1993 Prelude

I NT RO DUCT ION I G e n e ra l n fo
How to Use This Manual -

This manualis dividedinto 23 sect
tion is markedwith a blacktab that lin€sup with its co.responding
thumb indextab on this paqeand the back cover. you can auicklv
tind the tirst pageof each sectionwithout lookingthrougha full ta-
ble of contents.The symbolsprintedat the top cornerof each page
can also be used as a quick referencesystem.
Each section includes: Specifications f,|tr

1. A table of contents,or an explodedview index showing:
a Partsdisassemblvsequence.
a Bolt torquesand thread sizes.
a Pagereterencesto descriptionsin text.
2. Disassembly/assembly proceduresand tools. Maintenance t
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Engine ll=
SpecialInformation
@@ tnai""tes a strong possibility ot sevoro p€rsonal injury
Cooling It
or losa of lite it instluctions ar€ not tollowed.
ri!
CAUTION: Indicates a possibility of poBonal iniury ol oquipmont
damage if instructions aro not tollowed.
NOTE: Gives helpful information. Fueland Emissions

ZZ
CAUTfON: Detaifoddescriptionsol st ndard wo*shop procedures,
satety p nciplesand servic€opalationsaro not includod.pleasonot6
that this manualcontainswamings and cautionsagainstsoms spocit-
ic s€rvice methods which could cause PERSONALlNJURy, d8mag6
*Transaxle
a vahicl€ or mako it unsafe. Pleaaaund€ratandthat thos6 warnings
cannot cover all conc€ivableways in which sorvice, whethgr 01 not
recommended by HONDA might b6 dono, or of tho possible
hazardous consequences of evely conceivablo way, no. could
*Steering
HONDA invostigateallsuch ways. Anyono using sorvics proceduros
01toofs. whether or not rocommendedby HONDA,must satjslyhim- If." r
sel, thoroughly that ngithor p€r3onal aatety nor vohicl€ s8fety will
be jsopardized.
All informationcontainedin this manualis basedon the latest Droduct

info.mationavailableat the time of printing.We reservethe right
to makechangesat any time without notice.No part of this publica-
tion may be reproduced,storedin retrievalsystem.or transmitted,
in any form by any means,electronic.mechanical,photocopying, * Brakes
recording,or otherwise,without the prior written permissionoJ the
publisher.This includestext, figures and tables. (lncludin
First Edition9/92 1516 pages HONDA MOTORCO..LTD.
All Rights Reserved Seruic€ Publication Offics * Bo d y
Specilicationsapply to U.S.A. and Canada
* H e a te ra n d
Ai r C o n d i ti o n i n
* Electrical
-
I
L'___
As soctions with * includ6 SRS comDononrs.
sp€cial piocautions aro roquirad whoit so.vicing. (lncluding
- +
GeneralInformation
Chassis and PaintCodes................. 1-2

ldentification NumberLocations....... 1-4
Warning/Caution Labels.................. 1-s
Lift and SupportPoints
Lift ........... . . . . . . . . . . . . .1. .-.9
F l o o Jr a c k . . . . . . . . . . . . . .1. -. .1 0
S a f e t yS t a n d s . . . . . . . . . . .1. - 1 1
Towing .......1-12
ServicePrecautions
Handlingof SpecialNuts
and Bolts 1-13
'!.
7t
Chassisand Paint Codes
U.S. Model
EngineNumber
JHMBA814'PCOOOOol F22A1-9200001
Engine Type
Type of Vehicle F22A1; 2.2 / SOHC SequentialMulti-
port Fuel-injectedengine
J H M : H O N D AM O T O RC O . , L T D .
HONDA, PassengerCar H22A1t 2-2, DOHCVTEC Sequential
Multiport Fuel-iniectedengane
BA8: Prelude2.2 / H23A1t 2.3, DOHC SequentialMulti-
port Fu€l-injectedengine
BBl : Prelude2.2 t VfEC
BB2: Prelude2.3 / EmiesionGroup
Body and TransmissionTYPe lOO: Califolniawith H22A1 engine
1: 2-door s-sDeedManual 130: 49ST with H22A1 engine
2t 2-doot 4-speedAutomatic 2OO:Californiawith H23A1 engine
Vehicle Grade 23O: 49ST with H23A1 engine
4: PreludeS 920: Calilorniawith F22A1 engine
5: PreludeSi 923: 49ST with F22A1 engine
6: PreludeSi 4WS Serial Numbel
7: PreludeSi VTEC
Chock Digit
Model Yoat
'1993
P:,
M2F4-1000001
M2F4: Manualwith H22A1 engine

M2L5: Manualwith F22Al engine
M2S4: Manual with H23A1 engine
M2F4: l OOOOO1 -
-
Exceot M2F4: 20OOOO1
Vehicle ldentificationNumbel Paint Code

and FederalMotor Vehicle
Safety Standard Certification' COLOR
Fresco Blue Pearl
B-64P Brittany Blue Metallic
GranadaBlsck Peatl
SeablingSilver Metallic
Frost White
Mirano Red
ii
ir
i[i
CanadaModel
Vehicle ldentificationNumber
J H M B A 8 1 4 *P C 8 0 0 0 0 1
F22A1: 2.2 / SOHC SequentialMulti

J H M : H O N D AM O T O RC O . . L T D . port Fuef injected engine
HONDA, PassengerCa. H22A'l:2.2 / DOHC VTEC Seouential
Multiport Fuel-injectedengine
BA8: Prelude2.2 / H23A1: 2.3 / DOHC SequentialMulti-
B B 1 :P r e l u d2e. 2 . l E C pon Fuel-injected engine
BB2: Ptelude 2.3 I
Body and T.ansmission Type F22A1 engine; 928OOO1-
1: 2-door s-sDeedManual l-
H22A1 engine: l TOOOO
2', 2-doot 4-speedAutomatic H23A1 engine: 27OOOO1-
Vehicle Glade
4: Prelude
5: PreludeSR
6: PreludeSR 4WS
7: PreludeSR-V
M2F4-1000001
Check Digit
Model Y6at
P: 1993
M2F4: Manual with H22A1 engine
M2L5: Manualwith F22Al engine
C: SaitamaFactoryin Japan
M2S4: Manual with H23A 1 engine
M2F4: l OOOOOl -
-
ExceptM2F4: 2OOOO01
Vehicle ldentificationNumbe] Paint Code

and CanadianMotor Vohicle
Safety Standard Certification. COLOR
8,64P F esco Blue Pearl
Brittany Blue Met8llic
Granada Black Pearl
SeablingSilverMetallic
Frost White
Mirano Red
1-3
ldentificationNumberLocations
Vehicle ldentif ication

Number
V.hicl€ ldontitication
Numbo.
TransmissionNumber
(Automaticl
t Tiansmission Number
lManual)
'l i,
,l
Warning/CautionLabelLocations
A: CABLE REELCAUTION A D: DRIVERMODULEWARI{|]{G

CAUTION: ISRSI A WARI{ING
BEFOREINSTA-I.IINGCABLE REEL: THEAIRBAGI'{FLATOR IS EXPLOSIVE
AND,IF ACCIDEN.
. CENTERTHE FRONTWHEELS. TALLYDEPLOYED, CAt{ SERIOUSLY
HURTOF KILLYOU.
. ALIGN THE MARKS. . DOI{OI USEELECTRICAL TESTEOUIPMENT ORPNOB-
. READ SERVICEMANUAL. II{G DEVICES.THEY CAN CAUSE ACCIDENTAL
DEPTOYI'EI{T.
B: CABL€ REELCAUTION B . NO SERVICEABLE PARTSINSIDE,DO OT DISAS.
SEMBLE.
cAUTtOt{: . PLACEAIRBAGUPf,IGHTWHEI{BEMOVED.
NO SERVICEABLE
PARTSINSIDE;DO NOT DISASSEMBLE a Fou.ow sERvtcE MAI{UAL |]{STRUCT|O]{S
OR TAMPER. CAREFULLY.
C: DRIVERMODULE DANGER E: I FLATOR WARNING TAG
A DANGER A WARNING
EXPLOSIVE/FLAMMABLE ACCIDENIAL AIRBAG DEPLOYMEI{I CA]T SERIOUSLY
CONTACTWITH ACID, WATEROR HEAVYMETALSSUCH HURTOR KILLYOU. II{STALLTHE REDSERVICECONNEC-
AS COPPER.LEAD OR MEFCURYMAY PRODUCEHARM- IOB WHENTHE INFLATORHARITESSIS DISCONNECTED.
FUL AND IRRITATING GASES OR EXPLOSIVE COM-
POUNDS.STORAGETEMPERATURES MUST I{OT EXCEED F: STEERINGWHEEL t{OllCE
2OO"F{1OOOCI.FORPROPERHANDLII{G,STORAGEAND
DISPOSALPROCEDURESREFERTO SERVICEMANUAL, NOTICE
SRS SUPPI.EMENT. IMPROPERSTEERINGVYHEELREMOVAL OR II{STALLATION
POTSON CAN DAMAGE SRS COMPOT{EI{TS.
COI{TAINSPOISONOUSSODIUMAZIDEAND POTASSIUM FOLLOWSERVICEMA UA! INSTRUCTIONCAREFULLY.
NITRATE,
FIRSTAIO
IF CONTENTSARESWALLOWED.II{DUCEVOMITING.FOR
EYE CONTACT, FLUSH EYES WITH WATER FOR 15
MINUTES.IF GASES (FROMACID OR WATER CONTACT)
ABE INHALED, SEEI( FRESHAIR. IN EVERY CASE, GET
PROMPTMEDICAL ATTENTION.
KEEPOUT OF REACHOF CHILDREN.
(cont'd)
1-5
I Warning/CautionLabelLocations
(cont'dl
'E: Inflatorwarning tag (Reterto page l-5).

G: SRSWARNING{ENGINEHOOOI K: DRIVERINFORMATION
ISUNVISOB)
SUPPLEMENTALRESTRAIIIITSYSTEM ISRS) ALWAY WEARYOURSEATBELT

THIS VEHICLE IS EOUIPPEDWITH DRIVERAND FRONT CAR IS EOUIPPEDWITH A DRIVERAIRBAG AS A
SEAT PASSENGEB AIRBAGSAND FRONTSEAT BELTTEN. SUPPLEMENTALRESTRAINTSYSTEM {SRSI.
SIONERSYSTEMS. . IT IS OESIGNEDTO SUPPLEMENTTHE SEAT BELT.
ALL SRS ELECTRICALWIRING AND CONNECTORSARE . BEFORE ORIVINGREADLABELINSIDETHEGLOVEBOX.
COLOREOYELLOW.
TAMPERINGWITH, DISCONNECTING OR USINGELECTRI- 'K: DRIVERINFORMATION
CAL TEST EOUIPMENTON THE SRS WIRING CAN MAKE
THE SYSTEMINOPERATIVEOR CAUSEACCIDENTALFIR-
ING OF THE INFLATOR. ALWAY WEARYOURSEATBELT
CAR IS EOUIPPEOWITH A DBIVERAIRBAG AND
A WARNING A FRONTSEAT PASSENGER AIRBAGAS A SUPPIEMEN-
THE AIRBAG INFLATORIS EXPLOSIVEAND. IF ACCIDE . TAL RESTRAINTSYSTEM ISRS).
TALLY OEPLOYED.CAN SERIOUSLYHURTYOU. FOLLOW . IT IS DESIGNEDTO SUPPLEMENTTHE SEAT BELT.
SERVICEMANUAL INSTRUCTIONSCAREFULLY. . BEFOREDRIVINGREAOLABELINSIDETHEGLOVEBOX.
H: STEERING
COLUMNCAUTION L: GLOVEBOX INFORMATION
CAUTION ISRS DRIVER'SAIREAG INFORMATION

To AvotD DAMAGIIGrHE sRs CABLEoB REE|-.
wHtcH . SUPPLEMENTAL RESTRAINTSYSTEMISRSICAN PRO-
COULDMAKETHESYSTEMINOPERATIVE, REMOVETHE VIDE AOOITIONALPROTECTIONFORTHE DRIVERIN A
STEERING WHEELB€FOREREMOVING THE STEERING FRONTALCOLLISION.A FUNCTIONALDESCRIPTION OF
SHAFTCONNECTOR BOLT. THE SRS IS IN YOUR OWNER'S MANUAL.
. THE SYSTEMMUST BEINSPECTEDTEN YEARSAFTER
DATE OF MANUFACTURE,AS NOTEDON THE CERTIFI-
l: FRONTSEAT PASSENGER
AIRBAGMODULEDANGER CATION PLATE.
. ANY REPAIR,INSPECTIONOR NEARBYACCESSORYII{.
A DANGER STALLATIONSHOULD8E DONE BY AN AUTHORIzED
EXPLOSIVE/FLAMMABLE HONDA DEALER.
CONTACTWITH ACID, WATEROR HEAVY METALSSUCH . IF YOUR SRS INDICATOR:
AS COPPER,LEAD OR MERCURYMAY PRODUCEHARM. . LIGHTSWHILE DRIVINGOR FLASHES;
FUL AND IRRITATING GASES OR EXPLOSIVE COM- . FAILSTO LIGHTOR STAYS ON AFTERTHE IGNITION
POUNDS.STORAGETEMPERATURES MUST NOT EXCEED IS FIRSTTURNEDON:
2OOOF(lOOOC}FORPROPEB HANDLING,STORAGEANO SEE YOUR AUTHORIZEDHONDA DEALER.
DISPOSAL PROCEDURESREFERTO SERVICEMANUAL,
SRS SUPPLEMEI\'T.
'L: GLOVEBOX INFORMATION
POISON
CONTAINSPOISONOUSSOOIUMAZIDEAND POTASSIUM
NITRATE. DRIVER'SAND FRONTSEAT PASSENGER'SAIRBAG IN-
FIRSTAID FORMATION
IF CONTENTSARESWALLOWED,INOUCEVOMITING.FOR . SUPPLEMENTAL RESTRAINTSYSTEM{SRSICAN PRO.
EYE CONTACT, FLUSH EYES WITH WATER FOR T5 VIDEADDITIONALPROTECTION FORTHE DN|VERAND
MINUTES.IF GASESIFROMACID OR WATERCONTACTI FRONTSEAT PASSENGERIN A FRONTALCOLLISION.
ABE INHALED, SEEK FRESHAIR. IN EVERY CASE, GET A FUNCTIONALDESCRIPTION OF THE SRS IS IN YOUR
PROMPTMEDICAL ATTENTION. OWNER'S MANUAI..
KEEPOUT OF REACHOF CHILDREI\'. . THE SYSTEMMUST BE INSPECTEO TENYEARSAFTER
DATE OF MANUFACTURE,AS NOTEDON THE CERTIFI-
A WARNING
CATION PLATE.
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN. . ANY REPAIR,INSPECTION ORNEARBYACCESSORYIN-
TALLY DEPLOYED,CAN SEBIOUSLYHURT OR KILL YOU.
STALLATIONSHOULD BE DONE BY AN AUTHORIZEO
. DO NOT USEELECTRICAL TEST€OUIPMENTOR PROB- HONDA DEALER.
ING DEVICES. THEY CAN CAUSE ACCIDENTAL . IF YOURSRS INDICATOR:
DEPLOYMENT. . LIGHTS WHII-E DRIVINGOR FLASHES;
. NO SERVICEABLEPARTS INSIDE. DO NOT DISAS- . FAII.STO LIGHTOR STAYS ON AFTERTHE IGNITION
SEMBLE. rs FrRsTTUBNEDON;
. PLACEAIRBAG UPRIGHTWHEN BEMOVED. I
. SEEYOUR AUTHORIZED HONDA OEALER.
. FOLLOW SERVICEMANUAI- INSTRUCTIONS
CAREFULLY.
M: SRS UNIT CAUTION
CAUTIONi
. NO SERVICEABLEPARTS INSIOE.
. DO NOT OISASSEMELEOR TAMPER.
. DO NOT DROP.
. STOREIN A CLEAN,DRY AREA,
*This versionof the label is used on cars with lront passengerairbag. (cont'd)
1-7
Warning/CautionLabelLocations
AIR CLEAI{ERELEMEI{T,
OIL FILTEB,RECOMMENDATIOI{
ENGINEOll- and SPARK PLUG
tl i-l atl
;DZ"N
t:
RAOIATORCAP
CAUTION
I
I
I
.
\..
1-8
Lift and Support Points
@Q wnen heavy real components such as suspension, fuel tank. spare tile and trunk lid are to be removed,
plac€ additional weight in tha trunk betole hoisting. When substantial weight is removed trom the lear of th6 cal, the
center of gravity may change and can causs the car to tip forward on tho hoist.
NOTE: Sinceeach tire/wheelassemblyweighs approximately30 lbs { 14 kg), placingthe front wheels in the trunk can
assist with weight dist.ibution.
1. Placethe lift blocks as shown.
2. Raisethe hoist a few inches (centimeters)and .ock the car to be sure it is firmly supponed.
3. Raisethe hoist to tull height and inspect lift points for solid support.
DH
REARSUPPORTPOINT
(cont'd)
1-9
Lift and SuPPortPoints
Floor Jack
Set the parkingbrakeand blockthe wheelsthat are @
o Always uso sal€ty stands when wolking on or
not being lifted.
undor any vehiclo that is supponed only by a
jack.
When liJtingthe rear of the car, put the gearshift
lever in reverse{Automatictransmissionin @ po- a N€ver att€mpt to use a bumpel iack for lifting ol
sition). supporting tho cat.
Raisethe ca. high enoughto insertthe safety stands'
Adjust and placethe satety standsas shown on page

1-1 1 so the car will be approximatelylevel,then low-
er the car onto them.
CENTERBEAM
Centerthe iacking
bracket in the middle
of the jack lilt Platform. PLATFORM
Centerthejacking
bracketin the middle
LIFT PLATFORM
ol the iack lift Platform
1-10
Safety Stands
DH
FRONTSUPPORTPOINT SAFEW STANDS REARSUPPORTPOINT
1-11
j
Towing
ll the car needsto be towed. call a proJessional

towing
service.Nevertow the car behindanothercar with just
a roDeor chain. lt is verY dangerous
Emelgency Towing
There are three popularmethodsof towing a car:
TtEDOWIIHOOKS
Flat-bedEquipment- The operatorloadsthe car on the
back ol a truck. This is the best way of transponingthe
car.
Wheel Litt Equipmont - The tow truck uses two plvor-

ing arms that go underthe tires {tront or rear)and lifts
them otf the ground. The other two wheels remainon
the ground.
Sling-type Equipmont - The two truck uses metal ca-

bles with hooks on the ends. These hooks go around
Dartsof the trame or suspensionand the cableslift that
end of the car oft the ground.The car's suspensionand
body can be seriouslydamagedif this methodof towing
is attempted.
lf the car cannotbe transportedby flst-bed,it shouldbe

towed with the front wheels off the ground. lf due to
damage,the car must be towed with the front wheels TOWINGHOOK
on the ground, do the following:
5-spe6d Manual Tlansmission

a Releasethe Parkingbrake.
a Shift the transmissionto Neutral.
Automatic Tlansmission
a Releasethe Parkingbrake.
a Start the engine.
a Shift to @ position,then @ position.
a Turn off the engine.
NOTICE:lmpropertowing preparationwill damagethe

transmission. Followthe aboveprocedureexactly.It you
cannot shift the transmissionor start the engine(auto-
matic transmission), your car must be transponedon a
flat-bed.
.-)
t: a lt is best to tow the car no farther than 50 miles
(8okm),and keepthe speedbelow 35 mph (55 km/hl'
f NOTICE:Tryingto lift or tow the car by the bumperswill

'l causeseriousdamage.The bumpersare not designedto
suooortthe car's weight.
\.
1-1 2
Service Precautions
Handlingof SpecialNuts and Bolts
Becausethe tront sub frame sectionson this car a.e con- l. When replacing nuts and bolts, use only the same
structed with aluminum alloys. use only the special type.
"Dacro" type nuts and bolts recommendedby Honda.
Tighten the nuts and bolts with I torqua wrench to
NOTE: ths specificationsprovidedin this manual.
a Dacro finish can be identitiedby gray plating.
a Some Dacro tinish bolts have a green coating on J. Clean all thread ridges with a non wire type bristle
the th.ead sectionof the bolt for easielapplica- brush. Foroignmatter in the threads may cause the
tion. This type ot bolt is calleda "Torqu6r" bolt, bolt to loosen.
a Use of other types ot nuts and bolts may cause
electrolvsisand corrosion,which in turn could 4 . S€ctions on this car requiringthe use of Dacro nuts
caus€ the bolt to loosen. and bolts will be indicatedbv a l* I in this manual.
Gray
Grcon coating
on tha thraad!
of ao|lro bolta.
Gray plsting: "Dacro" type

Gray plating + Greencoating on the threads:
"Torquer" type
1-13
Specifications
Standards
and ServiceLimits ...........3-2
DesignSpecifications
......................
3-15
BodySpecifications ....... 3-18
Standardsand Service Limits
-
CytinderHead/ValveTrain {F22A1 engine} Section 6
I TTaEASuREMENT J sraruolnotruewt I senvtceumtr
Compression 25O rpm and Nominal 1.250 112.5,1781
wide open throttle Minimum 9 5 0 { 9 . 5 ,1 3 5 )
psi)
kPa{ks/cm2, r49l'm!Il9!919! 200 12.0.2al
0.o5 (0.002)
Cylind€rhead Warpage
Hoight 9 9 . 9 5 - 1 0 0 . 0( 53 . 9 3 5 - 3 . 9 3 9 )
o.05-o.15 (0.002-0.006) o.5 {0.02)
Camshaft End play 0.15 (0.006)
oil clearance
Camshalt-to-holder 0.o50-0.089(o.oo20-o.oo35)
0.03 {0.0o1)max. o.06 (0.002)
Total runout
Cam lobe height IN 3 8 . 5 2 6( 1 . 5 1 6 8 )
EX 3a.77a11.52671
Valve clearance IN o.23-0.28(0.o09-0.o1 1)
EX 0.27-0.30 (0.01 '0.01 3)
Valve stem O.D. IN 5 . 4 8 5 - 5 . 4 9150 . 2519 - 0 . 2613 ) oossro.:I oet
EX 5.450-5.460(0.2146-0.21 50) 5.4201o.21341
IN 0.o20-0.045{o.0008-o.oo20) 0.08(o.oo3)
Stem-to-guide clearance o.12 (0.oo5)
EX 0.055,0.o80{0.0022-o.oo3'l )
IN 1.25-1.55 ( 0 . 0 4 9 - 0 . 0 6
) 1 2.0 {0.08)
Valve seat width 2.0 10.08)
EX 1 . 2 5 - 1 . 5(5O . 0 4 9 - 0 . 0)6 1
IN 48.245-48.7 15 (1.8994-1.91 79) 4 8 . 9 6 5t 1 . 9 2 7 8 1
Stem installed height ( 1 . 9 8 0 9 - 1 , 9 9 9 4 ) 5 1 . 0 3 5( 2 . 0 0 9 2 1
EX 5 0 . 3 15 - 5 0 . 7 8 5
Valve spring Freelength lN 5 4 . 8 11 2 . 1 5 8 )
54.82(2.r 58) 2
EX 5 6 . 2 6{ 2 . 2 1 5 )
56.2A12.21612
IN 5.515,5.53010.217 1-0.2177| 5 . 5 3( 0 . 2 1 8 )
Valve guide t.D.
EX 5.515-5.5301o.211 1-O.21771 5 . 5 3{ 0 . 2 1 8 1
height
Installed IN 23.75-24.25(O.91 5-0.954)
EX 15.05-'5.55 1 {O.593-0.61 2)
Bocksr arm Arm-to-shaft clearance IN o.o17-o.050 l0.oo07'o.oo20) 0.08 (0.003)
EX o.o18-0.054(0.ooo7-o.0021
) o.08{o.oo3)
''l: CHUO HATSUJOmanulacturedvalve sprrng.

'2: NIHONHATSUJOmanulactllredvalve spring
I
Unit of tength:mm (in)
Cylinder Head/ValveTrain (H23A1 enginel - Section 6
MEASUREMENT srAr{DARDtt{Ewl I stnvtce urirr
Compression 250 rpm and Nominal 1,250 112.5,1181
wide open throttle Minimum 9 5 0 { 9 , 5 ,1 3 5 }
kPa lkg/cm2, psi) Maximumvaiation 200 12.o,2al
Cylinderhead Warpage 0.o5{0.oo2)
Heighr 1 3 1 . 9 5 - 1 3 2 . 0 5( 5 . 1 9 5 , 5 . 91 9 )
Camshatt End play 0.05 0.15 (0.oo2-o.006) o.5 {0.02}
Camshaft-to-holder
oil clearance o.050-0.089(o.0020-o.oo35) *1 o . 1 5{ 0 . 0 0 6 ) . 1
0. 100,o.139 (o.0039-0.0055)*2 0.20 (o.oo8)*,
Total runout 0 . O 3( 0 . O 0 1m1a x . 0.06 (0.oo2l
Cam lobe height IN 3 3 . 6 6 1{ 1 . 3 2 5 2 }
EX 3 3. 72 5 t 1. 3 2 78 )
Valve clearance IN o.07-0.11 (0.003-0.004)
EX o . 15 - 0 . 1 9t 0 . o o 60 . 0 0 7 )
Valve stem O.D. IN 6.580-6.590(O.2591 -0.2594) 6 . 5 5( O . 2 5 8 )
EX 6.550-6.560(O.2579-0.2583) 6.32 t0.257l
Stem to-guide clearance IN o.o2-o.05(o.oo1-0.002) 0.08 {o.oo3)
EX 0.o5-o.08(o.oo2-0.o031 0 . 1 1( O . O O 4 )
Valve seat Widrh IN 1 . 2 5 - 1 . 5(50 . 0 4 9 - 0 . 0)6 1 2.0 (o.081
EX 1 . 2 5 - ' 1 . 5( 5
0 . 0 4 9 , O . 0)6 1 2.0 (0.081
Stem anstalledheight IN 3 9 . 3 6 5 - 3 9 . 8 3t '51 . 5 4 9 8 - 1 . 5 6 8 3 )4 0 . 0 8 5{ 1 . 5 7 8 1 )
I.l Valvo spring
Valve guide
Freelength
t.D.
EX
lN
EX
IN
3 9 .19 5 , 3 9 . 6 3 (51 . 5 4 3-11 . 5 6 0 4 t 3 9 . 8 8 5{ 1 . 5 7 0 3 )
4 7 . 1 41 1 . 8 5 6 1
47.r4 (1.856)
6.61-6.63(O.260-0.261 I 6.70 to.264l
EX 6.61,6.63 ( 0 . 2 6 0 - 0 . 2)6 1 6.70 {0.264)
Installed height IN 13.25-13.75 1O.522-0.541 |
EX 13 . 75 - 14 . 2 5( O . 5 4-10 . 5 6 )1
' 1: ExhaustNo. 5 journal.
'2: ExceptexhaustNo. 5 journal.
{cont'd)
3-3
-
CylinderHead/ValveTrain (H22A1 engine) Sectit)n 6
STANDARDtNEwl I sERvlcELlMlr
MEASUREMENT
250 rpm and Nominal 1 , 3 0 O( 1 3 . 0 ,1 8 5 )

Compression 950 {9.5, 135)
wide open throttle Minimum
kPa (kg/cm2,psi) Maximum varlatron 200 (2.o, 28)
o.o5{0.002}
Cvlinderhead Warpage
Heisht 1 4 1 . 9 51 4 2 . 0 5{ 5 . 5 8 9 - 5 . 5 9 3 )
5 {O.OO2-0.006}
o.o5-o.1 0.5(0.02)
Camshaft End play (o.o020-o.oo35) o . 1 5( 0 . 0 0 6 )
Camshalt-to_holderoil clearance o.050-0.o89
0 . 0 3( O . 0 0|1m a x 0.06 {o.oo2)
Total runout
Cam lobe height lN Primary 34.04' 1{1.3402)
Mid 3 6 . 8 5 6( 1 . 4 5 1 0 )
Secondary 3 4 . 9 7 1{ r . 3 7 6 8 }
EX PrimarY 3 3 . 7 4 5{ 1 . 3 2 8 5 )
Mid 3 6 . 3 2 3( 1 . 4 3 0 0 1
Secondary 3 4 . 6 8 3( 1 . 3 6 5 5 )
Valve clearance lN 0.15-O.1 9 (0.006-0.oo7)
EX o.17 0.21 (O.OO7-O.OO8|
Valve stem O.D. lN 5.475-5.4851O.2'56'0.21 l 59) i.oou to.z'tool
EX 5.475-5.485(0.2156-0.2159) 5.445{0.2144)
lN o.025-0.055(0.0010-0.oo22) 0.08 (0.003)
clearance
Stem-to-guide
EX o.o5o-0.080{0.0020-0.0031 ) 0.11 (0.oo4)
IN 1.25-1.55 ( 0 . 0 4 9 - 0 . 0 6
) 1 2.0 10.079)
Valve seat widrh 2.0 t0.079)
EX 1 . 2 5 - 1 . 5(50 . 0 4 9 - 0 . 0)6 1
IN 37.465-37.935 (1.4750-' |.4935) 3 8 . 1 8 5( 1 . 5 0 3 3 )
Steminstalledheight
EX 3 7 .16 5 - 3 7 . 6 3 (51 . 4 6 3 2 - 1 . 478)1 3 7 . 8 8 5{ 1 . 4 9 1 5 }
Freelength lN Outer 4 5 . 1 6( 1 . 7 7 8 )' r
Valve spring
4 5 . 7 6 ( 1 . 8 0 2 )' 2
lnner 4 1 . 7 8 { 1 . 6 4 5 ') 1
41 .75 11.6441 '2
-r
EX Outer 46.72 (1.839)
'2
46.74 11.8401
tnner 3 9 . 3 2 ( 1 . 5 4 8 )* r
'2
39.28 (1.546)
IN 5.51o-5.530 1O.21 69-0.217 7 | 5 . 5 5( 0 . 2 1 9 )
Valve guide t.D. 5.60 {O.220)
EX 5 . 5 3 5 - 5 . 5 5 5( 0 . 2 17 9 ' 0 . 2 18 7 )
IN 12 . 5 5 - 13 . O 5 ( O . 4 9 4 - 0 . 5 1 4 1 1 3 . 3 0{ O . 5 2 4 }
height
Installed 1 3 . 3 0( 0 . 5 2 4 )
EX 12.55-13.O5 (O.494-0.51 4)
IN 0.025-0.052(O.OO1
0'0.0020) 0.o8(o.003)
Rockerarm Arm-to-shaft clearance o.08i0.oo3)
EX o.025-o.052(O.001
0 0.oo20)
CHUOHATSUJOmanufacturedvalve spr'ng'
, 2 | NIHONHATSUJOmanufacturedvalve spring'
ii
ii
3-4
_]] Unit of length:mm linl
EngineBlock Section
MEASUREMENT STANDARD{NEW} I SERVICELIMIT
Cylinder block Warpageof deck surtace 0.07 10.003)max. 0 . 1 01 0 . 0 0 4 1
Bore diameterF22A1 engine 8 5 . 0 10 8 5 . 0 2 0( 3 . 3 4 6 8 , 3 . 3 4 7 2 )
-'] 8 5 . 0 0 0 , 8 5 . 0 1( 03 . 3 4 6 53 . 3 4 6 8 ) 8 5 . 0 71 3 . 3 4 9 )
H23Al, H22A1engines 87.O'f 0-87.020\3.4256-3.4260)
87.OOO 87.01013.42523.42561 87.O7t3.4281
Bore taper 0.o5 (0.002)
Reboringlimit F22A1 engine 0 . 5 0( 0 . 0 2 0 )
H23A1, H22A1 engines 0 . 2 51 0 . 0 1 0 )
Piston Skirt O.D.*1 F22At engine No Letter (A) 8 4 . 9 8 0 - 8 4 . 9 9{ 30 . 3 4 5 7 - 3 . 3 4)6 1 8 4 . 9 7 0( 3 . 3 4 5 3 )
Letter B 8 4 . 9 7 08 4 . 9 8 0{ 3 . 3 4 5 33 . 3 4 5 7 ) 84.960(3.3449)
H2341, H22A1 enginesNo Letter {A} 86.990-87.003 13.424A-3.42531 87.980(3.4638)
Letter B 86.980-86.993 13.4244-3. 42491 87.97013.4634)
Cfoarancein cylinder F22A1 engine 0.020-0.o40(0.ooo8,0.001 6) 0 . 0 5{ 0 . 0 0 2 )
H 2 3 4 ' 1 ,H 2 2 A 1 e n g i n e s o.007-0.030(0.0003-0.001 2) o . 0 4{ o . 0 0 2 )
Groovewidth F22A1 engine Top 1.220-1.230 {O.04800.0484) 1 . 2 5( 0 . 0 4 9 )
{for ring} Second 1.220-1. 230 {O.0480,0.0484) 1 . 2 5( 0 . 0 4 9 )
oil 2.405-2.420(O.1104-0.11101 2 . 8 5( 0 . 112 )
H 2 3 A 1 ,H 2 2 At e n g i n e s T o p '1.230- 1.245{0.0484-0.0490t 1 . 2 6 5{ 0 . 0 4 9 8 )
Second 1.230-1.245t0.0484-O.0490) 1 . 2 6 5{ 0 . 0 4 9 8 )
oil 2.405-2.820(0.1104-0.1110) 2 . 8 5t O . 1 1 2 l
Pistonring Ring-to-grooveclearance Top 0.035-0.060(o.0014-0.0024) 0 . 1 3( 0 . o o 5 )
Second 0.030-0.055to.oo12-o.oo22l 0 . 1 3( 0 . 0 0 5 )
Ring end gap F22Al engine Top 0.20-o.35(0.008-0.01 4) 0.60 {0.024)
Second 0.40-o.ss(0.o16-0.022) 0,70 {0.028)
oil 0.20-0.70(0.0080.028) o . 8 0( 0 . 0 3 1 )
H 2 3 A 1 ,H 2 2 A 1 e n g i n e s T o p o . 2 5 - 0 . 3 {50 . 0 1
0-o.014) o.60 (0.024)
Second 0.60,0.75(o.0240.o30) 0 . 9 0( 0 . 0 3 5 )
oil 0.20-o.50{0.008-0.o20) *2 0.60 10.024)
0.20-0.70(0.oo8-0.0281 *3 0 , 8 0( o . 0 3 1 )
Piston Pin o.D. 21.994-22.OOO(0.8659-0.866
1)
Pin-to-pistonclearance F22A1 engine o.o12-0.o24{o.0005-o.ooo9}
H23Al, H22A1 engines 0.012-0.026to.0005-0.0o10)
Connecting rod Pin-to-rodinterlerence 0.o13-o.o32(o.ooo5-o.001
3l
Small end bore diameter 2 1 . 9 6 8 - 2 1 . 9 8 1( 0 . 8 6 4 9 - O . 8 6 5 4 )
Largeend bore diameter Nominal 5 1 . 0{ 2 . O 1 )
€nd play installedon crankshaft o. 15-0.30 (0.006-0.012) 0 . 4 0( o . o 1 6 )
Srhallend bore-tolargeend bore parallelism 0 . 1 2 ( 0 . O 0 5 ) / 1 0m0 ax. 0 . 15 ( 0 . o o 6 y 1 0 0
Crankshaft Main journaldiameter No. 1 and 2 journals 4 9 . 9 7 6 - 5 0 . 0 0 0( 1 . 9 6 7 6 - 1 . 9 6 8 5 )
No. 3 journal 4 9 . 9 7 24 9 . 9 9 6 ( 1 . 9 6 7 4 , 1 . 9 6 8 3 1
No. 4 journal 4 9 . 9 8 4 - 5 0 . 0 0 8( 1 . 9 6 7 9 - 1 . 9 6 8 8 )
No. 5 journal 4 9 . 9 8 8 - 5 0 . 021 ( 1 . 9 6 8 0 - 1 . 9 6 9 0 )
Rod journaldiameter 4 7 . 9 7 6 4 9 . 0 0 0 { 1 . 8 8 8 81- . 8 8 9 8 )
Taper 0.005 (0.0002) max. 0.006 (0.0002)
Out-of-round 0.OO5(O.0002)max. 0.006 {0.0002)
End play o.10,o.35 (0.oo4,0.014l 0 . 4 5{ O . 0 1 8 )
Total runoul O.03 {0.OOl) max. o.04 {o.002)
Eearings Main bearing-to-journal
oil clearance
_ No.1and2 journals 0.021-0.045(o.00080.0018) 0.050 (0.0020)
No. 3 journal 0.025-0.049(0.0o10-0.001
9) 0.055 (0.0022)
No. 4 iournal 0.013-0.037(0.ooo5-o.001
5) 0.050 {0.0020)
No. 5 journal 0.009-0.033(0.0004,0.001
3) 0 . 0 4 0{ o . 0 0 1 6 )
Rod bearing-to-journal
oil clearance
F22A1 engine 0.021-0.049{o.0008-0.oo20) 0.055 (0.oo22)
H 2 3 A 1 ,H 2 2 A t e n g i n e s 0.027-0.055(o.001'l-0.oo22) 0.060 (0.o024t
'1: Measuredat 2l.O mm (O.83inl on F22A1
engineand 15.0 mm (0.59 in) on H23A1. H22A1 enginesborh from bottom o{ skirt.
'2: TEIKOKUPISTONRINGmanufacturedpisron
ring.
'3: RIKENmanufacturedpiston ring.
3-5
Engine Block - Section 7 (cont'd)
MEASUREMENT STANOARD
INEW} I LIMIT
SERVICE
Balancershatl Journaldiameter No. 1 iournal(lront) 42.722-42.734(1.6820'1.68241 4 2 . 7 ' l{ 1 , 6 8 9 }

No. 1 journal(rear) 20.938-20.950 {O.8243-0.8248) 20.92 Q.A24l
No. 2 journals 3A.712-3A.724 11.5241-1.52461 3 8 . 7 0( 1 . 5 2 4 )
No. 3 iournals 34.722-34.7 34 (1.3670-1.3675) 3 4 . 7 1{ 1 . 3 6 7 )
Journaltaper 0.005 (0.0002)
End play Front 0. 10,0.35(O.OO4-0.O14)
Rear o.06-0.18 to.002-0.o07)
Total runout 0 . 0 2( o . o o 1 ) o.osro.oot t
Oil clearance No. 1 journallrear) o.050-0.075to.oo20-0.0030) o.09{o.oo4)
No. 1 (front)and No 3iournal 0.066-0.1 18 (0.0026-0.0046) 0 . 1 2( O . 0 0 5 )
No. 2 iournals o.o76-0i 2a {o.oo30-0.0050) 0 . 1 3{ 0 . 0 0 5 )
Balancershalt LO. No. 1 journal(frontl 42.AOO-42.820 {1.6850-1.6958) 4 2 . 8 3( 1 . 6 8 6 )
beanng No. 1 journal{rear) 3 { 0 . 8 2 6 8 - 0 . 8 2 7 3 ) 21.O2@.A2Al
2 1 . 0 0 0 -12. 0 1
No.2,ournals 38.800-38.820 11.527 6-1.52431 3 8 . S 3( 1 . 5 2 9 )
No. 3 iournals 34.8OO-34.82O (1.3701-1.3709) 3 4 . 8 3( 1 . 3 7 1 )
EngineLubrication- Section 8
MEASUREMENT STAI{DARD(IIEW} I SERVICE
LIMIT
Engineoil Capacityt (US qt, Imp qt) F22A1 engine 4.9 {5.2, 4.3} for engineoverhaul
3.8 14.0,3.3) for oil change,includinglilte.
H23A1 engine 5.4 (5,7, 4.81 for engineov€rhaul
4.0 (4.2, 3.5) lor oil change,includinglilter
H22A 1 engine 5.9 (6.2, 5.2) for engineoverhaul
4.A $i, 4.21 tor oil ch€nge,includingfilter
Oil p'rmp Displacement ? IUS qt, lmp qtl/min @rpm 73.5 177.7,64.7) @6,000
lnner-toouter rotor radialclearance
-o.006)
o.02-0.16 10.001 o.20 (0.008)
Pump body-toouter rotor radialclearance 0.10,0.19 (0.004-0.007) 0.21 (O.OO8)
Pump body-to-rotoraxialclearance o.02-0.07(o.oo1-0.003) 0 . 1 2( 0 . 0 0 5 )
Fleliefvalve Pressuresettingat oil termperature176oF (80oC)
kPa (kg/cm2,psi) at idle 70 {0.7, 1O}min.
at 3,0OOrpm 350 (3.5, 50) min.
Cooling - Section o
MEASUREMENT STAI{OARD(NEW}
Radiator Enginecoolantcapacity F22A1 engine M/T: 7.1 (7.5, 6.2) for overhaul
includingengine, 3.5 (3.7, 3.1) for coolantchange
heater,cooling AlTt 7.O 17.4, 6.2) tor ovorhaul
line and reservoir 3.4 (3.6, 3.0) for coolantchange
{ (US qr, lmp qt) H23A1 engine MlTt 7.4 17.9,6.5) for overhaul
3.8 (4.0, 3.3) for coolantchange
All: 7.3 17.7, 6.4) lor overhaul
3.7 (3.9, 3.3) lor coolantchange
H22A1 engine M/T: 7.8 (8.2, 6.9) Ior overhaul
4.2 14.4,3.7) for coolantchange
ReservoircapacitY o . 6( o . 6o, . 5 )
i; 9 5 - 1 2 5 ( 0 . 9 5 - 1 . 2 5 1, 3 . 5 ' 1 7 . 8 )
OpeningpressurekPa {kg/cm2,Psi)
I! Badiatorcap
oF {oc) 169-177 {76-80)
Ir
I i
Thermostat Start to open
F u l l yo p e n
'F {oC) 194 (90)
Valve lifi at Iully open 8 . O 1 O . 3 1m ) in.
,l
't Waler pump Displacement F22A1 engine 1 6 5 ( 1 7 4 ,1 4 5 )@ 6 , 0 0 0
I f {US qt. lmp qt)hin @rpm H23Al engine 1 s 9 1 1 6 8 1, 4 0 )@ 6 , 0 0 0
H22A1 engine 1 6 3 ( 1 7 2 ,1 4 3 )@ 6 , 0 0 0
Radialorfan E C Ts w i t c h" O N " F 2 2 A 1 ,H 2 3 A 1 e n g i n e s 194,205(90,96)
temperature H22A I engine 198-208(92-98) "ON" temperature
ECT switch "OFF" tempetatureoF (oC) Subtruct4'13 {l-7} tfom actual
Fuel and Emission- Section 1 1 Unil ol lengthi mm (in
MEASUREMENT STANDARD(NEW)
Fuel pump Displacement cc {US oz, lmp oz} in 10 seconds 205 (6.93, 7 .221 tnin.
Pressureregulator Pressurewith regulatorvacuumhose dtsconnected
k P a{ k g / c m 2p, s i } F 2 2 A 1 ,H 2 3 A 1 e n g i n e s 255-305(2.55,3.05,36-43)
H22A1 engine 230-280{2.3-2.8.33-40)
Fuel tank Capacity{ {US gal, lmp gal) 6 0 ( 1 5 . 9 ,1 3 . 2 )
Engine Fast idle rpm 1,400
ldle speedrpm with headlightand 700 150 (M/T:neurral)
cooling fan ott 7OO150 {A/T:E o. E position)
ldle CO % 0.1 max.
Clutch Section 1 2
MEASUREMENT STANDARD INEWI I SERVICE
LIMIT
Clutch pedal Pedal height ro ttoor 2 0 8( 8 . 1 1 )
Stroke 1 3 5 - 1 4(55 . 3 1 - 5 . 7 1 )
Pedalplay 1 . 0 - 7 . 0( 0 . O 4 - O . 2 8 )
Disengagement height to floor 9 4 { 3 . 7 0m ) in.
Flywheel Clutch surlacerunout 0.05 {O.002}max. o.15 (0.006)
Clutch disc Rivet head depth 'l.3 (0.O51)min.
o . 2(0.008)
Surface runout O.8(0.03)max. 1 . O(0.04)
Thickness 8 . 4 - 9 . 1( O . 3 3 1 - 0 . 3 s 8 ) 6 . O (0.2361
Clutch cover Pressureplate warpage 0 . 0 3( O . 0 0 1m1a x . o . 1 5( 0 . 0 6 )
-]']
Manual Transmission Section 1 3
MEASUREMENT STANDARo{NEw} I sERvIcELIMIT
Transmissionoil Capacityt (uS qt, lmp qt) 1 . 9 1 2 . O1
, . 7 1 f o ro i l c h a n g e
2.O 12.1, 1.Al tor overhaul
Mainshaft End play 0. 10-0.16 {0.0039-0.0063) Adjustwith a shim.
Diameter ot ball bearing contact area 2 7 . 9 7 7- 2 7 . 9 9 0( 1 .1 0 15 1 .10 2 0 ) 27.94 11.1001
Diameterof third gear contact ar€a 3 7 . 9 8 4 - 3 8 . O O1O1 . 4 9 5 41 . 4 9 6 1) 3 7 . 9 3( 1 . 4 9 3 )
Diameter ol ball bearing contact area 2 7 . 9 8 7- 2 8 . O O O( 1 .10 18 - 1 .1 0 2 4 ) 2 7 . 9 4( 1 . 1 0 0 )
Runout 0.02 (0.0008) max. 0.o5 (0.0021
Mainshatt3rd and LD. 4 3 . O O 9 - 4 3 . 0(215. 6 9 3 3 , 1 . 6 9 3 9 ) 4 3 . 0 8 0{ 1 . 6 9 6 1 )
fourth gears End play 0.06,0.21(0.0024,O.0083) o . 3 0( 0 . o 1 2 )
Thickness 3rd gear M2L5, M2S4 3 2 . 4 2 - 3427. t l . 2 76 -1 . 2 78 l 3 2 . 3( 1 . 2 7 2 1
M2F4 34.92-34.9711.37 5-1.3771 3 4 . 81 1 . 3 7 0 1
4th gear M2L5, M2S4 3 0 . 9 2 - 3 0 . 9171 . 2 1-71 . 2 1 9 1 3 0 . 8( 1 . 2 1 3 )
M2F4 31.42-31.4711.237-1.2391 3 1 . 3{ 1 . 2 3 2 )
Mainshaltsth gear t.D. 4 3 . 0 0 94 3 . 0 2 5{ 1 . 6 9 3 31-. 6 9 3 9 } 4 3 . 0 8 0( 1 . 6 9 6 1 )
Endplay 0.06-0.21(o.0024,0.oo83) 0 . 3 0{ 0 . 0 1 2 }
Thickness 3 0 . 9 2 - 3 0 . 9171 . 2 1-71 . 2 91l 3 0 . 8( 1 . 2 1 3 )
Countershaft End play 0.05,0.40 (0.0019-0.0157) o . 5 0{ o . 0 2 )
Oiameterof needlebearingcontact area 3 8 . O O O - 3 8 . 5O {11 . 4 9 6 '-11 . 4 9 6 7 ) 3 7 . 9 5( 1 . 4 9 4 )
Diameterof ball bearingand needlebearing
conlact area 24.947-25.OOO(O.9837-0.9845) 24.94lO.982l
Diameterot low gear contact area 39. 984-40.OOO11.5742-1.574al 3 9 . 9 3{ 1 . 5 7 2 }
Runout O.02 {O.0OO8) max. o.05 (o.oo2)
_]]] Countershaltlsl t.D. 4 6 . 0 0 9 - 4 6 . 0 2 5{ 1 . 8 114 - 1 . 8 12 0 } 46.08 (1.8't4)
gear Endplay 0.04,0.10 (o.002 0.oo4) Adiust with a washer.
Countershatt 2nd LD. 4 7. O O 9 - 4 7 2 5( 1 . 8 5 0 71 . 8 5 1 4 )
.O 47.08 ('t.854)
gea( Endplay o.04-0.10 {0.002-o.004) Adjust with a collar.
l Thickness 2 8 . 9 22 a . 9 7( 1 . '3t 9 , 1 . 1 4 1 ) 2 8 . 8( 1 . 1 3 )
(cont'd)
3-7
Manual Transmission- Section 13 (cont d l
MEASUREMENT STANOARD INEW) I SERVICELIMIT
Spacercollar LD. 36.48-36.49{1.4362-1.4366) 3 6 . 5 0( 1 . 4 3 7 1

lCountershaft o.D. 4 1 . 9 8 9 - 4 2 . O {010. 6 5 3-11 . 6 5 3 5 ) 4 1 . 9 4( 1 . 6 5 2 )
29.O2-29.O ( 14. 14 2 5 - 11. 4 3 3 )
2nd gear) Length
B 29.O7 -29.09(' |.144-1.145)
-Jo 3 1 . 0 0 2 - 3 1 . 20 1( 1 . 2 2 0 5 - 1 . 2 2 0 9 ) 3 1 . 0 6( 1. 2 2 3 )
Spacecollar LD.
(Mainshaft4th and o.D. a- 3 7 . 9 8 9 - 3 8 . O (O1O . 4 9 5 6 - 1 . 4 9)6 1 3 7 . 9 4( 1 . 4 9 4 )
5th gear) Length 56.45,56.5512.222-2.2261
la B 26-03-26.08 (1.0248-1.0268)
LD. 20.o16-20.O43(0.7880-0.7891 l 20.09(o.7909|
Reverseidlergear
Gear-loreversegearshalt clearance 0.036-0.084{o.oo14-0.00331 0.160 to.ooo6l
Syncro ring Ring-togear clearance(ringpushedagainst o.85-1.10 (0.034-0.043) 0 . 4 0{ o . o 1 6 l
gearl
Dual cone Clearance(ringpushedagainstgear)
sYncnronng Outer synchroring to_gear 0.95-1.68(0.037-0.066) 0.6 (0.024)
Innersynchroring-togear o.5-1.O(0.02-0.04) o . 3( 0 . o 1 1
Outersynchroring-tosynchrocone o.5-1.O(0.02-O.041 0 . 3( 0 . 0 1 )
Shift fork Fingerthickness M215, M2S4 6.2,6.41O.244-0.2521
M2F4 7 . 4 , 7 . 6( O . 2 9 1 - 0 . 2 9 9 )
Forkto syncrosleeveclearance o.35-0.65t0.014-0.026) 1 . O( 0 . 0 3 9 )
Reverseshitt fork r i ' w , groove
Pawl width
srouvc w ,uu, 1 3 . 0 - 1 3 .(30 . 5 1 - 0 . 5 2 )
A
Fork'to reverse idle gear clearance I 0 . 5 - 1 . 1( 0 . 0 2 - 0 . 4 3 1 1 . 8( 0 . 0 7 )
Groove width atA 7.O5-7.2510.27a-O.25541
atB 7.4-7.7 tO.29-O .301
Fork-to-tifth/ atA o.o5-0.3510.002-o.o14) o.5 to.02l
B 1 . 0{ o . 0 4 )
reverseshift atB 0.4,o.8{o.02-0.03)
shalt clearance
Shift arm LD. 15.973-16.000 {O.6289-0.6299)
Shift arm-to-shaftclearance o.005,0.059to.ooo2-o.oo23)
Shift tork diameterat contact area 12.9-13.O(0.508-0.512)
lork shaft clearance
Shift-arm-ro-shaft 0.2-o.5to.ol -o.02l
Selectlever Pin sizeof contact area 7.9,8.O (O.311-0.3' I5)
Selectleverto-shitt peice clearance o.o5 0.25 10.002-o.o10) o.5 (0.o20)
Shaft outer diameler 15 . 4 1 -15 . 6 8 ( 0 . 6 0 7 - 0 . 6 1 7 )
Shift arm cover clearance 0.032-o.102 (0.OO1 3-0.0040)
Shift arm lever o.D. 15.941-15.968 {0.6276-0.62871
Tlansmissionhousingclearance 0.027-0.139 (O.0011-O.OO55)
lntedock Eorediameter 16.00-16.O510.630'0.632)
Shitt arm lever clearance 0.032-0.109 (0.0013-o.oo43)
I
{r
I
Automatic Transmission- Section 14 Unit of length mm (in)
MEASUREMENT STANDARD {NEWI SERVICELIMIT

Transmission Capacityf (US qt, lmp qt) 6.0 (6.3, 5.3) Ior overhaul
tluid 2 A 1 2 . 5 ,2 . 1 1 t o rl l u i d c h a n g e
Hydraulic Line Dressureat 2.OO0rom 8 0 0 t 8 . 0 ,1 1 4 1 7 3 O1 1 . 5 1, O 7 l
pressure inEorEpositron throftleIully-closed throttlemorethan3/16
(F22A1 engine) open
I
8 5 0 ( 8 . 5 ,1 2 1 )
kPa lkg/cm2, lhrottlemorethan3/16 open
psr,
4th clutch oressureat 2.000 rom 530 (5.3, 75) 480 (4.8, 68) throttte
in @ position throttle fully,closed lully-closed
I I
850 (8.5.'121) 750 17.5,1071
throttle more than 3/16 open throttlemorethan3/16
open
3rd and 2nd clutch pressureat 2,000 rpm 5 0 0{ 5 . 0 , 7 1 ) 450 (4.5, 64)
in E posrtion throttleIullv-closed throttle fully-closed
I I
8 5 0 ( 8 . 5 ,1 2 1 ) 750 (7.5,107)
throttlomorethan3/16 open throttle more than 3/16
open
2nd clutch pressureat 2,OOOrpm
in Lzl position 8 0 0 - 8 5 0( 8 . 0 - 8 . 51.1 4 - 1 2 1 1 7 5 0 1 7 . 5 1, O 7 l
1st and 1st-holdclutch pressure
at 2.000 rpm in LLI position 800-850{8.0-8.5,114-121} 750 17.5,1071
Throttle B pressure Throttle fully closed 0 (0.o)
Throttle fully open 8 0 0 - 8 5t08 . 0 - 8 . 511. 4 - 1 2 1 1 7 5 0 1 7 . 5 ,1 0 7 )
Hydraulic Line pressureat 2.000 rom 8 5 0 ( 8 . 5 ,1 2 1 ) 8O0(8.0. t 14l
pressure in E or E]position thro le tully-closed throttlemorothan 3/16
(H23A1 engine)
I open
900 (9.o, 129)
kPa {kg/cm2, throttlemorethan 3/16 open
pst,
4rd clutch pressureat 2.OOOrDm 5 3 0( 5 . 3 , 7 5 ) 48O (4.8, 68) throtte
in @ positron throttlefully-closed tully-closed
I I
900 (9.o, 128) 800 (8.0,114)
throttlemorethan3/16 open throttle more than 3/16
open
3rd and 2nd clutch pressureat 2,0OOrpm 5 O O( 5 . 0 . 7 1 ) 450 {4.5, 64)
in E position throtlle tullv-closed rhrottle fully-closed
I I
900 (9.o, 128) 8 0 0 { 8 . 0 ,1 1 4 }
throttlemorethan3/16 open throttlemorethan3/16
open
2nll_glutch pressrue at 2,OOOrpm
in L2l position 8 5 0 , 9 0 0 1 8 . 5 - 9 . O1. 2 1 - 12 8 ) 800 {8.0,114}
1st and 1st-holddutch pressure
at 2,000 rpm in Lll posirion 850-900{8.5-9.0,121-128) 800 {8.0,114)
Throttle I pressure Throttle fully closed o (o,o)
Throtttefully open 850-900(8.5-9.0,121-128) 8 0 0 ( 8 . 0 .1 1 4 )
Stalf speed rpm F22A1 engine 2,350-2,650
{Checkwith car on level ground) H23A1 engine 2,600-2,900
{cont'd)
3-9
Automatic Transmission- Section 14 (cont'd)
MEASUREMENT STANDARD(I{EW) SERVICELIMIT
Clutch Clutch initialclearance lst-hold 0.80-1.00{0.031-0.039}

1st, 2nd 0.65-0.85{0.026'0.033}
3rd' 4th 0.4-o.6{o.016-0.024)
Clutchreturnspringfree length 1sr, 2nd, 3rd' 4th 33.511.32) s1.g tr.zat
Clutch disc thickness 1.88-2.00lO.O74-O.079) Untilgroovesworn out.
Clutch plate thickness 1st, 1st'hold 1.95-2.O5 (O.077-O.O81 ) Discolorataon
2nd, F22A1 engine
H234 1 engine
2.55-2.65(O.089-0.093)
1.95-2.O5 (0.077-0.081 |
tV
3rd,4th 2.25-2.35(O.089-0.0931 Discoloration
Mark l 2.05-2.10 (O.081 -O.083) Discoloration
Clutch end plate thickness
Mark 2
Mark 3
Mark 4
2.15-2.20(O.085-0.O87)
2.25-2.30(0.089-0.091)
2.35-2.40(0.093-0.094)
tI
Mark 5
Mark 6
2.45-2.50 t0.096-0.O98)
2.55-2.60(O.100-0.102) I
Mark 7
Mark 8
Mark I
2.65-2.70{0.104-0.
2.85-2.90(O.112-O.1
106)
2 . 7 5 - 2 . 8 10 0 . 1 0 8 -1o1. 0 1
14)
I
Discoloration
Valve body Stator shah needlebearingcontact l.D

Torque converter side 27.OOO-27.O21 (1.0630-1.
1638) wear ol damage
Oil pump side 29.OOO-29.O13 11.1417-1.14221
Oil pump gear side clearance 0.03-0.05{o.oo1-0.oo2l 0.07to.oo3)
Oil pump gear-to-bodyclearance Drive o.210-0.265l0.OO83-0.01 041
Diven 0.070-0.125 {0.OO28-O.00491
Oil pump drivengear I.D. 14.01F14.034(0.551 84.5525) ie", o, d"."ge
Oil pump shatt O.D. 13.980,13.990 (0.55040.55081 wear or damag€
Reverseshitt lork finger thickness 5.90,6.00(o.232-0.236) 5 . 4 0( O . 2 1 3 1
Shilting device,
parking brake Parkingbrakeratchet Pawl \ Wearor
Parkingbrakegear t otherd€fect
and throttle
control system Throttle cam stopper height 17.O-17.1{O.669-0,673)
Seryo body Shitt fork shaft bore l.D. r 4.00G14.010(0.551 6l
2-O.551
Shift lork shatt valve bore l.D- 37.OOO-37.039{1.4567-1.4582) 3 7 . 0 4 5t 1 . 4 5 8 5 )
Sealingring contact LD. 35.OOO-35.025(1.3780-1.3789) 3 5 . 0 5( 1 . 3 7 9 9 )
Regulatorvalve
body
Accumulator
Sealingring contact l.D. 3 {1.2598-1.2604)
32.OOG32.O1 3 2 . 0 5 0( 1 . 2 6 1 8 1
DOOy
Sealingring contact l.D. l'l.1417-1.14221
29.0OG29.013 2 9 . 0 5 0( 1 . 1 4 3 7 1
Stator shalt
Transmission Diameter ot needle bearing contact area
On mainshaft of stator shaft 22.9A4-23.@O (0.9049-O:90551 Wear or damage
On mainshaftot 3rd gear collar 45.984-46.000(1.8104-1.8110)
gear collar
On mainshalt oI 4th'tst 31.984-32.OOO 11.2592'1.2598)
On countershattof gear collar 40.984-41.OOO (1.6135-1.6142)
On countershaft of 4th gear 31.975'31.991 (' |.2589-1.2595)
On countershaftof Parkinggear 39.984-40.000 11.5742-1.57 4a'l
On countershaftof reversegeat 35.979-36.OOO (' 1.4165'1.41 73)
On secondaryshaft ot 1st gear 3 1 . 9 7 5 - 3 1 . 9 9 (11 . 2 5 8 9 - 1 . 2 5 9 5 )
On secondary shaft ol 2nd gear 3 ' t . 9 7 5 - 3 1 . 9 9(11 . 2 5 8 9 - 1 . 2 5 9 5 )
On reverseidler gear shaft 13.990-14.000 {0.5508-0.551 2)
lnsidediameter
ii Mainshaft3rd gear 52.OOO-52.O19 12.O472"2.O4aOl
i : Mainshaft4th gear 38.OOs-38.021 (1.4963-1.4969)
It Counte.shaftlst gear 47.OOO-47.O1
38.000-38.O1
6 {1.8504-1.8510)
6 (1.4961-1.4967)
f 'ji Countershaft 4th gear
Countershaftreversegear 42.OOO-42.O16 (1.6535-1.6542)
Countershaftidler gear 48.000-48.016 {1.8898'1.8904)
:t
Secondaryshatt lst gear 37.00G37.016 (1.4567'' 1.4573)
I 37.000,37.o16 {1.4567'1.4573}
Secondaryshaft 2nd gear
Reverseidlergear shaft holder 14.41 6-1.434 (O.5676-0.5683) Wear or damage
Unlt ot l€ngthi mm (in)
Automati c Transmission- Section 14
MEASUREMENT STANDARD {NEWI SERI/ICE LIMIT
Transmission Mainshaft3rd gear collarlengrh 1 9 . 5 01- 9 .s 5 ( 0 . 7 6 8 - 0 . 7 7 0 ) Wear or damage
{cont'd) Mainshaft4th gear collarlength 4 7 . 5 0 - 4.75 5 l t . 8 1 0 - 1 . 8 7 2 ) wear or damage
Countershatt1st gear collar length 2 7 . 5 0 - 2 7 . 5(51 . 0 8 3 - 1 . 0 8 5 ) Wear or damage
Thrust washerthickness
Countershaft1st gear 1 . 4 5 - 1 . 5(00 . 0 5 7 , O . 0 5 9 ) Weor or damage
Countershaft idler gear 3.45-3.55(0.136-0.140) Wear or damage
Countershaltparkinggear length 25.030-25.048 (0.98544.9861 l Wear or damage
Secondaryshaft 1st gear distancecollar
length 4.95-5.00{O.195-0.197) Wear or damage
Secondary shaft 2nd gear thrust washer
thickness 4.35-4.45 tO.t 7 13-O.17 521 Wear or damage
Secondaryshaft 2nd gear splinewasher 4.O2-4.05(O.158-0.159)
thickness 4.07-4.'t0 (0.160-0.161 )
4 . 12 - 4 . 15 ( 0 . 1 6 2 - 0 . 1 6 3 )
4. 17-4.20 (0.164-0.165)
4.22-4.25 tO.166-0.167)
4.27,4.30 {O.168-0.169)
4.32-4.35 lO.17 0-O.17 1|
4.37 -4.40 lO.17 2-O.173l
4.42-4.45 tO.17 4-O.17 5l
STANDARDINEWI
MEASUREMEI{T
Wir6 Dia. o.D. Frco Longth No, ot Collr
Spring Regul€tor valvespringA F22A1 engine 1 . 8( O . 0 7 1 ) 1 4 . 7( 0 . 5 7 9 ) 86.5 (3.406) to.5
H23A1engine 1 . 8( 0 . 0 7 1 ) 14.1 lO.579l 88.6 (3.488)
' 1 . 8( 0 . 0 7 1 )
Regulatorvalve springB 9.6(0.378t 44.Ot1.732t
Stator reaction spring 4.5 lO.177l 3 5 . 4( 1 . 3 9 4 ) 3 0 . 3t 1 . 1 9 3 1 1.92
Torqueconve er check valve spring 1. 1 ( O . 0 4 3 ) 8 . 4 ( 0 . 3 3 I1 3 6 . 4( 1 . 4 3 3 ) 12.0
Reliofvalve spring 1 . 0{ 0 . 0 3 9 ) 8.4(0.331) 3 9 . 1( 1 . 5 3 9 1 15.1
Coolerreliefvalve spring 1 . 1( 0 . 0 4 3 ) 8.4 t0.331) 4 6 . 8( 1 . 8 4 3 ) 1 7. O
2nd orificecontrol valve spring 0.6 10.o24) 6.6 (O.2601 58.3 (2.295) 15.8
Oriticecontrol valve spring 0.8(0.031) 6.6 (O.2601 52.5 t2.O61l 33.0
Servo control valve spring 1 . 0( 0 . 0 3 9 ) 8.1{0.319) 52.6 (2.O711 22.4
4th exhaust valve spring 0.9 (0.035) 7.1(0.280' 6 0 . 8( 2 . 3 9 4 1 28.9
Throttlevalve B adjustingsprang o.8 (0.o31) 6.2 lo.244l s 0 . 0{ 1 . 1 8 1 } 8.0
Throttlevalve B spring 1 . 4( 0 . 0 5 5 ) 8.5lO.335l 4 1 . 5{ 1 . 6 3 4 ) 10.5
1 . 41 0 . 0 5 5 1 8.5{0.335t 4 1 . 5{ 1 . 6 3 4 ) 11.2
1 . 4( O . O 5 5 ) 8 . 5 ( O . 3 3 5 ) 4 1 . 6( 1 . 6 3 8 1 12.4
1-2 shilt valve spring 1 . 0( 0 . 0 3 9 ) 8.6 tO.339) 4 1 . 3{ 1. 6 2 6 ) 16.9
2-3l3-4 shift valve spring o.9 (0.035) 7 . 6t O . 2 9 9 t 57.Ot2.2441
1st-holdaccumulatorspring 4.0(0.157) 2 5 . 0( 0 . 9 8 4 ) 64.7 12,547) 7.3
lst accumulatorspring 1 . 81 0 . 0 7 1 ) 1 6 . 3( 0 . 6 4 2 t 11 5 . 4( 4 . 5 4 3 ) 18.6
4th accumulatorspring 2 . 9{ 0 . 1 1 4 t 22.0 {0.866) 9 0 . 1( 3 . 5 4 7 ) 10.9
2nd accumulatorspring 3.3{0.130) 22.0 (0.866) 8 4 . 9( 3 . 3 4 3 ) 11 . 1
3rd accumulatorspring 2.6t0.102) 1 7 . 5( 0 . 6 8 9 ) 1 0 4 . 51 4 . 1 1 4 ) 18.0
Lock-up shitt valve spring 0.910.035) 7.6 tO.229l 73.7 t2.9021
Lock-uptirningvalve spring 0.8{0.031) 6.6 {0.260} 5 1 . 11 2 . 0 1 2 ) 14.7
CPC valve spring 'l.4
{o.055) 9.4{0.370) 3 3 . 0( 1 . 2 9 9 ) 10.5
Modulatorvalve spring 1 . 4( 0 . 0 s 5 ) 9.4 (0.370) 3 3 . O( 1 . 2 9 9 1 10.5
Lock-up control valve spring 0.7 (0.028) 6.6 (0.260) 3 8 . 01 1 . 4 9 6 ) 14.1
3rd kick-downvalve spring 1. 1 ( 0 . 0 4 3 ) 7 . 6 1 0 . 2 9 9 ) 4 8 . 3( 1 . 9 0 2 )
3-2 kick down valve spring 1 . 2t O . O 4 1 l 7 . 1{ 0 . 2 8 0 ) 4 6 . 9( ' t . 8 4 6 )
3-11
Differential (Manualtransmission) Section 1 5
MEASUREMENT STANDARD INEW} I SERVICELIMIT
Final driven Backlash 0.085-o.142 {O.OO33-0.0056) o.20(o.o08l

geal
'18.000,18.018 {0.7087-0.7094}
Dillerontial Pinionshaft contact area l.D.
carriet Carrier-to-pinionclearance 0.013-0.047(0.0005-o.oo1 9l 0.10{o.oo4t
Driveshatt contact aroa LD. 28.005-28.025 {' 1.1026-1.10331
Carrisr-to-driveshaftclearance Right 0.025-o.066(0.0010-o.oo26l 0 . 1 2t o . o o s t
Left 0.o55-0.091{o.oo22-o.oo36l 0.15 (0.006I
Dillerential Backlash o.05-0.'t5 to.o02-0.0061 ' l AdjLrstwith a shim
t.D. 18.042-18.066 tO.7103-0.71 3)
Piniongearto-pinion
shaftclaarance 0.055-o.095(0.oo22-o.0037) o.15 {0.006)
Taperroller StartingTorqueN.m {kg-cm,lb-in) 1.4-2.6( 4-26, 12-231 Adjust with a shim
bearingpreload
Differential (Automatic tlansmission) Section 1 5

MEASUREMENT (NEW}
STANDARO SERVICELIMIT
Finaldriv€ng€ar Escklash o.o85-o.142 {O.0033-0.0056) 0.20(o.oo8)
I Dlflerential
carnef
Differcntial
Pinionshaft contact area l.D.
Caftier-to-pinionclearance
Driveshaft contact area l.D.
CarrieFto-driveahaftclearanace
Backlash
18.000-1 8.018 t0.7087-0.7094)
o.o17-o.o47 {0.0007-0.oo1 9}
2 8 . 0 O 5 - 2 8 . 0{215.1 0 2 6 - 1 . 1 0 3 3 )
0.025-0.066to.oo10-o.oo26)
15 (o.oo2-o.oo6t
0.05,0.
0 . 1 0( 0 . 0 0 4 )
o . 1 2( 0 . 0 0 5 )
Adjust with a shim
LO. (O.7103-0.71
18.042,18.066 13)
Pinion gear-to-pinionshaft clearance (o.oo23-o.oo37)
0.059-o.o95 o.12 (O.OO5)
Taperroller Starting Torque New bearing 2.A-4.OQA-40, 24-3sl Adjust with I thim
bearim preload N.m lkg.cm, lb-inl Reusedbearing 2.5-3.7 t25-37, 22-321
F
Ste6ring Section1 7
MEASUREMEl{T STAI{DARDINEW}
St€sring whsel Play at steering wheel circumterence o-10(o-o.4)
Starting load at stoering wheel circuml€ronce N {kg, lbsl
Engine running 30 {3.O,6.61
When the hydraulic system to the power steerang
soeed sensor is cut ofl 50 (5.0,11.Ol
Gearbox Angle ot rack-guide-screwloosengd trom locked position
Pump Pump pressure with valve closed (oil temp./spoed: 1O5"F

{4OoCl min./idle. Do not run for more than 5 s€conds}.
kPa {kg/cm2, psi} 7.O00-8,OOO (70-80,995-1,138t
Power steering Recommend€dfluid Hondapowersteoringfluid-V
lluid Fluid capacity System 1 . 7 { 1 . 8 0 ,1 . 5 0 1
, (US qt. lmp qt) Reservoir 0.5 {o.53,0.441
'lOON (1o kg, 22 lbs) betweenpulleys 13.5-16.5 10.53-0.65)with used belt
Power st€gring Deflectionwith
belt' 9.5-11,5 {0.37-0.451with new belt
t Belt tension N (kg, lbsl 350-5OO{35-50. 77-1101with used bslt
!i Mgasured with belt tension gauge 7OO-9OO (7O-9O,154-198) with new b€lt
li * When using a nsw belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.
Readiust deflsction or tension to used belt values.
i !
Suspension- Section18 Unit of lengthmm {in
MEASUREMEIIT (NEWI
STANDARO SERVICELIMIT
Wheel Camber Front o" oo' r 10
argnment Rear -o" 45' 1 ' to
{2WS) Caster Front 20 40' !10
Total toe Front 0 r 2.0 (o !0.081
Rear rN 2.0 ! 2.0 t0.08 10.08)
Front whe€l turning angle Inward wheel 360 20' 12.
Outward wheel 290 40'
Carhber Front o" oo' i 10
alrgnment Bear -oo 45, 1300
{4WS} Caster Front 2040'!1.
Total toe Front o t 2.o(0 10.08)
Rear t N 2 . Ol 2 . O ( 0 . 0 8t O . O 8 l
Whgel turning angl€ Inward whoel Front 3 6 02 0 ' ! 2 "
Rear 6 . O O '! 1 "
Outward wheel Front 29" 20'
Rear 6" 20'
Rim runout {Aluminumwhe€l} Axial o-0.7 10-0.03) 2.OtO.08l
Radial o-o.7 (0-0.03) 1 . 5( 0 . 0 6 )
Rim runout (Steel wheell Axial o-1.0 (o-0.041 2.0 (o.08)
Radial 0-1.0 (o-0.041 r.5 to.o6)
Wheel bearinq End play Front 0-0.05(o.oo2)
Rear o-0.05(0.oo2l
Brakes Section
MEASUREMENT STANDARD(NEWI SEFVICELIMIT
Parkingbrake Playin strokeat 2OON (20 kg, 44lbsl lev€rforce To be locked when pulled
lever 6-10 notches
F""r braL Pedal height (with floor mat removod) M/T 1 6 5 { 6 . 5 }m i n .
pedal Atf 1 8 6 { 7 . 3 )m i n .
Free play 1-5(1/16-13/64)
M*t"|. "y["d* Piston'to-pushrod clearance Cars without ABS o-o.4(o-0.02)
Cars with ABS 0 - 0 . 2t o , o . 0 1 )
Oisc brake Disc thickness Front 23.O(0.09) 2 1 . O( 0 . 8 3 )
Rear 1 0 . 0( 0 . 3 9 ) 8.0(0.31t
Disc.unout Front 0,10 {o.004)
Rear o.10 (o.oo4)
Disc parsllslism Front ano rear 0.015 (0.ooo6t
Pad thickness ftont H22A1, H23A1 engine t r.u to.ogt 1 . 6( 0 . 0 6 )
H22A 1 engine 1 1 . O{ 0 . 4 3 ) 1 . 6( 0 . 0 6 )
Rear 9.0 {o.35) 1 . 6( 0 . 0 6 )
3-13
Air Conditioning Section 22
MEASUREMENT STANDARD{NEW)
Air conditioning Lubricant capacity Condenser 10(1/3)
system cc (ll oz) Evaporator 30(1)
Line or hose 10 {r/3)
R€servoir 10(1/3)
Compressor Lubricant capacity cc {tl oz} 1 3 0 - 1 5 0( 4 1 / 3 - 5 )
Fieldcoil resistanceEt 68oF {2OoC)0 3.05-3.35
Pulley-to-pressureplate clearance 0.35-0.65(0.014-0.026)
Comprgasor Dollectionwith lOO N (10 kg, 22 lbs) 10.0-12.0{0.39-0.471with usedbelt
belt' between pulleys 4.5-7.0{0.18-O.28} with new b€lt
Belt tsnsion N (kg. lbs) 450-600 (45-60, 99-132) with used bslt
M€asured with belt tension gauge 950'1.150 (95'115, 209-254) with new bslt
. Wh* u"ing I new belt, adjust dellection or tension to now values. Run tho engine lor 5 minutes thsn turn it o{f
R€Ediustd€flgction or tension to used belt values
Electlical - Section 23
MEASUREMENT STAI{DARDINEW)
lgnitioncoil Rated voltage V 12
Primarywinding resistanc€8t 68 oF (2OoC)o 0.6-0.8
S€coodarvwinding resistanceat 68 oF (20ocl kO
Spark Plug Type S6e Sgction 23
Gap 1 . 0 - 1 . 1{ 0 . 3 9 - 0 . 4 3 )
lgnitiontiming At idling o BTOC 1 5 ol 2 o { R e d )STDC
Alternator belt' Defloctionwith 1OON (10 kg, 22 lbs) 10.5-12.5 (0.42-0.51) with used belt
between pulleys 8.O-10.0 {0.32-O.4Olwith new b€lt
Belt tension N (kg, lbsl 3OO-45O{30-45, 66-99} with usod belt
Mgasured with belt t€nsion gauge 550-750 {55-75, 121-165) with new belt
MEASUREMENT STANDARD{NEW) SERVICELIMIT
Alternator Output 13.5 V at hot A 80/90
(NIPPONDENSOCoil r€sistance (rotor) O 2 . 7- 3 . 1
SIip ring O.D. 1 4 . 2 - 1 4 .{40 . 5 6 - 0 . 5 7 } t r.e to.sot
Erush l€ngth 1 0 . 5( O . 4 1 ) 1 . 5t 0 . 0 6 )
Brush spring t€nsion g {oz) 300-360t10.6-12.7)
Starter motor Tvpo Spargearreduction,Permanent magn€t
(MITSUBA Mica depth 0.4-0.5(0.016-0.o20) 0.15 t0.oo6)
1.4 kW) Commutator runout o-0.02{o-0.ooo8) o.o5(0.oo2)
CommutatorO,O. 2 8 . 0 - 2 8 . (11 . 1 0 2 , 1 . 1 0 6 ) 2 7 . 5( 1 . 0 8 3 )
Brush length 15.8-16.2(0.62-O.64t 10.0(0.39)
Brush spring t6naion (new) N (kg, lbsl 1 6 . 0 , 1 8 . (01 . 6 0 - 1 . 8 0 ,
3.53-3.93)
Starter motor Tvpe Spargearreduction,Permanent magnet
(MITSUBA Mic8 depth 0.4-0.5(o.0'16-0.o20l 0 . 1 5( 0 . 0 0 6 )
1.6 kW) Commutator runout o-o.02{o-o.ooo8) 0.o5 t0.o02)
CommutatorO.D. 2 8 . 0 - 2 8 . (11 . 1 0 2 - 1 . 1 0 6 ) 2 7 . 5{ 1 . 0 8 3 )
Brush length 15 . 8 - 1 6 . 2 (0.62-0.64) 10.0 (0.39)
Brushspringtensionln€w) N lkg, lbs) 1 6 . 0 - 1 8 .(O1 . 6 0 - 1 . 8 0 ,
il 3.53-3.93)
ii
:1
!I
* When usanga new belt, adjust detlection or tonsion to new valuos. Run the engine lor 5 minutes then turn it ofl.
Re€djust detloction or tension to used bolt and values.
I
Design Specifications
Overall Length 4,440mm I 1 7 4 . 8j n

Ov€.all Width 1 , 7 6 5m m I 69.5 in
OverallHeight 1 , 2 9 0m m | 5 O . 8i n
Wheelbase 2 . 5 5 0m m I t O O . qi n
Track F/R 1 , 5 2 5 / 1 , 5 1 5m m i 6 0 . 0 / 5 9 . 6j n
GroundClearance 145 mm | 5.7 in
Type F22A1 engine Water-cooled, 4,srroke SOHC

gasolineengjne
H23A1 engine Water-cooled, 4-stroke DOHC
gasolineengine
H224l engine Water-cooled, 4-stroke DOHC
VTECgasolineengine
CylinderA.rangement Inline4-cyljnder,transverse
l Bore and
Stroke
F22A1 engine
H23A1 engine
H22A 1 enigne
8 5 . 0 x 9 5 . Om m
8 7 . 0 x 9 5 . Om m
8 7 . Ox 9 0 . 7 m m
3 . 3 5x 3 . 7 4 i n
3 . 4 2x 3 . 7 4 i n
3.43 x 3 57 in
l
OisplacementF22A1 engine 2 , 15 6 c m 3 ( c c ) 132cu-in
H23A1 €ngine 2,259 cm3 {cc) 138 cu-in
H22A'l engine 2,157cm3 (cc) 132 cu-in
Compression F22A1 engine 8.8 : 1
Ratio H23A1 engine 9.8:1
H22At engine 1 0 . 0: 1
Valve Train F22A1 engine
l
Belt driven,SOHC4-vatveper cytinder
H2341 engine Belt driven.DOHC4-valveper cytinder
H22A'l engine Belt drive,DOHC4,valveper cylinderVTEC
Lubrication System Forcedand wet sump, trochoidpump
Fu€l Required F22A1 engine UNLEADEDgradegasolinewith 86 pump
OctaneNumberor higher
H23A1, H22A1 engines PremiumUNLEADEDgradogasolinewith
91 Pump OctaneNumberor
Makes/Type MITSUBA/Spurgear reduction,
permanentmagnet
Normal Output 1.4 kW, 1.6 kW
NominalVoltage 12V
Hour Rating 30 seconds
Directionof Rotation Counterclockwise as viewedfrom gearend
3 . 7k s | 8 . 2l b s
MIT Singleplatesdry, diaphragmspring
Torque converter
M/T 203 cm2 | 31
TRANSMISSION Synchronized s-speed forward, 1 reverse
Electronically
controlled
-speed automatic, 1 reverse
Direct 1 : 1
GearRatio lsr
2nd
3rd
4th
5th
Reverse
4.062 1 4.266 1 4.266
(cont'd)
3-15
Design Specifications
(cont'd)
ITEM METRIC ENGLISTI NOTES
Automatic Engine tYPe F2241 H23A1

TRANSMISSION
{conl'dl GearRatio lst 2.705 2.705
2nd 1.442
3rd 1.028 1.057
4th o.701 0.750
5rh
Reverse 2.O47 2.O47
Final Rsduction Gear tYPe Singl€helicalgear
Gear ratio 4.285 | 4.428
'14,682BTU/h
AIR CONDITIONING Cooling Capacity 3,7O0Kcauh
Conditions:
compressor Speed 1 , 8 0 ( rpm
Outsid€ Air Temparature 81 0F
Outeide Air HumidilY 50 %
Cond€nserAir TemPerature 35 0C 95.F
CondenserAir VelocitY 2.5 mlsec 8.2ltlsec
Blower Capacity 460 m3/h 16,247 ctt-ftlh
Compressor Typg/M€kes ScrooltyP€/SANDEN
No. oI cylinder
CaPacitY 85.7 cc/rev | 5.23 cu-in/rev
Max. Sp€sd 10,000 rpm
Lubric8nt CaPacitY 130 cc I 4 1/3 tl oz sP-10
Condenser TyPe Corrugatodlin type
Evaporator Type Corrugated lin type
Elower Type Sirocco lan
Motor Input 220 Wl12 V
Speod Control 4-spsod
Max. CaPacity 460 m3/h I 16.247 cu-ft/h
Temp. Control Air-mix type
Comp, Clutch Type Dry, single plat€, poly-V'belt drive
Power ConsumPtion 42 W max.l12 V
Rotrigerant Type F-l34a
Ouantity osO-8os 1 t8.a-9.ao
oz
STEERNG Type Power as8isted, rack and Pinion
SYSTEM Ovorgll R€tio 2 W S : 1 5 . 8 6 , 4 W S :1 5 . 1
Turns, Lock-to-Lock 2wS: 2.91, 4WSt 2'77
Steedng Whosl Di6. 380 mm I 15.0 in
SUSPENSION Type. Front lndependent double wishbone,
coil spring with stabilizer
Type, Rsar lndeDendentdouble wishbone,
coil spring with stabilizer
Shock Absorber, Front and R€ar Tolescopic, hydraulic nitrogen gas-filled
t,
l.,i
Camber Front
Rear
Caster
Front Omm i oin
Rear In 2.O mm I In 0.08 in
BRAKESYSTEM Type, Front Power-assistedselt,adjusting
ventilated disc
llear Power-assistodselt-adjustingsotid disc
Pad and LiningSurfaceArea: Front 5 8 . O c m 2x 2 8.99sq-inx2
I
Rear 27.Ocmzx2 | 4 . 1 9 s q - i n x2
ParkingErakeKind and Type Mechanical actuating, rear two whsel
brakes
Size 1 8 5 / 7 0R 1 4 8 7 H . 1
'1:S 2 0 5 / 5 5R 1 5 8 7 V * 2
f125l7o O l5 {Sparetirel *r
T135/80D 15 {Sparerire)*2
ELECTRICAL Battery 12 V-55AH/5HR
Starter 1 2 V - 1 . 4k W , 1 2 V - . t . 6k W
Allernator 1 2 V - 9 0A , 8 0 A
FusesIn UndeFdashFuse/Relay Box 7 . 5 A . ' 1 0A , 1 5 A , 2 0 A , 3 0 A
In UndeFhoodFuse/Flelay
Box 7 . 5A , 1 0 A , 1 5 A , 2 0 A , 4 0 A ,
50 A. 60 A, 100 A
1 2 V - 6 5W
1 2 V - 5 5W
FrontTurn SignalLights 1 2 V - 3 2C P
Front ParkingLights 1 2 V _ 5W
RearTurn SignalLights 1 2 V - 4 5C P
Brake/Taillights 12 V-43t3CP
High Mount BrakeLight 12 V -21 CP
Side Marker Lights Front 1 2 V - 3C P
Rear '12v-3 cP
Back{p Lights 1 2 V - 3 2W
LicensePlateLights 1 2 V - 8W
InteriorLights 1 2V , 8W
Trunk Lights 1 2 V - 3 . 4W
GaugeLights 1 2 V - 3 . 0W , 1 . 4W
IndicatorLighrs 'l2v-1.12W ,
1 . 4W , 3 . 0 W , 3 . 2 W
WarningLights 12V-1.4 W
llluminationand Pilot Lights 1 2 V - 1 . 4W , 1 . 1 2W , 0 . 8 4W , L E O
1 2 V - 1 . 4W
3-17
Body Specifications
Unit: mm (in)
I
lr;i
Maintenance
Lubrication
Points ..........4-z
MaintenanceSchedule ... 4-4
I
{lI LubricationPoints
Indexand variouswolk pro-

For detailsof lubricationpoints and types of lubricantsto be applied,referto the lllustrated
cedures(suchasAssemb|y/Reassemb|Y,RepIacement,overhau|,Insta||ation,etc.)containedineachsection.
"Energy ConservingII"
API ServiceGrade:Use
SG gradeoil.
F22A1, H23A1 engine:5 W-30 preferred.
H22A1 engine:1O W-30 Preferred.
SAE Viscosity:See chart below.
Transmission Manual API ServiceGrade:SF or SG

SAE viscosity:
10W-30or1OW-40
Automatic HondaPremiumFormulaAulomaticTransmission
Fluidor an equivalentDEXRON@II Automatic
transmissionfluid
Brakefluid DOT3 or DOT4
Brak€fluid DOT3 or DOT4
SteeringgreaseP/N 08733 - BOTOt
Shift lever pivots (Manualtransmission)

Releasefork {Manualtransmission)
Steeringboots
Steeringball joints
Selectlever (Automatictransmission)
Pedallinkage
lntermediateshaft
Brakemaster cylinderPushrod
Trunk hingesand latch
Door hingesupper/lowerand latches
Door openingdetents
Fuelfill lid
Enginehood hingesand enginehood latch
Clutch mastercYlinderPushrod
Throttle cable end
Caliper Pistonseal. Dust seal,
Caliperpin, Piston
Shift and select cable ends
Hondapower steeringfluid-V
Comoressoroil SPlO P/N 38899-P13-OO3
Selectthe oil for your car accordingto this chart:

l
I 'l
F22A1,H23A1ongine
Amblent Temoeraturo
An oil with a viscosityoJ 5 W-30 is preferredfor im- An oil with a viscosityof 1O W-30 is preferred
provedtuel economyand year-roundprotectionin the for improved{uel economYand year-roundprotec-
car. You may use a 1O W-30 oil il the climatein tion in the car. You may use a 5 W-30 oil if the
your area is limitedto the temperaturerange snown climatein your area is within the temperature
on the chart. range shown on the chart
L 4-2
4-3
MaintenanceSchedule
3.e .g
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B E
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dcicicidd 3 *
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'=u ;z ;z "- 1x E '
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22-?=
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gci ai.+
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P ; 4 P1 :td:
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P.9 BETH-I
t i ;!. t P . :E i; Eq -o N N A : ; is.sd
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4-5
MaintenanceSchedule(cont'd)
P P " ;
E * 6 - b
g 6 : ( l .
> . o ; 6
t t < = . 9
s €:R E
(,) * Ee6- ts
3 E EE! E
o E E l3! s
2 \ i o E
t ; E e i EE
: E € E:
!;,i.8 !
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L 6
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.9
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ir E
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.4
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r
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ri 3E8 <,iddci,ii,!
4-6
Engine
Constructionand Function
lH22Al engine) . . . . . . . . . .5 - 1
E n g i n eR e m o v a l / l n s t a l l a t i.o. .n. . . . . . . . . . .5. - 1 7
C y l i n d eH
r e a d / V a l vTer a i n . . . . . . . . . . . . . . . .6. - 1
E n g i nB e f o c k. . . . . . . . .........7-1
E n g i n eL u b r i c a t i o n . . . . . . . . .8 - 1
IntakeManifold/Exhaust System ........ 9-1
Cooling . . . . . .1 0 - 1
Construction
and Function
lH22A1 enginel
Outline
Description ................5-2
VTEC
Outline .... 5-4
Mechanism ................5-6
Control System ...........5-7
GylinderHead
Outline .... 5-9
Camshafts . . . . . . . . . . . . . .5. .-.1 0
ValvesandValveSprings............... 5-11
BeltTensioner
Outfine ....5-12
A u t o - T e n s i o n. .e. r. . . . . . . . . . . . . . . . . . . .5. .-1
. .3. .
C y l i n d e r B l o c. .k. . . . . . ......5 . -14
OilFlow ......5-15
Outline
Description
cooledand
ThenewH22A1 engineis an in-line4-cylinderDoHc designdisplacing2,157 cm31131.6 cu in) lt is water
equipped with a centerplug type pent-root combustion chamber. lt is specifiedto use premium unleadedfuel and usesa
pGM-Fl(SequentialMultipon FuelIniection)system.This engineincorporatesa mechanism calledHonda Variable Valve
Timing and Valve Lift ElectronicControl (VTEC) System.
This ststem allowsthe timing and litt oJthe intakeand exhaustvalvesto be changedsimultaneously. The enginealsoin-
cludesa electronically-controlled intake manitold system that varies the volume of the intake chamber.
i
I
il
5-2
L.
nd ll!i)r Specificstions
Type Water cooled4-stroke,In-line4-cylindergasolineengine

Oisplacement 2 , 1 5 7 c m 3( 1 3 1 . 6 c u - i n )
tn-
Eore x Stroke 8 7 . Ox 9 0 . 7 m m t 3 . 4 3 x 3 . 5 7 i n l
CompressionRatio 1O.O:1
Cam, Valve Mechanism Dual over-headcamshaft,VTEC
Valve Train
FuelSupply System SequentialMultipon Fuel Injection{SFl)
Main Features:
a The cylinderhead ls made of aluminumalloy,a centerplug type, pentroof-shaped combustionchamberis used, and
the 4-valvesystem uses 2 intakevalves and 2 exhaustvalves,
The camshaftsand the valvetrain are drivenwith the timing belt. andthe two balancershaftsare drivenby the timing
balancerbelt. Belt tension is automaticallyadjusted.
a The cylinderblock is made of aluminumalloy using fiber reinforcedmetal (FRM)sle€ves.
a The crankshaftis made by torging,the mainshsftis suppo.tedat tive points and has eight balancerweights.
a The balancershafts employ a gear-typereve,semechanismto reducesecondaryenginevibration.
a The intake manifoldis made ot aluminumalloy, and the heat riseris usedfor h€atingthe airlfuelmixture.
a The exhaustmanifoldis made of stainlesssteel.
a The electronicfuel injectionsystem is of a sequentialmaltiport fuel injectiontype and injects fuel into all four
cylinders,the throttle body is of a one-barrelside-drafitype.
a The ignitionsystem is a fully-transistorized,
contactlesstype. The spark advanceis electronic.
a The air cleaneris equippedwith a resonator.
a The radiatoris of a corrugatedtype. and th€ coolingtan is el€ctricallypowered.
5-3
VTEC
Outline
T h e e n g i n e i s e q u i p p e d w i t h m u | t . p | e c a m I o b e s p e r c y | i n d e r , p r o v i d i n g o n e v a | v e t i m i n g a n d v a | vand
eIiftpro'i|eatIowspe€
other is controlledelectronically' is selecied
and a differentproiileat haghspeed.switch-overfrom one profileto the
by monitoringcurrent enginespeed and load.
i CAMSHAFT
lr
r'l
CAM LOBESFOR LOW RPM
CAM LOBESFOR HIGH RPM
PRIMARYBOCKERARM
MID ROCKERARM
il SECONDARYROCKERARM
HYDRAULICPISTON(A}
HYORAULICPISTOI{ {AI
STOPPERPISTON
LOST MOTION ASSEMBLY
EXHAUST VALVE
INTAKE VALVE
5-4
rd In g€noral,it would be idealif the high rpm performanceof a racingengineand the low rpm pertormanceot a standard
!d passengercar enginecould be combinedin a singleengine.This would resultin a maximumperformanc€enginewith a
wid6 power band. Two of the major differencesbetweenracingenginesand standardenginesare the timing ot the in-
take/6xhaustvalvesand the degreeof valve lift. Racingengineshsve longerintake/exhaust timing and a highervalvelift
than standardengines,The Honda VariableValve Timing and Valve Lift ElectronicControlSystemtakes this into ac-
count, Wh€n valve actuationis set for low rpm timing and lift, low rpm torque is betterthan in a standardengine.Whon
valve actuationis then switchedlor high rpm timing and lift, output improvesto the levelgiven by a racingengine.Until
now. tew variablevalvetiming systemshave beencommercialized, In thosethat have,only the time that both vatves8re
open (intake/exhaust overlap)could be changed.Honda'ssystem is the first in the world in which both the valvetiming
and the degreeof valve litt can be changedas needed,makingit the most advancedvalve train mechanismavailable.
RacingEngine VTEC Engine StandardEngine
Valve Timing
(exhsust/intake) i
Valve Lift
Erh.u.t lntrk€ Erhrurt lntlk Exhlult Intrko
Max. Power
Low rpm Torque
ldling stability
'TDC = Top Dead Center *BDC = Bottom Dead Center
O = Ootimum Characteristic
The engineis equippedwith two valve timing and valve lift settingswhich changeaccordingto drivingconditions.
RPM switch ovgr

pornt
5-5
VTEC
Mechanism
At Low rpm:
Asshown,theprimaryandsecondaryrockelarmsalenotconnectedtothemidrockerarmbutaledrivenseparSte|yby
cam|obesAandBatdifferenttimrngandIift.A|thoughthemidrockera.misfo||owingthecentercam|obewiththe|ost-
valvesin the low rpm range'
motion assembly,it has no effect on the openingand closingof the
At Low rpm:
CAM PROFILESFOR
LOW RPM
CAMSHAFT
*A and B cam lobes

ddve the rocker arma
sepsrot6lY
RETURNSPftNG
HYDRAULIC
PISTON(AI PISTON
STOPPER
HYDRAULIC
PISTONIBI SECONDARY
PRIMARY MID ROCKEBARM
ROCKERARM ROCKERARM
At High rpm:
Whendrivingathighrpm,plstonlA)movesinthedirectionshownbYthearrowinthefigureba|ow.Asaresu|t,th€
primary.secondary,andmidrockerarmsareIinkedby2hydrau|icpistons(|ikeaskewerlandthe3rockerarmsmoveas
and closingthe valvesat the valvetiming
a singleunit. In this state. a the rockerarmsare drivenby cam lobec, opening
and valve lift set fot high operation.
At High Dm:
CAM PNOFILEFOR
HIGHRPII
I *The rock€r arms ere linked
l, ;
+ via the hydraulic Piston.
Cam lobe C drives the rocker
arms.
il
STOPP€R
PISTON
HYDRAULIC HYDNAULIC
PISTON (AI PISTON(B)
5-6
ControlSystem
The controlsystemfor this mechanism,as shown below, constantlymonitorsthe changesin enginestatussuch as load,
rpm and vehiclespeed.this intormationis transmittedto the EngineControlModule {ECM).
Valv€ Timing ChEngeConditions

