFT
O 5TH/REVERSE SYNCHROHUB @ INTERLOCK
nlruc
[0 sYrucxao @ SHIFTPIECE
ii i) 5TH GEAR @ SHIFTARM HOLDER
O 38 x 43 x 26 mm NEEDLEBEARING @ SELECTARM
t3 SPACEECOLLAR @ SELECTRETURNSPRING
O 4TH GEAR @ 10 mm SHIM
.iB SYNCHROFING 6D 10 mm WASHER
.Ii9SYNCHROSPRING q0 LOCKCOLLAR
{, 3RD/,ITHSYNCHROHUB o 3 x 16 mm SPRINGPIN Replace.
€x8 mm SPRINGWASHER
@ 3RD/4THSYNCHBOSLEEVE
t9 3RDGEAR v0 CHANGEPIECE
O MAINSHAFT @ SETSCREW
O wasHER 22 N.m {2.2kgf.m, 16 lbf.ft}
@) SPRINGWASHER @ SPRINGL.25.6mm {1.01inl
40 BALLBEARING 0! STEELBALLD. 5/16 in
O 28 x 41 x ? mm OIL SEALReplace. @ MAGNET
ad 35 x 56 x 8 mm OIL SEALReplace. @ CLUTCHHOUSING
a0 14 x 20 mm OOWELPIN @ 14 x 25 x 16 mm OILSEALReplace.
@ OIL CHAMBERPLATE @ SHIFTROD
'A BEVERSEIDLENGEARSHAFT al DIFFERENTIAL
ASSEMBLY
@ wasHER
t-2) Seesection15
.A REVERSE IDLERGEAF 61 BEARINGOUTERRACEI*2I
O REVERSE CHANGEHOLDER @ THRUSTSHIMI*2)
3A sTH/REVERSE SHIFTPIECE T. 2.5mm (0.098in,
O 1ST/2NDSHIFTFORK SHIFTRODBOOT {
04 3RD/.TH sHlFr FoRK OIL GUID€PLATE
@ 5TH/REVERSE SHIFTFORK 33 x 60 x 20 mm NEEDLEBEARING
O9'OIL GUTTERPLATE BEARINGRETAINERPLATE
6' SNAPRING LOCKWASHERReplace.
@ 72 mm THRUSTSHIM COUNTERSHAFT
) OIL GUIOEPLATE THRUSTSHIM
i!0 10 mm WASHERReplace. 37 x 42 x 25 mm NEEDLEBEARING
.4i]REVERSE IDLERGEARSHAFTBOLT lST GEAR
54 N.m {5.5kgt m, 40lblftl FRICTIONDAMPER
) TRANSMISSIONHANGERB SYNCHRORING
(3 BREATHER CAP SYNCHROSPRING
@ TRANSMISSIONHANGERA lST/2ND SYNCHROHUB
63 BACK.UPLIGHTSWITCH REVERSE GEAR
25 N.m (2.5ksf.m,18lbfftl DOUBLECONESYNCHRO I*2I
@r 14 mrn waSHER Replace. SYNCHRO BINGI*1)
67 16 mm SEALINGBOLT FRICTIONDAMPER
29 N.m (3.0kgl.m, 22 lbf ft) SPACER
@ 32 mm SEALINGBOLT 42 x 6? x 24 mm NEEDLEBEARING
25 N.m (2.5kgf.m.18lbt'ft| 2NDGEAR
@ 40 x 62 x 9 mm OILSEALReplace. 3RDGEAR
D STEELBALLD. 5/16 in 4TH GEAS
Gl SPRINGL. 30 mm {1.2in} 5TH GEAR
@ 12 mm WASHERReplace. NEEDLEBEARING
63)SETSCREW BALLBEARING
22 N.m 12.2kgl.m, 16 lbt'ft, SPRINGWASHER
@ OILORAINPLUG LOCKNUTReplace.
39 N.m {4.0 kgt.m,29 lbf'ftl 108- 0- 108N.m
( 1 1 . 0- 0 * 1 1 . 0k g tm ,
€9 WASHERReplace.
@ oIL FILLERPLUG 80- 0- 80lbf.ft)
4,1N.m14.5kgJm, 33 lblftl 005 x 22 mm SPRINGPIN Replace.
*1:81881engine
*2:B18Clengine

13-9
Transmission
Housing
Removal

NOTE: 5. Loosenthe transmissionhousingattachingbolts in

. l f t h e t r a n s m i s s i o nh o u s i n go r c l u t c h h o u s i n ga . e a crisscrosspattern in severalsteps.then remove
r e p l a c e d ,t h e b e a r i n g p r o l o a d m u s t b e a d j u s t e d them.
(818C1 engine). TRANSMISSION
. Placethe clutchhousingon two piecesof wood thick
enough to keep the mainshaftfrom the hitting the
workbench.

1. Removethe back-uplight switch.

2. Removethe transmissionhangerB,

3. Removethe set screws,the springs,and the steel

balls.

Tna sMtsstoN

SPBING ATTACHINGBOLT
L. 30 mm
11.2inl
Removethe 32 mm sealingbolt.

7. Expandthe snap ring on ths countershaftball bear-

SETSCBEW ing and removeit from the groove using a pair of
snap ring pliers.
WASHER
Replace.

4. Remov€the reverseidlergear shaftbolt,

32 mm SEALINGBOLT

L
WASHER
Replace.

SNAPRING
REVERSE

13-10
 ReverseChangeHolder,
ReverseldlerGear
ClearanceInspection
Separstethe transmissionhousingfrom the clutch Measurethe clearancebetween the reverse
re cnange
housing,and wipe it cleanof the sealant. holder and the sth/revsrseshift piece p t n .

R e m o v et h e 7 2 m m t h r u s ts h i m a n d t h e o i l g u i d e Standard:
platefrom the transmissionhousing. BevorseSido: 0.05- O.ilsmm (0.002-. 0( . 0 1 8i n l
5th Sido: o.ia- 0.9 mm 10.02- 0.0,1
),1in)
t2 mm
THRUSTSHIM
SHIFTPIECEPIN

REVERSE
CHANGE

€ ,
lf the clearanceare not within the standard,
sti mea-
surethe width of the groovesin the reverse
re change
HOUSING
TRANSMISSION holder.

1 0 . Removethe 16 mm sealingbolt and the oil gutter Standsrd:

plate. RovsreaSide: 7.05- 7.25 mm {0.278- 0.285
( in)
sth Sido: 7.1-7.7 mm (0.29- 0.30I inl

REVERSC
SIOE

REVERSE

OIL GUTTERPLATE

I ' '-- sTHSIDE

lf the width of the grooves are n o t w i t h i n t h e

Ingeholderwith
standard,replacethe reversechan€
a new one.
lf the width of the groovesare within
wi the stan-
rift piece with a
dard, replacethe sth/reverseshift
new one,
(cont'd)

1 3 - 11
ReverseChangeHolder,Reverseldler Gear
ClearanceInspectionlcont'd) Removal
Measurethe clearancebetween the reverss idler 1. Removothe reversechangeholder.
gear and the reversechange holder.

Standard: 0.5 - 1.1 mm (0.02- 0.04 inl

SorvicoLimit: 1.8 mm (0.07inl REVERSECHAMiE HOII'ER

REVERSE
CHA'{GEHOLDER
2. Remove the revorss idler g€ar, th€ rev6rs6 idlsr
gearshaft,and the washor{B18Clengine}.

4. lf the clearanceis more than the service limit, mea-

surethe width ofthe reversechangehold6r.

St.ndrrd: 13.0- 13.3mm (0.512- 0.52/tinl

REVERSE
IDI.TR
REVERSE
CHANGEHOTI'ER GEAFSHAFT

lf the width is not within the standard,replace

the reversechangeholderwith a new one.
lf the width is within the standard,reolacothe
reversaidler gearwith a new one.

13-12
ChangeHolderAssembly {
ClearanceInspection
Measurethe clearancebetween the shift piece and 3. Measure the clearancebetween the select 8rm and
the shift arm holder. the interlock.

Silndrd: 0.1 - 0.3 mm (0.004- 0.012inl Standlrd: 0.05- 0'25 (0.002- 0.010in)
Scwic. Limit: 0.6 mm (0.02inl Scrvica Limit 0.5 mm (0.02in)

SHIFT PIECE INTERLOCK

SHIFT ARM HOI.I'ER

It the cloaranceis more than the service limit, mea- 4. lf the clearanceis more than the servicelimit, mea-
sureth€ width of the groovein the shift piece. surethe width ot the interlock.

Stlndffd: 8.1 - 8.2 mm (0.319- 0.323inl Stlndrrd: 9.9 - 10.0mm (0.391t- 0.39ain)

SHIFTPIECE

ll the width of the groove is not within the stan- lf the width is not within the standard.replace
dard,replscethe shift piecswith a new one. the interlockwith a new one.
lf the width of the grooveis within the standard. lf the width is within the standard,replacethe
roolacethe shift arm holder with a new one. selectarm with a new one.
(cont'd)

13-13
ChangeHolderAssembly
ClearanceInspection{cont'd}
7, Measurethe clearancebetweenthe selectarm 9. Measurethe clearancebetweenthe shift arm holder
t h e 1 0m m s h i m . and the changepiece.

Stsndard: 0.01- 0.2 mm (0.0004- 0.008inl Standard: 0.05- 0.35 10.002- 0.01i1in)
SorvicoLimit: 0.8 mm (0.03in)

SETICTABM
SHIFTARM HOLDER

10 mm SHIM

1 0 . ll the clearanceis more than the servicelimit. mea-

8. lf the clearanceis not within the standard.select surethe grooveof the changepiece.
and installthe appropriate10 mm shim for the cor-
rectclearancefrom the chan below. Standafd: 12.05- 12.15mm {0.47ilil- 0.iU83 in)

10 mm Shim

Part Numbsr Thickn€ss

24435-689-000 0.8 mm (0.03'lin)
B 24436-689-000 '1.0mm (0.039
in)
24437-689-000 1 . 2m m ( 0 . 0 4 7i n l
24438-689-000 1 . 4m m { 0 . 0 5 5i n )
24439-689-000 1.6mm (0.063in)

lf the groove is not within the standard,replace

the changepiecewith a new one.
lf the groove is within the standard,replacethe
shift arm holderwith a new one.

13-14
 Removal

1 1 . Moasureth€ clsarancebetweenthe s6l6ctarm 8nd Removs the shift piece shaft, then remove the shift
thochangepiece. piecaand the interlock.

Sundrrd: 0.05- 0.35mm (0'002- 0'014in) SHIFTPIECE

SHAFT
S.rvic. Limit 0.5mm 10.02Inl

SEI.ECTARl,l

2. Removethe changeholderassembly.

1 2 . lf the clesranceis more than the servicelimit, mea-

surethe width ofthe changePiece.

- o.'U&l in)
Strndrrd: 12.05- 12.15mm {0./17,11

CHANGEHOLDERASSEMBLY

PIECE
CHANGE

lf ths width is not within the standard,replace

the changepiec€with a n€w one.
lf the width is within the standard,replacoth€
selectarm with a new one.

13-15
ChangeHolderAssembly
Disassembly/Reassembly
eriorto reassembling.
cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces.
I

10 mm SHIM

SELECTRETURNSPRING

3 mm PIN

13-16
 Shift Fork
Mainshaft,Gountershaft,
- Removal

1. Removethe mainshaftand the countershaftassem- 4. Removethe chamberplate.

blieswith the shift forksfrom the clutchhousing.

NOTE:Tape the mainshaftspline belore removing CLUTCHHOUSING

the mainshaftand the countershaft
assemblies.

2 Removethe springwasherand the washer.

CHAMBCRPLATE

Removethe differentialassemblyfrom the clutch

housing.
OIFFERENTIAL

CLUTCHHOUSING

13-17
Shift Rod
Removal
1. Removethe shift rod boots.

2. Romovethe change piece sttaching bolt and the

springwasher.

3. Removethe set screw,then removethe spring and

the steolball.

4. R e m o v €t h o s h i t t r o d , t h e n r e m o v e t h e c h s n g e
piece.

5. Removeth€ oilseal.

SETSCBEW
OIL SEAL
CHANGEPIECE Roploc€.

*q
SPRING
L 25.6
ll.0r in,

STEELAALL
(D.5/16

SPRINGWASHER
ACHINGBOLT

13-18
Shift ForkAssembly

erior,o ,"""sembling,cleanall the partsin solvent,dry them and apply lubricantto any contactparts
I

mm PIN PUNCH

5TH/REVEFSE
SHIFTFORK

3RD/{TH SHIFTFORK

13-19
Shift Fork Assembly
ClearanceInspection
NOTE:The synchrosl€€v€and the synchrohub should Measurethe clearancebetweenthe shift Dieceand
be replac€das a set, the shift fork shafts.

1. Measureth€ clearancebetweeneach shift fork and Strndard: 0.2 - 0.5 mm {0.qt8 - 0.02 in]
its matching synchro sleeve. S.rvico Limit: 0.8 mm (0.03inl

Strndud: 0.35- 0.65 mm (0.014- 0.026in)

S€rvicoLimit 1.0 mm (0.0'l in)

SYNCHROSLEEVE IFT FORK

SHIFTPIECE

SHIFTFORK

lf the clearanceis more than the servicelimit. mea- lf the clearanceis more than the servicelimit, mea-
sure the thicknessof the shift fork finoers. surethe width of the shift piece.

Standard:7.4 - 7.6 mm (0.291- 0.299inl Stsndard: 11.9- 12.0mm (0.469- 0.472in)

lf the thicknessof the shift fork fingers is not
within the standard, replacethe shift fork with a
now one.
lf the thickness of the shift lork fingers is within
the standard, replace the synchro sleeve with a
new one.
lf the width of the shift piece is not within the
standard,rsplacethe shift piecewith a new one.
lf the width of the shift pieceis within the stan-
dard,replacethe shiftfork with a new one.

1 3 -2 0
MainshaftAssembly

NOTE:The 3rd/4thand the 5th svnchrohubsare installedwith a press.

Priorto reassembling. cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces,The
3rdl,lthand the sth synch.ohubs,however,shouldbe installedwith a pressbeforelubricatingthem.

SYNCHROBING
page'13_35
Inspection,

818Cl cngino:
Inirllstion dstailr, pag. 13-27 STOPPER
RING

TAPERRING

NEEDLEBEARING
lnspectfor wear
and operation.
3RD/'TH SYNCHROSLEEVE
SPACER
3RD/'TH SYiICHROHUB

Insp6clron,
page13-35

SPRING

SYNCHROHUB
SPRING

3RDGEAR SYNCHROSI..EEVE
Inspectaon.
page 13-22 SYNCHRO
SPRING

NCEDE AEARING
Inspocltor wear Inspectaon.
and operalton. pag6 13-35
5TH GEAR
rnspec!on,
page13-24

SPACER
COLLAR

4TH GCAR
Inspection,
page13-23

13-21
MainshaftAssembly
ClearanceInspection
NOTE: lf replacementis required.always replacethe 2. lf the clearanceis more than the servicelimit, mea-
synchrosleeveand the synchrohub as a set. surethe thicknessof 3rd gear.

1. Measurethe clearancebetween2nd and 3rd gears. EngineType 818C1 81881

Standard 34.92- 34.97mm 34.42- 34.47mm
Standard: 0.06- 0.21 mm {0.002- 0.008inl (1.375- 1 . 3 7 7i n ) (1.355- 1 . 3 5 7i n )
Ssrvica Limit: 0.3 mm (0.01in)
ServiceLimit 34.8 mm 34.3mm
( 1 . 3 7 0i n ) (1.350
in)

3RD GEAR

lf the thicknessof 3rd gear is lessthan the ser-

vice limit, replace3rd gearwith a new one.
lf the thicknessof 3rd gear is within the service
limit, replacethe 3rd/4thsynchrohub with a new
one.

13-22
 ,
Measurethe clsarancebetw€en,lth gear and the 5. lf distanceO is not within the standard,replacethe
soacercollar. spacercollarwith a n€w one. lf distance@ is within
th€ standard,measurethe thicknessof 4th gear.
St.ndffd: 0.06- 0.21 mm (0.002- 0.(xt8in)
Scwicr Limh: 0.3 mm (0.01in) EngineType 818C1 81881
Standard 3 1 . 4 2- 3 1 . 4 7m m 30.92- 30.97mm
'1.2'19
(1.237 - 1.239 in) \1.211- inl
ServiceLimit 3 1 . 3m m 30.8mm
l'1.232inl ( 1 . 2 1i3n )

1. lf the clearanc8is more than the servicelimit, mea-

suredistance@ on the spacercollar

Stlnd.rd: 26.03- 26.m mm 11.025- 1.027in)

lf the thicknessof 4th gear is less than the ser-

vice limit, replace4th gearwith a new one.
lf the thicknessof 4th gear is within the service
limit, replacothe 3rdl4thsynchrohub with a new
one.

SPACERGOLLAR

(cont'd)

13-23
MainshaftAssembly
GlearanceInspection(cont'd)

M e a s u r et h e c l e a r a n c eb e t w e e n5 t h g e a r a n d t h e 8. lf distance@ is not within the standard,reDlacethe

spacerco ar. sDacercollarwith a new one.
lf distance@ is within the standard,measurethe
Standard: 0.06- 0.21mm (0.002- 0.008in) thicknessof sth gear.
Servicelimit: 0.3 mm 10.012
inl
Standard: 31.12-31.47mm (1.237- 1.239in)
ServiceLimit:31.3mm (1.232inl

sTH GEAR

sTH GEAR

lf the clearance is more than the service limit, mea

s u r e d i s t a n c e B o n t h e s p a c e rc o l l a r .
Standard: 26.03 - 26.08 mm (1.025- 1.027 in)
SPACERCOLLAR
lf the thicknessof sth gear is lessthan the ser-
vice limit,replacesth gearwith a new one.
lf the thicknessof 5th gear is within the service
l i m i t , r e p l a c et h e 5 t h s y n c h r oh u b w i t h a n e w
one,

13-24
- Disassembly

R e m o v et h e b a l l b e a r i n gu s i n ga b e a r i n gp u l l e ra s 3. S u p p o r t3 r d g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
mainshaftout of the 3rd/4thsynchrohub, as shown.

BEARING
PULLER

BALLB€ARING

CAUTION: Removethe synchro hubs using a press

and the steel blocks .s shown. Use of a jaw-type
puller can cau3edamags to the gear teeth.

S u p p o r t5 t h g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
mainshaftout of the 5th synchrohub,as shown.

13-25
MainshaftAssembly
Inspection
1 . Inspectthe gear surfacesand the bearingsurfacss 2. Inspectfor runout.
for wear and damage,then measurethe mainshaft
at pointsA, B. and C. Stlnd.rd: 0.02 mm (0.(xxl8inl M!I.
S.rvic. Limit 0.05 mm (o.qP inl
Standord:
A: 27.987- 28.000mm 11.1018 - 1.102'linl N O T E : S u D p o r tt h e m a i n s h € f ta t b o t h e n d s a s
B: 37.98/r- 38.q)0 mm {1.il95il- l.il960 in} shown.
Ct 27.977- 27.99Omm {1.1015- 1.1020in}

S€rvicoLimit;
A: 27.9{, mm (1.1(XXlin}
B:37.930mm 11.4933 inl
C: 27.930mm {1.0996in}

Inspectoil passagestor clogging.

l f t h e r u n o u t i s m o r 6 t h a n t h s s e r v i c el i m i t ,
rsplacethe mainshaftwith a n6w one.

lf any parts of the mainshaftare less thsn the

servicelimit. .eolacemainshaftwith a new one.

13-26
 ReassemblV
1_
CAUTION: 2, Installthe sth synchro hub using the specialtools
o Pless the 3rd/ilth and the 5th synchro hubs on the ano a pressas snown.
msinshafi without lubrication.
. When installing the 3rd/4th and the sth synchro PRESS
OBIVER,,O mm LD.
hubs, support the mainshaft on the steel blocks, and 0t7it6 - 003010O
install synchro hubs using a press,
. Install the 3rd/,lth and the sth synchro hubs with a
maximum pressureof 19.6kN (2.000kgf, 1+466lbt).

^JOTEiReferto page 13-21for reassemblysequence. ATTACHMENT, sTH SYNCHROHUB

35 mm l.D.
Support 2nd gear on steel blocks,then install the 077t6- 00304{x)
3rd/4thsynchro hub using the specialtools and a
press,as shown.

NOTE:After installing,checkthe operationof the

3rd/4thsynchrosleeveand hub.

B18Blsngine:

DRIVER.40 mm l.D.
ATTACHMENT, 07746- 0030100
35 mm LD. 3RD/4TH
07746- 0o30/rc0 SYNCHROHUB

Installthe ball bearingusingthe specialtools and a

prsssas shown.

NOTE:Installthe ball bearingwith the taperedend

facingdown.

2NO GEAR

8l8Cl engine: Assemble the 3rd/4th synchro hub and

sreevetogether before installing them on the mainshaft.

3RO/4TH PRESS
DRIVER- 4o mm l.D.
SYNCHROHU8 07746- tD30100
: osed end

3RD/TTH
SYNCHRO
SLEEVE

2NDGEAR

13-27
CountershaftAssembly
lndex

NOTE:The 4th and 5th gears are installedwith a press.

3 cleanall the pans in solvent,dry them and apply lubricantto any contactsurfaces.The 4th
Priorto reassembling.
and sth gears.however,shouldbe installedwith a pressbeforelubricatingthem.

SYNCHROSPBING
LOCKNUTReDlace.
l(E*0*10EN.m
/r1.0- 0 - 11.0kgtm,I
l8o- o-80rbf.ft I

WASHER

BALLBEARING
Inspectfor wear
and operat|on,

NEEDLEBEARING
InspectIor wear
and operation.

SYNCHRORING sTH GEAR

4TH GEAR

3RDGEAR

2ND GEAR

THRUST NEEDLEBEARING
BEARING Inspectfor wear
and operation.

SPACER
page13-29
Selection.

FRICTIONDAMPER
DOUB1I @NE
SYNCHROl818Cl .ngin.l
Inspection,page 13-35
SYNCHRORINGlBl8Bl .ngin )
Inspection,page 13-35

13-24
 Inspection
Glearance
'L Measurethe clearancebetweenthe thrust shim and 3. Measurethe clearancebetween2nd and 3rd g68rs.
1stgear,
Stlndlrd: 0.05- 0.12 mm (0.002- o.(x}5inl
StEndard: 0.0,1- 0.12 mm (0.fi12- 0.005inl Scrvice Limlt 0.18 mm (0.007inl
Servics Limit: 0.18 mm (0.007in)

'HRUST SHIM

2. lf the cleatanceis more than the servicelimit,select 4. lf the closranceis more than the service limit, selsct
and installthe appropriatethrust shim to. the cor- and install the appropriatespacer for the corr€ct
rectclearancefrom the chan below. clearancefrom the chartbelow.

Thrust Shim Spaccl

Part Numbar Thicknces Part Numb"r Thickncla

23921- PKs- 900 1.95mm (0.0768in) A 2 3 9 1 7 - P 2 1- 0 1 0 29.02- 29.0,{mm

( 1 . 1 4 2-5 1 . 1 4 3i3n )
B 23922-PKs-900 1.96mm (0.0772in)
B 23918-P2r-010 29.07- 29.09mm
23923-PK5-900 1.97mm (0.0776in) ( 1 . 1 4 4-5 1 . 1 4 5 i3n )
D 23924-PKs-900 1.98mm (0.0780in)
E 23925-PKs-900 1.99mm {0.0783in)
F 2 3 9 2 6 - P K s - 9 0 0 2.00mm (0.0787inl
23927-PKs-900 2.01mm (0.0791in)
H 23928-PKs-900 2.02mm (0.0795in)
2 3 9 2 9 - P K s - 9 0 0 2.03mm (0.0799in)
2 3 9 3 0 - P K s - 9 0 0 2.04mm {0.0803in)
K 23931- PKs- 900 2.05mm (0.0807inl
L 23932-PK5-900 2.06mm (0.0811in)
M 23933-PKs-900 2.07mm (0.0815in)
N 23934-PKs-900 2.08mm (0.0819in)
o 23935-PKs-900 2.09mm (0.0823inl
P 2 3 9 3 6 - P K s - 9 0 0 2.10mm (0.0827in)

13-29
 CountershaftAssembly
Disassembly
't.
S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a 4, Removethe bearing outer .ace, then remove the
benchvisewith wood blocks. needlebearingusinga bearingpulleras shown.

2. Raisethe locknuttab from the groove in the coun-

tershaft,then remove the locknut and the spring
washer.

BEARINGPULLER

BEARING

CAUTION: Romovethe gclrs using a pross and tho

steol blocks rs shown. U3a of a l.w.typo pullor can
cau36damaggto tho gsar iocth.

Removethe ball bearingusing a bearingpuller as Support 4th gear on steel blocks. and press the
shown. out of sth and 4th gears,as shown.
countershaft

PULlTR

13-30
\ - Y
Inspection
1. Inspectthe gear surfacesand the bearingsurfaces Inspgcttor runout.
for w€ar and damage,then measurethe counter-
shaft at points A, B, and C. Stlndrrd: 0.02 mm {0.(xn8 inl Max.
Srrvic. Limit 0.05 mm {0.(x)2in)
St.ndard:
- 1.1021inl
A: 2/t.980- 27.9!13mm (0.91|:15 NOTE: Suppon the countershaftat both ends as
B: 36.984- 37.q)Omm {1.4551- 1.'156?in} snown.
C: 33.qD - 33.015mm (1.2992- 1.2998inl
SorvicaLimit:
A: 2,a.930mm (0.9815in) Rotate tl/vo compl6t€
B: 35.930mm (1.a539inl rcvolutions.
C: 32.950mm 11.2972inl

Inspecttor wear
6nd damage.

Inspectoil passage
lor clogging.
. l f t h e r u n o u t i s m o r e t h a n t h e s e r v i c 6l i m i t ,
rgDlacethe countershaftwith a new one.
lf any parts of the countershaftare less than the
service limit, replacecount€rshaftwith a new
one.

13-31
CountershaftAssembly
Reassembly
GAUTION: 4. Installthe reversegear.
. Pr93r 4th and 5th goar3 on the qountorshrft without
lubricrtion. I n s t a l lt h e s y n c h r os p r i n g , a n d t h e d o u b l e c o n e
. Whon in3talling 4th and sth goa6, srpport the shaft s y n c h r o( 8 1 8 C ' le n g i n e ) ,o r s y n c h r or i n g ( 8 1 8 8 1
on st..l block3,8nd in3tall thc 9.116 uring a prors. engine), as shown.
. Inst.ll 4th lnd 5th gcar with a maximum pro33ur€of
25.5 kN (2,6@ksr. 18,806lbo.

NOTE:Referto page 13-28for reassemblysequence.

Installthe thrust shim and the needlebearinoson

the countershaft. SYNCHRO
SPRING

NEEDLEBEARING REVERSE
GEAfi

THRUSTSHIM

COUNTERSHAFT
Assemblethe friction damper,the needlebearing,
and 2nd gear,then installthem by aligningthe fin-
gers on the frictiondamper and the groovesin the
1sv2ndsynchrohub with the fingers of the double
Installthefrictiondamper.the synchroring,and the c o n e s y n c h r o a n d t h e g r o o v e so n 2 n d g e a r , a s
synchrospringon lst gear, shown.

Installthe lsv2nd synchrohub by aligningthe fin- Installthe spacer. 2ND GEAR

gers on the friction damperand the groovesin the
'lsV2ndsynchrohub, as
shown.

1ST/2ND

NEEDLEBEARING

SPACER

FRICTIONDAMPER

8. Install the parts assembledin steps 2 - 6 on the

countershaft.
lST GEAR

13-32
 9 . S u p p o r t t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d 1 1 .Installthe needlebearing.then installthe ball bear-
install4th gear usingthe specialtools and a press, ing usingthe specialtoolsand a pressas shown.
as snown.
PRESS PRESS
DRIVER.,l0mm l.D.
07746- 0030100

DRIVER,40 mm l.O.
077{6 - 0030100 ATTACHMENT,30 mm l.D.
07746 - d)30300
BALLBEARING

NEEDLEBEARING

1 0 . S u D D o r t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d
install5th gear using the specialtools and a press,
as shown.
12. S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.
1 3 . Installthe spring washer.tighten the locknut,then
stakethe locknuttab into the groove.

LOCKNUT
1 0 8 * 0 * 1 0 8N . m ( 1 1 . 0- 0 - 1 1 . 0k g f . m ,
DRIVER,40 mm l.O.
07746- 0030100 80+0*80lbf.ftl

LOCKNUT

ATTACHMENT, 30 mm l.O.
0?7a6- (X)303(x)

wooo BLocKs

13-33
SynchroSleeve,SynchroHub
Inspection Installation
'1. Inspectgear teeth on all synchrohubs and synchro When assemblingthe synchrosleeveand synchrohub,
sleevesfor rounded off corners,which indicates be sure to match the thr€e sets of longer testh (120
wear. degreesapart) on the synchro sleeve with the three sots
of deepergroovesin th€ synchrohub.
2. I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o
sleeveand checkfor Jrgedomof movement. CAUTION: Do not install thc synchro 3l.6yc with itt
longor tosth in tha 13t/2nd synchro hub 3lob, b.c!u3a
NOTE: lf replacementis required,always replace it will d.mago tho spring ring.
the synchrosleeveand synchrohub as a set.

TEETH
LONGER

sYt{cHRo
HUBSLOT

SYNCHRO
HUB

SLEEVE

13-34
SynchroRing,Gear
r Inspection
SYNCHROSPBING
1. Inspectthe synchroring and gear.

A: lnspectthe insideof the synchroring for wear.

B: Inspectthe synchro sleeveteeth and matching

teethon the synchroring for wear (roundedoff). SYNCHRORING

CC
GOODWORN
C: Inspectthe synchro sleeveteeth and matching
teethon the gearfor wear (roundedoffl.

oo
GOODWORN
D: Inspectthe gear hub thrustsurfacefor wear.

E: Inspectthe conesurfacefor wear and roughness.

F: Inspectthe teeth on all gears for uneven wear.

scoring,galling,and cracks.

Coatthe cone surfaceof the gearwith oil, and place

the synchroring on the matchinggear, Rotatethe
ring, makingsurethat it does not slip.

Measurethe clearancebetween the synchro ring

a n dg e a ra l l t h ew a y a r o u n d .

NOTE:Holdthe synchroring againstthe gear even-

ly while measuringthe clearance.

Synchro Ring-to-GgarClgarance
Standard: 0.85- 1.10mm
(0.033- 0.0/B in)
Service mm 10.02inl
Limit:0.i1

Double Cone Synchro-to-GearCloaiance

Standald:
@: {Outer Synchro Ring to Synchro Cone)
0.5- 1.0mm 10.02- 0.0i1in)
@: lSynchroConeto Goar)
0.5- 1.0mm (0.02- 0.04in)
O: loutsr Synchro Ring to Gsarl
0.95- 1.68mm (0.037- 0.066inl
ServiceLimit:
6): 0.3 mm 10.01inl SYNCHROCONE
@: 0.3 mm t0.01inl SYNCHRORING
G):0.6 mm (0.02in) o
lf the clearanceis lessthan the servicelimit, replace
the synchroring and synchrocone.

13-35
ClutchHousingBearing
Replacement
Mainrhaft: 3. Drivethe new oil seal into the clutch housingusing
the specialtoolsas shown.
1. Removethe ball bearingusing the specialtools as
shown.

3/8' - 16SI.IDEHAMMCR
(commercially av6ilable)

CTUTCH

ATTACHMEIVT,a2 x 4t rnm
0r7a5- 0010300

()|L SEAI
Roplacs.
ADJUSTABIT AEARING
PULER,25- a0mrn
07736- A01moA

Drive the ball bearing into the clutch housing usin!

2. Removethe oil sealfrom the clutchhousing. the sDecialtools as shown.

CLUTCHHOUSING

BATI.BEAMIO

13-36
Countcr'h!ft:
'1. Bsnd the tab on the lock washer down, then remove
the bolt 8nd bearingretainerplate.
3. Positionthe oil guide plate and new needlebearing
in the bore of the clutch housing,then drive in the
needlebearingusingthe specialtoolsas shown.
NOTE:Positionthe needlebearingwith the oil hole
facingup.

OIL GUIDCPLATE

CI-UTCH
HOUSING

CLUTCHHOUSING

Remove th€ needle bearing using the specisl lools

as shown,then removethe oil guide pl8te.

3rE' - 16SUI'€HAiiMER
{commorciallyavailabls) Installthe bearingretainerplateand new lockwash-
er, then bendthe tab againstthebolt head.

8 x 1 0m m
15N.mll.5 kd.m, 11lbf.ttl

LOCK
WASHEA
Repl6ce.
AD.'USTABIIBEARIITG
PULIIR, 25- ao mm
07t36- A0rm0a

13-37
MainshaftThrustGlearance
Adjustment
1. Removethe 72 mm thrust shim and oil guide plate 5. Measure distance @ betlveenthe end of the clutch
from the transmissionhousing. housingand bearinginnerrace.

NOTE:
72 mm THRUST
SHIM . Usea straightedgeand depthgauge.
a Measureat three locationsand averagethe read-
TRANSMISSION OIL GUIDEPLATE Ings.
HOUSING

\.u END of CLUTCHHOUSING

B
fr
o

INNEBRACEot BALLBEARltac

lnstall the 3rd/4th synchro hub, spacer collar, sth

synchrohub, spacer,and ball bearingon the main-
shaft.then installthe above assemblyin the trans- Selectthe prcpet 72 mm thrust shim from the chart
missionhousing. by usingthe formulabelow.

Installthewasheron the mainshaft. NOTE:Useonly one 72 mm thrustshim.

Measuredistance@ betweenthe end of the trans- Shim Sslsction Formula:

missionhousingand washer.
Fromthe measurements you made in steps4 and 5:
NOTE: -1. Add distance@ (step5lto distance@ (step4).
. Usea straightedgeand verniefcaliper.
. Measureat three locationsand averaoethe read- -2. From this number.subtract0.93 (which is the
Ing. ENDol midpointof the flex rangeof the clutchhousing
TRANSMISSION bearingspringwasherl.
HOUSING
MAINSHAFT
-3. Takethis number and compareit to the avaif
ableshim sizesin the chart.
WASHER (Forexample)

B:2.39 2.61
+ C: O.22 - 0.93

1.68

. Try the 1.68mm (0.0661in) shim.

AALLAEARING

13-38
72 mm Thrust Shim 7. Checkthe thrust clearancein the mannerdescribed
Part Number Thickness below.
23931- P21-000 0.60mm (0.0236in)
NOTE:Carryout the measurementat normal room
2 3 9 3 2 - P 2- 0
100 0.63mm (0.0248in)
remperarure.
c 23933- P21-000 0.66mm {0.0260in}
D 23934-P21 -000 0.69mm (0.0272in) -1. Install the thrust shim selectedand oil guide
- P21-000
23935 0.72mm (0.0283in)
-000
platein th€ transmissionhousing.
F 23936-P21 0.75mm (0.0295in)
2 3 9 3 7 - P 2- 0
100 0.78mm (0.0307in) ?2 mm THRUST otL PLATE
2 3 9 3 8 - P 2- 0
100 0.81mm (0.0319 in)
-000 TRANSMISSION
23939-P21 0.84mm (0.0331 in)
HOUSING
J 23940-P2r-000 0.87mm (0.0343 in)
K 23941- P21-000 0.90mm (0.0354 in)
L 23912-P21-OOO 0.93mm (0.0366 in)
M 23943-P21 -000 0.96mm (0.0378 in)
N 2 3 9 4 4 - P 2 -10 0 0 0.99 mm (0.0390in)
o 23915- P21-000 1.02mm (0.0402 in)
P 23946- P21,000 1.05mm (0.04'13in)
o 23947-P21 -000 1.08mm (0.0425 in)
23948- P21 000 1.11mm {0.0437 in}
s 23919-P21 -000 1.14mm (0.0449inl
T 23950-P21 -000 1.17mm (0.0461in)
I n s t a l lt h e s p r i n g w a s h e ra n d w a s h e ro n t h e
23951- P21-000 1.20mm {0.0472in)
ball bearing.
23952- P21 000 1.23mm {0.0484in)
2 3 9 5 3 - P 2- 0
100 1.26mm (0.0496in)
NOTE:
X 23954-P2r-000 1.29mm 10.0508 in)
. Cleanthe springwasher,washerand thrust shim
-000
23955-P21 1.32mm 10.0520 in)
throughlybeforeinstaliation.
z 2 3 9 s 6 - P 2, 0
100 1.35mm (0.0531 in)
. I n s t a l lt h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t
2 3 9 5 7 - P 2 -10 0 0 1.38mm (0.0543 inl
shim properly.
AB 23958- P21-000 1.41mm (0.0555 in)
AC 23959- P21-000 1.44mm (0.0567 in)
AD - P21-000
23960 1.47mm (0.0579 in)
AE 23961-P21 -000 1.50mm {0.0591in)
a-=s-.r*os".^
23962 P21,000 1.53mm {0.0602in)
23963-P21 -000 1.56mm {0.0614in}
AH 23964- P2'1-000 1.59mm (0.0626in)
.,,-B*^INGWASHER
AI 23965- P2'1-000 1.62mm (0.0638in)
23966-P21 -000 1.65mm (0.0650in)
-000
Installthemainshaftin the clutchhousing.
AK 23967-P21 1.68mm {0.0661in)
23968- P21-000 1.71mm 10.0673 in) - 4 . Placethe transmissionhousingover the main-
23969- P21 000 1.74mm (0.0685 in)
-000 '1.77mm (0.0697 shaftand onto the clutchhousing.
AN 23970-P21 in)
AO 23971 P21 000 1.80mm (0.0709 in)
Tighten the clutch and transmissionhousings
with severalSmm bolts.

NOTE:lt is not necessaryto use sealingagent

betweenthe housings.

8 x 1.25mm
27 N.m {2.8 kgf.m, 20 lbf.ft}

Tap the mainshaftwith a plastichammer,

(cont'd)

13-39
MainshaftThrustClearance
Adjustment (cont'd)
-7. Slidethe mainshaftbaseover the mainshaft. - 11.Zeroa dial gaugeon the end of the mainshaft.

MAINSHAFT 12.Turnthe mainshaftholderbolt clockwise;stop turn-

ing when the dial gauge has reachedits maximum
m o v e m e n t .T h e r e a d i n go n t h e d i a l g a u g e i s t h e
amountof mainshaftend play.

CAUTION: Turning the mainshaft holder bolt mor€

than 60 degrees after the needle ol the dial gauge
stops movingmay damagethe transmission,

DIALGAUGE

- ) , .
"7t/'-
'..' .'i' i. ,
MAINSHAFTBASE
07GAJ- PG20130

-8. Attachthe mainshaftholderto the mainshaftas fol- \

NOTE: MAINSHAFTHOLDER
. Back-outthe mainshaftholder bolt and loosen 07GAJ- PG201r0
the two hex bolts.
. F i t t h e h o l d e r o v e r t h e m a i n s h a f ts o i t s l i p i s - 13.lf the reading is within the standard, the clearance is
towardsthe transmission. correq.
. A l i g n t h e m a i n s h a f th o l d e r ' sl i p a r o u n dt h e lf the reading is not within the standard, recheckthe
g r o o v ea t t h e i n s i d eo t t h e m a i n s h a f ts p l i n e s , shim thickness.
then tightenthe hex bolts.
Standard: 0.11 - 0.18 mm {0.004- 0.007 in)
MAINSHAFT
HOLOER
BOLT

f- t{-c
l\-_.r'
nrTh l\nex
| \ ._/_/lrl Borrs
L ___E_J
\
MAINSHAFT
HOLDER
07GAJ- PG20110
MAINSHAFTBASE
07cAJ _ PG20130
- 9 . S e a t t h e m a i n s h a f tf u l l y b y t a p p i n g i t s e n d w i t h a
plastic hammer.

- 1 0 . T h r e a dt h e m a i n s h a f th o l d e r b o l t i n u n t i l i t j u s t c o n -
tacts the wide surface of the mainshaft base.

13 -4 0
Transmission
ReassemblV
;
1 . l n s t a l l t h en e w o i l s e a l . 8. Installthe differentialassembly.

2. Setthe changePiece. DIFFERENTIAL

ASSEMBLY

3. lnstallthe shift rod.

4 Installthesteelball,the spring,and the set screw.

5. lnstallthe changepieceattachingbolt.

6. Installthe shift rod boots.

SETSCREW
1 2x ' 1 . 0m m
8x1.0mm
22N.m{2.2kg{.m,16lbl.ft}
30 N.m 13.1kg{ m. SPRING
22 tbl.ltl L. 25.6mm

9 . Set the spring washer and the washer.

1 0 . Install the mainshaft, the countershaft, and the shift

fork assemblies.
SHIFTROD
N O T E :A l i g n t h e f i n g e r o t t h e i n t e r l o c kw i t h t h e
groovein the shiftfork shaft.

MAINSHAFT

I n s t a l l t h eo i l c h a m b e r P i a t e .

6x1.0mm COUNTERSHAFT
12 N.m (1.2kgt'm,9lbtft)
SHIFTFORKS

(cont'd)

13-41
Transmission
(cont'd)
Reassembly
11. Install the change holder assembly. 13. Measurethe distance@ after mounting the shift
pieceshaft.lf it's incorrect,checkthe installation.
6x1.0mm
15 N.m (1.5 kgf.m, DistanceO: 11.9- 12.3mm 10.47- 0.48in)
11 tbf.ftl

CHANGE
HOLDER
ASSEMBLY

12. Installthe shift piece and the interlock,then install

the shift pieceshaft.
1 4 . lnstallthe washer (B18C1engine),the reverseidlo.
gear.and the reverseidler gearshaft.

REVERSE
IDLERGEAR

13-42
15. Installthereversechangeholder. Installtheoil gutterplate.

'18. Bendthe hook of the oil gutterplate,then installthe

16 mm sealingbolt.

6x1.0mm NOTE:Apply liquidgasket{P/N08718- 0001)to the

15 N.m (1.5kgt'm,11lbfftl
threads,

16mm SEAI-ING BOLT

29 N.m t3.0kgf m, 22 lbl'ftt

Installtheoil guide plateand the 72 mm thrustshim

into the transmissionhousing.

1 9 . Apply liquid gasketto the surfaceot the transmis-

72 mm THRUSTSHIM sion housingas shown.

NOTE:
a Use liquidgasket(P/N08718- 0001)
Removethe dirt and oil from the sealingsurface'
of the bolt holesto
a Sealthe entirecircumference
preventoil leakage.
lf 20 minutes have passedafter applying liquid
gasket,reapply it and assemblethe housings,
a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t e sa f t e r
assemblybeforefillingthe transmissionwith oil.

Liquid g.!k.t

(cont'd)

13-43
Transmission
(cont'd)
Reassembly
20. Installthedowel oins. 23, Check that the snap ring is securely seated in the
groova of th€ countershaftbearing.
2 1 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n gb y a l i g n i n gt h e
groove in the housing with finger on the stopper Dimcntion O as inst.lbd: il.6 - 8.3 mm
.ing. (0.181- 0.327inl

GROOVE

Installth6 transmissionhang€rA and back-uplight

switch clamp,thon tighten th6 transmissionhous-
22. Lower the transmissionhousingwith the snap ring i n g a t t a c h i n gb o l t s i n t h e n u m b e r € d s e q u o n c o
pliers and set the snap ring in the groove of tha shown below.
countershaftbearing.
6 | i.25 mrn
TNANSMISSION 2t .m l2.8 lgf.m, 20 lbf.ftl
HOUSING

13-44
 {

24. Installth€32 mm seslingbolt. 27. I n s t a l l t h e s t e s l b a l l s , t h e s p . i n g s , a n d t h e s e t

screws.
NOTE:Apply liquidgasket(P/N08718- 0001)to the
threads. 28. lnstallthe back-uplight switchand the transmission
hangerB.
32 mm SEALINGBOLT 8 x 1.25mm
25 N.m {2.5 kgl'm, BAC|(-UPLTGHT SWITCH 24 N.m(2.4kgfm,
2s N.m{2.5kg{.m,18lbtft) 17lbtftl

,*"""."'" /
HAiIGER B I
SPRIMi
L. 30 mm
{1,2in}
l /

12x 1.0mm
22 N.m(2.2kgi.m.
10tbtft)

26. Tight€n ths teverse idler gear shaft bolt.

REVERSEIDI.^CR
SHAFT IOLT
l0 r 1.25rnm
5a t$m 15.5kg{.m.(} lbtftl

13-45
TransmissionAssembly
lnstallation

1. Inst€llthedowel pins on the clutchhousing. 6, Raisethe transmission,

then installthe transmission
mounI.
2. Apply greaseto the partsas shown,then installthe
releasefork and releasebeaaing. N O T E :T o r q u et h e m o u n t i n gb o l t a n d n u t s i n t h e
sequenceshown.
NOTE:Use only SuperHigh Temp Urea Grease
(P/N08798- 9002). CAUTION: Checkthat the bushings are not twistod
or offset,
3. Installthe releasefork boot.

O 12 x 1.25mm
BELEASEFORKBOLT 54 N.m {6.5kgt m,
29 N.m (3.0kgl.m, tPlN 08798- 90021 47 tbtfrl
22 tbt-ttl
RELEASE
BEARING

@
I
RELEASE REEASE
FORK FORK
@ 12 x 1.25mm
7,1N.m 17.5kg{.m,
BOOT
{P/N 08798- 90021 5/r lbtftl

7. Installthe three uppertransmissionmountingbolts

P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o ni a c k , and lower startermotor mountingbolt.
and raiseit to the enginelevel.

Installthe transmissionmountingbolts and the rear

mount bracketbolts
sELF-LocKrNG BoLT
Replace.
12x 1.25mm 1 4 x 1 . 5m m
6it N.m 16.5kgl.m, 47 lbf.ftl

1 2 x 1 . 2 5m m
64 N.m 16.5 kgf.m, 47 lbf.ftl

10 x 1.25mm
44 N.m lil,s kgt m,
33 tbf.ftl

13-4 6
8, Instsll the right tront mounvbracket. 1 0 . lnstall the tront ( 8 1 8 C 1e n g i n e )a n d r e a r e n g i n e
stiff€nsrs.

SELF.LOCKINGBOLT
Replac€.
12 x 1.25mm

12 x 1.25mm
5t N.tn {5.8
42 tbt ftt

8 x 1.25mm
24 N.m l2.a kgf.]n,
17 tbtftl
RIGHT 8 x 1.25
FROifTENGINE 2r N'm (2.4kg['m, 12 x 1.25ftm
10 x 1,25mm SnFFENERS 17lbf.ttl 5? N.rn l5.Ekg[.m,
il a N.m (i4.5kgf..n, lBl8Cl lngin.l 42 tbl.ft)
33 tbtftl

11. Installthechangerod,the springpin, and the clip.

NOTE:
9. Installtheclutchcover. . Installthe clip and the spring pin on the change
joint as shown.
. Turn the shift rod boot so the hole is facing
down as shown.
. Make sure the shift rod boot is installedon the
cnangeroo,

12. Installthe changeextension.

1 3 . I n s t a l l t h eh e a ts h i e l d( 8 1 8 C 1e n g i n e ) .
8 x 1.25mm CHANGEROD
6r1.0mm 22 N.rn 12.2kgl-m.
12 N.m 11.2kgtm, 16 tbtftl
9 rbf.ftl

. SPRINGPIN
l3- Replace.

I e-- nrr,l
ll'--PuNcH
CHANGE
EXTENSION

sHtFTROOaOOt
5xl.0mm /^ "-*
2M
i@
8 x 1.25mm 9.8 N.m 11.0kgt'm,
12 x 1.25mm 2il N'm 12.4kg{.m,
57 N.m ls.E kgf.m, 17 tbffrt
7 tbf.ftt qlL#
--7
a:I lbl.trl
l818Bl .ngin.l HEATSHIELD HOt.C
(B18Cl .nginol C LIP
(cont'dl

13-47
 Transmission
Assembly
Installation (cont'd)

1 4 . I n s t a l lt h e i n t e r m e d i a t e
s h a f ta n d t h e d r i v e s h a f t s 17. lnstall the exhaust pipe A, and the three way cat-
(seesection16)- a l y t i c c o n v e r t e r( B l 8 C ' 1e n g i n e ) ,a n d c o n n e c tt h e
heatedoxygensensor(HO2S)connector.
NOTE:Replacethe set ringswith new ones.

DNIVESHAFTS
GASKET

SELF-LOCKING NUT
Replace. HO2S
10 x 1.25mm CONNECTOR
33 N.m (3.4 kgt.m,
2s tbtftt

-Sl
SET RING
::.t Replace.

INTERMEDIATE
SHAFT GASKET
Replace. SELF.LOCKINGNUT
Replace. SELF.LOCKING NUT
10x 1.25mm THREEWAY 8 x 1.25mm Replace.
Replace. 38 N.m (3.9 kgt m, CATALYTIC 16 N'm 11.6kgt m, 10 x 1 25 mm
28 tbtft) CONVERTER l2tbt.ftl 54 N.m 15.5kgt m,
1818C'l
enginel iro lbf.ftl

15. Installthe ball joints onto the lower arm (see sec- 18. Installthe enginesplashshield.
tion18).

16. Installthe right damperfork (seesection18).

10x 1.25mm
43 N.m{4.oksf.m.32lbf.ft)

RIGHT
DAMPER
FOBK

LOWERARM
t
SELF.LOCKING NUT :\
Replace.
12 x 1.25mm
64 N.m {6.5 kgf.m, CASTLENUT
47 tbtft) 12x 1.25mm COTTERPIN
49 - 59 N.m 15.0- 6.0kgf m. Reptace.
36 - 43 tbf.frl

13-44
L
'19. Installthe slavecylinder,then installthe clutchpipe 22, lnstallthe lower radiatorhose clamp on the trans-
bracket. missionhang€rB.

N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e 2 3 . C o n n e c tt h e t r a n s m i s s i o ng r o u n d w i r e a n d t h e
(P/N08798- 9002). back-uplight switchconnector.

16 tbf.ftt BACK.UPLIGI{T
CLUTCHPIPE SWITCHCONNECTOR
6x1.0mm
9.8N.m {1.0kgf.m,7 lbfft)

GROUNDWIRE HANGERB
8 x 1.25mm
22 N-m 12.2kgl.tr't, 24. Install the air cleaner housing assembly and the air
tPlN 08798- 90021 16 rbf.ftl intake duct.
6x1.0mm
AIR CLEANER 9.8 N.m 11.0kgt'm,7 lbtftl
HOUSING
ASSEMALY
AIR INTAKE DUCT
20. Connectthe vehiclespeed sensor(VSS)conneclor
9 \
and the startermotor cables.

2 1 . Installthe wire harnessclamPs.

\<
6x1.0mm
9.8 N.m (1.0kgt m,7 lbf ftl
8 x 1.25mm
VSS CONNECTOR 8.8 N.m 10.9kgf.m,
6.s tbf.ft)

Refillthe transmissionwith oil (seepage 13-3).

Connectthe positive(+) cablefirst,then connectthe

negative( - ) cableto the battery.

27. Checkthe clutchoperation.

WIRE STARTER 28. Shift the transmission.and checkfor smooth opera-

HARNESS MOTOR
tron.
CLAMPS CABLES

29. Checkthe front wheelalignment(seesection18).

13-49
GearshiftMechanism
Overhaul

NOTE:
.Insp€ctrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts.
. lnstallthespringpin and the clip on the changejoint as shown.
. Turn the shift rod boot so the hole is facingdown as shown.
. Makesurethe shift rod boot is installedon the changerod.

8 x 1.25mm
t@)-- SHIFTIIVER KNoB 22 N.m {2.2 kgt m, 16 tbtft)
I -/l

#:
7.8N.m{0.8Isl.m, 6 lbt{tl
I t/
\U EXTENSION
WASHERA
END

@-tHrFrLEVERaoor
SHIFTLEVER
DUSTSEALA
6
(7\
RUBBER
EXTENSION
WASHERB

8x22mm
SPRINGPIN
Replace.

I "t't
CHANGEROD 9oo-
Replsc€.
5x1.0mm ,,'/ seu'locrtnc ruur
neptace.
9.8 N.m 11.0kgf.m,
8 x 1.25mm
7 tbf.ftt 22 N.m 12.2kg{ m, 16 tbtft)

SHIFTRODBOOT
= /

;1tffi
=ff
O.RINGS NEARJOINT CLIP
Replece. BUSHING

REARJOINT BUSHING

THRUSTWASHER

13-50
Automatic Transmission
'l4-2
Main Valve Body
14-3 Disassembly/lnspection/Reassembly 1 4 - 1 2 0
't
4-6 RegulatorValve Body
14-8 Disassembly/lnspection/Reassembly 14-122
14-14 Lock-up Valve Body
14-23 Disassembly/lnspection/Reassembly ....... 14-123
H v d r a u l i cF l o w . . . - - . . . . . 1. 4 - 2 4 Secondary Valve Body
L o c k - u pS y s t e m . . . . . . . .1 4 - 3 8 Disassembly/lnspection/Reassembly ....... 1 4 - 1 2 4
Eloctrical Systom Servo Body
C o m p o n e nLt o c a t i o n. . . . . . . . . . . . , . . . , . . . . . . . . . . . .I.4. .-.4 5 Disassembly/lnspection/Reassembly ....... 14-126
C i r c u i tD i a g r a m . . . . . . . . . . . .1 . 4-46 1st-holdAccumulator/RightSide Covet
' T r o u b l e s h o o t i nPgr o c e d u r e.s. . . . . . . , . . . . . . . . . .l.4, - 4 8 Oisassembly/lnspection/Reassembly .,..,.. 14-124
Symptom-to-Component Chart Mainshaft
ElectricalSystem ...... 14-50 Disassembly/lnspection/Reassembly -..-... 14- 129
ElectricalTroubleshooting lnsDection . . . . . . . . . . . . . . . .1. 4 -1 3 0
T r o u b l e s h o o t i nFgl o w c h a r t. . . . . . . . . . . . . . . . . .1. .4 - 5 2 Countershaft
Lock-uoControl SolenoidValve A/8 Disassembly/lnspection/Reassembly ....... 14-132
Test .................. - - . . . .\ 4 - 8 2 D i s a s s e m b l y / R e a s s e m. .b. l.y. . . . . . . . . . . . . . . . .1.4. - 13 3
ReDlacement , . . . , . . . , . . ,1 . 4-82 lnsDection . . . . . . . . . . . . . . . .1. 4 - 1 3 4
Shift Control SolenoidVslve A/B One-way Clutch/ParkingGear
Test .................. . . . . . .1 4 - 8 3 D i s a s s e m b l y / l n s p e c t.i .o. n. . . . . . . . . . . . . .-. . .- . 1 4 - 1 3 7
Reolacement . . . . . . . . . . . . .1. 4 - 8 3 Sub-shaft
TransmissionControl Module (TCM) Disassembly/lnspection/Reassembly ....... 14-138
*ReDlacement . . . . . . . . . . .1 4 - 8 4 D i s a s s e m b l v / R e a s s e m. .b. l. v. . . . . . . . . . . . . . . . .1.4. - 13 9
Mainshalt/CountershaJt SDeedSensors Sub-shaft Bearings
Reolacement . . . . . . . . . . . .1. 4 - 8 5 Replacement . . . . . . . . . . . . l. 4 - 1 4 0
Clutch
Hydraulic Systom d d e x. . . . . . . . . . . . . -. . . .- . . . - . . . . . . .1. 4. .- 14 1
f l l u s t r a t el n
Symptom-to-Component Chart Disassembly , , , . , , . . . . . . .1. 4 - 1 4 4
HydraulicSystem 14-86 . . . . . . . . . . . . .1. 4 - 1 4 6
Reassembly
Road Test 14-90 Torque Converter Housing Bearings
Slall Speed MainshaftBearing/OilSeal
't4-92
T e s t. . . . . . . . . . . . . . . . . . Reolacement . . . . . . . . .1 4 - 15 0
FluidLevel CountershaftBearingReplacement.......,, 14-15l
Checking/Changing 14-93 TransmissionHousingBearings
Pressu.e Testing 14-94 Mainshsft/Countershaft Bearing
Transmission Repfacement ...-..-..14-152
Transmission S u b - s h a fB t e a r i n gR e p l a c e m e n. .t. . . . . . . . . . .1. 4 - 15 3
R e m o v a. l. . . . . . . . . . . . . . . . . .1 4 - 9 9 Reve.seldler Gear
lllustratedIndex lnstallation . . . . . . . . . . . . . . .1. 4 - 1 5 4
R i g h tS i d eC o v e r. . . . . . . . . . . . . . . . . . . . . . . . . . .1. 4. .-.1.0. 4. ParkingBrakeStopper
T r a n s m i s s i oHn o u s i n 9. . . . . . . . . . . . . . . . . . , , . . . .I.4. .- 10 6 l n s p e c t i o n / A d j u s t m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . ' 1 4 - ' 1 5 4
Torque Converter HousingNalve Transmission
. . . 1 4 -1 O 8 .14_156
B o d y. . . . . . . . . . . . . . . . . . Reassemblv .............,.
Right Side Cover T o r o u eC o n v e r t e r / D r i vPel a t e. . , . . , . . . . . . . . . . . . .1. 4. - 16 3
R e m o v a. l. . . . . . . . . . . . . . . . . .1 4 - 1 1 0 Transmission
TransmissionHousing lnstallation 14-164
R e m o v a. l. . . . . . . . . . . . . - . . - .1 4 - 1 1 2 CoolerFlushing 14-168
Torque ConvenerHousingNalveBody 'Shitt Cable
R e m o v a. l. . . . . . . . . . . . . . . . . .1 4 - 1 1 4 . . . 70
. .n. . . . . . . . . . . . . . . . . . . . . . . .14-'t
R e m o v a l / l n s t a l l a t .i o
Valve Caps Adiustment . . . - . . - . . . . . . -1.4 - ' 1 7 1
Description .............1 . .4. - 1 1 6 *GearshiftSelector
Valve Body D i s a s s e m b l y / R e a s s e m. .b. l.y. . . . . . . . . . . . . . . . .1,4. - 1 72
R e p a i .r . . . . . . . . . . . . . . . . . . - . .1 4 - 1 1 7 *Shift IndicatorPanel
Valve Adjustment -..........-...14-173
A s s e m b l y. . . . . . . . . . . Throttle Control Cable
Oil Pump fnspection . . . . . . . , . . , . . . . .1. 4 - 1 74
Inspection Adjustment . . . . . . . . . . . . .1. 4 - 1 7 6
SpecialTools

Rol. No. Tool Numbsl Description Oty Page Reference

o OTGAB PF50lOO MainshattHolder 'I
1 4 - 11 1 . 1 6 0
oTGAB-PF50101
IA\ oTGAE-PG40200 Clutch SpringCompressorBolt Assembly I 14-144,147
,6\ oTHAC-PK4010A HousingPuller 1 1 4 - 113
@ oTHAE-PL50lOO Clutch SpringCompressorAttachment 1 1 4 -1 4 4 , 1 4 7
€/ oTLAE-PX40100 Clutch SpringCompressorAttachment ,1
14 144,'t47
OTLAJ PT30lOA Test Harness 1 14-49,90
o OTMAJ-PY4O'I
1A A/T Oil PressureHose, 221O mm 1 14-94
@ oTMAJ-PY40120 A/T Oil PressureAdapter 1 14-94
rt) oTPAZ-OO10100 SCS Short Connector ,| 't
4-44
@ 07406-OO20003 A/T Oil PressureGaugeSet w/panel 1 14-94
@ o7406 0070000 A/T Low PressureGaugew/panel 1 14-94
\9 07736 A01000A AdjustableBearingPuller,25-40 mm 1 14-150,151
@ o7746-O010100 Attachment, 32 x 35 mm 1 14-139,140
@ o7746-O010500 Attachment, 62 x 68 mm 1 1 4 - 1 4 0 .510 , 15 1 , 15 2 ,15 3
@ 07746-OO10600 Attachment, 72 x 75 mm I 14-150,152
@ 07746 0030100 D r i v e r ,4 0 m m l . D . I 14-134
o7749-O010000 'I
@ Driver 14 - 13 9 , ' 1 4 01, 5 0 . 15 1 , 15 2
@ 07947-6340500 OriverAttachment 1 14,150

Edrn$r--€

a)

a6l
@ o

@ @ @ @ ( r ) @
*@ Must be used with commerciallyavailable
3/8 in. x 16 threads/in.slide hammer.

14-2
The Automatic Transmissionis a combination of a 3-e,ement torque convefter and triple-shaft electfonically controlled
automatictransmissionwhich provides4 speedsforward and 1 speedreverse.The entireunit is positionedin line with
the engine.

Torque Converter, Gears and Clutches

The torqueconverterconsistsof a pump,turbineand statorassemblyin a singleunit, The torqueconverteris connected
to the enginecrankshaftso they turn togetheras a unit as the engineturns. Aroundthe outsideof the torque converter
is a ring gearwhich mesheswith the starterpinionwhen the engineis beingstaned. The entiretorqueconverterassem-
bly servesas a flywheel while transmittingpower to the transmissionmainshaft.
The transmissionhas three parallelshafts,the mainshaft.countershaftand sub-shaft.The mainshattis in line with the
enginecrankshaft.
The mainshaftincludesthe clutchesfor 1st, and 2ndl4th, and gearsfor 3rd. 2nd, 4th, reverseand l st (3rd gear is in-
tegral with the mainshaft,while reversegear is integralwith the 4th gear).
The countershaftincludesthe 3rd clutch and gearsIor 3rd, 2nd,4th, reverse,lst and parking.Reverseand 4th gears
can be lockedto the countershaftat its center, providing4th gear or reverse,dependingon which way the selectoris moved.
The sub-shaftincludesthe lst-hold clutch and gearsfor 1st and 4th
The gearson the mainshaitare in constantmesh with those on the countershaftand sub-shaft.When certaincombina-
tions of gearsin the transmissionare engagedby the clutches,power is transmittedfrom the mainshaftto the counter-
shaft via the sub-shattto provide@, E, tr. tr and @ position.

Electronic Control
The electroniccontrolsystemconsistsof the Transmission ControlModule{TCM),sensors,and 4 solenoidvalves.Shift-
ing and lock-upare electronicallycontrolledfor comfortabledriving under all conditions.
The TCM is locatedbelow the dashboard,behindthe left side kick panelon the driver's side.

Hydraulic Control
The valvebodiesincludethe mainvalvebody, secondaryvalvebody, regulatorvalvebody. servobody, and lock-upvalve
body throuqh the respectiveseparatorplates.
They are bolted on the torque converterhousing.
The main valve body containsthe manual valve, 1-2 shift valve, 2-3 shift valve, Clutch PressureCont.ol (CPC)valve,
4th exhaustvalve, relief valve, and oil pump gears.
The secondaryvalve body containsthe 4-3 kick-down valve,3-2 kick-down valve,2-3 orifice cont.ol valve, 3-4 shitt
valve, orifice control valve. modulatorvalve, and servo control valve
The regulatorvalve body containsthe pressureregulatorvalve.lock-upcontrolvalve,torqueconvertercheckvalve,and
cooler check valve.
The servo bodv containsthe servo valve which is integratedwith the reverseshift fork, throttle valve B, and accumulators.
The lock-ugvalve bodv containsthe lock-upshift valve and lock-uptiming B valve.and is boltedon the secondaryvalve
body.
Fluidfrom the regulatorpassesthrough the manualvalve to the variouscontrol valves.

Shitt Control Mochanism

Input to the TCM i.om varioussensorslocatedthroughoutthe car determineswhich shift controlsolenoidvalve should
be activated.
Activatinga shift control solenoidvalve changesmodulatorpressure,causinga shift valve to move. This pressurizes
a line to one of the clutches.engagingthat clutch and its correspondinggear.

Lock-up Mechanism
In @ position.in 2nd, 3rd and 4th, and E positionin 3rd, pressurizedtluid can be drainedfrom the back of the tor-
que converterthroughan oil passage,causingthe lock-uppistonto be held againstthe torque convertercover. As this
takes Dlace,the mainshaftrotatesat the samespeedas the enginecrankshatt.Togetherwith hydrauliccontrol,the TCM
optimizesthe timing ol the lock-upmechanism.
The lock-upvalvescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB
When lock-upcontrol solenoidvalves A and B activate,modulatorpressurechanges.Lock-upcontrol solenoidvalves
A and B are mountedon the torque converterhousing,and are controlledby the TCM.

(cont'd)

14-3
Description
(cont'd)

Gear Selection
The selectorlever has sevenposirions;E PARK,E REVERSE, N NEUTRAL,@ 1st through 4th positions.E 1st
t h r o u g h3 r d p o s i t i o n sQ
, l 2 n d g e a ra n d [ ] 1 s t g e a r .

Position Description
PARK
l3?]] Front wheels locked; parkingpawl engagedwith parkinggear on countershatt.All clutches
reteaseo,

[R] REVERSE Reverse;reverseselectorengagedwith countershaltreversegear and 4th clutch locked.

N NEUTRAL A l l c l u r c h e sr e l e a s e d .
'lst,
D+l DRIVE Generaldriving;starts off in shifts automaticallyto 2nd, 3rd, then 4th, dependingon vehicle
('lst through 4th) speed and throttle position.Do'vnshiftsthrough 3rd, 2nd and 1st on decelerationto stop.
The lock-upmechanismcomes into operationin 2nd, 3rd and 4th when the transmissionin lDt
posrtron.

Dgi DRIVE For rapid accelerationat highway speedsand generaldriving; starts off in 1st. shifts automatical-
(1st through 3rd) ly to 2nd then 3rd, dependingon vehiclespeed and throttle position.Downshiftsthrough lower
gearson decelerationto stop. The lock-upmechanismcomes into operationin 3rd.

El SECOND Drivingin 2nd geari stays in 2nd gear, does not shift up and down.
For enginebrakingor better traction starting off on loose or slipperysurfece.

L]l FIRST Drivingin 1st gear; stays in lst gear, does not shilt up.
For enginebraking.

Starting is possibleonly in @ and I Oositionthrough use ot a slide-type,neutral-safetyswitch.

Automatic Tlansaxle{A/T) Gear PositionIndicatol

A/T gear pos;tionindicatorin the instrumenlpanel shows what gear has been selectedwithout having look down at
the console.

14-4
 VALVE
BODIES

TOROUECONVERTER
ASSEMBLY

VEHICLESPEEDSENSORIVSSI 1ST-HOLDCLUTCH

3RD CLUTCH SUB SHAFT

MAINSHAFT

SPEEDSENSOR
SPEEDSENSOR 1ST CLUTCH

COUNTERSHAFT

14-5
Description
Clutches

The four speedautomatictransmissionuseshydraulically actuatedclutchesto engageor disengage the transmission gears.

When clutch pressureis introducedinto the clutch drum, the clutch piston is applied.This pressesthe iriction discs and
steel platestogether,lockingthem so they don't slip. Power is then transmittedthrough the engagedclutch pack to
jts hub-mountedgear.

Likewise,when clutch pressureis bled from the clutch pack. the pistonreleasesthe friction discs and steel plates,and
they are {ree to slide past each other while disengaged.This allows the gear to spin independentlyon its shaft, transmit-
ting no power.

1st Clutch
The l st clutch engages/disengages1st gear,and is locatedat the end of the mainshaft,just behindthe right sidecover.
The 1st clutch is suppliedclutch pressureby its oil feed pipe within the mainshaft.

1st-holdclutch
The 1st-holdclutch engages/disengages 1st-holdor I Fosition,and is locatedat the centerol the sub-shaft.The 1st-
hold clutch is suppliedclulch pressureby its oil feed pipe within the sub-shait.

2nd Clutch
The 2nd clutch engages/disengages 2nd gear, and is locatedat the center of the mainshaft.The 2nd clutch is joined
back-to-backto the 4th clutch. The 2nd clutch is suppliedclutch pressurethroughthe mainshaftby a circuitconnected
to the regulatorvalve body.

3rd Clutch
The 3rd clutchengages/disengages 3rd gea..and is locatedat the end oJthe countershaft,oppositethe right sidecover.
The 3rd clutch is suppliedclutch pressureby its oil feed pipe within the countershaft,

4th clurch
The 4th clutch engages/disengages 4th gear. as well as reversegear, and is locatedat the center of the mainshaft.
The 4th clutch is joined back-to-backto the 2nd clutch. The 4th clutch is suppliedclutch pressureby its oil feed pipe
within the mainshalt.

One-way Clutch
The one-wayclutch is posjtionedbetweenthe parkinggear and 1st gear. with the parkinggear splinedto the counter-
shaft. The 1st gear providesthe outer race, and the parkinggear providesthe inner race surface.The one-way clutch
locks up when power is transmittedfrom the mainshaft 1st gear to the countershaftlst ggel _
The 1st clutch and gears remainengagedin the 1st. 2nd. 3rd, and 4th gear rangesin the @, E or E position.

However,the one-way clutch disengageswhen the 2nd. 3rd, or 4th clutches/gearsare appliedin the E, lD.l o, E
oosttton.
This is becausethe increasedrotationalspeedof the gearson the countershaftover-ridethe locking"speed range" of
the one-way clutch. Thereafter,the one-way clutch free-wheelswith the lst clutch still engaged.

1ST GEAR
COUNTERSHAFT

LOCKS FREE

aF :>

NOTE:
Viewtrom rightsidecoverside.

14-6
 MAINSHAFT
4TH GEAR

MAINSHAFT3RD GEAR SUB.SHAFT4TH GEAR

lST,HOLD CLUTCH
MAINSHAFT
2ND GEAR SUB-SHAFT1ST GEAR
TOROUE
CONVERTER
2ND CLUTCH
STARTER SUB.SHAFT
NINGGEAR
4TH CLUTCH MAINSHAFT1ST
GEAR
LOCK-UP
CLUTCH
1ST CLUTCH
DRIVE PLATE
MAINSHAFT

ONE-WAY CLUTCH

PARKINGGEAR

,IST GEAR

COUNTERSHAFTREVERSEGEAR

REVERSESELECTOR

REVERSE HU8
SELECTOR

COUNTERSHAFT4TH GEAR

COUNTERSHAFT2ND GEAR

COUNTERSHAFT
3RD GEAR
FINALDRIVENGEAR
3RD CLUTCH
DIFFERENTIAL

14-7
Description
Power Flow

--.-.-___-t.-t*
TOROUE t5t- 1STGEAR2ND GEAR3RDGEAR 4TH REVERSE PARKING
coN- HOLD 1ST 2ND 3RD GEAR GEAR
VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH

E o X X X X X X X o
tr o X x X x X o o X
N o X X X X X X X X
1ST o X o x X X X X X
2ND o X 'o o x X X X X
E 3RD o X .o X o X X X X
4TH o X -o X X o o X X
1ST o X o X X X X X X
E 2ND o x -o o X X X X x
3RD o X -o X o X x X X
tr o X .o o X X X X X
tr o
':
o o X X X X X X
Q: Operates,X: Doesn'toperate, Althoughthe 1st clutch engages,drivingpowe. is not transmittedas the one-way
clutch sliDs.

14-8
@ Position
Hydraulicpressure to the countershaJt.
is not appliedto the clutches,Poweris not transmitted

@ Position
Hydraulicpressureis not sppliedto the clutches.Poweris not transmittedto the countetshaft.
is lockedby the parkingpawl interlocking
The countersha{t the parkinggear.

TOROUECONVERTER

REVERSESELECTOR
HUB

PARKINGGEAR

REVERSESELECTOR

REVERSEGEAR

SERVOVALVE/
SHIFTFORKSHAFT

14-9
Description
Power Flow lcont'dl

Lll Position Acceloration

In f position,hydraulicpressureis appliedto the lst clutch and lst-hold clutch.

The power flow when acceleratingis as tollows:

1. Hydraulicpressureis appliedto the 1st clutch on the mainshaltand power is transmittedvia the lst clutch to the
mainshaft1st gear.

2. Hydraulicpressureis also appliedto the 1st-holdclutch on the sub-shatt.Powertransmittedto the mainshaft1sl

gear is conveyedvia the countershaft1st gearto the one-wayclutch. and via the sub-shaft1st gearto the l st-hold
clutch. The one-way clutch is used to drive the countershaft.and the 1st-holdclutch drivesthe countershaftvia
the 4th gears.

3. Power is transmittedto the finai drive gear and drivesthe final d.iven gear,

SUB.SHAFT 'IST GEAR

SUB-SHAFT4TH GEAR
SUB-SHAFT
lST-HOLD CLUTCH

MAINSHAFT1ST GEAR

1ST CLUTCH

COUNTERSHAFT

ONE-WAY CLUTCH

PARKINGGEAR

,IST GEAR

FINAL DRIVENGEAR

14-10
L!_jPosition Deceleration

The power tlow when deceleratingis as follows;

1. Rollingresistancelrom the road surfacegoesthroughthe tront wheelsto the final drive gear,then to the sub-shaft
1st gear via the 4th gear, and lst-hold clutch which is appliedduring deceleration.

2. The one-way clutch becomesfree at this time becausetorque reverses.

3. The counterforceconveyedto the countershaft4th gear turns the sub-shaft4th gear via the mainshaft4th gear.
At this time, sincehydraulicpressureis also appliedto the 1st clutch, counterfo.ceis alsotransmittedto the main-
shaft. As a result, enginebrakingcan be obtainedwith lst gea.-

CLUTCH

SUB-SHAFT
4TH GEAR SUB-SHAFT1ST GEAR
TOROUECONVENTER

SUB'STIAFT

lST CLUTCH

MAINSHAFT

COUNTERSHAFT

FINAL DRIVE

REVEFSESELECTORHUB

REVERSESELECTOR

4TI1 GEAB

(cont'dl

14-11
Description
Power Flow (cont'd)

Ll Position

@ Positionis providedto drive only 2nd speed.

1. Hydraulicpressureis appliedto the 2nd clutch on the mainshattand power is transmittedvia the 2nd clutch to the
mainshaft2nd gear.

2. Powertransmittedto the mainshalt2nd gearis conveyedvia the countershaft2nd gear,and drivesthe countersha{t.

3. Power is transmittedto the final drive gear and drives the final driven gear.

NOTE:
Hydraulicpressureis also appliedto the lst clutch, but since the rotationspeedof the 2nd gear exceedsthat of
1st gear, power from 1st gear is cut off at the one-way clutch.

TOROUECONVERTER 2ND CLUTCH

MAINSHAFT

COUNTERSHAFT

FINAL DBIVE

2ND GEAR

FINALDRIVENGEAR

14-12
In [Q! or l!31 position.the optimumgear is automaticallyselectedfrom 1st, 2nd, 3rd and 4th speeds,accordingto con-
ditionssuch as the balancebetween throttle opening(engineload) and vehiclespeed.

D! or lE.l Position, lst speed

1. Hydraulicpressureis appliedto the lst clutch. which rotatestogether with the mainshaft,and the mainshaftlst
gear rorares.

2. Power is transmittedto the countershaft1st gear, and drivesthe countershaftvia the one-way clutch.

3. Power is transmittedto the final drive gear and drives the final driven gear.

NOTE:
In lDil or [Dl]l position,hydraulicpressureis not appliedto the 1st-holdclutch.

TOROUECONVERTER

1ST CLUTCH

MAINSHAFT

COUNTERSHAFT

FINALDRIVEGEAR

FINALDRIVENGEAR

(cont'd)

14-13
Description
PowerFlow (cont'd)

JD.l or lD"l Position, 2nd speed

1. Hydraulicpressureis appliedto the 2nd clutch, which rotatestogetherwith the mainshaft,and the mainshatt2nd
gear rotates.

2. Power is transmittedto the countershaft2nd gear, and drivesthe countershaft.

3. Power is transmittedto the tinal drive gear and drives the final driven gear.

NOTE:
In @ or @ position,2nd speed,hydraulicpressureis also appliedto the lst clutch. but sincethe rotationspeed
of 2nd gear exceedsthat of 1st gear. power trom lst gear is cut off at the one-way clutch.

2ND CLUTCH

TOROUECONVERTER

MAINSHAFT

COUNTERSHAFT

FINAL DRIVE GEAR

FINAL DRIVEN GEAR

14-14
I o.l or 16ll Position, 31d sp€od

1. Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshatt3rd gearis transmittedto the countershaft
3rd gear,

2. Power is transmittedto the tinal drive geat and drives the final driven gear.

NOTE:
In ]Dil or lDJl position.3rd speed.hydraulicpressureis also appliedto the Ist clutch, but sincethe rotationspeed
of 3rd gear exceedsthat of 1st gear, power trom lst gear is cut ofJ at the one-way clutch,

TOROUECONVERTER
MAINSHAFT 3RD GEAR

MAINSHAFT

COUNTERSHAFT
FINAL DRIVE
GEAR

3RD CLUTCH

FINAL DBIVEN
GEAR

14-15
Description
Power Flow (cont'dl

E Poshion. 4th sp6od

1. Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshatt, and th€ mainshaft 4th
gear rotates.

2. Power is transmifted to the countershaft 4th gear, and drives the countershaj-t.

3. Power is transmittedto the final drive gear and drivesthe final driven gear.

NOTE:
In @ Oosition,4th speed, hydraulic pressure is also applied to the 1st clutch, but since the rotation spe€d of 4th
gear exceedsthat oJ 1st gear, power from 1st gear is cut off at the one-way clutch.

TOROUECONVERTEB MAINSHAFT 4TH GEAR

4TH CLUTCH

MAII{SHAFT

COUI{TERSHAFT

REVERSE
SELECTOR
HUB

REVERSESELECTOR

14-16
llj Po.ltbn

1. Hydraulic pressure is swilched by the manual valve to the se.vo v8lve, which moves the reverse shilt tork to the
r€verseposition. The reverseshiJt fork engageswith the reverseselector, reverseselsctor hub,and the countershaft
raverss g€ar.

2. Hydraulic pr6ssure is also appli€d to the 4th clutch. Power is transmifted from the mainshaft reverse gear via the
revetse idler g6ar to the countershaft reverse gear.

3. Rotation dirsction ol the countershsft reverse gear is changed via the .everse idler gear.

4. Powef b transmitted to the linal drive gear and drives the final driven gear.

TOROUECONVEBTER
4TH CLUTCH MAI SHAFTREVERSE
GEAR

COUNTERSHAFf

REVERSE
SELECTOR
HUB
FII{AL DRIVEGEAR
REVEFSESELECTOR

COUIITERSHAFT
REVERSEGEAR

14-17
Description
ElectronicControlSystem
Electronic Control System
The electroniccontrolsystemconsistsof the TransmissionControlModule(TCM),sensors.and 4 solenoidvalves.Shift-
ing and lock-upare elect.onicallycontrolledfor comfortabledriving under all conditions.
The TCM is locatedbelow the dashboard,behindthe left side kick panel on the driver's side.

Lock-up Control
Solonoid Valvo A

14-18
Lock-up Control
From sensorinput signals,the TCM determineswhether to turn the lock-upON or OFF and activateslock-upcontrol
solenoidvalve A and/or B accordingly.
The combinationof driving siqnalsto lock-upcontrol solenoidvalves A and B is shown in the table below.

Lock-upcontrol Solenoidvalve
\ B
Lock-upcondition \
Lock-upOFF OFF OFF
Lock-up,slight ON OFF
Lock-up.halt ON ON
Lock-up.full ON ON
Lock-up ON Duty operation
during deceleration OFF-ON

Shifl Conrrol
The TCM instantaneously determineswhich gear shouldbe selectedby varioussignalssent trom sensors.and actuates
the shift controlsolenoidvalvesA and B controlshitting.Also. a GradeLogicControlSystemhas beenadoptedto control
shifting in E] positionwhile the vehicleis ascendingor descendinga slope, or reducingspeed.

Shift control solenoidvalve

\ ------\ B
t"*b" ,t"-l
('lst) OFF ON

E,E (2ndl ON ON
(3rd) ON OFF

E (4th) OFF OFF

a (2nd) ON ON

tr (lst) ON OFF
l-Rl {Reverse) ON OFF

(cont'd)

14-19
Description
ElectronicControl System (cont'd)
. GRADE LOGIC CONTROLSYSTEM

How it works:
The TCM comparesactual drivingconditionswith drivingconditionsmemorizedin the TCM. basedon the input trom
the vehiclespeed sensor,throttle positionsensor,enginecoolanttemperaturesensor,brake switch signaland select
lever positionsignal,to control shifting while a vehicleis ascendingor descendinga slope. or reducingspeed.

SIGNALSDETECTED

Dliving Resistance
Judgement of Controlling Area

Engine Coolant
TemDerature Sensor

. Flat road mode

. Asconding mode
(Fuzzylogic)
. Gradual Ascending
mode
. Steep Ascending

14-20
. Ascending Contlol

When the TCM determinesthat the vehicleis climbinga hill in @ position,the system extendsthe engagementarea
Irom frequenrlyshittingbetween3rd and 4th gears,so the vehiclecan run smooth
of 3rd gearto preventthe transmission
and have more power when needed.

NOTE: Shift schedulesbetween 3rd and 4th gear are stored in the TCM to enablethe transmissionto automatically
selectthe most suitablegear accordingto the magnitudeof a gradientby Fuzzylogic.

. Descending Control

When the TCM determinesthat the vehicleis going down a hill in @ position.the shift-upspeedfrom 3rd to 4th gear
when the throttle is closedbecomestaster than the set speedfor tlat road drivingto widen the 3rd gear drivingarea.
This, in combinationwith engine brake from the decelerationlock-up, achievessmooth driving when the vehicle is
descending.

Thereare two ascendingmodeswith different3rd gear driving areasaccordingto the magnitudeof a gradientstoredin
theTCM.

When the vehicleis in 4th gear, and you are deceleratingon a gradualhill, or when you are applyingthe brakeson a
steephill,the transmissionwill downshittto 3rd gear.When you acceleratethe transmissionwill then returnto 4th gear.

0 Vohicle SDood
. DecelerationControl

When the vehiclegoes around a corner,and needsto deceleratefirst and then accelerate,the TCM sets the data for
decelerationcontrolto reducethe numberof times the transmissionshiftsto obtain smooth driving.When the vehicle
from speedsabove27 mph (43 km/h).the TCM shiftsthe transmissionfrom 4thto 3rd earlierthan normal
is decelerating
to cope with upcomingaccelerationto maintainsmooth driving.

NOTE:
FuzzyLogic:Fuzzylogic is a from at artificialintelligencethat lets computersrespondto changingconditionsmuch like
a human mind would.

14-21
Description
ElectronicControl System {cont'dl

*t-l
T
777
TH
SCI

sHtfTc0mRoL

scs

ECM

SHFTCOI{rFOL
VALVEB
SOLINOIO

ACCL

AFSB

NEP LG1
LG2 TOCK-UPCONTROL
SOLENOIOVALVE
A

SPEEO
SENSOF

COUNTE8SHAFI
SPEEO
SENSOR
L_______.1
tGcotL LOC(- UPCONTROL
SOLENOIOVALVEB
f-r,'__l
I Jll6 i

A/T CEANPOSITION
INDICATOR

14-22
 Hydraulic Control

The valvebodiesincludethe main valvebody, secondaryvalvebody, regulatorvalvebody, servobody and lock-upvalve

body.
The oil pump is driven by splinesbehindthe torque converterwhich is attachedto the engine.Oil flows th.ough the
regulatorvalve to maintainspecifiedpressurethrough the main valve body to the manualvalve, directingpressureto
each of the clutches,

SHIFT CONTROLSOLEIIOID
VALVE ASSEMBLY

RTGHTSIDECOVER

LOCK.UPVALVEBODY

VALVEBODY

V
REGULATOR
4<.__i
:
)o.-
BODY

OIL PUMP GEARS

SOLENOIDVALVE
ASSEMBLY

14-23
Description
HydraulicControl(cont'dl
Ragularol Valve Body
The .egulator valve body is located on the main valve body. The regulator valve body consists of th€ regulator valva,
toroue converter check valve, cooler check valve, and lock-up contlol valve.

VALVE
REGULATOR

VALVE
REGULATOR
BODY

COOLERCHECKVALVE

TONOUECOI{VERTEB
LOCT.UPCONTROI.
VALVE CHECKVALVE

Lock-up Valvo Body

The lock-up valve body with the lock-up shilt valve and lock-up timing B valve is located on th€ regulator volvs body.

LOCK.UPSHIFT VALVE

TIMITG B VALVE

14-24
Rcgulator Valve
The r€gulator valve maintains a constant hydraulic pressure from the oil pump to the hydraulic control system, whil€
alEofurnishingoil to the lubricatingsystem and torque convener.
Oil flows through B and B'. The oil which entersthrough B flows thfough the valve orificeto A, pushingthe regulator
valve to the right. Acco.dingto the level of hydraulicpressurethrough B, the positionof the valve changes,and the
amount of the oil thlough D from B'thus changes.This operationis continued.thus maintainingthe line pressure.

IEI{GINE]IIOT RUNNINGI {ENGINERUNNING)

From OIL PUMP

Siator Reaction Hydtaulic PressureControl

Hydraulicpressureincrease,accordingto torque, is performedby the regulatorvslve using stator torque reaction.The
stator shaft is splinedto the stator and its a.m end contacts the fegulatorspring cap. When the car is acceleratingor
climbing (Torque Convener Range).stator torque reaction acts on the stator shalt and the stator shaft arm pushes the
rsgulator spring cap in this - direction in proportionto the reaction.The spring compressesand the regulatorvalve moves
to increasethe regulatedcontrol pressureor line pressure.Line pressureis maximum when the stator reactionis maximum.

TOR VALVE

STATOR SHAFT ARM

STATOR SHAFT

(cont'd)

14-25
Description
Hydraulic Control (cont'dl

Main Valvo Body

The manualvalve, 1-2 shift valve, 2-3 shift valve. 4th exhaustvalve. CPC valve, and relief vatve are all assembledin
the main valve body,
The primaryfunctionof this valve body is switchingoil passageson and off and controllingthe hydraulicpressuregotng
to the hydrauliccontrol system.

4TH EXHAUSTVALVE CPC VALVE

RELIEFVALVE

MANUAL VALVE
MAIN VALVE BODY
1.2 SHIFT VALVE

S€condary Vslve Body

The secondaryvalve body is locatedon the main valve body. The 3-2 kick-downvalve,4-3 kick-downvalve. 2-3 orifice
controlvalve.orificecontrolvalve,3-4 shift valve,modulatorvalve,and servocontrolvalveare assembledin the secon-
da.y valve body.

ORIFICECOIITROL
VALVE 2-3 ORIFICECONTBOLVALVE

3.4 SHIFT VALVE

VALVE BODY
COITTROLVALVE
MOOULA

14-26
S6rvo Body
The servo bodv is locatedon the secondaryvalve body.
The servovalveis integratedwith the shiit fork shatt, throttlevalve B. and accumulatorpistons,which are all assembled
in the servo bodv.

SERVOVALVE/
SHIFTFORKSHAFT

THROTTLEVALVE B SERVOBODY
THROTTLELONG VALVE

Accumulator Pislons
piston
The accumulatorpistonsare assembledin the servo body and right side cover. The l st-holdclutch accumulator
is in the right side cover, and the 1st, 2nd 3rd, and 4th accumulatorpistonsare assembledin lhe servo body.

1ST-HOLDACCUMULATOR RIGHTSIDECOVER

4TH ACCUMULATOR

IST ACCUMUI-ATOR
2ND ACCUMULATORPISTON 3RD ACCUMULATORPISTON

14-27
Description
HydraulicFlow

Genelal Chart ol Hydraulic Pressure

Line Pressure
Oil Pump - RegulatorValve - Torque ConverterPressure
LubricationPressure

Distribution ot Hydraulic Pressure

- , .
Ltne rressure
. RegulatorValve Torque ConverterPressure
]
LubricationPressure
L
. M a n u a lV a l v e To Select Line Pressure

. ModulatorValve ModulatorPressure

. 1-2ShiltValve
l
. 2-3 Shitt Valve Clutch Pressure
. 3 4 Shift Vlave
]
. Throttle Valve B Throttle B Pressure

NO. D E S C R I P T I OONF P R E S S U R EN O . D E S C R I P T I OONF P R E S S U R EN O . D E S C R I P T I OONF P R E S S U R E

LINE MODULATOR
I 6C 55 THROTTLEB
CONTROL
ITOCK-UP SOLENOID
VATVE
AI
2 LINE 6D MODULATOR
(IOCX.UP
CONTROT
SOTENOID
VALVE
B)
56 THROTTLEB

3 LINE 9 LINE 57 THROTTLEB

3' LINE 10 l ST CLUTCH 58 THROTTLEB

3" LINE 1ST-HOLD

CLUTCH 90 T O R O U EC O N V E R T E R

4 LINE It) l ST.HOLDCLUTCH 91 TOROUECONVERTER

LINE 18 LINE 92 T O R O U EC O N V E R T E R

5 LINE 20 2ND CLUTCH 93 O I LC O O L E R

5' LINE 21 2ND CLUTCH 94 TOROUECONVERTER

5" LIN E 25 LINE 95 LUBRICATION

6 MODULATOR 30 3RD CLUTCH 96 TOROUECONVERTER

6' MODULATOR 31 3RD CLUTCH 97 TOROUECONVERTER

6A MODULATOR 40 4TH CLUTCH

(SHIFT
CONTROL
SOTENOID
VALVE
A 99 SUCTION

6B MODULATOR 41 4TH CLUTCH

(SHIFT
CONTROL VALVE BLEED
SOLENOID B

14-28
E Position (99) and dis-
As the engineturns, the oil pump also startsto operate.Automatictransmissionfluid (ATF)is drawn from
(
chargedinto (1). Then,ATF pressureis controlledby the regulatorvalve and becomesline pressure 1). The torquecon-
verter inlet pressure(92) enters (94) of torque converterthrough the orifice and dischargesinto {90}.
The torque convertercheck valve preventsthe torque converterpressurefrom rising'
Under this condition,the hydraulicpressureis not appliedto the clutches.

NOTE:
. When used, "left" or "right" indicatesdirectionon the llowchart
. SOL-@: Shift Control SolenoidValve A
' SOL{D:Shift ControlSolenoidValve B
. SOL@: Lock-upControl SolenoidValve A
. SOL-@: Lock-upControl SolenoidValve B

(cont'd)

14-29
Description
HydraulicFlow (cont'd)

L1l Position
The line pressure{1) becomesline pressure(4) at the manualvalve and passesto the lst clutch and 1st accumulator.
Then line pressure(41flows through the 1st-holdclutch and lst-hold accumulator.

Fluid flows by way of:

- LinePressure{4} - 1-2 Shitt Valve * 2-3 Shitt Valve - 3rd Clutch Pressure{31) - 3-4 Shift Valve - 4th Clutch
Pressure(41) - ManualValve - lst-hold Clutch Pressure{15) - 1st-holdClutch

The modulatorpressure(6) is suppliedto the 1-2 and 2-3 shift valves.

The line pressure(1) also flows to throttle valve B.

NOTE:
. When used. "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shift Control SolenoidValve A
. SOL@: Shift Control SolenoidValve B
. SOL-@: Lock-upControlSolenoidValve A
. SOL-@: Lock-upControl SolenoidValve B

14-30
f4 Position
ihe line pressure(11becomesline pressure(41as it passesthrough the manualvalve.lt then goes through line l2O)
to the 2nd clutch via the 1-2 and 2-3 shift valves.Also, line pressure(1) goes to the modulatorvalve throughthe filter
and becomesthe modulatorpressure(6). Modulatorpressure(6) is not suppliedto the 1-2, 2-3 and 3-4 shift valves
becausethe shitt control solenoidvalves A and B are turned on by the TCM.

NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart
. SOL-@: Shift ControlSolenoidValve A
. SOL-@: Shilt Control SolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOt -@ : Lock-upControl SolenoidValve B

(cont'd)

14-31
 I
Description
HydraulicFlow (cont'dl

@ or @ Position

1. lst Spe€d
The flow of fluid throuth the torque convener circuit is the same as in S Oosition.
The line pressure( 1) becomesline pressure(4) and it becomesthe 1st clutch pressure(1O).The I st ctutchpressure
is appliedto the lst clutch and l st accumulator;consequently,the vehiclewill move as the enginepower is transmitted.
The line pressure(1) becomesthe modulatorpressure(6) by the modulatorvalve and travelsto 1-2 and 3-4 shift valves.
The 1-2 shift valve is movedto the right sidebecausethe shilt controlsolenoidvalveA is turnedoff and B is turned
on by the TCM. This valve stops 2nd clutch pressureand power is not transmittedto the 2nd clutcn.
Line pressu.e{4) also tlows to the seryo valve and line pressure(1} also flows to throttle valve B.

NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shitt ControlSolenoidValve A
. SOL-@:Shift ControlSolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOL-@: Lock-upControlSolenoidValve B

14-32
2nd Sgeed
prescribed
The llow of fluid up the 1-2 shift valve is the same as in 1st speed.As the speedof the car reachesthe
value,the solenoidvalve A is tulned on by meansot the TCM. As a result, the 1-2 shift valve is moved to the left
and uncoversthe port leadingto the 2nd clutch; the 2nd clutch is engaged'

Fluidflows by way of:

'l-2
- Line Dressurel4l - Shift Valve - 2-3 Shitt Valve - 2nd Clutch Pressure(2'1) * 2nd Clutch

The hvdraulicpressurealsoflows to the 1st clutch,However,no power is transmittedbecauseof the one-wayclutch.

NOTE:
. When used, "lett" or "right" indicatesdirectionon the flowchart
. SOL-@: Shift Control SolenoidValve A
. SOL@: Shift ControlSolenoidValve B
. SOL-@: Lock-upControl SolenoidValve A
. SOL-@: Lock-upControl SolenoidValve B

{cont'd)

14-33
Description
HydraulicFlow (cont'd)
3rd Speed
The tlow of fluid up to the 1-2 and 2 3 shift valves is the same as in 2nd speed.As the speedof the car reaches
the prescribedvalue,the shift controlsolenoidvalve B is turned off {shilt controlsolenoidvalveA remainson). The
2-3 shift valve is then movedto the left, uncoveringthe oil port leadingto the 3rd clutch. Sincethe 3-4 shitt valve
is moved to the right to cover the oil port to the 4th clutch, the 3rd clutch is turned on.

Fluid tlows by way of:

- Line pressure l4l - 1-2 shift valve - 23 Shift Valve * 3rd ctutch pressure(31) - 3-4 shift valve
(not controlled) 3rd Clutch Pressure(3O) - 3rd Clutch

The hydraulicpressurealsoflows to the l st clutch. However,no power is transmittedbecauseof the one-wayclutch

as in the 2nd speed.

NOTE:
. When used, "lett" o( " tight" indicatesdirectionon the flowcharl.
. SOL-@: Shift ControlSolenoidValve A
. SOL-@:Shift ControlSolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOL-@: Lock-upControlSolenoidValve B

14-34
Lq4 Position

4. 4th Spe6d
The flow of tluid up to the 1-2, 2-3 and 3-4 shift valvesis the sameas in 3rd speed.As the speedof the car reaches
the prescribedvalue, the shift control solenoidvalve A is turned oJt (shift control solenoidvalve B remainsoff).
As this takes place,3-4 shift valve is moved to the left and uncoversthe oil port leadingto the 4th clutch. Since
the 1-2 and 2-3 shift valvesare kept on the left side,the fluid flows throughthe 4th clutch;the power is transmitted
through the 4th clutch.

Fluid flows by way of:

- Line Pressurel4l - 'l'2 Shift Valve -t 2-3 Shitt Valve - 3rd Clutch Pressure(31) - 3-4 Shift Valve
4th Clutch pressure(41) - ManualValve 4th Clutch Pressure{4O) - 4th Clutch
'1st
The hvdraulicpressurealsotlows to the clutch.However,no power is transmittedbecauseof the one-wayclutch
as in 2nd and 3rd soeed.

NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchan.
. SOL-@: Shitt Control SolenoidValve A
. SOL-@: Shift Control SolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOL-@: Lock-upConttol SolenoidValve B

(cont'dl

14-35
Description
HydraulicFlow (cont'd)

LEI Position
The flow ot fluid throughthe torqueconvenercircuitis the same as in S position.The tluid ( 1) trom the oil pump flows
through the manualvalve and becomesline pressure(31.lt then flows through the 1-2 shift valve to the servo varve
via the servo control valve, causingthe shift tork shatt to be moved in the reversedirection.
Underthis condition,the shift control solenoidvalve A is turned on whereasthe valve B is turned ofJ as in 3rd speed
in [Dil or lDs]lposition.As a result,the 1-2 shift valve is also moved to the left. The ftuid (3'] will ftow throughthe ser-
vo valve and manualvalve to the 4th clutch; power is transmittedthrough the 4th clutch.

ReverseInhibitorControl
When the @ positionis selectedwhile the vehicleis movingforward at a speedover 6 mph ( 1Okm/h).the TCM outputs
1st signal (A: OFF, B: ON), and the 1-2 shift valve is moved to the right side. The line pressure{3) is interceptedbv
the 1-2 shift valve; consequently,power is not transmittedas the 4th clutch and servo valve are not oDerareo.

NOTE:
. When used, "lefl" ot "tight" indicatesdirectionon the flowchart.
. SOL-@: Shift Control SolenoidValve A
. SOL€: Shift Control SolenoidValve B
. SOL€: Lock-upControlSolenoidVatve A
. SOL-@: Lock-upControlSotenoidVatve B

14-36
Lll Position
The flow of fluid throughthe torque convertercircuit is the same as in I position.The line pressure( l ) becomesline
pressure(3) as it passesthroughthe manualvalve.Then line pressure(3) flows throughthe 1-2 shift valveto the servo
valve via the servo control valve. causingthe shift fork shaft to be moved to the reversepositionas in E position.
However.the hydraulicpressureis not suppliedto the clutches.Power is not transmitted.

NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shitt ControlSolenoidValve A
. SOL-@: Shift Control SolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOL-O: Lock-upControl SolenoidValve B

14-37
Description
Lock-up System
Lock-up Clutch
1. Operation(clutch on)
With the lock-upclutch on, the oil in the chamberbetweenthe torque convenercover and lock-uppiston is discharged,
and the converteroil exerts pressurethrough the piston againstthe convertercover. As a result,the converterturbine
is locked on the convertercover firmly. The etfect is to bypassthe converter,thereby placingthe car in direct drive.

tpowefJlo-wl
LOCK-UP
The power tlows by way of: TURBINE

Engine
TOROUECONVERTER
I COVER
Drive plate
, \
I
Torque convener cover
I
Lock-uppiston
To oil cooler
I
OUTLET
Damperspring
I
Turbine
t
t
Mainshaft

2. Operation(clutch off)
With the lock-upclutch off, the oil tlows in the reverseof CLUTCHON. As a result,the lock-uppiston is moved away
from the convertercover; that is, the torque converterlock-upis released.

Fowtttowl
TURBINE
Engine
I
Drive plate
I
Torque convertercover

Pump
I
Turbine
I
Mainshaft

14-38
In E positionin 2nd, 3rd and 4th, and @ positionin 3rd, pressurized fluid is drainedfrom the back of the torquecon-
verter through an oil passage,causingthe lock-uppiston to be held againstthe torque convertercover. As this takes
place,the mainshaftrotatesat the same speedas the enginecrankshaft.Togetherwith hydrauliccontrol,the TCM op-
timizedthe timing ot the lock-upsystem. Undercertainconditions,the lock-upclutch is appliedduringdeceleration,in
3rd and 4th sDeed.

The lock-upsystemcontrolsthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB.

When lock-upcontrol solenoidvalves A and B activate.modulatorpressurechanges.Lock-upcontrol solenoidvalves
A and B are mountedon the torque converterhousing,and are controlledby the TCM.

NOTE:
When used, "left" or " tight" indicatesdirectionon the tlowchart.

\ Solenoid valve
B
LOCK IJP COIITBOL
L""f."p "."aiti""\
Lock-upOFF OFF OFF
Lock-up,slight ON OFF
Lock-up,half ON ON
Lock-up.full ON ON
Lock-up Duty operation
ON
during deceleration O F F- O N

LOCI( UP TIMII{G B VAIVE

ott coot€R

{cont'd)

14-39
Description
Lock-upSystem(cont'dl
No Lock-uo
The pressurizedfluid regulatedby the modulatorworks on both ends of the lock-upshift valve and on the left side ot
the lock-upcontrolvalve.Underthis condition,the pressu.esworking on both ends ol the lock-upshitt valve ate equal.
the shift valve is moved to the right side by the tensionof the valve springalone.The tluid from the oil pump will flow
through the left side of the lock-upclutch to the torque converter;i,e., the lock-upclutch is in OFF condition.
"left" or "right" indicatesdirectionon the flowchart.
NOTE: When used.

LOCK.UPCONTRO!

<- MOOULATOi PBfSSURE

L O C K . U PT I M I G A V A L V E

14-40
 {
Partial Lock-up
Lock-upControlSolenoidValve A: ON Lock-upControl SolenoidValve B: OFF
The TCM switchesthe solenoidvalve A on to releasethe modulatorpressurein the left cavity ol the lock-upshift vatve.
The modulatorpressurein the right cavity of the lock-upshift valve overcomesthe springforce, thus the lockiup shifi
valve is moved to the left side.
The modulatorpressureis separatedto the two passages:
F1: Torque ConverterInner Pressure:enters into right side-toengagelock-upclutch
F2: Torque ConvenerBack Pressure:enters into left side-todisenqagelock-upclutch
The back pressure(F2) is regulatedby the lock-upcontrol valve whereasthe positionof the lock-uptiming B valve is
determined by the throttle B pressure, tension of the valve spring and pressure regulated by the modulator, Also the
positionof the lock-upcontrolvalveis determindedby the back pressureof the lock-upcontrolvalveand torqueconven-
er pressureregulatedby the check valve.With the lock-upcont.ol solenoidvalve B kept oft, the modulatorp.essu.eis
maintainedin the left end of the lock-upcontrolvalve;in other words, the lock-upcontrolvalveis moved slightlyto the
left side. This slight movementof the lock-upconlrol valve causesthe back pressureto be loweredslightly.resulting
in panial lock-up.

NOTE: When used. "left" or "right" indicatesdirectionon the flowchart.

LOCK.UPCOIIIROL LOCK UP COIITROI

SO!ENO|o VALVE A SOTENOIDVALVE B

<- MODUI.AIOi PAESSUFE

LOCK-UPIIMII{G B VATV€

otl coolEn

7
l.ont'al

14-41
Description
Lock-upSystem (cont'dl

Halt Lock-up
Lock up Control SolenoidValve A: ON Lock-upControl SolenoidValve B: ON
The modulatorpressureis releasedby the solenoidvalve B, causingthe modulatorpressurein the lett cavity of the lock-
uD control valve to lower.
Also the modulatorpressurein the left cavity of the lock-uptiming B valve is low. Howeverthe throttle B pressureis
still low at this time; consequently.the lock-uptiming B valve is kept on the right side by the spring force.
With the lock-upcontrolsolenoidvalve B turnedon, the lock-upcont.ol valve is moved somewhatto the Ieft side.caus
ing the back pressure(F2)to lower. This allows a greateramount of the fluid (F'1)to work on the lock,up clutch so as
to engagethe clutch. The back pressure(F2) which still exists preventsthe clutch from engagingtully

NOTE: When used, "left" or "right" indicatesdirectionon the flowcnarr.

LOCX UP CONTROL r.oct( uP corlTRol

sorENoto vatvE a

<-_ MOOULATORPRESSTJBE

LOCK UP IIMiI{G B VAI-VE

orr coorER

14-42
Full Lock-uo
Lock-upControl SolenoidValve A: ON Lock-upControlSolenoidValve B: ON
When the vehiclespeedfufther increases,the throttle B pressureis increasedin accordancewith the throttle opening.
The lock-uptiming B valve overcomesthe spring force and moves to the left side. Also, this valve closesthe oil port
leadingto the torque convertercheck valve.
Underthis condition,the throttle B pressureworking on the right end of the lock-upcontrolvalve becomesgreaterthan
that on the left end (modulatorpressurein the lelt end hasalreadybeenreleasedby the solenoidvalveB); i.e.,the lock-up
control valve is moved to the left. As this happens,the torque convener back pressureis releasedfully, causingthe
lock-upclutch to be engagedfully.
"right" indicatesdirectionon the tlowchart.
NOTE: When used, "left" or

LOC( UP COi{TAO! toc( uP coNtnol

SOIENOID VAIVEB

THRO]TIE A PFESSURE

PNESSUFE

FEGUTATOFVAIVE

LOCK-UPTIMIIIG B VALVE

orl cootER

(cont'd)

14-43
Description
Lock-up System (cont'dl

Dacslsration Lock-uD
Lock-upcontrol solenoid valve A: oN Lock-upcontrol solenoid valve B: Duty operation {oN - oFFl
The TCM switchessolenoidvalveB on and off rapidlyundercertainconditions.The slightlock-upand half lock-upregions
are maintainedso as to lock the torque converterproperly.

NOTE; When used, "left" or "right" indjcatesdirectionon the flowcnarr.

LOCK-I.PCOt{lFOt loc(,uP cot{TRoL

SOIENOID VATVEB

LOCI(,UPTtMt G B VAIVE

14-44i
Component Location

,/s\
)/

{ 7 v
A0t

AUTOMATIC TRANSAXLE IA/TI

GEAR POSITIONSWITCH

VEHICLESPEED
SENSOR{VSSI
COUNTERSHAFT MAINSHAFTSPEED THROTTLEPOSITION(TP}
SPEEDSEf{SOR SENSOR SENSOR

at

)''
(ECTI
ENGINECOOLANTTEMPERATURE
SENSOR

14-45
Circuit Diagram

UNDERHOODFUSE/RELAY
80X

No.411100A) (7.5A)
No.32

tGNtTtoN
c0 -

V
II
I
BLU

423 424 A20 D2

TRANSMISSION
CONTROL
MOOUI.E
{TCM)
Ar0 A8 A19 A18 A21 A17 A15 A13 Alt

AN GEAR
POSITION I A' V A-" t2
INDICATOR | *---i. t,,,:----<) l1
A/'I GEARPOSIIION
BLK swtrcH 8LK

T
G201
{
G201

14-46
 A/C . VEHICI.E
SPEED SERVICE
CHECK
COMPRESSOR SENSOR CONNECTOR
CLUTCH . SPEEOOMETER
REI.AY

/8tK 'HBOTfLE ENE'NE

Postto^l coolAlvr
SENSOR TEMPERA.
TURE
SENSOR

D 9 0 1 3 0 1 1D l 6 D 3 D6 D7 D5 A25 A26
TMNSMISSION
CONTROL
MODULE
{TCM}
Dls 019 Dl2 A5 A3 I

I.OCK'UPCONTROL SHIFTCONTROL
SOLENOIDVATVE SOLENOIO VALVE

COUNTERSHAFT MAINSHAFI
SPEEO
SENSOR SPEED
SENSOR

A3 A5 A9 A1: 421

A6 A8 A 1 ( ,/1,/1,/A 1 t
TCMT6rmin6lLocations

14-47
Troubleshooting
Procedures

when the TcM sensesan abnormalityin the input or output systems.the

E]indicator light in the gaugoassemblywill
blink.
when the service check Connector{locatedunder the dash on the passengerside} is connectedwith the
specaattool
as shown, the E] indicatorlight will blink the DiagnosticTroubleiode {DTCI when the ignitionswitch is turned
on.
When the lDil indicator light has been reported on, connect the service check connector with the
special tool.
Then turn on the ignition switch and observethe
@ indicatorlight.
GAUGEASSEMSLY
DAI'A LI]TK
(3P)
cor{r{EcToR
NOTE:
Do not atlach
jumpe.wire.

)
't
scs sHoRTCO[{]{ECTOR
oTPAZ-OOl0too

codes 1 through I are indicatedby individualshort blinks,codes 1o through 15 are indicatedby a series tong
of and
shon blinks.one long blinkequals l0 short blinks.Add the long and short blinkstogetherto dete;minsthe cod€.
Aft6r
determiningthe code, refer to the erectricarsystem symptom-to-componentchart on pages 14-5o and 51.

ahon

f"l
Sc. DTCI

So. DTC2

S.. DTC14

some PGM-FIproblemswill also make the @ indicatorlight come on. After repairingthe pGM-Frsystem, disconnect
the BACK UP tuse (7.5 Al in the under-hoodfuse/relaybox tor more than 1o secondsto reset the TcM memorv.

NOTE:
a PGM-FIsvstem
The PGM-FIsystem on this model is a sequentialmultipon fuel iniectionsvstem.
' Disconnectingthe BACK UP tuse also cancelsthe radio anti-theftcode, presetstationsand the clock
setting. G6t
the customer's code numbe. and make note of the radio presets befote temoving the fuse so you can reset them.

14-48
CAUTIOI{: a TCM Ro3at Procoduro
a All SRS eloctdcal wiring harna$os are covcred whh
yollow lnaulation. 1. Tum the ignition switch off.
a Sofora disconnecting any pan ot tho SRS wirc har'
n6ss, connoct the short connoctots (s€6 pago 23-701. 2. Removethe No. 32 BACK UP fuse {7.5 A} from the
a Roplacs tho entiro aff.ct d SRS ham6t. rssombly it under-hoodluse/relay box 'or 10 seconds to reset
ii has an opon circuil or damagcd wlrlng. the TCM.

NOTE; Disconnoctingthe No. 32 BACK UPtuse also

cancelsths radioanti-theft code, presetstations and
tho clock sefting. Get the customer's code number
and make note ol the radio presets before removing
the fuss so you can reset them.

BACKUP(7.5 A} FUSE

lf the inspection to. a particularlailure code requir6sthe

use of Test Harness {07LAJ - PT3O1OA):

1, Removethe left side kick panelon the driver'sside

(seepage 1+84).

2. Connect the wire harness to the Tsst Harness.

and/or connect the Test Harnessto the TCM sccord-
ing to the troubleshooting flowchart.

NOTE:
a Onlythe A and D terminalsof the TestHarnsssaro
used for Ay'Ttroubleshooting.
a Unless otherwise noted, use only the Digital
Multimeter, commerciallv available or KS-AHM- a Finll hoc.dulr
32{)03, for testing.

c NOTE: This procedure must be done after any

troubleshooting.

1. Removsths s9ocialtoolfrom the ServiceCheckCon-

noctor.

2. Resetthe TCM.

3, S6t th€ radio preset stations and clock setting.

DIG]TALMULTIMETER
Comm€rciallvavailable
KS-AHM-32-.003,
or gouivalEnt

) o o o o o o o o o o ) olo D o o o o o qoo o o o olo o o o o . o o o . c

To.miml Locrtlonr

14-49
Symptom-to-ComponentChart
ElectricalSystem

Numberof @
indicatorlight
blinks while
indicaror
Service Check @] PossibleCause Symptom
Referto
light page
Connectoris
connectedwith
the specialtool.
Blinks Disconnectedlock-upcontrol solenoid Lock-upclutch does not
valve A connector engage.
Short or open in lock-upcontrol sole- Lock-upclutch does not 14-52
noid valve A wire disengage.
Faulty lock-upcontrol solenoidvalve A Unstableidle speed.
Blinks Disconnectedlock-upcontrol solenoid . Lock-up clutch does not
valve B connector enga9e.
Short or open in lock-upcontrol sole- 14-54
noid valve B wire
Faulty lock-upcont.ol solenoidvalve B
Blinksor Disconnectedthrottle position (Tp) . Lock-upclutch does not
OFF sensorconnector engage.
Short or open in TP sensorwire 14-56
Faully TP sensor
4 Blinks Disconnectedvehiclespeed sensor . Lock-upclutch does not
(VSS)connector engage. 't
Short or open in VSS wire 4-57
Faulty VSS
Blinks . Short in A/T gear positionswitch wire . Failsto shift other than
. Faulty A/T gear positionswitch 2nde4th gears.
. Lock-up clutch does not 14-58
engage.
OFF DisconnectedA/T gear positionswitch Failsto shift other than
connector 2nd-4th gears.
Open in A/T gear positionswitch wire Lock-up clutch does not
Faulty A/T gear positionswitch en98ge. 14-60
Lock-upclutch engages
and disengagesalter-
nately.
7 Blinks Disconnectedshift control solenoid . Failsto shift (between
valve A connector 1st-4th, 2nd-4th or
Short or open in shitt control solenoid 2nd-3rd gears only). 14-62
valve A wire . Failsto shift (stuck in
Faulty shift control solenoidvalve A 4th gear).
8 Blinks Disconnectedshitt control solenoid . Failsto shiJt (stuck in
valve B connector lst or 4th gears).
Shon or open in shift control solenoid 't 4-64
valve B wi.e
Faulty shift control solenoidvalve B
a Blinks Disconnectedcountershattspeed sen- . Lock-upclutch does not
sor connector engage_
Short or open in the countershaft
speed sensorwire
Faultycountershaftspeed sensor

14-50
 Numberof @
indicatorlight
blinks while
indicator Refer to
ServiceCheck @ PossibleCause Symptom
light page
Connectoris
connectedwith
the specialtool.
'lo Blinks Disconnectedenginecoolant tempera- Lock-upclutch does not
rure (ECT)sensorconnector engage.
14-68
Short or open in ECT sensorwire
Faulty ECT sensor
1l OFF Disconnectedignitioncoil connector . Lock-upclutch does not
Short or open in ignition coil wire engage. 't4-70
Faulty ignitioncoil
13 Blinks . Shon or open in LT GRN wire between . No specificsymptom
the D3 terminaland ECM appears.
. Faulty barometricpressure{BARO)
14-71
sensor
NOTE:The BAROsensor is built into
the ECM
14 Blinks . Short of open in FAS {YEL}wire be- . Transmissionjerks hard
tween the D16 terminaland ECM when shitting.
. Faulty ECM
't5 . Transmissionjerks hard
OFF Disconnectedmainshaftspeed sensor
connecror when shifting.
Short or open in mainshaftspeedsen- 14-75
sor wire
Faulty mainshaftspeed sensor

LQ4 indicatorlight does not blink, perform an inspectionaccordingto the table below.
It the self-diagnosis

Symptom ProbableCause Ret.page

LQ! indicatorlight is on steady, not blinkingwheneverthe ignitionis on. 14-77

[Q3]indicatorlight does not come on for 2 secondsafter ignitionis first 14-78
turned on.
Lock-upclutch does not have duty operation(ON-OFFI. Check A/C signalwith
14-80
Lock-upclutch does not engage. A/C on.
Shitt leve. cannot be moved lrom @ positionwith the brake pedal
Check brakeswitch signal, 14-41
depressed.

a lf a customerdescribesthe symptoms for codes 3, (yet the LQ! indicatorlight is not blinkingl,6, 1 1 or 15, it will
be necessa.yto recreatethe symptom by test driving.and then checkingthe @ indicatorlight with the ignitionstill
oN.
e lt ttre @ indicatorlight displayscodes olher than those listed above or stays lit continuously,the TCM is faulty.
. Sometimesthe Lqd indicatorlight and the MalfunctionIndicatorLamp (MlL)/CheckEnginelight may come on simul-
taneously.lf so, check the PGM-Flsystem accordingto the numbe. of blinks on the MIL/CheckEnginelight. then
resetthe memoryby removingthe BACK UP fuse in the unde.-hoodfuse/relaybox for more than 1Oseconds.Drive
the vehicle for several minutes at speed over 30 mph (5O km/h), then recheck the MIL/Check Engine light.

NOTE:
. PGM-FIsystem
The PGM-Flsystem on this model is a sequentialmultiportfuel injectionsystem.
a Disconnectingthe BACK UP luse also cancelsthe radioanti-theftcode. presetstationsand the clock setting.Get
the customer'scode numberand make note ot the radio the fuse so vou can resetthem.

14-51
ElectricalTroubleshooting
TroubleshootingFlowchart
Possible Cause

. Disconnected lock-up control

s o l e n o a dv a l v e A c o n n e c t o r
. Short or open in lock-up control
Turn the ignition switch ON. solenoid valve A wire
. Faulty lock-up control solenoid

Check whether the Malfunction

IndicatorLamp (MlL) blinks (see
section I 1).

Repair the PGM-FI System (see

ls the MIL blinking?
section 1 l ).
NO

Turn the ignitionswitch OFF.

Disconnectthe 26Pand 22Pcon-

nectorsfrom the TCM.
Connectthe Test Harness"A"
and "D" connectorsto the wire
harnessonly, not to the TCM {see
page 14-49).
oooooooooooo ooooooooooo
oooooooooooo oooooooo9oo
Turn the ignitionswitch ON.

Measure the voltage between the

D18 and A25 or 426 terminals.

Repair open or shorl in WHT/

f s t h e v o f t a g e4 . 7 5 5 . 2 5 V ? BLK wir€ botwe€n th€ D18 termi-
nal and the ECM.
YES

A25 (-)

| | o" q" " ooo oo ooq litigse.*grq$:,1:d:sd:siia:l

" "" o" " oooo" I
Measurethe voltagebetweenthe IL--- r o ' r +
r r z 6r-t
l /trtr-- l
46 and A25 or A26 terminals-

Repail short to power sourco in

YEL wi.e between the A6 termi-
ls there voltage?
nal and the lock-up control sole-
noid valve A.
NO

Turn the ignitionswitch OFF.

To page 14'53

14-52
Me6surethe resistancebetween
the 46 andA25 or A26terminals.

Checkfor loos€ TCM connectors.

It necessary,substitute a known_
ls the resistance14 16 O? good solenoid valve assembly or
TCM and recheck.

