Vdocuments - MX Service Manual Honda Accord 1990

INTRODUCTION
How to Use This Manual - - - - - - - - - - - - - - - - - - - - - - .

This manual contains service information for the ACCORD. Separate volumes are publish-
ed regarding vehicle construction, engine, and transmission; the applicable reference
manuals are listed below.
This manual is divided into sections. This first page of each section is marked with a black
tab that lines up with one of the thumb index tabs on next page. You can quickly find the
first page of each section without looking through a full table of contents. The symbols
printed at the top corner of each page can also be us8d as a quick reference system.
Each section includes:

1. Atable of contents, oran exploded view index showing:
• Parts disassembly sequence.
• Bolt torques and thread sizes:
• Page references to descriptions in text.
2. Disassembly/assembly procedures and tools.
3. lnspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
r- Reference Manuals
! Date
Description Code No. Remarks
Published
1
1
ACCORD Construction and Function 62SM410 Sept. 1989
F18A/F20A/F22A ENGINE 62PT400 1 .8 2 Carbureted Engine Sept. 1989
Maintenance and Repair 2.0 2 Carbureted Engine
2.02 Fuel-lnjected Engine
2.2 ~ Fuel-lnjected Engine
!
H2 MANUAL TRANSMISSION 62PX500 5-speed Sept. 1989 ,,
Maintenance and Repair r
PX4B AUTOMATIC TRANSMISSION 62PX400 4-speed with lock-up Sept. 1989
Maintenance and Repair
Special lnformation - - - - - - - - - - - - - - - - - - - - - - - - - - ,
fjfil{.l¡lfiifM
lndicates a strong possibility of severe personal injury or loss of life if instruc-
tions are not followed.
CAUTION: lndicates a possibility of personal injury or equipment damage if instructions are

not followed.
NOTE: Gives helpful information.
CAUTION: Detailed descriptions of standard workshop procedures, safety principies and

service operations are not included. Please note that this manual does contain warnings and
cautions against so me specific service methods which could cause PERSONAL INJURY, or
could damage a vehicle or make it unsafe. Please understand that these warnings cannot
cover all conceivable ways in which service, whether or not recommended by Honda
Motor, might be done, or ofthe possible hazardous consequences of each conceivable way,
nor could Honda Motor investigate all such ways. Anyone using service procedures or
tools. whether or not recommended by Honda Motor, must satisfy himself thoroughly that
neither personal safety nor vehicle safety will be jeopardized.
All information contained in this manual is based on the latest product information available
at the time of printing. We reserve the right to make changes at any time without notice. No
part of this publication may be reproduced, stored in retrieval system, or transmitted, in any
form by any means, electronic, mechanical, photocopying, recording, or otherwise, without
the prior written permission of the publisher. This includes text, figures and tables.
First Edition 10/89 1266 Pages HONDA MOTOR CO .• LTD.

Service Publication Office
All Rights Reserved
Chassis and Engine Numbers
r---Vehicle ldentification Number----------, - Vehicle ldentification Number - - - - - - - - - ,
(1 . 8 t Carbureted Engine} (2. O t Fuel-lnjected Engine)
JHM CB3 54 O OC O QQ_OQ!
JHM CB1 52 O OC O QQ_O,Ql
Manufactu<e• Codo
and Vehicle Type
r 1
Manufacturar C o d e - - _ T
and Vehicle Type
JHM: HONDA MOTOR CO.,
JHM:HONDA MOTOR CO.,
LTD., JAPAN.
LTD., JAPAN.
HONDA Passenger Car
HONDA Passenger Car
Body and Engine Type
CB3: ACCORD 2.0t
CB1: ACCORD 1 .8 f!
Door and Transmission Type-----'
Door and Transmission Type - - - - - '
5 : 4-door, 5-speed Manual
5 : 4-door, 5-speed Manual
6 : 4-door, 4-speed Automatic
Vehicle G r a d e - - - - - - - - - - '
Vehicle Grade
2 :LX (KB)
4 : 2.0i, F20A4 with CATA (KG, KS)
3 :EX (KB)
F20A4 without CATA (KF, KE)
Fixed Code------------~
F20A5 (KB, KW)
Auxiliary N u m b e r - - - - - - - - - _ _ J
2.0i with ALB,
Factory Code - - - - - - - - - - - - - '
F20A4 with CATA (KG, KX,
C: Sayama Factory in Japan
KS)
N1ode1Year·-------------~
F20A4 without CATA (KF, KE)
0: 1990
F20A5 (KB, KW)
Serial N u m b e r - - - - - - - - - - - - - - - - - "
EXi, F20A5 (KU)
EXi with ALB, F20A5(KU)
Fixed Code - - - - - - - - - - - - - ' !j
i
Vehicle ldentification Number - - - - - - - - - . Auxiliary Number - - - - - - - - - - - - ' 1
(2.0 t Carbureted Engine) Factory C o d e 1 - - - - - - - - - - - - - - - '
C : Sayama Factory in Japan
JHM CB3 52 O OC O
- 00001
Manufacturar C o de
T- ,-- Model Year
o : 1990
and Vehicle Typ e Serial N u m b e r - - - - - - - - - - - - - - - - - "
JHM: HONDA MOTOR CO.,
LTD., J APAN.
HONDA Passenger Car .--- Vehicle ldentification Number - - - - - - - - - ,
Body and EngineType (2. 2 t Fuel-lnjected Engine)
CB3: ACCORD 2.0l
Door and Transmission Type JHM CB7 55 O OC O 00001
5 : 4-door, 5 -speed Manual
__T_J·~- --
Manufacturar Code - -
6 : 4-door, 4 speed Automatic and Vehicle Type
Vehicle Grade- JHM: HONDA MOTOR CO.,
2 : DX, F20A 2 (KG, KS) LTD., JAPAN
F20A 3 (KW) HONDA Passenger Car
:LX, F20A 2 (KQ)
F20A 3 (KP, KT, KU, KV) CB7: ACCORD 2.2 t
3 :EX, F20A 2 with CATA (KG, KX, KS) Door and Transmission Type-----'
F20A 2 without CATA (KF, KE) 5 : 4-door, 5-speed Manual
F20A3 (KB, KW, KP, KT, KU, 6 : 4-door, 4-speed Automatic
KV) Vehicle Grade
F20A 6 (KG) 5 : 2.2i, F22A3 with CATA
:EX with A LB, (KF, KG, KX, KS, KE)
F20A 2 with CATA (KG, KS) EXi, F22A2 (KV)
F20A 2 without CATA (KF) F22A5 with CATA (KQ)
F20A3 (KB) Fixed C o d e - - - - - - - - - - - - '
Fixed Code- Auxiliary Number------------..J
Auxiliary Number Factory Code - - - - - - - - - - - - - - '
Factory Code- C : Sayama Factory in Japari
C :Sayama Factory in Japan Model Year
Model Year- o : 1990
0 : 1990 Serial Number - - - - - - - - - - - - - - - - '
Serial Number
1-2
r--Engine Number - - - - - - - - - - - - - - - - , r--Engine Number
(DX: European, LX: General and (2. 2i: European)
EX: KG 90 ps)
T - _!~ QQ_O,Q! mr-!0ºº-9º1
Engine T y p e - - - - - - - - - - - - - 1
Engine T y p e - - - - - - - - - - - '
F18A2: 1 .8 t SOHC Carburated F22A3: 2.2 t SOHC Fual-lnjectad
Leadad gasoline: KB Unleaded gasolina with CATA
F20A2: 2.01 SOHC Carburatad Transmission Type ----------..........!
Unlaadad gasolina with CATA 1 0: 5-speed manual
: KG/KS (DXL KQ (LX) 1 5: 4-speed automatic
F20A3: 2.0 t SOHC Carburetad Serial N u m b e r - - - - - - - - - - - - - - . . . . 1
Laadad gasolina: KW (DXL
KP/KT/KU/KY (LX)
F20A6 : 2. O t SOHC Carburatad (90ps) Engine Nurnber - - - - - - - - - - - - - - - .
Unlaaded gasolina with CATA (EXi: KO, KV)
: KG (EX 90ps)
Transmission T y p e - - - - - - - - - - - - - 1 1000001
1 0: 5-spead manual
Engine Type - - - - - - - - - - - . 1
15: 4-speed automatic
F22A2: 2.2 t SOHC Fual-lnjacted
Serial Number - - - - - - - - - - - - - - - - '
Leadad gasolina: KY
F22A5: 2.2 t SOHC Fuel-lnjected
Engine Nurnber-----------------------~ Unleaded gasoline with CATA
: KQ
(EX except KG 90 ps)
Serial N u m b e r - - - - - - - - - - - - - - - '
Engine Type ----------....1 e--Manual Transrnission Nurnber - - - - - - - - ,

F20A2: 2.0 t SOHC Carburatad
Unleadad gasolina with CATA H2A5 1000001
: KG, KX, KS
Transmission Type - - - - - - - - - '
2. O t SOHC Carburated
H2C4: 2.0 t Fuel-lnjected and 2.2 t Fuel-lnjectad
Unlaaded gasolina without CATA
except KQ
: KF, KE
H2S8: 1 .8 f and 2.0 t Carburated
F20A3: 2.01 SOHC Carburated
H2U5: 2.2 t Fual-lnjactad: KQ
Laaded gasoline
Serial N u m b e r - - - - - - - - - - - - - - - - . . 1
:KB, KW, KP, KT, KU, KY
Transmission T y p e - - - - - - - - - - - - 1
1 0: 5-spead manual
Autornatic Transrnission Number-------.
15: 4-spaed automatic
Serial N u m b e r - - - - - - - - - - - - - - _ J PX4B 1000001
Transmission Type - - - - - - - - - ' 1

Engine Nurnber -----------------------. Serial N u m b e r - - - - - - - - - - - - - _ _ ¡ ·
(2.0i: European and EXi: KU)
- 10 00001
Engine Type - - - - - - - - - - . . . l .
F20A4: 2.0 l SOHC Fual-lnjected
Unlaadad gasolina with CATA
: KG, KX, KS
2.0 t SOHC Fuel-lnjected
Unleaded gasoline without
CATA: KF, KE
F20A5: 2.0 l SOHC Fuel-lnjactad
Laaded gasolina: KB, KW, KU
Transmission T y p e - - - - - - - - - - - '
10: 5-speed manual
1 5: 4-speed automatic
Serial Number - - - - - - - - - - - - - - - - '
1-3
ldentification Number Locations
Vehicle ldentification Number
Transmission Number Engine Number

(Manual)
1-4
Vehicla ldentification Number
(Europaan Modal)
Vahicla ldentification Numbar

(KQ, KT Modal)
Vahicla ldantification Numbar
(KS Modal only)
Trunk Room
Label Locations
Fuel-lnjected Engine: BONNET
COOLANT
CAUTION and
ALB CAUTION PRECAUTION
Standard for }
( sorne types
AIR CLEANER. SERVICE

OIL and FILTER SERVICE INFORMATION
SPARK PLUG CAUTION
EMISSION LABEL
KU Model only
COOLING FAN
CAUTION
TIRE INFORMATION
RHD LHD
1-6
Carbureted Engine: BONNET INSULATOR
Standard for ]
[ sometypes
COOLANT
CAUTION and
PRECAUTION
ALB CAUTION
Standard for J
[ soma types
SERVICE
INFORMATION
EMISSION LABEL
KU Model only
COOLING FAN
CAUTION
COOLING FAN
CAUTION
TIRE INFORMATION
RHD LHD
1-7
Lift and Support Points
Hoist------------------------------------------------------------------,
1. Place the líft blocks as shown.
2. Raíse the hoist a few inches and roe k the car to be sur e it is firmly supported.
3. Raíse the hoist to full height and inspect lift points for salid support.
f~!.i{.j;'#ilf'CI
When heavy rear components such as suspension. fuel tank. spare tire and trunk lid are to be removed.
place additional weight in the trunk before hoisting. When substantial weight is removed from the rear of the car. the
center of gravity may change and can cause the car to tip forward on the hoist.
NOTE: Since each tire/wheel assembly weighs approximately 14 kg (30 lbs). placing the front wheels in the trunk will assist
with the weight transfer.
LIFT BLOCKS
FRONT SUPPORT POINT REAR SUPPORT POINT
1-8
FloorJack--------------------------------------------------------~
1. Set the parking brake and block the wheels that are
not being lifted. • Always use safety stands when working on or
under any vehicle that is supported by only a
2. When lifting the rear of the car, put the gearshíft jack.
lever in reverse (Automatíc in PARKl. • Never attempt to use a bumper jack for lifting or
supportíng the car.
3. Raíse the car high enough to ínsert the safety
stands.
4. Adjust and place the safety stands as shown on

page 1-8 so the car will be approximately level,
then lower the car onto the stands.
Front---------------------------------------------------------------------------------
JACK LIFT PLATFORM

of the jack lift platform
Rear----------------------------------------------------------------------------------
Center the jacking

bracket -in the middle
of the jack lift platform. JACK LIFT PLATFORM
(cont'd)
1-9
Lift and Support Points (cont'd}
SafetyStands--------------------------------------------------~
FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINT
1-10
Towing
f"§i.ji§!liM Never use two chains or rope to tow a car;

your ability to safety control the car may be adversely
TOWING HOOKS/
affected.
TIE DOWN BRACKETS
We recommend the following:

Flat Bed Equipment-Entire car is winched on a flat bed
vehicle. This is the best way of transporting the car.
Wheel Lift Type-Tow with the front wheels off the
ground.
lf the car can only be towed with the front wheels on the
ground: make sure the transmission is full of fluid (see
Section 9) and tow with the transmission in neutral (N) and
the ignition key in the 1 position.
CAUTION: To avoid serious damage on automatic

transmission cars, first start the engine and shift to
D4, then toN and shut the engine off. lf the engine
does not run or the transmission cannot be shifted
while the engine is running. the car must be tran-
sportad on flat bed equipment.
When towing the 2.2i (with 4WS) even with the
front wheels off the ground. center the steering and
ti e the steering wheel in place.
TOWING HOOK
Check local regulations for towing.
CAUTION:
e Do not exceed 35 mph (55 km/h) or tow for
distances of more than 50 miles (80 km).
e lf a sling type tow is used, the tow truck driver
should position wood spacer blocks between the
car's trame and the chains and lift straps to avoid
damaging the bumper and the body.
e Do not use the bumpers to lift the car or to
support the car's weight while towing.
1-11
Preparation of Work
Special Caution ltems For This Car - - - - - - - - - - - - - - - - - - -
1. 4WS system servicing {with 4WSl 2. ALB piping system servicing
Do not disassemble the rear steering gear box. • Disassemble the ALB piping system after relieve
When towing the car even with the front wheels the high-pressured brake fluid.
off the ground, center the steering and tie the • Otherwise, the high-pressured brake fluid will
steering wheel in place. burst out and it is very dangerous.
When testing or adjusting the wheel alignment, • See section 13 how to relieve the high-
attach the rear steering center lock pin to the pressured brake fluid.
rear steering gear box. Make sure that the rear
steering gear box is loéated at the neutral ALB T WRENCH
position. 07 HAA-SG001 00
,cr::1r.
LJ ,....
Ne~t~al
00
.M.........r,....u
d
None neutral
3. Fuel Line Servicing

Relieve fue! pressure by loosening the service
bolt provided on the top of the fuel filter before
disconnecting a fuel hose ora fuel pipe.
SERVICE BOLT
12 N•m (1 .2 kg-m. 9 lb-ft)
FUEL PIPE
SHOPTOWEL
1-12
• Be sure to replace washers, 0-rings, and rubber 5. lnstallation of an amateur radio for cars equipped
seals with new ones when servicing fuel line parts. with PGM-FI.
Always apply oil to the surfaces of 0-rings and Care has been taken for the Fuel-lnjection, Car-
seal rings betore installation. Never use brake buretor, A/T, Cruise control and ALB control units
fluid, radiator fluid, vegetable oils or alcohol- and its wiring to prevent erroneous operation from
based oils. externa! interference, but erroneous operation of the
~~()~0-RING
control units may be caused by entry of extremely
RUBBER SEAL strong radio waves. Attention must be paid to the
k_..~·~
following items to prevent erroneous operation of the
control units.
\CUSHIONRING
• The antenna and the body of the radio must be
~ FUEL INJECTOR at least 200 mm (7 .9 in.) away from the
control units.
• When assembling the fiare joint of the high- The control unit locations:
pressure fuel line, crean the joint and coat with Fuel-lnjection, Carburetor, A/T: Passenger's side
new engine oil. front floor panel.
• When installing an injector, check the angle of Cruise control: Under dash panel of driver's side.
the coupler. The center tine of the coupler • ALB: Right side panel of trunk room.
should align with the setting mark on the • Do not lead the antenna feeder and the coaxial
injector holder. cable over a long distance parallel to the car's
wiring.
When crossing the wiring is required, execute
crossing at a right angle.
Do not install a radio with a large output (max.
10WI.
6. Apply liquid gasket to the transmission, oil pump

cover, right side cover and water outlet. Use
HONDA genuine Liquid gasket part No. OY740
-99986.
Check that the mating surfaces are clean and
dry before applying liquid gasket. Degrease the
mating surfaces if necessary.
Apply liquid gasket evenly, being careful to
cover all the mating surface.
• To prevent leakage of oil, apply liquid gasket to
the inner threads of the bolt holes.
• Do not install the parts if 20 minutes or more have
4. lnspection for tuel leakage elapsed since applying liquid gasket. In that case,
After assembling fuel line parts, turn ON the ig- reapply liquid gasket after removing the old residue.
nition switch (do not operate the starter) so that • Wait at least 30 minutes befo re filling with appropri-
the fuel pump is operated for approximately two ate liquid (engine oil, coolant and similar fluids).
seconds and the fuel is pressurized. Repeat this
operation two or three times and check whether
any fuel leakage has occurred in any of the vari-
ous points in the fuel line.
1-13
Preparation of Work
CAUTION: Observe all safety precautions and notes 5. Use the special tools when use of such is specified.
while working.
1. Protect all painted surfaces and seats against dirt and

scratches with a clean cloth or vinyl cover.
6. Parts must be assembled with the proper torque

2. Work safely and give your work your undivided atten- according to the maintenance standards established.
tion. When either the front or rear wheels are to be
raised, block the remaining wheels securely. Commu-
nicate as frequently as possible when a work involves 7. When tightening a series of bolts or nuts, begin with
two or more workers. Do not run the engine unless the the center or larger diameter. bolts and tighten them in
shop or working area is well ventilated. crisscross pattern in two or more steps.
8. Use new packings, gaskets, 0-rings and cotter pins

3. Prior to removing or disassembling parts, they must be
whenvere reassembling.
inspected carefully to isolate the cause for which
service is necessary. Observe all safety notes and
precautions and follow the proper procedures as de-
scribed in this manual.
@ ©
9. Use genuine HONDA parts and lubricants or those

equivalent. When parts are to be reused, they must be
inspected carefully to make sure they are not damaged
or deteriorated and are in good usable condition.
4. Mark or place all removed parts in order in a parts rack

so they can be reassembled in their original places.
1-14
.Eiectrical-----------....
1 O. Coat or fill parts with specified grease as specified Before making any repairs on electric wires or parts,
(Page 4-2). Clean all removed parts with solvent upon disconnect the battery cables from the battery staring
disassembly. with the negative (-) terminal.
• After making repairs, check each wíre or p~rt for proper

11 . Brake fluid and hydraulic components r:outing and installation. Also check to see that they are
When replenishing the system, use extreme care connected properly.
to prevent dust and dirt from entering the system. • Always connect the battery positive 1+) cable first, then
Do not mix different brands of fluid as they may not connect the negative (-) cable.
be compatible.
Do not reuse drained brake fluid.
Brake fluid can cause damage to painted surfaces.
Wipe up spilled fluid at once.
After disconnecting brake hoses or pipes be sure to
plug the openings to prevent loss of brake fluid.
Clean all disassembled parts only in clean BRAKE
FLUID. Blow open all holes and passages with
compressed air.
• Coat the terminals with clean grease after connecting

the battery cables.
Don't forget to instan the terminal cover over the positive
battery terminaL after connecting.
Befare installing a new fuse, isolate the cause and take
corrective measures, particularly when frequent fuse
failure occurs.
• Keep disassembled parts from air-borne dust and
abrasives.
• Check that parts are clean before assembly.
12. Avoid oil or grease getting on rubber parts and tu bes,

unless specified. . .. ·
13. Upon assembling, check every part for proper installa-
tion and operation.
Besure to install the terminal cover over the connections

after a wire or wire harness has been connected.
TERMINAL
(cont'dl
1-15
Preparation of Work
Electrical (cont'd)~~~~~~~~~~~~~~~~~~~~~~~~~
Since new type connectors are used, connection and dís- Pull up the locking tab to remove the connector from the
connection of them should be done paying attention to the bracket.
following precautions.
Because all the connectors except terminal of 1-P are Push-down to disengage
equipped with push-down type locks, unlock them first
befare disconnecting the connectors.
On the connectors installed on the bracket a pull type
!ock is equipped between the bracket and the connector.
Some connectors of this type can not be disconnected
unless they are removed from their brackets.
When disconnecting, check their shapes. ..
Pull-up to
~~ ~
CONNECTOR~~
On the bracket mounted connector with dual locks,
remove the connector from the bracket before discon-
necting.
"---./ BRACKET
When disconnecting locks, first press in the connector

tightly (to provide clearance to the locking device), then
operate the tab fully and remove the connector in the
designated manner.
LOCKING PAWL
LOCKING
PAWL
• Push the locking tab to disconnect. When disconnecting a connector, pull it off from the
mating coupler by holding on both connectors.
• Never try to disconnect connectors by pulling on their
wires.
GOOD
o
· NO GOOD NO GOOD
X
LOCKING TABS
1-16
Place the plastic cover over the mating connector after For the connector which uses insulation grease, clean
reconnecting. Also check that the cover is not distort- the connector then apply grease if the grease is insuffí-
ed. cient or contaminated.
NO GOOD
Before connecting connectors, check to see that the

terminals are in place and are not bent or distorted.
• lnsert the connector tightly and make sure ít is securely

locked.
Check all the wire harnesses are connected.
There are two types of locking tab: one that yo u have to
push and the other you should not touch when connect-
ing the connector. Check the shape of the locking tab
befo re connecting.
GOOD The locking tab having a taper end should not be
o touched when connectíng.
Check for loose retaíners and rubber seals. The illustra-

-~
tion shows examples of terminal and sea! abnormality.
The locking tab with an angle end should be pushed
when connecting.
X X
lnsert connectors fully untíl they wíll no longer go.
The connectors must be alígned and engaged securely.
• Don't use wire harnesses with a loose wire or coupler.
NO GOOD
~x
Example of waterproof connector:
RUBBER
X
RETAINER
SEAL
RUBBER SEAL (cont'dl
1-17
Preparation of- Work
Electrical ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - - - - - - - -
Before conneCting, check each connector cover for
damage. Also make sure that the female connector is
tight and not loosened from the previous use.
GOOD
• 'lnsert male connectors into the female connectors fully

until they will no longer go.
Be su re that plastic cove-r is placed over' the connection.
.Q
~
Position the wires so that the open of the cover is not
facing upward.
NO GOOD
X After .clamping, check each harness to be certain that it

is not interfering with any moving or sliding parts of thé
vehicle. ·
Keep wir_e harnesses away from the ·exhaust pipes and
other hot parts.·
Secure wires and wire harnesses to the trame with their

respective wire bands at the designated locations. Posi-
tion the wiring in the bands so that only the insulated
surfaces contact the wires or wire harnesses.
Remove with care not to damage the lock.
GOOD
Always keep a safe distan ce between wire harnesses and
any heated parts.
.x
NO GOOD
GOOD NO GOOD
Keep sufficient distance!
GOOD·
1-18
Do not bring wire harnesses in direct contact with sharp Seat grommets in their grooves properly.
edges or corners.
Also avoid contact with the projected ends or bolts,
GOOD
o
screws and other fasten~rs. NO GOOD
NOGOOO NO GOOD
X X ~
~
~
Route harnesses so they are not pulled taut or slackened
Apply sealant.
Do not damage the insulation when connecting a wire.

Do not use wires or harnesses with a broken insulation.
Repair by wrapping with protective tape or replace with
excessively.
new ones if necessary.
NO GOOO GOOO
X O
~~
GOOD
Protect wires and harnesses with á tápe ora tube if they • After installing parts, make sure that wire harnesses are.
are in contact with a sharp edge or comer. not pinched.
NOGOOO
Clean the attaching surface thoroughly if an adhesive is

used. First, wipe with solvent or alcohol if necessary.
o·
GOOO After routing, ·check that the wire harnesses are not
twisted or kinked.
Wire harnesses should be routed so that they are not
pulled taut, slackened excessively, pinched or interfer-
ing with adjacent or surrounding parts in all steering
u@ ece e r eG¿se
positions.
(cont'd)
1-19
Preparation of Work Symbol Marks
Electrical (cont'd)---------.
When using the Service Tester, follow the manufacturer's The following symbols stand for:
instructions and those described in the Shop Manual.
~ :Apply engine oil.
Are range and

porarity correct?
1 :Apply brake fluid .
Always insert the probe of the tester from the wire .., ~:Apply grease.
harness side (except waterproof connectors).
:Apply DEXRON® 11 Automatic

Transmission Fluid.
g :Apply Power Steering Fluid.
• Make sure to use the probe with a taper tip.
CD. ®. @,······
o
GOOD :Sequence for removal or installation.
0.8.8.······
e:
al
NO GOOD
X e!
á1
• Do not drop parts.
1-20
Abbreviation
2WS Front Wheel Steering [El Parking
4WS Four Wheel Steering [BJ Reverse
A/C Aír Conditioner @] Neutral
ALB Anti Lock Brake m Orive Position (1st-4th)
A/T Automatic Transmission QJ Orive Position ( 1st-3rd)
ATF Automatic Transmission Fluid m Fixed 2nd speed
B or BAT Battery rn Fixed 1st speed
CATA Catalytic Converter S S Signai/S Switch
EACV Electronic Air Control Valve
ECU Electronic Control Unit

for Fuel-lnjection System
EGR Exhaust Gas Recirculation
EX Exhaust
GNO Ground
IG lgnition
IN lntake
INT lntermittent
L. Left
LHO Left Hand Orive
M/T Manual Transmission
PCV Positive Crankcase Ventilation
PGM-FI Programmed Fuel-lnjection
P/S Power Steering
R. Right
RHO Right Hand Orive
SW Switch
SOL. V Solenoid Valve
TOC Top Oead Center
1-21
Special Tools
New Tools
Only new tools are lísted below. As to other tools, refer to each section.
Ref. No. Tool Number Description O'ty Remarks Sec.
CD 07LAA-PT501 00 02 Sensor Socket Wrench

1 ®
Q)
07LAA-SM401 00
07LAA-SM40200
Locknut Wrench 43 mm
Locknut Wrench 36 x 43 mm
11
11
® 07LAD-SM401 00 Seal Driver Attachment 10
@ 07LAE-PX401 00 Clutch Spring Compressor Attachment 9
® 07LAF-PT0011 O Clutch Alignment Shaft 7
(J) 07LAF-PT201 00 Bearing Replacment Too! Set Refer to F 18A/F20A/
F22A ENGINE Mainte-
nance and Repair
® 07LAF-SM40200 Brake Spring lnstaller 13
® 07LAF-SM40300 Support Base Attachment 10
@) 07LAG-PT201 00 Balancer Shaft Lock Pin 5
CD
r----------------------------------------------~
1r ' ®
a
o ®
:
\jo B {§)¡
~
L---- ---- ----------- -------- ---- -
{®')
~
-- --- - -- -
éEO
-- ---
1
_J @)
2-2
Ref. No. Tool Number Descríptíon Q'ty Remarks 1 Sec.
@ 07LAG-SM40000 4WS Tool Kit 11

@-1 07LAG-SM401 00 Pisten Sea! Ring Guide 11
([D-2 07LAG-SM40200 Pisten Sea! Ring Sizing Too! 11
@-3 07LAG-SM40300 Cylinder End Seal Slider 11
@-4 07LAG-SM40400 Cylinder End Seal Guide 11
@-5 07LAG-SM40500 Too! Box 11
@ 07LAJ-PT301 00 ECU Test Harness 6,9, 11
@ 07LAJ-PT30200 Test harness 6
@ 07LAK-SM40110 P/S Joint Adaptar (Pump) 11
@ 07LAK-SM40100 P/S Joint Adaptor (Hose) 11
@ 07LAZ-PT301 00 R.P.M. Connecting Adaptor 5,6
@ 07LAZ-PT3011 O R.P. M. Connecting Adaptar (A) 5,6
@ 07LAZ-PT30120 R.P.M. Connecting Adaptor (B) 5,6
1-------------------- ------ ------ - ---- - -- - - - -- -- --- --- - --- - - - - - - - - - - ...,

1
1 1
1
@-1 @-2 @-3 @-4

- - - - - - - - - - - - - - - - - - - - - - - - - -- - - - -- - - - - - - - - - - - - - - - - - _J
1
([D-5 @
1
L- - - - - - -- - - - - - - - _.J
~-----------------------------,
: 1
@ @
@
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -!
@
2-3
Special Tools
,.......-
5 . Engtne
Number Tool Number Description Q'ty 1 Remarks
CD 07HAD-PJ70200 Valve_Stem Seal lnstaller 1

@ 07HAF-PL201.02 Piston Base Head 1
@ 07HAH-PJ70100 Valve Guide Reamer, 5.5 mm 1
@ 07JAB-001 0000 Crank Pulley Holder Set 1
®-1 07JAA-0010200 Socket Wrench 19 mm (1)
@-2 07 JAB-001 0200 Handle (1)
@ 07JAB-0010400 Pulley Holder Attachment HEX 50 mm 1
® 07 JAZ-SH 20100 R.P.M. Connecting Adaptor 1
(f) 07JGG-0010100 Belt Tension Gauge 1
@ 07GAF-PH701 00 Pilot Collar 1
® 07LAF-PT201 00 Bearing Replacement Tool Set 1 -~-
@ 07LAG-PT201 00 Balancer Shaft lock Pin 1

@ 07LAZ-PT301 00 R.P.M. Connecting Adaptor 1
@ 07LAZ-PT3011 O R.P. M. Connecting Adaptor A 1
@ 07LAZ-PT30120 R.P. M. Connecting Adaptor B 1
(¡} 07406-0030000 Oil Pressure Gauge Adaptor 1
077 42-001 01 00 Valve Guide Remover, 5.5 mm
@ 077 46-001 0300 Driver Attachment 1 for Crankshaft
@ 07746-0010400 Driver Attachment 1 for Balancer Shaft
@ 07749-0010000 Driver 1
@ 07757-0010000 Valve Spring Compressor 1
@ 07912-6110001 Oil Filter Socket 1
@ 07924-PD20003 Ring Gear Holder 1
or 07924-PD20002
@ 07984-6570101 Valve Guide Reamer, 6.6 mm 1
@ 07942-8920000 Valve Guide Driver, 5.5 mm 1
@ 07948-SBOOl 01 Driver Attachment 1
@ 07973-PE0031 O Piston Pin Driver Shaft 1
@ 07973-PE00320 Piston Pin Driver Head 1 -
@ 07973-PE00400 Piston Pin Base lnsert 1

@ 07973-6570500 Piston Base 1
@ 07973-6570600 Piston Base Spring 1
@ 07GAF-PH60300 or Piston Pin Base lnsert 1
07993- PE00400
2-4
- 6 . Fu e andE miSSIOOS --
Number Tool Number Description . O'ty Remarks
CD 07JAZ-SH201 00 R_P.M. Connector 1

® 07LAA-PT501 00 02 Sensor Socket Wrench 1
@ 07LAJ-PT301 00 ECU Test Harness 1 1
@ 07LAJ-PT30200 Test Harness 1
@ 07LAZ-SH201 00 R.P.M. Connecting Adaptar 1
® 07LAZ-PT301 00 R.P.M. Connectíng Adaptar 1
@-1 07LAZ-PT3011 O R.P.M. Connecting Adaptar (A) ( 1)
]-camponent Tools
@-2 07LAZ-PT30120 R.P.M. Connecting Adaptar (B} ( 1)
G) 07 406-0040001 Fue! Pressure Gauge Set 1
G)-1 07406-0040100 Pressure Gauge ( 1)
( 1) P-component Tools
G:l-2 07 406-0040201 Hose Assembly
@ 07 411 -0020000 Digital Circuit Tester 1
® l_ 07614-0050100 Fuel Une Clamp 1
- 7 . Cl ute h
Number Tool Number Description O'ty Remarks
CD 07JAF-PM7011A Clutch Alignment Disc 1

® 07LAF-PT0011 O Clutch Alignment Shaft 1
@ 07924-PD20003 or Ring Gear Holder 1
07924-PD20002
@ 07936-371 01 00 Handle 1
- 8 . M anua ITransm•ss1on
Number Tool Number Description O'ty. Remarks
CD 07GAJ-PG201 02 Mainshaft lnspection Tool Set 1

CD-1 07GAJ-PG2011 O Mainshaft Holder (1}
:J--component Tools
CD-2 07GAJ-PG20130 Mainshaft Base ( 1)
® 07HAJ-PK40201 Preload lnspection Tool - 1
@ 07JAC-PH80000 Adjusting Bearing Remover Set 1
@-1 07JAC-PH801 00 Bearing Remover Attachment ( 1)
@-2- 07 JAC-PH80200 Bearing Remover Handle (1) }component Tools
@-3 01741-0010201 Bearing Remover Weight ( 1)
@ 07JAD-PH80400 Pilot Driver 28 mm 1
® 07JAD-SH30100 Oil Seal Driver 1
® 07744-0010400 Pin Driver 5.0 mm 1 07944-6110100 may al so
be used
!J) 07746-0010300 Attachment 42 x 47 mm 1
® 07746-0010400 Attachment 52 x 55 mm 1
® 077 46-0010500 Attachment 62 x 68 mm 1
@ 07746-0010600 Attachment 72 x 75 mm 1
@ 07746-0030100 Driver 1
@ 077 46-0030200 lnner Driver 25 mm 1
@ 07749-001 0000 Driver 1
@ 07944-SAOOOOO Pin Driver 4.0 mm 1
@ 07947-6110501 Oil Seal Driver 1
@ 07979-PJ40001 Magnet Stand Base 1
2-5
Standards and Service Limits
.-- 5 Eng1ne /C y rrn d er H ea d , V a 1ve T ra1n
MEASUREMENT STANDARD (NEW) ¡ SERVICE LIMIT
1
Compression 250 min ' (rpm) and wide-open Nominal 1,177 kPa (12.0 kg/cm', 171 psi)
throttle Mínimum 931 kPa (9.5 kg/cm', 135 psi)
1.8! 1
Maxímum varíatíon 196 kPa (2 kg/cm', 28 psi)
2.02 Nominal 1226 kPa (12.5 kg/cm', 178 psi)
Minímum 931 kPa (9.5 kg/cm', 135 psi)
2.2 t Maximum variation 196 kPa (2 kg/cm', 28 psi)
Cylinder ·head Warpage - 0.05 (0.002)
Height 99.95-100.05 (3.935-3.938) -
Camshaft End play 0.05-0.15 {0.002 0.006) 0.50 (0.020)
Oil clearance 0.05-0.089 (0.002-0.0035) 0.150 (0.006)
Aunout 0.015 (0.0006) 0.030 (0.001)
Cam lobe height IN 1. F18A2: 38.095 (1 .4998) -
2. F20A2: 38.526 (1.5167) -
3. F20A3: 38.526 (1.5167) -
4. F20A4: 38.741 (1.5252) -
5. F20A5: 38.741 (1.52521 -
6. F20A6: 38.526 (1.51671 -
7. F22A2: 38.741 (1.52521 -
8. F22A3: 39.167 (1.54201 MT -
38.741 {1.52521 AT -
9. F22A5: 38.526 {1.5167) -
EX 1. F18A2: 37.890 (1.49171 -
2. F20A2: 38.778 (1.52661 -
3. F20A3: 38.778 (1 .52661 -
4. F20A4: 38.972 (1.53431 -
5. F20A5: 38.972 (1.5343) -
6. F20A6: 38.778 (1.52661 -
7. F22A2: 38.972 (1 .5343) -
.·• 8. . ..f22A3: 39.356 (1-.5494) MT -
- 38.972 (1.5343) AT -
9._ F;22A5:· 38.778 {1 .5266) -
.
-
~~~
Val ve Valve clearance IN 0.24 0.28 (0.0094 0.0110)

EX 0.28-0.32 (0.0110-0.1259) -
Valve stem 0.0. IN CARB 5.485-5.495 (0.2159-0.2163) 5.455 (0.2147)
PGM-FI 5.480-5.490 (0.2157-0.21611 5.450 (0.2145)
EX 5.450-5.460 (0.2145-0.2149) 5.420 (0.2133)
Stem-to-guide clearance IN CAAB 0.020-0.045 (0.0007-0.00171 0.075 {0.0029)
PGM-FI 0.025-0.050 {0.0009-0.0019) 0.080 (0.0031)
EX 0.055-0.080 (0.0021-0.0031) 0.12 (0.0047)
Valve seat Width IN and EX 1.25-1.55 (0.049-0.0610) 2.00 (0.0787)
Valve stem installed height IN 48.245-48.715 (1 .8994-1.9179) -
EX 50.315-50.785 {1 .9809-1 .9994) -
Valve spring Free Length IN (NH) 1. F18A2: 56.28 (2.2157) -
2. F20A2: 54.82 (2.1582) -
3. F20A3: 54.82 (2.1582) -
4. F20A4: 53.15 {2.0925) -
5. F20A5: 53.15 (2.0925) -
6. F20A6: 54.82 {2.1582) -
7. F22A2: 53.15 (2.0925) -
8. F22A3: 53.15 (2.0925) -
9. F22A5: 54.82 (2.1582) -
(CH) 1. F18A2: 56.26 (2.2149) -
2. F20A2: 54.81 (2. 1578) -
3. F20A3: 54.81 (2.1578) -
1 4. F20A4: 53.16 (2.0929) '
i -
5. F20A5: 53.16 [2.0929) -
6. F20A6: 54.81 {2. 1578) -
7. F22A2: 53.16 (2.0929) -
8. F22A3: 53.16 {2.0929) -
9. F22A5: 54.81 (2.1578) -
1
1. F18A2: 1.81! CARB 6. F20A6 2.0! CARB with CATA NH: NIHON HATSUJO
2. F20A2: 2.0 t CARB with CATA 7. F22A2 2.2 t PGM-FI CH: CHUO HATSUJO
3. F20A3: 2.0 l CARB 8. F22A3 2.2 t PGM-FI with CATA
4. F20A4: 2.0t PGM-FI with CATA 9. F22A5 2.2 t PGM-FI with CATA
5. F20A5: 2.02 PGM-FI
3-2
5 . Eng1ne;e y r1nd er H ea d V a ve Tram
Unit of length: mm (in )
,....-
1
MEASUREMENT 1
STANDARD {NEW) SERVICE LIMIT
1 1
Valve spring Free length EX (NHl 1. F18A2: 59.89 (2.3578)
! -
2: F20A2: 59.89 (2.3578) -
3. F20A3: 59.89 (2.3578} -
4. F20A4: 55.78 (2.1960) -
5. F20A5: 55.78 (2. 1960) -
6. F20A6: 59.89 (2.3578) -
7. F22A2: 55.78 (2.1960) -
8. F22A3: 55.78 (2.1960) -
9. F22A5: 56.28 (2.2157) -
(CH) 1. F18A2: 59.88 (2.3574) -
2. F20A2: 59.88 (2.3574) -
3. F20A3: 59.88 (2.3574) -
4. F20A4: 55.80 (2.1968) -
5. F20A5: 55.80 (2.1968) -
6. F20A6: 59.88 (2.3574) -
1
7. F22A2: 55.80 (2.1968) -
8. F22A3: 55.80 (2.1968) -
9. F22A5: 55.80 (2. 1968) -
Valve 9uide 1.0. IN and EX 5.515-5.530 (0.2171-0.2177) 5.53 (0.2177)
Valve guide installed height IN 23.75-24.25 (0.9148-0.9547) -
EX 15.05-15.55 (0.5925-0.6122) -
Rocker arm Arm-to shaft clearance IN 0.017-0.050 (0.0007-0.0020) 0.080 (0.0031)
EX i 0.018-0.054 (0.0007-0.0021) 0.080 (0.0031)
- 5 . Engme /E ngtne 81 oc k
Cylinder block
MEASUREMENT
Warpage of deck surface
ii STANDARD (NEW)
0.07 (0.003) max.
SERVICE LIMIT
0.10 (0.004)
Bore diameter 85.00-85.02 (3.3464-3.3472) 85.07 (3.3492)
Bore taper - 0.05 (0.002)
Reboring limit - 0.5 (0.02)
Pisten Skirt O.D.(At 21 mm (0.83 in)} A 84.98-84.99 (3.3456-3.4605) 84.97 (3.3452)
from bottom of skirt 8 84.97-84.98 (3.3452-3.3456) 84.96 (3.3448)
Clearance in cylinder 0.02-0.04 (0.0008-0.0016) 0.05 (0.0020)
Pisten ring Piston-to-ríng clearance Top 0.035-0.060 (0.0014-0.0024) O. 130 (0.0051)
Second 0.030-0.055 (0.0011-0.0022) O. 130 (0.0051)
Ring end gap Top 0.20-0.35 (0.0079-0.0138) 0.60 (0.0236)
Second 0.40-0.55 (0.0157-0.0217} O. 70 (0.0276}
Oíl 0.20-0.70 (0.0079-0.0276) 0.80 (0.0315)
Connecting rod Pín-to rod interference 0.013-0.032 (0.0005-0.0013)
Small end bore diameter 21.968-21 .981 (0.8649-0.8654) - -
Large end bore diameter 1.8f '2.02 Nominal 48 (1.890) -
2.2 2 Norminal 51 (2.008) -
End play installed on crankshaft 0.15-0.30 (0.006-0.012) 0.40 (0.016)
Crankshaft Main journal diameter No. 1, 2 Journals 49.976-50.000 (1.9676-1.9685} -
No.3 Journal 49.972-49.996 (1 .9674-1 .9683) -
No.4, 5 Journals 49.948-50.008 (1 .9665-1.9688) -
Taper/out-of-round, main journal 0.005 (0.0002) max. 0.01 o (0.0004)
Rod journal diameter 44.976-45.000 (1.7710-1.7717) -
Taper/out-of-round, rod journal 0.005 (0.0002) max. 0.010 (0.0004)
End play 0.10-0.35 (0.004-0.014) 0.45 (0.018)
Runout 0.015 max (0.0006) 0.020 (0.0008)
Bearings Main bearing-to journal oil No. 1, 2 Journals 0.021-0.045 (0.0009-0.0018) 0.05 (0.002)
clearance No.3 Journal 0.035-0.044 (0.0014-0.0017) 0.054 (0.0021)
Rod bearing-to journal oil

No.4, 5 Journals
2.2t
¡ 0.013-0.037 (0.0005-0.0015)
0.021-0.044 (0.0008-0.0017)
0.05 (0.002)
0.05 (0.002)
1
clearance others 1 0.015-0.044 (0.0006-0.0017) ¡ 0.05 (0.002)
1. F18A2 1.8i CARB
2. F20A2 2.02 CARB with CATA
3. F20A3 2.0 i CARB
4. F20A4 2.02 PGM-FI with CATA
5. F20A5 2.02 PGM-FI
6. F20A6 2.02 CARB with CATA
7. F22A2 2.2 i PGM-FI
8. F22A3 2.2 2 PGM-FI wíth CATA
9. F22A5 2.2 e PGM-FI with CATA
3-3
,....--
5 Engme /E ng1ne Bl ock
MEASUREMENT STANDARD (NEWI SERVICE LIMIT
Balancer Journal diameter No. 1 journal (Frontl 42.722-42.734 (1.6820-1.6824) -
Shaft (Rear) 20.938-20.950 (0.8243-0.8248) -
No.2 journal 38.712-38.724 (1.5241-1.5246) -
No.3 journal 34.722-34.734 (1 .3670-1 .3674) -
Journal taper 0.005 (0.0002) --
End play (Front) 0.100-0.350 {0.0040-0.0138) -
(Rear) 0.060-0.180 (0.0024-0.0070) 1 -
Runout 0.020 (0.0008) -
Oil Clearance No.1 journal (Rear) 0.050-0.075 (0.0020-0.0030) -
1
No. 1, 3 journal 0.066-0.118 (0.0026-0.0046) -
1
No.2, journal 0.076-0.128 (0.0030-0.0050) -
Balancer I.D No.1 journal (Front) 42.800-42.820 (1 .6850-1.6858) -
Shaft Bearing (Rear) 21.000-21.013 (0.8268-0.8273) -
No.2 journal 38.800-38.820 (1 .5276-1.5283) -
No.3 journal 34.800-34.820 (1 .3701-1.371 0) -
,....--
5 Engme /E ng1ne Lu b.
ncat10n
'
MEASUREMENT STANDARD (NEWI SERVICE LIMIT
1 j
Engine oil Capacity (US. qt., Imp. qt.) 4.9 (5.2, 4.3) After engine disassembly
3.8 (4.0, 3.3) After oil change, including oil filter
1
3.5 (3. 7, 3.1) After oil change, without oil filter
Oil pump Displacement 43.9 2 (11 .6 US. gal., 9. 7 Imp. gal.)/6,000 min-• (rpm)
lnner-to-outer rotor radial clearance 0.02-0.16 (0.0008-0.0063) 0.2 (0.008)
Pump body-to-rotor radial clearance 0.10-0.19 (0.0040-0.0075) 0.21 (0.0083)
Pump body-to-rotor side clearance 1 0.02-0.07 (0.001-0.003) : 0.12 (0.005)
Relíef valve Pressure setting ao·c 1 ldle 69 k.Pa (0. 7 kg/cm', 1 O psi) min.
(176'F) 1 3,000 min '(rpm) 3431 kPa (3.5 kg/cm', 50 psi)
3-4
Unit of len9th: mm (in.)
r- 5 Eng1ne/C 00 rmg
i MEASUREMENT STANDARD (NEW) SERVICE LIMIT
1
Thermostat Starts to open 78'C±2 (172'F±3) 86-90'C (187-194'F)

Full open 90'C {194'F)
Valve lift at full open 8 (0.31) max.
Water Pump Displacement 1602 (42.2 US gal, 35.2 lmp gal)/6,000 min-' (rpm)
Radiator Capacity (incl. heater) f (US.qt., Imp. qt)
{lncludes reservoir tank 0.6 (0.63, 0.53)
after overhaul 1. F18A2 MT: 6.6 {6.97, 5.81) AT: 6.5 (6.87, 6.72)
2. F20A2 7.2 (7 .61' 6.34) 7.1 (7.50, 6.23)
3. F20A3 7.2 (7.61, 6.34) 7.1 (7.50, 6.23)
4. F20A4 7.2 (7.61, 6.34) 7.1 (7.50, 6.23)
5. F20A5 7.2 (7.61, 6.34} 7.1 (7.50, 6.23)
6. F20A6 7.2 (7.61, 6.34) 7.1 (7 .50, 6.23)
7. F22A2 6.6 (6.97, 5.81) 7.1 (7 .50, 6.23)
8. F22A3 7.2 (7 .61 o 6.34) 7.1 (7.50, 6.23)
9. F22A5 6.6 (6 97, 5.81) 7.1 (7.50, 6.23)
at change 1. F18A2 MT 3.0 {3.17, 2.64) AT: 2.9 (3.06, 2.55)
2. F20A2 3.6 (3.80, 3.17) 3.5 (3.70, 3.08)
3. F20A3 3.6 (3.80, 3.17) 3.5 (3.70, 3.08)
4. F20A4 3.6 (3.80, 3.17) 3.5 (3.70, 3.08)
5. F20A5 3.6 (3.80, 3.17) 3.5 (3.70, 3.08)
6. F20A6 3.6 (3.80, 3. 17) 3.5 (3.70, 3.08)
7. F22A2 3.0 (3.17, 2.64) 3.0 (3.17; 2.64)
8. F22A3 3.6 (3.80, 3.17) 3.6 (3.80, 3.17)
9. F22A5 3.0 (3.17, 2.64) 3.5 (3.70, 3.08)
pressure cap opanin9 pressura 88.3-123 kpa (0.9-1 .25 kg/cm', 12.8-17.8 psi)
Cooling fan "ON" temperatura 8T 93'C (189' 199'F)
"OFF" tamparature 80'-91'C (176'-196'F)
"ON" temperatura (Fan timer) 105'-111'C (221'-231'F)
"OF" temperature {Fan timer) 98'-1 09'C (208'-228'F)
1. F18A2: 1.8< CARB
2. F20A2: 2.0 € CARB with CATA
3. F20A3: 2.0t CARB
4. F20A4: 2.0l PGM-FI with CATA
5. F20A5: 2.02 PGM-FI
6. F20A6: 2.0 2 CARB with CATA
7. F22A2: 2.2 í PGM-FI
8. F22A3: 2.2 e PGM-FI with CATA
9. F22A5: 2.2 e PGM-FI with CATA
3-5
r- 6 Fue an dE ffiiSSIOOS
MEASUREMENT 1 STANDARD (NEW)
Fuel Pump Delivery pressure 250 kPa (2.55 kg/cm', 36 psi)

1Carburated Displacement (mínimum in 1 O seconds) 230 ce (7 .8 US oz., 8.1 lmp oz.)
engine) Relief valve opening pressure 441-588 kPa (4.5-6.0 kg/cm', 64-85 psi)
Fuel Pump Delivery pressure 9 14 kPa (0.09 0.14 kg/cm', 1.3-2.0 psi!
(PGM-FI) Displacement (mínimum in minute at 1 2V) 760 ce (25.7 US oz., 26.8 lmp oz.l
Pressure Pressure 240-279 kPa (2.45-2.85 kg/cm', 35-41 psi)
Aegulator
lPGM-Fil 1
Fuel Tank Capacity 2WS: 65 R (17 .2 US gal., 14.3 lmp gal.)
4WS: ¡ 60 f (15.9 US gal., 13.2 lmp gal.)
Engine Fast idle 1,400 min-• (rpm)
ldle speed MT with carburated engine: 800±50 min '(rpm)
(with MT' with PGM-FI engine: 770±50 min-• (rpm)
headlights AT with carburated engine: 750±50 min-• (rpm) in ::~\liJosition
and cooling AT with PGM-FI engine: 770±50 min·• (rpml in [Ql or N. positions
fan OFF)
ldleCO With CATA: 0.1% maximum
Without CATA: 1.0+1.0%
- 7 Cl u teh
MEASUREMENT STANDARD (NEW) SEAVICE LIMIT
Clutch pedal Pedal height 210 (8.3) to floor --
Stroke 142.0 (5.6) -
Pedal play 9-15 {0.4-0.6) -
Disengagement height i 90 (3.5) min. to floor
80 (3. 1) min. to carpet
--
--
Flywheel Clutch surface runout 0.05 (0.002) max. 0.15 {0.006)
Clutch disc Aivet head depth 1 .3 (0.05) min. 0.2 (0.0081
Surface runout 0.8 (0.03) max. 1.0 (0.04)
Thickness 8.5-9.2 (0.33-0.36) 6.1 (0.24)
Clutch cover Uneveness of diaphragm spring 0.6 (0.02) max. 0.8 (0.03)
- 8 . M anua ITransm•ss1on
MEASUREMENT 1 STANOARD(NEW) SERVICE LIMIT
1
Transmission Capacity 2 (U.S. qt., Imp. qt.) 1. 9 (2 .0, 1. 71 at assembly
2.0 (2.1, 1.8) at oil change 1
oil
Mainshaft End play 0.10-0.16 (0.0039-0.0063) 1 Adjust with a shim.
Oiameter of ball bearíng contact area 1 27.977-27.990 (1 .1 015-1.1020) 29.93 (1.1783)
Diameter of third gear contact area 37.984-38.000 11.4954-1.4961) 37.930 {1.4933)
Diameter of ball bearing contact area 27.987-28.000 (1.1018-1.1024) 27.940 (1 .1000)
Runout 1 0.02 (0.008) max. 0.05 (0.002)
43.009-43.025 (1.6933-1.69391 43.080 (1 .6961 ¡
Mainshat third
and fourth
l. D.
End play ! 0.06-0.21 (0.0024-0.0083) 0.30 (0.012)
gears Thickness 3rd gear 32.42-32.47 (1.276-1 .278) 32.3 (1.27)
4th gear 1 30.92-30.97 (1.217-1.219) 1 30.8 (1.21)
Mainshaft fifth 1.0 43.009-43.025 (1 .6933-1 .6939) 43.080 (1 .6961)
gear
1
End play 0.06-0.21 (0.0024-0.0083) 0.30 (0.012)
Thickness 30.42-30.47 (1.198-1.200) 30.3 (1.193)
Countershaft End play 0.05 0.21 (0.0019-0.0083) 0.50 (0.021
Diameter of needle bearing contact area 33.000-33.015 (1.2992-1 .2998) 32.95 (1.2971
Diameter of ball bearing needle bearing 24.987-25.000 (0.9837-0.98451 24.94 (0.982)
contact area
Diameter of low gear contact area 39.984-40.000 (1 .5742-1.5748) 39.93 (1 .572)
1 Aunout 1 0.02 {0.0008) max. i 0.05 {0002)
3-6
Unit of length: mm (in.)
- 8 Manua ITransm1ss•on
MEASUREMENT STANDARD (NEW} SERVICE LIMIT
1
Countershaft 1.0. 46.009 46.025 (1 .8114-1.8120) 46.08 (1.814)
low gear End play 0.04-0.10 (0.002-0.004) 1 Adjust with a washer.
Countershaft
second gear 1
1.0.
End play
Thickness
50.009-50.025 (1 .9689-1.9695)
0.04-0.10 (0.002-0.004)
33.92-33.97 (1 .335-1 .337)
l 50.08 (1 .972)
Adjust with a collar.
32.8 (1.2913)
Spacer collar l. D. 36.48-36.49 (1 .4362-1 .4366) 36.50 (1 .437)
(Countershaft 0.0. 43.989-44.000 (1. 7318-1. 7323) 43.94 (1.730)
second gear) Length A 29.03-29.05 (1. 1429-1 .1437) --
8 28.98-29.00 (1.1409-1.1417) --
Spacer collar 1.0. 31 .002-31.012 (1.2205-1.2209) 31.06 (1 .2231"
(Mainshaft 0.0. 37.989-38.000 (1 .4956-1.4961) 37.94 (1 .494)
A[B3:
fourth and fifth length A 56.45-56.55 (2.222-2.226) --
gears) B 26.03-26.08 (1 .0248-1 .0268) 26.01 (1 .024)
Reverse idler 1.0. 20.016-20.043 (0. 7880-0.7891) 20.09 (0. 7909)

gear Gear-to-reverse gear shaft clearance 0.036-0.084 (0.0014-0.0033) 0.160 (0.0006)
Synchronizer Ring-to-gear clearance (ring pushed against 0.85-1.10 (0.0335-0.0433) 0.40 (0.016)
ring gear)
Shift fork Synchronizer sleeve groove width 6. 75-6.85 (0.266-0.270) --
Fork-to-synchronizer sleeve clearance 0.35-0.65 (0.014-0.026) 1.0 (0.039)
Reverse shift Pawl groove width 13.0 13.3(0.51 0.52) --
fork Fork-to-reverse idle gear clearance 0.5-1 .1 (0.02-0.43) 1.8 (0.07)
Groove width atA 7.05-7.25 (0.278-0.2854) --
at B 7.4-7.7 (0.29-0.30) --
Fork-to fifth/ atA 0.05-0.35 (0.002-0.014) 0.5 (0.02)
reverse shift A at B 0.4-0.8 (0.02-0.03) 1.0 (0.04)
·~
Shaft clearance
Shift arm l. D. 15.973-16.000 (0.6289-0.6299) --

Shift arm-to-shaft clearance 0.005-0.059 (0.0002-0.0023) --
1 Shift fork diameter at contact area 12.9-13.0 (0.508-0.512) --
Shift-arm-to-shift fork shaft clearance 0.2-0.5 (0.01-0.02) 0.6 (0.02)
Se lect lever Pin size of contact area 7.9-8.0 (0.311-0.3151 --
Shaft outer diameter 15.41-15.68 (0.607-0.617) --
Shift arm cover clerance 0.032-0.102 (0.0013-0.0040) --
Shift arm lever O.D. 15.941-15.968 (0.6276-0.6287) --
lnter lock
i Transmission housing clearance
8ore diameter
0.027-0.139 (0.0011-0.0055)
16.00-16.05 (0.630-0.632)
1 --
--
1
Shift arm lever clearance 1 0.032-0.109 (0.0013-0.0043) --
Ring gear Backlash \ 0.085-0.142 (0.0033 0.0056) 0.200 (0.0079)
Differentíal Pinion shaft bore diameter 18.000-18.018 (0. 7087-0. 7094) --
carrier Carrier-to-pinion shaft clearance 0.017-0.047 (0.0007-0.0019) 0.100 (0.0039)
Driveshaft bore diameter 28.005-28.025 (1.1026-1.1033) --
Carrier-to-driveshaft clearance R 0.020-0.062 (0.0008-0.0024) 0.120
L 0.055-0.091 (0.0022-0.0036) 0.150
Differential Backlash 0.05-0.15 (0.002-0.006) Selection with 7 types of washers.
pinion gear Pinion gear bore diameter
Pinion gear-to-pinion shaft clearance
!
18.042-18.066 (0.7103-0.7113)
0.059-0.095 (0.0023-0.0037)
--
0.150 (0.0059)
Differential Preload 1.4 2.6 N·m Selection with 20 types of shims.
taper roller 1 (14-26 kg-cm, 1 .0-1.9 lb-ft)
bearing l
3-7
,- 9. A utomat1c T ransm1ss•on
Transmission
MEASUREMENT
Capacity l (U.S. qt .• Imp. qt.)
l STANDARD (NEWI
2.4 {2.5. 2.1) at oíl change
1 SERVICE LIMIT
! 6.0 (6.4, 5.2) at assembly

oil
Hydrauríc Líne pressure at 2.000 760 kPa 71 O kPa
min-• (rpm) \ (7. 75 kg/cm'. 11 O psi) (7.25kg/cm'. 103 psi)
pressure
Throttle valve full- closed Throttle valve more than 2/8 open
Carburetor 1
808 kPa
1 (8.25 kg/cm'. 117 psi)
Throttle valve more than 2/8 open
784 kPa 735 kPa
(8.0 kg/cm'. 113 psi) (7.5 kg/cm'. 106 psi)
Throttle valve full-closed Throttle valve more than 2/8 open
PGM-FI 1
1 833 kPa
1
(8.5 kg/cm'. 120psi)
4th clutch pressure at 2,000 411 kPa 352 kPa
min-• (rpm) (4.2 kg/cm'. 59 psi) (3.6 kg/cm'. 51 spí)
Throttle valve full-closed Throttle valve full-closed
Carburetor 1
808 kPa 1 71 O kPa
{8.25 kg/cm'. 117 psi) {7.25 kg/cm'. 103 psi)
1
Throttle Valve more than 2/8 open Throttle valve more than 2/8 open
509 kPa 460 kPa
(5.2 kg/cm', 74 psi) (4. 7 kg/cm'. 66 psi)
PGM-FI 1 1
833 kPa 735 kPa
(8.5 kg/cm'. 120 psi) (7 .5 kg/cm'. 106 psi)
Throttle valve more than 2/8 open Throttle valve more than 2/8 open
3rd clutch pressure at 2,000 392 kPa 352 kPa
min-• (rpm) (4.0 kg/cm'. 57 psi) (3.6 kg/cm'. 51 psi)
Throttle valve full-closed 1 Throttle vo:ve full-closed
Carburetor 1
808 kPa 71 O kPa
1
18.25 kg/cm', 117 psi) (7.25 kg/cm', 103 psi)
Throttle valve more than 2/8 open Throttle volve more than 2/8 open
490 kPa 441 kPa
(510 kg/cm', 71 psi) (4.5 kg/cm', 64 psi)
PGM-FI 1 1
i 833 kPa 735 kPa
(8.5 kg/cm', 120 psi! (7. 5 kg/cm', 106 psi}
Throttle vaive more than 2/8 open 1 Throttle valve more than 2/8 open
2nd clutch pressure at 2.000 392 kPa 352 kPa
min-• (rpm) (4.0 kg/cm', 57 psi) (3.6 kg/cm', 51 psi)
i Carburetor 1 1
808 kPa 71 O kPa
l
1 '
(8.25 kg/cm', 117 psi)
490 kPa
(7.25 kg/cm', 103 psi)
441 kPa
(5.0 kg/cm', 71 psi) (4.5 kg/cm', 64 psi)
PGM-FI 1
833 kPa 735 kPa
1 {8.5 kg/cm', 120 psi) (7.5 kg/cm'. 106 psi)
Throttle valve more than 2/8 open Throttle valve more than 2/8 open
1st clutch pressure at 2,000 750-808 kPa 71 O kPa
Carburetor
min-• {rpm) (7.75-8.25kg/cm', 110-117psi) {7 .25 kg/cm', 103 psíl
784-833 kPa 735 kPa
1
PGM-FI ' (8.0-8.5 kg/cm', 113-120 psi) (7.5 kg/cm'. 106 psi)
3-8
Unit of length · mm (ín )
.- 9. Automat1c Transm•ss1on
1
MEASUREMENT STANDARD (NEW) SERVICE LIMIT
Hydrouric Governor pressure at (37. 5 Carburetor 225 235 kPa 220 kPa
pressure mph) 60 km/h with CATA (2.30-2.40 kg/cm', 32-34 psi) (2.25 kg/cm', 32 psi)
Carburetor 166 176 kPa 162 kPa
without (1. 70-1 .80 kg/cm', 24-25 psi) (1.65 kg/cm', 23 psi)
CATA
Throttle pressure A closed o
Carburetor
with CATA open 514 530 kPa 509 kPa
(5.25-5.4 kg/cm', 74-76 psi) (5.2 kg/cm', 73 psi)
closed O
Carburetor
with CATA open 485 500 kPa 480 kPa
(4.95-5.10 kg/cm',70-72 psi) (4.9 kg/cm', 69 psi)
Throttle pressure B closed O
Carburetor
open760-808 kPa 710 kPa
(7 .75-8.25 kg/cm', 11Q-117 psi) (7 .25 kg/cm', 103 psi)
closed O
PGM-FI open 784 833 kPa 735 kPa
(8.0-8.5 kg/cm', 113-120 psi) (7.5kg/cm', 106psi)
Stall speed Check with car on leve! Carburetor 2.450-2.750 min '(rpm)
ground (1 .8 i)
1
Others 2.350-2.650 min '(rpml
Clutch Clutch initial clearance 1st hold 1 0.8-1.0 (0.031-0.039)
1st, 2nd 0.65-0.85 (0.026-0.033)
3rd, 4th i 0.4-0.6 (0.016-0.024)
Clutch return spring free 1st, 33.9 (1 .334) 31.9 (1.255)
length 2nd, 30.3 (1. 1921 28.3 {1.1141
Carburetor 3rd, 32.1 (1.263) 30.1 (1.185)
4th, 32.1 (1 .263) 30.1 (1.185)
PGM-FI 1st, 2nd, 3rd, 4th, 33.5 (1.318) 31.5 (1.240)
Clutch disc thíckness 1 .88-2.0 (0.074-0.079) Until grooves worn out
Clutch plate thickness 1st, 3rd, 4th, 1.95-2.05 Discororation
(0.0767-0.0807)
Carburetor
2nd, 2.55-2.65
(0.1003-0.1043)
1st, 1 .95-2.05 (0.0767-0.0807)
PGM-FI 2nd, 2.55-2.65 (0.1 003-0.1043)
3rd, 4th, 2.25-2.35
(0.0885-0.0925)
Clutch end plate thickness Mark 1 2.05-2.10 (0.081-0.83)
Mark 2 2.15-2.20 (0.085-0.087)
Mark 3 2.25-2.30 (0.089-0.091 1
Mark 4 2.35-2.40 (0.093-0.094)
Mark 5 2.45-2.50 (0.096-0.098)
Mark 6 2.55-2.60 (0.100-0.102)
Mark 7 2. 65-2.70 (0. 104-0.1 06)
Mark 8 2.75-2.80 (0.108-0.110)
Mark 9 2.85-2.90 (0.112-0.114)
*Mark 10 2.95-3.00 (0.116-0.118) Discotoration
*Carburated engme only.
3-9
1
r- 9. Automatic Transmiss1on {contd
1
Vatve body 1 Stater camshaft needle bearing

contact area l. O. (torque con verter side) 27.000-27.021 (1 .0630-1 .0638) Wear or damage
Stater camshaft needle bearing
contact area l. O. (oil pump side) 29.000-29.013 (1.417-1.1422) --
Oil pump driven gear l. D. 14.016-14.034 (0.5518-0.5525) Wear or damage
Oil pump shaft O. D. 13.980-13.990 (0.5504-0.5508) Wear or damage
Oil pump gear side clearance 0.03-0.05 (0.0012-0.0020) 0.07 10.0028)
Oil pump gear-to-body clearance
1
Orive 0.21-0.265 (0.0083-0.01 04) --
Driven 0.07-0.125 (0.0027-0.0049) --
Regulator valve Sealing ring contact area diameter 35.000-35.025 (1 .3780-1.3789) 35.050 (1.3799)
body
Accumulator Sealing ring contact area diameter 32.000 32.025 (1 .2598-1.2608) 32.05 (1.2618)
body
Stator Sealing ring contact area diameter 29.000-29.013 (1.1417-1 .1422) 29.05 (1.1436)
camshaft
Shifting device Reverse shift fork thickness 5.90 6.00 (0.232-0.236) 5.40 (0.213)
and parking Parking brake ratchet pawl -- Wear or other defect
brake control Parking gear -- Wear or other defect
Throttle cam stopper Carburetor 18.5-18.6 (0.7283-0.7322) --
PGM-FI 17.0-17.1 (0.66g2-0.6732) --
Servo body Shif fork Shaft 1.0. A 14.000 14.005 (0.5512-0.5514) --
B 14.006-14.010 (0.5514-0.5516) --
1
e 14.011-14.015 (0.5516-0.5518) --
Shift fork shaft valve bore l. D. 37.000-37.039 (1 .4567-1.4582) 37.045 (1.4585)
Transmission Oiameter of needle bearing contact area
On mainshaft and stator shaft 22.980-23.000 (0.9047-0.9055) Wear or damage
On mainshaft 4th gear collar 31.984-32.000 (1.2592-1.2598)
On mainshaft 3rd gear collar
Carburetor 41.984-42.000 (1.6529-1.6535)
PGM-FI 45.984-46.000 (1.8103-1.811 0)
On counter shaft 1st gear collar 40.984-42.000 (1.6135-1.6535)
On counter shaft 4th gear collar 35.980-35.996 (1.4165-1.4171)
On counter shaft reverse gear collar 35.984-36.000 (1.4166-1.4173)
On counter shaft parking gear 39.984-40.000 (1.5741-1.5748)
On secondary shaft 1st gear 31 .975-31 .991 (1.2588-1 .2594)
On secondary shaft 2sd gear 35.984-36.000 (1.4166-1.4173)
Reverse id le shaft holder l. D. 14.416-14.434 (0.5675-0.5682) i
1
Mainshaft 3rd gear l. D. 52.000-52.019 (2.0472-2.0479)

4th gear 1.0. 38.000-38.016 (1.4960-1 .4966) i Wear or damage
3-10
Unit of length· mm (in )
.---- 9 A utomat1c Transm1ss1on
Transmission Couter shaft 1st gear l. D. 47.000 47.016 (1.8504 1.8510) Wear or damage
1
4th gear l. D.
reverse gear l. D .
idle gear l. D.
Second.ary shaft 1st gear l. D.
2nd gear LD.
42.000-42.016 (1.6535-1.6541)
42.000-42.016 (1 .6535-1 .6541)
48.000-48.016 (1.8897-1.8903)
37.000-37.016 (1 .4566-1 .4573)
•42.010-42.025 (1.6539-1.65451
¡
Mainshaft 3rd gear collar length 20.000-20.050 (0. 7874-0. 7893)
!
4th gear collar length 47.500-47.550 (1 .8700-1 .8720)
Counter shaft 1st gear collar length 27.500-27.550 (1 .0826-1 .08461
4th gear collar length 20.04-20.08 (O. 7889-0. 7905)
reverse gear collar length 15.00-15.05 (0.5905-0.5925)
Secondary shaft distance collar length 4.95-5.00 (0. 1948-0.1968)
Counter shaft 1st gear thickness 1.45-1.50 (0.0570-0.0590)
Counter shaft parking gear length 25.030-25.048 (0.9854-0.9861) Wear or damage
3-11
- 9 Automat1c T ransm•ss1on (cont'd)
MEASUREMENT STANDARD (NEW)
WIRE OlA. O. D. FREE lENGTH No. of COILS

1
Spring 1st One way ball spring 0.29 (0.0114) 4.0 (0.01574) 14.0 (0.5511) 13.0
(Carburetor) Regulator valve spring A 1 .80 (0.0708) 14.7 (0.5787) 85.1 (3.3503) 16.5
Regulator valve spring B 1 .80 (0.0708) 9.6 (0.3779) 44.0 {1. 7328) 7.5
Stator reaction spring 5.50 (0.2165) 37.4 (1.4724) 30.3 (1.1929) 2.1
Throttle modulator spring with CATA 1.20 (0.0472) 9.4 (0.3700) 27.2 (1 .0708) 8.0
without CATA 1.20 (0.0472) 9.4 (0.3700) 26.3 (1 .0354) 8.0
Torque convertor check valve spring 1. 1 o (0.0433) 8.4 (0.3307) 36.8 (1.4488) 12.0
Relife valve spring 1.00 (0.0393) 8.4 (0.3307) 39.1 (1.5393) 15.1
Cooler check valve spring 1.10 (0.0433) 8.4 (0.3307) 46.8 (1.8425) 17.0
Governer spring A with CATA 1 .o (0.0393) 18.8 (0.7401) 44.3 (1. 7440) 4.0
without CATA 1 .o (0.0393) 18.8 (0.7401) 25.8 (1.0157) 4.0
Governor spring B with CATA 0.9 (0.0354) 11 .8 (0.4645) 18.4 (0. 7244) 6.2
without CATA 0.9 (0.0354) 11 .8 (0.4645) 21 .4 (0.8425) 6.2
Second olifice control spring 0.7 (0.0275) 6.6 (0.2598) 53.3 (2.0984) 20.5
Servo olifice spring 0.9 (0.0354) 7.1 (0.2795) 61.2 (2.4094) 28.2
Throttle spring A 1 .o (0.0393) 8.5 (0.3346) 21 .o (0.8267) 5.8
Throttle adjust spring A 0.8 (0.0314) 6.2 (0.2440) 30.0 (1.1811) 8.0
Throttle spring B 1 .6 (0.0629) 8.5 (0.3346) 41.4 (1.6299) 11.7
1 -2 shift spring with CATA 0.5 (0.0196) 4.6 (0.1811) 42.3 (1.6653) 25.0
without CATA 0.6 (0.0236) 6.1 (0.2401) 42.3 (1 .6653) 21.1
1 -2 shiftball spring e with CATA 0.4 (0.0157) 4.5 (0.1771) 13.0 (0.5118) 8.7
without CATA 0.4 (0.0157) 4.5 (0.1771} 12.6 (0.4960) 8.7
2-3 shift spring with CATA 0.9 (0.0354) 7.6 (0.2992) 70.0 (2.7559) 28.2
without CATA 0.8 (0.0314) 7.6 (0.2992) 58.9 (2.3188) 16.8
2-3 shft ball spring with CATA 0.5 (0.0196) 4.5 (0.1771) 11 .7 (0.4606) 10.5
without CATA 0.5 (0.0196) 4.5 (0.1771) 14.1 (0.5551) 10.5
3-4 shift spring with CATA 0.9 {0.0354) 9.6 (0.3779) 35.8 (1.4094) 10.3
without CATA 0.9 {0.0354) 9.6 (0.3779) 27.7 (1 .0905) 10.3
3-4 shift ball spring with CATA 0.5 (0.0196) 4.5 (0.1771) 11 .5 (0.4527) 7.4
without CATA 0.5 (0.0196) 4.5 (0.1771) 11 .3 (0.4448) 7.4
1st hold accumulator spring 4.0 (0. 1574) 21 .5 (0.8464) 71.7 (2.8228) 8.3
1st accumulator spring j
2.1 (0.0826) 16.3 (0.6417) 96.0 (3. 7795) 17.1
4th accumulator spring 2.6 (0.1023) 16.0 (0.6292) 84.6 (3.3307) 14.3
2nd accumulator spring 3.2 (0.1259) 20.7 10.8149) 80.7 (3.1771) 10.8
3rd accumulator spring 2.6 (0.1023) 17.5 10.6889) 78.6 (3.0944) 11.0
L/C shift spring 0.9 (0.0354) 7.6 (0.2992) 73.7 (2.9015) 32.0
L/C timing spring B with CATA 1 .o (0.0393) 6.6 (0.2598) 84.0 (3.3070) 42.4
without CATA 1 .O (0.0393) 6.6 (0.2598) 79.1 13.1141) 42.4
L/C timing spring A with CATA 0.9 (0.0354) 6.6 (0.2598) 55.9 (2.2007) 27.3
- without CATA 0.9 (0.0354) 6.6 (0.2598) 50.0 (1 .9685) 27.3
Governor cut spring 0.8 (0.0314) 7.6 (0.2992) 44.5 (1.7519) 17.0
L/C control spring 0.7 (0.0275) 6.6 (0.2598) 42.9 (1 .6889) 14.1
CPC valve spring 1 .4 (0.0551) 9.4 (0.3700) 31 .2 11 .2283) 10.9
3rd kick dawn spring 0.9 (0.0354) 7.6 (0.2992) 62.7 (2 .4684) 27.5
Reverse control spring 0.7 (0.0275) 7.1 (0.2795) 40.0 o .5748) 20.8
L/C cut spring 0.7 (0.0275) 7.6 (0.2992) 31 .o (1 .2204) 12.7
Accumulator control spring 1 .2 (0.0472) 7.7 (0.3031) 45.6 (1.7952) 21.8
2nd kick down spring 1 .2 (0.0472) 7.1 (0.2795) 46.9 (1.8464) 20.6
Servo control spring 0.9 (0.0354) 6.4 (0.2519) 32.5 (1.2795) 17.5
2-1 timing spring 0.7 (0.0275) 5.6 (0.2204) 33.0 (1 .2992) 21.7
4th exhaust spring 0.8 (0.0314 6.1 (0.2401) 51.1 (2.0118) 26.6
3-12
.-- 9 Automat1c Transm1ss•on
1
1
WIRE OlA. 0.0. FREE LENGTH No. of COILS
1 1
Spring Regulator valve Spring A 1 .8 (0.0709) 14.7 (0.5887) 1
1
86.5 (3.4055) 16.5
(PGM-FI) B 1 .8 (0.0709) 6.0 (0.2336) 44.0 (1. 7323) 12.7
Stator reaction spring 5.5 (0.2165) 37.4 (1 .4724) 30.3 !1.1929) 2.1
Torque converter check valve spring 1.1 (0.0433) 8.4 (0.3307) 1
33.8 (1 .3307) 12.5
Relief valve spring 1 .o (0.0394) 8.4 (0.3307) 39.1 (1 .5393) 15.1
Cooler check valve spring 1.1 (0.0433) 8.4 (0.3307) 46.8 (1.8425) 17.0
2nd orífice spring 0.6 (0.0236) 6.6 (0.2598) 52.2 {2.0551) 21.0
Servo orífice spring 0.8 (0.0315) 6.6 (0.2598) 52.2 {2.0551) 33.0
4th exhaust gpring 0.9 {0.0354) 7.1 (0.2795) 60.8 {2.3936) 28.9
1-2 shift spring 1 .o (0.0393) 8.6 (0.3386) 41 .3 {1 .6259) 16.9
2-3 shift spring 0.9 (0.0354) 7.6 (0.2992) 57.0 (2.2440) 26.8
1st accumulator spring 2.1 (0.0826) 16.3 (0.6417) 96.0 (3.7795) 17.1
4th accu mulator spring 2.9 (0.1142) 22.0 (0.8661) 84.5 (3.3267) 10.9
2nd accumulator spring 3.2 (0.1260) 20.7 {0.81491 80.7 (3.1771) 10.8
3rd accumulator spring 2.8 (0, 11 02) 17.5 (0.6889) 94.2 (3.7086) 16.1
UC shift spring 0.9 (0.0354) 7.6 (0.2992) 73.7 (2.9016) 32.0
L/C timing spring 0.8 (0.0314) 6.6 (0.2598) 64.0 (2.5196) 40.1
D-inhibitor spring 1 .o (0.0394) 8.1 (0.3188) 52.6 {2.0708) 22.4
3rd kick-down spring 1.1 (0.0433) 7.6 (0.2992) 48.3 11 .9015) 23.3
2nd kick-down spring 1 .2 (0.0472) 7.1 (0.2795) 46.9 (1 .8464) 20.6
Throttle adjust spring 0.8 (0.0314) 6.2 (0.2440) 30.0 (1 .1811) 8.0
Throttle B spring 1 .5 (0.0591) 8.5 (0.3346) 41.5 {1.6334) 11.2
1 st hold spring 4.0 (0.1574) 25.0 (0.9842) 64.7 {2.5472) 7.3
L/C modulator valve spring 1.4 (0.0551) 9.4 (0.3700) 33.0 (1 .2992) 10.5
UC control spring 0.8 (0.0314) 6.6 (0.2598) 41.0 (1.61411 25.0
3-13
,....- 9 Automat1c T ransm•ss1on cont'd)
1
MEASUREMENT 1
STANDARD (NEW) ¡
SERVICE LIMIT
Rígn gear Backlash ! 0.085~0.142 (0.003 0.006) 0.200 (0.008)
Differential Pinion shaft bore diameter 18.000~18.018 (0. 7087~0. 7094) --
carrier Carrier-to-pínion shaft clearance i 0.017~0.047 (0.001 ~0.002) o. 100 (0 004)
Driveshaft bore diameter 28.005~28.025 (1 .1026~1 .1 033) --
Carrier-to driveshaft clearance 1 0.025~0.066 (0.001-0.003) 0.120 (0.005)
Differential Backlash 0.08 o. 15 (0.03~0.006) Adjust with a washer
pinion gear Pinion gear bore diameter 1 18.042~18.066 (0.71 0-0.711) --
Pinion gear-to pinion shaft clearance 0.059~0.095 (0.002~0.004) o. 150 {0.006)
Differential For used bearing 2.5-3.7 N·m (25~37 kg-cm, 1.8 Adjust with a washer
taper roller After replacement of bearing -2.7 lb-ft) Adjust with a washer
bearing preload 2.8-4.0 N·m (28-48 kg-cm, 2.0
1 ~2.9 lb-ft)
,....- 1 1 . S teenng
1
Steering wheel Play ! 10 {0.39) maximum

Gearbox Pinion starting torque Below 1 .O N-m (1 0 k!J·Cm, 0. 72 lb-ft)
Angle of rack guide screw loosend from 35' -::0·
locked position
Pump Pump pressure with valve closed 7,845-8,826 kPa (80-90 k9/cm',
(oil temperature: 40'C/1 04'F mínimum) ' 1,138-1,280 psi) at idle
Do not run for more than 5 seconds
Power steering Capacity Reservoir 0.5 e (0.53 us qt., 0.44 lmp qt.)
fluid At change (approx.) 1 .8" 1.90 US qt. 1.58 lmp qt.)
Power steering Deflection between pulleys For used belt 12.5-16.0 {0.50-0.62)
belt with 98 N (10 kg, 22 lbs) For new belt 9.5~11.5 {0.37-0.45)
force
i Belt tension between pulleys For used belt 343-490 N (35-50 kg, 77-110 lb)
(measured with tension For new belt 686~882N (70-90 kg, 154-198 lb)
1gauge}
- 12 . S uspens1on
MEASUREMENT : STANDARD (NEW) SERVICE LIMIT
!
Wheel Total toe Front 0±2 (0±0.08) --
alígnment Rear 2WS: IN 2±2 (0.08±0.08) --
4WS: IN 3±2 (0.12±0.08) --
Camber Front o· OO" ± 1· -~
Rear 2WS: -o· 30' ± 1· --

4WS: -o· 2o· ± 1· --
Caster Front 3' oo· ± 1· --
Front Wheel turning angle lnward r 2.0/2.2 e engine: 39' ± 2' --
wheel ' 1 .8t engine: 40' 50'± 2' --
4WS: 38' 50'± 2' --
Outward 2.0/2.2 e engine: 29' 30' -~
wheel 1 .8 e engine: 31' 10' -~
(reference) 4WS: 29' 3<Y -~
Rear Wheel turning angle lnward 5' 50' ± 1' -~
(4WS only) wheel 6' 10':!: ,. --

Outward
wheel
(reference)
Wheel Rim runout Steel wheel Axial Below 1 .O {0.04) 2.0 (0.08)
Radial Below 1 .O (0.04) 1.5 (0.06)
Aluminum wheel Axial Below 0.7 (0.03) 2.0 (0.08)
Radial Below O. 7 (0.03) 1.5 (0.06)
Wheel bearing End play Front 0-0.05 (0-0.002) --
Rear 0-0.05 (0~0.002) -~
3-14
Unít of length· mm hn )
~
13. Brakes
!
MEASUREMENT STANDARD (NEWJ ! SERVICE LIMIT
Parking brake Play in stroke 200 N (20 kg, 44 lbs) T o be locked when pulled --
lever 4-8 notches
Foot brake Pedal heíght (from floor) MT 190 (7.5) --
pedal AT 195 (7.7) --
Master cylinder Piston-to-push rod clearance o 0.4 (0 0.016) --
Brake drum l. D. 220 (8.66) 221 (8.70)
Lining Thickness 4.5 (0.18) 2.0 (0.08)
Disc brake Disc thickness Front 23.0 (0.91) 21.0 (0.83)
Rear 10.0 (0.39) 8.0 (0.32)
Disc runout Front -- o. 1 o (0.004)
Rear -- O. 15 (0.006)
Disc parallelism Front and rear -- 0.015 (0.0006)
Pad thickness Front 12.5 (0.49) 1.6 (0.06)
2.2 2 model: 12.0 (0.47) 1.6 (0.06)
Rear 9.0 (0.35) 1.6 (0.06)
Brake booster Characteristics at 20 kg (44 lbs) line pressure Unit: kPa (kg/cm'ípsi)
pedal pressure Brakes Conventional type with ALB system
Vacuum
O mm (O in) Hg 922 (9.4/134) mínimum 813 (8.3/118) mínimum
300 mm (11.8 in) Hg 5,494 (56/796) mínimum 6,076 (62/882) minimum
500 mm {19.7 in) Hg 8,535 (87/1 ,237) minimum 8,134 (83/1, 180) mínimum
~
1s A"1r e on d"1t1oner
.
/

Air conditioner Lubricant capacity Con den ser 1 O ce (0.3 US oz .• 0.4 lmp oz.)
system Evaporator 25 ce (0.8 US oz., 0.9 lmp oz.)
Line or hose 1 O ce (0.3 US oz., 0.4 lmp oz.)
Reservo ir 1 O ce (0.3 US oz., 0.4 lmp oz.)
Compressor Lubricant capacity 900-950 g (31.7-33.5 oz)
Stator coil resistance at 20·c (68'F) 3.4-3.8 n
\ Pulley-to pressure plate clearance 0.35-0.65 (0.014-0.026)
Compressor Deflection between pulleys For used belt 10-12 (0.4-0.5)
belt with 98N (1 O k9, 22 lbs) For new belt 8.5-11 (0.3-0.4)
1 force
1 Belt tension between pulleys For used belt 441 -588 N (45-60 kg, 99-132 lbs)
l (measured with tension For new belt 931-1,127 N (95-115 kg, 209-254 lbs)
1 9auge)
3-15
Unít of length: mm (in.)
- 16. Electrica
MEASUREMENT STANDARD INEW) SERVICE LIMIT
1
lgnition coi! Rated voltage 12 Volts

Winding resistance Primary 0.6-0.8 o
<0.5-0.7 O>
Secondary 12.9-19.3 kn
< >: Carburated engine <14.4-21.6 kO>
lgnitíon wire Resistance 25 kn maximum
Spark plug Type standard ZFR6F-11 {NGK) or KJ20CR-l11 {ND)
( ) : Manufacturar KP. KT: ZFR5F-11 {NGK) -or KJ16CR-L11 (ND)
Option *' ZFR5F-11 {NGK) or KJ16CR-L11 (ND)
*: Except 2.2 ~ KP. KT only: UFR6F-11 (NGKJ or KJ20CR-L11 (N DI
engines other than Except KP. KT: ZFR7F-11 {NGK) or KJ22CR-L11 {NO)
KQ, KY types
Gap 1 .0-1 .1 {0.039-0.043)
lgnition timing At idling 15" ± 2' BTDC
KF. KB, KE. KW. KU, KT. KP (AT) 10' ± 2' BTDC
KY (AT/MT) 10' ± 2' BTDC
Battery Lightíng capacity 120-hours ratio) 65Ah
< >: KY. KQ, KP, KT <47Ah>
Starting capacity (voltage after 5 sec.) 8.4 V minímum/300 ampere draw at -15'C (59'F)
Alternator Output BOA
( >: Carburated engine (except KS. KW, KY) <70A>
Rotor coíl resístance 2.8-3.0 n --
Slip ríng 0.0. 14.4 (0.57) 14.0 (0.55)
Brush length 10.5 (0.41) 5.5 (0.22)
Brush spring tensíon 300-360 g (10.6-12.7 oz) --
Alternator belt Deflection at midway between pulleys with 98 10-12 (0.39-0.47) for used belt
N 11 O kg. 22 lbs) force 8.5-11.0 (0.33-0.43) after replacement of belt
Starting motor Output European MT: 1 .4 kw {2.2! : 1 .6 kw) AT:1.6 kw
i Except European MT: 1.4 kw AT:1.4 kw
Manufacturar: Mica depth 0.4-0.5 10.016-0.02) 0.15 10.006)
1 Mitsuba Commutator runout 0-0.02 (0-0.001) 0.05 {0.002)
Commutator O.D. 28.0-28.1 (1.10-1.11) 27.5 (1.08)
Brush length 15.8-16.2 (0.62-0.64) 10.0 (0.39)
i Brush spríng tensíon 16-18N (1 .6-1 .8 kg, 3.5-4.0 lbs) --
Manufacturar: ND Mica depth 0.5-0.8 {0.02-0.03) 0.2 {0.01)
Commutator runout 0-0.02 (0-0.001) 0.05 (0.002)
1
Commutator O.D. 29.9-30.0 (1 .18-1. 18) 1 29.0{1.14)
Brush length 15.0-15.5 (0.59-0.61) 10.0 (0.39)
1
B rush spring tension 19-24N {1.9-2.4 kg, 4.2-5.31 lbs} --
3-16
Design Specifications
ITEMS METRIC ENGLISH NOTES

1
DIMENSIONS Overall length 4,685 mm 184.4 in

4,680 mm 184.3 in KY
4,695 mm 184.8 in KW
4,700 mm 185.0 in KQ
Overall width 1,695 mm 66.7 in
1,720 mm 67.7 in KY
1,725 mm 67.9 in KQ
Overall height 1,390 mm 54.7 in
1,400 mm 55.1 in KY
Wheelbase 2,720 mm 107.1 in
Track Front 1,475 mm 58.1 in
Rear 1,480 mm 58.3 in
Ground clearance 160 mm 6.3 in
170 mm 1 6.7 in KY
Seating capacity
Turning circle diameter {at tire center) 4.9 m Fr 16.1 ft 4WS
5.4 m 17.7 ft 2WS
""'T
!
WEJGHT Curb weight
Max permissible weight {for European)
1.8í2.0 2 without ALB 1,740 kg 3-, 3,836 lb
1 .8í2.0 l with ALB 1 '760 kg 3,880 lb
2.2 t 1,840 kg 4,056 lb
ENGINE Type Water-cooled, 4-stroke OHC
Cylinder arrangement ln-line, 4-cylinders
Bore and stroke 85X81.5 mm 3.35X3.21 in 1.8 f
85X88 mm 3.35X3.46 in 2.0 t
85X95 mm 3.35X3.74 in 2.2 t
Displacement 1,849 cm' 112.8 cu. in 1.8 t
1,997 cm' 121.8 cu. in 2.0 t
2,156 cm' 131.5 cu. in 2.2 t
Compression Carbureted 9.0: 1 <8. 9 : 1 > < >: With
ratio 2. O i fuel-injected 9.6: 1 <9.5 : 1 > catalytic
2.2 i European 9.8: 1 converter
2.2 i KY 8.9: 1
1
2.2 1 KQ 8.8: 1
i Valve train Belt driven, Single Overhead Camshaft
Lubrication system Forced and wet sump
STARTER Type Gear reduction
Normal output European MT: 1 .4 kw (2.2 f: 1.6 kw) AT: 1.6 kw
Except Eu ropean MT: 1 .4 kw AT: 1.4 kw
Nominal voltage 12 V
Hour ratin9 30 seconds
Direction of rotation Clockwise as vieied from gear end
Weight ND 4.75 kg 10.5 lb
Mitsuba 1.6 kw 3.7kg 8.21b
Mitsuba 1 .4 kw 3.5kg 7.71b
Clutch MT Single plate dry, diaphragm spring
TRANSMISSION AT Torque converter with lock-up clutch
Clutch lining area 217 cm' 33.6sq. in
Transmission MT Synchronized 5-speed forward, 1 reverse
'
AT 1 4-speed forward automatic, 1 reverse
or Electronically controlled dual range
4-speed forward automatic, 1 reverse
Primary reduction ratio 1 : 1 ( Direct)
Gear ratio MT AT
CD: Carbureted Gear CD ® @ @ @ @ íJ)
@: 2.0 i PGM-FI
@: 2.2! (except KQ) 1st 3.307 3.307 3.307 3.307 2.705 2.705 2.705
@: 2.2 t KQ 2nd 1.857 1.809 1.809 1.809 1.464 1.366 1.464
@: Carbureted 3rd 1.269 1.230 1.230 1.230 1.028 1.028 1.028
2.0 i PGM-FI (KT) 4th 0.966 0.933 0.933 0.903 0.731 0.731 0.674
2.2 i KY 5th 0.787 0.757 0.757 0.705 -- -- --
®: 2.0 2 PGM-FI/2.2 R Reverse 3.000 3.000 3.000 3.000 2.047 2.047 2.047
(except KT, KQ, KY) Final 4.266 4.266 4.266 4.062 4.285 4.285 4.285
(J): 2.2 i KQ 1
3-17
Design Specifications
¡
ITEMS METRIC ENGUSH NOTES
1
AIR Cooling capacity 4,350 kcal/h . 1 17,259 BTU/h

CONOITIONER -Condition: Compressor speed 1,900 min-' (rpm)
Outside air temperatura 27'C 1 81'F
Outside air hu_midity·
Condenser air temperatura 35'C 51% 95'F
Condensar air velocity
Blower capacity
1' 4.5 m/sec.
440 m'
14.8 ft/sec.
15,542 cu. ft/h
Compressor Type Swash-plate
No. of cylinders 10
1
Capacity 178 cc/rev. 1 10.9 cu.in/rev.
Maximum speed 8,800 min-' lrpm)
Lubricant capacity 90-120 ce ·-r 3.0-4.0 US oz.
3.2-4.2 lmp oz. í
Condenser Corrugated fin type
Evaporator Corrugated fin type
Blower Type Sirocco fan
Motor input 210W(12V)
Speed control 5-s¡eed
Maximum capacity 500 m'/h 17,662 cu.ft/h
Temperatura control Air-mix type
Clutch Type Dry single-plate
Power consumption 40W ( 12V) maximum
Refrigerant Type R-.12
Quantity 0.90-0.95 kg 2.0-2.1 lb
STEERING Type Rack and pinion
SYSTEM Overall ratio 16.1: 1 <13.0: 1> < >: 4WS
Turns, lock-to-lock 3.13 <2.5> < >: 4WS
Steering wheel diameter 375 mm 14.8 in
Power steering fluid capacity 1 .8 f 1 ,1.9 us qt.
1 .6 lmp qt.
Power steering fluid Genuine Power Steering Fluid P/N: 08208-99961
SUSPENSION Type Front lndependent double wishbone, coil spring
Rear lndependent double wishbone, coil spring
Shock absorber Front and rear Telescopic, hydraulic {nitrogen gas-filled) ( ): except KP, KT
WHEEL Total toe Front 0±3 mm 0±0.12 in
ALIGNMENT Rear 2WS IN 2±2 mm ' 0.08±0.08 in
4WS IN 3±2 mm 0.12±0.08 in
Camber Front o·oo· ± 1·
Rear 2WS -o· 3o· ± 1·
4WS -o· 2o· ± 1·
Caster Front 3'00'
BRAKE Type Front Ventilated disc
SYSTEM
Rear Drum
2.2 2 (except KY) or ALB or 4WS: Solid disc
Pad and lining swept area (total)
Front 15 in 415 cm' 64 sq. in
14 in 311 cm' 48 sq. in
Rear Drum 242 cm' 38 sq. in
Disc 281 cm' 44 sq. in
TIRES Size 1 85/70R 14 88H
185/65R 15 87H
195/60R15 87V
1 95/60R 1 5 87H
Spare tire T105/70 014
T135/90 015
ELECTRICAL Fu ses In the ALB fuse box 15A. 40A
In the fuse box 1 7.5A, lOA, 15A, 30A
In the relay box 7.5A, lOA, 15A, 20A, 30A, 40A, 50A, BOA
Headlights High/Low 1 12V-65/55W
Turn signal lights Front 12V-21W
Rear 12V-21W
Position Úghts 12V-5W
License plate light 12V-5W
Buck-up lights 12V-21W
Stop lights 12V-21W
High mount brake light 12V-27W
Taillight 12V-5W
Rear fog light 12V-21W
Dome lights 12V-8W
Door courtesy lights 12V-3.4W
Vanity mirror light 12V-1.8W
Trunk light 12V-3.4W
Gauge lights 12V-3.4/1.4W
lndicator lights 12V-0.84/0.91 /1 .12/1 .4W
Warning lights 12V-1 .4/3.4W
Glove box light 12V-3.4W
lllumination and pilot lights 12V-1 .4/1 .2W LEO: 0.91W, 0.84W
Heater illumination lights 12V-1.2/1.4W 1
3-18
Unit: k9 (lb)
- WEIGHT SPECIFICATIONS
Manual Transmission Automatic Transmission
ENGINE TYPE GRADE
CARB WEIGHT WEIGHT DISTRIBUTION CARB WEIGHT WEIGHT DISTRIBUTION
1 .IFR/RR) (FR/RRl
1.8 e KB LX 1 ,200 {2,646) 730/470 (1,609/1,036) - -
Carbureted EX 1 ,215 (2,679) 735!480 (1,620/1 ,058) - -
2.0 e KG DX, EX 1 ,220 (2,690) '740/480 (1,631/1 ,058) 1,245 (2,745) 765/480 (1.687/1 ,058)
Carbureted KX ' EX 1 ,220 (2;690) 740/480 (1 ,631/1 ,058) 1,245 (2,745) 765/480 (1,687 /1 ,058)
KS DX 1 ,225 (2, 701) 745/480 (1 .642i1 ,058) 1,250 (2,756) 770/480 (1 ,698/1 ,058)
KS ! EX 1,230 (2.712) 750/480 (1,653/1 ,058) 1,255 (2, 767) 775/480 (1,709/1,058)
KF EX 1 ,220 (2,690) 740/480 (1,631 /1 ,058) 1 ,245 (2, 745) 765/480 (1.687 /1 ,058)
KB EX 1,215 (2,679) 740/475 (1,631/1 ,047) 1 ,240 (2, 734) 765/475 (1,687/1,047)
KE EX 1,225 {2,701) 740/485 {1,631/1,069) 1 ,250 (2, 756) 765/485 (1 .687/1 ,069)
KW DX, EX 1,225 {2,701) 745/480 {1,642/1 ,058) 1 ,250 (2, 756) 770/480 {1 .698/1 ,058)
KU, KP, KT LX 1,215 (2,679) 735/480 (1,620/1,058) 1,245 (2, 745) 765/480 (1 ,687/1,058)
KU, KP, KT. EX 1 ,220 (2,690) 735/485 (1,620/1,069) 1 .250 {2, 756) 765/485 {1 ,687/1 ,069)
KQ LX 1,210 (2,668) 730/480 (1,609/1 ,058) 1 ,240 (2, 734) 760/480 {1 ,675/1 ,058)
KY LX 1,245 (2. 745) 760/485 (1,675/1 ,069) 1,275 (2,811) 790/485 (1 '742/1,069)
KY EX 1 ,250 (2,756) 765/485 (1 ,687/1 ,069) 1 ,280 (2,822) 795/485 (1 '753/1,069)
2.0 e KG 2.0i 1,240 {2,734) 750/490 (1,653/1,080) 1,270 (2,800) 780/490 (1,720/1,080)
PGM-FI KX 2.0i 1,265 {2,789) 770/495 {1 ,698/1 ,091, 1,295 (2,855) 800/495 (1,764/1,091)
KS 2.0i 1 ,250 {2. 756) 760/490 (1,675/1 ,080) 1,280 (2,822) 790/490 (1,742/1,080)
KF, KB. KW 2.0i 1,245 (2, 745) 755/490 {1,664/1,080) 1 .275 (2,811) 785/490 (1.731/1,080)
KE 2.0i 1 ,255 (2. 767) 760/495 (1,675/1 ,091) 1 .285 (2,833) 790/495 (1, 742/1,091)
KU, KP, KT EXi i 1,240 (2,734) 750/490 (1 ,653/1,080) 1 .275 {2,811, 785/490 (1. 731 /1 ,080)
2.2 e KG 2.2i-2WS 1,305 (2,877) 795/510 (1,753/1,124) 1 '335 (2, 943) 825/510 (1,819/1' 124)
PGM-FI KG 2.2i-4WS 1 ,330 (2,932) 795/535 (1, 753/1 '179) 1,360 (2,998) 825/535 {1 ,819/1 '179)
KX, KS 2.2i-2WS 1,310 (2.888) 800/51 o {1 ,764/1. 124) 1,340 (2,954) 830/510 (1,830/1 '124)
KX, KS 2.2i-4WS 1 ,335 (2,943) 800/535 ( 1 '764/1, 179) 1 ,365 (3,009) 830/535 (1 ,830/1,179)
KF 2.2i-2WS 1 ,290 (2,844) 785/505 (1,731/1,113) 1,320 (2,91 0) 815/505 (1,797/1,113)
KF 2.2i-4WS 1,315 (2,899) 785/530 (1,731/1,168) 1,345 (2,965) 815/530 (1,797/1,168)
KE 2.2i-2WS 1,300 {2,866) 790/510 (1,742/1,124) 1,330 (2,932) o
820/51 (1,808/1 ,124)
KE 2.2i-4WS 1,325 {2,921) 790/535 ( 1. 742/1. 179) 1 ,355 (2,987) 820/535 (1.808/1,179)
KQ EXi 1,240 (2,734) 745/495 {1,642/1,091) 1 ,270 (2,800) 775/495 (1,709/1,0911
KY EXi 1,320 i2.910Í 790/530 Í1 742/1. 168) 1 350 Í2,976Í 825/525. ¡, 819/1, 157)
3-19
Body Specifications
2VVSM/TModel------------------------------~----------~
Unit: mm (in)
(L ·vsl os€· L
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450
513
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BASE
LINE
(c;25 Locate Hale)

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f-....ill 1226 128 52 513

469 1906 547
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SECTION EE
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POINT b POINT k
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Point) ~ ._ t.;15 Cross Beam Point)
a: _J
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-----~
POJNT p
(Reli_r_Da~r;..per
Center)
PO 1 N T O
~---~
. . .1
1~ 13 Upper Arm) -,
S.fl_
BASE
LINE
~Tt
PO 1NT b PO 1 NT J 1~25 Locate Hole)
(.P1~nt.BCamJ (.Ji25 LocateHole) 1~25 Locate Hole)
1
f-- PO 1 Nl m
CIJ
(k...J
1~25 Locate Hole)
LU
.:>
1
1\)
CIJ
(rJ
1
.,...
~ Q)
1\)
~ ~ 3
~~~!~ T~~~~- P 0 l NT J POINT k POINT 1 POINT m POINT n POINT O POINT t
en CD
l>
....... ::D
-t CD
3: "C
oQ. Q)
~~ ...-·
- n
INUT)
CD
~~ ~1 El ~ .,
1'-
CE N TER
LINE
"' :::r
PO 1 NT e POI NT e. h/1 1 1 Q)
PO 1N r f
~
SECT 1 ON AA. CC
--~--------------------
~
~'
V
E:::rV PO
1 J X16
1 SLOT)
POINT _e/ PO 1 NT r 3?\ SECTION FF
llt;;l- 390
~
366 443
" ------
333 12 26 122 63 f - - - - 4__
7_1_ _ ... 1
469 1906 i-c -··-.-------~?Ji ___ ----·--at--

70 664 2939 ~J.~
IHOL E)
3-011.5 ~ SECT 1ON OD
JK \C''"
? ·5
(RearDamper~ f/;"'
PO!NT O -0
1,123
POINT e Center) ~.
"'· POINT O
(,P13 ~up~pe~~A;.=n¡---.
,
'!_~~PD_I_~f_ -.
SECTION 88
"'1 :g¡ ~1 "'j -------------

BASE
LINE
1J~L;}l-,L~~~---~-~~~~~~~~~~~----------1L-.~~~~~~~~~~~~~~~~~~~
(1$14 Front Beam) (1,(.25 Locate Hole)
,_
"'w (¡J,25 Locate Hole)
::>
Lubrication Points
No. LUBRICATION POINTS LUBRICANT
1 Engine API Service Grade: SF or SG

SAE Viscosity: See chart below
2 Transmission Manual API Service Grade: SE or SF

SAE Viscosity: See chart below
Automatic DEXRQN® or DEXRON® II Automatic transmission fluid
3 Brake line Brake fluid DOT3 or DOT4

4 Clutch line Brake fluid DOT3
5 Power steering gearbox Steering grease P/N 08733-B070E

6 Shift lever pivots (Manual) Silicone grease with molybdenum disulfide
7 Steering ball joints

8 Suspension ball joints
9 Steering boots
10 Steering column bushings
11 Select lever (Automatic)
12 Pedal linkage
13 lntermediate shaft
14 Brake master cylinder pushrod Multi-purpose grease
15 Trunk hinges
16 Door hinges upper and lower
17 Door opening detents
18 Fuel filler lid
19 Engine hood hinges
20 Engine hood latch
21 Tilt lever
22 Rear brake shoe linkage
Piston seal
Dust seal
23 Caliper Silicone grease
Caliper pin
Piston
24 Power steering system Power steering fluid P/N 08208-99961
Recommended Engine Oil Recommended Manual Transmission Oil

(SF or SG Grade Oil) (SE or SF Grade Oil)
1
1 1
1
1 1 1 .
.. .
1
Single- 1 1 1 1 1 1
' • ,
..
grade
' 1 1 1 1 1 1
,,
• • •
1 1 1 1 1 1 1
1
,, -20 o 20 40 60 80 100°F
' ' i '
' •1 1
1
-30 -20 -10 o10 20 30 40°C
Multi- 1 •1
1 Transmission oil viscosity for
grade
1
' 1
ambient temperature ranges
1
1
1
CAUTION: Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for prolonged
-30-20-10 o 10 20 30 40°C
periods. Although this is unlikely unless you handle used
-20 o 20 40 60 80 100°F oil on a daily basis. it is still advisable to thoroughly
Engine oil viscosity for wash your hands with soap and water as soon as pos-
ambient temperature ranges sible after handling used oil.
4-2
o 2 8 (j])
6
16 ? 15
-=~=-·_~::='==!='--- J
, @ 41 3 4 3 (J) 19 18
@
4-3
Maintenance Schedule
Service at the interval listed x 1 ,000 km (or miles) or after R-Replace 1-lnspect. After inspection, clean,
that number of months, whichever comes first. C-Ciean adjust, repair or re place if necessary.
x1,000km 20 40 60 80 100
ITEM x 1 ,000 miles 12 24 36 48 60
months 12 24 36 48 60
ldle speed and idle C0*3 1 1 1 1 1 1
¡ ldle speed and idle C0* 4 i 1
Valve clearance 1 1 1 1 1
A!ternator drive be!t 1 1
Timing belt and timing balancer belt ! R
Water pump ! 1
Rep!ace every 10,000 km 1
•Engine oil and oil filter
(6,000 miles) or 6 months
•Transmission oil R R 1
•Radiator coolant i R*l 1
Cooling system hoses and connections 1

1 ! 1
E.G.R. system (Standard for sorne types) 1
Secondary air supply system (Standard for sorne types) l 1
Air cleaner element (Viscous type for European and KQ models) R R
Air cleaner element (Dry type except European and KQ models) R R R R R
Fuel filter (lncluding aux filter*5) R R
Tank, fuel line and connections 1 1
lntake a ir temp. control system * 3. * 5 1
Throttle control system*4. *5 1 1
Choke mechanism*5 1 1
Choke mechanism*7 C*B 1

Choke opener operation (only for carburetor automatic choke type} 1 1
Evaporative emission control system * 6 1
lgnition timing and control system*3 1 1
lgnition timing and control system* 4 1
Spark plugs (for cars using unleaded gasoline) R*2 R*2 i
Spark plugs (for cars using leaded gasoline) 1 R R R R R
Distributor cap and rotor*3 1 1
1 Distributor cap and rotorH 1
1
1
lgnition wiring*3 1 1
lgnition wiring *4 1
Positive crankcase ventilation valve*3 1 1 ¡

Positive crankcase ventilation valve* 4 1 1
Blow-by filter*5 í 1 1
1
•= These service intervals assume routine checking and replenishment has been done. as needed, by the customer.
* 1 Thereafter. replace every 2 years or 40,000 km (24,000 miles). whichever comes first.
* 2 For KS type, re place every 2 years or 40,000 km (24,000 miles) whichever comes first after 30,000 km ( 18,000 miles).
* 3 Except KS, KX models
*4 KS, KX models
* 5 Only for carbureted type (except KS m o del)
*6 Except KP, KT and 2.0 i of KE, KF
* 7 Only for carbureted type ( KS model)
* 8 Recommended by manufacturer only
4-4
Service at the interval listed x 1 ,000 km (or miles) or after R-Replace 1-lnspect. After inspection, clean,
that number of months, whichever comes first. adjust, repair or replace if necessary.
x 1,000 km 20 40 60 80 100
ITEM x 1 ,000 miles 12 24 36 48 60
months 12 1
24 36 48 60
!
Brake hoses and lines (lncluding ALB hoses and pipes for ALB models) 1 1 1 1 1
Brake fluid (lncluding ALB fluid for ALB models) R R
Front brake discs and calipers 1 1 1 1 1
lnspect every 10,000 km
Front brake pads
(6,000 miles) or 6 months
Rear brake discs, calipers and 'pads (for disk brake type) 1 1
Rear brake drums, wheel cylinders and linings (for drum brake type) 1 1
Parking brake 1 1 1
Exhaust pipe and muffler 1 1 1 1 1
Suspension mounting bolts ! 1 1 1 1 1
Front wheel alignment (except 4WS models) 1 1 1 1 1
Front and rear wheel alignment (4WS models) 1 1 1 1 1
Steering operation, tie rod ends, steering gear box and boots Except 4WS models 1 1 1
(lncluding center shaft for 4WS models) 4WS models 1 1 1 1 1
ALB high pressure hose (for ALB models) v R
ALB operation (for ALB models) 1 1 1
Power steering system 1 1
1 1 1 1
Power steering pump belt 1 1
Catalytic converter heat shield (Standard for sorne types) 1
1
CAUTION: The following items must be serviced more frequently on cars normally used under severe driving conditions.
Refer to the chart below for the appropriate maintenance intervals.
Severe driving conditions include:

A : Repeated short distance driving E : Driving on rough and/or muddy roads
B : Driving in dusty conditions F : Towing a trailer
C : Driving in severe, cold weather R-Replace.
D : Driving in areas using road salt or other corrosive 1- lnspect. After inspection, clean, adjust, repair or replace if
materials necessary.
Condition Maintenance item Maintenance lnterval

operation
. . 1
~~
Engine oil and oil filter R Every 5,000 km (3,000 miles) or 3 months
A B
. . Transmission oil R Every 20,000 km (12.000 miles) or 12 months
A B . D E Front brake discs and calipers 1 Every 10,000 km (6,000 miles) or 6 months
Rear brake discs, calipers and pads 1 Every 20,000 km (12,000 miles) or 12 months
A B
B e .
D E
E ~1 Power steering system 1 Every 10,000 km (6,000 miles) or 6 months
CAUTION: U sed engine oil may cause skin cancer if repeatedly left in contact with the skin for prolongad periods. Although
this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
4-5
Special Tools
SpeciaiTools------------------------------------------------------~
1
Ref. No. Tool Number Description O'ty Remarks
(!) 07912-610001 Oil Filter Socket

® 07 406-0030000 Oil Pressure Gauge Adaptor
@ 07JAZ-SH201 00 R.P.M. Connecting Adaptor
@ 07LAZ-PT30100 R.P. M. Connecting Adaptar
@ 07LAZ-PT30110 R.P. M. Con necting Adaptor A·
® 07LAZ-PT30120 R.P. M. Connecting Adaptar B
rJ) 07JGG-0010100 Belt Tension Gauge
(!) ®
®
5-2
Engine Tune-up
Radiator Cap Testing Coolant Level lnspection
fiféiiiifM The syste~ is under high pre~sure w~en CAUTION: When supplying coolant. be su reto shut the
the engine is hot. To avo1d danger of releas•ng scald.ng relay box lid and not to let coolant spill on the electrical
coolant, remove the cap only when the engine is cool. parts or the painted portian. lf any coolant spills, rinse it
off immediately.
1. Remove the r~diator cap, wet its seal with coolant,
1. Check whether the coolant leve! in the coolant reser-
then install it on the pressure testet".
voir is between "MAX" and "MIN"
2. Apply pressure of 93-123 kPa (0.95-1.25 kg/cm 2 ,
14-18 psi).
3. Check for a drop in pressure.
4. lf there is a drop in pressure, repla~e the cap.
RADIATOR CAP
\
2. Supply the coolant reservoir with coolant to "MAX", if
the coolant level is lower than "MIN" or near to "M IN"
NOTE:
e Use only HONDA-RECOMMENDED anti-freeze/
coolant.
e For best corrosion protection, the coolant concen-
tration must be maintained year-round at 50%
MINIMUN. Coolant concentrations less than 50%
may not provide sufficient protection against corro-
sien or freezing.
e Coolant concentrations greater than 60% will
impair cooling efficiency and are not recommend-
ed.
CAUTfON:
e Do not mix different brand anti-freeze;coolants.
e Do not use additional rust inhibitors or antirust
products; they may not be compatible with the
recommended coolant.
Radiator Coolant Refill Capacity: including reser-

voir (0.61(0.6 US qt, 0.5 lmp qt)) and heater.
1.8!
M/T: 6.6 t (7 .O US qt. 5.8 lmp qt)
A/T: 6.5 t (6.8 US qt, 5. 7 lmp qt)
2.0t and 2.2l (except 2.2i)
M/T: 7.2l (7.6 US qt, 6.41mp qt)
A/T: 7 .1l (7 .5 US qt, 6.3 lmp qt)
2.22 (2.2i)
M/T: 6.62 (7.0 US qt, 5.8 lmp qt)
A/T: 7 .1l (7 .5 US qt, 6.3 lmp qt)
3. See page 5-69 for refilling.
5-3
Engine Tune-up
Oil Level lnspection Engine Oil Replacement
1. Check engine oil with the engine off and the car parked 1. Warm up the engine.
on leve! ground. 2. O rain the engine oil.
2. Make certain that the oil leve! indicated on the dipstick P·iit.§9#ii$1Ci
·-····-"•••-
·
Be careful when 1oosenmg the dratn
·
is between the upper and lower marks. bolt while the engine is hot. Burns can result because
the oil temperatura is very high.
3. lf the level has dropped close to the lower mark, add oil CAUTION : Used engine oil may cause skin cancer
until it reaches the upper mark. if repeatedly left in contact with the skin for pro-
longad periods. Although this is unlikely unless you
CAUTION: Jnsert the dipstick carefully to avoid handle used oil on a daily basis, it is still advisable
bending it. to thoroughly wash your hands with soap and water
as soon as possible after handling used oil.
NOTE : Remove the filler cap to speed draining _
~/DIPSTICK
"TI'
LOWER o
OIL PAN DRAIN PLUG

45 N•m (4.5 kg-m, 33 lb-ft)
3. Reinstall the drain plug with a new washer, and refill
with the recommended oil.
3.8 2 (4.0 US qt, 3.3 lmp qt) at

Capacity change, including filter
4.9 E (5.2 US qt, 4.3 lmp qt)
Every 10,000 km (6,000 miles)
Change
1 or 6 months
5-4
Oil Filter Replacement
Recommended Engine Oil (SF or SG Grade only) f·''''i.);fijiiijM
After the engine has been run, the
exhaust pipes will be hot; be careful when working
around the exhaust manifold.
1
Single grade
1
CAUTION: U sed engine oil may cause skin canear
' if repeatedly left in contact with the skin for pro-
longad periods. Although this is unlikely unless you
handle used oil on a daily basis, it is still advisable
1 1 to thoroughly wash your hands with soap and water
as soon as possible after handling used oil.
Multi-grade
1. Remove the oil filter with the special oil filter socket.
2. lnspect the threads and rubber seal on the new filter.
Wipe off seat on engine block, then apply a light coat
30 20 10 1 20 30 40
of oil to the filter rubber seal.
Engine oil viscosity for ambient temperature ranges.
NOTE: Use only filters with a built-in bypass system.
NOTE:
• Oil filter should be replaced at each oil change.
• Because the oil will deteriorate rapidly under the following
conditions, it should be changed sooner than usual.
Frequent traveling on unpaved roads.
Use in cold climates.
Frequent idling.
Repeated short distance travel.
Use as a tractor.
--:7ll Apply oil to rubber seal

lil before installing.
ENGINE OIL COOLER

(Standard for sorne types)
(cont'd)
5-5
Engine Tune-up
Oil Filter Replacement ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - - - - .
3. lnstall the oil filter by hand. Eight numbers (1 to 8) are printed on the surface of
4. After the rubber seal is seated, tighten the oil filter the filter.
clockwise with the special tool.
The following explains the procedure for tightening
· Tighten: · 7/8 turn clockwise. filters using these numbers.
Tightening torque: 22 N·m (2.2 kg-m, 16 lb-ft)
1) Make a mark on the. cylinder block under the
CAUTION: lnstallation other than the above proce- number that shows at the bottom of the filter
dure could result in serious engine defects due to oil when the rubber seal is seated.
leakage.
2) Tighten the filter by turning it clockwise seven
numbers from the marked point. For example, if a
mark is made under the number 2 when .the:
rubber seal is seated, the filter should be tight-
OIL FILTER WRENCH ened until the number 1 comes up to the marked
07912-6110001 point.
Number when rubber Number after tightening.

se al is seated.
Number when rubber

1 2 3 4 5 6 7 8
seal is seated
ENGINE OIL COOLER
Number after tightening 8 1 2 3 4 5 6 7
5. After installation, fill the engine with oil up to the

specified level, run the engine for more than 3 min-
utes, then check for oil leakage.
5-6
Oil Pressure Test-------...., Air Cleaner Element lnspection/
Replacement ·
lf the oil pressure warning light stays on with the
engine running, check the engine oillevel. lf the oil lnspection
level is correct: 1. Remove the air cleaner element.
1. Connect a tacho meter. 2. Check the air cleaner element for fouling.
2. Remove the oil pressure sender and instan an oil NOTE : No cleaning is necessary for the air cleaner
pressure gauge. element, beca use its filter takes in oil (: viscous type}.
3. Start the engine and allow it to reach operating • The air cleaner element should be replaced more
temperature (the cooling fan comes on at least twice). frequently on cars normally used under severe
driving conditions.
4. Pressure should be:
Replacement
Engine Oil Pressure: 80°C (176°F) 1. Remove the air cleaner cover.
At ldle: 69 kPa (O. 7 kg/cm~. 10 psi)

minimum
At 3,000 min- 1 (rpm): 343 kPa (3.5kg/cm2 , 50 psi)
minimum Carbureted Engine:
• lf oil pressure is within specifications, replace the oil

pressure sender and recheck.
• lf oil pressure is NOT within specifications,
inspect the oil pump.
OIL PRESSURE
GAUGE
ADAPTOR
07406-0030000
Fuel-lnjected Engine:
ENGINE OIL COOLER

!Standard for some types)
(cont'd)
5-7
Oil Pressure Test-------...., Air Cleaner Element lnspection/
Replacement ·
lf the oil pressure warning light stays on with the
engine running, check the engine oillevel. lf the oil lnspection
level is correct: 1. Remove the air cleaner element.
1. Connect a tacho meter. 2. Check the air cleaner element for fouling.
2. Remove the oil pressure sender and instan an oil NOTE : No cleaning is necessary for the air cleaner
pressure gauge. element, beca use its filter takes in oil (: viscous type}.
3. Start the engine and allow it to reach operating • The air cleaner element should be replaced more
temperature (the cooling fan comes on at least twice). frequently on cars normally used under severe
driving conditions.
4. Pressure should be:
Replacement
Engine Oil Pressure: 80°C (176°F) 1. Remove the air cleaner cover.
At ldle: 69 kPa (O. 7 kg/cm~. 10 psi)

minimum
At 3,000 min- 1 (rpm): 343 kPa (3.5kg/cm2 , 50 psi)
minimum Carbureted Engine:
• lf oil pressure is within specifications, replace the oil

pressure sender and recheck.
• lf oil pressure is NOT within specifications,
inspect the oil pump.
OIL PRESSURE
GAUGE
ADAPTOR
07406-0030000
ENGINE OIL COOLER

!Standard for some types)
(cont'd)
5-7
Engine Tune-up
Air Cleaner Element lnspection/ Compression Pressure lnspection
Replacement (cont'd)
1. Before inspection, run the engine until it warms up
Carbureted Engine: (the cooling fan comes on at least twice).
2. Disconnect spark plugs (4).

3. Disconnect the 2-P connector (ignition coil primary
lead) from the distributor.
DISTRIBUTOR
4. Fit the compression gauge adaptar into a plug hole.

• Measure compression pressure at each cylinder.
2. Replace the element, install the air cleaner cover and

tighten the nuts or clips securely.
Compression pressure :
1.81: 1,177 kPa (12.0 kg/cm 2 • 171 psi)
at 250 min- 1 (rpm)
2.01. 2.2l: 1,226 kPa (12.5 kg/cm 2 • 178 psi)
at 250 min-'(rpm)
limit : 932 kPa (9. 5 kg/cm', 135 psi)
at 250 min-'(rpm)
Difference between cylinders:
196 kPa (2.0 kg/cm 2 , 28 psi)
NOTE : Use a full charged battery.
5. lf compression pressure is low, it is ca u sed by wear or
damage of piston rings or head gasket, and improper
seated valves.
6. When the pressure is high, inspect the following
item.
• Accumulated carbon on the piston head and the
cylinder head.
5-8
Engine Tune-up
Air Cleaner Element lnspection/ Compression Pressure lnspection
Replacement (cont'd)
1. Before inspection, run the engine until it warms up
Carbureted Engine: (the cooling fan comes on at least twice).
2. Disconnect spark plugs (4).

3. Disconnect the 2-P connector (ignition coil primary
lead) from the distributor.
DISTRIBUTOR
4. Fit the compression gauge adaptar into a plug hole.

• Measure compression pressure at each cylinder.
2. Replace the element, install the air cleaner cover and

tighten the nuts or clips securely.
Compression pressure :
1.81: 1,177 kPa (12.0 kg/cm 2 • 171 psi)
at 250 min- 1 (rpm)
2.01. 2.2l: 1,226 kPa (12.5 kg/cm 2 • 178 psi)
at 250 min-'(rpm)
limit : 932 kPa (9. 5 kg/cm', 135 psi)
at 250 min-'(rpm)
Difference between cylinders:
196 kPa (2.0 kg/cm 2 , 28 psi)
NOTE : Use a full charged battery.
5. lf compression pressure is low, it is ca u sed by wear or
damage of piston rings or head gasket, and improper
seated valves.
6. When the pressure is high, inspect the following
item.
• Accumulated carbon on the piston head and the
cylinder head.
5-8
Spark Pfug l n s p e c t i o n - - - - - - - - - - - - - - - - - - - - - - - - ,
1. lnspect the electrodes and ceramic insulator for: 2. Replace the plug if the center electrode is rounded as
shown below:
NOTE:
Wom or deformad e Do not use spark plugs other than those listed
electrodes • lmproper
below, beca use those plugs are a new type (ISO
gap
standard).
• Oil-fouling
• Carbon e These marks are sealed on the air cleaner cover.
Damaged deposits
gasket • Cracked
center
electrode .~.
lx ,.
Cracked
insulator ~
insulator
Spark Plug:
Except KP and KT models
Standard Optional
ZFR5F-11*
NGK ZFR6F-11
ZFR7F-11
KJ 16CR-L11 *
NO KJ20CR-L 11
KJ22CR-L 11
*: Except KF, KG, KS, KW, KE and KX models

Burned or worn electrodes may be caused by:
Advanced ignítion timing
Loose spark plug K P and KT models
Plug heat range too low Optional
Standard
lnsufficient cooling
NGK ZFR5F-11 ZFR6F-11
Fouled plug may be caused by:
Retarded ignítion timing NO KJ16CR-L11 KJ20CR-L 11
Oil in combustion chamber
lncorrect spark plug gap
Plug heat range too high 1.0-1.1 mm
Excessive idling/low speed running (0.039-0.043 in.) ROUNDED
Clogged air cleaner element ELECTRDDE
ii1~
Deteriorated ignition coil or ignition wires
3. Adjust the gap with a suitable gapping tool.
Electrode Gap: 1.Q-1.1 mm (0.039-0.043 in.)
4. Screw the plugs into the cylinder head finger tight,

then torque them to 18 N·m (1 .8 kg-m, 13 lb-ft).
NOTE: Apply a small quantity of anti-seize compound

to the plug threads befo re installing.
5-9
Engine Tune-up
Orive Belts lnspection
Orive Belts Deflection:
(When applying a force of 98 N (10 kg, 22 lb))
Used Belt New Belt
CDAiternator Belt 10.0-12.0 mm 8.5-11.0 mm

(0.39-0.47 in.) (0.33-0.43 in.)
CDAiternator Belt 10.0-12.0 mm 4.5-7.0 mm
with A/C (0.39-0.47 in.) (0.18-0.28 in.)
®P/S Pump Belt j13.0-16.0 '!lffi 9.5-11.5 mm
j (0.51-0.63 In.) (0.37-0.45 in.)
Measure with the belt tension gauge:
Used Belt New Belt
®Aiternator Belt 343-490 N 441-637 N

( 35-50 k~ ) [ 45-65 k~ )
77-110 1 99-143 1
@Aiternator Belt 441-588 N 932-1,128 N
with A/C ( 45-60 k~ ] ( 95-11 5 kf& ]
! 99-1321 209-2541
j ®P/S Pump Belt 343-490 N 686-883 N
1
1
( 35-50
77-1101
kfb ) [ 70-90 kg ) 1
154-1981b .
s·-1o
Alternator (A/C Compressor) Belt Adjustment
1. Apply a force of 98 N (10 kg, 22 lb) and measure the Measure with the belt tension gauge:
deflection between the alternator and crankshaft pul- Attach the belt tension gauge to the belt and measure the
ley. tension of the belt.
Deflection: 1Q-12 mm (0.39-Q.47 in.) Tension: 294-441 N {30-45 kg. 66-99 lb)
NOTE: On a brand-new belt, the deflection shoufd be NOTE: On a brand-new belt, the tension should be
8.5-11 mm (0.33-0.43 in.) when first measured. 441-637 N (45-65 kg, 99-143 lb) when first
·measured.
UPPER THROUGH BOLT
45 N·m (4.5 kg-m. 33 lb-ft) UPPER THROUGH BOLT
45 N•m (4.5 kg-m, 33 lb-ft)
CRANKSHAFT
ALTERNATOA PULLEY
NUT BELT TENSION GAUGE
24 N•m (2.4 kg-m. 17 lb-ft) CRANKSHAFT
07JGG-001 0100 PULLEV
2. Loosen the upper through bolt and alternator nut.
3. Move the alternator to obtain the proper belt tension,

then retighten the alternator nut and upper through
bolt.
4. Recheck the deflection of the belt.
5. After adjusting. if necessary, adjust the P/S pump belt

(see section 17).
5-11
Engine Tune-up
Alternator {A/C Compressor) Belt Adjustment
1. Apply a force of 98 N ( 1 O kg, 22 lb) and mea su re the Measure with the belt tension gauge:
deflection between the alternator and crankshaft pul- Attach the belt tension gauge to the belt and measure the
ley. tension of the belt.
Deflection: 10-12 mm (0.39-0.47 in.} Tension: 441-558 N (45-60 kg. 99-132 lb)
NOTE: NOTE:
e On a brand-new belt, the deflection should be 4.5 e On a brand-new belt, the tension should be 931
-7 mm (0.18-0.28 in.) when first measured. -1127 N (95-115 kg, 209-253 lb) when first
e lf there are cracks or any damage evident on the measured.
belt, replace it with a new one. e See the instruction for the belt tension gauge.
• lf there are cracks or any damage evident on the
belt, replace it with a new one.
UPPER THROUGH BOLT
45 N•m (4.5 kg-m. 33 lb-ft) UPPER THROUGH BOLT
· 45 N•m (4.5 kg-m, 33 lb-ft)
CRANKSHAFT
PULLEY
ALTER.NATOR
NUT
24 N•m (2.4 kg-m, 17 lb-ft}
A/C COMPRESSOR
BELT TENSION GAUGE
07JGG-0010100
2. Loasen the upper through bolt and alternator nut.
3. Move the alternator to obtain the proper belt tension,

then retighten the alternator nut and upper through
bolt.
4. Recheck the deflection of the belt.
5. After adjusting, if necessary, adjust the P/S pump belt

(see section 11)
5-12
\
P /5 Pump Belt Adjustment

1. A properly adjusted belt should deflect about 12.5 2. Loosen the special bolt and nut and turn the adjusting
-16 mm (0.50-0.62 in) when you push on it the bolt to get proper tension, then retighten the special
pulleys with a force of about 98 N ( 1O kg, 22 lbs). bolt and nut.
NOTE: On a brand new belt, the deflection should be

9.5-11 .5 mm (0.37-0.45 in) when first measured. SPECIAL BOL T
45 N·m
14.5 kg-m. 33 lb-ft)
CRANKSHAFT PULLEY
Test by the Belt Tension Gauge; 07 JGG-001 01 OO.

Attach the tension gauge to the belt and measure the ADJUSTING BOL T
tension of the belt.
Tension: 35-50 kg (77-110 lbs)
e On a brand-new belt, the tension should be 70-90 3. Start the engine and turn the steering wheel from
kg ( 1 54-1 98 lbs) when first measured. lock-to-lock severa! times, then stop the engine and
• See the instructions for the tension gauge. recheck the belt tension.
5-13
Engine Tune-up
Valve Clearance Adjustment
NOTE: 3. Adjust valves on No. 1 cylinder.
e Valves should be adjusted cold when the cylinder head lntake: 0.26 ± 0.02 mm (0.010 ± 0.01 in.)
temperature is less than 38 oc (100 °F}. Exhaust: 0.30 ± 0.02 mm (0.012 ± 0.01 in.}
Adjustment is the same for intake and exhaust valves. 4. Loasen locknut and turn adjustment screw until feeler
• lf pulley bolt broke loose while turning crank, retorque it gauge slides back and forth with slight amount of
to 220 N·m (22.0 kg-m, 1591b-ft). drag.
1. Remove valve cover. INTAKE and EXHAUST VALVE

LOCKNUTS 7 x 0.75 mm
20 N·m (2.0 kg-m, 14 lb-ft)
INTAKE
No.4 No.3 No.2 No.1
No.4 No.3 No.1

EXHAUST
FEELER GAUGE
2. Set No.1 piston at TDC. "UP" mark on the pulley
should be at top, and TDC grooves on the pulley
should align with cylinder head surface. The distributor
rotor must be pointing towards No. 1 plug wire. 5. Tighten locknut and check clearance again. Repeat
adjustment if necessary.
Number 1 piston at TDC
"UP" MARK
TDC GROOVES FEELER GAUGE
5-14
6. Rotate crankshaft 180° counterclockwise (cam pulley 8. Rotate crankshaft 180° counterclockwise to bring No.
turns 90°). The "UP" mark should be at exhaust side. 2 pisten to TDC. The "UP" mark should be at intake
Distributor rotor should point to No.3· plug wire. side. Distributor rotor should point to No.2 plug wire.
Adjust valves on No .3 cylinder. Adjust valves on No.2 cylinder.
Number 3 piston at TDC Number 2 piston at TDC
"UP" MARK
uup" MARK
7. Rotate crankshaft 180° counterclockwise to bring No.

4 piston to TDC. 8oth TDC grooves are once again
visible and distributor rotor points to. No.4 plug wire.
Adjust valves on No.4 cylinder. ·
Number 4 piston at TDC
5-15
Engine Tune-up
ldle Speed lnspection/ Adjustment
Carbureted Engine: 4. Turn the ignition switch OFF. Restart the engine and
hold engine at idle for 2 minutes. And hold engine at
(KS KG. KQ)
2,500-3,000 min- 1 (rpm) for 1 minute.
lnspection/ Adjustment Check idle speed with the headlights, heater blower,
rear window defogger, cooling fan and air conditioner
Propane Enrichment Method off.
ldle speed should be:
fiJ'Hñlfil§li
Do not smoke during this procedure.
Manual 800 ± 50 min- 1 (rpm)
Keep any open flame away from your work area.
Automatic 750 ± 50 min- 1 (rpm) (in "O")
NOTE:
• This procedure requires a propane enrichment kit.
• Check that the self diagnosis indicator before mak-
ing idle speed and mixture inspections.
1. Start the engine and warm up to normal operating

temperatura (the cooling fan comes twice).
2. Disconnect the #8 vacuum hose from the intake a ir

control diaphragm and clamp the hose end.
HOSE CLAMP
Adjust the idle speed, if necessary, by turning the

throttle stop screw.
NOTE: lf the idle speed is excessively high, check the
throttle control system (page 6-112)
5. Disconnect the 2P connector from the EACV and

disconnect the hose from the EACV, then cap the
EACV.
3. Connect a tacho meter.
R.P.M. CONNECTING ADAPTOR

07JAZ-SH 20100
R.P.M. CONNECTING ADAPTOR (B)

07LAZ-PT30120
BATTERY
R. P.M. CONNECTING ADAPTOR (A) EACV

07LAZ-PT30110
5-16
6. Disconnect the #2 vacuum hose from the carburetor,
Maximum Engine Speed
then cap the carburetor. o
o
o
1
~
o L___________________________________
• O - - - - - - - - - - - - - - - - Full
PROPANE VOLUME
Engine speed increase should be:
#2 VACUUM HOSE 160 ± 20 min- 1 (rpm)

Manual
Automatic 50 ± 10 min- 1 (rpm) (in "D")
7. Disconnect air cleaner intake tu be from air intake duct.

e lf engine speed does not increase per specification,
8. lnsert the hose of the propane enrichment kit into the mixture is improperly adjusted. Go to step 1 O.
intake tube about 1 O cm. e lf engine speed increases per specification, go to
NOTE: Check that propane bottle has adequate gas step 14.
before beginning test.
1 O. Remove the air cleaner and close the propane cotrol
valve.
Push down
11. Remove the mixture adjusting screw hole cap.
9. With engine idling, depress push button on top of

propane device, then slowly open the propane control
valve to obtain maximum engine speed.
Engine speed should increase as percentage of pro-
pane injected goes up.
MIXTURE AOJUSTING
NOTE: Open the propane control valve slowly; a sud- SCREW HOLE CAP
den burst of propane may stall the engine.
(cont'd}
5-17
Engine Tune-up
ldle Speed lnspection/Adjustment (cont'd)
12. Start engine and warm up to normal operating temper- 18. lf equipped with air conditioner, check the idle speed
ature ; the cooling fan will come on. with the A/C on.
13. Reinstall the propane enrichment kit and recheck ldle speed should be:
maximum propane enríched engine speed.
Manual 800±50min- 1 (rpm)
e lf.the propane enriched speed is too low, mixture is Automatic 750±50min- 1 (rpm) (in "D")
too rich: turn the mixture screw 1/4-turn clockwise
and recheck.
e lf the propane enriched speed is too high, mixture is
· to lean: turn the mixture screw 1/4-turn counter-
clockwise and recheck.
14. Close the propane control valve speed and remove the
BACK UP fuse for 10 seconds to reset control unit.
Recheck idle speed.

Automatic 750±50min- 1 (rpm) (in "D")
e lf idle speed is as specified (step 4). goto step 15.
e lf idle speed is not as specified, adjust by turning
throttle stop screw, then repeat steps 1 3 and 14.
15. Remove propane enrichment kit and reconnect air Adjust the idle speed, if necessary, by turning the
cleaner intake tube on the air intake duct. adjusting screw B.
16. Reinstall the mixture adjusting screw hole cap.
17. Disconnect the connector on the P/S oil pressure

switch, and check the idle speed.
Manual 950 ± 50 m in -l (rpm)


adjusting screw A.
5-18
{Except KS, KG. KQ) 4. Calíbrate the NDIR CO Meter in accordance with the
manufacturer's recommended procedures.
CO Meter Method
lnsert exhaust gas sampling probe ínto the tailpipe at
least 40 cm.
fitG•i¡RQ§M Do not smoke during this procedure.
5. Turn the ignition switch OFF. Restart the engine and
NOTE: Check that the self-diagnosis indícator {KXI hold engine at idle for 2 minutes. And hold engine at
before making idle speed and mixture inspections.
Check specification for id le CO with cooling tan, a ir
conditioner OFF and headlights OFF.
1. Start the engine and warm it up to normal operating
temperature (the cooling fan comes twice).
Specified CO%:
2. Connect a tacho meter. KX: 0.1% maximum
Except KX: 1 ±1%
e lf idle CO ís as specified, go to step 14.

• lf not, go to step 6 through 13.
6. KX;
Disconnect the #2 vacuum hose from the carburetor,
then cap the carburetor.
R. P.M. CONNECTING ADAPTOR (A)

BATTERY
07LAZ-PT30110

2,500-3,000min- 1 (rpm) for 1 minute.
Check idle speed with the headlights, heater blower,
off.
ldle speed should be: 7. KX:
Disconnect the 2P connector from the EACV and
Manual 800±50min- 1 (rpm) disconnect the hose from the EACV, then cap the
750±50min- 1 (rpm)(ín "D") EACV.
Automatic
CAP
{cont'd)
5-19
Engine Tune-up
ldle Speed lnspection/ Adjustment (cont'd)
8. KX: (KX)
Disconnect the wíre harness from the 0 2 sensor.
r
MIXTURE ADJUSTING
SCREW HOLE CAP
(Except KX)
9. KX:
Remove the rubber cap from the gas pipe.
- Turning mixture adjusting screw
clockwise: CO reading decreases

counterclockwise: CO reading increases
Readjust idle speed if necessary, and recheck idle CO.
12. KX:
Reconnect the connector and hose.
Remove BACK UP fuse for 1O seconds to reset control
unit.
13. KX:
10. KX: Turn the ignition switch OFF. Restart the engine and
Turn the ígnition switch OFF. Restart the engíne and hold engine at idle for 2 minutes. And hold engine at
hold engíne at ídle for 2 minutes. And hold engíne at 2,500-3,000 min- 1 (rpm) for 1 minute.
2,500-3,000 mín- 1 (rpm) for 1 minute. Recheck idle CO.
Check specificatíon for idle CO.
Specified CO%: O. 1%
Specífied CO%: 2.3±1.0%
• lf idle CO is as specified, go to step 14.
e lf not, specifícatíon, go to step 11. e lf not, check the self-diagnosis indicator (page
6-22). lf not, inspect the EACV {page 6-1 04) and
11 . Remove mixture adjusting screw hole plug and adjust the catalytic converter (page 6-1 03), then repeat
by turning mixture adjusting screw to obtain proper CO step 6.
reading.
14. Recheck id le speed.
Manual 800±50 min- 1 (rpm)

750±50 min- 1 (rpm)
Automatic
(in "D")
5-20
e lf idle speed is as specified, go to step 1 5. 18. lf equipped with a ir conditioner, check the id le speed
with the A/C on.
e Jf idle speed is not as specified, adjust by turning
throttle stop screw, then repeat step 5. ldle speed should be:
15. Reinstall the mixture adjusting screw hole cap. Manual 800±50 min- 1 (rpm)
Automatic 750±50 min- 1 (rpm) (in "D")
switch.
Except KX; Connect a jumper wire between the RED
terminal and the BLK terminal.
l
P/S OIL PRESSURE SWITCH J
1
ADJUSTING
SCREW B

adjusting screw B.
RED
1 7. Check the id le speed.

ldle speed should be :

adjusting screw A.
(cont'dl
5-21
Engine Tune-up
ldle Speed lnspection/ Adjustment (cont'd)
Fuel-lnjected Engine: (KS, KW)
lnspection/ Adjustment Manual 550 ± 50 min- 1 (rpm)
temperature (the cooling fan comes on). Automatic 550 ± 50 min-1 (in IN! orle])
2. Connect a tachometer. Adjust the idle speed, if necessary, by turning the idle
adjusting scr~w.
RPM CONNECTING ADAPTER
07JAZ-SH20100 IDLE ADJUSTING
SCREW
/(
RPM CONNECTING ADAPTER B

07LAZ-PT30120
5. Turn the ignition switch OFF.
RPM CDNNECTING ADAPTER A
07LAZ-PT3011 O
6. reconnect the 2P connector on the EACV, then
3. Disconnect the 2P connector from the EACV. remove BACK UP fuse in the underhood relay box for
1 O seconds to reset ECU.
EACV
7. Restart an idle the engine with no-load conditions in
which the headlights, blower fan, rear defogger, coo-
ling fan, and air conditioner are not operating for one
minute, then check the idle speed.

Automatic 700±50 min- 1 (rpm)
8. ldle the engine for one minute with headlights (Hi) and
rear defogger ON and check the id le speed.