Englne Speed: 4,9OO nm or higher
Vohicle Spood: 19 mph (3O km/hl 01 tastel
Engino Coolant Temperature: lrtooF {6OoC) or higher
ControlSystem
VTEC PRESSURESWITCH
VTECSOLENOIDVALVE
Et{Gtt{E
CONTROL
MODULE
F.oft {ECM)
OILPUMP +
5-7
ControlSystem(cont'd)
I
Lost Motlon Machanbm

at low sps€ds' At low spoeds' th€ lost motion
The mid rock€r arm is always driven by the high-spesd cam lobe' even
mechanismkeepsthemidrockerarmincontactwiththehigh.speedcam|obe'Athighsp6€ds,the|ostmotion
mechanismscts as part of the valve spring load'
CAM PfiOFILE
SPRII{G
SPRIIIGA
RETAINEN
GUIDEHOLDER
LOSTMOTIONASSEMELY
I Hydraulic Prg$ure Contlol Machanism

VTEC solenoidvalve/VTECpressuteswitch
the oil passagato the rocketarm at low speed'
The VTECsolenoid,ralve,in responseto a signalfrom the ECM,closes
a.ms ope]8t6 indopendent|y.At high sp66d, tho
This cuts oiI pressureto the hydrau|ic pistons in the rocker arms so the
EcMopsnstheVTEcso|enoidva|ve.Theincreasedoi|pressurecausesthehydrau|icpistonsto|ockthep'imary,sgcon
dary, and mid tocker arms together.
TheVTECpressureswitchsgrvesasasensortodetermineiftheswitch-overhastakenp|aceinl€sponsetoth€EcM
signsl.
i
I's
t. l:
5-8
CylinderHead
Outline
The one-piececylinderhead is made of aluminumalloy to reducethe weight while increasingefficiency

The combustionchamberis a compactpent roof shape,centerplugtype. The cylinderheadusesa DOHC4-valvesystem
with 2 intakevalvesand 2 exhaustvalvesarrangedfor cross flow. Combustionis stabledue to the optimizationof the
ignitiontiming, compressionratio and valve timing.
EXHAUST
CAMSHAFT
INTAKE
CAMSXAFT
EXHAUST
ROCKERARM
II{TAKE
ROCKERARM
EXHAUSTPORT
INTAKE PORT
INTAKEVALVE
EXHAUSTVALVE
5-9
GylinderHead
Camshafts
T h e c a m s h a f t i s a c a s t p i e c e . B y i m p r o v i n g d i m e n s i o n a | a c c u r a c y , i t b e c a m e p o s s i b | e t o a c h i e v e mforc-
inimumspacg
on five bearingiournalswith
tween cams,thus a owing a more compactcylinderhead.Eachcamshaftis supported
intakecyctesrequireI totaloJ 24 cam
ed lubrication.on the left end of eachcamshaftis a drivenpulley.The exhaustand
lobesto oDenand closethe valves
EXHAUST A: PRIMARY
B: MID
C: SECONOARY
CAMSHAFTJOURNALS
II{TAKE
CAMSHAFTJOURNALS
Low-speedvalve timing High-speod valve timing
<F i Intok6 valva opon

- : Exhau3t vslvg opon
INTAKEA INTAKE B
€XHAUSTB
INTAKE C
TDC: Top dead center

BDC: Bottomdead center
Valves and Valve Springs
t€- The valves are openedand closedby rocke. arms driven by the camshatt.
,c Light weight and large diametervalves made ot a high strength metal with small diameterstems are used. The air
lm resistanceis decreasedby the slenderstems and the intakeefticiencyis inc.easedby inlet ports that match with laroe
diametervalves,
Valve specitications
U n i t :m m ( i n )
VALVE
ITEM INTAKE EXHAUST
HEAD DIAMETER 3 5 . O( 1 . 3 8 ) 3 0 . o{ 1 . 1 8 )
STEMDIAMETER 5.5 tO.22l 5.5 lO.22l
OVERALLLENGTH r 0 6 . 7 5( 4 . 2 0 3 ) ' 1 0 6 . 9(54 . 2 r
1)
VALVE LIFT Secondary:8.O (O.31) S e c o n d a r y : 7 . 5( O . 3 O )
Mid: 11 . 5 ( O . 4 5 ) * Mid: 1 O . 5( O . 4 1 1 *
Primary: 6.5 (O.26) P r i m a r y : 6 . O{ 0 . 2 4 )
* Indicateshigh-speed valves
I oVERALLLENGTH
Fr
| | ,/|l
ffir HEAD
DIAMETER
The valve spring wire uses a moditiedcross-sectionto valve lift in a limitedsoace.
EGG SHAPE LEMON SHAPE
5-11
Belt Tensioner
Outline
ThetensionersforthebaIancersha'tdrivebe|tandthetimingbe|tarearrangedinpara||e|onasing|eaxisforamolecom
pact configuration,This tensionerallows easv belt maintenance'
TIMING BELT
WATER PUMP
PULLEY
TENSIOI{ERSPRINGfol
TIMING BALAIIICERBELT
AUTO.
for TIMING BELT
MAINTENANCEBOLT
TIMI G AELT
AOJUSTER
BALANCERBELT
TENSIONER
5-12
- Auto-tensioner
The auto-tensioner usesa torsionspringto regulatethe timing belt tension.The maincomponentsare the torsionsp.ing,
. malescrew and a temalerod. The assemblyis filledwith oil and sealed.The springturnsthe malescrew. which pushes
lhe lemalerod out againstthe belt. The designis such that the rod cannot be pushedback into the housingby belt ten-
s'on. To pull the female rod back into the assembly.the male screw must be turned with a screwdriver.
SCREWIMALEI
Machanbm:
8€lt Ro6ctlon Fo.ce
o The male screw is

rotated by the
ri The lemale rod is O The rod stops when the force
pushedout as lhe oI the torsion spring and
lorsron spflng. rod rotates, the timing belt equalize.
5-13
CylinderBlock
madeoJ FRM,a composite

The cylinderblock is a closeddeck designmadeof aluminumalloy . The cylindersleevesare
materialof aluminum, alumina tiber and carboniiber. The boresin the cylinderblockfor the shaftsand the deep
balancer
skirt designimprovethe rigidityof the block.
Cylinder spocitications
Bore x Stroke 8 7 . Ox 9 0 . 7 m m ( 3 . 4 3 x 3 . 5 7 i n )
Bore Pitch 9 4 . Om m ( 3 . 7 Oi n )
Block Height 2 1 9 . 5 2( 8 . 6 4 3i n )
Skirt Depth 5 0 . Om m ( 1. 9 7 i n )
Displacement 2 . 1 5 7 c m 3( 1 3 1. 6 c u - i n )
7.0 mm {0.28 inl
-.-----\L----J-JJ
\7-J\^/\-
O O O Q O
iEff
^ ,.\ /zr .\ ^
BALA'{CERSI{AFT
BORES
Oil Flow
Lubricationof the c.ankshattand connectingrod bearingsis done by oil pumpedthroughthe main bearingcaps ano Inro
passagesin the crankshalt.The pistonsand cylinderwalls are lubricatedby oil spray nozzlesmountedon the cvlinder
block.
INTAKECAMSHAFT
OIL CONTROL
ORIFICE
VTEC SOLENOID
VALVE
CAMSHAFT HOLDER
PIPEOIL VTEC
PRESSUBE
swtTcH
€IHAUST CAMSHAFT
.XXJRI{AL
ENGINEOIL COOLER
ENGINECOOI"ANT
ENGINEOIL FILTER
FRONTBALANCER
ENGINEOIL PRESSURESWITCH
OIL JET
NOZZLE
REAR BALANCER
(cont'd)
5-15
Oil Flow
(cont'd)
oi|pumpedtothecy|inderheadservestwopurposes;to|ub'icatethecomponentsandtooperatetheVTEC.oi|is
pumpedintothecamshaftho|dertoIub'icatethejourna|s,anditsprayslfomorificesintheho|derto|ubricatetherocker
this valveopensand oil is pumpedat high
arms and valves.oil is alsosuppliedto the VTECsolenoidvalve.At high RPM.
Dressurethrough the rockerarm shatts to operatethe VTEC'
r
)
VTEC SOLEIIOIDVALVE
OIL CONTROL
ORIFICE
ENGINEOIL FILTER
ENGINEOIL COOLER
OIL JET
NOZZLE
EngineRemoval/lnstallation
@
frla-i6iwe iacks and saletY stands 8re placod ploper-
5. Loosenthe drain plug on the radaator.
ly and hoist brackots are attachod to the corr'ct 6. Drainthe transmissionoil/lluid. Reinstallthe drain
positions on th€ 6ngin6. plug using a new washer.
a Mako suls tho car will not roll ofl stands 6nd lall
whlle you are working undal it. 7 . Orainthe engineoil. Reinstallthe drainplug usinga
new wasnef.
CAUTION:
a Use tend€l covers to svoid damaging paint€d CAUTION: Do not ovsrtighlan tho dlain plug'
surtacas.
a Unspocified itoma alo common 8. Lower the hoist.
a Unplug th€ wiring connoctolE carstullY while holding
the connoctor portion to avoid damago. 9. Removethe air cleanerhousingand intakeair duct'
a Mark all wiring and hosas to avoid miaconnection. 6 x 1.O ]||m
Also. bo 3u1€that thoy do not contact othar witing ol 10 .m {1.0 ks-m, 8 lb-ftl
hosos or into.ler€nco with othar parts.
NOTE: The radiomay hsve a codedthett protectioncir-

cuit. Be sureto get the customer'scode numb€rbelore
- Disconnecting the battery.
- Romovingthe No. 43 (10 A) Juse(ln the under-hood
tuse/relavboxl.
- Removingthe radio.
Atter service,reconnectpower to the radio and turn at
on.
"CODE" is displayed. enter the
When the word
customer's5-digit code to restoreradio operation.
1. Securethe hood as far open as possible.
2. Disconnectthe batterynegativeterminaltirst, then

the positivetetminal.
AIRCLEA'{EFHOUSI'{G
3. Removethe radiatorcap
1O. Removethe pulsed secondaryair iniectionIPAIR)
use care vuhonremoving tho radiator vacuum tank and bracket.
!@
cap lo avoid scalding by hot coolant ol atoam. PAIR
VACUUMTANK
4. Raisethe hoist to full height.
Remove the Jront wheels and the engine splssh
shield. 6x1.Omm
lO N.m 11.0kg-m,
I rb-trl
6 x 1 . Om m
'10t{.m (1.O kg-m,
a tb-ft|
BRACKET
6 x 1.0 mm
I
Front
1O N.ln (1.0 kg-m,
7 lb-ftl
5-18
11. Remove the battery, battery base, battery cable CAUTION:
and starter cable. a B€fore disconnocting any fu6l line, r6li€vs the
tuel pr€ssur€ os dosc.ibod above.
MANUALTRANSMISSION
tM/TI: a Place I shop towol ovel the tu€ltilter to prevent
prossulizod tuol trom sprsying ovor tho ongine.
8 r 1,25rnm
22 tt.m 12.2kg-m,
16 tb-ft) 13. Removethe fuel feed hose from the fuel rail.
WASHER
STARTER CABLE
AUTOMATIC
TRANSMISSION
{A/r}:
NOTE: When installingthe starter cable clamp.

make sure the tab is in the hole in the bracket,
14. Removethe injectorresistorconnectoron th8 left

side of enginecompartment.
INJECTOR
6x1.0mm RESISTOR
10 N.m {1.0 kg-m, INJECTOR
0 r 1.0 rnm
1 0 N . m( 1 . 0k g - m ,
7 tb-ftl
1 2 . Relievefuel pressureby slowly looseningthe ser-

vice bolt on the fuel rail aboutone turn (seesection
11 ) .
@ Do not smoke while working on tu€l

systom. Keop opsn tlame or spark away ttom work
alaa. Drain tuol only into an apptoved containet. (cont'd)
5-19
(cont'd)
emis-
15. Removethe throttlecableby looseningthe locknut' 18. Removethe brakeboostervacuum hoss and
sion control vacuum tubes from the intake
then slip the cableend out of the throttle linkage'
manilold.
NOTE; IEVAPICONTROL
EMISSION
EVAPORATIVE
a Take care not to bend the cablewhen removlng
it. Always replaceany kinked cable with a new
one.
a Adiust the throttle cable when installing(see
s e c t i o n1 1 ) .
BRAKEBOOSTER
VACUUMHOSE
1 9 .Disconnect the connector and vacuum tube' th€n

I remove th€ cruise control actuatol.
NUT
ADJUSYING
Ir to. Removethe engine wire harnessconnectors.rer-

minal snd clamps on the right side of engine
compartment.
CRUISECO'{TROL
ACTUATOR
8r1.Omm
10 .m (1.o kg-m,
7 tb-frl
Bemove the power cable from the under-hood
tuse/relaybox.
POWERCABLE UNDER.HOOD
t l
Il'
20. Remove the engine g.ound cable from the body 23. Loosenthe alternatormounting bolt, nut and ad-
side. justing nut, then removethe alternatorbelt,
21. Removethe power steering (p/Sl pump belt and
pump. MOUNTING EOLT
a Do not disconnectthe p/S hoses.
8 x 1.25 rhm
22 .m (2.2 kg-m.
t8
ALTERNATOR
AELT
PI,MPBELT
LOCKI{UT
r 1 . 2 5m m
22 N.m {2.2 kg-m, 16 tb-frl
P/S PUMP 24. Loosen the mounting bolt, then remove the A/C
compressof.Disconnectthe connector.
a Do not disconnectthe A/C noses.
22. Rsmove the air conditioning{A/C} condenserlan
shroud. then install a protector Dlate on the
radiator.
6x1.Omm
10 N.m (1.0 kg-m,
7 tb-ft}
8 x '1.25mm
22 N.m 12.2 kl-m.
16 rb-ft}
. Do not remove
tho bohs
(conr'd)
5-21
(cont'd)
25, Removethe upperand lower radiatorhosesandthe 27. Removethe shift cable and selectcable (M/T)'
heaterhoses.
NOTE:
a Take care not to bend the cablewhen removing
it. Always replaceany kinkedcablewith a new
one.
a Adjust the shiJtcable and seleci cable when in-
stalling(seesection 13).
I x 1 . 2 5m m
WASHER
BRACKET
i WASHER
\ SELECT
CAELE
COTTER
Roplace. PI.ASTIC WASHCR
STEELWASHER
26. Remove the transmissionground cable and the
automatic transmissionfluid (ATF) cooler hoses Removeth€ clutch slave cylinder and the pipe/hose
(A/T).
assembly(M/T).
NOTE:
a Do not ooerate the clutch pedal once the slave
cvlinderhas been lemoved.
a Take care not to bend the PiPe.
ASSEMBLY
SLAVECYLINDEB
t
I
8 r 1.25mm
22 N.m 12.2 kg-m,
16 rb-frl
5-22
29, Removethe clutch damperassembly. 31. Raisethe hoist to ful hoight.
NOTE: Take care not to bend the pipe. 32. Removethe exhaust pipe A and bracket.
tng
CLUTCHDAMPER GASKET SEI.F-LOCKIIIGNUT

rin- 18 N.m {1.8 ks-m, t3 tb-ft}
Replace.
@'
tHER
8 r 1 . 2 5m m
nc 22 N.m 12.2kg-m,
IER t6 tb_ftl
I{UT
55 N.tn (5.5 kg-h, 40 b-trl EXHAUSTPIPEA
Replace.
30. Remove the vehicle speed sensor {VSS)/power
steeringlPlS) speedsensorassembly.
33. Removethe A/T shift cable (A/T).
NOTE: Do not disconnectthe noses.
NOTE:
a Take ca.e not to bend the cable when removing
18 N.m (1.8 kg-m, it. Always r€placeany kinkedcable with a new
one.
ilave
a Adiust the shift cable when installing (see sec-
tion 14).
ISLY
P/S
6 x 1 . Om m
10 N.m (1.0 kg-m, 7 lb-ft)
tg N.m (1.8 kg-m,

13 tb-ftl (cont'dl
5-23
(cont'd)
34. Bemove the damper fork.

36. Removethe driveshafts.
SELF-LOCKINGBOLT
10 r 1.25 mm
/+4 N.m (4.4 kg-m, 32 lb-frl
I
I
h
t
I 1 2 x 1 . 2 5m m
65 N'm 185 kg-m,47 lb-ftI
DRIVESHAFT
RePlace.
|l 35. Disconnectthe suspensionlower arm balljointwith

the special tool. Refer to section 18 tor the
37. Swing the driveshaftunder the fender.
NOTE:
procedure. a Coat all precision-finished surfaceswith clean
engineoil or grease'
a Tie plastic bags over the driveshaJtends'
PLASTICBAG
CASTLENUT
14 x 2,O mm
50-60 N.m
fl 36-43 tb-ft)
38. Lower the hoist.
39. Attach the chain hoist to the engine.
5-25
lcont'd)
40. Removethe rear mount bracket 42. Removethe lelt side enginemount.
BEAR STIFFENER
4 3 . Remove the transmrsslon and mount

bracket.
41. Removethe front mount bracket.
44. Raisethe chain hoist to removeall slack from the
l
i'
chain.
45. Checkthat the engineis completelyfree of vacuum

hoses, fuet and coolant hoses, and elect.ical
wiring.
46, Slowly raisethe engineapproximately150 mm {6

an).
Check once again that all hoses and wires have
been disconnectedtrom the engane.
47. Raisethe engineallthe way and removeit Jromthe

car.
5-26
48. Installth8 enginein the reverseord€r of removal. a Check that the spring clip on the end ot each
driveshaftclicks in to olace.
NOTE: After the engineis in place:
a Torque the engine mounting bolts in the s€- CAUTION: lnstall now spring cllps
quence shown below.
Eleed air from the cooling system at the bleed
CAUTION: Fallur€to tlghton the bolts In the p?opor bolt with the heatervalve open.
aoquencccln cauae orcegtivo noiar and vlbrstion. a Adjust the throttle cable tension.
and rcduce bushing litc; check thst thc bushing! a Checkthe clutch pedalfree play {M/T).
aro not twirtrd or offsot. a Check thst the transmissionshifts into gear
smoothly.
l 2 x 1 . 2 6m m
1 0 r 1 . 2 5m m REAR MOUITIT @ es .m le.s tg-m,
TRAIISMISSIOT{
MOUI{T @2r 'm t2.1 1s b-ft} 47 b-trl
1 0 r 1 , 2 5m m R€place.
39 .m {3.9 kg-m.28lb-ft}
10 r 1.25mm
@ 39 .ln t3.9 ks-m.
O Tightsnsnugonty. 12 x 1.25mrn
1 2 r 1 . 2 5m m
@ 65 t{.h {6.5 kg-h, 47 b-trl O 55 .m 15.5ks-m, 40 tb-trl
ReDlace.
12 x 1.25mm
@ 65 .ln (6.5 kg-m, 47 tb".ft)
RgDlac6.
FROI{TMOUI{T
SIDEE'{GI E
IIOUNT
the
12| 7.29
@ 55 .m (5.5lg-ln, 40
tum
'acal
r {6
6Ve NOTE:
. Torque th€ mounting bolts/nuts in the
numbgred s€quenceas shown (O-@).
. After road t6sting, loosen and r€tighten @ Tighten only.
@ Tighton snug onty.
the l O x 1 . 2 5m m the thre€ bolts on the front r'lount 1 2 r 1 . 2 5m m
@ 39 N.m (3.9 kg-m,28 tb.ft} brackoi. O 65 t{.m lO.5 kg-m,47 tb-ftl (cont'dl
5-27
(cont'd)
a Adiust the tensionof the following drive belts: a InsDectfor fuel leakage.
Alternatorbelt (section23). After connectingall tuel line parts. turn on the
Power steeringpump belt (section17). ignition switch (do not operate the starterl so
Air conditionercompressorbelt {section22). that the fuel pump operatesfor approximately
a Clean battery posts and cable tetminals with two seconds and the fuel line is pressurized.
sandpaper,assemble,then apply greaseto pre- Repeatthis operationtwo or three times, then
vent corrosron. check for fuel leakageat any point in the Juel
line.
Mount and BracketBolts/NutsTorque Value Specifications:
TRANSMISSIONMOUNT MOUNT 1 2 r 1 . 2 5m m
95 N'm {9.5 kg-m, 69 lb-ftl
REABMOUNT
TRANSMISSION 10 r 1.25mm
MOUNT '10 r '1.25mm 39 N.m 13.9kg-m,
BRACKET 39 N.m (3.9 kg-m, 28 lb-tt)
2a tb-ft|
(Standardfor
some tvpos)
SIDE ENGINE '10x 1.25mrr

MOUNTING BRACKET 48 N.m (4.8 kg-m.
35 tb-ft|
I x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ftl
H23A'1.H22Al €ngine:
Et{GINEMOUNT
BRACKETA
h
!r
lO x 1.25mm
45 N.m {4.5 kg-m,
33 lb-tr)
12 x 1.25mm
95 N.m (9.5 kg-rn,69 lb-ftl FRONTMOUNT 8 x 1 . 2 5m m
22 N.n 12.2ks-m,
16 rb-ft|
lO x '1.25mm
48 N.m (4.8 kg-m, 35 lb-ft)
5-28
AdditionalTorqueValue Specifications;
P/S BRACKET
{F22A1 onginol
TRANSMISSIONMOUNT BOLTS
65 N.m 16.5kg-m,47 lb-ftl
8 x 1,25mm
22 N.m 12,2 kg-m,
16 tb-ftt
.ft)
INTAKE MANIFOLO
x 1.25mm
50 N.m {5.O kg-m,
36 rb-ftt
8 x 1.25mm
N.m {2.2 kg-m, 16lb-ftt
EXHAUST MANIFOI.D
BRACKET 10 x 1.25mm
50 N.m {5.O kg-m, 36 lb-frl
P/SBRACKET
(H23A1,H22Al ongino)
tg-m,
10 r 1.25mm
45 N.m {4.5 kg-m, 33 lb-ftl
I for 1 0 x 1 . 2 5m m
es) 50 .m {5.Okg-m,36 lb-trl
10 x 1.25mm
50 N.m (5.O kg-m, 36 lb-ftl
Apply liquidgasket ALTERNATORBRACKET
to the bok threads,
1 0 x ' 1 . 2 5m m
50 N.m {5.O kg-m, 36 lb-ftl A/C BRACKET
5-29
Cylinder Head/ValveTrain
F22A-1engine ............... 6-1

H 2 3 A 1e n g i n e . . . . . . . . . . . .6. .- 3 7
H22Al engine .............. 6-71
CylinderHeadA/alveTrain
lF22A1 enginel
SpeciafTools .........6-2 Valve Seats
l l l u s t r a t oIdn d e x . . . . . . . . . . . . . . . . . . . . . . .6. .-.3. Reconditioning .... 6-17
Valve Seals Valve Guides
Replacement (Gylinder head V a l v eM o v e m e n.t. . . . . . . . . . . . . . . . . .6. -. .1. 8
removalnot r€quiredl .............6-5 Replacement .......6-19
CylinderHead Reaming .............6-20
Removal . . . . . . . . . . . .6. - 7 Camshaft/Rocker Arms and
Warpage ............6-18 CamshaftSeals/Pulley
Installation .........6-23 fnstalfation .........6-22
Camshaft Pulley Timing Belt and Timing BalancerBelt
Removal .............6-12 lllustrated Indox ........................ 6-25
Rocker Arm Assembly Replacemont .......6-29
Removal . . . . . . . . . . . . . 6 - 1 2 Timing Belt
Rocker Arms lnspection ..........6-26
Overhaul . . . . . . . . . . .6. - 1 3 TensionAdjustment ................... 6-26
Clearance ...........6-15 PositioningCrankshaftBefore
Camshaft lnstalling TimingBelt .............. 6-28
Inspection . . . . . . . . . . 6 - 1 4 Timing BalancerBelt
Valves, Valve Springs and Valve Seals fnspection ..........6-27
Removal . . . . . . . . . . . .6. - 1 6 Valve Clearance
Valve Spring and Valve S6al Adjustment .........6-34
InstallationSequence..............6-21
Valve Installation....................... 6-2 1
SpecialTools
Ref. No. I Tool [tlumber

6-20
o 07HAH-PJ701OAor Valve Guide Reamer,5.5 mm
OTHAH_PJ701OB
6-22
o OTNAF_PTOOlOA InstallerCUP
lnstaller Shalt 6-22
@ OTNAF_PTOO20A
OA Seal Guide 6-22
@ OTNAG-PTOOl
Valve Guide Driv€r, 5.5 mm 6 - 1 9 ,2 0
@ o7742-OO10100
I
e:Gt'r----------E
@
o @
@
fllustratedIndex
CAUTION:
a To avoid damaging the cyllnder head. wsit until th6 engine coolant tompe.aturo drops bolow loooF {38ocl b€foro
romoving it.
a In handling a metal gaskot. tak6 caro not to fold it or damago the contacl surtaco ot tho gasket.
NOTE:
a Use new O-ringsand gasketswhen reassembling,
a Cleanthe oil control orifice before installino.
CAP NUT
6 r 1.0 rrn ?
10 N.m11.Okg-m.7lb-ftI
HEADCOVER
CYLII{OER
RUBEER SEALS
R€placowhon dEmag€d
or d€teriorst€d.
Put longer bolt
CYUITDER HEADBOLT
1 2 r 1 . 2 5m m
R 1OO ,m (lO.Okg{n, 72 lb-ft}
T Tightening.page6-23
Apply sngineoil to the thrgadg.
CYLII{DERHEAD
8 x 1 . 2 5m m
la N.m11.8kg-m,13lb-ftl
DOWELPI'{
otl coilTRol oRtFtcE

Clean.
O.RING
Roplace.
8 r 1.25mrn
CYLINDERHEADGASKET 22 t{,m (2.2 kg-m, 16 lb-ftl
{METALGASKETI
R€olacg. TIMINGBELT
Rsplacement,page 6-29
Inspoction/Adjustmont,
page 6-26
--- AD.'UST|IG ruT

./--'77'---)
10 r 1.25mm
45 [.m 14.5 kg-m, 33 lb-ft,
Loos6n, but do not r6movg.
(cont'd)
6-3
lllustratedIndex
(cont'd)
nl cleanall the partsin solvent,dry them.nd applylubricantto any contsctparts'
,rto, to teassembling,
6 x 1 . Om m
12 N'm tl.2 ks-m, 9 lb-ft)
r 1.25mm
@
u
I
e
I
22 trl,m (2.2 kg-h, 16 lb-ft)
ROCKEBARM ASSEMBLY
VALVE ADJUSTING SCREW Ovorhsul,pag€ 6-13
7 r 0.75 mm lnspoction, page 6-1 5
20 .m (2.0 kg-m, 14 lb-ft,
Apply oil.
Adjustment, psge 6-34
SEAL
lnstdflation, page 6-22
R€place.
oo*:..rn-y' E
;
CAMSHAFTPULLEY
Romovsl, page6-12
Installation,pago6-22
CAMSHAFT 8 x 1.25 mm
38 .m (3.8 kg-m.27 lb-ft)
VALVE KEEPERS-*_-_-\
-'^"'-"-'-"-' -------Ib
--_
spRtl{GRETATNER
vALvE
ExHAUsr
---ro
spRrNG...-_____la
;ili'
--"i
vALvE spntitc
i
I
w VALVEIGEPERS
I
q I ExHAUsr
ExHAUsrvALvEsEAL rgli valvE RETAII{ER
p8g€s6-5 8nd 16
Replac€ment,
Reptace. Fz-->.- I @ .Ve-une ITTAIG VALVE SPfiI C
II{TAKE VALVE SEAL
R€Dlace.
SEAT
VALVESPRING
II{TAKEVALVE GUIDE
EACr COVER
CYLINDERHEAD
6 x 1.Orm
12 N.mll.2 kg-m,9 lb-ftl
INTAKEV
B6movsl,pao€ 6-16
Installation, page 6-21
6-4
Valve Seals
Replacement(Gylinderhead removalnot requiredl
NOTE: Cylinder head removal is not required in this Intake V!lv. Soals:
orocedure. 6. S€lgct the 7/8 in diameter long compressor attach-
m€nt 8nd fasten the gttachment to th6 No. 5 hole
Ths proc€dur6shown below applies when using the in- of th€ levor arm with the speed pin suppli€d.
car valve spring compressor. (Snapon YA8845 with
YA8845-2 A 7/8' attachmentl Ins€rt an air adaptor into the spa.k plug hole. Pump
air into the cylinder to ke6p the valve closod whils
@E Alway woar approv.d oyc prot.ctron compr€ssing springs and rsmoving th€ valv€
whon uslng th6 in-cel valvo spring compt!3!or. ke6o6rs.
1. Turn the crankshaftso that th6 No. I 8nd the No. 6. Position the lev€r arm und6r ths cross shaft so the
4 pistons are at top desd center (TDC). lover is porpondiculsrto th€ shaft and the compres-
8or sttachm6nt rests on top of the rgtsinsr tor the
2. Removeth€ cvlinder head cover and the rocker arm spring being compress€d.Us€ th€ tront position slot
assembly. on ths l€vsr as shown.
NOTE; NOTE: RJt shop towek over the oil passagesto pre-
a Rsf€r to p8ge 6-12 for rocker arm assembly vent th6 valvo ke€p€B from falling into the cylindsr
removal. h6ad.
I When removing or installing the rocker arm 8s-
sambly, do not r6mov6th€ camshaft holdorbolts,
Th6 bolts will keepthe holders,sprir€s and rocksl
arms on th€ shaft,
OII. PA&gAGES
3. Remove the fuel injectors and the wire hsrn€ss.
4. Using the 8 mm bolts supplied with the tool, mount

the two uprightsto the cylinderh6adatthe end cam-
shaft holders. Th€ uprights tit ov8r the camshatt as
shown,
5. Insertthe cross shaft through th6 top hola of th€ two

uprights.
trl
(cont'd)
6-5
Valve Seals
lGylinderheadremovalnot required)(cont'dl
Replacement
'15. Using a downwatd motion on the levsr arm, com-
9. Using a downward motion on the l€ve, arm, com-
pressthe valvespringand removethe keepersfrom press the valve spring and remove the keepersfrom
the valve stem. Slowly release pressureon the the valve stem. Slowly release paessuleon the
sprlng. sprlng.
1 O . R e m o v et h e v a l v es e a l s( p a g e6 - 1 6 ) . 16. Removethe valve seals(page6-16).
1 1 . Installthe valve seals (page6-21). 17. Installthe valv€ seals lpage 6-21).
12. Installthe springs,the retainersand the keepersin 18. Installthe springs,the r€tainers8nd th€ koop€.sin
reverseorder of removal. rgvorso ord€r of romovSl,
ExhaustValv6 Seals: 19. Repeatsteps 6 to 18 on the other cylinde,s.
13. Selectthe 7/8 in. diametershortcompressor attach-

ment and lasten the attachmentto the No. 4 hole of
the lever arm with the speedpin supplied.
14. Positionthe lever arm under the cross shaft so the

leveris perpendicularto the shaft and the compressor
attachment rests on top of the retainerfor the spring
being compressed.Use the front position slot on the
lever as shown.
NOTE: Put shop towels over the oil passagesto pre-

vent the valve keepersfrom falling into the cylinder
head.
6-6
CylinderHead
Removal
Engineremovalis not requiredtor this procedure. 1 . Disconnectthe negativeterminalfrom the battery.
2 . Drainthe enginecoolant{seesection101.
o Make sur6 iacks and sefsty stands are placed propsdy . Removethe radiatorcap to speeddraining
and hoist bfackets are sttachod to co.roct @shions on
tho ongin€, 5. Relievethe fuel pressure.
o Maks sure the car will not roll off stfltds and tall whilo
you are working under it.
@ Do not snoke whlc wo*rng on ftrc
sydem, krop oFn ffrnc or spark away trom wor*
CAUTION:
s!. Drdn ft|ol ody into an approvrd contrlnor.
a Us€ t€nd€r covors to avoid damaging paintod surtacas.
a Unspecifiad h€ms arc common.
o Unplug tho wiring connec{ors carefully whil€ holding ths SERVICE EOLT
connoctor Fprtion to avok ddylago. SHOPTOWEI- 12 N.m {1.2 kg-m,9 tb-ft}
. Mark a[ wMng and hosos to avokt miEconnection.Abo,
bo su.o that they do not contact oth6. widng or hosos ol
innerto?e with othq parts.
o To avoid damaging th€ cylinder hoad. wah untilthe sn-
gine coolant temp€.aturs drop6 b€low 100oF (38oC)
botor€ loosoning tho l€taining boh.
o Inspect th€ timing beh bofore removing the cylnder FUELRAIL
hoad.
. Tum the crankshaft pulley so that tho No. 1 dston is at
top doad center {pag€6-281.
a Maks all emission hos€s betore disconnocting th€m.
NOTE; The radio may have a coded theft protectioncir- 4. R€movethevacuumtube,breatherhoseand intskeair
cuit. Be sure to get the customer'scode numberbefore duct.
Disconnectingthe battery.
- Removingthe No.43 (1OA)tuse (ln the under-hood Removethewater bypasshosefrom the cylinderhead
fuse/relavboxl.
Removingthe radio. Removethe fuel feed hose and evaDorativeemission
After service,reconnectpower to the radioand turn it on. (EVAP)controlcanisterhosefrom the intakemaniJold.
Whenthe word "CODE" is displayed.enterthe customer's
s-digit code to restoreradioope.ation.
(cont'dl
6-7
CylinderHead
Removal(cont'd)
7. Removethe brakeboostervacuum hose and vacu- 10. Removalthe ignitioncoil.
um hosemount (A/T only)fromthe intakemanitold.
* 8x 1.25mm
22 N.m(2.2kg-m,16lb-ftl
8 . Removethe luel return hose and cruisecontrol vacu-
um hose.
CRUISE
Removethe spark plug caps and the distributor,
9. Removethe throttle cableand the throttle control ca 1 2 . Removethe connectorand the te.minalfrom the alter-
bl; (A/T only) from the throttle body. nator, then removethe enginewire harnesstrom the
cylinderhead cover.
NOTE:
o Take care not to bend the cablewhen removingit. 1 3 .Removethe followingenginewire harnessconnectors
Always replaceany kinkedcable with a new one. and clamps f.om the cylinder head and the intake
a Adjust the throttle cable when installing(seesec- manitold:
tion 1 I ). a Fourtuel injectorconnectors
o Intakeair temDerature{lAT) sensorconnector
o ldle air control (lAC) valve connector
6r10mm . Throttle position (TP)sensorconnector
1 2 N . m( 1 . 2k g - mI, l b - f t l o Exhaustgas recirculation(EGR)valve lift sensor
connector
. Groundcableterminals
. Enginecoolant temperature(ECT)switch B con-
necror
o Heatedoxygen sensor (HO25)connector
a ECTsensorconnector
o ECTgaugesendingunit connector
. lgnition coil conneclor
THROTTLECONTROL . CKP/TDC/CYPsensorconnector
CABLE (A/T onlyl
. Vehiclespeedsensor(VSS)connector
a ECTswitch A connector
r!: CORROSION BOLT

RESISTANT
14. Removethe upper and lower radiatorhosesand heat- 18. Disconnectthe connectorandvacuumtube,then re-
er noses. move the cruisecontrol actuator
CNUISECONTROL
ACTUATOR
UPPERRADIATOR 6 x '1.0rnm
HOSE 10 N.m {'1.0kg-h, 7 tb-trl
\
VACUUMTUBE
HEATEROUTLET
HOSE
HEATERINLET
HOSE
cor{r{EcToR ,//
,4
15. Remove the emission vacuum hoses and water ./
bypasshosesfrom the intake manifoldassemblv.
'16.
Removethe water bvoass hose from thermostat 1 9 .Removethe enginegroundcablefrom the bodyside.
housing.
20. Removethe power steeringlP/S)pumpbelt and pump.
17. Remove the thermostat assemblv from intake
er- manifold. NOTE:
ne a Do not disconnect the P/S hoses.
. After installingsdiust the tension of the P/S pump
belt (seesection 17).
ke
P/S PUMP
THERMOSTATASSEMALY
I x 1.25mm
LOCKNUT 22 N-lm 12.2 kg-m,
1 5 N . m l t . 5 k g - m ,1 1 l b - f t ) 16 tb-ftt
P/S PUMPBELT
(cont'd)
6-9
CylinderHead
Removal{cont'd)
24. Removethe heat insulator(carsequippedwith air con-
21. Remove the intake manitold bracket and intake
ditioningonlY).
mani{old.
25. Removethe self]ocking nuts and disconnectthe ex-
haust manifoldand exhaustPiPeA.
MANtFoLo GASKET
TNTAKE
26. Bemove the exhaust manifold bracket and exhaust
manifold.
BRACKET
22. Lift the tront of the car up andplaceit on safetystands'
EXHAUSTPIP€A
Mako sure lifts, iacks and safaty stands aro dacsd
propsdy. and hoist brack€ts are attach€d to the cor-
r€ct position on the ongin€ (seo page 1-10 rhlu
1-121.
Apply pa*ing b.ake and block rear wheeb, so car
will not roll oft slands and lsll on you wh e workng
HEAT INSULATOR
und91il. (Carsoquippedwith air conditioningl
23. Removethe front wheelsand the enginesplashshield 2 7 . Remove the positive crankcase ventilation (PCV)
(page5-18). hose, then removethe cylinderhead cover.
24. Removethe upPercover.
29. Loosanthe adjuatingnut 27O - 3600.
30. Pushthe tensionerto releasetensionfrom the timing

b€lt, then retightenthe adiustingnut.
6-10
31 . Removethe timing belt from the camshaft pulley. NOTE: Separatethe cylinderhead from ihe block with a
llat bladescrewdriveras shown.
ex
CAUTION: Do not crimp or bend

tho timing balt mor€ than 90o or
less than 25 mm (1 inl in diameter.
GA No Good
32. Removethe cylinderhead bolts. then removethe

cylinderhead.
CAUTION: To prevont warpag€. unscrow tho bolts

in soquonc€ 1/3 turn at a timo; rop€at untllall bohs
ars loosonad.
CYLIT{OER
HEAOSOLTLOOSENING
SEOUENCE
ning)
>cv)
mrng
6-11
CamshaftPulleY RockerArm AssemblY
Removal Removal
1. To easereassembly,turn the camshaftpulleyuntilthe 1. Loosenthe sdjustingscrews, then remove the bolts

"UP" mark faces up, and the front timing mark is and the rockerarm assembly.
alignedwith the cylinderhead upper surface.
NOTE:
. Unscrsw the camshaft holderbolts two tums at a
time, in a crisscrosspsnern to pre\€nt damaging
the valvesor rocker arm assmbly.
,.UP"MARK . When removingthe rocker arm assembly.do not
remove the camshaft holder bohs. The bolts will
keep the camshaft holders, the springs and the
rockerarms on the shafts.
b%
TDCGROOVES
Alignfronttimingmarkon
Pulleywith the cylinder
headuppersurfac€,
Removethe timing belt.
J. Removethe retaining bolt, the special washer, the 6 mm BOLTS

camshaft pulley and the key, then removethe back
cover.
CAMSHAFT
PULLEY
BACK COVER
6-12
RockerArms
r Overhaul
NOTE:
a ldentifypartsastheyareremovedto ensurereinstallation
in originallocations.
a Inspectrockershafts and rockerarms (page6-15).
. Rockerarms must be installedin the same positionif reused.
a When removingor installingrockerarm assembly,do not removethe camshaftholderbolts. The bolts will keepthe
holders,
springsand rockerarms on the shaft.
o when reassembling,fit the projectionof the intakerocker shaft to the notch in the camshaftholder.
'
! Priorto reassembling.clean all the part in solvent, dry them and apply lubricantto any contact parts.
Letter "9" is stamped Lefter "A" is stampod

on tocker atm. on tocker arm.
IITITAKE
BOCKER INTAKEROCKER INTAKEROCKER
sHAFr@ sxmr @ ARMs
lshon, 2 placesl (long, 3 places) (4 plsces)
lh,,tr"o.,
HoLDER
I liif.ro" I ti;or"or, ll"t "o'
HoLDER I I HoLDER HoLDER
I I | | | .,nou.,,,or".^
|
ll | | l ' u " ' T I" '
| | t . l^ l , l ^
#,dffifu,Lffi,#u/=m
- *
LpC .ffig*ffir
l
|flry 16tr
l " r * l
' o s ' g U f "#

t [ U
or.,t o "*,n(' ROCKERARM
(short, 2 palces) (long, 3 places) (8 places)
rc
/
EXIIAUST ROCTERSHAFT
6-13
Camshaft
Inspection
Removethe bolts, then removethe camshaftholders
Note:
. Do not rotate the camshaftduringinspection. lrom the cylinderhead.
a Removethe rockerarms and rockershafts.
- Lift camshaftout ot cylidnerhead,wipe clean,then
1. Rrt the camshaft and the camshaft holders on the inspectlift ramps.Replacecamshaftif lobesarep't-
cylinder head, then tighten the bolts to the specilied ted, scored,or excessivelyworn.
torque.
- Cleanthe camshaftbearingsurfscesin the cylinder
head,then set camshaft back in place'
Specified tolque:
8 mm bohs: 22 N m (2.2 kg-m, 16 lb-ft)
- Insertplastigagestrip acrosseach iournal'
6 mm bohs: 12 N'm (1.2 kg-m,9 lbjt)
6 mm BOLTS lnstall the camshaft holders,the tighten the bohs to

the specijiedtorque as shown in the left column on
this page.
o. Measurewidest portionof plastigageon eachjournal'
Camshatt-tolloldcr Oil Clearance:

standard (Newl: 0 050-0.O89 mm
(o.0020-o.0O35 in)
Servbe Limh: O.15 mm {0.000 in)
8 mm BOLTS
PTASTIGAGE STNIP
Seatthe camshaftby pushingittoward distributorend

of cylinderhead.
Zerothe dial indicatoragainstend ol distributordrive.

then push the camshaft back and forth and read the
end play.
Camshaft End Play:

StandardlNow): 0.o5-o.1 5 mm
(O.0O2-O.0O6in)
S€rviceUmh: O.5 mm {O.O2in)
CAMSHAFT
6-14
RockerArms
Clearance
efs 7. lf camshaft-to-holderoil clearanceis out ot tolerance: Measureboth the intake rockershafts and exhaustrocker
shaft.
- And the camshaft has alreadybeen replaced,you
!€n must replacethe cylinderhead. Measure diameter ot the shaft at the tirst rocker
pit- - lt camshafthasnot beenreplaced,tirst checktotal location.
runout with the camshaft supportedon V-blocks.
der Canshaft Total Runout:

Standard(N€w): O.O3mm (0.0O1in) max.
Srvice Limit: 0.06 mm (0.002 in)
tto
on
nal.
Surfaceshouldbe smooth.
Zero the gaugeto the shaft diameter.
- lf the total runout of the camshaft is within toler-

ance, replacethe cylinderhead.
- lf the total runout is out of tolerance,reDlacethe

camshaftand recheck,lfthe oilclearanceis stillout
ol tolerance,replacethe cylinderhead.
Measurethe insidediameterof the.ocker arm and
Measurecam lobe height. check tor out-of-roundcondition.
Cam Lob€ Height: Rock€r Am-to-Shaft Cloarance:

lntakeStanda.d: 38.526 mm (1.5168in) Standdd(N€w)
Erhaust Standard: 38.778 mm { 1.5267 in) lmak6: O.O17-O.O5O mm
(0.OOO7-O.OO2O in)
Exhaust: O.O18-O.054mm
{O.OOO7-O.0O21 in)
Ssrvico Linit: 0.O8 mm
(O.0O3in)
Inspectrocker arm
laca tor wear,
Repeatfor all rockers.lf over limit, replacethe rocker

Inspectthis areator wear. shaft and all over-tolerancerockerarms.
6-15
Valves, Valve Springsand Valve Seals
Removal
4. Removethe valve seal.
NOTE: ldentify valvesand valve springsas they are re-
moved so that each item can be reinstalledin its original
Dosition.
1. Tap each valve stem with a plastic mallet to loosen

valvekeepersbeforeinstallingthe springcompressor'
2. Install the spring compressor.Compressthe spring

and removethe valve keepers.
COMM€RCIALLYAVAILABLE
3. Installthespecialtoolas shown.
lntako Valvo txrronsions

VALVEGUIDESEALREMOVER
LISLEP/N57900or KD3350 A Standtd(tlowl: 33.90-34.1O mm
COMMERCIALLY AVAILABLE (1.335- 1.343 in)
B Standtdocw): 1 1O.88-l 1 1.18 mm
(4.365-4.377 in)
C Strdard{ ow}: 5.485- 5.495 mm
{ O . 2 1 5 9 - O . 2 1 6 i3n )
C SorviceLinit: 5.455 mm (0.2148 in)
D Standard(t{ow}:0.85-1.1 5 mm
(0.033-O.045 in)
D S€rvbr Linit: 0.65 mm (0.026 inl
Exha.|3t Valvo Dlmonsions

A Sta.!dsd(t{ow): 28.90-29.10 mm
I t 1 . 1 3 8 - 1 . 1 4 6i n )
8 Stard1*d(ltswl: 122 15 -122.45 mm
(4.809-4.821 in)
C Siandsdl ewl: 5.450- 5.460 mm
( 0 . 2 1 4 6 - O . 2 1 5 0i n l
C SorvicoUmh: 5.420 mm (O.2134 in)
D Standard(Now): I .O5- 1.35 mm
(O.O41 -O.O53 in)
D S€rvicoLimit: 0.95 mm {0.037 in)
6-16
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a 5. After resurfacingthe s€at, inspectforeven valveseat-
valve seat cutter. ing; Apply PrussianBluecompoundto the valve face,
and insertvalvein originallocationin the head,then lift
NOTE: lf guidesare worn (page6-18),replacethem it and snap it closedagsinstthe seat severaltimes.
(page6-191beforecutting the valve sears.
PRUSSIAI{
6. The actualvslveseatingsurface,as shown bythe blue

compound,should be centeredon the seat.
. lf it is too high {clos€rto the valvestem), you must
make a secondcut with the 600 cutter to move it
doun,then one mor€ cut with the 45o cutter to re-
store sest width.
a lf it is too low (closerto the vslve edge),you must
make a secondcut with the 3Oo cutter to move it
2. Carefully cut a 45o seat, removing only enough
up, then one more cut whh the 45o cutter to re_
materialto ensurea smooth and concentricseat.
store seat width.
NOTE:The final cut should alwavs be made with
3. B€velthe upper edge ot the seat with the 3Oo cutter
the 45o cutter.
and the lower edge of the seat with the 600 cutter.
Check width of seat and adjust accordingty.
7. Insertintakeandexhaustvalvesin the headand meas-
ure vatve stem installedheight.
4. Make one more very light passwith the 45o cutter to
removeany possibleburrscausedbv the other cutter.
Intako Valv6 Stam lnstalsd H€ight:
Standnd (New): 48.245-48.]15 mm
Valve S€at Width:
(1.8994- 1.9179 inl
Stsdard (Nowl: 1.25-1.55 mm
SsrviceLimh: 48.965 mm (1.9278in)
(O.049-O.061in)
Exhaust Valve Stem I]rrtaH Hotght:
ServiceLimit: 2.OOmm (0.079 in)
Standrd (t{ow}: 50.315-8O.785 mm
1 1 . 9 8 0 91- . 9 9 9 4i n l
Sorvice Linh: 51.O35mm (2.OO92 in)
SEAI WIDTH
8. lf valve stem installedheight is over the servicelimit,

replacethe valve and recheck.li still over the service
limit, replacethe cylindef head; the valve seat in the
head is too deep.
6-17
CylinderHead ValveGuides
Warpage Valve Movement
NOTE: lf camshaft-to-holderoil clesrance{page6-14) are Measurethe guide-to-stemclearancewith a dial indicator

not within specitication, the cylinder head cannot be while rocking the stem in the direclion ol normal thrust
(wobblemethodl.
resurfaced.
lf camshaft-to-holderoil clearancesare within specitica- lntako Valve Stem-to4ulde Clearanca:

tions. check the cvlinderheadfor warpage. Standrd {New}: 0.04-O.O9 mm
(O.OO2-0.OO4 inl
. lf warpageis lessthan O.05 mm {0.OO2in)cylinderhead ServiceLimh: 0 16 mm (0.006 in)
resurfacingis not .equired.
. lf warpageis betweenO.O5mm (O.0O2in) and 0.2 mm Exhaust Valve Stom'to4uite Clea.ance:
(0.008 in), resurtacecrinder head. Standard(New): 0.1 1 -0.16 mm
a Maximumresurfacelimit is 0.2 mm {0.008 in) basedon {0.0O4-0.0O6in)
a heightof 10Omm {3.94 in). SorvicoLimit: O.24 mm (0.OO9in)
Valve extended 1Omm out from seat
STRAIGHTEDGE
PRECISION
o --\-_z
\ ' =
a lf measurementexc€edsthe servicelimit, recheck

using a new valve.
a l{ measurementis now within service limit, reas-
s€mbleusing a new valve,
a lf measurementstill exceedslimit, recheckusingal-
ternate method below. then replace valve and
guide, it necessary.
NOTE: An ahemate method oJ checking guide to

stem clearanceis to subtract the O.D. ol the valve
stem, measuredwith a micrometer,from the l.D. of
the valve guide, measuredwith an insidemicrometer
or ball gauge.
Takethe measurementsinthree placesalongthe valve
stem and three placesinsidethe valve guide.
The difference between the largest gulde measure-
ment and the smalleststem measurementshouldnot
exceedthe servicelimit.
Measurealong edges,and 3 ways acrosscenter. lntako Valvo Stom-to€ukle Clearance:

Standqd (Newl: 0.020-0.045 mm
Cyfnd€r Hoad Hoight: (0.ooo8-o.oo18
in)
Strdard lNew): 99.95- 1o0.O5mm S€rvicoLimit; O.Ogmm (O.OO3in)
(3.935- 3.939 in)
Exhaust Valvo St€m-to-Guide Clearancr:
Standcd (Newl: o.055-o.08o mm
(O.OO22-O'OO31 in)
SorvicaLimh: 0.1 2 mm {O.OO5in}
6-18
- Replacement
1. As illustratedin the removalst6ps of this procedure, 4. Workingtrom the camshaftside.Usethe driverand an

use a commercially-available air-impact ddver at- air hammer to drive the guide about 2 mm {0.1 in)
tachment modified to fit tho diameter of the valve towards the combustionchamber.This will knock off
guides. ln most cases, tho same procedurecan be some of the carbon and make removaleasier.
done usingthe ValveGuideOriverand a conv€ntional
nammer.
GAUTION:
o AlwEys woar satsty goggles or a face shiold when
VALVEGUIDEORIVER uCng tha air hamnr6r.
COMMERCIALIY
AVAILABLE . Hold th6 ak hdnmcf dkecdy in lina wlth iha valv€
guue to prev€ni darnaglng th€ driv$.
5. Turn the headover and drive the guideout toward the

camshaftside of head.
RcmovC.nd lrddlrtlon
VALVEGUIDEDR|VER. 8.5 mm
07742-0Or0100
Selectthe properreplacementguidossnd chillthem in

the treezersectionot a refrigeratorJor about an hour.
Usea hot plsteor ovento evenlyheattha cylinderhead

to 3OOoF(150oC). Monitor the temperaturewith a
cookingthermometer.
eck
)as-
J al-
and
,to
alve
r. ol
eler
alve c)o
iure-
nor
CAUTION:
. Oo mt uso a tordr; h may wrp thc hoad. lf a valveguidestillwon't move, drillit out with a I mm
. Do not glt dro he.d hotter rhan 3{X)oF fi5oocl: (5/16 inch)bh, then try again.
oxccsslvc hoat may looaan tl|c vdw rcat3.
a To avoid brrB. uco heavy gbves whon hsnding CAUTION: Ddd gridos only in €xtr€m6 casas; you
tho hoad cyrer h.ad. couH damago tho cytndcr hoad if ths guilo breaks.
6. Removethe new guide(s)from the refrigerator,one at

8 time, as you needthem.
(cont'dl
6-19
Valve Guides
(cont'dl
Replacement Reaming
7. Slipa 6 mm (0.2 in)steelwashet andthe correctdriver NOTE: For new valve guidesonly.
attachmert ov€r the end of the driver(Thewasherwill
absorbsome ot the impact and €xtend the life of the 1. Coat both reamerand valve guide with cutting oil
driver).
2. Rotatethe reamerclockwisethe full lengthol the valvs
guide bore.
3. Continueto rotatethe reamerclockwisewhile remov-
F:-p-qo
t t t 4.
ing it from the bore.
Thoroughlywash the guide in detergentand water to

DROER 6 mm (0.2In) ATTACHMENT removeany cutting residue.
WASHER
5. Check clesrancewith a valve {page6-181.
- Verify that the valve slides in the intake and ex-
Instsllthe new guide(s)trom the camshaftside of the haust vslve guideswithout exertingpressure.
head;drive each one in until the attachmentbottoms
on the head.lf you have all sixteenguidesto do, you
mav have to reheatthe headone or two more times.
VALVEGUIDEREAMER, HANDLE
REAMER
5.5 mft
OTHAH-PJ7OlOA ot
oTHAH-PJ70l08
Turn teamgrin
VALVEGUIDEDRIVER, clockwise diroctiononlY.
07742-OOlO100
Valve Gulde Insta{od H.iglrt:

fntak€: 23.75-24.25 mm (O.915-O.947 inl
Exhaust: 15.o5- 15.55 mm (0'593-0.61 2 in)
6-20
Valves,ValveSpringsand VatveSeals
ValveSpringand ValveSealInstallationSequence
NOTE: Exhsustand intakevalve s€alsare NOT intsrchangeable.
@A=----UO|-UEKEEPERS
NOTE: Pl6cs the snd ot valve
spring wilh clos€ly wound coitg
towa.d tllo cvlinds. he6d.
INTA(EVALVESEAL VALVERETAIT{ER
(WHTTESPRINGI
Replace.
ALVESPRII{G
VALVEGUIDESEAI-
I STALTIR
KD-2899
COUMERCIAI,I.YAVAILABT"E
t{OlE: UsgsrnalllO endof tool.
EXHAUSTVALVESEAL
IBLACTSPRIITGI
Replace.
I{OTE: Installlhe vatve springcests

bofore installinothe vstvg seals.
ValveInstallation
When installingvalves in cylinderhead, coat valve stems
with oil before insertinginto vslve guides,and make sure
valvesmove up and down smoothlv,
Whenvalvesand springsare in place,lightlytap the end of

eachvalvestem two or th.ee times with a plasticmalletto
ensureproperseatingof valve and valve keepers.
NOTE: Tapthe valvestem only alongits axisso you do not

bend the stem.
6-21
Arms and CamshaftSeals/Pulley
Camshaft/Rocker
lnstallation
OIL SEAL
CAUTION:
. Mako suro that alltoc*€rs aro in algffn€nt vvith valvas
wh€n to(qukrg rockr assambly bohs'
. Vshrs tocknds shodd bo bosonad and 8di$t Ecrows
backed ofi beloro in3tal8don'
. To Fovont rocker arm as!6mbly trom coming apart'
leavo baring crp holding bohs h tho hobs'
1. After wiping down the camshaft and journals in CUP

INSTALLEF
cylinder heod. lubricate both sur(aces and install SEAL GUTOE OTNAF_PIOOlOA
camshaft. o7t{AG - PT0010A
aubrt""a"""m tobesafterreassembly. o. Tiohteneach bolt two turns at a time in the sequence

I sh-ownbelowto ensurethatthe rockersdo not bind on
Turn the camshaftuntil its keywsy is facing up. the valves.
(No.1cylinderTDC).
Spcdffod torcuo:
Apply liquidgasketto the headmating surfacesof the 8 mm bolts: 22 N'm (2'2 kg-m, 16 lb-ft)
No. 1 and No. 6 camshaftholders' 6 mm bohs: 12 N'm ( l .2 kg-m, 9 lb-ft)
- Apply liquidgasketto the shadedareas.
6 mm BOLTS
No.1
-B
\J-
lt
v
Setthe rockerarm assemblyin place8nd looselyinstall 8 mm BOLTS

the bolts.
- Make sure that the rockerarms are propeflyposl-
7. lnstallthe back cover.
tioned on the valve stems.
8. Installths key and the camshaftpulleyonto the cam-
lnstallthe camshaftoil s8al using the speci8ltools as
shaft, then tighten the retaining bolt to the torque
shown.
shown.
CAMSHAFT SEAL GUIDE BACKCOVER

o7l{ac-PTOOl0A
Applyoil.
CAMSI{AFT
Mw
PULLEY
Sssl housing sudace

I
should b€ dry.
RETAININGBOLT
CAMSHAFT OIL SEAL 8 x 1.25 mm
Apply a light coar oI oil . N.rn{3.8 kg-m,
1 2 N m ( ' 1 . 2 k g - m38
to camshaft and inner INSTALLER SHAFT 27 tb-ft)
OTNAF_PTOO2OA I lb-ftl
lip of seal.
6-22
CylinderHead
Installation
Installthe cylinderhead in the reverseorder of removal: Installthe bolts that securethe intake manifoldto its
FT bracketbut do not tighten them yet,
NOTE:
,A
a Always use a new headgasket.
J. Positionthe camshaftcorrectly (page6-29).
. Cylinderheadand engineblock surfacemust be clean.
a "UP" mark on camshaftpulleyshouldbe at the too.
4. Tighten the cylinder head bolts sequentiallyin three
. Tum the crankshaftso the No. 1 cylinderis at TDC (psge
steps.
6-28t.
o Cleanthe oil contrclorifice before installino.
1rt stop to.que: 40 N.m (4.0 kg-m, 29 lb-ft)
\ 2nd stop torque: 70 N.m (7.0 kg-m, 51 tb-ft)
1. Cylinderhead dowel pins and oil control orifice must 3.d ctep to?quo: 10O N.m (10.Okg-m. 72 tb-ft)
be aligned.
nce
NOTE:
,on a W€ recommendusinga beam-typetorque wrench.
When using a preset-typetorque wrench, be sure
DOWELPIN
to tighten slowly and not to overtighten.
CYLINDER HEAD a lf a boh makesany noisewhile you are torquingit,
GASKET loosenthe boh and retightenit from the I st steo.
Replace.
ooml P {
a/ CYLI'{DERHEADBOLTSTOROUESEOUENCE
OILCONTROL
ORIFICE
Clean.
O-RING
Replace.
CYTJI{DER
12 r 1.25mm
lOO N.m ('lO.Okg-m, 72 tb-ftt
Apply clsan engineoil to bolt
threads and under bott heads,
(cont'd)
6-23
Cylinder Head
lnstallation(cont'd)
thenuts n a
the nuts In-a 7 . lnstall the exhaust mdtifold and tighten
"5. Installthe intakemanifoldandtighten "ri"""roo putt"a in 2 or 3 steps' beginning with the
in 2 ot 3 steps' beginningwith the
"t't"""too p.orn innel nut'
innernuts. a Always use 8 now exhaust manifoldgasket'
o Alwavsusea newintakemanifddgasket'
th€n instsll the
8 . lnstall th€ exhaust manifold bracket'
GASXET i"h"tt pip",q and the bracket, and then install the
Replace. cov€f.
GASKET
Replace.
8x l'25mm
32Nm13.2kg-m.
23 lb-ft)
Replace.
I x 1.25mm
22 N.m(2 2 kg-m'
MANIFOLD 8 x 1 . 2 5m m 16 tb-ft)
22 N.m {2.2 kg-m'
16 rb-ftl
1Ox 1.25mm
45 N.m(4.5kg-m,
33 tb-ft)
and the
lnstallthe heat insulatorto the cylinderhead 10 x 1.25 mm
block. GASKET 55 N.m {5.5 kg-m.
R€placo. 40 lb-ft)
Replace,
6r1.Omm
1ON.m(1.0kg-m,
7 tb-ft) EXHAUSTPIPEA
6-24
TimingBelt and TimingBalancerBelt
lllustratedIndex
NOTE:
o Referto page 6-28 tor positioningcrankshaftand pulley beforeinstallingtiming belt.
o Beforeremoving,mark directionof rotation.
ADJUSTING NUT
POWERSTEERING BELT 45 N.m(4.5kg-m, UPPER
COVER
Adjustment,
section17 33 rb-ft)
6x l.Omm RUBBER SEALS
12Nm(1.2kg-m, Replace whendamaged
\ I tb-ft) or detsrioratod.
\
I CAP NUT
LOWERCOVER 6 x l . O m m
Removethe five 1 0 N . m ( 1 . 0k g - m ,
bolts. 7 tb-ft)
CYLINDER
HEAD
COVER
6r l.Omm
12 N.m {1.2 kg-m,_,-
glb-tr) ,.'
-
l- CRAr{KSHAFT .^
::aNm(22.0ks-m,
/ WIIIV UAMSHAFT
:3 bft) ltrcnNartia aelr i"-*" PYLEY
"n" oir.
\:ot engineoil to the Adjustment, section 23
:crr threads,but not
u '- surfacethat
r.--ts the washet. SEALS
Replacewhen damaged
.uGAELT or dgt€rioroled.
.lo.ction, page 6-26
Sustm€nt, Page6-26
:,.dacement, pago 6-29
BELT
TE SIOITERS
AELT 8 x 1.25 mm
ADJUSTING BOLT 38 N.m (3.8 kg-m,27 tb-ft)
Remove 68 N.m(6.8ks-m,
any oil. SPRII{G 49lb-ft)
SPRING Installwith concave

6r 1.Omm surfacefacing in.
r 2 N . m( 1 . 2k s - m . Femove any oil.
I rb,ft) TIMII{G AALA CEREELT
Inspection,page 6-27
6-25
TimingBelt
Inspection TensionAdiustment
Disconnectthe altelnatorterminaland the connector. CAUTION: AhtvavsadFst timing boh tensbn with th6 on-
gin6 cold.
then removethe enginewire harnessfrom the cylinder
head cover.
Removethe cYlinderhead cover' NOTE:
o The tensioneris springloadedto applypropertens'onto
the belt sutomaticsllYafter making the lollowing ad-
Removethe upper cover.
justment.
a Always rotate the crankshaftcounterclockwisewhen
4. Inspect the timing belt for cracks and oil or coolant
soaking. viewed lrom the pulleyside. Rotatingit clockwisemay
result in improperadlustmentof the belt tension
. Inspectthe timing balancerbelt beforeadiustingthe belt
NOTE:
. Replacethe belt if oil or coolant soaked. tension.
a Removeany oil or solventthat gets on the belt' . Do not loosenthe adjustingnut morethan one full turn'
1. Disconnectthe alternatorterminaland the connector'

then removetheenginewire harnessflom the cylinder
Inspectthis arealor wear. headcover.
Removethe cylinderheadcover'
a Set the No. 1 piston at TDC (page6-28).
4. Loosenthe adiustingnut 2/3-1 turn, then tighten it'
ADJUSTINGNUT
45 N.m(4.5kg-m,33lb-ft)
Rotate the crankshaft counterclockwise3-teeth on

the camshaftpulley.then reloosenthe adiustingnutto
createtensionon the timing belt.
to Tightenthe adjustingnut.
: 5, After inspecting,retorquethe crankshaftpulleybolt 6.
220 N.m (22.Oks-m, 1 59 lb-ftl'
After sdiusting,retorquethe crankshaftpulleybolt to
22ON.m (22.0 ks-m, 159 lb-ft).
TimingBalancerBelt
Inspection
1. Disconnectthe altematorterminaland the connector,

then removethe enginewire harnesstromthe cylinder
headcover.
2. Removethe cylinderheadcover
3. Removethe uppercover.
4. Removethe crankshaftpulley.
5, Removethe lower cover,
6. Installthe crankshaftpulley.
7. Inspectthe timing balancerbelt for c.acks and oil or

coolantsoaking.
NOTE:
o Replacethe belt if oil or coolant soaked.
a Removeany oil or solventthat gets on the belt.
Inspectthis areator wear.
Botatepulley
andrnspectbelt.
After inspecting,retorquethe crankshaftpulleybolt to

22O N'm (22.Oks-m, 159 tb-ftl.
NOTE: Refer to page 6-32 tor timing batancerbelt

tension adjustment.
6-27
Timing Belt
PositioningCrankshaftBeforeInstallingTimingBelt
NOTE:
. Installthe timing belt with the No. 1 piston at TDC.
. After installingretorquethe crankshaftpulley bolt to
220 N.m (22.0 kg-m, 159 lb-ft).
CAMSHAFTTDC POSITION: CRANKSHAFTTDC POSITIO]T:
,,UP"MARK MANUAL TRANSMISSION:
FLYWHEEL INSPECTIOI{HOLE
AUTOMANC TRANSMISSION:
DRIVEPTATE INSPECNO HOLE
TOC MARK POINTERS

(WHITEI ot{ BLocK
NOTE: When turning the crankshaft with a socket

wrench, installthe crankshaftpulleyand rhe pulleybolt'
6-28
TimingBeltand TimingBalancerBelt
Replacement.
CAUTION: Inspoct tho walor pump whon radachg th6 3. Removethe mounting bolts, nuts and P/S pump belt
timing b€lt (Pag610-12) from the power steering(P/S)pump.
NOTE: Turn the crankshaftso that the No. 1 piston is at NOTE:

TDC (page6-28). a Do not disconnectthe PiS pipe and hose.
. After installing,adiustthe tensionof the P/Spump
I . Removethe splashshield. belt {seesection171.
LOCKNUT
POWEBSTEERING 1 5N . m{ 1 . 5k g - m ,
PUMP 11 tb-ft)
MOUNTINGBO(TS
8x1.25mm
22 N.m 12.2kg-m,
SPLASH SHIELD 1E rb-ftl P/SPUMPAELT
., Disconnectthe connector. then remove the cruise 4 . Disconnectthe alternatorterminaland the connector,
control actuator. then removetheenginewire harnessfrom the cvlinder
head cover.
NOTE:
a Do not disconnectthe control cable. Loosenthe alternatormountingbolt/nut and adjusting
a Takecarenot to bendthe cablewhen removingthe bolt, then rernovethe altematorbelt.
actuator.Always replacea kinkedcablewith a new
one. NOTE: After installing,adjustthe tensionof the alter-
nator bett lsee section 231.
CRUISE
ACTUATOR 6x1.Omm
10 t{.m {1.0 kg-m, MOUNTIM! EOLT
7 tb-ttl 1 Ox 1 . 2 5m m
45Nm{4.5kg-m,
33 tb-fr)
ALTENNATOR
AELT
MOUI{TINGNUT
8 x 1.25 mm
22 N.m (2.2 kg-m, 16lFft)
(cont'd)
6-29
TimingBeltand TimingBalancerBelt
(cont'd)
Replacement
Removethe cylinderheadcover. I 1. Removethe pulleybolt and the crankshaftpulley Re-
move the two rearboltsfrom the centerbeamto allow
Removethe sideenginemount bracketB {standardfor the engineto drop down and give clearanceto remove
some typesl. the lower cover.
Removeth€ uppercover. 12. Removethe rubbsr seal aound the adiustingnut. Do

not loos€n the adiusting nut.
Removethe side enginemount.
13. Removethe lower cover'
'10.Removethe dipstick and the pipe.
6 r 'l,Omm
12 N m ('t.2 kg-m,
9 rb-ft) 12 r, 1,25''un
55 N.m (5.5kgfl, 40 lb-ft|
CYUNDERHEAD
DIPSTICK/PIPE
COVER e
e
RUBEER
SEALS
l2 x 1,25 mm R€placewh€n
65 N.m (6.5 kg-m, SIDE damag€dor
47 tb-ft) MOUNT deterioratsd.
UPP€R
COVER RUBBERSEALS
Replacewhen
6xl.Omft damagedor
1 2 N . m ( 1 . 2k g - m , deterior6ted.
I rb-ft)
SEAL
RUEBER
Replacewhsn damaged
or detorioratod.
AOJUSTINGNUT
1 0 x 1 . 2 5m m
45 N.m (4.5 kg-m,
33 lb-ft)
PULTfYEOLT
14 x 1.25mm TIMING BALAITCEFBELT
Inspection,Page6-27
220 N.m 122.0ksn, 159 lb-ftl
Apply 6n9ineoil to th€ boli ihraads, 6xt.Omm
but not to the sudace that n LLEY 12 N m (1.2kg-m,
contads the washer. Removs
anyoil. I lb-ft)
6-30
'1
e- 4. Lockthe timing belt adjusterarm in placeby installing 17. Loosenthe 6 x 1.0 mm lock bolt andthe adjustingnut.
one of the 6 x 1.0 mm lower cover mounting bolts, Pushon the timing belt adjusterpulleyto removeten-
sion from the belt, then tighten the adiustingnut.
15. Loosenthe timing belt adjusringnut. push on the pu!
ley to removetension trom the timing balancerbelt, 18. Removethe timing belt.
)o then tighten the adjustingnut.
19, Installthe timing belt in the reverseorderof removal.
16. Removethe timing balancerbelt. Adjust the valve clesrances(page6-34)
- Betoreinstallingthe riming b€lt, the crankshaftand
NOTE: It you are removingonly the timing balancer camshaft pulleysas shown on page 6-28.
belt, goto step 22. lf you areremovingboth belts,con,
tinue with this procedure. 2O. Perform the timing belt tension adjustment lpage
6-26).
TIMINGBELT 21 . Tightenthe 6 x 1.0 mm bolr to tockthe timing belt ad-

ADJUSTERARM
aDJUsnNGNUT Justerarm'
45 N.m14.5kg-m,33lb-tt)
DRIVEPULLEY
(cont'd)
6-31
Timing Belt and Timing BalancerBelt
Replacement(cont'dl
22. Make surethe crankshaftis positionedwith the No 1 27. Turn the crankshaft pullev about one turn counter-
piston at TDC. clockwise,then tighten the adjustingnuit to the speci-
{ied torque.
23. Alignthe grooveon the front balancerafter pulleywith
the pointeron the oil pump housingas shown, NOTE: Both belt adiusters are spring-loaded to
properlytensionthe behs.Do not spply any extm pres-
24. Align the rear balancershaft pulleyby using 6 x 1OO sure to the pulleysor tensionerswhile performingthe
mm bolt or equivalentas an alignmenttool. adiustment,
Scribea line 74 mm (2.9 in) from the end ol the bolt. REARBALANCERSHAFT
Inserttheboh intothe maintenanceholeto the scribed
line.
25. Loosenthe adjusting nut and verity that the timing

balancerbelt adjustermovesfreely.
Installthe timing balancerbelt. Removethe 6 x 1OO

mm bolt from the rear balancershaft.
74 mm 12.9in) MAII{TENANCE
HOLE
6 x 10O mm BOLT
WASHER
Replace.
6 x 100 1'|mBOLT
12 mm SEAU G BOLT
30 N.m(3.0 kq-tn,22 lb-ftl
NOTE:Tightenthe boltafter
installingthe belt.
AI'JUSTII{GNUT
Align the groove of the

front driven pulley with the
pointer on the oil pump housing.
TIMINGBALA'TCERBELT
DRIVEPULLEY
Set the crankshaftat TDC.
6-32
24. Removethe 6 x 1.Omm bolt from the timing belt ad- 32. Installthe upper cover.
Justerarm.
29. Removethe crankshaftpultey.
34. Coat the threads and seatingtace oJ the putley bolt
30. Installthe lower cover. with engine oil. Install and tighten to the specified
rorque.
3 1 .Installa rubberseal aroundthe adjustingnut. Do not
loosenthe nut. Specifiodtorqus: 220 N.m {22.Okg-m. 159 tb-ft}
UPPERCOVER
6r1.0mm
12 N.m(1.2kg-m,I lb-ftl
ADJUSTING I{UT SEAL

1 0 x 1 . 2 5 rn Replgcswhon damsged
45 N.m (4.5 kg-m, or dsterioratsd.
33 rb-ft)
PULLEYBOLT
1 4x 1 . 2 5m m
22O N.m {22.0 kg-m, 159 lb-ft)
Apply engineoilto the
bolt threads. 6x1.0mm
12 N.m {1.2 kg-m,9 lb'ft}
6-33
Valve Clearance
Adiustment
NOTE: Adjust valves on No. 1 cylinder.
. Valvesshouldbe adjustedcold when the cylinderhead
temoerature is lessthan loOoF {38oC). in}1333fll13.ffi!lll
Intake:0.26mm{o.o1o
. After adiusting,retorquethe crankshaftpulley bolt to
in)13.33ffi13ffi9ili
Exhaut:o.30mm{0.o12
22ON.m (22.0 kg-m, 159 lb-ft).
Loosenlocknut and turn adjustmentscrew untilJeeler
1. Removethe cvlinderheadcover. gaugeslidesbackandforth with slightamountofdrag.
INTAKE
N o . 4 N o . 3 N o , 2 N o .1
N o . 4 N o . 3 N o . 2 N o .1 LOCKlrlUTTxO.T5mm
20 N.m(2.0kg-m,14lb-ft)
Applyengineoil.
EXHAUST
GAUGE
FEELER
"UP" mark on the camshaft 5. Tightenlocknut8nd checkclearanceagain.Repeatad-

2. Set No. 1 piston at TDC.
pulleyshouldbe at top, and TDC grooveson the cam- justment if necessary.
shaft pulleyshould alignwith cylind€rh€ad surface.
Numbor1 riston at TDC:
@-€
\ Ut\-/
) l-24
6-34
6. Rotatecrankshaft180o counterclockwise(Camshaft 8. Rotatecrankshat180o counterclockwiseto bring
pulley turns 9Oo). The "UP" mark should be at ex- No. 2 pistonto TDC. The "UP" mark shoutdbe at
haust side, Adjust valveson No. 3 cylinder. intske side. Adjust valves on No. 2 cylinder.
Number 3 Piston at TDC: Number 2 Pbton at TDC:
,,UP" MARK
7, Rotatecrankshaft180o counterclockwiseto bring

No.4 piston to TDC. Both TDC g.ooves are once
again visible.Adjust valves on No. 4 cylinder.
Numbor 4 Piston at TDC:
6-35
CylinderHead/ValveTrain
(H23A1engane)
SpecialTools .........6-38 Valve Guldes
lllustratodlndex ...........................
6-39 ValveMovement....................... 6-52
Valve Seals Replacernent .......6-53
Replacement (Cylinder head Reaming .............6-54
removalnot requiredl .............6-41 RockerArms/Camehafteand
Cylinder Head Camrhaft Soals/Pulleys
Romoval .............6-43 lnstallation .........6-57
Warpage ............6-52 Tlmlng Belt and Timing BalancerBelt
Installation .........6-56 lllustratodIndex ........................
6-59
Camshaft Pulleys Replacement .......6-63
Removal .............6-48 Timing Belt
Camshafts Inspoctlon ..........6-60
lnspection ..........6-48 TensionAdjustment ...................
6-60
Valves, Valve Springs and Valve Seala PositionlngCrankshaftBefore
Removal .............6-50 Installing
TlmingBelt .............. 6-62
Valve Spring and Valve Seal Timing BalancerBeh
InstallationSequence..............6-55 Inspoction ..........6-61
Valv€ Installation.......................
6-55 Valve Clearance
Valve Seats Adjustment .........6-68
Recondltioning ..... 6-51
SpecialTools
Ret.l{o. \ Too\ l{urnbor O6r,cdgl0tr\ qq \ Prq. Rd.r.nca
o 07GAD-PH70100 Valve Guide S€al lnstall6] 1

I
6-55
6-50
@ o7757-PJ1010A Valve Spring Compressor Attachment
@ 07942-6570100 Valve Guide Driver,6.6 mm 1 6-53,54
@ O 7 9 8 4 - 6 5 7 O 1 OoCr Valve Guide Reamer,6.6 mm 1 6-54
07984-657010D
t
o
--fl'------------
6-38
lllustratedIndex
CAUTION: To avoid darnaglngtho cylinder head, wait until tho engino coolant tomporature drop6 b€low 100oF (38ocl
betoro romoving it.
NOTE: Use new O-ringsand gasketswhen reassembling.
6 r 1 0m m
6 r 1 . 0m m 10 N'm {1.0 kg-m,7 lb-ftl
10 N..n l1.O kg-m.7 lb-ft}
o
e
WASHER
RUBBEB
SEAIS 8 x 1.25mrn
Replace wlrsn 22 .m (2.2 lg-m, lE lb-ttl
or doteriorat€d.
6rlOmm
12 N.m (1.2 kg-m,9 lb-ttl
frI n-'-''
E
6x10mm
lO N.m (1.2 kg-m,7 lb-ft}
flEufl-
DOWEL PIII
ffiHnfl
,&V,
ui /tt{TAKE CAMSHAFT
HOLDER
8 x 1 . 2 5m m
18N.ft11.a 13 lb-frl
W# L!, e
8-
iih
qub
|l{TAKE CAMSHAFT
roction,pag66-48
SEALS
Instsllation,psge 6-57
Roplacs.
o
HEX CAMSHAFT PULLEYS
Removal, pag6 6-48
Installation, page 6-57
DISTRIBUTOR
EXHAUST
CAMSHAFT
ROCKERARM
ADJUSTING SCREW
Adjustment, page 6-68
LOCKT{UT
27 N.n 12.7 kg-m, 20 lb-ft) 8 x 1.25mm
38 N.m (3.4 ks-m. 27 lb-ftl
tor ntanual
p.r-lllgnriant ot
caftah6tt {cont'd)
6-39
lllustratedIndex
(cont'd)
CAUTION: In handllng a motal gasket. tako car6 not to lold it or damage tho contact surtaco of tho gssk€t.
NOTE: Cleanthe oil control orifice beJoreinstalling.

'11
I clean all the pans in solvent, dry them and apply lubricantto any contact parts,
Priorto reassembling,
HEADBOLT
INTAKE VALVE GUIDE 12 x 1.26 mrn
Insp€ction, page 6-52 lOO N.m (10.0 ks-m, 72 lb-ft)
Replacement,page 6-53 Apply cleanongineoil to
Rsaming,pag€ 6-54 threadsand underthg
VALVE bolt heads.
SPRINGRET
nfl
EXHAUSTVALVE
EXHAUSTVALVESEAL VALVEKEEPERS
Rsplaca.
VALVESPRINGSEAT SPEINGRETAINER
A(E VAIV€ SPNI G
EXHAUSTVALVE I]{TAXEVALVE SEAL
Replacam€nt,
psg€s 6-41 and 50
ALVESPRI G SEAT
EIID PIVOTEOLTS
64 N'm 16.4kg-m,46 lb-ftl
CYLINDERHEAD
R€moval. page 6-43
Reconditioningvalve
BACK COVER seat, pago 6-51
Warpage, page 6-52
ENGII{EMOUNT Installation, pag€ 6-56
BRACKET B
1 0 r 1 . 2 5m m CYLINDERHEAD GASKET
45 N.m (4.5 kg-m, IMETAL GASKET}
33 rb-ft) Roplace.
8 x 1 . 2 5m m
22 N.m
{2.2 kg-m, 16 lb-ftl OOWEL PIN
INTAKEVALVE
Replacemont, OIL CONTROL
Dimonsions, pag€ 6-50 ORIFICE
Reconditioningvslve Clean.
s€at, pag€ 6-5'l
Adiustment. paga 6-68 O-RING
TIMING BELT Feplace.
Inspection/Adiristment,page
R6placoment.page 6-63
ADJUSTIT{G
10 x '1.25mm
45 N.m (4.5 kg-m,
33 tb-ft)
Loosen,but do not remove.
6-40
Valve Seals
Replacement{Cylinderhead removalnot requiredl
NOTE: Cylinder head removal is not required in this Intako Valva Sorb:
proc€dure. 8. Selectthe 1-1l18 in. diameterlongcompressorat-
tachment and fasten the attachment to the hole of
Usethe procedureshown below applieswhen usingthe the lever arm with the speed pin supplied.
in-car valve spring compressor(Snap-onYA8845).
9 . Insert an air sdaptor into the spark plug hole. Pump
l@ Alway waar approved oye protcction air into the cylinder to keep the valve closed while
when using tho in-car valvo spring comp€as{rr. compressing springs and removing the valve
keeoers.
1. Turn the crankshaftso that the No. 1 and the No.
4 Distonsare at TDC. 1 0 . Positionthe lever arm under the cross shalt so the
lever is perpendicularto the shaft and the compres-
2. Removethe cvlinderhead cover. sor attachment rests on top of the retainer for the
spring boing comp.essed, Use the tront position
3. Loosen and remove timing belt from the camshaft slot on the lever as shown.
pulleys.
NOTE: Put shop towels over the oil passagesto
4. Remove the distributor. prevent ths valve keepers from lalling into the
cvlinderhead.
5. Removethe camshsft holder bolts, then removethe
camshaft holders, the camshafts, and the rocker
arms. OIL PASSAGES
Usingthe 6 mm boltssuppliedwith the tool, mount

the two uprights to the cylinder as shown.
Insert the cross shaft through the bottom holes ol

the two uprights.
OIL PASSAGES
(cont'd)
6-41
Valve Seals
Replacement(Cylinderhead removalnot required)(cont'dl
1 1. Usinga downward motion on the leverarm, com- 1 8 . Using a downward motion on the lever arm, com-
pressthe valve spling and removethe keepersfiom pressthe valve spring and removethe keepersfrom
ths valve stem. Slowly releasepressureon the the valve stem. Slowly release pressurs on the
spnng. spflng.
12. Repeatstep 1 1 for the other intakevalve in that 1 9 . Repeatstep 18 tor the othor exhaust valve in that
cvlinder. cylinder.
13. Removethe valve seals (page 6-50). 20. Removethe valve s€als (page 6-50).
14. Replacethe valve seals (page6-55). 2 1 . Replacethe valve ssals (page 6-55).
15. Installthe springs,the retainers8nd the keepers 2 2 . Install the springs, the retainers and the keepers
in reverse order of removal. in reverse order of removal.
Exhaust Valvo Soals: 23. Rep€at st€ps 8 to 22 for the other cylinders.
16. S€lectthe 7/8 in. diametercompressorattachm€nt
8nd tasten the attachment to the No. 5 hole of the
lever arm with the speed pin.
17. Positionthe lever arm under the cross shaft so it

is perpendiculsrto the shaft and the compressor
attachment rests on top of the retainer for the
spring being comprcssed. Use the front position
slot on the lever as shown.
ll NOTE: Put shop towels over the oil passagesto

prevent the valve keepers from Jalling into the
cvlinderhead.
6-42
CylinderHead
Removal
Enginer8movalis not requiredJor this procedure. l. Disconnect the negative terminal trom the battery.
2 . Drainthe enginecoolant (seesection 1O).

a Mako sure iscks and safoty stands ars placad a Removethe radiatorcap to speed draining.
propedy and hoist bfacksG era attachod to cor-
ract positions on ths oingino. 3 . Relievethe fuel pressure,
a Mako suro tho car will not roll oft stands and fall
while you ar6 working und€r it. @ Do not smoko whilo workino on fuel
aystem, koop open flamo or spark arlay from work
CAUTION: area, Draln fuol only into an approved containar.
a Uso fendor covors to avoid damaging paintod
surtaces. 4. Removethe intske air duct.
a Unspocifiod items ara common.
a Unplug tlF widng connectoB caroft.fy while hol+ E Removethe fuel teed hose and evaporativeemission
ing th6 connocto? ponion to avoid damags, (EVAP) control canister hose from the intake
a Ma.k 8t wHng and hoss3 to rvdd rrisconncctlon. manifold.
Also, bo sur6 that thsy do not contact othor wir-
ing oi hosos o. intorfats with other parts.
a To avoid damaging the cylindar herd, w8it untll
tho engine coolant t€mporaturo &opr bclow
100oF (38ocl befoio loosanlng the rotllnlng
bohs.
NOTE:
a Inspect the timing belt befo.e removing the
cvlinder head.
a Turn the crankshaftpulleyso that tho No. 1 piston
is at top dead csnter (page 6-62).
a Mark 8ll emission hoses belore disconnecting
them.
a The radio may have a coded theft protection cir-
cuit. Be sure to get the customer's code number 6. Removethe throttle control cabletrom the throttle
before. body (A/T onlyl.
- Removingthe No. 43 (lOAl fuse. NOTE:
(ln the under-hood fuse/relav boxl a Take care not to bendthe cable when removing
- Removingthe radio. it. Always replaceany kinkedcablewith a new
After service. reconnect Dowe. to th€ radio and one.
turn it on. Whenthe word "COOE" is displayed, a Adiust the throttle cable when installing(seesec-
enter the customer's 5-digit code to restore ra- t i o n 11 1 .
dio ooeration.
6 x l.O mm
12 .ft 11.2kg-m, 9lb-ftl
THROTTLECAALE
THROTTLECONTROL
CABLE
LOCKNUT
(cont'd)
6-43
CylinderHead
Removal(cont'd)
7. Removethe tuel feed hose,the tuel returnhoseand 9. R€moveth€ engine ground cable Jtom th€ cylinder
the brake boostervacuum hose. head cover.
FUELFEEDHOSE 10, Disconnect the alternator terminal and connector,

then remove the engine wire harness from tho
cvlindsr head cover.
WASHER EI{GINEWIRE
Replace. HARNESS
6r 6x l.Orr|m
8 t{.m (0.8 kg-m, 6 lb-ftl 10 'm (1.0 kg-m,7 lb-ftl
11. Removothe powsr steeringlP/S)pump belt and

pump.
a Do not disconnectthe P/S hosos.
Removethe lollowingenginewire hsrnessconnec-
tors and clamps ftom the cylind€r head and the in- 8 x 1.25mm
take manifold: 22 .|n (2.2 kg-m,
16 tb-ft1
o Four fuel injectorconnectors
a lntake air temDerature(lAT) sensorconnector
a ldle air control (lACl valve connector
a Throttle position (TP) sensor connector
a Exhaust g8s recirculstion (EGR)valve lift sensor
connecror
a Groundcableterminals
a Enginecoolanttemperature(ECT)switch B con-
necror
o Heatedoxygen sensor (HO2S)connectot
a ECT sensor connector
a ECT gauge sendingunit connector
a lgnition control module llCMl connector
a CKP/ToC/CYPsensorconnector
a VehiclesDeedsensor (VSS)connector
15 N.m ll.5 *g-m,
a lgnition coil connector I I lb-ftl
a Intake air bypass solenoid valve connsctor
a ECT switch A connector
a Knock sensorconnector
6-44
12. Removethe ignitioncoil. 16. Remove the intake manifold bracket and intake
manitold.
IGNITIONCOIL
*8 x 1.25lnm *6x LOmm

22 N.m 12.2 ke-m, CO ECTOR 12 rr| {1.2 kgn,
16 tb-trl 9 tb-ft1
13. Remove the emission vacuum hoses and water

bypass hoses from the intake manifold asemblv.
14. Removethe radiatorupper hose and heater hose 17. Removethe selt-lockingnuts and disconnectthe ex_
from the cvlinderhead. haust manitold8nd exhaustpipe A.
1 5. Removethe water bypass hose and the thermostst 18. Removethe heat insulator(carsequippedwith A/Cl,
housing. exhaustmanifoldbracketand exhau$ manifold.
6 x 1.0mm
12 tt.m 11.2 kg_m,9 tb-ft|
HEAT INSULATOR
{carsoquippedwith A/C)
*: CORNOSIONRESISTANTBOLT EXHAUST PIPEA
(cont'd)
6-45
CylinderHead
Removal{cont'd)
1 9 . Remove the PCV hose, then remove the cylinder 24. Remove the camshatt Pullsys.
head cover.
NOTE: To set the camshafts at TDC for No. 1
20. Removethe middlecover. cylinder,alignthe holesin the camshaftswith thg
holesin the No. 1 camshaftholdersand insert 5.O
2 1 . Loosenthe adjustingnut 180". mm oin punches.
Pushthe tensionerto releasetension from the tim-

ing belt, then retightenthe adjustingnut.
8 r 1.25mm
38 .m 13.8kg{r,
27 tb-ft)
25. Loosen the rocker arm adiusting screws, then re-
move the camshaft holders and camshafts.
23, Removethe timing belttrom the camshaJtpulleys.