Disconnectthe 2P connectorlrom
the lock-upcontrol solenoidvalve

CheckIor continuitv between the

46 and A25 or 426 terminals.

Repairshort to groundin YELwiro

ls there continuity? between tho AG t€rminal and th€
lock-uo control solsnoid valve A.

View lrom terminalside

Measurelhe resistanceof the

solenoidat the 2P connector.

Ch€ck tor open in YEL wire bo-

ls the resistance14- 16 0? tween the A6 terminal and the
lock-uDcontrol solenoidvalve A.

RoDlacath6 lock-up control sol€-

noid valv6 assembly.

{cont'd}

14-53
ElectricalTroubleshooting
Troubleshooting
Flowchart(cont'dl
PossibleCause
. Disconnectedlock-up conlrol
solenoidvalve B connector
. Short or open in lock-up control
Turn the ignitionswitch ON. solenoid valve B wire
. Faultylock up controlsolenoid
valve B

Check whether the Malfunction

IndicatorLamp (MlL) blinks (see
section 1 1).

ls the MIL blinking? Ropair tho PGM-FI Sysrom (se€

soction 11).

Turn the ignitionswitch OFF.

Disconnectthe 26P and 22P con-

nectorstrom the TCM.
Connect the Test Harness "A"
and "D" connecto.slo the wire
harnessonly, not to the TCM (see
page 14-49).

Turn the ignitionswitch ON.

Measurethe voltage between the

D'18and A25 or 426 terminats_

Rapair opon or shon in WHT/

ls the voltage4.75-5.25 V? BLK wi.e botweon the O18 te.mi-
nal rnd the ECM.

lvleasurethe voltage between the

44 and A25 or 426 rerminals.

Ropsir shon to power source in

GRN/BLK wi.o betwoon the A4
t6.minal and th€ lock-up control
solonoid valve B.

Turn the ignitionswitch OFF.

14-54
Measurethe resistancebetween
the A4 and A25 or A26 terminals.

Check for loosoTCM connocto.s.

lf nocoasary,substitute a known-
is the resistance14- 16 0? good solenoid valvo assombly ot
TCM and rochock.

Disconnectthe 2P connectorfrom
the lock-upcontrol solenoidvalve
assemory,

Checklor continuitv between the

A4 and A25 or A26 terminals.

Ropair 3horl to Itound in GRN/

BLK wir6 botwoon tho 44 totmi-
nal and th6 lock-up cont.ol solo-
noid valv6 B. 2P CONNECTOR
View trom terminal side.

Measure the resistance ol the

solenoid at the 2P connector.
q

.UP CONTROL
SOLENOID
VALVE
ASSEMBLY
Chock lor opon in GRN/BLKwiio
ls the resistance14- 16 07 botwaen tho A4 torminal and th6
lock-up contrcl solonoid valvo B.

R6Dlacotho lock-up conttol 3016-

noid valvs assembly.

(cont'd)

14-55
TroubleshootingFlowchart (cont'd)

Sof{irgnolis D! indic€tor tight Possible Cause

blinks throo rim6s.
Turn the ignitionswitch ON.
. Disconnocted throttle position
{TP) sensoaconnoctor
. Short or oDenin TP s€nsorwire
. Faulty TP senaor

Check whother the Malfunction

IndicatorLamp (MlL) blinks(see
section 1 1).

ls the MIL blinking? Replir thc PGM-FI Syrtom l.s.

!.ction 111.

Turn the ignitionswitch OFF.

Oisconnectrho 26P 6nd 22P con-

nectors lrom the TCM.
Connect the Test Harness "A"
and "D" connectors to the wire
harnessonly, not to the TCM lsee
page |4-491.

Turn the ignitionswitch ON.

Measurethe voltage between the

Dl8 and A25 or A26 teiminats.

Rcpalr opon or shon In WHT/

ls the voltage4.75-5.25 V? BLK wlr. botw.cn th. D18 t.mi-
nsl rnd th. ECM.

Turn the ignirionswirch OFF.

Connect the Test Harness "A"

and "D" connectorsto the TCM.

Turn the ignition switch ON.

Measurethe voltage betwe€n the

D7 and A25 or 426 rerminals.

Roprlr oprn o. lhon in RED/BLK

ls the voltage0.4-0.6 V? wil. botwaan tha DT ta]minal and
tha TP ranaor.

Chock tor looro TCM connoctora.

ll noce$rry, subatitulo r known-
good TCM and rechock.
S. d.gno.b lql indic.to. light PossibleCaus6
bllnkr tour tlm...
. Disconnectsd vehicle speed
sensor{VSS}connector
. Short or open in VSS wire
. Faulty VSS

R.lor to Soctlon 23 for vohicle

rpood lonsoi {vSSl to!t.

a Mak€ sure lifts,lacks, and safety stands aro placod plopor-

ly {see Eaclion 1}.
to A position. a S6t th6 parking brake eecurely and block tho tear wh6ol3'
Shift t.nsmisiion
a Jack up tho f.ont ot tho car and rupport whh sstoty standa.

Disconn6ctthe 26Pand 22P con-

n.ctors trom th€ TCM.
"A"
Connect ths Tgst Harnoas
8nd "O" connectors to tho wire
harnsssonly, not to the TCM (see
page 1+49).

Turn the ignilionswitch ON.

Rotat€th€ tront wh6ol and chsck

fo. volt6g€ botwean the D9 and
A25 o. A26 terminals.Blockthe
other whaol 30 it do€s not turn.

Ch6ck to. shoft or opon in OFil

Doss lhe voltage O V and ap- wlro b€twoen tho .)9 t6tminsl and
p.ox. 10 V appe.r alternately? rho VSS. lf wiro is OK, ch€ck tho
VSS lsoo soction 231.

Ch.d( tor loo.. TCM co.!n.cto.r.

ll nacaaalay, lubrtituta ! known_
geod TCM and t chock.

(cont'd)

14-57
ElectricalTroubleshooting
TroubleshootingFlowchartlcont'dl

Solt-diagno8isl!4 indicato. tight PossibleCause

blinks fiv6 timos.
'Short in A/T gear posilion
switch wire
. Faulty A/T gear position switch
Turn the ignitionswitch ON.

Observethe A/T gear position in-
dicator,and selecteach position
separately.
NOTE:Code 5 is causedwhen
the TCM receivestwo gear po-
sition inputsat the sametime.

Do any indicators stay on The systom is OK ai this timo.

when the selectorlever is Ch.ck tho wiro ha|noss tor
not in that position? oamago.

Turn the ignitionswitch OFF.

Connect the Test Harness be,

tween the TCM and connectors
{see page 14-49}.

Turn the rgnitionswitch ON.

Or
4 2 5t - |
Shilt to other than E position.

Measurethe voltage b€tween the

A21 and A25 or 426 terminats.

Chock for short in GRN/REDwi.o botwoon tho A2t torminal

and th6 A/T goar po6ition swirch or A/T 96ar posirion indi-
cator. lf wire is OK, chock for loo8o TCM connocioF. lf
necassary,subatituto a known-good TCM and rochsck.

-l@r
A 1 9 l + ) A 2 5( - )
Measurethe voltage between the
419 and A25 or 426 terminals.

Ch6ck for 6hon in LT GRN/BLKwi.e borwoon tho A19 tor-

minal and tho A/T goar position indicato., o. a shon in
ls the battery voltage? GRN/WHT or GRN wiros botwson tho A/T goa. position in-
dicato. and tho A/T goa. position swhch. ll wire is OK. chock
YES for looso TCM connactoE. lf nocos$sry, substituto a known-
good TCM and .ech6ck,
To page 1 4 , 5 9

14-5 8
 14-58

shift ro other than E posirion.

Measurethe voltage belween lhe

A17 and A25 or A26 terminals.

Chock to. short in PNK/GRNwire betwoon tho Al7 torminal and

th6 A/T gsar position switch. It wire is OK, chsck for looso TCM
ls there battery voltage?
connoctors. lf nocessary, substitute a known-good TCM and
roch€ck.

Shifi to other than E] position.

oooooooooooo ooooooooooo
oooooooooooo oooooooo ooo
Measurethe voltage between the
A15 and A25 or 426 terminals.

Chock for short in GRN/BLUwire betweon the A15 terminal and

the A/T gosr position switch or A/T g€a. position indicato.. ll wiro
ls there batteryvoltage?
is OK, chock for loose TCM connectors. ll nocessary,substituls
a known-good TCM and rochock.

Shilt to other than E position.

oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Measurethe voltage between the
A13 and A25 or 426 terminals.

Chock for short in GRN/YELwire betweon ths A13 torminal and

ls there battery voltage?
the A/T gear position switch or A/T gear posilion indicator. l{ wiro
ll
is OK, check lor loose TCM connectors. lI necessarv,substituta
a known-good TCM and rechsck.

Shift to other rhan I oosirion.

oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Measurethe voltage between the
Al l and 425 ot 426 tetminals.

Chock tor shon in LT GRN/WHT wi.e b€twoan th6 A1'l lerminal

ls thgre battery voltage? and the A/T gear position switch or A/T gear position indicator.
lf wira b OK, ch6ck foi loose TCM conneclors. lf noc€ssary,sub-
stituto a known-good TCM and rocheck.
YES

Chock for looso TCM conn€ctors.

lf noce$ary, substitute a known-
good TCM and recheck.

{cont'd)

14-59
ElectricalTroubleshooting
TroubleshootingFlowchart{cont'dl

Self-diagnosisE indicator light PossibleCause

blinkasix timos.
Connect the Test Harnessbe,
tween the TCM and connectors
(seepage '14-49).
. DisconnectedA/T gear position
swrtcn connector
' Open in A/T gear positionswitch
. FaultyA/T gear positionswitch

Turn the ignitionswitch ON.

-
- r9t
a 2 1 ( +I A 2 5 { - )
oooooooooooo ooooooooooo
oooooooooooo ooooooooooo

Measurethe voltagebetweenthe
A21 and 425 or 426 terminals.

Ropairopen in GRN/REDwire be,

ls there voltage? tweon th6 A21 terminal and the
A/T gssr position switch.

Shilt ro N or E position.
A25t-l
oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Measure the voltage between the
A19 and A25 or A26 terminals.

Ropairopen in LT GRN/BLKwire
ls there voltage? b€tw6onthe 419 torminaland th€
A/T gear position indicato..
NO

T o p a g el 4 - 6 1

14-60
 oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Measurethe voltage betweenthe
A 1 7 a n d4 2 5 o r A 2 6 t e r m i n a l s .

Roprir opon in PNK/GRNwire botwoon

voltage? the A17 torminal and rh6 A/T goar posi-
tion switch.

oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Measurethevoltagebetweenthe
A 1 5 a n dA 2 5 o r A 2 6 t e r m i n a l s .

Ropairopen in GRN/BLUwir6 bolwoen

the A15 r6.minal and tho A/T goar posi-
tion switch.

oooooooooooo ooooooooooo
oooooooooooo ooOoooooooo
Measurethe voltage between the
A 1 3 a n dA 2 5 o r A 2 6 t e r m i n a l s .

ReDairopen in GRN/YELwito botw€on

voltage? the Al3 torminalandth€ A/T goarposi-
lion switch.

All(+ I
oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Measure the voltage between the
A11 and A25 or A26 terminals.

Ropaii opon in LT GRN/WIIT wiro bo-

voltageT tw€en the A 11 te.minaland tho A/T goar
oosition switch.

Checklor loos€ TCM connectors.

It necossaty,substituto a known_
good TCM and r6ch6ck.

(cont'dl

14-61
ElectricalTroubleshooting
Flowchart(cont'dl
Troubleshooting

S€ltdiagno3b Lql indicaror lighr PossibleCause

blinks sovon timgs.
Turn the ignition switch ON.
. Discohnectedshift control sole-
noid valve A connector
. Short or open in shift control
solenoid valve A wire
. Faulty shill control solenoid

Check whether the Malfunction

IndicatorLamp {MlL) blinks(see
section 11).

ls the MIL blinking? Ropai lhe PGM-FI Sysrem (so€

Bection1 11,

Turn th6 ignition switch OFF.

Disconnect the 26P and22P con-

nectors from the TCM.
Connect the Test Harness "A"
and "D" connectors to the wire
harnessonly not to the TCM (see
page 14-49).

D l 8 (r I
Turn the ignitionswitch ON.

Measurethe voltage betw€€n the

D18 and A25 or A26 lerminals.

Repairopon o. sho.t in WHT/BLK

fs the voftage4.75-5.25 V? wire botwoon th€ D18 tarminal
and the ECM.

oooooooooooo ooooooooooo
ooooo oooooooa t:tJio*ie*O:lt$!l$4lrulitEijt'lo oo oooooooo

Measurethe voltage between the

A5 and A25 or A26 terminals.

Ropair lhon to powor sourc6 in

BLU/YEL wiro botwoon the A5
torminal and th6 lhift control solo-
noid valve A.

Turn the ignitionswitch OFF.

 {

oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Measurethe resistancebetween
the A5 and 425 or 426 terminals.

Chock lor loora TCM connectoE.

ls the resistance14-16 0? lf n6c€53ary,sub3titut6a known-
good solonoid valvo assembly or
NO TCM and r6check.

Disconnectthe 3P connectortrom
the shift control solenoidvalveas-
sembly.

Check for continuitv between the

A5 and A25 or 426 torminals.

Ropair shon to ground in BLUI'EL

wir6 botwoon tho A5 tstminal and
tho shift conlrol solonoidvalvo A.

3P CONNECTOR
View from terminalside.

Measure lhe resistance of the

solenoidat lhe 3P connector.

Check fo. opon in BLU/YELwiro

ls the resistance'14-16 0? bolween th6 A5 torminal and tho
shift control solenoid valve A.
SHIFT CONTROL
SOLENOIDVALVE
ASSEMBLY

(cont'd)

14-63
ElectricalTroubleshooting
Flowchart(cont'dl
Troubleshooting

Solfdiagnolir [!4 Indicato. light PossibleCau6e

bllnk! eight tim6r.
Turn the ignition switch ON.
. Disconnected shift control sole-
noid valve B connector
. Short or open in shift control
solenoid valve B wire
. Faulty shilt control solenoid
valve B

Check whother the Malfunction

Indicator Lamp {MlL) blinks (see
section I 11.

ls the MIL blinking? Rcpsir rho FGM-FI Syrtem lso6

scciion l1l.

Turn the ignition swirch OFF.

Oisconn€ctthe 26P and 22P con-

nectors trom the TCM.
Connectthe Test Harness"A"
and "D" connectors to the wiro
hamessonly. not to the TCM {ses A2s(- |
p6ge 14-49). o oooooooooo oooooo ooooo
oooooooooooo oooo oooo
Turn the ignition switch ON. D l A (+ I

Measurethe voltage betwe€n the

D18 and A25 or A26 terminals.

Ropeiropon or short in WHT/BLK

ls the voltage4.75-5.25 V? wiro trotweon th6 D18 terminel
and tho EcM.

Measurethe voltage between th€

A3 and A25 or A26 terminals.

Ropair rhort to powor rourco in

GR /WHT wir6 b€twgan tho A3
tormirEl and shift conLol lolonoid
valve B.

Turn the ignitionswitch OFF.

To page
Measurethe resistance between
the A3 and A25 or A26 terminals.

Chod. lor looro TCM connoctoB.

ls the resistanceI +16 07 lf nocdaary. 3ubatltute a known-
good rolonold valv6 6ra6|nbly ot
TCM snd recheck.

Disconn€ctth6 3P conngctorfrom
the shift control solenoid valve
assembly.

oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Check for continuity between the
A3 and A25 or A26 terminals.

Ropair short to ground in GRt{/

WHT wiro botwoon th6 A3 tormi-
nrl and tho shitt control aolonoid
valve B.

Measure the resistance ot the

solenoid at the 3P connector.

Chock to. open in GRN/WHT wiro

ls the r€sistance14- 16 O? b6twe.n th€ A3 lerminal and tho
shifl control solonoid valvo B.
SHIFT CONTROL
SOLENOIDVALVE
Roplace lhe rhift control solenoid ASSEMELY
valve arr€mblv.

(cont'd)

14-65
ElectricalTroubleshooting
TroubleshootingFlowchart{cont'dl

Self-diagnosisLq! indicator lighr PossibleCause

blinks nino timos.
. Loose or faulty connection be-
rween the TCM and car harness.
. Disconnectedcountershaft speed
sensor connector
. Short or open in the counter-
shatt speed sensor wire
. Faulty counlershaft speed sensor

ls the countershaftspeed
sensor installed properly

Disconnectthe 2P conneclorlrom
the countershaft speed sensor
connector,

Measure the resistance ot the

co!ntershaft speed sensor.

2P CONNECTOR

COUNTERSHAFT
SPEEDSENSOR

ls the resistance 4OO 600 0?

To page 14-67

14 -6 6
Disconnoct the 22P connector
trom the TCM. Connecr tho T€st
Harness "D" connector to the
whe harnessonlv, not to the TCM
'14-49).
lsee page

Check for continuitv between

body ground and 017 terminal
and D15 terminslindividually.

Rgpllr short in BLU/GRI{ ot

BLU|/EL wlro b€twgon Dl7 and
Dl5 torminsla and ths countar-
rhaft apo€d sengor.

Reconnect the countershaft

sDe00sensor connector.

Msasure the rgsistancebetween

D 17 and 015 terminals.

Rgpairlooa6 ta.minsl or opon in

8LU/GRN o. 8LU/YEL wiro bo-
ls the r€sistance4OO-600 07 trvaon D'17 and D15 tormindg
and tho count6rlhafl !p6gd
!€ntor,

Ch6ck for looaa TCM conn6cto..

ll nocaslrry, aubrlitut6 a known-
good TCM a.d .6ch.ck.

(cont'd)

4-67
ElectricalTroubleshooting
Flowchart(cont'dl
Troubleshooting

Self-diagnosisE indicator light Possibl€Caus6

blinks ten times.
Turn the ignitionswitch ON.
. Disconnoct€dengine coolant
t€mp€rature (ECTI sensor con-
noctor
. Short or open in the ECT sensor
. Faulty ECT s€nsor

Check whether the Malfunction

IndicatorLamp {MlL} blinks(see
section 11)-

ls the MIL blinking? Rop.ir tho PGM-FI Syrt.m (!go

!.ction 111.

Turn the ignitionswitch OFF.

Disconnectthe26P and 22P con-

nectorstrom the TCM.
Connectthe Test Harness"A"
and "D" conneclorsto the wire
harnessonly, not to the TCM (see
p a g e1 4 4 9 ) .

oooooooooooo ooooooooooo
oooooooooooo oooo oooo
Dlal+ I
Measurethe voltage between the
D'18and A25 or A26 lorminals.

Bopairop.n or .hofi In WHT/BLK

ls the voltage4.75-5.25 V? wiro botwoon tho O18 tanni.|al
.nd the ECM.

Turn the ignition switch OFF.

Conneci the Test Hs.ngs6 "A"
and "O" connectorsto thg TCM.

Start the engine and warm it up

to normal ope.ating t€mpsratuG
(the rsdiator fan comes on).

Measurgthe voltage between the

05 and A25 or A26 terminals.

Rlplir opsn or rhort in BED/WHT

ls the voltago less th6n lV? wira botwaan tra D5 torr nC lnd
tha ECT lanaor.

Ch.ct tor loora TCMco.rmcror..

It nocgallry, sublthuta a known-
good TCM .nd rechrck.

14-69
ElectricalTroubleshooting
TroubleshootingFlowchart(cont'd)

Solt-diagnosislq.l indicstor light PossibleCause

blinks elovon tim6s. . Disconnected ignition coil con-
neclor
. Short or open in ignition coil

. Faulty ignition coil

Disconnect the 26P connector
Irom the TCM.

Turn the ignitionswitch ON.

Measurethe voltage between the

Ag (BLU)and A25 (BRNiBLK) or
A26 (BRN/BLK) terminals. NOTE: View from wire side.

ls there baftery voltage? R6pai?opon or short in BLU wiro

lrotwqan lh. A9 torminll 6nd th.
ignilion c!il.

Ch6ck lor loos6 TCM connactora.

It nacosaary,substituto a known-
good TCM and rochock.

14-70
Soll-diagnosisLq! indicator light
blinks thirtoon tim6.
ls rhe Malfunction lndicator
Lamp (MlL) on and does it
indicatecode 13?
Turn the ignitionswitch OFF.
Disconnectlhe 26Pand 22P con-
nectors trom the TCM
Connect the Test Hahess "A"
and "D" connectorsto the wire
harnessonly, not to th€ TCM {see
pare'14-49).
Turn the ignitionswirch ON.
Measurethe voltage between the
D18 and A25 or A26 terminals.
ls the voltage4.75-5.25 V?
Turn the ignitionswith OFF.
fo page 14-72
Possible Cause
. Short or open in LT GRNwire betweenthe D3
terminaland the ECM.
. Faukythe barometricpressure{8ARO}sensor.
NOTE:The BAROsensoris built into lhe ECM.
Do the TCM Rest Procedure(see
page 14-49).
Turn the ignitionswitch ON.
Substituto a known-
good ECM and rechock.
ls the MIL on and does it
indicarecode 13? ll symptom/lndication
goos away, .oplacethe
originalECM.
A25t-|
o o o o o o o o o o o o o o O O q g o p g I , o i O O O O ool o o o o o o o o o o
o o o o o o o o o o o o 0 ooocqooo:Joo.oipggl o oooooo o 9oo
Ropairopon or short in WHT/BLK
wir6 botwoon th€ D18 to.minal
and tho EcM.
14-71
ElectricalTroubleshootang
TroubleshootingFlowchart (cont'd)
'14-71
From page

NOTE: View from wire side.

Disconnect the 22P connectors

lrom the TCM and ECM.

ECM 22P COiINECTOR

Check for continuity between the
D3 {LTGRN)terminalol the TcM
22P connecrorand the D8 ILT
GRN) terminalof the ECM 22P
connector.

TCM 22P CONNECTOR

Ropai. opon In LT GRN rvi.a b.-

twoon tho TCM and ECM.

Checklor continuity between the

LT GRN wire and body ground.

Ropair short lo body ground in

LT GRN wir6.

Ch€ck lor loos6 TCM and ECM

connectors, lf necessary,aubari-
tute a known-good TCM and
rccheck.

14-72
S.fdl.enorl! L&l indicdor lighl
PossibleCause
blinks fourtoon tlmoa. . Sh"rt ". "e"" i" FAS |YEU ,"rirt
. FsultyECM.

ls the Malfunction Indicator Ropair tho PGM-FI Syrtom lloo

Lamp (MlL) onl ..ctlon 111.

Stan the ongine and warm it up

to normal operating temperature
{th€ radiatorlan com€s on).

Shift to E position,

Turn rhe ignition switch OFF.

Connect the Test Harness be-

tween the TCM and connociors
{seepage 14-491.

Turn the ignition switch ON and

wsit for at least two seconds.
o oooooo ooo ooo l.tto.oodooo l:,gEoo.ottl o ooooo oooo o
o oooo oooooooo o oooooooooo
l:OOOOOO60 l.,OO{tO.O6,'l
Measure lhe voltagebetwganths
o16l+ ) andA25 or A26(- | tor-
mrnals.

Chock for looro TCM connoctora.

ls thoro approx. 5 V? lf noco$ary, subatituta a known-
good TCM and .ech€ck.

Turn the ignition switch OFF.

Dkconnectthe TestHarnessfrom
the TcM.
Leaveconnect€dto car harness.

Turn the ignition switch ON.

fo page 14-74

lcont'd)

14-73
ElectricalTroubleshooting
TroubleshootingFlowchart(cont'd)

From page 14-73

o o o o o o o o O o O o O $:O.COOtt9O$:l:OtO:CtOiOi:l Oo OO OOo Oo o O
o o o o o o o o o o o o O I:f(O.{iltltO{t{t:I:OFA:F:d:O:l o o o o o o o Oo o o
Measurethe voltage between the
D 1 6 { + ) a n dA 2 5 o r A 2 6 { - ) t e r -
mtnals.

Check for loos€ TCM connoctors.

ls there approx. 5 V? ll ngcossary,substituto a known-
good TCM and rechock.

Disconnectthe 26P connector

from the ECM.

oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Check for continuitv between the
D16 andA25 or A26 rerminalsof
the Test Harness.

Ropairshortin YEL IFAS)wire be-

tw6on TCM and ECM.

Disconnectthe 26P and 22P con-

nectors from the Test Harness.
22P CONNECTOB

Check for continuity betweenthe

D16 (YEL)terminalot fCM 22P
connectorand A19 (YEL)terminal
of ECM 26P connector.
NOTE:View lrom wire side.

Chgck tor loos€ TCM connoctofs.

ls there continuity? lf nocassary,substitute o known-
good TCM and rech6ck.
NO

Ropairopon in YEL {FAS}wiro bo-

trve€n TCM and ECM.

solf-diagnosisE indicator light
blink tiftoon timos.
PossibleCause NOTE:
. A code 15 on the TCM doesn't alwsys
. Disconnected mainshaft speed mean there's an electrical problem in the
sensor connecror mainshaftor countershaftspeedsensorcir-
. Short or open in mainshalt '15may also indicatea mechani-
cuit; code
speedsensorwrre. cal Droblemin the transmission.
. Faulty mainshatt speed sensor.

Are the mainshaft and counter-

shalt speed sensors installed
properly?

Disconnectthe 3P connectorlrom
the mainshaftspeedsensor.

Measurethe resistanceot the

mainshaftspeedsensor. 3P CONNECTOR

ls the resistance4OO-600 O?

Disconnectthe 22P connector

from the TCM.
Connectthe Test Harness"D"
conneclor to the wire harness
only, not ot the TCM (see page
14-49).
Check the continuity between
D19 and D12 terminalsand body
ground.
I o o o o o o o oo o o o o I:OtlO$O$g:Sl!:OlXOl*Ofill o o o o o o o o o Oo |
I|
I ooooooooooooo l Sciii:ddii:ijii:l:i$idi$;d6#:l
o oooop oo ooo | 6
" - f
1(0) - L
Y
-!
Rcoair short in ORN/BLU ot
WHT/BLU wiros botween Dlg
and Dl2 to.minals and tho main-
shatt speod ronsor.

Reconnectthe 3P connectorto
the mainshattspeedsensor,

To page 14-76
(cont'd)

14-75
ElectricalTroubleshooting
TroubleshootingFlowchalt (cont'd)

From page 14-75

ooooooooooooo ooooooooooo
ooooooooooooo ooooooooooo
Measurethe resistancebetween
D19 and D12terminals.

ls the resistance4O0-600 0?
RunElectricalTroubleshootingfol
code 9.
Check for loos6TCM connectors.
It nocessary,substitute a known-
good TCM and r.check.

Disconneclthe 3P connectorfrom
the mainshaft speed sensor.
ooooooooooooo oooooooooo
ooooooooooooo ooooooooooo

Check tor continuitv between

D19 terminaland the mainshalt
speedsensotconnector.

MAINSHAFTSPEEDSENSOR

Ropairop.n in ORN/BLUwir6 b6-

tweon D19 terminalsnd th€ main'
shaft spa6d sensor.

Chock tgr continuity between

D12 terminaland the mainshatt ooooooooooooo ooooooooooo
speed sensor connector. ooooooooooooo ooooooooooo

3P CONNECTOR
View from terminalside

MAINSHAFTSPEEDSENSOR

Ropairopen in WHT/BLUwire be-

twe€n D12 tgrminaland th€ main-
shaft sD6ed sonsor.

Chsck for loos€TCM connoctors.

ll noco$ary, substitute a known-
good TCM and rocheck.

14-76
@ indic"to, light i8 on st6sdy
Inot blinkingl whenevor the ioni-
tion switch is ON.

Turn the ignitionswitch OFF.

Disconnectthe 26P connector

from the TCM.
Connectthe Test Harness"A"
connector to the wite harness
only, not to the TCM (see page
14-49).

Turn the ignitionswitch ON. o o o o oo o oo o oo o l:qssoo9pc,I:oocto:osil o o o oo o o o o oo

oooQooooooooo o ooooooo ooo

Measurethe voltage between the

A8 terminaland body ground.

Ropairshon to power in GRN/BLK

ls there voltage? wiro botwoen A8 terminal and
gauge assembly.

Connectthe Test Harness"A"

conneclorto the TCM.

Measurethe voltage between the

417 terminal and body ground
with the selectorleverin anv oo'
sition other than El.

Check for a sho.t to ground on the

ls there volrage? PNK/GRNwi.e. ll th€ wir. is OK,
roplac€ the A/T gear poaition in-
dicator.

ReDlace tho TCM.

{cont'd)

14-77
ElectricalTroubleshooting
TroubleshootingFlowchaft (cont'dl
Lq4 indicatorlight do6s not come
on with the ignitionswitch ON. (lt
should come on Ior about 2
seconds.l
ls the servicecheck connector
connectedwith the special
tool ISCS Short Connectod?
Does the @ indicatorlighr
come on?
Turn the ignitionswitch OFF.
Disconnectthe 26P connector
from the TCM.
Connectthe Test Harness"A"
conneclor to the wile harness
only, not to the TCM (see page
14-49).
Check for continuity between the
A25 terminal and body ground
and A26 and body ground.
Turn the ignitionswitch ON.
Measurethe voltage between the
A23 or A24 and A25 or A26 ter
mrnals-
ls there baftery voltage?
YES
Turn the ignitionswitch OFF.
To page 14-79
14-78
Diaconnect tho spocial tool from
th6 sgrvice check connoctor and
recheck.
Check {or loos6 TCM connoctors.
lf necessaw,substitute a known-
good TCM and recheck.
I A25
| | o ooooo o oo o ooo r:sjc.o.sl'1*st,li*os.s.4tcl
ooo oo oooooo I
ooooooooooooq lifrif.S..n${5git:li$gg-:aiiigitll
ooooooooooo I
I| - - . -I T ..-
I a26
+ d
+
R€pair open BRN/BLK wires be-
twe6n A25 or A26 torminals and
G1 0 1 .
I + )A23A25l- l
(+ tA24426(- |
t \
@
Repaii open or short in BLK/YEL
wire between tho A23 and /ot
424 terminals and underhood
tuse /relav box.
Connect the Test Harness "A"
connectorto the TCM.
a26t- |
oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Turn the ignitionswitch ON.
8e sure that voltage is available A8(+)
for 2 secondsbetweenthg A8 tor-
minal and A25 or A26 terminal.

Chrck for opon or rhort in GR /

8LK wirc bctw.on th. A8 termi-
nal and tha gauOaarrambly.

Turn the ignition switch OFF.

Disconnectthe Test Harness"A"

connector from the TCM.

Checkfor continuity between the

A8 terminal and the GRN/BLK
wire at tho gaugo assgmbly (see
section23).

B.p.ir op.n in GRI{/BLKwi.. bo-

lwaen the A8 terminal and th.
gauga 6aaombly.

Ch€ck for loor6 TCM conn6ctor3.

Check the A/T goa. polition
awitch. ll noc€$ary, subrtitutg a
known-good TCM .nd rochock.

(cont'd)

14-79
ElectricalTroubleshooting
TroubleshootingFlowchart{cont'dl

In3poction ol ths A/C aign6l.

. Lock-up clutch does not have
duty operation(ON-OFF).
. Lock-upclutch does not engage.

TLrrnthe blower switch ON.

Pushthe A/C switch ON.

Soe Air Condilioning inspoction

lsee rection 221.

Disconnect the 26P conneclor

from the TCM.

BR /ALK

Measurethe voltage between the

A22 {BLK/RED)and A25 (8RN/
BLKI or A26 IBRN/BLK)terminals.
(A/C compressorOFFI

Repairopon in 8LK/REDwiio b6-

twoon lho A22 torminal and A/C
comprossor clulch rel6y.

. A/C aignal ls OK.

. Chock lor looso TCM connec-
toB. lf n6co$ary, substitute a
known-good TCM and rschock.
. Inrpoct tho 6ir condhioning lsoo
loction 221.
 Symptom

Shift lever cannot be moved lrom

E position with the brake pedal
depressed.
Check thar the brake lights come
on with the brake pedal de-
pressed.

Aro brake lights ON? R.prir l.ulty br6ko rwitch cir-

cuita 18o6lactlon 231.

Disconnecllhe 26P and 22P con-

nectors from the TCM.
Connoct the Test Harness "A"
and "D" coonectors to th€ wire A 2 5t - )
harnessonly, not to the TCM {see oooooooooooo ooooooooooo
page 14-49).
oooooooooooo oooooooooo
D 2l + )

Measurethe voltage between the

02 and 425 or A26 terminals
with the brake pedal dopressed.

Ropalrop6n in GRt{/wHT wiro b.-

ls there battery voltage? tween tho D2 to7minsland brak.
!witch.

. Bfako switch signal OK.

. Check for 10036TCM connec-
tors. It noco$ary, sub3tiluto a
known-good TCM and ioch6ck.
. Insp6ct tho brako switch circuii
lsoo soction 23).
Lock-up Control SolenoidValve A/B
Replacement

NOTE: Lock-uDcontrolsolenoidvalvesA and B must be Removethe mountingboltsand lock-upcontrolsole-

removed/replaced
as an assemblv. noid valve assembly.

l. Disconnect2P connectortrom the lock-uocontrol NOTE: Besureto removeor replacethe lock-upcon-

solenoidvalve A/8. trol solenoidvalves A and B as an assembly.

2. Measurethe resistancebetweenthe No. 1 terminal Checkthe lock-upcontrol solenoidvalve oil passages

(solenoidvalve A) ot the lock-up cont.ol solenoid tor dust or dirt. and replace as an assembly,if
valveconnectorand body ground,and betweenthe neceSsary.
No. 2 terminal(solenoidvalve B) and body ground.

STANDARD:14- 16 O

2P CONI{ECTOR
View trom terminal side. 6 x 1.0 mm
12 N.m (1.2 kgf.m,8.7 lbf'ft)

Cleanthe mountingsudace
and oil passages.

VAI-VE
SoLENOTO
ASSEMBLY

? Reolacethe lock-uocontrol solenoidvalve assem- Cleanthe mountingsurtaceand oil passagesof the

bly if the resistanceis out of specitication. lock-upcontrolsolenoidvalveassembly.and install
a new filter/gasket.
4. lf the .esistanceis within the standard,connectthe
No. 1 terminalot the lock-uocontrolsolenoidvalve Checkthe connectorfor rust, dirt or oil and recon-
connectorto the battery positiveterminal.A click- nect rt securely.
ing sound shouldbe heard.Connectthe No. 2 ter-
minal to the battery positive terminsl. A clicking
soundshouldbe heard.Replacethe lock-upcontrol
solenoidvalve assemblyif no clickingsound is heard.

14-82
Shift Control SolenoidValve A/B
Test
NOTE: Shift controlsolenoidvalvesA and B must be re- 1 . Removethe shift control solenoidvaive assembly
moved/replaced as an assembly. protector.

1 . Disconnect3P connectorfrom the shitt controlsole- Removethe mountingbolts and shift control sole-
noid valve A/8. noid valve assembly.

Measurethe resistancebetweenthe No. 1 terminal
(solenoidvalveA) of the shift controlsolenoidvalve
connecto.and body ground,and betweenthe No.
2 terminal(solenoidvalve B) and body ground.
S T A N D A R D1: 4 - 1 6 O
NOTE: Be sure to removeor replacethe shitt con-
trol solenoidvalves A and B as an assembly.
Checkthe shitt controlsolenoidvalve oil passages
for dust or dirt, and replace as an assembly, it
necessary.

6 x 1.0 mm
12 N'm (1.2kgl.m,4.7 lbl.ftl

SHIFT CONTROLSOLENOIO
VALVE ASSEMBLY
VALVE ASS€MBLY Clean the mounting
surfaceand oil passages.

Replace.
3 . Replacethe shift controlsolenoidvalve assemblyif
the resistanceis out oI sDecificaiton.

lf the resistanceis within the standard,connectthe
No. 1 terminalofthe shift controlsolenoidvalvecon-
nector to the battery positiveterminal.A clicking
soundshouldbe heard.Connectthe No. 2 terminal
to the battery positiveterminal.A clicking sound
shouldbe heard.Replacethe shift control solenoid
valve assemblyif no clickingsound is heard.
Cleanthe mountingsurfaceand oil passagesof the
shitt control solenoidvalve assembly,and installa
new filter/gasket.
Checkthe connectorfor rust, dirt or oil, and recon-
nect it securely.

14-83
TransmissionControl Module
Replacement

I The Transmission ControlModule(TCMIis locatedbe- 1. Removetwo clips securingthe kick panelthen

low the dashboard,behindthe lelt side kick panelon move it.
the driver's side.

CAUTION:
a All SRS electrical wiring hahesses are covered with
yellow insulation.
a Betore disconnecting any pan ot the SRS wile har-
ness. connect the short connectorslsee page 23-7O).
a Replacethe entir6 affected SRS harness ass€mbly if
it has an open circuit or damaged wiring.

KICK PANEL

2. Disconnectthe connectorsand removethe TCM.

6 x 1.0 mm
SRS MAIN HARNESS 12 N'm
{1.2kgf.m,
8.7 tbf.Itl

WIREHARNESS/
CONNECTORS 6 x 1.0 mm
12 N.m
(1.2 kgf.m, 8.7 lbt.ftl

14-84
Mainshaft/Countershaft
SpeedSensors
Replacement

Disconnectthe speed sensorconnectors,then re-

move the harnessclampon the countershattspeed
sensorharnessfrom the harnessstay.

Removethe 6 mm boltssecuringthe mainshaftand

countershaltspeedsensorsfrom the transmission
housrng.

Remove the mainshaft and countershaft speed

sensors,

Installthemainshattand countershaltspeedsensors
in the reverseorder of the removal.

I{ARNESSSTAY

6 x'l,Omm
l2 N.m
{1.2kgf.m,
8.7 tbf.fr)

6 x 1 . Om m
12 N.m
(1.2kgf.m,
8.7 tbf.ltl

COUNTERSHAFT
SPEEDSENSOR

14-85
 Chart
Symptom-to-Component
Hydraulic System

Check these items on the Check these items

SYMPTOM on the NOTESList
PROBABLE CAUSEList

Engineruns, but car does not move in any gear. 1, 6, 7, 16 K,L,R,S

Carmovesin @ and@, but not in @, @ or I a, 29, 44. 4a c,M,o
posataon.
Carmovesin E, @, [, @, uut not in E position. 9,30,49 C, L
car movesin p:1, [o-il, [2-],[!, uut not in E position. 1, 11, 22, 34, 38, 39, 40 c,L,o
Car moves in N position. 1,8, 9, 10,11,46,47 C,D
Excessiveidle vibration. 5, 1'1 B,K,L
Slips in all gears. 6, 7, 16 C,L
No enginebrakingin E position. 12 C,D,L
Slips in 1st gear. 8, 29, 44, 4A c,N,o
Slips in 2nd gear. 9, 20, 23, 30, 49 C,L
Slips in 3rd gear. 1 0 ,2 1, 2 3 , 3 1, 4 9 C,L
Slips in 4th gear. 1 1 ,2 3 , 3 2 , 4 4 C,L,N
Slips in reverse gear. 11,32,34,44 C,N
Flareson 1-2 upshilt. 3 , 1 5 ,2 3 E,L,V
Flareson2 3 upshilt. 3, 15, 23, 24, 49 E,L,V
Flareson 3-4 upshift. 3, 15, 23, 25, 49 E,L,N,V
No upshift;transmissionstays in 1st gear. 14,19, G, L
No downshift to lst gear. 1 2 .1 9 G,L
Late upshift. 14
Erraticshitting. 2, 14,26
Harshshift (up and down shiftingl. 2, 4, 15, 23, 24, 25, 26, 27, A , E ,H , I ,L , V
47
H a r s hs h i t t { 1 - 2 ) . 2 , 9 . 1 5 ,2 3 C,D,E,V
Harshs h i l t ( 2 - 3 ) . 2, 10, 15, 23, 24 C,D,E,H,L,V
Harshshift (3-4). 2 , | 1, 15, 23, 25 C , D , E ,I , L , V
Harshkick'down shifts. 2, 15, 23, 26, 27. 2A E,L,O,V
Harshkick-downshift 12 1) 48 o
Harshdownshift at closedthrottle. 2 , 1 5 ,2 3 F T

Harshshift when manuallyshiftingto E] position. 33 L

Axle{s}slips out of transmissionon turns. 43,50
Axlels) stuck in transmission. 43 L,O
Ratchetingnoise when shiftinginro E position. 6,7,38,39,40 K,L,O
Loud poppingnoise when taking ott in E position. 3a,39,40 L,O
Ratchetingnoise when shiftingfrom E to E positionor from E
38,33,40,45 L,O
to N I oosition.
Noisefrom transmissionin all selectorlever positions. 6, 11 K,L,O
Noisetrom transmissiononly when wheels are rolling. 39, 42 L,O
Gear whine, rpm related(pitchchangeswith shitts). a, 13, 41 K,L,O
Gearwhine, speedrel6ted(pitchchangeswith speed). 38, 42 L,O
Transmissionwill not shift into 4th gear in @ position 1,21,24.32 L

Lock-upclutch does not lock-upsmoothly. 17,36, 37 L

Lock-upclutch does not operateproperlV. 2.3. 14, 15. 18,35, 36, 37 E,L,V
Transmissionhas multitudeof problemsshitting.
43 L,O
At disassembly,largeparticlesoI metal are found on magnet.

14 -8 6
 PROBABLECAUSE
1 Shitt cable broken/outof adiustment.
Throttle cabletoo short.
Throttle cabletoo long.
Wrong type ATF.
ldle rpm too low/high.
o. Oil pump worn or binding.
7. Pressureregulatorstuck.
8. l st clutch detective.
9. 2nd clutch detective.
10. 3rd clutch defective.
11 4th clutch defective.
12. 1st'hold clutch defective.
13. Mainshattworn/damaged.
14. Modulatorvalve stuck.
Throttle valve B stuck.
lo. ATF strainerclogged.
Toroue converterdefective.
18. Torque convertercheck valve stuck.
'I
9. 1-2 shift valve stuck.
2-3 shift valve stuck.
21 3-4 shift valve stuck.
Servo control valve stuck.
23. Clutch Dressurecontrol (CPC)valve stuck.
2-3 orifice control valve stuck.
Orificecontrol valve stuck.
26. 3-2 kick-downvalve stuck.
27. 4-3 kick-downvalve stuck.
24. 4th exhaustvalve stuck.
29. 1st accumulatordetective.
30. 2nd accumulatordetective.
31 3rd accumulatordefective.
4th accumulatordefective.
1st-hold accumulatordefective.
Servo valve stuck.
35. Lock-uptiming B valve stuck.
36. Lock-upshift valve stuck.
37. Lock-uocontrol valve stuck.
38. Shift fork benr.
39. Reversegears worn/damaged(3 gears).
40. Reverseselectotworn.
41 3rd gearsworn/damaged(2 gears).
Finalqearsworn/damaged(2 gearsl.
43. DifferentialDinionshatt worn.
44. FeedpipeO-ringbroken.
45. 4th qearsworn/damaged(2 gearsl
Gearclearanceincorrect.
47. Clutch clearanceincorrect.
48. One-way (sprag)clutch defective.
49. Sealinqrings/quideworn.
50. Axle-inboardjoint clip missing.
Symptom-to-ComponentGhart
HydraulicSystem(cont'd)

The following symptoms can be caused Checkthese items on the

Items on the
by improperrepairor assemblv PROBABLECAUSEDUETO
NOTESList
IMPROPER REPAIR List
Carcreepsin E position. R 1 ,R 2
Car does not move in @ or @ position. R4
Transmissionlocks up in @ position. R 3 ,R l 2
Excessivedrag in transmission. R6 K.R
Excessivevibration,rom related. R7
Noise with wheels moving only R5
Main seal pops out. R8
Variousshifting problems. R9, R1O
Harshupshifts. R11

PROBABLE
CAUSEDUE TO IMPROPER
REPAIR
R1 lmproperclutch cleatance.
R2. lmDroDerqear clearance.
R3. Parkingbrake lever installedupsidedown.
R4. One-way (spraglclutch installedupsidedown,
R5. Reverseselectorhub installedupsidedown.
R6. Oil oumo bindind
R7. Torque converternot fully seated in oil pump.
R8. Main seal improperlyinstalled.
R9. Springsimproperlyinstalled,
R10. Valves improperlyinstalled.
R11 Ball check valves not installed.
R12. Shitt fork bolt not installed.

14-8 8
 NOTES

A. See flushing procedure,page l4-168 and 169.

B. Set idle rpm in gear to specitiedidle speed.lf still no good, adiust motor mounts as outlinedin engine
section of servicemanual.
lf the largeclutch piston O-ringis broken,inspect the piston groove for rough machining.
lf the clutch pack is seizedor is excessivelyworn, inspectthe other clutchesJor wear, and check the
orifice control valves and throttle valves for free movement.
E. It throttle valve B is stuck, inspectthe clutchesfor wear.
lf the 1-2 shift valveis stuck closed,the transmissionwill not upshift.lI stuck open,the transmission
has no lst gear.
H. lf the 2-3 orifice control valve is stuck, inspectthe 2nd and 3rd clutch packs for wear.
ll the orifice cont.ol valve is stuck, inspect the 3rd and 4th clutch packs for wear.
lf the clutch Dressurecontrol valve is stuck closed,the transmissionwill not shilt out of 1st gear.
K. improperalignmentor main valve body and torqueconverterhousingmay causeoil pump seizure.The
symptoms ale mostly an rpm-relatedticking noise or a high-pitchedsqueak.
L. ll the ATF straineris ctoggedwith paniclesof steelor aluminum,inspectthe oil pump and ditferential
pinionshaft. lt both are OK and no causelor the contaminationis found, replacethe torqueconverter.
M. lf the 1st clutch feedpipeguidein the right sidecover is scoredby the mainshaft,inspectthe ball bear-
ing for excessivemovementin the transmissionhousing.lf OK. replacethe rightsidecover as it is dent-
ed. The O-ringunderthe guide is probablyworn.
N. ReDlacethe mainshsttif the bushingfor the 4th feedpipeis loose or damaged.
It the 4th feedpipeis damagedor out ot tound, replacethe right side cover'
Replacethe subjshaft it thtbushing for the 1st-holdJeedpipeis loose or damaged.
lf the 1st-holdfeedpipeis damagedor out of round, replaceit.
Replacethe mainshaftif the bushinglor the 1st feedpipeis loose or damaged.
lf the lst feedpipeis damagedor out ot round, replaceit.
o. A *o- r, da."s"d "p-g clutch is mostly a result of shifting the transmission in El or Lq! position
while the wheels rotate in reverse,such as rockingthe car in snow.
P. InsDectthe frame for collisiondamage.
o. Inspectfor damageor wear:
1. Reverseselectorgear teeth chamfers.
2. Engagementteeth chamtersof countershaft4th and reversegear.
3. Shift fork for scutt marks in center.
4. DifferentialDinionshaJtfor wear under pinion gears.
5. Bottom of 3rd clutch for switl marks.
Replaceitems 1, 2, 3 and 4 it worn or damaged.lf transmissionmakesclicking,grindingor.whirring
noise,atso replacemainshaft4th gear and reverseidler gear and countershaft4th gear in additionto
1,2,3ot4.
lf ditiersntialDinionshaft is worn, overhauldifferentialassembly,and replaceATF strainel,and thoroughly
clean transmission,tlush torque convertet,cooler and lines.
lf bottom of 3rd clutch is swirled and transmissionmakes gear noise, replacethe countershaft and tinal
driven gear.
R. Be wry carefulnot to dsmagethe torque converterhousingwhen replacingthe main ballbearing.You
may al;o damagethe oil pump when you torque down the main valve body. This will resultin oil pump
seizureit not detected.Use propertools.
q
Install the main seal tlush with the torque converter housing, lf you push it into the torque converter
housinguntil it bottoms out. it will block the oil return passageand result in damage.
T, Harsh do\/vnshiJt"\./l,'hencoasting to a stop with zero th.ottle may be caused by a bent-in throttle valve
retainer/cam stopper. Throttle cable adjustmentmay clear this problem.
ifuitle cable adjustment is essentialfor proper operation of the transmission. Not only does it affect
the shift points if misad,usted, but also the shift quality and lock-up clutch operation'
A cableadjustedtoo long will resultin throttle pressurebeingtoo low for the amountof enginetorque
input into ihe trsnsmissionand may causeclutch slippage.A cableadjustedtoo short will resultin too
hi;h throttle pressurewhich may cause harsh shitts, erraticshrfts and torque con

14-89
Road Test

NOTE: Warm up the engineto operatingtemperature(the coolingfan comes on).

1 Apply parking brake and block th€ wheels. Start the engine, them move the selector lever to E] position while
depressingthe brake pedal.Depressthe acceleratorpedal, and releaseit suddenly.The engineshould not stall,

2. Repeatsame test in @ position.

3. Shift the selecto.lever to E position,and chock that the shift points occur at approximatespeedsshown. Also
check fof abnormalnoise and clutch slippage.

NOTE: Throttle positionsensorvoltage fepresentsthe throttle opening.

- 1. Connect the Test Harness between the ECM and connector (see section 1 1).
-2. Setthe digitalmultimeterto check voltagebetweenD1 1{+)terminal and D22 - terminalfor the throttle
{ ) Dosi-
tion sensor.

TEST
HARI{ESS
OTLAJ_PT3OlOA

DIGITAL MULTIMETER
Commarciallyavsilablo o.
KS-AHM-32-OO3

0 1 1{ +
ooooooooooooo oooooooo oooooo ooooooooooo
o o o o o o o o o o o o o o o o o o o o o oooooo ooooooooooo

14-9 0
@ or @ Position
. Upshitt
Throftle Opening Unit of spe6d l st- 2nd 2nd-3rd 3rd-4th

Throttle positionsensor mph 20-22 27,30

voltage:O.75 V Km/h 17,O 19.O 3 2 . 5- 3 5 . 5 43.5-48.5
Throttle positionsensor mpn
v o l t a g e :2 . 5 V Km/h 3 3 . 5- 3 6 . 5 57.O-63.O 89.O-95.O
Full-openedthrottle mph 30- 34 62-65 98- 101
Km/h 49.O- 55.O 99.O- 105.O 15 7 . O - 1 6 3 . O

Downshift
Throttle Op€ning Unit ot speed 4th- 3rd 3rd - 2nd 2nd- l Et

Full-closedthrottle mph 1a-21 6-g (3rd- 1st)

Km/h 29.O-33.O 1O- 14 (3rd- lst)
Full-openedthrottle mph 85-89 54- 58 23-27
Km/h 13 7 . O - 1 4 3 . 0 87 . 0- 9 3 . 0 37.0-43.O

LOCK-Up

@ Position
Throttle Opening Unit of speed Lock-uo control solenoid Lock-up control solenoid
valve A ON valve B ON
Throttle positionsensor mpn tJ- to 1 7- 2 0
voltage: 2,5 V km/h 21.O- 25.O 2A.O-32.O
throttle
Full-opened mpn 92-96 92-96
km/h 1 4 8 . O- 1 5 4 . 0 r48.0,1 54.O
i

E Position
Throttlo Opening Unit of sp6ed Lock-up control solenoid Lock-up control sol€noid
valve A ON valv6 B ON
Throttle positionsensor mph b|-oJ 61 63
v o l t a g e :1 . OV kmih 98- 102 98- 102
Full-openedthrottle mph 85 89 85-89
km/h 137 143 137- 143

4. Accelerateto about 35 mph {57 km/h) so the transmissionis in 4th, then shift from @ Oositionto E position.
The car should immediatelybegin slowing down from enginebraking.
CAUTION: Do not shift from @ or @ positionto @ of E positionat speedsover 1OOmph (160 km/h); you
may damage the tlansmission,
5. Check lor abnormalnoise and clutch slippagein the following positions.

E (1st Gear)Position
- 1 . Acceleratefrom a stop at full throttle. Check that there is no abno.malnoise or clutch slippage.
-2. Upshiftsshould not occur with the selectorin this position
E (2nd cear) Position.
- 1 . Acceleratefrom a stop at full throttle. Check that there is no abnormalnoise or clutch slippage.
-2. Upshittsand downshitts should not occur with the selectorin this position.
E {Reverse)Position
Acceleratefrom a stop at full throttle, and check for abnormalnoise and clutch slippage.

6. Test in E {Parking)Position
Parkcar on slope(approx.16o ), applythe parkingbrake,and shift into LE position.Releasethe brake;the car should
not move.

14-91
Stall Speed

CAUTION:
a To plevent transmission damage, do not test stall speed fot mote than 1O seconds at a time.
a Do not shift the level while raising th€ engine speed.
a Be sure to remove the pressure gauge belot€ testing stall speed.

1. Engagethe parkingbrakeand block all four wheels.

2. Connectthe tachometer,and start the engine.
3. Make sure the A/C switch is OFF.
4. After the enginehas warmedup to normaloperatingtemperature(the coolinglan comeson), shift into ft position.
5. Fully depressthe brake pedal and acceleratorfor 6 to 8 seconds.and note enginespeed.
6. Allow 2 minutesfor cooling,then repeatthe test in [, fDil and @ positions.

NOTE:
a Stall speedtests should be used lor diagnosticpurposesonly.
. Stall speed should be the same in E, tr. tr and @ positions.

Stall SpeedRPM: rpm

Specification: 2,400 rym
Service Limit: 2,2OO-2,600 tpm

TROUBLE PROBABLE
CAUSE
Stallrpm hish in E, E, I and@ Low fluid level or oil pump output
posrtron CloqgedATF strainer
Pressureregulatorvalve stuck closed
Slippingclutch
Stall rpm high in I position Slippageof 1st clutch, 1st-holdclutch or 1st gear one-way clutch
Stall rpm high in @ position Slippageof 2nd clutch
Stall rpm high in @ position Slippageof 1st clutch, lst gear one-way clutch
Stall rpm high in @ position Slippageof 4th clutch
Stallrpm low in E, E, I ana@ Engineoutput low
position Torque converterone-way clutch slipping

14-92
Fluid Level
Checking/Changing

Checking Changing

NOTE: Checkthe fluid levelwith the engineat normal
operatingtemperature(the cooling lan comes on).
1. Parkthe car on levelground. Shut otf the engine.
2. Removethe dipstick (yellow loop) from the trans-
mission,and wipe it with a clean cloth.
3. Insertthe dipstick into the transmission.
1. Bringthe transmissionup to operatingtemperature
by drivingthe car. Parkthe car on levelground,turn
the engineoft, then removedrain plug.
NOTE: lf a cooler flusher is to be used, see page
1 4 - 1 6 8a n d 1 6 9 .
2. Reinstailthe drain plug with a new sealingwasher,
then refillthetransmissionto the uppermark on the
dipstick.

Automatic Transmission Fluid Capacity:

2.1 | l2.S US qt, 2.4 lmp qt) at change
5.9 ? (6.2 US qt, 5.2 lmp qt) at overhaul

TRANSMISSIONRIGHT SIDE COVER

DIPSTICK(YELLOWLOOPI

4. Removethe dipstick and check the fluid level.

should be betweenthe uoDerand lower marks.

P
il 1 8 x 1 . 5m m
49 N.m (5.0 kgl.m, 36 lbl.ft)

\---

T
IT
{J. U P P EM
RARK
LowERMARK
t)-i-

5 . lf the level is below the lower mark, add fluid into

the tube to bring it to the upper mark. Use Honda
PremiumFormulaAutomaticTransmissionFluidor
a n e q u i v a l e n t D E X R O Nl l@
AutomaticTransmission
Fluid (ATF)only.

6. lnse.t the diDstickback into the transmission.

14-93
PressureTesting

4. Start the engine,and measurethe respectivepres-

a While testing, be caretul of the rotating flont wheels.
sure as follows.
a Make aura litts, jacks, and sat€ty stands alo placed
a Line Pressure
plop6rly {see section 1}.
a Clutch Pfessure
a Clutch Low/High Pressure
CAUTION: Betoret€sting, be sure the transmissionfluid
a Throttle B Pressure
is tilled to rh6 ploper l€vet.
5. Installa new washer and the sealingbolt in the in-
1. Raisethe car (seesection i),
spectionhole and tighten to the specifiedtorque.
2. Warm up the engine{thecoolingfan comesonl, then
TOROUE:18 N'm {1.8 kgf.m, 13 tbf.ft)
stop the engineand connect a tachometer.
NOTE: Do not reuseold aluminumwashers.
3. Connectthe oil pressuregaugeto each inspection
holels). a Line Pressure M€asurement
TOROUE:18 N.m (1.8 kgf.m, 13 tbf.fr) - 1 . Set the parkingbrakeand block both rear wheels
securely.
CAUTION: Connect ths oil prsssure gauge s€cur€_
ly; be sule not to allow dust and other foleign pani_ -2. Run the engineat 2,OOOrpm
cl6s to 6nt€1 th€ inspection holo.
-3. Shift the selecr lever to S or @ position.
A/T OILPRESSUREGAUGE
SETWPANEL
07406-002oi+oo -4. Measureline pressure.

LINEPRESSURE
INSPECTION
HOLE

A/T LOW PRESSURE

GAUGE W/PANEL
07/rO6-0O70300

A/T OIL PRESSUREHOSE,

22'10 mm
OTMAJ_PY4OITA
{4 Roquirod)

A/T OIL PRESSUBEHOSE

ADAPTER
OTMAJ - PY/+O120
14 Roqui.odl

NOTE: Use the A/T Oil PressureGaugeSet (07406_

O02OOO3)or A/T Low Pressure Gauge (07406-
OOTO0OO). and the oil pressuregaugehosesand adap_
ters shown above.

FLUIDPRESSURE
PRESSURESELECTOR SYMPTOM PROBABLE
CAUSE
POStTTON
Standard Service Limit
Line No'E No (or low) Torque converter, 83O-88O kPa 78O kPa
lrne pressure orl pump, pressure ( 8 . 5 - 9 . O k g f / c m , , {8.0 kgl/cm,,1lO psi}
regulator,to.que 120- I 30 psi)
convener check
valve

NoTE: Higherpressuresmay be indicatedit measurementsare made in selectorpositionsother than

@ or @ position.

14-94
a Clutch Pressuro M€asur€ment

@ wtit" testing, be careful ot the rotating front wheols.

1. Set the parkingbrake and block both rear wheels securely.

2. Raisethe front of the car and supportwith safety stands.
-3. Allow the front wheels to rotate freely,
-4. Run the engineat 2,OOOrpm.
-5. Measureeach clutch Pressure.
LOCK.UPCONTNOLSOLENOID
VALVE ASSEMBLY

INSPECTIONHOLE

FLUIDPRESSURE
SELECTOB PROBABLE
CAUSE
rl|E!!UltE SYMPTOM
POST ON Standard Service Limit

83O-880 kPa 78O kPa

1st Clutch Eo'E No or low 1st Clutch
(8.5-9.O kgf/cm', { 8 . Ok g f / c m ' ,1 1 O p s i )
lst Pressure
120- 130 psi)
l st-hold
Clutch
tr No or low
1st-hold
1st-holdCIutch

pressure
2nd Clutch a No or low
2nd pressure
2nd Clutch

4'l o kPa
2nd Clutch E No or low
2nd pressure
2nd Clutch 460 kPa
|'4.7 kgtlcm2, 67 psil (4.2 kgt/cm' , 60 psi)
throttle control lever throttle control lever
3rd Clutch No or low 3rd Clutch
fully closed fully closed
3rd pressure
830-880 kPa 78O kPa
4th Clutch No or low 4th clutch (8.5 - 9.0 kgt/cm' , (8.O kgf/cm' , 1 1O psi)
4th pressure 120- l30 psi) throttle control lever
throttle control lever m o r et h a n 3 / 1 6 o p e n e d
m o r et h a n 3 / 1 6 o p e n e d

E Servo Valve or 4th 830-880 kPa

(8.5 9.0 kqf/cm' ,
780 kPa
(8.0 kgf/cm' , 1 1O psi)
Clutch
120- 130 psi)
(cont'd)

14-95
PressureTesting
(cont'dl
a Clutch Low/High P.essure Measuroment -6. With the engine idling, lift the throttle control lever
up approximately1/2 of its possibletravel and in-
@[ wtite resring. b€ calefut ot tha loraring crease the engine rpm until pressure is indicated
flont wh66ls. on the gauge,then measurethe highestpressure
readingobtained.
- 1. Allow the front wheels to rotate freely.
- 7. Repeatsteps 5 and 6 for each clutch pressurebe-
-2. Removethe cableend of the throttlecontrolcable ing inspected.
from the throttle control lever.

NOTE: Do not loosenthe locknuts.simplvunhook

the cable end.

CAALE END

-3. Start the engineand let it idle.

-4. Shitt the select leve. to E position.

-5. Slowly move the throttle linkageto increaseengine

rpm until pressureis indicaiedon the oil oressure
gauge.
Then releasethe throttlelinkage,allowingthe en-
grneto returnto an idle,and measurethe Dressure
resding.

14-96
 LOCK.UPCONTROL
SOLENOIDVALVE
4TI{ CLUTCH PRESSURE
INSPECTIONHOLE

SHIFT CONTROL
SOLENOIDVALVE
ASSEMBLY PROTECTOR
3RD CLUTCH PRESSURE
INSPECTIONHOLE INSPECTIONHOLE

SELECTOR FLUIDPRESSURE
PRESSUNE SYMPTOM PROBABLE
CAUSE
POStTtON
Standard Service Limit
2nd Clutch E No or low 2nd Clutch 460-88O kPa 41OkPa
2nd pressure (4.7 -9.O kgtlcmt, {4.2 kgf/cm,, 60 psi}
3rd Clutch No or low 3rd Clutch 67- 130 psil with throttle control
3rd pressure varies with throttle lever released
openrn9 78O kPa
4th Clutch No or low 4th Clutch
l8.O kgtlcm,, 1'lO psil
4th pressure
with throttle control
lever more than 3/1 6
opened

(cont'd)

14-97
PressureTesting
(cont'dl

a Throttle B Ptsssure Measuremcnt 3. Shift the selectorlever to @ or @ position.

-4. Run the engineat 1,OOOrpm
@@ wrril" resring, be caretut ot rhe rotaring -5. Measurefull-closedthrottle B pressure.
front wheels. -6. Move the throttle control leverto full-openedthrot-
tle position.
1. Allow the front wheels to rotate treelv. -7. Measurefull-openedthrottle B pressure.
-2. Removethe cableend of the throttlecontrolcable
from the throttle control lever.

NOTE: Do not loosenthe locknuts,simplyunhook

the cable end.

SELECTOR FLUIDPRESSURE
PRESSURE SYMPTOM PROBABLECAUSE
POSTTTON
Standard S€rvica Limit
Throttle B loil orlDll Pressuretoo Thfottle Valve B O-15 kPa
high { O - O . 15 k g f / c m , ,
0-2.1 psi)
throttle control lever
fully closed
No or low 83o 88O kPa 78O kPa
Throttle B (8.5-9.O kgf/cmz, (8.O kgl/cm,, l lO psi)
pressure 120 130 psi) throttle control lever
thfottle control levet tully closed
fully closed

14-98
Transmission
Removal

4. Bemove the t.ansmissionground cable from the

a Make sur€ lifts. iacks and safety stands are placad
properly, and hoist brackots are attachod to tho cor-
rect position on ths sngine {seo sectionl }.
o Apply parking brake and block rear wheels, so car will
not roll off stands and fall on you whil6 working un-
del it
transmissionhanger.
Disconnectthe lock-uDcontrol solenoidvalve con-
nectorand the shitt controlsolenoidvalve connec-
tor, then removethe harnessclamp on the lock-up
control solenoidharnessfrom the harnessstav.

CAUTION: Use tender covers to avoid damsging paint-

ed surlaces, LOCK-UPCONTROL
SOLENOIDVALVE
Disconnectthe battery negative{ - } and positive( + ) HARNESSCLAMP CONNECTOR
1.
cables from the battery.

2. Removethe intakeair duct and air cleanerhousino

assembly.

AIR CLEAI{ER
HOUSINGASSEMBLY

SHIFT CONTROL
SOLENOIDVALVE
CONNECTOR TRANSMISSION
GROUNDCABI-E

Disconnectthe vehiclespeed sensor(VSS),main-

shaft sDeedsensorand countershaftspeedsensor
connectors.

3 . Removethe startermotor cablesand cable holder VEHICLESPEED

from the starter motor. SENSORCONNECTOR

STARTERMOTOR CABLE
CABLE HOLDER

VEHICLESPEED
SENSOR

COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
STARTERMOTOR
?/\

MAINSHAFTSPEED
STARTERMOTOR CABLE SENSORCONNECTOR(cont,d)

4-99
Transmission
Removal{cont'd)

7. Removethe transmissionhousingmountingbolts. 9. Removethe splashshield.

6 x 10

CLIP
S pcs.
Removethe drainpluganddrainthe automatictrans-
10. Remove the cotter pins and castle nuts, then
missiontluid (ATF).Reinstallthe drain plug with a
separatethe balljointsfrom the lower arm {seesec-
new sealingwasher lsee page 14-93).
tion 18).

11. Removethe right dampe. fork bolt. then separate

right damperfork and damper.

PINCI{ BOLT

/\

SELF.LOCKING
NUT COTTERPIN
Replace. CASTLE NUT
Replace.
DRAINPLUG DAMPERFORK
1 8 x 1 . 5m m
49 N'm 15.0 kgt-m,36 tbt-fr)

14-100
12. Pry the right driveshaftout of the differentialand pry 17. Removethe intermediateshaft.
the lett driveshattout of the intermediateshaft.
'13.
Pull on the inboardjoint and removethe right and
left driveshafts(see section 16).

'14.
Tie plastic bags over the driveshaftends.

NOTE: Coat all precisionfinished surfaces with

clean engineoil.

1 8 . Removethe shift cablecover,then removethe shift

cable by removingthe control lever.
PLASTICBAG
CAUTION: Take care not to bend the shift control
Disconnectthe heatedoxygen sensor(HO2S)con- cabls whilo removing it.
necror.

1 6 . Removethe exhaust pipe A.

SHIFT CABLE

LOCKWASHER CONTROLLEVER
SELF-LOCKING Replace.
NUT
Replace.

Replace. (cont'dl

14-101
Transmission
Removal(cont'dl
'1
9. Removethe right tront mount/bracket,then remove 23. Placea jack underthe transmission,raisethe lrans-
the end ol the throttle cont.ol cabletrom the throt- mission just enough to take weight off ol the
tle control lever. mounts. then removethe transmissionmount.

20. Removethe ATF coolerhosesat the joint pipes.Turn

the endsof the coolerhosesup to preventATF from
flowing out, then plug the joint pipes.

NOTE: Check tor any sign ot leakageat the hose

joints.

THROTTLE
CONTROL 'i z/'l e
" (-J t'

RrcHTFRoNTiiouNT/BRAcKET BoLTs ATF COOLER

Replace. HOSES
24. Removethe t.ansmissionhousingmounting bolts
and rear enginemounting bolts.
21. Removethe enginestiftenerand totque converter
cover.
25. Pullthe transmissionaway from the engineuntil it
clearsthe 14 mm dowel Dins,then lower it on the
22. Removethe eight drive plate bolts one at at time
transmissioniack.
while rotatingthe crankshaftpulley.

WASHERS
Replace.

14-102
lllustrated Index
Right Side Cover

14-104
O RtcHTslDEcovERpRoTEcToR @ FEEDPIPEGUIDE
@ RrcHTstDEcovER @ SNAPRING
O MAtt{sHAFr
spEEDsENsoR @ MAINSHAFTLocKNUT{FLANGE NUT)ReDIace.
@ o-RtNGReptace. @ MAfISHAFTCONTCAL SpRtNGWASHERReotsce.
@ cour{TERSHAFT SPEEOSENSOR @ IsT cLUTcHASSEMBLY
@ HARNESS STAY @ O-RINGReptace.
O RoLLCR @ THRUSTWASHER
@ COLLAR @ THRUSINEEDLE BEARIG
O O-RINGReptace. @ EEDLEBEARING
@ FEEDPIPEFLAI{GE @ MAI'{SHAFTlsT GEAR
@ o-RrNG @ THRUSTWASHER
@ sIrlAPRING @ MAINSHAFTlsT GEARcoLLAR
@ 3RDCIUTCHFEEDPIPE @ RoLLER
@ COUNTERSHAFT LOCKNUT(FLAt{cEf{UTl Reptace. @ coLLAR
@ coultTERsHAFf col{tCAL SpRtt{cWASHERReotace. @ O-Rlt{cReptace.
@ PARKI G GEAR @ FEEoPIPEFLANGE
@ oNE-waY cLUTcH @ o-RINGR€ptace.
@ couNTERsHAFrlsr GEAR @ SNAPRING
@ NEEDLE BEARING @ lsr-HoLD cLUTcH FEEDptpE
@ couNTERsHAFrtsr GEARcoLLAB @ SUB-SHAFT LoCKNUTIFLAt{c€NUTIReptace.
@ O-RINGReptace. @ suB-sHAFr cot{tcAl spRtNGWASHERReptace.
@ l sT-HoLDaccuMuLAToR ptsToN @ SU8-SHAFT lST GEAR
@ isT-HoLD ACCUMULAToR spBfi{c @ LOCKWASHERf,eptace.
@ o-RtNGReptace. @ THRoTILEcor{TRoL LEVER
@ rsT-HoLDACGUMULAToR covER @ THRoTTLEcoNTRoL I.EVERSPRING
@ SNAPRrr{G @ oll sEAt Reptace.
@ PAFKINGBRAKEPAWL @ THRoTTI"E coNTRoL CABLESTAY
@ PARKING BRAKEPAWLSPRII{G @ sHtFTCONTROL SOLEI{O|OHARNESS
@ PARKING BRAKEPAWLSHAFT @ Jor T BoLT
@ PARKING aRAKEPAWLSToPPER @ ATF COOLER PIPE
@ LOCKwasHEn Reptace. @ SEAL|NGWASHERS Roptace.
@ PARKI G BRAKEs?oPPER @ ATF cooLER P|PE
@ PARKING BRAI(ELEVER @ ATF LEVELGAUGE
@ PARKI G BRAKELEVERSPBING @ JOINTEOLT
@ DowEL PrN @ vEHtcLEspEEDsEf{soR
@ O-RltIGReptace. @ o-RtNGReptace.
@ RTGHT stoE covER GASKETFeptace. @ DRAINPLUG
@ isT ct-uTcH FEEDptpE @ SEALINGWASHERReplace.
@ o-RtNGReptace.

TOROUESPECIFICATIONS

Ret No. Torque Value Bolt Size Remarks

'12 N.m (1
.2 kgf.m, 8.7 lbJ.tt) 6 x 1 , Om m
B 14 N.m (1.4 kgf.m, 10lbf.ft) 6 x 1 . Om m Specialbolt
D 22 N.m 12.2 kgf.m, 16 lbf.ft) I x 1 . 2 5m m
F 8 N.m (O.8 kgf.m, 6 lbf.ftl 5x0.8mm
28 N'm (2.9 kgf.m, 21 lbf.ttl 12 x 1-25mm ATF cooler pipe joint bolt
49 N.m (5.O kgf.m, 36 lbf'ft) '1.5
18 x mm Drainplug
93 N.m {9.5 kgf.m, 69 lbt.ft} t Y x t . z 5m m Mainshaftlocknut
(flangenut):
Left-handthreads
K 1 0 3 N . m { 1 O . 5k g f . m , 7 5 . 9 l b f . f t l - O - 2 3 x 1 . 2 5m m Countershaftlocknut
1 O 3N . m ( 1 0 . 5 k g f ' m . 7 5 . 9 l b f . f t ) (tlangenut)
Lett-handthreads
L 93 N.m (9.5 kg-m, 69 lb-ft) '19
x 1 . 2 5m m Sub-shattlocknut
(flangenut)

14-105
lllustrated lndex
Transmission
Housing

I ',
TTI]

a''-.2

14-106
O) COUNTERSHAFTREVERSEGEAR COLLAR @ SEAL|NGRtNGs, 3s mm
@ NEEDLEBEARING @ SEAL|NGR|NG,29 mm
G) COUNTERSHAFTREVERSEGEAR @ NEEDLEBEARING
@ LOcK WASHERReptace. @ sET RING
@ REVERSE sHIFT FoRK @ 1ST-HOLDCLUTCH
@ BEVERSESELECToR @ O-RINGReplace.
O REVERSESELECToRHUB @ THRUST WASHER
@ couNTERSHAFT 4TH GEAR @ THRUST NEEDLEBEARING
@ NEEDLEBEARING @ NEEDLEBEARING
@ DTSTANCECOLLAR, 29 mm Setecrivepart. @ SUB.SHAFT4TH GEAR
@ coUNTERSHAFT2ND GEAR @ THRUST NEEDLEBEARING
@ THRUSTNEEDLEBEARING @ SUB.SHAFT4TH GEAR COLLAR
@ GoUNTERSHAFT3RD GEAR @ SUB-SHAFT
@ NEEDLEBEARING @ SUB.SHAFTNEEDLEBEARING
@ THRUSTNEEDLEEEARING @ NEEDLEBEARINGSToPPER
G) COUNTERSHAFT3RD GEAR COLI-AR @ otL GUTDEcAP Reptace.
O 3RD cLuTcH ASSEMBLY @ REVERSEIDLERG€AR SIIAFT/HOLDER
(!) O-RINGSReplace. @ NEEDLEBEARII{G
@ coUNTERSHAFT @ sHIFT GONTROLSOLENOIDvAI.vE ASSEMBLY
@ REVERSEIDLERGEAR PROTECTOR
@ SNAP RING @ sHrFT CONTROLSOLENOTD VALVE A/B
@ THRUSTWASHER @ SHIFT CONTROLSOLENOIDVALVE A/B FILTER/GASKET
@ THRUSTNEEDLEBEARING Replace.
@ MAINSHAFT4TH GEAR @ TRANSMISSIONHANG€R
@) NEEDLEBEARINGS @ TRANSMtsstoN MouI{T BRAGKET
@ THRUSTNEEDLEBEARING @ oll SEAL Replace.
@ MAINSHAFT 4TH GEAR coLLAR @ sET RING Replace.
@ 2ND/4TH cLUTcH ASSEMBLY @ TRANSMISSIONHOUSINGGASKET Replace.
et O-RINGSReplace. @ DOWEL PrN
@ THRUSTwaSHER, 36.5 x 55 mm Setectivepan. @ SNAP RI G
@ THRUSTNEEDLEEEARING @ SUB-SHAFTIRANSMtSStON HOUSNG AEARTNG
@ MA|NSHAFT2ND GEAR @ MAINSHAFT TRANSMISSIONHOUSINGBEARING
€, NEEDI.EBEARING @ coUNTERSHAFT TRANSMISSIONHOUSINGBEARING
@ THRUSTNEEDLEEEARING @ DIFFERENTIALASSEMELY
.O MAINSHAFT @ OtL SEAL Replace.
@ CoNNECTORSTAY

TOROUESPECIFICATIONS

Rel No. Torque Value Bolt Size Remarks

1 2 N . m ( 1 . 2 k g f . m , 8 . 7l b t . t t ) 6 x 1 . Om m
B 1 4 N . m ( 1. 4 k g f. m . 1 0 l b f. f t ) 6 x 1 . Om m Specialbolt
E 44 N.m (4.5 kgt.m, 33 lbf.ft) ' l Ox 1 . 2 5m m
H 6 4 N . m ( 6 . 5 k g f. m , 4 7 l b f. f t ) 1 2 x 1 . 2 5m m

14-107
lllustratedIndex
Torque Converter Housing/ValveBody

^\

14-108
 OIL FEEDPIPE @ REGULAToRvALvE BoDY
ACCUMULATORCOVER @ STOPPERSHAFT
O-RINGReplace. @ O-RINGReptace.
OIL FEEDPIPE @ STATOR SHAFT
OIL FEEDPIPE @ otl FEEDPIPE
SERVOOETENTEASE @ MAIN vALvE BoDY
LOCNWASHERFeplace. @ CHECK EALL
ATF STRAINER @ DowEL PIN
SUCTIONPIPECOLLAR @ oIL PUMP DRIVEGEAR
SERVOBOOY @ OIL PUMPDRIVENGEARSHAFT
THROTTLECONTROLSHAFT Q9 OIL PUMPDRIVENGEAR
E RING @ MAIN SEPARAToR PLATE
SERVOSEPARATORPLATE @ DowEL PrN
1ST ACCUMULATORCHOKE @ coNTBoL sHAFT
CHECKBALL @ DETENTSPRING
STOPPERSHAFT STAY @ DETENTARM SHAFT
SECONDARYVALVE BODY @) DETENTARM
DOWEL PIN @ ATF MAGNET
SECONDARYSEPARATORPLATE @ COUNTEBSHAFT TOROUECONVERTER
HOUSING
LUBRICATORPLATE NEEDLEBEANING
OIL FEEDPIPE @ oIL GUIDE PLATE
LOCK.UPVALVE BODY @ TOROUECONVERTERHoUSING
DOWEL PIN @)MAINSHAFTTOROUECONVERTER HOUSINGBEARING
LOCK-UPSEPARATORPLATE @ oll SEAL Reptace.
TOROUECONVERTERCHECKVALVE SPRING @ LocK-upcoNTRoL
soLENotD
vALvEA/B
TOROUECONVERTER CHECKVALVE @ coNNECTORSTAY
COOLERCHECKVALVE SPRING @ LOCK-UPCONTROLSOLENOTD
VALVE A/B
COOLERCHECKVALVE FILTER/GASKET
Replace.

TOROUESPECIFICATIONS

ReI No. Torque Value Bolt Size Remarks

1 2 N . m ( 1. 2 k g f . m , 8 . 7 l b f . f t ) 6 x 1 . Om m

14-109
Right Side Cover
Removal

NOTE:
a Cleanall pans thoroughlyin solvent or carburetorcleaner,and dry with compressedair,
a Blow out all passages.
a When removingthe transmissionright side cover, replacethe following:
. Right side cover gasket
. Lock washers SIDE COVER PROTECTOR
. O-rings
. Each shaft locknut
. Conicalspring washers 1.O mm BOLTS
. Sealingwashers

RIGHT SIDE COVER

SUB.SHAFT
Replace. CONICAL
SPRING
WASHER
Replace. WASHER
MAINSHAFT Replace.
1ST GEAR
PARKINGGEAR

ONE.WAYCLUTCH
SUB.SHAFT 1ST GEAN
THROTTLECONTBOL
LEVER 1STGEAR
THRUST WASHER
,IST GEAB COLLAR BEABING
NEEDLE

lST GEARCOLLAR

JOINT AOLT
ATF LEVELGAUGE
ATF COOLERPIPES
SEALINGWASHERS
Replace.

14-110
'1.
Removethe 13 bolts securingthe right side cover
and right side cover protector,then removethem.
Slip the specialtool onto the mainshaftas shown.
5. Pry the lock tab of the mainshaftlocknut.
6. Cut the lock tabs of the countershaftand sub-shaft
locknutsusinga chiselas shown. Then removethe
locknut from each shatt.

MAINSHAFTHOLOER NOTE;
07GAB-PF50101
a Mainshaftand countershaftlocknuts have lett-
hand threads.
a Cleanthe old countershaftlocknut,it is used to
installthe parkinggear on the countershaft.
a Always wear safety glasses.

CAUTION:
Keop all of th€ chis€led panicles out of the
tlanamigsion.

llrF-"""*
LocKNUr
,fl(,-..-

@-.**'o'
7 . Removethe lock pin that was installedto hold the
sub-shaft.

3. Engagethe parkingbrakepawl with the parkinggear. 8 . Removethe specialtool from the mainshaftafter
removingthe locknut.
4. Align the hole ot the sub-shaft l st gear with the hole
q
of the the transmissionhousing,then inserta pin to Removethe 1st clutch and mainshaft1st gear as-
lock the sub-shaft while removing the sub-shaft sembly from the mainshaft.
locknut.
1 0 .Removethe sub-shaft 1st gear,

1 1 .Removethe parkingbrake pawl.

COUNTERSHAFT MAINSHAFT 8 mm pin.
LOCKNUT LOCKNUT comm€rcially 1 2 . Usinga universaltwo jaw puller.removethe park-
Replace. Replace. available ing gea..one-wayclutch and counlershatt1st gear
SU8-SHAFT assembly.
LOCKNUT
Replace.

PARKINGGEAR

1 3 .Removethe parking brake lever from the control

shaft.

1 4 . Removethe throttle control lever from the throttle

Align the holes.
control shaft.
CONICAL SPNING
WASHERS 1 5 . Removethe ATF cooler pipes.
Replace.

t o . Removethe ATF level gauge.

14-111
Transmission Housing
Removal

TRANSMTSSTOIr
HOUSIIG
MOUNTING
BOLTS

fl
TSAt{SMtSStOt{
HANGER
TRANSMISSIO HOUSII{G

TRA[{SMrSSrOr{
MOUNTBRACKET

'RAI{SMTSSTOHOUS|IG
GASKET
Rgolace.

REVERSEGCAR COLLAR

]{EEDLEBEARII{G

MAINSHAFT NEVERSE
GEAR
SUA.ASSEMBLY LOCTWASHEF
Replace.

SHIFT FORX

REVERSE
SEL€CTON

COUI{TERS}IAFT
SUB-ASSEMEI.Y

DIFFEFEI{IIAL
ASSEMBIY

(-t\

14-112
NOTE: Removethe countershaft reversegear with the col-
a Clean all parts thoroughly in solvent o. carburetor lar and needlebearing.
cleanerand d.y with compressedair.
a Blow out all passages. 6 . Remove the lock bolt securing the shitt fork. then
a When removingthe transmissionhousing,replacethe remove the fork with the reverse selector trom the
following: countershatt.
. Transmissionhousinggasket
. Lock washer Remove the countershaft and mainshaft sub-
assemblytogether.
1. Removethe transmissionmount b.acket.

2 . Remove the transmission housing mounting bolts

and hanger.

Align the spring pin of the control shaft with the

transmissionhousinggrooveby turningthe control
shaft.

4. Installthe specialtool on the transmissionhousing,

then removethe housingas shown.

HOUSING
PUI-LER
07HAC-PK4010A

8. Removethe ditferentialassemblv.

14-113
Torque GonverterHousing/ValveBody
Removal

Bolts, 7

\ otL
LOCK-UP
VALVE OII- FEEDPIPES
B . D Y \ u ll FEED
PIPES TOR COVER

DOWELPIN
A OIL FEEOPIPE

LOCK-UPSEPARATOR
PI.ATE Ll
ll|i
8oll3.3

SERVODETENT
BASE
REGULATORVALVE
AODY
|]V ATF STRAINER

OIL FEED PIPES

SUCTION PIPE
COLLAR

8olts, 4 Boll
DOWEL PIN MAIII VALVE
BODY
OIL PUMP DRIVENGEAR SHAFT SECONDARYVALVE
BODY
OIL PUMP DRIVEN
DOWEL PIN

SECONDARYSEPARATOR
MAIN S€PARATOR
PLATE
PLATE
rrr urcler
ft--

TOROUECONVERTER
HOUSING

14-114
NOTE: 1 5 .Cleanthe inlet opsningof the ATF strainerthorough-
a Clean all parts thoroughly in solvent or carbuetor ly with compressedair, then check that it is in good
cleanerand dry with compressedair. condition,and the inlet openingis not clogged.
a Blow out all passages.
a Whenremovingthe valvebody replacethe following:
. O-rings
. Lock wsshers

1 . Removethe oil feed pipes from the servo body, s€r-

vo detent base, accumulatofcover, lock-uDvalve
body and main valve body.

2, Removethe three bolts securingthe ATF strainerand

servo detent base, then remove them.

3. Removethe three bolts securingthe accumulator

cover. then removethe accumulatorcover.

4. Removethe six bolts secu.ing the servo body, then II{LET OPENING
removethe servo body and separatorplate.

5. Removethe bolt securingthe secondaryvalve body,

then removethe secondaryvalve body and separa-
tor plate. 1 6 . Replacethe ATF strainerit it is cloggedor damaged.

6. Removethe eight boltssecuringthe lubricatorplate NOTE: The ATF strainer can be reused if it is not
and lock-upvalve body, then removethe lubricator clo9ged.
plate, lock-upvalve body and separatorplate.

7. Femovethe bolt securingthe.egulatorvalvebody,

then.emove the regulatorvalve body.

8. Remove the stator shaft and stopper shaft.

9. Removethe detent spring t,om the detent arm. then

remove the control shaft from the torque convener
housing.

1O. Removethe detent arm and detent afm shaft t.om

the main valve bodv.

1 1. Removethe four bolts secu.ingthe main valve body,

then removethe main valve body.

12. Removethe oil pumpdrivengearshaft,then remove

the oil pump gears.
'13.
Removethe main separatorplate with two dowel
Dtns.

14, Removeand clean the ATF magnet.

14-115
Valve Caps
Description

Caps with one projectedtip and one flat end are in-
stalledwith the llat end toward the insideot the valve
body.
Caps with a projectedtip on each end are installed
with the smallertip toward the insideof the valve
body. The small tip is a spring guide.
Capswith hollow ends are installedwith the hollow
end away from the insideof the valve body.
Capswith notchedends are installedwith the notch
toward the insideof the valve body.
Capswith flat ends and a holethroughthe centerare
installedwith the smallerholetowardthe insideof the
valve body.

Toward outside ot valv6 bodv. Toward outside oI valv€ bodv.

lrj taj u
rq fq1 @.

Toward inside of valve body. Towa.d inside of valve body.

Caps with one projected tip and hollow end are in- Capswith llat ends and a groovearoundthe cap are
stalled with the tip toward the inside of the valve body. installedwith the groovedsidetoward the outsideof
The tip is a springguide. the valve body.

Towa.d outside ot valve body. Toward outside of valve bodv.

Sectional view

Toward inside of valve body. Toward inside of valve body.

14-11 6
Valve Body
Repair

NOTE: This repairis only necessaryil one or more of
the valvesin a valve body do not slidesmoothlyin their
bores.You may use this procedureto lree the valvesin
the valve bodies.
1. Soak a sheet of #600 abrasivepaper in ATF for
about 30 minutes.
5 . Removethe #600 paperand thoroughlywash the
entire valve body in solvent, then dry with com-
perssedair.
6 . Coat the valve with ATF then drop it into its bore.
It shoulddrop to the bottom o{ the bore under its
own weight. lf not. repeatstep 4 then retest.

2. Carefullytap the valve body so the stickingvalve

drops out of its bore.

CAUTION: lt may be necessaryto use a small

screwdiiver to pry the the valve lree. Be carelul not
to sclatch the bore with ihe sc.ewdliver.

3. Inspectthe valvetor any scuff marks.Usethe ATF-

soaked# 600 pagperto polishoff any burrsthat are
on the valve,than wash the valvein solventand dry
it with compressedair.
VALVE BODY
4. Rollup halt a sheetoI ATF-soakedpaperand insert
it in the valve bore of the stickingvalve.
Twist the paper slightly,so that it unrollsand fits
the boretightly,then polishthe boreby twistingthe
paper as you push it in and out.

CAUTION: The valve body is aluminumand doesn't

W
requiremuch polishingto removeany burs.

7 . Remove the valve and thoroughly clean it and the

valve body with solvent. Dry all parts with com
pressed air, then reassemble using ATF as a
lubricant.

14-117
Valve
Assembly
NOTE: a Set the springin the valve and installit in the valve
Coat all parts with ATF belore assemblv. body.
Pushthe springin with a screwdriver,then installthe
a Installthe valve, valve springand cap in the valve body spring seat.
and secure with the 10116r.

ROLLER

-6^<
5-1

SPBINGSEAT

VALVE BODY

VALVE BODY

Installthe valve, spring and cap in the valve bodv.

ROLLER Pushthe cap, then installthe cliD,

VALVE EODY

VALVE

CAP

14-118
Oil Pump
lnspection
l. Installthe oil pump gearsand oil pump driven gear Measurethe sideclearanceot the oil pumpdriveand
shait in the main valve body. driven gears.

Oil Pump Gsars Sido (Radisl) Clsarance:

Stsndard {N€w}: Drive g€ar
O . 2 1 O - O . 2 6 5m m ( O . O O 8 3 - O . O 1 0i 4
n)
Drivon g6al
O . O 7 O - O . 1 2 5m m ( O . O O 2 8 - O . O O 4i n9)
CHAMFER GROOVE

YI

Grooved and chamfered side

faces separator plate. OIL PUMP
DRIVENGEAR
Inspect teeth tor wear or damago.
DRIVEGEAR
Inspectteethlor wearor damaage.

Removethe oil pump drivengear shaft, and meas-

ure the thrust clearanceof the oil pump drivengear-
to-main valve body.

Oil pump Drive/DrivenGearthrust (Axiall Clearance:

Standard(Nawl:
0 . 0 3 - O . O 5 m m { O . O O-lO . O O 2i n )
Sorvice Limit:
O.O7mm {O.0O3in}

MAIN VALVE BODY

STRAIGHTEDGE

14-11 9
Main Valve Body
Disassembly/lnspection/Reassembly
NOTE:
a Clean all parts thoroughly in solvent or carburetor cloaner and dry with compressed air.
a Blow out all passaoes.
a Replacevalve body as an assemblyit 8ny parts are worn or damaged.
a Check all valves lor free movement.lf any fail to slide freely, see Valve Body Repairon page 14-117.

CAUTION: Do not use a magnot to romovo ths check batb; it may magnotize the balls.

CHECK BALLS, 3
2.3 SHIFTVALVE
DETENTARM SHAFT

DETEfITARM

F
J ST VALVE
rrl\.
i
'-ir, ,^r @

q---
RELIEFVALVE
t'-'t @
\\ i f l MANUAL
VALVE

@ \
VALVECAP CLIP
MAIN VALVE BODY

14-120
 Qr

DETENTARM SHAFT
MANUAL VALVE

sPat G sPEctFtcaTtot{s
Unit ot length: mm (in)
Standard lNowl
o, Epfng
Wiro Dia. o.D. F.oo Lsngth No. ot Coils

o Relief valve spring 1. 1 { O . O 4 3 l 8.6 (0.339) 3 7 . 1{1 . 4 6 1 ) 13 . 4

@ 4th oxhaust valve spring 1. 0 { 0 . 0 3 9 t 7.1 (O.2801 60.3 12.3741 18.5
o 2-3 shift valve spring 0.9 {0.035t 7.6 (O.2991 57.O 12.2441 26.4
o CPC valve spring 1 . 3{ O . 0 5 1 ) 9.4 (0.370) 3 5 . 3{ 1 . 3 9 O ) 12.4
@ 1-2 shift valv6 spring 0.9 {0.03s) 8.6 (O.339) 4 0 . 4{ 1 . s 9 1 t 14.5

14-121
RegulatorValve Body
Disassembly/lnspection/Reassembly
NOTE:
a Cleanall pans thoroughlyin solvent or carburetorcleaner,and dry with compressedait.
a Blow out all passages.
a Replacevalve body as an assemblyit any parts are worn or damaged.
a Check all valves for free movement.lf any fail to slide freely, see Valve Body Repairon page 14-117.

1. Hold the .egulatorspring cap in place while removingthe lock bolt. Once the bolt is removed.releasethe spring
cap slowlv.

CAUTION: The .egulator spring c8p can pop out whsn the lock bolt is removod.

2. Reassemblyis in the reverseorder of the disassemblyprocedute.

NOTE:
. Coat all pans with ATF.
a Align the hole in the regulatorspringcap with the hole in the valve body, pressthe springcap into the body and
tighten the lock bolt.
t,-V
REGULATORVALVE

LOCK.BOLT
6 x 1 . 0m m
,*6t'"
12 N.m (1.2 kgl.m,8.7 lbf.ftl

REGULATORSPRINGCAP
COOLERCHECK

OOWELPINS, 2
ROLLER
REGULATORVALVE BODY .
I',.-2"
"%=
. /
ll

VALVESLEEVE
SPRINGSPECIFICATIONS
Unit of length: mm (in)
Standard (New)
No. Spring
Wiro Dia. o.D. Free Longlh No. of Coils

o
/a
Regulatorvalve spring A
Regulatorvalve spring B
Stator reactionspring
@ Lock-upcontrol valve spring
Coolercheck valve spring
\9/ Torque convertercheck valve spring
1 . 8 0 ( O . O 7 1 ) 1 4 . 7 0( O . 5 7 9 18 8 . 6 0( 3 . 4 8 8 t 16.5
1 . 8 0 ( 0 . 0 7 1 ) 9 . 6 0 ( 0 . 3 7 8 ) 44.OOt't.7321
5 . 5 0 ( O . 2 1 7 1 ' 2 6 . 4 0 ( 1 . O 3 9 )3 0 . 3 0( 1. 19 3 t 2.1
o.80(o.o31) 6.60 (O.260) 3 9 . 5 0( 1 . 5 5 5 ) 25.O
'l2.5
1.10(0.043) 8 . 4 0 ( O . 3 3 1 ) 3 3 . 8 0( 1. 3 3 1I
1.10(O.O43t 8 . 4 0 ( 0 . 3 3 1 ) 3 3 . 8 0( 1. 3 3 1) 12.5
lnside Diameter

14-122
 Disassembly/lnspection/Reassembly
NOTE:
a Cleanall paris thoroughlyin solvent or carburetorcleaner,and dry with compressedair.
a Blow out all passages.
a Replacevalve body as an assemblyit any parts are worn or damaged.
a Check all valves tor free movement.lf any fail to slide fre€ly, see Valve Body Repairon page 14-117.
a Coat all parts with ATF before reassembly.

LOCK-UPSHIFT VALVE

TIMING8 VALVE
LOCK.UP

,ar

CAP
\,/

SPRINGSPECIFICATIONS
Unit ot length; mm (in)
Standard {Nsw}
No. Spring
Wile Di8. o.D. Flee Length No. of Coils

o Lock-upshift valve spring o . 9 0( o . 0 3 5 ) 7 . 6 0 ( 0 . 2 9 9 ) 73.70 i.2.9021 32.O

@ Lock-uptiming B valve spring o . 8 0( o . 0 3 1 ) 6 . 6 0 { O . 2 6 0 ) 6 0 . 8 0( 2 . 3 9 4 ) 22.1

14-123
SecondaryValve Body
Disassembly/lnspection/Reassembly

NOTE:
a Cleanall parts thoroughlyin solvent or carburetorcleaner.and dry with compressedair.
a Blow out all passages.
a Replacevalve body as an assemblyif any parts are worn or damageo.
a check all valves for lree movement.rf any fair to sridetreery,see varve Body Repairon page
14-1r7.
a Coat all parts with ATF betore reassembly.

CAUTION: Do not use a magnetto removethe check balls; it may magnetizethe balls.

CHECKBALLS.7

1ST ACCUMULATOR
@ CHOKE

a/
\.^l
"i\ SPRINGSEAT
'.'.) \ll /
'-
o{
-\)--
v
\
@

n
2.3 ORIFICECONTROL
VALVE

3-4 SHIFT VALVE

le
, r /

DOWEL PIN, 2 \i\

a-/ xii;.
SECONDARYVALVE EODY I b ');fi trd
MODULATORVALVE
a )

o
l"
@ \
VALVE

14-124
 CHECK BALL

CHECKBALLS

FILTER

SPRINGSPECIFICATIONS
Unit ot length: mm (in)
Standard(N€wl
No. Spring
Wire Dia. o.D. Free Length No. of Coils

o 3-2 kick-down valve spring 1. 3 { O . 0 5 1 ) 8.6 tO.339) 45.6 1.795) 1 7. O

4-3 kick-downvalve spring 1. O ( O . O 3 9 ) 6.6 (O.260) 28.5 1.1221 14.7
Orifice control valve spring o.8 (o.031) 6.6 (0.260) 48.2 1.898) 33.O
@ 2-3 orifjce control valve spring o.9 (o.03s) 6.6 (0.260) 33.O 1.299) 14.9
tcl 3-4 shift valve spring 0.9 {0.035) 7.6 (O.299) 52.O 2.O47l 26.8
\9 Servo control valve spring o.9 (o.o35) 6.4 lO.252l 34.1 1.343)
@ Modulatorvalve spring 1.3(O.O51) 9.4 (O.370) 37.3 1. 4 6 9 ) 12.4

14-125
Servo Body
Disassembly/lnspection/Reassernbly
NOTE:
a Cleanall pSrtsthotoughlyin solvent or carbu.etorcleaner,and dry with compressedair.
a Blow out all passages.
a Replacevalve body as an assembly it any parts are worn or damageo.
a Coat all parts with ATF before resssemblv.
a Replacethe O-rings.

THROTTLECAM
\P O-RING
SYOPPER 4TH Replace.
PISTON

6 r 1 . Om m
12 N.m
(1.2 kgf.m,
8.7 rbt.ftl
SERVOBODY
THROTTLEADJUSTIIIIGBOLT
CAUTION: Do not loo3on or

THROTTLE
VALVEB o
I
LONG VALVE

i '
r l
l l

Replace. V8;lilSl

O-RING
Replace.
3RD ACCUMULATOR
PISTON

14-126
SPRINGSPECIFICATIONS
Unit of length: mm (in)
St8ndard {Newl
No. Spring
Wire Dia. o.D. Fre6 Longth No. ot Coils

o Throttle valve B adiustingspring 0.7 (0.028) 6.2 t0.244l 3 4 . O( 1 . 3 3 9 ) 15.2

rar Throttle valve B sp.ing 1.4 (O.O55) 8.5 (O.33s) 4 1 . 5 ( 1. 6 3 4 1 10.5
6\ Throttle valve B spring 1.4 (O.O55) 8.5 (O.3351 4 1 . 5 ( 1. 6 3 4 ) 11.2
ra\ Throttle valve I spring 1.4 (O.O55) 8.5 {0.33st 41.6(1.638) 12.4
o 4th accumulatorspring 2.6 l0.102l 1 6 . 3( O . 6 4 2 ) 103.3(4.067)
'l
@ 1st accumulatorspring 2.5 (O.O98) 1 6 . 3( O . 6 4 2 ) 05.4 (4. 150) 16 + 8.6
(!, 3rd accumulatorsp.ing 2 . 8 ( O . 11 0 ) 1 7 . 5( O . 6 8 9 ) 105.2 14.142]. 19.1
@ 2nd accumulatorspring 3.6 (O.142) 2 2 . O( O . 8 6 6 ) 108.9(4.287) 15.2

14-127
1st-hold Accumulator/RightSide Cover
Disassembly/lnspection/Reassembly
NOTE:
a Clean all pans thoroughly in solvsnt o, carburetor cleaner, and dry with compressed 8ir.
a Blow out all passages.
a coat all parts with ATF betors raassembly.

SNAP RI]TG

l ST.HOLOACCUMULATORCOVER

1ST-HOLDACCUMULATORSPRING

PISTON
IST.HOLDACCUMULATOR

O.BING
R6place.

RIGHT SIDE COVER

SPRINGSPECIFICATIONS
Unit of length: mm (in)
St8ndard lt{ew)
No. Spring
Wlro Dia. o.D. Froo Length No. of Coils

o 1st-hold accumulatorspring 4 . 0 0 ( o . 15 7 ) 2 1 . 5 0 ( 0 . 8 4 6 ) 7 1 . 7 0l 2 . A 2 3 l 8.3

14-128
Mainshaft
Disassembly/lnspection/Reassembly
NOTE:
a Lubricateall pans with ATF during reassembly.
a Installthe thrust needlebearingswith unrollededge of bearingretainerlacing washer.
a Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
a Betoreinstallingthe O-rings,wrap the shaft splineswith tape to preventdamagingthe O-rings.
a Locknut has lett-handthreads.
LOCKNUT(FLANGENUT)
19 x 1.25mm
CONICAL SPRINGWASI{ER 93 N.m {9.5 kgf.m, 69 lbf.ftl
Replace. Replace.
Left-hand threads

SNAP RING lST CLUTCH

ASSEMBLY

\ THRUSTWASHER
MAINSHAFT o-ntNGs
Check splinestor excessive THRUSTNEEDLE Replace.
wear or damage. BEARING
Check bearing surface for scoring, THRUSTWASHER
scralches or excessive wear, THRUSTNEEDLE
4TH GEAR BEARING
BEANING

lST GEAR
NEEOLEBEARIT{GS

THRUST WASHER
1ST GEAR
COLLAR

4TH GEAR COLLAR TRANSMISSION

HOUSINGBEARING
2ND/4TH CLUTCH
ASSEMBLY

O.RINGS
Replace.

THRUST WASHER, 36.5 x 55 mm

Solective part.

THRUST NEEDLE
BEAFING

SEALINGRINGS,
35 mm 2ND GEAR

SEALINGRING.
29 mm NEEDLEBEARING

THRUST NEEDLE
BEARING
NEEDLEBEARING

SET RII{G
Mainshaft
Inspection

a ClearanceMeasurement Torque the mainshaft locknut to 29 N.m (3.0

kgf.m, 22 lbf.ft).
NOTE: Lubricateall parts with ATF during assembly.
NOTE: Mainshaftlocknut has lett-handthreads.
1. Removethe mainshaftbearinglrom the transmission
h o u s i n g( s e ep a g e 1 4 - 1 5 2 ) .

2. Assemblethe parts below on the mainshaft.

NOTE: Do not assemble the O-rings while in-

specting.

29 N.m (3.0 kgl.m, 22 lbt.ft)

LOCKNUT

1ST CLUTCHASSEMBLY
4. Hold 2nd gear againstthe 2nd clutch. then meas-
/ ure the clearancebetween 2nd gear and 3rd gear
THRUSTWASHER with a feelergauge.
lST GEARCOLLAR
TBANSMISSION NOTE: Takemeasurements in at leastthree Dlaces
HOUSINGBEARING and take the averageas the actual clea.ance.
THRUSTWASHER
STANDARD:0.05-0.13 mm {0.002-0.005 inl
4TH GEAR COLLAR
3RD GEAR 2ND GEAR
2ND/4TH CLUTCH
ASSEMBLY

THRUSTWASHER
Selectivepart.
TI{RUSTNEEDLE
BEARING
2ND GEAR

NEEDLEBEARING
THRUSTNEEOLE
BEARING

THRUSTWASHER-
36.5 x 55 ftm

MAINSI.IAFT

3RD GEAR 2ND GEAR

14-130
5. lf the clearanceis out of tolerance,removethe thrust
washer and measurethe thickness

6. Selectand installa new washer then recheck.

THRUSTWASHER36.5 x 55 mm

No, Part Number Thickness

1 9 0 4 4 1- P G 4 - O 1 0
90442 PG4-010
90443-PG4-O10
4 90444-PG4-O10
90445-PG4-O10
6 90446-PG4-Ol O
7 90447,PG4 0r0
8 90448-PG4-O10
q
9 0 4 4 9 - P G 4 - O r0
4 . O Om m ( O . 15 7 i n )
4 . 0 5 m m { O .15 9 i n )
4 . 1 Om m ( O . 1 6 1i n )
4 . 15 m m ( O . 1 6 3i n )
4 . 2 0 m m ( O . 1 6 5i n )
4 . 2 5 m m ( O . 1 6 7i n )
4 . 3 O m m ( O . 1 6 9i n )
4 . 3 5 m m { O . 17 1 i n )
4 . 4 O m m ( O . 17 3 i n )

7, AIter replacingthe thrust washer, make sure the

clearanceis within tolerance.

14-131
Countershaft
Disassembly/lnspection/Reassembly

NOTE:
a Lubricateall parts with ATF belore reassembly.
a Installthe thrust needlebearingswith unrollededge of bearingretainerfacing washer.
a Inspectthe thrust needlebearingsand the needlebearingstor gallingand rough movement.
a Beforeinstallingthe O rings, wrap the shaft splineswith tape to preventdamagingthe O-rings.
a Locknut has left-handthreads.
LOCKNUT{FLANGENUTI
23 x 1.25mm
CONICAL SPRING 1O3-0-lO3N.m
WASHER
{10.5-O-'l0.5ksf.m,
Replace. 75.9*O-75.9tbf.fr)
REVERSE
GEARCOLLAR Replace.
Left-hand threads
NEEDLEEEARING PARKINGGEAR

ONE.WAY
REVERSE CLUTCH
GEAR
BEVERSE
SELECTOR .IST GEAR

REVERSESELECTOR
HUB NEEDLEEEARING

4TH GEAR lST GEAR COLLAR

NEEDLEBEARING
TRANSMISSION
DISTANCECOLLAR, HOUSINGBEARING
28 mm
Selectivepart.
COUNTERSHAFT
Check splinesfor excessive 2ND GEAE
wear or damage.
Check bearingsurfacefor scoring,
scratchesor excessivewear_ THRUST NEEDLE
BEARING

3RD GEAR

NEEDLEBEARING

THRUSTNEEDLEBEARING
3RD GEARCOLLAR

3RD CLUTCH ASSEMBLY

O-RINGS
Replace.
 Disassembly/Reassembly

1, Usinga hydraulicpress,pressout the countershatt 2 . Assemblethe parts on the countershaftas shown

while supponing4th gear. oetow.

NOTE: Placean attachmentbetweenthe pressand NOTE:

the countershattto preventdamageto the shaft. a Lubricateall parts with ATF duringassembling.
a Before installingthe O-rings, wrap the shalt
CAUTION: Do not allow the countershaftto lall and splines with tape to prevent damaging the
hit the ground. O-rings.

4TH GEAR

NEEDLEBEARING

DISTANCECOLLAR. 29 mm
Selectivepart.

2ND GEAR

THRUSTNEEDLEBEARING

3RD GEAR

NEEDLEBEARING

THRUSTNEEDLEBEARING

3RD GEAR COLLAR

3RD CLUTCHASSEMBLY

O-RINGS
Replace.

COUNTERSHAFT

{cont'd)
Countershaft
(cont'd)
Disassembly/Reassembly Inspection
a Installthe reverseselectorhub on the countershaft a ClearanceMeasurement
sub-assemblV, and then pressthe reverseselector
hub using the specialtool and a press as shown. NOTE: Lubricateall parts with ATF during assembly.

1. Removethe countershaftbearingfrom the transmis-

s i o n h o u s i n g( s e ep a g e l 4 - 1 5 2 ) .

2. Installthe pans belowon the counte.shaftusingthe

specialtool and a pressas describedon this page.

NOTE: Do not assemble the O-rings while in-

specting.

REVERSESELECTOR
HUB

4TI{ GEAR

NEEDLEBEAFING

DISTANCECOLLAR, 28 m|n
Selective part.

COUNTERSHAFT

14-134
Install the parts below on the countershaftsub-
assembly,then torque the locknut to 29 N'm (3.O
kgf.m, 22 lbf.ft).
Measurethe clearancebetweenthe 2nd gear and
the distancecollar, 28 mm wilh a feelergauge.
NOTE: Takemeasurements in at leastthreeplaces.
and take the averageas the actual clearance.

: . O 5 - 0 . 1 3 m m ( 0 . O O 2 - O . O 0 i5n )
S T A N D A R DO

DISTANCECOLLAR,
2ND GEAR 28 mm

LOCKNUT
Left-hand threads
CONICALSPRI G
WASHER

PARKINGGEAR/ONE-WAY
CLUTCH/1STGEAR
ASSEMBLY

NEEEDLEBEARING

lST GEARCOLLAR

TRANSMISSIONHOUSING
BEARING
REVERSEGEAR
COLLAR

2ND GEAR

(cont'd)

14-135
Countershaft
Inspection(cont'dl
5. lf the clearanceis out of tolerance,removethe dis-
tance collaf, 28 mm and measurethe width,

6. Select and install a new distance collar, then

recheck.

DISTANCECOLLAR,28 mm

No. Part Number Width

1 90503-PC9-OOO
, 90504-PC9-OOO
90sos,Pc9-ooo
90507-PC9-000
5 90508-PC9-000
6 90509-PC9-000
7 90510 PCg*000
I 9 0 5 1I - P C g - O O O
90512 PCg 000
3 9 . O 0m m ( 1. 5 3 5 i n )
3 9 . 1 0m m ( 1 . 5 3 9i n )
3 9 . 2 0 m m ( 1 . 5 4 3i n l
3 9 . 3 0 m m ( 1 . 5 4 7i n )
3 9 . 0 5 m m ( 1. 5 3 7 i n l
3 9 . 15 m m { 1 . 5 4 1i n )
3 9 . 2 5m m ( 1 . 5 4 5i n )
3 8 . 9 0 m m { 1 . 5 3 1i n )
3 8 . 9 5m m { 1 . 5 3 3i n )

7, Altet selectinga new distancecollar,recheckthe

clearanceand make sure it is within tolerance.

14-136
One-way Clutch/ParkingGear
Disassembly/lnspection
1 . Separatecountershaft1st gearfrom the parkinggear Inspoct tha psrta a3 tollows:
by turningthe parkinggear in the directionshown.

PARKII{GGEAR
Inspectthg parking
tor w€s. or acoring.

COUNTERSHAFT1ST GEAR
O E.WAY
Inspect tho ono-way
clutch fo. damageaor
2. Removethe one-way clutch by prying it up with the faultv movement.
end of a screwdrive..

courrERsHAFrlsr.EAR
9IlYlL9iY^t.?I
NOTE: lnstall in this direction.

l ST GEAR
Inspect counior6haft 1
tor wegr or scoaing.

3. After the Dartsare sssembled,hold counte.shaft lst

gear and turn tho parkinggear in the directionshown
to be sur6 it turns freelv,

CLUTCH
O'TE.WAY
COUNTERSHAFTlST GEAR

1STGEAR
COU TERSHAFT
SCREWDRIVER

14-137
Sub-shaft
Disassembly/lnspection/Reassembly
NOTE:
a Lubricateall parts with ATF during reassembly.
a Installthe thrust needlebearingswith unrollededge ot bearingretainertacing washer.
a lnspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
a Beforeinstallingthe O-rings,wrap the shaft splineswith tape to preventdsmagingthe O-.ings.

TRANSMISSIOI{HOUSING

TRANSMISSION
HOUSINGBEARING

lST-HOLD CLUTCH
ASSEMELY

O.RINGS
Replace.
6 x 1.0 mm
12 N.m THRUST WASHER
(1.2 kgf.m, 8.7 lbf.ft)
THRUST NEEDLE
BEARING
SUB.SHAFT NEEDLEBEARING
Checksplinestor excessive
wear or damage.
Check bearingsurlacetor
sconng.scratchesor excessive 4TH GEAR

THRUST I{EEDLE
AEARIIIG
OIL GUIDECAP
Replace. 4TH GEAB COLLAR
NEEDLEBEARIT{G
STOPPER

NEEDLEEEARING
Disassembly/Reassembly
Removethe oil guide cap by pushingthe sub-shaft
insidethe transmissionhousing.

Removethe 1st-holdclutchassemblyby pullingthe

sub-shaft,then removethe sub-shatt.

Installnew O-ringson the sub-shaft.

NOTE: Wrap the shaft splineswith tape to prevent

damagingthe O-rings.

Placethe sub-shaftin the transmissionhousingand

installthe 1st-holdclutch assembly.

Installnew oil guide cap usingthe specialtools as

snown.

DRIVER
07749-0010000

ATTACHMENT-
32x35mm
07746-0010100

,IST.HOLD CLUTCH
ASSEMBLY

14-139
Sub-shaft Bearings
Replacement

NOTE: Lubricateall parts with ATF beforereassembly Installthe new needlebearingin the transmlsston
anda pressas shown.
housingusingthe specialtools
'l . To removethe sub-shaftballbearingtrom the trans-
missionhousing.expandthe snapringwith snapring PRESS
pliers,then push the bearingout using the special
tools and a Dressas shown.

32 x 35 mm
ATTACHMENT,
07746-0010100

ATTACHMENT,62 x 68 mm 5 . Expandthe snap ring with snap ring pliers,then in-

07746-0010500
sert the ball bearingpart way into the housingus-
ing the specialtoolsand a pressas describedin step
Removethe needlebearingstopper. 1. Installthebearingwith the groovefacingoutside
the housing.
Removethe needlebearingfrom the transmisslon
housingusing a drilt Punch. Releasethe pliers,then push the bearingdown into
the housinguntilthe snapringsnapsin placearound
rt.
DRIFTPUNCH
7 . After installingthe ballbearing,verifythe following:

a The snap ring is seatedin the bearingand hous-

ing grooves.
a The snap ring ope.atesproperly
a The ring end gap is correct.
E N DG A P :0 - 7 m m

?A
SNAP RING

14-140
Clutch
lllustratedIndex

3RD CLUTCH

CLUTCH
O-RINGS
DRUM
Replace.
CLUTCH PISTON

DISC SPRING
RETURNSPRING
SPRINGRETAINER
SNAP RING

1ST CLUTCH

CLUTCHEND
PLATE CLUTCH DISCS
Stsndard thickness:
1.94 mm {0.076 in)
SNAP RING
SNAP RING

O-RINGS
Replace.

SNAP RING

CLUTCH PLATES
Standard thicknass:
2.00 mm {0.079 in}

CHECKVALVE

(cont'd)

14-141
Clutch
lllustratedIndex (cont'd)

2ND/4TH CLUTCH

SNAP RING

CLUTCH END PLATE

CLUTCH DISCS
Standard thickno3s:
1.94 mm 10.076in)

CLUTCH PLATES
Standard thickness:
2.OOmm 10.079inl )
SNAP RING l
SPRINGRETAINER
RETURNSPRING

CLUTCH PISTON
SPRING

RETURNSPRING
CHECKVALVE
RETAINER

SNAP RING
4TH CLUTCHDRUM

CLUTCH PLATES ;;i;;; /

Standa.d thickness:
2.00 mm 10.079 in)
( / \

Y)

CLUTCH DISCS
Stsndard ihickn€ss:
1.94 mm 10.076in)

CLUTCH END PLATE

SNAP RING

14-142
lST.HOLD CLUTCH

SNAP RING
CLUTCH END PLATE

CLUTCH DISCS
Standard thicknoss:
1.94 mm 10.076 inl

DISC SPRING

CLUTCH PISTON
O-RINGS
Roplace.

CLUTCH PLATES
Standard thickno3si
2.00 mm (0.o79 in)

14-143
Clutch
Disassembly
Removethe snap ring. then.emove the clutch end 3. Installthe sDecialtools as shown.
plate, clutch discs and plates.
CLUTCHSPRIT{G
COMPRESSOR
ATTACHMET
oTLAE-PX40100

SNAP RII{G

cLuTcHspnrc
COMPNESSOR
ATTACHMET
2. Removethe disc spring. oTHAE-Pr60tOO

SPNING

otsc sPfit c

CLUTCH SPRII{C
COMPNESSOR
ATTACHi'ENT
OTLAE-PX,l{,TOO

2ND CLUTCH

DISC SPBING

CLUTCH SPBII{G
COMPRESSOR
ATTACHMEI{T
oTHAE-Pt50100

1ST, 3RD, 4TH .nd

l ST.HOLD CLUTCH

14-144.
CAUTION: lf either end ot the comprassol attachm€nt 5 . Remove the snap ring. Then remove the special
is sel ovsl an araa ol the spdng retaine. which is unsup- tools, spring retainerand return spring.
ported by the retum spring.the letainermay be damag6d,

S AP RING

Do not set horo.

6. Wrap a shop towel aroundthe clutch drum and ap-

ply air pressureto the oil passageto remove the
4. Compressthe return spring. piston.Placea fingertip on the other end while ap-
plying air p.essure.

COMPRESSEDAIR
HOSE NOZZLE
OSHA-approved30 psi
rype onry

CLUTCH

RETURNSPRING

PISTON

14-145
Clutch
Reassembly
NOTE: 3, Installthepistonin the clutchdrum. Apply pressure
a Clean all psrts thoroughly in solvent or carburetor and rotate to ensureproper seating.
cleaner.and dry them with compressedair.
a Blow out all passages. NOTE: Lubricatethe pistonO-ringwith ATF before
a Lubricateall pans with ATF before .eassembly. installing,

1. Inspectthe check valve; if it's loose, replacethe CAUTION: Do not pinch rh6 O-ringby installingth€
prston, piston with too much lorco.

NOTE: Except 1st-holdclutch.

CLUTCH DRUM
CHECKVAIVE

4. Installthereturnspringand springretainer.and po-

sition the snap ring on the retainer

SNAP RING

SPRINGRETAINER

RETURNSPRING

CLUTCHORUM

PISTON

14-146
 r
5, Installthe specialtools as shown. CAUTION: lf €ithor end of the comprossor attach-
ment is set over an area of the spring rotainerwhich
iE unsupportedby tho retum spring, the latainer may
bo damaged.

CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE-PX40100

CLUTCH SPRING
COMPRESSOR
ATTACHMENT Do not set here.
oTHAE-Pl50100
CLUTCH SPRING
COMPNESSOR
BOLT ASSEMBLY
oTGAE-FG40200

6, Compressthe return spring.

CLUTCII SPRING
COMPRESSOR
ATTACHMENT
oTLAE-PX40100

CLUTCH SPRIIIG
COMPRESSOR
ATTACHMENT
oTHAE-Pl50100 RETURNSPRING
CLUTCH SPRING
COMPRESSOR
AOLT ASSEMBLY
07GAE-PG40200
(cont'd)

14-147
Clutch
Reassembly(cont'd)

7. Installthe snap ring. 1O. Soakthe clutch discsthoroughlyin ATF for a mini-
mum of 30 minutes.

11. Starting with a clutch plate, alrernatelyinstallthe

clutch platesand discs. Installthe clutch end plate
with flat side toward the disc.

NOTE: Beforeinsrallingthe platesand discs,make

sure the insideof the clutch drum is free ot dirt or
other toreign matter.

CLUTCH END PLAT€

Installin this direction

SNAP RING

Removethe specialtools.

Installthe disc spring.