4. Check idling in no- r pad conditions in which the head-
lights, blower tan, rear defogger, cooling fan, and air 9. ldle the engine for one minute with heater fan switch
conditioner are not operating. at Hl and air conditioner on, then check the idle speed.
ldle speed should be: ldle speed should be:
(Except KS, KW) Manual 770±50 min- 1 (rpm}

Automatic 600±50 min- 1 (rpm) (in [N] or [f])
NOTE: lf the idle speed is not within speciiications, see
System Troubleshooting Guide on page 6-192.
5-22
Tailpipe Emissions lnspection
Carbureted Engine: Fuel-lnjected Engine:
lnspection lnspectin
NOTE: lt is not possible to use a CO meterto adjust the fST.fJ.IUii!faDo not smoke during this procedure. Keep
idle mixture; the effect of the catalytic converter pre- any open ame away from your work area.
vents accurate tracking of such small changes in air-
fuel ratio. 1. Start the engine and warm up to normal operating
temperature (cooling fan comes on).
&,ll.j;j§ii§IC!
Do not smoke during this procedure, Keep
any open flame away from your work area. 2. · Connect tachometer.
1. KX, KS, KG, KO: 3. Check idle speed and adjust the idle speed, if neces-
Check the idle speed/mixture using the propane sary (page 6-207)
enrichment method.
2. Warm up and calibrate the CO meter according to the 4. Warm up and calibrate the COmeter according to the
meter manufacturer's instructions. meter manufacture"s instructions.
3. Start the engine and warm it up to normal operating 5. Check idle CO with the headights, heater blower, rear
temperature (the cooling fan comes on twice). window defogger, cooling fan, and air conditioner off.
4. Turn the ignition switch OFF. Restart the engine and Specified CO%:
hold engine at idle for 2 minutes. With CATA: 0.1 % maximum
And hold engine at 2,500-3,000 min- 1 (rpm) for 1 Without CATA: 1.0±1.0%
minute.
e lf unable to obtain this reading
5. Check idle CO with the headlights, heater blower, rear On With CATA, see ECU troubleshooting guide (page
window defogger. cooling fan, anda ir conditioner off. 6-144).
On other models, adjust by turning the adjusting
screw of the IMA sensor.
Specified CO %:
KX, KS, KG. KQ: 0.1% maximum
Except KX, KS. KG. KQ: 1.0 ± 1.0% ADJUSTING SCREW
- lf unable to obtain a CO reading of specified % by

this procedure, check the engine tune-up condi-
tion.
5-23
Engine Tune-up
lgnition Timing lnspection and Setting
Euel-lnjected Engine: 4. Adjust ignition timing, if necessary, to the follow-
ing specifications:
<KG. KS, KX and KQ models>
NOTE: To be made at idle with the service check connector
shorted, the blue service check connector is located in the lgnition Timing
far passenger corner under the dashboard. e All models: 15 ± 2° BTDC (RED)
at 800 ± 50 min- 1 (rpm) in neutral
1. Start the engine and allow it to warm up (cooling fan NOTE: The illustration shows A!T.
comes on).
2. Connect the ORN/RED and GRN/WHT terminals of

the service check connector (BLUJ with a jumper wire.
A/C DIODE
ORIVE PLATE RED MARK
5. Adjust as necessary by loosening the distributor adjust-

ing bolts, and turn the distributor housing counter-
clockwise to advance the timing, or colckwise to retard
PASSENGER'S the timing.
KICK PANEL
JUMPER WIRE
3. Connect a timing light to the engine; while the

engine idles, point the light toward the pointer on
the flywheel (for M/T), or on the drive plate (for
AJTl.
HOLD-DOWN BOLTS
22 N·m (2.2 kg-m, 16 lb-ftl
6. Tighten the adjusting bolts and recheck the timing.
7. Remove the jumper wire and install the rubber caps

to the inspection window.
TIMING LIGHT
5-24
<Except KG. KS. KX and KQ models> 3. lnspection ignition timing at idle.
1. Start the engine and allow it to warm up (cooling fan lgnition Timing:
comes on). 15±2° BTDC (RED) at 800 ± 50 min- 1 (rpm) in
neutral
2. Connect a timing fight to the engine; while the engine
id les, point the light toward the pointer on the flywheel
(for M/T), or on the drive plate (for A/T). NOTE: The illustration shows A/T.
RED MARK
4. Adjust ignition timing, if necessary, by turning the

adjusting screw on the ignition timing adjuster in the
TIMING LIGHT control box.
(cont'd)
5-25
Engine Tune-up
lgnition Timing lnspection and Setting (cont'd)
5. Remove the cap from the ignition timing adjuster. 6. Adjust as necessary by turning the adjusting screw on
the adjuster; turn the adjusting screw counterclock-
wise to retard the tiníing, or clockwise to advance the
timing.
o¡~ADVANCE
ADJUSTING SCREW
7. After adjusting, reinstall the cap to the ignition timing

adjuster.
5-26
Carbureted Engine: 6. Connect a timing light to the engíne; while the engine
id les, point the light toward the pointer on the flywheel
<KP, KT, KU and KV (A/T) models>
(for M/T). or on the drive pi ate (for A/T).
1 . Disconnect the vacuum hose from the vacuum
advance diaphragm, then connect the vacuum pump/
gauge to the vacuum hose.
VACUUM
PUMP/GAUGE
VACUUM
TIMING LIGHT
HOSE
7. Read ínitial timing when tímíng mark (white) is aligned

to the pointer.
2. Start the engine.
lnitial Timing: 0° TDC
KP and KT models: Let it idle.
• Manual Transmission [at 800 ± 50 min -1 (rpm)
KV (A/T) model: Hold the engine at 4,000
in neutral]
min- 1 (rpm).
e Automatic Transmission [at 750 ± 50 min-1
{rpm) in gear]
3. Check the vacuum hose for vacuum.
The vacuum hose should have vacuum. NOTE: The illustration shows A/T.
e lf the vacuum hose has no vacuum, check the
vacuum hose of proper connection, cracks, block-
age or disconnected hose.
4. Connect the vacuum hose to the vacuum advance

diaphragm and allow the engine to warm up (cooling
fan comes on).
5. Disconnect the vacuum hose from the vacuum

advance diaphragm and plug them.
RED MARK
(cont'd)
5-27
Engine Tune-up
lgnition Timing lnspection and Setting (cont' d)
8. Adjust as necessary by loosening the distributor adjust- 1 O. Connect the vacuum hose to the vacuum advance
ing bolts, and turn the distributor housing clockwise to diaphragm and inspect ignition timing at idle.
retard the timing, or counterclockwise to advance the
timing. lgnition Timing
M/T: .15° ± 2° BTDC (Red)
A/T: 10° ± 2° BTDC (Red)
• Manual Transmission [at 800 ± 50 min- 1 {rpm)
in neutral]
• Automatic Transmission [at 750 ± 50 min- 1
(rpm} in gear]
lf advance is not as specified, check the vacuum

advance diaphragm and distributor advance mecha-
nism.
AOJUSTING BOLTS
9. Tighten the distributor adjusting bolts, then recheck

the timing.
5-28
<KP, KT and KV (A/T) models> 4. Connect the vacuum hoses to the vacuum advance
1 . Disconnect the vacuum hoses from the vacuum diaphragm and allow the engine to warm up. (cooling
advance diaphragm, then connect the vacuum pump/ fan comes on).
gauges to the vacuum hoses.
5. Disconnect the #5 hose from the vacuum advance
diaphragm and connect the vacuum pump/gauge to
the #5 hose.
6. Check the #5 hose for vacuum.

The #5 hose should have no vacuum.
7. Disconnect the vacuum hoses from the vacuum

8. Connect a timing light to the engine; while the engine

ídles, poínt the líght toward the pointer on the flywheel
(for M/T), or on the drive plate (for A/T).
2. Start the engine and let it id le.
3. When the engine is cool, coolant temperature is below

55°C (131 °F).
Check each hose for vacuum. The #2 and #5 hoses
should have vacuum.
e lf the #2 hose has no vacuum, check the #2 hose of

proper connection, cracks, blockage or discon-
nected hose.
e lf the #5 hose has no vacuum, check the #5 and

connected hoses for proper connections, cracks,
blockage or disconnected hoses, and the check
valve is not clogged.
lf the #5 and connected hoses, and the check valve
ha\le no problem, recheck the #5 hose for \lacuum. TIMING LIGHT
(cont'd)
5-29
Engine Tune-up
lgnition Timing lnspection and Setting (cont'd)
9. Read initial timing when timing mark (white) is aligned 11 . Tighten the distributor adjusting bolts, then recheck
to the pointer. · the timing.
lnitial Timing Connect the vacuum hose to the vacuum advance

All models: 0° BTDC diaphragm and inspect ignition timing at idle.
e Manual Transmission [at 800 ± 50 min- 1 (rpm)
in neutral] lgnition Timing
e Automatic Transmission [at 750 ± 50 min- 1 M/T: 15° ± 2° BTDC
(rpm) in gear] A/T: 10° ± 2° BTDC Except KQ, KX, KS)
( and KG models
NOTE: The illustration shows A/T. 15° ± 2° BTDC KO. KX, KS J
[ and KG models
WHITE MARK e Manual Transmission [at 800 ± 50 min- 1 (rpm)
in neutral]
e Automatic Transmission [at 750 ± 50 min- 1
(rpml in gear]

nism.
1 O. Adjust as necessary by loosening the distributor adjust-

ing bolts, and turn the distributor housing clockwise to
timing.
5-30
Special Tools
- Special Too s (Common with Other Models) - - - - - - - - - - - - - .

CD 07 JAB-00 10000 Crank Pulley Holder Set 1 for crankshaft pulley bolt
CD-1 07JAA-001 0200 Socket Wrench 19 mm (1)
CD-2 07JAB-001 0200 Handle ( 1)
® 07JAB-001 0400 Pulley Holder Attachment HEX 50 mm 1
® 07LAG-PT201 00 Balancer Shaft Lock Pin 1
{~
r---
1 Q:> 1
o 6'
)
~
CD-1 CD-2
0~)---<1.._)--~~l!
'
5-32
Timing Belt
lllustrated lndex
NOTE:
e Refer to page 5-39 for positioning crank and pulley befare installing timing belt.
e Befare remaving, mark direction of ratation.
UPPER COVER
ADJUSTING NUT
-45 N•m (4.5 kg-m.
33 lb-ft)
POWER STEERING
;~
BELT
CROWN NUT
6 x 1.0 mm
10 N·m (1.0 kg-m,
~ ¡y-
~
-
6 x 1 · 0 mm
m(1 k/-·m,
'
LOWER COVER
Remove the
four bolts.
7.2 lb-ft)
and
14 x 1.25 mm
220 N•m (22.0 kg-m.
1
CRANKSHAFT
PULLEY
12 N•
9 lb-ft)
.2
VALVE COVER
WASHER
GROMMET
~
l
)
159 lb-ft)
Apply engíne oíl to the
ALTERNATOR RUBBE SEALS
bolt threads.
BELT
Adjustment, page 5-11
HAN OLE
8 x 1.25 mm
38 N•m (3.8 kg-m,
07JAB-001 0200 27 lb-ft)
TIMING BELT
6 x 1.0mm
12 N•m (1.2 kg-m.
9 lb-ft)
surface facíng in.
lnspectíon, page 5-35

5-33
Timing Belt
lnspection Tension Adjustment
1. Disconnect the alternator terminal and the connector, CAUTION: Always adjust timing belt tension with the
then remove the engine wire harness from the valve engine cold.
cover.
2. Remove the valve cover. NOTE:
3. Remove the timing belt upper cover. • Tensi.oner is spring-loaded to apply proper tension to the
4. lnspect the timing belt for cracks and oil soaking. belt automatically after máking the following adjust-
NOTE: ment.
e Replace the belt if oil soaked. e lnspect the timing balancer belt befare belt tension
e Remove any oil or solvent that gets on the belt. adjusting.
e Do not loasen the adjusting nut more than one full turn.
1. Disconnect the alternator terminal and the connector,
then rémove the engine wire harness from the valve
cover.
2. Remove the valve cover.
3. Set the No. 1 pisten at TDC {page 5-41).
4. Loosen the adjusting nut 2/3-1 turn, then tighten the
adjusting nut.
ADJUSTING NUT
45 N•m
14.5 kg-m, 33 tb-ttl
Direction of
Rotation.
5. Rotate the crankshaft counterclockwise 3-teeth on the

camshaft pulley, then reloosen the adjusting nut to
Rotate pulley
create tension on the timing belt.
and inspect belt.
6. Tighten the adjusting nut.
7. lf the pulley bolt loosens while turning the crank,
retorque it to 220 N·m (22.0 kg-m, 159 lb-ft).
5. lf the pulley bolt loosens while turning the crank,
retorque it to 220 N ·m (22 .O kg-m, 1 59 lb-ft). ·
5-34
Timing Balancer Belt
lnspection Tension Adjustment
1. Dísconnect the alternator terminal and the connector, CAUTION: Always adjust timing belt tension with the
then remove the engine wire harness from the valve engine cold.
cover.
2. Remove the valve cover. NOTE:
3. Remove the timing belt upper cover. e Tensioner ís spring:.Joaded to apply proper tension to the
4. Remove the crankshah pulley. belt automatically aher making the following adjust-
5. Remove the timing belt lower cover. ment.
6. lnstall the crankshah pulley. e lnspect the timing balancer belt befare belt tension
7. lnspect the timíng balancer belt for cracks and oil adjusting.
soaking. e Do not looseri the adjusting nut more than one full turn.
NOTE:
• Replace the belt if oil soaked. 1. Disconnect the alternator terminal and the connector,
e Remove any oil or solvent that gets on the belt. . then remove the engine wire harness from the valve
cover.
lnspect this 2. Remove the valve cover.
area for wear. 3. Set the No. 1 piston at TDC (page 5-41).
4. Loosen the adjusting nut 2/3-1 turn, then tighten the
adjusting nut.
ADJUSTING NUT
45 N·m
(4.5 kg-m, 33 lb-ft)
Direction of Rotation.
Rotate pulley
and inspect belt.
5. Rotate the crankshah counterclockwise 3-teeth on the
camshaft pulley, then reloosen the adjusting nut to
8. lf the pulley bolt loosens while turning the crank, create tension on the timing belt.
retorque it to 220 N·m (22.0 kg-m, 159 lb-ft). 6. Tighten the adjusting nut.
7. lf the pulley bolt loosens while turning the eran k,
retorque it to 220 N·m (22.0 kg-m, 159 lb-ft).
5-35
Timing Belt and Timing Balancer Belt
Replacement
NOTE: 3. Remove the mounting bolt, nut and V-belt from the
e Turn the crankshaft so that the No. 1 cylinder is at TDC. power steering pump, then without disconnecting the
e lnspect the water pump after removing the timing belt. hoses, pull the pump away from the mounting
bracket.
10 x 1.25 mm
45 N•m (4.5 kg-m,
33 lb-ft)
\
SPLASH SHIELD 8x1. mm
22 N•m (2.2 kg-m,
16 lb-ft)
2. Disconnect the connector, then remove the cruise 4. Disconnect the alternator terminal and the connector,
control actuator. then remove the engine wire harness from the valve
NOTE: cover.
e Do not disconnect the control cable. 5. Loasen the alternator mounting bolts and the adjusting
e Take care not to bend the cable when removing the nut, then remove the alternator belt.
actuator. Always replace a kinked cable with a new
one.
CRUISE CONTROL
ACUTUATOR
AOJUSTING
BOLT
5-36
6. Remove the valve cover. 12. Remove the special bolt and the crankshaft pulley.
7. Remove the side engine mount bracket stay B (Stan- 1 3. Remove the lower cover.
dard for sorne types). 14. Push the timing balancer belt tensioner and the timing
8. Remove the upper cover. belt tensioner to remove tension of the belts, then
9. Remove the side engine mount. tighten the adjusting nut.
10. Remove the dipstick and the pipe. 15. Remove the timing balancer belt and the timing belt.
11. Remove the adjusting nut.
12 x 1.25 mm
55 N•m (5.5 kg-m,
40 lb-ftl
6 x 1.0 mm
TIMING BELT
8 x 1.25 mm---------:!~
45 N·m (4.5 kg-m,
33 lb-ft)
~..-V\í
SPECIAL BOL T ~
14 x 1.25 mm_____...- ·
220 N·m (22.0 kg-m, 6x 1.0mm
159 lb-ftl 12 N·m (1.2 kg-m,
Apply oil to the CRANKSHAFT 9 lb-ftl
bolt threads. PULLEY (cont'd)
5-37
Timing Belt and Timing Balancer Belt
Replacement (conrd)~~~~~~~~~~~~~~~~~~~~~~~
16. lnstall the tíming belt in the reverse order of removal; NOTE: Align the bolt hole and the balancer shaft
adjust the valve clearances (page 5-14). hole, then insert the special tool to fix the rear
-Refer to page 5-41 for posítíoníng the crankshaft balancer shaft.
and the camshaft pulley before installing the new
tíming belt.
17. Positíon the timíng balancer belt driven pulleys befo re
installing the new tíming balancer belt as shown.
18. lnstall the new timing balancer belt if necessary, then
remove the adjusting nut:
19. Perform the tension adjustment of the timing belt and
the tíming balancer belt (page 5-41).
MAINTENANCE
BLANCER SHAFT
LOCK PIN
07LAG-PT201 00 -¡:--fHPl~~
8 x 1.25 mm
30 N•m (3.0 kg·m, 22 lb-ftl
Align the groove of the
NOTE: Tighten the bolt
front driven pulley and
after installing the belt.
the pointer on the oil
pump body.
REAR TIMING BALANCEA BELT

DRIVEN PULLEY
FRONT TIMING BALANCEA TIMING BALANCEA BELT

BELT DRIVEN PULLEY ORIVE PULLEY
Set the crankshaft
at the TDC.
5-38
20. After adjusting the belt tension, lock the timing belt 22. Turn the crankshaft pulley about noe turn; tighten the
adjuster arm with the 6 x 1 O mm bolt used to tighten - adjusting nut (adjustment is completed).
timing belt lower cover.
21. Loosen the adjusting nut and check that the timing NOTE: Do not apply tension on the tensioner when
balancer belt adjuster moves freely. tightening the adjusting nut as the tensioner is spring
loaded.
COUTION: Do not apply excessive tension to the

timing balancer belt. lt is designad to operate with
smaller tension than those of other belts.
TIMING
ADJUSTER ARM
TIMING BALANCEA BELT

ADJUSTER
freely.
Lock with
6 x 1.0 mm
bolt
TIMING BALANCER BELT

ORIVE PULLER

ADJUSTER
23. Tighten the adjusting nut and the 6 x 1 .O mm bolt from

the timing belt adjuster arm.
24. Remove the crankshaft pulley.
(cont'd)
5~39
20. After adjusting the belt tension, lock the timing belt 22. Turn the crankshaft pulley about noe turn; tighten the
adjuster arm with the 6 x 1 O mm bolt used to tighten - adjusting nut (adjustment is completed).
timing belt lower cover.
21. Loosen the adjusting nut and check that the timing NOTE: Do not apply tension on the tensioner when
balancer belt adjuster moves freely. tightening the adjusting nut as the tensioner is spring
loaded.
COUTION: Do not apply excessive tension to the

timing balancer belt. lt is designad to operate with
smaller tension than those of other belts.
TIMING
ADJUSTER ARM
TIMING BALANCEA BELT

ADJUSTER
freely.
Lock with
6 x 1.0 mm
bolt

ORIVE PULLER

ADJUSTER
23. Tighten the adjusting nut and the 6 x 1 .O mm bolt from

the timing belt adjuster arm.
24. Remove the crankshaft pulley.
(cont'd)
5~39
Cylinder Head
Rem.oval
CAUTION:
e To avoid damaging the cylinder head, wait until the coolant temperatura drops below 38 oc (100 °F) before removing
it.
e In handling a metal gasket. care should be taken not to fold it or damage the contact surface of the gasket.
NOTE: Use new 0-rings and gaskets when reassembling.
CROWN N U T - - - - - - - o
6 x 1.0mm
10 N•m (1.0 kg-m,
7 lb-ft)
RUBBER SEAL
Replace when damaged
or deteriorated.
CYLINDER HEAD BOLT

12 x 1.25 mm
108 N•m (10.8 kg-m,
78 lb-ftl
Tightening, page 5-49
Apply engine oil
DISTRIBUTOR to the threads.
8 x 1.25 mm
22 N•m (2.2 kg-m,
16 lb-ft)
POWER STEERING
PUMP BRACKET
TIMING BELT
Replacement, page 5-36
1nspection/Adjustment,
page 5-34
ADJUSTING NUT
10 x 1.25 mm
45 N·m (4.5 kg-m.
33 lb-ftl
Loosen, but do
not remove.
5-42
NOTE: Engine removal is not required in this procedure. 8. Remove the brake booster vacuum hose and mount
CAUTION: To avoid damaging the cylinder head, wait vacuum tube (A/T only) from the intake manifold.
until the coolant temperatura drops below 38 oc (100 o 9. Remove the fuel return hose.
F) before loosening the retaining bolts. 1O. Remo ve the cruise control vacuum hose.
NOTE:
e lnspect the timing belt before removing the cylinder Fuel-lnjected Engine:
head. BRAKE BOOSTER
VACUUM HOSE
e Turn the crankshaft so that the No.1 cylinder is at
top-dead-center (page 5-41 ) .
e Mark all emissions hoses before disconnecting them.
1 . Disconnect the negative terminal from the battery.
2. Drain the cooling system (page 5-69).
3. Relieve fuel pressure (Fuel-lnjected Engine).
f$l,i{.jfjj@Ci Do not smoke while working on fuel

system, keep o pan flama or spark away from work
area. O rain fuel only into an approved container.
FUEL RETURN HOSE
11 . Remove the throttle cable from the throttle body (page

5-55).
12. Remove the throttle control cable at the throttle body
(A/T only).
1
NOTE: Take care not to bend the cable when removing
FUEL PIPE
it. Do not use pliers to remove the cable from the
4. Disconnect the fuel feed hose. linkage. Always replace a kinked cable with a new one.
5. Remove the vacuum hose, breather hose and air intake
duct.
6. Remove the water bypass hose from the cylinder head. Carbureted Engine:
7. Remove the charcoal canister hose from the throttle
body.
BREATHER HOSE
~~
THROTTLE CONTROL
CABLE (A/T only)
FUEL FEED HOSE

(cont'd)
5-43
Cylinder Head
Removal (cont'd)
Fuel-lnjected Engine: 18. Remove the radiator hoses and heater hoses, then
remove the heater outlet pipe bracket bolt from the
intake manifold.
6 x 1.0 mm
12 N•m (1 .2 kg-m, 9 lb-ftl
Carbureted Engine:
HEATER OUTLET PIPE

UPPER RAOIATOR HOSE
¡
tD
4b
_./~
THROTTLE CONTROL
CABLE (A/T only)
HEATER INLET
13. Disconnect the two connectors from the distributor. HOSE LOWER
e lgnition coil connector RADIATOR HOSE
e TDC/CRANK/CYL sensor connector
14. Remove the spark plug caps and distributor.
1 5. Remove the emission control box (page 5-55). Fuel-lnjected Engine:
e Do not disconnect emission hoses.
e Disconnect the two connectors before removing it.
16. Remove the connector and the terminal from the
alternator, then remove the engine wire harness from
the valve cover.
17. Disconnect the engine wire harness connectors, then
remove the harness clamps from the cylinder head and
the intake manifold.
e Four injector connectors (Fuel-lnjected Engine)
e EACV connector
e TA sensor connector {Fuel-lnjected Enginel
e Thermoswitch (thermostat cover)
e EGR valve lift sensor connector (Standard for sorne
types)
e Throttle angle sensor connector (Fuel-lnjected
Engine) HEATER OUTLET
e TW sensor connector HOSE
e Coolant temperature gauge sending unit
e Thermoswitch (water outlet cover) (Standard for
sorne types)
e Carburetor solenoid valve connectors (Carbureted HEATERINLET
HOSE
Engine)
e Air vent cut solenoid valve connector (Carbureted
Engine except KP, KT models)
5-44
1 9. Remove the thermostat assembly from the intake 21 . Remove the mounting bolts and the V-belt from the
manifold. power steering pump, then without disconnecting the
hoses, pull the pump away from the mounting
bracket.
8 x 1.25 mm
22 N•m (2.2 kg-m,
POWER STEERING 16 lb-ft)
PUMP
THERMOSTAT ASSEMBLY
POWER STEERING
PUMP BELT
20. Disconnect the connector and the vacuum tube, then 22. Lift the car up and support it on safety stands.
remove the cruise control actuator.
NOTE: e Make sure jacks and safety stands are placad

e Do not disconnect the control cable. properly and hoist brackets are attached to cor-
e Take care not to bend the cable when removing the rect positions on the engine (See section 1)
actuator. Always replace a kinked cable with a new e Apply parking brake and block rear wheels, so
one. the car will not roll off stands and fall while you
are working under it.
23. Remove the left front wheel.
CRUISE CONTROL 24. Remove the splash shield (page 5-36).
ACTUATOR 25. Remove the intake manifold bracket bolts.
(cont'd)
5-45
Cylinder Head
Removal (cont' d)
26. Remove the exhaust manifold upper shroud. 31. Remove the valve cover and engine ground wire.
27. Remove the exhaust manifold bracket. 32. Remove the side engine mount bracket stay, then
28. Disconnect the exhaust pipe A from the exhaust remove the timing belt upper cover.
manifold. 33. Loosen the timing belt adjusting bolt, and release the
29. Remove the exhaust manifold from the cylinder head. timing belt.
30. Remove the exhaust manifold heat insulator. NOTE: Push the tensioner to ralease tension from the
belt, then retighten the adjusting bolt.
except 2.2i: EXHAUST 34. Remove the timing belt from the driven pulley.
GASKET MANIFOLD
Replace. BRACKET CAUTION: Do not crimp or bend the
timing belt more than 90° or
EXHAUST less than 25 mm (1 in.) in diameter.
MANIFOLD
35. Remove the cylinder head bolts, then remove the

cylinder head.
CAUTION: To prevent warpage, unscrew the bolts
HOTAIR in sequence 1/3 turn at a time; repeat the sequence
HOSE until all bolts are loosened.
CYLINDER HEAD BOLTS LOOSENING SEOUENCE
(Standard for some types) (Fuel -lnjected

Engine)
EXHAUST PIPE A
2.2i:
EXHAUST MANIFOLD
BRACKET
NOTE: Separate the cylinder head from ·the block with
a flat brade screwdriver as shown.
HEAT INSULATOR
(Standard for soma typesl
5-46
lnstallation
36. Remove the intake manifold. lnstall the cylinder head in the reverse arder of removal:
• Always use a new head gasket.
Carbureted Engine: e Cylinder head and engine block surface must be clean.
• "UP" mark on camshaft pulley should be at the top.
e Turn the crankshaft so the No.1 cylinder is at TDC (top
dead center) (page 5-41).
1 . lnstall the intake manifold and tighten the nuts in a
criss-cross pattern in 2 or 3 steps, beginning with the
inner nuts.
• Always use a new intake manifold gasket.
Carbureted Engine:
t
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ft)
GASKET GASKET
Replace.
INTAKE MANIFOLD
\
8 x 1.25 mm
INTAKE MANIFOLD 22 N·m (2.2 kg-m,
'
16 lb-ft)
8 x 1.25 mm
22 N•m (2.2 kg-m,
16 lb-ftl
{cont'd)
5-47
Cylinder Head
lnstallation (cont'd)
2. Cylinder head dowel pins and oil control jet must be 3. lnstall the bolts that secure the intake manifold to its
aligned. bracket but do not tighten them yet.
4. Position the ca m correctly (page 5-41 J.
5. Tighten the cylinder head bolts sequentially in three
steps.
CYLINOER
HEAO GASKET 1st step torque: 40 N·m (4.0 kg-m, 29 lb-ft)
Replace.- 2nd step torque: 70 N·m (7 .O kg-m, 51 lb-ft)
3rd step torque: 108 N·m (10.8 kg-m, 78 lb-ft)
NOTE:
• We recommend to use a plate-type torque wrench.
When using a preset-type torque wrench, be sure to
tighten slowly and not to overtighten.
• lf the bolt sounds, retighten the bolt from 1st step.
CYLINDER HEAD BOLT TORQUE SEOUENCE

LONGER BOLT
CYLINDER HEAD BOLT

12 x 1.25 mm
108 N·m (10.8 kg-m. 78 lb-ft)
Apply clean engine oil to bolt
thread and under bolt heads.
5-48
6. lnstall the heat ínsulator to the cylinder head and the 2.2i:
cylinder block.
7. lnstaU the exhaust manifold and tíghten the nuts in a 8 x 1.25 mm GASKET
criss-cross pattern in 2 or 3 steps, beginning with the 32 N·m (3.2 kg-m, Replace.
23 lb-ft)
inner nut. ·
e Always use a new exhaust manifold gasket.
8. lnstafl the exhaust manifold bracket, then install the
exhaust pipe A and the bracket, and then install the
upper cover.
except 2.2i:
SELF-LOCKING NUT
8 x 1.25 mm
32 N·m {3.2 kg-m, 23 lb-ft)
Replace.
EGR PIPE GASKET

10 x 1.25 mm
45 N•m (4.5 kg-m,
33 lb-ft)
10 x 1.25 mm
45 N•m (4.5 kg-m,
33 lb-ft)
UPPER
SHROUD
10x 1.25 mm
55 N·m (5.5 kg-m, 40 lb-ft)
Replace.
HEAT INSULATOR
UPPER SHROUD
(Fuel-lnjected Engine)
HEAT INSULATOR
(Standard for soma types)
EXHAUST PIPE A
8 x 1.25 mm
22 N·m {2.2 kg-m, 16 lb-ft)
5-49
Special Tools
;-- S pec1a
. 1 T 00 S
1
Ref. No. Tool Number Description Q'ty Remarks

1
CD 1 07KAK-SJ40100 Engine Tilt Hanger Set 1
~ CD
:
5-52
Engine Removal/lnstallation
4. Remove the battery base.

Hjf4iij§h§id
e Make sure jacks and safety stands are placad
properly and hoist brackets are attached to cor-
rect positions on the angina. (See section 1).
e Apply parking brake and block rear wheels, so
car will not roll off stands and fall on you while
working under it.
CAUTION:
e Use fender covers to avoid damaging painted
surfaces.
e Unspecified items are common for the carburetor
cars, PGM-FI cars, M/T cars. A/T cars, and the
A/C equipped cars.
e Remove the wiring slowly while holding the
coupler and the connector portion to avoid dis- 5. Drain the engine oil. Remove the oil filler capto speed
connecting. draining. Reinstall the drain plug using a new washer.
e Mount the wiring or tubas to avoid mis-
connection. Also, be sure that they do not con- CAUTION: U sed engine oil may cause skin cancer
tact other cords or tubes or interference with if repeatedly left in contact with the skin for pro-
other parts. longad periods. Although this is unlikely unless you
handle used oil on a daily basis, it is still advisable
1. Fix the engine hood in a vertical position. to thoroughly wash your hands with soap and water
e Do not remove the hood. as soon as possible after handling used oil.
2. Remove the engine splash shield.

6. Draín the coolant from the radiator ínto a clean pan so
it may be reused. Remove the radiator cap to speed
draíning.
f·f.S.$¡i§ii§ICJ
Use care when removing the radiator
cap to avoid scalding by hot coolant or steam.
7. Draín transmission oil/fluid. Use a 3/BH drive socket

wrench to remove the drain plug. Remove the oil filler
plug or gauge to speed draining. Reinstall the drain
plug using a new washer.
8. Remove the air intake duct and the air cleaner.
9. Disconnect the connector and the vacuum tube, then
remove the cruise control actuator.
6x1.0mm
10 N·m {1.0 kg-m, 7 lb-ft)
CRUISE CONTRO:,
ACTUATOR
3. Disconnect the battery negative terminal first, then the

positive terminal. Remove the battery.
CAUTION: Clean battery posts and cable terminals

with sandpaper. assemble. then apply grease to
prevent corrosion.
CONNECTOR
(cont'd)
5-53
(cont'd)
1O. Relieve fue! pressure by slowly loosening the service 11 . Remove the fuel feed hose.
bolt on the fuel pipe about one turn (Fuel-lnjected
Engine) (See section 11). 12. Remove the fuel return hose from the PCV valve.
BJ1.¡Df!I§ICI Do not smoke while working on the 1 3. Disconnect the vacuum tu be from the charcoal canis-
fu el system. Keep open flame away from work ter.
area. Drain fuel only into an approved container.
14. Disconnect the charcoal canister hose from throttle
CAUTION: body.
• Before disconnecting any fuelline, the fuel pres-
sure should be relieved as described above. 1 5. Remove the brake booster vacuum hose and mount
• Place a shop towel over the fuel filter to prevent vacuum tu be from the intake ·manifold.
pressurized fuel from spraying over the engine.
16. Remove the ground cable from transmission.
BRAKE BOOSTER
VACUUM HOSE
Fuel-lnjected Engine: Fuel-lnjected Engine:
TRANSMISSION
GROUND TERMINAL
5-54
(cont'd)
22. Remove the mounting bolts and V-belt from the power 24. Disconnect the heater inlet hose from the cylinder
steering pump, then without disconnecting the hoses, head and the heater outlet hose from the connecting
pull the pump away from the mounting bracket. pipe.
POWER STEERING PUMP 10 x 1.25 mm

45 N·m (4.5 kg-m,
33 lb-ft)
25. Disconnect the hoses and connectors to remove the

radiator assembly.
• Upper and lower radiator hoses
e A/T cooler hoses
• Cooling fan motor connectors
MOUNTING BRACKETS
8 x 1.25 mm
22 N·m (2.2 kg-m, 16 lb-ft)
23. Remove the mounting bolts and V-belt from the air
conditioning compressor, then without dísconnecting
the hoses, pull the compressor away from the mount-
ing bracket.
AIR CONDITIONING LOWER CUSHION

COMPRESSOR
A/T COOLANT HOSES
26. Remove the speed sensor.
NOTE: Do not disconnect the hoses and the con-

nector.
6 x 1.0 mm SPEED SENSOR

10 N•m (1.0 kg-m,
7 lb-ft)
Sx 1.25 mm
22 N-m (2.2 kg-m.
16 lb-ft) Remove the connector.
5-56
27. Remove the center beam. Manual transmission equipped cars:
28. Remove the exhaust pipe A self-locknut and bracket 31 . Remove the clutch release hose from the clutch
mounting bolts. damper on the transmission housing.
29. Remove the balljoints of the tierod ends and suspen- 32. Remove the shift cable and the select cable with the
sion lower arms (See section 12). cable bracket from the transmissíon.
30. Remove the driveshafts (See section 10).
NOTE: Take care not to bend the cable when removing
NOTE: Coat all precision finished surfaces with clean it. Do not use pfiers to remove the cable. Always
engine oil or grease. re place a kinked cable with a new one.
Tie plastic bags over the driveshaft ends.
8x1.25mm ~
22 N·m (2.2 kg-m,
16 lb-ft)
Do not remove.
SELECT CABLE
'\
COTTER
PIN
Replace.
/
@)
CONTROL CABLE
HOLDER
CENTER BEAM
TORQUECONVE~
COVER 10 x 1.25 mm Automatic transmission equipped cars:
\ 39 N·m (3.9 kg-m, 33. Remove the engine stiffener, then remove the torque
8 x 1.25 mm 28 lb-ft) converter cover.
1
18 N·m (1 .8 kg-m. 34. Remove the cable holder, then remove the shift con-
13 lb-ftl trol lever bolt and shift control cable.
6 x 10 mm NOTE: Take care not to bend the cable when removing

12 N·m (1.2 kg-m, it. Do not use pliers to remove the cable. Always
9 lb-ft) replace a kinked cable wíth a new one.
5-57
(cont'd)
35. Attach a chain hoist to .the engine. Raise the hoist to 41. Sfowly raise the engi ne approximately 6.
remove all slack from the chain. Check once again that all tubes, hoses and wires have
36. Remove the rear engine mounting bolt. been disconnected from the engine/ transaxle.
37. Remove the front engine mounting bolt. 42. Raise the engine/transaxle all the way and remove it
38. Remove the side transmission mount and mounting from the car.
bolt. 43. Remove the rolling insulator from the rear beam.
39. Remove the side engine mount and mounting bolt.
40. Check that the engine/transaxle is completefy free of
vacuum tubes, fuel and coolant hoses, and electric
wires.
AUTOMATIC TRANSMISSION:
REAR ENGINE
MOUNT
Carbureted Engine
with MANUAL TRANSMISSION
5-58
44. lnstall the engine in the reverse order of removal. • Check the clutch pedal free play.
After the engine is in place: e Check that the transmission shifts into gear
e Torque the engine mounting bolts in sequence smoothly.
shown below. • Adjust the tension of the following drive belts
Alternator (Air Conditioner) belt (page 5-11).
CAUTION: Failure to tighten the bolts in the proper Power steering belt (page 5-13).
sequence can cause excessive noise and vibration. • Clean battery posts and cable terminals with sand-
and reduce bushing life: check that the bushings are paper, assemble, then apply grease to prevent
not twisted or offset. corrosion.
e lnspection for fuel leakage.
e Check that the spring clip on the end of each • After assembling fuel line parts, turn on the
driveshaft clicks into place. ignition switch (do not operate the starter) so
that the fuel pump is operated for approximately
CAUTION: Use new spring clips on installation. two seconds and the fuel is pressurized. Repeat
this operation two or three times and check
e Bleed air from the cooling system at the bleed bolt whether any fuel leakage has occurred at any
with the heater valve open. point in the fuel fine.
e Adjust the throttle cable.
<DTighten snug only.
Engine Mounting Torque Sequence: 12 x 1.25 mm
@55 N•m (5.5 kg-m. 40 lb-ftl
CAUTION: After loosening the special bolts. be
sure to re place them with new ones.
~
~!~~~~~--J
T~SMI.SSlON:
Carbureted Engine:
with MANUAL TRANSMISSION: @Tighten snug only.
12 x 1.25 mm
@55 N·m (5.5 kg-m.40 lb-ftl
5-59
(cont'd)
Additional Torque Valve Specifications:
NOTE: 8 x 1.25 mm
e For manual transmission removal/installation, refer to Section 8. 22 N·m (2.2 kg-m,
16 lb-ft)
e For automatic transmission removal/installation, refer to Section 9.
POWER STEERING
BRACKET
SIDE TRANSMISSION
MOUNTING BRACKET
8 x 1.25 mm
BRACKET STAY 22 N·m ( 2 · 2 kg-m.
~···~ftl~
10 x 1.25 mm
39 N·m (3.9 kg-m,
28 lb-ft)
Carbureted Engine
with MANUAL TRANSMISSION: {)
10x 1.25 mm
48 N•m (4.8 kg-m.
35 lb-ft)
10x1.25mm
39 N•m (3.9 kg-m,
28 lb-ftl
ALTERNATOR
BRACKET
10 x 1.25 mm
50 N·m (5.0 kg-m.
10 x 1.25 mm
36 lb-ft)
50 N•m (5 .O kg-m, Apply liquid gask.et
36 lb-ft) to the bolt threads.
COMPRESSOR
BRACKET
5-60
Subframe Torque Value Specifications:
CAUTION: After loosening the special bolts. be sure to

replace them with new ones.
REAR BEAM
SPECIAL BOLT
12x1.25mm
60 N•m (6.0 kg-m.
43 lb-ft)
Re place.
SPECIAL BOLT
12 x1.25 mm 10 x 1.25 mm
60 N•m (6.0 kg-m. 39 N·m (3.9 kg-m. 28 lb-ft)
43 lb-ft)
Replace. ®
FRONT BEAM
)
SPECIAL BOLT
12 x 1.25 mm
60 N·m (6.0 kg-m.
43 lb-ftl
Re place.
5-61
Exhaust Pipe and Muffler
Replacement
NOTE: Use new gaskets and self-locking nuts when reassembling.
MUFFLER
Fuel-lnjected
Engine {except
KQ,KU,KY
models)
CATALYTIC CONVERTER
TORQUE SEQUENCE 6 x 1.0 mm
10 N·m {1.0 kg-m. 7 lb-ft)
HEAT SHIELDS
6 x 1.0 mm
10 N•m (1 .O kg-m. 7 lb-ft)
Re place.
EXHAUST PIPE B
SELF-LOCKING NUT
10 x1.25 mm
Replace. 34 N•m (3.4 kg-m. 25 lb-ft)
Replace.
GASKET SELF-LOCKING NUTS
---SELF- LOCKING NUT

10 x 1.25 mm
SELF-LOCKING NUTS 34 N·m {3.4 kg-m, 25 lb-fd
10x1.25mm EXHAUST PIPE A Replace.
55 N•m (5.5 kg-m, (except 2.2i)
40 lb-ft)
Replace.
5-64
Radiator
lllustrated lndex
Carbureted Engine:
H\t.Ji§ilfM System is under high pressure when

engine is hot. To avoid danger of releasíng scalding
coolant, remove cap only when engine is éool.
Total Cooling System Capacity (lncluding heater and RAOIATOR
reservoir) Refilling and bleeding, page 5-69
1.8i Leak test, page 5-70
M/T: 6.6l (7.0 US qt, 5.8 lmp qt) lnspect soldered joints and
A/T: 6.5l (6.8 US qt, 5.7 lmp qt) seams for leaks.
2.02 Blow out dirt from between
core fins w[th compressed air.
M/T: 7 .2l (7. 6 US qt, 6.4 lmp qt)
lf insects, etc., are clogging
A/T: 7.1 t (7 .5 US qt, 6.3 lmp qt)
radiator. wash them off with
CAUTION: When supplying coolant, be sure to shut the low pressure water.
relay box lid and not to let coolant spill on the electrical
parts or the painted portion. lf any coolant spills, rinse it
off immediately. RAOIATOR CAP
Pressure test, page 5-70
NOTE:
• Check all cooling system hoses for damage, leaks or
1 e
deterioration and re place if necessary.
Check all hose clamps and retighten if necessary.
• Use new 0-rings when reassembling.
-~
El
1COOLANT
RESERVOIR
6x 1.0mm
7 N•m {0.7 kg-m, 5 lb-ft)
CONNECTING PIPE ~~~,~

LOWER
RAOIATOR
HEATER INLET HOSE HOSE
5-66
fi'f".j;ffi@ICI
System is under high pressure when
engine is hot. To avoid danger of releasing scalding RADIATOR
coolant. remove cap only when engine is cool. · Refilling· and bleeding, page 5-69
Leak test, page 5-70
Total Cooling System Capacity (lncluding heater and lnspect soldered joints and
reservo ir) seams for leaks.
2.0l and 2.2i (except 2.2i) Blow out dirt from between
M/T: 7 .21. (7 .6 US qt. 6.4 lmp qt) core fins with compressed air. RADIATOR CAP
A/T: 7.11. (7.5 US qt, 6.3 mp qt) lf insects, etc., are clogging Pressure test, page 5-70
2.2 i {2.2i) radiator, wash them off with
M/T: 6.6l (7.0 US qt, 5.8 lmp qt) low pressure water.
A/T: 7 .H (7 .5 US qt, 6.3 lmp qt)
CAUTION: When supplying coolant, be su reto shut the
relay box lid and not to let coolant spill on the electrical
parts or the painted portion. lf any coolant spills, rinse it
off immediately.
NOTE:
e Check all cooling system hoses for damage, leaks or
deterioration and replace if necessary.
e Check all hose clamps and retighten if necessary.
e Use new 0-rings when reassembling.
6 x 1.0 mm Replace.
7 x N·m {O. 7 kg-m, 5 lb-ft)
ENGINE Oll COOLER
HEATER OUTLET
HOSE
LOWER
RADIATOR
HEATER INLET HOSE
HOSE
5-67
Radiator
Replacement
1. Drain the coolant from the radiator. 3. Disconnect the upper and lower radiator hoses from
• Remove the radiator capto speed draining. cylinder head.
Ni·i#ijiifM Use care when removing radiator to 4. Disconnect the ATF cooler hose (A/T).
avoid scalding by hot coolant or steam.
NOTE: Plug the hoses and pipes.
2. Remove the connectors from the cooling tan motor
and thermoswitch. 5. Remove the radiator bracket and radiator.
6 x 1.0 mm
1 O N·m 11 .O kg-m. O. 7 lb-ft)
UPPER UPPER CUSHION

RADIATOR
HOSE
LOWER
RADIATOR
HOSE
NOTE:
e lnstall the radiator in the reverse order of removal.
e Before installing the radiator, set the radiator lower cushion securely under it.
5-68
Refilling and Bleeding
CAUTION: When supplying coolant. be sure to shut the 9. Loasen the air bleed bolt in the water inlet, then fill the
relay box lid and not to let coolant spill on the electrical radiator to the bottom of the filler neck with the
parts or the painted portian. lf any coolant spills, rinse it coolant mixture. Tighten the bleed bolt as soon as
off immediately. coolant starts to run out in a steady stream without
bubbles.
1. Set the heater temperature dial to maximum heat.
2. Remove the engine splash shield under the engine. BLEED BOLT
10 N·m (1.0 kg-m, 7 lb-ft)
3. When the radiator is cool, remove the radiator cap.
Loasen the drain plug, and drain the radiator.
4. Remove the drain bolt from the rear side of the cylinder
block to drain the block and heater.
5. Apply liquid gasket to the drain bolt threads, then

reinstall the bolt with a new washer and tighten it
securely.
6. Tighten the radiator drain plug securely.
7. Remove, drain and reinstall the reservoir. Fill the tank

halfway to the MAX mark with water, then up to the
MAX mark with coolant.
8. Mix the recommended anti-freeze with an equal

amount of water in a clean container.
NOTE:
e Use only HONDA-RECOMMENDED anti-freeze/
coolant.
ENGINE OIL COOLER
e For best corrosion protection, the coolant concen- (Standard for some types)
tration must be maintained year-round at 50 %
MINIMUM. Coolant concentratíons less than 50 %
may not provide sufficient protection against corro-
sien or freezing.
e Coolant concentrations greater than 60 % will

impair cooling efficiency and are not recommended.
CAUTION:
e Do not mix different brands of anti-freeze/
coolants.
e Do not use additional rust inhibitors or anti-rust
products: they may not be compatible with the
recommended coolant.
Radiator Coolant Refill Capacity: including reser-

voir (0.6i (0.6 US qt, 0.51mp qt)) and heater. DRAIN BOLT
WASHER 50 N•m 5.0 kg-m, 36 lb-ft)
Replace.
Apply liquid gasket to
bolt threads when installíng.
1.8 t
M/T: 6.61 (7.0 US qt, 5.8 lmp qt)
A/T: 6.5i (6.8 US qt, 5.7 lmp qt)
2.01 and 2.21 (except 2.2i) 10. With the radiator cap off. start the engine and let it run
M/T: 7.2i (7.6 US qt, 6.41mp qt) until warmed up (the cooling fan comes on at least
A/T: 7.11 (7.5 US qt, 6.3 lmp qt) twice).
2.2l (2.2i) Then, if necessary, add more coolant mixto bring the
M/T: 6.61 (7.0 US qt, 5.8 lmp qt) leve! back up to the bottom of the filler neck.
A/T: 7.1 l (7 .5 US qt, 6.3 lmp qt)
11 . Put the radíator cap on, then run the engine again and
check for leaks.
5-69
Radiator
Cap Testing
1. Remove the radiator cap, wet its seal with coolant,
then insta\\ it on the pressure tester.
2. Apply a pressure of 93-123 kPa {0.95-1.25 kg/

cm 2 , 14-18 psi).
3. Check for a drop in pressure.
4. lf the pressure drops, replace the cap.
RADIATOR PAESSUAE
TESTEA
Testing
1. Wait untilthe engine is cool, then carefully remove the
radiator cap and fill the radiator with coolant to the top
of the filler neck. RADIATOR PAESSURE TESTEA
2. Attach the pressure tester to the radiator and apply a

pressure of 93-123 kPa (0.95-1.25 kg/cm 2 , 14
-18 psi).
3. lnspect for coolant leaks anda drop in pressure.
4. Remove the tester and reinstall the radiator cap.
NOTE: Check for engine oil in the coolant and/or

coolant in engine oil.
5-70
Thermostat
Replacement
NOTE: Use new 0-rings when reassembling.
(m BLEED BOLT
{1.0 kg-m. 7 lb·ftl
6 x 1.0 mm
12 N·m (1.2 kg-m. 9 lb-ft)
Replace.
THERMOSTAT
HOUSING
THERMOSTAT HOUSING
INLET
Testing
Replace the thermostat if it is open at room temperature.
T o test a el o sed thermostat:
1. Suspend the thermostat in a container óf water as

shown. THERMOMETER
2. Heat the water and check the temperature with a

thermometer. Check the temperature at which the
thermostat first.opens, and at which it is fully open.
CAUTION: Do not let the thermometer touch the

bottom of container.
3. Measure lift height of the thermostat when fully open.

THERMOSTAT
STANDARD THERMOSTAT
Lift height: above 8.0 mm (0.31 in.)
Starts opening: 76-80 °C (169-176 °F)
Fully open: 90 oc (194 °F)
-
....,//....
,/
----~./
5-71
Water Pump
lnspection Replacement
1. Remove the timing belt (page 5-36). 1. Remove the timing belt (page 5-36).
2. Check the water pump pulley turns freely. 2. On screw the bolt, then remove the water pump.
NOTE: Small amount of uweeping" from the bleed hole
is normal.
BLEED HOLE
RUBBER SEAL
Apply sealant to
water pump mating
surface.
3. Instan the water pump in the reverse order of removal.
5-72
Special Tools
SpeciaiTools----------------------------------------------------.
Ref. No. Tool Number Description Q'ty Remark
CD 07411-0020000 Digital Circuit Tester

® 07614-0050100 Fuel Une Clamp
® 07 JAZ -SH 201 00 R.P. M. Connecting Adaptor
@ 07LAJ-PT30100 ECU Test Harness
® 07 LAJ -PT30200 Test Harness
® 07LAZ-PT301 00 R.P. M. Connecting Adaptor
®-1 07LAZ-PT3011 O R.P.M. Connecting Adaptor (A)
@-2 R.P.M. Connecting Adaptor (B) ] - Component Tools
07LAZ-PT30120
([) 07LAA-PT50100 02 Sensor Socket Wrench
CD
®
@(@-1)
®1®-2)
6-2
Component Locations
lndex--~----------------------------------------~--------------
(KX. KS, KG)
CONTROL BOX
page 6-9
EGR VALVE
COOLANT TEMPERATURE (TW)
SENSOR
Troubleshooting, page 6-36 THERMOVALVE B
THERMOVALVE A
Troubleshooting, page 6-24

Troubleshooting, page 6-1 04
Troubleshooting,
P/S OIL PRESSURE
page 6-39
SWITCH
'\ \
PGM CARB CONTROL UNIT

6-3
Component Locations
lndex--------------~----------------------------------------------
(KQ)
AIR SUCTION VALVE CONTROLBOX

Testing, page 6-107
AIR BLEED VALVE
6-4
(KB, KF, KW, KV, KP) THROTTLE CONTROLLER CONTROL VALVE (M/T)
T esting. page 6-11 3
IDLE BOOST SOLENOID VALVE
A/C IDLE BOOST SOLENOID VALVE

THERMOVALVE
AIR BLEEDVA~
~
6-~~~~
Testing, page
P/S OIL PRESSURE SWITCH
(KE, KT)
THROTTLE CONTROLLER CONTROL VALVE (M/T)
Testing, page 6-113
THERMOVALVE

THERMOVALVE
AIRBLEEDV~
Testing. page 6-1 00
P/S OIL PRESSURE SWITCH
6-5
Component Locations
lndex-------------------------------------------------------------
AIR CLEANER ELEMENT

• EC, KQ: Replace every
2 years or 40,000 km (24,000
miles) whichever comes first.
• Others: Replace every 1
year or 20,000 km (12,000miles)
whichever comes first.
THROTTLE CABLE
lnspection/Adjustment, page 6-99
lnstallation, page 6-99
6-6
FUEL PUMP
Testing, page 6-94
Replacement page 6-95
CARBURETOR
Removal, page 6-90
FUEL FILTER {REAR)

Replace every 2 years or 40,000 km
(24,000 miles) whichever comes first.
Testing, page 6-115
FUEL FILTER {FRONT) FUEL TANK

Replacement, page 6-94 Replacement, page 6-97
Replace every 2 years or 40,000 km
(24,000 miles), whichever comes first. FUEL FEED PIPE
(LH) (RH)
FUEL CUT-OFF RELAY

. Testing, page 6-96
6-7
Sy~emDescri~io:n~-----------------
Vacuum Connections
(KX, KS, KG)
AIR CLEANER
AJC (KX, KS)
6-8
Control Box
(KX. KS, KG)
EGR CONTROL VALVE

VACUUM SWITCH Testing, page 6-11 O
PURGE CUT-OFF SOLENOID VALVE

AIR LEAK SOLENOID VALVE


Troubleshooting,
page 6-56
MANIFOLD ABSOLUTE PRESSURE

(MAP) SENSOR
POWER VALVE
CONTROL SOLENOID AIR SUCTION CONTROL
VALVE SOLENOID VALVE CHECK VALVE AIR FILTER
Troub!eshooting, page 6-71 Troubleshooting, page 6-108
6-9
System Description
Vacuurn Connections---------------------------------------------------
(KOI
CONTROL
BOX
AIR CLEANER
6-10
Control Box
(KQ)
AIR LEAK SOLENOID VALVE

PURGE CUT-OFF A/C IDLE BOOST SOLENOID VALVE
SOLENOID VALVE Troubleshooting, page 6-61
POWER VALVE CONTROL

SOLENOID VALVE
T roubleshooting, page 6-71

MANIFOLD ABSOLUTE PRESSURE (MAP)

VACUUM SWITCH
SENSOR
6-11
System Description
Vacuurn Connection--------------------------------------------------~
(KT, KP)
THROTTLE CONTROLLER CONTROL VALVE (M/T)
AIR CHAMBER {M/T)
AIR CLEANER
6-12
(KV, KF, KB, KE, KW)
THROTTLE CONTROLLER CONTROL VALVE lM/T)
AIR CHAMBEM (M/T)
AIR CLEANER
A/C IDLE BOOST

SOLENOID VALVE
6-13
System Description
Vacuurn Connections-----------------------------------------------------
{KX, KS, KG, KQ)
¡ {KQ)
1
~-r--11
1
1
1 1
1:
J
.
1
• 1
®
'1
1 1
:
to (KX, KS)
--tuel
tan k
,----ÁJCl
1
1'
_ ____:_~
{KX, KS)
:-(,=~toA.J¡.-c~
l!t=~. i
,2nd-
1
® ®
L____ to carburetor
L=~l=--... toca~~ [_ _____ _j
CDAIR CONTROL DIAPHRAGM @POWER VALVE CONTROL SOLENOID VALVE

®AIR BLEED VALVE @THROTTLE CONTROLLER
®CHECK VALVE @CHOKE OPENER
@VACUUM SWITCH @AIR SUCTION VALVE
@FAST IDLE UNLOADER @AIR SUCTION CONTROL SOLENOID VALVE
®EACV @AIR CHAMBER
(])SECONDARY DIAPHRAGM @IDLE BOOST THROTTLE CONTROLLER
@AIR LEAK SOLENOID VALVE @IDLE BOOST SOLENOID VALVE
®AIR FILTER ~A/C IDL.E BOOST SOLENOID VALVE
@EGR CONTROL VALVE @AIR VENT CUT-OFF SOLENOID VALVE
(j])EGR VALVE @CANISTER
@MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @TWO-WAY VALVE
@THERMOVALVE A @PURGE CUT-OFF SOLENOID VALVE
@POWER VALVE @THERMOVALVE B
®CHECK VALVE
6-14
(KF. KB. KE, KV. KW)
,y,-~-~-~=~=~=-~--~-~=~~~~~~~~~~~~~~~~~~~-~--~-~=~~~~~~~~~--~--~--~-~=~-~--~-~-~-~-~-~-~-~-~-~-~-~-~-~-~-~-~-~--~-
1
1
1
1
1
1
1
1
1
L--------------------
lKYl
~--~ 1
! fuel --- =~ \ ¡
1
~------'·11
<DAIR CONTROL DIAPHRAGM @CHOKE OPENER

®AIR BLEED VALVE @IDLE BOOST THROTTLE CONTROLLER
®CHECK VALVE @IDLE BOOST SOLENOID VALVE
@FAST IDLE UNLOADER @A/C IDLE BOOST SOLENOID VALVE
@POWER VALVE @SECONDARY DIAPHRAGM
@THROTTLE CONTROLLER (M/T) @THERMOVALVE D
CDTHROTTLE CONTROLLER CONTROL VALVE (M/T) @THERMOVALVE C
@AIR CHAMBER (M/T) @THERMOVALVE A
®THROTTLE CONTROLLER (A/T) @CANISTER
@CHECK VALVE (A/T) @TWO-WAY VALVE
@AIR VENT CUT-OFF SOLENOID VALVE
6-15
System Description
Vacuum C o n n e c t i o n s - - - - - - - - - - - - - - - - - - - - - - - - - -
(KP, KT)
(------------------------------------------------------
r-- ----------------------------------------------- ------¡ :
1 1 1 1
=t
1 1 1
' 1 ~ ~
!)!,----~
. .!!! ____ ,
®
1
t!J:1(])
:rr---J )
to head cover : 1 ,---J
(~
1 1
i lLhJ r~tr
,i ! ir
. ·---------------------
1
11,1
1 1
1 1
~
1'
1 1
1'
'1
1 1
1 '1
1
1 1'
1'
1 ! 1
L ______________ _
1 1 1
==-~-----------~-= =-=--_-:_)
e@
CDAIR CONTROL DIAPHRAGM <[DCHOKE OPENER

®AIR BLEED VALVE @IOLE BOOST THROTTLE CONTROLLER
®CHECK VALVE @IDLE BOOST SOLENOID VALVE
@FAST IDLE UNLOADER ®A/C IDLE BOOST SOLENOID VALVE
@POWER VALVE @SECONDARY DIAPHRAGM
@THROTTLE CONTROLLER (M/T) @THERMOVALVE D
(l)THROTTLE CONTROLLER CONTROL VALVE (M/T) @THERMOVALVE C
@AIR CHAMBER (M/T) @THERMOVALVE A
®THROTTLE CONTROLLER {A/T)
@CHECK VALVE (A/T)
6-16
Electrical C o n n e c t i o n s - - - - - - - - - - - - - - - - - - - - - - - -
(KX. KS. KG. KQ)
YEL~
FUEL
CUT-OFF
RElAY
FUEL
PUMP
p
IGNITION BlKI
COIL YEL BLK BLK
AIC
SWITCH
AIT
SHIFT
POSITION
INDICATOR
A/C
CUJTCH
RERAV
j__l
VACUUM G401 G601
SWITCH
·-~\
~~
1 BLKI
YEI..I BLU
BLK
06 os A19 AS A3 07 02 018 015 022 020 011 01

ACS ACC NE EACV+ PC TA TW SG vcc PB IG1
BLK/. 09
YEL VSP
08 011 A21 013 021 A10 A23 AS AZ6 A6 A4 A2
CLU PSW FCS 02 LG PG IUSI PJS SLS1 ASS PGS IUS2
GRNJ
REO
CLUTCH
SWITCH
{MITJ
.JAIR VENT CUT-OFF SOlENOID VALVE

@PRIMAAY SLOW MIXTURE CUT-OFF SOLENOIO VAl... VE
J'lDLE BOOST SOLENO!D VALVE
.:!'PQWER VALVE CONTROL SOlENOIO VAL VE
O, SENSOR ~AIR LEAK SOLENOID VALVE
-~AIR SUCTION CONTROL SOLENOJD VAL VE
.J)PURGE CUT-OFF SOLENOIO VAL VE
:tA/C /OLE BOOST SOlENOID LAlVE
PIS
OH. PRESSVER
SWITCH
BLK
BLK
G401
1 G301 Gl01 GZ01
Al A3 AS A7 A9 Al! Al J. Al5 Al7 Ai9 A21 A23 A25 Dt 03 DS. 07 09 DI! 013015017 019 021
0000000000000 00000000000
0000000000000 00000000000
A2 A4 A6 AB AJOAI2AI4AI6AI8 A20AZZA24 A26 02 04 D6 08 010012 014 016 018020 022
TERMINAL LOCATION
6-17
System Description
Electrical C o n n e c t i o n s - - - - - - - - - - - - - - - - - - - - - - - -
(Except KX, KS, KG, KQ)
FUEL
CUT-OFF
RE LAY
r-------------~
YEL
BLK/
~FUEL
YEL YPUMP
DE LAY
CONTROL
IGNITION - -
1_
UNIT
COIL
G401 G601
BLK/
1 YEL r---....--RED
RED PRIMARY BLK/
SLOW YEL BLK/
ID LE MIXTURE 1 YEL
BOOST CUT-OFF GRN/
SOLENOID AIR
A/C SOLENOID RED
VALVE VENT
ID LE VALVE
CUT-OFF
BOOST RED SOLENOID
V
SOLENOID VALVE
VALVE (Exept KP, KT)
BLK
1 G301
A/C SWITCH
1
G301
6-18
Troubleshooting
Self-Diagnostic Procedure - - - - - - - - - - - - - - - - - - - - - - - - - ,
Turn the ignition on, pull down the passenger's side carpet from under the dashboard and observe the LED on the top of the
control unit. The LED indicates a system failure code by its blinking frequency.
The control unit LED can indicate any number of simultaneous component problems by blinking separate codes, one after
another.
LEO
DISPLAY
Separate Problems:
= See Problem CODE 1

Simultaneous Problems:
= See Problem CODE 1 and 2

= See Problem CODE 2 and 4
= See Problem CODE 1.2 and 3
SELF-DIAGNOSIS
! SYSTEM INDICATED PAGE
INDICATOR BLINKS
1 OXYGEN CONTENT 6-24
2 VEHICLE SPEED PULSER 6-26
3 MANIFOLD ABSOLUTE PRESSURE 6-27
4 VACUUM SWITCH SIGNAL ! 6-32
5 MANIFOLD ABSOLUTE PRESSURE 6-29
' 6 COOLANT TEMPERATURE !
6-36
8 IGNITION COIL SIGNAL 6-38
10 INTAKE AIR TEMPERATURE 1 6-39
14 ELECTRONIC AIR CONTROL 6-105
lf CODE 7, 9, 11, 12, 13 (or more than 14), count the number of blinks again; if the indicator is in fact blinking these codes,
substitute a known-good control unit and recheck. lf the indication goes away, replace the original control unit. The control unit
LED may come on, indicating a system problem, when, in fact, there is a poor or intermittent electrical connection. First, check
the electrical connections, clean or repair connections if necessary.
(cont'd)
6-19
Troubleshooting
Self-Diagnostic ·Procedure (cont'd) - - - - - - - - - - - - - - - - - - - - - ,
lf the inspection for a particular code requires the ECU test harness, remove the door sill moldíng, the small cover on the kick
panel, and pull the carpet back to expose the control unit. Unbolt the control unit bracket. Remove the control unit from the
bracket. Connect the ECU test harness. Then check the system according to the procedure described for the appropriate code
(s) listed on the following pages.
DIGITAL
CIRCUIT
TESTEA
07411-0020000
ECU TEST HARNESS

07LAJ-PT301 00
0000000000000 00000000000
0000000000000 00000000000
A2 A4 A6 AS Al O Al2 Al4 Al6 Al8 A20 A22A24 A26 D2 D4 D6 D8DIODI2DI4D16DI8D20D22
TERMINAL LOCATION
CAUTION:
• Puncturing the insulation on a wire can cause poor or intermittent electrical connections.
• For testing at connectors other than the ECU test harness, bring the tester probe into contact with the terminal
from the connector side of wire harness connectors in the engine compartment. For female connectors, just
touch lightly with the tester probe and do not insert the probe.
RUBBER SEAL - TESTEA PROBE
WIRE HARNESS
TERMINAL
6-20
How to Read Flow C h a r t s - - - - - - - - - - - - - - - - - - - - - - - ,
A flow chart is designed to be used from start to final repair. lt's like a map showing you the shortest distance~ But beware; if
you go off the "map" anywhere but a "stop" symbol, you can easily get lost.
j START 1
Describes the conditions or situation to start a troubleshooting flow chart.
(bold type)
1 ACTION l Asks you todo something; perform a test. set up a condition, etc.
<DECISION) Asks you about the result of an action by giving an "answer" and asking did you get the same answer: Yes or No.
STOP i The end of a series of actions and decisions, describes a final repair action and sometimes directs you toan earlier
(bold type) part of the flow to confirm your repair.
NOTE:
e The term "lntermittent Failure" is used severa! times in these charts. lt simply means a system may have had a failure, but it
checks out OK through all your tests. You may need to road test the car to reproduce the failure or if the problem was a loose
connection, you may have unknowingly solved it while doing the tests.
e "Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental
connection of a wire to ground. In simple electronics, this usually means something won't work at all. In complex electronics
{like electronic control units), this can sometimes mean something works, but not the way it's supposed to.
e lf the electrical readings are not as specified when using the ECU test harness, check the test harness connections befare
proceeding.
6-21
Symptom-to System Chart
(KX. KS. KG. KQ)

NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the order they should be
inspected starting with CD. Find the symptom in the left column, read across to the most likely source, then refer to the page listed
at the top of that column. lf inspection shows the system is OK, try the next most likely system ®, etc.
~
PGM-CARB CONTROL SYSTEM
IPAGE
PGM-CARB VEHICLE MANIFOLD COOLANT
:
OXYGEN ABSOLUTE VACUUM TEMPERA- IGNITION 1
CONTROL SENSOR SPEED COIL
UNIT PULSER PRESSURE SWITCH TURE SIGNAL
1
SENSOR SENSOR
'SYMPTOM 41 24 26 27, 29 32 36 38
1 SELF-DIAGNOSIS
. (LED) BLINKS
INDICATOR
~r0 -0 0- {j)o~ 0 0 m
1 ENGINE WON'T START
:
DIFFICULT TO START @ :
ENGINE WHEN COLO
WHEN COLO
FAST IDLE OUT @ :
~
OF SPECIFIC 1
:
ROUGH toLE @ @ ® i
.,
¡IRREGULAR
.IDUNG WHEN WARM
1 ENGINE SPEED @
, TOO HIGH
1
WHEN WARM
ENGINE SPEED @
TOO LOW
WHILE
FREQUENT
WARMING UP @ !
® @
STALLING
AFTER
®
1
i
WARMING UP @ i
1 MISFIRE OR
ROUGH
, RUNNING
@ @ @ ®
FAILS
POOR
PERFORMANCE
EMISSION
TEST
@ (2) CD
:
LOSS OF
POWER @ @ ¡
1 1
CODE 7, 9, 11, 12, 13, or exceeds 14: count the number of blinks again. lf the indicator is in fact blinking these codes,
substitute a known-good control unit and recheck. lf the indication goes away, replace the original ECU.
@: When the self-diagnosis indicator is on, the back-up system is in operation.
Substitute a known-good control unit and recheck. lf the indication goes away, replace the original ECU.
6-22
PGM-CARB CONTROL SYSTEM EMISSION CONTROL
1 INTAKE A/T
AIR SHIFT CLUTCH P/S OIL CARBURETOR FUEL SUPPLY AIR INTAKE ELECTRONIC OTHER
SWITCH PRESSURE A/C AIR CONTROL EMISSION
\ TEMPERA- POSITION SIGNAL
TURE SlGNAL SWITCH VALVE CONTROL
SIGNAL
SENSOR 1
39 42 44 46 48 50 93 98 105 101
(gt <8!
1
1 i
1
CD CD
CD
¡
® CD ® 1
1 !
® CD ® ® 1
! ® @ CD
1
CD 1
1
CD ®
1
1
CD CD
CD (2)
1
CD 1
® ® ®
1
® 1
1
(2) CD CD
6-23
PGM-CARB Control System
Troubleshooting Flow Chart--Oxygen S e n s o r - - - - - - - - - - - -
-0 Self-diagnosis LED blinks once: A problem in the Oxygen (02J Sensor circuit.
LEO indicates CODE 1.
Turn the ignition switch OFF.
Remove BACK UP fuse in the

•· ' under-hood relay box for 1 O sec- ·
t
. onds to reset control unit.
J
Warm up engine to normal operat-
ing temperatura (the cooling fan
comes on).
1
>N_O___-ll lntermittent failure {test driveJ
Does LEO indicate CODE 1
l
!,
may be necessary).
\ YES
lnspect fuel pressure at the fuel
filter.
1
Repair fuel supply system (page

ls pressure as specified ?
6-93).
YES
Disconnect wire harness from in-

dicated 02 sensor.

ing temperatura again, then open
the throttle wide open then close
it.
i Measure voltage between the con-
l nector terminal and body ground.
DIGITAL CIRCUIT TESTER

07411-002000
ls voltage abo ve O. 6 V at wide \
open throttle and below 0.4 V ;NO Replace 02 sensor.
\ when the throttle is quickly
\released ?
1
1 YES
(To page 6-25)
6-24
(From page 6-24}
Stop engine.
Reconnect 02 sensor.
Connect the ECU test harness

between the control unit and con- 0.4-o.sv 7
nector (page 6-20). ,----,
0131+1 021 (-}
0000000000000
Restart and warm up engine to 0000000000000
normal operating temperature,
then open the throttle wide open
then close it.
Mea su re voltage between O 13 ( + 1

terminal and 021 (-) terminal.
ls voltage above 0.6 V at wide

Repair open or short in WHT wire
open throttle and below 0.4 V
between control unit (013} and
when the throttle is quickly
the Oz sensor.
\released?
1 YES
Substituta a known-good control

unit and recheck. lf symptom/
indication goes away, replace
the original control unit.
©
~ ........_ (r¡~
/~r/
OzSENSOR SOCKET WRENCH
07LAA-PT501 00
45 N·m (4.5 kg-m, 33 lb·ft}
6-25
Troubleshooting Flow Chart--Vehicle Speed Sensor------------.
W Self-diagnosis LEO indicator blinks two times: A problem in the Vehicle Speed circuit.
Connect the ECU test harness i'

between the control unit and con-
i nector (page 6-20).
Block rear wheels and set the park-

fiifl.S¡I§IIHM Block
1 rear wheels before
ing brake. Jack up the front of the
jacking up front of car.
car ánd support with safety
stands.
1
1
1 Turn the ignition switch ON. 1

0-5 V?
1 1 1
09 (+) 021 (-)
Slowly rotate front wheel and
measure voltage between 09 (+) 0000000000000
terminal and O 2 1 ( -) terminal. 0000000000000
!
NO 1
Does voltage pulse O V and 5 V? Turn the ignition switch OFF.
\
1 VES 1
Substituta a known-good control Oisconnect O connector from the

unit and recheck. lf prescribed control unit only, not the wire
voltage in now available replace harness.
Turn the ignition SWitCh ON.

1
Slowly rotate front wheel and

measure voltage between 01 (-)
terminal and 09 (+)terminal.
-Repair open or short
1 in ORN wire bet·
NO ween control unit
Does voltage pulse O V and 12 V ?
(09) and the speed
1 VES sensor.
-Faulty speed sensor.
unit and recheck. lf prescribed
voltage is now available replace
the eriginal control unit.
1
0000000000000
0000000000000
6-26
Troubleshooting Flow Chart-- MAP S e n s o r - - - - - - - - - - - - - - .
Self-diagnosis LEO indicator blinks three times: Most likefy an electrical problem in the Manifold Absolute Pressure
(MAP) Sensor system.
Self-diagnosis LEO indicator blinks five times: Most likely a mechanical problem (broken hose) in the Manifold Absolute
Pressure (MAP) Sensor system.
-Engine is warm and running.

-LEO indicates CODE 3.

under-hood relay box for 1 O sec-
onds to reset control unit.
Start the engine and atlow to idle.
lntermittent failure {test drive TEST HARNESS

Does LEO indicate CODE 3 7 m ay be necessary). 07 LAJ-PT30200
i YES
Connect the test harness between

the MAP sensor and wire harness.
Turn the ignítion switch ON.
Measure voltage between RED ( +)

terminal and GRN (-)terminal.
Measure voltage between RED{+ l

ls there approx. 5 V ?
terminal and body ground.
YES
Repair open in BLU/
Measure voltage between WHT YES WHT wire between
(+)terminal and GRN (-) termi- control unit (022} and
nal. NO MAP sensor.

(To page 6-28)
(To page 6-28)
(cont'd)
6-27
Troubleshooting Flow Chart--MAP Sensor (cont'd)-----------
(From page 6-27) IFrom page 6-27)
-Replace MAP sen-

sor.
NO -Repair short in WHT/
/s there approx. 3 V ?
BLU wire between
VES control unit (017) and
MAP sensor.
Turn the ignitíon switch OFF. Connect the ECU test harness
nector (page 6-20).
nector (page 6-20). Measure voltage between 020
(+)terminal and 022 (-)terminal
with the ignition switch on.
Turn the ignition switch ON.
Repair open in RED/
VES WHT wire between
control unit (020) and
Measure voltage between D 1 7 ( + 1 NO MAP sensor.
terminal and 022 (-)terminal.
Substitute a known-good control
unit and recheck. lf prescri~ed
voltage is now available. replace
0000000000000 000000000
0000000000000 000000000
Repair open in WHT/BLU wire

ls there approx. 3 V ? between control unit [017) and
MAP sensor.
VES

indication goes away. replace 017 (+)
0000000000000 00000000
3V7
0000000000000 00000000
022(-)
6-28
1
Turn the ignition switch OFF. /
1
under-hood relay box for 10 sec-
\,.
Start engine and keep engine 1
speed at id le. J
~----~~------~
NO 1 lntermittent failure (test drive

Does LED indicate CODE 5 ? >------1 m ay be necessary).
1 VES
~~1 _____s_to_p-,en_g_i_n_e_._____ ~ (KX, KS, KG) (KQ)
Remove #21 hose from the vac-

uum hose manifold and connect a
T-fitting from a vacuum gauge
between the vacuum hose mani-
fold and the MAP sensor.
Start engine.
VACUUM
PUMP/ VACUUM
T-FITTING PUMP/GAUGE
GAUGE
ls there vacuum ? Repair as necessary.
VES
(KX. KS. KG) (KQ)
Connect a vacuum pump to #21

hose and apply vacuum.
NO
Does it hold vacuum ? Replace #21 hose.
VES
1
(To page 6-30)
(cont'd)
6-29
Troubleshooting Flow Chart--MAP Sensor (cont'd)----------,
(From page 6-29)
\
Stop engine.

the MAP sensor and wire harness.
Tu m the ignition switch ON.
Measure voltage between WHT

(+)terminal and GRN (-) termi-
nal.
ls there approx. 3 V ? Replace MAP sensor.

TEST HARNESS
VES 07LAJ-PT30200
Substitute a known-good control

indicatioh goes away, replace
6-30
Troubleshooting Flow Chart--Vacuum S w i t c h - - - - - - - - - - - -
-Engine is warm running.

-LEO índicates CODE 4.
1
l Turn the ignition switch OFF.
No.S No.9
Re m ove BACK UP fu se in the

under-hood relay box for 1O sec-
(KQ)
KX, KS, KG:

Disconnect the 1 OP connector on
the control box.
KQ:
Disconnect the 2 P connector on
the control box.
KX, KS, KG:

Measure resistance between No.8
terminal and No. 9 terminal on the
control box.
KQ:
Measure resistance between No. 1
terminal and No.2 terminal on the
control box.
(To page 6-33)
6-32
(KX, KS, KG}
(From page 6-32}
Re m ove #7 hose from the vacuum

YES hose manifold and connect a T-
Ooes continuity exist ? fitting from a vacuum gauge
between the vacuum hose mani-
NO fold and the vacuum switch.
-Replace vacuum
switch.
Measure voltage between BLK/ ls there more than 30 mmHg of -,:N..:.O=-.._ ___¡
-Repair open BLK/
YEL terminal and body ground on vacuum?
YEl or WHT wire in
the wire harness.
YES the control box.
Check routing of #7 hose.
Repair open in BLK/YEL wire

NO
ls there battery voltage ? between connector and No.2
fuse.
YES
Reconnect the connector to the

control box.

nector (page 6-20).
Remove #7 hose from the vacuum

hose manifold and connect a vac- BLK/YEL LT GRN/ BLK/YEL
uum pump. WHT
12 V 7
Apply vacuum. 1 1
07(+} 021 (-)
0000000000000
Measure voltage between 07 (+) 0000000000000
terminal and 021 (-)terminal.
(To page 6-34)
(cont'd)
6-33
Troubleshooting Flow Chart--Vacuum Switch (cont'd) - - - - - - - - - - - .
(From page 6-33)
NO Repair open in LT GRN/WHT

ls there battery voltage ? wire between control unit (07)
and vacuum switch.
YES
Substítute a known-good control

indication goes away. replace
6-34
Troubleshooting Flow Chart - - TW S e n s o r - - - - - - - - - - - - - -
Self-diagnosis LEO indicator blinks six times: Most likely a problem in the Coolant Temperatura (TW) Sensor circuit.
LEO indicates COOE 6.
Turn the ígnition switch OFF.
Remove BACK U P fuse in the

NO lntermittent failure
Ooes LEO indícates COOE 6 ?
may be necessary).
YES

ing temperatura (the cooling fan
comes on).
Disconnect the 2P connector on

the TW sensor.
Measure resistance between the 2

terminals on the TW sensor.
ls there 200-400 n ? Replace TW sensor.

YEL/GRN
YES
Measure voltage between YEL/

GRN (+) terminal and body
ground.
NO
ls there approx. 5 V ? Turn the ignition switch OFF.
YES
Connect the ECU test hamess

nector (page 6-20).
(To page 6-37) (To page 6-37)
6-36
(From page 6-36) (From page 6-36)
1
Measure voltage between YELI
1 GRN (+) tenminal and BLU/WHT
l (-)terminal.
1 Repair open in BLU/
~
WHT wire between
ls there approx. 5V? control unit (022) and
1 YES TW sensor.

i Turn the 1gmtion switch ON.
Measure voltage betWeen 015 (+)

terminal and D22 (-)terminal.
Repair open in YEL/

GRN wire between
j NO TW sensor.
Disconnect D connector from the

wire harness only, not the control
unit.
1
Measure voltage between D 15 { +)

terminal and D22 (-)terminal.
1
1 Repair short in YELI

VES GRN wire between
\ NO TW sensor.

1
voltage is now available. replace
i the original control unit.
5V?
015 !+)
0000000000000
0000000000000
6-37
Troubleshooting Flow Chart --lgnition Coil Signa l - - - - - - - - - - - - . ,
-$ Self-diagnosis LEO indicator blinks eight times: A problem in the ignition coil signal circuit.
LED indicates CODE 8.

Turn the ígnition switch ON.
Does LEO indicates CODE 8 ?

NO 1 lntermittent failure (test drive l
may be necessary). 1
1

between the control unit and con- ~-----------------8V7--------------------~
nector (page 6-20}. A9 (+} D21 (-}
00000000 0000000000
00000000 0000000000
Measure vottage between AS 1+)
terminal and 021 (-) terminal.
Repair short or open BLU wire

NO
ls voltage above approx. 8 V ? between control unit (A9) and
1 VES l ignition coil.

------------------------~

6-38
Troubfeshooting Flow Chart - - TA Sensor-----------------.
~ Self-diagnosis LEO indicator blinks ten times: Most likely a problem in the lntake Air Temperatura (TA) Sensor circuit.

lntermittent failure (test drive

Does LEO indicates CODE 1 O ? TA SENSOR
may be necessary).
YES
the T A sensor.

terminals on the TA sensor.
ls there 1 -4 kn ? Replace TA sensor.
YES
Measure voltage between WHT/
RED (+) terminal and body GRN/WHT
ground.
i 1
NO 1
ls there approx. 5 V ? Turn the ignition switch OFF.
1 1
YES
Measure voltage between WHT1 Connect the ECU test harness

RED 1+) terminal and BLU/WHT between the control unit and con-
(- 1 terminal. nector (page 6-20).
(To page 6-40) (To page 6-40)
(cont'd)
6-39
Troubleshooting Flow Chart --TA Sensor (cont'd)-----------.
(From page 6-39)
.--------(-F~ro-m----,''1'
1
6-39)
Repai r open in BLU/

NO WHT wire between
contro 1 unit (022) and ·'
VES TAse nsor.

unit and recheck. lf symptom/ Turn the ignition switch ON.
1
Mea su re voltage between 018
(+)terminal and 022 (-) termí-
na l.
Repair open in WHT1

VES RED wire between
NO TA sensor.
Oísconnect O connector from the

1
wire harness only. not the control
unit.
1
! Measure voltage between 018

(+)terminal and 022 (-) termí-
1
1
na l.
Repair short in WHT 1

VES RED wire between
control unít (0181 and
NO TA sensor.
1
voltage is now available, replace
1
0000000000000
0000000000000
5V7
6-40
Input Troubleshooting Flow Chart- Power Source (IG1, Bat) and Ground
lnspection of Power Source

(IG1. Bat) and Ground.

nector (page 6-20).
Check for continuity between the

body ground and the following
terminals índivídually: •AlO, •
021.
-Repair open in BRN/BLK wire
between control unit (021 1and
NO G101.
Ooes continuity exist ?
-Repair open in BLK wire bet-
VES ween control unit (A 1 O) and
G101.
Measure voltage between 02 (+) 00000000 0000000000

terminal and A 1 O {-) terminal. 00000000 0000000000
A10 (-} 02(+)
' - - - - - - - - 12 V 7 ---------1
ls there banery voltage ? lnspect BACK U P fuse.
VES
NO
Turn the ignition switch ON. ls BACK UP fuse OK ? Replace fuse.
VES
Repair open in WHT/YEL wire

between BACK UP fuse and con-
trol unit (02). 12 V 7
01 (+1
00000000 0000000000
Measure voltage between 01 (+)
00000000 0000000000
terminal and A10 {-)terminal.
A10 (-)
ls there banery voltage ? Turn the ignition switch OFF.
YES
lnspect ~o.2 fuse.
Power Source {IG1, Bat) and

Ground are OK.
ls No.2 fuse OK ?
NO
----i Replace fuse.
VES

between No.2 fuse and control
unit (01).
6-41
Input Troubleshooting Flow Chart-A/T Shift Position Signar (A/T only) - -
lnspection of A/T Shift Position

Signal.
Observe the A/T shih indicator and

select each position separately.
See A/T shih position indicator

Does the indicator light properly ?
inspection (section 16}.
YES
i
nector. But disconnect D con-
nector from the wire harness only,
not the control unit {page 6-20).
1 Turn the ignítion switch ON. 1 00000000

¡'----~-----1 00000000
A10(-) 08(+)
Measure voltage between 08 ( +)
terminal and A 1 O (-) terminal. 12 V?
Substituta known-good control

NO unit and recheck. lf prescribed
ls there battery voltage ?
voltage is now available, replace
VES the original control unit.
Reconnect D connector to the wire

hamess.
Measure voltage between 08 (+) 0000000000000

terminal and 021 (-)terminal in 0000000000000
Neutral position.
OV7
(To page 6-43)
6-42
(From page 6-42)
-Repair open in LT GRN wire

between control unit (08) and
combination meter.
YES
ls there voltage ? -Repair open in the GRN wire
between the combination
NO meter and A/T shift position
switch.
Measure voltage between 08 ( +) 0000000000000

terminal and 021 (-)terminal in 0000000000000
all other shift positions except
Neutral. 08(+)
1
Repair short in LT GRN wire

NO
ls there battery voltage ? between combination meter and
control unit 108).
VES
A/T Shift Position Signal is OK.
6-43
Input Troubleshooting Flow Chart-- P/S Oil Pressure Switch Signal---
lnspection of P/S Oil Pressure

Switch Signal.

nector (page 6-20).
011 (+} 021 (-)
Measu re voltage between D 11 ( +) 0000000000000

terminal and 021 (-)terminal. 0000000000000
YES
ls there voltage ? Turn the ignition switch OFF.
NO

the PIS oil pressure switch.
Connect RED terminal to BLK ter-

minal.
Replace the PIS oil

ls there voltage ?
pressure switch.
' YES
-Repair open in RED wire

between control unit (011) and
P/S oil pressure switch.
-Repair open in BLK wire
between PIS oil pressure
switch and G301 .
Turn steering wheel slowly.
BLK
(To page 6-47)
6-46
{From page 6-46) 3-7V7
011 {+) 021 (-)

Measure voltage between D 11 0000000000000
( +) terminal and 021 (-)terminal 0000000000000
while steering wheel is tuming.
NO
ls there battery voltage ? Turn the ignition switch OFF.
YES

the P/S oil pressure switch.

2 terminals on the P/S oil pressure
switch.
Replace the PIS oil

Does continuity exist ?
pressure switch.
NO
-Repair short in RED wire

between control unit { D 11 ) and
-Substituta a known-good ECU
and recheck. lf prescribed volt-
age in now available, replace
the original ECU.
P/S Oil Pressure Switch Signal

is OK.
6-47
Input Troubleshooting Flow Chart--Air Conditioning Signal------
lnspection of Air Conditioning

Signa l.

nector (page 6-20). Oisconnect
"O" connector from the main wire
harness only, not the control unit.

00000000
00000000
A10(-) +)
terminal and A10 (-)terminal.

NO unit and recheck. lf prescribed
vóltage is now available. replace
YES the original control unit.
Reconnect ·o· connector to the

main wire harness.
00000000000
00000000000
Connect A 19 terminal to A 1 O ter-
minal. A10(-j
Connect the REO/BLU terminal of

Ooes A/C operate ? the 4P connector on the A/C
RED/BLU-$
clutch relay to body ground.
YES
Start engine. NO See Air conditioner

Ooes A/C operate ? inspection (section
151.
YES
Blower switch ON.
Repair open in RED/BLU wire
between ECU (A19) and A/C
clutch relay.
(To page 6-49)
6~48
(From page 6-48)
A/C switch ON.
NO See Air conditioner

Does A/C operate ? inspection (section
15).
VES
Measure vo.ltage between 06 (+)

terminal andA lO(-) terminal.
A10(-) 06(+)
L-------Below 1 V 7--------..J
Repair open in BLU/

BLK wire between
ls voltage below 1 V ?
ECU (06) and A/C
VES switch.
Air Conditioning Signal is OK.
6-49
Carburetor
Symptom-to-Sub System C h a r t - - - - - - - - - - - - - - - - - -
(KX, KS, KG, KQ)

NOTE:
e Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the order they should be
inspected, starting with CD. Find the symptom in the left cofumn, read across to the most likely source, then refer to the page
listed at the top of that column. lf inspection shows the system is OK, try the next system <Z:l, etc.
e Before starting inspection, check that other items that affect engine performance are within specification. Check the self-
diagnosis indicator, valve clearance, a ir cleaner, and PCV valve. In addition, check the ignition timing, function of the vacuum
and centrifuga! advance, and the condition of the spak plugs. lf those items are all within specifications, begin with the
troubleshooting listed in pages 6-50 and 6-51 .
~'
PAGE
AUTOMATIC AIR VENT
IDLE SPEED/ ID LE CHOKE/ 1 CUT-OFF
MIXTURE BOOST FAST IDLE SOLENOID VALVE
SYSTEM
SYMPTOM 1 FLOAT LEVEL
80 54 84 83, 121
ENGINE WON'T START CD

cv
1
DIFFICULT TO
WHEN COLO CD
START ENGINE
WHEN WARM cv
WHEN COLO FAST
IDLE OUT OF
SPECIFICATION i
® CD
l IRREGULAR
IOLING
WHEN WARM ENGINE
SPEEO TOO HIGH CD cv @
WHEN WARM ENGINE
1
SPEEO TOO LOW CD CD
1
ROUGH IOLE/
FLUCTUATION CD ® ®
FREQUENT
WHILE
WARMING UP cv CD
STALLING
1 AFTER
WARMJNG UP CD cv ®
: :
MISFIRE OR
ROUGH RUNNING CD CD
i POOR
LOSS OFF
POWER cv
PERFORMANCE
AFTERBURN CD
'
HESITATION/SURGE
1
6-50
PRIMARY
SLOW SLOW VACUUM ACCELE-
POWER MIXTURE AIR JET CONTROLLED RATOR
VALVE CUT-OFF CONTROL SECONDARY PUMP
1
SOLENOID !
1
VALVE 1
69 73 67 65 1
26
!
® (])
1
i
(j) (])
(j) - (])
i
® (])
--· -
(])
i
(])
CID ®
-
® (j)
(j) (j) 1
(]) 1
CID j (j) @
i
(]) (j)
6-51
Symptom-to System Chart - - - - - - - - - - - - - - - - - - - -
(Except KS. KX. KG, KQ)

NOTE:
inspected, starting with CD. Find the symptom in the left column, read across to the most likely source, then refer to the page
listed at the top of that column. lf inspection shows the system is OK, try the next system 12>, etc.
diagnosis indicator, valve clearance, air cleaner, and PCV valve. In addition, check the ignition timing, function of the vacuum
and centrifuga! advance, and the condition of the spark plugs. lf those items are all within specifications, begin with the
troubleshooting listed in pages 6-52 and 6-53.
~
PAGE CARBURETOR
AIR VENT
AUTO M A TIC CUT-OFF
SYMPTOM
IDLE SPEED/
MIXTURE
80
1
'
ID LE
BOOST
55
CHOKE/
FASTIDLE
SYSTEM
84
1
i
SOLENOID VALVE
FLOAT LEVEL
83, 121
ENGINE WONT START

1
CD
DIFFICULTTO
WHEN COLO ¡ CD cv i
START ENGINE
cv
1
WHEN WARM
1
-
!
WHEN COLO FAST
IDLE OUT OF
SPECIFICATION
cv :
i
CD
IRREGULAR
IDLING
WHEN WARM ENGINE
SPEED TOO HIGH CD cv @
i
WHEN WARM ENGINE
SPEED TOO LOW CD CD 1
ROUGH IDLE/
FLUCTUATION CD @ cv l
FREQUENT
WHILE
WARMING UP cv CD
STALLING
AFTER
WARMING UP CD cv cv 1
MISFIRE OR
ROUGH RUNNING CD CD
POOR
LOSS OFF
POWER
!
cv
PERFORMANCE
AFTERBURN CD
HESITATION/SURGE
6-52
CARBUAETOR 1
i
PRIMARY SlOW VACUUM EMISSION
MIXTURE ACCELERATOR FUEL SUPPLY AlA INTAKE CONTROLS
POWER VALVE CONTROLLED PUMP
CUT-OFF SECONDARY
SOLENOID VALVE
70 75 66 83 93 98 102
cv CD ®
CD cv ®
CD !
¡
1
®
cv cv 1
®
:
1
cv
1
cv cv
cv CD 1
i
®
CD ¡ ®
1
i cv ®
!
1
®
® CD ® cv CD 1 CD
:
i
cv CD
cv 1
i ® cv CD CD
6-53
Carburetor
ldle Control S y s t e m - - - - - - - - - - - - - - - - - - - - - - - - - ,
Testing 5. Oisconnect the #20 vacuum hose at idle boost throttle
(KX, KS, KG, KQ) controller and check vacuum wheel is turning.
There should be vacuum.
temperature {the cooling tan comes on). # 20 VACUUM HOSE
2. Check the idle speed with headlights, heater blower,
off.

Automatic 750 ± 50 min- 1 (rpm} (in "O")
• lf OK, go to step 4.
VACUUM
PUMP/GAUGE CONTROLLER
• lf not, go to step 3.
3. Oisconnect the two vacuum hoses at idle boost throt-

tle controller and check each for vacuum.
e lf there is vacuum, check the throttle valve shaft for
binding or sticking and replace the id le boost throt-
There should be no vacuum in both hoses.
tle controller.
#22 VACUUM HOSE e lf there is no vacuum, check the #20 and #12
vacuum line for proper connection, cracks, block-
age or disconnected hose. lf OK, go to the idle
boost so len o id valve troubleshooting (page6-56).
6. Check the id le speed with the A/C on.

e lf not, disconnect the two vacuum hoses at idle

boost throttle controller and check each for vac-
#20 VACUUM HOSE
uum.
- lf there is no vacuum at the #20 vacuum hose,
e lf there is no vacuum, check the throttle valve shaft check the #20 and #12 vacuum line for proper
for binding or sticking and replace the idle boost connection, cracks, blockage or disconnected
throttle controller. hose. lf OK, go to the idle boost solenoid valve
e lf there is vacuum at the #20 vacuum hose, go to troubleshooting (page6-56).
idle boost solenoid valve troubleshooting (page - lf there is no vacuum at the #22 vacuum hose,
6-56). check the #22 and #12 vacuum line for proper
e lf there is vacuum at the #22 vacuum hose, go to connection, cracks, blockage or disconnected
A/C idle boost solenoidvalve troubleshooting (page hose. lf OK, go to the A/C idle boost solenoid valve
6-61 ). troubleshooting ( page 6-61 ) .
4. Oisconnect the connector on the P/S oil pressure


• lf OK, go to step 6.
e lf not, go to step 5.
6-54
ldle Control System - - - - - - - - - - - - - - - - - - - - - - - - - ,
Testing 5. Dísconnect the #20 vacuum hose at idle boost throttle
(Except KX, KS, KG. KQ) controller and check vacuum.

temperatura (the cooling tan comes on).
2. Check the idle speed with headlights, heater blower,

rear window defogger, coo!ing tan and air conditioner
off.

• lf OK, go to step4.
e lf not, go to step3.
3. Disconnect the vacuum hoses at idle boost throttle

controller and check each tor vacuum.
There should be no vacuum in both hoses.

e lf there is vacuum, check the throttle valve shaft for
#20 VACUUM HOSE OUTSIDE VACUUM HOSE binding or sticking and replace the idle boost throt-
tle controller.
\ • lf there is no vacuum, check the #20 and # 2

vacuum líne for proper connection, cracks, block-
age or disconnected hose. lf OK, go to the idle
boost solenoid valve troubleshooting (page 6-58).
6. Check the idle speed with the A/C on.

• lf not, disconnect the two vacuum hoses at idle

boost throttle controller and check each for vac-
• lf there is no vacuum, check the throttle valve shaft
uum.
for binding or sticking and replace the idle boost
throttle controller.
There should be vacuum in both hoses.
e lf there is vacuum at the #20 vacuum hose, go to
idle boost solenold valve troubleshooting (page
- lf there is vacuum in both hoses, replace the idle
6-58).
boost throttle controller.
• lf there is vacuum at the outside vacuum hose, go
- lf there ís no vacuum at the # 20 vacuum hose,
to A/C idle boost solenoid valve troubleshooting
check the #20 and #2 vacuum line for proper con-
(page 6-63).
nection, cracks, blockage or disconnected hose. lf
OK, go to the idle boost solenoid valve trouble-
shooting (page6-58).
switch. Connect a jumper wire between the RED ter-
- lf there is no vacuum at the outside vacuum hose,
minal and the BLK terminal.
check the vacuum line for proper connection,
Check the idle speed.
cracks, blockage or disconnected hose.
Id le speed should be:
lf OK, go to the A/C idle boost solenoid valve
Manual 950 ± 50 mín- 1 (rpm) trouble shooting (page 6-63).
Automatíc 820 ± 50 min- 1 (rpm) (in "D")
• lf ok, go to step 6.
• lf not, go to step 5. (confd)
6-55
Carburetor
ldle Control System (cont'd)-----------~--------
Troubleshooting Flowchart ldle Boost Solenoid Valva

(KX, KS, KG, KQ)
(KX. KS. KG) (KQ)
lnspection of ldle_ Boost Solenoid
Valve.
VACUUM
IDLE BOOST
PUMP/
SOLENOID VALVE
Operi the control box. GAUGE
Disconnect the lower vacuum

hose of the solenoid valve from the
joint and connect a vacuum pum p.
Disconnect #20 vacuum hose of

' 11
"'"
{KX. KS. KG)
#20 HOSE
the solenoid valve from the vac-

VACUUMPUM~
vacuum gauge.
JOINT
GAUGE ~1
Start the engine.
Apply vacuum.
BLK
ls vacuum indicated on the gau'ge ? Tum the ignition switch OFF.
NO
Turn steering wheel slowly. Disconnect the connector on the

control box.
Start'the engine.
Measure voltage between;

KX, KS, KG: LT GRN (+) and BLK
BLK
(-) terminals
KQ: RED (+) and BLK (-) termi-
nals
Check the 'self-
-~ ------.-:-:-=----~>VE_
< _ ls there voltage ?
1 NO
. S .
diagnosis indicator
(page 6-22).
lf OK, check the input
troubleshooting (page
6-22).
Replace the solenoid valve.
Apply vacuum.
(To page 6-57)
6-56
(From page 6-56)
ls vacuum indicated on the gaugé ? Turn the ignition switch OFF.
YES
Disconnect the connector on the

control box.
Start the engine.
1

KX, KS, KG: LT GRN (+) and
BLK (-) terminals
KQ: RED(+) and BLK (-) termi-
nals
1
ldle Boost Solenoid Valve is OK. YES Replace the solenoid
valve.
1
1 NO

KK KS, KG: LT GRN (+) and
body ground
KQ: RED (+) and body ground
1
YES Repair open in BLK wire
ls there battery voltage ? between the solenoid
valve and G251. 1
1 NO '
'
! Check the self-diagnosis indica-

tor (page 6-22). lf OK, inspect
: open in LT GRN or RED wire
i between the solenoid valve and
control unit (A23).
(cont'd)
6-57
Carburetor
ldle Control System ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - -
Troubleshooting Flowchart ldle Boost Solenoid Valve IDLE BOOST

(Except KX. KS, KG. KQ) SOLENOID VALVE
lnspection of ldle Boost Solenoid

Val ve.

joint and connect a vacuum pump.

uum hose manifold and connect a ~ACUUM PUMP/
vacuum gauge.
' "AUGE
Start the engine.
Apply vacuum.
YES
ls vacuum indicated on the gauge ? Turn the ignition switch OFF.
NO

solenoid valve.
Measure voltage between BLK/

YEL (+) terminal and RED (-)
Apply vacuum. terminal on the solenoid valve.
NO Replace the solenoid

ls there voltage ?
valve.
YES

PIS oil pressure switch.
(Te page 6-59) (To page 6-59)
6-58
(From page 6-58} (From page 6-58)
1
i
1
Check for continuity between RED
terminal and body ground. - Repair short in RED
1 wire between
1
solenoid valve and
YES PIS oil pressure
Does continuity exist ? switch.
-Repair short in RED
1 NO wire between
solenoid valve and
-See Power Steering lnspection A/C switch.
(section 11).
-See Air Conditioner lnspection
(section 15).
ls vacuum indicated on the gauge '>'-N_0-'------1 Turn the ignition switch OFF.
while steering wheel is turning ?
YES
so len o id valve.
Start the engine.
Blower switch ON. Turn steering wheel slowly.
Turn the A/C switch ON. Measure voltage between BLK/

YEL (+) terminal and RED (-)
terminal while steering wheel is
turning. !
YES Replace the solenoid

ls there battery voltage ? 1
valve.
1
NO

YEL (+) terminal and body
ground.
Repair open in BLK/

NO YEL wire between No.
2 fuse and the con-
YES nector.
(To page 6-60} (To page 6-60) (cont'd)
6-59
Carburetor
ldle Control System (cont'd) - - - - - - - - - - - - - - - - - - - -

Check for continuity of RED wire

between the sofenoid valve and
Repair open in RED

NO wire between solenoid
valve and P/S oil pres-
VES sure switch.
See Power Steering lnspection

(section 11 ) .
-Repair open in RED wire

NO between solenoid valve and
ls vacuum indicated on the gauge ? A/C switch.
-See Air conditioner inspection
VES (section 15).
ldle Boost Solenoid Valve is OK.
6-60
A/C IDLE BOOST
SOLENOID VALVE
Troubleshooting Flowchart A/C ldle Boost Solenoid Valve
(KX, KS, KG, KQ)
lnspection of A/C ldle Boost 1

(KX. KS. KG) (KQ)
Solenoid Valve )
1
1 VACUUM A/C IDLE
Open the control box. PUMP/GAUGE BOOST SOLENOID VALVE
¡1
1
!

rt' #22 HOSE

uum hose manifold and connect a VACUUM
vacuum gauge. JOINT
PUMP/GAUGE
Start the engine.
Apply vacuum.
NO
Blower switch ON. Disconnect the connector on the

control box.
Turn the A/C switch ON.

Start the engine.
Measure voltage between GRN

( +) terminal and BLK (-) termi-
nal.
Check the self-
diagnosis indicator
VES (page 6-22).
ls there voltage ?
lf OK. check the input
NO troubleshooting lpage
6-22).
(To page 6-62) (cont'd)
6-61
Carburetor
ldle Control System (cont'd) - - - - - - - - - - - - - - - - - - -
(From paga 6-61)

1
NO
ls vacuum indicated on the gauge ? Turn the ignítion switch OFF.
YES

control box.
Start the engine.
Blower switch ON.
A/C ldle Boost Solenoid Valve is Measure voltage between GRN

OK. (+)terminal and BLK (-)terminal
on the control box.
Replace the solenoid

valve.
NO
Measure voltage between GRN

(+)terminal and body ground.
YES Repair open in B LK wire

valve and G251.
NO
Check the self-diagnosis indica-

tor (page6-22). lf OK, inspect
open in GRN wire between the
solenoid valva and control unit
{A2).
6-62
•
Troubleshooting Flowchart A/C ldle Boost Solenoid Valve

(Except KX. KS. KG. KQ)
lnspection of A/C Id le Boost

Solenoid Valve A/C IDLE BOOST
1 SOLENOID VALVE
!
vacuum hose manifold and con-
nect a vacuum pump.
Disconnect upper vacuum hose of

vacuum gauge.
T !:.... VACUUM PUMP/
Start the engine. • "GAUGE
Apply vacuum.
ls vacuum indicated on the gauge? Turn the ignition switch OFF.
NO
Blower switch ON. Disconnect the connector on the

solenoid valve.
Tu m A/C switch ON.

Start the engine.
Measurevoltage between RED(+)

terminal and BLK (-)terminal.
VES See Air Conditioner

ls there voltage ? inspection (section
15).
NO
Raplace the solenoid valve.
6-63
Carburetor
ldle Control System ( c o n t ' d ) - . . , . - - - - - - - - - - - - - - - - - - - - - .
{From page 6-63)

!
VES

solenoid valve.
Start the engine.
Blower switch ON.
A/C ldle Boost Solenoid Valve is Measure voltage between RED ( +)

OK. terminal and BLK (-)terminal.
VES Replace the solenoid

valve.
NO
Measure voltage between RED ( +)

i
VES Repair open in BLK wire 1

valve and G301.
1 ON
-Repair open in RED Wire

between the solenoid valve
and delay control unit.
-See Air conditioner inspection
(section 15).
1
6-64
Vacuum Controlled Secondary - - - - - - - - - - - - - - - - - - - - - ,
Testing • lf it holds vacuum, check the vacuum line for proper
IKX. KS, KG. KQ) connection or cracks. lf OK, go to the air leak
solenoid valve troubleshooting (page 6-67).
1. Disconnect the secondary diaphragm vacuum hose
and attach a spare piece of hose between the dia- 5. Raise the engine speed to 5,000 min- 1 (rpm}. then
phragm and a vacuum pump. cfose the throttle suddenly. And then appy vacuum.
lt should hold vacuum.

2. Dpen the throttle valve fully and apply a vacuum.
Check the diaphragm rod moves as vacuum is applied e lf it does not hold vacuum, check the vacuum line
and that the vacuum then remains steady. for proper connection, blockage or disconnected
hose. lf OK, go to the air leak solenoid valve trouble-
shooting (page 6-67).
6. Disconnect the vacuum hose from the 3-way joint and

connect to a vacuum pump/gauge.
Apply a vacuum.
lt shou/d not ho/d vacuum.
3-WAYJOINT
SECONDARY DIAPHRAGM
e lf the vacuum does not hold or the rod does not

move, first check the hose for proper connection
and condition, then replace the diaphragm and
recheck.
e lf vacuum does not hold, test is complete.

3. Start the engine and warm up to normal operating • lf vacuum is held, check the hose, the 3-way joint
temperatura (the cooling fan comes on). and clean the vacuum port.
4. Disconnect the vacuum hose from the 3-way joint

connect a vacuu~ pump and apply vacuum.
lt should not hold vacuum.
· (cont'd)
6-65
Carburetor
Vacuum Controlled Secondary (cont'd)--------------------.
(Except KX, KS, KG, KQ) • lf it holds vacuum, check the vacuum line for proper
connection or cracks. lf OK, replace the ther-
1. Disconnect the secondary diaphragm vacuum hose movalve D.
and attach a spare piece of hose between the dia-
phragm and a vacuum pump. 4. Start the engine and warm up to normal operating
temperatura (the cooling fan comes on).
2. Open the throttle valve fully and apply a vacuum.
Check the diaphragm rod moves as vacuum is applied 5. Apply vacuum.
and that the vacuum then remains steady. lt should hold vacuum.
• lf it does not hold vacuum, check the vacuum line

for proper connection, blockage or disconnected
hose. Jf OK, replace the thermovalve D.
6. Disconnect the vacuum hose from the 3-way joint and

connect to a vacuum pump/gauge.
Apply a vacuum.
SECONDARY DIAPHRAGM
e lf the vacuum does not hold or the rod does not

move, first check the hose for proper connection
and condition, then replace the diaphragm and
recheck.
3. Disconnect the vacuum hose from the 3-way joint,

connect a vacuum pump and apply vacuum.
NOTE: KP, KT ; The engine coolant temperatura must
be below 60°C (140°F).
Except KP, KT ; The engine coolant temperatura must
be below 55°C (131°F).

e lf vacuum does not hold, test is complete.
• lf vacuum is held, check the hose, the 3-way joint
and clean the vacuum port.
6-66
Slow A ir Jet Control System - - - - - - - - - - - - - - - - - - - - - - - .
Troubleshooting Flowchart Air Leak Solenoid Valve

(KX. KS, KG. KQ)
VACUUM PUMP/
GAUGE
lnspection of Air Leak Solenoid 1
Valve.
Discannect the #2 vacuum hose

from the carburetor and connect a
vacuum pump, then cap the car-
buretor.
Start the engine.

#2VACUUM HOSE
NOTE: Engine coolant temperature

Apply 100 mmHg (4 in.Hg) vac-
must be below 63°C {145°F).
uum to the hose.
NO
Does solenoid valve hold vacuum ? Turn the ignition switch OFF.
VES BLK

control box.
Start the engine.
Measure voltage between BLUf

YEL (+) terminal and BLK (-)
terminal.
BLK
1

Raise the engine speed to 5,000 valve.
1 NO
1
min- 1 (rpm), then close the throt-

tle suddenly. ¡
Measure voltage between BLU/
ground.
1
1
YES Repair open in BLK wire
valve and G251 .
1 NO

tor (page 6-22}. lf OK, inspect
open in wire between the
solenoid valve and control unit
(A26).
1
6-67
Carburetor
Slow Air Jet Control System (cont'd) - - - - - - - - - - - - - - - - - - .
(From page 6-67)
r
l Apply 100 mmHg {4 in.Hg) vac-
uum to the hose.
1
VES
Does solenoid valve hold vacuum ? -¡ Tum the ignition switch OFF.
!
NO 1

1 control box.
1
Start the engine. 1
Raise the engine speed to 5,000

min- 1 (rpm), then close the throt-
tle suuddenly.
Mea su re vottage between BLU/

YEL (+) terminal and BLK (-)
terminal.
Check the self-
1 diagnosis indicator
YES (page 6-22).
ls there voltage ?
1 NO troubleshooting lpage
6-22).
.Air Leak Solenoid Valve is OK. Replace the solenoid valve .
6-68
PovverValve------------------------------------------------------1
Testing e lf not, check the #14 and #12 vacuum line for
(KX, KS. KG. KQ) proper connection, cracks, blockage or discon-
nected hose. lf OK, go to the power valve control
1. Disconnect the #14 vacuum hose from the vacuum solenoid valve troubleshooting (page 6-71).
hose manifold and connect a vacuum pump. Apply
vacuum and listen for a clicking noise from the power 4. Warm up to normal operating temperature (the cooling
valve. fan comes on).
5. Check the vacuum.
e lf not, check the #14 and #12 vacuum line for

nected hose. lf OK, go to the power va!ve control
solenoid valve troubleshooting (page 6-71).
#14 VACUUM HOSE
e lf a clicking sound is heard, go on to step 2.

e lf no sound is heard, replace the power valve and
retest.
2. Disconnect the #14 vacuum hose from the carburetor

and connect a vacuum gauge to the hose.
3. Start the engine and check the vacuum.

There shou!d be no vacuum for about 3 seconds after
the engine is started. And there should be vacuum
within 15 seconds after the engine is started.
NOTE: The engine coolant temperature must be below
30°C (86°F). (cont'd)
6-69
Carburetor
Power Valve ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - - - -
Testing e lf there is vacuum, check the vacuum hose for
(Except KX, KS, KG, KQ) proper connection. lf OK, replace the thermovalve
C.
1. Disconnect the #14 vacuum hose from the vacuum
hose manifold and connect a vacuum pump. Apply 4. Warm up to normal operating temperatura (the cooling
vacuum and listen for a clicking noise from the power fan comes on).
valve.
5. Check the vacuum.
e lf there in no vacuum, check the #14 and #6 (KT, KP:

#12) vacuum line for proper connection, cracks,
blockage or disconnected hose. lf OK, replace the
thermovalve C.
#14 VACUUM HOSE
• lf a clicking sound is heard, go on to step 2.
• lf no sound is heard, replace the power valve and

retest.
2. Disconnect the #14 vacuum hose from the carburetor

and connect a vacuum gauge to the hose.
3. Start the engine and check the vacuum.

NOTE: The engine coolant temperatura must be below
35°C (95°F).
There should be no vacuum.
e lf there is vacuum, check the #14 and #6 (KT, KP:

#12) vacuum line for proper connection.
6-70
Troubleshooting Flowchart Power Valve Control Solenoid Valve
(KX, KS, KG. KQ) POWER VALVE
(KX. KS. KG) CONTROL SOLENOID (KQ)
Jnspection of Power Valve con- VALVE
trol Solenoid Valve.
1
Open the control box.

1
Disconnect the Jower vacuum

1
1
.tt'
VACUUM PUMP/
GAUGE
NOTE: The engine coolant tempera-
Disconnect #14 vacuum hose of 1
the solenoid valve from the vac- ture must be below 30°C (86°F).
vacuum gauge.
1
Start engine.
1 1
Apply vacuum for about 3 seconds

after the engine is started.
VES
NO

control box.
Start the engine.
Measure voltage between VEL (+)

terminal and BLK (-)terminal. Check the self-
diagnosis indicator
Warm up engine to normal operat- (page 6-22). lf OK.
ing temperatura (cooling fan VES substituta a known-
comes on). ls there voltage ? good control unit and
retest. lf symptom
NO goes away. replace
the original control
Replace the solenoid valve. unit.
6-71
Carburetor
Power Valve {cont'd) - - - - - - - - - - - - - - - - - - - - - - - - - - .
(From page 6-71 )
1
NO
YES
1

control box.
Measure voltage between YEL { +)

terminal and BLK (-) terminal.
\
Power Valve Control Solenoid
Valve is OK. ¡ 1
YES 1 Replace the solenoid 1
valva.
1 NO
l Measure voltage between YEL 1+)

1
VES
Repair open in BLK wire
valve and G251 .
l NO
1
tor (page 6-22). lf OK. inspect
open in YEL wire between the
solenoid valve and control unit
(AS).
6-72
Primary Slow Mixture Cut-off Solenoid Valve-----------------.
Troubleshooting Flowchart Primary Slow Mixture Cut-off Solenoid Valve

(KX. KS, KG. KQ}
lnspection of Primary Slow Mix-

ture Cut-off Solenoid Valve.
Check the clicking sound of ~

solenoid italve. '""\
PRIMARY SLOW MIXTURE
CUT-OFF SOLENOID VALVE
NO
Does the solenoid valve click ? Turn the ignition switch OFF.
VES
Disconnect the 2P connector.
Turn the ignition switch O N.
Measure voltage between GRN/

RED (+) terminal and body
ground.

valve.
NO
-Repair open in GRN/RED wire

between the solenoid valva
and control unit (A21 ).
-Check the self-diagnosis indi-
cator (page 6-22). lf OK, check
Start the engine and warm up to
the input troubleshooting {page
normal operating temperatura (the
6-22).
cooling fan comes on).
1
6-73
Carburetor
Primary Slow Mixture Cut-off Solenoid Valve (cont'd) - - - - - - - - - -
(From page 6-73)
r
Raise engine speed to 5, 000 min - 1
(rpm) and close the throttle sud-
1 denly.
NO
YES 1
r
Start the engine.
1
Raise engine speed to 5,000 min-1
(rpm) and close the throttle sud-
denly.
Measure voltage between GRN/

groun d .
1
Check the self-
1 diagnosis indicator
NO (page 6-221.
ls there no voltage for a moment ?
1 YES troubleshooting (page
6-22).
r 1
Primary Slow Mixture Cut-off
Solenoid Valve is OK.
6-74
Troubleshooting Flowchart Primary Slow Mixture Cut-off Solenoid Valve PRIMARY SLOW MIXTURE
CUT-OFF SOLENOID VALVE
{Except KX, KS, KG. KQ)
lnspection of Primary Slow Mix-

ture Cut-off Solenoid Valve.
Check the clicking sound of

solenoid valve.
NO
YES
GRN/
Measure voltage between GRN/ L---"'"-'--4J ~,.... RED
ground.
YES Replace the solenoid

valve.
NO
Repair open or short in BLK/

YEL, GRN/RED wire between
the 2P connector and the ignition
switch as well as No.2 fuse.
Primary Slow Mixture Cut-off

Solenoid Valve is OK.
(cont'd}
6-75
Carburetor
Primary Slow Mixture ,Cut-off Solenoid Value (cont'd)----------.,
1. Remove the 2P connector, cut the harness band, and 4. Connect the respective terminals to a new connector
open the harness clamp on the idle controller bracket. and install a new terminal retainer.
Disconnect the fuel cut-off solenoid valve harness NOTE:
from the clamp. e Be su reto connect the terminal before installing the
terminal retainer.
CAUTION: Take care not to apply excessive force e Replace the connector and terminal retainer with
on the clamp at it is broken easity. the new ones.
e Note the location of the terminal.
PRIMARY SLOW MIXTURE CUT-OFF

SOLENOID VALVE
CHOKE COIL
HEATER
PRIMARY SLOW
MIXTURE CUT-OFF
SOLENOID VALVE TERMINAL RETAINER
.5. Secure the harness with the clamp as shown in the

drawing and use the harness band to hold the two
CLAMP harnesses together 180mm from the tip of the con-
nector.
CAUTION: Cut off the excess of the harness band
and set it on the harnesses so that the tip of the
band points to the vacuum hose manifold.
2. Disconnect the terminal retainer from the connector
and remove the two terminals.
CONNECTOR
CLAMP
3. Replace the solenoid valve.
6-76
(KS KG. KQ} 4. Turn the ignition svyjtch OFF. ··Restart the engine and
lnspection/Adjustment hold engine at idle for 2 minutes. And hold·engine at
Propane Enrichment Method Check idle speed with the headlights, heater blower,
5f.1ijf'QI3 Do not smoke during this procedure.
off ..
Manual 800 ± 50 mín-1 (rpm)
NOTE:
e This procedure requires a propane enrichment kit.
• Check that the self diagnosis indicator befare mak-
ing idle speed and mixture inspections.

temperatura (the cooling fan comes twice).
2. Disconnect the #8 vacuum hose from the intake air

control diaphragm and clamp the hose end.
HOSE CLAMP
STOP SCREW

NOTE: lf the idle speed is. e1(cessively high, check the
throttle control system (page 6-112)
INTAKE AIR CONTROL
DIAPHRAGM 5. Disconnect the 2P connector from the EACV and
disconnect the hose from the EACV, then cap the
EACV.
3. Connect a tachometer.
R. P.M. CONNECTING ADAPTOR

07JAZ-SH 20100
R.P.M. CONNECTING ADAPTOR (B)

07LAZ-PT30120
BATTERY
R. P.M. CONNECTING ADAPTOR (A) EACV

07LAZ-PT30110 (cont'd)
6-77
Carburetor
ldle Speed/Mixture (cont'd) - - - - - - - - - - - - - - - - - - - -
6. Disconnect the #2 vacuum hose from the carburetor,
then cap the carburetor. o Maximum Engine Speed
o
o
1
CAP
~
jf
==========;::-¡;~-
• 0'--
00
PROPANE VOLUME
Full
Engine speed increase should be:
#2 VACUUM HOSE
Automatic 50 ± 1 O min- 1 (rpm} (in "D")
7. Disconnect air cleaner intake tube from air intake duct.

e lf engine speed does not increase per specification,
8. lnsert the hose of the propane enrichment kit into the mixture is improperly adjusted. Go to step 10.
intake tu be about 1 O cm. e lf engine speed increases per specification, go to
NOTE: Check that propane bottle has adequate gas step 14.
before beginning test.
1 O. Remove the air cleaner and close the propane cotrol
valve.
Push down
· 11. Remove the mixture adjusting screw hole cap.
PROPANE ENRICHMENT
KIT
9. With engine idling, depress push button on top of

propane device, then slowly open the propane control
valve to obtain maximum engine speed.
Engine speed should increase as percentage of pro-
pane injected goes up.
MIXTURE ADJUSTING
NOTE: Open the propane control valve slowly; a sud- SCREW HOLE CAP
den burst of propane may stall the engine.
6-78
12. Start engine and warm up to normal operating temper- 18. lf equipped with air conditioner, check the idle speed
ature ; the cooling fan will come on. with the A/C on.
13. Reinstall the propane enrichment kit and recheck Id le speed should be:
maximum propane enriched engine speed.
e lf the propane enriched speed is too low, mixture is Automatic 750±50min- 1 (rpm) (in "O")
too rich: turn the mixture screw 1/4-turn clockwise
and recheck.
e lf the propane enriched speed is too high, mixture is
to lean: turn the mixture screw 1/4-turn counter-
clockwise and recheck.
14. Close the propane control valve speed and remove the
BACK UP fu se for 1 O seconds to reset control unit.
Recheck idle speed.

Automatic 750±50min- 1 (rpm) (in "O")
ADJUSTING SCREW B
e lf idle speed is as specified (step 4), go to step 15.

e lf idle speed is not as specified, adjust by turning
throttle stop screw, then repeat steps 13 and 14.
1 5. Remove propane enrichment kit and reconnect air Adjust the idle speed, if necessary, by turning the
cleaner intake tube on the air intake duct. adjusting screw B.
16. Reinstall the mixture adjusting screw hole cap.
17. Oisconnect the connector on the P/S oil pressure



adjusting screw A.
(cont'd)
6-79
Carburetor
ldle Speed 1 Mixture ( c o n t ' d ) - - - - - - - - - - - - - - - - - - -
(Except KS, KG, KQ) 4. Calibrate the NDIR CO Meter in accordance with the
COMeter Method manufacturer's recommended procedures.
lnsert exhaust gas sampling probe into the tailpipe at
Bi.iij§!i§fiDo not smoke during this procedure. Jeast 40 cm.
NOTE: Check that the self-diagnosis indicator {KX) hold engine at idle for 2 minutes. And hold engine at
befare makíng idle speed and mixture inspections. 2,500-3,000 min- 1 (rpm) for 1 minute.
Check specification for idle CO with cooling fan, air
1. Start the engine and warm it up to normal operating conditíoner OFF and headlights OFF.
temperature (the cooling fan comes twice).
Specified CO%:
2. Connect a tachometer. KX: 0.1% maximum
Except KX: 1 ± 1%
R.P.M. CONNECTING ADAPTOR
07JAZ-SH20100
• Jf ídle CO is as specífied, go to step 14.
e lf not, go to step 6 through 13.
6. KX;
Dísconnect the #2 vacuum hose from the carburetor,
then cap the carburetor.
R.P.M. CONNECTtNG ADAPTOR (B)

07LAZ-PT30120
BATTERY
3. Turn the ignition switch OFF. Restart the engíne and

2,500-3,000min- 1 (rpm) for 1 minute.
Check idle speed with the headlíghts, heater blower, #2 HOSE
off.
ldle speed should be: 7. KX:
Disconnect the 2P connector from the EACV and
Manual 800±50min- 1 (rpm) disconnect the hose from the EACV, then cap the
Automatíc 750±50min- 1 (rpm)(in "D") EACV.

NOTE: lf the idle speed is excessively high, check the
thronle control system (page 6-112)
6-80
8. KX: (KX)
Disconnect the wire harness from the 0 2 sensor.
r
MIXTURE ADJUSTING
SCREW HOLE CAP
(Except KX)
9. KX:
Remove the rubber cap from the gas pipe.
- Turning mixture adjusting screw
clockwise: CO reading decreases

counterclockwise: CO reading increases
Readjust idle speed if necessary, and recheck idle CO.
12. KX:
Reconnect the connector and hose.
Remove BACK UP fuse for 1 O seconds to reset control
unit.
13. KX:
10. KX: Turn the ignition switch OFF. Restart the engine and
Turn the ignition switch OFF. Restart the engine and hold engine at idle for 2 minutes. And hold engine at
hold engine at idle for 2 minutes. And hold engine at 2,500-3,000 min- 1 (rpm) for 1 minute.
2,500-3,000 min- 1 (rpm) for 1 minute. Recheck idle CO.
Check specification for id le CO.
Specified CO%: O. 1% maximum
Specified CO%: 2. 3± 1 . O".k
e lf idle CO is as specified, go to step 14.
e lf not, specification, go to step 11 . e lf not, check the self-diaghosis indicator (page
6-22). lf not, inspect the EACV (page 6-1 04) and
11 . Remove mixture adjusting screw hole plug and adjust the catalytic converter (page 6-1 03), then repeat
by turning mixture adjusting screw to obtain proper CO step 6.
reading.
14. Recheck idle speed.
Manual 800±50 min- 1 {rpm)

750±50 min- 1 (rpm)
Automatic
{in "D")
(cont'd)
6-81
Accelerator Pump--------, Float Level - - - - - - - - - - - - ,
lnspection Adjustment
1. Befare measuring the accelerator pump linkage travel, b#éiñi§ii§l§Do not smoke while working on fuel sys-
make su re the pump shaft travels freely throughout the tem. Keep open flame away from work area.
pump stroke. Make sure the pump lever ís in contact
with the pump shaft. 1. Place the car on level ground.
2. Start and warm up the engine, snap the throttle

between idle and 3,000 min- 1 (rpm) severa! times then
Do not bend
thís tang allow it to idle.
3. When the fuellevel stabilizes, check that it is centered

in the inspectíon window.
THROTTLE
CONTROL
BRACKET
Measure accelerator 4. lf the fuel leve! is not centered, adjust it by slowly

pump travel here. turning the adjusting sc.rew.
5. Paint the adjustment screw with white paint after

adjustment.
NOTE: Do not turn the adjusting screw more than 1/
2. To check línkage travel, measure gap between bottom 8-turn every 15-seconds.
end of pump lever (tang) and stop as shown.
Limits: 11.5 to 12.0 mm (29/64" to 31/64")
6-83
Carburetor
ChokeOpener------------------------------------------------------
Testing 4. lf coolant temperatura is below about 14°C (57 .2°F},
Tab A on the choke opener lever should not be seated
1. Disconnect the 2P connector of the choke coíl heater. against the carburetor.
2. Open and close the throttle fully to let the choke close.
The choke valve should partially open.
e lf the choke partially opens, go on to step 4 or step

5, depending on coolant temperatura.
e lf the choke does not open partially, check the

linkage for free movement, repair as necessary, and
retest.
e lf the choke valve still does not open partially, check

the choke opener diaphragm: Remove the choke Coolant Temperature
opener, and cónnect a vacuum pump. Block the below 14°C (57.2°F)
orífice in the opener while you apply enough vac-
uum to pull the opener rod all the way in, then stop.
• lf TabA is not seated, go on to step 5.
CHOKE OPENER • lf TabA is seated, disconnect the #24 vacuum hose
from the choke opener.
CHOKE
OPENER
VACUUM PUMP/GAUGE
OPENER ROO
- lf the rod will not stay in, replace the opener.

- lf the rod stays in, check the vacuum port in the
carburetor for blockage.
NOTE: After replacing or reinstalling the choke opener,

retest it, then adjust it if necessary (page 6-88). #24 VACUUM HOSE
- lf TabA comes off its seat, check the #24 vacuum

line for proper connection or disconnected hose.
\f OK, replace the thermovalve A.
6-84
Choke Coil Tension and linkage
5. lf coolant temperatura is above about 25°C (77°F). lnspection (COLO ENGINE)
Tab A on the choke opener lever should be seated
against the carburetor. 1. Remove the air cleaner.
2. Open and close the throttle fully to let the choke close.
The choke valve should clase completely.
NOTE; Above about 28°C I82°F) the choke will not

close completely, but should still close to less than 3
mm (1/8 in.).
• lf the choke closes properly, go on on to the fast

id le unloader test on page 6-89.
e lf the choke does not close properly, spray its lin-
kage with carburetor cleaner, and check the linkage
for sings of mechanical binding (use a spray can
with an extension on the nozzle to reach the lin-
kage).
TABA CAUTION: Carburetor cleaner is very caustic;

Coolant temperatura always wear safety goggles or a face shield when
above 25°C (77°F) spraying.
e lf TabA is not seated, check the #24 vacuum line

for proper connection, cracks, blockage or discon-
nected hose. lf OK, replace the thermovalve A.
e lf the choke still does not close properly, remove

the choke cover (page 6-86) and inspect the lin-
kage for free movement. Repair or replace parts as
necessary. Then reinstall the cover and adjust it so
the index marks line up, and retest.
• lf the choke still does not close properly, replace the

cover (page 6-86).
INDEX
MAR KS
KX
KG
6-85
Carburetor
Choke Coil Heater---------------------------------------------------
Testing Replacement
Start the engine and let it run. As the engine reaches normal 1. Remove the air cleaner.
operating temperatura, the choke valve should fully open:
2. Remove the 2P connector, cut the harness band and
e lf it does, go on to the fast idle unloader test on page disconnect the choke cap harness from clamp.
6-89.
CAUTION: Take care not to apply excessive force
• lf it doesn't inspect the linkage, and clean or repair itas on the clamp as it is broken easily.
necessary (page 6-85).
e lf the choke still does not open all the way, disconnect
the connector, and measure voltage between WHT/BLU
{ +) terminal and body ground.
There should be battery voltage with the engine running.
\\
\ \
3. Disconnect the terminal retainer from the connector

and remove the two terminals.
CONNECTOR
- lf there is no voltage, inspect open in WHT/BLU wire
between the connector and the alternator.
lf OK, inspect the alternator (section 16).
TERMINAl
RETAINER
(Replacel
6-86
4. KX, KG: 7. Secure the harness with the clamp as shown in the
Using a 5/32" or 4.1 mm diameter drill, drill out the drawing and use the harness band to hold the two
rivets and remove the choke cover. harnesses together 180 mm from the tip of the con-
nector.
CAUTION: Cover the carburetor with a clean shop
rag to prevent chips from falling into the carburetor CAUTION: Cut off the excess of the harness band
throat. and set it on the harnesses so that the tip of the
band points to the vacuum hose manifold.
Except KX, KG:
Remove the screws and remove the choke cover.
5. Reinstall the cover and adjust it so that index marks

align (KX, KG:, then secure it with rivets).
INDEX MARKS
VACUUM
HOSE
MANIFOLD
180±10 mm
8. Reconnect the connector and reinstall the air cleaner.
CHOKE COVER
6. Connect the respective terminals to a new connector

and install a new terminal retainer.
NOTE:
• Be su reto connect the terminal befare installing the
terminal retainer.
e Replace the connector and terminal retainer witli
the new ones.
e Note the location of the terminal.
PRIMARY SLOW
MIXTURE CUT-OFF TERMINAL
SOLENOID VALVE RETAINER
6-87
Carburetor
Choke linkage------------------------------------------------~
Adjustment 5. Remove the check valve, and reconnect the choke

opener hose.
NOTE:
• This check is not necessary unless the linkage has been
bent, choke opener has been replaced, or the car has 6. Hold both levers together, then push them toward the
poor cold starting. diaphragm again until they stop (Tab A on the opener
lever seats against the carburetor), and measure the
• This check can be made with the engine HOT or COLO.
clearance at the choke valve.
1. Remove the choke cover (page 6-87)
Measure clearance here
2. While holding the choke valve closed, open and close
the throttle fully to engage the choke and fast idle
linkage.
3. Disconnect the choke opener hose from the vacuum

hose manifold, and attach a check valve to it as
shown. Then pressurize the choke opener with low
pressure compressed air, 1 03-586 kPa ( 1 5-85 psi)
is OK, to hold the bleed valve in it closed.
2nd Stage clearance:

3.1 ± 0.11 mm (0.122 ± 0.004 in.)
Adjust clearance by bending Tab A.
CHOKE OPENER LEVER
7. While still holding opener lever Tab A against its seat,
release the choke drive lever, and meassure the clear-
ance at the choke valve (Tab C on the drive lever
COMPRESSED AIR e;>~·,___ ___..
should stay seated against the spring loop; if not,
repeat step 2 and recheck):
CHECK VALVE
4. Gently push the choke opener lever towards the

opener until is stops (until you feel the opener rod seat
against the pressurized bleed valve), then pull the
choke drive lever down against the opener lever (to
take all free play out of the linkage), and measure the
clearance between the choke blade and casting:
1st Stage Clearance

0.88 ± 0.07 mm (0.035 ± 0.003 in.)
Adjust clearance by bending Tab D.
SPRING LOOP
3rd Stage Clearance:

5.2 ± 0.28 mm (0.205 ± 0.011 in.)
6-88
Fastidie------------------------------------------------------~
Testing
1. Disconnect the two hoses from the fast idle unloader.
FAST IDLE UNLOADER
5. Reconnect the hoses.
6. Warm up to normal operating temperatura (the cooling

fan comes on).
When the engine warms up, its speed should drop

2. Open and close the throttle fully to engage the fast idle
below 1,400 min- 1 (rpm) as the unloader pulls the
ca m.
interna! choke linkage off the fast id le cam.
FAST IDLE CAM
e lf fast id le does not drop below 1 ,400 m in - l (rpm).
disconnect the two unloader hoses, and check the
vacuum.
VACUUM PUMP/
GAUGE
~~
Fast idle should be 3,400 ± 500 min-1 (rpm)

e lf there is no vacuum, check the #25 and #26
Adjust the fast idle speed, if necessary, by turning the vacuum line for proper connection, cracks, block-
fast id le adjusting screw. age or disconnected hose. lf OK, replace the ther-
movalve A.
e lf there is vacuum, replace the fast idle unloader,

and then inspect the choke coil tension and linkage
(page 6-85).
6-89
Carburetor
Remova------------------------------------------------------~
AIR CLEANER COVER
AIR CLEANER ELEMENT

• EC, KO: Replace every
2 years or 40,000 km {24,000
INTAKE AIR
CONTROL
• Others: Replace every 1
DIAPHRAGM
year or 20,000 km (12,000 miles)
whichever comes first.
AIR
CLEANER
CASE
HOT AIR TUBE
THROTTLE CABLE
0-RING
Replace
6-90
Replacement
(KX, KS , KG , KQ)
AIR HORN
PUMP LEVER
AIR VENT
SOLENOIOCUT-OFF
VAL VE
PRIMARY ~LOW
MIXTURE
SOLENOIDCVUATLVE
-OFF
CHOKE COVER :~;~LERATOA

DIAPHRAGM
=
-
CHOKE
OPENER
THROTT LE CONTRO LLER
THROTTLE
BODY
SECONDARY IDLE BOOST
DIAPHRAGM THROTTLE CONTROLLER
6-91
Carburetor
Replacernent-=-----------------------------------------------------
AIR CORN LEVER
PUMP
l~
'
® PRIMAMY
SLOW MIXTURE
CUO-OFF
SOLENOIO
VALVE
CHOKE _ ___._p..
OPENER
SECONDARY
DIAPHRAGM
ID LE
BOOST
THROTTLE
CONTROLLER
6-92
Carburetor
Replacernent-=-----------------------------------------------------
AIR CORN LEVER
PUMP
l~
'
® PRIMAMY
SLOW MIXTURE
CUO-OFF
SOLENOIO
VALVE
CHOKE _ ___._p..
OPENER
SECONDARY
DIAPHRAGM
ID LE
BOOST
THROTTLE
CONTROLLER
6-92
Fuel Supply System
Symptom-to-sub System C h a r t - - - - - - - - - - - - - - - - - - -
NOTE:
inspected, starting with CD. Find the symptom in the feft column, read across to the most likely source, then refer to the page
listed at the top of that column. lf inspection shows the system is OK, try the next system ®. etc.
e Before starting inspection, check that other items that affect engine performance are within spedfication. Check the self-
diagnosis indicator, valve clearance, air cleaner, and PCV valve. In addition, check the ignition timing, function ofthe vacuum
troubleshooting listed in this page.
~
PAGE
FUEL FUEL
FUEL CUT-OFF 1 FUEL CONTAMI-
FILTERS PUMP RELAY TANK NATED FUEL 1
1
SYMPTOM 94 94 96 97
*
ENGINE WON'T START (3). (Í) el) C2J
MISFIRE OR (Í)
ROUGH RUNNING (Í) 1
POOR
PERFORMANCE
LOSS OF (Í)
POWER (Í)
* Fuel with dirt, water or a high percentage of alcohol is considered contaminated.
6-93
Fuel Supply System
Fuel Filters------------. Fuel Purnp-------------------
Replacement Testing
Replace both front and rear filters every 2 years or 40,000
km (24,000 miles) whichever comes first.
N.hJiii§M Do not smoke during the test. Keep
any open flame away from your work area.
t'ih;ff"E Do not smoke while working on the
NOTE: Check for a clogged fu el filter and or fu el line
fuel system. Keep open flame away from work
before checking fuel pressure.
area.
1. Remove the dashboard under cover and the fuel cut-
Front
off relay.
1. Use fuel line clamps to pinch off the fuel lines.
2. Connect a jumper wire between the No .1 terminal and
2. Disconnect the fuel lines and remove the fue! filter.
the No.2 terminal.
CAUTION: When disconnecting the fuellines, slide
back the clamps then twist the lines as you puiL to
avoid damaging them.
3. Instan the new fu el filter.

4. Remove the fuel line clamps.
No.2
FUEL CUT-OFF RELAY
3. Dísconnect the fuel line at the fuel filter in the engine

compartment, and connect a pressure gauge to it as
shown.
Rear
1. Block front wheels. Jack up the rear of the car and FUEL PRESSURE
support with jackstands. GAUGE
2. Push in the tab of the fu el filter to relea se the holder
then remove the filter from its bracket. '
3. Attach fuelline damps to the fuellines and disconnect
the lines from the filter.
CAUTION: To avoid damaging the fuel lines when

disconnecting, slide back the clamps then twist the
fines as you pull.
4. Instan in the reverse order of removal.

FUEL LINE CLAMP PLUG
07614-0050100
4. Turn ignition ON until pressure stabilizes, then turn key
10
off.
Pressure should be 8.8-13.7 kPa (1.3-2.0 psi).
• lf gauge shows at least 8.8 kPa (1.3 psi), go on to

step 5.
• lf gauge shows less than 8.8 kPa (1 .3 psi), replace

the pump and retest.
HOLDER
6-94
Fuel Supply System
Fuel Cut-off Relay - - - - - - - - - - - - - - - - - - - - - - - - - .
Testing • lf there is no voltage, check the BLU wire from the
ignition coil and fuel cut-off relay.
1. With the ignition .switch off, remove the dashboard
under cover. 6. Turn the ignition switch OFF.
2. Remove the fu el cut-off relay. Connect a jumper wire between the No.1 terminal and
3. Check for continuity between the No.J terminal and the No.2 terminal.
body ground.
Continuity should exist.
e lf there is no continuity, check the BLK wire

between the fuel cut-off relay and G401.
4. Attach the positive probe of the voltmeter to the No.2

terminal and the negative probe to the No.J terminal.
Then turn the ígnition switch ON.
Battery voltage should be available.
7. Turn the ignition switch ON.
The fuel pump should run.
• lf the fuel pump does not run, and disconnect the

JP connector in the luggage area.
Attach the positive probe of the voltmeter to YEL
terminal and negative probe to body ground.
Battery should be available.
e lf there is no voltage, check the BLK/YEL wire from

the ignition switch and fuel cut-off relay as well as
No.2 fuse.
5. Turn the ignition switch OFF.

Attach the positive probe of the voltmeter to the No.4
terminal and the negative probe to the No.J terminal.
Then turn the ignition switch ON.
- lf OK, check BLK wire between the fuel pump and

G601, and YEL wire between the fuel pump and JP
connector. lf OK, replace the fuel pump.
- lf not, check YEL wire between the fu el cut-off relay
and fuel pump.
lf the wires are OK, replace the fuel cut-off relay and retest.
6-96·
Fuel T a n k - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ; , "
Replacement
Bifii;ifdii Do not smoke while workiilg on fuel system. Keep open flame away from your work area.
1. Block front wheels. Jack up the rear of the car and support with jackstands.
2. Remove the drain bolt and drain the fuel into an approved container.
3. Disconnect the fuel gauge sending unit alid fuel pump connectors.
4. Disconnect the hoses.
CAUTION: When disconnecting the hoses, slide back the clamps. then twist hoses as you pull. to avoid damaging
them.
5. Place a jack, or other support, under the tank.

6. Remove the strap nuts and let the straps fall free.
7. Remove the fuel tank.
NOTE: The tank may stick on the undercoat applied to its mount. To remove, carefully pry it off the mount.
8. lnstall a new washer on the drain bolt, then install parts in the reverse order of removal.'
FUEL PUMP
MOUNTING BOLT
6-97
Air lntake System
Symptom-to-Sub System Chart - - - - - - - - - - - - - - - - - -
NOTE:
listed at the top of that column. lf inspection shows the system is OK, try the next system ®, etc.
diagnosis indicator, valve clearance, air cleaner, PCV valve. In addition, check the ignition timing, function of the vacuum and
centrifuga! advance, and the condition of the spark plugs. lf those items are all within specifications, begin with the trouble-
shooting listed in this page.
L:::~
PAGE
THROTTLE CABLE AIR INTAKE CONTROL
SYMPTOM ~·~-------------9-9------------~,-------------,-o-o------------~
LOSS OF POWER
l
1
AFTERBURN CD
HESITATION/SURGE CD
6-98
Throttle C a b l e - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
lnspection/ Adjustment lnstallation
1. Warm up the engine to normal operating temperature 1. KX, KS, KG, KQ and KF, KB, KE, KY, KW, KP, KT
(the cooling fan comes on). (M/T);
Disconnect the hose from the throttle controller and
2. Check that throttle cable operates smoothly with no connect a vacuum pump to the controller, then apply
binding or sticking. Repair as necessary. vacuum.
VACUUM PUMP/GAUGE
3. Start the engine and check cable free-play at throttle
linkage at idle. Cable deflection should be 4-1 O mm
(3/16-3/8 in.).
THROTTLE
CONTROLLER
2. Fully open the throttle and choke valves, then close

the throttle valve. Now, release the choke valve; the
throttle linkage wilf be off the fast idle ca m.
4. lf deflection is not within specs, loasen locknut and
turn adjusting nut until you can deflect cable as speci- 3. lnstall the throttle cable in the throttle linkage.
fied. Then tighten locknut.
4. Remove the cable housing from the throttle bracket,
5. With cable properly adjusted, check throttle valve to set the adjusting nut on throttle bracket.
be su re it opens fully when yo u push accelerator pedal Adjust the adjusting nut so that its free play is O mm.
to the floor.
5. Remove the cable housing from the throttle bracket,
CAUTION: Check throttle valve to be sure it returns reset the adjusting nut and tighten the bocknut.
to idle position whenever you release accelerator.
ADJUSTING NUT
THROTTLE CABLE
6. KX, KS, KG, KQ and KF, KB, KE, KY, KW, KP, KT
(M/T):
Disconnect the vacuum pump and reconnect the
throttle controller hose.
7. On models with automatic transmission, adjust the

throttle control cable. See section 9.
6-99
Air intake System
lntake Air Control S y s t e m - - - - - - - - - - - - - - - - - - - - - - - ,
Testing (COLO ENGINE) Testing (HOT ENGINE)
NOTE: lntake air temperatura must be below 25-°C (77°F} 1. Start the engine and ·warm up to normal operating
temperatura (the cooling fan comes on).
1. Disconnect the air intake duct and start the engine.
The a ir control door should be down.
The air control door should rise.
AlA INTAKE DUCT
e lf not, disconnect the #8 vacuum hose from the air e lf not, disconnect the #8 vacuum hose from the air
control diaphragm, ·and connect a vacuum pump. control diaphragm, and connect a vacuum pump.
There should be vacuum. There should be no vacuum.
118 V~,CUUM HOSE - lf there is no vacuum, replace the aír control dia-
phragm and retest.
- lf there is vacuum, replace the air bleed valve and
retest.
AIR CONTROL
DIAPHRAGM
- lf there is vacuum, replace the air control dia-

phragm and retest.
- lf there is no vacuum, check the #8 vacuum hose
for proper connection, cracks, brockage or díscon-
nected hose, and replace the air bleed valve.
6-100
Emission Control System
Symptom-to-sub System Chart - - - - - - - - - - - - - - - - - -
(KX, KS, KG, KQ)

NOTE:
inspected, starting with CD. Find the symptom in the left column, read across to the most likely source. then refer to the page
listed at the top of that column. lf inspection shows the system is OK, try next system @. etc.
diagnosis indicator, valve clearance, air cleaner, and PCV valve. In addition, check the ignition timing, function ofthe vacuum
troubleshooting listed in this page.
1 1
~-
PAGE
FEEDBACK THROTTLE EGR EVAPORATIVE AIR
CONTROL CONTROL CONTROL INJECTION
)
~
1
SYMPTOM 112 110 115 107
104
ENGINE WON'T START cv CD
DIFFICULT TO
1 WHEN COLO 1
l
(j) cv '
cv CD
START ENGINE
WHEN WARM CD cv <]) CD 1
WHEN COLO FAST

IDLE OUT OF
SPECIFICATION
(j) cv 1
cv
1
i
WHEN WARM ENGINE
IRREGULAR SPEED TOO HIGH CD
IDLING
WHEN WARM ENGINE
SPEED TOO LOW CD cv
cv
1
ROUGH IDLE/ (j)
FLUCTUATION
FREQUENT
WHILE
WARMING UP CD cv
STALLING
cv
1
AFTER
WARMING UP CD
MISFIRE OR
ROUGH RUNNING cv í
CD
LOSS OFF !
POOR
POWER CD CD
PERFORMANCE
AFTERBURN
'
CD cv cv
HESITATION/SURGE CD cv
6-101
/
/
/
E~ion Control System
/ Symptom-to-sub System Chart - - - - - - - - - - - - - - - - - -
PAGE
r
SYMPTOM
S::
~
THROTTLE CONTROL
113
EVAPORATIVE CONTROL
117
1
~,
ENGINE WON'T START ~ CD

1
l WHEN COLD ~ CD
1 DIFFICULT TO
START ENGINE
WHEN WARM
~ CD
1
WHEN COLD FAST

IDLE OUT OF
SPECIFICATION
CD 1
WHEN WARM ENGINE

IRREGULAR SPEED TOO HIGH ~ CD
IDLING
WHEN WARM ENGINE i ~ CD
1
SPEED TOO LOW
ROUGH IDLE/
FLUCTUATION ~ CD
WHILE
WARMING UP ~ CD
FREQUENT 1
STALLING
AFTER
WARMING UP ~ CD
MISFIRE OR
ROUGH RUNNING
1
CD
1
LOSS OFF
POOR
. POWER !
CD
PERFORMANCE
/ AFTERBURN
CD ~
HESITATION/SURGE
l
CD
1
6-102
Tailpipe Emissions---------, Catalytic Converter--------,
lnspection (KX, KS, KG, KQ)
NOTE: lt is not possible to use aCOmeter to adjust the lnspection

idle mixture; the effect of the catalytic converter pre-
vents accurate tracking of such small changes in air- lf excessive exhaust system back-pressure is suspected,
fuel ratio. remove the catalytic converter from the car and make a
visual check for plugging, melting or cracking of the cata-
fiit#.];ifii§(i
Do not smoke during this procedure, Keep lyst, Replace the catalytic converter if any of the visible area
any open flame away from your work area. is damaged or plugged.
1. KX, KS, KG, KQ:

Check the idle speed/mixture using the propane
enrichment method.
2. Warm up and calibrate the COmeter according to the
meter manufacturer's instructions.

temperature (the cooling fan comes on twice).

hold engine at idle for 2 minutes.
And hold engine at 2,500-3,000 min- 1 (rpm) for 1
minute.
5. Check idle CO wíth the headlights, heater blower, rear

window defogger, cooling fan, and air conditioner off.
Specified CO %:
KX, KS. KG, KQ: 0.1% maximum
34 N·m (3.4 kg-m, 25 lb-ft)
Except KX, KS. KG. KQ: 1.0 .± 1.0%
34 N•m (3.4 kg-m, 25 lb-ft)
CATALYTIC
CONVERTER
Removal lnstallation, section 5
lnspect housing for cracks or
other damage.
lnspect element for clogging
by looking through the inside.
6-103
Feedback Control--------------------------------------------------
Troubleshooting Flow Chart EACV
PORT
(KX. KS, KG. KQ)
· lnspection of EACV.
Start the engine and warm up to

normal operating temperatura (the
cooling fan comes on).
Remove the air cleaner cover.
Raise the engine speed to 5, 000

min- 1 (rpm).
YES Check the self-diagnosis indica-

ls there vacuum ? ter (page 6-22). lf OK, replace
the EACV and retest.
NO
Raise the engine speed to 5,000

min- 1 (rpm). then close the throt-
tle suddenly.
Check the self-diagnosis indicator

ls there vacuum ?
(page 6-22).
YES
YES Go to EACV trouble-

Does LED índícate cede 14 ? shooting flowchart
(page 6-105).
NO
Check the hose for proper con-

nectíon, cracks, brockage or dis-
connected hose. lf OK. replace
the EACV and retest.
EACV ís OK.
6-104
-$- Self-diagnosis lED indicator blinks fourteen times: A problem in the Electronic Air Control Valve (EACV) circuit.
-Engine is running.