ADJUSTING SCREWS
CAUTION: Do not crimp or bond
tho timing belt more than 90 o ol lsss
than 25 mm ( l inl in diametor.
G4z
No Good
ADJUSTING SCREWS
6-46
Removethe side engine mount bracket B and back NOTE: Separatethe cvlinderheadfrom the block with
covea. a flat tip screwdriveras shown.
ENGII{EMOUI{T
SRACKET B 10 r 1.25mm
45 N.m (4,5 kg-m,
33 rb-ft}
8 x 1 . 2 5m m
22 N.m 12.2kg-m,
BRACKET 16 tb-ftl
27. Removethe cylinderhead bolts, then removethe

cylinderhead.
CAUTION: To prevont vvalpaga,unscrlw tho bohr

in sequenc€ 1/3 turn at a timo; rapaat until all bohr
arg loosaned,
CYLINOERHEAD BOLT LOOSEI{INGSEOUEI{CE
6-47
Gamshaft Pulleys Camshafts
Removal Inspection
"UP"
1. To easereassembly,turn the pulleyuntil the NOTE: Do not totate camshaft during inspection'
marks face up, and the front timing marks are aligned
with the marks on the Dullevs. 1. Removethe rocker arms.
NOTE: Rockerarms musi be installedin the same

oosition if reused.
"UP" m6rks 2. Put the camshaftsand the camshaftholderson the

cylinder head, then tighten the bolts to the specified
toroue.
Specifled torque:
Exc8pt Intake @, @. Exhaust @, @:
l0 N'm (1'0 kg'm, 7 lb'ft|
Intake @, @. Exhaust @' @:
12 N'm (1.2 kg-m, 9 lb-ft1
SEOUECE
TIGHTEI{II{G
Align the marks on the pulleys.
Removethe timing belt,
Removethepulleybolts,then removethe camshaft

pulleys.
NOTE: To set the camshafts at TDC for No. 1

cylinder,alignthe holesin the camshsftswith the @ @ @
holes in the No. 1 camshaftholdersand insert 5 0
mm pin punches.
t ,
PULLEYBOLTS
6-48
I
? Seatcamshaftsby pushingthem toward distributor 7. lf camshaft-to-holderoilclearancsis out oftolerance:
end of cylinderhead.
a And th6 camshaft has alreadybeen replaced,you
4. Zero dial indicatoragainstend of camshsft, then must r6placgthe cylinderhead.
push camshaft back and forth, and readthe end play. r lf camshaft has not been replaced,first check to-
tal runout with th6 camshaft supported on V-
Camshaft End Play: blocks.
Standard(New): 0.O5-O.15 mm
(0.0O2-O.006 in) Crmrheft Total Runout:
Sorvice Limit: 0.5 mm {0.02 in} Standard (Nowl: 0.03 mm (O.0Ol Inl max.
Sorvlce Llmh: 0.06 mm (0.002 Inl
Rotate camshaft
while msssuring
5. Removethe camshaft holder bolts from the cylinder

head.
a LiJt camshaft out of cylinder head, wipe clean,

then inpsect lift ramps,/Replac€camshaft if lobes - lf the total runout of the camshsft is within toler-
are pitted, scored, ot excessively worn,
ance, replace the cylinder head.
a Clean the camshaft beadng surfaces in the
cylinderhead.then set csmshaft back in place. - lf the total runout is out ot tolerance, replacethe
a Insert plastigagestrip acrosseach journsl.
camshaft and recheck. lf the oil clearanceis still
a Install the camshaJt holders and torque bolts to
out of tolerance,replacethe cylinderhead.
the valuesand in the sequenceshown on page
6-48.
8. Measurecamshaft lobe height.
6. Measure widest portion ot plastigage on each
journal.
Intak. Standlrd: 33.661 mm (1.3252 inl
Exhlurt Stlnda.d: 33.725 mm (1.3278 Inl
Camshsfi-to-Holdor Oil Cloaiance:
Standard(Now): O.O5O-0.089 mm
(0.0020-O.OO35 inl
SorvicaLimit: O.15 mm (0.0O6inl
Exhaust No. 5 Jounal:

Standard(Newl: O.lOO-0.139 mm
{0.0039-0.OO55 inl
Servics Limit: 0.20 mm (O.OOBinl
Inspect this are for wear.
6-49
Valves,Valve Springsand Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are re- 4. Removeth€ valve se8l.
mov6d so that €ach item can be reinstalledin its original
position.
1. Tap €ach valve stem with a plastic mallet to loosen

valve keepers before installing the spring com-
Dressor.
2. Installthespling compressor.Compressspringand
remove valve keeper.
VALVESPFINGCOMPRESSOR
COMMERCALLY AVAILABLE
VALVESPRING
COMPRESSOR
ATTACHMENT
07757-PJIOIOA
3. Installthe sDecialtools as shown,

lntake Valvo Dlncndons
A Standard (Nowl: 33.90-34.10 mm
(1.335- 1.343inl
B Standard l]{.wl: 102.6O-1O2.8O mm
VALVE GUIDESEALRETVIOVER (4.035-4.047 lnl
LISLEP/N57900 or KD335o C Standard {rw}: 6.58O-6.590 mm
COMMERCIALLY AVAILABLE 10.2691-O.2594inl
C Sorvic. Llmh: 6.55 mm 10.258Inl
D StandErd ( !rv): O . 8 5 -1 . 1 5m m
(O.O33-o.o45Inl
D Servic€ Llmh: 0.65 mm (O.O26inl
Exhoust Valvo Dlmcnalonr

A Standsrd(Newl: 28.9o-29.10 mm
( 1. 1 3 8 - 1 . 1 6 1I n l
B stand.rd lt{cw}: 1 0 1 . 4 0 -1 O 1 . 7 0m m
(3.992-4.oO4inl
C StandErd lt{ewl: 6.550-6.560 mm
Inl
10.2579*O.2583
C Servico Lknh: 6.52 mm 10.257inl
D Standard (Nrw): 1 . 0 5 - ' 1 . 3 5m m
(O.O41-0.O53 In)
D Sorvico Lirit: o.85 rnm (O.O33inl
6-50
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a After resurfacing the seat, inspect Jor even valv€
valve seat cutter. seating: Apply PrussianBlue compound to the valve
face, and insen valv€ in originallocation in the he8d,
NOTE: lf guidesare worn (page6-52), replacethem then lift it and snapit closedagainstthe seatsever-
(page6-531betorecutting the valve seats. al times.
ACTUAL
SEAN G
SURFACE
VALVE
SEAT
o PRUSSIANBLUE COMPOUI{D
K@"8 The actualvslve seatingsudace, as shown by the

blue compound,should bo centeredon the seat.
a lf it is too high (closer to the valv6 stem), you
must make a second cut with the 600 cuttef to
move it down, then onB more cut with the 45o
cutter to rgstore saat width.
a ]f it is too low (closeto th6 valve edge), you must
make a second cut with the 30o cutter to move
it up, then one more cut with the 45o cutter to
restore seat width.
Carefully cut a 45o se8t. removing only enough
materialto ensurea smooth and concentricseat. NOTE: The tinal cut shoutdalways be made wirh
the 45o cutter.
Bevelthe upper edge of the seat whh the 3Oo cutter
and the lowsr edg€ of the seat with the 600 cutter, Insen intake and exhaust valves in the head and
Check width of sest and adjustaccordingly. measurovalve stem installedheight.
Make one more very ligt|t pass whh tha 45o cutte, to Intake Valve St.m Inliall.d Hright:
removeany possibleburrscaussdby the other cufters. Standard (l{cwl: 39.365-39.835 mm
(1.5498- 1.5683 inl
VCv. Sct Wld$ (ht!k lnd.xhaltl: Scrvlce Limlt: 4O.Oa5 (1.5781 tnl
Standlrd: 1.25- 1.55 mm Exhau* Valve Stom lnstallcd Hdght:
(O.O49-O.061int Standard(Now): 39.165-39.635 mm
Sendcellmh: 2.0O mm (0.079 in) 1 1 . 5 4 1 9 -1 . 5 6 0 4i n l
S.rvlce Limit: 39.885 mm ('1.5703inl
)
VALVESTEM
INSTALLEDHEIGHT
8. It valve stem installedheight is over the servicelimit,

replacevalve and recheck.lf still ovef the service
limit, replacecylinderhead;the valve seat in the head
is too deeo.
6-51
CylinderHead Valve Guides
NOTE: lf camshaft-to-holderoil clearances(page 649) Measurethe guide-to-stemclearancewith € dial indicstor

are not within specitication,the cylinder head cannot be while rocking the stem in the direction of normsl thrust
resurfaced. (wobblemethod).
lf camshaft-to-holderoil clearancesare within specifica- lntsko Vdvo St.m-to{iukla Clearance:

tions, check the cylinderheadlor warpage Standard(New): 0.04-0' 10 mm
{0'002-0.0O4 in)
. lf warpageis lessthan0'05 mm (0.0O2in)cylinderhead Sewlca Umh: O.16 mm (0.006 in)
resurfacingis not requar€d
. lf wsrpage is b€tw6€n O.05 mm {0.0O2 in) 8nd 0.2 Exha6t Valve Stom-to4ulde Clearanca:
mm (0.008 in), rosurfacecylinderhead. Standrd lNow): O.10-0.16 mm
. Maximumresurfacelimit is 0.2 mm (0.OO8in) basedon (O'0O4-O.006 in)
a heightof 132.o mm (5.20 in) Sowic. Limh: 0 22 mm (0.OO9in)
1O mm out trom s€at.
.. .o
a lf measuremantexce€dsthe servicelimit, r8check

using a new valvs.
a lf measurement is now within the servic€ limit.
M€ssuro along gdggg. and 3 ways across center' reassembleusing a ngw valv€.
a lf measurementstill excaads limit, recheck using
alternate m€thod b€low, then replace vslve snd
guide, if necessary,
NOTE: An altsrnate m€thod of ch€cking guide to

stem clearanceis to subtract the O.D. of ths valve
stem, measurgdwith a micrometer. from the l.D. ot
the valve guide, measured with an inside microme-
ter o. ball gauge.
Take the measurements in three places along the
valve stem and three placesinsidethe valve guide.
The difference betwesn the largest guide measure-
ment and the smalleststem measurementshouldnot
exceedthe servicelimit.
Cyllrdor H6ad H€ight: Intake Valvo Stom-tecuida Closrsnca:

Stardard(Nowl: 131.95- 132.05mm Stardtd lt{rw}: 0.02-0.05 mm
15.1955
- . 1 9 9i n l (O.OOl-O.OO2 in)
Servba Limit: O.08 mm (O.0O3in)
Erhaust Valw Stom-to4uidc Cbarancs:

Stsrdrd (ltlew): O.05-O.O8 mm
(O.OO2-0.OO3 inl
ServlccLimit: O.11 mm (O.0O4in)
6-52
Replacement
1. As illustratedin the removalsteps of this procedure, 4. Workingfrom the camshaftside, usethe driverand an
use a commercially-available air-impact driver at- air hammer to drive the guide about 2 mm (0.1 in)
tachment moditied to fit the diameter ot the valve towards the combustionchamber.This will knock off
guides. In most cases, the same procedurecan be some oJthe carbonand make removaleasier,
done using Valve Guide Drivers and a conventional
hammer. Tool numbers are at the end of this CATUION:
Drocedure. a Always wear sal€ty goggles 01 a taco shield when
using th€ aL hamm6..
. Hold the ak hammer directly in lin€ with tho valve
VALVECUIDEDRIVER
Y AVAILAELE $.rido to pr8vont damaging the driver.
6,4 mm
{O.25ln} 5, Turn the headover and drivethe guideout toward the
l_l camshaftside of head.
87 mm +tr+- 57mln lr_r

l3.rt:l In) I l2-24h,tl 1 1 . 3m m
O.44In)
R€moval
andinstallation
VALVEGUIDEDRIVER. 6.6 mm
07942-6570100
Selectthe properreplacementguidesand chillthem in

the freezersectionof a refrigeratorfor about an hour.
Usea hotplate oroven to evenlyheatthecylinderhead

to 3OOoF{150oC). Monitor the temperarure\îith a
cooking thermometer.
VALVEGUIDEDRIVER
COMMEBCIALLY
AVAILABLE
lo -\
R@ig
CAUTION: lf a valve guide still won't move, drill it out with a
a Do not uss a lorch; h may wan rh€ h€ad. I mm (5/16 inch) bit, then try again.
. Do not got ths head hotr6r than 3O0oF (1soocl;
oxcasaivo hsat may loosen tho valve seats. CAUTION: Drill guides only in extremo casos; you
a To avoid burns. uso hoavy glovas when handling could damage tho cylinder head it th€ gukte breaks.
ths heatod cylinde. hoad.
6. Removethe new guide(slfrom the refrigerator,one at
a time, as you needthem.
{cont'd)
6-53
Valve Guides
Replacement
{cont'd} Reaming
7. SliDa 6.5 mm (0.26 in) steel washer and the correct NOTE: For new valve guidesonly.
driver attachment over the end of the driver (The
washerwill absorbsome of the impact and extendthe 1. Coat both reamerand valve guide with cuning oil.
life of the driver).
2. Rotatethe reamerclockwisethe fulllengthofthe valve
guide bore.
T:-r-w
3. Continueto rotatethe teamerclockwisewhile remov-
ing it trom the bore.
4. Thoroughlywash the guide in detergentand water to

DRIVER 6.5 rm 10.26hl ATTACHMET removeany cutting residue.
WAHSER
5. check clearance with a valve (page 6-52)
o Verify that the valve slides in the intake and ex-

Insta,,thenew guidels)trom the camshaftside ot the
haust valv€ gurUeswithoui exerting pressufe.
head:drive each one in until the attachmentbottoms
on the head.lf you have allsixteen guidesto do, you
mav have to rcheat the head one ot two more times
REAMER
HA'{DLE
VALVEGUIDEDRIVER,
6.6 mm
07942-65701fi,
07984-65701OC ol
07984-657010D
Vdvo Guide InstatredHoight:
Standard(Newl:
l m a k e : 1 3 . 2 5 - 1 3 . 7 5m m
(O.522-O.541 in)
Erhaust: 13.75- 14.25 mm
(O.541-O.561 in)
VALVEGUIDE
6-54
Valves,ValveSpringsand ValveSeals
ValveSpdngand ValveSealInstallationSequence
NOTE: Exhaustand intake valve sealsare NOT interchangeable.
@A.--.--.-uo..uEKEEPERS
NOTE: Placethe end ol valve
spring with closely wound coils
toward the cylinderhead.
IIITAKEVALVESEAL VALVERETAINER
WHITESPRIIIGI
Beplace.
VALVESPNNO
VALVEGUIDESEAL
IITSTALLER
oTGAO-PH701(x)
EXHAUSTVALVESEAL
(BTACKSPRING}
Replac€.
SPRINGSEAT
NOTE:Installthe valve springseats before
installinothe valve seals.
ValveInstallation
When installingvalves in cylinderhead. coat valve stems
with oil before insening into valve guides,and make sure
valvesmove up and down smoothly.
When valvesand springsare in place,lightlytap the end of

each valvestem two or three times with a plasticmalletto
ensureproperseatingof valve and valve keeprs.
NOTE; T8p the valvestem only alongits axisso you do not

bendthe stem.
6-55
CylinderHead
lnstallation
in three
2. Tightenthe cylinderheadboltssequentially
Installthe cylinderheadin the reverseorderol removal:
steps.
NOTE:
a Always use a new head gasket lst stoptorque: 40 N m (4.0 kg-m,29 lb-ft)
a Cylinderhead and engineblock surfacemust be clean 2ndsteptorque:70 N'm (7.0kg-m,51 lb-ft)
a "UP" marks on camshaft pulleysshouldbe at the top. 3rd stoptorquo: 10ON m {10.0kg-m,72 lb-ft)
. Turn the crankshaftso the No. 1 piston is at TDC (page
6-62). NOTE:
a We recommend usinga beam-typetorquewrench'
a Cleanthe oil control orifice beforeinstalling
When usinga preset-type
torquewrench, be sure
to tightenslowlyandnot to overtighten'
1. Cylinderhead dowel pins and oil control orifice must . It a boltmakesanynoisewhileyou aretorquingit,
be aliqned. loosenthe bohandretightenit tromthe Ist step'
BOLTS
HEAD
CYLINOER SEOUENCE
TONOUE
DOWEL
\ CYLINOER
\ HEADGASKET
Replace.
\
0
OIL CONTROL
ORIFICE
Clean.
O-RING
Replace.
CYLII{OER HEADBOLTS
1 2 x 1 . 2 5m m
1OON.mllO.Okg-m.72lb-ft)
Applycleanengineoil bolt
threadsandunderboltheads
6-56
RockerArms/Camshafts
and Seals/Pulleys
Installation
lnslallthe intakemanifoldand tighten the nuts in a
criss-crosspaltern in 2 or 3 steps. beginningwith . Mak6 sura drat the keyways on th€ camdrafts a]€ fac-
the Inner nuts. krg up. (No. 1 r* on TDCI.
a Valv€ locknuts should b€ loosonedand boforo scrsws
GASKET backed off botoio installation.
a Replac€the rocker arms in thsir origlnal positions,
1. Placethe rockerarmson the pivotboltsandthe valve

srems.
2. Installthe camshaftsand the camshalt sealswith

the open side (spring)facing in.
8 r 1 . 2 5m m
22 N.m(2.2kg-m,
16 tb-ft)
22 N.m(2.2kg-m,
16 tb_ft}
ROCKERARM
4. Installthe exhaustmanifoldand bracket.Tightenthe
3. Apply liquidgasketto the head mating surtacesof
nuts in a criss-crosspatternin 2 or 3 steps, begin-
the No.1 and No. 6 camshaft holders,then install
ning with the inner nuts.
them, along with No. 2, 3. 4 and 5.
GASKET NOTE:
I x 1.25mm Replace. a "1" or "E' marks are stampedon the camshaft
32 N.m{3.2kg-m,
23 rb-ft) holders.
a Do not apply oil to the holdermating surfaceof
camshaftseals.
a Apply liquid gasketto the shadedareas.
a The a.rows marked on the camshaft holders
should point toward the timing bett.
No.2
l"'ln_m*ll
1
1 0 x 1 . 2 5m m
^/'""1"'"1*"
trBfr m ffi ,
/No.
I x 1 . 2 5m m
22 N.m (2.2 kg-m,
45 N.m (4.5 kg-m,
33 rb ft)
6 x 1 . 0m m
K g H H F HWi TNTAKE
M H
16 rb-ft) 1 ON . m ( 1 . Ok g m ,
ffi4.n**"
GASKET 7 tb-tr) 6r 16r
Replace. Ili H H &{
pI
M
tru
HEAT INSULATOR liT
1 0 x 1 . 2 5m m
LOJ tl
55 N.m 15.5kg,m,40 lb,ft)
Replace.
{cont'd)
6-57
RockerArms/Camshaftsand Seals/Pulleys
Torque:Exhaust
SDecifi6d
4. Tightenthe camshaftholderstemporarily'
ExceotG), (O: 10 N m {1.0kg-m,7lb-ft)
a Make sure that the rocker arms are properlyposl- 1 2 N . m{ 1 . 2k s - m 9
, lb-ft)
tioned on the valve stems' @, @i
\ lnstallthe back cover.
5. Pressin the camshaftsealssecurely. 8 . Installkeys into camshaftgrooves.
NOTE: To set the camshaftsat TDC positionfor No'

1 piston, align the holes in the cdnshafts with the
holesin llo. 1 camshaftholdersand insert 5'O mm pin
punchesin the holes.
Tighteneach bolt in two stepsto ensurethat the rock-

ers do not bind on the valves.
Specified Torque: lntake

qceq@,O, 1ON.m (1.Okg'm, 7 lb-ft)
(9,(r, 12 N.m (1.2 kg-m,I lb-ft)
INTAKE
I x 1 . 2 5m m
9. Push camshaft pulleys onto camshafts,then tighten

the retainingbolts to the torque specified'
1 0 . Adjust the valve cle316nes(page6-68).
1 1 .After installation,check that the all tubes, hosesand

connectorsare installedcorrectly.
6-58
lllustratedIndex
NOTE:
. Referto page 6-62 for posilioningcrankshaftand pulley beJoreinstallingtiming belt.
a BeJoreremoving,mark directiono{ rotationon each belt.
POWERSTEERING IP/SI ALTERNATOR

PUMPBELT BELT LOWERCOVEB
Adiustment,section17 Adjustment,
section23 ADJUSTTNG
NUT COVER Removethe tive bolts.
45 N.m {4.5 kg-m,
33 rb-ft)
6x1.0mm
12Nm(1.2kg-m, RUEBERSEALS
9 ReDlace
when
damagedor deto.iorated.
CAPt{UT
6 r 1 . 0] n m
'lON.m
l1.Okg-m,7 lb-ftl
CYLINDERHEAD
6x1.0mm
1 2 N . m ( 1 . 2k g - m ,
CRANKSHAFI I lb'ft)
PULLEY8OL R'LLEY WASHEB------+o
14 x 1.25 mm Removgany oil.
RUEBER SEALS
220 N.m (22.0 kg-m, 159 tb-ft) Roplacewhen damaged
Apply engineoil to th6 bolt
or detoriorated.
thrcads, but not to the
surfacethat contacts the 8 r 1.25 mm
washer. 38 N.m(3.8ks-m,27lb-ft)
KEYS
TEI{SIO'{ER
SPAII{G
BELT CAMSI{AFT PULLEYS

TE SIOI{ER tENStOa{ERS
SPRII{G
I(EY
TIMINGBELT
ADJUSTING BOLT
68 N.m(6.8kg-m,49lb'ft)
Remove BELT
any ofl. Inspection,pag6 6-60
6 x 1,0 rhm Adjustment,page 6-60
12 N.m (1.2 kg-m,I lb-ftl Beplacement,page 6-63
TIMING BALANCERBELT surlacelacing in.

Inspectjon, page 6-61. Bemoveany oil.
6-59
TimingBelt
Inspection TensionAdiustment
1. Disconnectthe alternatorterminaland the connector, CAUTION: AtwaF adiust timing boh tension with thew
then removetheenginewire harnessfrom the cylinder enginecold.
head cover.
NOTE:
2. Removethe cylinderheadcover. o The tensioneris springJoadedto applypropertensionto
the belt automaticallyafter making the following ad-
3. Removethe middlecover. justment.
. Alwavs rotate the crankshaft counterclockwise when
4. lnspect the timing belt for cracks and oil or coolant viewed trom the pulleyside. Rotatingit clockwisemay
soaking. result in improperadiustmentot the belt tension.
. Inspectthe timing balancerbelt beforeadjustingthe belt
NOTE: tension.
a Replacethe belt if oil or coolant soaked. a Do not loosenthe adjustingnut morethan one full turn'
. Removeany oil or solvent that gets on the belt.
1. Disconnectthe alternatorterminaland the connector,
Inspectthis
area{or wear.
then removetheenginewire harnesstrom the cylinder
head cover.
2. Removethe cylinderheadcover.
3. Set the No. 1 piston at TDC (page6-62).
4. Loosenthe adiustingnut 2/3-1 turn, then tighten it'
Rotatepulley
ano rnspect
belt.
After inspecting, retorque the crank*|aft pulley bolt to Rotatethe crankshaftcounteclockwise3-teethon the
22ON.m (22.Okg-m, 159 lb-ft). camshafqpr.rlley,then reloosenthe adjusting nut to
createtensionon the timing belt.
o. Tightenthe €diustingnut.
After adiusting,ratorquethe crankshaftpulleybolt to

22O N.m {22.Okg-tn, 159 lb-ft).
6-60
TimingBalancerBelt
Inspection
1, Disconnectthe alternatorterminaland the connector,
then removethe enginewire harnessfrom the cylinder
headcover.
2. Removethe cylinderheadcover.
3. Removethe middlecover.
5. Removethe lower cover.

soaking.
NOTE:
a Replacethe belt if oil or coolant soaked.
o Removeany oil or solventthat gets on the belt.
Rotatepullgy
andinspectbglt.
After insp€cting,retorquethecrankshaftpulleybolt to
22O N.m (22.Okg-m, 159 lb-ft).
NOTE: Refer to psge 6-66 for timing batancerbelt

tensionadiustm€nt.
6-61
Timing Belt
PositioningCrankshaftBeforeInstallingTimingBelt.
NOTE: TDCFOSITION:
CAMSHAFT
. Installthe timing belt with the No. 1 piston at TDC.
. After installing,retorquethe crankshaftpulley bolt to ,,UP''MARKS
22ON.m (22.Oks-m, 159 lb-ft).
CMN(SHAFTTDCFOSITION:
POINTERS
ON BLOCK
TDC MARKS
Align the marks
on the pullays.
FLYWHEEL DRIVEPLATE
PI Pt CHES,5.0nm
CAUTIOI{: Romovc thr pln Frnchos attor installlng

th. tlming boh.
NOTE: When turning the crankshaft with a socket

wrench, installthe crankshaJtpulleyand the pull€y
bolt.
6-62
TimingBeltandTimingBalancer
Belt
Replacement
CAUTION: lmpoct tho water pump whon roplacing the 3. Removethe mountingbolts,nutsandpoly-V-b€lt
from
timing b€h lpags 10-12). the powersteering(P/Slpump.
NOTE; Turn the crankshaftso that the No. I oiston is at NOTE:
TDC (page6-62). . Oonot disconnect the P/SpiDeandhose.
. Afterinstalling,
adiustthetensionot the P/Spump
1. Removethe sDlashshield, belt (seesection 171.
LOCKI{UT
' 1 5N . m( 1 . 5k g - m ,
P/S PUMP 11 tb-ft)
BOLTS/T{UTS
8 r 1.25rfn
SPLASHSrmU) 22 N.m 12.2kg-m,
16 rb-ftt
Disconnectthe connector, then remove the cruise 4. Disconnectthe alternatorterminaland the connector,
control actuator. then removethe enginewire hamessfrom the cylinder
headcover.
NOTE:
a Do not disconnectthe control cabte. Loosen the altemator mounting bolt, nd rnd the ad-
. Takecarenot to bendthe cablewhen removingthe
iusting boh, then removethe ahernatorbeh.
actuator.Always replacea kinkedcablewith a new
one. NOTE: After installing,adiustthe tensionof the alter-
CNU|sECONTROL nator beh {seesection 23).
ACTUATOR 6r1.0mm
1oNm(1.okg-m, MOUI{TIXGBOLT
7 tb-ft) J:aLIERNlton tO x 1.25mrn
ool{]{ECTOR 45 N.m(4.5kg{, 33 lb-ft)
ADJUSTING MOUNTI{G NUT ALTERI{ATOR

BOLT 8xt.25mm BELT
22 N.m {2.2 kg-m,
16lb_ft} (cont'd)
6-63
TimingBeltandTimingBalancerBelt
(cont'd)
Replacement
6. Removethe cylinderheadcover. 1 0 . Removethe pulleybolt and the crankshaftpulley.Re-
move the two rearboltsJromthe centerbeamto allow
7. Removethe middlecover. the engineto drop down and give clearancetoremove
the lower cover,
8. Removethe side enginemount.
1 1 .Removeth€ rubberseal aroundthe adiustingnut. Do
9. Removethe dipstick and the pipe. not loos€nthe adjustingnut.
6x1.0mm
1 2 N . m( 1 . 2k g ' m ,9 rb-ftt
12 x 1.25 mft
55 N.m (5.5 kg-r(,
40 tb-ft)
O-RING
Replace.
1 2 x 1 . 2 5m m
65 N.m {6.5 kg-m,
47 tb,ft)
RUBBERSEALS
Replacewhsn
damagedor
deterio.ated.
RUBBERSEALS
Replace
when
RUBBERSEAL
Replacewhen MIDDLE COVER oamageool
damagedor
det€aiorated.
Semove any
o .
6x1.0mm
12 N.m (1.2 kg-m.9 lb-ft)
PULLEYBOLT
1 4 x 1 . 2 5m m
220N.m(22.Okg-m,159lb-ft)
Apply engineoil to the
bolt threads, but not
to the surfac€that
TIMII{G BELT
contacts the washer. Inspoction, pago 6-60
Adiusting, page 6-60
CRAI{KSHAFT ADJUSTIf{GNUT 6 x 1 . O m m
PUI.LEY 10 r 1.25 mm 1 2 N . m { 1 . 2k g - m ,
Removeany oil. 45 N.m {4.5 kg-m, 9lb-ft)
33lb-ft)
6-64
t
13. Lockthe timing belt adlusterarm in placeby install- 16. Loosen6 x 1.O mm lock bolt and the adjustingnut.
ing one of the 6 x 1 .O mm lower cover mounting Pushon the timing belt adjusterpulleyto removeten-
bolts, sion trom the belt, then tighten the adjustingnut.
14. Loosenthe timing belt adjustingnut. Pushon the pul- 17. Removethe timing b€lt.
leyto removetensionfrom the timing balancerbelt,
then tighten the adjustingnut. 18. lnstallthe timing beh in the reverseorderof removal.
- Beforeinstallingthe timing belt, positionthe crank-
'15.
Removethe timing balancerbelt. shaft and camshaft pulleys as shown on page
6-62.
NOTE: lf you are removingonly the timing balancer
belt, go to step 21 . li you are removingboth belts, 19. Per{orm the timing belt tension adiustment {page
continuewith this procedure. 6-60t.
20. Tightenthe 6 x 1.Omm bolt to lock the timing belt ad-

rusterarm.
TIMINGBELT
ADJUSTERARM
ADJUSTING t{UT
45 N.m(4.5 kg-m,33 lb-ft)
(cont'd)
6-65
(cont'd)
Replacement
21 , Make surethe crankshaftis positionedwith the No. 1 26. Tu(n the crankshaft pulleYabout one turn counter-
piston at TDC. clockwise. then tighten the adiusting nut to the specl-
tied torque.
22, Alignthe grooveon the front balancershaft pulleYwith
the pointeron the oil pump housingas shown. NOTE: Both belt adiusters are spring-loaded to
properlytensionthe belts.Do not applyanyextra pres-
23. Align the rearbalancershaft pulleyby usinga 6 x 1OO sure to the pulleYsor tensionerswhile performingthe
mm bolt or equivalentas an alignmenttool. adjustment.
Scribea line 74 mm (2.9 in) Irom the end of the bolt. REARBATANCER
lnsertthe boh into the maintenanceholeto the scribed
line.
24. Loosenthe adjusting nut and verifY that the timing

balancerbelt adiustermoves freely.
25. Installthe timing balancerbelt. Removethe 6 x 1OO

mm bolt from the rear balancershaft.
74 mm (2.9 in)
6 r 1OOmm BOLT
R€place.
6 x 100 rm BoLT
12 mm SEALI G AOLT
30 N.m (3.0 kg-m, 22lb-ft)
NOTE: Tighten the bolt after
installingthe belt.
ADJUSTING]{UT
Align the g.oove oI the TIMII{GBALAT{CER

EELT
front driven pulley with DN|VEIT
PULI..EY
the pointer on the oil
pump housing
BALAI{CER BELT
ORIVEPULLEY
Set the crankshaft
at TDC.
6-66
27. Removethe 6 x 1,Omm bolt from the timing belt ad- 31. Installthe middlecover.
juster arm.
32. Installthe crankshaftputley.
33. Coat the throads 8nd seating face of the pulley bolt
29, Installthe lowercover. with engine oil. Install and tighten to the specified
toroue.
30. Installa rubberseal aroundthe adiustingnut. Do not
loosenthe nut. Spocifiedto|ql|3: 220 N.m {22.0 kg-m, 159 tb-ft)
RUBBERSEAL RUBEERSEAL RUEBERSEALS

Replacewhen Replac€when Repl6c6when
damagedor damagedot damag€dor
deteriorat€d. MIODLECOVER deteriorated. dsteriorated.
6 x 'l.Omm
1 2 N m ( 1 . 2 k s - mI,l b , f t )
PULLEYEOLT
1 4 r 1 . 2 5m m
22ON.m 122.0ks-tn 6 x 1.Orrn
159lb-ft) 12 N.m ll.2 kg-m,I lb-ftl
CRANKSHAFT
PUI.LEY 10 x 1.25rm
Bemoveanyoil. 45 N.m(4.5 kg-rn,33 lb-ftl
6-67
Valve Clearance
Adjustment
NOTE: Adjust valves on No. 1 cylinder.
temperature is lessthan 1oOoF(38oC). Valve Cl6a?anca:
. After adjusting,retorquethe crankshaftpulley bolt to lntak€: 0.07-O.11 mm (O.0O3-0.0O4in)
220 N.m (22.0 ks-m, 159 lb-ft) Exhaust:0.15-0.19 mm (0.006-0.007 in)
1. Removethe cylinderheadcover 4, Loosenlocknut and turn adjustingscrew until feeler

gaugeslidesback andJonhwith slightamountofdrag.
INTAKE
27 N.m{2.7kg-m.20 lb-ftl
Applyongine
oil.
"UP" markson the camshaft Tightenthe locknut andcheckclearanceag8in.Repeat

2. Set No. 1 pistonat TDC.
pulleysshouldbe attop. andTDC Arooveson the cam- adjustmentif necessary.
shaft pulleysshould align with cylinderheadsurface.
Number 1 fiston at TDC:
,,UP" MARKS
TDC MARKS
Align the marks
on the pulleys.
6-68
6. Rotatecrankshsft 18Oocounterclockwis€(C8mshaft 8. RotatecrankshaftI8Oo counterclockwiseto bring
pulleystums 9Oo).The "UP" marks should b6 at €x- No.2 Distonto TDC. The "UP" marks shouldbe at
haust side. Adjust valveson No. 3 cylindor. intake side. Adjust valveson No. 2 cylinder.
filumber 3 Diston at TDC: Number 2 dston at TDC:
,,UP" MARKS
7. Rotatecrankshaft18Oocounterclockwiseto bring
No. 4 piston to TDC. the TDC groovesare onc€ agsin
aligned.Adjust valves on No. 4 cylinder,
Numbor 4 piston 8t TDC:
6-69
1
GylinderHeadA/alveTrain
lHz2!-l engine)
SpecialTools ...........6-72 Camshafts
lllustrated
lndex..............................
&73 Inspectbn ............6-93
wEc Vdves, VafueSpringsand ValveSeals
Troubleshooting Flowc*rart - Removal ..............6-95
WEC Solenoid Vdve ................6-75 Vdve Springand Vdve Seal
WEC PressureSwitch... . . ....... . .. 6-77 lrutalationSequence................. 6-101
VTEC Sol€noidValve Inspoction...... 6€0 Vdve lnstallation ... 6-102
Rocker Arms Vaho Seats
ManualInspection. . . . . . . . . . . . . .. . . . . . . . . . 6€1 Reconditioning ......6-97
Inspeabn UsingSpecialToo|s........6€1 Vdve Gukles
Inspectbn . .... .... . .. 6-92 Valve Movernent ........................,6-98
Cylinder llead Replacemst..... ..,.6-99
Removal ..............6€:l Reaming .........,....6-t0O
Warpage......... .....6-98 TimingBdt and nming BalancerB€at
Instalhtion ...........6-103 ltusratodlndex....................,.....
. 6-107
Rocker Armg and Shafts Feplacemem..... ....6-109
Removal ..............6€g TimingB€lt
Locations. . . . . . . . . ....6-90 Inspection ............6-108
Clearance ...... .. .....6-91 TimlngBdancerBeh
Installation ...........6-102 Inspoction ............6-10g
Lost motion AssemHies Vaho Cbarance
Inspection ............ 6-92 Adfu3rnora ..........6-1tE
Ref. No. I Tool Number Descfption Oty ] Page Rotorcncr
o OTHAH_PJ701OA
or O'?HAH-Pl'lO1OB vaNe Gu\de Reame(, 5.5 mm 1 6-100
@ OTLAJ_PR3O2OA Air Stopper 1 6 - 8 1 ,8 2
@ oTMAA-PR70t10 Tappet Adiuster 1 6 - 11 5
@ 07MAA-PR70120 Tappet Locknut Wrench 1 6-115
\!, OTMAF_PR90IOA Valve SpringCompr€ssorAttachment
Extension 6-95
@ 07NAG-P130100 Timing Belt Slider 6-106
o 07742-O010100 Valve Guide Driver, 5.5 mm 6-99, 100
6-95
@ o7757-PJ10l0A Valve Spring Compressor Attachment
--!_rr--_--__---b
P
o
il
B
A---J
U @ \9 @
:r------------ r-blrrrlllsaf q:\

"_-___e.dD/
o @
6-72
lllustratedIndex
CAUTION: To avokl damaging the cylinder h6ad, wait until the engine coolant t€mporatur€ dlope below IOOoF (38oC) before
removing h.
NOTE:
a Use new O-ringsand gasketswhen reassembling.
. Use liquidgasket, Pan No. 08740-OOO1.
a Clesnthe oil controlorifice betoreinstalling.
Prio,to r"""sembling, clean all the parts in solvent.dry them, and apply lubricantto any contact pans.
I
x 1 . 0m m
PLUGWINE 1 0 N . m ( 1 . 0k g - m ,7 l b - t t )
COVER
CLAMP
CYLINDERHEAD
COVER
6 x 1 . 0m m
1 ON m ( 1 . 0k g - m , 7 l b ' f t )
WASHER
Apply liquid gask€t

to these pornts.
RUBBEB
SEALS
Replacewh€n I r 1 . 2 5m m
or deteriorated. 26Nm{k2.6kg-m,
't lb,ftl
9
6r t.Omm 6x1.Omm
1 2N . m( 1. 2 k g , m ) 1 2 N . m { 1 . 2k g - m ,
RUBBERCAP 9tbft)
Replacewhen
damagedor CAMSHAFTHOLOER
dete orated.
AKE CAMSHAFT
8 x 1.25 mm page 6-93
18Nm(1.8kg-m
13 tb-ft)
page6-105
Installation,
Replace. CAMSHAFTPULLEYS
DISTBIBUTOR Removal,page 6-86
page6-105
Installation.
KEYS
wEc
SOLENOID
VALVE
1 0 x 1 . 2 5m m
5 x kl.0 mm 5 1 N . m ( 5 . 1k g - m ,
12 N . m ( 1 . 2k g - m 37 tb-ft)
I tb-ft) EXHAUST 'lO
x 1.25 mm
CAMSHAFT 45 N m (4.5 kg m, 33 tb ftl
VTEC SOLENOID O-RING
VALVE FILTER Replace.
Replace. 8 x 1.25 |nrl
22Nm(2.2koJn-
OIL CONTROL 6x1.0mm qo.' r o ru--ttt
ORIFICE 1 2 N . m ( 1. 2 k g m
Clean. BACKCOVER I lb{tl enctrue
uourur {cont'd)
BRACKETB
6-73
lllustratedIndex
(cont'd)
CYLINDERHEAD
NOTE: Cleanthe rocksr shaft orificeswhen installing. BOLTS
1 2 x 1 . 2 5m m
100 N.m {10.0 kg-m,72 lb-ft)
Apply clean engineoil
VALVE KEEP€RS
ROCIGRABM ASSEMBLY to threads and
EXHAUSTVALVE IPRIMARY,MIO, SECOI{DARY) underthe bolt heads.
SPRIG NI{ER VALVEKEEPERS
,f,"*'*o"'o'n"
INTAKEVALVE
EXHAUSTVAL SPRINGINNER
SPRINGOUTER
SEALINGBOLTS20 mm INTAKEVALVE
60 N.m (6.0 kg-m,43lb-ftl SPNINGOUTER
O.RINGS
Replace.
WASHEB Replacement,pag€s6-95
Replace.
SPRINGSEAT
ROCKERSHAFTS ALVE GUIDE
I
Replacement,page 6-99
Roaming,page6-10O
LOSTMOTION
ASSEMBLY
VALVESEAL INTAKEBOCKER
SHAFTORIFICE
Clean.
VALVE
CYI"INOER HEAD
Removal,page 6-83
Roconditioningvslve
LOSTMOTION s€st, page 6-97
ASSEMBLY Warpage,page 6-98
Installation,page 6-103
EXHAUSTROCKER
SHAFTORIFICE
Clean. EXHAUST VALVE
i INTAKE VALVE
R€placement,
Oimension,pag€ 6-95
CYLINDER HEADGASKET Reconditioningvalve
{METALGASKETI seal, pago 6-97
Replace. Adiustment, page 6-1 '15
DOWEL
PINS
NOTE: Do not installthe oil control orifice.
6-74
VTEC
TroubleshootingFlowchart - VTEC SolenoidValve
-f6il lttll Indicato.Lamp(MlL)indicatesCliagnostic

Maffunction TroubleCode(DTC)21:A problemin the \rrEC
Solenoid
ValvecircNJit,
-r-' \
---.1- /
116l -l 21l--
----i-
- MIL hr! b€on ,aoon6d on.

- With s€rvlc€ chock connoctor
Fmpod lp.go 11-42), cod6 2 1
i8 indhatod.
Do tho onglno c-ontrol modole

(ECMI Rosot Plocoduro (p.go
11-43).
Wann up ongino to normd op€rat-

ing tompo.ature lradiator t6n
como! onr. *Road Test:
Acceleratein 2nd gear to an onginespgedover 6000 rpm.
Hold that enginesp€edfor at least two seconds.
Do thg RoadTest.r Ropeatthis test at least threo times.
Intorrnlttaot lailuro, 3y8tom ir OK

ls MIL on and does it indicate at thi! tim6.
code 21? Ch6ck tor poo. connoctiona o.
10036 wiro. at VTEC aolonoid
valve and ECM,
Dbconnoc-t tho 1P connoctd from

tho VTEC aolonold vdv6.
Ch6d( lor cootinuitv betwoon lP

connoctoa torminal and body
ls there 14-300?
lTo page6-761
(cont'd)
I
VTEC
Flowchart-VTEC SolenoidValve(cont'd)
Troubleshooting
{Frompage 6-75}
Reconnoct 1P connoctof to VTEC

solonoidvalv6. Conngct tho ECM
tost hamds lo the moin ha.n$t
Measuro the rosfutanco botween

A4 t€rmlnaland 426 t6rminal.
Ch€d( lor ogdt or !ho.l In wlto ba-

ls there14-30 0? tw.on ECM lnd VTEC lohnold
vdvg.
substituts a known{ood ECM

and rccheck. ll symplom/indlc'-
tion goos away toplaco thc odginal
ECM.
6-76
TroubleshootingFlowchart- VTECPressureSwitch
@'l l2rl I Uafun"tionIndicatorLsmp{MlLlindicatesDiagnostic
TroubteCodelDfcl 221 A Droblem in the
VTECPressureSwitch circuit.
r.-l - f-;;r
!r{=r j- ta I
- MIL h6 baan rcponod on.

- Wlth ..wlca chccl corn.cior
Fmp.d {p.gr I 142). Cod. 22
l! Indlcltrd.
Do the ongine control moduls

(ECMI Bgset Procedure lpags
11-43).
Warmup engineto normaloper-

ating temp€mtur€lradiEtorfan *Ro6d Test:
comesonr. Accelorgte in 2nd 96.r to on gngine spoed ovfl 6000 rpm.
Hold that engino speod for at loast two s€conds.
Repsat this test 6t lgagt thr6€ timos.
Do the RoodTest.'
lr tmltt nt dura, !y!t!m b OK

rt lhl! tlmc.
Chlck td poor conn.ctlionr ot
loota wklr rt VTEC prct.or.
rwltch lnd EM, VTECPRESSURE
Tu.n the ignition switch OFF.
Digconnoct the 2P connoctor from

th€ VTEC oressuro switch.
Chsckfor continuivbstwoentho
2 terminalson the VTECpreasurs
switch.
Turn the ignition switch ON.
Mga6urcthe voltags betw66n the

8LU/BLK wire 6nd body grolnd.
{To pags 6-78)
(cont'd)
VTEC
TroubleshootingFlowchart- VTECPressureSwitch (cont'dl
(Frompage 6-77)
Inspoct lor an opon oa thort to VTECPRESSURE
ground ln th. BLU/BLKwiro b.- swtYcH
tw6€n tho 2P connccto. tnd D6
ls there approx. 10 V? t.rmlnll ol th. EcM. It wko b oK,
rub.iltuto r known-good ECM
and ictort.
Measurs the voltage across the
8LU/BLKand BLK wires in 2P con-
nector.
Rgpolropon d.ori In BLK wko bo-

ls ther6 approx. 10 V? twc€n lha 2P connoctor gnd body
ground.
Turn the ignitionswitch OFF. 1 0v ?
Reftove 10 mm soaling bolt €nd

connect oil prgss!re gauge. OIL PRESSURE
GAUGE
COMMERCIALLY
AVAILABLE
Connoct a tachomster {se€ sec-
tion 1'1).
Start the €ngine and warm it uP

I to normsl operatingtemperature.
WASHER
Replaco.
Check oil prossure at engine

'l,OOO,3,0OOand 5,0OO
speedof
rpm.
NOTE: Keepmeasutingtimo as shon SEALINGEOLT GAUGE JONT ADAPTOR
ri as Dossiblebecausgengineis running
with no load (lessthan one minutel.
20 N.m (2.Okg-ln, SNAP.ON MT26-17
t 4 tb-ftt 10 x l.O mm
. Use new wash€r when
ls pressurebelow 50 kPa (O.5 In3pocl tho VfEc tol.nold v.lv!. installing the sealing bolt.
kg/cm', 7 psi)7
'l
Disconnectth€ P connectorfrom
the VTEC solenoid valve,
F.
iiri Aftach the battory positive termi-
;i nal to the GRN/VVHTtermin6l
{To p€ge 6-79)
6-78
(From page 6-78)
Start th6 engine €nd check oil

p.essure at 5,OOOrpm.
PRESSUREGAUGE
COMMERCIAI.IYAVAILAALE
WASHER
R6place.
NOTE: Keep rl|ossuring timg as short

as poasiblebgcauseengin€is running
with no losd (l6ssthan one minute).
SEALIIIGBOLT
20 N.ln l2.O kg-ln, S]{AP-ONMT26-17
14 tb-frl 10 r 1.0 rnm
. Usonew washgrwhen
installingthe sealingbolt.
ls p.essure above 4OO kPa

(4 kg/cm', 57 psi)? Inrpoct tho VTEC rol.nold vCv..
Turn the ignition switch OFF.
Reconnect the 2P conn€ctor to

the VTEC Dressureswitch.
Install the tgst hamess (page

11-251.
Stsrt the engins and run above

5,OOOrpm. Measurethe voltage
between D6 l+l and O22 l-l
terminal ol the ECM.
Subrlhute a known,good ECM

.nd r.chock, It rymptoh/lndic.-
tlon gooa lwsy rcplsce tha o.igi-
nll ECM.
6-79
t-
WEC
WEG SolenoidValve InsPection
1. Disconnectthe 1P connectorfrom the VTECsolenoid 4. lf the filter is not clogged, push the VTEC solenoid
valve. valve with your finger and check its movement'
2. Measureresistancebetween the terminal and body o lf VTECsolenoidvalve is normal,checkthe engine
grouno. oil oressure.
Resistance: approx 14-30 ohms
6x1.0mm
12 N.m 11.2kg-m,9lb-ft)
lf the resistanceis within specifications,removethe

VTEC solenoid valve from the cylinder head, and
check the VTECsolenoidvalve filter for clogging.
o lf there is clogging,replacethe engineoil filter and
the engineoil.
;.1
Fl VTEC SOLENOIDVALVE
i
' Il
r t
I
VTEC SOLENOIDVALVE
FILTER
Replace.
6x1.0mm
l 2 N . m ( 1 . 2k g - m ,g l b ' f t )
6-80
RockerArms
ManualInspection InspectionUsingSpecialTools
Removethe cylinderheadcover.
o B€toro using the spodd tool (Valv! lmp€ction Tooll,
Push the mid rocker a.m on the No, 1 cylinder mak6 sure that tho aL pnesaurogauga on th6 air com_
manually. pressor indkrat.s ovor 250 kpa (2.S kg/cmr, 36 p3l).
o Inspect th€ valv€ clearance before rock€r arm in-
Checkthatthe mid rockerarm movesindependentlyof spoctbn.
the primaryand secondaryintake rockerarms. a Covcr thc dming bah with a lhop towol to fotoct thc
beh frcm o0 roakhg,
MID ROCKER . Check th. mH rocksr e]m of 6sch xilton Et TDC.
ARM
1. Removethe cylinderhead cover.
2. Plugthe relief hole with th€ speciattool.
EXHAUST
4. Checkthe mid rockerarm of each cylinderat TDC.

a lf the mid rocker arm does not move, r€movethe
mid, primaryand secondaryrocker arms as an as-
sembly and check that the pistons in the mid and
pfimary rockerarms move smoothly.
o lf any rocker arm needs .eplacing, replace the
primary,mid, and secondaryrockerarms as an as_
semblv.
(cont'dl
6-81
RockerArms
InspectionUsingSpecialTools(cont'd)
3. Removethe bolt and w8sherfrom the inspectionhole 4. Loosenthe regulatorvalveon the valveinspectiontool
and connectthe valve inspectiontool. . and applythe specifiedair pressureto the rockerarm
pistons.
Sp6dfied A Pr$sui€:
250 kPa (2.5 kg/cm', 36 psil
- 5Oo kPa (5.0 kg/cm', 71 Fil
Makesurethat the intakeprimaryand secondaryrock-

REGULATOR VALVE
Pullthe leverand er armsaremechanicallyconnectedby the pistonsand
turn to adiust. that the mid rocker arms do not move when pushed
manuallv.
MID ROCKER
ARM
LOSTMOTION
ASSEMBLY
1 0x 1 . Om m
ADAPTER o lt any mid rockerarm independentlyof the primary
SEAUNGBOLT
1 Ox 1 . 0m m S]{APONMT26-17 and secondary rocker 8rms, replace the rocker
20 N.m(2.0kg-m, o. EOUIVAEI{T
arms, as a ser,
14 lb-ft)
,,1 Removethe tools.
Checkfor smooth operationoI the lost motion assem-

'f
bly. lt is compressedslightlywhen the mid rockerarm

is lightlypushedand compresseddeeplywhen the mid
rockerarm is stronglyPushed.
. ReDlacethe lost motion assembly iJ it does not
move smoothly.
After insDection,check that the malfunctionindicator

lamo lMlL) does not come on.
6-42
CylinderHead
Removal
Engineremovalis not requiredlor this procedure. 1 . Disconnect the negative terminal from the battery.
@E Drainthe enoinecoolant(seesection 1Ol.

. MalG surs Fcks and salaty stands re dac.d p(opody a Removethe radiator cap to speed draining
ard hoist brack6is ar€ attachod to co.roct positions on
ths engln6. J. Relievefuel pressure.
. Mako sur€ the car wlll not loll off stards and fall while
you aro working undor it. @ Do not moke whllo wor{ng on ft,"l
sFt€m, k€3p opan f!|m or rFrt away from work
CAUTION: Eroa. Drain fr.rCor{y lnto an apFov€d contakrr.
. Uss tender covors to avokl damaglng paintad surfaces,
o Undug rhe wiing connoctoB ceefuf,y whte holdlng th€ 4. Removethe intak€ air duct,
conn€ctor ponion to avokt damage,
a Ma.k aI wiing and hosos to avoH misconnectbn. Also, Removeth€ fud feed hose and evaDorativeemission
bo sur€ that they do not contact othor widng or hosa3 01 (EVAP)controlcanistor
hos€from the intakemanifold.
interfere whh oth€r DarB.
. To avokl dsmaging the cytrder hrad. wait until tho
coolanttemp€raturedropobelow IOOoF(38oC)engine
b€foro bosening the rotaining bolts,
NOTE:
. Inspect the timing belt belore removing the cylinder
head.
a Turn the crankshaftpulleyso that the No, 1 piston is at
top dead center (page6-1061.
a Mark allemissionhosesbeforedisconnectingthem.
NOTE: The radiomay have a coded theft protectioncir-

cuit. Be sure to get the customer'scode numberbefore POSITIVECRANKCASE
- Disconnectingthe b8ttery.
- Removingthe No. 43 (1O A) tuse (ln the under-hood
fuse/relavboxl. o. Removethe throttle cable from the throttle body,
After service,reconnectpower to the radio and turn it NOTE:
on. a Take care not to bend the cablewhen removing
When the word "CODE" is displayed.enrerthe cus- it. Always replaceany kinkedcable with a new
tomer's s{igit code to restoreradiooperation. one.
a Adjust the throttle cable when installing(see
s e c l i o n1 1 ) .
ADJUSNNGNUT {cont'd)
6-83
{
"t.
CylinderHead
Removal(cont'dl
7. Removethe fuel teed hose, the tuel return hose and 9. Remove the engine ground cable lrom the cylinder
the brakeboostervacuum hose. head cover.
FUELFEEOHOSE 10. Disconnect the alternator terminal and connector,

, thsn removetheenginewire harnessflom the cylinder
h9€d cover.
6 x 1 . 0m m 6 x 1 . 0m m
8 N.m(O8 kg-m,5.8lb-ft) 10 N.m (1.0 kg-m.7 lb-ft)
l ,}
1 1. Rdmovethe power stsering (P/S)pump bolt and pump.

a Do not disconnecl the P/S hoses.
Removethe Jollowingenginewire harnessconnectors

and clamps from the cylindet head and the intake u'o-n,
li,l.3u,ll*n-..'
manifold:
a Fourfuel injectorconnectors
a lntake air temperature{lAT) sensolconnector
a ldle air control (lAC) valve connector
a Throttle position {TP)sensorconnector
a Exhaustgas recirculation(EGR)valve lift sensorcon-
nector
a Groundcableterminals
fo Enginecoolanttemperature(ECTIswitch B connector
a Heatedoxygen sensor(Ho2S)connector
a ECTsensorconnector
o ECTgaugesendingunit connector
o lgnition control module (lCMl connector
o CKP/TDC/CYPsensorconnector
o VehiclesDeedsensor {VSS}connector LOCKNUT
a lgnitioncoil connector 1 5N . m( 1 . 5k g - m ,
a VTECsolenoidvalve connector 1't rb-ft) P/SPUMPBELT
o 8 x 1.25 mm
VTECpresserswitch connector 22 N.m (2.2 kg-m.
a Intake 8ir bypasssolenoidvalve connector 16 rb-ftl
a ECTswitch A connector
a Knock sensorconnector
6-84
I
I
1 2 .Bemovethe ignitioncoil. 16, Femove the bracket and intake manifold.
*: CORROTION
RESISTANT
BOLT
* 8x1.25mm
22 N.m (2.2 kg-m, 16 lb-ft)
* 8x 1.25mm
22N,n 12.2kg-r'|,,
16 tb_ft)
1 3 . Remove the emission vacuum hoses and water '17.

Removethe selflocking nuts and disconnectthe ex,
bypasshosesfrom the intakemanifoldassembly.
haust manitoldand exhaustpipe A.
1 4 . Removethe radiStorupperhose and heaterhosetrom '18.
Remove the heat insulator, brackets and exhaust
the cylinderhead.
manifold.
15. Removethe water bypass hose and the thermostat
housing.
BBACKETS
o-Rt]{G
Replace.
6-85
CylinderHead
Removal(cont'd)
1 9 . R€movethe cylinderheadcover. 23, Removethe belt from the camshaftpulleys.
20. Removethe middlecover.
Use a wrench to loosen the maintenancebolt lf it CAUTION: Do not caimp oi b.nd

cannot be loosenedwilh an open-endwrench, a box tho tlr$ng bdt mors fran 9Oo or
wrench can be used after pullingout the lock pin bss thtn 25 mm | 1 in) h damcter'
NOTE: Useof a tool shotildbe limhedto initialloosen-

ing only.
22, Loosen the maintenanceboh by hand until it stops'

The auto-tonsionerbracketis now tixed.
NOTE:
a Neverusea tool to loosenthe maintenancebolt af-
G4?
ter initisl loosening. No Good
a ll tha auto-tensioner has been extendsd 8nd the
timing beh cannot b€ install€d,remove the auto-
tensionsr,@mpressit and lainstsllh (page6-1 12).
24. Removethe camshaftPulleYs'
CAMSHAFTPULLEYS
MAINTENANCE
AOLT
Auto-tonsioner
funstistl.
;*,6r*;i*
MAINTENAI{CE
BOLT
Auto-tensaoner
fixed in plac6.
6-86
25. Loosenthe rockerarm adjustingscrews,then remove 27, R€move ihe cylinder head bolts, then remove the
the camshaft holdersand camshafts cylinderhead.
CAUTION: To p.event warpag€, unscr€w the bolts in

soqu€nce 1/3 tutn at a time; rspeat the sequonce until
ADJUSTINGSCREWS
all bohs aro loossned.
CYLINDER
HEADSOLTLOOSENING
SEOUENCE
ADJUSTINGSCREWS
24. Rsmovethe side enginernount bracket B and timing

b€h back cover.
NOTE: Separatethe cylinderheadfrom the block with a

flat tip screwdriveras shown.
'lO
x 1,25 mm
45 N.m (4.5 kg-m,
33 rb-ft)
8 x 1 . 2 5m m
22Nm12.2kg-n',
16 tb ft)
6-87
RockerArms and Shafts
Removal
Loosenthe adjustingscrews, then remove the bolts

and the rockerarm assemblY
NOTE:
a Unscrew the camshaft holderbolts two turns at a
time, in a crisscrosspattem, to preventdamag'ng
the valvesor rocker arm assembly.
a when removingthe rocker arm assembly,do not
remove the camshaft holder bolts. The bolts will
keep the camshaft holders, the springs and the
rockerarms on the shafts.
INTAKE
No.4 No.3 No.2 No.1
i t
2. Removethe VTECsolenoidvalve 8nd fiher.
wEc solEflolD
VALVE
No.4 No.3 No.2
EXHAUST
,i"
VTECSOLENOID
VALVEFILTER 6 x k 1 . Om m
Replace. 1 2 N . m { 1 . 2k g - m ,
I tb-ft)
6-88
3. Hold the rocker arms together with a rubber band to Screw 12 mm bolts into the rocker arm shafts. Re-
preventthem trom separating. move each rockerarm while slowly pullingout the in-
lake and exhaustrockerarm shafts.
RUBBER
BAND
BOCKER
ARMS
12 mm EOLTS
4. Removethe intake and exhaustrockershaft orifice.

ROCKERSHAFT
NOTE: The shapesof the rockershaft ori{icesof the
intakeand exhaustare difterent. ldentify the parts as
they areremovedto ensurereinstallationin the original
locations.
6-89
Locations
h8s ba€n im€rtod
CAUTION: Attd hstafling the ]ockor shrtt odfic.. try to tum ihe locker shaft to mak€ sura that iho oriffco
in th6 holo ot rodcr shaft conectlY. lf th. odfica b in plsce' it ehorld not tum'
NOTE:
a ldentify parts as they are removedto ensurereinstallationin originallocations'
. Inspectrockershafts and rockerarms (pages6-93 and 941.
a Rockerarms must be installedin the same positionit reused.
o Cleanthe intakeand exhausttocket shaft orificesbetoreinstalling.
erior to reinstalling,clean all the parts in sopent, dry thern and apply lubricantto any contact surfaces,
I
ARMASSEMBLIES
ROCKER
TNTAKE
cyLtNoERNUMBEB
m
I , |/ | t /
No.3 No.2 No.1
SEALINGBOLTS20 mm TNTAKE
ROCKER
60 N.m{6.0ks-m,43lb-ft} SHAFT
ri
i
I
II
ll
I
rli No.4 No.3 No.2 *oi,
\
\
RUBBER
BAND
t \
EXHAUSTROCKERARM ASSEMBLIES
\
CYLINDERNUMBER
6-90
Clearance
Measure both the intake rocker shaft and exhaust rocker 3. Measureinsidediameterof rocker arm and check tor
shaft. out-of-roundcondition.
1, Measurediameterof shaft at first rockerlocation. Rocksr Arm-to-Shatt Clearance:

l sko and Erhaust
Standard{N€w}: 0.025-0.052 mm
(O.OO1O0.OO2Oin)
S€wice Limit: O.08 mm (0.003 in.)
2. Zero gaugeto shaft diameter.

Surfaceshould be smooth.
Repeatfor all rockers.

- lf over limit, replace rocker shaft and all ove.-
tolerancerockerarms.
NOTE: lf any rocker arm needsreplacement,replace

all three rocker arms in that set (primary.mid. and
secondarvl.
MICROMETER
6-91
RockerArms Lost MotionAssemblies
Inspection Inspection
NOTE: When reassemblingthe primaryrocker arm, care- Removethe lost motion assemblyfrom the cylinder
fully applyair pressureto the oil passageol the rockerarm. head and inspect it. Pushingit gently with the linger
will causeit to sink slightly.Increasingthe force on it
1. Inspectthe rockerarm piston.Pushit manually. will causeit to sink deeper.
- ll it does not move smoothly, replacethe rocker - lf the lost motion assemblydoesnot move smooth-
arm assemblY. ly, replaceit.
I
il PRIMARYROCKENARM LOSTMOTIONASSEMBLY
Check piston movement
a Apply oil to the pistonswhen reassembling.

a Bundlethe rocker arms with a rubberband to pre-
vent them from separatlng.
6-92
Camshafts
Inspection
NOTE: Oo not rotate camshaftduring inspection. Seat camshafts by pushingthem toward distributor
end ot cylinderhead.
1. Removethe .ocker arms and rockershafts,
4. Zero dialindicatoragainstend of camshaft.then push
NOTE; Rockerarmsmust be installedin the samepo- camshaft back and torth and readthe end play.
sition if reused.
CamshaftEnd Play:
2, fut the camshafts,camshaftholdersand holderpipes Standa.d{New): O.O5-O.'15 mm
on the cylinder head, then tighten the bolts to the {O.OO2-O.006 in)
specitiedtorque. S€rvicoLimh: O.5 mm lO.O2in)
Specified tolque:
@-@: 8x 1.25mm
26 N.m (2.6 kg-m, 19 tb-ft)
@-@: 6x 1.Omm
1 2 N . m ( 1 . 2k g - m ,I t b - f t )
Removethe camshaft holdersand holderoiDes

trom the cylinderhead.
. Lift camshaftout of cylinderhead.wipeclean,then

inspect lift ramps. Replacecamshaft if lobes are
pitted, scored,or excessivelyworn.
. Cleanthe camshaftholdersurfacesin the cylinder
head,then set camshaft back in olace.
a Insertplastigagestrip acrosseach journal.
o Installthe camshaft holdersand holder oiees and
torque bolts to the values and in the sequence
shown in left column.
(cont'd)
6-93
Gamshafts
Inspection(cont'd)
Measure widest portion ot plastigage on each Measurecam lobe height.
journal.
Camshaft-to-Holder Oil CNearance:

StandardlNowl: 0.050-O.089 mm
(0.0020-0'0035 in)
ServiceLimh: O.15 mm (0.006 in)
lnsooct this arca tor wear.
INTAKE EXHAUST
Pf,I MID SEC SEC MID PBI
it
7. lf camshaft-to-holderoil clearanceis out of tolerance:
a And the camshaft has alreadybeen replaced,you

\
T/B
T/B
t, T/8
must replacethe cylinderhead. Pql: PRIMARY MID: MID SEC:SECO DARY

o lf camshsft has not been replaced,first check to- T/8: Tlill G BELT
tal runout with the camshaft supported on V-
blocks.
Camshatt Total Runout: Cam l-obe Holght Standrd (Ncwl:

Standad {Newl: O.O3mm {O.OOIin} max.
Servica Limit: O.O6 mm (0.0O2 Inl II\ITAKE EXHAUST
34.041 mm 33.745 mm
PRIMARY ( 1 . 3 4 0 2i n ) ( 1 . 3 2 8 5i n l
36.856 mm 36.323mm
MID (1.451Oin) {1.43OO inl
34.971 mm 34.683mm
SECONDARY ( 1 . 3 7 6 8i n ) { 1 . 3 6 5 5i n }
Rotate camshaft
while measuring
N
- lf thetotalrunout ot the camshaftis within toler-
ance, replacethe cylinderhead,
- lf the total runoutis out of tolerance,replacethe

camshaftand recheck.It the beanangclearance
is still out of tolerance. replacethe cylinder head.
6-94
Valves, Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve sprinos as they are re- 2. Install spring compressor. Compress spring and re-
moved so that each item can be reinstalledin its original move valve keeDef.
position.
1. Using an appropriately-sized socket and Dlastic

mallet. lightly tap the valve retalner to loosen the
valve keepersbefore installingthe valve spring com-
pressor. VALVESPNI G VALVESPRING
COMPRESSOR ATTACHMENT COMPRESSOR
EXTENSION ATTACHMENT
OTMAF_PR90lOA 07757-PJ1010A
PLASTICMALLET
SOCKET
{cont'd)
6-95
Valves, Valve Springs and Valve Seals
Removal (cont'd)
3. lnstallthe specialtool as shown. Valve Dimemions:
VALVE GUIDESEALREMOVER
LISLEP/t{ 579oo or KD 3350
COMMERCIALLY AVAILABLE
lntako Valvo
A Stsndrrd (Now): 34.9O-35.10mm
(1.374- 1.382 In)
B Standard (Ncwl: 105.rO- 1O5.7O
mm
1 4 . 1 5 0 - 4 . 1 6 1l n l
C StEndard {t{ew}: 5.475-5.483 mm
4. Removethe valve seal. (O.2156-0.2159lnl
C Ssrvlco Limit: 5.W 10.2144lnl
;r D Standard (Newl: 1 . 0 5 - 1 . 3 5m m
(O.O41-0.O53In)
D Scruico Limit: 0.86 mm (O.O34Inl
ExhaGt vllvc
A Standard {Nsw}: 29.90-3O.1Omm
( 1 . 1 7 -7 1 . 1 8 5i n l
B Standard (t{ow,: 105.OO-105.30mm
(4.134-4.1116inl
C Standard (Ncw): 5.475-5.485 mm
(O,2156-0.2159In)
5.rt45 (O.21.14Inl
iri C Service Llnh:
D Stand8rd (Ncwl: 1 . 6 5 - 1 . 9 5m m
(O.O05-O.o78In)
D S€rvico Limit; 1.45 mm (O.O57inl
6-96
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a
valve seat cutter.
VALVE
SEAT
PRUSSIANBLUE COMPOUI{D
o. The sctual valve seating surface, as shown by the

blue compound, should be centered on the seat.
a lf it is too high (closer to the valve stem), vou
must make a second cut with the 600 cutter to
move it down, then one more cut with the 45o
cutter to restoreseat width.
a lf it is too low (closeto the valve edge),you must
make a second cut with the 3Oo cutter to move
it up, then one more cut with the 45o cutter to
restore seat width,
NOTE: lf guidesare worn (page6-98), replacethem
(page 6-991 before cutting the valve seats. NOTE: The final cut shouldalways be made with
the 45o cutter.
Carefullycut a 45o seat, removing only enough
material to ensure a smooth and concentric seat. Insert intake and exhaust valves in the head and
measure valve stem installed height.
Bevel the upper edge of the seat with the 30" cut-
ter and the lower edgeof the seatwith the 60o cut- Intak€ Valv. Stsm lmtallod Height:
ter. Check width of seat and adjust accordingly. Standa.d {Now}: 37.465-37.935 mm
(1.4750- 1.4935 int
Mak€ one mor€ very light pass with the 45o cutter So.vic€ Limit: 38.185 mm {1.5033 inl
to remove any possible burrs caused bv the other
cutters. Exhalst Valve Stom Installad Height:
Standard(Newl: 37.165-37.635 mm
Valvo Soat Width (lntake and exhaustl: (1 .rt632- 1.rt817 in)
Standard(N6w): 1.25- 1.55 mm Servicol-imit: 37.885 mm (1.4915 inl
(0.0r1!l-0.061 inl
Sorvice Llmit: 2.0O mm 10.079 in)
SEATWIDTH
VALVESTEM
INSTALLEDHEIGHT
5. After resurfacing the seat, inspect for even valve

seating; Apply PrussianBluecompound to th€ valve 8. lf valve stem installedheight is ove. the servicelimit,
fEce, and insert valve in originallocation in the head, replace valve and recheck. lf still over th€ service
then lift it and snap it closed against the seat sever- limit, replacecylinderhead;the valve seat in the head
al tames. is too deeD.
6-97
Cylinder Head Valve Guides
oil clearances(page6-93)
NOTE: lf camshaft-to-holder Measure the guide-to-stem clearance with I di6l indi-
are not within speci{ication,the head cannot be cator while rocking the stem in the dirsction of nor-
resurfaced. mal thrust (wobblemethodl.
oil clearancesare within specifica-

lf camshaft-to-holder lntako valvo Stsm-to-Guldo Clearancc:
tions, check the head tor warpsge Standard(Now): 0.05-O.11 mm
tO.O02-0.OO4in)
. lf warpageis lessthan O.05 mm (0.OO2in) cylinder Servic6 Limit: 0.16 mm (O.OO6Inl
head resurlacing is not required
o lf warpageis between O.O5mm (0.OO2in) and O.2 Exhaust Valvo Stem-to-Guldc Cloarancc:
mm (O.OO8in), resurlacecylinderhead. standard (Now): 0.1O-0.16 mm
a Maximumresurfacelimit is 0.2 mm (o.oo8 in) based (O.oO4-o'006 inl
'132.0 0.22 mm (O'OO9Inl
on a height of mm (5.20 in). Sarvice Limh:
vrlvs anondcd 10 mm out trom t!|t'

PRECISIONSTRAIGHTEDGE
.rl
.,il
. . o
a lf measursmentexceedsthe servicelimit, recheck

using a new valv6.
a lf measurement is now within th€ service limit,
reassemble using a new valve.
a lf measurementstill exceeds limit, rechack using
alt€rnate method below, then replsce valve and
Measurealong edges, and 3 ways acrosscente.. guide, if nec€ssary.
NOTE: An ahernate method of ch€cking guide to

stem clearanceis to subtract the O.D. ol the vslve
stem, measuredwith a micrometer, from the I'D of
the valvs guide, measuredwith an inside microm€-
ter or ball gauge
Take the measuromentsin three plsces along th€
valve stem and three placas inside the vslve guide.
The difference between the largest guids measurs-
ment and the smalleststem measurem€ntshouldnot
exceed the service limit.
lntako Valvo Stam-to-Gddo Clcalanco:

Standard{Now): O.O25-O'055 mm
t0.O01O-O.0O22in)
Sorvlce Limit: 0.O8 mm lO.0O3 inl
Cylindol Head Hoight:
Standard(New): 141.95-142.05 mm Exhaust valvo Stom-to-Guida Cbarlncai
(5.589-5.593 in) Standard (New): O.O50-O.080 mm
(0.o020-0.0O31 inl
Sorvice Limit: 0.1 1 mm (0'0O4 Inl
6-98
Replacement
l. As illust.ated in the removalsteps o{ this procedu.e, 4. Workingfrom the camshaftside,use the driverand
use a commercially-available air-impactdriver attach- an air hammer to driver the guide about 2 mm
ment modifiedto tit the diameterof the valve guides. (O.1in) towa.dsthe combustionchamber.This will
In most cases,the same procedurecan be done us- knock off some of the csrbon and make removal
ing Valve GuideDriversand a conventionalhammer. easier.
Tool numbersare at the end of this procedure.
CAUTION:
a Always wear satoty goggles or a tace shield whon
using th€ ai. hammot.
a Holdthe air hamnrerdhectly in line with th€ valvo
VAI.VE GUIDEDBIVER guide to prev€nt damaging the driver.
Y AVAIIAALE 5.3 mm
lO.2'l in) Turn the head over and drive the guide out toward
I the camshaftside of head.
l r
t-
l_rl
10.8 mm
10.42 Inl
Removaland Installation
VALVEGUIDEDR|VER,5.S ftm
07742-d)10100
2 . Select the proper replacementguides and chill them

in the freezer section of a retrigerator for about an
hour.
Use a hot plate or oven to evenly heat the cylinder

head to 3OOoF(150oC). Monitor the temoerature VALVEGUIDEDRIVER,
with a cookingthermometer. COMMERCIAIIY
AVAILABTI
<reDi-k
lf a valve guide still won't move, d,ill it out with a
8 mm (5/16 inchl bit, then try again.
CAUTION: CAUTION: Drill guidos only in extrcmo cas€s; you

a Do not us6 a torch; lt may warp th6 hoad. could damagotho cyllnd€r head lftho guide breaks,
a Do not get tho h6ad hotter rhan 3OOoF(150"C);
€xcesslvo heat may looron tho valvo soats, 6. Removeth€ new guide(sltrom ths refrigerator.one
a To avoid burns, uso hoavy glovos whon handling at a time, as vou need them.
tho h€Eted cylindsr head.
{cont'd}
6-99
I
Valve Guides
(cont'd)
Replacement Reaming
7. Slip a 6 mm (0,2 in) steel washer and the correct NOTE: Fo. n€w valve guidesonly.
driver attachment over the end ol the driver (the
washerwill absorbsome ot the impact and extend 1. Coat both reamerand valve guide with cutting oil.
the lite ot the driver).
Rotate the reamer clockwise the full length of th€
valve guide bore.
Continue to rotate the reamer clockwise whil€

/--Tr-
-1-l--l- al;\ -r rnr removing it from the bore.
\---jY
Y
t
DRIVEB
t
6 mm 10.2in)
t
ATTACHMENT
4. Thoroughly wash the guide in dstergent and water
to removeany cutting residue.
WASHER
Check clealancewith a valve (page 6-98).
a Verify that the vslve slides in the intake and ex-

8 . tnstallthe new guide(s)Jromthe camshaftside oJ haust valve guides without exerting pressure.
the head;driveeachone in untilthe attachmentbot-
toms on the head.It you have 8ll sixteenguidesto
F do, you may have to reheatthe head one or two
more times.
VALVE GUIDEDRIVER,
5 . 5m m
07742-@10100
9*6W
)/>-A()
5.5 mm
OTHAH-PJTOIOA
oTHAH-PJ70108
Valvo Guid6 Install€d Hoight:

Standard {New):
lnrak€: 12.55-13.O5 mm (O.494-0'514 in)
Exhaust:12.55- 13.O5 mm (O.494-O.514Inl
VALVEGUIDE
6-100
Valves, Valve Springsand Valve Seals
ValveSping andValveSealInstallationSequence
NOTE: Exhaustand intakevalve sealsare NOT interchangeable,
VALVEKEEPERS
e{t'
---.,-VALVE SPRING
RETAINER
A\---.'-
v VALVE SPRING
NOTE: Pt.c. the ond ot valvo OUTER
.prlng whh clo3.ly wound coll!
row..d tho cyllndor herd.
VALVE SPNNG
INNER
II{TAKEVALVE SEAL
{WHITESPRING}
Replace.
:,.^,7
NOTE: In6tallthe valve spring seats
before installingth6 valv€ seals.
VALVE GUIDESEALINSTALLER
KD-2899
NOTE:Usesmalllo
€ndol tool.
wre
6-101
Valves,Valve Springsand
Valve Seals RockerArms
Valve Installation lnstallation
When installing valves in cylinder head, coat valve 1 . lnstallthe rockerarms in the reverseorderof removal:
stems with oil bejore insertinginto valve guides, and o Valve adjustinglocknuts should be loosenedand
make sure valvesmove up and down smoothly. adjustingscrew backedoff betore installation.
o The comDonentDans must be reinstalledin the
Whenvalvesand springsare in place.lightly1apthe end originallocations.
ol each valve stem two or three times to ensureproper
seating of valve and valve keepers (use hammer.grip Installthe lost motion assembly.
bottom).
3 . Installthe rocker arms while passingthe rocker arm
NOTE: Tap the valvestem only alongits axisso you do shaft through the cylinderhead.
not bend the stem.
NOTE: Removedthe rubber band after installingthe
rockerarms.
Il
I
4. lnstallthe rockershaft orifices.lf the holesin the rock-

er 8rm shaft and cvlinderheadare not in line with each
other, threadsa 12 mm boh into the rockerarm shaft
and rotate the shaft.
ri NOTE:
a The shapesof the rockershaft orificeslor the intale
and exhaustare different.The oriticesmust be in-
stalledin the originallocations.
o Cleanand installthe rockershaft oriticeswith new
O-rings.
EXHAUSTROCKER
SHAFTORIFICE
6-102
CylinderHead
lnstallation
Install the cylind€r head in the reverse ord6r ol 3. Tighten the cylinder head bolts sequentiallvin thr6e
removal: steps.
a Always use new h€adand manifoldgaske$.
. The cylinder head gask€t is a m6tal gasket. Take lst stop torquo: 40 N.m (4.0 kg-m, 29 lb-ft)
care not to bend it. 2nd stop torquo: 70 N.m {7.Okg-m, 51 lb-ftl
. Rotate the crsnkshaft, s6t the No. 1 piston at TDC &d st€p torque: 10O N.m {10.Okg-m, 72 lb-ftl
(pase&106).
NOTE:
Installthe cylinderhesd gasketand dowd pins on the o We recommendusinga beam-typetorque wrench,
cvlind€rhead. When using a preset-typetorque wrgnch, be sure
to tighten slowly and not to overtighten.
. lf a bolt makesany noisewhile you 8re torquingit,
loosenthe bolt and retightenit from the lst step.
CYLINOERHEAO
CYUNDERHEADBOLTSTOROUESEOUENCE
DOWELPIN
oowEl n
CYUI{DERHEADBOLTS
12 x 1,25mm
1OON.m(10.0kg-m.72 lb-ftl
Applyclean€nginooilto bolt
thrsads8ndunderboltheads.
{cont'd)
6-103
CylinderHead
Installation(cont'd)
4. lnstall the int€ke manifold and tighten the nuts in a 6. lnstallthe camshaftsand camshaft oil seals.
crisscrosspattern in 2 or 3 steps, beginningwith the
Innernuls. NOTE:
o Installthe camshaftswilh keyway facing up.
INTAKEMANIFOLD
GASKET . Installth€ oil s8al with the springside fscing in.
. The dl seal housingsurfaceshouldbe dry.
7 . Cleanand installthe oil controlorificewith new O-ring

in the oil passageof the No. 3 camshaft holde..
I x 1 . 2 5m m
22Nm{2.2kg-m,
16 lb-ft)
I x 1.25 mm
2 2 N . m1 2 . 2 l . g - m , ERACKET
16 tb-ft) o-RrNG
;;;--
ReDlac€.
Instsllthe exhaustmanifoldand brackets.Tightenthe a Apply liquidgasketto the headmating surtaceof the

nuta in a crisscrosspattern in 2 or 3 steps, b€inning No. 1 and No. 5 camshaftholderson both the intake
with th€ innernuts, and exhaustside. Confirmthat the csmshaft k€vway
are face up, then plscethe holders,togetherwith the
EXHAUSTMANIFOLD No. 2. No. 3 and No.4 camshaftholders,on the
8 x f.-$.mm GASKET
Replace. cylinderhead.
32 N.m-|C.2ks-m,
23 tb-ir)
NOTE; The arrows markedon the camshaft holders
8xL25mm shouldpoint to the timing b€lt.
22 N.m12.2kg-m,
16 tb-ft)
CAMSHAFTHOLDERS
I No.5 o.4 No.3 No.2 t{o.l
I
Ifr Ai ,:)t Bqt
I
I i
o
6x1.Omm
FA
t t l IITTAKE
10N.m We)
M H S
BFl f'q ffiTn
( 1 . 0k g - m ,
7 tb-ft) n A
' 1 0x 1 . 2 5m m ffil"t EXHAUST
I
SEI.f,-LOCKING NUT 8 x 1.25 mm

45Nm14.5kg-m,
33 tb-ft) K- \t \t ta/\el
l O x 1 . 2 5m m APPIvliquid gasket
22Nm(2.2kg-m, to tne shadedareas.
55 N.m (5.5 kg-m, 16 lb-fr)
40 tb-ft)
Replace.
6-104
9. Temporarilytighten the bolts ot the camshaft holders 1 1. Tightenthe bolts in the sequenceshown below.
and the camshaftholderoioes.
1 0 . fush the camshaftoilseal securelyagainstthebaseof O-@:8x1.25mm

the camshaft holder. 26 N.m (2.6 kg-m, 19 lb-ft)
@-@:6x1.Omm
12 N.m (1.2 kg-m,9 lb-ft}
12. Installthebackcoverot the timingbelt.
13. Installthecamshaftpulleys.
.. KEY
l
,7*, I
W&
CAMSHAFTPULLEY 1 0 r 1 . 2 5m m
5 1 N m 1 5 . ' k1 g - m , 3 7 l b - f t )
6-105
CylinderHead
1 4 . Installthe timing belt in the reverseorder of removal. 16. Installthe timing belt.
Adjust the valve clearanceslpage 6-1 151
- Beforeinstallingthe timing belt, positionthe crank- NOTE:
shaft and camshaft pulleysas shown a It the autotensioner has been extended and the
timing belt cannot be installed.remove the auto-
TDCPOSITION:
CAMSHAFT tensioner.@mpressit ard reinstallit {page6-1 12}.
,,I" MARKS . Take care not to damagethe timing belt when in-
stallingit.
TDC MARKS
CRANKSHAFTTDG POSITION
:
17. Tighten the maintenance bolt to make the auto-

tensionertunctional.
NOTE: Turn the maintenancebolt bv hand until it

stoos.
TDC MARK ON
THEFI.YWHEEL
Auto-tensioner
1 E lnstallthe specialtool on the intake camshaftpulley. tix€d in ploce.
EXHAUST
CAMSHAFT
PtJLLEY
Auto-tensioner
lunctional.
6-106
lllustratedIndex
NOTE:
a Reterto page 6-1OOtor positioningcrankshaftand pulley beforeinstallingtiming belt.
o Beforeremoving,mark directionof rotationon each belt.
ADJUSTING NUT
'lOt 1.25mm
MIDOLE
45 N.m (4.5 kg-m,33lbJt)
RUBEERSEAL
RUBBERSEALS Replacewhen damaged
Replacewhen or deteriorated.
damagedor deteriorated.
CRANKSHAFT
PULLEY
Removeany ojl.
CAP NUT
6xl.Omm PULLEYEOLT
10Nm{1.0kg-m,7lb-ft) 1 4 r 1 . 2 5m m
220 N.m {22.Okg m, 159 lb-tt}
Applyengineoilto the bolt
threads, but not to the
WASHER surtacethat contacts the
LOWERCOVER
Romovethe five bolts. POWER STEERING
BELT
Adiushent, s€ction17
RUBBERSEALS
Replacewhen damaged
or deteriorated.
6x1.Omm
'l2
N.m (1.2 kg,m, 9 lb-ft)
CAMSHAFTPULLEYS
1 Ox 1 . 2 5m m
5 1 N . m ( 5 . 1k g - m ,
37lb-ftl
ALTEBNATOR
Adjustment,section 23
TIMINGEELT
Inspectaon, page6-108
Installation,page 6 109
AUTO.TEI{SIONER
AI'JUSTING BOLT
68 N.m (6.8 kg-m,49 tb-ftl TIMING BALANCERBELT
Apply liquid gasker page6-'l08.
Inspectaon,
to the bolt lhreads
installedin the
blockside. lnstall with concave
surtacefacing in.
Removeany oil.
6-107
Timing Beft Timing BalancerBelt
lnspection Inspection
1. Disconnectthe alternatorterminaland the connector' 1. Disconnectthe alternatorterminaland the connector,

then removethe enginewire harnessfromthe cylinder then.emovethe enginewire harnessfromthe cylinder
head cover. headcover.
2. Removethe cylinderheadcover 2. Removethe cylinderheadcover
3. Removethe middlecover. 3. Removethe middlecover.
4. Inspect the timing belt for cracks and oil or coolant 4. Removethe crankshaftpulley.
soakang.
NOTE:
a Replacethe belt if oil or coolant soaked. 6. Installthe crankshaftpulleY.
. Removeany oil or solventthat gets onthe belt.
soaking.
Inspectthis
areafor wear, NOTE:
. Replacethe belt if oil or coolant soaked.
a Removeany oil or solventthat gets on the belt.
Inspectthis
areator wear,
Rotatepulloy
and inspect belt.
pulleyboltto
crankshaft
retorquethe
Afterinspecting, After inspecting,retolquethe ctankshaftpulleybolt to
220 N.m(22.Oks-m,159lb-ft). 220 N.m (22.Oks-m, 159 lb-ft).
.{d.,
NOTE: Reterto page 6-1 l3 for timing balancerbelt
tension adiustment.
6-108
TimingBelt and TimingBalancerBelt
Replacement
CAUTION: Insp€ct th€ wst€r Frmp whon roplacing tho Removethe mounting bolts, nuts and belt from the
timhg boh (pag61O-121. power steering(P/S)pump.
NOTE: Turn the crankshaftso that the No. 1 Distonis at NOTE:

TDC {page6-106}. o Do not disconnectthe P/S pipe and hose.
o After installing,adjustthe tensionof the P/Spump
1, Removethe splashshield. belt (seesection 171.
MOUNTINGEOLTS LOCKNUT
15Nm(1.5kg-m,
l l
SPLASH
SHIELD
8 x 1 , 2 5m m P/SPUMPBELT
2. Disconnectthe connector, then remove the cruise 22N,m 12.2kg-m,
control actuator, 16 tb-ft|
NOTE: Disconnectthe ahetnatorterminaland the connector.

a Oo not disconnectthe control cable. then removethe engine wire ha.nessfrom the body
a Takecarenot to bendthe cablewhen removingthe srde.
actuator,Always replacea kinkedcablewith a new
one. Loosenthe ahernatormounting bolt, nut and th€ ad-
justing nut, then removethe alternatorbelt.
CBUISECONTROL
ACTUATOR 6x1.0mm NOTE: After installin€,adjustthe tensionof the atter-
10 N.m ('l.Okg-m, nstor belt (seesection 23).
7 tb-fr) MOUNTNG AOLT
1Ox 1.25 mm
ALTERNATOR 45 N.m (4.5 kg-m,
COI{NECTOR 33 tb-ft)
AL
MOUNTINGNUT BELI
CONNECTOR 8 x 1.25 mm
TERMINAL 22N m 12.2kg-m,
16 tb-ft) (cont'dl
6-109
Replacement(cont'dl
Bemovethe cylinderhead cover. 1 0 .Removethe crankshaftbolt and the pulley.

Removethe two rear bolts lrom the center beam to
Removethe middlecover. allow the engineto drop down and give clearanceto
removethe lower cover.
Removethe side enginemount.
1 1 .Removethe adiusterrubber seal. Do not loosenthe
1 2x 1 . 2 5m m adjustingnut.
5 5 N . m{ 5 . 5k g m ,
40 rb-ft)
1 2 . Removethe lower cover.
1 3 . Loosenthe adjustingnut. Pushon the pulleyto remove

tensiontrom the timing balancerbelt, then tightenthe
adjustingnut.
il
il
t ,
l l
1 4 . Removethe timing balancerbelt.
12 x 1.25 fifi tD. Removethe timing belt.

65Nm(6.5kg-m,
47 tb-fr)
1 6 . Removethe auto-tensioner.
9. Removethe dipstick and the PiPe
6x1.0mm
1 2 N . m( 1 . 2k g - m ,9 tb ft)
Replace.
6-110
CYLINOERHEAD
COVER
TIMING BELT
6x1.Omm
12 N.m(1.2kg-m,9 lb-ft)
MIDOLECOVER
TIMINGBALANCERBELT
page6-108
Inspection,
ADJUSTIT{GNUT
l 0 x 1 , 2 5m m
45 N.m {4.5 kg-m,
33lb-tt)
RUBBER SEAL
Replace whendamaged
or deleriorated.
AUTO.TENSIONER
rullEY BOLT
1 4 x 1 . 2 5m m
220 N m (22.0 kg-m, 159 lb-ft)
RUBBER
Replacewhen
damagedor
deteriorated.
6t1.0mm
12Nm(1.2kg-m,
9 tb-ft)
PULLEY
Remove any oil.
6-111
Replacement{cont'd}
1 7 . Installthe timing belt in the reverseorder ol removal. NOTE: Take care not to damagethe threads or the
- Beforeinstallingthe timing belt, positionthe crank- gasketcontacl surfacewith the sctewdriver'
shaft and camshaft pullevsas shown
MAINTENANCE
,,T" MARKS BOLT
FLAT BLADE
SCREWDRIVER
STOPFER
P/N 14540-Pl3-003
2 1 . Removethe screwdriverand reinstallthemaintenance

bolt.
NOTE: Be sureto ube a new gasket.
i
MAINTENANCE
BOLT Replace.
I N.m(0.8kg-m,
6lb{r)
TDC
MARK
the auto-tensionerwith the maintenancebolt

.l , pointingup. Loosenand removethe maintenancebolt. Make sure no oil is leakingaround the maintsnance
bolt. Installthe auto-tensioneron the engine.
NOTE: Handlethe auto-tensionercarefullyso the
oil insidedoes not spill or leak. Replenishthe auto- NOTE: Make sure the stopperstays in place.
t tensionerwith oil if any spills or leaks. The total
' capacityis 8 cc {1/4 ii oz). STOPPER
I 19. Clamp the boss oJ the auto-tensionerin a vise. Use

P/N
; DiecesoJ wood or a cloth to protect the boss,

I NOTE: Do not grip the housingot the auto-tensioner.
20. lnsert a flat blade screwdriverinto the maintenance

hole. Placethe stopper {P/N 1454O-P13-OO3)on the
auto-tensionerwhile turning the screwdriver clock-
wise to comDressthe bottom.
8 x 1 . 2 5m m
22 N.m (2.2 kg-m,
16 rb-ft)
6-112
23. Removethe stopper. 26. Align the rearbalancershsft pulleyby usinga 6 x 10O
mm bolt or equiv€lentas an alignmenttool.
ADJUSTER Scribea line 74 mm (2.9 in) trom the end of th€ boh.
Insertthe bolt into the maintenanc€holeto the scribsd
line.
27. Loosen the adjusting nut and verify that the timing
balancerbelt adiustermoves freely.
28. Instsll the timing balancerbelt. Removethe 6 x 10O

mm bolt trom the rear balsncershsft.
29. Turnthe crankshaftpulleyaboutoneturn, then tighten

the adjustingnut to the specifiedtorque.
P/N 14540-P't3-OO3 NOTE: Both belt adjusters are spring-loaded to

properlytensionthe belts.Do not applyany extra pros-
24. Make surethe crankshaftis positionedwith the No. 1 sureto the pulleysor tsnsionerswhile performingtha
cylinderat TDC. adjustmenl.
25. Align the grooveon the front balancershaft pulleywith REARBALANCERSHAFT

the pointeron the oil pump housingas shown.
74 mm 12.9in)
6 r 100 mm BOLT
12 mm SEALINGBOLT
30 N.m {3.0 kg-m, 22lb-ft}
NOTE:Tighten the bolt after
installingthe belt.
Align the groove of the

tront driven pulley with REARTIMING BALANCEREELT
the pointer on the oil DRIVENPULLEY
pump housing.
BALANCERBELT
DRIVEPULLEY
Setthe crsnkshaftat TDC. (cont'dl
6-113
Timing Belt and Timing BalancerBeh
(cont'dl
Replacement
30. lnstallthe lower cover. 32. Installthe middlecover.
3 ' 1 Install
. a rubberseal aroundthe adjustingnut. Do not 33. Installthecrankshaftpulley.
loosenthe nut.
34. Coat the threads and seating face of the pulley bolt
with engine oil. Install and tighten to the specified
torque.
Spocifiedtorquo: 22O N'm (22.Okg-m. 159 lb-ft)
6x1.Omm
MIDDLECOVER 12 N.m (1.2 kg-m,9 lb-ft1
I SEALS
AD.'USTINGt{UT
Ii
RUBBER
when
Roplace
damagedor deteriorated.
1Ox 1.25tnm
45 N.m(4.5kg-m,33lb-ft)
RUBBER SEAL
Roplace whgndarn€ged
or deteriorated.
A'LLEY EOLT
-ldl
1 4 r 1 . 2 5m m
220 N.m {22.0 kg-m, 159lb-ft)
Apply engineoil to the
bolt thrsads, but not
to the surfacethat
contacts the washer.
ALTEN ATORBELT
Adiustm€nt,soction23
6x1.Omm
'12N.m(1.2kg-m,I lb-ft}
iili
I
f,
PULLEY
6-114
ValveClearance
Adjustment
NOTE: 3. Adjustvalveson No.1cylinder.

temperatureis lessthan 1oOoF(38oC). Valve Cloalance:
. After adjusting,retorquethe crankshaftpu ey bolt to Intaks: O.15-0.19 mm {0.0O6-0.O07in}
22ON.m (22.Okg-m, 159 lb-ft). Exhaust:O.17-0.21 mm (O.O07-O.OO8in)
1. Removethe cvlinderheadcover. 4. Loosenlocknut and turn adjustingscrew until feeler

gaugeslidesbackandfonh with slightamountof drag.
INTAKE TAPPET
ADJUSTER
o7MAA-PR70'110
2. Set No.l pistonat TDC. "f" markson the pulleys 20 N.m(2.Okg'm, WRENCH
14 tb-ft) oTMAA-PR70120
should be at top. and TDC grooves on the pulleys
shouldalign with cylinderheadssurface.
Tightenthe locknutandcheckclearanceagain.Repeat
Number1 pistonat TDC: adjustmentit necessary.
FEELENGAUGE
TDC MARKS
Alignthe marks
on the pulleys
(cont'dl
6-115
Valve Clearance
Adjustmentlcont'd)
6. Rotate crankshaft 180o counterclockwise(camshaft 8. Rotate crankshaft 18Oo counterclockwiseto bring
"i" marks shouldbe at in-
pullevsturns 9Oo). The "f" marks should be at ex- No. 2 piston to TDC. The
haust side. Adjust valves on No.3 cylinder' take side. Adjust valves on No. 2 cylinder.
Numbd 3 glstonat TDc: Numbrr2 Di.tonat TOC:
,,I,, MARKS
1
I
7. Rotate crankshaft 1800 counterclockwiseto bring

No. 4 pistonto TDC, The TDC groovesare once again
aligned.Adjust valves on No. 4 cylinder.
Number4 Dl.tonat TDC:
li
I
ld
l
I
6-116
EngineBlock
SpeciafToofs ..................................7-2
lllustratedIndex................ .............
7-3
Flywheeland DrivePlate
Replacement ,.........,,..................7-7
ConnectingRod and Crankshaft
EndPlay ..........7-7
Main Bearings
Clearance ....,,..7-g
Selection .........7-9
ConnectingRod Bearings
Cfearance ....,,..7-10
Sefection .........7-11
Crankshaft, BalancerShafts and Pistons
Removal ........,,7-12
Crankshaft
Inspection .......7-15
Pistons
Inspection .......7-16
fnstallation ......7-25
CylinderBlock
fnspection ..,....7-17
Bore Honing lH23A1,H22Al enginesl ................7-18
BoreHoning(F22A1engine)............................... 7-19
Piston Pins
Removal ..........7-19
fnstallation ......7-20
fnspection .......7-21
ConnectingRods
Sefection .,.,,,,..7-2O
Piston Rings
EndGap ...........7-22
Repfacement ,.............,.,........,,...7-23
Ring-to-GrooveClearance ........7-23
Afignment .......7-24
CrankshaftOil Seal
fnstaflation ......7-25
Crankshaftand BalancerShaft Oil Seal
Installation(engineremoval is not requiredl ....7-30
Crankshaft and balancershafts
fnstration ,.......,7-26
BalancerShafts
fnspection .......l-91
SpecialTools
I
R.l. No. I Tool Number D6cripiion Oty I Pag6Rdorence
O I oTcAF- PH6o3oo PistonPin BaseInsert 1-19,20

07GAF- PH7ol00 PilotCollar 7 -19,20
o
O I orcar-seoozoo Hub AssemblyGuideAttachment 7-30
oTHAF-PL2o1o2 PistonBaseHead 7 -19,20
@ |
oTLAD- PT3oloA Se8lOriver 7-30
@ I
@ | o;Lnr - lvootooor RingGearHolder
| 07924- PD20oo3
07746- oo3o3oo Attachment,30 mm l.D. 7-30
O |
07749- ooloooo Driver 1-25,30
@ I 7- 2 5 , 3 0
I
O | 07948-sBoo101 Driver Attachment
07973- PEoo3lo PistonPin DriverShaft 7-19,20
@ |
07s73- PEoo32o PistonPin DriverHead 7-'t9,20
@ |
07s73- 6570500 Piston Ease 7 -19,20
@ |
07973- 6570600 Piston BaseSpring 1-19,20
@ I
t
i
1
l
o o @
1 o @ @
@
!1
ti
t
I
.'
(0 o @
7-2
lllustratedIndex
Lroric"t" "tl inrernalpartswith engineoil during reassembly.