NOTE: Installthediscspringin the directionshown.

DISCSPRING
1 2 . I n s t a l tl h e s n a p r i n g .

SCREWDRIVER

SNAP RING

.\

):ll
1ST, 3RD, 4TH and
l ST.HOLDCLUTCH

14-148
'13. Measurethe clearancebetweenthe clutchend plate lST CLUTCHEND PLATE
and top disc with a dial indicator.Zerothe dial indi-
catorwith the clutchend plateloweredand lift it up PlateNo. PartNumber Thickness
to the snap ring. The distancethat the clutch end 1 22551-PF4-000 2 . 1 m m 1 0 . 0 8 3i n )
platemovesis the clearancebetweenthe clutchend 2 22552-PF4 000 2 . 2 m m ( 0 . 0 8 7i n )
plate and top disc. 3 22553 PF4 000 2 . 3 m m ( 0 . 0 9 1i n )
4 2 2 5 5 4 - P F 4 - O O O 2.4 mm (0.094in)
N O T E r M e a s u r ea t t h r e el o c a t i o n s . 5 22555 PF4-000 2 . 5 m m ( 0 . 0 9 8i n )
6 22556 PF4-000 2 . 6 m m { 0 . 1 0 2i n }
Clutch End Plate-to-Too Disc Clearance: 7 22557-PF4 000 2 . 7 m m i 0 . 1 0 6i n )
8 22558-PF4 000 2 . 8m m ( 0 . 1 1 0 in)
Clulch Service Limit I 2 2 5 5 9 -P F 4 -0 0 0 2 . 9m m ( 0 . 11 4 i n )
lst O.65 o.85 mm ( O . 0 2 6 O . O 3 3i n ) 10 22560-PF4 000 3 . 0 m m ( 0 . 11 8 i n )
2nd O . 6 5- O . 8 5 m m { O . 0 2 6 - O . O 3 3i n ) 11 22561 PF4-000 3 . 1 m m ( 0 . 12 2 i n l
3rd O . 4 O - O . 6 0m m ( 0 . O 1 6 o . O 2 4i n ) 1 ) 22562-PF4 000 3 . 2 m m { 0 . 1 2 6i n }
4th 0.4O-0.60 mm (0.016-0.024 in) I J 22563-PF4 000 3 . 3 m m ( 0 . 13 0 i n )
1st-hold 0.50-0.8O mm { O . 0 2 O - 0 . 0 3 1i n } 14 22564 PF4-OOO 3 . 4 m m ( 0 . 1 3 4i n )

2ND- 3RD and 4TH CLUTCHEND PLATE

IAL INDICATOR
PlateNo. PartNumber
1 22551 P56,N00
2. 22552-P56-N00
3 22553-P56-N00
4 2 2 5 5 4 -P 5 6- N 0 0
5 22555-P56 N00
6 22556 Ps6-N00
7 22557- P56 N00
8 22558 P56-N00
I 22559-P56 NOO
10 22560 P56-N00
Thickness
2 . 1 m m ( 0 . 0 8 3i n )
2 . 2 m m ( 0 . 0 8 7i n )
2 . 3 m m ( 0 . 0 9 1i n )
2.4 mm (0.094in)
2 . 5 m m ( 0 . 0 9 8i n )
2 . 6 m m { 0 . 1 0 2i n )
2 . 7 m m { 0 . 1 0 6i n i
2 . 8m m ( 0 . 1 1 0 in)
2 . 9 m m ( 0 . 11 4 i n )
3 . 0 m m ( 0 . 11 8 i n )

lST.HOLD CLUTCHEND PLATE

PlareNo. Part Number ThicknEss

1 22551-PS5 003
2 22552 PS5-003
3 22553-PS5 003
4 22554-PS5-003
14. lf the clearanceis not withinthe servicelimits,select 5 (Nomark) 2 2 5 5 5 - P S 5 - 0 0 3
a new clutch end plate lrom the following table. 6 22556 PS5-003
7 22557 PS5-003
NOTE: It the thickest clutch end plate is installed,
but the clearanceis still over the standard,replace
the clutch discs and clutch Dlates.
2 . 1 0m m ( 0 . 0 8 3i n )
2 . 2 0m m ( 0 . 0 8 7i n )
2.30 mm (0.09'1in)
2 . 4 0m m ( 0 . 0 9 4i n )
2 . 5 0m m { 0 . 0 9 8i n )
2 . 6 0m m { 0 . 1 0 2i n }
2 . 7 0m m ( 0 . 1 0 6i n )

PLATENUMBER Thickn€ss

CLUTCHEND PLATE

14-149
Torque Converter Housing Bearings
MainshaftBeadng/OilSeal Replacement

1. Driveout or pull up the mainshaftbearingand oil seal, 2 . Drivein the new mainshaftbearinguntil it bottoms
using the specialtools as shown. in the housing,using the specialtools as shown.

DRIVEN

07749 -OOIOOOO

ATTACHMENT,
62x68mm
07746-0010500

3 . Installthenew oil sealflush with the housingusing

the sDecialtools as shown.

Slide Hammer
CommerciallyAvailable
3/8 in.x 16

ATTACHMENT,
72x75mm
07746-0010600

14-150
 CountershaftBearingReplacement
l. Removethe countershattbearingusingthe special
tools as shown.

SlideHammer
CommerciallyAvailable
3/8 in. x 16

ADJUSTABLE
BEARING
PULLER,
25-40 mm
07736-AOIOOOA

K-i.<trE)t
'/'

',--CZ_ ( (
-)

_-=\._
-) ))\
-:-:-:1.-=41"
Installthe oil guide plate.

Drivethe new bearinginto the housingusingthe spe-

cial tools as shown.

14-151
TransmissionHousingBearings
Mainshaft/Countershaft
BearingReplacement
1. To removethe mainshaftand counte.shaftbearings Expandeach snap ring with snap ring pliers,insert
trom the transmissionhousing,expandeach snap the new bearingpan-wayinto the housingusingthe
ring with snap ring pliers,then pushthe bearingout specialtoolsand a pressas shown. Installthebear-
using the specialtools and a press as shown, ing with the groove tacing outsidethe housing.

NOTE: Do not remove the snap rings unless it,s
necessafyto cleanthe groovesin the housing.
PRESS
NOTE: Coat all parts with ATF.
Releasethe pliers.then push the bearingdown into
the housinguntil the ring snaps in placearoundit,
DRIVER
o7749-OOIOOOO

Mainshatt Inltallation us6:

ATTACHMENT,
72x75mm
07746-0010600
Counto.shalt In3talldtion uso:
ATTACHMENT, GnoovE

I
ATTACHMENT.
62x68mm 62x68mm
o7746- 07746-O010500

---7i
\)

4. After installingthe bearingverify the lollowing:

a The snap ring is seatedin the bearingand hous-

In9 grooves.
MAINSHAFT a The snap ring operatesproperly
a The ring end gap is correct.

END GAP: O-7 mm

Mainshaft Removal uaoi

ATTACHMENT-
72 ,, 75 mm
o7746-OOlO600
Counterrhaft Removal uao:
ATTACHMENT,
62x68mm
07746-O010500

TRANSMISSION SNAP BING

t|oustitc

14-152
 Sub-shaftBearingReplacement
I. To remove the sub-shaft bearinglrom the transmis-
sion housing,expandthe snap ring with snap ring
pliers, then push th€ bearing out using the special
tools and a Dressas shown.
2 . Expandthe snap ring with snap ring pliers,insert the
new bearingpart-way into the housingusingthe spe-
cial tools and a pressas shown. Installthe bearing
with the groove facing outside the housing.

NOTE: Do not remove the snap ring unless it's NOTE: Coat all parts with ATF.
necessary to clean the groove in the housing.
a Releasethe pliers,then pushthe bearingdown into
the housinguntil the ring snapsin placearoundit,
using the specialtools as shown.
PNESS
DRIVER
07749-0010000

ATTACHMEI{T,
62 x 68 mrn
077/+6-OOlO500

GROOVE

4. After installingthe bea.ingverify the following:

ATTACHMENT,
62x68m|n a The snap ring is seatedin the bearingand hous-
07746-(Xr10500 ing grooves.
a The snap ring operatesProperlv
a The ring end gap is correct.

El{DGAP:o-7 mm

HOUS[{G

14-153
Reverseldler Gear ParkingBrake Stopper
Installation Inspection/Adjustment
1. Installthe reverseidler gear. 1 . Set the parkingbrake lever in the E position.

2. Measurethe distancebetween the parking brake

pawl shaft and the parkingbrakeleverrollerpin as
shown.

STANDARD:72.9-73-g mm (2.87-2.91 in)

ROLLERPIN
PANKING
BRAKE
LEVER

7A\
Meaauring
\v

PARKINGBRAKE
Installthereverseidle,gearshaft holderand needle STOPPER
bearinginto the transmissionhousing,then tighten PARKING
BBAKE
the bolts. PAWLSHAFT

6 x l.O mm
lf the measurementis out of tolerance,select and
12 N'm 11.2 kgt.m. installthe appropriateparkingbrakestopperfrom the
4.7 lbf.ft) table below.

PARKINGBRAKESTOPPER

Mark PartNumbol Lz
1 - PA9-003 11 . 0 0m m
24537 1 1 . 0 0m m
{0.433in} {0.433in)
2 -003
24538-PA9 10.80mm 1 0 , 6 5m m
(0.425in) ( 0 . 4 1 9i n l
24539- P49,003 1 0 . 6 0m m 1 0 . 3 0m m
( 0 . 4 1 7i n ) {0.406in)

4. After replacingthe parkingbrakestopper, make su.e

the distanceis within tolerance.

14-154
Transmission
Reassembly
NOTE:
a Coat all parts with ATF.
a Replacethe parts below:
. O-rings
. Lock washers
. Gaskets
. Locknuts
. Conicalspring washers
. Sealingwashers

T O R O U E1: 2 N . m ( 1 . 2 k g t . m , 8 . 7 t b f . f r )

OIL FEEDPIPE
/ LUBRTcAToR orL
LOCK-UPVALVE , PLATE FEED OIL FEEDPIPES
EODY
f| l n / PIPES
ACCUMULATOBCOVER
/ /""n
OOWELPINS,2

*'
v{
e'f _\
OIL FEEDPIPE

_! 1.-...-]] Bolts,3

\ "o't LOCKWASHER
vaLVE spRtNGS
\_(< e
ToRouE coNvERTE
n \-\.-- SERVODETENT
--'r CONTROL BASE
CHECK VALVE ----.-. \ -
E SHAFT
COOLERCHECKVALVE
-. :-,.
REGULATORVALVE
BODY

OIL FEEDPIPES

Bolts,4
SERVOBODY
DOWELPINS.2
SERVOSEPARATOR
PLATE
MAIN VALVE "1- Bolt
EoDY .
|
OIL PUMPDRIVEN
GEARSHAFT
SECONDARYVALVE
OIL PUMP DRIVENGEAR
BODY

DOWELPINS,2
MAIN S€PARATOR
PLATE OOWELPINS,2
SECONDARYSEPARATOR
PLATE

ATF MAGNET

14-156
 E
'.

1 . Installthe ATF magnetand suctionpipecollarin the 7. Installthe servo body and separatorplate with six
torque converternousrng. bolts.

2 . Installthe mainseparatorplatewith two dowel pins
on the torqueconverterhousing.Then installthe oil
pump drivegear,drivengearand drivengearshalt.
NOTE| Install the oil pump driven gear with its
groovedand chamteredside facing down.
OIL PUMP
DRIVEGEAR
8. lnstallthe accumulatorcover with three bolts
9. lnstallthe servodetent base and ATF strainerwith
three bolts and new lock washers.
1 0 . T i g h t e nt h e f o u r b o l t st o 1 2 N . m ( 1 . 2 k g f ' m , 8 . 7
lbf.ft) on the main valve body.
Make sure the oil pump drive gear and oil pump
driven gear shaft move smoothly same as in the step

11. lf the oil pump drive gear and oil pump driven gear
shaft do not move freelY.loosenthe four bolts on
the main valve body and disassemblethe valve
bodies.
Realignthe oil pumpdrivengearshaft and reassem-
OIL PUMP ble the valvebodies,then retightenthe bolts to the
ORIVENGEAR specifiedtorque,
Groovedand chamfered
side faces separator CAUTION: Failureto align the oil pump d1iv6ngear
plate. shaft corroctly will result in a seized oil pump drivo
geal of oil pump drivon gear shatt.
J. Loosely install the main valve body with Iour bolts.
Make sure the oil pump drive gear rotates smoothly
in the normal operating direction and the oil pump
driven gear shaft moves smoothly in the axial and
normal operating directaons.

Installthe secondary valve body, separator plate and

two dowel pins on the main valve body.
(l . . \. l
Installthe control shaft in the housing, with the con-
trol shatt and manual valve togelher.
=L,1ffi#
.. N
6. Installthe detent arm and arm shatt in the main valve
j-*/:
body, then hook the detent spring to the detent arm.

OIL PUMP OIL PUMP OIL PUMP

SERVOSEPARATORPLATE DRIVEGEAB DRIVENGEAR DRIVENGEAR
36 SHAFT

DETENT --- 8ixli"' 12. Installthe stator shaft and stoppershatt.

SHAFT
13. Installthe stoppershatt stay on the secondaryvalve
body with the bolt.

14. Installthe regulatorvalve body with the bolt.

15. Installthe torque convertercheck valve,coolercheck

DETENI SPRING
valve and valvespringsin the requlatorvalve body.
DETENTARM
16. Installthe lock-upvalvebody, separatorplate,two
dowel pins and lubricatorplatewith the eight bolts.

1 7 . I n s t a l tl h e o i l f e e d p i p e s . (cont'dl
MANUAL VALVE

14-157
Transmission
(cont'dl
Reassembly

TRANSMISSIONHOUSING
MOUNTINGBOLTS,18
l0 x 1.25mm
44 N.m (4.5 kgl.m. 33 lbf.trl

fl
TRANSMISSION
HANGER
TRANSMISSIONHOUSING

TRANSMISSION
MOUNT BBACKET
'1.25
12 x fifi
64 N.m {6.5 kgt'm,
TRANSMISSION
HOUSING
47 tbt'tr)

T=
GASKET
Replace.

CONNECTORSTAY REVERSEGEAR COLLAR

NEEOLEBEARING
MAINSHAFT REVEBSEGEAR
SUB-ASSEMBLY
LOCKWASHER
Replace.
SHIFTFORK

DOWELPINS,3 REVERSESELECTOR
COUNTERSHAFT
SUB.ASSEMBLY

DIFFERENTIAL
ASSEMBLY

TOROUECONVERTER
HOUSING

14-158
 ,,1
18. Installthe sub-shaftassemblyin the transmission lnstall the reversegear with the collar and needle
h o u s i n g{ s e ep a g e 1 4 - 1 3 8 ) . bearingon the countershalt.

19- Installthe reverseidler gear and gear shatt holder
( s e ep a g e 1 4 - 1 5 4 ) .
20. Installthe differentialassemblyin the torque con-
verter housing.
21. Installthe mainshaftand countershaftsub-assembly
together in the torque converterhousing.
24. Align the spring pin of the control shaft with the
transmissionhousinggrooveby turningthe control
shalt.
25. Placethe transmissionhousingon the torque con-
verterhousingwith a new gasketandthe dowelpins.
CONTROL

MAINSHAFT
SUB.ASSEMBLY
COUNTERSHAFT
SUB.ASSEMBLY

/K"\
// 2 " \
TRANSMISSION
HOUSING

Installthe transmissionhousingboltsalongwith the

t.ansmissionhangerand the connectorstay, then
torque the bolts in two or more steps in the sequence
shown.
2 2 . Turn the shift fork so the largechamteredhole is fac-
ing the fork bolr hole.then installtheshift fork with TOROUE:44 N.m (4.5 kgf.m, 33 lbf'ft)
the reverseselectorand torquethe lock bolt. Bend
the lock tab againstthe bolt head. TRANSMISSION
HANGER

CONNECTOR
SHIFTFORK

LOCI( WASHER
Replace.

6 x 1.0 mm
4 N.m
(1.4 kgl.m, rO lbt.ft)

Largechamferedhole
faces this way.

14-159
Transmission
(cont'dl
Reassembly
27. Slip the specialtool onto the mainshaftas shown. 32. Use th6 old locknut and old conicsl spring washot
to tighten th€ parking gear to th€ sp€cifi€d torque,
then loosen the locknut.
MAII{SHAFT HOLDER .m (1O.5 kgf.m, 75.9 lbf'ftl
oTGAa - PF5010I
TOROUE:103

NOTE: Locknut has left-hand threads.

PARKII{GGEAR

24. Install the parking b.ake lever on the control shaft.

29. Installthe mainshaft 1st g6ar collar and thrust wash-

er on the mainshaft.

30. Installthe countershaft1st gear collarand n6€dls

bearing,then installthe count€rshatt1st gear/one-
way clutch/parking gea, assembly on the coun-
tershalt.

3 1 .Install the parking b.ake pawl in th€ transmission

housing,then engageit with the parkinggear.
33. Install the sub-shaft lst gear on thg sub-shaft.

34. Install new O-rings on the mainshaft.

lST CLUTCH
NOTE: Wrap the shaft splines with tspa to prevont
PARKI''IGGEAR damago to the O-rings.
PARTI G
ARAKE Assembloth€ thrust wash6r, thrust naedle bearing,
LEVER needlebearingand msinshsft lst gear on tho lst
clutch assombly,then installthem on the mainshaft.

SUB-SHAFT
MAIt{SHAFT COU TERSHAFT

14-160
36. Alignthe holeof the sub-shaft1st gearwith the hole 3 9 . Stake each locknut using a 3 . 5 m m p u n c h .
of the transmissionhousing,then inserta pinto lock
the sub-shaftwhiletighteningthe sub-shaftlocknut. . MAINSHAFT

37. Installnewconicalspringwashersand new locknuts

on each shaft.

CAUTION: Installthe conical spdng washers in the

dilection shown.

38. Tightenthe locknutsto the specifiedtorque.

TOROUE:
MAINSHAFT 93 N.m (9.5 kgf'm, 69 lbf.ft)
COUNTERSHAFT
103 N.m
(1O.5 kgf.m, 75.9 lbf.ft)
SUB-SHAFT 93 N.m (9.5 kgf.m. 69 lbf.fi)

NOTE: Mainshaltand countershaftlocknutshave

left-handthreads.

. COUNTERSHAFT

O,7- 1.2 mm

CONICAL DISC SPRINGS

lnstallin rhis direcrion.

0.7- 1.2 mm
in)
1O.03-O.05
SUB-SHAFTLOCKNUT

14-161
Transmission
Reassembly(cont'dl

40. Set rhe parkingbrakelever in the E position,then 44. Installthe throttlecontrolleverwiththe leverspring
verifythat the parkingbrakepawl engagesthe park- on the throttle control shaft.
Ing gear.
TOROUE:7.8 N.m (O.8 kgf.m, 5.8 tbf.ft)
4 1 . l f t h e p a w l d o e sn o t e n g a g e f u l l yc,h e c k t h ep a r k i n g
brakepawl stopperclearanceas describedon page 45. Installthe tramsmissionmount bracket.
14-154.
TOROUE:64 N.m (6.5 kgf.m, 47 lbf.trl
42. Tightenthe lock bolt and bend the lock tab.
46. Installthe ATF cooler pipes and ATF level gauge.

6 x 1 . 0m m
10 tbf.frl

PARKINGGEAR
PARKINGBRAKEPAWL

Installthe right side cover and right side cover pro

lecror.

TOROUE:12 N.m {1.2 kgf.m, 8.7 lbf.ftl

14-162
Torque Converter/DrivePlate

6 x'l.Omm
12 N.m {1.2 kgf.m, 8.7 lbf'tt)

12 x 1.0mm
74 N.m {7.5 kgf.m, 54 lbl.ftl
Torquein a crisscrosspattern.

0
0d

DRIVE PLATE

TOROUECONVERTER
ASSEMELY

14-163
Transmission
Installation

1 . F l u s ht h e A T Fc o o l e ra s d e s c r i b eodn p a g e sI 4 - 1 6 8 5. Installthe transmissionmount.

'l
thru 69.
12 x 1.25mm
2. Installthe starter motor on the transmissionhous- 64 N.m 16.5 kgl.m, 47 lbf.ft)
i n g ,t h e ni n s t a l l t h el 4 m m d o w e lp i n si n t h e t o r q u e
converrernousrng.

STARTERMOTOR 45 N.m 14.5 kgf'm,

'14 mm DOWELPIN

i.'l,i;
1 2 x 1 . 2 5m m
O-RING 14 mm OOWELPIN 74 N.m 17.5kgf'm,
TOROUE Replace.
CONVERTER 54 rbt'ft)

J. Placethe transmissionon a transmissionjack, and 6. Installthe transmissionhousingmountingbolts.

raiseto the enginelevel.

Attach the transmissionto the engine,then install

the transmissionhousingmounting bolts and two
rear enginemounting bolts with new washers.

TRANSMISSION
HOUSING REARENGINE
MOUNTINGBOLTS MOUNT BOLTS
1 4 x 1 . 5m m
59 N.m 16.0 kgf.m,43 lbl.ftl

TRANSMISSION HOUSING
MOUNTING BOLTS
12 x 1.25 rnm
74 N.m (7.5 kgf'm, 54 lbf.ftl

14-164
 7 . Removethe transmissionjack. 11. Connectthe ATF cooler hosesto the joint pipes.

L Attach the torque converterto the drive plate with 12. Connectthe throttlecontrolcableto the throttlecon-
eight bolts and torque: trol lever and installthe right front mount/bracket.
Rotatethe crankshattas necessaryto tighten the
boltsto 1/2 of the speciliedtorque,then to the final
toaque,rn a cnsscrosspattern. THROTTLECONTROLLEVER
THROTTLECONTROL
After tighten the last bolts, check that the crankshaft CABLEEND
rotatesfreely.
JOINT PIPES
T O R O U E1: 2 N . m { 1 . 2 k g l . m . 8 . 7 l b f . f t }

9 . Install the torque converte. cove. and engine

stiffener.

6 r 1 . Om m
12 N.m 11.2 kgt.m, 8.7 lbl.ltl

ATF COOLERHOSES
10 x 1.25mm RIGHT
44 N.m (4.5 kgf'm, FRONT 1 2 x 1. 2 5 m m
33 rbl.ftl MoUNT/ 64 N.m {6.5 kgf.m,
BRACK€T 47 tbf.ftl
Replace.

t5. Install the control lever with a new lock washer to

the control shalt. then install the shift cable cover.

10 x 1.25mm CAUTION: Take care not to bend the shift cable.

44 N'm {4.5 kgf.m.
33 rbt'frl
SHIFTCABLE

CONTROL
8 x '1.25mm SHAFT
24 N.m (2.4 kgl.m,
17 tbf.trl

1 2 N . m 1 1 . 2k g f . m , l O x ' 1 . 2 5m m
8.7 rbt.ft) 43 N.m
14.4 kgf.m, 32 lbf.ltl

1 0 .Tighten the crankshaft pulley bolt to specified 6 x 1.0 mm

12 N.m
rorque. {1.2kgf.m,
8.7 lbl.rr)
TOROUE:177 N.m {18.O kgt.m, 130 lbf'ft}
SHIFT CABLE
COVER CONTROLLEVER

LOCK ASHER 6 x 1.0 mm

Replace. 1 4 N . m 1 1 . 4k g l . m ,
10 lbf.fr)

(cont'dl

14-165
Transmission
Installation{cont'd)

1 4 . Installnew set ringson the end of the intermediate
shaft and the driveshaft.
1 5 . Installthe intermediateshaft.
17. Installthe right and left drivershafts(seesection l6l.
NOTE: Turnthe right and left steeringknucklefully
outward, and slide the right driveshaft into the
differentialuntil you feel its springclip engagesthe
side geaf. Slidethe left driveshaftinto the intermedi-
ate shaft until you teel the springclip of the inter-
mediateshaft engagethe driveshaft.

18. Installright damperfork, then installthe right and

lett balljointsto eachlowerarm with the castlenuts
and new cotter Dins.
DAMPER PINCH BOLT
10 x 1.25mm
43 N.m 14.4 kgf.m,
32 tbr.ftl

SET RING
Beplace.

10 x 1
39 N.m
14.Okgf.m, 29 lbf.ftl
SHAFT

1 6 . Installexhaustpipe A. and connectthe heatedoxv-

gen sensor{HO2S)connector.
\
SELF.LOCKINGNUT COTTER
1 2 x 1. 2 5 m m Replace.
64 N.m (6.5 kgl.h, 47 lbt.ftl CASTLE NUT
Replace. 1 2 x 1 . 2 5m m
49-59 N.m
{5.O-6.0 ksf.m, 36-43 rbt'ft1
1 9 . I n s t a l tl h e s p l a s hs h i e l d .

SELF-LOCKINGNUT
GASKET
10 x 1.25mm
Replace.
54 N.m (5.5 kgl.m,
40 rbt.trl
Replace. SELF.LOCKINGNUTS
I x 1.25mm
22 N.m 12.2 kgl'n, 6 x 10 mm BOLT
16 lbt.trl
Repl6ce. cltPs, 5

14-166
20. Connectthe vehiclespeedsensor(VSS),mainshatt 23. Connectthe startercableto the startermotor, and
speed sensor and counterchalt speed sensor con install the cable holder.
nectors.
NOTE: When installingthe starter motor cable,
VEHICLESPEEDSEiISOR
makesurethat the crimpedsideof the ringterminal
CONNECTOR
is facing out (see section 23).

CABLE 6 x 1 . 0m m
'12 N.m (1.2 kgf'm,8.7 lbt.tl)
HOLDER

N.m
lO.9 ksr.m, 7 tbr-rtt

STARTERCAELE

2 4 . Installthe air cleanerhousingassemblyand intake

a r ro u c l .

AIR CLEANERHOUSING INTAKEAIR

ASSEMBLY DUCT
21. Connectthe lock-uDcontrolsolenoidvalveconnec-
tor and shift controlsolenoidvalveconnector.then
clampthe lock-upcontrolsolenoidharnesswith the
harnessstay.

22. Connectthe transmissionground cable.

LOCK-UPCONTROL
SOLENOIDVALVE HARNESSSTAY

25. Retillthe transmissionwith ATF(seepage '14-93).

26. Connectthe battery positive( + ) and negative( - )

cablesto the battery.

Startthe engine.Setthe parkingbrake,and shift the

transmissionthrough all gearsthree times.

24. Checkshitr cableadjustmentas describedon page

14-171
.

2 9 . C h e c kt h a t f r o n t w h e e la l i g n m e n(ts e es e c t i o n1 8 ) .

30. Letthe enginereachoperatingtemperature (thecool-

ing tan comeson) with the transmissionin S or @
position,then turn it off and check the fluid level.

3 1 . R o a dt e s t a s d e s c r i b e do n p a g e 1 4 - 9 o a n d 9 1 .

14-167
Transmission
CoolerFlushing

S!@ ro prevent iniury to tace and eyes, always 7. With the water and air valvesoff. attach the water
wear safety glas$esor a tace shieldwhen usingthe trans- and air supplies to the flusher. (Hot water it
mission flusher. available.)

NOTE: This procedureshouldbe performedbeforerein-

stallingthe transmission. OFF

1. Check tool and hoses for wear or cracks before

using.
lf wear or cracks are found, replacethe hoses be-
fore using.

2. Usingthe measuring cup, tillthe tankwith 21 ounces

{approximately213 lulll of biodegradabletlushing
fluid (J35944-20).Do not substitutewith any other
fluid.
Followrhe handlingprocedure on the fluidcontainer.

Securethe tlusherfillercap and pressurizethe tank

with compressedair to between 550-829 kPa
( 5 . 6 - 8 . 4 5 k g t / c m , ,8 0 - 1 2 0 p s i ) ,
NOTE: The air lineshouldbe equippedwith a water
trap to ensurea dry air system.
8. Turn on the flusherwater valve so water will tlow
throughthe oil coolerfor 1Oseconds.lf water does
not flow through the oil cooler it is completely
plugged,cannot be flushed,and must be replaced.

Hang the tool under the vehicle. 9. Depressthe triggerto mix the tlushinglluid into the
water tlow. Use the wire clip to hold the trigger
Attach the dischargehoseof the tank to the return oown.
line of the transmissioncooler using a clamp.
10. While flushingwith the water and flushingfluid for
6. Connectthe drainhoseto the inlet lineof the trans- 2 minutes.turn the air valveon for 5 secondsevery
missioncoolerusinga clamp.Securelyclampthe op- 15-20 secondsto create a surgingaction.
posite end of the drain hoseto a bucket or floor drain. AIR PRESSURE:
MAX 829 kPa (8.45 kgt/cm,, 12O psi)
DISCHARGEHOSE
1 1. Turn the water valve off. Releasethe trigger,then
reversethe hosesto the coolerso you can flush in
the oppositedirection.Repeatsteps 8 through 1O.

12. Releasethe triggerand allow water only to rinsethe

cooler with water for one minute.

13. Turn the water valve off and turn off the water
supply.

14. Turn the air valve on to dry the systemout with air
for two full minutesor until no moistureis visible
leavingthe drain hose.

CAUTION: Residual moisture in the oil cooler 01

pipes can damage the transmission.
DRAIN HOSE
15. Removethe flushertrom the coolerline.Attach the
TRANSMISSION
drain hose 10 a oil container.
TRANSMISSION
COOLERFLUSHEB
BUCKET CommorciallyAvailablo 16. lnstallthetransmissionand leavethe drainhose at-
KENT MOORE#J38405_A tached to the cooler line.

14-168
't 7. Make sure the transmission is in
@ position. TOOL MAINTENANCE
Then fill the transmission with ATF and run the en-
gins tor 30 sacondsor until spproximatelyons quart 1. Empty and rinse aftor each use. Fill the can with
iB discharged. water and pressurizethe can. Flush the discharge
line to ensurethat the unit is clean.
1 8 .Rsmove the drain hose and reconnect the cooler
return hoae to th€ transmission. 2. lf dischargeliquiddoesnot toam, the orificemay be
blocked.
1 9 .Refillth€ trsnsmission with ATF to the prop€r levol.
3. To clean,disconnectthe plumbingtrom the tank 8t
the large couplingnut.

4. Remov€the in-linefilter trom the dischargeside and

clean it necossarv.

5. The fluid orilice is located behind the tilter.

Cleanit with the Dickstoredin the boftom ot the tank
handleor blow it cl6anwith air. Securelvreassem-
ble all Darts.

FILLERCAP
COUPLII{GI{UT

FILTER

---0--L--

I
O.BI G ORIFICE

14-169
shift cable
Removal/lnstallation

3. Removethe shift cable bracket.

a All SRS electrical wiring hamosses are covor€d with
yellow insulation.
a Before disconnecting any pan ot th€ SRS wire har-
noss, connect the short connectorc(soepage 23-7O1.
a Roplaceth€ entiro attect€d SRS haness assembly it
it has an open circuit ot damaged wi.ing.

6x1.0mm
1 2 N . m 1 1 . 2k g f . m , 4 . 7l b f . f t l

4. Removethe shitt cable holder.

@@[ uar" sul€ litts are placed proparty {so6
section 1). 5. Removethe shift cable cover.

1. Removethe center console {seesection 20). 6. Removethe control leverfrom the control shaft, then
removethe shift cable.Take care not to bend the
2. Shift to N position.then removethe lock pin from cable when removing/installing it.
the cable adjuster.

SHIFT CABLE I{OLDER

@J^ll
AJUI
[qJ ]l tl
---l

LOCK NUT
7 N.m 12 N.m 11.2 kgf.rh, 8.7 lbf.ftl
(O.7 kgf.m, 5 lbf.ft)
14 N.m 11.4 kgl.m, 10lbt.ft)

7 . Installthe shift cable in the reverseorde. of removal.

8. Checkthe cableadjustmenton reassembly,

on page
14-171.

14-170
 Adjustment

CAUTION: 4. Check that the hole in the adiuste. in perfectly

a All SRS electrical widng harn€ssesare covar€d with alignedwith the hole in the shift cable.Thereare two
yollow insulation. holes in the end of the shitt cable, They are posi-
a Before disconnecting any part of ths SRS wire har- tioned 9Oo apart to allow cable adiustmentin 1/4
ness, connect the shon connectors(seepage 23-701. lurn Incremenls.
a R€placethe entire affected SRS halnass asssmbly it
it has an op€n circuit or damaged wiring.
ADJUSTER

Cable Cable Exact

I oo snon Too Long Alignment

@ tu"t" sure lifts a.e placed properly ls66 5. It not perfectlyaligned,loosenthe locknut on the
ssction 1). shift cable and adjust as required.

'1.
Start the engine.Stritt to @ positionto see if the
reversegear engages.lf so, refer to troubleshoot-
ing on page 14-86 thru 89.
Wilh the engineoff, removethe centerconsole{see
section 20).
Shilt to N position.then removethe lock pin from
the cable adjuster.
6. Tightenthe locknut to 7 N.m (O.7kgf.m, 5lbf.ft).
7. Installthe lock pin on the adiuster.lf you feel the
lock pin bindingas you reinstallit, the cable is still
out of adjustmentand must be readjusted.
8. Move the selector to each gear and verify that the
automatictransaxlegear positionindicatortollows
the automatictransaxlegear positionswitch.

9. Startthe engineand checkthe shift leverin allgea.s.

]H
lf any gea. does not work properly, refer to
@ troubleshootingon page 14-86 thru 89.
@
@ 1O. lnsert the ignitionkey into the key cylinderon the
shift indicatorpanel,ve.ify that the shift lock lever
is released,

''fidlfr
/ I
t+@ \
\ /
CABLE -.'.-_--l../
ADJUSTER

14-17 1
GearshiftSelector
Disassembly/Reassembly
CAUTION:
a All SRS electrical wiing haln€ssss are covered with
y6llow insulation.
a 8€fore disconnecting 8ny pan of the SRS wire har-
neaa.connOctth6 short connectors(sse page 23-701.
a Roplacethe entire affected SRS hahess assembly if
il has an opon circuit or damaged wiring.

SRS MAIN HARNESS

[E--__ rocK ptN

ADJUSTER
9.8 N.m {1.O kgf.m, 7.2 lbf.frl

SHIFT LOCK SOLENOID

-6{
stLtcoNE LEVERCOVER
GREASE
e-

-#q
SILICONEGREASE

CONTROLBRACKET LOCK PIN ROD

5 N.m (0.5 kgt.m, 4 lbt.ftl

@6
9.8 N.m (1.0 AUTOMATIC TRANSAXLE
7 .2 tbt.ltl GEAR POSITIONSWITCH
SELECTLEVERBRACKET
Testing,see Section23

CONTROLSEAL

12 N.m (1.2 kgf.m, 8.7 lbf.ftl

9 . 8 N . m 1 1 . 0k g f ' m , 7 . 2 l b f . f t l

14-172
Shift Indicator Panel
Adjustmet

CAUTION: 1 . Check that the index mark on the indicatoraligns

a All SRS olectrical wifng harnessesaro covered with
yellow insulation.
a Bofors disconnecting any pan of the SRS wire har-
ness, connect tho sho.t connectors{sse page 23-7O),
a Replacethe entire aflect€d SRS harness assembly if
it has an open circuit or damaged wiring,
with the N]mark on the shift indicatorpanelwhen
the transmissionin NEUTRAL.
lf not aligned,removethe centerconsole(seesec-
tion 2O).
Removethe shift indicatorpanelmountinqscrews
and adjust by moving the panel.

NOTE: Wheneverthe shift indicator panel is re-

moved, reinstallthe panel as describedabove.

INDEXMARK

@
@
@

SRS MAIN HARNESS

MOUNTING SCREW
3 N'm lO.3 kst.m, 2 lbf.ftt

14-173
Throttle Control Cable
Inspection

the throttlecontrolcable,make
NOTE: Betoreinspecting
sure:
a Throttle cable free play is correct (seesection 1 1).
a ldle speed is correct (see section 1l).
a To warm up the engineto normaloperatingtempera-
ture {the coolingfan cor'reson)
Verify that the throttlecontrollevelis synchronized
with the thronlelinkagewhiledepressing and releas-
ing the acceleratorpedal.
lf the throttlecontrolleveris not synchronizedwith
the throttle linkage.adjust the throttle control cable.

1. Verifythat the throttlecontrolcableis clampedcor-

rectly with three positions.

,r: \

14-174
4. Check that there is play in the th,ottle control lever
while dep.essing the accelerator pedsl to th€ full
throttle Dosition.

F.o. play

Remove the cable end of the th.ottle control cable

from the throttle control lever.

o. Check that the throttle control lever moves

smoothlv,

14-175
Throttle Control Cable
Adjustment
NOTE: Beforeadjustingths throttle control cable, make 4. Remove the free play of ths throttl6 control cabl€
sute: with the locknut, whils pushing thg throttlo control
leve. to the full-closed Dotision as snown,
a Throttle cable free play is correct {see section 11).
a ldle speed is correct (seesection 11).
a To warm up the engine to normal oporsting tempera-
ture {the coolinglan comes on}.

I. Verify that the throttle control c8ble is clamDedcor-

rsctly with three positions.
THROTTLE ATF COOLER
COI{TROL
CABLE PIPE

Clamp on blu6

5. Tighten the locknuts.

CLAMP

Verify that the throttle linkage is in the full-closed

position.

5. Loosen the locknut of the throttle control cable at

the throttle linkage.
THROTTLELII{KAGE

After tightening the locknuts, inspect the synchroni-

zation and throttlg control l6ver movemenr.

LOCKI{UTS

14-176
Differential

ManualTransmission
81881 engine 15-1
8 1 8 C 1e n g i n e. . . . . . . 15-9
AutomaticTransmission ..................
15-19
Differential(81881 enginel

S p e c i aTf o o l s. . . . . . . . ........15-2
Differential
lllustrated Index......... . 15-3
BacklashInspection .... 15-4
FinalDrivenGearReplacement ...... 15-4
BearingReplacement 15-5
....................
Oil SealRemoval ........15-5
SideClearance Adiustment...........15-6
Oil Seallnstallation ..... 15-8
 SpecialTools

Ref. No. I Tool Numbol Description Oty I Pag€ Reference

o oTJAD-PH80101 Seal DriverAttachment 15-8
07746-OO30100 D r i v e r ,4 0 m m l . D . 15 - 5 . 6
ra) o7749-OO10000 Driver 15-8
@ o7947-SO90200 Seal DriverAttachment 15-8

o (^

I A
s
F

$-l)

o @

15-2
Differential(B1881 engine)
lllustrated Index

OIL SEAL Replace.

Removal,page 15-5
Installation,page 15-8

FINAL DRIVENG€AR
Inspectfor wear and damage,
Replacement, page 15-4

DIFFERENTIALCARRIER
Inspection.page 15-4

BALL BEARING
Inspect lor wear and operation.
Replacement, page 15 5

BALL BEARING
Inspect for wear and operation.
Replacement, page'15-5

10 x 1.0 mm
101 N.m llO.3 kgt'm,74.5 lbf.ftl
Left-handthreads

80 mm SHIM
Selection,page 15-6

'l5-5
Removal,page
lnstallation,page 15-8

15-3
Differential(818B1 enginel
BacklashInspection FinalDrivenGearReplacement
'1.
Placedifterentialassemblyon V-blocksand install 1 . Remove the bolts in a crisscross Datt€rn in several
both axles. steps, and remove the final driven gear from the
differentialcarrier.
M€asurethe backlashof both pinion gears.
NOTE: The final driven gear bolts have left-hand
Standard(New):0.05-O.15mm (0.OO2-0.006 inl threads.
1 0 x 1 . 0m m
101 N.m llO.3 kgl.m,74.5 lbf.ftl
Lelt-handthreads
DIAL II{OICATOR

FINAL DRIVEIIIGEAR
Chamfer on inside diameter ot
linal driven gear taces carrier.

DIFFEREI{TIAL
CARBIER

3. It the bscklsshis not within the standard,reDlace Installthe final driven gear by tighteningthe bolts
the differential carrier. in a c.isscross pattern in several steps.

15-4
 Bearing Replacement Oil Seal Removal

NOTE: Checkthe ball bearingsfor wear and rough ro-
tation. It bearingsare OK, removalis not necessary.
1. Removethe ball bearingsusing a standatdbearing
puller and bearingseparatoras shown.
1 . Remove the ditterential assembly.
Remove the 8O mm shim from the transmission
housing.

BEARINGPULLEB

80 mm SHIM

TRA[{SMtSStON
HOUSING

3. Removethe oilseal from the t.ansmissionhousing.

BALL BEARING

Installnew ball bearingsusing the specialtool as

snown.

NOTE: Drivethe bearingssquarelyuntil they bot-

tom againstthe carrier.

DRIVER,40 mm l.D.
07746-0030100

4. Removethe oil seal from the clutch housing,

BALL BEARING

OIL SEAL
R€plac6.

15-5
Differential(81881 engine)
Side ClearanceAdjustment
l. Installthe diflerentialassembly,makingsureit bot- ? Installthe transmissionhousing(seesection 13).
toms in the clutch housing.usingthe specialtoolas
shown. NOTE: Do not applyliquidgasketto the matingsur-
,ace ot the clutch housing.

4. Tighten the transmissionhousing attaching bolts

(see section 13).

8 x 1.25 mm
27 N.m 12.8 kgf'm, 20 lbf.ftl

Usethe specialtool to bonom the differentialassem-

bly in rhe clutch housing.

tt. Measure clearance between the 80 mm shim and

bearing outer race in the transmission housing.

HOUSING

2. Installthe 80 mm shim.

NOTE: Instsllthe 80 mm shim that was removed.

mm SHIM

15-6
'l
lf the clearanceis not within the standard, select a
new 80 mm shim from the following table.
Strndard: 0-O.1O mm (O.O04inl
8 . Remove the bolts and transmission housing.
9 . Replacethe 8O mm shim selected in step 7, thon
recheck the clearance.

8O mm Shim 1 0 . Reassemblethe transmission and install the trans-

missionhousing{see section 13).
Pan Number Thicknoss
A 41441-PL3-BO0 1 . Om m 1 0 . 0 3 9 4i n )
B 41442-PL3-BOO 1 . 1 m m ( O . O 4 3 3i n )
41443-PL3- BOO 1 . 2 m m ( O . O 4 7 2i n )
D 41444-PL3-BOO 1 . 3 m m ( 0 . 0 5 1 2i n )
E 41445-PL3-BO0 1 . 4 m m { 0 . 0 5 5 1i n l
f 41446- PL3-BO0 1 . 5 m m ( O . O 5 9 1i n )
41447-PL3 -BOO 1.6 mm (0.0630in)
H 41448-PL3- B00 1 . 7 m m ( 0 . 0 6 6 9i n )
J 41449-PL3- BO0 1 . 8 m m ( 0 . 0 7 0 9i n l
K 41450- PL3-BOO 1 . 0 5m m { o . o 4 1 3i n l
L 4 1 4 5 1 - P L 3 - B O O 1 . 1 5m m ( 0 . 0 4 5 3i n )
M 4 1 4 5 2 - P L 3 - B O O 1.25 mm (O.O492 in)
N 4 1 4 5 3 - P L 3 - B O 0 1. 3 5 m m ( 0 . 0 5 3 2i n )
P 41454-PL3-BOO 1 . 4 5 m m ( 0 . 0 5 7 1i n )
o 41455-PL3-BOO 1. 5 5 m m ( 0 . 0 6 1 Oi n )
R 41456-PL3-800 1 . 6 5 m m ( 0 . O 6 5 0i n )
s 41457 - PL3-BOO 1 . 7 5m m ( 0 . 0 6 8 9i n )
T 41441-P21-OOO 1 . 8 5 m m ( 0 . 0 7 2 8i n )
U 41442-P21-OOO 1.90 mm (o.o748in)
41443-P21-OOO 1 . 9 5 m m ( 0 . O 7 6 8i n )

NOTE: lf tho clearancemeasuledin step 6 is within

th€ standard, it is not necessary to go to step 9.

15-7
Differential(8188l enginel
Oil Seal Installation

1. Installthe oil sealinto the t.ansmissionhousingus- Installthe oil seal into the clutch housingusingthe
ing the specialtools as shown soecialtools as shown.

DRIVER DRIVER
07749-0010000 07749-0010000

OIL SEAL OIL SEAL

Replsce. Replace.

HOUSING

15-8
Dif f er en ti a(8
l 18C1enginel

S p e c i aT l ools ........ 15 - 1 0
Differential
l l l u s t r a t e dI n d e x . . . . . . . . . 1 5 - 11
BacklashInspection 15-12
F i n a lD r i v e nG e a rR e p l a c e m e n.t. . . . . 15-12
TaperedRollerBearingReplacement.1 5 - 1 3
Oil Seal Removal 15-13
BearingOuter Race Replacement... 15-14
TaperedRollerBearingPreload
Adjustment 15-15
Oil Seal Installation 15-17
 SpecialTools

Ref. No. I TootNumber I Descriprion Oty I Page Reference

o
(
oTHAJ-PK40201 PreloadInspectionTool I 1 5 - 15
oTJAD-PH80101 Seal DriverAttachment I 15- 14
,a\ oTNAD-PX40100 DriverAttachment 1 1 5- 14
@ o7746-O030'l
OO Driver,40 mm l.D. I 15-131 4
r.l o7749-OO10000 Driver I 15- 14 1 7
@ o7947-SD90200 Seal Drive. Attachment 1 15 - 1 7

I o rt\ aa\

$
s

@ tl

15-10
Differential(B18C1 engine)
lllustrated Index

NOTE: lf the ' mark parts were replaced,the tape.ed roller bearingpreloadmust be adiusted(see page 15-15).

OIL SEAL Replace.

Removal,page 15-13
Installation,page 15-17
'THRUST SHIM
T. 2.5 mm lO.O98inl

TAPERED ROLLER BEARING

Inspectfor wear and oporation.
Replacement, page'15-13

}DIFFERNTIALCARRIER
*BEARING OUTERRACE Inspection,page 15-12
Inspect tor wear and damage.
Replacement. page 15-14
10 x 1.0 mm .TAPERED ROLLERBEARING
101 N.m 11O.3kgt.m,74.5 lbt.ft) Inspect for wear and operation.
Left-hand threads Replacement, page 'l5-13
FINAL DRIVENGEAR
Inspectlor wear and damage.
Replacement, page 15-12

T. 2.0 mm (0.079 inl

*79.5 mm SHIM
Selection,page 15-16

OIL SEAL Replace.

R e m o v a lp, a g e ' l 5 - 1 3
Installation,page 15-17
Differential(818C1 enginel
BacklashInspection
Placeditterentialassemblyon V-btocksand instatl
both axles.
Measurethe backlashof both pinion gears.
Standard(Now):0.o5-o.15 mm {0.oo2-0.O06 in)
lf the backlashis not within the standard,reDlace
the differentialcarrier,
15-12
FinalDrivenGearReplacement
1. Romovethe bolts in a crisscrossDatternin several
steps, and remove the tinal driven gear f.om the
differentialcarrier.
NOTE: The tinal driven gear bolts have lett-hand
threads.
1 0 x 1 . Om m
101 N.m (10.3 kgt.m, 74.5 lbf.ftl
Left-hand threads.
FII{AL DN|VENGEAR
Chamfer on inside diameter
of linal driveng€ar taces carrier.
DIFFERETTTIAL
CABRIER
Installthe final driven gear by tighteningthe bolts
in a crisscrosspattern in severalsteps.
 TaperedRollerBearingReplacement oil SealRemoval
NOTE: 1 . Removethe differentialassembly.
a The tapered roller bearingand bearing outer race
should be replaced as a set. Removethe oil sealfrom the transmissionhousing.
a Inspectand adjustthe taperedrollerbearingpreload
whenevef the taperedrollef bearingis replaced.
a Checkthe taperedrollerbearingstor wear and rough
rotation.lf taperedrollerbearingsare OK, removalis
not necessary.

1. Removethe taperedrolle. bearingsusinga bearing

puller and bearingseparatoras shown,

BEARING

BEARII{G
SEPANATOR
(Commercially
available)

3. Removethe oil seal from the clutch housino.

Installnew taperedrollerbearingsusingthe special

tool as shown.

NOTE: Drivethe taperedrollerbearingson until they

bottom againstthe differentialcarrier.

15-13
Differential(B18c1 eng:nel
BearingOuter RaceReplacement
CAUTION: Do not rous€ the thrust lhim and tho 79.8 4. Installthe new thrust shim and 79.5 mm shim,then
mm shim il tho outer rac6 was ddvon out. drive the bearing outer races in the both housings
using the specialtools as shown.
NOTE;
a The bearing outer race and taper€d toller bearing NOTE:
should be reDlacedas a set. a Install the bearing outsr race squarely.
a Inspect and adjust the tapered roller bearing proload a Check that there is no clearance between tha
whenever th€ tapered roll€f bearing is roplac€d. bearingouter race, thrust shim, and transmission
housing.
1. Removethe oil seals from the transmissionhousing
and clutch housing(see page 15-13).
BEARIl{G
OUTER
2. Removethe bearingouter raca, the thrust shim, and
the 79.5 mm shim from th€ transmissionhousing.

TRANSMtSStOl{
HOUStl{c

Removethe bearingouter racs and thrust shim trom

the clutch housing.

07749-OOTOOOO
ONNER
ATTACHMENT
OTttAD-PX/IOlOO

5. lnstallthe oil sesl (see page 15-171.

15-14
 Tapered Roller BearingPreloadAdjustment

NOTE: lf any of the items listedbelow were replaced,
the taperedrollerbearingpreloadmust be adjusted,
a Transmissionhousing
a Clutch housing
a Diffe.entialcarrier
a Taperedrollerbearingand bea,ingouter race
a Thrust shim
1. Removethe bearingouterrace,the thrust shim,and
the 79.5 mm shim from the transmissionhousing
(see page 1 5- 14).
CAUTION: Do not reuss lhe thrust shim it the bear-
ing outer raco was driven out.
2. First t.y the same size 79.5 mm shim that was
removeo.
CAUTION; Do not uso moro than two shims.
Instsllthethrustshim and 79.5 mm shim,then drive
the bearingouter race in the transmissionhousing
{ s e ep a g e l 5 - 1 4 ) .
NOTE:
a Installthe bearingouter race squarely.
a Check that there is no clearancebetween the
bearingouter race.thrust shim and transmission
housing.
4. With the mainshaftand countershaft.emoved,in-
stsllthe differentialassembly,andlorquethe clutch
housingand transmissionhousing,
8 x 1.25 mm
27 N.m 12.8 kgf.m, 20 lbf.ft)
NOTE: lt is not necessaryto use sealingagent be-
tween the housings.
Rotate the ditterential assembly in both directions
to seat the taperedrollerbearings.

o. Measurethe starting torque of the differenlialassem-

bly with the specialtool and a torque wrench.
79.5 rnm SHIM
NOTE: Measurethe taperedrollerbearingpreload
in both directions.

STANDARD:2.1 1 -3.O4 N.m

(21.5-31.0 kgf'cm,
18.7-26.9 lbf.inl

HOUSING

{cont'd}

15-15
Differential(B18C1 enginel
TaperedRollerBearingPreloadAdjustment(cont'dl
7. It the taperedrollerbearingpreloadis not within the
standard,selectthe 79.5 mm shimlrom the follow-
ing table which will give the taperedrollerbea.ing
preloadclosestto the standardmeanvalueof 2.50
N . m ( 2 5 . 5 k g J . c m ,2 2 l b f . i n ) .
NOTE: Changingthe 79.5 mm shimto the next size
will increase or decreasetapered roller bearing
p r e l o a da b o u t O . 3 - O . 4 N . m ( 3 - 4 k g f . c m ,
2 . 6- 3 . 5 l b t . i n ) .
79.5 mm SHIM
Recheckthe taperedroller bearingpreload.
9 . How to selectthe correct 79.5 mm shim:
- 1) Comparethe taperedrollerbearingpreloadyou
get with the 79.5 mm shim that was removed
with the specifiedmean preloadof 2.50 N.m
(25.5 kgf.cm. 22 lbf.inl.
-2) lf your measuredtaperedrollerbearingpreload
is lessthan specified,subtractyour's from the
soecified.
lf your's is more than specified,subtractthe
specifiedfrom your measurement.

Part Numbel Thickness Forexamplewith a 1.38 mm (O.O543in) shim:

41460-PY4-000 0 . 6 6 m m ( 0 . 0 2 6 0i n )
@ specified2.50 N.m (25.5 kgf.cm, 22 lbf.in)
AB 41461-PY4-000 1 . 1 7 m m ( O . 0 4 6 1I n , - you measure0.54 N.m (5.5 kgt.cm, 5lbt'in)
AC 41462-PY4-000 1 .2O mm (0.0472 in) 2 . 0 N . m { 2 0 k g f . c m ,1 8 l b t . i n }l e s s
AD 41463-PY4-000 1 . 2 3 m m ( O . O 4 8 4i n )
AE 41464-PY4-000 1 . 2 6 m m ( 0 . 0 4 9 6i n ) @you measure 3.29 N.m {33.5kgl.cm,29 lbl.in)
- specified
2.50 N.m {25.5kgf.cm,22 lbf.in)
AF 41465-PY4-OOO 1 . 2 9 m m ( O . O 5 O i8n )
0.8 N.m (8 kgf.cm,7lbt.in) more
AG 41466-PY4-OOO 1 . 3 2 m m ( O . O 5 2 O
in)
AH 41 467-PY4-0001 . 3 5 m m { O . O 5 3 1i n ) 3) Each shim size uD or down from standard
makesabout O.3-O.4 N.m (3-4 kgf.cm,
AI 41468-PY4-000 1 . 3 8 m m ( O . O 5 4 3i n )
2.6-3.5 lbf.in) difJerencein tapered roller
AJ 41469-PY4-000 1. 4 1 m m ( O . 0 5 5 5i n ) bearingpreload.
AK 41470-PY4-OOO 1 . 4 4 m m ( 0 . 0 5 6 7i n )
a In example@, your measuredtaperedroller
AL 41 47 1-PY4-OOO 1 . 4 7 m m ( 0 . 0 5 7 9i n )
bearingpreloadwas 2.O N.m (20 kgf'cm,
AM 41 47 2-PY4-OOO 1 . 5 0 m m { O . O 5 9 1i n ) I 8 lbl.in) less than standard so you need a
AN 41473-PY4-000 1. 5 3 m m ( 0 . 0 6 0 2i n ) 79.5 mm shim five sizesthickerthsn stan-
dard {trv the 1.53 mm (0.0602 inl shim and
AO 41 47 4-PY4-OOO 1 . 5 6 m m ( 0 . 0 6 1 4i n ) recheck).
AP 4 1 4 7 5 - P Y 4 - O O O ' l. 5 9 m m ( O . 0 6 2 6i n ) a I n e x a m p l e@ y o u r ' s w a s O . 8 N . m ( 8
AO 4'1476-PY4-O00 1 . 6 2 m m ( 0 . 0 6 3 8 i n ) kgf.cm, 7 lbJ.in)more than standard, so
you needa thrust shim two sizesthinner (try
AR 41 47 7 -PY4-OOO 1. 6 5 m m ( 0 . 0 6 5 0 i n ) the 1.32 mm (0.0520in) shimand recheck).
AS 41478-PY4-000 1. 6 8 m m { 0 . 0 6 6 1 i n )
1 0 . After adjustingthe tapered.oller bearingpreload,as-
41479-PY4-OOO 1 . 7 1 m m ( O . 0 6 7 3i n )
semblethe transmission, and installthetransmission
AU 41480-PY4-OOO 1 . 7 4 m m ( 0 . 0 6 8 5i n ) housing{see section 13).
41481-PY4-OOO 1 . 7 7 m m { 0 . 0 6 9 7 i n }
8 x 1 . 2 5m m
41442-PY4-OOO 1 . 8 0 m m ( O . O 7 O i9n )
27 N.m 12.8 kgt.m. 20 lbf.ttl
AX 41483-PY4-OOO 1 . 8 3m m ( 0 . 0 7 2 0i n l
1 1 .Rotatethe diJJerential
assemblvin both directions
to seat the taperedrollerbearings.

15-16
 Oil Seal lnstallation
1 . lnstalltheoil seal into the transmissionhousinqus- Installthe new oil sealinto the clutch housingusing
ing the specialtools as shown. the soecialtools as shown.

DRIVER DRIVER
07749-OOIOOOO 07749-OOlOO00

OIL SEAL OIL SEAL

Replace. Replace.

HOUStl{G

15-17
Differential(AutomaticTransmissionl

S p e c i aTl o o l s . . . . . . . . . . . . . . . .1 5 - 2 0
Differential (Automatic Transmission)
f l f u s t r a t eIdn d e x . . . . . . . . . .15-21
BackfashInspection .... 15-22
B e a r i n gR e p l a c e m e n.t. . . . . . . . . . . . . . . . . 1 5 - 2 2
DifferentialCarrierReplacement.... 15-23
O i l S e a fR e m o v a l ........15-24
Oil Seal Installation/
S i d eC l e a r a n c .e. . . . . . . . . . . . 15-24
SpecialTools

Ref. No. I Tool Number Dascription Oty I Pago Retelonco

o
r^
oTJAD-PH80200 Pilot, 26 x 30 mm 1 15-26
oTNAD-P200100 Driver, 52 x 55 mm 1 15-26
aa) 07746-0030100 Driver,40 mm l.D. 1 15-22,24,25
07749-0010000 Driver 't 5-26
@ I
o7947-SD90200 OriverAttachment 1 15-26

o @ o

@ @

15-20
Differential(AutomaticTransmissionl
lllustrated Index

FINAL DRIVENGEAR

BALL BEARING

ENTIAL.ARRIER

--ttot"'

' - 6
ROLLER.5xlOmm

BALL BEARING

15-21
Differential(Automatic Transmission)
BacklashInspection BearingReplacement
1 . Placethe differentialassemblyon V-blocksand in- NOTE: Checkthe bearingsfor wear and roughrotation.
stall both axles. lf the bearingsare OK, removalis not necessary.

Check backlashof both pinion gears. 1. Removethe ball bearingsusing a bearingpuller.

Standard(New):0.05-O.15 mm (0.002-0.006 inl

BEARINGPULLER

SIDE GEARS

BALL BEAING

3. lf backlashis out of tolerance,replacethe differen- Installthe new ball bearingsusing the specialtool
tial carrier. with a Dressas shown.

DRIVER,40 mm l.D.
07746 0030100

15-22
 DifferentialCarrierReplacement
1 . Remove the final driven gear from the differential 5. Align the hooked end of the snap ring with the pin-
carrier. ion shaft as shown, then installthesnap ring in the
diff€rential carrior groove.
NOTE: Tho final driven gear bolts have left-hand
threads. SI{APRII{G
Hooksd €nd Installin this direction.
Pry the snsp ring ofl differentialcarrier.then remove
the speedometerdrive gear 8nd 5 x 1O mm roller.

DRIVE GEAR
o. Install the final driven gear, then tighten the bolts
to th6 spscified torque.
5. lnstall th6 5 x 1Omm roller in the differentisl csrrier'
TOROUE:101 N.m (10.3 kgf.m, 74.5 lbf.ft)
4. Installthe speedom€terdrive gear with its chamfered
side facing the carrier, Align the cutout on the bore NOTE: The final driven gear bolts have left-hand
of the speedometerdrive gesr with the 5 x 10 mm threads.
roll€r.

BOLTS
10 r 1.0 mm
lOi N.m (1O.3 kgf.m,
SPEEDOMETEB 74.5 tbt'ft)
DRIVEGEAR Left-hand thrgads
Instsllin this
diroction.

7. Installthe ball bearings{see page 15-22).

15-23
Differential(Automatic Transmissionl
Oil Seal Removal
1 . Removethe differentialassembly.
2 . Removethe oil sealfrom the transmissionhousino.
Oil Seal Installation/SideClearance-
1. lnstalla2.50 mm (O.O98in)thrustshim in the rrans-
missionhousing.
NOTE: Do not installthe oil seal yet.

TRAt{SMtSStON
HOUSING

TRANSMISSIO
OIL SEAL HOUSING
Replace.

seal from the rorque convener Installthe differentialassemblyinto the torquecon_

v€ner housingusing the specialtool as shown.

DRIVER,40 mm l.D.
07746-OO30100

DIFFERENTIAL
ASSEMBLY

/-l TOROUECONVERTER
HOUSING

Assemblethe transmission(see section 14).

Installthe transmissionhousingand tighten the bolts
TOROUECONVERTER (see section 14).
HOUSING

15-24
Tap on the transmissionhousingsideof the differen- Measurethe clearancebetween the thrust shim and
tial assembly with the special tool to seat the outer race of the ball bearingin the t.ansmission
dilferentialassemblyin the torque converterhousing. housing.

STANDARD:O-0.15 mm {0-O.OO6 in}

lf out of limits, selecta new thrust shim from the

following table:

THFUSTSHIM, 80 mm

Pan Numb€r Thickness

90414-689-OOO 2.50 mm (O.O9843in)
90415-689-OOO 2.60 mm {0. I 0236 in)
90416-689-000 2 . 7 0 m m ( O . 1 0 6 3 0i n )
9041 7- 689-000 2 . 8 Om m ( O .1 1 O 2 4i n )
904r 8-689-OOO 2 . 9 0 m m ( 0 . 11 4 1 6 i n )
90419-PH8-OOO 3.OOmm{O.11811in)

NOTE: It the thrust shim-to-ballbearingouter race

clearancemeasuredin step 5 is lessthan the specifi-
cation, it is not necessa.yto pertorm steps 7 and 8.

Removethe transmissionhousing.

8. ReDlacethe 2.50 mm (0.098 in) thrust shim with

the one oJ the correct thickness selected in step 6.

9. Installthe transmissionhousing(see section 14).

(cont'd)

15-25
Differential(Automatic Transmissionl
Oil Seal Installation/SideClearance
(cont'dl
9. Installtheoil sealin the transmissionhousingusing
the specialtools as shown.

DRIVER
07749-0010000

ATTACHMENT
07947 -SD90200

PILOT
26x30mm
oTJAD-PH80200

10. Installthe oil seal in the torque converterhousing

using the specialtools as shown.

DFIVER
07749-0010000

DRIVER,52 x 55 mm
oTNAD-P200100

15-26
SpecialTools
R!t. No. I Tool Numbcr
o 07JAF- SH20400
@ 07LAD- PW50601
o 07MAC- 5100200
@ 07746- 0010300
@ 07746- 0010400
@ 07746- 0030400
o 07749- 0010000
@ 07965- SD90100
16-2
D.lcription Oty I Psgo Rctcr.nct
Suppon BsseAttachment 1 1 6 -1 3
Attachment,40 x 50 mm l.O. 1 16-14
BallJoint Remover,28 mm 1 16-4
Anachment, 42 x 47 mm 1 16-13
Attachment,52 x 55 mm 1 16-14
Attachment,35 mm l.D. 1 16-'r4
Driver 1 1 6 - 1 31, 4
Support Bas€ 1 16-13
(4,
Driveshafts
Inspection Removal
DriveshaftBoot Loosenthe wheel nuts slightly.
Checkthe boots on the driveshaftfor cracks,damage,
leakinggreaseor looseboot bands. Raise the front of car and support it with safety
l f a n y d a m a g e i s f o u n d , r e p l a c et h e b o o t a n d b o o t standsin the properlocataons(seesection1),
Danos.
Removethe wheel nuts and front wheels,
Looso Splines
Turn the driveshaftby hand and make sure the splines Drainthe transmissionoil or fluid (seesection13 or
and joint are not excessivelV
loose. 14).
lf damageis found, replacethe inboardjoint,
NOTE:lt is not necessary to drainthe differentialoil
Twistod or Cracked when the left driveshaftis removed.
Makesurethe driveshaftis not twistedor cracked.
Replaceit if necessarv. R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut.

WHEELNUT
DBIVESTIAFT

Replace.
6. Removethe self-lockingnut and self-locking
bolt.
EOOTBANDS
GAUTION: Roplacoth€ s€lt.locking bolts if you can
sasily thread a non€elf-locking nut prst thoir nylon
locking inserts.
(lf should require I N.m (0.1 kgt.m, 0.7 lbf.ft) ol
torqus to turn lhs nut on the bolt).

Removethe damDerfork.

SELF.LOCKINGBOLT
10 x 1.25mm

SELF-LOCKINGNUT
12 x 1.25mm
Replace.
(cont'dl

16-3
Driveshafts
Removal(cont'dl
8. Removetha cotter pin from the lower arm ball joint
castlenut, and removethe nut.
9. Installa 12 mm hex nut on the ball ioint. Be sure
that the hex nut is flush with the ball joint pin end,
or the threaded section of the ball ioint pin might be
damag6dby the balljoint remover.
10. Use th€ ball joint remover, 28 mm, as shown on
page 18-11.to separatethe ball joint and lower arm.
CAUTION: Bo crrolul not to damrgo th. ball ioint
boot.
NOTE: lf necesssry,apply penetratingtype lubri-
cant to loosenthe ball joint.
1 1 . Pry the driveshaft assembly with a screwdriver, as
shown, to force the set ring at the driveshaftend
past the groove.
SCREWDRIVER
16-4
12. Pull the inboardjoint, and removeth6 right drive-
shaft from the differentialcase as an assemblv.
CAUTION:
. Do not pull on tha dlivo3haft, a! th! inborrd
ioint may comc !p!rt,
. U3c carc when prying out tha a$qnbly, lnd pull
it rtraight to lvoid drmlging thc diftcrrntial oil
soal or thc int.rmcdirto shrft outel saal.
SCREIYDRIVER
- Left Driveshaft:
Removethe left driveshaftfrom the bearing sup-
port by tapping the inboard joint of the drive-
shaftwith I Dlastichammer.
BEARINGSUPPOFT
13. Pullthe knuckleoutward,and removethe driveshaft 1 . Removethe set ring from the inboardjoint.
outboard joint from the front wheel hub using I
Dlastichammer. To removethe boot band, pry up the lockingtabs
with a screwdriverand raisethe end of the band,

CAUTION: Taks caro not to damagc thc boot.

KNUCKLE
NOTE:Carefullyclamp the driveshaftin a vise with
soft iaws.

DRIVESHAFT

SET RING
Replace.

- lf the boot band is the welded type, cut it off as

snown,

16-5
Driveshafts
Disassembly(cont'd)
3, Mark each roller and inboard joint to identify the 9. Wrap the splineson the driveshaftwith vinyltape to
locationsof rollersand groovesin the inboardjoint. preventdamageto the bootsand dynamicdamper.
Then removethe inboardjoint on the shop towel.
10. Removethe boot bandand inboadboot.
NOTE: Be carefulnot to drop the rollerswhen sepa-
ratingthem from the inboardjoint. CAUTION: Take car. not to damageth€ boot.
INBOARD JOINT
Checksplines tor w6aror damage. 1 1 . R e m o v et h e d y n a m i cd a m p e r b a n d a n d d y n a m i c
Ch€ckinsideborefor wear. damoer.
Inspecttor cracks.
CAUTION: Tako cars not to damage the dynamic
damper.

12. Removethe boot bands and outboard boot, then

removethe vinyltape.

CAUTION: Take csre nol to damagetho boot.

INBOARD BOOT DYNAMICDAMPER
Inspectlor cracking, Checktor damage.
splitting
andwear.

DYNAMICDAMPER

Marka

Mark the rollersand spiderto identifythe locations

of rollerson the spider.Then removethe rollers.

Removethe circlip.

o. Mark the spider and driveshaftto identifythe posi-

tion of the spideron the shaft.
OUTBOARD BOOT
Removethe spider using a commerciallyavailable lnspectfor cracking,
spliningandwear.
bearingremover.
13. Inspectthe outboardjoint for faulty movementand
Removethe stopperring. wear. lf any roughnessor excessplay is felt, replace
BEARING the outboardjoint.

14. Checkthe outboardring for damage.

,'0
CIRCLIP
STOPPER
RING

OUTBOARDJOINT

ROLI-€RlFor loft ddvcshrfrl

16-6
Reassembly
NOTE:
panswith solvent,
o Cleanthe disassembled anddrythemthroughly air.Donotwashthe rubberparts
with compressed
with solvent.

o *.'.l|@l : Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
ser.

G.ea3o quontity:

lnboardJoint 120- 130g |'4.2- 4.6 ozl

OutboardJoint 90 - 100g {3.2- 3.5oz}

ROLI.TR
RIGHTINBOARDJOINT {For lcft
SETRING

w
Replace.

b
,RDJOINT

INAOARDBOOT

---"-G1
Packcavity with gr€ase.

-Gl
Pack cavity wrth grease.
DYNAMICDAMPER

EOOTBANDS
Replace.

(cont'd)

16-7
Driveshafts
Reassembly(cont'dl

1. Wrap the splineswith vinyl tape to preventdamage 6. Packthe outboardjoint with the joint greaseinclud-
to the bootsand dynamicdamper. ed in the new driveshaftset,

2. I n s t a l lt h e o u t b o a r d b o o t , d y n a m i c d a m p e r a n d Greasequantity: 90 - 100 g (3.2- 3.5 oz)

i n b o a r db o o t t o t h e d r i v e s h a f tt,h e n r e m o v et h e
vinyl tape.

CAUTION: Take care not to damage the boots and

dynamicdamp€r.

,.% VINYLT
OUTBOARDBOOT

DYNAMICDAMPER 7. Fit the rollersto the spiderwith their high shoulders

facingoutward.
INBOARD
BOOT
NOTE:
Installthestopperring into the driveshaftgroove. . Reinstallthe rollersin their originalpositionson
the spiderby aligningthe marks.
NOTE:Always rotatethe stopperring in its groove . H o l d t h e d r i v e s h a f tp o i n t e du p t o p r e v e n tt h e
to be sure it is fully seated. rollersfrom fallingoff.

Installthe spider on the driveshaftby aligningrhe

markson the spiderand end of the driveshaft.

Fit the circlipinto the driveshaftgroove. + {l- -r ROLLER

{For left driv8hattl
SPIDER
NOTE:Always rotatethe circlip in its grooveto be
sure it is fully seated. ROLLER

CIRCLIP

SPIDER

STOPPER
RING

16-8
8. Packthe inboardjoint with the ioint greaseincluded
in the new driveshaftset.
Greasequantity; 120- 130 g 11.2- 4.6 ozl
1 0 .Adjust the length of the driveshaftsto the figure
below. then adjust the boots to halfway between
full compressionand full extension.
NOTE:The ends of boots seat in the groove of the
driveshaftand joint.

Left:475- 480mm {18.7- 18.9inl

Right: 475 - 480 mm (18.7- 18.9inl

9. Fitthe inboardjoint onto the driveshaft.

NOTE;
. Reinstallthe inboardjoint onto the driveshaftby
aligningthe marks on the inboardioint and the
rollers.
. Holdthe driveshaftso the inboardjoint pointsup
to preventit from fallingoff.

Left drivoshaft: 1 1 . lnstallnew boot bandson the boots,and bend both

Align the holder directionof the rollers setsof lockingtabs.
toward the slot ot inboard joint as
Lightlyrap on the doubled-overportionsto reduce
their height.

/,.-:--\\\ \
I di,ection
sotine
INBOARD
JOINT A\
{(@}
HOLDER

{cont'd)

16-9
Driveshafts
(cont'dl
Reassembly Installation
t5. Positionthe dynamicdamperas shown below. 1. Installthe outboardjoint into the knuckle.
. Installa new dynamic damper band. and bend
down both sets of locking tabs.
Lightly tap on the doubl€d-overponion of the
bandto reduceits height, KNUCIGE

Loft/Right 29 r 2 mm (1.1r 0.1 inl

DAMPER
DYNAMIC

DYNAMICDAMPERBANO

OUTBOARD
JOINT

Apply 1.0- 1.5s (0.04- 0.05oz) of specifiedgroase

to the whole splined surtace of the intermediats
shaft.

NOTE: After applying grease,remove the grsase

f.om the splinedgroovesat intervalsof 2 - 3 sDlines
and from the set ring grooveso air can bleedfrom
the inboardjoint.

Installthe new set ring onto the driveshaftor inter-

mediateshaftgroove.

CAUTION: Always uso a now sot ring whcncycr

tho driveshaft is boing in3tallod.

RING

b
SET RINGGROOVE

16-10
 Insertthe inboardend of the driveshaftinto the dif- 1 . Installthe knuckleon the lower arm, then tighten
f e r e n t i a lo r i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n g the castlenut and installa new cotterpin.
locksin the groove.
NOTE: Wipe off the grease before tightening the
INBOARD
JOINT nut at the ball joint.

CAUTION:
. B€ careful not to damago tho ball ioint boot.
. Torqu€ tho castle nut to ths lower torquo 3paci.
fication, then tighlon it only tar snough to slign
the slot with th€ pin hole. Do not align tho nut
by loossning,

INAOARDJOINT
GROOVE

COT1ERPIf{
On reassembly,
OIFFERENTIAL bend the cotter pin
CASTLENUT
as shown.
12 x 1.25rnm
5. Installthe damperfork over the driveshaftand onto a9- 59N.m15.0- 6.0kgt.m,36- a:tlbtftl
t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r 8. Installa new spindlenut,then tightenthe nut,
fork so the aligning tab is alignedwith the slot in
the damperfork. 9. Installthe front wheelwith the wheel nuts.

L o o s e l yi n s t a l lt h e s e l f - l o c k i n gb o l t a n d t h e n e w NOTE: Beforeinstallingthe wheel,cleanthe mating

self-lockingnut. surfacesof the brakediscand the wheel.
FRONTWHEEL WHEELNUT 12 x 1.5 mm
NOTE:The bolts and nut should be tightenedwith 108N.m (11.0kgf.m,80lbtft,
the vehicle'sweight on the damper.

SELF.LOCKING BOLT ALIGNINGTAB

10 x 1.25mm
a:' N.m lir,4 kgt m, 32 lbf.ftt

NUT 22 x 1.5mm
181N m 118.5 kgl'm,134lbt'ftl
NOTE:Altortightening,usea driftto
stakethesPindle nutshoulder
againstthe driveshaft
1 0 . Tightenrhe self-lockingbolt and the new self-lock-
ing nut with the vehicle'sweight on the damper.
'I.
1 Refill the transmissionwith recommendedoil or
SELF.LOCKING NUT fluid (seesection13 or 14).
12x 1.25mm
64 N.m (6.5 kgt m, 47 lbf.ftl 12. Checkthe front wheel alignmentand adjust if nec-
essary{seepage 18-4).

1 6 - 11
Intermediateshaft
Removal Disassembly
Drsinthe transmissionoil or fluid (seesection13 or NOTE:Be carefulnot to damagethe metal rings on the
14). intermediate
shaftduringdisassembly.

2. Removethe left driveshaft(see page 16-3). 1. Removethe set ring,

Removethe three dow€l bolts. 2. Removethe intermediateshaft outer seal from the
bearingsupport.

3. Removethe eldernalcirclip.

Removethe intermediateshaft f.om the differential. t

OUTEBSEAL SETRING
Replsce. Replace.
CAUTION; Hold the intormediato shaft horizontrl
until it b clear of the dittorential to prevent damago
to thr dittarontial oil so!|.

16-12
1. Pressth6 intermBdiateshaft out of the shaft bearing Pressthe intermediateshaft bearing out of th€ boar-
using the specialtools and a press as shown. ing support using ths spscialtools and a prsss as
snown.
5. Removethe internalcircliD. Praa!

SUPPORT BASE ATTACHMENT,

Pmar 1i2xa7fim
ATTACHMENT
INTEBNALCIRCLIP
I 07JAF- SH2oalXt FLOANNGRUBB€R
DA'iIPER
07ta6 - 00ro:!00

Checkfor det€rioration
and dama9e. SUPPORTBASE
BEARINGSUPFORTRING ATTACHMENT
- SHZ!(|O
Chscktor damagg or distonion.

BASE
07965- Sll9or00

INIERiIEDIAIE SHAFT SUPPORTBASE

Checkfor damage. 07965 - SDg,|q'
BEARINGSUPPORT
Checkfor damage.

NOTE:
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
parts with solvent.
. Be car€ful not to damagethe metal rings on the intermedists shaft during reass€mbly

DOvvELBOLTS
10r 1.25ftm
:tlt N.m {a.Otgt m, 29 lbfftl

EXTENTALCIRCUP

ob. Packthe intorior

of the outer saal.
2.0- 3.5 g {0.07- 0.12oz}

SETRING
Replace.

INTERMEOIATESHAFT BEABING
Reolaco.
BEARING
v
ourER SEAL {conr'd)
Rspbce.
IntermediateShaft
(cont'dl
Reassembly
'1. Press
the intermediateshaft bearinginto the bear- Seatthe externalcirclip in the groove of the inter-
ing support using the specialtools and a press as mediate shaft.
shown.
NOTE:Installthecirclipwith the taperedend facing
our.

Installthe outer seal into the bearingsupportusing

the specialtools as shown.

NOTE: Installthe seal flush with the bearingsup-

port.

ATTACHMENT,
52x55mm
07716- 001o/UX)
DRIVER
07749- 00t(xD0

Packthe interior
ol the olter seal.
2.0 - 3.5 g 10,07- 0.12 o2l

Seatthe internalcirclipin the grooveof the bearing OUTERSEAL

suoDon.

CAUTION: Install the circlip with the tapersd end

facing out.
ATTACHMENT,
Pressthe intermediateshaft into the shaft bearinq aOx 5{)mm l.D.
usingthe specialtoolsand a press. 07LAD - PW50601

Pross

lnstall the new set ring in the intermediateshaft

groove.

16 -1 4
lnstallation
lnsert tha intermediate shaft assembly into the dif-
ferential.

CAUTION: Hold th€ inlorm.diltc ahrft horizontsl

to prryonl dsmrge to thc difflrontill oil taal.

INTERMEDIATESHAFT

2. Installthe threedowel bolts,then tightenthem.

DOWELBOLTS
10x 1.25mm
39 N.m {a.Orgl.m, 29 lbl.ft}

INIERMEDIATESHAFT

16-15
 Steering
SpecialTools .............17-2 * SteeringColumn
Component Location Removaf .................17-28
lndex ................ ......17-3 Inspection ..............
17-30
System Description Installation .............
17-31
Ffuid Flow Diagram ......................... 17-1 Power Steering Hoses.Pipes
SteeringPump .................................
17-5 Replacemont .........17-3tl
SteeringGearbox............................. 17-7 Power SteeringPump
Troubleshooting Removal .................
17-35
GeneralTroubleshooting................ 17-10 Disassembly ..........17-35
Noiseand Vibration......................... 17-14 Reassembly ...........
17-'10
FluidLeaks .............17-16 lnstallation ........,...,
l7-tltl
Inspection and Adiustment Steering Gearbox
SteoringOperation .......................... 17-14 Removaf .,.,.............
17-45
Power Assist Check Disassembly ..........17-/E
with CarParked........................... 17-18 Reassembly ...........
17-53
SteeringLinkageand Gearbox.......17-19 lnstallation .............
17-63
Pump Beh ..............17-20 Ball Joint Boot Replacement..........17-65
RackGuideAdjustment ............. .....17-21
Ffuid Replacement .....17-21
......................
Pump PressureCheck.................. .... 17-22
FfuidLeakagelnspection ................ 17-23
+Steering Wheel
Removal ..,,,,,,,........17-24
Disassembly/Reassembly ...............17-25
fnstallation 17-26
,......,,,,,.

SUPPLEMENTALRESTRAINTSYSTEM{SRSI
The IntegraSRS includesa driver's airbag.locatedin the steeringwheel hub, In addition,all modelsexcept the
RS modelfor Canadahave a front passenger'sairbaglocatedin the dashboardabovethe glove box. Information
necessarvto safelyservicethe SRS is includedin this ServiceManual.ltems markedwith an asterisk{') on the
contents page include,or are locatednear, SRS components.Servicing.disassembling or replacingthese items
will requirespecialprecautions and tools, and should thereforebe done by an authorizedAcura dealer.

a To avoid rsndering ths SRS inoporative, which could load to po.sonal iniury 01 d€ath in th€ event ot a ssvare
lrontal collision, all SRS service work muat be performod by an authorizod Acura deal6t.
a lmploper service procodules. including incorloct romoval and installation of the SRS,could lead to personaliniu-
ry caused by unintontional activation ot the airbags.
a All SRS elsctdcal wiring harnessesara covorod with ysllow insulation. Rolalod compon€nts 8re locatsd in tho
stse ng column, tront console, dashboard, and dashboard lower panel, and in the dashboard above the glove
box. Do not use oloctrical tost equipmoni on thosa cilcuits.

NOTE: The originalradiohas a codedthett protectioncircuit. Be sure to get the customer'scode numberbefore
- disconnectingthe battery.
- removingthe No. 32 (7.5 A) tuse from the under-hoodfuse/relaybox.
- removingthe radio.
"CODE" is displayed'enter the cus-
Alter service,reconnectpower to the radioand turn it on. When the word
tomer's 5-digit code to restoreradio operation.
 Rcf. No. I Tool Numb€l Dcscription O'ty I P!9. Relrrrncc

o 07GAF- PH70100 PilotCollar 1

'17-52
@ 07GAF- SD40700 Hub DivAssembly Base I 17-39
@ 07GAG- SD40100 PistonSealRingGuide 1 17-57
(t 07GAG- SD40200 PistonSealRingSizingTool 1 17-57
@ 07GAG- SD40400 Cylinde.End Sealcuide 1 17-EO

@ 07JGG- 0010104 BeltTensionGauge 1 17-20

o 07MAC- 5100200 BallJoint Remover,28 mm 1
't7-15
@ 07MAG - 5100100 BallJoint BootClip Guide 1
@ 07NAD- SR30200 Cylinder End Seal RemoverAttachment 1 17-50
@ 07NAG- SR30900 ValveSsalRingSizingTool 'I 17-5{
@ OTNAK- SR3O11A P/SJoint Adapter(Pump) 1 17-22
@ OTNAK- SR3O12A P/SJoint Adapter (Hos6) 1 1 7- 2 2
@ 07406- 0010001 P/S PressureGsuge 't1-22
1
@.r 07406- 0010300 PressureControl Valve 1 17-22
@-2 07405- 0010400 PressureGauge 1
@ 07725- 0030000 UniversalHolder 1 17-35,53
@ 07746- 0010100 Attachment,32 x 35 mm 'l 17-55,56
@ 07746- 0010200 Attachment,37 x 40 mm 1 17-1'l
@ 007i$ - 0010000 Driver I t7-55
@ 07916- SA50001 LocknutWrench, i[0 mm 1 17-2'l
@ 07947- 6340500 Driver Anachment 1 17-11
@ 07974- 6890801 CylinderEnd SealSlider 1 17-57,58
@ 0797,1- SA50200 SleeveSesl RingSizingTool 1 17-55

aL2
re q e
t l e
I U
F--,'---l
TJ
o @ o @ \v

g a
t.-, \, I
o @ @ @

,h z6) 6
<Z€€ V,.) @ w
@ @ @-r @,2 @

16)
v
^dN
Y lx:__E @:

@@ @ @ @ @

17-2
ComponentLocation
lndex

Powar Siooring:

NOTE:
It an intact airbag ass€mbly has been r€moved from a scrappedcar or has been found defective or damaged during
transit. storage or service,it should be doploy€d (seesection 23).
a Before removing tho gearbox, remove ths ignition key to keep the steering shaft Jrom turning.
a After installingthe gearbox,checkths whe€l alignmentand adiustif necessary.

CAUTION:
. All SRS aloctricll wiring h!m!|$a rrc covcred with
yrllow in3uhtion.
. 8€for€ disconnocling lny ptrt ol thc SRS wiro h!r'
ne*r, connect thc lhort conncctor{3l.
. Rcplsce lhc ontira ttfact d SRS harnccc a$embly il
it hs3 !n oprn circuh 01 dtm!9.d wiring.

SIEERING COLUiIN
Removal,page 17-28
Inspection,pago 17-30
Installation,p6ge 17-31
rcNMON SwlTCH
See s6ction23

STEERII{GGEARBOX
RackGuide Adjustment,pag.11-21
Removal,pags 17-45
Diossombly,page 17-{8
Bea65€mbly,page 17-53
Installation,page 17-63

POWENSTEERINGPUMP
Pump Beft Inspoction.page 17-2O STEERINGWHEEL
Pump EeftAdjustm6nl, pago 17-2O Removal.page 17-24
Pump PressurgCh€ck,page 17-22 page 17-25
Oisassembly/Reassembly,
Removai,p6go 17-35 page17-26
Installation,
Disassembly,p3gs 17-35
Reassombly,psge l7-40
lnstallation,page 17-44

TIE'RODEND BALLJOINT
Ball Joint Eoot Replacement,page 17-63

17-3
System Description
FluidFlow Diagram
The system is a compact rotary-valvs-typepower stssring, connoctedto the st€oring gearbox. Th6 fluid pressureis pro-
vided by a vane-type pump which is driven by the engine crank pulley. The amount of fluid and pressurs is regulsted by
the flow control valve built into ths pump, The fluid prssaursfrom th6 pump is dolivsred to tho valve unit sround the pin-
ion of the steering g€arbox. The vslv€ inside the valvs unit controls the hydraulic prossur€End changosthe direction ot
the flow. The fluid then flows to the power cylinder, where rack thrust is gen6rat6d.Fluid returning from th6 powsr cylin-
der flows backto the .eservoir,where the fluid is 'filtered" and supplied to the pump Egain.

17-4
Construetion
The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is driven by a V-beltfrom
the crank pulley. The pump features 10 vanes, Each vane performs two intake/dischsrgeoperations for every rotation of
the rotor.This meansthat the hydraulicfluid pressurepulsebecomesextremelysmallduringdischarge.

INLETPORT CAM RING

VALVE
FLOWCONTBOL

DRIVESHAF'

VANE

Operation
The belt-drivenpulley rotatesthe rotor through the drive shaft,As the rotor rotates,the hydraulicpressureis appliedto
the vanechamberof the rotor and the vaneswitl rotatewhile beingpushedonto the innercircumference of the cam .ing.
The inner circumferenceof the cam ring has an extonded portion with respect to the center of the shaft. so the rollers
move downwardin the axialdirectionas the carrierrotates.As a resultof this rollermovemsnt,the internalvolumeof the
vane chamberwill change,resultingin fluid intakeand discharge.

STARTOF FLUIDINTAKE: FLUIDINTAKE: FLUIDMOVEMENT: FLUIDDISCHABGE:

DISCHARGE
P('BT

The vanes are pushed onto
the inner circumferenceof th6
cam ring.
Th6 volumsotth€ van€cham-
ber increasosso that lluid is
suckodin.
T h 6 s u c k e d - i nf l u i d m o v e s
towsrd the discha196pon.
As the vanes returnto th€
their original positionon the
inner side,the volume of the
vane chamber decreasesso
the fiuid is discharg6dfrom
the dischargeport.

(cont'd)
System Description
SteeringPump(cont'dl
Flow Control
FLOWCURVE
The flow controlvalve in the pump performsthe follow-
ing steps@ throughO to controlthe flow of fluid, i.e.to
increasethe dischargevolum€ wh6n engine speed is . J5
low and to decreaseit when the enginespeedincreases. I

The assistancethrust of the steeringgearboxchangesin l o

compliancewith the changein the dischargevolume. tr o=

PUMPR.P,M.

o When the engine starts,fluid dischargedfrom the

dischargeport starts to run through the metering
orificein the pump.The dischargevolume increas€s
as the enginespeedincreases,

@ A s t h e f l o w h a s a l r e a d y b e e n r e g u l a t e db y t h e
meteringorificewhen the enginespeedis at or near
the idle speed,a constantand regulatedamount ot
fluid is dischargeduntil the engine speed reaches
t h e m i d d l e s p e e d r a n g e .A s t h e e n g i n es p e e d
increases, the pressuredifferencebetweenthe ends
of the meteringorificeincreases.A pressurediffer-
ence is createdbetweenthe top and bottom ends of
the flow controlvalve,too, pushingthe flow control VALVE
valveto open the by-passpassage.This allowsthe
excessfluid to return to the inlet pon preventing
pressureat the dischargeport trom rising exces-
sively.

@ As the enginespeedcontinuesto increase,the tlow

c o n t r o l v a l v e i s p u s h e d b a c k f u r t h e r .W h e n t h e
enginespeedreachesa given speed.the returnpas-
sage outside the metering orifice is connectedto
t h e i n l e t p o r t , a n d t h e o p e n i n gt o t h e i n l e t p o r t
w i d e n s i n p r o p o r t i o nt o t h e i n c r e a s ei n e n g i n e
speed.This makespan of the fluid regulatedby the
meteringorificereturnto the inlet pon of the pump;
t h e r e b y d i s c h a r g e df l u i d f r o m t h e p u m p i s
decreasedslowly by this amount.

@ T h e o r i f i c e i n t h e r e t u r n p a s s a g er e g u l a t e sa n d
m a i n t a i n st h e f l o w o f f l u i d d i s c h a r g e df r o m t h e
pump at a given level until the enginespeedreach-
es the high speedrange.

17 -6
PressureRelief
Pressu.6outside of the metering orifice is directedto
the bonom ot the flow control valve. When the pressure
buildsup, the relietvalvein the flow controlvalveopens
to relieve the pressure.As the flow control valve is
pushed back by the pressuredifferencethis time, the
flow of fluid in the bypasspasssgeincreases, convolling
the pressureoutside the metering orifice. The above
operationsare repeatedto provide constantdischarge
prsssurelrom the pump,
VALVE

{Dacrarlai cxco33iva
Yibrationin iha valva.l

(cont'dl

17-7
SystemDescription
SteeringGearbox
The rack-and-pinion type steeringgearboxhas a valve unit incorporatedwith the pinionto controlthe steeringfluid pres-
sure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve unit and is sentthroughthe cylinderpipe to
the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylinderreturns
throughthe cylinderpipe and valveunitto the reservoir.

VALVEUNIT
CYLINDERPIPE

POWEBCYLINDER

Valve Unit

Insidethe valve unit is the valve,which is coaxialwith the pinionshaft,and controlsthe steeringfluid pressure.The valve
housingis connectedwith the fluid pipe from the pump, return pipe to the pump, and the two cylinderpipesfrom the
respectivepowercylinder.
The pinionshaft is double- structuredwith the input shaftconnectedto the piniongear,both of which are interconnected
with the torsionbar.
The pin insenedin the valve and the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the

directionbetweenthe input shaftand the valve

the differencein angle in the circumferential
Becauseof this construction,
becomeslarger accordingto the torsional strength of the pinion or steering resistance.However,maximum torsion
betweenthe shaftsis regulatedby the engagedsplinesof the shaftsat the pin engagementsectionto hold the torsion bar
within the set value.
This allowsthe steeringsystemto lunctionas an ordinaryrack-and-pinion type steeringif the steeringfluid is not pressur-
izedbecauseof a faulty pump.

VALVE
Difforcnco in .ngl. bo{w€cn tha
input shalt rnd pinion !h.tt

ln
-1
INPUTSHAFT
B
<sEcnoN B-B>
lEngag€with the pinion
shaft groove)

1 7 -8
PressureControl
Low assistat higherspeeds:
When steeringresistanceis low. such as when driving at high speeds.or when driving straightahead,the input shaft is
near or in the neutralposition,so there is little or no flow to any of the power cylinderorifices,Most of the feed pressure
trom the pump is bypassedto the reservoir.Becauseof this, the pressurestaysthe same in both sidesof the power cylin-
der, resultingin low or no assist.

vALVE F.om PUMP

RESERVOIR az =- S
\->/
-\7/ RETURNPASSAGE
(To RESERVOIRI

VALVE UNIT
<sEcnoN A-A>
A INPUTSHAFT

Highassistat lower speeds:

When steeringresistanceis high, suchas when drivingat low speed,or when turningthe wheelwith the car stopped,the
differencein anglecreatedbetweenthe input shaftand the valveopensthe fluid passageon one side,and closesthe fluid
passageon the other side,at each pair of orifices.The fluid pressureincreasesin the side of the powercylinderfed by the
largerfluid passage.This increasedpressurepusheson the rackpiston,allowingthe steeringwheelto be turnedwith light
effon. On the other side of the power cylinder,the returnpassageopensallowingthe steeringfluid to returnthroughthe
input shaftto the reservoir.The fluid passagesto the power cylinderautomaticallychangein size,increasingas the steer-
ing resistanceincreases. In other words,the passagesbecomelargerand power assistincreaseswhen the steeringeffort
would normallybe high, (for example.when parkingor makinglow speedturns).and the passagesbecomesmallerand
power assistdecreaseswhen the steeringeffort would normallybe low, (for example,when driving at high speedsor
straightah€ad).
FLUIOPASSAGETO
POWERCYLINDER From PUMP
/t-:\
v" =iJ
RETURN
PASSAGE

FLUIDPASSAGEFROM
POWERCYLINDER

<SECTIONA.A>

17-9
Troubleshooting
GeneralTroubleshooting
Checkthe followingbetoreyou begin:
. Hasthe susp€nsionbeenmodifiedin a way that would affectsteering?
. Are tire sizesand air pressurecorrect?
. ls the steeringwhe€loriginalsquipmentor equivalent?
. ls the power steering pump belt properly adiusted?
o ls steering fluid reservoirfilled to proper level?
o ls the engineidle speedcorrectand steady?

Checkpump fluid pressurg(soe r Fluid pro$ure is too low:

page 17-221, Chockth€ rgturn circuit pipe and hose between tho
Measure steady-statefluid pres- gearbox and pump tor clogging and dotormation.
sure while idling with the shut-off * Fluid pressureis too hioh:
valve fully open. Checkthe pipe and hosg connectedfrom th6 pump
I r s h o u t db e 1 , 5 0 0k P a ( 1 5 k g t to tho georboxtor clogging and delormation.
cm' , 213psi)or bolow.

Normal

Checkpump fluid pr€ssur€{se€

page 17-221.
Checkthe flow control valve.
M e a s u r ep u m p r e l i e f p r e s s u r e * Checklhe valve for smooth movement in thg hou6-
while idling with the shut-off
Ing.
valvefullyclosod. * Chockthg reli€f valve for leaks.
h should be 6,400- 7,400kPa {65
- 75 kgtcm,, 924- 1,067psi)

Normal reliel pressure Abnormal

II II
Gotopatetu.lt Faultyflowtontroi valve

17-10
Ch6ck force r6quired to turn tho
wheel(seepage17-18).
S t 6 t h e e n g i n ea n d m 6 a s u r e
force required to turn the whgel
to the right and left. Dilferenceol
t h e l o . c e r e q u i r e dt o t u r n t h e
who€l to the right and to the lett
should be 5 N (0.5 kgf, 1 lbf) or
below.

Normal

Ch6ckpump fluid pressure(see

page 17-221.
Turn the steeringwheel lully to
the right and left whil€ idling Abnormal -----|. Faultygearbox
with the shut-off valvo fully op6n,
and measuretho fluid pressu.e.lt
should be 6,400- 7,400kPa (65 -
75 kg?cm,,924- 1,067psil.

Normal

Chockthe gearbox.
Removethe goarbox and mea-
surethe piniontorque.
The torqueshouldbe;
* 0.7- 1.2N.m (7 - 12 kgf.cm,6 -
'10lbt in) with the steering rack
in the straightdrivingposition.
Chsck the other parts than the gearbox-ralatedpsrts for
propor rotstion,
* lmpropor rotation ofthe steeringcolumn-rolat€dpan(sl
Abnormal |r 'Faulty st6€ringjoint
a Faultyrack end^ie-rodend balljoints
'Intederence in the steeringsystem

Normal

Adjust the rack guide (see page

11-211.
Adiust the rackguide and recheck lmproperly adjustedrackguide
the pinion torque.

(cont'dl

17-11
Troubleshooting
GeneralTroubleshooting{cont'd}
Assist (excessivelylight steering)at
high speed.
Shockor vibration when wheel is
turned to tull lock.
Wheelwillnot returnsmoolhly.
17 -1 2
Check the rack guido proper ad'
justment (seepago 17-21).
Checkthe rack guide tor proper
adjustment(ses psge 17-21).
Rackguide is adjustedprop€rly.
Ch6ckthe belt tor slip and adjust
as nocessary(see page 17-20).
lf the cylinderpip6 A and B are
normal, remove the gearbox
from th€ f.ame and mossure the
pinion torqug on the gearbox.
ll the problem is not correctedby
adjustingth6 rack g!ide. adjust
the front wheel alignment (see
section 18).
lf th€ problem is not correct€dby
adiusting the rack guide, roplace
the gesrbox.
lf oither one or both of the cylin-
der pip€ A and B is/aredeformed,
rsplace,
It shouldbe 0.7- 1.2N.m {7 - 12
k g f . c m ,6 - 1 0 l b f . i n )o r b e l o w
with the sleering rack in the
straight aheaddriving position.
lf lhe measurem€ntsare out of
specilications.adjust the rack
guid6.
ll ihe problem is not correctedby
adjusting the rack guide, replace
ihe gearbox.
Unovonor rcugh 8te6ring.
ldl6 soosd low or orrrtic.
Air in rssorvoir. or ch€ck pow6a
steoringfluid l6v6l.
Pump b6lt slippingon pull6y
(pump stops momontarily).
Sel the power itooring p.oasure
gaug6. Cl066th€ shut-off v6lv6
f u l l y a n d m € a 5 u r ot h o p u m p
pr6ssur6(6s€pagg 17-221,
Adjustrackguide(se€poge 17-21).
ll the probl6m is not correctedbY
adjusting lhe rack guide. replaco
the gearbox.
Adiud bolt t€nsion.Roplaceb€lt, if
n€c€ssary{s€e page 17-20).
lf the ongin€ stallswhen wheel is
turned whil€ car is stoDPedor
moving at low spoed,adjust idle
sp€€d (soesection 11).
Chockpower sieeringIluid levol.It
lgv6l ie excessivoly low, ch€ck for
leaks in the system. Add fluid to
tho spocifiod level.
lf fluid lev6l is OK, check o-rings
and seals on both €nds of iho
pump inlet hose, and th€ oil
pump housing mating surfacos
for suction leaks. Reolace oarts
65 n€CeSSAry.
Adjust belt tonsion (see page 17-
m) or r€Dlacobeh.
Checkif pump prossureis within
the ranoe6.400- 7,100kPa(65- 75
kgr/cm,, 924 - 1,067psil and th6
gsuge needls travol is 1500 kPa {15
kgflctn2,t71 p6i) or less. Checkthe
flow control valve if the needle
tr.vel €xcoods 1500 kPa {15
kg?cm,,i71 psi).lf rhe flow control
valvo is normal, replaceth€ pump
as an assomblv.
7-13
Troubleshooting
Noiseand Vibration
NOTE:Pump noisein first 2 - 3 minutesafterstartingin cold weather(-20.C,-4"F or colder)is normal.

Humming Humming due to pulsation ol fluid is no.mal, paniculady when wheel is turned
with ca. stopped.

lf equippedwith automatictrans-
mission,the hum could b€ tor- Confirm by temporarily removing
pump b€lt.
que conveneror pump notse.

High pressureline touching the

frame, Reposhiontho line.

Right cylinder end soal squeak

Rattleor chattering Loose steeringshaft connector. C h e c ka n d t i g h t e n , o r r e p l a c e

tie-rod,or balljoint. pa s as necessary.

Column shaft wobbling. Replacecolumnassembly.

Checkthe rack guide for proper

adjustment(16opage17-21). Adjust, if n€ca€ssry.

Rattlingsound and feeling when turning the steoringwheel right and lett with tho
engine OFFis a sound when th6 valve unit contactstho stopper.This is normal.

Striking sound wh6n turning the ste€ringwhoglfully right o. left is a sound when
the r6ckend contactsth6 stopper.This is normal.

Pump noise. though not loud,lrom the vslvo bodv unit can be heard when turn-
ing the steeringwheel right or left. This is normsl.

17-14
 Checkfluid level.
l f l o w . f i l l r e s e r v o i rt o p r o p e r
Gratingnoisefrom pump level,and checktor l€aks.
Tighten or roplac6as n€cessary.

Checkfor crushedsuction hose

or a loose hose clamp allowing
air into the system.
Tighten or replaceas noce$ary.

NOTE: Pump noise up to 2 - 3

m i n u t e sa l t e r s t a r t i n gi n c o l d
lf pump noiseis abnormallyloud,
weather (-20'C, -4'F or colder) is
Pumpgearnoise chgckthe pump ball b€aringand
normat,
any pans (seepage 17-351.
Comparopump noise at operat-
in9 temperatureto anothercar.

1 7 -1 5
Troubleshooting
Fluid Leaks

Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points.dependingon locationof the
faultyoil seals/seal
rings.Checkthe followingbeforeremovingthe gearboxfrom the frame.

SteeringGearbox Leakingfrom the oil seal on the Roplacethe valve oil seal from
top of the valvehousing. the valvehousing.

Leakingfrom cylinder end into Replacethe valve oil seal lrom

left tie'rod boot. the pinion shaft.

R e o l a c et h e c v l i n d e r e n d s e a l .

Leakingfrom cylinder end into

right tie rod boot.

Leaking from the vslve body

Tighten attachingbolts or replace
uniVhousingmounting soction.
the valvebody unit or gearhous-
Ing.

Leakingfrom cylind6rpipeA or B Tightenconnector.It still leaking.

connection(attlarenut). r e p l a c et h e p i p e , c y l i n d e r o r
valvehousingunil.

Leakingcausedby damagedcy-
R e p l a c et h e c y l i n d e r p i p e A o r B .
linderpipeA or B.

L e a k i n gf r o m f e e d p i p 6 a n d Tightenconnector.lI still leaking,

returnpipe of the valvebody unit replacethe pipe or valve hous
(atflarenut). In9,

17-16
 ReplacehousingO-rings.
lI the housingstill leaks,replace
the pump.

Reservoiroverfilled.
Pullotfthe hoseand drainto pro'
per tevet.

Air leakin suctionside of system

lreservoitinlet hose,front pump
seal),

Pump outlet line

(highpressure)

Leaking b€causeol dsmage, de'

Low pressurehoses terioration,or improp€r assem- Replaceor repairas necessary.

Tightenconnector.lf still leaking,

Leakingat g6srboxconnection. replacethe pipe or v€lve hous'
{atflarenut}. Ing,

17-17
Inspectionand Adjustment
SteeringOperation
Placethe front wheelsin the straightahesdpositionand
measurethe distSncethe steeringwheel can be turned
without moving the front wheels.
ROTATIONALPLAY:0 - 10 mm l0 - o.:Xlinl
lf the plsy excsedsthe service limit, psrform rack guide
adjustment (see page 17-211.
lf the play is still excessiveafter rackguide adjustment,
inspectthe stsering linksgoand gearbox as described
on the next page.
ROTANONAL PLAY
1 7 -18
PowerAssist Gheckwith
GarParked
1. Checkthe power steeringfluid level (see page 17-
21) and pump belttensionlsee page l7-20).
2. Startthe engine,allow it to idle, and turn the steer-
ing wheel from lock-to-locksev€raltimes to warm
uo the fluid.
Attacha springscaleto the steeringwheel.With the
engine idling and the car on a clean,dry floor, pull
the scaleas shown and read it as soon 8s the tires
beginto turn,
il. The scal6should read no more than 33 N (3.4 kgf,
7.5 lbf). lf it reads more or less, ch€ck the gearbox
and pump.
SteeringLinkageand Gearbox

STEERINGCOLUMN
lnsoecttor loosecolumn
mountingboltsand nuts.

BOOT
Inspect
f6r damage
anddeterior6tion.

STEERINGJOINTS
Checktor loosejoint bolts.

PINIONSHAFTGROMMET
Inspectlor damage and deterioration.

TIE.RODLOCKNUT
STEERING Checkfor looselocknut.
Inspectlor loose mounting bolts.
GEARBOXMOUNTINGCUSHIONS
Inspectfor deterioration.

BALLJOINT BOOT
Inspecttor damageand deterioration.
Seepsge 17-63for replacement.

17-19
Inspectionand Adjustment
PumpBelt
NOTE: When using a new b€li, first adiust the deflection Adiu3tmant
or t€naion to the values for the new belt, thsn readiust
ths deflection or tension to the values tor the used b€lt 1, Loosenthe power stesring pump mounting bolts.
after running sngine for five minutss.
2. Turn ths adiusting bolt to gst the propor bolt ten-
lnspoction sion, then rstighten the bolts.

Attach th€ belt tonsion gauge to th6 belt and measure 3, Start ths €ngine and turn the steering wheel trom
ths tension of the bslt. lock-tolock s€veraltimes, then stop the engino and
recheckths deflection of the belt.
Tanaion:
U3.d Brft: 391,- 5/O N (lO - 55 kgf, 88 - r20 |bf)
AD'USN G BOLT
Ncw Bch: 7aO- 89, N (75 - 90 kgt, 170 - 20OlbO

NOTE:
. lf thsre are cracksor any damage evident on the belt,
raplacait with a now ono.
. Follow the manufacturer'sinsructions for the tonsion
g8uge.

PUII"EY
07JGG- 00r0r0a
Inspectthe pump belt for cracksor any damage.
Replacethe belt with a new one if nec€ssary.

Mc!3uramrnl without Bch Tcntion Grugr:

Apply a torce of 98 N (10 kgl, 22 lbll and measure ths
deflectionbetweentho power ste€rin9 pump and tho
crankshaftpulleys.

Daffaction:
U:ed Bch: 11.5- 13.5mm (0.,t5-0.53 inl
Nlw Brh: 8.0 - 10.0mm (0.31- 0.39 inl

here,

17-20
NOTE:Performrack guide adjustmentwith the wheels Checkthe reservoirat regularintervals.and add fluid as
in the straightaheadposition. necessary.
GAUTION: Use only Genuine Honda Power Stosring
1 . Loosenthe rack guide screw locknutwith the spe-
Fluid-V. Using othsr fluids such as ATF or other manu-
cialtool,then loosenthe rackguidescrew. facturer's power stoering fluid will damags ths systcm,
Tightenthe rackguide screwuntil it compresses
the SYSTEMCAPACITY:
springand seatsagainstthe .ackguide,then loosen LO6 litor (1.12US. qt, 0.93lmp.qtl
it. at disasssmbly
RESERVOIR CAPACITY:
R e t i g h t e nt h e r a c k g u i d e s c r e w t o 3 . 9 N . m { 0 . 4 0.79lit6r (0.8:lUS.qt, 0.70 lmp.qt)
kgf'm, 2.9 lbf.ft),then back it off to specifiedangle.

SpecifiedR6turn Angle: 20 t 5"

UPPERLEVELUNE
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.

LOWERLEVELLINE

Raisethe reservoirand disconnectthe return hose

that goesto the oil cooler.
RACKGUIDESCREW Connecta hose of suitablediameterto the discon-
nectedreturn hose and put the hose end in a suit-
ablecontainer.
CAUTION:Tako caro not to 3pill tho tluid on tho
body and parts. Wipe off the spilled tluid at onqe.
,l
Startthe engine.let it run at idle.and turn the steer-
ing wheel from lock-to-lockseveraltimes. When
f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
engine.Discardthe fluid,

L(rcKNUTWRENCH, 40 mm
25 N.m 07916- SAs(xtOl
12.5kgf.m, 18lbtftl

Checkfor tight or loose steeringthrough the com-

pleteturningtravel.

6. Performfollowinginspections: Refitthe returnhoseon the reservor.

. Steeringoperation(seepage 17-18). Fillthe reservoirto the uDoerlevelline.
. Power assistwith car parked. Startthe engineand run it at fast idle,then turn the
steeringfrom lock-to-lock severaltimes to bleedair
f.om the system.
7. Recheckthe fluid leveland add some if necessary.
CAUTION: Do not lill the roservoir beyond tho
uppgr lovel line.
lnspectionand Adjustment
PumpPressureCheck
C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e Startthe engineand let it idle.
whetherthe troubleis in the pump or gearbox.
1 . Turn the stee.ing wheel from lock-to-lockseveral
NOTE: First check the power steering fluid level and timesto warm the fluid to operatingtemperature.
pump belttension,
M e a s u r es t e a d y - s t a t fel u i d p r e s s u r ew h i l e i d l i n g
CAUnON: Dilconn€st the high pros3uroho3s with cale with the shut-offvalvefully open. lf the pump is in
!o e3 not to spill tho powor stooring fluid on th6 lramo good condition, the gauge should read less than
lnd olhor parG. 1500kpa (15 kgf/cm,,213psi).
lf it reads high, checkthe feed line or valve body
1. Disconnect the outlet hosefrom the oumo outletfit- unit (seeGeneralTroubleshooting l7-10).
t i n g , 8 n d i n s t a l lt h e p u m p j o i n t a d a p t e ro n t h e
pump outlet. Close the shut-off valve. then close the pressure
c o n t r o l v a l v e g r a d u a l l yu n t i l t h e p r e s s u r eg a u g e
2, Connectthe hose joint sdapterto the power steer- needleis stabl6,Readthe pressure.
ing pressuregauge,then connectthe outlet hoseto
the adaotor. 1 0 . lmmediatelyopenthe shut-offvalvefully.

3. Instsll the power steering pressuregauge to the CAUTION: Do not keep the shut-ott valvs closod
pump joint adaptoras shown. moro thgn 5 soconds or th9 pump could b6 dam"
agod by over-h6ating,
HOSEATTACHINGBOLT
OUTLETHOSEFlTnNG 1l Nm11.1kg{ m 8lbf.ftl
lf the pump is in good condition,the gaugeshould
read at least 6.400- 7,400 kpa (65 - 75 kgIlcm,,924
- 1,067psi). A low readingmeans pump output is
too low for full assist.Repairor replacethe pump.

P/S PRESSURE
GAUGE

6 x 1.0 m.n BOLT

{P!rt of tooll
11 N.m
11.1kgtm,8lbf.ftl

P/S JOINTADAPTORIPUMPI
o?NAK- SmolrA

PUMPOUTI.TT
FITIING

Openthe shut-offvalvefully.

Openthe pressurecontrolvalvefully.

1 7- 2 2
FluidLeakageInspection

BOOT GEARBOXrnd VALVEBODYUNIT

Check
lor leaks. Checkfor leaksat the matingsurface
and rlare nut connections.

PUMPASSEMBLY
Ch€ckfor leaksat the pump
seal, inlet and outlet fiftings.

Inspecthosesfor d6mage,leaks,
interferenceor tlvisting,
Inspectfluid linesfor damage,
rustingor leakage.
Inspectfor leaksat hose and
lineiointsor connections,

17-23
Steering Wheel
Removal

Airbag Removal the negativeand positivecablefrom the

1 . Disconnect
battery.
CAUTION:
. All SRS electrical wiring harnossesare covered with Removethe accesspanel from the steeringwheel
yellow insulation. lowercover,then removethe shon connector.
. Before disconnecting any part oI the SRS wiro har-
ness,connect the 3hort connector{g}. Disconnectthe connectorbetweenthe airbag and
. Replacethe entire sffected SRS harness assembly it cablereel.
it has an opon circuit or damagedwiring.
Connectthe shon connectorto the airbag side of
the connector.
AIRBAG CABLEREEL
CONNECTOR CONNECTOR

R e m o v et h e l i d B a n d c r u i s ec o n t r o l s e t / r e s u m e
switch cover.

Removethe TORX@ T30 bit bolts then removethe

airbagassembly.

AIRBAGASSEMBLY

17-24
 Removal

Disconnectthe connectorstrom the horn and cruise 8. Removethe steeringwheel nut.

controlsevresumeswitches.
R e m o v et h e s t e e r i n gw h e e l b y r o c k i n gi t s l i g h t l y
HORN
from side-to-sideas you puil steadily with both
hands. STEERING WHEEL
STEERINGWHEEL NUT
Replace.

Disassembly/Reassembly
store a removed airbag assembly with CAUTION:
@
the pad 3urfacs up. lf the airbag is improperly stored C8r€{ully inspoct ihe sirbag assombly betors install.
face down, accid€ntaldaployment could prop€l tho unit ing. Do not install an airbag ass6mblythat 5how3
with enough forca to causeserious iniury. signs ol boing dtopped or improperly handled, such
as dents, crack3or deformation.
NOTE:lf an intact airbag assemblyhas been removed Always k€gp tho short connector on the aitbag con-
f r o m a s c r a g o e dc a r o r h a s b e e n f o u n d d e f e c t i v eo r nector when ths harneggi9 disconnected.
damagedduring transit.storageor service,it should be Do not disassembleor tamper with the airbag as-
deployed(seesection23). sombly.
TORX6BOLT
10 N.m {1.0 kgf m, Tlbt.ttl TORX6BOLT
10 N.m {1.0 kgf.m, 7lbf.ft)
t
HORNCONTACTPI-ATE
STEERINGWHEEL

LID

\s SPACER

@
CRUISECONTROLSET/
NESUMESWITCHES

CRUISECONTROLSET/
RESUMESWITCHESCOVER

17-25
SteeringWheel
Installation
Airbag installation 2. Installthe steeringwheel.

CAUTION: NOTE: Be sure the steeringwheel shaft engages

. B€fore inrtalling the stooring wheel, align tho front the cablereeland cancelingsleeve.
who6l3 etraight ahead.
. Bo sure to install the harness wires so that thGy are
not pinched or intorfsring with othor car parts.
. Do not roplace thc original stsoring wheel with any
othor design. since it will maks it impo$ibla to prop-
erly install the airbag. {Only use genuine HONDA
replscomont parts)
. After rols3embly. confirm thai the whoels are still
straight ahoad 8nd that steoring wheel spoke anglo
is correct. lf minor spoke anglo adiustment is noc€s-
srry, do so qnly by adlustment ol th€ tie-rods, not by
romoving and repositioning the steering wh€€|.

@ contirm ihat the airbag assombly is

socurely attachsd to the stooring wheel; oth€rwise,
scvoro porsonal iniury could r€sult during airbag
doploym6nt.

1. B e f o r e i n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e r t h e
cablereel.
Do this by tirst rotating the cable reel clockwise
until it stoos.
Then rotate it counterclockwise(approximatelytwo
turnsl until:
- The yellow gear tooth linesup with the mark on a9 N.m (5.0 ksf'm,36 lbf.ftl
the cover.
- The arrow on the cablereel label pointsstraight
UD. Attach the cruise control sevresume switch€s con-
nectorto the steeringwheelclip.

Connectihe horn connector.

YELI-OWGEAR
CRUISECONTROL
SET/NESUME
SWITCHES
CONNECTOR

ALIGNMENTMARK

17-26
5. Installthe airbagassemblywith new TORXobolts. Connectthe battery positive terminal and th€n con-
nectthe nsgativeterminal.

1 0 . After installing the sirbag assembly,confirm proper

system opera(on:
. Turn the ignitionto ll: the instrum€ntpan6l SRS
indicatorlight should come on for about 6 sec-
onds and then go off,
. Confirm operation of horn buttons.
. Confirm oDerationof cruise control sevresume
switches.
a Turn the steering wheel countetclockwiseand
make su.e the yellow gear tooth still lines up
with the alignmentmark.

YELLOWGEARTOOTH

TORXOBOLTS
10N.m{1.0kgf'm.7lbfftl

the shortconnectortrom the airbagcon-

Disconnect
nector.

7. Connectthe airbag3-Pconnectorand cablereel3-P ALIGNMENTMARK

connector.

Attachthe short connectoron the accesspanel.and

installthe accesspanelon the steeringlowercover.
CABLEREEI-
CONNECTOR

17-27
Steering Golumn
Removal
CAUTION: 5. Removethe connectorholder and disconnectthe
. All SRS el€ctrical wiring hlrnesses are coversd with SRSmain harnessfrom the cablereel wire ha.ness
yollow insuhtion. at the underside ot the column bracket.
. Bctore dieconnocting any part ol tho SRS wiro h!r-
nesa,connoct the thort connector (s).
. Roplacetho ontire aftected SRS harness asr€mbly if
it has !n open circuit or d!mlgod wiring.

Removethe airbag assemblyand steering wheel

page 17-25).
.(see
Removethe lower cover.

Removethe driver'skneebolster.

HARNESS

R e m o v et h e c a b l e r e e l a n d t u r n s i g n a lc a n c e l i n g
steeve.

7. Removethe combinationswitch from the steering

LOWER
COVER columnby disconnecting
the connectors,

R e m o v et h e c o l u m n c o v e r s b y r e m o v i n g t h e TURNSIGNALCANCELING
screws. SlTEVE

CABI..E
REEL
COMA|NANON SW]TCH

STEERING
COLUMN

scREws

17-2A
8. Remov€the stesringioint cover. 1 0 . Disconnoctthe ignition switch connectorsfrom th6
undor-dashfuse/relavbox.
'l1.
R e m o v et h o s t e e r i n g c o l u m n b y r e m o v i n g t h e
attaching nuts 8nd bolts.

JOIMTOOVER

STEERINGCOLUMN

BOITS

Removetho steering joint bolts, and move the ioint

towardths column.

17-29
SteeringColumn
lnspection
Checkthe steeringcolumn ball bearingand steering Checkthe tilt mechanismfor proper movementand
joint bearingsfor play and propermovement. oamage.
lf there is noiseor excessiveplay,replacethe joint or
columnassembly. - Attacha springscaleto the knob of the tilt lever.
Measurethe preloadrequiredto move the lever.
Checkthe retainingcollarfor damage.
lf it is damaged,replacethe retainingcollar. Pr6load:70 - 90 N 17- 9 kgt, 15 - 20 tbf)

COI-UMNBALL
- lf the preloadmeasuredis not within the sDecifica-
STEERINGJOINT
EEARING BEARINGS tion. removethe 6 mm bolt and stoDDer.
Adjustthe preloadby retighteningthe rilt tockbolt
untilthe correctforcecan be obtained.
- Reinstallthe stopperand 6 mm bolt and recheck
the Dreload.