Start engine.
lntermittent failure (test driving

Does LEO indicates CODE 14 ?
may be necessary). EACV
VES
Stop engine.
Disconnect the 2 P connector on

the EACV.

terminals on the EACV.
ls there 10-15 .O ? Replace EACV.
YES
Check for continuity to body

ground on each terminal on the
EACV.
YES
Does continuity exist ? Replace EACV.
NO
(To page 6-1 06) (cont'd)
6-105
Feedback Control (cont' d) _ _ _ _ _ _ _ ___;,_._ _ _ _ _ _ _ _ _ _ ______,
(From page 6-105)
Reconnect the 2P connector to

EACV.

nector (page 6-20). Disconnect
00000000000
"A" conneffior from the main wire
00000000 00000000000
harness only, not the control unit.
A10
Check for continuity between A 1 O

-=-
terminal and the body ground.
NO Repair open in BLK wire

Does continuity exist ? between control unit (A10) and
G101.
YES
10-15Q
Mea su re resistan ce between A 1 A3
( +) terminal and A3 (-) terminal.
00000000000 00000000000
00000000000 00000000000
Repair open in BLK/BLU wire

between control unit (A 1) and
ls there 10-15 O?
EACV or YEL/BLK wire between
YES control unit (A3) and EACV.

voltage is now available replace
6-106
(KX, KS, KG, KO) 4. Warm up to normal operating temperature.
NOTE: Engine coolant temperature must be below
Testing 70°C ( 158°F).
1. Start the engine. A bubbling noise should be heard.

2. Remove the air cleaner cover and filter.
3. Start the engine and check for a bubbling noise from e lf bubbling noise is not heard, disconnect the #5
the a ir suction port idle. vacuum hose from the air suction valve and connect
a vacuum pump.
A bubbling noise should not be heard.
NOTE: Engine coolant temperature must be below
30°C (86°F) - lf there is vacuum, replace the air suction valve
AIR SUCTION and retest.
PORT - lf there is no vacuum, check the #5 and #12
vacuum line for proper connection, cracks, ·
blockage or disconnected hose. lf OK, go to
troubleshooting (page 6-1 08).
e lf a bubbling noise is heard, disconnect the #5

vacuum hose from the air suction valve and connect
a vacuum pump.
There should be no vacuum.
#5 VACUUM HOSE
SUCTION
VALVE
- lf there is no vacuum, replace air suction valve and

retest.
- lf there is vacuum, go to troubleshooting (page
6-1 08).
(cont'd)
6-107
Air lnjection Control ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - -
Troubleshooting Flow Chart Air Suction Control Solenoid Valve
l lnspection of Air Suction Control

Solenoid Valva.
1 (KX. KS. KG) (KQI
AIR SUCTION
CONTROL
AIR SUCTION
1
CONTROL SOLENOID VALVE SOLENOID VALVE
Open the control box lid.
l
Disconnect the #5 vacuum hose of

vacuum gauge. VACUUM
PUMP/GAUGE
VACUUM
Start the engine. PUMP/GAUGE JOINT
NOTE: Engine coolant temperature must

App!y vacuum.
be below 30 °C (86 °F)
YES

control box.
NOTE: Engine coolant

Warm up normal operating tem-
temperatura must be
peratura.
below 70 °C (158 °F)
Start the engine.
Measure vo!tage between;

KX, KS, KG: PNK (+) and BLK BLK
(-) terminals
KQ: LT GRN {+) and BLK (-)
terminals 1
Check the self-
1 11 diagnosis indicator
(page 6-22). lf OK.
1
YES substituta a known-

ls there voltage ? good control unit and
retest. lf symptom
1 NO goes away. replace
the original control
(page 6-1 09) Replace the solenoid valve.
1
unit.
6-108
(From page 6-1 08)
VES

control box.
Start engine.

valve.
1 NO

KX, KS, KG: PNK (+) and body
ground.
KQ: LT GRN (+) and body
ground.
VES Repair open in BLK

1
ls there battery voltage ? wira betwaen tha con-
NO l trol box and G251.

L-----------------~
Allow it to idle.
1
Replace the solanoid ¡
ls vacuum indicated on the gauge ?
valva. 1
Check the salf-diagnosis indica-

ter (paga 6-22). lf OK, inspect
opan in PNK or LT GRN wire
Air Suction Control Solanoid between the control box and con-
Valva is OK. trol unit (AS).
6-109
EGR Systern--------------------------------------------------~
Testing (COLO ENGINE) Testing {HOT ENGINE)
NOTE: The engine coolant temperature must be below the 1. Disconnect the vacuum hose from the EGR valve and
thermovalve 8 set temperature (55°C, 13PF). connect a vacuum gauge to the hose.
1. Disconnect the vacuum hose from the EGR valve and

connect a vacuum gauge to the hose.
EGR VALVE
2. Start the engine and wait for the cooling fan to come
on.
3. Remove the control box and remove the control box

2. Start the engine and raise the engine speed to 3,000 cover.
min- 1 (rpm)
Vacuum should be as shown below:
Vacuum should not be available.
Condition Vacuum at EGR hose
e lf vacuum is not available, go on to the hot engine
inspection (right column). 1 Id le No
e lf vacuum is available, replace thermovalve B and 2 3,000 min- 1 (rpm) Y es, 50-152 mm
retest.
3,000 min- 1 (rpm)
with blocked vacuum
3 Less than 50 mm Hg
bleed (shown next
column)
4 Rapid acceleration Yes, 50-152 mm Hg

5 Deceleration No
6-110
EGR Valve
1. Start engine and allow to idle.
2. Disconnect vacuum hose from EGR Valve and connect

EGR CONTROL VALVE
a vacuum pump to EGR Valve
VACUUM (
AIR FILTER PlJn/IP/
GAUGE
e lf vacuum is available at idle (condition 1) check the

vacuum hoses for proper routing and connections, EGR VALVE
then check for correct idle speed and idle mixture,
and make adjustment as necessary.
e lf there is no vacuum in conditions 2 and 4, check

the #1 O, #11, #15, #16 and #17 vacuum line for
proper connection, cracks, blockage or discon- 3. Apply 150 mm Hg (6 in. Hg) vacuum to EGR Valve.
nected hose. lf OK, replace the thermovalve B and Vacuum should remain steady and engine should die.
retest.
e lf vacuum remains steady and engine dies, EGR
e lf vacuum is more than 50 mm Hg in condition 3, valve is working properly, remove the vacuum
replace the EGR control valve and check the vac- pump and reconnect EGR vacuum hose ; test is
uum hoses for proper routin!i! and connections. complete.
• lf vacuum does not remain steady and engine does

not die, replace EGR valve and retest.
e lf vacuum remains steady but engine does not die :

Remove EGR valve ; check EGR valve and manifold
for blockage, clean or replace as necessary and
retest.
6-111
Throttle Control System - - - - - - - - - - - - - - - - - - - - - - -
Testing (HOT ENGINE) e lf the engine speed does not change, connect a
(KX, KS, KG, KQ ANO KF, KB, KE, KV, KW, KP, KT vacuum pump to the #6 vacuum hose and check
(A/TI) vacuum.
1. Start the engine and warm up to normal operating There should be vacuum.
temperatura (the cooling fan comes on). '
2. Disconnect the #6 vacuum hose from the throttle
controller and check the engin~ speed. #6VACUUM
HOSE
Engine speed should be: 1 ,800 ± 300 min- 1 (rpml
#6 VACUUM HOSE
~ VACUUM
PUMP/GAUGE
THROTILE CONTROLLER
- lf tf:¡ere is no vacuum, check the #6 vacuum hose

for proper connection, cracks, brockage or discon-
nected hose.
THROlTLE CONTROLLER - lf there is vacuum, replace the throttle controller
and retest.
3. Reconnect the #6 vacuum hose and check the idle

e lf the engine speed is excessively high, adjust by speed.
turning the adjusting screw. ldle speed should be within specification (page 6-77).
6-112
Testing Throttle Controller Control Valve Testing
(Except KX, KS, KG, KQ and KF, KB, KE. KV, KW. (Except KX, KS. KG, KQAND KF, KB, KE, KV, KW.
KP, KT (A/T)) KP. KT (A/T))
1. Start the engine and warm up to normal operating 1. Start the engine and warm up to normal operating
temperatura (the cooling fan comes on). temperatura (the cooling fan comes on).
2. Connect a vacuum pump to the #6 vacuum hose.
2. Disconnect #6 vacuum hose from the throttle control-
ler, connect a vacuum pump to the controller and Raise the engine speed to 3,500 min-' (rpm) and close
appfy 400 mmHg (16 in. Hg) vacuum. the throttle suddenly, then check vacuum.
Engine speed should rise to 1,300-2,300 min- 1 There should be vacuum.

(rpm) with in 1 minute.
tf'-o
~~:;,~~:,.~
e lf there is vacuum, replace the throttle controller
and retest.
#6 VACCUM HOSE e lf there is no vacuum, check the #6 vacuum hose

for proper connection, cracks, blockage or discon-
nected hose, and disconnected the lower vacuum
e lf the engine speed is excessively high, adjust the hose from the throttle controller control valve.
engine speed by bending TAB. Check the vacuum.
e lf the engine speed does not change, replace the - lf there is no vacuum. check the lower and #3
throttle controller and retest. vacuum line for proper connection, cracks, block-
lf OK, replace the throttle controller control valve.
3. Reconnect the #6 vacuum hose and check the idle

speed.
ldle speed should be within specification (page 6-77}.
6-113
Positive Crankcase Ventilation S y s t e m - - - - - - - - - - - - - - - - - - ,
PCV Valve Testing Blow-by Filter Testing
1. Check the crankcase ventilation hoses and connec- lnspect the condition of the blow-by filter.
tions for leaks, cracks or clogging.
e Replace the filter in the following instances;
PCV_HOSE
- When the filter is stuck fast and oil is dripping or
seeping through.
- When the filter is covered with dust and dirt so that

clogging is evident.
BLOW-BY FILTER
BREATHER HOSE
2. At idling, make sure there is a clicking should from the

PCV valve when the hose between PCV valve and
intake manifold is lightly pinched with your fingers or
pliers.
BLOW-BY CASE
PCVVALVE
Gently pinch here
e lf there is no clicking sound, check the PCV valve

grommet for cracks or damage. lf the grommet is
OK, replace the PCV valve and recheck.
6-114
Evaporative Emission C o n t r o l s - - - - - - - - - - - - - - - - - - - - - - - ,
(KX, KS, KG. KQ) Testing (HOT ENGINE)
Testing (COLO ENGINEI
1. Disconnect the vacuum hose (KO: #19) at the purge
NOTE: Engine coolant temperature must be below 63 control diaphragm valve and connect a vacuum pump/
""C (145°F) gauge to the hose.
1. Disconnect the vacuum hose (KQ: #19) at purge PURGE CONTROL

control diaphragm valve and connect vacuum pump/ DIAPHRAGM VALVE
gauge to the hose.
PURGE CONTROL
DIAPHRAGM VALVE
VACUUM
PUMP/GAUGE
#19 VACUUM HOSE

VACUUM
PUMP/GAUGE
#19 VACUUM HOSE
2. Start the engíne and warm up to normal operatíng

temperature (the cooling fan comes on).
Block rear wheels and set the parking brake. Jack up
the front of the car and support with safety stands.
2. ·Start the engine and allow to idle.
fiftil·!Q§!i§M Block rear wheels before jacking up
There should be no vacuum. front of car.
e lf there is no vacuum, go to hot engine ~est (next Place the shift or selector lever in 2nd gear or "2"
column). range and accelerate above 5 km/h, 2,000 min- 1
e lf there is vacuum, go to troubleshooting (page (rpm).
6-119).
e lf there is vacuum, go to step 3.

e lf there is no vacuum; check the #19 and #12
vacuum line for proper connection, cracks, block.-
age or disconnected hose. lf OK, go to trouble-
shooting (page 6-119).
3. Disconnect a vacuum pump/gauge and reconnect

hose.
4. Remove fuel filler cap.
(cont'd)
6-115
Evaporative Emission Controls (cont'd)---------------..;...._-
5. Remove the canister purge air hose from frame and e lf vacuum remains steady, go on to step 9.
connect hose to a vacuum gauge as shown.
e lf vacuum drops, replace the canister and retest.
VACUUM/PRESSURE GAUGE .
9. Restart the engine. Reconnect the hose to the canister
1 PCV fitting, and raise engine to 3,500 min- 1 {rpm) (in

2nd gear or "2" range}.
PURGE sida vacuum should drop to zero.
e lf PURGE side vacuum does not drop to zero,

replace the canister and retest.
10. Connect a vacuum pump to TANK fitting as shown,

and apply vacuum.
lf should not hold vacuum.
"TANK" FITTING
6. Place the shift or selector lever in 2nd gear or "2"
range and raise the engine speed to 3,500 min- 1
{rpm).
Vacuum should appear on the gauge within 1 minute.
e lf vacuum appears on the gauge in 1 minute,

remove the gauge and go on to step 8.
e lf no vacuum, disconnect the vacuum gauge and

reinstall the fuel filler cap.
7. Remove the charcoal canister and check for signs of

damage.
e lf damaged, replace the caníster.

e lf OK, g_o on to step 8.
8. Stop the engine. Disconnect the hose from the canis-

ter PCV fitting.
Connect a vacuum pump to the canister PURGE fitting
as shown, and apply vacuum.
Vacuum should remain steady.

e lf it does not hold vacuum, reinstall fuel filler cap
"PCV" FITTING and canister; test is complete.
• lf it holds vacuum, replace canister and retest.
VACUUM
PUMP/GAUGE
"PURGE" FITTING
6-116
(Except 10(, KS, KG, KQ) 6. Remove charcoal canister and check for signs of dam-
Testing age or defects.
1. Disconnect vacuum hose at the charcoal canister, e lf detective, replace the charcoal canister.
connect a vacuum pump/gauge to hose.
• lf OK, except KY: test is complete (KY: go on to
step 7). ·
7. KY:
Connect vacuum pump/gauge to TANK fitting as
shown, and apply vacuum.
2. Start the engine and raise speed to 3,500 min- 1 (rpm).
e lf vacuum is available, go on to step 3.
e lf vacuum is not available, check the·vacuum fine.

e lf vacuum does not remain steady, test is complete.
·J. Disconnect a vacuum pump/gauge and reconnect
hose. Remove fuel filler cap. e lf vacuum remains steady, replace the charcoal
canister.
4. Remove canister purge air hose from trame and con-
nect hose to a vacuum gauge as shown.
5. Raise engine speed to 3,500 min- 1 (rpm). Vacuum

should appear on gauge within 1 minute.
e lf vacuum appears on gauge in 1 minute, remove

gauge and go on to step 7.
e lf no vacuum, disconnect a vacuum pump/gauge
and go on to step 6.
(cont'd)
6-117
Evaporative Emission Controls ( c o n t ' d ) - - - - - - - - - - - - - - - - - .
(KX. KS. KG. KQ, KV) 4. Move hand pump hose from vacuum to pressure fit-
Two-Way Valve ting, and move vacuum gauge hose from vacuum to
pressure si de as shown.
1. Remove the filler cap.
PRESSURE SIDE
2. Remove vapor line from the fuel tank and connect a
T-fitting from a vacuum gauge and vacuum pump as
shown.
VACUUM/PRESSURE GAUGE
VACUUM
PUMP/
GAUGE
T-FITTING
5. Slowly pressurize the vapor line-while watching the

3. Slowly draw a vacuum while watching the gauge. gauge.
Vacuum should stabilize at 5 to 15 mmHg (0.2 to 0.6 Pressure should stabilize at 1Oto 35 mmHg (0.4 to 1 .
in.Hg). 4 in.Hg).
e lf vacuum stabilizes momentarily (two-way valve • lf pressure momentarily stabilizes (valve opens) at
opens) between 5 and 15 mmHg (0.2 and 0.6 in. 10to 35 mmHg (0.4to 1.4in.Hg). thevalveisOK.
Hg), go on to Step 4.
• lf pressure stabilizes below 10 mmHg (0.4 in. Hg)
• lf vacuum stabilizes (valve opens) below 5 mmHg or above 35 mmHg (1.4 in.Hg). install a new valve
(0.2 in.Hg) or above 15 mmHg (0.6 in.Hg), install and retest.
new valve and retest.
6-118
Troubleshooting Flowchart Purge Cut-off Solenoid Valve
(KX, KS, KG. KQ)
lnspection of Purge Cut-off

J (KX. KS. KG) (KQ)
Solenoid valve.
1
#1_9 HOSE
1
Open the control box.
L
-D-is_c_o_n_n_e_é_t
1
_t_h_e~l-ow_e_r_v_a_c_u_u_m
hose of the solenoíd valve from the
__liiJ t1' --....¡:::::-----./'1'.
Disconnect vacuum hose (KO:#

.t..
' fl VACUUM
PUMP/GAUGE
1 9) of the solenoid valve from the
vacuum hose manifold and con-
nect a vacuum gauge.
Start the engine.
Apply vacuum.
VES
1
NO
1
Block rear wheels and set the park- Disconnect the connector on the l
ing brake. Jack up the front of the control box. (KQ)
car and support with safety stand.
1
1
Start the engine.

1
Place the shift or selector lever in
second or "2" and accelerate 1
above 5 km/h, 2,000 min- 1 Measure voltage between;
~
(rpm). KX, KS, KG: LT GRN/BLK (+)
and BLK (-) terminals.
KQ: ORN {+) and BLK {-) termí-
nals.
ORN BLK
:
1

valve.
1 NO

KX, KS, KG: LT GRN/BLK {+)
and body ground.
KQ: ORN (+) and body ground.
l.
(To page 6-1 20)
f: WS#fiiijM
5 Block
rear wheels befo re
jacking up front of car.
6-119
Evaporative Emission Controls ( c o n t ' d ) - - - - - - - - - - - - - - - - -
YES Repair open in B LK wire

valve and G251 .
NO

tor (page 6-22). lf OK, inspect
open in LT GRN/BLK or PNK
wire between the solenoid valve
and control unit (A4).
NO
ls vacuum indicated on the gauge ? Turn the ignition switch OFF. !
YES
control box.
Start the engine.

1
Place the shift or selector lever in

second or "2" and accelerate ·
above 5 km/h, 2,000 min- 1
Purge Cut-off Solenoid Valve is (rpm).
[ OK.
r
Measure voltage between,

KX, KS, KG: LT GRN/BLK (+)
and BLK (-) terminals.
KQ: PNK (+) and BLK (-) termi-
nals. / Check the self-
diagnosis indicator
(page 6-22).
YES lf OK, substituta a
ls there voltage ? known-good control
unit and retest. lf
NO
symptom goes away.
replace the original
control unit.
6-120
AIR VENT CUT-OFF
SOLENOID VALVE
Troubleshooting Flowchart Air Vent Cut-off Solenoid Valve
(Except KT. KP)
lnspection of Air Vent Cut-off

Solenoid Valve.
Disconnect the vacuum hose from

the vacuum hose manifold.
Apply 100 mmHg (4 in.Hg} vac-

uum to the hose.
Does solenoid valve hold vacuum ? Replace the solenoid valve.
NO
Apply 100 mmHg (4 in.Hg} vac-

uum to the hose.
NO
VES
Disconnect the connector of the

solenoid valve.
Air Vent Cut-off Solenoid Valve

is OK.
YEL (+} terminal and body BLK/YEL
ground.
Repair open in BLK/

NO YEL wire between the
ls there battery voltage ? ignition switch and the
connector as well as
VES No.2 fuse.
Replace the solenoid val ve.
6-121
Special Tools
SpeciaiTools------------------------------------------------~
CD 07LAA-PT501 00 Oz Sensor Socket Wrench 1

~ 07LAJ-:PT301 00 ECU Test Harness 1
@ 07lAJ-PT30200 Test Harness 1
® 07JAZ-SH20100 R.P.M. Connecting Adaptor 1
® 07LAZ-PT301 00 R.P. M. Connecting Adaptor 1
@-1 07LAZ-PT30110 R.P. M. Connecting Adaptar {A) (1)
R.P.M. Connecting Adaptar (8) {1)
p-component Tools
@-2 07LAZ-PT30120
® 07 406-0040001 Fuel Pressure Gauge Set 1
®-1 07406-0040100 Pressure Gauge { 1)
omponent Tools
®-2 07406-0040201 Hose Assembly ( 1)
([) 07411-0020000 Digital Circuit Tester 1
CD @
®
® ®
®-1 ®-2
6-124
Component Locations
lndex--------------------------------------~---------------------
2.0l with CATA: THROTTLE

CONTROL BOX
EGR VALVE page 6-140 ANGLE
SENSOR
Troubleshootíng,
page 6-176
FAST IDLE VALVE
lnspectíon, page 6-206
TDC/CRANK/CYL SENSOR
AIR BOOST VALVE
JNJECTOR
RESISTOR
Testíng, page 6-212
COOLANT TEMPERATURE
(TW) SENSOR
HEATED
OXYGEN(Oz)SENSOR
Troubleshooting, page 6-156 EACV IN TAKE AIR TEMPERATURE
Troubleshooting, page 6-194 (TA) SENSOR
Troubleshootíng, page 6-178
2.0 t without CATA:

THROTTLE
MANIFOLD ABSOLUTE ANGLE
PRESSURE IMAP) SENSOR
SENSOR Troubleshootíng, page 6-176
FAST IDLE VALVE
AIR BOOST VALVE
INJECTOR
RESISTOR
Testing, page6-212
COOLANT TEMPERATURE
(TW) SENSOR
Troubleshootíng, page 6-17 4
IN TAKE AIR TEMPERATURE

EACV {TA) SENSOR
Troubleshooting, page 6-194 Troubleshooting, page 6-178
6-125
Component Locations
lndex--------------------------------------------------------------
2.2 t except KQ, KY:
CONTROL BOX THROTTLE
ANGLE
SENSOR
FAST IDLE VALVE
lnspection, page 6-206
COOLANT TEMPERA TU RE
(TW} SENSOR
T roubleshooting, page 6-1 7 4 BYPASS CONTROL
Troubleshooting, SOLENOID VALVE
page 6~235 Troubleshooting, page 6-225
HEATED
EACV OXYGEN(02ISENSOR
Troubleshooting, Troubleshooting, page 6-1 56
page 6-194
2.2t KQ, KY:

.MANIFOLD ABLOSUTE PRESSURE
(MAP) SENSOR
THROTTLE
ANGLE
SENSOR
TDC/CRANK/CYLSENSOR
Testing, page 6-212
COOLANT TEMPERATURE
(TW} SENSOR
HEATED
OXYGEN I02l SENSOR
(KQ only) INTAKE AlA TEMPERATURE
Troubleshooting,
Troubleshooting, page 6-1 56 ITA) SENSOR
page 6-194
6-126
LH:
IMA SENSOR
Troubleshootíng
page 6-180
ELECTRONIC CONTROL UNIT (ECUI

Troubleshooting, page 6- 152
RH:
IMA SENSOR
Troubleshooting
page 6-180
MAIN RELAY
Relay Testing, page 6-216
Hamess Testing, page 6-2l6
ELECTRONIC CONTROL UNIT (ECU)

Troubleshooting, page 6- 152
6-127
Component Locations
lndex----------~----~-------------------------------------------
AIR CLEANER ELEMENT

e EC: Replace every 2 years or 40,000 km (24,000
e Others: Replace every 1 year or 20,000 km THROTTLE BODY
(12,000 miles) whichever comes first.
Disassembly, page 6-224
THROTTLE CABLE
lnspection/Adjustment, page 6-222
INTAKE
CONTROL
SOLENOID
VAL VE
Troubleshooting
page 6-229
6-128
LH
FUEL FILTER
TWO-WAY VALVE
Testing, page 6-245
CHARCOAL CANISTER
Testing, page 6-21 5

Replacement, page 6-21 5
Troubleshooting, PRESSURE REGULATOR Replacement,

page 6-210 Testing, page 6-213 page 6-218
Replacement, page 6-211 Replacement, page 6-213 FUEL VAPOR PIPE
AH PRESSURE REGULATOR FUEL FILTER

Testing, page 6-213 Replacement, page 6-214 TV>fO-WAY VALVE
Replacement, page 6-213 Testing, page 6-245
CHARCOAL CANISTER
Replacement,
page 6-219
FUEL
RETURN
PIPE
Troubleshooting, FUEL
page 6-210 FEED
Replacement, page 6-211 PIPE
6-129
/
System Description
2.0 l without CATA:
MANIFOLD ABSOLUTE
PRESSURE (MAP)
SENSOR
Troubleshooting, Page 6-1 62
TO ENGINE MOUNT
CONTROL SOLENOID
VALVE CA/T ONLV)
AIR BOOST
VALVE
FRONT OF
VEHICLE
6-130
2.0i without CATA:
TO AIR ----...¡;
FLOW
TUBE
CD MANIFOLD ABSOLUTE PRESSURE (MAPI SENSOR @ FUEL PUMP

CV ELECTRONIC AIR CONTROL VALVE {EACV) @ FUEL TANK
@ FAST IDLE VAL VE ® INTAKE CONTROL SOLENOID VALVE
@ AIR BOOST VALVE @ AIR CHAMBER
@ AIR CLEANER @ CHECK VALVE
@ FUEL INJECTOR @ INTAKE CONTROL DIAPHRAGM
(J) PRESSURE REGULATOR @ PCVVALVE
@ FUEL FILTER
6-131
System Description
Vacuum Connections _____________________;....._____
2.0t with CATA:
CONTROL
BOX
page 6-140
CHARCOAL
CANISTER
Troubleshooting,
Page 6-229
FRONT OF
VECICLE
6-132
2.02 with CATA:
1
[1
~
\
®
lj
'~
Q)OXYGEN (Oz} SENSOR @AIR CHAMBER
®MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @CHECK VALVE
@ELECTRONIC AIR CONTROL VALVE (EACV) @INTAKE CONTROL DIAPHRAGM
@FAST IDLE VALVE @JPCV VALVE
@AIR BOOST VALVE @EGR VALVE
@AIR CLEANER @CONSTANT VACUUM CONTROL (CVC) VALVE
(])FUEL INJECTOR @AIR CHAMBER
@PRESSURE REGULATOR @EGR CONTROL SOLENOID VALVE
®FUEL FILTER @CHARCOAL CANISTER
@)FUEL PUMP @PURGE CUT-OFF SOLENOID VALVE
@FUEL TANK @PURGE CONTROL DIAPHRAGM VALVE
@INTAKE CONTROL SOLENOID VALVE @TWO-WAY VALVE
6-133
System Description
2.2 .e Except KE, KQ, KY:
BYPASS CONTROl
CONTROl SOlDNOIO VAlVE
BOX Troubleshootíng,
page 6-140 page 6-225
CHARCOAl
CANISTER
Troubleshooting
page 6-229
BYPASS CONTROl
DIAPHRGM
FRONT OF
VEHIClE
6-134
2.2 2 KE:
CONTROL
BYPASS CONTROL
BOX
SOLENOID VALVE
Troubleshooting,
page 6-225
TO ENGINE MOUNT
CONTROL SOLENOID
VALVE (A/T ONLYI
)...ooi----AIR BOOST
VALVE
BYPASS CONTROL
DIAPHRAGM
FRONT OF
VEHICLE
INTAKE
CONTROL SOLENOID
VALVE
Troub/eshooting, page 6-229
6-135
System Description
Vacuum Connections----------------------....;,_____
2.2 ~ Except KQ,KY:
CD
<DOXYGEN (02) SENSOR @INTAKE CONTROl DIAPHRAGM

®MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @BYPASS CONTROL SOlENOID VALVE
@ELECTRONIC AIR CONTROL VALVE (EACV) @AIR CHAMBER
@FAST IDlE VALVE @CHECK VAlVE
@AIR BOOST VAlVE @BYPASS CONTROl DIAPHRAGM
@AIR CLEANER @PCVVALVE
(l)FUELINJECTOR @EGR VALVE
@PRESSURE REGULATOR @CONSTANT VACUUM CONTROL (CVC) VALVE
@FUEL FILTER @AIR CHAMBER
@)FUEL PUMP @EGR CONTROL SOLENOID VALVE
@FUEL TANK @CHARCOAL CANISTER
@INTAKE CONTROL SOLENOID VALVE @PURGE CUT OFF SOLENOID VALVE
@AIR CHAMBER @PURGE CONTROL DIAPHRAGM VALVE
@CHECK VAlVE @TWO-WAY VALVE
6-136
2.2 t KQ:
PURGE CUT-OFF
SOLENOID VALVE
MANIFOLD ABSOLUTE
Troubleshooting,
PRESSURE (MAPl
Page 6-241
-- .. SENSOR
CHARCOAL
CANISTER
TO ENGINE MOUNT
CONTROL SOLENOID
VALVE IA/T ONLY)
Troubleshooting,
Page 6-229
FRONT OF
VEHICLE
6-137
System Description
2.2 i KY:
MANIFOLD ABSDlUTE
PRESSURE (MAP)
SENSOR
Troubleshooting, Page 6-162
Troubleshooting,
page 6-229
FRONT OF
VEHIClE
6-138
2.2 t KQ, KY:
TOPCV--~~
1 r
1 1
1 1
1 1
1 1
1 1
f 1
1 1
1 1
1 1
1 1
L-----------------, r-------------~
: ~ {KQ ONLY)
1 1
·~ 11 11
~@C:::::l®=========~
CDOXYGEN (02) SENSOR (KQ only) @INTAKE CONTROL SOLENOID VALVE

®MANIFOLD ABSOLUTE PRESSURE (MAP} SENSOR @AIR CHAMBER
@ELECTRONIC AIR CONTROL VALVE (EACV) @CHECK VALVE
@FAST IDLE VALVE @INTAKE CONTROL DIAPHRAGM
®AIR BOOST VALVE @PCV VALVE
@AIR CLEANER @CHARCOAL CANISTER
Q)FUEL INJECTOR @PURGE CUT-OFF SOLENOID VALVE
@PRESSURE REGULATOR @PURGE CONTROL DIAPHRAGM VALVE (KQ only)
@FUEL FILTER @TWO-WAY VALVE
@FUEL PUMP
(j])FUEL TANK
6-139
System Description
Control Box (Except 2.21 KE):
PURGE CUT-OFF
SOLENOID VALVE
EGR CONTROL
SOLENOID VALVE
T roubleshooting,
MANIFOLD ABSOLUTE
page 6-235
PRESSURE(MAP)SENSOR
CONSTANT VACUUM CONTROL (CVC)

VALVE
AIR CHAMBER
6-140
Control Box (2.2l KE):
MANIFOlD ABSOLUTE
PRESSURE (MAP)
SENSOR
Troubleshooting, Page 6-162 CONSTANT VACUUM CONTROL (CVC)
VALVE
PURGE COU-OFF
SOLENOID VALVE
T roubleshooting,
page 6-235
6-141
Systems Description
Electrical Connections (With C A T A ) - - - - - - - - - - - - - - - - - - .
FU SES
Q)ECU ! 1 0 Al*
®No.2 \15 Al MAIN RELAY
FUEL
¡,·-
®No.9 P.S'Al PUMP
..-
Hi )--YEL~
@No.7 {7.5 A} YE\..iBLU---o
®No.\ ílOA) (1)--
- .,...,_
~
@BACK UP {7 .5 A!*
Q::IG (50 A)* BlK/YEL
-,.l
m_-
vv
®BATíERY \80 A1 * 1 [,. IG'
SL
-'
J
(?).,...
BUUAE )---GRN/BLK-
*In the ~a in tuse box m- 1
IG' ;;y- .¿.
~;? IGNtTION YEjBLK
~
SWITCH ¡--veL
--.!.
..:r_
.:1: ~ A251GP1
81 IGP2 PG1 A23 ~
.-,.,_ WHT/GRN---! 01 VBU PG2A24

(¡~ A26 LG1 ~INJECTOR
- RESISiO'R
To Startar
1- 82 LG2
IJ1 A1
No.l
N~~
f"'"X"l'r\
89 STS IJ2 A3 :o- uv

É'. CYL
811 CYlP
'812 CYLM
IJ3 A5
)J4 A2
~~
-<>-VV
813 TDCP
~~é~~~~~~~ §: TDC 614 TDCM
FlR1 A7
é: ~
815 CRNI<P
CRANK ALR2A8
816 CRNKM
CHi::CK ENGINE
WARNING LIGHT
MAP
SENSOR
I
I
021 SG1
017 PB
WARN A13
-o@
019 VCC1
EACV A.9 ~
P20 VCC2 ~~~
SWSA17
.~~~
022 SG2
ICSA19 1
~~
J¡
011 ;TH
ESA11
'"~n"G
0-<>'VV
D4SCS
ANGlE f-
PGS A20
~-~ .,
(AIT onlyl
SENSOR f- AFSA 83 1
012 EGRL
AFSB 84
A/T 1
CONTROL 1
SEAVICE
CHECK
~ D13TW
FASA'f8
VREf 018
UNIT
1
CONNECTOR f- D15TA
01402
J
r SIGP1 A21 IGNITER
EGR
VALVE\U=
UFT SENSOR \
D9ACGF
88 PSW
e1GP2 A22 ;,_] 1 UNlT 1
(Exce pt KQ) ..L
A6 HTCNT
1 A.CCA'f5
1
.- 87 ATNPS j ACS 85 >---
1
l
1
1
1
·J
í
1
1
1 VSP 810
>---
IG'
-·
~NsonL
1 CONPfiESSOR
1 1 CLUTCH RELA'f
1 1 1 -v-
1 1 1 ["
TA
SENSOR" -L 1
1
1
1
1
1
RADIATOR
FAN
RADJAT OR
~
1 1 = FAN
_j 1 1 AEtA Y
1 ~----------,
1 - 1 -
~~
o XVGEN
S ENSOR
li t
1
~ITCH} [ ~
n~
1
~ r-;;- 1
[~
li1 8t
l SHIFT NOENSOR
1
~~
FA N
l
T
POSITION
~ <M<«o•
RE LAY
1
1
-=
ALT€RNATOR 'i ¡1 SP:EED
SENSOR
\
-b 1 -
1
1 RAOIATOR
P/S OtL :PRESSURE 1 - SHlFT POSiTION M M
FAN
SWITCH 1
CONSOLE SWITCH 1
SWITCH j_ 1.
L__________ fA/T only) 1
_J
A/C
SWITCH
A; BYPASS CONTROL SOLENOID VAlVE (2.2 t)

e: !NTAKE CONTROL SOLENOID VALVE
C EGR CONTROL SOlENOID VALVE
O· PURGE CUT-OFF SOLENOID VALVE
NOT USEO
TERMINAL LOCATION
6-142
Electrical Connections (Without C A T A ) - - - - - - - - - - - - - - - - ,
FUSES
(])ECV (10 Al*
MA1N RELAY
FU El
PUMP
®No.2 (15AI
@No.9 (7,5A)
@No.7 (7 .5 A)
@No. 1 !10 Al
@BACK UP 17.5 Al
QliG !50 A) •
RN/BlK- @BATTERY (80 Al*
(7) * In the main fuse box
~GNITION YEL BLK
SWITCH ~<';)J~~-r--YEl---r----------------------_,~------------t,
~}-A-25~1G_P_1-+------~
-" ""-- '--r-=:.:.:C.:~G::.;,=U__+-_;_PG::_l::_A::::2=2~)--
'---------------t----<"'(J~ --WHT/GRN- PG2 A24 ~--
A26 tG1
INJECTOR
To Startar1----------~ B2 LG2 RESJSTOR
}
- IJ1 Al ~'0--o-.JW\..-0-.
:~~~~~~~~~~~~~~B~9~SIS~~~U~2~A31~:·~-~~~~~U~~~1f~
Bll CVLP IJ3 AS NNoo·~'!!'
4-<.>-~ A ~
e: CYL 812 CYLM IJ4 A2
¿~~¡;::s~~ §: TDC ::: ~:~~
B15 CRNKP :~:: : : r f
e. CRANK 816 CRNKM )---'
CHECK -ENGINF
021 SG1
W~~LIGt.f.'
MAP 1 017 PB
WARNA13~
SENSOR
1 EACV
019 VCC1
D20VCC2
EACV A9 >-------<>fciu
fNT AKE CONTROL
SOL~VALVE
ICSA19 -<>' (Jl)
1 ACC A15
rl
j
--=.:::=-
f
í
~~Gg
87 ATNPS ACS 85 )o----
1 1 +B
1 1 VSP 810 >-
1
1
r
1
1
RADIATOR
TERMINAL LOCATION
6-143
Troubleshooting
Troubleshooting Guide [With C A T A ] - - - - - - - - - - - - - - - -
NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the arder they should be
inspected startíng with d). Find the symptom in the left column, read across to the most likely source, then refer to the page listed
at the top of that column. lf inspectíon shows the system is OK, try the next most likely system (Í), etc.
\ PGM-FI
PAGE SYSTEM
MANIFOLD ! COOLANT 1 INTAKE AIR ATMO-
ECU OXYGEN ABSOLUTE TDC/CRANK/CYLI TEMPERA-,· THROTTLE
ANGLE TEMPERA- SPHERIC
~
SENSOR PRESSURE SENSOR TURE SENSOR TURE PRESSURE
SENSOR SENSOR SENSOR SENSOR
SYMPTOM 152 156,158 162 168 174 176 178 182
\CHECK ENGINE WARNING
LIGHT TURNS ON DorO :IQE :I9E :IQE :I9E :IQE 39E 3QE
SELF-DIAGNOSIS INDICATOR
. (LEO) BLINKS $or<$} {!}or<{j} {!lar$ $or@or$ $ 0 (g} <!)
ENGINE WON'T START @ 1 @ '
DIFFICULT TO START
ENGINE WHEN COLO ® @ @ CD @
WHEN COLO 1
l FAST IDLE OUT
OF SPEC
® 1
CID '
IRREGULAR
ROUGH IDLE ® CID
IDLING WHENWARM
IDLE SPEED
TOO HIGH
® '
WHENWARM
IDLE SPEED @
TOO LOW
WHILE
FREQUENT
WARMING UP ® 1 ®
STALLING
AFTER
WARMING UP @ 1
@
] MISFIRE OR
ROUGH ® @ 1
RUNNING
FAILS
POOR @ (2)
PERFORMANCE
EMISSION
TEST
®
LOSS OF
POWER
1
® @ ®
if codes other than those listed above are indicated, count the number of blinks again. lf the indicator is in fact blinking these
codes, substitute a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
@:When the Check Engine warning light and the self-diagnosis indicator are on, the back-up system is in operation.
Substítute a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
6-144
PGM-FI IDLE CONTROL FUEL SUPPLY EMISSION CONTROL
A/T A!T
IGNITION ) VEHICLE
OUTPUT i SPEED
Fl
Signal A
Fl
ELEC-
TRONIC AIR
Signal B ¡ CONTROL
OTHER
ID LE
FUEL ¡ OTHER
FUEL
AIR
INTAKE
EGR 1 OTHER
CONTROL EMISSION
SIGNAL ; SENSOR CONTROLS INJECTOR 1 SUPPLY SYSTEM CONTROLS
VALVE 1
184 186 188 190 194 192 210 208 221 235 232
1.QE :ItQE CJ CJ :I.QE 19E

{!)
1
{!) ~ ® 11) ~ 11)
1
CD 4
(V (3)
Cil 1
1
CD (V
CD Cil (3)
1
CD 1
(V
i
CD Cil '
1
1
CD cv (3)
1
(3) CD ® 1
@ 1
@ CD @
l
cv @ CD
l CID CD @
1
@
6-145
Troubleshooting
Troubleshooting Guide [Without C A T A ] - - - - - - - - - - - - - - -
inspected starting with <D. Find the symptom in the left column, read across to the most likely source, then refer to the page listed
at the top of that column. lf inspection shows the system is OK, try the next most likely system @, etc.
: PGM-FI
PAGE SYSTEM
MANIFOLD COOLANT THROTILE INTAKE AIR 1 ATMO-
ABSOLUTE TOC/CRANK/CYL TEMPERA-
ECU ANGLE TEMPERA- IMA SPHERIC
~
PRESSURE SENSOR TURE TURE SENSOR 1PRESSURE
1 SENSOR
SYMPTOM 152 162 168 174 176 178 180 182
CHECK ENGINE WARNING
LIGHT TURNS ON c::Jorq :IQE 19E l~llOI :IQE 1~E 1~E
SELF-OIAGNOSIS INDICATOR
(LEO) BLINKS $or<$} $ o r $ $or$or{j) ®- m ~ iÚ} ~
ENGINE WONT START @ 1 @
1
DIFFICULT TO START
@ @ @
1
ENGINE WHEN COLO

1 1
CD @
WHEN COLO
FAST IOLE OUT 1
@ ! @
OF SPEC
ROUGH IDLE @ @
IRREGULAR
IOLING WHEN WARM
IDLE SPEED
TOO HIGH
WHEN WARM
IOLE SPEEO
1
@
@
1 l
1 1
TOO LOW 1 l 1
¡wHILE @ 1
@
¡WARMING UP 1
1
FREOUENT 1
STALLING
IAFTER
.WARMING UP @ 1
@ 1
i
MISFIRE OR
ROUGH @ @ 1
1 RUNNING
\pooR IFAILS
PERFORMANCE [ TEST
EMISSION @ (2) 1
1
!
LOSS OF @ (2)
@
POWER
l \
codes, substituta a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
@: When the Check Engine warning light and the self-diagnosis indicator are on, the back-up system is in operation.
Substituta a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
6-146
PGM-FI IDLE CONTROL FUEL SUPPLY T 1
1 VEHICLE A/T ELEC-AIR 1 OTHER AIR EMISSION 1

1
IGNITION A/T TRONIC 1
FUEL OTHER
1 OUTPUT SPEED Fl Fl IDLE . FUEL INTAKE CONTROL ,
SIGNAL SENSOR Signal A Signal B CONTROL . CONTROLS INJECTOR SUPPLY '
VALVE .
184 186 188 190 194 192 210 208 221 232
:ItQE :IQE C) C) 3QE i 3QE

{1) {!) ~ -(j} ~ (§}
CD (X) @
1
® 1
1
CD ® 1
!
CD í
®
1
CD ®
CD 1
®
!
CD (2) @
1 @ CD cv
1
'
1
@ CD
cv 1
@ 1 CD
l
1 1 1
@
1
CD @ @
6-147
PGM-FI IDLE CONTROL FUEL SUPPLY EMISSION CONTROL
A/T A!T
IGNITION ) VEHICLE
OUTPUT i SPEED
Fl
Signal A
Fl
ELEC-
TRONIC AIR
Signal B ¡ CONTROL
OTHER
ID LE
FUEL ¡ OTHER
FUEL
AIR
INTAKE
EGR 1 OTHER
CONTROL EMISSION
SIGNAL ; SENSOR CONTROLS INJECTOR 1 SUPPLY SYSTEM CONTROLS
VALVE 1
184 186 188 190 194 192 210 208 221 235 232
1.QE :ItQE CJ CJ :I.QE 19E

{!)
1
{!) ~ ® 11) ~ 11)
1
CD 4
(V (3)
Cil 1
1
CD (V
CD Cil (3)
1
CD 1
(V
i
CD Cil '
1
1
CD cv (3)
1
(3) CD ® 1
@ 1
@ CD @
l
cv @ CD
l CID CD @
1
@
6-145
Troubleshooting
Troubleshooting Guide [Without C A T A ] - - - - - - - - - - - - - - -
inspected starting with <D. Find the symptom in the left column, read across to the most likely source, then refer to the page listed
: PGM-FI
PAGE SYSTEM
MANIFOLD COOLANT THROTILE INTAKE AIR 1 ATMO-
ABSOLUTE TOC/CRANK/CYL TEMPERA-
ECU ANGLE TEMPERA- IMA SPHERIC
~
PRESSURE SENSOR TURE TURE SENSOR 1PRESSURE
1 SENSOR
SYMPTOM 152 162 168 174 176 178 180 182
CHECK ENGINE WARNING
LIGHT TURNS ON c::Jorq :IQE 19E l~llOI :IQE 1~E 1~E
SELF-OIAGNOSIS INDICATOR
(LEO) BLINKS $or<$} $ o r $ $or$or{j) ®- m ~ iÚ} ~
ENGINE WONT START @ 1 @
1
DIFFICULT TO START
@ @ @
1
ENGINE WHEN COLO

1 1
CD @
WHEN COLO
FAST IOLE OUT 1
@ ! @
OF SPEC
ROUGH IDLE @ @
IRREGULAR
IOLING WHEN WARM
IDLE SPEED
TOO HIGH
WHEN WARM
IOLE SPEEO
1
@
@
1 l
1 1
TOO LOW 1 l 1
¡wHILE @ 1
@
¡WARMING UP 1
1
FREOUENT 1
STALLING
IAFTER
.WARMING UP @ 1
@ 1
i
MISFIRE OR
ROUGH @ @ 1
1 RUNNING
\pooR IFAILS
PERFORMANCE [ TEST
EMISSION @ (2) 1
1
!
LOSS OF @ (2)
@
POWER
l \
codes, substituta a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
@: When the Check Engine warning light and the self-diagnosis indicator are on, the back-up system is in operation.
Substituta a known-good ECU and recheck. lf the indication goes away, replace the original ECU.
6-146
PGM-FI IDLE CONTROL FUEL SUPPLY T 1
1 VEHICLE A/T ELEC-AIR 1 OTHER AIR EMISSION 1

1
IGNITION A/T TRONIC 1
FUEL OTHER
1 OUTPUT SPEED Fl Fl IDLE . FUEL INTAKE CONTROL ,
SIGNAL SENSOR Signal A Signal B CONTROL . CONTROLS INJECTOR SUPPLY '
VALVE .
184 186 188 190 194 192 210 208 221 232
:ItQE :IQE C) C) 3QE i 3QE

{1) {!) ~ -(j} ~ (§}
CD (X) @
1
® 1
1
CD ® 1
!
CD í
®
1
CD ®
CD 1
®
!
CD (2) @
1 @ CD cv
1
'
1
@ CD
cv 1
@ 1 CD
l
1 1 1
@
1
CD @ @
6-147
Troubleshooting
Self-diagnostic P r o c e d u r e - - - - - - - - - - - - - - - - - - - - - -
When the Check Engine warning light has been reportad en, turn the ignition on, pull down the passenger's side carpet from
under the dashboard and observe the LEO on the top of the ECU. The LEO indicates a system failure code by blinking frequency.
The ECU LEO can indicate any number of simultaneous component problems by blinking separate cedes, one after another.
Problem cedes 1 through 9 are indicated by individual short blinks. Problem cedes 1O through 41 are indicated by a series of long
and short blinks. One long blink equals 10 short blinks. Add the long and short blinks together to determine the problem code.
LEO DISPLAY
Separate Problems:
short
M
=See Problem CODE 1
~----=See Problem CODE 2
-j f~ =See Problem CODE 12
long short
Simultaneous Problems:
=See Problem CODE 1 and 2
=See Problem CODE 2 and 4
~__ílíl_ =See Problerri CODE 2 and 12
When the two terminals of the service check connector are connected with a jumper wire the LEO on the ECU, the check engine
warning light will indicate the same cede. ·
LH:
SERVICE CHECK CONNECTOR
CHECK ENGINE WARNING LIGHT
RH:
SERVICE CHECK CONNECTOR
//,r--'_P·,~- ____ _--
(,...,,
/
. . l_#.r-----. . \_;-.. . . --\ --- ----
JUMPER
WIRE
6-148
SELF-DIAGNOSIS SYSTEM INDICATED
INDICATOR BUNKS PAGE
o ECU 6-152
1 OXYGEN CONTENT (With CATA) 6-156
3 6-162
MANIFOLD ABSOLUTE PRESSURE L
5 6-166
4 CRANK ANGLE 6-168
6 COOLANT TEMPERATURE 6-174
7 THROTTLE ANGLE 6-176
8 TDC POSITION 6-170
9 N0.1 CYLINDER POSITION 6-172
10 INTAKE AIR TEMPERATURE 6-178
11 IMA {Without CATA) 6-180
12 EXHAUST GAS RECIRCULATION SYSTEM 6-235
13 ATMOSPHERIC PRESSURE 6-182
14 ELECTRONIC AIR CONTROL 6-194
15 IGNITION OUTPUT SIGNAL 6-184
i
17 VEHICLE SPEED SENSOR 6-186
30 A/T Fl SIGNAL A 6-188
31 A/T Fl SIGNAL B 6-190
41 OXYGEN SENSOR HEATER (With CATA) 6-158
e lf codes other than those listed above are indicated, verify the code. lf the code indicated is not listed above, replace the ECU.
e The Check Engine warning light may come on, indicating a system problem, when, in fact, there is a poor or intermittent
electrical connection. First, check the electrical connections, clean or repair connections if necessary.
e The Check Engine warning light and 54 warning light may light simultaneously when the self-diagnosis indicator blinks 6, 7 and
17 Check the PGM-FI system according to the PGM-FI control system troubleshooting, then recheck the S4 warning light. lf
it lights, see page 9-28, 29.
e The Check Engine warning light does not come on when there is a malfunction in the A/T Fl signa!. However the ECU LEO
will indicate the codes.
(cont'd)
6-149
Troubleshooting
Self-diagnostic Procedure ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - .
lf the inspection for a particular failure code requires the ECU test harness, remove the right door sill molding, the small cover
on the right kick panel, and pull the carpet back to expose the ECU. Unbolt the ECU bracket. Connect the ECU test harness. Then
check the system according to the procedure described for the appropriate code{s) listed on the following pages.
DIGITAL CIRCUIT TESTEA

07411-0020000
~~----------------~LJ_LECU
TEST
HARNESS
07 LAJ-PT301 00
Al A3 AS A7 A9A11A13A15A17A19A21A23A2581 83 85 87
000000000000000000000
000000000000000000000 00000000000
A2 A4 A6 AB A10A12A14A16A18A20A22A24A26 82 84 86 88 810 812 814 816 02 04 06 08 010012014 D16D1BD20 022
TERMINAL LOCATION
CAUTION:
e Puncturíng the insulation on a wire can cause poor or intermittent electrícal connections.
e For testing at connectors other than the ECU test harness, bring the tester probe into contact with the terminal from the
connector side of wire harness connectors in the engine compartment. For female connectors. just touch lightly with the
tester probe and do not insert the probe.
TESTEA PROBE
RUBBER SEAL
WIRE HARNESS
TERMINAL
6-150
How to Read F l o w c h a r t s - - - - - - - - - - - - - - - - - - - - - - - ,
A flowchart is designed to be used from start to final repair. lt's like a map showing you the shortest distance. But beware: if you
go off the "map" anywhere but a "stop" symbol, you can easily get lost.
1START j
Describes the conditions or situation to start a troubleshooting flowchart.
(bold type)
1 ACTION 1 Asks you todo something; perform a test, set up a condition, etc.
( DECIS/ON) Asks you about the result of an action, then sends you in the appropriate troubleshooting direction.
STOP The end of a series of actions and decisions, describes a final repair action and sometimes directs you to ar,¡ earlier
(bold type) part of the flow to confirm your repair.
NOTE:
e The term "lntermittent Failure" is used in these charts. lt simply means a system may have hada failure, but it checks out OK
through all your tests. You may need to road test the car to reproduce the failure or if the problem was a loase connection,
you may have unknowingly solved it while doing the tests. In any event, if the warning light on the dash does not come on,
check for poor connections or loose wires at all connectors related to the circuit that you are troubleshooting.
e Most of the troubleshooting flowcharts have you reset the ECU and try to duplicate the problem code. lf the problem is
intermittent and you can't duplicate the code, do not continue through the flowchart. To do so will only result in confusion
and, possibly a needlessly replaced ECU.
e "Open" and "Short" are common electrical terms. An open is a break in a wire or ata connection. A short is an accidental
connection of a wire to ground orto another wire. In simple electronics, this usually means something won't work at all. In
complex electronics {like ECUsl. this can sometimes mean something works, but not the way it's supposed to.
e lf the electrical readings are not as specified when using the ECU harness, check the test harness connections befare
proceeding.
6-151
PGM-FI Control System
Troubleshooting Flowchart-- ECU - - - - - - - - - - - - - - - - -
Check Engine warning light isn't

on for two seconds after ignition
is first tumed on.
NO
ls oil pressure warning light on ? lnspect No. 1 fuse.
YES
Turn the ignition switch OFF. ls No.1 fuseDK? _ Replace fuse.-
YES
Connect the ECU test" harness Repair open in YEL wire between
between the control unít and con- No.1 fuse and combination
nector (page 6-150). . meter.
Connect A 1 3 terminal to body

ground.
00000000 00000000000
00000000 00000000000
Turn the ignítíon switch ON.
=
-Replace warning light bulb.

-Repair open in GRN/RED wire
ls Check Engine warning light on ?
between ECU (A13} and com-
YES bination meter.
00000000000 00000000000
Measure voltage between body 00000000000 ooooooooooo
ground and the following termínals A24A26B2
1
índívídually to: • A23, • A24. • Less than 1 V 7 1
1
A26,eB2 ISO
-::!:--
Repair open in wire between

ls there less than 1 V ? ECU and thermostat housing
{G101) that had more than 1 V.
VES
Substituta a known-good ECU

and recheck. lf symptom/indica-
tion goes awav. re place the orig-
inal ECU.
6-152
ll
NOTE: lf the Service Check Con-
-Check Engine warning light
nector in jumped. The Check Engine
has been reportad on.
-LEO doesn't bl!nk.
warning light will stay on.
Turn the ignition switch on.

l lntermittent failure, system is !
OK at this time. (Test drive may 1
be necessary) Check for loose

ls the Check Engine warning light .NO wires or poor connections at the
still ON 2 seconds afterthe ignition
thermostat housing. main relay
switch is turned ON ?
connector ECU fuse (undemood
VES relay box), and No.2 fuse (dash
fuse box).
VES Go to troubleshooting procedures

Does LEO indicate any CODE ?
(page 6-148). j
NO
< Did the engine start ?
NO
>YES Turn the ignition switch
OFF.
Remove and inspect the 10 A

(ECU) fuse in the underhood relay
¡
1
box.
Disconnect "A· con-

NO
ls the fuse OK ?
YES
l
l Replace the fuse.
J nector from the ECU .
lnspect the No.2 ( 15 A) fuse in the

dash box.
l
1
Turn the ignition switch

ON.
ls the fuse OK ?
YES
NO
Replace the fuse.
l
Turn the ignition switch ON. _ _ _..cN..:.Oc:.; ls the Check Engine
1
warning light ON ?
l YES
Disconnect the 3P connector of 1 Substituta a known-good ECU r
each sensor one ata time: and recheck. lf symptom/indica-
e MAP sensor tion goes away. replace the orig-
•• Throttle angle sensor

EGR valve lift sensor
inal ECU .
1
Repair
l
ground in GRN/RED
NO Replace the sensor that caused
Ooes Check Engine warning light wire between the ECU
the light to go out upon its dis-
remain ON ? (A 13) and check
connection.
angina warning light.
1 YES
(To page 6-154) lcont'd)
6-153
Troubleshooting Flowchart-- ECU (cont'd) - - - - - - - - - - - - - - - ,
(From page 6-153)
1 Turn the ignition switch OFF.
! Connect the ECU test harness

(page 6-150). But disconnect the
·o· connector from the ECU only, oooooooooooooloooooooo
not the main wire harness. [ oooooooooooooloooooooo
1
i
Check for continuity between
1 body ground .and the following
terminals: 019, 020.
Repair short to body ground in
l
<
1
RED/WHT wire between ECU

YES (019), YEL/WHT wire between
ECU (020) and throttle angle
_1 NO sensor, EGR valve lift sensor J
and MAP sensor. _j

Reconnect all the connectors.
Reconnect the "D" connector to
the ECU.
j
1
J
\ lndividually connect the following
terminal to Body Ground. 62 •
¡ A26
1 -Repair open in BLK/REO wire !

between ECU (A26) and ,
ls the Check Engine warning light N_O
_ _ ____,
7 G101. .
still ON after 2 seconds ?
-Repair open in BRN/BLK wire
1 YES between ECU (82) and G1 01.
1
Measure voltage between A26 ( -)

and the following: 81 (+) and
A25 (+).
-Repair open in YEUBLK wire
1 between ECU (A25, 811 and
NO
ls there battery voltage ? main relay. ~
-Check main relay and wiring
1 YES connectors at main relay (page
6-216).
substituta a known-good ECU
tion goes away, replace the orig-
inal ECU.
6-154
6-155
Troubleshooting Flowchart--Oxygen S e n s o r - - - - - - - - - - - - -
-.... 1 /
-[01-
/ -....
Self-diagnosis LEO indicates code 1: A problem in the Heated Oxygen (02I Sensor circuit.

Re m ove BACK UP fu se in the

under-hood relay box for 1 O sec- i
onds to reset ECU.
1
lnspect fu el pressure (page 6-

213).
1
ls it normal ?
YES
NO 1
l
Go to page 6-208 Fuer Supply
System. j
ing temperature (cooling fan
comes on).
Run engine for 1 O seconds.
Road test with the Transmission in )

2nd gear, accelerate using wide
open throttle for at least 5 sec-
onds. Then decelerate for at least
5 seconds with the throttle com-
pletely closed.
1
! lntermittent failure, system is
ls Check Engine warning light on NO 1
OK at this time. Check for poor
and does LED indicate CODE 1 ?
connections or loose wires.
1
1 YES
(To page 6-157)
6-156
2.2 t except KQ:
(From page 6-156)
Turn the ignition switc.h OFF.
Disconnect the D2 sensor con-

nector and connect A (- J terminal
to B ( + l terminal with a battery.
After two minutes, measure volt-

age between C (-) terminal and D
(+ l terminal.
02 SENSOR
Start the engine. 45 N·m (4.5 kg-m, 33 lb-ftl
ls the voltage above 0.6 V at wide

open throttle to 4,500 min- 1 (rpm)
and below O .4 V when the throttle Replace 02 sensor.
is quickly released from 4, 500
min- 1 (rpm) ?
VES
Stop engine.
Connect the 02 sensor connector

to engine wire harness.

between the ECU and connector
(page 6-150).
02SENSOR
2.0t and KQ:
(To page 6-158)
02 SENSOR SOCKET
WRENCH
07LAA-PT501 00
45 N·m (4.5 kg-m, 33 lb-ft)
!cont'd)
6-157
Troubleshooting Flowchart--Oxygen Sensor (cont'd)-----------,
(From page 6-157)

000000000000 00000000
Restart and warm up engine to 000000000000 00000000
normal operating temperatura
(cooling fan comes on).
A (-) Above 0.6 V at wide open
26
to 4,500 min- 1 (rpm). 014 (+1
L__ throttle
Below 0.4 V when the throttle __j
Measure voltage between 014 is quickly released from
1
4,500 min- (rpm).
( +) and A26 (-) terminal.
ls the voltage above 0.6 V at wide

open throttle to 4,500 min- 1 (rpm) Repair short or open in WHT wire
NO
and 0.4 V when the throttle is between ECU (014) and 02 sen-
quickly relea sed from 4, 500 sor.
min- 1 (rpm)?
YES

inal ecu.
6-158
6-159
Troubleshooting Flowchart--Oxygen Sensor Heater----------
-€)}- Self-diagnosis LEO indicates code 41: A problem in the Oxygen (02) Sensor Heater circuit.
2.2 t except KQ :
-Engine is running.
-Check Engine warning light DIGITAL MULTIMETER
07411-0020000
has been reported on.

onds to reset ECU .
Start engine.
lntermittent failure.
system is OK at this
time (test driving may
ls Check Engine warning líght on NO
and does LEO índícate CODE 41 ? ;r--------1 be necessary).
Check for poor connec-
YES tions or Joose wires at
Oz sensor connector.
Stop engíne.
Oísconnect the 4P connector from

the 02 sensor.
Measure resistance between ter-

mínals A and B on the 02 sensor.
2.02and KQ:
NO
Js there 15-20 !l ? Replace Oz sensor.
YES
Check for continuíty to body

ground on each terminal on the 02
sensor.
YES
Ooes continuity exist ? Replace Oz sensor.
NO
Check for continuity between ter- DIGITAL MULTIMETER

minal A and terminals C and O 07411-Q020000
individually.
VES
Does continuity exist ? Replace 02 sensor.
NO
(Topage 6-161}
6-160
(From page 6-160)

BLK (+) terminal and ORN/BLK
(-) terminal.
Disconnect the ·A" connector

fs there battery voltage ?
from the ECU.
NO

BLK (+) terminal and ORN/BLK
(-) terminal.
Measure voltage between YELI Repair short in ORN/

BLK ( + l terminal and body YES B LK wire between
ground. ECU {A6) and 02 sen-
NO sor.
-Repair open in YELI

B LK wire between the
02 sensor and Main
NO
ls there battery voltage ? Relay.
-Replace blown ECU
YES fuse (10Al in the under-
hood relay box.
Turn the ignition ~witch OFF.

Reconnect the 4P connector to 02 and recheck. ff symptom/indica-
sensor. tion goes away, re place the orig-
inal ECU.
Connect the ECU test harness "A"

conneétor to the main wire har-
ness only, not the ECU (page 6-
150).
12 V 7
A23{-)
00000000 00000000 00000000000
00000000 00000000 00000000000
Measure voltage between A6 ( + l

NO Repair open in ORN/BLK wire

ls there battery voltage ? between ECU (A6) and 02 Sen-
sor.
VES
tíon goes away, replace the orig-
inal ECU.
6-161
Troubleshooting Flowchart--MAP S e n s o r - - - - - - - - - - - - - -
Self-diagnosis LEO indicares code 3: Most likely an electrícal problem in the Manifold Absolute Pressure
(MAP) Sensor system.
Self-diagnosis LEO indicates code 5: Most likely a mechanical problem (broken hose) in the Manifold
Absolute Pressure (MAP) Sensor system.
' 1 / ~
-OCSJ-
/ \ ............
~
-Engine is warm and running.

-Check Engine warning light Except 2.2 t KE:

onds to reset ECU.

ing temperatura (cooling fan
comes on).
lntenmittent failure, system is

OK at this time (test drive may
ls Check Engine warning light on >-N_0
_ _ _---1 be necessaryl.
and does LEO indicate CODE 3 ? Check for poor connection or
loose wires at MAP sensor con-
YES nector and ECU.
Disconnect the 3 P connector from

the MAP sensor.
(To page 6-163)
6-162
(From page 6-162)
1
1 Measure voltage between RED/

;~:nd~+) terminal and b~~
l_
YES Measure voltage between

ls there approx. 5 V ? WHT ( +) terminal and K'" tvv•M Repair open in BLU/
(-)terminal. WHT wire between
1 NO ECU (021) and MAP
sensor.
Repair open in REO/WHT wire
lf wire is OK, substi-
between ECU (019) and MAP ·¡
tuta a known-gttd ECU
sensor.
and recheck. lf pre-
lf wire is OK, substituta a '
scribed voltage is now
known-good ECU and recheck. lf 1'
available, replace the

prescribed voltage is now avail- .
ECU.
able, replace the original ECU. _
Repair open or short in

WHT/BLU wire
between ECU (017)
and MAP sensor.
lf wire is OK, substi-
tuta a known-good
ECU and recheck. lf
prescribed voltage is
available, replace
ECU.

the MAP sensor.

(paga 6-150).
(To paga 6-164)
(cont'd)
6-163
Troubleshooting Flowchart--MAP Sensor (cont'd)----------,
(From page 6-163)
Measure voltage between

(+)terminal and D21 (-)
na l.
3V7
n
017 1+1 021(-)
0000000000000 00000000 00000000
0000000000000 00000000 00000000
ls there approx. 3 V ? N_O_ _ _--l Replace MAP sensor. _j

~------------
VES

inal ECU.
6-164
6-165
Troubleshooting Flowchart--MAP Sensor ( c o n t ' d ) - - - - - - - - - -

l
Turn the ignition switch OFF. 1
Remove BACK UP fuse in the (1

onds to reset ECU .
Start the engine.

-lntermittent failure. system is
1 OK at this time (test drive may
be necessary}.
_ _ _--1
-Check vacuum hoses, pipes
and connections.
i YES -Make sure all connectors are
secure.
Stop e:ngine.
Disconnect #21 hose from the

throttle body, connect vacuum
pump to the hose and apply vac-
uum.
VACUUM PUMP/GAUGE
NO Connect a vacuum pump to the

Does ít hold vacuum ?
MAP sensor and apply vacuum.
YES
NO
Does ít hold vacuum ? Replace MAP sensor.
YES
Replace #21 hose.

Connect a T-fitting from a vacuum
gauge between the throttle body
and MAP sensor.
{To page 6-167)
6-166
(From page 6-166)
s .. rt ;,.;,•.
l
ls there manifold vacuum ?
NO
-Remove restriction from throt-
tle body.
-Replace throttle body.
1 YES
Stop engine.
i
(page 6-150).
Mea su re voltage between D 1 7 0000000000000 00000000 00000000

( +) terminal and D21 ( -) termi- 0000000000000 00000000 00000000
nal.
ls there approx. 3V ? Replace the MAP sensor.
YES
Start the engine and allow it to idle.
ls there approx. l V ? Replace MAP sensor.
YES

tion goes away. replace the orig-
inal ECU.
6-167
Troubleshooting Flowchart--TDC/CRANK/CYL S e n s o r s - - - - - - -
1
"- /
-lúl-
/ 1 "-
0 Self-diagnosis LEO indicates code 4: A problem in the circuit of the CRANK Sensor.
1
"- /
-lúl-'
/ \
0 Self-diagnosis LEO indicates code 8: A problem in the circuit of the TOC Sensor.
~fú]:: 0 Self-diagnosis LEO indicates code 9: A problem in the circuit of the CVL Sensor.
/ 1 "-
"- /
-fu]-
/ 1 "- 0

1

onds to reset ECU.
Start engine.
lntermittent failure. system is

ls Check Engine warning light on >-N_0_ _ _-1 be necessary).
and does LED indicate CODE 4 ? Check for poor connections or
loose wires at distributor con- B
YES nector.
Stop engine.
Disconnect the 8P connector from

the TDC/CRANK/CYL sensor.
Measure resistance between B ter-

minal and F terminal.
NO Replace the distributor assembly

ls there 350-700 O 7
(section 16).
YES
(To page 6-169)
6-168
A/T only
NO Disconnect the 22P connector Repair open or short in

1
ls there approx. 5 V ? from the A/T control unit. YEL/GRN wire
YES
l 1 between ECU (013},
1
A/T control unit and
NO TW sensor.
ls there approx. 5 V ? lf wire is OK, substi-
tuta a known-good
1 VES ECU and recheck. lf
prescribed voltage is
Replace the A/T control unit. now available, replace
1 1
----------------------------------------------- original ECU.

GRN !+)terminal and GRN/WHT
( -) terminal.
NO Repair open in GRN/WHT wire

ls there approx. 5 V ? between ECU ID22) and TW
sensor.
YES

and recheck. lf symptomlindica-
j
inal ECU.
6-175
PGM-FI Control 'System
Troubleshooting Flowchart - - Throttle Angle S e n s o r - - - - - - - - - -
~r6r=
/ 1 "-
0 Self-diagnosis LED indicates code 7: Most likely a problem in the Throttle Angle Sensor circuit.
~ra¡:= 0
/
"
-Engine is running.
has be en reportad on.

under-hood relay for 1 O seconds
to reset EC U .
Start engine.
lntermittent failure, system is

_ _ _--1 be necessary).
and does LEO indicate CODE 7 7 Check for poor connections or
loose wires at throttle angle sen-
VES sor connector.
Tu m the ignition switch OFF.

the throttle angle sensor.
Measure voltage between VELI

WHT i+) terminal and GRN/WHT
(-)terminal. Measure voltage between YELI
WHT ( + l terminal and body
ground.
ls there approx. 5 V ? Repair open in GRN/

VES WHT wire between
VES ls there approx. 5V ?
ECU (022) and throttle
NO angle sensor.
Tum the ignition switch OFF.
Reconnect the 3P connector. í

Connect the ECU test harness {page 6-150).
(page 6-150).
1
1
(To page 6-177) (To page 6-1771
6-176
1
Turn the ignition switch ON. Turn the ignition switch ON.
1
Measure voltage between D20
(+)terminal and D22 (-) termi-
1 na l.
1 Repair open in YEL/

YES WHT wire between
ls there approx. 5 V?
ECU (020) and throttle
1
angla sensor.
1 NO 1

age is now available. replace the
original ECU.
Measure voltage between D 11
(+) terminal and D22 (-! termi-
nal. 0000000000000 00000000 000000000
0000000000000 00000000 000000000
020(+).022(-)
c;;-;J
1
0111+1
0000000000000 00000000
0000000000000 00000000
A/T only
ls voltage approx. O. 5 V at full
el ose throttle, and approx. 4. 5 V
at full open throttle ? Disconnect the 22P connector
NOTE: There should be a·smooth from the A/T control unit.
transition from 0.5 V to 4.5 V as
the throttle is depressed.
- Replace throttle
YES ls voltage approx. 0.5 V at full angle sensor.
close throttle, and approx. 4. 5 V -Repair open or short
Substituta a known-good ECU at full open throttle ? NO in REO/BLK wire
and recheck. lfsymptom /indica- NOTE: There should be a smooth )---,-----; betwee n EC U
tion goes away, replace the orig- transition from 0.5 V to 4. 5 V as 1011). A/T control
inal ECU. the throttle is depressed. unit and throttle.
angla sensor.
YES
Replace the A/T control unit.
6-177
Troubleshooting Flowchart--TA S e n s o r - - - - - - - - - - - - - - -
Self-diagnosis LEO indicates code 10: Most likely a problem in the lntake Air Temperature (TA) Sensor
circuit.

has been reported on
!
Remove BACK U P fuse in the

onds to reset ECU.

ls Check Engine Warning light on )-N_O
_ _ __ be necessary).
and does LED indicate CODE 1 O ? Check for poor connections or
loase wires at T A sensor con-
YES nector.

the T A sensor.
Measure resístance between the 2

terminals on the TA sensor.
NO
ls there 1-4 kO ? Replace TA sensor.
YES
Measure voltage between RED/

ground.
Repair open or short in RED/YEL
wirebetween ECU (015) andTA
1
sensor.
NO
ls there approx. 5 V? lf wire is OK, substitute a
known-good ECU and recheck. lf
1 YES prescribed voltage is now avail-
(To page 6-179) able, replace original ECU.
6-178
l From page 6-178)
l
Measure voltage between RED/
YEL (+) terminal and GRN/WHT
(-) terminal.
1
) Repair open in GRN/WHT wire
NO
ls there approx. 5V ? between ECU (022) and TAsen-
sor.
1
1 YES

inal ECU.
6-179
Troubleshooting Flow Chart--IMA Sensor (Without CATA)------
{Ú} Self-diagnosis LED indicates code11: Most likely a problem in the IMA Sensor circuit.

-LEO indicates COOE 11

onds to reset ECU.

ls check Engine warning light on ? >-N_0
_ _ _---1 be necessary).
and does LEO indicate CODE 11 ? Check for poor connections of
B
YES
loose wires at the IMA sensor A e
connector.

the 1MA sensor.
Measure resistance between A ter-

minal and C terminal on IMA sen-
sor harness.
IMASENSOR
<'--
. ls there 4-6 kn ?
---r-:-:::-:=---->NO
1 YES
. . Replace IMA sensor.
Measure resistan ce between A and

B termínals and between C and 8
termínals.
Does the sum of the two resis- >-N_0

_ _ _--1
Replace IMA sensor.
tance checks equal 4-6 kn ?
GRN/WHT
YES

WHT (+)terminal and GRN/WHT
(-)terminal on the wire harness.
(To page 6-181)
6-180
(From page 6-1 80)
Measure voltage between VELI

NO
ls there approx. 5 V ? WHT (+) terminal and body
ground.
YES
Repair open in GRN/
Turn the ignition switch OFF. VES WHT wire between
ECU. (022) and IMA
NO sensor.
between the ECU and connector Turn the ignition switch OFF.
(page 6-150)

Tum the ignition switch ON. between the ECU and connector
(page 6-150).
Measure voltage between D 1 O

(+) terminal and 022 (-) termi- Turn the ignition switch ON.
nal.
í
Measure voltage between 020
( +) terminal and 022 (-} termi-
na l.
! VES
Repair open in Y EL/
WHT wire between
ls there approx. 5 V.?
ECU (020) and IMA
1 NO sensor.
1

age is now available, replace the
original ECU.
0000000000000 00000000 000000000

0000000000000 00000000 000000000
020(+) 022(-1
w
5V7
NO Repair open or short in BRN wire

ls voltage 0.5-4.5 V? between ECU (01 0) and IMA
sensor.
VES

and recheck. lf symptom/indica- 0000000000000 00000000
tion goes away, replace the orig- 0000000000000 00000000
inal ECU.
0.5-4.5 V 7
6-181
.---- Troubleshooting F owchart - - PA S e n s o r - - - - - - - - - - - - - - - - .
...... 1 /
-rul- ~ Self-diagnosis LEO indicates code 13: A problem in the Atmospheric Pressure (PA) Sensor.
/ 1 '-
'- 1 /
-ro]-
/ 1 ......

1
Turn the ignition switch OFF. (
JI, Re m ove BACK U P fuse in the !

under-hood relay box for 1 O sec- li
i onds to reset ECU.
Turn the ignitíon switch ON.
1
_ _ _----1
and does LEO indicate CODE 13 ?
be necessary).
Substitute a known-good ECU 1
and recheck. lf symptom/Lin-

dication goes away, replace the
original ECU.
6-182
6-183
Troubleshooting Flowchart--lgnition Output S i g n a l - - - - - - - - - -
~ Self-diagnosis lED indicates code 15: A problem in the lgnition Output Signal circuit.

has been reportad.
Tum the ígnítíon switch OFF.

onds to reset ECU.
Start engine.

OK at thís time (test drive may
ls Check Engine warning light on >-N_O_ _ __, be necessary).
and does LEO índícate CODE 15 ? Check for poor connections or
loose wires at the distributor con-
YES nector.
Turn the ígnítíon switch OFF.

the distributor.
Turn the ignítíon switch ON.

ground.
NO
Repair open in BlK/YEl wire
ls there battery voltage ? between the 2P connector and
ignition switch.
VES
Reconnect the 2P connector.
(To page 6-185)
6-184
(From page 6-184)
1 ,...---10V?--¡·
A21 1+1
Connect the PGM-FI test harness.
0000000000 00000000 00000000000
{page 6-150). 0000000000 00000000 00000000000
(-)
Measure voltage individually

between A21 ( +), A22 1+ J termi-
nals and A26 (-)terminal.
-Replace the igniter unit.

NO - Repair open or short YEL/GRN
ls there approx. 1 O V 7
wires between distributor and
YES ECU (A21 or A22).
NOTE: lf the YELIGRN wire was shorted,

Substitute a known-good ECU the igniter may be damaged.
inal ECU.
6-185
Troubleshooting Flowchart--Vehicle speed Sensor------------.
......
-la_]-
/
1
1
/
'
-® Self-diagnosis LEO indicates code 17: A problem in the Vehicle Speed Sensor circuit.

has be en reported on.

onds to reset ECU.
Road test necessary.

In 2nd gear accelerate to 3,500
min _, (rpm), then decelerate to
1,500 min -1 (rpm) with throttle
fully closed.
1
_ _ _ _-1 OK at this time.
and does LEO indicate CODE 17 ? Check for poor connections OT
loose wires.
1 YES
Block rear wheels and set the park-

ing brake. Jack up the front of the fW.flMtii§M
rear wheels
Block
before
car and support with safety
stands. jacking up front of car.

(page 6-150).
\ 0000000000000(00000000 00000000000
Turn the ignition switch ON. 1000000000000~ 0000~000 00000000000
A26(-) B 1(J(+ 1
1
f 1
Slowly rotate left front wheel and o~s v 7
measure voltage between B 1O { +)
terminal and A26 (-)terminal. - Repair open or short in ORN 1
1
;~n::::::~s:~u (8101 and
1
NO - Faulty speed sensor.

Does voltage pulse O V and 5 V?
1 YES and.recheck. lf symptom/indi-
cation goes away, replace the
Substitute a known-good ECU original ECU.
inal ECU.
6-186
6-187
Troubleshooting Flowchart--A/T Fl Signal A - - - - - - - - - - - -
o Self-diagnosis LEO indicates code 30: A problem in the line (83) of between A/T control unit and PGM-FI
ECU.
Self-diagnosis LEO indicates code 31: A problem in the (84) of between A/T control unit and PGM-FI
PGM-FI ECU.
1
l
Remove BACK UP fuse in the ,
onds to reset ECU.
1
Test drive necessary.

Orive the car for severa! miles so
that the transmission upshifts and
downshifts several times.
1 1
NO lntermittent failure. system
Ooes LED indicate CODE 30 ? is .J
OK at this time.
1
1 YES

!
1

not to the ECU (page 6-1 50).
83
0000000000000 00000000000
1
0000000000000 00000000000
Disconnect the 22P connector
from the A/T control unit.
Continuity ?
Check for continuity between 83

YES
Repair short in WHT/RED wire
between ECU (831 and the A/T
control unit.
J
NO
(To page 6-1 89)
6-188
(From page 6-1 88)
1 83
Check for Continuity WHT/RED 0000000000000 00000000000
wire between B3 and 22P con- 00000000000
0000000000000
nector of the A/T control unit.
Repair open in WHT/REO wire

Does continuity exist ? between ECU {83) and tlle A/T
control unit.
¡ YES
Substitute a known-good ECU

tion goes away, re place the orig-
inal ECU.
6-189
Troubleshooting Flowchart--A/T Fl Signal 8 - - - - , . . . . . - - - - - - - - -
Tu m the ignition switch OFF.

1
Remove BACK UP fu se in the

onds to reset ECU.
Test drive necessary.

Orive the car for severa! miles so
that the transmíssion upshífts and
downshifts severa! times.
1
1
NO lntermittent failure, system is
Does LEO indícate CODE 31 ? OK at this time (test drive may
l YES
be necessary).

1

not to the ECU (page 6-1 50)
0000000000000 00000000000
0000000000000 00000000000
Disconnect the 22P connector 84

from the A/T control unit.
-J-
Continuity ?

YES Repair short in GRN wire ECU

Ooes continuity exist ?
!84) and the A/T control unit.
NO
i
(To page 6-191)
6-190
(From page 6-190)
!
0000000000000 00000000000
Check for Continuity GRN wire 0000000000000 00000000000
between 84 and 22P connector of
the A/T control unit. 84
Repair open in GRN wire

NO
Does continuity exist ? between ECU (B4) and the A/T
control unit.
VES

inal ECU.
6-191
Id le. Control System
Symptom Troubleshooting Guide - . , . . . . . - - - - - - - - - - - - - - - - - - -
NOTE:
• Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the order they should be
listed at the top of that column. lf inspection shows the system is OK, try the next system ®. etc.
• lf the idle speed is out of specification and LEO does not blink CODE 14, go to" inspection described on page 6-193.
~!toLE
PAGE A/T
AIR ALTER- P/S Oll HOSES
1 ADJUST- 1 CON DI- NATOR SHIFT STARTER FAST AIR
ING
EACV
TIONING FR POSITION SWITCH PRESSURE ID LE BOOST AND
SIGNAL SIGNAL SWITCH CONNEC-
~ SIGNAL SIGNAL SIGNAL VALVE VALVE
SCREW (A/T ONLYl TIONS
1
SYMPTOM 207 194 198 1
200 202 204 205 206 ! -
*
DIFFICULT TO START
ENGINE WHEN COLO CD
WHEN COLD FAST ID LE OUT OF (2)
SPEC [1 ,000-2,000min- 1(rpm)] @ CD
1
'
ROUGH IDLE (2) 1
CD
i WHEN WARM RPM TOO HIGH @ CD 1 @ (2) ®

:
lidie speed is
¡ below specified CZ)
engine s¡eed 1 CD
(no load 1
1
1 :
ldle speed does
not increase after
initial start up.
CD
1
On models with
automatic transmis- l.
WHEN sion, the idle (2) CD i
WARM speed drops in gear

RPM TOO
LOW ldle speeds drops
(2)
!
when air conditioner
in ON 1
CD
ldle speed drops
when steerin¡:¡
wheel is turnmg ¡
(2) CD
ldle speed
fluctuates with
electrical local
(2) CD
WHILE
WARMING UP CD
FREQUENT i
STALUNG
1
AFTER
WARMING UP
1
CD
1FAILS EMISSION TEST CD

1
L 1 1
6-192
1. When the idle speed is out of specification and LEO does not blink CODE 14, check the following items:
• Adjust the idle speed (page 6-207)
• Air conditioning signal (page 6-198)
• Alternator FR signal (page 6-200)
• A!T shift position signal (page 6-202)
• Starter switch signal (page 6-204)
• P/S oil pressure signal (page 6-205)
• Fast idle valve (page 6-206)
• Air boost valve
• Hoses and connections
• EACV and it mounting 0-rings
2. lf the above items are normal, substituta a known-good EACV and readjust the id le speed (page 6-1 94)
e lf the idle speed still cannot be adjusted to specification (and LEO dose not blink COOE 14) after EACV replacement,
substitute a known-good ECU and recheck. lf symptom goes away, replace the original ECU.
6-193
ldle Control System
Troubleshooting Flowchart-- EACV - - - - - - - - - - - - - - - -
'-
-[OJ-
"'
1
1
/
'
-s Self-diagnosis LED indicates code 14: A problem in the Electronic Air Control Valve (EACV) circuit.
'- 1 /
-[d-
/ 1 '-
-Engine is running.
-LEO índicates CODE 14.

1 onds to reset ECU.
1
1
¡
Start engine.
ls Check Engine warning light on ~N_O_ _ __,

VES
S<op ~og;,,
Disconnect the 2 P connector from
the EACV.

terminals on the EACV.
ls there 8-1511 ? Replace EACV.
VES
Check for continuity to body

ground on each terminal on the
EACV.
VES
Does continuity exist ? Replace EACV.
NO
(To page 6-195)
6-194
(From page 6-.194)
1
Me asure voltage between VE L/
BLK (+) terminal and BLK/BLU
(-)terminal.
!
VES 1 Disconnect the "A" connector

from the ECU.
1
NO
'
Measure voltage between V EL/
1
BLK (+) terminal and BLK/BLU
(-) terminal.
1
!
Measure voltage betwe.en VE L/ Repair short in BLK/
BLK (+) terminal and body VES
ls there battery voltage ? BLU wire between
ground. ECU (A9) and EACV.
T NO
NO 1 Repair open in YELI

ls there battery voltage ? BLK wire between the
EACV and M a in Relay.
1 VES

1
tion goes away , replace the orig-
inal ECU.
EACV.
l
Connect the ECU test harness "A"
connector to the main wire har-
ness only, not the ECU (page 6-
150).
Turn the ignition switch ON. ¡12V ?¡

A9{+) A2~ (-l
1 1
00000000 00000000000
Measure voltage between A9 ( +) 00000000 00000000000
terminal and A23 (-) terminal.
Repair open in BLK/BLU wire

between ECU (A9) and EACV.
VES
(To page 6-196)
(cont'd)
6-195
ldle Control System
Troubleshooting Flowchart - - EACV (cont'd) - - - - - - - - - - - - - - - - .
Connect and
lFrom page 6-195)
i
Connect and disconnect A9 termi-

nal to A23 terminal. 00000000 00000000000
00000000 00000000000
Does EACV click when the con-

nector is connected and discon-
NO J
>-------'¡ Replace EACV.
nected? 1
1 VES

inal ECU.
6-196
6-197
ldle Control System
Troubleshooting Flowchart--Air Conditioning S i g n a l - - - - - - - - -
lnspection of Air Conditioning

Signa l.

(page 6-150).
Disconnect "8" connector from
the main wire harness only, not
the ECU.
1
85(+)
Turn the ignition switch ON. 1 000000000000 00000000000

5V?
000000000000 00000000000
Measure voltage between 85 (+) A26(-)

terminal and A26 (-)terminal. 1 1

ls there approx. 5 V ? and recheck. lf prescribed volt-
VES original ECU.
Reconnect "B" connector to the

main wire harness. 1
A15
1 00000000 00000000000
Short
Momentarily connect A 1 5 termi- 00000000 00000000000
nal to A26 terminal severa! times.
NO 1 Connect the RED/BLU terminal of

ls there a clicking noise from the
the 4P connector on the A/C
A/C compressor clutch ?
VES l clutch relay to body ground.
ffi(D/BLU
ew from wire side
Start engine. Se e A ir conditioner

1 1 ls there a clicking noise from the NO
inspection (section
A/C compressor clutch ?
15).
¡ Blower switch ON.
1
VES
between ECU (A15) and A/C 1
clutch relay.
J
1
(To page 6-199)
6-198
(From page 6-198) .------Less than 1 V 7 - - - - . . . ,
85(+)
A/C switch ON. 00000000000 00000000000
00000000000 00000000000
A261-)

Does A/C operate ?
terminal and A26 ( -) terminal.
YES
Air conditioning signal is OK.
1 Repair open in BLU/

NO 8lK wire between
ls voltage less than 1 V ?
ECU (85) and A/C
YES switch.

inal ECU.
6-199
ldle Control System
Troubleshooting Flowchart--Aiternator FR S i g n a l - - - - - - - - - -
lnspection of Alternator FR sig-

nar.

(page 6-150).
Disconnect "Dn connector from
the main wire harness only, not
the ECU.
r----------------------5V7----------------------~
09(+)
Turn the ignition switch ON. 000000000000 00000000

000000000000 00000000
A26(-)


NO and recheck. lf prescribed volt-
In there approx. 5V ?
age is now available, replace the
VES original ECU.
Reconnect "Dn connector to the

main wire harness.

ing temperatura (cooling fan
comes on). r----~-------Voltage 7-------------,
09(+)
000000000000 00000000
000000000000 00000000
Measure voltage between D9 ( +)
terminal and A26 (-)terminal. A26(-)
Does the voltage decrease when NO

headlights and rear defogger are >---------l Stop engine.
turned on? e_-------.--------'
/ VES
/
Alternator FR signa! is OK.
(To page 6-201)
6-200
(From page 6-200)
Disconnect "D" connector from

ECU only, not the main wire har-
ness. 09
0000000000000 00000000
0000000000000 00000000
Disconnect the negative battery
cable from the battery.
Continuity?
Disconnect GRN · t:onnector from

the alternator. GRN CONNECTOR
NO
Disconnect GRN connector from

the alternator.
Connect WHT/RED wire to body Check for continuity between D9

ground. terminal and body ground.
Check for continuity between 09 See Altemator lnspec-

terminal and body ground. tion (section 16).
VES
YES Repair short in WHT/REO wire

Does continuity exist ? between ECU (09) and alter-
nator.
NO
Repair open in WHT/REO wire

between ECU (091 and alter-
nator.
See Altemator lnspection (sec-

tion 16).
6-201
ldle Control System
Troubleshooting Flowchart--A/T Shift Position S i g n a l - - - - - - - - -
lnspection of A/T Shift Position

Signal.
Observe the A/T shift indícator and

select each position separately.
See A/T shift position lndicator

Does the índicator líght properly ?
lnspection (section 16).
YES
Turn the ígnition switch OFF.

(page 6-150). Disconnect "B" 000000000000 00000000000
connector from the main wire har-
ness only, not the ECU.
000000000000 ooooooooooo
A26(-l
Measure voltage indivídually

between 87 ( +) terminal and A26
(-)terminal.

NO and recheck. lf prescribed volt-
age is now available, re place the
YES original ECU.
Reconnect "B" connector to the

maín wíre harness.
Turn the ígnition switch On.
(To page 6-203)
6-202
(F~m 'T 6-202)
. - - - - - - Less than 1 V 7 - - - - - .
87{+)
000000000000 00000000000
1 000000000000 00000000000
A26(-)
Measure voltage between B7 (+)

terminal and A26 (-) terminal in
Neutral position.
-Repair open in LT GRN wire
between ECU (87) and combi-
nation meter.
NO
ls voltage less than 1 V ? -Repair open in GRN wire
between the combination
1 VES meter and shift position con-
sale switch.
Me asure voltage between B 7 ( +)

terminal and A26 (-) terminal in 00000000000 00000000000
Park position. 00000000000 00000000000
A26(-)
1
Repair open in GRN/WHT wire

NO
ls voltage less than 1 V? between combination meter and
shift position console switch.
VES
terminal and A26 (-) except in
Park and Neutral.
1
NO Repair short in LT GRN wire

ls there approx. 5 V ? between ECU (87) and combina-
tion meter.
VES
A/T shift position signal is OK.
J
6-203
ldle Control System
Troubleshooting Flowchart - - Starter Switch S i g n a l - - - - - - - - - - ,
lnspection of Starter Switch Sig-

,..-------12 V?------,
na!.
89(+)
000000000000 00000000000
Connect the ECU test harness 000000000000 00000000000
(page 6-1 50). A26(-)
Measure voltage between 89 (+) NOTE: Clutch pedal must be depressed

terminal and A26 (-) terminal on M/T models.
with ignition switch in the start
position.
NO
ls there battery voltage ? lnspect No.9 fuse.
YES
ls No. 9 fuse OK ? Replace fu se.
YES
Repair open in BLU/RED wire

between ECU (89) and No.9
fuse.
Starter switch. signa! is OK.
6-204
Troubleshooting Flowchart-- P/S Oil Pressure Signal------------...,
lnspection of P/S Oil Pressure

Signal 000000000000 ooooo·oooooo
00000000000

(page 6-150).

the PIS oil pressure switch.
Measure voltage between B8 (+)
terminal and A26 ( -) terminal.
Connect RED terminal to BLK ter-
minal.
ls there voltage ?
NO Replace P/S oil pres-

ls there voltage ?
sure switch.
Start engine.
YES
Repair open in RED wire

Turn steering wheel slowly. between ECU (88) and P/S oil
pressure switch or 8LK wire
between P/5 oil pressure switch
and G301.
Measure voltage between 88 1+)
terminal and A26 (-) terminal
while steering wheel ís turning.
Disconnect "B" connector from

main wire harness only, not the
ECU.
YES
Substituta a known-
good ECU and re-
NO check. lf prescribed
P/S oil pressure signal is OK. ls there battery voltage ?
voltage is now avail-
YES able. replace the origi-
nal ECU.
Reconnect HB" connector to main
wire harness and disconnect 2P
connector on the P/S oil pressure
switch.
Replace P/S oil pres-

sure switch.
NO
Repair short in RED wire

. between ECU {881 and the P/5
oil pressure switch.
6-205
ldle Control System
Fast ldle V a l v e - - - - - - - - - ,
lnspection
NOTE: The fast idle valve is factoryadjusted, it should not

be disassembled.
2. Remove the cover of the fast id le valve.

3. Put your finger on the valve seat area and make su re
that there is air flow with the engine cold (coolant
temperature below 30°C, 86.F} and idling.
e lf not, replace the fast idle valve and retest.
(12N·m
1 11.2 kg-m, 9 lb-ft)
Replace
4. Warm up the engine (cooling fan comes on).
5. Check that the valve is completely closed. lf not, air

suction can be felt in the valve seat area.
e lf any suction is, felt the valve is leaking. Replace
the fast idle valve and recheck.
6-206
lnspection/ Adjustment (KS, KW)
1 . Start the engine and warm it up to normal operating
temperature (the cooling fan comes on). Manual 550 ± 50 min- 1 (rpm)
Automatic 550 ± 50 min - 1 (in I!S!J or !El)
2. Connect a tachometer.
Adjust the idle speed, if necessary, by turning the idle
adjusting scr~w:
IDLE ADJUSTING
SCREW
RPM CONNECTING ADAPTER B

07LAZ-PT30120
RPM CONNECTING ADAPTER A

07LAZ-PT30110 5. Turn the ignition switch OFF.
6. reconnect the 2P connector on the EACV, then

3. Disconnect the 2P connector from the EACV. remove BACK UP fuse in the underhood relay box for
1O seconds to reset ECU.
EACV
7. Restart an id le the engine with no-load conditions in
which the headlights, blower fan, rear defogger, coo-
ling fan, and air conditioner are not operating for one
minute, then check the idle speed.

8. ldle the engine for one minute with headlights (Hi) and
rear defogger ON and check the idle speed.

4. Check idling in no- 1 pad conditions in which the head-
lights, blower fan, rear defogger, cooling fan, and air 9. ldle the engine for one minute with heater fan switch
conditioner are not operating. at Hl and air conditioner on, then check the ídle speed.
ldle speed should be: ldle speed should be:
(Except KS, KW~ Manual 770±50 min-1 (rpm)

Automatic 600±50 min- 1 (rpm) (in {N] or [El)
NOTE: tf the id le speed is not within specifications, see
System Troubleshooting Guide on page 6-192.
6-207
Fuel Supply System
Symptom Troubleshooting Guide - - - - - - - - - - - - - - - - - -
inspected starting witli (!). Find the symptom in the left column, read across to the most likely source, then refer to the page listed
at the top of that column. lf inspection shows the system is OK, try the next most likely system @.etc.
~
PAGE
FUEL INJECTOR PRESSURE FUEL FUEL MAl N CONTAMI-
INJECTOR RESISTO A REGULATOR FILTER PUMP RELAY NATED FUEL
!SYMPTOM
:
~ 210 212 213 214 215 216
*
ENGINE WON'T START @ @ @ ! CD CZ) @
DIFFICULTTO START ENGINE
WHEN COLO OR HOT CD
ROUGH IDLE CD CZ) @
MISFIREOR
ROUGH RUN-
· NING
CD CZ) @ @
POOR FAILS EMISSION
PERFORMANCE TEST CZ) @ CD
1 LOSS OF POWER @ @ CD @ CZ)
Fu el with dirt, water or a high percentage of alcohol is considered contaminated.
6-208
Fuel Pressure--------------------------------------------------------,
Relieving lnspection
tlfi·liiif' 1. Relieve fuel pressure.
2. Remove the service bolt on the fuel pipe while holding

the banjo bolt with another wench and attach the fuel
pressure gauge.
3. Start the engíne. Measure the fuel pressure with the

NOTE: Before disconnecting fuel pipes or hoses, release engine idling and vacuum hose of the pressure·regula-
pressure from the system by loosening the 6 mm service tor disconnected.
bolt at the fuel pipe.
Pressure should be:
1. Remove fuel filter cap. 240-279 kPa (2.45-2.85 kg/cm 2 , 35-41 psi)
2. Disconnect the battery negative cable from the battery

4. Reconnect vacuum hose to the pressure regulator.
negative terminal.
Pressure should be:
3. Use a box end wrench on the 6 mm servíce bolt at the
200-240 kPa (2.04-2.45 kg/cm 2 , 29-35 psi)
fuel pipe, white holding the special banjo bolt with
another wrench.
4. Place a rag or shop towel over the 6 mm service bolt.
5. Slowly loosen the 6 mm service bolt one complete

turn.
PRESSURE
REGULATOR
SHOP TOWEL
e lf the fuel pressure is notas specified, first check the fuel
pump (page 6-215), lf the pump is OK, check the
following:
- lf the pressure is higher than specified, inspect for:
• Pinched or clogged fuel return hose or piping.
NOTE: • Faulty pressure regulator (page 6-213).
e A fuel pressure gauge can be attached at the 6 mm - lf the pressure is lower than specified, inspect for:
service bolt hole. • Clogged fuel filter.
e Always replace the washer between the service bolt • Pressure regulator failure (page 6-213).
and the special banjo bolt, whenever the service • Leakage in the fuel line.
bolt is loosened to relieve fue! pressure.
e Replace all washers whenever the bolts are
removed to disassemble parts.
lnspection
6-209
Fuel Supply System
Fuel lnjectors
Testing lf the engine cannot be started:
NOTE: Check the following ítems before testíng: ídle 1 . Remove the connector of the lnJector, and measure
speed, ignition tíming and idle CO % the resistance between the 2 terminals of the ínjector.
lf the engine will run: Resistance should be: 1.5-2.5 .n

1. With the engine idling, disconnect each injector con-
nector individually and inspect the change in the idlíng
speed.
e lf the idle speed drop is almost the same for each

cylinder, the injectors are normal.
e lf the idle speed or qualíty remains the same when

you disconnect a particular injector, replace the
injector and re-test.
2. Check the clíckíng sound of each ínjector by means of

a stethoscope when the engine is idling.
e lf the resistance is not as specífied, replaé:e the

injector.
e lf the resistance is as specified, check the fuel

pressure {page 6-209}.
- lf the fuel pressure is as specified, check the follow-
ing:
Whether there is any short-circuiting, wire
breakage or poor connection in the YEL/BLK
wire between the main relay and the resistor.
Whether the resistor is open or corroded {page
6-212).
e lf any injector faíls to make the typical clicking Whether there is any short-circuiting, wire
sound, check the sound again after replacing the breakage, or poor connection in the RED/BLK
injector. wire between the resistor and the injector
-· Whether there is any short-circuiting~ wire
lf clicking sound is still absent, check the following. breakage or poor connection in the wire between
Whether there is any short-circuiting, wire the injector and the ECU.
breakage or poor connection in the YEL/BLK
wire between the main relay and the resistor. lf all is OK, check the ECU (page 6-144).
Whether the resistor is open or corroded (page
6-212).
Whether there is any short-circuiting, wire
breakage or poor connection in the RED/BLK
wire between the resister and the injector.
Whether there is any short-circuíting, wíre
breakage or poor connection in the wire between
the injector and the ECU.
lf all is OK, check the ECU (page 6-144).
6-210
Pressure Regulator----------------------------------------------__,
Testing Replacement
BSf·j;lfiftiDo not smoke during the test, Keep open HMtf"rli Do not smoke while working on fuel sys-
flamas away from your work area. tem. eep open flama way from work area.
1. Anach a pressure gauge to the service port of the fuel 1. Place a shop towel under pressure regulator, then
pipe (page 6-209} relieve fuel pressure (page 6-209).
Pressure should be: 2. Disconnect the vacuum hose and fuel return hose.
240-279 kpa (2.45-2.85 kg/cm2, 35-41 psi)
(with the regulator vacuum hose disconnectedl 3. Remove the two 6 mm retainer bolts.
0-RING
Replace.
\ 1
PRESSURE
REGULATOA
2. Reconnect the vacuum hose to the pressure regulator.
3. Check that the fu el pressure rises when the vacuum

NOTE:
hose from the regulator is disconnected again.
e Replace the 0-ring.
e lf the fuel pressure did not rise, replace the regula- e When assembling the regulator, apply clean engine
ter and retest. oil to the 0-ring and assemble it into its proper
e Check vacuum hose and port for kinks or blockage. position, taking care not to damage the 0-ring.
PRESSURE REGULATOR
RETURN HOSE SHOPTOWEL
6-213
Fuel Supply System
Fuel Filter--------------.
Replacement
t§fl.iij§ilri Do not smoke while working on fuel

system. eep open flame away from work area.
The filter should be replaced : every 2 years or 40,000 km,

(24,000 miles), whichever comes first or whenever the fuel
pressure drops below the specified value (240-279) kPa,
2.45-2.85 kg-cm 2 , 35-41 psi with the pressure regula-
ter vacuum hose disconnected after making sure that the
fuel pump and the pressure regulator are OK.
1. Place a shop towel under and around the fuel filter.
2. Relieve fuel pressure (page 6-209)
3. Remove the 1 2 mm banjo bolt and the fu el feed pipe

from the fílter.
4. Remove the fuel filter clamp and fuel filter.
5. When assembling, use new washers, as shown.
1
10N·m (1.0 kg-m. 7 lb-ft)
38N·m (3.8 kg-m. 27 lb-ft)
CAUTION: Clean the flared joint of high pressure

hoses throughly before reconnecting them.
6-214
Fuel Purnp--------------------------------------------------------~
Testing Replacement
Nfl.iñl§"fM Do not smoke during the test. Keep open fi,S.iJfiifi! Do not smoke while working on fuel sys-
flame away from your work area. tem. eep open flamas away from your work area.
lf you suspect a problem with the fuel pump, check that the 1. Remove the fue! tank (page 6-218).
fu el pump actually runs; when it is ON, yo u will hear sorne
noise if you hold your ear to the fuel filler port with the fuel 2. Remove the fu el pump mounting nuts.
filler cap removed. The fuel pump should run for two
seconds, when ignition switch is first turned on. lf the 3. Remove the fuel pump from the fuel tank.
pump does not make noise, check as follows:
2WS: 6N·m (0.6 kg-m,
1. Disconnect the 3P or 4P connector in the trunk. 4 lb-ft}
CAUTION: Be sure to furn the ignition switch OFF

befare disconnecting the wires.
2. Disconnect the main relay connector and connect the

BlK/YEL ® wire and YEL (i) wire with a jumper wire.
(J)YEL
@ BLK/YEL Jumper
wire
3. Check that battery voltage is available at the fuel pump
connector when the ignition switch is turned ON (posi-
tive probe to the YEL wire, negative probe to the body
ground). 4WS:
• lf battery voltage is available, replace the fue!

pum p.
• lf there is no valtage, check the main relay and wire
harness (page 6-216).
6-215
Fuel Supply System
Main R e l a y - - - - - - - - - - - - - - - - - - - - - - - - - - -
Relay Testing Harness Testing
NOTE: lf the car starts and continuas to run, the main
relay is OK. 1. Keep the ignition switch in the OFF position.
2. Disconnect the main relay connector.
1. Remove the main relay.
2. Attach the battery positive terminal to the No.6 termi- 3. Check for continuity between the BLK wire (])in the
nal and the battery negative terminal to the No.8 connector and body ground.
terminal of the m ain relay. Then check for continuity
between the No. 5 terminal and No. 7 terminal of the • lf there is continuity, go to step 4.
main relay. e lf there is no contintnuity, repair open in BLK wire.
e lf there is continuity, go on to step 3. 4. Attach the positiva probe of volmeter to the YEL/BLU
e lf there isno continuity, replace the relay and retest. wire (j) and the negativa probe to the BLK wire ®.
No.S No.6 No.2
No. 7 No.5 No.1

No.3
TO IGN 1
e lf there is no voltage, check the ECU fuse (main

TO GROUNO fuse box) and the wiring between the main.relay and
the ECU fuse (10 A).
TO ST SWITCH 5. Attach the positive probe of voltmeter to the BLK/YEL

wire® and the negativa probe to the BLK wire®.
TO ECU (A7, 8}
3. Attach the battery positive terminal to the No. 5 termi-

nal and the battery negative terminal to the No.2
terminal of the main relay. Then check that there is
continuity between the No.1 terminal and No.3 termi-
nal of the main relay.
e lf there is continuity, go on to step 4.

e tf there is no continuity, replace and retest.
4. Attach the battery positiva terminal to the No.3 termi-

nal and battery negativa terminal to the No.8 terminal
@ BLK/YEL
of the m a in relay. Then check that there is continuity
between the No.5 terminal and No. 7 terminal of the 6. Turn the ignition switch ON.
main relay.
e lf there is continuity, the relay is Ok;
lf the fuel pump still does not work, go to harness • lf there is no voltage, check No.2 fuse and the
Testing in the next column. wiring from the ignition switch to' the fuse box and
e lf there is no continuity, replace the realy and the. wiring from the fu se box to the main re! ay.
retest.
6-216
Fuel Supply System
Fue1Tank(2VVS)-------------------------------------------,
Rep\acement
fSiiJ;iiiijM Do not smoke while working on fuel system. Keep open flame away from work area.
(
1. Block front wehhls. Jack up the rear of the car and support with jackstands.
2. Remove the drain bolt and drain the fu el into an approbed container.
3. Disconnect the 3P connector in the trunk.
4. Remove the two-way valve cover and fue! hose protector.
CAUTION:
• When disconnecting the hoses, slide back the clamps. then twist hoses as you pull, to avoid damaging them.
• Clean the flared joint of high pressure hoees thoroughly before reconnecting them.
7. Remove the strap and let the straps fall free.
NOTE: The tank may stick on the undercoat applied to its mount. To remove, carefully pry it off the mount.
9. lnstall a new washer on the drain bolt, then install parts in the reverse order of -removal.
37 N·m (3.7 kg-m,

26 lb-ftl
FUEL GAUGE
SENDJNG
UNIT
DRAIN BOLO
50 N·m (5.0 kg-m, 36 lb-ftl
MOUNTING BOLT
38 N·m (3.8 kg-m, ..L..-----~
27 lb-ft)
6-218
Fue1Tank(4VVS)--------------------------------------------~
Replacement
ffi¡.jiii§H Do not smoke while working on fuel syste. Keep open flame away from work area.
1. Block front wheels. Jack up the rear of the car and support with jackstands.
2. Remove the drain bolt and drain the fuel into an approbed container.
3. Disconnect the 4P in the trunk.
4. Remove fuel hose protector.
CAUTION:
e When disconecting the hoses, slide back the clamps, then twist hoses as you pull, to avoid damaging them.
e Clean the flared joint of high pressure hoses thorooughly before reconnecting them.
7. Remove the strap bolts and let the straps fall free.
9. Instan a new washer on the drain bolt, then instan parts inthe reversa order of removal.
37 N·m (3.7 kg-m,

26 lb-ft)
FUEL GAUGE
SENDING
UNIT
DRAIN BOLT
50 N·m (5.0 kg-m, 36 lb-ft)
MDUNTING BOLT TANK STRAPS

38 N·m (3.8kg-m.
27 lb-ft)
6-219
Air lntake System
System Troubleshooting Guide - - - - - - - - - - - - - - - - - - -
NOTE: Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the arder they should
be inspected starting with (!). Find the symptom in the left column, read across to the most likely source, then refer to the page
listed at the top of that column. lf inspection shows the system is OK, try the next system @.etc.
2.0t and KQ, KV:
PAGE
~EM THROTTLE CABLE THROITLE BODY
INTAKE
CONTROL 1
SYSTEM
------=====
1
sYMPTOM 222 223 229
WHEN WARM RPM TOO HIGH cv CD

LOSS OF POWER
1
CD cv
2.2! except KQ, KV:
PAGE
THROTILE BODY INTAKE CONTROL BYPASS
L:::M TH ROTILE CABLE
SYSTEM CONTROL
SYMPTOM
------=====
WHEN WARM RPM TOO HIGH
222
cv
223
CD
229 225
LOSS OF POWER CD @ cv
6-221
Air lntake System
Throttle Cable----------------~---------..
lnspection/ Adjustment lnstallation
1. Warm up the engine to normal operating temperatura 1. Fully open the throttle valve, then install the throttle
(cooling fan comes on). cable in the throttle inkage and install the cable hous-
íng in the cable bracket.
2. Check that the throttle cable operates smoothly with
no binding or sticking. Repair as necesary. 2. Warm i.Jp the engine to normal operating temperatura
3. Cehck cable free play at the throttle lingage. Cable (the coolíng fan comes on).
deflection should be 10-12 mm (0.39-0.47 in.).
THROTTLE LINKAGE
LOCKNUT
DEFLECTION BRACKET
10-12 mm LOCKNUT
3. Hold the cable sheath, removing afl slack from the

4. Jf deflection ís not wíthín specs, loosen the locknut and cable.
turn the adjusting nut until the deflection is as speci-
fied. 4. Turn the adjusting nut until it is 3 mm awayfrom the
cable bracket.
5. With the cable properly adjusted, check the throttle 5. Tighten the locknut. The cable deflection should now
valve to be sure it opens fully when you push the be 10-12 mm. lf not, see inspection/Adjustment.
accelerator pedal to the floor. Also check the throttle
valve to be su re it returns to the id le position whenever
you release the accelerator.
ADJUSTING NUT
CABLE BRACKET
LOCKNUT
6-222
Throttle Body------------------------------------------------~
lnspection
CAUTION: Do not adjust the throttle stop screw since it
can not be reset except at the factory.
1. Start the engine and allow to reach normal operating

temperatura (cooling fan comes on).
2. Disconnect the vacuum hose (to the canister) from the

top of the throttle body ; connect a vacum gauge to
the throttle body.
THROTTLE STOP SCREW.

VACUUM PUMP/GAUGE There should be
(Non-adjustable)
no clearance.
Replace the throttle body if there is excessive play in the

throttle valve shaft or if the shaft is bínding or sticking.
3. Allow the engine to idel and check that the gauge

indicates no vacuum.
e lf there is vcuum, check the throttle cable ( page

6-222).
4. Check that vacuum is indicated on the gauge when the

throttle is opened slightly from idle.
e lf the gauge indicates no vacuum. check the throt-

tle body port is clogged, clean it with carburetor
cleaner.
5. Stop the engine and check that the throttole cable

operates smoothly wíthout bíndíng or sticking.
e lf there are any abnormalities in the above steps,

check for:
- Excessive wear or play in the throttle valve shaft.

- Sticky or binding throttle lever at full clase position.
- Clearance between throttfe stop screw and throttle
lever at full clase position.
6-223
Air lntake System
Throttle Body------------------------------------------------~~
Disassembly
CAUTION:
e The throttle stop screw in non-adjustable.
e After reassembly, adjust the throttle cable (page 6-222).
Replace.
6-224
Bypass Control System (2. 2 l Except KQ, K V ) - - - - - - - - - - - - - - .
Troubleshooting Flowchart
lnspection of Bypass Control

System
Start engine and allow to idle.
Remove #13 vacuum hose from VACUUM PUMP/GAUGE

the bypass control diaphragm and
connect vacuum gauge to the
hose.
Remove #12 vacuum hose from
the vacuum tank, then check for
NO
ls there vacuum ? vacuum at the tank.
VES Repair the blockage or

NO vacuum leak between
ls there vacuum ?
the vacuum tank and
YES the intake manifold.

the Bypass Control Solenoid
Valve.

YEL (+) terminal and PNK/BLU
(-) terminal.
SOLENOID VALVE
Replace the bypass
control solenoid val ve.
·No

YEL ( + 1 terminal and body
ground.
1
(To page 6-226) {To page 6-226) (cont'd)
6-225
Exhaust Gas Recirculation System (cont'd)-------____;_ _ _ _ __
"(From page 6-235)
YES
ls there any vacuum ?
NO
Move the vacuum pump/gauge to

the EGR valve.
Check vacuum hose

With the engine at idle, apply 200 routing of the entire
YES EGR system. lf hose
mmHg of vacuum to the EGR ls there any vacuum ?
valve. routing is OK, replace
NO EG R control solenoid
valve.
lnspect for short to body ground
in PNK wire between EGR con-
trol solenoid valve and ECU(A8).
lf wire is DK, substituta a
known-good ECU and retest. lf
symptom/indication goes away,
replace the original ECU.
Except 2.2 2 KE:
Does the engine stall and does the

Replace EGR.valve.
EGR valve hold vacuum?
YES
the control box.

YEL 1+) terminal on the main wire
harness and body ground.
Repair open in
NO
ls there battery voltage ? between the solenoid valve and
No.2 fuse.
YES
2.2 t KE:
Reconnect the vacuum pump/
gauge to the #16 hose.
Start the engine and allow it to

id le.
(To page 6-237)
6-236
Except 2.2 i KE:
!From page 6-236)
Connect the battery positive termi-

nal to the B terminal of the 4P
connector. While watching the
vacuum gauge, connect the bat-
tery negativa terminal to the D
terminal.
2.2 t KE:
Turn the ignition switch OFF and

ls there approx. 200 mmHg within
inspect the #1 6 and #24 hoses for
1 second?
leaks, restrictions, or mis-routing.
VES
Are the hose OK ? Connect as necessary.
reconnect the 4P connector.
VES
Disconnect th.e lower hose on EG R

control solenoid valve and connect
a vacuum gauge to the hose.

idle.
VACUUM
PUMP/GAUGE
ls there 1 50-250mmHg of vac-

uum? Replace CVC valve.
VES
Replace the EGR control
solenoid valve.
6-237
Exhaust Gas Recirculation System (cont'd) - - - - - - - - - - - - - -
(From page 6-237)

!

the EGR valve lift sensor and
engine wire harness.
TEST
HARNESS--------~~
07LAJ-
Measure voltage between RED ( + l PT30200
terminal and GRN (-)terminal.
-Repair open in YEL/WHT wire

between EGR valve and ECU
NO (020}.
-Repair open in GRN/WHT wire
VES between EGR valve and ECU
(022).
Measure voltage between WHT

{+) terminal and GRN {-1 termi-
nal.
-Replace EGR valva.
-Repair short in WHT/BLK wire
between ECU (012) and EGR
NO valve lift sensor.
ls there approx. 1 .2V ?
VES and recheck. lf prescribed volt-
age is now available, replace
the original ECU.
While watching the voltmeter,
slowly apply a continuous 200
mmHg of vacuum to the EGR .
valve. Repeat several times, com-
pletely releasing vacuum between.
ls the maximum voltage approx. 4 V? Aeplace EGR valve.
YES
Does the voltage consistently

increase/decrease as the vacuum Replace EGR valve.
increases decreases ?
YES
Reconnect the #16 hose to the

EGR valve.
(To page 6-239)
6-238
(From pa!¡le 6-238)

(page 6-1 50).

idle.
/
j 000000000000010000000 o
0000000000000 0000000 o
Me asure voltage between 012
( +) terminal and 022 (-) termi- 012(+)022{-1
na l. L1v1_J
1
Repair open in WHT/BLK wire
NO
ls there approx. 1.2 V? between ECU (012) and the sen-
sor.
! VES
Connect A11 terminal to A26 ter-
minal with a jumper wire.
1
Repair open in PNK wire
NO
Oíd the engine stall ? between ECU (A11) and EGR
control solenoid valve.
l VES

inal ECU.
6-239
Air lntake System
lntake Control System ( c o n t ' d ) - - - - - - - - - - - - - - - - - - -
(From page 6-229} (From page 6-229)
Repair open in BLK/

NO YEL wire between the
Raise engine speed to 3, 700 mín-1 ls there battery voltage ?
(rpm). 2P connector and No. 2
VES (10 A) fuse.

(page 6-1 50}.
Check for continuity of WHT wire

between ECU (A19) and the 2P
connector.
A19
Repair open in WHT

NO wíre between ECU
(A19) and the 2P con-
VES nector.

and rachee k. lf symptom/indica-
inal ECU.
ls there vacuum ? Dísconnect the 2P connector.
NO
Replace intake control
ls there vacuum ?
solenoid valve.
NO
Disconnect ·A· connector from

ECU.
Check for continuity to ground on

WHTwire.
(To page 6-231) (To page 6-231)
6-230
(From page 6-230) {From page 6-230)
1 Repair short to ground

YES in WHT wire between
ls there contínuity to ground ?
ECU {A19) and the 6P
1 NO connector.
Substituta a known good ECU

and recheck. lf symptom goes
away, replace the original ECU.
Connect a vacuum pump to the #8

vacuum hose.
INTAKE
DIAPHRAGM
Apply vacuum.
1
Check the vacuum line for proper 1
connection or disconnected ¡
NO
Does it hold vacuum ? hose.
lf OK, replace the intake dia-
VES phragm.
j lntake control system is O K.
6-231
System Troubleshooting Guide - - - - - - - - - - - - - - - - - - - -
inspected starting with Q). Find the symptom in the left column, read across to the most likely source, then refer to the page listed
With CATA:
J;::
PAGE POSITIVE
CATALYTIC EGR SYSTEM CRANKCASE EVAPORATIVE
CON VERTER (except KQ) VENTILATION EMISSION
SYSTEM CONTROLS
SYMPTOM ~ 234 235 240 241
ROUGH IDLE CD Cí)
FREOUENT(AFTER )
STALLING WARMING UP CD
i
FAILS
POOR
EMISSION
TEST
CD cv 1
PERFORMANCE
LOSS OF
POWER CD
i
KV:
PAGE
S::
POSITlVE EVAPORATIVE
CRANKCASE EMISSION
VENTILATION CONTROLS
SYSTEM
¡SYMPTOM ~ 240 241
:'
ROUGH IDLE CD
POOR (AILS )
PERFORMANCE EMISSION
TEST
CD
6-232
Tailpipe Emission-----------.
lnspectin
@•jij@i~ Do not smoke during this procedure. Keep

any open ame away from your work area.

temperature {cooling fan comes on).
2. Connect tachometer.
3. Check idfe speed and adjust the idle speed, if neces-

sary (page 6-207)
4. Warm up and calibrate the CO meter according to the

meter manufacture's instructions.
5. Check idle CO with the ceadights, heater blower, rear

window defogger, cooling fan, and air conditioner off.
Specified CO%:
With CATA: O. 1 % maximum
Without CATA: 1 .O± 1 .O %
e lf unable to obtain this reading :

On With CATA, see ECU troubleshooting guide (page
6-144).
On other models, adjust by turning the adjusting
screw of the IMA sensor.
ADJUSTING SCREW
- lf unable to obtain a CO reading of specified % by

thís procedure, check the engine tune-up condi-
tion.
6-233
Catalytic C o n v e r t e r - - - - - - - - - - - - - - - - - - - - - - - - _ _ ,
lnspection
lf excessive exhaust system back-pressure is suspected, remove the catalytic converter from the car and make a visual check for
plugging, melting or cracking of the catalyst. Replace the catalytic converter if any of the visible area is damaged or plugged.
34 N•m (3.4 kg-m, 25 lb-ftl
HEAD SHIELD
34 N•m(3.4 kg-m,
25 lb-ft) GASKET
FRONT OF
~·
~ VEHICLE
CATALYTIC
CONVERTER
Remove/lnstallation, section 5
lnspect housing for cracks or
other damage.
lnspect element for clogging
by looking through the inside.
\
10 N•m (1.0 kg-m, 7 lb-ft)
6-234
Exhaust Gas Recirculation System -----------------~
_A
-íO]-
' 1 /
~ Self diagnosis indicates code 12: Most likely a problem in the Exhaust Gas Recircul~tion (EGR) system.
/ 1 "-
0t
"- 1 /
-[0]-
/ 1 ...__
-Check Engine waming light

1 has been reportad on.
j -LEO indicates COOE 12.
Remove the BACK UP fuse in the

onds to reset ECU.
Road test necessary: Warm up the 1

engine to normal operating tem- ,
perature (cooling fan comes on). 1
Orive the car on the road for ap-

prox. 1 O minutes. Try to keep the ¡·
engine speed in the 1 700-2500

l range.

OK at this time [test drive may #16 HOSE
_ _ _--1 be necessary).
and does LED indicated CODE 12?
Check for poor connections or
VES loose wires at EGR and ECU.
With the engine at id le, disconnect

the #16 hose from the EGR vatve
1
and connect a vacuum pump/
¡
1
gauge to the hose.
VACUUM
PUMP/GAUGE
6-235
Evaporative Emission Controls - - - - - - - - - - - - - - - - - - - - . . . ,
lnspection of Evaporative Emis-

sion Controls.
PURGE CONTROL
Oisconnect 13 vacuum hose from DIAPHRAGM VALVE
the purge control diaphragm valve
(on the charcoal canisterl and con-
nect a vacuum gauge to the hose.
Start the engine and allow to idle.

NOTE: Engíne coolant tempera- VACUUM PUMP/GAUGE
ture must be below 75°C (167°
F).
Disconnect the 4P (KQ: 2P) con-

ls there vacuum ?
nector.
NO
Except KQ:
y__..._,
RED/GRN (-) BLK/VEL (+)
(RHI

YEL (+) terminal and RED/GRN
(-) terminal.
lnspect vacuum hose

VES routing.
lf OK. replace purge
NO cut-off solenoid valva.

YEL ( + 1 terminal and body
ground.
KQ:
BLK/VEL (+)
RED/GRN (-)
(To page 6-242) (To page 6-242) (cont'd)
6-241
Special Tools
SpeciaiTools--------------------------------------------------~
Ref. No. ! Tool Number Description Remarks
07JAF-PM7011A Clutch Alignment Disc 12-8

07LAF-PT0011 O Clutch Alignment Shaft 12-8, 11
07924-PD20003 or Ring Gear Holder 12-8. 9, 10
07924-PD20002
07936-371 01 00 Handle 12-8. 11
7-2
lllustrated lndex
NOTE:
• Whenever the transmission is removed, release bearing sliding surface should be cleaned and greased.
e lf the *
mark parts were removed, the clutch hydraulic system must be bled.
*15 N•m
1
(1.5 kg-m, 111b-ft)
1
'
1
'
1
1
Gf
CLUTCH
' PEDAL
______________
PI~VOT
F18A Engine: ,)
""e
__/
PIN CLUTCH LASTER CVUNDER
10 N•m (1.0 kg-m, Slb-ftl
__ __,_ *15 N•m
Overhaul/lnspect1on. page 7-5
(1.5 kg-m. 11 lb-ft)
RESERVOIR Removal, page 7-6
*Oil eoLT Disassembly, page 7-7
30 N·m (3.0 kg-m. 22 lb-ftl ~ Assembly, page 7-7
~ O;~
--- * f~*
~", ~ ·~
CLUTCH DAMPER * 15 N•m (1.5 kg-m. *19 N•m (1.9 kg-m,
AS~EMBLY 11 lb-ft)
14 lb-ft)
RELEASE BEARING
Removal, page 7-10
\
··;p
FLYWHEEL
lnspection/Removal, page 7-13
lnstallation, page 7-1 3
CLUTCH DISC
lnspection. page 7-12
lnstallation. page 7-13
PRESSURE PLATE
Removal/lnspectíon. page 7-11
RELEASE FORK
Removal, page 7-10
TRANSMISSION *S LAVE CYLINOER
Removal, page 8-9 *19 N·m (1.9 kg-m. Overhaul/lnspection, page 7-8
lnstaltation, page 8-1 3 14 lb-ftl Removal, page 7-9
7-3
Pedal Free Play
LOCKNUT B
16N•1i[] lb-~
LOCKNUT B 1
i
15 N•m (1.5 kg-m. 11 lb-ft)
CLUTCH PEDAL SWITCH A
LOCKNUT A
10 N•m (1.0 kg-m. Slb-ftl
______ _/ _____....,
F18A Engine: ,/
_.../
PEDAL IN CONTACT
WITH SWITCH
CLUTCH PEDAL HEIGHT

CLUTCH ASSIST SPRING / 210 mm {8.27 ;n.)lo floo<.
-~
•
PEDAL PLAY
1-7 mm (0.04-0,28 in.l ·
Determinad by the
clearance between
J
[ the master cylinder
CLUTCH PEDAL piston anrl push rod.
DISENGAGEMENT HEIGHT:
90 mm (3. 54 in.) minimum to the floor
NOTE:
• The clutch is self-adjusting to compensate for 3. Tighten locknut B.
wear.
• Total clutch pedal free play is 9- 1 5 mm 4. Screw in the clutch pedal switch until it contacts the
(0.35-0.59 in). clutch pedal.
CAUTION: lf there is no clearance between the 5. Turn the switch in further 1/4-1/2 turn.
master cylinder piston and push rod. the release
bearing is held agaínst the diaphragm spring. 6. Tighten the locknut A.
resulting is slipping clutch or other faulty clutch
operation.
1. Loasen locknut A. and back off the pedal switch until

it no longer touches the clutch pedal.
2. Loosen locknut B, and turn the push· rod in or out to
get the specified stroke and height at the clutch pedal.
7-4
Clutch Master Cylinder
Overhaul/lnspection
RESERVOIR CAP
RESERVOIR
MASTER CYLINDER BODY

• Check the cylinder wall for
scoring or wear.
~~ -VALVESEAL
VALVE STEM
SPRING RETAINER - - - - -
NOTE: Check for damage or
• Disengage the retaining bending.
pawl from the piston
to assemble. VAL VE SPRING
• Hook the piston on
the retaining pawl \ VAL VE GUIDE
when assembling.
RETURN SPRING
V
CLUTCH MASTER
PISTON
- r¡;¡;;.l
1 \ \ ~~~;!~.~·m~age
CIRCLIP 1
YOKE
\
15 N•m
DUST SEAL
(1 .5 kg-m,
COTTER PIN _ _ _ /
Replace. 11 lb-ft)
7-5
Clutch Master Cylinder
Removal
1. Pry out the cotter pin, and pull the pedal pin out of 2. Remove the nuts and bolts attaching the master
the yoke. cylinder and remove the cylinder from the engine
compartment.
3. Remove the clutch pipe and reserve hose from the
COTTER PIN
Replace. master cylinder.
PEDAL PIN
CAUTION:
... r¡;;;;fl • Avoid spilling brake fluid on paint as it may
damage the finish.
• Plug the end of the clutch pipe and reserve hose
with a shop towel prevent fluid from flowing out
of the clutch pipe and reserve hose after discon-
necting.
RESERVOIR CLUTCH PIPE
MASTER CYLINDER RESERVE HOSE

ASSEMBLY
7-6
Disassembly Assembly - - - - - - - - - - - - - ,
CAUTION: Avoíd spilling brake fluid on paint as it may CAUTION:

damage the finish. • Before assemblíng, make sure all parts are com-
pletely clean.
1. Remo ve the dust se al from the master cylinder. • Replace parts with new ones whenever specified to
do so.
• Do not allow dust or water to enter the system.
• Do not mix different brands of brake fluid as they
may not be compatible.
• Do not reuse the brake fluid which was drained out.
• Avoid spilling the brake fluid on painted surfaces, as
DUST SEAL
it may damage the finish.
1. Assemble the piston noting the proper direction of

the parts (page 7-51.
2. Pry the circlip off the master cylinder.
3. Carefully remove the piston by applying air \ Push the piston in until it engages
1
pressure through the clutch line hole. the pawl of the retaíner.
CAUTION:
e Hold a shop towel over the master cylinder. to
stop the piston in case it comes out suddenly.
e Plug the end of the clutch hose port with a shop 2. Slide the piston assembly into the master cylinder.
towel to prevent fluid from coming out.
e Clean all disassembled parts in solvent and blow
through all ports and passages with compressed 3. lnstall the circlip in the groove of the master
air. cylinder.
PIS TON
ASSEMBLY
CIRCLIP
SHOPTOWEL
MASTER
CYLINDER
4. lnstall the dust seal.
7-7
Slave Cylinder
Overhaul!lnspection
SLAVE CYLINDER BODY

Check the cylínder wall for
scoring or wear.
SLAVE CYUNDER SPRING

lnstall with small end BLEEDER SCREW
10 N•m (1.0 kg-m, Slb-ftl
BOOT
SLAVE CYLINDER PISTON Check that it is fitted securely
Check for wear or damage. over cylínder body.
!Molybdenum
Disulfiedl
7-8
Removal lnstallation
1. Disconnect the clutch pipe from the slave cylinder. 1. Instan the slave cylinder assembly on the clutch hous-
CAUTION: ing.
e Avoid spilling brake fluid on the painted sur-
faces. as it may damage the finish.
e Plug the end of the clutch pipe with a shop towel SLAVE CYLINDER ASSEMBLY 19 N•m (1 .9 kg-m,
to prevent brake fluid from coming out. 14 lb-ft)
2. Remove the slave cylinder from the clutch housing.
CLUTCH PIPE
J BLEEDER
SCREW
10 N•m (1.0 kg-m,
8 lb-ft)
22 N•m (2.2 kg-m, 161b-ftl

(Molybdenum
Disulfide)
2. Bleed the clutch hydraulic system:

e Atta eh a hose to the bleeder fitting and suspend the
hose in a container of brake fluid.
BOOT
Remove and check for signs of leaking e Make su re there is an adequate supply of fluid at the
or deterioration. master cylinder, then slowly pump the clutch pedal
until no more bubbles appear at the bleeder hose.
e Re-fill the master cylinder fluid when done.
e Use only DOT 3 brake fluid.
7-9
Release Bearing and Release Fork
Disassembly /lnspection lnstallation - - - - - - - - - - - - - - ,
1. Remove the boot from the clutch housing. 1. lnstall the release fork set spring on the release
fork.
2. Remove the release fork from the clutch housing by
squeezing the release fork set spring with pliers. RELEASE FORK SET SPRING
Remove the release bearing.
BOOT RELEASE FORK
CAUTION: Use only molybdenum disulfide grease

FORK SET in this step.
SPRING
2. With the release fork slid between the release bear-
ing pawls, install the bearing on the mainshaft
while inserting the release fork through the hole in
clutch housi~g.
3. Align the detent of the release fork with the release

fork bolt and press down on the fork on the release
fork bolt squarely.
RELEASE FORK
RELEASE FORK SET SPRING RELEASE
BEARING
RELEASE FORK SET

·SPRING
3. Check the release bearing for play by spinning it by

hand.
BOOT
CAUTION: The bearing is packed with grease. Do
not wash it in solvent. FORK BOLT
30 N•m 13.0 kg-m, 22 lb-ftl
CAUTION: Use only molybdenum disulfide grease

in this step.
4. lnstall the boot, being sure that there is no

clearance: release fork-to-boot, and boot-to-clutch
housing.
5. Move the release fork ríght and left to make sure

that the fork fits properly against the bearing, and
that the bearing slides smoothly.
4. Replace the bearing with a new one if there is ex-

cessive play.
7-10
Pressure Plate
Removal/lnspection .-------------~--------------,
1. lnspect the fingers of the diaphragm spríng for 5. To prevent warping, unscrew the pressure plate
wear at the release bearing contact area. mounting bolts two turns at a time in a crisscross
pattern using a 1O mm T·wrench, then remove the
2. Assemble the special tools as shown. pressure plate and clutch disc.
NOTE: Assemble the Clutch Alignment Disc with
RING GEAR HOLDER
side "A" facing the diaphragm as shown. 07924-PD20003 or
3. Check the diaphragm spring fingers for height us- 07924- PD20002
¡
ing the special tools and feeler gauge.
Standard INew): 0.6 mm (0.02 in.) Min.

Service Limit: 0.8 mm (0.03 in.) Max.
1 O mm T-WRENCH
RING GEAR HOLDER
07924-PD20003 or 07924-PD20002
6. lnspect the pressure plate surface for wear, cracks,

or burning.
CLUTCH ALIGNMENT SHAFT
07LAF-PT00110
7. lnspect for warpage using a straight edge and
l feeler gauge.
Standard (New): 0.03 mm (0.001 in.) Min.
4. lnstall the Ring Gear Holder. Service Limit: 0.15 nm (0.006 in.) Max.
Measure across pressure plate.
FEELER GAUGE
Adjust the holder height

to the flywheel by turning
¿
the adjuster nut.
STRAIGHT EDGE
7-11
Clutch Disc
lnspection
1. Remove the clutch disc. 4. Check for loose rubber torsion dampers. Replace
the clutch disc if any are loose.
2. lnspect lining of the clutch disc for signs of slipping
or oil. Replace it i.f it is burned black or oil soaked. 5. Measure the depth from the lining surface to the
rivets, on both sides.
Rivet Depth:
Standard (Newl: 1.3 mm (0.051 in.) min.
Service Limit: 0.2 mm (0.008 in.)
RING GEAR HOLDER

t
\
07924- PD20003 or
07924- PD20002 CLUTCH DISC
CLUTCH DISC
3. Measure the clutch disc thickness. TORSION DAMPER
Clutch Disc Thickness:

Standard (New): 8.5-9.2 mm (0.33-0.36 in.)
7-12
Flywheel and Clutch
Flywheel Di se
lnspection/Removal----------, lnstallation - - - - - - - - - - - - ,
1. lnspect the ring gear teeth for wear or damage. 1. Align the hole in flywheel with the crankshaft
dowel pin and assemble. Jnstall the bolts only
2. lnspect the clutch disc mating surface on the fly· finger tight.
wheel for wear, cracks or burníng.
2. lnstall the Ring Gear Holder, then torque the fly-
3. Measure the flywheel runout using a dial indicator wheel bolts in a crisscross pattern, as shown.
through at least two full turns. Push flywheel to RING GEAR HOLDER
ward engine to take up the crankshaft thrust 07924- or 07924- PD20002
washer clearance.
NOTE: The runout can be measured with engine

ínstalled.
FLYWHEEL
Standard (New): 0.05 mm (0.002 in.) max.
RING GEAR HOLDER

07924- PD20003 or
07924-PD20002
3. lnstall the clutch disc and pressure plate by aligníng

the flywheel dowels with dowel holes in the pres-
sure plate.
FLYWHEEL
4. Remove the eight flywheel mounting bolts and fly·
wheel. RING GEAR HOLDER
07924-PD20003 or
07924- PD20002
FLYWHEEL
ENGINE
BLOCK
RING GEAR HOLDER 4.

1
PRESSURE PLATE
lnstall the attaching bolts finger tight.
07924-PD20003 or
07924- PD20002 /cont'd)
7-13
Maintenance Back-up Light Switch
Transmission oil Replacement - - - - - - - - - -.....
Oil Level lnspection NOTE: Check the switch see Section 16.
1. Check with oil at operating temperatura, eng.ine 1. Disconnect the back-up light switch wire con-
OFF, and car on level ground. nectors.
2. Remove oil filler plug and check level with finger.
3. Oillevel must be up to fill hole. lf it is below hole, 2. Remove the back-up light switch.
add oil until it runs out, then reinstall plug.
Oil Change
Use only SAE 10W-30 or 10W-40 oil rated SF grade
1. With transmission oil at operating temperatura,

engine OFF, and car on level ground, re m ove drain
plug and drain. transmission.
2. Reinstall drain plug with new washer, and refill to

proper level.
NOTE: Drain plug washer should be replaced at

every oil change. 3. lnstall the new washer and back-up light switch.
Oil Capacity
1.9 f (2.0 U.S. qt.) after drain.

2.0 f (2. 1 U.S. qt.) after overhaul.
---......_
OIL FILLER PlUG
45 N•m (4.5 kg-m, 33 lb-ftl
8-2
Gearshift Mechanism
Overhaul ---------------------------------------------------------
NOTE:
• lnspect rubber parts for wear or damage when disassembling.
• Check that new cotter pin is seated fírmly .
..
Re place.
~
CHANGE WIRE PLA T E /
-
' SELF-LOCKING
NUT
Replace.
Re place. SELECT CABLE
8-3
Gearshift Mechanism
Cable Adjustment
Select Cable: Shift Cable:
1. With the transm1SS1on in neutral, measure the 1. With the transmission in neutral, measure the
clearance between ® and @. clearance between ®
and @.
®
1-.
212.5-213.5 mm
(8.37-8.40 in) ., ® @
174.3-175.3 mm
(6.86-6.90 in)
®
( .
2. lf there is no clearance between ®
and@, lo osen 2. lf there is no clearance between ®
and @, loosen
the locknut and turn the adjuster as necessary. the locknut and turn the adjuster as necessary.
ADJUSTER ADJUSTER
3. Tighten the locknut and install the select cal:lle to 3. Tíghten the locknut and install the shift cable to the
the linkage. change lever.
NOTE: NOTE:
• Check that new cotter pin is seated firmly. • Check that new cotter pin is seated firmly.
• After adjustment, check operation of the gear- • After adjustment, check operation of the gear-
shift lever. shift lever.
WASHER ASSEMBL Y
• Plastic washer is the cotter pin • Plastic washer is the
síde. cotter pin side.
8-4
Transmission Assembly
Removal
6. First remove the cable stay and disconnect the

e Make su re jacks and safety stands are placed proper- cables from the top housing of the transmíssion.
ly, and hoist brackets are attached to correct posi-
tions on the engine.
• Apply parking brake and block rear wheels, so car NOTE: Remove both cables and the stay together.
will not roll off stands and fall on you while working
under it. CAUTION: Take care not to bend the cables.
CAUTION: Use tender covers to avoid damaging

painted surfaces.
1. Disconnect the battery negative (-) and posítíve

(+) cables from the battery, and remove the
battery.
2. Remove the air intake hose and battery base.
3. Disconnect the starter motor cables, remove the

starter mounting bolts, then remove the starter
motor.
4. Dísconnect the transmission ground cable.
5. Disconnect the back-up light switch wire.
BACK-UP LIGHT
SWITCH
7. Disconnect the connector and remove the speed

sensor, but leave its hoses connected.
TRANSMISSION GROUND
CABLE
(cont'd)
8-9
Removal (cont'd)
8. Remove both front wheels. 13. Remove the center beam.
9. Remove the undercarriage splash shield. 14. Remove the header pipe.
1 O. Drain transmission oil.
11 . Remove the mounting bolts and clutch slave

cylinder with the clutch pipe and push rod.
SELF-LOCKING
1 2. Remove the mounting bolt and clutch hose joint NUTS
with the clutch pipe and clutch hose. Replace.
GASKET
Replace.
NOTE:
GASKET
• Do not operate the clutch pedal once the slave
cylinder has been removed.
• Take care not to bend the pipe.
HEADER
PIPE
CLUTCH HOSE
JOINT CLUTCH PIPE
Re place.
10 x 1.25 mm BOLTS
15. Remove the cotter pin and lower arm ball joint nuts,
then separate the ball joints and lower arms (See
Section 12).
16. Remove the damper fork bolt.
SLAVE.CYLINDER Replace.
OAMPER FORK
BALL JOINT NUT BOLT
COTTER PIN
Re place.
8-10
1 7. Pry the right and left driveshafts out of the differen- 23. Remove the engine stiffener.
tial and the intermediate shaft.
24. Remove the clutch cover.
18. Pull on the inboard joint and remove the right and
left driveshafts (See section 1O).
19. Remove the 3 mounting bolts and lower the bear-

ing support.
20. Remove the intermediate shaft from the differential

(See section 1O).
DRIVESHAFT
INTERMEDIATE SHAFT (Right sidel
SET RING
Replace. CLUTCH COVER
25. Remove the intake manifold bracket.

NOTE: Coat all precision finished surfaces with
clean engine oil or grease.
Tie plastic bags over the driveshaft ends.
BRACKET
21. Remove the right damper pinch bolt, then separate
the damper fork and damper.
22. Remove the bolts and nut, then remove the right
radius rod.
RADIUS ROO
(cont'd)
8-11
Removal (cont'd)
26. Remove the rear engine mount bracket stay. 30. Place a floor jack under the transmission and raise
transmission just enough to take weight off
27. Remove the 3 rear engine mount bracket mounting mounts.
bolts.
31. Remove the transmission mount mounting bolt and
28. Remove the transmiSSIOn housing mounting bolt loasen the mount bracket mounting nuts.
(Engine side).
REAR ENGINE MOUNT BRACKET 32. Remove the 3 transmission housing mounting
BRACKET MOUNTING BOL TS bolts.
29. Swing the right driveshaft to the inner fender.