I
6x1.0mm
12 N.m 11.2
OIL SCAEEN
6x1.Omm GASKET
12 t{.m 11.2kg-m. Roplace.
6x1.0mm
12 N.rnlt.2 kg-m,9lb'ftI
BAFFLEPLATE
11 x 1.5mm AEARINGCAP
75 N.rn {7.5 lg-m, BRIOGE
54 tb-ttl
Applyengineoilto the bolt
throada. DOWEL PIN
NOTEr
Aftor torquing o6chcap.
-rx
turn crankshaftto check TOROUECONVERTER
Ior binding. COVERIA/T)
12 x 1.0mm
75 N.m 17.5kg-m,
5t tb-ftl
Torquesequence,
DOWEL PINS page7-7
WASHER
DRIVEPLAIE {A/T)
Checkfor cracks.
CLUTCH COVER
(M/T)
6 t 1 . Om m
12 N.m (1.2 kg-m,
9 rb-ftl
FLYWHEEL 12 x 1.0mm
105N{n (10.5kg-m, 76lb-ft,
Torquesequence,page7-7
(cont'd)
7-3
lllustrated Index
(cont'dl
Luuri"ut""tl internalpartswith engineoil duringreassembly. CRANI€}IAFT

I Endplay,Page7'7
Runout.Tapor 6nd
Out-of-Round,Page7-15
NOTE: Installation,Page7-26
Apply liquid gasketto the mating surfacesot the right
side coverand oil pump casebetoreinstallingthem
Useliquidgasket,part No. 08718- 0001
MAIN BEARINGS
Oilclearance,page7-8
S€lection,page7-9
NOTE:New main boaringsmust
be selectedby matchingcrank and
markings.
blockidentification
I
:l Groovedsidestac€ outward.
NOTE: Thrust washerthicknoss
ll
I 8 x 1.25mm
25 N{n {2.5 kg-m,
is lixed and must not be changed
by grindingor shimming.
CRAI{KSHAFTOIL SEAL
Install6tion,pag* 7-25and 30
18 tb-frl O.RINGS
Replace.
CRANKSHAFT OIL SEAL

psges7-308nd 8-'11
Installation,
Replace.
THRUSTWASHER
RIGHTSIDE @VEB
Apply liquid g88k€tto
AALANCERDRIVEN block mating surface.
GEAR
Gr1.0mm
12Nrn (1.2
9IEftI
I PIN
OIL PUMP
Apply liquid g8skstto
the boft threads.
'Il
S€e page8-9
Apply liquid gssk6t
6x1.0mm to block mating surtace.
12 l$m 11.2kg-m,9 lb"ftl
il Apply liq!id gasketto
the bolt threads.
il
BALANCERSHAFTOIL SEAL
pages7-30and 8-11
Installation,
Reolace.
TIMINGBALANCERBELT
DRIVENPULEY
7-4
OIL JET
Handlethe nozzlewith
OII-JET BOLT care.Do not damage or
ito N.rn {a.0tg-m, 29 lb-ftl detormed.
Inspection,page 8-8
Inspection,page 8-8
H22Al engincl
REARBALANCERSHAFT
End play, p6ge 7-31 BALANC€R SHAFT
Runout.Tapor and BEARINGS
Out-of-Round,psges 7-31,32 page7-31
Insp€ction,
Inst6llation,pag€ 7,26
BETAINER
NOTE: Retainerthicknossis tixed
and must not bs changedby
Orindingor shimming.
\ )
BALANCER
(cont'd)
7-5
lllustratedIndex
lcont'd)
lruri""t" "tl internalpartswithengineoil orr'nn,"u""".b'J;ron
I
INSTALLATIONDIRECTION
NOTE; New rod bearingsmust be selectedby matching EXHAUST

markings
connectingrod and crankshaftidentification
( p a g e s7 - 1 0 1
, l ) .
A ?/ A Ae-l
A
\3 -/ (3 \9,-// \Eo.J
1r;--..l@
ft##**if{*{"}H
\7 \7
INTAKE
'\7 '\r'
PISTON
Removal,page7-12
M6asurement, page7-16
PISTONPIN NOTE:To maintainproperclearance,
Removal,page7-19 matchthe lefter on the piston top with
page7-20
Installation the lettor for eachcylinder stamped on
lnspection,page7'21
the block.
On the pistontop On the block
No letter <- A or I
Bor'l
CONNECNNGROO
Endplay,page7-7 ENGINEBL(rcK
Selection,page 7-20 Cylinderboreinspection, p6oo7'17
Page7-21
Smallend measurement, Warpageinspection,Page7-17
Cylinderborehoning,pag667-18,19
Inspecttop of each cylinder bore
tor carbon build-up or ridge before
removing Pigton.
Removeridge if n6cessary,pagB7.14
CONNECTING ROD
BEARINGS
page7-10
Clearance,
page7 11
Selection,
CONNECNNGRODBEARINGCAP
Installation,page7-26
NOTE:Installcap so the bearingrocessis
on the samesideasthe recessin the rod CYUNDERBORESIZES
(A or l, B or rl)
NOTE: To maintain proper piston
clearance,rnatchthese lefterswith
the letterson the pistons.The letters
on the block readfrom left to right,
CONNECTING RODNUT..-_.-....-__-.} No. 1 throughNo. 4 cylinders.
9 x 0.75 mm
47 N{n (i1.7kg-m, 34 lb-ft, e On the block On the pistontop
A or | --------------- > No letter
After torquing each bearingcaP, B or,l --------------- > B
rotate crankshaftto checklor No.4
binding.
7-6
GonnectingRodand
Flywheel and Drive Plate Crankshaft
Replacement End Play
ManualTransmission: ConnectingRod End Plsy:
Standard (Newl: 0.15- 0.30 mm
Remove the eight flywheel bolts, then separatethe fly- {0.006- 0.012in)
w h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n , SorviceLimit 0.40 mm 10.016inl
tightenthe bolts in the sequenceshown.
CONNECTING
ROO
RINGGEAi
07LAB- PVtDl(x)
or 0792it - PO20O03
BINGGEARHOLDER
07LAB- Pv(xrltx)
or 07924- PD2qr03
. lf out-of-tolerance,install a new connecting rod.

aoo . lf still out-of-tolerance,replacethe crankshaftlpages
\o; 7-11and7-26]..
Pushthe crankshaftfirmly away from the dial indicstor.

and zerothe dial againstthe end of the crsnkshaft.Then
pull the crankshaftfirmly backtoward the indicator;dial
readingshouldnot exceedservicelimit.
Inspgctring gear 12x 1.0mm

teoth for w6ar or damage. 105 N.rn 110.5kg-m, tG lb-ft,
AutomaticTransmission:
Removethe €ight drive plate bolts, thon separatethe
drive platefrom the crankshaftflange.After installation.
tightenthe bolts in the sequenceshown.
SCREWDRIVER
CrankshaftEnd Phy:
Standard lNqwl: 0.10- 0.35 mm
(0.004- 0.014in)
/ AXid-*a\Ao Ssrvice Limit 0.45 mm {0.018inl
. lf end play is excessivethan the servicelimit, inspect

the thrust washersand thrust surfaceon the crank,
shaft.Replacepartsas necessary.
NOTE:Thrustwasherthicknessis fixed and must not be

changedeitherby grindingor shimming.
Thrust washersare installedwith groovedsidesfacing
outwaad.
7-7
Main Bearings
Clearance
L T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
removethe main capsand bearinghalves
L C l e a ne a c h m a i n i o u r n a l a n d b e a r i n gh a l f w i t h a
cleanshoptowel. STRIP
PLASTIGAGE
l. Placeone strip of plastigageacrosseach main jour-

nal.
NOTE:lf the engineis still in the car when you bolt

the main cap down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plastF
gage further than just the torque on the cap bolt.
and give you an incorrectreading.For an accurate
r e a d i n g ,s u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e
c o u n t e r w e i g h t as n d c h e c ko n l y o n e b e a r , n ga t a
time.
4. R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e
bolts.
75 N.m {7.5kg-m,54lb-ft) lf the plastigagemeasurestoo wide or too narrow,

(removethe engine if it's still in the car). remove
NOTE:Do not rotatethe crankshaftduring inspec- the crankshaft,and remove the upper half of the
tron. bearing.Install a new, complete bearingwith the
same color code (selectthe color as shown on the
5. Removethe cap and bearingsagain,and measure next pags),and recheckthe clearance.
the widest part ot the Plastigage.
CAUTION: Do not fi16,3him, or 3crapoth€ b.arings
Main Bearing-to-JournalOil Clearance: or the caps to adiu3t clearance.
Siandard {Newl:
No. 1. 2: 0.021- 0.0i15mm 7 . lf the plastigageshows the clearanceis still incor-
{0.(xn8 - 0.0018in) rect,try the next largeror smallerbearing(the color
SqrviceLimit 0.050mm (0.0020inl listedaboveor belowthat one),and checkagain.
No. 3 0.025- 0.0,19mm
{0.0010- 0.0019in} NOTE: lf the groper clearancscannot be obtained
ServiceLimii: 0.055mm 10.0022inl by usingthe appropriatelargeror smallerbearings,
No. 4 0.013- 0.037mm reDlacethe crankshaftand startover.
10.0005- 0.d115in)
ServiceLimit: 0.050mm {0.1X120 in)
No. 5 o.(xlg- 0.033mm
(0.0004- 0.0013in)
ServicaLimii: 0.040mm (0.0015inl
7-8
Selection
CAUTION: lf the codes ars indecipherabls b€causo of Main Journal Code Locations
an accumulationof dirt and dust, do not scrub them (Numbers or Bars)
with a wiro brush or scraper,Cleanthgm onlv wiih sol.
vent or .tot€rgont. H22Al engine:
CrankshaftBors Code Location

{Numbers,Lettgrs or Bars} Main JoumalCodeLocationslNumbersor Ba'sl
Numbersor Lettersor Bars have been stampedon the

end of the blockas a code for the size of each of the 5
main journalbores.
Use them, and the numbersstampedon the crankshaft
(codesfor main journalsize),to choosethe correctbear-
Ings.
H23A1.F22Al engines:
The Main Journal Codesare stampedin one of the fol-
lowing locations.
Main Jou.nalCodoLocations(Numbalsor Bar3)
No. 5 JOURNAL
IPULI.TYEND} {FLYWHEEL ENDI
BcaringDosign
PROJECTION
LOWER
Berring ldentitication ---------------- Largercrankbore Main Journrl Coda Locationi {Numbersor Br.!}
Colorcodeis on the
edgeofthe bearing. No. 5 JOURNAL No. 1 JOURNAL
----------> Smaller bearing (Thicker) IFLY WHEELENDI (PULLEY ENDI
No. 1 CRANK WEB
Smaller Smaller NOTE:When usingbearinghalvesof

main bearing different colors, it does not matter
iournal (Thicker) whichcolor is usedin the top or bottom.
GonnectingRod Bearings
Clearance
Removethe connectingrod cap and bearinghalf. lf the plastigagemeasursstoo wide or too narrow,
removethe upper half ot the bearing,installa new,
Cleanthe crankshaftrod journal and bearing half complete bearing with the same color code (select
with a cleanshoptowel. the color as shown on the next page),and recheck
the clearance.
Placeplastigageacrossthe rod journal.
CAUTION: Do not file, shim, or scrapothc boaring3
Reinstallthe bearing half and cap, and torque the or tha cap3to adiust cloaranc€.
nutsto:
1. lf the plastigageshows the clearanceis still incor-
47 N.m (4.7 kg-m, 34 lb-ft) rect,try the next largeror smallerbearing(thecolor
listed above or below that one), and check clear-
NOTE:Do not rotatethe crankshaftduring inspec- anceagarn.
tion.
NOTE: lf the proper clearancecannot be obtained
5. Removethe rod cap and bearinghalf and meassure by usingthe appropriatelargeror smallerbearings,
the widestpart of the plastigage. reolacethe crankshaftand startover.
ConnectingRod Bearing.to.Journll Oil Clearsnce:

P'AAI €ngin6:
Standard (Newl: 0.021- 0.049mm
10.0008- 0.0019in)
Servic€Limh: 0.05 mm (0.002in)
H23A1,ll22Ai enginos:
Standald {Newl: 0.027- 0.055mm
(0.0011- 0.0022inl
Ssrvice Limh: 0.06 mm (0.002in)
PLASTIGAGESTRIP
iI
H
t;,
ili
tit
il
it;
'll
:'l
I!:
7-10
Selection
CAUTION: lf th6 cod6s aro indscipherable because of Conn€qtingRod Journal Code Locations
an accumulationof dirt and dust, do not scrub them (Lettersor Barsl
with a wirg brush or licrapor.Clsan them only with sol
v6nt or detergent. H22A1engine:
ConnectingRod Journal Code Locations

{Numbersor Bars) ConnectingRod Journal Code Locliion! lLstterr or BrBl
N u m b e r so r B a r s h a v e b e e n s t a m p e do n t h e s i d e o f
each connectingrod as a code for the size of the big
end. Use it, and the lettersor barsstampedon the crank
lcod€sfor rod journal size),to choosethe correctbear-
ings,
H23Al, F22Al cngincs:

The ConnectingRod Journal Codesare stampedin one
Halfot numberor bar ol the followinglocations. ..,:-.
is stampedon bearingcap
and the otherhalf is
stampedon rod
ConnoctingRod Journrl Codo Locltion3 {Latta'3 or B!1!}
BoaringD6i9n
PBOJECTION
ConnectingRod Journd Coda Location3llatta.3 or B.rrl
No. 5 JOURNAL No. 1 JOURNAL

Eoaring ldantif ication .---..-----+ Largerbig end bore IPULTIY END}
Colorcodeis on the
edgeol the bearing.
+ Smallerbearing(Thicker)
Elue
No. I CRANKWEB
Smaller Smaller
rod bearing
journal lThicker)
Grankshaft,BalancerShaftsand Pistons
Removal
1. Removethe right side cover. 3. Removethe front balancordrivenpulleyas thown.
BALANCER
DOWELPIN DF]VENPULEY
MANTE'{ANCEHOI€
;
I
I
) SCREWT'RIVER
I
t1 Align the bolt hole and the bslancershaft hole.thon
il
;l
insert a 6 x 100 mm bolt to hold the rear balsncsr
shaft.
2. Removethe balancergearcase.
Ii Removeth6 bolt and the balancordrivengs8r.
REARBALA]IIGEB
DOU'ELPIN SHAFT
8 x 1.25mm
25 N.m 12.5kg-m, 18lb-ft)
6 x lm .nm BOLT
va mm {2.9inl
BALANCER DOWELPIN
GEARCASE
REARBALANCERSHAFT
7-12
R€movethe oil screenand the oil pump. 8. Removethe bolts and the bearingcap bridge,then
removethe bearingcaps.
7. Rsmov€the baffle plate.
CAUTION: To provent wsrpago. un3crew tha bolts
in loqucnc€ 1/3 turn at a timc; ropcst tho srqucnco
until rll bolt3 are loosGnod.
o|LscaEE BAFFLEPLATE
MAIN BEARINGCAP BOLTSLOOSENINGSEOUENCE
7-13
Grankshaft,BalancerShaftsand Pistons
Removal(cont'dl
9. Turn the crankshaftso No. 2 and 3 crankpinsare at 15. lf you can teel a ridge of metal or hard carbon
the top. around the top of each cylinder,remove it with a
ridge reamer. Follow the reamer manufactursr's
1 0 . Removethe rod caps/bearings and main caps/bear- instructions.
in order.
ings.Keepall caps/bearings
CAUTION: lf the ridgo k not rcmoved, h mly dtm-
1 1 . Lift the crankshaftout of the engine,being careful ag6 the pistons a! thcy lrc purhod out.
not to damagejournals.
Use the wooden handle of a hammer to drivo the

pastonsout.
CRANKSHAFT
CAUTION:
. Tako caro not to dtmago thc contlct turflcc of
tho motal g.!kot.
. Whan romoving thc pirton/connactlng rod trka
'12. Removethe bolts and the retainer.then removethe cara not to hit thr oil irt (H22Al cngine onlyl.
. It th. oil ict nozzlo is drmlg.d or d.formld, rr-
front balancershaftand the rearbalancershaft.
placo the oil iet .srombly {H22Al .ngin. only,
page 8-81.
't1. Reinstalltheconnectingrod bearingsand capsaftor

RETAINER removing each piston/connectingrod assombly.
1 3 . Removethe upperbearinghalvesfrom the connect- 1 8 . Mark each piston/connectingrod 8ss€mbly with its
ing rods and set them aside with their respective cylindernumberto avoid mixup on .eassembly.
caps.
NOTE:The existingnumbsr on the connsctingrod
1 4 . Reinstallthe main caps and bearingson the engine does not indicateits positionin the engine,it indi-
in properorder, catesthe rod bore size.
Crankshaft
Inspection
C l e a n t h e c r a n k s h a f to i l p a s s a g e sw i t h p i p e Out-of-Roundand Taper
cleanersor a suitablebrush.
Checkthe keywayand threads, o Measure out-of-round at the middle of each rod
and main journalin two places.
Alignment . The differgncebetyveenmeasurementson each
journalmust not be more than th€ servic€limit,
a M e a s u r er u n o u t o n a l l m a i n i o u r n a l st o m a k e
surethe crankis not bent, Journal Oui-ot.Round:
. The difference between measurementson each Standa.d (Ncw): o.qE mm {0.0002in}
journalmust not be more than the servicelimit. SorvicoLimit: O.q)6mm (0.0002inl
CrsnkehaftTotal lndicatod Runouti

Standard (N€w): 0.03 mm (0.001in)
Ssrvico Limit: 0.04 mm (0.002in)
DIALINDICATOR
Rotatecrankshafttwo
compteterovolutions.
M6asursin two
pl6cesat middl€.
Suppon with lathe- Measu16 taper

type tool or V-blocks. near edg€s.
Measuretaper at the edge of each rod and main

journal.
The difference between measurementson each
journalmust not be more than the servicelimit.
Journal Taper:
St.ndrrd (Now): 0.005mm (O.(xXr2int m!x.
Scrvicc Limit 0.006mm (0.(xn2 in)
Pistons
Inspection
Checkthe Distonfor distonionor cracks. C a l c u l a t et h e d i f f e r e n c eb e t w e e nc y l i n d 6 r b o r e
diameteron (page7-17)and pistondiamet6r.
NOTE:lf the cylinderis bored,an oversizedpiston
must be used. Pbton-to-CvlinderClsrranco:
F22Al engine:
Measurethe piston diameterat a point F22A1:21 mm Standard (N€w): 0.020- 0.0/(, mm
(0.8in),H23A1,H22A1:15mm (0.6in)from the bottom l0.00oB- 0.0016in)
of the skirt. ServiceLimil: 0.05 mm {0.002in)
e i s t o n s( N o
N O T E :T h e r ea r e t w o s t a n d a r d - s i zp H2341,H22A1engines:
Letter(A) or B). The letteris stampedon the top of Standard (Newl: 0.007- 0.030mm
the piston. There letters are also stamped on the (0.0003- 0.0012in)
blockas cylinderbore sizes. SorviceLimit: 0.04 mm (0.002inl
Piston Diameter:
F22Al engine:
Standard lNewl:
No Letter lA): 8i[.980- 8i1.990mm
(3.3457- 3.3451inl
B: 84.970- 84.980mm
13.3453- 3.3,157in)
ServiceLimit:
No Letter {A}: 8i0.970mm (3.3453in}
B: 84.950mm (3.3449in)
H23A1,H22A1enginss:
Standard lNewl:
No Letter (A): 86.990- 87.003mm
(3./1248- 3.4253inl
B: 86.980- 86.993mm
- 3.42,19inl
{3.,[2/14
ServiceLimit: lf the clearanceis near or excesdsthe servicelimit,
No Lettor {A}: 86.980mm {3.,12,14 inl inspectthe piston and cylinderblockfor excessive
B: 86.970 mm (3.,[2'10in] wear.
F22Al sngino: SKIRT

DIAMETER
OvorsizePiston Diamoter:
21 mm 10.8inl
F22A1engine:
0.25:85.230- 85.2/0 mm {3.3555- 3.3559in}
0.50:85.,180- 85.tlln mm {3.3653- 3.3657in}
H23A1.H22Al rngin.3:
O.25t87.230- 87.2,(l mm (3./8/02- 3.,13{8in)
4. Checkthe piston pin-to-pistonclearance.Coat ths

piston pin with engineoil. lt should then be possi-
ble to push the piston pin into the piston hole with
thumb Dressure,
Piston Pin-to Piston Clctrtnco:

F22Al engine:
Standard (Newl: 0.012- 0.02amm
(0.fi)05- 0.qt0o in)
H23Al, H22Al ongines:

Standard {N€w}: 0.012- 0.026mm
10.000t- o.(XllOin)
7-16
CylinderBlock
Inspection
1 . M e a s u r ew e a r a n d t a p e r i n d i r e c t i o nX a n d Y a t Boro Taprr:
three levelsin eachcvlinderas shown. Limil: {Diftorcncabotw.on lirst snd third
6 mm 10.2in) maasuromcntl 0.05 mm {0.002inl
Firrt . l f m e a s u r e m e n t si n a n y c y l i n d e r a r e b e y o n d
Ma!!urcmant OversizeBore ServiceLimit, replacethe block.
w
S.cond . l f t h e b l o c k i s t o b e r 6 b o r e d ,r e f e r t o P i s t o n
Mar!uramcnt Clearance Inspection(page7-16)afterreboring.
Third
Mer3uramant NOTE: Scored or scratch€dcylinder bores must be
6 mm 10.2inl honed.
F22Al engine: 0.50 mm (0.020inl

H2341,H2/IA1rngincr: 0.25 mm (0.010inl
2, Checkthe top of the block for warpage.

Measurealong the edgesand acrossthe centeras
snown.
SUNFACES
TO BEMEASUBED
CYLINDERBORESIZES
lA or I, B or rll
Readth€ l€tterstrom lelt-to'right
for No. 1 throughNo.4 cylinders.
CYLINDER
BONE
Enginc Block W..prge:

Stlndlrd {Ncw): bclow 0.07 mm (0.003in}
Cylindcr Boro Size: S.rvico Limit: 0.10 mm (0.(Xt4inl
F22Al engino:
Stendlrd (Ncw): PRECISIONSIRAIGHT EDGE
A or l: 85.010- 85.020mm {3.3458- 3.3/t?2in)
B ot ll: 85.000- 85.010mm (3.3i165 - 3.3i168in)
Sorvicr Limit: 85.070mm (3.3492in)
H23A1,HPAI ongines:
Stlndffd {Now,:
A or l: 87.010- 87.020mm {3.4256- 3.4260in)
I or ll: 87.000- 87.010mm (3.'1252- 3.i1256in)
Srrvicc Limit: 87.070mm {3.i|:l79inl
OvoEizo:
F22Al cngino:
0.25:85.250- 85.260mm (3.356:t- 3.3569inl
0.50:85.500- 85.510mm {3.3661- 3.3665in)
H2341, H22Al 6nginsr:
0.25:87.260mm 13.4:l5i[inl
7-1
CylinderBlock
BoreHoning(H2341,H2241engines)
l. rbv^ ,,
CAUTION: Thir cylinder linor ussr FRM (Fiber 3. W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a nt h e

ReinlorccdMatall. Hono only !s diroctod below. cylinderblockof all metal particles.Washthe cylin-
der bores with hot soapy water. then dry and oil
1. M€asurecylinderboresas shown on page7-16. immediatelyto preventrusting.
It the block is to be reused,hone the cylindersand
remeasurethe bores, NOTE: Never use solvent, it will only redistribute
the grit on the cylinderwalls.
2. To honecylinderbores;
. Useonly a rigid hone. 4. lf scoring or scratchgsare still presentin cylinder
. Honingstone: GC- 600- J or finer stone boresafter horningto servicelimit, reborethe cylin-
(for nonf6rrousmetals) der block.
. Pressure: 2OO- 3OOkP;
(2-3 kg-cm', 28 - 43 psi) NOTE:Some light verticalscoringand scratchingis
. Honingrpm: 45 - 50 rpm acceptableif it is not deepenoughto catchyour fin-
. Honingthickness;Lessthan 0.02mm (0.0008in) gernailand does not run the full lengthof the bore.
Do not hone mote than
20 cvcl€s
. Honinglubricant Oil type
. Roughnessof
finishedsurfaces:VVV or 1.2S
. Honingpattern: 60 degr€ecross-hatch
CAUTION: Cloantho honing stono oyory 5 cyclos.

PistonPins
BoreHoninglF22A1enginel Removal
Measurecylinderboresas shown on page7-16. Assemblethe PistonPin Toolsas shown.
lf the block is to be reused,hone the cvlindersand
rem€asurethe bores. PISTONSASEHEAD
OTHAF-PUM102
Honecylinderboreswith honing oil and a fine (400
grit) stone in a 60 degree cross-hatchpattern, PISTON PIN BASE INSENT
OTGAF- PHq'3U'
NOTE:
. Use only a rigid honewith 400grit or finer stone
suchas Sunnen,Ammco,or equivalent.
. Do not use stonesthat are worn or broksn.
tl
PFTONBASE
0tt3 - 65t0500
Adjust the length A of the piston pin driv8r.

A: 51.5 mm (2.G1inl
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
engine block of all metsl particles.Wash the cylin-
der bores with hot soapy water, then dry and oil PISTON PIN DRIVERHEAD
immediatelyto preventrusting. 0t9t3 - PE|D320
NOTE; Never use solvent, it will only .edistribute

the grit on the cylinderwalls.
\
lf scoring or scratchesare still presentin cylinder R
bores after honing to the servicelimit, rgbore the l l
cvlinderblock.
H
trl-
PISTOI{PII{ DRlvENSHAFT
or9r3- Fdto3ro
NOTE:Some light vsrticalscoringand scratchingis
u
m--.--
acceptableit it is not deep enough to catch your fin-
g€rnailand does not run the full lengthof the bore. PILOTOOLLAN
o'GAF- PHt0100
Emboesed
marklacingup.
CYLINDEBHONE
NOTEiUEea hydraulicpro6s.
When prossingpin in or out,
make sure that th€ rgco$ad
ponionofthe pistonoligns
with tho liD3on th€ collar.
NOTE:
. After honing,cleanthe cylinderthoroughlywith
soapy water.
o Only a scored or scratchedcylind€r bore must be Placeths piston on the piston base and pressthe
honed. pin out with a hydraulicpress.
7-19
ConnectingRods PistonPins
Selection lnstallation
Each rod falls into one of four toleranceranges(from 0 1. Usea hydraulicprossfor installation.
to 0.024mm {0.0009in), in 0.006mm (0.0002in) incre-
ments) dependingon the size of its big end bore. lt's . Wh6n pressingthe pin, in or out, bo sureto posi-
then stampedwith a numberor bar \'1,2,3, ot 4ll, t, ttl, tion ths recessodtlat on the piston againstthe
or Irl) indicatingthe range. lugs on the base8ft8chment.
'1,2,3, ot 4/1,t, ttl,o(
You may find any combinationoI
Irl in any engine.
Normal Boro Sizr: 51.0 mm (2.01in) The arrow must laco the
timing belt side of the
6nOine.
NOTE:
Refer€nc€numbersor bars are for big end bore
sizeand do not indicatethe positionof th€ rod in
the engine.
Inspectconnectingrod for cracksand heat dam-
age.
CONNECTING RODBORE Tho ma* must faco

BEFEBEITCE NUMBERoi BAR the timing beltsid6
Half ot number is sttmpsd on ol th6 engin6.
bearingcap, ths other half on
connectingrod.
2. Adjust the length B of the piston pin driver.

B: 51.5mm (2.G1in)
PISTONPINDRTVER
HEAO
- PEqB2o
0797:1
PISTONPIIIIDBIVERSHAFT
07973- PE00310
Emboss€dmark
I
ffi*r,"ron'n
PILOTCOLLAR
07GAF- PH701d)
Inspgctbolts
and nuts for
strogscracks.
PISTONPIN BASE NSEBT

07GAF- PH6o3q)
PISTONBASE HEAD
07HAF- P120102
PISTONBASE
07973 - 6705{X'
NOTE: Installthe assembledpiston and rod with

t h e o i l h o l e f a c i n g t h e i n t a k em a n i f o l d ( E r ( c e p t
H22A1enginel.
7-20
PistonPins
Inspection
Measurethe diameterof the pistonpin. Measurethe pistonpin-to-piston
clearance.
Pbton Pin Diamoter: NOTE:Checkthe pistonfor distortionor cracKs.

Standard (Nawl: 21.994- 22.(XX'mm
(0.86s9- 0.8561inl l f t h e p i s t o n p i n c l e a r a n c ei s g r e a t e rt h a n F 2 2 A 1
Ov6rsizg: 21.997- 22.003mm e n g i n e : 0 . 0 2 4 m m { 0 . 0 0 0 9i n ) H 2 3 A 1 ,H 2 2 A 1
{0.8560- 0.866:linl engines:0,026mm (0.0010in), remeasureusing an
oversizepistonpin.
NOTE:All replacementpistonpins are oversize.
Piston Pin-to.PistonClearanco:
F22A1engine:
Standird (Ncw): 0.012- 0.024mm
{0.0005- 0.q)(xt in,
H2341, H22Al ongines:

Stlndsrd lNewl: 0.012- 0.026mm
2. Zerothe dial indicstorto the DistonDindiameter. 4. Checkthe diferrencebetweenpiston pin diameter

and connectingrod smallend diameter.
Pbton pin-to ConnoctingRod Interfa.oncs:

Standa.d (Ncwl: 0.013- 0.032mm
{0.00OS- 0.0013in)
7-21
PistonRings
EndGap
1. Using a piston, push a new ring into th€ cylindor
'15
bore - 20 mm {0.6- 0.8 in) from the bottom.
M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l € r
gauge:
lf the gap is too small,checkto see if you have

the properringsfor your engine.
lf the gap is too large,recheckthe cylinderbore

diameteragainstthe wear limitson page7-17.
lf the bore is over the servicelimit, the cylinder
blockmust be rebored. I
Pistoo Ring End-Gap:
F22Al ongio€:
PISTONRING iiii
r.---iLi.i----
Top Ring
Standard (Newlr 0.20- 0.35 mm
(0.008- 0.014in)
SorvicoLimil: 0.60 mm 10.024in)
S€condRing
ENDGAP
Slandard {N6wl: o.i(t - 0.55 mm
(0.015- 0.022inl
SorviceLimh: 0.70 mm (0.028inl
Oil Ring
Standard (Newl: 0.20- 0.70 mm Ovg6izo:
{0.008- 0.028in} F22Al lnginel
Servic€Limit 0.80 mm (0.03'linl 0.25185.25mm (3.356inl
0.50:85.50mm (3.366inl
H23A1,H22Al engine3:
Top Ring H23A1. H22Al .nginc:
Standard {New): 0.25- 0.35 mm 0.25:87.25mm (3.i|il5inl
10.010- 0.014in)
SorvicaLimit: 0.61tmm (0.02'lin)
Socond Ring
Standard (N6w): 0.60- 0.75 mm
10.02,t- 0.030in)
ServiceLimit: 0.90 mm {0.035inl
Oil Ring
Stsndard (Newl:
TEIKOKUPISTONRINGmanufacturs:
0.20- 0.50 mm (0.fi)8 - 0.020inl
RIKENmanufacture:
0.20- 0.70 mm (0.008- 0.028inl
S€rvics Limit:
TEIKOKUPISTONRINGmanutactur€:
0.60 mm (0.02i1in)
RIKENmanutaqture:
0.80mm (0.031in)
7-22
Replacement Ring-to-Groove
Clearance
1. Usinga ring expander,removethe old pistonrings, After installinga new set of rings. measurethe ring-to-
grooveclearances:
2. Cleanall ring groovesthoroughly.
Top Ring Cl€arlnc6
NOTE: Standard (New): 0.035- 0.060mm
. U s e a s q u a r e d - o fbf r o k e nr i n g o r r i n g groove {0.0014- 0.002,tinl
cleanerwith bladeto fit pistongrooves. SorvicoLimit: 0.13 mm (0.005in)
. Top and 2nd ring groovesare 1.2 mm ( 0 . 0 5i n )
wide and the oil ring groove is 2.8 mm ( 0 . ll i n ) Second Ring Clsaranco
wide. Standard (Now): 0.030- 0.055mm
. Filedown bladeif necessarv. (0.fl)12- 0.fl122inl
SorvicoLimit: 0.13 mm (0.005inl
CAUTION: Dq not uss a wire brush to clean the ring
groovgs, or cut ring groove3 d9€per with cloaning
tools.
NOTE:lfthe pistonis to be separatedfrom the con-
nectingrod, do not installnew ringsyet.
Installnew rings in the proper sequenceand posi-

tion (page7-24).
NOTE:Do not useold pistonrings.
RINGEXPANDER
PistonRings
Alignment
I
1 , lnstalltheringsas shown. Rotatethe rings in their groovesto make sure they
do not bind.
ldentifyrop and secondrings by the chamferon the
edge.Makesurethey are in their propergrooveson
the paston. MARK
TOP RING
NOTE: The manufacturingmarks must be facing

upwaro.
SECONDRING
3. Positionthe ring end gsps 8s shown:
DO NOT position any rinOgap

SECONDRINGGAP at piston thrust surfaces.
H23A1,H22Al onginos:
Approx.90'
OIL RING
Appiox. GAP
90"
TOPRINGGAP GAP
DO NOT posilion any ring gap

in linewith the oistonoin hole. OIL RINGGAP
CrankshaftOil Seal Pistons
;I Installatio lnstallation
| .11 The sealsurfaceon the blockshouldbe dry. B e f o r e i n s t a l l i n gt h e p i s t o n , a p p l y a c o a t o f

'E
| Apply a light coat of oit to the crankshaftand to engine oil to the ring groovesand cylinder
the lip of the s6al. bores.
l. Drivein crankshaftoil sealagainstright sidecover. 1. ll the crankshaftis alreadyinstalled:

. Setthe crankshaftto BDCfor eachcvlinder.
NOTE:Drivethe crankshaftoil sealin squarely. o Removethe connectingrod caps and slip short
sectionsof rubber hose over the threadedends
DRIVER of the connectingrod bolts.
07749- 0or(xDo . Installthe ring compressor,checkthat the bear-
ing is securelyin place,then position-thepiston
in the cylinder and tap it in using the wooden
handleof a hammer.
a Stop after the ring compressor pops free and
checkthe connectingrod-to-crankjournal align-
ment beforepushingpistoninto place.
. Installthe rod capswith bearings,and torquethe
nutsto:
47 N.m {4.7kg-m.34lb-ft)
2. lf the crankshaftis not installed:
Installsealwith the . Removethe rod caps and bearings,install the
part number sid6 nng compressor,then positionthe piston in the
facingout. cylinderand tap it in usingthe wooden handleof
a nammer.
. Positionall pistonsat toD deadcenter,
DRIVEBATTACHMCNT
079ir8- SBlXtl01
The arrow must tace the
timing beltsideot the
C o n f i r m t h a t t h e c l e a r a n c ei s e q u a l a l l t h e w a y engine.
aroundwith a feelergauge.
Cloarancc:0.5 - 0.8 mm (0.02- 0.03 inl
The mark muBttace

the timing beltside
RIGHTSIDE of the engine.
COVER
NOTE:Maintaindownward force on the ring com-

0.5 - 0.8 mm p r e s s o rt o p r e v e n tr i n g s f r o m e x p a n d i n gb e t o r e
enteringthe cylinderbore,
Usethe wood€nhandle
of a hammorto push,or
NOTE:Referto pages7-30and 8-11for installation

of the oil pump sidecrankshaftoil sear.
Grankshaftand BalancerShafts
lnstallation
Betoreinstallingthe crankshaft,apply a coat of 6. Installthe thrust washers,main bearingcaps and

e n g i n eo i l t o t h e m a i n b e a r i n g s .r o d b e a r i n g s bearingcap bridge.
and balancershaft bearings. Check clearancewith plastigage(page 7-8), then
tightenthe bearingcap boltsin 2 steps.
Insertbearinghalvesin the cylinderblockand con- ln the first step tighten all bolts in sequence,to
nectingrods. about 30 N.m (3.0 kg-m, 22 lb-ft);in the finsl step
tighten in same sequenc€,to 75 N.m {7,5 kg-m.54
Holdthe crankshaftso rod journaisfor cylindersNo. tb-ft).
2 and No,3 are straightup.
NOTE:Coatthe bolt threadswith engineoil.
Lowerthe crankshaftinto the block,seatingthe rod
journalsinto connectingrods No. 1 and No. 4.
lnstallthe rod capsand nutsfingertight.
CAUTION: Whlnovor any crankshaft or connccting

rod baaring i3 roplacad, it ir nocosarY lftcr lc!s-
scmbly to lun tho cngin. Ei idling tpoed until it
RODNo. 2 WASHERS RODNo. a rcacho! normal opcrrting iamporltula. thcn Gon.
tinue to run it lor approximataly 15 minut6.
7. Insenthe balancershaftsinto the block,then install

Rotatethe crankshaftclockwise,seat journals into the retainerto the front balancershaftand block.
connectingrods No, 2 and No.3, and installthe rod
I capsand nuts fingertiqht.
I
NOTE:Installcaps so the bearingrecessis on the
\ sameside as the recessin the rod.
'l
Checkrod bearingclearancewith plastigage(page
7-10),then torquothe capnuts.
47 N.m (4.7kg-m.34lb-ft)
NOTE: Referencenumbers on connectingrod are

for big-endbore toleranceand do not indicatethe
positionof pistonin the engine.
7-26
NOTE:
. Useliquidgasket,parrNo.087t8-0001.
Apply liquidgasket
. Checkthat the matingsurfacesare cleanand dry to block mating surface.
beforeapplyingliquidgasket.
. Apply liquidgasketevenly,beingcarefulto cover
allthe matingsurface.
. To preventleakag€of oil. apply liquid gasketto
the innerthr6adsof th6 bolt holes,
. Do not install the parts if 20 minutes or more
haveelapsedsinceapplyingthe liquidgasket.
Insteadreapplyliquid gasketafter removingthe
old residue,
. After assembly, wait at least 30 minutes before
filling th6 enginewith oit.
6 x 1,0 rnm
12 N.m (1.2 kg'm, 9 lb-ft)
8. Apply liquid gasket to the block mating surfaee of Apply liquid gasket RIGHTSIDECOVER
the right side cover, then install it on the cylinder to the bolt threads.
block.
BIGHTSIDECOVER:
9. Apply liquid gaskstto the oil pump mating surfac€
of the block,then installthe oil pump on the cylin-
der block.
. Apply greaseto the lips of the oil seals.

T h e n , i n s t a l lt h e o i l p u m p w h i t e a l i g n i n gt h e
inner rotor with the crankshaft.When the pump
i s i n p l a c e , c l e a n a n y e x c e s sg r e a s e o f f t h e
crankshaftand the balancer shaft, then check
that the oil se8llips are not distorted.
OIL PUMP:
Apply liquid gaskst along

the broken line.
{cont'd)
7 -27
Crankshaftand BalancerShafts
Installation (cont'd)
12. Holdthe rearbalancershaftwith a 6 x 100mm bolt,

then installthebalancerdrivengear.
OIL SCREEN
6x1.0mm REAFBALANCERSHAFT:
12 N.m (1.2kg-m,9lb-ftl
8 x 1.25mm
25 N'm {2.5 kg-m, 18 lb-trl
O.RINGS
Applyengineoil. 6 r lOOmm BOIT
Replace.
DOWELPIN 74 mm 12.9inl
6x1.0mm
12 N.m 11.2kg-m, OIL PUMP
9 tb-ft) Applyliquidgasketto
Applyliquidgasket block mating surface.
to the bolt threads. Applygreaseto the seallips.
REARBALANCERSHAFT
10. Installthebaifleplate,then installtheoil screen.
'11. Apply molybdenumdisulfideto the thrust surfaces
of the balancergears as shown, before installing '13. Hold the front balancershaft with a screwdriver,
t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
then installthetiming balancerbelt drivenpulley.
case.
Applymolybdenum FRONTBALANCERSHAFT:
disutfide. EALANCER SHAFT
DRIVEN
BALANCERBELT BALANCERDRIVEGEAR
DRIVENPULLEY AALANCERGEAR CASE
7-28
14. lnstallthebalancargea|.caseto the oil pump. 16. Install the oil pan.
NOTE:Align the groovo on the pulley sdg€ to the

pointoron the gear casswhile holdingths rear bal- OIL PAN GASKET Apply liquid
ancer with 6 x 100 mm bolt, then install the gear Replace. gasketto here.
casg.
DOWELPIN
E x 1.25mm
25 N.rn 12.5lg.m.
18 rb-ft|
O.RING
Applyengineoil,
BALAI{CER DOWELPIN Roplace.
GEAR$SE WASHER 6xl,0mm
Replace. 12 N.m {1.2kg.h,
POINTEB 9 rb-ft}
Alignthe groov€
to pornter. 45N.m(4.5kg.m.
33tb-ftt
Donot overtighten,
1 1 . Tightenthe boltsand nuts as shown below,
Torqu.: 12 N.m (1.2 kg-m, 9 lb.ft)
GROOVE
Checkalignmentof pointersafter installingthe gear

case.
POINTER
ONTHEPUL1TY
NOTE:Tightenthe bolts and nuts in two stoosand

torquethem in a criss-cross
pattern.
7-29
Crankshaftand BalancerShaft Oil Seals
Installation{engineremovalnot requiredl
NOTE:The crankshaftand front balancershaft 3. Using the specialtool, drive in the crankshaftoil
oil sealhousingsurfaceshouldbe dry. seal into ths right side coverto the point where the
Apply a light coat oJgreaseto the crankshaft,the clearancebetween the bottom of the crankshsft oil
balancershaftand to the lips ot the seals. seal and right side cover is 0.5 - 0.8 mm (0.02-
0.03in) lpage7-251.
Using the specialtool, drive in the crankshaftoil
sealuntil the driverbottomsagainstthe oil pump. NOTE:Align the hole in the driver attachmentwith
When thg seal is in place.clean any excessgrease the pin on the crankshaft.
off the crankshaftand checkthat the oil seal lip is
not distorted.
SEALDRIVER - (x)1|xno
07749
O'LAD - PI':IOIOA
lnslall se6l with the
part number sido
facing out.
DRIVERATTACHMEMT
079a8- SB@r01
lnstollsealwiththe
part number side
2, Using the specialtool, d.ive in the front balancer facing out.
shaft oil seal until the driver bottomsagainstthe oil
pump. When the seal is in pl8ce,clean any excess
greaseoff the balancershaft 8nd checkthst the oil
I sealliDis not distorted.
HUBASSEMBLYGUIDE ATTACHMEITT,
ATTACHMENT 30 mm l.D.
OTGAF_ 077t6 - @30300
7-30
BalancerShafts
Inspection
NOTE: Inspectthe balancershaft before removingthe Removethe balancershafts(page7-12).
right sidecoverand the balancergearcase{page7-12).
'1. NOTE:Cleanthe balancershsfts,

Push the balancershaft firmly away from the dial
indicator,and zerothe dial againstthe front end of Inspectthe surfaceof the balancershaftjournaland
the balancershaft,then pull the balancershaftfirm- balancerbearing.
ly backtoward the indicator.
Replaceif there is wear,damageor discolorationon
Froni BalancorShaft End Play the surfaceof the bearingor the balsncershaftjour-
Standard (Nsw): 0.10- 0.35 mm nal. When replacingthe rear No. 1 bearingbe sure
l0.00il- 0.014in) to replacethe oil pump housingwith a new one.
NOTE;A mirro.-likesurfaceis normat.
Measuretaperat the edgesof eachjournal.
. The differencebetweenmeasurementson each

lournal.
Journal Tapor
Standard (Newl: 0.005mm (0.0002in)
. lf end play is excessive,inspectthe retainerand

thrustsurfaceson the balancershaft.
Rsar BalancorShrft End Play

Stsndard(N€w):0.06- 0.18mm
10.002- 0.007inl
. lf end play is excessiv€,inspectthe thrust wash-

er and thrust surfaceson the driven qear and oil
pump Dody.
N O T E :T h e t h i c k n e s so f t h e r e t a i n e r( f r o n t ) a n d
t h r u s t w a s h e r ( r e a r )a r e f i x e d a n d m u s t n o t b e
changedeitherby grindingor shimming. {cont'd)
7-31
BalancerShafts
Inspection(cont'd)
6. Measurerunout on the No. 2 journal of each bal-
ancershaftto makesurethe balancershaltsare not
bent,
Ealanc6rShaft Total IndicatodRunout

Standrrd (Now): 0.02 mm (0.001inl
Sewice Limit: 0.03 mm 10'001inl
Journal Diamot€r
Stlndard (New)
No, 1 ioutnal:
Front: 12-722- 12..731mm
11.6820- 1.6824inl
Rear: 20.938- 20.950mm
{0.824:l- 0.82'18in}
Measurethe diametersof the balancershaft jour- No. 2 iourn.l: 38.712- 38.724mm
n al s . l1.52al- 1.5245inl
: No. 3 iourn.f : 31.722- 31.731mm
I
(1.3670- 1.3675inl
MEASURINGPOINTS
Scrvica Limit:
No. I iournal:
i Front: 42.71mm {1.681in)
I Rcar: 20.92mm 10.82,1 inl
No. 2 iouinll: 38.70mm (1.524inl
No. 3 iournal:34.71mm (1.367in)
Removethe crankshaft,the pistons and the other

oartsfrom the block,then cleanthe balancershaft
I i o u r n a l b e a r i n g so f t h e b l o c k a n d t h e o i l p u m p
housingwith a cleanshoptowel.
9. Checkthe surfaceof the bearings,if there is wear.

damage or discoloration,replacethe bearingsor
i the oil pump housing.
7 -32
1 0 . Measurethe inner diametersof the balancer shaft Bearing Inner Diametor
journalbearings. Standard {Nswl:
No. I iournals:
MEASUREPOINTS
Fronl: 12.8OO- 12-82Omm
No. 2 BEARING (1.6850- 1.6858in)
IBLOCKI Rear: 21.flD - 21.013mm
{0.8268- 0.8273inl
No. 2 iournals: 38.800- 38.820mm
(1.5276 - 1.5283in)
No. 3 iournals: 34.800- 3,1.820mm
{1.3701- 1.3709inl
ServicoLimit:
No. l iournals:
Front: 42.8:lmm 11.686inl
R6ar: 21.02mm (0.828in)
No. 2 iournals: 38.tIl mm (1.529in)
No.3 iournsls:3i1.83 mm (1.371in)
11. Calculatethe shaft-to-bearings

oil clearances.
BEARINGl.D. - JOURNALO.D. = OtL CLEARANCE
Boaring-to-shaftOil Cl.aranc€
No. 2 BEARING Standard (Newl
IBLOCK) No. I iournal front and No. 3 iournsls:
0.066- 0.118mm {0.0026- 0.0046inl
BLOCK No. 2 iournab:
0.076- 0.128mm (0.0030- 0.0050in)
No. 1 iournal r€ar:
0.050- 0.075mm (0.0020- 0.0030in)
S6rviceLimit:
No. I iournal tront and No. 3 iournats:
0.12mm (0.005inl
No. 2 tournsls: 0.13mm {0.005inl
No. I iournal roar: 0.09 mm (0.004in)
DIALGAUGE
No. 1 REARBEARING
IOIL PUMP HOUSINGI
7-33
EngineLubrication
Speciaf Tools.......... ...........9-2
lllustratedlndex........... .....8-3
EngineOil
Inspection ......................
8-5
Replacement .......................................
8-5
Oil Filter
Rep|acement .......................................
8-6
Oil Pressure
Testing ......8-8
OilJet
fnspectionlHz2Al engineonly) ........8-8
Oil Pump
Overhaul .........................
8-9
RemovaUlnspection/lnstallation ......8-10
SpecialTools
Rs{. No. I Tool Numbel Drtcription Oty I PEg. Rctercnc.
o OTLAD- PT3O1OA SealDriver 8-11

8-1 1
@ 07746- 0010300 Attachment,42 x 47 mm
Ar 07749- 0010000 Driver 8-1' I
@ 0 7 9 1 2- 6110001 Oil Filterwrench a-7
I
o
o o
8-2
lllustratedIndex
NOTE: CAUTION: Do not overtighten the drain plug.

a Us€ new O-ringswhen reassembling.
. Apply oilto O-ringsbeforeinstallation.
. Useliquidgasket,PartNo. 08718- OOO1.
. Cleanthe oil controlorificewhen installing. OILPUMP
8 x 1.25mm Overhaul,pageI 9
Inspection,page8-10
Apply liquidgasketto
blockmatingsurface.
O-RINGS
Replace. F22A1,H23At enginesj
8 x 1.25mm OIL CONTROLORIFICE
30 N.m (3.0 kg-m, Do not installit on the H22A1engine.
22tb-ft1 Clean.
O.RING
Replace. F22Al engin€:
ENGINEOIL PRESSURE SWITCH
BALANCEN 18 N.m (1.8 kg.m, t3 tb-ft)
GEARCASE 1/8in. BSP{British
standardpipetaper)
28 threads/inch.Use
properliquidsealant.
H23A1,H22At engin.s:
KNOCKSENSOR
32 N.m 13.3kg-m, 23 tb-ftl
O.RING
Replace.
DOWEL
PIN
8 x 1.25mm ENGINEOIL COOI..ER
25 N'm 12.5kg-m, i8 tb-ft} {H23A1,H22Al ongin6)
DOWELPIN
GASKET
Replace.
OIL SCREEN OIL FILTER
7/8 turn or
22 N.m l2.2lg-m, i6 tb-ft|
Replacemg6lp6gs g 6
6x1.0mm Replaceevery 7,500miles
OIL PAN GASKET 12 N.m 11.2kg-m,9 tb-ft| {12,000km) or 6 months.
Roplace. H23A1,H22At engin$:
ENGINEOIL PRESSURE SWITCH
18 N.m {1.8 kg-m, t3 tb-ftl
6x1.0mm
12 N.rn(1.2kg-m.9 tb-ft)
WASHER
Replace.
DRAINBOLT
1 4x 1 . 5m m
OIL PAN 45 N.m 14.5kg-m,33 lb-ttl
Do not overtighten. (cont'd)
8-3
lllustratedIndex
lcont'd)
NOTE:
a Usenew O-ringswhen reassembling.
. Apply oilto O-ringsbeforeinstallation
. Use liquidgasket,PartNo. 08718- 0001.
1 1x 1 , 5m m
75 N.m (7.5kg-m, 5x1.0mm
54 tb-ft} 12 N.m 11.2kg-m,9lb-ft|
Applyengineoiltolhe bolt
threads and th€ washers
NOTE:
Alter torquing each cap,
turn crankshaftto chock
for binding. BAFF1TPLATE
EEARINGCAP
BRIDGE
OIL JET BOLT

40 N.m {a.0 kg-m,
29 tb-ft)
OIL JET
Handlethe nozzlewith
care.Replaceil any pan
is damagedor detormed.
6x1.0mm
12 N.m {1.2lg-m,9lb-ft}
i
CRANKSHAFT
i THRUSTWASHERS
Groovedsidesface outward.
a-4
EngineOil
Inspection Replacement
Checkengine oil with the engine off and the car CAUTION:Removs the drain bolt carofullywhile th6
parkedon levelground. ongine is hot oil m8y caus6scalding.
Makecertainthat the oil level indicatedon the dio- L W a r mu p t h e e n g i n e .

stickis betweenthe upoerand lowe. marks.
2. Drainthe engineoil.
lf the level has dropped close to the lower mark.
add oil until it reachesthe upDermarK.
CAUTION: In36rt thc dipstick cardully to avoid

bonding it.
WASHER
45 N.m{a.5kg-m,33 tb-ft| R6placo.
R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r , a n d
refillwith the recommendedoil.
CAUTION: Do not ov6rtight6n the drain bolt.
Requirement API ServiceGrade:Use "Energy Conserving

ll" SG gradeoil.
F22A1,H23A1engines:5 W- 30 preferred.
H22Al engine:10W - 30 preferred.
Capacity F22A1enginel
3.8f (4.0US qt,3.3 tmp qt)
change,includingfilter.
4 . 9 1( 5 . 2U S q t , 4 . 3 l m pq t )
atter engine overhaul.
H23A1engine:
4.3f (4.5US qt, 3.8tmp qt)
chang€,includingfilt6r.
5.4f (5.7US qt, 4.8lmp qt)
afterengineoverhaul.
H22A1engino:
4.8f (5.1US qt, 4.2 lmp qO
change,includingfitter.
5.9f (6.2US qt, 5.2lmp qt)
aflerengineoverhaul,
Change Every7,500miles {12.OOO
krn) or 6 months
{cont'd)
8-5
Engi n eOi l Oil Filter
Replacement(cont'd) Replacement
The numbersin the middle of the API Servicelabeltell

you the oil's SAE viscosityor weight. Selectthe oil for o Ltter tte engine has been run. the exhaurt pipo will
your car accordingto this chart: be hot; be caroful when working around the axhau3t
pipo.
F22A1.H23A1engines: Be careful when loo3oning the drain bolt while tho
engino i3 hot, Burns can rosult becausothG oil lgm'
peraturc is very high.
Ambi€nt Temperaturo
R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r
wrench.
Inspectthe threadsand rubber seal on the new fil-

ter.
Wipe off seat on engine block,then apply a light
coat of oil to the filter rubberseal.
NOTE: Use only filters with a built-in bypasssys-

A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r rem.
improved fuel economy and year-roundprotection in
the car. You may use a 10 W - 30 oil if the climate in
your area is limitedto the temperaturerangeshown on Applyengineoilto rubb€r
the chart. sealbeforeinstalling.
H22A1engine:
Ambiont Temo6raturs
-20
An oil with a viscosity of 10 W - 30 is preferredfor

improved tuel economy and year-roundprotectionin
the car. You may use a 5 W - 30 oil if the climate in
your area is within the temperaturerangeshown on the
chan.
N O T E : T h e o i l f i l t e r s h o u l d b e r e p l a c e da t e a c h o i l
change.
8-6
Installtheoil filter by hand. eight numbers(1 to 8l are printedon the surfaceof the
filter.
A f t e r t h e r u b b e rs e a l s e a t s .t i g h t e n t h e o i l f i l t e r
clockwisewith the specialtool. The following explainsthe procedurefor tighteningfil,
ters usingthesenumbers.
Tighten: 7/8 turn clockwise
Tightoning torque: 22 N.m (2.2 kg-m, 16 lb-ftl 1) Make a mark on the cylinderblock under the num-
ber that shows at the bottom of the filter when the
CAUTION: lnstallation other than the abov€ procs- rubbersealis seated.
dur6 could result in sgrious ongine damage due to
oil l6ak.go.
I
2) Tightenthe filter by turning it clockwisesevennum-
bersfrom the markedpoint. For example,if a mark
is made under the number 2 when the rubberseal
OIL FILTERWRENCH i s s e a t e d t, h e f i l t e r s h o u l d b e t i g h t e n e du n t i t t h e
07912- 611t)00r number1 comesup to the markedpoint.
Numberwhen rubber Numberaftertightening.

sealis seated.
Numberwhen rubber
4 7 8
sealis seated
ENGINEOIL COOLER
(H23Al, H22A1engine3l Numberaftertightening 8 1 1
5. After installation,fill the engine with oil up to the

specifiedlevel,run the enginefor more than 3 min
utes,then checkfor oil leakage.
a-7
Oil Pressure Oil Jet
fnspectionlH22A1engineonlyl
lf the oil pressurewarning light stayson with the engine Removethe oil jet (page8-4) and inspectit as fol-
running.checkthe engineoil level.lf the oil level is cor- rows.
rect:
Make sure that a 1.1 mm {0.04in} diameterdrill
'1.
Connecta tachometer. will go throughthe nozzlehole {1.2mm t0.05in)
diameter).
Removethe engine oil pressureswitch and install Insertthe other end of the same 1.1mm {0,04in}
an oil pressuregauge. drill into the oil intake(1.2 mm (0.05in) diame-
ter). Make sure the check ball moves smoothlv
S t a r t t h e e n g i n e . S h u t i t o f f i m m e d i a t e l yi f t h e and has a strokeof approximately4.0 mm (0.16
gauge registersno oil pressure.Repairthe problem In,.
beforecontinuing. Checkthe oil jet operationwith an air nozzle.lt
should take at least200 kPa (2.0 kg/cm,,28 psi)
Allow the engine to reach operatingtemperature to unseatthe checkball.
(radiatorlan comeson at leasttwice).The pressure
shouldbe: NOTE:Replacethe oil jet assemblyif the nozzl€
is damagedor bent,
Engine Oil Tamp6rrture: 176'F {80'C)
EngineOil Pressure:
At ldle: 70 kP8 (9.7 kg/cm,, 10.0psi)
minimum
At 3,flt0 rpm: 350 kPa (3.5kg/cm,, 50 p3il
minimum
1!
lf oil pressureis within specifications, replacethe
I oil pressureswitch and recheck.
l f o i l p r e s s u r ei s N O T w i t h i n s p e c i f i c a t i o n s ,
:. inspectthe oil pump (pages8-10,11|.
'
ENGINEOIL PRESSURE OIL PRESSURE

GAUGE
SWITCHMOUNTINGHOLE
{F22A1engino}
I
I
i
I
I
ENGINEOIL PRESSURE SWiTCH Mounting torque is critical.Be very precisewhen

MOUNTINGHOLE installing.
lH23A1,H22Al cneinos)
lH23A1,H22A1.ngin.!l Torquo: 40 N.m (4.0 kg-m, 29 lb-ft)
8-8
Oil Pump
Overhaul
NOTE:
Usenew O-ringswhen reassembling,
Apply oilto O-ringsbeforeinstallation.
Use liquidgasket,PartNo.08718- 0001.
6x1.0mm
7 N.m {0.7 kg-m, 5.1 lb-ftl
PUMPCOVER
OUTERROTOR
OOWELPIN page8-10,11
Inspection,
6x1.0mm
INNERROTOR
12 N.m {1.2kg-m,9lb-ft}. page8-10,t 1
Inspection,
Apply liquid gasker
to the bolt threads,
OIL SEALS
Replace. PUMPHOUSING
pageI 10.11
Insp€ction,
8-9
Oil Pump
Removal/lnspection/lnstallation
1 . D r a i nt h e e n g i n eo i l . 9. Removethe screwsfrom the pump housing,then

separatethe housingand cover.
2. Turn the crankshaftso that the No. 1 pistonis at top
'10.
d e a d c e n t e r( F 2 2 A 1e n g i n e :p a g e 6 - 2 8 ,H 2 3 A 1 Checkthe inner-to-outerrotor radial clearanceon
engine:page6-62,H2241engine:page6-106). the oumo rotor.
Removethe timing belt and the timing balancerbelt lnner Rotor-to-OuterRotor RsdialClea.anc€
(F22A1engine:page6-29,H23A1engine:page6-63, Sland8ld (Newl: 0.02- 0.16 mm (0.001- 0.006in)
H22A1engine:page6-'l07). ServiceLimit: 0.20 mm 10.008inl
R e m o v et h e t i m i n g b e l t t e n s i o n e ra n d t h e t i m i n g
balancerbelttensioner.
Bemovethe timing belt drive pulleyand the timing

balancerbelt drivenpulley(page7-12).
6. R e m o v et h e b a l a n c e .g e a r c a s ea n d t h e b a l a n c e r
drivengear(page7-121.
Removethe oil pan and the oil screen.
R e m o v et h e m o u n t i n gb o l t s a n d t h e o i l p u m p
assemory.
t
ii
I
DOWELPIN OIL PUMP

- lf the inner-to-outerrotor clearanceexceedsthe
servicelimit, replacethe innerand outer rotors.
1'1. Checkthe housing-to-rotoraxial clearancson the

oumo rotor.
O.RINGS
Replace-
Housing-to-RotorAxial Clcaranco
Standard lNewl: 0.02- 0.07 mm (0.001- 0.003in)
SorvicoLimit 0.12 mm 10.005inl
PUMPHOUSING OUTER
OUTERROTOR
ROTOR
Replace.
OIL SCREEN
- lf the housing-to-rotoraxial clearanc€exceeds

t h e s e r v i c el i m i t , r e p l a c et h e s e t o f i n n e r a n d
outer rotorsand/orthe pump housing.
8-10
12. Ch€ckthe housing-to-outer
rotor radialclearance,
Housing.to-OuterRolor RadialClrarsnc€
Stlnda.d {Nsw}: 0.10- 0.19 mm (0.004- 0.007in}
SorvicaLimit: 0.21 mm (0.fi)8 in)
,rJ:|xaTmm
077a6_ 00,t0300
Rsassemblethe oil pump, applying liquid thrcad

lockto the pump housingscrews.
1 7 . Checkthat the oil pump turnsfreely,
?8. Installa dowel pin and the new O-ringon the pump,
NOTE:
a Useliquidgasket,Pan No. 08718- 0001.
a Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
Apply liquidgasketevenly,in a narrowbeadcen-
- l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e teredon the matingsurface.
exceedsthe service limit, replacethe set of inner . To preventleakageof oil, apply liquid gasketto
and outer roto.sand/orthe pump housing. the innerthreadsof the bolt holes,
. Do not install the parts if 20 minutes or more
1 3 . Inspect both rotors and the pump housing for scor- haveelapsedsinceapplyingliquidgasket.
ing or other damage.Replaceparts if necessary. Insteadreapplyliquid gasketafter removingthe
old residue.
Removethe old oil sealsfrom the oil pump. . After assembly, wait at least 30 minutes before
filling the enginewith oil.
t5. Gentlytap in the new oil sealsuntil the specialtool
bottomson the pump. 19. Apply liquidgasketto the oit pump and insta it.
NOTE:The oil sealsalon€ can be reolacedwithout . Apply greaseto the lips of the crankshaftoil seal
romovingth€ oil pump usingthe specialtool. and the balancershaft seal.Then, installthe oil
pump Inner rotor onto the crankshaft.When the
pump is in place,cleanany excessgreaseoff the
crankshaftand the balancer shaft, then check
that the oil seal liDsare not distorted.
Apply iiquidgasket
alongthe brokenline.
(cont'd)
8-11
Oil Pump
Removal/lnspection/lnstallation
{cont'd}
23, Hold the rear balaocorshaft with the 6 x 100 mm
bolt,then installthe balancerdrivengear.
Apply grease
to the seallips. 6 x 10 mm REARBALANCER:
OIL PUMP 12 N.m 11.2kg-m, 9 lb-ft|
Applyliquidgasket Apply liquidgasketto the
to block mating surface. bolt threads.
I x 1.25mm
O.RINGS 25 N.m {2.5 kg-m, 18lb-ft}
Applyengineoil.
Replace.
6 x 100mm EOLT
6x1.0mm t4 mm 12.9inl
12 N.m (1.2kg"m,
OIL SCREEN 9 tb-ttl
Installthe baffleplate.
2 1 . Installthe oil screen.
Apply molybdenumdisultideto the thrust surfaces REANBALAI{CERSHAFT

of the balancergears.as shown, before installing
t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
case.
Apply molybdonum BALANCERDBIVEN 24. Hold the front balancershaft with a screwdriv€r,
disulfide. GEAR then installthe timing balsnce.b€lt driv€npull6y.
FRONTBALANCER:
BALANCERDRIVE
GEAR
8-12
25, lnstallthebalancergear caseon the oil pump. 27. Install the oil pan.
NOTE;Align the groove on the pulley edge to the

pointeron the gear casewhile holdingthe rear bal- Apply liquid
OIL PAN GASKET gask€there.
ancerwith the 6 x 100mm bolt,then installthe gear Replace.
case.
DOWELPIN
8 x 1.25mm
25 N.m 12.5kg-m, 18 lb-ftl
O.FING
Apply6ngin€oil. WASHER
BALANCER Replace. Replac6. 6x1.0mm
GEARCASE DOWELPIN
DRAINEOLT
POINTER ils .m 14.5ks-m, 33 tb_ft)
Alignthe O.ooveto Donotovertightsn.
pornter,
24. Tightenthe boltsand nuts as shown below.
Torquo: 12 Nfl (1.2tg-m,9 lb-ft)
GROOVE
26. Checkalignmentof pointersafter installingthe gear

case.
POINTER
ONTHEPULLEY
a -------_
POINTERON
THEOIL PUMP
NOTE:Tightenthe bolts and nuts in two stepsand
torquethem in a crisscrosspattern.
8-13
Intake Manifold/Exhaust
System
Intake Manifold
Replacemen . .t. . . . . . . . . . . . . . . . . . . . . . .9. .- .2. . .
ExhaustManifold
R e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . . . . . . . .9. .- .4. . .
ExhaustPipe and Muffler
R e p | a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . 9
. .-.7. .
Intake Manifold
Replacement
a Chock tof folds or scratchos on ths surlace of th6 gaskot.

a Replaco with a new gasket it dsmaged.
8 r 1,25mm
H2341, H2241 engines: 22 N.m (2.2 ks-m, 16 lb-tll
STARTINGAIR VALVE
INTAKE MANIFOLD 6xl.0mm
CHAMBER 12 N.m 11.2 kg-m, 9 lb-ft|
Replacoif cracked or
if mating surfaces are IDLE AIR CONTROL
damaged. {tAc}val-vE
8 x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft}
THROITLEBODY
O-RINGS
Replace.
GASKET
Replsce.
INTAKE AIR BYPASS FAST IDLE TXERMO VALVE

IIAB}VALVEBODYASSEMELY 8 r 1.25mm
Replaceif crackedor 6 x 1 . 0m m 22 N.m 12.2 kg-m, 16 lb-ft)
if mating surlaces are 12 N.m ('1.2kg-m,I lb-ttl
oamageo.
GASKET
Y"Sft
Replace.
|l['sJ!'J[*%''
(fAT) SE[{SOR
EXHAUSTGAS
NECIBCULATIOI{
IEGR}VALVE
./
O.RING
Replace.
INTAKE
Replaceit crackedor
if mating su aces are 8r1.25mm
damaged. 22 N.m
(2.2 ks-m,l6 lb-tt)
GASKET
Replace.
8x1.25mm
22 N.tn 12,2 kg-m, 16 lb-ftI
8 x 1.25mm
22 N.m 12.2 kg-m, '16 lb-ftl INTAKE MANIFOLD BRACKET
9-2
CAUTION:
a Check fol tolds or scfatchos on tho surfac6 ot the gaskst.
a Roplsco with a n€w gasket if damaged.
F2241 engino:
8 x 1.25mm
FAST IDI-ETHERMOVALVE
22 N'm 12.2ks-m, 16 lb-ftl
I x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ftl
STARTINGAIR VALVE IAC VALVE

O-RINGS
Replace.
6 x 1.0 mm
12 N.m 11.2 kg'm, 9 lb-ft}
6 x 1.0 mm
12 N.m 11.2 kg-m, 9 lb-ttt O.RINGS
Replace. THROTTLEBODY
INTAKE MANIFOLD
CHAMBER 8 x 1 . 2 5m m
Replaceif cracked or 22 N.m 12.2kg-m,
if mating surfaces are 16 tb-ftl
damaged.
GASKETS
Replace.
8 x '1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)
EGR VALVE
GASKETS
Replace.
8 r 1.25mm
22 N.rn 12,2 kg-m, 16 lb-ft)
INTAKE MANIFOLD
8 x 1.25mm BRACKET
22 N.m 12.2 kg-m, 16 lb-ft)
9-3
Exhaust Manifold
Replacement
NOTE: Use new gasketsand seltiocking nuts when reassembling'
CAUTION:
a Check for folds or scratchas on the sutfaca of tho gasket'
a Rsplace with 6 new gaskot il damagod.
H23A1 engine:
SELF-LOCKINGNUT
I x 1.25mm
32 N.rn (3.2 kg-m, 23 lb-ft) GASKET
Replace. R6place.
8 r 1.25mm
22 N.n 12.2 kg-m, 16 lb-ft)
EXHAUSTMA IFOID
BRACKET
lO x 1.25mm
45 t{.m (4.5 kg-m. 33 lb-ft}
r 1.25mm
GASKETS 22 N.m 12.2 kg-m, l6 lb-ftl
Roplace.
1 0 r 1 . 2 5m m
45 N.m t4.5 kg-m.33 lb-ft)
6 x 1.0 m]n
12 N.m ll.2 kg-m. 9 lb-ft)
T INSULATOR
SELF-LOCKING NUT 6 x 1.0 mm

10 x 'l,25 mm 10 N.m (1.0 kg-m, 7 lb-ft)
55 N.m t5.5 kg-m,40 lb-ftl
9-4
NOTE: Use new gasketsand selflocking nuts when reassembling.
GAUTION:
a Check tor folds or sclatches on th€ surfacs of the gask€t.
a Replacewith a new gaskot if damaged.
F2241 ongine:
GASI(ET
Replace.
EXHAUST
SELF.I.OCKING 1{UT
8 x 1 . 2 5m m
32 'm 13.2 kg-m, 23 lb-ft|
Replace. ,.(
HEATEDOXYGEI!
SENSOR{HO2Sl
45 N.m 14.5 kg-m, 33 lb-ft)
Be carelul not to EXHAUSTMANIFOI.D
BRACI(ET
8 x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)
GASKET
Replace.
10 x 1.25mm
45 N.m {4.5 ks-m, 33 lb-ft}
SELF.I-OCKIl{GNUT
10 x 1.25mm
55 N'm 15.5 kg-m. 40 lb-fi)
Replace.
COVER HEAT INSULATOR

HO23
CONNECTOR lCars equippedwith air conditioningl
6 x 1 . Om m
10 N.m (1.O kg-m, 7 lb-fil
9-5
Exhaust Manifold
Replacement
NOTE: Use new gasketsand self-lockingnuts when reassembling.
CAUTION:
a Chock tor folds or scratchoa on tho surface of the gasket.
a Replaco with a now gaskot it damaged.
H22A'l ongino:
SELF.LOCKINGt{UT
8 r 1.25mm
32 N.m {3.2 kg-m, 23 lb-ft) GASKET
lr
I
Replace.
EXHAUST MAf{IFOLD
Replace.
COVER
1 0 r 1 . 2 5m | n
.m 14.5 lg.|n,
33 lb-tt)
GASKETS
R6place.
8 x '1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)
HEATINSULATOR
SELF-LOCKII{GNUT
10 x 1.25mm 8 x 1.25mm
55 N.m (5.5 kg-m, il.O lb-ft) 22 N.m 12.2 ks-m, 16 lb-ft1
EXHAUST PIPEA 6 x 1.0 mm
10 N.m (1.0 ks-m, 7 lb-ft|
9-6
Exhaust Pipe and Muffler
Replacement
NOTE: Use new gasketsand self-lockingnuts when reassemblino.
6 x 1 . 0m m
10 N.m {1.Okg-m.7 lb-ftl
HEAT SHIELD
SELF-LOCKINGNUT
1 2 x 1 , 2 5m m
55 N.m {5.5 kg-m,4O lb-ft|
Replace.
€.
€ \
EXHAUST PIPETIP
THREEWAY
CATALYTIC
COI{VERT€R
TTWCI
TOROUESEOUENCE MUFFLER
GASKET
Replace.
EXHAUSTPIPEB
SEI.F.LOCKINGNUT
45 N.ln 14.5 kg-m, 33 lb-ft| 10 x 1.25mm
Be carefulnot to damage. 34 N.m {3.4 kg-m, 25 tb-ftl
Replace.
oor*rrr\ 3
Replace.
V SELF-LOCKINGNUTS
I x 1,25mm
18 N.m (1.8 kg-m, 13 tb-ftl
GASKET Replace.
SELF-LOCKINGNUT
10 x 1-25mm
34 N.m (3,4 kg-m, 25 lb-ttl
R6place.
SELF-LOCKINGNUT
10 x 1.25mm
55 N.m (5.5 kg-m,40 lb-ttl
Replace.
I
9-7
Cooling
Radiator
fffustrated Index......... . 1O-2
R e p | a c e m e.n. t. . . . . . . . . . . . . . . . . . . . . . . 1. .O. .-.5.
EngineCoolantRefilling
a n dB l e e d i n g . . . . . . . . . . .1. 0 - 6
C a pT e s t i n g . . . . . . . . . . . . .1. .0 - 7
Testing ..... 1O-7
Thermostat
R e p | a c e m e.n. .t . . . . . . . . . . . . . . . . . . . . . . 1. .O. .-.8.
Testing ..... 10-9
Water Pump
lllustrated Index......... . 1O-1O
fnspection . 10-12
Repfacement .............. 1O-12
Radiator
lllustratedIndex
@ sy"t". is under high pressurewhon engino CAUTION: Wh€n poudng ongino coolant, be suts
is hot, To avoid dangel ot releasingscaldingcoolant, re- to shut the relay box lid and not to spill coolant on
move cap only when engine is cool. the electlical parts or tha paintsd po ion. lf 8ny
coolant spills, rinse it off imm€diately.
Total Cooling System capacity {lncluding hoater and
res€rvoir) NOTE:
a Checkallcoolingsystemhosesfor damsge,leaks
F2241 engin€: or deteriorationand replaceif necessSry.
", a Check all hoss clamps and retightenif necessary.
Manuaf: .1 | l7 .5 US qt, 6.2 lmp qt)
Automatic: 7 .O | (7 .4 US qt, 6.2 lmp qt) a Use new O-ringswhen reassembling.
H23A1 sngin€:
Manuaf: 7 ,4 (. 0,A US qt, 6.5 lmp qtl RADIATOR
Automatic: 7 .3 I 17.7 US qt. 6.4 lmp qt) Engine
coolant
Refillingand bleoding.p6ge 'l0-6
H2241 engin€: Leak test, page 1O-7
Manual: 7.6 | (8.O US qt, 6.7 lmp qt) Inspect soldered joints and
seamsfor leaks.
Reselvoircapacity:O.6 t {0.6 US qt, O.5 lmp qt) Blow out dirt from between
core fins with compregsedair.
l{ insects,etc., are clogging
radiator, wash them off with
low oressule water.
RADIATOB CAP
testing,pago 1O-7
Pressure
6 x 1.0 mm
1 0 N . m { ' l . Ok g - m ,
7 tb-ft)
FLUID (ATF) COOLER
FAN MOTOR
O-RING
DRATNPLUG Replace.
6 r 1 . 0m m
' l ON . m( 1 . 0rg-m,
o. -
7 tb-ttl ;t'i.*:l:XS[YJ,,,
Replace.
COOLINGFAN
FAN SHROUD
10-2
Engino Ho86 Connoctions:
F22A1 engine: IOLEAIR CONTROL

{IACI VALVE
FAST IDLE
THERMO V
THERMOSTAT
HOUSING
HEATEROUTLET
LOWERHOSE
CONI{ECTINGPIPE HEATERINLET
HOSE
BYPASS HOSE
Replace.
H23Al engine: POSITIVECRANKCASE

VENTILATION(PCV} PIPE
IAC VALVE
EYPASS HOSES
O.RING
Replace.
OIL COOLER
BYPASS HOSE
O-RING
HEATER Replace.
* 8 x 1 . 2 5m m CONNECTINGPIPE
22 N'm
12.2 kg-rn, OIL COOLER
16 tb-ft) BYPASS HOSE COOLER
r:: CORFOSIONRESTSTANT
BOLT (cont'd)
10-3
Radiator
lllustratedIndex (cont'd)
I
Engin€ Hose Connections:
H22A'l €ngin€:
THERMOSTAT
HOUSING
HEATERINLET
HOSE
HEATEROUTLET
HOSE O-RING COOLER
PIPE
CONNECTING Replaco.
* 8 x 1 . 2 5m m
22 N.m 12.2kg-m,
16 tb-ft}
RESISTANTBOLT
*: CORROSION
10 -4
Replacement
1 . Dr€inenginecoolant. 5. Removethe fan shroudassembliesand other parts
from radiator.
Romovethe upper and radiatorhoses,and ATF
coolor hoses. Instsllthe radiatorin the reverseorder of removal:
a Disconnect the fan motor connectors. NOTE:
a Set the upper and lower cushionssecurly.
4. R€movethe radiatorupper brackets,then pull up the a Fillthe radistorwith enginecoolantand bleedthe
radiator. ai''.
6 x 1.0 mm
10 N.m (1.0 kg-n, 7lb-ft1
RADIATOR
page 1O-7
BADIATOR CAP
6x1.0mm Testing,page 'lO-7
10 N.m ll.O kg-m,7 lb-ft}
UPPERBRACKET
UPPERI{OSE ANDCUSHION
:tt'l13l3l=.--_g F/o
"l F
sng
7.r.
I x 1.0 mm
lO N.in (t.O kg-m.7 tb-frt @
FAN MOTOR P
CON'VECTOR
1\ RESERVOIRHOSE
owER CUSHTON
ATF COOLER
DRAIN PLUG HOSE$
O-RING
Replace.
LOWERHOSE
RESERVOIR
10-5
Radiator
EngineCoolantnefill\ and Bleeding
CAUTlOttl: When pouting enginocoolaisQgsuro to shut H23Al engine:
th6 ralay box lid and not to lst coolanl spill on tho elec- Manual: 3.8 X (4'O US qt, 3.3 lmp qrl
trical part6 or lh€ paint. lf any coolant spills, rinse it off Automatic: 3.7 t {3.9 US qt, 3.3 lmp qt}
immodiat6ly. H22Al engino:
1. Set the heatertemperaturelever or conttol dial to Manuaf: 4.O f 9.2 US qt, 3'5 lmp qt)
maxamumheat.
9 . Loosenthe air bleed bolt in the thetmostat housing,
then fillthe radiatorto the bottom of the tiller neck
2. Removethe engine splashshield.
with the coolantmixtu.e. Tightenthe bleedbolt as
soon as coolant stans to run out in a steadv stream
3. When the radiatoris cool, removethe radiatorcap.
without bubbles.
Loosenthe drain plug, and drain the coolant.
4. Removethe drain bolt trom the rear side of the BLEEDBOLT

cylinderblock to drain the block and heater,
5. Apply liquidgasketto the drain bolt threads,then

reinstall the bolt with a new washer and tighten it
securely.
6. Tightenthe radiatordrain plug securely.
7, Remove,drainand reinstallthereservoir.Fillthetank
haltway to the MAX mark with water, then up to the
MAX mark with anti-freeze.
8. Mix the recommendedanti-freezewith an equal

amount ol water in a clean container.
NOTE:
a Use only genuineHonda anti-Jreeze/coolant.
a Fof best corrosionDrotection,the coolant concen-

tration must be maintainedyear-roundat 50
minimum.Coolantconcentrations lessthan 50%
may not provide sutficient protection againstcor-
rosion or treezing.
a Coolantconcentrationsgreaterthan 60% will im-

paif cooling efficiency and are not recommended.
CAUTION:
a Do not mix dilferent brands of anti-freoze/
coolants.
a Do not uso additional rust inhibitors or anti-rust
products; they may not be compatible with tho DRAII{ BOLT
g€nuine coolant. 60 N.m {6.0 kg-m,43 lb-ft}
Applvliquidgasketto the
boltthreadswheninstalling.
Engine Coolant Refill Capacity: including reservoir
{0.6 t {0.6 US qt, 0.5 lmp qt}l and heatar{0.6 f (o.6 1O. With the radiatorcap oft, start the engineand let it
US qt, 0.5 lmp qt)|. run until warmed up (Radiatorfan goes on at least
twice). Then,if necessary,add more coolantmix to
F22Al engine: bring the level back up to the bottom ot the filler
Manual: 3.5 I (3.7 US qt,3.1 lmp qt) neck.
Automatic: 3.4 f {3.6 US qt, 3.0 lmp qtl
11. Put the radiatorcap on tightly, then run the engine
again and check tor leaks.
10 -6
Cap Testing
Removethe radiatorcap, wet its seal with engine
coolant,then insmll it on the pressuretester.
A p p l y a p r e s s u r eo f 9 5 - 1 2 5 kpa (0.9b-1.25
k g / c m , ,1 4 - 1 8 p s i ) .
Check for a drop in pressure.
4. lf the pressuredrops, replacethe cap.
RADIATORPRESSUBETESTER
COMMERCIALLYAVAILABLE
ADAPTOR
{for smallcap)
Testing
1. Wait until the engineis cool. then carefullyremove

the radiator cap and fill the radiator with engine
coolant to the toD of the filler neck. RADIATOR
PBESSURE
TESTER
COMMERCIALLYAVAILABLE
2, Attach the pressuretesterto the radistorand apply
a p r e s s u r eo f 9 5 - 1 2 5 k P a ( 0 . 9 5 - 1 . 2 5 k g / c m r ,
14. 18 psi).
3. Inspect for enngine coolanl leaks and a drop in

pressure,
4, Removethe tester and reinstallthe radiatorcao.
NOTE; Check for engineoil in the coolant and/or

coolant in engineoil.
10-7
Thermostat
Replacement
NOTE: Use new O-ringswhen reassembling.
F22A1, H23Al engin6s:
ELEED BOLT
10 N.m lt.0 kg-m,7 lb-ftl
6 x 1.0mm
'12 N.m (1.2 kg-m, 9 lb-ft)
ENGIfTE COOLANT
TEMPERATURE (ECT}
SWITCHA
28 t{.m (2.8 ks-m, 20 lb-ft|
CONNECTING
PIPE
6 x ' l . Om m
12 N.m l'1.2kg-m,9 lb-ft}
RUBBERSEAL
Replace.
THERMOSTAT
Installwith pin up.
AT COVER
H22Al enginor
BLEEDBOLT
10 N.m (1.0 kg-m.7 lb-ftl
THENMOSTAT
Instaliwith pin up.
ECTSWITCHA
28 N.m {2.8 kg-m,20 lb-ft|
6x1.0mm AT COVER
'12 N'm
11.2 kg-m, 9 lb-ttl
10-8
Testing
Replacethe thermostat if it is open at room temperature,
To test a closed thermostat;
1. Suspendthe the.mostatin a containerof wate. as

snown.
2. Heat the water and check the temperaturewith a

thermometer.Checkthe temperatureat which the
thermostatfirst opens.and at which it is fully open.
CAUTION: Do not l6t the thelmometor touch tho

bottom of hot containor.
3. Measurelift height ot the thermostat when fullv

ooen.
STANDARD THERMOSTAT
Lift h.ight: above 8.0 mm {O.31 in.}
Stans oponing: 169 - 176oF {76-8OoCl
Fully open: 194oF (9OoC)
THEBMOSTAT
10-9
Water Pump
lllustrated Index
NOTE: Use new O-ringswhen reassembling.
F22A1, H23Al onginsE:
WATER OUTI.ET
HOUSING
Apply liquidgasketto
ENGINECOOLANT cylind€rhead mating
TEMPERATURE{ECT) surface.
SENSOR '13lb-ft)
18 t{.m (1.a kg-m'
ECTGAUGE
SEI{DINGUNIT
9 N.m lO.9 kg-m,6.5 lb-ft|
x 'l,O mm
12 N.m (1.2 kg-m,
€t{Gtl{EOILCOOLER 9 tb-fr)
(H234l engine) B
28 N.m {2.8 kg-m, 20 tb-ft|
ECT SWITCH A
2a .m (2.8 kg-m, 20 lb-ft)
BLEEDBOI.T
10 x 1.25mm
1 O N . m 1 1 . 0k g - m ,
7 tb-trl
6 x l.O mm
12 N.m (1.2kg-m,
I rb-ft)
O-RINGS
Replace.
*8 x 1.25mm
22 N.m 12.2 kg-n,
16 tb-fr)
6 x 1 . 0m m
1 2 N . m( 1 . 2k g - m ,
9 rb-ft)
DRAIN BOLT
O-BING
60 N.m 16.0 kg-m, Repl6ce.
43 rb-frl
Apply liquid gasket to bolt
threadswhen installing.
CONI{ECTINGPIPE
(F22A1 enginel
R€SISTANTBOLT
*: CORROSION
10-10
H22A1 cnglne:
ECT SEI{SOR
18 N.m (1.8 kg-m, 13lb-ft}
6 x 1.0 mm
12 N.m {1.2kg-m,
9 rb-ttl
ECTGAUGE
SENDIT{G UNIT
9 N.m lO,9kg-m,
6.5 rb-ft|
ECTSWITCHB
28 N.m (2.a kg-m,20 lb-ftl
6 r 1.0 ir|m
1 2 . m 1 1 . 2k g - m ,
glb.ft) BLEEDBOLT
10 x 'l.25 mm
lO N.m {l.O kg-m,
7 tb-ftl
E GINE OIL COOLER
A
28 N.m 12.8kg-m,
20 rb-frl
WATEFR,MP o-Rtt{Gs
Replace.
*8 x 1.25mm
22 N'm 12.2 kg-m, 16 lb-fr)
CONNECTINGPIPE
6 x l.O mm
12 .ln lt.2 kg-m. 9 lb-ft}
*: CORROSION
RES|STANT
BOLT
1 0 - 11
Water Pump
Inspection Replacement
Removethe timing balancerbelt and timing belt Removethe timing balsncerbelt and timing b€lt
(F22A1 engine: page 6-29, H23Al engine: page (F22A1 engine: page 6-29, H23A1 engine: page
6-63, H22A1 engine:page 6-109) 6-63, H22A1 engine:Page6-1091
check that the water pump pulleY turns freely. Unscrew the bolts, then remove the water pump'
Check for signs ol seal leakage.