RETAININGCOLLAR TILT LOCKBOLT

Checkthe absorbingplates,absorbingplate guides

and slidingcapsulesfor distonionor breakage.
Replacethem as an assemblyif they are distonedor
broken.

ABSONBING

9.8 N'm {1.0kgt.m,7.2lbt'ftl

SLIDINGCAPSULE
This part is attached
to the columnbracket
with the plasticinjections.

17-30
lnstallation

STEERINGCOLUMNASSEMBLY

RETAININGOOLLAR

STEERING JOINTBOLIS
22 N.m{2.2tst m, 16lbf.ftl

FLANGEBOLT
22 N m 12,2kgl.m, 16lbf.ftl

FLAMiE NUT
13 N.rn {1.3kgt m, 9 lbt ftl

17-31
SteeringColumn
Installation(cont'dl
CAUTION: I n s t a l lt h e s t e e r i n gc o l u m n w i t h t h e f l a n g e n u t s ,
. All SRS electrical wiring hrrnossos are covgrod wilh then installthecolumnholderand flangebolts.
yellow insulation,
. When disconn€ctingthe SRS wire harness,install Tighten the upper and lower steering joint bolts
the short connector on the airbag. th€n dbconnoct looselyinstalledin steD2,
the wire harness.
. Replacathe entire alfected SRS harness assembly if
there is an open circuit or damage to tho wiring.

1. Slip the upperend of the steeringjoint onto the col-

umn shaft {line up the bolt hole with the flat on the
shaft),and loosely install the upper steeringjoint
bolt.
Finaltorque: UPPERSTEERING JOINT BOLT
22 N.m Bolt must line up with
{2.2kgf.m, 16lbt.ftl flat on shaft.

FLANGEBOLTS
22 N.m
12.2ksi.m,16tbtftl
STEERING
JOINT Installthe steeringjoint cover with the clampsand
clip.
Slip the lower end of the steeringjoint onto the pin-
i o n s h a f t .L i n e u p t h e b o l t h o l e w i t h t h e g r o o v e
aroundthe shaft)and looselyjnstallthelower bolt.

NOTE:
. B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t . i s
securelyin the groove in the steering gearbox
pinion.
. Beforetighteningthe steeringjoint bolts,pull on
the sleeringjoint to make sure that the steering
joint is fully seated.
LOWERSTEERINGJOINT BOLT
Fin6ltoroue:
22 N.m {2.2kgt m. 15 lbf.ftl

CLIP

1 7 -3 2
 Connectthe ignition switch wire connectorsto the 9. Installthecolumncovers.
under-dashfuse/relavbox.

7. Installthe combinationswitch and turn signalcan-

UPPER
COLUMNCOVER
celingsleeveonto the steeringcolumn.

NOTE:Be sure the wires are not caughtor pinched

by any parts when installingthe combination
switch.

coMatNATroN
swncH

scREws

TURNSIGNALCANCELING
SLEEVE

1 0 . lnstallthe driver'skneebolster.

1 1 . lnstallthe lowercover.
Installthe cablereel onto the steeringcolumn,then
't2. Installthesteeringwheel '17-26).
connectthe SRS main harnessand cable reel wiro {seepage
harnessand installthe connectorholder.

NOTE:Align the slot in the cablereel with the pro-

jectionon the cancelingsleeve.

17-33
PowerSteeringHoses,Pipes
Replacement
NOTE: CAUTION: Chock all clampsfor doterioration 8nd dstor-
. Connecteachhosgto the correspondingpipe securg- mation, and rsplacGwith new onss if n6co33!ry,
ly until it stopsat the stopp€ron the pipe.
Installthe clamp or ad,ustableclamp at the specified
distancsfrom the hoseend as shown in the drawing.
. Add the power steeringfluid to the speciliedlevelon
the reservoirand checkfo. leaks(seepage17-23).

<AIUUSTABII HOSECLAMP:> <HOSECLAMP:>

Putov6rthe pipe untilthehosestopsat the Putoverthe pipe untilthe

$opper. hose stops at the stopper.

2.5 - 5.5 mm
2.5 - 5.5 mm 2.0 - 4.0 mm 10.01- 0.22 in)
{0.01- 0.22 inl 10.08 - 0.16inl

OUYI.fT HOSE
11 N.m
ABLECLAMP
{1.1 kgl.m, 8 lbl.ftl

INI."ETHOSE

RETURNHOSE

CLAMPS

coot"ER
CLAMPS

17 -34
PowerSteeringPump
Removal Disassembly

NOTE: Before disconnectingthe hoses from the pump, Pulley Removal

placea suitablecontainsrunderthe car.
1. Drainthe fluid from the pump.
1. Drain the power steeringfluid from the rsservoir.
2, Holdthe stee.ingpump in a visewith soft iaws, and
2. Removethe belt by looseningthe pump adjusting hold the pulleywith the specialtooland removethe
bolt and mountingbolts. pulleynut and pulley.

3. D i s c o n n e c t h e i n l e t a n d o u t l e t h o s e sf r o m t h e CAUTION: Bo clrstul not to damage the pump

pump and plug the hoses. ho$ing with thr iaw3 of ths vise.

NOTE;Take care not to spill ths tluid on the body NOTE:Pullevnut has left-handthreads.
or parts.Wipe off spillodfluid at once.

4. Removethe pump mountingbolt, then removeth€

pump

N O T E : D o n o t t u r n t h e s t e e r i n gw h e s l w i t h t h e
pump removeo

5. Wrap the opening of th€ pump with a piece of taps

to provent any foreign mat€rial. Se6 pags 17-44for
oumDinstsllstion,

OUTI.TTHOSE tNt.€THOSE

PULLEYNUT {Left-handthread)

(cont'dl

17-35
PowerSteeringPump
(cont'dl
Disassembly
Flow GontrolValveRemoval/lnspoction il. Inspectthe bore for the flow control valvs for scrat-
ches or wear.
l. Rsmovethe control valve cov€r by romoving the
threeflangebolts. 5. Slip the valve back in the pump and chockthat it
movesin and out smoothly.
2. Removethe spring, flow control valve and O-rings.

FLOW
CONTROL
VALVE

- lf OK, go on step 6, if not replace th6 valve and

rochsckthe valve movsment.

NOTE: The original valve was selectedfor a precise

fit in the pump housingbore,so makesureths n€w
on6 has the same identificationmark.

Outsid€Oiam€ter

Outside Diameter
Mark Part Name
Checkthe flow control valvg for wgar, burrs, and mm (in)
other damage to the edges of th€ groovos in tho FLOWCONTROL 17.991- 17.996
A
VALVEA (0.7083- 0.7085)
FLOWCONTROL 17.996- 18.001
VALVEB {0.7085- 0.7087}
FLOW
OONTROLVALVE
- lf the valve movement still incorr€ct, replacothe
pump as an assembly.

6. Attach a hose to the end of the valve as shown.

HOSE

Ch6ckfor
damags to €dgos.

FLOW CONTROLVALVE

17-36
7 . Submergethe valve in a containerof power steer- Pump Rotor Removal
ing fluid or solvent,and blow in the hose.lf air bub-
b l e s l e a kt h r o u g h t h e v a l v e a t l e s s t h a n 1 0 0 k P a CAUTION: Tho pump components are made ot alu-
11.0kgf/cm,,14.2psi),replaceor repairit as follows. minum. B€ car6ful not to damagethem when servicing.

1. Removethe inletjoint and O-rjng.

AIR PRESSURE

i- POWERSTEEBING
FLUIDor SOLVENT
13x 1.9mm
O.RING
Replac€.

8, Hold the bottom end of th€ valve with a oDenend

wrencn.
'\)4.
9. Unscrewthe seat in the top end of the valve, and nlll
removeany shims,the reliefcheckball, reliefvalve
and reliefvalvespring,
REUEFVALVE RELIEFCHECKBALL
sHrM(sl
lf us€d. SEAT
13 N.m
11.3ks[.m, I lbf.tt]
2. Removethe pump coverand O-ring.

PUMPCOVER

Clampthisend in
a vise with sott iaws. 58.5x 1.5mm
O.RING
FLOWCONTROL
VALVE REUEFvALvE Feplace.
SPBING
10. Clean all the parts in solvent, dry them off, then
reassembleand retestthe valve.Sge page 17-43for
f low controlvalve installation.

NOTE: lf necessary,relief pressureis adiustedat

the facto.y by adding shims under the check ball
seat.lf you found shims in your valve,be sure you
reinstallas many as you took out, (cont'd)

17-37
Power Steering Pump
Disassembly{cont'd}
3. Removethe pump cam ring from the pump hous- Removethe two rollersfrom the side plate.
Ing.
Removethe side piateand preloadspring.
N O T E :R e p l a c et h e p u m p a s a n a s s e m b l y i. f t h e
cam ring must be replaced. N O T E : R e p l a c et h e p u m p a s a n a s s e m b l y i, f t h e
side platemust be replaced.
PUMPCAM RING
Checkfor damageor wear. ROLI..ER
5 x 26.8 mm

SIDEPLATE
Checkfor damageor wear.

ROLLER
4,5 x 119.8
mm

Removethe pump rotorand vanes.

N O T E :R e p l a c et h e p u m p a s a n a s s e m b l y ,i f t h e
pump rotor or vanesmust be replaced. 7. Remove the O-rings from the side plate.

PUMPROTOR
Checklor damageor wear.

16.8x 1.9mm
O.RING
Replace.

54 x 1.9 mm
O-RING
Replace.

17 3 4
 R e m o v €t h e c i r c l i p ,t h e n r e m o v et h e d r i v e s h a f t Removeand discardthe bearingusing the special
assemblyfrom the pump housing using a plastic tool and a gress.
namm€r.
Pra3s

+
Removethe sealspacerand oil seal.

Inspectthe pump housingfor damageon the seal-

ing surfaces.

/-clRcLlP
ra-,"
Q'/
DRIVESHAFT
for bend,
damageor wear,

I{UB DIS/ASSEMBLYBASE
07GAF- SD40700

1 3 . Installthe new bearingusing the special tool and a

press.

Press

PUMPHOUSING

11. lnspectthe bearingby rotatingthe outar raceslow-

+
ly. lf any play or roughnessis felt, replacethe bear-
ing.
Installwiththe
red shieldedside
lacingdown.

07GAF- SDis)700
NOTE:Supportthe innerrace
with the tool securely.

17-39
PowerSteeringPump
Reassembly
CAUTION: The power steering componsnts are mado of sluminum. Avoid dsmaging th€ componcnts during assombly,

NOTE:
. Cleanthe disassembledpans with a solventand dry them with compressedair. Do not dip the rubber parts in a sof
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply recommendedpower steeringfluid or steeringgrease(HondaP/N:08733- B070E)to the parts indicatedin the
assemblvprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe powersteeringsystem.
. Replacethepump asan assemblyifthe partsindicatedwith asterisk(*) are worn or damaged.

ROLLER
5 x 26.8 mm
."'MP cAM RING
PUMPcovEn
/ .",orr*r,
\ , /
-e^urrae
vrues
\ ^ / pratesl / / sirx1.smm
\A
\Al {ro
{roPlatesl o_nrNc
o-ntNG
I I / Replace.
d A - h 1 / / E Z i l * l / / / ' ^ e e ' a c e
,h$;@:",n1 16.8x 1.9mm O-RING
.PUMP HOUSING

xf:.i'/pp@6{fr;ry
i'"otr
tt.m,1a|t t.fti//
ROLLER
RoLLER
ag.amm /
a.5 x 49.8
1.5
/-V#m
/
/
|
|
/
\E PUMPSEAL
SPACER
DRIVESHAFT

68.5x 1.9 mm I

>ei
o-RING
O-R|NG INLETJO-INT
//
Reptace.
Replace.
I
'PUMP ROTOR

iiij:f:,ll-T;-,",,,,ll;il'- g--lblY""."*";Replace. :
srntnc
$+---
E -5.8x1.9mm
o^::t:\-G
22.r x r.9 mm o-RfNG ------t@-<'t Replace.
Replace.

FLANGEBOLT
'11N.m
11.1kg-m,8lb-ftI
CONTROLVALVECOVEN

17-40
Pump Rotor Installation 6. Install the preload spring in the pump housing.

L Coatthe lip of the new oil sealwith steeringgrease 7. Set the 4.5 x 49.8 mm roller in the 4.5 mm hole in
(HondaP/N08733- 8070E). t h e p u m ph o u s i n g .

I n s t a l lt h e n e w o i l s e a l i n t h e p u m p h o u s i n gb y 8. Setthe side plateover the rollerand installit on the

hand,then installthe pump sealspacer. p u m ph o u s r n g .

NOTE:Insertthe oil seal with its groovedside fac- 9. Set the 5 x 26.8mm roller in the 5 mm hole in the
ingin. side plate.
5 x 26.8 mm
3. Installthe pump drive shaftassemblywith the spe- ROLLER
cialtool.

4. Installthe 38 mm circlipwith its taperedsidefacing

out, 5 mm HOLE
DRIVERATTACHMENT
38 mm SIDEPLATE
07947 - 6:1io500
crncuP

- DRIVE PRELOAD
SPRING
fu'/'i,Er
t\=zl4

I"J PUMPSEAL
If /sprcen
x,
tY -ot seal
,1.5mm

-Gll

ATTACHMENT, 37 x ,r0
07t,16- dt102d,

1 0 . Assemblepump rotorto the drive shaftwith the "o"

markon the rotorfacingupward.

1 1 . Setthe 10 vanesin the groovesin the rotor.

5. Coatthe side plate grooveswith the recommended NOTE:8e surethat the round ends of the vanesare
p o w e r s t e e r i n gf l u i d , t h e n p o s i t i o nt h e 1 6 . 8x in contactwith the slidingsurfaceof the cam ring.
1.9 mm and 54 x 1,9mm O-ringson the side plate. PUMPROTOR
16.8x 1.9mm
O.RING

5a x 1,9
O.RING

(cont'd)
SIDEPLATE

17-41
PowerSteeringPump
(cont'dl
Reassembly
Set the pump cam ring over the two rollerswith the 1 7 . Setthe 13 x 1.9mm O-ringon the inletjoint.
"8" markon the cam ring upward.
1 8 . Installthe inletjoint on the pump housing.
1 3 . Apply clean power steeringfluid to the vanes and
cam ring.
11.1kgt.m. t lbf.ftl
PUMPCAM RING INLETJOINT

1 3x 1 . 9
O.RING

T9
1 4 . Installthe 68.5x 1,9mm O-ringon the pump cover.

1 5 . Align the rollerset holesin the pump coverwith the

rollers.
'16. Align
the projectionon the pump housingand the
projectionon the pump cover,and tighten the four
bolts.
20N.m
{2.0 kg .m, lil lbf.ftl

PUMPCOVER

PROJECTIONS

17 -42
Flow Gontrol Valve Installation PulleyInstallation

1. Apply steeringgrease(HondaP/N08733- B070E)to 1. Holdthe steeringpump in a visewith softjaws.

new O-rings.
CAUTION: Be careful not to damago the pump
2. Coatthe flow controlvalvewith clean power steer- hou3ing with the laws ol th€ vise.
i n gf l u i d .
2. Installthe pump pulley as shown. Then installthe
3. Install the flow control valve, spring and control pulleynut.
valvecoveron the pump housing.

4. Tightenthe threecontrolcover bolts.

PULLEYNUT
FLOWCONTROL
VALVE

E;W
SPRING

11 N.m {1.1kgl.m,8lbtftl

2 Holdthe pulleywith the specialtool and tightenthe

pulleynut.
PULLEY

PULLEY NUT
6irN.m(6.5kgt.m,47lbt tt)

Checkthat the pump turns smoothlyby turningthe

pulrey.

17-43
Power Steering Pump
lnstallation
1. C o n n e c tt h e i n l e t a n d o u t l e t h o s e s .T i g h t e nt h e Adjustthe pump belt (seepage 17-201.
pump fiftingssecurely.
5. Fillthe reservoirto the uoDerlevelline.
Looselyinstallthe pump in the pump bracketwith
mountingbolts. NOTE;Takecare not to spill the fluid on the body
11N.m and parts.Wipe off the spilledfluid at once.
11.rkgf.m,8lbf.ftl
OUTIIT HOUSE
GAUTION: Uro only Ganuino Honda Powor Stsor.
ing Fluid-V. Using othor tlui& 3uch a3 ATF or oiher
INI.TTHOSE manutacturor's powor steering tluid will drm89e
O-RING
Replaco. the rystgm.

SYSTEM CAPACITY:
ADJUSTING 1.06litor(1.12US.qt,0.93lmp.qt)
BOLT RESERVOIR CAPACIW:
0.79 litor (0.1|:|US.qt, 0.?0 lmp.qtl

UP?ERI.fVEL LINE

IEVEI LINE

- Start the engine,let it run at idle, then turn the

PUMPMOUNTINGBOLTS steering wheel lock-to-lockseveraltimes to bleed
2,r N.m {2.4 kgl.m. 17 lbf'ft} air from the system.

- Recheckthe fluid level and add some if neces-

s8ry.
Installthe DumDbelt.
CAUTIONTDo not fill tha .63ervoir boyond th6
CAUTION: upp€r lcvol lino.
. Make surs that thg powor gtooring bslt i!
securglyon the grooyos of ths pulloy!.
. Do not get powor stggring fluid o. groaso in thg
power steering bclt or pulley trc6. Cloanoft 8ny
tluid or groa36belore installation.

POWER BELT
STEERING

PULI..EY

17 -44
SteeringGearbox
Removal
NOTE:Usingsolventand a brush,wash any oil and dirt R e m o v et h e c o t t e r p i n t r o m t h e c a s t l e n u t a n d
off the valve body unit, its lines, and the end if the gear- removo the nut.
box. Blow dry with compressedair.
Installthe10 mm hex nut on the balljoint.
1. Drain the power steering fluid as describedon page Be surethat ths 10 mm hex nut is flush with the ball
1 7- 2 1 . ioint pin end, or the threaded section of the ball
i o i n t p i n m i g h t b e d a m a g e db y t h e b a l l i o i n t
2. Rsisethe front of car, and support on safety stands remover.
in the propsr locations(seesection 1).
NOTE: Removethe ball joint using the Ball Joint
3. Removethe front wheels. Remover,28 mm {07MAC- 5100200}.Referto page
l8-11 fot how to use the ball joint rcmover,
il. Removsthe st€eringjoint cove.,
8. Separat€the tie-rodball joint and knuckleusingthe
soscialtool.

SIEERINGJOIi{TCOVEB CAUTION: Avold d.maging th. blllloint boot.

28 mm
BALLJOlt{T REMOVER.
07MAC- SLqt2|X)

Removethe steering joint lower bolt, and move the Disconnectthe shift linkage {MfI model: see section
joint towardthe column. 13,A/[ model see section 14).

NOTE: Lock the steering shaft with the ignition key 1 0 . Disconnectthe heatedoxygen sensor (H02S)con-
to retain the steering shaft position. ngctor, and separatethe three way catalyticconver-
ter by removing the s€lf-lockingnuts.

NOTE: Always replacethe gasketswith new ones.

HEATEDOXycEt{S€NSOnOONNECTOR SELF.LOCKINGNUT

{cont'd)
IHREE WAY
Replacs. CA?ALYTICCONVERTEN

17-45
SteeringGearbox
Removal(cont'dl
1 1 . Removethe return pipe clamp from the left side of 14. Disconnectthe two linesfrom th€ valve bodv unit
the rear beam.and move the returnpiDeabovethe on the steering gea.box.
steeringgearbox.
CAUTION: Aftor dkconnccting tho ho3o and pip.,
12. Removethe rearbeambrace. plug or r.d thc ho3. rnd pipc whh I pioco of tapo
or .quivll.nt to prcvont torcign m!tori!|3 f.om
ritrdng thc vdv. body unit.
RETURNPIPECLAMP
NOTE:
. Placethe pipe disconnectedin the previous step
at the rear side of the gearboxso that they do
not hinderin the gearboxremoval.
. Do not loosen the cylinder pipes A and B be-
tweenthe valvebody unit and cylinder,

RETUR]T
HOSE

1 3 . Removethe left tie-rod end, then slide the rack

the way to the right.

I.TFTTIE-ROD
END

15. Removethe steeringgearboxmountingbolts.

GEARBOXMOU NNG BOLTS

17-46
 Pull the steeringgearboxall the way down to clear
the pinion shaftfrom the bulkhead,and removethe
pinionshaftgrommet.

1 1 . Move the steeringgearboxto the right so the left

rackgnd clearsthe rearbeam.

1 8 . Hold the steeringgearboxand slidethe rackall the

way to the left, then placethe left rack end below
the rearbeam.

1 9 . Move the steeringgearboxto the left. and tilr the

left side down to remove it from the car.

PINIONSHAFTGROMMET

STEEBINGGEARBOX

17-47
Steering Gearbox
Disassembly
Stssring RackDisassembly 5. Hold the steeringrack with a wrench and unscrew
the rackend with a wrench.
NOTE:
. Before disassemblingthe gearbox,wash it off with
solventand a brush.
. Do not dip sealsand O-ringsin solvent.

1. Removethe steeringgearbox(seepage 17-45).

2. Removethe air hoseand clips.

3. Removethe tie-rodend and locknut.

L o o s e nt h 6 l o c k n u t a n d r e m o v e t h a r a c k g u i d e
screw.

7. Ramovethe spring and rack guide from the gear

CLIP housing.

4. Removethe boot bands and tube clamps.Pull the

bootsawayfrom the endsof the gearbox.

TUBECLAMP
LOCKNUT RACKGUIDE

BOOT

17-48,
Removethe cylinder pipe A and B from the gear-
box.
Drainthe fluid from the cylinderfittings by moving
the steeringrackbackand forth,
1 1 . Drill a 3 mm {0.12in) diameterhole approximately
2.5 - 3.5 mm (0.10- 0.14in) in depth in the staked-
point on the cylinder.
NOTE: Do not allow metal shavingsto enter the
cylinderhousing.

CYLINDERPIPEB STAKEOPOINT
D.prh:2.5- 3,0mm 10.10
- 0.12inl

CYUNDER
END

12. Installa pulleryoke to the stesringgearbox.Clamp

the puller yoke in a vise with soft iaws as shown,
then loosenand removethe cvlinderend.

Removethe two flangebolts,then removethe valve PULLER YOKE:

body unit from the gearbox. {See page 17-51for CommercirllyAvrilablo
valvebody unit disassembly.) Sn.p-OnoT/N qrie'-1
oTcloT/N 7372
VALVEBODYUNIT

FLANGEBOLT

(cont'd)

17-49
SteeringGearbox
Disassemblylcont'd)
13, Setthe gearboxin a pressso the gearhousingpoints
upward.
14. Installtheflangeboltintothe endofthe steeringrack
until it bottomsin the hole,then backthe flangebolt
out 1/4 turn. Hold the tlange bolt and tighten the
flangenut againstthe rackby hand.
1 7 . Removethe 12 mm bolt and nut from the steering
rack,then installa 24"long.3/8"driveextension,and
the specialtool into the cylinderfrom the gearbox
side.
CAUTION: Be caretul not to damagc th€ in3idr
surfaceot ths housing with tho tool3.

15. Pressthe cylinderend sealand steeringrackout of 1 8 . Setthe gearboxin a press,then pressout the cylinder
the gearbox, end sealand backupring trom the gearbox.

NOTE: Holdthe sreeringrackto keepit from talling CAUTION:

when pressedclear. Ksepthe tool straight to avoid damagingthacYlind.r
Pre$ wall. Chscktis tool angls, and corr€st if nrcolrary,
VINYL TAPE
whsn rsmoving the cylinder end seal.
I Use ! prors to r6movo tho cylinder end rgal. Do not
try to remove the soal by 3triking ths tool. h will
break the brckup ring and tho cylind€r end leal will
romain in ths gsarbox.

2it" LONG3/8" DRIVEEXTENSION:

Comm€rcirllyAvailobl.
12 mm STEERING
FLANGENUT GEARBOX

1 6 . Removethe soecialtool and cylinderend seallrom

the steeringrack.
ENDSEAL
CYLINDER
REMOVERATTACHME?ST

CYLINDERENO
SEAL

19. Carefullypry the pistonseal ring and O-iing off the

pistonof the rack.

CAUTION: Be careful not to damags th€ insidc ot

seal ring groove whgn romoving th€ seal ring.

Replace.

17-50
20. Apply vinyl tape to the pinionshaft. 2 3 . C h e c kf o . w e a r . b u r r s a n d o t h e r d a m a g et o t h e
edgesof the groovesin the sleeve.
2 1 . Separatethe valve housingfrom the pinion shafv
valveusinga press. NOTE:The pinion shaft and sleeveare a precision
matched set. It either the pinion shaft or sleeve
must be replaced,replacethe both partsas a set.
VALVEHOUSING

SLEEVESEALRINGS
Ch6ckfor oeel off or
oamag0,

Vinyl t.p.

22. Checkthe innerwall of the valve housingwherethe 24. Removethe circlipand pinionshaft sleevefrom the
seal ring slideswith your finger.lf there is a step in oinionshaft.
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valvehousing.

NOTE:
There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valvehousingonly the wall is stepped.
When the valve housingis replaced,installnew
3 2 m m s h i m ( s )o n t h e b e a r i n gs u r f a c eo f t h e
housingto adjustthe thickness.

(cont'd)

17-51
SteeringGearbox
Disassembly(cont'dl
25. Using a cutter or an equivalenttool, cut and remove Removathe valve oil seal 8nd backup ring from the
the four seal rings from the sl6eve. pinionshaft.

CAUTION: Bc clroful not to drmrg. ths .dgc. ot NOTE:

thc alcava g1oov6 whan rcmoving the 3cd rings . Inspectthe ball bearing by rotating the outer
lnd O.ring. race slowly. lf thsre is excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
. The pinion shaft and sleeve are a precisefiu do
not intermix old and new pinion shaftsand
SI-EEVE
steev8s,

26. Using a cutter or an gquivalenttool, cut the valve

seal ring and O-ring Et the groove the pinion shaft. 28, Pressth6 valve oil s€al and roller besring out ofthe
Removethe valv€ saal ring 8nd O-ring, valve housing using a hydraulicpress and special
tool shown below.
CAUTION: Br crrltul not to drm.gr thc cdgct of
thc plnion rhdt grooya whcn rcmoving the vllvc
!.!l ring rnd O-ring.
PILOTCOLLAR
O?GAF- PHTO1OO

Cutting slot position.

17.52
Reassembly
NOTE:
. Cleanthe disassembledpartswith a solventand dry them with compressedair. Do not dip the rubberparts in a sol-
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply power steering fluid or steering grease{HONDAP/N: 08733- 8070E)to the parts indicated in the assembly pro-
cedures.
. Do not allow dust,dirt. or otherforeignmaterialsto enterthe powersteeringsystem.
. Usethe appropriatespecialtoolswhere necessary.

FLANGCBOLT
20 N.m 12.0kg{.m, lil lbt'ftl

CYLINDERPIPEA VALVEI{OUSING
26 N'm (2.7 kgf.m, 20 lbf.ftl

BOLI..ERBEARING
Replace.

VALVE SEAL RING +-cncl|P

Replace.
SITEVE
S1IEVE SEAI RINGS
Reolace.
BACKUPRIM}

VALVE SEAL RING

Raplacs.
RACKGUIDESCREW O.RING
LOCKNUT Replac€.

PINIONSHAFT
CYLINDERHOUSING
\ SHIMS
O-RING
BACKUPRING \ Replace. O-RING
Replace.
CYUNDERENDSEAL
Reolace.
GEARHOUSING

CYLINDEREND SEAL O.RING

Replaco. Replace.

I
x$ Ynd#
I
PISTONSEALRING
STEERINGRACK
Replace.

(cont'd)

17-53
SteeringGearbox
Reassembly
lcont'd)
Vllvc Body Rea3sombly 7. Apply power steering fluid to the surface of the
v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n
1. Apply vinyl tape to the steppedportion of the pin- shaft.
ion shaft,and coat the surfaceof the vinyl tape with 8. Apply power steeringfluid to the insideof the spe-
the power steeringtluid, cial tool. Set the largerdiameterend of the special
2. I n s t a l lt h e b a c k u p r i n g w i t h i t s t a p e r e d s i d e a s tool over the valvesealring.
shown below. 9. Move the specialtool up and down severaltimes to
3. Coat the inside surface of the new valve oil seal makethe valvesealring Jit in the pinionshaft.
with powersteeringfluid. 10. Removethe specialtool.
4. Slide the valve oil seal over the pinion shaft.being . 1 1 . T u r nt h e s p e c i atlo o l o v e ra n d s e t t h es m a l l e r d i a m -
carefulnot to damagethe sealinglip. eter end of the specialtool over the valveseal ring.
Move the sDecialtool uD and down severaitimes to
CAUTION: ln3tall the valve oil ssal with hs groovad m a k et h e v a l v e s e a l r i n g s n u g l yf i t i n t h e p i n i o n
3idetacing opposits the besring. shaft.

Vinyl trpo Taperedposition.

lst.ppcd ponion,

Groove side.

VALVESEALRING

VALVEOIL SEAL S€alinglip

E
(H(ffi
Usethe widerdiameter
Fit the new O-ringin the grooveof the pinion shaft. end ot the special
Then slide the new valve seal ring over the shaft tool first to make
the valvesealring
and groovein on the pinionshaft. fit in the pinion
Removethe vinyl tapefrom the pinionshaft. shaft.
Make the valve seal ring
snuglyfit in the.pinion
shaftusingthe otherend
(smallerdiameterend)of
the specialtool.

NOTE:Do not over - expandthe valvesaalring.

PINION SHAFT

VALVESEALRING

17-54
 Apply powersteeringfluid to the surfaceof the spe-
cialtool. Set the new sealrings overthe specialtool
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l , a n d
expandthe seal rings.Do two rings at a time from
eachend of the sleeve,
NOTE:
. Do not over-expand the seal ring.Installthe resin
seal rings with care so as not to damagethem.
After installation,be sure to contract the seal
rings usingthe specialtool{sizingtool}.
. There are two types of sleeve seal rings: black
a n d b r o w n . D o n o t m i x t h e d i f f e r e n tt y p e s o f
sleevesealringsas they are not compatible.
't7. Apply power steeringfluid to the surfaceol the pin-
ion shaft,then assemblethe sleeveover the pinion
shaft,aligningthe locatingpin on the insideof the
sleevewith the cutoutin the shaft,
NOTE:Be carefulnot to damagethe valveseal ring
when insertingthe sleeve.
1 8 . Installthe circlipsecurelyin the pinionshaftgroove.
NOTE:Installrh€ circlipwith its taperedside facing
OUI.
Cutout,

1 3 . Setthe specialtool in the groovesin the sleeve.and

set eachring in eachgroovesecurely.

NOTE: After installation,compressthe seal rings

with your fingerstemporarily.

BALLJOINT BOOTCLIPGUIDE
o?MAG - SL001d)

19. Apply power steeringfluid to the seal ring lip of the

v a l v e o i l s e a l .T h e n i n s t a l lt h e s e a l i n t h e v a l v e
housingusinga hydraulicpressand specialtools as
shown.

14. Apply power steeringfluid to the seal rings on the ATTACHMENT,

32x35mm
sleeveand to the entireinsidesurfaceof the special 077{6 - 0010100
tool.
15. Insertthe sleeveinto the specialtoolslowly.
1 6 . M o v e t h e s l € e v ee a c h d i r e c t i o ns e v e r a lt i m e s t o
makethe sealringssnuglyfit in the sleeve.

NOTE:Be surethat the sealringsare not turnedup.

SLEEVESEALRING
SIZINGTOOL
07974- 5450200

VALVEOIL SEAL

{cont'd) ir

17-55
SteeringGearbox
(cont'd)
Reassembly
20. Pressthe new roller bearinginto the valve housing 2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
usinga hydraulicpressand specialtool as shown. Dressas shown.

NOTE:Placeths roller bearingon the valve hous- CAUTION: Before irserting the pinion 3haft, bo
ing with its letter stamped facing up towards the suro that the backup ring is csntored with the pin.
valveside. ion shaft bearing,
Pr.33, ATTACHMENT,
32x35mm
I - (x)1010O
077/aO

BACKUPBING
ROLLERBEARING
Letterstampedface

2 1 . Apply vinyl tape to the pinion shaft,then coat the

vinyl tape with powersteeringfluid.

Insertthe pinionshaftinto the valvehousing.

CAUTION: Be carotul not to damage tho valvs soal

rings.

23. Removethe vinyltapefrom the pinionshaft.

Soalinglip frc..

VALVEOIL SEAL

VALVCHOUSING

PINION

E
SI,-EEVESEAL RINGS
Be surethat the
searings are not
turnedup,then
install.

17-56
25. Coatthe pistonseal ring guide with power steering 3 1 . Coatthe sliding surfaceof the specialtool and new
fluid, and slideit onto the rack,big end first. cylinderend sealwith powersteeringfluid.

26. Positionthe new O-ringand new pistonseal ring on 32. Placethe seal on the specialtool with its grooved
the specialtool, then slide them down towards big sidefacingoppositethe specialtool.
end of the tool.

NOTE:
. Do not over expand resin seal rings. Installthe
resin seal ring with care so as not to damage
them. After installation,be sure to contractthe
Groovedside.
sealring usingthe specialtool (sizingtool).
. Replacepiston'sO-ringand sealring as a set.

Pull the O-ringoff into the pistongroove,then pull

the pistonsealring off into the pistongrooveon top
of the O-ring.

PISTON CYLINDEREND
SEALSLIDER
0797a - 6890801
CYLINDEREND SEAL
PISTONSEALRING
GUIDE
07GAG- SD,OI00 Apply a thin coat of greaseto the insideof the spe-
cial tool, and installit on the steeringrack.

CAUTION:Make sure the rack teeth do not tace

O.RING
the slot in the specialtool.

PISTONSEALRING
CYLINOERENDSEAL

28. Coat the piston seal ring and inside of the special
toolwith power steeringfluid.

Carefullyslide the tool onto the rack and over the

pistonsealring.

30. Move the specialtool back and forth severaltimes

to makethe pistonsealring fit snuglyin the piston.

PISTON

SEALSLIDER
0t974 - 6890801 (cont'd)

17-57
SteeringGearbox
Reassembly
lcont'dl
34. Separatethe cylinderend sealfrom the spscialtool,
then remove the tool from the steering .ack.
CYUNDERENDSEAL
12 x 170 mm FLANGEBOLT
lnstall the backup ring on the steering rack, then
placethe cylinderend sealto piston.
BACKUPRING
CYLINDERENDSCAL
Greasethe steering rack teeth, then insert the steer-
ing rackinto the gear housing.
CAUTION: Be clrs{ul not to d.mage to inn9r !ur-
ftca of thc goar housing with th€ rsck cdg6.
17-58
3 7 . Setlhe gearboxin a presswith the cylindorhousing
facing upward.
Installthe flangebolt intothe end of the steeringrack
until it bottomsin the hole,then backthe flang€bolt
out 1/il turn. Hold the flange bolt and tighten the
flangenut againstthe rackby hand.
'to
Installthe cylinderend seal into the bottom of the
cylinder by pressingon the bolt with a press as
shown.
CAUTION: Do not push on ihc bolt with excelcivr
forcc; 83 it may dEmagothr cylindor ond 3o!1.
Pr9!t
12 mm FLANGENUT
STEERINGRACK
CYUNDERENDSEAL
Removethe flangebolt and centerthe steeringrack.
4 1 . Installthe specialtool or vinyl tape onto the end of
the steering rack, then coat the specialtool or vinyl
tapewith powersteeringfluid.
Coatthe insidesurfaceof the new cylinderend seal
with power steeringfluid.
Installthe cylinderend seal onto the ste€ringrack
with its grooved side toward the piston.
Removethe specialtool. Push in the cylinder end
sealwith finger.
NOTE: Take care not to damagethe cylinder end
seal with the threads and burrs at the stakod oosi-
tion of the gearbox.
St k d po3ition.
c.oov.d3id...--#
<r|'
---_-EE]TmIrnTr-
--------EJl Li IL ll
CYUNDERENDSEAL
 Installa puller yoke to the steeringgearbox,then ,t8. Selectthe 32 mm shim(s).
clamp the puller yoke in a vise with soft jaws as
shown. N O T E :O n l y r e i n s t a ltl h e o r i g i n a l3 2 m m s h i m ( s )
when the steering gearbox is reassembledwithout
replacingthe pinion shaft,valve housing,and gear-
PULLER YOXE:
CommcrcirllyAvrihblo box housingwith new ones.
Sn.p-OnoT/N Cr123-l l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x
orco T/N 7372 housingare replaced,selectthe new shim{s)as fol-
or aquivrlani rows.

Shim r€lection:
-'1. Set the four 32 mm shimson the b€aringsurfaceof
the gearbox housing. Total thicknessof the four
shimsshouldeoualno more than 0.70mm.
Shim set: tour 32 mm shims (Thickness:0.10 mm,
0.15mm, 0.20,0.25mm respectivelyl

CAUTION: The tour 32 mm shimr do not hlva

thlckn$s idcntitication mukt. Mo!3ur. tho thicl-
oa33 of rach 3him using a miclomctrl, and mlrk
tho shim lor id6ntific8tion.

- 2 . I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x ,a n d
Greasethe insidesurfaceof the cylinderend, then tighten the flange bolts to the specitiedtorque
installthe cylinderend by screwingit into the cylin-
d e rh o u s i n g . VALVEBODYUNIT

4 1 . After tighteningthe cylinderend, stakethe point of

the cylinderhousingshown below. FLANGEBOLT
NOTE:Stakein the cylinderin the positionopposite 20 N.m {2.okgtm, 14lbt'ftl
from where the stake was removed during disas-
semblv. SHIM SET
{foul thim.)
Strke point, D.pth: 1.0 mm (0.04inl
4.0 mm 10.15inl
CYLINDERHOUSING
CYLINDEREND

Measurethe clearancebetween the gearbox and

valvebody unit usinga feelergaugeas shown.
NOTE:Measurethe clearanceat the point midway
betweenthe two mounting bolts.

CYLINOER
69 N.m 17.0kgf.m, 51 lbtft)

(cont'd)

17-59
SteeringGearbox
Reassembly
lcont'd)
- 4 . D e t e r m i n et h e r e q u i f e dt h i c k n e s so f t h e 3 2 m m 54. Installthecylind6rpipesA and B.
shims by subtractingthe clearanceobtainedin the
step-3 from the total thicknessof the four shims. NOTE:
( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( C l e a r a n c e=) . Cleanthe jointsofthe cylinderpipeA and B tho.-
Requiredthicknessof the shims oughly. The joints must be free of foreign mat€.i-
at,
NOTE:Selectthe shims so that th6 total thickness o Installthe cylinderpipe A and B by tighting the
is closeto, but lessthan the requiredthickness. flare nuts by hand first, then tighten the flare
nuts to the specified torque starting with the
Exampls: cylinderside nuts.
Measu.ementis 0.28mm (0.011in):
0.70- 0.28= 0.42mm (0.028- 0.011= 0.0't7in) CYLINDER
PIPEB
26 N.m (2.7kg{.m,20lbtft)
The selectedshims should be 0.25 mm (O.O1O
in) and
0.15mm (0.005in) in thickness.

l f t h e r e q u i r e ds h i m t h i c k n e s si s 0 . l O m m o r l e s s ,n o
shims are necessary.

i[9. Set the selected32 mm shims on the bearingsur-

faceof the g€arboxhousing.
50, Coatthe new O-ringwith gresseand installit in the
groovein the gearboxhousing.
c t . Apply greaseto the needlebearingin the gearbox
housing.
Installthe valve body unit on the gearboxhousing Greasethe sliding surface of the rack guide and
by engagingthe gears. installit onto the gear housing.
Apply a thin coat of greaseto the n€w O-ring and
NOTE: Note the valve body unit installationposi- installit on the rackguidescrew.
tion (directionof pipe connection). Installthe spring, rack guide screw and locknuton
the gear housing.
Tightenthe flangeboltsto the specifiedtorque. Adjustthe rackguide screw(seepage l7-21).

NOTE:After adjusting,checkthat the rack moves

FLANGEBOLT
20 N.m (2.0 kgt m, 14lbf.ft) smoothlyby slidingto rackright and left.

VALVEBODYUNIT

-6t
O-RING

-ffiti
LOCKNUT

NEEOLEBEARING

_#{ BACKGUIDESCREW

17-60
 Install the new lock washor in the groov€ in the 62. Apply steering groass to the circumferenc6 of tho
steering rack. rackend housing.

60. Hold the steering rack with I wrsnch and tighten Coat the rack end groove and inside of the boot
the rackend. with siliconegreas€.

o l After tightening th€ rack end, stskethe four sections 64. l n s t s l l t h e b o o t s i n t h s r a c k e n d w i t h t h e t u b e

of lock washer with a commerciallyavailableroll clamos.
Dindrift and a mallet.
NOTE: Installthe boots with the rack in the straight
ahsad position (i.6. right and l€ft tis-rods ar€ squal
ROLL PIN DRIFT
in length).
Comm.rcl.lly Av|il.bl.
lsnrp-On No. PPR8or .rquiv.lenll

NOTE: Wipe ths gro.se off

the thread s€ction.

NOTE: This drift has a fl8t,

to prevent puncturing
of motal washer.

TUEE CLAJTIP
(cont'dl

17-61
SteeringGearbox
Reassembly(cont'dl

65. Adjust the air hose fitting position of the boots by 6 7 . Install new boot bands on the boot and bend both
turning it as shown below. sets of locking tabs.

Lightlytap on the doubled-overportionsto reduce

their height.

GAUTION: Stake tho band locking tabs firmly.

Front

Slide the rack right and left to be certainthat the

AIR HOSEFITTING boots are not detormed or twisted.

70. Install the right and left tie-rod ends on the rack
ends.

C o n n e c t h e a i r h o s e b e t w e e nt h e r i g h t a n d l e f t
boot.then installthe clips on the cylinderpipe B as
snown.

Installtherightclip
in thisposition.
CLIP

17-62
 lnstallation
CAUTION; BGGlrc{ul not io bcnd or drm8go tho piping 7. Centerthe steering rackwithin its stroke.
whcn in3tllling tho gea.box.
Makesurethat the cablereelof the SRSis centered
1. Beforeinstallingthe gearbox,slide the rack all the as follows:
way to right.
. Turn the steeringwheel left approx.150degrees,
2. Passthe right side of the steeringgearbox above to checkthe cablereelpositionwith indicator.
and throughthe right sideof the rearbeam. . lfthe cablereelis centered.the yellowgeartooth
linesup with the alignmentmarkon the cover.
3. Hold the steeringgearboxand slidethe rackall the . R e t u r n t h e s t e e r i n gw h e e l r i g h t a p p r o x . 1 5 0
wav to the left. degrees to position the steering wheel in the
straightaheadposition.
4. Raisethe left side of the steeringgearbox above YELLOWGEARTOOTH
and throughthe leftside of the rearbeam.

5. Installthe pinion shaft grommet and insertthe pin-

ion shaft up throughthe bulkhead.

NOTE:Align the tab on the pinion shaft grommet

with the slot in the valvebodv.
TAA

MARK
ALIGNMEi'IT

Slip the lower end of the steeringjoint onto the pin-

ion shaft(line up the bolt hole with the groove
aroundthe shaft),and tightenthe lower bolt.

NOTE:
. Connectthe steeringshaft and pinion with the
cablereeland steeringrackcentered.
. Be sure that the lower steeringioint bolt is se-
curelyin the groove in the steeringgearboxpin-
ion.
. lf the steeringwheel and rack are not centeted,
r e p o s i t i o nt h e s e r r a l i o n sa t l o w e r e n d o f t h e
steeringjoint.

6. Installand tightenthe gearboxmountingbolts.

NOTE: After installingthe gearbox,check the air

h o s e c o n n a c t i o n sf o r i n t e r f e r e n c ew i t h a d j a c e n t
pans.

58 N.m 15.9kg[.m, $ lbl.ftl

LOWERBOLT
22 N.m 12.2kgi.m, 16lbf.ftl
(cont'dl
38 N m 13.9kgl.m, 28 lbt.ftl

17-63
SteeringGearbox
Installation(cont'd)
10. Installthe steeringjoint cover with the clampsand 1 2 . I n s t a l lt h e r e a r b e a m b r a c e r o d a n d r e t u r n p i p e
cliDs. clampon the rearbeam.

N O T E : I n s t a l lt h e r e a r b e a m b r a c et o w a r d t h e
returnpipeclamp.

STEERINGJOINTCOVER 38 N.m 13.9kg{.m,28 lbf.ft)

CLIP

13. Install the three way catalyticconverter with the

new gasketsand new self-lockingnuts,and connect
11. Connectthe fluid linesto the valvebodv unit. the heatedoxygensensor(H02S)connector,

RETURNHOSE HEATED
OXYGEN
SENSOR
CONNECTOF
SELF.LOCKINGNUT
33 N.m 13.4

SELF.LOCKING NUT
22 N.m (2.2 kgt m, 16 lbt.ftl

14. Connectthe shift linkage (M/T model: see section

13,A/T model:seesection14).

17-64
 BallJoint Boot Replacement
1 5 . Threadthe right and lefi tie-rodends onto the rack Removethe boot set ring and the boot.
an eoualnumberof turns.
CAUTION:Do not contaminateihe boot in3talls-
TIE-ROOEND TIE.RODLOCKNUT tion section with gr€aso.

Packthe interiorof the boot and lip with grease.

Wipe the greaseoff the sliding surfaceof the ball

pin,then packthe lower areawith freshgrease.

CAUTION:
. Ke€p g;eass off the boot in3tallation section and
tho laperad section of the ball pin.
. Do not altow dust, di.t, or other toreign mat6ti-
als to enter tho boot,
LIP BALLPIN TAPERED
SECTION
Wipe off the grease.
R€connect the tie-rodends to the steeringknuckles,
tighten the castle nut to the specifiedtorque, and
installnew cotterpins.

CAUTION:Iorquo tho castle nut to tho lower tor-

que lpocification, thsn tighton it only far cnough to
align thc slot with tho pin hole. Do not align tho
nut by loosoning. BOOTINSTALLATION
BOOTINSTALLATION SECTION
NE.RODEND SECTION Wipe off the grease.
wiDe off the grease.

Installthe boot in the grooveot the boot installation

sectionsecurely,then bleedair.

SALLJOINTBOOT
CLIPGUIDE
07MAG- SL(x)l00
Adiust the depth by
turningthe tool.

CASILE NUT COTTERPIN

39 - 47 N.m On reassembly,bend SET RING
14.0- a.8 kgf.m. 29 - 35 lbf ftl the cotterpin as shown.

17. lnstallthe front wheels.

18. Fill the systemwith pgwer steeringfluid and bleed
air from the system(seepage 17-21).
performthe followingchecks.
19. After installation.
. Checkthe gearboxJor leaks(seepage 17-231
. Adjustthe front toe (seesection18).
o Checkthe steeringwheel spokeangle.Adjust by
turningthe right and lefttie-rods,if necessary.
Insertthe specialtool into the threadsin the ball pin
and align the end of the tool with the groovein the
boot.
Slidethe clip overthe tool and into position
CAUTION: After installing the boot, check th. b.ll
pin taperod section tor grease contamiration and
wipe it if nocossary.

Turn the right and lefttie-rodsequally.

17-65
R6ar Door: -3 Loosenthe locknutssecuringthe centerglass
guide,and adjustthe glassfore and aft by mov-
'13.
Adjust clearance"H" as follows. ing the center glassguide.

NOTE: Hold the adjusting bolts with a hex

"H" wrench or tlat tip screwdriverwhen loosening
lsos page 20-421
the locknuts.

- 1 Loosenthe nut securingthe stopperplates.

2 Loosenthe nut securingthe rollerguide, and

move the guide up or down to alignthe glass
with the body at the rear and center pillars.

GLASS

I
-4 Repeatsteps-2 and -3 until clearance"H" is
within the specifiedlimits.then fasten the center
ROLLERGUIDE
glass guide and rollerguide.
Pressthe stopperplatesagainstthe glassstop-
pers, then fasten the stopper plates.

NOTE: Checkthat the stopperplatescontact

the glassstoppersevenly.

STOPPERPLAYE
lF ontl

204s
Doors
GlassAdjustment(cont'dl
14. Adjust clearance"8" as follows. -3 Loosenthe upper locknut on the center glass
guide, and turn the adiustingbolt until cleatance
"B" is within the soecifiedvalue.

ADJUSTING
EOLT

"8" (see page 20-421

LOCKNUT
-l Lower the glass 1O mm {0.39 in). 1 2 x 1 . 2 5m m
22 N.m 12.2kgf.m,
- 2 Pushthe glassoutward 1Omm (O.39inl. then 16 tbt.ft)
againstthe glssslight-
pushthe insidestabilizers
ly. Fastenthe insidestabilizers.

NOTE: Checkthat the glassmoves smoothly. *

GLASS

NOTE: Do not adjustthe lower adjustingbolts

on the center glass guide.

-4 Move the glass up and down to seat it, then

measureclearance"8" at the designatedlo-
cattons.

- 5 Measureclea.ance"H" againto make sure it

is still wilhin the specifiedlimits at the desig-
nated locations.

NOTE: Repeatthe above steps until the correct

clearancesafe obtained.

20-46
15. After the clearanceshave been adjusledproperly. 1 7 . Check for water leaks.
reinstallthe weatherstrip.
NOTE; Do not use high pressurewater.
16. Check that the glass contacts the weatherstrip
evenly.

NOTE: Measuringpoints are describedon page

20-42.

18. Routethe door harnessand connectors,and fasten

them to the door (see pages 20-22, 331.
WEATHERSTRIP
19. Disconnectthe oowef window switchfrom the doo.
harness,then installthe power window switch on
the door panel (see page 20-41).
Conter Pillar soction:
2O. Attach the plasticcover,then installthe door panel
(see pages 2O-2O, 321.

2047
Doors
PositionAdjustment Striker Adjustment

NOTE: Placethe vehicleon a tirm, levelsurfacewhen Make surethe door latchessecurelywithout slamming.
adjustingthe doors. lf it needs adjustment;

After installingthe door, check for a flush fit with the 1 . Draw a line aroundthe st.iker for reJerence.
body, then checkfor equalgapsbetweenthe front, rear,
and bottom door edges and the body. Loosenthe screws,and move the strikerlN or OUT
The door and body edgesshouldalso be parallel.Adiust to make the latch tit tighter or looser.Move the strik-
at the hingesas shown. er UP or DOWN to align it with the latch opening.
Then liqhtly tighten the screws and recheck.
CAUTION: Plac€ a shop towsl on tho jack to pre-
vent damage to the door when loosening the dool
and hingo mounting bolts for adjustmont.

DOORMOUNTING BOLTS
8 x 1.25 mm 29 N.m l3.Okgl m, 22lbftrl
Loosen lhe door mo!nting bolts
slightlyto move the door lN or OUT
until ir's flush waththe body. It
necessary,you can installa shim be-
hind one hingeto make the door
edgesPAFALLELwith the body.
DOOR scREws
HIIGE xrruceMouNTTNG
BoLTs I x 1.25mm
I x 1.25mm 18 N.m ('1.8kgt.m, 13lbf.ttl
29 N.m l3.O kgt'm,22 lbl'ft)
Loosenthe hingemounting
bolts, and move the door
BACKWARDoI FORWARD,
UP or DOWN as necessary
to equalizethe gaps. NOTE: Holdrhe outerhandleout, andpushthe door
againstthe body to be sure the striker allows a flush
fit.

lf the door latchesproperly,tightenthe screwsand

Lower the glass, recheck.

SHOPTOWEL

The door and body edges should be parallel.

NOTE: Check tor water leaks.

20-48
Mirrors
PowerDoor Mirror Replacement
Hstchback Sedan

1. Pry out the cover panelwith a flat tip screwdriver, 1. Removethe door panel (seepage 20-201and dis-
then removeit. connect the connector.

CAUTION: When prying with a flat tip screwdriver. 2. Pry the cover panelout with a flat tip screwdriver,
w'ap it whh protoctiva tapo to pravont damage. then remove the cover panel.

CAUTION: Whsn prying with a flat tip scrowd.lv€l,

wrap it with protectiv€ taps to p.svont damag6.

HOOKS
2. Disconnectthe connector.Removethe nuts, then 3. Removethe screws while holdingthe door mirror.
removethe door mirror while holdinoit.
< i Scrow locations

< : Nut locltion3,3

, A< : Scrow, 2 , B< : Scr6w, I
^^ sxo.8mm I ! ,"",''@ I 66
| l m-t uto.+
l$9| +111 rst..
.+rg r.m, I
3 lbl'lrl i I s ' 0 . 4(0.4
.- | sro.'"e-.
- ---J'/ \ 4 N.m kst.m, \ + w.m (0.4 kgt.m,
\3_!!t.rrr__ \!Lbllq
cot{t{EcToB
(Doo. mirror ddol

DOOR MIRROR

CONNECTOR
lDoor harnoss
.ide)

CONNECTOR CONNECTOR

3. Installation is the reverse o{ the removal procedure. 4. Installation is the reverse of the removal procedure,

20-49
Mirrors
Mirror Holder Replacement

1. Carefullypry out the mirror holder with a tlat tip

Mirror Visor and Mirror Covel -
Replacement
I
screwdriveras shown. Hatchback

CAUTION: To p.ev€nt damage to tha mirlor, wrap 1. Removethe mirror holder.

ths end ot a tlat tip screwdriv€r with a shop towel.
2. Turnthe actuatorforward.then removethe screws.

< : Scrawlocation3,4

MIRRORHOLDER

2. Installationis the reverseof the removalorocedure.

NOTE: Apply greaseto the locationsindicatedby

the arrows.

Hatchback

3. Detachthe hooks, then removethe mirror visor.

JOINT PIN

Sedan

MIRRORVISOR

JOINT PIN

20-50
4. Turn the actuatorto the originalposition. Sedan
Removethe screws,then removethe mirrorcover.
1, Removethe mirror holder.
< : Scrowlocttions,3
2. Turn the mirror base forward, then remove the
screws.
< : Sciow location!

A< : Sc.ew, 4 8<: Screw, I

ACTUATOR

@ I 4E0 l
_ J _ . _ J

MIRRORBASE
-

5, Installationis the reverseol the removalDrocedure,

3. Detach the hook. then removethe mirror visor.

{cont'd)

20-51
Mirrors
Mirror Visor and Mirrol Covel RearviewMirror Replacement
Replacement{cont'd)
4. Removethe actuator,then removethe screws. 1 . Pry the cover off using the end ot a flat tip screw-
driver.
<: Scraw locations
CAUTION: To provent damage to tho miror and
A < : S c r € w ,3 B { : S c r e w ,2 C < : S c . e w ,1 cov€l, wrap tho end of the screwdriver with I shop
towol.

Remove the screws, then remove the rearview

mtrror.

SCREW
5x0.8mm
4 N.m {0.4 kgf.m,
3 tbf.ftl

ACTUATOR
REARVIEW
MIRROR

Turn the mirror base as shown, then removethe mir-

ror cover

SHOP TOWEL

3. Installation is the reverse of the removal procedure.

MIRRORCOVER

lnstallationis the reverseof the removalprocedure.

20-52
Windshield,RearWindow, OuarterGlass
lndex

NOTE: The numbersafter the part names show the quantitiesof the parts used.

Hatchback
UPPERMOLOING
UPPERRUBBERDAM
RIGHTSIDE
CLIP E. 2 Whir€

Cl-lP F, 2 Loft. Whito

Right. Bluo

CLIP A, I Rod

RETAINER,6 Orengo

CLIP B, 2 O.an96

CLIPC, 2 Black

LEFTSIDEMOLDING
Removal,page 20-55
CLIP D. 2 G.6en
Installation,page 20-56
e.'.
RETAINER, 2 Ysllow

REARWINDOWMOLOING
page 2O-65
Replacement,
UPPERSEAL

UPPERFASTENER,2
(S€lt-adh.sive-type,glass sid6l

UPPERFASTENER,2
(Self-6dhosiv6-type,hatch sidel

SIDERUAAER
DAM. 2

SIOESPACER.2

REARWINDOW
Removal,page 20'6'1
f ? *
""'^i^r.{"'/\
Instaflataon,page 20-62

LOWERFASTENER.2 LOWERFASTENER,2
{Self-adh6siv€-type, {Selt-adhosive-1ype,
glass sidel hatch sid6) ADHESIVETAPEB, 2

20-53
Windshield,RearWindow
lndex
NOTE: The numbersafter the part names show the quantitiesof the parts used.

Sodan

UPPER
MOLDII{G
UPPERRUEBEROAM
RIGHT SIDE MOLDING
cLtP E, 2 Whir6

CLIP F, 2 L6ft. Whlto

Righl. Bluo

CLIP A, I Rod

&...- *aro,nr*. 6 o'!.gc

€
e CLIP B, 2 B?own

WINDSHIELD
bq ,@
Removal,page20-55
Installation,page20-56 A
\
/ '
GLASSBRACKET,
2 RET
AINER. 2 Yollow

REARWINDOWMOLOING

UPPERFASTENER, 2
{S.ll-.dho!lvo-typo,gh$ .ldcl

g
.qB.....--
REARWINDOW
Removal, page 20-68 urra" FAslEr{ER,2
(Cllp-typo, body .ld.l
Installation,
page 20-69
&'.....- r,o, sPAcER,
4

R.-.......-"-.owER FA'TENER.
2
lsolf-.dhe3ivo-type, sla$ sidol

\
LOWERFASTENER, 2
(Solt-rdhe.lvo-typo.
body sidol
LOWERCOVER

20-54
Windshield
Removal
CAUTION: 3. Removethe right and left glass brackels.
a Woar glovos to l€mov€ and install the windshiold,
a Us€ saat covers to avoid damaging any surfaces.

1. To removethe windshield,first removethe:

a Front pillartrim (seepage 20-911
. Headliner(seepages 20-98. 1OO)
a Front wipers and air scoop (seesection 23)

2. Detach the clips trom the retainers,then remove

both side moldingsas shown.

NOTE: lf necessary,replaceany dsmagedclips.

4. Peeloft the upper molding.

NOTE: Whenthe uppermoldingremovalis ditticult,

cut the upper rubber portion O off, then cut the side
rubber portion@.

UPPER
MOLDII{G

ADHESIVE

WINDSHIELD

f--
CLIPC, D
>
5. Removethe other retainerstrom the bodv.

lcont'd)

20-55
Windshield
Removal(cont'd) lnstallation

6. Apply protective tape to along the edge ot the dash-
board and body as shown.
Usingan awl, make a hole throughthe rubberd8m
and adhesivefrom insidethe car. Pushthe pianowire
th.ought the hole, 8nd wrap each end arounda paece
of wood.
1. ScraDethe old adhesivesmooth with a knife, to a
thickness of about 2 mm (O.O8in) on ths bonding
surtace aroundthe entite windshieldopeningflange,
NOTE:
a Do not scrapedown to the paintsd surfaco ot the
body; damaged paint will interfere with proper
bonding.
a Remove the rubber dam from the bodv.
a Mask off surrounding surfaces betore painting.

w|l{osHlELo 2. Cleanthe body bondingsurtacewith a spongedamp-

ened in alcohol.

NOTE: Atter clesning,keep oil, greaseand water

from getting on the surface.

3. lf the old windshi€ldis to be reinstalled,use a putty

WII{DSHIELD knife to scrape df{ all iraces oJ old adhesive, then
cleanthe windshieldsurfacewith alcoholwhere new
PIANOWIRE adhesiveis to bs applied.

NOTE: Make su.e the bonding surface is kept {ree

of water, oil and grease.

CAUTION: Avoid sotllng thE wlndshiold on hs

edges; small chips may latct dcvelop into crack3'
ADHESIVE
DAM
a Cleanthe shadowedarea.
a Cleanthe area@ as shown.
Wilh a helperon the outside.pullthe pianowire back
and forth in a sawing motion. and carefully cut
InCd.
through the rubberdam and adhesivearoundthe en-
tire windshield. +
CAUTION: Hold tho dano vyi]oas clos6to tho wind-
shield as possible to pr€vsnt damag€ to ths body and vn77777ri_
dashboard. t
wtt{DsHtELo

WINDSHIELD

8. Carefullyremovethe windshield.

20-56
.--
4. Center and glue the upper moldingto the upper edge 6. Installthe glsss bracketsand retainersas shown.
of the windshield.
NOTE: The numbersatterthe pan namesshow the
quantitiesof the psrts used.

ALIGNMENTMARK
BRACKET,2

GIuethe uDDerand lower rubberdamsto the inside
face ot the windshield,as shown, to contain the
adhesiveduring installation,
NOTE: Be careful not to touch the windshieldwhere
adhesivewill be applied.
7. Set the windshieldon the glassbrackets,then center
it in the opening.Make alignmentmarksacrossthe
windshieldand body with a greasepencilatthe four
points shown.
ALIGNMENTMARK

RUBBER UPPERMOLDING
UPPER
12 mm {0.47 inl DAM

1O mm 10.39ln)

8. Removethe windshield.

20-57
Windshield
Installation(cont'd)

With a sponge.apply a light coal oJ glass primer
aroundthe edgeot the windshieldas shown, then
lightly wipe it olt with gauzeor cheesecloth.
NOTE:
a Do not apply body primerto the windshield,and
do not get body and glassprimerspongesmlxed
up.
a Nevertouch the primedsurfaceswith your hands.
ll you do, the adhesivemay not bondto the wind-
shieldproperly,causinga leakafterthewindshield
is installed.
o Keep water, dust, and abrasivematerialsawaY
from the primed surface.
V//f, : apptv stassptimer hors.
UPPERRUBBER UPPER
16 mm
WINDSHIELD 1O.63inl
10. With a sponge,apply a light coat of body primerto
the originaladhesiveremainingaround the wind-
shieldopeningflange. Let the bodY primerdry tor
at least 1O minutes.
NOTE:
a Do not apply glass primerto the body, and be
careful not to mix up glass and body primer
sponges,
a Nevertouch the primedsurfaceswith your hands.
a Mask otl the dashboard before painting the
flange.
//////, I Aeely bodv Primerh6te.
16mm
{0.63in)
5 mm {0.19 inl
6 mm (0.23 in)

5mm
RUBBER
- ( O . 1 9i n l
DAM .YJ * o 16 mm

>\ast,
/ \
10.63inl

WINDSHIELD
\
UPPERMOLOING

1 1 . Thoroughlymix the adhesiveand hardenertogether

on a glass or metal plate with a putty knife.

NOTE:
a Cleanthe platewith a spongeand alcoholbefore
mixlng.
a Follow the instructions that come with the
adhesive.

12. Beforefilling a cartridge,cut the end ol the nozzle,

as shown.

Cut nozzleend,
10 mm (O.39inl

7 mm 10.27in)

20-58
,*-
13. Pack adhesiveinto the cartridgewithout air pock- 15. Installthe clips on both side moldings.
ets to ensurecontinuousdelivery.Put the canridge
in a caulkinggun, and run a beadot adhesivearound >: Clip localione
the edge ot the windshieldas shown.
A> : Clip A, I B < : C l i pB , 2
NOTE: Apply the adhesivewithin 30 minutesafter
applying the glass primer. l A i
12 mm (0.47 in,
T-/
l_/ : roxesrve
UPPER
RUBBER f f i l
"___)
_)
U
8 m m lO.3'l inl
C<: Clip C lHatchback,2l
lsodan,4l
D<: Cllp D {Hatchback,2l E V : C l i pE , 2

Make a slightlythicker MOLDING

2mfi LOWER
I
lO.O7 inl RUBBEB
DAM

F) F llelt. Whitel
lRight. Bluel

A lRodl
I
E lwhite)

'14.
Use suction cups to hold the windshieldover the
opening,alignit with the alignmentmarks made in
step 7, and set it down on the adhesive.Lightly push SIDE A (Rod) /
on the windshielduntil its edgeis fully seatedon the MOLDING B lHatchback, Orangel
adhesiveall the way around. lsedan, B.own)
It
NOTE: Do not close or open the doors until adhe- \
sive is dry. C (Hstchback, Elack)
(Sodan, Orangel

SUCTION
D lHatchback, Green)
C (Sodan, O.ange)

16. Sc.apeor wipe the excessadhesiveoff with a Dut-

ty knife or towel.

NOTE: To removeadhesivetrom a paintedsurface

or the windshield,wipe with a solt shoptowel damp-
ened with alcohol.

20-59
Windshield
lnstallation(cont'd)
17. lnstall both side moldings. 18. Let the adhesivedry tor at least one hour. then spray
water overthe windshieldand checkfor leaks.Mark
leakingareas,and let the windshielddry, then seal
with sealant.

g
NOTE:
a Let the car stand tor at leastfour hoursafter wind-
shieldinstallation,lf the car hasto be used with-
in the first four hours,it must be drivenslowly
a KeeDthe windshielddry for the first hour after
installation.
CLIPE a Check that the ends of the side moldingare set
under the air scooP.

19. Reassembleall removedPans.

SIDEMOLOING

RETAINER

CLIP B

CLIP C, D

20-60
RearWindow
Removal
Hatchback 4. With a helperon the outside,pullthe pianowire back
CAUTION; and forth in a sawing motion, and carefully cut
a Use covsrs to avoid damaging tho interior. through the adhesivethe along the top and the sides
a Wear gloves to romove and install the glass. oJ the rear window.
a Do not damags the defroster grid linss.
a Tako care not scratch th€ raar window molding, CAUTION: Hold ths piano wire as clos€ to the roat
window as possibleto prevont damageto the body
1. To removethe rear window. first removethe: and molding.
a Rearshelt (seepage 20-91)
a Hatch side trim and hatch trim panel (seepage
20-146)
. High mount brake light (see section 23)
a Rearwiper and wiper motor (seesection 231

2. Removethe rear window trim and disconnectthe

connectors.

PROTECTIVETAPE

PROTECTIVE
TAPE
CONNECTOR
Cut the adhesivewith a knife at the bottom of the
aearwindow.
3. Apply protectivetape to the innerand outer edges
of the hatch. NOTE: Do not use piano wire in this area.
Usingan awl. make a hole th.ough the adhesivetrom
the inside.at the top ot the hatch. Pushpiano wire 6. Carefullyremovethe rear window.
through the hole, and wrap each end a.ound a piece
of wood.

MOLOING

NOTE: Replace the fasteners with new ones

wheneverthe rear window has been removed.

20-61
 -r

RearWndow
lnstallation
Scrapethe old adhesivesmooth with a knife to a 4. Apply the upper sealto the insideface of glassas
thicknessof about 2 mm (O.O8in) on the bonding snown.
surface around the entire rear window opening
flange. Gluethe uppertasteners,lower fastenersand side
spacers,to the insidetace ot the rear window on
NOTE: each side.
a Do not scrapedown to the painted surface of the
body; damagedpaint will interferewith proper UPPERSEAL
bonding.

a Removethe upperand lower fastenerstrom the

hatch.

a Mask otf surroundingsurtacesbefore applying

primer.

Clean the hatch bonding surface with a sponge

dampenedin alcohol.

NOTE: After cleaning,keepoil, greaseor water trom

getting on the surface.

lI the old rearwindow is to be reinstalled,usea put-

ty knile to scrapeott all tracesot old adhesive,then
cleanthe rear window surfacewith alcoholwhere
new adhesiveis to be applied.

NOTE: Make sure the bondingsurfaceis kept tree

of water, oil and grease.
F A S T E N E' R , 2
/ FASTENER,2
CAUTION: Avoid s€tting ths rear window on its ALIGNMENT
sroE
edges; small chips may lator devalop into cracks, SPACER,2

NOTE: Cleanthe shadowedarea, G||lethe lower fastenersand upperJastenersto the

hatch, as shown.

REARWINDOW

20-62
7 . Set the rear window upright on the hatch, then 1O. Installthe rear window trim.
center it in the opening. Make alignmentmarks
acrossthe rearwindow and body with a greasepen-
cil at the tour points shown.

ALIGNMENT
MARKS

1 1. With a sponge, apply a light coat of glass primer

around the edge of the rear window, then lightly
wipe it ott with gauzeor cheesecloth.

8 . Removethe rear window. NOTE:

a Do not applybodyprimerto the rearwindow,and
cl Centerand glue the side rubbe.dams to the inside do not get body and glassprimerspongesmixed
face of the rearwindow, as shown, to containthe up.
adhesiveduring installation. a Nevertouch the primedsurfaceswith your hands.
lf you do, the adhesivemav not bondto the rear
NOTE: window properly,causinga leak after the rear
a Gluethe siderubberdams,usingthe printeddots window is installed.
as a guide- a Keep water, dust. and abrasivematerialsawav
a Be carefulnot to touch the rear window, where from the primed surlace.
adhesivewill be applied.
a Mask off surroundingsurfacesbefore applying //// , appV glass primor hero.
pnmeI.
NOTE: Apply the glass primer, UPPER 15 mm
using the printeddots as a
guroe. (0.0ainl
REARWINDOW

10.6inl

MOLOING 1 5 m m
{0.6 in}

REARWINDOW
MOLDING
(cont'd)

20-63
RearWindow
Installation(cont'd)

1 2 .With a sponge,apply a light coat ol body primerto 15. Pack adhesiveinto the cartridgewilhout air pock-
the originaladhesiveremainingaroundthe rearwin- ets to ensurecontinousdelivery.Put the cartridge
dow openingflange.Let the body primerdry tor at in a caulkinggun, and run a beadof adhesivearound
least 10 minutes. the edge of ihe rear window, as shown.

NOTE:
a Do not apply glass primer to the body, and be it.E\,",1/: ADHESTVE
UPPER 5 m m
careful not to mix up glass and body primer SEAL 1 0 . 1 9I n l
sponges. 8mm
a Nevertouch the primedsurfaceswith your hands 10.31inl

7//, I Applv body p.lmor h.]o.

MOLDING
10 mm 40 mm 11.6 Inl
{0.4 in)
16 mln 10.63Inl

1 mm {0.04 inl NOTE: Apply the adhesiv€,

fu.:*1", using the printed dots aa

a guide.

lO.Oainl

16 mm {0.63 inl
t|nm
)E--lT-*
-\
(O.35 Inl
MOLDING

I J. Thoroughlymix the adhesiveand hardenertogether

on a glassor metal plate with a putty knife'

NOTE:
a Cleanthe platewith a spongeand alcoholbefole
mixing.
a Follow the instructions that came with the
adhesive.
-C=
/ \
/ MOLDING
GLASS
1 4 . Beforelilling a cartridge,cut the end of the nozzle'
as shown.

1O mm {0.39 inl

7 mm (0.27 inl
 RearWindow Molding
Replacement
16. Use suctioncups to hold the rear window over the 1. Remove the rear window, then remove the uppGr
opening,align it with the alignmentmarks made in
seal.
step 7, and set it down on the adhesive.Lightlypush
on the rear window until its edges are fulty seated 2. Placethe rear window on its surface,as shown, with
on the adhesiveall the way around,
a helperholdingthe rear window.
NOTE: Do not open or close the doors until the CAUTION: Avold setting the rea? ryindow on h!
adhesiveis drv. odgos: small chips may latol dovolop into cracka.
ALIGNMEI{T MARKS
3. Cut the innerside rubberportionO olf the molding,
then cut the top rubber portion @.
REAR
wtNDow

REARWINDOW

17. Scrapeor wipe the sxcessadhesiveotf with a Dut-

ty knife or towel, 4. Turn the rearwindow over, then cut the outer side
rubber portion@ of the motding.
NOTE: To remove adhesive lrcm a painted swface
or the rear window, use a soft shop towel damDened
with alcohol.

18. Let the adhesivsdry tor at least one hour, then spray
watgr over the raar window and check tor leaks.
Mark leakingareasand let the rear window dry, then
seal with sealant.

NOTE: Let the car stand for at least tour hours al_
ter rearwindow installation.lf the car has to be used 5. Scrapeall tracesof old moldingtrom the chamtered
within the first four hours,it must be drivenslowlv. edges of the glass.

19. Reinstallall remainingremovedparts. NOTE: Be sure to scrapeall traces of old molding

thoroughly.

6. Cleanthe rear window su.tacewith alcoholwhere

new moldingis to be installed.

NOTE: Makesurethe su.faceis kept tree of waler,

oil and grease.
{cont'dl

20-65
RearWindow Molding
Replacement(cont'd)

7. With a brush. apply a light coat of glass primer 1O. Placethe rearwindow outside-up.then alignthe joint
"T" mark at the top ot the
aroundthe edge of the glass. ot the moldingwith the
glass as shown.
NOTE: Scrapeotl excessglassprimerwith a putty
knife after installingnew molding.
JOINT

6mm MOLOING
1O.23Inl
SUBFACE
INSIDESURFACE
6mm
(0.23inl

8 . Degrease the inner surfaces ol new molding

thoroughly,then apply a light coat ot glass primer
to the surtaces.
wtNDOW
NOTE:
a Apply glassprimeraroundthe entiregrooveof the
new molding,
a Do not apply glass primerto the outer surface.
1 1 .Pressthe molding into position around the entire
edge of the rear window.

NOTE: Checkthat the moldingis not wrinkledor lift-

ed awav at corners.

L Run a bead oJ adhesivein the groove of the molding'

MOLDING

MOLDING

20-66
 12. Scrape o. wipe the excess adhesiveofJ with a Dut-
ty knife or gauge.
NOTE: Cleanthe moldingand rearwindow surface
with alcoholwhere upper seal is to be apptied.
1 5. Scribe a line on the molding lip with a greas€pencil
to show the cutting portion ot the molding lip, as
shown.

{Gla*r Surtacel
Surfaco to be
wiped clean.

{Gla$ Insido Surtacel

1 mm (0.04 In)

16. Cut the moldinglip off, as shown.

13. Apply the uppersealto the insideface of glass(see
page 2O-621.

14. After the adhesiveis dry, use suctioncups to hold

the rearwindow over the opening,set the rearwin-
dow on the hatch, then center it in the opening.

SUCTION CUPS

MOLDING LIP

17. Closethe hatch, then check the gap between the

moldinglip and body.

18. lf the moldinglip contactsthe body, cut the mold-

ing lip off. keepingthe gap para el wiih the body.

20-67
RearWindow
Removal

Sadan 4. Peel off the molding.

CAUTION: NOTE: When moldingremovalis difficult, cut the

a Wear gloves to remove and install the leal window. moldingwith a knife.
a Do not damage the delloster grid lines. MOLOING

1. To removethe rear window, f irst remove:

. Trunk lid {see page 20-149)
a Rearseat-backside bolsters(seepage 20-11 1)
. Rearshelf (see page 2O-95)
a Rearpillartrim panel {seepage 20 95)
REARWINOOW
2. Disconnectthe defrosterleads, and remove their
holders.

NOTE: Avoid scratchingthe rearwindow with the

S
cutter blade.

3. Removethe clips, then removethe lower cover.

NOTE: Use a clip removerto removelhe clips.

REAR
wlNDow

Pull down the rear of the headliner (see page

20-101).

CAUTION: Take care not to bend the headlinerex-

cessively.

o. Apply protectivetape to the edge of the body, as

shown.
Usingan awl. makea holethroughthe adhesivefrom
insidethe car. Pushthe pianowire throughthe hole
and wrap each end around a piece of wood.

PROTECTIVETAPE

ADHESIVE / - a,o*o*'*a

MOLDING

HEADLINER

PIANOWIRE
LOWERCOVER
PRorEcrtvE
LowERsPAcER/
;ru/ rlee
FASTENER
LowER oore,srvr \3

20-68
---

7 . With a helperon the outside,pullthepianowire back
and torth in a sawing motion, and carelully cut
through the adhesivearoundthe entire rear window.
CAUTION: Hold tho piano wir€ as closo to the real
window as possibleto prevent damageto the body.
REARWINDOW
2.
3.
PIANO wlRE
8. Carefullyremovethe rear window.
Installation
Scrapethe old adhesivesmooth with a knite, to a
thicknessof about 2 mm (O.08in) on the bonding
surface around the entire rear window opening
flange.
a Do not scrapedown to the painted sudace of the
body; damagedpaint will interferewith proper
bonding.
a Removethe upper and lower fastenerstrom the
body.
a Mask off surroundingsurfacesbefore applying
Dflmer.
Cleanthe body bondingsurfacewith a spongedamp-
ened in alcohol.
NOTE: After cleaning,keep oil, greaseand water
from getting on the surface.
ll the old rearwindow is to be reinstalled,usea Dut-
ty knifeto scrapeoft all tracesof old adhesive.then
cleanthe rear window surfacewith alcoholwhere
new adhesiveis to be aDolied.
NOTE: Make sure the bondingsurfaceis kept free
of water, oil and grease.
CAUTION: Avoid setting the rear window on its
edges; small chips may later develop into cracks.
Cleanthe shadowedarea.
/s
\\--
t\
{cont'd)
20-69
RearWindow
lnstallation (cont'd)

4. Apply the double-facedadhesivetape to the inside 6. Install the upper fasteners and glue the lower
o{ the rear window, as shown fastenersto the bodY,as shown.

NOTE: The numbers atter the parts names show

lnside quantity of the Part used.

0.16 mm (0.006 inl

5 0 0 m m ( 1 9 . 7i n ) 5OOmm 119.7in)

ALIGNMENT MARKS

Glue the moldingaroundthe edge oi the rear win- 7. Gluethe sideandlower spacersand tastenersto the
dow, as shown. inside face ot the rear window and molding, as
shown.

NOTE: The numbersafterthe part namesshow the

quantitiesof the Partsused.
5 O Om m 1 1 9 . 7
> : Spac6r,lastonellocations

SIDE
S P A C E R , 4^
MOLDING lo, \./O
l\ 4!9!llEN,r_r\,ry!s
q
'7:^ c la,Loqrcen.t

rs
s-."
(4relycv!|I!"
l$;*
\'*'w
\\t--

MOLDING

\ o.f9!T.nl"1"*"
ALIGNMENT
MARKS

20-70
8. Set the rearwindow, then centerit in the opening.
Make alignmentmarksacrossthe rearwindow and
body with a gfease pencilat the tout Dointsshown.
ALIGT{MENTMARKS
1 1. With a sponge.apptya light coat ot body primerro
the originaladhesiveremainingaroundthe rearwin-
dow opening flange. Let the body p.imer d.y tor at
least 10 minutes.
NOTE:
a Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.
a Nevertouch the primedsurfaceswith vour hands.

S l//////1,:appv body p'imo' hero.

i"lT
;o:d:';", 16 mm 10.63inl

9. Removethe rear window.

O. With a sponge, apply a light coat of glass primer

around the edge of the rear window as shown, then
lightly wipe it otf with gauze or cheesecloth.
6 mm 10.23inl
NOTE:
a Do not apply body primerto the rear window, and 16 mm 10.63inl
do not get body and glassprimerspongesmixed
up.
a Nevertouch the primedsurfac€swith your hands.
lf you do, the adhesive may not bond to the rear
window prope.ly, causing a leak after the rear
window is installed.
a Keep water. dust, and abrasive materials awav
f,om the D.imedsurtace. 12. Thoroughlymix the adhesiveand hardenertogether
on a glassor metal plate with a putty knife. Fo ow
72/: Appl,t gltst onmrr sctc. the instructionsthat came with the adhesive.

NOTE: Cleanthe plate with a spongeand alcohol

All around. before mixing.
10 mm lO.4 inl
13. Beforefillinga cartridge,cut the end of the nozzle,

/.s
as shown.

s 10 mm (0.39 in)

7 mm (0.27 inl

{cont'd)

20-71
RearWndow
Installation(cont'dl
14. Pack adhesiveinto the cartridgewithout air pock- 16. Scrapeor wipe the excessadhesiveoff with a put-
ets to ensurecontinuousdelivery.Put the cartridge ty knife or towel.
in a caulkinggun, and run a beadof adhesivearound
the edge oI the rear window, as shown. NOTE: To removeadhesivefrom a paintedsurtace
or the rear window, use a soft shop towel dampened
NOTE: Apply the adhesivewithin 30 minutesafter with alcohol.
applyingthe glass Primer.
17. Installthe lower cover.
12 mm (O.47inl
ADHESIVE
[/ , aoxesrve
t-l
8 mm (o,31inl
^X-"--"-,
s-_T--r-
REAR WINDOW \ cr-rss
I MOLOING

'18. Let the adhesivedry for at least one hour, then spray
1 5 . Use suctioncups to hold the rearwindow over the
opening,align it with the alignmentmarks made in water over the rear window and check Jor leaks'
step8, andset it down on the adhesiveLightlypush Mark leakingareas,let the rearwindow dry, then seal
on the rear window until its edgesare fully seated with sealant.
on the adhesiveall the way around.
NOTE: Let the car stand Jo. at leastfour hoursaf-
NOTE: Do not close or open the doors until the ter rear window installation,lf the car has to be used
adhesiveis drv. within the tirst tour hours,it must be drivenslowly'

SUCTION ALIGNMENT 19. Raisethe headlinerback up into position,then install:

a Rear pillart.im Panel
a Rear shelf
a Rearseat-backside bolstels

20-72
OuarterGlass
Replacement

3. Pullthe piano wire back and forth in a sawing mo-

a W€ar glov€s to romove and installthe quartol glass. tion, and carefullycut throughthe adhesivearound
a Use seat covers to avoid damaging any surfaces. the entire quarterglass.

NOTE: Replacethe quarter glass with new one when CAUTION: Hold th€ tiano wire as closoto the qurt-
removingit. er glass as possibleto prevent damage to th6 body
and quarter pillar trim panol.
1. To removethe quarterglass,first removethe quarter
trim (seepage 20 93). NOTE: Wheneachcornercut is difficult.usea knife
to cut through the adhesivefrom insidethe car.
2. Apply protectivetape to the edgeof the quarterpil-
lar trim panel and body as shown.
Usingan awl. make a holethrough the adhesivefrom
insidethe car. Pushthe pianowire throughtthe hole,
and wrap each end around a piece of wood.

OUARTERPILI.AR
TRIM PANEL
AOHESIVE PROTECTIVE
TAPE
OUARTERGLASS
PROTECTIVE PIAI{O wlRE
TAPE

OUARTERGLASS

CLIP

PROTECTIVE
TAPE

ADHESIVE
TAPE

ADHESIVE
ADHESIVE

OUARTERPILLAR
TRIM PANEL PROTECTIVE
TAPE

4. Carefullyremovethe quarterglass.

20-73
OuarterGlass
Replacement(cont'd)

Scrapethe old adhesivesmooth with a knife. to a 8. adhesivetapesto the mold-

Apply the double-faced
thicknessof about 2 mm (O.08in) on the bonding ing, as shown,
surface around the entire quaner glass opening
flange. NOTE:
o Be careJulnot to touch the quarter glass where
NOTE: adhesivewill be applied.
a Do not scrape down to the painted surface of the a Do not peel the separatoroff the double-taced
body: damagedpaint will interferewith proper adhesivetaPes.
bonding.
a Mask oft surroundingsurfacesbefore applying
orimer.
srDE
sPAcERI
b- Cleanthe body bondingsurfacewith a spongedamp- 3 mm (0.12 inl
ened in alcohol.
\ nrolonci
\ / i ADHESIVE
TAPE8
NOTE: Atter cleaning,keep oil, greaseand water IfR-.s
-l I
from getting on the surtace. i MOLDING
_c$$l
Cleanthe new quarter glass surface with alcohol
where adhesiveis to be aDDlied.

NOTE: Make surethe bondingsurfaceis kept tree

of water, oil and grease.

CAUTION: Avoid setting th€ quartsr glass on its

edgas; small chips may later d€velop into cracks.

195 mm 150 mm
(?.68 in) 15.9 inl
CLIP

4 . 5 m m 1 O . 1 8i n l

ADHESIVE MOLDING

Clean the shadowed area all

the way around.
CLIP
MOLDING
9. With a sponge.applya light coat of glassprimerto 1O. Installthe quartertrim.
the insideface ot the quarterglass,as shown, then
lightly wipe it ott with gauze or cheesecloth.
OUARTER
NOTE:
a Do not apply body primerto the quaner glass,and
do not get body and glassprimerspongesmixed
up.
a Nevertouch the primedsurlaceswith your hands.
lf you do, the adhesivemay not bond to the quan-
er glassproperly,causinga leakafter the quarter
glass is installed.
a Keepwater, dust. and abrasivematerialsawav
from the primedsurface.

V/// , AooV glass primer h6re-

1 1. With a sponge.apply a light coat of body primerto
the originaladhesiveremainingaroundthe quarte.
glass openingflange.
Let the body primer dry lor at least 1O minutes.

NOTE:
a Do not apply glass primerto the body, and be
careful no1 to mix up glass and body prime.
sponges.
a Nevertouchthe primedsurfaceswith your hands.

'////7, , aepty body p.imer here.

5 m m lO.2 inl

ffi '16
mm
(0.63 inl

OUARTER
6mm 16 mm TRIM
10 mm lO.4 inl
10.24in) {0.63 in}

10 mm lO,4 inl

5 mrr| 10.2inl

(cont'd )

20-75
OuarterGlass
(cont'd)
Replacement
12. Thoroughlymix the adhesiveand hardenertogether t5. Installthe fastenersto the body as shown.
on a glass or metal plate with a putty knife.
to. Use suctioncups to hold the quarterglassover the
NOTE: opening,alignit with the clip settingpoints,and set
a Cleanthe platewith a spongeand alcoholbefore it down on the adhesive.Lightlypuch on the quart-
mixing. er glassuntil its edgesare tully seatedon the adhe-
a Follow the instructions that came with the sive all the way around.
adhesive.
NOTE: Do not open or close the doors until the
13. Beforetillinga cartridge,cut the end of the nozzle, adhesiveis dry.
as shown.

Cut nozzleend,
as shown.
10 mm 10.39in)

7 mm {0.27 inl

14. Pack adhesiveinto the cartridgewithout air pock-

ets to ensurecontinuousdelivery.Put the cartrige
in a caulkinggun, and run a beadof adhesivearound
the edge of the quarter glass as shown.

NOTE:
a After applyingthe adhesive,peel the separator
off the double-facedadhesivetapes.
a Apply the adhesivewithin 30 minutesafter ap-
plying the glass Primer.

:ADt'Es'vE
t1;T,,1\ 17. Scrapeor wipe the excessadhesiveoff with a put-
ty knile or towel,
I mm 10.3in)
NOTE: Usea soft shoptowel dampenedwith alco-
8 mm lO.3 in) hol to removeadhesivefrom a paintedsurfaceor the
quarler glass.
AOHESIVETAPES 8
IL_-_
J, 18. Letthe adhesivedry for at leastone hour,then spray
water over the quarter glass and check for leaks'
-1r
2mm{0.08
Markleakingareasand let the quarterglassdry, then
seal with sealant.
*-{6 NOTE: Let the car stand for at least tour hoursat-
ter quarterglassinstallation. lf the car hasto be used
SIOE SPACER
within the f irst four hours,it must be drivenslowly.

ADHESIVE '19.
Reinstallall remaningremovedparts.
TAPEA
'12 mm (0.47 inl 2 mm lO.O8in)

20-76
Moonroof
Index

Hatchback

CABLE ASSEMBLY
SUNSHADE Replacement,page 2O-81
page 20-79
Replacement,

MOTOR
page 20-80
Replacement,

GLASS BRACKET
page 20-81
Replacement,

SUI{SHADE
RAIL

FRONT DRAII{
CHANNEL
DRAIN CHANN€L a'# /
-4

FRAMESEAL GUIDERAIL
page 20 8l
Replacement,

FRONTRAIL
HOLDER

,**4
REAR ORAINTUBE

U
\a
FRAME

20-77
Moonroof
Troubleshooting

Symptom Probable Cause

Water leaks 1 Cloggeddrain tube.
Gap between glass weatherstripand roof panel.
Defectiveor improperlyinstalledglass weatherstrip.
4 GaDbetween drain seal and roof panel.
Wind noise 1. Excessiveclearancebetween glass weatherstripand roof panel.
Motor noise 1. Loosemotor.
2. Worn gear or bearing.
3. Cableassemblydeformed.
Glassdoes not move, but motor 1. Clutch out of adjustment.
turns 2. Foreignmatter stuck between guide rail and slider,
3. Inner cable loose.
4. Cableassemblynot attachedproperly.
Glassdoes not move and motor 1 . B l o w nf u s e .
does not turn (glasscan be moved 2. Faultyswitch.
with moonroofwrench) 3. Battery run down.
4. Defectivemotor.
5. Faulty realy.

GlassHeightAdiustment
The roof panelshouldbe even with the glassweather- Y : Bolt locstions, 6
s t r i p ,t o w i t h i n l 8 t O . 5 m m ( O . O 7I 0 . O 2i n ) a l l t h e
way around. It not, slidethe sunshadeback, and:

1 . Tilt-up the glass.

2 . Loosenthe bolts and adjustthe glass.

Repeaton oppositeside it necessary.

1 . 8 1 0 . 5 m m l O . O 7i 0,O2 in)
i

ROOFPANEL
GLASS ERACKET
GLASS WEATI{ERSTRIP GLASS BRACKET

4. Side-to-side fit ot glass weatherstrip can be adjust-

ed by loosening the frame mounting bolts and mov-
ing the frame right or lelt and forward or backward
by hand (see page 2O-8O). f )

20-78
 RearEdgeClosingAdjustment Glass and Sunshade Redacernent
Open the glass about a foot, then close it to check where 1. Open the sunshade.
rear edge beginsto rise. lf it rises too soon and seats too
tightly againstthe roof panel,or too late and does not 2. Tilt-upthe glass.
seat tightly enough,adjust it.
3. Removethe bolts, then removethe glassfrom rhe
1. Removethe headliner(seepsge 20-98). glass bracket.

2. Removethe glass.
V : 8oh locations,6
3. Removethe motor {see page 2O-8O).

4. Align the tilt-up positionof the lifter on each side.

GLASSBRACKET

4. Removethe screw and lift the sunshaderailon each

side.

Checkthat the alignmentleft and right. then install 5. Silde the sunshade forwa.d, then remove the
the motor. sunshade.

Installthe glass,then check for water leaks. V : Scrawlocations,2 SUNSI{ADE

NOTE: Do not use high pressurewate..

II l-t
lnstallthe headliner. )

6 Installationis the reverseof the removalprocedure.

7 Check for water leaks.

NOTE: Do not use high pressurewater.

20-79
Moonroof
Motor, DrainTube and FrameReplacement
CAUTION: B€ caretul not to damag€ lhe seats, dash- 4. Disconnectthe drain tubes.
board and other interior trim.
Removethe bolts,then removethe trame from the
1. Removethe glass (see page 2O-79)and headliner car.
(see page 20-98).
NOTE: You may requireassistancewhen removing
2. Disconnectthe motor connector,and removethe the frame.
clips securingthe ceilinglight wire harness.
: Eolt locations, I DRAIN TUBE
To install,slidethe drain
< : CliD locations. 2 tube over the ftame nozzle
6 x 1.0 mm at least 10 mm {O.4 in}.
CEILIINGLIGHT 9.8 N.m (1.0kgt m,
7.2 rbr.ttl
) TUBECI-IP

FRAME FRAME

3. Removethe bolts and nuts,then removethe motor, 6. Pull the drain tubes out the front and rear pillars.
if necessarv,
NOTE; Betorepullingout the draintube, tie a string
NOTE: Make sureboth slidersare parallelwhen in- to the end of it so it can be reinstalled.
stalling the motor.

: 8olt, nut locationg

A : Bolt, 2 B : N u t ,3
6x1.Omm I
9.8 N.m I
Ld tt.o kgf.-,
,.?-", _,/I

FRONT

7 . Installationis the reverseol the removalprocedure.

NOTE:
a Cleanthe surtaceof the frame.
a Check the trame seal.
a Check for water leaks.

20-80
 GlassBracket/Slider,
Lifter, GuideRailsand CableAssemblyReplacement
1 . Removethe frame from the car {see page 2O-8O). 5. Removethe front rail holderon each side.

Removethe motor (seepage 2O-8O). V : Nut, scrow locations

AV : f{ut, 2 BV: Screw,
Removethe drain channel.

NOTE: Take care not to damage,twist or lift the

seat.
SUNSHADE
V : Screwlocations,2

DRAIN
CHAI{NEL

b. Removethe anchorspring on each side.

7. Removethe nuts and screws, then lift and remove

both guiderailsand cableassemblyfrom the trame.
Removethe sunshadeand both sunshaderails.

V : Nut, rcrow locations

AV : Nut. 2 BV : Sciow, 4

4. Removethe front drain channel on each side.

V : Clip locations,2
NOTE: To instalt,Iill the
gtoove rn each grommet with sealant,

GUIDERAIL

GUIDE RAIL

20-81
Moonroof
GlassBracket/SliderLifter GuideRailsand CableAssemblyReplacement
(cont'dl
8. Slidethe guide rail fofward, then removeit. 1 0 .Slide the anchor rod forward, then remove it from
the guide rail.
NOTE: Take care not to bend the inner cable.

CABLE ASSEMBLY

To install. insort the anchor

STOPPER rod by turning the stopper 9Oo.

GUIDERAIL

q
Separatethe glassbracket,lifter, slidestopperlink ROD
AIT|CHOB
and slider,

11. lnstallationis the reverseol the removalprocedure.

INNERCABLE GLASS
NOTE:
a Dsmsgedpansshouldbe replaced.
. Applygreaseto the slidingportion.

SLIOER

NOTE: To inst€ll,apply multipurposegreaseto

the lifter and slide stooDer link.

20-82
 Opening Drag Check
(Motor Removedl
Betoreinstallingthe motor, measurethe etfort required
to open the glass using a spring scale as shown.
CAUTION: When using a spring scale, protoct the
leading edg6 ot th€ glass with a shop towel.
lf load is over 40 N (4 kgt, 9lbf). check side clearance
and glass height adjustment(see page 2O-78).
Closing Force Check
(Motor Installedl
1. After installingall removedparts,havea hetperhotd
the switch to close the glass while you measure
torce requiredto stop it. Attach a spring scale as
shown. Readthe force as soon as the glasssiops
moving, then immediatelyreleasethe switch and
spnng scare.
CAUTION: When using a spring scale, protoct tho
leading odge ol th€ glass with a shop towel.

200-290 N
(20- 30 kgf, rt4- 66 lbf)

GLASS

lf the force is not within specification,installa new

lock washer,adjustthe tensionby turningthe mo-
tor clutch adjustingnut, and bend the lock washer
againstthe motor clutch adjustingnut.

LOCK
WASHER
Replace.

'r
coul{TER-
cLocKwrsE
To decrease

20-83
Moonroof
lndex
Ssdan

GLASS BRACKET
Replacement,page 20-88

----/_--4
DRAIN CHANNEL

SUNSHAOE
Replacement,page

SLIDE STOPP€RLINK

SUNSHADERAIL
FRONTORAIN
GUIDERAIL
Replacement,page 20-88

MOTOR REARRAIL
page20-87
Replacement, HOLDER

SEAL

REAR DRAIN

('

V
/ \ \
FROi{TDRAINTUBE FRAME
Repfacement,page 20-87
e

20-84
 Symptom Probable Cause
Water leaks 1. Cloggeddrain tube.
2. Gap between glass weatherstripand roof panel.
3. Defectiveor improperlyinstalledglass weatherstrip.
4. Gap between drain seal and roof panel.
Wind noise 1. Excessiveclearancebetween glass weatherstripand root panel.
Motor noise 1. Loosemotor.
2, Worn gear or bearing,
3. Cableassemblydeformed.
Glassdoes not move, but motor 1. Clutch out of adjustment.
turns 2. Foreignmatter stuck between guide rail and slider.
3. lnner cable loose.
4. Cableassemblynot attachedproperly.
Glassdoes not move and motor 1 . B l o w nf u s e .
does not turn {glasscan be moved 2. Faulty switch.
with moonroofwrench) 3, Battery run down.
4. Defectivemotor.
5. Faulty relay.

Glass Height Adjustment

The roof panelshouldbe even with the glassweather- V : Eolt localions, 6

s t r i p t, o w i t h i n1 . 8 t O . 5 m m { O . O 71 O . O 2i n }a l l t h ew a y I
around. lf not, slidethe sunshadeback, and: 6x LOmm
"),
9 . 8 N . m 1 1 . Ok g f m
7.2 tbf.ttt
1 . Tilt-upthe glass.

2 . Loosenthe bolts and adjust the glass.

GLASS
Repeaton oppositeside if necessary.

4'/ 12
10.5 mm lO.O7 1O.02 inl

ROOF PANEL GLASS BRACKET Forward

GLASS ERACKET
GLASSWEATHERSTRIP

4. Side-to-sidefit of glassweatherstripcan be adjust-

ed by looseningthe frame mountingbolts and mov-
ing the frame right or lett and forward or backward
by hand (see page 20-87).
Moonroof
Rear Edge Closing Adjustment Glass and SunshadeReplacement

Open the glassabout a foot, then close it to check where 1. Open the sunshade.
rear edge beginsto rise. It it risestoo soon and seats too
tightly againstthe roof panel,or too late and does not 2. Tilt-up the glass.
seat tightly enough,adjust it.
3, Removethe bolts, then removethe glassfrom the
1. Removethe headliner(seepage 20-1OO). glass bracket.
Using the moonroof
2. Removethe glass.

3. Removethe motor (see page 20-87). BOLTS

6 x 1 . Om m
9.8 N'm lt O kgf m,
4. Align the tilt-up positionof the lifter on each side. 7.2 tbt.ftl

GLASS BRACKET

4. Removethe screws and lift the sunshaderails.

5. Silde the sunshade forward. then remove the

sunsnaoe.
5 . Checkthat the alignmentlett and right, then install
the motor. SUlTSHADE
RAIL
o. Installthe glass.then check for water leaks.

NOTE: Do not use high pressurewater.

7. Installthe headliner.

Installationis the.everseot the removalprocedure.

Check for water leaks.

NOTE: Do not use high pressurewater.

20-86
 Motor, DrainTube and FrameReplacement
CAUTION: Be carotul not to damago th€ seats, dash-
board and other int6rior trim,

1. Removethe glass (see page 2O-86)and headliner

(see page 20-10O).

Disconnectthe motor connector,and removethe

clips securingthe ceilinglight wire harness.

NOTE: To removethe motor, removethe screws. SCREW

Disconnectthe drain tubes. \/

4. Loosenthe front bolts.

Removethe bolts,then removethe trame from the

CONNECTOR Make sure the sliders are
car. parallel when installing the
motor,
NOTE:
a You may requireassistancewhen removingthe
trame.
a Take care not to bend the sunshaderails.
TUBE
CLIP FRAME

BOLT
6 x 1 . 0m m
9.8 N.m (1.Olg{.rn.
7.2 tbt.ttl
DRAINTUBE
To install,sladethe drain tube ov6r
the frame nozzleat least 10 mm lO.4 in).
Loosen the tront bohs

Fo?w!?d
SUNSHADE
RAILS

tt. Pullthe draintubes out of the tront and rearoillars.

NOTE: Beforepullingout the draintube, tie a string

to the end of it so it can be reinstalled.

Installationis the reverseof the removalgrocedure.

FRONT
NOTE: DRAIN VALVES
a Installthe tube clips with the ends facing the side to ease installation of the headliner.
a Cleanthe surtaceof the frame.
a Check the frame seal.
a Check for water leaks.
a Make sure the sunshademoves smoothlv.

20-87
Moonroof
-
Lifter,GuideRailsand CableAssemblyReplacement
GlassBracket/Slider,
1 . Removethe frame (seepage 20-87). 3. Removethe screws,then removethe sunshaderail
by slidingit backward.
2. Removethe drain channel.

NOTE: Take care not to damage,twist or litt the SUNSHADERAIL

seal.
SCREW

4. Removethe motor (seepage 20-87).

5. Removethe front drain channel.

6. Removethe nut, then removethe front rail holder.

7. Removethe screws @ attschingthe guide rail. then litt the guide rail.
ITUT
6xl.Omm
8. Removethe nut. then removethe rear rail holder. 9.8 t{.m {1.0 kgt.m,
7.2 tbf.ttl
NOTE: Removethe anchorspring.
REAR RAIL
AI{CHOR HOLDER

SUB-SEAL

NUT
6 x 'l.O mm
9.8 N.m {1.O kgf.m,
7 .2 tbt-lrl

NOTE: Installthe rear rail holder, then glue

the sub-seal to the trame.

9, Slidethe glass bracket/slider,liJterbackward,then removeit.

20-88
10. Separatethe glass bracket, lifter, slide stopper lank 1 2 . Slidethe guide rail backward, then removeth€ gude
and slider. rail from the inner cable.

GLASS NOTE: To install.apply the caulkingro gurde rarl

INNERCABLE LIFTER BRACKET mount faces of the frame.

GUIDE RAIL

SLIDER
Applycaulking before
NOTE:To install,applymuttjpurpose grcase instaing the guiderait.
to th€ liftsr and slidestopperlink.

1 3 .Removethe screws,then removethe cableassem-

1 1. Slidethe anchorrod forward, then removeit from bly from the frame.
the guide rail.
NOTE: Take care not to bend the cable pipes.

FRAME

To install, inson tho anchor

STOPPER rod by turning tho stopper 9Oo

NOTE:lo install,fill the groovein

eachgrommetwith sealant.

1 4 . Installationis the reverseof the .emovalprocedure.

AI{CHOR ROD
NOTE:
a Damagedpsrts should be replaced.
a Apply greaseto the slidingportion.

20-89
 Moonroof
OpeningDragCheck
(Motor Removed)
Beforeinstallingthe motor. measurethe effort required
to open the glass using a springscale as shown
CAUTION: Whon using a spring scalo. protoct the
l€ading odge ol the glass with a shop tow€I.
lf load is over 40 N (4 kgl, 9lbt), check side clearance
and glass height adiustment(see page 20-85)'
Closing Force Check
lMotor Installed)
1. After installingall removedparts,havea helperhold
the switch to close the glass while you measure
force requiredto stop it. Attach a spring scale as
shown. Readthe torce as soon as the glass stops
moving, then immediatelyreleasethe switch and
spring scale.
CAUTION: When using a sp ng scala. protect th€
leading odge ol the glass with a shop towel'

ClosingForce:200-290 N
120-30 ksf. 44-66 lbf)

GLASS

lf the lorce is not within specification,installa new

lock washer.adjustthe tensionby turnangthe mo-
tor clutch adjustingnut, and bend the lock washe.
againstthe motor clutch adjustingnut.

clocKwlsE/i 1 coutren-
Toincrease
\ l, ctocKwlsE
torce, I Io decrease
force

20-90
L.
InteriorTrim
Replacement

Hatchback
a W€al glovesto removeand installth€ trim and panols.
a When prying with a flat tip screwd.ivor. wrap it with Rear trim panet/Sidetrim panel/Ouarterpillar trim p-l
protective tap€ to prevent damaga. 16moval:

NOTE: Take care not to bend or scratchthe trim and 1. Open the hatch.
Danels.
2. Removethe .ear shelt.
Kick panel/Front pillar trim removal:

REARSHELF
l. Removethe kick Danel.
< : Clip locations

A< | Cllp,1 B< : Ctip,1 CV : C[p, 1

U ry-ry
J t l , M l *
NOTE: Removethe driver'skick panelwhile pulling
the hood releasehandle.

REARSHELF

KICK PANEL
Removethe rear seat (seepage 20-'l08).

4. Removethe trunk mat and sparetire lid.

Pullthe door trim back,then removethe front oillar

rflm.

< : Clip locations, 4

SPARETIRELID

FRONTPILLAR

TRUNKMAT
lnstallationis the reverseof the removalprocedure.

NOTE: lf necessary,.eplaceany damagedclips.

ao..t dr

20-91
lnteriorTrim
(cont'd)
Replacement
5. Removethe rear trim panel. 7. Removethe side trim Panel.

v : Clip locations,7 > : Clip locations

A> : Clip. 4 BD : Clip, 4
1 ) P u s ht h e i n n e rc l i p . - 2 ) D e t a c ht h e c l i p b y

W-tNj
NOTE:Do not push pulling it.
it in too lar.

INNERCLIP

@ M)
CD : Clip, 3 DV : Clip, 1

,,zqzz4 |

w) !)
,Ull |

> : Boll, screw locations

A> : Bolt,2 B > : S c i o w ,2

@-,
PANEL

Removethe speakerlid and left accesspanelfrom

the side trim panel.

> : Clip locaiions

A> : Clip, 2 8V : CliP,2

,e-,ff)
ffi i,Gffi'^*^

,Kl^\ NOTE: Disconnectthe cargo area light connector

trom the left side trim Panel.

CARGO AREA
LIG}IT
fo B
SPEAKER
\ LID

LEFT
accEss
PANEL
 8. Removethe upper anchorbolts from the front and 11. Removethe quarterpillartrim panel.
rear seat belts (seepages 20-1 15, 1 19).
> : Clip locations
9. Removethe door trim.
A>: Clip7
, Btr: Clip3
.

S;+
NOTE: When installingthe door trim, align it with
the door openingflange notch.

)
NOTE: Removethe front seat belt lrom the belt
9UrOe.

BELT
1O. Removethe quartertiim and coat hangerfleft sidel. '12.
Installationis the reverseof the removalprocedure.

: Screw locstions, 'l Pry lhe lid. NOTE:

a lf necessary,.eplaceany damagedclips.
a When installingthe side trim panel, make sure
there are no twists or kinks in the front and rear
seat belts.
a Wheninstallingthe reartrim panel,installtheclip
as follows.

- 1 I Pull the inner clip up as shown.

t
Q-.-INNER
cLrP
(./ilk
\c4z )
\/
tl
\#
-2) Installthe clip in the rear trim panel.then
push the inner clip until it's flush.

INNERCLIP

20-93
lnteriorTrim
Replacementlcont'dl
Sodan 3. Removethe front and rear door trim

Center pillar lower trim/Center pillal trim removal: NOTE: When installingthe ffont and rear door trim,
align them with the door openingflange notch.
1. Removethe belt hole cap, then slip the front seat
belt through the slit in the belt hole cap.

<: Sc.ew location,1

e)
I

FRONT SEAT BELT

BELTHOLE
CAP

)
CENTERPILLAR
v
LOWERTRIM
2. Removethe upperand lower anchorbolts trom the
tront seat belt, then removethe center pilla.lower
tirm.

NOTE:
a When removingthe anchorbolts, use a 17 mm 4. Removethe center pillartrim.
socket or box-endwrench. < : Cllp locations.2
a On reassembly,replacethe upperanchorbolt (* )
and use liquidthread lock.

A : Clip localions.2
nfa147zzn

trui
L_,)
*UPPER ANCHOR
7/t6-20 UNF
EOLT

32 N m (3.3 kgf'm, 24 lbl ft)

ANCHOR COVER

FRONT
SEAT CENTERPILLAR
EELT TRIM

CENTERPILLAR
LOWERTRIM

lnstallationis the reverseoJthe removalprocedure.

LOWERANCHOR
BOLY NOTE:
7/16-20 UNF a lf necessary,replaceany damagedclips.
32 N.m 13.3 kgt.m, a Beloreattachingthe centerpillarlower trim and
ANCHOR CAP 24 lbt.ltl
belt hole cap. make sure there are no twists or
kinks in the front seat belt.

20-94
Roar pillar tlim panel/Rearshell trim panel/Rsar she 4. Bemove the rear shelf trim panel.
removal:
V : Clip locrtions, 2
1. Remove both seat-back side bolsters {see page
2 0 - 11 1 ) .
f r l
2. Removethe upperportionof the reardoor sill mold- ^affi-_--.]-"t't
ing, then pull the reardoor trim awav on each side. Y,r\-J/ '/
\t -
- REARsHEr-F
> : Clip locations, 2 TRIMPANEL

REAR PILLARTRIM PANEL

5. Slip the rearseat belr throughthe slit in the rearshelf.

3. Removeboth rear pillartrim panels. REARSHELF

> i Cliplocalionr,12

REAR PILLAR

W.,
TRIM PANEL

NOTE: When installing,make sure

the rear window defoggerwire
harnessis .outed properly.

6. R e m o v et h e s e a tl o c kc o v e r{ s e ep a g e2 0 1 1 1 ) a n d
high mount brake lighr (seesection 23).

(cont'd)

20-95
lnteriorTrim
(cont'd)
Replacement
7. Removethe rear shelf.
q
lnstallation is lhe reverseof the removal plocedure.

V : Clip locations NOTE:

a lf necessary,replaceany damagedclips.
AV : Clip, 4 BV: Cllp,2 a When installingthe rear shelf, make sure there
are no twists or kinks in the rear seat belt'
N i
==: w "ff=
t
;
_) =)

8. lf necessary,removethe belt hole cap and speaker

cover from the rear shelf,

: Screwlocatlons,3

AELTHOLE
CAP

REARSHELF

20-96
Trunk Trim
Replacement

NOTE: Take care not to bend or scratchthe panels. 4. Removethe clips,then removethe trunk side panel
'1. on each side.
Fold the rear seat-backforwaro.
NOTE: A clips on the trunk side panel can be re-
2. Lift the trunk mat, then removethe sparetire lid. moved in the same way as those on the rea. trim
paner.
TRUNK MAT
< : Cllp locationt
A{ : Cllp,6
8v : Cllp,4
FASTENERS

@q lF l
-- t"

3. Removethe clips,then removethe reartrim Danel.

V : Clip loc.tlorE
AV : Clip, 4
- I l Push the inner clip. -2) Detach the clip by
NOTE: Do not push it pullingit.
in too Iar.

II{NEB CLIP

ffi
gV I Cllp, 2

- I I Loosen the inner clip. -21 Detach the clip by

5 . Installationis the reverseot the removalprocedure.

NOTE:
a lf necessary,replaceany damagedclips.
a When installingthe reartrim panel,installthe A
pullingit. clip as follows.
II{NER

w
(8r-ct-tp - 1) Pull the inner clip up as shown.
{* ,/
hfr
)J"'J t tNt{ER
..&G\ F
4 cLrP
eEdf,
Y_) rd[h
H
v
-2) Installthe clip in rhe rear trim panel,rhen
push the inner clip until it,s flush.

INI{ER CLIP

20-97
Headliner
Replacement
CAUTION: Whon Fyhg with I flat tip sclewdrivsr, wrap 3. Removethe tront and rear ceilinglights, then dis-
it whh protectivs tapo to prevent damaga. connect the conneclors.

NOTE: : Sc.ew, nut localions

a Take care not to bend and scratchthe headliner.
A : Scrcw, 2 B : Nut, 2
a Be caretulnot to damagethe dashboardand other in-

&) ?)
terior lrim.
a Fold the front seat-backbackward.

Halchback CONNECTOR

1. Remove;
. Door trim (see page 20-93)
a Front Dillartirm {see page 20-91)
a Ouartertrim (see page 20-93)
a Coat hanger(see page 20-93)
a Rearviewmirror {seepage 20-52)

2. Removethe sunvisorand holderfrom each side.

HOOK
: Scrowlocation!,6

a l LOCK WASHER A
ffi)
(Outside)

u) "^/
H
Aaqr+- SUNV|SOR
HOLDEB BRACKET LENS
CONNECTOR

HOOK
NOTE:
a lf necessary,remove the sunvisor bracket as I
m)
shown. ,r--T-\
a When installingthe sunvisorbracket,apply grease
and make sure it's installedproperly.
HOOKS
suNvlsoR
BRACKET
H
suNvrsoR LENS

20-98
 4. Removethe grabhandle(frontpassenger.s)
and grab 6. Removethe upperanchorbolts from the front and
hole caps (driver's), rear seat belts (seepages 2O-l j 5, I l9).

: Scrowlocationsl2l 7. Removethe upper ponion of the quaner pilla.trim

panel,then detach the headlinerclio on each side.

e)
A : Clip locotions,2

HEADLINER

HOOKS

_ t : 8 . Removethe roof trim (moonrootmodel).

Open the hatch, then removethe rear root trim.
Removethe headliner.

ROOF TRIM socxET

5. Removethe socket plug (moonroofmodel).

FRAME
HEADLII{ER

-@'
//Gr OUARTERPILLAR
TRIM PANEL

I
n{ +=s ,

SOCKET
PLUG
(cont'dl

20-99
Headliner
{cont'd)
Replacement
9, Lower the headlineras shown. Sodan

'1.
NOTE: Take care not to bend and scratch the Remove:
headliner. a Center Dillarlower trim (seepage 20-94)
a Front and rear door trim lsee page 20-94)
HEADLINER a Front pillartrim (see page 2O-9 .
a Center pillartrim (seepage 20-94)
a Rear pillartrim panel (seepage 20 95)
a Rearview mirror (see Page 20-521

2 . Removethe sunvisorand holderfrom each side

: Screw locationS, 6

^ l
s,1
LOCKWASHER
loutsidel
LEFT OUARTERPILLAR RIGHTOURTERPILLAR
TRIM PANEL TRIM PANEL
/

1O. Bemovethe headlinerthrough the hatch opening'

HOLDER
$-.unu,"o"
BRACKET
/'
HEADLINER

1 1 .Installationis the reverseof the removalprocedure. NOTE:

a lf necessary,remove the sunvisor bracket as
NOTE: shown.
a When insertingthe headlinerthrough the hatch a Wheninstallingthe sunvisorbracket,applygrease
opening,be carefulnot to fold or bend it. Also, and make sure it's installedproperly.
be carefulnot to scratchthe bodY.
a Checkthat both sidesof the headlineraresecure-
ly attachedto the trim and Panels.
a When installingthe roof trim, install the Joint
toward the rear.

, @
suNvrsoR

20-100
3. Removethe tront and rear ceilinglights, then dis- 4. Remove the grab handles (tront and rear pas'
connect the connectors. senger'sland grab hole caps (driver,s).

A : Screw,nut locations : Sc.sw locatioh!l2l

A A : S c . 6 w 2, B : N u r ,2

-A-iorlx
CONNECTOR

CEILING

.-L----- ----z

GRAB HOLE CAPS

CONNECTOR

REARCEILING
LIGHT

HOOKS

20-101
Headliner
{cont'd)
Replacement
5. Removethe .ool trim (moonroofmodell.

6. Detach the clips by slidingthe headlinerforward.

A : Clip locations,3

HEADLINER

Removethe headlinerthroughthe passenger's

door
opening.

HEADLINER

lnstallationis the reverseot the removalprocedure

NOTE:
a When insertingthe headlinerthrough the door
opening.be carefulnot to fold or bend it. Also,
be careful not to scratchthe body
a Check that both sidesot the headlinerare secure-
ly attachedto the trim and Panels.
a When installingthe roof trim, install the joint
toward the rear.

20-102
Seats
Front Seat Removal
NOTE: Take care not to scratch the seat covers and 3. Remove the bolts.
bodY.
V:Boh locatlong
1. Slidethe lront seat backward,then removeth6 bohs,

> i Eolt locltlon.. 2

A V : Bolt, 1
I' > : 8olt,

8 x '1.25mm I
@ ii i.:iiil..i'xst.^.
16:t'ftt
I
- /)

NOTE: When insralling,use--i

liquid thread lock.

Slide the front seat forward, then romove the seat 4. Lift the front seat, then disconnectthe connector
track end covers. (driver's).

CAUTlOltl: When prying wlth E flat tip scr.wddvor,

w.ap lt whh protactive tapo to prevont damago,

CONNECTOR

Carefullyremove the front seat through the door

opening.

Installationis the reverseof the removalprocedure.

20-103
Seats
Front Seat RePlacement
NOTE: Take care not to scratch the seat covers and 5, Foldthe seat-backcover and pad, then removethe
body. bolts.

(see > : Bolt location., 2

1. Removethe front seat through the door opening
page 20-1O3). SEAT.gACK
lnnrnt
v)* I COVER
2. Removethe screws and reclineknob, then remove |
l O x 1 . 2 5m m i PAO
the reclinecover. 47 N'm 14.8kgl ln, I
"?"!."t_J

COVER
RECLINE SCREW

Removethe screws,then removethe centercover. 6. Removethe Pivot nut.

PIVOT WASHER

SEATBELT
BUCKLE '1 PLAIN
{seepage2O'1 7) WASHER

PIVOT NUT
8 r 1.25mm
22Nm12.2kgl'm,
16 lbf.ftl
CENTERCOVER

scREws 7 . Removethe seat-back.

NOTE: Take care not to bend the hinge bracket.

Removethe hook and fastener,then lold the seat-
back cover back.
+ sEAr-BAcK

20-104
8. Separatethe seat cushionand seat tracks. RECLINE
AOJUSTER
NOTE:
a B e f o r e s e p a r a t i n g ,s l i d e t h e s e a t c u s h i o n
backward.
a Take care not to bend the joint rod.

< : Bolt locations, 4

9. Separatethe seat track and reclineadiuste..

: Bolt, nut locations

A : Bolt, I BY : Nut,2
j
j @i+ilJ
A;iil;iiry-,'-
_o()_ _/ _ _].'*",

RECLINE
ADJUSTER

JOINTBOD

Disconnect
the rearseataccesscable(hatchback
passenger'sl.

REARSEAT
ACCESSCABLE

1 0 . Installationis the reverseof the removalprocedure.

NOTE:
a To preventwrinkleswhen installinga seat-back
cover,make sure the materialis stretchedeven,
ly over the pad beforesecuringall the hooks.
a Apply greaseto the moving surtaces.

20-105
 Seats
Front Seat CoverRePlacement
CAUTION: Wear gloves to removo and install the 36at 4. Removethe lumbarsupport knob.
cov€rs.