TRANSMISSION
HOUSING
MOUNTING BOL T
TRANSMISSION
MOUNT
TRANSMISSION
MOUNT BRACKET
LOWER ARM
8-12
lnstallation
1. Place the transmission on the transmission jack, 5. lnstall the transmiSSion housing mounting bolts
and raíse to the engine leve!. (Engine sidel.
6. lnstall the 3 rear engine bracket mounting bolts.
2. Check that the 4 dowel pins are installed. 7. lnstall the rear engine mount bracket stay.
NOTE: Loosely install the stay mounting bolt and
3. lnstall the 3 transmission housing mounting bolts.
nut, then torque in the sequence shown.
TRANSMISSION HOUSING BRACKET

MOUNTING BOL TS MOUNTING BOLTS
12 x 1.25 mm REAR ENGINE MOUNT ~ 12 x 1.25 mm
65 N·m {6.5 kg-m, 47 lb-ft) BRACKET ~55 N·m (5.5 kg-m, 40 lb-ft)
1
1J
TRANSMISSION HOUSING
MOUNTING BOL TS {Engine sideJ ·
12 x 1.25 mm
65 N•m (6.5 kg-m, 47 1~-ftl--
10x1.25mm
REAR ENGINE
MOUNT
BRACKET
4. lnstall the transmission mount and mount bracket.

8. lnstall the intake manifold bracket.
NOTE: Torque mounting bolt and nuts in sequence 8 x 1.25 mm
shown. BRACKET 22 N·m (2.2 kg-m. 16 lb-ft)
CAUTION: Check
twisted or offset.
that the bushings are not
V
8 Tighten
10 x 1.25 mm
55 N•m 15.5 kg-m, 40 lb-ft)
lNOTE: Check that the
engine leve!.
O
O Tighten
12 x 1.25 mm
J
Tighten temporarilly~,'--......,~
65 N•m (6.5 kg-m, 47 lb-ftl (cont'dl
8-13
Special Tools
Special Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - . ,
Ref. No. Tool Number Description a·tv Remarks
<D 07406-0020003 Oil Pressure Gauge Set

(])-1 07 406-0020201 Oil Pressure Gauge Hose Component Tool
® 07 406-0070000 Low Pressure Gauge
CD CD-1
9-2
Symptom-to-Component Chart
Hydraulic System - - - - - - - - - - - - - - - - - - - - - - - - -
Check these items on the Check these items on the

SYMPTOM
PROBABLE CAUSE UST NOTES CHART
Engine runs, but car does not move in any gear. 1,6,7,16 K, L,R, S
Car moves in R and 2, but not in 03, 04 or 1 . 8,29,44,48 C,M,O
Car moves in 03, 04, 1, R, but not in 2. 9, 30,49 C, L
Car moves in 03, 04, 2, 1 , but not in R. 1' 11. 34, 38, 39, C, L, O
40
Car moves in N. 1, 8, 9, 1 O, 11, 46, C,D
47
Excessive idle vibration. 5, 17 B, K, L
Slips in all gears. 6, 7, 16 C, L, U
No engine braking in [IJ position. 12 C, D, L
Slips in low gear. 8, 29,44,48 C,N,O,U
Slips in 2nd gear. 9, 20, 23,30,49 C, L, U
Slips in 3rd gear. 10, 21,23, 31,44 C, L, U
Slips in 4th gear. 11' 23, 32 C, L, U
Slips in reverse gear. 11' 32, 34 e
Fiares on 1 -2 upshift. 3, 15 E, L, V
Fiares on 2- 3 upshift. 3, 15, 24, 44 E, L, V
Fiares on 3-4 upshift. 3, 15, 25, 44 E, L, V
No upshift, trans stays in low gear. 14, 19, 23 G, L
No downshift to low gear. 12, 19 G, L
Late upshift. 14 L, V
Erratic shifting. 2, 14, 26 V
Harsh shift (up and down shifting). 2, 4, 15, 23, 24, 27, A, E, H, 1, L, V
47
Harsh shift ( 1 -21. 2, 9 C,D,V
Harsh shift (2-3). 2, 10,23,24 C, O, H, l, V
Harsh shift (3-4). 2, 11' 23, 25 C, O, 1, L, V
Harsh kickdown shifts. 2, 23, 27, 28 L, V, Q
Harsh kickdown shift (2 -1}. 48 o
Harsh downshift at closed throttle. 15 E, T
-
Harsh shift when manually shifting to ITJ. 33 L
Axle(s) slips out of trans on turns. 43, 50 L. P, Q
Axle(sl stuck in trans. 43 L, Q
Ratcheting noise when shifting into R. 6, 7,38,39,40 K, L, Q
loud popping noise when taking off in R. 38,39,40 L. Q
Ratcheting noise when shifting from R to P or from R 38, 39,40,45 L, Q
to N.
Noise from trans in all selector lever positions. 6, 17 K, L, O
Noise from trans only when wheels are rolling. 39,42 L, Q
Gear whine, rpm related (pitch changes with shifts). 8,13,41 K, L, O
Gear whine, speed related (pitch changes with speed). 38,42 L, Q
Trans will not shift into 4th gear in 04. 1, 21, 28,32 L
Lock-up clutch does not lock up smoothly. 17, 36, 37 L
Lock-up clutch does not operate properly. 2, 3, 1 5, 18, 35, 36, E, L, V
37
Transmission has multitude of problems shifting. 43 L, Q
At disassembly, large particles of metal are found on
magnet.
9-4
PROBABLE CAUSE
1. Shitt cable broken/out of adjustment.
2. Throttle cable too short.
3. Throttle cable too long.
4. Wrong type A TF.
5. ldle rpm too low/high.
6. Oíl pump worn or binding.
7. Pressure requlator stuck.
8. 1st clutch detective.
9. 2nd clutch detective.
10. 3rd clutch detective.
11. 4th clutch detective.
12. 1st hold clutch detective.
13. Mainshaft, countershaft, and secondary shaft idler gears worn/damage.
14. Modulator valve stuck.
15. Throttle B valve stuck.
16. ATF strainer clogged.
1 7. Torque convertor detective.
18. Torque convertor check valve stuck.
19. 1-2 shift valve stuck.
20. 2- 3 shitt val ve stuck.
22. EA T D inhibitor valve stuck.
23. Clutch pressure control va/ve stuck.
24. 2nd orífice control valve stuck.
25. Orífice control valve stuck.
26. 3-2 kíckdown valve stuck.
27. 3rd kickdown valve stuck.
28. 4th exhaust valve stuck.
29. 1st accumulator detective.
30. 2nd clutch accumulator detective.
31. 3rd clutch accumulator detective.
32. 4th/reverse accumulator detective.
33. 1st hold clutch accumulator detective.
34. Servo valve stuck.
35. lock-up clutch timíng valve stuck.
36. lock-up clutch shift valve stuck.
37. Lock-up clutch control valve stuck.
38. Shift fork bent.
39. Reverse gears worn/damaged (3 gearsl.
40. Reverse selector worn.
41. 3rd gears worn/damaged (2 gears).
42. Final gears worn/damaged (2 gears}.
43. Ditferential pinion shaft worn.
44. Feedpípe 0-ring broken.
45. i 4th gears worn/damaged (2 gears¡.
46. Gear clearance incorrect.
47. Clutch clearance incorrect.
'
48. Sprag clutch detective.
49. Sealing rings/guide worn.
50. Axle-inboard joint clip missing.
9-5
Hydraulic System (cont'd) - - - - - - - - - - - - - - - - - - - - - -
Check these items on the 1

The following symptoms can be caused ltems on the
PROBABLE CAUSE OUE
by improper repair or assembly. NOTES CHART
TO IMPROPER REPAIR
Car creeps in N. 1
Rl, R2
Car does not move in 03 or 04. R4
Trans locks up in R. R3,R12
Excessive drag in trans. R6 R, K
Excessive víbration, rpm related. R7 1,
Noise with wheels moving only. R5 !

Main seal pops out. RB S
Various shifting problems. R9, R10
Harsh upshifts. R11
PROBABLE CAUSE OUE TO IMPROPER REPAIR
R1. lmproper clutch clearance.

R2. lmproper gear clearance.
R3. Parking brake lever installed upside down.
R4. Sprag clutch installed upside down.
R5. Reverse hub installed upside down.
R6. Oi\ pump binding.
R7. Torque converter not fully seated in oil pump.
R8. Main seal improperly installed.
R9. Springs improperly installed.
R10. Valves improperly installed.
R11. Ball check valves not installed.
R12. Shift fork bolt not installed.
9-6
NOTES
A. Flush ATF in the ATF cooler.
B. Set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in
engine section of service manual.
C. lf the large ciutch pistan 0-ring is broken, inspect the pistan groove for rough machining.
D. lf the clutch pack is seized or is excessively worn, inspect the other clutches for wear and check
the orífice control valves and throttle valves for free movement.
E. lf throttle valve B is stuck, inspect the clutches for wear.
G. lf the 1-2 valve is stuck closed, the transmission will not upshift. lf stuck open the transmission
has no 1st gear.
H. lf the 2nd orífice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
l. Jf the orífice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
J. lf the clutch pressure control valve is stuck closed, the transmission will not shift out of 1st gear.
K. lmproper alignment of main valve body and torque convertor case may cause oil pump seizure. The
symptoms are mostly an rpm-related ticking noise or a high pitched squeek.
L. Jf the oil screen is clogged with particles of steel or aluminum, inspect the oil pump and differential
pinion shaft. lf both are OK and no cause for the contamination is found, replace the torque con-
verter.
M. lf the 1st clutch feedpipe guide in the end cover is scored by the mainshaft, inspect the ball bearing
for excessive movement in the transmission housing. lf OK, replace the end cover as it is dented.
The 0-ring under the guide is probably worn.
N. Replace the mainshaft if the bushings for the 1st and 4th feedpipe are loase or damaged. lf the 1st
feedpipe is damaged or out of round, replace it. lf the 4th feedpipe is damaged or out of round,
replace the end cover.
o. A worn or damaged sprag clutch is mostly a result of shifting the trans in 03 or 04 while the wheels
rotate in reverse, such as rocking the car in snow.
P. lnspect the trame for collision damage.
Q. lnspect for damage or wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center ..
4. Oifferential pinion shaft for wear under pinion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1, 2, 3 and 4 if worn or damaged. lf trans makes clicking, grinding or whirring noise,
also replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to 1, 2,
3 or 4.
lf differentíal pínion shaft is worn, overhaul dífferential assembly and replace oil screen and
thoroughly clean trans, flush torque converter, cooler and lines.
lf bottom of 3rd clutch is swirled and trans makes gear noise, replace the countershaft and ring
gear.
R. Be very careful not to damage the torque converter case when replacing the main balf bearing. You
may also damage the oil pump when you torque down the main valve body. This will result in oil
pump seizure if not detected. Use proper tools.
S. lnstall the main seal flush with the torque converter case. lf you push it into the torque converter
case until it bottoms out, it will block the oil return passage and result in damage.
T. Harsh downshifts when coasting to a stop with zero throttle may be caused by a bent-in throttle
valve retainer/cam stopper. Throttle cable adjustment may clear this problem.
u. Check if servo valve stopper cap is installed. lf it was not installed, the check valve may have been
pushed out by hydraulic pressure causing a leak (interna!) affectíng all forward gears.
V. Throttle cable adjustment is essential for proper operation of the transmission. Not only does it af-
fect the shift points if misadjusted, but also the shift quality and lock-up clutch operatíon.
A too long adjusted cable will result in throttle pressure being too low for the amount of engine tor-
que input into the transmission and may cause clutch slippage. A too short adjusted cable will
result in too high throttle pressures which may cause harsh shifts, erratic shifts and torque con-
verter hunting.
9-7
Road Test
NOTE: After transmission is installed:

e Make su re the floor mat does not interfere with accelerator pedal travel. Fully depress accelerator pedal and check to make sure
the throttle lever is fully opened.
e Release the accelerator pedal and check both inner control cables to be sure they have slight play.
Warm up the engine to operating temperature.
IQ;] and ~ Range

1. Apply parking brake and block the wheels. Start the engine, then move the selector to ~ while depressing the brake pedal.
Depress the accelerator pedal, and release it suddenly. Engine should not stall.
2. Check that shift points occur at approximate speeds shown. Also check for abnormal noise and clutch slippage.
3. Apply parking brake and block the wheels. Start the engine, then move the selector to IQiJ while depressing the brake pedal.
KF, KW, KB, KE, KV, KP, KT and KU Models

e Upshift
IQ;! (and lllil 1st-2nd 2nd-3rd 3rd-4th lock up Clutch ON Fulllock up ON
1
km/h 15-19 33-37 42-48 49-53 68-74
Ysthrottle
Coasting down-hill from a stop
i mph
1
9-12 21-23 26-30 30-33 42-46
km/h 26-32 66-72 96-104 92-99 96-103

1
¡ .l1 throttle
Acceleration from a stop mph 16-20 41-45 60-65 57-62 60-64
km/h 48-55 100-108 146-155 - 135-143

Full-throttle
Acceleration from a stop mph 30-34 62-67 91-96 - 84-89
1 1
e Downshift
~ (and IQil) lock up Clutch OFF 4th-3rd 3rd-2nd 2nd-1st
(4th-2nd)
km/h 49-53 - 7-13
Ysthrottle 13-19
Coasting or braking to a stop mph 30-33 - (4th-2nd)
4-8
8-12
.l1 throttle km/h 92-99 - - -
When car is slowed by
increased grade, wind, etc. mph 57-62 - -
1
-
Full-throttle km/h - 129-138 85-94 41-48
increased grade, wind, etc. ! mph - 80-86 53-58 25-30
1
9-8
KS, KX, KO and KG Models
• Upshift
1ru
(and ~) 1st-2nd 2nd-3rd 3rd-4th lock up Clutch ON Full lock up ON
km/h 16-19 l 33-37 42-48 49-53 66-72

1
J.1i throttle 1
Coasting down-hill from a stop mph 10-12 21-23 26-30 30-33 41-45
km/h 26-32 66-72 95-104 92-99 96-104

Y2 throttle
Acceleration from a stop mph 16-20 41-45 59-65 57-62 60-65'
1
1 km/h 48-56 100-108 146-156 - 135-143

Full-throttle 1
Acceleration from a stop mph 1
30-35 62-67 91-97 - 84-89
l
e Downshift
lru
land IQi\} Lock up Clutch OFF 4th-3rd 3rd-2nd 2nd-1st
- (4th-2nd)
km/h 49-53 13-19 7-13
J.1i
throttle
Coasting or braking to a stop (4th-2nd)
mph 30-33 - 8-12 4-8
1
i Y2 throttle km/h 92-99 - - -
increased grade, wind, etc. mph 57-62 - ! - -
Full-throttle km/h - 146-156 85-95 39-47

When car is slowed by T
inreased grade, wind, etc. mph - 91-97 53-59 24-29
1 1
CAUTION: Do not shift from [QJ or ~ to lg] at speeds over 100 km/h (62.5 mph); you may damage the transmission.
[1] (1st Gear)

1. Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
2. Upshifts and downshifts should not occur with the selector in thís range.
~(2nd Gear)
2. Upshifts and downshifts should not occur with the selector ín this range.
(B] (Reverse)
Accelerate from a stop at fu/1 throttle, ar;'d check for abnormal noise and clutch slippage.
~ (Park)
Park carona slope (approx. 16°), apply the parking brake, and shift into Park. Release the brake; the car should not move.
9-9
Pressure
Testing
CAUTION: 1. Stop the engine and connect a tachometer.

e Before testing, be su re the transmission is filled to
the proper level. 2. Connect an oil pressure gauge to each inspection
e Connect an oil pressure gauge securely, being sure hale.
not to allow dust and other foreign particles to enter
the inspection hole. GAUGE SET 07406-0020003 (lncludes Pressure Hoses)
e Warm up the engine before testing. A/T Oll PRESSURE GAUGE HOSE 07406-0020201
e Set the parking brake securely, and block both rear
wheels. LOWER PRESSURE
• Raise the front of the car and support with safety GAUGE
stands. 07406-0070000
NOTE: Do not reuse old aluminum washers.

1
·~¡
lnstall the sealing bolt in the inspection hole and tighten to
the specified torque 18 N·m (1 .8 kg-m, 12 lb-ft). 01:"
f'-..._l;,.d./ir'i
t
HOSE FITTING
3. Start the engine and measure respective pressures as

follows.
Line Pressure Measurement

1. Set the parking brake and block both rear wheels securely.
2. Run the engine at 2,000 min- 1 (rpm).
3. Measure the line pressure.
UNE PRESSURE
INSPECTION HOLE
SELECTOR 1 PROBABLE FLUID PRESSURE

PRESSURE SYMPTOM 1
POSITION 1 CAUSE Standard Service Limit
Line ~ or [el No {or low) Torque converter, 760-809 kPa 711 kPa
Line pressure oil pump pressure 1
(7.75-8.25 kg/cm2, (7.25 kg/cm2, 103 psi)
1 regulator, torque 110-117 psi)
converter check
valve. oil pump
1 1 1 1 1
NOTE: Higher pressures may be indicated if measurements are made in selector positions other than ~ or [!:].
9-10
Clutch Pressure Measurement
2. Raise the front of the car and support with safety stands.
3. Allow the front wheels to ro tate freely.
5. Measure the clutch pressure.
1st CLUTCH PRESSURE

INSPECTION HOLE
LOW-HOLD CLUTCH
PRESSURE INSPECTION
HOLE
~ \
\
\
\1
3rd CLUTCH PRESSURE

INSPECTION HOLE
4th CLUTCH PRESSURE 2nd CLUTCH PRESSURE

INSPECTION HOLE INSPECTION HOLE
PRESSURE
SELECTOR
SYMPTOM
PROBABLE l FLUID PRESSURE
! POSITION
l 1
CAUSE Standard Service Limit
Low-Hold w No or low Low-Hold 765-814 kPa 716 kPa
! Clutch 1 low-hold Clutch {7 .8-8.3 kg-m/cm 2 , (7.3 kg-m/cm2,
_1 pressure 1 11 -11 8 psi) 104 psi)
1 1
:
1st 1
rn No or low 1st Clutch
1
Clutch ¡ 1st pressure
2nd
Clutch
¡~ No or low
2nd pressure
2nd Clutch
1 3rd ~or!Q!l No or low 3rd Clutch

Clutch 3rd pressure 1
1
--¡
4th No or low 4th Clutch
1 1
Clutch 4th pressure 1
1
1
4th IBl No or low Servo Valve
Clutch 4th pressure 4th Clutch
1
9-11
Pressure
Testing ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - - - - -
Clutch Low/High Pressure Test 8. With the engine idling, lift the throttle controllever up
1. Raise the car and support with safety stands. approximately 1/2 of its possible travel and in crease
the engine rpm until pressure is indicated on the appro-
2. Attach the gauge set to the appropriate pressure test priate gauge. Record the highest pressure reading
port. obtained.
3. Remove the cable end of the throttle controllever.
NOTE: Do not loosen the locknuts, simply unhook the

cable end.
LOCKNUT
LEVER
<X
THROTTLE CONTROL
9. Repeat step 8 for each clutch pressure being inspect-

ed.
4. Warm up the engine to normal operating temperatura
(cooling fan comes on).
5. With the engine idling, move the selector lever to llli or

~.
6. Slowly move the throttle linkage to increase engine

rpm until pressure is indicated on the appropriate
gauge. Then release the throttle linkage, allowing the
engine to return to an idle, and record the pressure
reading.
7. Repeat step 6 for each clutch pressure being inspect-

ed.
THROTTLE LINKAGE
9-12
3rd CLUTCH PRESSURE
INSPECTION HOLE
4th CLUTCH PRESSURE 2nd CLUTCH PRESSURE

II\ISPECTION HOLE INSPECTION HOLE
··~,----------
SELECTOR PROBABLE FLUID PRESSURE

PRESSURE SYMPTOM
POSITION CAUSE Standard Service Limit
2nd or No or low 2nd Clutch 392~814 kPa 343 kPa (3.5 kg/cm2,
Clutch 2nd pressure (4.0-8.3 kg/cm 2, 50 psi) with lever
1
57-118 psi) released.
735 kPa (7 .3 kg/cm2,
3rd No or low 3rd Clutch 1 04 psi) with lever in
Clutch 3rd pressure half or more
throttle position.
4th No or low 4th Clutch Ar22 -8 4 kPa 373 kPa (3.8 kg/cm2,
Clutch 4th pressure ti1.3 ·8 kg/cm 2, 54 psi) with lever
-118 psi) released.
735 kPa (7 .3 kg/cm2,
with lever in
more
" , '"''""" position. ·~
9-13
Pressure
Testing (cont'd) ~------------------------
Throttle Pressure Measurement
1 . Set the parking brake and block both rear wheels securely.
3. Disconnect the throttle control cable from the throttle lever and set the control lever in full throttle position.
THROTTLE B PRESSURE
INSPECTION HOLE
THROTTLE A PRESSU:RE
INSPECTION HOLE
--
SELECTOR PROBABLE FLUID PRESSURE 1
PRESSURE SYMPTOM
POSITION CAUSE 1 Standard Service Limit
Throttle A /Q;] or [Q¡] No or low Throttle valve A with 514-530 kPa 509 kPa
Throttle A CATA (5.25-5.4 (5.2 kg/cm 2.. 73 psi)
: pressure kg/cm 2 ,
74-76 psi)
1
~''"
1 without 485-500 kPa 480 kPa
CATA (4.95-5.1 (4.9 kg/cm2, 69 psi)
kg/cm 2 ,
70-72 psi)
IQll or [!l~ No or low Throttle valve B 760-808 kPa 710 kPa

Throttle B (7 .75-8.25 kg/cm2, (7.25 kg/cm2,
pressure ' 11 0-11 7 psi)
1 ¡
9-14
Governor Pressure Measurement
2. Raise the front of the car and support wíth safety stands.
3. Run the vehicle at 60 km/h (38 mph).
GOVERNOR PRESSURE
INSPECTION HOLE
~~~ SELECTOR SYMPTOM

PROBABLE
~----------------
FLUID PRESSURE
---------------~
~S·S~_u_R_E~_P_OSITION CAUSE Standard • Service Limit
! Governor [Q1J or Q;i No or low Governor valve with 1 225-235 kq-220 kPa
1
governor CATA (2.3-2.4 [ (2.25 kg/cm 2 , 32 psi)
pressure kg/cm 2 , .
. 32-34 psi~:-t--
1
~ithout1 166-176 kPa ! 162.~k-P_a_ __
,__L_
!
1
CATA (1. 7-1 .8
kg/cm2, ¡. (1.65 kg!cm2, 23 psi)
___........;.___ 24-25 psi) ·---·-·------------'
9-15
Stall Speed
Test------------------------------------------------------------1
CAUTION:
• To prevent transmission damage, do not test stall speed for more than 10 seconds ata time.
• Do not shift the lever while raising the engine speed.
• Be sure to remove the pressure gauge before testing stall speed.
1. Engage parking brake and block the front wheels.

2. Connect safety chains to both front two hooks and attach, with minimum slack, to sorne strong stationary object.
3. Connect tachometer, and start the engine.
4. After the engine has warmed up to normal operating temperature, shift into !lli.
5. Fully depress the brake pedal and accelerator for 6 to 8 seconds, and note engine speed.
6. Allow 2 minutes for cooling, then repeat same test in m
and !Bl.
Stall speed in illi, mand IBl must be the same, and must also be within limits:
NOTE:
Stall speed test must be made only for checking the cause of trouble.
Stall Speed RPM:

Specification: 2,500 min- 1 (rpm)
Service limit: 2,35Q-2,650 min- 1 (rpm)
TROUBLE PROBABLE CAUSE
Stall rpm high in !lli. m & IBl . Low fluid level or oil pump output.
.
1
. Clogged oil strainer.
. Pressure regulator valve stuck closed .

Slipping clutch .
Stall rpm high in [8j . Slippage of 4th clutch
Stall rpm high in !lli&m . Slippage of 1 st clutch or 1st gear one-way clutch
Stall rpm low in !lli. m & IBl . Engine output low
. Torque converter one-way clutch slipping
9-16
Fluid Level
Checking/Changing----------~----------------------------------,
Checking Changing
With the car on level ground, pull the transmission dipstick 1. Bring the transmission up to operating temperature by
and check the level of fluid immediately after the engine is driving the car. Park the car on level ground, turn the
shut off (within one minute). The fluid level should be engine off, then remove drain plug.
between the full and low marks. Push the dipstick all the
way in to check the fluid level. lf the level is at, or below, 2. Reinstall the drain plug with a new washer, then refill
the low mark, add DEXRON- II type automatic transmission the transmission to the full mark on the dipstick.
fluid.
Automatic transmission Capacity:
2.4l (2.5 us qts, 2.1 lmp qts) at changa
6.0l (6.3 us qts, 5.3 lmp qts) after overhaul
DRAIN PLUG
40 N•m (4.0 kg-m, 29 lb-ft)
9-17
Special Tool
SpeciaiTool----------------------------------------------------~
CD 07 406-0020003 Oil Pressure Gauge Set

CD-1 07406-0020201 Oil Pressure Gauge Hose Component Tool
® 07LAJ-PT301 00 ECU Test Harness
CD CD-1
9-20
9-21
Component Location
LHD:
TW SENSOR THROTTLE ANGLE
SENSOR
LOCK-UP CONTROL
SOLENOID VALVE
NM SPEED
SENSOR
/~
1' .1 11
i
SHIFT CONTROL . \
1'
~~ 1
J
SOLENOID VALVE \ \_/ 1
A/T CONTROL UNIT

PGM-FI ECU
BRAKE SWITCH
S SWITCH
SHIFT POSITION
CONSOLE SWITCH
9-22
RHD:
TW SENSOR
NC SPEED
SENSOR
LOCK-UP CONTROL
SOLENOID VALVE
NM SPEED
SENSOR
SHIFT CONTROL
SOLENOID VALVE
PGM-FI ECU
BRAKE LIGHT SWITCH
A/T CONTROL UNIT
SHIFT POSITION CONSOLE SWITCH S SWITCH
9-23
Circuit Diagram
UNDER-HOOD RELAY BOX
BRAKE
LIGHT IGNI110N
SW!TCH COIL
·PGM-FI ECU
·AUTO A/C
CONTROL UNIT
DASH
FUSE
BOX
BRAKE LIGHT
"~h
WHT/YEL GRN/WHT BLU
BLK/YEL BLK/YEL
UGHllNG
SW!TCH A23 A24 A20 02 A9
A/T CONTROL UNJT
AS A10 A19 A21 A17 · A15 A13 A11
T
RED/BLK
YEL
GRN YEL
GRN/BLU
GRN/YEL
LT GRN /WHT
.,_._.....__.._-ó--GRN/WH T -
l - - - 4 - - ó - - GRN/RED
)---._-C...--- GRN
l-----o-- GRN/BLK
DIMMING
CIRCUlT ) - - - - - 6 - - GRN/BLU
}---_;...--6-- GRN/YEL
l-----o.- LT GRN/WHT
RED - - 0 - - - - l N e D4 03
R ~ ~
2
DASHUGHT
BRIGHTNESS ..._ \ J 1
p
CONTROLLER ..._ \ 1 1 ---- 1
)....
'..._~ 1 --.::...----
SHIFTLEVER POSillON
INDICATOR
SHIFT POSJllON
CONSOLE BLK
BLK BLK SW!TCH
1_ _¿_ 1_
G401 G401 G401
G402 G402
9-24
Problem codes 1 through 9 are indicated by individual short blinks, Problem codes 1 O through 1 5 are indicated by a series
of long and short blinks. One long blink equals 1 O short blinks. Add the long and short blinks together to determine the
problem code. After determining the problem code, refer to the electrical system Symptom-to-Component Chart on page
9-28.
short
rl
_n~_____.n.__ _ ___.n..___ ___.n~-'---- See Problem CODE 1
See Problem CODE 2
See Problem CODE 14
long short
Sorne PGM-FI problems will also make the S indicator light come on. After repairing the PGM-FI system, disconnect the
Back Up fu se {7. 5 A) in the under-hood re la y box for more than 1 O seconds to reset the A/T control unit memory.
NOTE: Disconnecting the Back up fuse also cancels the radio preset stations and the clock setting. Make note of the
radio presets befare removing the fuse so you can reset them.
A1 A3 AS A7 A9A11A13A15A17A19A21A23A25 01 03 05
000000000000
000000000000
A2 A4 A6 AS A10A12A14A16Al8AZOA22A24A26
Terminal Locations
NOTE:
• Only the A and D sections of the ECU test harness are used for A/T troubleshooting.
• Unless otherwise noted, use only the Digital Multimeter for testing.
9-27
Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - -
Number of LEO S indicator Refer to

Possible Cause Symptom
display blinks light page
1 Blinks • Disconnected lock-up control • Lock-up clutch does not engage. 9-30
solenoid valve A coupler • Lock-up clutch does not
• Short or open in lock-up control disengage.
solenoid valve A wire • Frequent engine stalling.
• Faulty lock-up control solenoid
valve A
2 Blinks • Disconnected lock-up control • Lock-up clutch does not engage.- 9-31
solenoid valve B coupler
• Short or open in lock-up control
solenoid valve B wire
• Faulty lock-up control solenoid
valve B
3 Blinks • Disconnected throttle angle sen- • Lock-up clutch does not engage. 9-32
or OFF sor coupler
• Short or open in throttle angle
sensor wire
• Faulty throttle angle sensor
4 Blinks • Disconnected sensor coupler • Lock-up clutch does not engage. 9-33
• Short of open in speed sensor
wire
• Faulty speed sensor
5 Blinks • Short in shift position console • Fails to shift other than 2nd - 9-34
switch wire 4th gears.
• Faulty shift position console • Lock-up clutch does not engage.
switch 1
6 OFF • Disconnected shift position con- • Fails to shift other than 2nd - 9-36
sole switch coupler 4th gears.
• Open in shift position console • Lock-up clutch does not engage.
switch wire • Lock-up clutch engages and
• Faulty shift position console disengages alternately.
switch
7 Blinks • Disconnected s_hift control • Fails to shift (between 1st - 9-38
solenoid valve A coupler 4th, 2nd +----+ 4th or 2nd - 3rd
1
• Short or open in shift control gears only).
solenoid valve A wire • Fails to shift (stuck in 4th gear)
• Faulty shift control solenoid 1
valve A
8 Blinks • Disconnected shift control • Fails to shift (stuck in 1st or 4th 9-39
solenoid valve B coupler gears).
• Short or open in shift control
1
solenoid valve B wire
~
• Faulty shift control solenoid
1 valve B
9-28
Number of LEO S índicator Reter to
Possible Cause Symptom
display blinks light page
9 Blinks • Oisconnected NC speed sensor • Lock-up clutch does not engage. 9-40
coupler
• Short or open in the NC speed ¡
sensor wire
• Faulty NC speed sensor 1
10 Blinks • Oisconnected water temperature • Lock-up clutch does not engage. 9-42
1 sensor coupler
• Short or open in the water
temperature sensor wire
• Faulty water temperature sensor
11 OFF • Oisconnected ignition coíl • Lock-up clutch does not engage. 9-44
coupler
• Short or open in ignition coil
wire
• Faulty ignition coil
14 OFF • Short or open in FAS wire • Transmission jerks hard when 9-46
• Trouble in PGM-FI unit shifting.
15 OFF • Oisconnected NM speed sensor • Transmission jerks hard when 9-50
coupler shifting.
• Short of open in NM speed sen-
sor wire
• Faulty NM speed sensor ¡
e lf a customer describes the symptoms for codes 3, 6, or 11, yet the LEO is not blinking, it will be necessary to recreate
the symptom by test driving, and then checking the LEO with the ignition still ON.
• lf the LEO displays codes other than those lísted above or stays lit continuously, the control unit is faulty.
• Sometimes the S indicator light and the Check Engine warning light may come on simultaneously. lf so, check the
PGM-FI system according to the number of blinks on the PGM-FI ECU self-diagnosing indicator, then reset the memory
by removing the Back Up fuse in the under 11ood relay box for more than 1 O seconds. Orive the ve hiele for severa!
minutes at speed over 50 km/h (30 mph), then recheck the lights.
NOTE: Oisconnecting the Back up fuse al so cancels the radio preset stations and the clock setting. Make note of the
radio presets before removing the fuse so you can reset them.
9-29
Electrical Troubleshooting
Self-diagnosis LEO indicator

blinks once.
BLK/RED
~..___,! ng lllllD
from the control unit.
- - - - - 4 ,
1 O V?
Me asure the voltage between

the A6 (YELl and A25 (BLK/RED)
terminals.
Repair short to power

1 source in YEL wire be-
~
tween the AS terminal
ls there voltage?
and the lock-up control
solenoid valve A.
1 NO
F§ 11 ti~
1
from the lock-up control solenoid
valve assembly.
1
gJ1111
Check for contínuity between
the A6 (YEL) and A25 (BlK/RED) om
termínals.
Repair short to ground

1
ls there continuity?
l NO
r in YEL wire between
the AS terminal and
the lock-up control
solenoid valve A.
Connect the 2P connector to the

lock-up control solenoid valve
assembly.
Measure the resistance between

the A6 (YEL) and A25 (BLK/RED)
termínals.
Check for open in YEL
wire between the AS
1
terminal and the lock- BLK/RED
up control solenoid
ls the resistance 1 2- 24 n?
~ valve A. lf wire is OK,
check the Lock-up
1 YES Control Solenoid Valve
A.
Check for loose control unit con-
nectors. lf necessary, substitute
a known-good control unit and
recheck. 12-24 m
9-30
blinks twice.
1 GRN/BLK BLK/REO
~~~ §! 11111¡n
Oisconnect the 26P connector
1 11
Turn the .ignítion switch ON.
O V?
1
Mea su re the voltage between
the A4 (GRN/BLKl and A25
(BLK/RED) terminals.
source in GRN/BLK
1 wire between the A4
Js there voltage?
~ terminal and the lock-
up control solenoid
valve B.
jNo GRN/BLK BLK/REO
~ 1~
Q
l
1
1 1 1 1 1 1
the A4 (GRN/BLK) and A25
(BLK/RED) terminals. Check for open in 12-24a?
GRN/BLK wire be-
tween the A4 terminal
1
ls the resistance 12- 240?
1 YES
r and the lock-up control
solenoid valve B. Jf
wire is OK. check the
Lock-Up Control Sale-
noid Valve B.
from the lock-up control solenoid
valve assembly.
1

the A4 (GRN/BLKJ and A25
l
l Repair short to ground
r
in GRN/BLK wire be- O!l?
ls there continuity? tween the A4 terminal
and the lock-up control
solenoid valve B.
!No

lock-up control solenoid valve
assembly.
1
re check.
(cont'd)
9-31
Troubleshooting Flowchart (cont'd)

blinks three times.
Check whether the PGM-FI LEO

· display blinks (Section 6).
Repair the PGM-FI

Does the LEO blink?
System.
NO
Disconnect the 26P and 22P

connectors from the control unit.
4.75-5.25 V?
Measure the voltage between

the 018 (LT GRNfBLK) and A25
(BLKfRED) terminals. ·
Repair open or short in LT GRNIBLK
L T GRN/BLK wire be-
tween the 0'18 ter-
NO
ls the voltage 4. 75-5.25 V? minal and the 014 ter-
minal of the PGM-FI
YES ECU.
Turn the ignition switch OFF. 0.44-0.5 V?
r-------------~~~-------------
A25 07
between the connectors and the
control unit. 00000000 00.00000
00000000 0000000

the 07 and A25 terminals.

RED/BLK wire be-
ls the voltage 0.44-0.56 V?* tween the 07 terminal
and the throttle angle
YES * ± 10% sensor.

recheck.
9-32
blinks four times.
Jack up the front of the car and •·t.IIM.i!i~"

block one wheel. Set the parking
brake securely
and block the
rear wheels.
Shift _transmission to [ill... Jack up the front
of the car and
support with a
rigid rack.

,..------1 V
Rotate the front wheel and check

for voltage between the A25
(BLK/REOI and 09 IORNI ter-
minals.
Check for short or

ORN
open in ORN wire be-
Does ·the voltage 0-5 V appear NO tween the 09 terminal
alternately? and the Speed Sensor.
. lf wire is OK. check the
YES Speed Sensor.

nectors. lf necessary, substituta
recheck.
rcont'd)
9-33
Troubleshooting Flowchart (cont' d)
Self-diagnosis LED indicator

blinks five times.
1
1
l
1
Observe the A/T shift indícator

and select ea eh position sepa-
rately.
Does the indicator light properly? YQ_ See A/T shift position
indicator inspection
(Section 16).
r VES
1
between the control unit and
connectors.
1
1 1 1 1
1
GRN/RED BLK/RED
Shift to other than [[! position.
1
Measure the voltage between '
the A21 (GRN/RED) and A25 Check for short in
(BLK/RED) termínals. GRN/RED wire be-
tween the A21 ter-
minal and the shift
1 position consola
~
switch. lf wire is OK.
1s there battery vo\tage 7
check for loose con-
nectors.
1 VES lf necessary, substi-
tute a known-good
Shift to other than [BJ and 0 control unit and re-
position. check.
1
the A19 (LT GRNl and A25
(BLK/REDl terminals.
Check for short in LT
GRN wire between the LT GRN BLK/RED
1
1 A 19 terminal and the
ls there battery voltage?
~ shift position console
switch. lf wire is OK,
check for loose control
1 YES unit connectors. lf
To page 9-35 necessary, substitute
a known-good control
unit and recheck.
9-34
From page 9-34
! Shift to other than ~ position.

i
1
the A17 (GRN/BLK) and A25 Check for short in GRN/BLK BLK/RED
(BLK/REDl terminals. GRN/BLK wire be-
tween the A17 ter-
minal and the shift
1
1 YES
r position console
check for loase control
unit connectors.
lf necessary, substi-
Shift to other than ~ positíon. tute a known-good
control unit and re-
check.
1
the A15 (GRN/BLU) and A25
(BLK/RED) terminals. Check for short in
GRN/BLU wire be-
tween the A15 ter-
1
( YES
r minal and the shift
position console
check for loase control
unit connectors. lf
GRN/BLU BLK/RED
Shift to other than ~ position. necessary, substitute

unit and recheck.
f
the A13 IGRN!YEL) and A25
(BLK/REDl terminals. Check for short in
GRN/YEL wire be-
tween the A13 ter-
r
1
minal and the shift
ls there battery voltage? position con so le
GRNfYEL BLK/RED
¡VES check for loase control
unit connectors. lf
Shift to other than OJ position. 1
necessary, substituta
1
unit and recheck.
1

the A 11 (lT GRN/WHT) and A25
(BLK/REDl terminals. Check for short in L T
GRN/WHT wire be-
tween the A 1 1 ter-
NO minal and shift position
ls there battery voltage? consola switch or shift
position indicator. lf
YES wira is OK, check for
loose control unit con- LT GRN/WHT BLK/RED
Substituta a known-good control nectors. lf necessary,
unit and recheck. substituta a known-
good control unit and
rechack.
rcont'd)
9-35

blinks six times.
. 1 .,
1
1
Observe the A/T shift .indicator ..
and · select each position sepa-
rately.
-·
1
NO
Does the indicator light properly? See A/T shift position
indicator.
l
1 YES
1
..
connectors.
1
1
Shift to [[] position.
1
GRN/RED BLK/RED
the A21 (GRN/RED) and A25
l Repair open in GRN/

RED wire between the
ls there voltage?
~ A21 terminal and the
shift position console
switch.
INo
Shift to [ill or [E] position.
1
Me asure the voltage between
the A19 (LT GRN) and A25
(BLK/RED) termínals.
LT GRN BLK REO
l
1
Repair open in L T GRN
~1
1 wire between the A 19
ls there voltage? terminal and the shift
position console
switch.
JNo
To page 9-37
9-36
From page 9-36
1
Shift to ~ position.
1
the A17 {GRN/BLKI and A25 GRN/BLK BLKJRED
(BLK/REDI termínals.
Repair open in GRN/

1
~
BLK wire between the
ls there voltage? A17 terminal and the
¡No switch.
Shift to ~ position.

the A15 (GRN/BLUI and A25 .GRN/BLU BLK/RED
(BLK/REDI tl;lrminals.
Repair open in GRN/

1
ls there voltage?
1 NO
r BLU wire between the.
A 15 terminal and the
switch.
Shift to 8] position.
1
the A13 IGRN!YELI and A25 GRN/YEL BLK/RED
(BLK/REDI termínals.
Repair open in GRN/

J
ls there voltage?
1 NO
r YEL wire between the
A 13 terminal and the
switch.
Shift to [2] position.

1
the A 11 (lT GRN/WHT) and A25
(BLK/REDI terminals.
Repair open in LT LTGRN/WHT BLK/RED

1
ls there voltage?
1NO
r GRN/WHT wire be-
tween the A11 ter-
minal and the shift
position console
switch.
Check for loase control unit con-
recheck.
(cont'dl
9-37

blinks seven times.
1
Disconnect the 26P connector O V?
1
1
BLU/YEL BLK/RED
Mea su re the voltage between
the A5 IBLU/YEL) and A25
source in BLU/YEL
1
ls there voltage?
[No
r wire between the AS
terminal and the shift
control solenoid valve
A.
12-24 m
l
the A5 (BLU/YEL) and A25
BLUIYEL BLKIRED
Check for open in
l BLU/YEL wire between

the A5 terminal and
~
the shift control sole-
ls the resistance 12-24 !l?
noid valve A. lt wire is
OK, check the Shift
1 VES Control Solenoid Valve
A.
from the shift control solenoid
valve assembly.
1
the A5 {BLU!YEL) and A25 BLU/YEL BLK/RED
{BLK/RED) terminals.
Repair short to ground

1
INO
r in BLUIYEL wire be-
and the shift control
solenoid valve A.

shift control solenoid valve
assembly.
\
recheck.
9-38
blinks eight times.
J O V?
~~
1
Dísconnect the 26P connector

1
1
Bi 11 R
GRN/WHT
1 1 1 1 1 1
BLK/RED

the A3 (GRN/WHT) and A25
(BLK/REO)terminals.

1
ls there voltage?
1 NO
r so urce in GRN/WHT
wire between the A3
terminal and shift con-
troJ solenoid valve B.
12-24 !l?
1
the A3 (GRN/WHT) and A25 GRN/WHT BLK/RED
Check for open in
GRN/WHT wire be-
1 tween the A3 terminal
~
ls the resistan ce 12-24 !J?
solenoid valve B. lf
wire is OK. check the
1 YES Shift Control Solenoid
Valve B.
Disconnect the 2P connector 1
from the shift control solenoid
valve assembly.
l
the A3 (GRN/WHT) and A25
(BLK!RED) terminals.
Repair short to ground .

1
'NO
r- in GRN/WHT wire be-
solenoid valve B.

shift control solenoid val ve
assembly.
1
nectors. lf necessary. substituta
recheck.
(cont'dl
9-39

blinks nine times.
Check the state of ínstallatíon of

the NC SPEED SENSOR.
NO
OK? Reinstall and recheck.
YES
Dísconnect the 2P connector

from the NC speed sensor
coupler.
Measure the resístance of the NC

speed sensor.
ls the resistance 400-600 NO Replace the NC speed

ohms? (20°C) sensor.
YES
· Reconnect the NC speed sensor.
Disconnect the 22P coupler from

the control unit.
400-600 ()?
A
nr~111
017 ILT GRN/GRN) and 015
(BLU/YEL).
ls the resistance 400-600 NO

11111
BLU/YEL L T GRN/GRN
ohms? (20°C)
YES.

recheck. To page 9-41
9-40
From page 9-40
1
D 17 fl T GRN/GRNJ terminal and
body ground.
Repair short in LT
1
ls there continuíty?
!No
r GRN/GRN or BLU/YEL
wire between 017 and
O 1 5 terminals and the
NC speed sensor.
Check for continuity on the l T

GRN/GRN wíre between 017 ter-
minal and the NC speed sensor.
·1
NO Repair open in LT
GRN/GRN wire.
IYES
Check for continuity on the
BLUIYEL wire between 015 ter-
minal and NC speed sensor.
(cont'dl
9-41

blinks ten times.
Check whether the PGM-FI LEO

display blínks (Section 6).
Repair the PGM-FI

Ooes the LEO blink?
System.
NO


the O 18 (LT GRN/BLKl and A25
1 Repair open or short in
1 LT GRN/BLK wire be-
~
tween the 018 ter-
ls the voltage 4. 75-5.25 V?
minal and the D 14 ter-
1 VES minal of the PGM-FI
ECU.
1
1
between the control unít and the
connectors.
1
Start the engíne and warm it up
l to normal operating temperature.
1
the 05 and A25 termína!s.
l
~
YEL/GRN wire be-
ls the voltage 0.50-1.20 V? tween the OS terminal
and the coolant te m-
l VES
1
perature sensor.
1
nectors. lf necessary. substitute
a known-good control unit.
9-42
r--
r--
BLK/
RED r----
r--
r-----
LT
GRN
BLK
4.75-5.25 V?
0.5-1.2 V? 81---------,~
A25 05
00000000
00000000
{cont'd)
9-43
Self-diagnosis lEO indicator

blinks eleven times.
Disconnect the 26P connectors

Shift to IEJ posítion.

the A9 (BLUI and A25 (BLK/RED)
terminals.

YES
~ BLU wire between the
A9 terminal and the ig-
nition coil.
1 Check for loose control unit con-

nectors. lf necessary. subst1tute
J
1
recheck.
9-44
V
BLU BLK/
RED
(cont'd)
9-45
Troubleshooting Flowchart (cont' d) - - - - - - - - - - - - - - - - - -

blinks fourteen times.
Start the engine and warm it up

to normal operating temperature.
5 V?
Shift to [E] position.
Connect the ECU test harness 0000000

connectors.
Turn the ignition switch ON and

wait for at least two seconds.
Using an analog voltmeter,

measure the voltage between
the 016 (+) and A25 (-) ter-
minals.
NO
ls there approx. 5 V for over five Does the meter jerk from O V to YES i Refer to PGM-FI A/T
seconds? 4 V approx. every four seconds? Signal (Section 6).
YES NO
ls the Check Engine warning light Repair the PGM-FI

Jack up the front of the car.
on? System ISection 6).
NO
Start the engine.
Shift to [.QiJ position. Turn the ignition switch OFF.
Raise the engine to over Disconnect the A connector from

2,000 min- 1 (rpm) (over 40 mph the PGM-FI ECU.
in 4th gear) tor five seconds.
To page 9-47 To page 9-47
9-46
From page 9-46 From page 9-46
1
1
Release and depress the throttle Check for continuity on the

so that the transmission down- BRN/WHT wire between the D 16
shifts and upshifts. terminal on the A/T control unit
and the A 18 terminal on the
PGM-FI ECU.
Using an analog voltmeter,

measure the voltage between
D16 (+) and A25 (-) terminals ls there continuity? Repair open in BRN/
WHTwire.
YES

BRN/WHT wire between the 016
terminal on the A/T control unit
PGM-FI ECU.
ls there continuity? Repair short in BRN/

WHTwire.
NO
Check for loase control unit con-

a known-good unit and recheck.

Does the meter jerk toward O V YES nectors. lf necessary, substitute
only when the transmíssion a known-good control unit and
shifts? recheck.
\ 1
NO
To page 9-48
(cont'dl
9-47
From page 9-4 7
Apply the brake and shift to !E]

position.
Disconnect the A connector from

the PGM-FI ECU.

BRN/WHT wire between the D 16
terminal on the AJT control unit
PGM-FI ECU.
Repair open in BRN/

WHT wire.
YES
To page 9-49
9-48
From page 9-48
Check for continuity, on the

BRN/WHT wire between the 016
terminal on the A/T control unit
and the A1 terminal on the
PGM-FI ECU.
YES
Repair short in BRN/
WHTwire.
J
NO

nectors. lf necessary. substitute
lcont'dl
9-49

blinks fifteen times.
Check the state of installation of

NM (NC) speed sensor.
OK? Reinstall and recheck.

L-----------------------~
YES
Oisconnect the 2P connector

from the NM speed sensor.
Measure the resistance of the

NM speed sensor.
NO r-----------------------~
ls the resistance 400-600
Replace the NM speed sensor.
ohms?
YES
the NM speed sensor.


019 (ORN/BLU) and 012 (WHT/
BLU) terminals.

ls the resistance 400-600
O 19 (ORN/BLU) terminal and
ohms? (20°C)
body ground.
YES
Disconnect the 2P connector ls there continuity? Repair short in ORN/

from the NC speed sensor. BLU or WHTfBLU
NO wires between 019
and D 12 terminals and
the NM speed sensor.
Me asure the resistan ce of the NC
speed sensor.
O 19 (ORN/BLU) terminal and the
NM speed sensor.
To page 9-51 To page 9-51
9-50
From page 9-50 From page 9-50
NO
ls there continuity? Repair open in ORN/
BLU wire between 019
terminal and the NM
YES speed sensor.

012 IWHT/BLUI terminal and the
NM speed sensor.
NO
ls there continuity? Repair open in WHT/
BLU wire between D 12
terminal and the NM
YES speed sensor.

ls the resistance 400-600 NO

Replace the NC speed sensor.
ohms? (20°Cl
YES

the NC speed sensor.

BLU/YEL
017 (BLU/ORN) and 015
(BlU/YELl terminals.
ls the resistance 400-600 YES Check for loose control unit con-
ohms? (20°C) nectors. lf necessary. substitute
recheck.
NO
To page 9-52 (cont'dl
9-51
From page 9-51

017 (BLU/GRNI terminal and
body ground.
YES
-ls there continuity? Repair short in BLU/
GRN or BLU/YEL wires
between 017 and 015
terminals and the NC
NO speed sensor.

017 (BLU/GRNI terminal and the
NC speed sensor.
NO
ls there continuity? Repair open in BLU/
GRN wire between
017 terminal and the
NC speed sensor.
YES

015 (BLU/YEU terminal and the
NC speed sensor.
NO
ls there continuity? Repair open in BLU/
YEL wire between 015
terminal and the NC
speed sensor.
YES

nectors. lf necessary. substituta
9-52
Oll?
{cont'd)
9-53
lnspection of the brake light

signal.
Check that the brake lights come

on with the brake pedal pushed.
1
NO
Are brake lights ON? Faulty brake light circuit.
1 YES

1
1
Measure the voltage between 02

(GRN/WHT) and A25 (BLK/RED)
l
terminal with the brake pedal
pushed.
1
1
Repair open in (GRN/WHTI wire
~ between 02 terminal and brake
light switch.
1 YES
Brake light signal OK.
1 1 1 1
BLK/RED
9-54
lnspection of the A/C signal.
1
Start the engine.
Turn the blower switch ON.
1
Push the A/C switch ON.
1
Does A/C compressor clutch NO See Air Conditioner inspection.
engage? 1
1 VES
Stop the engine.

1
Start the engine.
J
1
A22 IRED/BlU) and A25 IBLK/
RED) terminals. (A/C compressor
OFFl
1
Repair open in RED/BLU wire be-¡!
'----------,----------J ~ tween A22 terminal and A/C
clutch relay.
1 VES
A/C signal is OK.
(cont'd)
9-55
Troubleshooting Flowchart -(cont' d) - - - - - - - - - - - - - - - - - -
S indicator light is on steady (not

blinkingl whenever the ignition
switch is ON.

Connect the ECU test harness to

the wire harness only, not to the
control unit.

the 020 (RED) terminal and body
ground.

from the S switch.
NO
Connect the ECU test harness to
the 020 (REDl terminal and body
the control unit.
ground.
Turn the ignition switch ON. VES

ls there continuity? Repair short in RED
wire between 020 ter-
NO minal and S switch.
Measure voltage between AS
IGRN) terminal and body ground. Replace S switch.
ls there voltage? Replace the A/T control unit.
YES
To page 9-57
9-56
From page 9-56
1
Measure voltage between the
GRN wire at the gauge assy. to
body ground.
1
NO Replace faulty shift position in-
ls there voltage?
1 YES
dicator.
1
Repair short to power source on
GRN wire between AS terminal
and gauge assy.
(cont'd)
9-57
S indicator light does not come

on with the ignition switch ON.
lit should come on for about 2
seconds.l
Shift to~or!Q1land depress the

S switch.

Does the S indicator light come YES
nectors. lf necessary, substituta
on?
recheck.
NO


the 020 (RED) and A25
Check for continuity on the RED

ls there continuity? wire between 020 terminal and
the S switch.
YES
Reconnect the 26P and 22P con- Repair open in RED

nectors to the control unit. NO
ls there continuity? wire between 020 ter-
minal and S switch.
YES
Turn the ignition switch ON. Check for continuity on BLK wire
between S switch and G401,
G402.
Check for voltage on GRN wire at

the gauge assy.
ls there continuity? Replace S switch.
NO
To page 9-59
Repair open in BLK wire between
S switch and G401, G402.
9-58
From page 9-58
NO Disconnect the 26P and 22P

ls there voltage
YES
Check for continuity on BLK wire Check for continuity between A8

from the gauge assy. to body (GRNl terminal and gauge assy.
ground.
Check for loose control
YES unit connectors. lf
,---------~----------,
necessary. substitute
ls there continuity? a known-good control
unit and recheck.
NO
Repair open in GRN wire be-
tween AS terminal and gauge
assy.
NO Repair open in BLK wire between

Js there continuity?
gauge assy and G401.
YES
Replace shift position indicator.
9-59
Lock-up Control Solenoid Valve A/B
Test----------------------------~ Replacement---------------------.
NOTE: lock-up control solenoid valves A and B must 1. Remove the mountíng bolts and lock-up control
be removed/replaced as an assembly. solenoid valve assembly.
1. Oisconnect the connector from the lock-up control NOTE: Be sure to remove or replace the lock-up
solenoid valve A/8. control solenoid valves A and B as an assembly.
NOTE: Do not remove the lock-up control solenoid 2. Check the lock-up control solenoid valve oil
valve A/B stay. passages for dust or dirt and replace as an
assembly, if necessary.
2. Measure the resistarice between the No. 1 terminal
!SOL. V Al of the lock-up .control solenoid valve BOLT
connector and body ground and between the No. 2 LOCK-UP CONTROL
terminal (SOL. V Bl and body ground.
STANDARD: 14-16 n (25°C)
View from
terminal side
Clean the mounting surface

and oil passages.
LOCK-UP CONTROL
SOLENOID VALVE
ASSEMBLY
3. Clean the mounting surface and oíl passages of the

3. Replace the lock-up control solenoid valve lock-up control solenoid valve assembly and install
assembly if the resistance is out of specification. a new base gasket.
4. Connect the No. 1 terminal of the lock-up control 4. Check the connector for rust, dirt or oil and recon-
solenoíd valve connector to the battery positiva ter- nect it securely.
minal. Connect the No.2 terminal to the battery posi-
tiva terminal.
A clicking sound should be heard each time the
connection is made.
5. lf not, check for continuity between the A/T control

unit A24 or A25 harness and body ground. (page
9-30, 31).
6. Rep!ace the lock-up control solenoid valve assembly if

there is continuity between the A/T control unit A 24
orA 25 harness and body ground. (page 9-30, 31)
9-60
Shift Control Solenoid Valve A/8
Test--------------------------~ Replacement --------------------.
NOTE: Shift control solenoid valves A and B must be 1. Remove ttie mounting bolts and shift control solenoid
removed/replaced as an assembly. valve assembly.
1. Disconnect the connector from the shift control sole- NOTE: Be sure to remove or replace the shift control
noid val ve A/B. solenoid valves A and B as an assembly.
NOTE: Do not remove the shift control solenoid valve 2. Check the shift control solenoid valve oil passages for
A/B stay. dust or dirt and replace as an assembly, if necessary.
2. Measure the resistance between the No. 1 terminal

(SOL. V A) of the shift control solenoid valve con-
nector and body ground and between the No.2 termi-
SHIFT CONTROL
nal (SOL. V B) and body ground.
SOLENOIO VALVE
ASSEMBLY
STANDARD: 14-16 O (25°C)
View from
terminal side
Replace.
3. Clean the mounting surface and oil passages of the

SHIFT CONTROL
shift control solenoid valve assembly and instaU a new
SOLENOIO VALVE
ASSEMBLY base gasket.
4. Check the connector for rust, dirt or oil and recon-

3. Replace the shift control solenoíd valve assembly if the
nect it securely.
resistance is out of specification.
4. Con nect the No. 1 terminal of the shift control solenoid

valve connector to the battery positiva terminal. Con-
nect the No. 2 terminal to the battery positiva terminal.
A clicking sound should be heard each time the
connection is made.
5. lf not, check for continuity between the A/T control

unit A 11 or A 12 harness and body ground. (page
9-38, 39).
6. Replace the shift control solenoid valve assembly if

there is continuity between the A/T control unit A 11 or
A12 harness and body ground. (page 9-38, 39)
9-61
S Switch A/T Speed Sensor
Test----------------------------~ Replacement - - - - - - - - - - . ,
1. Remove the center console. 1. Remove the 6 mm bolt from the transmission housing
and remove the A/T speed sensor assembly.
2. Disconnect the switch connector.
6 x 1.0 mm
NC SPEED
3. Check for continuity between A and B terminals. 12 N·m (1.2 kg-m, 9 lb-ft)
SENSOR
There should be continuity when the switch is
\
pressed.
Replace.
NM SPEED SENSOR
2. Replace the 0-ring with a new one before reassem-

bling the A/T speed sensor.
CAUTION: Carefully inspect the A/T speed sensor
before installing. Do not install if it shows signs of
being dropped or improperly handled.
9-62
Hydraulic System - - - - - - - - - - - - - - - - - - - - - - - - -
Check these items on the Check these items on the

SYMPTOM NOTES .CHART
PROBABLE CAUSE LIST
Engine runs, but car does not move in any gear. 1,6,7,.16 K, L, R, S
Car moves in R and 2, but not in 03, 04 or 1. 8, 29,44,48 C,M,O
Car moves in· 03, 04, 1, R, but not in 2. 9,'30, 49 C, L
Car moves in 03, 04, 2, 1, but not in R. 1, 11' 22, 34, 38, 39, C, L, O
40
Car moves in N. 1' 8, 9, 1 o. 11' 46, C,O
47
Excessive idle vibration. . 5, 17 B,K, L
Slips in all gears. - 6, 7, 16 C, L, U
No engine braking in DJ position. 12 C, D, L
Slips in low gear. 8, 29,44,48 C,N,O,U
.· Slips in 2nd gear. 9, 20,23,30,49 C, L, U
Slips in 3rd gear. 10, 21, 23, 31, 44 C, L, U
Slips in 4th gear. 11' 23, 32 C, L, U
Slips in ·reverse gear. 11' 32, 34 e
. Fiares on 1 -2 upshift. 3, 15 E, L,.V
·Fiares on 2-3 upshift. 3, 15, 24, 44 E, L, V
Fiares on 3-4 upshift. 3, 15, 25, 44 E, L. V
No upshift, trans stays in low gear. 14, 19, 23 G, l
No downshift to low gear·. 12, 19 G, L
·Late upshift. 14 L, V
Erratic shifting. 2, 14, 26 V
. Harsh ~hift {up and down sl:liftingl. 2, 4, 15·; 23, 24, 27' A, E, H, 1, L, V
47
Harsh shift (1-2). 2,9 C,D, V
Harsh shift (2-3). 2, 10, 23, 24 C, D,H,L,V
Harsh shift (3-4). 2, 11' 23, 25 C, O, 1, L, V
Harsh kickdown shifts. 2, 23,27,28 l, V, O
Harsh kickdown shift (2-1 ). 48 o
Harsh downshift at closed throttle. 15 E, T
Harsh shift when manually shifting to []]. 33 L
Axle(s) slips out of trans on turns. 43, 50 l, P, O
Axle(s) stuck in trans. 43 L, O
Ratcheting noise when shifting into R. 6, 7, 38,39,40 K, L, Q
'
Loud popping noise when taking off in R. 38,39,40 l, o
Ratcheting noise when shifting from R to P or frori1 R 38,39,40,45 L, Q
toN.
Noise from trans in all selector lever positions. 6, 17 K, l, Q
Noise from trans only when wheels are rolling. 39, 42 L, O
Gear whine, rpm related (pitch changes with shifts). 8, 13, 41 K, L, Q
Gear whine, speed related (pitch changes with speed). 38, 42 L, Q
Trans will not shift into 4th gear in 04. 1, 21, 28, 32 L
Lock-up clutch does not lock up smoothly. 17,36,37 L
lock-up clutch does not operate properly. 2, 3, 1 5, 18, 35, 36, E; L, V
37
Transmission has multitude of problems shifting. 43 L. Q
At disassembly, large partides of metal are found on
magnet. 1
9-64
PROBABLE CAUSE
1. Shift cable broken/out of adjustment.
2. Throttle cable too short.
3. Throttle cable too· long.
4. Wrong type A TF.
5. ldle rpm too low/high.
6. Oil pump worn or binding.
7. Pressure requlator stuck.
8. 1st clutch detective.
9. 2nd clutch detective.
10. 3rd clutch detective.
11. 4th clutch detective.
12. 1st hold clutch detective.
13. Mainshaft, countershaft, and secondary shaft idler gears worn/damage.
14. Modulator valve stuck.
15. Throttle B valve stuck.
16. A TF strainer clogged.
17. Torque convertor detective.
18. Torque convertor check valve stuck.
19. · 1 -2 shitt valve stuck.
20. 2 ,.-- 3 shift valve stuck.
22. EAT D inhibitor valve stuck.
23. Clutch pressure control valve stuck.
24. 2nd orífice control valve stuck.
25. Orífice control valve stuck.
26. 3-2 kickdown valve stuck.
27. 3rd kickdown valve stuck.
28. 4th exhaust valve stuck.
29. 1st accumulator detective.
30. 2nd clutch accumulator detective.
31. 3rd clutch accumulator detective.
32. 4th/reverse accumulator detective.
33. 1st hold clutch accumulator detective.
34. Servo valve stuck.
35. Lock-up clutch timing valve stuck.
36. Lock-up clutch shift valve stuck.
37. Lock-up clutch control valve stuck.
38. Shift fork bent.
39. Reverse gears worn/damaged (3 gears).
40. Reverse selector worn.
41. 3rd gears worn/damaged (2 gears).
42. Final gears worn/damaged (2 gears).
43. Ditferential pinion shaft worn.
44. Feedpipe 0-ring broken.
45. 4th gears worn/damaged (2 gears).
46. Gear clearance incorrect.
47. Clutch clearance incorrect.
48. Sprag clutch detective.
49. Sealing rings/guide worn.
50. Axle-inboard joint clip missing.
9-65
Hydraulic System (cont'd) - - - - - - - - - - - - - - - - - - - - - -
Check these items on the

The following symptoms can be caused ltems on the
PROBABLE CAUSE DUE
by improper repair or assembly. NOTES CHART
TO IMPROPER REPAIR
!
Car creeps in N. R1, R2

Car does not move in 03 or D4. R4
Trans locks up in R. R3, R12
Excessive drag in trans. R6 J R,K
Excessive vibration, rpm related. R7 ;
'
Noise with wheels moving only. R5
Main seal pops out. RB S
Various shifting problems. R9, R10
Harsh upshifts. R11
PROBABLE CAUSE DUETO IMPROPER REPAIR
R1. lmproper clutch clearance.

R2. lmproper gear clearance.
R3. Parking brake lever installed upside down.
R4. Sprag clutch insta!led upsíde down.
R5. Reverse hub ínstalled upside down.
R6. Oil pump binding.
R7. Torque converter not fully seated in oil pump.
R8. Main seal improperly insta!led.
R9. Springs improperly ínstalled.
R10. Valves improperly installed.
R11. Ball check valves not installed.
R12. Shift fork bolt not installed.
9-66
NOTES
A. Flush ATF in the ATF cooler.
B. Set id le rpm in gear to· specified id le speed. lf still no good, adjust motor mounts as outlined in
engine section of service manual.
c. i lf the large clutch pistan 0-ring is broken, inspect the pistan groove for rough machining.
D. lf the clutch pack is seized or is excessively worn, inspect the other clutches for wear and check
1
: the orífice control valves and throttle valves for free movement.
E. lf throttle valve Bis stuck, inspect the clutches for wear.
G. Jf the 1-2 valve is stuck closed, the transmission will not upshift. lf stuck open the transmission
has no 1st gear.
H. lf the 2nd orífice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
l. lf the orífice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
J. lf the clutch pressure control valve is stuck closed, the transmission wíll not shift out of 1st gear.
K. lmproper alignment of main valve body and torque convertor case may cause oil pump seizure. The
symptoms are mostly an rpm-related ticking noise or a high pitched squeek.
L. lf the oil screen is clogged with particles of steel or aluminum, inspect the oil pump and differential
pinion shaft. lf both are OK and no cause for the contamination is found, replace the torque con-
verter.
M. lf the 1st clutch feedpipe guide in the end cover is scored by the mainshaft, inspect the ball bearing
for excessive movement in the transmission housing. lf OK, replace the end cover as it is dented.
The 0-ring under the guide is probably worn.
N. Replace the mainshaft if the bushings for the 1st and 4th feedpipe are loase or damaged. lf the 1st
feedpipe is damaged or out of round, replace it. lf the 4th feedpipe is damaged or out of round,
replace the end cover.
o. A worn or damaged sprag clutch is mostly a result of shifting the trans in 03 or 04 while the wheels
rotate in reverse, such as rocking the car in snow.
P. 1
lnspect the trame for collision damage.
o. lnspect for damage or wear:
1 . Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Oifferential pinion shaft for wear under pinion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1, 2, 3 and 4 if worn or damaged. lf trans makes clicking, grinding or whirring noise,
also replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to 1, 2,
3 or 4.
lf differential pinion shaft is worn, overhaul differential assembly and replace oil screen and
thoroughly clean trans, flush torque converter, cooler and lines.
lf bottom of 3rd clutch is swirled and trans makes gear noise, replace the countershaft and ring
gear.
R. Be very careful not to damage the torque converter case when replacing the main ball bearing. You
may also damage the oil pump when you torque down the main valve body. This will result in oil
pump seizure if not detected. Use proper tools.
S. lnstall the main seal flush with the torque converter case. lf you push it into the torque converter
case until it bottoms out, it will block the oil ret.urn passage and result in damage.
T. Harsh downshifts when coasting to a stop with zero throttle may be caused by a bent-in throttle
valve retainer/cam stopper. Throttle cable adjustment may clear this problem.
u. Check if servo valve stopper cap is installed. lf it was not installed, the check valve may have been
pushed out by hydraulic pressure causing a leak (interna!) affecting all forward gears.
V. Throttle cable adjustment is essential for proper operation of the transmission. Not onfy does it af-
fect the shift points if misadjusted, but also the shift quality and lock-up clutch operation.
A too long adjusted cable will result in throttle pressure being too low for the amount of engine tor-
que input into the transmission and may cause clutch slíppage. A too short adjusted cable will
result in too high throttle pressures which may cause harsh shifts, erratic shifts and torque con-
verter hunting.
9-67
Road Test
NOTE: After transmission is installed:

e Make sure the floor mat does not interfere with accelerator pedal travel. Fully depress accelerator pedal and check to make su re
the throttle lever is fully opened.
e Release the accelerator pedal and chl¡lck both inner control cables to be sure they have slight play.
IQ;] and ~ Range

1. Apply parking brake and block the wheels. Start the engine, then move the selector to IQll while depressing the brake pedaL
3. Apply parking brake and block the wheels. Start the engine, then move the selector to IQlJ while depressing the brake pedal.
Depress the accelerator pedal, and release it suddenly. Engine sl)ould not s~all. ·
KF, KB, KE. KW. KV. KT and KU Models

• Upshift
IQll (and IQli) 1st-2nd 2nd-3rd 3rd-4th lock up Clutch ON
Y8 throttle km/h 14-18 27-31 40-46 17-21

Coasting down-hill from a stop mph 9-1 t 17-19 25-29 11-13
1
Y2 throttle km/h 27-33 52-58 74-82 97-104

Acceleratíon from a stop mph 17--.:21 32-36 46-51 60-65
Full-throttle km/h 42-49 102-110 149-158 1 129-137

Acceleration from a stop mph 26-30 63-68 ¡ 93-98 í 80-85
e Downshift
IQll (and IQli) Lock up Clutch OFF 4th-3rd 3rd-2nd 2nd-1st ·
- (3rd-1 st)
.Yá throttle km/h 15-21 26-32 8-14
1
Coasting or braking to a stop (3rd-1st)
mph 9-13 16-20 - 5-9
l
Y2 throttle km/h 87-94 - - -
! When car is slowed by
increased grade, wind, etc. mph 54:_ 58 - - -
Full-throttle km/h 126-134 124-133 85-94 39-46
increased grade, wind, etc. mph 78-83 77-83 53-58 24-29
e Upshift
IQll (and IQlJ with S switch in operationl 1st-2nd 2nd-3rd 3rd.,--4th Lock up clutch ON
l Y8 throttle km/h 17-21 27-31 46-52 24-28

i
Coasting down-hill from a stop mph 11-13 17-19 29-32 15-17
t
km/h i 37-43 72-78 106-114 118-125
Y2 throttle
Acceleration from a stop :
mph 23-27 45-48 66-71 73-78
i
km/h 43-50 102-110 149-158 130-138
F ull-throttle :
Acceleration from a stop
1
1
1 mph 27-31 63-68 ! 93-98 81-86
e Downshift
¡g;j (and IQíl with S switch in operation) Lock up Clutch OFF 4th-3rd 3rd-2nd 2nd-1st
(3rd-1 st)
km/h 23-28 31-37 -
1
1 .Yá throttle 11-17
1
Coasting or braking to a stop - (3rd-1st)
mph 14-17 19-23 1 7-11
Y2throttle km/h 98-105 - - -
increased grade, wind, etc. mph 61-65 - - -
1 1
1
9-68
KS, KX, KG and KQ Models
e Upshift
[Q;I (and illi) · 1st-2nd . 2nd-3rd 3rd-4th Lock up Clutch ON
.YB throttle km/h 21-25 41-45 58-64 23-27

Coasting down-hiU from a stop mph 13-16 25-28 36-40 14-17
1
1
).1 throttle km/h
1
28-34
i 57-63 88-96 96-103
Acceleration from a stop mph ¡ 17-21 ! 35-39 55-60 60-64

Acceleration from a stop mph 30-34 66-71 96-101 81-'-86
e Downshift
[Q;I (and illil Lock up Clutch 4th-3rd 3rd-2nd 2nd-1st
21-27 - (3rd-1st)
Ysthrottle km/h 29-35 10-16
Coasting or braking to a stop mph 13-17 18-22 - (3rd-1st)
6-10
).1 throttle km/h 77-84 - - -
increased grade, wind, etc. mph 48-52 - - -
• Upshift
[Q;I (and illi with S switch in operation) 1st-2nd 2nd-3rd 3rd-4th Lock up Clutch ON
.YB
throttle km/h 17-21 38-42 61-67 38-42
Coasting down-hill from a stop
1
mph 11-13 24-26 ! 38-42 24-26
).1 throttle km/h 28-34 66-72 100-108 ! 111-118

Acceleration from a stop mph 17-21 41-45 62-67 69-73

Acceleration from a stop mph 30-34 66-71 96-101 81-86
1
e Downshift
[Q;I (and illi with S switch in operation) Lock up Clutch OFF 4th-3rd 3rd-2nd 2nd-1st
- ! (3rd-1 st)
.J.1i throttle km/h 35-41 29-35 10-16
Coasting or braking to a stop mph 22-25 18-22 - (3rd-1 st)
6-10
).1 throttle km/h 84-91 - - -
When car is slowed by 1
1
íncreased grade, wínd, etc. mph 52-57 - - -

1
i
When car is slowed by 1
increased grade, wínd, etc. mph 79-84 78-83 55-61 1

25-29
CAUTION: Do not shift from [Q;1 or illi to ~ at speeds over 100 km/h (62.5 mph); you may damage the transmission.
[1] (1st Gear)

2. Upshifts and downshifts should not occur with the selector in this range.
[21, (2nd Gear)

2. Upshifts and downshifts should not occur with the selector in this range.
[B] (Reverse)
Accelerate from a stop at full throttle, and check for abnormal noise and clutch slippage.
~ (Park)
Park carona slope (approx. 16°). apply the parking brake, and shift into Park. Release the bral<e; the car should not move.
9-69
Pressure
Testing-------------------------------------------------------------
e Befare testing, be sure the transmission is filled to
e Connect an oil pressure gauge securely, being su re hole.
e Warm up the engine before testing. A/T OIL PRESSURE GAUGE HOSE 07406-0020201
wheels.
e Raise the front of the car and support with safety
stands.
NOTE:Do not reuse old aluminum washers.

the specified torque 18 N· m ( 1 . 8 kg-m, 1 2 lb-ft).
HOSE FITTING

follows.
line Pressure Measurement
UNE PRESSURE
INSPECTION HOLE
SELECTOR PROBABLE 1 FLUID PRESSURE l

PRESSURE SYMPTOM
Line ~ or !E No (or low) Torque converter, 785-834 kPa 735 kPa

Une pressure oil pump pressure {8.0-8.5 kg/cm 2 , (7.5 kg/cm2, 107 psi)
regulator, torque 114-121 psi)
converter check
valve, oil pump
1
NOTE: Higher pressures may be indicated if measurements are made in selector positions other than ~ or [EJ.
9-70
Clutch Pressure Measurement
1 . Set the parking brake and block both rear wheels securely.
2. Raise the front of the car and support with safety stands.
3. Allow the front wheels to rotate freely.
5. Measure the clutch pressure.
1st CLUTCH PRESSURE

INSPECTION HOLE
LOW-HOLD CLUTCH
PRESSURE INSPECTION
HOLE
2nd CLUTCH PRESSURE

INSPECTION HOLE
4th CLUTCH PRESSURE 3rd CLUTCH PRESSURE

INSPECTION HOLE INSPECTION HOLE
SELECTOR 1
PROBABLE FLUID PRESSURE
PRESSURE SYMPTOM
POSITION CAUSE Standard Servíce Límít
1
Low-Hold [IJ No or low Low-Hold 784-834 kPa 1

735 kPa
Clutch low-hold Clutch (8.0-8.5 kg/cm2, (7.5 kg/cm 2, 107 psi)
pressure 114-121 psi)
1st [IJ No or low 1st Clutch

Clutch 1st pressure
2nd ~ No or low 2nd Clutch

Clutch 2nd pressure
490 kPa (5.0 kg/cm2, 441 kPa (4.5 kg/cm2,
3rd ~ No or low 3rd Clutch
71 psi) 64 psi) i
Clutch 3rd pressure (throttle fui/y closed) {throttle fui/y closed)
785-834 kPa (8.0-8.5 735 kPa (7.5 kg/cm2,
4th llli No or low 4th Clutch kg/cm 2 , 11 4-1 2 1 psi) 107 psi)
(throttle more than 2/8 (throttle more than 2/8
Clutch 4th pressure opendl opend)
4th [Bl No or low Servo Valve 785-834 kPa 735 kPa
Clutch 4th pressure 4th Clutch (8.0-8.5 kg/cm', (7.5 kg/cm', 107 psi)
114-121 psi)
(cont'd)
9-71
Pressure
Testing ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - - - - - -
Clutch Low/High Pressure Test 8. With the engine idling, lift the throttle controllever up
1. Raise the car and support with safety stands. approximately 1/2 of its possible travel and in crease
the engine rpm until pressure is indicated on the appro-
2. Attach the gauge set to the appropriate pressure test priate gauge. Record the highest pressure reading
port. obtained.
3. Remove the cable end of the throttle control lever.
NOTE: Do not loasen the locknuts, simply unhook the cable

end.
CABLE END
THROTTLE CONTROL
LEVER
4. Warm up the engine to normal operating temperature
(cooling fan comes on). 9. Repeat step 8 for each clutch pressure being inspect-
ed.
5. With the engine idling, move the selector lever to DJ or
04.
6. Slowly move the throttle linkage to increase engine

rpm until pressure is indicated on the appropriate
gauge. Then release the throttle linkage, allowing the
engine to return to an idle, and record the pressure
reading.
7. Repeat step 6 for ea eh clutch pressure being inspect-

ed.
~~
9-72
2nd CLUTCH PRESSURE
INSPECTION HOLE
3rd CLUTCH PRESSURE

4tfl CLUTCH PRESSURE
INSPECTION HOLE
INSPECTION HOLE
1 SELECTOR PROBABLE FLUID PRESSURE

PRESSURE SYMPTOM
PO SITIO N CAUSE Standard Service limit
2nd iQ1J or IQ!J No or low 2nd Clutch 471-834 kPa 735 kPa
Clutch 2nd pressure (4.8-8.5 kg/cm2, (7.5 kg/cm2 , 107 psi)
68-121 psi)
3rd [Qj] or IQil No or low 3rd Clutch

Clutch 3rd pressure
4th (Q;J No or low 4th Clutch

Clutch 4th pressure
(cont'd)
9-73
Pressure
Testing (cont'd) - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
Throttle B Pressure Measurement

2. Aun the engine at 1 ,000 min- 1 (rpm).
3. Dísconnect the throttle control cable from the throttle lever and set the controllever in full throttle position.
THROTTLE B PRESSURE
INSPECTION HOLE
SELECTOR PROBABLE FLUID PRESSURE

PRESSURE SYMPTOM 1
i
Throttle B IQi] or~ No (or low) Throttle 784-834 kPa 735 kPa
1
Throttle B valve B (8.0-8.5 kg/cm2, (7.5 kg/cm 2 , 107 psi)
i
pressure 114-121 psi)
! 1
9-74
Pressure
Testing-------------------------------------------------------------
e Befare testing, be sure the transmission is filled to
e Connect an oil pressure gauge securely, being su re hole.
e Warm up the engine before testing. A/T OIL PRESSURE GAUGE HOSE 07406-0020201
wheels.
e Raise the front of the car and support with safety
stands.
NOTE:Do not reuse old aluminum washers.

the specified torque 18 N· m ( 1 . 8 kg-m, 1 2 lb-ft).
HOSE FITTING

follows.
line Pressure Measurement
UNE PRESSURE
INSPECTION HOLE
SELECTOR PROBABLE 1 FLUID PRESSURE l

PRESSURE SYMPTOM
Line ~ or !E No (or low) Torque converter, 785-834 kPa 735 kPa

Une pressure oil pump pressure {8.0-8.5 kg/cm 2 , (7.5 kg/cm2, 107 psi)
regulator, torque 114-121 psi)
converter check
valve, oil pump
1
NOTE: Higher pressures may be indicated if measurements are made in selector positions other than ~ or [EJ.
9-70
Stall Speed
Test-------------------------------------------------------------.
CAUTION:
• To prevent transmission damage. do not test stall speed for more than 10 seconds ata time.
• Do not shift the lever while raising the engine speed.
• Be sure to remove the pressure gauge before testing stall speed.
1. Engage parking brake and block the front wheels.

2. Connect safety chains to both front two hooks and attach, with mínimum slack, to sorne strong stationary object.
3. Connect tachometer, and start the engine.
4. After the engine has warmed up to normal operating temperature, shift into !m.
5. Fully depress the brake pedal and accelerator for 6 to 8 seconds, and note engine speed.
6. Allow 2 minutes for cooling, then repeat same test in Il and !B].
Stall speed in !m. [!] and !Bl must be the same, and must also be within limits:
NOTE:
Stalf speed test must be made only for checking the cause of trouble.
Stall Speed RPM:

Specification: 2,500 min- 1 (rpm)
Service Limit: 2,35o--2.650 min- 1 (rpm)
TROUBLE PROBABLE CAUSE
Stall rpm high in !lli. [!] & [B] . Low fluid level or oil pump output.
.
.. Clogged oil strainer .
Pressure regulator valve stuck closed .
Slipping clutch .
Stall rpm high in !Bl . Slippage of 4th clutch
Stall rpm high in {Q;J & [f] . Slippage of 1st c/utch or 1st gear one-way clutch
Stall rpm low in !lli. ITJ .
& [B]
. Engine output low
To·rque converter one-way clutch slipping
9-75
Fluid level
Checking/Changing------------------------------------------~----~
Checking Changing
With the car on level ground, pull the transmission dipstick 1. Bring the transmission up to operating temperature by
and check the level of fluid immediately after the engine is driving the car. Park the car on level ground, turn the
shut off (within one minute). The fluid level should be engine off, then remove drain plug.
between the full and low marks. Push the dipstick all the
way in to check the fluid level. lf the level is at, or below, 2. Reinstall the drain plug with a new washer, then refill
the low mark, add DEXRON-II type automatic trañsmission the transmission to the full mark on the dipstick.
fluid.
Automatic transmission Capacity:
2.4 t (2.5 us qts. 2.1 lmp qts) at change
6.01 (6.3 us qts, 5.3 lmp qts) after overhaul
DIPSTICK
FUll
LOW
DRAIN PLUG
40 N•m (4.0 kg-m, 29 lb-ft)
9-76
Transmission
Removal------------------------------------------------------~
t"i*'*"''
e Make sure jacks and safety stands are placed proper-
ly, and hoist brackets are attached to correct posi-
7. Remove the rear mount bracket stay nut first.
Remove the bolt, then remove the rear mount bracket
stay.
tions on the engine. 8. Remove the speed sensor, but léave íts hoses con-
e Apply parking brake and block rear wheels, so car nected.
will not roll off stands and fall on you while working 9. Dísconnect the lock-up control solenoíd valve and shíft
under it. control solenoíd valve wire connectors.
1 O. Drain transmission fluid. Use a socket wrench to
CAUTION: Use fender covers to avoid damaging paint- remove the drain plug. Remove the oíl filter plug to
ed surfaces . speed draining. Reinstall the draín plug with a new
washer.
1. Disconnect the battery negative (-) and positive ( +) 11 . Disconnect the cooler hoses at joint pipes.
cable from the battery, and remove the battery. Turn the ends up to prevent ATF from flowing out.
2. Remove the air intake hose, aír cleaner case and
battery base (See sectíon 5). NOTE: Check for any signs of leakage at the hose
3. Disconnect the throttle cable from the throttle control joints.
lever.
4. Disconnect the transmission ground cable.
5. Disconnect the speed pulser connectors.
6. Disconnect the starter motor cables, remove the
starter mounting bolts, then remove the starter motor.
REAR MOUNT
BRACKET
REAR MOUNT
BRACKET STAY
(cont'dl
9-77
Transmission
Removal (cont'd) - - - - - - - - - - - - - - - - - - - - - - - - -
12. Remove the center beam.

13. Remove the oxygen sensor connector.
NOTE: The oxygen sensor is equipped on the exhaust
pipe A for sorne types.
14. Remove the exhaust pipe A.
OXYGEN SENSOR
~EXHAUST
CONNECTOR
Standard for sorne types.
PIPE A
Replace.
1 5. Remove the splash shield.
9-78
16. Remove the cotter pins and lower arm ball joint nuts, 19. Remove the right damper pinch bolt, then separate the
then separate the ball joints and lower arms (See damper fork and damper.
section 1 2}. 20. Remove the bolts and nut, then remove the right
radius rod.
SELF-LOCKING NUT
Replace.
DAMPER PINCH
BOLT
RADIUS ROO MOUNTING
/\
BOLTS
COTTER PIN BALL JOINT

Replace. NUT 22. Tie plastic bags over the driveshaft ends.
NOTE: Coat all precision finished surfaces with clean
engine oil or grease.
1 7. Pry the right and left driveshafts out of the differential.
18. Pull on the inboard joint and remove the right and left SET RING
driveshafts (See section 1 O). Replace.
DRIVESHAFT
!Right side)
\
\ \
\ \
\ 1
~
DRIVESHAFT
Ríght side only
DRIVESHAFT
(Left side)
(cont'd)
9-79
Transmission
Removal (cont'd)
23. Remove the torque converter cover and control cable 25. Remove the plug, then remove the drive plate bolts
holder. one at a time while rotating the crankshaft pulley.
24. Remove the shift control cable by removing the cotter 26. Re m ove the rear transmission housing mounting bolts
pin, control pin and controllever roller from the; control (Engine side).
lever. 27. Remove the mounting bolts from the rear engine
mount bracket.
CAUTION: Take ca re not to bend the control cable.
MOUNTING BOLTS(Engine side) MOUNTING BOLTS
REAR ENGINE
MOUNT BRACKET
CONTROL PIN
\SHIFT
CONTROL CABLE
CONTROL LEVER
TORQUE CONVERTER
COVER
CONTROL CABLE
HOLDER
9-80
28. Attach a chain hoist to the transmission housing hoist-
ing brackets, then lift the engine slightly.
29. Place a jack under the transmission and raise transmis-
sion just enough to take weight off mounts.
30. Remove the 4 transmission housing mounting bolts
and 3 mount bracket nuts.
31. Pull the transmission away from the engine until it
clears the 14 mm dowel pins, then lower it on the
transmission jack.
DOWEL PINS
MOUNTING BOLTS
9-81
Transmission
lnstallation - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1. Place the transmission on the transmission jack, and 3. lnstall the 4 transm•ss1on housing mounting bolts,
raise to the engine level. then instal! the transmission on the engine block.
2. Check that the two 14 mm dowel pins are installed in 4. lnstal! the transmission to transmission mount bracket.
the torque con verter housing. 5. Remove the trarismission jack.
14 mm DOWEL
~
0
PINS
TORQUE CONVERTER TRANSMISSION HOUSING

HDUSING MOUNTING BOLTS
TRANSMISSION MOUNT 12 x 1.25 mm
BRACKET NUTS 65 N•m (6.5 kg-m. 47 lb-ft)
10 x 1.25 mm
39 N·m
(3.9 kg-m, 28 lb-ftl
9-82
6. lnstall the 2 transmission housing mounting bolts 9. lnstall the torque converter cover.
~Engine side} and rear engine mount bracket bolts. 1O. Remove the chain hoist by removing the hanger
7. Attach the torque converter to the drive plate with plates.
eight bolts, and torque to 12 N· m ( 1 .2 kg-m, 9 lb-ft),
Rotate the crankshaft as necessary to tighten bolts to
1/2 torque, then final torque. in a criss-cross pattern.
Check for free rotation after tightening the last bolt.
8. lnstall the shift control cable and control cable holder.
CAUTION: Take ca re not to bend the shift control
cable.
TRANSMISSION HOUSING REAR ENGINE MOUNT

MOUNTING BOLTS (Engine sidel BRACKET BOLTS
12x1.25mm 12 x 1.25 mm
65 N•m (6.5 kg-m, 47 lb-ft) 55 N·m (5.5 kg-m. 40 lb-ft)
ORIVE PLATE
BOLTS (8 bolts)
6 x 1.0 mm 0
\
12 N•m
(1.2 kg-m. 9 lb-ftl
TORQUE CONVERTER
COVER BOLTS
6 x 1.0 mm CONTROL CABLE
12 N•m l1 .2 kg-m. 9 lb-ft) HOLDER BOLTS
8 x 1.25 mm
18 N•m (1.8 kg-m, 13 lb-ftl
(cont'd)
9-83
Transmission
11 . 1nstall the radius rod. 15. lnstall the damper fork bolts and ball joint nuts to the
NOTE: Check for deterioration or damage of the radius lower arms.
rod rubber bushings.
12. lnstall the damper fork.
SELF-LOCKING NUT
Repta ce.
SELF-LOCKING NUT 12 x 1.25 mm
OAMPER PINCH Replace. 55 N·m (5.5 kg-m, 40 lb-ft)
BOLT 12 x 1.25 mm
10 x 1.25 mm 44 N•m (4.4 kg-m, 32 lb-ft)
44 N·m (4.4 kg-m, 32 lb-ft)
DAMPER FORK
.. ,
RADIUS ROO
MOUNTING BOLTS
12 x 1.25 mm
105 N·m (10.5 kg-m. 76 lb-ft) COTTER PIN
Replace.
/! BALL JOINT
NUT
BOLT
\
DAMPER FORK
12 x 1.25 mm
55 N•m (5.5 kg-m, 40 lb-ft)
13. lnstall a new set ring on the end of each driveshaft.
14. lnstall the right and left driveshafts (See section 1 O).
16. lnstall the splash shield.
NOTE: Turn the right and left steering knuckle fully
outward, and slide axle into the differential until you
feel its spring clip engage the side gear.
DRIVESHAFT
{Right side)
DRIVESHAFT
(Left side) SPLASH SHIELD
9-84
17. Instan the center beam and exhaust pipe A.
18. Connect the oxygen sensor con nector.
NOTE: The oxygen sensor is equipped on the exhaust pipe A for sorne types.
10x 1.25 mm
39 N•m
(3. 9 kg-m. 28 lb-ft)
OXYGEN SENSOR SELF-LOCKING NUTS

CONNECTOR Replace.
10 x 1.25 mm
55 N•m
(5.5 kg-m. 40 lb-ft)
CENTER BEAM
GASKET
Replace. EXHAUST PIPE A
SELF-LOCKING NUTS SELF-LOCKING NUTS

Replace. Replace.
10 x 1.25 mm 8 x 1.25 mm
34 N·m 16 N•m (1.6 kg-m. 12 lb-ft)
(3.4 kg-m. 25 lb-ftl
(cont'd)
9-85
Transmission
1 9. lnstall the speed sensor. 28. Connect the battery positive ( +) and negative (-)
20. lnstall the rear mount bracket stay. cables to the battery.
NOTE: Tighten the bolt first and then tighten the nut. 29. Start the engine. Set the parking brake, and shift the
21. lnstall the starter motor and connect the starter motor transmission through all gears three times. Check for
cable. proper control cable adjustment.
22. Connect the lock-up control solenoid valve and shift 30. Check the ignition timing (See section 16).
control solenoid valve connectors. 31. Let the engine reach operating temperature with the
23. Connect the speed sensor connectors. transmission in Neutral or Park, then turn it off and
24. Connect the transmission ground cable. check the fluid level.
25. Connect the throttle control cable. 32. Road test as described on page 9-68.
26. lnstall the battery base, air cleaner case and air intake
hose.
27. lnstall the battery.
STARTER MOTOR
NUT
~\e ~..-,\U~N:j)
10 x 1.25 mm
21 N•m
(2. 1 kg-m, 15 lb-ftl
10 x 1.25 mm
39 N·m (3.9 kg-m,
28 lb-ft) OIL COOLER JOINT
PIPES
9-86
Gear Shift Selector
PUSH KNOB SPRING
LOCK PIN
ROO
SHIFT INDICATOR
PANEL
LOCK PIN
\ ~
SHIFT POSITION
CONSOLE SWITCH
Se e section 1 6.
~ LEVER COVER
10 N•m (1.0 kg-m.

7 lb-ft)
SELECTOR MOUNT 10 N•m (1.0 kg-m, 7 lb-ft)

BRACKET
9-87
Shift Cable
Adjustrnent------------------------------------------------------~
1. Start the engine. Shift to reverse to see if the reverse 4. Check that the hole in the adjuster is perfectly aligned
gear engages. lf not, refer to Troubleshooting. with the hole in the shift cable.
2. With the engine off, remove the console.
3. Shift to ~ position, then remove the lock pin from the

cable adjuster.
ADJUSTER
SHIFT CABLE
--1---f_-
~
1------------,it-- -1--
e~~--..,__ 1---~--o_-_-_-....~-t-
r-
Cable Cable Exact

Too Short Too Long Alignment
NOTE: There are two holes in the end of the shift

cable. They are positioned 90° apart to -allow cable
adjustments in 1/4 turn increments.
5. lf not perfectly aligned, loasen the lock nut on shift

cable and adjust as required.
6. Tighten the lock nut.
7. lnstall the lock pin on the adjuster.
NOTE: lf you feel the lock pin binding as you reinstall

it, the cable is still out of adjustment and must be
readjusted.
8. Start the engine and check the shift lever in all gears.
lf any gear does not work properly, refer to trouble-
shooting on page 9-64 thru 67.
9-88
Removal/lnstallation - - - - - - - - - - - - - - - - - - - - - - - - - .
"*'*"*"
5. Remove the torque converter cover and cable holder.
e Make sure jacks and safety stands are placed proper-
ly and hoist brackets are attached to correct positions 6. Remove the shift cable by removing the cotter pin,
on the engine. control lever pin and control lever roller from the
e Apply parking brake and block rear wheels, so car control lever.
will not roll off stands and fall on you while working
under it. CAUTION: Take care not to bend the cable when
removing it.
1. Remove the front console.
7. Insta U the shift cable in the reverse order of removal.
2. Remove the lock pin from the cable adjuster. NOTE: On reassembly, check the cable adjustment.
3. Remove the bolts, then remove the cable bracket and

cable guide.
4. Remove the exhaust pipe A and center beam.
CONTROL CABLE
HOLDER
18 N•m (1.8 kg-m,

13 lb-ft)
9-89
Throttle Control Cable
Adjustment/lnspection - - - - - - - - - - - - - - - - - - - - - - - - . . .
NOTE: Before adjusting the throttle control cable, make Adjustment:
su re: 1 . Loasen the nuts on the control cable at the trans~is
sion end and synchronize the control lever to the
e The throttle cable free play is correct. (See section 6) throttle.
e The engine is at normal operating temperatura (cooling NOTE: To tailor the shift/lock-up characteristics toa partic-
fan comes on). ular customers driving expectations, you can adjust the
control cable up to 3 mm shorter than the "synchronized"
e The id le speed is correct. point.
{See section 6)
lnspection:
NOTE: You can work the throttle linkage body with your
hand. THROTTLE CONTROL
CABLE
1. Remove the throttle cable free play.
lOCKNUT
2. Apply light thumb pressure to the throttle control
lever, then work the accelerator or throttle linkage.
The lever should move just as the engine speed
increases above idle. lf not, proceed to Adjustment.
LOCKNUT
THROTTLE
CONTROL
CABLE
BRACKET
CABLE
END
THROTTLE LINKAGE
9-90
Special Tools
- S peca.a 1 T 005
CD 07GAD-PG401 00 5eal Driver Attachment 1

® 07GAF-5D40700 Hub Dis/Assembly Base 2
® 07LAD-5M401 00 5eal Driver Attachment 1
® 07746-0010200 Attachment, 37 x 40 mm 1
® 07746-0010300 Attachment, 42 x 4 7 mm 1
® 077 46-00301 00 Driver, 40 mm l. D. 1
(j) 07749-0010000 Driver 1 i
® 07947-5D90101 5eal Driver Attachment 1
® 07965-5D901 00 5upport Base 1
@l 07LAF-5M40300 5upport Base Attachment 1
~
~ ~ ~·
CD ® ®
1 @ @) [] 1~~~~~
® ® ®
re )
q
(j)
rxxx·~J
® ®
~
®
~
o @)
10-2
Driveshafts
Removal (cont'd)--------,
1 O. Pry the driveshaft assembly with a screwdriver as
shown to force the set ring at the driveshaft end past
the groove.
SCREWDRIVER
11. Putl the inboard joint and rémove the driveshaft and
CV joint out of the differential case or intermediate
shaft as an assembly.
with intermediate shaft:
CAUTION:
e Do not pull on the driveshaft, as the CV joint may
come apart.
e Use care when prying out the assembly and pull
it straight to avoid damaging the differential oil
seal or intermediate shaft dust seal.
10-4
Disassembly11 nspection
_ ~ Thoroughly pack the inboard joint and both

NOTE:
e Mark the rollers and roller grooves during dísassembly to
joint boots with high quality molybdenum disulfide grease
ensure proper positioning during reassembly.
when reassembling.
e Befo re disassembly, mark the spider and driveshaft so
they can be reínstalled in their original posítions.
Grease Ouantity:
e The inboard joint must be removed to replace the boots.
e lf the boot band is the welded type, cut off as shown. lnboard Joint 120~130 g
CAUTION: Take care not to damage the boots.
Outboard Joint 130~140 g
Automatic Transmission
Instan the holder or roller

toward the slot of the
inboard joint as shown
below.
Spline
direction
Manual Transmission
. t~ ROLLER
High shoulder faces
toward outside.
Section AA'
HOLDER
BAND
Pack cavtty
wtth grease.
OUTBOARD JOINT
DYNAMIC DAMPER ;~( / ' . l lnspect for faulty movement and wear.
Automattc Transmlsston left ' !!f .!l# '-./ lnspect ball bearings while rotating.
driveshaft only. Do not try to disassemble.
BOOT BAND
Replace. OUTBOARD RING
Check for damage.
OUTBOARD JOINT BOOT

BOOT BAND
lnspect for cracking,
Re place.
splitting and wear.
10-5
Driveshafts
Reassernbly--~~~-------------------------------------------------
1. Wrap the splines with vinyl tape to prevent damage to 6. Pack the outboard joint boot with molybdenum disul-
the boots and dynamic damper. fide grease.
2. Instan the outboard boot, dynamic damper and in- Grease Quantity: 130-140 g
board boot to the driveshaft, then remove the vinyl
tape.
OUTBOARD BOOT
~
/~
VINYL TAPE
DYNAMIC DAMPER
Automatic Transmission left
driveshaft only.
INBOARD BOOT
3. lnstall the stopper ring onto the driveshaft groove.
4. lnstall the spider on the driveshaft by aligning the

marks on the spider and end of the driveshaft.
7. Fit the rollers to the spider with their high shoulders

5. Fit the circlip onto the driveshaft groove. facing outward.
CAUTION:
• Reinstall the rollers to their original positions on
the spider.
• Hold the driveshaft assembly so the spider and
CIRCLIP
roller points up, to prevent it from falling off.
MARKS d SPIDER
10-6
8. Pack the in board joint with molybdenum disulfide 11 . lnstall new boot bands on the boot and bend both sets ·
grease. of locking tabs.
12. lightly tap on the doubled-over' portions to reduce
Grease Quantity: 120~130g
their height.
9. Fit the inboard joint onto the driveshaft.
CAUTION: Hold the driveshaft assmbly so the in-

board joint points up. to prevent it from falling off.
Manual Transmission Only:

Align the holder direction of the rollers
toward the slot of
inboard joint as shown
below.
~
t Spline
directíon
13. Position the dynamic damper as shown below.
DYNAMIC DAMPER
Automatic Transmission left
driveshaft only.
HOLDER
150 ± 2 mm (5.9 ± 0.08 i~l
1 O. Adjust the length of the driveshafts to the figure

below, then adjust the boots to halfway between full
compression and extension.
NOTE: The ends of boots seat in the groove of the

driveshaft and joint.
14. Lightly tap on the doubled-over portian to reduce its

height.
15. lnstall a new dynamic damper band and bend down

both sets of locking tabs.
Manual Transmission:
L. R. 478.7-483.7 mm (18.85-19.04 in)
Automatic Transmission:
L. 836.7-841.7 mm (32.94-33.14 in)
R. 478.7-483.7 mm (18.85-19.04 in)
(cont'd)
10-7
Driveshafts lntermediate Shaft
Reassembly (cont'd)------..., Replacement
16. lnstall a new set ring in the driveshaft groove. 1. Draín oíl from the transmíssíon.
17. lnstall the inboard end of the driveshaft into differ- 2. Remove the three 1 O mm flange bolts.
ential or intermediate shaft.
FLANGE BOLT
CAUTION: 10 x 1.25 mm
• Always use a new set ring whenever the drive- 39 N·m (3.9 kg-m, 28 lb-ft)
shaft is being installed.
• Make sure the driveshaft locks in the differential
side gear groove. and the CV joint subaxle bot-
toms in the differential or intermediate shaft.
3. Lower the bearíng support close to the steering gear-

18. Refíll the transmíssíon.
box and remove the íntermedíate shaft from the díffer-
ential.
CAUTION: To prevent damage to the differential oil

seal. hold the intermediate shaft horizontal until it is
clear of the differential.
lnstallatíon ís the reverse order of removal.
10-8
Disassernbly-----------------------------------------------------,
1. Remove the intermediate shaft outer seal. 4. Remove the intermediate shaft inner seal.
2. Remove the externa! circlip. 5. Remove the interna! circlip.
EXTERNAL CIRCLIP INTERNAL CIRCLIP
INTERMEDIATE SHAFT INTERMEDIATE SHAFT

OUTER SEAL INNER SEAL
3. Press the intermediate shaft out of the shaft bearing 6. Press the intermediate shaft bearing out of the bearing
using the special tool. support.
Hydraulíc Press
Hydraulic Press
DRIVER ATTACHMENT,
077 49-001 0000 37 x40 mm
07746-0010200
ATTACHMENT.
42 x47 mm
SUPPORT BASE 07746-0010300
ATTACHMENT
07LAF-SM40300
¡.·
SUPPORT BASE
~~ ATTACHMENT
l 07LAF-SM40300
HUB DIS/ASSEMBLY BASE *

li
SUPPORT BASE
SUPPORT BASE
07965-SD901 00
07GAF-SD40700 'J 07965-SD901 00
HUB DIS/ASSEMBLY BASE

07GAF-SD40700
10-9
lntermediate Shaft
lndex/lnspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
INTERMEDIATE SHAFT RING
INTERMEDIATE SHAFT BEARING

Replace.
INTERMEDIATE SHAFT
BEARING SUPPORT
Check for damage.
Replace.
inner seal.
outer seal.
10-10
Reassembly--------------------------------------------------~
1. Press the intermediate s~aft bearing into the bearing 4. Press the intermediate shaft into the shaft bearing.
support using the special tool.
Hydraulic press
• DRIVER
07749-0010000
INTERMEDIATE
SHAFT
SEAL DRIVER
ATTACHMENT
07947-SD90101 DRIVER, 40 mm l. D.
07746-Q0301 00
2. Seat the 58 mm interna! circlip in the groove of the 5. Seat the 38 mm externa! circlip in the groove of the
bearing support. intermediate shaft.
CAUTION: lnstall the circlip with the tapered end CAUTION: lnstall the circlip with the tapered end
facing out. facing out.
3. Press the intermediate shaft inner seal into the bearing 6. Press the outer seal into the bearing support using the
support using the special tool. special tool.
INNER SEAL
DRIVER
07749-0010000 '"
DRIVER
Hydraulic press ~~~¡g~~:~T
07GAD-PG40100
\ \J,,(c~r·
07749-0010000
SUPPORT BASE
ATTACHMENT
OIL SEAL DRIVER 07LAF-SM4030~~
ATTACHMENT )d
07LAD-SM401 00
HUB DIS/ASSEMBL Y
BASE
SUPPORT BASE 07GAF- SD40700
07965-SD90100
10-11
Special Tools
.
,-----
S pec1a IToos
Ref. No. ' Tool Number Oescription Q'ty Remarks
<1) 07GAG-SD40300 Cylinder End Seal Slider 1
® 07HAG-SF10100 Piston Seal Ring Guide 1
@ 07HAG-SF 10200 Piston Seal Ring Sizing Tool 1
@ 07HAG-SD40400 Pinion Seal Ring Guide 1
®-1 07LAK-SM40110 P/S Joint Adapter (Pump) 1
®-2 07LAK-SM40120 P/S Joint Adapter (Hose) 1
® 07406-0010001 P/S Pressure Gauge Set 1
®-1 07406-0010300 Pressure Control Valve 1
®-2 07406-001 0400 1
Pressure Gauge 1
(]) 07406-0010101 1 Bypass Tube Joint (included with
07406-0010001) 1
® 07725-0030000 Universal Holder 1
® 07746-0010300 Attachment 42 x 47 mm 1
@) 07749-0010000 Driver 1
@ 07916-SA50001 locknut Wrench 40 mm 1
@ 07941 -6920003 Ball Joint Remover 1
@ 07947-6340300 Driver Attachment 1
@ 07JGG-0010100 Belt Tension Gauge 1
@ 0797 4-SA50600 Pinion Seal Guide 1
@-1 ®-2
1
® @-1 ®-2
0====>
® ® @ @
@ @
11-2
.--- Special Too s (4WS only) - - - - - - - - - - - - - - - - - - - _ _ _ ,
CD 07703-:-0010101 Torx Bit Driver T40

® 07LAG-SM40000 4WS Tool Kit
®-1 07LAG-SM401 00 Piston Seal Ring Guide
®-2 07LAG-SM40200 Piston Seal Ring Sizing Tool
®-3 07LAG-SM40300 Cylinder End Seal Slider
®-4 07LAG-SM40400 Cylinder End Seal Guide
®-5 07LAG-SM40500 Tool Box
@ 07HAG-SF1 0000 4WS Tool Kit
@-1 07HAG-SF1 0400 Piníon Seal Ring Sizing Tool
@-2 07HAG-SF1 0500 Driven Seal Ring Guide
@ 07HAJ-SF10100 Rack Adjuster Gauge Holder Set
® 1 07HAJ-SF1 0201 Rear Steering Center Lock Pin
® 07HAJ-SF10300 Stroke Rod Holder Set
(J) 07HAJ-SF1 0400 lnspection Adapter
® 07LAA-SM401 00 Lock Nut Wrench 43 mm
® 07LAA-SM40200 Lock Nut Socket 36 x 43 mm
(~ =
CD ®-1 ®-2 ®-3 ®-4 ®-5
1-
@-1 ®-2 ® ®
® ®
11-3
Component Location
lndex--------------------------------------------------------------~
STEERING WHEEL
Steering wheel positioning,
see Suspensíon/Aiignment
IGNITION SWITCO~~m~y/R••~\embly, page 11-24
STEERING Steering Lock Replacement and

GEARBOX Switch Test, see Electrical Section
Rack Guide Adjustment, page 11-1 9
lndex, page 11-47
Removal, page 11-44
Overhaul, page 11-50
SPEED SENSOR
Replacement, page 11 -22
Removal, page 11-25

VALVE BODY UNIT

Removal, page 11-38
PUMP Overhaul, page 11-42
Pump Belt Adjustment, page 11-18 lnstallation, page 11-43
Fluid Replacement, page 11-1 9
Pump Pressure Check, page 11-20
Pump Replacement, page 11-31
Control Valve lnspection and Replacement, page 11-32
Housing Disassembly, page 11-35
Housing Reassembly, page 11-36
1.1-4
lndex (4WS)
~TEERING GEARBOX
ndex, page 11-48
Removal, page 11-44
lnstalfation, page 11-86
CENTER SHAFT
lndex/lnspection,.page 11-90
REAR GEARBOX
Replacement, page 11 -91
Neutral Positioning, page 11-92
Strok~ Rod Holders, page 11-93
Funct1onal lnspection
Tie-rod R ' page 11-94
eplacement, page 11 _95
Off-set Shaft Cov Replacement, page 11 _96
er
11-5
Troubleshooting (2WS)
General Troubleshooting
Check the followíng before you begín:
• Has the suspension been modified in a way that would affect steering?
• Are tire sizes and air pressure correct?
• ls the steeríng wheel original equípment or equivalent?
• ls the power steering pump belt properly adjusted?
• ls steering fluid reservoír fílled to proper level?
• ls the erigine idle speed correct and steady?
Hard Steering
1
1 l
Little or no assist in both directions Assist in one direction only, little or
with car parked. no assist in the other.
1 1
Check for bubbles in power steer- Remo ve the control val ve and
ing fluid. check the pinion pin for free move-
ment. lf OK check the control valve
l for free movement (page 11-40).
1 1
Repair as necessary.
lf there are no bubbles, check if lf there are bubbles, check the
assist improves when engine RPM reservoir input side hose and pump
is increased to 3000. front seal for air leaks. Repair as
necessary.
1
1
lf assist improves, check the pump lf assist does not improve, measure the force required
flow control valve for interna! leak- to turn the wheel with the speed sensor hose plugged
ing, and clean or re place as and the car parked (page 11-21).
necessary (page 11-33). lf the
valve is OK, re place the steering
pum p.
1 1
Steering effort abo ve 32 N {3.2 kg, 7 lbs). Steering effort below 32 N (3.2 kg, 7 lbs). Check fluid pres-
Check the gaín control valve for stícking or a clog- sure, using power steering gauge with shut-off valve closed
ged orífice; clean or replace the valve as necessary (page 11-20).
(page 11-39). lf the gain control valve is OK, check l
the pinion pin for free movement. lf seized or
binding overhaul the steering gearbox. 1 l
1
Fluid pressure below 7845 kPa (80
l
Fluid pressure 7845-8826 kPa (80-
kg/cm 2 • 1138 psi l. 90 kg/cm 2 , 1138-1 280 psit.
1
Check the pump flow control valve
l
The speed sensor is leaking
for interna! leaking, and clean or re- internally; replace the speed
place as necessary(page 11-33) .lf sensor (page 11-22).
the valve is OK, replace the pump.
11-6
Belt slipping on pulley. Adjust belt tension. Replace belt, if
1 Gain control valve sticking or leak- 1

Check gain control valve; clean or
replace the gain control valve or
1 ing. 1
control unit.
lf the engine stalls when wheel is

turned while car is stopped or mov-
ing at low speed, adjust idle speed
(see Fuel Section).
J ldle speed low or erratic. ~
Check power steering pump preload
(page 11-31).
lf preload ís above 8 N·m (0.8 kg-
Uneven or·rough steering. m, 70 lb-in.), the pump is probably
damaged internally; clean, repair, or
replace as necessary (page 11-32).
Check fluid level.

-~ Air bubbles visible in reservoir fluid. 1 lf low, check for leaks.
Add fluid to proper level (page 11-
19).
1
l ' f fluid level is OK, check 0-rings and
seals on both ends of the pump inlet
1 hose, and the oil pump housing
mating surfaces for suction leaks.
Replace parts as necessary.
1 lmproperly adjusted rack guide. 1 1 Adjust rack guide (page 11-1 9).
1
lf the rack guide adjustment is OK,
check the pinion bearings for wear or
damage. Replace them as neces-
sary.
(cont'd)
11-7
General Troubleshooting {cont'd) - - - - - - - - - - - - - - - - - - - - - .
Shock or vibration when wheel is -

rl Pump belt slipping on pulley lpump
stops momentarily).
Adjust belt tension (page 11-18)or 1
replace belt.
turned to full lock. Check flow control val ve {page

Sticking relief valve; pulsation ex- 11-33}; clean or replace as
L..- 2
ceeds 980 kPa {10 kg/cm , 142 1 - - - necessary. lf the flow control
psi). valve is OK, replace the pump.
Me asure force required to turn lf below 50 N (5.0 kg, 11 lbs).

wheel with bypass tube joint in- check gain control/pressure con~
Assist (excessively light steering) at
high speed.
- stalled, and car parked on dry pav-
f---
trol valves and control unit and
ed surta ce {page 11 -21 ) . re place parts as necessary.
Adjust belt tensíon {page 11-18) or

Pump belt slipping.
replace belt.
Sticking gain control valve or Replace gain valve or control

Steeríng kicks back during wide turns.
control valve. unit.
Rack guide adjusted too loose. Adjust rack guíde (page 11-19).
Tire pressure too low. lnflate to correct pressure.
Readjust front wheel alignment or

replace parts as necessary.
lmproperly adjusted rack guide. Adjust rack guide ( page 1 1 -1 9) .
11-8
Noise and Vibration
NOTE: Pump noise in first 2-3 minutes after starting in cold weather (- 20°C,- 4°F or colderl is normal.
Humming, due to pulsation of fluid, is normal, particularly when wheel is turned

with car stopped.
lf equipped with Automatic

Humming - - - - - - - - - - - - + - - - - - l transmission, the hum could be
~
Confirm by temporarily removing
l
torque converter or pump noise. '--'p'-u_m........;p_b_e_lt_._ _ _ _ _ _ _ _ _ ____¡
J High
'---------;
pressure líne touching the
Reposition the line.
1 trame.
Belt slipping. Tighten or replace belt. 1
J Pinion shaft seal not lubricated. Grease it. 1

Squeaking
;----1
j Horn contact not lubricated, or Grease the contact. or bend it
1 under too much pressure. reduce the pressure.
Burrs on the pinion gear. Replace the pinion gear.
j NOTE: A single "clunk" may be a normal amount of linkage clearance. To 1

.------11 distinguish this type of clunk, turn the wheel back and forth with the engine OFF.
Tighten or re place pulley. \

J Loose pump pul ley.
lf shaft is loose, replace the pump.
Rattle or chattering - - - - - - - - - 1
t----1
J Loose steering shaft connector, tie- Check and tighten, or replace parts 1
1 rod, or ball joint. as necessary. 1
J Lower column hanger bushing

Re place column assembly.
'-----¡1 damaged. 1
Lines or hoses from the control unit Reposition lines so they don't
Hissing - - - - - - - - - - - - - 1 touching each other. touch.
Noise from control valve. Replace the control unit.
NOTE: Pump noise up to 2-3

minutes alter starting in cold lf pump noíse is abnormally loud,
Pump gear noise weather I-20°C, -4°F or colderl
is normal.
- check the pump drive and driven
gears (page 11-35).
Compare pump noise at operating
temperature to another car.
Check fluid leve!.
Jf low, lill reservoir to proper leve!,
Cavitation caused by air bubbles in and check for leaks.
Grating noise from pump - - - - - - - - 1
fluid. Tighten or re place as necessary.
Check for crushed suctíon hose or

a loose hose clamp allowing air into
the system.
Tighten or replace as necessary.
11-9
Troubleshooting {2WS)
Fluid Leaks
leaking from left side.

_l_
Remove the control valve and in-
spect the 11 mm 0-ring and the
port housing bore for pits, burrs.or
scratches (page 11-40). Repair as
necessary.
11leaking from cylinder end seal into

tie-rod boots.
t 1
lf no abnormality is found, replace
the 0-ring, reseal the gearbox and
inspect the steering rack sealing
NOTE: When fluid leaks from one surface for burrs or scratches be-
side of the rack the balance tube tween the steering rack gear teeth
transfers the fluid to the other side, and the piston. lnspect the seal re-
giving the appearance that both tainer bore in the gearbox housing
sides are leaking. To troubleshoot, for proper chamfer and sharp edges
remove both boots, clean the rack (page 11-55).
and locate the leak.
leaking from right side. 1
1
Reseal gearbox and inspect the

rack sealing surface between the
steering rack pistan and the right
end (page 11-52).
[ Leaking from control unit mating Tighten attaching bolts or replace

J surfaces. valve body or port housing.
Steer ing gearbox
1 Leaking from either side of valve Replace all control unit seals and
j body. 0-rings.
1 Leaking from drilled passage plug Replace control valve body.

l (steel ball).
Front seal leaking. Replace front seal.
Pump
Replace housing 0-rings.
Pump housing leaks at either end. j-- lf the housing still leaks. replace
the pump.
Speed sensor --------------~L~e~a~k~i~n~g~.-----------_J~ Replace the sensor.
Reservoir overfilled.
Reservoir l Leaking from around dipstick. J-r- Pull off the hose and drain to proper
leve l.
Air leak in suction side of system

L.-
(reservoir, inlet hose, front pump
seal).
Tighten fitting. lf still leaking,

replace hose.
leaking at swagged joint. Replace hose.
leaking because of damage,

Low pressure hoses - - - - - - - - - - - l deterioration. or improper as- ~ Replace or repair as necessary. 1
sembly.
Tighten connector. 11 stí/1 leaking.l

Pipes -----------------IL._L_e_a_k_i_n.::g_a_t__:::g_e_a_r_bo_x_c_o_n_n_ec_t_i_o_n_._ __,
replace the pipe or control unit.
11-10
General Troubleshooting
Check the following befare you begin:
• Has the suspension been modified in a way that would affect steering?
• Are tire sizes and air pressure correct?
• ls the steering wheel original equipment or equivalent?
• ls the power steering pump belt properly adjusted?
• ls steering fluid reservoir filled to proper level?
• ls the engine idle speed correct and steady?
Hard Steeríng
1
! -¡
líttle or no assist in both dírectíons Assist in one direction only, little or
with car parked. no assist in the other.
1 1
Remove the control val ve and
Check for bubbles in power steer-
check the piníon pin for free move-
ing fluid.
ment. lf OK check the control valve
1 for free movement (page 11-40).
1 Repaír as necessary.
lf there are no bubbles, check if lf there are bubbles, check the
assist ímproves when engine RPM reservoir input side hose and pump
is íncreased to 3000. front seal for air leaks. Repair as
necessary.
1
1
lf assist improves, check the pump lf assist does not improve, measure the force required
flow control valve for interna! leal<- to turn the wheel with the speed sensor hose plugged
ing, and clean or re place as and the car parked (page 11-21 ) .
necessary (page 11-33). lf the
valve is OK, replace the steering
pum p.
1 1
Steering effort above 32 N (3.2 kg, 7 lbs}. Steering effort below 32 N (3.2 kg, 7 lbs). Check fluid pres-
Check the gaín control valve for sticking or a clog- sure, using power steering gauge with shut-off valve closed
ged orífice; clean or replace the valve as necessary (page 11-20).
(page 11-39). lf the gain control valve is OK, check
the pinion pin for free movement. lf seized or
binding overhaul the steering gearbox.
'1
¡ l
Fluid pressure below 7845 kPa (80 Fluid pressure 7845-8826 kPa (80-
kg/cm2, 11 38 psiL 90 kg/cm 2 • 11 38-1 280 psi}.
1 1
Check the pump flow control valve The speed sensor is leaking
for interna! leaking, and clean or re- internally; re place the speed
place as necessary(page 11-33}.1f sensor (page 1 1-22).
the valve is OK. replace the pump.
(cont"d)
11-11
General Troubleshooting (cont' d) - - - - - - - - - - - - - - - - - - -
Adjust belt tensíon. Replace belt, if

Belt slipping on pulley.
Gain control valve sticking or lea- Check gain control valve; clean
king. or replace the gain control valve '
or control unit.
lf the engine st¡¡lls when wheel is

turned while car is stopped or
moving at low speed, adjust idle
speed (see Fuel Section).
ldle speed low or erratic.
Check power steering pump pre-
load (page 11-31 ).
lf preload is above 8 N· m (0.8
'--
kg-m, 70 lb-in.), the pump is
Uneven or rough steering. probably damaged internally;
clean, repair, or replace as nec-
essary (page 11-32).
Check fluid leve!.
----i Air bubbles visible in reservoir fluid. f-- lf low, check for leaks.
Add fluid to proper leve! lpage
11-19).
l
lf fluid leve! is OK, check 0-rings
and seafs on both ends of the pump
inlet hose, and the oil pump hous-
ing mating surfaces for suction
leaks. Replace parts as necessary.
r------1 lmproperly adjusted rack guide. Adjust rack guide (page 11-19).
1
lf the rack guide adjustment is OK,
check the pinion bearings for wear
or damage. Repface them as
necessary.
---1 lnterference with center shaft.

r-- Visually inspect that the front and
rear gearboxes are installed
properfy.
U neven rear steering.

NOTE: Measure the wheel align- Confirm the rear gearbox neutral
- ment (Toe, camber) and confirm
that they are within limits.
- position and check the rear wheel
angle.
1
lf the wheel angle is not within
limit, replace the rear gearbox.
11-12
Shock or vibration when wheel is -
rl Pump belt slipping on pulley (pump
stops momentarilyl.
Adjust belt tension (page 11-18) or 1
replace belt.
turned to full lock. Check flow control val ve (page

Sticking relief valve; pulsation ex-
11-33); clean or replace as
'-- ceeds 980 kPa (10 kg/cm 2 , 142 ¡.....__
necessary. lf the· flow control
psi).
valve is OK, replace the pump.
Measure force required to turn lf below 50 N (5.0 kg, 11 lbs).

Assist (excessively light steering) at - , - - wheel with bypass tube joint in- ¡.....__ check gain control/pressure con-
high speed. stalled, and car parked on dry pav- trol valves and control unit and
ed surface (page 11-21). replace parts as necessary.
Check the installation of the lf installation is OK, perform a func-

t-- f--- tion check of the rear gearbox
front/rear gearboxes and center
shaft. (page 11-94).
1
lf detective, replace the rear gear-
box (page 11-90).
y Check installation of the front/rear

gearboxes.
1-- lf the torque of the mounting bolts
is normal, perform a function check
of rear gearbox (page 11-94).
1
lf detective, replace the rear gear- [
box assembly (page 11-91).
Adjust belt tension (page 11-1 8) or

Pump belt slipping.
replace belt.
Sticking gain control valve, pres-

Steering kicks back during wide turns. sure control valve or control ---1 Replace valves or control unit.
valve.
Rack guide adjusted too loose. Adjust rack guide (page 11-1 9).
(cont'd)
11-13
General Troubleshooting (cont'd)
--1 Tire pressure too low. Infla te to correct pressure. l

Re-adjust front wheel alignment or
Wheel will not return smoothly. -----l---11 lmproper front wheel alignment.
re place parts as necessary.
--{ lmproperly adjusted rack guide. Adjust rack guide (page 11-181.
--1 Check the steering joint. lf there is any rattling or defects,l

etc, replace the joint.
Excessive friction around the steer- l _j The joint cover is not lubricated.
ing linkage. lÍ\ Grease the steering joint cover.
H 'The ball joint is seize or binding.

Replace the ball joint.
1
J
lnterference· with the joint cover of
the center steering shaft.
1
Check installation of the front/rear
gearboxes.
Peor installation of the front/rear ~ Check the mounting rubbers of
Y gearboxes. both steering gearboxes.

lf necessary, replace them.
11-14
Noise and Vibration
NOTE: Pump noise in first 2-3 minutes after starting in cold weather (- 20°C, - 4°F or colder) is normal.
Humming, dueto pulsation of fluid, isnormal, particularly when wheel is turned 1

with car stopped.
Humming
1f equipped with Automatic
transmission, the hum could be
torque converter or pump noise.
'---i Confirm by temporarily removing 1
pump belt.
High pressure line touching the

Reposition the line.
1 trame. 1
1 Belt slipping. Tighten or replace belt. 1
1 Pinion shaft seal not lubricated. Grease it . 1
. Squeaking
Horn contact not lubricated, or Grease the contact, or bend it to 1
1 under too much pressure. reduce the pressure.
Remove pinion and file burrs 1

Burrs on the pinion gear.
smooth.
The joint cover is not lubricated or

the joint dust seal is worn (the ~ Grease the joint cover or replace 1
bushing section of the lower the joint dust seal.
dashboard).
J NOTE: A single "clunk" may be a normal amount of linkage clearance. To 1

1 distinguish this type of clunk, turn the wheel back and forth with the engine OFF.
Tighten or replace pulley.

1 Loose pump pulley.
lf shaft is loose, replace the pump.
Rattle or chattering
1 Loose steering shaft connector, tie- Check and tighten, or replace parts
1 rod, or ball joint. as necessary.
1 Lower column hanger bushing

Replace column assembly. 1
1 damaged.
r--
• Adjust the drive pinion assembly
and the rack.
1 Manually rotate the center steering • Tighten the steering joint. lf
1 shaft, checking for rattling. necessary, replace it.
• Perform a function check of the
rear gearbox (page 11-94). lf
necessary, re place it.
(cont'dl
11-15
Noise and Vibration (cont'd) ---------------------~
Unes or hoses from the control unit Reposition fines so they don't
Hissing - - - - - - - - - - - - - 1 touching each other. touch.
Noise from control valve. Replace the control unít.
NOTE: Pump noise up to 2-3

minutes after starting in cold lf pump noíse is abnormally loud,
Pump gear noise weather (-20°C, -4°F or colderl ,..___ check the pump drive and driven
is normal. gears (page 11-35).
Compare pump noise at operating
temperature to another car.
Check fluid level.
Grating noise from pump --------~~l Cavitation

fluid.
caused by air bubbles in t-l lf low, fill reservoir to proper level,
and check for leaks.
Check for crushed suction hose or

a loose hose clamp allowing air into
- the system.
11-16
Fluidleaks--------------------------------------------------------~
1 Leaking from drive pinion area. Tighten the drive pinion housing 1
bolts or replace the seal rings.
J Leaking from cylinder end seal into

1 tie-rod boots.
r- Leaking From left side:
Remove the control valve and in-
spect the port housing for pits,
burrs or scratches, steering rack
NOTE: When fluid leaks from one sealing surface for burrs or scrat-
si de of the rack, balance tu be ches and seal retainer bore for pro-
trancefers the fluid to the other per chamfer and sharp edges (page
side, giring the apparance that both 11-71).
sides are leaking. To troubleshoot, Leaking From right side:
remove both boots clean the rack lnspect the rack sealíng surface
and locate the leak. (page 11-68).
1 Leaking from control unit mating Tighten attaching bolts or replace

1 surfaces. valve body or port housing.
Steen·ng gearbox - - - - - - -
1 Leaking from either side of valve Re place all control unit seals and
1 body. 0-rings.
1 Leaking from drilled passage plug

Replace control valve body.
J tsteel ball).
Front sea! leaking. Replace front sea!.
Pump
Replace housing 0-rings.
Pump housing leaks at either end. !---- lf the housing still leaks. replace
the pump.
Speed sensor -------------i_~L~e~a~k~in~Qª-:_·____________j~ Re place the sensor.
Reservoir overfilled.
Reservoir I!:L~e~a~k~in::!g~f~ro~m~~a~ro~u~n~d~d~i:!:p~s::t~ic~k:.:_._ __jt---
---------------t._ Pul! off the hose and drain to proper
leve l.
Tighten fitting. lf still leaking,

replace hose.
Leaking at swagged joint.
Leaking because of damage,

Low pressure hoses - - - - - - - - - - - 1 deterioration, or improper as· ----j Re place or repair as necessary. 1
sembly.
Tighten connector. lf still leaking,

Pipes-----------------¡~L=e~a~k~in~g~a~t~g~e~a~rb~o~x~c~o~n~n~e~c~t~io~n~·-_1
replace the pipe or control unit.
1 Mating surfaces of the rear gear- L_ Tighten the attaching bolts. lf still
r-----l¡ box cover. 1 leaking, replace the rear gearbox
assembly ( page 11 -91 ) .
Rear gearbox -------------1
.___ _-;j The offset shaft and the dust Replace the dust cover with a new
1 cover. one (page 11-96).
11-17
Maintenance
Pump Belt Adjustment
1. A properly adjusted belt should deflect about 12.5 2. Loasen the special bolt and nut and turn the adjusting
-16 mm (0.50-0.62 in) when you push on ít the bolt to get proper tension, then retighten the special
pulleys wíth a force of about 98 N ( 1 O kg, 22 lbs). bolt and nut.
NOTE: On a brand new belt, the deflectíon should be
9.5-11 .5 mm (0.37-0.45 in) when fírst measured.
SPECIAL BOLT
45 N•m
(4.5 kg-m, 33 lb-ft)
CRANKSHAFT PULLEY
,.........__
Test by the Belt Tensíon Gauge; 07JGG-.0010100. ("NUT
Attach the tensíon gauge to the belt and measure the 22N•m
tensíon of the belt. (2.2 kg-m, 16 lb-ft}
Tension: 35-50 kg (77-110 lbs)
e On a brand-new belt, the tension should be 70--:90 3. Start the engine and turn the steering wheel from
kg ( 1 54-1 98 lbs) when fírst measured. lock-to-lock severa! times, then stop the engíne and
• See the ínstructions for the tensíon gauge. recheck the belt tension.
11-18
On-Car Checks
Rack Guide Adjustment Fluid Replacement
1. Remove the gearbox shield. Check the reservoir at regular intervals, and add fluid as
necessary.
CAUTION: Use only GENUINE HONDA Power
Steering Fluid. Using other fluids such as ATF or
other manufacturer's power steeríng fluid wíll dam-
age the system.
Fluid Replacement
CAPACITY: 1.8 liter (1.9 US qt. 1.58 lmp qtJ at
change
GEARBOX
SHIELO
2. Loosen the locknut on the rack guide screw with the

special too! as shown . 1. Disconnect the return hose from the gearbox at the
reservoir, and put the end in a suitable container.
2. Start the engine, let it run at idle, and turn the steering
2WS: lOCKNUT WRENCH 40 mm wheel from lock-to-lock several times. When fluid
07916-SA50001 stops running out of the hose, shut off the engine.
4WS: LOCKNUT WRENCH 43 mm Discard the fluid.
07LAA-SM401 00
3. Refit the return hose on the reservo ir.
4. Fill the reservoir to the upper level mark.
3. Tighten the guide screw until it compresses the spring 5. Start the engine and run it at fast idle, then turn the
and seats against the guide, then loosen it. steering from lock-to-lock severa! times to bleed air
Retighten it to about: 4 N·m (0.4 kg-m, 3 lb-ft) from the system.
Then back it off about: 35° ±8'
Tighten the locknut to about 25 N·m (2.5 kg-m, 18 lb-ft) 6. Recheck the fluid level and add sorne if necessary.
while preventing the guide screw from turning.
CAUTION: Do not fill the reservoir beyond the
4. Check the steering effort as described. upper level mark.
11-19
On-Car Checks
Pump Pressure Check
Check the fluid pressure as follows to determine whether 6. Start the engine and let it idle.
the trouble is in the pump or gearbox.
7. Turn the steering wheel from lock-to-lock severa! times
NOTE: First check the power steering fluid level and to warm the fluid to operating temperature.
pump belt tension.
8. Clase the shut-off valve, then clase the pressure con-
1. Disconnect the outlet hose from the pump outlet trol valve gradually until the pressure gauge needle is
fitting, and install the pump joint adaptar on the stable. Read the pressure.
pump outlet.
9. lmmediately open the shut-off valve fully.
2. Connect the hose joint adaptar to the power steer-
CAUTION: Do not keep the shut-off valve closed
ing pressure gauge, then connect the outlet hose to
more than 5 seconds or the pump could be damaged
the adaptar. by over-heating.
3. lnstall the power steering pressure gauge to the lf the pump is in good condition, the gauge should
pump joint adaptar as shown. read at least 7845-8826 kPa (80-90 kg/cm 2 , 1138
-1280 psi). A low reading means pump output is too
low for full assist. Repair or replace the pump.
6 x 1.0 BOLT
P/S JOINT ADAPTER (PUMPI PRESSURE

07LAK-SM40110 CONTROL VAL VE
P/S PRESSURE GAUGE SET

07406-0010001
PIS JOINT ADAPTER (HOSE)
07LAK-SM40120
4. Open the shut-off valve fully.

SHUT -OFF VAL VE
5. Open the pressure control valve fully.
11-20
Steering Wheel Rotational Play Power Assist Check with Car
1·~··
Parked
1. Place the front wheels in a straight ahead position and
measure the distance the steering wheel can be turned
without moving the front wheels. 1. Check the power steering fluid level and pump belt
tension.
2. lf the play exceeds the service limit, check all steering
components. 2. Start the engine, allow it to idle, and turn the steering
wheel from lock-to-lock severa! times to warm up the
fluid.
0-10 mm (0-0.4 inl max.
3. Attach a spring scale to the steering whee1. With the
engine idling and the carona clean, dry floor, pull the
sea le as shown and read it as soon as the tires begin to
turn.
4. The scale should read no more than 32 N (3.2 kg, 7

lbs). lf it reads more or less, go on step 5.
5. Stop the engine. Disconnect the hose from the speed

sensor and plug the hose and the sensor fitting as
shown.
6. Start the engine and let it idle.
e lf the reading is now 32 N (3.2 kg, 7 lbs) or less,

re place the speed sensor, see page 11 -22.
e lf the reading is still more than 32 N (3. 2 kg, 7 lbs),
check the gearbox and pump.
11-21
On Car Checks
Assist Check Speed Sensor Replacement
1. Check the power steering fluid leve! and pump belt 1. Remove the rear mount bracket stay.
tension. 2. Disconnect the speed sensor wire coupler from the
speed sensor.
2. Start the engine, let it warm up to normal temperature, 3. Remove the speed sensor mounting bolt and pull the
and turn the steering wheel lock-to-lock a few times to speed sensor from the transmission housing.
warm up the fluid.
4. Disconnect the speed sensor hoses and plug the fit-
3. Stop the engine. To simulate speeds above 50 km/h tings.
(30 mph), disconnect the hoses from the speed sensor
SPEED
and connect them to the Bypass Tube Joint. Plug the SENSOR HOSES
end of the bypass. tu be joint.
SPEED SENSOR MOUNTING
BOLT
19 N•m (1.9 kg-m.
14 lb-ft)
BYPASS TUBE JOINT
07406-0010101
0-RING
4. Attach the spring scale to the steering wheel. With the 5. Remove the speed pulser from the speed sensor.
engine idling and the carona clean, dry floor, pull the
scale as shown and read itas soon as the tires begin to
turn.
e lf the scale reads a normal 50 N {5.0 kg, 11 lbsL or

more, the assist problem at high speeds is being
caused by reduced speed sensor output. Replace
the sensor.
e lf the scale reads less than 50 N (5.0 kg. 11 lbs).

the sensor is OK, and the problem is in the sensor 6. After installing a new sensor, turn the steering wheel
feed line, the pump, or the control unit. See if the lock-to-lock with the engine idling to bleed air from the
feed line is pinched or bent then check pump. system.
e See General Troubleshooting (2WS: page 11-6,
4WS page 11-11). 7. Check the reservoir and add fluid if necessary.
11-22
1·&1
4WS Steering Gearbox Centering Rear Wheel Turning Angle lnspec-
tion (4WS)
NOTE: Use the following procedure after reassembl-
ing/replacing the steering gearbox components, or in 1. Set the turning radius gauges at the rear wheels.
preparing to salve customer complaints of mis-adjusted
steering wheel angle. 2. Apply the brake turn the steering wheel 127° to
right and check the rear wheel
1. Center the steering and steering wheel "by Turning angle: 1 o os· ± 30'
sight."
3. Turn the steering back to center, apply the brake
2. lnstall the Center Lock Pin in the rear steering and turn the steering wheel 127° to the left. Check
gearbox. the rear wheel turning angle again: 1 o os· ± 30'
• Raise the rear of the car and support on safety

stands in proper focations. 4. Apply the brake and turn the steering wheel right
and left to full lock.
• Remove the gearbox cap bolt using a Special
Tool. 5. At both left and right full lock, the rear wheel max
turning angle should be:
Wheel pointing inward: ~so 50' ± 1 o
Wheel pointing outward : 6° 10' ± 1 o (Reference)
t;J-...:
te>
22 N•m 12.2 kg-m, 161b-ftl
~TORX• BIT ORIVER T40

07703-0010101
3. Turn the steering wheel right or left slightly until

the Center Lock Pin seats fully.
• The red mark on the pin should not be visible.
• Do not turn the steering wheel quickly when the

Center Lock Pin is seated and do not force past
the locking point after the Pin is seated, or the 6. lf not as specified, see Alígnment, see Suspension
Pin may be damaged. Section. lf not correctable by re-alignment, the rear
steering gearbox may need to be replaced'
--~~:@·
Red Mark REAR STEERING CENTER
Otherthan LOCK PIN
07HAJ-SF10201
Neutral
11-23
Steering Wheel
Disassernbly/Reassernbly ------------------------------------------~
STEERING SHAFT NUT

Replace.
50 N·m
(5.0 kg-m, 36 lb-ft)
~
'" 1 ~~·"0
~~o
""® ' ~
~
STEERING SHAFT NUT

Replace.
50 N·m
CRUISE CONTROL
SWITCH
See Electrical section
CRUISE CONTROL
SWITCH
See Electrical section
11-24
Column
Removal
1. Remove the center pad. 5. Remove the upper and lower column covers.
2. Remove the steering shaft nut.

UPPER COLUMN COVER
3. Remove the steering wheel by rockíng ít slightly
from side-to-side as you pull steadily with both
hands.
LOWER COLUMN
COVER
6. Disconnect each wire coupler from the combina-

4. Remove the lower cover and driver's knee bolster.
tion switch.
7. Remove the turn signal canceling sleeve and com-

bination switch assembly.
COMBINATION. SWITCH
ASSEMBLY
TURN SIGNAL
CANCELING
SLEEVE
(cont'd)
11-25
Wiring Diagrams
lndex--------------------------------------------------
Air Conditioner · ..... 1 7 Lights, Interior
Anti-Lock Brake System (ALB) ... 1 4 Courtesy Lights · ·3
Automatic Transmission Control System 14 Dashlight Brightness Control· .. 6
Battery · .... 1 Dome Lights · 3
Blower Controls 17 Glo ve Box Light · ... 6
Charging System · · ... 1 Trunk Light · · .. 6
Cigarette Lighter · · . 1o Van ity Mírror Light · · · ... 6
Clock · 1o Lighting System · .. 6
Cooling Fan Control· · 16 Mirror, Power· ... 6
Cruise Control System · . 12 Seat, Power · . 13
Defogger, Aear Window · .. 1 1 Starting System . .1
Door Lock, Power · . 12 Stereo Sound System · . 1o
Fuel and Emissions · · . . 16 Sunroof · · · · · .... . 11
Gauges · ·2 Turn Signa! 1. Hazard Flasher System · ....... 13
Headlight Adjuster System · ·4 Warning System
Horns 4 ALB Warning · . 2
lgnition Switch 1 Brake Warning · .. 2
lgnition System .1 Charge Warning · .. .. .. . 2
lndicators Check Engine Warning · · ·2
Cruise Control lndicator · · ·2 Hazard Warning 2
Trunk Open lndicator · ·2 Light-on Warning·· 5
High Beam lndicator · 2 Oi/ Pressure Warning· . 2
Shift Lever Position lndicator · · ... 4 Washers
Turn Signa! lndicator · .. 2 Windshield · 13
lntegrated Control Unit 5 Headlight Washer · · . 13
Líghts, Exterior Windows, Power · . 7
Back-up Lights · 1o Wipers
Brake Lights · ... 3 Windshield · ... 7
Hazard Lights · .. 2
Headlights · 6
License Plate lights · 6
Marker Lights · . 6
Taillights · · · · · · · · ·6
16-274
Column
Removal (cont'd)
8. Disconnect each wire coupler from the fuse box under 1 O. Remove the steering joint bolts and move the joint
the left side of the dash . toward the column.
9. Remove the steering joint cover. 11 . Remove the column holder.