"weeping" Irom bleedhole
NOTE: Smsllamountof
is normal.
6x1.Omm
12 N.m {1.2kg-m. O.RING
9 tb-ft| R6place.
I
, 3. Install the water pump in the reverse order of
removal.
BLEEDHOLES
BLEEDHOLE RUBBERSEAL
Apply liquid gaskst
to the water pump
mating surtace.
10-12
Fuel and Emissions
S p e c i aTl o o l s . . . . . . . . . . . - . . .1. ' l - 2

ComoonentLocations 1-113
I n d e x. . . . . . . . . . . . . . . . . . . . . . .1 1 - 3 ' t- ' l 1 4
System Description 1 - 11 4
V a c u u mC o n n e c t i o n. .s, . . . . . . . . . . . . . , . . . . . .1.1.-. 8, . Fuel Injectors 1 - 11 6
E l e c t r i c aCl o n n e c t i o n.s. . . . . . . . . . . . . . . . . . . , . . .1. .1.- 12 Iniector Resistor 1-'t21
S y s t e mC o n n e c t o r s. . , . . . . . . . . . . , . . . , . . . . . . . . .1.l.-. 2 O Fuel PressureRegulator 't-122
Troubleshooting Fuel Filter 1-123
T r o u b l e s h o o t i nGgu i d e . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 4 0 1-124
S e l f - d i a g n o s tPi cr o c e d u r e s , , , . . . . . . . . , . , . . .1. '. l.- 4 2 t-tzo
H o w t o R e a dF l o w c h a r t s. . . . , . , . . . . . . . . . . , , . ,1. 1 . -47 1 -1 3 0
PGM-FISystem Intake Air System
System Description ....... 1 1-48 System T.oubleshootingGuide 11-13r
Troubleshooting Flowchans System Description 11-132
Engine W i l l N o t S t a r t. . . . . . . . . . . . . . . . . . . . . . .1.1.-. S . .0 Air Cleaner 11-133
E n g i n eC o n t r o lM o d u t e. . . . . . . . . . . . . . . . . . . . . . .1. .1.- 5 1 Intake Control Svstem
H e a t e dO x y g e nS e n s o r , , . . . . . . . . . . , . . . . . . 1 . .1.-. 5. .6 lExcept F22A't engine(Sll 1-134
H e a t e dO x y g e nS e n s o rH e a t e r. . . , . . . . . . . . . ,1. 1 - 5 8 Throttle Cable 1-138
F u e lS u p p l yS y s t e m. . . . . . . . . . . . . . . . . . . . . . . .1. 1 . .- .6. 2
. Throttle Bodv 1 - 13 9
ManifoldAbsolute PressureSensor .,...... l1-64 Intake Air Bypass Control System
Top Dead Center/Crankshsft position/ lExcepr F22A'l engine(Sll 1-143
C y l i n d eP r o s i t i o nS e n s o r . . . . . . . , . . . . ....., . ' l 1- 7 O I n t a k eM a n i f o l dI F 2 2 4 1 e n g i n e ( S l .] . . . . . . . . . . . . 1 - 14 8
EngineCoolantTemperatureSensor ....... 11-72
T h r o t t l eP o s i t i o nS e n s o r. . . . . . . . . . . . . ...... .- . .- 1 ' l- 74 EmissionControl System
I n t a k eA i r T e m p e r a t u rS e e n s o r. . . . . . . . . . . . . .1. 1 - 7 6 System TroubleshootingGuide .... 1-149
B a r o m e t r iP c ressurS e e n s o r. . . . . . . . . . . . . . . . . 1 . .l - 7 8 System Description 1 - 15 0
l g n i t i o nO u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .I. .1.- 8 0 TailpipeEmission 1-150
V e h i c l eS p e e dS e n s o r. . . . . . . . . . . . ...... . . . . . . . . 1 . 1- a 2 T h r e eW a y C a t a l y t i cC o n v e n e r. . . . . . . - . . . . . . . . . .1 - 1 5 1
E l e c t r i c aLlo a dD e t e c t o r. . . . . . . . . . . . . . . . . . . . . .1.1. - 8 4 E x h a u sG
t a s R e c i r c u l a t i oSnv s t e m . . . . . . . . . . . . . 1 - 1 5 3
Knock Sensor PositiveCrankcaseVentilationSystem .,.,.,.. 1 - 15 9
l E x c e p tF 2 2 A 1 e n g i n e { S ).l . . . . . . . . . . . . . . .I .1- 8 8 EvaporativeEmissionControls 1-160
A / T F l S i g n aAt / B . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. .9.0.
ldle Control System

S y s t e mT r o u b l e s h o o t i nGgu i d e . . . . . . . . . . . . . . . . I. .1- 9 2
System Description ....... 1 1-93
TroubleshootingFlowcharts
l d l eA i r C o n t r o Vl a l v e . . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 9 6
A i r C o n d i t i o n i nSg i 9 n a 1. . . . . . . . . . . . . . . . . . . . . .I. .1.- 9 8
A l t e r n a t oFr RSignal .. I1-1OO
AutomSticTransaxle
G e a rP o s i t i o S n i g n a l. . . . . . . . . . . . . . . . . . . . 1. 1- 1 0 2
S t a r t e .S w i t c h S i g n a l. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .- 10 4
B r a k eS w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . 1. .1.-.1.0. 6
Power SteeringPressufeSwitch Signal ... 1l-108
F a s tl d l eT h e r m oV a l v e. . . . . . . . . . . . . . . . . . . . . . . I. .1. -. .1.0 9
S t a r t i nA g i r V a l v e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1.-.1. 1. .O.
l d l eS p e e dS e t t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.l.j .1.
Special Tools
Rel. No. Tool Number Dascription I O'ty I Pag€ Roforence
o A973X_041_XXXXX Vacuum Pump/Gauge 1 1 1 - 6 8 ,1 3 5 , 1 3 9 ,

144, 154, 162, 165
KS-AHM_32 OO3 DigitalMultimeter 11 - 4 5 ,5 8 , 6 3
,ar OTLAJ PT30l OA Test Harness 11 - 4 5
@ 07JAZ-OO1000B Vacuum/Pressure Gauge0-4 in. Hg 1 1 - 1 6 4 1, 6 5
/A 07406-OO40001 Fuel PressureGauge 1 ' l - 1 1 5 ,1 2 2
I \a) \9
11-2
ComponentLocations
Index
H23A1 engine (USA: Si/Canada:SRI:
ELECTRICAL
LOADDETECTONIELOI
THROTTTE (TPISENSORMANIFOLO
POSITIOI{ ABSOLUTE
Troubleshooting, page 1 I-74
Troubleshooting, PRESSURE IMAPI SENSOR
page 1 1-84 Troubleshooting,
EXHAUST GAS RECIRCULATION{EGR) FAST IDLE page 1 1-64, 68
VALVE LIFT THERMO
sEr{son VALVE IDLE AIR CONTROL(IACI VALVE
Troubleshooting, Inspection Troubleshooting,
p a g et l - 1 5 3 p a g e1 1 - 1 O g page 1 1-96
IGNITIONCONTBOLMODULE (ICM)
page |'l -80
Troubleshooting, EVAPORATIVEEMISSION
(EVAP} PURGECONTROL
INTAKE CONTROL SOLENOIDVALVE
SOLENOIDVALVE page 1 1-162
Troubleshooting,
\ Troubleshooting,
\ . o a q e1 1 1 3 5
TOPDEADCEITTER/ STABTING AIR VALVE
} Description,
POSITION/\. //'
CRANKSHAFT p a g e1 1 - 1 1 0
CYLII{DERPOS]TION
ITDC/CKP/CYP'
Troubleshooting,
page11-70 IIIIJECTOBRESISTER
Testing,page 11-'121
'trt
?,{oL
AKE AIR TURE

IIATI SENSOR
Troubleshooting,
p a g e1 1 - 7 6
ENGINECOOLANT EXHAUST GAS RECIRCULATION{EGR}

TEMPERATUBE{€CT) SENSOR VACUUM CONTBOLVALVE
Troub16shooling, Troubleshooting,
page 11-72 p a g e1 1 - 1 5 3
KNOCK SENSOR{t(Sl
page 1 1-88
Troubleshooting,
HEATEDOXYGEN
SENSOR tHO25)
Troubleshooting,
p a g e 11 - 5 6 EXHAUST GAS RECIRCULATION{EGR)CONTBOL
INTAKE AIR BYPASS {IAB} VALVE
SOLENOIDVALVE
Testing.page 1 1-146 page 1 1-153
Troubleshooting,
POWER PRESSURE(PSP}SWITCH
page 1 1-108
Troubleshooting,
INTAKE AIR BYPASS IIAEI CONTBOLSOLENOIOVALVE

page 11-144
Troubleshooting,
11-3
Component Locations
lndex
H22Al ongino {USA: Si VTEC/Canada:sB-v)
EI-ECTRICALLOAD DETECTOB{ELD)
Troubleshooting,
p a g e1 1 - 8 4 IDLE AIR CONTROL{IAC) VALVE
Troubleshooting,
11 - 9 6
€XHAUST GAS RECIRCULATIONIEGRI THBOTTLE POSITION ITPISENSOR
VALVE LIFT SENSOR Troubleshooting, 11-74
page 1 1-153 Page
Troubleshooting,
FAST IDLE
INTAKECONTROL THERMO MANIFOLOABSOLUTE
SOLENOID VALVE VALVE PFESSUNEIMAP} SENSOR
Troubleshooting, lnspection Troubleshooting,
p a g eI 1 - 1 3 5 p a g o1 1 - 1 O g page '11-64,68
IGNITIONCONTROLMODULE (|CM} EVAPOBATIVEEMISSION

page 1 1-80
Troubleshooting, (EVAP} PUFGECONTROL
ToP DEAOCENTER/ .. SOLET{OIDVALVE
page 1 1-162
\ Troubleshooting,
CR} .KSHAFT^POSITION/\
CYLINDERPOSITIOl{ STARTII{G AIR VALVE
{TDC/CI(P/CYP}SENSOR Description,
Troubleshooting,
p a g e11 - 11 0
page 'l 1-70 INJECTOR RESISTER
T e s t i n gp,a g e1 1 - 1 2 1
INTAKEAIR TEMPERATURE
0AT) SEI{SOB
Troubleshooting,
p a g e1 1 - 7 6
GAS
(EGRI
RECIRCULATIOT{
VACUUMCOI{TROL VALVE
ENGIf{ECOOLANT page11-l53
(ECTISENSOR Troubleshooting,
TEMPERATURE
Troubleshooting,
page 11-72
EXHAUST GAS RECIRCULATIONIEGRI
CONTROLSOLENOIDVALVE
page 1 1-153
Troubleshooting,
KNOCK SEI{SOB {KS}
Troubleshooting, page 11'88 POWERSTEERINGPRESSURE(PSPI SWITCH
HEATEDOXYGEN p89e 1 1-1OB
Troubl€shooting,
SENSOR tHO2S)
Troubleshooting,
p a g e1 1 - 5 6
INTAKE AIR BYPASS (IAB) VALVE INTAKE AIR BYPASS {IABI CONTROLSOLENOIDVALVE
'l1-146 page 1 1-144
Troubleshooting,
Testing.page
11-4
F22Al ongins (S):
ELECTRICALLOAD DETECTOR
{ELDI IDLE AIR CONTROL{IAC} VALVE
Troubleshooting. Troubleshooting.
psge11-84 p a g e1 1 - 9 6
MANIFOLD
ABSOLUTE
THROTTLEPOSITIOT{ PRESSURE
ITP) SEITISOR {MAPI SENSON
EXHAUST GAS BECIRCULATION{EGRI Troubfeshooting.page 1 1-74 Troublsshooting.
VALVELIFTSEI{SOR page 11-64, 68
pago11-,|53
Troubleshooting.
EVAFORATIVEEMISSION (EVAP)
IGNITIONCO TBOLMODULEIICM} PURGECONTROL SOLENOID
pag611-80\\
Troubleshooting. VALVE
Troubleshooting.
page11-,|62
TOPDEADCENTER/
CRAN(SHAFTPOSITIOI{/
CYLINDER
POSITION FASTIDLE
{TDC/CKP/CYP} THERMOVALVE
Troubleshooting. page11-110
Inspoction,
p a g e1 1 - 7 O
II{JECTOR
RESISTER
Testing, 11-121
STARTII{G
AIR VALVE
Description,
p a g e1 1 - 1 1 0
I TAKE AIR
TEMPERATUR:
(IAT} SENSOR
Troubleshooting.
page 1'l-76
EXHAUSTGASRECIRCULATION IEGR)
VACUUiI CO TROLVALVE
page11-153
Troubleahooting,
. ,-/ /
ENGINECOOLANT
TEMP€RATURE(ECT) SENSOR
'-''./
EXHAUSTGAS RECIRCULATIOI{ (EGRICONTROL
Troubl€shooting, SOLEiIo|DVALVE
page 11-72 page11-'l53
Troubleshooting,
POWER STEERII{G PNESSUREIPSPI SWITCH

HEATEOOXYGEI{ Troubleshooting, pago 1 1-1OB
(Ho2st
sEr{soR
Troubleshooting,
page 1 1-56
11-5
ComponentLocations
Index
EVAPORATIVE EMISSIOI{ FUEL

ruMP
{EVAPITWO WAY VALVE Tosting,p6ge 'l t -125
Testing,page11-165 Roplacemgnl,paoo 11-125
FUEL FUELFILL
CAP I
FUEL FIITER
Replacoment,page 1 1-123
EVAPORATIVEEMISSION
IEVAP)CONTROL CAI{ISTEB
page11-'162
Troubleshooting,
TAI{K
Replacemgnt,
p s g € 11 - 1 3 0
FUEL
PNESSURE REGULATOR
Testing,page11-122
R€phcomont, p.g6 11-123
FUEL VAPOR
HOSE FUEL RAIL
I]{JECTORS
Troubleshooting,
ptgo11-116
Replacomedt, page 11-1 19
11-6
AIR CLEANER{ACL) THROTTLE BOOY
Oisass6mbly. page11,139
Inspection,
p a g e1 1 - 1 3 3 Disassembly,pagel l -141
II{TAKEAIB
II'ITAKE
cot{TRoL
DIAPfIRAGM
(Exclpt F22A1
.ngin.l
Troubloshooting
p a g €1 1 - 1 3 5
lnspection/Adjustment,
page 1 1- l38
Installation, page 1 1-'l 38
POSITIVECRAI{KCASEVENTILATIOI{ (FCV) VALVE

Insp€ction.pago 1 1-159
PGM-FI MAII{ RELAY

RolayT6sting,page 'l 1-126
page 1 1-128
Troubloshooting,
ENGINECO TROL MODULE {ECMI

Sell-diagnostic Procedures.page 1 1-42 SEBVICECHECK CONNECTOR(2PI
Troubleshooting.page 1 1-50 S€ff-diagnosticProcedures,page 1 1-42
Romoval,page 11-45
11-7
System Description
Vacuum Connections
H23Al engine{USA: Si/Csnada:SR}

SR-V}
H22Al engine{USA: Si VTEC/Canada:
EVAPORATIVEEMISSIOI{IEVAPI
PURGECOI{TROL
VALVE
SOLEI{OID
EVAPORATIVE EMISSION
{EVAP)R'IRGECONTROL VALVE
DIAPI.IRAGM
EVAPORATIVEEMISSIOI{
{EVAPI COI{TROLCANISTER
TO
EVAPORATIVEEMISSION
{EVAPITWO WAY VALVE
EXHAUSTGAS RECIRCULATION
IEGR)
VALVELIFTSENSOB
EXHAUSTGAS RECIRCULATION
I€GR)
VALVE
MAI{IFOLDAESOLUTE
PREESURE I API 8E1{8OR
STARTII{GAIR VALVE
I TAKE AIR BYPASS

IIABI CHECTVALVE
INTAKE
CONTROL
SOLENOID
VALVE
:?'
FRONTOF VEHICLE FUEL
INTAKEAIR BYPASS
IIABI CO TROL
REGULATOR SOLEI{OID VALVE
TO
CRUISECOI{TROL
INTAKE AIR BYPASS IIAB} COI{TROL ACTUATOR
OIAPHRAGM EXHAUSTGAS
RCCIRCULATIO
IEGR)VACUUM
CO TROLVALVE
EXHAUST GAS (EGR)

CONTROL SOLEI{OID
CONTROL VAIVE
DIAPHRAGM
11-8
F22Al ongine (S):
EVAPORATIVEEMISSION
IEVAPI CONTROI.CANISTER EVAPORATIVEEMISSION
{EVAP}
EVAPORATIVEEMISSION ruBGE COTITROL
(EVAPI PUBGECONTROLDIAPHRAGMVALVE SOLENOIDVALVE
TO
EVAPORATIVEEMISSION
{EVAPITWO WAY VALVE
EXHAUST GAS
RECIRCULATIONIEGR}
VALVE LIFT SENSOR
MANIFOLD AESOLUTEPNESSURE
(MAP} SENSOR
EXHAUSTGAS STARTII{G AIR VALVE

RECIBCULATION
IEGR}VALVE (EGR}
EXHAUSTGAS NECIFCULATION
VACUUMCOI{TROLVALVE
FUEL PRESSURE
REGULATOR
TO
CRUISECONTROL
ACTUATOR
EXHAUST GAS BECIRCULATIOI{(EGR}

CONTROLSOLEI{OIDVALVE
11-9
System Description
Vacuum Connections
H23A1 ongino (USA: Si/Canada:SR)

H22A1 ongine{USA: Si VTEC/Canada:SR-V}
o) HEATED (Ho2s) \--J@

oxycENsENsoR @ II{TAKEAIR BYPASSIIABIVACUUMTANK
O MANIFOLD ABSOLUTE PRESSURE {MAPISENSOR @ ra{TAKEArRBYPASS0AB)CHECI(VALVE
O ENGINE COOLANTTEMPERATURE (ECT)SENSOR @ II{TAKECOI{TROLDIAPHRAGM
@ TNTAKE AIR TEMPERATURE (IAT}SEI{SOR SOLENOTD
@ tt{TAKECOIT|TROL VALVE
@ KNocK sENsoR(Ksl @ I TAKECONTROL VACUUMTANK
@ |DLEAtR co rRoL flact vALvE @ INTAKECONTROL CHECKVALVE
O IDLEADJUSTING SCREW @ THREEWAY CATALYTTC CONVERTEn (TWCI
@ FASTIDLETHERMOVALVE @ postT|vE CRANKCASE VENTILATTON{FCV)VALVE
@ STABTING AIR VALVE @ EXHAUSTGASBECTRCULAIION (EGRIVALVE
@ FUEL[rtJEcToR @ EXHAUSTGASRECIRCULATION (EGR}VALVELIFT
@ FUELFILTEB SENSOR
@ FUELPRESSURE REGULATOF @ EXHAUSTGAS REC|RCULAT|OII (EGRIVACUUM
@ FUELPUMP CONTBOL VALVE
@ FUELTANK @ EXHAUSTGAS RECTRCULATTON {EGR}CONTROL
@ AIRCLEANER SOLENOID VALVE
@ RESONATOR @ EVAPORATTVE (EVAP}CONTROL
EM|SS|OT{ CAt{ISTER
@ INTAKEAIR BYPASS(IAB}COIIITROL DIAPHRAGM @ EVAPORATTVE EMTSSION(EVAP)PURGE COI{TROL
@ TNTAKEAtR BYPASSflABl CONTROLSOLENOIDVALVE SOLENOID VALVE
@ EVAPORATTVE EMTSSTON{EVAP}PURGE CONTROL
DIAPHRAGM VALVE
@ EvapoRATtvEEMtsstoN{EvaPl rwo wAY vALvE
11-10
F22A1 ongine
O HEATEDoxYGEr{sEr{soR(Ho2sl @ THREE way caTALyTrccoNvERTEn fiwcl

O MAr{rFoLDABSOLUTE pREssuREtMApt sENsoR c) posrTlvEcRAl{KcasE (PcvtvalvE
vEr{TrLATror{
@ ENGINE coolA T TEMPERATUBE tEcTI sEI{soR @ EXHAUST (EGR}
GAsREcrRcuLATtOr{ valvE
@ II{TAKEAIR TEMPERATURE (IAT)sEI{soR @ EXHAUST (EGR}
GAsREcrRcuLATror{ valvE L|FT
O |DLEAtR co rRoL 0Acl valvE SENSOR
@ IDLEADJUSTI G scREw (EGRI
@ ExHAUsrGAsREctRcuLATtot{ vAcuuM
@ FASTIDLETHERMOVALVE COI{TROL
VALVE
@ START|NG ArRvALv€ @ EXHAUST (EGR}
GAsBEcrRcuLATror{ coNTRoL
@ FUELI JEcToR SOLEIIOID
VALVE
@ FUELFILTER @ EVAPORATIVEEMISSION(EVAPIcO TRoL CAI{ISTER
O FUEI.PRESSURE REGULAToR @ EVAPORATTVEEMTSSIONTEVAP) PUnGECOI{TROL
@ FUELPUMP SOLENOIDVALVE
@ FUELTANK @ EvApoRATrvEEMrssroN(EvAp)PURGE conrRol
@ AIR CLEANEn DIAPHRAGM VALVE
@ RESOI{ATOR @ EvapoRATrvEEMtsstoN(EvApl Two wAy vALvE
11-11
System Description
ElectricalConnections
FUEL
PUMP
'1_
CYP
SEI{SOR
TDC
sEf{soR
CKP
sEitsoR
wEc
PfiESSURE
swtTcH
SERVICE
CHEGX
cot{t{EcroR
col{DEl{SOR
FAl{
RELAY
A/C
swtTcH
GAUCE ASSEMSIY
i FUsEs
c) clocx RADrot10al. o. 4 BACKUP(10 A)
@ SATTERY tlOOAt. ECUGcill (15 Al
@ rGsw tso A). t{o. 13 ttlETER{1OAl
A/T GEAR @ sToPHORir(15Al. cot{oEI{sERFAt{ t15 At.
POStTtOt{ @ FUSE BOXtr$ Alr o. 11 nEARDEFROSTER REIAY110At
swtrcH l{o.2 ATARTER SIG AL 17.5Al
L _ _ _ _ _ _ _ _ _ _ _ _
': in the UI{OER-HOOOFUSE/RELAYBOX
at-tz
TIAP
sE son
TP
8EI{SOR
EGR
vAt-vE
LIFT
SEI{sOR
SOLEOIDVALVE r--=-l
H22Al .nglnc)
€Gn co TnoL solEftolo valvE

EVAP PUNGECO TNOLSOLEI{OIDVAIVE
IAB CO[{TROLSOlEtrtOtOVALVE
INTAXE COITROL AOLETTOID VALVE
o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o
TERMI AL LOCATIONS
(cont'dl
11-13
System Description
ElectricalConnections(cont'd)
Cttt HO23
YEIiTLK
oR /wlft
nco/Btu-
f
t
E
I
WHT/GRt{
WHT/RED- w,si
1l ,arn*"rfl
q101
cl13
---J------'l
vrr.rvyxr
R€D,srx---l lrP sE SoR I
GRx/wHTr _!l________J
---------.r-T------------'l
__jl.:l*r1l
tto prg. 1I -16l lTo p.gp t1-151 lTo p.!. 11-15)
11-14
11-141 ( F r o r np . g . 1 l - 1 4 1 l F r o m p . g . 1 1 - j 4 )
c425
TDC/CXP/CYP
c 133 SEI{SOR
:-:wHT---_----
c102
nroisrxl-[dfiiiJidi5il
BRn---l-[I:jl__l
clo3
c1(x
nronu---1-f
iiliifididil
BLU- ]lltro. 3l I
c105
n:omx --j-liiiiili6i5i-l
YEL-l
lr o. a) |
cl11
srr'---1-ffii----l
RED/GR'{ ]-E!lf9r-___l
ct 09
sLxryel ---- iid--]
ox{ I| lsolCtoro I
| vatvE I
lErccpt F22A1 .ngin.)
cl22
Hiiii;l I."' ".n"o*

|
c10g
$ffiElfl | ,"r senson

I
BED^^rHrlJ-----l
wxrierr I I EGRVALVE I
cRil/wHr,l I tlFr sEI{soRI
System Description
ElectricalConnections(cont'dl
c31O-..._-
at-K/YEt---l l€ci co liol I
RED, ----llj95:g:i1:l
sa".;-l
ffi#ffll
TO COi{DEiISER FAI{
Bt-u/RED_____'
-----i Toa/cHcRoMPnEssoR
RED/8LU
-----> TO A/C SYVITCH
-l I r^ra co|rnol I
I lsor.Er{oro I
llJ !!E-J
lErc.Dl F2241 f,{arl
J I6ERVTCE I
llcHEct( |
ll-99!!!9r98--J
t-Jl
r C43-
T GRX/RED LT GFI{/RED_Il DATA Lt K I
BLI(/RED-l I cO ECTORI
[E+_ REDiErx
E<-YEL/BLU
TCil lA/Tl
ORIIl
PI{K
[T GN[{/BLX
11-16
UI{DED.HOOO
FUSE/RELAYBOX Ut{DED-HOOD
BATTERY {1(x)A) FUSE/RELAY
tG sw l5o Al
FUSE8OX liro Ar c421
CLOCKRADIO{10 A) c422
sToP HOR[{t15 Al WHT/RED
WHTA'EL WHT/YEL
c424
WHT/YEL
c420
ATKATEL
I
r BIK
Grl03
BATTERY
PGM.FI
YE|-/SL(
YEL/BLK
GRI/BLKt
E<--BLK
FUEL
-C537 pUMp
fl_ v:l- _-____j-1 ____h
(PJ
Eszzaer-x ll
G52r tc tTtON
swrTcH
UI{DER.DASH TO
FUSE/REI.AYBOX M/T: STARTER
c) ECUiECMItls At CUTRELAY
@ Ito. 2 STAKTERstcilAl A/T: A/T GEAR
t7.5Al POStTtot{
@ o.4 BACKUPt10 Al SYVITCH
O o. 13 METER tlo A)
c466
c471
BLU/RED
GRiUwHT' GRt{/WHTI
GRI{MIHT
FUSE/RELAYBOX
c479..-........................"-.".-.-
rHrljl
GRr{^ BRAKE I
wnrrrer-ll_llcH l
lTo p!96 11-18, (cont'd)
11-17
System Description
ElectricalConnections(cont'dl
l F . o mp ! g ! 1 1 . 1 7 1 GAUGE ASSEi'BLY
N |-'FFGEF_I
I I HPOSmOI{ |
ll ltrlswmcx I
c13a
c4a4 - cr39
cRr/YEL-- wEc solEl{olD
VALVE
lH22A'l.n!rn.l
swrTcH
tH22.A1
ri
11-18
System Description
System Connectols lEngine Compartment]
SR-V}
H22Al engine{USA: Si VTEC/Canada:
H23A1 ongine{USA: Si/Canada:SR)
ENGINE
WIRE HARTTESS
MAIN WIR€
HARNESS
11-20
c114 cll5 c117 c122
rF|-r
l l l 2 1 |3
IO) IGRN^^/HTZ I l-6''I"*t----.',

lEilwlr-- - lO IBL(,"/eL I
O loRt,M/Hr I l6F'it------1
ldlYE BLK i
C137 lH22Al onglnql C138 (H22Al .nginol c420
lrJ
tr
l-6'l6iNrEi-----'l
c422
r-FF-r 1 2 4 5
l l j 2 1 3 l
7 8 9 10 1 1
r'-T"*----l REO/6LU
2IBLX/GRI-- ---1
I
f5-lwxr 3 a LX tASSt
FEOr'GFN LKI''EL IA65)
5
NOTE: Diflerent wi,es with the same color have been given a number suffix to distinguish them {for example YEL/BLK1
and YEL/BLKzare not the samel.
l: Relatedto Fuel and EmissionsSvstem.
System Description
SystemConnectors[EngineCompartment](cont'd]
H22Al engine (USA: Si VTEC/Canada:SR-V)
H23A1 engine (USA: Si/Canada:SRI
6'
!,,-
.lv
c432
c135
MAIN WIRE
HARNESS c4a4
c139
ENGINEWIRE
HARNESS
11-22
c426 c429
c/*12 (M/Tl C484 (H22Ai onglnrl
{,t( --l
lO--lCiNrEL
IBLUI"'EL IT
'It,,YEL RED/II.U
\oTE: Diffotent wir€s with the same color hsve baen given a number suffix to distinguish them (for example YEL/BLK1
and YEL/BLK, are not the same).
O: R€lated to Fuel and Emissions Svst€m.
(cont'd)
11-23
System Description
SystemConnectorslEngineCompartment](cont'd]
H22A1 engine (USA: Si VTEc/Canada: sR-vl
H23Al ongina (USA: Si/Canads:SRI
LEFTE GIT{E
COIIPARTIIIENT
WIREHARI{ESS
HARNESS
11-24
ct 02 c103 c 104 c105
tr-r-rl tr---T---ll tr---r---rl t--T----rl

2tl tl ti 2tl tl ll 2 I 1 ll ll 2 | 1 ll
---- -'l
|6'TREo/BIK - - - - to) tRED/Blx I l6TnED/aLi----- lSTiED/ELr ---]
j@ leRN -----
lZiTREp-l f6-lilu l6ltrL
c106 c107 c108 cl 09 clt1.
c310 c320 c321
r+
l l l 2 l
NOTE: Difterentwi.es with the samecolor have beengiven a numbersuffix to distinguishthem (tor exsmpleyEL/BLKI
and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSvstem.
System Description
SystemGonnectors[EngineCompartment](cont'd]
F22Al ongino{Sl:
I
ti
MAIN WIRE
HARNESS
HART{ESS
11-26
clr3 cl14 c 11 5 c117 c122
rf:lr
l 1 l 2 1 3 l
16loRNi------l
lO IBLK/YEL ---l I
loFii'-
c420 c421
E
r--Fl_____1
lrl2l3l
FT-,--__l
2
l l8r(/GFN I
16lwii-.
c424
1 2 4
8 9 10 tt
1 REO/6LU 6
2
3 I
I ALK/YELIAAS)
5 10
NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem (for
exampteyEL/BLKr
and YEL/BLK2are not the samel.
System Description
SystemGonnectors[EngineCompartment](cont'd]
F22A1anginolsl:
MAIN
WIBE
HARNESS
ENGI'{E WIRE
HARI{ESS
11-28
c426 c432 (Mtf I
ALK/BIU
RED/6LK
LU'EL
ALK/iED
FEO'
8LU
YEL BLI.I/GiN
c432 lA/Tl
'LU/GRIiI BfiI'I/6LK
a
HT
NOTE: Different wires with tho same color have been given a number suffix to distinguish them (for example yEL/BLK1
and YEL/BLK2are not the sam€).
O: Related to Fuel and Emissions Svstem.
System Description
SystemConnectors[EngineCompartment](cont'd)
F22A1 engine{S):
'j
11-30
ct ol cl02 c103 c104 c105
J r-----r1-
I I----T-----rI -J r-----rl-
tffJl tErll ll 2 | 1 ll Il2 | 1 ll
c106 c107 c108 c111
c3lo c320
l 1 l 2 l
NOTE: Oifferent wires with the same color have been given a numbe. sulfix to distinguish them (tor exampte YEL/BLKi
.-r:Relatedto Fuel and EmissionsSvstem.
System Description
System Connectors [Dash and Floor] lcont'd)
DASHBOARDWIRE
HARNESS
MAIN WIRE
HARNESS
I-EFTENGINE
COMPARTMENT
WIRE
LEFT SIDE
WIRE HARNESS
11-32
c442 c443 c445 (A/Tl c451
r-EFr 2 3 4 r-----.-t I
| 1 1 2| 1 l / 1 3|
|r------y.____J__l 6 8 9 llol11 ll;Tvrtl
I r_____lz_____r_J
I
I(, ]LTGRN/RED I lElwH------l

2 ALK t 2 t I
lO lBLx/R€o . 3 GRNTYEL | 3 BLKIVHT I
t o Y€L
5
12
c461 c463 c466
l1l2l3l
l BLU/REO
2 BLX/GFN" 12 q) RED/ALU
3 l 3 RIO/SLK 3 YEL/BLK @ BIU/BLK
15
Y€L 16
7 aLu
8 BCU,IYEL 1A
I 1 9 RED/YEL BLK/ryEI
1o 20
FED/GRN
c469
12
2 BIU/REO 2 ALK 1 3 ALK
YEL/BLU 10 L&'YEL
BLK,YEI
5 6LU 12 BLK/YEL BLK/REO
8L( 1 3 BLU
YEL BLK/tEL 1A
8 1 9 BLK,YEL
YEL/BCO 20
Y€L/8LK
NOTE: Differentwi.es with the samecolor have beengiven a numbersuftix to dastinguish

them (for exampleYEL/BLK1
* : Canada
* *: Canada(with heatedseatsl
11-33
System Description
SystemConnectors[Dashand Floor](cont'd
OASHBOARDWIFE
HARNESS
MAIN
WIRE
HARI{ESS
11-34
c479 c601 c612
I 4 X ,/t7
I 9 t 0 1 1 l2lxh3 1 4 1 5 1 €
RED/BLK
2 GRA/YEL
3 AtK'/EL 3 1t
YEL 12 12
LIJ/FEO GFN
BLK 6
ALU
I GiN/ALU r 6 ALK/RED l 6 BLK
c614
1€
2 BLK/ryEL 17
3 YEL'
ALU' t9
20 GFN/BLK
21 GhN/REO
22
a YEL
REO
BLU/FEO
26
1 2 YEL/iED 2 7 RED/BLK
13
15 3(
NOTE: Ditferentwires with the same color have beengiven a numbersuffix to distinguishthem (for exampleYEL/BLK1
and YEL/BLK,a.e not the same).
*: Canada
System Description
System Connectors [Dash and Floorl (cont'dl
OASHBOARD
WIBE
HARNESS
MAIN WIRE
HARNESS
11-36
c404 c411 (A/Tt c415 {ECM-A}
1t 12
2 YEL
3 RED
giN/BLK r5 H?2rlri?rul I
GRNTYI!
15 YEL/BLU
RED/gL( LI GFN]BLK
ta 8 19 YEL/GFN
I I 20 €LK/8!U
I
AED/BLU 20 BLK'
22 o
c4t6 (ECM-BI c417 tECM-D)
311'r9 7 5 3 1
ldl/rfl 210 8 4 2
YEL/BLK BLU/FED WHI/YEL ['

GRN/IYHT' (}
AEo/BLlr"' l@
BRN,IVHT I(' a€0//EL
BLU/ALK i1a
@ LT3{urtr22lrmnr l{il
8LU/GAN o
BLU/^rlt
REO/ALK
NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem {for exampleYEL/BLK1
and YEL/BLKrare not the same).
* * * : E x c e p tF 2 2 A 1 e n g i n e
System Description
SystemConnectorslFuel Pump](cont'd)
11-38
c537
E
NOTE: Ditfe.ent witos with the same color have been given I number suffix to distinguish them (for example YEL/BLKr
and YEL/BLKzare not the same).
O: Related to Fuel 8nd EmissionsSvstem.
11-39
Troubleshooting
TroubleshootingGuide
NOTE: Across each row in the chart, the systems that could be sourcesof a symptom are ranked in the o.der they should
be inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likely source,then refer
to the pagelistedat the top of that column,It inspectionshows the systemis OK, try the next most lik€lysystemO, etc,
SYSTTM
TOPDEADCENIER/ TNGINC
at'iclNE HEAIEO THNOTTLE EANOMEIRIC IGNITON vtHtclE
ABSOLUTE COOTANT TEM.
CONTROI OXYGEN
PNESSUfiE POSITON/CYUNDES
PO9TtOtl
FCi^TURE
PitssuSE OUTPUT SPfED
MOOULE SENSOR
SENSOR POSftOt'tsE|so8 fuiE sEt{sof
sc soR SENSOR
sfNsoR stcNA! sE[son
50 56, 54, 62 64, 6a 70 76 7A 80 a2
-r.tr-
MALFUNCTIONINDICAIOR
LAMP IMIII" TURNS ON n or-Ll
.o: :i6):
-mi :r6t:
/---\
:r6t1
/---\ -mi rg: lrm.t: \.--r-r /
MAIFUNCTION INOICATOB
EorEl lll or Lll O or-8.o.:ft - --i-t r t - \.--l-
- t r t / - - t__i-r t l - - t t l t - -t---i-15l- \.--1-,
-l_--l-\
t? t-
LAMP IMILl" BLIN(S . \ ---'_-\ / \ /'_-i- \ / \ /
ENGINEWON'T STAFT @ @ @
OIFFICUITTO STAFT
ENGINEWHEN COID
IBU) @ @ o
WHEN COLO
FAST IDLE
OUT OF SPEC.
@ @
ROUGHIOLE @ @
IDTING
HIGH
@
a9
'
:l FREOUENT
IBU)
@
'lr STALLING
@
ROUGH
RUNNING
@ @ @
ANCE
EMTSSTON
TEST
@ @ @
LOSS OF
@ @ @
* lf codesother then those listedaboveare indicated,count the numberof blinksagain. It the MIL is in fact blinking
these codes, reDlacethe ECM.
@ tt ttr" MIL is on while the engineis running,jump the servicecheck connector.lf no code is displayed(MlL stays
on steady),the back-upsystem is in operation.
Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM.
** USA: Canada:
MALFUNCTTON -[tglt- r-tr- '6+r-
CHECK
;ND;CATOR ENGTNE ;t-\+:
,
LAMP {MILI LIGHT
'** E x c e p tF 2 2 A 1 e n g i n e( s )
engine (USA: Si VTEC/Canada: SR-V)
11-40
IOLECONTFOL FUELSUPPTY EMISSIONCONTFOL
ETH USI GAS
ELECTRICAL XNOCK IOIEAIF OTH'i OTHER nEcncu.
FUEI INIAKT OTHER
LOAO uFrE|lcTnoMc LIFTELECNOMC SENSOF CON'FOL IDL' FUEL EMtSS|ON
DETCCTOR :o{TnoLsoLENoto
:OIITROL
PiESS!iI SIGNALA SIGNAL
8 INJECTOF
c0NTROTS c0[TioL coNTiots
sYstE
84 6-75 677 8a 90 90 96 92 116 r13 131 153 149
tf -q. rg- / - \ D E ffil

/---\
-r6t-
/_l-\
-r6t-
- ' .
\.--r-l
-t 201 -t-_-i--2r I t 2 2| -t 23I 11361,lrt- - l r 6I \.--.1- /
/---,_-. , \ /-....-. @ | | 2t\ -
z --"i--
@ o
o @
o @ @
o @
@ o @
o o @
@ o @
o @
o
@ @ @ o @
11-41
Troubleshooting
Self-diagnosticProcedures
When the MaltunctionIndicatorLamp (MlL) has been reponed on, do the following:
1. Connectthe servicecheckconnectorterminalswith a jumperwire as shown (the servicecheck connectoris lo-

cated behindthe center console).Turn the ignitionswitch on.
OATA LINK
co it€cToR{3Pl
Do not attach
the jumperwire.
CHECK
SERVICE
CONNECTOR(2P)
JUMPERWIRE
2. Note the DiagnosticTroubleCode (DTC):The MIL indicatesa code by the lengthand numberof blinks.The MIL
h can indicstesimultaneouscomponentproblemsby blinkinqseparatecodes,one atter another.Codes 1 through
I are indicatedby individualshon blinks.Codes10 through43 are indicatedby a seriesof long and shon blinks.
The numberof long blinks equalsthe first digit, the numberoJ short blinks equalsthe seconddigit.
USA: CANADA:
MALFUNCTION CHECK
INDICATOR ENGINE
LAMP LIGHT
{MIL}
S6pa1.t. Ptobl.mr:
Shon
l-1 -jl-rL- = Soe DTC 1
tU-X-r- r]r1.f1--JlrrL = Seo OTC 3
X{I- = scoDTC13
Long sho.l
SimuhanoouaProbloms:
J rJTxrL-----n l'lr]rL = 566 DTc 1 and 3
Jltll-r-r]f1J-1l-L-
--n-trxrrl_nnrL = 566 OTC 3 and 4
J-lt-x-L-J = Soo DTC 3 and 14
11-42
ll. EngineControl Module {ECM}ResetProcedure
1. Turn the ignitionswitch off.
2. Removethe the CLOCKRADlO ( 1O A) f use f rom the under-hoodtuse/relavbox for 1O secondsto resetthe ECM.
NOTE:
a Disconnectingthe CLOCKRADIO(10 A ) fuse also cancelsthe radio preset stationsand the clock setting.
Make note of the radio presetsbefore removingthe fuse so you can.eset them.
a The radio may have a coded theft protectioncircuit. Be sure you get the customer's code numberbefore removing
the CLOCKRADIO{10 A) fuse.
t . FinalProcedure(this proceduremust be done sfter any troubleshooting)
1. Removethe jumper wire.
NOTE: lf the servicecheck connectoris jumped, the MIL will stay on.
2, Do the ECM ResetProcedure.
3, Set the radio presetstationsand the clock.
11-43
Troubleshooting
Self-diagnosticProcedures(cont'dl
DIAGONOSTIC
TROUBLE SYSTEMINDICATED Page
coDE (DTC)
o ENGINECONTROLMODULE(ECMI 11 - 5 0
HEATED
OXYGEN (HO23)
SENSOR I t-50
11 - 6 4 ,
(MAP SENSOR)
MANIFOLDABSOLUTEPRESSURE
5 68
4 CRANKSHAFTPOSITION(CKPSENSOR} 11-70
6 ENGINECOOLANTTEMPERATURE (ECTSENSORI
7 THROTTLEPOSITION(TP SENSOR} 11-74
I TOP DEAD CENTERPOSITION(TDC SENSOR} 11-70
9 N o , 1 CYLINDERPOSITION{CYP SENSOR) 11-70
10 (IATSENSOR}
INTAKEAIRTEMPERATURE 11-76
't2 EXHAUST GASRECIRCULATION
IEGRVALVELIFTSENSOR) 11 - ' l5 3
13 EAROMETRIC (8ARO SENSOR)
PRESSURE 11-79
14 IDLEAIR CONTROL(IAC VALVE) 11 - 9 6
tc IGNITION
O U T P U TS I G N A L 11 - 8 0
to FUELINJECTOR 11-116
VEHICLESPEEDSENSORIVSS) 1' 1-82
20 ELECTRICAL (ELD) 'I
LOADDETECTOR 1-84
'.1
21 VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC

CONTROL{VTEC}
6-75
SOLENOIDVALVE*'
'tJ
22 VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC
CONTROL{VTECI
6-77
PRESSURESWITCH**
23 K N O C KS E N S O R( K S } I 11 - 8 8
4'l HEATEDOXYGEN (HO2S)HEATER
SENSOR 11 - 5 8
43 FUELSUPPLY
SYSTEM 11-62
*: ExceptF22A1 engine(Sl
": H22A'l engine{USA: Si VTEC/Canada:SR-V)
a lf codesotherthan those listedaboveare indicated,verify the code. It the code indicatedis not listedabove,replace
the EcM.
a The MalfunctionIndicatorLamp (MlL) may come on, indicstinga system problemwhen, in fact, there is a poor or
intermittentelectricalconnection.First,check the electricalconnections,clean or repairconnectionsif necessary.
a The MIL and D4 indicatorlight may light simultaneouslywhen the code blinks 6, 7 and 17.
Checkthe PGM-FIsystem accordingto the PGM-FIsystem troubleshooting,then recheckthe D4 indicatorlight. lf
it lights, see page l4-36.
a The MIL does not come on when there is a maltunction in the A/T Fl signalor slectricsl losd detector circuits. However,
it will indicatethe codes when the servicecheck connectoris iumDed.
11-44
lf the insp€ctionfor a panicularfailurscode requiresthe test harness,removethe right door sill moldingand the small
coveron the right kick panel8nd pull the carpetbsck to exposethe ECM.Unboltthe ECMcover.With the ignitionswitch
off, connectthe test harn€ss.Checkthe system accordingto the proceduredescribedtor the appropriatecode(s)listed
on the following pages.
DIGITALMULTIMETER
KS-AHM-32-003
TERMII{AL LOCATIOI{S {cont'd)
11-45
Troubleshooting
Self-diagnosticProcedures(cont'd)
a Punctudng th6 insulation on a wile can causa poor or Intermittent eloctdcal connectlona,
a For lasling at connectora othor than ths test harness, brlng tho taster probo into contact wltlr tho telmlnll tlom tho
connoctor side of wiro harnoaaconnoctors in th€ engin€ companmont. For temelo connectoB,lust touch llghtly whh
tho tostsr probe and do not insort th€ probe.
TERMII{AL
t,-l
l-rI
,i,1i
-it1
11-46
How to Read Flowcharts
A flowchart is designedto be used from start to final repair.lt's like a map showing you the shortestdistance.But be-
ware: it you qo off the "map" anywherebut a "stop" symbol, you can easilyget lost.
TSTAR-T] Describesthe conditionsor situationto start a troubleshootingflowchart.

Eotaivpet
Fdfibxl Asks you to do something;perform a test, set up a conditionetc,
@ Asks you about the resultof an action,then sendsyou in the appropriatetroubleshootingdirection.
trroFl The end of a seriesof actionsand decisions.describesa tinal repairaction and sometimesdirects
(bold typel you to an earlierpart of the flowchart to confirm your repair.
NOTE:
a The term " lntermittentFailure"is usedin thesecharts.lt simplymeansa systemmay havehad a tailure.but it checks
out OK at this time. It the MaltunctionIndicatorLamp(MlL)on the dashdoesnot come on, checkfor poorconnections
or loose wires at all connectorsrelatedto the circuit that you are troubleshooting(see illustrationbelow,.
a Most of the troubleshooting flowchartshaveyou resetthe EngineControlModule(ECM)and try to duplicatethe diag-
nostic troublecode (DTC).lf the problemis intermittentand you can't duplicatethe code, do not continuethrough
the tlowchart. To do so will only result in confusionand, possibly,a needlesslyreplacedECM.
a "Open" and "Short" are common electricalterms. An open is a break in a wire or at a connection.A short is an
accidentalconnectionof a wire to groundor to anotherwire. In simpleelectronics,this usuallymeanssomethingwon't
work at all. In complexelectronics{likeECM's),this can sometimesmeansomethingworks, but not the way it's sup-
poseoro.
a It the electricalreadingsare not as specifiedwhen usingthe test harness,checkthe test ha.nessconnectionsbefore
proceeding.
11-47
PGM-FISystem
System Description
ENGINECONTROLMODULE{ECM) OUTPUTS
TDC/CKP/CYPSensor Fuel Injectors
MAP Sensor PGM-FlMain Relay(FuelPump)
ECT Sensor MIL
IAT Sensor IAC Valve
TP Sensor A/C CompressorClutch Relay
HO2S rcM
vss F"*li"",---fl-ni-l-".M;l EVAP Purge Control Solenoid Valve
BAROSensor --_]l HO25 Heater
StarterSignal @;bbc-t.d VTEC Solenoid Valve"
ALT FR Signal ALT
Air ConditioningSignal EGR Control Solenoid Valve
A/T Gear PositionSignal Fit"rJ,,"o,,"-',....-,,,"o.*-,,cont,ot,,cont.trr".**-_-l
IAB ControlSolenoidValve'
BatteryVoltage(lGN. 1) lntake Control Solenoid Valve*
BrakeSwitch Signal Eil,*"s c-,'d I
PSP Switch Signal
EGR Valve Lift Sensor
Knock Sensor* fEcMB*k',p F;tb";-ll]]l
VTEC PressureSwitch* *
': Exc€ptF22A1 enqine

": H22A'l engine
PGM-FISvst.m
The PGM-FIsystem on this model is a sequentialmultipon fuel injectionsystem
't,
Fuel Inlector Timing and Duration
i:r The ECM containsmemo.iesfor the basic dischargedurationsat variousenginespeedsand manifoldpressures.The
basicdischargeduration,after beingreadout from the memory,is further moditiedby signalssent from varioussansors
fii to obtain the final dischargeduration,
ldle Air Control

ldle Air ControlValve (lAC Valve)
When the engineis cold, the A/C compressoris on, the transmissionis in gear (A/T only) or the alternatoris charging,
the ECM controlscurrent to the IAC Valve to maintsincorrect idle speed.
lgnition Timing Control

o The ECMcontainsmemoriesfor basicignitiontiming at variousenginespeedsand manifoldpressures.lgnitiontiming
is also adjustedtor enginecoolanttemperature.
a A KnockControlSystemisalsoused.When detonationis dotectedbythe knocksensor,the igntiontiming is retarded
(ExceptF22A1 engine).
Other Control Functions

1. Starting Control
When the engineis started,the ECM providesa rich mixture by increasing{uel iniectorduration.
2. Fuel Pump Control
a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-FImain relay that supplies
current to the fuel pump fo. two secondsto pressurizethe fuel system.
a When the engineis running.the ECMsuppliesgroundto the PGM-Flmain relaythat suppliescurrentto the fuel pump.
a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FImain relaywhich cuts
currentto the fuel pump.
3. Fuel Cut-off Control
a Duringdecelerationwith the th.ottle valveclosed.currentto the fuel injectorsis cutoff toimprove fuel economy
'l
at speedsover ,1OOrpm.
a Fuel cut-otf action also takes place when engine speed exceeds, F22A1 (S): 6,6O0 rpm. H23A1 (USA: Si/
Canada:SR): 6,8O0 rpm. H2241 (USA: Si VTEC/Canada:SR-VI: 7,7OOrpm, regardlessof the positionof the
throttle valve. to protect the enginetrom over-revving.
11-48
4. A/C CompressorClutch Relay
When the ECMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorJrombeing
energized,and enrichesthe mixture to assuresmooth transitionto the A/C mode.
5. EvaporativeEmission(EVAP)purge ControlSolenoidValve
when the enginecoolanttemperatureis betow 167 oF (75 "Cl IH22A'| engine(USA:Si VTEC/Canada: SR-V):1bg oF
(70oC)1,the ECMsuppliesa groundto the EVAPpurgecontrolsolenoidvalvewhich
cuts vacuumto the EVAp purge
control diaphragmvalve.
6. IntakeAir Bypass(lAB) ControlSolenoidValve

When the enginespeed is below 4,8OOrpm IH22A1 engine(USA: Si VTEC/Canada: SR-V):4,600 rpml, the IAB
controlsolenoidvalveis activatedby a signalfrom the ECM,intakeair tlows throughthe long intakepath, then high
torque is deliveredAt speedshigherthan 4,8OO(or 4,600) rpm, the solenoidvalve is deactivatedby the ECM.
and
intake air flows through the short intake path in order to reducethe resistancein airflow.
7. Intake Control SolenoidValve

When the enginespeedis below 4,000 rpm, the ECM suppliesa groundto the intakecontrol solenoidvalve. This
opens the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm.
8. ExhaustGas Recirculation{EGR)Control SolenoidValve

when the EGRis requiredtor control of oxidesof nitrogen(NOx)emission,the ECM suppliesground to the EGR
control solenoidvalve which suppliesfegulatedvacuum to the EGRvalve.
9. Alternator(ALT) Control
The system controlsthe voltagegeneratedat the altematorin accordancewith the electricalload and drive mode,
and reducesthe engineload to improvethe fuel economv.
ECM tail-safe/back-upFunctions
1. Fsil-safeFunction
When an abnormalityoccursin a signalfrom a sensor,the ECM ignoresthat signaland assumesa pre-programmed
value fof that sensot that allows the engineto continueto run.
2. Back-uDFunction
When an abnormalityoccursin the ECM itself,the fuel injectorsare controlledby a back-upcircuit indeDendent
ot
the system in order to permit minimaldriving.
3. Self-diagnosisFunctionIMalfunctionIndicatorLamp (MlL]1
When an abnotmalityoccurs in a signalfrom a sensor,the ECM lights the MIL and stores the code in erasablememory.
When the ignitionis initiallyturned on, the ECMsuppliesgroundtor the MIL for two secondsto check the MIL bulb
condition.
11-49
PGM-FISystem
Flowchart- EngineWill Not Stan
Troubleshooting
Watch the Mallunction Indicator

Lamp (MlL)and turn th€ ignition
swirch ON.
Porfo.m tioubleshooting on pago

Did the MIL come on at all? 11-51.
Portorm t.oubloshootingon pago

11-52.
Turn the ignitionswitch OFF.
Connectthe test harnessb6tw96n

the ECM and connectors (see
page 1 1-45).
1 . OV ?
Turn the ignitionswitch ON.
Measure voltage between body

ground and the tollowing termi-
I nafs individually:A23, A24.
R6psir op6n in wir6(61 botwoon

ECM 6nd GlOl llocst€d at ther-
ls there less than 1.O V?
moltat houringl that had mo.6
thsn 1.0 V.
Inspect tuel pressure (see page

1 1 - 11 5 ) .
Popair as nocoaaa.y {ago pag6

11 - t t 5 ) .
Portorm ignition systom chock

{3o6 Baction 231.
11-50
TroubleshootingFlowchart - EngineControl Module (ECM)
Tho Maltunction Indlc.tor Lamp

(MlLl nover com6! on l6vcn tor
two sgcondsl aftei ignition i3
tuhgd on.
Inspect No. 13 METER110 A)

ls the low oil p.essurelight on? fuse (in the under-dashfuse/relay
oox,.
Connectthe test harnessbetween

the ECM and connectors (se€ R6palropan in YEL wir6 botwoon
page 1 1-45). No. 13 METER(1O A) ture.nd
gaugo alrombly.
o o o o o o o o o o o o o ooooo ooo I o@#qPt}| ooooooooooo

ooooo odooo ooo I oooooo oo ooooooooooo
- RaDlocoth6 MIL bulb.

- Ropairop6n in 8LU/WHT wire
ls the MIL on?
botwoon ECM lA13l and
gaugs a88ombly.
| 423
t-.-----+-
II LoooooooooooQo I ooooo999l1!9!t!1!!lg{ ooooooooooo I
|---T-
L Le.. than 1 .0 V? --{
a,
+-
Measure voltage between body
ground and the tollowing termi-
nals individuallv: A23, A24.
Ropalr opon in wiro(sl botwson

ls thsre less than 1.0 V? ECM and GlO1 {locatod at thor-
mostat housing) that had moro G101
than 1.0 V.
Subrtituto a known-good ECM

6nd rechock, lf symptom/lndica-
tlon gooa away, raplaco tho origi
nal ECM.
11-51
PGM-FISystem
TroubleshootingFlowchart - Engine Control Module IECM)
NOTE: When there is no code stored,the MIL will stay
The Mallunction Indicator L6mP on if the servicecheck connectoris jumped.
(MlL) 3tays on or com63 on allo.
two soconoS.
Connect the service check con-

nector terminalswith a jumper
wire {see page 11-42).
Does the MIL indicate Go to rslf-diagnoatic ptocodutos

any Diagnostic Trouble
lso6 pags 11401.
code (DTc)?
o oooooooo oooo I oooooooom oooooooooo

ooooo ooooo oo ol oooooooo
R€movethe iumper wire from the D 4l + l
service check connoctor. r_S V?
{A/T:
Try to start the engine.

the ECM and conneclors {see
p a g e1 1 - 4 5 ) .
Measurevoltage between D4 (+)

terminaland D21 l-) terminal.
Connect the service

ls thereapprox.5V (A/T: 11 V)? check connector terma-
nalswith a jumper ware.
Bopair shorl to body ground in

BRN/ WHT wiro botwo€n tt|o ECM Mgasure voltage be-
{t}4}, lrsnsmission Control Mod- tween D4 (.t ) terminal
ulo lTCMl, ABS contrcl unit or and D21 {-) terminal.
4WS control unit and seryico
chock connoqtor.
- Repairopen in BRN/WHTwite
botwoon ECM (O4l and sorv- ls there spprox. 5 V
ico chock connoctor. ( A / T :1 1 V l ?
Removeand inspectthe NO. 4 - Repairop6n in BLU/WHTwite
BACKUP(10 Altuse in the under- botwoon sorvico check con-
dash fuse/relaybox. noctor and ECM {O211.
Remove the ,umper
wire from the service
check connector.
ls the fuse OK7
page 11-53)
YES 'NorE: After reDair,disconnectrhe servicecheck con- lro
nector iumper wire, test drive the car, and recheck the
{ T o p a g e1 1 - 5 3 ) MIL for code.
11-52
11-52)
Insp6ctthe ECU (ECM) (15 A)

Iuse anthe underdash tuse/relay
box.
Disconnect"A" con,
nectorlrom the EcM.
Substituto . known{ood ECM

Disconn6ct the 3P connector of and rochock. lt lymptom/indica-
tion gooa awsy, roplaca the origi- ls the MIL ON?
each sengor one at a time:
. MAP sensor n8l ECM.
. EGRvalve litt s€nsor
. Throttle Position (TP) sensor
R€prir rhort to body
ground in BLU/WHT
wlro betwoontho ECM
{A131rnd th6 MlL.
Doesthe MIL romainON? RoDlacatho aenaor that causod
thc light to 9o our.
"l;_-l
Connect the test harness.
Oisconnoct the "O" connector I o o o o o o o o o o o o o I o o o o o o o o f , S & l * * * * No o o o o o o o o o o |
I
|
Irom the ECMonlv, not the m6in
wire hamess(seepage | 1-451. D20
-l-
\:-----:J
Continuitv?
Check tor continuity between
body groundterminalsD'l9, D2O.
- Bopair .hort to body ground in
RED/WHTwiro bctwe.n ECM
{Dl9} ond MAP 3onso.or EGR
ls th€re continuityT valve lift sonror.
- Bopair shon to body g.ound in
NO YEL/WHT wlre botw66n ECM
lD2Ol and TP !on3or.
Reconnect all the sensor con-
nectors.
Reconnectthe "D" connector to
the ECM.
Turn th€ ignirionswitch ON.
(To page 1 1-54)
(cont'd)
11-53
PGM-FlSystem
TroubleshootingFlowchart - Enginecontrol Module IECMI (cont'd)
(Frompage 1 '!-53)
Measurevoltage between body

groundandthe tollowingterminal
individually:A26, B2.
A26 82
l l
'1.0 v?
Less than
]L
Repai.op6nin BLK/REDlA26) or
ls rhere lessthan 1.0 V? BRN/BLK(B2l.nd G101 llocatod
6t thormoslat housingl.
A 2 5( . r ) 8 1 { + )
Measurevoltage between A26

I - ) andthe following:81 {+ ) and
A25 (+). BATTERY
BATTERY
VOLTAGE? VOLTAGE?
- Repair opon in YEL/BLK wir6

betweon ECM (425, 81) and
PGM-Fl main iolay.
- Check PGM-FImain tolaY .nd
wiring connoctors at PGM-FI
main r6lav.
Substitute a known-good ECM
and recheck. lf symptom/indica-
tion goes avray, replacethe otigi-
nal ECM.
11-54
Y
PGM-FISystem
TroubleshootingFlowchart - Heated Oxygen Sensor (HO2S)
The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTroublecode {DTC)1: A problemin th€

mr-
ff'_
ri--ri
_.-i- _ HeatedOxygen Sensor(HO2S)circuit.
The HeatedOxygen Sensor(HO2S)detectsthe oxygen content in the exhaustgas and signalsthe ECM. In op€ration,
the ECM receivesthe signalsfrom the sensorand variesthe durationduring which fuel is injected.The HO25 has an
(H2341 engine
internalheater,The heaterstabilizesthe sensor'soutput. The HO2S is installedin the exhaustmanifold
(USA: Si/Canada:SR). H22A1 engine(USA: Si VTEC/Csnada:SR-VI:in the exhaust pipe A)'
HEATER
TEBMINALS
VOLTAGEIVI
SENSOR
TERMINALS - LEAI{
RICH- AIR.
FUEL
lm;rl lrirl RATIO
-Y- -.-i-
- Tha MIL hsa becn roDortodon.
- Yvlth sorvico chack connoclor
iumpod l.60 page I 142), codo
1 i3 indicatod.
Do the ECMResetProcedure{see
p a g e1 1 - 4 3 ) .
Warm up engine to normal oPeF

atingt€mperature(the radiatorfan
comeson),
Run enginetor 60 seconds.
Roadtest with the manualtrqls-

mission in 4th geat I AfIt lA
position).
Starting st 1,600 rpm, accelerate
using wide open throttl€ for at
least 5 seconds.Then doceler€te
tor at least 5 seconds with the
throttle completoly closed.
Intormittont lrllur., systom l. OK

al thb time. Ch.ck to,. poot con-
ls the MIL on and does it indi- noctlons o. loorc wiror at C432
cate code 1? {locatod al tight shock towcr),
C114 (HO2S)and ECM.
Go !o pagl. and p€rtorm tcat for

.-.3 l- p.fo 11-62).
-
11-56
PGM-FISystem
Flowchart- HeatedOxygenSensor(HO2SlHeater
Troubleshooting
:ml1:f,f-f : The MattunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)41: A problemin
-Y- -*- the HeatedOxygen Sensor(HO2S)Heatercircuit.
-[6]- ]l-rTll
-]-\
/ 7.---:- \
- Engino ia running,
- Tho MIL hsr bcon roportodon.
With rervica chock connoctol
iumpod (soopage 11421, codo
41 ir indicalod.
Do the ECM RssetProcedure(see H23Al ongino {USA: Si/Clnada: SR)

p a g e1 1 - 4 3 ) . H22Al engin. {uSA: Si vTEc/Canada: SR-VI:
lrrtd$frqrttS$6,3ys-
tom 13OK at thi! tlmo
Itost drlvo maY bo
nacrsrsryl. D
ls the MIL on and does it indi- Chock lor poot connoc-
cate code 41? tionr or 10036wirot rt
C432 llocat.d at right
shock toworl, C114 10-r|o
lHO2Sl and EcM. o?
DIGITAL
MULTIMETER
KS-AHM-32-003
Disconnectthe 4P connectorfrom
the HO25.
Me6sute tesistance betweon ter-

minsls C and D on the HO2S.
ls there 1O-4O 0?
DIGITAL
MULTIMETEB
( T o p a g e1 1 - 5 9 ) KS-AHM-32-003
11-58
11-58)
H23A1 engino
IUSA: Si/Canada:SRl.
H22Al ongino
Check lor continuity to body (USA: Si VTEC/Canada:SB-V):
ground on telminalsC and D ot
the HO2S.
Check foi continuity between ter-

minalD and terminalsA and B in-
dividually.
HO2S
45 N.m
F22A1 ongine (S): (4.5 kg-m,
At HO25 harness,measurevol,
tage between YEL/BLK{+ I termi-
nal and ORNMHT {- ) terminat.
YES Disconnectthe "A" connector HO2S

ls there battery voltage?
from the ECM. 45 N.m
{4,5 kg-m, 33 tb-ftl
Meosure voltage bstween YEL/

BLK (+l re.minal and body At HO25 harness, measure vol-
ground. tage between YEL/BLK(+ )termi
nal and ORN/WHT(- ) teiminal.
Repair 3hon in ORf{/

ls there battery voltage? WHT wire botwoen
ECM (A6l and HO2S.
Ropairopon in YEL/BLK
wiro botwoon HO2S
and PGM-FImsin rolav.
Turn the ignirionswitch OFF.
Reconnectthe HO25 connector.
{To page 1 1-60} {To page 1 1-60)
{cont'd}
11-59
iM-Fl System
PGM-FI
TroubleshootingFlowchart - HeatedOxygen Sensor(HO2S)Heater {cont'd)
(Frompsge 11-59)
"A"
Connoct the tesl harness
connector to the main wile haF
ness only. not the ECM (seepage
11-45).
Connect an ammetet b€tween tel-

minalsA6 { + ) and A26 (- )
' Monitor over a 5 minutes period.
ls the curront less than

0.1A?'
Subrtltut. a knownSood ECM

lnd rochock. ll .ymptom/indica-
tion 9o6a away, roplaco tha origi_
nal ECM,
Reconnect the 4P connector to

the Ho2s.
"A" oooooooo ooooooooooo

Connect the test hahess BATTERY o o o o o o o o o o o o o
connector to the main wi.e haF VOLT oo ooooooooooo oooooooo ooooooooooo
ness onlv, not the ECM (s.e page
11-45).
Turn th6 ignitionswitch ON.
Measurevoltage between A6 {+}

terminsland A23 {- } terrninal.
Rep.lr op€n in OR /WHl wir. bc-

ls there battery voltage? twcrn ECM lA6) .nd HO2S.
Subllltuto 6 known-good ECM

and$chock. ll symptomlindica-
t'roril'golr ay{ay, rsplaco tho otigil_
nal ECM.
11-60
F
PGM-FISystem
TroubleshootingFlowchart - Fuel Supply System
:r,*n-- \r-r-l
-t 13l The MatfunctionIndicatorLamp (MlL) indicatesDiagnosticTroublecode (DTC)43: A problemin
- - - | t / | \ the HeatedOxygen Sensor{HO25) circuit or a problemin the Fuel Supply System
l@r rE.
- Tho MtL hc! b.cn roportod on . Fiom cod. 1 troubb-
'l
- Wlth rorvico chock connoctoi 3hootlng lpag. I -561.
iurDod t!.3 p.Oe 1 142), codo
43 l. indicatod.
ls the codo 43 accompaniod by Go to Fu.l Supply Systam (3.o

the MIL and poor driveabilitY? p!9. l1-'1131.
Do the ECM Reset Procedure

lse6 page 1 1-43).
warm up engineto normSloper'

ating tompgrature{the radiatorfan
comes on).
Hold engineat 3,OOOrpm lor two

mtnutes.
(A/T:NorEposition.)
Intlrmlttdrt t ilurc, ly.tom is OK
,,ti at thir dm€ (t6st drlv. may ba
nocoalarYl.
i,l
ls the MIL on and doss it
indicate code 43? Chock tor ooor connactiona o.
loor. wirst at C432 lloclt.d !t
rtght rhock low.tl, C1f4IHO2S) -
and ECM.

NOTE:
. Use DIGITALMULTIMETER
(KS-AHM-32-OO3)or equival6nt.
Connect the test hamess bgtween . Use 2 Volt range.
the ECM and connoctors {see
page 1'l-45).
With the ignitionswhch OFF,wait

tor st least two minutes. 6 A26
JUMPERWIRE
Install a iumper wire on the test
harnessbotween A6 and A26.
Voltaga .hould ttan tl D 1 4( + l

A26{-t
I 0.4-0.5 v wh.n thc
ignltion .whch i. fit8t
tunad oo, and dactaaso
Measure voltage between Dl4 to b.low O.l V In L.t
l+) terminaland A26 {- ) termi- than two mlnut6a.
nal as soon as the ignition switch
is turned on,
lTo page 11-63)
11-62
lFrom page 11-62)
ls there 0.1 V or l€ss when the

ignition switch is tirsr turned
on?
Measurevoltage belween D14

{ + ) t e r m i n a la n d A 2 6 ( - )
telminal.
ls there more than 0.1 V?
Disconnect the "D" connector

trom the main wire harness.
Measurevoltage between D14

{+} terminaa
l nd A26 {-) rer
minal.
Bop.ir rhon in WHT

ls there more than 0.1 V? wlro b.tw.on ECM
(Dl4l andHO2S.
Measu.e voltage at the engine Substitute a known{ood ECM

wi.e harness side ot the HO2S and r6.hock. lf symptom/indlca-
connector between GRNMHT tion goos away, roplact the orlgl-
( - ) a n d W H T( + ) . nal ECM.
ls th€re mor€ than 0.1 V?
Chock for oDcn in IIVHTwiro be-

tw..n ECM (D141 and HO2S. lf
wlrs ir OK, r6poir opcn in
GBN/WHT wiro berw66n ECM
(D221and HO2S. H23A1 ongin6 (USA: Si/CanadarSR), GRl{/ W H T( + )
H22Al ongino (USA: Si VTEC/Conada:SR-V); WHT
F2241 sngino {S):
GRI{/ WHT
IVHT - l (+l
moro than
o.'t v?
DIGITAL MULTIMETER HO25 HO2S
45 .m DIGITAL MULTIMETER
KS-AHM-32-OO3 45 N.m KS-AHM-32-OO3
(4.5 kg-m,33 lb-ft|
14.5 kg-m, 33 lb-ft)
11-63
PGM-FISystem
-
TroubleshootingFlowchart -Manifold Absolute Pressure(MAP) $gn5s1
- -l-- - ---1- - The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 3: An electricsl
t 1 6 l - /- l 3, l \-
/--l-\ oroblemin the ManifoldAbsolutePressure{MAP) Sensorsystem.
\ | /-
{-61--fr-r- The MalfunctionIndicatorLamp {MlL) indicatesDiagnosticTroublecode (DTC) 5: A mechanical
/- | problem(vacuumleak) in the ManifoldAbsolutePressure(MAP) SensorSystem'
\ /---i- \
The MAP sensorconvertsmanifoldabsolutepressureinto electricalsignalsand inputs the EcM.
CAVITY OUTPUT
VOLTAGE
(vl3.5
3.0
2.5
2.0
1.5
-16l- - 0.5
/-\/
o lar. Hll OAUOE
N: DING
- Engin6 is watm ond running.

- Tho MIL has b6€nloPortodon
- With soryico ch6ck connoctot
jumpod (so€ pago 1'142), codo
3 is indicalod.
r',i Do the ECM ResetProcedure{see

i , l' p a g e1 1 - 4 3 ) .
I'iI
l l
Intgrmittont failuro, 3yltam is OK

at this time ltort ddve may D6
noc{r!ry}.
ls the MIL on and does it indi- Chock tor Poor connoction! ol
cate code 3? loose wiror at O163 (locatod un-
dor loft 3ideol drshl, C32O IMAP
3.n3otl and ECM.
the MAP sonsor.
(To psge l1-65)
11-64
l F r o mp s g e 1 1 - 6 4 )
Measure voltage between RED/

WHT (+) terminal and body
ft
D 1 9t r l D 2 1( _ l
ground. ooooooooooooo I o oooo ooo
ovooooooooooo I oooooooo

ls there approx. 5 V? WHT (+ ) terminaland BLUMHT
{ - ) terminal.
Turn the ignirionswirch OFF. Ropai. op6n in BLU/

ls there approx. 5 V? WHT wiro betwoon
ECM {D21} and MAP
s6n8l't.
Connect the test harness "D"
connecto.to the ECMonly, notto
the main wire harness (see page
1145).
Measurevollage between D19

l + ) t e r m i n a la n d D 2 1 ( - )
terminal.
Measure voltage betweon WHT/

ls there approx. 5 V? BLU {+ ) terminaland ELUMHT
{ - ) terminal.
Ropairopon in RED/WHTwiro bo-

twcon ECM (D191 and MAP
son3()r.
Sub3tituto a known-good ECM

and rochock. lf 3ymptom/indica-
tion 9003away, .eplacotho origi-
nal ECM.
ls there approx. 5 V?

the MAP sensor.

the EC|VIand connectorlsee page
11-45).
{ T o p a g e1 1 - 6 6 } (cont'd)
{To page 1 1-66)
11-65
PGM-FISystem
(MAPISensorlcont'dl
Flowchart- ManifoldAbsolutePressure
Troubleshooting
{Frompsge 11-65) (Frompage 1 1-65)
MeasuG voltage bstween D'l7

(+l terminaland D21 (-)
terminal.
"D"
Connect the test harn€ss
connectorto the ECMonly, not to
the main wire harness {see page
11-45). ls there approx. 3 V?
Sub.tituls . known{ood ECM

rnd r.chock. lf 3ymptom/lndica-
Turn the ignitionswitch ON. tion goo! 6w!y, r.plact th. odgi
nal ECM.
Measurevoltage betweon D17

( + l t e r m i n a la n d D 2 1 { - )
tetmlnal.
- Roplir rhort In WHT/BLU wiro

botworn ECf,l {D17) rnd MAP
loflto],
ls there approx. 5 V7 - R.prir opon in WHT/BLU wlrc
botwo.n ECM (Dl7l.nd MAP
36nao..
Substltuto a known{ood ECM

and rochock. lf aymptorn/indicr-
tion goo3 away, taplace tho origi-
nal ECM.
11-66
PGM-FISystem
{MAP}Sensorlcont'dl-
Flowchart- ManifoldAbsolutePressure
Troubleshooting
,g: -g-
- The MIL has boon reponod on.
- With sorvic€ chock connector
jumpod ls6opago 1 142), code
5 is indicatod.
Do the ECM ResetProcedure{see

p a g e1 1 - 4 3 ) .
Start the engine and keep engine

speed at 2,000 rpm tor one
minutewith the manualtransmas
sion in neutral {A/T: @ or S po-
sition).
- Intgrmitl6nt lailuro, 3y3tom is
OK al this tlm6 lt$t ddvo mav
bo nocoasaryl.
ls the MIL on and does it indi- - Chock vacuun ho3or, PiPo3
cate code 5? ond connoctionS.
- Mako turo all conn9ctota ar6
30cu16,
MAP SENSOR
l l
'1i
r:ttl
Hrl
Disconnect#21 hose lrom the
throtle body, connect vacuum
pump to the hose and apply
VACUUMPUMP/
GAUGE
A973X-041-XXXXX
#21 HOSE
Connect a vacuum pump to the

MAP sensorand apply vacuum.
Does it hold vacuuml
Connecta T-titling from a vacu- Repairvscuum lsak in hoa€ rout-

um gauge between the throttle ing betwaon MAP asn3or lnd
body and #21 hose. rhrottlo body .
{ T o p a g e1 1 - 6 9 }
11-68
{Frompag6 1 1-68)
Start the engine.
ls there manifoldvacuum?
Connectths test harnessbetween

p a g e1 1 - 4 5 ) .
T-FITTING
Turn the ignitionswitch ON. 3V?

n
D l 7 t + l D 2 1{ - }
Measurevoltage between D17

(.t ) terminal and 021 ( - )
lermrnal,
ls there approx.3 V?
Start the engineand allow it to

idle.
Subltitute a known-good ECM

and rocheck. ll symptom/indica-
tion 9063away, ropl6cotho o.igi-
nal ECM.
11-69
PGM-FISystem
Flowchart- TDC/CKP/CYP
Troubleshooting Sensor
- I 7 -
16l- Tr-l- The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)4: A problemin the

-Yt-._r-- CrankshaftPosition(CKP)Sensorci,cuit.
\ \ The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTtoubleCode{DTC)8: A problemin rhe

- l r G./l - --_-1_/
l 8l-
/-i-\ / \ Top Dead Center (TDC)Sensorcircuit.
\_ j_'-,2 \_ _/ IndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)9: A problemin the

The fiilalfunction
- 1--t-\
16l--l e l-
/ /---- \ CvlinderPosition(CYP)Sensorcircuit.
The CKP Sensordeterminestiming fo. fuel injectionand ignitionof each cylinderand also detects enginespeed.The
TDC Sensordeterminesignitiontiming at start-up(cranking)and when crank angleis abnormal.The CYPSensordetects
the position of No. I cylinder for sequential fuel injection to each cYlindet.
-@Jtrl:;m:-;F-
- Tho MIL ha. b€€n Jooortod on.
; - lilfith loruice ch€ck conn.ctol
iump€d (3ooprgo 1142), codc
.ir 4. 8 rnd/or 9 aro indicstgd.
l,l Do the ECM Resetprocedurelsee

pago 1 1-43).
l ormittont l.ilur., syltom b OK

at this timo ltelt driv6 may bo
neco$aryl.
ls lhe MIL on and does it indi Chock for Door connoctiona or
cate code 4. 8 and/or 9? loos6 wir.s at Al25 (locatod at
dght shock towo.), Cl25 (TDC/
CKP/CYPionsorl .nd ECM.
H23A'l ongino{USA: Si/Canada:SRl, .,.

Turn the ignition switch OFF. vrew rrom
H22a1 engino
sa-vt,
iiisr, si vlicrca"aaa $jT'"'
Disconnectthe 8P conn€ctorfrom
the TDC/CKP/CYPsensor.
( T op a g e1 1 - 7 1 )
11 -7 0
1 1-70)
Measurerosistancebetween ter-
minals of the indicnted senso.. SENSOF ECM
'9oo tsblg SENSOR oTc
COLOF
815 ALU/GRN
cxP
416 SLUTYEL
Roplacathe di.Mbuto. c al3 OFN/aLU
ls there 350- 700 O? houalng {16o soction TOC a
G at4
231. Bll OFN
Bt2
Ch€ck lor continuitv to bodv
ground on both terminals of the
indicatgd sensor.
RoDlrc. th. di.trlbutor

houling (soo aocdon
231.
Connect the test harness to the

main whe harnossonlv, nottothe 8:16 350-7OOO?
ECM (seepag€ 1 1-45).
Measurerosistancebetween t€r- o oooooooooooo I oooooo o l:1E$iq#Cittl o o o oo o oo oo o

minals of the indicated sensoron ooooo oooooooo I oooooo
test harness.
o ooooo oo oo o
'see tablg B1l-
350-7ooo?
o o o o o o o o o o o o o I o o o o o o o o r . s E t $ d i 6 d qo o o o o o o o o o o
ooooo oooooooo I ooooo0oo lfrlE#lls*llooooooooooo
350-7000? 812
R9pai.op.n In tho indi-

ls there 35O-7OO 0? catad alnlor wi10a.
'!oo trble
Check tor continuity to body

groundon Bl 5, 813 or 81 1 ter-
mtnals,
Subltltuto a known-good ECM

lnd r6chock. lt aymptom/indicr-
tion goor away, rcphca tho origi-
n.l ECM.
11-71
PGM-FISystem
TroubleshootingFlowchart - Engine Goolant Temperature(ECTI Sensot -
f'at-
-
lri-tl The MalfunctionIndicatorLamp (MlL) indicstesDiagnosticTroubleCode (DTC)6: A problemin
, - ---;-- the EngineCoolantTemperature(ECT)Sensorcircuit.
The ECTSensoris a temperaturedependantresistor(thermistor).The resistanceof the thermistordecreasesas the en-

gine coolanttemperatureincreasesas shown below.
RESISTANCE
(KO)
-
- h- l 6
--
l- -r - -l---i-
-!/
5l-
/----, - - -20 0 ,ro ao ao r roo 12o (rc,
. 12 aa r0. !.ro 1ta 2r2 2.r r.fl
- The MIL has b6onroDongdon.
- With sorvica ch6ck connoctol COOLANTTEMPERATURE
ENGIT{E
'l
,ump6d l.oo pag€ 1421, c!d6
6 is indicatsd.
Do the ECM ResetProcedure{see

page 1 1-43).
Turn the ignition switch ON,

j Intermitt€nt failure, systgm i3 OK
at thir timo lt6st d.ivr m.y b.
n6ce!l|'yl.
ls the MIL on and does it indi Chock tor poor connootions or
cate code 6? looro wir6 at 9125, 9126 (locrt-
od at righl shock toworl, Cl22
IECT lenrotl, AIf: C411 (TcMl
and ECM.
Warm up engine to normal oper-
ating temperature(th€ radiatorfan
comeson).
the ECT sensor.
Measureresistancebetween the
2 terminals on the ECT sensor.
ls there 2OO-4OO0?
{To pagc 1 1-73)
11-72
( F r o mp a g e 1 1 - 7 2 )
Measure voltage between YEL/ GBN/

BLU and body ground. wHT
YEL/BLU
Measure voltage between YEL/

ls there approx. 5 V? BLU (+ ) torminaland GRNA/VHT
(- ) terminal.
Turn the ignitionswitch OFF. Repair op€n in GRN/

ls there approx. 5 V? WHT wlra brtw.on
EGM (D22) and ECT
tonaoa.
A/T only
Subrrituto r known{ood ECM
Disconnect the 22P connector and iocheck. lf lymptom/lndlcr-
trom the TCM. tion goaa aw!y, rol aco tha origi-
nal ECM.
YES
NO
I
Turn the ignitionswitch OFF. I
I

connectorto the ECMonly, notto
the main wire harnsss ls€e page
11 - 4 5 ) .
v?
T-5
O13l+l
D22 t-l
Measurevoltage belween D13
( + l t e r m j n a la n d D 2 2 ( - )
rermtnat.
Ropairopen or rhon in YEL/BLU

ls there approx. 5 V? wir. betwoon ECM lDl3l snd
ECT sensor.
NO
Subatituto a known-good ECM
and rechock. lt symptom/indica-
tion goos away, r6pl6cothe origi-
nal ECM.
11-73
PGM-FISystem
TroubleshootingFlowchart - Throttle Position (TP) Sensor
lf1=lllfifl The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode IDTC) 7: A problemin

.:. : the Throttle Position{TP) Sensorcircuit.
The TP Sensoris a potentiometer.lt is connectedto the throttle valve shaft. As the throftle positionchanges,the TP
Sensorvariesthe voltage signalto the ECM.
ERUSH
HOLDER OUTPUTVOLTAGENI
BRUSH 5
4
3
RESISTOR
2
lr6t1 :.t1 1
-Yr -t- o.5 THROTTLE
0 oPEt{rNG
- Engino b running. TERMINAL ;;ii-
- Tho MlLhas beonreDortedon. THROTTLE
- With sorvico check connoctot
iumpsd ls6opage 1 142), codo INNER
7 is indicatod. BRUSH
Do the ECM ResetProcedure(see

p a g e1 1 - 4 3 ) .
I Inlormittont Iailure, systom b OK
i ls the MIL on and does it

at this timo lt6st d.ivs m6y b6
nocossaryl.
Chock tor Dooi connections or
indicatecode 7? loos€ wiros at O125, g*13 llocat-
od at right shock rowerl, C113
(TP sonsorl, A/T: C4'l l ITCMI
and ECM.
the TP sensor.

WHT (+ ) terminaland GRNMHT
(- ) terminal.

ls there approx. 5 V? WHT (+) rorminal and body
grouno,
YES YEL/ RED/ GNN/
WI{T BLK WHT
{ T o p a g e1 1 - 7 5 }
(To page 'l1-75)
11-7 4
(F om p8O€11-741 (Frompage 1 1-74)
Repaii opon in GBN/

WHT wiro botwo6n
ls there 6pprox. 5 V?
ECM (D221 End TP
Turn the ignition switch OFF. 30n3('t.
Turn th6 ignition switch OFF.
Connoct
th€testharness
b€tween
tho ECM snd connectors{see
p8ge11-451.
Connoct the test hamess b9tw6€n Turn the ignition switch ON.
the ECM and connoctors ls€e
p a g e1 1 ' 4 5 1 .
Measure voltage betwgen D2O

( + ) t e r m i n a la n d D 2 2 { - )
terminal.
Turn the ignhion switch ON. Rop.ir op.n in YEL/

ls there aoo.ox. 5 V? WHT wlra bolwoon
ECM {D2O} a.|d TP
aonlot,
Subltltut. . known{ood ECM

Measurevoltago b€tween Dll .nd r.ch.ck. It piclcribcd voltage
{+) t€rminaland D22 (-, i! now lvoilabl., rrphco tho orlgi-
terminal. n.l ECM.
o o o o o o o o o o o o o I o o o o o o o o E f f n f f i n S HoFol o o o o o o o o o
o o o o o o o o o oo o o I o o o o o o o o ooooooooo
D 2 0t + l D 2 2 l - l
tsv,J
0.5 V at tull close throttle?
4.5 V at lull open throttle?
ls voltago 0.5 V at full clos€

throttle, and approx.4.5 V 8t
full open throttls?
NOIE: There should be a Diaconngct the 22P connecto.
smooth transition from O.5 V from th6 TCM.
to approx.4.5 V as the throttle
is depressgd.
ls voltageO.5 V at full clos6 - Roplac6 the TP
throftls, and 4.5 V at full
open throttl€? lonaoa.
Sub.litulc ! known-good ECM - Rapairoponoarhon
.nd rochsck. lf symptom/lndic.- NOTE: Thero should be a
smooth transition from 0.5 V in RED/BLKwiro be-
tlon goat rway, ropl.c. the odgi- tw.€n ECM {Dl 11,
nll ECM. to 4.5 V 8s the throftlo is
d€pressed. TCM and TP r.n!or.
11-75
PGM-FISystem
Flowchart- IntakeAir Temperature(lAT) Sensor
Troubleshooting
f6l F The MaltunctionIndicatorLamp(MtL)indicatesDiagnosticTroubleCode(DTC)1O:A problemin the

---:- l-
Intake Air TemDerature(lATl Sensorcircuit.
The IAT Sensofis a temperaturedependantresistor(thermistor).The resistanceofthe thermistordecreasesas the intake

air temoeratureincreasesas shown below.
RESISTANCE(KO}
THERMISTOR
. 12 aa ro4 1aolta :12 t a |.Fr
INTAKEAIR TEMPERATURE
IA7 SENSOR GR N'VHT
:[611:frnl
--i-
/ / --T-
\ \
- Tho MIL har b6onropon6d on.

- Wlth s6rvico chock connoctol
iumpod {3€opago 1142}. cod6
i: 10 is indicsrod.
Do the ECM ResetProcedur€(see

p a g e1 1 - 4 3 ) .

Intermitl.nt tailu.o, sydom iB OK
at thir tims (tost ddvo may bo
noc6ssttyl.
ls the MIL on and do€s it
Chock for poor connoction! ol
indicatecod6 10?
loo!. wircr .t O+25, 9126llocll-
ed ot right .hock towor), CiOS
llAT sonsorl and ECM.
Disconnectthe 2P connectortrom
the iAT sensor.
Measureresistanc6between the
2 terminalson the IAT sensor,
ls there 0.4 -4.0 k0?
lro page 11-771
11 -7 6
(Frompag€ 1 1-76)
Measurevoltage between RED/

YEL (+) terminal and body
ground.
Mgasure voltage betweon BED/

ls th6re approx. 5 V? YEL (+ ) terminaland GRNMHT
{- ) terminal.
Ropair opcn in GRN/

Turn the ignitionswitch OFF. WHT wlr6 botwoon
li there approx. 5 V?
ECM (D221 and IAT
lon301.
Connect the test hamess "D" Subrtitut. . known-good ECM

connectorto the EcM only, notto and rochock. ll lymptom/indica-
the main wire harness lsee page tioh goe! aw!y, r6pl.ce th. orlgl-
11-45). nel ECM.
Measurevoltage between Dl5

{+} terminafand D22 l-)
terminal.
Ropairoponor lhort in REOrYEL

ls ther6 approx.5 V? wirebotweenECM{D15}.ndIAT
aona{tr.
Substilute a known-good ECM

and .ochock. lI symptom/indica-
tion go6s awsy, roplac6tha origi-
nal ECM,
11-77
PGM-FISystem
Flowchart- BarometricPressure(BARO)Sensor
Troubleshooting
lmil frrf: ThsMalluncrionIndicatorLamp{MlLlindicst€sDiagnosticTroubleCode(DTC)13: A problemin the

.(-- .+. B a r o m e t rPi cr e s s u r(eB A R OS) e n s o r .
The BAROSensoris builtinto the ECM.
-\ 13\-
/--i- -
- Tho MIL hsr boon r.ponod on.

- With sr|.ico chack connacto.
iumpcd l!.o p.06 I 142), cod€
13l! Indlcstod.
Do the ECM R€sotProc6dlre (se6

page 'l1-43).
ls the MIL on and do6s it Int.rmltt.nt f.llut . lyltgm Ir OK

indicatecode 13? at thlr tlm. lt6!t drlv. mly b.
nacoar!ry1.
Subrtituto a known{ood ECM

.nd rcchock. lf symptom/indlc!-
tion goo! away, r6phca tha odol-
nsl ECM.
11^78
i - t
PGM-FISystem
TroubleshootingFlowchart - lgnition Output Signal
i151 :16: The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)15: A problemin the

: lgnitionOutput Signalcircuit.
H23Al ongine IUSA: Si/Caneda:SRl,

H22A1 ongino IUSA: Si VTEC/ Clnada
sR-v):
- Tho MIL ha5 beenroponod on.
- With sorvice chock connoctot
iumpod {!€€ p.g€ 1142), code
15 is indic.ted.

p a g e1 1 - 4 3 1 .
NOTE: lf the engino won't stari. it

mav take 20 seconds of cranking to
set the code.
lnt€rmittant failute. tYllam i! OK

.t this timo (t.!l drive may bo
nac6slary).
ls the MIL on and doos it Chcck for poot connactions or
indicatecode 15? looso wi.or ot C433 {locrtod at
.ight shock towet). Ct2S llgntdon
Conlrol Modulo llCMl) and ECM.
Measure voltage betwegn YEL

(+ ) termin€land body ground.
YES
{ T o p a g e1 1 - 8 1 } (To page 1 1-81)
1 1 -8 0
Turn the igniitionswitch OFF.
Reconnectthe 2P connector.
ls the ignirioncoil OK?

the ECMand connector(seepage - Repsii opon in YEL wiro bo-
11-45). twoon tho 2P oonngcto. and
ignition coil,
- Ropaii opon in BLK|'EL wi.o
botwoon tho ignition coil ond
Turn the ignition switch ON. ignition $witch.
Measurevoltage individually be-

t w e e nA 2 1 ( + ) , A 2 2 { + l t 6 r m i -
nals and A26 t-) terminal.
1OV? ---r
A 2 1{ + }
oooooooooooo
oooooooooooo
A 22l+t 426 l-l
t-J
1 0v ?
- Roolocs lho lCM.

- Repair opon oi lhon in YEL/
ls th6ro approx. 10 V?
GRN wir. botwo€n ICM lnd
ECM {A2l or A221.
NOTE:lf the YEL/GRNwire was shorted.

the ICM may be damag6d.
Substituto . known-good ECM
and roch.ck. lf symptom/lndic.-
tlon goos awsy, .oplacoth6 origi-
nal ECM.
11 - 8 1
PGM-FISystem
Flowchart- VehicleSpeedSensor(VSSI
Troubleshooting
-c+l - -
:'; r- The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCod€(DTC)17: A problemin the
I r'' l- vehicle speed sensor {vss) circuit.
--lKgll-
The VSS generatesa pulsingsignalwhen the front wheels turn.
- Th6 MIL has bo6n r€portodon.

- With sorvico ch6ck connoctor
iumped ls6opage I 142), cod€
'17 is indicatod.
Do the ECM Res€tProcedure(see

p a g e1 1 - 4 3 ) .
Road test necessary.

With manualtransmission in 2nd
gear (A/T: E position)accelerate
to 4,000 rpm, th€n decelerateto
1,5OO rpm with throttle tully
croseo.
Intormlttont lallurc, 3ystcm ls OK

at this tim€.
ls the MIL on and does it Chock tor Door connoctiona ol
indicatecode 17? loose wir6s at C433 {locrtod at
.ight shock tow6.). Cl15 {VSSI
and ECM,
Block rear wheels and set the

I parkingbrake.Jack up the front
oI the car and support with sale- @emr
rl ty stands. ro.l wheel beloro
jacking up front ot
cat,
Turn the ignitionswilch OFF.
Connectthetest harnessbetween
p a g e1 1 - 4 5 ) .
o oooooo ooo ooo I oooooooo &ruffi ooooooooooo
ooooooooooooo I oooooooo EEwryl oooooooo ooo
Turn the ignitionswitch ON. A 2 6l - ) 8 1 0( + )
O - 1 2v
Block the right front wheel and ot O *5.o v?
slowly rotate left lront wheel and
measurevoltage between B1O
{ + } t e r m i n a la n d A 2 6 { - ) NOTE: Transmissionin @ position{A/T).
Iermrnat.
Does voltage pulse 0 V and

'12 V Turn the ignition switch OFF.
lH22A1 engine{USA: Si
VT€C/Canada: SR'V)5.0 V)?
Substituto a known-good ECM

( T o p a g e1 1 - 8 3 )
and rochock, lf symptom/indica-
tion gooaaway, roplacoth6 origi-
nal ECM.
11-82
(From page 1 'l-82)
Disconnoctthe B connector trom

the ECM only, not the main wire
harngss.
Block the right front wheel and

slowly rotate left front wheel and
m€asurevoltage between 810
(+) terminaland A26 (-) - Reprir 3hort in ORN
tefmrnal. wi.e b6twoon ECM
(8101and tho VSS,
Tianlmission Con-
trol Modulc, spo6d-
Does voltage pulse O V 8nd omotor, 4WS con-
12 V lH22A1 engine (USA: trol unit, or cruiso
Si VTEC/Canada: SR-V):5.0 contrcl unit.
VI? - Ropoiropon in ORN
wire b6two6n ECl,
{8101and VSS.
- lf wlr€ i8 OK. tort th€
Sub.tituto r known{ood ECM VSS {!oo .oction
.nd r.ch.ck. lf lymptom/indica- 23t.
tion goar rway. roplace tho origi-
nal ECM.
11-83
PGM-FISystem
TroubleshootingFlowchart - ElectricalLoad gs1s61q1(ELD)
- --r--' The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)20: A problemin the
tf I 20 l- EtectricalLoad Detector(ELD)circuit.
With sorvice chock connoctor

jumpcd (3oepago 1142), code
20 is indicatod.
Do the ECM Resetprocedure{see

page 1 1-43).
Start engineand keep enginerpm

at idle.
Turn on headlighls.
Intormitlgnl lalluro, system is OK
at this timo {to.t ddv€ m.Y bo
nocoa!4ry1.
Doesthe MIL indicatecode 20? Chock tor ooor connociion3 ot
looso wlr6s at C420 IELD) 8nd
ECM.
Turn the ignitionswilch OFF.
Remove the undeFhood tuse/

,i
relay box and remove the fuse/
relay box lower cover,
it
(+ }
SLKTYEL
Measure voltage between BLK/

l nd BLK (-l
Y E L ( + ) t e r m i n aa
terminal. LOWERCOVER

YEL {+) terminal and body
ground.
Roplir opon In BLK rvk.

batwcan tha 3P con-
ls there battery vollage? n ctor and erc3 llocat-
cd undor middlo ol
dashl.
Ropairopon in BLK/YELwlto bo-

tweon ECU IECMI {'15Al fu3o {in
tho undor-dash tuso/rolay boxl
and lho 3P connector.
(To page 1 1-85)
11-84
{Frompsge 1 1-84}
Measure voltage between GRN/

8LK termin€l and body ground.
Rep.ir opon or short in GRN/BLK

rvi.€ brtwoon ECM lDlO) and tho
ls there 4.5- 5.0 V? 3P connoctoa.
It wiro is OK, aubstitut6a known-
good ECM and ..chock.
GRI{/BLK
I+ )
LOWERCOVER
Connectth6 t€st hsmossbetween

the ECM and conneclors (see
p a g e1 1 - 4 5 ) .
{To poge 1 1-86}
(cont'd)
11-85
PGM-FISystem
TroubleshootingFlowchart - ElectricalLoad Detectol (ELDI (cont'd)
Condition Voltage
Headlightswitch, first position (.) 1 . 5 - 3 . OV
Headlightswitch, second position( a) 1 . 0 - 2 . OV
Underthe conditions list€d in the

chart to the right, measure vol_
tage between D1O {+ } terminal
and A26 (- l terrninal.
Substituto a known{ood ECM

and recheck, ll symptom/indica-
tion goos away. 6phco tha otigi-
' nel ECM.
it
11-86
PGM-FISystem
Flowchan- KnockSensor(KSl [ExceptF22A1 engine(S]l-
Troubleshooting
t-7=.l- -r#-
-l .l l- The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)23: A problemin
_lltlllll- the Knock Sensor(KS) circuit.
-e-tm-
- Thc MlLhas boenroponed on.
- With !6wico chack connoctol
lump€d l..o pago I 1421, codo
23 is indicatod.
Do tho ECM Res€tProcedursls€e

p a g e1 1 - 4 3 ) .
Warm up the sngine to normsl

opgratingtempotature (tho radia-
tor lan comgs on).
Hold engine8t 3,OOo- 4,0OOrpm

tor 1Osecondswith manualtrans-
miesion in neutral {A/T: lll or lq
position).
Int.mittonl l.llur., sy.t.m b OK
at thir tim. (tod driv. maY bo
nocolaorYl.
ls the MIL on and does it Chack for poot conncctlon! ot
indicats code 23? loolq wlro3 al O+32 (loortrd rt
right shod( tow.r), Cl l2lKS) and
ECM,
Turn the ignition swirch OFF.
Connect the test harness to the

engine wire harneasonly, not to
the ECM (seepage 1 1-45), o3
t_
-
Continuity?
Ch6ck lor continuity between D3

t€rminal and body ground.
Rop6ir.hon in RED/BLUwite bc-

trY.en ECM lD3l snd th. KS.
(To page 11-89)
1 1-88
Check tor continuity on RED/BLU
wire betweenD3 terminaland2p
connectorof enginewhe harness. l-
Continuity?
Ropairopon in RED/BLUwiro bo-
twoon ECM lD3) and tho KS.
Warm up tho engineto normal

operatingtemperature{theradia,
tor fan comgs on).
Hold engineat 3,OOO-4,OOOrpm

lor 1Osgcondswith manualtrans-
missionin noutral (A,rf: @ or @
oosr!onl.
ls the MIL on and does it

indicatecode 23?
Subslituto a known-good ECM

and rsch6ck. lt symptom/indic!-
tion goos aw6y, .oplacothe origi-
nal ECM.
32 N.m 13.2ks-m.23 lb-ftl
11-89
PGM-FISystem
Flowchart- A/T Fl SignalA/B (A/T only)
Troubleshooting
---l-- The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)30: A problemin
-l 30 l-
tne A/T Fl Signsl A circuit between TransmissionControl Module {TCM) and ECM.
- - (MlLl indicatesDiagnosticTroubleCode {DTCI 31: A problemin

r;;--] The MaltunctionIndicatorLamp
I Jr l- the A/T Fl SignalB circuit between Transmissioncontrol Module {TCM) and ECM.
\.----_/\r---:-/
- l 3 0l - o , - l 3 l l
------ - ---j- \
With 3orvico chock connactor

jumpod, (ra. pagc 1142), codo
30 .nd/or 31 arc indicatod.
Do the ECMR6setProcedure{see
p a g e1 1 - 4 3 ) .
Test drive necessarv.