NOTE: Take care not to tear the seamsor damagethe

seat covers.
ilff-]s) \\

fH".,
Soat-back covor lomoval:
1. Slidethe Jrontseat forwa.d and told the seat-back
forward.

2. Removethe hooks and fasteners.then fold the seat-

back cover back.

FASTE]IIER
5. Removethe seat-backcover by releasingthe inside
FASTENER
chps.
Cllp removrl:

Removethe headrestand headrestguide.

Scr€w location,

,e, I
Y i 6. Pull back the edge of the seat-backcover all the way
c J / around,then releasethe clips.

HEAOREST

SEAT.BACK

20-106
-
Seat cushion romoval: Installationis the reverseof the removalptocadtr!.
1. Removethe seat cushionfrom the seat tracks (see
p a g e2 0 - 1 0 5 ) . NOTE:
a To preventwrinkleswhen installinga seatcover,
2. Removeall clips from underthe seat cushion,then make sure the materialis stretchedevenlyover
loosenthe seat cushioncover the pad before securingall the clips.
a Replacethe.eleased clips with new ones.
Cllp romoval:
CLIP
UPHOLSTERYRING PLIERS

NEW CLIP

PAD

WIRE {Pad sido}

SEAT CUSHIONCOVER

2 Pullback the edgeof the seat cushioncover all the

way arounC,then releasethe clips.

SEAT CUSHION
COVER

20-107
Seats
RearSeat Replacement
Hatchback 3. Removethe cliD pin on each side.
Slidethe seat-backsoutward, then removethe seat-
NOTE: Take care not to scratch the seat covers and backs from the pivot bracket.
body.

1. Fold the seat-backs{orward. CLIPPIN

(seepage 20-1Og)
SEAT.BACK

SEAT.BACKS

2. Remove the clips, then fold the trunk mat.

V: Clip locations,14

I
+ |
v / J
TRUNKMAT

SEAT-BACK PIVOTBRACKET

20-108
4. Removethe bolt, then removethe seat cushion.
LATCH COLIAR

: Bolt locations,t l--): Xoot locations,2

6 r 1.0 mm
9.8Nm I

SEAT-BACK
SEAT CUSHION COVER

NOTE: When removingthe striker,removethe side

t.im panel (see page 20-91).

> : Bolt locations,2

STRIKER
.a\ |
tDt@ l
<Jt I
6x1.0mm i
9 , 8 N . ml 1 . Ok g l . m , l
1.2lbl..ttl
._ /l
CUSHION

5. lf necessary,removethe seat latch lrom the seat-

back and removethe striker.

CAUTION: Wear gloves to remov€ and install the 6. Installationis the revelseof the removalprocedure.
soat latch and latch collar.
NOTE:
> : Bolt, sc.€w locrtions a Make sure the seat,backslock securely.
a lf necessary,adjust the strikers.
A > : B o l t ,2 8 ) : S c r e w ,1 a Betoreattachingthe seat-backsand seat cushion,
^ { l l makesurethere are no twists or kinks in the rear

.,,W ' Gp" II seat belts.

a When installingthe seat cushion,stipthe seat belt
9 . 8N . m1 1 . 0k s fm . I bucklesthrough the slits in the seat cushion.
7 2 tP!ft!---/' ./
LATCH COLLAR REARSEATEELT
.otc" rtroa
El

LATCH COVER

SEAT LATCH

t'

T-8ACK

( c o n t ' d)

20-109
Seats
(cont'd)
RearSeat Replacement
Sedan 3. Detach the hook, then removethe trunk mat.

NOTE: Take care not to scratch the seal covers and

booy. TRUNK
MAT
1. Fold the seat-backforward. a-^
I { \ t \
SEAT.BACK

Nry
Y HOOK

TRUNK
MAT

SEAT-8ACK

2. Removethe clips. 4. Removethe bolts. then removethe seat-back.

V : Clip locations,I V : Eolt locations,4

l I
/-.;-\
---M-
----+tl Il
I E gel?"Til.*,,",
iI
\r/ / I
7.2 tbt'trl
"
-----r"
,/ REARSEATLAICH/
TRUNKMAT LOCKCYLINDER REARSEAT
{seepage2O-'l11l PIVOTBRACKET
(seepage2O-111)

REARSEAT
PIVOT BRACKET
SEAT-BACK SEAT.BACK

20-110
5. Removethe bolt, then .emove the seat cushion. 7. lf necessary,removethe rearseat latch, lock c!ftiab
and rear seat pivot bracket.
-r
Y: Bolt location. 1 i i Hool loc.lion3. 2
Roar soat latch/Lock cylinder r€moval:
6r1.0mm i
9.8N.m I Pry the rear shelj up after removing the rear shelt
trim panel (seepage 2O-95)and seat lock cover.

NOTE: Take care not to bend the lock rod.

SEAT CUSHION
V i Bolt. scrow locations
AV i Boll, 2 BV : Sc?ow, 2
4x0.7mm
9: l;o--'
9.8 tt.m i
I 4 N.rrt
I
lr.o tgf
l1.O .m,
kgf.m, I {O.4 kgf'm,
EI )
v_ 7.2 tbf.ft!____// 3tbt.ttt
J
SEATLOCK SEATLOCK
covER\-_L/-R\ COVER

B
w-"1/ -

LOCK
CYLINDER Pry here.

LOCKROD

Removethe bolts, then removethe seat-backside REARSEAT

bolstersby lifting them upward. LATCH

: Bolt locationr, 2 r'): Hook locetions, 2

6 r 1 . om m I
9.8 N.m R6ar seat pivot brackol removal:
i
( 1 . 0k g l ' m , I
7.2 tbt.fti NOTE: When installingthe pivot bolt, applygrease
)
to it.

TOOTHED
BUSHTNGLOCKWASHER

REARSEAT
PIVOT BRAC(ET

PIVOT BOLT
8 x 1.25mm
22 N.m (2.2 kgf m,
16 tbf.ftt

WASHER

20-111
Seats
(cont'd)
RearSeat Replacement RearSeat CoverRePlacement

8. lnstallationis the reverseot the removalprocedure CAUTION: Wear glov€s to l€movo and install tho seat
covgls.
NOTE:
a Make sure the seat-backlocks securely. NOTE:
a It necessary,adiust the rear seal latch and a Take care not to tear the seamsor damagethe seat
seat-back. covels,
a BeJoresttaching the seat-back,side bolstersand a Removethe cliDsas shown.
seat cushion,make sure there are no twlsts or
kinks in the rear seat belts and center belt
a When installingthe seat cushion,slip the seat belt
bucklesthrough the slits in the seat cushion.

SEAT-BACK

Soat-back cover romoval:

Hatchback

1 . Removethe seat-back(see page 20-108).

2. Removethe latch cover and latch collar (seepage

20-109).

Removeallthe clipstrom the back of the seat-back,

then loosenthe seat-backcover.

SEAT.BACK
COVER

E
ilgF]
CLIP

4. Pull back the edge of the seat-backcover all the way

around,then releasethe clips.

SEAT-BACK

CLIP

20-112
 Sodan Seat cushion cover lsmoval:

l. Removethe seat-back(seepage 2O-11O1. Harchbacr(

2. Removeall the clipsfrom the backof the seat-back, 1. Removethe seat cushion (see page 20-lOg).
then loosenthe seat-backcover.
2. Removethe cushioncentertrim panel.
SEAT-BACKCOVER
V : Scrowlocations,2
/+r I
Y I
v ,-.,)

CEITTER

J. Removeall :he clips from under the seat cushion.

then loosenthe seat cushioncovers.
CLIP SEAT CUSHION
covERs

3. Pullback the edge of the seat-backcover all the way

around,then releasethe clios.

SEAT-8ACK COVER

CLIP

4. Pullbackthe edgeof the seatcushioncoversallthe

way around,then releasethe clips.

SEAT CUSHION
covEBs

CLIPS

CLIP

lconl'dl

20-113
Seats
Rear Seat Cover Replacement
(cont'd)
S6dan

1 . Removethe seat cushion (see page 20-1 1 1).

Removeall the clips from under the seat cushion,

then loosenthe seat cushioncover

SEAT CUSHION
COVER

)rir
ry"M
CLIP

Pullback the edge of the seat cushioncover all the

way around.then releasethe clips.

SEAT CUSHION
COVER

t)
ll
ll

CLIPS

Installationis the reverseof the removalprocedure.

NOTE:
a To preventwrinkleswhen installinga seat cover.
mark sure the materialis stretchedevenlYover
the pad before securingall the clips.
a Replacethe releasedclips with new ones.
UPHOLSTERYRING PLIERS
Commerciallyavailable.

{Cover sid6}

20-1 1 4
Seat Belts
Front Seat Belt Replacement

cAUTloN: chock tho tlont seal belts for damage and lsplace them if necessary.
B€ carelul not to damag€ then during
romoval and installation.

F.ont seat belt romoval:

Hatchback

1. Removethe following parts, and slidethe front seat fo.ward fullv.

. Rearshelf (seepage 20-911 a Rearseat (seepage 20-1Og)

. Rear trim panel (see page 20-921 a Side trim panel (see page 2c,-92}

2 Removeall the anchorbolts, the retractorbolt and the retractormountrngbott, then

removethe front seat belt.
NOTE: When removingthe anchor bolts and the retractorbolt, use a l7 mm socket
or box-endwrench.
3. Check that the retractorlockingmechanismfunctions as describedon page 20_122-

Pry the anchorcover. Remove the tront seat belt trom the belt ouide-

UPPERANCHOR BOLT
7/16-20 UNF
32 N.m (33 kgl.m,
EELTGUIDE
24 tbt.ttl

RETRACTORMOUNTING
BOLT
6 x 1 . Om m
9.8 N.m (1.0 kgt.rn.
7.2 tbl.ftl

RETRACTOR

LOWERANCHORBOLT
RETRACTORBOLT 7/'16-20UNF
7/16-20 UNF 32 N.m 13.3 kgl.m,
32 ltl.m {3.3 kgl,m, 24 rbf.ft)
24 tbt.ftl

{cont'd)

20-115
Seat Belts
FrontSeat Belt Replacement
{cont'dl
Sedan 4. Removethe retractorbolt and retractormounting
bolt, then removethe front seat belt.
1. Slide the front seat tully forward.
NOTE: When removingthe retractorbolt, use a 17
2. Removethe belt hole cap. then slip the front seat mm socket or box-endwrench.
belt through the slit in the belt hole cap.

< : Screwlocation,1
I

FRONTSEATBEI.T
FRONTSEAT
BELT

II BELTHOLE
CAP
RETRACTOB
BOLT
6x 'l.Omm
MOUNTING

I v
9.8 N.m {1.o kgl.m,
7 .2 tbt.ltl

RCTRACTOR
)
CENTERPILLAR
LOWERTRIM SLIT

3. Removethe upperand lower anchorbolts from the

front seat belt, then remove the center pillar lower
trim.
RETRACTOFSOLT
7/16-20 UI{F
NOTE: When removingthe anchorbolts, use a 17 32 N.m {3.3 kgl.m.
mm socket or box-endwrench. 24 tbf.ftl

A : Clip locations, 2
Check that the retractorlocking mechanismfunc-
f '" f
-1t'- i l *UPPERANCHORBOLT tions as describedon page 2O-122.

r _Ju i
l
7/16-20UNF
32 N.m (3.3 ksf'm, 24 lbf.ftl 6 . Removethe centerpillartrim {seepage20-94}.then
_.| removethe shoulderanchoradjuster.
ANCHORCOVER

u-. FRONT
SEAT
BELT

8 x 1.25mm
23 N.m 12.3 kgl.m,
17 tbt.ft)

LOWERANCHOR
BOLT
7/16-20 UNF
32 N.m (3.3 kgt.m,
24 tbt.ftl
ANCHORCAP

20-116
Seal b6lt buckle romoval: > : Scrow locations, 2
1. Removethe rear console(see page 20-128).

2. Slidethe front seat until you can removethe screw.

then removethe center cover. SEATBELT
BUCKLE
3. Oisconnectthe connector (driver's),remove the
center anchorbolt, then removethe seat belt buckle.

CONNECTOR

iCENTER ANCHOR BOLT

7/16-20 UNF
32 N.m (3.3 ksf.m,7.2 lbf.ftl

CENTEBCOVER

Upper and lower anchor bolt construction:

Hatchback

LOCK
WASHER
PLAIN WASHER

COLLAR PLAIN LOWERA CHOR

WASI{ER BEARING
BOLT

lcont'd)

20-117
Seat Belts
(cont'd)
Front Seat Belt Replacement
Sodan

.UPPERANCHOR
BOLT

Canter anchor bolt consttuction: Rotractor bolt conslruction:

BEARING

WAVE WASHER

Installationis the reverseot the removalprocedure.

NOTE:
a Make sure you assemblethe washersand collarson the upper and lower anchor bolts as shown.
a Beforeattachingthe sidetrim panel(Hatchbacklor centerpillarlower trim (Sedanl. makesurethe.e are no twists
or kinks in the front seat belt.
a On reassembly,replacethe upper anchor bolt {Sedanland center anchorbolt (*), and use liquid thread lock.

20-118
 Rear Seat Belt Replacement

CAUTION: Check lhs roar saat bslts tor damago and ioplaca them it necassary. 86 careful not to damago thcm d.rhe
romoval and imtallation.

Hatchback

1. Remove:

o Rearshelf {seepage 20-911 . R€arseat (seepage 20-1081

a Reartrim panel (seepage 20-921 a Side trim panel (see page 20-921

Removeall the anchorbolts, the retractorbolt and the retractormountingbolt, then removethe rearseat belt and
center belt.

NOTE: When removingthe ancho. bolts and the retractorbolt, use a 17 mm socket or box-endwrench.

Check that the retractorlockingmechanismfunctions as describedon page 2O-122.

Pry the anchor cover.

RETRACTOR MOUNTING
BOLT
6xl.Omm
9.8 N.m {'l.Okgf.m,
7 .2 tbt.ttl UPPERANCHORBOLT
7/16-20Ul{F
32 N.m (3.3 kgt.m,
24 tbt.ft)

RETRACTOB

REAR SEAT
AELT
NETRACTORBOLT
7/16-20 UNF
32 N.m (3.3 kgl.m,
24 tbt.fr)

LOWERANCHOR BOLT
7 t16-20 UNF
32 N'm 13.3 kgf.m,
24 tbt.ftl

CENTERANCHOR BOLT BUCKLE

7/16-20 UNF
32 N.m {3.3 kgl m,
24 lbf.ft) (cont'd)
Seat Belts
(cont'd)
RearSeat Belt Replacement
Sodan

'I . Remove:

a Rear seat {see page 20-1 10) a Trunk mat (see page 20-97}
a Rear pillartrim panel (seepage 20-951 a Reartrim panel {see page 20-971
a Rear shelf trim panel (seepage 20-95) . Trunk side panel (seepage 20-97)
. Rear shelf (see pag€ 20-96)

Remove all the anchor bolts, the retractor bolt and the retractor mounting bolts, then remove the rear s€at belts
and center belts.

NOTE: When removingthe anchor bolts and the retractorbolt, use a 17 mm socket or box-endwrench.

Check thst the retractorlockingm€chanismtunctions as describedon page 2O-122'

UPPER ANCHORBOLT
7/16-20UNF
32 N.tn (3.3 kgf'm, 24 lbl ft)

RETRACTOR MOUNTING
BOLT
6 x 1 . 0m m
9.8 il.m (1.0 kgt.m,
7.2 tbt.tll RETRACTOR BOLT
7/16-20UNF
32 .m (3.3 kgl.m,
24 tbt.ft)

RETRACTOR REAR SEAT

BELT

CENTER AI{CHORBOLTS
7/16-20UNF LOWERANCHORBOLT
32 N.m (3.3 ksl'm, 7/16-20UNF
24 lbl ftl
32 N.m (3.3 kgf.m,
24 tbf.ftl

CENTERBELTS

20-120
Uppo. anchor bolt construction:

Hatchback Sedan
LOCK
WASHER
ANCHOR COVER
UPPERANCHOB UPPERAI{CHOR

BEARING COLLAR

TOOTHED
LOCKWASHEN
COLLAR

WASHER

Lower and cantol ancho. bolt conatluction: Rotracto. mounting bolt construclion:
TOOTHED
RETRACTOR LOCKWASHER
MOUNTINGBOLT {Sedanl
LOWEBAI{CHORBOLT/
ANCHORBOLT \ /
\ /{- tr- J
l-n(
l$t".,-,fu
tYlf-\ u tY
\

Rotractor bolt construction:

RETRACTOR TOOTHED
AOLT LOCKWASHER

TOOTHEO
LOCK WASHER b'ryd
Installationis the reverseof the removalprocedure.

NOTE:
a Make sure you assemblethe washersand collarson the upper anchorbolt as shown.
a Beforeattachingthe side trim panel (Hatchbacklor rear shelf (Sedan),make sure there are no twists or kinks
in the rear seat belt.
a Beforeattachingthe seat-back,side bolsters{Sedan)and seat cushion,make sure there are no twisls or kinks
in the rear seat belts.
a When instsllingthe seat cushion,slip the seat belt bucklesthrough the slits in the seat cushion.

20-121
Seat Belts
lnspection
Retractol InsDection Rear:
1. Beforeinstallingthe retractor,check that the seat
belt can be pulledout freely.

2. Make surethat the seat belt doesnot lock when the

retractoris leanedslowlyup to 150 from the mount-
ed oosition. The seal belt should lock when the
retractoris leanedover 4O".
RETRACTOR
CAUTION: Do not attempt to disassemble the
tgtractol.

Hatchback ' : Mounted Position

3. Replacethe seat belt with a new one if there is any

abnormality.

On-the-Cal S€at Belt Inspection

1 . Checkthat the seat belt is not twisted or caughton
anythrng.

2 . After installingthe anchors,check lor free movement

RETRACTOB
removethe anchor
on the anchorbolts.lf necessary,
boltsandcheckthat the washersand otherpans are
Forwald - not damagedor improperlyinstalled.
Rear:
3 . Check the seat belts for damageor discoloration.
Cleanwith a shop towel iI necessary.

CAUTION: Use only soap and water to clean.

NOTE: Dirt build-upin the metalloopsof the upper

anchorscan causethe seat beltsto retractslowly.
WiDethe insideof the loopswith a cleanclothdamp-
ened in isopropylalcohol.

4. Checkthat the seat belt does not lock when pulled

out slowly.The seatbeltis designedto lockonlydur-
Forward Iniid6 ing a suddenstop or impact.

Sedan Make sure that the seat belt will retract automata-
Front: cally when released.

Replacethe seat belt with a new one it there is any

abnormality.

Forward lnsido

20-122
 Child Seat Anchor Plate

Attachmentpointsare providedfor a rearseat mounted

child restraintsystem which uses a top tether,
The attachmentpointsare locatedon the reartrim panel
or rear shelf, just behindthe rear seat-back.
Whenusinga childseatwith a top tether,installthechild
seat anchor platessecurely.

Hatchback

NOTE: The reartrim panelhas perJorations at each

attachmentpoint. Cut the reartrim panelalongthe
perforationsto make a hole, TOOTHEDWASHER

BEAR TRIM PANEL

NOTE:
a Do not removethe toothed washer from the child
seatanchorplate.Usethe childseatanchorplate
with the toothed washer attachedto it.
a When installinga childseat on the rearseat, fol-
low the intructionsof the manufacturerof the
child seat,
a Additionalanchor platesare available.

a Do not use the child seat anchor plate for any

other puipos€; it is dosigned exclusively tor in-
ATTACHMENT POINTS stallation of a child seat.
a Mako sure tho roar seat-back is locked firmlv
wh€n installing a child soat.
Sedan

NOTE: Removethe plug covers from the attach-

ment points of the rear shelf (Canada).
Use a razor bladeor sharp knife to carefullycut a
1 inch diametercircleat the locationof the attach-
ment point (USAI.

IOO mm
265 mm 13.94inl
( 1 0 . 4i n l

REAR SHELF

20-123
Garpet
Replacement
SRS wire harnessesare routed near the carpet. 1. Remove:

CAUTION:
a All SRS slectrical wiring harn€ssosal€ covorod
with yollow insulation.
a Belore disconn€cting 8ny patt of th€ SRS wite
harness,connoct th€ short connectors {see pago
20-2721.
a ReDlacethe €ntire affected SRS haln€sa assam-
bly if it has an opan cilcuit or damaged wiring.
Hatchback
a Front seat (seepage 2O-103)
a Rear seat (seepage 20-108)
a R e a rs h e l l { s e ep a g e 2 O - 9 1 }
a Rear trim panel {see Page 20-921
a Side trim panel (see page 20-92)
a Front seat belt lower anchor(seepage 20-115)
a Front and rear consoles(seepage 2o-128)
. Kick panel (seepage 2O-91)
a Dashboardlower cover (see page 20-131)
a Openercover (see page 20-154)

ORIVER'SAIRBAG Sedsn

a Front seat (seepage 20-103)

a Rearseat {seepage 2O-110)
a Rear pillartrim panel (seepage 20-95)
a Center pillarlower trim (seepage 20-94)
a Front seat belt lower anchor{seepage 20- 1 16l
a Front and rear consoles(seepage 20-128)
a Kick panel (seepage 20-91)
a Dashboardlower cover (seepage 20-131)
o Openercover (seePage20-155)

2. Removethe footrest.

V : Bolt locatios,2

I
6 x 1 . Om m

v
9.8 N.m {'l.o
7 .2 tbt.ftl

FOOTREST

20-124
 Removethe door sill moldinglrom each side. V : Clip locatlons

NOTE: AV : Clip, 2 B< : Ctip, 'l C < : C l i p ,1 O > : C t 9 .r

a Take care not to damagethe door sill moldings.
a lf necessary.separatethe door sill moldingand ------l-
| ru4l
.l\-\\\).\\\1,
carper. | /rryz)' rA

: Push nul locatlon3, 5

l_ w_)
MW i -) _)I W I
: Push nut locations, 2

DOORSILL MOLDING

Sedan

A : Clip location3, : Push nut locations, 4

''*'N*
<l\lt.fe- CARPET I
I
lt I

w /
EI I
{ NUr I
":-/

FRONTDOOR
SILL MOLDII{G

| 20-125
Carpet
(cont'd)
Replacement
4. Removethe SRS unit covers. 6. Cut the carpet under the parkingbtake lever'

PARKINGBRAKE
> : Clip locations,2

CARPET

Cut here.

7. Removethe dashboardcenter bracket and center

beam bracket.

V : Bolt locatlona

AV : Boll, 4 B > : B o l t ,1

s x 1.2smm I
22 N.m I
SRS UNIT COVERS 12.2ksf m, I
16 tbt.ftl 6x1.Omm I
/,/ 9.8 N'm tl.O kgl m, I
Cut tne @ ana@ areasin the carpet,then pull it C> : goli, 2 l:?'o'!"t -'/
back, as shown.
6 x 1.0 ftm I
9.8Nm I
11.0kst'm, i
SRS MAIN
'1Y"!_/

20-126
8. Removethe carpet by slidingit rearward. a Reattachthe @ cut area of the carpet {seepage
2 0 - 1 2 6 ) .a s t o l l o w s .
V : Cllp loc6tions
- 1) Cleanthe back of the carpetwith a sponge
AV : Clip, 3 B > : C l i p ,1 damoenedin alcohol.
Attach the fastenersto the edgeof the car,
:ft
r,,-, pet with double-facedadhesivetape.

FASTENERS
Hatchback
FASTENERS

-2) Attach the other tastener.as shown.

FASTENERS

CARPET
CARPET

Ssdan
-3) Align the carpet with the fastener, then
FASTENERS pressthe carpet down securely.

FASTENER

SILL MOLDING CARPET

REARCONSOLE
BRACKET
SILL MOLDING Reattachthe cut area under the parking brake
leverand(9 cut area(seepage20-126)with wire
Installationis the reverseof the removalprocedure. ties, as shown.

NOTE:
a Take care not to damage,wrinkle or twist the Cut otf.
carpet.
a Make sure the seat harnessis routed correctly.
a Slip the slits in the carpetover the rear console
bracket.
REARCONSOLE
BRACKET WIRETIE

SLIT

a lf necessary,replaceany damagedclips.

20-127
Frontand RearConsoles
Replacement
SRS wire harnessesare routed near the front console. NOTE: Take care not to scratch the tront and rear con-
soles,and dashboard.
CAUTION:
a All SFS electrical wiring harnessesaro coverod 1. Removethe accesscap.
with y6llow insulalion.
a Betore disconnecting any part of lho SRS wire CAUTION: liYhenprying with a flat tip scr€wd.lv€r,
harness,connect th€ short connoctorc (so€ pago wrap it with protoctivo tape to provent damag€.
20-272t.
a Replacotho sntilo aftocted SRS halness assom-
bly it it has an opon circuit or damaged wlring. ACCESSCAP

FBONT
PASSENGER'SAIRBAG

2. Remove the sctews.

v : Scraw loc€tlona

At : Scr.w, 2 Bv : Scrow, 2

E) w)

20-128
3 . Removethe rear console,
NOTE:
a Lift up the parking brake lever.
a Oetach the hooks by lifting the front ot the rear
consoleand slidingit rearward.
5. Remove the trim ring, then remov€ th€ console
panel.
NOTE:
a Take cafe not to scratch the selecter l6ver 8nd
A/T gear positionindicatorpanel.
a Removethe shiJtlever knob (M/T).

A : Cllp,hook loc.tions

AA : Clip,2 BA : Cllp,2 CA : Hook,2

SHIFTI.EVER
KNOB
CONSOLEPANEL
IM/TI
TRIM RI'{G

\ r
"onroar€
,"Hr"tz{o$

co soLE
4. Removethe sshtrsy and front consolepanel. SELECTER
POStTtON LEVEB
> : Scrowlocatlon3,2 INDICATOR
PANEL
6. Removethe screws.
l > : Screwlocationr,4
Diaconn€ct the connector.

6bo''
: . /
I

20-129
Front and RearConsoles
(cont'd)
Replacement
7. Removethe Jront consoleas shown. 8. It necessary, disassemble the Jront and rear
consoles.
NOTE: Wrsp the selecterlever and A/T gear posi-
tion indicator psnel with a shop towel to prevent : Scrowlocations,5
damage.
CONSOLEPANEL (MTI

A
_Y_)
i SHIFT LEVER
BOOT (M/TI

CONSOLE

: Scraw locations, I

A
Y,/
I ARMREST

REAR CONSOLE

PARKINGBRAKE
COVER

COVERSET
PLATE

cof{solE Box

9. Installationis the reverseof the removalprocedure.

20-130
Dashboard
Component Removal/lnstallation

SRSwire harnessesare routednear the dashboardand
steeringcolumn.
CAUTION:
a All SRS olectrical wiring harnessesar6 covolod
with yallow insulation.
a Betoro disconnecting any paft ot th6 SRS wiro
harn€ss,connoct th€ shoi connectots (s66page
23-2721.
a Replacoth€ entire Itlocted SRS hsrness asaem-
bly il h has an open circuh or damagod wiring.
CAUTION: Whan prying with a flat tip scrowdiv... wrap
it with protoctiv€ tape, and apply protectivo tapo a.ound
th€ felatsd parts. to provent damag€.
Instiumont p8n6l, Dashboad lower covor. Knec bobtcf
ramoval:
l. Lower the steeringcolumn.
2. Remove the screws and detach the cliDs, then re-
move the instrumentpanel.

3. Removethe coin oocket.

4. Removethe screws and detach the clips, then re-

move the dashboardlower cover.
Disconnectthe connector.

: Scraw A i Clip locationg

location3, 5 AA: Cllp, 2 B> : Clip, 2

A I
_:n
,,4< I
| ,-__-,
l-l L'l
)
F
A
| ]
-ft itrvi
\ g )
) 4Z)
INSTRUMENTPAI{EL

COIN POCKET

(cont'd)

20-131
Dashboard
Component Removal/lnstallation(cont'dl

5. Removethe knee bolster.

: Bolt locations, 3
CONNECTOR i Bolt locations. 2
fi 6rt.omm
6 x 1.0 mm
6 i;i'i#.,
7.2 tbr.ftl
9.8 N.m {1.0kgl.m,

?
KNEE
CASSETTE

6. Installationis the reverseof the removalDrocedure. 3, Carefullypry the hazardwarning switch and rear
window defoggerswitch out of the heatercontrol
Stol€o radio/cassette, Heater control panal removal: Daner.
Disconnectthe connectors.
1. Removethe rearconsole,then removethe front con- HAZARD WARNING REARWINOOW
s o l e ( s e ep a g e 2 0 - 1 2 8 ) . swtTcH DEFOGGERSWITCH

Loosen the bolts, then remove the stereo radio/

cassetteby pullingit out.
Disconnectthe connectorand antennalead.

NOTE: The originalradiohas a codedtheft protec-

tion circuit,Besureto get the customer'scodenum-
ber belore
- disconnectingthe battery.
removingthe No. 32 17.5A)fuse from the under-
hood fuse/relaybox.
- removingthe radio.

After service,reconnectpower to the radioand turn

i1 on. When the word "CODE" is displayed.enter
the customer's 5-digit code to restore radio
operation.

20-132
 4. Removethe screws. Pullthe heatercontrol panelout, then disco.rEt rhG
Detachthe harnessclip and connectorclip. conneclors.

> : Screwlocations,2 NOTE: Take care not to bend the atr mtx control
cable.

AIR MIX COI{TROL

CABLE

HEATER
CONTROI
PANEL

7, lnstallationis the reverseo{ the removalprocedure.

NOTE: Make sure the connectorand air mix con-

CONNECTORCLIP trol cable are connected properly.

Disconnectthe air mix control cablefrom the heat-

er unrt.

AIR MIX CONTROL

CABLE

HEATERCONTROL

AIR MIX CONTROL

CABLE

(cont'd)

20-133
Dashboard
(cont'd
ComponentRemoval/lnstallation
Side air vent .emoval: Front passsng€r's

Drivsi's Careiullypry the side air vent at the lower edge, then
pull it out.
1. Remove the dashboard lower cover (see page
2 0 - 13 1 ) . A : Clip,hook locationg

AA : Clip, 1 BV : Hook, 2
2. Caretullypry the moonroofswitch out of the side
air vent, then disconnectthe connector.

MOONROOF
swrTcH

CONI{ECTOR

SIDE AIR
Hi
1.'' 11,/
VENT

SIDE AIR
VENT

PROTECTIVE
TAPE
3, Removethe screw, then removethe side air vent.

< : Clip, hook locatlont

> : Sc.6w location, Sido detoggor t m romoval:
A< : Clip, 1
I BV : Hook, 3
Carefullypry the side detoggertrim at the rearedge,then
o@) remove rt.

A : Cllp,hook location!

AA : Clip,l B A: Hook, 1

PROTECTIVE

SIDEAIR
VENT

4. lnstallationis the reverseof the removalprocedure.

NOTE: Make sure the connector is connected

properly.

20-134
 Clock rsmoval: 4. Remove the damper and striker.

Caretullypry the clock at the left edge.then pull it out.

>: Nut, icrgw locations
Disconnectthe connector.
A> : l{ut, 1 B : Scrow, 2
CLOCK , - . \ ' F l
o
\ +t ] ! } l l aE l l
CONNECTOR *'
_ __,/ ,/

tl
@

Glove box removal:

'1.
Open the glove box.
DAMPER
2. Removethe screw, then removethe damperfrom
the glove box.
5. Installationis the reverseo{ the removalorocedure.
3. Removethe screw, then removethe glove box.

: Bolt, scr6wlocstions
A : Bolt, 2 B < : S c r o w 1,
A l ^ l
6)P)

20-135
Dashboard
Precautions
Replacement
SRSwife harnessesare routed nearthe dashboardand
2 . lnstallthe short connectors(RED)
steeringcolumn.
Ddvar's:
Removethe accesspanel,then disconnectthe con-
CAUTION:
a Alt SRS olectrical wiling harness€sale covorad nector betweenthe cable reel and driver's airbag'
Connectthe short connector(RED)to the driver's
with Yollow insulation.
a Botore disconnecting any part ot the SRS wiro airbag connector lsee page 23-27 2l'
harness,connect ths short connscto6 (seepage
23-2721. DRIVER'SAIRBAG
a Roplac6ih€ entiro aflectod SRS halnoss assem- CABLEREEL
DRIVER'S
bly il it has an opon cilcuit or damagod wiling' AIRBAG CONNECTOB
CONNECTOR

DRIVER'SAIREAG

SHORT ACCESSPAI{EL
CONNECTOR
(RED)

SRS UNIT Front passongor's:

Removethe glove box {seepage20-135},then dis-
LEFT DASH connect the connector between the tront pas'
SENSOR senger'sairbagand SRSmainharness Connectthe
short connector(RED)to the front passenger'sair-
bag connector(seePage 23-273).

Bstora lomoving the dashboaid: FROf{T PASSENGER'S

AIRBAG
!@@ To avord accioenlal dsployment and
""iUU inir.v, always install the plotoctive short FRONT PASSET{GER'S
AIRBAG CONNECTON
;onnectors on the driver's and tlont pass€ngel'sair-
bag connectorsbolors working near any SRSwiring'

1. Disconnectthe batterynegativecable,then discon-

necl the positivecable.

NOTE: The originalradiohas a codedtheft protec

tion circuit.Be sureto get the customer'scodenum-
ber before
- disconnectingthe battery.
- removingthe No 32 (7.5A) Iuse from the under- SHORT
hood fuse/relaYbox' CONNECTOR
- removingthe radio. (REDI

After service,reconnectpower to the radioandturn

"CODE" is displayed,enter
it on. When the word
SBS MAIN HARNESS
the customer's 5 digit code to restore radlo CONNECTOR
ooeration.

20-136
 Replacement
To removethe dashboard,first removethe: 3.
a Front seats (seepage 2O-103)
a Front and rear consoles(seepage 20-128)
a Dashboardlower cover (seepage 2O-131)
a Knee bolster (seepage 2O-132)
a Glove box lsee page 2O-135)
. Clock (seepage 20-135)
a Moonrootswitch (seepage 20-1341
a Stereo radio/cassette{seepage 20-132)
Removethe nuts, then removethe front passsnger,s
airbagbracket,
To avoid accidantar daploym.nr ",'d
@
possibls iniury, always install th€ protoctiv. 3hqt
connoctor on tho ,ront passongor'aairbag conncc-
tor whon tha SRS main ha.na$ is disconncctod llcr
pago 20-136).
: Nut locatlons,4

Lower the steeringcolumn (seesection 17). FRONTPASSENGER'S

@@ ro avoid accidentat dedoyment and

possiblo in ury, always install the prot€ctive short
connector on tho drivsr's airbag connector bgtor€
lowering tho stooring column (so€ page 20-1361.

NOTE: To preventdamageto the steeringcolumn,

wrap it with a shoDtowel.

: 8olt, nul locations

A : Bolt, 2 8 : u t ,2

8 x 1 . 2 5m m 8 x 1.25mm

gill$"'l
22 N-m 12.2ksl.m,
16 lbt.frl

FRONTPASSENGER'S
AIRBAG BRACKET
SRS MAIN
HARNESS

STEERINGCOLUMN 4. Disconnect the air mix controlcable and connectors.

AIR MIX CONTROL

CAELE

CONNECTORS

(cont'dl

20-137
Dashboard
(cont'd)
Replacement
5. Disconnectthe antennalead. 8 . Remove the bolts, then lift and remove the
dashboard.

CAUTION: Use protoctive tspe on the bottom ol tha

lront tillar trim;

NOTE:
a Take care not to scratchthe dashboard.
a To prevent damageto the shift lever (M/T) or
selecter lever and A/T gear position indicator
panel (A/T), wrap them with a shop towel.

V : Bolt locations,6

6. Disconnectthe connectorsfrom the under-dash

6 x 1 . 0m m
fuse/relaybox. 9.8 N.m (1.0 kgt'm, I
7.2 tbt.ftt

____/
PROTECTIVE

CONNECTOR
(A/T only)

CONNECTORS
SHOPTOWEL

Removethe accesspanelson both sides. 9. lnstallationis the reverseof the removalprocedure

GAUTION: When prying with 8 tlat tip scrowdrivor' NOTE:

wrap it with protective tapo to pl€vent damaga' a Make surethe dashboardfits onto the body cor-
rectly.
a Beforetighteningthe bolts, make surethe dash-
DASHBOARD
board wire harnessesare not pinched,and thal
the dashboardis not interferingwith the air mix
accEss control cable.
PANEL

HooK\ ___E-- RE=-cLrP

ffiL
lcCesS Plnel /

20-138
Bumpers
Front Bumper Replacement

NOTE: 3. Removethe bolts, then removethe front bumoer.

a An assistantis helpfulwhen removingthe front bum-
per and lront bumper beam. V : Bolt locations : Clip locadrn., 2
a Take care not to scratchthe front bumper.
a Open the hood. A V : B o h ,I B V : B o l r ,2 A A
1. Removethe tront turn signallight, then disconnect
+Et=
-+EP_
the connectorson each side. :

< : Sci6w locatlons,2

CONNECTORS

FNONTTURN
SIGNAL LIGHT FRONTBUMPER

2. Pull the inner fender down. then remove the screws NOTE: lf necessary,disassemble
the tront bumper.
from the front bumper and lower bumper on each
5rcte. > : Boll, screwlocations

: Scr6w locations A > : 8 o l t ,2 8>: Bolr5

, C V : B o l r I, D < : S c r e w8,

A : Scrow, 2 BA: Scrow, 2

q-l -ry-l_9, =g
_A_,
__s_, A : Clip locarions

AA : Clip, 2

/H\ i
BA : Ctip,4
{-r--
*=\
FRONT
BUMPERr
-<€L9-
'a- /
I
__tr:i!uF&, FRONTTURN
SIGNALLIGHT

g nolt

Et2"
D
/
HOLOER
/
D
sroe
SEAL
stoE
CLIPS
'l-eo
fr:**M
INNERFEl{DER

BUMPER LOWERBUMPER

20-139
Bumpers
Front Bumper RePlacement(cont'd)

4. Removethe absorberand bumperbeamgusset on Installation of the removalprocedure.

is the reverse
each side. then removethe front bumperbeam.
NOTE:
: Eolt locotions. 4 o Installthe holesin the front bumperbeamover
the hookson the bodY.
E
6
rcr
8 r 1.25mm
22 N.m (2.2 kgt'm,I
't6 tbt fti
_/ FRONTBUMPERBEAM

FrBo*sidor
HOLE
(Frontbumperb€amsidel

Align the front bumperside clips with the tront

fender properly,then installthe front bumper.

FRONTFEiIDER

FRONT
BUMPER
ABSORBER

a Make surethe connectoris connectedproperly.

20-140
 Rear Bumper Replacement

NOTE: 4. Removethe bolts, then removethe rear bumper.

a An assjstantis helpfulwhen femovingthe rearbum-
per and rear bumperbeam. : Bolt locations,2
a Take care not to scratch the rear bumper.

Hatchback

1. Removethe screw from each side.

: Scrow I
A
A\

REARBUMPER
REARBUMPER

5. lf necessary,removethe bumperupperbeam from

Openthe hatch, then removethe reartrim panel (see the rear bumper.
page 20-921-
: Screwlocotions
J. Removethe nuts, and disconnectthe licenseplate
light connectorand grommet. A : Scr€w,4 B <: Sc.ow,4 V: Cliplocations,
I

.--r-Fl^ |
> : Nut locotions, 4 ^ i --lEr-
6x1.OmmI
--E- I @ s l
/\ _ ' / _\"., J

Q) i;L'i$-.l BIGHTSIDE
LICENSEPI-ATE
_':'y:) ,/ TRIM PANEL LIGHT HARNESS

LEFTS|DE L|CENSEPLATELtcHT

To remove the nuts, remove the rear REARBUMPER

portionof the side trim panelon
each slde {see page 20-921.

(cont'd)

20-141
Bumpers
(cont'dl
RearBumperReplacement
6. Removethe absorber,bumper beam gusset and rear Sadan
bumper beam.
1. Removethe screw from each side
y: Boltlocalions,
4
: Sciow locations,2
1 2x 1 . 2 5m m I
64Nm{65kgfm,I
* "r:,
)
ACCESSCAP

REARBUMPER

2. ODenthe trunk lid, then removethe reartrim panel

(see page 20-97).

3. Disconnectthe license plate light connector and

grommet from the rear trunk atea. Removethe clips
and bolts, then removethe rear bumper'

v: Cllploc.tions,5 2
: 8ok locations,

€ l 6 x 1.0mm I
\\rLlF/d,rft
#.,1 9 . 8N . m
l 1 . Ok g l m ,
7.2 rbr.ft)
i
I
J

REAREUMPER
BEAM
BEAM
EUMPER
GUSSET

lnstallationis the reverseof the removalprcedure.

NOTE: Make surethe licenseplate light connector

is connected,and the grommetis installedproperly,

GBOMMET

20-142
4. lf necessary,removethe licenseplate light harness, 6. Installationis the .everseof the removalprocedure.
bracket and lens from the rear bumper (see page
20-1411. NOTE:
a Make sure the licenseplate light connectoris con-
5. Removethe absorb€r,bumper beam gusset and fear nected, and the grommet is installedproperly.
bumper beam. a Make sure the rear bumper engagesthe side clips
securelv.
V i Bolt locatlons,4

12 x 1.25mm
64 .m (6.5 kgf. m ,
I
j
47 tbt.ftl
)

REARBUMPER

REAR BUMPER
BEAM

BUMPERBEAM
GUSSET

20-143
Hood
Replacement
NOTE: NOTE: It necessary,removethe hood hinge.
a An assistantis helplul when removingthe hood.
a Take care not to damagethe hood and body. V : Boh locationa,4
a When removingthe clips, use a clip remover.
a Open the hood.

1. It necessary,removethe hood edge protector. I3;;,iH"-,,.,

j .rtor"t
I
: Cliploc.tions,16
- )
HOOD HINGE

HOODEDGE
PROTECTOR

\
HOOD

2. Removethe bolts. then removethe hood. lnstallStionis the reverseof the removalprocedure.

: Boltlocalions,
4 NOTE:
a lf necessary,replaceany damagedclips.
6x1.0mm a Make su.e the hood locks securely.
9.8 N'm
{l.O kgl m, a Make sure the hood opens properly.
7.2 lbl.fr) a Adjust the hood alignment(seepage 20-1451.

n
r)
HOOD

20-144
 Adjustment
NOTE: Beforeadjustingthe hood, looseneach bolt slightly.

1. Adjust the hood hingesright and left as well as tore and att by using the elongatedholes.

2. Turn the hood edge cushions,as necessary,to make the hood lit flush with the body at front and side edges.

3. Adjust the hood latch to obtain the proper height at the forward edge.

NOTE: Move the hood latch right or left until the striker
is centeredin the hood latch, as shown. HOOD LATCH

HOOD LATCH

6 r 1 . om m

4. After adiustment,tighten each bolt securely.

20-145
Hatch
Replacement
NOTE: NOTE: Detachthe clips by slidingthe hatch trim panel
a An assistantis helpfulwhen removingthe hatch. forward, then remove it.
a Take care not to damagethe hatch and body.
a Take care not to scratchthe hatch sidetrims and hatch
tnm paner.
a Open the hatch.
a Removethe high mount brakelight {seesection23).

1. Removethe hatch side trim on each side.

HATCH < : Clip locations, 8

3. Remove the hatch spoiler as describedon page

2 0 - 1 5 9 ( f o r s o m et y p e ) .

4. Disconnectthe connectors,then removethe wire

harnessesfrom the hatch.

: Speclal bolt V : Clip locations

locetlons,2 Av : Clip, 3 BA: CliP,6

t + L l
2. Remove the hatch trim panel.

A : Clip localions

AA : Clip, 11 BV : Clip, 3
A

@ ,/l ' L,/

R@t
t f r l
4
NOTE: Before pulling out the wire harness,tre a
)

strinqto the end of it so you can pull it backin when

W',dtri
::::/ _:_/
HATCI{
the hatch is reinstalled.
WIRE I{ARNESSES

HATCH TRIM PANEL

CONNECTORS

CONNECTOR

WIRE
HARNESS

5. Removethe rear wiper motor (seesection 23).

20-146
o. Removethe uDDeranchorbolts from the tront and NOTE:
rear seat belts {seepages 20-1 15, 'l 19), then re- a lf necessary,replacethe supportstrut.
move the upperportionof the quarterpillartrim panel a When scrappingthe suppon $rut, dispose ir as
(see page 20-991. describedon page 20-149.

7 . Removethe rearroof trim, then pull the rearof the

headlinerdown (see page 2O-99).

NOTE: Take care not to bend the headliner,

8 . Removethe supportstfut on each side while hold-

ing the hatch.

HATCH

I x 1 . 2 5m m
22Nm
12,2kgt'm,
16 tbt.ftl

SUPPORT a lf necessary,removethe hatch hinge.

STRUT

V : Solt locdlions,4
9. Removethe nuts, then removethe hatch.
8 x 1 . 2 5m m
22 N.rn
a : Nut locations,4 12.2kgt.m, HATCH
16 tbf.ft) HINGE
HATCH
12.2kgl.m, I
,6'y!:t ,/
HATCH

1O. Installationis the reverseot the removalprocedure.

NOTE:
a lf necessary,replaceany damagedclips.
a Make surethe connectorsare connectedproperly.
a Make sure the hatch locks securely.
a Make sure the hatch opens properly.
a Adjust the hatch alignment(seepage 20-148).

20-147
Hatch
Adjustment
NOTE:
a Beforead,usting the hatch.looseneachbolt andnut slightly.
a Do not installthe suDDort
struts.

1 . Adjust the hatch hingesright and left as well as fore and aft by using the elongatedholes.

Turn the hatch edge cushions,as necessary.to make the hatch tit flush with the body at each side.

Adjust the hatch fit to the hatch openingby moving the striker,

4. Use shims, as necessary,to make the hatch tit flush with the body at the rear edge.

HATCH

8 x 1.25mm

HATCH
EDGECUSHION

HATCH

NOTE: Move the striker right or left until it's centered

in the hatch latch, as shown.

HATCH
LATCH

t
+Q.

6x1.0mm
9.8 N m (1.0 kgl m,
7 .2 tbt.trl

5. Atter adjustment,tighten each bolt and nut securely,

 Trunk Lid
SupportStrut Disposal Replacement

@ Tha support strut contains nitrog.n gas and NOTE:

oil unde. pr€ssul€. a An assistantis helpfulwhen removingthe trunk lid.
The pressuremust be relievedbsfo.e disposalto prevant a Take care not to damagethe t.unk lid and body.
explosion and possible injury wh€n sc.apping. a Open the trunk lid.

Placethe support strut on a level surface with its rod ex- 1. Disconnectthe connectorsand trunk lid openerca-
tended,and drilla hole 2-3 mm (3/32"1diameterin the ble.Removethe wire harnessandt.unk lid opnerca-
body to releasethe gas. ble from the trunk lid.

NOTE: Before pullingout the wire harness,tie a

stringto the end ot it so you can pull it backin when
the trunk lid is reinstalled.

> : Clip locationg

AD : Clip, 3 B< : Clip, 1 CA : Clip, 5

20 mm (O.79inl

_rP
e-i ,/

TRUNKLID WIRE HARNESS

OPEN€RCABLE
CONNECTOR CONIIECTOR
TRUNKLID
SUPPORTSTRUT LATCH
{seepage20-157}

@ always w€ar €ye prot6ction to avoid get-

ting motal shavings in your eyea when roloasingth€ gas
fiom the support st.ut. TRUNK LIO
OPENER
CABLE
A
A

(cont'd)

20-149
Trunk Lid
(cont'dl
Replacement
2. Removethe bolts. then removethe trunk lid. a Remove the bolts, then remove the trunk lid
hinge.
> : Bolt loc.rlons.4
V : Bolt locaitons,4

NOTE: Take care not

to hit the rear window
when removing the bolts.

TRUNKLID

removethe trunklid hinge

lf necessary. 4. lnstallationis the reverseot the removalprocedure.

NOTE: NOTE:
a Removethe rearshelf{seepage20-95). a Make surethe connectorsare connectedproperly.
a Removethe torsionbarswith the torsionbar as- a Adjust the torsion bars tore or aft with the tor-
sembly tool. sion bar assemblvtool as shown.

TRUNKLID
HINGE O =NormalPosition
O = Highertension

a Make sure the trunk lid locks securely.

a Make sure the trunk lid opens properly.
O Adjustthe trunk lid alignment(seepage20-151).

TORSION8AB
ASSEMBLYTOOL

20-150
 Adjustment

NOTE: Beto.e adjustingthe trunk lid, looseneach bolt slightly.

1. Adjust the trunk lid hingesright and left as well as fore and aft by using rhe etongatedholes.

2. Turnthe trunk lid edgecushions,as necessary,to makethe trunk lid fit flush with the body at the rearand sideedges.

3. Adjust the lit betweenthe trunk lid and the trunk lid openingby moving the striker.

TRUNKLID EDGE
CUSHION

/21
ft(M
TRUNK LID
HINGE Y4Y
TRUNI(LID

6r1.Omm
9.8 N.m 11.0 ksl m, 7.2 lbt'ft|

NOTE: Move the st.iker right or left until it's centered

in the trunk lid lalch, as shown,
6 x '1.0mrn
STRIKER 9.8 N m 11.0 lo,f.m,
7.2 tbt.hl

STRIKER

4. Atter adjuslment,tighten each bolt securelv.

20-151
OpenerCables
Replacement
NOTE:
a Whenremoving the clips,usea clip remover.
a Takecarenot to bendthe openercables.
HOODOPENER
Hood Opener Cable: CABLE

v : Clip location. > : Scrow locrtions, 6

Av:CllP,5 HOODRELEASE
Otr" I
M)
HAI{DLE
(se€page20-154)
:_ _)

Bv:Clip.6 HOOD LATCH

(seepage 20"154)
E \ I
:=r
____lEt-

- ,/
-\-
L

NOTE: Loosen the screw, then remove INNER FENDER

the clip using a clip remover.

Hatch/Fuol Lid Oponer Cabls lHatchback):

(seepage2O-91),then pull thecar-
NOTE: Removethe rearseat (seepage 20-108), reartrim pan€land sidetrim panel
Det back. as necessarylsee page 20-124).

A : Clip,csblocushionlocation3
AA : Clip, 8A : Clip, CA : CliP, DD : Cllp, Etr : Cllp, FA : Cllp, GA : Clip, HA : C.bl6 cushlon, 5

s-,$, g, e&r@)s,l Wt9)

i r 2 , 7 , 1 , I ,

HATCH LATCH FUEL LID LATCH

Right sids: lsee page 2O-156) Loft 3ido: lsse page 2O-155)

HATCH HATCH
OPENERCABLE
HATCH/FUELLID
OPENER
{seepage2O-'l54)

20-152
Trunk Lid/Fuol Lid Opan.. Cablo (Sodanl:
NOTE: Removethe rearseat {seepage 2O-110) and centerpillarlowertrim (seepage20-94}, then pullthe carDetback.
as necessa.y(see page 2O-1241.Removerhe left trunk side panel (see page 20-97).

> : CliD, c.bla cu.hion locstlon!

A > : C l l p ,1 BV:Clip,2 C A: Clip,,t D >: Clip,3 E A r C l l p ,1 F < : C.ble culhlon, 1

ws@:ffi;6,1
7--
TRUITIKLID LAICH
(s€ep6ge20-157)

FUEL LID

OPENER
{se6page 20-155)

FUEI.LID LATCH
(soopago20_'|55)

Installationis the reverseof the removalorocedure.

NOTE:
a Make sure each openercable is routed and connectedproperly.
a Make sure the hood, hatch. trunk lid and fuel lid open properlt.

20-153
Openerand Latch
Replacement
NOTE: Take care not to bend the openercables.

Hood RelsaseHandle: Hood Latch:

< i Bolt locations,2 < : Bolt locations

6 x 1.0 mm HOODOPENER 6 x 'l.O mm
9.8Nm CABLE 9.8Nm
(1.0kgl m, (seepage20'152) 1 1 . 0k g l m ,
7.2 tbl.lrl 7 .2 tbt ftl ,/ HANDLE

HOOD
LATCH

HOOD RELEASE
HANOLE
Removethe kick
panel (seepage
20-91). Removethe bolt while
HOOD HOOD pullingthe handle.
LATCH OPENER
I CABLE

Hatch/FuelLid OpenerlHatchback):

< : Bolt, sclow locations

A<rBolt.2 HATCHiFUELLID
OPENER

the

6 x 1.0 mm
9.8 N m 11.0kgl'm,
7.2 tbl.fr)
OPENER
COVER
J't o
t-
@
BV:Sc.sw, 1

6'\ I
v l
/

FUEL LID
OPENERCAELE

HATCH
OPENERCABLE
(seepage 20-152)

lnstallationis the reverseof the removalprocedure'

NOTE:
a Make sure each openercable is connectedproperly
a Make sure the hood locks securely
a Make sure the hood, hatch and fuel lid open properly.

20-154
NOTE: Take care not to bend the openercables.

Trunk Lid/Fuel Lid Oponer {Sodan}:

Pry the ljd.
< : Bolt, scrowlocatlon! OPENER
COVER
A<:Bolr,2 o
*rr*@ OPENERLOCK
CYLINDER
t -
o

6 r 1 . 0m m
9 . 8 N m 1 1 . Ok g l m ,
TRUNKLID/FUEL
LID OPENER
B V: Scrow, 1

A
-}{- II
H. I

_:_)
()t
FUELLID
OP€NERCABLE
(seopage 2O-153)

TRUNKLID
OPENER CABLE
(seepage20-153)

Fuol Lid Lstch:

< : Boh,locotions,2

6r1.0mm
9 . 8 N m 1 1 . 0k s l ' m , i
7 '2 tbt'''l FUELLIDOP€NER
------,// CAALE
( s e ep a g e s2 0 - 1 5 2 1, 5 3 )
FUEL LIO LATCH
Removethe fuel lid latch
by turning it 90o.

LIO LATCH
Hatchbock: Remove the rear shelf and rear trim oanel.
FUEL LID then pull the rear edge ot the lett side
trim panelback (soepage 2O-91).
Sodan:Removethe rear trim panel,
then pull the rear edge of the left trunk side
panelback {seepage 2O-971.

lnstallationis the reverseof the removalorocedure.

NOTE:
a Make sure each openercableis connectedproperly.
a Make sure the fuel lid fits flush with the body.
a Make sure the tuel lid locks securelv.
a Make sure the trunk lid and fuel lid open properly.

20-155
Hatch Latch and Lock CYlindet
Replacement

NOTE: Takecarenot 10 bendthe cylinderrod and hatch 4. Disconnectthe hatch openercable.

openercable.

1. Removethe rear trim panel (see page 20-921.

2. Disconnectthe cylinderrod and connector.

HATCH LATCH

5. Removethe lock cylinderby turning it 45o

>: Bolt localion,1

CYLINDERROD

3. Remove the hatch latch.

>: Screw locatiois, 3

^ 6x1.omm I
{-D m s . e N m ( 1 . 0k s l m ,
,?tb:tn
__/
o. lnstallalionis the reverseof the removalprocedure.

NOTE:
a Apply greaseto the hatch latch.

HATCH LATCH

a Make sure the hatch locks securely.

a Make sure the hatch opens properly.
a Make surethe connectoris connectedproperly.

20-156
Trunk Lid Latch and Lock Cylinder
Replacement

NOTE: Takecarenot to bendthe cylinderrod and trunk 4. Removethe lock cylindercover.

lid openercable.
HOOKS

l. Disconnect
the connectorand trunk lid openercable. CLIP

CONNECTOR

LOCKCYLINDER
CLIPS COVER
LID
CABLE
5. Removethe bolt, then pullthe lock cylinderout. Re,
move the lock cylindertrom the cylinderrod, then
take them out.

: Boltlocation,'l
2. Disconnectthe cylinderrod.
F 6xl.Omm I
q;i!!"jy
LOCK
CYLINDER CYLINDER
ROD

Removethe bolts, then removethe trunk lid latch.

CYLINDER
ROD
A : Bolt locations,3

6. Installationis the reverseol the removatproceoure.

NOTE:
a Apply greaseto the trunk lid latch,

/ ./,.,
,/'e4

a Make sure the trunk lid locks securelV.

a Make sure the trunk lid opens properly.
a Make sure the connectoris connectedproperly.

20-157
Retainersand WeatherstriP
Replacement

CAUTION: Wear gloves to lemov€ and install tho i€tain€rs'

NOTE: Take care not to bend the retarners.

< : Screwlocalions,19 < : Clip locations,I

REAR CLIP
| .€\

!9 !:

RETAINER
q
l{ SHOPTOWEL

CENTERPILLAR
MOLDING

WEATHERSTRIP

Boot side section:

RETAINER
Center oillar section:
PILLAR
FRONT CENTER
I
CENTERPILI-AR
MOLDING
NOTE: The numbers atter the part names
show the quantities ot the parts used

WEATHERSTRIP RETAINER

lnstallationis the reverseof the removalprocedure.

NOTE:
a Check the weatherstriplor damageor deterioration,and replaceif necessary'
a After installingthe weatherstrip,check for water leaks'
a lf necessary,adjust the positionof the door glass (see page 20-40)
a It necessarv,replaceany damagedclips.

20-158
 FenderWell Trim and
Hatch Spoiler WheelhouseProtector
Replacement Replacement

a Take care not to scratch the hatch. a Take care not to bend the tender well trim.
a Open the hatch. a Beforeinstallingthe lender well trim, cleanthe bodv
bondingsurfacewith a spongedampenedin alcohol.
1. Removethe hatchsidetrim and hatchtrim panel(see a After cleaning,keepoil, g.easeor wafer lrom getling
p a g e2 O - 1 4 6 ) .
on the surface.
2. Removethe nuts and disconnectthe connector. > i Scr€wlocations.
: Nut locations,4
6 x 1 . 0m m
Ch 9.8 N.m
I
(J (1.0 ksl m, I
__. 7,4b1!t ,/
coI{t{EcroR

Removethe hatch spoilerby turningthe clip nut on

the left side counterclockwise.

HATCH SPOILER

FENDERWELL
ADHESIVE TRIM

3. Installationis the reverseof the removalprocedure.

20-159
Hatch Weatherstdp/TrunkLid Weatherstrip
Replacement
HatchWeatherstrip:

NOTE:
a Beforeinstallingthe hatchweatherstrip, applyclearsealantinto its channelat the > locations.
a After applyingthe sealant,installthe hatchweatherstrip.

ALIGNMENT MARK
ff6llowl

HATCH
WEATHERSTRIP

Trunk Lid W€athorstrip:

MAE(
ALIGI{MENT
(Whitol

TRUNKLID
WEATHERSTRIP

HATCH/TRUNKLID
WEATHERSTRIP
When installingthe hatchor ttunk lid weatherstrip.align
it with the alignmentmark on the hatch or trunk lid
openrng.

NOTE:
a Make surethere are no wrinklesin the weatherstrip.
a Check tor water leaks.
ALIGNMET{'
MARK

Forward
Roof Molding
Replacement
CAUTION: When prying with I flat tlp scrowddv€r, wrap a Pullthe roof molding up and detach the bracket lrom
it with protoctivo tapo to pravent damag6. the pin, then removethe roof molding.

NOTE: Take care not to scratch the bodv and root

molding.

1. Pry the rool molding with a flat tip screwdriver as

snown.

CAUTlOfil: Use protoctivo rape on tho body.

ROOF MOLDING

SIDEMOLOII{G
BRACKET

Pull and slide the root molding, then detach the 4. Installation
is the reverse
of the removalorocedure.
bracket on the end of the roof molding from the pin.
NOTE:
a Takecare not to damagethe windshieldside
ROOF MOLDING molding.
a Make sure the roof molding is installed securely.

R(X)F MOLDING
PIN
{Body ddq)

ROOF MOLDING

20-161
Door and Side Moldings
Replacement
protective tape to pr€vont damag€'
CAUTION: When prying with 8 flal tip screwdriver, wrap it with

NOTE:
pages 2O-4' 2O' 32],'
a To remove the doot moldlng, temove the door panel and plastic cover {see
(see page 20-91)
a To removethe rear side molding,removethe side trim panel
a Take care not to bend the door moldings.
is bent. Replacethe door molding
a The steel core in the door moldingcann-otbe restoredto its originalshapeonce it
if the steel core is bent.

V : Clip locations
BV: clip (Hatchback' 3) CV: Cllp (Halchback,1l Dv: Cliplsodan,1)
av : cllp (Hatchb6ck, 5)
{Sodan,2l

STEEL

CLIP

V: Plastic nui locatlon

Hatchbsck (Hatchback, 1)
(Sedan,1)

l r >
O '
r9
NOTE:
a BeJoreinstatlingthe rear door molding,
scrapethe adhesivetape from the mold-
ing and body.
a Cleanthe motdingand door bondingsur-
Jaceswith a spongedampenedin alcohol'
a Atter cleaning,keepoil, greaseand water
Jrom getting on the surface.
a Gluethe new adhesivetape to the mold-
ing as shown.
6mm 30mm
ls 2f 61 . t.l.18inl REAR DOOR
MOLDING

30 mm
( 1 . 1 8i n l
lnstallationis the reverseoJ the removalProcedure.
Forward
NOTE: It necessary,replaceany damagedcliP. NEW ADHESIVETAPE
Thicknoss:1.2 mm lo.o5 inl

20-162
Side Sill Panel
Replacement
V : Clip locations > : Screw locations, 4

q,
AV: Ctip {Harchbsck,8) BA : Clip (Harchback,7)
{Sodan. 8 l {sodan,7l

SIDECLIP NOTE: Loosenthe screw,

Removethe side clips from rhe body then .emovethe lower clip
by turning them 45o using a clip remover.

Remove the lower clips, then removethe side sill panel

by sliding it forward.

Hatchback

\y':
NOTEj When removing the side
sill panel, lhe side clips will

SIDE SILL PANEL

To installthe side sill panel,removethe side clips from

the body, installthem on the side sallpanel,then instatl
FENDER the side sill panel on the car.

NOTE:
a Take care not to twist the side sill panet.
a lf necessary,replaceany damagedside and lower
clips,

20-163
RearEmblems
lnstallation
body, as shown, then press
Align the applicaliontape with the rearturn signallight and the gap betweenthe taillightand
the emblem into place. Removethe applicataon tape'

NOTE:
a Beforeapplying,clean the body surlace with a spongedampenedin alcohol'
a After cleaning,keep oil, greaseand water from getting on the surface'
a When applying,make sure there are no wrinklesin the emblem'

Attachment Point:

REARTURN
SIGNALLIGHT
Hatchback

REARTURN
SIGNAL LIGHT

!---_-----------,-i-J

TAILLIGHT

20-164
Sub-frame

Sub-t.ame Torque Sequence:

cAUTloN: After rooseningtho rsar beam mounting borts be sura to repracothom with new onea.

6 x 'l.O mm
9,8 N.m (1.0 kgt.rn,
7.2 tbt-fll REABBEAM BBACE

1 0 x 1 . 2 5m m
44 N.m {4.5 kgt.m,
FEAR BEAM 33 rbr.ftl
COLLAR

REAR BEAM

REARBEAM
14 x 1.5 mm
89 tt.m (9.1 kst.m,
66 lbf.ftl
Beplace.

20-165
FrameRepairGhart

-!
ar"tr*,,,ua

\ Model
M/T
Dls6ft-\
514.5 5 0 1. 5
@ 120.261 (19.7)
2.5 25
U-) (0.10) {o.98)
(J
{10.53) 112.03)

\---!e!s!
Distance \
Sedan

2100 2150
o lE2.71 (84.6t
2632 2642
{103.6) {105.6}
J5 2 6 11
(102.8) (104.8)
2607 2657
@ (102.6) (104.6)
674
t22.Ol (26.5)

B A S EL I N E
d11.5

d l 1 . 5t O _ I cir (o-36;E;\ry+
, Poinr
Aoad | 9rl lv
011.5
c r 1 . 5( 0 . Front Osmpsr Lowsr Bush

20-166
 POINT w

d 2 5 l l . o l L o c a r eH o l e g
@

20-167
 Heater and Air Conditioning

Heater . . . . . . . .2 1 - 1
A i r C o n d i t i o n i n .g. . . . . . . . . ..22-1

RESTRAINTSYSTEM{SRS}
SUPPLEMENTAL

The IntegraSRS includesa driver'sairbag,locatedin the steeringwheel hub. In addition.all modelsexcept the
RS model for Canadahave a front passenge.'sairbaglocatedin the dashboardabove the glovs box. Information
necessaryto safely servicethe SRSis includedin this ServiceManual.ltems msrk€d with an asterisk(') on the
conlents page include,or are locatednear, SRS components.Servicing,disassemblingor,eplacing thes€ items
will requirespecialprecautionsand tools, and shouldthereforebe done by an authorizedAcura dealer.

a To avoid r6nd6dng tho SRS inoporativo. which could lead to personal injury or dealh in tho svont ot a sevele
frontal collision, all SRS servica work musl b€ portormed by an authorized Acura dealer.
a lmpropor sorvico procaduro3,including incorrect romoval and installatlon of tho SRS,could load to porsonaliniu-
ry causod by uninlonlional activation of tho ailbag8.
a All SRS eloctdcal widng harnossosare covored with yollow in3ulation. Relatsd compononts a.o locatod in tha
stsering column, flont console, daehboard,and dashboafd low6r pan6l, and in lhe dsshboa.d above lh€ glove
box. Do not uao electdcal tost equipmont on theae circuhs.

NOTE: The originalradiohas a coded theft protectioncircuit. Be sureto get the customer'scode numberbeto.e
- disconnecting the battery.
- removingthe No. 32 (7.5 A) luse from the under-hoodfuse/relaybox.
- removingthe radio.
"CODE" is displayed,enter the cus-
After service,reconnectpower to the radioand turn it on. When the word
tomer's 5-digit code to restore radio operation.
 Heater
l f l u s t r a t eIdn d e x . . . . . . . . . . . . . .........21-2
HeaterDoor Positions .........,..,.21-3
C i r c u i tD i a g r a m . . . . . . . . . . . . . . . . . . . .2. .1.- 6
Troubleshooting
S y m p t o mC h a r t . . . . . . . . . . . . . ......21-8
Flowcharts
B l o w e rM o t o rS p e e d. . . . . . . . . . . . . . . . . . . . . . . . . . 2. .1. -. .9
B f o w e rM o t o r . . . . . . . . . , . . , , , , ,2. 1
. -11
M o d eC o n t r o M l o t o . . . . . . . . . . ...... . . . . . . . . . . . . . .2. 1. - 1 4
Recircufation ControlMotor ......,...,.,,,.,.... 21 -17
Heater Control PanelInput/
O u t p u tS i g n a l s ..............21-19
Blower Unit
Repfacoment . . . . . . . . . . . . . . . . . . . .2. .1.- 2 0
Overhaul .......21-21
+HeaterUnit
Repfacement . . . . . . . . . . . . . . . . . . . .2. .1. - 2 2
Overhaul .......21-24
DefrosterDoor Adjustment ...,............. ......,, 21 -25
Heatel Control Panel
Repfacoment . . . . . . . . . . . . . . . . . . . .2. .1. - 2 5
Overhaul .......21-26
Heater Valve Cable
Adjustment ...21-27
Air Mix Control Cable
Adjustment ... 21-27
Mode Control Motol
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1.-. 2 e
Repfacement . . , . . . . . . . . . . . . . . , , ,2, .1. - 2 8
Recirculation Control Motor
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1. -. 2 9
Repfacement . . . . . . . . . . . . . . . . . . . .2. .1. - 2 9
Relay
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1. -. 3 0
Heater Fan Switch
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1.-. 3 0
Mode Control Switch
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1. -. 3 1
Recilculation Control Switch
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .1.-.3 1

*: Read SRS precautionsbefore working in this area.

 lllustratedIndex

CAUTION:
a All SRS electrical wiling harnessesare covered with
y€llow insulation.
a Bafore disconnecting any pan of the SRS wile har-
ness. connect the sholt connectorlsl.
a Replacethe sntire aflected SRS halness assembly if
it has an open circuit or damaged wiring.

NOTE: The originalradio has a coded thelt protection

circuit. Be sure to get the customer'scode numberbefore
- disconnectingthe battery.
- removingthe No. 32 (7.5 Al fuse lrom the under-
hood fuse/relavbox. SRS MAIN HARNESS
- removingthe radio.
After service,reconnectpower to the radio and turn it
"CODE" is displayed,enterthe cus-
on. when the word
tomer's 5-digit code to restoreradio operation.

BLOWERUNIT
Replacement,page 21-2O
O v e r h a u lp, a g e2 1 - 2 1
HEATERUNIT
page2l 22
Repfacement, RECIRCULATIONCONTROLMOTOR
page21-24
Overhaul, Test, page 21-29
I{EATERVAIVE CABLE Replacement,page 21 29
Adjustment,page21-27

BLOWENRESISTOR
Test, page 21-9

W, AIR MIX CONTROL

CABLE
Ad,ustment,page 21-27
Replacement.page 21-26

a/c swrTcH
(wirh A/cl
Test,page22-20

RECIRCULATION
CONTROLSWITCH
T e s t ,p a g e2 1 - 3 1

HEATERFAN
swtTcH
Test, page 2'l-3O

MODE CONTROLMOTOR MODE CONTROLSWITCH

Test, page 21-28 T e s t ,p a g e2 1 ' 3 1
Repfacement,page 21'28 TEMPERATURECONTROL
LEVER

I
(Adjustmonl: See AIR MIX
HEATERCONTROLPANEL CONTROLCABLE}
Repfacement, page 21 -25
Overhaul,page 21-26

21-2
Heater Door Positions

*)
xor coor.
! fr

VENTOOOR

-*)
(HEAT/VENTI

(cont'd)

21-3
Heater Door Positions
(cont'd)

\)
IHEATI

El
IHEAT/DEF)
N
CircuitDiagram
- OASH
UiIDEN
- HOOO
UNOER FUSE/REI.AY
8OX FUSE/RETAY
8OX
(7.5A1
N0.13
WtlT/BtK.+WtfT

RECIRCUI.ATION
Moron
coMTBor-

nrot
G401

21-6
 UGHTIG
swtTcH

I
RED/BI.K

I r . l . A . t t A _ A- l_t r r A- l. - f_ r r A- l.
A A
- l -r l
| | I l t I I | | |
r t , / , f r r , / , / t t f , f t t , / , f I
I t v v I r v v I r v v I r v v I

HEATER
CONTROL
PANEI.

OASHIIGTTTS
EnrGFr ESS
coNTROU.IT

21-7
Troubleshooting
Symptom Chart

NOTE: Check the enginecoolant level and allow the engineto warm up before troubleshooting.

SYMPTOM
Hot air flow is low. Blower motor runs, but one ol more
speeds are inoperative.
Blower runs properly.
REMEDY
Follow the tlowchart (see page 21-9).
Check for the following:
. Cloggedheaterduct
. Cloggedheater outlet
. Incorrect door position

No hot air Jlow Blowel motor does not run at all. F o l l o wt h e f l o w c h a r t( s e ep a g e2 l - l 1 l

Blower motor runs. Check for the following:
. clogged heatet duct
. Cloggedblower outlet
. Cloggedheatervalve
. Faultv air mix door
. Heatervalve cable sdjustment lsee page 2'l-271
. Air mix control cable adjustment(see page 21-27)
. Faultythermostat (seesection lO)
. Cloggedevaporator(with air conditioning)
. Frozenevaporator(with air conditioning)

Mode control motor does not run, or one or more modes are Follow the flowchart (see page 21-14).
inooerative.
Recirculationcontrol door does not changebetween FRESH Follow the flowchart (see page 21- 17).
and RECIRCULATE.

21-A
Blower Motor Speed

Blowor motor run3, bul ono ol

mors rpoodt aro inoporotivo.

-l

iii
Turn the ignitionswirch ON lll).
and the heater tan switch OFF. |t|

lI
Does the blower motor run?
\\
To pago 21-1O
\

Turn the ignitionswitch OFF. I!i

Measurethe rosistancebetwoen
the No. 2 and No. 4 terminalsoI
the blow€r resistor.

ls there aDorox.2-3 ohms?

Removethe heater conlrol pan€l

{seo page 21-25}.

Turn the ignitionswitch ON (li).

At the heater fan switch 6P con-

nector, ground each of these
waresindividuallyin ths lollowing
order:
. BLU wire
. BLUMHT wir€
. BLU/YELwire
. 8LU/BLK wi.e

T o p a g e2 1 - 1 0

(cont'd)

21-9
Troubleshooting
Blower Motor Speed (cont'd)

From page 21-9

Does the blower motor run at Raplacatho hollar fan rwitch.

progressively higher speeds?

Ropair opon or cau36 ol oxcoalivt

rosbtanco in tho appaopaiato
wire(3| b6twoon thg hostct lan
switch and tho blower todstor. View trom whe side

From page 21-9

Turn the ignition switch OFF.

Removethe heater control panel

(seepage 21-25).

Iilil
-l

View from wire side

Checkeach wire for continuitybe-

tween the heater tan switch 6P
connector and body ground.
BLU/U,HT !\i
. BLU wire
. BLUMHT wire
. BLU/YELwke
. BLU/BLKwire

Raplaca tha haater lan awltch.

Bopair shon in the wir6{s} b€-

lwo€n lho heatot lan switch rnd
th6 blowor ro3bto?.

21-10
--
BlowerMotor

Blowor motor doos noi iun at all.

check the No. 37 (4o A) fuse in

tho under-hood fuse/relay box.

View from wire side

At th€ blower motor 2P connec-

tor, connectthe BLU/8LKwirc ter-
minal to body ground wath a
jumpe. wire.

Turn the ignitionswitch ON (ll).

Does the blower motor run? To page 21-12

Disconnect the blower motor 2P

connector, and measurethe vol-
tago between the ELU/wHT wire View from wire side
terminal {+} and body ground "uf"'\'
{-}.
,)

Turn the ignitionswitch OFF.

Remove the blower motor relav

from the under-hood fuse/relav
box and test it {seepage21-3O}.

Roplacotho blowor motor rolay.

Measurethe voltage betwgen the

No. 1 terminal (+) and body
g r o u n d( - ) .

T o p a g e2 l - 1 3
(cont'dl

21-11
Troubleshooting
Blower Motor (cont'dl

F r o mp a g e2 1 - 1 1 View trom wire side

BLU/BLK{+ }
Turn the ignition switch OFF.

Removethe heater control pan6l

(seepage 21-25).

Turn the ignitionswitch ON (lll.

Measurethe voltage b€twsen the

8LU/BLKwire terminal l+) and
body ground {- ).

Rgp.lr op.n In lh. BLU/BLK wh.

ls there battory voltage? batwoen lh! blowar motor lnd
tho hcolar f.n .wltch.

Turn the ignition switch OFF.

Check tor continuity in lhe BLK

wire between the heater lan
switch and body ground.

Ch.ck tor an opan in lhr Bl-K wiro

bdtwaan tho hortar tln lwftch
.nd body ground. lf tho wlra l.
OK, ch.ck for poor ground .t
G201 .nd /rO1.

Roplacotho hsator tan lwitch.

21-12
 From page 21-11

Tu.n the ignition switch ON (ll).

Measuretho voltage botwoon tho

No. 4 torminal (+) 6nd bodv
ground (- l.

Ropair opan in tho BLK/YEL wir.

ls there battery voltage? batworn lha undor-hood fuaa/ra-
hy box snd tho undor-dr.h
tur./rolay box.

Turn the ignirion switch OFF.

Checkfor continuity between the

No. 2 torminal and body ground.

Ch.d( to. !n oF|rn in th6 BLK wiro

batwagn lho undar-hood luro/ra-
lry box lnd body ground. ll th.
wlre it OK. chock tor poo. ground
at G2Ol lnd G/lol.

Rop.ir opon in th. BLU/WHT wlr.

betweon tho undsr-hood lura/l.-
lay box and tho blowor motoi.
Troubleshooting
Mode ControlMotor

Modo control motor dooa not nm,

or ono oa moto modo arc In_
oporgtivo.

Disconnectth6 mode control mo_

tor 8P connector.

Turn the ignition switch ON (ll).

Measuroth€voltage b€tween tho

BLK/YELwire terminal (+) and
bodv ground (- ).

R.p.lr op.n In lho BLrrYEL wl..

bctw.rn lha undard!.h fuaa/ru-
l.y box .nd ih. mod! corttol
motor.

Turn the ignition switch OFF.

To page 21-15

21-14
 From page 21-14 View lrom wi.e side

GRl{/YEL
Check for continuity in the BLK
wire betweon the mode control
motor and body ground.

Chock lor an op6n In tho BLK wt

botwo€n tho modo control motot
lnd body ground. It thr wlro i!
OK, chock for poo. grouhd ot
G2O1 8nd G/tOl.

Test the modo control motor (see

page 21-281.

ls the mode control motor OKI Romovothe mode control motor

(soo pag6 21-281.

Removethe heater control oanel

{soe page 21-25). Ch€ck the modo control linkago
and doo.s tor smooth movoment.

Disconnect the heater control

Do tho mode control linkage Ropairth6 mod6 control
Danel14P connector.
and doorc movs smoothlv? linkago or doors.

Ch€ckeach wire for continuitybo-

Raplace thc modo control moto..
twoon the mod6 control motor
and body ground.
. YEL/BLUwire
. Y€L wire
. 8LU,^/VHTwire
. GRNI/EL wire
. YEL/REDwire

Roprir any .hort in th. wlrol!) b.-

tworn tha moda control anotot
and tha holtar control pan6l.

Checkthe samewires lor vohage.

Roplir rho.t to powar In tha

8LK^'EL wiro b.two.h lh. modo
ls the.6 any voltage? conlrol hotor rnd tha haat* con-
trol p!rr.|. (Thi! damrg.. tha
NO hello. control p!nel.)
To psg6 2'l - 16

lconl'dl

21-15
Troubleshooting
Mode Control Motor (cont'd)

View from wire side yEL

From page 21-'l 5

Checkeach wire for conlinuitybe-

tween the mode contiol motor
and the heater control panel.
. YEL/BLUwire
. YEL wire
. BLU/WHT wire
. GRN/YELwire
. YEL/REDwire

R.psir any opon in fro wir6{.1 bo-

twocn tho mod€ control motol
snd tho holtar contiol prnal.

Rsplocotho hoator conlrcl panol.

21-16
RecirculationControlMotor

Rocirculation control doo. dooa

not chsng€ botwoon FRESH6nd
RECIRCULATE.

ffi
Disconnectthe rgcirculationcon-
trol motor 4P connector.

Turn the ignilion switch ON l).

Measurethe voltage betweenthe

BLK^/ELwire rerminal {+) and
body ground (- ).

Reprir op.n In th. BIK/YEL wir.

ls there battery voltage? botwoon thr und.r+rh fu!./r.-
by box 6nd lha radrculdion co.r-
trol motoi.

Turn the ignition switch OFF.

T o p a g e2 1 - 1 8

{cont'd)

21-r7
Troubleshooting
RecirculationControl Motor (cont'd)

F r o mp a g e2 1 - l 7

Test the recirculationcontrol mo_

tor (see page 21-29).

ls the recirculationcontrol Removethe recirculationcontrol

motor OK? motor (see pag. 21-291.

Check the recirculation control

linkage and door for smooth
movement.

Removethe heater control pan€l

{seepage 21-25). Do the recirculation Ropalrtho ioclrculatioo
control linkage and door conirol linkaga ot dool.
move smoothly?

Disconnect the heater control

panel 14P connector. No. 5 GRN/RED
o. 6 GRI{MHT

View from wire side

Check for continuity in the

GRNMHT and GRN/REDwires
between the recirculationcontrol
motor 6nd body ground.

RoDair shorl in rhs GRNMHT

and/or GRN/REDwitols) botwoen
the rocirculation conl.ol motot
and tho hoster control Panol.

Checkthe same wircs for voltage.

ls there any voltage?
Check for contin!ity in the
GRN/WHTand GRN/REDwires
between the recirculationcontrol
motor and the heater control
Ropair 3hon lo Power in tho
BLK/YELwiro botwoon ths rocit-
culalion control motoi and lhe View from wire sid6
ho6tor control Panel' {Thir
ddmagos tho h€atot cont.ol GRN/RED
oanol.)

ffii
panel.

Ropair opsn in the GRi|/WHT

and/o. GRN/REDwiro{sl botwoon
ths rocirculstion conttol motot
and tho hoator control Panol.

Reolaceth€ heatsr control Panal.

21-18
 HeaterControlPanelInput/OutputSignals

No. Wire Color Signsl N o . Wire Color Si9n8l

I BLU/WHT HEAT INPUT 8 GRN/YEL HEATA/ENT INPUT
2 YEL I{EAT/DEF INPUT q
RED/BLK COMBINATION
LIGHTSWITCH INPUT
YEL/BLU DEF INPUT 1 0 RED BRIGHTNESSCONTROLLER OUTPUT
4 BLK GROUND OUTPUT 1 1 BLU/RED A/C THERMOSTAT INPUT
5 GRN/RED RECIRCULATE INPUT 12 GRN HEATERFAN SWITCH OUTPUT
o GRN/WHT FRESH INPUT 1?

YEL/RED VENT INPUT 't4 BLK/YEL tG2 INPUT

21-19
 Blower Unit
Replacement

NOTE: The blower motor, recirculation control motor With Air Conditioning
and blower resistor can be replaced without lemoving 3-b. Removethe evaporator(see page 22-261.
t h e b l o w e ru n i t ( s e ep a g e2 l - 2 1 ) .

1. Removethe glove box (see section 2O), CLIPS

2. Removethe fou. bolts and the glove box frame.

6 x I
9.8 .ft 11.Okgt.m,
7.2 tbt.ftl
GLOVE BOX FRAME

Without Ail Conditioning 4. Oisconnectthe connectors from the blower motor,

3-a. Removethe wire harnessclips trom the heat€rduct. blower resistor and the recirculationcontrol motor.
Removethe Jour self-tapping screws 8nd the heat-
er duct. Removethe wire harnessclip from the recirculation
control motor, and releasethe wire harnessfrom the
clamo on the blower unit.
Removethe two mountingbolts, mountingnut and
the blower unit,
6 x 1 . 0m m
9.8 .m (1.O kgl'm,
7.2 lbf'ft}

HEATERDUCT 6 x 1 . Om m
9.8 N'm (1.0 kgf'm.
7.2 tbt.ftl

6. lnstall in the reverse order of removal, and make sure

there are no air leaks.

21-20
--
Overhaul

NOTE:
' Before reassembly, make sure that the recirculation control door and linkage
move smoothly without binding.
' When teattaching the recirculationcontrol motor, make sure its positioning
will not allow the recirculationcontrotdoo.
to be pulled too fat. Attach the recirculationcontrol motor and 8ll links, then connect power
and ground, and watch
the movement ol the reci.culation control door.

BLOWERRESISTOR
Test. pags 2l-9

21-21
HeaterUnit
Replacement
CAUTION:
a All SRS electrical witing hame$os are covoed wlth
yollow insulation.
a Before disconnecting any patt of tho SRS wito har-
neas, connect tha shott connoctol(s|.
a Roplacoth€ enlire sffacted SRS harnosr a$smbly if
it has an opon cilcult or dsmaged wiring.
3. Disconnect the heater hoses from the heater unit'
CAUTIOII: Engino coobnt will damago paint. orick-
ly dnse any rpilled engine coolant from paintod
surfac63.
NOTE: Enginecoolantwill tun out when the hoses
are disconnected,drain it into a clean drip pan'

CLAMFS

NOTE: The original radio h8s a coded theft protection

circuit. Be sureto get the customer'scode numberbetors
- disconnecting the bafterY.
- removingthe No. 32 (7.5 A) fuse from th€ under-
HEATERHOSES
hood tuse/relavbox.
- removingthe radio
After service. teconnect power to the radio and turn it
"CODE" is displayed,enterthe cus-
on, when the word
tomer's 5-digit code to restoreradio operation. 4. Remove the mounting nut from the heater unit.

1. When the engineis cool, dtain the enginecoolant NOTE: When removingthe mounting nut, take care
from the radiator(see section 1O). not to damage or bend the fuel pipes, brake pipes,
etc.
@@ oo not lomove tho radiator cap whan
the ongine is hol; tha ongino coolant is undot 8 r 1,25rn|n
22 N.m 12.2kgt.m, tO lbf'ftl
pressure and could a€voralYtcald you.

2. Snap open the clamp and disconnect the heater

valve cable from the heater valve arm.

HEATERVALVECABLE

21-22
 5. Rsmove the dashboard (see section 2O).
9. Install in the reverse order of removal, and:
6 . Remove the heater duct (see page 21-20) or the
a apply sealant to the grommets.
evaporator lse€ page 22-26).
a do not int6rchange the inlet and outl€t hoses.
Make sure that the hose clamps are secure.
7. Rsmovethe two bolts, nut and the passenger,sSRS
a loosen th€ ble6d bolt on th6 engine and r€fillthe
(}eam.
tadiator and coolant r€servoirwith the propsr en_
gine coolant mixture (sse section 1O).
8 x 1,26 mln Tightenthe blsed boh when all the trappedair has
22 N.m 12.2kgf.m, 18 tbt.ttl 6sc8p6dand engine coolant begins to flow from
it (seesection 1O).
a connect all csblesand make surethey 8re properly
adiusted (see pdge 21-271.

PASSEIVGER'S
SRSEEAM

8 . Disconnect the mode control motor conngctor, and

remove the wire harness clip from the h€8ter unit.
Removethe two mounting nuts and the haater unit.

6 r 1 . 0m m
9.8 .m (l.O kgt.m,7.2 tbt.frl

MODE COI{TROLI,IOTOR
col{t{€cToF

21-23
HeaterUnit
Overhaul

1 . Remove the screw and the damper arm cover. Pull out the heater core.

Disconnect the link from the dampar arm, and re- NOTE: Be careful not to bend the inlet and outlet
move the screw and the damper arm. pipes during heater core removal.

? Removs the two screws and the heater core cover. Assemble in the rev€rse older of disassembly.

4. Remove the screw and the pipe clamp.

HEATERCORECOVER

DAMPERARM COVER

HEATERCORE

DAMPEFARM

21-24
 HeaterControlPanel
DefrosterDoor Adjustment Replacement
Set the mode control switch on HEAT. Disconned the air mix control cable from the heat-
er unit lsee page 21-271.
Loosen the adiusting screw.
Remove the rear window defogger switch and the
Turn the adjusting arm to the left, as shown, so that hazardwarning switch.
there will be no heat leakagefrom the defrosterdoor,
Remove the two self-tapping screws, then pull out
4. Tighten the sdjusting screw. the heater control panel and the center air vent. Dis-
connect the connectots,and removethe heatercon-
trol panel and the center air vent.
AD.'USTII{G ARM
NOTE: The locking tabs of the hazard warning
switch and heater control panel connectors are on
the bottom.
REARWITIDOW
CE]TTER
AIR VEI{T DEFOGGER
swtTcH

ADJUSTI G SCREW

AIR MIX CONTROLCABLE

4. Removethe four self-tappingscrews and the center

air v€nt.

CENTEBAIR VE T

Installin the reverseorder of removal.and adjust the

air mix control cable at the heater unit lsee page
21-27). lf necessary,adjustthe heatervalve cable
l s e ep a g e 2 1 - 2 7 ) .

21-25
HeaterControlPanel
Overhaul
HEATERFAN SWITCH
Test, page 21-30

AIR MIX CONTROLCABLE

Adjustment, page 21-27

Air Mix Control Cable Replacom€ni

1. Removethe ait mix control caDle'
lever, and push the cable housinguntil it
2. Hook the tip of the new air maxcontrol cableto the temperaturecontrol
is locked.

AIR MIX CO]IITROLCABLE

NoTE:Alterassemb|y,checkthatthetemperaturecontro||eve's|idessmooth|ythroughthe'u||strokefromright
to left.

21-26
Heater Valve Gable Air Mix ControlCable
Adjustment
Disconnectthe heatervalve cablefrom the heater 'l
. Disconnectthe air mix control cable from the air max
valve arm and the clamp,and from the heatercon-
trol arm and the clamp.
2.
2 . Set the temperaturecontrol leverto MAX. HEAT.
3,
Turn the heatercontrolarm as shown. and connect
the end of the heatervalvecableto the heatercon-
trol arm.
4.
Gentlyslidethe heatervalve cablehousingback from
the end enoughto take up any slack in the heater
valve cable,but not enoughto make the tempera-
ture controllever move. Holdthe end of the heater
valvecablehousingagainstthe stop, then snapthe
heatervalve cable housinginto the clamp.
Adjustment
control arm and the clamp.
Set the temperaturecontrol lever to MAX, HEAT.
Turnthe air mix controlarm as shown. and connect
the end of the air mix cont.ol cable to the air mix
control arm.
Gently slidethe air mix control cable housingback
trom the end enoughto take up any slack in the air
mix controlcable,but not enoughto makethe tem-
pe.aturecontrol lever move, then snap the air mix
control cable housinginto the clamp.
NOTE: The heatervalvecableshouldalwaysbe ad-
justed wheneverthe air mix controlcablehas been
disconnected.

AIR MIX CONTROL AIB MIX CONTROL

CABLE ARM

HEATERCOIITBOL
ARM HEATEBVALVE
CABLE

5. Turn the heate.valve arm as shown, and connect

the end of the heatervalvecableto the heatervalve
arm.

Gentlyslidethe heatervalve cablehousingback from

the end enoughto take up any slack in the heater
valve cable, but not enoughto make the tempera-
ture control levermove,then snapthe heatervalve
cable housinginto the clamp,

NOTE: The air mix controlcableshouldalways be

adjustedwheneverthe heatervalvecablehas been
disconnected.

CLAMP

21-27
Mode Control Motor
Test Replacement

ConnectbatterYpower to the No. 4 terminslof the Disconnoct ths mode control motot 8P connector,
modecontrol motor and connectgroundto the No' and remove it from lhe heater unit.
8 terminal.
Remove the two sclsws, mode control motot, and
Using a jumper wire, short the No. 8 terminsl in- flango coll8,.
dividuallyto the No. 1, 2, 3. 6 and 7 terminals,in
that order. MODECONTROL
iioroR
a Eachtime the short circuit is mad€,the mode con-
trol motor should run smoothly and stop.

NOTE: ll the modecontrolmotordoesnot run when

shortingthe tirst terminsl,short that t€rminalagain
after shortingthe other terminals.
The mode control motor is no.mal it it runs when
shortingthe tirst terminalagain.

3. lnst8ll in tho rsvsrse order of removal. After inst8l-

lstion, make sur€ the modo control motor runs
smoothlv.

lf the modecontrolmotor doesnot run in step 2, re'

move it, and check ths mode control linkage8nd
doors for smooth movement.It the mod€ control
linkageand doors move smoothly, replaceth€ mod€
control motor.

21-28
Recirculation
ControlMotor
Test Replacement
Connectbafterypower to the No. 1 terminalof the Disconnectthe 4P connector from the recirculation
recirculation control motor, and connect ground to control motor, and removethe wire harnessclio from
the No. 2 and No. 4 terminals;the recirculation
con- it.
trol motor should run smoothly.
Removethe two screws, recirculationcont.ol mo,
Disconnectthe groundfrom the No. 2 or No. 4 ter- tor and flange collar.
minals; the recirculation control motor should stoo
at FRESHor RECTRCULATE.
4P CONNECTOR
CAUTION: N6v€r conn€ct the batt6ry in ths oppo-
aite direction.

NOTE: Don't cycle the recirculationcontrol motor

for a long time.

SCREWS REC|RCULAT|OII
CONTROLMOTOR

3. Instsllin the reverseorderof removal.After instal-

lation, make sure tha tecirculationcontrol motor runs
smoothlv.

It the recirculationconttol motot does not run in steD

'1,
removeit, and check the recirculationcontrol link-
age and door for smooth movement.lf the recircu-
lation control linkage and doo. move smoothly,
replacethe recirculationcontrol motor.

21-29
Relay Heater Fan Switch

There should be continuity b€tween the A and C termi- Check for continuitv bstween the terminalsaccordingto
nals when Dower and ground are connectedto the B and the table below.
D terminals.
There should be no continuity when power is discon-
Terminal
nected. A D B E
Position
OFF
,l
o- -o
o- -o
3 o- -o
4 -o

I
rl
r? I

21-30
 RecirculationControl
Mode Control Switch Switch
Test
Check for continuity between the terminalsaccordingto Check for continuity between the terminalsaccordingto
the table below. the table below.

Terminal Terminal
4 J 7 8
Position 4 5 6
Position
Heat o --o Fresh o- --o
Heat/Def o- --o -- -o
Recirculate o-
Def G -O
Vent o- --o
Heat/Vent G- --o

21-31
Air Conditioning
*Evaporator
Repfacement .........22-26
Overhauf ................
22-27
Compressor
Description ............
22-28
fffustratedfndex ...............................
22-29
Replacement .........22-30
Cfutch lnspection .......................
......22-32
Cfutch Overhaul...............................
22-33
Refief Vafve Replacement............... 22-34
A/C Compressor Belt
Repfacement .........22-35
Adiustment ............22-36
Condenser
Replacement .........22-37
A/C System Service
Evacuation ....,.......,22-38
Charging ................
22-39
LeakTest ...............22-40

+: Read SRS precautionsbefore working in

this area.
 SpecialTools

Ref. No. I Tool Numbel

OTLAJ- PT3O1OA Test Harness
07JGG- 001010A BeltTensionGauge

I
22-2
lllustratedIndex

CAUTION:
. All SRS electrical wiring harnossosare cover€d with
yellow insulation.
. B€fors disconnacting any part of the SRS wire har-
ness,connsct the 3hort connsctor(s).
. Replacethe entirs affscted SRS harness assembly it
it has an open circuit or damaged wiring.

NOTE;The original radio has a coded theft protection

c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
before
- disconnecting the battery.
- r e m o v i n gt h e N o . 3 2 ( 7 . 5A ) f u s e f r o m t h e u n d e r -
hood fuse/relaybox. SRSMAIN HARNESS
- removingthe radio. lcover€d with yellow insulationl
After service,reconnectDowerto the radio and turn it
on. When the word "CODE"is displayed,enter the cus-
tomer's5-digitcodeto restoreradiooperation.

EVAPORATOR
page22-26
Replacement,
Ovethaul.Oase22.27

SERVICEVALVE
SERVICEVALVE IHIGHPRESSURESIDE)
(LOWPRESSURE SIDEI

RECEIVER/DRYER

CONDENSER
Replacement,
page22,37

COMPRESSOR
A/C PRESSURE SWITCH page22-30
Replacement,
W h e n t h e r e f r i g e r a n tp r e s s u r ei s b e l o w 2 0 0 k p a ( 2 . 0
kqflcm,,28 psi) due to refrigerantleakageor above3]OO
kPa (32 kgf/cm,, 460 psi) due to coolant btockage,the A,/C
pressureswitch opens the circuit to the A"/Cswitch and
stopsthe air conditionang to protectthe compressor.

22-3
Wiring/ConnectorLocations

A/C DIODE
CONNECTOR
(Loc.ted .bovo tho.ight kick p.n.ll

RADIA'OR FAN RELAY

{Localedin the undel-hoodfu3o/reltY box)

A/CTHERMOSTAT CONDENSERFAN
CONNECTOR CONNECTOR

MAIN WIREHARNESS

A/C WIREHARNESS
CONNECTOR

RADIATORFAN
CONNECTOR

A/C WIREHARNESS

COMPRESSORCLUTCH A/C PR€SSURESWTTCH

CONNECTOR CONNECTOR

22-4
Circuit Diagram

N0.41l10oAl No.39{5OAl No.1317,5A)

MOIATOR
REI.AY

22-5
Description
Outline
refrigerantthroughthe sys-
The air conditionersystemdeliverscooledair into the passengercompartmentby circulating
tem as shown below.
Hightemperature/ Hightemperature/ Trapsdebris Hightemperature/
gas
high pressure hilh pressureliquid and removes high pressureliquid
SuctionandcomPression of
Radiation heat molsture

coMpRESsoR - RECEIVER/DRYER
-coNDENSER

Less moisturized Moreliquidified

low pressurevaPor vaPor
low Pressure
Absorptionof heat
EVAPORATOR VALVE
EXPANSION
<-'----------.-

EVAFORATOR

CONDENSOR

to the following
{R-134a)refrigerantwhich does not containchlorofluorocarbonsPay attention
This car uses HFC-134a
service items:

. Do not mix refrigerantsCFC-I2(R-l21and HFC-134a (R-134a)They are not compatible'

potyatkytenegtycol {PAG) refrigerantoil (ND-OIL8: P/N38899-PR7-A01) designedfor the R-
. Use onty the recommended
oil
refrigerant will resultin com-
134acompressor.Intermixingthe recommended(PAG)refrigerantoil with any other
pressortailure.
.A||lvcsystemparts(compressor.dischargeIine,suotionIine,evaporator,condenser.receiver/dryer,expansionva|ve.
o-ringsforioints}havetobeproperforre'rigerantR-l34a.DonotconfusewithR.l2parts.
. Usea halogengas leakdetectordesignedfor refrigerantR-134a'
. R-.12and C-l34a refrigerantservicingequipmentare not interchangeable. Only use a Recovery/Recyclins/Charging
and is certifLd
Systemthat is U.L.-listed to meet the requirements of sAE J2210 to serviceR-134aair conditioningsys-
rems.
Systembeforedisconnecting any
. Always recoverthe refrigerantR-134awith an approvedRecover/Recycling/Charging
A,/Cfitting.

22-6
Troubleshooting
Reference
Ghart
. Any abnormality must be correctsd before continuing the test.
. Becauseof the precisemeasurgmentsneeded,use a multimeter when testing.

Before performing any troubleshooting procedurescheck:

. Fus€s.r No. 35120A), *1 No. 33 (20A), ), No. 13(7.5A)
. G r o u n d sN o . G 4 0 1 G
, 2 0 1G
, ' 1 5 1G, 1 0 1
. Cleanliness and tightnessof all connectors
*1:In the under-hoodfuse/relaybox
*2:In the under-dashfuse/relaybox

SYMPTOM
Radiatorfan does not run 8t all.
Condenserfan does not run at all.
Both fans (radiatorand condenser)do not
run for engine cooling, but they both run
with the Ay'Con.
Eothfans do not run at all.
Compressorclutchdoes not engage.
Ay'Csystem does not come on
{compressorand both fans}.
REMEDY
Performthe proceduresin the flowchan(seepage22-8).
Performthe proceduresin the flowchart(seepage22-10).
Performthe proceduresin the flowchan(seepage22-12).
Performthe proceduresin the flowchart(seepage22-13).
Performthe proceduresin the flowchart(seepage22-14).
Performthe proceduresin the flowchart(seepage22-16).

22-7
Troubleshooting
RadiatorFan

Redi.to. fan doo3 not run at all.

check rhe No. 33 {20 A) fuse in

the under-hoodluse/relaybox.

R e m o v et h e r a d i a t o rl a n r € l a y
from the under-hoodIuse/relay
box and test it (seepage 22-19).

Raplacatha radiator tln rahy.

Measurethe voltage betweenthe

No. 3 terminal (+) and body
ground{-}.

ls therg batteryvoltag€?

Connectthe No. 1 and No. 3 ter-

minalswith a jumperwire.

Doesthe radiatorIan run? To p3ge 22-9

Chockfor continuityin the BLK./

REDwire between the No. 1 ter-
minaland the radiatorfan.

R.p.ir opdr in th. 8LK/RED wir.

batwaon th. unda.-hood fut./
ralay box rnd tha radirtor f.n.

Checkfor continuity in th€ BLK

w i r e b e t w e e nt h e r a d i a t o r{ a n
and body ground.

Ch.ck to..n op.n in th. BLK

wirc batwaan th. rldirtor hn
lnd body ground, lf tha wita i!
OK, chack tor poor gtound rt
G2ol lnd GiOl.

Rephco tho radi.tor frn motor.

22-A
 Fromprge 22€

Disconn.ct the iump.r wirc lnd

tu.n th6 ignition gwitch ON (fD.

Mo66u,otho voltlgs botwoontho

No. 4 torminll (+) 6nd bodv
ground {-}.

Rap.lr o9.|| ln th. GRN wlr. b+,

twaan tha ondar.hood tuaa/
rtLy box .nd thr A/C diod..

B.p.lr olrn h th. BLX.IYEL

wlrr
batw..n th. undar.hoodtu../
rcl.y bor aDd iha undar.darh
fur/r.Ly box.

22-9
Troubleshooting
CondenserFan

BLK/WHTl+l

Removethe condenserfan relay

and test it (seepage22-19).

Replacothe condan3arfrn rclay.

Measurethe voltag€ betwe€nthe

WHT wire terminal(+) and body
ground(-).

Replir opcn in tho WHT wiro bo-

twoen tha undor-hoodfura/Jolay BLU/YEL
box rnd tha condonr.rlan rclay.
Viewlrom wireside

Connoctthe WHT and BLU/BLK

w i r e t e r m i n a l sw i t h a j u m P e r

Doesthe condenserfan run? 10 page 22-11

View from wire side

Checkfor continuityin the BLU/

BLK wire betweenthe condenser
Ian relayandthe condenserfan
BLU/BLK

Reprir op€n in th. BLU/BLKwiro

batwcen the condenrai lan rolay
and the condcntor ftn

Checkfor continuity in the BLK

wire between the condenser fan
and body ground.
C h e c kf o t . n o p . n i n t h o B L K
wire botween the condental trn
and bodv g.ound. It the wiro i3
OK, chock lor Poo. ground rt
G151.

Raplaco the condon36r fan motor.

22-10
 Frompage22-10

Disconnectthe iumper wire and

turn the ignitionswitchON (ll).

Measurethe voltage betweenthe

BLK/WHTwire terminal (+) and
body ground(-).

Reptir open in tha BLK/WHT o.

BLK/YELwire betwoon tho con-
den3o. f.n rel.y and tho unde.-
dash tus6/rel.y box.

Remove the iay'Cdiode from the

Ay'Cdiode 3P connector.

ls the A,/Cdiode OK?

Reprir op6n in th. BLU/YELwire

betwocn tho conden3ertsn reltv
.nd tho A/C diod€.

22-11
Troubleshooting

Bolh tanr lradiltor and con-

dan.arl do not run fot angina
cooling. bul th.y bolh tun whh
th. A/C on.

Disconnecttho engino coolanl

temporsture(ECT)switch 2P con-
n6ctor.

Turnrhe ignitionswitchON (ll).

Measureth€ voltago botw€enth6

cRN wire terminal(+) and body
ground{-}.

R.p.ir op.n in ih. GRN wir. b.-

tw..n th. ECT .wilch .nd th.
undrr.hood ful./t l.y box.

Turn the ignition switch OFFand

check lor continuity in the BLK
wire beMeen the ECTswitch and
body ground.

Ch.ck tor.n op.n in th. BLK

wir. b.lw.!n th. ECT .witch
.nd body ground. It th. wit. i.
OK, chacl lor poor Oround tt
G10r.

Do€s it road above normal?

22-12
Both Fans

Both tans do not run at all.

Remove the A,/Cdiode from the

A,/Cdiode 3P connector.

ls the !y'Cdiode OK?

Rep.ir op€n in tho 8LU/REDwirc

belwoen tho A/C diod. lnd th.
A/C o.$sure lwitch.

22-13
Troubleshooting
Gompressor

R6movethe comPressorclutch BLK/YEL{+l

refayand test it (see Page22-19l..

WHTl+l

Measurothe voltage bgtlveenth€

WHT wire terminal{+) and body
ground{-}.

Rap.ir op.n in ih. WHT wit. BLK/RED

batwaan tha undar-hood fuaa/
ralay box and thg comptaalol Viewfromwir€side
clutch r.l.y.

Connect tho WHT and 8€D wire

terminalswith a jumPerwire.
View lrom wire side

Disconnect the comPressor

clutch1Pconnsctor.

To page22-15
Checkfor continuityin the RED
w i r o b o t w e e nt h e c o m P r e s s o r
clutch relay and the comPressor
clutch.

Replir op.n in th. REO wi.c

batwaan tho comPrdaor clutch
rol.y and the compr.33oi clulch.

Inapact tha compter3oa clutch

clelranca !nd ihc comPacaaor
ctutch fi€ld coil {!.. P.9.22'32}.

22-14
 Frcm page22-11

Turn the ignition switch ON (lI).

M€asurethe voltage betweonth6

BLK/YELwire terminsl {+) and
body ground (-).

R.p.i. opcn in th. 3LX/YEL wirr

ls there battery voltage? balwarn tha undar.da3h tuaa/
.clay box and iha como.aaao.
clutch rahy.

Turn the ignition switch OFFand

i n s t a l l t h e c o m p r o s s o rc l u t c h
relay.

Bdt ry vohro.? Blttary vohago?

Connectthe test harness"A" and
"8" _@_____-l
conoectorsto th6 main wire r_--@_
harnessonly, not to the ECM(s6g Bs {+)
section11).

Turn th6 ignition switch ON (II).

TESTHARNESS
07t4, - PT3010a
Measurethe voltagGbetweenthe
A15 terminal (+) and body
ground(-1.

R.prir op.n in th. BLK/REDwirt

b.twran the compraa.or clotch
..1.y .nd th. ECM.

Make sure the A/C and heate. ten

switch6sare OFF.

Measuretho voltage b€tweenthe

85 terminsl(+) and body ground
(-).

R.p.ir op.n in th. BI-U/REDwir.

b.tw.rn th. A/C diod. .nd th.
CCM.

Sub.titute r known-good ECM

and rocheck. lt lymptom/indicr-
tion go€3rwry, rapbca th. origi-
nrl ECM.

22-15
" , -1llltf,'tfrSfiiwiafi
Troubleshooting
A/G System

A/C ay3t6m doe3 not como on

(compro!3orand both f.ns).

D i s c o n n e c tt h e A / C p r e s s u r e
switch 2P connector.

Turnthe ignitionswitchON (II).

Measurethe voltage beoveenthe

BLU/RED w i r e t e r m i n a l( + ) a n d
View from wire side
bodv ground1-).

Reprir opon in thc 8LU/REDwire

batwoan tho A/c prossute
rwitch rnd th. A/C diod.. YEL/WHT BLU/RED{+l

Turnthe ignitionswitchOFF.

Checklor continuity betwoenthe

No. 1 and No. 2 terminalsof the
A,/Cpressureswitch.

Checkfor NC system Pressure.

R e c on n e c t t h e A / C p r e s s u r e
switch2P connector.

10 page22-17 Rophcetha A/C pre3!u.6 awitch.

22-16
 Frompage22-15

Turnthe ignitionswitchON (IIl.

YEL/WHTl+l
Measuretho voltage betweonthe
BLK/YELwire terminal (+) and
body ground(-).

R.p.i. op.n ir th. BLX/YEL wiro

batwc.n tha unda.-darh fuao/
r.l.y box .rd rh. A/C th.rmo.t!r.

Measureth€ voltage betweenthe

YEL/WHTwire terminal {+} and
body ground (-).

R.prir op.n in th. YEL/WHT

ls there battoryvoltage? wiro bctwaan tha A/C praaau.c
rwhch .nd th. A/C th..mo.ht.

T!rn the ignition switch OFF.

R€connectthe Ay'Cthermostat 3P
conn€ctorand connectthe BLU/ View from wir€ side
REDwire terminalto groundwith
a l!mper wire,

Do the radiator and con-

d o n s e rf a n s r u n a n d t h e
compressorclutchengage?

Turn the ignition switch OFFand

disconn6ct the jumperwire.

To page 22-18

(cont'd)

22-17
Troubleshooting
A/C System(cont'dl
Frcm page22'17

Removethe heatercontrolPanel
(seepage21 25) No. 11 BLU/REDl+l

D i s c o n n e c t h e h e a t e rc o n t r o l
panel14Pconnector' View lrom wire side

Turnthe ignitionswitchON (lI).

Measurethe voltagebetweenthe
BLU/RED w i r e t e r m i n a l( + ) a n d
body ground{ }

Rop.i. opon in tho BLU/BEDwir.

b.twoon tha A/C thermort.t lnd
the haat.r control Panal

Turnthe ignitionswitchOFF.

ls the A/C switch OK?

Checkfor continuitYin the GRN

wire betweenthe heatercontrol
paneland the heaterfan switch

R.prir op.n in the GRN wiro be'

twoen thc hartet contlol Panal
and tho h.rtor fln switch.

Checkfor continuity in the BLK

wire between the heater{an
switchand body ground.
Chock fol an opon in the BLK
wi.a b.tween th. hotte. hn
lwitch tnd bodY ground. ll tho
wiro it OK, chock for Poor
g.ound .t G4ol .nd G402.

Replace the heater lan switch.

22-18
A/C Thermostat
Test
Connectbatterypower to terminalC and ground termi-
nal B, and connecta test light betweenterminalsA and
N O T E :U s ea 1 2V , 3 W - 1 8 W t e s tl i g h t .
Relays
Thereshould be continuitybetweenthe A and C term!
n a l s w h e n p o w e r a n d g r o u n da r e c o n n e c t e dt o t h e B
and D terminals.
There should be no continuitywhen power is discon-
nected.

Dip the A-/Cthermostat into a cup filled with ice water,

and checkthe test light.

The light should go off at 37"F(3"C)or less.and should ,r I - b

I
come on at 39"F(4"C1or more.
.I I n P
I
lf the light doesn't come on and go off as specified,
replacethe Ay'Cthermostat.

. Radiatorfan relay

12V.3W-18W

A B C

a Condenser
fan relay
a Compressorclutchrelay

22-19
Diode A/C Switch
Test Test

NOTE: The diode is designedto pass current in one NOTE:The Ay'Cswitch containsa diode. Use an analog
directionwhile blockingit in the oppositedirection. ohmmeter,or a digitalohmmeterequippedwith a diode
U s e a n a n a l o g o h m m e t e r ,o r a d i g i t a l o h m m e t e r tester.
equippedwith a diodetester.
Checkfor current flow in both directions betweentermi
Checkfor currentflow in both directionsbetweenthe A nals 11 and 12.Thereshouldbe currentflow in only one
and B. and B and C terminals.There should be current direction.
flow in onlv one direction.
Terminal
11
Position
ON o
OFF

22-20
A/C ServiceTips and Precautions

The air conditionersystemusesHFC-134a (R-134a) .efrigerantand polyalkyleneglycol (PAG)retrigerantoil (ND-OILg: p/N

38899- PR7- A0l ), which are not compatiblewith CFC-12 refrigerantand mineraloil. Do not use R-12refrigerantor
\R-'12)
mineraloil in this system,and do not attemptto use R-'12servicingequipment;damageto the air conditionersystemor
your servicingequipmentwill result.
only use serviceequipmentthat is u.L,-listedand is certifiedto meet the requirementsof sAE J2210to removeR-134a
from the air conditionersvstem.
CAUTION: Exposurelo air conditioner refrigorant and lubricanl vapor or mi3t cln irritato gyos, nose and throat. Avoid
breathing lhe air conditioner refrigerant and lubricant vapor or mist.
lf accidentalsystemdischargeoccurs,ventilatework areabefor€resumingservice.
R-134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed
air.
@ some mirtures of air and R-l3ifa have been 3hown to be combu3tible at slsvated prossurosand can relult
in fire or explosion causing inlury or property damage. Never use complessod ai. to prgssuret€|st R-134aservice equip-
ment or vehicle air conditiongr systems.
Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers.
'1. Alwaysdisconnect
the negativecablefrom the batterywheneverreplacingair conditioningpans.
2. Keepmoistureand dust out of the system.When disconnecting any lines,plug or cap the fittingsimmediately;don't
removethe capsor plugsuntil just beforeyou reconnecteachline.
3. Beforeconnectingany hoseor line,applya few dropsof refrigerantoil (ND-OIL8: P/N38899- PR7- AO1)to the O-ring.
4. Whentighteningor looseninga fitting,usea secondwrenchto supportthe matchingfitting.
5. When recoveringthe system,use a R-134arefrigerantRecovery/Recycling/Charging System;don't releaserefrigerant
into the atmosDhere.
6. Add refrigerantoil (ND-OlL8: P/N38899- PR7- A01)after replacingthe followingparts:
NOTE:
. To avoidcontamination, do not returnthe oil to the containeroncedispensed,and nevermix it with other refriqer-
ant orls.
. lmmediatelyafterusingthe oil, replacethe cap on the containerand sealittoavoid moistureabsorption,
. Do not spill the refrigerantoil on the car; it may damagethe paint;if the re{rigerantoil contactsthe paint,wash it
off immediately.
Condenser..................... 25 m/ (5/6fl.oz,0.9 lmp.oz)
Evaporator................. ilo mf 17113fl.oz,1.4lmp.oz)
Line or hose 10 ml (1/3 fl.oz. o.il lmp'ozl
Receiver/Dryer .....,.,,...., 10 m{ l1l3 tl.oz,0.4 lmp.ozl
Leakagerepair .............. 25 mf (5/6fl.oz,0.9 lmp.ozl
Compressor For compressor .eplaco-
m€nt, subtract the volumo of oil drained from tho
removed compressor trom 140 ml 11 213 ll.oz, 1,9
imp.ozl, and drain the calculalgdvolume of oil from
t h o n e w c o m p r e s s o r :1 4 0 m f 1 1 2 1 3 l l . o z , 1 . 9
imp.ozl- Volume ot removod compressor= Volume
to drain from n€w compressor.
NOTE:Even if no oil is drainedfrom the removed
c o m p i e s s o rd, o n ' t d r a i n m o r e t h a n 5 0 m l 1 1 2 1 3
fl.oz,1.8lmp .oz)from the new comDressor.
O Dischargo hoseto the compresso.(6 x 1.0mml ..............................
9.8N.m {1.0kgt.m,7.2lbf.ft)
(, Dischargehosato ths condenser(6 x 1.0mm) . 9.8 N.m {1.0kgf.m,j.Z lbl.ftl
@ Condenser pipeto tho condenser(6 x 1.0mml 9.8N.m n.O kaf.m,t-2tbl.ftl
@ Condenser pipeto the receiver/dryer
(6 x 1.0mm) 9.8N.m (1.0katm,7.2lbf.ft)
.........................
@ ReceiverpipeA to tho receiver/dryer16x 1.0mm) 9.8N.m(1.0kttm. 7.2lbt.ft)
.........................
@ Receiverpipe A to th6 receiverpipe B ...................................... ........13N.m {1.3kgt.m.9.4lbt'ft)
O Receiverpipe B to the receiverpipe C ...................................... 13 N.m {1.3 kgf.m.9.4 lbf'ft)
@ Receiverpipe C to the evaporator(6 x 1.0mm) 9.8 N.m {1.0kgf.m, j.Zlbl.ftl
@Suaion pip€B to the evaporator{6x 1.0mm) ................ ................
9.8N.m tt.Ot!f.-, r.Z tUttt}
@ SustionpipeA to the suctionpipeB .................. 3t N.m (3.2klnm,23 lbf.ft)
(, Suctionhoselo the suctionpipeA ................ ......31 N.m (3.2kgf.m,23 tbf.ftl
OASuctionhoseto the compressor {5x 1.0mm} ................ .................
9.8N.m11.0kgt.m,7.2lbf.ft)

22-21
A/C System Service
Recovery
Onlv use serviceequipmentthat is U.L.-listed and is cer-
tified to meetthe requirementsof SAEJ2210to remove
HFC-134a (R-134a)from the air conditionersystem.

CAUTION: Expo3ute to air conditioner rcfrigelant rnd

lubricant vapor or mist can irritatc oyo!, no3o and
throat. Avoid bresthing the lir condhionot rofrigorlnt
R.cov.rylR.cycling/Ch.rging sy.t m.
and lubricant vapor or misl.

lf accidentalsystem dischargeoccuts, ventilate work

areabeforeresumingservice.

R-134aserviceequipmentor vehicleair conditionersys-

tems should not be pressuretested or leak tested with
comoressedair.

!!@ some mixturos ot Eir and R'134. hsvc

bsen shown to be combu3tible st elavllcd prs33urc3
and can result in fire or oxplosion cau3ing iniurY or
property damage,Nsvor u36 comprg3Sodlir to P|'3turl
test R-134aservic€ equipmont o. vohiclc rir condhioncr
3ystems.

A d d i t i o n a lh e a l t h a n d s a f e t y i n f o r m a t i o nm a y b e
obtained from the refrigerantand lubricant manufac-
rures.

'1. Connecta R-134arefrigerantRecovery/Recycling/

ChargingSystem to the car, as shown, following
the equipmentmanufacturer'sinstructions.
Pf,ESSUFE

2. M e a s u r et h e a m o u n t o f r e f r i g e r a n to i l r e m o v e d
from the A/C system after the recovery process is
comoleted.

NOTE:Be sure to installthe same amount of new

r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o t e
charging.

22-22
 PressureTest Chart
NOTE: PerformanceTest on page 22-24.