12. Remove the attaching nuts, then remove the steering
column assembly.
STEERING JOINT COLUMN HOLOER

COVER
11-26
lnspection
Tilt lever adjustment:

Attach a spring se ale 1 O mm (0.39 inl from the end of lf the force measured is not within the specification,
knob. Measure the force required to move the lever. remove the spin stopper then adjust the tilt lock bolt
~
(tighten or loasen) until the correct force can be
obtained.
Preload: 75 N (7.5 kg. 171bsl
SPIN STOPPER
10 mm (0.39 inl
STEERING COLUMN
ASSEMBLY COLUMN HOLDER
4----_39 N·m
(3.9 kg-m, 28 lb-ft)
22N•m
{l,g·m, 161b-ftl
16N•m /
( 1. 6 kg-m, 12 lb-ftl
STEERING SHAFT
Pull down while
tíghteníng bolt.
STEERING JOINT
Slip the upper end of the steering joint onto the steering
shaft llíne up the bolt hole wíth the groove around the
shaft) and loosely install the upper bolt.
1
LOCK WASHER
STEERING
UPPER BOLT
JOINT COVER
Bolt must line up wíth
flat on shaft.
CLAMPS
l!J~f
CLIP
Final torque: STEERING

22 N•m JOINT
11-27
Column
lnstallation
1. Slip the lower end of the steering joint onto the pinion 4. lnstall the steering joint cover with the clamps and clip.
shaft.
2. Instan the steering column assembly with the nuts and

column holder.
STEERING CLIP
JOINT
COVER
39N•m
C3.9 kg-m, 28 lb-ftl
5. Connect each wire coupler to the fuse box under the
left side of the dash.
3. Loosely install the steering joint on the steering gear-

box pinion.
NOTE:
e Be sure that the lower bolt is securely in the groove
in the steering gearbox pinion.
e Be sure the pinion shaft and the steering column
shaft are aligned; the joint should slip on freely. lf
not, reposition the steering rack to correct the
misalignment.
22 N•m
12.2 kg-m, 16 lb-ftl
11-28
h . h assemb 1Y and turn
com b .m ation swltc .
9. Insta 11 the dnver 's knee bos
1 ter and lo wer cover.
lnstall t e r g sleeve.
6. slgnal canee'" the comblnation
7. Connect each wire coupler to
switch.
COMBINATION SWITCH
ASSEMBLY
DRIVER'S KNEE
BOLSTER
LOWER COVER
8. lnstall the upper co lumn cover an d lower column 11 the steering whee 1 .1n a stra1·ght ahead
cover. 10. '""" N·m
position. d torque to 50
.
the steenng shaft nut an
11 . TlgOten 36 11>-ft). h
(5.0 kg-m, then install t e
UPPER COLUMN COVER 12. Chec k that the horn wor ks properly,
center pad.
.
NOTE: Be sur_e the steenng wheel engages the
canee l.in g sleeve.
LOWER COLUMN
COVER
STEERING
WHEEL
11-29
Steering Pump
lllustrated lndex
CAUTION: Pump components are made of aluminum. Be careful not to damage them when servicing.
e Clean all of the disassembled parts thoroughly.

e Replace all 0-rings and seals. Do not díp new 0-rings and seals in solvent; coat 0-rings with steering grease before
installation, and. make sure they stay in place during reassembly. ·
e The shaded parts are selectively fitted, and should not be disassembled except to replace seals lf any one of them is faulty~
replace the whole pump as an ass(\lmbly. ·
9 8 1 9
· x · mm HOUSING PORT COVER B
0-RING
PORT HOUSING
Check for damage to
sealing face. HOUSING SEAL
3.8 x 1.9 mm
0-RJNG
Re place. PUMP HOUSING
Check for damage to
HOUSING
PORT COVER
VALVESPRI,
o PlUNGER 8
Check for damage
and wear.
PLUNGER SEAL
Replace.
ORIVE GEAR
OIL SEAL
and wear.
CONTROL VAL VE
Check for pressure
leak. PLUNGER A
17.8 x 1.9 mm Check for damage
0-RING and wear.
Replace.
6 x 16 mm Re place.
FLANGE BOLT
12 N•m 11.2 kg-m. 91b-ft)
PULLEY
Check for damage to Check for distor\iOn
sealing tace. and cracks.
FLANGE BOLT PULLEY NUT

12 N•m 11.2 kg-m, 91b-ft) 65N•m
11-30
Steering Pump
lllustrated lndex
CAUTION: Pump components are made of aluminum. Be careful not to damage them when servicing.
e Clean all of the disassembled parts thoroughly.

e Replace all 0-rings and seals. Do not díp new 0-rings and seals in solvent; coat 0-rings with steering grease before
installation, and. make sure they stay in place during reassembly. ·
e The shaded parts are selectively fitted, and should not be disassembled except to replace seals lf any one of them is faulty~
replace the whole pump as an ass(\lmbly. ·
9 8 1 9
· x · mm HOUSING PORT COVER B
0-RING
PORT HOUSING
Check for damage to
sealing face. HOUSING SEAL
3.8 x 1.9 mm
0-RJNG
Re place. PUMP HOUSING
Check for damage to
HOUSING
PORT COVER
VALVESPRI,
o PlUNGER 8
Check for damage
and wear.
PLUNGER SEAL
Replace.
ORIVE GEAR
OIL SEAL
and wear.
CONTROL VAL VE
Check for pressure
leak. PLUNGER A
17.8 x 1.9 mm Check for damage
0-RING and wear.
Replace.
6 x 16 mm Re place.
FLANGE BOLT
12 N•m 11.2 kg-m. 91b-ft)
PULLEY
Check for damage to Check for distor\iOn
sealing tace. and cracks.
FLANGE BOLT PULLEY NUT

12 N•m 11.2 kg-m, 91b-ft) 65N•m
11-30
Replacement Preload lnspection
1. Drain the fluid from the system (page 11-1 9). Check the pump preload with a torque wrench after over-
hauling a pump or installing a replacement pump.
2. Disconnect the inlet and outlet hoses from the pump
and plug them. Preload: 8 N•m (0.8 kg-m, 70 lb-in.) max.
3. Remove·_the belt by loosening the special bolt, nut and

adjusting bolt.
4. Remove the special bolt and nut, then remove the

pump.
11 N•m
!1.1 kg-m, 8 lb-ftl
SPECIAL BOLT
45N•m
{4.5 kg-m, 33 lb-ft)
ADJUSTING BOLT
5. Loosely instan a new pump on the bracket.
6. Connect the inlet and outlet hoses to the pump.
7. Instan and adjust the belt (page 11 -1 8).
8. Fill the reservoir with new fluid to the UPPER LEVEL on

the reservoir.
9. Start the engine and let it run at fast idle while turning
the steering wheel lock-to-lock severa! times to bleed
air from the system.
10. Check the reservoir and add fluid if necessary.
11-31
Steering Pump
Pulley Replacement Control Valve lnspection
and Replacement
Removal:
Hold the steering pump in a vise with soft jaws, and hold
1. Remove the two 6 x 16 mm flange bolts, then remove
the pulley with the special tool and remove the pulley nut
the housing port cover, valve spring and 0-rings.
and pulley.
NOTE: Pulley nut has leh-hand threads. 6 x 16 mm

FLANGE BOL TS
UNIVERSAL HOLDER
07725~0IOOOO
17.8 x 1.9 mm
0-RING Q
~
Replace. ~
3.8 x 1.9 mm
0-RING
Replace.
PULLEY NUT
65 N•m (6.5 kg-m, 47 lb-ft)
lnstallation:
lnstaflation:
1. Insta!! the pulley key in the groove of the pump shaft. 2. Remove the control valve from the port housing.
2. Slide the pulley onto the pump shaft by aligning the
groove of the pulley and pulley key.
GROOVE ~PULLEYKEY
3. Hold the pully with the special tool and tighten the
pulley nut.
11-32
3. Check for wear, burrs, and other damage to the edges lf OK, go on to step 5, if not, replace the valve:
of the grooves in the valve.
• The original valve was selected for a precise fit in the
pump housing bore, so make sure the new one has
the same identification mark.
CONTROL VALVE
'--____,..-..
Check for
damage to edges. IDENTIFICATION
MARK
Mark Part Number 1 Part Name Size mm(in)
56350-PC1 15.995-16.000
4. Slip the valve back in the pump and check that it A
-000
CONTROL VALVE A
(0.6297-0.6299)
moves ín and out smoothly.
Without 56360-PC1 16.000-16.006
CONTROL VALVE B
mark -000 (0.6299-0.6302)
5. Atta eh a hose to the end of the valve as shown.
t /
CONTROL VALVE HOSE
9.5 mm ID (0.374 in)
(The power steering
return hose is recommended)
\:::.----.__
CONTROL VALVE
(cont'd)
11-33
Steering Pump
Control Valve lnspection and Replacement (cont'd) - - - - - - - - - - . . . . . . ,
6. Then submerge the valve in a container of power 9. Clean all the parts in solvent, dry them off, then re-
steering fluid or solvent, and blow on the hose. lf a ir assemble and retest the valve.
bubbles !eak through the valve, replace or repair itas
follows. NOTE: lf necessary, relief pressure is adjusted at the
factory by adding shims under the check ball seat. lf
you found shims in your valve, be sure you reinstall as
many as you took out.
AIR PRESSURE
At less 19.6 kPa 1O. lnstall the control val ve in the reverse order of removal.
(0.2 kg/cm 2 , 0.3 psi)
• Apply steering grease (Honda P/N 08733-B070E}
to new 0-rings.
e Coat the control valve with power steering fluid

then instan it and valve spring.
12 N•m 11.2 kg-m, 91b-ftl

POWER STEERING
FLUID or SOLVENT
7. Clamp the bottom end of the valve in a vise with soft

jaws.
8. Unscrew the seat in the top end of the valve, and

remove any shims, the relief check ball, relief val ve and
relief valve spring.
SEAT
13 N•m
RELIEF VAL VE ( 1 · 3 kg-m, g lb-ftl
,-- <~!1-Do~Ó~
t
L __
1
RELIEF CHECK BALL
__j
QUJ
1 CON!.Ol VALVE
Clamp this end in
a vise with soft jaws.
RELIEF VALVE
SPRING
11-34
Housing Disassernbly----------------------------------------------~
CAUTION: The pump components are made of alumi- 7. Remove the pump drive and driven gears from the
num. Be careful not to damage them when servicing. pump housing.
1. Remove the pu mp from ca r (page 11-31 ) . 8. Remove the plungers from the pump housing.
2. Remove the pulley (page 11-32).

ORIVE GEAR
3. Remove the control valve (11-34).
4. Remove the five bolts then remove the pump front

cover, housing seal, plunger seal and dowel pins. ORIVEN GEAR
HOUSJNG SEAL
PLUNGER
Replace.
SEAL
PUMP FRONT
COVER
9. Pry the oil seal out from the pump front cover.
5. Remove the dowel pins and housing seal from the port
housing.
6. Separate the port housing from the pump housíng.
PORT HOUSJNG
HOUSJNG SEAL
Replace.
11-35
Steering Pump
Housing Reassembly
1. Coat the outer surfaces of the plungers with power 4. Coat the port housing groove with power steering fluid
steering fluid, then instan them in the pump housing. first, then position a new housing seal on the port
Make sure the plunger hales are positioned as shown. housing.
NOTE: lnstall the plungers so the cutouts are aligned 5. Coat the bushings on the port housing with power
as shown. steering fluid.
6. lnstall the dowel pins in the pump housing.

ALIGN CUTOUTS
7. lnstall the port housing on the pump housing.
PORT HOUSING HOUSING SEAL
8 x 10 mm
DOWEL PINS PUMP HOUSING
2. Coat the inside of the plungers with power steering

fluid. 8. Coat the port housing groove with power steering
fluid, then position a new housing seal on the pump
3. lnstall the pump drive and driven gears in the pump housing.
housing.
9. Coat the new plunger sea! with the power steering
fluid and install it over the plungers.
ORIVE GEAR
1 O. lnstall the dowel pins in the pump housing.
DRIVEN GEAR HOUSING SEAL
8 x 10 mm
DOWEL PINS
11-36
11 . lnstall the new oil seal in the pump front cover; get it 14. Slide the pump front cover over the drive gear, being
started by hand, then use a socket to push it in the rest careful not to damage the sealing lip or dislodge the
of the way. spring of the oil seal. then remove the vinyl tape.
12. Coat the lip of the seal with steering grease (Honda P/
N 08733-8070E).
15. lnstall the five bolts. Torque them to the specified

torque in the arder shown.
13. Wrap the splined area of the drive gear with vinyl tape
and grease the surface of the tape.
FLANGE BOLT
12 N•m (1.2 kg-m, 9 lb-ftl
VINYL TAPE
1 6. lnstall the control valve (page 11-34).
17. Instan the pulley (page 11-32) and check the pump
preload with a torque wrench (page 11-31 ) .
11-37
Steering Gearbox
Valve Body Unit Overhaul
Removal: 5. Remove the two 8 mm flange bolts and remove the
control únit from the gearbox.
1. Drain the power steering fluid (page 11-19).
6. Remove the 0-rings and port orífices from ·the gear-
2. Remove the gear box shield. box.
Aeplace.
CONTROL
UNIT
~ mm
8 FLANGE BOLT
3. Using solvent and a brush, wash any oil and dirt off the Disassembly:
control unit, its lines, and that end of the gearbox,
Blow dry with compressed a ir. 1. Remove the 0-ring from the control unit.
4. Using fiare nut wrenches, disconnect the four lines 2. Remove the three 6 mm flange bolts, and remove the
from the control unit. cap from the valve body.
A: From pump: 14 mm wrench 3. Remove the cap sea! from the cap.
8: To oil cooler: 12 mm wrench
C: To reservoir: 17 mm wrench
D: To speed sensor: 12 mm wrench
CAP SEAL
Replace ..
\
45.5 x 2 mm
0-RING
Replace.
e B D A
11-38
4. Remove the pressure control valve and spring from the 6. Remove the gain control valve and spring from the
valve body. valve body.
GAIN CONTROL
VALVE
PRESSURE CONTROL
VALVE VALVE SPRING
5. Check the pressure control valve: 7. Check the gain control valve:
e lnspect its surface for scoring or scratches. • lnspect its surface for scoring or scratches.
e Slip it back into the valve body, and make su re it • Slip it back into the valve body and make sure it
slides smoothly without drag and without side play. slides smoothly without drag and without side play.
PRESSURE CONTROL VALVE

Check for scoring or GAIN CONTROL VALVE
scratches, and rough Check for scoring,
operation. scratches, or rough
operation.
NOTE: Jf the valve body is damaged, replace the valve NOTE: lf the valve body is damaged, replace the valve
body unit (valve body, pressure control valve, gain body unit (valve body, pressure control valve, gain
control valve, controi valve) as an assembly. control valve, control valve) as an assembly.
(cont'd)
11-39
Steering Gearbox
Valve Body Unit Overhaul (cont'd)
8. Separate the valve body and port housing. 13. Check the plungers.
9. Remove the seal and dowel pins from the port hous- e lnspect their surface for scoring or scratches.
ing.
• Slip each plunger into the valve body, and make
su re it slides smooth/y, without drag or side play.
VALVE BODY PORT HOUSING lf any plunger is damaged, replace it.
NOTE: lf the valve body is damaged, replace all three

parts (valve body. cut-off valve and control valve) as a
set.
PLUNGERS
VALVE BODY
DOWEL PIN
PLUNGERS
Check for scoring or
scratches. and rough
1 O. Remove the rollers from the control valve by pushing sliding.
the valve out one side of the valve body, and then the
other.
14. Check the control valve.
NOTE: When removing the rollers, hold the plungers
with your fingers to keep them from popping out. e lnspect its surface for scoring or scratches.
e Slip it into the valve body, and make sure it slidies

smoothly, without drag or si de play.
11 mm 0-RING
VALVE BODY
CONTROL VALVE
RETURN
ROLLER SPRINGS
NOTE: /f the valve body is damaged, replace the valve

11 . Remove the plungers, return springs and control valve body unit (valve body, pressure control valve, gain
from the valve body. control valve, control valve) asan assembly.
12. Remove the 11 mm 0-ring from the control valve.
11-40
15. orifice
Using a 3 ;m
and . 4 m(1/64")
O-rmg
. ·drill b"t
1 ' remo ve th e sensor
~-4 mm 0-RING
eplace.
SENSOR ORIFICE
11-41
Steering Gearbox
Valve Body Unit Overhaul
Assembly:
1. Thoroughly clean the disassembled parts shown below.
2. Coat the plungers, pressure control valve, gain control valve and control valve surfaces with power steering fluid.
3. Reassemble the parts in the reverse order of disassembly.
CAUTION:
e Replace the 0-rings and seals with new ones.
e Do not dip the 0-rings and seals in solvent.
e Apply grease in the seal grooves to keep the seals in place.
e Apply grease to new 0-rings to keep them in place.
e - e¡;;;.. STEERING GREASE ...... Part Number 08733-B070E
45.5 x 2 mm
0-RING
PORT HOUSING
... p;:;ffi
11 mm 0-RING
Replace.
PRESSURE
6 mm FLANGE BOLT
9 N•m {0.9 kg-m, 7 lb-ftl
~ 3.4 mm 0-RING
Replace.
v.~LVE BODY CAP

CAP SEAL
Replace.
NOTE: lf the valve body ís damaged, replace the valve body unit (valve body, pressure control valve, gain control valve,
control valve) asan assembly.
11-42
4. Make sure the control valve moves smoothly, and 3. Connect the four lines to the control unit, using fiare
returns to neutral position. nut wrenches.
A: From pump: 14 mm wrench

38 N·m (3.8 kg-m, 28 lb-ft)
8: To oil cooler: 12 mm wrench
13 N•m (1.3 kg-m, 9 lb-ft)
29 N·m (2.9 kg-m, 21 lb-ft)
--- 0: To speed sensor: 12 mm wrench

· 13 N·m (1.3 kg-m, 9 lb-ft)
lnstallatíon:
1. Coat the 9.8 x 1.9 mm 0-rings with grease, and instan

them together with the orífices.
C B D A
2. Instan the valve body unit on the gear housing with the
two 8 mm bolts.
4. Fill the reservoír wíth power steering fluid and bleed air
CAUTION:
from the system by turning the steering wheel from
e When installing, be careful not to hit the píníon lock to lock several times with the engine warm.
holder pín.
e Make sure the 0-ríngs are in place and not pin- 5. Make sure there are no fluid leaks, then install the
chad.
shield.
PINION HOLDER PIN 6. Recheck the fluid leve! in the reservoir.
10 N•m
( 1.0 kg-m. 7 lb-ftl
11-43
Steering Gearbox
Removal
1. Drain the power steering fluid as described on page 6. Disconnect the tie rods from the steering knuckles
11-19. using the special tool shown.
2. Raise the front of car and support on safety stands in CAUTION: Avoid damaging the ball joint boot.
the proper locations.
NOTE: lf necessary, apply penetrating type lubricant
3. Remove the front wheels. to loosen the ball joint.
4. Remove the steering joint cover.
STEERING JOINT COVER
CLAMP
5. Remove the steering joint bolts, and move the joint

toward the column. 7. Remove the gear box shield.
GEARBOX SHIELD
11-44
8. Using solvent anda brush, wash any oil and dirt off the 12. Remove the self-locking nuts that connectthe header
control unit, its lines, and that end of the gearbox, pipe to the catalytic converter, and the header pipe to
Blow dry with compressed air. the exhaust manifold.
9. Using fiare nut wrenches, disconnect the four lines 13. Remove the header pipe.
CAUTION: Replace the exhaust gasket and self-
A: From pump: 14 mm wrench locking nuts when you reinstall the pipe.
B: To oil cooler: 12 mm wrench
O: To speed sensor: 12 mm wrench
SELF-LOCKING NUT
Replace.
C B O A
1 O. Disconnect the 4P connector from the oxygen sensor.

Automatic transmission:
11 . Remove the header pipe bracket nuts. 14. Remove the control cable from the clamp by removing
the cable holder.
4P-CONNECTOR
(cont'd)
11-45
Steering Gearbox
Removal (cont'd)
4WS Only. 16. Remove the steering gearbox mounting bolts.
• Separate the joint guard cap and the joint guard.
• Remove the joint bolt from the driven pinion side.
GEARBOX
SI DE
JOINT
STEERING GEARBOX
MOUNTING BOLTS
JOINT GUARO
CENTER
STEERING
SHAFT SIDE
17. Slide the tie rod all the way to the right side.
18. Slide the gearbox right so that the left tie rod clears the
bottom of the rear beam, then remove the gearbox.
CAUTION: Be careful not to bend or damage the

e Remove the joint bolt from the center steering shaft four power steering lines when removing the gear-
side, then slide the joint back to disconnect it from box assembly. /
the driven pinion.
15. Remove the bolts, and lower the stabilizer.
STABILIZER
11-46
Steering Gearbox
lllustrated lndex (2WS)
NOTE:
e LH Orive shown, AH Orive is similar.
e The valve body unit removal see pages 11-38.
CAUTION:
·e Before disassembling the gearbox, wash it off with solvent anda brush.
e Thoroughly e lean all disassembled parts.
e Always replace 0-rings and seals.
e Replace parts with-damaged sliding surfaces.
e Do not dip seals and 0-rings in solvent; coat 0-rings with gréase, make sure they stay in position during reassem-
bly. and use the appropriate special tools to install them where necessary.
e - ~ STEERING GREASE ...... Part Number 08733-B070E

CYLINDER END BUSHING
SEAL \ CLAMP
Replace. ~\ / PINION DUST SEAL
~fiJo~
Replace. 6 mm FLANGE BOLT
'\. ~ 11 N·m (1.1 kg-m. Slb-ft)
~ f
~/
46 x 1.5 mm
::ACK BUSING B
lnspect for damage to
\
inner surface. BACK-UP RING
SEAL RETAINER
CYLINDER CAP
PORT ORIFICES ----+-~ ~

/®
-~/,~
9.8 x 1.9 mm 0-RING
Re place.
RACK BUSHING A /
lnspect for damage to PISTON
inner surface. (part of rack)
,®~'{,~~~~ STEERING RACK

lnspect surface for damage.
BOOT BAND CYLINDER BARREL

lnspect inner wall
for damage.
~ ~ CYLINDER BOLT
~ 22N·m
TRANSFER HOSE (2.2 kg·m. 16 lb-ft) o
CLAMP LOCK WASHER ~-~- CYLINDER

_-@~Replace. BACK-UP RING ~ ENO SEAL
STOP WASHER ~ BOOT BAND Replace.
· ....-'~ .R . 1 PISTON SEAL
RACK END ~ ~ epa ce. RING
55 N•m (5.5 kg-m. 40 lb·ftl

V~
1J. -V~ t!Í!~,
_.. _- _ -_---._ ._•.--.___-_- -.
{¡ --~
. Replace.
TUBE CLAMP
. COTTER PIN
~ Reptace.
o•
• • •
1 ~~ , 7~ TIE-ROO BOOT
TRANSFER HOSE
BOOT
~,__ --.......
TIE-ROO CIRCLIP
LOCKNUT
11-47
6 mm FLANGE BOLT
-
10 N·m
!fiiiÜéi 11 .O kg-m, 7 lb-ft}

R ACK
GUIDE PI N ION
DUST SEAL
Replace.
PRESSURE
SPRING
PINION DUST SEAL
RETAINER
I_//~~R~~G5 mm
~----- 30""""·
~ mm SNAP RING
~ ,. . BALL BEARING
\ PINION HOLDER
SEAL RETAINER
BUSHING
- $iiÑo STOPPER R~ ... ~

PINION
RACK BUSHING B ~ ~
lnspect for damage
to inner surta ce. fJ
CYLINDER BARREL~ J·~

lnspect inner wall \
for damage. CYLINDER END
U SEAL
Replace.
~ Replace.
29.7 x 1.9 mm
0-RING
Replace .
...______ STEERING RACK

lnspect surface for
P....-- damage.
l -~35.5 x 2.4 mm
PISTON SEAL
RING
Replace.
0-RING
11-49
Steering Gearbox
Overhaul (2WS)
1. Remove the control unit as described on page 11-38. 6. Loasen the rack screw locknut, and remove the· rack
guide screw.
2. Carefully clamp the gearbox in a vise with soft jaws.
3. Loosen the bands, pull the boots away from the ends
of the gearbox, and unbend the tie-rod lock washers.
4. Hold the rack with a 22 mm wrench, and unscrew the

tie-rods with a 1 7 mm wrench.
RACK
GUIOE LOCKNUT
Unbend.
7. Remove the 28 mm snap ring from the bottom of the
gear housing.
5. Push the right end of the rack back into the cylinder
housing so the smooth surface that rides against the
seal won't be damaged. 28 mm
SNAP RING
CYLINDER
STEERING RACK
o
o
11-50
8. Remove the pinion from the gear housing by tapping it e Remove the bearing using a commercially available
1ightly. bearing pulley.
9. Check the ptmon lower ball bearing for play; if it is e Using a press, install the lower bearing on the
good and the grease in it is clean, go on step 10. pinion, with its shielded síde facing down.
lf the bearing is noisy or has excessíve play, re place the
bearing.
e Remove the 12 mm snap ring.
lnstall wíth the

shielded síde
facing down.
PINION
12 mm SNAP RING ATTACHMENT 42 x 47 mm

07746-0010300
(cont'd)
11-51
Steering Gearbox
Overhaul (2WS) (cont'd)
• Apply grease to the lower ball bearing and check for 12. Remove the 0-ring. back-up ring, steering rack bush-
smooth operation. lnstall the 12 mm snap ring. ing A and cylinder spring.
1 3. Remove the cylinder end seal from the cylinder hous-

PINION LOWER ing.
BAll BEARING
14. Use your fingers ora wooden stick to avoid damaging
the housing.
12 mm SNAP RING
END SEAL
1 O. Remove the tour bolts from the end of the cylinder 15. Remove the cylinder, cylinder seal retainer, cylinder
housing, then s!ide the housing off the rack. cap and steering rack from the gear housing.
11 . Remove the cylinder housing.
GEAR HOUSING
CYLINDER SEAL
RETAINER
0-RING Replace.
RACK BUSHING A
CYLINDER SPRING CYLINDER CAP
CYUNDER
11-52
16. Remove the retainer washer from the gear housing. 20. Check the upper bearing for free movement and exces-
sive play; if it is good and the grease in it is clean. go
on step 21.
lf it is damaged, or if dirt has gone past the seal into
the grease, replace the bearing.
e Remove the 30 mm snap ring from the pinion

holder.
30mm
SNAP RING
17. Remove the gear housing cap from the gear housing
by removing the tour 6 mm flange bolts. e Remove the pinion holder from the gear housing.
18. Remove the steering pinion seal from the gear housing
cap. PINION HOLDER
19. Remove the 0-ring from the gear housing. GEAR HOUSING
(cont'd)
11-53
Steering Gearbox
e Remove the pinion upper ball bearing from the gear e Pack a new upper bearing with grease, then dríve
housing. the bearing into the gear housing with its sealed
side facing out.
~PINION UPPER BALL

~ BEARING
ATTACHMENT
42 x 47 mm
07746-0010300
GEAR HOUSING
e Check the needle roller bearing in the pinion holder • Instan the pínion holder in the gear housing.
and in the gear housing for damage; if they are OK,
pack them with grease. lf the bearings are
damaged, replace them as a set. PINION
HOLDER
GEAR HOUSING
11-54
e Reinstall the 30 mm snap ring with its tapered side 22. Remove the 0-ring and snap ring from the seal
facing out. retainer, then remove the cylinder cap from the seal
retainer.
NOTE: Snap ring ends must be aligned with the flat
area. 23. Remove the 0-rings from the cylinder cap.
0-RING
/n
Replace.
SNAPRING
J CYLINOER CAP
0-RINGS
30mm Replace.
SNAP RING SEAL RETAINER
21 . Remove the cylinder and seal retainer from the steeri ng 24. Remove the bushing stopper ring from the seal
rack. retainer.
25. Remove the cylinder end seal and rack bushing B.
BUSHING STOPPER RING

CYLINDER
- - - STEERING RACK
~
SEAL RETAINER
CYLINDER END SEAL
~
RACK BUSHING B
(cont'd)
11-55
Steering Gearbox
Overhaul (2WS) (cont'd) - - - - - - - - - - - - - - - - - - - -
26. Carefully pry the piston seal ring and 0-ring off the 28. Coat the pinion sea! ring guide with power steering
rack. fluid, then slide it onto the rack, big end first.
29. Position the new piston seal ring on the special tool,
slide it down onto the big end of the tool, then pull it
off into the piston groove on top the 0-ring.
PISTON SEAL RING

GUIDE
07HAG-SF10100
31.5 x 2.4 mm ~~/il

PISTON RING
0-RING
PIS TON
SEAL RING
/
0-RING
31.5 x 2.4 mm
NOTE: Before reassembling any parts, inspect them as 30. Coat the piston seal ring and inside of the special tool
described on page 11-48 and make sure they are with power steering fluid.
clean. Replace worn or damaged parts. Carefully slide the tool onto the rack and over the
pistan ring, then rotate the tool as you move it up and
27. lnstall a new 0-ring on the rack with its narrow edge down to seat the piston ring.
facing out.
31.5 x 2.4 mm
0-RING
,..
IJ
PISTON RING
/. - PISTON SEAL RING
SIZING TOOL
07HAG-SF1 0200
11-56
31. Coat new 0-rings with grease and install them on the 34. Grease the sliding surface of the steering rack bushing
cylinder cap. B, and install the bushing on the steering rack with the
groove of the bushing facing the steering rack piston.
CYLINDER CAP
RACK BUSHING 8
37 x 1.5 mm 0-RINGS
STEERING RACK
32. Slide the cylinder cap ·onto the sea! retainer. 35. Grease the sliding surfaces of the new cylinder end seal
and the special tool , then place the seal on the special
33. lnstall the snap ring and 0-ring on the seal retainer. tool with its grooved si de facing opposite the slider.
~
27.5X2 mm
0-RING
CYLINDER CAP
WJING ;ACK-UP
In :\)~~
~-
CYLINDER END SEAL ~
Instan end seal with its g r o o v e d /
SNAP RING stde facmg oppos1te
seal slider.
CYLINDER END
SEAL SLIDER
07GAG-SD40300
(cont'd)
11-57
Steering Gearbox
36. Grease the steering rack, and install the special tool. 38. Fit the seal retainer on the steering rack.
CAUTION: Make sure the rack teeth do not face the
slot in the special tool.
CYLIND.ER END SEAL
RACK BUSHING B
SLIDER
37. Remove the special tool from the cylinder end seal, 39. Push the rack bushing B toward the seal retainer by
then separate the ends of the tool and remove it from hand until the cylinder end seal is seated in the
the rack. retainer. Fit the seal stopper ring in the groove of the
seal retainer securely.
CYLINDER END SEAL

CYLINDER END
SEAL SLIDER
07GAG- 5040300
11-58
40. lnstall the retainer washer on the gear housing. 43. lnstall the cylinder spring over the rack, then coat the
rack bushing A with power steering fluid and install it
on the spring.
44. Wrap the end of the steering rack with vinyl tape or
use the special tool. Coat the tape or tool with grease.
GEAR HOUSING
PINJON SEAL
RING GUIDE
~ ·
07 HAG-5040400
RACK BUSHING A~
CYLINDER SPRING ~
STEERING R A C K - r l
41 . Place the gear housing on the work bench and insert

the seal retainer and steering rack into the gear hous- 45. Coat the inside surface of the cylinder with power
ing. steering fluid and instan the cylinder end seal with its
grooved side facíng out.
42. Coat the ínside surface of the cylinder with power
steering fluid, slide ít over the rack and into the gear
housing; press it into to housing until it seats.
CYLINDER END SEAL
CYLINDER
STEERING RACK
t
o
~J
--r;]!/1 SEAL RETAINER
CYLINDER
HOUSING
GEAR HOUSING
(cont'd)
11-59
Steering Gearbox
46. lnstall the 0-ring and back-up ring on the gear hous- 50. Tighten the cylinder housing to the gear housing.
ing.
NOTE: Before tightening the bolts, make sure the
4 7. Carefully position the cylinder on the gear housing and mating surfaces of the cylinder and gear housings fit
loosely install with four bolts. properly by pushing them together; hold them
together while tightening the bolts.
CAUTION: Be careful not to damage the end seal in
the cylinder housing.
48. Remove the special tool from the steering rack.
CYLINDER 22N•m
HOUSING (2.2 kg-m 16 lb-ftl
CYLINDER BOL TS
51. lnstall the steering pinion in the pinion holder.
SOCKET
(0.0. Should be less
49. lnsert the steering rack into the cylinder housing,
PI NION HOLOE~ <h•n 27.9 mm/1.1 O in)
being careful not to damage the steering rack sliding
surface.
CYLINDER HOUSING
~ATTACHMENT42 x 47 mm
07746-0010300
11-60
52. lnstall the 28 mm snap ring securely in the pinion
holder groove.
NOTE: Instan the snap ring with its tapered side facing
out.
28 mm SNAP RING
o
o
46 x 1.5 mm 0-RING
53. Grease the steering pinion seal, and instan it on the 55. Grease the special tool and fit it over the steering
gear housing using the special tools. pinion.
DRIVER
07749-0010000 STEERING PINION
A-
u PINJON SEAL GUIDE
07974-SA50600
DRIVER ATTACHMENT
0794 7-6340300
-~
STEERING
PINION SEAL
GEAR HOUSING CAP
(cont'd)
11-61
Steering Gearbox
Overhaul (cont'd)
56. Slide the gear housing cap over the steering pinion, 59. lnstall the 0-ring on the rack guide screw.
being careful not to damage the sealing lip of the
pinion seal. 60. Coat the rack guide with grease.
61. lnstall the rack guide, spring and rack guide screw on
the gear housing. ·
~ 62. lnstall the control valve unit (page 11-43).
GEAR ~~ -
HOUSING
CAP
RACK
GUIDE RACK GUIDE SCREW
57. Remove the special too!. 63. Tighten the rack guide screw until it compresses the
spring and seats against the rack guide, then loasen it.
58. Tighten the four flange bolts.
64. Retighten it to 4 N·m (0.4 kg-m, 2.9 lb-ft). back off
about 35°:!:1f and install the locknut on the rack guide
screw.
65. Tighten the locknut while holding the rack guide screw
with the special tool.
11 N•m
(1.1 kg-m. 8 lb-ft)
A
u LDCKNUT WRENCH 40 mm RACK GUIDE SCREW
\
07916-SA50001 Hofd.
25 N•m (2.5 kg-m. 18 lb-ftl
t¡
11-62
66. lnstall the transfer tube clip as shown. 68. Instan the new boot band on the boot.
NOTE: LH Orive shown, RH Orive is similar.

NOTE: Coat the rack end and inside of the boot with
the grease.
OFFSET SHAFT
CENTER LINE TRANSFER TUBE CLIP
RACK END
--
View from right
side (cylinder side).
67. Instan the band rubber and band; position the band as 69. Screw each tie-rod into the rack while holding the lock
shown and tighten it. washer so its tabs are in the slots in the rack end.
NOTE: LH Orive shown, RH Orive is similar. NOTE: lnstall the stopper washer with the chamfered
side facing out.
70. Tighten the tie-rod securely, then bend the lock

washer back against the flat on the flange as shown.
8± 3mm
10.32 ± 0.12 in)
BAND
/RUBBER
STOPPER WASHER
TRANSFER
TUBE BAND Replace.
/~
View from
right side(cylinder side).
55 N·m
45.5 kg-m, 40 lb-ft) (cont'd)
11-63
Steering Gearbox
71 . Instan the boots so that the angle of ·the offset shaft 72. Instan new boot bands on the boot and bend both sets
center line is as shown. of locking tabs.
NOTE: LH Drive shown, RH Drive is similar. 73. lightly tap on the doubled-over portions to reduce
their height.
<CYLINDER SIDE>
OFFSET SHAFT
LOCKING T ABS
CENTER UNE
* Front.
<CYLINDER SIDE>
NOTE: LH Drive shown. RH Drive is similar.
OFFSET SHAFT
CENTER UNE
¿ LOCKING
TABS
<GEAR HOUSING SIDE> • Front.
OFFSET SHAFT
CENTER UNE
TUBE JOINT <GEAR HOUSING SIDE>

lleft side boot)
LOCKING
TABS
Front. ~
1 r
V
74. Instan the air transfer tube.
75. After assembling, slide the rack right and left to be

certain that the boots are not deformed or twisted.
11-64
Overhaul (4VVS)----------------------------------------------~
1. Remove the steering gearbox assembly (page 6. Loasen the rack screw lock nut, and turn off the
11-44). guide screw.
2. Remove the control valve assembly (page 11-38).
3. Strainghten the tab of the lock washer.
4. While holding the steering rack with a 22 mm

wrench, remove the tie-rod with a 17 mm wrench.
RACK
LOCKNUT
GUIDE
5. Slide the steering rack into the cylinder housing un- 7. Remove the 28 mm interna! snap ring from the bot-
til the end is projected 62.2 mm (2.4 in.) from the tom of the gear housing.
rack bushing retainer.
RACK BUSHING RETAINER 28 mm INTERNAL SNAP RING
o
o
(cont'd)
11-65
Steering Gearbox
Overhaul (4WS) (cont'd) lnstallation
123. Jnstall the transfer tu be clips as shown. CAUTION: lf the rear steering gearbox and center shaft
NOTE: LH Drive shown, RH Drive is similar. are removed, care must be taken to reinstall them cor-
rectly. Be sure to refer to page 11-90 and install proper-
ly.
TRANSFER TUBE CUPS 1. Reinstall the gearbox in the reverse order of removal.
CAUTION: Be careful not to bend or damage the

four power steering lines when installing the gear-
box assembly.
OFFSET
View from CENTER View from
left side SHAFT right síde
UNE
2. Tighten the stabilizer mounting bolts.
124. lnstall the air transfer tube.
125. After assembling, slide the rack right and left to be

certain that the boots are not deformed or twisted.
22 N·m
(2.2 kg-m, 161b-ft)
11-86
3. Tighten the gearbox mounting bolts. 5. 4WS only
e Connect the joint and the driven pinion.
44N•m
{4.4 kg-m, 32 lb-ftl
22 N·m
(2.2 kg-m, 16 lb-ft)
4. lnstall the steering joint on the steering gearbox pinion. e Tighten the bolt at the driven pinion.
e Connect the joint guard and the joint guard cap.
NOTE:
e Be su re that the lower bolt is securely in the groove 6. Automatic transmission only
in the steering gearbox pinion. • lnstall the control cable to the clamp.
e Be sure the pinion shaft and the steering column
shaft are aligned; the joint should slip on freely. lf
not, reposition the steering rack to correct the
misalignment.
22N•m
(cont'd)
Steering Gearbox
7. Connect the fluid lines to the control unit. 9. lnstall the header pipe with a new gasket, then tighten
A: From pump: 14 .mm wrench the new self-locking nuts and bolts.
38 N•m (3.8 kg-m, 28 lb-ft)
B: To oil cooler: 12 mm wrench CAUTION: Replace the exhaust gasket and self-
13 N·m (1.3 kg-m, 9 lb-ft) lockin,g nuts when you reinstall the pipe.
29 N·m (2.9 kg-m, 20 lb-ft)
0: To speed sensor: 12 mm wrench
13 N·m (1 .3 kg-m, 9 lb-ft)
34 N·m 13.4 kg-m. 25 lb-ft)
NOTE: Check the gearbox for leaks. 1 O. lnstall the header pipe bracket. Connect the 4P con-
nector to the oxygen sensor.
8. lnstall the splash guard.
4P CONNECTOR
GEARBOX SHIELD '

10N•m
n.o kg-m, 7 lb-ftl
11-88
11 . Reconnect the tie-rods to the steering knuckles,
tighten the ball joint nut to the specified torque, and
ínstall new cotter pins.
FRONT TIE-ROD
COTTER PIN
Bend the pin as shown.
44 N•m (4.4 kg-m, 32 lb-ft)
12. Fill the system:

e Fill the reservoir with new Honda Power Steering
Fluid.
e Start the engine and let it run at fast idle, then turn
the steering wheel from lock-to-lock severa! times
to bleed air from the system.
e Check the fluid again. and add more if necessary.
11-89
Rear Steering Gearbox
lllustrated lndex - - - - - - - - - - - - - - - - - - - - - - - - - - -
CAUTION:
e Do not apply torque of more than O. 1 kg-m (0. 72 lb-ftl to the offset shaft.
• Do not stñke the stroke rod.
e N e ver lo osen the offsét shaft screw and lock nut screw.
• Do not remove the gearbox cover.
e Use the special tool "Rear Steering Gearbox Center Lock Pin" when removing the rear steering gearbox. and leave it
intact except when the gearbox is inspected for function, etc.
• Also use the special tool "Rear Steering Gearbox Center Lock Pin" when removing the front or rear of the center
shaft.
e lf the rear steering gearbox .and center shaft are removed. care must be taken to reinstall them correctly. . .
e When installing the rear steering gearbox and center shaft. take care not to apply dírectional strain and twisting force.
to the rubber !>ection of the center bearing holder. Tighten the bolts in the.following order.,
1. Loosely tighten the flangé bolt CD.
· 2. Tighten the washer bolts ® to the specified torque.
CD
3. Tighten the bolts @ to the specified torque. 30 N·m
4. Tighten the flange bolt CD to the specified torque.
(3.0 ···~b-ñ)
(Tighten from the right side of the car by using a box-wrench)
5. Tighten the flange bolts@ to the specified torque.
CENTER BEARING
HOLDER
CENTER SHAFT
~
REAR STEERING
JOINT GUARO
@
~
.~
22 N•m
{2. 2 kg-m. 16 lb-ftl
@22 N·m
. (2.2 kg-m. 16 lb-ft)
~ STEERING JOINT
@j)l~ CENTER GUARO
STEERING JOINT
FRONT GUARO
REAR STEERING
GEARBOX
\1)39 N·m
JOINT GUARO CAP (3.9 kg-m. 28 lb-ft)
~·
1
OFFSET SHAFT
LOCK NUT SCREW
STROKE ROO
DUST COVER
11-90
Neutral Positioning Off-car - - - - - - - - - - - - - - - - - - - - - - - - .
1. Remove the cap bolt from the gearbox using a 4. Turn the offset shaft by hand to be certain that the
"TORX® BIT" T40. steering gear box is in the neutral position.
Red Mark Offset Shaft

Otherthan
Visible Movable
Neutral
Neutral Not visible locked
5. Slide the tie-rod boots away from the housing to

make sure the stroke rod is centered in the gearbox
housing.
2. Position the offset shaft so the cutout faces the

underside of the gearbox and the flat area faces the
top.
3. lnstall the special tool in the gearbox.
11-92
Stroke Rod Holders - - - - - - - - - - - - - - - - - - - - - - - - - .
NOTE: The stroke rod holders are used for the function 5. lnsert the tool betwen the tie-rod stopper washer
inspection and rear tie-rod replacement. and gearbox.
1. Set the gearbox in the neutral position (page 6. Remove the rear steering center lock pin from the
11-92). gearbox housing.
2. Loosen the tie-rod boot band, and slide the boot
away from the gearbox housing. 7. Tighten stroke rod holder B (Turn counterclockwise
to tighten).
NOTE: There should be no play between the

stroke rod holders and the gearbox housing.
STROKE ROO HOLDER B

07HAJ- 0300
3. Slide the special tool between the tie-rod stopper

washer and gearbox.
4. Screw the outer piece of the special tool onto the

inner piece; align the cutouts.
STROKE ROO
HOLDER B
07HAJ-SF1 0300
\ ¿=~::...
11-93
Function lnspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
Preload lnspection 3. lnstall the di~l indicator using a cap bolt.

1. Set the rear steering gearb?x to _neutral (page
NOTE: Set the dial indicator on the. flat end of the
11-92}.
special tool:
2. Remove the rear steering gearbox center lock pin.
4. lnstall the torque wrench in the special tool, then
3. lnstall the special tool in the offset shaft ..
read the dial gauge when applying a torque of 1 O
Up to 45° N·m (1.0 kg-m, 7 lb-ft) in the clockwise and
counterclockwise directions. respectively.
The tóial deflection range when applying a torque

of 10 N·m (1.0 kg--m, 7 lb-ftf in both directions
should be 5.0 mm (0.20 in) or less.
10 N•m (1.0 kg-m,

7 lb-ftl
4. lnstall á torque wrench in the special tool, and

check the starting torque when rotatíng the wrench
in the clockwise and counterclockwise directions.
Starting Torque: 1 N·m (0. 1 kg-m. O. 7 lb-ftl or less
NOTE:
• Check the torque after severa! rotations.
• Do not apply a torque of 5 N·m 10.5 !<.g-m, 4 lb-
ft) or more to the offset shaft.
Free-play lnspection
1. Set the · rear steering gearbox to neutral (page
11-92).
2. Remove the rear steering gearbox center lockpin
and install the stroke rod holders (page 11-93).
3. lnstall the special tool in the offset shaft.
Example: With a deflection of 2.50 mm (0.1 O in) in

the clockwise derection and 2.40 mm (0.09 in) in
the counterclockwise direction, the gearbox is OK.
NOTE: lf the total deflection is more than 5.0 mm

(0.20 in) replace the rear steering gearbox
assembly.
5. Remove the special tools, then screw in the cap

bolt and sealing washer into place.
Tightening Torque: 22 N·m {2.2 kg-m, 161b-ft)
11-94
Tie-Rod Replacement
CAUTION: Never strike the stroke rod. 7. lnstall the tie-rod stopper washer, tie-rod lock
washer and rack end on the stroke rod.
1. Set the gearbox in Neutral (page 11-92).
TIE-ROD STOPPER WASHER
2. Loosen the tie-rod boot band, and remove the dust Hold
sea l.
3. lnstall the stroke rod holders (page 11-93).
NOTE: Be sure to use the stroke rod holders so as

not to rotate or move the stroke rod in an axial
direction.
4. Straighten the tab of the lock washer.
STROKE ROO HOLDER Align tab with slot

07HAJ-SF10300B in stroke rod
55 N•m (5.5 kg-m, 40 lb-ft)

TIE·ROD CUP
8. Hold the stroke rod with the special tool {page

11-93}.
9. Bend the lock washer against the flat on the flange.
10. Remove the stroke rod holder.
11 . Reinstall the tie rod dust seal.

5. Remove the holder.
12. lnstall the boot bands.
6. While hoiding the stroke rod with a 21 mm wrench,
remove the tie-rod with a 1 7 mm wrench. NOTE: After tightening the boot bands, check that
the boots are not twisted or distorted.
CAUTION: Be sure to hold the stroke rod securely
to prevent it from being turned with the tie-rod. lnstall the boot bands as
Never turn the stroke rod.
BOOT BANDS
11-95
Off-set Shaft Dust Cover .- - - - - - . ,
Replacement
1. Remove the off-set shaft dust cover.
OFF-SET SHAFT DUST COVER
2. Grease the special tool and fit it over the off-set

shaft.
3. Pack the sealing lip of the dust cover with grease.
4. lnvert the inner end ot the dust seal, then place 'the
end over the lock nut.
5. Remove the special tool.
11-96
Special Tools
SpeciaiTools-----------------------------------------------------,
CD 07HGK -0010200 Wheel Alignment Gauge Attachment

® 07703-001 01 00 TORX® T40 BIT
Q) 07HAJ-SF1 0201 Rear Steering Center Lock Pin }4wS Only
@ 07HGJ-001 0000 Toe lnspection Gauge Set 1
® 07941 -6920003 Ball Joint Remover 1
® 07GAF-SD401 00 H ub Assembly Pin 1
(j) 07965-6340301 Hub Dis/assembly Base 2
® 077 49-001 0000 Driver 1
® 07965-6920201 Hub Dis/Assembly Base 1
@H 07HAF-SF10110 Ball Joint Remover Base
@-2 07HAF-SF10120 Ball Joint lnstaller Base
@)-3 07HAF-SF1 0130 Ball Joint Remover/lnstaller
(jJ) 07GAG-SD40700 Ball Joint Boot Clip lnstallation Guide
@ 07GAE-SE001 01 Spring Compressor
@ 07GAF-SD40330 Ball Joint Remover/lnstaller
@ 07947-SB00100 OiiSeal Driver 14WS Only
@ 07GAF-SE00200 Hub Assembly Guide Attachment
® Q) ®
F4
®
p
CJ 8
® @-1
g
@l-2
@ g @-3 (jJ)
e~=
@
@@®
.@®
t3 o @ @
tJ@
12-2
Component Location
lndex
ff•M·1dfi!§li The front and rear dampers contain nitrogen gas and oil under pressure. The pressure must be relieved before
disposal to prevent explosion and possible injury when scrapping.
Front Suspension:
UPPER ARM
O AMPER
Removal, page 12-24
KNUCKLE/HUB
Disassembly/lnspection,
Removal, page 12-17
page 12-24
Bearíng removal, page 12-18
Reassembly, page 12-26
lnstallatíon, page 12-26
Disposal, page 12-39
Rear Suspension:
OAMPER
Removal, page 12-38
D ísassembly/lnspection,
page 12-38
DisposaL page 12-39
KNUCKLE/HUB
Removal, page 12-31
Bearíng removal, page 12-32
12-3
Wheel Alignment
Two Wheel Steering-2WS - - - - - - - - - - - - - - - - - - - - - -
Preparation NOTE: Caster angle can be adjusted by increasing/decreas-
1. Check the tire pressure. íng the number of the adjustíng shims. Remove and install
the radius rod each time the caster angle is adjusted.
2. Check the steering wheel angle. lf significantly off 6. Raise the front end of the car and place safety stands
center, it may be necessary to remove the steering in the proper locations.
wheel and reposition it on the splines. Turn the
7. Remove the self-locking nut on the end of the radius
rod.
steering wheel to the straight-ahead position.
8. Remove the radius rod attaching bolts at the lower
arm, and radius rod.
3. Alignment should be checked/adjusted in one con- 9. Adjust the caster angle by increasing/decreasing the
tinuous procedure: caster, front camber, rear adjusting shims.
camber, rear toe, front toe and re-check. • One adjusting shim changes the caster angle by 25'
and the caster angle can be adjusted by 50' maxi-
Front Caster: mum.
e One adjusting shim is 3.2 mm (0. 126 in) in thick-
1. Remove the center cap or wheel cap. lnstall the Wheel ness.
Alignment Gauge Attachments on the wheels.
ADJUSTING SHIM
NOTE: Make sure the wheel hubs are clean and
rust-free before installing the wheel alígnment
attachments.
2. lnstall a camber/caster gauge on the Wheel Align-

ment Gauge Attachment and apply the front brake.
Turn the wheel 20° ínward.
3. Turn the adjust screw so that the bubble in the

caster gauge is at O 0 •
4. Turn the wheel 20° outward and read the caster on

the gauge with the bubble at the center of the
SELF·LOCKING NUT
gauge.
Re place.
44 N·m (4.4 kg-m. 32 lb-ft)
Caster Angle: 3°00' ± 1 o RADIUS ROO
WHEEL ALIGNMENT
GAUGE ATTACHMENT
NOTE:
07HGK-001 0200
e Do not use more than two adjusting shims.
e After the adjustment, tighten the self-locking nut to
the specified torque.
1 O. Recheck the caster angle .
. -'~·=
~
·-a:~~~~:;;:::>
#~~-::JI
CAMBER/CASTER
TURNING RADIUS GAUGE GAUGE
5. lf adjustment is required, record the caster reading,

then go to step 6. lf adjustment is not required, pro-
ceed to step 11 .
12-4
Front Camber: Toe:
11 . Return the steering wheel to the straight-ahead posi- 16. Check the rear toe-in.
tion.
Right Rear: 1 mm
Left Rear: 1 mm
12. Read the front camber on the gauge with the bubble at
the center of the gauge. Total: 2 ± 2 mm (0.08 ± 0.08 in)
Front Camber Angle: 0°00' ± 1° NOTE: Left and right toe should be the samé.
- lf adjustment is required, go to step 1 7.
13. lf out of specification, check for bent or damaged - lf no adjustment is required, proceed to step 20.
suspension components.
1 7. Hold the adjusting bolt on the rear lower arm A ánd
loosen the locknut.
18. Adjust the rear toe by turning the adjusting bolt un-
ti! toe is correct.
19. lnstall a new locknut and tighten while holding the
adjusting bolt.
AD.JUSTING
BOLT
WHEEL ALIGNMENT
GAUGE ATTACHMENT
07HGK-OO 10200
Rear Camber:
14. Read the rear camber on the gauge with the bubble at
the center of the gauge.
LOCKNUT
Rear Camber: -0°30' ± 1° 10 x 1.25 mm
55 N•m (5.5 kg-m, 40 lb-ft)
15. lf out of specification, check for bent or damaged
WHEEL ALIGNMENT
GAUGE ATTACHMENT
07HGK-0010200 (cont'dl
12-5
Wheel Alignment
Two Wheel Steering-2WS {cont'd) Four Wheel Steering-4WS - - - - -
20. Check. the front toe-in: · Using Toe lnspection Gauge:
Right Front: O mm
Left Front: O mm Preparation
Total: O ± 2 mm (0 ± 0.08 in)
1. Check the tire pressure.
- lf adjustment is required, go to step 21. 2. Remove the cap bolt from the rear steering gear-
- lf no adjustment is required, proceed to step 23. box, install the center lock pin in the rear steering
gearbox and determine the neutral position.
21 . loosen the tie-rod locknut and turn the tie-rod until
toe-in is correct.
22. After adjusting, tighten the tie-rod lock.nuts.
NOTE: Reposition the tie-rod boots if twisted or
displaced after adjustment has been made. ·
NEUTRAL
TI E-ROO
Red mark
neutral
;m.....,¡.-TORX® T 40 BIT
07703-0010100
REAR STEERING
CENTER LOCK PIN
07HAJ-SF10201
3. Check the steering wheel angle.

lf it is more than 13 mm (0.512 in) (4°) off center,
adjust it as follows:
45 N·m
(4.5 kg-m. 33 lb-ft)
OFF CENTER
23. Recheck the camber. lf camber still as specified 1} Remove the center lock pin from the rear steer-
alignment is finished. ing gearbox.
Front Camber Angle: 0°00' ± 1 o 2) l.oosen the steering wheel nut. IDo not remove
Rear Camber Angle: -0° 30' ± 1 o the steering wheel this time.)
3) lnstall the center lock pin in the rear steering
gearbox.
Turn the steering wheel right or left slightly until
the center lock pin seats fully. The red mark on
the pin should not be visible.
Do not turn the steering wheel quickly when the
center lock pin is seated and do not force past
the locking point after the pin is seted, or the
gearbox may be damaged.
4) Remove the steering wheel and reset it in the
position as close as to center.
5) Remove the center lock pin from the rear steer-
ing gearbox.
12-6
6) Tighten the steering wheel with a new steering NOTE: Caster angle can be adjusted by increasing/decreas-
wheel nut. ing the number of the adjusting shims. Remove and install
the radius rod each time the caster angle is adjusted.
TORQUE: 50 N·m (5.0 kg-m. 36 lb-ftl
6. Raise the front end of the car and place safety stands
NOTE: On steering wheel nut removal/installa- in the proper locations.
tion, be sure to remove the center fock pin from 7. Remove the self-locking nut on the end of the radius
the rear steering gearbox to prevent damage to rod.
the gearbox.
4. Place the car on level surface. 9. Adjust the caster angle by increasing/decreasing the
5. Release the parking brake. adjusting shims.
6. Move the car 1 m (3.28 ft.) forward and take off e One adjusting shim changes the caster angle by 25'
the slack in the bushing. and the caster angle can be adjusted by 50' maxi-
7. Turn the steering wheel to the straight-ahead posi- mum.
tion and hold it. e One adjusting shim is 3.2 mm (0.126 in) in thick-
ness.
8. Alignment should be checked/adjusted in one con-
tinuous procedure: caster, front camber, rear
NOTE:
camber, rear toe, front toe and re-check.
Front Caster: e After the adjustment, tighten the self-locking nut to
1. Remove the center cap or wheel cap. lnstall the Wheel
Alignment Gauge Attachments on the wheels. ADJUSTING SHIM
NOTE: Make sure the wheel hubs are clean and
rust-free before installing the wheel alignment
attachments.
ment Gauge Attachment and apply the front brake.
Turn the wheel 20° inward.
3. Turn the adjust screw so that the bubble in the
caster gauge is at 0°
gauge.
Caster Angle: 3°00' ± 1a
WHEEL ALIGNMENT SELF-LOCKING NUT RADIUS ROO
GAUGE ATTACHMENT Replace.
07HGK-0010200 44 N • m (4.4 kg-m, 32 lb-ft)
1O. Recheck the caster angle.
CAMBER/CASTER
TURNING RADIUS GAUGE GAUGE
5. lf adjustment is required, record the caster reading,

then go to step 6. lf adjustment is not required, pro-
ceed to step 1 1 . (cont'd)
12-7
Wheel Alignment
Four Wheel Steering-4WS (cont'd)
Front Camber: Toe:
11 . Return the steering wheel to the straíght-ahead posí- 16. lnstall the toe ínspectíon gauge set attachment on
tíon. each wheel and turn the wheel díameter adjusting
screws and tire diameter adjusting screw right or
12. Read the front camber on the gauge with the bubble at
left so that the attachment fits on the wheel disc
securely.
Front Camber Angle: 0°00' ± 1o
• Be sure that the tread compensation screw is on
1 3. lf out of specification, check for bent or damaged the front of the front wheel disc and on the rear
suspension components. of the rear wheel dísc.
TOE MEASUREMENT SCALE

TIRE DIAMETER
ADJUSTING SCREW
WHEEL ALIGNMENT
GAUGE ATTACHMENT
07HGK-0010200
Rear Camber: TREAD COMPENSATION

SCALE
14. Read the rear camber on the gauge wíth the bubble at
TREAD COMPENSATION SCREW
Rear Camber: -0°20' ± 1°
15. lf out of specificatíon, check for bent or damaged

suspensíon components.
• Align the center of the gauge with the center of
the wheel.
TIRE DIAMETER ADJUSTING SCREW
~
~
WHEEL ALIGNMENT
r
CAMBER/CASTER WHEEL DIAMETER AD.JUSTING SCREW
GAUGE ATTACHMENT . GAUGE
07HGK-OO 10200
12-8
• Set the toe inspection gauge on each wheel so 18. Attach the string to the bumper and secure with
that it makes right angle to the wheel. the hook A.
NOTE: Be sure that the toe gauge does not in- 1 9. Route the string around the car and secure with the
terfere with the balance weight of the wheel. hook B. Be sure that there is no slack in the string.
NOTE: Be sure that the string does not contact the

exhaust pipe.
TOE GAUGES
lP_._
HOOKA
HOOKA
17. Set the tread compensation sea le on the front
wheel at 52. 5 and on the rear wheel at 50.
FRONT WHEEL
Fiil52.5)
REAR WHEEL
=
Ff:"o' Secure the string;

there should be no
slack.
20. Hook the string on each tread compensation scale.
• Keep a slight clearance between the string and

toe gauge.
• Be sure that the toe gauge is parallel with the

ground.
~CE
(cont'd)
12-9
Wheel Alignment
Four Wheel Steering (4WS) (cont' d)
21 . Read the tread compensation scale and measure- Using Full-floating Turn Table:
ment scale and culculate their difference.
. Preparation
Measurement varíes according to the angle you
are looking. NOTE: Alignment equipment must be capable of 4
Read all the measurements at the same height. wheel alignment and must use full-floating turn-
tables at all four wheels.
• Check the side of the string that is closer to a
division of the tread compensatibn scale, and 1. Check the tire pressure.
read the measurement scale at the same side of 2. Jack up the car and temporarily place on safety
the string. stands.
3. lnstall the 4WS Center Lock Pin (see page 12-6).
• Toe of all wheels is zero if the measurements of lnstall lock pins in the full floating turntables.
the tread compensation scale and measurement
4. Lower the car . onto the turntables. Remove the
scale on each wheel are the same.
turntable lock pins and "settle" the suspension by
Giitt
FRONT WHEEL pushing the car up and down severa! times.
~
Remove the 4WS Center Lock Pin.
5. Check the steering wheel angle. lf significantly off
center, it may be necessary to remove the steering
wheel and reposition it on the splines (page 12-6).
Gm.:0r
Turn the steering wheel to the straight-ahead
position.
NOTE: lf the wheel removal is necessary, loasen
the nut, then temporarily reinstall the 4WS Center
Lock Pin before repositioning the wheel.
6. Alignment should be checked/adjusted in one con-

tinuous procedure: caster, front camber, rear
camber, rear toe, front toe and re-check.
22. Adjust so that the front toe and rear toe are O when Front Caster:
the front camber is 0° and rear camber -0° 20'. 1 . Remove the center cap or wheel cap. lnstall the Wheel
Alígriment Gauge Attachments on the Wheels.
23. After the front and rear toe are adjusted to zero, 'NOTE: Make sure the wheel hubs are clean and
loasen the right and left rear wheel tie-rods 60° rust-free befare installing the wheel alignment
and set the rear toe-in to 2 mm (0.079 in). attachment.
24. After adjusting, tighten the tie-rod locknuts. ment Gauge Attachment and apply the front brake.
Turn the wheel 20° inward.
or 3. Turn the adjust screw. so that the bubble in the
caster gauge is at 0°.
gauge.
Caster Angle: 3°00' ± 1 o
WHEEL ALIGNMENT
GAUGE ATTACHMENT ~<
07HGK-0010200 _.-- -
1j ~
25. Recheck the camber.

alignment is finished.
Front Camber Angle: 0° 00' ± 1 °

Rear Camber Angle: -0° 20' ± 1 o
12-10
5. lf adjustment is required, record the caster reading, Front Camber:
then go to step 6. lf adjustment is not required, 11 . Return the steering wheel to the straight-ahead posi-
proceed to step 1 O. tion.
NOTE: Caster angle can be adjusted by increasing/ 12. Read the front camber on the gauge with the bubble at
decreasing the number of the adjusting shims:. Remove the center of the gauge.
and instan the radius rod each time the caster angle is
adjusted. Front Camber Angle: 0°00' ± 1 o
6. Raíse the front end of the car and place safety stands 13. lf out of specification, check for bent or damaged
in the proper locations. suspension components.
7. Remove the self-locking nut on the end of the radius
rod.
9. Adjust the caster angle by increasing/decreasing the
adjusting shims.
e One adjusting shim changes the caster angle by 25'
and the caster angle can be adjusted by 50' maxi-
mum.
e One adjusting shim is 3.2 mm (0.126 in) in thick-
ness.
ADJUSTING SHIM
Rear Camber:
14. Read the rear camber on the gauge with the bubble at
SELF-LOCKING NUT Rear Camber: -0°20' ± 1 °

Re place. RADIUS ROO
44 N·m (4.4 kg-m. 32 lb-ft) 15. lf out of specification, check for bent or damaged
NOTE:
e After the adjustment, tighten the self-locking nut to
10. Recheck the caster angle.
·~
~
WHEEL ALIGNMENT
r
CAMBER/CASTER
GAUGE ATTACHMENT GAUGE
07HGK -00 10200
(cont'd)
12-11
Wheel Alignment
Four Wheel Steering-4WS (cont'd) - - - - - - - - - - - - - - - - - - - .
Toe: 19. Check the front toe-in:

16. Check the rear toe-in. Right Front : O mm
Right Rear : 1.5 mm Left Front : O mm
Left Rear : 1.5 mm Total : O ± 2 mm (0 ± 0.08 in)
Total : 3 ± 2 mm 10.12 ± 0.08 in)
NOTE: Left and right toe should be the same.
NOTE: Left and right toe should be the same.
- lf adjustment is required, go t step 20.
- lf adjustment is required, go to step 1 7. - lf no adjustment is required, proceed to step 21.
- lf no adjustment is required, proceed to step 19.
20. Loosen the tie-rod locknut and turn the tie-rod until
1 7. Loosen the tie-rod locknuts.
toe-in is correct.
18. After adjusting, tighten the tie-rod locknuts.
21. After adjusting, tighten the tie-rod locknuts.
displaced after adjustment has been made.
displaced after adjustment has been made.
TI E-ROO
55 N•m (5.5 kg-m. 40 lb-ft)
45 N·m (4.5 kg-m, 33 lb-ft)
22. Recheck the camber. lf camber still as specified

alignment is finished.
Front Camber Angle: 0°00' ± 1 o
Rear Camber Angle: -0° 20' ± 1 o
12-12
~~=~----~~~-----~~~0~
Bearing End Play
Rear Wheel End Play

Standard: 0-0 · O5mm
011111111
12-13
Wheel Measurements
Run out-------------------------,
Front and Rear Wheel Axial Run out
Standard:
Steel Wheel: o-1.0 mm
Aluminum Wheel: Q-0.7 mm
Front and Rear Wheel Axial Run out
Standard:
Steel Wheel: 0-1.0 mm
Aluminum Wheel: o-o. 7 mm
12-14
Front Suspension
Torque Specifications
CAUTION:
• Replace the self-locking nuts after removal.
• Replace the self-Jocking bolts if you can easily thread a non-self-locking nut past their nylon locking inserts.
(lf should require 1 N•m (0.1 kg-m, O. 7 lb-ft) of torque to turn the test nut on the bolt).
The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened.
NOTE: Wipe off the grease before tightening the nut at the ball joint.
FLANGE NUT SELF-LOCKING NUT

10 x 1.25 mm 10 x 1.25 mm
39 N•m (3.9 kg-m, 28 lb-ft) 30 N·m (3.0 kg-m, 22 lb-ft)
Replace.
FLANGE NUT
12 x 1.25 mm
65 N·m {6.5 kg-m. 47 lb-ft)
FLANGE NUT CASTLE NUT

10 x 1.25 mm
30 N•m (3.0 kg-m, 22 lb-ft)
NUT
8 x 1.25 mm
13 N•m (1.3 kg-m, 9 lb-ft)
SELF-LOCKING BOLT
10 x 1.25 mm
SELF-LOCKING BOLT 45 N·m (4.5 kg·m. 33 lb-ft)
12 x 1.25 mm
55 N•m {5.5 kg-m. 40 lb-ftl
SELF-LOCKING BOLT
12 x 1.25 mm
105 N•m {10.5 kg-m. 76 lb-ft)

12 x 1.25 mm 245 N·m (25 kg-m, 180 lb-ft)
44 N•m (4.4 kg-m. 32 lb-ft) Replace.
Replace. NOTE: After tightening, use a drift to
stake the spindle nut shoulder against
CALIPER MOUNTING BOLT
CASTLE NUT the spindle.
12 x 1.25 mm
110 N•m (11.0 kg-m. 80 lb-ft) 12 x 1.25 mm
55 N•m (5.5 kg-m, 40 lb-ft)
12-15
Front Suspension
Knuckle/Hub------------------------------------------------------
NOTE:
e Use only genuine Honda aluminum wheel weights. Non-genuine aluminum wheel weights may corrode and damage aluminum.
wheel.
e Remove the center cap by prying it out with a flat screwdriver. Avoid damage to the cap by not allowing it to fall during
removal. Use a rag at the point you are going to pry, because aluminum alloy wheels can be easily damaged.
CAUTION: Use a rag at the point you are going to pry, because aluminum alloy wheels can be easily damaged.
SELF-LOCKING BOLT
(NYLON INSERT)
10 x 1.25 mm
45 N•m (4.5 kg-m,
10 N•m
~(1.0 kg-m, 7 lb-ftl
12 x 1.25 mm
55 N•m (5.5 kg-m. 40 lb-ft)
SPINDLE NUT
24 x 1.5 mm
WHEEL BEARING
245 N·m (25 kg-m, 180 lb-ft)
Replace.
Replace.
NOTE: After tightening, use a drift to
FRONT HUB stake the spindle nut shoulder against
Check for damage or the spindle.
cracks.
Replacement,
page 12-19
BRAKE DISC
Check for wear or
rust.
Removal, page 12-18
lnspection, section 13.
FLANGE BOLT
10 x 1.25 mm
55 N·m (5.5 kg-m. 40 lb-ft)
WHEEL NUT
12x1.5mm
108 N•m (11.0 kg-m, 80 lb-ft)
12-16
Knuckle/Hub Replacement - - - - - - - - - - - - - - - - - - - - - - ,
1. Pry the spindle nut stake away from the spindle, then 6. Remove the cotter pin and the tie-rod ball joint nut.
loasen the nut.
7. Break toase the tie-rod ball joint using the special tool,
After tightening, use a then lift the tie-rod out of the knuckle.
drift to stake spindle nut
shoulder against the
CAUTION: Avoid damaging the ball joint boot.
driveshaft.
NOTE: lf necessary, apply penetrating type lubrican!

to loose the ball joínt.
BALLJOINT
REMOVER
07941-6920003
11
SPINDLE NUT
24 x 1.5 mm
245 N•m (25 kg-m, 180 lb-ft)
Replace.
2. loasen the wheel nuts slightly.
3. Raise the front of car and support on safety stands in On reassembly,

proper locations. BALL JOINT NUT (CASTLE NUT) bend the pin
44 N•m (4.4 kg-m, 32 lb-ft) as shown.
4. Remove the wheel nuts, wheel, and spindle nut.
8. Remove the cotter pin and loosen the lower arm ball
joint nut half the length of the joint threads.
5. Remove the caliper mounting bolts and hang the
caliper assembly to one side.
9. Separate the ball joint and lower arm using a puller
with the pawls applied to the lower arm.
CAUTION: To prevent accidental damage to the
caliper assembly or brake hose. use a short piece of
wire to hang the caliper assembly from the under-
carriage.
10 N·m (1.0 kg-m, 7 lb-ft)
BALL JOINT NUT

CALIPER MOUNTING BOLT (CASTLE NUT) 12 x 1.25 mm
110 N·m (11.0 kg-m, 80 lb-ft) 55 N·m (5.5 kg-m, 40 lb-ftl (cont'd)
12-17
Front Suspension
Knuckle/Hub Replacement ( c o n t ' d ) - - - - - - - - - - - - - - - - -
1 O. Pull the knuckle outward and remove the driveshaft Hub unit and Wheel bearing Removal
outboard joint from the knuckle using a plastic ham- 13. Remove-the knuckle from the hub unit.
mer.
11. Remove the cotter pin and the upper ball joint nut.
12. Break loose the upper ball joint using special tool.
14. Remove the splash guard screws from the knUckle.
SCREW
NOTE: lf necessary, apply penetrating type lubricant
to loasen the ball joint.
BALLJOINT
REMOVER
07941-6920003
BALL JOINT NUT

(CASTLE NUT} 10 x 1.25 mm
44 N·m {4.4 kg-m. 32 lb-ft)
12-18
15. Remove the four bolts, then separate the hub unit 17. Remove the outboard bearing inner race from the hub
from the brake disc. using the special tools shown and a bearing puller.
CAUTION: To prevent damage to the tool make

sure the threads are fully engaged befare pressing.
BE•~RiiNG PULLER HUB DIS/ASSEMBLY TOOL

07GAF-SE001 00
BRAKE DISC
16. Separate the wheel bearing from the hub using the FRONT HUB
special tools and a hydraulic press.
CAUTION:
e Hold onto the hub to keep it from falling when NOTE: Wash the knuckle and hub thoroughly in high
pressed clear. flash point solvent before reassembly.
e To prevent damage to the tool make sure the
threads are fully engaged before pressing.
WHEEL BEARING HUB DÍS/ASSEMBLY TOOL

07GAF-SE001 00
(cont'd)
12-19
Front Suspension
Knuckle/Hub Replacement (cont'd) - - - - - - - - - - - - - - - - - - - ,
Wheel bearing and Hub unit lnstallation. 20. lnstall the splash guard and tighten the screws.
NOTE: Replace the bearing with a new one after 10 N·m

re m oval. 11.0 kg-m, 7 lb-ft)
18. Press a new wheel bearing into the hub using the
special tools shown and a hydraulic press.
CAUTION: To prevent damage to the tool make

sure the threads are fully engaged before pressing.
DRIVER HUB ASSEMBLY GUIDE

07749-0010000 ATTACHMENT
07GAF-SE00200
HUB DIS/
ASSEMBLY
TOOL
07GAF-
SE00100
21. lnstall the knuckle on the hub unit and tighten the
HUB 015/ASSEMBLY BASE bolts.
07965-6920201
19. lnstall the hub unit on the brake disc and tighten the
bolts.
12-20
Lower Ball Joint Replacement Ball Joint Boot Replacement
1. Remove the knuckle (page 12-17). Jolt the ball pin and back and forth check the ball joint for
wear. Replace the ball pin if it worn excessively.
2. Remove the boot by prying the circfip off. 1. Remove the cirCÍip and the boot.
CAUTION: Do not contaminate the boot installation
3. Remove the 40 mm circlip. section with grease.
2. Pack the interior of the boot and lip with grease.
4. lnstall the special tool on the ball joint and tighten the
ball joint nut.
BALL PIN TAPERED SECTION
5. Position the special tool over the ball joint as shown
then set the assembly in a vise. Press the ball joint out LIP
of the knuckle.
BALL JOINT REMOVER/INSTALLER

07HAF-SF10110
. ---.
BOOT INSTALLATION SECTION
BOOT INSTALLATION
SECTION
3. Wipe the grease off the sliding surface of the ball pin
and pack with fresh grease.
BALL JOINT REMOVER BASE CAUTION:
07HAF-SF10130 e Keep grease off the boot installation section and
the tapered section of the ball pin.
e Do not allow dust, dirt, or other foreign materials
to enter the boot.
6. Place the ball joint in position by hand. 4. lnstall the boot in the groove of the boot installation
section securely, then bleed a ir.
7. Jnstall the special tools over the ball joint as shown, 5. Adjust the special tool with the adjusting bolt until the
then press the ball joint in. end of the tool aligns with the groove on the boot.
6. Slide the clip over the tool and into position.
BALL JOINT REMOVER/

INSTALLER BALLJOINT ADJUSTING BOLT
07HAF-SF1 011 O BOOT CLIP Adjust the depth by
BALL JOINT INSTALLER BASE
GUIDE turni ng the bolt.
07HAF-SF10120
07GAG-SD40700
Ball joint housing

surface.
40 mm CIRCLIP
CAUTION: After installing the boot, check the ball

pin tapered section for grease contamination and
8. lnstall the 40 mm circlip.
wipe it if necessary.
12-21
Front Suspension
lllustrated lndex
Overall Suspension
CAUTION:
e Replace the self-locking nuts after removal.
e Replace the self-locking bolts if you can easily thread a non-self locking nut past their nylon locking inserts.
(lf should require 1 N•m (0.1 kg-m, O. 7 lb-ft) of torque to turn the test nut on the bolt).
NOTE:
e Wipe off the grease before tightening the nut at the ball joint.
e Torque specifications, see page 12-1 5.
STABILIZER BAR
Check for bending or
damage.
~ ARM ASSEMBLY
RAOIUS ROO RUBBER

BUSHING A
Check for deteríoration
or damage.
- !!jiifté
SILICONE
GREASE
~ 1 M,_--::7 STABILIZER ENO
~~
@..'\\\\~7',_/_!~~~~~;E~:BOLT\
IBLUE) / \
RUBBER BUSHINGS
Check for deteríoratíon
or damage.
RAOIUS ROO RUBBER \

BUSHING B
Check for deteríoratíon
or damage.
1 1 - r¡¡¡;;;,
SILICONE
GREASE
BALL JOINT BOOT
RAOIUS ROO WASHER Check for deteríoratíon
FRONT LOWER ARM
or damage.
')<:RONT RAOIUS ROO, Check for damage.
SILICONE
GREASE
~OAMPER PINCH BOLT
>~
jY {SELF-LOCKING BOLTI
Check for deterioration

or damage .
... !!jiifté ----OAMPER

SILICONE FORK BOLT
GREASE
OAMPER FORK
NOTE: RUBBER BUSHING
Adjust the caster angle by increasing/decreasing the adjust- Check for deterioratíon
ing shíms (page 12-4). or damage.
CAUTION: Do not interchange the radius rod rubber
bushings. The thick bushing should be installed in front ... s;;,l
position. SILICONE
GREASE
12-22
Upper Arm Ball Joint lnspection
1. Loosen the front wheel lug nuts.
2. Raise the front end of the car and place safety stands
in the proper locations.
3. Remove the front wheels.
4. Rock the upper ball joint front-to-back.
5. Replace the upper arm assembly as follows if there is

any play.
12-23
Front Suspension
Damper Removal Damper Disassembly/lnspection
1. Remove the brake hose clamps from the damper. 1. Compress the damper spring with the spring compres-
sor according to the manufacturer's instructions, then
2. Remove the damper pinch bolt. remove the self-locking nut.
3. Remove the damper fork bolt and remove the damper CAUTION: Do not cornpress the spring more than
fork. necessary to rernove the nut.
BRAKE HOSE
CLAMPS
SELF-
LOCKING NUT
DAMPER
PINCH BOLT
ISELF-LOCKING
BOLT)
10 x 1.25 mm
2. Remove the spring compressor then dísassemble the

damper as shown on the next page.
lnspection:
4. Remove the damper by removing the three flange 1. Reassemble all parts, except the spring.
nuts.
2. Push on the damper assembly as shown.
O AMPER 3. Check for smooth operation through a full stroke, both

FLANGE NUT 10 x 1.25 mm ASSEMBLY compression and extension.
NOTE: The damper should move smoothly. lf it does

not (no compression or no extension), then gas is
leaking, and the damper should be replaced.
NEEDS
NORMAL REPLACEMENT "f"~"=i"''----''---
o X
t•
1 ' ••
•
Wood
block
4. Check for oil leaks, abnormal noises or binding during

these tests.
12-24
lnspection
SELF-LOCKING NUT
10 x 1.25 mm
¡
30 N•m (3.0 kg-m, 22 lb-ft)
OAMPER MOUNTING WASHER

DAMPER MOUNTING Check for weakness.
DAMPER SPRING
RUBBER Check for weakness,
compression or damage.
~ ~ER STOP PLATE
FLANGE NUT
10 x 1.25 mm OUST COVER PLATE
'"':. BUMP STOP
Check for weakness or
damage.
~ ~
39 N·m (3.9 kg-m,
28 lb-ft)
~
.
e
. .
.
. e
DAMPER MOUNTING
1
BASE DAMPER MOUNTING
RUBBER
SPRING MOUNTING RUBBER

Check for damage.
DUST COVER
Check for bending or damage. DAMPER UNIT
• Check for leaks and
faulty operation.
• Check for rust.
12-25
Front Suspension
Damper Reassembly --------... Damper lnstallation - - - - - - - - .
1. lnstall the damper unit, damper spring, bump stop, 1. Loosely install the damper on the trame with the
boot, upper spring seat, damper bushings, and collar aligning tab facing inside.
on the spring compressor.
39 N•m (3.9 kg-m, 28 lb-ftl
.¡
ALIGNING TAB
2. lnstall the damper fork on the driveshaft and lower

arm. lnstall the damper in the damper fork so the
aligning tab is aligned with the slot in the damper fork.
3. Hand tighten the bolts and nuts.
4. Raise the knuckle with a floor jack until the car just lifts
off the safety stand.
SPRING COMPRESSOR NOTE: The bolts and nuts should be tightened with the
07GAE-SE001 01 vehicle's weight on the damper.
10 N•m
(1.0 kg-m. 7 lb-ft)
NOTE: Left side shown, right side is opposite.
3. Compress the damper spring.
4. lnstall the damper mount washer and a new self-

locking nut 1 O mm.
5. Hold the damper shaft and· tighten the 10 mm self-

locking nut.
44 N·m (4.4 kg-m, 32 lb-ftl
5. Tighten the damper pinch bolt.
6. Secure the damper fork bolt with a new 12 mm nut.
7. Secure ihe damper assembly to the frame wíth the

flange nuts.
8. lnstall the brake hose clamps with. the two,.bolts.
1.2-26
Rear Suspension
Torque Specifications-4WS---------------------
CAUTION:
e Replace the self-locking nuts aher removal.
e Replace the self-locking bolts if you can easily thread a non-self-locking nut past nylon locking inserts.
(lf should require 1 N ·m (0. 1 kg-m, O. 7 lb-h) of torque to turn the test nut on the bolt).
30 N•m (3.0 kg-m. 22 lb-ft)
39 N•m {3.9 kg-m, 28 lb-ft)

65 N·m (6.5 kg-m, 47 lb-ft)
Replace.
SELF-LOCKING NUT
10 x 1.25 mm
30 N•m (3.0 kg-m, 22 lb-ft)
Replace.
SELF-LOCKING NUT SELF-LOCKING NUT

12 x 1.25 mm 10 x 1.25 mm
65 N·m (6.5 kg-m, 30N•m
47 lb-ft). (3.0 kg-m. 22 lb-ft)
Replace. Replace.
SELF-LOCKING NUT
22 N•m {2.2 kg-m, 16 lb-ft)
Replace.
SELF-LOCKING BOLT
12 x 1.25 mm
65 N·m
{6.5 kg-m. 47 lb-ft)
Replace.
SELF-LOCKING BOLT
12·x 1.25 mm
65 N•m {6.5 kg-m. 47 lb-ftl
SELF-LOCKING BOLT 22 x 1.5 mm

12x1.25mm 185 N·m (18.5 kg-m. 1341b-ftl
65 N·m (6.5 kg-m. 47 lb-ft) Replace.
SELF-LOCKING BOLT
12 x 1.25 mm
65 N•m (6.5 kg-m. 47 lb-ft) 55 N·m (5.5 kg-m, 40 lb-ft)
12-27
Rear Suspension
Torque Specifications-2WS - - - - - - - - - - - - - - - - - - - - -
CAUTION:
e Replace the self-locking nuts after remova!'.
e Replace the self-locking bolts if you can easily thread a non-self-locking nut past their nylon locking inserts.
(Jf should require 1 N•m (0.1 kg-m. O. 7 lb-ft) of torque to turn the test nut on the bolt).
30 N•m (3.0 kg-m, 22 lb-ft}
39 N•m (3.9 kg-m, 28 lb-ftl
39 N·m (3.9 kg-m, 28 lb-ft)
SELF-LOCKING NUT
10 x 1.25 mm
36 N•m
(3.6 kg-m, 26 lb-ft)
55 N•m (5.5 kg-m, 40 lb-ft)
55 N•m 15.5 kg-m. 40 lb-ftl
22 x 1.5 mm
185 N·m (18.5 kg-m. 134 lb-ft)
SELF-LOCKING BOLT Replace.
8 x 1.25 mm 10 x 1.25 mm
13 N·m (1.3 kg-m, 91b-ft) 55 N·m
Replace. 15.5 kg-m. 40 lb-ft)
Replace.
SELF-LOCKING NUT
65 N•m (6.5 kg-m. 47 lb-ft) 12 x 1.25 mm
SELF-LOCKING NUT 65 N•m (6.5 kg-m. 47 lb-ft)
10 x 1.25 mm Replace.
36 N·m (3.6 kg-m, 26 lb-ft)
Replace.
12-28
CASTLE NUT
44 N•m (4.4 k g-m. 32 lb-ft)
KNUCKLE
10 N·m {1 · O kg-m
7 lb-ft) •
~45 N•m (4.5 k
g-m, 33 lb-ft)
SPINDLE
Check for crackin
O'dom•g•~
SPLASH GUARO
REAR WHEEL ~CASTLENUT

HUB UNIT el / 55 N·m (5.5 k g-m. 4 0 lb-ft)
Check for crackin
or damage. 9
WHEELN/
12x1.5mm
108N·m(11 k g-m • 80 lb-ft)
12-29
Rear Suspension
lndex-2VVS------~----------------------------------------------
CASTLE NUT
44 N•m (4.4 kg-m, 32 lb-ftl
~· 1~
9 N·m (0.9 kg-m, 7 lb-ft) ~~ ~
KNUCKLE
PROTECTOR
SPINDLE NUT
185 N•m (18.5 kg-m, 1341b-ft)
Re place.
NOTE: After tightening, use a drift REAR WHEEL
punch to lock the spindle nut shoulder HUB UNIT
into the spindle. Check for cracking
or damage.
BRAKE DRUM
BRAKE SHOES ASSEMBLY
HUB UNIT CAP CASTLE NUT

44 N·m
. . . 14 4 kg-m: 32 I~O\' ---"'
9 N•m (0.9 kg-m. 7 lb-h) ~i11l:: .

KNUCKLE
PROTECTOR
REAR WHEEL
HUB UNIT
Check for cracking
SPINDLE NUT or damage.
185 N·m (18.5 kg-m. 1341b-ft)
Replace.
NOTE: After tightening, use a drift
punch to lock the spindle nut shoulder
into the spindle.
HUB UNIT CAP SPLASH GUARO
~· Check for wear or

rust.
12-30
Knuckle/Hub Replacement-4WS -----------------~
1. Pry the spindle nut stake away from the spindle, then
loosen the nut.
7.
•
Remove the 6 mm brake disc retaining screws.
8. Screw two 8 x 1 .O mm bolts into the disc to push it

away from the hub.
SPINDLE NUT
22 x 1.5 mm
185 N•m (18.5 kg-m, 1341b-ft) NOTE: Turn each bolt two turns ata time to prevent
Replace. cocking disc excessively.
NOTE: After tightening, use a drift
punch to stake the spindle nut shoulder
~'"'' "" 'Piodlo.
RETAINING
SCREW
2. Loosen the wheel nuts slightly.

BRAKE DISC
3. Raise the front of car and support on safety stands in
proper locations. 8 x 1.0 mm BOLT
4. Remove the wheel nuts, wheel, and spindle nut.

9. Remove the hub bearing unit.
5. Remove the caliper bolts and hang the caliper assem-
1 O. Remove the splash guard screws from the knuckle.
bly to one side.
CAUTION: To prevent accidental damage to the

caliper assembly or brake hose, use a short piece of
wire to hang the caliper assembly from the under-
carriage.
6. Remove the caliper mounting bracket.
39 N•m (3.9 kg-m, 28 lb-ft)

BRAKE HOSE \
J
1
27 N·m (2.7 kg-m, 20 lb-ft)
(cont'd)
12-31
Rear Suspension
Knuckle/Hub Replacement-4WS (cont'd) - - - - - - - - - - - - - - . . . . . ,
11 . Remove the cotter pin from the tie-rod end and 15. Remove the cotter pin and the upper ball joint nut.
remove the castle nut. 16. Break loose the upper ball joint using the special tool,
12. Break loose the tie-rod ball joint usíng the special tool, then remove the knuckle.
then lift the tie-rod out of the knuckle.
CAUTION: Avoid damaging the ball joint boot. NOTE: lf necessary, apply penetrating type lubricant
to loosen the ball joint.
BALL JOINT REMOVER CAUTION: Avoid damaging the ball joint boot.
07941-6920003
PIN
On reassembly,
PIN
Re place. bend the pin as shown.
13. Pry the cotter pin off and loosen the lower arm ball
joint nut half the length of the joint threads. BALL JOINT NUT Replace.
(CASTLE NUT)
14. Separate the ball joint and lower arm using a puller 44 N•m (4.4 kg-m, 32 lb-ft)
with the pawls applíed to the lower arm.
17. Remove the spindle from the knuckle.
Hang puller
pawls on lugs
on lower arm.
45 N•m (4.5 kg-m, 33 lb-ft)

PIN
PIN BALL JOINT NUT

Replace. 18. lnstall in the reverse order of removal. Tighten the new
(CASTLE NUT)
55 N·m (5.5 kg-m, 40 lb-ft) spindle nut to specified torque, then stake the nut.
12-32
Hub Bearing Unit Replacement
-2WS
Upper Arm Ball Joint Removal
-2WS
•
1. Raise the rear of car and support it with safety stands 1. Remove the cotter pin and loasen the upper ball joint
in proper locations. nut half the length of the joint threads.
2. Remove the rear wheel.
3. Remove the brake drum. 2. Position the special too! between the knuckle and
Rear Disc Brake: upper armas shown, and remove the knuckle from the
- Remove the rear brake caliper and brake disc. upper arm.
4. Remove the hub unit cap, then pry the spindle nut lock
tab away from the spindle and loasen the nut. CAUTION: Avoid damaging the ball joint boot.
5. Remove the hub bearing unit.
BALL JOINT:
REMOVER
07941-6920003 KNUCKLE
í
HUB BEARING
UNIT
BALL JOINT NUT

(CASTLE NUT)
10 x 1.25 mm
44 N·m {4.4 kg-m,
32 lb-ft)
SPINDLE ___,@ ~
WASHER ~
PIN
Replace.
On reassembly,
bend the pin
as shown.
SPINDLE NUT BRAKE DRUM

22 x 1.5 mm
185 N•m (18.5 kg-m, 1341b-ftl
Replace.
NOTE: After tightening, use a drift to
stake the spindle nut shoulder against
the spindle.
6. lnstall in the reverse order of removal. Tighten the new

spindle nut to specified torque, then stake the nut.
12-33
Rear Suspension
lower Ball Joint Replacement ---, lower Ball Joint Boot-----...,
-4WS Replacement-4 WS
1. Remove the knuckle (page 12-31). 1. Remove the circlip and the boot.
CAUTION: Do not contaminate the boot installation
2. Remove the boot by prying the snap ring off. section with grease.
2. Pack the interior of the boot and lip with grease.
3. Remove the 40 mm circlip.
BALL PIN TAPERED

4. lnstall the Ball Joint Remover/lnstaller on the ball joint
SECTION
and tighten the ball joint nut.
5. Position the Ball Joint Remover Base over the ball joint
as shown below, then place the assembly in a vise.
Press the ball joint out of the knuckle.
BALL JOINT REMOVER/INSTALLER

07HAF-SF10110
BOOT INSTALLATION
SECTION
3. Wipe the grease off the sliding surface of the ball pin
and pack with fresh grease.
CAUTION:
• Keep grease off the boot installation section and
the tapered section of the ball pin.
• Do not allow dust, dirt, or other foreign materials
BALL JOINT REMOVER BASE to enter the boot.
07HAF-SF10130
4. lnstall the boot in the groove of the boot installation
section securely, then bleed air.
5. Adjust the special tool with the adjusting bolt until the
6. Place the· new ball joint in position by hand. end of the tool aligns with the groove on the boot.
Slide the clip over the tool and into position.
7. lnstall the Ball Joint lnstaller Base over the ball joint as
shown below, then press in the ball joint.
f-.___,_.,_......-- ADJUSTlNG BOLT
Adjust the depth by
turning the bolt.
BALL JOINT
REMOVER/INSTALLER
BALLJOINT
07965-SB001 00
BOOT CLIP
GUIDE
07GAG-SD40700
CIRCLIP
BALLJOINT
INSTALLER BASE
07HAF-SF10120
CAUTION: After installing the boot. check the ball
pin tapered section for grease contamination and
wipe it if necessary.
12-34
Upper Arm/Stabilizer/Trailing Arm/Lower Arm
lndex/lnspec~on4WS-~~~~~~~~~~~~~~~~~~~~-
Overall Suspension
NOTE:
e Use only genuine Honda aluminum wheel weights. Non-genuine aluminum wheel weights may corrode and damage aluminum
~~- .
e Remove the center cap. by prying it out with a flat screwdriver. Avoid damage to the cap by not allowing it to fall during
removal.
e Torque specifications, see page 12-27.
OFF-CENTER STABILIZER SPRING

CAM Check for bendíng or
NOTE: lnstall the off-center cam damage.
with the -12 o'clock" point of the
dial facíng straight up as shown.
STABILIZER BUSHINGS
Check for deterioration or
lnspect for faulty movement

of ball joínt.
LOWER ARM
Check for damage.
or damage.
Check for damage. Check for

deterioratíon
or damage. BUSHINGS
Check for deterioration or
TRAILING ARM
damage.
BUSHING
Check for deteríoration
Check for damage.
or damage.
12-35
Upper Arm/Stabilizer/Trailing Arm/Lower Arm
lndex/lnspection-2WS - - - - - - - - - - - - - - - - - - - - - - -
Overall Suspension
NOTE:
e Use only genuine Honda aluminum wheel weights. Non-genuine alliminum wheel weights may corrode and damage aluminum
wheel.
e Remove the center cap by prying it out with a flat screwdriver. Avoid damage to the cap by not allowing it to fall during
removal.
e Torque specífications, see page 12-28.
CAUTION:
e Use a rag at the point you are going to pry, because aluminum alloy wheels can be easily damaged.
e Lower arms A and B are interchangeable from side to side. Make sure their left and right side marks ( D L. UP. DR. UP)
are facing up for assembly.
OFF-CENTER
) STABILIZER BAR
CAM
NOTE: lnstall the off-center cam
"'¡ Check for bending
with the "12 o'clock" point of the J ~ or damage.
dial facing straight up as shown.
STABILIZER BUSHING
or damage.
UPPER INNER BUSHING

or damage.
-..~-r.:..._ ___ STABILIZER

BUSHING
Check for damage. or damage.
lnspect for faulty movement

of ball joint.
Check for damage.
TRAILING ARM
Check for damage.
LOWER ARM BUSHING

or damage

or damage. LOWER ARM B
Check for bending
or damage.
LOWER ARMA
Check for bending
or damage.
12-36
Bushing Replacement
Knuckle Bushing lower Arm Bushings
Removal: BALLJOINT 1lower Arm A/ lower Arm B)
REMOVER/INSTALLER Instan the bushingsso that 8.5 ± 0.5 mm (0.34 ± 0.02 in)
07GAF-SD40330 protrudes from the /ower arm A or B as shown.
Removal:
LOWER ARM
studs first.
KNUCKLE
1nstallation: lnstallation:
Hydrau!íc press.
Oll SEAL DRIVER 8.5 ± 0.5 mm (0.34 ± 0.02 in)
07947-5800100
8.5 ± 0.5 mm (0.34 ± 0.02 in)
Align
KNUCKLE
LOWER ARM A or B
12-37
Rear Suspension
Damper Removal Damper Disassembly/lnspection
1. Jack up the rear of car and support on safety stands in Disassembly:

proper locations. 1 . Compress the damper spring with the spring compres-
sor according to the manufacturers instructions.
2. Remove the rear wheel.
CAUTION: Do not compress the spring more than
3. Remove the trunk side garnish. necessary to remove the 1 O mm flange nut.
4. Remove the damper mounting nuts. 2. Remove the 1 O mm flange nut from the damper
assembly.
FLANGE NUT
10 x 1.25 mm
SPRING COMPRESSOR
07GAE-SE001 01
5. Break loase the upper ball joint (4WS: page 12-32,

2WS: page 12-33). 3. Remove the spring compressor and disassemble the
damper as shown on page 12-40.
6. Remove the bolt fixing the brake hose to the damper
assembly. lnspection:
1 . Reassemble all parts, except the spríng.
7. Remove the damper mountíng bolt.
2. Push on the damper assembly as shown.
8. Depress the entire suspension, then remove the 3. Check for smooth operation through a full stroke, both
damper assembly. compression and extension.
NOTE: The damper should move smoothly.

lf it does not (no compression or no extension). then
gas is feaking, and the damper should be replaced.
NEEDS
NORMAL REPLACE-
MENT
o X
t•
BRAKE
HOSE
1• •••
Wood
block
4. Check for oilleaks, abnormal noises or binding during

these tests.
12-38
Rear Suspension
lnspection----------------------------------------------------------1
FLANGE NUT
10 x 1.25 mm
30 N·m (3.0 kg-m. 22 lb-ftl
DAMPER SPRING
DAMPER Check for weakened
MOUNTING compression or damage. BUMP STOP
WASHER
PLATE
~
~
= DAMPER
DAMPER ~~~ ~ MOUNTING
MOUNTING RUBBER @ COLLAR
~/
[j) i}- BUMPSTOP
Check for weakness
or damage.
O AMPER
MOUNTING SEAL
~
Check for
deterioration or
damage.
SPRING SEAT RUBBER
Check for damage
or cracks.
DAMPER (2WS Only)
MOUNTING BASE
~
DAMPER MOUNTING
NUT
BUMP STOP___.,...
10 x 1.25 mm
PLATE
39 N·m (39 kg-m, 28 lb-ftl
SPRING MOUNTING
RUBBER
Check for damage
or crack.
DUST COVER
SLEEVE
DAMPER UNIT
Check for oil leak
FLANGE BOLT
or faulty operation.
10 x 1.25 mm
55 N•m
(5.5 kg-m, 40 lb-ft)
12-40
Reassembly lnstallation
1. lnstall the damper unit on a spring compressor. 1. Lower the rear suspension and set the damper assem-
2. lnstall the spring seat rubber, bump stop, bump stop bly in its original position.
plate, dust cover sleeve, damper spring, bump stop
plate, damper mounting collar, damper mounting rub-
ber, spring mounting rubber and damper mounting
base on the damper unit.
3. Compress the damper spring.
1
~SPRING
COMPRESSOR
/
BRAKE
07GAE-SE001 01 HOSE
2. loosely install the damper mounting bolts.

CAUTION: lnstall the damper mounting base so
that the angle of the stud bolts is as shown.
3. Raise the rear suspension with a floor jack until the
weight of the car is on the damper.
Left síde Right side
4. Reconnect the upper arm to the knuckle, tighten the
ball joint nut to the specified torque, and install the
new cotter pin.
5. Loosely install the damper mounting nuts.

NOTE: The bolts and nuts should be tightened with the
damper under vehicle load.
39 N•m (3.9 kg-m, 28 lb-ftl
2WS: 44°10' ± 3° 2WS: 44°10' ± 3°

4WS: 17°00' ± 3° 4WS: 17°00' ± 3°
4. lnstall the damper mounting rubber and damper

mounting washer, and loosely install a new 1 O mm
self-locking nut.
5. Hold the damper shaft and tighten the 1 O mm flange
nut.
(cont'd)
12-41
Special Tools
SpeciaiTools--------------------------------------------------~
Ref. No. Tool Number Description Q'ty Page Reference .
CD 07HAE-SG001 00 Brak_e Spring Compressor 13-25, 13-26, 13-27'

13-28, 13-29 -
® 07GAG-SE001 00 Push rod Adjustment Gauge- 1 3-1 7' 1 3-1 8
® 07914-SA50000 Snap Ring Pliers 1 13-26, 13-29
® 07973-SA50000 Rear Caliper Guide 1 13-25, 13-28
® 07921-0010001 Fiare nut wrench 1 13-38
® 07LAF-SM40200 Brake spring installer 1 13-33, 13-35
(J) 07410-5790100 Pressure Gauge Attachment 2 . 13-16
® 07510-6340100 Pressure Gauge Joint Pipe 1 13-16
® 07HAK-SG00110 Pressure Gaúge Joint Pipe 1 - 13-16
@J 07 51 0-6340300 Vacuum Joint Tube A 1 13-16'
([j) 07 404-5790300 Pressure Gauge Attachment 2 13-16
@ 07410-5790500 Tube Joint Adaptar 1 13-16
@ 07 406-5790200 Pressure Gauges 2 13-16
CD @
® ® ®®
13-2
Brake
lllustrated l n d e x - - - - - - - - - - - - - - - - - - - - - - - - -
BRAKE BOOSTER BRAKE PEDAL

Do not disassemble Pedal Height Adjustment, page 13-4
Testing, page 13-16 Brake .Light Switch Adjustment, page 1 3-4
Pushrod Adjustment, page 13-17
Pushrod Clearance Adjustment, page 13-1 7
MASTER CYLINDER
lndex, page 13-11
Overhaul/lnspection, page 1 3-12
Disassembly, page 13-13 BRAKE HOSES/PIPES
Reassembly, page 1 3-14 lnspection, page 13-36
Brake Hoses Replacement,
page 13-38
FRONT BRAKES lnspection, page 13-19

lnspection, page 13-5 Brake Pad lnspection/Raplacement, page 1 3-21
Brake Pad lnspectíon/Replacemant, page 13-6 Braka Caliper Disassembly, page 1 3-24
Brake Caliper Disassembly/ Brake Caliper Reassambly, paga 13-27
Reassembly, page 1 3-7 BRAKE SHOES
Braka Disc lnspectíon, page 13-9 lndax and lnspection, page 13-31
Bleeding, page 13-1 O lnspaction, page 13-32
Disassambly, page 13-33
Reassembly, paga 13-34
PARKING BRAKE
Adjustmant, page 13-4
Disassembly and Reassembly, page 13-39
13-3
Pedal Height Parking Brake
Adjustment Adjustment - - - - - - - - - - . . ,
1. Loasen the brake light switch locknut and back off the NOTE: After rear brake caliper servicing, loasen the
brake light switch until it is no longer touchirig the parking brake adjusting nut, start the engine and
brake pedal. depress the brake pedal severa! times to set the self-
adjusting brakes befare adjusting the brake pedal.
· PUSHROD
LOCKNUT
Pt!d.l;l@fiN Block the front wheels before jacking up
the rear of the car.
1. Raise the rear wheels off the ground.

2. Make sure the lever of the rear brake caliper con-
tacts the brake caliper pin.
PEDAL PLAY
1-5 mm (0.04-0.20 in)
PEDAL HEIGHT:
MANUAL TRANSMISSION: 190 mm (7.5 in.)
AUTOMATIC TRANSMISSION: 195 mm (7.7 in.)
Measure without floormat.
2. Loasen the pushrod locknut and screw the pushrod in

or out with pliers until the pedal height from the floor
is properly adjusted. After adjustment, tighten the
locknut firmly.
Lower the pedal
3. Pull the parking brake lever up one notch.

4. Tighten the adjusting nut until the rear wheels drag
slightly when turned.
5. Release the parking lever and check that the rear
wheels do not drag when turned. Readjust if
3. Screw in the brake light switch until its plunger is fully necessary.
depressed (threaded end touching pad on pedal arm).
6. With the equalizer properly adjusted, the rear
Then back off switch 1 /2 turn and tighten locknut
brakes should be fully applied when the parking
firmly.
brake lever is pulled up 4 to 8 clicks.
CAUTION: Check that the brake lights go off when
the pedal is released.
NOTE: After adjusting the pedal height, check for

ADJUSTING NUT
cruise control operation.
13-4
Front Brakes
lnspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Do not use an air hose to blow the brake • Before reassembling, check that all parts are
assembly clean. Use an OSHA-approved vacuum free of dust and other foreign particles.
cleaner, to avoid breathing brake dust. • Replace parts with new ones whenever
specified todo so.
CAUTION: • Make sure no dirt or other foreign matter is
• Do not spill brake fluid on the car; it may damage allowed to contaminate the brake fluid.
the paint; if brake fluid does contact the paint, • Do not mix different brands of brake fluid as
wash it off immediately with water. they may not be compatible.
• To prevent spills, cover the hose joints with rags • Do not reuse the drained fluid.
or shop towels.
• Clean all parts in brake fluid and air dry; blow out NOTE:
all passages with compressed air. • Coat piston, piston seal and caliper bore with
clean brake fluid.
e Use only DOT 3 or DOT 4 brake fluid.
CALIPER BRACKET
Check for cracks.
WEAR INDICATOR
lnstall inner pad with
its wear índicator upward.
INNER SHIM A
Check for wear.
Apply Molykote M77 compound
to both sides \
of shim.
PAD SHIM
Check for wear.
Apply Molykote M77
compound to both sides
of shim.
INNER SHIM 8
Check for wear.
Apply Molykote M77 Check lining
compound to both sídes thickness.
PAD SPRING
of shim. Apply Molykote M77 compound
Check for weakness
to the back of the pads.
or damage.
50 N•m 15.0 kg-m,-

36 lb-ft)
SCREW~
PISTON
Check for scoring
on surface.
BLEEO
9 N·m (0.9 kg-m,
7 lb-ft)
CALIPER BODY
Check for scoring
on cylinder wall. Replace.
13-5
Brake Pad
lnspection/Replacernent---------------------------------------------
5. lf lining thickness is less than service limit, replace both
fifjl.t¡lfii§ICI pads as a set.
e Do not use an air hose to blow the brake assembly
clean. Use an OSHA-approved vacuum cleaner, to
NOTE: Engagement of the brake may require a greater
avoid breathing brake dust.
pedal stroke immediately after the brake pads have
e Contaminated brake pads or disc reduce stopping been replaced as a set. Several applications of the
brake pedal will restore the normal pedal stroke.
power. Keep grease or oil off the brake pads or disc.
Wipe any excess grease off the parts.
1. Remove the front wheels and support the front of the

car on safety stands.
2. Remove the caliper bolt (flange bolt) and pivot caliper
up out of the way.
6. Clean the caliper thoroughly; remove any rust, and

check for grooves or cracks.
7. Instan the pad retainers.

3. Remove the pad shims, pad retainers and pads.
4. Using vernier caliper, measure the thickness of each RETAINER

brake pad lining.
Brake Pad Thickness:

Standard: 12.5 mm (0.49 in.)
PGM-FI:
THICKNESS
PAO BACKING
RETAINER CALIPER
NOTE: Measurement does not include pad backing BRACKET
thickness.
13-6
Brake Caliper
Disassembly/Reassembly -----..
8. Apply Molykote M77 compound to both sides of the CAUTION:
pad shims and the back of the pads. e Make sure all parts are clean before reassembly.
e Use only new replacement parts.
9. lnstall the brake pads and pad shims correctly. e Use only clean DOT 3 or DOT 4 brake fluid.
e Do not allow dirt or other foreign matter to contami-
NOTE: lnstall the pad with the wear indicator on the nate the brake fluid.
inside. e Do not mix different brands of brake fluid.
e Avoid spilling brake fluid on painted, plastic or rubber
surfaces as it can damage the finish; Wash spilled
brake fluid off immediately with e lean water.
INNER SHIM B
Apply Molykote M77 to 1. Remove the banjo bolt and disconnect the brake hose
inner side of shim. from the caliper.
2. Remove the caliper bolts, then remove the caliper.
BANJO BOLT
10 x 1.0 mm
35 N•m (3.5 kg-m, 25 lb-ft)
Apply Molykote
M77 to both
si des of shim.
1 O. Push in the piston so that the caliper will fit over the
pads. Keep the boot in position to prevent damaging
the boot when pivoting the caliper down.
11. Pivot the caliper down into position, then instan the
caliper bolt (flange bolt) and tighten to the specified
FLANGE BOLT
50 N·m (5.0 kg-m, 36 lb-ft)
FLANGE BOLT
50N·m
(5.0 kg-m.
36 lb-ft)
NOTE: Make sure the pin is clean before installation,

then apply a clean silicone grease to the inside boot
and pin.
12. Depress the brake pedal severa! times to make sure the
brakes work, then roadtest. (cont'd)
13-7
Brake Caliper
Disassembly/Reassembly (cont'd) - - - - - - - - - - - - - - - - - - - - .
3. Remove the pad spring. CAUTION:
Place a wooden block or shop rag in the caliper oppo- • Make sure all parts are clean before reassembly.
site the piston, then carefully remove the piston from • Use only new replacement parts.
the caliper by applying air pressure through the brake • Use only clean DOT 3 or DOT 4 brake fluid.
line hole. • Do not allow dirt or other foreign matter to contami-
P.i'k!Ui'W"
• Do not place your fingers in front of the piston.
nate the brake fluid.
• Do not mix different brands of brake fluid.
• Do not use high air pressure; use an OSHA • Avoid spilling brake fluid on painted. plastic or rubber
approved 30 PSI nozzle. suñaces as it can damage the finish.
• Wash spilled brake fluid off immediately with clean
water.
PISTON SEAL
-RUBBER
liijjjffiGREASE
BOOT~
5.
----
PISTON
SILICONE GREASE
Clean the piston and caliper bore with brake fluid and
4. Remove the piston boot and piston seal. inspect for wear or damage.
CAUTION: Take care not to damage the cylinder. 6. Apply rubber grease toa new piston seal, then install
the piston seal in the cylinder groove.
7. Apply silicone grease to a new piston boot. then install

the piston boot.
8. Lubricate the caliper cylinder and piston with brake

fluid, then install the piston in the cylinder with the
dished end facing in.
PISTON BOOT
Replace.
9. Reinstall the caliper in the reverse order of removal.
10. Fill the brake reservoir up and bleed the brake system
(page 19-10).
13-8
Brake Disc
Run-Out lnspection - - - - - - - - , Thickness and Parallelism ------,
lnspection
1. Remove the front wheels, and support the front of the
1. Remove the front wheels, and support the front of the
lnstall the flat washer and wheel nut.
CAUTION: Use wheel nuts and 3 mm thick flat
2. M ove the caliper and pads out of the way as described
washers to hold the disc securely.
in the preceding column.
2. Remove the caliper bolt, pivot the caliper up out of the

3. Using a micrometer, measure disc thickness at eight
way on the caliper bolt, then remove the pads and pad
points, approximately 45° apart and 1 O mm (0.390
retainers.
in.) in from the outer edge of the disc.
3. lnspect the disc surface for grooves, cracks, and rust.

Clean the disc thoroughly and remove all rust.
4. Mount a dial indicator as shown and measure the

runout at 1 O mm (0.390 in.) in from the outer edge of
the disc.
Brake Disc Runout:

5. lf the disc is beyond the service limit, refinish the rotor

with an on-car brake lathe. The Kwik-Lathe produced
by Kwik-Way Manufacturing Co. is approved for this
operatíon.
Brake Disc Thickness:

Standard: 23 mm {0.906 in.)
Max: Refiníshing Limít: 21 mm (0.827 in.)
Brake Disc Parallelism:

The difference between any thickness measure-
ments should not be more than 0.015 mm (0.0006
in.)
4. lf the disc is beyond the limits for thickness or parallel-

ism, refinish the rotor with an on-car brake lathe. The
Kwik-Lathe produced by Kwif-Way Manufacturing.
Co. is approved for this operation.
NOTE: A new disc should be ground if its run-out is

WHEEL NUT greater than 0.10 mm (0.004 in.).
ANO
THICK FLAT
WASHER
110 N•m
(11 kg-m, 80 lb-ft)
13-9
Bleeding
CAUTION FRONT
• Make sure all parts are clean before reassembly.
• Use only cleim DOT 3 or DOT 4 brake fluid. 9 N•m (0.9 kg-m. 7 lb-ftl
• Do not allow dirt or other foreign matter to con-
taminate the brake fluid.
• Avoid spilling brake fluid on painted. plastic or
rubber surfaces as it can damage the finish;
Wash spilled brake fluid off immediately with
e lean water.
NOTE: The reservoir on the master cylinder must be

full at the start of bleeding procedure, and checked
after bleeding each wheel cylinder. Add fluid as
required. Use only DOT 3 or 4 brake fluid.
Bleeding Sequence
• • REAR
Drum brake
7 N·m (0. 7 kg-m. 5 lb-ft)
1. Have someone slowly pump the brake pedal sev-

era! times. then apply steady pressure.
2. Loasen the brake bleed screw to allow air to

escape from the system. Then tighten the bleed
screw securely.
3. Repeat the procedure for each wheel in the Disc brake

sequence shown above, until air bubbles no Ion-·
ger appear in the fluid.
9 N•m (0.9 kg-m. 7 lb-ft)
4. Check brake performance by road testing.
13-10
Master Cylinder, Booster
lndex
CAUTION:
Master cylinder and booster does not disassembly.
Replace them with a component assembly.
BRAKE BOOSTER
Testing, page 19-1 2
Do not disassemble.
COTTER PIN
Replace.~ MASTER CYLINDER
ij
8 x 1 .25 mm -------r__,~
13 N•m
(1 .3 kg-m, 9 Jb-ftl
To left front brake
Do not disassemble. 10x1.0mm

19 N•m (1.9 kg-m. 14 lb-ft)
13-11
Master Cylinder
~verhaul/lnspection~~~~~~~~~~~~~~~~~~~~~~~~~
CAUTION: e Replace the master cylinder if the bore is damaged or

e Avoid spilling brake fluid on painted surfaces as worn. Do not hone or attempt to refinísh the bore.
severe damage can result. Wípe up spilled fluid at NOTE:
• :
once and rinse well clean water.
1 This symbol represents brake fluid.

Use only DOT 3 or 4 brake fluid.
• Wash all removed parts in brake fluid and blow dry with
compressed air. Blow open all passages and fluid ports .
e To prevent damage, liberally apply clean brake fluid to
the piston cups before installation.
e Do not attempt to refinish master cylinder bore~ Replace
e~ Use only HONDA Brake Cylinder Grease if pitted or worn .
(P/N 08733-B020EI or equivalent. • Use only DOT 3 or DOT 4 brake fluid.
e Carefully inspect the bore of the master cylinder for
pits, scratches or scoríng.
RESERVOIR CAP
Check for blockage
of vent holes.
PRIMARY
PISTON ASSEMBLY
Check for
wear or damage.
1 MASTER CYLIND
ROO SEAL
Re place.
~
SILICONE GREASE
9 N•m ~
(0.9 kg-m, 6.5 lb-ft} CUP
Replace.
0-RING
Replace.
13-12
Disassembly
CAUTION: 3. Remove the stop bolt while pushing in the secondary
• Avoid spilling fluid on painted, plastic or rubber piston assembly.
parts as it may damage the finish.
• Plug the end of the brake hose with a shop rag to
prevent brake fluid from flowing out of the brake
hose after disconnecting .
• Use only new clean DOT 3 or DOT 4 brake fluid.
• Clean all parts thoroughly with brake fluid. Blow
out all passages with compressed a ir.
• Do not allow foreign matter to enter the system.
• Be careful not to bend or damage the brake pipe
when removing the master cylinder.
1. Remove the rod seal.
Re place.
SECONDARY PISTON
ASSEMBLY
ROO SEAL
Replace.
4. Remove the piston guide, secondary piston assembly

and prímary píston assembly.
NOTE: lf the primary piston assembly is difficult to

remove, apply compressed air from the primary piston
si de outlet.
CAUTION:
2. Push the secondary piston assembly, then remove the • Do not use high pressure air or bring the nozzle
snap ring. too close to the ínlet.
• Place a shop rag over the master cylinder to
CAUTION: Avoid damaging the master cylinder prevent the primary piston from becoming a
projectile.
wall.
5. Clean all parts with brake fluid.
SECONDARY PISTON
ASSEMBLY
SNAP RING
Replace.
13-13
Master Cylinder
Reassernbly---------------------------------------------------------
CAUTION: 3. Make sure that the primary piston assembly and secon-
• Make sure all parts are clean before reassembly. dary piston assembly are in good condition.
• Use only new r~placement parts.
• Use only clean DOT 3 or DOT 4 brake fluid. PRIMARY PISTON ASSEMBLY
• Do not allow dirt or ,other foreign matter to con~ 'SPACER
taminate the brake fluid.
• Avoid spilling brake fluid on painted, plastic or
rubber surfaces as it can damage the finish.
Wash spilled brake fluid off immediately with
clean water.
1. Lubricate the new piston assemblies with brake fluid.
2. Insta U the new 0-ring and secondary cup onto the - .¡¡;¡;..
SlliCONE GREASE
piston guide.
PIS TON GUIDE ASSEMBl Y

SECONDARY PISTON ASSEMBLY
SECONDARY PISTON CUP

PISTON GUIDE PISTO N
STOPPER
SPACER
- e;;l
SECONDARY CUP
SECONDARY SPRING SECONDARY
SPRING STOPPER PISTON A
NOTE: Replace the secondary cup and piston guide as

a set if necessary.
13-14
4. lnstall the pistan assemblies in the master cylinder. 7. lnstall a new rod seal.
NOTE: To ease assembly, rotate the pistons while

inserting.
5: lnstall tl"]e stop bolt and new sealing wa.sher while

pushing in the secondary pistan assembly, then
tighten the stop bolt.
SECONDARY ROO SEAL

PISTON ASSEMBLY.
SILICONE GREASE
CAUTION: When connecting the brake pipes,

make sure that there is no interference between the
brake pipes and other parts
6. lristall the snap ring while pushing in the secondary

pistan assembly.
SECONDARY PISTON
ASSEMBLY
SNAP RING
13-15
Brake Booster
Test
Leak Test 4. Start the engine.
l. lnstall the Brake Power Kit (07504-63401 00) as
shown. 5. Depress the brake pedal with a 200 N (20 kg, 44 lbs)
of pressure. The following pressures should be obser-
2. Start the engine, adjust the engine speed with the ved at the pressure gauges in each vacuum.
accelerator pedal so that the vacuum gauge readings
show 300-500 mmHg (11.8-19. 7 inHg), then stop
the engine. PRESSURE GAUGE
3. Read the vacuum gauge.
lf the vacuum readings decreases 20 mmHg (0. 8 inHg)

or more after 30 seconds, check following parts for
leaks.
Check valve
Vacuum hose
Seals
Diaphragm
Master cylinder 0-ring and cup /~
VACUUM JOINT TUBE A VACUUM GAUGE
(1
07510-6340300 or 07404-5790300 ~/
6340400
/
Vacuum Line pressure kPa (kg/cm 2 , psi
mmHg Without ALB ALB
o 921 (9.4, 134) 814 (8.3, 118)
300 5491 (56.0, 797) 6080 (62.0, 882)
1 500 8532 (87.0, 1238) 8159 (83.2. 1183)
6. lnspect the master cylinder pistons and cups in the

TUBE JOINT ADAPTOR readings do not fall within the limits shown above.
07410-5790500
Check Valve Test
1. Remove the check valve, blow on one end of the hose
Function Test
and then the other; if you can blow through the
1. lnstall the vacuum gauge as same the leak test.
booster end, but not through the manifold end, the
check valve is OK.
2. Connect the oil pressure gauges to the master cylinder
using the attachments as shown.
3. Bleed air through the valves.
CAUTION: Avoid spilling brake fluid on painted.

plastic or rubber partsas it may damage the finish.
PRESSURE GAUGE
07406-5790200
MANIFOLD
END
ATTACHMENT C
07410-5790100
PRESSURE GAUGE
JOINT PIPE
0751Q-6340100
PRESSURE GAUGE JOINT PIPE (Use ALB Booster

07HAK-SG00110 only)
13-16
Pushrod Adjustment - - - - - - - - , Pushrod Clearance Adjustment ----.
lnstall the locknut and pushrod yoke on the pushrod, and NOTE: Master cylinder pushrod-to-piston clearance
adjust the pushrod length as shown. must be checked and adjustments made, if necessary,
befare installing or when replacing master cylinder or
booster.
1. Using the special tool, adjust bolt so the top of it is

116 ± 0.5 mm
flush with end of master cylinder pistan.
(4.6 ± 0.020 in)
PUSHROD ADJUSTMENT
GAUGE
07GAG-SE00100
ADJUSTING NUT
CENTER SHAFT
2. Without disturbing the adjusting bolt's position. install

PUSHROD the master cylinder rod seal on the special tool and put
the special tool u psi de down on the booster.
3. Instan the master cylinder nuts and tighten to the

specified torque.
4. Connect the booster in-line with a vacuum gauge (O

-30 in Hg) to the booster·s engine vacuum supply,
and maintain an engine speed that wil/ deliver 500 mm
Hg (20 in Hg) vacuum.
5. With a feeler gauge, measure the clearance between

the gauge body and the adjusting nut as shown.
CLEARANCE: D-0.4 mm (D-0.016 in.)
e lnspectiori with the booster off the car.
VACUUM
GAUGE
(0-30 inHg)
15 N•m
(1 . 5 kg-m, 11 lb-ftl
FEELER GAUGE
PUSHROD ADJUSTMENT
GAUGE
07GAG-SE001 00
(cont'd)
13-17
Brake Booster
Pushrod Clearance Adjustment (cont' d)
• lnspection with the booster on the car. 8. After adjustment, loosen the clevis end pushrod lock-
nut and turn the pushrod to obtain the correct pedal
height.
"VACUUM
PEDAL HEIGHT FROM FLOOR:
GAUGE
ID-30 ;,;Hg) MANUAL TRANSMISSION: 190 mm (7.5 in.)
CLEARANCE
ICOMMERCIALLY AUTOMATICTRANSMISSION: 195 mm (7.7 in.)
AVAILABLEI (with floÓr mat removed!
The pedal should have
1-5 mm free play.
9. Adjust the brake light switch (page 19-4).
PUSHROD ADJUSTMENT VACUUM

GAUGE HOSE
07GAG-SE001 00 (SUITABLE
HOSE)
6. lf clearance is incorrect, loosen the star locknut and

turn the adjuster in or out to adjust. Hold the clevis
while adjusting.
7. Tighten the star locknut securely.
PUSHROD ADJUSTMENT
GAUGE
07GAG-SE001 00
STAR LOCKNUT
22 N•m
(2. 2 kg-m, 16 lb-ftl
0-0.4 mm (D-0.016 in.)
NOTE: lf the clearance between the gauge body and

adjusting nut is O mm, the pushrod-to-piston clear-
ance is 0.4 mm. lf the clearance between the gauge
body and adjusting nut is 0.4 mm, the pushrod-to-
piston clearance is O mm.
13-18
Rear Disc Brakes
lnspection----------------------------------------------------------
Do not use an air hose to blow the brake • Before reassembling, check that all parts are
clean. Use an OSHA-approved vacuum free of dust and other foreign particles.
cleaner. to avoid breathing brake dust. • Replace parts with new ones whenever speci-
fied to do so.
CAUTION: • Make sure no dirt or other foreign matter is
• Do not spill brake fluid -on the car; it may ·dam- allowed to contaminate the brake fluid.
age the paint; if brake fluid does contact the • Do not mix different brands of brake fluid as they
paint. wash it off immediately with water. may not be compatible.
• To prevent spills, cover the hose joints with rags • Do not reuse the drained fluid.
or shop towels.
• Clean all parts in brake fluid and a ir dry; blow NOTE:
out all passages with compressed a ir. • Coat piston, piston seal· and caliper bore with
clean brake fluid.
: BRAKE CYLINDER GREASE (P/N 08733-B020E)
OR EQUIVALENT RUBBER GREASE e Use only DOT 3 or DOT 4 brake fluid.
- ~ : SILICONE GREASE
23 N•m (2.3 kg-m.

17 lb-ft)
(4 Wheel Steering)
PARKING NUT
10 x 1.25 mm INNER PAD SHIM
28 N•m (2.8 kg-m. Check for wear.
20 lb·ftl Apply Molykote WOi to
both si des of shím.
r4---CALI PER
SPRING~ RETURN SPRING BRAKE PADS
WASHER ~ Check líníng thíck- · ~ BRACKET
Check for
ness. /
cracks.
~ ARM PIN BOOT
BOOT~~LEVER ~
Check for deteriorat1on
or damage.
CAM
Replace. ~- <D
-~CAM "",..
Check ~
for damage. RETAINER~ O U O U T E R PAD SHIM
Check for weakness Check for wear.
0 1
or damage. Apply Molykote M77 to
PAD SPRING both sídes of shím.
Check for wear or
~
damage.
BLEED SCREW
9 N·m (0.9 kg-m,
7 lb-ft)
CALIPER BODY
Check for scoring
on cylinder wall.
Replace.
Check for wear or

Replace. damage.
BEARING A
13-19
.
lnspectton (cont'd)
(2 Wheel Steering)
8 mm FLANGE
BOLT
8 x 1.0 mm
23 N·m
(2.3 kg-m,
17 lb-ft)
PAD SPRING
Check for wear or
INNER PAD SHIM
damage.
Check for wear. M77 to
Molykote
Apply. of shim.
both Sldes
RETAINER eakness
Check for w
~~
or damage.
OUTER PAD SHIM
Check for wear. M77 to
Molykote
ApplySI"des of shim.
both
23 N•m
17 lb-ft)
{23/g-m.
·
PIN
CheckBOO~eterioratíon
for
or damage.
13-20
Brake Pad/Disc
lnspection and Replacement - - - - - - - - - - - - - - - - - - - - - - - - ,
1. Block the front wheels, support the rear of the car on 5. Remove the pads and measure the thickness of each
safety stands, then remove the rear wheels. brake pad lining using a vernier caliper.
2. Remove the caliper shield. Brake Pad Thickness:

3. Remove the two caliper bolts. Service Limit: 1.6 mm (0.06 in.)
(4WS}
CALIPER
BOLTS
NOTE: Measurement does not include pad backing

thickness.
6. lf the lining thickness is less than service limit, replace

the brake pads as a set.
CALIPER SHIELD
(4WSI as shown:
(2WS)
CALIPER
SHIELD e
~·
~d~
1
~~
4. Remove the pad shims, pad retainers and pads.
13-21
Brake Pad/Disc
lnspection and Replacement - - - - - - - - - - - - - - - - - - - - -
(cont'd)
11 . Replace the disc if it exceeds the following service
limits.
7. fnspect the disc surface for grooves, cracks, and rust.
Clean the disc thoroughly and remove all rust.
Brake Disc Thickness:
8. Mount a dial indicator as shown and measure the
runout at 1O mm (O. 390 in.) infrom the outer edge of Service Limit: 21.0 mm (0.83 in.)
the disc.
Brake Disc Parallelism:
CAUTION: Use wheel nuts and 3 mm thick flat The difference between any thickness measure-
washers to hold the disc securely. ments should not be more than 0.015 mm (0.0006
in.).
Brake Disc Run-out;
Service Limit: 0.15 mm (0.006 in.) 12. Resurface or repface the brake disc if beyond the
fimits.
9. Resurface or replace the brake disc if beyond the NOTE: A new disc shoufd be resurfaced if its run-out is
service limit. greater than 0.15 mm (0.006 in.).
13. Remove the two caliper bracket bolts and caliper

bracket.
1O. Using a micrometer, measure the rear brake disc thick-

ness at eight points, approximately 45° apart and 1O
mm (0.390 in.) in from the outer edge of the disc.
14. Remove the two 6 mm screws and brake disc.
NOTE: (Without 4WS) lf the brake disc is difficult to

remove, instan 8 mm bolts into the threaded holes and
tighten them.
13-22
15. lnstall the new or resurfaced brake disc. 18. lnstall the brake caliper and caliper shield.
16. Clean the catiper bracket and retaíners, then install the
caliper bracket with two bolts and retainers. (4WS)
lnstall the new brake pads and pad shíms onto the
caliper bracket. 8 mm FLANGE BOLTS
23 N·m (2.3 kg-m.
17 lb-ft)
CALIPER SHIELD
(2WS)
RETAINER
SPRINGS 8 mm FLANGE BOLTS
23 N•m (2.3 kg-m.
17 lb-ft}
17. Rotate the caliper piston ctockwise into place in the

cylinder, then align the cutout in the piston with the
tab on the inner pad by turning the piston back.
CAUTION: Lubricate the boot with silicone grease

· to avoid twisting the piston boot. lf the piston boot
is twisted, back it out so it sits properly.
13-23
Rear Caliper
Disassernbly--------------------------------------------------------
CAUTION: 3. Remove the banjo bolt and disconnect the brake hose
• Make sure all parts are clean before ressembly. from the caliper.
• Use only new replacement parts·.
• Use only new clean DOT 3 or DOT 4 brake fluid. 4. Remove the two caliper mounting bolts and the caliper
• Do not allow dirt or other foreign matter to contami- from the bracket.
• Do not mix different brands of brake fluid. CAUTION:
• Avoid spilling brake fluid on painted. plastic or rubber • Thoroughly clean the outside of the caliper to
surfaces as it can damage to finish. Wash spilled prevent dust and dirt from entering inside.
brake fluid off immediately with clean water. • Plug the end of the brake hose to prevent brake
fluid from flowing out.
1. Remove the caliper shield (page 1 9-21).
Bx 1.0mm
2. Disconnect the parking brake cable from the lever on 23 N·m (2.3 kg-m,
the caliper by removing the lock pin. 17 lb-ft)
PARKING BRAKE
CABLE
LOCK PIN
Replace.
13-24
5. Remove the pad spring from the caliper. 8. Remove the pistan seal.
CAUTION: Take care not to damage the cylinder

6. Remove the piston and piston boot while rotating the bore.
piston.
CAUTION: Avoid damaging the pistan and piston

boot.
PISTON BOOT
PISTON SEAL
Replace.
PISTON
7. Remove the circlip, then washer, adjusting spring A, 9. lnstall the special tool in the cylinder, aligning the
and the adjusting nut from the piston. cutout on the tool with the tab on the spring cover.
PISTO N REAR CALIPER GUIDE
1 .
AOJUSTING
SPRING A
Replace.
07973-SA50000
·/~J
~@.
TAB
~~
AOJUSTING
NUT
Replace.
WASHER
/
Re place.
1
\Y'
24 mm CIRCLIP
Replace.
(cont'd)
13-25
Rear Caliper
Disassembly(conrd)~~~~~~~~~~~~~~~~~~~~~~~
1 O. lnstall the special tool between the caliper body and 14. Remove the sleeve piston, then remove the· rod from
rear caliper guide as shown. the cam.
11 . Compress the adjusting spring B by turning the shaft

of the special tool, then remove the circlip with snap
ring pliers.
BRAKE SPRING
COMPRESSOR
07HAE-SG00100
0-RING ROO
Replace.
15. Remove the return spring, parking nut, spring washer,

lever, cam and cam boot.
12. Remove the brake spring compressor from caliper
body.
13. Remove the spring cover, adjusting spring B,spacer,

RETURN SPRING
bearing A, adjusting bolt and cup.
CAM
l
LY/~·~·~
./CAMBOOT
~Si
AOJUSTING BOLT
SPRING COVER
LEVER
SPRING WASHER
13-26
Reassernbly----------------------------------------------------~
CAUTION: 4. lnstall the cam with threaded end facing up.

• Make sure all parts are clean before reassembly.
• Use only new replacement parts. CAUTION: Avoid damaging the ca m boot since it
• Use only new e lean DOT 3 or DOT 4 brake fluid. must be installed before th-e ca m.
• Do not allow dirt or other foreign matter to contami-
• Avoid spilling brake fluid on painted, plastic or rubber ~
surfaces as it can damage the finish. Wash spilled Brake Cylinder
brake fluid off immediately with clean water. Grease
(P/N: 08733-B020EI
CAM
1. Adjust the special tool as shown. Apply locking
sealant to
thread.
BRAKE SPRING COMPRESSOR

07HAE-SG001 00
CAM BOOT
81.5 mm
(3.21 in.J
5. lnstall the lever and spring washer. Tighten the parking

nut after applying locking sealant to thread.
6. lnstall the return spring.
2. Pack all cavities of the needle bearing with Brake

Cylinder Grease (P/N: 08733-B020EL or equivalent
rubber grease.
3. Coat the new cam boot with Brake Cylinder Grease (P/
N: 08733-B020E). or equivalent rubber grease and
install in the caliper.
(cont'd)
13-27
Rear Caliper
Reassernbly (cont'd)----------------------------------------------
7. lnstall the rod in the cam. 12. lnstall the special tool is the cylinder, aligning the
cutout on the tool with the tab on the spring cover.
8. lnstall a new 0-ring on the sleeve pistan.
9. lnstall the sleeve piston so the hole in the bottom of

the pistan is aligned with the rod in the cam, and the REAR CALIPER GUIDE
two pins on the piston are aligned with the holes in the 07973-SA50000
caliper.
/
~
0-RING
TAB
13. Adjust the special tool as shown.

SLEEVE PISTON
10. lnstall a new cup with its groove facing the bearing A
side of the adjusting bolt.
11. Fit the bearing A, spacer, adjusting spring B and spring

cover on the adjusting bolt, then install it in the caliper
cylinder.
81.5 mm
(3.21 in.)
¡~
BRAKE SPRING COMPRESSOR
07HAE-SG001 00
13-28
14. lnstall the special tool as shown. 18. lnstall the adjusting nut, adjusting spring A, and
washer, then secure with the circlip.
BRAKE SPRING
COMPRESSOR ~ PISTON
07HAE-SG00100 ~
AOJUSTING
NUT
j WASHER
. ADJUSTING
SPRINGA
~·J.
r ~"
24 mm CIRCLIP
15. Compress the spring until it bottams out. 19. Coat the new pistan seal and pistan boot with silicone
grease and ínstall them in the calíper.
16. Check that the flared end af the spring caver is belaw
the circlip graave.
17. lnstall the circlip, then remove the special toal. PISTON SEAL
NOTE: Check that the circlip is seated in the groave -~

SILICONE GREASE
praperly.
PISTON BOOT
-~
SILICONE
GREASE
SNAP RlNG PUERS

07914-SA50000
(confdl
13-29
Rear Caliper
Reassembly (cont'd)
20. Coat the outside· of ttie piston with silicone grease, arÍd
instan it on the adjusting bolt while .rotating it clock-
wise. •
CAUTION: Avoid damaging·the piston boot.
PISTO N
21. lnstall the brake pad retainers and brake pads.
22. Instan the pad spring on the caliper.
23. 1 nstall the caliper on the caliper bracket and tighten the
caliper bolts.
24. Connect the brake hose to the caliper with new se~ling
washers and tighten the barijo bolt.
25. Connect the parking brake cable to the arm on the

caliper.
26. Fill the brake reservoir up and bleed the brake system
(page 19-10).
27. Operate the brake pedal severa! times, then adjust the
parking brake lever.
NOTE: Before adjustments, make sure the parking

brake arm on the caliper touches the pin.
28. lnstall the caliper shield and tighten the bolts.
13-30
Brake Shoes
lndex and lnspection - - - - - - - - - - - - - - - - - - - - - - - -
bftJ{.jüf!ifM Block the front wheels before jacking up the rear of the car.
l. Raise the rear of the car and support with safety stands in proper locations.
2. Loosen the parking brake. · ·
3. Remove the rear wheels and rear brake drum.
fj,j.IQfilfM Do not use an air hose to blow the brake assembly clean. Use an OSHA-approved vacuum cleaner, to
avoid breathing brake lining dust.
CAUTION:
e Do not spill brake fluid on the car; it may damage e Make sure no dirt or other foreign matter is
the paint; if brake fluid does contact the paint, allowed to contaminate the brake fluid.
wash it off immediateiy. with water. · e Do not mix different brands of brake fluid as they
e To prevent spills, cover the hose joints with rags may not be compatible.
or shop towels. e Use only DOT 3 or DOT 4 brake fluid.
e Clean all parts in brake fluid and a ir dry; blow out e Use only a genuine Honda wheel cylinder special
all passages with compressed a ir. bolt.
e Before reassembling, check that all parts are e Do not reuse the drained fluid.
free of dust and other foreign particles.
e Replace parts with new ones whenever specified
todo so.
'I
SPECIAL BOLT
- • N·m kg-m. 7 .,_"'
MARK
'
SPECIAL
BOLT HEAD
~
WAVE WASHER
PARKING BRAKE LEVER

WHEEL CYLINDER Mark left and right.
Disassembly and lnspection BRAKE SHOE
page 13-36 lnspection, page 19-32
lf brake shoes are to be
re u sed, mark and reassemble
in same position.
WAVE WASHER
TENSION PIN
Mark left and right.

ADJUSTER
BOLT
or damage.
""'1,
UPPER RETURN SPRING U-CLIP
Check for weakness or Replace.
damage.
lnstall securely on tension pin.
SELF-ADJ USTER
SPRING
13-31
Brake Shoes
lnspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . . . ,
1. lnspect the wheel cylinders for leakage. 4. lnspect bearings in hub unit for smooth operation.
lf detective, refer to Section 12.
2. lnspect the brake linings for cracking, glazing, wear or
contamination. 5. Measure inside diameter of the brake drum.
3. Measure the brake lining thickness. Drum lnside Diameter:

Standard: 220 mm (8.661 in.)
Lining Thickness Service Limit: 221 mm (8. 701 in.)
(Does not include brake shoe thickness)
Standard: 4.5 mm (0.177 in.) NOTE: lf the refinishing limit stamped on the drum
Service Limit: 2.0 mm (0.079 in.) does not match the one listed above, use the one on
the drum.
WHEEL CYLINDER
6. lnspect the brake drum for scoring, grooving, cracks.
13-32
Disassernbly------------------------------------------------------~
1. Remove the upper return spring from the brake shoe as 5. Disconnect the parking brake cable from the parking
shown. brake lever.
Wear eye protection when using the brake spring

tool.
BRAKE SPRING INSTALLER

UPPER RETURN
SPRING
~
07LAF-SM40200
_!
PARKING BRAKE CABLE
6. Remove the upper return spring, self-adjuster lever

and self-adjuster spring, and separate the brake shoes.
UPPER RETURN SPRING
2. Remove the tension pins by pushing the retainer spring

and turning them.
3. Lower the brake shoe assembly and remove the lower

return spring.
NOTE: Make su re not to damage the dust cover on the

wheel cylinder.
4. Remove the brake shoe assembly.
PARKING BRAKE LEVER ADJUSTER SPRING
WHEEL 7. Re m ove the wave washer, parking brake lever and

CYLINDER
pivot pin from the brake shoe by removingthe U-clip.
WAVE WASHER PARKING BRAKE

LEVIVOTPIN
BRAKE
SHOE
LOWER RETURN
SPRING
13-33
Brake Shoes
Reassembly
1. Apply brake cylinder grease to the sliding surface of Apply grease on each sliding surface.
the pivot pin, and insert the pin into the brake shoe.
CAUTION: Contaminated · brake linings reduce
2. lnstall the parking brake lever and wave washer on the . stopping power. Keep grease or oil off the brake
pivot pin and secure with U-clip. linings. Wipe any excess grease off the parts.
NOTE: Pinch the U-clip securely to prevent the pivot

pin from coming out of the brake shoe.
U-CLIP
Replace .• PIVOT PIN
~ ( 11- !!iiñjffl
Apply grease
to sliding
U-CLIP
WAVE WASHER surface. Greasing symbols: rubber grease {made by COSMO)
~ e Moving portion
Replace. P RKING BRAKE
LEVER
3. Connect the parking brake cable to the parking brake

lever.
4. Apply grease on each sliding surface.
CAUTION: Contaminated brake linings reduce

stopping power. Keep grease or oil off the brake
linings. Wipe any excess grease off the parts.
UPPER RETURN SPRING

ADJUSTER BOLT
Grease symbols: MOLYKOTE 44MA

(Made by Dow Corning Co., ltd.)
~ e Brake shoe ends
o O Opposite the edge of the shoe
5. Clean the threaded portions of devises A and B.

Coat the threads of the devises with grease. To
shorten the devises, turn the adjuster bolt.
6. Hook the adjuster spring to the adjuster lever first,

ADJUSTER SPRING then to the brake shoe.
13-34
7. lnstall the brake shoes onto the brake panel. 10. lnstall the brake drum.
NOTE: Make sure not to damage the wheel cylinder
dust covers. 11 . lf the wheel cylinder has been removed, bleed the
brake system (page 19-1 0).
8. lnstall the tension pins and the return springs.
1 2. Depress the brake pedal several times to set the self
adjusting brake.
TENSION PINS 13. Adjust the parking brake (page 19-4).
RETURN SPRINGS
9. lnstall the upper spring with the special tool.
UPPER RETURN SPRING
BRAKE SPRING INSTALLER

07LAF-SM40200
13-35
Wheel Cylinder
Disassembly and l n s p e c t i o n - - - - - - - - - - - - - - - - - - - - - - - - - ,
CAUTION:
• Use only clean DOT 3 or DOT 4 brake fluid.
• Use only new replacement parts.
• Brake fluid will damage the painted, plastic and rubber parts. Whenever handling brake fluid, protect the painted,
plastic or rubber parts by covering_ with a rag. lf fluid does get on these parts, wipe it off with a clean cloth.
• Blow all passages with compressed air before reassembling.
• Clean all parts thoroughly with the clean brake fluid.
• Do not allow dirt or otherforeign matter to contaminate the brake fluid.
• Do not mix different types of fluid. They are not compatible ..
• Never reuse the brake fluid once it has been drained.
• Lubricate all parts with clean brake fluid during reassembly.
• Apply sealant between the wheel cylinder and backing plate whenever the wheel cylinder has been removed.
BACKING PLATE
WHEEL CYLINDER SEALANT
DUST COVER
Replace if damaged.
BLEED SCREW
7 N·m
!0. 7 kg-m. 5 ft-lbl
1 BLEED SCREW CAP
1
~ ~=:~~ sconng
for
or grooving.
r' . ~
le~({{{(¡)
~
!~~\ 9 N·m (0.9 kg-m, 7 lb-ft)
1 ~~~¡~~-CUP 1 (n
·~ ,·. - DUST COVER
:OJ ~
~~
WHEEL CYLINDER SPRING _• Re. P.---l-a c---e_ if damaged.
Check for weakness or damage.
1
WHEEL CYLINDER (\ .r~
1 .. lnspect bore and
~~~~~~~~scored or PISTON CUP
< _-\!0
- ,-.;• .
1 • :
Replace .
··_: PISTON
lnspect for scoring
or grooving.
13-36
Brake Hoses/Pipes
lnspection
1. lnspect the brake hoses for damage, leaks, interference or twisting.
2. Check the brake lines for damage, rusting or leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
BLEED SCREW
BRAKE LINE-TO-BRAKE HOSE 7 N•m (0. 7 kg-m. 5 lb-ftl
15N•m(1.5kg-m.111b-ft)
BRAKE PIPE-TO-WHEEL CYLINOER
19 N·m (1.9 kg-m, 14 lb-ft)
MASTER CYLINDER-TO-LINE
19 N·m (1.9 kg-m, 14 lb-ft)
BLEED SCREW
9 N•m (0.9 kg-m, 7 lb-ft)
BRAKE LINE-TO-BRAKE HOSE

15 N•m (1.5 kg-m, 10 lb-ftl
BRAKE HOSE-TO-CALIPER
35 N·m (3.5 kg-m, 25 lb-ftl
BRAKE PIPE-TO-PROPORTIONING VALVE

19 N•m (1.9 kg-m. 14 lb-ftl
13-37
Brake Hose/Pipes
Brake Hose Replacement
CAUTION: 5. lnstall a new brake hose clip to the brake hose.
e Before reassembling. check that all parts are free of
dust and other foreign particles. 6. Connect the brake pipe to the brake hose.
e Replace parts with new ones whenever specified to
do so.
e Use only clean .DOT 3 or DOT 4 brake fluid.
e Make sure no dirt or other foreign matter is allowed to
contaminate the brake fluid.
e Do not mix different brands of brake fluid as they may
not be compatible.
e Do not spill brake fluid on the car. it may damage the
paint; if brake fluid does contact the paint. wash it off
immediately with water.
1. Replace the brake hose if the hose is twisted, cracked

or if it leaks.
2. Disconnect the brake hose from the brake pipe using a
. 1 O mm fiare nut wrench.
7. Connect the brake hose to the caliper.

FLARE NUT BRAKE HOSE
WRENCH
8. lnstall the brake hose on the knuckle and damper
07921-D01 0001
mountíng clamp.
9. After ínstalling the brake hose, check the hose and line
3. Remove and discard the brake hose clip from the brake joínts for leaks, and tighten íf necessary.
hose.
· 4. Remove the banjo bolt and disconnect the brake hose

from the calíper.
13-38
~
----------------~--==···=.=
Parking Brake
Disassembly and Reassembly
(4WS DISC BRAKE) PARKING BRAKE LEVER
Check for smooth
PARKING BRAKE CABLE

Check for smooth
operation.
f
~áº~
PARKING BRAKE
SWITCH ~¡"'
CABLE
EQUALIZER
. CABLE AD.IUSTING NUT
(2WS DISC BRAKE}
(ORUM BRAKE)
caliper by removing the lock ~able from the lever on the

Disconnect the parking brake
p1n.
PARKING BRAKE CABLE
12 mm
PARKING BRAKE CABLE OFFSET WRENCH LOCK PIN
13-39
ALB
Special Tools .............................. 13-42 lnstallation ................................. 13 -68
lllustrated lndex ........................... 13 -43 Pistan
Circuit Diagram ........................... 1 3-44 Removal .................................... 1 3- 69
ALB Checker lnstallation ................................. 13-70
Function Test ........................... 1 3-45 Power Unit
Wheel Sensor Signa! lndex/lnspection ........................ 1 3-71
Confirmation .............................. 1 3- 4 7 Disassembly/Reassembly ......... 1 3-72
Troubleshooting Accumulator Unit
Dash Warning Light .................. 1 3- 48 1ndex ....................................... 1 3 - 7 3
Symptom-to-System Chart ......... 1 3-50 Accumulator/Pressure Switch ... 13 -74
Flowcharts ................................. 13-51 Accumulator Disposal ............... 1 3- 7 4
Hydraulic System Master Cylinder
Hydraulic Connections ............... 1 3-63 Overhaul/lnspection .................. 13 -75
Relieving Accumulator/ Disassembly .............................. 1 3- 76
Line Pressure ........................... 13-64 Reassembly .............................. 1 3- 7 7
Modulator Bleeding ....................................... 1 3-79
lndex/lnspection ........................ 1 3-65 Electronic Components
Solenoid Control Unit Replacement ......... 1 3- 80
Solenoid Leak Test ..................... 13-66 Relays 1nspection ..................... 1 3- 81
Removal .................................... 1 3-67 Pulsers/Sensors ........................... 1 3-81
lnspection ................................. 13-68
Special Tools
Special Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
Ref. No. Tool Number Description O'ty Page Reference
CD 07HAA-SG001 00 Bleeder T-Wrench 13-53, 13-64, 13-79

® 07HAJ-SG00601 ALB Checker 13-45, 13-47
or
07 508-SBOOOOO ALB Checker 13-45, 13-47
-07HAJ-SG00400 Adaptor 13-45, 13-47
CD ®
13-42
lllustrated lndex
fj§i.jri§iifi The accumulator contains high pressure

nitrogen gas, do not puncture expose to flame or attempt
to disassemble the accumulator or it may explode;
severe personal injury may result.
MASTER CYLINDER
Overhaul/lnspection, 13-75
Disassembly, 1 3-7 6
MODULATOA Reassembly, 1 3-7 7 CONTROL UNIT
lndex/lnspection, 13-65
13-80
BOOSTER
MOTOR RELAY Do not Disassemble
lnspection, 13-8ü' FAIL SAFE RELAY
lnspection, 13-80
ACCUMULATOR UNIT
lndex. 13-73
Disposal, 13-74
REAR SPEED SENSOR

lndex/1 nspection, 1 3-71
Replacement, page 13-82, 83
Disassembly/
Reassembly, 13-72
FRONT SPEED SENSOR

13-43
Circuit Diagram
FUSE BOX
BA TTERY
1 -;;:.
IGNITION
+ SWITCH 2 (lSA)
No.19(50A) IG1 )
r. oliBAT No.1(10A)
IG2~~--~~~~-+--~----------~---------+------~----------,
No.8(7 .5A)
ALB FUSE BOX
ALB(40A)
~e D ALB
WARNING
LIGHT
<D e [@]~1
Jv-- ~RNIRED
No.2 5
(20A)
ALB
(15A)
B1~ALB B3~ALB
(15A)
82
(15A)
v V
BLA KE
FLUID
LEVEL
1
PARKING
BRA KE
~ACG
ALB SWITCH SWITCH

MOTOR
RELAY - -
(lHDlG301
RHD G25 1
,......_
WHTIYEL WHT/BLU
r-BLK-
r+--+--,
(~
BRAKE FRONT
LIGHT YEL/BLK FAIL
SWITCH SAFE
AELAY
.,__ _ YEL/BLK ---+--+---,
WHT/GRN WHT
REAA
FAIL el ~
GRN/WHT WHT/BLK Y EL/RED SAFE
YELrRN ct--
RELA Y 1
L-t-+--'
BRAKE - - YELIG RN - -.... --+---..1
LIGHT BLU/RED GRN/AED BLK YELIBLK
-GRN/BLK-
BLU/BLK BLU/RED WHTIBLU WHT/BLU
SELENOIDS
FRONT -R FRONT-L REA R
G701 BLK BLK BLK
~~~., ~~~ ~~~~L

RED rl R~D v;L RED
30 2 9 12
YELIGRN
118
YELIGRN
23117
1 1 RED~BLU.
REDIIBLK,
8
1 1
YELtLK
1
t. .l.
1o
YELtLU
3
RED/IW HT
11
YELtHT
6 4 16 22 13
;;; .,., a: a: :z: ~
,_ ~
,_
"-
o
,_ +
co
+
""
""
+
:::¡¡ ""
e:>
~ ::!:
!:;
o --'
::::> a: ::::>
o
""
~ ""
--' ""
a:
(!)
:X:
u
~ ""'
"- U- <
Cl)
:::: a: < a_
REDIW HT
~Gr
ALB UNIT
Cl Cl :::¡¡ -:;;:: -3:: -:;;::
:z: :z o + a: + a: '
<!> <!> u -u.. - a: -+ -'
a: '
BLK/WHT
BLK
~_!_
FRONT- R FRONT- L REA R- R REA R- L
SPEED SENSORS G201 G702 G201
L------- BLKIW HT ---------..1 L . . . - - YELI B l K _ _ _ _ _ _ _ ____.
13-44
ALB Checker
Function Test
NOTE: NOTE: Place the vehicle on level ground with the
• The ALB checker is designed to confirm proper wheels blocked, put the transmission in neutral for
operation of the ALB system by simulating each manual transmission models, and in P for automatic
system function and operating condition. Befare transmission models.
using the checker, confirm that the dash ALB
warning light is not indicating sorne other problem 2. Start the engine and release the parking brake,
with the system. The light should go on when the
ignition is first turned on and then go off and stay
off two seconds after the engine is started. 3. Operate the ALB checker as follows,
• The checker should be used through all modes, ( 1)Turn the Mode Selector switch to "1."
0-6, to confirm proper operation of the system, (2)Push the Start Test switch:
in any one of the following situations: - The test in progress light should come ON.
- After replacing any ALB system component. - In one or two more seconds, all four monitor
- After replacing or bleeding the system fluid (0 lights should come on (lf not the checker is
mode not necessary). faulty).
- After any body or suspension repair that may - The dash warning ALB light should not come ON (lf
have affected the sensors or their wiring. it comes on the checker harness to the 6-P con-
nector connection is faulty).
- As part of P.D.I.
f!i{IJ.i$JI!.ild
Disconnect the ALB checker before Monitor lights
driving the car. A collision can result from a reduc-
tion, or complete loss, of braking ability causing
severe personal injury or déath. 4W ALB CHECKER R L
Front "' a
NOTE: Set the Pulse Selector switch to 50 when using
ALB checker 07HAJ-SG00601. Test in progress
¡
Rear "' C>
'--
2 3 4 ~
1. With the ignition switch off, disconnect the 6-P in-
spection connector from the connector cover under
the passenger seat and connect the 6-P inspection
o 50
,<E).-5
connector to the ALB checker.
~ ~ ~ o1 6
\ \
L.,aN\ Start Test Mode Selector
Pulse Selector
(Use 50 pulse)
ALB CHECKER 6-P INSPECTION

07HAJ-SG00601 CONNECTOR
or
07508-SBOOOOO
and
07 HAJ-SG00400
(Adaptor) (cont'dl
13-45
ALB Checker
Function Test (cont'd)--------------------------~--------------------~
4. Turn the Mode Selector switch further to "2." Mode 5:

Sends the driving signa! of each wheel, then sends
5. Depress the brake pedal and push the Start Test· the lock signa! of the front right wheel to the con-
switch. trol unit. There should be kickback ..
The dash warning ALB light should not go on while the
Test in Progress light is ON. There should be kickback
on the brake pedal. lf notas described, go to trouble- Sends the driving signa! of each wheel, then sends
shooting, page 13-50. the lock signa! of both front wheels tó the control
unit. There should be strong kickback.
NOTE: The operation sequence simulated by
Modes 2, 3, 4, 5 and 6: ·NOTE: lf little or no kickback is felt from ttie brake
pedal in modes 2-5, repeat the function test of
modes 1-5 severa! times before beginning to
troubleshoot other parts of the system.
START About 30 seconds END
6. Turn the Mode Selector switch to 3, 4, 5.