Drive th3 car for severalmiles so
that the transmissionupshiftsand
downshifts soveral times.
lhtdmittont failurs, gylt.m i. OK

l ai thir tlmo.
Does th€ MIL indicat€ code Chock for poot connoction! or
30 and/or 31? loo.. wiro. at C4ll (TCMI snd
I
I ECM,
r'l
Connect the test harnssg to the

msin h€rnessonly, nottothe ECM
'l1-45).
{see page
Disconnect the 22P connector

from rhe TCIV.
+
Conlinuity? Continuity
Check for continuity between 93
and/or 84' terminal and body
grouno. *r codo 31 {A/T Fl signal B)
RoDairrhort in ORN or Pf{Kr wilo

botw.€n ECM {B3 or B4r I .nd rh.
TCM.
NO
( T op a g e1 1 - 9 1 )
11-90
(Frompsge 11-9O)
Check lor continuity on ORN or

PNK'wire between 83 or 84*
and 22P connectorot rhe TCM.
Ropsiiopon in ORI{ or P{lK. wir6

botween ECM {8:} o?84. I and rhc
TCM.
Subltitute a known{ood ECM

and rochack. lt lymptorh/indica-
tion gogs rway, roplaca tha origi-
nal ECM.
11-91
ldle Control System
System TroubleshootingGuide
NOTE:
a Acrosseachrow in the chart,the sub-systemsthat couldbe sourcesof a symptomare rankedin the orderthey should
then refer
be inspected,startingwith @. Findthe symptomin the left column,read aclossto the most likelysource.
to ths page listed at the top ot that column. lf inspectionshows the system is OK' try the next system @' etc'
a lf the idle sDeedis out ot specificstionand the MalfunctionIndicatorLsmp (MlLl does not blink DiagnosticTrouble
Code {DTC) 14, go to inspection described on page 11-95.
IOLE ALIER, HOSES

PAGE STARTER ERAKE STEERING FAST IDLE STAFTING AND
ADJUST I D I E A I R coNDr- NATOs swtTcH swtTcH PFESSUNE THERMO
l s u s - s Y s T € M ING CONTROL
TIONING FR srGt'rALSIGNAL SIGNAL
CONNEC.
SCREW SIGNAL S I G N A I TIONS
-'\ -
SYMPTOM 100 102 l04 106 104 l09 110
ttl 96 98
TO START
DIFFICULT
ENGINEWHENCOLO
O
WHEI.{COLDFASI IDLEOUTOF
SPEC.(1,000- 2,000rpm) @ @ o
ROUGHIDLE @ o
WHENWARMRPiNTOOHIGH @ O @ @ @
load)
@ o
o
WHEN @ o
T00 Low
liomr in ON
@ \,
@ o
@ @ o
FREOUENT
WHII,EWARMING
UP @ o
STALLING
AFTERWARMING
o @
TEST
FAILSEMISSION O
11-92
System Description
The idle speed of the engine is contro ed by the ldte Air Control ACI Vatve.
The vElve chsnges th€ smount of air bypassing into the intake manifold in responseto
electric current contro ed by the
ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle
speed.
TO PGM.FI
MAIN RELAY
.,\ vARtous
\r- SENSORS
STARTITIG FAST
AIB VALVE IOLE
THERMO
VALVE
11-93
ldle Gontrol System
System Description(cont'd)
1. After the enginestarts,the IAC valveopensfor a certaintime. The amountof air is increasedto raisethe idle sp6€d
'l
about 50- 3OOrPm.
2. When the engine coolant temperatureis low, the IAC valve is openedto obtain the prope. fast idle speed. The amount
of bvoassedair is thus controlledin relationto the enginecoolanttemperature'
IDLE SPEEO
{rpml
104 140
& 60
11-94
l. When the idlespeedis out of specificationand the MalfunctionIndicatorLamp(MlL)does not blinkDiagnosticTrou-
ble Code lDTC) 14, check the following items:
. Adjust the idte speed (page I 1- l 1 I
)
. Air conditioningsignal (page 11-99)
. A L T F R s i g n a t{ p a g e1 1 - 1 0 0 )
. A/T gear positionsignat{page 11-1O21
. Starterswitch signal (p8ge 1j-1O41
. Brakeswitch signal(page 11-106)
. PSPswitch signat(page t 1-108)
. Fast idle thermo valve (page l.l_109)
. Starting air valve
. Hosesand connections
. IAC valve and its mountingO-fings
2. It the above items are normal,substitutea known-goodIAC valve and readiustthe idle speed
{page 11-l1l).
. lf the idle speed still cannot be adjustedto specification(and the MtL does not blink
code 14) sfter IAC valve
replacement,substitutea known-goodECM and recheck.ll symptom goes away, replscethe originalECM.
11-95
ldle Control System
TroubleshootingFlowchart - ldle Air Gontrol (lAC) Valve
-r---i
-tgll - - -;lr The MaltunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 14: A problemin
I l_ the ldte Air controt {tAc) vatve circuit.
The IAC Valve changesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM in
order to maintainthe proper idle speed.
TO INTAKE FROM AIR
MANIFOLD CLEANER
VALVE SPRING
--t6t-
-
:Frl
l- ---r--
- Tho MIL has boen r6portodon.

- With sgrvico check connoctor
jumped ls€opago 1 1421, codo
l4 is indicatod.
Do the ECMResetProcedure(see
p a g e1 1 - 4 3 1 .
With lhe engine running and the

ls the MIL on and does it indi- accelerator pedal released, dis-
cale code 14? connect the 2P connector lrom
the IAC valve. Intormitlant lafluro, ay8-
tom is OK dt this timo
{to3t d.iving may bo
Remove the 2P connector ttom nocassa,yl.
the IAC valve. ls there a reduction Chock tor ooor connoc-
in enginerpm? tion or looso wiros at
c+25, C433 (locarod at
right ahock towoil.
C106 llAC valvo) and
Substhute a known-good IAC ECM.
valve and retost.
( T op a g e1 1 9 7 )
11-96
(Frompage 1 1-96)
Measure voltage between the

YEL/BLKwire 8nd body ground.
Rop6iropen in YEL/BLKwiro bo-

twoon ths IAC valvc.nd PGM-FI
main relay.
Turn the ignition switch ott and

reconnectthe 2P connectorto the
IAC valve.
Connect the test hamess "A"

connector to the main wire har-
ness only. not the ECM lsee page
11 - 4 5 ) .
Mofientarily connect Ag terminal

to A26 terminsl several times.
Subrtitut . known{ood ECM

Doosthe IAC valve click? .nd r.to.t. lt rymptom/ktdicrtkrn
gooa away, raplaca tho original
ECM.
Ropairopon or .hort in BLX/aLU

wirc b.tw.on IAC v.lvo and ECM
(A9l . It tho wlr. i! OK, r6pl.co th6
IAC valv6.
ldle Control System
Troubleshooting Flowchart - Air Conditioning Signal
This signalsthe ECM when there is a demandfor coolingfrom the ai. conditioningsystem.
Connectthe test hatnessbetween

the ECM and connectors.
Disconnect"B" connectorfrom
the main wire harness only, not
the ECM (seepage 11-45)
Turn lhe ignitionswitch ON.
A26 t-t
Measurevoltage between 85 (+)
terminaland A26 (-) terminal.
Substituto a known-
good ECM and ]e fieck.
ls there approx. 5 V? It prssc bod voltago i3
now availablo, rapl6c6
th6 origln.l ECM.
Reconnect "8" connector to the

main wirc harness.
Clicklng?
Momentarily connect A15 ter-
minal to /q26 t€rminal several
times.
ls thsre a clicking nob€ ftom the Connecrrho RED/BLU torminrl ot

A/C comprc$or clulch? ihe 4P conneclor on tho A,/C
clutch rolty to body g.ound.
Vigw from wire harness side
S6a alr condltlonat in-

13thorc I clicking noiaetrom the
rpaetlon lrac toction
A/C comore6sor clutch ?
22t.
Ropairopen in RED/BLUwlr6 bo-

rwo.n ECM {A 15} rrd A/C drnc*l
relay.
{ T o p a g e1 1 - 9 9 }
11-98
r- Lo!! rhan 1.0 v? --------.1
(Fromp8g6 1 1-98)
I es t*t
| | ooooooo ooooo o looooc
I looooooooooooQ I ooooc
r----------------
I A26 t_l
Measure voltage between 85 (+)

terminaland A26 {-) terminal.
Ropairopen in BLU/BLK
ls voltagelessthan 1.O V? wiro botwoon ECM lB5l
Air conditioning iignal i3 OK. and A/C awitch.
Substituto a known-good ECM

and rodrock. ll proscribod voltago
is .row availoblo, rsplacg tho origi-
nal ECM.
11-99
ldle Control System
TroubleshootingFlowchart- Altelnator (ALT) FR Signal
This signalsthe ECM when the alternatoris charging.
Inspoction ol ALT FR sign.l.

Oisconnect"D" connectorfrom
the main wire harnessonly, not
the ECM (see page 11-45).
4.5 V? -
Turn the ignirionswitch ON.
A26 t-l
Measure voltage between D9
(+) rerminal and 426 (-) ter-
mrnat,
Subltitut. a khown{ood ECM

ls thereapprox.4.5 V? and r..hock. lf pr.rcribed voltlgo
ir now availabl., rophce lh. ottgi-
nel ECM.
'l
Turn the ignitionswrtchOFF.
li Reconnect
"D"
connector to the
main wire harness.
Warm up engineto normaloPer

ating temperatu€ (the radiatortan
comes onl. Vohfo ?
D 9l + l
Measure voltage between Dg ooooooooooo

l+) terminal and A26 {-) ter- ooooooooooo
minal.
Does the vohage decreasewhen

heedlighls and rear d€fogggr 8re Turn the ignition switch OFF.
turnedon ?

p a g e11 - 4 3 ) .
ALT FR sign.l is OK.
(To page 'l 1-10'l)

(Frompage 1 1-1OO)
NOTE: The radio may have a coded theft protection

Disconnect"O" connectortrom
ECM only, not the main wire circuit. Be sure you get the customer'scode num-
harness. ber before disconnectingthe battery cable.
Disconnecl the negative banery

cable trom the battery.
Check tor continuity between D9

t€rmanaland body ground.
DisconnectGRNconnectorfrom
the ALT.
Check tor continuity between D9

t€rmin.l and body g.ound.
Check for continuity betwoon Dg

terminaland body ground.
Ropair3hon in WHT/REDwiro bo-

twoon ECM (Dgl snd ALT.
Ropoi.op€n in WHT/REDwiro b6-

two€n ECM lDgl and ALT.
11 - 1 0 1
ldle Control System
TroubleshootingFlowchart - AutomaticTransaxle(A/Tl Geat Position-
Signal(A/T only)
This signalsthe ECM when the automatictransmissionis in @ or@] position.
Tum the ignition switch ON.
Observethe A/T gear position in-

dicator and select gach Position
separately.
S6e A/T goar position indicatoi in-

Ooesrhs indicatorlight ProP€rlY? specdon (soction 141.
Turn the ignitiongwitch OFF.

"B" connector trom
Disconnect
the main wire hamess only, not
the ECM (see page 11-451 5V?
87(+)
Turn the ignitionswilch ON.
A26 (-l
Measure voltage between 87
{+} terminal and A26 (-} ter-
minal.
Subltituto a known-good ECM

and rech.ck. ll prsc.ibod voltago
b now avriloblo, taplaco the origi-
nal ECM.
Turn the ignition 3wilch OFF.
Reconnect"8" connectorto the

main wire harness.
(To page 1 1-1031
11-102
( F r o mp a g e1 ' l - 1 0 2 )
L6s8 than 1.O V7 --.--

87 l+l
ooooooooooooo
oooooooooooo
A26 t-l
Measurevoltago botween 87 (+ )
terminal and A26 (-) tellninal
gith the trsnsmission in LNI and
lll position individually.
Ropair opon in LT GBN wir. be-

ls there lessthan 1.0 V? twoon ECM lB7) .nd gaug6 ae-
lombly.
12V7-
Measure voltage b€tween 87

{+l terminal and A26 (-) ter,
minal with the transmission in
gear.
Ropalr rhort ir| LT GRN wir6 b.-

ls ther€ approx. 12 V7 tw.cn ECM {87} and gaugo .r-
lombly.
A/T gear poritlon .lgn.l i. OK.
11-103
ldle Control System
Troubleshooting Flowchart -Starter Switch Signal
This signalsthe ECM when the engineis cranking.
BATTERY
ooooooooooooo
Connectthe test harnessbetween oooooooooooo
the ECM and connectors {see A26 (-t
p a g e1 1 - 4 5 )
NOTE:
a M/T: Cluich pedal must be
Measurevoltage between Bg (+) deoressed.
terminal and ,426 (-) terminal o Ait: Transmission in @] or @
when the ignitionswitch in the posltlon.
start posrton.
InsoectNo. 2 STARTER SIGNAL

ls there battery vollage ? (7.5 A) fus€ (in the und€r-dash
fusefielavboxl.
Rap.i. opon In BLU/REDwlr. b.-

tw.sn ECM (B9l rnd t{o. 2
STARTER SIGNAL17.5Al lur!'
Start€r switch signol i3 OK.

ldle Control System
TroubleshootingFlowchart - Brake Switch Signal
This signalsthe ECM when the brake pedal is depressed.
Inspoclion ol Brak6 Srvhdi Signal.
Are the brake lights on without Inapoct th6 br!k6 3wltch (!€o aoc-
depressingthe brake pedal? tion 19).
InspectSTOPHORN('l5 A) luse
Oo the brake lighB come on7 (in th€ under-hood Iuse/rel8y
boxl.
Connect the t6st harnoss to the - Roprir op.n In WHT^'EL wlrc

main wire harn€ssonlv, nottothe b.twoon bruks lwitch lnd
ECM (see page 11-45). STOP HOR[{ 115 A} tu!o.
- Inrpgcl tho b'r6ko rwltch l!o.
lection l9l.
( T op a g e1 1 - 1 0 7 1
( F r o mp a g e 1 1 - 1 0 6 )
02 t+l
MeasurevoltagebetweenD2 (+) I BAI-TERY
lerminal and A26 (-) terminal VOLTAGE?
with the brake oedal deDressed.
Roplir opon in GRII/WHT wlro be-

ls there bane.y voltage t twoon th. brakq lwltch rnd ECM
{D2t.
Br.k. .wilch lional i. OK.
11-107
ldle Control System
Troubleshooting
l ,uurEJl l ! ! t l , r l I I l g Flowchart
flt.,Yvvrrql I - Power
rvYYtEI Steering
r Pressure(PSP)Switch Signal
This signalsthe ECM when the power steeringload is high.
Inrp.clion ol PSP twltch Signal
ooooooooooooo oooooooo ooooooooooo

Connectthe t€st harnes6between oooooooooooo oooQoooo oooooooooo
p a g e1 1 - 4 5 ) .
Tu.n tho ignilion swilch ON.
Moasurevoltage b€tween 88 {+}

torminsland A26 (-l terminsl.
the PSPswitch.
ls rhere more than 1.0 V?
Tum rtaaring whool slowly. ls ther6 more than 1.0 V?
M66sure voltage betw66n BB (+) Repairopon in RED/GRNwir6 b6-

t6rminal and A26 {-} torminsl tw6on ECM (88) snd PSPswitch
whilo stggring wheel is turning. or BLK wir. bolwog.i PSP.wilch
a n dG l O l .
Disconnectthe 2P conneclorfrom
PSP 3wirch slgnal i! OK. the PSPswitch. swtTcH
Measurevoltage between 88 {+ )
terminaland 426 l- l terminal.
Rooairshon in RED/GRNwilo bo-

twoon ECM {88) and P1SP switch.
lI wire is OK, substituto a known-
good ECM and rochock. lf
proscdbodvoltege ir now availa-
bl6, roplace tho original ECM.
11-108
Fast ldle Thermo Valve
Description lnspection
To preventerraticrunningwhen the engineis warming H23A1 engino(USA: Si/Canada:SR),
up, it is necessaryto raisethe idls speed.The fast idle H22Al 6ngin€ (USA: Si VTEC/Canada:SR-V)
thermo valve is controlledby a thermowax plunger.
When the engineis cold, the enginecoolant surround- NOT€: The fast idle thermo valve is factory adiusted;
ing the thermowax contractsthe plungef,allowingad- it should not be disassembled.
ditionalair to be bypassedinto the intake manifoldso thst
the engineidlesfaster.When the enginereachesope.-
1. Removethe intakeair duct from the throttle bodv.
ating temperature,the valve closes.reducingthe amount
of air bypassinginto the manitold.
2. Stan the engine.
3. Put your finger over the lower port in throttle body

and makesurethat there is air flow with the engine
cold {engine coolant temperature below 860F,
300c).
FAST
IDLE
THERMO
VAIVE
thermo valve and
12 .m
(1.2 kg-m, 9 lb-ttl
4. Warm up the engine (the radiatorfan comes on).
Check that the valve is completelyclosed. lf not,

air suctioncan be telt at the lower gort in the throt-
tle body.
a lf any suclion is felt, the valve is leaking.Check
enginecoolantlevelandforair in the enginecool-
ing system (seesection 1O).
lf OK, reDlacethe tast idle thermo vslve and
recheck.
11-109
ldle Control System
Fast ldle Thermo Valve (cont'd) Starting Air Valve
F22A'l onginelS): Description

Whencrankingthe engine,the startingair valvesuppliss
NOTE: The tast idle thermo valve is factory adjusted; additionalair to the intake maniJoldto ease engine
it should not be disassembled. starting.
1. Removethe cover of the fast idle thermo valve.
2. Start the engine.
3. Put your fingeron the valveseat areaand makesure

thst ther€ is 8ir flow with the enginecold {engine
coolanttemperaturebelow 86oF, 30oCl and idling.
I DIAPHRAGM
iI
i
I
TO INTAKE
MANIFOLD
ADDITIONAL
AIR FROM
lf not, replacethe tast idle thermo valve and AIR CLEANER
retest. 't2 N.m
(1.2 ks-m.I lb-ttl
4. Warm up the engine (the radiatortan comes on).

radaatorfan
5. Checkthat the valveis completelyclosed.lf not, air

suction can be {elt in the valve seat area.
a It any suction is felt, the valve is leaking.
Checkenginecoolantleveland for air in the en-
gine coolingsystem (see section 'lO).
It OK, replacethe fast idle thermo valve and
recheck.
1 1 - 11 0
ldle Speed Setting
lnspection/Adjustment Adjust the idle speed, if necessary,by turning

the idle adjustingscrew.
NOTE: (Canada)Pull the parkingbrake lever up.
Start the engine,then checkthat the headlightsare olf. IOLEADJUSTING
SCREW
1. Startthe engineand warm it up to normaloperating

temperature(the radiatorfan comes on).
2. Turn the ignitionswitch OFF.
3. Connecta tachometer.
4. Disconnectthe 2P connectorfrom the ldle Air Con-
7 . Turn the ignirionswitch OFF.
Reconnectthe 2P connectoron the IAC valve.then

removeCLOCKRADIO(1OA) Iuse in the under-hood
fuse/relaybox tor 1O secondsto reset the ECM.
Restartand idle the enginewith no-loadconditions

for one minute, then check the idle speed.
NOTE: {Canada)Pull the parking brake lever up.

Start the engine,the checkthat the headlightsare
off.
Start the enginewith the acceleratorpedalslightly ldle speed shoul.dbe;

depressed.Stabilizethe rpm at 10O0,then slowly
releasethe pedal until the engineidles. H23A1 engine(USA: Si/Canada:SRI:
M/T 7OO 1 50 rpm

Checkidlingin no-loadconditions:headlights,
blower
fan, reardefogger,radiatorfan, and air conditioner 7OO I 50 rpm {in @ or @ position)
are not operating.
H22Al engine (USA: Si VTEG/Canada:
SR-V):
ldle speed should be;
7OO 1 50 rpm
H23A1 engine (USA: Si/Canada:SRI:
F22Al engine {S}:
M/T 55O t 50 rpm
A/T 55O + 50 rpm {in S or @ position} Mfi 7O0 1 50 rpm
AlT 7OO t 50 rpm (in S or @ position)
H22A1 engine {USA: Si VTEC/Canada:
SR-V):
55O 1 50 rpm
F22Al engine (Sl:
M/T 55O I 50 rpm

NT 550 t 50 rpm (in I or @ position) (cont'd)
11-111
ldle Control System
ldle Speed Setting (cont'dl
1O. ldle the enginefor one minute with headlights{Hi}

and rear defoggerON and check the idle speed,
ldl€ speod should be;
H23A1 engine {USA: Si/Canada:SR}:
M/T 78O t 50 rpm

A/T 78O 1 50 rpm {in S or @ posirionl
H22A1 ongino (USA: Si VTEC/Canada:SR-V):
79O t 50 rpm
F22Al engine {S):
l\illT 77O t 50 rpm

Afi 770 I 50 rpm (in S or E position)
1 1 .Turn the headlightsand rear defoggeroff.

ldle the enginefor one minute with heatertan switch
at Hl and air conditioneron, then check the idle
speeo.
ldlo speod should be;

I
I
H23Al engin€ (USA: Si/Canads:SRI:
:
ri ,
M/T 78O t 50 rpm
NT 78O t 50 rpm (inI or E position)
H22A1 engin€ (USA: Si VTEC/Canada:SR-VI:
79O 1 50 rpm
F22A1 engina (S):
M/T 77O i 50 rpm

NT 770 t 50 rpm lin S or @ Fosition)
NOTE: lf the idle speedis not within specification,

see SystemTroubleshooting Guideon page 1'l-92.
11-112
t
FuelSupply System
NOTE; Across each row in the chart,the sub-systemsthat could be sourcesof a symptom are rankedin the orderthey
shouldbe inspectedstartingwith O. Findthe symptom in the left column,read acrossto the most likelysource,then
referto the page listedat the top of that column.It inspectionshows the systemis OK, try the next most likelysystem
!), etc.
PAGE SU8-SYSTEM
FUEL FUEL PGM-FI
FUEI. FUEL coNTAtrl
INJECTOF PRESSURE FILTER MAIN
PUI\4P NATEDFUEL
REGULATOR RELAY
-------
SYMPTOM 116 122 123 124 126 *
ENGINEWON'T START
@ o @
OIFFICULT
TO STARTENGINE
WHENCOLDORHOT o
ROUGH
IDL€
o @
MISFIFEOR
ROUGH
RUNNING
O @ @
FAILS
POOR
PERFORMANCE EMTSStON @ o
Loss0F
POWER @ o @ @
WHILE
FREOU€NT
WARMING
UP
o
STALLING AFTEF
WARMING
UP
e
Fuel with din, water or a high percentageof atcoholis consideredcontaminated.
11-113
Fuel Supply System
System Description FuelPressure
The tuel supplysystem consistsof a Jueltank, in-tank Relieving
high pressurefuel pump, PGM-Flmain relay,fuel filter,
fuel pressureregulator,fuel injectors,injectorresistor, @
and Juel deliveryand return pipes and hoses. a Do not smoke while working on the fu6l syst€m.
This systemdeliverspressure-regulated fuel to the fuel Keep open llames or sparks away ftom your work
iniectorsand cuts the fuel deliverywhen the engineis alea.
not running. a Be sure to relieveluel pressulewhile the €ngins is off.
NOTE: Beforedisconnectingluel pipes or hoses,release

pressurefrom the system by looseningthe 6 mm serv-
ice bolt on top of the fuel rail.
1. Disconnectthe batterynegativecablefrom the bat-

tery negativeterminal.
NOTE: The radiomay havea codedthett protection

circuit. Be sure you get the customer'scode num-
ber before disconnectingthe battery cable.
2. Removethe fuel fill caD.
3. Use a box end wrench on the 6 mm servicebolt at

the fuel rail,while holdingthe specialbanjobolt with
anotherwrench.
4. Placea rag or shop towel over the 6 mm servicebolt.
5. Slowly loosenthe 6 mm servicebolt one complete

turn.
12 N.m {1.2 kg-m, 9 lb-ft)
NOTE:
a A fuel pressuregaugecan be attachedat the 6
mm servicebolt hole.
a Always replacethe washerbetweenthe service
bolt and the specialbanjobolt, wheneverthe serv-
ice bolt is loosened.
a Replace all washers whenever the bolts are
removed.
11-114
Inspection a lf the fuel pressureis not as specified.first checkthe
fuel pump(seepage1 1-125).lf the pumpis OK, check
1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e 1 1 - 1 1 4 1 . the following:
2. Removethe servicebolt on the fuel rail while hold- - lf the fuel pressureis higherthan specified.inspect
ing the banjobolt with anotherwrench. Attach the loti
tuel pressuregauge. a Pinchedor cloggedJuel return hose or pipe.
a Faultyfuel pressureregulstor{seepage 11-1221,
3. Start the engine. *Measurethe fuel pressurewith - lf the fuel pressureis lower than specifiedinspect,
the engineidlingand vacuumhose ot the fuel pres- for:
sure regulatordisconnectedfrom the fuel pressure a Cloggedfuel filter.
regulatorand pinched. a Faultyfuel pressureregulator{seep age 11-1221,
a Leakagein the tuel pipes or hoses.
Plessur€ should be;
H23A1 ongine (USA: Si/Canada:SR),
F22Al engine (S):
2 5 5 - 3 O 5 k P a( 2 . 5 5 - 3 . O 5 k g / c m 2 , 3 6 - 4 3 p s i )
H22A1 engine (USA: Si VTEC/Canada:

SR_V):
23O-2AO kPa 12.3-2.8 kg/cmr. 33-4O psi)
4. Reconnect vacuum hose to the fuel Dressure

regulator.
Pr€ssureshould b€:
H23Al engine (USA: Si/Canada:SR).
F22A1 ongine (S):
195-245 kPa (1.95-2.45 kg/cm2,28-35 psi)
H22A1 engine (USA: Si VTEC/Canada:SR-V):

17O-22O kPs 11.7-2.2 kg/cmr. 24-31 psi)
PRESSURE REGULATOR
': lf the enginewill not stan, turn the ignitionswitch
on, wait for two seconds,turn it otf then back
on again and read the iuel pressure.
11-115
Fuel Supply System
Fuel lnjectors
TroubleshootingFlowchart
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroublecode (DTc) 16: A problemin
the Fuel Injectorcircuit.
The Fuel Iniectors are a solenoid-actuatedconstant-stroke pintle type consisting ol a solenoid, plunger needle valve and
housing.When currentis appliedto the solenoidcoil, the valve lifts up and pressurized tuel is injected.Becausethe nee-
dle valve liJtand the fuel pressureare constant,the injectionquantity is determined by the lengthof time that the valvo
is open (i.e.,the durationthe current is suppliedto the solenoidcoil).The FuelIniectoris sealedby an O-ting and seal
ring at the top and bottom. These sealsalso reduceoperatingnoise.
SEAL
BII{G
PLUNGER
FUEL
INJECTOR
- __l=- - \.__.,:_ / INSULATOR
-tFJ- ;ull:
- Th6 MIL has boonrooortodon.
- With sorvice chock conncctor
iumpod {s6€pago 11421, codo
'l6 is indicatod.

p a g e1 1 - 4 3 ) .
NOTE:lf enginewill not start, it may take

10 secondsof crankingto set the code.
Into.mittent lailuro, 3yst6m ir OK

at this tim€ (to3t drivo moy bs
nocossary).
Chock fo. Door connoctiona ot
ls the MIL on and does it indi looso wires at C433, C425 llocat-
cate code 16?
od ar right shock towotl, C1O2,
ClO3, ClO4, C1O5 (tuel ini.c-
toBl, Cl07 {iniocto. r€isto.), and
ECM.
(To page '1'1-1171
11-116
r f
2P CONNECTOR
Starl engingand lislenai 6ach luel
injectorror a clickingsound.
the fuel injector that dogs not
click.
Measure rgsistancebetween the

2 terminals of luol injector.
l s t h e r e1 . 5 - 2 . 5 O ? Ropl.c. th6 tu.l ini€ctor/inioctor!

thlt aro not 1.5-2.5 O. FUEL
IITJECTOB
MeasurovoltaoebetweenREO/
8LK { + } terminalin rhe 2P con-
ngctorand body ground.
Tu.n tho ignition switch OFF.
Measure voltsge between YEL/

BLK {+) terminal and body
ground.
(To page 1 1-118)

{To page 1 1-l 18)
11-117
Fuel Supply System
Fuel Injectors(cont'dl
{Frompage 1 1-'l17} ( F r o mp a g e 1 1 - 11 7 )
Rgpair op6n in tho

YEL/BLKwire botws6n
the inioctor resistot and
tho PGM-FImain ,olaY.
Testthe injectorresistor(seepage
11-1211.

the tuel iniector.
B€pair op6n RED/BLK wiro bo-
twe€n lhe 2P connocto. end inioc-
tor roaistor.
Connectthe test harnessbetwoen

p a g e1 1 - 4 5 ) .
Measure voltage between A23

{-) terminal and following
termrnal:
. No. 1 tuel iniector:
A1 {+) terminal.
. No. 2 fuel iniector:
A3 (t)terminal.
. No. 3 fuel injector:
A5 {+ | terminal. 13. rott.*t
. No. 4 tuel injector:
42 {+) terminal.
$Li6iiitl'--
A 1 { + } lA 5 l + )
oooooooooo oooooooo ooo ooo ooooo
oooooooooooo oooooooo ooooooooooo
Ropairop6n in tha wire batwoon

ls there battery voltage? the ECM(A1, A3, A5 or A2) and
tho luol inioctor.
Substilute a known-good ECM

and rechock. ll symptom/indica-
tion goos away, roplacetho origi
nal ECM.
11-118
Replacoment
@@ oo not smoke when working on tha fuel system. Keep open llam6s away from your wolk a.sa,
l Relievefuel pressure(see page 11-114).
2 . Disconnectthe connectorsfrom the fuel injectorsand IAC valve.
Disconnectthe vacuumhose trom the fuel pressureregulatorand EGRvalve,and the luel returnhosefrom the fuel
pressureregulator.
NOTE: Placea rag or shop towel over the hoses before disconnectingthem.
4. Disconnectthe tuel hose from the fuel rail.
5. Loosenthe retainernuts on the fuel rail and harnessholder.
6. Disconnectthe PCV valve and fuel rail.
7. Removethe fuel injectorstrom the intake manifold.
SEALING
WASHER
Replsc6.
00
00
CUSHION
RING
Replace.
8. Slidenew cushionrings onto the fuel injectors.
9. Coat new O-ringswith clean engineoil and put them on the fuel injectors.
1O. Insertthe fuel iniectorsinto the fuel rail first.

'I
1. Coat new seal rings with clean engineoil and press them into the intake maniforo. (cont'd)
11-119
Fuel Supply System
Fuel Injectors lcont'dl
12. lnstallthe tuel injectorsand fuel rail assemblyin the manifold'
CAUTION:
a To prevent damag€ to ths O{ings, install the lu€l inioctors In th€ fuol rall first. then inslall th€m in tho intaks manifold.
FUEL RAIL
13. Align the center line on the connectorwith the mark on the Juel rail.
'14, Install
and tighten the retainernuts.
15. Connectthe Juel hose to the fuel rail with new washers.
16. Connectthe vacuumhoseto the tuel pressureregulatorand EGRvalve,and the fuel returnhoseto the tuel pressure
regulator.
17. Installthe connectorson the fuel injectorsand IAC valve.
18. Replacethe 6 mm servicebolt washer and tighten the bolt.
19. Turnthe ignitionswitch ON. but do not operatethe starter.After the fuel pump runsfor approximately two seconds,
the luel pressurein the fuel line rises.Repeatthis two or three times, then check whetherthere is any tuel leakage.
11-120
InjectorResistor
Description Testing
The resistorlowersthe currentsuppliedto the fuel 1. Disconnectthe injectorresistorconnector.
injectorsto preventdamageto the fuel injectorcoils.
This allows a faster responsetime of the fuel in- 2. Check for resistance between each of the inisctor
rectors, resistorterminals{E, D, C 8nd B) and the power t€r-
minal (A).
Resistanceshould be: 5-7 O
LLLLL
FUEL
a Replacethe injectorresistorwith a new one if any
of the resistancesare outsideof the sDecification.
11-121
Fuel Supply System
Fuel PressureRegulatol
Description Testing
The fuel pressureregulatormaintainsa constant fuel Iry Do not smok€durlngtho test. K€ap
pressureto the fuel injectors.When the differencebe- opan flamesaway lrom your work area.
tween the luel pressureand manifoldpressureexceeds
300 kpa (3.0 kg/cm' , 43 psi), the diaphragmis pushed 1 . Attach a fuel pressuregaugeto the serviceport of
uDward,and the excessfuel is fed back into the fuel tank t h e f u e l r a i l ( s e ep a g e 1 1 - 1 1 5 ) .
through the return line.
Pressurs should be;
CLOSE INTAKEMANIFOLD H23A1 engino (USA: Si/Canada:SR),
VACUUM F22A1 engino (S):
255-3O5 kPa (2.55-3.05 kg/cm2,36-43 psi)
H22Al engino (USA: Si WEC/Canada:SR-VI:

23o-2ao kPa (2.3-2.8 kg/cm2.33-4o psil
{with the fu6l pressuro logulator vacuum hose dis-
connectod and pinchedl
INTAKE MANIFOLD
VACUUM
DIAPHRAGM
REGULATOR
PRESSURE
2. Reconnectthe vacuum hose to the fuel ptessure

regulator.
ar
\-
t FUEL
INLET
3. Check that the fuel Dressurerises when the vacu-
um hose from the tuel pressureregulatoris discon-
nected again.
lf the fuel pressuredid not rise, replacethe fuel pres-

sure regulalor.
FUELRETURN
11-122
Fuel Filter
Replacement Replacement
E@ oo not smok6whilewolkingon fuelsys- @ oo not amoko whib working on fuol sys-
t€m. Keep open flame arvay from yout work area. tem. Kesp open flame away ftom yout wolk atea.
1. Placea shop towel unde. the tuel pressureregula- The fuel filter should be replacedevery 4 yea.s or 60.OOO
tor, then relievefuel pressure(see page 1l-114). miles(96,000 kml, whichevercomesfirst or whenever
the fuel pressuredrops below the specifiedvalue IH23A1
2. Disconnectthe vacuum hose and fuel returnhose. e n g i n e ,F 2 2 4 1 e n g i n e :2 5 5 - 3 O 5 k P a , 2 . S 5 - 3 . 0 s
kg/cm' , 36-43 psi (H22A1 engine: 23O-280 kpa,
3. Removethe two 6 mm mounting bolts. 2.3-2.8 kg/cm2,33-40 psi) with the fuel pressure
regulato.vacuumhosedisconnectedand pinchedlafter
O,RING making sure that the fuel pump and the fuel pressure
VACUUM HOSE Replace regulatorare OK.
1. Placea shop towel under and aroundthe fuel rail.
2, R e l i e v ef u e l p r e s s u r e( s e ep a g e 1 1 - 1 ' 1 4 ) .
3. Removethe 12 mm banjobolt and the fuel feed pipe

trom the fuel filter.
4. Removethe fuel Jilterclamp and fuel filter.
5. When assembling,use new washers,as shown.
28 N.m (2.8 ks-m,20 lb-ft)
FUEL
PRESSURE
REGULATOR
NOTE:
a Replacethe O-ring.
a Whenassemblingthe fuel pressureregulator,ap-
ply clean engineoil to the O-ringand assemble
it into its proper position, taking care not to
damagethe O-ring.
NOTE; Cleanthe flaredjoint of high pressurehoses

thoroughlybefore reconnectingthem.
11-123
Fuel Supply System
Fuel Pump
Description
Becauseof its compactimpellerdesign,the iuel pump is installedinsidethe tuel tank. therebYsavingspaceand simplify-
ing the fuel line system.
FUEL PUMP CROSS SECTION(Side vtew) FUEL pUMp CROSS SECTION(ToD viowl
DISCHARGEPORT rNrETPOBr
FUEL ,
rFrrFFVALVE
RELIEFvar vF PUMPCOVER
IMPEI.LER
CASING
GROOVES
CHECKVALVE
ARMATUBECOIL FUEL PUWIPCASING
IMPELLER
protectingthe fuel linesystems,

The fuel pumpis comprisedof a DC motor, a circumterenceflow pump,a telietvalvetor
valve for retainingresidualpressure,an inlet port, and a dischargeport. The fuel pump assemblyconsistsof
a check
pumpingchamber),and the fuel pump cove,.
the imoeller(drivenby the motorl, the fuel pump casing{which forms the
OPERATION
(1) When the engineis stsrted, the "o PGM-FImain telaY actrratesthe fuel pump' and the motor turns tlle impeller'
relav actuates
Differentialpressureis generatedby the numerousgroovesaroundthe impeller'
(2) Fuetenteringthe inlet port flows insidethe motor from the pumpingchambefand is torced throlgh the dischargo
valve will open
oort via the check valve. lf fuel Jlow is obstructedat the dischargesside of the fuel line, the relief
to bypass the fuel to the inlet port and prevent excessive fuel pressure'
(3) Whe; the enginestops,the fueipump stops automatically.However,a checkvalveclosesby springactionto retain
the residualpressurein the line. helpingthe engineto restart more easily'
11-124
Testing Replacement
E@E Do not smokeduringthe test. Ke€popon @@l Donot smokewhilowolkingon fuetsys-
flame away from your work area, tam. Ke€p open flsmes away ttom yout wotk area.
lf you suspecta problemwith the fuel pump,checkthat 1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e 1 1 - 1 1 4 ) .
the tuel pump actuallyruns;when it is ON, you will hear
somenoiseif you holdyour ea. nearthe tuel till port with 2. Removethe accesspanel in t.unk.
the fuel fill cap removed.The fuel pump shouldrun for
two secondswhen the ignitionswitch is first turnedon. 3. Disconnectthe 2P connectorJrom the tuel pump.
lf there is no noiseat the fuel fill port, check as follows;
4. Removethe fuel pump mountingnuts.
1. Removethe accessDanelin trunK,
5. Removethe tuel pump from the fuel tank.
CAUTION: B€ sure to turn tha ignition switch OFF
betore disconnecting tho wiles. 6 N.m
(O.6 kg-m,
4 tb-ftl
2. Disconnectthe 2P connector-
? Disconnectthe PGM-Ftmain relay conneclor and

connect the BLK/YEL@ wire and yEL @ wirc with
a jumper wire. FUELPUMPUNIT
\< pcm-H
\ ..-\
MA|N
I
28 N.m (2.8 kg-m,
20 tb-ftI
BLK/ JUMPER
'WIRE YEL€)
YELG)
Check that battery voltage is availableat the fuel
pump connectorwhen the ignitionswitch is turned
ON (positiveprobeto the yEL wire, negativeprobe
to the BLK wire).
Y E L{ + }
lf battery voltage is available,replacethe fuel
DUMO.
lf there is no voltage, check the fuel pump grouno
and wire harness(see page 1j- 128).
11-125
Fuel Supply System
PGM-FIMain Relay
Descdption Relay Testing
NOTE: lf the car starts and continues to run, the
The PGM-Flmain relayactuallycontainstwo individual PGM-FImain relay is OK
retavs.
The relay is located at the left side of the cowl. 1. Removethe PGM-Flmain relay.
One relayis energizedwheneverthe ignitionis on which
supplies the battery voltage to the ECM, power to the 2. Attach the b8ttery positivete.minalto the No' 6 ter-
fuel injectors,and power for the secondrelay. minal and the batt8ry negativeterminalto the No.
The second r€lay is energizedlor 2 seconds when the I terminalof ths PGM-Flmain relay.Then checktot
ignitionis switched on, and when the engineis running continuity between the No. 5 terminal 8nd No' 7 tet-
which suppliespowet to the fuel pump. minal of the PGM-FImain r€laY.
a It there is continuity.go on to step 3.
a ll there is no continuity, replacethe relay and
FGM.FI
MAIN RELAY
TO IGN.1 TO 8AT C)
TO GROUND
to EcM (A25,Btl
TO ST. SWTTCH
TO ECM{A7, 8} TO FUELPUMP
3. Attach the battery positive terminal to the No' 5 tsr-

minal and the battery negative terminal to the No.
2 terminslof the PGM-Flmain relav.Then check that
there is continuitybetweenthe No. 1 terminal8nd
No. 3 terminalot the PGM-FImain relay.
a lf there is continuity, go on to step 4.
a lf there is no continuity, replacethe relay and
relesl.
4. Aftach the baftery positive terminal to the No. 3 ter-

minal and the batterY negative terminsl to the No.
8 terminalof the PGM-Flmain relav. Then check that
there is continuitv between the No. 5 terminsl and
No. 7 terminalof the PGM-Flmain relay'
a lf there is continuity,the relay is OK.

a lf there is no continuity, replacethe relay and
retesl
(cont'dl
11-126
! t
FuelSupplySystem
PGM-FlMain Relay(cont'd
- Engino will not 3tan.
- InlDcction ot PGM-FI
rclay.
Check for continuitY between

BLK terminal @ and bodY
ground.
Ropairopon in 8LK wirc b6tw.en

PGM-FImain relay and GlOl {lo-
catod at th6amostot housing).
Measure the voltage between

YEL/BLU terminal O and bodv
gtouno.
- Roplace tho No. 4 BACK UP
{10 Al tu36 {in tho undordash
fu3o/rolay borl.
ls there battery voltage? - Ropoir op6n in rho YEL/BLU
wire b€tweon tho NiM-Fl rnain
relay and ths No. 4 BACK uP
{10 Al lu8o.
PGM-FI
Measure the voltago between
MAIN
BLK/YEL terminal @ and body
glouno, RELAY
- Roolacoth. ECUIECMI {15 A}
tuis {in tho und6r{eh tut /ro-
lay boxl.
ls there battery voltage? - R6pai opgn In tho BLK/YEK
wiro b€tween d|o FGM-FI tnein
r6laYand tho Ecu (ECM) {15
Al fu3e.
Turn the ignition swilch to the
START position. NOTE:
. M/T: Clutch pedal must
be depressed.
a A/T: transmissionin I n I BLK @
Measure the voltage betw€en or [E position.
BLU/REDterrninal@ and body
ground.
- Replaco lhc No. 2 STARTER
SIGNAL {7.5 A} furo lin tho
undor-dashf uso/ralay borl.
ls there baltery voltage? - B.p.ir op.n in tho BLU/RED
wiro b.twoon th6 FGM-FI rtain
r6lay .nd lh. ignition twitch
(sr). BLK€) YEL€)
( T op s g e I ' l - 1 2 9 )
11-128
11.12Al
Connectthe test harnessbetwgen

Disconnoct "A" connector from
the ECMonlv, not the main wire
harness(see page 11-451.

GRN/BLK terminal @ and rhe
followingterminals;A7. A8.
R6palropen in GRN/BLKwlr. b€-

twoon ECM lA7, A8l and PGM-FI
main rohy.
Turn the ignitionswirch ON.

423 1-) terminaland the tollow-
ing terminals:A25 (+) 81 lf).
R.pair opon in tho YEL/BLKO
rvi 6 botwoon th. ECM (A25,
ls there battery vokage? 811 lnd PGM-FIh.in iohy.
R.pl.c. PGM-FImain r6lay.
Turn lhe ignilion switch OFF.
o o o o o o o o o o o o o o ooooooo lfitoHruffs{sl
ooo ooo ooooo
o oooo ooooo ooo I oo oooo oo ooooooooooo
Connect a voltmeter between A7
l+l te.minal and A23 l-) rer
mtnat.
ls there batt€ry voltage tor lwo Subrtltulc 6 known-good ECM

seconds when the ignition and raatrock. ll p.eacriH voltago
switch is first tu.ned on? b now svail.Hg, rgf aco tho origi-
nal ECM.
Chock th. PGM-FI mlin r.l6y (.eo

pag. l1-126).
1 - 129
FuelSupplySystem Ir
FuelTank
Replacement
@ Do not smoke while working on fuel syst€m. Keep open llame away from your work area.
1. Block front wheels. Jack up the rear of the car and supportwith jackstands.
2. Removethe drain bolt and drain the fuel into an aoorovedcontainer,
3. Removethe accesspanel.
4. Disconnectthe connectorsfrom the fuel gaugesendingunit and the fuel pump,then removethe fuel feed line and
return hose.
CAUTION: Be sur€ to turn the ignition switch OFF before disconnecting the wires.
5. Removethe fuel hose protectors.
6. Oisconnectthe hoses.
CAUTION: Whon disconnocting the hos6s. slide back ths clamps, then twist hosos as you pull to avoid damaglng
them.
7. Placea iack, or other support,underthe tank.
8. Removethe strap bolts and nuts. and let the strapsfall free.
9. Removethe fuel tank,
NOTE: The tank may stick on the undercoatappliedto its mount. To remove,caretullypry it off the mount.
1O. lnstalla new washer on the drain bolt and the fuel pump line, th€n installpans in the reverseorderol removal.
38 N m 13.8ks-m.28 lb-ft|
CAUTION: Cloanthe flared ioint of high prossu.oho8e3 FUEL PUMP

thloughly botoro .oconnecting thom. GAUGE
SENOINGUNIT
FUELTANK
WASHER
R€place
DRAII{ BOLT
50 N.m (5.o kg-m, 36 lb-tt)
3a N.m (3.8 ks-m. 28 lb-ft|
11-130
Intake Air System
NOTE: Acrosseach row in the chan, the sub-systemsthat could be sourcesof a symptomare rankedin the orderthev
shouldbe inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likelysource,then
refer to the page listed at the top of the column. lf inspectionshows the system is OK, try the next system @, etc.
SYMPTOM
WHEN COLD FAST IDLEOUT OF SPEC
W H E NW A R M I D L ET O O H I G H
LOSSOF POWER
*: Except F224 1-engine{S)
11-131
Intake Air System
System Description
The systemsuppliesair lor all engineneeds.lt consistsof the Air Cleaner(ACL).intakeair pipe, intakeair duct, Throttle
*intakecontrol
Bodv {TB},ldle Air Control(lAC)Valve,tast idlethermo valve, *lntake Air Bypass(lAB)ControlSystem,
system,and intakemanifold.A resonatorin the intakeair pipeprovidesadditionalsilencingas air is drawn intothe system.
*: Except F22A1 engine (S)
.IAB .tA8
CONTROL VACUUM
SOLENOID TANK
VALVE
?!t'----_'o ECU|ECM){'r5 A' FUSE
Xll'----'oPGM.FIMAINRELAY
VARIOUS
SENSORS
INTAKEAIR DUCT
r|AB CONTROL
DIAPHRAGM
FAST
IOLE
THERMO
BODY VALVE
INTAKE
SLK/ .- TO ECU{ECM}(15 AI AIR
:II{TAKE YEL FUSE
CONTROL PIPE
SOLENOID WHT RESOI{ATOR
VALVE
.If{TAKE
CONTROL
CHECK
VALVE
-1 32
Air Cleaner{ACL}
Air Cl6anel (ACL) Element Raplacemont
ACL HOUSINGCOVER
ACL EL€MENT
Roplac€€very 3O,OOOmiles (48,OO0 kml
or 24 months.
'l5.OOO
Cleanair cleanerelementeverv
mil6s (24,OOO kml or 12 months under
ACL HOUSING conditions, rough or muddv roads.
INTAKE AIR DUCT
11-133
Intake Air System
Intake Control System [Except F22A1 engine (S)l
Description
The intake control svstem decreasesair intake noise.
BLK/ ------? - TO ECU (ECMIll5 Al

YEL FusE
INTAKE CONTROI-
SOLENOIDVALVE
II{TAKE CONTROL
VACUUMT
INTAKE CONTROL
CHECKVALVE
BLK
I
I
=
RESONATOR
When the engine speed is below 4,OO0rpm, the ECM provides ground for the intako control solenoid valv6. This opens
the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm.
11-134
Troubleshooting Flowchart VACUUMPUMP/GAUGE
A973X-O41-XXXXX AKE
CONTROL
SoLENOTO
VALVE
St.n onginernd allow to idle.
Remove the #8 vacuum hos6

from the hose joint and connect
a vacuum gaug€ to the solenoid
Oisconnect lhe lower vacuum

hos€ofthe solonoidvalv6from the
air chamb6r and connecl a vac-
uum gau96 to th€ hos6.
Chcck tho v.cuum
lina tor profEr con-
n6ctlon, crack!,
blockrg! or dtr;on-
n*tod ho!o.
Closn manltold m.t.
Disconnect th€ 2P connector

from the intake control solehoid
Measurs votiag€ botwson BLK/

YEL (+ l terminaland WHT (- )
tornanal.
INTAKE
CONTROL
SOLENOID
VALVE
R.pl.co th. Intlko

ls there battery vollag€? control aobndd volve.
Measure voltage betwe€n BLK/

YEL {+l torminal and body
ground.
{To page 11-136) (To page 1 1-136) (cont'dl
11-135
Intake Air System
Intake Control System lExcept F22A1 engine (S)l {cont'd}
{ F r o mp a g o1 1 - 1 3 5 } lFrom psge 1 1 - 1 3 5 )
Ropairopoo in BLK|/EL
wi.o botwoon tho 2P
connoctor and ECU
ls there battery voltage? (ECMI (15 Al tuso lin
tho undo.-dsshfus€/r6-
l6y box).

page 1 1-45).
Turn the ionition switch ON.
Connect a jumper wire between

A19 terminaland A26 terminal.
Ropair opon in WHT

wiro betwoon ECM
lA19) and tho 2P con-
nectot.
Substituto s known-good ECM

and .ochock. lf symptom/indica-
tion goos away, replgceth6 odgi-
nal ECM.
Turn the ignilion swilch OFF.
Check for continuity to ground
(To pago 1 1 - ' t 3 7 )
{ T o p a g e1 1 ' 1 3 7 )
11-136
(Frompage 11-136) lFrom psge 1 1-136)
R6pai. ahort lo ground

in WHT wira b6tw€en
ECM {A19).nd rhe 2P
connoctot.
Subltitute a known-good ECM

and rechock. lf symptom goaa
away, .oplaco tho originsl ECM.
Connect a vacuum pump to the

#8 vacuum hose.
Chack dr€ vecuum line for propor

connaction oa diaconnected
Does it hold vacuumT noaa.
lf OK. '.plac6 tho inllk. control
dl.phrlgm.
l aha contol ayatam b OK,
11-137
Intake Air System
Throttle Cable
Inspection/Adjustment lnstallation
1. Warm up the engineto normaloperatingtempera- 1. Fully open the throttle valve,then installthe throt-
ture (the radiatorfan comes on). tle cablein the throttle linkageand installthe cable
housingin the cable bracket.
2. Check that the throttle cable operates smoothly
with no bindingor sticking.Repairas necessary. 2. Warm up the engine10 normaloperatinqtemp€ra-
ture (the radiatortan comes on).
3. Checkcablefree play at the throttle linkage.Cable
d e f l e c t i o ns h o u l db e 1 O - 1 2 m m ( O . 3 9 - 0 . 4 7 i n . )
2 Hold the cable sheath. removingall slack from the

DEFLECTION cable.
10- 12 mm
1O.39-O.47 in.)
Turnthe adiustingnut untilit is 3 mm (0.12 in.)away
from the cable bracket.
Tightenthe locknut. The csbledetlectionshouldnow

b e 1 O - 1 2 m m ( O . 3 9 - O . 4 7i n . ) .l f n o t ,s e ei n s p e c -
tion/adjustment.
It deflectionis not within specs,loosenthe locknut.
turn the adjustingnut untilthe deflectionis as speci- CABLE
fied, then retightenthe locknut, ARACKET
5 . With the cableproperlyadjusted,checkthe throttle

valve to be sure it opens fully when you push the
acceleratorDedalto the tloor. Also checkthe throt-
tle valve to be sure it returnsto the idle position
wheneveryou releasethe acceleratorpedal.
38
Throttle Body
Description Inspection
The throttls body is ot the single-barrelside-dratttype. CAUTION: Do not adiust the throttls stop screw,
The lower portion oJ the throttle valve is heated by en- It i3 presot at tho tactory.
gine coolant which is fed from the cylinder head.The idle
adjustingscrew which increases/decreases bypass 8ir 1. Stan the engineand allow it to reachnormaloper
and the EvaDorativeEmission{EVAP)ControlCsnister ating temperature(the radiatorfan comes on).
port are locatedon the top ot the throttle body.
2. Disconnectthe vacuum hose (to the EVAP' ccontro
ontrol
IDLEADJUSTING canister)trom the top of the throttle body; connect
connec
SCREW I vacuum gaugeto the throttle body.
VACUUMPUMP/GAUGE \
A973X-04t -XXXXX
3 . Allow the engineto idle and check that the gauge

indicatesno vacuum.
a lf there is vacuum,check the throttle cable (see
p a g e11 - 1 3 8 ) .
4. Checkthat vacuumis indicatedon the gaugewhen

the throttle is op€nedslightlyfrom idle.
a lf the gauge indicates no vacuum, check the
throttle body port. ll the throttle body port is
clogged,cloan it with carburetorcleaner.
Stop the engine and check that the throttle cable

operatessmoothly without bindingor sticking.
a It there are any abnormalities
in the abovesteps,
check for:
- Excessivewear or play in the throttle valve

sh8tt.
- Sticky or binding throttle lever at full close
position.
- Clearance between throttle stop screw and
throttle lev€r at full close oosition,
11 - 1 3 9
Intake Air System
Throttle Body (cont'd)
THROTTLELEVER
There should be
no clearance.
THROTTLE STOPSCREW
(Non-adiustable)
Replacethe throttlebody if there is excessiveplay in the

throttle valve shatt or if the shatt is bindingor sticking.
11-140
Throttle Body
Disassembly
GASKET
Rgplaco
THROTTLECABLE
(2.2 kg-m, 16 lb-ft} A/T THROTTLE

CONTROL
CABLE
11-141
r
Intake Air System
Throttle Body (cont'd)
a The throttle stop scr€w is non-adiustable,

a Aftd rrllrombly. adiust tho throftle cabl€ {seo pag6 'l 1-138}. and A/T throttlo control cable (s66 section 141tor cars l
whh A/T.
F22A1 angine (S):
IDLEADJUSTING
SCREW
H23Al €ngino (USAr Si/Can8d8:SR),

H22Al engine (USA: Si VTEC/Csnada:SR-VI:
FAST
IDLETHEBMOVAVLE
pago1'l-110
Inspection,
('1.2kg-m, 9 lb-lt)
11-142
lntake Air Bypass (lABl Control System fExcept F22A1 engi,ne(Sll
Description
Two air intake paths are providedin the intake manifoldto allow the selectionof the intake path most tavorablefor a
given enginespeed.
Optimum perlormance at any RPM is achieved by c\osing and opening the \ntake Air ByDass(tA,Bl\ratves. High torque
at low RPM is acheivedwhen the IAB valves are closed, whereashigh powe, at high RPM is achievedwh€n the IAB
valves are ooened.
tA8
CHECK
VALVE
IAB CONTROL
DIAPHRAGM
(15A]
tEcM]
9i['-_------->
I$.i"u
tA8
CONTROL
SOLENOID IAB VACUUMTANK
VALVE
VARIOUS
SENSORS
IAB CONTROLSOLENOIDVALVE OFF
ET{GINERPM IS ABOVE
4,800 rpm (H23A1 onginel
or 4,600 .pm (ll22Al €nginol
(cont'd)
11-143
IntakeAir System
lntakeAir Bypass(lABlGontrolSystem[ExceptF2241engine{S}](cont'd)-
Troubleshooting Flowchart
#13 VACUUM
HOSE
COI{TROLDIAP}IRAGM
In.poction ot IAB Control Sy.t.m
Stan ongino lnd allow to idl€.
Remove # 'l3
vacuum hose trom
the lAg control diaphragm €hd
/f
VACUUM
PUMP/GAUGE
A973X-O4t-XXXXX
connecl vacuum gauge to th6
nose,
the IAB control sol€noid valve.
Measure voltagg between BLK/

YEL (+) terminaland PNK (-)
terminal.
IAB COI{TROL
SoLENO|O VATVE
'
t
I
I
II
II
I
Pl{K
Rcp.lr th. block.g. or

vlcuu|n lark bltwaan
ls tho.o banory vohrgo ? lh. intlk€ m.ntlold .nd
d!ph.!gm, it vrqrxn l!
OK, r.pl.c. the IAB
contrcl lolcnold vllva.
Matturu voh.ge b€twe€n BLK/
YEL (+) t.rmin.l and bodv
gaouno,
R.p.lr op.r| in BLK|rEL
wlre bctwaon th! 2P
13there bancry vohage ? connaclor lnd ECU
IECMI (15 Al tur. {ln
tha undardrah lura/.c-
hy boxl.
Turn the €nrtion swilch OFF.
(To page 1 1-145) (To page 1 'l-145)
11-144
(Frompage 1 1-1441 {Ffom page 1 1-144)

the IAB control solenoid valve.
Connect the tost harness to the

mainwire harnessonly {seepage
11 - 4 5 ) .
Turn the ignitionswitch ON and

connect a jumper wiro between
A17 terminaland A26 torminal.
Rop.ir opon in P K wlro
botwoon ECM {A17)
Does the solenoid valve click ond tho 2P conn€ctor. lf
tho wiie i. OK, ,oDlac6.
th6 IAB cootol 8olongid
Substhuto a known-good ECM

and .echack. lf proacriH vohlgo
i3 now sveilabloroplacetho origi-
nll ECM.
the IAB controisol€noidvalve.
Turn the ignilion swatchOFF.
Check for continuity to ground on

rhe PNK wire.
IAB control syrtom i! OK.
Ropair short to giound
rt PNK wir6 b6twoen
ECM {A17) and tho 2P
conneclol.
Substituts a known-good ECM

and rachock. lt symptom goos
away, rcplaco the original ECM.
11-145
Intake Air System
IntakeAir Bypass(lABlControlSystem
lExceptF22Al engine{S}l(cont'd}
IAB Valve Testing
CAUTION: Do not adjust the IAB valve full-close5c1€w.

It was preset 8t the factory.
1. Check the IAB valve shaft for bindingor sticking,
2. Check the IAB valve for smooth movement.
3. With the engineOFF,ctreckthat @ of the bypass

valve is in close contact with the stoDper.
4. With the engine at idle, check that (9of the IAB

valve is in close contact with the full-closescrew.
a ll sny fautt is found, cl€anthe linkagoand shafts

with calbuistor clssner.
lf the Droblemstill exists after cleaning,disassem-

ble the intakemanifoldand check the IAB valve
( s e ep a g e 1 1 - 1 4 7 )
11-1 4 6
fntake Air Bypass (lAB) Control System lExcept F22A1 engine (S)l
e s 22 N.m
(2.2 kg-m,16 lb-ttl
22 N.m
12.2kg-m, 16
H
s ll
e
E
IA8 VALVE
@ ^ ^
IAB t- @-,rrn.^
CONTROL {2.2 kg-m, 16 tb-frl
SOLENOIDVAI-VE
11-147
Intake Air System
fntake Manifold 1F22A1engine (S)l
e g
22 N.m (2.2 kg-m.
16 rb.ftl -l€9
HEn
@
*
^\,,^^
EmissionControl System
NOTE: Acrosseach row in the chan, the sub-systemsthat could be sourcesof a symptom a.e rankedin the orderthey
should be inspectedstartingwith O. Find the symptom in the left column,read acrossto the most likelysource,then
referto the pagelistedat the top of that column.It inspectionshows the system is OK, try the next most likelysystem
@. etc.
POSITIVE
PAGE SUB-SYSTEM THREEWAY EXHAUSTGAS EVAPORATIVE
CRANKCASE
CATALYTIC RECIRCULATION VENTILATION EMISSION
CONVERTER SYSTEM CONTROLS
SYSTEM
SYMPTOM t 5 l t55 159 160
ROUGHIDLE o o
FREOUENT
STALLING WARMINGUP o
MISFIREOR
ROUGH
RUNNING
o
FAILS
POOR
PERFORMANCE
EMTSSTON
TEST
o @ @
LOSSOF
POWER o @
11-149
EmissionGontrol System
SystemDescription Tailpipe Emission
The emissioncontrol system includesa Three Way Cata- lnspection

lytic Converter(TWC),ExhaustGasRecirculation IEGR)
system, Postitive CrankcaseVentilation (PCV) system @ Do not smoke during this procedure.Keep
and EvaporativeEmission(EVAP)control system. The any open flame away ltom your wotk alea.
emissioncontrolsystemis designedto meet federaland
1. Start the engineand warm up to normaloperating
state emissionstandards,
temperatureby driving on the road.
Connect a tachometer.
Check and adjustthe idle speed,if necessary(see

p a g e1 1 - 1 1 1 ) .
Warm up and calibratethe CO meter accordingto

the meter manufacturer'sinstructions.
Check idle CO with lhe headlights,heaterblower,

rea. window defogger,coolingfan. and air condition-
er oft.
CO meter should indicateO.1 % maximum,-
11-150
ThreeWay CatalyticConverter(TWC)
Description
The ThreeW8y CatalyticConverter(TWC) is used to convert hydrocarbons(HC),carbon monoxide(CO),and oxides
of nitrogen(Nox) in the exhaustgas to carbon dioxide {co2), dinitrogen(N2)and water vapor.
HOUSING
THREEWAY
CATALYST
FROI{TOF VEHICLE
11 - 1 5 1
Three Way Catalytic Converter (TWC) (cont'd)
Inspection
lf sxcessiveexhaust systgm back-pressureis suspected, .emove the TWC from the car and make a visual check for plug-
ging, meltingor crackingof the cstalyst. Replacethe TWC if any of the visiblearea is damagedor plugged.
34 N.m
13,4 kg-m,
SD
SN
HEAT SHIELD
34 N.m 10 N.m 11.Okg-m, 7 lb-ft)

13.4 kg-m, 25 lb-ft)
ia"\
IJ
FRONTOF
VEHICLE
11-15,2
(EGRISystem
ExhaustGasRecirculation
\ l /
-lra-ll- lf;-f l The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 12: A problemin
- | \ . L-l!J _ the ExhaustGas Recirculation(EGR)system.
The EGRsystem is designedto reduceoxidesof nitrogenemissions{NOx)by recirculatingexhaustgas throughthe EGR

valveand the intakemanifoldinto the combustionchambers.lt is composedof the EGRvalve.EGRvcuum cont.olvalve.
EGRcontrol solenoidvalve, ECM and varioussensors.
The ECM memorycontainsidealEGRvalve lifts tor varyingoperatingconditions.The EGRvslve lilt sensordetectsthe
amount of EGRvalve lift and sendsthe informationto the ECM. The ECM then comparesit with the jdeal EGRvalve
lift which is determinedby signslssent from the other sensors.lf there is any di{ferencebetween the two, the ECM
variescurrent to the EGRcontrol solenoidvalve to further regulatevacuum appliedto the EGRvalve.
EGR ---l>
BLK/YEL ECUIECMI{15 A}
CONTROL
sol-Et{otD
VALVE EGB
VACUUM
CONTROL
VALVE
RED/
EGRVALVE 5-J WHT
LIFTSENSoR I.+-WHT/BLK
BLK
I
I
:
{cont'd)
11 - 1 5 3
{EGR)System{cont'd)
ExhaustGasRecirculation
- - \ ---r-l
- h--J-6 l - -l12l-
-.-_:- /--\
- lho MIL has boon roportedon.
' With rsNico chcck connoctot
iumpedlsoopa06 1142), cod.
12 is indicatod.
Do the FCM ResetProcedure{see

p a g e1 1 - 4 3 1 .
Roadtost necessary:Warm upthe

engine to normal operating tem- VACUUMPUMP/
perature {the radiator fan comes GAUGE
on). 4973X-04't -XXXXX
Drive the car on lhe road for ap- II
prox. 10 minutes.Keep th6 en-
gine speedin the 1.700-2.500 | #16 HOSE
rpm. Intormitlrnt t llur6, .yltom ir OK
at thi! tlm..
Chock for poor connaction! ot
loo.. wlr.s at Ot25, gl28llocat-
ls the MIL on and does it od at rlght ihock towqr), C463
indicatecode 12? (locatod at loft .ida und.r dashl,
C1 17 (EGR vllvo lift $n.or),
C31O GGB comrol .olonoid vrlv.l
and ECM.
With the engineat idle, discon-
nect the # 16 hosefrom the EGR
valve and connect a vacuum
pump/gauge to the hose.
Disconnoct2P connoctorfrom the EGRVALVE

EGR control solgnoid valve and
ls there any vacuum?
checkthe # 16 hosgfor vacuum
again.
Move the vacuum pump/gaugeto
# 16 HOSE EGRVALVE
LIFTSENSOR
EGR VALVE
{To page
l T o p a g e1 1 - 1 5 5 1
1 1 -1 5 4
{Frompage 1 1-154} (Frompage t 1-154)
Check vacuum hoso
rouling of the ontiro
With the engineat idle, apply 2O0 ls there any vacuum? EGR system. It hoss
mm Hg (8 in Hglof vacuumto the routing ir OK, roplac.
EGRvalve. EGR control 3olenoid
Turn the ignitionswitch OFFand

disconnect the "A" conngctor
from the ECM.
Checktor continuity to ground on

REDwire of the 2P connector.
Ropairsho.t in REDwir6
botween EGR control
solonoid valvo ard ECM
{A11t.
Substitut. a known€ood ECM

and rot$t. It symptom/indication
goos away, roploco tho odginol
ECM.
EGR
CONTROL
SOLENOID
VALVE
Ooesthe enginestall or run
rough and does the EGR
valve hold vacuum?
the EGRcontrol solenoidvalve.
Measurevoltage between BLK/

YEL(+lterminalon the mainwire
harness and body ground.
Repairopon in BLKrYELwir6 bo-

ls there battery voltage? tween th6 EGR contrcl iolenoid
v6lv. .nd ECU (ECM)(15 Al fuso
(in tho und6r{a.h turo/,olay borl.
Reconnectthe vacuum pump/

gaugeto the # |6 hose.
( T op a g e11 - 1 5 6 )
{cont'd)
11 - 1 5 5
EmissionGontrolSystem
(EGRISystem(cont'dl
ExhaustGas Recirculation
'11-1551
{ F r o mp a g e
Connect battery oower lerminal

to the A terminal of the 2P con-
nector. While watching the vacu-
um gauge, ground the B terminal.
Turn the ignitionswitch OFFand

ls there approx.2OOmm Hg inspectthe # 16 and #24 hoses
(8 in.Hg)within 1 second? for leaks, restrictions, or mis-
routing.
Turn the ignition swith OFF and

reconnectthe 2P connector, Are the hoses OK?
EGRVALVE EGRVACUUM
LIFT CONTROLVALVE EGRCOI{TROL
SOLENOIDVALVE
Disconnect the lower hose on VACUUMPUMP/

EGR control solenoid valve and GAUGE
connect a vacuum gaugeto the A973X-O4t -XXXXX
hose.
Disconnect3P connectorfrom the

EGR valve lift sensor.
ls there 150-250 mrn Hg Roobca the EGB vacu-

Turn the ignitionswitch ON. 16- 1o in.Hg) ol vacuum? um control valvg.

wHT (t ) terminaland GFN^dHT
{- ) terminal.
Measure voltage betwe€n RED/

ls there approx. 5 V? WHT {+} terminal and bodv
ground.
( T op a g eI l - 1 5 7 ) l T o p a g e1 1 - ' l 5 7 1
11-156
{Frompage 1 1-156} 't
{Frompage 1 - 1 5 6 )
Ropair open in GRN/

WHT wii. botweon
EGR vrlv6 lift sonsor
ond ECM (D22).

connectorto the ECMonly. not to
th6 main wire harness (see pags
11 - 4 5 ) .
Measure voltage botween D19

(+) terminaf and O22 l-l
terminal.
Rgpair opon in RED/

WHT wir. batwoon
EGR valv. litt !.n3or
.nd ECM (Dl91.
Subrtituto a known{ood ECM

and .ech6ck, lf symptom/lndic€-
tion go6i away, ,ophc6 rha origi-
nal ECM.
Reconnoct the 3P connector to

the EGRvalve lift sensor.
D 1 2t + t D 2 2 t - l
Connectthe test h€messbelween t l
the ECM and connectors (see 1.2 V wirh no vacuum appli.d?
p a g e1 1 - 4 5 ) . 4.3 V rvith 2OO mm Hg (8 in.Hol
of vacuum appliod?
Measure voltage between O'l2

f+) terminaf and D22 l-)
terminal.
ls the voltageapprox. 1.2 V Ropair opon or lhort in WHT/

with no vacuum applied and BLK wir. botwo.n EGR valvo
approx.4.3 V with 2OOmm lift !.n.or and ECM {D12}.
Hg {8 in Hg) of vacuum ap- ll YYi.ob OK, r.Dlac. th. EGR
plied to the EGR valve?
(To page 1 1-158)

(cont'd)
11-157
ExhaustGas Recirculation(EGR)System (cont'd)
( F r o mp a g e 1 1 - 1 5 8 )
,: Does the voltageconsistenly

increase/decreaseas the
vacuum increases/decreases?
Connecl 41 1 terminalto 426 teF

minal with a jumper wire.
Ropair open in RED uviro botwoon

Did the enginestall ECM lAl ll and EGRconlrol3do-
or run rough? noid valv6.
Substitute a known-good ECM

and rech€ck. ll symptom/indica-
tion goes away, replac€the origi-
nal ECM.
11-158
Positive CrankcaseVentilation (PCVI System
Description Inspection
The Positive CrankcaseVentilation (PCV) system is 1. Checkthe PCVhosesand connectionsfor leaksand
designedto preventblow-by gas from escapingto the clogging.
atmosphere.The PCV valve contains a springjoaded
plunger.When the enginestarts.the plungerin the PCV
valve is lifted in proportionto intake manifoldvacuum
and the blow-by gas is drawn directly into the intake PCV
HOSE
manifold.
BREATHER
PIPE
VALVE
At idle,makesurethere is a clickingsoundfrom the

PCV valve when the hose betweenPCV valve and
intakemanifoldin lighttypincfiedwirh your fingers
or olrers.
- : BLOW-BYVAPOR
Cf I FRESHAIR
Ll\l
.t
Gently pinch here
lf thereis no clickingsound.checkthe pCV valve

grommetfor cracks or damage.ll the grommet
is OK, replacethe PCV valve and recheck.
11 - 1 5 9
EmissionControl SYstem
EvaporativeEmission(EVAPI Controls
Description
vapor escapingto the atmosphere'The
The evaporativeemissioncontrotsare designedto minimizethe amountof fuel
system consistsof the following components:
A. Evaporative Emission (EVAPI Control Caniatot

be purgedfrom
An EVAPcontrol canisteris used tor the temporarystorageof fuel vapor until the fuel vapor can
the EVAP control canisterinto the engineand burned
B Vapor Putgo Control System

EVAPcontro|canisterpurg|ngisaccomp|ishedbydrawingfreshairthroughtheEVAPcontro|canisterandintoa
portonthethrott|ebody.Thepurgingvacuumiscontro||edbytheEVAPpurgecontro|diaphragmva|veandthe
EVAP putge control solenoidvalve
EVAP PURGECONTROLSOLENOIDVALVE OFF AFTER

STARTINGENGINE
ENGINECOOLANTTEMPERATURE ABOVE I67OF (75OC)

[H22A1 e n g i n e( U S A :S i V T E C / C a S:R - V ) :1 5 8 " F ( 7 O o C ) 1
nada
Fuel Tank Vapor Conttol SYstem

When fuel vapor pressurein the fuel tank is higherthan the set value of the EVAPtwo way valve,the valve opens
and regulatesthe flow of fuel vapor to lhe EVAPcontrol canister.
11-160
EVAP
PURGE
cot{TRoL
SOLENOID
VALVE
TO ECU(ECM)
{15 A} FUSE
FUEL FILL CAP
FUELTANK EVAP CONTROL

t
FRESH
CANISTER
11-161
EvaporativeEmission{EVAP) Controls (cont'd
TroubleshootingFLowchart EVAP # 3 VACUUMHOSE
PURGECONTROL
OIAPHRAGMVALVE
Disconnect #3 vacuum hose

from the EVAP purge control di-
aphragmvalve (on the EVAPcon-
trol canister) 6nd connect a VACUUMPUMP/GAUGE
vacuum gaugelo lhe hose. A973X-041-XXXXX
Start the ongine and allow it to

idle. EVAP CONTROL
NOTE: Enginecoolant tempera- CANISTER
ture mustbe below 158oF{70oC}

YEL (+ ) terminaland REO/GRN
(- ) terminal.
Inspoct vacuum hoso

routin9.
ls there battery vollage ? lf OK, .oplaco EVAP
purge control solenoid
Measure voltage betwgon BLK/

YEL (+) terminal and body
ground.
(Topage11-163) {To page 1 1-'163)
11-162
( F r o mp a g e 1 1 - 1 6 2 ) l F r o mp a g e1 1 - 1 6 2 )
Ropairopon in BLK/YEL
wir6 betwoon ECU
(ECM) (15 Al lus6 lin
Warm up the engine to normal ls there battery vohage ?
tho undordash fuso/ro-
operatingtemperature{th6radia- lay boxl 6nd ths 2P
tor fan comes on).
connoclor.
lBpoct RED/GRNwlro tor an op€n

beiw€en ECM (4201 end tho con-
nocrot.
lf wir6 is OK. substitut6 a known-
good ECM and rcchock. lf sym-
ptom go€s away, ioplaco tho
original ECM.
Hold engineat 2,OO0rpm.
Check for vacuum at rF3 vacuum

hose after starting the engine.
ls theremanifoldvacuum?
InSD6ct vocuum hose

routing.
ls there manifoldvacuumT It OK. r6placo EVAP
purge control 3olenoid
Insp6ct lor . short in RED/GRN

wiro b6tw6on ECM lA2O) and tho
conn6ctol,
ll wir6 is OK, sub3titutoa known-
good ECM and rech6ck. lt 3ym-
ptom goo3 away, r6placo tho
original ECM.
(To page 'l 'l - 164)

( c o n t ' dI
11-163
EvaporativeEmission(EVAP) Controls {cont'd)
{Frompage 1 1-1631
VACUUM PRESSUNE
GAUGE0-4 in. Hg
o7JA2 -OO10008
Connect a vacuum gauge to

EVAP control canister purge air
nose,
Connect a vacuum gauge to the

Does vacuum appgar on gauge purge hose and raise lhe €ngine
'l
within minute?
sDeedto 3,5OOrpm.
Inlpacl tho purgo hoas

Soo EVAP two way valvo tost to ..d throt r body po.t
comoloto. tor pinch or blockag..
Evaoorativo ombsion control! aro
oK.
Rsol6c6 th6 EVAP conttol caniator.
11-1 6 4
EVAP Two Way Valve Test
1. Removethe fuel fill cap.
2. Removevapor line lrom the fuel tank and connect

to T-tittinglrom vacuumgaugeand vacuum pump
as snown.
VACUUM/PRESSURE
GAUGE
0-4 in. Hg
07JAZ-0010008
VACUUM PUMP/
GAUGE
A973X-
o4'l -
xxxxx
F T-FITTING
3. Applyvacuumslowly and continuouslywhile walching

the gauge.
Vacuumshouldstabilizemomentarilyat 5 to 15 mm
H g ( O . 2t o 0 . 6 i n . H g ) .
a lf vacuum stabilizes(valveopens)below 5 mm
H s ( 0 . 2 i n . H g )o r a b o v el 5 m m H g { o . 6 i n . H g l ,
installa new valve and retest.
4. Move vacuum pump hose from vacuum to pressure

tifiing, and move vacuumgaugehosefrom vacuum
to oressureside as shown.
Slowly pressuraze
the vaporline while watchingthe
gauge.
Pressureshould stabilizeat 1O to 35 mm Hg {O.4

to 1.4 in. Hg).
a It pressuremomentarilystabilizes(valveopens)
a t 1 Ot o 3 5 m m H g ( O . 4t o 1. 4 i n . H g ) .t h e v a l v e
is OK.
a lt pressurestabilizes below 1Omm Hg (O.4in. Hg)
o r a b o v e3 5 m m H g ( 1 . 4 i n . H g ) , i n s t a l a
l new
valve and retest.
11-165
Transaxle
Clutch ...........12-1
ManualTransmission
............................
13-1
AutomaticTransmission
..................
.....14-1
Differential
ManualTransmission.........................
15-1
AutomaticTransmission...................
15-10
Driveshafts ... 16-1
Clutch
Special Tools.......... ...........12-2
fffustrated Index........... .....12-3
ClutchPedal
Adjustment ....................
12-4
ClutchMasterGylinder
RemovaUlnstallation ....12-5
SlaveGylinder
Removal .... 12-6
Installation .....................
12-6
ReleaseBearing
Disassembly/f nspection.................... 12-7
fnstaflation................;....
.....................
12-7
PressurePlate
RemovaUlnspection ......12-8
GlutchDisc
Inspection ......................
12-9
Flywheel
fnspection/Removal ......12-10
Flywheeland ClutchDisc
lnstaflation .....................
12-10
SpecialTools I
Re{.No I Tool Numbqt

O T J A -F PM7011A ClutchAlignmentDisc 12-8
07LAB- PV00100or RingGearHolder 1 2 - 89, , r 0
07924- PD20003
07LAF- PT00110 ClutchAlignmentShaft 12-4,10
07936- 3710100 Handle 1 2 - 8 t. 0
g
o 6,
I B @
12-2
lllustratedIndex
NOTE:
a Wheneverthe transmissionis removed,cleanand greasethe releasebearingslidingsurface.
a When partsmarked"*" are removed,the clutchhydraulicsystemmust be bled.
. Bleedthe clutchhydraulicsystem(seepage 12-6).
. Inspectthe hosesfor damage,leaks,interference,
and twisting.
PEDAL
PIN
r19 N.m lt.g kg.m, la lb-fil
6x1.0mm
8 x 1.25mm 10 N.m {1.0lg.m,
22 N{n 12.2kg-m, 16 lb-ft) 7 rb.ftl
.CLUTCHMASTERCYLINDER
J .rg runrfl.g tg-m, 14lb-ft1 R6moval/lnstall6tion.
pag6 12-5
.RESERVOIF
.OIL BOLT 'REsERvolR
'15 N{n l'1.5kg-m, \ l/A+, HosE
8 x 1.25mm 30 t&n {3.0kg-m,
Y*
11 tb-ft| 22 N.ln {2.2 kg-m, z2tb-ftI
16 |b-ft) WASHER
R.pl|c..
\_-/ \ 7 ^r*V
(fr&..- " lJYr-'
Pro
]{{r+--->
| \\l n x r.o mm
'Fr t \\ ^*i!- 10N.m{1.0ls-m, 7 tb.ft}
I x1,25 mm ..-
virh.
IJUz tt.r"tz.zrg.m, tW /
r15 N{n 11.5kg-ft, r15 N{n {1.5rg-., V \ ^
CLUTCHDAMPER
11 tb.ftl lt tb-ft|
RET-EASESEANING
Romoval,p8gol2-7
pago12-7
Inspoction,
page12-7
Installation,
DOU'ELPIN
FLYWHEEL
page12-10
Inspection/Removal,
page12-10
Installation,
CLUTCHDISC
Inspection,page12-9
psge 12-10
Installation,
PRESSURE PLATE
Femoval/lnspection,pa96 12-8
page12-10
Installation,
RELEASEFORK
Removal.page12-7
page12-7
Installation,
*CLUTCH TSLAVE CYLINOER
TRANSMISSION
See section 13 15 N{n (1.5kg-m, R e m o v a l / l n s t a l l a t i o np
, a g e 12 ' 6
11 tb-ft}
12-3
GlutchPedal
Adjustment
NOTE Threadthe clutchpedalswitchA in until it contacts
. To checkthe clutchpedalswitchA and B, seesection the clutchpedal.
. The clutchis self-adjusting

to compensatefor wear. Turn the clutchswitchA in 114- '12lurn further.
CAUTION: ll th€ro is no cl6aranc6betwo€n tho mastel TightenlocknutA.

qylindor piston and push rod, the releasebearing is held
lgainrt tho diaphrrgm spring, which can result in clutch 7. LoosenlocknutB and clutchpedalswitchB.
slippago or other clutch probl€ms.
8 . Measursthe clsarancebetweenthe floor board and
1, L o o s e nl o c k n u tA , a n d b a c k o f f t h e c l u t c h p e d a l clutchpedal.lviththe clutchpedalfully depressed,
switchA or bolt until it no longertouchesthe clutch
peoal. q
Releasethe clutchpedal '15- 20 mm (0.59- 0.79
i n ) f r o m t h e f u l l y d e p r e s s e dp o s i t i o na n d h o l d i t
2. LoosenlocknutC, and turn the push rod in or out to there.
g e t t h e s p e c i f i e ds t r o k ea n d h e i g h t a t t h e c l u t c h Adjust the positionof clutch pedalswitch B so that
Deoat. the engine will start with the clutch pedal in this
position.
3. TightenlocknutC,
10. Thread the clutch pedal switch B in 114- 112-tu'n
further,
11. TightenlocknutB.
LOCKNUTC LOCKNUT B
15 N.m 11.5 tl tb-ft} 10N.m{1.0kg-m,7 lb.ftl
CLUTCHPEDALSWITCHB
CLUTCIIPEDALSwlTCHA
PUSHROD
L(rcKNUTA
10 l,I.|n(1.0kg.m, 7 lb.ft)
CLUTCHMASTERCYLINOER
Padrl in contld whh awhch
CLUTCHASSISTSPRING
-6El
@ (STROKE8t PEDALI:135- 1ir5mm (5.31- 5.71 in)

@ (TOTALCLUTCHPEDALFREEPLAY):9.0 - 15.0mm 10.35- 0.59 in) includo ths psdal plsy 1 - 7 mm t0.0t - 0.28 in).
@ ICLUTCHPEDALHEIGHT): 190mm (7.48in)
@ ICLUTCHPEDAL DISENGAGEMENT HEIGHT):9,[ mm (3.70in) minimum to the ftoor.
2-4
ClutchMasterCylinder
Removal/lnstallation
CAUTION:Avoid spilling brake fluid on paint.d sur- 5. Removethe clutchmast€rcvlinder.
tacos,as it may damagoths tinish.
NOTE:Plug the end of the res€rvoirhose,and cap the

end of the clutchpipe,with a plug and cap suchas those
discardedfrom an A/C kit.
1. Removethe reservoirhose from the clutch master

c v l i n d e ra n d d r a i n t h e b r a k ef l u i d i n t o a s u i t a b l e
contarner,
NOTE:The brakefluid csn be suckedout through

the top ot the reservoirwith a syringe.
2. Removethe reservoirfrom the enginecompartment

bulkhead.
3. Disconnectthe clutch pipe from the clutch mastsr

cylinder.
CLUTCH
PIPE
19 N.m 11.9kg-m, la lb-ttl CLUTCHMASIER
6x1.0mm
10ll.rn 11.0ke-m, CYLINDER
7 tb-ft)
6. Install the clutch mastor cylinder in the rev€rse

order of removal.
NOTE: Blsed the clutch hydraulic systom (see psge

12-6t.
CLUTCH RESERVOIR
MASTER RESEBVOIR
HOSE
CYLINDER
Pry out the cotterpin, and pull the pedal pin out of
the voke.Removethe nuts.
COTTERPIN PEDALPIN
Replac€.
-6rl
NUTS
13 N{n (1.3kg.m,9lb-ft|
2-5
SlaveCylinder
Removal lnstallation
the clutchpipefrom th€ slavecylinder.

Disconnect -6ll, SuperHighTemp LJreaGrease(P/N08798-
9002).
CAUTION: Avoid spilling braks tluid on the paintod : BrakeAssemblyLubeor equivalentrubber
3u.facos,as it may damagoth€ tinish. grease.
NOTE:Plug the end of the res€rvoirhose,and cap 1 . Install the slave cylinder on the clutch housing.
the end of the clutchpipe,with a plug and cap such
as those discardedfrom an IVC kit. Connect the clutch pipe.
Removethe slavecylinderfrom the clutchhousing.

CLUTCHPIPE
15 N'm {1.5kg-m.
SLAVE CYUNDER
CLUTCHPIPE
BLEEOER SCREW
l, 10 N{n (1,0kg-m,
7 tb-ft|
8 x 1,25mm
22 N.m {2.2 kg-m,
16 tb-ft|
-#,1
(P/N08798-
BOOT
Relhov€and chocktor signs of leaking
and deterioration.
(BraksAssembly
Lub6)
3. Bleed the ciutch hydraulic system:
Attacha hoseto the bleederscrewand suspend

the hosein a containerof brakefluid.
Makesurethere is an adequatesupplyof fluid at
the mastercylinder,then slowly pump the clutch
pedaluntil no more bubblesappearat the bleed-
er hose.
a Refillthe mastercvlinderfluid when done.
a Useonlv DOT3 or 4 brakefluid.
12-6
ReleaseBearing
Disassembly/lnspection lnstallation
Removethe boot trom the clutchhousing. N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e( P / N
08798- 9002).
Removethe releasefork from the clutchhousingby
squeezingthe releasefork set spring with pliers. Installthe releasefork set springon the releasetork.
Removethe releasebearing.
RELEASE
FORK RELEASE
FORKSETSPBING
-#l
{P/N08798-
RELEASEFOBK
-6El
{P/N08798*
With the releasefork slid betweenthe releasebear-

ing pawls, installthe releasebearingon the main-
shaft while insening the releasefork through the
hole in clutchhousing.
Align the detentof the releasefork with tlle release

f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e
releasefork bolt souarelv.
RELEASEFoRK RELEAS€
RELEASEFOBK SETSPRING BEARING
(P/N08798- 9002t
RELEASE
FORKSET CLUTCHHOUSING
SPRING
Checkthe releaseb€aringfor play by spinningit by

h an d .
CAUTION: Tho reloass besring is packed with BELEASEFORKBOLT

groas€.Do not wa3h it in solvsnt. 30 N.rn {3.0 kg-m, 22 lb-ftl f-
Installthe boot, being sure that there is no clear-
ance:releasefork-to-boot,and boot-to,clutchhous-
ing,
.Move the releasefork right and left to make sure

that the releasefork fits properlyagainstthe release
bearing,and that the releasebearingslidessmooth-
RCLEASE
BEARING
lf there is excessiveplay, replacethe releasebear

ing with a new one.
RELEASEFORK
12-7
PressurePlate
RemovaUlnspection
Inspectthe fingersof the diaphragmspringfor wear To prevent warping. unscrew the pressure plate
at the releasebearingcontactarea. mounting bolts in a crisscrosspattern in several
steps.then remove the pressureplate.
Assemblethe specialtoolsas shown.
N O T E :A s s e m b l et h e C l u t c hA l i g n m e n tD i s cw i t h
side "A" facingthe diaphragmspringas shown.
Checkthe diaphragmspringfingersfor heightusrrg

the specialtoolsand a feelergauge.
Standard(New): 0.6 mm {0.02in) max.

ServiceLimit: 0,8 mm {0.03in)
PRESSUREPLATE
CLUTCH Inspectthe pressureplate surfacefor wear, cracks,

ALIGNMENT a n db u r n i n g .
Dtsc FEELERGAUGE
OTJAF-
PM7O11A 1. Inspectfor warpage using a straight edge and a
feelergauge.
NOTE:Measureacrossthe pressureplate at three

CLUTCHALIGNMENTSHAFT pornts.
07LAF- PTOo110
HANDLE I Standard (lrl6wl: 0.03 mm (O.0Olin) max.
07936- 3710100
Sorvicc Limit 0.15 mm (0.006in)
4. Install the special tools as shown.
FEELERGAUGE
45 N.m
(4.5kg-m,
33 tb-ft) HANDLE
07936- 3710100
* /
/ '
CLUTCHI ALIGNMENT
SHAFT
07LAF- PT00110
RINGGEARHOLDER
RINGGEARHOLDER ENGINEBLOCK ADJUSTERNUT
07LAB- PV00100 AOJUSTEBBOLT
07924- PD20003
STRAIGHTEDGE
BOLT
WASHER
12-8
ClutchDisc
Inspection
L Removethe clutchdisc. Measurethe depth from the lining surfaceto the
rivets,on both sides,
2. lnspectthe lining of the clutchdiscfor signsof slip-
p i n g o r o i l . R e p l a c ei t i f i t i s b u r n e d b l a c ko r o i l Riv€t Dspth:
soaked. StandardlNewl: 1.3mm {0.05in) min.
S€rvicoLimit: 0.2 mm (0.01in)
xi (
CLUTCHOISC
CLUTCHDISC
3. Measurethe clutchdiscthickness.
Clutch Disc Thickn€ss.

Standard(New|: 8.4- 9.1 mm {0.33- 0.36in}
ServiceLimit: 6.0 mm 10.24inl
12-9
Flywheel Flywheeland ClutchDisc
Inspection/Removal lnstallation
1, Inspectthe ring gearteethfor wear and damage, .-Alignthe hole in the flywheel with the crankshsft
dowel pin and assemble.Installthe mountingbolts
2. Inspectthe clutch disc mating surfaceon the fly- only tingertight.
wheelfor wear,cracks,Sndburning.
Installthe specialtool. then torque the mounting
Measurethe flywheel runout using a disl indicator b o l t s i n d c r i s s c r o s sp a t t e r n i n s e v e r a ls t e p s a s
through at least two full turns. Push the flywheel shown.
towardsthe engineto take up the crankshaftthrust
washerclearance.
N O T E :T h e r u n o u t c a n b e m e a s u r e dw i t h e n g i n e FLYWHEEL
installed.
Standard lNowl: 0.05 mm {0.002in) mrx.