TESTRESULTS RELATED SYMPTOMS PROAABLE CAUSE REMEDY

Dischsrge AftErstoppingcompressor,pressure Air in system Recover,evacuate and recharqo
(high)pressure dropsto about200kPa(2.0kof/cmr.28 -
psi)quickly,andthenfallsgr;dua y. with sDecifiedamount.
abnormally Evacuation:see Daqe22-38
nrgn Charoino:se6 D;op--2?-?q
No bubbles in sight g16sswhen con- E-\cessive
refrigerantin sys- Recover,evacuate and recharqe
denser is cooled bv water. -
with specitiedamount.
Reducedor no air flow through con- Cloggedcondenseror Clean
oenser. radiato. fins Checkvoltage and fan rpm
Condenser o. radiator fan unecKlan ofeclton
not working properly
Lineto condenseris excessivelvhot. Restrictedflow of refriger- . Restricted
lines
ant In syslem
Dischargepres- Excossive bubblesin sightglass; Insufficient refrigerant in Checkfor leak
sure abnormal- condenser is not hot. syslem Charge system
Highand low pressures arebalanced Faultycompressordis- Replacethe compressor.
soonafterstoppingcompressor. Low cnargevaNs
sideis higherthannormal, Faultycompressorseal
Outletof expansionvslve is not frost- . Faultyexpansionvalve . Replace
ed,low pressure gaugeindicates vacu- . Moisturein sysiem . Recover,evacuateand recharoe
um, -
with specifiedamount.
Suction(lowl Excessive bubblesin sightglass; Insufficientrefrigerant Reoairthe leaks.
pressure conqenser rsnot hot_ Reaover,evacuateand recharoe
abnormallylow -
with sDecifisdamount.
Charqeas required.
Expansion valveis nottrostedandlow Frozen expansion valve Replacethe expansion valve.
pressur€line is not cold. Low pressure Faulty expansion valve
gaugeInorcates vacuum.
Discharge temperaturg is low and the Frorenevaporator Runthe tan with comoressoroft
air flow from vents is restricted. then checkAy'Cthermostat.
Expansionvalveis frost€d. Clogged expansion valve Cl€anor replace.
Receiver/dryer
outlet is cool and inlet Cloggedr€ceiver/dry€r Replace
isrryarm(shouldbe warm duringoper-

Suctionpres- Low pressurehose and checkjoint are ' u"lu"oD"ntoo Repairor replace.
sure abnormal- coolerthan the temDeraturoaround ffin"nsion
ly high evaDorator. . Looseexpansioncapillary

Suctionpressure is loweredwhencon- Excessive

refrigerantin sys- Recover,evacuateand recharqe
denseris cooledby water, rem -
with sDecifi€damount.
Highandlow pressure areequalized Faultv oasket Replacethe compressor.
as soon as the compressoris stopped, FaultyFigh pressurevalve
andbothgaugesfluctuatewhilerun- Foreign particle stuck in
nrng. high pressure valve
Suctionand Reducedair flow through condenser. . Cloggedcondenseror Cleancondenserand radiator
discharg€ pres- radiatorfins Checkvoltageand fan rpm
sufes aonor- . Condenseror radiatorfan Checkfan direcrion
mally high not working properly.
No bubblesin sight glasswhen con- Excessive
refrigerantin sys- Rgcover,€vacuate and recharoe
cl€nser is cooled bv water. rem with sp€cified amount.
Suctionsnd Low pressure hose and metal end Cloggedor kinkedtow pre€- Fepair or replace.
dischargepres- afeas are cooler than evaDorator. sure nos€ pans
sur€ abnormal- Temperaturearound
expansionvalve Cloggedhigh pressureline Repairor replace.
is too low compared with that around
recerver/orver.
Refrig€rant Compressorclutchis dirty. Compressorshaftsealleak- Replacethe comDressor.
leaks Ing
Compressorbolt(s)are dirty. Leaking around bolt(s) Tightenbolt(slor replace
com-
pressor.
Compressorgasketis wet with oil. I Gasketleaking Replacethe compressor.

22-23
A/G System Service
PerformanceTest
The performancetest will help determineif the air con-
ditionersystemis operatingwithin specitications.

and is cer- Rocov.rylB.cycling/Ch!lging SFtrm.

Only use serviceequipmentthat is U.L.-listed
tified to meet the requirementsof SAE J2210to remove
HFC-134a {R-134a) from the air conditionersystem.

CAUTION: Exposure to air conditioner relrig€rant and

lubricant vapor ot mist can irritate eyes, nose and
throat. Avoid breathing the air conditioner rstrigerant
and lubricant vapor or mi3t.

It accidentalsystem dischargeoccurs,ventilate work

areabeforeresumingservice.

R-134aserviceequipmentor vehicleair conditionersys-

tems should not be pressuretested or leak testedwith
comPressed atr.

!@ some mixtures ot air and R'1344 hrv6

been shown to be combustibls at elovatod prsssurel
and can result in firg or explosion causing iniury 01
property damage.Ngvor usg compregsedail to prossuro
t€st R-134assrvice equipment or vohicl€ air conditioner
syst€ms.
LOWPRESSURE
A d d i t i o n a lh e a l t h a n d s a f e t y i n f o r m a t i o nm a y b e
obtainedfrom the refrigerantand lubricantmanufactur-
ers.

1. Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystem to the car, as shown, iollowing
the equipmentmanufacturer'sinstructions.

2. Inserta thermometerin the centervent outlet.

Determinethe relativehumidityand air temperature
by callingthe localweatherinformationline,

3. Testconditions:
. Avoid directsunlight.
. Open hood.
. Openfront doors
. Set the temperaturecontrol leverto MAX COOL,
the mode control switch on VENTand the recir-
culationcontrolswitchon RECIRCULATE.
. Slidethe heaterfan switchon MAX
. Runthe engineat 1,500rPm
. No driveror passengers in vehicle.

4. A f t e r r u n n i n gt h e a i r c o n d i t i o n i n gf o r 1 0 m i n u t e s
under the above test conditions.read the delivery
temperaturefrom the thermometerin the dash vent
and the high and low systempressurefrom the A,/C
gauges.

22-24
 To completethe chans:
. Markthe deliverytemperaiurealongth€ venicalline.
o Mark the intaketemperature (ambient air temperature)8long the bottom line.
o Drsw a line strsightup from the air temperatureto the humidity.
. Mark I point one line above and one line below the humidity l6vel (10 % above and 10 % below the humidity
l6vsl).
. Fromeachpoint,drawa horizontalline acrossthe deliverytemparaturs.
. The deliverytemperatureshouldfall betweenthe two lines,
. Completethe low side pressuretest and high side pressur€test in the sameway.
o Any measurementsoutside the line may indicatethe need for further inspection.

kp.
lksf/cm')
lpril
29q) at%
(301
Ii(t0l

2stx'
t25)
t360l kpr 30%
lkgflclrfl
lpril
2qx) 500 T'EUVERY
t20l ts) PRESSUNE
t2q)l 171!

15{Xt ,o0 86
{151 {4) t30)
12r0t tsTl
OEUVERY
PRESSURE
9BO 3q, 71
t10l {3t l25l
t1()l I€I

ax) 68
l2l 120,
t28t

100 59
t1l t15l
n4l
INTAKE
PRESSUBE
50
(101

11
ts)
DEUVERY
TEMPEMTURE

77 6 95 104 "F
{25t t30t (35} laltl fc}

INTAKETEMPERATURE

22-25
Evaporator
Replacement
CATION: 3. Removethe glove box (seesection20).
. All SRS eloctrical wiring harnessesare coverod with
yollow in3ulation. Removethe four boltsand the glove box frame.
. B€tore disconnocting 8ny part of tho SRS wire har-
nsss,conngqtth€ 3hort connestor{sl.
. Roplacaths entire aftected SRS harness a$embly if
it has an op€n circuit or damaged wiring.

Disconnectthe connector from the Ay'Cthermostat,

lcove.edwith yellowinsulation)
L Recoverthe refrigerant with a Recovery/Recycling/
ChargingSystem lsee page 22-22]-.
1.
2. Femovethe bolts,and disconnectthe receiverline
and the suctionline from the evaporator.
and removethe wire harnessclips from the evapo-
rator.
Removethe four self-tappingscrews,mountingbolt
and the mountingnut.
Disconnectthe drain hose,and removethe evapo-
rator.

NOTE:Plug or cap the lines immediatelyafter dis-

connectingto avoid moistureand dust contamina-
tion into the svstem.

SUCTIONLINE

6x1.0mm
9.8 N.m {1.019f.m,
1.2 tbl.ttl 6x1.0mm
APORATOR
9.8Nm{1.0kg{.m,
7.2 tbtft)

8. Installin the reverseorderof removal.and:

it you're installinga new evaporator,add refrig-

erant oil (ND-OIL8: P/N 38899- PR7- A01) (see
page22-2'll.
replacethe O-ringswith new ones at eachfitting.
and apply a thin coatof refrigerantoil (ND-OlL8:
P/N38899- PR7- A01l beforeinstallingthem.
NOTE:Be sure to use the right o-rings for HFC-
RECEIVEB
LINE 134a{R-134a} to avoid leakage.
applysealantto the grommets.
a makesurethat there is no air leakage.
a chargethe system (see page 22-39)and test its
performance(see page 22-241.

22-26
 Overhaul
L Pull out the Ay'Cthermostat sensor from the evapo- 5. Assemblein the reverseorderof disassembly,
and:
ratorfins.
. feplacethe O-ringswith new ones at eachfitting,
2. Removethe self-tappingscrews and clamps from and applya thin coat of refrigerantoil (ND-OIL8:
the housing. P/N38899- PR7- A01)beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFC-
3. C a r e f u l l ys e p a r a t et h e h o u s i n g sa n d r e m o v et h e 134a{R-134a) to avoidleakage.
evaporator. . i n s t a l lt h e e x p a n s i o nv a l v e c a p i l l a r yt u b e w i t h
the capillarytube in contactwith the suctionline
4. lf necessary,
removethe expansionvalve. di.ectly,and wrap it with tape.
. reinstallthe Ay'Cthermostatsensorto its original
NOTE:When looseningthe expansionvalve nuts. location.
usea secondwrenchto hold the expansionvalveor
evaporatorpipe.Otherwise,they can be damaged.
6 th fin trom inlet 3id6

1 2 0 1 5m m
14.72! 0.2 inl

EVAPOAATOR
blow dirt out of fins
with compressedair.
A/C THERMOSTAT
Test.page22-19

16 N,m 11.6kgl.m,
12 tbt.ttl 8 N.m (0.8 kgf'm, 6 lbf.ftl

24 N.m (2.i1kg{.m,
17 rbt.ftl

EXPANSIONVALVE

LOWERHOUSING

CAPILLARY
TUBE

TAPE
Replace.
Make sure there is no foreign matter stuck between
the capillarytube and outletline.

22-27
Gompressor
Description
This compressoris a Nippondensopistontype compressorfor HFC-134a A revolvinginclineddiscdrivesthe sur-
(R-' |34a).
prstons.
As the inclineddisc it
revolves. pushesthe pistons,protectedby a ceramicshoe,thus
rounding10 reciprocating
compressingthe refrigerant

o /al

?-*:-=3
22-28
 lllustrated lndex

CENTER
BOLT

CLUTCH
SET
Inspoc!on,
page 22-32

SNAPRINGA
Replace.

colL
Inspection, pag6 22 32

-t
COMPRESSOR COMPLETE
f-- lDo nor disassemble)

RELIEFVALVE
R e p l a c e m e n t ,p a g e 2 2 - 3 4

22-29
'-f
Compressor
GlutchInspection
Checkthe platedpartsot the pressureplatetor color of the tield coil.
Checkresistance
changes.peelingor other damage.lf there is dam-
8ge,replacethe clutchset. Fisld Coil Rosistance:3.6 t 0.2 ohm at 68"F {20'C)

Checkthe pulley bearing play and drag by rotating replacethe

lf resistanceis not within specifications,
the pulleyby hand.Replacethe clutchset with a new field coil.
one if it is noisvor hasexcessiveplay/drag

Measurethe clearancebetlveenthe pulley and the

pressureplate all the way around.lf the clearanceis
not within specifiedlimits,the pressureplatemust be
removedand shims added or removed as required.
Jollowingthe procedureon page22-33.

Clearrnce:0.50t 0.15mm {0.02i 0.01inl

NOTE:The shims are availablein three thicknesses:

0 . 1m m , 0 . 3m m a n d0 . 5m m .

22-32
 GlutchOverhaul
l. Removethe centerbolt while holdingthe pressure R e m o v et h e s n a p r i n g B w i t h a s n a p r i n g p l i e r s ,
ptate. then removethe pulley.

NOTE:
. B e c a r e f u ln o t t o d a m a g et h e p u l l e ya n d c o m -
A/C CLUTCHHOLDER CENTERBOLT
13.2N.m (1.35kgt.m,9.76lbf.ftl presso.during removal/installation.
commorciallyavailsble a Oncethe snap ring B is removed,replaceit with
Robinair: P/N 10204
Kont.Moore:P/N J37872 a new one,

SNAPRINGB
Replace.

Removethe pressureplateand shim(s),takingcare

not to losethe shims.

sHrM{s)

(cont'd)

22-33
Compressor
ClutchOverhaul(cont'dl

Removethe screwfrom the field coil ground terma- 1. Removethe reliefvalveand the O-ring.
nal. Removesnap ring A with snap rjng pliers,then
removethe field coil. NOTE:
. Do not let the compressoroil run out.
NOTE: . Make sure there is no foreign matter in the sys-
. Be carefulnot to damagethe field coil a n d c o m tem.
pressorduring removal/installation.
. Once snap ring A is removed,replaceit with a
new one.

SNAPRINGA
Replace.

FIELD
4t-N r-l\
corL -l/
\

RELIEFVALVE
13.2N.m {1.35kgtm,9.76lbtftl

2. lnstall and tighten the relief valve.

5. lnstallin the reverseorderof removal,and: a Cleanthe matingsurfaces.

a Replacethe O-ringwith a new one at the relief
install the field coil with the wire side facing
down (see above).
clean the pulley and compressor sliding surfaces
with non-petroleum solvent.
a check the pulley bearings for excessive play.
a make sure the snap rings are in the groove prop-
efly.
apply locking agent to the threads of the center
bolt, and tighten it securelY
make sure that the pulley turns smoothly after
it's reassembled.
v a l v e ,a n d a p p l y a t h i n c o a t o f r e f r i g e r a no t al
(ND-OIL8: P/N38899- PR7- A01) beforeinstall-
ing it.
NOTE:
. To avoid contamination,do not returnthe oil
t o t h e c o n t a i n e ro n c e d i s p e n s e da, n d n e v e r
mix it with other refrigerantoils.
. l m m e d i a t e l ya f t e r u s i n gt h e o i l , r e p l a c et h e
c a p o n t h e c o n t a i n e r ,a n d s e a l i t t o a v o i d
moistureabsorption.
. D o n o t s p i l l t h e r e f r i g e r a not i l o n t h e c a r ; l t
may damage the painu if the refrigerantoil
contactsthe paint,wash it off immediately.
Checkfor leaks,and insertthe cap in the top of
the valve.

22-34
 A/C CompressorBelt
Replacement
Automatic TransmissionType Manual TransmissionType
1. Loosenthe adjust pulley bracketpivot bolt and the 1. Loosenthe adjust pulley bracketpivot bolt and the
adjusting bolt, then remove the A/C compressor adjusting bolt, then remove the A/C compressor
beltfrom the oullevs. beltfrom the pullevs.

2, Removethe two mounting bolts from the left front
engine mount, then pass the A,/Ccompressorbelt
through the gap betweenthe body and left front
en9rnemount.
2. Removethe two mounting bolts from the left front
enganemount.
Removethe enginemount nut, washer,bolt and the
leftfront enginemount.
Removethe A,./C comoressorbelt.

ADJUSTPULLEYBRACKET ADJUSTPULLEYBRACKET
ADJUSTINGBOLT PIVOTBOLT PIVOTEOLT
ADJUSTINGBOLT
14x 1.25mm
l!l', 83 N.m 18.5kgl.m.
61 tbf.ft)
I

LEFTFRONT
ENGINEMOUNT

- l
a ar-
1 2x ' 1 . 2 5m m
69 N.m {7.0 kgf.m,
10 x 1.25mm
51 tbf.ftt
54 N.m (5.5 kgf.m,
4(' rbr.ft)
WASHER 10 x 1.25mm
54 N.m (5.5 kgtm, irc lbf.ft)

Installin the reverseorder of removal,and adjust Installin the reverseorder of removal,and adjust
the A,/Ccompressorbelt (seepage22-36). the Ay'Ccompressorbelt (seepage22-36).

N O T E : W h e n t i g h t e n i n gt h e e n g i n e m o u n t n u t ,
make sure the washer is set properly on the left
front enginemount as shown.

22-35
"t.M'
A/C CompressorBelt
Adjustment
Dstlsqtion Method
1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflection between the A,/Ccompressor and the
crankshaftDullev.
A/C CompressorBelt
Us€dEelt:81881engine7.5- 9.5 mm (0.3- 0.4 in)
Bl8Cl engine8.5- 10.5mm (0.3-0.11 inl
New Belt: 5.0- 7.0 mm (0.2- 0.3 inl
Power Stesring Pump Belt
'l1.5- 13.5mm (0.,[5- 0.53inl
UsedBeli:
New 8€lt: 8.0- 10.0mm (0 3 - 0.39inl
NOTE:
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
for lessthan five minutes.
2. Loosenthe adjust pulley bracketpivot bolt and the
adjustingbolt locknut of the Ay'Ccompressorbelt.
3. Turn the adiustingbolt to get proper belt tension,
then retightenthe adjust pulley bracketpivot bolt
and the adjustingbolt locknut.
4. the deflectionof the lvc compressorbelt
Recheck
22-36
Tonsion Gauge Method
1. Attach the belt tension gaugeto the Ay'Ccompres-
sor belt as shown below, and measurethe tension
of the belt.
A/C CompressotBelt
Used 8€lt: Bl8Bl engine 390 - 540 N
(40 - s5 kgf, 88 - 120 lbfl
Bl8Cl ongine 3il0 - il90 N
(35 - s0 kgf, 77 - 110 lbfl
N€w Belt 7,10- 880 N {75 - 90 kgf, 170-200lbl}
Powor Steoring Pump Belt
Used Belt: 390 - 5,{l N (40 - 55 kgf, 88 - 120 lbll
N6w Bolt: 74O- 880 N 175- 90 kgf, 170-200lbt)
NOTE:
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n sf o r t h e
belttensiongauge.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
tor lessthan five minutes,
2. Loosenthe adjust pulley bracketpivot bolt and the
adjustingbolt locknut of the AVCcompressorbelt.
3, Turn the adjustingbolt to get proper belt tension,
then retightenthe adjust pulley bracketpivot bolt
and the adjustingbolt locknut.
4. Recheckthe tensionof the A{/Ccompressorbelt.
 Condenser
Replacement
Recoverthe relrigerantwith a Becovery/Recycling/ Removethe bolts.and disconnectthe dischargeline
ChargingSystem (see page 22-221. and the condenserlinefrom the condenser.
NOTE:Plug or cap the lines immediatelyafter dis-
Removethe coolantreservoir, connectingto avoid moistureand dust contamina-
tion into the system.
NOTE: Do not disconnectthe reservoirhose from
DISCHARGE
LINE
the coolantreservoirand the radiator.

COOLANT
RESERVOIR

6x1.0mm ......-.....
9.8 N.m (1.0kgl.m,7.2 lbt.ft)

CONOENSER
LINE

Removethe two mounting bolts, then lift out the

condenseras shown.
NOTE: Do not damagethe radiatorand condenser
fins when removingthe condenser.
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbl.tt)

R e m o . v teh e b o l t s a n d t h e r a d i a t o ru p p e r m o u n t
brackets,and removethe bolt from thg suctionhose
bracket.

9.8 N.m {1.0 kgf.m.7.2 lbtftl

Installin the reverseorderof removal.and:

. if you'reinstallinga new condenser,add refriger-
ant oil (ND-OIL8: P/N 38899- PR7- A01) (see
page 22-21t,.
. replacethe O-ringswith new onesat eachfitting,
and apply a thin coat of refrigerantoil {ND-OIL8:
P/N38899- PR7- A01)beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFC-
1 3 4 a( R - 1 3 4 at o) a v o i dl e a k a g e .
a do not damagethe radiatorand condenserfins
when installingthe condenser,
. be sure to installthe condensermount cushions
RAOIATORUPPEN securelyinto the holes.
MOUNT BRACKETS
. chargethe system (see page 22-39)and test its
performance(see page 22 24!.

22-37
'1Iffi
A/G System Service
Evacuation
Only use serviceequipmentthat is U.L.-listed and is cer-
tified to meet the roquirementsof SAE J2210 to remove R.cov.ry/R.cycling/Chtroing Syttom
HFC-134a (R-134a) lrom the 8ir conditionersystem.

CAUTION: Exposulo to 6ir conditioner refligorrnt and

lubricani vapor or mi3t crn i.ritato 9y33, noaa and
thrort. Avoid bratthing ths .ir conditionor rsfrigorrnt
snd lubricsnt vtpor or mist.

lf accidentalsystem dischargeoccurs,ventilate work

area before resuming service.

R-134aserviceequipmentor vehicle8ir conditionersys-

tems should not be pressuretested or leak tested with
compressedait.

!@ somo mixtuto3 ot ril and R'134! hav.

been shown to bo combustible at olevltad prossulo3
and can re3ult in fire or explosion crusing inlurY or
property damago,Navor us! comprossodair to prgsauro
test R-13/aa3orvicr €quipmlnl or vohiclo air conditionol
sy3lems.

Additional health and safety information may be ob- aotnPRESSURE

tainedfrom the retrigerantand lubricantmanufactures. SIDE

1. When an Ay'CSystemhas beenopenedto the atmo-

sDhere,suchas during installationor repair,it must
be evacuated using a R-134arefrigerant Recovery/
Recycling/ChargingSystem. {lf the system has been
open for several days, the receiver/dryershould be
replaced.l

2. C o n n e c ta R - 1 3 4 ar e f r i g e r a n tR e c o v e r y / R e c y c l -
ing/ChargingSystemto the car, as shown, follow-
ing the equipmentmanufacturer's instructions.

NOTE; lf tow pressuredoes not reach more than

9 3 . 3 k P a ( 7 0 0m m H g , 2 7 . 6 i n ' H g )i n 1 5 m i n u t e s ,
t h e r e i s p r o b a b l ya l e a k i n t h e s y s t e m .P a r t i a l l y
charge the system and check tor leaks {see Leak
Test).

2234
 Charging

Only use serviceequipmentthat is U.L.-listed and is cer-

tified to meet the requirementsof SAE J2210 to remove R.cov.rylRccacling/Ch.rging Syrtom
HFC-134a (R-134a) from the air conditionersvstsm.

CAUTION: Exporuro to rir conditionor .etrigorant and

lubric8nt yapor or misl can irritats cyos, no36 and
throlt. Avoid broathing tho lir conditionor rofrig6rant
lnd lubricant vlpor or mbt,

It accidentalsystem discha.ge occurs, ventilate work

a r e a b e f o r e r e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t ha n d
safety information may be obtained from the refrigerant
and lubricantmanufactures.

Rofrigerantcapacity:f00:3n g (24.7:l,oz)

CAUTION: Do not ovorchlrgo thc syrtem; tho compr6s-

sor will be damagad.

C o n n e c t a R - 1 3 4 ar e f r i g e r a n t R e c o v e . y / R e c y c l i n g /
Charging System to the car, as shown, following the
equipmentmanufacturer's instructions.

22-39
A/C System Service
LeakTest
Only useserviceequipmentthat is U.L.-listed and is cer-
Rocov.ry/R.cycling/Ch.tging Sy3tcm
tified to meetthe requirementsof SAEJ2210to remove
HFC-134a (R-134a)from the air conditionersystem.

CAUTION: Exposura to air condition ratrigerant and

lubaicant vapor or mist can irritato oyes. nose and
throat. Avoid br€athing tho sir conditionsr reftigolant
and lubricant vapor or mist.

lf accidentalsvstem dischargeoccurs,ventilate work

areabeforeresumingservice.

R-134aserviceequipmentor vehicleair conditionersys-

tems should not be pressuretested or leak tested with
comoressedair.

@ some mixturos ot air and R'13'la have

b.6n shown to b€ combustible at glsvated pressur€s
and can result in firo or sxplo3ion causing iniury or
proporty damage. Ngvar uso compress€dtir to pro33ure
tost R-134a$rvics oquipmont or vohicl€ air Gonditionsr
systcms.

Additional health and satetYinformation may be ob- LOW PRESSURE

tainedfrom the refrigerantand lubricantmanufactures' SIDE

1. Connecta R-134aretrigerantRecovery/Recycling/ HIGH

ChargingSystem to the car. as shown, following SIDE
the equipmentmanufacturer'sinstructions.

NOTE:Be sure to installthe same amount of new

r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o r e
chargtng.

2. Open high pressurevalve to chargethe system to

about 98 kPa (1.0 kgf/cm' , 14 psi), then close the
supplyvalve.

3. Checkthe systemfor leaksusing a R-134arefriger-

'!4 g
ant leak detectorwith an accuracyof {0.5 oz)
per year or better.

4. l f y o u f i n d l e a k st h a t r e q u i r e t h e s y s t e m t o b e
opened (to repair or replacehouses,fittings,etc.),
recoverthe system accordingto the Recover
Procedureon page22-22.

5. Aiter checkingand repairingleaks,the systemmust

be evacuated (see System Evacuationgn page 22-
38).

22-40
 Electrical

Special Tools tfnteglated Control Unit

...29-144
* l n t e r l o c kS y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 2 3 - 13 g
Lights, Exteriol
T i p s a n d P r e c a u t i o n .s. . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3.-. 3 B a c k - u pL i g h t s ..........2 . 3-179
Five-stop T l o u b l e s h o o t i n.g. . . . . . . . . . . . . , . . . - . . -Z. .3. - s B r a k eL i g h t s . . . . . . . . . . . . .2. 3 - t 8 l
S c h e m a t i cS y m b o l s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. .3. _- 6. tDaytime RunningLights
{Csnada}........... 23-156
w i r e C o l o rC o d € s. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 6 .... F r o n tP a l k i n gL i g h t s . . . . . . . . . . . . . . . . . . . . . . . . . 2 . .3. .- 16 5
Relay and Control Unit Locations F l o n t S i d e M a r k e rL i g h t s. . . . . . . . . . . . . . . . . . . . 2 . .3. - 1 6 5
E n g i n eC o m p a r t m e n .t . . . . . . . . , . . . . . . . . . . . .- - .2 3 - 7 F r o n tT u r n S i g n a lL i g h t s. . . . . . . . . . . . . . . . . . . . .2. .3. - 16 5
Dsshboard a n d D o o r . . , , . . . . . . . . . . . . . . . . . . . . . 2. .3. .- g * H a z a r dW a r n i n gL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . -
2g-1A4
D a s h b o a ra d n d F l o o r. . . . . . . . . . . . . . . . . . . . . . . . . 2. .3. .- t O Headlights . . . . . . . . . . . . . . .2 . .3 - t 6 t
O u a n e rP a n e l .....-.....23-12 L i c e n s eP l a t eL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. .- 16 9
Connector ldentification and Wire Taillights
HarnessRouting ........ 23-i 3 (Harchback) . . . . . . . . . .2 3 - 1 6 6
{ S e d a n.). . . . . . . . . . . . . .. 23-167
Index to Circuits and Systems Lights. Inteliol
Airbag ............... ...-..-..2 . g-26s Cargo Area Light {Hatchback)......-..-..-... 23-177
Air Conditioning ....,.. Section2l C e i f i n gL i g h t ........-..-.23-175
Altelnator . . . . . . _ . . . . . . . . . . .2. .3. - 9 9 Dash Lights BlightnessControt ..............23-t70
Anti-lock Brake Systsm (ABS) Section 19 G l o v eB o x L i g h r. . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .-.1.6. 9.
Automatic Transmission Section 14 S p o t f i g h r. . . . . . . . . . . . ....-.23-174
Battery.............. . . . . . . . . . .2 3 - 6 6 T r u n kL i g h t ( S e d a n l. . . . . . . . . . . . ...... . . . . . . . . .-. .2 3 . - 1 7 7
C h a f g i n gS y s t e m ..........2 . 3-98 *LightingSysrem .......-.-...23-152
r C i g a l s t t eL i g h t e r. . . . . . . . . . . . . . . . . . . . . - . . . - . . . . . . - . . - . . :Moonroof
Z3-2O4 ,,.,.......,..,,,,,.-.23-211
C f o c k. . . . . . . . . . . . . . . . . ..........23-197 PGM-FISystom ........ S€crion 11
rcruise Controf
.......--..-...23-242 Power Distribution .,.-..--..23-54
Distributor . . . . . . . . . . . . . . . . . .2. .3 - 8 7 P o w e rD o o r L o c k s . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . .2. .3. .- .2 3 3
F a nC o n t r o l s . . . . . . . . . . . . . . .2. .3 - 1 o g P o w e rM i r o r s . . , . . , . . . . - . . .2- 3 - 2 1 6
Fuel and Emissions ... Section 1i P o w e rR e l a y s . . . . . . . . . . . , . . . 2. .3 - 6 8
*Fuses
Power Windows ............ 29-222
U n d e r - d a sFhu s e / R e l aByo x . . . . . . . . . . . . . . . . .2. .3 - 4 8 * R e a rW i n d o w D e f o g g e r. . . . . . . . , . . . . . . . . . . . , . . . . .
- 23-20,6
Undor-hoodABS Fuse/Retay Box ............23-51 Reminder Systems
U n d e r - h o oFd u s e / R e l aByo x , . . . . . . . . . . . . . . . . 2
. .3 - 5 2 K e y - i nR e m i n d eS l y s t e m . . . . , . . . . . . . . . . . . . , .2 . .3. - 15 0
rGauges
L i g h t s - o nR e m i n d eS r y s t e m . . . . . . . . . . . . . . . . .2. .3 - l 5 f
Engine Coolant Temperature {ECT) *MaintenanceRemindersystem ..,,....-..--.
23-.12g
G a u g e. . . . . . . . . . . . . . . . ..23-126 S e a t B e l t R e m i n d eS r y s t e m . . . . . . . . . . . . . . . . . 2. -3 - 1 2 5
F u e fc a u g e . . . . . . . . . . . . . .2. g - 1 2 3 *Side Markel/Turn Signal/Hazard
' G a u g eA s s e m b l y
....--.23-113 F f a s h eS r ystem .,..,..-.23.-1A4
Speedometer . . . . . - . . . , , 2. 3 - 1 1 4 S p a r kP f u g s . . . . . . . . . - . . . - . . .2. .3 - 9 7
Tachometer . . . . . , . . . . . - .2. 3 - 1 1 4 Starting System ....,,.....-.23-73
GroundDistribution ........ 23-60 * S t e r e oS o u n dS y s t e m . . . , . . . . . . . . . . . . . . . . . . . . . . . , , . . g g
23-l
H e a t e r, , , . . . . . . . . , . . . . . . . . . S e c t i o n2 l SupplementalRestraintSystem {SRS}......... 23-265
r H o r n. . . . . . . . . . . . . . . . .
.........2 . .3 - 1 9 9 V e h i c f eS p e e dS e n s o r{ V S S ). . . . . . . . . . . . . - - . . - . 2. .3. - 1 2 2
* f g n i t i o nS w i t c h * W i p e r / W a s h eSr y s t o m . . . . . . . . . . . . . . . - - . . . . . . . . . - . . -
. . . . . . . . . . . .2. 3 - 7 0 Zg 254
fgnitionSyst6m .......-..-..23-A7
l g n i t i o nT i m i n g . . . . . . . . . . . . .2. 3 - 8 9 rRead SRSpi€cautions on Page23-271
betore working
Indicator Lights in these areas.
" A / T G e a rP o s i t i o n. . . . . . . . . . . ...... . . . . . . . . . . . . . . . .
2 3 - 13 2
B 1 a k 6S y s t e m ...,..,..-.23-127
E n g i n eO i l P r e s s u r .a. . . . . . . . . . . . . . . . . . . . . . . . _
. .2. .3. - 15 1
L o w F u e l. . . . . . . . . . . . ......23-125
MalfunctionIndicatorLamp {MlL} ...,,. Section I l

- +
 SpecialTools

Rel. No. I Tool Numbol Description Oty. I Pago R6toronce

o 07HAZ-SG00400 DeploymentTool 23-300

o 07JAA-001000c Antenna Nut Wrench 23-195
23-108
@ 0 7 J G G - 0 0 1 0 1 0 A Belt TensionGauge
@.' 07LAZ-S140300 Test HarnessC 23-201,248,285
@' oTLAZ-S140400 Test HarnessD 23-247
@' oTMAZ-S100500 Test HarnessA 23-241
o-- oTMAZ-SP00500 Test HarnessB 23-244
23-124
@ o T N A C - S R 2 0 1 0 0 Fuel Senderwrench
@ oTPAZ-0010100 SCS Short Connecto. 23-89
lncludedin SRSToolSet oTHAz-SGoOooA
Includedin SRSToolSet OTMAZ-SLOo10A

@ @

I z3-2
Troubleshooting
Tips and Precautions
Before Troubloshooting a Nevertry to disconnectconnectorsby pullingon thei.
a Check applicablefuses in the appropriatefuse/relay wires; pull on the connectorhalvesinstead.
DOX. a Always reinstallplastic covers.
a Check the batteryfor damage,state of charge,and
clean and tight connections.
a Check the alternatorbelt tension.

CAUTION:
a Do not quick-charg€ a battery unless the battery
ground cabla has be€n disconnoctsd. oth€rwiso
you will damage the alternator diodss.
a Do not att6mpt to crank the engine with the bat-
tery ground cable looselyconnectsd or you will se-
vorsly damag€ tho widng.
a The original radio has a codod thatt plotection ci.- Beloreconnectingconnectors,make sure the lermi-
cuit. Be sul€ to got tho customor's code numbet nals are in Dlaceand not bent.
before
- disconnecting th€ battery.
- lomoving tho No. 32 (7.5 Al tuso f.om the
under-hood tuse/lelay box.
- removing tho radio.
Aflor s€lvic€. reconn€ct powet to tho radio and
turn it on. Whon the word "CODE" is displayed,
€nt€l the customer'E s-digit codo to .astore ladio
operation.

Handling Connectors
a Makesurethe connectorsarecleanand haveno loose
wire terminals.
a Make sure multiple cavity connectots are packedwith
grease(exceptwatertight connectors).
a All connectorshave push-downreleasetype locks. a Check tor loose retainerand rubber seals.

LOCKII{GTAA
RETAINER

LOCKING
TAB
a Someconnectorshavea clio on their sideusedto at-
tach them to a mount bracket on the body or on
anothercomponent.This clip has a pull type lock.
a The backs of some connectors are oacked with
grease.Add greaseif needed.It the greaseis contami-
a Some mountedconnectorscannot be disconnected
nated, reDlaceit.
unlessyou first releasethe lock and removethe con-
nector from its bracket.

LOCKING
PAWL ON
OTHER
HALF OF Pull to
CONNECTOR orsengage BRACKET
(cont'd)

23-3
Troubleshooting
Tips and Precautions(cont'dl
a lnsert the connector all the way and make sure it is a Seat grommets in theil grooves properly.
securelylocked.
a Positionwires so that the open end of the cover taces
down.
Faca GOOD ]TOTGOOD
opon and n , / r /

V
ll ,,' ll ,,

-.w-- --ry\
cown
s*j -:ut*/
i l , ,

Tosting and Ropails

Handling Wir€s and Hamorao8
a Secure wires and wile harnessesto the frame with
their respectivewire ties at the designatedlocations'
a Removeclips carefully;don't damagetheir locks'
a Do not us€ wires or harness€swith broken insulation.
Replacethem or repair them by wrapping th€ break
with electricaltape.
a After installing pans, make sure that no wir€s are
Dinchedundsr them.
a When using electrical test €quipment, follow the
manufacturer's instructiona and those dsscribed in
this manual,
a It possible,insert the probe of the toster from the wire
side {except waterproof connector).

a Use a probe with a tapered tip.

Stip pliers under the clip base and through the hole at an
angle,then squeezethe expansiontabs to releasethe
clio.

SI'IAP-ANG PLIERS

a After installingharnessclips, make su.€ the hatness Referto the instructionsin the HondaTerminsl Kit for
doesn't interfe.e with any moving parts. identificationand .eplacemento{ connectortelminals'
a Keeo wire hatnessesaway from exhaust pipes and
other hot parts, ftom sharp edges of brackets and
holes, and from exposed screws and bolts.

23-4
 Five-stepTroubleshooting

1. Verify The Complaint 4. Fix The Problem

Turn on all the componentsin the problemcircuitto
verifythe customercomplaint.Notethe symptoms.
Do not begindisassemblyor testing until you have
narroweddown the Droblemarea.
5.
2. Analyze The Schomatic
Look up the schematicfor the problemcircuit. De-
termine how the circuit is supposedto work by trac-
ing the current paths from the power leed through
the circuitcomponentsto ground.It severalcircuits
fail at the same time, the luse or ground is a likely
cause.
Once the specilic problemis identified,make the
repair. Be sure to use proper tools and safe
proceoures.
Mak6 Suro The Circuit Wolks
Turn on all componentsin the repairedcircuit in all
modes to make sure you've fixed the entire problem.
It the problemwas a blown Juse,be sureto test all
of the circuits on thst tuse. Make sure no new
problemsturn up and the originalproblemdoes not
recuf.

Basedon the symptomsand your understandingof

the circuitoperation,identity one or more possible
causesof the Droblem.

3. lsolato The Problom By Testing The Circuit

Make circuittests to checkthe diagnosisyou made
in step 2. Keepin mind that a logical,simpleproce-
dure is the key to etticienttroubleshooting. Test for
the most likely cause of failure first. T.y to make
tests at points that are easilvaccessible.

23-5
Troubleshooting
ym
Schematic Symbols
BATTERY GROI,ltD FUSE LIGHTER
COIL,SOLENOID CIGANETTE
Ground terminal Componontground

H t+j A
le @l
l l

e-
I I

+ ilHe
RESISTOR VARIABLERESISTOR THERMISTOR tcNtTtol{
swTcH BULB HEATER

MOTOR
e H PUMP CIRCUITBREA(ER
-1o oF

HORI' DIODE SPEATER,BUZZER

+ + D
I

a 0
Mast
ANTI INNA
T
TRA SISTORlTrl
Wire GolorCodes

Y II
RELAY {ln no rmal poritionl
Normallyopen relay Normally closed relay
The tollowing abbreviationsare used to identity wire
colors in th€ circuit schematics:
w H T . . . . . . . . . . .W . hite
Y E L . . . . . . . . . . . . .Y. 6 l l o w
B L K . . . . . . . . . . . . .B. l a c k
B L U . . . . . . . . . . . . .B. l u e
CO'IDENSER G R N . . . . . . . . . . . .G . reen
R E D . . . . . . . . . . .R . . e. d

*G
t-i- | I O R N . . . . . . . . . . . .O . range
P N K . . . . . . . . . . . . .P. i n k
B R N. . . . . . . . . . . . .B. r o w n
l l l
l'*^f T G R Y . . . . . . . . . . . .G . ray
P U R. . . . . . . . . . . . .P. u r p l e
L T B L U . . . . . . . . .L i g h tB l u e
L T G R N . . . . . . . . .L i g h tG r € e n
SWITCH (ln ngrmal position) LIGHTEMITTING
Normally open ' Normally closod DIODE(LEDI
switch I switch The wi.e insulation has one color or one color with

@
t i
@
l
A[, another color stripe. The s€cond color is the stripe.

l i l T T WHT/ALK
, / t
, / l
CONNECTION
Inpur Output
CONNECTON

--+>-
BEEDSWITCH
--</ . / l

A
f7
I
\
I/
tl' l
lril
Y
R
23-6
Relay and Control Unit Locations
EngineCompartment
ABS PUMP MOTOR
RELAY

ELECTRICALLOAD DETECTOR(ELD)

UNDER.HOOD
UNOER-HOODABS FUSE/RELAY
BOX
FUSE/BELAY
BOX

. ABS FRONTFAILSAFERELAY
I Wirc colors:WHT/GRN,BRN/BLK,
I
IYEL/GRN snd BLK I
. ABS REARFAILSAFERELAY
I Wire colors:WHT, BLU/BLK,
I
I YEL/GRN and BLK I

. CONDENSER FAN RELAY

I Wi]o colors: WHT, BLUiBLK, I
I BLKMHT and 8LU/YEL I
. A/C COMPRESSORCLUTCH RELAY
I Wiro colors: WHT, RED,I
I BLK/YELand BLK/RED I

23-7
Relay and Control Unit Locations
Dashboardand Door

STARTER CUTRELAYIMIT)
I wir. colo]s:BLKMHT,BLU/BLKI
I BLKMHT ANdBLK/RED I
MOONROOFRELAY REARwlNDOW DEFOGGER
Wirs colors: FELAY
WHT,GBN/BLK, I Wirocolo6: I
GRN 6nd BLK I BLKA'EL,BLK/GBN, I
I BLUffEL8nd BLK^^THT
I

CRUISECONTROLUNIT

PGM-FI
MAIN RELAY

POWERWINDOW
RELAY

IIORNRELAY
INTEGRATEO J wi.o color3:WHT/GRN,BLx,l
CONTROLUNIT I BLU/GBN, and BLU/RED I
TURN SIGI{AL/
HAZARDRELAY UNDEB-OASH
FUSE/RELAY8OX

23-8
 I
I

POWERDOOR LOCK
COI{TROLUNIT

ENGINECONTROLMODULE
(ECM}

23-9
Relay and Control Unit Locations
Dashboardand Floor

INT€RLOCKCONTROL
UNIT IA/T)

23-10
MAINTENANCE
REMINOERUNIT

TRANSMISSIONCONTBOL
MODULEITCMI

23-11
Relay and Gontrol Unit Locations
OuarterPanel

ABS CONTROLUNIT

23-12
Connectorldentificationand Wire HarnessRouting
How to ldentity ConnoctolS:
ldentification numbers have been assignedto all connectors. The number is preceded by the letter ,,C,, for connecrors,
"G" for
singleground terminalsot "f" hr singlenon-groundterminals.

Location Othors (Floor, Door,

Hamess Engino Compartmont Darhboard
Trunk, Rootl
Starter cables T1, T2, and (E
Battery ground cable G1 and O
Engineground cable A T3

Engineground cable B T4
G3
Under-hoodABS fuse/relavbox cable T5 and (D
Enginewire harness C 1 0 1 t h r o u g hC 1 3 4
Tl Ol andT102
G1 0 1
A/C wire harness C l 5 ' l t h r o u g hC 1 5 6
G151
ABS modulator unit wir€ harness C 1 6 1 t h r o u g hC 1 6 8
Engine companment wire ha.ness C3O'l through C32O
G301
Main wire hatness C2O1 through C223 C4O1 through C449
G2Ol and G2O2 G401
Rear wire harness C501 through C536
G 5 0 1 ,G 5 0 2a n dG 5 O 3
DashboSrdwire harness C551 through C569
G551
Driver's door wire harness C 6 0 1 t h r o u g hC 6 1 2
Front passenger's door wire harness C626 through C634
Left rear door wire harness(Sedan) C651 through C654
Right rear door wire harness(Sedan) C656 through C659
Roof wire harness C661 through C667
Heater sub-harnessA C671 through C677
Heatersub-hatnessB C681 through C684
ABS sub-harness C7O1 through C7O6
G7O1,G702 and G703
(Sedan)
Tailgatewire harness(Hatchback) C751 through C756

Spoilersub-ha.ness(Hatchback) C761 through C763

Rearwindow defoggerground wire c77'l
(Hatchback)
G771
SRS main harness C8O1 through C8O7
G801

23-13
Gonnectorldentificationand Wire HarnessRouting

Startol cablos
Connector or Numbsr of Location Connects to Notos
Terminal Cavities
T1 Right side of enginecompartment Under-hoodfuse/relaybox
r2 Right side of enginecompartment Starter motor
@ Battery Battery positive terminal

B8ttory Ground Cable

Conn€ctor or Numborof Location Connects to Notos
T€rminal Csvities
G1 Right front shock tower Body ground,via battery ground
cable
\l Battery Battery negative tetminal

Engine Ground Cable A

Connoctor or Number of Connocta to Notes
Location
Tolminal Cavities
T3 Left side of engine Valve cover
G2 Left side of engine compartment Body ground. via engineground
wire A

Engine Ground Cable B

Connoctor or Number ol Connocts to Not€s
Location
Torminal Cavitios
r4 Right side of enginecompartment Transmissionhousing
G3 Right side of front frame Body ground, via engineground
wire B

A/C Wiro H81n6ss

Connoctor 01 Numbor of Location Connects to Notes
Terminal Cavities
cl51 I Right side ol enginecomPartment Main wire harness(C2O7)
cl52 4 Left side of enginecompartment Condenserfan relay
c153 4 Left side of engine comPartment A/C compressorclutch relay
c154 Lett side ot enginecompartment A/C pressure switch
c155 Left side of enginecomPanment Condenserfan motor
c156 1 Left side of enginecompartment A/C compressorclutch
G151 Right side of tront Jrame

Under-hood ABS Fus€/RelavBox Cablo

Conngctor or Numbor ot Localion Connects lo Notes
Terminal Caviti€s
T5 Right side of enginecomPartment Under-hoodABS fuse/relaybox
@ Right side of enginecompartment Battery positive terminal

23-14
 UNOER.HOODA8S
FUSE/RELAY
BOX CABLE

BATTEBYGROUND
CABLE

ENGIT{E
GROUND
CABLEB

EI{GINEGROUND
A/C WIRE HAFNESS CABLEA

23-15
Gonnectorldentificationand Wire HarnessRouting

EngineWire Harness{B1881 engine)

Connector 01 Numberof Connectsio Notes
Location
Terminal Cavities
c10'l Right side of enginecompartment M a i n w i r e h a r n e s s( C 2 2 1 )
c102 10 Right side of enginecompartment Main wire harness{C222}
c103 14 Right side of enginecompartment Main wire harness(C223)
c104 6 Right side ol enginecompartment Main wire harness{C220)
c105 1 Right side of enginecompartment Startersolenoid
c106 Right side of engine Enginecoolanttemperature{ECT)
sensor
c107 1 Right side ol engine Enginecoolant temperature(ECT)
gauge sendingunit
c108 2 Transmission Back'up light switch M/T
c108 Transmission Lock-upcontrolsolenoidvalveA and B NT
c109 2 Middle of engine lgnitioncoil
c110 8 lvliddleof engine Top dead center/Crankshaft
position/Cylinder position
(TDC/CKP/CYP) sensor
c111 2 Right side ot engine Enginecoolanttemperature(ECT)
switch
Right side of enginecompartment Vehiclespeedsensor (VSS)
c113 ldiddlerearof enginecompartment Heatedoxygen sensor (HO2S)
c114 3 Middle of engine MAP sensor
c115 Middle ol engine Throttle position (TP)sensor
L t t o t Middleof engine ldle air control (lAC) valve
c117 Middle o f e n g i n e Evaporativeemission(EVAPIpurge
control solenoidvalve
c118 1 Middle ot engine Engineoil pressureswitch
c119 Left side of engine Alternator
c't 20 lvliddleof engine Intake air temperature{lAT} sensor
'l
c121 2 M i d d l eo f e n g i n e No. fuel injector
c122 2 Middle of engine No. 2 tuel injector
c123 ) Middle ot engine No. 3 fuel injector
cl24 2 Middle ol engine No. 4 fuel injector
c125 8 Left side of enginecompartment Junction connector
c't26 Left side of enginecompartment Enginecompartmentwire harness
(c304)
c127 14 Left side of engine compartment Enginecompartmenlwire harness
(c305)
c128 Transmission Shift control solenoidvalve A and B
c129 2 Transmission Countershaitspeed sensor NT
c130 2 Transmission Mainshaftspeed sensor NT
T1 0 1 Lelt side oI engine Alternator
r102 Right side of enginecompartment Under-hoodtuse/relaybox
G1 0 1 Right side of engine Engine ground, via engine wire
harness

23-16
ENGINEWIRE HARNESS
(B188i snginel

cl19
c126

clla
c121
c122
c123
c124
cl13

23-17
Gonnectorldentificationand Wire HarnessRouting

Engine Wire Harnoss (B18Cl enginol

Connoctor 01 umbor ol Connecla to f{orc!
Location
Totminal Cavitio8

c101 4 Right side of enginecompartment Main wire harness(C221)

cl 02 10 Right side of engine compartment Main wire harness(C222)
c103 14 Right side ot engine comPanment Main wire harness(C223)
c104 Right side of engine compartmsnt Main wire harness(C22O)
,l Right side of engine compartment Starter solenoid
c105
c106 2 Righrside ot engine Engine coolant temperature (ECT)
sensor
c107 Right side of engine Enginecoolant temperature{ECTI
gauge sendingunit
c108 2 Transmission Back-up light switch
c109 Middle ol engine lgnition coil
c110 8 MiddleoJ engine Top dead center/Crankshaft
position/Cylind€r Position
(TDC/CKP/CYP) sensor
c111 2 Right side of engine Enginecoolanttemperature{ECT)
switch
cl12 J Right side ot engine comPartment Vehiclespeed sensor (VSS)
c113 4 Middl€ reat of enginecompartment Hsated oxygen sensor{HO2S}
c114 Middle of engine MAP sensor
c115 3 Middle of engine Throttle position {TPl sensor
c116 Middle ol engine ldle air control (lAC) valve
c117 Middleo{ engine Evaporativeemission{EVAPIpurge
control solenoid valve
'I Middle of engine Engineoil pressureswitch
c1r8
c119 4 Lelt side ot engine Alt€rnatot
c120 Middle of engine Intake 8ir temperature(lAT) ssnsor
cl2'l Middle of engine No. 1 fuel injector
c122 Middle ol engine No. 2 fuel iniector
c123 2 Middle ot engine No. 3 fuel injeclor
c124 Middle of engine No. 4 fuel injector
c125 I Left side of engine companment Junction connector
c't26 2 Lelt side ot engine compartment Enginecompartmentwareharness
{c304)
't4 Left side of engine compartment EnginecomPanmentwire harness
c'127
(c305)
c131 1 Right side ot engine VTEC solenoid valve
c132 Right sid€ of engine VTEC oil pressureswitch
c133 Middle ot engine Knock sensor (KS)
c134 Middle of engine Intaka air bypass (lAB) control sole-
noid valve
T101 Left side of engine Alternator
r102 Right sid6 ot engine compartment Under-hood fuse/relay box
G1 0 1 Right side of engine Engineground, via enginewire
harness

23-18
EI{GINEWIRE HARNESS
lBl8C'l onginel

c126
c119
cl17
'13
crrs cl14

23-19
Connector ldentificationand Wire HarnessRouting

ABS Modulatol Unit Wile Harness

Connoctor or Numbor ot Location Connocta to oies
Torminal CaviiieE
't4 Right side of enginecomPartment Main wire harness(c21 1)
L t o l
c162 ABS modulatorunit ABS Dressureswitch
c163 ABS modulatorunit ABS right Jront solenoid(OUT)
c164 ABS modulatorunit ABS right front solenoid(lN)
c165 2 ABS modulatorunit ABS rear solenoid(OUT)
c166 2 ABS modulatorunit ABS rear solenoidllN)
c't 67 ABS modulatorunit ABS le{t front solenoid {OUT)
c168 ABS modulatorunat ABS left tront solenoid(lNl

Engine Compartmont Wile Hatnaaa

Connector or Numbd of Location Connocta to t{oioE
Tolminal Cavilies
c301 20 Behindleft kick Panel Main wire harness(C4231
c302 20 Behindleft kick panel Main wire harness(C424)
Behindlett kick Panel Front fog light sYstem Option
c303 1
c304 2 Left side of engine compartment Enginewire harness(C126)
c305 14 Left side of enginecomPartment Enginewire harness(C127)
c306 2 Left side of enginecomPartment Test tachometer connector
Left side o{ engine comPartment Daytime running lights resistor Canada
c307
c308 Left side of enginecomPartment Windshi€ld wiper motot
c309 1 Left side of engine compartment Brake fluid level sensor ( + |
c310 1 Lelt side oJ engine comPartment Brakefluid level sensor (- )
c311 Middle of engine comPartment Power steering pressure (PSPI switch USA
Left side of engine comPartment Lett front wheel sensor ABS
c312 2
c313 4 Left side oJ enginecomPafiment Cruise control actuator
c314 2 BehindleJt headlight Left headlight(Low beam)
c315 2 Behindleft headlight LeJ-theadlight(High beam)
Behindleft headlight Front fog light system Option
c316 1
c317 2 Behind left corner ot front Windshieldwasher motor
bumper
c318 Behind lett corner ot front Rearwindow washer motor
DUmper
c319 2 Behindleft corner of ftont Left front side matker light
DUmper
c320 5 Behindleft cornet of front Left front tu.n signal/parking lights
DUmper
G301 Lett side of enginecomPartment Body ground,via enginecomPart-
ment wire harness

23-20
ABS MODULATORUI{IT
WIREHARI{ESS

Et{GI1{ECOMPARTMET{T
WIRE HARI{ESS

23-21
Connector ldentificationand Wire HarnessRouting

{Undor-hood

Behindright side of tront bumper Horn

c201
Behindright corner of tront Right tront turn signal/Parking
c202
bumper light
Behindright corner of front Right Iront side marker light
c203
bumpet
Behindright headlight Right headlight(Low beam)
c204
Behindright headlight Right headlight(High beam)
c205
Right side of enginecomPartment Radiatorfan motor
c206
Right side of enginecomPartment A / C w i r e h a r n e s s( C 1 5 1 )
c207 8
Right side ot enginecomPartment ABS front fail saJerelay
c208
Right side oJ enginecomPartment ABS rear fail sate relay
c209 4
Right side of enginecomPartment ABS pump motor
c210
Right side oJ enginecomPartment ABS modulatorunit wire harness
c211 14
(c161)
Right side of enginecomPartment Under-hoodABS fuse/relaYbox
c212 (c901)
box
c213 Right side of enginecomPartment Under-hoodABS fuse/relaY
(c902)
Bight side ot enginecomPattment Under-hoodfuse/relaybox (C907)
c214
Right side of enginecomPartment Under-hoodtuse/relaYbox (C909)
c215
Right side of enginecomPartment Under-hoodfuse/relaybox (C9l Ol
c216
Right side of enginecomPartment Under-hoodfuse/relaYbox (C908)
c217 7
Right side of enginecomPartment Under-hoodfuse/relaYbox (C911)
c218 J
2 Right side of enginecomPartment Right front wheel sensor
c219
Right side of enginecomPartment Enginewire harness{C104)
c220
(C'l04)
c220 Righl side ot enginecomPartmenl Enginewire harness
(C101)
c221 Right side of enginecompartmenl E n g i n ew i r e h a r n e s s
Engine wire harness (Cl 02)
c222 Right side of enginecomPartmen'
Right side of enginecomPartment Engine wire harness {C103)
c223
wire
Right side of enginecompartment Body ground, via main
harness
wire
Right side of enginecomPartment Body ground, via main
harness

23-22
 UNDER.HOOD
FUSE/RELAY
BOX

MAIN WIRE HARNESSlcont'dl

c222
c221
c223
c220

c212
c213
Continuos on
pago 23-25

23-23
itfltfitfi
Connector ldentificationand Wire HarnessRouting

Main Wire Ha.ness {Right branch}

Connactor or Numbsr of Location Connscts to ttlotor
Terminal Caviti€s
c401 ,E Front Passenger'sdoor Front passenger'sdoor wire
harness(C626)
c402 Under right side of dash A/C diode
c403 Under right side ot dash Heatersub-harnessA (C672)
c404 10 Under right side of dash Heatersub-harnessA {C671}
c405 2 Under right side of dash SCS short connectol
c406 Under right side ot dash Data link connector(DLC)
c407 22 Behindright kick panel ABS sub-harness(C7011
c408 lo Behindright kick panel Enginecontrol module (ECM)
c409 22 Behindright kick panel Enginecontrol module (ECM)
c410 26 Behindright kick panel Enginecontrol module (ECMI

23-24
 MAIN WIRE HARNESSlcont'dl

Continuos on Continuod from

pago 23-27 pa90

23-25
Connector ldentificationand Wire HarnessRouting

Msin Wiie Harness (Left branch)

Connector or Numbel ot
Location Connects to Notes
Terminal Cavities
c411 Centerfloor A/T gear positionconsolelight Afi
c412 Centerfloor Shift lock solenoid AiT
c413 14 Centerfloor A/T gear positionswitch Afi
c414 8 Under left side ot dash Interlockcontrol unit Afi
c415 4 Behindleft kick panel Daytimerunninglights control unit Canada
c416 I Behindleft kick panel Daytimerunninglights control unil Canada
c4'17 14 Behindleft kick panel Cruisecontrol unit
c418 20 Behindleft kick panel Junction connector
c419 22 Behindleft kick panel Transmissioncontrol module Arf
(TCM)
c420 26 Behindleft kick panel Transmissioncontroi module An
{TCM)
c42'l 10 Behindleft kick panel Rearwire harness(C501)
Behindleft kick panel Rear wire harness{C502)
c423 20 Under left side of dash Enginecompartmentwire harness
(c301)
c424 20 Under left side of dash Enginecompartmentwire harness
(c302)
c425 Under lett side of dash Roof wire harness(C663)
't4 Securitysystem (Option)
c426 Under left side ot dash Canada
c427 4 Under lett side of dash SRS main harness(C802)
c42A Under lett side of dash Clutch interlockswitch M/T
c429 2 Under lett side of dash Clutch switch (Cruisecontrol) M/T
c430 10 Under lett side of dash Dashboardwire harness(C552) Atr
c431 Under lett side ot dash Brakeswitch (Without cruise
control)
c43l 4 Under left side of dash Brakeswitch (With cruisecontrol)
c432 7 Under left side ol dash lgnitionswitch
c433 Under left side of dash Securitysystem (Option) Canada
c434 4 Under left side of dash Combinationlight switch
c435 o Under left side of dash Combinationlight switch
c436 7 Under left side of dash Combinationlight switch
c437 I Under left side of dash Combinationlight switch
c438 Behinddashboardlower cover Under-dashfuse/relaybox {C9131
c439 7 Behinddashboardlower cover Under-dashfuse/relaybox {C9161
c440 22 Behinddashboardlower cover Underdash tuse/relaybox (C9'l7l
c44'l 6 Under left side of dash Securitysystem (Option) Canada
c442 4 Under left side of dash Securitysystem {Option) Canada
c443 7 Under left side of dash PGM-FImain relay
c444 4 Under lett side of dash Starter cut relay M/T
c445 Under left side of dash Rearwindow defoqgerrelay
c446 15 Behindunder-dashfuse/relaybox Integratedcont.ol unit
c447 Under left side ot dash Securitysystem {Option) Canada
c448 Behinddashboardlower cover Horn relay
c449 to Behinddashboardlower cover Dashboardwire harness(C553)
G401 Behindleft kick panel Body ground,via main wire
harness

23-26
 MAIN WIRE HANNESS

Continuod from
poge 23-25

c418

C430 9432

c412
c41t

c449 c440

UNDER.DASH
FUSE/RELAYBOX

23-27
Connector ldentificationand Wire HarnessRouting

Roar wiro Harn$s (Hatchbsckl

Connector or Numbor of
Connecta to llotos
Location
Torminal Cavitios
c501 10 Behindleft kick panel Main wire harness(C4211
'14 Main wire harness(C422)
c502 Behindleft kick panel
c503 10 Behind dashboard lower cover Under-dashfuse/relaybox (C912)
c504 12 Behind dashboard lower cover Under-dashfuse/relaybox (C915)
c505 Behinddashboardlower cover Dashboardwire harness(C554)
c506 25 Driver's door Driver'sdoor wire harness{C6011
c507 2 Center tloor Driver's seat belt switch
c508 1 Center lloor Palkingbrakeswitch
c509 1 Left qusrter panel Driver'sdoor switch
LStt 2 Fueltank Fuel pump
c 5 11 Fueltsnk Fuel gauge sendingunit
c512 I Right quarter panel Passenger'sdoor switch
c513 2 Right quarter panel Right rear speaket
c514 Left quarter panel Left rear speaker
c515 Left quarter panel Noise condenser
c516 20 Left quarter panel ConnectorC517
c517 20 Left quarter panel ConnectorC516
c 5 r8 Left side corner of cargo area Power antennamotor
c519 2 L€ft side corner of cargo area Cargo area light
c520 6 Left side corner of cargo area Traile.lightingconnector
c521 b Left rear corner of cargo area LeJt taillight
c522 2 Center ot cargo area bulkhead License plate lights
c523 Right rear cornor oJ cargo area Right taillight
c524 2 Center of cargo area bulkhsad Tailgate latch switch
c525 2 Right side of cargo area Tailgatewire harness(C752)
c526 4 Right side of cargo area Tailgatewire harness(C751)
G501 Behindleft kick psnel Body ground, via rear wire
harness
G502 Left side of Jloor Body ground, via rear wire
harness
G503 Center ot cargo area bulkhead Body ground,via rear wire
harness

23-28
REARWIRE HARNESS

G503

23-29
Connector ldentificationand Wire HarnessRouting

Rear Wire HamsEs (S6danl

Connector ol Number ot Notos
Locaiion Connocts to
Torminal Caviti6s
c501 10 Behindleft kick panel Main wire harness(C421)
Behindleft kick panel Main wire harness(C422)
c503 10 Behinddashboardlower cover Under-dashtuse/relaybox {C912}
c504 Behinddashboardlower cover Under-dashfuse/relaybox (C915)
c505 12 Behinddashboardlowe, cover Dashboardwire harness(C554)
c506 25 Driver'sdoor Driver'sdoor wire harness(C6Ol )
c507 Centerfloor Driver'sseat belt switch
'I
c508 Centerfloor Parking brake switch
c509 1 Left B-pillar Driver'sdoor switch
c510 Fueltank Fuel pump
aEt t a Fueltank Fuelgauge sendingunil
c512 1 Right B'pillar Front passenger'sdoor switch
L9 IJ 2 Above right side of trunk Right rear speaker
c514 2 Above left side ot trunk Left rear speaker
c515 Left quarter panel Noisecondenser
c516 20 Left quarter panel C o n n e c t oC
r 517
c517 20 Left quarter panel C o n n e c t oC
r 516
c518 Left side corner of trunk Power antenna motor
c519 2 Above center of trunk Trunk light
c520 6 Left side corner of trunk Trailerlightingconneclor
c521 4 Left rear corner of trunk Left outer taillighr
c522 Right rear corner of trunk Licenseplate lights
c523 4 Right rear corner of trunk Right outer taillighr
c527 6 Left ,ear door Left rear door wire harness
(c651)
c52A 6 Right rear door Right rear door wire harness
(c656)
LCZY 1 LeJt quarter panel Lett rear door switch
,| Rearwindow delogget (+ )
c530 LeJtside oJ rear window
c531 2 Above right side of trunk High mount btake light
c532 1 Right quarter panel Right rear door switch
c533 I Right side of rear window Rear window defogger(- )
c534 4 Left side ot trunk lid Left inner taillight
c535 Centerot trunk lid T,unk latch switch
c536 4 Right side ot trunk lid Right inner taillight
G501 Behindlett kick panel Body ground,via rear wire
narness
G502 Left side of floor Body ground,via rear wire
narness
G503 Above center of trunk Body ground,via rear wire
narness

23-30
 c528
c533
c532
13

REARWIRE HARNESS

23-31
Connector ldentificationand Wire HarnessRouting

Dashboardwile Ha.n6ss
Connector ot Number of Notes
Location Connects to
T€rminal Caviti6s
20 Behinddashboardlower cover Under-dashfuse/relaybox (C919)
10 Behinddashboardlower cover Main wire harness(C43Ol Afi
c553 to Behinddashboardlower cover Main wire harness(C4491
c554 12 Behinddashboardlower cover Rear wire harness{C505)
L55b 5 Under lett side oJ dash Cruisemain switch
c556 22 Under left side of dash Junction connector
c557 Behindgauges Gaugeassembly
c558 10 Behindgauges Gaugeassembly
13 Behindgauges Gaugeassembly
c560 16 Behindgauges Gaugeassembly
LCO I Behindmiddleof dash Clock
Left side of dash Dash lights brightnesscontroller
c563 10 Behindmiddleof dash Hazardwarning switch
c564 6 Behindmiddleof dash Rear window defoggerswitch
c565 Right side of dash Glov€ box light
c566 to Under middleof dash Stereo radio/cassette PlaYer
c567 2 Under middleof dash Chime
c568 Behinddashboardlower cover Maintenancereminde.unit
a 6ACl Under middleof dash Cigarettelighter
Under middle of dash Body ground, via dashboardwire
harness

23-32
 c5P3 csor
cl6a cs,aa
"ru.,

DASI{BOARD
WIRE HARNESS

UNDER-DASH
FUSE/RELAY8OX

23-33
Connector ldentificationand Wire HarnessRouting

Drlvar's Door Wir6 Hamors

Connectot 01 Number of
Location Connocts to Notos
Torminal Cavitles
c601 25 Driver'sdoor Oriver'sdoor wire harness(C506)
c602 2 Driver's door Driver'sdoor speaker
c603 4 Driver'sdoor Driver's power window motor
c604 14 Driver'sdoor Power door lock control unit
c605 I Behindmirror panel Left power mirror Hatchback
c605 I Driver'sdoor Left power mirror Sedan
c606 Driver'sdoor Lett tweeter 818C1
engrne
c607 Driver'sdoor Driver'sdoor lock switch
c608 10 Driv€r's door Power mirror switch
c609 10 Driver's door Power window masterswitch
c610 o Driver's door D.iver's door lock actuatoras-
sembly
c611 2 Oriver'sdoor Driver'skey cylinderswitch
c612 I Driver'sdoor Power window master switch Sedan

23-34
Hatchback:

Sedan:

23-35
Connectorldentificationand Wire HarnessRouting

Flont Pasa€ngol's Door Wire Hamosg

Conngctor or Numbel of Locatlon Connocts to Not6s
Talminal C8viti63
c626 25 Front passenger's door Main wire harness(C4O1)
c627 2 Front passsngel's door Front passenger's door speaker
c628 2 Front pssseng€r's door Front passeng€r's power window
motot
Behind cover panel Right power mirror Hatchback
c629 8
c629 tt Front passenger's door Right power mirror S6dan
Front passengor's door Right tweeler 8 1 8 C1
c630
6n9ino
c631 2 Front passenger's door Front passenger's door lock
switch
c632 5 Front Passonger'sdool Front passengor's Power window
switch
c633 2 Front passeng€r's door Front passenget's door lock ac-
tuator
c634 Front pass€ngot's door Front passengor's door key
cylind6r switch

23-36
Hatchback:

PASSENGER'SDOOR WIRE HARNESS

Sedan:

FRONT PASSENGEB'SDOOR WIBE HARNESS

23-37
Connectorldentificationand Wire HarnessRouting

Left R6ar Door Wil8 Harn6ss (Sedan)

Connoctol ol Number ot Locstion Connocta to l{ot.t
Tarminal Caviiies
Lbc I b Lett rear door Resr wira harness(C527)
c652 Left rear door Loft rsar power window motor
c653 Left rear door Left rsar gower window switch
c654 Left rear door L€It roar Powor window sctuator

Right Rear Door Wilo Hatnosr (S6danl

Right rear door Rear wira harness {C528)

Right rear door Right 168r power window motor
Right r€ar door Right 168rpower window switch
Right rear door Right rear Powor window actuator

23-38.
 LEFTREARDOOR
WIRE HARNESS

WIRE HARNESS

23-39
Gonnectorldentificationand Wire HarnessRouting

Roof Wire HanesE

Connector ol Number ot Connccts to Notct
Location
Terminal Cavitiss
c661 Behindleft kick panel Under-dashfuse/relay box (C918) with
moonroof
c662 4 Behindleft kick panel Moonroot relay with
moonroof
LOOJ Behindleft kick panel Main wire harnoss(C425)
c664 4 Left side of dashboa.d Moonroof switch with
moonroof
LOO5 2 Roof Moonroof motor with
moonroot
LOOO I Roof Spotlight with
moonroot
c667 Roof Ceilinglight

23-40
Hdchback:

FUSE/RELAY
BOX

Scdrn:

ROOF WIRE HABNESS

UNDEB.DASH
FUSE/RELAYBOX

23-41
Gonnectorldentificationand Wire HarnessRouting

ABS Sub-harn6ss
Connactor ol Number of Conn€cts to Notas
Location
Terminal Cavities
c701 22 Behindright kick panel Main wire harness(C407)
c702 Right side of Jloor ABS maintenanceconnecto.
c703 20 Right quarter panel ABS control unit
c704 22 Bighl quarter panel ABS control unit
c705 Right side of cargo area ABS right wheel sensor Hatchback
c705 2 Right side of trunk ABS right wheel sensor Sedan
c706 2 LeJt side of cargo area ABS left wheel sensor Hatchback
c706 Left side ot trunk ABS left wheel sensor Sedan

G701 Right quarter panel Body ground, via ABS sub-harness

G702 Right quarter panel Body ground, via ABS sub-harness

23-42
Hatchback:

Sedan:

23-43
Connector ldentificationand Wire HarnessRouting

Hatch Wire Harnsss {Hatchbackl

Connector or Numbor ol Connscts to l{otos
Location
Torminal Cavilies
c751 4 Right side oJ cargo area Rearwire harness(C526)
c752 Right side of cargo area Rear wire harness(C5251
L/5J 1 Right side of reat window Rearwindow defogger(+ I
c754 Right side of hatch Spoilersub-harness(C761) 8 1 8 C1
engine
c755 4 Middle of hatch Rear window wiper motot
Middleof hatch High mount brake light 8 18 8 1
engine

G751 Right side oJ hstch Body ground, via hatch wire

naaness

Spoilor Sub-harn6ss(Hatchback with B18C snginel

Connoctor or Number ot Connocls to Notos
Localion
Terminal Cavitios
c761 Right side of hatch Hatch wire harness(C754)
c762 I Middle of hatch High mount btake light ( + )
c763 1 Middle of hatch High mount brake light ( - )

Roar Window Defoggor Ground Wire (Hatchbackl

Connoctol or Numbor of Connoctg to Notes
Location
Tgrminal Caviti6s
c77'l 1 Lett side ot rear window Rearwindow defogger(-)
G771 Left side ot rear window Body ground, via tear window
deJoggerground wi.e

23-4r'i
 HATCH
WIRE

BEARWII{DOW
DEFOGGER
GROUND IVIBE

c763
SPOILERSUB.HAFIIESS

23-45
'r]fi
Connector ldentificationand Wire HarnessRouting

Hoator Sub-harneEsA
Connoctor or Numb€r of Location Conn6cts to Notog
Terminal Cavities
'lo Under right side ot dash Main wire harness(C404)
c671
c672 Under right side of dash Main wire harness(C4o3)
c673 2 Under right side of dash Blower motor
c674 4 Behindglove box Blower resistor
c675 4 Behindglove box Recirculationcontrol motot
c676 Behindglove box A/C thermostat
c677 14 Behindmiddleof dash Heatersub-harnessB (C681)

Hoator Sub-hameEsB
connoctor 01 Number of Location Connocts to Notos
T6rminal CavitioE
c681 14 Behindmiddleof dash Heatersub-harnessA (C677)
c682 I Middle ol floor Mode control motor
c683 6 Behindmiddleof dash HeaterJan switch
c684 14 Behindmiddle of dash Heaterconttol Panel

HEATERSUB-HARI{ESSB

23-46
Connector ldentificationand Wire HarnessRouting

SRS Main Harness

Connector or Number ol
Location Connocts to l{otos
Terminal Cavities
c801 2 I Behinddashboardlowet cover Under-dashf use/rclay box (C929)
c802 4 J Under left side of dash Main wire haness 1C427)
c803 o Under left side of dash Cable reel
c804 18 Middle of floor SRS unit
c805 Under left side of dash Left dash sensor
c806 2 Under right side of dash Right dash sensor
c807 Behindglove box Passenger'sairbagassembly
G801 Middle of floor Body ground, via SRS main
harness

UNDER-DASH
FUSE/RELAYBOX

23-47
Fuses
Under-dashFuse/RelayBox

c918 c919
lTo root wiro harness (C661ll lTo dashboardwire harness(C55'l)l c920
.elayl
lTo lurn signal/hszard

c928
lTo SRS luso block {C931}l

cg22
lTo powor window rclayl Auxili.ry fulo holdei

Elnnnr.'trJnnrJn
1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 22 23
UUIJUIJULJLILIIJ UIJ
n|:]nnnnnn
1 2 (7) 8
r''lN11
9. 1 0 1 1
3 t4l 5 6
LIIJLIULJUUU U LILI

r: Not usod
.: Canadd
| ): S6dan r . - - - - - - - l
O: C923 loplion lBATll c929
@: C924 toption (BATll J To SRSmain I
O: C925 toption llc2)1 I harnass
{C8011I
@r C926 loption{No.19 fusoll
@: C927 loption {ACC)I
c930
I To ignitionl
I switch i

c931
I To und€rdash I
I fuso/rolaybox {C928)I

SRS FUSE BLOCK

23-48
 Fuse Numb€r AmDs Wire Colol Gomponent ls) or Circuit (s) Prot8cted
1 30A WHT Moonroof motor
2 Not used
3 7 . 5A WHT/RED Integratedcontrol unit, Ceilinglight, Power antennamotor. Data link connec-
tor (DLC)
4 20A YEL/BLK Right rea. power window motor (Sedan)
5 20A WHT/YEL Driver'spower window motor
o 20A WHT/GRN Power door lock control unit
7 20A GRNiBLK Lelt rear power window motor (Sedan)
I 20A BLU/BLK Passenger'spower window motor
I 1 0A RED/BLU Right headlight{High beaml
10 1 0A R E D / G R N Left headlight(High beam). High beam indicato.tight
11 Not used
12 Not used
13 7.5 A BLK/YEL Rearwindow defoggersystem, A/C system, ABS control unit, power mrrror
actuator
14 20A GRN/BLK Wiper/washersystem, Moonroof relay, Integratedcontrol unii
'15
1 0A YEL Gauges,Clock, Back-uplights, Maintenancereminderunit
to 7.5A YEL/BLK Daytimerunninglights control unit (Canadal
17 1 0A WHT/YEL Daytimerunninglights control unit (Csnada)
7.5A BLU^tvHT ECM, PGM-FImain relay
'to
1 0A RED/BLK Dash lights, Parkinglights, Taillights,Licenseplate tights
20 Not used
21 1 0A RED/WHT Right headlight(Low beam)
1 0A RED/YEL Left headlight(Low beam)
23 1 5A YEL/RED Stereo radio/cassette player, Cigarette lighter
24 REO SRS unit
BLK/YEL PGM-FImain relay, TCM, Cruisecontrot unit, VSS, ELOunit IUSA)
25 1 0A PNK SRS unit
26 1 0A YEL/BLK Turn signal/hazard
relay
' 1 N o . 24 115 Al: 8 1 8 8 1 e n g i n e
N o . 24 t2O At:. B 1 8 C l e n g i n e

23-49
Fuses
Under-dashFuse/RelayBox (cont'd)
NOTE: View from the backside of the under-dashtuse/relay box

c916
[To m.in wlro h.rnr.t lol39]l

cgt5
tTo ..r wftt hJtr.r (CsOrDl
c9r4
[To Int grrtad control unhl
c917
[To mrin wh.

c913 c91
lTo m.in wlro hlni.rr (qt38)l tTo r..r w|? hrt|.|t (C6O3ll

23-50
 Under-hoodABS Fuse/RelayBox

T5 [To undo]-hood ABS fuso/rolay box cabl.l

C9O3 ITo ABS pump molor rolayl

C9O1 [To main wiro ham6$ (C212]l

C9O2 [To moin wiro hs1n6ss(C213]l

Wire Color Componont (s) or Circuit (sl Protectsd

ABS 81 20A WHT/GRN Right/left ABS front solenoids
ABS 82 1 5A WHT ABS control unit, ABS rear solenoid
ABS MOTOR 4 0 A ABS pump motor relay, ABS unit (10 A) fuse
ABS UNIT 1 0A BRN/YEL ABS control unit

23-51
Fuses
Under-hoodFuse/RelayBox

n F n nn
46 45 /t4 35 3l
ALTERI{ATOR
fTo .ngino wlto hsrno$ {Tlolll UU U UU
n
32
U
n
n
42
33
U
U r:r
n
43
g
U
U

[To rldidor hn r.l.Yl

Not usod

r: l\lot u3.d

umbor Amps Color Componon! (sl 01 Clrcuit 13)Protoqtod

31 1 5A YEL/WHT PGM-Flmain relay
32 7.5 A WHT/BLU ECM, TCM. Clock, Stereo radio/cassette plsyer, Maintenance reminder unit
a2 204 BLK/RED Radiator Jan motor
34 Not used
35 204 WHT Condenserfan motor, A/C compressorclutch
50A WHT/RED N o . I { 3 OA ) , N o . 3 ( 7 . 5 A ) . N o . 4 l 2 O A l , N o 5 ( 2 OA ) , N o . 7 ( 2 OA ) ,
No. I (20 A) fuses
37 40A BLU/lVHT Blower motor
38 30A BLK/GRN Rear window defogger,Noisecondenser
?q 50A WHT/BLK lgnitionswitch {BAT}
40 50A WHT Combinationlight switch, No. 17 (1O Al fuse
41 1 0 0A Power distribution
42 20A WHT/GRN Horn system, Brake system, Key interlock solenoid (Aff)
43 1 0A WHT/GRN Turn signal/hazard.elay
44 Not used
45 Not used
46 Not used

23-52
NOTE; View from the backside of the under-hood fuse/relav box

c907
lTo m.ln wiro h.mo$ (C214)l lTo mrin wiro hameq lC217ll

[To msinwlro hEmosslc215l] lTo mlln wlr. hlmct. (C216li

c911
lTo ftain wiro hamers(C218)l:USA

23-53
PowerDistribution
Gircuit ldentification

8OX
ABSFUSE/FEIAY
UNOER-HOOD
ABS81 {2OA)
WHT/GRN
f Bight tromsotcooia
r- blt ) nas

A8682II5AI

ABSoumomotor

8n /YEL- A8Scontol unit

Btx/YEL tu!.
ib.l3l7.5Al
<

-
YER/RED A&Scontrol
unit

BATTERY
Stldar motor
r BLKffEL
_o_ - HOODFUSE/RELAY
UNDER 8OX
:

No.43ll0Al
-
wHT/GRt{ Turnsi0nrl/h.z.rd|thY
I
AL]ERNATOR

L"I
No.1l(100A) no.42l20A)
WHT/GRN tlom
llom mLy
Keyintodocklohnokl{A/Tl
ECM
Cruisocontrolunil
Tran.mksion controlmodub(TcMl
ABScontiolunh
&6k lighl!

.r"-
oiot
G401
{Topsge23- 55)
-
GRi{/REo ECM

23-54
 _HOODFUSE/NEUY
UNDER 8OX

{Fromp.So23- 541

-
YELJWHT PGM-R mlin |rhv

TrdEmirConco rolrl|oduL
frcMt
UI{DEF-OASH
n^OIATOR FUSSRELAY BOX
FANREI-AY tTop!9c23- 581

No.l317.5Al -
8LK/RED Radi.torfln molor
FUSE

V L swyel
ENGII{E
COOTAMI
TEMPEMTURE
swtTcH
*@"r;1
IECT)

oiot

BTOWER
MOTOR
RETAY
'"----

G20t
G40t
-
8LU/WHT 8bw.r motor

8tX/GRtl-f R!!r windowd,.to![.r

E Noia€condsn..r

WHT----- Cord.nrorlan motor

- IJC como.a.lorclutdt

-IB>
wHTnED ut{DER-oAsH y
R sE/nEL
1/- BoX(Toprs.23- 58I

*,"r^*__E> Fl,$SlrrrrTgl,*r,
No,40l50Al
COMBIMTON UGHTSWTTCH
{Top!!€ 23-59 )

- DASIIFUSAREUY
UiIDER
BOXfTop{6 23- 58 llc$.d!l

23-55
PowerDistribution
Circuit ldentification

- DASHFUSE/REIAY
UNDER BOX

IGNITION
SWITCH sRsFusE
81-0cK
No.25l10Al

l r c z
Ml t -'-

\'- _ ^ACC

+
p age23- 5 7 1
Chuging sY3l.m light
lln tho g6ug€s3€mblyl
Cruis€controlunit
Cdis6 msin 3whch itdicttor light

r 1 No.24115A):
81881 engin€
No.24l20A):Bl8C16ngin. PGM- Flmlin r6lry
lrrmmirdon controlmodulo[ICM)
)
Vohag6rcoulator
Vehiclosp.€dsomorIVSS)
E|.l)unitIUSA)
Crubeconttolunit

No.14l20A)
GRNiEI( Moonrcofrclay
GRNAt( Wind.hicldwipotmotor
Wirdlhi€ldwaah6.motor
R6arwindowws3hormotot{Hrtchblctl
Int.gGtodcontrolunit
PowerwirdowtclaY
Int6lrat€dcontrclunit
-
GRN/8I..K R6afwindow wipor motol
(H3tchbtck)
BLKffEt

No.l5{1041

N0.40{504)
FUSE
(Frompago23- 551
-EiT"h#,H#J:r"
YEt..-- ShittlocksolenoU{Ml
Eack-up lights

* 2 N o . 1{71 0 4 1 bor sockstl

optionconn€ctor:
C924

runninglightsconttolunit
Daytimo

23-56
IGNITIONSWTCHISTI
lFromp.!€ 23- 561
f7
I
.---F-------
l I - l
STARTFP
i Bffi,!'HT6u?'ili,iY i
'| r- r l\ \ clurcr I
;rui8rrH inl-rhicicxswrcr
t-11iPt 1,,,,,,
I t i l
l-+{ .'.io-F --.5
BIK/RED -
BLX/!\,HT st.dersotenoid i
l - l I r
BLK/REO

fr
r---
uxrivnSr$!gfr*,r.,
L€-eumo BLKMHT- Starlsrsolenoki

-------J

-DASHFUSEiRELAY
UNDER BOX

No.l817.5A)
ELUMHT--?- PGM_ Ftmsinrctay
- ECM
(From
pag623-56
)
lnt€gretodcontrol unit

No.23ll5Al
--E
YEURED St6r6oradio/c$r€tt6 playot
Cig€ronelightor
lG2 boxsockotl
{Fus€/relay
lFromp.!623- 56 ) Optionconnoctor:
C927

Pow6rminor *tuetols

noarwandowdologgorswitch
indicrtorlight

R6dietorfan roby
Elowormotor rclay
fuC compr$sor clutch rsl6y
A/C lhomGtst
Cond6ns&tan ml6y
Mod6controlmotor
Rocicubtion control motor
H6at€rcontrolpanol
Rearwindow deloggorrelay
ABS pompmotor tolay
ABSinsp€ctionconnoctor
ABScontrcl unit
+ l,lo,16
{7.5A1
Optionconnoctor:C925

Daytimerunninglights
controlunit

23-57
PowerDistribution
Circuit ldentification

- OASHFUSE/REI-AY
UNOER BOX

WHT/RED
- TrunUcergo.rur lght
- Fbwer.nr.nn! moror

WHT/REof Spotlight(Wrt'hmoonmoll

E C.ilin! light
Drl! link conn ctor lDLCl
boxsockstl
Irtogrltad control unit

-
WHT/GRN Pow6rdoor locl control unit

optionconnoclor:
C923

No,14l20l
FUSE

{lntomalconnaclionl
*-

G20t
G40l
WHTIYEL
* Powor windowconttolunrt
| {&ih intoDoworwindowmarloirwhchl
l- p,i""1" *;n6o* no1o,
BLU/4X+l
l_ | l,lssrng6r'swndowmotor

GRN/BLX
- Leftrerrwindowmoror
)

YEUE|-K
- ftenroar winoowmotor
)
r: Sedln

23-58
 - DASHFUSE/RELAY
UNOER 8OX

DIMMEN
No.9l10A)
neontu ? o *c--i- -
REo/BLU ftghtl
i
|
--E:::::l-
| No.lolloAl I I hordlishr b.rml
lHish

| l"JnJ"",,**".

No.2lll0A)
REDiU,HT+REo^wHT _ Rgh,I
I I No.22ll0Al | | h.rdliohtlLowb€rml
-TiED,TEL-L.trr
|
t l

optioncondsclor:
C926
RED/BLK
* o.sh hhts briohtners
co .oll€r
L Dlshlght!
REDALK ..- A/T gorr pGition conloh hht
- Horler control Drnellioht
REDEL(+ Rishn.
l_tft Iro parung
rgnr

fff')t.'..,nt
f#t) inner
tillisht{s€danl
Lic.n!€ pbt€ li0hts
Truilorliglfi ng connoclor

tGNtTloN
swtTcHltcl)
lFrom 23- 56)
p3€6
FUS€
HOLDER
V t l
I
l- #
BLK,ryEL
I m.ze
rroo I
YEUBTK- Tumdgnd/hazrrdr6i.y
tt l
l
I _ _ _ _ - l

23-59
GroundDistribution
Gircuitldentification

Blttory

_d_
:
GI

Tnnll|iltirn houinc

_d_
:
G3

Et - Y€||tr rpo€ollrEor rYSq

- VrECDlaaaura rwitch
18| 8Cl.r{i|r)
Engino coohnttomporlru|!ICCTI
!wilch
ux_r]---..o eu{l{ "- *" ",
E iTl*;,,

Dlt linl connctor lDl"Cl

I Tranamildrficontroldbduh
t (TcMt
ECM(-G
ECMILG2I

Xmct t rmr l(Sl

{VTEC}
lLatadorvo.n
!.ruor lHozsl

Cnnkd|rft Doritiont ECM

ICKPI$nlor t
I
TDC!.No. t

Cylndaroolitirn f
ICYPI!.ir.o. 1
L-----------

Mdn httt !p6od on[/8LU-r-. I

..n.or lAlTl WHT/BI-U+
I Tnnln&don codaol moduL
sLu/GRN-F frcMt
Co(||llanhrft !p.€d I
r.Bor WT) BLUrYEL
-

E: Irn ry oroundcebh E , Etgi," *ir" ha."o

E: Enoina 0oondcrbL A E , Etgir. *rp"nn"nt *ir. han*"s
E | €nginogroundc.bL 8 E: Mdnwirbhem6r

23-60
 l-
Cor|danlor
lan motor

-f,
:
G15l

h.ldtgh lLow be.ml

+ Rbhttror pr*ino^um .ign.l lehr

s Righttro li,. m|.t rhht
EtounitIUSAI

- HOOO
UI{DER FUSE/R€TAY
8OX

Elowormotorrolay

R6!r*indow dsloegrrrcby

G40t
fro p.g. 23- 62)

AB{iF np motor

au#eu ABSpr..&r! lwltch

E , A/c*ir" tr".osr
E : ABSdbduknor unitwitchrrn.r
Ul : Min wirrh.moB

23-61
GroundDistribution
Circuit ldentification

lHi0hberm)

'LK H[l[llsf#"ff'"Jfl1"'o"

Homrol.y
lgdtionkoylrvitch
8r -;€rv@.nciw*'*.,
F {M/Twhhcruisccontroll
Cftxchsvynch
L conlrclunit I lArt
Intorlocl
oq_
r- Ct rch htodock swhch lM/Tl
Ra'r window wioar/washotlwitdl

t .
BIK -{ |-{N| - 4.X -7 P!.rsong.r'!dootloct kcycylind€rsYritch
l- l- P!s!6n06r'sdoorbck 3witch

BIK Windlhiald wio.r/w$h6r rwhch

tr Engin6comprrtmonl wiro htrnds @ :llort.| lub - hamar! A

tr Main wiro hftn.ss tlt . H6!t6r lub - harara$B

E Frcnt prsongor'! door wim hlmosg

23-62
 G,Ol
lR!6t p.g! 23-621

I
cod$rionl
Porvlrwidow rlhy

Tlm demlftd.id nhy

Intaeiltadcontrolunh

*-----ilHHlifr,

g..( SRslidbnor loht/&dit

JUNCtOI{ d{ Daahhhr Mchinalaconto{..
coif{EcroR
n"K Clocl
Grler. .nd hdixor hhtr
Mdntandranrnlidarurlt
R.r rvlndoud.foglr r*hdr
Chino
Cigrfi.ItDt.r
Gbv! boxhhl
Crui$ contmlmin .witdr

Starao[do/clalatta pbyal

c56l

) snsu'*

G80r

E: MdnYdoh.m..! E'sasnr*rtrrtu
E, ootrtoct ,lo ttetr"..
@: noor*in |trttan

23-63
GroundDistribution
Circuit ldentification

Hstchbsckl

Pow6rdoorlockcontolunh
Driver'Bdoorlockectrrtor
Driv6r'sdoorlockk6ycylind6lswhch
Drivor'sdoorlockswitch
Powormirroa swhch
] Pow6rwindowmanorswitch
)

8r-K Ddver'3seat bah 3whch

-----
BLK,lVHT Fuolg&lge s€odiogunil
R rl pump

nuo,
Poworsntonmmotor
Tnibr lighingconn€ctor
L Lrh I
;l:. I taillisht
E Lic€nroph6 light3

eLx -i]- BLK- HishrDunt br.k6tisht

BtK---------
) ABs*nuoruni

AIY_I
I_ I ABScontolunh
BI.KA.VHT ABScontrolunh

Rorrwirdowwipcrnotor

cirt
Ro window d€foggor

nirt

E Roarwiroharnoss @ :Tailgatowirc hamoss

E Ddv6r's
doorwileham63s @ : R6erwindow d6lo9g€rgro{nd wirc
E ABSsub-hernoss

23-64
 S€d8n:

,.-*-{.4rr-* Powgrdoorlockcontrclunit
Drivor'sdoor lock actustor
D ve/s door lock key cylind€l rwhch
Ddv6r'sdoor lock switch

] Powerwindow mrster switch

)

Drivor's soat bolt swhch

--E
Brx,4/vHr *",r *n
lfr]ff;nj

G5o2

Irunk latchswhch
f l8iler lightingconnector
Licoruopl.to lights
RiohtI .
nnst rrn gnr
L€-ft J
Riohr) .... .
ran||gnr
L€-ft J
Poweranlonnamotot
Highmo0ntbt'k6light
Rearwindow dotoggor

otoa

oo "onuo,unn
]

t,*----l ,_^
ABscontrclunh
=,-"*- - f

.:
G702

@:
@ :Ddvo/sdoorwir€ hemoss
E ' ABSsub- hafn6s.

23-65
Battery

a Battory tluid (6lectrolyt€l contains sulturic acid. lt may cauaa aevere burns iI it gots on your skin or in youl oyos.
Woar protoctivo clothing and I fac€ shield,
- ll aloctrolyt6 gots on youl skin or clothos, rimo it off with wator immediately,
- lf eloclrolyto g6ts in your oyos, tlush it out by splashingwat6r in youl eyes for at least 15 minutes; call a physiclan
immediately,
a A battery gives off hydrogon gas, lf ignit6d. tha hydrogsn will orploda and could crack tho baflory cas6 and splattor
acid on you. Koep spa*s. flames, and cigarottos away from the baftery.
a Overchargingwill raiso ths tempelature ot th€ electrolyte. This may force electrolyte to splay out of the battery venta.
Follow lhe chargor manutacturer's instluctions and chargo tho battory at a prop61rate.

NOTE: The originalradiohas a codedtheft protectioncircuit. lt serviceto the car requiresany of the lollowing, be sure
to get the customer'scode number before
- disconnectingthe battery.
- removingNo. 32 (7.5 Al fuse from the under-hoodfuse/relaybox
- removingthe radio,
After service,reconnectpower to the radioand turn it on. When the word "CODE" is displayed,enter the customer's
s-digir code to restore radio operation,

Use eithera JCI or BearARBSTtester, and follow the manufacturer'sprocedures.It you don'r have one of these com-
puterized testers, follow this conventional test procedure:
To get accurateresults,the temperatureot the electrolytemust be between TOoF l21ool and IOOoF{38oCl.

lf the case is cracked or the posts are loose,

replace the battery.

lf the indicator shows low electrolvte, add

distilledwater it oossible.

Test Load Cspacity (# 1)

. Apply 3OOamp losd fo. 15 secondsto remove
surJacecharge.
. Allow 15 secondsrecoveryperiod.
. Apply test load (see Test Load Chartl.
. Recordvoltage at the end of 15 seconds.

Voltagestays above 9.6

volts: The batterv is OK.

23-66
 Chargeon High Setting {4O ampsl
Chargeuntil EYEshows chargeis OK; plus an
additional30 minutesto assuretull charge.
NOTE:lf the battery chargeis very low, it
may be necessaryto bypassthe charger's
polarityprotectioncircuitry.
lf the EYEdoes not show chargeis OK within
three hours,the battery is no good; replaceit.
Write down how long the battery was
charged.

Test Load Capacity l#21

Apply 300 amp load for 15 secondsto removesurfacecharge.
Allow 15 secondsrecovervDeriod.
Apply test load (seeTest Load Chan).
Recordvoltaoe at the end of 15 seconds.

Voltagestays abov€ 9.6 volts: The Uatteryis Of. I Voltagedrops below 9.6 volts: The battery
is no good.

For oramplo: AOD26L.MF

.-
I
I
BATTERY
ERY COOE
COOE
TEST LOAD CHART
Use the test load ot 112the cold crankingamps (CCA)print-
ed on the labelon the top of the battery. lf neithe. is indicat-
ed, us€ the informationbelow:
BATTERY COLD CRANKING TESTLOAD
CODE AMPS (CCA) lamps,
80 550 270
70 440 220
55 405 200

23-67
Power Relays
RelayTest
t{ormally-op€n Type: a Power window relay
a Radiator fan relay
1. Remove the power relay from its sockat. a glower motor relav

2. Check continuity between relay terminals.

a There should be continuity between the A and C

terminals when power and ground ar€ connect-
ed to the B and D t€rminals
a There should be no continuitv wh€n power is dis-
connected.

T6rminal
A
(B- D)
PowEr
Connactod

Di!c!nnact6d

I
IP a Staner cut relay
tb a Condenser fan .elay
I a
a
A/C compressor clutch relay
ABS t.ont {ail-saferelay
a ABS lear fail-saterelav

. A B
\ /

tffit
t[fT4r
\ C D ,

23-68
8 D

A c

23-69
lgnition Switch

CAUTION: J. Chsck tor continuity b€tween the terminals in each

a All SRS electdcal wiring harnessssaro covotod whh switch position according to the table.
yollow insulation.
a Botore disconnocting any part ot th6 SRS wiro har-
n6ss. connoct tha shon connoctor(t).
a Replac€tho ontiro affected SRS hames! asllmbly It
it has an op6n circuit 01 damagod widng.

SRS MAIN HARI{ESS

(Cov6red with Yollow inrulltiori)

1. Removethe dashboardlower cover and knee bolster.

Terninal
\ BAT tG1 ST
P6ition

--o
o-
I
KNEE BOLSTER
DASHBOARDLOWERCOVER

Disconnect the 5-P connector flom the undsr-dash 4. lf continuity checks do not agre€ with the tabl6,
fuse/relav box and the 7-P connector from the main reolace the €lectrical part of the switch lsee page
wire harness. 23-72t.

23-70
 ElectricalSwitch Replacement

4. Removethe steeringcolumn covers.

a All SRS €lectric8l wiring hamossesar€ covorsd with
yellow insulation,
a Befora disconnecting any pan of tho SRS wilo har- UPPERCOVER
neas. connect the short connoctor(sl.
a R6placethe entire attect6d SFS harnessassombly if
it has an opon circuit 01 damaged wiling.

NOTE: The originalradio has a coded theft protection E Insertthe key and turn it to ,,O',.
circuit, Be sure to get the customer'scode numberbefore
- disconnectingthe battery. Removethe two bolts and replacethe switch.
- removingthe No. 32 (7.5 Al fusefrom the under-hood
luse/relaybox.
- removangthe radio.
After service,reconnectpower to the radio and turn it
on. Whenthe word "CODE" is displayed,enterthe cus-
tomer's 5-digit code to restoreradio ope.ation.

1. Disconnectthe negativecable from the batery.

2. Removethe dashboardlower cover and knee bolster

{seepage 23-70).

3. Disconnectthe 5-P connectorfrom the under-dash

fuse/relaybox and the 7-Pconnectorfrom the main
wire harness (see page 23-70).

7. Installin the reve.seorde. of removat.

23-71
lgnition Switch
Steering Lock Replacement

CAUTION: 6. Lower the steeringcolumn sssembly.

a All SRS electrical wiring harnessesale covsred with
yellow insulation.
a Belore disconnecting any parl ot the SRS wir€ hal-
ness, connecl the short connector{s).
a Replacethe entire alfected SRS harness a$6mbly il
it has an open circuit or damaged wiring.
7. Center-Dunch each oJ the two shearbolts and drill
their heads off with a 5 mm {3/16 in) drill bit'
CAUTION: Do not dama96 tho switch body whon
r€movlng the shoar bol$.

NOTE: The originalradio has a coded thett protection

circuit. Be sureto get the customer'scode numberbetore
- disconnectingthe batterY.
- removingthe No. 32 (7.5 A) fusefrom the under-hood
fuse/relaybox.
- removingthe radio.
After service,reconnectpower to the radio and turn it
"CODE" is displayed,enterthe cus-
on. Whenthe word
tomer's 5-digit code to restoreradio operation.
8 . Remove the shear bolts from the switch body.
1. Disconnectthe negativecable from the battery. q
Installthe new ignitionswitch without the key in-
2. Removethe dashboaldlowercoverand kneebolster serted.
(see page 23-7'l).
1 0 . Loosely tighten the new shear bolts.
3. Disconnectthe 5-P connectorfrom the under-dash
fuse/relaybox and the 7-Pconnectortrom the main 1 1 .Insert the ignition key and check for proper opera-
wire harness{see page 23-71). tion of the steering wheel lock and that th€ ignition
key turns freely.
4. Remove the steering column covers (see page
23-711. 1 2 . Tighten the shearbolts untilthe hex headstwist off.

5. Removethe columnholdermountingboltsand nuts'

NUT
13 N.m
(1.3 kgf.m, 9.4 lbl'ftl

BOLT
22 N.m
12.2 kgl'm. 16 tbt.ftl

23-72
StartingSystem
GomponentLocationIndex

STARTERCUT RELAY {M/T}

Test, page 23,68

A/T GEAR POSITIONSWITCH

Test, page 23-136
Replacement, page 23-137 CLUTCHINTERLOCK SWITCH(M/T}
Test, page 23-78
Switch Adiustment.section 12

BA
Test, page23-66

Test, page 23-76

SolenoidTest, page 23 78
Repfacement, page 23 79
Overhaul,pages23-8O
Reassembly, page 23,85

23-73
Starting System
GircuitDiagram(M/Tl

tGNtTt0t{
UNOER-
HOOO
FUSE/REI.AY
BOX SWTCH
/.^1\tOFr
+O
\_:/ I
I
BT.KMHT

STARTER
CUTREIAY

I
EUqWHT
II
t*u*
I
I
8l-K

r H l
I STARTER

G 20r
G40r
Circuit Diagram(A/T)

-HOOD
UI{DER
G?{rao
FUSE/NEUY
BOX swncH

-{€ 6i\ o+
N,0.41
{l00Al Io.39160t

\_v II
Bl-torvHT

II
I
,(h\ A/I GEAR
g, ffi.:11?[:#ir11,",,
II
BI.K/BED
Starting System
Startel Test

NOTE: The air temDeraturemust be between 59 8nd Chock Stan€r Engag6ment:

10OoF(15 and 38oC) beforetesting.
1. Disconnectthe 2-P connector(ignitioncoil primary
Recommendsd Procodure: lead) from the distributor.

a Use a staner svstem tester.

a Connect and operatethe equipmentin accordance
with the manutacturer'sinstructions.
a Test and troubleshootas described.

Altohato Procedure:

a Use the following equipment:

- Ammeter. 0-4OO A
- Voltmeter, O- 20 V {accuratewithin 0.1 volt)
- Tachometer,O- 120O rpm
a Hook up voltmeterand ammeteras shown' 2 . Pressthe clutch pedalallthe way in (M/T),and turn
"Start". The starter should
the ignition switch to
crank the engine.

NOTE: On cars equippedwith manualtransmission,

the enginewill not crank unlessthe clutch pedalis
fully depressed.

lf the staner does not crank the enginego to step 3.

J. Check the baftery, battery positive cable, ground,

and the wire connections for looseness and cor-
rosion,

Test again.lf the starterstill does not crankthe en-

gine, go to step 4.

4. Bvpassthe ignitionswitch citcuit as follows {make

sure the transmissionis in neutral):
Unplug the connector (BLK/WHTwire and solenoid
terminsl) trom the starter. Then connect a jumper
wire from the battery positive ( + ) terminal to the
solenoid terminal. The starter should crank the
engrne.

a lf the starter still does not crank the engine,

TERMINAL
NEGATIVE replace it and diagnose its internal problems.
a lf the starter cranks the engine,go to step 5.

NOTE: After this test, or any subsequent repair,

resetthe ECMto clearany codes (seesection 1 1)

23-76
5. Check lor 8n op€n in the BLKMHT wire circuit be- Chack Cranking rpm:
tween the staner and ignition switch, and con-
nectors. Enginespsod during cranking should be above 1O0rpm.

6. Check the ignitionswitch (see page 23-70). lf spe6d is too low, ch€ck for:

7, On cars with automatic transmission,check the A/T
gear position switch (neutral position switchl and
connector.On cars with manualtransmission,check
the staner cut relay, clutch interlock switch, and
connectors.
a Loose battsry or starter teminals
a Excessively worn starter brushes
a Open circuit in commutator segments
a Dirty or damaged helical spline or drive gear
a Defective drive gear overrunning clutch

NOTE: Check the No. 39 (5O A) fuse in the under-hood
fuse/relay box for the starter cut relay.
Check tor Woar and Damago:
The starter should crank the engine smoothly and stead-
ily. lf th€ startsr engages, but cranks the engine errati-
cally, remove it. Inspect the starter, drive gear, and
flywheel ring gesr for damage.
Chock StErtor Disongagomoni:
Pressthe clutch pedalallth€ way in (M/T),turn the ioni-
tion switch to "lll" and roleaseto "11".
The starter drive gear shoulddisengagefrom the tlywheel
ring gear. When you roleasethe key.
lf the drive gear hangsup on th€ flywheel ring gear, check
for:

a Check the drive gear overunning clutch for binding a Solenoid plunger and switch malfunction
or slippingwhen the armatureis rotated with the drive a Dirty drive gear assembly or damaged overrunning
gear held. Replacethe gesrs if damaged. clutch

Check Cranking Voltago 8nd Current Draw:

Cranking voltage should be no less than 8.O volts.

Current draw should be no more than 360 amperes.

lf cranking voltag€ is too low, or current draw too high,

check for:
a Fully charged battery
a Open circuit in starter armaturecommutatot segments
a Starter armature dragging
a Shoned armature winding
a Excessivedrag in engine

23-77
Starting System
Clutch Interlock Switch Test Starter Solenoid Test

1. Removethe dashboardlower cover and knee bolster 1. Check for continuitv between the tetminals accotd-
(seepage 23-70), then disconnectthe 2-P connec- ing to the table.
tor from the switch.

2. Check tor continuity between the terminals accord-

ing to the table. Tsrminal
\ M D Housing
Coil

T€rminal HOLD-IN o- ---c

ClutchPedal
A B
PULL-IN o- ---.o
RELEASED
PUSHED o o

Pt LL- tt{ coll HOLD- |l{ COIL

lf necessary.replacethe switch or adjust the switch

oosition (seesection 12).

23-78
 Starter Replacement

1 . Disconnectthe negativecable from the batterv. 4. Disconnect the staner csble from the B terminal on
the solenoid,then the BLK/WHTwire from the S
2. Removethe intake air duct. terminal.

Removethe two bolts holdingthe staner, then re-

move the startef.

UPPER MOUI{TII{GBOLT
44 N..h (4.5 kgl.m, 33 lbt,ftl
8 TERMII{ALMOUIITTI{G NUT
9 .ln (0.9 kgf.m, 6.5 tbf.ttl

AIR CIEANER
HOUS|L
TERMINAL

Removethe enginewire harnessand startefcables

from their brackets.

BLI(AA/HTWIRE

ENGINEWIRE HARI{ESS

6. Installin the reverseorder of removal,

CAALES

23-79
StartingSystem
Startel Overhaul
STARTER
CAUTION: Disconneclth€ battery n€gativecable befole SOLENOID SOLENOID
lomoving the startet. PLUNGER Test, page 23-78
Inspection,page 23-85
NOTE: The originalradio has a coded theft protection
citcuit. Be sureto get the customer'scode numberbefore
- disconnectingthe batterY.
- removingthe No.3 2 (7.5 A) fusefrom the under-hood
fuse/relaybox.
- removingthe tadio.
Atter service,reconnectpower to the radio and turn at
"CODE" is displayed,enterthe cus-
on. Whenthe word BRUSHHOLOER
tomer's 5-digit code to restoreradio operation.
ARMATURE
PINIONGEAR IDLERGEAR

ENOCOVER

t r . /
.' BRUSH HOLDER
Test, page 23-8'l
ERUSH
Inspection,page 23-11

COVER

I
SOLENOIDHOUSING 6 IDLERGEAR
ARMATURE
lnspection and Test,

I ROLLERBEARINGS
and CAGE
page 23-82

Prevenl rollers trom being scattered and lost.

HARNESSBRACKET

STEELBALL
@* MOLYBDENUMDISULFIDE

installsteel ball
from clutch side.

-s@]
MOLYBDENUM
DISULFIDE
OVERRUNNING CLUTCHASSEMBLY
Inspection,page 23_84
_R1
MOLYADENUM
DISULFIDE
GEAR HOUSING

23-80
 Starter Brush Holder Test Starter Brush Inspection
1. Checkthat there is no continuity between the O and Measurethe brush length. lf it is less than the service
O brush holders.lf continuity exists. replacethe limit, replacethe armaturehousingand brushholderas-
b,ush holderassembly, sembly.

Brush L€ngth
Standard{Now): 15.O- 15.5 mm (0.59-0.61 inl
Se.viceLimit: 10.0 mm (0.39 inl
G) BRUSHHOLDER E BRUSHHOLOER

O BRUSHI{OLDER O BRUSHHOLDER

Insertthe brushinto the brushholder,and bringthe

brush into contact with the commutator,then attach
a springscaleto the spring,Measurethe springten-
sion at the moment the spring lifts off the brush.

SpringTension:17.7 -23.5 N {1.8-2.4 kgf, NOTE: To seatnew brushesafter installingthem in their

4.O_5.3 tbfl holders,slip a strip of # 5OOor # 600 sandpaper,with
the grit side up. over the commutatorand smoothlyro-
tate the armature.The contact surfaceof the brushes
will be sandedto the same contouras the commutato..

SPRINGSCLAE

23-81
StartingSystem
ArmatureInspectionand Test
1. Inspectthe armaturefor wear or damagedue to con- CommutrtorRunout
tact with the field coil magnets. Standard(Naw):0-O.O2 mm (0-O.OO08inl
SowicoLimit: 0.O5 mm (O.O02inl

Inspect tor damage

COMMUTATOR

A dirtv or burnt commutator surface may be l€sul- 3 . lf the commutator runout and diamete. are within
faced with emery cloth or a lathe within the follow- limits, check the commutator tor damageor for car-
ing specilications. bon dust or brass chips between the segments.

Commutator Diamet€r 4. lf the surf6c6 is dirty, recondition it with # 50O or

S t s n d a l d( N 6 w ) :2 9 . 9 - 3 O . O m m ( 1 . 1 7 - 1 . 1 8 I n l # 600 sandpsper.
Selvico Limit: 29 mm (1.14 lnl

VERNIEBCALIPER

23-82
Checkfor mica depth. It necessary,undercutmica Placethe armatuteon an armaturetester. Hold a
with a hacksaw bladeto achieveproperdepth. hacksawblade on the armaturecore,

ITOTGOOO
ARMATURETESTER HACKSAW BLADE

MICA DEPTH

Commutator Mica D6pth

Stsndard{Nsw):0.5-0.8 mm (O.O2-0.03 in}
Sslvice Limit: 0.2 mm (O.OO8inl
ARMATUFE

Check tor continuity between the segments of the

commutator.lf an open circuitexists betweenanv
segments,replacethe armatute.

It the blade is attracted to the core or vibrstes while

the core is turned,the armatureis shorted.Reolace
the armature.

8. Check with an ohmmeterthat no continuityexists

betweenthe commutatorand armatutecoilcore. and
between the commutator and armatureshaft. lf con_
tinuity exists, replacethe armature

M
SHAFT COMMUTATOR

23-83
StartingSystem
Starter Field Winding Test OverrunningClutch InsPection

1. Check for continuity between the brushes.lf there's Slidethe overrunningclutch slong the shatt.
no continuity, replace the armature housing. Does it move treely? ll not, replace it.

2. Check for continuity between each brushand the ar- Rotate the overrunning clutch both ways.
mature housing{ground) lf continuity exists, replace Does it lock in one direction and rotate smoothly in
the armatulehousing. reverse? lf it does not lock in either direction or it
locks in both directions, replace it.

BRUSHES

CLUTCH GEAR

DRIVEG€AR

ll the starter drive gear is worn or damaged, replsce

the ovsrrunning clutch assembly; the gea. is not
available separately.

4. Check the condition of the flywheel or torque con-

verter ring gear if the starter drive gear teeth ale
damaged.

23-8,4
 Solenoid PlungerInspection
Check the contact points and the face of the staner sole-
noid plunger for burning, pitting or any other defects. lf
surfacas are rough, recondition them with a strio of
# 500 or #600 sandpaper.
StarterReassembly
R€assemblethe starter in the reverse order of disas-
sembly.
1. Pry back each brush spring with a screwdriver,thon
position the brush about halfway out of its holder,
and release the spring to hold it there.

2. Instsllthe armaturein the housing.Next pry back

each brush spring again and push the brush down
soLEr{otD until it seats against the commutator, then release
PIUNGER the spring against the end of the brush.

a&T&'
3.
s..
V
BRUSH

Installthe end cover on the brush holder.

23-85
StartingSystem
PerformanceTest
NOTE: Beforestaning the tollowing checks. disconnect Rotracting Test:
the wire Jrom te.minal M, and make a connectionas
describedbelow usingas heavya wire as possible{prefer- Disconnectthe battery negative cable. ll the pinion
ably equivalentto the wire used for the car). retracts immediately, it is working properly.

Pull-in Coil Tasl: NOTE: Do not leavethe battery connectedtor more than
1O seconds.
Connectthe battervas shown. It the starterpinionpops
out, it is working properly.

GAUTION: Do not leavothe battery connectodfor mora

than 10 seconds.

Startoi Noioad Test:

1, Clamp the starte. firmly in a vise.

2, Connectthe starterto the battery as shown and con-

tirm that the motor starts 8nd keeps rotating.

Hold-in Coil Tost:

Disconnectthe battetv from the M terminal.lf the pin-

ion does not retract,the hold-incoilis working properly.

CAUTION: Do not l6avetho battory Gonnectedfor moro

than 10 soconds.

It the electric current and motor speed meet the

sDecifications when the batteryvoltageis at 11 V,
the staner is working properly.

Spacifications: 90 A or less {Eleciric curentl.

3OO0 rpm or more (Motor speodl

23-86
lgnition System
Gomponent Location Index

IGNITIONTIMINGCONTROLSYSTEM
a Troubleshooting,section I1
a Inspectionand setting, page 23-89

DISTRIBUTOR
Top End Inspection,page 23-91
Removal/lnstallation,
pages23-91, 92
Overhaul,page 23-93
Reassemblv, page 23,94
lgnitionCoil Test/Replacement,
page 23-95
lgnitionControlModule {lCM} Inpur Test, page 23-96

SPARK PLUGS
fnspection, Page 23-97

WIRES
Inspection, psge 23-94

23-87
lgnition System
Circuit Diagram

HOOO
UNOER- BOX
FUSE/RELAY

ECM

V
I
YEUGNiI

posilioo
CKP:Cr6nk.halt sonsor
position
CYP|Cylindor s€nsor tG tTtoNc0NTROl-
MoDUr.r (cMl
-
/ H8sbuilt in \
TOC/CKP/CYP
SENSOR I OOrsO I

-_r_1=__E

-J---L--L--Lr

U'+++
ORN

23-88
 lgnition Timing Inspection and Setting

1 . Startthe engine.Holdthe engineat 3,00Orpm with 4. Adiust ignitiontiming, if necessary,to the follow-
no load (A/T in S or E position,M/T in neutral)until ing specifications:
the radiatorfan comes on, then let it idle.
lgnition Timing:
Pullout the servicecheckconnectorlocatedbehind 16 t 2 BTDC (RED)at 75O 1 50 rpm in noutral
the rightkick panel.Connectthe BRN/WHTand BLK
terminalswith the SCS short connector. NOTE:
a Shift lever must be in neutral.
a All electricalsystemsshould be turned OFF.
DATA LINK
CONNECTOR{3-P}
NOTE: Do not attach
the jumper wire.

POINTER

SCS SHORT CONNECTOR

{0?PAZ-O010't00t

SERVICECHECKCONNECTOR I2.PI
NOTE:Locatedbehindthe right kick
oanel

Connecta timing light to the No.1 ignitionwire and

point it toward the pointeron the timing belt cover. REOMARK

TIMINGLIGHT

lcont'd)

23-89
lgnitionSystem
lgnition Timing lnspection and ldle Speed Inspection
Setting (cont'd)
5. To adjust ignition timing, loosen the distributor Shift to neutral or Ll] and start the engine. Hold the
mounting bolts, and turn the distributor housing engineat 3,OOOrpm with no load until the radiator
counterclockwise to advance the timing, or clock- fan comes on, then let it idle.
wise to retard the timing.
2 . Connect a tachometer to the test tachometer con-
nector.

MOUNN G BOLTS
24 N.m (2.4 kgl.m, 17 lbt'ftl

b. Tighten the adjusting bolts and recheck the timing.

Remove the SCS short connector trom the service

check connector.

ldle sp6od
M/T: 750 t 50 rpm in neuttal
A/T: 75O t 50 rpm in @ or @

NOTE: Allelectricalsystemsshouldbe turnedOFF.

Adjustthe idlespeedil necessary(seesection 1 1).

23-90
 DistributorTop End Inspection Distributor Removal
1 . Checkfor rough or pitted rotor and cap tefminals. 1. Disconnectthe 2-P and 8-P connectorsfrom the dis-
tributor.
2 . Scrapeor file oft the carbondeposits.
Smooth the rotor terminal with an oil stone or #600 2 . Disconnectthe ignitionwires from the distributor
sandpaperi{ rough. cap.
2 Check the distributorcap Jor cracks, wear, and
dSmage,lf necessary,clean or replaceit.

3. Removethe distributor mounting bolts, then remove

the distributorIrom the cvlinderhead.

23-91
lgnitionSystem
DistributorInstallation
Coat a new O-ring with engine oil, then install it. 5. Connect the ignition wires as shown.

Slip the distributorinto position.

NOTE: The lugs on the end of the distributorand

its mating grooves in the camshaft end are both off-
set to eliminate the possibility ot installing the dis-
tributor 18Oo out of time.

DISTRIBUTOR
END CAMSHAFTEND

Set the timing with a timing light (se€page23-89).

After setting the timing, tighten the mounting bolts.

24 N.m (2.4 kgf'm' 17 lbt'ft|

Install the mounting bolts and tighten them tem-

porarily.

Connect the 2-P and 8-P connectors to the dis-

tributor.

23-92
DistributorOverhaul
BLKTYEL

DlsTNIBUTOR

ROTORRETAII{IITGSCREW
lMust be madeof
diamagnsticmateriall

Chock tor cracks, wear, damage,

or fouling.
Clean or replace.

HOUSING
Check for cracks
oa damage.
IGNITIONCONTROLMODULE {ICM)
Troubleshooting,section 1 1
Input tost, page 23-96

23-93
lgnition System
Distributor Reassembly lgnition Wire lnspection and Test

1 . When reassemblingthe dislributor, install the distri- CAUTION: Caretully removo the ignition wiros by pull-
butor rotor so on the shaft that it faces in the direc- ing on tho rubbq boots. Do not bend the wilos; you might
tion shown (toward the No. 1 cylindetl, bl€ak tham inside.

1. Checkthe conditionof the wire terminals.lf any te.-

minalis corroded,cleanit. and if it is brokenor dis-
torted. reolacethe wire.

IGNITION
WIRE
2 . Alignthe indexmarkon the distributorhousingwith
the index mark on the end of the shaft.
2 . Connect ohmmeter probesand measureresistance.

lgnition Wile Roaistanco:

25 k0 max. at 68oF (2OoCl

INDEX MARKS

IGNITIONWIRE

3. lf resistanceexceeds25 kO,replacethe ignitionwire,

23-94
 lgnitionCoil Test lgnition Coil Replacement
With the ignition switch OFF, remove the distribu- 1. With the ignition switch OFF, remove the disrribu-
lor cap. tor cap, rotor, and cap seal, then remove the leak
cover.
Removethe two screws to disconnect the BLK^/EL
and WHT/BLUwires from terminalsA (+ ) and B ( - )
respectively.