Perform step 5 for each of the test mode positions.
Mode 1:
Sends the simulated driving signa! O km/h (0 mphl
-+ 180 km/h (112.5 rriph)-+ O km/h !O mph) of
each wheel to the control unit to check the control
unit self diagnosis circuit. There, should be NO
kickback.
Mode 2:
the lock signa! of the rear left wheel to the control
unit. There should be kickback.
Mode 3:
the lock signa! of the rear right wheel to the control
Mode 4:
the lock signa! of the front left wheel to the control
13-46
Wheel Sensor· Signal Confirmation
Monitor Lights
NOTE:
• Use the ALB checker (mode 0) to confirm proper wheel
1
sensor operation . 4W ALB CHECKER R f L
• Set the Pulse Selector switch to 50 when using ALB
7' ;........
Front <> <>
checker 07HAJ-SG00601.
Rear o <>
1. Disconnect the 6-P ínspection connector from the

connector cover under the passenger seat and connect 2 ~ 4 ~
the 6-P inspection connector to the ALB checker. o 50 1-f?lJ-s
~ o~-s
1 1 \
Power ON Start Test Mode Selector
1
Pulse Selector
(Use 50 pulse)
5. With the transmission in neutral, rotate each wheel

briskly (one revolution per second) by hand, and
confirm that its respective monitor light on the
checker blinks as the wheel rotates.
NOTE:
• Rotating a wheel too slowly will produce only a
weak blink of its monitor light that may be dif-
ficult to see.
• In bright sunlight, the monitor light may be dif-
ALB CHECKER 6-P INSPECTION ficult to see. Perform tests in a shaded area.
07HAJ-SG00601 CONNECTOR
• In some instances, it may not be possible to
or
07508-SBOOOOO spin the front wheels fast enough to get a
and monitor indication, if necessary, start the engine
07HAJ-SG00400 and slowly accelerate and decelerate the front
(Adaptar} wheels.
The monitor lights should blink indicating a good
2. Raise the car so that all tour wheels are off the
wheel sensor signa!.
ground and support on safety stands.
lf any monitor light fails to blink, check the suspected

sensor, its air gap and its wiring/connectors.
4. Turn the Mode Selector switch to "0."
13-47
Troubleshooting
Dash VVarning Light-------------------------------------------------
Temporary Driving Conditions: Warning Light Circuit:
1. The dash warning light will come on and the control 1. The dash warning light, does not go on when the
unit memorizes the problem under certain conditions. ignition switch is turned on.
Check the following items. lf they are OK, check
NOTE: Problem codes explained on pages 13-50. the control unit connectors.
lf not loose or disconnected, install a new control
• The tire(s) adhesion is lost due to excessive cor- unit and recheck:
nering speed.
Problem codes: 5, 5-A, 5-8. e 81own dash warning líght bulb.
• Open circuit in YEL lead between No.1 fuse and
• The vehicle loses traction when starting from a combination meter.
stuck condition on a muddy, snowy, or sandy • Open circuit in BLU/RED lead between combina-
road. tion meter and control unit.
Problem code: 4. • Loose component grounding of the control unit
to the body.
• When the parking brake is applied for more than
30 seconds while the vehicle is being driven. 2. The dash warning light remains ON or after the engine
Problem code: 2. is started, however the LEO on the control unit does
not blink any code, check for the following:
• The vehicle is driven on extreme/y rough road.
The ALB system is OK, if the dash warning light: • Loose or poor connection of the wire harness at
goes off after the engine is restarted. the control unit.
e Faulty ALB 82 ( 15 A) fuse.
DASH WARNING ALB LIGHT • Open circuit in WHT lead between ALB 82 ( 15 A)
fuse and control unit.
e Open circuit in YEL!BLK lead between fuse No.8
(7. 5 A) and fail safe relay(s),
e Open or short circuit in the YEL/GRN lead between
control units.
• Short circuit in BLU/RED lead between combina-
tion meter and control unit.
• Open circuit in WHT/BLU lead between alter-
nator and control unit.
lf the problem is not found substitute a known-

good control unit and recheck whether the warning
light remains ON.
2. lf you receive a customer's report that the dash warn-
ing light, sometimes comes on, check the system
using the AL8 checker to confirm whether there is any
trouble in the system.
See page 1 3-45.
3. The dash warning light will come on and the LEO (see
page 13-49) will display a problem code when there is
insufficient battery voltage to the control unit. An
exampre would be when the battery is so weak that the
car must be jump-started.
After the battery is sufficiently recharged, the dash
warning light will work normally after the engine is
stopped and restarted.
However, after recharging the battery, the LEO pro-

blem code must be cleared from the control unit's
memory by ·disconnecting the AL8 82 fuse for at
least 3 seconds.
13-48
Troubleshooting
Symptom-to-System Chart
PROBLEM AFFECTED
CODE PROBLEMATIC
OTHER
COMPONENT/ S~e page. See page
FRONT FRONT REAR. REAR COMPONENT.
MAl N SUB 'SVSTEM
CODE CODE RIGHT LEFT RIGHT LEFT
-ALB fuse
Hydraulic -Motor relay 13-80
* - Controlled
Components .
Parking brake
~
- - - - 13-51
-
o
-Pressure Switch
..:Accumulator
-Modulator.
Brake fluid level
**
- switch-related - - - - 13-54- switch
problem 1 BRAKE !light
o
:$
*
Pulser{s)
o 13-81
oo
* )t( o
o
* *
*
Speed sensor
o 13-55
o
* oo
**
-
Speed sensor {s)

o 13-56 -Modulator
** - - -
o- - Front or rear
*
fail safe relay
13-57
- - - -
Fail safe relay (Function Front fail safe relay
l
*
'* * - - - -
Test)
Rear fail safe relay
:41: o ALB 3 fuse
m* Solenoid related
problem
(Open or short) o 13-61 ALB 1 fuse
oo -Rear fail safe relay
*
-Pressure Switch
-Motor relav
NOTE: In the event-cíf simultaneous speed sensor or solenoid problems (codes 4 or 7), the control unit will only indicate the higher
number sub-code.
13-50
Troubleshooting
Flovvchart---------------------------------------------------------,
Problem Code 1: Hydraulic Controlled Components.
NOTE: The LEO does not blink when the following failures occur.
• The contáct points of the motor relay rema in closed (the motor runs continuously even after the ignition key is removed).
• YEL/RED lead is shorted or the control unit is internally shorted (the motor stops when the ignition switch is turned lock).
Pre-test steps:
• Check ALB 40A Fuse.
• Check all brake system hoses and pipes (low and high pressure) for signs of lea~ing, bending or kinking.
• Check reservoir fluiq levet and if necessary, fill to the_ MAX level ..
BLK YEL
~
Disconnect the pressure switch
connector and check the continu-
ity between BLK and YEL termi-
nals. lTii)
@
JUt
ll ~
Bleed high pressure fluid from
ls there continuity? ""'YES
~ the maintenance bleeder with the
'----------r----------/ ALB T-wrench. (see page 13-79).
NO
J
Check the continuity of pressure
switch between BLK and YEL
terminals.
J
YES j Replace the pressure switch 1
(closed).
l
~----------------------~' NO
Reconnect the pressure switch
connector.
Bleed high pressure fluid from the p¡j§l.i¡M'fld Block

maintenance bleeder with the rear wheels before
ALB T-wrench. (see page 13-79). jacking up front of car.
Jack up the front of car and sup-
port wíth safety stands, then run
the engine in gear above 6 mph
(10 km/h).
(To page 13-52).
(cont'd)
13-51
Troubleshooting
Flowchart {cont'd) - - - - - - - - - - - - - - - - - - - - - - - -
( From page 13-51)
1
YES
Does the pump motor run? (To page 13-53)
1 NO

!
YEL terminal and body ground.
1 Repair short in YEL wire between

~ the control unit and pressure
switch. 1
CONTROL UNIT: 18P Connector
1 YEL
1 NO
Connect the YEL/RED terminal to

body ground using a jumper wire.
1
Does the pump motor run?
VES
Faulty control unit.
f 1 1 M1 r IIJ
YEL/RED
View from wire side
~NO
Remove the pump motor relay
and check the pump motor relay
{page 1 3-80). MOTOR SIDE
Ef)TERMINAL
1
Connect the motor side EB terminal
of the pump motor relay and its
output terminal with jumper wire.
1
NO
Does the pump motor run? (To page 19-54)
<.
l VES
Check voltage between the pump

motor relay motor side EB terminal Co
and body ground (- ).
1
Repair open in YEL/BLK wire
~ between the No.8 (7.5 A) fuse
and pump motor relay.
1 YES
! = i r open in YEURED wire

een the control unit and
pump motor relay.
1
13-52
(From page 13-52)
1
Pump runs with a constant soft
Does the pump motor run with an NO
sound:
increasingly loud, raspy sound?
Bleed a ir from ALB system using
the procedure on page 13-79 and
YES check the pump sound again.
Does the pump motor stop after NO Pump stops after about 120 sec-
about 60 seconds? onds:
faulty pressure switch (open).
YES
Does the reservoir fluid level go • lf level stays the same and
NO
down, and are there no bubbles in there are bubbles in the modu-
the modulator reservoir tank? lator reservo ir tan k. check the
accumulator fluid quantity by
YES bleeding the high pressure line
with the Bleeder T-wrench:
-lf ovar 160 ce (upper limit}.
faulty accumulator.
-lf under 115 ce (Jower limit).
modulator inlet solenoid leak
or accumulator leak.
• lf level goes up: faulty modula-
tor assembly.
System is OK; recheck pump

motor. to confirm no intermittent
problem.
BLEEDER T-WRENCH
07 HAA-SG001 00
~60 ce (UPPER LIMIT)______--r
-150~
-140-
-130-
-110_go
-100-
-90-
115 ce (LOWER LIMIT: 4 mm (0.2 in) -80-
below 120 ce upper linel
-6~
-so-
-40-
(side view)
NOTE: The fluid enters the reservoir under pressure; wait 1 or 2 minutes for air bubbles to disappear and leve! to
stabilize.
(cont'd)
13-53
Troubleshooting
Flowchart ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - - - -
(From page 13-53)
1
PUMP MOTOR HARNESS
WHT/BLU terminal ( +) of the
SIDE CONNECTOR
pump motor and body ground
(-).
1
Repair open in WHT/BLU wire
between motor relay and pump ~~o""d;._. •. F~m P"mp reOy
~ motor, or open in BLK wire
between pump motor and ground
or poor ground. BLK WHT/BLE
1 YES
Faulty pump motor. ·¡ View from terminal side
Problem code 2: Parking Brake Switch Related Problem
lf the parking brake has been released, the following items are possible causes. lf they are OK, check the control unit connectors for good
connection. lf not loose or disconnected, substitute a known-good control unit and recheck.
NOTE: Before Troubleshooting Problem Code 2, remove the ALB 2 fu se for three seconds to clear the control unit's memory, then test drive
the car.
lf the dash warning light and LED stay off, the probability is that the car was driven with the parking brake applied.
• The parking brake is applied for more than 30 seconds while driving.
• The brake fluid leve! in the master cylinder is too low.
• GRN/RED lead is shorted between the 1 BRAKE 1warning light and parking brake switch.
• GRN/RED lead is shorted between the 1 BRAKE 1warning light and brake fluid leve! switch.
• The 1 BRAKE 1warning light is blown.
• GRN/RED has an open between the .,.B"'R""A"K""'E"I warning light and parking brake.
r¡
• GRN/RED has an open between the parking brake switch and control unit.
13-54
Problem Code 4-1 to 4-8:. Speed Sensor SENSOR SIDE CONNECTOR
NOTE: Control unit will only indicate the higher number sub-code. FRONT RIGHT FRONT LEFT
lgnition switch: OFF
-
Disconnect wire harness from
speed sensor.
G RN GRN/BLK BRN GRN/BLU

Check for resistance between sen-
sor terminals. View from terminal side
ls there 500-1 ,000 o? Faulty speed sensor.
VES
4WS: 2WS:
SENSOR SIDE CDNNECTOR SENSOR SIDE CONNECTOR
Disconnect the 18P connector REAR RIGHT REAR LEFT REAR RIGHT REAR LEFT
o
-$~9$~9
GRY8 LT BLUEf) BLE/YEL GRN/YEL GRN/YEL BLE/YEL GRY LT BLU
e EtJ
View from terminal side
CONTROL UNIT 18P CONNECTOR
BRN: FL8 GRN: FR8 GRN/BLU: FLEf) GRN/BLK: FREf)
Check each wire for continuity

between the sensor and control
unit:
GRN/BLK: Front Right Positive
GRN/BLU: Front left Positíve
GRN/YEL: Rear Right Positive GRY: RL8 BLU/YEL: RR8 LT BLU: RLEB GRN/YEL: RREf)
l T BLU : Rear left Positive
GRN: Front Right Negative View from wire side
BRN: Front Left Negative
BLU/YEl: Rear Right Negative
GRV: Rear left Negative
Repair open in sensor wire:
NO GRN/BLK: Front Right Positiva GRN: Front Right Negative

GRN/BLU: Front Left Positiva BRN: Front Left Negativa
VES GRN/YEL: Rear Right Positiva BLU/YEL: Rear Right Negativa
LT BLU: Rear Left Positive GRY: Rear Left Negativa
Faulty control unit
(cont'd)
13-55
Troubleshooting
Flowchart (cont'd) - - - - - - - - - - - - - - - - - - - - - - - -
SENSOR SIDE CONNECTOR
Problem Code 5 to 5-4. 5-8: Speed Sensor(s) FRONT RIGHT FRONT LEFT
Disconnect wire
speed sensor.
harness from
Check for resistance between sen-

sor terminals.
o -
GRN GRN/BLK BRN
GRN/BLU
ls there 500-1 ,000 n? Faulty speed sensor.
VES
4WS: 2WS:
SENSOR SIDE CONNECTOR SENSOR SIDE CONNECTOR
Disconnect the 18P connector REAR RIGHT REAR LEFT REAR RIGHT REAR LEFT
Check each wire for continuity

between the sensor and control
unit:
GRN/BLK: Front Right Positiva
•
GRV8 LT BLU$
•
BLE/VEL
ffi~e ffi~e
GRN/VEL GRN/VEL BLE/VEL GRV LT BLU
GRN/BLU: Front Left Positiva
GRN/VEL: Rear Right Positiva
e ® View from terminal side
LT BLU: Rear Left Positiva CONTROL UNIT 18P CONNECTOR
GRN: Front Right Negatíve
BRN: Front Left Negativa BRN: FL8 GRN: FR8 GRN/BLU: FL$ GRN/BLK: FR$
BLU/YEL: Rear Right Negative
G RV: Rear left Negativa
NO
VES
GRV: RL8 BLU/VEL: RR8 LT BLU: Rl$ GRN/VEL: RR$
the control unit and connectors to View from wire side.
the speed sensors.
Repair open in sensor wire:

Connect ALB checker to inspec-
tion connector. GRN/BLK: Front Right Positiva GRN: Front Right Negativa
GRN/BLU: Front Left Positiva BRN: Front Left Negativa
GRN/VEL: Rear Right Positiva BLU/VEL: Rear Right Negativa
Check ALB function in MODE 2 LT BLU: Rear Left Positiva GRV: Rear Left Negativa
and 3.
Does it work properly? Faulty modulator.
VES
• lncorrect the air gap (paga 13-

81)
• Faulty control unit.
13-56
~
~
Problem Code 6-1 : Front Fail Safe Relay Circuit
Remove front fail safe relay.
Check relay function (page

13-80}. FRONT FAIL SAFE RELAY
CONNECTOR HARNESS SIDE
NO
Does it work properly? Faulty the front fail safe relay.
YES

BLK lead and body ground.
YEL/BLK BRN/BLK
Repairopen in BLK wire between View from terminal side
NO
ls there continuity? the fail safe relay and ground or
poor ground.
YES
Turn ignition switch ON.
Check for voltage between

YEL/BLK lead ( +} and body
ground (-).
NO Repair open in YEL/BLK wire

ls battery voltage available? between the fail safe relay a11d
No.8 fuse (7.5 A).
YES
FRONT SOLENOIDS
Turn ignition switch OFF. CONNECTOR HARNESS SIDE
LEFT: RIGHT:
Disconnect the 3P connectors

from the front solenoids.
RED/BLE YEL/BLE RED/BLK YEL/BLK

Check for continuity in BRN/BLK
BRN/BLK BRN/BLK
lead between fail safe relay and
solenoids. View from terminal side
NO Repair open in BRN/BLK wire

ls there continuity? between the solenoids and fail
safe relay.
YES
(To page 13-58)
(cont'd)
13-57
Troubleshooting
Flovvchart(cont'd)--------------------------------------------------
( From page 13-57)
FRONT SOLENOID CONNECTOR
Check for resistance between

RED and BLK terminals of front
solenoid.
NO
ls there 1 -3 Q? Faulty solenoid.
REO YEL
YES
BLK

YEL and BLK terminals of front
solenoid.
ls there 1-3 Q?
NO
Faulty solenoid.
YES
FRONT SOLENOIDS
LEFT: RIGHT:


control unit and front solenoid:
RED/BLK: Front Right lnlet
YEL/BLK: Front Right Outlet
RED/BLU: Front Left lnlet
YEL/BLU: Front Left Outlet.
•tt:~LoL•
••o¡o;'
BRN/BLK
RED/BLK YEL/BLK
BRN/BLK
CONTROl UNIT 12P CONNECTOR

RED/BlU: REO/BLK:
from Fl IN SOL. from FR IN SOL.
YEL/BLU:
from FL OUT SOL.
View from wire side.

Repair open in wire:
'------------.------------~
YES
r 1
YEL/BLU: Front left Outlet
• Faulty control unit. 1

• lncorrect air gap (paga 13-81 ). _j
13-58
Problem Code 6-4: Rear Fail Safe Relay Circuit
Remove rear fail safe relay.
Check relay functíon (page

13-80).
REAR FAIL SAFE RELAY CONNECTOR
HARNESS SIDE
NO
Does it work properly? Faulty relay.
VES
To control
unit ---- To ground
From No.8 ~From
BLK lead of wire harness and
fu se rear
body ground.
so len oíd
YEL/BLK BLU/BLK
Repair open in BLK wire between View from terminal side
NO
ls there continuity? the relay and ground or poor
ground.
VES
Turn ignitíon switch ON.
Check for voltage between

YEL/BLK lead (+) of wire harness
and body ground (-).

ls battery voltage available? between the relay and No.S
fusa.
YES
REAR SOLENOID CONNECTOR
HARNESS SIDE
Turn ignition switch off.
Torear solenoid Torear solenoíd (outlet}

Oole<) ~ YEL/WHT
from the rear solenoid.
RED/WHT 1li.J~
~rBLE/BLK
Check for continuity in BLU/BLK
solenoid. To rear fail safe relay
ls there continuity? Repair open in BLU/BLK wire

between the relay and solenoid.
VES
(To page 13-60)

(cont'd)
13-59
Troubleshooting
Flowchart (cont'd) - - - - - - - - - - - - - - - - - - - - - - -
( From page 13-59)
REAR FAI l SAFE RELAY CONNECTOR
HARNESS SI DE
1
~~N¿-Towo~d
Disconnect the 18P and 12P con- YEL/G
nectors from the control unit.
To control -----
=~-;;;;n
1 unit
From No.B _ .
Check for continuity in VEL/GRN
fu se solenoid
control unit. VE LIBLK BLU/BLK

1
Repair open in YEL/GRN wire
~ between the relay and control
unit.
1 VES

control unit and rear solenoid.
RED/WHT: Rear lnlet
VEL/WHT: Rear Outlet
1 Repair open in wire between the
~
ls there continuity: solenoid and control unit:
RED/WHT: Rear lnlet
YEL/WHT: Rear Outlet.
1 VES
Faulty control unit. HARNESS SIDE
To rear solenoid To rear solenoid (outlet)
AED/~::~~YELm~ ~p--BLE/BLK
Torear fail safe relay
CONTROL UNIT 18P CONNECTOR 12P CONNECTOR
GRN: from FAIL SAFE RELAY RED/WHT: from REAR IN SOL.
\
f 1 ~~~ 1~\ ~ 11 J
YEL/WHT: from REAR OUT SOL.
View from wire side
13-60
Problem Coda 7-1 and 7-2 Front Solenoid Related Problem
FRONT SOLENOID CONNECTOR
LEFT: RIGHT:
Disconnect wire harness from

front solenoids.

RED and BLK terminals of front
sofenoid. VEL
BLK BLK
ls there 1 -3 f.!? Faulty solenoid.
YES

YEL and BLK terminals of front
solenoid.
ls there 1 -3 f.!? Faulty solenoid.
FRONT SOLENOIDS
YES
Disconnect the 12P connector LEFT: RIGHT:

control unit and front solenoid:
iJ}
RED/Bl~L/BLE RED/BLK VEL/BLK
RED/BLU: Front Left lnlet BRN/BLK BRN/BLK
YEL/BLU: Front Left Outlet.
Repair open in wire:
CONTROL UNIT 12P CONNECTOR
NO RED/BLK: Front Right lnlet
ls there continuity ? VEL/BLK: Front Right Outlet RED/BLU: RED/BLK:
RED/BLU: Front Left lnlet from FL IN SOL ·from FR IN SOL.
YES VEL/BLU: Front Left Outlet
Check for continuity between con-

trol unit and body ground.
YEL/BLU: Front Left Outlet
Repair short in wire: VELIBLU:

YES RED/BLK: Front Right lnlet from FL OUT SOL.
ls there continuity? VEL/BLK: Front Right Outlet
RÉD/BLU: Front Left lnlet View from wire side
NO YEL/BLU: Front Left Outlet
• Faulty control unit.

• lncorrect air gap (page 13-811.
(cont'd)
13-61
Troubleshooting
Flowchart (cont'd) - - - - - - - - - - - - - - - - - - - - - - - . ,
Problem Code 7-4: Rear Solenoid Related Problem
Disconnect wire harness from.
rear solenoid.

RED and BLK terminals of rear
solenoid. RE D YEL
BLK
NO
ls there 1 -3 !l? Faulty solenoid.
VES
Check for resistan ce between

YEL and BLK terminals of rear
solenoid.
NO
ls there 1 -3 !l? Faulty solenoid.
YES REA A SOLENOID CONNECTOR

HAR NESS SIDE
]~:~~~:::··•1
Disconnect the 12P connector Torear
from the co'ntrol unit. (inlet)
~$
RED/WHT
Check for continuity between BLE/BLK

control unit and rear solenoid:
RED/WHT: Rear lnlet
Torear fail safe relay
YEL/WHT: Rear Outlet
Repair open in wire between the

NO 1
rear solenoid and control unit:

ls there continuity ? -¡ RED/WHT: Rear lnlet
YES 1
RED/WHT: from REAR iN SOL

Check for continuity between con-
trol unit and body ground.
YEL/BLU: Front Left Outlet
Repair short in wire:

~ RED/WHT: Rear lnlet
YEL/WHT: from REAR OUT SOL.
NO View from wire side.
Faulty control unit.

1 1
13-62
Hydraulic System
Hydraulic Connections
CAUTION:
• Do not spill brake fluid on the car; it may damage • The brake pipes and modulator pipe fittings are col-
the paint; if brake fluid does contact the paint, or coded.
wash it off immediately with water.
12 x 1.0 mm
19 N•m
(1.9 kg-m. 14 lb·ftl
BOOSTER
Do not Disassemble
10 x 1.0 mm
19 N·m
(1.9 kg-m,
14 lb-ft)
MASTER CYLINDER
12x1.0mm
19 N·m
11.9 kg-m,
14 lb-ft)
¡¡l
From
To reJ
right
~~i~~;r
secondary
Torear left
To front left
From
master cylinder
primary
13-63
Modulator
lndex/lnspection
CAUTION: • Before reassembling, check that all parts are

• Do not spill brake fluid on the car; it may damage free of dust and other foreign partícles.
the paint; if brake fluid does contact the paint, • Replace parts with new ones whenever
wash it off immediately with water. specifíed todo so.
• To prevent spills, cover the hose joints with rags • Make sure no dirt or other foreign matter is
or shop towels. allowed to contaminate the brake fluid.
• Clean all parts in brake fluid and air dry; blow out • Do not mix different brands of brake fluid as
all passages with compressed air. they may not be compatible.
• Use only new DOT 3 or DOT 4 clean brake fluid. • Do not reuse the drained fluid.
• Replace all rubber parts with new ones
whenever the modulator is disassembled.
RESERVOIR CAP
FRDNT RIGHT
REAR SOLENOID
SOLENOID
RESERVOIR LEFT
STRAINER ~
Remove sediment. ~
5mmSCREW
~
~
3.5 N·m (0.35 kg ~
2.51b-ft) ~
.¡
SOLENOID
0-RING
SOLENOID DIVIDER
HEAD 0-RING HEAD
0-RING
SOLENOID
SET PLATE
PUMP JOINT
MODULATOR
BODY
13-65
Solenoid
Solenoid leak Test
1. Connect circuit tester (U range) between the BLK 4. Apply 1 2 V across the BLK and RED terminals of
and YEL terminals. of the accumulator pressure the solenoid connector momentarily.
switch connector.
NOTE: Modulator reservoir may overflow.
2. Attach the positiva.(+) lead of a fully charged 12V
battery to the RED/WHT terminal of the power unit
motor connector and negativa (-) lead to the GRN
terminal, and install a switch between as shown·.
3. Turn the switch on to allow sufficient pressure to

build up within the accumulator and check for con-
tinuity with the circuit tester. lf ·the circuit tester
shows continuity (pressure switch turned on), run
the power unit for 4 seconds more, then turn the
switch off.
RED BLK
• Check if the solenoid hisses or squeaks. Replace

the modulator if the solenoid hisses or squeaks.
• Make sure that the solenoid does not hiss or

Check for continuity 1 minute after switch was turned squeak after it has clicked into position. Replace
off. the modulator if the solenoid hisses or squeaks.
No continuity: Leaky solenoid (if the pipe joint is tight) or
faulty divider 0-ring. • Check the pressure switch for continuity within
one minute. lt is normal if there is continuity. lf
there is no continuity, solenoid is faulty and
must be replaced.
13-66
Removal
1. Drain the brake fluid from the modulator tank. 8. Remove the hexagonal socket screws and loosen
the solenoid set plate.
2. Drain the high pressure brake hose (page 13-64).
9. Turn the solenoid valves severa! times until they
3. Disconnect the inlet hose. move freely and turn the solenoid valves 1/~ turn to
align their projection with the cutout in the set
4. Remove the reservoir strainer. plate.
Remove the solenoid valves together with the set
5. Remove the 5 mm screws and remove the plate. ·
reservoir.
CAUTION: The solenoid valves are delicate parts.
6. Screw the 6 mm bolt into the threaded hole in the Be careful not to drop them.
center of the solenoid head, reaise the solenoid
head parallel to the ground and remove it. FRONT
RIGHT
SOLENOID
7. Remo ve the solenoid cover.
FRONT
~
STRAINER
o
~ ~.
-~·
""~ l f
5mmSCREW
SOLENOID
ADJUST
SPRING
SOLENOID
HEAD
HEXAGONAL
SOCKET
SCREW
13-67
Solenoid
lnspection - - - - - - - - - - - - - - - , lnstallation - - - - - - - - - - - -
1. Connect a tube to the inlet of the solenoid valve. 1. Fill the modulator body with brake fluid up to the
Apply compressed air to the solenoid valve through step in the solenoid mounting hole.
the tube.
NOTE: On solenoid valve assembly, place shop
2. Check the solenoid valve for proper operation by rags over the solenoid valve and under the
connecting a 12 V fully charged battery to the 3-P modulator valve to prevent the brake fluid from
coupler terminals: spilling on the valve.
Voltage not applied: There should be no air flow.
Black - Red: There should be air flow through IN

and OUT.
Black - Yellow: There should be air flow through

IN.
FOR EXAMPLE:
FRONT SOLENOID 3-P COUPLER
OUT
IReservoir
side)
2. Coat the 0-ring with the clean brake fluid and in-
stalf the 0-ring onto the solenoid valve.
3. lnstall the solenoid valves on the set plate.
1%1f.i-jd!.i!i
Each solenoid valve and set plate are
marked for correct installation. lf the solenoid
valves are interchanged, the system will not work
properly. Refer to the marks and be sure to install
them in correct positions.
• Align the projection on the solenoid valve with

the cutout in the set plate and turn the valve 1 /2
turn. The solenoid wire should face rearward.
0-RING
REAR
0-RING
Repface
(cont'd)
13-68
Piston
Rernoval------------------------~
4. lnstall the solenoid adjust springs on the modulator 1. Remove the modulator heads.
body.
5. lnstall the solenoid valves and set plate and secure

with the hexagonal socket screws.
6. lnstall the solenoid cover and solenoid head.
7. lnstall the reservoir tank.
8. lnstall the tank filter.
9. Connect the low pressure hose.
18 No m O .8 kg-m, 13 lb-ftl
2. lnsert the driver into the spring, pry off the pistan
assembly until it lifts up slightly and pull out the
lock nut with a pair of pliers.
CAUTION:
• Set the washer between the driver and
modulator body to.prevent damage to the body.
• Be careful not to damage the piston sleeve.
LOCK NUT
Set the wire here and

install securely.
13-69
Pistan
lnstallation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
1. Apply rubber grease to the shaded sectians of the 3. Set the piston assembly in the piston mounting
piston assembly, shown in the drawing below. hale in the modulator bady and push dawn an the
pistan.
4. Push on the piston about 5 times until no bubbles

come out of the solenoid side.
5. lnstall the modulator springs.
6. lnstall the solenoid heads with care not ta pinch the

0-rings.
2. Adjust so that the brake fluid flows inta the pistan
mountíng hole in the madulatar body.
22 N·m (2.2 kg-m, 16 lb-ft)
THICKER SPRING:
INNER SIDE
THINNER S;:::: ~
OUTERSIDE ~
0-RING
·13-70
Power Unit
lndex/lnspection
CAUTION: • Befare reassembling. check that all parts are

• Do not attempt to disasemble the power unit free of dust and other foreign particles.
parts except for those shown exploded in this • Replace parts with new ones whenever
illustration. specified todo so.
• Do not spill brake fluid on the car; it may damage • Make sure no dirt or other foreign matter is
the paiot; if brake fluid does contact the paint, allowed to contaminate the brake fluid.
wash it off immediately with water. • Do not mix different brands of brake fluid as
• To prevent spills. cover the hose joints with rags they may not be compatible.
or shop towels. • Do not reuse the drained fluid.
• Clean all parts in brake fluid and air dry; blow out
all passages with compressed air.
BAJO BOLT
MAINTENANCE
---38N•m
(3.8 kg-m. 28 lb-ft)
~=---------PUMP
BRACKET
13-71
Power Unit
Disassembly 1Reassembly
1. Remove the pump bracket. 4. Wash the motor with clean brake fluid only on the
exposed end and blow dry with compressed a ir.
2. Remove the 6 mm bolts attaching the pump to the
pump motor.
0-RING
6 mm BOLTS
DRAIN HOLE
NOTE: Do not wash or dip the motor in brake fluid.

Also be careful not to allow oil or water to enter the
inside through the water drain hale.
PUMP BRACKET
5. lnstall a new 0-ring on the pump motor.
6. Coat the 0-ring with clean brake fluid and install the
6 mm BOLT pump on the motor while rotating it right and left by
hand.
3. Separate the motor from the pump while rotating
the pump right and left. PUMP
... r
MOTOR ASSEMBL Y PUMP
NOTE: About 1 O ce (0.6 cu-in) ot brake fluid will 7. lnstall and tighten the 6 mm bolts.
flow out when the motor is removed from the 8. lnstall the removed parts in the reverse order of
pum p. removal.
13-72
Accumulator Unit
Accumulator1Pressure Switch Accumulator Disposal
1. Drain the high pressure brake fluid from the power i¡jj,dé'!.iii The accumulator contains high pressure
unit (see page 1 3-64). nitrogen gas, do not puncture expose to flame or at-
tempt to disassemble the accumulator or it may ex-
2. Remove three 6 mm flange bolts, then remove the plode; severe personal injury may result.
accumulator from the accumulator bracket.
1. Secure the accumulator in a vice so that the relief
3. Remove the pressure switch bolt and oil bolt then plug points straight up. ·
remove the pressure switch from the bracket.
2. Slowly turn the plug 3-1/2 turns and then wait 3
minutes for all pressure to escape.
PRESSURE SWITCH 3. Remove the plug completely and dispose of the ac-
cumulator unit.
PRESSURE
SWITCH
- 6 mm FLANGE
BOLT
10 N·m {1.0 kg-m,
7 lb-ft)
Re place.
OIL BOLT
35 N•m
13.5 kg-m,
25 lb-ft)
ACCUMULATOR
13-74
~
Master Cylinder ~
~verhaul/lnspection~~~~~~~~~~~~~~~~~~~~~~~~
CAUTION: e Carefully inspect the bore of the master cylinder for

• Avoid spilling brake fluid on painted surfaces as pits, scratches or scoring.
severa damage can result. Wipe up spilled fluid at • Replace the master cylinder if the bore is damaged or
once and rinse well with clean water. worn. Do not hone or attempt to refinish the bore.
NOTE:
• 1-: -
This symbol represents brake fluid. Use only
DOT 3 or 4 brake fluid.
• Wash alt removed parts in brake fluid and blow dry with
compressed air. Blow open all passages and fluid ports.
~Use only HONDA Brake Cylinder

• Replace all rubber parts with new ones whenever the
• cylinder is disassembled.
Grease (P/N 08733-B020E) or equivalent. • To prevent damage, liberally apply clean brake fluid to
the piston cups befare ínstallatíon.
• Do not attempt to refinish master cylinder bore. Replace
if pitted or worn.
RESERVOIR CAP
Check for clogged aír hole.
RESERVOIR SEAL - - - - - . - l \
PRIMARY PISTON
STRAINER ASSEMBLY •
Remove accumulated ----. • ·: PISTON CUP
sediment. -SILICONE
::aillilalGREASE
FLUID RESERVOIR
MASTER CYLINDER ROO SEAL

Check for damage or
wear.
1 (INNERWALL
OF CYLINDER) --7""'-- 15 N ·m
(1.5 kg-m.
11 lb-ftl
- c;;:;m
SILICONE
GREASE
PISTO N
Re place. ~~~:__------- GUIDE
STOP BOLT
Replace.
9 N•m (0.9 kg-m.
1
7 lb-ft)
~
SILICONE GREASE
Brake Cylinder Grease
(P/N OB733-B020E)
or equivalent
- e¡¡;;;..
SILICONE GREASE 1 PISTON CUP
13-75
Master Cylinder
Disassernbly--------------------------------------------------------~
CAUTION: 3. Remove the stop bolt while pushing in the secondary

• Avoid spilling fluid on painted, plastic or rubber piston assembly.
parts as it may damage the finish.
• Plug the end of the brake hose with a shop rag to
prevent brake fluid from flowing out of the brake
hose after disconnecting.
• Use only new clean DOT 3 or DOT 4 brake fluid.
• Clean all parts thoroughly with brake fluid. Blow
out all passages with compressed a ir. STOP
• Do not allow foreign matter to enter the system. BOLT
• Be careful not to bend or damage the brake pipe
when removing the master cylinder.
1. Remove the rod seal.
Replace.
ROO SEAL
Replace.
4. Remove the piston guide, secondary pisten assembly
and primary piston assembly.
NOTE: lf the primary piston assembly is difficult to

remove, apply compressed air from the primary piston
side outlet.
CAUTION:
• Do not use high pressure air or bring the nozzle
too close to the inlet.
• Place a shop rag over the master cylinder to
2. Push the secondary piston assembly, then remove the prevent the primary piston from becoming a
snap ring. projectile.
CAUTION: Avoid damaging the master cylinder

wall.
13-76
Reassembly~--------------------------------------------------~
CAUTION: 3. Make sure that the primary piston assembly and secon-
e Do not spill brake fluid on the car; it may damage the dary piston assembly are in good condition.
paint; if brake fluid does contact the paint. wash it off
immediately with water.
e To prevent spills. cover the hose joints with rags or
PRIMAR Y PISTON ASSEMBL Y
shop towels.
e Clean all parts in brake fluid and air dry; blow out all
passages with compressed a ir.
e Use only new clean DOT3 or DOT4 brake fluid.
e Before reassembling. check that all parts are free of
dust and other foreign particles.
e Replace parts with new ones whenever specified to
do so.
e Make sure no dirt or other foreign matter is allowed to
contaminate the brake fluid.
e Do not mix different brands of brake fluid as they may
not be compatible.
PRIMARY PISTON CUP
e Do not reuse the drained fluid.
1. lubricate the new pistan parts with brake fluid. NOTE:
• Reaching through the primary piston stop bolt
2. lnstall the new 0-ring and secondary cup onto the hole. lightly press on the valve stem to see if it
pistan guide. moves smoothly.
• Make sure that the dimensionA is 1.85-2.45
mm.
PISTON GUIOE ASSEMBLY
0-RING SECONDARY PISTON ASSEMBLY

Re place.
SECONOARY PISTON CUP

PISTON
GUIDE 1
FRONT~ VALVE GUIDE VAL VE STOP PIN

ASSEMBLY STEM GUIDE
NOTE:
SECONOARY e Confirm that the dimension 8 is 0.9-1.5 mm while
CUP pushing the stop pin guide forward on the pisten
sub-assembly.
• Lightly press the stop pin guide to see if the

NOTE: Replace the secondary cup and piston guide as val ve stem moves smoothly.
a set if necessary.
(cont'd)
13-77
Master Cylinder
Reassembly (cont'd)
4. Assemble the priinary piston assembly, secondary 7. lnstall the rod seal.
piston assembly ··and pis ton guide assembly in the
master cylinder body.
NOTE: lnstall the primary piston with the slot on

the cylinder facing the stop bolt hole side.
5. Push the secondary piston in until slot aligns with

the stop bolt hole, then install and tighten the stop
bolt.
CAUTION:
e Replace the stop bolt seal with a new one when-
ever disassembled. ROO SEAL
e Apply brake fluid to the inner wall of the cylínder
and piston cups, being careful that they are not
turned inside out during installation.
SILICONE
GREASE
CAUTION:
• Make sure that there is no interference between
the brake pipes and other parts when installing.
• Adjust the pushrod length and clearance (paga
13-17 and 18).
6. Press the secondary piston in and install the snap

ring.
CAUTION: Avoid damaging the sliding surface of

the secondary piston when installing the snap ring.
13-78
Bleeding
Air Bleeding With ALB C h e c k e r - - - - - - - - - - - - - - - - - - - ,
NOTE: 1 O. Turn the mode switch to 2.
e Set the Pulse Selector switch to 50 when using ALB
checker 07HAJ-SG00601.
e Do not depress the brake pedal during air bleeding. Or
the air bleeding may be affected.
1. Fill the modulator reservoir with brake fluid up to

the MAX level.
2. Disconnect the 6P coupler (PNK) from the cover

mounted in front of the console and connect it to
the ALB checker.
11. Press the start switch.
1 2. Brake fluid in the reservoir will bubble briskly for 20

seconds after the switch ís pressed. Wait for 4 to 5
minutes until the brake fluid stops bubblíng.
13. Turn the mode switch to 6.
ALB CHECKER 14. Repeat steps 11 and 12.

07 HAJ-SG00601 ....._
or 07 508-SBOOOOO 1 5. Repeat steps 1 O through 14 two or three times.
and 07HAJ-SG00400
(Adaptorl
16. Fill the reservoir with brake fluid up to the MAX
CAUTION: Place the car on level ground with the level.
wheels blocked. Shift the transmission to P or
Nutra l. RESERVOIR CAP

MAX
4. Release the parking brake.
5. Turn the power switch of ALB checker ON.
POWER SWITCH
17. lnstall the cap.
18. Check the ALB function in all modes (page 13-45).

6. Turn the mode selector switch to 1. There should be kickback in modes 2 through 5.
7. Press the start switch. CAUTION: lf the kickback is weak, re-bleed air
from the system.
8. Mal<.e sure that the motor runs.
9. Wait for the motor to stop.
13-79
Electronic Components
Control Unit Replacement ------., Fail Safe Relays/Motor Relay - - - -
lnspection
Remove the control unit attaching bolts, then
remove the control unit. 1. Check for continuity between terminals @ and @.
CAUTION: There should be no continuity.

e lf the control unit attaching bolts are removed,
the control unit's memory is cleared. 2. Connect a 12V battery across teminals G) and 0.
e Handle the control unit with care.
There should be continuity between terminals @
and@.
Faíl Safe Relays
CONTROL
UNIT
lnstallation is the reverse order of removal.
NOTE: Check "the dash warning light function by turn-

ing the ignition switch ON. Motor Relay
13-80
Wiring Diagrams
lndex--------------------------------------------------
Headlights · 6
Taillights · · · · · · · · ·6
16-274
Pulsers/Sensors
lnspection------------------------------------------------------------~
Front Rear
1. Check the pulser for chipped or damaged teeth. 1. Check the rear pulser for chipped or damaged
teeth.
FRONT SENSOR
FRONT PULSER
2. Measure air gap between the sensor and pulser all 2. Measure the air gap between the sensor and pulser
the way around while rotating the driveshaft by all the way around while rotating the hub bearing
hand. unit by hand.
STANDARD: 0.4-1.0 mm (0.02-o.04 in.) Standard: 0.4-1.0 mm (0.02-o.04 in.)
NOTE: lf the gap exceeds 1.0 mm (0.04 in.}, the NOTE: lf the gap exceeds 1.0 mm (0.04 in.). the pro-
probability is a distorted knuckle which should be babi\ity is a distorted knuckle which should be replaced.
replaced.
13-81
Doors
lndex
Front:
GLASS
Adjustment, page 14_13
~~POWERDOORLOCK
LA TCH ASSMBLy ~ " ' SWITCH
INSIDE DOOR
HANDLE
Passenger:-s ~
(t(~_'l
~7'
DOOR PANEL
BRACKET
_1\.j 1
DOOR INNER
WEATHERSTRIP
~ OOORPANEL
DOOR POCKET SPEAKER COVER

(cont'd)
14-3
Doors
lndex (cont'd) - - -
Rear:
WEA THERSTRIP
CENTER CHANNEL
QUARTER
GLASS
1
GLASS RUN
CHANNEL
LOWER RUN
CHANNEL
DOOR GLASS
Disassembl Adjustment , page 14-13
Assembl Y, page 1 4-8
Adjustm Y' page 1 4-1 2
ent, page 14-1 5
FRONT
CHANNEL
PLASTIC COVER
~,~
DOOR PANEL
POWER WINDOW
SWITCH
COURTESY LIGHT
14-4
Disassembly
Front: 4. Remove the 2 door panel screws, then pry apart the
door panel clips. Lift the door panel straight up off the
1. lf applicable, remove the regulator handle by pulling sill, and disconnect the power window and courtesy
the clip out with a wire hook. light wires.
REGULATOR HAN OLE
2. Remove the mounting screw, then pull the inside

door handle out half-way and disconnect the latch
rod and power door lock connector.
HOOKS
INSIDE DOOR
HAN OLE
: Clip locations
CLIP
LATCH ROO
5. Remove the power window control unit, door panel
bracket, speaker and cover panel.
6. Carefully remove the plastic cover.
POWER WINDOW
CONTROL UNIT
PLASTIC COVER
NOTE: Remove the panel with as little bending as

possible to avoid creasing or breaking it.
\ 95mm \
DOOR PANEL
12mm
.,j_~
~
RELEASE TOOL
1 mm
DOOR PANEL
TI 45mm
1 BRACKET (cont'd)
14-5
15. Remove the 4 mounting bolts and loasen the 2 motor 17. Remove the mounting bolts, then remove the front
bolts, then take out the regulator assembly through and center channels.
the center hole in the door.
NOTE: Scribe a line around the roller guide moun-

ting bolt to show the original adjustment.
ROLLER GUIDE
BOLT
GLASS RUN
CHANNEL ~
FRONT
CHANNEL
CENTER
CHANNEL
REGULATOR REGULA TOR ASSEMBL Y

ROllER GUJDE .
16. Remove the screw and, starting at the rear, pry the 18. Peel off the glass run channel and remove the
molding up, detach the clips, then remove the outer mounting screws, then remove the door sash gar-
molding. nish by hand:
SASH
GARNISH
REAR CLIP
14-7
Door
Disassembly
Rear: 5. Remove the door panel bracket and carefully remove

the plastic cover.
1. lf applicable. remove the regulator handle by pulling
the clip out with a wire hook ( page 1 4-5).
2. Remove the inside door handle and disconnect the

latch rod.
3. Remove the screws and detach the clips attaching the

door panel. (See door panel release too!, page 14-5}.
4. Disconnect the power window and courtesy light

harnesses.
HOOKS
INSIDE DOOR HANDlE
DOOR PANEL BRACKET
6. Remove the screw attaching the door lock crank.

Disconnect the latch rod from the latch side.
DOOR LOCK
CRANK
· : Clip locations LATCH ROO
CLIP
14-8
7. Reconnect the window switch or use a 1 2V battery to 13. Carefully lower the window until you can see its
operate the window regulator. mounting bolts.
Use protective tape on the lower door sash garnish
8. Roll up the window fulty. and center channel as shown.
Remove the lower bolt from the front channel and slide
9. Use protective tape around the edge of the door the channel forward.
handle to prevent scratching the paint.
Remove the 3 mounting screws, then slide the
latch assembly down. GLASS
1O. Remove the outside door handle mounting bolts.
OUTSIDE DOOR HANDLE
PROTECTIVE
TAPE
FRONT
DOOR HANDLE
MOUNTING BOLT
LA TCH ASSEMBL Y
NOTE: Take care not to bend the latch rods. GLASS MOUNTING
BOLTS
11 . Pull the outside door handle out, and pry the joint
14. Remove the mounting bolts and pull the glass out
off the handle with a flat tip screwdriver. Remove
through the window slot.
the handle from the rod.
15. Remove the 5 regulator mounting bolts and loosen
NOTE: To ease reassembly, note the location ® of the the upper bolt, then take out the regulator
rod on the joint before disconnecting it. assembly through the hole in the door.
OUTSIDE DOOR HANDLE

REGULATOR
12. Pull the latch assembly out through the hole in the ASSEMBLY
door panel. (cont'd)
14-9
Doors
Disassembly (cont'd)
16. Starting at the rear, pry the molding up and detach the 20. Peel off the door weatherstrip.
clips, then remove the outer molding.
21. Remove the quarter glass from the door sash.
NOTE: Take care not to scratch or score the glass

and molding.
17. Peel off the door weatherstrip and remove the

center channel upper mounting screws.
18. Remove the lower mounting bolts and glass run

channel, then remove the center channel.
19. Remove the front channel.
22. Remove the rear door sash garnish in the same way
CENTER as the front door sash garnish (page 14-7). ·
CHANNEL
FRONT
CHANNEL
NOTE: When installing the center channel, make sure

there is no gap between center channel and quarter
glass.
14-10
Weatherstrip Replacement
NOTE: Befare installing the weatherstrip, apply clear sealant to the shadowed areas of the door as shown.
*: 40 mm {1.6 in)
Sealant: cemedine #8500
WEATHERSTRIP WEATHERSTRIP
CLIP
WEATHERSTRIP
14-11
Doors
Assembly
Assemble the door in the reverse arder of disassembly, 4. Fix the wire harness correctly on the door.
and also:
5. When reinstalling the plastic cover, apply adhesive
1. Grease all the sliding surfaces of the window along the edge where necessary to maintain a con-
regulator where shown. tinuous seal and prevent air/water leaks.
2. Befare removing the motor, make the location by

marking fine across the sector gear and regulator,
and install using the three mounting bolts. Move
the window regulator to the original position by
connecting a 12V battery to the motor (See section
16) ..
Rear:
Rear:
6. lnstall the regulator handle so it points forward and

up at a 45 degree angle with the window closed.
3. Roll the glass up and down to see if it moves freely

without binding. Also make sure that there is no
clearance between the glass and glass run channel
FRONT OF
when the glass is closed. Adjust the position of the VEHICLE
door glass as necessary (page 14-13).
14-12
Glass Adjustment
NOTE: 4. Te adjust glass fit in the door, raise the glass as far
• Place the vehicle on a firm, level surface when ad- up as possible and hold it against the door sash.
justing door fit. Then tighten the roller guide bolts or motor moun-
• Check the weatherstrip and glass run channel for ting bolts.
damage or deterioration and replace if necessary. Check the smooth movement of door glass.
1. Remove the door panel and peel off the plastic cover Front:
(pages 14-5, 8).
2. lnstall the regulator handle on the door regulator.
(Power Window Model)

Driver's:
Remove the power window switch from the armrest.
POWER WINDOW
SWITCH
Rear:
CLIP
Passenger' s/Rear door:

Remove the power window switch from the armrest.
ffF
POWER WINDOW
SWITCH
3. Connect the power window switch to the door

harness. (cont"d)
14-13
Doors
Glass Adjustment (cont'd)
5. lower the window until there is a small gap between 7. Raise the window glass fully and check gap.
the door glass and the glass run channel.
8. Perform the operation test.
6. Loasen the roller guide bolts and adjust the window
glass so it is parallel with the glass run channel.
NOTE: Check .that the glass run channel is not
pinchad by the glass.
Front:
GLASS RUN
CHANNEL
9. With the door and glass closed fully, check for

Rear: water leaks.
NOTE: Loasen the upper regulator mounting bolts NOTE: Do not use high pressure water.
and adjust the window glass.
1 O. lnstall the door harness.
11. Attach the plastic cover, and install the door panel.
12. Check for air leaks.
14-14
Door Position Adjustment Door Striker Adjustment - - - - - . . ,
After installing the door, check for a flush fit with the Make sure the door latches securely without slamming.
body, then check for equal gap between the front and lf it needs adjústment:
rear, and top and bottom door edges and the body.
The door and body edges should also be parallel. Adjust 1. Draw a line around the striker plate for reference.
at the hinges as shown.
CAUTION: Place a shop towel on the jack to pre- 2. Loosen the striker screws and move the striker IN
vent damage to the door when the hinge bolts are or OUT to make the latch fit tighter or looser. Move
loosened for adjustment. the striker UP or DOWN to align it with the latch
opening. Then lightly tighten the screws and
recheck.
HINGE MOUNTING BOL TS NOTE: Do not tap the striker with an iron hammer to
Loosen the bolts, and move the adjust the position.
door BACKWARD or FORWARD,
UP or DOWN as necessary
to equalize the gaps. STRIKER
\ (.
~
1
NOTE: Hold the outside handle out and push the

door against the body to be sure the striker allows a
DOOR MOUNTING BOLTS
flush fit.
Loosen the bolts slightly to move the
door IN or OUT until it's flush with the 3. lf the door latches properly, tighten the screws and
body. lf necessary, yo u can install a recheck.
shim behind ene hinge to make the
door edges PARALLEL with the NOTE: Replace the striker if a crack is seen on any
body. parts of the resin.
The door and body edges should be parallel.
NOTE: Check that the water and air leaks.
14-15
Power Door Mirror
Removal Mirror Glass Replacement
1. Pry out the cover panel with a flat tip screwdriver, 1. lnsert a screwdriver in the mirror througli the ser-
then remove the cover panel. vice hole, and loasen the actuator retaining screw.
Oisconnect the power mirror connector.
2. Remove the mirror mounting screws while holding

the mirror.
DOOR MIRROR
2. Pull the actuator out from the mirror housing.

3. Pull the lock cap stopper and remove the stopper
pin, then separate the actuator and mirror holder.
3. lnstall the door mirror in the reverse arder of

remo val.
4. With the door and door glass closed fully, check for
water and air leaks.
LOCK CAP
NOTE: Do not use high pressure water. STOPPER
4. Heat the edge of the glass with a low powered heat

gun for severa! minutes, then remove the glass.
5. lnstall the glass in the mirror case, narrow end first.
14-16
Manual Door Mirror
Removal Mirror Glass Replacement
1. Remove the cap and the screw, then remove the 1. lnsert a screwdriver in the mirror through the ser-
control knob. vice hole and loosen the glass retaining screw.
2. Remove the cover panel.
3. Remove the mirror mounting screws while holding

the mirror.
DOOR MIRROR
2. Carefully pry out the mirror with a flat tip

screwdriver as shown.
CAUTION: To prevent damage to the mirror, wrap

the end of the screwdriver with a shop towel.
r~
CONTROL KNOB r
CAP
SHOPTOWEL
\
4. lnstall the door mirror in the reverse arder of
remaval.
3. lnstall the mirror in the reverse arder of removal and
5. With the door and door glass closed fully, check for also apply grease ta the location indicated by the
water and air leaks. arrow.
NOTE: Do nat use high pressure water.

PIVOT
MIRROR STOPPER PIN
14-17
Control Unit Input T e s t - - - - - - - - - - - - - - - - - - - - - - - - - - .
NOTE: Check the No.2 {15 A) fuse before input test.
Disconnect the 5-P connector from the control unit.
Make the following input test at the harness pins.
View from wire side
BLK/YEL
~----- BLK GRN/WHT
No. Wire Test condition Test: desired result Possible cause (if result is not obtained)
Under all conditions. Check for continuity to ground: · Poor ground (G401 , G402).
1 BLK
should be continuity. • An open in the wire.
lgnition switch ON. Check for voltage to ground: · An open in the wire.
2 BLK/YEL should be battery voltage.
lgnition switch ON. Check for voltage ground: · Faulty solenoid valve.
3 GRN;WHT should be battery voltage. · An open in the wire.
Start the engine. Check for voltage ground: • Faulty ignition system.
4 BLU
should be battery voltage. • An open in the wire.
e Replace the control unit if the mount is not detective and no defects are found in the above input tests.
16-273
Wiring Diagrams
lndex--------------------------------------------------
Headlights · 6
Taillights · · · · · · · · ·6
16-274
Windshield, Rear Window
·lndex
( · ): Ouantity of part used. UPPER MOLDING
* SIDE CLIP Color:
¡
CORNER MOLDING
C: Gray
D: White
E: Red ;;RNER CUP B {11
V *SIDE CLIP
C.D.E
~~RETAINER
l!l/1"' (41
SIDE CLIP A (4)
WINDSHIELD SIDE MOLDING

Removal, page 14-21
LOWER
SPACER (2)
UPPER CLIP 8 (51

REAR WINDOW GLASS
Removal, page 14-26
))y
CORNER CLIP ICI
LOWER
COVER
J\
SIDE CLIP B (21
14-18
lnstalltion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
Body Glass
Center the glass
Mix adhesive and

hardener
--Parts-.----------------------------------------------------------------~
Part Number Contents Comment
Adhesive kit - low temperature

08718-99960
High temperature
l Adhesive sealant 1500 g)
Hardener {75 g)
Glass primer G (20 g)
Body primer M (20 g)
08718-99961 Piano wire (0.6</l x 1 m (3fll
Gauze
Cartridge For glass primer (G}
Sponge For applying primers
~Tools----------------------------------------------------------------~
Tooi/Material Remarks
Glass or steel plate To mix adhesive and hardener on

Putty knife To mix adhesive and remove excess
Caulking glin To apply bead of adhesive to windshield
Suction cups To install windshield
K ni fe To scrape bonding surface around window opening

Awl To make hole through existing adhesive for piano wire
Two wood sticks To hold piano wire
T oluene or alcohol To clean bonding surfaces
14-19
Windshield, Rear Window
Workable Time Notes - - - - - - - - - - - - - - .
Adhesive workable time varies widely according to • 8oth kits have two types of adhesive primer: one
temperatura, so choose the correct adhesive kit for the for the body (metal), and one for glass.
temperatura range you will be working in.
After mixing and applying adhesive, you should install • Always use new genuine Honda adhesive, or
the windshield within the time shown on the chart. equivalent.
For example, when the ambient temperatura is 25°C • Do not use the adhesive if 6 months have elapsed
(77°FI. the glass should be installed within 45 minutes since date of manufacture.
using the high temperatura type adhesive.
Kit part numbers and contents are listed on the page • Store adhesive in a cool, dry place.
befare.
• Open only immediately befare you are going to use
it.
95.0
A~heslve ~it f~r
1
! 86.0 30 \
'\ ~gh temperatures
~
«1 77.0 25 ,.....
G>
Q.
68.0 20
1 '-.... ,/
E
<11
1- 59.0
1
1
..........
r---,_
e '' 1 Adhesive kit for
<11 50.0 10 low temperaturas
:e
E 41.0 ' .... #f 1 1 J l
<(
32.0
1
1-t- -l
30 45 60 90 120
0
( f)
- - - - - - - -...... working time (mini
Hardening Time - - - - - - - - - . . . . , Broken Glass Removal

Hardening time can be shortened by heating with in- Remove as much broken glass as possible with a vacuum
frared light. cleaner.
Blow out the glass in the heater and behind the dashboard
For example, the adhesive will start to harden within with low pressure compressed air:
270 minutes mixing at 20°C (63°F). lf however, it is
heated to 35°C (95°F), it will start to harden within 90 f'i§'§hMI~M Wear eye protection while using the air
gun.
minutes.
1. Set the temperature control lever to COLO.
2. Push the HEAT button on the function panel.
104.0 40 r--r--.-.--....----,,.-.----.--r-...--.--, 3. Make su re the recircufation button is out (OFF).

95.0 35~~,.~~~~~~--+-,-~,-~,~,~~,--4
1\ FÓr high 4. Blow compressed a ir through the defroster center vent
86.0 30 1--+-':~~-+--+-~temperature adhesive- outlet.
77.0 25 1 ,..,
5. Remove the blower duct, and remove any glass from
-~--±-t-+-t--+-t--1
20 1--+"""1,.--t-+---=
1
68.0 1
the air mix chamber.

1 -r--
59. O 151----+-+,-+.::'---+-+--+-F+---t=-t-----l-+---1
1 1 6. Remove the any glass from the top of the vent/defrost
50.0 1 0 ~~-+-~-+"'--lr---+- or ow temperature
...._ [;/, ad~esiv e
41.0
1 1 1
51--+-~~+--+~~q--+-+--!r-+---!
door.
32.0
-¡- t- -l 7. Remove any glass from top and bottom of carpet and
o 60 120180240300360420480540600660 seats with a vacuum cleaner.
90
------~ Hardening time lmin) NOTE: lt is recommended to remove the seats to shake off
any glass (page 14-40).
14-20
Windshield
Removal
CAUTION: 3. Raise the upper molding slightly away from the wind-
• Wear gloves to remove and install the glass. shield at the locations where the molding clips are
• Use seat covers to avoid. damaging surface. used, then fit the end of the molding clip release tool
at each clip, and pull it toward you until the clip is clear
of the molding.
1. To remove the windshield, first remove the:
e Rearview mirror (page 14-49). UPPER MOLDING GLASS
e Sun visors and holders.
e Front pillar trim (page 14-38).
e Front wiper and air scoop.
2. Detach the clip A trom the retainer, then remove

the side molding with comer molding as shown.
RETAINER
TOOL
4. Remove the other clips and retainers from the body.
MOUNTJNG SCREW
5. Lower the front of the headliner.
CAUTION: Take care not to bend the headliner

excessively. ·
6. Apply protective tape along the edge of the dashboard

NOTE: You will need a molding clip release tool to and body next to the glass as shown.
remove sorne moldings. lf necessary, make one
that has the dimensions shown.
PROTECTIVE TAPE
Molding Clip Ralease Tool

Thickness: 2 mm (0.08 in.). pointed
at the end.
38mm
11.49 in.)
14-21
Windshield
Removal (cont'd) lnstallation - - - - - - - - - - -
7. Using an awl, make a hole thrugh the windshield 1. Scrape the old adhesive smooth with a knife, to a
adhesiva from inside the car. Push piano wire thickness of about 2 mm 10.08 in.) on the bonding
through the hole and wrap each end around a piece surface around the entire windshield flange.
of wood.
NOTE:
PIANO WIRE • Do not scrape down to the painted surface ot
the body; damaged paint will interfere with
proper bonding.
• Remove all traces of th~ rubber spacer material
from the body.
• Mask off surrounding surfaces before painting.
2. Clean the body bonding surface with a sponge

dampened in alcohol.
NOTE: After cleaning, keep oil, grease or water

from getting on the surface.
3. lf the old glass is to be reinstalled, use a putty knife

to scrape off all traces of old adhesiva, then clean
the glass surface with alcohol where new adhesive
is to be applied.
ADHESIVE
NOTE: Make sure the bonding surface is kept free of
8. With a helper on the outside, pull the wire back and water, oil and grease.
forth in a sawing motion and carefully cut through
CAUTION: Avoid setting the glass on its edges;
the adhesive around the entire windshield.
small chips may later develop into cracks.
CAUTION: Hold the piano wire as close to the

glass as possible to prevent damage to the body
and dashboard.
Clean the shadowed

area.
9. Cut the rubber .spacers away from the body with a

knife; they are cemented in place.
NOTE: Replace the rubber spacers with new ones

whenever the windshield has been removed.
14-22
4. lnstaU the molding clips and retainers as shown. 7. Glue the dashboard seal and rubber da m to the in-
side face of the windshield as shown to contaín the
5. Peel the backing off each spacer, then install the adhesive during installation.
spacers by pressing them firmly into place at the Joca-
tions shown. NOTE: Be careful not to touch the glass where
PIN (Body sídel
adhesive will be applied.
9 mm {0.35 in)
~
DAM ~ DAM
LOWER SPACER {2) 8. With a sponge, apply a light coat of glass primer
around the edge of the glass as shown, then lightly
wipe it off with gauze or cheesecloth.
NOTE:
• Do not apply body primer to the glass, and do
6. Set the windshield upright on the lower spacers. then not get body and glass primer sponges mixed
center it is the opening. Mark the location by markíng u p.
lines across the glass and body wíth a grease pencil at • Never touch the primed surfaces with your
the four points shown. hands. lf you do, the adhesive may not bond to
the glass properly, causing a leak after the wind-
shield is installed.
ALIGNMENT MARKS • Keep water, dust, and abrasive materials away
from the primed surface.
~ : Apply glass primer here.
(cont'dl
14-23
Windshield
9. With a sponge, apply a light coat of body primer to 12. Pack adhesive into the cartridge without air
the original adhesive remaining around the window pockets to ensure continuous delivery. Put the car-
opening flange. The glass should be installed 1 O tridge in a caulking gun and run a bead of adhesive
minutes after you apply the primer. around the edge of the glass as shown.
NOTE: NOTE: Apply the adhesive within 30 minutes after

• Do not apply glass primer to the body, and be applying the glass primer.
careful not to mix up glass and body primer
sponges. ---~..l.- 2 mm
• Never touch the primed surfaces with your 11 (0.08 in) 1 mm
hands. 12 mm T~ ADHESIVE : (0.04inl
·~~~
• Mask off the dashboard before painting the {0.5in1a.
flange. 1--------l
8 mm (0.3 in)
~ : Apply body primer here
Make a slightly thicker

bead at each comer.
10. Thoroughly mix all the adhesive and hardener 1 3. Use suction cups to hold the glass over the open-
together on a glass or metal plate with a putty ing, align it with the marks made in step 6 and set it
knife. down on the adhesive. Lightly push on the glass
until its edge it fully seated on the adhesive all the
NOTE: way around.
• Clean the plate with a sponge and alcohol before
mixing. NOTE: Do not close or open the doors until adhesive
• Follow the instructions that come with the is dry.
adhesive.
11. Before filling a cartridge, cut off the end of the noz-
zle at the angle shown.
Cut off nozzle end

as shown.
7 mm (0.28 in.)
14-24
14. Scrape or wipe the excess adhesive off with a put- 16. lnstall the upper molding.
ty knife or gauze.
UPPER MOLDING
1
NOTE: Wipe with a soft shop towel dampened
with alcohol to remove adhesive from a painted
surface or glass.
15. lnstall the clips on the side molding and upper

molding.
UPPER CLIP A
1 7. lnstall the front side molding.
UPPER CLIP A (4)
NOTE: Check the proper application of side clips

C, D, E.
SIDE MOLDING '. SIDE CLIP
1r~C.D,E
1 1
..·'
18. After the adhesive is dry, spray water over the glass
and check for leaks. Mark leaking areas and let the
glass dry, then seal with sealant.
NOTE: Let the car stand for at least 4 hours after glass
installation. lf the car has to be used within the first 4
hours, it must be driven slowly.
19. Reassemble all removed parts.
NOTE: lnstall the rearview mirror rubber damper

SIDE CLIP after the adhesive has dryed thoroughly.
C.D. E
CORNER CLIP B !11
14-25
Rear Window
Rernoval---------------------------------------------------------------
CAUTION: 4. Detach the clips and remove the upper molding with a
• Wear gloves to remove and install the glass. molding clip release tool.
• Do not damage the defroster grid lines.
1. To remove the rear glass, first remove:
• Rear shelf (page 14-38). CLIP B

(5)
• Rear pillar tri m panel (page 14-38).
2. Disconnect the defroster leads, and remove their

holders.
NOTE: Avoid scratching or scoring the glass with

the cutter blade.
3. Remove the screws and detach the clips, then

remove the side molding.
CLIP A
SHOPTOWEL
5. Remove the other clips and retainers from the body.
6. Lower the rear of the headliner.
CAUTION: Take ca re not to bend the headliner

excessively.
7. Apply protective tape along the edge of the body

SIOE MOLOING next to the glass as shown.
PROTECTIVE TAPE
NOTE: You will need a molding clip release too! to

remove ·sorne moldings. lf necessary, make one
that has the dimensions shown:
Molding Clip Release Tool

Thickness: 2 mm (0.08 in), pointed
at the end.
PROTECTIVE TAPE
DAM
38mm
(1.49 in.) ADHESIVE
14-26
lnstallation - - - - - - - - - - - - - ,
8. Using an awl, make a hole through the glass 1. Scrape the old adhesive smooth with a knife, to a
adhesiva from insida the car. Push piano wire thickness of about 2 mm {0.08 in.) on the bonding
through the hole and wrap each end around a piece surface around the entire glass flange.
of wood.
NOTE:
• Do not scrape down to the painted surface of
9. With a helper on the outside, pull the wire back and
the body; damaged paint will interfere with pro-
forth in a sawing motion and carefully cut through
per bonding.
the adhesiva around the entire glass.
• Remove all traces of the rubber spacer material
from the body.
CAUTION: Hold the. piano wire as close to the • Mask off surrounding surfaces before applying
glass as possible to prevent damage to the body. primer.
2. Clean the body bonding surface with a sponge
dampened in alcohol.
PROTECTIVE NOTE: After cleaning, keep oil, grease or water
TAPE PIANO WIRE
from getting on the surface.
3. lf the old glass is to be reinstalled, use a putty knife to
scrape off all traces of old adhesiva, then clean the
glass surface with alcohol where new adhesive is to be
applied.
NOTE: Make sure the bonding surface is kept free

of water, oil and grease.
CAUTION: Avoid setting the glass on its edges;
small chips may later develop into cracks.
Clean the
shadowed
. area.
10. Cut the rubber spacers away from the body with a
knife: they are cemented in place.
NOTE: Replace the rubber spacers with new ones

whenever the windshield'has been removed.
(cont'd)
14-27
Rear Window
4. lnstall the molding clips and retainers as shown. 7. Glue the rubber dams to the inside face of the glass
as shown to contain the adhesive during
5. Peel the backing off each spacer, then install the installation.
spacers by pressing them firmly into place at the loca-
tions shown. NOTE: Be careful not to touch the glass where adhe-
sive will be applíed.
9 mm (0.35 in)
CA;D;:,
#(;· LOWER SPACER (2}

8. With a sponge, apply a light coat of glass primer
around the edge of the glass as shown, then lightly
wipe it off with gauze or cheesecloth.
NOTE:
• Do not apply body primer to the glass, and do
not get body and glass primer sponges mixed
u p.
• Never touch the primed surfaces with your
hands. lf you do, the adhesive may not bond to
6. Set the glass upright on the lower spacers, then
the glass properly, causing a leak after the glass
center it in the opening. Mark the location by marking is installed.
línes across the glass and body with a grease pencil at
• Keep water, dust, and abrasive materials away
the four points shown.
from the primed surface.
~ : Apply glass primer here.
DAM
~#!1)
14-28
9. With a sponge, apply a light coat of body primer to 13. Pack adhesive into the cartridge without air
the original adhesive remaining around the window pockets to ensure continuous delivery. Put the car-
opening flange. tridge in a caulking gun and run a bead of adhesive
around the edge of the glass as shown.
NOTE:
• Do not apply glass primer to the body, and be NOTE: Apply the adhesive within 30 minutes after
careful not to mix up glass and body primer applying the glass primer.
sponges. --tt- 2 mm {0.8 in)
• Never touch the primed surfaces with your
hands.
~ : Apply body primer here.
13 mm r..
(0.5in1a.
ADHESIVE
1-----1
8 mm {0.3 inl
Make a slightly thicker
bead at each comer.
Use suction cups to hold the glass over the open-

ing, align it with the marks made in step 6 and set it
down on the adhesive. Lightly push on the glass
until its edges are fully seated on the adhesive all
the way around.
1 O. Thoroughly mix the adhesive and hardener
together on a glass or metal plate with a putty NOTE: Do not close or open the doors until
knife. adhesive is dry.
NOTE: Clean the plate with a sponge and alcohol

before mixing.
11 . Follow the instructions that carne with the

adhesive.
12. Before filling a cartridge, cut off the end of the noz-
zle at the angle shown.
Cut off nozzle

end as shown.
7 mm (0.28 in.)
icont'd)
14-29
Rear Window
15. Scrape or wipe the excess adhesive off with a put- 18. lnstall the side moldings.
ty knife or gauze.
NOTE: Use a soft shop towel dampened with

alcohol or· unleaded gasolina to remove adhesive
from a painted surface or glass.
16. lnstall the clips on the upper molding and side

molding.
~·
~~~
SIDE CLIP A
~¡
RETAINER
MOLDING
HOLDER
19. After the adhesiva is dry, spray water over the

glass and check for leaks. Mark leaking areas and
let the glass dry, then se al with sealant.
NOTE: Let the car stand for at least 4 hours after

SIDE CLIP A 141 glass installation. lf the car has to be used within
the first 4 hours, it must be driven slowly.
20. Fix the headliner back into position then install:
• Rear pillar trim panel.

17. lnstall the upper molding.
• Rear shelf.
UPPER CLIP B
14-30
Sunroo~f~----------------------------------------------
lndex
SUDING GLAS\s 14-32, 33

Adjustment, pag e 14-34
Replacement, pag
. ASSEMBLY
OUTER CABLE e 14-36
Replacement, pag
MOTOR e 14-35
Replacement, pag
SUNSHADE
RAIL
REAR EDGE LIFT~~~~~IDE

Adjustment, pag -
FRONT SHIM
~
REAR DRAIN TUBE
~~~Tl
r&
¡¡
J)
14-31
Sunroof
Troubleshooting
Symptom Probable Cause

Water leak 1
1. Clogged drain tube.
1 2. Gap between glass weatherstríp and roof panel.
!
1 3. Detective or improperly ínstalled glass weatherstrip.
4. Gap between drain seal and roof panel.
Wind leak, noise 1. Excessive clearance between glass weatherstrip and roof panel.
Deflector noise 1. lmproper clearance between detlector seal and trame seal.
2. lnsufficient deflector extension.
3. Deformed deflector.
Motor noise 1. Loase motor.
2. Worn gear or bearing.
3. Outer cable deformed.
Sliding glass does not 1. Clutch out of adjustment.
move, but motor turns 2. Foreign matter stuck between guide raíl and slider.
3. lnner cable loase.
4. Outer cable not attached properly.
Sliding glass does not 1. Blown fuse.
move and motor does not 2. Faulty switch.
turn (Siiding glass can be 3. Battery run.down.
moved with sunroof 4. Detective motor.
wrench) 5. _Wrong operation of relay.
Rear Edge Closing Adjustment - - - - - - - - - - - - - - - - - - - - - - - .
Open the glass about a foot, then clase it to check

where rear edge begins to rise. lf it rises too soon and
seats too tightly against the roof panel, or too late and
does not seat tightly enough, adjust it.
1. Open the glass fully.
2. Remove the raíl covers from both sides, and loasen

the lift-up guide nuts.
3. Move the lift-up guides and link stopper forward or

backward, then tighten nuts and recheck roof
closing.
The guides have pitches of 1.5 mm (0.06 in) each

and can be adjusted 2 pitches forward or
backward.
4. lf necessary, lower the · rear of the headliner and

remove the motor, then adjust the inner cables (loca-
tion of sliders) uotil they are parallel.
LIFT-UP GUIDE
14-32
Glass Height Adjustment ----....., Wind Deflector Adjustment -------,
Roof panel should be even with the glass weatherstrip, NOTE: A gap between deflector seal and roof panel
to within 1 ± 0.5 mm (0.04 ± 0.02 in) all the way will cause wind noise when driving at high speed with
around. the sunroof open.
lf not, open the glass fully, and:
1. Open the sunroof and pry the rail covers off both
1 ± 0.5 mm /GLASS WEATHERSTRIP sides.
: 4N\,\~7L/~ 2. Loosen the deflector mounting nuts.
NOTE: Wind deflector can be adjusted 2 mm (0.08
~ROOFPANEL
in) forward or backward.
Front:
1. Pry out the rail holder cover and loasen the moun-
ting nut.
2. Instan shims between sunroof trame and sunshade

rail holder.
FRONT: Shim thickness Max. 2 mm (0.08 in)
SUNSHADE
RAIL HOLDER
DEFLECTOR
MOUNTING NUT
On reassembly, use liquid
thread lock.
WIND
DEFLECTOR
3. Adjust the deflector forward or backward so the
edge of its se al touches the roof panel evenly.
Rear: The deflector seal should touch the roof panel
1 . Remove the rail cover and loasen the lift-up guide across entire front edge.
mounting nut.
2. lnstall shims between guide rail and sunshade rail.
REAR: Shim thickness Max. 2 mm (0.08 in}
LINK STOPPER
17 mm 10.7 in}
DEFLECTOR
SEAL
3. Repeat on opposite side if necessary. ROOF PANEL
4. Side-to-side fit of glass weatherstrip can be ad- NOTE: The height of the deflector arm when open
iusted by loosening the sunroof frame mounting bolts cannot be adjusted. lf damaged or deformed,
and moving the frame (page 14-35). re place it (page 14-37).
14-33
Sunroof
Glass and Sunshade Replacement - - - - - - - - - - - - - - - - - - - - .
1. Open the glass fully. 5. Remove the link slider from the inner cable slider by
lifting the glass, then remove the glass.
2. To remove the glass, first remov.e:
•• Raíl holder cover

Raíl cover
• Sunshade raíl holder
• Wind deflector
• Link stopper
• Lift-up guide
3. Lift the sunshade rail with guide rail and inserta spacer
such as a wooden block in arder to avoid interference
between the sunshade rail and bolt when removing the
sunshade.
INNER CABLE SLIDER
LINK SLIDER
6. Slide the sunshade forward, then remove the

sunshade.
SUNSHADE
NOTE: The block must be taller than the bolt.
4. Slide the glass forward by sunroof wrench, then

remove the front sliders from sunshade rails.
NOTE: Do not scratch the roof panel with the front

sliders.
7. lnstall the glass and sunshade in the reverse arder

of removal
NOTE:
• Take care not pinch the drain seal in the sun-
shade raíl.
• Check for water and air leaks.
14-34
Motor, Drain Tube and Frame Replacement - - - - - - - - - - - - - - - - - - .
CAUTION: Be careful not to damage the seats, dashboard and other interior trim.
1. Remove the glass (page 14-34) and the headliner (page 14-39).
2. Disconnect the motor wire harness. Remove the clips securing the dome light wire harness.
3. Remove the sunroof motor by removing the two bolts and three nuts.
4. Disconnect the drain tubes.
5. Remove the ten 'mounting bolts from the trame, and remove the frame from the car.
NOTE: You may require assistance when removing the frame.

REAR HOOK
MOTOR ANO LIMIT
SWITCH WIRE
·HARNESS
Remove the front mounting

bolts last. SUNROOF MOTOR
DRAIN TUBE Make sure the sliders are
To install, slide the drain tube over parallel when installing the
the trame nozzle at least 1O mm. motor.
-..............
6. Pull the drain tubes out the front and rear pillars.
NOTE: Before pulling out the drain tube, tie a str-

ing to the end of it so it can be reinstalled.
REAR DRAIN TUBE
DRAIN VALVE
7. To install, insert the frame"s rear hooks into the body holes. then install parts in the reverse order of removal.
NOTE:
e lnsert over 1 O mm of the drain tube onto the nozzle.
e Instan the tu be clips with the ends facing the side to ease installation of the headliner.
e Check the drain seal assembly.
e Check for water and air leaks.
14-35
Sunroof
Guide Rails/Cable Replacement - - - - - - - - - - - - - - - - - - - - - - - .
1. With sunroof out of the car, remove the sunroof motor from the frame (page 14-35).
2. Remove the guide raíl mounting nuts and lift off the guide rails, then remove the cables with sliders attached.
3. lf necessary, remove the sunshade raíl and trame seal from the sunroof trame.
NOTE: Take care not to bend the cable pipes and guide rails.
GUIDE RAIL INNER CABLE
Apply molybdenum grease.
DRAIN SEAL
\
SUNSHADE
RAIL
lnstall the guide rails and cables in the reverse order of

removal.
NOTE:
e Take care not to damage, twist or lift the drain seal.
e Make su re the sliders are parallel when installing the
motor.
Link Slider/Lift-up Link Disassembly---------------------,

1. Remove the sliding glass (page 14-34).
LINK LIFTER
2. Pull the front slider from the front stay.
3. Remove the link lifter, then remove the E-clip.
4. Remove the lift-up link from the rear stay. Strike

the link shatt out, then separate the lift-up link and
link slider.
CAP
\~~
COLLAR
'~- LIFT-UPLINK
5. Assemble the slider and lift-up link in the reverse

order of removal.
NOTE:
• Damaged parts should be replaced.
• Apply the grease to the sliding portian.
14-36
Closing Drag Check Closing Force Check - - - - - - - .
(Motor Removed) (Motor lnstalled)
Before installing the sunroof motor, measure effort re- 1. After installing all removed parts, have a helper
quired to open sliding glass using a spring scale as hold the switch to close the sliding glass while you
shown. measure force required to stop it. Attach spring
scale as shown. Read force as soon as glass stops
CAUTION: When using the spring scale, protect moving, then immediately release the switch and
the leading edge of the sunroof with a shop towet. spring scale.
lf load is over 98 N ( 1 O kg, 22 lb}, check side clearance CAUTION: When using the spring scale, protect
and glass height adjustment (page 14-33). the leading edge of the sunroof with a shop towel.
Closing Force: 196-245 N

120-30 kg. 44-55 lbl
Lift-Up Guide/Wind Deflector -----,

Replacement
2. lf force is not within specification, install a new
Mounting nuts torque: 9 N·m (0.9 kg-m, 6.5 lb-ft) lockwasher, adjust the tension by turníng the
sunroof motor clutch adjusting nut, and bend the
lockwasher against the adjusting nut.
RAIL HOLDER
LOCK-
~
WIND DEFLECTOR
WASHER
Check that the deflector seal touches Replace.
the roof panel.
ADJUSTING NUT
LIFT -UP GUIDE

Check the side-to-side location.
-v CLOCKWISE
To increase
COUNTER-
CLOCKWISE
To decrease
force.
14-37
Interior Trim
Replacement
Disassemble in numbered sequence.

:.) : Clip locations
CL~
@) REAR PILLAR
TRIM PANEL
To remove the panel, first remove the
lower anchor bolt from the rear seat
belts (page 14-47).
@) FRONT PILLAR
TRI M
To remove the trim, first remove the
upper anchor bolt from the front seat
belt.
@ SIDE SEAT TRIM
@ TRUNK SIDE PANEL

To remove the panel, first
remove the rear side seat
back (page 14-44).
(!) TRUNK FRONT

SIDE PANEL -..............
Remove the rear speakers and

rear seat lock cylinder escutcheon.
14-38
Headliner
Replacement
1. Remove: • Grab handles.

• Sun visors and holders. • Rear roof side trim (page 14-38).
• Dome light. • Rear seat {pages 14-44, 45)
• Rearview mirror assembly (page 14-49). • Front seat {Passenger's).
• Front pillar trims (page 14-38). e Recline down the front seat back rearward (Driver's).
• Rear pillar trim panels (page 14-JS}.
• Roof trim (Sunroof model).
1
Sunroo~model; ~
2. Remove the 2 mounting screws.
ROOF TRIM
(Sunroof model) lM ~ GRAB HANDLE
MOUNTING
SCREW
3. Remove the front and rear clips, then remove the

headliner.
4. Remove the headliner from behind the front passen-

ger's seat door opening.
NOTE:
• Take care not to bend the headliner.
• Keep water away from the headliner.
• Be careful not to damage the seats, dashboard
and other interior trim.
5. lnstall the headliner in the reverse order of removal.
NOTE:
• When installing the headliner inside the passenger cabin, be careful not to fold or bend it. Also, be careful not to
scratch the body.
• Check that the two sides of the headliner are securely attached to the trim.
e When installing the roof tri m, install thé joint towards the rear (Sunroof model).
14-39
Front Seat
Replacement
NOTE: Take care not to scratch or score the seat covers and body.
1. 5. Remove the mounting bolts, then remove the seat

2. cushion.
SEAT CUSHION
10x1.25mm
35 N·m (3.5 kg-m.
25 lb-ft)
3.
~j - 1
Remove the bracket cover and center cover.

10 x 1.25 mm
43 N·m {4.3 kg-m, 31 lb-ft)
6. Remove the seat back cover.

7. Turn over the seat cover and remove the 2 mounting
bolts.
8. Remove the pivot nut, then remove the seat back.
PIVOT NUT
8 x 1.25 mm
22 N•m {2.2 kg-m, 16 lb-ft)
BRACKET COVER
4. Remove the reclining adjuster cover and power seat
switch.
\
~
·-:-~
BACK
COVER
1
INSIDE
CLIPS
14-40
Interior Trim
Replacement

:.) : Clip locations
CL~
@) REAR PILLAR
TRIM PANEL
To remove the panel, first remove the
lower anchor bolt from the rear seat
belts (page 14-47).
@) FRONT PILLAR
TRI M
To remove the trim, first remove the
upper anchor bolt from the front seat
belt.
@ SIDE SEAT TRIM
@ TRUNK SIDE PANEL

To remove the panel, first
remove the rear side seat
back (page 14-44).
(!) TRUNK FRONT

SIDE PANEL -..............
Remove the rear speakers and

rear seat lock cylinder escutcheon.
14-38
Headliner
Replacement
1. Remove: • Grab handles.

• Sun visors and holders. • Rear roof side trim (page 14-38).
• Dome light. • Rear seat {pages 14-44, 45)
• Rearview mirror assembly (page 14-49). • Front seat {Passenger's).
• Front pillar trims (page 14-38). e Recline down the front seat back rearward (Driver's).
• Rear pillar trim panels (page 14-JS}.
• Roof trim (Sunroof model).
1
Sunroo~model; ~
2. Remove the 2 mounting screws.
ROOF TRIM
(Sunroof model) lM ~ GRAB HANDLE
MOUNTING
SCREW
3. Remove the front and rear clips, then remove the

headliner.
4. Remove the headliner from behind the front passen-

ger's seat door opening.
NOTE:
• Take care not to bend the headliner.
• Keep water away from the headliner.
• Be careful not to damage the seats, dashboard
and other interior trim.
5. lnstall the headliner in the reverse order of removal.
NOTE:
• When installing the headliner inside the passenger cabin, be careful not to fold or bend it. Also, be careful not to
scratch the body.
• Check that the two sides of the headliner are securely attached to the trim.
e When installing the roof tri m, install thé joint towards the rear (Sunroof model).
14-39
Front Seat
Replacement
NOTE: Take care not to scratch or score the seat covers and body.
1. 5. Remove the mounting bolts, then remove the seat

2. cushion.
SEAT CUSHION
10x1.25mm
35 N·m (3.5 kg-m.
25 lb-ft)
3.
~j - 1
Remove the bracket cover and center cover.

10 x 1.25 mm
43 N·m {4.3 kg-m, 31 lb-ft)
6. Remove the seat back cover.

7. Turn over the seat cover and remove the 2 mounting
bolts.
8. Remove the pivot nut, then remove the seat back.
PIVOT NUT
8 x 1.25 mm
22 N•m {2.2 kg-m, 16 lb-ft)
BRACKET COVER
4. Remove the reclining adjuster cover and power seat
switch.
\
~
·-:-~
BACK
COVER
1
INSIDE
CLIPS
14-40
Seat Device Disassembly - - - - - - - - - - - - - - - - - - - - - - - - .
Full power adjusted type:
NOTE:
e Before installing the seat, make sure there are no twists or pinch in the seat wires.
e Grease the moving surface.
Bolts torque:
CD 20 N·m (2.0 kg-m, 14 lb-ft) SEAT HEATER To body.
® 5 N·m (0.5 kg-m, 3.6 lb-ft) RE LAY
@ 9 N·m (0.9 kg-m, 6.5 lb-ft)
NOTE:*On reassembly, use Jiquid thread lock.
To switch.
To seat back heater

u ni t.
To seat cushion heater From seat back.
unit.
l. SEAT CUSHION BRACKET
RECLINING
ADJUSTER
REAR ELEVATION
GEAR BOX
INNER SUDE
GEAR BOX
~
SUDE JOINT CABLE
OUTER SLIDE
GEAR BOX
(cont'd)
14-41
Front Seat
Seat Device Disassembly (cont' d)
Height power adjusted type:
NOTE:
e Before installing the seat, make sure there are no twists or pinch in the seat wires.
e Grease the moving surfaces.
To body. To body.
Bolts torque:
CD 5.0 N·m (0.5 kg-m, 3.6 lb-ft)
® 12 N·m (1.2 kg-m, 9 lb-ft)
NOTE: *On reassembly, use liquid thread lock.
SEAT HEATER
RE LAY
INNER SEAT TRACK
L. SEAT CUSHION
BRACKET
To seat cushion heater unit

: - . . - - - - RECLINING
ADJUSTER
OUTER SEAT TRACK

SEAT HEATER
To body.
SPRINGS
q¡,~ RE LAY
Manual adjusted type:
To seat back heater..-.-----r

unit.
INNER SEAT
TRACK
To seat cushion heater
unit.
OUTER SEAT
TRACK
14-42
Cover Replacernent------------------------------------------------~
CAUTION: Wear gloves to remove and install the seat Seat cushion cover removal.
cover. 1 . Remove the seat cushoin from the seat tracks
(page 14-40).
NOTE: Take care not to open the seams or damage the
cover. 2. Remove all hooks, clips and inside springs from
under the seat cushion, then turn over the seat
Seat back cover removal. cover.
1 . Remove the seat back from the seat track and
reclining adjuster (page 14-40). 3. Turn up the edge of the trim cover all the way
around, then release the clips of the cushion.
2. Remove the lumbar support knob.
3. Turn over the seat cover by releasing all the hooks

and inside springs.
4. Remove the headrest guides, then remove the seat

cover.
HEADREST
GUIDES
LUMBAR SUPPORT
KNOB
(Driver' si
CAP
NOTE: To prevent wrinkles when installing a seat

cover, make sure the material is stretched evenly
over the frame before securing all the clips.
14-43
Rear Seats
Replacement------------------------------------------------------
Folded down type:
NOTE: Before tightening the seat back mounting

bolts, adjust the seat back fit and latch.
HEADREST
LOCK CYLINDER
Dísconnect the lock rod
and remove the mounting
bolts.
HEADREST
GUIDES (See page 14-43)
G) SEAT BACK MOUNTING BOLTS

8 x 1.25 mm
i i N·m 12.2 kg-m. 16 tb-ttl
@ SIDE SEAT BACK

MOUNTING BOL T
6 x 1.0 mm
10 N•m {1.0 kg-m, 7 lb-ft)
6x1.0mm
@ SEAT CUSHION MOUNTING 10 N•m (1 .O kg·m, 7 lb-ft}
BOLT
6x 1.0 mm
10 N•m (1 .O kg-m, 7 lb-ftl
14-44
Standard/ Armrest through type:
CLIP PIN ARMREST LID FRAME
ARMREST
'
l @HOOK
\
@ SEAT CUSHION
14-45
Front Seat Belts
Replacernent----------------------------------------------------------~
CAUTION: Check the seat belts for damage and repalce them if necessary. Be careful not to damage them during
removal and installation.
1. Remove the center pillar lawer trim.
2. Remave the upper anchor balt, lower anchor bolt and retractar balt with a 17 mm sacket or bax-end wrench.
3. Remove the frant seat, then remove the balt and the center anchor.
8 x 1.25 mm 1
22 ··~ (2.2 · · - · 161b·ft} !~"'______
7/16 in x 1.25 mm
32 N•m (3.2 kg-m, 23 lb-ftl
7/16 in x 1.25 mm
32 N•m (3.2 kg-m,
23 lb-ft)
LOWER ANCHOR BOLT
7/16 in x 1.25 mm
32 N·m (3.2 kg-m, 23 lb-ft)
4. Check that the retractar lacking mechanism func-

tions as described on page 14-48.
5. lnstall the front seat belts in the reverse arder of

remaval.
NOTE:
• Make sure you assemble the washers and col-
lars an the upper and lower anchor bolts as 1
shown.
• Befare attaching the center pillar lower trim,
make sure there are no twists or kinks in the CE N TER ANCHOR BOLT
7/16 in x 1.25 mm
belts.
32 N•m (3.2 kg-m. 23 lb-ft)
14-46
Rear Seat Belts
Replacernent----------------------------------------------------~
CAUTJON: Check the seat belts for damage and replace them if necessary. Be careful not to damage them during removal
and installation.
1. Remove the rear seat (pages 14-44, 45).
2. Remove the rear pillar trim panel.
3. Remove the upper anchor bolt, the lower anchor bolt and retractor bolt with a 17 mm socket or box-end wrench.
*UPPER ANCHOR
BOLT
UPPER ANCHOR BOL T

RETRACTOR BOLT
32 N•m 13.2 kg-m. 23 lb-ft) 7116 in x 1.25 mm
32 N•m {3.2 kg-m, 23 lb-ft)
LOWER ANCHOR BOLT

7/16 in x 1.25 mm
32 N·m (3.2 kg-m, 23 lb-ft)
CENTER ANCHOR BOLTS
4. Check that the retractor locking mechanism functions as described on page 14-48.
5. lnstall the seat belt in the reverse order of removal.
NOTE:
• Before attaching the rear pillar trim panel and rear seat, make sure there are no twists in the belt.
• * On reassembly, replace the upper anchor bolt and use liquid thread lock.
14-47
Seat Belts
lnspection
On-the-Car Belt 1nspection
Retractor lnspection
1. With the retractor installed, check that the belt can be 1. Check that the belt is not twisted or caught on any-
pulled out freely. thing.
2. Make sure that the belt does not lock when the
retractor is leaned slowly up to 1 5° from the mounted 2. After installing the anchors, check for free movement
position. The belt should lock when the retractor is on its retaining bolt. lf necessary, remove the bolt and
leaned over 40· check that the washers and other parts are not
damaged or improperly installed.
CAUTION: Do not attempt to disassemble the
retractor. *:
Mounted Position. 3. Check the belts for damage or discoloration. Clean
with a shop towel if necessary.
Front: CAUTION: Use only soap and water to clean.
4. Check that the belt does not lock when pulled out
· slowly. The belt is designed to lock only during a
sudden stop or impact.
5. Make sure that the belt will retract automatically when

released.
6. Replace the belt with a new one if there is any abnor-

mality.
Forward lnside
Rear:
Forward lnside
3. Replace the belt with a new one if there is any abnor-

mality.
14-48
Rearview Mirror 1 Console
Rearview Mirror Replacement - - - - - - - - - - - - - - - - - - - - - - - .
1. Remove the rubber damper. 3. Remove the 3 mounting screws from the mirror base,
then remove the mirror assembly.
2. Pry the cover off using the end of a flat tip screwdriver. 4. Remove the base from the bracket by removing the
screw.
MIRROR ASSEMBLV
COVER
BASE
1
1
J 1
l '~
--------- ___/ / MIRROR
Console Replacernent---------------------------------~
4WS: 2WS:
.1
1
.
1
1
'
/
'
r
1
1
1
1
®
@ REAR CONSOLE
NOTE:
e Remove the front and rear consoles as an assembly.
e Lift up the parking brake lever.
e For manual transmission models, remove the shift lever knob.
14-49
Carpet/Door Sill Moldings
Replacernent------------------------------------------------------~
1. Remove:
e Front seats and rear seat cushion.
e ·Front seat belt lower anchor bolts (page 14-46).
e Center console.
• Right and left kick panels.
e Door sill moldings.
e Opener cover.
e Footrest.
2. Pry out the clips at the rear edge and under the
dashboard, peel off the tape.
3. Cut the ® area first, then pull back the carpet as

shown.
4. Remove the carpet by sliding it rearward.
5. lnstall the carpet in the reverse order of removal.
NOTE: Take care not to damage, wrinkle or twist the carpet. RETAINER
14-50
Dashboard
Component Removal/lnstallation - - - - - - - - - - - - - - - - - - - - - - .
NOTE: Take care not to scratch or score the dashboard and instrument panel.
CLOCK
Aemove the clock from left side.
CRUISE 1
SUNROOF
CONTROL SWITCH
MASTER
SWITCH
GLOVE BOX
NOTE: First remove the DAMPER
damper mounting screw.
Pry out the air

vent.
1. Remo ve:
• Console (page 14-49).
• Ashtray and ashtray holder
• Stereo cassete/radio
• Coin box, cruíse control master switch • sunroof
switch and panel brightness controller.
----------
2.
• Side and Center air vents.
e Disconnect the cool vent cable (See section 15).
Remove the 12 mounting screws and disconnect the
/r-
1
connectors.
3. Carefully pull out the inst_r_um_e_n'-t panel from th""___/

dashboard.
----
STEREO CASSETTE/RADIO
Remove the console, ashtray and ashtray holder.
Loasen the 2 screws from underneath and disconnect the POCKET
wire harness (antenna lead), then pull the stereo cassette/radio ASHTRAY HOLOER
out half-way and separate the pocket. (2WS)
14-51
Dashboard
Replacernent--------------------------~--------------------------~
STEERJNG COLUMN
NOTE: Take care not to scratch or score the dashboard and
use protective tape on the bottom of the front pillar trim.
1. To remove the dashboard, first slide the seats back

fully.
2. Remove the console (page 14-49).
3. Remo ve the steering column (See sectíon 11).
4. Disconnect the dashboard wire harness from the

connectors and fuse box.
5. Remove the carpet clips and disconnect the anten-

na lead.
10 x 1.25 mm
39 N·m (3.9 kg-m. 28 lb-ftl \
8 x 1.25 mm
39 N•m 13.9 kg-m. 28 lb-ft)
6. Disconnect the heater control cable and function
~
control cable or cool vent cable (See section 1 5).
-~
7. Remove the caps on both side and clock. LOWER PANEL
PROTECTIVE
TAPE
8. Remove the 7 dashboard mountinQ bolts.
9. lift and remove the dashboard.
FUSE DASHBOARD
BOX WIRE HARNESS
COOLVENT
Reassembly NOTE: CABLE
• Make sure the dashboard fits onto the body correctly.
• Befare tightening the dashboard bolts, make su re the dashboard wires are not pinchad. and that the dashboard is
not interfering with the heater control and function cables.
14-52
Front Bumper
Replacement
1. Open the hood, then remove the bumper mounting nuts.
2. Remove the front turn signal lights.
3. Remove the 2 bumper mounting screws on each side at the cerner edge of the bumper.
4. Remove the 2 lower bumper mounting clips and the 4 bumper mounting bolts.
5. Disconnect the headlight washer hose.
6. Remove the bumper by sliding it forward.
NOTE: Take care not to scratch the bumper tace. CORNER SUDE CLIPS
BUMPER MOUNTING ¡~
NUTS
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ft) (\ d~@tfll!
!
\ CORNER SUDE
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ft)
8 x 1.25 mm
22 N•m (2.2 kg-m, 16 lb-ft)
LOWER BUMPER
MOUNTING CLIPS
FRONT TURN
SIGNAL LIGHT
Loasen the mounting screw
and pull off and disconnect
the connector.
7. lnstall parts in the reverse order of removal.
14-53
Rear Bumper
Replacernent------------------------------------------------------~
1. Open the trunk lid and pry off the maintenance caps, then remove the 2 upper bumper mounting nuts from the trunk
area.
2. Remove the 2 mud guard screws and 2 bumper mounting screws on each si de at the comer edge of the bumper.
3. Remove the clips, then remove the under protectors on each side from under the trunk floor.
4. Remove the 2 lower bumper mounting nuts and center clip from under the trunk floor.
5. Remove the bumper by sliding it to the rear.
NOTE:
• Do not damage the threads of the bumper bolts.
• Take care not to scratch the bumper tace.
UPPER BUMPER MOUNTING NUTS
BUMPER MOUNTING
SCREWS
~~--~~
()
t~\ BUMPER MOUNTING
SCREWS
~
~
1
LOWER BUMPER MlTING NUT
8x1.25mm
22 N•m (2.2 kg-m. 16 lb-ftl
_!-- L__
6. lnstall parts in the reverse order of removal. se order of removal.
14-54
Hood
Replacement/ Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - .
1. Disconnect the windshield washer hose at the

Y-joint, then pull it out of the hood.
2. Remove the hood by removing the 2 hood moun-

ting bolts on each side.
3. To remove the hood hinges, remove the front wind-

shield wipers and air scoop.
4. lnstall the new hood. After installing, adjust the

hood fit to the opening.
HOOD HINGE
MOUNTING BOLTS
HOOD HINGE
HOOD MOUNTING BOLTS

6x1.0mm
10 N•m (1.0 kg-m, 7 lb-ftl
------- ALIGNMENT
• The hinges can be adjusted right and left as well as
NOTE: Before pulling out the opener cable, tie a
string to the cable so you can pull it back in later. fore and aft by using the elongated holes.
• The hinges should be shimmed to adjust the height
of the hood at the rear edge.
• Adjust the hood látch to obtain the proper height at
the forward edge.
To remov:e the latch,

first remove the front grille.
5. After installing, adjust the hood fit to the opening.
ALIGNMENT:
HOOD EDGE CUSHION
Turn as necessary, to make the • Move the latch up or down or right or left as
hood fit flush with the body at necessary to equalize the gap between the hood and
front and side edges. the body.
14-55
Trunk Lid
Replacement/ Adjustment - - - - - - - - - - - - - - - - - - - - - _ _ ,
1. Pull the harness and trunk lid opener cable out of the trunk lid.
NOTE: Befare pulling out the wire harness, tie a string to the end of it so you can pull it back in when the trunk lid is
reinstalled.
2. Remove the trunk lid hinge bolts, then lift off the lid. TRUNK LID EDGE. CUSHION
3. Remove the torsion bar using a assembly tool. Turnas necessary, to make the trunk
lid fit flush with the body at front and
4. Remove the rear shelf.
side edges.
5. Remove the hinge bracket mounting bolts, then remove the hinges from the trunk.
6. Assemble in the reverse order.
NOTE:
CLIP_
SHIM
Use shims as required to make
the trunk lid fit flush with the TORSION BAR
body " th• " : ' .::~- - - CENTER CLIP
r----
1 /
~
'-.!! t____s¡j)
STRIKER MOUNTING
BOlTS
' t TORSION BAR
TORSION BAR
.....f (
~~
~-
Use TORX® T30
~
1
Adjust the torsion bar front ASSEMBLY TOOL
or rear with the release tool
as shown.
07GAZ-SE301 00
TORSION BAR
¡/ 1
~
STRIKER
Adjust the striker right or left to
align it with the latch.
O = Normal position
~ = Higher tension
14-56
Wiring Diagrams
lndex--------------------------------------------------
Headlights · 6
Taillights · · · · · · · · ·6
16-274
~::.:acernent------------------------------------------------~~~~~~
Opener/Latch ...,.
OPENER LOCK
CYLINDER
TRUNK LID LOCK

CYLINDER
FUEL LID LA TCH

=~:f:e t_he left trunk Slde panel
el lid latch by turning it goo
'
fe .f": •
' 1 ,,.
FUEL LID ---------1 .

After installing, check for · ---
a flush fit with the body. - !ijjjji:f¡
--------
Opener Cables:
'
NOTE:
• Take ~are not to bend the cable
• After Jnstalling, check that . .
opener cables are routed ~he trunk hd and fuel lid
an connected properly.
,~·~~~~0~1
14-57
Wiring Diagrams
lndex--------------------------------------------------
Headlights · 6
Taillights · · · · · · · · ·6
16-274
Front Grille/Side Sill Panel
Front ~rille Replace~ent~~~~~~~~~~~~~~~~~~~~~~~
1. Remove the 5 screws.
2. Push the clips on ea eh side with a tlat tip screwdriver

as shown, then remove the front grille.
3. Set the clips on to the front grille, then install the

front grille in the reverse order removal.
CLIP·
~~
~ MOLDING MOUNTING
'O SCREWS (1 21
Remove the 2 screws.
Side Sill Panel Replace~ent ~~~---:--~-~-~---~-----~~-.
1. Remove the mud guard.
2. Detach the all lower screws and clips.
3. Pull the side sill panel out and remove the side clips, then remove the side sill p~nel.
SIDE Slll 1
PANEL · •
LOWER CLIP (91
MUO GUARO
4. lnstall the panel in the reverse order removal.
NOTE: lf necessary, replace any damaged clips.
14-58
Roof Molding/Side Moldings
Roof Molding/Side Window Moldings Replacement--------------,
ROOF
ROOF MOLDING MOLDING
ROOF MOLDING
FRONT SIDE WINDOW

MOLDING
Remove the screw and
detach the clips with a
flat tip screwdriver.
REAR SIDE WINDOW MOLDING

Remove the screws and carefully INSIDE
slide down and off of the CLIP
inside clip.
Side Moldings Replacement - - - - - - - - - - - - - - - - - - - - - - ,
1. Remove the door panel and turn over the plastic cover.
2. Remove the plastic nut and detach the center clips from inside of the door.
3. Peel off the molding and detach the side clips, then remove the door moldings. ~~ - ADHE-;1~
1 TAPES
NOTE: Before reassembling, clean the body bonding surface with a sponge dampened in 1 A
alcohol.
FRONT DOOR
MOLDING
..,.__ REAR DOOR
MOLDING
1
1
1 CENTER
CLIP
1
-~
~1 FRONÍ MOLDI;G 1 B
1'
1
area.
FRONT SIDE MOLDING 1 1

To remove the molding, first remove the 1 1
mud guard, front of side sill panel and
rear ot inner tender. SIDE
CLIP
1 1
14-59
Heater
lllustrated lndex - - - - - - - - - - - - - - - - - - - - - - - - -
(Button type)
RECIRCULATION CONTROL
MOTOR
Test, page 15-37
HEATER VALVE CABLE
Test, page 1 5-37
COOL VENT CABLE

Replacement, page 1 5-33
AIR MIX CABLE
HEATER CONTROL PANEL

1 FAN SWITCH
Test, page 15-34
Test, page 15-35
RECIRCULATION CONTROL SWITCH

Test, page 1 5-35
15-2
(Levar type)
RECIRCULATION CONTROl
MOTOR
BlOWER
Test, page 1 5-37
Replacement, page 1 5-1 9
Overhaul. page 1 5-21
HEATER VALVE CABLE
AIR MIX CABLE

Adjustment, page 1 5-32

Overhaul, page 15-28 RECIRCULATION SWITCH
Test, page 15.:.35
FAN SWITCH
Test, page 15-34
15-3
Heater
Circuit Diagram ·--------'--------------___;,..________
(BUTION TYPE) IG2
FUNCTION CONlROL MOTOR
BLOWER
RELAYrlf----,--+--,
BLK
YEL/BLK
GRN/WHT
A/C UGHTING
THERMOSTAT LT GRN/RED LT GRN/BLK BLU/RED SWITCH
?
LT GRN/WHT YEL/GRN
?
BLU
BLU/RED RED/BLK
BLU/WHT
BLU
HEATER CONlROL PANEL
BLK
HEATER
FAN SWITCH
DASHUGHT
BRIGHTNESS
CONlROLLER
I
G401
G402
15-4
(LEVER TYPE)
IG2
-------+---YEL/BLK
WHT RECIRCULA llON
CONTROL MOTOR
GRN/RED GRN/WHT
A/C UGHllNG
THERMOSTAT S'MTCH
y
BLU/RED
y
RED/BLK
R F
BLU/WHT
BLU
HEATER
FAN S'MTCH
HEA TER CONTROL PANEL
BL.K
DASHUGHT
BRIGHTNESS
CONTROLLER
I
G401
G402
15-5
Heater Door Position
(LH Type)
• Always blowing air in every mode.
~HOT
~COLO
(COOL VENT)
...,
15-6
1111
... •
,~
(cont'd)
15-7
Heater Door Position (cont'd)
(AH type) ~HOT

e Always blowing air in every mode.
(COOL VENT)
... ~
15-8
1111
15-9
Troubleshooting
Symptom Chart - - - - - - - - - - - - - - - - - - - - - - - - -
SYMPTOM REMEDY
No hot air flow Blower motor does not run Perform the flowchart (page 1 5-12)
Blower motor runs Check following:
· Clogged heater duct
• Clogged blower outlet
• Clogged heater valve
· Faulty air mix door
· Air mix cable adjustment
· Faulty thermostat
Hot air flow is low Blower speed does not change Perform flowchart (page 1 5-11 )
Blower runs properly Check following:
· Clogged heater duct
· Clogged blower outlet
· lncorrect door position
Function does not change Button Function control motor does not run Perform flowchart (page 1 5-1 5)
Type Function control motor runs Check the heater door linkage and the
heater assembly.
Lever · Check the heater door linkage and
1
Type the heater assembly.
·Check the function cable adjust-
ment.
Recirculation door does not change Recirculation motor does not run Perform flowchart (page 1 5-1 7)
Recirculation motor runs Check the door linkage and the
blower.
15-10
Troubleshooting Flowchart-Biower - - - - - - - - - - - - - - - - - - - .
Blower motor runs, but one or

more speeds are inoperative.
Disconnect the 5-P connector

from the blower resister.
Check the resistance between the

No. 1 and No.5 terminals of the
resister.
ls there about 2. 7 O ? Replace the resister
. VES
5 2
Reconnect the 5-P connector to
the resister. View from wire side

from the fan switch.
Measure the voltage between:

• BLU terminal and body ground.
• BLU/WHT terminal and body
ground.
• BLU/VEL terminal and body
ground.
• BLU/BLK terminal and body
ground.
• BLU/RED terminal and body
ground.
BLU/WHT BLU/YEL
Repair open in BLU, BLU/WHT,
NO BLU/YEL, BLU/BLK or BLU/ View from wire side
RED wire {s) between the fan
VES switch and resister.
Replace the fan switch.
15-11
Troubleshooting
Troubleshooting Flowchart- B l o w e r - - - - - - - - - - - - - - - - -
NOTE: Check for a blown No.18 (30 A), No.B (7.5 Al fuse.
Blower motor does not run at all.

from the blower motor.
Tu m the ignítion switch ON.

YEUBLK terminal (+) and body
ground (-).
NO
ls there battery voltage ? ~-=----To page 15-138 View from wire side
( ): RH TYPE
YES
NOTE:Connect the battery positive to the YEL/BLK terminal
lnspect the blower motor. and negative to the BLU/RED terminal and check that the
blower motor runs.
Replace the blower

ls the blower motor OK ?
motor
YES

the blower motor.

from the heater fan switch.

BLU/RED terminal (+) and body
ground (-).
Víew from wire side
To page 15-13 A
15-12
1111
.,
From page 15-12 A
Turn the ignition switch ON .-
T
~N...::O:___ _--If
j
Repair open in BLU/RED wire
between blower and tan switch.
¡
1 VES
1
lnspect the fan switch (page 1 5-
34).
1
NO 1
ls the fan switch OK ? Replace the fan switch 1
1
1 YES

between the fan switch and body
ground or poor ground (G401,
402).
From page 1 5-1 2 B

1
1
Disconnect the blower relay from
the fuse box.
lnspect the blower relay. (page

15-34).
NO Replace the blower 1

ls the blower relay OK?
relay
1
1 VES
Measure the voltage between the

fuse box No.t terminal (+) and
body ground {-).
T
T o page 1 5-14
(cont'd)
15-13
Troubleshooting
Troubleshooting Flowchart-Biower (cont' d) - - - - - - - - - - - - - - - ,
From page 1 5-13
NO Repair open in WHT wire 1

ls there battery vo!tage ? between No.18 (30 Al fuse and
blower relay
1
1 VES
fuse box No. 1 terminal (+) and
body ground (-). Turn the ígnitíon
switch ON.
1
NO 1
ls there battery voltage ? Repair the fuse box.
1
l VES
1
l
BLK terminal and body ground
(G401, 402).
1
Repair open B LK wire
1
NO between the fuse box
ls there continuity ? and body ground or
poor ground (G401.
1 VES 402).
Repair open YEL/BLK wire

between the fuse box and blower
relay.
15-14
Troubleshooting Flowchart- Function Control--------------.
NOTE: Check the following • blown No.B (7.5 Al fuse

.--------------·-s_t_ic_k_in,g. function link and function doors
Function control motor does not
run.

from the function control motor.

YEL/BLK terminal (+) and body
ground (-).
Víew from wire side
NO
ls there battery voltage ? between the function control
motor and fuse box.
YES
Check for continuity from BLK

terminal to body ground.
Repair open in B LK wire

NO between the function control
ls there continuity ?
motor and body ground or poor
YES ground (G401, 402)
lnspect the function control motor

(page 15-37).
Replace the function

ls the function control motor OK?
control motor.
VES
To page 15-16
(cont'd)
15-15
Troubleshooting
Troubleshooting Flowchart- Function Control (cont'd) --------~-----.
From page 1 5-1 5

the function control motor.

from the heater control panel.

BLK, LT GRN/RED terminals and
body ground.
View from wire side

NO Repair open in BLK, LT GRN/
ls there continuity ? RED wire or poor ground (G401,
402).
VES
NOTE: lf the function control motor is in the vent position,

Connect each wire LT GRN/WHT, it will not run when the LT GRN/WHT wire is grounded. In·
LT GRN/BLK, VEL/GRN, BLU/ this case, ground the LT GRN/WHT wire again after groun-
RED, BLU to body ground. ding the other wires.
Áepair open in wire (LT GRN/

WHT, LT. GRN/BLK. VEL/GRN,
Does the function control motor >-N_O
_ _ _--l
BLU/LED. BLU) between the
run normally ?
function control motor and heater
VES control panel.
Replace the heater control

switch.
15-16
.Troubleshooting Flowchart- Recirculation Control-----------.
NOTE : Check following; • Sticking blower side link and recirc door
• Blown No.8 (7 .5 A} fuse
.------------------------,
Redrculation control door does
not change between FRESH and
REC, or continues to run.
Push the REC button and turn the

ignition switch ON.
• Repair short in GRN/RED wire

YES between recirc. motor and fan
Does the motor run all the time ?
switch.
NO • Replace the control switch
Push the FRESH button and turn

the ignition switch ON.
• Repair short in GRN/WHT

YES wire between recirc. motor
Does the motor run all the time ?
and fan switch.
NO • Replace the control switch

from the recirc. motor at the bot-
tom of the blower assembly.

YEL/BLK (+) and body ground
(-).
To page 15-18
View from wire side
(cont'd)
15-17
Troubleshooting
Troubleshooting Flowchart-- Recirculation Control (cont'd) - - - - - - - - - - .
From page 1 5-1 7
1 NO Repair open in YEL/BLK wire

ls there battery voltage ? between the fuse box and the
recirc motor.
1 VES
lnspect the recirc. motor (page

15-37).
1
NO Replace the recirc
ls the recirc. motor OK ?
motor.
1
1 YES
Check the GRN/WHT terminal for

continuity to body ground in
FRESH position.
1
NO Repair open Ín GRN/WHT wire
ls there continuity ? between recirc. motor and the
heater control panel.
1 YES
Check the GRN/RED terminal for

continuity to body ground in REC
position.
1
NO Repair open in GRN/RED wire
ls there continuity ? between tfle recirc. motor and
the heater control panel.
l VES
Replace the heater control panel.
15-18
Blower
Replacement
1111
1. Remove the glove box. 4. {Without A/C)
2. Remove the glove box frame. Remove the blower mounting nuts (3).
Disconnect the connectors from the blower motor,
resister and recirculation control motor, then remove
the blower.
GLOVE BOX
3. lWithout A/C) 5. (With A/C)

Remove the self-tapping screws (2) and remove the Turn over the carpet and remove the side cover.
heater duct. Remove the control unit bracket mounting nuts (4).
Disconnect the connectors (5) and remove the control
unit bracket.
(cont'd)
15-19
Bl;ower
Replacement (conrd)~~~~~~~~~~~~~~~~~~~~~~~
6. (With A/C) 7. lnstall the blower in the reverse order of removal and
Remove the A/C ban,ds (2) and remove the blower make sure there is no air leakage.
under cover. NOTE: When installing the glove box frame, the face
NOTE: Be careful not to break the tabs while removing which covers the dashboard is installed with double-
the blower under cover. sided adhesive tape.
Remove the blower as in step 4.
GLOVE BOX
15-20
Overhaul
1111
NOTE:
• Before reassembly, make sure that the air door and
linkage moves smoothly without binding.
• When reattaching the actuator, make su re its position-
ing will not allow the air door to be pulled too far. Attach
the actuator and alllinkage, then apply battery voltage
and watch the door movement. lf necessary, loosen the
holding screw and move the actuator up or down.
To adjust the control rod:

Connect the recirc. control motor connector to the cabin
wire harness and turn the FRE/REC switch to "REC". Hold
the air door closed, then connect the control rod to the clip
on the arm.
15-21
Heater Assembly
Replacernent------------------------------------------------------~
1. When the engine is cool, drain the coolant from the 7. Remove the heater mounting nuts (4), then remove
radiator (Section 5). the heater assembly.
e Do not remove the radiator cap when the engine

is hot; the coolant is under pressure and could
severely scald you.
e Keep hands away from the radiator fan. The fan
may start automatically without warning and run
for up to 30 minutes, even after the engine is
turnad off.
CAUTION: Radiator coolant will damage paint.

Ouickly rinse any spilled coolant from painted sur-
faces.
2. Disconnect the heater hoses at the heater.
NOTE: Coolant will run out when the hoses are discon-
nected, drain it into a clean drip pan.
3. Disconnect the heater valve cable from the heater HEATER ASSEMBLY
valve.
8. lnstall in the reverse order of removal and:

• Apply sealant to the grommets.
• Do not interchange the inlet and outlet hoses. Make
sure that the hose clamps are secure.
• Loasen the bleed bolt on the engine and refill the
radiator and reservoir tank with the proper coolant
mixture.
Tighten the bleed bolt when a/1 the trapped air has
escaped and coolant begins to flow from it.
• Connect all cables and make sure they are properly
adjusted (page 1 5-30).
4. Remove the duct cover.
5. Remove the dashboard (Section 14).

6. Remove the heater duct.
15-22
Overhaul------------------------------------------------------~
1. Remove the heater assembly. FUNCTION CONTROL MOTOR (Button type only)
2. Remove the air mix rod from the clip. e When installing the function control motor, be careful
3. Remove the self-tapping screws (2) and heater core when connecting the link.
cover. e Try the function control motor in every mode for two
4. Remove the self-tapping screw and clamp. minutes, and make sure the motor operates correctly in
5. Pull out the heater core from the heater housing. each mode.
6. lnstall the heater in the reverse order of removal.
(Lever type)
HEATER CORE
HEATER CORE
COVER
Adjustment
1. Heater linkage: page 15-24
2. Air mix rod: page 15-31
3. Function control cable (lever type only): page 15-32
15-23
Heater Assembly
Heater Linkage Adjustment - - - - - - - - - - - - - - - - - - - - - - - - .
(LH) (RH)
(Button Type) (Button Type)
(DEF door adjustment) (DEF door adjustment)
Set the heater control switch on HEAT, to adjust for DEF Set the heater control switch on HEAT, to adjust for DEF
leak (shut~20 %). leak (shut~20 %).
1 . Loosen the adjusting screw. 1 . Loosen the adjusting screw.
2. Adjust the heater linkage as shown. 2. Adjust the heater linkage as shown.
3. Tighten the adjustíng screw. 3. Tighten the adjusting screw.
(HEAT door adjustment)

When HEAT door is closed, air should not leak from the
HEAT door.
1 . Loasen the adjusting screw.
2. Adjusting the heater linkage.
3. Tighten the adjusting screw.
ADJUSTING SCREW
(FOR DEF DOOR)
(RH)
(Lever Type)
(HEAT door adjustment)
When HEAT door is closed, air should not leak from the
HEAT door.
1 . Loosen the adjusting screw.
2. Adjust the heater línkage.
3. Tighten the adjusting screw.
AOJUSTING SCREW
(FOR HEAT DOORI
ADJUSTING SCREW
15-24
Heater Control Panel
Replacement----------------------------------------------~
1111
1. Remove the ashtray.
Remove the console.
2. Remove the switches, coin box, a ir vent, and ashtray

lighting bracket.
(cont'd)
15-25
Replacement (cont' d)
3. Remove the radio/cassette player and the meter visor. lf a heater control panel is button type, release the cool vent cable
from heater unit side.
NOTE: e Loosen the self-tapping screws under the radio, and remove the radio/cassette player.
e Tilt the steering column down, then remove the meter visor.
AH TYPE
COOL VENT CABLE
METER VISOR
RADIO/CASSETTE PLAYER
LH TYPE
COOL VENT CABLE
SELF-TAPPING SCREW
15-26
4. Disconnect the cables at the heater assembly. .
5. Remove the self-tapping screws(4), pull out the heater control panel, disconnect the wire harness connectors, then remove
the heater control panel.
(Button type)
(Levar type)
6. lnstall in the reverse arder of removal, reconnect the

cables, making sure they are properly adjusted (page
15-3\' 32).
15-27
Overhaul
(Button type)
(Levar type)
e Cable replacement (page 1 5-33)
15-28
1111
15-29
Heater Control Cables
Heater Valve Cable Adjustment
(LH) (RH)
1. Remove the a ir mix cable. NOTE: Befare adjusting the heater valve cable, air mix
2. Turn the cable arm to the stopper A and connect the cable should be adjusted.
end of the cable to the arm. 1 . Set the temperature control dial (lever) on COOL.
3. Gently slide the cable outer housing back from the end 2. Turn the cable arm to the stopper and connect the end
enough to take up any slack in the cable, but not of the cable to the arm.
enough to make the temperature control dial (lever) 3. Gently slide the cable outer housing back from the end
move, then snap the cable housing into the clamp. enough to take up any slack in the cable, but not
• Hold the end of the cable housing to the cable enough to make the temperature control dial (lever)
stopper B. move, then snap the cable housing into the clamp.
STOPPER B
4. Turn the water valve arm to SHUT and connect the 4. Turn the water valve arm to SHUT and connect the
end of the cable to the arm. end of the cable to the arm.
5. Gently slide the cable outer housing back from the end 5. Gently slide the cable outer housing back from the end
enough to take up any slack in the cable, but not enough to take up any slack in the cable, but not
enough to make the temperature control dial (lever) enough to make the temperature control dial (lever)
move, then snap the cable housing into the clamp. move. then snap the cable housing into the clamp.
HEATER VALVE CABLE
HEATER
VALVE CABLE
WATER VALVE ARM
15-30
Air Mix Rod, Air Mix Cable Adjustment - - - - - - - - - - - - - - - - ,
1111
ILH) IRH)
1. Set the temperatura control dial (lever) on COOL. 1. Set the temperature control dial (lever) on COOL.
2. Turn the rod arm to the engine compartment side, then 2. Remove the heater .control cable.
connect the rod to clip. 3. Turn the rod arm to the engine compartment side, then
connect the rod to clip.
RODARM
ROO ARM
3. Turn the cable arm to the stopper A and connect the 4. Turn the cable arm to the stopper and connect the end
end of the cable to the arm. of the cable to the arm.
4. Gently slide the cable outer housing back from the end 5. Gently slide the cable outer housing back from the end
enough to take up any slack in the cable, but not enough to take up any slack in the cable, but not
enough to make the temperature control dial (lever) enough to make the temperatura control dial (lever)
move, then snap the cable housing into the clamp. move, then snap the cable housing into the clamp.
AIR MIX CABLE STOPPER
CABLE ARM
5. After adjusting of air mix rod and cable, set the temper-
ature control dial (lever) on HOT, blow warm air from 6. lnstall the heater control cable and adjust it.
the heater unit, then set ít on COOL and blow cool air
from it.
NOTE: Air mix cable should be adjusted if the heater
valve cable has been disconnected.
15-31
Heater Control Cables
Function Control Cable ·Adjustment Cool Vent Adjustment
(lever type only) _1. Set the cool vent lever on SHUT.
1. Slide the function control lever to ~. 2. Turn the cable arm to the stopper and connect the end
2. Turn the function control arm to the front and connect of the cable to the arm.
the end of the cable to the arm. 3. Gently slide the cable outer housing back from the end
3. Gently slide the cable housing back from the end enough to take up any slack in the cable, but not
enough to take up any slack in the cable, but not enough to make the temperature control lever move,
enough to make the temperature control lever move, then snap the cable housing into the clamp.
then hold the cable housing and snap it in the clamp.
(LH)
CABLE ARM
FUNCTION CONTROL CABLE
COOL VENT CABLE
(RH)
CABLE ARM COOL VENT CABLE
15-32
Cable Replacement
1. Remove the self-tapping screw.
2. Remove the cable.
3. lnstall the new cable.
NOTE:
• Hold the end of the cable to the stopper.
e After installing and adjusting the cable, make sure
that the dial or lever move smoothly without bind-
ing.
(AIR MIX CABLE. FUNCTION CONTROL CABLE) (COOL VENT CABLE)
(Button type)
STOPPER COOL VENT CABLE

(Lever type)
15-33
Test
Fan Switch Relay
1. Disconnect the 8-P connector from the tan switch. 1. Remove the relay from the dash fuse box.
2. Check for continuity between the terminals of the fan 2. There should be continuity between the A and 8 termi-
switch according to the table below. nals when the battery is connected to the C and D
SWITCH CONNECTION terminals.
There should be no continuity when the battery is
Terminal
"
Position
OFF
A
'\
CD ®
o- -o- Lo
® @ @ ® (j) disconnected.
B o- -o D
e o- -o D ¡
D o- -o i
D
E o- -o D
A e
B D
15-34
Recirculation Control Switch Function Control Switch
1. Disconnect the (button type: 14-P, lever type: 10-P) (Button type only)
connector from the heater control switch. 1 . Disconnect the 14-P connector from the heater con-
2. Check for continuity between the terminals of the trol switch.
heater control switch according to the table below. 2. Check for continuity between the terminals of the
heater control switch according to the table below.
(Button type)
'\. Terminal
5 4 3 2 1 6
Position \ 1
..-,.;-,;
..,J
1
l
o
o
o-- k
-o
o
~,J o D i
<aY o D
(Lever type)
Terminal
e B A
""'Poe$)(
sitian
OFF)
-""' o- ~
~ON) o -o
15-35
-Test
A/C Switch
(Type for with A/C only)
1. Disconnect the (button type: 14-P, lever type: ·1 0-P)
connector from the heater control switch.
2. Check for continuity between the terminals of the
heater control switch according to the table below.
(Button type) (Lever type)
Terminal
CD @
Position
OFF
ON
15-36
Recirculation Control Motor Function Control Motor
1. Connect the battery positive to the CD terminal of the (Button type only)
recirculation control motor connector and negatíve to 1 . Connect the battery positive terminal to the CD terminal
® and@ termínals; the recirc. motor move smoothly. of the function control motor and negative to the ®
2. Disconnect the battery negative from 2 or 3; the terminal.
recirc. motor should stop at FRESH or REC. 2. Using jumper wire short the ®terminal individually to
CAUTION: Never connect the battery in the oppo- the @. @, @,@ and <D terminals to follow the order.
site direction . e The motor should run each time the short circuit is
NOTE: made.
e Don't cycle the recirc. motor for a long time. NOTE: lf the function control motor does not run
e After adjusting the recirc. control rod, check the when you short the first terminal, short that terminal
recirc. motor on FRESH or REC for two minutes to agaín after shortíng the other terminals.
make sure it operates properly.
View from wire side
15-37
Special Tools
Special Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
Ref. No. Tool Number Description Q'ty Paga Reference
CD 07LAB-SK701 00 A/C Clutch Holder 15-76

® NO Tension Gauge 15-64, 65
@ 07LAJ-PT301 00 ECU Test Harness 15-58
CD
15-40
Air Conditioner
lllustrated lndex - - - - - - - - - - - - - - - - - - - - - - - - -
EVAPORATOA
As refrigerant circulates, heat is
absorbed from the surrounding
passenger compartment air.
Overhaul, page 1 5-68
Dissipates the heat which was

absorbed by the refrigerant.
RECEIVER ANO FILTER/DRYER
Serves as a reservoir which filters and
DUAL PRESSURE SWITCH removes moísture from the refrigerant.
When the refrigerant pressure is below 265 kPa (38 psi)
due to refrigerant leakage or above 1667 kPa (242psi)
due to coolant blockage the dual pressure COMPRESSOR (NIPPONDENSO)
switch opens the circuit to the A/C control Compresses the refrigerant and
unit and stops the air conditioner to then forces it through the condenser:
protect the compressor.
15-41
Circuit. Diagram
Carbureted Engine IGNITION

SWITCH
BATTERY No.15 No.19 No.7
{80A) (50 A) (7 .5A)
BLKIYEL BLK/YEL BLKIYEL BLK/YEL
No.39 No.B No.29 MG

(15A) (7 .5A) (15A) CLUTCH
RELAY
WHT
REOfBLU REO
BLK/YEL PfS SWITCH
BLU/BLK
BLU
COOLING
FAN
RELA Y
CONOENSER
FAN
RELA Y
$
BLU/BLK
BLU/BLKt. BLU/BLK
MG
CLUTCH
COOLING
~RED
FAN A/C
SWITCH 1 PRESSURE
ON : above) SWITCH HAC lBLK
( 93°Cf199°Fl,
BLU/YEL SELENOIO
t
COOLING CONO ENSER
:~251
LIGHTING AIC
FAN FAN SWITCH LH (EXCEPT KY,KP)
MOTOR MOTOR THERMOSTAT
RH g:g~(KY,KP)
-..,
BLK
?
REDIBLK BLUIRED
r-
1
1
1
1
1
1
LH : G401 . 402
RH : G301
II 1
1 1
1 1
_____ J 1
r- 1
1 1
1 1
1 1
G201 G101 G281 1 1
L.-
BLOW ER RESISTER
OASHLIGHT
BRIGHTNESS
GONTROLLER
OFF
HEATER FAN SWITCH
G401
6402
15-42
PGM-CARB Engine IGNITION
SWITCH
BA TTERY No.15 No.19 No.?
(9 OA) (50A) (7 .5A)
BLK/YEL BLKIYEL BLK/YEL
No.39 No.S No.29 (J MG

CLUTCH
(15A) (7 .5A) (15A)
1 RE LAY
WHT REDIBLU RED

BLK/YEL
COOWIG
FAN
RELAY
CONDENSER
FAN
RELAY
7 ECU
MG
CLUTCH
BLUIBLK
BLU
BLUIBLK¡ BLU/BLK ECU
COOWIG
FAN A/C
SWITCH 1 PRESSURE
SWITCH
(ON : above}
9J0Cj1990f)
BLU/YEL
t
COOLING CONDENSER LIGHTING A/C
FA N FA N
y
SWITCH THERM OSTA T
MOTOR MOTOR
r- -..,
1 1
1 1
BLK BLK BLK REDIBLK BLUIRED 1 1
1
11 1
1
1
_____ J 1 1
r- 1
1 1
1 1
1 A/C
SWITCH 1
G201G101 G281 1 1
L- ----------....1
RED BLOWER RESISTER
7
DASHLIGHT
BRIGHTNESS
CONTROLLER
OFF
HEATER FAN SWITCH
G401 (cont'dl
G402
15-43
Circuit Diagram (cont'd)
PGM-FI Engine (KO. KV}

16NITION
SWITCH
BATTERY No.15 No.7
(80A) (7 .SA)
No.39 No.29 No.S MG

(15A) (15A) (7 .5A) CLUTCH
RELAY
BLKIYEL YELIBLK
REDIBLU RED
COOLING
FA N
RELAY
WHT/GRN
~ECU
MG
CLUTCH
BLUIBLK
BLU BLU
t---------~--~----------~-+--~~~BLU/BLK-.---c ECU
COOLING
FAN TW AIC
SWITCH SWITCH PRESSURE
ON : above) (ON : above ~ SWITCH
( 93°CI199°F) 108°C(246°F
BLU/YEL
f'"
COOLING CONDENSER LIGHTING
FA N FAN
y
SWITCH THERMOSTAT
MOTOR MOTOR
r- -,
1 1
1 1
BLK BLK BLK BLK REO/BLK BLU/REO 1 1
1 1
1
1
1
_____ J 1
r- 1
1 1
1 1
1 A/C
SWITCH 1
1 1
L- ----------....1
G201 G101 G281 G401 RED . BLOW ER RESISTER
V
6402
OASHLI6HT
BRIGHTNESS
CONTROLLER
OFF
HEA TER FAN SWITCH
6401
G402
15-44
1111
PGM-FI Engine (except: KQ, KY)
IGNITION
SWITCH
BA TTERY No.?
(7 .5A)
oJr-....-<J\....1>--- BLKIY EL ---""""4~-- ....- -..
No.39 No.29 No.8 MG

(15A) (15A) (7 .5A) CLUTCH
RELAY
BLKIYEL YELIBLK
RED/BLU REO
~
YEL
YELIW HT
MG
CLUTCH
ECU
BLUIBLK
BLU
ECU
COOUNG TW
FAN SWITCH A/C
SWITCH PRESSU RE
ON : above \ SWITCH
ON : above) { 1 08'C(246•¡:y
( 93°C(1990f]
BLUIYEL
~~tRMOSTAT
t
COOUNG CONDENSER UGHTING
FAN FAN
y
SWITCH
MOTOR MOTOR
r- -,
1 1
1 1
BLK BLK BLK RED/BLK BLU/RED 1 1
1 1
1
I
1
_____ J 1
r- 1
1 1
1 1
1 A/C
SWITCH 1
1 1
L- ----------....1
G201 G101 G281 G401 RED BLOWER RESISTER
G402
V
DASHLIGHT
BRIGHTNESS
CONTROLLER
OFF
HEATER FAN SWITCH
G401
G402
15-45
Wire Harness Routing
A/C THERMOSTAT
DELAY RELAY
COOLING FAN RELAY IDLE-UP SOLENOID (Carburated Engine only)
COOLING FAN TIMER UNIT

(PGM-FI Engine
only}
• COMPRESSOR CLUTCH RELAY

• CONDENSER FAN RELAY
CONDENSER FAN COMPRESSOR
• DIODE
MOTOR CONNECTOR CONNECTOR
PRESSURE SWITCH
CONNECTOR
15-46
Troubleshooting
Symptom Chart
NOTE:
e Any abnormality must be corrected befare continuing the test.
e Because of the precise measurements needed, use a voltmeter and ammeter when testing.
SYMPTOM REMEDY
Cooling fan does not operate at all. See flowchart (page 1 5-48)
Check following:
Water temperature is too high when A/C system is not in Faulty radiator fan switch
use. Open BLK wire from the radiator fan switch to body
ground or poor ground (G1 01)
Condenser fan does not operate at all. See flowchart (page 1 5-51}
Check following:
1 Both fun• do not ope,ote" all. Faulty diode
Open BLU/BLK wire from the diode to pressure switch
1 A/C system does not come on.

See flowchart (page 1 5-53)
: Compressor and both cooling fans do not come on.
~ Compressor does not come on.