ServiceLimit 0.15 mm {0.(X)6in)
lf the runout exceedsthe servicelirnit, reDlacethe

flywheel. (} rLvwxeel
07LAB- PV00100or MOUNTTNG BOLTS

07924- PD2fi)O3 tO5N.rntj9.5 k,-m, ?Gtb-ft1
l " I n s t a l lt h e c l u t c h d i s c u s i n g t h e s p e c i a lt o o l s a s
shown.
4. R e m o v et h e e i g h t f l y w h e e l m o u n t i n g b o l t s i n a FLY\AIHEEL
crisscrosspattern in ssveral steps, and remove the
flywheel.
FLYWHEEL
HANDI.I
07936- 3710100
CLUTCHALIGNMENT
CLUTCHDISC SHAFT
07LAF- PT|X)I10
RII{GGEARHOLDER (P/N08798- 9002)

o?LAB- PVO010O ol
0?924 - PD2o003
4. Installthe DressureDlate.
Pf,ESSUREPLAIC
Torquethe mountingbolts in a crisscrosspatternas

shown.Tightenthem severalstepsto preventwarp-
ing the diaphragmspring.
MOUNTINGBOLTS
26 N.m (2.6kg-m, 19 lb-ft|
6. Removethe soecialtools.
12-11
ManualTransmission
SpeciafTools... ...........
13-2 Countershaft
Maintenance fndex ................ ......13-23
Transmission Oil ..............................
13-3 Cfearancefnspection.......................
13-24
Back-up Llght Switch Disassembly ..........13-25
Replacement .,.,,....13-3 Inspection ..............
13-26
Transmission Assembly Reassembly ...........
13-25
Removal .................
13-4 Shift Fork Assembly
Gearshift Mechanism Disassembly/Reassembly ...............
13-28
Overhaul ................
13-9 Clearance Inspection.......................
13-29
lllustratedIndex ...................................
13-10 SynchroSleeve,SynchroHub
Shift Arm Assembly Inspection
fndex ................ ......13-12 Installation .............
13-30
Disassembly/Reassembly ...............
13-13 SynchroRing,Gear
TransmissionHousing Inspection ..............
13-31
Removal .................
13-15 MainshaftBearing/OilSeal
ReverseShift Fork Replacement .....,.,,13-32
Glearance Inspection,,,....,.............., 13-16 CountershaftBearing
Reverseldler Gear Replacement .........13-33
Removal .................
13-17 MainshaftThrust Shim
Mainshaft, Countershaft Adiustment ............
13-34
Removal .................
13-17 Transmission
Mainshaft Reassembly ...........
13-37
lndex ............... .......13-18 TransmissionAssembly
Clearance Inspection......,................13-19 Installation .............
13-40
Disassembly ..........13-20
Inspection ..............
13-21
Reassembly ...........13-22
NOTE:The radio may havea codedtheft protectioncircuit.Be sureto get the customer'scode numberbefore
- Removingthe No. 43 {10A)fuse in the under-hoodfuse/relaybox.
After service,reconnectpowerto the radioand turn it on.
Whenthe word "CODE"is displayed,enterthe customer's5-digitcodeto restoreradiooperation.
SpecialTools
R€{.No. I Tool Number Description Oty I Pag€Referonc€
o 07GAJ- Pc2o' r'r0 MainshaftHolder 1 tJ-JO, J/
@ 07GAJ- PG20130 MainshaftBase 1

*07736- ,l
/a\ A010004 AdjustableBearingPuller,25- 40 mm 13-32.33
't3-22,21
@ 07746- 0010300 Attachment,42 x 47 mm 1 ,32
,|
@ 07746- 0010500 Attachment.62 x 68 mm 13-32.33
't3-22
@ 07746- 0030100 Driver,40 mm l.D. 1
o 07746- 0030400 Attachment35 mm LD. 1 13-22
@ 07749- 0010000 Driver 1 13-22,21
,32,33
't3-21
o 07947- 6890100 SealDriver 1
* Must be usedwith commerciallvavailable3/8 in x 16 thread/inSlideHammer.
o o
@ @ o
13-2
TransmissionAssembly
Removal
Removethe intakeair duct and air cleanerassem-
@Makr 3uro 4.
iacks and safoty 3tlnds aro placed proper' Dtv.
ly, rnd hoi3t brlckot! aro sftached to corroqt posi'
lion on tho cngins.
Apply parking brako and block roar whool3 30 car
will not roll off stand3 lnd fdl on you whilo working
uodor it.
CAUTION: U3o lcndrr coveB to 8void dEmlging print'

ed surfaces.
NOTE: The radio may have a coded theft protection cir-

cuit.Bo sureto get tha customer'scode numberbefore
- Disconnectingthe battery.
- Removingthe No. 43 (]0 A) fuse.
{Under-hoodfuse/relaybox)
After service,reconnectpower to the radio and turn it
fti
on.
" C O D E "i s d i s p l a y e de
, n t e rt h s c u s -
When the word
tomer's5-digitcodeto restoreradiooperation.
1. Disconnectthe negative(-) and positive(+) cabl€s

from the b8ttery,then remove the battery.
2. Drainthe transmissionoil (seepage13-3). Removethe intakecontrol vacuumtank and brack-

€t,
3. Removethe battery base and bsse stay,
NOTE:Do not disconnectthe hoses,
INTAKEOONTROL
13-4
6. Disconnectthe starter motor cables,then remove 1 1 .Disconnectthe vehiclespeedsensor(VSS)connec-
the startermotor. tor and removethe VSS/powersteeringspeedsen-
sor, but leaveits hosesconnected.
7. Disconnectthe back-uplight switchconnectorsand
transmissiongroundcable.
8. Removethe wire harnessclamp. vss coNNEc?oR
WIRE LIGHTSWITCH
BACK.UP
HARNESS
POWER
STEERING
SPEED
SENSOR
STARTEB
MOTOR
STARTER O-RING
MOTOR Replace.
CABLES
TRANSMISSION
GROUNDCABI.T
12. Removethe slavecylinder.
9 . Shiftthe transmissioninto reverse.
NOTE:
1 0 . Firstremovethe cablebracket,then disconnectthe . Do not operatethe clutch pedal once the slave
cablesfrom the top housingof the transmission. cylinderhas beenremoved.
. Takecarenot to bendthe clutchpipe.
NOTE:Removeboth cablesand the brackettogeth-
er. CLUTCHHOSE
CAUTION: Take crre not to bond ths cables.
Do not aamovo.
WASI{EB
WASHER
Inspectfor
and
'}{FT CAALE
Replace.
STEEL PLASTIC SLAVECYLINDEB
WASHERI WASHER
Inspectfor
wear and (cont'd)
oamage.
13-5
Removal(cont'd)
1 3 . R e m o v €t h e c l u t c h d a m p e r m o u n t i n g b o l t s , a n d Removethe cotterpins and ball joint nuts,then sep-
raisethe clutchdamDer. arate the ball joints and lower arms on both sides
(seesection'18).
1 6 . Removethe right damperfork bolt.

CLUTCHOAMPER
't1. Remove the right radius rod.
BOLTS
SELF.LOCKING
Replace. SELF.LOCKING
NUT
Replace.
I,
l '
36i'J'--*€
NUr DAMPER
MOUNTINGBOLTS f
NUT
SELF.LOCKING
a. COTTERPIN Replace.
Replace.
I
14. Removethe rearenginemount bracketstay.
18. Removethe driveshaftsand intermediateshaft (see
section16).
N O T E : C o a t a l l D r e c i s i o nf i n i s h e ds u r f a c e sw i t h
cleanengineoil or grease.Tie plasticbags over the
driveshaftends.
REAR
ENGINE
MOUNT
BRACKET
S?AY
SHAFT
INTERMEDIATE
13-6
19. Removethe centerbeam. 21. Removethe intakemanifoldstav.
INTAKEMANIFOLOSTAY
20. Removethe front enginestiffenerand clutchcover. 22. Removethe rear beam stiffener.
REARBEAMSTIFFENER
13-7
TransmissionAssembly G
Removal(cont'dl
23. Removethe three rearenginemount bracketmoun- Removethe two uppertransmissionhousingmoun-
ting bolts. ting bolts.
UPPERMOUNTING BOLTS
!
:
Placea floor jack under the transmissionand raise 27. R e m o v et h e t h r e e l o w e r t r a n s m i s s i o nh o u s i n g
the transmissionjust enoughto take weight oft of mountingbolts.
the mounts.
Removethe transmissionmount and mount brack-

et.
LOWERMOUNNNG BOLTS
MOUNT BRACKET 28. Pull the transmissionaway ftom the engine until it
clearsthe mainshaft.
13-8
GearshiftMechanism
Overhaul
NOTE:
. Inspect
rubberpartsfor wearanddamagewhendisassembling.
. Checkthatthe newcotterpin is seated
firmly.
6x1.0mm CHANGEWIREPLATE
10 N.rn (1.0 kg-m, Replace.
7 tb-ft)
SELECTCABLE I
tr
COTTERPIN
Replace.
l', 6x1.0mm
l0 N.m {1,0kg-m,
7 tb-ftt
PLASTIC
WASHER
Inspectfor
@---=.-
sELF-LocKrNG
NUT
Replace. damsge.
'10N.m (1.0
kg-m, 7 lb-ft|
6x1.0n
'10N.m CHANGE
11.0kg-n
kg-m,7 lb-ft} LEVER
LINKAGE
\ CHANGEI,.EVER
\ - - CHANGEBALL
\-ry CHANGE
\\\ N
\
\
LEVER O-RINGS
Feplace.
IL \ &
*ou.)@o\
WAVE
WASHER
WASH
SELF.LOCKING
SELF.LO NUT
Replace.
CHANGEBALL
HOLOER
CHANGELEVER
Ptvot
CHANGEPIVOT
GUIDE
6x1.0mm
10 N.m 11.0kg-m,
7 tb-ft)
SHIFTLEVERBRACKET
FLOATINGCOLLAR
13-9
lllustratedIndex
Referto the drawingbelowfor the transmissiondisassembly

Cleanall pans thoroughlyin solventand dry with compressedair.
Luuri""t""tl partswithoil beforereassembly.

I
This transmissionusesno gasketsbetweenthe major housings;use liquidgasket(P/N08718- 0001)

(seepage 13-14.39).
Alwayscleanthe magnetO wheneverthe transmissionhousingis disassembled.
t
.>_._------.\\
__----.--
_._i---.---'l
.-.-_.-.-_---
o CLUTCHHOUSING
/---ry
@ REVERSEIDI.IR GEARSHAFT G' SHIFTFORKASSEMBLY
. Index,page 13-28
oll SEALReplace. @ REVERSEIDLERGEAR
. Seesection15 @ OIL SEALReplace. G' MAINSHAFTASSEMBLY
an 14 x 20 mm DOWELPIN o BALL BEARING . lndex,page13-18
o OIL GUIDEPLATE 'Inspectfor wear and operation. E) COUNTERSHAFT ASSEMBLY
' Index,pago13-23
NEEDLEBEARING @ SPRINGWASHER
. Inspectfor wear and oporation. @ WASHER CD DIFFERENTIAI- ASSEMBLY
. Seesection15
0 RETAININGPLATE @ REVERSESHIFI FORK
7 MAGNET
13-10
0n
_l
I
'ei
,w
L 6 H '
l_
q
I
r I
E9 SHIFTARM ASSEMELY €9 TRANSMISSIONHANGER (' OIL FILIfR BOLT

. Index,page13-12 @ 28 mm SEALINGBOLT WASHERReplace.
@
E4 OIL GUTTERPLATE 60 32 mm SEALINGBOLT Q} TRANSMISSION HANGER
@ THnusrsHrM 6D waSHER Reptace. @ TRANSMISSIoNHoUSING
. S e l e c t i o n ,p a g e 1 3 - 3 4 €' BEVERSEIDIEN GEAR
@ oIL GUIDEPLATE SHAFTBOLT
@ WASHER Replace. T8]OIL SEAL
@ BACK-UP LTGHTswITcH . Seesection15
@ sErflNG scREw .'9 OIL DRAINPLUG
@ WASHER Reptace. a{o)WASHERReplace.
Ql SPRTNG lL.30 mmt
@ srEELEALL{D.s/16inl
1 3 - 11
Shift Arm Assembly
lndex
NOTE:
. The shift arm covercan be removedand installedwith the transmissionin the car.
. Lubricateall movingand slidingsurfaceswith grease.
. Turn the boot so the hole is facingdown
SELEGTLEVER
-G1
08798 - 9lD2l
6x1.0mm OIL SEAL

12 N.m {1.2kg-m, Replac€.
9 rb-ftt
SHIFTARM
. Inspoction,page 13_29
SHIFTARM COVER
8x1.0mm
29 N.m 12.9kg-m,
2'l tb-ftl
SELECTRETURNPIN 6xl.0mm
LOCKWASHEB
6x1.0mm 15 N.m 11.5kg-m,
Replace.
'12N.m 11.2kg-m,
11tb-ftI
9 tb-ft}
5TH/REVERSE INTERLOCX
SELECTSPRING BOLT
sE[rcT
RETURNSPRING
SELECTARM
-6ll
/N 08798-
OIL SEAL 4xBmm

Replace. DOWELPINS
13-12
Disassembly/Reassembly
NOTE:Duringreassembly,
greaseall slidingparts. 4. Removethe reverselockcam.
1. Removethe shift arm coverassembly.

6x1.0mm
15 N.m (1.5kg-m,11 lb-ftl
6x1.0mm
12N.m(1.2kg-m,9lb-ft|
SHIFTARM COVER
ASSEMALY
{x8mm
DOWEI-PINS
R e m o v et h e s p r i n g p i n , t h e n r e m o v e t h e s e l e c t 5. Removethe oil seal.

lever,selectarm and springs.
Removethe selectreturnpin.
OIL SEAL
R€place.
SELECTARM
5x22mm ,/
SPRINGPIN -'
SELECTRETURNSPRIMi
SELECTRETURNPIN 5TH/REVERSE
6x l.0mm SELECTSPRING
12 N.m 11.2kg-m,9lb-ft|
SELECT
LEVER
.JG (cont'dl
13-13
Shift Arm Assembly
(cont'dl
gend the tab of the lock washer,then remove the 9. Installthe shift arm assemblyin the reverseorderof
bolt. removal.
Removethe interlockbolt. NOTE:

. Use liquidgasket(P/N08718- 0001).
NOTE: Apply liquid gasket(P/N 08718- 0001)to o Removethe din oilfrom the sealingsurface.
the threadsbeforereassembly. . Sealthe entirecircumference of the bolt hole to
preventoil leakage.
8x1.0mm . lf 20 minutes have passedafter applying liquid
29 N.m {2.9kg-m, g a s k e t ,r e a p p l yi t a n d a s s e m b l et h e h o u s i n g s
21 tb-ft) a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t a sa f t e r
assemblybeforefillingtransmissionwith oil.
o --: LIOUID
GASKET
\ .oi* *os".^
Replace.
8. Removethe shift lever,shift arm. and interlock.
NOTE:Turn the boot so the hole is facingdown,
13-14
Transmission
Housing
Removal
NOTE: Removethe 32 mm sealingbolt.
. lf the transmissionhousing or clutch housingwere
replaced,the bearingpreloadmust be adjusted. 7. Expandthe snap ring on the countershaftball bear-
o Placethe clutchhousingon two piecesof wood thick ing and remove it from the groove using a pair of
enough to keep the mainshaftfrom the hitting the snap ring pliers.
workbench.
Separatethe transmissionhousingfrom the clutch
'1. Removethe shift
arm coverassembly(seepage 13- housingand wipe it cleanof the sealant.
131.
SNAPRING
Removethe reverseidlergear shaftbolt.
Removethe settingscrews,then removethe wash-

ers,springs.and steelballs.
STEELBALLlD.5/16 in)
-/
r-^ WASHERReplace.
SETTINGSCREW
9. Removethe 28 mm sealing bolt, then removethe

oil gutterplate.
NOTE:The transmissionhousingcan be removed

with the oil gutter plate in the transmissionhous-
ing.
28mm SEALTNG BOLI
4. Removethe back-uplight switch.
OIL GUTTERPLATE
Removethe l0 mm bolts and 8 mm bolts in a criss-
cross pattern in severalsteps.
OIL GUTTERPLATE
BACK.UPLIGHT
swlTcH
1 3 - 15
ReverseShift Fork
ClearanceInspection
1. Measurethe clearancebetween the reverseshift l. Measurethe clearancebetween the reverseidler
shift piecepin.
fork and 5th/reverse gear and reverseshiftfork.
Standard: A: 0.05- 0.35 mm 10.002- 0.01i|in) Standard: 0.5 - 1.1 mm (0.020- 0.043in)
B: 0.,1- 0.8 mm {0.016- 0.031in) Srrvico Limit: 1.8 mm (0.071inl
ServicoLimit; A: 0.5 mm (0.020inl
B: 1.0mm {0.039in)
lf the clearanceexceedthe service limit, measure 4. lf the clearanceexceedsthe servicelimit, measure

the width of the groovein the reverseshiftfork. the width of the reverseshift tork.
Stand8rd:A: 7.05- 7.25 mm (0.278- 0.285inl Standard: 13.0- 13.3mm {0.512- 0.52'l in)
8: 7.4- 7.7 mm (0.291-0.303 inl
REVERSE
SHIFTFONK REVERSE
SHIFTFORK
lf the width of the groove exceedsthe standard, l f t h e w i d t h e x c e e d st h e s t a n d a r d ,r e D l a c et h e

replacethe reverseshiftfork with a new one. reverseshiftfork with a new one.
It the width of the groove is within the standard, l f t h e w i d t h i s w i t h i n t h e s t a n d a r d ,r e o l a c et h e
reolacethe sth/reverseshift Diecewith a new one. reverseidlergearwith a new one.
13-16
Mainshaft,
Reverseldler Gear Countershaft
Removal Removal
1. Removethe reverseshift fork. 1. Removethe mainshaftand countershaftassemblies

with the shift forksfrom the clutchhousinq.
NOTE:Tape the mainshaftspline before removing

the mainshaftand countershaitassemblies.
REVERSE
SHIFT
MAINSHAFTASSEMBLY
COUNTERSHAFT
ASSEMBLY
Tapethe mai
shattspline.
SPRINGWASHER
Removethe reverseidler gear shaftand the reverse

idlergear.
CLUICH
HOUSING
2. Removethe differentialassembly.
DIFFERENNAL
ASSEMBLY
REVERSE
IDLER
GEARSHAFT
13-17
Mainshaft
lndex
B"for" """"mbling. cleanall partsin solvent,dry them with compressedair,then coatthem with cleanoil.
I
RING
STOPPER
3RD/irTH
SYNCHROHUB
TAPERRING
t 3RD/4TH
1,. SYNCHRO
SLEEVE
3RD/irTHSYNCHROHUB NEEOLEBEARING
page'1330
Inspection, Checkwear and ooeiation.
SPACERCOLLAS
SYNCHRORING
page13 31
lnspection,
SYNCHRO SYNCHROSPRING
SYNCHROSPRING
SPRING
I SYNCHRO
sTH SYNCHROHUB
page13-30
Inspection,
RING SYNCHNORING sTH SYNCHROSLEEVE
page13-31
Inspection, page13-30
Inspection,
" o oro /
3ROGEAR SYNCHROSPRING
Inspec!on,page
13,19,31
SYNCHRORING
NEEDLEBEARING page13-31
Inspection,
Checkwear and operation.
MAINSHAFT
page13?1
Inspection,
13-18
NOTE:lf replacementis required,always replacethe Measurethe clearancebetween 4th gear and the
synchrosleeveand hub as a set. soacercollar.
1 . Support the bearing inner race with a socketand Standard: 0.06- 0.21 mm {0.002- 0.fl18 in}
push down on the mainshaft. ServiceLimit: 0.3 mm {0.012in}
Measurethe clearancebetween2nd and 3rd gears. I

Stands.d: 0.06- 0.21 mm
{0.002- 0.008in)
ServiceLimit:0.3mm 10.012 inl
I
v
5. lf the clearanceexceedsthe servicelimit, measure

distance@ on the spacercollar.
Standard: 26.03- 26.08mm (1.025- 1.027in)

ServiceLimit:26.01mm {1.024inl
lf the clearanceexceedsthe servicelimit. measure
the thicknessof 3rd gear.
6J-l-l .nrcean
L+ 1, S|DE
Transmission
M215.M254 M2F4 coLLAR ----+l_J
SPACER
Type
32.42-32.41 mm 34.92- 34.97mm
Standard - 1.2'18inl { 1 . 3 7 -5 1 . 3 7 7i n ) 6. lf distanceO is lessthan the servicelimit, roplace
1'1.276
the spacercollarwith a new one.
32.3mm 34.8mm tf distance@ is within the service limit, measure
ServiceLimit ( 1 . 3 7 0i n )
11.272 inl the thicknessot 4th gear.
Transmission
M215,M254 M2F4
3RD GEAR Type
30.92- 30.97mm 3 1 . 4 2- 3 1 . 4 7m m
Standard - 1.219inl ( 1 . 2 3 7- 1 . 2 3 9i n )
11.217
30.8mm 3 1 . 3m m
ServiceLimit ( 1 . 2 1 i3n ) l'1.232inl
I
t,A . .THGEAn
El
r-
\--t
1
| ^J-_-6 I
l
lf the thicknessof 4th gear is lessthan the service
lf the thicknessof 3rd gear is lessthan the service limit, replace4th gearwith a new one.
limit,replace3rd gearwith a new one. l f t h e t h i c k n e s so f 4 t h g e a r i s w i t h i n t h e s e r v i c e
l f t h e t h i c k n e s so f 3 r d g e a r i s w i t h i n t h e s e r v i c e limit, replacethe 3rd/4thsynchro hub with a new
limit, replacethe 3rd/4thsynchro hub with a new one.
one. (cont'd)
Mainshaft
GlearanceInspection{cont'dl Disassembly
Measurethe clearancebetweenthe spacer collar CAUTION: Removethe synchro hubs using a press and
and 5th gear. steel blocks as shown. Use of a iaw.typ€ puller can
damagethe gsar teeth,
Standsrd: 0.06- 0.21mm
(0.002- 0.008in) Removethe ball bearingusing a bearingpuller as
SsrviceLimit: 0.3 mm 10.012inl shown.
BEARINGPULLER
BALLBEARING
lf the clearanceexceedsthe servicelimit, measure

distance@ on the spacercollar.
Standard: 26.03- 26.08mm

{1.025- 1.027in)
SorviceLimit: 26.01mm {1.02'lin)
SPACER
COLLAR BAI-L
BEARING
STOPPER
sTHGEAR RING
SIDE
lf distance€) is lesathan servicelimit, replacethe

spacercollarwith a new one.
lf distance@ is within the service limit, measure
MAINSHAFT
thicknessof sth gear.
Standard: 30.92- 30.97mm (1.211-1.219inl

ServiceLimit: 30.8mm 11.213
inl
5TH GEAR
lf the thicknessof sth gear is lessthan the service

limit, replace5th gearwith a new one.
l I t h e t h i c k n e s so f 5 t h g e a r i s w i t h i n t h e s e r v i c e
limit, replacethe sth synchrohub with a new one.
13-20
lnspection
'1. Inspectthe gear surtace and bearing surface for
S u p p o r t s t h g e a r o n s t e e l b l o c k sa s s h o w n a n d
Drsssthe shaftout of the sth synchrohub. wear and damage,then measurethe mainshaftat
pointsA, B, and C.
Standard:
A {88ll bearing surlacol: 27.987- 28.000mm
( 1 . 1 0 1-8 1 . 1 0 2 'i ln )
B (Needlebearing surfaco): 37.98'l- 38.000mm
(1.irgsit- 1.,t961in)
C (Ball bearing 3urface): 27.977- 27.99Omm
( 1 . 1 0 1-5 1 . 1 0 2 0in)
Ssrvico Limit A: 27.940mm (1.1000in)
B: .37.930mm (1.4933in)
C: 27.940mm (1.1000in)
I n s p e c t o i l p a s s a g e sf o r c l o g g i n g .
In the same manneras above,supportthe 3rd gear lf any part of the mainshaftis lessthan the service
on ste€l blocks and pressthe shaft out of the limit, replaceit with a new one.
3rd/4th svnchro hub as shown.
Inspectfor runout.
Standard: 0.02 mm (0.001in) max.

Seivico Limit: 0.05 mm 10.002in)
N O T E : S u p p o r t t h e m a i n s h a f ta t b o t h e n d s a s
snown.
lf the runout exceedsthe servicelimit, reolacethe

mainshaftwith a new one,
13-21
Mainshaft
Reassembly
NOTE:Referto page13-18for reassemblysequence. Installthe sth synchro hub using the spocialtools
ano a pressas snown.
1. Support 2nd g€ar on steel blocks as shown, then
i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n gt h e s p e c i a l ORIVER.,40mm l.D.
tools and a pressas shown. 07746- (x)30100
NOTE:After installing,inspectthe operationof the

3rd/ 4th synchrohub set.
M2L5,M2S4(T..nsmi$ionTypol: HUB
sTHSYNCHRO
PRESS
1
3RD/4TH
SYNCHROHU8
3. lnstallthe ball bearingusingthe specialtools and a
pressas snown.
M2F4 {Transmis3ionTypel:
BCARING
ATTACHMENT,
ATTACHMENT,35mm l.D. a2xaTmm
07745 - (x}301o0 07?46- 0010300
2ND GEAR
13-22
Countershaft
lndex
B"for" """"mbling. cleanall partsin solvent,dry them with compress€dair,then coatthem with cleanoil.
I
LOCKNUTReplsce.
130 + 0 + 130N.m
+ 0 + 13kg-m,
113
r 9a + 0 + 9a lb-ft
GEAB
REVERSE
SPRINGWASHER
BALLBEARING
lSI/2ND SYNCHROHUB Checkwear and oporation.
Insp€ction,page 13-30
NEEDLEBEARING
Checkwear and operation.
FRICTIONDAMPER
Checkw€ar and d6mag€. 5TH GEAR
SYNCHROSPRING
ilTH GEAR
SYNCHRORING
Inspection,pa96 13-31
lST GEAR 3RD GEAR

page13-24,
Inspection, 3'l
NEEDLEBEARING
2ND GEAR
Checkwearsndoporation pag€13-24,31
Inspoction,
THRUSTWASHER NEEDI..E
BEARING
page13-?4
Solection, Chsckwear and operation.
SPACERCOLLAB
pag€13-24
Sel6ction,
FRICTIONOAMPER
OOUNTERSHAFT Checkwear and damage.
InsDection,p8g€ 13-26 Removal,page13-25
page13-27
Installation,
INNERSYNCHRORING
Inspection,page13-31
SYNCHROCONE
OUTERSYNCHRORING
page'13-31
Insp€ction,
SYNCHROSPRING
13-23
Gountershaft
ClearanceInspection
l, Measurethe clearancebetweenthe 1st gear and 3. Measurethe clearancebetwoenthe 2nd gear and
thrustwasher. 3rd gear.
Standard: 0.04- 0.10mm Strndlrd: 0.0,1- 0.10mm

{0.002- 0.0O'lin} {0.002- 0.00il in)
ServicaLimit: 0.18 mm 10.007inl SorvicoLimil:0.18mm (0.007in)
THBUSTWASHER
2. lf the clearanceexceedsthe servicelimit. selectthe 4. lf the clearanceexcesdathe service limit, selectthe

appropriatethrust washerfor the correctclearance appropriatespace.collar for the correctclearance
from the chartbelow, from the chart below.
THRUSTWASHER SPACERCOLLAR
Part Number Thicknaes Prrt Numbcr Thickn..s

23921- PG1- 000 1 . 9 6m m ( 0 . 0 7 7 i1n ) 29.02- 29.04mm
A 23917-P21-O10
B 2 3 9 2 2 - P G 1- 0 0 0 1.99mm (0.0783in) ( 1 . 1 4 2- 51 . 1 4 3i 3
n)
23923-PG1-000 2.02mm (0.0795in) 29.07- 29.09mm
B 23918-P2'r-010 ( 1 . 1 4 4-5 1 . 1 4 5 i3n )
D 23924-PG1-000 2.05mm (0.0807in)
E 23925- PGl -000 2.08mm 10.0819
inl
13-24
'1.
S e c u . e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n I 4. Remove the friction damper trom the spacer collar
benchvisewith wood blocks. using a prgss and a socket as shown.
Raisethe locknuttab from the groove ot the shaft

PRESS
and removethe locknutand the springwasher,
+
CHISEL
SPRINGWASHER
BENCH
vtsE
WOODBLOCKS Replac€.
3. Removethe ball bearingusinga pressas shown.
PRESS
ATTACHMENT
4TH GEAR
COUNTERSHAFT
STEELBLOCKS
3-25
Countershaft
Inspection Reassembly
'1. lnspect the gear surface and bearing surface for
NOTE:Referto page13-23for reassemblysequence.
wear and damage,then measurethe countershaft
at pointsA, B, and C. 1, Installthe thrustshim, needlebearing,lst gear,fric-
tion damper,synchroring,and synchrospring.
StandErd: A:38.fi10- 38.015mm
l1.i(t61 - f.il967 inl NOTE:Reassemble th€ lst gear and frictiondamper
B: 39.984- /{1.000mm beforeinstallation.
{1.5742- 1.57'18 inl
C: 24.987- 25.000mm SYNCHROSPRING
{0.98:17 - 0.9843in)
Limit:A:37.950
Sorvico mm (t.t*t41in) SYNCHRORING
B:39.930 mm (1.5729 inl FBICTIONDAMPER
C:2il.9il0mm (0.9819 inl
lST GEAR
NEEDI.EBEARING
THRUSTSHIM
Inspectfor wearand damage. COUNTERSHAFT
lf any part ot the countershaftis lessthan the ser-

vice limit. replaceit with a new one.
Inspectfor runout.
St.ndard: 0.02 mm 10.001in)

S€rvicoLimh: 0.05 mm (0.002in)
2. Installthe 1sv2ndsynchrohub by aligningthe fric-
NOTE:Support th6 countershaftat both ends as t i o n d a m p e r f i n g e r s w i t h 1 s t / 2 n ds y n c h r o h u b
snown. grooves.
lST/2ND
SYNCHROHUB
Rotatetwo complelerevolutions,
It the runout exceedsthe servicelimit, reDlacethe

countershaftwith a new one.
13-26
Installthe Jrictiondamperon the spacercollarusing Installthe needlebearing,
the soecialtoolsand a Dressas shown.
Installthe ball bearing using a specialtool and a
pressas shown.
PRESS
PRESS
t
DRIVER
+
077€ - 0010000
ATTACHMENT,42 x 47 mm
07746- (X)103q)
SPACERCOLLAR
ffi!--;.+a'-,
1. Installthe springwasher.
8. S e c u r e l yc l a m p t h € c o u n t e r s h a f ta s s e m b l yi n a
I n s t a l tl h e 2 n d g e a r b y a l i g n i n gt h e s y n c h r oc o n e benchvisewith wood blocks.
fingerswith 2nd geargrooves.
o Tightenthe new locknutto the correcttorque,th€n
stakethe locknuttab into the groove
Torqus:130+ 0 + 130N.m (13.0- 13.0kg-m,

9 4 + 0 + 9 al b - f t )
LOCKNUT
Replace.
GROOVE
FINGER
BENCH
vtsE
wooD Bl-ocKs
13-27
Shift ForkAssembly
cleanall the partsin solvent,dry them and apply lubricantto any contactparts.
e,ior.,o reassembling,
I
5 mm PIN PUNCH
1ST/2NDSHIFTFORK
13-24
NOTE:The synchrosleeveand synchrohub should be 3. Measurethe clearancebetweenthe shift fork and
replacedas a set. the shift arm.
1. Measurethe clearancebetweeneach shift fork and Standard: 0.2 - 0.5 mm l0.fi)8-0.019in)

its matchingsynchrosleeve. Sorvic€Limit 0.6 mm (0.02i1inl
Standard: 0.35- 0.65mm {0.014- 0.026in}

ServiceLimit: 1.0{ mm {0.039in)
sTH/REVERSE
SHIFTPIECE
3ND/'TH
SYNCHROSIfEVE
SHIFTFORK
SHIFTFORK
SHIFTARM
lf the clearanceexceedsthe servicelimit, measure

the width of the shift arm.
2. lf the clearanceexceedsthe servicelimit, measure Stlndard: 12.9- 13.0mm (0.508- 0.5f2 inl
the thicknessof the shiftfork fingers.
Standard:
M2F4(Transmission Type) 7 . 4- 7 . 6m m
3rd/4th shift fork (0.291- 0.299in)
SHIFTARM
M2L5/M2S4(Transmission
Type) 6.2- 6.4 mm
|'0.244- 0.252inl
d
3rd/4th shift fork
iy SHFTFORK
lf the thicknessof the shift fork finger is less than lf the width of the shift fork finger is less than the
the standard,replacethe shjftfork with a new one. standard,replacethe shiftarm with a new one.
lf the thicknessof the shift fork finger is within the lf the width of the shiftfork finger is within the stan-
standard, replacethe synchro sleeve with a new dard, feplacethe shift fork or shift piecewith a new
one. ones.
SynchroSleeve,SynchroHub
Inspection lnstallation
1. Inspectgear teeth on all synchrohubs and synchro Eachsynchrosleevehas three sets of longerteeth (120
sleevesfor rounded off corners. which indicates degreesapan)that must be matchedwith the three sets
of deepergroovesin the synchrohub when assembled.
I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o NOTE:Installingthe synchrosleevewith its longer

sleeveand checkfor freedomof movement. teeth in the 1sV2ndsynchrohub slots will damage
the spring ring.
NOTE:lf replacementis required,always replace
ths synchrosleeveand synchrohub as a set.
LONGERTEETH
SYNCHRO
HUB SLOT
SYNCHRO
HUB
13-30
SynchroRing,Gear
Inspection
1. Inspectthe synchroring and gear. SYNCHBO
A: Inspectthe insideof the synchroring for wear.
B: Inspectthe synchrosleeveteeth and matching

t e e t h o n t h e s y n c h r or i n g f o r w e a r { r o u n d e d SYNCHRO
off).
GOODWORN
C: Inspect the synchro sleeve teeth and matching
teethon the gearfor wear (rounde;$).
GOOO WORN
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe cone surfacefor wear and rough-

ness.
F: Inspectthe teeth on all gearsfor unevenwear.

scoring,galling,and cracks.
2. C o a t t h e c o n e s u r f a c eo f t h e g e a r w i t h o i l a n d
p l a c et h e s y n c h r o r i n g o n t h e m a t c h i n gg e a r .
Rotatethe rjng, makingsurethat it does not slip.
Measurethe clearancebetweenthe synchro ring

and gear all the way around.
N O T E : H o l d t h e s y n c h r o r i n g a g a i n s tt h e g e a r
evenlywhile measuringthe clearance.
Synchro Ring-to-GearClearance
Standard: 0.85- 1.10mm
(0.033- 0.0,|:|inl
ServicoLimit: 0.4 mm {0.015in)
Doubl€ Cone Synchro-to-GearClearance

Standard:
@:(Outer Synchro Ring to Synchro Con€)
0.5- 1.0mm (0.020-0.039 inl
@: (synchro Cone to Gear)
0.5- 1.0mm (0.020- 0.039in)
@:lOuter Synchro Ring to Gear)
0.95- 1.68mm (0.037- 0.066in) SYNCI{FORING
Ssrvice Limit:
@:0.3mm (0.012in) SYNCHRORING
@:0.3mm (0.012in)
@:0.6mm (0.024in)
l f t h e c l e a r a n c ei s I e s s t h a n t h e s e r v i c e l i m i t ,
replacethe synchroring and synchrocone.
INNEN
SYNCHRO
RING
13-31
MainshaftBearing/OilSeal C
Replacement
1. Removethe differentialassembly. 4. Drivethe new oil seal in from the transmissionside

usingthe specialtoolsas shown.
R e m o v et h e b a l l b e a . i n gw i t h t h e s p e c i a tl o o l a s
snown.
3. Removethe oil sealfrom the clutchside. DRIVER

07749- 001(x)00
ATTACHMEN?,
U 2 x 1 7m m
3/8 in r( 16 thr.rd/in SLIDEHAMMER 07746 - (x)l0300
{Comm.rci.lly .v.il.blc)
Aq,USTABLEBEARING
PULER, 25 - 40 mm
07736- A01rDoA
OIL SEAL
Replacs.
6 Drivethe new ball besringin from the transmission

side usingthe specialtoolsas shown.
BALLBEABING
ATTACHMENT,
62x68mm
AALLBEARING 077a6 - (X)105(x)
AALLAEARING
13-32
CountershaftBearing
Replacement
1. Removethe retainingplatefrom the clutchhousing. Positionthe oil guide plateand new needlebearing
in the bore of the clutchhousing.
NOTE:Positionthe needlebearingwith the oil hole

facingup.
OIL HOLES
NEEDLEBEARING
Removethe needle bearing with the specialtool,

then removethe oil guide plate.
Drive the needlebearingin using the specialtools

as shown.
DRIVER
3/8 in x 16 throad/in SLIDEHAMMER 07749- (xll(xx)O
(Commc.ciallyrvailrblel
ADJUSTAB1IBEARING
PULLER,25 - i(, mm
0t736 - A01@0A
NEEDl-E
NEEDLEBEARING
(cont'd)
13-33
CountershaftBearing MainshaftThrustShim
Replacement(cont'dl Adjustment
lnstallthe retainingplsteand stakethe bolt headsin 1. Removethe thrust shim and oil guide plate from
the groovein the retainingplate. the transmissionhousing.
6x1.0mm otl GUIDEPLATE rHnr rcr qHlM

12 N'm {1.2kg-m,9lb-ftl
Replaco.
RETAININGPLATE
Installthe 3rd/4thsynchrohub, spacercollars,sth

synchro hub, and ball bearing on the mainshaft,
then installthe aboveassemblyin the transmission
housrng.
lnstallthewasheron the mainshaft.
Measuredistance@ betweenthe end of the trans-

missionhousingand washer.
NOTE:
a Usea straightedgeand verniercaliper.
a Measureat three locationsand averagethe read-
Ing.
ENDot
TRANSMISSION
HOUSING
MAINSHAFT
WASHER
3RD/4THSYNCHROHUA
SPACERCOLLAR
sTH SYNCHROHUB
SPACER
BALLBEARING
1 3 -3 4
5. Measure distance @ between the end of th€ clutch 78 mm THRUSTSHIM
housingand bearinginnerrace.
Part Numbor Thiqkno!!
23941- PK5- 000 '1.20mm (0.0472
NOTE: in)
. Usea straightedg€and depthgauge. 23942-PKs-000 1.23mm (0.0484in)
! Measureat three locationsand averagsthe read-
a 23943-PKs-000 1 . 2 6m m ( 0 . 0 4 9 i6n )
ings.
D 23944-PK5-000 1.29mm (0.0508in)
E 23945-PKs-000 1.32mm (0.0520in)
ENDof CLUTCHHOUSING 23946-PKs-000 1.35mm (0.0531in)
F
23947-PKs-000 1.38mm (0.0543in)
H 23948-PKs-000 1.41mm (0.0555in)
23949-PKs-000 1.44mm (0.0567in)
23950-PKs-000 1.47mm {0.0579in)
K - PKs- 000
23951 1.50mm (0.0591in)
L 23952-PKs-000 1.53mm (0.0602
in)
M 23953*PKs-000 1.56mm (0.0614in)
BEARING
N 23954-PK5-000 1.59mm (0.0626in)
o 23955-PKs-000 1.62mm (0.0638in)
P 23956-PKs-000 '1.65mm (0.0650in)
o 23957-PKs-000 1.68mm (0.0661in)

6. S e l e c tt h e p r o p e rt h r u s t s h i m f r o m t h e c h a r t b y R 23958-PKs-000 1.71mm (0.0673in)
usingthe formulabelow.
s 23959-PKs-000 1.74mm (0.0685in)
NOTE:Useonly one thrustshim. T 23960-PKs-000 1.77mm (0.0697in)
U 23961- PKs- 000 1.80mm (0.0709in)
Shim SoleqtionFormula:
23962-PKs-000 1.83mm (0.0720in)
Fromthe measurements you made in steps4 8nd 5: 23963-PKs-000 1.86mm (0.0732in)
-1. Add distance@ {step5) to distsnce@ (step4). '1.89mm (0.0744
X 23964-PK5-000 in)
-2. Ftom this number,subtract0.93 (which is the mid- 23965-PK5-000 1.92mm (0.0756in
point of the flex rangeof the clutchhousingbearing z 23966-PKs-000 1.95mm (0.0768in
springwasher).
23967-PKs-000 L98 mm (0.0780in
-3. Take this number and compare it to the available AB 23968-PKs-000 2.01mm (0.0791in
shim sizesin the chart. AC 23969-PKs-000 2.04mm {0.0803in
(Forexample) AD 23970-PKs-000 2.07mm {0.0815in

AE - PK5- 000
23971 2 . 1 0m m ( 0 . 0 8 2 i7n
B: 2.39 , 2.61 AF 23972-PKs-000 2.13mm (0.0839in
+ C: O.22 - 0.93
/,/ 23973-PK5-000 2.16mm (0.0850in
= ,.tr/ = t* AH 23974-PKs-000 2.19mm (0.0862in)
AI 23975-PKs-000 2.22mm (0.0874
in)
. Try the 1.68mm (0.0661in) shim.
AJ 23976-PKs-000 2.25mm {0.0886in}
AK 23977-PK5-000 2.28mm (0.0898in)
AL 23978-PKs-000 2.31mm (0.0909in)
AM 23979-PKs-000 2.34mm (0.0921in)
AN 23980-PKs-000 2.37mm (0.0933in)
{cont'd)
13-35
MainshaftThrustShim
Adiustment(cont'd)
Checkthe thrust clearancein the mannerdescribed -7. Slidethe mainshaftbaseover the mainshaft.
below,
MAINSHAFT
NOTE:Carryout the measuremsntat normal room
temperature. TRANSMISSION
-1. Installthe thrust shim selectedand oil guide

platein the transmissionhousing.
OIL GUIDEPLAYE
-2. Install the spring w a s h e ra n d w a s h e ro n t h e

ball bearing. -8, Attachthe mainshaftholderto the mainshaftas
follows:
NOTE:
. Cleanthe springwasher,washerand thrustshim NOTE:
throughlybeforeinstallation. o B a c k - o u tt h e m a i n s h a f t h o l d e r b o l t a n d
. l n s t a l l t h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t loosenthe two hex bolts.
shim properly. . Fit the holderover the mainshaftso its liD is
towardsthe transmission.
WASHER . Align the mainshaftholder'slip around the
g groove at the insideof the mainshaft
splines,then tightenthe hex bolts.
MAINSHAFT HOLDER
aSttRrNGwasHER EOLT
Installthemainshaftin the clutchhousing.

lla-F.
l:vli ffir"
-4. Placethe transmissionhousingover the main-
shaftand onto the clutchhousing.
Tighten the clutch 8nd transmissionhousings

with several8 mm and l0 mm bolts MAINSHAFT
HOLDER
Tap the mainshaftwith a plastichammer. O?GAJ- PG2O11O
MAINSHAFT BASE
07GAJ- PG20130
-9. Seatthe mainshaftfully by tappingits end with
a plastichammer.
-10. Threadthe mainshaftholderbolt in until it just

c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t
Dase.
-1 1.Zero a dial gaugeon the end of the mainshaft.
13-36
Transmission
Reassembly
-12, Turn the mainshaftholder bolt clockwise;stop Installthe differentialassemblyin the clutch hous-
t u r n i n g w h e n t h e d i a l g a u g e h a s r e a c h e di t s ing.
maximum movement.The readingon the dial
OIFFERENTIAL
ASSEMBLY
gaugeis the amountof mainshaftend play.
CAUTION: Turning iho mainshaft holder bolt

mor€ than 60 dogrecs after tho noodle of ths
d i a l g l u g a 3 t o p s m o v i n g m a y d a m a g ot h e
transmission.
DIALGAUGE
CLUTCH
HOUSING
MAINSHAFTHOLDER
07GAJ- FG20110 Installthe springwasherand washerwith the angle
againstthe clutchhousingas shown
-13. lf the readingis within the standard.the clear- lnsertthe mainshaftand countershaftinto the shift
ance is correct. forks 8nd installthemas an assemblv.
lf the reading is not within the standard. re-
checkthe shim thickness. NOTE: Beforeinstallingthe mainshaftand counter-
tape the mainshaftsplinesto pro-
shaft assemblies,
Strndard:0.10- 0.16mm (0.00i1- 0.006in) tectthem.
MAINSHAFT
ASSEMBLY
Tapethe mainshaft
splrn6.
(cont'd)
13-37
Transmission
(cont'dl
Reassembly
4. Installthe reverseidler gear and reverseidler gear NOTE:Selectthe thrust shim accordingto the mea-
shaft in the clutchhousing. sur€mentsmadeon page13-34.
6. Installthe oil guide plate and thrust shim into the

transmissionhousing.
CLUTCH
TRANSMISSION
HOUSING
5. Installthe reverseshift fork in the clutch housing

with th€ sth/reverse shift piecepin positionedin the 7. Installthe oil gutter plate in the transmissionhous-
slot of the reverseshift fork, ing.
NOTE:Checkthat the steelball is in the properposi- NOTE:Bendthe hook of the oil gutter plateinto the
Ilon. holeon the transmissionhousing.
Installthe28 mm sealingbolt.
6x1.0mm
REVERSE
SHIFTFORK 15 N'm 11.5kg-m.11lb-ft, NOTE:Apply liquid gasket(P/N 08718- 0001)to
the threads.
28 mm SEALINGBOLT
15 N.m 14.5kg-m, 33 lb-ftl
OIL GUTTERPLATE
TNANSMISSIONHOUSING
13-38
Apply liquid gasketto the clutch housing mating 12. Lower the transmissionhousingwith the snap ring
surfaceas shown. p l i e r sa n d s e t t h e s n a p r i n g i n t h e g r o o v eo f t h e
countershaftbearing.
NOTE:
. Useliquidgasket(P/N08718- 0001). SNAPRING
. Removethe dirt oil fromthe sealingsurface.
. Seal the entirecircumference of the bolt hole to
preventoil leakage.
. lf 20 minutes have passedafter applying liquid
g a s k e t ,r e a p p l yi t a n d a s s e m b l et h e h o u s i n g s
a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t e sa f t e r
assemblybeforefillingtransmissionwith oil.
---: Liquid g6k.t

*: Dow6l pin
1 3 . Checkthat the snap ring is securelyseated in the

grooveof the countershaftbearing.
1 0 . Installthe14 x 20 mm dowel pins.
DimensionA as installed: 3.60 - 6.32 mm
1 1 . Set the stopperring as shown. Placethe transmis- l0.i,r2_ 0.249inl
sion housingover the clutchhousing,being careful
to line up the shafts. 1 4 . Installthe 32 mm sealingbolt.
NOTE:Align the long arm of sth shift fork with the NOTE:Apply liquid gasket(PiN 08718- 0001)to
hook on the stopperring. the threads.
32mm SEAI-ING BOLT

25 N.m12.5kg-m,18lb-ftl sNAperN.:
{ c o n t ' )d
13-39
Transmission Assembly
Transmission
Reassembly(cont'dl lnstallation
tc, Torque the bolts in a crisscrosspattern in several 1. Installthe dowel pins.

stepsas shown.
I x 1.25mm bolts: 28 N'm (2.8 kg"m, 20 lb-ft)

10 x 1.25mm bolts: ,15N.m (4.5 kg-m, 33 lb-ft|
1O mm BOLTS
O Or 8 x 50 mm bolts
Other:8 x /U'mm bolts
Apply greaseto the pans as shown,then installthe
16. Installthe reverseidlergearshaft bolt. releasebearingand releasefork (seepage 12-7).
17. Installthe steel balls,springs,washersand settlng N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e

screws. (P/N08798- 9002).
STEEL BALLlD.5/16in)
WASHER RELEASEFORK
Beplace. RELEASEFORK SETSPRING
G SCREW
22 N.m {2.2kg-m, 16lb-ft)
I
I
RELEASE
FORK
BOOT
FORKBOLT
30 N.m 13.0kg-m, 22 lb-Itl
3. lnstallthereleasefork boot.
BOLT
55 N.m 15.5kg'm. 40 lb'ttl
18 shift arm cover assembly (see page 13-
13).
19. Shift the transmissionthrough all the gears before

installingit.
1 3 -4 0
P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o ni a c k , 7. R a i s et h e t r a n s m i s s i o n ,t h e n i n s t a l l t h e m o u n t
and raiseit to the enginelevel. bracketand transmissionmount.
Installthe three lowertfansmissionmountinqbolts. NOTE:

. T o r q u e m o u n t i n gb o l t s a n d n u t s i n s e q u e n c e
snown.
. Makesurethe bushingsare not twistedor offset.
12 x 1.25mm
65 N.m 16.5kg-m.
O Tighren
TBANSMISSION 10x 1.25mm
MOUNT
O Tighten
10 x 1.25mm
39 N.m 13.9kg-]n,
tb-ft)
BRACKET
66 N.m (6.5kg-m, ia1lb-ft)

O tidhron O Tighton
10x 1.25mm 10 x 1.25mm
39 N.m (3.9kg-m, 39 N.rn 13,9kg-m,
28 tb-ft) 28 rb-ft)
6. Installthe two uppertransmissionmountingbolts. O Tight.n t.mpor..ily
@ Tighron
12x 1.25mm
65 N{n (6.5 kg-m, a7 lb"ftl
8. Install the th.ee rear engjne mount bracketmount-

ing bolts.
MOUNTINGBOLTS
Replace.
12 x 1.25mm
55 N.m 15.5kg-m, 40 lb-ft)
12 x 1,25mm
65 N.m (6.5kg-m, 4t lb-ft}
(cont'd)
Installation(cont'dl
9. lnstalltherearbeamstiftener. 11. Installthe front enginestiffenerand clutchcover.
NOTE:Torque the front engine stiftenermounting

boltsfollowingthe numberedsequenca.
Torque: 39 N.m 13.9kg-m. 28 lb-ft)
3!, N.m {3.9 kg-rn, 28 tb-ft)
'10. Install the intake manifold staY.
INTAKEMANIFOLDSTAY
12. lnstallthe centerbeam,
10 x 1.25mm
60 N.m 16.0kg-m, 43 lb-ftl
13-42
Installthe intermediateshaft and driveshafts{see 1 7 . Installthe rearenginemount bracketstay.
section161.
NOTE: Loosely installthe stay mounting bolt and
10x 1.25mm nut, then torque in the sequenceshown.
39 N.m13.9kg-m,28lb-ft|
10x 1.25mm
SPECIALBOLT 21 N.m {2.'l kg-m,
10 x 1.25mm 15 tb-ft|
39 N.m (3.9tg-m,
28 tb-ft,
1 4 . Installtheradiusrod.
NOTE: Check for deteriorationor damage of the

radiusrod rubberbushings.
10x 1.25mm
39 N.m 13.9kg-m, 28 lb-ft)
1 5 . Connectthe ball joint to the lower arm, then install
t h e b a l l j o i n tn u t .
16. Installthe damper fork bolt,
SELF.LOCKING BOLTS SELF.LOCKING NUT 18. Installtheclutchdamoer.

Replac€. Replace.
12 r 1,25mm 12 x 1.25mm
105 N{n (10.5kg-m, ?6lb-ft| 55 N{r| (5.5 kg-m,
40 tb-ft|
ROD
/
/1*-
corrERPrN
SELF.LOCKING
Replace.
12x 1.25mm
NUT
Replace.
/ 65 N.m {6.5 kg-m, a7 lb-ft|
AALLJOINT NUT I x 1.25mm
14xZtmm 22 N.m 12.2kg-m, 16 lb-ft|
55 N.m 15.5kg-m. 40 lb-ltl
(cont'd)
13-43
lnstallation (cont'dl
19. Installthe slavecylinder,then installthe clutch pipe 21. Installthe shift cable and selectcable to the shift
joint and stay. leverand to selectleverrespectavely.
CAUTION: Take care not to bend the clutch pipe. CAUTION: Tako care not to bsnd the cabl€s.
NOTE:
! Checkthat the new cotterpin is seatedfirmly.
. Turn the boot of the shift leverso the hole is fac-
Ing down.
I x 1.25mm
I x 1.25 mm
22 N.m 12.2kg-m, 16 lb'ft}
{P/N 08798- 90021
COTTERPIN
Replace-
STEEL
WASHER
PLASTIC
WASHER
SELECT
6x1.0mm CABLE
10 N.m {1.0kg-m,
7 rb-ft} CABLE
)
BOOT
PIN SHIFTLEVER
8 x 1.25mm COTTEB
tP/N 08798- 9002) 22 N.m Replace.
WASHER WASHER
{2.2kg-m, 16lb-ft}
22. Connectthe transmissiongroundcableand back-up
light switchconnectors.
20. Installthe vehiclespeedsensor(VSS)/powersteer- 23. Installthewire harnessclamp.

ing speedsensor,then connectthe VSSconnector'
24. Installthe starter motor, then connect the starter
I x 1.25mm motor cables.
19N.m11.9 kg-m,14lb-ft)
S CONNECTOR N O T E : W h e n i n s t a l l i n gt h e s t a r t e r m o t o r c a b l e ,
Mr"' POWERSTEERING
SPEEDSENSOR
makesurethat the crimpedside of the ring terminal
is facingout (seesection23).
6x1.0mm l0 x 1.25mm
t 'o-ft1 45N'm(il5 ks-m,33lb-ft|
io r'i'"'ii.i 11n--,
fnt$rtt ,"o""",..to"
GROUND
CABLE
WIRE
HARNESS- ,
CLAMP
STARTER
MOTOB
CABLES
8 x 1.25mm 12 x 1.25mm
22 N.m (2.2kg-m, 75 N.m (7.5kg-m,
16 tb-ft) 54 tb'ft)
6x1.0mm
't0 N.m 11.0kg-m,7 rb-ft)
13-44
25. Installthe bracketand intakecontrolvacuumtank. 27. Installthebasestayand batterybase.
INTAKECONTROL
x 1,0mm
10 N.m 11.0kg-m,
7 tb-ft|
BASE
STAY
6x1.0mm
10 N.rn (1.0kg-m,
7 tb.ftl
BRACKET
I 8 x 1,25mm
Front 22 N.m (2.2 kg-m,
16 rb-ft}
26. Installthe air cleanerassemblvand intakeair duct.
6x1.0mm
10 N.m {1.0kg-m,7 lb-ft|
24. Refillthetransmissionwith oil (seepage13-2).
29. Install the battery. then connect the battery positive

(+) and negative(-) cablesto the battery.
30. Checkthe clutchoperation.
3 1 . Shift the transmissionand checkfor smooth opera-

tron.
32. Checkthe front wheel alignment{seesection18).
{cont'd)
13-45
Installation (cont'd)
33. Loosenthe three mountingbolts of the front engine

m o u n t b r a c k e t ,t h e n t o r q u e t h e t h r e e m o u n t i n g
bolts.
NOTE:Make sure the bushingsare not twisted or

offset.
MOUNTBRACKET
ENGINE
FRONT
13 -4 6
Automatic Transmission
SpeciafTools..... ........14-2 OilPump
Description ........ ........14-3 Inspection.......... ....14-101
C1utches.............................................1
4-6 MainValve Bodv
PowerF|ow.......................................1
4-9 Disassembly/lnspection/Reassembly. .....'l4-102
Electrical
ControlSvstem................1 4-10 SecondaryValveBody
HydraulicFlow.................................,1
4-13 Disassembly/lnspection/Reassembly. .....14-104
Lock-upSystem...............................1
4-22 RegulatorValve Body
HydrauficContro1..............................1
4-28 Disassembly/lnspection/Reassembly...... 14- 106
ThrottleValveBody
EloctricalSystom Disassembly/lnspection/Reassembly. .....14'107
Component Location.......,...................1
4-31 Servo Body
CircuitDiagram. ........14-32 Disassembly/lnspection/Reassembly...... 1+ 108
* Troubleshooting Procedures...,,,,.,,,,,,,1
4-g 1st/2ndAccumulatorBody
Symptom-to-Component Charr Disassembly/lnspection/Reassembly...... 14- 109
ElectricalSvstem..............................1
4-36 Mainshaft
ElectricalTroubleshooting Disassembly/lnspection/Reassembly. .....1+1 1O
Troubleshooting F|owchart...............,....
14-38 Countershaft
Mainshaft/Countershaft SoeedSensors Disassembly/lnspection/Reassembly. .....14-11 1
Replacement .........14-61 Remova1............. ....14-112
Lock-upControlSolenoidValveA/B lnstallation 13
.,...........14-1
Test..........,......... ....14-62 One-wavClutch
Repfacement .........14-62 Disassembly/lnspection/Reassembly. .....1+1 14
Shift ControlSolenoidValveA/B SecondarvShaft
Test.................... ....14-63 Disassembly/lnspection/Reassembly......14-1 15
Replacement .........14-63 Insoection.......... ....14-116
Clutch
HydraulicSystom flfustratedfndex................... +1 17
..............1
Symptom-to-Component
Hydraulic
* RoadTest.......
StallSoeed
Chart
System.............................1
+64
...........14-68 'i45"Hgffi
*i:|i'',i',
Test....................................................1
4-71
FluidLevel CountershaftBearing Replacement...,.,..1 +1 28
Checking/Changin9.......................
....1+72 Secondary ShaftBearing Replacemen1...1 4-128
Pressure Testin9.................,,..,,..,...,.....1
4-73 Transmission HousingBearings
Removal/lnstallation ....14-129
.....................
Transmission Transmission
Transmission Reassembly ....... ....1+130
Remova1............. ....14-80 RightSideCover
lllustratedlndex +1 36
FeedPipeInsta;;ation......................,.1
RightSideCover...............................1
4-86 ParkingBrakeStopper
Transmission Housin9......................1
4-88 Inspection/Adlustment 4-1s?6
....................1
TorqueConverterHousin9...........,,.1 4-90 ToroueConverter
RightSideCover Disassemblv ..........1+'137
Remova1............. ....14-92 Transmission
Transmission Housing Installation .............1+138
Remova|............. ....14-94 CooferFlushing.. ..,.14-142
TorqueConverter Housing/Vafue Body shifr cable
Remova|............. ....14-96 *Removal/lnstallation ..............,...
.,,,,,.14-144
ValveBodv *Adjustment...... ......14'146
Repair................. ....14-98 * Gearshift 4'147
Selector.............,,..,,.,,,,,.,...,.1
Valve A/T GearPositionIndicatorPanel
Assembly........... ....14-99 *Adjustment...... .,'.1+148
ValveCaos ThrottleControlCable
Description ...,.... ....14-100 Insoection.......... ....14-149
Adiustment........ ....14-150
SpecialTools I
Rot. t{o. Tool Numbar Dolcrlptlon otv PagoRoferanca
o 07GAB-PF5010Oor MainshsttHoHer 1 1+92,1U

07GAB-PF50101
ri oTGAE-PG40200 ClutchSprinoCompressor
BoltAss€mbv 1 1+121,124
o oTHAC-PK4010A HousingPullor 1 1+93
o 07HAE-PL50100 Clutch SpringCompressorAttachment I
I
1+121,124
1+121,124
@ 07LAE-PX40100 Clutch SpringCompresaorAttachm6nt
@ OTLAJ-PT3O1OA Test Harnass I 1+35,68
o 07406-@20201 A/T oilPressure
Hose{ReDlacementHos€s} I
1
1+73
1+73
@ 07406-@20@3 A/T OilPressureGsugeS€t
@ 07106-0070@0 A/T Low PressureGauge 1 1+73
'@ 07730-A010@A AdjustableBesringPuller,25-40 mm 1 1+1n
@ 07746-@10400 Attschment, 52 x 55 mm 1 1+18
@ 07746-OO10500 Attachment, 62 x 68 mm 1 1+127,'128
@ 07746-0010600 Attachment, 72 x 75 mm 1 1+'127
G 07749-OO10000 Oriver 1 1+127,14
@ 07947-63zto5@ Attachment 1 1+127
'I 1+142
@ J38405-A TransmissionCool€rFlushor
6,rmr--€
I
@
\!, @ o @
o o @ G
0 a
'0 Must be used with commerciallyavailable3/8 in, x 16 throads/in.slid6nammer.
14-2
Description
The Automatic Transmissionis a combination of a 3-element torque converter 8nd tripls-shaft electronicaly controllod
sutom8tic transmissionwhich provides 4 speedsforward and 1 speed reverse.The entire unit is poshionedin line with the
engrne.
Torqug Convarter, G6arsand Clutches

The torque converter consistsof a pump,turbine and stator Sssembledin a singlsunh,
Thsy are connectedto the enginecrankshsJtso they turn togeth€r as a unh as the engineturns. Around th€ outside of the
torque conv€rter is a ring gear which meshes with the stsrtel pinion wh6n the engin€ ig b€ing st8rt6d. The antir€ torque
converter assemblyservesas a flywheel while transmittingpower to the transmissionmainshaft.
The transmissionhas three psrsllelshatts: the mainshatt,the countershaft, and ths secondaryshaft. The mainshaftis in line
with the enginecrankshsJt.
The mainshaftincludesthe clutchestor 3rd. snd 4th, and gearsfor 3rd, 4th, R6vsrseand ldlor (Rsversegesr is intogralwith 4th
gear).
The countershaftincludesthe lst-hold clutch and gearsfor 2nd, 3rd, 4th, Reverse,lst EndHler.
Th6 secondaryshaft includesthe 1st and 2nd clutches,andgesrstor 2nd, 1st and Hler.
The 4th 8nd reverse g€arscan be lockedto the countershaft 8t its center, providing4th gear or Reverse,dependingon which
w8v the selectoris moved.
Ths gears on the msinshaJtare in constsnt m€sh with thosa on ths countershatt and the secondaryshaft. When certain
combinationsof gears illbe lMsDl9giol lre etglged by the clutches, power is tr8nsmitted from the mainshalt to the
countershaftto pro"ia" O.-l,f-O"-l,f , T and@oosirions.
EleqtronicControl
The electroniccontrol system consistsof the TransmissionControl Module{TCM),sensors,and 4 solonoidvalves.Shifting 8nd
lock-upare €l6ctronicsllycontrolledfor comtonable drivingunder allconditions,
The TCM is locatedb8low the dsshboard,behindthe right sido kick panolon the psss6ng6r'ssids.
Hydr8ullcConilol
The vslve bodiesincludethe main valve body. secondaryvafue body, servo body, regulatorvafue body, throttl€ vsve body and
lst/2nd accumulatofbody.They 8re bohedto the torque converter housingas an assembly,
The main vslve body containsthe msnualvalve, 1-2 shift valvs, 2-3 shift valvs, coolel relief valve, lock-up shift vafue, lock-up
control valve, 3-2 kick-down valve, modul8torvatue.CPCvalve and oil pump gears,
The secondaryvalvo body includesthe 4th exhaust valve, 3rd kick-down v8lve,3-4 shift vafu€, servo control vslve, orific€
controlvalveandthe 2ndotificecontrolvalv6.
The servo body contains the accumulator pistons 8nd servo valve. The rogulEtorvafus body contains the roguhtor valve,
torque converter check valve, and lock-uptiming v8lve. The throttle valve body contains ths throttle valve B and relief valve.
Fluidfrom the regulatorpassesthroughthe manuslvatveto the variouscontrol valves.
The clutchesreceiveoiltrom their respectivefeed pip6sor internalhydrauliccircuit,
Shlft Control Mechanism

Input from various sensors located throughout the car determin€swhich shift control solsnoidvalve the TCM will activate.
Activating 8 shiJt control solenoidvalve chsngesmodulator pressure,causingI shtft valve to move. This pressurizesa line to
one of the clutches,engagingthat clutch and its correspondinggear,
Lock-up Machanlsm
InL91l position,in 2nd, 3rd and 4th. andI D3 | positionin 3rd, pressurizedfluid is drainedfrom the back of the torque converter
througir an oil pass8ge,csusing the lock-up piston to be heH agsinst the torqus converter cover. As this takes phcs, th€
mainshaftrotates 8t the samespeedas the enginecrankshaft.Togetherwith hydrsuliccontrol, the TCM optimizesthe timingof
the lock-upmechanism.
The lock-upvatuescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalves A and B, andthrottle valve B.
When lock-up controlsolsnoid vslves A and B activate, modulatorpressurechanges.Lock-up controlsolenoidvslv€s A and B
are mountedon the torque converter housing.and are controlledby the TCM,
lcont'dl
14-3
Description
(cont'd)
Gaar Sobction
Thesetectorteverhassevenpositions:@PARKt, gear,"n0"", @
@ rueurnef-,1o. 11stthroush4th
Fl REVERSe,
3rdgearrangss,
1stthrough | 2l2ndgearandl1 llstge8r.
Position Dolcrlptlon
@ernr Front wheelslocked;p8rkingpswlengsgsdwith parkinggesr on countershaft.Allclutches released.
I nl nevensr Reve.se;reverseselectorengagedwith countershaftreversegear8nd 4th gearclutch locked.
I n-]r.reurnnr- Allclutches released.
oo-l
I(1st onve Generaldriving;starts oft in lst, shifts automaticallyto 2nd, 3rd, thsn 4th, dependingon vehiclespeed
through and throttle poshion. Downshift tEglgh 3rd, 2nd and 1st on decelerationto stop. The lock-up
4th) mechanismcomes into operstionin LP1Jpositionin 2nd, 3rd and 4th speed.
I o.lonve For rapidaccelerationat highwayspeedsand genersldrivlng;up-hillanddown-hilldriving;starts otf in

Flst throush lst, shifts automsticslly to 2nd, then 3rd, dspsnding on vehicle speed and throttl€ position.
3rdl DownshiJtsthrough 2nd to 1st on dsceler€tionto stop. The lock-up mechsnismcomes into operation
in 3rd sDeed.
@secor.ro For enginebrskingor better traction starting off on looseor slipporysurfaces;stsys in 2nd gsar,doos
not shitt up or down.
f rrnsr For enginebrsking;stays in lst ge8r,does not shift up.
St8rting is possibleonly in Ll,l andL!_.1positionsthrough th€ use ol 8 slide-type,n€utral-ssfetyswitch.
Automatlc TransaxlolA/Tl GoEl PoshlonIndlcatol

A/T gear position indicator in the instrument panelshows what gear has been selectedwithout hsving to look down at the
consore.
14-4
RINGGEAR
VA\
,IST CLUTCH
N TOBOUECOT{VERTER
2I{D CLUTCH
COU TEASHAFT
SPEEDSE SOR
lST-HOLD
CLUTCH
PARKINGGEAR
4TH CLUTCH 3RD CLUTCH
14-5
Description
Clutches
The four-speed automatic transmissionuses hydraulicallyactuated clutches to engageor disengagethe transmissiongears.

When clutch pressureis introducedinto the clutch drum, the clutch piston is Epplied.This press€sthe friction discs and sts€l
plstes together. locking them so they don't slip. Power is then transmitted the through the engagedclutch psck to its hub-
mountedgear.
Likewise,when clutch pressureis bledlrom the clutch pack, the piston releasesthe triction discs and stsel plstes,snd th€y are
tree to slidepast each other while disengaged.
This allowsthe gearto spin independentlyof its shaft, trsnsmittingno power.
13t Clutch
The lst clutch eng€ges/disengages lst gear,and is locatedat the center of the secondaryshaft.
The lst clutch is joinedback-to-b8ckto the 2nd clutch.
The 1st clutch is suppliedclutch pressureby its oilfeed pipe within the secondsryshaft,
1st-hoH Clutch
'l
The 1st-holdclutch engages/disengages st-holdor 1 1 i position,and is locatedat the end of the countershaft,just behind
the torque converter housing.The I st-holdclutch is-suppliedclutch pressureby its oil teed pipe within the countershsft.
2nd Clutch
The 2id clutch engages/disengages 2nd gear,and is locatedat the center of th6 secondaryshaft, The hd clutch is ioined back-
to-back to the 1st clutch. The 2nd clutch is suppliedclutch pressurethrough th€ socondaryshsft by a circuit connectedto th6
internalhydrauliccircuit.
3rd Clutch
The 3rd clutch engages/disengages 3rd geaf,and is locatedat the center of the msinshsft.
The 3rd clutch is joinedback-to-backto the 4th clutch.
The 3rd clutch is suppliedclutch pressurethroughthe mainshaftby a circuit connoctodto ths regulatorvalve body,
4th Clutch
The 4th clutch engages/disengages 4th gear, as well as reverse gear, and is located at the c6nt6r of the msinshaft.The4th
clutch is joined back-to-back to the 3rd clutch. The 4th clutch is supplied clutch proasuraby its oil feed pipe within the
mainshaft.
One-way Clutch
The one-wayclutch is positionedbetweenthe countershaft lst gear and 3rd 968r,with the 3rd gsar splinedto th€ countsrshsft.
The 1st gear providesthe outer racs surface, and the 3rd gear providesthe inner race surfacs, The on€-way clutch locks up
when power istransmitted from the mainshaft1st gearto the countershEft1st gear.
_
The lst clutch and gearsremainengagedin the 1st. 2nd, 3rd, and 4th g€sr rangssin the ll1l, fQg,lor l ll oosition.
However, the one-wayclutch disengageswhen the 2nd, 3rd, or 4th clutches/gsErsare aooliedin th@ , I olorl2l position.
This is becausethe increasedrotationalspeedof the gesrson the countershstt overridesths locking"spe6d range" of th6 ons-
way clutch,Thereafter,the one-way clutch freewheelswith the 1st clutch still6ngaged.
COUNTERSHAFT1ST GEAA
LOCKS
FREE
NOTE:
Viewlrom rightsid€covorsid€.
14-6
COUNTERSHAFT
3RDGEAR MANSHAFT
COUI{TERSHAFT 3RD CLUTCH

1ST GEAB
4TH CLUTCH
MAII{SHAFT
4TH GEAR
MAIITSHAFT
REVERSEGEAR
MAII{SHAFT
IDLERGEAR
COUNTERSHAFT
4TH GEAR
REVERSE
SELECTOR
MAIl{SHAFT
SEI.ECTOR
HUB
COUTTERSHAFT
IDLER
GEAR
FII{ALDRIVE
lST.HOLD ARKINGGEAR
SECOI{DARY
SHAFT COUNTERSHAFT
2NDGEAR
COUiITERSHAFT
REVERSEGEAR
SECONDARYSHAFT
IDLERGEAN
SECOI{DARYSHAFT
2NO GEAR
2ND CLUTCH
FI AL DRIVEI{GEAR
14-7
Description
Clutches(cont'd)
Lock-up Clutch
1. Operation{clutchon)
With th€ lock-up clutch on, ths oil in the chsmbor between the converter cover and lock-up piston is drsined otf, snd the
converter oil exerts pr€ssurethroughthe piston againstthe convertsr cover. As a resuh,the converter turbine is lockedto the
converter cover. The effect is to bypassthe converter, thereby placingthe car in direct drive.
tF"*"'ffil PISTON
LOCK.UP DAMPERSPRING
The power flows by way of:
Engine
J
Driv€ plat€
J
Torqueconverter cover
J
Lock-up piston
J
Dsmperspring
J
Turbine
J
Msinshalt
MAINSHAFT
2. Operation(clutchotf)
With the lock-upclutch off, the oil flows in the revers€ of CLUTCHON.As s resutt,the lock-up piston moves away from the
converter cover andth€ torouo converter lock-uDis rel€as€d,
TURBINE
Engine
tirive plate
J
Torqueconv€rtercover
J
Pump
J
Turbine
J
Mainshaft
MAINSHAFT
14-8
PowerFlow
}K TOROUE1STGEAR lST GEAF 1 S TG E A F2NDGEAF3RDGEAR

coN- 'IST-HOLD l S T ONE-WAY 2ND 3RD
4TH
VERTER CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
REVERSEPARKING
GEAR GEAR
tr o X X X X X X o
t^-l o X X X X X o o X
tr'| o X X X X X
E sT o o o X X X X X
2ND o -o X o X X X X
3RD o -o X o X X X X
4TH o X .o X o o X X
E t5l o o o X X X X X X
2ND o .o X o X X X X X
3RD o X .o o X X X X
f;t
Lil o .o X o X X X X X
tr o o o o X X X X X X
O: Operates, x: Doesn't operate, *: Akhough the 1st clutch engsges,driving pow6r in not transmittsd as the one-wav clutch
sliDs.
COUNTERSMFT MAINSHAFT
1STGEAR 3RD GEAR 3RDCLUTCH MANSHAFT
4THCLUTCH REVERSE
GEAR
COUt'ITERSHAFT
3RDGEAR MAII{SHAFT / REVERSEIDLERGEAR
4TH GEAR
MAINSHAFTIDLERGEAR
MAINSHAFT
COUiITERSHAFT
2I{D GEAR
COUNTERSHAFT
IDLERGEAR
PARKI G GEAR
<- coul{TERSHAFT
PARKI]'IGPAWL
SECONOARYSHAFT
OIL PUMP
TOROUECONVEBTER SECONDARYSHAFT
IDLERGEAR
FINAL
GEAR SECODARYSH/TFT
2NDGEAR
lST.TIOLDCLUTCH SHAFT 1ST COUI{T€RSHAFT
GEAR REVERSEOEAR
lST CLUTCH REVERSE
SELECTOR
2NDCLUTCHI COUI{TERSHAFT
4TH GEAR
SERVOVALVE
14-9
Description
ElectronicControlSystem
Eloctror c Contlol Systom
The sloctroniccontrol system consistsot the TransmissionControl Module{TCM},sensors,and 4 sol€noidvalves. Shitting8nd
lock-upars sloctronicsllycontrollsdfor comfortabledrivingundersllconditions,
The TCM is locatedbslow the dsshboard,behindthe right side kick panelonthe passengar'ssida,
Shlft Control
Gstting a signslfrom each sensor,the TCM determinesthe appropriategearand activatesshift controlsolenoidvavos A and/or
The combinationof drivingsignalsto shift controlsolenoidvafuesA and B is shown in the tsble below.
\Shitt control solenoidvalve

A B
Position(gesr) \
f trstt ON OFF
@a'at ON ON
1o.-llos-ltrstt OFF ON
I o.-llo.-lrznar ON ON
15.-llo.-lts,ar ON OFF
E (4th) OFF OFF
tr ON OFF
Lock-up Contlol
From sensor input signals,the TCM determineswhether to turn the lock-up ON or OFFand activates lock-up control solenoid
valve A and/or B accordingly.
The combinationot drivingsignalsto lock-upcontrolsolenoidvalves A and B is shown in th6 table below.
Solenoidvalve
\ A B
t*"*"-*----\
Lock-up OFF urr OFF
Lock-up,slight ON Duty operstion

OFF1) ON
Lock-up,hstf ON ON
Lock-up,full ON ON
LOCI(-Up ON Duty operation
during dec6leration OFF<J ON
14-10
I
Throttlo Position U Shlft Conlrol
SonsorSignal SolenoidValve A
Shift Control
EnginoCoolam Shift Control

Sobnoid Valve B
Senso. Sienal
ENGINE
cot{TRoL Lock.up Control
MODULE Sorylco Check SoLnoid V.tue A
IECM} Connector Lock-up
Control
Lock-upControl
Solonoid Valv6 B
EngineSpood P I]]] II{TERLOCK

CONTROLUNIT
Alr Conditioning ' R

Signal
BrakoSwitch N
Signal
Main!haft/Countor$haft D.
Spo6dSsnso. Signal
Vohlclo Sp€edSeNor Slgnal Dr
not"ao,Lretr 2
@
Solt-Diagnosi3
Signol
14-11
Description
ElectronicControl System (cont'd)
Clrcuh Diagramand Terminal Locstion
;
-:.'
nr
r 1 r9 : n{FoTrt! 9osllroN
r 2 ECT: ENGIIE COOLiTTTIMPIiATLJRI
'/;scs
m-
s|rtFlcoiTior
rocx utco{nol
A13lA1!
A1€
TCM TERMINALLOCATION
14-12
HydraulicFlow
No, DESCRIPTION No. DESCRIPTION No. DESCRIPTION No, DESCRIPTION

OF PRESSURE OF PRESSURE OF PRESSURE OF PRESSTIRF
1 LINE 6' MODULATE 30 3RDCLUTCH 93 OILCOOLER
(DUTYCONTROL)
LINE I 31 3RD CLUTCH
LINE 10 l ST CLUTCH 4A 4TH CLUTCH 5 LUBRICATION
LINE 15 lST.HOLDCLUTCH 41 4TH CLUTCH qA
TOROUECONVERTER
LINE lST.HOLDCLUTCH THROTTLEB s9 SUCTION
4 LINE 18 LINE THROTTLEB X BLEED
L' LINE n 2NDCLUTCH 90 TOROUECONVERTER
LINE 21 2NDCLUTCH 9l TOROUECONVERTER
6 MODULATE zc LINE 92 TOROUECONVERTER
I N I Position
As the enginetufns, the oil pump alsostarts to operate.Automatic transmissionfluid (ATFI is drawn from (g9l and dischsrged
into (1).Then, ATF pressureis controlledby the regulatorvalve and becomesthe line pressure{1).The torque converter intet
pressure(921enters (94)of torque converter throughthe orifice and dischargesjnto (90).
The torque conve,ter check valve preventsthe torque converter pressurefrom rising.
Underthis condition,the hydraulicpressureis not appliedto the clutchesas the manualvalv6 stoDsline oressure{l ).
NOTE:
When used,"lett" or "right" indicatesdirectionon the flowchart.
(cont'd)
14-13
Description
HydraulicFlow (cont'dl
I 1 lPositlon
Th6 linepressure(1)becomeslinepressure{4)at the manualvalveandpassesto the lst clutchand lst accumulator.
Then line pressure(4) flows throughthe 1st-holdclutch and 1st-holdaccumulator.The power is transmittedonly during
deceleration throughthe lst-holdclutch,
Fluidflows bv wav of :
- LinePressurel4)+ 1-2 Shift Vatve+ 2-3 Shift Valve- 3rd ClutchPressure(31)+ 3-4 Shift Vslve-4th ClutchPressure
(41)r ManualValve- I st-holdClutchPressure(16)J 1st-holdClutch
The modulatorpressure(6)is supplied to the 1-2and2-3 shift valves.

The line pressure(1)alsotlows to throttle valve B.
NOTE;
"left" or "right" indicatesdirectionon the flowchart.
When used,
14-14
I 2 lPosition
The linepressure(1)becomeslinepressure{4) as it passesthroughthe manualvslve.h then goesthroughline (2O)to the 2nd
clutch.Also.linepressure(1)goesto the modulatorvalvethroughthe fiher andbecomesthe modulatorpressure(6l,Modulator
pressure{6)is not supplledto the l-2, 2-3 and3-4 shift valves.
Lin€pressure(1)alsoflows to throttlevalveB.
NOTE:
When used,"lett" or "right" indicatesdirectionon the flowchart,
{cont'd)
'14-15
Description
HydraulicFlow {cont'd}
I oglo.lEl Positio"
1. 1st Sp€od
The f low of f luidthroughthe torqueconvertercircuitis the sameas inI N lposition.
The line pressure (1) becomesline pressure{4} and it becomesthe 1-stclutch pressure{10).The lst clutch prossureis
aooliedto the 1st clutch and 1st accumulator;consequently,the vehiclewill move as the enginepower is transmitted.
The line Dressure(1) becomesthe modulatorpressure(6) by the modulatorvalve snd travsls to 1-2 8nd 3-4 shift v8lv€s.
The 1-2 shitt vave is moved to the right side becausethe shift control solenoidvalve A is turned ofJ 8nd B is turned on by
the TCM, This valve stops 2nd clutch pressureand the power is not transmittedto the 2nd clutch.
Lins pressure{4)alsoflows to the servo valve and line pressure{1)slso tlows to throttle valve B
NOTE:
"left" or "right" indicatesdirectionon the flowchart.
When used,
1 4 - 16
2nd Speed
The flow of fluid up the 1-2 and 2-g shift valves ls the same as in the lst spe€d. As the speed of th6 car reachesthe
prescribedv€lue,the solenoidvalve A is turnad on by meansof the TCM. As a resuh, the 1-2 shift vav€ is moved to the
left and uncoversthe port leadingto the 2nd clutch; the 2nd clutch is engaged.
Fluidflows by way of ;
-Line pressure{4) + 1-2 Shift Valve+ 2-3 Shift Valve-2nd ClutchPressure
{21)J Orifice-2nd ClutchPressure
(20)-r 2nd Clutch
The hydraulicptessurealsoflows to the 1st clutch. However, no power is transmittedbecauseof the one-wavctutch.
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchart.
(cont'dl
14-17
Description
HydraulicFlow (cont'd)
3rd Spoed E
aFt
The flow of tluid up to the 1-2, 2-3 and 3-4 shift valves is the sameas in the 2nd speed.As the speedof the car roachesthe
prescribedvalue,the shift control solenoidvalve B is turned oft (shift control solenoidvalve A remainson). The 2-3 shift Thc
valve is then moved to the laft, uncoveringthe oil port leadingto the 3rd clutch. Sincethe 3-4 shitt valve is moved to the prrt
right to cover the oil port to the 4th clutch, the 3rd clutch is turned on. Asd
shift
Fluidtlows by w8y of :
-Line Pressure(41J 1-2Shift ValveJ 2-3 Shift Valve- 3rd ClutchPressure(31)J 3-4 Shift Valve (not controlled)
-3rd Clutch Pressure(30)-r 3rd Clutch Fbn
The hydraulicpressurealsotlows to the 1st clutch, However, no power is transmitted becauseof the one-wayclutch as in
the 2nd sDeed.
Tho
NOTE: M
When used, "left" or "right" indicatesdirectionon the tlowchart.
NO
wh
14-18
I Da lPoshion
!he Fth Speed
hft The flow of fluid up to ths 1-2, 2-3 and 34 shift vslves is the same as in the 3rd speed.As th€ spe€d of tho car reachesthe
the pr€scribedvalu€,the shitt control sol8noidvatueA is turned olt (shitt control sol€noidvalv€ B remsinsoff).
As this takos place,3-4 shift valve is moved to th€ left and uncoverstho oil port leadingto ths 4th clutch, Sincathe 1-2and 2-3
shift vslves are kept on the l€ft side,the fluid flows th.ough the 4th clutch; the power is trsnsmitted throughthe 4th clutch.
Ed)
Fluidflows by way of :
-Line Pressure(4) J1-2 Shift Vslvo J 2-3 Shift Vslve-3rd Clutch Pressure(31) + 3-4 Shift Vslvs-4th Clutch pressuro
tin (41)+ ManualVslve-4th Clutch Pressure(4O)J 4th Clutch
Ths hydraulicprossurealsoflows to th8 1st clutch, However, no power is transmittedbecsuseof ths one-wsy clutch 8s in
2nd and 3rd sDeed.
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchan.
(cont'd)
14-19
Description
HydraulicFlow (cont'd)
I R lPolhlon
Th; tlow of fluid through th6 torque converter circuit is the same ss in the I N I position.The fluid {1)trom the oil pump flows
tr
The
prst
throughth€ manualvatveand becomesline prsssure(3). lt then flows throug-hthe 1-2 shift valv€ to the servo valve {3),causing
the shift tork shsft to be moved in the rovorsedirection, End
Undeqthis condition,the shift controlsolenoidvalve A is turned on whereasthe valve B is turned off 8s in 3rd speedinLqllor Hot\
I D3 I position.As a resuh, tho 1-2 shift valve is also moved to th8 lsft. The Jluid (3') will flow through the seryo valve and
m:Ei[alvalve to the 4th clutch; power is transmittedthroughthe 4th clutch, NOI
Wix
Rev6rsoInhibito!-.lE=ontrol
When the I R I positionis selectedwhile the vehicleis movingforward at a speed over 6 mph (10 km/h), the TCM
outputslst;i6;al (A: OFF,B; ON),and the 1-2shift valve is moved to the right side.Th6 line pressure(3)is interceptedby
th€ 1.2 shift vave; consequ€ntly,pow6r ia not transmittedas the 4th clutch and servo vatueare not operated.
NOTE:
"right" indicstesdirectionon the tlowchart.
When used,"left" or
14-20
I P I Poshlon
The flow of fluid th.ough the torque converter circuit is the same as in
fTl position.Tho line prsssuro {11bscomes the tine
prsssure{31as it passesthrough the manualvatue.Then line pressure(3)*flows
ins through the l-2 shitlgrvs to the sarvo v8vs
and the servo control valve,causingthe shift tork shatt to be movedto rhe reversepositionas in th€ R position.
I I
,J However,the hyd.auilcpressureis not supptiedto the crutches.The power is not trsnsmittod.
rrd
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchart,
CM
E
a
14-21
Description
Lock-upSystem
h l5r-l positionin 2nd, 3rd and 4th, andI 03 | position in 3rd, pressurizedfluid is drainedjrom the back oJ the torque convsrtsr
th;o6h an oil passage,causingthe lock-up piston to be held against the torquo converter cover. As this takes pl8cs, th€
mainshsttrotates at the samesp€edas the enginecrankshaft.Togetherwhh hydrauliccontrol, th€ TCM optimizosthe timing of
the lock-upsystem. Undercenain conditions,the lock-upclutch is appliedduringdecsleration,in 3rd 8nd 4th sp66d.
The lock-up systam controls the rangeof lock-up accordingto lock-up control solenoidvav€s A and B,8nd throttle valve B'
When lock-up control solenoidvslves A and B activate. modulstor pressurechanges.Lock-up controlsolenoidvalvos A 8nd B
are mountedon the torque converter housing,and are controlledby the TCM,
NOTE:
When used, "left" or "right" indicatesdirectlonon the flowchart,
LOCKUP II V 1
coNrRoL ll
S O L E N O I IDl L O C K u pC O N T R O L
V A L V E :A l l S O L E N O TVOA L V E :
FEGULATOF
14-22
l,lo Lock-up
The pressurizedfluid regulstedby the modulatorworks on both ends of the lock-up shift vsfue and on the left side
of the lock-
up controlvslvo. Underthis condition,the pressuresworking on both ends of the lock-upshift valveireequat. ttre stritt vatve
is
movsd to the right side bv the tensionof the v8tuespringalone.The fluid trom the oil pump willflow throught;e bft side of
the
lock-upclutch to the torque converter; i,e.,the lock-upclutch is in OFFcondition.
NOTE;
When used,"left" or "right" indicatesdirectionon the flowchart,
!BRi?'",
I v 1
;9ii?9P! !B:i,VBS",jffi?f"
I\4ODULATOR
PRESSURE
T O R O U €C O N V E R T E R
C H E C KV A L V €
(cont'd)
14-23
Description
Lock-upSystem (cont'd)
PartialLoqk-up
Lock-upControl SolenoidValve A: ON Lock-upControlSolenoid VslveB: OFF
Tho
The TCM switches the solenoidvalve A on to releasethe modulatorpressurein the lett cavity of the lock-up shift valve'
pressure in the right cavity ot the lock-up shilt valve overcomes the spring forc8, thus the lock-up shitt valve is
modulator
movedto the left side,
The modulatorpressureis separatedto the two passages:
Torque Converter InnerPressure:enters into right side-toengagelock-upclutch
Torque ConverterBack Pressure:enters into left side-todisengagelock-upclutch
The bici pressure(FA is regulatedby the lock-upcontrol vave whereasthe positionot the lock-uptiming valve is doterminad
positionoJ the lock-up
by the throttle B pressure,tension ot the valve springand pressureregulatedby the modulator.Also the
is determinded by the back pressuie oithe lock-up controlvalve and torque converter p.essurer€gulatedby the
controlvalve
end of th€ lock-
check valve.With the lock-upcontrolsolenoidvalve B kept oJf, ihe modulatorpressureis maintainedin the left
,p--nt-iu"V"; in other woios, the tock-upcontrol vave is moved slightlyto the leJtside.This slightmovement of the lock-up
controlvalve causesthe back pressureto be lowered slightly,resuttingin partiallock-up'
NOTE:
"left" or "right" indicatesdirectionon the tlowchart.
When used,
IOCKUP
CONTfiOL
SOLENOID LOC(UP CONTFOL
SOLENOIDV A L v E :B
PRESSURE
MODULATOR
TOROIJE CONVERT€A
14-24
Half Lock-up
Lock-upControlSolenoid VafueA: ON Lock-upControlsolenoid ValveB:ON
The modulator pressureis releasedby the solenoidvalve B, causingthe modulator pressurein the l€ft cavity of ths
lock-up
controlvalve to lower.
Also the modulator pressurein the leJtcavity ot the lock-uptiming v8lve is low. However the throttle B pressurois still low
at
thjs.time;consequently,the lock-uptimingvalve is kept on the righi side by the springforce.
With the lock-upcontrolsolenoidvalve B turned on, the lock-up controlvalve is moved somewhat to tho lelt side,causing
ths
back pressure(F2)to lower. This allows a greater amount of the fluid (Fi ) to work on the lock-u; ;bich ;; 8s ro engage
the
clutch. The back pressure(Fa which stillexists preventsthe clutch from engagingfully.
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchart.
ixi"iivflL !3:i",3,3"J:'&?."
MODULATOR
PRESSURE
VALVE
T O F O U EC O N V E R T E R
C H E C KV A L V E
(cont'd)
14-25
Description
Lock-upSystem (cont'd)
Ful Lock-up
Lock-uDControlSolenoidVaVe A: ON Lock-up ControlSolenoidVaMe B: ON
When the vohiclespeedfurther increases,the throttle B pressureis increasedin accordancewith the throttl€ opening.
The lock-upttmingvalve overcomssthe springforca and movesto the left side.Also, this vslve closesthe oil port leadingto the
torou€ conv€rter chsck vave.
Underthis condition,the throttle B pressuraworking on the right end ol the lock-upcontrolvalve becomesgleatsr than that on
the left end (modulatorpressurein the lelt end has alreadybeen relessedby the solenoidvatue B); i.e.,the lock-upcontrolvalve
is mov6d to ths l6ft. As this happ6ns,the torque convertar back pressureis releasedtully, causingthe lock-up clutch to bs
€ng8gedJully.
NOTE:
"left" or "right" indicatesdir€ctionon the flowchart.
When used,
coNlROL ll X
SOLENOIDII LOCKUPCONTROI
VALVE: A ll SOIENOIDVALVE: A
B PRESSURE
THROTTLE
MODULATOR
PRESSURE
T O R O U EC O N V E R T E R
C X E C KV A L V E
orr cooLEA
14-26
DacoleratlonLock-up
Lock-upcontrolsorenoid VatveA; oN Lock-upcontrorsoronoidvatueB:Dutyoperation(oN€oFF)
TheTCMswitchessolsnoidvslveB on andotf iapidlyunderceitainconCitions.
Tfreslightlock-upandhalflock-upregions8re
msintEinedso 8sto lockthe torqueconverterproperV.
NOTE:
Whenused,"left" or "right" indicatos
directionon the flowchan.
rocr(uP JI
33i,'î":i
I
LOCXIJ
MOOULATOR
PRESSURE
T O R O U EC O N V E R T E R
C H E C KV A L V E
F E L I E FV A L V E
14-27
Description
HydraulicControl
TheValvebodyinc|udesthemainva|Vebody,the'egulatorVa|vebody,thethrott|evalvebody,thesecondaryvslv€body,the
servo body and the 1st/2ndaccumulatorbody.
oilllows throughthe
The oil pump is driven by splineson the right snd of the tolqus convener which is attachedto the engine'
through the main valve body to the manualvalv€ and the servo bodv, dirocting
,"si,[i;, rriv" t" mainiiin specitieJ pies--sure
oressureto eachof the clutches.
THROTTLEVALVE SERVOBOOY
BODY
VALVE
REGULATOR
BODY VALVE
SECONDANY
BODY
SHIFTCONTROL
VALVEB
THROTTLE VALVE
SOLE]TOID
ASSEMBLY MAINVALVEB(X'Y
THROTTLELO[{G
VALVE l ST/2ltD
ACCUIUIULATOR
BODY
RELIEFVALVE
COrTROL
LOCK.UP
VAI.VE
SOLENOID OILPUMPDRIVEGEAR
ASSEMBLY Ot purip
ORIVEiIGEAR
4TH ACCUMULATOR
3RD
ACCUMULATOR
lST-HOLD
ACCUMULATOR sEnvo
VALVE
LOCK.UPTIMING
REGULATOR VALVE TOROUECONVERTER
VALVE CHECKVALVE
1STACCUMULATOR
2]IDACCUMULATOR
3RDKICK-DOWI{ 2 D ORIFICE
VALVE COT{TBOLVALVE
CPC VALVE
VALVE co TnoL
oRrFrcE
1-2 SHTFT 34 SHIFT VALVE
VAL
MODULATOR VALVE VALVE
SERVO
COOLER 4THEXHAUST cot{TRoL
VALVE VALVE VALVE
LOCK.UP
SHIFT
VALVE
MANUAL VALVE
VALVE
2-3 SHTFT
14-28
RogulatorValve
The regulstorvalv8 maintainsa constant hydraulicpressuresent trom the oil pump to th€ hydrsuliccontrol svstem, while also
turnishingoilto the lubricstingsystem and torque convarter.
Oil flows through B and B', The oilwhich enters through B flows through ths vslve orifice to A, pushingtho regulatorvalve to
the right. Accordingto the level ot hydraulicpressurethrough B, the poshion ot the valve changes,and the smount of th€ oil
through B'from D alsochanges.This operationis conttnued,maintainingline prossure.
I{OT RUN II{G)