CAP SEAL

Removethe two screws to disconnect the BLK/YEL

and WHT/BLUwires from the coil.
3. Using an ohmmetet, measur€ tesistance betwe€n
the terminals,Replacethe coil if the resistanceis not 3 . Remove the two screws and slide the ignition coil
within specifications. out of the distributorhousing,

NOTE: Resistancewill vary with th€ coil t€m9er-

ature; sp€cificationsare at 68oF l20oC)

Prlmary Winding Rosistanco

(8otwo6n tho A and B torminalsl: 0.6-0.g ohms
Secondary Winding Rssistanc6
(Botwoon the A and socondary winding tomlnalsl:
1 2 . 8- 1 9 . 2 k O

A l+)

I11
t L B{-}
l

WHT/BLUWIRE

23-95
lgnition System
lgnition ControlModule(lCMl Input Test

NOTE: 4. Turn the ignitionswitch ON. Checkfor voltagebe-

a SeesectionI 1 if the malfunctionindicatorlamD(MlL) tween the WHT/BLUwire and body ground.
blinks. There should be battery voltage.
a Pertorman input test for the ignitioncontrol module
(lCM)after finishingthe fundamentaltests for the ig- a lf there is no battery voltage,check:
nition system and the fuel and emissionssystems. - lgnition coil
a The tachometershouldoperatenormally. - WHT/BLUwire betweenthe ignitioncoil and
the ICM
1. Removethe distributorcap, the distributorrotor, and a lf there is battery voltage. go to step 5.
the leak cover.
Checkthe YEL/GRNwire betweenthe ECMand the
2. Disconnectthe BLK/YEL,WHT/BLU,YEL/GRN,and tcM.
BLU wires from the lCM.
6 . Checkthe BLUwi.e betweenthe tachometerand the
rcM.
7 . It all tests are normal,replacethe lCM.

YEL/GRN
wlRE

3. Turn the ignitionswitch ON. Checkfor voltagebe-

tween the BLK/YELwire and body ground.
There should be battery voltage.

a lf there is no batteryvoltage,checkthe BLK^/EL

wire betweenthe ignitionswitch and the lCM.
a lf there is battery voltage,go to step 4.

23-96
 Spark Plug Inspection

1. Inspectthe electrodesand ceramicinsulatorfor: Replacethe plug if the centerelectrodeis round-

ed as shown below:

ROUNDED
ELECTROOE
. rmpropergap
. Oil-touling
. Carbondeposits
. Crackedcenter
Damaged electrodeinsulator
gask6t

Bl8Cl engine:
a Make surethat the '1.4mm (0.055 in) wire-type
pluggaugedoes not go into the gap for the plati-
num tip plug. lf the gaugegoes into the gap, do
not attemptto adjustthe side electrode;replace
the plugwith a new one.Useonlythe sparkplugs
listed below.

ROUNDEOELECTRODE
Electrode Gap
Burned or worn electlodes may be caused by: Standard:1 .2-'l .3 mm
. Advancedignitiontiming {0.047-O.051 in)
. Loose spark plug ServiceLimit: 1.4 mm
. Plug heat rangetoo low {0.055 in)
. Insufficientcooling

Fouledplug may be causedby:

. Retardedignitiontiming CAUTION: Do not use a blade-type plug gaugs, it
. Oil in combustionchamber may damagethe platinumtip of the centerolectrodo.
. lncorrectspark plug gap
. Plug heat rangetoo high S p a r kp l u g sf o r t h e 8 1 8 8 1 e n g i n e :
. txcessive idling/lowspeed running
. Cloggedair cleanerelement Z F R s F -11( N G K )
. Deterioratedignitioncoil or ignitionwires K J l 6 C R - 111 For all normaldriving
(Nippondenso)
Check the electrodegap.
Z F R 6 F -1 ( N G K )
For hot climatesor con-
KJ2OCR-11 1
Bl88l engine: (Nippondenso) tinuous high speed driving
a Adjust the gap with a suitablegappingtool.

ElectrodeGap S p a r kp l u g sf o r t h e B ' l 8 C l e n g i n e :
Standard: 1 . 0 - 1 . 1 m m ( O . O 3 9 - 0 . O 4 3i n )
P F R 6 G _ 1( N
3GK) I
PK2OPR-113 I Forall normaldriving
{Nippondenso)
1 . 1m m
{0.0,$ in)

3. Applya smallquantityol anti-seize compoundto the

plug threads.
Screw the plugs into the cylinderheadiingef-tight,
t h e n t o r q u et h e m t o 1 8 N . m ( 1 . 8 k g f . m , 1 3 l b f . f t ) .

23-97
ChargingSystem
ComponentLocationlndex

CHARGINGSYSTEM LIGHT
lln the gauge sssemblyl
T€st. pages23-1OO.101
Bulb Locations, page 23-1 15
UI{DER.HOOD FUSE/BELAY BOX
(USA:Hasbuilr-inELECTRICAL
LOADDETECTOR {ELD)UNIT)
ot ELD,s€ction11
Troubleshooting

BATTERY
Tost,

ALTERNATORBELT
Inspoction and Adiustment, page 23-108
Alt6rnator/Regulator
Tosl, pag€s23-102, 1O3
Replacament.page 23-'l 04
Ovsrhaul, pago 23-105

23-98
CircuitDiagram

- HOODFUS€/REI.AY
UI,IDER 8OX
No.4t11004) /a\ ilo.39l50Al *1 :USA
+2 llo.24ll SAl:81881.min
tlo.24{2041: 818C| .niin6

UNDER_OASH
FUSE/REIAY
8OX

. NTEGRATED
COMTNOL
UMT
. aBscoilTRor-
uNn

VI
I
ECM

VI
I

Fr€|'l)
wNort'lc

AI.TERNATOR

oiot
G401

23-99
ChargingSystem
Troubleshooting
Bofore troubleshooting check
- tightnessof the alternatorbelt (see page 23-1Og).
- that the malfunctionindicatortamp lMlL) of the ECM does not blink. lf it blinks,refer to section 1 1.

lf the charging system light is on, or th€ battery is dead or low, p€rtorm the following tests in the order listed below:

1. Baftery Test (see page 23-66)

2. Charging System Light Test
3. Alternator/RegulatorTest

ChErging Sysrom Light T6tt

Tu]n tho ignhlon srvitch on (lll.

Does th€ charging syslem o pago23-1011

light come on7

Does tho charging system

light go ott?

FUSE/RELAY BOX
(r..r tid.)

Turn the ignition switch otf.

I'{TEGRATED
CO]TTROLUI{IT

Disconnect the 4-P connoctor

lromt th€ altornator.
Turn the ignitionswitch on {ll),
Does the charging system
light come on?
H.tchb.ck:
tlo rhon o. opon h ih. WIfT/BLU
who. Porfom dtomrtor/rogdttol
rost beo pag. 23-l02l.
Ramova tfto 26-P connactd trom NOTE: After this test or relaled
th. ABS control unh snd lh. in- rep6irs, roconnoct the control
tggrotad conrol unh ttoln tha tad units. th6n aosetth€ ECMto cloar
ol tho und..dlrh tu!a/r.l.y box. any cooos.
It thr .hlrglng .yrtom lighl .l.Y.
on, rrpalr tho ahon to ground In
rhr WHT/BLU wi...
Sad.n:
UNIT
ABS COI{TROL

2A-P CONi{ECTOR 26.P CON ECTOR

ABS CONTROL

23-100
 lFrom page 23-10O) ' N o . 2 4 ( 1 5 A ) : 8 1 8 B ' l ongrne
N o . 2 4 ( 2 0 A ) : 8 1 8 C 1 engine

Turn the ignition switch ott.

Check fuse *No. 24 in the under-

dash tuse/relay bor.

Disconnect the 4-P connector

Irom the alternator.

Turn the ignitionswitch on {ll).

Ch6ckforvoltago between tho lG

terminal(BLK/YELwire) of rho il-P
connectorand body ground.

ls there battery voltage? Rgp.i. op.n in th. BLK|'EL wiro. wirg side L IWHT/BLUI

Ground the WHT/BLUwire at the

L terminal ot the 4-P connector.

Does the charging system light Chockfor ! blownchrrgingry3-

come on? rom llghr bulb. It rh. butbi! oK,
ropairopenin lho IiYHT/BLUwiro.

(cont'd)

23-101
ChargingSystem

Altornator/RegulatorTest

NOTE; Mske surethe battery is sufficientlychargod(sa€ FULLFIELD

page 23-66). TESTEB
LOADADJUSTER LEAD(BLUI
ICARBONPILE)
Connoct tho Sun VAT4O {ot
ooulvslont lgrt equipmonl) and
tum tho s6l6ctor rwitch ro posi_
tion I |rtarting). VOLTMETER
t{EGATIVE
LEAD(8LK}
O IOAD
shift to neurralorlPland start the
engino. Hold the ;;gine at 3oO0
rpm wiih no load until the radia_
tor lan com€s on. then let it idle.

VOLT TEST
Raisethe engine speed to 2OOO SELECTON swlTcH
rom and hold il there.

II{DUCTIVE
ls lhe voltageover 15.1V? FICK.I.|P
IGR '

VOLTMETER
POStTtVE
Releasethe acceleratorpedaland LEADIREDI
let the enginoidle.
EGATIVETESTER
CABLE(BLKI
Make sure all electrical systems INDUCTIVE
are turned otf. Turn the selector PICK.UP
swilch to position2 (charging).

B TERMI]TAL
WIRE
Removethe inductivepick-upand
zero the ammeter.

Place the inductive pick-uP over

the B terminalwire oI the altgrna-
tor so that the arow Dointsaway
trom the alternator.

Raisethe engins speed lo 20OO

rpm and hold it there.

ls the voltagelessthan 13.9V? T..t itr b.ttry (.- 9|e. 8€Al.

NO
tropagezJ-ruJ,

23-102
 (Frompage 23-1021

Apply a load wirh the VA'-4O un-

til the battery voltagedropsto be-
t w e e n 1 2 - 1 3 . 5V .

ls the amperage 60 A or more?

NOTE; Attach a probeto the VAT-4Ofull field test lead and insert the orobe
With the engine spe6d still at
into the full tield sccesshole at the back of the alternator.Switch the field selector
to the "A (Ground)" positionmomentarilyand check amperagereading.
2OOOrpm, full-tieldthe altemalor.

CAUTION: The voltago will ris6 quickly whon the slternator is full-fiolded. Do
not allow th€ voltago to oxc66d 18 V 01 it may damage the elect.ical system

REGULATOR
{Locatod
the end cover)

FULL FIELD
ACCESSHOLE

Toat rnd rooalr d|e dtomEtor {soo

psg.. 23-104 to 23-tO7). 4-P CONNECTOR

Turn the ignition switch off; then

turn aton again.

Disconnocl lhe 4-P connector

Irom the altornator.

Check lor voltage between the lG

terminal (BLK/YEL) and body
ground.

ls there battery vokage? Rop.ii open in tho BLK/YELwiro.

IG IBLKATELI

wire side L IWHT/BLUI

23-103
 ChargingSystem
Alternator Replacement

NOTE: The originalradio has a coded theft protection 7. Removethe lower and upper mounting bracket bolts
circuit. Be sure to get the customer'scode numberbefore and the mountingbrackets.
- disconnectingthe battery.
- removingthe No. 32 {7.5 A) fuse from the under-hood
fuse/relaybox.
- removingthe radio.
After service,reconnectpowet to the radioand turn it on.
"CODE" is displayed,enler the cus-
When the word
tomer's 5-digit code to restoreradio operation. UPPERMOUNTII{G
BRACKET BOLTS
il4 N.m {4.5 kgl'm, 33 lbl'ft}
1. Disconnectthe groundcablefrom the batterynega-
tive (- ) terminal.

2. Disconnectthe alternatorconnectorfrom the al-

rernaror. ,\\\- ( \ \ \(^

NUT
\-/ I
TERMINAL

B TERMINAL

24 N.m 12.4 kgf'm,

't 7 tbf.ftl
ALTERNATOR
CONNECTOR

Removethe terminal nut and the WHT wire from the

B terminal. BRACKET BRACKET BOLTS
44 N.m (4.5 ksl.m, 33 lbt'ft1
Loosenthe adjustingnut. then removethe mount-
Ing nul.
ADJUSTING NUT
8. Removethe adiustingnut and uppermountingbolt,
then lift out the alternator.

9. lnstall the altetnator in the reverseorder of removal.

CAUTION: Adiust tho alternalor belt tension aftor

installation (seo Page 23-1O81.

NOTE: Reconnectthe battery ground cable and turn

"CODE" is displayed,
the radioon. When the word
enter the customer's5-digit code.

MOUNTING NUT
44 N.m (4.5 kgt.m, 33 lbf'ftl
5. Removethe alternatorbelt from the alternatorpulley.

6. Removethe lower mountingbolt, then lift the alter-

nator upward.

23-104
w
 AlternatorOverhaul
CAUTION: Do not r€move th€ pulley unl€Esthe t.ont PULLEY
bearing needs r6placsm6nt.

To loosenthe pulley locknut, use 10 mm and 22 mm

wrenches.It necessary,use an impact wrench.

Test, page 23-107

SPACER RING
REAR BEARING 10 mm BOX WRENCH
PULLEYLOCKI{UT
rl 1 ' l l N . m 1 1 1 . 3k g t . m , 8 2 t b f . t r l
@n
FRONTBEARING STATOR/DRIVEEND
HOUStt{G

CAUTION: Do not get grease

or oil on the slip rings.

BBUSHHOLDER
INSULA
TOR

ARUSH HOLOER STATOR THROUGH

) BOLT
(@P
" VOLTAGEREGULATOR

%A
re
DIODEIRECTIFIER)ASSEMBLY PULLEYLOCKNUT
Test, page 23-106 111 N.m (11.3 kgt.m,82 lbf.ft)

REAR HOUSING

6
Inspection,page 23- q
TERMINALINSULATOR qt

fu"- "o*n.r"
-
".," BRACKET

23-105
GhargingSystem
Rectifier Test AlternatorBrushInspection

NOTE: The diodesare designedto allow currentto pass Remove the end cover, then lake oul the brush
in one directionwhile blockingit in the oppositedirec- holder by removing its two screws
lion. Each diode must be tested for continuitvin both
directionswith an ohmmeterthat has diode checking Measurethe length of the brusheswith a vernier
capability.Since the alternatorrectifier is made up of calioer.
'16
eight diodes(four pairs),there are a total of checks,
Aliornatol Brush Longlh:
1. Checkfor continuityin each ditectionbetweenthe Standard:10.5 mm (O.41 in)
B and P terminals,and betweenthe E (ground)and Servic. Limit: 1.5 mm (O.06 in)
P terminalsof each diode pair. All diodesshouldhave
continuity in only one direction,

VERI{IEBCALIPEB

lf the brushesare less than the service limit, replace

the b.ush holderassemblv.

lf any of the eight diodestails, replacethe rectifier

assembly.(Diodesare not availableseparately.)

23-106
 RotorSlip RingTest Stator Test
1. Checkthst there is continuity betweenthg slip rings. 1. Chockthat there is continuitybetweeneach pair of
l6ads.

ROTORSHAFT

cotl coRE

2 Check th8t there is no continuity betw€en the slip Ch6ck that there is no continuity between each lead
rings and the rotor or rotor shaft. and the coil core.

3 lf the rotor fails either continuity check, rsplace th€ lf th€ coil fsils eithercontinuitycheck. replacethe
alternator. alt6rnator.

23-107
ChargingSystem
AlternatorBelt Inspectionand Adjustment
Deflection Method: Boh Tsnsion Gaug6 Mothod:
Apply a force of 100 N (1o kgt, 22 lbJ)and measurethe Foltowingthe gauge manuJacturer'sinstructions,attach
deflection between the alternator and the crankshatt the belt tension gauge to the belt and measurethe
pulley. tension.

Detlsction:9-11 mm (0.35-O.43 inl Tension:340-49O N (35-50 kgl, 77-110 lbfl

NOTE; On a brand-new belt {one that has be€n run NOTE: On a brand-new belt (one that has been run
for lessthan five minutes),the deJlectionshouldbe for less than tive minutes), tension should be
6-8 mm 1O.23-O.32 in) wh€n first measured.lf 690-880 N (70-90 kgt, 154- 198 lbJ)when tirst
the belt is worn or damaged,replaceit. measured.lf the belt is worn or damaged,replaceit.

ALTERI{ATOR ADJUSTING NUT

24 .ln 12.4 kst'm, 17lbl'ft}

ALTER'{ATOR ADJUSTIT{G NUT

24 N.m {2.4 kgl'm, 17 lbl'ft1

MOUt{Tlt{G
NUT
44 t{.m (4.5 kgt.m,
33 tbf.ft)

PULLEY ALTEBNA oTJGG-0O1010A

lf adiustment is nocessarY: lf adi$tmsnt is nscaasary:

1. Loosenthe alternatoradjustingnut and mounting 1. Loosen the alternator adiusting nut and mounting
nur. nut.

2. Move the alternatorto obtain the properbelt tension, 2. Move ths ahernatorto obtain the properbslt tension,
then retighten the adjusting nut and mounting nut then retightenthe adjustingnut and mountingnut
to the specifiedtorques. to the specified torques.

3. Recheck the deflection ot the belt. 3. Recheckthe tension of the belt,

NOTE: lt necessary,adiust the P/S pump belt (see NOTE: lf necessary,adjust the P/S pump belt (see
section 17) and A/C compressorbelt lsee section section 17) and A/C compressor belt (see section
22t. 22t.

23-108
Fan Gontrols
ComponentLocationIndex
For the A/C system, see section 22.

RADIAIOR FAN REI.AY

Test, page 23-68

UNDER-HOOD CONDCNSER FAI{ BELAY

FUSE/RELAY
BOX lwir6 color3:ELKnirHT,WHTI
IBLUryEL,and BLU/BL( I
Test, page 23-68

ENGII{E
cooLA T
TEMPERATURE FAN MOTOR
{ECT) Test, page 23-112
SwlTCH
Tesr,page23-'l12

BADIATORFAN MOTOR
Test,page23-112

23-109
 FanControls
Circuit Diagram(WithoutA/Cl

- DAstl
ul{o€R
- HOODFUS€/REI.AY
UI{OER BOX GIINONSWITCH FUSC/RELAYBOX
No.4l{lmA, No.39l50Al 6r\ F'rrr^'l
.{
\-Y -l
ots YEt{<\o*r

ECM

Gtr{

l,*^,
($fffiHil'r"n.''
t?i'r?Tdf.ol
I

I
ffi,"'l
I
Btl(

II
:
G10l

23-110
FIIF.-
Gircuit Diagram(With A/Cl

- HOOO
UNOER FUSE/REIAY
BOX G FIONSWIICH

,5
No.41l100Al No.39l50At

RAOIATOR
FAN
REI.AY

GRt{

| ,*n,n,
,z*r CoOtAt{T
qU llffffarunErEcrr
t?i'i."1",i:"ol
I

monronI
FAN I
MOTOR
I
I
BI-K
I
II
:
G10l

23-111
Fan Controls
Fan Motor Test Engine Coolant Temperature (ECT)
Switch Test
1. Disconnectthe 2-P connectorfrom the fan motor. NOTE: Bleedair from the cooling system atter install-
ing the enginecoolanttemperature(ECT)switch (seesec-
2. Test the motot by connectingbatterypower to the tion 1O).
B terminal,and groundto the A terminal
1. Remove the ECT switch from the thermostat
3. lf the Jan motor fails to run smoothly, replaceit. housing.

NOTE: The illustrationshows the radiatorfan. 2. Suspendthe ECT switch in a containerof coolant
as shown.

Heatthe coolantand checkenginecoolanltempera-

ture with a thermometer.

Checkthe continuitybetweenthe A and B terminals

accordingto the table:

Terminal
\ B
;;,".,"---\

Above196 2O3"F
o_ -o
{91-95'C)
Switch
B e l o w1 8 1 - 1 8 9 o F
(83-87'C)

23-112
GaugeAssembly
ComponentLocationIndex
CAUTION: (C61'iostho SBS indicator signal)
a All SRS electrical wiring harnossesare cov€rod with
yellow insulation.
a Bofore disconnecting any prn ot th€ SRS wire har-
ness, connect tho short connector(sl.
a R€placeth6 entirs affGctedSRS halne$ assembly if
it has an open circuit o? damaged wiring.

SRS MAIN HARNESS

{Cov.r6d with yollow inrularionl

GAUGE ASSEMBLY
GaugeLocationIndex,page 23-114 FUEL GAUGE SENDINGUNtT
IndicatorLocationIndex,page 23-114 Test, page 23'124
TerminalLocationIndex,page 23-114 Repfacemenr,page 23-124
Bulb Location.page 23-'l 15
Disassembly.page 23-119
Removal,page 23-118

VEHICLESPEEOSENSOBIVSS}
Test, page 23-120
fnput Test. page 23-120
Repfacement,page 23-122

PARKITTG BRAKESWITCH
Test, page 23-127

BRAKE FLUID LEVELSWITCH

Tesr, page 23-127

EI{GINEOIL PBESSURESWITCH
Test, page 23-122

ENGINECOOLANTTEMPERATUREIECTI GAUGE
SENOINGUNIT
Test, page 23-126

23-113
 GaugeAssembly
LocationIndex
Gauge/lndicator/Terminal
CAUTIOI{:
a All SRS olectrical wiring harnessosaro covorod with
yellow insulation,
Belol€ disconnecting any part ot tho SRS wiro hat-
nesa. connoct the short connoctol(El.
Replacoth6 entire aff6cted SRS hamess sssombly lf
it has an open circuil or damagod widng.

"8"
CoNNECTOR (c5601
co r{EcroR"c" (c558}

Bi ----------+ B16 Cl ----+ClO

A/T GEARPOSIT|O
IIDICATOR SYSTEI
Seepags23-132

TACHOMETER:
FUEL GAUGE: Indicatos lOO rpm at
GaugeTest, page 23-123 20O puls€s per minul€
Sending Unit Tost, page 23-124 of the ignition control
modul€llCM).

f',. /i)
)Y
- " b \-___--
\_./ \J

E GI[{E COOLAI{TTEIIPEFATUREIECTI
c6uge TEst, p6g6 23-126
a1 -----> A5 Sending Unit Tsst, pago 23-126

Dl-------.>D13

SPEEDOMETER:
Indicates (60 mph 6i 1025 rpml or
{60 km/h at 637 rem) of th€
v€hicle spe6d sonsor lVSSl.

"A" (C557)
coNNECfOR
col{]{ECTOR"D" (C5591

23,-114
rtrF --
 BulbLocations

HIGH BEAM INDICA L|GHT{r.4 Wl

LEFT TURI{ SIGNAL INDICATORLIGHT II.4 WI

RIGHTTURN SIGNALINDICATORLIGHT(I.4 W}
CHARGINGSYSTEMLIGHTII.4 WI

BBAKESYSTEMLIGHT(1.4 W)

SEAT BELTREMINDER
LIGHTI1.4 WI

INDICATORLIGHT{1.4 WI
OOOR-OPEN POSITIOIII]{DICATORLIGHT (1.12 W x 7l

LOW EI{GII{EOIL PRESSURE

TOBLIGHT11.4WI

MALFUI{CTIONINDICATORLAMP
(MrLl fi.4 wt
iSRS INDICATORLIGHT(1.4 W}

LIGHTS
LOW FUEL INDICATORLIGHT {3.4 WI MAINTENANCE
REMINOER
{3.4 W x 3} LIGHTIT.4 WI

cRutsE LTGHT
tl.4 Wl

ABS INDICATORLIGHT(1.4 W}

TAILGAT€-OPENINDICATORI-IGHT{1.4 W): Harchback

TnUNK-OPENINDICATORLIGHT 11.4 W): Sodan

*: On the SRS printed

circuit board

23-115
GaugeAssembly
GircuitDiagram

r3 [o.24 ll5 ): 81E81dttr

10,24120 ):B1&1.mir ulocn-DsH
&X
RISC/RELAY

Tw'lcu I
+ 3r,4ts.
r
t_gstr
sas
tNtT FUSE I
l{l(

I
T A
:
6t0l

sns
txocAloR
UGTIT [fffi"vv

.lsffiisl
{,MT

VI
- r Gin&no
".lJ
r l
GMVn!O I C,afi/ilD

#n ir ll N'ElGAI.EE
sExDr6 ulllT
I RUNIiITGI
I uGfiTs \ r l a{G|l|€
l8flfl*';
-"
i| \()n c@lat{T
Il$EiA'l il
tErcTt
SAdTG
ht0/Git{ | | snrxt txt

I
Gn[/Ft0
. r I Rlp
ir |ffi.
l
6mii'
I
Itrr
r l
it A
- :
r6ii G30r

23-116
IIFT fircll r |l{rE|Arcc stAT Et T M Ut[CrOrl nooB-oPEtl
TURt{ E€AT Sfn 0ER 6tc|l|€ Oh. gIDEN OG TOi fptc^Ton
stcll L lotc ToR ucfir mEssunr IJGHT TIGHI
DtCATOn TIGHT [oic Toi txtu
UGHI IIGHT
.,tlvt
tt,4w)
' I|
. _ l
B1 a2

HflHh*'F:

€trtc[iE
olL
FnISSUNE
I
OFVEFS
SCAT*LT
6
1-
s1vlrcH slvtTcH

:
G501
G502

23-117
GaugeAssembly
Removal

CAUTION: Tilt the steeringwheel down with the tilt adjustment

a All SRS electrical wiling harnessesara cover6d with tevet.
yollow insulation.
a Eofore disconnecting any part ol the SRS wiro har- Removethe three mountingscrews, and spreada
n6ss, connoct lhe short connector(sl. protectivecloth on the steeringcolumn.
a Roplacetho entirs affocted SRS harneasassembly if
it has an open circuit 01 damaged wi.ing.

lcarrio. tho SRs indicolor 8ignal)

CLOTH
PROTECTIVE

Prythe gaugeassemblyout, and disconnectallcon-

nectorsfrom it.

SBSMAIN HARI{ESS
(Covor6dwith Yollowin.ulationl

1 . Removethe two screwslrom the instrumentpanel.

2 . Removethe instrumentpanel.

NOTE: Remove the instrument panel careJully

without damagingthe cliPs.

CLIPS
GAUGE ASSEMBLY

o. Take out the gauge assembly as shown.

23-118
 Disassembly
NOTE: Handlethe terminalsand printedcircuit boardscaretullyto avoid damagingthem.

MOUI{TINGSCREW(x 3l
TAGHOMETER

SPEEDOMETER
MOUNTTNG
SCREWtx 4l ENGINECOOLA]TT
TEiIPERATURE
{ECT}
GAUGE
MOUNTING SCREW(x 3)

-
k)T
n
FUELGAUGE UNIT
Test, psge 23-123

. SPEEDOMETER
Specilication, pa96 23-1 14
Troubfeshooting. page 23-1 20
. ODOMETER
Troubleshooting,page 23-1 20
. TRIP METER
Troubfeshooting,page 23-120

23-119
Speedometer/TripMeter/Odometer
Troubleshooting

NOTE: The numbersin the table show the troubleshootingsequence.

Item to be inspected

:
-9 lt)
a

o
E
; 6 o q)
+* 6
c.r i '
. ( D
E E
z c E qlv
* f 'i
F
-9
;5 o
9 c o
Symptom d)= a (L > g

Odometerand trip meter wotk, but speedometerdoes 1 2

not.
works, but odometerand trip meter do
SDeedometer
nor, 1

Speedometer.odometer,and trip meter do not work.

VSS Input Test (At ham€ss side of 3-P connector)

No. Wir6 Tost condition T€st: Desirsdresult Possiblecause it result is not obtained
Under all conditions Check for continuityto ground: . An open in the wire
1 BLK . P o o rg r o u n d( G 1 O 1 )
There should be continuity.
lgnition switch ON (ll) Check tor voltageto ground: Blown *No. 24 fuse in the unde.-
There should be battery dash tus€/relay box
BLK/YEL voltage. Short to ground
An open in the wire
lgnitionswitch ON (ll) Check for voltageto ground: . Shon to ground
ORN . An open in the wire
There should be about 5 V.
NOTE:A shortto groundin the ORN wire can be causedby a short in any componentconnectedto lt.

vSS Tost
Speedometerdoes not work. 3-P CONNECTOR

Inspect'No. 24luse in the under-

dash tuse/relay box belore
testing.

Turn the ignitionswitch ON lll).

Measure voltage between the

BLK/YEL wire terminal and the
8LK wire terminalin the harness
side of the 3-P connector.

{To next page) 2 4 ( 1 5 A ) : 8 1 8 8 1 e n g i n e N o . 2 4 { 2 0 A ) : 8 1 8 C 1e n g i n e

23-120
 {From previous page)

ls there battery voltage? Check tor continuity between the

BLK terminaland body ground.

Measure voltage between the Ropair opon belw€on

ORNand the BLKwire terminals. VSS and groundG101.

Ropairopon in tho BLKrYELwiro

ls there about 5 V?
botwoen VSS and undor-dssh
luse/rolay box.

Ropair op6n in th6 ORN wire or

Raisethe tront of the car and sup-
port it with salety stands. shon to body ground.

Touch a probe to the ORN wire

and connect at to body ground
through a voltmeter.

Putthecar in neutralwithkevON.

Slowly rotate one wheel with the

other wheel blocked.

Does voltage pulse from O to Roplac. tho VSS {see page

about 1O V? 23-1221.

Touch a probe to the ORN wire

and connect it to body ground
througha voltmeter.

Slowly rotate one wheelwith the

other wheel blocked.

Ooes the meter indicate Ropairopon in th6 OBil wire bo-

pulsingvoltage? tween tho VSS and th6 3p.odo-
molgt.

23-121
 EngineOil Pressure
VehideSpeedSensor(VSSI IndicatorSystem
Replacement EngineOil PressureSwitch Test
Disconnectthe 3-P connectortrom the vehiclespeed 1. Removethe YEL/REDwile from the engineoil pres-
sensor{VSS). sure switch.

Remove ihe two mounting bolts, then remove the

VSS.

ENGI'{EOIL PRESSURESWITCH

TERMII{AL
POSITIVE

Check tor continuitv between the positive torminal

and the engine{gtound)with the ignhionswhch OFF.

a lf there is continuity,go to step 3.

a lf there is no continuity, replace the switch.

Check for continuity again, this time with th€ engine

InstSll in the revsrse order of removal. runnrng.

NOTE: The VSS drive link is a very small paru a lf there is continuity,go to step 4,
caretul not to lose it. a lf there is no continuity, the switch is OK.

Make sureengineoil levelis OK, then checkengin€

oil pressure (s€e section 8).

a lf engineoil pressureis OK, replacethe switch'

a lf engineoil pressureis low, checkthe sngineoil
pump (seesection 8) and, if necessary,replac€it.

23-122
nlmlliitl
FuelGauge
GaugeTest
NOTE: Referto page23-1 16 for the luelgaugesystem o. Turn the ignition switch OFF. Attach 8 jumper wir€
circuit. between the BLKA HT and YELMHT terminats.
'1. then turn the ignitionswitch ON 0l).
Check the No. 15 {1O A) fuse in the under-dash Check that the pointer of the fuel gauge starts mov-
fuse/relaybox beforetesting. ing toward the "F" mark.

2. Removethe rear seat (seesection 2Ol. CAUTION: Turn th€ ignition switch OFFboforo the
pointer roachas "F" on tho gauge dial. Failuroto do
3, Removethe protective cover and access DanelJrom ao may damage tho fuel gauge.
the tloor.
NOTE: The fuel gaugeis a bobbin(c.oss-coitltype
4. With the ignition switch OFF, disconnectthe 3-p gauge.hencethe tuel levelis continuouslyindicat-
connectotfrom the fuel gauge sendingunit. ed even when the ignitionswitch is OFF, and the
pornter moves more slowly than that of a bimetal
PROTECTIVE rype gauge.

a lf the pointerof the fuel gaugedoes not move at

all, replacethe gauge.
a lf the gaugeis OK, inspectthe {uel gaugesend-
ing unit.

Connect the voltmete. positive paobe to the

YELMHT terminal and the negativeprobe to the
BLKMHT terminal,then turn the ignitionswitch ON
(ll). Thereshould be between 5 and 8 V.

a lf the voltage is as specified.go to step 5.

a It the voltage is not as specified,check for
- an open in the YEL/WHT. BLU/WHT or
BLK/WHTwire.
- poor ground (G5O2).

23-123
FuelGauge
SendingUnit Test/Replacement

@ oo not lmoke while working on tho fuol 5. Measurethe resistancebetween the A and B termi-
system. Kaop open flamos away from your wotk aroa. nalsat E (empty),1/2 (halffull) and F (full)by mov-
ing the tloat.
1. Remove the rear seat (see section 2O).
Float Position E
2. Removethe protective cover and accesspanel lrom Resistance lO) 1 0 5 - 1 1 0 25.5-39.5 2-5
the floor.

3. With the ignition switch OFF, disconnect the 3-P 6. Check the change in resistanceby moving the float
connector from the fuel gauge sending unit. uo and down.

4. Removethe tuel gauge s€ndingunit.

lf unableto obtain the above readingsor it resistance

do€s not change,replacethe fuelgauge sendingunit.

23-124
 Seat Belt Reminder
Low FuelIndicator System
IndicatorLight Test Seat Belt Switch Test
NOTE: Reterto page 23- 1 16 tor the wiring description 1 . Slide the driver's seat to the middle position, then
of the low fuel indicatorcircuit. disconnect the 2-P connector Jrom the back ot th€
sear.
1. Park car on level ground.
2 . Check for continuity between the A and B terminals
@ oo not rmoko whil6 working on th€ in each conditionaccordingto the table.
fuol system, Keop op€n llamg3 awsy from your work
area. Drain fuel only into an approvod container,
Terminal
\
A B
Drain tuel into an 8pplov€d container. Then install C"** \
the drain bolt with a new washer.
UNEUCKLED o-- o
J. Add lessthan 8.2 t (2.2 U.S.Gal,1.8 lmp.Gal)of fuel
BUCKLED
and turn the ignitionswitch ON (ll).The low fuel in-
dicator light shouldcom€ on within lour minutes,

a lf the light does not come on, remove the access

Daneland disconnect the 3-P connector from the
fuel gauge sending unit, Connect the A
(BLKMHT) terminal to the C (BLU/WHT)termi-
nal with a iumper wir€.
- lf the light comeson, the problemis eitherthe
sendingunit or its ground.
- lf the light does not come on, the problemis
an openin the BLU/WHTwire to the gaugeas-
sembly, no power to the gauge, or a blown
bulb.

a l f t h e l i g h t c o m e s o n , a d d a p p r o x .4 , { 1 . 1
U.S.Gal,O.9lmp.Gal)ot tuel, the light shouldgo
ofJ within four minutes.

ANCHOR
3-P CONI{ECTOB

NOTE: Befer to page 23-146 for the seat

reminderinout test.

3. lf necessary.replacethe seat belt switch.

View lrom wire side

23-125
EngineCoolantTemperature(ECTIGauge
GaugeTest ECT Sending Unit Test

NOTE: Referto page 23-116 fot the wiring description
oJ the enginecoolant temperature(ECT)gauge circuit
diagram.
1. Check the No. 15 (10 A) fuse in the under-dash
tuse/relay box before testing.
Disconnectthe YEL/GRNwire from the ECT send-
ing unit.
With the enginecold, use an ohmmeterto measure
resistancebetween the positiveterminal and the en-
gine (ground).

2. Make sure the ignitionswitch is OFF,then discon-

nect the YEL/GRNwire from the ECT gaugesend-
ing unit and g.ound it with a jumper wire.

TERMINAL
POSITIVE

Check the temperatureof the coolant.

Runthe engineand measurethe changein ,esistance

with the engineai operatingtemperatu.e{the radi-
ator tan comes on).

J. Turn the ignitionswitch ON (lll.

Check that the pointer of the ECTgaugestarts mov- 185.F(850C)-
Temperatu.e 1330F(560C)
ing toward the "H" mark, 2 1 2 0 F( 1 0 0 0 c )
't37 46-30
Resistance(O)
CAUTION: Tuln th6 ignition switch OFF botore th€
point reaches "H" on tho gaugo dial. Failuroto do
so may damago tho gaugo. 5. ll the obtainedreadingsare substantiallydifferent
Jromthe specificationsabove, replacethe ECTsend-
a It the pointerof the gaugedoes not move at all, ing unit.
check Jor an oDenin rhe YEL or YEL/GRNwire.
lf the wires are OK, replscethe ECT gauge.
a It the ECT gauge works, test the ECT sending
untt.

23-126
BrakeSystemlndicator
ParkingBrakeSwitch Test Brake Fluid Level Switch Test

Removethe tloor console, and disconnect the con- Removethe reservoircaD.

nector from the switch.
Check for continuity b€tween the positive terminal
and body ground in each lever position accordinoto
the table.
Check that the tloat moves up and down freely, if
it does not, replacethe reservoircap sssembly.
Chsck for continuitv between the terminals in each
float positionaccordingto the table.

Torminal
POSITIVE EODY Terminal
L6vorposition POSITIVE NEGATIVE
Floatposition
UP
UP
DOWN
DOWN -o

POStTtVE

CAP
RESERVOIR DOWN POSITION

TERMINAL when float drops.

Canada:
lf the parking brake switch is OK, but ths brake sys-
tem indicator does not function, pertorm the input
test for the daytime running lights control unit (see
p a g e2 3 - 1 5 6 ) .
Switch contacts open at
proper fluid level.

4. lf necessary,replacethe reservoircap assemblv.

23-127
MaintenanceReminderS ystem
Gomponent Location Index

CAUTION:
a All SRS eloctrical wiring haln€sses are coveled with
y€llow insulation.
a Bsfore disconnocting any part of the SRS wire har-
ne6a, connect tho shon connoctor(s).
a Replacethe entire affoctod SRS hsrness ass6mbly if
it has an open circuil or damag€d wiring.

MAINTENAf{CEREMINDERLIGHT
(ln th6 gaugo 63.smblyl
GaugeAssembly.page 23-113

VEHICLESPEEDSENSOR{VSS)
MAINT
{On the t.ansmirsion houaingl
Test, page 23-120, 121
REOD
Input Test, page 23-120
Repfacement, page 23-122

MAINTENANCEREMINDERUNIT
lBohind tho dashboard lowor covor)
Input Test, page 23-131

23-128
 Description
Basedon signalsrecaivedtrom the vehiclespeedsensor (VSS),the microcomputerin the maintenanceremande,
unit,
which is located behind the dashboardlower cover, computes the distances traveled. When you turn the ignition switch
on, the reminder light in the gauge assembly will come on for two seconds (bulb check tunction).
Ar 9,650 t 160 km (6,000 t lOo miles)intervals,the reminderlight witl gtow for two secondsand then btankten
sec-
onds att€r you turn the ignitionswitch on. This will repeateverytime you turn the ignitionswitch on until the car reaches
12,O7O! 160 km (7,500 1 10O mites).
Beyondthe 12,O7O! 160 km (7,500 t IOO mite)interval,the tight will continuero gtow after the butb check until
you turn the ignition switch off or reset the unit.
To reset the unit, the car must be pa.ked and the ignition switch must be on. Pressthe reset button on the unit for mo.e
than three seconds,and the remindertight will go otf.

NOTE:
a Turn the ignitionswitch OFF b€foreyou r€movethe 5-P connectorfrom the maintenancereminderunit.
otherwise
you will cancel all data in the memorv.
a The data will remainin the memoryeven when the ignitionswitch is turned ofJ, or if the unit is disconnected.
When
the ignitionswitch is turned on, and the car is driven. additionaldata will be stored.

sEt{son
tvss

-----------------l
MAINTENANCEREMINDENUN|T

23-129
Maintenance
ReminderSystem
CircuitDiagram
UNDER-HOOD
FUSE/REIAY
8OX

MAINIET,IAT,ICE
REMINOER
UiIIT

23-130
 MaintenanceReminderUnit Input Test
1 . With the ignition switch OFF, disconnectthe 5-P
connectorfrom the reminderunit,

Inspect the connector and socket terminals to be View trom wire side
sufe they are all makinggood contact.

a lJ the terminalsare bent, looseorcorroded, repair

them as necessary,and recheckthe svstem.

a It the terminalslook OK, make the following in-

Put tests at the connecto..
- lf a test indicates a problem, tind and correct
the cause,then recheckthe system.
- It allthe input tests proveOK, the reminderunit
must be taulty; replace it.

No. Wire Tost condltion Test: DaEiredrasult Possibl€cause if result is not obtained
Unde. all conditions Check for continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 O 1 )
I BLK . An open in the wire
Thereshould be continuitv.
Under all conditions Check tor voltageto ground: . B l o w nN o . 3 2 ( 7 . 5 A ) f u s e i n t h e
WHT/BLU There should be battery voltage under-hoodtuse/relaybox
. An open in the wire
lgnitionON (lll Check for voltageto ground: . B l o w n N o . 1 5 ( 1 OA ) f u s e i n t h e
YEL There should be batte.y voltage under-dashfuse/relaybox
. An open in the wire
lgnitionON (ll) Connectto body ground; The B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e
reminderlight shouldgo on. under-dashfuse/relaybox
4 PNK
Blown bulb
An open in the wire
lgnition ON {ll), car in Check for voltageto g.ound: . Faulty vehiclespeed sensor (VSS)
neutral with lront ol Meter should indicatepulsing . An oDenin the wire
E ORN car raised,one wheel voltage.
rotated with other
wheel blocked

23-131
A/T GearPositionIndicator
ComponentLocationlndex
cAUTtOt{:
a All SRSolectdcalwiring harnossos
a16covarodwith
yellow insulation.
Boforo disconnocting any part ot the SRS wlr. har-
noaa, conngct the short conn6ctor(sl.
Roplacotho entire aff6ct6d SRS harn$s assombly il
it has an op6n cilcuit or damagod wiling,

SRS MAIN HARI{ESS

(Cov.rod whh ygllow io.ul.tlonl

GAUGE ASSEMBLY
Bemoval,page 23-118
Disassombly,pag€ 23'1 19
Bulb Locations,pago 23-115 A/T GEARPOSITION
IiIIERLOCK SYSTEM IlTDICATOR
page 23-139
DGscription. InputTest,pago23-134

A/T GEAR P('SITIOI{ SWITCH

Test, page 23-136
ReDlacement,6ection 14

23-132
CircuitDiagram

IGNITION UNOER-OASH
UNOER_HOOD
FUSE
/ REI.AY
8OX swrTcH FUSSREI-AY
8OX

/-?t CH- ftrt*l

wHT/BLX
+wHT+
\ty "l
Bl.x/Y€t-+<.\-o+!

No.19ll0A)
FUSE

I
YEL
TMI{SMrSSr0r,l
c0IJTRor
i.IODULE
ITCMI
lln thogtugo8ls€mbvl D4 fitMritc-;-
CANCEL lgll

AN GEAR
POSITION
INDICATOR
DIMMING
CIRCUIT
t
YELTWHTGRN/8L|(
l

t
INTERLOCK
. _
II
l
TRANSMISSION
coMtRot MODU|.! [TCM}
UNJ]_

I
GRT'IMHT o*nn,o_yTT
pr{x/cR1
-J
No.19
{l
I
GR €|-U -l
FUSE
V GRiITYEt

I LTGNNiW{T

A/TGEAN
POStTt0N
coNsot-E
LIGHT
0.4w)

M GEAR
PosrTroN
swncH
I
DASHI-IGHTS
BRIGHTNESS
CONTROI.IER
I
G201
G40t
G2ol
G401

23-133
A/T Gear PositionIndicator
Indicator Input Test

CAUTION:
a All SRS electrical widng harn6ssosara cov6r6d whh
yellow insulation.
a Before disconnecting any part ot the SRS wiro hEr-
ness. connect the shon connoctolls).
a Replacethe entire affectod SRS harnosr assombly il
it has an op€n circuit or damaged wiring.

Removethe gauge assemblyfrom the dashboard(see

page 23- l 18), and disconnectconnectors"8", "C" and
"D" from it. lnsoectthe connecto.terminalsto be sure
they are all makinggood contact.

a lf the terminalsare bent. looseor corroded,repairthem

as necessary,and recheckthe system.
a lf the terminalslook OK, makethe following input tests
at the connector.
- lf any test indicatesa problem,find and corect the
cause,then recheckthe system.
- lf all the input tests prove OK, the gaugeassem-
bly must be taulty; replaceit.

"8"
CONI{ECTOR

SS

23-134
CONNECTOR"D": Visw from wire side ot femals
tetminals

No. Wila Test condition Test: D€sirod rasult Possiblecause if result is not obtainod
Under all conditions Check for continuityto ground: . P o o rg r o u n d( G 2 O 1 G
, 4O1)
BLK
There should be continuitv. . An open in the wire
lgnitionswitch ON {ll} Check for voltageto ground: . B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e
2 YEL There should be battery voltage. under-dashfuse box
. An open in the wire

CONNECTOR"8": View from wire sid6 of fem.l6 RED/BLK

i6lminals

No. Wile Tost condition Tost: D€sir6d result Possiblocause if result is not obtained
Combinationlight Check for voltage between . Faulty dash lights b.ightnesscontrol
RED/BLK
switch ON and dash RED/BLK and RED terminals: system
1 ano
lights brighlnesscontrol There should be baftery voltage. . An open in the wire
RED
dial on full bright

GRNA HT GRNITEL
YELAA'HT GRN/BLK
CONNECTOR"C": Vi3w lrom wire sido of temale
t6rminals

No. Test condition
Shift lever in position@
GRN^^/HT NOTE:Don't pushthe
brakepedal.
GRN/RED Shift lever in position@
Tost: Desirod r6sult
Check for continuityto ground:
Thereshould be continuitv.
NOTE:Thereshould be no
continuity in any other position.
Possiblecause it result is not obtained
Faulty A/T gear positionswitch
Poor ground
An open in the wire

GRN Shift lever in positionS

GRN/BLU Shitr leverin position@
GRN/YEL Shitt lever in positionf2 ]
LT-
Shift lever in positionE
GRNMHT
lgnitionswitch ON (ll)
and shift lever in any
positionexcept @
2 GRN/BLK
lgnition switch ON (ll)
and shitt lever in any
positionexcept @
3 YEL/vVHT
lgnitionswirch ON {ll}
LT.
4 Thereshould be mofe than 5 V
GRN/BLK
Check for voltageto ground:
There should be battery voltage
for two seconds after the
ignitionswitch is turned ON,
and less than 1 V two seconds
later.
Check for voltage to ground:
There should be less than 'l V
tor two seconds after the
ignitionswitch is turned ON
and more than 5 V two
secondslater.
Check for voltageto ground:
. Faultyt,ansmissioncontrol module
(TCM)
. An open in the wire
. Faultytransmissioncontrol modute
(TCMI
. An open in the wire
. Faulty transmission control module
ITCM) or ECM
. An open in the wire

23-135
A/T GearPositionIndicator
I I gear
A/T Gea Position I esr -
Switch Test
Fosluon Dwtrcn

1 . Removethe console.then disconnectthe 14-Pcon-

nector from the switch.

2 . Checkfor continuitvbetweenthe terminalsin each

positionaccordingto the table.
tgrminal
90e
a Move the lever back and forth at each position
without touchingthe pushbutton,and checktor
continuity within the rangeof free play.
a lf there is no continuitywithin the.ange of free
play, adjustthe installingpositionol the switch
as describedon the next page.

14-P CONI{ECTOR

Back-up Noutrrl
A/T Goar Position Swhch (Without crulso contloll Ught Swhch Polition Swhch
Terminal
\ B F N M D K
P*ii-_\

tr o-
a o- --o
E o- --o
E o-
N o- -.o o-
tr o- -o o- --o
tr o- --o o- --o

Back-up t{outral
A/T Goar Position Switch (With cruiss controll Llght Swltch Potidon Swltch
Terminal
\ _\ 6 N M D J K
P*,i-

tr o- --o
a o- --.o
E o- --o
E --o
E G_ o-
E o- o- --o
E o- --o o- --o

23-136
 A/T GearPositionSwitch A/T Gear Position Switch
Replacement Adjustment
Removethe console, then disconnectthe 14-P con- 1. Shift to the ill position,and loosenthe nuts.
nectof from the switch.
2. Slide the switch in the direcrionof E position
Remove the two console switch mounting nuts. [within2.Omm (O.079in.)lso that thereis continuity
betweenthe "A" and "L" terminalsin the ranqeof
free plsy oJ the shiJt lever.

swtTcH 3. Recheckfor continuity between each ot the ter-

SHIFTLEVER
minals.

NOTE:
a lf adiustmentis not possible.check for damage
to the shiJt lever detent and/or the bracket. lf
there is no damage,replacethe consoleswitch.
a The engineshouldstart when the shift leveris in
position LN] in the range of free play.

LOCKPIN

Positionthe switch sliderto "Neutral" as shown

above.

4. Move the shift lever to then slip the

switch into position.
@ porition
Attach the switch with the two nuts.

Test the switch in the @ and E] position ot the shift

lever.The engineshouldsta.t when the shift lever
is in position p anywhere in the range of free play.

Connectthe 14-Pconnector,clampthe harnessand

installthe console.

NUTS

23-137
Interlock System
ComponentLocationIndex

All SRS electrical wiring harnass€sare covered with

yallow insulation.
Before disconnecting any part of the SRS wire har-
ness, connect the shon connector(sl.
Replacethe entire affected SRS halness ass€mbly it
it has an open circuit or damagedwiring.

INTERLOCK SRS MAI[{ HARNESS

CONTROL lcovorod with yellow insulstionl
UNIT
fnput Test, page 23-141

KEY INTERLOCKSOLENOID
snd KEY INTERLOCKSWITCH
(ln the steeringlock assembly)
Test, page 23-142

SHIFT LOCK SOLENOIO

Test, page 23- 143
Repfacement,page 23-143

23-138
 Descraption
The car is squippod with thq following dovlc6. to prevont inadvoft.nt shitting:

a A/T selector with shift lock

a Key cylinder with interlocked ignition key

Shift Lock Syst6m;

The shitt lock system prevents the shift lever from moving to
@ or lDil from the @ position unless the brake pedal
is depressed and the accelerator is in its rest oosition.

NOTE:
a The shift lever cannot be shifted when the brake pedsl and the accelerator are depressed on at the same time.
a In case ot system malfunction, the shift lever can be releasedby pushing a key into the releaseslot near the shift lever.

Koy Ints.lock Systsm:

The ignition key cannot be removed from the ignition switch unless the shil-t lever is in the
E position
When the shift lever is in any position other than @, a sol€noid is activated, making it impossible for the key to be re-
moved until the shift lever is moved to the llj position.

Th€ shift lever is in the E position.

SOLEI{OID
ON: LOCK KEY CYLINDER
OFF:UNLOCK

The shift lever is in any position except pl .

II{TERLOCKLEVER swtTcH

23-139
lnterlockSystem
CircuitDiagram
NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem (tor examplg,
GRNMHT 1 and GRNMHT 2 are not the same).

-HOODFUSE/REi.AY
UNOER BOX

N0.41(1OCA)
No.39l50A)
W}IT/BLK+WHT

WHT/GRN

THROTTLE
POSITION
ITPI
SENSOR

I
Y I ^'v"'
i I
if,f,trfi

,
IN/vt,H]
I
l......................_GRNA,t/r{rz1
/r\ S'ftiei
f lJlT,ll*n""n,

23-140
 ControlUnit Input Test
Oisconnectthe 8-P connector from the interlock control
unit. Check for good contact between the connectorand
socketterminals.lf the terminals8re OK, make Iollow-
ing input tests at the connector.lf all inputtests are OK,
but the problemremains,replacethe cont.ol unit,

NOTE: lf the shilt lock solenoidclickswhen the ignition

switch is ON and the brake pedal is pushed (shift tever
is in lfl position, acceleratoris in rest position), the shift
lock system is electronically normal; test the A/T gear
positaonswitch as described on page 23- 134.

Shift Lock Sy.tem:

No, Wlr6 Tost condition Tost: Dosiredresult Possiblocause if rssuh is not obtainod
lgnitionswitch ON (ll) Check for voltage to ground: Blown No. 41 (15 A) fuse in the
Brakepedal pushed There should be bsttery voltage under-hood fuse/relay box
Faulty transmission control module
'I (TCM}
wn t/hEu
lgnitionswitch ON I [ ) , Check for voltage to ground: Faulty ECM
brske pedal and There should be less than Faultv brake switch
accelerator pushed at battery voltage. Faulty throftle position lTP) sensor
the same time An oDen in the wire
Shift lever in @ Check lol continuity to ground: Faulty A/T gear position switch
GRN^/vHT' There should be continuity. Poor ground {G201, G401}
An oDenin the wire
lgnitionwitch ON (lll Check for voltageto ground: Blown No. 15 (10 A) luse in the
There should be battery voltage under-dashfuse/relay box
YEL/BLK
Faulty shift lock solenoid
An oDenin the wire

Koy Intodock Systam:

No. Wire T6st condition
Under all conditions
BLK
Shift lever in position
2 E
lgnition switch tu.ned
to ACC (ll 8nd the key
3 WHTAYEL pushedin
lgnition switch turned
to ACC (ll and the key
4 WHT/BLU pushedin
T6st: Desiled reault
Check for continuity to ground:
There should be continuitv.
Check for continuityto ground;
Ther€ should be continuity.
Check for voltage to ground:
There should be battery voltage
Check tor voltage to ground:
There should be batery voltage,
Possible caure if rosult is not obtainsd
. Poor ground (G2O1,G4O1)
. An ooen in the wire
Faulty A/T gear position swirch
Poor ground (c2O1, G4O1)
An oDenin the wire
Bfown No. 42 l2O Al fuse in the
under-hood tuse/relay box
Faulty steering lock assembly
(kev interlock solonoid)
An oDenin the wire
Bfown No. 42 l2O Al fuse in the
under-hood fuse/relav box
Faulty steering lock assembly
(key interlock solenoid)
An oDenin the wire

23-141
Interlock System
Interlock Dorenoro
Kev IntenocK
Key I esr -
Solenoid Test

CAUTION: 4. Checkfor continuitvbetweenthe terminalsin each

a All SRS electrical wiring harnessesar€ covered rYith switch positionaccordingto the table.
yollow insulation.
a 8eforc disconnecting any pan of the SRS wire har-
ness. connecl tha short connoclol{s|.
a Raplacethe ontire affected SRS harness assembly if
it has an opon circuit or damaged wiring,
\______________rry
Position
7

lonition
Koypush€din o- --o
S hchAcc r
KoyroleEsod --o
* : l5-20ohms

5, Checkthat the key cannot be removedwhen the bat-

tery is connectedto the No. 6 8nd No. 7 terminals.

a It the kev cannot be removed, the key interlock

solenoidis OK.
a lf the key can be removed, replace the steering
lock assembly(key interlock solenoidis not avail-
{Covorod with yollow inlulrtionl able separately).

1 . Removethe dashboardlower cover

Removethe knee bolster.

Disconnectthe 7-P connectorfrom the main wire

narness.

23-142
 Shift Lock Solenoid Test/Replacement

Removethe console,then disconnectthe 2-p con-

neclor oJ the shift lock solenoidfrom the main wire
harness.

NOTE: Do not connectpowe. to the B { - ) terminat

(reversepolarity)or you will damsgethe diode in-
side the solenoid.

Connect battery power to the A terminal,groundthe

B terminal momentarily. and check solenoid
oDeralron.

Replace.
9,8 N.m {1.0 kgl.m,
7.2 tbl.hl
5. Check and, if necessary,adjust the solenoid'spo-
sition.

a When the shift lock solenoidis ON, check that

there is a clearanceol 2.5 1 O.5 mm {O.O98I
O.O2Oin) between the toD rear corner ot the shift
lock lever 8nd the lock pin groove,then tighten
the selflocking nuts.

NOTE: Use new self-lockingnuts.

2.5 t O.5 mm
{0.098 t 0.020 inl

SHIFT LOCK
LEVEB

a lf the solenoiddoes not operate,replaceit as

describedin steps 3,4, and 5.
a lJ the solenoiddoes operate, check and, if neces-
sary, adiust its two positionsas shown in step 5. LOCKPINGROOVE

a a When the shift lock solenoidis OFF,make sure

Removethe shift lock collar and the solenoidpin.
that the lock pin is blocked bv the shift lock lever.
Removethe selflocking nuts and shift lock solenoid, LOCK PIN LOCK PIN
then installthenew solenoidin the reverseotderot GROOVE
removat.

23-143
IntegratedControl Unit
Circuit Diagram

D.3c ptlon
An integrat€d control unit, located in the left kick panel, integratss the functions of tho keyin/seat beh r6mind€r, sido
markar light {lasher, wiper/washer, lights-on r6minder, rear window dsfogger timer, brak€ system light bulb check, and
enging oil pressure indicator flasher circuitE,

NOTE: Difforent wires with the same color have be6n given a numbor suffix to distinguish them (for Example,
GRN/RED1 and GRN/RED'are not the same).

HOOD
UNOER- FUSE/RELAY
8OX

- DASHFUS€/RETAY
UNOER BOX

Ir l
WIPER/
WNOSHIELD
WASHER
SWITCH I
I I
IMT OFFiINT
I
I
I
I t r 3 t-0w
I ErGrilE
0|l
I r 8 PRESSI'RE
I r e INDICATOR
I P l i LIGI{T
I t ;
I r B
I t 5
I I r COI{TROI
NTEGRATED UNIT

WINDSHIELO
WIPERAVASHER YEUEE
swtTcH
tr-/
I
BLK/GRNBI

WINDSHIELO VOLTAGE
WIPER REGULATOR
MOTOR {lnahamator,
{Asl

washef-wip€roporation
lr ) : Withcombinod

23-144
 Br-u/Brx
+ fr,rTrtl.*
r*r.,

/\
J L
r--------Y----__tfl
I moan
i PosrIoN
swtTcH
t,x*rt €- BLK/RE9
-
t v
-----J

- OASHFUSE/REI-AY
UND€R 8OX

ERAKE
SYSTEM
I.IGHT
YEI- ll.4wl

SEAT8EI-T 3
REMIi/OER
LIGHT a
t1.4Wl
E
t
.?

RED/BLU

I
I
I | *rt RIGHT
FRONT
a'u,[!
tsl QiftHl.
| (3CP,
SIDE
MASKER
I,IGHT
t3cP'

BI-K
I I
BI..K

{ {
G20r G30l
G40l

23-145
IntegratedControlUnit
Input Test
CAUTION:
a All SRS elocttical widng hatness€sato covored with
yollow insulation.
a Botolo disconnocring any pan ot the SRS wile hal'
ness, conn€ct tho shon connoctor(3l.
a Replaca tho ontlrg affsctod SRS hE noaa assombly if
it has an opon circuit or damag6d wifng.

Remove the dashboSrd lower cover and knee bolstar.

then disconnect the 1 5-P connector Jrom the integratsd
control unit.
Removethe integrated control unit from the under-dash
Juse/relavbox.
SRSMAII{ HARI{ESS
Inspect the connector and socket tetminals to be sure
they are all makinggood cont8ct.
NOTE:
a Diftorent wires with the sam€ color have been given
a lf the terminalsare bent, looseot corrod€d,repairthem
a number suffix to distinguish th€n {for 6xample,
as necessary, and recheck the system
a lf the terminalslook OK, makethe tollowing input tssts GRN/BLUIand GRN/BLU' arenot the same).
a Do not disconnect any connectors on tho under-dash
at the connector and under-dashtuse/relsy box.
- lf any test indicatesa problem,find and correct the fu8e/relay box except the integratsd contlol unit.
cause, then recheck the system.
- It all the input tests prove OK, the control unit must
be faulty; replace it.

H_____-t{

.BLK/GBI{ LT

15.P CONNECTOR

BLU/WHTI BLU/GR]{I BLU/YELI LT GB /BED

YEL/BLU GRN/BLUI GRI{/RED

23-146
All Systems:
No. Tsrminal T€st condition T6st: Desired rosult Possiblacause it result is not obtained
Under all conditions Check for continuityto ground: . Poor ground (G201, G4O1)
1 N
There should be continuitv. . An open in the wire
Under all conditions Check for voltageto ground: . Blown No. 3 (7.5 A) fuse in the
There should be battery voltage. under-dashfuse/relaybox
. An oDenin the wire
lgnition switch ON {ll) Check for voltage to ground: . B l o w nN o . 1 5 ( 1 0 A ) t u s e i n t h e
F There should be bsttery voltage under-dashfuse/relay box
. An open in the wire

R€ar Window Detogger Timer System:

No. Wire Tost condition Test: Dosiled result
Defoggerswitch Check lor continuityto ground:
I YEL pushed There should be continuityas
the switch is Dushed.
lgnitionswitch ON (ll) Connectto ground:The rear
window defoggershould work
BLUiYEL and the detoggerswitch indica-
tor light should come on.
Possiblecause il rosult i8 not obtained
Faultydefoggerswitch
P o o rg r o u n d{ G 2 0 1 ,G 4 O 1 }
An open in the wire
Blown No. 13 {7.5 Al fuse in the
under-dashfuse/relaybox
Faulty defogger relay
Blown bulb
An open in the wire

Intermittent Wip6r Relay System:

Wir€/
No. Terminal Test condition T€Et: Desir6d result Possiblocause if rosult is not obtained
lgnitionswitch ON (ll) Check tor voltageto ground: Bfown No. '14 l2O Al fuse in the
,| YEL/BLU
and windshieldwipet There should be battery voltage under-dashfuse/relay box
switch INT Faulty windshieldwiper switch
An oDenin the wire
Windshieldwiper Check for continuity between Faulty windshieldwiper switch
BLU/WHT
switch OFF or INT the BLUMHT and BLU/GRNter- Faultv windshieldwiDer motor
ano
and wiper bladesin minals:There should be An open in the wire
BLUiGRN
park position continuity.
.E lgnitionswitch ON (lll Check for voltageto ground: . An open in the wire
There should be battery voltage.
lgnitionswitch ON (ll) Check for voltageto ground: . Faulty windshieldwasher switch
* B L K / G R N and windshieldwasher There
should be battery voltage. . An open in the wire
motor switch ON
*: With combinedwasher-wiper
operation
(cont'd)

23-147
 IntegratedControl Unit
Input Test (cont'd)

rWith combined washeFwipot operation

Engine Oil PressureIndicator Flashal System:

Wire/
No. Telminal Tsst condition Test: Desired result Possiblo c€use if r6rult is not obtainod

Enginerunning Check for voltageto ground: . Faulty charging system

1 There should be battery voltage . An oDenin the wire
lgnitionswitch oFF Check for continuityto gtound: . Faulty engine oil ptessure switch
There should be continuitv. . An oDenin the wire

lgnition switch ON (ll) Check indicatorlight. lf the light . Blown bulb

does not come on, Sttach the . An open in the ware
YEL/REDterminalto ground:
YEL/RED The light should come on as the
ignitionswitch is turned ON.
Start the engine. Check for voltage to ground: Insufficientoil
There should be battery voltage lmproper lubrication
Faulty engineoil pressureswitch

Key-in/Seat Bolt Reminder Systam:

No. Wila Test condition Test: Dosired lesuh Possiblecauso if resuh is not obtainod
Driver'sdoor open Check for continuityto ground; . Faulty driver's door switch
GRN/BLU' There should be continuitv. . An ooen in the wire

Front passenger'sdoor Check tor continuityto ground: . Faultylront passenger'sdoor switch

switch open There should be continuitv. . An ooen in the wire
LT GRN/
NOTE:Betoretesting,
RED
remove No. 3 (7.5 A)
tuse from the under-
dash fuse/relaybox.
lgnition key inserted Check for voltage to ground: Faulty ignition key switch
LT BLU into the ignitionswitch There should be 1 V or less. Poor ground (G201, G401)
An ooen in the wite
lgnition switch ON (ll) Check lor voltageto ground: Faulty seat belt switch
RED/BLU and driver's seat belt There should be 1 V or less. Poor ground {G551)
unbuckled An open in the wire

NOTE: Referto page 23-125 for the seat belt switch test.

23-148'
;.rqFft,
Bulb Check System (blake system lightl
No. Tsrminal Test condition
lgnitionswitch at
START
I M
lgnition switch ON (ll),
brake fluid reservoir
D
tull, and parkingbrake
lever down
Lights-on Romind6rSystom:
Wire/
No, Toiminal T6Et condition
Driver's door open
GRN/8LU'
Combinationlight
switch ON.
H
Connectthe I terminal
5 to the J terminal.
Side Markol Light Flashar System:
Wiro/
No. Terminal Test condition
Combinationlight
1 H switch ON
lgnition switch ON {ll)
G R N / B L U 1and turn signalswitch
to "Left"
lgnitionswitch ON {ll)
2 GRN/YEL and turn signalswitch
to "Right"
lgnitionswitch ON (ll)
4 GRN/WHT and turn signalswitch
to "Left (or Rightl":
Connectthe H terminal
GRN/REDl to the GRNMHT
(or GRN/REDl)terminal.
Tost: Desirod resuh Possibls caus6 it result is not obtainod
Check lor voltageto ground: Blown No. 18 {7.5 Al fuse in the
There should be battery voltage. under-dashfuse/relay box
Faulty clutch int€rlock switch or
starter cut relay {M/T}
Faulty neutral position switch (A/T)
An open in the wire
Connectto ground: Brake . Blown brake system light
system light should come on. . An oDenin the wire
Tost: Dositod rosuh Possibl6caus6 if rosuh is not obtainod
Check for continuityto ground: . Faulty driver's door switch
There should be continuity. . An oDenin the wire
Check for voltage to g.ound: Blown No. l9 (1O A) tuse in the
There should be battery voltage under-dashfuse/relav box
Faulty combination light switch
An oDenin the wire
Check chime operation:Chime . Faulty chime
should activate each time the . An open in the wire
batterv is connected,
Tast: Desired rosult Po$ible cause if result is not obtained
Check for voltageto ground: . Blown No. 19 (1O A) tuse in the
There should be battery voltage under-dashfuse/relay box
. An open in the wire
Check for voltageto ground: Blown No. 26 (10 A) luse in the
It should changefrom under-dashfuse/relav box
O-12-O V repeatedly. Faulty turn signal/hazardrelay
An oDenin the wire
Check the front side marker Blown bulb
light: Left (or Right) front side P o o rg r o u n d( G 2 O 1 c, 3 O 1 , G 4 O 1 l
markerlight shouldcome on as An open in the wire
the batterv is connected.
23-149
Key-in ReminderSystem
lgnition Key Switch Test Door Switch Test

NOTE: Referto page 23-145fot a diagramof the key- l. Open the door.
in lemindercircuit,and to page23-148 Jorthe inputtest
ol the beepercircuit. Removethe screw, then pull out the door switch.

When the ignitionkey is not removed,the key-inreminder Disconnectthe 1-P connectorfrom the switch.
in the integratedcontrolunit sensesgroundthroughthe
closedignitionkey switch. When you open the driver's
door, the beepercircuit sensesgroundthrough the closed
"LT BLU" and "GRN/
door switch, With groundat the
BLU" terminals,the beepersounds.
BASE PLATE

1. Removethe dashboardlower cover and knee bolster

(see page 23-70).

2. Disconnectthe 7-P connectorfrom the main wire

harness.

4. Check lor continuity between the positive terminal

and the baseplate (ground)in each switch position
accordingto the table.

Terminal
POSITIVE BASEPLATE
Position
Checkfor continuitybetweenthe No. 2 and No. 4
{doorclosedl
PUSHED
terminalsin each conditionacco.dingto the table.
ldooro!en)
RELEASED o o
Terminal
4
Condition

KEYINSERTED --o
KEYREMOVED

23-150
EngineOil Pressure
Indicator System
Description
NOTE: Reterto page 23-144 tor the circuitdiagramot
the engine oil pressureindicatorflasher,snd to page
23-148 lor the input test of the flashercircuit.
The low engine oil pressureindicator tight works in two
ways. lt will flash continuouslyfollowinga momentary
loss of oil pressure, or it will go on and stay on with a
completeloss of oil pressure.
When the engine first starts, before oil Dressurerises
above 29.4 kP8 10.3 kgf/cmr, 4.3 psi), current flows
through the low engineoil pressureindicatorlight and
the oil pressureswitch to ground.This tests the circuit.
Wilh the enginerunning,voltageis appliedro the ftash-
er circuit of the integrated control unit. With normal oil
pressure,the oil pressureswitch is openandthe low en-
gine oil pressureindicatorlight does not operate.lf the
oil pressureswitch closesmomentarily(morethan O.5
secondsl,but then opensagain,terminal"yEL/RED,'will
sensegroundthrough the switch. The integratedcon-
trol unit willthen provide and remove ground for th€ low
engine oil pressure indicator light through terminal
"YEL/RED".
The light will flash on and olf until the igni-
tion switch is turned to "OFF".
lf engineoil pressurefalls below 29.4 kPa (O.3kgJ/cmr,
4.3 psi) and does not increase,the oil pressureswitch
willstsy closed.The low engineoilpressureindicatorlight
will go on and stav on.
NOTE; Referto page23-122lot the engineoil pressure
switch test.
Lights-onReminder
System
Description
NOTE: Referto page23-145 tor a diagramof the lights-
on remindercircuit, and to page 23-149 for the input
tests of the circuit.
When the ignitionkey is turnedto OFF8nd removed.with
the lights on, voltageis apptiedto the remindercircuit
in the integrat€dcontrol unit. When you open the driver,s
door, the circuit senses ground through the closed door
switch.
With voltage at the "H" terminal, ground at the
"GRN/BLU2"
terminaland no voltageat the ,,F,' termi-
nal, the chime sounds to remindthe driver to turn oJf the
lights.
ChimeTest
Removethe dashboardlower cover and knee bolster
{see page 23-70).
Disconnect the 2-P connector t.om the dashboard
wire hamess.
CHIME
Test the chime by connecting battery power to the
"A" te.minal
and groundto the "B" terminal,and
cycling the power on-off repestedly.
lf the chime fails to sound every time power is cy-
cled, reDlaceit.
23-151
 Lighting System
ComponentLocationsIndex

All SRS el€ctrical wiring harnessesale covered with

yallow insulation.
B€fore disconnocting any pan of th€ SBS wire har-
ness, connect the short connactor(sl.
Replac€th6 entire affocted SRS harnessassembly it
it has an open circuit or damagod wiring.

HIGI{ BEAM INDICATORLIGHT

(ln the gaugeassembly)
Bulb Locations,page 23-115

COMBINATIONLIGHT SWITCH
Replacement, page 23-160
Test, page 23- l58

OAYTIME
RESISTORlC.nodal
Test, page 23-160

HEAOLIGHTS
Adjustment, page 23-162
Replacement, page 23-164

FRONT PARKING/FRONTTURN FRONTSIDE

SIGNAL LIGHT MARKERLIGHT
page 23-165
Replacement, page 23-165
Replacement,
DAYTIME RUNNIT{GLIGHTS
CONTROLUNIT {C6nada)
Input Test, page 23-156

23-152
-
Hatchback:

LICENSEPLATE LIGHTS
page 23-169
Replacement.

TAILLIGHT
. Replacement,page 23-166
. Eulb replacement,page 23-166

Sodan:

LICENSEPLATE LIGHTS
page 23'169
Roplacement,
INI{ER TAILLIGHT
. Replacement,page 23-167
. Bulb replacement.page 23-168
TAILLIGHT
. Repfacement,page 23-167
. Bulb replacement,page 23-168

23-153
LightingSystem
CircuitDiagram(USAI

- HOOD
UNOER RJSE/NELAY
8OX

-r lo| ,-. otF

DIMMER I'I

No.lo
t
'1
No,22
t
''t No.g No.2l iil;
- D SH
UtrloER
RJSE/RELAY
sox
tloAr (0oA) (floAr |l0A]
)
I T
REO/GNN

RIGHT
HEADLIGHT HEAOUGHT
HIGHEEAM

@il,", @f,*, 6il* 6p*

INOICATOR
LIGHT DASHUGI{TS
fi.4W) 88rGr{TESS
CONTrcUTR
DASHUGHTS
. PAR(II{C
PAR(II{G
UGHI
UGHTS
. TAItUGt{TS
TAILUGI{TS
. UCENSE PI.ATE
UGHTS

8LK 8tK

I
G 20l
G401
G301 G20'|
G40l

23-154
GircuitDiagram(Canadal

UNOER_HOOD
FUSEiRETAY
8OX
BATTERY

G"*
-il w
/ d \
coMBrNAtor{
rcHrswnc BAT rGNrTrot{
tG2 swITcH
'.=r"

tlL-J
\9-l
| I
l l ' L I I
"- l-'li'
I I *o\." "orr ;-\d " ;j
r.r-,9
I LI I L
RED/BLU REO/}VHT RED,
GRN
t'
l l
I UNDEN-DASH I
I FUSEiIEI,AY
8OX I

t l (
I

i,"# No.2l
fl0A)
No.l9
|l04]
Jm.tr
t10A)t
No.l6
{7.54}
llrrff li'rrt,I \
I t t
I
RED/
GRtI BLU REOr'
TVHT NED/B WHTTYEL

V
. DASH LGHTS BRIGHTNESS
COI{TROLLER
. DASH I-IGHTS
. PARKING I-GHIS
. TAII,LIGHTS
. UCENSE N"AT€LIGI{TS
I a-r
jllA/Vr
neonru l"
oI f# wxrinto
RED/GRI{
+\{H I
RED/
GRN
I DAYTIMERUNNING
UGI{TS
RESISTOR

Hr I r-0 HI LO
1651,1/) | l55W) t85W) t55Wl

HIGHBEAM RIGHT PARKIIIG

INOICATOR HEADLIGHT BRAKE
UGHT sw{TcH
fl.4W

I
23-155
Lighting System
DaytimeRunningLightsControlUnit Input Test (Canada)
CAUTION:
a All SRS eloc{dcal wi ng harn€ssesare covelod with
yollow insulation.
a Boforo dbconnocting any psrt of the SRS wir€ h8r-
noss, connoct tho shon connector(s).
a Roplacethe entire affected SRS harness assombly it
it has an opon Gilcuit or damagod wifng.

1. Removethe dashboardlower cover and knee bolster.

2. Disconnectthe connectorsfrom the daytime running

lights control unit.

3. Insoectthe connectofand socket terminalsto be

sure they are all making good contact.

a ll the terminalsare bent, loose or coroded, repair

them as necessary. and recheck the system,
a lf the terminalslook OK, make the followingin-
put tests at the connector,
- lf any test indicates a problem, find and cor-
.ect the cause, then recheck the system.
- ll allthe input tests proveOK, the controlunit
must be taulty; replaceif

4-P CONI{ECTOR
8-P CONNECTOR

YEL/ALK
GRN/RED

WHT/RED

WHTA'EL

RED/GRI{

View from wire side Vi6w from ware side

23-156
 T€st condition
Under all conditions
1 BLK
Under all conditions
WHT/YEL
lgnition switch ON (ll)
YEL/BLK
Combinationlight
switch in "O" position
4 RED/WHT
Combinationlight
switch is OFF; connect
a iumper wire between
5 WHT/REOthe YEL/BLKand
WHT/REDterminals,
then turn th6 ignition
switch ON.
lgnition switch ON (ll),
brake fluid res€rvoil
tt GRN/RED
full, and parking brake
lever down
Parking brake lever up
RED/GRN
Test: Desirad losult
Check for continuityto ground:
There should be continuity.
Check Jor voltageto ground:
There should be battery voltage.
Check tor voltageto ground:
There should be battery voltage.
Check for voltageto ground:
The.e should be battery voltage.
Left and right headlight(high
beaml should be on but dim, and
high beam indicatorlight should
come on.
Connectto ground:The brake
system light shouldcome on.
Check for continuityto ground:
The.e should be continuitv.
Possiblacause if rosult is not obtainad
. P o o rg r o u n d{ G 2 0 1 ,G 4 0 1 )
. An open in the wire
. Blown No. 17 { 10 A} luse in the
under-dashtuse/relay box
. An ooen in the wiae
Blown No. 16 (7.5 A) tuse in the
under-dashfuse/relay box
Faulty ignition switch
An open in the wire
Blown No. 40 {5O A) fuse in the
under-hood fuse/relay box
Faultycombinationlight switch
An ooen in the wire
Poor ground (G201. G401. G301)
Blown bulbs
Faulty daytime runninglights
reststor
An open in the wire
B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e
under-hood fuse/relay box
Blown brake system light
An open in the wire
. Faulty brake lever switch
. An open in the wire
23-157
Lighting System
Combination Light/Turn Signal Switch Test

CAUTION:
a Atl SRS Oloctricslwiring harnessesar6 covered with
yellow insulation.
a Bslor€ disconnecting any pan ot the SRS wire har-
ness, connact the short connsctollsl.
a Replacethe sntire aftectad SRS harne$ assembly if
it has an opon circuit or damagod wiring.

1. Remove the dashboardlower cover and steering

column covers (see page 23-71).

2. Disconnectthe 4-P and 7-P connectorsfrom the

switch.

3. Checkthe connector and socket tetminalsto be sure

they are all making good contact. lf the terminalsare
bent, loose, or cotroded, repair them as necessary,
and recheck the system.
SRS MAIN HAR ESS
4. Checktor continuitvbetweenthe terminalsin each
switch positionaccordingto the table.

4-P CONI{ECTOR

B
D

G
H

7.P CONNECTOR

23-158
ComHnrtlon llght Swhch :

TErminsl
E t- H J
Position
Hsrdfightstvitch OFF

1J

a
L0w n --o o
HIGH o
OFF
Passing
switch
ON G o

Tum Slgn.l Swhch :

/ t \
RIGHT

Tsrminal
A 8 D
Position
RIGHT o -o
NEIIIMT
uFr o (J

23-15,9
Lighting System
Combination Light Switch Daytime RunningLights Resistor
Replacement Test lCanada)
'1.
Removethe steeringcolumn covers. CAUTION: The daytime running lights resistor becomas
vely hot when the daytime running lights are on; do not
touch it or the attaching hardware immediatelyaftel th€
UPP€RCOVER lights h8ve b€en turned otf.

1. Disconnectthe 3-P connectorfrom the resistor.

DAYTIMERUNNING
LIGHTS RESISTOR

?nd
Disconnectthe 4-P and 7-P connectorsfrom the
combination lighr switch, then remove the two
screws and lift out the switch. V
- c
View trom lerminalside

Measurethe resistancebetweenthe resistortermi-

nals (A and B) and the DowerterminalC.

R€sistance:1.4 O I O.O7O

Replacethe resistorwith a new one if any ot the

resistancesare bevond soecification.

23-160
Headlight
Description

The low beam lightsare proiector-typelightswhich are more compactwhile maintainingsufficientbrightness.Bundling

the light raysreducesstray light and yieldsa spotlight-effect
which improvesvisibilityduringnight or foul weatherdriving.
For easieraiming,the headlightsare equippedwith vertical and horizontalgauges.

NOTE: As the oute. lensesare made oI a resin material,don't cover the headlightswhen they a.e turned on.

OUTER LENS
coNvExLEI{S
SUB-REFLECTOR
sEcoND FOCUS
INTERRUPTER PLATE
REFLECTOB
FIRST FOCUS
BULB

23-161
Headlight
Adjustment

Belol€ adiusting lha hoadlights:
a Parkthe car on level ground.
a Make sure the luel tank is full.
3. Turn the low beams on. lJ necessary,align the ver-
tical indicator with its "O" mark by turning the ver-
tical adiuster with a Phillipsscrewdriver, and check
aiming with the chart on page 23-163.

a The driveror someonewho weighsthe same should

sit in the driver's seat.

a Loadthe trunk with the items you usuallycarry (if you

usuallypull a trailer,attach it to the carl.

a Push down on the tront and rear bumDersseveral

times to make sure the car is sitting normally.

a When installinga new headlightassembly,tighten the

four mountingbolts so that.theindicatorin the verti-
"O" mark.
cal gauge comes to the

4. lf necessary,alignthe horizontalindicatorwith its

"0" mark by turningthe horizontaladjusterwith a
Phillipsscrewdriver,and check aimingwith the chart
o n p a g e2 3 - 1 6 3 .

1. Open the hood.

2. Check that both the horizontaland verticalgauge

read " O" .
. lf the gaugesrcad "O", check headlightaiming
with the aimingchartson page 23-163. (lf aim-
ing isn't correct,refer to the trame repairchart
in section 20.)
a lf one o. both gaugesdon't read "O". go to step
5. Recheckthat the verticalindicatorbubbleis aligned
with "o" 1 1.
lf necsssary,adjust as describedin step 3.
Turn the high beamson and check aimingwith the
charts on page 23-163.

23-162
Measurements (Standardl:
A: 9 fi 10 in (3000 mm)
B: 23 in (585 mm)
C: 46.1 in (1170 mml
D: 33.5 in (85O mm)
E; 1.2 in {31 mm}

FLOOR

Headlight Aiming

Low beam: High besm:

HEADLIGHT
HEADLIGHT HIGH BEAM
LOW BEAM
CEt{TER

FLOOR

CAUTION: Th6 out6r lonses get very hot when tho hoadlights are on; do not cover them.

23-163
Headlight
Headlight Replacement Bulb Replacement
1. Removethe front bumoer. CAUTION:
a Halogon headlights can bocomo voly hot in usa; do
not touc$ them or tho attaching hardware imm6diatoly
arter they hava been lurnod off,
a Do not try to roplaceor cl6an the headlights with the
lights on.

I. Oisconnectthe 2-P connector(s)from the headlight.

FRONTBUMP€R

Removethe mountingbolts,then pullout the head-

light, and disconnectthe connectorsfrom it.
coNlrtEcToR

2. Turn the bulb(s)counterclockwiseand removethe

bulb(s).

HEADLIGHT

Afte. replacement.the horizontaland verticalaim-

ing must be checkedusing conventionalmethods,
Use the aimingcharts on page 23-163.

23-164
Front Parking/Front
Turn Front Side Marker
Signal Lights Lights
Replacement Replacement

l. Removethe screw, and pull the front parking/front Remove the screw, and pull the front side marker
turn signal lights out ot the tront bump6r. light assemblyout of the tront bumper.

Disconnectthe 2-P connectorfrom the lioht.

Turn the bulb socket 45o counterclockwiseto re-

move it from the housing.

BULE{3 CPI
Disconnect the 2-P conn€ctor trom the tight.
FRONTSIDE MARKERLIGHT
Turn the bulb sock€t 45o counterclockwise to re-
move it from the housing.

23-165
 Taillights(Hatchbackl
Replacement Bulb Replacement

1 . Open the resr hatch. R6ei tum slgnal/Rolr parking lights:

Removethe rearpanelliningandthe sidelining{see 1. Openthe rearhatch,then removethe accesspanel.

section 20).
2. Removethe bulb lrom the bulb socket.
Disconnect the 4-P connector from the taillight.
ACCESS PANEL
4. Removethe six mounting nuts, then pull out the
taillight.

4-P CON[{ECTOR

@: REARTURN SIGNALLIGHTBULB(32 CPI

@: REARPARKINGLIGHTBULB{3 CP)

Brake/T8illight/Back-uplights:

1. ODenthe rear hatch.

NOTE:
a Inspect the gasket. Replaceit if it is distorted or
2. Removethe rear panel lining {see section 20).
stavs compresseo.
a After installation. run wate. over ths lights to
make sure thev don't leak.

o: BACK-UPLIGHTBULB{32 CP}
BULB(32l3 CP)
@: ERAKE/TAILLIGHT

23-166
-
Taillights (Sedan)
Replacement

Tsillight: Innol Taillight:

1. Open the trunk lid, then removethe r€ar panel lin- 1. Open the trunk lid.
ing and side lining (seesection 20).
2. Disconnectthe 4-P connectorfrom the innertaillight.
2. Disconnect the 4-P connector from the tsillight.
3. Remova the four mounting nuts, then pull out the
3. Removethe four mountingnuts, then pull out the inner taillight.
tsillight.
INNERTAILLIGHT

TAILLIGHT 4-P CONi{ECTOR

NOTE:
a Inspect the gasket. Replaceit if it is distoned or stsys
compresseo.
a After installation, run water over the lights to make
sure thev don't leak.

23-167
 Taillights(Sedanl
Bulb Replacement

Tsillight: lnnor T.illlght:

1. Open the trunk lid. then removethe rear panel lin- 1. Open the trunk lid, then removethe bulb housing.
ing and side lining {see section 20}.
2. Remove the bulb from the bulb housing.
2. Removethe bulb from the bulb socket.

BULBHOUSII{G

BULB(32l3 CP}
@: BRAKE/TAILLIGHT
@: T U R NS I G N A LL I G H TB U L B( 3 2 C P } O: LIGHTBULB(32 CP}
BACK-UP

@: REARPARKINGLIGHTBULB{3 CP) BULBI3213CP}

@: BRAKE/TAILLIGHT

23-168
l'r'qn'F',
LicensePlateLights Glove Box Light
Replacement Test
Remov€ the screws and pull out th6 license plate Removethe glove box and disconnectthe 2-p con-
lights. neclor.

Turn the bulb socket 45o counterclockwise to re- Checkfor continuitybetweenthe A and B terminals
move it from the housing. in each conditionaccordingto the table.

T€rminal
B
Condition
PUSHED
{lidclosodl
REI"EASED
{lidoDen) o- /:\
\7
---o

BULB
(3.4 W)

ql
-----11
dl

cior
G4{t1

23-169
DashLightsBrightnessGontrol
CircuitDiagram

UNDER-DASH
UNDER.HOOD 8OX
FUSE/REIAY COMBII{ATION 8OX
FUSE/NETAY
LIGI{TSWTTCH
wnr-@- neorenn

REO/BLK

. GATJGEUGHTS
. CruEECOITNOL DIMMING CIRCUTT
. A/TGEAR POSMON N(ICATOR
DIMMII{G
CIRCUIT
' HAZAnD WARi{|NG
S:WltCHLIG}fr
. REAR WINOOWOEFOGGER SiWTTCH UGHT
. CFUISECOMTROT UGHT
MAINS,IVITCH
. A,ITGEANPOSITION
CONSO|.!UGHT
. HEATERCOMTNOL PANELUGHTS

TR €D

BI.K

G201
G40t

23-170
 Controller Input Test

NOTE: 8e carefulnot to damagethe controllerand the

instrumentpanal.

1. Removethe instrumentpanel lrom the dsshboard

{ s e ep a g e 2 3 - 1 1 8 1 .

2. Remove the dash lights b.ightness controller {rom

the dashboard.then disconnect the 3-P connector.

Inspect the connector and socket terminals to be

sure they are all making good contact. View from whe side

a lf the terminalsare bent. looseo. corroded,repsir

them as necessary, and recheck the system.

a It the terminalslook OK, make the tollowing in-

Dut tests at the connector.
- lf any test indicates a problem, find and cor-
rect the cause, then recheck the system.
- lf all the input tests prove OK, the dash lights
brightnesscontrollermust be faulty; replaceit.

3-P CON[{ECTOR

OASH LIGHTS
COI{TROLIER

Wire Tost condition Togt: Dasired resuh Possiblecauso it resull is not obtained
Under all conditions Check for continuity to ground: . Poor ground (G20l , G4O1)
1 BLK
There should be continuitv. . An open in the wire
Headlightswitch ON Check Jor voltageto ground: B l o w n N o . 1 9 ( 1 OA ) t u s e i n t h e
There should be battery voltage. under-dashfuse/relay box
RED/BLK
Faulty combinationlight switch
An open in the wire
a Headlightswitch ON Connectto ground: Dash lights . An open in the wire
RED
shouldcome on full bright.

23-171
 Area Lights, Spotlights
Ceiling/Trunk/Gargo
Component Location Index
r 1: Sedan
r2: Hatchback

CEIIING LIGHT
Test/Replac€mont.page 23-175

SPOTLIGHTS
Test/Rsplscement, page 23-1 74

.1 LEFT REAR
DOOR SWTCH
Test. page 23-150

FRONT
PASSEl{GER'S
DOOR
swtTcH
Test, pago23-150

*2 HATCH LATCH 11 RrcHTBEAR

swtTcH DOORSWrCH
Test/Replacement, Tost. page23-150
page 23-178
11 TRUNK LATCH
SWITCH '1 TRUI{K LIGHT
Test/Replac€ment, Test/Replacemont
page 23-178 Page 23-177

23-172
rII-
CircuitDiagram
U DEN-DASH
- HOOD
UNOER FUSE/RELAY
8OX FUSE/RELAY
8OX

- - - - -Hltcnb&n
--1 lS.d.nl

CARGO TBUi{K
ASEA UGHT
UGHT t3.4Wl
t3.4Wl

GRI{

I
l**,-0,,n
I rNorcAToR
I UGHT

IY
LT

II{IEGRATED
1
cotlrnor I
I,NIT I

i'
GRN GRr{/Bt
U t-t

Iq*",,.,
d_ I DOOR
FROiTT
PASSEiIGEB'S

f-
I swncH DOOf,
SWTCH

II
: :
J

23-173
 Area Lights, Spotlights
Ceiling/Trunk/Cargo
Spotlight Test/Replacement

1. Turn the light switch OFF. 4. Disconnectthe connectorfrom the housing.

2. Pry off the lens. 5. Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.
3, Removethe two screws,then pull out the housing.

Torminal
Hatchback: \ ----l A BorB' CorC'
;r,,-
CONNECTOR ON o- /:\
\:/
--o
tEFr
OFF

ON o- --o
RIGHT
OFF

Sedan:

""li **li
B'O B

BULB

23-174
 Ceiling Light Test/Replacement

With moonrool: 5. Checkfor continuitybetweenthe terminalsin €sch

swatchpositionaccordingto the table.
1. Turn the light switch OFF.

2. Pry otJ the lens.

\ re.mrnal
3. Removethe two mountingnuts, then pull out the A 8or8' c D
Position \
housing.
OFF o- za
\7
--o
DOOR o- \7
--o
ON G- /1
\:.,/ --o
3-P CONNECTOR

F om o.3l7.5Al FUSE
(ln th. snd.. - dr.h fu!./r€by boxl

4. Disconnectthe 3-P connectorf.om the housing.

23-175
 Area Lights' Spotlights
Geiling/Trunk/Cargo
Geiling Light Test/Replacement

Without moonroot: 5. Check for continuity between the terminals in each

switch position according to the table.
1. Turn the light switch OFF.

2. Pry ofJ the lens. T6ninsl

\ A BorB' D
3. Removethe sctew, then pull out the housing' P"riti"" \
OFF o- /:\
\:.,/
--o
DOOR o- A --o
ON LF
/A --o

3-P
CONNECTOR

F om o.3l7.5Al FUSE
tln thr uid.r - ddr h|. /,.LY borl
4. Disconnectthe 3-P connectorfrom the housing. A

23-176
 Trunk/CargoArea Light Test/Replacement

Pry the trunk/cargoafea light lens out of its housing.
Pry out the light assembly.
Disconnectthe 2-P connectortrom the housing.
4. Make surethat the bulbis in good condition.Check
for continuitybetweenthe A (+) and B (-ltermi-
nals. There should be continuitv (Hachback:the
switch must be Dushed).

Hatchback: Hatchback:

2.P CONNECTOR
Froh o.3 (7.5A1FUSE
{ln th. undor- d!.h
fur./r.hy box)

BULE13.4Wl

To HATCH
LATCH
A {+} B{-) swtTcH

Sedan:

2.P CONNECTOR
F om o.3 (7.5A1FUSE
{ln th. und.i- da.h
tur€/r.hy box)

HOUSING

BULB{3.4 W)

To TRU K
LATCH
swtTcH

23-177
 Area Lights,Spotlight
Ceiling/Trunk/Cargo
Latch Switch Test/Replacemsnt
Sedan: lhtchb.ck:

1. Openthe trunk lid. and disconnectthe 2-P connec- 1. Op6n the hatch, and disconnect the 2-P connector
tor from the trunk latch switch. trom the hatch latch switch.

2. There should be continuity between the A and B ter- 2. There should be continuity between thg A terminal
minals. and component ground.

\j

C C

3 . lf necessary,removethe three mounting bolts to pull

out the hatch latch switch trom the latch, then dis-
connact the lock rod Jrom the hatch latch switch

4. Disconnect the hatch opener cable trom the hatch

ll necessary,removethe three mounting bolts to pull latch switch,
out the trunk latch switch from the trunk lid, then
disconnectthe lock rod from the trunk latch switch.

4. Disconnect the trunk opener cable from the trunk

latch switch.

TRU'{KOPG ER

TRUNK LATCH SWITCH

23-178
Back-upLights
CircuitDiagram

UI{DER_
IIOOOFUSEiBEIAY
BOX

wHT/Bt(+WHT

A/TGEAR
PosrnotrswrTcH
'l
f 8ek- uplioht

--------_J L---------

23-179
Back-up Lights

Manual Transmigsion: Automatic Transmission:

NOTE: Checkthe No. 1 5 { 1O A) fuse in the under-dash NOTE: Checkthe No. l 5 ( 1O A) fuse in the under-dash
fuse/relaybox befote testing. fuse/relay box belore testing.

'1. Test the back-uplight switch by placingthe shift
lever in reverseand turning the ignition switch to ON
( ).
2. It the back-uplightsdo not go on, check the back-
up light bulbs in the taillightassembly.
3. lf the tuseand bulbsareOK. disconnectthe connec-
tor from the back-uplight switch.
1. Test the back-up light switch by shitting the shift
lever to l3l and turningthe ignitionswitch ON (ll).
2. lf the back-uplights do not go on, checkthe back-
up light bulbs in the taillightassembly.
3. lf the tuse and bulbs are OK, disconnectthe 14-P
connector from the A/T gear position switch (back-
up light switch).

terminal sade

This washer must

always be replaced
tor the switch to
lunction properlY
and to ptevent oll 4. Move the lever back and torth at the LBI position
teaKs. without touching the push button, and check tor
continuitv between th€ C and D terminals. There
should be continuitY within the range of free plsy of
4. With the shift leverin reverse.checkJor continuity
the shift lever.
betweenthe A and B terminalswith the switch in-
stalled.
a lf there is no continuity within the range oJ J.ee
There should be continuity. play, adjust the position ot the A/T gear position
switch lsee section 141.
a lf there is no continuity,replacethe switch {see
a lt there is continuity, but the back-uplights do not
s e c t i o n1 3 ) .
go on,check{or:
- Poor ground {G503)
a lf there is continuity, but the back-uplights do not - An oDen in the wire
go on, check for:
- Poor ground (G5O3)
- An open in the wire

23-180
BrakeLights
CircuitDiagram

UNDEE-HOOO
FUSE/NELAY
BOX

. HORi{
. IMTERI.OCK
SYSTEM

{u
8tK
{.
*H-i {.
BLK

23-181
Brake Lights
Brake Switch Test HighMount BrakeLightReplacement
(LEDtypel
lf the brakelights do not go on, check the No. 42 1. Removethe four screws and the high mount btake
{2O A) fuse in the under-hoodfuse/relaybox, and light, then disconnectthe connectors.
the brakelight bulbs in the taillighrassemblyand high
mount brake light.

lf the fuse and bulbsare OK. disconnectthe 2-P or

4-P connector {rom the brake switch.

A
'|Frt B

jr'li
C D

HIGHltlOUt{T BRAKELIGHT{LEDTYPEI

3. Check fo. continuitv between the B and C terminals.

There should be continuity with the brake pedal
pushed.

a lJ there is no continuitv, replscethe switch or ad-

just pedal height {see section 19).

a lf there is continuity,but the brakelightsdo not

go on, inspectfor:
- Poor ground (G5O3)
- An ooen in the wire

23-1A2
 High Mount BrakeLight Replacement
{Bulbtype)
Hatchback: Sadan:

1. Open the hatch. 1. Openthe trunk lid, and disconnectthe 2-P connec-
tor trom the high mount brake light.
2. Removethe two clips and the cover.
2. Removethe two nuts, then remove ths high mount
3. Removethe two nuts and the high mount brakelight, brake light from the rear shelt.
then disconnectthe 2-P connector.

2-P CONt{ECTOR

4. Turn the socket 45o counterclockwiseto removethe 2 Installthe high mount brakelight in the reverseor-
bulb. der of removal. Cleanthe rear window glass before
installingrhe light.
Installthe high mount brakelight in the reverseor-
der of removal,and cleanthe rearwindow glassbe-
tore installing.

CAUTION: Whon installing ih6 high mount brake

light. make sur6 the rubber soal fits against the real
window ev6nly.

23-183
 Side Marker/TurnSignal/HazardFlasherSystem
Component Location Index

GAUTION:
a All SRS electrical wiring harnessosar6 covered with
yellow insulation.
a Belor€ disconnocting any pan of the SRS wire har-
ngss, connoct the short connector{s).
a Rsplacetho 6ntir€ affect€d SRS harnoss sssembly il
it has an op€n cilcuit or damaged widng.

TURN SIGNAL INDICATORLIGHTS SRS MAIN HARI{ESS

(ln the gaugeassembly) (Cov.rod with Ysllow in3ulationl
Bulb Locations, 23-115

COMBINATIONLIGHT SWITCH
Replacement, page 23-160 HAZARD WARI{ING SWITCH
Test, page 23-1 Replacement, page 23-187
Test, page 23-187

UNDER-DASH
FUSE/RELAY8OX

TURN SIGNAL/HAZARORELAY
Input Test, page 23-186

23-184
-
GircuitDiagram
UNDEN-HOOD
FUSE/RELAY
8OX
COMBINATION UNDER-DASH
FUSE/RELAY
8OX
N0.411100A) No.40(50A) LIGHTSWTCH
A.
---of-RED/GRN

IGNITION
SWITCH FUSE
HOTJER

WHT/BTK
+WHT+
/6i\\ BIK/YET
+-
\jv

GRN/BtU

TURNSIGiIAL
swtTcH

SIOE MAFKER
FLASHER
LIGHT
CIRCUIT
llnthointogruted
controlunitl
I
| l
RIGHTTURNSIGNATTIGHTS
+
DASHTIGHTS
BRIGHTNESS
CONTROLLER

INOICATOR
I FRONTI REAR
L|GHT I t32CD I t32CPl
(1.4W1

2 3 - 185
 Side Marker/TurnSignal/Hazard
FlasherSystem
Turn Signal/Hazard
RelayInput Test
CAUTION:
a All SRS electrical wiring harn6ss6sar€ covered with
yellow insulation.
a B€foro disconn6cting any part of th€ SRS wire har-
noss, connoct tho short connector(s).
a Replacotho ontiro sftoctod SRS harness ass€mbly it
it has an open circuit or damagod wiring,

I. Removethe turn signal/hazardrelay from ths under-

dash Juse/relaybox.

2. Inspectthe relayand socketterminalsto be surethey

are all makinggood contact.

a It the terminalsare bent, looseor coroded, repair SBS MAIN HAR ESS
them as necessary,and recheckthe system. {Covg.ed with yollow inrulltion)
a lf the terminalslook OK, make the tollowing in-
put tests at the socket.
- lf a test indicatesa problem,find and correct
the cause, then recheck the system.
- lf all the input tests prove OK, the turn sig-
nal/hazardrelay must be taulty; replaceit.

UI{DEB-DASH
FUSE/RELAY
BOX

Telminal TeEt condition Test: D€sired rosult Po$iblo causo it fosult is not obtainod
,l Under all conditions Check for continuityto ground: . Poor ground (G201, G4O1)
E . An oDenin the wire
There should be continuitv.
lgnitionswitch ON (ll) Check for voltageto ground: Blown No. 26 (10 A) fuse in ths fuse
and hazardwarning There should be battery voltage. holder
switch OFF Faulty hazardwarning switch
An open in the wire
2 B
lgnitionswitch OFF and Check for voltageto ground: Blown No. 43 (10 Al fuse in the
hazardwarning switch There should be battery voltage. under-hood fuse/relay box
ON Faulty hazard warning switch
An ooen in the wire
Hazardwa.ning switch Hazardlights should come on. Poor ground (G2O1,G3O1, G4O1
is ON; connect the B G503)
terminalto the L Faulty hazard warning switch
termrnat. An open in the wire
3 lgnition switch ON (lll Right or left turn signallights . Faultyturn signalswitch
and turn signalswitch should come on. . An open in the wire
in right or left; connect
the B terminalto the L
terminal.

23-186
-
 HazardWarningSwitch HazardWarning Switch Test
Replacement
CAUTIOI{: Bo car.ful not to damag8 tho switch and con- 1 . Removethe hszardwarning switch.
lolo panol.
2 . Check fo. continuity between the terminals in each
1. Prythe hazardwarning switch out of the centervent, switch positionaccordingto the table.

2. Disconnectthe 10-P connectortrom the switch.

\ I"j'!ld A I D F H
Position

OFF
@ r)
ON
o
@

10-PCO ECTOR

A B C D

\ uorr
) to.uwl

23-187
 StereoSoundSystem
ComponentLocationIndex
CAUTION:
a All SRS el€ctrical wlring harneaseEare covered with
yallow insulation.
a Belore dbconnscting any part of the SRS wire har-
nass, connect tho short connector(sl.
a Replacetho entir6 affoctod SRS harn6ss assembly if
it has an opan circuit or damag6d widng.

NOTE: The original radio has a coded theft protection

circuit. Be sureto get the customet's code numberbelore
- disconnecting the battery.
- removingth€ No. 32 (7.5 A)tuse from the under-hood
fuse/relay box.
- removingthe radio.
After service, reconn€ct power to th€ radio and tutn it
"CODE" is displaved,enterthe cus-
on. Whenthe word SBS MAII{ I{ARI{ESS
(Covor€d wirh y6llow in3ulationl
tomer's 5-digit code to restore radio opelation.

Hatchback: STEBEORADIO/CASSETTE
PTAYER
paoe23-191
Removal.
page23-192
Terminals,

RIGHTREAR
SPEAKER
Replacement.
page23-193

DOOR
SPEAKER
page23-192
Repfacement,

LEFTTWEETER
page
Replacement,
23-192

DRIVER'S
DOOR
SPEAKER
Repfacement,page 23-192

LEFT
SPEAKER
Replacemenr.page 23-193 ANTENNA MOTOR
Test, page 23-194
Replacement, page 23-196

23-188
!iltil;s'
Soden:

i FIGHT TWEETER
STEREO RADIO/CASSETTE page 23-192
Replacement,
PLAYER *: USA
R€moval,paoe23-191 FBONT PASSENGER'S
T€rminals.page23-192 DOOR
SPEAKER
page 23-192
Replacement,

RIGHTREAR
SP€AKER
page2 3 - 1 9 3
Replacement,

DRIVER'S
DOOB
SPEAKER
Repfacement,p8ge 23-192

POWERANTENNA MOTOR
Test, page 23-194
Replacement, page 23-196

23-189
StereoSoundSystem
CircuitDiagram

FUSE
UNDER-HOOO i RETAY
BOX tGNtTOt{
SWTTCH
tlo.4lllo0Al No.39l50Al
+WHT
WHT/BI"K

UNDEN-DASH No.l9ll0Al
FUSENEIAY RJSE
8ox

-L-fl
SIER€OMOO
CASSETTE
N.AYER
AI{TE?{NA
MAST

AMTEI{iIA
ITAD
4
-fi1
.a'J
RIGI{T
REAR
SPEAXER

POWER AIT€NI{AMOTOF
ntrrct d fulvl
M_nhthoantanna
| : Excoot!ad!n of Crnede

23-190
 Unit Removal

CAUTION: 3 . Removethe four mounting screws, then removethe

a All SRS oloctrical wi ng harn.$.s ara covcrrd with front console.
yellow insulation.
a B€toro disconnocting any part ot tho SRS wirc hrr-
nosa, connsct tho short conn6ctol(rl.
a Raplaco the sntirs sttoctod SRS hamoas asacmbly it
it has an opon circuil 01 damagod widng.

SRS MAII{ HABNESS FRONTCONSOLE

NOTE: The original radio has a coded theft protection 4. Loosen the two mounting screws, then disconnect
circuit. Be sureto get the customer'scode numberb€lore the 16-P connectorand the antennalead, and oull
- disconnecting the battery. out the stereo .adio/cassette player.
- removingthe No. 32 (7.5 A) fuse in the under-hood
fuse/relaybox.
- removingthe radio.
After ssrvice,reconnectpower to the radioand turn it on. 16-P COi{i{ECTOR
When the word "CODE" is displayed,enter the cus-
tomer's 5-digit code to restore radio operation.

1. Remove the center console (see section 2O).

2, Remove the cigarette lighter assembly {see page

23-205t.

ANTENlTASUB-LEAD

23-191
Stereo Sound System
Stereo Radio/CassettePlayer Front Speaker/Tweeter
Terminals Replacement
Front Spoakor:

1. Carefullypry out the speakercover.

2. Removethe three screws,then disconnectthe 2-P

connector Jrom the speaker, and remove the
\ speaker.

*i,.,-terlll A
FO] ANTENNA LEAD

T I!NM[IAL
r^lt
I
\ 7
2.P CONNECTOR
r
SPEAKER
COVER

A9---------+A16
Twootor:

1. Removethe door paneland disconnectthe tweeter

2-P connector.

Connects to 2. Remove the two screws, then remove the tweeter

A1 RED/GRN Frontpassenger's
door speakerO ano covet.
A2 BLU/GRN Driver'sdoor speaker@
A3 RED/BLK Lights-onsignal
A4 WHT/8LU Constantpower {Tuningmemory)
A5 YEL/RED ACC (Mainstereopowe. supplyl
A6 YEL/GRN Radioswitchedpower (To antenna)
A7 BLU/YEL Left rearspeakerO
A8 RED/YEL Rightrearspeaker@
A9 BRN/BLK Frontpassenger's
door speakerO
A10 GRY/BLK Driver'sdoor speakerO
A lnot used)
412 (notused)
A13 (not usedl
A14 BLK Ground(G551)
Al5 GRY/WHT Left rearspeakerO
A16 BRNAA/HT Rightrearspeakere

23-192
 RearSpeakerReplacement
Hatchback:

1. Remove the sDsakercover. 1 . Removethe three screwsfrom the trunk side,then

2. Removethe three screws, then disconngct the 2-P
connocter trom the rear spoakor.
remove the soeaker cover.
Removethe tour screws, then disconnectthe 2-P
connector t.om the s9eaker, and remove the
soeake,.

LEFTREAR OUARTERTRIM PAI{EL

SPEAKER SPEAKERCOVER
,r--I

LEFT REAR
SPEAKEN

2-P CONNECTON

SPEAKERCOVER

REABTRAY

23-193
 StereoSound System
Power AntennaMotor Test

Removethe quartertrim panel(Hatchback)or trunk AI{TE T{A MAST

side trim panel (Sedan).

Disconnect the 3-P connector from the motor, and

remove the connector from its clamD.

3 . Check for power to the motor at the connector ter-

minals:
a There should be battery voltage between the AI{TEI{I{A
WHT/RED(+l and BLK{-} terminalsall thetime. LEAD
a There should be battery voltage between the
YEL/GRN {+) and BLK(-} terminalsonlvwith the
ignition and radio switched ON.

4. Test motor oDeration:

EXTEND:Connect battery power to the "A" 8no

"B" terminals
and groundthe "C" terminal.
C ftYhh lha lnLnn. r.tr.ci.d t|Ilyl
RETRACT:Then disconnectpower trom the "4"
terminal,

Sticking Ant6nna:
The antennasticks in either the up or down position.

*ft'^to 1 . Usingthe antennawrench, removethe antennanut,

?r* spacer (see page 23-195).

*r'
TIFIT Cleanthe antennamast housingthreads,and rein-
stall the soacer.
YEL/GRN

PLASTICSLEEVE AIITENNA MAST

Cloan mast
housing
throads.

Usethe antennanut wrench and tightenthe anten-

lf the motor fails to run or does not run smoothlv,
reDtacetr.
na nut to 2.3 N.m (0.23 kgf-m, 1.7 lbf-tt). lJ you
overtightenedthe nut. the antenna may stick. lf
stickingoccurs, back the nut off a little, then turn
the radioon and off to raiseand lower the antenna
again. Repeatuntil the antennamoves treely.

23-194
fmft,
 Antenna MastReplacement

Ramoval: Installation:

NOTE: The antennamast alone can be replacedwithout 1. Holdthe antennaso that the teelh on the drive ca-
havingto removethe power antennamoror. ble tace in the directionshown. then insen the ca-
ble into the antennahousing.
1. Removethe antennanut and spacer.

2. Carefullywithdraw the antennamast while extend-

ing it by turning the radio switch ON.

AI{TENNA I{UT

SPACER

ANTENI{A NUT WRENCH Direction oI the

teeth

, Checkfor engagementof the cableteeth with the

ANTENNA NUT drive gear by carefully moving the cable up and
2.3 N.m 10.23kgl-m, 1.7 lbt-ft) oown.

Turnthe rsdioswitch "OFF", and let the motor Dull

the drive cable into the antennahousing.

4. Cleanthe antennahousingthreads,then insen the

antennainto the housing.Installthe bushingspacer,
and installand tighten the antennanut to 2.3 N.m
{O.23 kgl-m. 1.7 lbf-Jt).

Checkthat the antennamast retaactsand extends

fully when the radio switch is tu.ned ON and OFF
fepeatedly. It you overtightenedthe nut, the anten-
na may stick. lf stickingoccurs,back the nut otf a
little,then raiseand lowerthe antennaagain.Repeat
until the antennamoves treelv.

POWERANTENNA
MOTOR UNIT

23-195
StereoSoundSystem
PowerAntennaMotor Replacement
1 . Removetho quart€r trim panel (Hatchback)or trunk
side trim panel (Sedan).

Disconnectthe 3-P connectorand antennaleadtrom

the motor, then remove the antenna nut and motor
bracket nut.

AI{TENNA1{UT AT{TEI{]{AI{UT
2.3 l{.m WBEI{CH
oTJAA-OOlo(xrc

3+CO ECTOR

DRAI HOSE

MOTOR
BRACKET
TUT

3 . Remove the motor and antenna as an assemblv.

NOTE: Tighten the antenna nut, then tighten tha

motor bracket nut.

23-1 9 6
Circuit Diagram

V
STEREO
RADIO/
CASS€TIE
PI-AYER

23-197
Clock
Replacement Terminals
CAUTION:
a Pry th6 clock out at th€ left sido,
a Be carsful not to damage the clock and the dashboE d
whon prying the clock out.

1. Pry the clock out from the dashboard,then discon-

nect the 4-P connector.

4-P COI{NECTOR

CLOCK

Torminal Wiro Connecta to

A BLK Ground
{Main clock power sup-
YEL
plv)
RED/BLK Lights-on signal
Constantpower
D WHT/BLU (Time
memory)

23-198
Horn
Component Location Index
CAUTION:
a All SRS €lectricsl wiring harnessesal€ covered with
yellow insulation.
a B€fore disconnecting any part of the SRS wiro har-
neaa, connect tho short connectol(sl.
a Replacothe entire aftected SRS harnessassembly if
it haa an open circuit ot damaged wiring.

HORN
Test,page23'2O3

{Covo.ed wiih yollow insulationl

HORNSWITCHES
Test, pago23-2Ol

<------\
-\----.....=

UNDER.DASH
FUSE/RELAYBOX
CABLE REEL
Repfacement,page 23-302

HORN RELAY
I Wiro coloB: BLU/RED,BLK, I
IWHT/GRN, and BLU/GR l
Test, page 23-68

23-199
Horn
CircuitDiagram

MTTERY

------------.,1

r-T-l
lll- l ()
l1'l I
SHORT
c0ill{EcToR
L------------J
Wrthoutcrub6conlrol,

23-200
 Switch Test
CAUTION: 4.
a All SRS el6ctrical wiring harnossosare covarod with
yellow inaulation.
a Beforo disconnecting any pan ot the SRS wire har-
neaa, connoct ths short connector(s).
a Roplacethe entil€ afloctod SRS harne$ a$6mbly if
it has an open circuit or dsmagad wlring.
Disconnect the cable reel harness 6-P connector
from the SRSmain harness,then connect Test Har-
ness C onlv to the cable reel harness.
CABLEREEL
HARNESS

NOTE; The originalradio has a coded theft protection

circuit. Be sure to get the customer'scode numberbefore
- disconnecting the battery.
- removingthe No. 32 {7.5 A) fuse lrom the under-hood
tuse/relavbox.
- removingthe radio.
After service, reconnect power to the radio and turn it
on. Whenthe word "CODE" is displayed,enterthe cus-
tomer's 5-digit code to restore radio operation.

1. Disconnectthe battery negative cable, then discon-

nect the positivecable.

2. Connectthe short connector(slto the airbag(sl.

DRIVER'S CABLEREEL TESTHAR ESSC

AIRBAG 3.P CO NECTOR oTLAz- SL/l{,3OO

5 . Check for continuity between the No, 3 terminal ot

the 8-P connector of Test Harness C and body
ground with the horn switch pressed.
a lf there is continuity,the horn switch is OK.
a lf there is no continuity, go to step 6.

TESTHARNESS C
OTLAZ-SI/I()3OO

DRIVER'S
AIRBAG ACCESS
3-PCO'TNECTOR COI{NECTOR PAI{EL
{RED}
SHORT CONTIECTOR
{REO}

Removethe dashboatdlower cover and kne€ bolster

(see page 23-701. (cont'd)

23-201
Horn
Switch Test (cont'd)

6 . Removethe two TORX@bolt6 using a TORX@T30 Check for continuity between the horn positive ter-
bit, then removethe driver's airbagassembly. minal and the steering column shaft with the horn
switch pressed, There should be no continuity.

HORNSwlTCH
DB|vEN'S TERMIITAL
POSITIVE
AIRBAGASSEMBLY

TORXO BOLT
(U!6 s TORxo T3O bitl

a lf there is continuitv:
- With cruise control: Test the set/resume
switch. lJ the switch is OK, replacethe cable
reel.
- Without cluise control: Replacethe cable reel.

a lJ there is no continuity. remove the steering

wheel and the four screws, then remove the
steering wheel cover. Replace the faulty horn
switch.

8. Reinstallthe steeringwheel {see section 17).

23-202
 Horn Test
t . Removethe front bumper (seepage 23-164).

2 . Disconn€ct the 2-P connector from the hofn.

5. Remove the horn.

2-P COt{t{ECTOB

MOUNTI G AOLT

4. Test the horn by connecting battery power to one

terminsland groundingthe other, The horn should
sound.

5. Reolacethe horn if it fails to sound.

23-203
CigaretteLighter
CircuitDiagtam

UNOER-HOOD
FUSE/RELAY
BOX

No.tgll0Al
FUSE UIIOER-DASH
FUSE/N€[AY
BOX

BI.K

G20t
Gilol

23-204
 Replacement
CAUTIOI{: Disconnect the thermotuse case from the socket
a All SRS sloctdcal wiring harnossasare covered whh €no.
yollow insulatlon.
a B.tore disconnoctlng any part ot the SRS yyi16 h.r- 3 . Remove the thermal protector. and pull out the
nosa, connrct tho short connoctot(al. cigarette lighter socket.
a Rsplaco th. onti.e !ffoct.d SRS hamoss a$ombly lf
It ha! an opon cilcuit or damagod wiring. CIGARETTELIGHTEN
LTGHT(1.4 Wt
ASHTRAY LIGHT
( r . 4w l

FROI{TCO|{SOLE

THERMOFUSE
CASE

RI G NUT

THERMALPAOTECTOR

Removethe two ashtray mountingscrews. Then pull

out the ashtray from the front console, and discon-
nect the 4-P conn€ctor,

SOCKET

4 . When installing the cigarette lighter, align each lug

on the face panel, illuminationring, and cigarefte
lighter socket with the groove of the hole, then po-
sition the bulb housing on the thermal protector be-
tween the stops in the console panel.

Make sure that the ground wire, bulb socket, and

thermofuse housingare seatedto the cigarette light-
er assomblv.

scREws

23-205
.--
Rear Window Defogger
Component Location Index

CAUTION:
a All SRS olectrical wi ng ham€$6s are covoled with
y€llow insulation.
B6foro disconnocting any part of ths SRS wire har-
ness. connoct tho short connector(s).
Roplacsthe ontire affectod SRS harness assombly if
it has an open circuit or damagcd wiring.

REABWINDOW
DEFOGGER RELAY
Test,page23-68

SRS MAII{ HAR'{ESS

REARWINDOW
DEFOGGERSWITCH
Removal, page 23-209
Test, page 23-2Og

REARWINDOW DEFOGGER
Test, page 23-210

UI{DER.DASHFUSE/RELAYBOX

REARWINDOW DEFOGGERTIMER CIRCUIT

{ln the integrated control unil)
fnput Test, page 23-147

The rear window defoggeris controlledby the integratedcontrol unit, Pushingthe defoggerswitch in the instrument
panel it sends a signalto the defoggertime. in the integratedcontrol unit, and the detoggerstays on tor 25 minutes
or until the ignitionswitch is turned off. The indicatorlight in the switch comes on when the deJoggerworks.

23-206
 UNDER-
HOOO
FUSE,NE[AY
80X

B[K/GRN

I
[ql
t=l
BLK/GRN
trI
I NOISE
;ERI
CONDENSER
I

I'
8LK
I
I:
H.tchback:G77
Ssdan:G50

23-207
 RearWindow Defogger
Troubleshooting

NOTE: The numbersin the table show the troubleshootingsequence.

Item to be inspected

.E
o
o.- 0to
9\
*o-- c g
< f : E
g o <E @ =
oP

o! o5 =
. E 6 ('r6
o ! 3
g8
z i z ) o
o
o
o
ED
o
o o
' i i ;5 o o o
9 c o o o
Symptom lD 5. o- o5

Defoggerworks, but indicator oTBLU/YEL

BLKTYEL
1
light does not go on.
Defogger does not work and G201
1 2 2 YEL, BLUfYELor BLK/YEL
indicatorlight does not go on. G401
'1i G771 BLU|YELor BLKIYEL
Defogger does not work, but 1 4 2 3 ',: G5O3 BLK/GRNoTBLKMHT
indicstorlight goes on.
Defogger-ontime is too long or
too short (normaloperationtime 1
is 25 minutes).
'1: Hatchback
'2: Sedan

23-208
IINIilfi
 Switch Removal Switch Test
CAUTION: Be caroful not to damags the hoator con- NOTE: Be caretul not to damage the heate. con-
tlol/centel ail vent. trol/centerair vent.