See flowchart (page 15-57}
8oth fans operate normally.
COOLING FAN TIMER UNIT INPUTS TEST ---+15-61

PRESSURE TEST ---+15-85
15-47
Troubleshooting
Troubleshooting Flowchart- Cooling Fan - - - - - - - - - - - - - -
NOTE: Check for blown No.2 (15 AL No.39 {15 A}. No.S (7.5 A) fuse
Cooling fan does not operate at all.
Disconnect the cooling fan relay

from the relay box.
Conllect a fused jumper from (2)

terminal to @ terminal.
VES
Does cooling fan operate ? >-__:_---To page 15-49
NO
Connect voltmeter between ®ter-

mina/(+) and body ground (-).
NO Repair open WHT wire between

ls battery voltage present ? • No.39 115 Al fuse and cooling
fan relay.
VES
Dísconnect the coo/ing fan motor
connector.
Connect the voltmeter between

BLU/BLK wire (+) BLK wire (-).
ls battery voltage present ? Replace the cooling fan motor.
VES
Repair open BLK wire between
cooling fan motor and body
ground or poor ground (G201).
15-48
1111
From page 1 5-49
l
Connect voltmeter between <D ter-
minal ( +) and ® terminal (-) of
connector
1
Turn A/C switch to ON.
Turn fan switch to ON.
~Turn ignition to RUN.
1
VES
ls battery voltage present ? Aeplace cooling fan relay.
1 NO
Check for <D terminal for battery

voltage.
(PGM-CAAB Engine. Carbureted
1
Enginel
YES
ls battery voltage present ? Repair open in YEL/BLK wire
between No. 8 (7. 5 Al fuse and
1 NO cooling fan relay.
Repair open in BLU wire

between cooling fan relay and - • PGM-FI Engine (KQ, KY): page 15-50 A
diode. • PGM-FI Engine (except KQ. KY): page 15-50 8
(cont'd)
15-49
Troubleshooting
Troubleshooting Flowchart- Cooling Fan (cont'd) - - - - - - - - - - - .
PGM-FI Engine (KQ, KY)

From page 1 5-49 A
Check for voltage on YEL wire at

cooling fan timer unit.
NO See timer input test.

ls battery voltage present ? r - - - - - 1Í
1 (page 15-61)
1
1 YES
Repair open YEL wire between

cooling fan timar unit and cooling
fan relay.
PGM-FI Engine (except KQ, KY)

From page 1 5-49 8
Disconnect 2-P connector from

diode.
1
BLK terminal ( +) and body ground
(-).
1
NO Repair open in YELIBLK wire
ls there battery voltage ? between No. 8 (7. 5 Al fuse and
diode.
1 YES
Check for continuity between YEL/

1
Repair open VE L wire
NO
ls there continuity ? between diode and
cooling fan relay.
YES
1
Replace diode.
15-50
Troubleshooting Flowchart- Condensar Fan - - - - - - - - - - - - - - - .
NOTE: Check for blown No.2 (15 AL No.29 (15 A), No.7 {7.5 A). No.S (7.5 A) fuse
Condenser fan does not operate at

all.
Disconnect the condensar fan PGM-FI Engine: YEL/WH

relay connector. PGM-CARB Engine,
Carbureted Engine: BLK/
1
Connect a fused jumper from WHT

wire to BLU/GRN wire.
1
Does condenser fan operate ?
l YES
NO
To page 15-52 A (
BLU
\1
Connect voltmeter between wire

(PGM-FI Engine: YEL/WHT,
PGM-CARB Engine, Carbureted View from termi
Engine: BLK/YEL} (+) and BLU
wire (-).
1
Tum A/C switch to ON.
Turn fan switch to ON.
Turn ignition to AUN.
1
VES 1
ls battery to voltage present ? Replace condensar fan Relay.
j NO
Connect voltmeter between

PGM-FI Engine: YELIWHT,
PGM-CARB, Carbureted Engine:
BLK/YEL wíre (+) and body
ground (-}.
l (PGM-CARB Engine, Carbureted

NO
ls battery voltage present ? Enginel
Repair BLK/YEL wire
j VES
Check BLU wire. or A/C diode

' - - - • PGM-FI Engine: page 1 5-52 B
for an open.
(cont'd)
15-51
Troubleshooting Flowchart- A/C System - - - - - - - - - - - - - - - - - ,
NOTE: A/C compressor clutch will not come on without the engine running.
A/C System does not come on.
BLU/YEL, BLU/BLK
Turn ignition OFF.

from the pressure switch.
Tum the heater fan, A/C switch

ON and start the engine.
Connect a jumper wire between

the BLU/BLK terminal and body
ground.
Repair open in BLU/BLK wire

Do both fans and the compressor >-N_O
_ _ _--¡
between pressure switch and
run ?
diodes.
VES
Connect a iumper wire between

the BLU/BLK and BLU/YEL termi-
nals.
Check refrigeran! pressure. lf

Do both fans and the compressor >-Y_E_S_ _ _-l
pressure good, replace A/C pres·
run?
sure switch.
NO
To page 15-54 (cont'd)
15-53
Troubleshooting
Troubleshooting Flowchart-A/C System ( c o n t ' d ) - - - - - - - - - - -
{From page 15-53)

the pressure switch.

from the thermostat switch.

the BLU/YEL terminal and body
ground. View from wire side
Repair open in BLU/YEL wire

Do both fans and the compressor )-N_O
_ _ _--l
between pressure and thermo-
run ?
stat switches.
YES

the BLU/YEL and BLU/RED termi-
nals.
Check evaporator temperatura.

Do both fans and the compressor )-Y_E_S_ _ _...J
lf temperatura is above 41 ° F,
run ?
replace A/C thermostat.
NO

the thermostat switch.
Disconnect the connector (Button

type: 14-P, lever type: 10-P)
from the heater control panel.
(To page 15-55)
15-54
(From page 15-54)

the BLU/RED terminal and body
ground.
Start the engine.
Repair open in BLU/REO wire

Do both fans and the compressor ,_N_0
_ _ _--1
between the thermostat and A/C
run ?
switch.
View from wire side
YES
Connect a jumper wíre between

the BLU/RED and GRN terminals.
Do both fans and the compressor Jnspect the A/C switch.

run ? (page 15-36)
NO
Reconnect the connector (button

type: 14-P, lever type 1 0-P) to
the heater control panel and turn
A/C switch ON.

from the fan switch.

the GRN terminal and body
ground.
(To page 15-56)
(cont'd)
15-55
Troubleshooting
Troubleshooting Flowchart-A/C System (cont'd)------------,
(From page 15-55)
\
Repair open in GRN wire
Do both fans and the compressor NO
between fan switch and function
run ?
control panel.
1 YES

1
1
l Check for continuity from

terminal to body ground.
1
BLK
1

NO between the fan switch and body
ls there continuity ?
ground or poor ground {G401.
1 YES
402).
Replace the fan switch.

1 1
15-56
Troubleshooting Flowchart- Compressor - - - - - - - - - - - - - - - - .
1111
NOTE: Check for blown No. 7 (7 .5 A) fuse
Compressor does not come on.

from the compressor clutch relay.

BLK/YEL 1 terminal ( +) and body
ground.

NO
ls there battery voltage ? between the No.7 (7.5 A) and
compressor clutch relay. View from terminal side
VES

BLK/YEL 2 terminal ( +) and body
ground.

NO
ls there battery voltage ? between the No. 7 (7. 5 Al and
compressor clutch relay ..
YES
Connect the jumper wire between

the BLK/YEL 1 terminal and RED
terminal.
Turn the ignition OFF and Recon-

Does the compressor clutch >-N_O
_ _ _--!
nect the 4-P connector to the
engage?
compressor clutch relay.
YES
PGM-FI, PGM-CARB Engine: To page
15-58 (To page 15-60)
Carbureted Engine: To page 15-59
(cont'd)
15-57
Troubleshooting
Troubleshooting Flowchart-- Compressor (cont'd) - - - - - - - - - - -
<PGM-FI. PGM-CARB Engine>

(From page 1 5-57)

reconnect 4-P connector to the
1 compressor clutch relay.
Turn the ignition switch ON, and

connect a jumper wire between
RED/BlU terminal and body
ground.
Does the compressor clutch NO Replace the compressor clutch

engage? relay.
1 YES
85 (PGM-FI)
! Turn the ignition switch OFF and
~1
disconnect PGM-FI, PGM-CARB
ECU connector and connect the
PGM-FI ECU test harness.
1 1
1oooooo~~~ ooo 1ooi)oooo o
>~00
1
0000000 00000000
Turn the ignition switch ON and
connect a jumper wire between --!.:.. \ \ A19 (PGM-CARB)
A15 (PGM-FI) or A19 (PGM-
CARB) terminal and body ground. _L - A 15 (PGM-FII
-
1
Does the compressor clutch NO
between the compressor clutch
engage?
relay and ECU.
j YES
Disconnect a jumper wire and con-

nect a jumper wire between 85
(PGM-FI) or 06 (PGM-CARB) ter-
minal and body ground.
¡
Repair open in BLU/BLK wire
Do es the compressor clutch NO
between A/C pressure switch
engage ?
and ECU.
1 YES
Substituta a Known- good ECU

original ECU.
15-58
<Carbureted Engine>
(From page 15-57)

reconnect 4-P connector to the
compressor clutch relay.
j
Turn the ignition switch ON, and
connect a jumper wire between
RED/BLU terminal and body
ground.
Does the compressor clutch NO Replace the compressor clutch

engage? relay.
1 VES
Disconnect 6-P connector from

the delay control unit.

RED/BLU terminal and body RED/BLU
ground.
B
1
Repair open in RED/BLU wire View from wire side
Does the compressor clutch NO
between compressor relay and
engage? delay control unit.
1 YES

BLK/VEL terminal (+) and body
ground (-).
j
NO Repair open in BLK/YEL wire
ls there battery voltage ? between the No. 7 (7 .5 A) fuse
and delay control unit.
1 VES
Check the continuity between BLK

1
NO
ls there continuity ? between delay control unit and
body ground or poor ground.
1 VES
Check the continuity BLU/BLK

terminal between del ay control
unit and body ground. Then A/C.
heater tan switches ON.
1
NO Repair open in BLU/BLK wire
ls there continuity 7 between delay control unit and
body ground.
j VES
Faulty delay control unit.

(cont'd)
15-59
Troubleshooting
Troubleshooting Flowchart - - Compressor (cont'd) - - - - - - - - - - - .
(From page 1 5-57)
Disconnect the RED terminal from

compressor and turn the ignition
switch on.
Measure voltage between the RED

terminal(+) and body ground.
Repair open in RED wire
NO between the compressor clutch
relay and compressor clutch con-
VES nector.
Replace the compressor clutch.
15-60
Cooling Fan Timer Unit Input Tests
NOTE:
Perform the following tests with the cooling fan timer
connected and the ignition switch ON.
Correct any abnormality before continuing.
;..---COOLING FAN
TIMER UNIT
CORRECTIVE ACTION
WIRE TEST DESIRED
IF DESIRED RESULTS
POSITION CONDITION RESULTS
1 ARE NOT OBTAINED
i
¡
Check for continuity to Should have continuity. Repair open to body ground.
@BLK
body ground. 1
1
!1 Check for battery Check No.29 fuse, if OK repair open in
@WHT
voltage WHT wire.
Check for battery Check No.2 fuse, if OK repair open in

(])BLK/YEL voltage Should have battery voltage. BLK/YEL wire.
(lgnition switch-ON)
Check for battery ' Check No.S fuse, if OK repair open in
@YEL/BLK voltage YEL/BLK wire.
(lgnition switch-ON)
Check for battery Replace cooling fan timer unit.

CDYEL/WHT
voltage.
Check for battery Replace cooling fan timer unit.

Q)YEL
voltage.
Connect to body Condenser fan and cooling fan Check for open in BLU between coo-
ground. should come on. ling fan timer and condenser fan relay
or cooling tan relay.
lf OK, check for open YEL/WHT
@BLU between cooling fan timer and con-
denser fan relay or YEL between coo-
ling fan timer and cooling fan relay.
lf OK, test condenser fan relay or
cooling fan relay.
Check for voltage. Approx 11V lwater-temperature Faulty water temp switch, short to
@WHT/GRN below 108 °C) body ground or faulty cooling tan
timer unit.
15-61
Service Tips
Hf.i.ldf!lf'd When handling refrigerant (R-12):

e Always wear eye protection.
e Do not let refrigerant get on your skin or in your eyes; if it does:
- Do not rub your eyes or skin.
- Splash larga quantities of cool water in your eyes or on your skin.
- Rush toa physician or hospital for immediate treatment. Do not attempt to treat it yourself.
e Keep refrigerant containers (caos of R-121 stored below 40 °C (100 °F).
e Do not handle or discharge refrigerant in an enclosed area near an open flame; it may ignite and produce a poisonous
gas.
CAUTION:
1. Always disconnect the negativa cable from the battery whenever replacing air conditioner parts.
2. Keep moisture and dust out of the system. When disconnecting any lines. plug or cap the fittings immediately; don't
remove the caps or plugs until just before the lines are reconnected.
3. Before connecting any hose or line. apply a few drops of refrigerant oil to the seat of the 0-ring or fiare nut.
4. When tightening or loosening a fitting, use a second wrench to support the matching fitting.
5. When discharging the system. don't let refrigerant escape too fast; it will draw the compressor oil out of the
system.
6. Add refrigerant oil after replacing the following parts;
Condensar ························10 ce (1/3 fl oz)
Evaporator ························25 ce (5/6 fl oz)
Line or hose························1 O ce (1/3 fl oz)
Receiver ···························10 ce (1/3 fl oz)
Compressor ························On compressor replacement. subtract the volume of oil drained from the removed
compressor from 100 ce (3 1/3 fl oz). and drain the calculated volume of oil from the
new compressor:
100 ce (3 1/3 fl oz)-Volume of removed compressor=Draining volume.
OLD COMPRESSOR NEW COMPRESSOR
(¡
U~SAME LEVEL
DRAINING
VOLUME
7. Before charging the system. it is necessary to evacuate the system.

S. e Chage the system with, the correct quantity of refrigerant exactly.
e Avoid discharging with the refrigerant unnecessarily.
e When using an auto gas charger, operate it according to the manufacturer's instructions.
9. Check that the cooling fan motor runs when tuming the A/C switch and fan switch ON.
15-62
10. Torque Specifications.
SUCTION PIPE
RECEIVER PIPE A
CONDENSER PIPE
([) Suction hose (evaporator side) ·······································32 N· m (3.2 kg-m, 23 lb-ft) (@ with ALB 30 N·m (3.0 kg-m, 22
lb-ft)J
(g) Discharge hose to condenser ··········································22 N·m (2.3 kg-m, 16 lb-ft)
@ Condenser pipe to condenser ··········································22 N·m (2.3 kg-m, 16 lb-ft)
@ Receiver tan k································································ ··17 N· m (1 . 7 kg-m, 12 lb-ft)
@ Receiver pipe A, B. C (both side) ····································17 N·m (1. 7 kg-m, 12 lb-ft)
@ Compressor hose mounting bolts ····································30 N·m (3.0 kg-m, 22 lb-ft)
(]) Compressor bracket mounting bolts (10 x 351 ···············50 N·m (5.0 kg-m, 36 lb-ft)
® Compressor bracket mounting nut (8 mm) ·····················50 N·m (5.0 kg-m, 36 lb-ft)
® Compressor mounting bolts (8 x 94) ······························25 N·m (2.5 kg-m, 18 lb-ft)
15-63
BeiT Ten S .IOn
Compressor Belt
• UNew
5 . b e1t u refers to a
eog;~":'"
• u mmutes
Used beltuon a runmng
. beltengin
which has been used le
~~:',e t.Checkf~~;,;;;n~te'
mnn;ng to e belt :.;;eh "'theo
m:.:•
0' been uoed on,
' necessa ry, replace
amage . .f
Belt tension
15-64
Power Steering Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
1111
e "New belt" refers to a belt which has been used less than
5 minutes on a running engine.
e "U sed belt" refers to a belt which has· been used on a
running engine for 5 minutes or more.
NQTE:Check for belt damage. if necessary,'replace the
belt. Using NO tension gauge:
Belt tension [mm/10 kg] Belt tension [kg]
Nel!lf belt Used belt New belt Used belt

1
9.5~11.5 12.5~16 70~90 1

1
35~50
15-65
Performance Test
The performance test will help determine if the air condi- 3 VALVE GAUGE 2VALVE GAUGE
tioning system is operating within specifications.
1. Attach the gauge and pump as shown, connecting the
center charging hose to the pump inlet. To purge air
from the hose loosen both charging hoses fitting at the
stop valves, until they hiss for a few seconds, then
tighten them again.
2. Start the pump, then open both gauge valves and the
evacuate valve (2 valve gauge: evacuate stop valve).
The low gauge should indicate above 700 mmHg
(27in-Hg). then run the pump about 1 minute.
3. Close both valves and the evacuate valve (2 valve
gauge: evacuate stop valve) and stop the pump. Open
both stop valves.
4. lnsert a thermometer in the vent outlet. Determine the
relative humidity and ambient air temperature by a
portable weather station or calling the local weather
station.
5. Test conditions:
• Avoid direct sunlight.
e Open engine hood.
e Open front doors.
• (button type}
Set the temperature control dial to COLO and push
;J and 4&1t buttons.
(lever type)
Slide the temperature controllever to COLO and the
function control lever to ;J and push 4&1t but-
tons.
e Turn the fan switch to MAX.
e Turn the A/C switch ON.
e Run the engine at 1,500 RPM.
e No driver or passengers in vehicle.
6. After running the air conditioning for 1O minutes under
the above test conditions, read the delivery tempera-
ture from the thermometer in the dash vent and the kPa
high and low system pressure from the A/C gauges. 2500
7. To complete the charts: w
a::
e Mark the delivery temperature along the vertical :::;)
(1)
line. (1) 2000
w
e Mark the intake temperature (ambient air tempera- a::
Q.
ture) along the bottom line. > oc (psi) kPa

a::
e Draw a line straight up from the air temperature to w
>
1500 30 150) 400
the humidity. :::;
w
e Mark a point one line above and one line below the Q
humidity level. ( 1 O % above and 1O % below the 1000J 25 (40) 300 ~

:::;)
humidity level) U)
e From each point, draw a horizontal line across to w U)
a: w
the delivery temperature. :::;) (30) 200 ~
1-
e The delivery temperature should fall between the
two lines.
e Complete the low side pressure test and high side
<1:
a::
w
Q.
::¡¡ 15
'"1 (20) 100
w
:.::
<1:
~
w
pressure test in the same way. 1-
>
e Any measurements outside the line may indicate the a:
need for further inspection. ~ 10 (101 o
:::;
w
Q
DELIVERY
5 TEMPERATURE
(70) (801 (901 11001

20 25 30 35 40 oc
INTAKE TEMPERATURE
15-66
Evaporator
Replacernent----------------------------------------------------~
1. Disconnect the battery negative terminal. 6. Remove the nuts, then remove the evaporator.
2. Discharge the refrigerant (page 1 5-80).
3. Disconnect the receiver line and suction hose from the
evaporator.
CAUTION: Cap the open fittings immediately to
keep moisture out of the system.
(Without ALB) (With ALB)
~
EVAPORATOR (Without ALB)
SUCTION HOSE RECEIVER

PIPE
4. Remove the glove box and the glove box frame. (page 7. lnstall in the reverse order of remove, and:
15-19) e Apply a sealant to the grommets.
5. Remove the self-tapping screw (3) and A/C band, then • Make sure that there is no air leakage.
disconnect the connector from the thermostat. e Charge the system (page 15-81) and test perfor-
mance (page 15-66).
15-67
Evaporator
Overhaul
1. Pull out the evaporator sensor from the evaporator fins.
2. Remove the self-tapping screws and clips from the housing.
3. Carefully separate the housings and remove the evaporator covers.
4. Remove the expansion valve if necessary.
Assemble the evaporator in the reverse order of disassembly, and:
e lnstall the expansion valve capillary tube against the suction line, and wrap it with tape.
e Reinstall the evaporator sensor in its original location.
A/C THERMOSTAT
Blow dirt out of fins

with compressed air.
EXPANSION VALVE
'
':' ____ ... -- -- ,\-
•
~
¡ __ ,. .. '
..- ..---
'
·-
' '
WithoutALB
TAPE
Replace.
Make sure there is no foreign matter stuck between
the capíllary tube and outlet line.
LOWER HOUSING
15-68
Condensar
Replacement
1111
1. Discharge the refrigerant (page 1 5-80). 4. Disconnect the connector from the radiator tan motor,
2. Temporarily remove the radiator reservoir tank and remove the mounting bolts (4) and remove the radiator
intake tube, then remove the suction pipe bracket. fan shroud.
CAUTION: Do not damage the radiator fins when
removing the fan shroud.
RADIATOR RESERVOIR TANK
RADIATOR FAN SHROUD
5. Disconnect the connector from the condenser fan

motor and remove the connector from the compres-
sor. Remove the mounting bolts (3) and remove the
condenser fan shroud.
CAUTION: Do not damage the radiator fins when
removing the tan shroud.
3. Remove the front grille.

NOTE: Remove the boss as shown.
CONDENSER FAN SHROUD
GRILLE BOSS {cont'd)
15-69
Compressor (Nippondenso)
Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
This compressor is a piston type. A revolving inclined disc drives the surrounding 1 O reciprocating pistons. As the inclined disc
revolves, it pushes the pistons, protected by a ceramic shoe, thus compressing the refrigerant.
--
15-71
Compressor
Replacement
1. lf the compressor is marginally operable, run the 5. Remove the alternator harness clamp and disconnect
engine at id le speed and turn on the air conditioner fan . the alternator harness.
a few minutes, then shut the engine off and discon-
nect the battery negative terminal.
2. Discharge the refrigerant very slowly from the system
(page 1 5-80).
3. Remove:
e power steering mounting bolt and nut
e adjusting bolt
e adjusting bolt bracket
e power steering belt
e power steeríng pump
'l 1 11
~ {(r7\-t:\lo>'1., ; - - J -
r
~\ i /¡ 6. Remove:
ADJUSTING BOLT e alternator mounting bolt and nut
BRACKET • adjusting bolt
e adjusting bolt bracket
ADJUSTING BOLT POWER STEERING POWER STEERING
• compressor belt
PUMP MOUNTING NUT
e alternator
(With cruise control} ALTERNATOR
4. Remove the auto cruise actuator mounting bolts (2),
disconnect the connector (1) and remove the auto
cruise actuator.
ALTERNATOR
MOUNTlNG NUT
ADJUSTING BOLT
BRACKET
ADJUSTING BOLT
15-72
Compressor
Replacement (cont'd) - - - - - . _ ,
11. lnstall in the reverse order of removal and:
• lf a new compressor is installed, calculate the refrig-
erant oil as below and drain through the suction
fitting on the compressor:
100 cc(3 1/3 fl oz) minus contents of old compres-
sor, equals amount to drain from new compressor.
e Do not damage the radíator fins when install the
compressor.
e Be careful to connect the alternator harness as
shown.
e Adjust the belt (page 15-64)

• Charge the system (page 15-81)
e Test the performance (page 15-661
15-74
Clutch lnspection
• Check pulley bearing play and drag by rotating the pulley • Measure the clearance between the pulley and pressure
by hand. Replace the pulley with a new one if it is noisy plate all the way around. lf the clearance is not within
or has excessive play/drag. specified limits, the pressure plate must be removed and
shims added or removed as requited.
CLEARANCE: 0.5±0.15 (0.020±0.006 in.)
NOTE: The shims are available in three sizes: 0.1 mm, 0.2
mm and 0.5 mm of thickness.
CENTER BOLT
14 N•m (1.4 kg-m, 10 lb-ft)
• Check resistance of the fíeld coil:

Field Coil Resistance: 3.6 ± 0.2 ohm at
/ .
20 °C) (68 °F)

·lf resistance is not within specifications, replace the coil.
15-75
Compressor
Clutch Overhaul
1. Remove the center bolt. 3. Use circlip pliers to remove the snap ring B, then
remove the pulley.
SPECIAL TOOL
07 LAB-SK701 00
SNAP RING B
\ ,.,..,.,.__...-
PULLEY
2. Remove the pressure plate and shim(s) taking care not

to lose the shíms.
PRESSURE
PLATE
~
SHIM(S)
15-76
1111
4. Remove the snap ringA and the field coil.
SNAP RINGA
5. Instan in the reverse order of removal and:

e lnstall the fíeld coil wíth the wíre síde facíng up (see
above).
e Clean the pulley and compressor slidíng surfaces
with non-petroleum solvent.
e Check the pulley bearíngs for excessive play.
e Make sure the círclip is fitted to the groove proper-
ly.
e Apply locking agent to the thread of the center bolt
and tighten it securely.
e Make sure that the pulley turns smoothly.
15-77
Test
A/C Thermostat Relay - - - - - - - - - - - - - - .
Dip the evaporator sensor into a pan filled with ice water, There should be continuity between the A and B terminals
and check for continuity between the terminals. when the battery is connected to the C and D terminals.
Cut off 1 .5--0.5 oc (35-33 °F) There should be no continuity when the battery is discon-
Cut in 2.5-5 oc (36-41 °F) nected.
lf cut off or cut in temperature is too low or too high,
replace the A/C thermostat.
[W
-ºo-t-----.
A~
B
r~ O
A e
A e
B o
15-78
Test
Diode ------------------------~
Refrigerant Can
Attachment 1111
NOTE: The diodes are designed to pass current in one 1. Loosen the opener.
direction and block current in opposite direction. Most NOTE: Check for a rubber packing on the can-joint.
ohmmeters, unless equipped with a diode tester, should
not be used to test diodes.
RUBBER PACKING
Check for continuity in both directions between A and B
terminals. There should be continuity in only one direction.
2. Attach a refrigerant can toa can-joint.

NOTE: lf attaching three caos toa four can, can-joint,
attach an empty can to the fourth joint.
A _........_1- Q
Üf---..... B
15-79
Discharge Procedure
""'*'''
4. Slowly open the high side manifold valve slightly to let
• Keep away from open flames. The refrigerant. refrigerant flow from the center hose only. Do not
although nonflammable, will produce a poisonous open the valve too wide. Check the shop towel to
gas if burned. make sure no oil is being discharged with the renger-
• Work in a well-ventilated area. Refrigerant evapo- ant.
rates quickly, and can force all the a ir out of a small CAUTION: lf refrigerant is allowed to escape too
enclosed area. fast, compressor oil will be drawn out of the sys-
1 . Connect the gauges as shown. tem.
2. Disconnect the center hose of the gauge set and place 5. After the high pressure gauge reading has dropped
the free end in a shop towel. below 1000 kPa ( 1 42 psi), open the .low side valve to
3. Open the both stop valves and the evacuation valve (2 discharge both high and low sides of the system.
·valve gauge: evacuate stop valve). · 6. Note the gauge reading and, as system pressure
drops, gradually open both high and low side valves
fully until both gauges indicate O kPa (O psi).
(3 valva gauge) (2 valva gauge)
EVACUATION VALVE
LOW PRESSURE HIGH PRESSURE

VALVE VALVE LOW PRESSURE
VALVE
VACUUM HOSE
CHARGE HOSE
(with STOP VALVE) EVACUATION STOP
"-~--~~~~...,- VALVE
CHARGE HOSE
(with STOP VALVE)
HIGH PRESSURE
STOPVALVE
HIGH PRESSURE
STOP VALVE
15-80
System Charging
System Evacuation
1111
The following are the procedures to be adhered to when evacuatíon valve (2 valve gauge: evacuation stop
servicing air conditioners to reduce the amount of Fron valve) and stop the pump. The low gauge should
R-12 into the atmoshpere. indicate above 700mmHg (27 in-Hg) and remain
1 . When an A/C System has been opened to the atmo- steady with the valves closed.
sphere, such as during installation or repair, it must be NOTE: lf low pressure does not reach more than 700
evacuated using a vacuum pump. (lf the system has mmHg (27 in-Hg) in 15 minutes, there is probably a
been open for severa! days, the receiver/dryer should leak in the system. Check for leaks, and repair (see
be replaced). Leak Test).
2. Connect a gauge, pump and refrigerant contaíners 4. lf there are no leaks open the valves and continue
(cans of R-12) as shown. pumping for at least another 15 minutes, then close
NOTE: Do not open the cans. both valves, stop the pump.
3. Start the pump, then open the both pressure valves,
both pressure stop valves and evacuation valve (2
valve gauge: evacuation stop valve). Run the pump for
about 15 minutes. Clase the both pressure valves and
3 VALVE GAUGE
2 VALVE GAUGE
LOW PRESSURE
VALVE
Attach the joint

by pushing
valve core
into the air into the air
purge valve. purge valve.
1
1
'
CHARGE HOSE -._.j
REFRIGERANT t'
CANS ICLOSEDI '
1 REFRIGERANT
CANS (CLOSEO)
~ CHARGE HOSE
th STOP
VALVE)
j'HtGH PRESSURE
STOPVALVE
j
LOW PRESSURE LOW PRESSURE

STOPVALVE STOP VALVE
15-81
System Charging
Leak Test
The following are the procedures to be adhered to when 2. Open the cans.
servicing air conditioners to reduce the amount of Fron 3. Open high pressure valve to charge the system to
R-12 into the atmoshpere. about 1 00 kPa ( 14 psi), then close the supply valve.
NOTE: Close the low pressure valve.
f#J.IQf!lfli When handling refrigerant (R-12): 4. Check the system for leaks using a leak detector.
e Always wear eye protaction. NOTE: Particularly check for leaks around the com-
e Do not let refrigerant gat on your skin or in your eyes. pressor, condenser, and receiver-dryer.
lf it does: 5. lf you find any leaks, tighten the joint nuts and bolts to
- Do not rub your eyas or skin. the specified torque.
- Splash larga quantities of cool water in your eyes 6. Recheck the system for leaks using a leak detector.
or on your skin. 7. lf you find leaks that require the system to be opened
- Rush to a physician or hospital for immediate treat- (to repair or replace hoses, fittings, etc.), release any
ment. Do not attempt to traat it yoursalf. charge in the system according to the Discharge Pro-
e Kaap refrigarant containers (cans of R-12) stored cedure on page 15-80.
below 40 oc(100°F). 8. After checking and repairing leaks, the system must be
e Keep away from open flama. Refrigerant, although evacuated (see System Evacuation on page 15-81).
non-flammable, will produce poisonous gas if
burned.
e Work in well-vantilatad area. Refrigerant evaporatas
quickly, and can force all the a ir out of a small.
enclosed area.
NOTE: Check for leaks after evacuation.
1. Close the evacuation valve (2 valve gauge; evacuation
stop valve).
3 VALVE GAUGE 2 VALVE GAUGE
HIGH PRESSURE
VALVE (OPENI
-
LOW PRESSURE
t
' LOW PRESSURE ; ''
VALVE (SHUT)
'' VALVE (SHUT) ! t~., lC ______ _
r
¡
REFRIGERANT
CANS(OPENI f' r---· REFRIGERANT
CANS (OPEN) ti ,.:
EVACUATION STOP
VALVE (SHUT)
J
~,.
\ ~ j
'~
p ,¡
-
: HIGH PRESSURE
i STOP VALVE (OPEN)
LOW PRESSURE
STOP VALVE (OPEN)
LOW PRESSURE
STOP VALVE (OPEN)
15-82
Charging Procedures
1111
The following are the procedures to be adhered to when 2. Open the front door.
servicing air conditioners to reduce the amount of Fron Turn the A/C switch on.
R-12 into the atmoshpere. Turn the air mix dial (lever) to COOL.
Turn function control switch (lever) on -,J.
f'\lfi.¡DfiifM When handling refrigerant (R-12): Turn the heater fan switch on "E" (MAXJ.
e Always wear eye protection. 3. Open the low pressure valve and charge with refriger-
e Do not let refrigerant get on your skin or in your eyes. ant.
lf it does:
- Do not rub your eyes or skin. 6 'ihñif 1i
1R
- Splash larga quantities of cool water in your eyes e Do not open the high gauge valve.
or on your skin. e Do not turn the cans upside down.
- Rush toa physician or hospital for immediate treat- 4. Charge the system with refrigerant capacity.
ment. Do not attempt to treat it yourself. Refrigerant capacity: 900-950 g (32-34 oz)
e Keep refrigerant containers (cans of R-12) stored 5. When fully charged, close the low pressure valve and
below 40 oc
(100 °F). the refrigerant cans. Check the system.
e Keep away from open flame. Refrigerant. although 6. Close the high pressure stop valve.
non-flammable, will produce poisonous gas if 7. Open the low pressure valve and gradually open the
burned. high pressure valve. When both pressure gauge are
e Work in well-ventilated area. Refrigerant evaporates the same, close the low pressure stop valve and stop
quickly. and can force all the a ir out of a small. the engine.
enclosed area. 8. Disconnect the charge hose quickly.
CAUTION: Do not overcharge the system; the 9. Check the system for leaks using a leak detector.
compressor will be damaged. NOTE: Particularly check for leaks around the com-
1 . After leak test, check that the high pressure valve is pressor, condensar, and receiver-dryer.
closed and start the engine.
NOTE: Run the engine below 1500 rpm.
3 VALVE GAUGE 2 VALVE GAUGE
EVACUATION VALVE
HIGH PRESSURE
VALVE
REFRIGERANT
CANS
LOW PRESSURE
STOPVALVE LOW PRESSURE
STOPVALVE
15-83
Pressure Test 1111
NOTE: Performance Test on page 15-66.
!
TEST RESULTS RELATED SYMPTOMS PROBABLE CAUSE REMEDY
Discharge (high) pres- After stopping compressor, pressure drops Air in system Evacuate system: then recharge
sure abnormally high to about 196 kPa (28 psi) quickly, and 1 1
Evacuation: page 15-81
then falls gradually. Rechargíng: 15-83
No bubbles in síght glass when condenser Excessive refrigerant in system Discharge refrigerant as neces-
is cooled by water. sary
Reduced or no a ir flow through con- · Clogged condenser or radiator · Clean
denser. fins
· Condenser or radiator fan not · Check voltage and tan rpm
working properly
Line to condenser ís excessively hot. Restricted flow of refrigerant in Expansion valve
system
Discharge pressure Excessive bubbles in sight glass: con- lnsufficient refrigerant in system · Check for leak
abnormally low denser is not hot 1 · Charge system
High and low pressures are balanced soon · Faulty compressor Replace compressor
1
after stoppíng compressor discharge or inlet valve
1
· Faulty compressor seal
Outlet of expansion valve is not frosted. · Faulty expansion valve Replace
low pressure gauge indicates vacuum
Suction llow) Excessive bubbles in sight glass: con- lnsufficient refrigerant Check for leal<.s.
pressure abnormally denser ís not hot Charge as requíred.
low
Expansíon valve ís not frosted and low · Frozen expansíon valve Replace expansion valve
pressure line is not cold. low pressure • Faulty expansion valve
gauge indicates vacuum.
Discharge temperatura is low and the air Frozen evaporator Run the fan with compressor off
flow from vents is restricted then check the thermostat and
capillary tube.
Expansion valve frosted Clogged expansion valve Clean or Replace
Receive dryer is cool (should be warm Clogged receiver dryer Re place
during operation)
Suctíon pressure low pressure hose and check joint are · Expansion valve open too Repair or Replace
abnormally high cooler than around evaporator. long
1
• loase expansion valve
Suction pressure is lowered when con- Excessive refrigerant in Discharge refrigerant as neces-
denser ís cooled by water system sary
High and low pressure are equalized as · Faulty gasl<.et Replace compressor
soon as the compressor is stopped · Faulty high pressure valve
· Foreign particle stuck in
high pressure valve
Suction and discharge Reduced air flow through condenser · Clogged condenser or · Clean condenser and
pressure radiator fins radiator
abnormally high · Condenser or radiator tan · Check voltage and tan rpm
not working properly
No bubbles in sight glass when condenser Excessive refrigerant in system Discharge refrigerant as
is cooled by water necessary
Suction and low pressure hose and metal end areas are Clogged or kinked low Repair or Replace
discharge pressure cooler than evaporator pressure hose parts
abnormally low
Temperature around expansion valve is too Clogged high pressure line Repair or Replace
low compared with that around receiver-
dryer
Refrigerant leaks Compressor clutch is dirty Compressor shaft seal leaking Re place compressor
Compressor bolt(s) are dirty : leaking around bolt(s) Tighten bolt(s) or replace com-
pressor
Compressor gasket is wet with oil Gasket leaking Re place compressor
15-85
Special Tools
SpeciaiTools----------------------------------------------------_,
Ref. No. Tool Number Description Q'ty Page Reference
CD 07GAC-SE00200 Fuel Sender Wrench 16-127

® 07 JGG-001 01 00 Belt Tension Gauge 16-101, 102
CD
16-2
Troubleshooting
Troubleshooting Precautions - - - - . . - - - - - - - - - - - - - - - - - - - - ,
Befare Troubleshooting • Push the locking tab to disconnect.

• Check the main fuse and the fuse box.
• Check the battery for damage, state of charge, and

clean and tight connections.
• Check the alternator belt tension.
CAUTION:
• Do not quick-charge a battery unless the battery
ground cable has been disconnected. or you will
damage the alternator diodes.
• Do not attempt to eran k the engine with the bat-
tery ground cable connected incompletely or
you will severely damage the wiring.
While You're Working

• Make sure connectors are clean, and have no loose
pins or receptacles.
• Make sure multiple pin connectors are packed with
grease (except watertight connectors).
Since new type connectors are used, connection and

disconnection of them should be done paying attention
to the following precautions.
• Because all the connectors except terminal of 1-P
are equipped with push-down type locks, unlock
them first befare disconnecting the connectors.
• On the connectors installed on the bracket a pull

type lock is equipped between the bracket and the
connector.
Sorne connectors of this type can not be discon-
nected unless they are removed from their brackets.
When disconnecting, check their shapes.
• On the bracket mounted connector with dual locks,

remove the connector from the bracket befare
disconnecting.
LOCKING
PAWL
Pull to
disengage BRACKET (cont'd)
16-3
Troubleshooting
Troubleshooting Precautions (cont' d ) - - - - - - - - - - - - - - - - - -
• Pull the locking tab to remove the connector from • Place the plastic cover over the mating connector
the bracket. after reconnecting. Also check that the cover is not
distorted.
X
CONNECTOR BRACKET
• When disconnecting locks, first press in the connec- • Befare connecting connectors, check to see that the
tor tightly (to provide clearance to the locking terminals are in place and not bent or distorted.
devicel, then operate the tab fully and remove the
connector in the designated manner.
LOCKING PAWL
• When disconnecting a connector, pull it off from the • Check for loase retainer and rubber seals.
mating connector by holding on both connectors. The illustration shows examples of terminal and seal
abnormality.
• Never try to disconnect connectors by pulling on
their wires.
o
X
• Example of waterproof connector:
X X RUBBER SEAL
X
RUBBER SEAL
X
16-4
• For the connector which uses insulation grease, • Before connecting, check each connector cover for
clean the connector then apply grease if the grease is damage. Also make sure that the female connector
insufficient or contaminated. is tight and not loosened from the previous use.
X
• lnsert mate connectors into the female connectors
fully until they will no longer go.
• Be sure. that plastic cover is placed over the

• lnsert the connector tightly and make sure it is connection.
securely locked.
• Position the wires so that the open end of the cover
• Check all the wire harnesses are connected. faces down.
• There are two types of locking tab: one that you

have to push and the other you should not touch
when connecting the connector. Check the shape of
the locking tab befare connecting.
• The locking tab having a taper end should not be

X
touched when connecting.
• Secure wires and wire harness to the frame with
their respective wire bands at the designated
-~ locations.
Position the wiring in the bands so that only the in-
sulated surfaces contact the wires or harnesses.
• The locking tab with an angle end should be pushed
when connecting. • Remove with care not to damage the lock.
• lnsert connectors fully until they wifl no longer go.
• The connectors must be aligned and engaged

securely.
• Do not use wire harnesses with a loose wire or

connector.
o X
\ -1
SNAP-RING PLIER
~~ (cont'd)
16-5
Troubleshooting
Troubleshooting Precautions (cont' d) - - - - - - - - - - - - - - - - - - - -
• Do not bring wire harnesses in direct contact with

sharp edges or corners. ,
• Also avoid contact with. the projected ends of bolts,

scr.ews and other fasteners.
o
~ • Route harnesses so they are not pulled taut or
slackened excessively.
• After clamping, check each harness to be certain

that it is not interfering with any moving or sliding
parts of the vehicle.
· • Keep wire harnesses away from the exhaust pipes
and other hot parts.
• Protect wires and harnesses with a tape or a tube if

they are in contact with a sharp edge or corner.
• Always keep a safe distance between wire

harnesses and any heated parts.
• Clean the attaching surface thoroughly if an

adhesive is used. First, wipe with solvent or alcohol
if necessary.
o X
16-6
• Seat grommets in their grooves properly. • When using the Service Tester, follow the manufac-
turer's instructions and those described in the Shop
oj l Manual.
T
• Do not damage the insulation when connecting a
wire.
• Do not use wires or harnesses with a broken • Always insert the probe of the tester from the wire
insulation. harness side (except waterproof connector).
Repair by wrapping with protective tape or replace
with new ones if necessary.
• After installing parts, make sure that wire harnesses

• Make sure to use the probe with a tapered tip.
are not pinched.
X
o e:
m
X el [{(
• Do not drop parts.
• After routing, check that the wire harnesses are not

twisted or kinked.
X
• Wire harnesses should be routed so that they are not
pulled taut, slackened excessively, pinched, or in-
terfering with adjacent or surrounding parts in all
steering positions.
16-7
Troubleshooting
Five-Step Troubleshooting-----------------------,
1. Verify The Complaint 4. Fix The Problem
Turn on all the components in the problem circuit to Once the specific problem is identified, make the
check the accuracy of the customer complaint. Note repair. Be su re to use proper tools and safe proce-
the symptoms. Do not begin disassembly or testing dures.
until you have narrowed down the problem area.
5. Make Sure The Circuit Works
2. Analyze The Schematic
Turn on all components in the repaired circuit in all
Look up the schematic for the problem circuit. Deter- modesto make sure you've fixed the entire problem. lf
mine how the circuit is supposed to work by tracing the problem was a blown fuse, be su reto test all of the
the current paths from the power feed through the circuits on that fuse. Make sure no new problems turn
circuit components to ground. lf severa! circuits fail at up and the original problem does not recur.
the same time, the fuse or ground is a likely cause.
Based on the symptoms and your understanding of the

circuit operation, identify one or more possible causes
of the problem.
3. lsolate The Problem By Testing The Circuit
Make circuit tests to check the diagnosis you made in

step 2. Keep in mind that a logical, simple procedure is
the key to efficient troubleshooting. Test for the most
likely cause of failure first. Try to make tests at poiiJts
that are easily accessible.
16-8
...... S e hema t.1c Sy m bl
os
BATTERY GROUND FUSE COIL, SOLENOID CIGARETTE UG HTER
le $j
Ground terminal Component ground
e--
or
RESISTOR
1
VARIABLE RESISTOR
1
THERMISTOR
--<:rv>--
IGNITION SWITCH
$
BULB
1
~
HEATER
~ h % $ -o ~
MOTOR PUMP CIRCUIT BREAKER HORN DIO DE
'
SPEAKER, BUZZER
$
ANTE NNA
~ ~
TRANSISTOR (Tr)
$ t [)
Mast Window .....- Wire Color Codes
~ ~ -.;
The followíng abbreviations are used to identify wire
T
colors in the circuit schematics.
WHT ......... White

YEL ......... Yellow
RELAY (In normal condition) CONDENSER BLK ......... Biack
BLU ......... Biue
Normal open relay Normal closed relay GRN ......... Green
RED ......... Red
m w 1 ORN ......... Orange

PNK ......... Pink
T BRN ... "' .... Brown

GRY ......... Gray
LT BLU ... Light Blue
LT GRN ... Light Green
SWITCH (In normal condition) LUMINOUS DIODE (LEO)
Normal open switch Normal closed switch Wire insulator has one color or one color with another
r
color stripe. The second color is the stripe.
a? ~ ~ ~WHT¡BLK
14
o
CONNECTION CONNECTOR REED SWITCH
y7
Input : Output
~>-
M ale
+
Female
~ -~
16-9
Relays and Control Unit Locations
Engine Cornpartrnent-------------------------------------------------
DIMMER RELAY
LIGHTING
RELAY
ALB FUSE BOX
A/C DIODE
DISTRIBUTOR
Built-in igniter unit) ·A/C COMPRESSOR CLUTCH RELAY
[ and ignition coil Wire colors: BLK/YEL, BLK/YEL)
( RED/BLU and RED
• CONDENSER FAN RELAY
Wire colors: BLK/YEL. BLU/GRN J
( WHTand BLU
16-10
Located under the relay box J
Wire colors: BLU/WHT, BLU/WHT _
{
GRN/RED and BLK
SPEED SENSOR
DIM-DIP RESISTOR
(KE modal only)
16-11
Dashboard--------------------------------------------------------
NOTE: RHD type is symmetrical to LHD type.
COOLING FAN TIMER UNIT Fuel-injected engine: PGM-FI MAl N RELAY

Carbureted engine: FUEL CUT RELAY
IGNITION TIMING
AOJUSTER
SUNROOF OPEN RELAY

( Wire colors: GRN/YEL, GRN/YEL, )
l YEL/GRN, GRN and BLK - - - -
BLOWER MOTOR SUNROOF CLOSE RELAY

RE LAY
(
Wire colors: GRN/RED, GRN/RED. 1 CRUISE CONTROL UNIT
YEL/GRN, GRN and BLK
KS, KE, KX, KYJ
[ and KO modela
DASH FUSE BOX
16-12
CIGARETTE LIGHTER RELAY SER VICE
fWire coiOf'S: WHT/BLU. YEL/RED) CHECK
l WHT/RED and BLK CONNECTOR
DELAY RELAY
SEAT HEATER MAIN RELAV

IKS. KW and KX models onlyl
Wire colors: VEL/BLK. WHT/BLKJ
( BLK/GRN and BLK
ENGINE MOUNT CONTROL
UNIT (A/T onlyl
HEADLIGHT WASHER CONTROL UNIT
(European model only)
16-13
Relays and Control Unit locations
Floorand Door-----------------------------------------------------
NOTE: RHD type is symmetrical to LHD type.
Fuel-injected engine: PGM-FI ECU
Carbureted engine: PGM-CARB. CONTROL UNIT (Except KP and KT models)
A/T CONTROL UNIT
DRIVER'S POWER WINDOW SWITCH

(Built-in control unit)
POWER DOOR LOCK
CONTROL UNIT
16-14
Seat-----------~
16-15
Trunk-------------------------------------------------------------,
ALB CONTROL UNIT
ALB FRONT FAIL

SAFE RELAY
[
Wire colors: BRN/BLK. YEL/BLK 1
YELIGRN and BLK
16-16
Wire Harness and Ground Locations
Engine Cornpartrnent--------~~-----------------------------------
G1 G2
ENGINE GROUND WIRE
G281
(cont'd)
16-17
Fuses
Relaybox--------------------------------------------------~
NOTE: Relay box is located right side, engine compartment.
To Starter cable
n
37
17 18 u
~ w::-~~::::1
n
38
C22::::JE:n::l~ u
~~~~n nnn
35 36 39
c24::::1~~~u uuu
To Cooling fan relay

To Dimmer relay
To Main wire harness
16-31
Fu ses
Dash Fuse Box--------------------------------------------------~
NOTE: Dash fuse box is located behind left kick panel (LHD) or right kick panel (RHD).
To Blower motor relay

To Reilr window defogger relay
harness
harness
To lgnition switch
To Floor wire
hamess
Auxiliary Auxiliary fuse holder {LHD)

fuse (KF, KG, KS, KW, KB and KX models)
holder(RHD}
(KE model}
• : Spare fuse
* :Not used
<>:KS, KW and KE models only
16-32
ALB Fuse Box------------------------------------------------~
NOTE: ALB fuse box is located right side, engine compartment.
To Starter cable
o
lol lol 40A
ALB
o ALB1
15 A
ALB3
'~0
..JIO
<(..-
15 A 1
ALB motor relay

·16-33
Fu ses
Dash Fuse Box--------------------------------------------------~
NOTE: Dash fuse box is located behind left kick panel (LHD) or right kick panel (RHD).
To Blower motor relay

To Reilr window defogger relay
harness
harness
To lgnition switch
To Floor wire
hamess
Auxiliary Auxiliary fuse holder {LHD)

fuse (KF, KG, KS, KW, KB and KX models)
holder(RHD}
(KE model}
• : Spare fuse
* :Not used
<>:KS, KW and KE models only
16-32
ALB Fuse Box------------------------------------------------~
NOTE: ALB fuse box is located right side, engine compartment.
To Starter cable
o
lol lol 40A
ALB
o ALB1
15 A
ALB3
'~0
..JIO
<(..-
15 A 1
ALB motor relay

·16-33
Power Distribution
Circuit l d e n t i f i c a t i o n - - - - - - - - - - - - - - - - - - - - - - - - - -
ALB FUSE BOX
----
1
ALB 1(15A)
AL8 2(15A) 1
WHTIGRN---
(+8 1)}
1
~ WHT (+8 2) ALB control unit
ALB 3{15A)
~ WHT/8LK- ( + 8 3)
1 AL8 4(40A) 1
1 1
ALB MOTOR
RELAY
1
'-f-0'"";- 1
WHTIBLU--- ALB moler
1 1
No.8(7 .SA)FUS E[::>- YELIBLK YEL/RED--- A LB control unit
8A TTERY '--------
~
+ 1 Starler motor
UNDER-HOOD RELA Y BOX
1
--
No.20(1 OA)
--
~~
-
!
1
b(20A)
!
1
WHTIGRNL Hazard lights
WHTIYEL- R.Horn
Turn signai/Hazard relay
Gl
No.15(BOA) WHT/YELL L.Horn
1
1
-v~ 1
Brake lights,Brake signa!
High mount brake líght(KQ model only)
ALTERNA TO A 1
No.19(50A)
IGN ITION SWITCH
WHT----C> (To page 16-40)
No.\ 7(40A)
"'V
.
1
REA R WINDOW DEFOGGER RELA Y

BLK/GRN-{:> (To page 16-40)
No.1 8(30A)
BLOWER MOTOR RELAY
"V
1 WHT----C> (To page 16-40)
1
No.21 (7 .5A)
"'V WHT/GRN--- A lternator(S ter m in al)
No.27(20A) 1
1
"V WHT Power door lock control unit
No.28(10A)
-v YELIBLU - - - PGM-FI main relay(+ B)
1
1
No.29(15A)
WHT Condensar tan m otor(W ith AIC)
-v
No.31(20A)
L Cooling tan ti mer unit
(With fan timer system)
1
"'V GRN Sunroof motor
COOLING FAN RADIATOR
TIMEA UNIT mf:>-YEL-!- FAN
(W ith tan timar sysle RElAY
No.39(15A)
;::;-r-
1 RED/BLK--- Radiator fan m olor
1 1
No.8(7.5A)FUS E[::>- YELIBLK

1
1
........
nc- ~
V
.
1
BLU
L
Coolant te mperature switch
Coolin!! tan timar unit
(W ith tan lim er system)
16-34
UNOER-HOOO RELA Y BOX
From page 16-34
lgnition key lighl

Dome light
Courtesy lighls
Trunk ligh!
Cigaretle lighler
Pow er antenna motor
lntegrated control unit
No.24(7 .5A)
WHTIYEL~ PGM-CARB.ECU
PGM-FI ECU
AIT control unit
Slereo radiO/cassette player
Clock( + B)
WHTIGRNL Power seat

(Reclining motor,Rear height motor)
Pow er seat heighl adjuster motor
WHT/REDL Power sea!

(Siiding molor ,Fronl heig ht molor)
Pow er sea! height adjuster motor
..
1
1
1
..
1
r --------------------------,
1 1
1 "-'J---------+- WHTIBLK--~t-- L } 1
1 L- · Heated seat 1
1 R. 1
L -----------------~--------------------------J
--------------------~1
L.Heated seat :
. -----------------
POWER WINOOW
RELAY
--------------------~
1
No.30{20A)
l:J-+-~....-cr"\..J:>--o!- WHTIY EL --ct-- L.Front pow er w indow switch
No.33(20A)
'-..!J---t-- BLU /BlK --c
....- l.Front power window motor
R.Front pow er w indow switch
R.Front power w indow motor
L.Rear pow er w indow motor
No .5 (7 .5A)
FUSE
From page)
[>- YELIGRN -+----Hf-'!t!'\:~1-------t- BLK ----------,1
'-..C>---+- YELIBLK - - - - R.Rear pow er w indow motor
( 16-41 B
(cont'd)
To pages 16-36,37,38 an!l 39 G251
16-35
Power Distribution
Circuit ldentification ( c o n t ' d ) - - - - - - - - - - - - - - - - - - - - -
KF, KG. KB and KX models:
UNDER- HOOD RELA Y BOX
1
1
B 1
1
LIGHTING
RELAY
• L.HEADLIGHT No.37(20A)
(Hi hl
•HIG~ llEAM ;..f.-0"-::: ~ REDIYEL------4c:-- L.Headlight(Low)
IN DI CA TOA LIG HT 1 1
l. Head ligh t( Hig h)
1 No.39(20A) 1
--::T""\.. R E D I G A N - - - - - - - - R.Headlight(Low)
l REDIGAN R.Headlight(High)
~...rvV'
R.HEA DLIGHT
1 REDIGAN High beam lndicator Light
1 1
(H igh l 1 1
LIGHTING SWITCH
7
RED lBLU
.
DIMMER
RELAY
¡,...r. (\
1
LO DIMMER
RED /BLU
1 .. _
1
1 1
1 1
G401
G402
1 1
o----+-RED/YEL-- Rear fog lighl
1 No.23(15A) 1
L___: __ -- --
BLK
- AED/BtKJ
G251
1 AUXILIARY FUSE HOLDER

REDIBLK
(ISA)
RED IBLK ----+-----::r-.....c>-----+--~,
•--------------~RED/BLK
....-- RED/BLK ~ L.}
R. Front position light
'
(Interna! connection)
(Light-on warning)
+---....,------------- (Option C)
controller
1
1 1
RED/BLK
~ R E D I B L K - - - - - - - - L.TaiUight
16-36
KY. KO. KP and KT models:
UNOER-HOOO RELAY BOX
1
1
B 1
1
LIGHTING
AELAY
• L.HEADLIGHT -r-- No.37(20A)
(H' hl
• Hld~ BEAM P-r<J RED/YEL------'1~~- L.Headlight(Low)
1
INDICATOR LIG HT 1
1 No.38(20A)
1
1
L- L.Headlight{High)
~ R E D I G A N - - - - - - - - - A.Headlight(low)
1 REDIGAN A.Headlight(High)
R.HEA DLIGHT
""'
'V
"""
V
f REDIGAN High beam lndicator Light
1 1
(High )
y
1
1
LIGHTING SWITCH
DIMMER LO DIMMEA
RELAY
RED :BLU Hl
1 " 1
REDIBLU-+-...-(:)
1
RED IBLU
1
'
1 1
1 1
G401
G402
11 1
1 No~3(15A)
:
L __ -- --
BLK
_¿_
G251
RED/BLK-----~E,...._ L }
R·. Front position light
REDIBLK Shifl lever position

DA SH FUSE BOX consola light
1 -----1----.~--
........- - - - - - - - - - - - - lnlegrated control unit
(Lignt- on warning)
(Option C)
1 . . ._ _ _ R E D I B L K - - - - - - t - - Dashlight brightness controller
1
Dashlights
Glove box light
Dim ming signal
(Ciock,AIT shift position indicator
1 Cruise control indicator lighl)
Heater control panel lights
AIC switch light
.....-+-- REDIBLK------E,...._ L.} Tailligh!
:.·} License plate líght

R.
(cont'dl
16-37
Power Distribution
With Daytima Light:
UNOER-HOOD RELAY BOX
From paga 16-35
B
LIGHTING
1 RELAY 1
c--
1 1
• L.HEADLIGHT No.37(20A)
•
(H i hl
HIG~ llEAM.
INDICATOR LIG HT
"""r-o.- - RE o/vEL------.. L.Headlight(LowJ
. L.Headlight(Hígh)
No.38(20A)
RE 0 / G R N - - - - - - - - R.Headlíght(Low)
1
1 -:1\. 1 1
RE D/GRN R.Headlight(Hígh)
V V
J RE D/GRN Hígh beam lndicator Light
R.HEA
(High ¡''""' 1 LIGHTING SWITCH
7
RED ¡sLU
1
1
DIMMER
RELAY
1..1-1'1
1
1
G}-
2 REDIBLU
LO
Hl
YEL-.....-...(")
DIMMER
RED IBLU
1
1
1 -....-
1
1
1
1
1 3 8
G401
No.36(7.5A)
REDIYEL L
G402
Rear fog light
1 (For trailer)
1 1
1 1
LJ_, --
No.23(15A)
~
--
BLK
R
_¿_
6251 .,__ _ _ R E D / B L K - - - - - Shífl levar position
consola light
INTEGRA TED . - - - - Y EL/RED-----,
CONTROL RED/BLK
UNIT DASH FUSE BOX
(D--YEL No.1G(7.5A)
+--+---------- (Option C)
DAYTIM E RED/BLK~ Dashlíght brtghtness controller

CD-- RED/BLU RUNNING
LIGHT RELAY
Dashhghts
Glove box líght
Dimmmg signa!
(Ciock,AIT shifl pos1t1on indtcator
Crutse control tndicator light)
A/C SW I!Ch light
Cigar box light(4 WS)
light
BLK
LIGHT -ON WARNING
CIRCUIT _¿_
G401
L.} License
R.
plata light
G402
(For trailer)
16-38
With Dim-Dip Light:
. B
i
i LIGHTING
RELAY
• L.HEADLIGHT
(Hi hl
• HIG~ l>EAM
INDICA TOA LIGH T .
~
41- ~
No.37(20A)
~
1
1
RED /YEL ------.. e-- L.Headlight(Low l
L. Head lig h t(H íg hJ
No.38(20A)
~ RED IG A"-
· · - - - - - - - - - R.Headlight(low)
1 RED IGRN R.Headlight(Hígh)
-v·v T RED /GRN - - - - - - - - - High beam lndicator light
OLIGHT! 1
) 1 1 UGHTING SWITCH
LO DIMMER
DIMMER Hl
jBLU 1
RELAY
1
0--- YEL -+--o
1
- i...-1)" 2 RED/BLU
1
RED /BLU
1
.r.
- "V'
.
1 1
3
G401
No.35(15A) G402
11
1
~
No.36{7 .5A) .
1
BLU IYEL--(D
n----+- REDIYEL......- Rear fog light
L. (For trailer)
.1
1
No.23(15A) 1
1
L __ R
~
'-'
-- --
BLK
RED/YEL~ L.HEADLIGHT _¿_
L-.A,A~+- REDIGAN~ R.HEADLIGHT
G251
REDIBLK~ ~·.} front posi11on light
INTEGRATED -----YELIRED------, REDIBLK

L
EC~O~NT_R_o_L ~~-------r--JD~A~S~H2F~U~SE~BO~X~-t----r-~
Shift lever pos1l10n
UNIT console Jight
__
WHT 1---1-------- (Oplion C)
G)--YEL
No.10(7.5A)
R E D I B L K ! Dashlight brightness controller
~~:~li~~!s light
Di m ming signa! . . ·
(Ciock,AIT shifl posillon ~~d!cator
DIM-DIP RELAY Cruise control 1nd1cator hght)
AIC switch light
RED/BLKg ~·.} Ta1llight

A-----------r-;--, l.}
R.
license plata light
LIGHT-ON WARNING (For tra1ler)

CIRCUIT
Cigar box hght(4WS) (cont'd)
G401
G4112
16-39
Power Distribution
AUXILIAAV FUSE HOLDER
{KS,KW and KE models only)
r-------------,
1 (30A} 1
l
WHT-~L..---_-_-_""_'J"...JJ
_______ ; WHT/BLK--- Headlight washar control
_ unit and w asher molor
_O_ASH FUSE sq_x_
No.19(50A)FUSE
(From page16-34)
[>-wHT WHT-+--1-------t------- {Oplion O)
IGNITION SWITCH
No. 7(7 .5A)
IG2
WHT
IG1
YEL
- BLKIYEL
L A/C compressor clutch relay
Delay relay(Carburetad angina)
ce 1
(Option B)
+····] ~
1
WH~IBLK
No.B(7 .SA)
ST ~ YEL/BLK Cooling lar ti mer uni!
BlK/YEL 1 1
1 1
BLK/WHT ('"
16-41
AA
(To pagas )
~ ! - Y E u s L K E Heater func!ion control motor
Racirculation control mótor
16-38 and 39 Heater control panel
e Seat heater relay
No. 1 7(40A} ( )
1
1
1
1
FUSE To page
From ¡age) 16-41
( 16-3
YEL/BLKE ALB motor relay
y
BLK
1
1
1
AEAR WINDOW
DEFOGGEA AELA Y
1
1
~~~oanr;l} ALB
ALB control unit
fail-safe relay
tAN
-- 7
BLK/G RN Rear w indow de!ogger
~~S1E8(30A) 1 1
1 1
( From page) r-" V V YELIGRN Rear w indow delogger switch
16-34
BLOWEA MOTOR
7wr 1
1
RELAY
~1-
" 1
BLK
1
YELIBLK Blow er motor
=-.:z:..= .G251
No.9{7.5AI
'------------+-'f---Cl'"""-.1>-......-t- BLU/RED - - - - Starter signa!
BLUIRED - - - Gauge(Brake check circuit)
NEUTRAL SAFElY
SW ITCH(A/T)
BLKIWHT--®--- BLKIRED--- Starter solenoid
16-40
DASH FUSE BOX
lgnition coi!
YEL ~ Gauge and w arninglindicator lights

Shilt le~er. posi1ion indicator}IA/T)
Satety md1cator
Back-up lights
Speed sensor
Turn signa! lightslretay
Ctock
- - - - - - - - - - l n t e g r a t e d control unit{IGt)
No.2 (15A)
'-...1=>----BLKIYEL-1~-- PGM-FI main.relay and fuel pump
+---- Emission control solenoid valvas
. .- - - Vo\tage regulator(IGt)
Coolíng tan timar uní!
(With tan timer system)
+---- AIT control unit
Charge warning light
Fuel cut ralay(Carburetad angina)
lntake air control solenoid valve
Engine mount control solenoid valva
Engine mount control unil
Air vent cut solenoid valva
(Carbureted angina : Except KT and KP mode\s)
No.4 {7 .5A) Bypass control solenoid valve
'-!:--o+ BLK/RED - - - - Cruise control main switch and
Cruise control unit
YELIG RN ~ Sunroot relay(Open)} and· sunroot

Sunroot relay(Ciosa) motor
Pow er w indow relay(To paga16-35)
• ~J Headlight adjuster uní!
YEL/GRN---- Pow er door mirrors
GRN/BLKE Wmdsh1eld wiper motor

Washer motors
lntermittent w1per relay
Headhght washer control unit
-+--------
(Interna\ connection)
(w iper w asher circuit)
IGNITION SWITCH
From paga)
[}>--
e WHTIBLK
No.11(10A)
YELIRED -.~~-- Stereo radio/cassette player
( 16-40 L - - Cigarette lighter ralay
L ___-+-------- __, (Option A)
16-41
Ground Distribution
Circuit ldentification--------------------"--------
1
...
_ó_
--------------___,0 BLK ------11::- Battery
Transm ission
G1
_!_.........................................................................--¡(ID BRN - - - - - - - Engine

G2
Carbureted Engine:
B L K - - - - - - - - - - - - - - - - - Coolant temperatura switch
B L K - - - f~ BLK PGM-CAAB control unit
-1J----{]J
_~_~~~~K- ________ ~-a::~~K_-J
1/BLK
...._-_-0-xy-9-80- 5~~~rcARB.control (PG) unit
Shielded wiras
G101
(A] : Battery ground wira (]] : Engine w ire harness

(ID : Engine ground wire []] : Main wire harness
16-42
~--------~C BLK----------------------------~~ Coolant temperatura switch A
Coolant te mperal u re switch B
(Wilh tan timer system)
-----------1~ :~::::::4]1----~:~:-----------t:::- ~~~}PGM-FI ::

...
BLKIRED jC BLKIRED --+--~-

PGM-FI main relay
(LG 1) PGM-FI ECU

} AIT control unit
ECU
BRNIBLK O BRN/BLK .........._______ (LG 2)PGM-FI ECU
: } TDC sensor
: } Crank angle sensor
: } CYL sensor
: : } NM speed pulser
: : } NC speed pulser
G101 - - Oxygen sensor
Shielded wires
[]] : Engine wire harness

!]] : Maín wire harness
(cont'd)
16-43
Ground Distribution
Circuit ldentification ( L H D ) - - - - - - - - - - - - - - - - - - - -
NOTE: See page 16-19 for illustrated ground locations.
D B L K - - - - - - - - - - - - - - - - -... t::-- A.Front turn sígnal líght

Radíator fan motor
BLK ----101------lrQ BK------ L Speed sensor

(Carbureted engíne)
B L K - - - - - - - - - - - - - - - -... L-- R.Headlight (lo)

L.Headlight (Lo)[KY and KP models onfyj
6201
D BLK L Wíndshiefd w asher motor

Cruíse control actuator
o BLK
~
L.Front turn sígnal líght
(g BLK S~eed sensor
( uel-ínjected engine)
D BLK L L.Front position light
Headlight washer motor
D BLK Windshield wiper ·motor
o BLK L L.Headlíght (Lo)

PIS oil pressure switch
o BLK Brake fluid fevel switch
6301 RELAY BOX
---.----t~L---'----'
Pow er w indow relay
D BLK
Dim mer reJa y
L------------...L-- Seat heater main relay

8:~t~r~1~a¡ en ine :
{Except KY an~ KP models}
---------10 BLK ----------------~L,__ lntermittent wíper relay
Emíssion control solenoid valvas
(KF,KG,KS and KX models}
G251
(g: Engine wire harness
1]] : Main wire harness
16-44
(RHD)------------------------------------------------
r-+-----------1 D BLK ------------------lit::,__ R.Front turn signa! light

Radíator fan motor
.,_-+----------...¡ D BLK -----------------~t::,__ ALB pressure switch

R.Front posítion light
G20!
+--+----------...; D BLK -----------------~t::,__ WindshieJd washer motor

L.Headlíght (Lo)
G301 RElAY BOX
--------....¡ -----------------"1t::,__
D BlK WindshieJd washer motor
Emíssion control solenoíd valves
(Carbureted engine : KO modal only)
G251
[Q: Engine wire harness
[[! : Main wire harness
(cont'd)
16-45
Ground Distribution
Circuit ldentification ( L H D ) - - - - - - - - - - - - - - - - - - - - -
DASH FUSE BOX
1--------------------------lD B L K - - - - - - Fuel cut relay (Carbureted angina)
1--------------------------10 BLK - - - - - - Ciutch switch
1--------------------------1 O ----t::-- BLK Cruise ~ontrol unit

Cooling lan timer unit
(With fan timar system)
1-------------------------10 BlK _ _ _....,_ _ Mode molor
lighting switch
Cigarel\e lighter ralay
Chime (KY and KP models)
A/C compressor solenoid valve
Carbureted angina : )
( KF,KB,KW ,KY and KP models
S switch }
Shift lever posítion (A JT)
con sola switch
1--------------------------1 F BLK - - - -....- Gauga and indicator lights
Dimming circuit (for cruisa control)
Shi!t levar position indicator
Clock
Cruise main switch
Sunroof switch
Rear w indow dafogger switch
Raar !og light switch
B L K - - - - t - - Hazard switch
Cigarette lighter •
R E D - - - - - - Shift levar position consola light
1---------------------------------- lntegraled control unit
1---------------------------------- Turn signaiiHazard relay
1---------------------------------- Blower motor relay
O BLK
o l]] BLK
t:: g¡oes: rr~la¡y} Su mol
o BLK
o IT]BLK - - - - - - Slereo radio/cassette player
o BLK
o IT]BLK - - - - - - Oashlighl brighlness controller
o BLK
o IT]BLK E Heatar control panel
Healer control switch
Cigarette lighter
Glove box
O BLK----------------------~E...,._ Engine mount control unit

Headlight w asher control unit
Wiper/W asher switch
Delay relay
Carbureted engine : )
( KY and KP models only
[]] : Main wire harness

G402 Without dashlight brígh\ness controller
IT] ; Oashboard w ire harness
1]] : Sunrool wiras
16-46
(RHD)-----------------------------------------------
DASH FUSE BOX
B l K - - - - - - Feul cut relay

{Carbureted angina : KQ modal only)
- - - - - - Clutch switch
- - - - t : : - - Cruise control unil

Cooling tan tim er unit
1--------------------------1 F BLK ----t-- Gauge and indicator lights

Di mming circuit {for cruise control)
Shift lever position indicator
Heater control panel
Heater control switch
Clock
Cruise main switch
Sunrool switch
Rear window defogger switch
Rear fog light switch
Hazard switch
Cigarette lighter'
1---------------------------1 O R E D - - - - - - Shilt tever position consola light
1---------------------------------- lntegrated control unil
1---------------------------------- Turn signai/Hazard relay
1---------------------------------- Blow er molor re la y
O BlK
o @]BlK----•t::-- Open relay} Sunroof
Close relay
o BLK
o ~-----------Q]BLK------ Dome light{W ith sunroof)
o BLK
ot-------,_,ITJ BLK - - - - - - Dashlight brightness controller
D BlK
o BÜ ------..t::--
1-------------~m Cigarette lighter
Gfove box
o BLK Eng1ne mount control umt

Headlight washer control un~l
W iper/W asher sw 1tch
Lighting SW IICh
S SWIICh(AIT)
Shift lever posit1on con so le sw 1lch(AIT)
Mode molor
Delay relay
Carbureted engme : )
( KE,KT and KU models
1]] : Main w ira harnass

G402
ITJ : Dashboard w ire harness
@] : Sunroof w ires
[}J : Roof wires
Without Dashlight brightness controller
(cont'd)
16-47
Ground Distribution
Circuit ldentification ( L H D ) - - - - - - - - - - - - - - - - - - - - -
H BLK----.,J m BLK Dome light
H BLK----.,J (J] BLK R.Door mirror delog~er

(KS, KW and KX mo els}
H BLK R.Seat heater switch

R.Side turn light
G501
r---+---lH BLK-----i]t----~Q] BLK----------~

...- Power door lock control unit
Pow er door mirror switch
} Pow er window switch
Driver's
Power window motor si de
Pow er door loe k knob switch
L.Door mirror defogger
(KS, KW and KX modeis)
H B L K - - - - - - - - - - - - - - - - - - - - • t g l - - L.Seat belt switch (KY modal only)

~'}Sea! heater sw 1tch
l.Side turn lignt
Headlight adjuster switch
H BLK----.,J [jJ BLK L} Pow er seat switch or seat height

adjuster switch
BLK----.,J []) BLK ----------.L-- R.Seat heater(KS and KW models only)

L.Seat heater (KF,KG,KS,KW and KX models)
H BLK---D (]] BLK

L ~J Headlight adjuster unil
G502
lr-----~[IJBLK---------------------.- ~~0 ~ 1 }ALB lail-sale relay

8
G702
[]] : Main wíre harness

m: Rool wires
[]] : Floor wire harness
[JJ : Right front door wire harness
Q] : Driver door wire harness
ITJ : Pow er se al wires
[]] : Seat heater wiras
W : Rear wire harness
16-48
(RHD)------~----------------------------------------
-------lH BLK~I-----lQ]BLK----------~
....- Power door lock control unit
Pow er door mirror switch
} Pow er w indow switch
Driver's
Pow er w indow motor si de
Pow er door loe k knob switch
R.Door mirror defogger
(KE model only)
H BLK ---------------------~E,__ R.Side turn light

L.} f'ow er sea! switch or sea! height
R. adjuster switch
G501 (With power window)
r------+-i H BLK - - - - - - - - - - - - - - - - - - - - - - - - (KE

L.Door mirror defogger
model only)
- - - - - - - - - - - - - - - - - - - - - - - L.Side turn lighl
G502
(]] : Floor w ire harness

QJ : Driver door wire harness
16-49
Ground Distribution
Circuit ldentification ( L H D ) - - - - _ _ _ ; . - - - - - - - - - - - - - - - -
NOTE: See pages 16-17, 26 and 30 for íllustrated ground locatíons.
[[] BLK Fuel gauge sending unit
l
Fu el pum p
6601
m BLK
~JTaillight(trunk side)assembly
l
6701
~J Taillight(lid
~J license
side}assembly
plate light
Paw er antenna motor
Trunk latch switch
For trailer
ITJ BLK Condensar fan

_[
G281
l]] BLK Rear window defogger

_[
G821
[]] : Fue! tan k wiras

m :Rear wire harness
ITJ : A/C w ire harness
1]] : Delogger ground wire
is~so
(RHD)------------------------------------------------
NOTE: See pages 16-17, 27 and 30 for illustrated ground locations.
[]] BLK Fuel gauge sendíng unít
l
G601
Fuel pump
(1] BLK
~'} Taillight{trunk side)assem bly
l
G701
~J Taillight(lid
~'} lícense
sidejassembly
plata light
High mount brake light(KQ model only)
Pow er antenna motor
Trunk latch switch
For trailer
(KE model only)
(1] BLK
~~08~ 1 } ALB
1 fail-safe re la y
G702
fl] BLK Condensar tan
1
G281
(!] BLK Rear window defogger
1
G821
[]] : Fuel tan k w ires

IEJ : Aear wire harness
fi] :A/C w ire harness
[!] : Delogger ground wire
16-51
Battery
Test--------------------~--------------------------------~------~
NOTE: To get accurate results, the temperature of the 3. Test battery load capacity by connecting a battery
electrolyte must be between 15 and 38°C (59 and tester, and applying a load of 3 times the battery
1 00°F) befare testing. ampere hour rating.
When the load has been applied for exactly 15 sec·
Test Equipment Required: onds, the battery voltage reading should stay above
9.6 V.
• Battery tester with:
Voltmeter with 0-18 V scale, Arilmeter with • lf the reading stays above 9.6 V, the battery is
0-100 A and 0-500 A scales, and a carbon pile OK; clean its terminals and case, and reinstall it.
with 0-300 W.
• lf the reading ís between 6.5 and 9.6 V, fast
• 1 2 V Battery Charger: charge the battery by connecting a battery
Fast charge capability of 50 A and slow charge charger, for 3 minutes at an initial rate of 40
capability of 5 A. amps.
Test Procedure: CAUTION: Amperage will drop as voltage increases;

do not increase the amperage to compensate or you
f¡Ji§.j;!J!WNKeep sparks, flames and cigarettes may damage the battery.
away while charging battery.
Watch the battery· voltage duríng the entire 3
CAUTION: Battery electrolyte is a sulfuric acid so· minutes; the highest reading should s-tay below
lution. 15.5 V.
• lf it spills on painted surfaces, clothing, or skin, lf the reading stays below 15.5 V, the battery
rinse it off with water immediately to minimize ís OK; clean its terminals and case, and re·
the damage. install it.
• Always wear safety goggles or a face shield lf the reading exceeds 15.5 V any time during
when servicing a battery. the 3 minutes of fast charge, the battery is no
good; replace it.
1. Check for damage: lf the case is cracked or the
posts are loase, replace the battery. • lf the reading drops below 6.5 V, slow charge the
batteiy by connecting a battery and charge, at 5
2. Check the battery electrolyte level: amps for no more than 24 hours, (or until the in·
Check the electrolyte level in each cell. dicator shows full charge, or the specific gravity
lf it's low, add distilled water until the electrolyte rises of the electrolyte is at least 1.250).
to the UPPER mark. Then 'test load capacity again.
lf the voltage stays above 9.6 V, the battery is

OK; clean íts terminals and case, and reinstall
it.
lf the voltage still drops below 6.5 V, the bat·

ter y is no good; replace it.
LOWER LEVEL
lgnition Switch
Lock Cylinder Replacement
1. Remove the steering wheel, then remove the steer- 5. Turn the key to "O" and align the lock cylinder with
ing column covers. the lock body.
2. Remove the bulb/socket from the key light case by 6. Turn the key almost to "1" and insert the lock
turning the socket 45 °, then remove the screw and cylinder until the pin touches the body.
the key light case from the lock body.
7. Turn the key to the "1", push the pin and insert the
3. Turn the ignition key to "l." lock cylinder into the lock body until the pin clicks
into place.
4. Push the pin in and remove the lock cylinder from
the lock body.
SCREW
SCREW
1
LOCK CVLINDER
16-54
Steering Lock Replacement-----------------------.
1. Remove the steering wheel, then remove the steering 5. lnstall the new ignition switch without the key insert-
column covers. ed.
2. Remove the instrument panel and the gauge assembly 6. Loosely tighten the new shear bolts.
(see page 16-120}.
NOTE: Make sure the projection on the ignition switch
is aligned with the hole in the steering column.
3. Center punch each of the 2 shear bolts and drill their
heads off with a 3/16 in. dril! bit.
7. lnsert the ignition key and check for proper operation of
the steering wheel lock and that ignition key turns
CAUTION Do not damage the switch body when
freely.
removing the shear heads.
4. Remove the shear bolts from the switch body. 8. Tighten the shear bolts until the hex heads twist off.
TWIST-OFF PORTION
16-55
Starting System
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - -.. .
SHIFT POSITION
CONSOLE SWITCH
(NEUTRAL SAFETV SWITCH)
(A/T only)
Test, page 16-142
STARTER
Test, page 16-58
Solenoid Test, page 16-60
Overhaul, page 16-61, 62
16-56
Lighting System
Circuit Diagram (With Dim-Dip Headlight}----------------.
UNDER-HOOO RELA Y BOX
BA TTERY
No.15(80A) No.23(15A)
+~~~~--.-~----------------------------------~-a~~----~
No.36f7 .SA)
LlGHTING
RELA Y
No.37 No.38 DIMMER

(20 A) (20A) RELAY
REDIYEl REDIGAN REOtGRN REO/BLU

1
l. R.
HEADLIGHT REOJGRN HEADLlGHT
REDIBLU BLU/RED REO REDIGAN
HIGH BEAM
CED GD
lO Hl
G> INDICA TOA
LIGHT
(1.4W)
Hl
~D QQ)
LO
BLUIYEl
(55W) (65W) (65W) (55W)
No.10
(7.5A)FUSE
RED/
GRN
REO 1
YEL
y
YELrEO
BLU/YEL
1 BLUtED
RED\BLU
·1
.[r------1----..!
Y~l YEL REDIBLU BLUIRED REO REDIGAN
r--
LIGHT-
ING •
SWITCH
OIM -DIP RELA Y
-
f--
DIM-DIP
(in \he inlegrated control unit)
~RED/BLK-i--------~--------------~~--~--------t
RESISTOA
RED~BLK
wrr REAR REDrCEL O
RED/BLK FOG SWITCH
l.......l
~ r¡
(; ::'\ INDICA TOA LIGHT
\,: ~ (0.84W) ,. \,: (0.91W)
• FAONT POSIJION E A
LIGHTS r----t
• TAILLIGHTS
• SHIFT LEVER BLK BLK REDIBLK
~
POSITION CONSOLE
LIGHT
• LICENSE PLA TE
LIGHTS
• TRAILER
• CIGAR BOX
V
•OASHLIGHTS
LIGHT(4W S) •DASHLIGHT
BRIGHTNESS
BLK BLK BLK BLK • fNOT~~~~j~~R BLK
l l l l DASHLIGHT
BRIGHTNESS
CONTROL UNITl
G301 G401 G201 G4Q1 G701 CONTAOLLER G251

G402 G402
16-160
Circuit Diagram (KG model only)--------------____;.------.
Headlight Adjuster :
UNDER-HOOO RELA Y BOX IGNITION SWITCH DASH FUSE BOX
BA TTERY N0.15(BOA) N0.19(50A) No.5 (7 .5A)

0--f-- BLK/Y EL --+---o'"'-..o-~--+--
- - - - - - YEL/GRN----------....1
YELIGRN YEL/GRN
r
BLU
A
HEADLIGHT
ADJUSTER
SWITCH
BLK
1
G501
G502
16-161
Lighting System
Lighting/Turn Signal Switch T e s t - - - - - - - - - - - - - - - - - -
1. Remove the instrument lower panel.
2. Disconnect the 20-P connector from the main wire

harness.
3. Check for continuity between the terminals in each

switch position according to the tables.
..... J"
1 2 3 4 ¡::::=::¡ 5 6 7 8 9
10 11 12 13 14,15 16 17 18 19 20
_l
View from wire side
~
INSTRUMENT LOWER PANEL
lighting/Dimmer/Passing Switch (Except KS, KW and KE models)

20-P CONNECTOR
~ Terminal
5 6 17 18 20
Position
Lighting
switch
OFF
""
( ·) or
(e) LOW
;ooo
o l
o
-o
-o
or
!O HIGH" o "
'--' =o
Passing OFF
switch ON o "'
'-../ -o
Turn Signa! Switch
1\ Terminal
7 1
8 9
Position \
' R o -o
NEUTRAL
L o -o
16-162
Ughting/Dimmer/Passing Switch (KS, KW and KE models only)
~ Terminal
5 6 17 18 19 20
""
Position
OFF
o -o
lighting
switch
§D
*--
LOW o -o
HIGH o "
\J -o
Passíng OFF
switch ON o "'--" -o
Turn Signal Switch
1"- Terminal
7 8 9
Position \
R o -o
NEUTRAL
L o :0
16-163
Lighting System
Lighting Switch Replacement---. Rear Fog Light Switch Removal
1. Remove the steering wheel and the steering column 1. Carefully pry out the rear fog light switch from the in-
cover. strument panel.
2. Disconnect the 12-P connector. NOTE: Be careful not to damage the switch or instru-
ment panel when prying out the switch.
3. Remove the 2 screws and slide the lighting switch out
of the housing as shown. 2. Disconnect the 8-P connector from the switch.
NOTE: Be careful not to damage the steering wheel cover.

On cars with cruise control, remove the lighting switch after 8-P CONNECTOR
removing the slip ring (see page 16-262).
HOUSING
GRO OVE
SELF- LOCKING NUT
50N·m
(5.0 kg-m, 36.2 lb-ft)
Replace.
LIGHTING SWITCH
16-164
Rear Fog Light Switch Test----, Headlight Adjuster Unit-------,
Input Test (KG model only)
1. Remove the instrument panel (See page 16-1 20}.
NOTE: Check for blown No.5 (7 .5 A) fuse in the dash fuse
2. Remo ve the fog light switch. box before input test.
3. Check for continuity between the terminals in each 1. Disconnect the 3-P connectors for the R and L head-
switch position according to the table. light adjuster units.
HEADLIGHT ADJUSTER
\ Terminal
A B e D E
UNIT
Position \
OFF
"""'
\V o 1
¡fiN.
\ 'V
ON
"""
'V
1
"""
'V
-ot
3-P CONNECTOR BLK
2. Check for continuity between the BLK terminal and

body ground.
There should be continuíty.
REAR FOG e lf there is no continuity, check for
LIGHT SWITCH -An open in the BLK wire.
-Poor ground (G 502).
• lf there is continuity, go to step 3.
3. Check for voltage between the YEL/GRN terminal and

body ground with the ignition switch ON.
There should be battery voltage.
• lf there is no voltage, check for an open in the YEL/
GRN wire.
e lf there is battery voltage, go to step 4.
4. Using an ohmmeter, measure resistance between the
BLU terminal and body ground in "O" posítion of
headlight adjuster switch. There should be approxi-
mately 7150.
e lf resistance is not withín specification, check for
o e -An open in the BLU wire.
INDICATOA -Faulty headlight adjuster switch.
LIGHT e lf resistan ce is within specification, go to step 5.
(0.84W)
5. lf all tests are normal, but the headlight adjuster unit
does not operate. Check for frozen, stuck or improp-
erly installed the headlight adjuster unit. lf mechanical
check is OK, replace the headlight adjuster unit.
A B E
NOTE: Check for connection of 3-P connectors after
test. For example, malfunction of headlight adjuster is
occurred by improper connection of one side.
16-165
Lighting System
Headlight Adjuster Switch-----. Headlight Adjuster Switch Test
Removal (KG model only) (KG model only)
1. Carefully pry out the headlight · adjuster switch from 1. Remove the switch from the floor console.
the floor console.
2. Measure the resistance between the A and B terminals
NOTE; Be careful not to damage the switch or floor at •. 1, 2 and 3 positions by moving the knob.
console when prying out the switch. Replace the switch if th!3 resistan ce is not within speci-
fications. ·
2. Disconnect the 5-P connector from the switch.
S B
Knob Position
1
• 1 2 3
1
o
Resistance (O)
1
i
715 310 160
l
FLOOR CONSOLE
16-166
Dim-Dip ResistorTest--------------------------------------------~
CAUTION: Dim-Dip resistor becomes very hot in use of RESISTOR (Located left side,
Dim-Dip headlights; do not touch it or the attaching engine compartment)
hard-ware immediately after they have been turned off.
1. Disconnect the 3-P connector from the resistor.
2. Using an ohmmeter, measure resistance between the

terminals. Replace the resistor if the resistance is not
within specifications.
NOTE: Resistance will vary with the resistor tempera-

ture; specifications are at 20°C (70°F).
L. Headlight Resistance
(between the 1 and 3 terminals):
1.9-2.1 ohms
R. Headlight Resistance
(between the 2 and 3 terminals):
1.9-2.1 ohms
16-167
Lighting System
Lighting Relay T e s t - - - - - - - , Dimmer Relay Test----------,
1. Remove the lighting relay in the under-hood relay 1. Remove the dimmer relay in the under-hood relay
box. box.
2. There should be continuity between the A and B 2. There should be continuity between the A and e
terminaís when the battery is connected to the e terminals · when the battery is connected to the E
and O terminals. and F terminals.
There should be no continuity when the battery is There should be no continuity when the battery is
disconnected. disconnected.
A e F A 8 (Not used}
8 D
E e
16-168
lgnition System
lgnition Timing lnspection and Setting (Fuel-lnjected Engine, cont'd)
<Except KG, KS, KX and KQ models> 3. lnspection ignition timing at idle.
1. Start the engine and allow it to warm up (cooling fan lgnition Timing:
comes on). 15±2° BTDC (RED) at 800 ± 50 min- 1 (rpm) in
neutral
2. Connect a timing light to the engine; while the engine
idles, point the light toward the pointer on the flywheel
(for M/T), or on the drive plate (for A/T). NOTE: The illustration shows A/T.
RED MARK
4. Adjust ignition timing, if necessary, by turning the

adjusting screw on the ignition timing adjuster in the
TIMING LIGHT control box.
16-72
5. Remove the cap from the ignition timing adjuster. 6. Adjust as necessary by turning the adjusting screw on
the adjuster; turn the adjusting screw counterclock-
wise to retard the timing, or clockwise to advance the
timing.
ADJUSTING SCREW
7. After adjusting, reinstall the capto the ignition timing

adjuster.
16-73
lgnition System
lgnition Timing lnspection and Setting (Carbureted Engine)--------
<KP, KT, KU and KV (A/T) models> 6. Connect a timing light to the engine; while the engine
1 . Disconnect the vacuum hose from the vacuum id les, poínt the light toward the poínter on the flywheel
advance diaphragm, then connect the vacuum pump/ (for M/T), or on the drive plate (for A/T).
gauge to the vacuum hose.
VACUUM
PUMP/GAUGE
VACUUM
HOSE
TIMING LIGHT
2. Start the engine. 7. Read inítial timing when timing mark (whíte) is aligned
to the pointer.
KP and KT models: Let it idle.
KV (A/T) model: Hold the engine at 4,000 lnitial Timing: 0° TDC
min- 1 (rpm). e Manual Transmission [at 800 ± 50 min - 1 {rpmJ
in neutral]
3. Check the vacuum hose for vacuum. e Automatic Transmission [at 750 ± 50 min-1
The vacuum hose should have vacuum. (rpm) in gear]
e lf the vacuum hose has no vacuum, check the NOTE: The illustration shows NT.
vacuum hose of proper connection, cracks, block-
4. Connect the vacuum hose to the vacuum advance

diaphragm and allow the engine to warm up (coolíng
fan comes on).
5. Dísconnect the vacuum hose from the vacuum

RED MARK
16-74
8. Adjust as necessary by loosening the distributor adjust- 10. Connect the vacuum hose to the vacuum advance
ing bolts, and turn the distributor housing clockwise to diaphragm and inspect ignition timing at idle.
timing. lgnition Timing
M/T: 15° ± 2° BTDC (Red)
A/T: 10° ± 2° BTDC (Red)
in neutral]
e Automatic Transmission [at 750 ± 5.0 min- 1
(rpm) in gear]

nism.
ADJUSTING BOLTS
9. Tighten the distributor adjusting bolts, then recheck

the timíng.
(cont'd)
16-75
lgnition System
lgnition Timing lnspection and Setting (Carbureted Engine)----___;__ __
<Except KP, KT and KY (A/T) models> 4. Connect the vacuum hoses to the vacuum advance
1. Disconnect the vacuum hoses from the vacuum diaphragm and allow the engine to warm up. (cooling
advance diaphragm, then connect the vacuum pump/ fan comes on).
gauges to the vacuum hoses.
5. Disconnect the #5 hose from the vacuum advance
VACUUM HOSE#5 diaphragm and connect the vacuum pump/gauge to
PUMP/GAUGE the #5 hose.
6. Check the #5 hose for vacuum.

The #5 hose should have no vacuum.
7. Disconnect the vacuum hoses from the vacuum

8. Connect a tíming light to the engine; while the engine

idles, point the light toward the pointer on the flywheel
(for M/T), or on the drive plate (for A/T).
2. Start the engine and let it idle.
3. When the engine is cool, coolant temperature is below

55°C (131 °f).
Check each hose for vacuum. The #2 and #5 hoses
should have vacuum.
e lf the #2 hose has no vacuum, check the #2 hose of

nected hose.
e lf the #5 hose has no vacuum, check the #5 and

connected hoses for proper connections, cracks,
blockage or disconnected hoses, and the check
valve is not clogged.
lf the #5 and connected hoses, and the check valve
have no problem, recheck the #5 hose for vacuum.
16-76
9. Read initial timing when timing mark (white) is aligned 11 . Tighten the distributor adjusting bolts, then recheck
to the poínter. the timing.
lnitial Timing Connect the vacuum hose to the vacuum advance

All models: 0° BTDC diaphragm and inspect ignition timing at idle.
in neutral] lgnition Timing
e Automatic Transmíssion [at 750 ::!:: 50 min- 1 M/T: 15° ± 2° BTDC
(q:Ím) in gear] A/T: 10° ± 2° BTDC Except KQ, KX, KS)
( and KG models
NOTE: The illustration shows A/T. 15° ± 2° BTDC KQ, KX. KS
( and KG models
J
WHITE MARK e Manual Transmission [at 800 ± 50 min- 1 (rpm)
in neutral]
e Automatic Transmission [at 750 ::!:: 50 min- 1
(rpm) in gear]

nism.
1 O. Adjust as necessary by loosening the distributor adjust-

ing bolts, and turn the distributor housing clockwise to
timing.
16-77
lgnition System
Advance Diaphragm lnspection Top End lnspection--------..
1. Remove the distributor cap and vacuum hoses from 1. Check to be sure that the air gaps are equal (carburet-
the advance diaphragm. ed engine only).
2. Connect a vacuum pump/gauge to the advance dia- 2. lf necessary, back off the screws and move the
phragm A (inside port). stator as required to adjust.
SCREWS
"'\ VACUUM
PUMP/GAUGE
AIR GAPS
3. Check for rough or pitted rotor and cap terminals.
4. Scrape or file off the carbon deposits. ·

Smooth the rotor terminal with an oil stone or
#600 sandpaper if rough.
3. When vacuum (more than 500 mm Hg, 20 in. Hg) is
applied to the diaphragm, the stator should turn coun-
5. Check the distributor cap for cracks, wear and
terclockwise and stay. lf the stator does not turn or
damages. lf necessary, clean or replace it.
stay, replace the diaphragm.
When vacuum is released, the stator should return. lf

the stator does not return, repair or replace as neces-
sary.
4. Repeat thé step 2-3 for the advance diaphragm B

(outside port).
ROTOR
TERMINAL
16-78
Reluctor Replacement-------, Distributor Removal----------.
(Carbureted Engine) (Fuel-lnjected Engine)
1. Carefully pry up the reluctor by using two screwdrivers 1. Disconnect the 2-P and 8-P connectors from the
as shown. Do not damage the reluctor and stator. distributor.
RELUCTOR
2. Disconnect the spark plug wires from the distributor
cap.
8-P CONNECTOR
2. When installing the reluctor, be sure to drive in the pin

with its gap away from the shaft. CAP (With catalytic converterl
NOTE: The number or letter manufacturing code on

the reluctor must always tace up. 3. Remove the distributor hold-down bolts, then remove
the distributor from the cylinder head.
16-79
lgnition System
Distributor lnstallation (Fuel-lnjected Engine)----------------,
1. Coat a new 0-ring with engine oil then install it. 5. Connect the spark plug wires as shown.
2. Slip the distributor into position.

No.2 No.1 CYL. MARK
NOTE: The lugs on the end of the distributor and its No.1
mating grooves in the camshaft end are both offset to
eliminate the possibility of installing the distributor 180°
out of time.
DISTRIBUTOR
END
6. Set the timing with a timing light as shown.on page

16-71.
7. After adjusting. tighten the hold-down bolts, then

install the cap (with catalytic converter} on the bolt.
HOLD-DOWN BOLTS
22 N•m (2.2 kg-m. 16 lb-ftl
CAP
(With catalytic converter)
3. lnstall the hold-down bolts and tighten temporarily.
4. Connect the 2-P and 8-P connectors to the distribu-

tor.
16-80
Distributor Removal/lnstallation (Carbureted Engine)
D
Removal: lnstallation:
1. Disconnect the 2-P connector from the dístributor. 1. Coat a new 0-ring with engine oil then install it.
2. Disconnect the spark plug wires from the distributor 2. Slip the distributor into position.
cap.
NOTE: The lugs on the end of the distributor and its
3. Disconnect the vacuum hoses from the advance dia- mating grooves in the camshaft end are both offset to
phragm. eliminate the possibility of installing the distributor
180· out of time.
DISTRIBUTOR
END
2-P CONNECTOR
CAP
With
[ catalytic )
converter
j
HOLD-DOWN BOLTS ---
HOLD-DOWN BOLTS
22 N•m (2.2 kg-m, 16 lb-ft)
3. Instan the hold-down bolts and tighten temporarily.
4. Connect the 2-P connector to the distributor and the

4. Remove the distributor hold-down bolts, then remove vacuum hoses to the advance diaphragm.
the distributor from the cylinder head.
5. Connect the spark plug wires as shown.
6. Set the timing with a timing light as shown on page

16-74.
7. After adjusting, tighten the hold-down bolts, then

install the cap (with catalytic converter) on the bolt.
16-81
........... -- -
lgnition System
Distributor Overhaul (Fuel-lnjected Engine)------------_..:.._-
CAP SEAL
LEAK COVER
~/ CARBON
IGNITER
UNIT
a~
POINT CARBON POINT
~.¿·:·
/
ROTOR
/~
CONTACT POINT
SPRING
IGNITER UNIT
Troubleshooting, section 6
CAP
Check for cracks, wear,
damage, or fouling.
Clean or replace.
IGNITION COIL
Test, page 16-86
TOC/CYL/CRANK ANGLE SENSORS

Troubleshooting, section 6
Do not disassemble.
DISTRIBUTOR
HOUSING
1 Check for cracks

or damage.
16-82
(Carbureted E n g i n e ) - - - - - - - - - - - - - - - - - - - - - - - - - ,
NOTE: After installing the reluctor, adjust the air gaps between the stator and reluctor (see page 16-79).
BLU (IGNITION COIL)
IGNITOR~
UNIT VBLU
. o~ BLKIYEl
BLK/WHT
CAP SEAL
Check for damage.
CAP
~ Check for cracks, wear,
damage, or fouling,
Clean or replace.
IGNITER UNIT
RELUCTOR
J~oomo<n p•go16-79
BREAKER PLATE
STATOR
OIAMAGNETIC SCREW
COUPUNG
OISTRIBUTOR
.,#~ ~ HOUSING
7 p
. Check for cracks
/~
PON RETAINER
IGNITION COIL
Test, page 1 6-86
THRUST WASHER
0-RING
VACUUM ADVANCE
OIAPHRAGM
Test, page 16-78 PRIMARY LEAO
16-83
lgnition· System
Distributor Reassembly - - - - - - - - - - - - - - - - - - - - - - - - - ,
Reassemble the distributor in the reverse order of disassem- 2. Set the thrust washer and coupling on the shaft.
bly.
3. Check that the rotor is stíll pointing toward the No. 1
1. lnstall the rotor, then turn it so that it faces in the cylinder, then align the index mark on the housing with
direction shown (toward the No. 1 cylinder). the index mark on the coupling.
Fuel-injected engine: Fuel-injected engine:
INDEX MARK
Carbureted engine: Carbureted engine:
INDEX MARK
16-84
lgniter Unit Input Test
Fuel-injected engine: 5. Check the YEL/WHT wire between the PGM-FI ECU
NOTE: and the igniter unit.
e See section 6 when the self-díagnostíc índicator blinks. 6. Check the BLU wire between the tachometer and the
e Perform an input test for the igniter unit after finishing igniter unit.
the fundamental tests for the ignition system and fuel 7. lf all tests are normal. replace the igniter unit.
emission system.
e The tacho meter should operate normally. Carbureted engine:
NOTE: The tacho meter should operate norma lly.
1. Remove the distributor cap, the rotor and the leak
cover. 1. Remove the dístributor cap and the rotor.
2. Disconnect the BLK/YEL, WHT/BLU, YEL/GRN and 2. Disconnect the BLK/YEL, BLK/WHT, BLU and BLU
BLU wires from the igniter unit. (ignition coi!) wires from the igniter unit.
IGNITER UNIT
BLU WIRE
3. Turn the ignition switch ON. Check the voltage

between the BLK/YEL wire and the body ground. BLK/YEL WIRE
e lf there is no battery voltage, check the BLK/YEL
wire across the ignition switch and the igniter unit. 3. Turn the ignition switch ON. Check the voltage
e lf there is battery voltage, go to step 4. between the BLK/YEL wire and the body ground.
4. Turn the ignition switch ON. Check the voltage e lf there is no battery voltage, check the BLK/YEL
between the WHT/BLU wire and the body ground. wire across the ignition switch and the igniter unit.
There should be battery voltage. · e lf there is battery voltage, go to step 4.
e lf there is no battery voltage, check the following. 4. Check the BLK/WHT and the BLU wires between the
- lgnítion coil. ignition coil and the igniter unit.
- WHT/BLU wire between the ignition coil and the 5. Check the BLU wire between the tachometer and the
igniter unit. igniter unit.
e lf there is battery voltage, go to step 5. 6. lf all tests are normal, replace the igniter unit.
16.-85
lgnition System
lgnition Coil Test (Fuel-lnjected E n g i n e ) - - - - - - : - - - - - - - - - -
1. With the ignition· switch OFF, remove the distributor 3. Using an ohmmeter, measure resistance between the
cap. terminals. Replace the coil if the resistance is not
2. Remove the 2 screws to disconnect the BLK/YEL and NOTE: Resistance will vary with the coil temperature;
WHT/BLU wires from the terminals A and B respec- specifications are at 20"C (70"F)
tively.
Primary Winding Resistance
(between the A and B terminals}:
0.6-0.8 ohms
Secondary Winding Resistance
(between the A and secondary winding terminals):
IGNITION COIL 12,88o-19,320 ohms
SECONDARY
WINOING
TERMINAL
BLK/YEL WIRE
SECONOARY
WINDING
TERMINAL
16-86
(Carbureted E n g i n e ) - - - - - - - - - - - - - - - - - - - - - - - - - - ,
D
1. With the ignition switch OFF, remove the distributor 3. Using an ohmmeter, measure resistance between the
cap. terminals. Replace the coil if the resistance is not
2. Disconnect the BLK/WHT and BLU wires from the NOTE: Resistance will vary with the coil temperature;
terminals A and B respectively. specifications are at 20'C (70'F)
Primary Winding Resistance

(between the A and B terminals):
0.5-0. 7 ohms
TERMINAL A Secondary Winding Resistance
(between the A and secondary winding terminals):
14,400-21 ,600 ohms
SECONDARY SECONDARY
BLU WIRE
WINDING WINDING
TERMINAL TERMINAL
16-87
lgnition System
lgnition Coil Replacement {Fuel-lnjected E n g i n e ) - - - - - - - - - - -
1. With ignition switch OFF, remove the distributor cap, 3. Remove the 2 screws and slide the ignition coil out of
rotor, and cap seal, then remove the leak cover. the distríbutor housíng.
2. Remove the 2 screws to disconnect the BLK/YEL and

WHT/BLU wires from the terminals A and B respec-
tively.
IGNITION COIL
LEAK COVER
ROTOR
16-88
(Carbureted Engine) - - - - - - - - - - - - - - - - - - - - - - - - ,
D
1. With ignition switch OFF, remove the distributor cap 3. Remove the rubber caps from the distributor housing.
and cap seal. ·
4. Remove the 4 screws and slide the ignition coil out of
2. Disconnect the BLK/WHT and BLU wires from the the distributor housing.
terminals A and B respectively.
NOTE:
• Replace the rubber caps if they are worn out.
e lnstalling the rubber caps, apply silicon grease to
them.
e Make sure that the wires are clamped and apart
from a stator, etc.
A
CAP SEAL
CAP
IGNITION COIL
16-89
lgnition System
Spark Plug lnspection----------------------------------------------~
.1. lnspect the electrodes and ceramic insulator for: 2. Replace the plug if the center electrode is rounded as
shown below: ·
NOTE:
Worn or deformad e Do not use spark plugs other than those listed
electrodes • lmproper
below, because those plugs are a new type (ISO
gap
standard).
• Oil-fouling
• Carbon
e These marks are sealed on the air cleaner cover.
Damaged deposits
gasket • Cracked
center
electrode
insulator
Spark Plug:
Except KP and KT models
Standard Optional
ZFRSF-11*
NGK ZFR6F~11
ZFR7F-11
KJ16CR-L11*
NO KJ20CR-L 11
KJ22CR-L11
*: Except KF, KG, KS, KW, KE and KX models

Burned or wom electrodes may be caused by:
Advanced ignition timing
Loose spark plug K P and KT models
Plug heat range too low
Standard Optional
lnsufficient cooling
NGK ZFR5F-11 ZFR6F-11
Fouled plug may be caused by: 1
Retarded ignition timing NO KJ16CR-L 11 1 KJ20CR-L 11

Oil in combustion chamber ¡ j_
lncorrect spark plug gap
• Plug heat range too high 1.0-1.1 mm
Excessive idling/low speed running {0.039-0.043 in.) ROUNDED
iifji
Clogged air cleaner element
~OOE
Deteriorated ignition coi! or ignition wires
3. Adjust the gap with a suitable gapping tool.
Electrode Gap: 1.o-1.1 mm (0.039-0.043 in.)
4. Screw the plugs into the cylinder head finger tight,

then torque them to 18 N·m (1.8 kg-m, 13 lb-ft).
NOTE: Apply a small quantity of anti-seize compound

to the plug threads before installing.
16-90
lgnition Wire lnspection and Test
D
CAUTION: Car$fully remove the ignition wires by pull-
ing on the rubber boots. Do not bend the wire or the
conductor may be broken.
1. Check the condition of the wire terminals. lf any

terminal is corroded, clean it, and if it is broken or
distorted, replace the wire.
Check for broken,

corroded, or bent
terminals.
2. Connect ohmmeter probes and measure resistance.
lgnition Wire Resistance:

25,000 ohms max. at 20°C (70°F)
3. lf resistance exceeds 25,000 ohms, replace the ig-

nition wire.
16-91
Charging System
Component location l n d e x - - - - - - - - - - - - - - - - - - - - - - - - .
CHARGE WARNING LIGHT

(in the gauge assemblyl
Test, page 1 6-96
ALTERNATOR
Alternator and Regulator Test, page 1 6-94
Overhaul, page 16-98 ALTERNATOR BELT
Adjustment, page 16-1 01
16-92
are~ m~~-----------------------~[:~::+:)~
IGNITION SWITCH
BA TTERY
~WHT~
No.21(7 .5A) ~ 1
BLKIYEL
BLKIYEL
B~LKIYE~HARGE
WARNING
LIGHT(1.4W)
ALB CONTROL
WHT /BLU UNIT
WHT/RED
WHTIGRN
BLK/YEL ~WHTIBLU_]
WHTIBLU
PGM-FI ECU
F~~~- r....L---:~~---_.J---1-+-- WHTIRED_j
~~
1
AECTJFJER
1"'
1 1
1 1
~------·--··
FA* : PGM-FI only
16-93
Charging System
Alternator and Regulator T e s t - - - - - - - - - - - - - - - - - - - -
1. First make su re you have a good battery, and that the 3. lf these check OK, connect a voltmeter between the
alternator belt, and connections at the alternator and alternator terminal B and body ground, andan amme-
main fuses are good. Next, check the No.2 (15 A) ter 11 00 amp capacity or higher) between the alter-
fuse in the dash fuse box. (lf blown, the charge nator terminal B and the WHT/RED wire as shown.
warning light will come on even if the system is (An inductiva pick up can be used instead of discon-
working properly) necting the WHT/RED wire.)
2. Disconnect the alternator connector from the alter-

nator.
To avoid shorting to
With the ignition switch on, there should be battery ground, cover at the
voltage between the IG (BLK/YEL) terminal and body terminal with and insulator.
ground.
View from
Fuel-injected
engine
TERMINAL B
4. Start the engine, and turn on the headlights, blower

motor, rear window defogger, etc.
NOTE: lf voltage stays above 13.5 V, apply electrical

load more to lower the voltage to less than 13.5 V.
lf the voltage exceeds 16 V. stop the engine and
replace the voltage regulator.
e lf there is no voltage, check for an open in the BLK/
YEL wire between the dash fuse box and voltage
regulator.
16-94
5. Compare the readings to the chart below. lf no output 7. Perform a full-field test: lnsert a short screwdriver into
or below specification, go to step 7. lf output is within the full field access hole at the back of the alternator.
specification, go to step 6. While grounding the screwdriver and check amperage
reading.
NOTE: Subtráct 5 to 1 O amperes from the maximum
reading dueto engine operation. CAUTION: The voltage will rise quickly when the
alternator is full fielded. Do not allowthe voltage to
exceed 18 volts or damage to the electrical system
1 may result.
120
! .1 J
13.5 V (const) REGULATOR
110 (Located inside
the end cover)
100
e-ro
90
so
V
1v . . .,...
¡,'
/, -- f--- f - - 1--- 1--
¡,.....--: ¡,....-- ~- r-
1
"Hiñ-=--
--
5...
e
70
lit/ /
~ 'I/
:S
(.)
.
:S
60
50
1/ 1
1
~
o
40
J
1
30
1
20
10
2 4 6 8 10 12 14 16 18
Alternator Speed [X 1000 min- 1 (rpm)]
END COVER
'®1 2000
1 1
4000
1
6000
e lf the amperage is not within specification, replace
the alternator.
e lf the amperage is within specification, replace the
voltage regulator.
1 1 1
@' 2000 4000 6000
Engine Speed [min- 1 (rpm)]

® - - : Fuel-injected engine (AII models)
Carbureted engine (KS, KW and KV models)
@ - - - : Carbureted engine (Except KS. KW and KV
models)
6. Turn off allloads in step 4, then measure the alternator

output voltage at 1,500 min- 1 (rpm).
e lf the voltage is between 13.9 V and 15.1 V, the

alternator and regulator are OK.
lf the charge warning light is still on, see Charge
Warning Light Test.
16-95
Charging System
Charge Warning Light T e s t - - - - - - - - - - - - - - - - - - - - - - .
NOTE: Befare testing, check the wire harness connection, 3. Without ALB: There is a short to ground in the WHT1
alternator belt tension and No.2 (15 A) fuse in the dash BLU wire between the warning light and
fuse box. the dash fuse box, or the dash fuse box
and the voltage regulator.
1. Turn the ignition switch on. The charge warning light With ALB: Go to step 4
should come on.
lf it does not come on, unplug the alternator connector 4. Unplug the alternator connector, then remove the
and short the pin of the L (WHT/BLU) terminal to right trunk trim paneL
ground. Disconnect the 1 8-P connector from the ALB control
unit.
With the ignition switch ON, the charge warning light
View from should go off.
Fuel-injected
L {WHT/BLU)
e lf the warning light still does not come on, check e lf the light goes off. there is a short in the ALB
for: control unit.
- Bad bulb. e lf the light does not go off, there is a short to

- An open in the WHT /BLU wire between the ground in the WHT/BLU wire between the ALB
warning light and voltage regulator. control unit and the dash fuse box, or the dash fuse
- An open in the BLK/YEL wire between the box and the voltage regulator.
warning light and the dash fu se box, or the dash
fu se box and the ignition switch.
e lf the light comes on, check the alternator and

regulator (see page 1 6-94).
2. Start the engine and let it idle. The charge warning

light should go off.
lf it stays on this time, check the alternator and regula-
ter (see page 16-94).
lf the system is charging, proceed as follows.
16-96
Cooling Fan Control
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - .
RADIATOR FAN RELAY

(Located in the under-hood
relay box)
Test, page 16-109
RELAY BOX
COOLANT TEMPERATURE
SWITCH A
Test, page 16-1 09
COOLING FAN TIMER

UNIT (with A/C)
Terminals, page 16-1 08
COOLANT TEMPERATURE
SWITCH B
Test, page 16-109
RADIATOR FAN
MOTOR
Test, page 1 6-1 08
Replacement, section 5
COMPRESSOR CLUTCH
and CONDENSER FAN RELAYS
CONDENSER FAN
(with A/CI
MOTOR
Test, page 16-109
Test, page 16-1 08
16-103
Cooling Fan Control
Circuit Diagram (KV and KQ m o d e l s ) - - - - - - - - - - - - - - - - - - - .
BATTERY N0.15{80A) N0.19(50A)

4-~~~-----a~o--.~Y'~------+---WHT 2 --------~~ IGNITION
SWITCH
N0.39(15A) N0.29(15A)
YEL BLK/YEL
N0.7
) (7 .5A)
~ (7NO.S
.5A)
N0.2
(15A)
DASH
FUSE
aox
RADIATOR
FAN
RE LAY
¿
BLK/YEL2
1
BLU/BLK
COM PRESSOR
BLU CLUTCH
YEL/BLK BLK/YEL1
COOLIN6 FAN TIM EA UNIT
BlU + BLU
BLU-...----1---
BlK
BLU
~ u,~,r±t
PGM-FI lfJ CONDENSER
ECU BLU/BLK3 FAN
RELAY
COOLANT TU RE
TEMPERA ~ COOLANT
SWITCH A TEMPEAATUAE
ON : above J
[ 90° C(194° F)
YELIW HT
SWITCH B
ON : aboveJ
[ 1os•c¡22s•F¡
RADIA TOR
FAN MOTOR M ·A/C SYSTEM
• PGM-FI ECU
BLK CONO ENSER

FAN MOTOR BLK
rr
6201 G101
BLK
l_
G281
I
6401
G402
16-104
Circuit Diagram (Except KV and KQ models: With Fan Timer System)----.
Cl
BA TTERY N0.15(80A) N0.19(50A)

+ !--t----o""\.....r>-.....-0'"'\J>---+--- WHT 2 ----'0 IGNITION
SWITCH
N0.39(15A) N0.29(15A)
YEL BLK/YEL
DASH
DIO DE
NO.B 3:;¡ N0.7 N0.2
FUSE
BOX
VEL~
~ (7 .5A) (7 .5A) (15A)
RADIATOA
FAN
AERAY
Y EL/BLK YEL/BLK BLKIYE@
BLUIBLK1
1 ~
COM PRESSOA
BLU
WHT 1 YELIBLK CLUTCH BLK/YEL 1
L-y.----:_~~--_-_ __,---J, COOLING FAN TIM EA UNIT
BLU YEL/W HT W HTIGRN BLK
BLU _L BLU --+---.. . .---.

BLU
BLU
A/C
VIOOELtJ
ril
COOLA NT CONDENSER COOLANT
¿
TEMPERA TU RE BLUIBLK 2 FAN TEM PERATURE
SWITCH A RELAY SWITCH B
ON : above
[ 90°C(194°F)
J ON : above 1
[ 108°C(226•F)J
YELIW HT
• A/C SYSTEM
• PGM-FI ECU
BLK CONOENSER
FAN MOTOR BLK
Ir
G201 G101
I
G281
I
G401
G402
(e o nt' d)
16-105
Cooling Fan Control
Circuit Diagram (Except KV and KQ models: Without Fan Timer System)
UNDEA-HOOD RELAY BOX
IGNITION
BA TTERY SWITCH
N0.15(BOA) N0.19(50A)
+ WHT 2
N0.39(15A) N0.29(15A)
~ ·-
WHT 1
YEL
N0.7
{7 .5A)
$ NO.B
(7 .5A)
DASH
FUSE
BOX
BLK/YEL 2
r------+--- YELIBLK
RADIA TOA BLK/YEL 2
1 FAN
RERAY BLK/Y EL 2
1
• COM PRESSOA
lD CONO ENSER
FA N
CLUTCH
• DELAY RELA Y
RELA Y
BLUIBLK 1
lt;> ) {KE and KB modeis)
BLU
1 1
BLUIGRN BLU
B U PGM-FI ECU
PIS Oll Pf\ESSURE
SWITCH
COOLANT
7
TEMPERA TURE
SWITCH A
ON : above
[ 90•C(194°FI
J
BLK
tj:,h'&.
BLU/BLK BLU/BLK
1
BLU/BLK
t
BLK ~
I I
G201 G101
l
G291
• PGM-Fl ECU
• PGM-CAAB. ECU
• DELA Y AELA Y
(KE and KB models)
16-106
Circuit Diagram (Without A/C)
UNOER-HOOD RELAY BOX 16NITION
SWITCH OASH FUSE BOX
ATTERY
+
No. 15(80A) No.19(50A)
WHT-@- BAT
IG2
YEL
N0.8(7 .5A)
No.39(15A)
L........::ru:l YELIBLK
RADIA TOA 1
FAN ::>
RELAY 1
BLU/BlK
T
[
6201
"'~ FAN MOTOR
COOLANT
SWITCH
@:ot--- B L K l
TEMPERA TU RE
ON : above
[ 90°C(194°F)
J
6101
Troubleshooting (With A / C ) - - - - - - - - - - - - - - - - - - - - - - ,
NOTE: The numbers in the table show the troubleshooting sequence.
Q)
V>
ltem to be ínspected
....;::,
<(
> o
LO
-en
~
e"' oE \
o
M-
o o
z.D
>
o~
• X
-"'"' -"'
e:
á>
e:
e:
....
Q)
"'e Q)
V>
;::,-
<(
.r;
.S
·~
....
·¡:
;::,
á> 1
m
.r;
.S
·~
Q)
V>
o
E
O .:Ero
<( ~
QJ QJ
'+- X
<JI
E "'
.!= ·=
"O "O o
"O
e:
o
e
o <(.D
z
~ ·.¡::;
e E
QJ
"' E
Q)
--
LO O o o 3: ....
o LO
Q) ro ~ e
-
en Q)
.!.
.r; o oe ~
"'
;::, á>
Q. Cl)
Q)
a. e -
Q)
·=oo -
· ; "'O
N e: N.r; E E "O
e
....ro ...."' E
-
·- Q)
• "O
o e
z ;::,
Q)
"O
ci
2"0
"'"' $
....e:
$ Q)
ti o
;::, o.... o
;::, Q)
~ ~ o o e, ·¡:¡ e
e G> :¡:; e Cll e ~ e
ro Z':
Symptom
!!:.S :¡:; "'
:¡:; u
..__
3: .S
E
o"'o ::; o"'o u
..__ oo e
Q)
oo
E e e
m= "'
a: "'
a: <( m= u
ro
u.. u <( a.. oa. :e"'
BLU, BLU/BLK 1 , BLU/BLK 2
Only one fan operates G401 BLU/BLK 3 , BLU/YEL,
1 2 3 4
(with engine and A/C ON). G402 YEL/BLK, YEL/WHT,
BLU/GRN, YEL or WHT 1
Under all
Fans do 1 2 3 G101 YEL/BLK, YEL or BLU
conditions.
not rotate.
A/C ON 1
Fan timer unit fails to G401 WHT 1 , WHT/GRN
2 1
function properly. G402 or YEL/WHT
16-107
Cooling Fan Control
Timer Unit Terminals Fan Motor Test-----------,
1. Disconnect the 2-P connector from the fan motor.
TIMER UNIT
2. Test motor operation by connecting battery positíve to
the A terminal, and .negative to the B terminal.
3. lf the motor fails to run smoothly, replace it.
Radiator Fan Motor:
A B C
= F G
Terminal Wire Destination
1 VEL• 1 Radiator fan relay EB Condensar Fan Motor:

A
VEL/WHT* 2 Condenser fan relay e
, Power supply (For condenser 1
B VEL/BLK tan relay by way of timer unit
wíth ignition switch ON) .
WHT/VEL* 1 Condenser fan relay e

e
*2 (Not used)
i
D BLK Ground
E WHT/GRN Coolant temperature switch B
Constant power (For con-

F WHT denser fan relay by way of
tímer unit)
1
G BLK/VEL IG 1 (Timer reset signal)
¡ H BLU Condenser fan relay EB 1
¡ 1
* 1 : KV and KQ models
* 2: Except KV and KQ models
16-108
Relay T e s t - - - - - - - - - - - . Coolant Temperatura Switch Test
There should be continuity between the A and B terminals 1. Remove the coolant temperature switch A form the
when the battery ís connected to the C and D terminals. termostat housíng or the switch B from the water
There should be no contínuity when the battery ís díscon- outlet cover.
nected.
2. Suspend the coolant temperature switch in a container
NOTE: Test procedures are same for all relays. of coolant as shown.
RADIATOR FAN RELAY

(in the relay box}
THERMOMETER
COOLANT
TEMP. SWITCH
CONDENSER FAN RELAY (With A/Cl
A e
3. Heat the coolant and check coolant temperature wíth

a thermometer.
4. Measure the resistance between the A and B termínals

accordíng to the table.
:~ Terminal
A B
Temperature
~
87-93°C
Switch
Above
(189-199°F) o- ~ 1
A e A 80-91 oc
Below
1 (176-196°F)
105-111 oc
Switch
Abo ve
(221-232°F) o- ~o
B 98-109°C
Below
(208-228°F)
B D
16-109
Cooling Fan Control
Circuit Diagram (KV and KQ m o d e l s ) - - - - - - - - - - - - - - - - - - - .
BATTERY N0.15{80A) N0.19(50A)

4-~~~-----a~o--.~Y'~------+---WHT 2 --------~~ IGNITION
SWITCH
N0.39(15A) N0.29(15A)
YEL BLK/YEL
N0.7
) (7 .5A)
~ (7NO.S
.5A)
N0.2
(15A)
DASH
FUSE
aox
RADIATOR
FAN
RE LAY
¿
BLK/YEL2
1
BLU/BLK
COM PRESSOR
BLU CLUTCH
YEL/BLK BLK/YEL1
COOLIN6 FAN TIM EA UNIT
BlU + BLU
BLU-...----1---
BlK
BLU
~ u,~,r±t
PGM-FI lfJ CONDENSER
ECU BLU/BLK3 FAN
RELAY
COOLANT TU RE
TEMPERA ~ COOLANT
SWITCH A TEMPEAATUAE
ON : above J
[ 90° C(194° F)
YELIW HT
SWITCH B
ON : aboveJ
[ 1os•c¡22s•F¡
RADIA TOR
FAN MOTOR M ·A/C SYSTEM
• PGM-FI ECU
BLK CONO ENSER

FAN MOTOR BLK
rr
6201 G101
BLK
l_
G281
I
6401
G402
16-104
Circuit Diagram (Except KV and KQ models: With Fan Timer System)----.
Cl
BA TTERY N0.15(80A) N0.19(50A)

+ !--t----o""\.....r>-.....-0'"'\J>---+--- WHT 2 ----'0 IGNITION
SWITCH
N0.39(15A) N0.29(15A)
YEL BLK/YEL
DASH
DIO DE
NO.B 3:;¡ N0.7 N0.2
FUSE
BOX
VEL~
~ (7 .5A) (7 .5A) (15A)
RADIATOA
FAN
AERAY
Y EL/BLK YEL/BLK BLKIYE@
BLUIBLK1
1 ~
COM PRESSOA
BLU
WHT 1 YELIBLK CLUTCH BLK/YEL 1
L-y.----:_~~--_-_ __,---J, COOLING FAN TIM EA UNIT
BLU YEL/W HT W HTIGRN BLK
BLU _L BLU --+---.. . .---.

BLU
BLU
A/C
VIOOELtJ
ril
COOLA NT CONDENSER COOLANT
¿
TEMPERA TU RE BLUIBLK 2 FAN TEM PERATURE
SWITCH A RELAY SWITCH B
ON : above
[ 90°C(194°F)
J ON : above 1
[ 108°C(226•F)J
YELIW HT
• A/C SYSTEM
• PGM-FI ECU
BLK CONOENSER
FAN MOTOR BLK
Ir
G201 G101
I
G281
I
G401
G402
(e o nt' d)
16-105
Cooling Fan Control
Circuit Diagram (Except KV and KQ models: Without Fan Timer System)
UNDEA-HOOD RELAY BOX
IGNITION
BA TTERY SWITCH
N0.15(BOA) N0.19(50A)
+ WHT 2
N0.39(15A) N0.29(15A)
~ ·-
WHT 1
YEL
N0.7
{7 .5A)
$ NO.B
(7 .5A)
DASH
FUSE
BOX
BLK/YEL 2
r------+--- YELIBLK
RADIA TOA BLK/YEL 2
1 FAN
RERAY BLK/Y EL 2
1
• COM PRESSOA
lD CONO ENSER
FA N
CLUTCH
• DELAY RELA Y
RELA Y
BLUIBLK 1
lt;> ) {KE and KB modeis)
BLU
1 1
BLUIGRN BLU
B U PGM-FI ECU
PIS Oll Pf\ESSURE
SWITCH
COOLANT
7
TEMPERA TURE
SWITCH A
ON : above
[ 90•C(194°FI
J
BLK
tj:,h'&.
BLU/BLK BLU/BLK
1
BLU/BLK
t
BLK ~
I I
G201 G101
l
G291
• PGM-Fl ECU
• PGM-CAAB. ECU
• DELA Y AELA Y
(KE and KB models)
16-106
Circuit Diagram (Without A/C)
UNOER-HOOD RELAY BOX 16NITION
ATTERY
+
No. 15(80A) No.19(50A)
WHT-@- BAT
IG2
YEL
N0.8(7 .5A)
No.39(15A)
L........::ru:l YELIBLK
RADIA TOA 1
FAN ::>
RELAY 1
BLU/BlK
T
[
6201
"'~ FAN MOTOR
COOLANT
SWITCH
@:ot--- B L K l
TEMPERA TU RE
ON : above
[ 90°C(194°F)
J
6101
Troubleshooting (With A / C ) - - - - - - - - - - - - - - - - - - - - - - ,
Q)
V>
ltem to be ínspected
....;::,
<(
> o
LO
-en
~
e"' oE \
o
M-
o o
z.D
>
o~
• X
-"'"' -"'
e:
á>
e:
e:
....
Q)
"'e Q)
V>
;::,-
<(
.r;
.S
·~
....
·¡:
;::,
á> 1
m
.r;
.S
·~
Q)
V>
o
E
O .:Ero
<( ~
QJ QJ
'+- X
<JI
E "'
.!= ·=
"O "O o
"O
e:
o
e
o <(.D
z
~ ·.¡::;
e E
QJ
"' E
Q)
--
LO O o o 3: ....
o LO
Q) ro ~ e
-
en Q)
.!.
.r; o oe ~
"'
;::, á>
Q. Cl)
Q)
a. e -
Q)
·=oo -
· ; "'O
N e: N.r; E E "O
e
....ro ...."' E
-
·- Q)
• "O
o e
z ;::,
Q)
"O
ci
2"0
"'"' $
....e:
$ Q)
ti o
;::, o.... o
;::, Q)
~ ~ o o e, ·¡:¡ e
e G> :¡:; e Cll e ~ e
ro Z':
Symptom
!!:.S :¡:; "'
:¡:; u
..__
3: .S
E
o"'o ::; o"'o u
..__ oo e
Q)
oo
E e e
m= "'
a: "'
a: <( m= u
ro
u.. u <( a.. oa. :e"'
BLU, BLU/BLK 1 , BLU/BLK 2
Only one fan operates G401 BLU/BLK 3 , BLU/YEL,
1 2 3 4
(with engine and A/C ON). G402 YEL/BLK, YEL/WHT,
BLU/GRN, YEL or WHT 1
Under all
Fans do 1 2 3 G101 YEL/BLK, YEL or BLU
conditions.
not rotate.
A/C ON 1
Fan timer unit fails to G401 WHT 1 , WHT/GRN
2 1
function properly. G402 or YEL/WHT
16-107
Cooling Fan Control
Timer Unit Terminals Fan Motor Test-----------,
1. Disconnect the 2-P connector from the fan motor.
TIMER UNIT
2. Test motor operation by connecting battery positíve to
the A terminal, and .negative to the B terminal.
3. lf the motor fails to run smoothly, replace it.
Radiator Fan Motor:
A B C
= F G
1 VEL• 1 Radiator fan relay EB Condensar Fan Motor:

A
VEL/WHT* 2 Condenser fan relay e
, Power supply (For condenser 1
B VEL/BLK tan relay by way of timer unit
wíth ignition switch ON) .
WHT/VEL* 1 Condenser fan relay e

e
*2 (Not used)
i
D BLK Ground
E WHT/GRN Coolant temperature switch B
Constant power (For con-

F WHT denser fan relay by way of
tímer unit)
1
G BLK/VEL IG 1 (Timer reset signal)
¡ H BLU Condenser fan relay EB 1
¡ 1
* 1 : KV and KQ models
* 2: Except KV and KQ models
16-108
Relay T e s t - - - - - - - - - - - . Coolant Temperatura Switch Test
There should be continuity between the A and B terminals 1. Remove the coolant temperature switch A form the
when the battery ís connected to the C and D terminals. termostat housíng or the switch B from the water
There should be no contínuity when the battery ís díscon- outlet cover.
nected.
2. Suspend the coolant temperature switch in a container
NOTE: Test procedures are same for all relays. of coolant as shown.
RADIATOR FAN RELAY

(in the relay box}
THERMOMETER
COOLANT
TEMP. SWITCH
CONDENSER FAN RELAY (With A/Cl
A e
3. Heat the coolant and check coolant temperature wíth

a thermometer.
4. Measure the resistance between the A and B termínals

accordíng to the table.
:~ Terminal
A B
Temperature
~
87-93°C
Switch
Above
(189-199°F) o- ~ 1
A e A 80-91 oc
Below
1 (176-196°F)
105-111 oc
Switch
Abo ve
(221-232°F) o- ~o
B 98-109°C
Below
(208-228°F)
B D
16-109
Gauge Assembly
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - - .
FUEL SENDER UNIT

Test, page 16-126
GAUGE ASSEMBLY
Replacement, page 1 6-1 2 7
Gauge Location lndex. page 16-111
Bu lb Location, page 1 6-1 04
Disassembly, page 1 6-11 8
Removal, page 16-120
Beeper Test (NO), page 16-120
BRAKE FLUID LEVEL

SWITCH
Description, page 16-124
Test, page 16-124
PARKING BRAKE SWITCH

Description, page 16-124
Test, page 16-124
OIL PRESSURE
SWITCH
Test, page 16-125
COOLANT TEMPERATURE
GAUGE
Test, page 16-128
SPEED SENSOR
(located under the
thermostat housing)
Input Test, page 1 6-122
T roubleshooting, page 1 6-121
16-110
D
NO:
SPEEDOMETER
COOLANT TEMPERATU RE GAUGE lndicates 60 km/h [60 mph]
Gauge Test, page 16-128 at 637 [1 ,026] min- 1 {rpm) TACHOMETER
Sender Test, page 16-128 of the speed sensor. lndicates 1 00 min- 1 (rpm) at 200
pulses per minute of
the igniter unit.
FUEL GAUGE
Gauge Test, page 16-126
Sending Unit Test/Rep/acement, page 16-127
NS:
SPEEDOMETER
TACHOMETER
lndicates 60 km/h [60 mph]
COOLANT TEMPERATURE GAUGE lndicates 100 min- 1 (rpm) at 200
at 637 [1 ,026] rpm of
Gauge Test, page 16-128 pulses per minute of
the speed sensor.
Sender Test, page 16-128 the igniter unit.
/
FUEL GAUGE
Gauge Test, page 16-126 SPEED ALARM CIRCUIT (KV model)
Sending Unit Test/Replacement, Beeper sounds when speed exceeds 106 ± 4 km/h.
page 16-127
16-111
Gauge Assembly
Circuit Diagrann--------------------------------------------------------
BATTERY
C\,+
UNDER- HOOD RELA Y
N0.15(80A} N0.19(50A)
\2:)¡------fo--~--+-----WHT
-(g- IGNITION
SWITCH
BLKIYE
1
DASH
FUSE
N0.2 N0.1 aox
(15A} (1 OA)
YEL--0
r----,-----,
1 HAZARD 1 STARTER 1 LIGHTING
l SWITCH l SIGNAL l SWITCH
'V v1
BLKIYEL
1 J
IGRNIWHT
1
1
1
l
1
BlUIRED
1
1
l
1
7
RED/BLK
YEL
es WARNING DISPLAY 1 CS 1 1 C6
----------------------------~- --~--
1
CHECK OIL SEAT 1 HIGH
CHARGE ENGINE PRESSURE BRAKE BELT 1 BEAM
WARNING WARNING WARNING WARNING
LIGHT LIGHT LIGHT LIGHT r~i~lfDEA 1 INDICA TOA
LIGHT
(1.4W) (1.4W) (1.4W) (1.4W) BRAKE (1.4W) 1 (1.4W)
CHECK
CIRCUIT 1
1
1
----
C1
----r--·
C2 l
1
WHTIBLU YEL/RED IYEL/RED 1
¡~
1
1
1
1
1
PGM-FI ECU HAZA RO 1 I~HEGRA TED 1 CRUISE LIGHTING
CONTROL SWITCH
SWITCH 1 CONTROL 1 UNIT
Except ) l UNIT
( KY model KY modal) 1
1 ( only 1
L ____ ..J. _ _ _ _ .J
VOLTAGE ENGINE OIL
REGULA TOA PRESSURE
(ín ALTERNATOR) SWITCH
G301
16-112
A~------------------------~~------------------------------~
TURN SIGNAL SWITCH
IGNITION Ll6HTING
~
y y
COIL SWITCH
GRNISLU GRNIYEL YEL

yBLU
y
RED/BLK
C11 C12 A4 A1
-·---·~
l.TURN R.TURN
SIGNAL S\GNAL
INDICA TOA INDICA TOA
l!GHT LIGHT
(l.4W) (1.4W)
C13 814
r .,
BLK GRNIRED BLK RED
l BLK l
YELIWHT 1 1
1 1
1 1
1 1
• P6M-FI ECU
1 1 DASHUGHT
-FiiJEL • P6M-CARB.ECU SPEEO SENSOR BRIGHTNESS
GAUGE • AIT CONTROL 1 1 CONTROLLER
SENDING UNIT
• CRUISE 1 1
t----:J
CONTROL UNIT 1 1
1 1
1 1
FUEL 6AUGE UNIT 1 1
1 1
COOLANT
1 1
TEMPERATURE 1 1
I I
GAU6E SENOER 1 1
1 1
1 1
1 1
1 1
G40t G60t 6401 Fuel-injec!ed engíne : 6301 l G¡01 f
G402 6402 Carbureted engine : 6201 1 6402 1
L_...J
Wíthout
DASHUGHT
BRIGHTNESS
CONTAOLLER
16-113
Gauge Assembly
Terminal L o c a t i o n s - - - - - - - - - - - - - - - - - - - - - - -
16-114
~
A1()--oii-------A1
16-115
Gauge Assembly
Bulb Locations ( N O ) - - - - - - - - - - - - - - - - - - - - - - -
GAUGE LIGHTS (1 .4 W x 2)
ALB
CHARGE
WARNING (1 .4 W)
WARNING (1.4 W}
CRUISE CONTROL
INOICATOR {1.2 W)
CHECK ENGINE
OIL PRESSURE WARNING (1 .4 W)
WARNING (1 .4 W)
L. TURN SIGNAL
INDICATOR (1 .4 W}
GAUGE LIGHT
(3.4Wl
HAZARD
GAUGE LIGHTS WARNING (1.4 W} [Except KY model]
S INDICATOR HIGH BEAM (3.4 W X 2)
[Long socket type] INDICATOA (1 .4 W) or
(1.2W) SEAT BELT
LOW FUEL
REMINDER {1 .4 W) [KY model]
WARNING
(1.4 W)
16-116
(NS)-----------------------------------------------.
GAUGE LIGHTS (1.4 W x 2)
ALB
CHARGE
WARNING (1 .4 W)
WARNING (1.4 Wl
CRUISE CONTROL
CHECK ENGINE
INDICATOR (1.2 W)
WARNING (1 .4 W)
L.TURN SIGNAL
R.TURN SIGNAL INDICATOR {1.4 W)
INDICATOR (1 .4 W)
HIGH BEAM
INDICATOR (1 .4 W) HAZARD
GAUGE LIGHTS WARNING (1 .4 Wl
(3.4 W X 2) [Except KV model]
LOW FUEL WARNING (1.4 Wl: or
on the main print panel, see page 16-125 SEAT BELT
REMINDER (1.4 W ) [KV model]
16-117
Gauge Assembly
Disassembly ( N O ) - - - - - - - - - - - - - - - - - - - - - - -
NOTE: Handle the terminals and printed circuits carefully to avoid damaging them.
COVER
HOUSING
TACHOMETER
Specification, page 1 6-111
MAIN PRINT PANEL

• SHIFT LEVER POSITION INDICATOR
See page 16-138.
• SAFETY INDICATOR
See page 16-129.
SPEEDOMETER
Specification, page 16-111 COOLANT TEMPERATURE/
Troubleshooting, page 16-121 FUEL GAUGE
Test, pages 16-126 and 127
000/TRIP METER
Troubleshooting, page i 6-121
VISOR
~
TRIPMETER~
RESET BUTTON
16-118
(NS)----------_!r;--~+1
COVER
TACHOMETER
Specification, page 16-111
MAIN PRINT PANEl

• SHIFT LEVER POSIT
See page 16-138 ION INDICATOR
• SAFETY INDICATOR
See page 1 6-129
SPEEDOMETER
Specification
Troubleshootinpage 1 6-111
g, page 16-121
000/TRIP METER
Troubleshoofmg, page 16-121
UGHT CASE
TRIP METER VISOR

RESET BUTTO--N_ _ ___._
16-119
Gauge Assembly
Rernoval-------------------------, Beeper Test (ND)----------.
1. Remove the console and the instrument panel from the 1. Remove the beeper from the gauge assembly.
dashboard, then disconnect each switch connector. 2. Test the beeper operation by connecting the battery
positive to the E8 terminal (E!1 mark), and negative to
the 8 terminal.
EB MARK {Surface of the beeper)
®TERMINAL
3. lf the beeper fails to operate, replace it.
2. Remove the 4 screws and the gauge assembly, then

disconnect 1 0-P, 1 6-P and 22-P connectors.
GAUGE ASSEMBLY
16-P CONNECTOR
22-P
CONNECTOR
16-120
Speed/Odo/Trip meter Troubleshooting-----------------,
ltem to be inspected NO NS
'O
~
-¡¡;
--
5l
:::;)
_o
)(
<{.D
;:;
....~
:::;)
;:;
.!:
oe:
--
o..- 5l a.
.!:
....a;
:::;) .!!!
..- ~
~(1) (1) o o 'O
e:
o g¡ E <ll
e: "'e: :J
z-o E a. (1)
~~ o
e: (1) o ·¡: ·~ "' 'O u o,
'O 'O
~ ~
;: -E (1)
(1) o o (1)
(1)
QJ
QJ
QJ
::: oo
~5 a. c. a. o
'O 'O
Symptom (f) o o (f) (f) u a..
Speedometer does not operate. ORN
Speedometer operates, but

2 2
deflection error is great.
Odo/trip meter does not

operate.
Speedometer and odo/trip meter G401

3 3 2 YEL or ORN
do not operate. G402
NOTE:
e NS speedometer circuit is built in the main print panel assembly.
e Replace all of the m ain print panel, the tachometer, the speedometer and the odo/trip meter as a set if one of the above parts
is detective.
16-121
Gauge Assembly
Speed Sensor Input Test------------------------------------------_,
NOTE: Check the No. 1 {1 O A) fu se in the dash fuse box 4. Check for voltage between the ORN terminal and body
befo re testing. ground with the ignition switch ON.
There should be approximately 5 V.
1. Disconnect the 3-P connector from the speed sensor. • lf there is no voltage, check for:
- A6 terminal of gauge assembly {see page 16-
115).
- An open in the ORN wire.
• lf there is approximately 5 V, go to step 5.
View from 5. lf all continuity and voltage tests are normal, but the
terminal side speedometer and the odo/trip meter do not operate,
replace the speed sensor.
SPEED SENSOR
2. Check for continuity between the BLK terminal and

body ground.
There should be continuity.
• lf there is no continuity, check for:
- An open in the BLK wire.
- Poor ground ( Fuel-injected engine: G301 )
Carbureted engine: G201
• lf there is continuity, go to step 3.
3. Check for voltage between the YEL terminal and body

ground with the ignition switch ON.
e lf there is no voltage, check for an open in the YEL
wire.
16-122
Replacement-----------.
1. Disconnect the 3-P connector from the speed sensor.
2. Remove the mounting bolts and the speed sensor from

the power steering speed sensor.
MOUNTING BOLTS
POWER
STEERING
SPEED SENSOR
3. lnstall in the reverse order of removal.
NOTE: Be careful not to loose the joint shaft, for it is

a tiny part.
16-123
Brake Warning System
Description------------. Parking Brake Switch Test----.
NOTE: Refer to page 16-112for wiring description of the 1. Remove the center console and disconnect the con-
circuit check system. nector from the switch.
Description: 2. There should be continuity between the positive termi-

The brake warning light goes on if the parking brake is nal and body ground with the brake lever up.
applied, if the brake fluid level is low, andas a circuit test There should be no continuity with the brake lever
while cranking the engine. down.
Parking Brake:
With the ignition switch in "Run"or "Start", and the parking
/ R A K E LEVER BODV GROUND
brake switch closed, the brake warning light operates to
remind the driver that the parking brake is applied. UP
Brake Fluid Level:

With the ignition switch in "Run"or"Start", and the brake
fluid level switch closed, the brake warning light operates to
warn the driver of low brake fluid level in the brake master
cylinder.
DOWN
NOTE: Low fluid level indicates brake wear or system leaks;
check brake pad wear before adding fluid.
Circuit Check: KV model only

With the ignition switch in "Start", voltage is applied through POSITIVE TERMINAL
the No.9 (7.5A) fuse in the dash fuse box to the circuit
check built into the integrated control unit. The circuit
check transistor is on, and current flows through the No.1
(1 OA) fuse in the dash fuse box, the brake warning light and
the circuit transistor to ground. The brake warning light
opera tes. This operation tests the brake warning circuit and
bulb.
Brake Fluid Level Switch Test----.
1. Remove the reservoir cap. Check that the float moves
up and down freely.
Replace the reservoir cap assembly if the float does not
m ove freely.
2. Check for continuity between the terminals with the

float up and down.
There should be continuity with the float down and no
continuity with the float up.
Replace the reservo ir cap assembly if necessary.
RESERVOIR CAP
1
MAGNET
~------- FLOAT
Switch contacts closed

when float drops.
Switch contacts open, at

proper fluid level.
16-124
Oil Pressure
Low Fuel Warning System Warning System
Warning Light Test Description-------------,
NOTE: Refer to page 1 6-112 for wiring description of NOTE: Refer to page 16-112 for wiring description ofthe oil
the low fuel warning circuit. pressure warning circuit.
1. Park car on level ground. With the engine running and normal oil pressure, the oil
pressure switch is open and the oil pressure warning light
P¡JIM.I;IfM!N Do not smoke while working on fuel does not operate. lf engine oil pressure fa lis below 24.5 kpa
system. Keep open flama away from work area. (0.25 kg/cm 2 , 3.6 psi), the oil pressure switch is closed,
Drain fuel only into an approved container. current flows through the oil pressure warning light and the
oil pressure switch to ground, and the oil pressure light goes
2. Orain fuel tan k into an approved container. on.
Then install the drain bolt with a new washer.
3. Add less than 8.6 t (2.2 U .S. Gal, 1 .S Imp. Gal} offuel
and turn the ignition switch on.
The low fuel warning light should come on within 4
minutes. Oil Pressure Switch Test-------.
4. Then add one more gallon of fuel [approx. 4 t (1 .1
U.S. Gal, 0.9 Imp. Gal)]. 1. Disconnect the YEL/RED wire from the oil pressure
The light should go out within 4 minutes. switch.
e lf the warning light did not come on in step 3, 2. There should be continuity between the positive termi-
remove the maintenance access cover and discon- nal and the engine(ground) with the engine stopped.
nect the 3-P connector from the fuer gauge sending There should be no continuity when the engine runs.
unit. Connect the A (GRN/RED) terminal to the C
(BLK) terminal with a jumper wire. OIL PRESSURE SWITCH
18 N·m (1.8 kg-m. 13 lb-ft)
1 /8 in. BSP {British Standard
- lf the light comes on, the problem is either the
Pipe Taperl 28 Threads/inch.
sending unit or its ground. Use proper liquid sealant.
- lf the light does not come on, the problem is an
open in the GRN/RED wire to the gauge assem-
bly, no power to the gauge or bad bulb.
FUEL GAUGE
SENDING UNIT
OIL FILTER
POSITWE TERMINAL
3. lf the switch fails to operate, check the engine oillevel,

then inspect the oil pump and pressure if the oíl level ís
correct (see section 5).
A lGRN/REDI
16-125
Fuel Gauge
GaugeTest----------~------------------------------------------~
NOTE: 3. eonnect the voltmeter positive probe to the B (YEL/

e Refer to page 1 6-112 for wiring description of the fuel WHT) terminal and the negative probe to the e (BLK)
gauge circuit. terminal, then turn the ignition switch ON.
e Check the No.1 (1 O A) fuse in the dash fuse box before There should be between 5 and 8V.
testing.
1 . Reinove the maintenance access cover. • lf the voltage is as specified, go to step 4.
2. Disconnect the 3-P connector from the fuel gauge • lf the voltage is not as specified, check for:
sending unit. - An open in the YEL, YEL/WHT or BLK wire.
- Poor ground (G401}.
4. Turn the ignition switch OFF. Attach a jumper wire

between the B (YEL/WHT} ande (BLK) terminals.