1, Carefully pry the switch out of the heater con- 1. Carefully pry the switch out of the heater con-
tfol/centerair vent. trol/center air vent.

2. Disconnectthe 6-P connecto,from the switch. 2. Checktor continuitybetweenthe terminalsacco.d-

ing to the table.

Torminal
\
I D F
P*il*__\

o- \../
-o o- _o
PUSHED
o- -\ -o
RETEASED
o- /\
\:,,t

/:\
o- \7

REARWINDOWDEFOGGER
SWITCH

Remove the indicator bulb (turn the socket 45o

counterclockwise),and removethe illuminationbulb.

REARWINDOW
DEFOGGERSWITCH

[-4 I
) ll:g'",li'T

to.a4wt

23-209
Rear Window Defogger
Function Test DefoggerWires Repair

CAUTION: Be carelul not to scratch 01 damago ths NOTE: To make an eftective repair. the broken section
defogger wires with th€ tsster probe. must be no longerthan one inch.

1. Check for voltage between the positiveterminal and 1. Lightly rub the area around the break with line steel
body groundwith the ignitionswitch andthe delog- wool, then clean it with alcohol.
ger switch ON. There should be battery voltage.
2. Carefullv mask above and below the broken portion
a lf there is no voltage,check for of the defoggerwire with cellophanetape.
- laulty detoggerrelay.
- faulty defoggerswitch.
- faulty integratedcontrol unit. OPEN
- an open in the BLK/GRNwire

a lJ there is baftery voltage, go to step 2.

NEGATIVETERMIiIAL TERMINAL
POSITIVE

Using a small brush,apply a heavy coat of silvercon-

ductive paint extendingabout 3 mm ( 1/8 inl on both
sides of the break. Allow 30 minutesto dry.

NOTE: Thoroughly mix the paint before use.

Turn the rearwindow detoggerswitch OFF,Check

for continuity between the negativeterminal and
body ground.
a It there is no continuity,checkto. an open in the
defoggerground wire.
a ll there is continuity,go to step 3.

Touch the voltmeter positive lead to the halfway

point of each defoggerwire, and the negativelead
to the negativeterminal.
Thereshouldbe apptoximately6 V with the ignition
switch and defoggerswitch ON.

a lf the voltageis as specified,the defoggerwire

is OK.

a lf the voltage is not as specified.repai,the defog-

ger wire:
lf it is more than 6 V, look for the damageon
the negativehalf on the grid. 4. Check for continuity in the repaired wire.
- lf it is less than 6 V. iook for the damageon
the positivehalf of the grid. t Apply a secondcoat of paint in the same way. Let
it drv three hours betore removing the tape.

23-210
Moonroof
GomponentLocationlndex

a All SRS oloctrical wiring harnessesaro covared with

yellow insulation,
a Eoforo disconnocting any part of tho SRS wire har-
neaa, connoct th6 shon connector(sl.
a Roplaceth6 entire 8ff6cted SRS harness assombly if
it has an open circuit or damaged widng.

SRS MAIN HARI{ESS

{Covered with yellow insulation)

MOO BOOFSWTTCH
page23-214
Remov8l, MOO ROOFMOTOR
Test, page 23-215 Test,pag€23-215
Replacoment,
section20

23-211
 Moonroof
CircuitDiagram

lo - ---------
f"------------

i|OoNRoOFMOf0R H.rchb.ckl MoOnOoFttoton 6.ddl

23-212
-
 ElectricalTroubleshooting
NOTE: The numbers in the table show the troubleshooting sequence.

It€m to be insoected

es
( ! O
EE :
FE3
b 9 o
o

. o 6 -9
- . 9
:t< 3 E .9
;o-
'r3
; g : < € E-
<-c
oiSE o 9 3tr € t 3E
o
g
bE* F 6
\ f i
3 l
.', o
o
5 : 3 l ct

?t; z a z ) o o
o o .::
: - = c 9 o
iE d 3 t t5 o o o
a-g
Symptom 9 c o o o
o 6 6 dl= > l o 6
Moonroof does not move,
but motor tums.

Moonroof
does not In all switch G201 WHT, GRN/BLK,
positions 1 a 4 5
move and G401 GRN,BLK
motor does
not tum With OPEN
lmoonroot switch I 2 GRN/REO
can be
moved with
moonroof with closE
switch I 2 GRN/YEL
wrenchl.

23-213
Moonroof
FunctionTest
Removethe dashboardlower cover, and if neces- CheckJor continuity between the No. 2 terminal and
sarv, removethe knee bolste.. body ground.

a ll there is no continuity,check for

- an ooen in the BLK wire.
- poor ground (G201, G4Ol).
a lf there is continuity,go to step 4.

4. Check tor voltagebetweenthe No. 4 terminal( + )

and No. 2 terminsl{ - ) with the ignitionswitch ON
{ll). There should be battery voltage.

a lf there is no baftery voltage, check tot

- blown No. 1 (3o Al or No. 14 {20 A) fuse in
the under-dashtuse/relay box.
- an open in the wires (GRN/BLK,GRN,WHT)
or loose terminals.
- faulty moonroof relay.
a lf there is battery voltage, go to step 5.

Connectthe No. 4 terminalto the No. 3 terminal,

and the No. 1 terminalto the No, 2 terminalwith jum-
per wires. The moonrootshouldopen when the ig-
KNEEBOLSTER nition switch is turned ON (ll).

lf the moonroof ooens, check the moonroof

DASHBOARD switch,
LOWER ll it doesn't open, removethe headlinetand check
COVER the motor.

2. Carefullypry the switch out of the left side air vent

panel,then disconnectthe 4-P connectorto remove
the switch.

4-P CONI{ECTOR

SWITCH
MOOi{ROOF

. r - - r
l l l 2--t l
f--T
l 3 1 4 l

View from wire side

23-214
 Switch Test Motor Test
1, Removethe dashboardlower cover. Removethe headliner(see section 20).

2. Carefully pry the switch out of the left side air vent
Danel, then disconnect the 4-P connector and re-
move the switch.
3. Checklor continuitybetweenthe terminalsin each
switch positionsccordingto the table,
Disconnect the 2-P connector from the moonroot
moror.
Checkthe motor by connectingpower and ground
accordingto the table.
NOTE: Motor clutch test is in section 20.

\ Torminal
---__\ A I D
P"ri i- \ Te.minal
-- ---------l A B
Condition
OFF G- --o OPEN o
OP€N o- --o G- CLOSE @

o- --o
CLOSE

SWITCH
MOONROOF

lHatchblckl (Scd!n)
View from terminalside

4. It the motor fails to run or doesn't run smoothly.

replaceit.

,l
IOPEiI
Ir\./ dcLos€
OFF

23-215
PowerMirrors
Component Location Index

POWERMIRRONS
Test, page 23'220
Repfacement,page 23'221

POWERMIRRORSWITCH
Function Test, page 23'219
Test, page 23-218

23-216
GircuitDiagram

- HOOO
UNDER FUSE/BELAY
8OX

*,,^.-**Q !.,$iii.,i

LEFTT

---il;----

;--------------;
ln rI

G501
G502

23-217
Power Mirrors
Switch Test

Removethe driver's door panel (see section 2O).

Checktor continuitvbetweenthe terminalsin each

switch positionaccordingto the table.

Mirror Switch

\ rermrnal
J
Position \
OFF G"
-o
UP
o- -<>-
-o
DOWN aaaaaaaa
R o- -o A-------+J
o-
LEFT
-o
-o
RIGHT
o-
OFF o- -o
UP
o- -(J_
-o
DOWN
G- -o
-o
tEFT
-o
RIGHT
G-
P -o

23-214
 FunctionTest
NOTE: To test, removethe driver's door panel (seesec- Loft mirror inopsrative:
tion 20), then disconnectall of the connectorsfrom the
door oanel. Connectthe BLK/YELterminalof the 10-Pconnectorto
View from wire side
the YEL/RED1 terminaland the YEL/WHT(or YEL/BLKr)
terminalto body ground with jumper wires.
The left mirror should tilt down (or swing leftl when you
turn on the ignitionswitch.

a lf the mirrordoes not tilt down (or does not swing leftl,
check Jor an open in the YEL/WHT (or YEL/BLK1)
wire betweenthe left miffor and the switch. It the wir€
is OK, check the left mirroractuator.

a lf the mirro. neithertilts down nor swings left, repair

the YEL/RED1wire between the left mirror and the
switch.

a lf the mirror operates properly, check the mirror

swatch.

Right mirror inoporative:

Connect the BLK/YELterminal of the 1O-Pconnector to

th€ BLU/WHTterminaland the YEL/WHT{or BLU/BLK)
terminalto body ground with iumper wires.
The right mirrorshouldtilt down (or swing left) when you
turn on the ignitionswitch.

a lf the mirrordoes not tilt down (or does not swing left),
removethe right door paneland checkfor an open in
the YELMHT (or BLU/BLK)wire betweenthe right mir-
ror and the switch. lf the wire is OK. checkthe right
mtrroractualor.
Miror Tost
a ll the mirror neither tilts down nor swings lelt, repair
NOTE; Checkthe No. 13 (7.5 A) tuse in the under-dash the BLUMHT wire between the right mirror and the
fuse/relaybox beforetesting. switch.

Ono or both inop€rativa: a lf the mirror operates properly, check the mirror
swatch.
1. Checkfor voltagebetweenthe BLKIrEL terminal8nd
body ground with the ignitionswitch ON (ll).
There should be battery voltage.
a lf there is no voltage,check tor:
- Blown No. 13 {7.5 A) fuse in the under-dash
fuse/relav box
- An ooen in the BLK/YELwire
a It there is battery voltage, go to step 2.

2. Checkfor continuitybetweenthe BLKterminaland

body ground.
There should be continuity;check Jor:
- An ooen in the BLK wire
- Poor ground (G501, G5O2)

23-219
Power Mirrors
Door MirrorTest
1, Removethe mirror panel and door panel (Sed8n). TILT:
then disconnect the 8-P (Hatchback)or 3-P (Sedan)
Terminal '|(H)
connector from the power mirror actuator. 2(G)
Position
Sedan: UP @ I

DOWN tJ o
SWING:
Terminal
MIRNOR 2(G) 3(Ft
Position
LEFT o
RIGHT (D

Hatchback: 3. lf the mirror fsils to operate properly, replace it.

Check actuator operation by connecting power and

ground accordingto the table.

23-220
 PowerMirror Replacement
l. Carefully pry out the miror panel with a llat tip
screwdriv€r.

2 . Remove th€ door panel (see section 20).

HEtchblck:
hca! hara to
rolalaa lha conn9clor

MIRRORPA]IEL

CO ECTOR

t Disconnectthe 8-P (Hatchb€ck)or 3-P (Sedan)con-

nector from thg oower mirror actuator.

4. While holding the mirror with one hand, remove its

mounting nuts (Hatchback) or mounting screws
(Sedan) with the other.

23-221
PowerWindows
ComponentLocationIndex

POWERWINDOWRELAY UI{DER-DASH
Test, page23-68 FUSE/RELAYBOX

FOWERWINDOW
MASTERSWITCH
{Has built-in control unitl FRONTPASSEI{GER'S WII{DOWSWITCH
fnput Test, page 23-226, 228 Test, page23-230
Tost, page 23-229, 23O Repfacement. page 23-231
Ropfacement,page 23-231
FRONTPASSENGER'S WII{DOWMOTOR
fosr, page 23-232
RIGHTREARWll{DOWSWITCH(Sodrn}
Tost, page23-230
Replacement,page23-231

RIGHT REARWII{DOW
MOTOR (Sod.nl
Test, page 23-232

DBIVER'SWINDOW MOTOR
Test, page 23-232

LEFT REARWINDOW MOTOB {S6dan)

Test. page 23-232

LEFT REAR Wlt{DOW SWITCH lsodanl

Test, page 23-230
Repfacement,page 23-231

23-222
CircuitDiagram(Sedanl

UNOER-HOOO
FUSE/RELAY
8OX DASHFUSE/RELAY
UNDER_ BOX

DRiVER'S
WINOOW
MOTOR

RIGHT
REAN
WINOOW LEFTREARWINDOW FROI{T
PASSENGER'S G501 G20r
MOTOR MOTOR wrNoow
i,roToR G502 G401

23-223
PowerWindows
Circuit Diagram(Hatchback)

- HOODFUS€/REI.AY
UNDER BOX UNOER-
OASHFUSE]NEI.AY
8OX

tlo.41l100Al ilo.39{50A)

8LXz
D PASSENGER'S
wrNDow
swITcH

G50t
PASSENGEN'S G502 G401
wtN00wM0T0n

23-224
 Troubleshooting

NOTE: The numbers in the table show the troubleshooting sequence

Item to be insoected
o
1 0 x

9 I
;
.= E .=
-
3E o o (t ' 3 ;
3
o E
<.i I ; 3
-g E
o E x E
S H 3
r! i SJ
@
N N
F\
! t t .9 3
: !

z ) t
,i
z z
o
z
;
z t o t = -
g 3
' . c
i
t5 o qt
o () o
; i 3 - i i I .E 3
9 c o o a
Symptom o- 6 6 6 o- o o o- o- O E
All windows do not work. G20r BLK/YEL
G401 WHT/RED
G50l
G502
Driver's window does not
I 4 5 WHT/YEL
Driver'swindow does not BLU,
work in AUTO. 1
BLK/WHT
Passengsr's Right tront 1 5 BLUi BLK
windows do *Lett rear
3 4 GRN/BLK
not work.
r Right rea. I 2 4 YEL/BLK

23-225
PowerWindows
Master Switch Input Test (Sedan)

NOTE; The control unit is built into the Dowerwindow

maste. switch, and onlv controlsdriver'sdoor window
ooerations.

1. Removethe driver'sdoor paneland disconnectthe

16-P and 1-P connectorsfrom the master switch.

2. Inspectthe connectorand socket terminalsto be

sure they are all makinggood contact.

a lf the terminalsare bent, looseor co.roded, reDair

them as necessary.and techeckthe system.
a It the terminalslook OK, make the following in-
put tests at the connecto..
- It a test indicatesa problem,tind and correct
the cause,then recheckthe system.
- lf allthe input tests proveOK, the power win-
dow masterswitch must be faulty; replaceit.

BEDI'EL I GRN

8LU/YEL I YEL/BLK

View from wire side

View lrom wire side

23-226
 Test condition T€st: Desirod rosult Possibl€cause if result is not obtainad
BLK2 Under all conditions Check for continuityto ground: . Poorground{c501, G502)
ano There should be continuitv, . An openin the wire
BLK3
WHT/YEL lgnitionswitch ON (lll Check for voltageto ground: Blown No. 14 (20 Al fuse in the
The.e should be battery voltage. under-dashfuse/relaybox
BLU/BLK
Bfown No. 5, 8, 7 ot 4 l2O Al fuse
GRN/BLK in the under-dashfuse/relay box
Faulty power window relay
YEL/BLK An open in the wire
Connect the WHT/YEL Check the driver's window . Faulty drivea'swindow motor
and RED/YEL1 terminals, motor: . An open in the wire
RED/BLU1
ano
and the RED/BLU1 and It should run (the window
BLK3terminalswith jum- moves down).
REDATELl
per wires, then turn the
ignitionswitch ON (lll.
Connectthe BLU/BLK Check the tront passenger's . Faultyfront passenger'swindow
and BLU/GRNterminals, window motor: motOa
BLU/YEL
and the BLU/YELand It should run {the window . An open in the wire
4 and
BLK, terminalswith jum- moves down).
BLU/GRN
per wires, then turn the
ignitionswitch ON (ll).
Connect the GRN/BLK Check the left fear window Faulty left rear window motof
and GRN terminals,and motor: Faulty lett rear window switch
GRN/YEL
the GRN/YELand 8LK, It should run (the window An oDenin the wire
5 ano
terminalswith iumper moves down).
GRN
wires, then turn the igni-
tion switch ON (ll).
Connectthe YEL/BLK Check the right rear window Faulty .ight rea. window motor
and YEL/GRNterminals, motor: Faulty right rear window switch
YEL/GRN
and the YEL and BLK, It should run (the window An open in the wire
6 and
terminalswith iumper moves down).
YEL
wires, then turn the igni-
tion switch ON (ll).
Connectthe WHT/YEL Conned an analogohmmeterto Faulty pulser
and RED/YEL1 terminals. te.minalsBLU and BLK/wHT: Faultydriver's window motor
BLU
and the REo/BLU1and The meter needleshould move An open in the wire
7 ano
BLK3terminalswith jum- back and lorth alternatelvas
BLK/VVHT
per wires. then turn the the driver's window motor runs.
ignitionswitch ON (ll).

23-227
Power Windows
MasterSwitch lnput Test (Hatchback)

NOTE: The control unit is built into the power window

master switch, and onlv controls driver's door window
operations,

1. Removethe driver'sdoor panaland disconnectthe

1O-Pconnectol from the masterswitch.

2. lnsDect the connector and socket terminals to be

sure they are all makinggood contact.

a lf the terminsls arc bent, loose or corroded,rspair

them as necessary, and recheck the system.
a lf the terminals look OK, make the following in-
put tests at the connector terminals.
- lf a test indicates a problem, find and correct
RED/YEL
the cause, then recheck the systsm.
- lf all the input tests proveOK, the powsr win- RED/BLU BLU/GR'{ BLU/BLK
dow master switch must be faulty; replace it. View from wirs sido

Wiro Tost condition Tost: Dashodr€suh PGslblo cluso if rosuh ir not obtalnad
BLK' Underall conditions Ch€ck for continuity to ground: Poor ground (G501, G5O2)
1
8LK3 There should be continuity. An oDen in the wire
lgnitionswitch ON {ll) Ch6ck for voltags to ground: Blown No. 14 l2O Al fuse in the
WHT/YEL Th€re should be battery voltage. under-dashfuso/relay box
Blown No. 5, or No. 8 (2O A) tuse
in the under-dashluse/relay box
BLU/BLK Faulty power window relay
An oDen in the wire
Connectthe WHT/YEL Check the driver's window . Faulty driver's window motor
and REDfYELIterminals, motor: . An ooen in th€ wire
RED/BLU1
and the RED/BLU1 and It should run (the window
ano
BLK3terminalswith jum- moves down).
RED/YELI
per wires, then turn the
ignitionswitch ON {ll).
Connectthe BLU/BLK Check ths passengor's window . Faulty pass€nger's window motor
and BLU/GRNterminals, motor: . An oD€n in the wire
BLU/YEL
and the BLUTYEL and It should run (the window
4 and
BLK2terminalswith jum- moves down).
BLU/GRN
per wires, then turn the
ignitionswitch ON {ll).
connect the WHTTYEL Conn€ct an analog ohmmeter to Faulty pulser
and BEDrYELIterminals, thE BLU ANd BLKMHT t€Tr Faultv driver's window motor
BLU
and the RED/BLU1 and minals: An oDenin the wire
5 anq
BLK3terminalswith jum- The meter needle should move
BLKMHT
pe. wires, then turn the back and torth alternately as
ignitionswitch ON (ll). th€ driver's window motor runs.

23-228
 MasterSwitch Test (Sedan)
1. Remove the driver's door pan6l (sse section 2O). Front Paslongrr't Swltch:

2. Disconn€ct the 16-P and l-P connectors trom the \ Terminal

switch. I Main \ H o
Position I Swirch \
3. Check for continuity b€tw€€n tho terminals in each ON o- r) --o
OFF
switch position according to the tables.
OFF G-- --o
--o
ON
UP O-
DRIVER'S
SWTCH
OFF o- --o
LEFTREAR MAtit swtTcH
ON
POWERwl DOW
DOWN o- --o
MASTEBSW]TCH OFF o- -_o
Lcft Rear Swhch:
\ Terminal
j Main I E F o
Position I Switch \

PASSEI{GER'S OFF
ON o- o --o
swtTcH OFF o- --o
RIGHT REAN SW|TCH
o- --o
ON
UP o- --o
A B C D E ut'f o- --o
ON
o- --o
DOWN G- --o
OFF -o

Rlght Roar Swhch:

\ Teminal
If
I Main N 0 o
Position I Switch \

OFF
ON G_ o --o
OFF o- --o
o- --o
ot'l
UP --o
OFF o- ---o
ON
o- --o
Ddv.r't Swh.tr;
Th6 driv€r's switch is combined with the cont.ol unit so
DOWN o- -o
you cannot isolatethe switch to t6st it. Instead , run the OFF G- --o
maater switch input test procedurss No. 1, 2. 3, and 7
on page 23-226. lf the tests are normal, th6 driver,s
switch must be fsulty.

23-229
Power Windows
Master Switch Test (Hatchbackl Window Switch Test
Passenger's
1 . Removethe drivef's door panel (seesection 201. Front:
1 . Removethe passenger'sdoor panel {seesection 20).
Oisconnectthe 1O-Pconnectorfrom the switch.
2. Disconnectthe 5-P connectorfrom the switch.
Checktor continuitybetweenthe terminalsin each
switch positionaccordingto the table. 3. Checkfor continuitybetweenthe terminalsin each
switch positionsccordingto the table.
pOWERWTNDOW PASSENGEB'S
MASTERSWTTCH SWITCH

\ Torminal
A R D
il;_\
i 1 \ i o-
\4r-I^l,r
OFF
--o
)rvti\ UP
o- --o
--o
.Fi'ilj G_
DOWr.l
o- --o

Drive.'s Switch: Rear (Sedanl:

The driver'sswitch is combinedwith the controlunit so
you cannotisolatethe switch to test it. Instead, run the
masterswitch input test proceduresNo. 1, 2, 3, and 5
on page 23-228, lf the tests are normal, the d.ivet's
switch must be faultv.
1. Removethe inn€r handle (seesection 2O)'
2, Disconnectthe 5-P connectorfrom the switch.
3. Checkfor continuitybetweenthe terminalsin each
switch position according to the table.

Passengsl'r Switch:
\ Te.minsl
I Msin \ D H J
Position I Switch\
ON o- --o
(J

o- -o
OFF
OFF

o--
o- --o
ON \ Terminal
UP I D
OFF o- -o ;;__\
G_ --o
o- -o OFF
--o
ON
o- --o o-
DOWN
-o G_ --o
OFF o- UP
o- --o
o- --o
DOWN
o-

23-230
 Master Switch Replacement Passenger's
Window Switch
Replacement
Hatchback: Flont:

1. Removethe driver's door panel (seesection 20). 1. Removethe passenger'sdoor panel (seesection 201.

2. Disconnectthe 1O-Pconnectorlrom the switch, 2. Disconnectthe 5-P connectorfrom the switch.

3, Removethe threemountingscrewsand the switch. 3. Removethe two mountingscrews and the switch.

swtTcl{

Roar (S6danl:

Sedan: 1. Removethe inner handle(see section 20).

1. Removethe driver's door panel (seesection 2O). 2. Disconnectthe 5-P connectorfrom the switch.

2. Disconnectthe 16-P and 1-P connectorsfrom the 3. Removethe two mountingscrews and the switch.
switch.

3. Removethe two mountingscrews and the switch. w|I{Dow

.swtTcH
POWERMIRROR
swtTcH

scREws INNERHANDLE

23-231
 Power Windows
Driver'sWindow Motor Test Window Motor Test
Passenger's
Motor Test: l. Removethe passenger'sdoor panel (seesection 20).

1 . R e m o v et h e driver's door panel (seesection 20). 2 . Disconnectthe 2-P connectorfrom the motor.
NOTE:
2. Disconnectthe 4-P connectortrom the motor.
a Frontpassenger'sdoor is symmetricaltodriver's

. ,-,.f,/ll/ ooor.
a The illustrationshows the right reardoot, left rear

NZJI I
..Q]qql,fiftl\ I
door is svmmetrical.

$e /tE \
View from lerminal side 2.P CONNECTOR

4.P CONNECTOR
3. Test the motor in each directionby connectingbat-
tery power and ground accordingto the table.

Terminal
\ B
(B) {A}
Direction View from terminalside
UP @
3. Test the motor in each direction by connecting bat-
DOWN O tery power and ground accordingto the table.

Terminal
\ B A
O*** \
UP o o
DOWN @

{ }: Sodan
CAUTION: When the motor stops running. discon-
nect one lead immediately.

4. lf the motor does not run or tails to run smoothly,

replaceit.

PulserTest: CAUTION: When the motor stops tunning. discon-

nect on€ lead imm€diately.
5. Connectthe test leadsof an analogohmmeterto the
C and D terminals. lf the motor does not run or Jailsto run smoothly,
reDlaceit.
6- Runthe motor by connectingpower and groundto
theAandBterminals,
The ohmmeterneedleshouldmove back and torth
alternately.

23-232
-'
 Power Door Locks
Component Location Index

FRONTPASSENGER'SDOORKEY
CYLII{DERSWITCH
Test,page23-240

FRONTPASSENGER'SDOOR LOCK ACTUATOR

Test. pago 23-239 RIGHT REAR DOOR LOCK ACTUATOR lsodanl
Reolacement.section 20 Test, 23-239

LEFT REAR DOOR LOCK ACTUATOR {Sodan}

Test, page 23-239
FRONTPASSENGER'S
DOOR LOCK SWITCH
fest, page 23-241

1
DOOR
KEY CYLINDERSWITCH
Test. page 23-24O

DBIVER'S LOCK ACTUATOR

Test, page 23-238
Roplacement,seclion 20

DOOR
LOCK SWITCH
'lest, page
23-241

POWEROOOR LOCK
CONTROLUNIT
fnput Tost, page 23-236

Description
For this model, a new door lock system has been adopted to improve convenienceand safety. lf the kev is insened into
the driver'sdoor key cylinder,turned to the unlock position,and pulledout immediatelythereafter,oNLy the driver.s
door will unlock. However,if the key is kept in the unlock positiontor one secondor more, ALL doors wi unlock.

23-233
 PowerDoorLocks
CircuitDiagram
UiIDER-HOOD
FUSE/RELAY
BOX
BATTENY
No.41l100Al iJo,36l50A)
@'"t

DRIVER'S
OOOB
KEYCYI,INDER
swITcH
DRIVER'S
oooRrocK
swtTcH

o00Rtoc( KN08

V L____
I

POWEROOOR
FRONT LOCKCONTROI.
PASSENGEN'S
DOORLOCK
swncH

FROMT
PASSENGER'S
oooRt-ocK
ACIUATOR

@r
I uFt REAR
000RLocK
ACTUATOR

@"
r RIGHT
REAR
000RLocK
ACTUATOR

@'
BLK 8rl( 8LK

I
G501
G5o2
.&
;
G201
G401
A
-l
GSot
G502
A
=
G501
G5o2

23-234
I
 Troubleshooting

NOTE: The numbersin the table show the troubleshootingsequence.

Item io be inspected

.=
= 3
-9 3-
-.9 t
)x< o
o
3
:
St o o
c
o o c
z ) 9 E
c o) - c
It O E
o'o
Symptom
9 c
dl= ;-s o TL o o (L o-

Power door lock system doesn't G501

1 WHT/GRN
ooerateat all. G502
Doors don't lock or All doors G501 GRN/REDor
unlock with the GRN^/lr'HT
driver's door lock O n eo r
1
WHT/REDor
switch. more doors
J
YEL/RED
Doors don't lock or All doors G 2 0 1 BLK/RED
or
unlock with the G 4 0 1 BLK/WHT
passenger'sdoot
One or WHT/REDor
lock switch. more ooors
1
YEL/RED
Doo.s don't lock or All doors G501 BLU/REDor
1
unlock with the G502 BLU/WHT
driver's door lock
One or WHT/REDor
knob. 1
more ooors YEL/RED
Doo. don't lock o. All doors G 2 0 1 L T G R No r
unlock with the G401 LT BLU
passenger'sdoot
O n eo r WHT/RED or
key. more doors 2 5
YEL/RED
Doors don't unlock Oriver's G501 BRN,WHT/RED
wilh the driver's ooor G502 or YEL/RED
door key. 'All doors
I
Gsol BRN,WHT/RED
G502 or YEL/RED
+ It the system is working normally,€lldoorswill unlockwhen you
holdthe door key in the unlockposition(kev cvlinder
switch and door lock knob switch turned ON) for one secondor more.

23-235
Power Door Locks
Control Unit Input Test

Removethe driver's door panel {see section 2O).

Disconnectthe 1+P connectorJromthe control unit.

Inspectthe connectorand socket terminalsto be

sure they are all makinggood contact.

a It the terminalsare bent. loose or corroded,repair

them as necessary.and recheckthe system.
a lf the terminalslook OK. make the following in-
put tests at the connector.
- lf any test indicatesa problem,find and cor-
rect the cause,then recheckthe syslem.
lf all the input tests proveOK, the controlunit
must be faultv; replace it.

POWERDOORLOCK
UNIT
CONTROL

t4-P COI{NECTOR

View from wiro side

23-236
Disconnectthe 14-P connectorfrom the power door lock control unit.
I{o. Wire Tost condltlon Test: Dosirsd rosult Possibls cause if rosult is not obtainod
Under all conditions Check tor continuity to ground: . Poor ground (G501, G502)
I BLK . An open in the wire
There should be continuitv.
Connectthe YEL/RED Check door lock oDeration: Faultv actuator
tarminal to the WHT/ All doors should unlock. An open in the wire
GRN terminal,and the Blown No. 6 (2O A) fuse in the
WHT/REOterminalto under-dashfuse/relav box
WHT/REDthe BLK terminsl
2 and momentarily.
YEL/RED Connectthe WHT/RED Check door lock ooeration:
terminal to the WHT/ All doors should lock.
GRNterminal,and the
YEL/REDterminalto
the BLK terminal
momentarilv.

Reconnecttho 14-Pconnectorto th6 powor door lock control unit.

t{o. Wlro Tost condition Tost: Dolir6d r6auh Posslblo caus6 it rosuh is not obtainod
Under all conditions Check tor voltage to ground: . Blown No. 6 {2O A) fuse in the
e WHT/GRN There should be battsry voltage. under-dashfuse/relay box
. An open in the wire
Driver's door lock Check for voltagg to ground: Faultv driver's door lock switch
GRN/WHT
switch in LOCK There should be I V or less. Poor ground (G501, G5O2)
4 An oDenin the wire
Driver's door lock
GRN/RED
switch in UNLOCK
Right tront door lock Check for voltage to ground; Faulty front passenger's door lock
BLK/wHT
switch in LOCK There should bs 1 V or less. switch
I
Right lront door lock Poor ground (G201, G4O1)
BLK/RED An ooen in the wire
switch in UNLOCK
Driver'sdoor lock knob Check for voltage to ground: Faulty driver'sdoor lock actuator
BLUMHT
in LOCK There should be 1 V or less. Poor ground (G501, G5O2)
6 An ooen in the wire
Driver'sdoor lock
BLU/RED
knob in UNLOCK
Driver'sdoor key Check for voltage to ground: Faulty d,iver's door key cylinder
cylinderin UNLOCK There should be 1 V or less as switch
7 BRN
the switch is turned. Poor ground {G501, G5O2l
An open in the wire
Front passenge.'sdoot Check for voltageto ground: Faulty tront passenger's door
LT BLU
key cylinderin LOCK There should be 1 V or less as cylinde.switch
I the switch is turned. Poo. ground (G201, G401)
Front passenger'sdoor
LT GRN An oDen in the wire
key cylinderin UNLOCK

CAUTION: To provonl damago to tho molor, rpply battory voltago only momrntadly.

23-237
Power Door Locks
Driver'sDoor Lock Actuator Test
1 . Removethe door panel (seesection 20). 5. Check fo. continuity between the terminals in each
switch positionaccordingto the table.
Disconnectthe 6-P connectorfrom the actuator.

Terminal
\ I
il;----t
LOCK o o
UNLOCK o- -o

DOORLOCKKI{OB

Checkactuatoroperationby connectingpower and

ground accordingto lhe table.

Terminal
\ ---\ D
;;"
LOCK @ o
UNLOCK lJ @

CAUTION: To prevont damagolo tho actualol, ap-

ply battery voltage only momentarily.

lf the actualor fails to work properly,replaceit.

23-238
 Passenger'sDoor Lock Actuator Test
1. Removethe door panel (seesection
s 20). Rear Passenger's Dool:

2. Disconnectthe 2-P connector

r from the actuator. NOTE: Left rear actuato, is shown, right rear actuator
is similar.
Front Passonger's Door:

terminalside

View from terminalside

Checkactuatoroperationby connectingpower and

ground accordingto the table.

Terminal
\
B
2-P Position \
CONNECTOR LOCK @
ACTUATOR UNLOCK @ ,-,

CAUTION: To prevent damageto the actuator, ap-

ply battery voltage only momentarily.

4. It the actuatorfails to work properly,replaceit.

23-239
Power Door Locks
Driver's Dool Key Cylinder DoorKeyGylindet
FrontPassenger's
Switch Test Switch Test
1. Removethe door panel (see section 20). 1. Removethe door Danel{see section 2O).

2. Disconnectthe 2-P connectorfrom the switch. 2. Disconnectthe 3-P connectortrom the switch.
FRONT
PASSENGER'S
DOOB KEY
CYLINDER
swtTcH

coN ECIOR

terminalside

3. Checkfor continuitybetweenthe terminalsin each 3. Check tor continuitv between the terminals in each
switch positionaccordingto the table. switch position according to the table.

Terminal Terminal
B \ A B c
Position P""ft;---l
UNLOCK G o LOCK o ----o
OFF OFF

UNLOCK o ----o

UNLOCK
UNLOCK
< -r--O

I
I LOCK

tfil*rr

23-240
 Door Lock Switch Test
1. Removethe insidehandle.

Disconnectthe 3-P connectorfrom the switch.

Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.

\ termtnal
n c
Position \
LOCK o o
OFF
UNLOCK o

23-241
CruiseControl
Component Location Index

a All SRS 6l6ctrical wiring harnessosaro covorod with

yallow insulation,
a Bofo.6 disconnecting any part of th6 SRS wire har-
ness, connoct th€ shon conneclor(s).
a Replacothe ontiro affected SRS halness assombly if
it has an op€n circuit or damagod widng.

SRS MAIN HARNESS

(Cov.rod wilh yollow In.ulation)

CRUISELIGHT
(Builtinto gaugeassembly)
Bulb Locations,page 23-115
MAINSWITCH
Test, page23-250 SET/RESUME SWITCH
Replacement,page23-250 Test. page23-248
Repfacemont,page23-248

BRAKE SWITCH
Test. page 23-251

CLUTCH SWITCH (M/TI

Test, page 23-251

CRUISECONTROL A/T GEAR POSITIOI{

fnput Test, page 23-246 swtTcH
Test, page 23-136, 252

23-242
ACTUATORASSEMBLY
Test,page23-253
CableAdjustment,
page23-253

23-243
CruiseGontrol
CircuitDiagram
+ No.24
ll5Al:81881
onoine
No.24
l20Al:818C1
ensine
_HOODFUSE/RELAY
UNOER BOX FUSE/RELAY
UNDER-DASH BOX
No.4l(100A)No.39l50A)

HORN

Y
INDICATOR
TIGHT
{0,91W}

IP
I D Suur

PNK BTK
II
I
f7
VEHICLE
SPEED
SENSOR
iVSS)

M/r : CLUTCH
SWITCHI
6yffi Bi,G#,,'. A/T: A/TGEAR
POS|T|oN
I
SWTTCH
I
InIEI,E) I
BI-K

T
G201
t
-
G201
G401 G401

23-244
 Troubleshooting

NOTE:
a The numbersin the table show the troubleshootingsequence.
a Beforetroubleshooting,
- check the No.15 {10 A) and *No. 24 fuses in the under-dashfuse/relaybox, and the No.41 (1OOA), No.39
(50 A). and No.42 (20 Al fuses in the under-hoodfuse/relavbox.
- check that the horn sounds.
check the tachometerto see if it wo.ks pfoperly.
*No.24 {15A): Bl8B1engine
N o . 2 4 { 2 OA } : 8 1 8 C 1 e n g i n e

Item to be inspected
!
F

o)
a
'F F a
_9 .9
c f oi
f

E E 3
.9
; c
c
'.E :
-c.
!
U) 3 B I f
'9o1 E
2
I
_q
.!o F E
E l

^ .E
o og
Symptom dl L

BLU/GBN,LT GRN/RED.
G301,
BLU, BLK/YEL,LT GRN,
Cruisecontrol cannot be set. 1 3 G201,
GRY, ORN. BRN/WHT,
G401
BRN/BLK,BRN/REDor PNK
Cruisecontrol can be set, but G201,
2 YEL or RED/BLU
indicatorlight does not go on. G401
Cruisespeed is noticeablyhigher
I 3
or lower than what was set.
Excessiveovershootjngor
undershootingwhen trying to set 2 I
speed
Steady speed is not held even on
2 3
a flat road with cruisecontrol set.
Car does not decelerateor
LT GRN/BLK
accelerateaccordinglywhen SET 2
LT GRN/RED
or RESUMEbutton is pushed.
Set sDeedis not cancelledwhen ,1
clutch Dedalis oushed(M/Tl.
Set sDeed is not cancelled when
I 2
shift lever is moved to fM tnnt.
Set speed is not cancelledwhen 'I
2
brake pedal is pushed.
Set speed is not cancelledwhen
1
main switch is pushedOFF.
Set speed is not resumedwhen
RESUMEbutton is pushed(with LT GRN/BLK
main switch on, but set speed LT GRN/RED
temporarilycancelled).

23-245
CruiseControl
ControlUnit Input Test
CAUTION:
a All SRS olectrical wi ng harnessosare covored with
yellow insulation.
a Botore disconnecting any part of th6 SRS wire har-
neaa, connect the short connoctor(sl.
a Roplacethe €ntir€ affectod SRS hamass assembly il
il has an opan circuit or damaged wifng.

1, Removethe dashboardlower cover and knee bolster

(see page 23-70).

2. Disconnectthe 14-Pconnectortrom the control unit.

Insoectthe connectorand socket terminalsto be

sure they are all makinggood contact.

a lf the terminalsare bent, loose or corroded,repair

them as necessary,and recheckthe system. SRS MAIN HARNESS
a It the terminalslook OK, make the following in-
Dut tests at the connector.
- It any test indicatesa problem,find and cor-
rect the cause.then recheckthe svstem.
- lf allthe input tesls proveOK, the controlunit
must be faulty; replaceit.

CRUISECONTROLUNIT

14-P COI{NECTOR

Viow from wire side

23-246
 tlo. Wlfe Tost condition Tost: Desired rosult Possibl6caus€ it losult is not obtained
Under all conditions Check for continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 0 1 1
I BLK
There should be continuitv. . An open in the wire
lgnitionswitch ON (ll) Check for voltage to ground: . Blown rNo. 24 fuse in the under-
2 BLKryEL There should be battery voltage. dash fuse/relay box
. An open in the wire
lgnition switch ON (ll) Check for voltageto ground: . Faulty main switch
5 LT GRN
and main switch ON There should be battery volt€ge. . An open in the wire
lgnitionswitch ON lll), Check for voltageto g,ound; . Faulty brakeswitch
main switch ON and There should be O V with the . An open in the wire
4 GRY
brake pedal pushed, pedal pushedand battery
then released voltage with the pedal released,
Brakepedal push€d, Check tof voltage to ground: Blown No. 42 l2O Al tuse in the
then r€leased There should be battery voltage under-hood fuse/relay box
GRN/wHT
with the pedal pushed,and O V Faulty brake switch
with the Dedalreleased. An open in the wire
lgnitionswitch ON (ll) Connectto ground; Indicator Blown bulb
light in the gauge assembly B l o w nN o . 1 5 ( 1 0 A ) f u s e i n t h e
comes on. under-dashfuse/relaybox
6 RED/BLU
Faulty dimmingcircuit in the gauge
assembly
An open in the wire
LT GRN/ RESUME button Check for voltageto ground: Faulty SET/RESUME switch
7
BLK pushed There should be battery voltage. Faultycable reel
LT GRN/ SET button pushed An open in the wire
6
RED
MT/: Clurch pedal Check for continuityto ground: Faulty or misadiustedclutch switch
released There should be continuity. (M/T)
q A/T: Shift l€ver in -[Zl, NOTE:There should be no con- Faulty A/T gear position switch
PNK
lD:I,orlE.l tinuity when the clutch pedal is (A/T)
depressed or when the shift Poor ground (G201,G4O1)
lever is in other positions. An open in the wire
Start the engine. Chsck for voltageto ground: . Faulty ignitionsystem or ECM
10 BLU
There should be battery voltage. . An open in the wire
lgnitionswitch ON (ll) Check Jor voltage between the . Faulty vehiclespeed sensor(VSSI
and main switch ON; ORN @ and BLK O terminals: . An oDen in the wire
11 ORN rsise the front of the There should be O- about
car, rotat€ one wheel 1 0 V - O - a b o u t 1 OV
slowly. repeatedly.
'12 8RN/WHT Connect battery power Check the sound of the actuator . Faulty actuator
to the BRN/WHT motor: You should hear the mo- . An opsn in the wire
terminaland ground to tor runningsmoothly.
1 3 BRN/BLK the BRN/BLKterminal.
Connect battery power Check the operation of the mag- Faulty actuator
1 4 BRN/RED to the BRN/RED netic clutch: Clutch should click An open in the wire
terminal. and output link should be locked. Poor ground (G3O1)
*No. 24 (15 Al: 81881 engine
N o . 2 4 l 2 OA ) : 8 1 8 C 1e n g i n e

23-247
CruiseGontrol
Set/ResumeSwitch Test/Replacement
CAUTION:
a All SRS ol6ct cal widng herne$a3 err covorod with
y6llow insulation.
a Bototo disconnecting any part ot tho SRS wiro h8r-
n6sa, connoct tho ghort connector(sl,
a Rsplacothe antire aftected SRS harness arsombly if
it has an op6n chcuit or damagod wiring.

SRS MAIN HARNESS

3. Removethe dashboardlower cover and knee bolster

(seepage 23-70).

4. Oisconnectthe cable reel harness6-P connector

from the SRSmain harness,then connectTest Har-
nessC onlv to the cablereelside of 6-P connector.
NOTE: The original radio has a coded theft protection
circuit, Be sureto get the customer'scode numberbefor€
- disconnectingthe battery.
- removingthe No. 32 (7.5 A) fuse from the under-hood
fuse/relay box.
- removingthe radio.
Afte, service, reconnect power to the radio and turn it
on. Whenthe word "CODE" is displayed,enterthe cus-
tomer's s-digit code to restore radio op€ration. CABLE REEL
CONNECTOR
lHlrnoa!
1. Disconnectthe battery negativecable, then discon- Eidol
nect the Dositive cable.

2. Connectthe short connector(s)to the airbag(s).

DRIVER'S SHORT ACCESS

AIRBAG CON]TECTON PANEL
3-P CONNECTOR (REDI

23-248
5. Check lor continuity between the terminals of Test 7. Remove the two screws and remove the switch.
HarnessC in each switch positionaccordingto the
table.

Terminal
2
Position
SETIONI o- ---o
RESUME
{ONI o- ---o

a lf there is continuity, the switch is OK.

a lf there is no continuity, go to step 6.

6, Remove the cover carefully by prying between the

cover and the switch in the sequenceshown.

8. Check lor continuitv between the terminals in each

switch positionaccordingto the table.

\ Tominal
A A' B
Position
OFF \_r-
SFT(ON) o- -o
RESUME
ION) o- ---o
a lf there is no continuity in any position, rsplace
the switch,
CRUISE
CONTROL a lf thsre is continuity in every position, replacethe
SET-RESUME cable reel (see psge 23-302).
swtTcHcovEF

23-249
CruiseGontrol
Main Switch Test/Replacement
NOTE: Be carefulnot to damagethe switch and the in- 3. Ch6ck for continuity betwo€n the terminals in each
strument oanel. switch position according to the table.

1. Removethe instrumentpaneltrom the dashboard

(see page 23-1 18).

2. Removethe switch from the dashboard,then dis-

connect the 5-P connecto,.
\ Tenninrl
A B D
P".ii";--\
OFF -o o- /a

ON
A A
\7
-o

a lf thera is no continuity in any position, replace

th€ switch.

y' ucsr
rxorcaToR
UCI{T [ ()
to.grwl \ 7 lo.grwl

A B C D E

23-250
 BrakeSwitch Test GlutchSwitch Test (M/T)
'1.
Disconnectthe 4-P connectorfrom the switch. I Disconnectthe 2-P connectorfrom the switch,

2. Checkfor continuitvbetweenthe terminalsaccord-

ing to the table.
2. Check{or continuitvbetweenthe terminalsaccord-
ing to the table.

\ Terminal
B
il"*on---\ \ | ormtnal
BELEASED o- --o Clutchpodal \
PUSHED -o RELEASED o o
PUSHED

3. It necessary,replacethe switch or adjust pedal

height {see section 19).
3. lf necessary,replace the switch or adjust pedal
height (seesection 12).

I
23-251
CruiseControl
A/T GearPositionSwitch Test
1 . Removethe center console,then disconnectthe View trom terminal side
14-P connectortrom the switch.
A B C D E F G
Checkfor continuitvbetweenthe terminalsin each
switch positionaccordingto the table.

NOTE:
a Move the lever back and forth at each position
without touchingthe button, and check for con- H I J K L M
tinuity within the rangeof free play ot the shift
lever.
a ll there is no continuitywithin the rangeof free
play, adjustthe installationposition of the switch.

A/T Gear Position Swhch (For cruis€ control)

\ Terminal
il;---t
tr
a o 3. lf necessary,replacethe switch (seesection 13).
E o
lu4l o ---o
N
B
E

23-252
 Actuator AssemblyTest
1 . Disconnect the 4-P connector from the actuator.
2 . Check that the output linkage moves smoothly.
3 . Connect battery power to the D terminaland ground
to the A terminal,
ACTUATOR
Actuator CableAdjustment
Check that the actuator cable operaressmoothtv
without bindingor sticking.
Start the engineand warm it up to normaloperating
temperature(radiatorfans come on twicel,
Measurehow far the output linkage moves from the
fully closedposition.Freeplay shouldbe 1 1 1 1.5
mm (O.43 I 0.06 in).

FREEPLAY:
1 1 I 1.5 mm (0.43 r 0.06 int

FULLYCLOSED
POSITION
4. Check for I clickingsound trom the magneticclutch,
and that the output linkage is locked. lf the outDut
linkageis not locked, replacethe actuator asssmblv. 4. lf the free play is not within specs,loosenthe lock-
nut and turn the adjustingnut as required.
Check the operation oJ the actuator motor in each
output linkago position according to the table (you NOTE: lf necessary,checkthe throttlecontrolsys-
should be able to hear the motor). tem {seesection 1 I }, then recheckthe output link-
age free play.
Battery Output linkage
polarities position 5. Retightenthe locknut and recheckthe free play.
FULLY M I D D L E FULLY
o CLOSED POStTtON OPEN
The The The
B
Terminal Terminal molor molor molor
runs. runs. srops.
I The The The
Terminal Terminal motor motor motor
stops. runs. runs.

FULLY CLOSED

23-253
Wipers/Washers
Component Location Index

WII{DSHIELD/REARWINDOW
WIPERAA'ASHEBSWITCH
Test,page23-258
oase23 257_..
Replacement,

wtNosHlELDWIPER 2
ARMS/BLADES ___-=4,
Page23'261 /tt'
Repfacemont, /

WINOSHIELD
IVIPERMOTOR
Test, page23-260
Repfacement,paee23-281

INTERMITTENTWIPER
BELAY CIRCUIT
(ln the int€gral.d control onitl
FUSE/RELAY
BOX Input Test, page 23-146

REARWII{DOW WIPERMOTOR
Test, page 23-262
Replacemont, pago 23-263

23-254
 Circuit Diagram
- HOOO
UNOER FUSENEUY UNOER-DASH
8OX FUSE/RELAY
BOX

WHT/ll-X-FWHr

GRX/4X

WII{DSHI€ID
WIPERAIVASHER
S1VITCH

si 4.t,,1/'i;",ry)"'.,

REARWINOOW
WIPER
MOTOR
8tK

REARWINOOW
WIPER/WASHER
swtTcH

l*_
(ittwA!
Mor 8LK BLK
REAR
wtN00w
WASHER
Y MOTOR

|-
8LK BLK

I
G30l G20r G503 G20'I
{
G30l
G101 G401
. : whh comtinadwchar-wllbr olrnlirn

23-255
,r-
Wipers/Washers
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence

Item to be insDected

6
i 0,
(t o i=
o
o-;i '96 ;5 o .45
i 5
>;
bE
a.P e b
o .

: 6
rD!
otD t €3
r! E
;E i
d O
:!
o ; cqt ot
3 E
z ) E =Y. - c
ID
E P o
o o
it .9! O
o E r
o c
o o o
Symptom = ; 3 3 z o o-

Wipers ln all GRN/BLK

do not positions I 4 2 2 G301,
G401
ln INT I 3 YEL/BLU,8LU/GRN
In LO or Hl 1 2 BLU,BLU/YEL
ln MIST 1 BLU/YEL
Rear window wiper does a
G503, GRN/BLK,GRN
1
not work. G751 LT GRN/BLK

Blades do not return to BLU/wHT,

park position when the I LT GRN/BLK
switch is turned OFF.
Intermittent cycle is BLU/GRN
YEL/BLU.
erratic or wipers do not 1 2
work intermiftently.
Little or no washer fluid G301 BLU/BLK
BLK/GRN,
4 ? 1 2
is pumped.
WiDersnd washer do not BLK/GRN
1
work at the same time.

23-256
 Wipers/WashersSwitch Replacement

Disconnectthe 8-P and 6-p connectorsfrom the

a All SRS electrical wiring harnessesale covered with switch.
yellow insulation.
a Belorodisconnectingthe SRSwif6 harnoss,installthe Removethe two sctews and the switch.
short connector(sl.
a R€placethe entire atlscted SRS hamess assombly il wIPERS^IITASHEBS
SWtTCl.t
it ha6 an open citcuii ot damaged wiring.

A-P CONNECTOR 6-P CONNECTOR

4. Install in the reverse order of removal.

Removethe steeringcolumn covers.

UPPERCOVER

23-257
Wipers/Washers
Switch Test
Wipers/Washers
CAUTION:
a All SRS electrical wiring harn6ss6salo covered with
yellow insulation.
a Belore dkconnecting any part ot th6 SRS wire har-
neaa. connect the short connoctor(sl.
a Replac6the 6ntire affoctod SRS harnessassembly it
it has an open cilcuit 01 damaged wiring.

1. Removethe steeringcolumn covers.

2. Disconnectthe 8-P and 6-P connectorsJrom the

swatch.

5 It necessary,removethe two screws and the switch.

4 Checkfor continuitvbetweenthe terminalsin each

switch positionaccordingto the table.
SRS iIAIN HARNESS
{Covor.d rvilh yollow inrulation}

I J K A B C D

scREws

23-258
Windshield WiperAi\laEhelSwitch

'w*+t+*i' 4l ?u
1 o"/j^o-"-
_J
l=f,.
M|ST M|ST

I-
OFF/INT

E B

\ Terminal
c D E n
il;----__\
OFF o- ---o
INT
o- *--o
o- ---o
LO G- *-o
HI o- --o
Mistswitch"ON' G-- ---o
Washerswitch"0N" o- ---o

R6ar Window Wip€r/Washol Switch

I L

I
,i1..___.______,x..
I
fr."ql|.fr
tiT
\ rermrnal
L N
Position \
switch"0N"
Washer o- ---o o- ---o
OFF o- -*o
ON o- --o
Washerswitch"ON"
(withwiDer'0N") o- ---o o- ---o

23-259
Wipers/Washers
Windshield Wiper Motor Test

Open the hood and remove the cap nuts and the
wiper arms (see page 23-261).

NOTE: Removethe wiper arms carefullywithout

damagingthe hood. A SLUTYEL}

Removethe hood seal and air scoop by prying out D IGB /BLK) B (BLUI
their trim clips.

Disconnectthe 5-P connectorfrom the windshield

wiper motor.

Test the motor by connectingbattery power and

ground accordingto the table.

\ Terminal D B
Pi"i,i""---\ {GRN/BLK) {8LU) (BLU/YEL}
LOW SPEED @
H I G HS P E E D @

Reconnectthe 5-P connector to the wiper motor as-

sembly.

Connect an analog voltmeter between the E

{BLU/wHT)and the C (BLK)terminals.Runthe mo-
tor by turning the wipet switch ON (LO or Hl po-
sition).
The voltmeter should alternately indicate O V and
more than 4 V.

NOTE: Use an analogtester.

lf the motor does not run or fails to run smoothly,

replacerr.

23-260
Windshield Wiper Motor Replacement

Openthe hood and removethe cap nuts and wipel o. Separatethe wiper linkageand crank arm at thejoint.
atms.
Removethe three mounting bolts and wipet motor.
NOTE: Removeth€ wiper arms carefullywithout
damagingthe hood.
MOUNTII{G
Remove the hood seal and air scoop by prying out BOLTS
9.8 N.m
their trim clios. (1.0 kgm.l,7.2 lbI.ftl

Disconnect the 5-P connector trom the windshield

wiDer motor.

8. Installin the reverseorder of removal.

Removethe four mounting bolts and wiper linkage

assembly.

Removethe wiper harn€ssfrom the wipe. linkage.

23-261
Irflnfi]
Wipers/Washers
-Keal wlnqow Wiper
Rear Window Motor Test
wlper |Yloror I esr

1. Disconnectthe 4-P connectorfrom the wiper motor. lf the moto. does not run or fails to tun smoothly,
replaceit.

4. Reconnectthe 4-P connectorto the wipet motor as-

sembly.

Connect an analog voltmeter between the D (LT

GRN/BLKIand B (BLK)terminals.Run the motor by
turning the wiper switch ON.
The voltmeter shouldslternatelyindicateO V and
more than 4 V.

NOT€: Use an analogtester.

4-P
CONNECTOR

A (GBN/BLK)

C IGRNI

Viewtrom terminal
side

2. Test the motor by connectingbatterypower to the

A (GRN/BLK) and groundto the C (GRN)terminals.
The motor should run smoothly.

C (GRI{}

23-262
 Rear Window Wiper Motor Washer Motor Test
Replacement
1 . Removethe cover, mounting nut, and wiper arm. l. Removethe front bumper (see section 20).

Removethe rubberseal, specialnut, and washer. 2. Disconnectthe 2-P connector lrom the washer
motor.

RESERVOIR

MOUNTINGNUT
14 N.m
11.4 kgf.m,
10 tbt.trl
WIPERARM

RUBBERSEAL -4
SPECIALNUT )
8.8 N.m
{0.9 kgt'n,
6.5 rbt.fr)

Openthe tailgate and removethe tailgatetrim panels

(seesection 20).
WINDSHIELD REAR
wrNDow
Disconnectthe 4-P connectorfrom the wiper motor.
Test the motor by connectingbatterypower to the
Removethe threemountingboltsand the wiper mo- A ( + ) terminaland ground to the B (- ) terminal.
tor assembly.
MOUNTING a ll the motor does not run or fails to run smooth-
BOLTS ly, replaceit.
9.8 N.m
(1.O kgf.m, 7.2 lbf.ttl
a lf the motor runssmoothly,but littleor no wash-
er fluid is pumped.check for a disconnectedor
blockedwasherhose, or a cloggedpump outlet
in the motor.

6, Installin the reverseorder o{ removal.

23-263
Wipers/Washers
Washer Replacement

1 . Bemovethe Jront bumper (seesection 2Ol.

Removethe left lront inner fender.

Disconnectthe 2-P connectorand hose from the

washer motor.

Removethe three mountingbohs and the washer

reservorr.

5 . Removethe washer motor from the reservoir.

6. Removethe windshieldwiper arms and air scoop

(see page 23-261). Then removethe washer noz-
zles and hoses.

7 . lnstall in the reverseorder of removal.

NOTE:
a Take care not to pinch the hosesduring instal-
lation.
a Installthe clips tirmly.
a After installing,adjust the aim of the washer
nozztes.
REAR
wtt{Dow

WINDSHIELD
WASHER
n
V
WASHER
t{ozzLE

NOZZLE
..,.,,@
lH (
n

MOUNTING
BOLTS
9.8 N.m
{1.O kgf.m, 7.2 lbf.ftl

23-264
SupplementalRestraintSystem
(sRst
GomponentLocationIndex..................
23-266
Description ..23-267
Circuit Diagram 23-268
Wiring Locations 23-270
Precautions/Procedures ..23-271
Troubfeshooting ............. ..23-276
AirbagAssembly
Repfacement .................. 23-295
Disposal ....23-299
CableReel
Replacement .................. 23-301
DashSensor
Replacement .................. 23-305
SRSUnit
Replacement .................. 23-307
SupplementalRestraintSystem(SRS)
ComponentLocirtionIndex

SRSINDICATORLIGHT
(ln th6 gaug6 assembly)
Troubleshooting, page23-276
Gaugeassembly,page23-113

To CRUISECONTROL
CABLEREEL SET/RESUMESWITCH
Replacement,
page23-301

AIRBAG
page23.295
Beplacement,

UNDER.DASH
BOX
FUSE/RELAY

FRONTPASSENGER'S
AIRBAG
lExceptCanadsRS model)
page23-295
Replacement,
page23'299
Disposal,

RIGHTDASHSENSOR
page23-305
Replacement,

LEFTDASHSENSOR
R e p l a c e m e n t ,p a g e 2 3 - 3 0 5
SRSMAIN HARNESS-
FRONTPASSENGER'S AIREAG
BRANCHlExc€ptCaned. RS modol)

SRSUNIT (lncludingcowl sensorl

Replacement,page23-307

23-266
 RestraintSystem(SRSI
Supplemental
CircuitDiagram(WithoutFrontPassenger's
Airbagl
SRSINOICATOR CIRCUIT
{lnth€glug€sssombv}

r----
r n
r t l
ill
-

SADH-
UNOER_
HOOD DRIVER'S
FUSE/ AIRBAG
RELAY
80x
INFLATOR
o
a
a
@
o
a
a
SAOC @
a
BUC @
a
GNO @
rDc @
MI @
a
a

23-268
GircuitDiagram(With FrontPassenger's
Airbagl
UNOE8-
DASH
FUSSRELAY
BOX SRSINOICATOF CIRCUIT
lln lh6 grugo.$.mblyl

I
I
I
I n
I ll
I tl
t U
I

SADH

UNDER
HOOD DRIVER'S
FUSE/ AIREAG
REI.AY INFI.A]OR
80x o
@
FROI.IT
o
PASSENGER'S
AIREAG
@
INFLATOR @
a
a
@
a
@
a
@
@
@
a
a

SRSUNITl8-P COI'INECTOR

23-269
SupplementalRestraintSystem (SRSI
Wiring Locations
CAUnON:Makesureall SRSgroundlocrtion3lrc clrln rnd ground3tra |.curalv rltachad.

NOTE:
o AltSRSelectricsl arecovered
wiringharnesses withysllowinsulation.
the entireaffectedSRSharnessassemblyif it hasan opencircuitor damagedwiring.
. RsDlace

CABIEREELto DdrrEFS AnaAC

3+ OOI{iECTOR
DASHBOARDWIRE HARNEi9
to INDICATOBUGHT in GAUGE ASSEMBLY
5-PCONNECTOB aFs irA[t H^RiEss
Ana G
to FROiITPASSEMIEFS
3t coftf'Eclon
C. b Ra nod.ll
SRS MAIN HARNESStO
MAIN WIREHARNESS
+P OONNECTOR

SRSMAINHARNESS
to UNDER-DASH
FUSE/RELAY
BOX
2"P@NNECTOR

MAIN WIREHARNESS SnS Alt{ ll^ntc8s to

to DASHBOARDWIRE o sHSErson
HARNESS 2+ OOt{tlEcT()R
lGP CONNECTOR

SBS MAIN HARNESSto

LEFTDASHSENSOR
2.P CONNECTOA

23-270
GeneralPrecautions Airbag Handlingand Storage
Carefullyinspectany SRSpart beforeyou installit. Do not try to disassemble the airbagassembly.lt has no
D o n o t i n s t a l la n y p a r t t h a t s h o w s s i g n s o f b e i n g serviceableparts. Once an airbag has been operated
droppedor improperlyhandled,suchas dents,cracks (deployed), it cannotbe repairedor reuseo.
or deformation:
F o r t e m p o r a r ys t o r a g eo f t h e a i r b a ga s s e m b l yd u r i n g
- Airbagassembly{driver'sand front passenger's) service,pleaseobservethe followingprecautions:
- Dashsensors
- Cablereel . Storethe removedairbagassemblywith the pad sur-
- S R Su n i t faceup.

!@ It the airbag is impropsrty stored facs

down, accidentaldeployment could propel the unit with
enough force to causesetious iniury

Use only a digital multimeterto checkthe system.lf

it's not a Hondamultimetermakesure its output is 10
mA (0.01A) or less when switchedto the smallest
value in the ohmmeterrange.A testerwith a higher
outputcould damagethe airbagcircuitor causeacci
dentaldeploymentand possibleinjury.

Do not installusedSRSpartsfrom anothercar.When

makingSRSrepai.s,useonly new pans.

E x c e p tw h e n p e r f o r m i n ge l e c t r i c a il n s p e c t i o n s ,
alwaysdisconnectboth the negativecable and posi-
tive cableat the batterybeforebeginningwork.
R e p l a c e m e n to f t h e c o m b i n a t i o n l i g h t a n d
wiper/washerswitchesand cruisecontrol switchcan
be donewithout removingthe steeringwheell
- C o m b i n a t i o nl i g h t a n d w i p e r / w a s h e rs w i t c h
replacement (seepage23-160).
- Cruisecontrolsevresumeswitch replacement {see
page 23-2491.
SHORTCONNECTON
{REDI
Store the removedairbagassemblyon a secureflat
suffaceaway from any high heat source(exceeding
212"Fl1OO'Cland free of any oil. grease,detergentor
CAUTION: lmproper handling or storage can internally
damagethe airbag assembly,making it inoperativ€.
ll you suspect the airbag assembly has been damagod,
install a new unit and rgler to the Deployment/Digposal
Procedureslor disposing of the dsmaged airbag.

The originalradiohasa codedtheft protectioncircuit.

Be sure to get the customer'scode number before
disconnecting the battery.

When reinstallingthe SRSunit cover,be sure it snaps

togetherproperly.

23-271
SupplementalRestraintSystem(SRSI
Wiring Precautions
o Neverattemptto modify.spliceor repairSRSwiring. Connecting the Short Connectors

NOTE:All SRS electricalwiring harnessesare covered @ To avoid accident8l deploymont and pos-
with yellow insulation. 5ibl6 iniury, slways insiall the protectiva short connec-
tor(s) on tho drivgr'3 and passengor'sairbag connec.
tor(s) be{oreworking noar any SRSwiring.

NOTE:The original radio has I coded theft protection

c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
beforedisconnecting the batterycables.

1. Disconnectthe batterynegativecable.then discon-

nectthe Dositivecable.

2. Connectthe shortconnector(s)
{RED):

Driver's Side:
. Removethe accesspanel from the steeringwheel.
t h e n r e m o v e t h e s h o r t c o n n e c t o r( R E D )f r o m t h e
Daner.
DRIVER'S
AIRBAG

Be sure to installthe harnesswires so that they are

not pinchedor interferingwith othercar pans.

CONNECTOR
IREDI
Disconnectthe 3-P connectorbetweenthe driver's
airbagand cablereel,then connectthe shortconnec-
tor {RED}to the airbagside oi the connector.

M a k e s u r e a l l S R S g r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-to-
metal contact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.

23-272
Front Pas3enger'sSide: Disconnectingthe SRS Connector at the
. Removethe glove box damper (seesection20),and Under-dash Fuse/relay Box:
then removethe glove box.
CAUTION: Avoid br.aking the connoctor; it's doubte-
. Disconnectthe 3-P connector between the front oas- locksd.
senger'sairbagand the SRSmain harness,then con-
nect the short connector (RED)to the airbag side of 1. First lift the connectorlid with a thin screwdriver,
the connector. then pressthe connectortab down and pull the con-
neclorout.
SHORTCONNECTOR
(REDI
CONNECTOR
t_tD

SRSMAIN HARNESS

To reinstallthe connector.push it into positionuntil

it clicks,then closeits lid.

23-273
SupplementalRestraintSystem(SRS)
Steering-relatedPrecautions
SteeringWheel and CableReelAlignment Steering Column Removal

NOTE:To avoid misalignmentof the steeringwheel or CAUTION:

airbagon reassembly,make surethe wheelsare turned
straightaheadbeforeremovingthe steeringwheel.
. Bofore romoving tho 3l6oring column, first discon'
nect tha connector between ths cablo 16ol snd tho
SRSmain harness.
. lf th6 stssring column is going to be removed with-
out dbmounting the stesring wh6el, lock the sl6sr-
ing by turning th€ ignition k.y to o-LOCKpo3ition or
removo tha k€y llom ths ignilion so that th6 3loaring
wheel will not turn.

Rotatethe cablereelclockwiseunit it stops.

T h e n r o t a t e i t c ou n t e r c l o c k w i s e( a p p r o x i m a t e l yt w o
t u r n s lu n t i l :

- T h e y e l l o w g e a rt o o t h l i n e s u p w i t h t h e a l i g n m e n t
markon the cover.
- The arrow mark on the cablereel labelpointsstraight
up.

ARROWMARK

D o n o t r e p l a c et h e o r i g i n a ls t e e r i n gw h e e i w i t h a n y
other design,sinceit will make it impossibleto properly
instsllthe airbag(only use genuineHondareplacement
oans).

After reassemblvconfirmthat the wheelsare still turned

straightaheadand that the steeringwheel spokeangle
is correct,lf minor spokeangleadjustmentis necessary,
do so only by adjustmentof the tie-rods,not by remov-
ing and repositioning the steeringwheel.

ALIGNMENTMARK

23-274
 SensorInspection
CAUTION: Tak€ €xtra care whon painting or doing
body work in the ar€a bslow th6 dalhboard.
Avoid dirost exposure ot lh6 sonsors or wiring to hest
guns, wolding, or spraying equipmont.
Di3connact both the nogativo and po3itivo b!ftery
cable3.
Connsct tho short conneclor(s) before working
bslow the da3hboardor nsar lhe dash sen3o.3.
After any degree of frontal body damage, inspect
both dash sensors.Replacea sensor if it is dented,
cracked,or deformed.
DASHSENSOR
a Be surethe sensorsare installedsecurelv,
BOLTS
InspectionAfter Deployment
After a collision in which the airbags were deployed.
inspectthe following:
1. Inspectthe dashsensorsfor physicaldamage.
lf the sensorsare damaged,replacethem.
2. Inspectall the SRS wire harnesses,ReDlace,don't
repair,any damagedharnesses.
3. Inspectthe cable reel for heat damage.lf there is
any damage.replacethe cablereel.
4. After the car is completelyrepaired.turn the igni-
tion switch on. lf the SRS indicatorlight comes on
for about six secondsand then goes off, the SRS
systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting (nextpage).
23-275
SupplementalRestraintSystem(SRSI
Troubleshooting

Self-diagnosisFunction Connectingthe Short Connectors

The SRS unit includesa self-diagnosis function.lf there @ To avoid.ccidental doploymont and pos.
is a failure in the sensors.SRSunit, inflator,or their cir- siblo iniury. alway3 connect ths protoctive short con.
c u i t s ,t h e S R S i n d i c a t o rl i g h t i n t h e g a u g e s s s e m b l y noctor to tha driver's airbag connectot and, on caf!
comesON. equippod with front passongor'sairbag, conncqt Prolac-
tivs ghort connoctors to the d.ivsr's and tront passsn-
gar's airbag before working nsai any SRSwiring.

NOTE:The original radio has a coded theft protection

c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
before disconnectingthe battery cables,

1 . Disconnectthe battery negative cable, then discon-

nectthe oositivecable.

As a system check,the SRS indicatorlight also comes 2. (RED):

Connectthe shortconnector(s)
on when the ignition is first turned ON to the (ll) posi-
tion. lf the light goes off after approximatelysix sec- Drivsr's Sido:
onds,the systemis OK. . R o m o v e t h e a c c o s sp a n e l t r o m t h e s t e e r i n g
lf the SRSindicatorlighr remainson (or failsto come on wheel, then remove the shon connector(BED)
in the systemcheckmode),one of the SRScomponents from the panel.
DRIVER'S CABLER€EL
(or the wiring/connectors inbetween)is laulty AIRBAG
3-P
TroubleshootingPrecautions
a Always use the test harness.Do not use test probes
directlyon componentconnectorterminalsor wires;
you may damagethem or the SRSunit.
a When connectingany of the test harnessesto the
system,push the connectorsstraight-in;do not bend
the connectorterminals,
. Beforedisconnectingany part of the SRSwire har-
ness,connectthe shon connector(RED)on the driv- ACCESS
er's airbag. On cars equippedwith a front passen- SHONTCONNESTOR PANEL
ger'sairbag,connectshortconnectorson the driver's (REDI
airbagand the front passenger's
airbag. . Disconnectthe connectorbetweenthe driver's
a i r b a g a n d c a b l e r e e l ,t h e n c o n n e c tt h e s h o r t
SRS Indicator Light Troubleshooting connector{RED}to the airbagside of the connec-
Possibloconditions: tor.
1. SRS indicatorlight does not come on at all - see
page 23-278. Front Pas€ngo/s Sido:
. Removethe glove box damper (seesection20),
2. SRS indicatorlight stays on constantly- see page and then removethe glovebox.
23-242. . Disconnectthe connectorbetweenthe front pas-
senger'sairbagand SRSmain harness,then con-
3. SRSindicatorlight comeson in combinationwith a nectthe short connector(RED)to the airbagside
failure of another electricalsystem (chargingsys- of the connector, SHORTCONNECTOR
t e m l i g h t ) . C h e c k f o r d a m a g e / c o r r o s i o na t t h e
under-dashtuse/relaybox connector.

NOTE:
. Beforestartingthe applicabletroubleshooting. check
t h e c o n d i t i o no f a l l S R Sc o n n e c t o r sa n d g r o u n d
points.
. lf the fault is not found after completingthe applica-
ble troubleshooting,substitutea known-goodSRS
unit and checkwhetherthe indicatorlight goesoff. MAIN HARNESS

23-276
 Test Harnesses
and AttachmentPoints
TestHsrnessA
SRSUNIT

TESTHARNESSA
07MAZ - SL|D500 TESTHARNESSC
2 3 8
07LA:Z- SL.()3(X'
to n 12 l 3 1 6 16

Tast HarnessB

TESTHARNESSB
07MAZ - SP@500

ROWA ISRSUNfT ENDI

2 13 1 5 16 17 | l
I 2 12 1 5 l6 17 1A

ROW B IWIREHARNESSEND)

23-277
SupplementalRestraintSystem(SRS)
Troubleshooting

The SRSIndicatorDoesNot Light

CAUTION: Uss only a digital multimeter to check the system. lf it's not a Honda multimeter, make sure its output is
10 mA {0.01Al or less when switched to the smallest value in the ohmmeter rang€. A tester with a highor ouiput could
damagethe airbag circuit or causeaccidentalairbag deployment and possibleiniury

NOTE:The originalradio has a codedtheft protectioncircuit.Be sure to get the customer'scode number beforediscon-
nectingthe batterycables.

Dilconn6ct the battory negaiive

cable rnd thon tho positive
cable.
Connest the short connectorlsl
to tho airbaglsl (seo p6ge 23-
272t.

R€connectthe batterY Positive

c a b l ea n d t h e n t h e n e g a t i v e
cable.

Turnthe ignitionswitchON (ll).

Does the brake system

I n s p e c tt h e N o . l 5 1 1 0A ) f u s e
light come on (in the (under-dash tuse/relay box).
gaugeassembly)?

ls No. 15fuseOK?
Turnthe ignitionswitchOFF.

Repairopen in dashboardwir6
D i s c o n n e ctth e S R S m a i n h a r - harnessbetween the No. 15 tus€ SRSUNIT
n e s s l 8 - P c o n n e c t o rf r o m t h e and gauge a3sombly.
SRSunit.

SRSMAIN HARNESS
18.PCONNECTOR
Turnthe ignitionswitchON (ll).

D o e st h e S R S i n d i c a t o r The SRSunit is faully.

lightcomeon?

Turn the ignition switch OFF.

Io page 23'2791

23-274
 SRSMAIN HABNESS
(From plgr 23.27E1

Disconnocttho SRS m.in h6,-

ng88 {-P conn6clorf,om tho
mrin wiaoharn6$.

Tum lhq ignition switch ON (lll.

MAIN VNRE
HARNESS

D o o 3t h o S R S i n d i c . t o r
light com6 on? Th. SRS rnlin h..n... i.t ulty.

Tu.n tho ignition switch OFF.

R o m o v ot h o g ! u 0 c ! s s . m b l y
th6n inrpoct ths SBS indicator
light bulb.

DASHBOARDWIFEHARNESS
5-PCONNECTOR
Raplacalh. indlc.toi llOht birlb.

Connoct ! voltmotoa bdwoln thr

No. 5 lormin.l (+) of tho 5-P con-
noctor rnd body ground (-).

Turn the ignition switch ON (ll).

Moaaurotha voltrgo bolwcon tha

No. 5 termin.land body g.ound.

(Top.go 2+280)

8tU{+

@
I
:

23-279
SupplementalRestraintS ystem(SRSI
Troubleshooting(cont'd)
(Frompage23-279)

Short in 8LU wire ol the da.h-

ls therelesslhan8.5V ? borrd wi.o halno3s. Roplacatha
d.3hbosrd wiro ha.no$.

Turnthe ignitionswitchOFF
DASHBOARDWIREHARNESS

Connecttho voltmeter between

the No. 1 terminal(+)and the No.
3 terminal (-) of the dashbo€rd
wire harness5-Pconnector.

YELI+,BLK{-I
Turn the ignitionswitchON (ll).

View lrom wire side.

Measurethe voltage betweenthe
No. 1 terminaland th€ No.3 ter-
mrnal,

Ch6ckfor continuity betweenth6

ls there batteryvohage?
No.3 terminaland body ground.

R.prir opcn in tho BLK wir. (No.

3 tarmin!l) batwaan th. gluga
Turnthe ignitionswitchOFF. araambly and body ground ot
look tor. poor ground 1G201,
cilol I.
{To page23-281}
Rcprir open in th. YEL wi.o lNo.
t t6rminall of the d.3hbo.rd
wir6 hamer! batwaen tho gtugo
r3s6mblv rnd tho No. 15 ll0 Al
fu36.

23-280
 (From page 23-280)

Reconnecteach connectorto the

g a u g e a s s e m b l ya n d S R S u n i t
then connect Tgst Harness A to
the SRSunit.

Turn the ignirion ON 0l) and

moasureth€ voltage betwegnthe
No. 13 terminal (+) and body
ground (-) tor six seconds.

TEST HARNESSA
07MAZ - S!IX)s{X'

4 8
9 10 It l2 13 l 4 15 16

ls th€r6 more than 8.5 V? SBS indic.tor circqit {in th.

e.ug. r.t mblv, i. hulty,

23-2a1
,;l tflEt$ r'
SupplementalRestraintSystem(SRSI
Troubleshooting(cont'dl
SRSIndicatorLight Stayson Continuously NOTE:The original .adio has a coded theft protection
c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
NOTE: Beforetroubleshooting,make sure that battery before disconnectingthe battery cables.
voltageis 12 V or mo.e. Otherwiseyou'll obtain wrong
test readings. Beforedisconnectingany pan of the SRSwire har-
ness,connectthe short connecto(s) {RED)to the
1. Make a photocopy of the chart on page 23-283, airbag(s)(seepage23-2721.

2. ConnectTestHarnessA to the SRSunit as shown. Connect Test Harness B between the SRS unit and
SRSmain harn€ss18-Pconnector.

I 2 1 I
to ll l2 t3 t l rt

TEST HANNESS
Tu.n the ignitionswitchON (lll.
"battery
. Voltagesin the chart assumethe car's 7. Checkfor continuitvbetweenthe 85 terminal and
voltage"is about 12 volts.Lessthan 12 volts will b o d y g r o u n d , a n d t h e B l 5 t e r m i n a la n d b o d y
result in different or possiblytalse readings. ground.
. Do not disconnectthe airbags ftom the circuit
when checkingSRSunit voltages.

F i r s t , c h e c k f o r v o l t a g e b e t w e e nT e s t H a r n o s s
TerminalNo. 12 (+)and ground(-).
TEST HARNESSB
. lf no voltageis indicated,go to stepI and contin- 07MAZ - SPqrS{X)
ue checkingall the otherterminals.
o lf vottsge is indicated,there is a poor ground at
the SRSunit.Readthe followingNOTE,and then
go on to step 5.

lf there is continuityat eitherterminal,the SRS

unit is faulty. Replaceit and checkthe voltages
accordingto the chan on page23-283.
lf there is no continuity at either terminal, the
S R S u n i t g r o u n d ,t h e S R S u n i t c o m p o n e n t
g r o u n d s o r t h e S R S m a i n h a r n e s si s f a u l t y
Checkthe grounds (checkwire and control unit
mounting bolts) and, if necessary,replaceth€
S R S m a i n h a r n e s s .T h e n c h e c kt h e v o l t a g e s
accordingto the charton page23-283

23-282
8. Recordyou. voltagereadings.for eachterminal,in
the row of blank boxes near the top of the chart.
Compareeach readingwith the voltagerangeslist-
ed in the column below it. lf ths readingis within a
range,circlethat range.
lf you circledall the FailureMode rangesacrossany
row. checkthe car for the ProbableFailureMode list-
sd at the end of the row. (Referto the letter for that
mode on the followingpages),

4.5 12,O
o o 1/4.3 I
/
".)6r- 4.5 12.O It youcircl€d
alltheranges
in thisrow,tollowthe
at'9\r t.g 5.5 - 14.3 troubleshooting underfailuremode,,C"on the
procedure
5.t 4,5 r2,o followingpages.
-t4.3
lf you did not circle all the rangesacrossany row,
4.6 2.9 rl.5 12.0 replacethe SRS unit with 8 known-good unit, and
-5.5 - 14.3
retest.
2 . 91 8 . 7 | - l..s lr2.ol - - l f a l l y o u r v o l t a g e r e a d i n g sa r e n o w n o r m a l ,
3 . 7l - r r . 2 l | - 5 . 8l - r a . 3 l replacethe originalSRSunit.
- lf your voltage readingsare still not normal but
Circlethe rangeif your readingis within it.
t h e y d o n ' t f i t w i t h i n a c o m p l e t er o w o f F a i l u r e
Mode ranges,checkthe conditionof the terminals
in esch of the SRS connectorsshown in the svs-
tom diagram on page 23-270,

NOTE:Do not disconnectthe airbagwhen checkingSRSunit voltages.

Whh tront passongor'ssirbag:
1 2 5 a 10 t3
SAOH SADC aucl GNO tDc
4,3 4.3 4.5 12.0 t1,5 4.4
5.4 -5.6 -14.3 - 14.5 o 1 3 . 6 - 10.9

2.5 2_A 4.5 12.O 3.1 11.5 2.O 4.4

-3.7 - 1rt.3 -4,9 - r4.5 o -4,5 10.9

o o 4.5 12.0 11.5 2.O 8.4

-5,5 14_3 o 14.5
o 4.5 - 1 0 . 9

8,6 a_6 4,5 12.0 11.2 11.5 2.O 4.4

l1_3-11.3 5.5 - 14.3 -14.6 - 14.5 o 4.5 10.9
5_7 4.5 12.0 r1,5 2.O 8.4
- 14.3 -9.7 -14,5 o 4.5 to.9
4.6 2.9 4.5 1 2 , O 3,7 I1.5 2.O 8.4
-3,7 -5.5 -14.3 4.9 0
l4_5 4.5 10.9

2.9 4.7 4.5 '12.o 3.7 11.5 2.O 4.4

- 1 1. 2 -5.5 -14.3 4.9 - 14.5 o a_5 10.9

4,6 a_6 4.5 12.O I t.5 2.O 4.4

l1_3-t1.3 5.5 - 1 4 . 3 o - r4.5 o -4,5 10.9

4.3 4.3 11.5 2.O

-5,6 5.6 o o - t lt.5 o -4.5
4.4
- 1o.9

4.3 4_3 4.5 12.O 11 . 5 o 18.5 4.4

5,6 5.6 5.5 r4.3 -7.3 - 14.5 o - 13.6 1 0 . 9

23-283
SupplementalRestraintSystem(SRSI
Troubleshooting(cont'd)
NOTE:Do not disconnectthe airbagwhen checkingSRSunit voltages.
Without lront Passongor'ssirbag:
l 5 8 10 12 13 t4
SAOH vcc saoc BUCI Gto toc
5,6 11.5 a _ 5 8.:a
4,3 12.O
-7.3 - 14,5 o - 1 3 . 6 ro.9
5.6 5.5 - 1 4 . 3

't2.o 3.7 11,5 2 . O 8.4

2.4 4.5
4.9 -14.5 o -8.5 - r 0 . 9
3.7 5.5 14.3

4 . 5 12.O 11.5 2 . O 8./a

o o -14,5 o -8.5 - r 0 . 9
5,5 - 1 4 . 3

12.O 11.2 11.5 2.O 8./t

4.6
- 14.6
o -r0.9
-11.3 -5.5 - 14.3 14,5

t2.o tt.5 8.1

5.7 4.5
-9.7 - 14_5 o -8.5 -10.9
14,3

4.5 12.0 3.7 1t.5 2.O a.a

4.6
-4.9 o - 8 . 5 -r0.9
11.3 - 5 . 5 - 14.3 14.5

4.3 5,6 11.5 2,O 8.it H ll{o. 26 lo Al o.

o o -7.3 14,5
o ,r0.9

t1.5 o ta,5 E,4

4.3 4.5 12.O
- 14.3 -7.3 - 14-5 o - 1 3 . 0 t- 1 0 . 9
-5.6 -5.5

Modo A: Open in one cowl sonsor conlact
r The SRSunit is faultY.Substitutea known-goodSRS
unit and recheckthe voltagesaccordingto the chart
on page23-283.
Mods B:
. Short to driver's or Passonger'saitbag inflator body
(body groundl
. Short in dash sonsor
. Opsn in both cowl sgnsor contacts
NOTE:The original radio has a coded theft protection
c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
before disconnectingthe battery cables.
1. Disconnectthe batterynegativecable and then the
positive cable.Then connectthe short connectots(s)
(RED)to the airbag(s)(seepage23-272).
2. ConnectTest HarnessB betweenthe SRS unit and
SRSmain harness18-Pconnector.
'...
SRSMAIN HARNESS
18.PCONNECTOR
3. Reconnectthe driv€r's airbag connector,then check
continuity betweenthe B1 terminal and body
ground, and b€twesn the 87 terminsl and body
grounq,
B
TESTHABT{ESS
A
B
. lf there is continuity at either terminal, go to step
o.
. lf there is no continuity at sither terminal'
- go to step 5 (without front passonge/sairbag)'
- go to step il (with front passenger'sairbag)'
SRSUN]T Reconnectthe front passonger'ssirbag connector,
then checkcontinuitybetwo€nihs 82 t€rminaland
body ground, and between the 88 terminal and
body ground.

lf there is continuityat eitherterminal,go to step

10.
lf there is no continuityat eitherterminal,go to
step 5.

23-284
Checkcontinuity between body ground and each 7. Checkcontinuity betweenthe No. 4 terminal and
terminalof both dssh sensors. body ground, and between the No. 5 terminal and
body ground.
TESTHARNESSB
o?MAZ- SFmSd)

TEST HABI{ESS C
07LAiZ- SLIO:loo

. lf there iscontinuityat anyof theterminals,go to

step 12.

. lf thsre is no continuity at any terminal, go to

steo 13.
Disconnectthe cable reel 6-p connectorfrom the
SRS main harn€ss,then connect Test HarnessC
only to the cablereel sideof the 6-p connector.
CABLENEEL&P CONNECTOR
lf there is continuity at either terminal, go to step
8.
lf there is no continuity at either terminal, the
SRS main harnessis faulty. Replaceit and re_
c h s c k t h e v o l t a g e sa c c o r d i n gt o t h e c h a r t o n
page 23-283.

(cont'd)

23-285
SupplementalRestraintSystem(SRS)
Troubleshooting{cont'd}
8. Disconnectthe drive/s airbag 3-P connectortrom 10. Disconnect the front passenger'sairbag3-Pconnec-
the cable reel,then connectTest HarnessC to the tor from the SRS main harness,then connectTest
driver'sairbag3-Pconnector. HarnessC to the airbagside of the connector.

FRONTPASSENGER'S
ANBAG

DRIVER'SAIRBAG

o7LAiZ- Slao:tq,

Checkcontinuitv betweenthe No. 7 terminal and 1 1 . Checkcontinuitv betweenthe No. 7 terminal and
body ground,and betweenthe No. 8 terminal and body ground,and betweenthe No. 8 te.minal and
body ground. body ground.

lJ there is continuityat eitherterminal,the driv- lf there is continuitvat eitherterminal,the Jront

e r ' s a i r b a g i n f l a t o r i s f a u l t y . R e p l a c ei t a n d passenger'sairbag inflator is faulty. Replaceit
recheckthe voltagesaccordingto the chart on and recheckthe voltagesaccordingto the chart
page z3-z6J. on page 23-283.

lf there is no continuity at either terminal, the lf there is no continuitv at either terminal, the
cable reel is faulty. Replaceit and recheckthe S R S m a i n h a r n e s s i s f a u l t y . R e p l a c ei t a n d
voltagesaccordingto the charton page23-283. recheckthe voltagesaccordingto the chart on
page 23-283.

23-286
 12. Connect Test Harness D between the dash sensor o lt rssistanceis 3.8 - 4.2 kO for both sensors.the
and SRS main harness2-P connector.Checkconti- SRSunit is faulty.Substitutea known-goodSRS
nuity betweenthe No. 1 terminsland body ground, unit €nd recheckthe voltagesaccordingto th€
8nd betweenthe No.2 terminaland body ground, chart on page 23-283.

o lf resistancsis l6ss thsn 3.8 kO for either sensor.

sRs MA[{ go to step 14.
HARNESS
2-POOTTNECTOR
1il. Connect Test Harness D between the dash sensor
and SRSinain harness2-P connector.Measurethe
resastancebetweenthe No. 1 terminal and No. 2 ter-
minal.

SRSMAIN
HARNESS
2.PCONNECTOR

TESTHARNESS D
o?LAiZ- SL()a(xt
TESTHARNESSD
otlA:z- sl(,(x)

rffi-l
? ? TEST HAR ESS D
07LAZ - SL.{)a(xl
TESTXARNESS D
otlA:z - sl4|)4tx)

. lf there is continuityat eitherterminal,the dash

sensor is faulty. Replaceit and recheckthe volt-
agesaccordingto the chan on page23-293.

. lf there is no continuity at either terminal, the

S R S m a i n h a r n e s s i s f a u l t y . R e p l a c ei t a n d
recheckthe voltagesaccordingto the chart on is 3.8- 4.2kO,the SRSmain harness
lf resistance
page 23-283. is faulty. Replaceit and recheckthe voltages
accordingto the chan on pag€23-283.
t'l Measure the resistancebetween the l6ft dash sen-
sor terminalsB'12and Bl6, and betweenthe right lf resistanceis lessthan 3.8 kO,the dash sensor
dashsensorterminalsB4 and 86. is faulty. Replaceit and recheckthe vottages
accordingto the charton psge 23-283.

IESTHARNESS B
07MAZ- SPqt500

(cont'd)

23-287
SupplementalRestraintSystem(SRS)
Troubleshooting(cont'd)
Modg C: Shon in one cowl son3ol, or open in both dash 3. Measure the resistancebetween the left dash sen-
sensors sor terminals812 and 816, and betweenthe right
Mode D: Open in ono da3h sensol dashsensorterminals84 and 86.

NOTE:The original radio has a coded theft protection

c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
beforedisconnecting the batterycables

1. Disconnectthe batterynegativecable and then the

positivecable.Then connectthe short connector(s)
to the airbag(s)(see page 23'2721.

2. ConnectTest HarnessB betweenthe SRS unit and

SRSmain harness18-Pconnector.

lf resistanceis more than 5 kO for eiiher set of

terminals,go to step4.

lf resistanceis less than 5 kOtor both sets of ter-

m i n a l s , t h e S R S u n i t i s f a u l t y . S u b s t i t u t ea
known-goodSRS unit and recheckthe voltages
accordingto the charton page23-283.

23-2AA
4. Connect T6st Harness D between the dash sensor
and SRSmain harness2-Pconnector.
Measurethe resistancebetween the No. 1 terminal
and No. 2 terminal.
Mode E: Op€n in driver's airbag inflator or cable reel
NOTE:The original radio has a coded theft protection
c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
beforedisconnecting the bafterycables.

1 . Disconnectthe batterynegativecableand then the

SBSMAIN
HARNESS positivecable.Then connectthe short connector(s)
2-PCOI{NECTOR (RED)tothe airbag(s)(seepage23-272).

2. ConnectTest HarnessI betweenthe SRS unit and

SRSmain harnessl8-P connector.

sRsuNtt

TEST
HARNESSD
orlA:a- sl{tarx)

TESTHARI{ESSD
OTLAZ- sl/to4{lo

Reconnect the driver's airbag connector, then mea-

sure the resistance between the 81 and the 87 ter,
m rn a l s .
lf resistance
is more than 5 kO,the dash sensoris
faulty.Replacethe dash sensorand recheckthe
TESTHARNESSB
voltagesaccordingto the charton page23-283. o?MAZ - SP00500

lf resistanceis lessthan 5 kO,the SRSmain har-

nessis faulty.Replacerhe SRSmain harnessand
recheckthe voltagesaccordingto the chart on
page 23-283.

lf resistance
is more than 0.2 kO,go to step4.

lf resistanceis lessthan 0.2 kO,the SRS unit is

f a u l t y .S u b s t i t u t ea k n o w n - g o o dS R S u n i r a n d
recheckthe voltages accordingto the chan on
page23-283.
(cont'd)

23-289
; r.il
SupplementalRestraintSystem(SRS)
Troubleshooting{cont'd}
4, Disconnectthe cable reel 6-P connectorfrom the
SRS main harness,then connect Test HarnessC
onlv to the cable reel side ot the connector.
CAB1I REEL&P CONNECTOB
TESTHARNESS C
07LAZ- SLIO300
Measurethe resistancebetween the No. 4 terminal
and the No, 5 terminal.
TEST HARI{ESS C
OTLAiZ- Sl/t{r3q)
lf resistance.ismore than 0.2 ko, go to step 6.
It resistanceis less than 0.2 k0, the SRS main
harnessis faulry. Replaceit and recheckthe volt-
agesaccordingto the charton page23-283.
23-290
6. Disconnectthe driver's airbag 3-P connsctorfrom
the cabls reol harness,then connoct Test Harn6ssC
to the driver's airbag 3-P conn6ctor.
DRIVER'SAIRBAG
7. Measurethe resistancebetween the No. 7 terminsl
and the No. 8 terminal.
TESTHARI{ESSC
OTLAZ- AL/|{,3OO
lf resistanceis more than 0.2 kO, ths drivsr's
a i r b a g i n f l a t o r i s f a u l t y . R e p l a c et h e a i r b s g
ass€mbly and recheckthe voltages according to
the chart on page 23-283,
lf resistanceis lessthan 0.2 kO.the cable reel is
f a u l t y . R e p l a c ei t a n d r e c h e c kt h e v o l t a g € s
accordingto the chart on page 23-283.
Modc F: Opon in tront pa3s6ngs/s rirbag inflstor Disconnectthe front passenger'sairbag 3-P connec-
tor from the SRS main harness,then connectTest
NOTE:The original radio has a coded theft protection HarnessC to the front passenger'sairbag sids of
c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r the connector,
before disconnectingthe battery cables.
FAONT
1, Disconnectthe batterynegativecableand then the
positivecable.Then connectthe short connoctor{sl
{RED}to the airbag(s)(seepage23-272).

2. Connect Test Harness B between the SRS unit and

SRSmain harness18-Pconnector.

SRSUNIT

TESTHARNESS C
- SL/O300
07LA,Z

Measurethe resistancebetweenthe No. 7 terminal

a n dt h e N o .8 t e r m i n a l .

07MAZ - SP|D500

Reconnectthe front passenger'sairbag connector,

then measurethe resistancebetweenthe 82 termi- TEST HAB ESS C
071-Aiz- sll|{,300
nal and the B8 terminal.

TESTHARNESSB
oTMAZ - SP005(x)

lf resistanceis more than 0.2 kO,the front pas-

lf resistanceis more than 0.2 k0, go to step 4.
lf resistanceis lessthan 0.2 kO,the SRS unit is
faulty. Substitutea known-good SRS unit and
recheckthe voltages accordingto the chart on
page 23-283.
s e n g e r ' sa i r b a g i n f l a t o ri s f a u l t y . R e p l a c et h e
front passenger'sairbag assemblyand r€check
the voltagesaccordingto the chart on page 23-
243.
lf resistanceis lessthan 0.2 kO,the cable reel is
faultv. Replacethe cable reel and r€checkthe
voltages accordingto the chart on page 23-283.
(cont'd)

23-291
SupplementalRestraintSystem(SRSI
Troubleshooting{cont'dl
Modc H: Blown SRSNo. 25 fur., ol opcn in the wire Reconnectth6 positiv€ 8nd negativecable to the
battery.
NOTE:The original radio has a coded theft protection
circuit. Be sure to get the customer's code number Measureths voltage betweenthe 813 terminal (+)
betore disconnectingthe battery cables. and body ground{-)with the ignitionswitchON (ll).

1. Ch€ckthe SRSNo. 25 (10 A) fuse in the under-dash

fuse/relaybox. lf it's OK, go on to step 2.
lf it's blown, replace it with a now 10 A fuse, then TESTHAN ESSB
turn the ignitionswitchON (ll): oTMA:Z- SPOOs{X'
2 3 a 7 a 10 n l3 1 6 1a 1 7 ra
. lf the fuse doesn't blow, 90 on to step 2. 12 1 6 1a 1 7 |a
2 6 1 6 1o ll

. lf the fuse blows. troublsshoot as necessaryto

find th6 short.

2. Disconnectthe battery negative cable and then the

positive cable. Then connect the short connector(sl
(RED)to the airbag(s)(see page 23-272).
3. Conn€ct Teat Harnsss B between the SRS unit and
the SRSmain harness18-Pconnector.
lf there is battery voltage, the SRS unit is faulty.
Replaceit and rscheckthe voltages accordingto
the chan on page 23-283.

lf there is lsss than b8ttery voltage,the SRSmain

harnessis faulty. Replaceit and recheckthe volt-
ag6s accordingto the chart on page 23-283.

SRSUNIT

23-292
Modc l: Short 01 opcn in SRS indicrtor whc hrrnaas
1. Disconnecttho SRS main harness 4-p connector
from the main wirs harn6ss.
Disconnectthe battery negative cable and then the
positive cable. Then connect the sho.t connector(s)
(REDltothe airbag(s)(seepage23-272).
Connect Test Harness B between the SRS unit and
SRSmain harness18-Pconnector.

WIREHABNESS

2. Turn the ignitionswitchON (ll) 8nd wait for six sec-

onds. Measu.s the voltage betweenths No. il termi-
nal (+) in the SFS main harness4-P connectorand
body ground, 5. Reconnectthe battery positivecable and negative
caote.

6, Checkfor continuitybetweenthe 811 terminal

*-
F4 BLU
body ground.

d.L
Vrowllom wi|! rftro.

. lf voltage is more thsn 8.5 V, go to step 8.

. It voltage is lessthan 8.5 V, go to step 3.
NOTE: The original radio has a coded theft protec-
tion circuit. Be sure to get the customer's code
number before disconnectingthe banery cables.
lf there is continuity,the SRS main harnessis
s h o r t e d . R e p l a c et h e S B S m a i n n a r n e s sa n o
recheckthe voltagesaccordingto the chart on
page23-283.
lf there is no continuity,go to step7.

(cont'dl

23-293
SupplementalRestraintS ystem(SRSI
Troubleshooting(cont'dl
7. Checkfor continuity betweenthe 811 terminal of o Turn ths ignitionswitchON {ll} and wait for six sec-
Test HarnessB and the No. 4 terminal of the SRS onds. Measurethe voltagebetweenthe No. 5 termi-
main harness4-Pconngctor, nal (+)and body ground (-).

OASHSOAROIVIRE HARNESS
TESTHARNESSB s.PCO ECTOR
07MAZ - SF|D500

Vrawfromsil! rira,

. l f t h e r e i s c o n t i n u i t y ,t h e S R S u n i t i s f a u l t y ,
Replaceit and recheckthe voltages according to lf voltage is mora than 8.5 V, the SRS indicator
the charton page23-283. circuitis faulty (in the gaugeassemblyl.Replace
the SRS indicatorcircuit assemblyand recheck
. lf there is no cootinuity.there is an open in the the voltsges according to the chart on page 23-
SRS main harness.Replacethe SRS main h8r- 243.
ness and recheckthe voltagesaccordingto the
charton page23-283. lf voltageis lessthan 8.5 V, the dashboardwire
h a r n e s s( o r t h € m a i n w i r e h a r n e s s )i s f a u l t y .
8. Reconnectthe SRS main harness4-P connecto.to Replaceit and recheckthe voltages accordingto
the main wire ha.ness.Disconnectthe dashboard the chart on page 23-283.
wire ha.ness5-Pconnectorfrom the gaugeassem-
Dtv.

DASHBOARDWIRE HARNESS
5.P OONNECTOR

23-294
 AirbagAssemblyReplacement

@E storc a r.movcd lirb.g rslombty with thc Fror{ P$!.ngar/3 Sida:

p.d surfaco up, if tho lirbrg is improparly 3iorad frca
down, accidontald.ploymert could plopcl tha unit with . Remove th6 glove box damper, then remove the
cnough torcr lo causclariour iniury. glove box.

CAUTION: . Disconnoctthe front psssenger'sairbag 3-p connec-

. Do not inst.ll urld SRS plrts trom lnothar c!1, t o r f r o m t h e S R S m a i n h a r n e s s ,a n d c o n n e c tt h e
Whon lepairing, uss only now SRSprrt!. short connoctor (RED)to the front passenger,sairbag
o Carefully inlpcct thc airblg rlrcmbly bltorc you 3-Pconnector.
install it. Do not inst.ll an airbag !$.mbly thrt
3how! sign3 of bcing droppcd or improparly hrn-
dlod, such as dont!. crack3or dstormation. FROIVTPASS€NGEF'S SHOBTOONNECTOR
. Alwry! koop ths rhort connactor(3l (REDI on tha AIRBAG
3.PCONNECTOR (REDI
airbrg{s} whon tho hsrnca3i! dirconnastld.
. Do not diras3ombl! or tamp€l with tha lirbrg
a$ombly.

NOTE:The original radio has a coded th6ft protection

c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
before disconnectingthe battery cables.

1. Oisconnectthe battery nogative cabl6, then discon-

nect the positive cable.

2. Connect the short connecto(s) (R€D)to the aifbag

side of the connector(s);

Drivo/s Sido:

a Removethe accesspanel from the steeringwhesl,

then ramove the short connector (REDI from th6
paner.

. Disconnectthe 3-P connectorbetwesn the driv6r's

airbagand cablereel,then connectth6 short connec-
tor {RED}to the airbagsideof the connector.

(cont'd)

23-295
SupplementalRestraintSystem(SRSI
AirbagAssemblyReplacement(cont'd)
3. Removethe airbag(s): Front Palsugor'r Sidc:

Driver's Side: . Removethe four mounting nuts, then lift the front
passenger's
airbagout of the dashboard.
. Removethe two TORXobolts using a TORX0T30 bit,
then removethe driver'sairbagassembly. NOTE:Oo not confusethe lower mountingnutswith
the upper mounting nuts. The upper mounting nuts
are not selt-locking.
DRIVER'S
AIRBAG ASSEMBLY
FRONTPASSENGER'S
AIBBAGASSEMBLY

23-296
CAUTION: Bo 3uro to in3tsll tho SRSwiring so that it is Front Pa$aogsr's Sid€:
not pinchod or intoforing with other car parts.
. Placethe front passenger'sairbag assemblyin the
4. Installthe new airbag(s): dashboard.

Driver's Sido: Placethe driver's airbag assembly in Looselyinstallall four mountingnuts.

the steeringwheel, and secureit with new TORX@
bolts. Tighten the upper two nuts first, then the lowsr two
TORXCBOLT nuts. Adjust the lower mounting bracketif necessarV.
9.8 N'm 11.0kgt m.
7.2lbf.ftl Replace.
Uio a TORXOT30 bit

UPPER
MOUNTINGNUTS
FRONTPASSENGER'S
AIRBAG
ASSEMALY

TORXOBOLI
9,8 N'm l'1.0kgf.m,
7.2lbtftl Replaco.
Us. . TORX6T30 bit

LOWER
MOUNTINGNUTS CONNECTOR
9.8 N.m (1.0lgtm, t.2lbtftl IREDI
Reolace.

{cont'd)

23-297
SupplementalRestraintSystem(SRSI
(cont'd)
AirbagAssemblyReplacement
5. Removeand properlystore the short connector(s), Connect the battery positive cable, then the nega-
then reconnectthe airbagconnector(s). tive cable.

Front Pass€ng€r'sSide: 7. After installingthe airbagassembly,confirm proper

systemoperataon:
. Remove the short connector (RED)from the front
p a s s e n g e r ' sa i r b a g c o n n e c t o r ,t h e n c o n n e c tt h e . Turn the ignition ON (ll): The instrumentpanel
airbag 3-P connectorto the SRS main harness3-P SRSindicatorlight shouldcome on for aboutsix
connector. secondsand then go off.
SHORTCONNECTOR . Make sure both horn buttons work.
FRONTPASSENGER'S ,,' a Take a test drive and make sure the cruise con-
AIRBAG3.P CONNECTOR trol sevresum€switch works.

8. Enter the code number to restoreradio oDeration

(seepage23-191).

. Then reinstallthe glove box on the dashboard,

Driver's Side:

Removethe short connector(RED)from the driver's

airbag connector,then connectthe airbag 3-P con-
nectorto the cablereel3-Pconnector.

CABI-EREEL
3-PCONNECTOR

SHORTCONNECTOR
IRED)

DRIVER'S
AIRBAG3.P
CONNECTOR

Attachthe short connector(RED)to the accesspanel,

then reinstallthe panelon the steeringwheel.

23-294
 Airbag Assembly Disposal

Beforescrappingany airbag(s)(includingone in a whole Front Passonger'sAirbag:

car to be scrappedl,the airbag must be deployed. t{ the
car is still within the warranty period, before you deplov 4. R e m o v et h e g l o v e b o x d a m p e r ( s e es e c t i o n2 O ) .
the ai.bag,the AcuraDistrictServiceManagermust give then removethe glove box. then disconnectthe 3-p
approvaland/or specialinstructions.Onlv after the air- connectorbotweenthe front passenger,s airbagand
ba9 has beendeployed(asthe resultof vehiclecollision, SRSmain harness.
for example),itcan be scrapped.
lf the airbag(s)appear(s)intact (not deptoyed,treat it
{them)with extremecaution. FRONTPASSENGER'S SHORT CONNECTOR
Followthis Drocedure: AIRBAG3.PCONNECTOR IRED}

Doployingthe Airbag(sl:In-car

N O T E : l f a n S R S c a r i s t o b e e n t i r e l y s c r a p p e d .i t s
airbag(s)should be deployedwhile still in the car. The
a i r b a g ( s )s h o u l d n o t b e c o n s i d e r e da s s a l v a g e a b l e
pan(sland shouldneverbe installedin anothercar.

@ confirm that osch airbsg assemblyis

s6cursly mounted; oihorwis6. s€voro parsonal iniury
could result from doployment.

1. Disconnectthe banerynegativecable.then discon_

nectthe Dositivecable.

2. Confirmthat the specialtool is functioningproperly

by followingthe checkprocedureon the labelof the
tool set box, or on page23-300, SRSMAIN I{ARNESS

Driver's Airbag:

3. Removethe accesspanel,then disconnectthe 3_p Cut off the airbag connector,strip the ends of the
connecto.betweenthe driver'sairbagand the cable airbagwires, and connectthe specialtool alligator
reel. clips to the sirbag.Placethe specialtool aboutthir_
ty feet (10meters)awayfrom the airbag.
CABLEREEL
3.P CONNECTOR
DRIVER'S FRONTPASSENGER'S
AIRBAG AIRBAG

ALLIGATOR
CLIPS
lY.llowl

12 V BATTERV OPERATION
swrTcH
DEPLOYMENT
TOOI (cont,dl
07HAZ- SG00400

23-299
SupplementalRestraintSystem(SRSI
AirbagAssemblyDisposal(cont'd)
Connecta l2 volt battervto the tool: Doploying the Airbag: Out-ot{!r.

. lf the green light on the tool comes on, th€
a i r b a g i g n i t e r c i r c u i t i s d € f e c t i v ea n d c a n n o t
d e p l o y t h e a i r b a g . G o t o D s m a g € dA i r b a g
SpecialProcedure.
. lf the red light on the tool comeson, the airbagis
readyto be deployed.
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h 6 s i r b a g
should deploy (deploymentis both highly audible
and visibls- a loud noiseand raDidinflationof the
bag, followed by slow deflationl.
NOTE: lf an intsct airbag assembly has been removed
from a scrappedcar, or has been found dofectiveor
damagsd during transit, storage or service, it should bs
dsployed as follows:
@ Porition th6 lirbrg rr:.mbly t.ce up, out-
doo6 on flat ground !t lorrt thirty foot from rny ob3t..
clar or pcoplo.

. lf audible/visibledeploym€nt happsns and the

green light on the tool comes on, continuswith
this Drocedure.
. lf the airbag doesn't deploy, yet the green light
comes ON, its igniter is dofectiv€. Go to
DamagedAirbagSpecialProcedure.

@ Duringdeploym€nt,the airbsg assom- 1. Confirmthat the specialtool is functioningproperly

bly can becomehot enoughto burn you. Wait thirty by followingthe checkprocedureon this pageor on
m i n u t e s a f t e r d e p l o y m e n tb e f o r o t o u c h i n g t h e the tool box label.
assemblv. 2. Removethe short connectorfrom the airbag con-
nector.
Disposeof the completeairbag sssembly.No pan 3. Folfowsteps5,6,7, and 8 of the in-cardeployment
of it can be reused. Place it in I sturdy plastic bag orocequre.
and sealit securelv.
Dlmlged Airbsg Sp.ci8l Procoduro.
CAUTION:
Woar a taco shiold lnd glov.s whon hlndling ! E!@ f rn lirbag crnnot be deploy.d, it rhould
doploy.d airbag. not br trcltcd !s normll scrrp; ii 3hould still bc comid-
Waeh your hands and rin3a tham wall with ercd a potantillly oxplolivr dcvicc thli cln c!u3a 3ari-
wslor aftor handling r deploycd !irb!g. ou3 iniury.

1. lf instslledin a car,follow the removalprocedureon

page 23-295.
2. In all cases,make sure a short connector is properly
installedon the airbagconn€ctor.
3. Packagethe airbag in sxacily the same packaging
that the now replacement part cama in.
i[. Mark the outside 0f the box "DAMAGEDAIRBAG
NOT OEPLOYED"so it does not get confused with
your parts stock.
5. Contact your Acura District Service Manager for
how and where to return it for disoosal.

Dcploymont Tool: Chcck Procedure.

1. Connectthe yellow clips to both switch protector

handleson the tool; connectthe tool to a battery.
2. Pushth€ operationswitch:green meansthe tool is
OK; red means the tool is faulty.
3. Disconnectthe battery and the yellow clips.

23-300
 CableReelReplacement

!!@ store r rcmov.d rirbrg rsldnbty with thr 5. Connectthe sho.t connector(s)
prd ruf.cc up. It th. .irb.g to the airbag(s).
i3 impropcrly 3to.rd f.cc
down, sccid.ntd d.ploym.rf could propcl th. unit with DRIVER'S
rnough torca to caure a.?iour iniury. AIRBAG

GAUTION:
o Clrdully in3pcct thc airbrg r$.mbly brtorc instll_
ling it. Do not inttrll !n lirb.g |3..mbly ihst fiow3
rignr of bring droppcd or improp.rly handled. ruch
.3 dant!, crrck3 or dafo?mation.
. Atw!$ krro th. tkroR connctot(3l on ths rtbrg\t\
connactor whan tha h|rn!|a l! dbconncstad,
. Do dis.tlambla or tampar with thc ai.brg !r-
lo-t
t.mbly.

NOTE: The original radio has a codod theft Drotoction

c i r c u i t . B s s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r
bsfore disconnectingth6 battery cables.

l. Disconnectth6 banory negstive cable and thsn the

positive cable. IRED}

2. Makesurethe whe€lsare alignedstraightahoad.

3. Removo th€ dashbosrd lowsr covsr and kne6 bol_

$er.

SRSMAIN HARNESS

R e m o v et h e d r i v e r ' s a i r b a g a s s e m b l yf r o m t h e
steerangwheel (two T30 TORXObolts), then remove
the steering wheet nut.
TOR)(' BOLTS DRIVER'S
U.. . TORX. T30 bh AIRBAG
ASSEMBLY

DASHBOANO
LOWEROOVER

Removs tho glove box damper (s6e s€ction 2O),

then removethe glove box,

(cont'd)

2 3-301
-
SupplementalRestraintSystem(SRSI
GableReelReplacement(cont'd)
Disconnectthe connectorsfrom the horn and cruise
controlsevresumeswitches,then removethe cable
reel3-Pconnectorfrom its cliD.
10. Disconnectthe 6-P connector between the cable
reel and SRS main harness,then remove the con-
nectorholderfrom the steeringcolumn.

CABITBEEL

CONNECTOFHOI-DER

'l l. Removethe cablereelfrom the column,

8. Removethe steeringwheelfrom the column.

9. Removethe upperand lowercolumncovers.

UPPER COVER
COLUMN

23-302
GAUTION:
o Eatorainstdlingtho steoringwhosl,lha front whaels
lhould bo alignod straight !ho!d.
. Bc auro to imtalt tho hrrnass wiros so that th6y !16
not pinchod or intsrt6ring with othor crr parts.
. Aftor rsassambly. conlirm that tho whods lre 3till
turnad straight ahead and lh.t the steering wheol
rpoko angle is corrsct {rosd tesi}. lf mino. spok€
angl6 adiustmont is necols!ry, do 30 only by ldiust_
mgnt ol tho tio-rod9. not by removing and rgposi-
tioning tho rteering whoel.
12. Align th€ cancelsleevegrooveswith the cable reel
projections.
1 4 . Installthesteeringcolumnupperano towercovers.
t5. Centerthe cable reel. Do this by first rotatingthe
cable reel clockwise until it stops. Then rotate it
counterclockwise(approximately
two turns)until:
. T h e y e l l o wg e a rt o o t h l i n e su p w i t h t h e a l i g n -
ment markon the cover.
a The arrow mark on the cable reel label Doints
straightup.
ABROWMARK

CABLEREEL

YELLOWGEAR
ALIGNMENTMARK TOOTH

16. Installthe steeringwheel and attach the cable reel

3-Pconnectorto the clip. CRUISE CONTROL
SET/RESUME
Carefullyinstallth€ cable reel on the steeringcol- HORNCONNECTOR
umn shaft.Then attachthe connectorholderto the
steeringcolumn.

CABI.I REEL

CONNECTOR
HOLDER
't7.
Connectthe horn connectorand cruisecontrol sev
resumeswitchconnector.
(cont'd)

23-303
SupplementalRestraintSystem{SRSI
(cont'd)
CableReelReplacement
18. Installthesteeringwheel nut. 2 1 . Removeand properlystore the shon connector(s)
{RED},then reconnectthe airbagconnector(s}(and
reinstallthe glove box).

TORXOBOLTS 22. Reconnectthe battery positive cable,then the nega-

9.8 N.m (1.0kgf.m,7.2lbtftl tive cable.
Replace.
Us6 a TORX6T30 bit
23. After installingthe cable reel,confirm proper sys-
l€m operalron:

Turn the ignition ON (ll); the instrument panel

SRS indicator light should go on for about six
sscondsand then go off.
a Make sure both horn buttons work.
a M a k e s u r e t h e h e a d l i g h ta n d w i p e r s w i t c h e s
work.
Go for a test drive and makesurethe cruisecon-
trol switcheswork.
Rotatethe steering wheel counterclockwiseto
make sure the yellow gear tooth lines up with

STEERING WHEELNUT AIRBAG ASSEMBLY

,19N.m 15.0kgt m, 36 lbt ft)
Replace.

1 9 . Installthe driver'sairbagassembly.

20. Connectthe cable reel 6-P connactorto the SRS

m a i n h a r n e s s ,t h e n i n s t a l lt h e k n e e b o l s t e ra n d
dashboardlower cover.

24. Enterthe code number to restore radio operation

(seepage23-191).

DASHBOARDLOWEROOVER

23-304
 DashSensorReplacement
GAUTION: Removethe footrestdriver,sside only and door sill
. Oo not drmrgc the sensor wiring.
molding,then pull the carpetback,and removethe
. Do not instrll used SBS part3 from anothor c!t,
dash sensor protector.(Left side shownj right side
When repairing an SRS:use only new part3.
is similar.)
o Roplaco. 3onsor it it is dented, crackod,or doform.
od.

NOTE;The original radio has a coded theft protection

c i r c u i t . 8 e s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r
before disconnectingthe b€ttery cabres,

1. Oisconnectthe batterynegativecableand then the

posative
cable.

2. Remove the glove box damper (see section 201.

then remove the glove box.

SHOBTCONNECTOR
IREDI

DASH
PROTECTOR

SRS MAIN HARNESS 5. Removethe two mounting bolts.then removethe

dash ssnsor.

3. Connectthe shortconnector(s)
to the airbag(s). DASH SENSOB

DRIVER'S
AIRBAG

DRNEN'S
ANAAG SHORT
3.P CONNECTOR CONNECTOR MOUNTIITGBOLTS
IREDI
(cont'd)

23-305
SupplementalRestraintSystem(SRSI
(cont'dl
DashSensorReplacement
CAUTION:
. Be 3ure to install the harnesswires so that theY ars
not pinchcd or interfering with othor car parte.
o Carefully inspest the dash sensorslor signs of boing
dropped or improperlyhandled,3uchas dents,
cracksor dsformation.
. For the SRS to lunction propotly, ths right and lsft
sensorsmust be installsd on the propor sidos.
6. Installthe sensorsecurely.
Removeand properlystore the short connector{sl,
then reconnectthe airbag connector(s)(and rsin-
stallthe glove box).
Reconnectthe battery positive cable,then the nega-
tive cable.
1 0 . After installingthe dash sensor,confirm proper sys-
tem operation:Turn the ignition ON (ll):the instru-
ment panel SRSindicatorlight should come on for
aboutsix secondsand then go off.

1 1 . Enter the code number to restoreradio operation

(seepage23-191)-
DASH SENSOR

MOUNTINGBOLTS
8 mm x 1.25
22 N.m (2.2kgf.m, 16lbfftl
Replace.

7. Reinstallall other removedparts.

23-306
 SRSUnit Replacement
CAUTION: 4. Removethe left side cover from the SRSunit. then
. 8€tor6 disconneciing any part of the SRS wire har- disconnectthe SRS main harness lg-p connector
ness, connect the short connectorlsl (RED)to tho from the SRSunit.
sirbagl3).
o Do nol drmsgo thc SRS unit terminal! o. connoc-
to.s.
. Do not disassemblotho SRS unit; it ha3 no rervico- SRSUNIT
.blo parts.
. Storo tho SRS unit in a cleln, dry srea.
. Do not us€ lny SRS unit which h.s been subisctod
to wator damag€ or shows sign3 ol b€ing droppad or
improperly handl6d, such as dents. cracki or d6tor-
mation.

NOTE:The original radio has a coded theft protection

c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r
before disconnectingthe baftery cables.

1. Disconnect the batterynegativecable,then the pos_

itivecable.

Connectthe short connector(s)

to the airbag(s)(see
page 23-2721.

Removethe right sidecoverfrom the SRSunit.

Removethe four TORXobolts from the SRS unit,

then pull out the SRSunit from the driver,sside.

(cont'd)

23-307
SupplementalRestraintSystem{SRSI
(cont'd)
SRSUnit Replacement
CAUTION: B€ suro to install tho SRS wiring ro thlt it i3 Remove and properly storo the short connector{s),
not pinched or interfeling with other car plrts. thgn roconnectthe sirb8g connector(s)(and rein-
st8ll tho glove box).
6. Installthe new SRSunit,
Roconnoctthe battery positivo cable,th€n the n€98-
SRS UNIT tivo cabls.
SRSMAIN HARNESS
18.PCONN€CTOR
1' l. After installing the SRS unit, confirm proper system
operation: Turn the ignition ON (ll): th€ instrumont
panel SRS indicator light should come on for about
six sscondsand then go off.

12. Ent6r tho code number to rostors radio operation

(seepage23-191).

TORX' BOLTS
9.8N.m11.0ksl'm.
7.2tbf.ftl
Replace.
U.. . TORX' T30bit

LEFTSIDECOVER

SRSUNIT

TOD(' BOLTS
9.8N.m(1.0tc[.m,
7.2tbf.ftl
Ur. . TORX.T30bit

COVER

Connectthe SRS main harness18-Pconnectorto

the SRSunit;push it into positionuntil it clicks.

Installthe SRSunit covers(rightand left).

NOTE: Make sure the coverssnap tog€ther in the

middle.

23-308