Check that the pointer of the fuel gauge starts moving
toward"F"mark.
CAUTION: Tum the ignition switch OFF before the

pointer reaches "F"mark on the gauge dial. Failure
to turn the ignition switch OFF before the pointer
reaches the "F" mark may cause damage to the fuel
gauge.
NOTE: The fuel gauge is a bobbin (cross coil} type.

hence the fuel level is continuously indicated even
when the ignition switch is OFF, and the pointer
moves more slowly than that of a bimetal type.
• lf the pointer of the fuel gauge does not swing at

all, replace the gauge.
• lnspect the fuel gauge sending unit if the gauge is

OK.
View from
terminal side
A {GRN/REO)
16-126
Sending Unit Test/Replacement-----------------~
D
IIIMJM!!.iioo not smoke while working on fuel sys- 4. Measure resistance between the A and B terminals atE
(EMPTY), 1/2 (HALF FULL) and F (FULL) by moving
tem. Keep open flama away from work area.
the flo_!:!t.
1. Remove the maintenance access cover.
2. With the ignition switch OFF, disconnect the 3-P ·¡ Float Position E 1/2 F
connector from the fuel gauge sending unit.
r Resistance (O) 105-110 25.5-39.5 2-5
3. Remove the fuel gauge sending unit.
FUEL SENDER WRENCH

07GAC-SE00200 A
FUEL GAUGE
SENDING UNIT
Float Position ® ® ©
121.5 mm 70.0 mm 17.0 mm
With 4WS
(4.8 in) (2.8 in) (0.7 in)
146.0 mm 80.0 mm 17.0 mm

Without4WS
(5.7 in) (3.1 in) (0.7 in)
5. lf unable to obtain the above readings, replace the fuel

gauge sending unit.
16-127
Coolant Temperatura Gauge
Gauge T e s t - - - - - - - - - - - - . SenderTest--------------------~
NOTE: 1. Disconnect the RED wire from the sender.

e Refer to page 16-112 for w1nng description of the
coolant temperature gauge circuit. 2. With the engine cold, use an ohmmeter to meas u re
e Check the No.1 (10 A) fuse in the dash fuse box befare resistance between the positive terminal and the
testing. engine (ground).
1. Make su re the ignition switch is OFF, then discon-

nect the RED wire from the coolant temperature gauge
sender and ground it with a jumper wire.
RED WIRE
3. Check the temperatura of the coolant.
RED WIRE
4. Run the engine and measure the change in resist-
ance with the engine at operating temperature (cool-
ing fan comes on).

Check that the pointer of the coolant temperature T emperature 56°C (133°F) 85°C (185°F)-
gauge starts moving toward "H" mark. ["C" mark] 100°C (212°FI
Resistance (n) 142 49-32

CAUTION: Turn the ignition switch OFF before the
pointer reaches "H" mark on the gauge dial. Failure
to turn the ignition OFF quickly enough may cause 5. lf obtained readings are substantially different from
damage to the gauge. specifications above, replace the gauge sender.
• lf the pointer of the gauge does not swing at all,

check for an open in the YEL or RED wire.
Replace the coolant temperature gauge if the

fuse and wiring are normal.
• lnspect the gauge sender if the gauge is OK.
16-128
Oil Pressure
Low Fuel Warning System Warning System
Warning Light Test Description-------------,
NOTE: Refer to page 1 6-112 for wiring description of NOTE: Refer to page 16-112 for wiring description ofthe oil
the low fuel warning circuit. pressure warning circuit.
1. Park car on level ground. With the engine running and normal oil pressure, the oil
pressure switch is open and the oil pressure warning light
P¡JIM.I;IfM!N Do not smoke while working on fuel does not operate. lf engine oil pressure fa lis below 24.5 kpa
system. Keep open flama away from work area. (0.25 kg/cm 2 , 3.6 psi), the oil pressure switch is closed,
Drain fuel only into an approved container. current flows through the oil pressure warning light and the
oil pressure switch to ground, and the oil pressure light goes
2. Orain fuel tan k into an approved container. on.
Then install the drain bolt with a new washer.
3. Add less than 8.6 t (2.2 U .S. Gal, 1 .S Imp. Gal} offuel
and turn the ignition switch on.
The low fuel warning light should come on within 4
minutes. Oil Pressure Switch Test-------.
4. Then add one more gallon of fuel [approx. 4 t (1 .1
U.S. Gal, 0.9 Imp. Gal)]. 1. Disconnect the YEL/RED wire from the oil pressure
The light should go out within 4 minutes. switch.
e lf the warning light did not come on in step 3, 2. There should be continuity between the positive termi-
remove the maintenance access cover and discon- nal and the engine(ground) with the engine stopped.
nect the 3-P connector from the fuer gauge sending There should be no continuity when the engine runs.
unit. Connect the A (GRN/RED) terminal to the C
(BLK) terminal with a jumper wire. OIL PRESSURE SWITCH
18 N·m (1.8 kg-m. 13 lb-ft)
1 /8 in. BSP {British Standard
- lf the light comes on, the problem is either the
Pipe Taperl 28 Threads/inch.
sending unit or its ground. Use proper liquid sealant.
- lf the light does not come on, the problem is an
open in the GRN/RED wire to the gauge assem-
bly, no power to the gauge or bad bulb.
FUEL GAUGE
SENDING UNIT
OIL FILTER
POSITWE TERMINAL
3. lf the switch fails to operate, check the engine oillevel,

then inspect the oil pump and pressure if the oíl level ís
correct (see section 5).
A lGRN/REDI
16-125
Fuel Gauge
GaugeTest----------~------------------------------------------~
NOTE: 3. eonnect the voltmeter positive probe to the B (YEL/

e Refer to page 1 6-112 for wiring description of the fuel WHT) terminal and the negative probe to the e (BLK)
gauge circuit. terminal, then turn the ignition switch ON.
e Check the No.1 (1 O A) fuse in the dash fuse box before There should be between 5 and 8V.
testing.
1 . Reinove the maintenance access cover. • lf the voltage is as specified, go to step 4.
2. Disconnect the 3-P connector from the fuel gauge • lf the voltage is not as specified, check for:
sending unit. - An open in the YEL, YEL/WHT or BLK wire.
- Poor ground (G401}.
4. Turn the ignition switch OFF. Attach a jumper wire

between the B (YEL/WHT} ande (BLK) terminals.

Check that the pointer of the fuel gauge starts moving
toward"F"mark.
CAUTION: Tum the ignition switch OFF before the

pointer reaches "F"mark on the gauge dial. Failure
to turn the ignition switch OFF before the pointer
reaches the "F" mark may cause damage to the fuel
gauge.
NOTE: The fuel gauge is a bobbin (cross coil} type.

hence the fuel level is continuously indicated even
when the ignition switch is OFF, and the pointer
moves more slowly than that of a bimetal type.
• lf the pointer of the fuel gauge does not swing at

all, replace the gauge.
• lnspect the fuel gauge sending unit if the gauge is

OK.
View from
terminal side
A {GRN/REO)
16-126
Sending Unit Test/Replacement-----------------~
D
IIIMJM!!.iioo not smoke while working on fuel sys- 4. Measure resistance between the A and B terminals atE
(EMPTY), 1/2 (HALF FULL) and F (FULL) by moving
tem. Keep open flama away from work area.
the flo_!:!t.
1. Remove the maintenance access cover.
2. With the ignition switch OFF, disconnect the 3-P ·¡ Float Position E 1/2 F
connector from the fuel gauge sending unit.
r Resistance (O) 105-110 25.5-39.5 2-5
3. Remove the fuel gauge sending unit.
FUEL SENDER WRENCH

07GAC-SE00200 A
FUEL GAUGE
SENDING UNIT
Float Position ® ® ©
121.5 mm 70.0 mm 17.0 mm
With 4WS
(4.8 in) (2.8 in) (0.7 in)
146.0 mm 80.0 mm 17.0 mm

Without4WS
(5.7 in) (3.1 in) (0.7 in)
5. lf unable to obtain the above readings, replace the fuel

gauge sending unit.
16-127
Coolant Temperatura Gauge
Gauge T e s t - - - - - - - - - - - - . SenderTest--------------------~
NOTE: 1. Disconnect the RED wire from the sender.

e Refer to page 16-112 for w1nng description of the
coolant temperature gauge circuit. 2. With the engine cold, use an ohmmeter to meas u re
e Check the No.1 (10 A) fuse in the dash fuse box befare resistance between the positive terminal and the
testing. engine (ground).
1. Make su re the ignition switch is OFF, then discon-

nect the RED wire from the coolant temperature gauge
sender and ground it with a jumper wire.
RED WIRE
3. Check the temperatura of the coolant.
RED WIRE
4. Run the engine and measure the change in resist-
ance with the engine at operating temperature (cool-
ing fan comes on).

Check that the pointer of the coolant temperature T emperature 56°C (133°F) 85°C (185°F)-
gauge starts moving toward "H" mark. ["C" mark] 100°C (212°FI
Resistance (n) 142 49-32

CAUTION: Turn the ignition switch OFF before the
pointer reaches "H" mark on the gauge dial. Failure
to turn the ignition OFF quickly enough may cause 5. lf obtained readings are substantially different from
damage to the gauge. specifications above, replace the gauge sender.
• lf the pointer of the gauge does not swing at all,

check for an open in the YEL or RED wire.
Replace the coolant temperature gauge if the

fuse and wiring are normal.
• lnspect the gauge sender if the gauge is OK.
16-128
Safety lndicator
SAFETY INDICATOR
• Troubleshooting, page 16-1 34
• Removal. page 16-120
• Input Test, page 16-133
• Bulb Replacement, page 16-11 8
HIGH MOUNT BRAKE LIGHT (KQ modell

DOME LIGHT Replacement, page 1 6-1 82
Removal page 16-174
BRAKE LIGHT SWITCH Test, page 16-174
Test, page 16-263
R.DOOR SWITCH
Pedal Height Adjustment,
section 13
L. OOOR SWITCH
Test, page 16-175 Test, page
L.BRAKE LIGHTS
Replacement, page 1 6-1 71
16-129
Safety lndicator
Circuit Diagrann--------------------------------------------------------
BA TTERY
t-----crv.>-+-------- WHT/YEL - - - - - - - - - - - - - - - WHT/YEL ------0

To page 16-131
W HTIYEL (Except KQ model)
?
lo page 16-132
WH~
(KQ model)
BA T IGNITION
IGI SWITCH • INTEGRA TED
CONTROL UNIT
(KG model only)
BLK/YEL
bDASH
~FllSEBOX
WHT/Blll YEL
A4 In tne GAUGE ASSEMBLY
....-6---------~
SAFETY INDICÁTOR CIRCUT(MAIN PRINT PANEL) 1
.!
B' DOME
.1.
LIGHT
BLK/W HT GRNIBLK ..
1
B21
1
B9 •
GANIBLK
L-
INTEGRA TED
CONTROL
UNIT
---a-:,.,.,
B1 o·-
GAN/RE01
820
GRN/BLU
82 2
GRN/WHT
819
GRN/YEL
87
WHTIGAN
88
BLK GAN
Y GeN/RED
GANIRE02
To page 16-131
¿
Except KO)
( modal
WHT/GAN
TRUNK To paga 16-132
LATCH (KQ model)
L.REAR
SWITCH DOOA
SWITCH
INTEGRATEO • BRA KE
CONTROL FLUID
urm LEVEL
(KG model onlyl SWITCH
• PARKING
~Mr~~ G401
G402
16-130
Except KQ model:
Description
Safety lndicator Warning System:
The warning lights are used to indicate when the trunk lid or
a door is not fully closed, or when a brake light is faulty.
The warning lights will remain ON for about 2 seconds after
the ignition switch has been turned ON to show that the
system circuit is functioning.
Brake Light Bulb Failure Warning:
lf all brake light bulbs are OK, the warning light stays off
because the WHT/GRN 2 wire is constantly being grounded
by the two brake light failure sensors connected in series.
With the brakes off, the ground is provided through the
diode, the failure sensor relay coils and bulb filaments to
ground. With the brake lights on, all 2 relays, (1 in the /eft
sensor, 1 in the right) connected in series, supply ground.
lf any of the 2 bulbs or either of L. brake lights and R. brake
lights are not working, the e ha in is broken and the WHT1
GRN 2 wíre ís not being grounded. The warning light comes
From paga
0 on.
Brake Líght Círcuit Failure Warning:
16-130
{ B
1
WHTIYEL
When the ignition switch is turned ON, the brake light
warning light stays on.
+¡w~t:
When the brake pedal is depressed once, the warning light
should go out.
lf there is defect in the brake system (blown fuse, faulty
brake light switch, open or short circuit and/or blown
bulb(s)), the brake light warning light stays on with the
WHT/GRN GRN/WHT brake pedal operated.
GRN/W HT--·~----GRNIW HT----"1~~-------~~

(Except KG model)
LTA!Lljc¿H~T'--+---.
GRN
R.TAILLIG_H_T _ _-t---ll
GRN/WHT GRN/WHT
~
• BAA KE LIGHT
for trailer : )
( Europian model only
• CR\JlSE CONTROL
UNIT
• A/T CONTROL UNIT
• ALB CONTROL UNIT
1 • INTEGRA TED CONTROL
1
UNIT
~FA~I~L~UR~E~-+------------~
(KG modal only)
FAILUREI
SENSOR
r---:---- - ., SENSOR
1 GRNIRED 1 •
1 ,.,-- 1
1
BR~KE
1 1
1 1
1 1 LIGHT
(21W)
BRAKE : BRAKE:
LIGHT 1 LIGHT 1
(21W) 1 (21W) 1
1 1
1 1
BlK. BLK 1 BLK J
1
..._...,...___
___.(____ BLK ¡ 1 __ ....¡
(KY ,KP,KT and KU modais only}
lBLK
.!
(cont'd)
G701
16-131
Safety lndicator
Circuit Diagram (cont'd)
KQ model: Description
Safety lndicator Warning System:

The warning lights are used to indicate when the trunk lid or
a door is not fully closed, or when a brake light is faulty.
The warning lights will rema in ON for about 2 seconds after
the ignition switch has been turned ON to show that the
system circuit is functioning.
Brake Light Bulb Failure Warning:

lf all brake light bulbs are OK, the warning light stays off
8 beca use the WHT/GRN 2 wire is constantly being grounded
From Page{ by the two brake light failure sensors connected in series.
16-130 0~----- .. With the brakes off, the ground is provided through the
diode, the failure sensor relay coils and bulb filaments to
1
WHT/YEL
ground. With the brake lights on, all 5 relays, (3 in the left
sensor, 2 in the ríght) connected in series, supply ground.
~ ¡~~~:
lf any of the 5 bulbs is not working, the chain is broken and
the WHT/GRN 2 wire is not being grounded. The warning
light comes on.
GRNIWHT WHT/GRN
~GRNIWHT------t-------------------------GRN/WHT------~
• CRUISE CONTROL GRN

UNIT
• A/T CONTROL
UNIT
=il
L.TAILUGHT R.TAilliGHT
- - - - = = - - - - + - - f - -~ ~o-~-----=--~-
• 1 1
1 1 '
: : 1
L-~------~--FA_I_l_U-RE--~------~----f------------1 1 1 L__
SENSOR~-- __ _j l_---1---:¡ FAILURE
SENSOR 1
GRNIBLU GRNIREO 1
BRAKE
r,~ME
{21W)
r,~Met :L
{21W)
BRAKE
LIGHT
{21W) --
J
t - - - - BLK GRNIYEl BLK
HIGH MOIJNT
BRAKE LIGHT
(27W)
I
G701
BLK
'
T
16-132
lndicator Input Test
Remove the gauge assembly from the dashboard to discon- 16-P CONNECTOR
nect the 1 0-P, 1 6-P and 22-P connectors from the indica-
ter.
Make the following input tests at the harness pins.
lf all tests prove OK, yet the indicator still fails to work, 10-P CONNECTOR
replace the main print panel, the tachometer, the speedom-
eter and the odo/trip meter as a set.
'------'--'--'-...c._¡l___,~l~=u
YEL BLK
No. Wire Test condition Test: desired result Possible cause {if result is not obtained)
Under all conditions. Check for continuity to ground: · Poor ground (G401, G402)
1 BLK
should be continuity. · An open in the wire.
lgnition switch ON. Check for voltage to ground: · Blown No.1 {10 A) fuse.
2 YEL
should be battery voltage. · An open in the wire.
Brake pedal pushed. Check for continuity to ground: · Blown No. 25 (20 A) fuse.
should be continuity with the pedal · Faulty brake light switch.
pushed. · Blown brake light bulbs.
3 WHT · Faulty brake light failure sensors.
1 • Poor ground (G701).
' · An open in the WHT/GRN or
GRN/WHT wire.
. Trunk lid opened. Check for continuity to ground: · Faulty trunk latch switch.
4 GRN/BLK
NOTE: Before testing, remove No.22
(15 A) fuse.
GRN/RED1 Right front door opened. Check for continuity to ground: · An open in the wire.
GRN/BLU Left front door opened. should be continuity. · Faulty door switch.
5 NOTE: Before testing, remove the No. · Poor installation of the switch.
GRN/WHT Right rear door opened. 22 (15 A) fuse.
¡GRN/YEL Left rear door opened.
!
! Dome light switch in
MIDDLE position.
Attach to ground: Dome light should
come on.
· Blown No.22 (15 A) fuse.
· Faulty dome light.
6 ''BLK/WHT
· An open in the WHT /BLU or 1
BLK/WHT wire.
lgnition switch ON. Attach to ground: Brake light warning · Faulty safety indicator circuit.
7 GRN/RED 2 in the safety indicator should come on. · Blown bulb.
· An open in the wire.
KG model only:
With brake pedal Check for continuity in both directions · Faulty brake light circuit failure sen-
released, ignition between the GRN and BLK terminals: sor.
switch OFF to ON. should be continuity in only one direc-
8 GRN
tion as the ignition switch is turned
ON, then no continuity in both direc-
tions with brake pedal pushed. 1
16-133
Safety lndicator
Troubleshooting--------------------------------------------------~
NOTE:
• The numbers in the table show the troubleshooting sequence.
e Make sure that the dome light bulb and the trunk light bulb are not blown up.
ltems to be inspected Q)
-
V t:
(/)
1 o;¡
::;, a.
e ....e
:¡:
o "§. o
' m e
·¡¡¡
Q)
(/)
o
..Q
É
..... o
(/)
"
o -¡¡¡(/)
·::; ..Q
e
Q) (/)
~ "3 (/) Q) .!:
·a ..Q ~
~ .:: E
~ .l:l 5: ....
2 .l:l
.9 .9
- - $
"§ 1
<( ·¡¡¡ "§ .!:
<( o;¡ «l (/)
(/) "O
1!) o o ~ "O
..... .l:l ~ ..... e ·::; $
::::::. o 'O 'O ~
.B ~ ::;, o
::::::. .S .S g "§ g o ~ Q)
N .!E o, ·a t:
~
o
~
o
e
~
e
5:
Q)
.:.t.
(/)
oo .:.t.
e
Q)
.:.t.
oo e o
e
a. o(/)
Q)
z o ~ :::¡
~
Symptom z lO
(/) m co o .= co a... O 'O
G401
No indicators operate. 1 2 YEL
G402
Warning lights fail to come on
when ignition switch is turned 1 2
to ON.
The indicator lights do not turn

on or sorne indicator lights 1 2
do not turn off.
Trunk warning light not lit

2 3 1 GRN/BLK
with trunk lid opened
GRN/RED 1
Door warning lights not lit GRN/BLU
2 3 1
with doors opened. GRN/WHT
1 GRN/YEL
GRN
Brake warning light not
2 1 WHT/GRN
lit with blown brake light bulb.
GRN/RED2
GRN
Brake warning light remains
2 1 WHT/GRN
on with good brake light bulbs.
GRN/RED 2
1
Dome light not operated with

door opened (When switch 1 3 2
position is in MIDDLE)
16-134
Brake Light Failure Sensor Test (Except KQ model)--------------.
1. First make sure the brake lights come on when the 4. Open the maintenance lid of the right taillight.
brake pedal is pressed. Make sure the lBRAKE LAMPl does not come on
when the ignition switch is turned OFF to ON with
• lf none of the brake lights come on, check the the GRN terminal of the 8-P connector grounded
brake light circuit (see page 16-180). and the brake pedal pressed.
e lf one of the brake lights does not come on, R.FAILURE SENSOR
check whether the bulb is blown. lf the bulb is
OK, go to step 2.
• lf all the b~ake lights come on, go to step 2.
2. Open the trunk lid and the maintenance lid of the

left taillight. Make su re the 1BRAKE LAMP l of the
safety indicator does not come on when the
WHT/GRN terminal of the 8-P connector is ground-
ed and the ignition switch is turned OFF to ON.
l. FAILURE SENSOR
View from wire side
• lf thel BRAKE LAMPl comes on, there is an open

in the GRN wire between the left failure sensor
and the right failure sensor.
• lf the 1BRAKE LAMPI does not come on, go to

step 5.
GRN MAINTENANCE LID
5. Make sure the 1BRAKE LAMP 1 does not come on
View from wire side
.when the ignition switch is turned OFF to ON with
the BLK terminal of the 8-P connector grounded
and the brake pedal pressed.
• lf the 1BRAKE LAMP 1comes on, check for an
open in the WHT/GRN wire between the safety • lf the 1 BRAKE LAMP 1 comes on, replace the
indicator and the left failure sensor and whether right failure sensor.
the safety indicator circuit (main print panel) has a
problem. • lf thel BRAKE LAMP 1 does not come on, check
for an open in the BLK wire between the right
• lf the 1BRAKE LAMP 1do es not come on, go to faiture sensor and ground, and check whether
step 3. the G701 terminal is poor.
3. Make sure thel BRAKE LAMPldoes not come on

when the ignition switch is turned OFF to ON with
the GRN terminal of the 8-P connector grounded
and the brake pedal pressed.
• lf the.l BRAKE LAMP lcomes on, replace the left

failure sensor.
• lf thel BRAKE LAMPl does not come on, go to

step 4.
16-135
Safety lndicator
Brake Light Failure Sensor Test (KQ m o d e l ) - - - - - - - - - - - - - - - -
1. First make sure the brake lights come on when the e lf the 1 BRAKE LAMP 1 comes on, check for an open
brake pedal is pressed. in the WHT/GRN wire between the safety indicator
and the right failure sensor and whether the safety
e lf none of the brake lights come on, check the brake indicator circuit (main print panel) has a problem.
light circuit (see page 1 6-1 81 ) .
e lf the ¡ BRAKE LAMP 1 does not come on, go to
e lf one of the brake lights does not come on, check step 3.
whether the bu lb is blown. lf the bulb is OK, go to
step 2. 3. !
Make sure the BRAKE LAMP 1 does not come on
when the ignition switch is turned OFF to ON with the
e lf all the brake lights come on, go to step 2. GRN terminal of the 8-P connector grounded and the
brake pedal pressed.
2. Open the trunk lid and the maintenance lid of the right
taillight. Make sure the 1 BRAKE LAMP 1 of the safety e lf the 1 BRAKE LAMP 1 comes on, replace the right
indícator does not come on when the WHT/GRN failure sensor.
terminal of the 8-P connector ís grounded and the
ignitíon switch is turned OFF to ON. e lf the 1 BRAKE LAMP 1 does not come on, go to
step 4.
4. Open the maintenance lid of the left taillight.

R.FAILURE SENSOR
Make sure the 1 BRAKE LAMP 1 does not come on
GRN terminal of the 8-P connector grounded and the
L. FAILURE SENSOR
MAINTENANCE UD
View from wire side
MAINTENANCE LID
View from wire side
16-136
• lf the 1 BRAKE LAMP 1 comes on, there is an open
in the GRN wire between the left failure sensor and
the right failure sensor.
• lf the 1 BRAKE LAMP 1 does not come on, go to

step 5.
5. Make sure the 1 BRAKE LAMP 1 does not come on

BLK terminal of the 8-P connector grounded and the
• lf the 1 BRAKE LAMP 1 comes on, replace the left

failure sensor.
• lf the 1 BRAKE LAMP 1 does not come on, check for

an open in the BLK wire between the left failure
sensor and ground, and check whether the G701
terminal is poor.
16-137
Shift. Lever Position 1ndicator
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - - - .
• GAUGE ASSEMBLY
Disassembly, page 16-118
• A/T CONTROL SYSTEM
See Automatic Transmission, section 9.
SHIFT LEVER POSITION

INDICATOR
Input Test, page 16-140
SHIFT POSITION
CONSOLE SWITCH
Test, page 16-142
See Automatic
Transmission,
See Automatic Transmission,
section 9
section 9
16-138
Circuit Diagram-------------------------------.
-§
UNDER-HOOD RELAY BOX IGNITION
BATTERY No.15 No.19
(80AJ (SOA)
+ l-+--<:l'""'\....ó---ó~~-+- WHT
1
B LK /Y EL
LIGHTING
y
SWITCH
AIT CONTROL
UNIT · ,
• PGM-FI ECU
v· .
• PGM-CARB.ECU
YEL 1 REOIBLK ~
• AIT CONTROL UNIT
in the GAUGE ASSEMBLY
1 ,-.----- - - - < > - - - - - - 0 - .

LT GRN, SHIFT LEVER POSITION INDICATOR DIMMING CIRCUIT
82~~---~-~---~·---~
yy
83 81 811 812 813 B16 817 A3 A9
AIT CONTROL UNIT
6RNIWHT GRN2 GRN/BLU LT GRN/WHT BLK RED
GRNIREO GRNIBLK GRM/YEl
~----1------1-----'--GRN/REO
LIGHTIN6 t---~--~~--~------------~----------.--GRN/BLK
SWITCH
t---~--~~------------._---------+--GRN/BLU--------~
V
REDIBLK
t----+--------------1----------~- GRN IY EL
t-------------+---------'1- LT
-----------...J
GRN/W HT------------...J
SHIFT 1 Without DASHLIGHT

POSITIDN1 04 BRIGHTNESS CONTROLLER
CONSOLEi
N 03 r---------,
A \ 1 1
LIGHT .... \ / 1
(1.4W) .... /
.... .... 1
.... 1
1
1
1
1
SHIFT POSITION 1
CONSOLE SWITCH 1
1
BLK 1
1
1
DASHLIGHT 1
BR16HTNESS 1
CONTROLLER 1
1
1
1
1
1
1
1
6401 G401 1
6402 G4021
"---------~
16-139
Shift Lever Position lndicator
lndicator Input Test-------------------------------------------------
Remove the gauge assembly from the dashboad and dis-
connect the 10-P, 16-P and 22-P connectors from the
gauge assembly. Make the following input tests at the
harness pins. lf all tests prove OK, yet the indicator still fails
to work, replace the main print panel, the tachometer, the
speedometer and the odo/trip meter as a set.
NOTE: Several different wires have the same color.
They have been given a number suffix to distinguish
them (for example GRN 1 and GRN 2 are not the same).
GAUGE ASSEMBLY 16-P CONNECTOR
10-P
CONNECTOR
J-ilh--~ ~~=~_g_,-,--m~
--J=::I
RED/BLK ~
BLK
View from wire side
16-140
Under all conditions. Check for continuity to ground: • Poor ground (G401, G402)
1 BLK
1 should be continuity. • An open in the wire.
lgnition switch ON. Check for voltage to ground: · Blown No.1 (1 O A) fuse.
2 YEL 1
' should be battery voltage. • An open in the wire.
GRN/WHT Shift lever position in P. · Faulty shift position console
switch
GRN/RED Shift lever position in A.
1
· Poor ground (G401, G402)
l GRN 2 Shift lever position in N. · An open in the wire.
Check for continuity to ground:
3 GRN/BLK Shift lever position in D4 ¡ should be continuity.
GRN/BLU Shift lever position in 03
GRN /YEw Shift lever position in 2.
1 LTGRN!WHT Shift lever position in 1 .
1
Lighting switch ON and Check for voltage between RED/BLK • Faulty dashlight brightness control
1 RED/BLK dashlight brightness and RED terminals: system.
4
and RED control knob on full should be battery voltage. · An open in the wire.
bright. 1
1 1
lgnition switch ON, Check for voltage to ground: • Faulty S switch. ¡
1
shift lever position in Da should be about 5 V. · Faulty shift position console switch.
1 5 GRN 1
or D4 and S switch ON. · Faulty A/T control system.
• An open in the wire.
lgnition switch ON, Check for voltage to ground: · Faulty S switch.
shift lever position in D3 should be battery voltage. • Faulty shift position console switch
6 YEL2
or D4 and S switch ON. 1
· Faulty A/T control system.
lgnition switch ON. Check for voltage to ground: • Faulty PGM-Fl ECU.
7 1 LT GRN should be about 5 V. · Faulty PGM-CARB. ECU.
16-141
Shift Lever Position lndicator
Shift Position Console Switch Test Shift Position Console ·switch----.
Replacement
1. Remove the console, then disconnect the 12-P and
2-P connectors from the console switch.
1. Remove the console, then disconnect the 12-P and
2. Check for continuity between the terminals in each 2-P connectors from the con so le switch.
position according to the table.
2. Remove the 2 console switch mounting bolts.
NOTE:
e Move the rever back and forth without touching the
push button at each position, and check for conti-
nuity within a range of free play of the shift rever.
e lf no continuity within a range of free play, adjust
the installation position of console switch.
CONSOLE SWITCH
CONSOLE SWITCH
Shift Position Consola Switch

3. Position the switch slider to "Neutral" as shown above.
r'\ Terminal
8 1 2 3 4 5 6 7 11
Position \
4. Shift the select lever to "Neutral", then slip the console
1 o -o switch into position.
2 o "'-" -o
1 Os o "'--" -o 5. Attach the switch with the 2 bolts.
04 o- f--0 -o i
6. Test the console switch with P and N position of shift
N o -o i rever (see page 16-142).
R o 1 -o 1
p o -o NOTE: The engine should start when the shift lever is

in the N position in the range of free play.
Back-up Neutral
light Switch Safety Switch 7. Connect the 12-P and 2-P connectors, clamp the
Terminal
ha.rness and install the consofe.
1\ 9 10 13 14
Position \
1
2
03
04
N o- t--o
R o- kJ
p o- K>
16-142
lntegrated Control Unit
Circuit Diagram (Without Daytime and Dim-Dip L i g h t ) - - - - - - - - - - - .
Description:
A multi-functíon control unit located on the driver's side kíck panel, integrates the functions of the combinad operation with
wiper/washer circuit, líght-on warning circuit, entry light timer circuit, seat belt reminder circuit (KY model only) and brake light
circuit (KG model only) onto one circuít board sharíng common círcuít functions.
NOTE: Severa! different wires have the same color. They have been given a number suffix to distinguish them (for example
GRN 1 and GRN2 are not the same).
UNnER-HOOD RaAY BOX DASH FUSE BOX

BATTERY No.15(80A) No.19(50A) ~ No.1(10A)
~-+~~7'-0--.--<"J>-----+---WHí~BLK/YEP-------~~~~~~---.
No.22(15AI
interna! connection
INTERM ITTENT REDIGRN

WIPER RELAY
WINDSHIELD SA FEíY !NO !CA TOR
WIPER/WASHER CIRCl!IT
SWITCH in the ¡¡auge)
( assem bly
WfHTIBL~GNITION W~HT/Bll!fYH SEAT
~
,.----A--..
.I,I
KEY BEL T
'YT
UGHT REM INDER
UGHTJNG LIGHT
(l.4W) (1.4W)
BLKIY EL SWITCH
IGNITION
KEY 1
SWITCH
BLKdYEL GRNIRED WHTIBLU BLUIWHT2
'\17 GRN
1 WHTIBLK VEl/RED WHTIYEL GRN2
B6
BEEPER
89 B5
A8
(A11 : KY _:n_!ldel) A13 A1_2_ __
--+---,
Al A6 A2
COM BINED OPERATION SEAT BELT BRAKE FAILUAE

WIPER WASHEA LlGHT-ON ENTRY LIGHT REMINDER CIRCUIT SENSOR CIRCUIT
WARNING CJRCUIT TIM ER CIRCUIT
.
'
CIRCl!IT (KY model only) (KG model ontv)
L __ --+-
83
----+-----t--..,__--+-4~-----'
Al4 A3
-+--_j
A5
Bl INTEGRA TED BS
CONTROL UNIT
BRAKE
LIGHT
SWITCH
BLU/W HT 1
~ BlU/WHT'
GANIBLU
[GRNIRED]
REDIBLU
ORN V GRNIWHT
LGRN/WHT_j
[ ] : RHD
DA IV ER'S
7
DRIVER' S
SEAT
INTERM lfTENT 1 DOOR
SWITCH BELT
SWITCH
CHJME
WIPER PELA Y
WINDSHIELD
WIPER MOTOR
I
G401
I I
G502 6401
G402 G402
16-143
KQ and KV models: Except KQ and KY models:
ORN WHT/YEL GRN
View from
terminal side GRN/WHT WHT/BLK
YEL/RED WHT/GRN
View from wire side View from wire side
Wiper System:
No. Terminal Test condition Test: desired result Possible cause (if result is not obtainedl
1
1 H
should be continuity.
;
lgnition switch ON and Check for voltage to ground: · Blown No.6 (30 A) fuse.
2 e wiper switch 1NT. should be battery voltage. · Faulty wiper switch.
1
lgnition switch ON and ! Check for voltage to ground: · Blown No.6 (30 Al fuse.
3 D washer switch ON. should be battery voltage. • Faulty washer switch.
1
lgnition switch ON. Check for voltage to ground: · Blown No.6 {30 Al fuse.
4 1
Wiper switch LO. Check for continuity to ground: · Faulty wiper switch.
5 J should be continuity. · An open in the wire.
· Poor ground (G401, G402).
1
Light-on Warning System:

No. Terminal Test condition Test: desired result Possible cause (if result is not obtainedl
Under all conditions. Check for continuity to ground: · Poor ground (G401, G402}
1 H
Lighting switch ON. Check for voltage to ground: · Blown No.23 (15 A) fuse.
2 M should be battery voltage. · Faulty líghtíng switch.
lgnition switch ON. Check for voltage to ground: · Blown No.1 (10 A) fuse.
3 B
should be battery voltage. • Faulty dash fuse box.
1 j
Driver's door opened. Check for continuity to ground: · Faulty driver's door switch. 1
4 A
NOTE: Befare testing, remove No.1
! (10 A) fuse.
1
(cont'd)
16-145
Input Test (Without Daytime and Dim-Dip Light, cont'd)
KQ and KV models: Except KO and KV models:
ORN
WHT/YEL GRN
~~
lR:fl!-=T-=t~~ View from
HIJKLMN terminal side GRN/WHT WHT/BLK
WHT/GRN
View from wire side
View from wire side
Entry Light Timer Svstem:

Terminal
No. or Wíre Test condition Test: desired result Possible cause (if result is not obtained)
Under all conditions. Check for continuity to ground: · · • Poor ground (G401 , G402)
1 H
Under all conditions. Check for voltage to ground: · Blown No.22 (15 Al fuse.
2 L
Under all conditions. Check ignition key light operation: · Blown bulb
3 WHT/BLK connect the WHT/BLK terminal to the · An open in the wire.
H terminal.
Driver's door opened. Check for continuity to ground: · Faulty drivers door switch.
A
4 1 NOTE: Befare testing, remove No.1
¡ ¡ (10 Al fuse.
Seat Belt Reminder System (KV model only):

Terminal
No. or Wire Test condition Test: desired result Possible cause (if result is not obtained)
1 H
lgnition switch ON. Check for voltage to ground: 1 · Blown No.1 110 A) fuse.
2 YEL!RED
lgnition switch turned Check for voltage to ground: · Faulty ignition key switch.
3 BLU/WHT form "W to "O" posi- should be battery voltage. · An open in the wire.
tion.
Driver's seat belt is not Check for continuity to ground: · Faulty seat belt switch.
4 RED/BLU buckled. should be continuity. • Poor ground (G502).
i 1
lgnition switch ON and Check chime operation: Chime should · Faulty chime.
5 ORN connect the B terminal actívate each time the battery is con- • An open in the wire.
to the ORN terminal. nected.
1 1
16-146
KQ and KV models: Except KQ and KV models:
WHT/VEL GRN
View from
terminal side GRN/WHT WHT/BLK
WHT/GRN
View from wire síde
View from wire side
Brake Light System (KG model only):

Terminal
1 H
Under all conditíons. ! Check for continuíty to ground: · Poor ground (G401, G402)
1 should be contínuíty. · An open in the wíre.
U nder all conditions. Check for voltage to ground: · Blown No.25 (20 A) fuse.
¡ 2 WHT/YEL
Brake pedal pushed. Check for continuity to ground: · Faulty faílure sensor.
1
3 WHT/GRN should be continuity · An open in the wire.
1
1 · Poor ground (G701)
lgnition switch ON. Attach to ground: Brake indicator light • Faulty safety indícator (in the gauge
4 GRN in the safety indicator should come assembly}.
on. · An open in the wire.
Brake pedal pushed. Check for voltage to ground: · Faulty brake light switch.
51GRN/WHT Brake pedal released. Check for continuity to ground: · Poor ground (G701)
16-147
Circuit Diagram (With Daytime L i g h t ) 1 - - - - - - - - - - - - - - - -
Description:
A multi-function control unit located on the left side kick panel, integrates the functions of the combined operation with wiper/
washer circuit, light-on warning circuit, entry light timer circuit and daytime running light relay onto one circuit board, sharing
common circuit functions.
NOTE: Severa( different wires have the same color. They have been given a number suffix to distinguish them (for example
RED/BLK 1 and RED/BLK 2 are not the same).
UNDER-HOOD RELA Y BOX IGNITION OASH FUSE BOX

BA TTERY SWITCH
No.15(80A) No.19(50A) ~ No.10(7.5A)
+ l--+-<r'-.J.>-....No.23(15A)
"J'\.....J:>--+--WHT - - - - - - - - - - - - -
BAT IG2
YEL --1--=Í'
~:>---+--REDIGAN------------. IGl BLKIY EL
No.t
(1 OAJ
(interna! connection)
INTERM ITTENT
WIPER RELAY
DIMMEA
REDIG RN RE LAY
WINDSHIELD
L~H ~
WIPER/W A SH ER WHT/BLU
SWITCH
IGNITION
\(
BLKIY EL
LIGHTING
SWITCH
KEY
LIGHT
(1 .4W)
'11' RED/BLU
BLKn
\7 BlKIYEl GRN GRN/RED REOIBLK WHT/BLU WHTIBLK
REDIBLU
REDIGAN BLU/REO Y El/REO
WINDSHfELO
WASHER MOTOR
B11 B10 B2 86 B9 85 AS Al A7 A3 A2
----~ ----~ --~--
8EEPER
COM BINED OPERATION LIGHT -ON ENTAY UGHT

WIPER WASHER WARNING CIRCUIT DAYTIME RUNNING LIGHT AELAY
TIMER CIRCUIT
CIRCUIT
___ _j
BLUIW HT GRNIBLU YEL

RED!YELl
~ t'""
BlU/W HT
DRIVER' S REDIBLK
~
OOOR
SWITCH
INTERM ITTENT DIMMER
WIPER RELAY SWITCH
BLK
WINOSHIELO
WIPER MOTOR 1 FRONT
POSITION LIGHTS
• TAILUGHTS
• UCENSE PLATE
LIGHTS
• TRAILER
G401
G402
16-148
Description:
A multi-function control unit located on the right side kick panel, integrates the functions of the combined operation with wiper/
washer circuit, light-on warning circuit, entry light timer circuit and dim-dip relay circuit onto one circuit board, sharing common
circuit functions.
UNDER-HOOD RELAY BOX . DA SH FUSE BOX

BA TTERY No.15(80A) No.19(50A) flo.10(7.5A)
~~~~~~~~~~~--~----WHT---------------------~YE
flo.35(10A) BAT IG2
'-..(>---+-- BLU /Y EL----------~ IG1 8 LKIY EL --1--.,
No.1
(1 OA)
(inlernal conneclion)
INTERM ITTHH REDIGAN LIGHTING DIMMER

WIPER RELA Y RELAY RELA Y
yy
WINDSHIELD
WIPERIWASHER LIGHTING
SWITCH SWITCH
~ r-'-----,
WHTIBLU
.YElY t
IGNITION
LIGHTING KEY
SWITCH LIGHT .
B~L
c--t BLK/YEL
GRN
GRN/RED REDIBLK WHTIBLU WHTIBLK
f1.4W)
BLUIYEL BLU/RED RED.IBLU

BLUIRED REDIBLU
YEL/RED
WINDSHIELD
WASHER MOTOR 811 B10 82 86 B9 85 AS Al A3 A4 A2
BEEPER
COM BINED OPERA TI ON

WIPER WASHER LIGHT-ON ENTRY LIGHT DIM-DIP RELAY CIRCUIT
CIRCUIT WARNING CIRCU IT TIM ER CIRCUIT
'
L______ 83------~--------~--------------~----~----------~----;-
81
INTEGRA TED BB A6 AS
CONTROL UNIT
BLUIW HT
~ BLUIWHT
GRNIRED YEL WHT
~
~
DRIVER'S
1 DOOR
~
INTERMITTENT SWITCH DIMMER
WIPER PELA Y SWITCH
WINDSHIELD DIM-DIP
WIPER MOTOR RESISTO A
I
G401
G402
16-149
Input Test (With Daytime and Dim-Dip L i g h t ) - - - - - - - - - - - - -
Remove the driver's side kick panel cover then disconnect
the 8-P connector from the integrated control unit.
Remove the integrated control unit from the dash fuse box.
Make the following input tests at the harness pins. lf all ·

tests prove OK, yet the system still fails to work, replace the
control unit.
NOTE: Do not disconnect all of the connectors on the

dash fuse box except the integrated control unit.
KE model only
wire side
DASH FUSE BOX
INTEGRATED
CONTROL UNIT
16-150
KE modal: Excapt KE modal:
YEL/RED YEL/RED
View from
terminal side
WHT WHT/BLK BLU/RED
Wiper System:
No. Terminal Test condition Test: desired result Possible cause (if result is not obtained)
Under all conditions. Check for continuity to ground: · Poor ground {G401, G402)
1 H should be continuity.
lgnition switch ON and Check for voltage to ground: • Blown No.6 (30 Al fuse.
2 e wiper switch INT. should be battery voltage. • Faulty wiper switch.
lgnition switch ON and Check for voltage to ground: · Blown No.6 (30 A) fuse.
3 D washer switch ON. should be battery voltage. • Faulty washer switch.
J · An open in the wire.
lgnition switch ON. Check for voltage to ground: 1 · Blown No.6 (30 A) fuse.
4 1
1
1
Wiper switch LO. Check for continuity to ground: · Faulty wiper switch.
5 J should be continuity. • An open in the wire.
1 · Poor ground (G401, G402).
1
light-on Warning System:

1 Under all conditions. Check for continuity to ground: · Poor ground (G401, G402)
1 H
Lighting switch ON. Check for voltage to ground: · Blown No.23 (15 A) fuse. !
2 M should be battery voltage. · Faulty lighting switch.
1
j • An open in the wire.
lgnition switch ON. Check for voltage to ground: · Blown No.1 (10 A) fuse.
3 B
should be battery voltage. · Faulty dash fuse box.
Driver's door opened. Check for continuity to ground: · Faulty drivers door switch. 1
4 A
(10 A) fuse.
1 1
(cont'd)
16-151
Input Test (With Daytime and Dim-Dip Light, c o n t ' d ) - - - - - - - - -
KE model: Except K E model:
YEL/REO
BLU/YEL + BLU/REO
View from
terminal side
~[~TIBLK
RED/BLU YEL
View from wíre side View from wire side
Entry Light Timer System:

Terminal
i Under all conditions. 1 Check for continuity to ground: 1 · Poor ground (G401. G402)
1 H 1
\ should be continuity. • An open in the wire.
2 L
Under all conditions. ¡ Check for voltage to ground:
should be battery voltage.
Under all conditions Check ignition key light operation: · Blown bulb.
3 WHT/BLKI ! connect the WHT /BLK terminal to the
H terminal.
1
1 Driver's door opened. Check for continuity to ground: · Faulty driver's door switch.
4 A ! 1 should be continuity. · An open in the wire.
1
1 1 1 (10 A) fuse.
Daytime Running Light System (Except KE model):

Terminal
Under all conditions. Check for continuity to ground: • Poor ground (G401. 402)
1 H
1 should be continuity. • An open in the wíre.
Under all conditíons. Check for voltage to ground: · Blown No.23 (15 A) fuse.
2 ¡REDIGAN!
Líghting switch ~ Check for voltage to ground: · Faulty lighting switch.
BLU/RED
should be battery voltage. · Faulty lighting reiay.
3 and
• Faulty dimmer relay.
M
1
Passing switch ON. 1 Check for voltage to ground: · Faulty lighting switch.
4 IRED/BlU should be battery voltage. · Faulty lighting relay.
lgnition switch ON. Check for voltage to ground: · Blown No.10 (7.5 A) fuse.
5 YELíRED should be battery voltage. · Fault dash fuse box.
i · An open in the wire.
Connect the REDIGAN Front posítion lights, taillights and · Blown bulbs.
6 N terminal to the N termi- license plate lights should come on. • An open in the wire.
¡ na l.
1
7 ¡ YEL
1
Dímmer switch Hl. Check for continuity to ground:
· Faulty lighting switch.
• Poor ground (G251).
16-152
KE model: Except KE model:
BLU/¡EL
YEL/RED
~ BLU/RED RED/\RN ¡
YEL/RED
RED/BLU
RED/~ ~T/BLK
View from
terminal side
WHT WHT/BLK BLU/RED

Dim-Dip Headlight System (KE model):

Terminal
1 H
1 Under all conditions. Check for voltage to ground: · Blown No.35 {10 A) fuse.
2 BLU/YELI !
' lgnition switch ON.

should be battery voltage.
Check for voltage to ground:
· Blown No.10 (7.5 A) fuse.
3 YEL/RED should be battery voltage. · Faulty dash fuse box.
Lighting switch ~ Check for voltage to ground: • Faulty lighting switch.
BLU/RED should be battery voltage. · Faulty lighting relay.
4 and · Faulty dimmer relay.
M
! · An open in the wire.
Lighting switch ~ Check for voltage to ground: · Faulty Dim-Dip resistor.

should be battery voltage. · Blown No.37 (20 A) fuse.
5 WHT · Blown No.38 (20 A) fuse.
· Faulty lighting relay.
_1 · An open in the wire.
Passing switch ON. Check for voltage to ground: · Faulty lighting switch.
6 RED/BLU should be battery voltage. ¡ · Faulty lighting relay.
1 ! · An open in the wire.
Dimmer switch Hl. Check for continuity to ground: · Faulty lighting switch.
7 YEL
should be continuity. • Poor ground (G251) 1
16-153
Light-on Warning System Entry Light Timer System
Description-------------, Description------------.
NOTE: Refer to page 1 6-143, 1 6-148 or 1 6-149 for wiring NOTE: Refer to page 16-143, 16-148 or 16-149 for wiring
description of the light-on warning circuit, and page 16- description of the entry light timer circuit, and page 16-146
145 or 16-1 51 for the input test of the warning circuit. or 16-152 for the input test of the timer circuit.
When the light on, voltage is applíed to the warning circuit lf the driver's door has been opened, the ignition key líght
on the integrated control unit. goes on and stays on for about 8 seconds after the driver's
When you open the drivers door. the warning circuit door is closed.
senses ground through closed door switch.
With voltage at the "86" terminal, ground at the "88"
terminal, the beeper is activated to remind the driver to turn
off the lights.
lgnition Key Light Replacement

1. Remove the steering wheel and the steering column
covers.
2. Remove the bulb/socket from the key light case by

turning the socket 45°.
e Ooor switch test: Se e page 16-1 7 5.
16-154
Seat Belt Reminder System (KV model only)
Description - - - - - - - - - - - - - , Chime T e s t - - - - - - - - - - - .
NOTE: Refer to page 1 6-11 2 for wiring description of the 1. Remove the left side kick panel and disconnect the 2-P
seat belt reminder circuit. connector from the main wire harne·ss.
. With the ignition switch in "Run" or "Start", voltage is 2. Test chime operation by connecting battery positive to
applied to the reminder of the integrated control unit. the ORN terminal, and negative to the BLK terminal,
When you unbuckle the driver's seat belt, the reminder and cycling the power on-off repeatedly.
circuit senses ground at the "A 14" terminal. With voltage at
the "89" terminal and ground at the "B 1" terminal, the seat 3. lf the chime fails to sound every time power is cycled,
belt reminder chime sounds and the timer contacts clase replace it.
and open. This causes the seat belt reminder light to flash
on and off. After 5 seconds the chime stops and the
contacts remain open.
Seat Belt Switch Test
1. Slide the drivers seat forward until the seat belt center
anchor bolt is accessible, to disconnect the 2-P con-
nector from the seat belt switch.
2. There should be continuity between the A and B termi-

nals when the driver's seat belt is not buckled.
There should be no continuity when the driver's seat
belt is buckled.
ORN
~
View from wire side
CENTER
ANCHOR
terminal side
16-155
Lighting System
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - - - - - .
e CIRCUIT DIAGRAM
• KF, KG, KB and KX models, page 16-157
• KY, KQ, KP and KT models, page 16-158
• With DAYTIME LIGHT, page 16-159 INTEGRATED CONTROL UNIT
• With DIM-DIP LIGHT, page 16-160 • DAYTIME RUNNING
• Headlight adjuster, page 16-1 61 LIGHT RELAY (KS and KW models)
• DIM-DIP RELAY (KE model)
HIGH BEAM
INDICATOR LIGHT
(in the gauge assembly)
Gauge Assembly, page 1 6-11 2
LIGHTING SWITCH
HEADLIGHT
ADJUSTER
SWITCH HEADLIGHT ADJUSTER UNIT
Test, page 16-166 (KG model)
Removal, page 16-166 Input Test, page 16-165
REAR FOG LIGHT

SWITCH
Test, page 16-165
Removal, page 1 6-164
Adjustment, page 16-1 69

LIGHTING RELAY
Test, page 16-168

(located in the engine room, right side)
16-156
Circuit Diagram {With Daytime Light)-:-------------------,
UNDER-HOOD REtA Y BOX
BATTEAY . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . . ,
No.15(80A) No.23{15A)
LIGHTING
RELAY
DIMMEA
AELAY
REDIYEl REDIGAN REDIGAN REDIBLU
l.
HEADLIGHT
- REDIGAN
R.
HEADLIGHT
RED/BLU BLU/RED RED REDIGAN
©<J D GD e~
HIGH BEAM
INDICATOR f--
3
LO Hl
LIGHT
{1.4W)
Hl
-
LO
{55W) (65W) (65W) {55W)
No.IO
{7 .5A)FUSE
Y'"""J
YELtED BLUtED l Vr1
miBLu Y~L LIGHTING RED/BLU
SWITCH
BLUIRED RED REDIG RN
PASSING
) 4:J- _:e-) )
DA YTIME RUNNING LIGHT RELA Y Hl' LO
(in the integrated control unit)
;Dl':~:~FF~ Ób t~
L RED/BLK
.
RED~BLK REDIBLK
RED ~~El
RJYEL
REAR
FOG SWITCH D
\7
Q~DICATOR f,
REDIYEL • OASHLIGHTS
• OASHLIGHT
~
f
REDIBLK 0D LIGHT
BRIGHTNESS
CONTROLLER
• INTEGRA TED
CONTROL UNIT
FRONT
\7
• TAILLIGHTS
PO SITIO N • LICENSE PLATE
(0.84W)
B E
REDIGAN
(0.91W)
A
• SHIFT LEVER
PO SITIO N
CONSOLE llGHT
• CIGAR BOX LIGHT
(4WS)
~'
LIGHTS LIGHTS -------~
• TRAILEA ~ 1 1
1
L. ----, 1Without
EA R 1 10ASHUGHT
~~T RED
1 ]K 1 BRIGHTNESS
¿ :1:
REDIGAN 1 1CONTROllE
BLK BLK 21W) 1 1
BLK BLK BLK
.D..
1 l G201 G401
TRA llER OASHLIGHT
G701 BRIG HT NESS
: -::
1 G40 1 :
1
G251
G301 G401 G402 CONTROLLH\ 1 G402 1
G402 '---~
16-159
Headlights
Adjustment----------------------------------------------------~
Outside Headlight Adjustment: Outside headlight:

Adjust the points A and B. (Except KG model)
KG modal only: ADJUSTIIIÍG POINT A
1. Adjust the outside headlight with "O" position of

headlight adjuster switch.
2. Check the dip of beam in each position of the headlight

adjuster switch, after outside headlight adjustment.
lnside Headlight Adjustment:

Adjust the points C and O.
NOTE: Adjust the headlights to local requirements.
(KG model only)
ADJUSTING ADJUSTING
ADJUSTING POINT A
POINT D POINT A
ADJUSTING POINT e ADJUSTING

POINT B
ADJUSTING
POINT B
HEADLIGHT ADJUSTER
UNIT
lnside headlight:
ADJUSTING
POINT e
16-169
Headlights
Replacernent---------------------------------------------------------
CAUTION:
• Halogen headlights can become very hot in use; do
not touch them or the attaching hardware immediate-
ly after they have been turned off.
e Do not try to replace or clean the headlights with the

lights on.
1. Disconnect the 3-P connectors from behind the unit.

Befare disconnecting right side connector, remove the
l;>attery and coolant reservoir.
2. Re.move the rubber boot from behind the light by

pulling the tab.
3. Unhook the retaining spring and remove the bulb.
4. Remove the screw and front position light, then dis-

connect the 2-P connector.
5. Remove the front grille and front bumper.
6. Remove the 5 mount bolts, then remove the unit.
7. After installing the unit, adjust the headlights to local

requirements.
16-170
Taillights
Replacernent----------------------------------------------------~
Trunk side: lid side:

1 . Open the trunk lid and remove the trunk paneL 1 . Open the trunk lid and remove the trunk panel.
2. Disconnect the 8-P connector from the trunkside tail- 2. Disconnect the 4-P connector from the lidside taillight
light. [Built in the rear fog light (Oíiver's side)].
3. Remove the 4 rriount nuts and the taillight. 3. Remove the 4 mount nuts and the lidside taillight.
TAILLIGHT NEWGASKET
[Built in the rear fog
light (Driver's side)]
4. lnspect the gasket; replace if it is distorted or overly 4. lnspect the gasket; replace if it is distorted or overly
compressed. compressed.
5. Make sure that there is no water leakage in the tail- 5. Make sure that there is no water leakage in the tail-
lights, after installing the taillights. lights, after installing the taillights.
16-171
Front Turn Signal Lights Front Position Lights
Replacement-----------. Replacernent------------------~
1. Aemove the screw and the front turn signallight, then 1. Remove the screw and pull out the front positíon light
disconnect the 2-P connector. from the stay, then disconnect the 2-P connector.
2-P
CONNECTOR
2. Turn the bulb 45° counterclockwise to remove it from 2. Turn the bulb 45° counterclockwise to remove it from
th~ housing. the front position light.
16-172
License Plate Lights Glove Box Light
Replacement---------..., Test----------------------------~
1. Remove the 2 screws from the trunk lid and discon- 1. Open the glove box.
nect the 2-P connector, then remove the license plate
light. 2. Disconnect the 2-P connector from the light.
2. Remove the cover from the license plate light, then

3. There should be continuity between the A and B
remove it from the housing.
terminals with a bulb installed.
BULB (5 W)
HOUSING
HOUSING
From LIGHTING SWITCH
B
To GROUND
16-173
Dome Light
Test----------------------------------------------------------~
1. Turn the light switch OFF. With Sunroof:
2. Pry off the lens.
3. Remove the nuts or screws and the housing.
4. Disconnect the 3-P connector from the housing.
Without Sunroof:
5. Remove the dome light.
6. Check for continuity between the terminals in ea eh

switch position according to the table.
From No.22 (15 A) FUSE
o
\ Terminal
A B or B" e o
Position \ (8 W)
OFF o mv.
~ -o
MIDO LE o =
'V D
ON ·o ""'
'V D
OFF
To DOOR SWITCH
with Sunroof: RHD: G401, G402

LHD: G501, G502
without Sunroof: At MOUNTING NUT
16-174
Courtesy Lights and Door Switches
Courtesy Light Replacement ---...., Door Switch Test
NOTE: The bulb or lens alone can be replaced 1. Open the door.
without having to remove the door tri m panel.
2. Remove the screw and pull out the door switch.
1. Remove the door tri m panel.
3. Disconnect the 1-P CONNECTOR from the switch.
2. Remove the 2 screws and the retainer plate to
remove the light from the door trim panel.
RETAINER
TV
.,.
CLOSE
(OFF)
POSITIVE
TERMINAL
From No.22 (15 A) FÚSE 4. There should be continuity between the positive
terminal and base plate (ground) with the switch
released (door opened).
There should be no continuity with the switch
pushed (door closed).
To DOOR SWITCH
16-175
Trunk Light and Latch Switch
Trunk Light Replacement/Test-----. Latch Switch Test/Replacement
1. Pry off the trunk light lens from the housing. 1. Open the trunk lid and disconnect the 2-P connector
from the trunk latch.
2. Pry off the light assembly.
2. There should be continuity between the A and B termi-
3. Disconnect the 3-P connector from the housing. nals .
.-.---BULB {3.4 W)
LENS
TRUNK LATCH
4. Make sure that the bulb is in good condition.
Check for continuity between the A(+) and B(-) 3. lf necessary,remove the 3 bolts to pull out the latch
terminals. from the trunk lid, then disconnect the lock rod from
the latch.
NOTE: Do not connect the tester probes in the wrong
polarity because there is a diode inside the trunk light. 4. Disconnect the trunk opener cable from the latch.
A~B
i+lfo ojc-l
To TRUNK LATCH (3.4W)

From No.22 (15 A)
SWITCH FUSE
A(+)
1
TRUNK LATCH
16-176
Back-up Lights
Circuit D i a g r a m : - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
BATTERY
UNOER-HOOO RELAY BOX
No.15
(80A) {50A)
No.19
+ 1----!f--:'J"....J>--ofJ""'-..(:-+--- WHT
--&
1 B EL-
IGNITION
SWITCH
LK/Y
No.l OASH
~ {1 OA) FUSE
BOX
(AIT)
r---------- --------1r--------------YEL--------------·----------, r-------
{M IT)
Wl~
1 1
1 1
1 1
1
1
l
1 "'" :ARN6S {
1
1
1
1
1 YEL
1
1
1 YEL
1 BACK-UP
1 SHlFT POSITION LIGHT
1 CONSOLE SWITCH MAIN WIRE HARNESS ENGINE WIRE HARNESS SWITCH
1 (BACK-UP LIGHT) on the
1 SWITCH transm ission)
1 ( case
1 GRN/BLK
1
1
1
1
GRNIBLK
1
1
1
1
1
1 MAIN WIRE HARNESS GRN/BLK
t
1
1
1
1
1
1
1
1
1
1
1
1 GRNrK } FLOOR WIRE HARNESS FLOOR WIRE HARNESS { GRNIBLK
1
r
1
1
1 1
1 1 1
1
1
L-------------------J
1
1
GRN/BlK
L-----------------J
GRN
F1
~
V
lor traíler :
( Europian model onty
)
BLK
_l
-:-
BACK-UP
UGHTS
(21Wx2)
REAR WIRE HARNESS
G701
16-178
Test----------------------------------------------------------.
Manual Transmission: Automatic T ransmíssion:
NOTE: Check the No.1 {1 O A) fuse in the dash fuse box NOTE: Check the No. 1 ( 1O A) fu se in the dash fu se box
before testing . befo re testing.
1. Test back-up !ight switch by placing the select lever in 1. Test back-up light switch by shifting the select lever to
reverse and turning the ignition switch to ON. "R" and turning the ignítion switch ON.
2. lf the back-up lights do not go on, check the back-up
2. lf the back-up lights do not go on, check the back-up
light bulbs in the taillight assemb!y.
light bulbs in the taillight assembly.
3. lf the fuse and bu!bs are OK, disconnect the con- 3. lf the fuse and bulbs are OK, remove the center con-
nectors from the back-up light switch. sole, then disconnect the 12-P connector from the
shift position console switch (back-up light switch).
TRANSMISSION CASE
1 2 3 lld 4 si
6 7 8 9 110 11 12
This washer must

always be replaced
for the switch to
B {GRN/BLK) A (YEL) function properly
and to prevent oil
leaks.
CONSOLE SWITCH
4. Check for continuity between the A and B wires with

4. Check for continuity between No.2 and No.3 termi-
the switch instaUed to the transmission case. There
nals. Move the lever back and forth without touching
should be continuíty as the select lever engages "A".
the push button at the "A" position, and check for
e lf no continuity, replace the switch. continuity within a range of free play of the shíft lever.
e lf there is continuity, but the back-up lights do not e lf there is no continuity within the range of free
go on: play, adjust the installation position of console
switch (see page 16-142).
- Poor ground (G701)
- An open in the YEL or GRN/BLK wire.
e lf there is continuity, but the back-up lights do not
go on:
- Poor ground (G701)

- An open in the YEL or GRN/BLK wire.
16-179
Turn Signai/Hazard Flasher System
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - - - - ; ,
HAZARO WARNING HAZARO SWITCH

LIGHT (Europian modal only) Removal, page 16-186
Gauge Assembly, page 1 6-11 O Test, page 16-186
LIGHTING/TURN SIGNAL SWITCH

TURN SIGNAL INOICATOR LIGHTS Test, page 16-162
Gauge Assembly, page 1 6-11 O Replacement, page 1 6-1 64
TURN SIGNALI
HAZARO RELAY
Input test, page 16-185 OASH FUSE BOX
16-183
Circuit D i a g r a m - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
UNDER-HOOD RELAY BOX IGNITlON DASH FUSE BOX

SWITCH
BATTERY No.15 No.19 ~ No.1
(80A) (50A} (10A)
+ )--lo....
-::r""-.P--:r'\...~--l-- WHT Bl K/Y EL-+--or'\...~--1.....
l No.20
(1 OA}
L-----<:rV:.>---+-- W HT /G RN
1
W HT /G R N - - - - - - .
LIGHTING
SWITCH
WHT/GRN
~%t\WG
LIGHT
(Europian model only,1.4W) YEL
7
RED/BLK
GRNIWHT
GRNIYEL
TURN SIGNAL
SWITCH
GRNIBLU
e
l1 1 R OFF
li6HT
{0.84W)
A
HAZA RO A H
SWITCH
GRNIRED GRNIWHT
L....-----1---GRN /RED -----1 GRNIRED

B
RED
~
TURN SIGNA L/
GRNIB LU GRNIVEL HAZA RO RELA Y
BLK
1 1 1 1 DASHLI6HT
BRIGHTNESS
CONTROLLER
r- -,
1 1
1 1 Without
1 -:- 1 DASHLIGHT
6701 G502 G301 G401 G401 G201 G501 G701 G401 : 6401 ~ ~~~N~é~fl\
G402 G402 G402 1 G402 1
L--.J
16-184
Turn Signai/Hazard Relay Input T e s t - - - - - - - - - - - - - - - - - - .
Remove the turn signal/hazard relay from the dash fuse
box.
Make the following input tests at the relay holder pins.
lf all tests prove OK, but the relay fails to work, replace the
turn signal/hazard relay.
TURN SIGNAL/
HAZARD RELAY
DASH FUSE BOX
Under all conditions. Check for continuity to ground: · Poor ground (G401 , G402) 1
1 E
should be continuity. · An open in the BLK wire.
lgnition switch ON. Check for voltage to ground: · Blown No.1 (1 O A) fuse.
should be battery voltage. · An open in the YEL or GRN/WHT
2 8
í wire.
• Faulty hazard switch.
Hazard switch ON and Hazard lights should come on. · Blown No.20 ( 1 O A) fuse.
connect the B terminal · Blown bulb.
to the L terminal. · Poor ground (G201, G301, G401,
3 B and L G402, G501, G502, G701)
· Faulty hazard switch.
1
· An open in the WHT/GRN, GRN/ 1
RED, GRN/YEL or GRN/BLU wire.

lgnition switch ON and R or L side turn lights · Faulty turn signal switch.
turn signal switch in R should come on.
or L and connect the B
terminal to the L termi-
na l. 1 1
16-185
Hazard Switch Removal-------. Hazard Switch Test------_,
1. Carefully pry out the hazard switch from the instru- 1. Pry out the hazard switch from the instrument panel.
ment panel.
NOTE: Be careful not to damage the switch or the 2. Check for continuity between the terminals in each
instrument panel when prying out the switch. switch position according to the table.
\ Terminal
A B e D E F G H 1
HAZARO SWITCH
Position \
o- -D
OFF
o -ol
o- i---- -Q
ON
1 o-t-o o- tQ_
= E F G H 1
E F B o e G
LIGHT
(0.84 Wl
16-186
Dashlight Brightness Control
Component Location l n d e x . - - - - - - - - - - - - - - - - - - - - - - - .
DASHLIGHT
BRIGHTNESS
CONTROLLER
Removal, page 1 6-1 88
LIGHTING SWITCH
Test, page 16-162
Replacement, page 16-1 64
Circuit D i a g r a m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
BATTERY No.15 No.23

{BOA) (15A)
+ J------t-0'""\ '-...0-+---- REDIGRN---+o ~---1-<:r~~--
r---------- REOIBLK ,~,

REDIBLK
• GAUGE LIGHTS (3.4Wx3,1.4Wx4l
• SHJFT POSITION CONSOLE LJGHí (1.4W)
• SUNROOF SWITCH LIGHT (1.12W)
• REAA WlNDOW DEFOGGER SWITCH LIGHT {0.91W)
•CRUISE CONTROL INDICATOR LIGHT (1.2W)
• A/C SW JTCH liGHT 11.4 W!
• SHIFT LEVER POSITION INDICA TOA (1.2WxB)
DASHLIGHT
BRIGHTNESS
e ~ UGHT
(1.14W)
• HAZAAD SWITCH LIGHT (0.91Wl
• HEATER CONTROL PANEL LIGHiS (1.4Wx3)
• REAR FOG LIGHT SWITCH (0.91Wl
• CIGA RHTE LIGHTER LIG HT (1.4 W')
• SEA T HEA TER SW !TCHES (0.84 Wx2)
y
CONTROL
CONTROLLER UNIT :-
RED
I
G401
G402
16-187
Dashlight Brightness Control
Controller Input T e s t - - - - - - - - - - - - - - - - - - - , - - - - - - - - - - - .
NOTE: The control unit is built in the dashlight brightness
controller.
Pry out the switch from the instrument panel, then discon-
nect the 3-P connector from the controller.
Make the following input tests at the harness pins. lf all
tests prove OK, yet the dashlights still cannot be controlled,
check the connector for good connection. lf OK, then
replace the controller.
NOTE: Be careful not to damage the switch or the instru-

ment panel when prying out the switch.
No. Terminal Test condition Test: desired result Possible cause lif result is not obtained)
l 1 BLK
Under all conditions.
Lighting switch ON.

Check for continuity to ground:
Check for voltage to ground:
· Poor ground (G401 , G402)
1
should be battery voltage. · Blown auxiliary fuse (15 A}*.

1 2 RED/BLK¡
· Faulty lighting switch.
1
l
lighting switch ON. Attach to ground: Dashlights · An open in the RED/BLK or RED
3 RED
should come on full bright. wire.
NOTE: lf the fuse blows, the BLK and the RED/BLK wires are connected.
* :
KF, KG. KB and KX models only
16-188
Stereo Sound System
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - - - - - .
REAR SPEAKERS FRONT SPEAKERS

Replacement, page 16-1 94 Replacement, page 1 6-1 96
STEREO RADIO/CASSETTE PLAYER

Terminal, page 16-192
POWER ANTENNA MOTOR

Test, page 16-193
16-189
Stereo Sound System
Circuit Diagram (Except KE m o d e l ) - - - - - - - - - - - - - - - - _ _ _ ,
LIGHTING
BATTERY No.15 No.24 SWITCH
(BOA) (7.5A)
+ )--.....(JI....O-....-t-<J\....C~I-------W HTIYEL -------"'1
No.22 No.19 DASH FUSE BOX
{15A) (50 A) IGNITION
SWITCH
-----WHT~
No.11
(!OA)
WHTIBLK
YEL/AED AED/BLK
WHT/YEl
A5 A4 A3
80 80 G0 G0
STEREO RADIO 1 CASSETTE PLA VER
BLK
YEL/WHT
ANTEN NA
LEAD
MAST ANTENNA
WHT IBLU
--------1
RELAY
1
POWER ANTENNA MOTOR

(w ilh !he antenna retracted fully)
BLK
l
G701 G401
G402
16-190
Circuit Diagram (KE model o n l y ) - - - - - - - - - - - - - - - - - - . . . . . ,
liGHTING
BATTERY rsoó~5) (~~'lt) SWITCH
+ 1--ii-CJ"'""J>-~.....-<:r\....C......j..._------W HíiYEL - - - - - - - - - - -
No.22 DASH FUSE BOX

(15A) IGNITION
SWITCH
&...----WHT~WHTJBLK
No.11
(1 OA)
YELIRED REO/BLK
WHT/YEL
AS A4 A3
80 80 80 80
STEREO RADIO 1 CASSETTE PLA VER
BLK
YELIW HT
ANTENNA
LEAD
MAST ANTENNA
WHT/BLU
'------W HTIBLU - - - - - . ,
AELAY
1'
TRUNK LIGHí
6R~H/:L:,,J
-------- --------
POWER ANTENNA MOIOR
7
(w ith the antenna re1racted fully)
TRUNK
1 LATCH
BLK SWITCH
.b_
6701 6701 6401
6402
16-191
Stereo Sound System
Unit Removal-----------. r--Unit Terminals,----------.
A-Type:
Remove the needle remover to pul! out the unit.
A1--------A8
A9--------A16
Terminal (Wire color) Destination

A1 (RED/GRN) Right front speaker EB
A2 (BLU/GRN) Left front speaker EB
A3 (RED/BLK) Light-on signal
A4 (WHT/YEL) Constant power (Tuning memory)
AS (YEL/RED) ACC (Main stereo power supply)
A6 (YEL/WHT) Radio switched power (To antenna)
A7 (BLU/YEL) Left rear speaker EB
B-Type: AS (RED/YEL) Right rear speaker ®
1 . Remove the floor console.
2. Remove the 3 screws and ashtray.
! A9 (BRN/BLK) Right front speaker e
3. Loosen the 3 screws and pull out the unit. A10 (GRY/BLK) left front speaker e
4. Disconnect the 16-P connector and antenna lead, A11 ( - ) (Not used)
then remove the unit.
A12(-) (Not used)
A13(-) (Not used)
A14 (BLK) Ground (G401, G402)
A 1 5 (GRY/WHT) Left rear speaker 8
A 16 (BRN/WHT) Right rear speaker e
16-192
Power Antenna Motor T e s t - - - - - - - - - - - - - - - - - - - - - - - ,
1. Remove the trunk side trim panel. 5. lf the motor fails to operate properly, replace it.
2. Disconnect the 6-P connector from the motor and
remove the connector from its clamp.
3. First check power to the motor at the harness pins: Except KE model: MAST ANTENNA
There should be battery voltage between the WHT1
BLU ( +) and BLK ( -) terminals all the time. There
should be battery voltage between the YEL/WHT ( +)
and BLK (-) terminals only with the ignition and radio
switched ON. RE LAY
4. Test motor operation:
FULL EXTEND: Connect battery positive to the No.3

and No.4 terminals and negative to
the No. 1 terminal.
RETRACTED: Except KE model:
Then disconnect battery positive from
the No.3 terminal.
KE model only:
Short the No.2 terminal to the No.1
terminal, then connect battery posi-
tive to the No.6 terminal and negative
to the No.1 terminal.
View from wire side
~
[GRN/BLK]
BLK
[ ]: KE model
( \
[WHT/BLU]~ kl;RJ\
WHT/BLU ·
~
YEL/WHT
KE model: MAST ANTENNA
View from wire side
16-193
Stereo Sound System
Front Speaker Replacement ---..., Rear Speaker Replacement - - - - - .
1. Remove the speaker grille from the door trim panel. 1. Open the trunk lid, then remove the 3 nuts.
2. Remove the screws, then disconnect the wires or 2-P 2. Disconnect the 2-P connector from the speaker
connector from the speaker. assembly.
3. Remove the speaker grille and speaker from the

speaker box.
SPEAKER
GRILLE
2-P CONNECTOR
16-194
Mast Antenna Replacement---------------------------,
Removal lnstallation
NOTE: The antenna mast alone can be replaced 1 . Carefully direct the teeth of antenna mast drive
without having to remove the power antenna cable as shown, and insert the drive cable into the
motor unit. antenna housing.
1. Remove the special nut, spacer and bushing.
2. Carefully withdraw the antenna mast whife ex-

tending it by turning the radio switch u ONU.
Direction of the
teeth.
2. Check for engagement of the cable teeth to the

drive gear; by carefully moving the cable up and
down.
3. Turn the radio switch "OFF", and let the motor pull
the drive cable inside the antenna housing.
4. lnsert the antenna mast into the antenna housing,

and install the bushing and spacer, tighten the
TEETH special nut.
5. Check that the mast antenna retracts and extends

fully when the radio switch is turned ON and OFF
repeatedly.
POWER ANTENNA ANTANNA MAST

MOTOR UNIT ORIVE CABLE
16-195
Stereo Sound System
Power Antenna Motor Retractar Relay Test---------.
Replacement
1. Remove the relay from the motor antenna.
1. Remove the trunk side trim panel.
2. There should be no continuity between the B and O
2. Disconnect the 4-P [6-P] connector and antenna lead terminals when the battery is connected to the C and
from the motor, then remove the special nut and F terminals.
mounting nuts to take out the motor with the mast There should be continuity when the battery is discon-
antenna. nected.
[ ]: KE model
~
O F
3. lnstall in the reverse order of removal.
NOTE: Tighten the special nut, and then tighten

mounting nuts to motor bracket.
F o
e B
16-196
Power Antenna Motor T e s t - - - - - - - - - - - - - - - - - - - - - - - ,
1. Remove the trunk side trim panel. 5. lf the motor fails to operate properly, replace it.
2. Disconnect the 6-P connector from the motor and
remove the connector from its clamp.
3. First check power to the motor at the harness pins: Except KE model: MAST ANTENNA
There should be battery voltage between the WHT1
BLU ( +) and BLK ( -) terminals all the time. There
should be battery voltage between the YEL/WHT ( +)
and BLK (-) terminals only with the ignition and radio
switched ON. RE LAY
4. Test motor operation:
FULL EXTEND: Connect battery positive to the No.3

and No.4 terminals and negative to
the No. 1 terminal.
RETRACTED: Except KE model:
Then disconnect battery positive from
the No.3 terminal.
KE model only:
Short the No.2 terminal to the No.1
terminal, then connect battery posi-
tive to the No.6 terminal and negative
to the No.1 terminal.
View from wire side
~
[GRN/BLK]
BLK
[ ]: KE model
( \
[WHT/BLU]~ kl;RJ\
WHT/BLU ·
~
YEL/WHT
KE model: MAST ANTENNA
View from wire side
16-193
Clock
Removal-------------,
1. Pry out the dock from the dashboard, then disconnect
the 4-P connector.
NOTE: Be careful not to damage the clock or the

dashboard when prying out the dock.
CLOCK 4-P CONNECTOR
Terminals:
e e

1
A RED/BLK light-on signal
B BLK Ground
e YEL
IG1 (Main clock power sup- i
ply)
1
Constant power
D
¡ WHT/YEL (Time memory)
'
16-197
Cigarette lighter
Component Location lndex------------------...:..__ __
CIGARETTE LIGHTER
CIGARETTE LIGHTER
RELAY
Test, page 16-200
L. KICK PANEL
16-198
Horns
Test--------------------------~ Switch Test---------------------,
1. Remove the front bumper. 1. Remove the steering wheel, then turn it over.
2. Disconnect the 2-P connector from the horn. 2. Check for continuity between the hub core and the
3. Test the horn by connecting battery voltage to the A contact ring, or the hub core and the BLU/RED lead
and B terminals. The horn should sound. for cars equipped with cruise control, according to the
4. lf the horn fails to sound, replace it. table.
With Cruise Control:

1\ Terminal HUB
BLU/RED
Position \ CORE
PRESS
FREE
Horn Circuit:
e Slip Ring Test, see page 16-262.
BA TTERY
UNOER- HOOO
RELAY BOX
+--
WHT/YEl
WHTIYEL
WHTIYEL Without Cruise Control:
1\ Terminal HUB CONTACT
Position \ CORE RING
PRESS
FREE
1
BRAKE LIGHT
CIRCUIT
BLU/RED
CONTACT
Q
HUB CORE
RING
SLIP RING
or
CONTACT AING
BLU/AED
I~HORNSWITCH
3. lf OK, reinstall the steering wheel, then test the combi-
nation switch.
16-201
Power Door Mirrors
DOOR MIRROR SWITCH

Function Test, page 16-204
Test, page 16-205
DOOR MIRROR
Test, page 16-206
16-202
Circuit Diagrann------------------------------------------------------~
UNDER-HOOD AELAY BOX

BA TTERY
No.15(80A) No.19(50A)
+ J---t--=:r......o---o"'I....C>--+- WH~ IGNITION

~SWITCH
BLK/YEL
1 ~r,'~A~ OASH FUSE 00>
YEL/GRN
1
YEL/G RN
t
YEL/G RN
1
YELIGAN
~
11 9 POWEA OOOA MIRROR SWITCH
• SUNROOF SYSTEM AIGHT

• POWER WINOOW SYSTEM 1
• HEADLIGHT AOJUSTER 1
UNIT 1
1
1
- _j
----- -DOWN-- ----

R
12 10
YELIBLK BLK
ORN BLUIBLK
G501 G501 G501

G502 G502 G502
• : KS,KW ,KE and KX models
16-203
Power Door Mirrors
FunctionTest------------------------------------------------------~
NOTE: Befare testing, remove the driver's door trim panel, 2. Check for continuity between the BLK terminal and
then disconnect all of the connectors from the door trim body ground.
panel. There should be continuity.
e lf there is no continuity. check for
KS. KW. KE and KX models: - An open in the BLK wire.
- Poor ground {G501, G502).
View from wire side left inoperative:
Connect the YEL/GRN terminal to the YEL/RED terminal
and the BLU/WHT (or YEL/BLK) terminal to the body
ground with jumper wires.
The left mirror should tilt down (or swing left) when the
ignition switch is turned ON.
e lf the mirror does not tilt down (or does not swing left),
YEL/GRN remove the left door trim panel and check for open in the
BLU/WHT (or YEL/BLK) wire between the left door
mirror and switch.
lf the wire is OK, check the left door mirror.
• lf the mirror neither tilts down nor swings left, repair the
YEL/RED wire.
e lf the mirror operates properly, check the mirror switch.
Right inoperative:
Connect the YEL/GRN terminal to the BLU/GRN terminal
and the BLU/WHT (or BLU/BLK) terminal to the body
ground with jumper wires.
DRIVER'S The right mirror should tilt down (or swing left) when the
DOORTRIM ignition switch is turned ON.
PANEL
• lf the mirror does not tilt down (or does not swing left),
YEL/RED remove the right door trim panel and check for open in
the BLU/WHT (or BLU/BLK} wire between the right
door mirror and the switch.
lf the wire is OK, check the right door mirror.
e lf the mirror neither tilts down nor swings left, repair the
BLU/GRN wire.
• lf the mirror operates properly, check the mirror switch.
View from wire side
Defogger Test
(KS. KW, KE and KX models)
1 . Check for voltage between the YEL/GRN terminal of
the 2-P connector and body ground with the ignition
Mirror Test
NOTE: Check the No.5 (7.5 A) fuse in the dash fuse box switch ON.
before testing.
One or both inoperative:
1. Check for voltage between the YEL/GRN terminal and • lf there is no voltage, check for open in the YEL/
body ground with the ignition switch ON. GRN wire between the dash fuse box and the
There should be battery voltage. defogger switch .
e lf there is no voltage, check fÓr an open in the YEL/ e · lf there is battery voltage, go to step 2.
GRN wire.
e lf there is battery voltage. go to step 2. 2. Connect the YEL/GRN terminal of the 2-P connector
to the ORN terminal with a jumper wire.
Both the right and left mirrors should gradually warm
up when the ignition switch is turned ON.
e lf neither warm up, repair the ORN wire.
e lf only one fails to warm up, check its mirror

defogger element (see page 1 6-205).
e lf both warm up, check the switch.
16-204
Switch Removal - - - - - - - - - , Switch T e s t - - - - - - - - - - - ,
D
1. Remove the driver's door trim panel, then disconnect 1. Remove the power door mirror switch from the power
all of the connectors from the door trim panel. window master switch.
2. Remove the arm rest from the door tri m panel by 2. Check for continuity between the terminals in each
removing the retainer and the screws. switch position according to the table.
Mirror Switch
1\ Terminal 1,
'\1 3 4 5 6 7 9 10
Position
OFF o- -o- -c. o
UP o D
DOWN
o- - --o
R o D
o- - -o
LEFT
RIGHT e
lo D
)
OFF o-t---0--- f - - - H Q
UP o D
DOWN
o- ro
L g :9
o-
LEFT
o ~
RIGHT (' 0
3. Aemove the power window master switch from the

D e fo gg er Switch
arm rest by removing three screws.
(KS, KW, KE and KX models)
4. Push out the switch from the reverse side of the power
window master switch.
ARM REST
16-205
Power Door Mirrors
Door Mirror Test---~----..., Door Mirror Replacement-----.
1. Carefully pry out the cover panel .lid, then disconnect 1. Carefully pry out the cover panel lid.
the 8-P connector from the mirror.
2. Disconnect the 8-P connector from the mirror.
2 .. Test actuator operation:
TILT UP: Connect battery positive to the No.S 3. While holding the mirror with one hand, remove íts
terminal and negative to the No. 7 mount screws with the other.
terminal.
TILT DOWN: Connect battery positive to the No.7
terminal and negative to the No. 8
terminal. DOOR MIRROR
SWING LEFT: Connect battery positive to the No.7
terminal and negative to the No.6
terminal.
SWING RIGHT: Connect battery positive to the No.6
terminal and negative to the No. 7
terminal.
3. lf the mirror fails to operate properly, replace it.
COVER PANEL LID
d 6 7 8
8-P CONNECTOR
16-206
PowerSeat ~
Component Location lndex-------------------=1._1====
FRONT HEIGHT MOTOR

Test, page 16-209
RECLINING MOTOR
Test, page 16-209
POWER SEAT SWITCH

Test, page 1 6-209
16-207
Power Seat
Circuit Diagram
A TTERY
No.15(80A) No.26(20A)
+
No.40(20A)
-:::1""
WHTIRED WHTIGRN
A POW EA SEA T SWITCH
DOWN 1 f UP\} REAR 1 } FRONT 1 ) DOWN 1 )
e G H K D E
BlK BLK
FRONT SLIDING REA A RECLINING

HEIGHT MOTOR MOTOR HEIGHT MOTOR MOTOR
G501 G501
G502 G502
16-208
Switch T e s t - - - - - - - - - - . Motor Test-------------.
CAUTION: Be careful not to damage the seats, the CAUTION: Be careful not to damage the seats, the
inteTior trims or the body. interior trims or the body.
1. Remove the driver's seat, then disconnect the 6-P 1. Remove the driver's seat, then disconnect the 2-P
connectors. connector from the motor.
2. Check for continuity between the terminals in each 2. Test motor operation by connecting battery voltage to
switch position according to the table. the No.1 and No.2 terminals.
Test the motor in each direction by switching the leads
from the battery.
1\ K~L
i
Terminal
AIB e o E F G H 1 j
Position \ CAUTION: When a motor stops running, disconnect a
FOR- battery terminal immediately.
SLIDING WARD
'¡o :Lo
¡
SWITCH BACK
WARD :o -o
FOR-
RECLIN-
WARD lo -o
ING
BACK
WARD lO
SWITCH
FRONT UP o '
-o
HEIGHT
SWITCH DOWN o -o.
REAR UP ,o -o
HEIGHT
SWITCH DOWN ,O -o
REAR
HEIGHT
MOTOR
View from wire side
16-209
Power Seat (Height Adjuster)
Componentlocation lndex.~~~~~~~~~~~~~~~~~~~~~-
POWER SEAT SWITCH

Test, page 16-212
16-210
.--t 1rcu1t Diagram
UNDER-HOOO RELAY BOX

BA TTERY
No.15(80A) No.40(20A)
+ "V ~ 'V ,..,_ WHT/RED-
No.26(20A}
--<::J"\. WHTIREO
BLK BLK
WHT/RED
A E e
HEIGHT
ADJUSTER
SWITCH
DOWN <\ )
UP 6,
') )
B o
'I~J" HEIGHT MOTOR

BLK
1-
6501
G502
16-211
Power Seat (Height Adjuster)
Switch Test-------------. Motor Test---____;.--------.
CAUTION: Be careful not to damage the seats, the CAUTION: Be careful not to damage the seats, the
interior trims or the body. interior trims or the body.
1. Remove the driver·s seat. then disconnect the 5-P 1. Remove the driver's seat, then disconnect the 2-P
connector from the switch. connector from the motor.
2. Check for continuity between the terminals in each 2. Test motor operation by connecting battery voltage to
switch position according to the table. the No.l and No.2 terminals.
Test the motor in each direction by switching the leads
from the battery.
\
Position
Terminal
\1
1
A B e 1
i
D 1
E
UP
SWITCH
DOWN ~r-o
CAUTION: When a motor stops running, discon-
nect a battery terminal immediately.
16-212
Seat Heaters
Component location lndex
R.SEAT HEATER RELAY R.SEAT BACK HEATER

(KS and KW models only} (KS and KW models onlyl
Test, page 16-217 Test, page 16-21 7
Replacement, sectíon 14
R.SEAT CUSHION HEATER

Removal, page 16-216 (KS and KW models only)
Test, page 16-216 Test, page 16-217
Replacement, sectíon 14
L.SEAT BACK
HEATER
Test, page 16-217
l.SEAT CUSHION
SEAT HEATER MAIN RELAY HEATER
[Wire colors: BLK/YEL, BLK/YEL. BLK/YEL, BLK] Test, page 16-217
Test, page 16-217 Replacement, sectíon 14
L.SEAT HEATER RELAY

Test, page 16-217
Description
Two heaters are provided in each front seat; one in the seat cushion and one in the seat back. In normal use, temperature ís
automatically controlled by the thermostat [OFF above 40"C (1 04"F)] built in each seat cushion heater. In emergency case, the
breaker 1 [OFF above 50"C (122"F)] and the breaker 2 [OFF above 70"C {158"F)] cut off the circuit'to prevent abnormal
temperature rise.
16-213
Seat Heaters
Circuit Diagrann------------------------------------------------------~
BATTERY
UNDER-HOOO RELAY BOX
No.15
(BOA)
No.19
(50A)
+ l---t--r:::r-J:>-....-<f"""'-.;:>-+-WHI
-©--l
IGNIIION SWITCH
2
EL
'-...C--+--WHI/BLK ------+--~
DASH
FUSE No.B
BOX (7 .SA)
No.35 : KS and KW models
No.36 : KF,KG and KX models
LIGHTING LIGHTING
SWITCH SWITCH
SEAT
7
1
HEA TER
MAIN
RELA Y
REDIBLK
r----------------------BLK------------------t------1 REOIBLK
r - - - - - - - - - + - B L K I G R N - - -.....- BLKIGRN
4
l. SEA T R. SEA T
HEATER HEA TER
SWITCH INDICA TOA liGHT SWITCH liGHT
LIGHT
(0.91W) {O.B4W) {0.84W)
r----- BLK - - - , r-+--+-----BLK WHTIGRN

BLK
BLK~
l. SEA T
HEA TER R.SEAT
RELAY HEATER
RELAY
DASHLIGHT DASHLIGHT
BLU WHT/BLU BRIGHTNESS BLU WHT/BLU BRIGHTNESS
WHT/RED CONTROLLER WHT/RED CONTROLLER
l.SEAT BACK R.SEAT BACK

HEATER HEATER BLK
l.SEAT HEATER BLK R.SEAT HEATER

(KS and KW models)
G251 BR1 : BREAKER [OFF above so•C(122°FlJ G501 G501

TH1 : THEAMOSTAT [OFF above 40°G(104°F)] G502 G502
BR2 : BREAKER [OFF above 70•C(158°F)J
16-214
Troubleshooting---------------------------------------------------,
ltem to be inspected
Q)
(/}
o
.o ..Q (/}
-x
Q)
(/}
~
'S
.o
....
....
~
o .E<ae:
a. (/}
~o
<C.o ..e:
~ ..e: .!: e
'§ ~
B
--"'
ID >
s
Q)
r...: (/}
'§ ro 'O
-
~
~ .!: $
ro (/}
'O oQ)
00 ..e: o ....
....a;
·:; e:
o
(/}
'O $ ....a; e:
~
e e:
z 'O .!:
"' ..e:"' ..e:"'
Q) Q) Q)
o
e, ·¡:¡ o
e: Q) e: ..e: o
:¡: -E :¡: .... ....ro ....ro oo e: .!!!
<1>'0
o o
Symptom iXi g iXi "' en en
Q)
en
Q) Q)
a... o
a. ....
o
Seat heaters operate, but indicator light does not G501

1
go on. G502
!
Seat heaters do not operate and indicator light does G251

2 G501 YEL/BLK, WHT /BLK
not go on. 1 G502
Seat heaters do not

G501 WHT/BLK, WHT/GRN, BLU,
operate, but indicator Left and Right seat 1
G502 WHT/RED, WHT/BLU
light goes on.
Seat cushion heater or seat back heater does not

1 !
operate, but indicator Íight goes on.
¡
!
No.35 (15 A): KS and KW models

No.36 (15 A): KF, KG and KX models
16-215
Seat Heaters
Switch Removal-----------. Switch T e s t - - - - - - - - - - - .
1. Pry out the switch from the floor console. 1. Pry out the seat heater switch from the floor console.
2. Disconnect the 6-P connector to remove the switch. 2. Check for continuity between the terminals according
to the table.
Terminal
Position
GRO OVE
ON
OFF
6-P CONNECTOR
D E F
E B
INDICATOR
LIGHT LIGHT
(0.91 W) (0.84W)
o e F
16-216
HeaterTest------------------~ Relay Test------------.
1. Disconnect the 6-P connector and 2-P connector as Heater relay:
shown below. 1. Remove the driver's seat, then remove the relay from
the bottom of the seat.
NOTE: Left front seat ís shown. Right front seat is
similar. 2. There should be continuity between the F and A;
between C and D terminals when the battery is con-
nected across the F and E terminals.
There should be continuity between the F and D termi-
nals when the battery is disconnected.
2-P CONNEeTOR
e F
SEAT HEATER RELAY
o A E
Main relay:
There should be continuity between the A and B terminals
when the battery is connected across the C and D termi-
nals.
There should be no continuity when the battery is discon-
2. Check for continuity between the No.1 and No.5 nected.
terminals; between the No.7 and No.8 terminals (R x
10' scale)
There should be continuity.
A e
8 o
16-217
Rear Window Defogger
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - - - .
REAR WINDOW REAR WINDOW DEFOGGER

DEFOGGER SWITC Function Test, page 16-221
Test, page 16-222 Defogger Wires Repair, page 16-221
'ni=FC'IGC::ER RELAY
Test, page 16-220
16-218
Circuit D i a g r a m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
UNOEA-HOOO RELAY BOX IGNITION OASH FUSE BOX

SWITCH
BA TTERY
No.15(80A) No.19(50A) ~ No.8(7.5A)
+ l - -.....-cro......a-+--:n....r>--+- WHT ~ YEL-t--n...o.....-+-.- YEL/ BLK ~
• ALB SYSTEM
• HEA TER CONTROL PANEL
• SEAT HEATER MAIN RELAY
• COOLING FAN TIMEA UNIT
YELIBLK
y
(Interna! Connection) LIGHTING SWITCH
REO/BLK
INOICATOA LIGHT REA R

LIGHT (0.91 W) WINDOW
(0.84W)
OEFOGGER
SWITCH
BLK/GAN 1
A e
o
REAR
WINOOW
OEFOGGEA
AELAY
BLK YELIG RN RED
B o
BLKIGRN 2
DASHLIGHT
BAIGHTNESS
CONTROLLEA
REAR
WINOOW
DEFOGGEA
BLK
l
G821 G401
:±:
1-
1 -
1
1
1 G401 1
G402 1 G402 1
1...--.J
Without
OASHLIGHT
BRIGHTNESS
CONTROLLER
16-219
Troubleshooting---------------....,.-----------...
¡ 1
11
..e
3
..e
ti
$ ....
e Q)
o
·,¡:;
Cl
Cl
o
e .E
Q)
::J
Symptom u.. o
Defogger operates, but indicator

light does not go on.
1
Defogger does not operate
G401
and indicator 2 YEL/BLK or BLK
G402
light does not go on . 1 1
Defogger does not operate,

1 2 3 4 G821 BLK/GRN,
but indicator light goes on.
! 1 i 1
RelayTest----------------------------------------
1. Remove the relay from the dash fuse box.
2. There should be continuity between the A and B terminals when the battery is connected to the C and D terminals. There
should be no continuity when the battery is disconnected.
A e
A e
~ a
p
8 o
-16-220
Function Test-------------. Defogger Wire Repair---------.
D
CAUTION: Be careful not to scratch or damage the NOTE: Repair section must be no longer than one
defogger wires with the tester probe end. in ch.
1. Check for voltage between the positive terminal 1. Lightly scour area around the break with the fine
and body ground with the ignition switch and the steel wool, then clean with alcohol.
defogger switch ON.
There should be battery voltage. 2. CarefuUy mask broken portian of the defogger wire
with cellophane tape.
• lf there is no voltage, check for:
- Faulty defogger relay.
- An open in the BLK/GRN 1 or BLK/GRN2 wire.
lf there is battery voltage, go to step 2.
NEGATIVE TERMINAL POSITIVE TERMINAL

[POSITIVE TERMINAL] [NEGATIVE TERMINAL]
¡--+---~
3. Using a smalf brush, apply heavy coat of silver con-
ductive paint extending about 1/8 in. on both sides
of the break. Allow 30 minutes to dry.
[ ]: RHD
NOTE: Thoroughly mix paint befare use.

2. Check for continuity between the negative terminal
and body ground.
lf no continuity, check for open in the defogger
ground wire.
3. Connect. the voltmeter positive pro be to the center

of each defogger wire, and the negative probe to
the negative terminal.
There should be approximately 6 V with the igni-
tion switch and the defogger switch ON.
lf the voltage is as specified, the defogger wire

is OK.
• lf there is battery voltage, the defogger wire is 4. Check for proper operation with a voltmeter (ap-
broken in the negative side of the center. proximately 6 V at the mid-point).
lf there is no voltage the defogger wire is broken 5. Apply a second coat of paint in the same manner.
in the positive side of the center. Dry 3 hours befare removing tape.
16-221
Rear Window Defogger Switch Switch Test
Removal
1. Carefully pry out the rear window defogger switch 1. Pry the switch from the instrument panel.
from the instrument panel.
NOTE: Be careful not to damage the switch or the 2. Check for continuity between the terminals according
instrument panel when prying out the switch. to the table.

1\ Terminal
A D F B E
Position \
PUSHED
tfiffi
\.V -o- t-o
o- ~ f-o
RELEASED
6-P CONNECTOR
GROOVE
A E
LIGHT
(0.91 Wl
F D B
16-222
~
lndex--------~------------------------=IL....JI====:::
Sunroof
Cornponentlocation
SUNROOF SWITCH
Function Test, page 16-226 SUNROOF MOTOR
Test, page, 16-226 Test, page 16-227
SUNROOF OPEN RELAY

Test, page 16-227
SUNROOF CLOSE RELAY
Test, page 16-227
DASH FUSE BOX

(Located driver sida, kick panel)
16-223
Sunroof
-Circuit D i a g r a m - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
UNDER-HOOD RELAV BOX

IGNITION SWITCH
BATTERV No.15(80A) No.19(50A) ~
UGHilNG SWITCH
+)---f--<Jr"'\...~......--cru>---t--WHT ~ BLK/VEL-
~ No.31(2DA)
DASH No.5
FUSE BOX ~ (7.5A)
u1---- u------~= uu-u--- u[J¡~~;~u -~

GRN YEJGRN
~-----u
GRN YEL!GRN _1 :
(GRN/BLUI f 1
~--+--~~~--------BLK----------~ YELIGRN 1
{GRNIBLU! 1
A. D
r-0+--A~---F+-~ :
1
)1 SUNROOF \ ~ SUNROOF:
OPEN \+---+~~~ CLOSE l
RELAY ,- RELA Y l
1
1
e e 1
1
GRN/VEL GRNIYEL GRN/RED GRN/RED :
~--~-u --;,f--~~-~-~~--G~r~~1~D----~ RED/BLK
GRN/YEL
A B D
~- '?
( DLIGHT
1 OPEN CLOSE
(1.12W)
,,
SUNROOF SWITCH e E
r
1
--------------- , BLK 1
BLK L.
--------------- .J
1
Without DASHLIGHT
BLK BRIGHTNESS RED
CONTROLLER
-
G401
G402
1 1: RHD G401
G402
l-
~
DASHLIGHT
BRIGHTNESS
CONTROLLER
16-224
Electrical Troubleshooting--------------------------.
1
1
-o
e:
;:)
o
e,
o
o
Symptom a..
Sunroof does not move. but motor turns.
With alt switches 2 3 5 4

G401 GRN, YEL/GRN i
G402 GRN/YEL. or GRN/RED ·
Sunroof does not move

and motor does not turn With OPEN
3 GRN/YEL
(sunroof can be moved switch.
with sunroof wrench).
With CLOSE
2 1 3 GRN/RED
switch.
16-225
Sunroof
Function T e s t - - - - - - - - - - , Switch T e s t - - - - - - - - - - - ,
1. Carefully pry out the cruise main switch/sunroof 1. Remove the switches from the ínstrument panel.
switch from the instrument panel.
NOTE: Be careful not to damage the switch or the 2. Check for continuity between the terminals in each
instrument panel when prying out the switch. switch position according to the table.
2. Disconnect the 5-P and 6-P connectors from the

switch es. J\ Terminal
A B e D E
3. Connect the GRN/YEL terminal to the BLK terminal 1 Position \
with a jumper wíre. OFF
The sunroof should open when the ignition switch is
OPEN o () t'fiiffi ~
turned ON. :._..j_

o- f--J ... '1 -
~
r. \V
CLOSE
e lf the sunroof opens, check the switch.
e lf not, connect the GRN/YEL terminal to body

CRUISE MAIN SWITCH/
ground.
SUNROOF SWITCH
- lf the sunroof opens, check for open in the BLK

wire, and check whether the G401 and G402
terminals are poor.
- lf not, remove the headliner and check the
motor.
e"~
o~ E
a--yVEL A 8 o
~LK CLOSEir
CRUISE MAIN SWITCH/
LIGHT
SUNROOF SWITCH View from wire side (1.12 W)
e E
16-226
Motor Test-------------------~ Relay Test----------------.
1. Remove the headliner. 1. Remove the sunroof relays on the dash fuse box.
2. Disconnect the 2-P connector from the sunroof 2. There should be continuity between the A and B
motor. terminals when the battery is connected to the F
and e terminals.
3. Test motor operation by connecting battery to the There should be continuity between the B and D
No.1 and No.2 terminals. Test the motor in each terminals when the battery is disconnected.
direction, by switching the leads from the battery.
4. lf the motor does not run, replace it.
NOTE: See Closing Force Check in section 14 for

motor clutch test.
View from
wire side
F A o
e B
16-227
Power Door Locks
Component Location l n d e x . - - - - - - - - - - - - - - - - - - - - - - - - .
R.FRONT DOOR LOCK ACTUATOR

Test, page 1 6-232
R. REAR DOOR LOCK

ACTUATOR
Test, page 16-232
CONTROL UNIT
DRIVER'S DOOR LOCK KNOB SWITCH

Test, page 16-232
L.REAR DOOR LOCK ACTUATOR

Test, page 16-232
16-228
r-- arcuat D iagram

BA TTERY No.15 No.27
(80A) (20A)
....,
+ ,;., -v ~ WHT
CONTROL UNIT
BJREO
J. 1 LOCK@ UNLOCK@ q 1
W HT/RED RIGHT REAR YEL/RED
BLU/W HT
1
WHT/REO
102
LEFT REAR
l
Y EL/RED
l
WHT/RED
~02
RIGHT FRONT
~LEFT FRONTJ
-t
Y EL/RED
1 02
1
V 1
1
3
DOOR
1
l U N-.O
LOCK
f. LOCK OOOR
LOCK
LOCK KNOB
KNOB ) SWITCH
BLK ( l : RHD
1
G501
6502
-
-
.J~
G501
G502
L.-
16-229
Power Door Locks
Troubleshooting----------------------------------------------------~
.>(.
()
.!2
o
o o
xo -o Q)
Ul
-o o
Q) .o ...
Q)
.!2
!/)
..2 <U
;;¡- ~
>-
..e:
¡:
s"'
<U
:J
()
2.
tí
o <a
!/)
!/)
e:
.§ . .o
o -o o 5Q.
o
Cll
o .§ .E
~
"'
N
-.s::¡.
,....
o .o
o oo -oo .S ~
N ID
-o
e
.>(.
.!:
·e:... -o
... .2l -o
e:
...
·::;
-o
Q)
o e:
Q)
o
1~o .S
..><: Ol :J
z :J (J
:J Q)
<U o ~ Q)
e: Q) .!2 g
oo eo
Ol
e:
Q)
.>(.
o, ·¡; e:
e o
e
~
o
-5 !/)
"'Cll
() "-
-o oo Q) o 1
Symptom m§ o u CL a"' e CL
o.
"'
o '5
1
Power door lock system does not G501

1 2 WHT
J operate at all. G502
G501 1 BLU/WHT, YEL/RED,

\ Doors do not lock or 1 2 3 4
G502 WHT/RED or BLK/RED
unlock with driver's door .
lock knob switch. . One or more YEL/RED

1
passenger door.
1 i ¡ or WHT/RED
1
CAUTION: To prevent damage to the motor,

apply battery voltage momentarily.
16-230
Control Unit Input T e s t - - - - - - - - - - - - - - - - - - - - - - . .
Remove L.door trim panel, then disconnect the 12-P con-
nector from the control unit.
Make the followíng input test at the harness pins.
NOTE: Recheck the conneétions between the 12-P con-

nector and the control unit, then replace the control unit if
all input tests prove OK.
~WHT/RED
BLK/RED BLU/WHT WHT

View from wíre side
Under all conditions. Check for continuity to ground: • Poor ground G501, G502
1 BLK • An open in the wire.
1
Under all conditions. Check for voltage to ground: • Blown No.27 (20 A) fuse.
2 WHT
Drivers door lock knob Check for continuity to ground: • Faulty door lock knob switch.
3 BLU/WHT in LOCK. should be continuity. • Poor ground (G501, G502).
Driver's door lock knob Check for continuity to ground: • Faulty door lock knob switch.
4 BLK/RED in UNLOCK. should be continuity. • Poor ground (G501, G502).
Connect the WHT ter- Check door lock operatíon:

minal to the WHT/RED Passenger doors should lock as the
terminal, and the YEL/ battery in connected momentarily.
RED terminal to the
1 BLK terminal :
momentaríly. • Faulty actuators.
YEL/RED
5 and
WHT/RED
Connect the WHT ter- Check door lock operation: • An open in the wire.
minal to the YEL/RED Passenger doors should unlock as the
terminal, and the WHT1 battery is connected momentarily.
RED terminal to the
BLK terminal
momentarily.
CAUTION: To prevent damage to the motor, apply battery voltage momentarily.
16-231
Power Door Locks
Passenger's Door Actuator Test Door lock Knob Switch Test----.
1. Remove the door trim panel. 1. Remove the driver's door trim panel.
2. Disconnect the 2-P connector from the actuator. 2. Disconnect the 3-P connector from the switch.
3. Test actuator operation by connecting battery voltage 3. Check for continuity between the terminals in each
to the WHT/RED and YEL/RED terminals. switch position according to the table.
Test the actuator in each direction by switching the
leads from the battery.
Terminal
1 2 3
CAUTION: To prevent damage to the motor, apply
battery voltage momentarily. ""'
Position
UNLOCK
~
-D
LOCK o 1
View from wire side
4. lf the actuator fails to operate properly, replace it.

View from wire side
16-232
Power Window
UNDER-HOOO
RELAY BOX
R.REAR SWITCH
Test, page 16-240
R. FRONT SWITCH
Test, page 16-240
R.REAR MOTOR
Test, page 16-242
DRIVER'S SWITCH
Test, pages 16-238, 239 R. FRONT MOTOR
Replacement, page 16-240 Test, page 16-242
DRIVER'S MOTOR
Test, page 1 6-242
Replacement, section 1 4
~
L.REAR MOTOR
Test, page 23-242
Replacement, section 1 4
L.REAR SWITCH
Test page 16-240
Replacement, page •16-241
16-233
Power Windows
Circuit Diagrann--------------------------------------------------------,
NOTE:
• Severa! difieren! wires ha ve !he same color. They ha ve be en given a number suffix lo distinguish them (lor exampl RED/BLU and REDIBLd are not the same
• 'DN' in the switch circuit denotes DOWN. · .
UNOER-HOOO RELAY BOX DASH FUSE BOX

IGNITION SWITCH
+ )----t---o'-1>-"""1~-<f""'u:>--+-·~
BA TTERY • No.5(7.5A)
. No.15(80A) No.19(50A)
WHT ~ BLK/YEL -t-<r"..J.::>--+--------,_-.
YEL/GRN
POWER
WINDOW
RELAY
¿
GRN/BLK 1
No.32 No.34 No.33
(20A) (2 OA) (2 OA)
GRN/BLK YEL/BLK BLUIBLK WHTIYEL

POWER
DOOR
[N[ l [LI N M DRIVER'S SWITCH MIRRORS
L.REA R R.REA R [L.FRONT] R.FRONT
!,l OFF
., ,! !,, OFF .!
. , 1 DN
!,¡ OFF .!
"\ 1
.....
z::::>
u p ) ) DN UP u p) DN _,
oa:
1-
:z
o
MAIN
SWITCH
....-----1~------o o
®
o [F) D 1 E[ e !DI F [C] E B A H
GRN/YEL GRN YEL YEUGRN BLUIY El BLU/GRN BLK 2 REDIYEL1 REDIBLU 1 BLU
A E e e E A [A] e E [C] A
u.~~N u~~N U~DN

OFF
1 1 l.REAR
OH SWITCH OFF
1 1 R.REA R
OFF SWITCH OF~ 1 1
OFF
o B ·a o D B [L.FRON T]
R.FRON T
RED/Y E@ RED/VE~ BLUIRED SWITCH
BLK 2 REDIBLU3 REDIBLU2 [BLUIW HT]
BLUIW HT
[BLU/RED]
1 2
DRIVER'S MOTOR
L.REAR MOTOR R.REAR MOTOR R.FRONT MOTOR
[L.FRONT]
• UP(A UTO) : Standard for so me types.

[ ] : RHD
G501 G251
G502
16-234
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
16-235
Power Windows
Driver's Switch Input T e s t - - - - - - - - - - - - - - - - - - - - -
NOTE: The control unit is built into the driver's switch, and
only controls driver's door window operation.
Remove the driver's door trim panel and disconnect the

14-P and 1-P connectors from the driver's switch.
NOTE: Recheck the connections between the 1 0-P or 14-P

and 1-P connectors, and the driver's switch, then replace
the driver's switch if all input tests prove OK.
LHD:
YEL/GRN
GRN/YEL GRN/BLK
BLU
RED/BLU 1
GRN
BLK 2
BLU/YEL RED/YEL1
BLU/GRN
BLU/YEL
YEL/GRN BLK 2
RED/BLU1
BLU
YEL YEL/BLK
BLK 1
GRN BLU/BLK
GRN/YEL GRN/BLK
16-236
Under all conditions. Check for continuity to ground: • Poor ground (G501, G502)
1 BLK 2 J
!WHT/YEL lgnition switch ON. Check for voltage to ground: • Blown No.30, 32, 33 or 34 (20 A)
should be battery voltage . fuse.
BLU/BLK • Faulty power window relay.
¡ • An open in the wire.
2 !
1
1 YEL/BLK
1
GRN/BLK
Connect the WHT/YEL Check the driver' s motor operation: • Faulty driver's motor.
1 terminal to the RED/ should run. • An open in the wire.
RED/BLU
BLU 1 terminal, and the
3 and
RED/YEL terminal to 1
RED/YEL 1 1
the BLK2 terminal, then
ignition switch ON.
Connect the BLU/BLK Check the right front motor operation: • Faulty R.front [L.front] motor.
terminal to the BLU/ 1
should run. • Faulty R.front [L.front] switch.
BLU/YEL • An open in the wire.
YEL terminal, and the
4 and
BLU/GRN terminal to
BLU/GRN
the BLK 2 terminal, then
ignition switch ON.
Connect the YEL/BLK Check the right rear motor operation: • Faulty R. rear motor.
terminal to the YEL ter- should run. • Faulty R. rear switch.
YEL
minal, and the YEL/ • An open in the wire.
5 and
GRN terminal to the
'YEL/GRNI
BLK terminal, then igni-
tion switch ON.
1
! Connect the GRN/BLK Check the left rear motor operation: • Faulty L. rear motor. 1
terminal to the GRN/ should run. • Faulty L. rear switch.

GRN/YELI
i YEL terminal, and the • An open in the wire.
6 and
GRN terminal to the
GRN
BLK terminal, then igni-
tion switch ON.
Connect the WHT/YEL Check for resistance between the BLU • Faulty pulser.
terminal to the RED/ and BLK 2 terminals: • Faulty driver's motor.
BLU YEL 1 terminal, and the should indícate between 20-50 ohms • An open in the wire
7 and BLK 2 terminal to the as the driver's motor runs.
BLK 2 RED/BLU 1 terminal,
then ignition Switch
ON.
[ ] RHD
16-237
Power Windows
Driver's Switch Test--~----------------------
LHD: DRIVER'S SWITCH
1. Remove the switch from the arm rest. 1~ Terminal

G H 1 J
· 2. Check for continuity between the terminals in each
Position
~
switch position according to the tables. OFF o- \-0-- ~
1
UP
DOWN o- f-o
DOWN (AUTO) o- f-o
R.FRONT SWITCH
~ Terminal
A B M o
Position Main ~
Switch
OFF
ON o- l-o
OFF o-N ¡
UP
ON o- f-o
OFF o- ~
DRIVER--~;.....¡.~~"""
ON
SWITCH
DOWN
OFF
l.REAR-~~~-
SWITCH
R.REAR SWITCH
~ Terminal
E F N o
Position Main ~
Switch
OFF
ON o- -o
o-+-o
o~
OFF
:
ON o--o
UP
OFF o- -o
G ~ A
~___IC: ~~ DOWN
ON
J=t· ~
~=fi]'~
~[ o L.REAR SWITCH
OFF
M ~:!~E
N ~F ~ Terminal
e D L o
Position Main ~~
Switch
ON o- f-o
OFF
OFF o- f-o
ON o-N
UP
OFF o- ~
ON o
DOWN
OFF
16-238
RHD: DRIVER'S SWITCH
~ Terminal
G H 1 J
~
l
Position
OFF o-'--o- -o
UP (AUTO)
UP
L.FRONT
SWITCH DOWN ~ --o 1
DOWN (AUTO) o- --o

w:::::::!<!:~--MAIN L.FRONT SWITCH
SWITCH
""
~-fT-->.f-,A--- DRIVER Terminal
SWITCH Main ~
A B M o
Position Switch
~---:.r--~74'-~~~- R. REAR
ON o- f--o 1
OFF
SWITCH OFF o- ~
ON o--o
UP
OFF o--o
ON
DOWN
OFF
R.REAR SWITCH
""
Terminal
Main ~
e D L o
Position Switch
ON
1
o- -o
OFF
OFF o- --o
ON o- --o
UP
OFF o-+-o
ON
DOWN
OFF
L.REAR SWITCH
~ Terminal
E F N o
Position Main ~
Switch
ON o- -o
OFF
OFF o- --o
1
ON o- --o
UP
OFF o- --o
ON
DOWN
OFF
16-239
Power Windows
Passenger's Switch Test------. Driver's Switch Replacement----.
1. Remove the switch from the arm rest, then disconnect 1. Remove the driver's door trim panel, then disconnect
the 5-P connector. all of the connectors from the drivers door trim panel.
2. Check for continuity between the terminals in each 2. Remove the arm rest from the driver's door trim panel
switch position according to the table. by removing the retainer and the screws.
NOTE: Right [Left] front switch is shown. Rear

switches are similar.
[ ]: RHD
~~ Terminal
A B e 1
o E
Position
UP "" o 1-o ¡
1
,....,
'
OFF
o- r-vl ¡
DOWN
1
o+o
o- -o¡ 1
3. Remove the power window master switch from the

arm rest by removing three screws.
POWER WINDOW
MASTER SWITCH
1
ARM REST
16-240
Passenger's Switch Replacement Relay Test-------------.
1. Remove the switch from the arm rest by removing the 1. Remove the relay from the under-hood relay box.
1 mounting screw, then disconnect the 5-P connector
from the switch. 2. There should be continuity between the A and B termi-
nals when the battery is connected to the C and D
terminals.
There should be no continuity when the battery is
disconnected.
ARM REST
A e
B o
16-241
Power Windows
Driver's Motor Test----------, Passenger's Motor Test-------.
Motor Test: 1. Remove the door trim panel.
1 . Remove the door trim panel.
2. Disconnect the 2-P connector from the motor.
2. Disconnect the 4-P connector from the door wire
harness. 3. Test motor operation by applying battery voltage to
the No.1 and No.2 terminals.
3. Test motor operation by connecting battery voltage to Test the motor in each direction, by swítching the
the No.3 and No.4 terminals. leads from the battery.
Test the motor in each direction, by switching the
leads from the battery. 4. lf the motor does not run, replace it.
4. lf the motor does not run, replace it.
Pulser Test:
Measure resistance between the No.l and No.2 terminals
when running the motor by connecting battery voltage to
the No3 and No.4 terminals.
Ohmmeter should indicate between 20-50 ohms as the
2
motor runs.
4 3 2
PULSER
DRIVER'S
DOOR
MOTOR
16-242
Wipers/Washers
Component Location l n d e x - - - - - - - - - - - - - - - - - - - - - - ,
• Troubleshooting 16-246
WINDSHIELD
WIPER/WASHER
SWITCH
WINDSHIELD WIPER Test, page 16-24 7
ARMS/BLADES Replacement, page 16-248
Test, page 16-251
HEADLIGHT WASHER
CONTROL UNIT
INTERMITTENT WIPER
RE LAY
WINDSHIELD WIPER
(Located under the
MOTOR ASSEMBLY
relay box}
Test, page 16-248
Test, page 16-246
WINDSHIELD WASHER
MOTOR
Test, page 16-251
DASH FUSE BOX
Test, page 16-251
INTEGRATED CQ'NTROL UNIT

(Combinad operation with
wiper/washer)
Input Test, pages 16-145, 151
16-243
Wipers/Washers
Circuit Diagrann-------------------------------------------------------,
IGNITION
UNDEA-HOOD RELA Y BOX SWITCH DA SH FU SE BOX
No.15(80A) No.19(50A) ~ 1 N~.~(3~A) 1

WHT~ BLKIYEL ~ GRN/BLK
,.._,--+--1- T - - G R N I B L K - - - - - - t l
GRN/BLK
GANIBLK GRN/BLK GRNIBLK
WIPERIWASHER SWITCH 84
OFF
W ASHER
SWITCH
BLK/Y EL GRN BLUIWHT' BLK BLU

BLUIYEL COMBINED
OPERATION
WITH WIPER
GRN IWASHER
610 (in INTEGRA TED)
CONTROL UNIT
GANIBLK
WIPER MOTOR 83
Hl
IN TER-
LO MITTENT
GRN/BLK BLU WIPER
RELA Y
BLKIYEL GRNIRED
82
BLU/WHT 2
811 81
As
"---+--+---+----+- BLU/W HT , _ _ _ _ _ __.
BLKIYEL
WASHER
MOlOR
BLK BLK BLK BLK BI.K
l l l l 1
G301 G301 G401 G251 G401
G402 G402
16-244
Circuit Diagram (Headlight Washer) D
---------------=
IGNITION
SWITCH
WHT
-® G
BLK/YEL
WHT
- LIGHTING
y
( AUXILIA AY SWITCH
{30A) FUSE HOLDER GRNIBLK
KS,KW and KE)
t;> ( models only
--+--....J
RED/BLK
e o
HEA DLIGHT
WASHER
LIGHT SWITCH
(0.84W)
RED
~
DASHLIGHT
BRIGHTNESS
CONTROLLER
WHTIBLK---.r. HEADLIGHT WASHER

CONTROL UNIT
HEADLIGHT
WASHER
MOTOR
BK
1
G401
G402
16-245
Wipers/Washers
Troubleshootingl--------------------------------------------------~
l>em 10 bo '"''"Cied 1
'5
Q;
.r::.
e
!ll o
U)
"'S: ·¡: "'~ Q;

.r::. U) Q>
U)
::l
.S
U)
Q)
Ol o
-5 ~ "'S: .2
Q)
> "O 1
"'
~
o ro
.z"' xo >
"'
-~
E ·s "O ~
U)
!1
:0 ~ e o ¡¡:: Q) U)
e
~ ..e E o o ~ Q; ~
o Q)
QJ Q; ·;:::
"O
Q;
.r::.
o
o a. -~
'§
"'"'"'
c. E ~ :0 -~
~ .z"' .r::.
.r::.
B l5 '§ Q)
c. E "'"'S: "O 8,1 "O
~
.!: "O
....
<O
ci
.r::.
U) B .r::. B -~ oE E o Ol.
~
....e ~
oQ)
Ol
o ~
oQ)
"O
e ·s ~
z "'.,, '§ B o
"'Q; ~
"O
Q)
.!: QJ u ::l
o ~
o
QJ
"O E ·¡:; e e
e "'Q; §
.r::.
Q;
·~
e
:.0 Q)
¡¡: e: o e: ~ ·¡:;
e: e:
e
0"'
.s::;, Q; .S:. o o o
S: c. U) <J)
E -5 o QJ o l5
Symptom
o
iii i] a..
~ ~ ~ $"'
'
1 ~
~
.!:
o
u :§.
::l
IJ)
.!: o"' .r::."'o o"' o

Cl.
c. o
QJ
o '6"'
1 n all positions 1 4 2 3 G301 GRN/BLK
Wipers do not In INT 1 2 ORN, BLU/WHT1

operate In LOor Hl 1 2 BLU/YEL, BLU
In MIST 1
Blades do not return to park position

2 1 1
BLU/WHT1
when wipers are turned OFF.
GRN/BLK, GRN
Erratic íntermittent cycle or wipers
1 BLU/WHT1,
do not operate intermittently. l
GRN/RED
'
Little or no washer fluid is pumped.
1
4 3 1 2 ! G301 BLK/YEL
Wipers do not operate simultaneous-

BLK/YEL
ly with washer.
1
lntermittent Wiper Relay T e s t - - - - - - - - - - - - - - - - - - - - - - .

1. Remove the intermittent wiper relay.
2. There should be continuity between the A ande termi-

nals when the battery is connected to the E and F
terminals.
There should be continuity between the 8 and e termi-
nals when the battery is disconnected.
F A B
~
B 8 E
E e
16-246
Wiper/Washer Switch T e s t - - - - - - - - - - - - - - - - - - - - - . ,
1. Remove the instrument lower panel.
2. Disconnect the 7-P connector of wiper washer switch from the main wire harness.
3. Check for continuity between the terminal in each switch position according to the table.
7-P CONNECTOR
,.....,
',,
View from wire side

INSTRUMENT LOWER COVER
Terminal
1 2 3 4 5 6 7
Position
'""'
1
OFF
""' o
INT
\
o D
Lo 1
Hi
Mist switch "ON"
Washer switch "ON" o

1
16-247
Wipers/ Washers
Wioer/Washer Switch------. Windshield Wiper Motor Test--.....,
Replacement
1. Remove the steering wheel. 1. Disconnect the 5-P connector of the wiper motor
assembly.
2. Remove the lower and upper covers from the steering
column. 2. Test motor operation:
LOW SPEED: Connect battery positive to the B
3. Disconnect the 8-P and 2-P connectors from the (GRN/BLK) terminal and negative to
wiper/washer switch. the Lo (BLU) terminal.
HIGH SPEED: Connect battery positive to the B
4. Remove the 2 screws and slide the wiper/washer (GRN/BLK) terminal and negative to
switch out of the housing as shown. the Hi (BLU/YEL) terminal.
NOTE: 3. lf the motor fails to run smoothly, replace it.

e Be careful not to damage the steering wheel cover.
e lf equipped with cruise control, remove the wiper/
washer switch after removing the slip ring (see page
16-262).
SELF-LOCKING NUT
50 N•m (5.0 kg-m. 36.2 lb-ft)
Replace.
WIPER/WASHER
SWITCH
As (BLU/WHT)
16-248
Windshield w·1per Motor Re 1
Opeothe hood ' d p acement
1. arms n remove the cap nuts and th e w1per
. 4. Remove the 3 mounting b
linka ge assembly o remove
1
th and. nut from the
olts .
remb~.
1
MOUNTING e W'P" moto"' W'P"'
BOLTS
NOTE·
. · earefu!ly re
Wlper
R arms d o not touch
move th
thee hwi per arms so th "
ood. the
10 N•m (1 O
7.2 lb-ft) . kg-m.
2. ~move the hood s
tnm e~l and
clips and removmg theair scoo P by prying off the
screw
S.
WIPER
ASS l INKAGE
EMBLY
~WIPER MOTOR
5. lnstall
emoval . w·lper motor assembly .In the reve rse order of
the
r
16-249
Wipers/ Washers
Headlight Washer Control Unit Input T e s t - - - - - - - - - - - - - - - - .
Disconnect the 6-P connector from the control unit, locat-
ed at left kick panel.
lf all tests prove OK, yet the system still fails to work,
replace the control unit.
View from wire side
1 BLK ¡ Under all conditions. Check for continuity to ground:

• Poor ground (G401, G402).
Under all conditions. Check for voltage to ground: • Blown 30 A fuse in auxiliary fuse
2 WHT/BLK * should be battery voltage. holder.
i • An open in the wire.
¡ lgnition switch ON and Check for voltage to ground: • Blown No.6 (30 A) fuse.
3 jGRN/WHT headlight washer should be battery voltage. • Faulty headlight washer switch
switch ON. • An open in the wire.
!,
1
Connect the WHT ter- Check the headlight washer motor • Faulty headlight washer motor.
4 WHT/RED minal to the WHT/RED operation: should run. • Poor ground (G401, G402).
terminal. • An open in the wire.
lgnition switch ON. Check for voltage to ground: • Blown No.6 (30 A) fuse.
5 GRN/BLK
1
*: KS, KW and KE models only
16-250
Headlight Washer Switch Test---. Washer Motor Test--------,
1. Pry out the switch from the floor console, then discon- 1. Remove the front bumper and disconnect the 2-P
nect the 4-P connector from the switch. connector from the washer motor.
2. Check for continuity between the terminals according
to the table. 2. Test washer motor operation by connecting battery
positive . to the EB terminal and negative to the 8
NOTE: Be -careful not to damag~ the switch or the terminal.
instrument panel when prying out the switch.
~~
Terminal
B e A D
Position ~
OFF
~
ON o- --o
1
WASHER FLUID
RESERVOIR
[fT=f=f]
A B C O
16-251
Wipers/Washers
VVasher Replacernent------------------------------------------------~
1. Remove the bumper, then remove the washer reservoir by removing the 3 mounting bolts.
2. Disconnect the hoses and the 2-P connectors from the windshield and the headlight washer motors.
3. Remove the washer nozzles.
NOTE:
e Clamp the hose in the left front tender.
e Take care not to pinch hoses during reinstallation.
e lnstall the grommets firmly.
e After installation, adjust the washer nozzles.
.~--:;;al' MOUNTING
BOLTS
CLAMP
HOSE
HEADLIGHT
WASHER MOTOR
16-252
Cruise Control
Component Location lndex---------------------~
INDICATOR LIGHT and

DIMMING CIRCUIT
(in the gauge assembly)
Ga uge Assembly, page 1 6-11 2
CRUISE CONTROL MAIN SWITCH

Test, page 16-260
SLIP RING
Test, page 16-262
Reptacement, page 16-262
CONTROL UNIT
- ~
~¡·,, \1
SHIFT POSITION
CONSOLE SWITCH
Test, page 1 6-142
Test, page 16-263

Pedal Height Adjustment, section 7 BRAKE LIGHT SWITCH
Test, page 16-264
Pedal Height Adjustment, section 13
16-253
. Control
Crulse t"•on lndex
Component Loca
SE~:-~~
SPEED
Test, page 2
IBUTOR
DIST~ . nition coill
(Built-m •9 1 6-86
Test, page
CABLE
ACTUATOR ge 16-266
Adjustment, pa
VACUU M RESERVOIR
VENT HOSE
ACTUATOR e 16-264
SolenOI·d Test,_265
pag
16
Test, page ge 16-266
Replacement, ':ge 16-267
Disassembly, P
16-254
Description---------------------------------.
The cruise control system uses mechanical, electrical and vacuum operated devices to maintain vehicle speed at a set-
ting selected by the driver.
System Description:
The cruise control unit receives command signals from the cruise control main switch and the cruise control
SET/RESUME switch. lt receives information about operating conditions from the brake switch, the ignition coil. the
speed sensor, the clutch switch (with manual transmissionl. or the shift position switch (with automatic transmission).
The cruise control unit sends operational signals to the devices that regulate the throttle position. The throttle position
maintains the selected vehicle speed. Essentially, the control unit compares the actual speed of the vehicle to the
selected speed.
Then, the control unit uses the result of that comparison to open or close the throttle.
The brake switch·releases the system's control of the throttle at the instant the driver depresses the brake pedal. The
switch sends an electronic signa! to the control unit when the brake pedal is depressed; the control unit responds by
allowing the throttle to close. The clutch switch (manual transmission) or the shift position switch (automatic transmis-
sion), sends a disengage signal input to the control unit that also allows the throttle to close.
System Operation:
The cruise control system will set and automatically maintain any speed above 40 kph (25 mph). To set, make sure that the main
switch is in the "On" position. After reaching the desired speed, press the SET switch. The cruise control unit will
receive a set signa! input and, in turn, will actuate the cruise control actuator.
When the SET switch is depressed and the cruise control system is on, the "cruise control" indicator on the warning
display will light up.
You can cancel the cruise control system by pushing the main switch to "Off". This removes power to the control unit
and erases the set speed from memory. lf the system is disengaged temporarily by the brake switch, clutch switch, or
shift position switch, press the RESUME switch. With the RESUME switch depressed and the set memory retained, the
vehicle automatically returns to the previous set speed.
For gradual acceleration without depressing the accelerator pedal, push the RESUME switch and hold it there until the
desired speed is reached. This will send an acceleration signal input to the control unit. When the switch is released, the
system will be reprogrammed for the new speed. For gradual deceleration without depressing the brake pedal, push the
SET switch and hold it there until the desired speed is reached. This will senda deceleration signal input to the control
unit causing the vehicle to coast until the desired speed is reached. When the desired speed is reached, release the SET
switch. This will reprogram the system for the new speed.
16-255
Cruise Control
Circuit Diagrarn--------------------------------------------------------,
$1GNITION
IGI SWITCH
BLK/YEL
DA SH FU SE BOX
No.1 No.4
(1 OA) (7 .5A)
LIGHTING SWITCH
BLK/RED
RED/BLK-If-C-----, CRUISE CONTROL

MAIN SWITCH
HOAN
SWITCH
UGHT
YEL REDIBLK (1.12W)
BRA KE
LIGHT
BLI ~
A SWITCH 1
1
1
1 L......-----JI--...:......-+
1
1
1 1 DASHLIGHT
1 1 BRIGHTN ESS
1
________ J
1 CONTROL UNIT
L-
GAUGE ASSEM BLY
RED LT GRN
CRUISE CONTROL UNIT

BRAKE
LIGHTS
BRN BRN/BLK BRNIWHT PNK BLK
CRUISE
CONTROL
ACTUATOR
MIT : CLUTCH SWITCH

A/T : SHIFT POSITION
CON SO LE SWITCH
I
6301
I
6401
6402
16-256
Troubleshooting--------------------------------------------------~
"O
e
::l
o
o,
oo
1 Symptom o._
, G301 ,G401 LT GRN

Cruise control can't be set. 2 3
G402 or BLK/RED
Cruise control can be set, but

REDor YEL
indicator light does not go on.
Cruise speed noticeably higher

or lower than what was set.
¡ Excessive overshooting and/or

undershooting when trying to 1 2 3
set speed.
Steady speed not held even on

i a flat road with cruise control 1 3 2 4
set.
1
Car does not decelerate or ac- 1
celerate accordingly when SET 2

or RESUME button is pushed.
Set speed not cancelled when

1 1 2
clutch pedal is pushed. (M/T}

1 2
shift lever is moved to N. {A/T) 1
r------------------------------t-----r--r----t--t-~--t-------~--~~----+--4--+----------4---------------~
2 3
brake pedal is pushed.
Set speed not resumed when

RESUME button is pushed
2
(with main switch on, but set
11
1 speed temporarily cancelled). ¡
16-257
Cruise Control
Control Unit Input T e s t - - - - - - - - - - - - - - - - - - - - - -
Disconnect the 14-P connector from the control unit,
located under instrument panel.
Make the following input test at the harness pins.
NOTE: Recheck the connections between the 14-e

connector and the control unit, then replace the con-
trol unit if all input tests prove OK .
..____(_______]
14-P CONNECTOR
View from wire side
16-258
Under all conditions. Check for continuity to ground: · Poor ground (G401, G402).
1 BLK
should be continuity. . · An open in the wire .
lgnition switch ON Check for voltage to ground: · Blown No.4 (7.5 A) fuse.
and main switch ON. should be battery voltage. • Faulty main switch.
2 LT GRN
· An open in the LT GRN or BLK/RED
wire.
LT GRN/ RESUME button Ground each terminal: • Blown No.25 (20 A) fuse.
3 BLK pushed. Horns should sound as the · Faulty SET/RESUME switch.
switch is pushed. · Faulty slip ring.
LT GRN/ SET button pushed. · An open in the WHT/YEL, BLU/RED,
4 RED LT GRN/BLK or LT GRN/RED wire.
M/T: Clutch pedal Check for continuity to ground: • Faulty or misadjusted clutch switch
pushed. should be continuity. (M/T).
A!T: Shift lever in • Faulty shift position console switch
5 PNK (A/T).
2, D3 or D4
· Poor ground (G401, G402)
1
1 Start the engine. Check for voltage to ground: • Faulty ignition system.
6 BLU
lgnition switch ON Check for voltage between the LT GRN · Faulty speed sensor.
and main switch ON. EtJ
and ORN 8 terminals: · An open in the wire.
7 ORN Raise the front of should be
the car and rotate 0-5-0-5 V repeatedly.
one wheel slowly.
lgnition switch ON, Check for voltage to ground: · Faulty brake light switch
1 main switch ON and should be O V with the pedal • An open in the GRY or LT GRN wire.
8 GRY
brake pedal pushed, pushed and battery voltage
then released. with the pedal released.
Brake pedal pushed, Check for voltage to ground: • Faulty brake light switch.
then released. should be battery voltage with · An open in the wire.
9 GRN!WHT
the pedal pushed, and O V with
the pedal released.
lgnition switch ON. Attach to ground: · Blown bulb.
lndicator light in the gauge · Blown No.1 (10 A) fuse.
10 RED assembly comes on. · Faulty dimming circuit in the gauge
i
assembly.
Under all conditions. Check for resistance to ground: · Faulty actuator solenoid.
11 BRN
should be 80-120 n. • Open or short in the wire.
Under all conditions. Check for resistance to ground:
12 BRN/BLK
should be 70-110 n.
U nder all conditions. Check for resistan ce to ground:
13 BRN/WHT
should be 40-60 n.
16-259
Cruise Control
Cruise Control Main/Sunroof ----. Cruise Control Main Switch Test
Switch Removal
1. Remove the switch from the instrument panel.
1. Pry out the switch from the instrument panel.
2. Disconnect the 6-P and the 5-P connectors·from the switch position according to the table.
switch.
NOTE: Be careful not to damage the switch or the

instrument panel when prying out the switch.
GROOVE
e o
PILOT LIGHT
LIGHT (1.12 W)
.(1.12 W)
B A E
16-260
SET/RESUME Switch T e s t - - - - - - - - - - - - - - - - - - - - .
1. Remove the dashboard lower panel. 4. Remove the steering wheel and repeat step 3, but this
time test at the 4-P connector of the steeríng wheel.
2. Disconnect the 20-P connector from the maín wire
harness.
View from wíre side
11@
B
View from wire side
2.0-P
CONNECTOR
STEERING
WHEEL
e lf there is no continuity in one or sorne switch

positions, repair the SET/RESUME switch.
e lf all of the continuity check is OK, check the slip
ring (page 16-262).

Terminal
A B e
rPosition \
OFF
SET (ON) o- f--o
RESUME (ON) o -o
e lf all of the continuity check is OK, the SET/
RESUME switch is OK.
e lf there is no continuity in one or sorne switch

positions, go to step 4.
16-261
Cruise Control
SET/RESUME Switch Replacement Slip Ring Test/Replacement-----.
1. Remove the steering wheel. 1. Remove the steering column lower cover.
2. Remove the body covers. 2. There should be continuity between the No.3 and A
terminals, the No.2 and B terminals, and the No.1 and
3. Remove the 3 screws and the SET/RESUME switch e terminals, as you turn the slip ring.
from the steering wheel.
BOOY COVER
View from
terminal side
SET/RESUME
SWITCH STEERING
WHEEL
3. lf necessary, remove the steering column upper cover
and the 4 screws to replace the slip ring.
COMBINATION
SWITCH
5-P CONNECTOR
16-262
Clutch Switch Test Shift Position Console Switch Test
1. Disconnect the 3-P connector from the switch. 1. Remove the front console, then disconnect the
12-P connector from the console switch.
2. Check for continuity between the terminals ac-
cording to the table. 2. Check for continuity between the terminals in each
\ Terminal
A 8
Clutch Pedal \
,.... ,....
....,
RELEA SED ~
,\ Terminal
5 8
PUSHED Position \ 1
1
1 1
2 o 1
-o 1
D3 o -o
D4 o -o
N
R
p
CLUTCH PEDAL
3. lf necessary, replace the switch or adjust pedal

height (see section 7).
3. lf necessary, re place the switch (see page 16-142).
16-263
Cruise Control
Brake light Switch Test Actuator Solenoid Test
1. Disconnect the 4-P connector from the switch. 1. Disconnect the 4-P connector from the actuator.
2. Check for continuity between the terminals ac- 2. Measure resistance between the terminals.
cording to the table.
Resistan ce
VACUUM SOLENOID (between B and DI:
!\ Terminal
A B e D
30-50!1
VENT SOLENOID (between C and DI:
Brake Pedal \ 40-6012
PUSHED o- e-O SAFETY SOLENOID (between A and DI:
RELEA SED o ,....
~ 40-6012
NOTE: Resistance wíll vary slightly with tempera-

ture; specified resistance is at 20°C (70°F).
3. lf necessary, replace the switch or adjust pedal

height (see section 1 3).
From VENT To CHECK

HOSE VAL VE
O A e B
16-264
ActuatorTest------------------------------------------------------~
D
1. Disconnect the actuator cable from the actuator 5. With voltage and vacuum still applied, try to pull
rod and the 4-P connector. the actuator rod out by hand.
You should not be able to pull it. lf you can, it is
2. Connect battery positive to the D terminal and defective.
negative to the A, 8 and e terminals.
3. eonnect a vacuum pump to the check valve.

Then apply vacuum to the actuator.
CHECK VALVE
ACTUATOR
6. Disconnect battery negative from the e terminal.
CABLE
The actuator rod should return.
lf the actuator rod does not return, and the vent
hose and filter are free, the solenoid valve
assembly is detective.
V1ew from 7. Repeat steps 2-6, but this time disconnect battery
terminal side negative from the A terminal.
The actuator rod should return. lf it does not return,
and the vent hose and filter are free, the solenoid
valve assembly is detective.
8. lf the solenoid valve assembly is replaced, be sure

4. The actuator rod should pull in completely.
to use new 0-rings at each solenoid.
lf the rod pulls in only part-way or not at all, check
for a leaking vacuum line or detective solenoid.
ACTUA TOR ROO
16-265
Cruise Control
Actuator/Cable Replacement----, Actuator Cable Adjustment - - - - - .
1. Pull back the boot and loosen the locknut, then dís- 1. Check that the actuator cable operates smoothly
connect the cable from the bracket. with no binding or sticking.
2. Disconnect the cable end from the actuator rod. 2. Start the engine.
3. Measure the amount of movement of the actuator

rod until the cable pulls on the accelerator lever (en-
gine speed starts to increase). Free play should be
11 ± 1.5 mm (0.43 ± 0.06 in).
ACTUATOR ROO
ADJUSTING NUT
LOCKNUT
ADJUSTING NUT
LOCK NUT
BOOT
3. Disconnect the 4-P connector from the actuator.
4. Pull the vent hose from the grommet.

LOCKNUT FREE PLAY: 11 ± 1.5 mm
5. Disconnect the vacuum hose from the check valve. {0.43 ± 0.06 in)
6. Remove the 2 mount bolts and the actuator with
4. lf free play is not within spécs, loasen the locknut
the bracket and reservo ir.
and turn the adjusting nut as required.
VACUUM HOSE NOTE: lf necessary, check the throttle cable free

Play (see section 6), then recheck the actuator rod free
ACTUATOR
play.
BRACKET
5. Retighten the locknut and recheck the free play.
GROMMET
4-P
CONNECTOR
7. lf necessary, disconnect- the cable end from the

linkage over the acceterator pedal, then turn the
grommet 90° in the firewall and remove the cable.
8. lnstall in the reverse order of removal, and adjust

free-play at actuator rod after connecting the cable
(see next column).
16-266
Actuator Disassembly
D
SOLENOID SEAL
Check for damage
·~
CHECK VALVE
1 VENT HOSE
®
t
GROMMET
VACUUM HOSE
ACTUATOR 265
'
Test, page 16-
DRAIN HOSE
VACUUM
RESERVO IR
16-267
Wiring Diagrams
lndex--------------------------------------------------
Headlights · 6
Taillights · · · · · · · · ·6
16-274

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Vdocuments - MX Service Manual Honda Accord 1990

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INTRODUCTION

How to Use This Manual - - - - - - - - - - - - - - - - - - - - - - .

Each section includes:

CAUTION: lndicates a possibility of personal injury or equipment damage if instructions are

NOTE: Gives helpful information.

CAUTION: Detailed descriptions of standard workshop procedures, safety principies and

First Edition 10/89 1266 Pages HONDA MOTOR CO .• LTD.

Engine Type ----------....1 e--Manual Transrnission Nurnber - - - - - - - - ,

Transmission Type - - - - - - - - - ' 1

Vehicle ldentification Number

Transmission Number Engine Number

Vahicla ldentification Numbar

Fuel-lnjected Engine: BONNET

AIR CLEANER. SERVICE

SPARK PLUG CAUTION

4. Adjust and place the safety stands as shown on

JACK LIFT PLATFORM

Center the jacking

FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINT

f"§i.ji§!liM Never use two chains or rope to tow a car;

We recommend the following:

CAUTION: To avoid serious damage on automatic

3. Fuel Line Servicing

6. Apply liquid gasket to the transmission, oil pump

1. Protect all painted surfaces and seats against dirt and

6. Parts must be assembled with the proper torque

8. Use new packings, gaskets, 0-rings and cotter pins

9. Use genuine HONDA parts and lubricants or those

4. Mark or place all removed parts in order in a parts rack

• After making repairs, check each wíre or p~rt for proper

• Coat the terminals with clean grease after connecting

12. Avoid oil or grease getting on rubber parts and tu bes,

Besure to install the terminal cover over the connections

When disconnecting locks, first press in the connector

Before connecting connectors, check to see that the

• lnsert the connector tightly and make sure ít is securely

o touched when connectíng.

Check for loose retaíners and rubber seals. The illustra-

RUBBER SEAL (cont'dl

• 'lnsert male connectors into the female connectors fully

X After .clamping, check each harness to be certain that it

Secure wires and wire harnesses to the trame with their

Do not damage the insulation when connecting a wire.

Clean the attaching surface thoroughly if an adhesive is

~ :Apply engine oil.

Are range and

:Apply DEXRON® 11 Automatic

g :Apply Power Steering Fluid.

• Make sure to use the probe with a taper tip.

2WS Front Wheel Steering [El Parking

4WS Four Wheel Steering [BJ Reverse

A/C Aír Conditioner @] Neutral

ALB Anti Lock Brake m Orive Position (1st-4th)

A/T Automatic Transmission QJ Orive Position ( 1st-3rd)

ATF Automatic Transmission Fluid m Fixed 2nd speed

B or BAT Battery rn Fixed 1st speed

CATA Catalytic Converter S S Signai/S Switch

EACV Electronic Air Control Valve

ECU Electronic Control Unit

EGR Exhaust Gas Recirculation

LHO Left Hand Orive

M/T Manual Transmission

PCV Positive Crankcase Ventilation

Throttle control system4. 5 1 1

Choke mechanism7 CB 1