IENGI]TE GiIGI]TE RUN ING)
To TOROUECOIWERTER
To RELIEF
VALVE
Stator RoactionHydtaulc P1!ssur6Control

Hydraulicprossuroincreaseaccordingto torque is performod by the regulatorvalve using stator torqus reaction.The stator
shEft is spllnedin the ststor, and hs arm end contacts the ragulatorspringcap. wh€n the car is acc€lerEtingor climbing(Torque
Converter Range),stator to.que reaction acts on the stator shaft, snd the stator arm pushesthe r€gulsto; springcap in the -)
direction in proportion to the reaction.The stator roaction spring compressos,and the regulatorvalve movss to increasethe
regulatedcontrol pressureor line pr€ssure.Line prgssureis maximumwhen the stStor reactionis maximum.
REGULATOR
VALVE
STATOR REACTIONSPRII{G
REGULATOf,SPRINGCAP
STATOR SHAFTARM
STATON SHAFT
{cont'd}
14-29
Description C
HydraulicControl (cont'd)
Thlottle V8tuo B
Throttle vave B converts changesin the throttle openingto changesin transmissionhydraulic pressute.The end ot throttle
vave B contscts the throttle cam which is connectedby a cable to the throttle body. The cable pullsthe cam which, in turn,
moves the throttle valve B. The throttle valve B-to-camengagementis adiustablefor shitt smoothnessand lock-up.Throttle
valve B controlsthe accumulators,to make smooth changesfrom one gearto snother.An assist tunction is used to lessenthe
throttle load.
ModulEtor Valv6
The modulstorvalve maintainsline pressureJrom the regulator,to the pressureshitt control sol€noidvatuesA/B and lock-up
control solenoidvalves A/8, thus maintainingaccurateshi{t and lock-upcharacteristics.
2nd Ollflce Contiol Vslvo

For smooth shifting between 2nd and 3rd. the 2nd orifice controlvalve relievesthe 2nd clutch pressure.
As 3rd clutch Dressureis incressed,the 2nd orilice controlvalve movesto uncover the oil port relievingthe 2nd clutch pressure.
14-30
ComponentLocation
TRAl'ISMISSION
CO]\ITROL
MODULE (TCMI
BRAKESWITCH
ENGINE MODULE(ECM}
CONTROI. AUTOMATIC TRANSAXLE(A/TI
GEARPOSITIONSWITCH
LOCK.UPCONTROL
SOLENOIDVALVE VEHICLESPEEDSENSOR{VSS} THROTTLE
POSITION
{TPISENSOR
ASSEMBLY
COUNTERSHAFT
SPEEDSENSOR ENGINECOOLANT
TEMPERATURE{ECT}SENSOR
MAINSHAFTSPEEDSENSOR SHIFTCONTROLSOLENOID
VALVE ASSEMBLY
14-31
Circuit Diagram
HOOD
UNDER- FUSE/FELAY
8OX
t l o . 4 t( 1 5 4 i
tlo.32l100Al No.43ll0A|
423 424 A2O D2

IRAI{SMISSION
CONTROL
MODULE
{TCM}
AIO A8 A19 A7 Ar8 A21 A17 A15 At3 All
A/T GEARPOSITIOI'I
I DtCAT0R
8LK
I :
8U(
G40r 4
G40l
14-32
SERVICE
CHECX I THROTTTEENGINT
CONNECTOR I POSInON CoOtANr
I sENsoR
REO/BIX
+iHr*_
SENSOR
Dl8 A22 D9 013 Otl Dt6 D6 D7 D5 A25 A26

TRANSMISSION
CONTEOL
MOOUIE
IICM}
017 Dt5 D19 012 A6 A4 A5 A3
wHT/EU(
I
GRN/BL(
8LU,^TEL
r,oct(- uPcoNTRot-sHtFrcorTRol-
SO[TNODVALVESOI-EI\OIDVAI.VE
COUTIIERSHAFI MAINSHAFI
SPEEDSENSOR SPIEDSENSOR
A3 A 5 A9 A11 A13A l 5 A 1 7Ar9 421 atr
A4 A6 A8 A ! C A18 ^ tttta t'ltt ) aa, t
TCMT.nnin.lLocnbns
14-33
TroubleshootingProcedures
When the TCM sensesan abnormslityin the input or output systems, th€ | D4 lindicator light in the gsugeasseEUlLwillblink.
Wh€n the Service Check Connector (locatedbehindthe center console)is-E6nnectodwith I jumper wire, the I Da lindicator
light will blinkthe DiagnosticTroubleCode (DTC)when the ignitionswitch is turned on'
When the I D;l indicatorlight has beenreported on, connect the two terminalsof the ServiceCheck Connectortogether whh a
iumperwire,
Thon turn on the ignitionswitch and observethel Da lindicator light.
DATA LI'{K
coNiEcToRt3Pt
cAUTlOir:
GAUOEASSEMELY Do not attadr tha
lumper wlre,
JUiIPER
3'S,Y,!"3reJl'ii['
Codes1 throuqh 9 are indicatedby individualshort blinks,codes 10 throught 15 8re indicatedby a soriesof longand short blinks.
On€long blink equals10 short blinks.Add the long and short blinkstogether to determinethe code. After dsterminingthe code,
refer to the electricalsystem Symptom-to-ComponentChart on pages1+36 8nd 37.
rhort
n
S.. DTC I
Soo DTC 2
s.. DTC '14
L]
rhort
Some PGM-FIproblemswill also make the I D4 lindicator light com€ on. After repairingthe PGM-FIsyatem, disconnectth€
CLOCKRADIOfuse (1OA)in th6 under-hoodtuse/relavbox for more thsn 1Osecondsto reset the TCM memory.
NOTE;
. PGM-Flsystem
The PGM-Flsystsmon this modelis I sequenti8lmuhipon tuel iniectionsystem.
. Disconnectingthe CLOCK RADIOfuse also cancelsthe radio antFthett code, preset stations 8nd the clock setting. Get the
custom€r'scode numbe. and make note oJ the radio presetsbefore removingthe Juseso you can .eset th€m.
14-34
CAUTION: . TCM Roset Procodure
. Al SRS electrlcal whlng haro6sres are covorod with
yelow outor insuhtlon. 1. Turnthe ignitionswitchoft.
. Before dsconnoctlng the SRS wila harnoss, install th€
lhort connoclor(s)on tho ailbag(s)(so6soction 23 I. 2. Remove the No. 43 CLOCK RADIO fuse (10A) lrom
. Roplaceiho snllro affectod SRS harness assombly if it the under-hoodtuse/relaybox tor 10 secondsto reset
ha! sn opon circuit or damagodwlring. the TCM.
NOTE:
Disconnecting the No.43 CLOCK RADIOluse aho
cancelsthe radio anti-theft code, Dr€setstations and
the clock setting. Get the customer's code number
8nd mske note of the rsdio presets befors romoving
the fuse so vou can resat them.
CLOCKRADIOFUSE
lf the insp€ctionfor a particularfailure code requiresthe

usa ot Test Harnesa(07LAJ-PT3010A);
1, Removethe right door sill molding,door trim and right

side kick psnel(seesection 20).
2. Pullthecsrpetbackto exposethe TCM.
3, Connectthe wire harnessto the Test Harness.and/or

connect ths Test Harnessto the TCM accordingto the
troubl€shootingf lowchart.
NOTE:
. OnV the A and D terminalsof the Test Harnessare
usedfor A/T troubleshooting.
. Unloss otherwise noted, use only the Digital
UI{DER-HOOD
Muhimeter,KS-AHM-32-003, tor testing. FUSE/RELAY
BOX
DIGITALMULTIMETER
KS-AHM-32-O03 . FinalProcodure
NOTE:
This proceduremust be done after any trouble-
shooting.
l. Remove the iumper wire from the Ssrvice Chsck

Connector.
Resetthe TCM.
Sst the rsdio preset stations and clock setting.
, o o o o o o o o o o o olio o o o o oo qo o o o o 6to o o o o r o o o ) c
14-35
Chart
ElectricalSyst
NumbsroI Da
indicatorlight
blinkswhile Da indicator PossibleCause Symptom Referto
Ssrvice Check light page
Connectoris
jumped.
I Blinks Disconnectedlock-up controi solenoidvafue Lock-up clutch does not 14-38

A connector engage.
Shon or open in lock-up control solenoid Lock-up clutch does not
vafueA wire disengage.
Faultvlock-uocontrolsolenoidvalve A Unstableidlespeed.
2 Blinks Disconnectedlock-up control solenoidvafue Lock-up clutch does not 1+39

B connector engage.
Short or open in lock-up control solenoid
valve B wire
Faultylock-upcontrolsolenoidvalve B
5 Blinks Disconnectsd throttle position (TP) sensor Lock-up clutch does not 1440
or OFF connector engage.
Short or oDenin TP sensorwire
FauhvTP sensor
4 Blinks Disconnected vehicle speed sensor {VSS) Lock-up clutch does not 1441
connector engage.
Shortor openin VSS wire
FauftyVSS
Blinks Short in A/T 9e8r positionswitch wire ' Failsto shi{t other than 1442
FauhyA/T gear poshionswitch zrde4th gears.
' Lock-up clutch does not
engage,
OFF Diconnected Nf geat position switch Failsto shift other than 1444
connector 2ndo4th ge8rs,
Open in A/T gear positionswitch wire Lock-up clutch does not
FaultyA/T gear positionswitch engage.
Lock-up clutch sngages
and disengagesahernate-
Disconnectedshift control solenoidvalve A ' Failsto shitt (between 1 1446

Blinks
connector ste4th, 2nde4th or 2
Short or open in shift control solenoidvalve nde3rd gesrsonly).
' Failsto shift (stuck in 4
A wire
Fauhyshift controlsolenoid valveA th gear)
Disconnectedshift control solenoidvalve B ' Failsto shift (stuck in I 14-47

I Blinks
connecror st or 4th gears).
Short or oDBnin shitt control solenoidvalve B
Fsuhv shift controlsolenoidvalve B
9 Blinks Disconnected countershaft speed sensor Lock-up clutch does not 1+44
connector engage.
Short or opon in the countershaft speed
sensorwir€
Fauhycountershaftspeedsensor
14-36
Numberof Dr
indicslor light
blinkswhile Da indicator PossibleCsuse Symptom Referto
ServiceCheck light pa9e
Connsctoris
iumped.
10 Blinks Disconnected engine coolsnt temperature Lock-up clutch does not 14-50
(ECT)sensorconnector engage.
Short or open in ECTsensorwire
FauhvECTsensor
11 OFF Disconnectedignitioncoil connector Lock-up clutch does not 1+51

Short or open in ignitioncoil wire engage.
Fauhyignitioncoil
't4 'Short or open in FAS
OFF wire be- ' Transmissionjerks hard
{ORIVRED} 14-52
tween the D16 terminalandECM when shifting.
' Troublein ECM
OFF Disconnectedmainsh8ft speed sensor con- Transmissionjerks hard 1+U

nector when shifting.
Shon or openin mainshattspeedsensorwire
Faulty mainshaftsDeedsensor
f the setf-diasnois
L91l indicatoflight does not blink,perform an inspectionaccordingto the tabtebelow.
Symptom ProbableCause RBf. page
Da indicator light does not come on for 2 seconds atter ignhion is first 14-56
turn€don.
D4 indicstorlight is on steady,not blinkingwheneverthe ignitionis on. 1+58

Lock-upclutch does not have duty operation{ON-OFF). Check A/C signal 1+59
with A/C on.
Lock-upclutch does not engage.
Shift lever cannot be moved from P Dosition with the brake oedal Checkbrakeswitchsignal. 14-60
d€oressed.
. It a customer describesthe symptoms f or codes 3, 6, or t t ,

Jeqn" I Oo--l
inaicatorlight is not blinking,it wilt be necessaryto
r€crsglg1lie symptom by tost driving,andthen checkingthe I D4 | indic8torlightwith the ignitionstill ON.
o lf the
ElJindic$gllight displsyscodesother than those liste-daboveor stays lit continuously,the TCM is tauhy.
. Sometimesthe
Lgllind;cator light and the MalfunctionIndicatorLamp (MlL)/CheckEnginelight may come on simuhaneously.
It so, chsck the PGM-FIsyst€m accordingto the number ot blinkson the MIL/CheckEnginelight. then reset the memorv bv
removingthe CLOCK RADIOfuse in the under-hoodfuse/relaybox tor more than 10 seconds.Drive the vehicle for several
minutesat speedover 30 mph (50 km/h).rhen recheckthe MIL/CheckEnginetight.
NOTE:
. PGM-FIsvstem
The PGM-Flsystem on this modelis a sequentiatmuhiport fuel iniectionsystem.
' Disconnectingth€ CLOCK RADIOfuse also cancelsthe radio anti-thett code. preset stations and the clock
setting. Get the
cuatomer'scode numberand make note of the radiopresetsbefore removingthe fuse so you can reset them.
14-37
ElectricalTroubleshooting
Soff-dirgnosis I I,a I indicstor Possib16

Caus6
lght blink. onc.--
. Oisconn6ct€dlock-up control
sol€noidvalv6 A connector
Disconnect the 26 P connec- ' Short or open in bck-up con-
tor trom the TCM, trolsol€noidvslv6 A wire
' Fauhylock-upcontrol solenoid NOTE: Vi6w f rom terminalsid6.
Turn the ignitionswhch ON.
Msasure the vohago betw€6n

th6 AO (RED/WHT)and A25
(BLK/RED) or A26 (BRN/BLK)
terminals.
Ropairthorl to power rouaca

in REDMHT wlro botwo6n
tho AO tormln l and the lock-
uDconlrol lolonold valvo A.
Measure the resistance b6-

tw€6n th€ A6 (RED/WHT)and
A25 (BLK/RED)or A26 (BRtl/
BLKlterminals.
Chcck for bo.o TCM cor|r|oc-

ls th6 resistanco
12-24 O ? torg. It nacollgry, lubrtftute
a known-good aolenoid vtlvo
assombly o. TCM ond
rochock.
Diconn6ct th6 2P connector
i.om the lock-up control sob.
noidvalve assembv.
Check tor continuity betw€on

the A6 (BED/WHT)snd A25
GLKiRED)or A26 (BRIVBLK)
tgrminsls.
Bopah lhort to ground In RED

/wHT wire betwoon tho AB
tormlml and tho bck-uD con-
trol 3olonoldvrlva A.
Mgasureth6 resistanceot the

solenoid at the 2P connsctor
(1+62).
Chock for opon In RED/WHT

fs the resistanc€12-24 A? wire between thc A6 tarmlnal
and the lock-up control roL-
nold valve A.
Rophce the bck-up cofirol

aolonoid vafuo a$ombly.
14- 3 8
PossiblsC6use
' Disconn6ctod lock-up control

aolono'xtvafu6 B connoctor
Diocomect the 26 P conn6c- . Short or oD6n in bck-uD coft
to. f.om the TCM. trolsolenoidvafueB wko
' Fauhybck-up controlsolonoil Vi6w f rom terminalside.
vafueB
Meaaur6tho vohago b€twoon

6.\ 12-24 Q7
th6 A4 {WHT/BLK) and A25 BRN/BLK-r-Y-WHT/BLK
(BLK/RED)or A26 {BRIVSLK) I V,, Voh.sa?
terminab.
Rapllr ahort to Dowar aolrca

In WHT/BLK wlr. b.twoon
ths A4 t.rmlnal lnd th. loct.
up control roLnold vrlva B.
Turn tho ignitionswitch OFF.
M€rsua€ th6 resistanc6 b€-

tweon th€ A4 {WHT/BLK)and
A25 (BLK/REDIor A26 lBFl!
BLKltormingls.
Chad( tor loota TCM connoc-

ls th€ r€sistance12-24 Q ? toaa. ll nacaltary, tubttltuta
r known-good toLnold vllva
.t!.mbly or TCM !nd
rachack.
Disconn€ctth6 ? connector
lrom th€ lock-up cootrol solo-
noidvafueassernbv.
Ch6ck for continuity betw6en

the A4 (WHT/BLKI 8nd A25
(BLK/RED)o. A26 {BRI,I/BLK)
tsrminsb.
Rapalr rhort lo ground In

WHT/BLX wh. brtw.on thr
A4 t.ri| ml rnd lha lock-uo
control aoLnold valva B.
Me63uretho rosistanceof th6

aolonoidat th6 2P connector
t1+6,4.
Ch.ck tor oD.n In WHT/BLK

ls tho rosbtance 12-24 O ? wlra baiwaon tho A4 tarmlnal
ard th. lock-up control aob"
nold v.lv.8.
R.pbc. th. bck-up control

rcLnold vtlva r'!an|blv.
(cont'd)
14-39
Flowchart(cont'd)
Troubleshooting
S.ltdlomrl! { Xr4| lndlc.tor Possibh Csus€

leht bl|rb thr..-i6.r.
' Disconnected throttl€ position
{TP}sonsorconnoctor
' Shon or op€n in TP sonsor
Turn the ignitiooswitch ON. ' FEulty TP sonsor
Chock whothor tho Malfunc-

tion Indicato. Lamp (MlL)
blinkslsse soction 111.
ls th6 MIL blinking? R.p.h th. PGM.FI Sy.t.m

{r....ctlon l1}.
Disconnoct th6 26P and 22P

connectorstrom th€ TCM.
C o n n o c tt h 6 T 6 s t H a r n e s s
"4" arfr "D" connoctora to
the wire harno$ onv, not to
the TCM 114-3$. oooooooooooo ooooooooooo
oooooooooooo ooooooooooo
Turn the ignhionswitch ON.
4 . 7 5 - 5 . 2 5V ?
Mosgursths vohsg€ b€twe6n

the D1I ard A29A26 torm'F
na|s.
R.plli op.n or rhort In LT

ls the vohago4.75-5.25 V? ORiUBLKwl.. b.tw..n th.
D I I tcrmlnll aid thc ECM.

Appror.0.5V?
C o n n e c tt h 6 T e s t H a r n e s s
"A" snd "0" conn6ctors to
tho TCM. oooooooooooo ooooooooooo
A26
Turn th€ ignitionswitch ON,
Moasurotho voltago b€twe€n

th6 D7 snd A2tA26 torminal€.
R.pdr op.n or thon In RED/

ls tho vohagbapprox.O.5V? BLK wlrr b.twarn lh. D7
tcrmlnd lnd lha TP $naor.
YES
Chack tor boao TCM connac-

to.a. ll nacoraary, aubrlhula
a known-good TCM lnd
mclract.
14-40
Selt-diagnosl. I 04 | Indlcator PossibloCaus€
llght blnk! four tm.,
' Disconnoctod v€hicl€ spood
s€nsor{VSS)congctor
. Short or op€n in VSS wir6
' FauhyVSS
R.l.J to S.ctlon 23 tor v.H-

cle speed s.nlor (VSSI l.{.
. Mak. ru16 lft!,lrckr, end lrloty stends are plac.d properly

(!oo sactlon 11,
. Sot tho parklng blaks r.cul.ly lnd block lhc rcer whccb.
. Jeck up tho troni ol the clr .nd ruppoit whh srtcty .t!rdr.
Disconnect the 26P and 22

connoctorg trom th6 TCM.
C o n n e c tt h s T 6 s t H a r n e s s
"4" and "D" connectors to
th6 wire harnessonv, not to
tho TCM {1+35). oooooooooooo ooooooooooo
Turn th6 ignhionswitch ON.
Botate the f.ont wh€61 snd

check for voltag€botweonthe
Dg and A2ryA26 terminats.
Block th6 other whe6l so it
do€s not tum,
Chock for lhort or oDon ln

Doesth€ vohageO-12 V ORI{ wh! bglwaln th. Dg tcr-
spp6arsh€rn€teV? mlnll .nd th. VSS. It wl.a lr
OK, check rh. VSS (rc.
lecllon 23).
Chack to. bosa TCM conrEc-

lor3. lf n€ceaaary,aubatftuto
a known-good TCM tnd
.echock.
(cont'd)
1441
Flowchart(cont'd)
Troubleshooting
s.fil|lno.lt I D4 | Indcliot PossibloCauE6

|!t'n b&*! tlv!-m.t.
' Sho.t in A/T g6sr position
switch wir6
Turn th6 ignhionswhch ON. ' Faulty A/T g€sr positioh
switch
Obs€rvetho A/T 906r position

indbator, 6nd saloct oach posF NOTE:
tion sopr6aat6ly. Codg 5 is causod wh6n th€
TCM rsc6iv6s two gpar posi-
tion inputs at tho 3ametim6,
Do ony irdicalors tail to So. A/T g€.r po.hlon Indl-

lightwh€n shift€dthrough €ior l.Epactlon (raa aactlon
sll positionsT 23).
Turn tho ignitionswhch OFF.
Connoct the Tost Hamoss

b€twoon th6 TCM and connoc-
tors {'l+3$.
Turn the ignhionswhch ON.

r@l Bsnery vohaoo?
a21 A25
o o ooooooooOo O I O:66irOO:fto:lG6{ticie,Olooo ooooooo o
ooooooooooooo I oogsgooc,l'g ottgoo I oooooooo ooo
426
Mo.surc tho vohago botwoen

tho A21 and A2gA28 termi
nals.
Chock to. .ho.l ln GRI{/RED wl.. b.tween tho A2l to.irjnrl |nd
ls th€re battory volta€g? th. A/T o.!r po.hlon lwhch or A/T gelr po.ltlon Indhlto.. It wlr.
l! OK, chack fof bolo TCM connoctorr. ll nacallary. aubtthula a
known.goodTCM and rochock.
.-@r Estt€rv voftaoo?

A19 A25
Msssure th6 vohag€ b€twoen oooooooooooo ooooooooooo
tho A19 ard A2tA26 tormi- oooooooooooo ooooooooooo
na|s.
Chock loJ .hort ln LT GRN wlr. belw..n tho A19 tormlnll rnd th.
A/T gelr po.ltlon Indlcltor or . lhort In GRN/IVHT o. GRI{ wlrer
b.tw..n th. A/T g€lr po.ltio.r Indlcltor lnd tho A/T golt pothlon
YES awhch. lf wlia b OK. c$acl tor loora TCM c$nactot!. lf nacoatlry,
.ubrtltut. t known-good TCM .nd r.chock.
To paga1+43
14-42
Frcm. page 1442
Battery vohag6?
r-@-r
Moasurothe vohsge betwosn
the Af7 and A2gA tetmi-
nals.
A26
Chock fo. lhon In GRN/8LKwire betwoon th. Al7 t.rmln.l rnd tho
ls thore battery vohag€? A/T g.ar polition luyitch. lf wiro is OK, chock fo. loolo TCM connoc-
tor!.It noco$ary, 3ubstllutc a known-goodTCM and.ochock.
M€asur€the vohage between

the A15 and A2tA26 termi- A26
n6ls.
Check tor.hort in GRN/BIUwlro botwoon ths A'15 torminal rnd tho

ls ther6 battory vohago? A/T gear position switch or A/T g6ai po.hlon indlcator.lf wira ls OK,
chock for looso TCM connesto''. It necersa.y, lubatliuto a known-
good TCM and rochock.
Moasurethe vohago b€twogn oooooooooooo ooooooooooo

trho A13 and 429A26 t6rmi- oooooooooooo ooooooooooo
nals.
426
Chock tor short in GRN/YELwire betwoon tho A13 t.rmlnal and the
ls th6r€ battery vohage? A/T goor posltlon swltch or A/T g.ar porition indlc.tor. lf wl.o b OK,
check lo. loor6 TCM connociors, It n6cas3!rv, subatitute a known-
good TCM and recheck.
Moasurethe voltage botwe€n
th6 A11 and A2tA26 termi- a26
na|s.
Check for short in LT GRN/W}|T wiro botw.on the A11 torminrl and
the A/T opar polition lwitch or A/T go.i po.hion indicator. lf wi.e i!
OK, chack for loose TCM connoctora. lf nocorsa.y. rubrtltuto a
known-goodICM and rachock.
Ched( tor bo36 TCM connac-

tor!. It necolsa.y, substilute
a known-good TCM and
rochock.
lcont'd)
1443
TroubleshootingFlowchart (cont'd)
Solf-dlrgno.lr I D4 I Indlcrtor Possibl€C.uso

Ight bll.I(. !h tma.
. Disconn€ctod A/T gpa. posF
tion sw?tchconnector
' Op6n in A/T g6ar position
Connoct tho Tgst Hamess switch wirs
b€tweon th€ TCM and conn6c- ' Faulty A/T 066r position
tors {1+35}. switch
M€esurstho vohage b€twoen o o oooo o oo o o o o t:ltoooojs9$:*:occD.gol ooo oo o oo ooo

th6 A21 6nd A29A26 termi- o oo oo o oo o o oo o l,(to.ooogrri6:{lifxl{lotllt:lo oo oooo o oo o
nab.
R.pdr op€n In GR /RED wlr.

batwaan th. A21 tarmlnal
lnd th. Al g.!r po.ltlon
rwhch.
M€ssuroth6 vohag€ b€two6n

the A19 and A2tA26 te.mi-
nals.
Rcprlr opln In LT GB wl..

b.two.n th. A19 tormlnC
and th. A/T g.!r po.lllon
hdlclto..
To psg€1+45
14-44
From p.g6 1/+-44
Voh6g.?
Measur6ths vohago botwaon

tho A17 dld A2dA26 r6rmF ooooooooOooo ooooooooooo
nab. oooooooooooo ooooooooooo
R.p!h op.n ln GRN/8L|( wiro b.tw.cn th€

A17 t.rmln l .nd tho A/T g6a. polhlon
.wltch,
Volt.go?
Mo!8urotho vohag€botweon oooooooooooo ooooooooooo

th6 415 ard A2gA26 tsrmi- oooooooooooo ooooooooooo
nab.
Ropll op.n In GRT BLU wlro betw..n thr

Al5 t.rmlnll ..rd th. A/Y 96r. l|orhlon
!wltch.
Vollrg.?
Moasuro the vohago t atweon oooooooooooo ooooooooooo
th€ A13 sd A2dA28 t6.tr*
n6b.
R.pllr op.n In GRT YEL wl.. b.tw.en tno

413 t.rmlnll rnd lh. A/T g€ar polhlon
twltch.
Voh!96?
Meaguretho vohago bgtwoon
th6 A11 and A2ryA28 termi-
nab.
R.pllr op.n In LT GRN/WHT wlra

b.tw..n tho All t.rmln.l .nd tho A/T
gclr poohlon lwhch.
Chact lo. loo.. YCM codr.c-

tora. lt nacaaaary. lr$atltuta
t known-good TCM .nd
rochodr.
{cont'dl
1445
Flowchart(cont'd)
Troubleshooting
Possibl€Caus€
. Disconngctod shilt control

solonoidvafu6A connector
Disconnoctths 26P connsctor ' Short or opon in shift control
trom th6 TCM. solsnoft,valve A wire
' Fauhy thift control sol€noid
Turn th6 ignitionswitch ON. {rslK-l 12-24 A?

6\
BLK/RED ___r_5_ _
BLU/YEL
Moasureth6 vohag€ b€twson
tho A5 {BLU/YEL} ANd A25
GLK/REo) or A26 (BRII/BLK)
t6rminals.
Roplir ahon to powai loulca

ln BLU/YELwh. botw.en tho
A5 tordml ard thc lhlft con- NOTE: View from terminals'Nls.
trol loLnold valvc A.
Turn tho ignitionswhch OFF,
M6aure the resistanco b€-

tws6n th€ AS (BLU/YEL)snd
A25 (BLK/RED)or A26 (BRiU
BLK)t6rminals.
Chock fo. loo.. TCM codr.c-

ls tho resistanc612-24 Q ? tor!. lf naceaaary, rubltlistc
! known-gpod lolonold vllvo
lrtambly or TCM rnd
iechack.
Disconn€ctth6 3P connoctor
trom the shift control solonoid
valvs assombv.
Chgck for continuity bstw€on

th€ A5 (BLU/YEL}8Nd A25
(BLK/RED)or A26 (BR|I/BLK)
t6rminals.
Ropllr rhort to g.ound in BLU

/YEL wlro botw€en tho A5 tot-
rnlnll and th6 lhllt corttol
aolenold vllvo A.
Measur€th€ resistanc6of tho

solgnoid at the 3P connsctor
{1+63).
Ch.ck tor opon In BLU/YEL

fs the r€sistsnce12-24 Q7 wlre botwoon the A5 tormlnal
.nd tho rhlfl comrol lolenold
valva A.
Roolace lho !hlft control

sobnoid valvo a!!€mblY.
14-46
Self-diagnoli3 | D4 Indlcator PossibhCause
light btnkr oight tlm.s,
. Disconn€ctod shitt control
solenoidvalv6 g connoctor
Disconnectth€ 26P conn€ctor ' Short or opsn in shift control
trom the TCM. sol€noidvalvo B wire
' Fauhy shift control solonoid
vslv€ B
Measurethe vohag€ b€tween

th6 43 (GRN/YEL)snd A25
(BLK/RED) or A26 (BRN/BLK)
lermanals.
Ropllr rhort to powar tource

In GRIIUYEIwlro botw..r th.
A3 termln.l and rhlfl coDtrol NOTE: View from t€rminalsid6.
lolenold vrlvo B.
Measure th€ resistance be^

tween the 43 (GRN/YEL)and
A25 (BLK/BEO)or A26 (BRll/
BLK)terminals.
Chack for bolo TCM conn.c-

ls th€ resistsnc612-24 O ? to.r. It noco$ary. lubrtltuto
a known-good roLnold valvo
!rrembly or TCM ond
rachack.
Disconnsct the 3P connoctor
lrom the shift control solonoid
vave assembv.
Chsck tor continuity bstw€en

the 43 (GRi.i/YEL)and 425
(BLK/RED)or 426 {BRN/BLK)
t6rmrnals.
Rcpalr rhort to g.ound In GRN

/YEL wlr. b.twe.n lhe A3 ter-
mlnal and the lhift control
lolonold valvo B,
Measureth6 resistanceof the

solenoidat th6 3P conn€ctor
(1+63).
Chock to. oD.n ln GFTUYEL

ls the rosistance12-24 O ? wl.g botwoon tho A3 tormlnal
and the lhlfl conlrol lolonold
vllvo B.
Replaca the 3hilt control

lolonold valvo a$amblv.
(cont'd)
14-47
S.ltdl.g|lorl! | Da I lrdlcltor Possibl€Cause

lghtbtr*.nln.-il-m...
' Loose or falhy connoction
b€tweon th€ TCM and car har_
ness.
' Disconn€ct6d count6rshatt
gpoedsonsoaconnoctoa
' Shon or op€n in tho count6t_
shaft sp€edsenaorwire
' Fauhy countorshaft sp€€d son-
sot
ls tho coumsGhaft sposd

s€nsorinstalledproporv?
Disconnsct th€ 2P connoctor

Irom tho count€rshaft spood
sensorconnector,
Moasureth6 rosistancoof th6

countsrshaftsPeeds6nsor.
lsthe r€sistance
400- 6@ o ?
(at7OoF.2OoC)
Cootl lty?
Disconnecttho 22P connoctor
from th€ TCM. Connoct the
"O" connoctoa
Tost Hsrn6ss
to th€ wir6 harnossonlY, not
to tho TcM {14-3$.
Check for cottinuitY betwoon

body ground8nd D17 torminsl
and D15 terminalindividuslly.
R.o.l. rhort In BLU/GRN or

BLU/YEL wlr. b.tw..n D17
lnd Dl5 tcrmlnaL and lh.
coumorrhaft apead tdrtor.
Roconn€ct th6 countershoft

sp6edsensorconnector.
To pdss1+/{)
14-48
From pag€ 14-/18
400 -600 0?
l\teaaurc thg roaisttnco bo-

tw6€n Dl7 E ld Dl5torminah.
Rapllr boaa tarmlnrl or opan

b th6 a6!iat6nc6 In BLU/GR o. BLU/YELwlr.
4@-8(D O? b.tw...r D17 did D16 farrt-
lar 7OoF,
2OoC) nala |r|d tha coumarlhnft
apaad lanror.
Chad( for loa. TC co.rrc-

ior. lf r|.c...Jy, rubathul. .
lnown-good TCM lnd
rachad(.
1449
Solt-diagnoslsI D4 | indicatoi Possibl€Cause

lghl blinks tont-ime..
' Disconnacted engine coolant
t6mperature (ECT) sensor
Turn the ignitionswitch ON. connector
' Short or op6n in th€ ECT
sensorwire
' FauhyECTsensor
Chock whethor the Malfunc_
tion Indicator Lamp (MlL)
blinkslse6 section 11).
Booah lho PGM-FI Syttem

l!.o 3oction 111.
Turn the ignitionswhh OFF
Disconnect the 26P and W

connectors lrom the TCM.
C o n n e c tt h e T e s t H a r n e s s
"A" and "O" connoctors lo
th€ wire harnessonly, not to
the TCM(14-35).
A?5
Turn tho ignitionswitch ON. oooooooooooo oooooooo
Measurethe vohage betwoen

the 018 ard A2tA26 termi-
na|s.
Ropair opon or rhort in LT

ls the vohag64.75-5.25V? GRN/BLKwir. botween the O
18 t.rmin6l and tho ECM,
C o n n 6 c tt h e T 6 s t H a r n e s s oooooooooooo ooooooooooo
..A,. and ,,D,, connectols to
tho TCM.
Start th€ engino and warm it

up to normalop€ratingtemper-
ature (the radiator fan comes
on).
Measurethe voha96 betwoen

the D5snd A2ryA26 terminals
Ropoil opon or short in YEL/

'lV? BLU wiro botvvsenthe D5 tor_
ls the vohagel€ssthan
mlnrl and th6 ECT!on3or.
check for loolo TCM connoc_

tor!. ll noce!.s.Y, subatitut6
a lnown-good TCM snd
aactEck.
14-50
PorrlbL Caula
. Disconn6cted ignition coil

connocror
. Short o. opon in ionhioncoil
Oiaconngct the 26P connector
from tho TCM. . F6uhyignhioncoil
Turn ths ignitionswhch ON.
Moasurotho vohago botwoon

tho A9 IBLU and A25 (BLK/
RED) or A26 {BRN/BLK)
torminab.
Vi€w trom l€rminal6id6.
Raprl? opon or .hort ln BLU

wh. b.tw.on tho A9te.mlnal
lnd tho lgnhloncoll.
Chod. fof l@q. YCM con-

lracto.a. lf naca$lry, tubttl-
tqt. a known.good TCM lnd
aachad(.
14-51
Flowchart(cont'd)
Troubleshooting
s.||d.enodt I D4 | Indlcato. PorrlbL cluto

leht bld.. to|rtTi'tlmrt. r Make sure llfts, iacks and satety stands 416
Shortor openin FAS{OBiY placed propsrly, and hoisl blackots aro
RED)wi.€ attachad to the corl6c-t position on tho ongino
Troubl€in ECM (seosection 1).
. Whlle testing, bo caroful of the lotatlng flont
wheels.
15ths Maltunction hdicator n.o!L th. PGM.FI SYltem
L.mp (MlL)on ? (r.. !.ctlon 111.
Start th€ ongin€ and wtrm it

up to normal operrlino
temp6ratuao{tho rsdiator fan
comesonl.
Approx.5 v?
Turn tho ignitfttnswhch OFF. oooooooooooo ooooooooooo

oooooooooooo oooooooQooo
Connoct th6 Tolt Harnoss

botwo€n th6 TCM tr|d coonec-
tor3 (1+351.
Turn the hnition swhch ON

a.d wait Ior at l6aat two
ggcotxt5.
l\reaaurethe voh.go tgtweon

the 016 {+) rnd A2gA26(-l
torminab.
Ch.d( to. l@a TcM con-

rrcto.r, ll nacortxy, !t btti-
tul. ! known-good TCM and
rcch.ck.
Turn th6 ignitionswitch OFF.
Dkconnoct ths ToEt Haangss

from tho TCM.
L66ve conn6ct6d lo car
n6anoa8.
switch ON.
Turn th6 i{tnit'ron
To prg61+lB
14-52
From pag€14-52
Msasurgth6 vohago botwoon

the D16(+) and A2gA26(-)
torminab.
Ch.ck tor bola TCM corr

nacto[. lt ]raca$ary, rubtd-
tut. ! known-good TCM ard
rachack.
Disconnoctthe 26P connector

from th€ ECM.
Check for continuity b€tw€sn

the D18 and A25lA26
torminalsot th€ Test Harn6ss.
R.o.h .hort ln OR /RED

{FAS} wh. b.tw..n Tcltl
lnd ECM.
Ch6ck for continuity on tho

ORÎ/REOwire botween the D
18 t€.min8l on ths TCM snd
tho AlStorminalontho ECM.
Ch.d( tor loot! TCtt oo.r

nactora. It nacattary. tubttl-
tuto r known-gogd TCM and
rcchack.
R.p!|. lhoit In OR /REO

(FASI wlr. b.tw..n TCM ..d
ECM,
(cont'd)
14-53
NOTE:
Po.rlblo C!u!. A cod€ 15 on th€ TCM doesn't th/vay6msan th6re'e an
sl6ctricsl probl€m in ths main8h.ft or countorahatt
. Disconnectodmainshaft sp6€d sonsor circlh; code 15 may 8bo indicato 6
9pe6dsonsorconnector mochanicalprobl€min th€ transmbsion.
. Shon or op6n in mainahaft
sp€€dSonsorwilo
. F6uhymainshaftsp66d
€0nsoa
Ars th€ mainshstt and

count6rshaft sPsed senaors
install€dproperly?
Disconnectthe 2P connector
trom th6 mainshaft spood
s6nsor.
M€asur6th€ resistanceof the

mainshrft spoodsengor.
ls th€ rssistanc€4OO-
600 O 7 (6t7OoF,2OoCl
Disconnectth€ 22P conn6ctor

trom th6 TCM.
C o n n 6 c tt h e T o s t H a r n o s s
"0" conn€ctor to ths wire
harnoss only, not to thg TCM
(1+35). ooooooooooooo ooooooooooo
ooooooooooooo ooooooooooo
Ch6ck th€ continuity botwoen

D19 and D12 torminalsand
body ground.
Ropllr lhort In O8N/8LU or

WHT/BLU w1..3 b.tw..n D
19 and Dl2 t.lmlnab lnd lhc
rmlmhlfl apaed tanaoa.
Roconnsct the 2P connoctor

to th€ rnsinshdftapeodsonaor'
To psg€ 1+55
14-54
From p6ge1+54
D' l I
Measure th€ resistance ooooooooooooo ooooooooooo
between D19 and O12 ooooooooooooo ooooo9ooooo
t€rminals.
400-600 0?
ls th€ resistance4OO- Chgck tor corninuity between
600 Q ? lat 70oF.2OoCl D19 terminal and the
mainshaft sp6edsensor.
R.palr op.n in ORN/BLUwi.e

batwaan D19 t..min!l and
tha malnlhatt spcad r.n!or.
Ch6ck fo. continuity b€tw66n

O12 terminal and th6
mainshaft spg6dsensor.
Rep.ir opon In WHT/BLU wlro

botwaan D12 tormlnal and
tho malnahlft rDoodlanror.
Run El.clricsl Troublc- Ch.ck tor loor. TCM cor!

rhooting to. codc 9. nacto6. It nacalatry, aubrtl-
Ch.ck tor looro TCM cfi- tute t known-good TCM and
necto.. It necsrrlry. rubatl- rachack.
tuta ! known-good TCM lnd
rochock,
(cont'dl
14-55
TroubleshootingFlowchart {cont'd)
I or I tndicator llght do.t not

6-m. oo with the lgnition
3vYttchON. lh thouH c!m. on
lor gbout 2 aocond!.)
Ch.ck lo. bot. TCM connac_

Does tne @ indicator lhhl tola, lf nacoraary, aubllltut.
r known-good TCM lnd
Echrck,
Turn the ignitionswitch OFF
Disconngctthe 26P connector

{rom the TCM.
connect th6 T€st Harn6ss
"A" connector to tho wire
harnsss only, not to the TCM
(1+35).
Cor ollty?
Check for continuity b€tweon

rhe A25 lorminal and bodY
ground and 426 and body
ground.
R.Drl, opon BLK/REDo. BR /

BLK wirc. b.tw.!n A25 ot A
20 t.rrnln.lt .nd GI 01 .
Turn tho ignitionswitch ON. [P oattc,vvatecr

A23A25
Measurethe vohage betw€on

th€ A23 or A24 and A25 or A
26 t€rmlnals.
R.prlr opon o. lhon In BLK/

ls thers batterYvohag€? YEL wlr. botwoon tho A23
andloJ A24 taamlnala and
YES undo?-hoodf uaa/r.ltY box.
To psge 1+57
14-56
From page1+56
C o n n 6 c tt h e T 6 s t H a r n e s s
"A" connsctor
to the TCM.
oooQoooooooo ooooooooooo
Be sure th6t voltago is A8 A25
Lo-.._----J
availabl6 tor 2 seconds
b6tween the Ag terminal and Voh!ge?
A2gA26 t€rminal.
Chack lor opan or ahort In

GRN/OR wlro betwe.n tho
AB tormlnsl ond tha gaugo
a!!omblv.
Turn ths ignitionswhch OFF.
Oisconngct the T€st Hsrness

"A" connector
from the TCM.
Check ior cominuhy between

th6 A8 t€rminal and rhe GRI/
ORN wiro at the gauge
assemDry.
Ropairop.n In GRwOnN wh.

betwo€n the A8 tormlnll .nd
tho gaug€llrombly.
Chod( for loo6o TCM connoc-

tor!.
Ch.ck tho A/T gear po!ftlon
awftdr. lf noco3aary, aubstl-
tut. I known-good TCM and
rechock.
(cont'd)
14-57
I D4 I Indlc.tor llght It on
;i--adY {not bllnllng}
whon.vd th. lgnltlon twttch
b oN.
Turn tho ignitionswitch OFF.
oisconhoctths 26P connoctor

trom the TCM.
C o n n o c tt h o T 6 s t H a r n e s s
"A" coonectoa to the wiro
harngssonv, not to the TCM.
(1+35).
Iurn the ignitiooswitch ON.
Measuroth€ voltago betwoen

th6 A8 torminal and bodY
ground.
C o n n 6 c tt h o T o s t H a r n 6 s s
"A" connectorto the TCM.
Moasureth€ vohag6 b6tw69n A8

the GR[{/ORN wir6 at th6
gaug6 assembt and to bodY
gaouno. I Volt.gc?
RaDllr rhort to powot toutco

oo G8N/ORNwlr. brtweon A
8 tarml[l and lEugp a!!em_
blv.
14-58
l.Ep.ctlon ot rh. A/C tlgnll. Symptom
. Lockrp chnch doos not havo

duty opo.dtion(ONe OFFI.
. Lock-up chjtch do€s not
eng6g6.
Tu.n tho bbwer switch ON.
Pu3htho A,/Cswitch ON.
8c. Alr Condhlonlng Inrp.ctlon

(... r.cilon 22).
NOTE: trom torminalsid€.
Disconnoctth6 26P connector

from th6 TCM.
Measuroths vohag€ botweon RED/BLU

the A22 IRED/BLU)6nd A25
IBLK/RED)or A26 {BRwBLKI Eanaryvoltage?
tsrminals. {A/C comDaealror
OFF)
Rcpah open lo RED/BLU wlr.

b.tw..n th. A22 t.rmln.l and
A/C compr.$or clutch rcLy.
'A/C.ler|llbOK.
' CH( lo. loor. TCM corF
.racto.a, It nacaaatay, ar5.
.inul. a Lnown-good TCM
and rachack.
' lnlD.ct th. .lr cor|dtlonftt
(!.. r.ctlon 22,.
(cont'd)
14-59
Svmptom
Shift hv6r camot bo mov6d

irom E position with tho
brako p€d6ld6prsssed.
Ch6ck that the brak€ lights
come on with the brake P€dal
dopressod.
Disconnect the 26P and 22P

connectorsfrom the TCM.
C o n n e c tt h e T o s t H a r n e s s
"A" and "O" connoctors to
th6 wil6 harn€ssonly, not to
the TCM (1+35).
oooooooooooo oooooooooo
ris ^ D2
Moasuroth6 vohagg betwoon t_----{}-
th6 02 and A2tA26 termin3k Baitery voh.g.?

with the br6ko Podal
depresssd.
Rrplh op.n In GRN/WHT

wlrc b.lw..n lh. D2 t rmlnd
and b]ak. lwhci.
' Br.ko rrvhch tlgnal OK.

. Chod( for loot€ TCM con-
nacto.r. lf nocoltary, tub_
rtltuto a known-good TCM
and rcchack.
. lnrDoct the brgka twhch
circuh {!.a aociion 23}.
14-60
Mainshaft/Gountershaf
t
SpeedSensors
Replacement
1. Remov€the 6 mm bolt f.om th€ transmissionhousing

and remove the mainshaft and countershaft soesd
sensors.
COUNTERSHAFT 6 x 1 . 0m m
SPEEDSENSOB 12 N.m {1.2 ks-m , g b-tt}
o-R[{GS
R€plsc6. 6x1.Omm
12 N.m (1.2 ks-m , I lb-ft)
MAINSHAFTSPEEDSE SOR
Replac€the O-ringswith a new one before reassem-

blingthe mainshaftand countershaftspeedsensors.
14-61
Lock-upControlsolenoidValveA/B
Test Replacement
NOTE: 1. Remove the mounting bolts and lock-up control

Lock-up control solenoidvaves A and B must be removed/ solenoidvalve assembly.
reDlacedas an assembly.
NOTE:
1. Disconnect the connector trom the lock-up control Be sure to r€move or replsce the lock-up control
solenoidvave A/8. solenoidvakes A and B 8s an assembly.
2. Measure the resistsnce between the No, 1 terminal 2, Check the tock-up control solenoidvalv€ oil passages
(solenoldvalve. A) of the lock-up control solenoid for dust ot din, 8nd replscs 8s sn sssembv, if
valve connector and body ground, and between the necessarv.
No. 2 terminsl (solenoidvalve B) and body ground.
LOCK-UPCONTROL 6r1.0mm
SOLENOIDVALVE 12 N.m {1.2 kem , 9 lb-ft)
ASSEMBLY
STANDARD: 12- 24Q
LOCK-UPCONTROL Cloanth€ mountingaurface

SOLENOIDVALVE andoil passag68.
ASSEMBLY FILTER/GASKET
Roplac6.
ReDlacethe lock-uDcontrol solanoidvatue assemblyil

the resistanceis out of specification. Clean the mounting surface and oil psss€gesof the
klck-up control solenoidvslve assembly,8nd install I
lf the resistanceis within the standard, connect the new tilter/gasket.
No. 1 terminal of the lock-up control solenoid valve
connector to the batterv positive terminsl' A clicking Check the connector for rust, dirt or oil, and racon-
sound shouldbe he8rd. Connect th€ No. 2 terminsl to nect it securely.
the battery positive terminsl. A clicking sound should
be heard. Replacethe lock-up control solenoidvave
assemblyif no clickingsound is heard'
14-62
Shift ControlSolenoidValve A/B
Replacement
NOTE: 1. Removethe mounting bohs and shift control solenoid

Shift control solenoidvalves A and B must be remov€d/ vafueassamblv.
reolacedas an assemblv.
NOTE:
1. Disconnect the connector from the shiJt control Be sure to remove or replacethe shift control solenoid
solenoidvave A/8. valvesA and B as an assembly.
2. M€asurethe resistance between the No. 1 terminal 2. Check the shift control solenoidvatue oil passagesfor
(solenoidvalve A) of the shitt control solenoidvalve dust or dirt, and replaceas an assembly,if necesssry.
connactor and body ground, snd between the No. 2
terminal(solenoidvalve B) and body ground.
6x1.Omm
12 N.m11.2kg"m, 9 lb-ft)
STANDARD: 12- 24Q
Cl6anthe mountingsurfac6
and oilpass€gBs.
FILTER/GASKET
R6placs. sHtFTCOI{fROL
SOLENOID
VALVE
ASSEMBLY
3. Clean the mounting su ace and oil passagesof the

shift control solenoidvalve assembly,and installa new
fiher/gasket,
4. Chsck the connector for rust, dirt or oil, and recon-

nect it securely.
Replacethe shfft control solenoid valve assembtyif

th€ r€sistanceis out of soecification.
lf the resistsnce is within the standard, connsct the

No. 1 terminal of the shift control solenoid valve
connector to the battery positive terminsl. A clicking
sound shouldbe heard.Connect the No, 2 terminalto
the battery poshive terminsl. A clicking sound should
be he8rd. Replace the shiJt control solenoid valve
assemblyif no clickingsound is hesrd,
14-63
Chart
HydraulicSystem
Checktheso items on ths Check these items on th8
SYMPTOM PROBABLECAUSEList NOTESList
Emine runs, but.car oasnot move m anYgaar."D+" K, , . R , S

Car movos in
"8" and "2" but not in "Dg"
, , or "1" a,8,44,4a c,M,o
oosition.
"Ds" "D1" "1" "R" but not in "2" 9, 30,49 C,L
Car moves n , , , ,
Dosition.
"Ds" "Dt" "2' "'1" but not in "R" ,22, 34,34,39,&
Car moves in . , , ,
Dosition.
''Dosition.
C8r moves in "N .4
Excessiveidlevi )rauon.
liosin 8 oaars.
"1"
No enqinebrakinqin Dosition.
os in 1st oe8r,
rs in 2nd qear.
rs in 3rd gear,
lios in 4t n oear N
SliDsin reversegsar.
Flsreson uos
Flareson 2-3 uDs t .
Flareson 3- uos
No upshift; transmissionstays in 1st gear.
No downsh ift to lst qeat
Late upshift.
Erraticshittins.
Harshshi t {uDand down s
Har tn-
t 12- 4 i.H
Har t(3
Harshkick-dowr 2
h kick-down shi
Harshdowns 8t closedtl
Har h shift when manuallvs ngto "1" Dosition.
Axle s) slipsout of transmissionon turns.
Axle sl stuck in transmission.
"R" position.
Ratc ns noisewh€n shifting into
"R posrtion.
Loud ooooinono sewhen takins off in
"R" to "P" positionor 38,39,40, 45 L,O
Ratcheting noise wh8n shifting from
from "R" to "N" oosition.
Noisefrom transmissionin all selectorl€ver positions,
Noise{rom transmissionon v when wheeF are rollrnq. .4i
Gesr whine, rom relsted (Ditchchanseswith shi ,41
Goarwhine.sDeed16 tangeswnn spee(
"D4"
Transmissionw nor s to 4th qesr in Dosition,
.ock-uoclutch does not lock-up smool 7
.ock-uDclutc r does not oDerateDroDel
Transmissionhas multitudeof problemsshifting. 43 L,O
At disass€mbly,large particlss ot metsl are found on
maqnet.
14-64
PROBABLE
CAUSE
Shift cablebroken/out of adiustment
2. Throttls cabletoo short.
Throttls cabletoo lono.
4. Wronq tvoe ATF.
5. e rDmtoo low/hish.
il oumDworn or bindino.
7. ressurerequlatorstuck,
e st clutch defective.
nd clutch defective,
3rd clutch defective.
clutch defective.
st-holdclutch d6fectivs.
Mainshatt,countsrshatt,and s€condarvshatt idlsrq6arsworrvdsmaosd.
Modulatorvalve stuck.
e vafueB stuc
TF strainercloqoed.
oroue converter defective.
oroue convgrter check valvs stuck,
- 2 shift vefue stuck-
shift valve stuck.
2 shift valve stuck.
z orvo control vSlvestuck.
2i ftch oressurecontrol (CPC)valve stuck.
2nd oritice controlvalve stuck.
Ori{icecontrol valve stuck,
3-2 kickdown velve stuck.
z 3rd kick-down valve stuck.
4th exhaustvalve stuck.
st accumulatordafectivs.
nd accumulatordefective.
3rd accumulatordefective.
3i 4th accumuletordefective,
st-holdaccumulatordetective.
ervo vave stuck.
35. ock-uo timinq valve stuck.
2A ock-uo shit'tvalve stuck
37. ock-uo control valvs stuck.
38. Shift tork bent.
39. Reveraeqearsworn/damaoed{3 qsars}.
€versesebctot worn.
4 rd q6arsworn/damaqed(2qesrs).
4 inaloearsworn/damaqed(2 osars).
4i DitferentialDinionshaft worn.
4 esdoiDeO-rinqbroken,
r searsworn/damased(2ssars).
eat cl€aranceincorgct.
47. Clutch clssranceincorrect.
ne-way (soraq)clutch dsJective.
ealinqrinqs/quideworn.
t. Axl€-inboardioint clip missino.
14-65
Ghart
Symptom-to-Gomponent
HydraulicSystem (cont'dl
The followingsymptoms can be caused Checkth€ssitemson th6 hsms on th6

by improperr€pairor assembly. PROBABLE CAUSE DUE NOTESList
To IMPROPER REPAIRList
)ar creeosin N Dosition.
"D3" or "D4" position.
)ar do€s not move in
ransmissionlocks uD in "R" position.
(cgssivedraqin transmission,
ve vibration,rom r€
Noisewith wheels movinoor R
n aeal DoDsout.
ariousshiftins problems.
HarshuDshifts.
PROBABLE
CAUSEDUETO IMPROPER
REPAIR
14-66
NOTES
A. Seeflushinqprocedure,Daqe1+142snd 143.
R Sst idle rpm in gear to specitiedidle speed.lf stillno good, adjust rnotor mounta as outlinsd in enginesection
ol service manuel.
lf th€ l8roeclutch oiston O-rinois broken,insoactthe Distonqroovefor rouqh machininq.
D, It the cfutch psck is seizedor is exceasivelyworn, inspect the oth€r clutchgstor wear, and chsck th6 orifice
controlvefuesand throttle valves for free movem€nt.
lf throttle valve B is stuck. insoectthe clutchesfor wear.
lf the I - 2 shift v8lve is stuck closed,th6 transmissionwill not upshift. lf stuck open, the transmissionhas no
lst oaer.
th€ 2nd orifice controlvalve is stuck, insDectthe 2nd and 3rd clutch oscks tor wear.
th€ oaificecontrol valve is stuck. insDecttho 3rd 8nd 4th clutch Dscksfor wear.
the clutch oressurecontrolvalve is stuck closed.th€ trsnsmissionwill not shift out of lst qe8r.
K. lmpropor alignmentor main vav€ body snd torqus conv€rt€r ho$ing may causo oil pump seizure.The
svmbtoms er6 mostlv en rom-rdletgd tickino noise or d hioh-Ditchod sdueek-
tf the ATF strainer is clog€edwith particlesol steelor aluminum,inspoct the oil pump 8nd diff6rentialpinion
sheft- lf both 616OK snd no caus6lor the conteminetionis {ound. roolecethe tordua convertor.
M. lf th€ lst clutch feedpipe guide in the right sida cover i8 scorod by the secondaryshaft, insp€ct tho ball
be8ringlor €xc6ssiv6mov6m6ntin tho transmissionhousing,lf OK, roplacoth6 right sid6cov6r as it is dsntad.
Th€ O-rinound€rtho ouideis Drobablvwo.n.
N. Replacothe mainshaftiJ the bushingfor th€ 4th feedpipeis looseor dsmag€d.
lf th6 4th {eedpipeis dsmsgedor out of round, roplacsit.
Bsplsceth€ countershaftif the bushingfor the 1st-hoHfgedpipeis loossor dsmsged.
lf th€ 1si-hoHfeedpipeis damagedor out of round,replac€h.
Rsplacethe secondaryshaft it the bushingfor the 1st feodpipeis looseor damgod.
lf the 1st f66doiDeis damaoddor out of round.rsDlacsh.
o. A worn or damagadspragclutch is mostly a result oJ shitting the transmissionin "D3" or "D4" posrtionwhile
the wheels rotato in aoverse.such as rockinothe caain snow.
nsDectthe frame tor collisiondamase.
Inspectlor damageor wear:
1. Reverseselectorgearteeth chamfers,
2. Engsgementteeth chamfersof countershatt4th snd revsrseg€ar,
3. Shift fork for scuff marks in center.
4. Differentialpinionshatt lor wear under piniongears.
5. Bottomof 1st-holdclutchfor swirlmsrks.
Replaceitems 1, 2, 3 and 4 it worn or damaged.lf transmissionmskes clicking,grindingor whirring noise,also
replacemsinshaft4th gear and reverseidlergear andcountershsft 4th gear in additionto 1, 2, 3 or 4,
lf differential pinion shaft is worn, overhaul differential€ssembly,and replsceATF strain6r,and thoroughly
cleantransmission,flush torque convartsr, cooler and lines.
lf bottom oJ 1st-holdclutch is swirled and transmissionmakes gear noise, replaceth€ countershaft and tinal
driven oeer-
R. 86 very careful not to damagethe torque converter housingwhen replaclngth€ main bsll besring.You may
also damagethe oil pump when you torque down the main valve body. This will resuh in oil pump seizureif
not detected.[Jseorooertools.
s. Installthe main s6alflush with the torque converter housing.lf you push it into the torqus converter housing
until it bottoms out. h willblock the oil return Dassaoeand resuftin damaoe.
r. Harsh downshifts when coasting to a stop with zero throttle may be cauaed by a bent-in throttlo valve
retainer/camstooDer.Throttle cablesdiustmentmav clearthis Drobl€m.
U. Check if servo vatue stopper cap is installed.lf it was not installod,th€ check vave may have been pushed
out bv hvdraulicoressurecausinoa leak (internal)atfectinq sllforward qears.
Throttle cable adjustmentis essentialfor proper operation of the transmission.Not only does it sffect the
shift points if misadjusted,but alsothe shift qualityand lock-upclutch operation.
A cable adjustedtoo long will resuh in th.ottle pressureb6ingtoo low for th6 amount of enginetorque input
into the trsnsmissionand m8y causeclutch slippage.A cablesdjustedtoo short will resuttin too highthrottle
oressurewhich mav causeharshshitts, erratic shitts andtorque conveter hunting,
14-67
RoadTest
NOTE:
Warm up the enginsto normsloporatingtemperature(the radiatortsn comes on).
position while
1. AppV parking brake 8nd block th€ wheels. Start the engine, thon mov€ the selector lever to @]
depressingth€ brak6 pedal.Dopressthe accelaratorpedaland releaseit suddenly.Engineshouldnot stall.
2. Repeetsametest in I D3 l poshion
3. ShiJtthe selectorlev-ertol Dn-lpositionand check that the shiJ'tpoints occur at approximatsspeedsshown. Also check
for abnormalnoiseand clut-chslippage.
NOTE:
Throttle positions€nsorvoltagBtepresentsth€ throttls opening.
- 1. Connectthe Test Harnessbetween the ECMand connector (seesection 11l'
-2. Set the digital multimst€r to check voltage betw€en Dl1 (+) terminal and D22 {-) t€rminal for the throttle
posiiionaenaor.
CAUTION:
. Al SRS oloctrlcal wldng harnot3as aro covolad whh yelow
outor Inrulatlon.
. Bololo dsconnecllng tho SRSwlro herna$, Installtho short
connoctor{ll on tho !lrb.g(!}.
. Replac6tho or|tlle sffocted SRS hlrnoss ass.mblY if h has
an opon chcuh or damrgod wlring.
SRS MAI'{ HARI{ESS
DIGITALMULTIMETER
KS_AHM_32
14-68
F22Al Engln.:l Da I Polhlor
1st+2nd 2ndJ3rd Lock"up

Cinchof'l
Throttlo polhlon lorEor voltago: mph 13- 15 26-24 36-40 l4-17

o.83V
Coaatlngdown-hll from a stop km/h 21-24 42-45 58- 64 23-27
Throttlcporhlonlomor vohago: mph 17- 2'l 37 -4'l 57-63 6 1- 6 7
2.'t8V
Accobratlon from a stop km/h 27-34 60-66 92-101 98- 108
Fu[throttlo mph E-34 60-65 88- 94 8t -86
AcceLrltlon from a stop km/h 47 -55 97- 105 142-'151 130-138
Dowruhltt Lock-up
Clutch
oFF 4thJ3rd 3rdJ2nd 2nd-+ l st
Throftlo porhlon sg]lor voltego: mph 13- 16 18-22l4tHld) 6- 10

o.83V
Corstlng
or braklng
to ! stop km/h 2't-26 E-35{4thrhdl 10-16
Throttb po3ltlon lsmor Yoftago: mph 53- 59
2.18V
When car is sbwed by increr3od
grldo, wlnd, oic. km/h &5-95
Fd-throttlo mph 77-82 76-42 52- al 2'l -26
When car lr tbwed by Increased
grada,wlnd, etc. km/h 124-132 123-132 u-92 34- 42
{cont'd)
14-69
RoadTest
(cont'd)
H23Al Engine:I Da I Position
'Upshift lst-2nd 2nd--r3rd 3rd -,4th Lock-up

Clutch
0N
Throttlepositionsonsolvohago: mph 13-15 26-A 36-40 14-'17

o.83V
Coastingdown-hlllfrom a stop km/h 42*45 58- 64 23-27
Thlottls positionsensorvohago: mph 1A-22 36-40 54-60 58- 64

2.18V
Accalorationfrom I stop km/h 29-35 58- 64 87 -97 93- 103
Full-throttle mph E-34 57-62 &l-88 s-85

Accelerationtrom a stop km/h 47-55 92- 100 134-142 l?9-137
.Downshift Lock-uD
Clutch
oFF 4th-J3rd 3rdJ2nd 2nd+lst
Thlottlepositionsensolvoltago: mph 13- 16 18- 22(4thJzd) 6- 10

0.83V
Coasling 01 blaking to a stop km/h 21-26 29-35{4th+hd} 10-16
Throttle position 3onsorvohage: mph 48-5/.

2.18V
wh6n car is slowed by incleased
grado,wind. otc. km/h 77-47
Full-throttlo mph 73-& 73-79 51-56 24-A

When car is slowed by Incroased
grade,wind, etc. km/h 117-lE 1 1 7- 1 2 7 82- 90 39- 47
4. Accelersteto about 35 mph(57km/h) so the transmisionis in 4th, then shift lE+-Jpositionto f Z-l position.The car should
immediatelyboginslowingdown from enginebraking,
GAUTION:
Donotshifrtrom-Ioi lor lE-l position at sposdsover63 mph(1ookm/h];youmeydamaso
to E-lor F-l posltlon
the transmission.
5. Check lor abnormalnoiseand clutch slippagein the following positions.
L! ] {lst Gear)Position
-1. Acceleratetrom a stop €t lullthrottle.Checkthat ther€is no abnormalnoise
or clutchslippago.
- 2. Upshiftsshouldnot occur with the selectorin this position.
[7 (2ndcear) Position
- 1. Acceleratefrom I stop at tull throttle. Checkthat there is no abnormalnoiseor clutch slippage.
- 2. Upshiftsand downshifts shouldnot occur with the selectorin this position,
T-:-1,-
tl |lr|everselrostuon
A.ccelerstefrom 8 stop at fullthrottle, and check to. abnormslnoiseand clutch slipp8ge.
6. Test in I P I lParkino)Position
Parkcar on slope(approx.16o),sppv the parkingbrake,and shift intoI P I position.Release
the brake;the car should
not move.
14-70
StallSpeed
Test
CAUTION:
. To provont tlansmissiondamago,do not t6st stall spoodfor mors than 1Olocond! at r tlma,
. Do not shlft tho lovel whlle lalsing tha enginespeed.
. 86 suro lo romovo the prossuregaugobefolo testlng stal spood.
1. Eng€geparkingbrakeand block the front wheels.

2, Connecttachometer.and sta.t the engine.
3. Makesurethe A/C switchis OFF.
4. After the enginehas warmed up to normaloperatingtempersture (the rad;8tortan comeson), shift into @ Ooshion.
5. Fullydepressthe brakepedalandaccelerator for 6 to 8 seconds,
andnoteenginssp€ed,
6. Allow2 minutesfor coolins,thenrepeatthe test inloil, [Tl , ana[_] oositions.
NOTE:
. St8llspeedrestsshouldbe usedlor diasfEtiplqrpos€sonly.
. Stallspeedshouldbethe samein
L91l , L?l , L1l andL!_l positions.
Stall SoeedRPM:
F22Al Engin€
Spoclficatlon: 2,500rpm
Sarvice Limit: 23&-2,6fu rpm
H23Al Engino
Sp€cification: 2,7@rpm
Service Limit: 2,60O-2,90O rpm
TROUBLE PROBAELE
CAUSE
hishi" F;] ,E .E -o E
starlrpm Low fluidleveloroil pumpoutput
posruons CloggedATF strsiner
Pressurer€gulstolvafuestuck clossd
Slippingclutch
Stallrom hiohin @ nosition Slippageol 4th clutch
Stallrom hiehin@ and@ oositions Slippageof 2nd clutch
StallrpmhishinE position Slippageof 1st clutch or lst gesr one-wayclutch
stallrpmlowi" [D;l .E ,f a.a@ Engineoutput low

positions Torque converter one-way clutch slipping
14-71
FluidLevel
Checking/Changing
Chocklng ChEnglng
NOTE: 1. Bring the trsnsmission up to normal op€rating

Chsck ths fluid l€vsl with th6 6ngin6 at normal tampsrature lths radistorf8n com€s on) by drivingthe
opsrstingtemperaturs (th€ rsdistorf8n comes on). car. P6rk ths car on l6vel ground,turn the 6ngin6olf,
andth€n romovothe drain plug.
1. Psrk the car on l€v6lground,Turn oft th€ 6ngin6.
NOTE:
2. Remov6 ths dipstick {yellow loop) from th€ lf 8 cool€r flushar is to be usad, sa6 paee 14-142 and
transmission,and wipe it with a cls8ncloth. 143.
2
3. Insertths diDstickinto th€ trsnsmission, Roinstsllths drain plug with a nsw s€aling wssh€r;
thon rsfill ths tranamisaionto the uDDermark on th€
dipstick.
DIPSTICK{YELLOWLOOPI
Automatlc Tranlmllllon FhrldCapachy:
2.4 t (2.5 US qt , 2.1 lmp qt) at chsngins
6.0 e (6.3 US $ , 5.3 lmp qt) at ovsrhaul
Romoveths dipstick and ch6ck ths fluid bvel. lt shouH

be bstw66n th6 uDDerand lowgr marks.
DRAI'{PLT'G
18r 1.5rnm
DIPSTICK
50 N.m(5O ks-m , 36 lb-tt)
IA UPPER
Ell- LOWER
lf the l€vel is below the lower mark, add lluid into tho
tub€ to bringh to the upper mark. Use HondsPremium
Formula Automstic Transmission Fluid or an
equivalentDEXROIIall Automstic TrsnsmissionFluid
(ATF)only.
hsert th€ dipstick bsck into th6 transmission.
14-72
I 4. Stsrt the engins, and msasurs ths rospoctivs
Dr€ssuroas follows:
. Whlle t$tlng, bs careful of ths rotallng tront whoob, ' LinePr6ssuro
. Mak6 suro tfts, lackr. End safoiy stands aro phccd . Throttl€ B Prossur€
proparly(3oosoctlon 1l. . Clutch Pr6ssur6
' Clutch Low/High Prassurs
CAUTION:
. Botora toltlng, bo surc tho tra]lmirlion fluld lr flled R Instsll a new waahsr and the sesling boh in th6
to tho plopol loval. inspectionhols, andtighton to th6 sp6cifi6dtorqus.
. Wsrm up tha onglneb€toro toltlng.
TOROUE: 18 N.m (1.8 kgm , 13 lb-ft)
1. Raisethe car.{seesection1).
NOTE:
2. Warm up the engine, thon stop ths sngine End Do not rsuse old aluminumwashers.
connect a tachometer.
3. Connect the oil pressuregaugeto esch insp6ction

hole.
TOROUE: 18 N.m (1.8 kg-m, 13 lb-ft)
CAUTION:
Connect tho oll pr€ssuragaugo 3ecuroly;be rure noi
to allow dust and other folelgn partlcl$ to ent.l th€
lmpoctlon hol€.
A/T OILPRESSURE
GAUGESET
07406- 0020003
A/T OILPRESSURE
HOSE
07406- 0020201
A/f LOW PRESSURE

GAUGE
07408-OO7o(xXr
(cont'd)
14-73
PressureTesting
(cont'd)
. Llno Prcrluro Maalurcmcnt
- 1. Set the psrkingbrake 8nd block both rear wheels securely.

-2. RunthE 6ngineat 2,000 rpm.
- 3. Shift ths s6l6ct l6v6r to N or E position.
NOTE:
Highsrprossures
msyboindicEted ar€madein sol€ctorpositionsoth€rthanLryl orLll position,
it measurements
-4, M€8sursline pressur€.
LINEPRESSURE
I SPECTION
HOLE
F22A1 Engin€
SELECTOR FLUIDPRESSURE
PRESSURE POSITtON SYMPTOM PROEABLE
CAUSE
Standard Scrvlcc Llmh
Line E*E No (or low)

line pressure
Torqu6conv6rt6r,
oil pump, prossurs
&O- 85O kP8 750 kPa(7.5 ks/cm,,
(8.O-8.5 ks/cm' , 107 psi)
regulator,torque 1 1 4 - 1 2 1p s i )
converter check
valve
H23A1 Englno
PRESSURE POST|oN SYMPTOM PROBAELE
CAUSE
Stand!rd Scrvlco Llmh
Ltne Eo'E No (or low) Torqueconverter, 85O-9OOkPa &O kPa(8.Oks/cm,,

line pressu,e oil pump, pressure (8.5-9.O ks/cm, , '114psi)
regulator,torqug 1 2 1 - 1 2 8p s i )
convert€r check
vatve
14-74
. Thlotllo I Prossul€Moasurement
- 1. Set the parkingbrakesecurelyand block the wheels.
-2, Runthe ongine8t 1,00Orpm.

-3. Disconnectthe throttle control cable lrom the throttle control lev6r and set the throttle control l€ver in full throttle
position.
B PRESSURC
THROTTLE
INSPECTIOI{
HOLE
THROTTLE
COiTTROL
CABLE
THROTTLE
COiITROL
LEVER
F22Al Englno
PRESSURE POStTtot{ SYMPTOM PROBABLE
CAUSE
Standard SorvlceLlmlt
Throttle B E Pr€ssure
hish
too Throttls VElveB 0 kP8 (O kgy'cm',
0.0 psi)
throttle l€ver tully-
closod
No or low &0-850 kPa 75O kPa (7.5 kg/cm, ,

pressure 18.0-8.5 ke/cnt' , 1O7 psi)
114-121 psi) throttle lever fully-
throttl€ lever fully- openeo
opensd
H23A1 Engine
PRESSURE POSITtON SYMPTOM CAUSE
PROBABLE
Standard SorvlcoLimh
Throttle B E Pressuretoo
high
Throttl€ Vslve B 0 kP8 (0 ks/cm' ,
O.O psi)
throttle lever fulv-
clos€d
No or low 85O- 9OO k P8 SO kPa {8.0 ksr'crn,.

pressure (8.5-9.0 kdcnP . 114 psi)
121- 128 psi) throttle lever fully-
throttle leve. fully- opened
open6d
{cont'dl
14-75.
PressureTesting
(cont'dl
. Clutch PressuloMeaaurmant
@
Whila t$ting, bo ca.€fulof tho totatlng front wheals.
-'1. Set the parkingbrskeandblockboth rearwheelssecurely.
-2. Raisethe front of the car and support h whh salety stands.
-3. Allow the Jront wheelsto rotate freely,
-4, Runthe engineat 2,0OOrpm.
-5. Measureeachclutchpressure.
PRESSURE
lST CLUTCH 2NDCLUTCHPRESSURE
INSPECTION
HOLE II{SPECTION
HOLE
lST-HOLD CLUTCHPRESSURE
INSPECTIONHOLE 4TH CLUTCHPRESSURE 3RDCLUTCHPFESSUBE
II{SPECTK)]T
HOLE INSPECTIOI{
HOLE
CENNEB
BEAM
14-76
F22Al Englno
SELECTOR PROBABLE FLUIDPRESSUBE

PRESSURE POSITtON SYMPTOM CAUSE
Standard Servic6 Limit
1st Clutch E",F;] No or low

lst pressure
lst Clutch SO-85O kPa
{8.0-8.5 kgy'cm',
75O kPa (7.5 ks/cm, .
1O7 psil
114-121 psi)
1st-hold
Clutch
tr No or low lst-
hold pressure
1st-holdClutch
2nd Clutch tr;-] No or low 2nd Clutch

L1l
2nd pressure
2nd Clutch E No or low

2nd pressure
2nd Clutch 5OOkPa (5.0 kg/cm, ,
71 psi)
450 kPa (4.5 kg/cm, ,
64 psi)
(Throttlelsv€r fully closedl (Throttlel€ver fully closedl
85O kPa (8.5 kg/cm, , 75O kPa (7.5 ks/cm' .
3rd Clutch No or low 3rd Clutch 121 psi) 107 psil
3rd pressure {Throttlelever more (Throttlelsver more
than 3/16 oDened) than 3/16 oDenedl
53O kPa {5.3 kg,icm,, 4$ kPa 14.8 kg/cm, ,
4th Clutch llo or low 4th Clutch 75 psi) 68 psi)
4th pressur€ (Throttlelever fully clos€d) (Throttle levor fully closed)
85O kPa (8.5 ks/cm, , 75O kPa {7.5 kg/cm, ,
'121psi)
107 psil
(Throttlelever more (Throttle lever more
than 3/16 ooen6d) thsn 3/16 oD€nedl
Servo Vslve or gJO-a5O kP8 lE.O-8.5 75O kP8 (7.5 kg,/cm',
tr 4th Clutch kg/cm, , 114-121 psi) 107 psi)
H23Al Englne
SELECTOR PROBABLE FLUIDPBESSURE

PRESSURE POSITrON SYMPTOM CAUSE
Standrrd Sorvico Limlt
lst Clutch E-[5.'] No or low 1st Clutch 85O- 9OO k Pa &O kPa{8.0 ks/cm' ,
1st pressure (8.5-9.0 ks/cmz, l14 psi)
1 2 1 - 1 2 8p s i )
1st-hold
Clutch
tr No or low lst-
hold pressure
1st-holdCluich
2nd Clutch tr;-l No or low

IA 2nd Clutch
2nd prsssure
r=---l
2nd Clutch l u 4I No or low 2nd Clutch 50O kPa (5.O kslcm, , 45O kP8 (4.5 ks,/cm' ,
Zrd pressure 71 psil 64 psi)
(Throttle lever fully closed) (Throttlelever tully closed)
90O kPa (9.0 kg/cm' . 800 kPa (8.0 kgy'cm,,
3rd Clutch No or low 3rd Clutch 128 psil 114 psi)
3rd pr€ssure (Throttle lover more than {Throttlo lever more than
3/16 oDencdl 3/16 ooened)
53O kPa (5.3 ks/cm, , 4m kPa (4.8 ks,/cm' ,
4th Clutch No or low 4th Clutch 75 psi) 68 psi)
4th pressure (Throttlelever fully closed) (Throttle lever fully closed)
9OO kPa (9.O kg/cm, , 80O kPa (8.0 kg/cm, ,
128 psi) 114 psi)
(Th.ottle lever more than (Throttlelever more than
3/16 ooened) 3/16 ooened)
S€rvoValve or 8S-9OO kPa (8.5-9.0 DO kPa (8O ks/cm' ,
E 4th Clutch ks/cm' , 121-128 psi) 1'14 psi)
14-77
PressureTesting
(cont'd)
. Low/Hlgh ProssuroTost -8. With the engin€idling,lift the throttle control l6v€r
up approximately 1/2 of its possible travel and
-1, Set the psrkingbrake and block the rear wheels increasethe engine.pm until pressureis indicated
securety. on the appropriate gaug€. Record th8 highest
pressurereadingobtained.
-2. Raisethe car and support with satety stands.
-3. Attach the gaugeset to the approp.iatepressure
inspectionholes.
-4. Remove the throttle control cable end of the
throttle control lever,
NOTE:
Do not loosen the locknuts; simply unhook the
throttle control cableend.
THROTTLE
CO TROL
CABLE
LOCKNUT
THROTTLE
CONTROL
LEVER
THROTTLE
COIVTNOL
LEVER
-9. Repe8tsteps -7. and -8. tor each clutch pressure
-5. Warm up the engine to normal operating beinginspect€d.
temperature(the radiatorfan comeson).
with the engineidling,move the slector leverto

E position.
-7. Slowly move the throttle linkageto increasesngin€

rpm until pressure is indicated on the appropriate
gauge.Then releasethe throttle linksge,sllowingthe
engineto return to an idle. and record the pressure
reading.
THROTTLELINKAGE
14-78
CE TERBEA]II
Englno
PRESSURE POSITtON SYMPTOM DD'IEADI E 'TA I ICE
Standard SorYiceLlmlt
2nd Clutch L9! No or low 2nd Clutch 5OO- 85O kPa 45O kPa {4.5 ks/cm, ,
2nd pressure lc.u-5,9 Kg/cm' , 64 psil
71-121 psi) {Throftleleverfullycbsed)
3rd Clutch No or low 3rd Clutch vsries with throttle 75O kPa (7.5 kg/cm, ,
3rd pressure lever op€ning 107 psi)
(Throttlelever more
than 3/16 open€d)
4th Clutch No or low 4th Clutch 53O-850 kPa 4& kP8 {4.8 ks/cm, ,
4th pressure (5.3-8.5 ksy'cm,, 68 psi)
75-121 psi) {Throttleleverfulv closed}
varies with throttle 75O kPa (7.5 ks/cm, ,
lever opening 107 psil
(Throttle lever more
than 3/16 opened)
Engino
PRESSURE POSITtON SYMPTOM PROBABLE
CAUSE
StEndard Sorvlce Llmit
2nd Clutch E No or low

2nd pressure
2nd Clutch 50O- 9OO kPa
(5.0-9.O ksy'cm,,
45O kPa (4.5 ks/cm, ,
64 psil
71- 128 ps') {Throttleleverfullycbsed)
3rd Clutch No or low 3rd Clutch varieswith throttle &O kPa (8.O kg/cm, ,
3rd pressure leveropening 114 psi)
(Thfottle lever more
than 3/16 opened)
4th Clutch No or low 4th Clutch 53O- 90O kPa 48O kPa {4.8 kg/cm, ,
4th pressure (5.3-9.O ksy'cm', 68 psil
75-128 psi) {Throftleleverfulv cbs€d)
varieswith throttle 8OO kPa (8.O kg/cm2,
lever opening 114 psi)
(Throttle lever more
than 3/16 opened)
14-79
Transmission
Removal
t. Disconnectthe battery negative (-) 8nd positive {+)
cablesfrom the battery.
. Make Eu16ltfts. iacks and safoty stands aro placed
properv, 8nd hoist brackots ato attachod to the Remov€ the battery set pl8te, then remove the
corroct positlon on th6 6n9lne(360soctlon 1). battery.
. Apply psrklng brak6 and Hock roar wheols, so car will
not roll otf stands and ta[ on you while worklng 5. Remove the drsin plug, and drain the automatic
und6r h. transmissionlluid (ATFl. Reinstallthe drsin plugwith a
new sealingwasher.
CAUTION:
Uso f€nder covols to avold damagingpaintodsurfac€s. TOROUE: 50 N'm (5.O kem , 36 lb-ft)
CAUTION:
. A[ SRS olsctrical wi]ing halnossas are covet€d whh
yellow outor insulation.
. Bofore dlsconn€cting the SRS wlro harnoss, install
tho short connoclor (3)on the slrbag ls).
. Reolacotho entlre affocted SRS ham$s assemHy if
it has an open circuit or damagedwirlng.
NOTE:
The radio mav have I cod€d theft protection circuit. Be
sure to get the customer'scode numberbefole.
- Removing the No.43 (10 Alfuse.
{ln the under-hoodfuse/relayboxl
- Removingthe radio, DRAINPLUG
AJter service, reconnect power to the r8dio and turn it 18x 1.5 rrm
on. 50 N.m (5.0 ks-m ,
"CODE" is displsyed, enter the 36 b-ft)
When th€ word
customer's Sdigh code to restore radiooperation.
4. Removethe resonator,intaks air duct and air clesnet
housing.
Disconnect the connectot from the intak€ conttol

vacuum tank, then removs the intake control vacuum
tank 8ndtank bracket.
NOTE:
Do not remove the vacuum tube from the intsko
controlvacuumtank.
AIRCLEAI{ER
HOUSIM!
I]YfAKECOi{TROLVACUUMTANK
14-80
6. Disconnect the glound cabsl from the transmission 1 3 . Removethe starter rnotor cables.
and body.
1 4 . Disconnectthe countershattspeedsensorconnector.
Removethe bEttery basewhh th€ groundcable.
COUNTERSHAFT
SPEED
6. Removsthe battery bassstay. SENSOR
CONNECTOR
GROUNDCABLE
BATTERY
BASESTAY
STARTSER
MOTOR
q
Disconnectthe lock-upcontrol solenoidvalve and shift
control solenoidvalve connectors. 15. Disconnect the vehicle speed sensor connecter.
Remove the rear stiffener, then remove the vehicle
1 0 . Disconnectthe throttle control cablefrom the throttle speedsensor/powersteeringspaedsensor.
controllever.
NOTE:
1 1 . Disconnectthe mainshaftspeedsensorconnector. Do not disconnectthe power steeringpressurehoses
from the vehicls speed sensor/pow€r steering speed
12. Removeths ATF cooler hosesat the joint pipes. s9nsor,
Turn the ends of the ATF cooler hoses uo to Drevent
POWERSTECRING VEHICLESPEED
ATF from flowing out, then plugthe ioint pipes. PRESSURE HOSES SENSOR
REAREI{GINE
NOTE: MOUI{T
Check for any signsof leakageat tha hose joints.
MAI]TSHAFT SPEED SOLENOIDVALVE

SE SOR COI{NECTOR coNf{EcToRs
TRANSMISSK)N
GROUD
CABLE
POU'ERSTEERIT{G
\ SENSOR
\SPEED
REARSTIFFENER O-RING
Replac6.
(cont'dl
14-81
Transmission
Removal(cont'd)
16. Removethe transmissionhousingmountingbohs. 1& Removsthe transmissionmount.
TRAl{SMlsSOt{MOUI{T
TRANSMISSIONHOUSING
MOUI{TINGBOLTS
17. Loosenthe Jront enginemount brscket bolts. 19. Rsmovethe splsshshield.
-
FROiIT E]{GII{E MOUNTT
BRACKETBOLTS
SHIELD
SPLASH
FRONTENGINE
MOUiTT
14-82
20. R€movethe center beam8nd r6ar beamstifJener. B. Pry the driv€shaftsout ot ths differentisl.
24. Pullon the inboardjoint and remove the right and left
driv€shafts(s€6ssction 16).
Tie plasticbagsov6r the driv€sh8ftenos.
NOTE:
Coat 8ll precisionfinished 9urf8c6s with clean ongine
oilor groass.
DRIVESHAFT
E D
21. Romovsths cott€r pins and castls nuts, thsn sep8r8t6 26. Removethe right dsmpsr pinch boh, then separatetho
the ballioints from the low6r arm (seesection 18), damoerfork and dsmoor,
22 Remove the damper tork bohs. then separste tha 27. Remove the self-locking bolts and self-locking nut,
dampertork and lower arm. then romoveths right radiusrod.
SELF.LOCKIIIG
NUT
DAMPERFORK ReDhco.
r
DAMPERPII{CH
EOLT
R6plac€.
SELF.LOCKING
UT
Roploco.
rY
P6*ii53., cAsrLENur
sELF-L(rcKhIG
BOLT
R6place,
RADIUSROD
(cont'd)
14-83
Transmission
Removal(cont'd)
n. R€movo ths torque convorter cov€r and shift csbb 31. Plsce 8 jack und€r the transmission, and raise th€
covgt. transmissionjust enough to take weight oft of the
mount.
E. R6moveths lock bott sscuringthe control l€ver, then
rsmovo the shift cablswith the controllsvsr. 32. Romovethe intake manitoHbracket.
CAUTION: 33, Removethe trsnsmissionhousingmountingbolts 8nd

Tlks care nol to b.nd tha lhlft cable whllo removlng rear anginemountingbolts,
h.
34. Pull the transmissionaway trom the €ngine until it
clesrs the 14 mm dowel pins, then lower it on the
transmissionjack.
SHIFTCABLE
TRANSMISSIONHOUSING INTAKETIAI{IFOLD
MOUiTTI'{G EOLTS ERACKET
TOROT,E
COI{VERTER
COVER
30. Rsmovoths eight drive plate bolts one at a tims whils

rotatingth€ cr8nkshEftpulby.
TRANSMISSION
JACK
DN|VEPLATCBOLT
6x1.Omm
DRIVEPLATE
14-84
lllustratedIndex
Right Side Cov
14-86
SIDECOVERPROTECTOR @SECONDARY SHAFTLOCKNUT,24 x 1.25 mm
SPEEDSENSOR {Flangenut) R€place.
Replace, @CONICALSPRINGWASHERReptace.
SIDECOVER CISECONDARYSHAFT IDLERGEAR
Replace. @LOCKWASHERReplace.
TH CLUTCHFEEDPIPE @THROTTLECONTROLLEVER
SIDECOVERGASKETReDlsce. @THROTTLECONTROLLEVERSPRING
Replace. @'TRANSMISSION HANGER
PIPEGUIDE @ATF LEVELGAUGE
RING @DRAINPLUG
ST CLUTCHFEEDPIPE @SEALINGWASHERReplace.
Replace. E)PARKINGBRAKEPAWL
PIPEGUIDE @)PARKINGBRAKEPAWL SPRING
RING @PARKINGBRAKEPAWL SHAFT
Replace. @PARKINGBRAKEPAWL STOPPER
SPEEDSENSOR @LOCK BOLT
lST.HOLDCLUTCHFEEDPIPE @LOCK WASHERReplace.
PIN @PARKINGBRAKELEVER
@O-RlMisReDtsce. OPARKINGBRAKESPRING
@FEED P|PEGUTDE g) PARKII{GBRAKESTOPPER
OSNAPR|NG 6)TRANSMTSSTON HOUSTNG
@CouITERSHAFT LocKNUT,24 x 1.2s mm 6)TRANSMISSIONHOUSINGGASKETReDtace.
(Flange
nutlReplsce. @)DOWEL P[rl
SPRINGWASHERReDlace. 6)ATF COOLEFPIPES
ARKINGGEAR BOLT
@tJorNT
NEEDLEBEARING @ SEALINGWASHERSReplace.
IDLERGEAR 6)JOTNTBOLT
EEARING @SEALINGWASHERSReplace.
NEEDLE
BEARIMi @VEHIGLESPEEDSENSOR/POWER STEERINGSPEED
WASHER SENSOR
LOCKNUT,24 x 1.25 mm @ O-Rll,lGReplace.
(Flange
nut)Replace. G)REVERSEIDLERGEARSHAFT HOLDER
NOTE:Left-handthreads @ NEEDLEBEARING
OCONICALSPRTNG WASHERReptace.
@)MAIN!|HAFTIDLERGEAR
TOROUE
SPECIFICATIONS
Ref No. TorqueValue Bolt Size Remarks
A 1 2 N . m( 1 . 2 k g - m , I l b - t t ) 6x1.Omm
B 14 N.m (1.4 ks-m, 10 lb-ft) 6x1.Omm
18 N'm (1.8 ks-m, 13 lb-ft) I x 1 . 2 5m m
55 N.m (5.5 ks-m ,4O lb-ftl 1 0 x 1 . 2 5m m
E 29 N.m (2.9 kg-m,21 lb-ft) 1 2 x 1 . 2 5m m Joint Boft
50 N.m (5.0 kg-m,36 lb-ftl 1 8x 1 . 5m m DrainPlug
H 23O N.m (23.0 ks-m, 166 lb-ft) z+x t.zcmm MainshartLocknut
170 N.m (17.0 kgrm, 123 lb-ft) Left-handthreads
230 N'm (23.0 ksFm,166 lb-ft) 24 x 1.25mm SecondarySh8tt
1 7 0 N . m( 1 7 . 0k s - m , 1 2 3 l b - f t ) Locknut
23O N.m (23.0 ks-m , 166 lb-ft) z4 x t.zc mm Countershaft
170 N.m (17.0 kg-m, 123 tb-ft) Locknut
K 8 N'm (0.8 ks-m , 5.8 lbjtl 5x0.8mm
14-87
lllustratedIndex
Housing
Transmission
@ B
@
@
o
@
{}
o
@
(t
@
14-88
OTHRUSTWASHER Replace.
OTHRUSTNEEDLE BEARING
OSEcoNDARYSHAFT2NDGEAR
@NEEDLEBEARINGS
@THRUST NEEDLE BEARING NEEDLE
EEARING
@SPLINEDWASHERStectiveosrt 4TH/REVERSEGEAR
@1ST/2NDCLUTcHASSEMBLY BEARII{GS
@o-RlNGsReptace. I{EEDLEBEARING
(9)SECONDARYSHAFT GEARCOLLAR
@THRUST NEEDLE BEARING TH CLUTCHASSEMBLY
ONEEDLEBEARING GEARCOLLAR
@SECoNDARY SHAFTlsr GEAR THRUST]TEEDLE
BEARIITIG
@DtsrANcEcoLLAR.s.o mm BEARING
@corrERs, 29 mm 3RD GEAR
RETAINER NEEDLE8EARI]{G
RING Rephce.
RINGS,32 mm
BOLT RINGS,35mm
WASHERReplace. RING,29 mm
FORK BEARING
2ND GEAR RII{G
REVERSEGEAR IDLERGEARSHAFf HOLDER
BEARING BEARING
SELECTOR
HUB SEAL Reolace.
SELECTOR HOUSINGOIL SEAL Reolace.
4TH GEAR SHIM SelectiveDart
BEARING OUTERRACE
RING HOUSINGGASKETReplsce.
32 mm
TERS,
29 mm
ANCECOLLAR HOUSII{GMAINSHAFTEEARII{G
3RD GEAR HOUSIMI SECOI{DARYSHAFT
NEEDLEBEARING EEARI'{G
@oNE-WAY CLUTCH @)TRANSM|SS|OI{HOUS|NG
COUI\TTERSHAFTBEARTNG
€}COUMIERSHAFT1ST GEAR @NEVERSE IDLERGEAR
€)NEEDLEBEARING ASSEMBLY
GDIFFERET\ITIAL
@THRUSTWASHER OUTERRACE
G)EEARIIIIG
@COUNTERSHAFT lST GEARCOLLAR @)TOROUE COI{VERTERHOUSING OILSEALReDtace.
@tlsT-HoLD cLuTcH ASSEMBLY @TOROUE COI{VERTERHOUStitc
TOROUESPECIFICATIONS
Ret No. TorqueValu€ Boh Size Rsmsrks

1 2 N . m( 1 . 2k g - m , 9 l b - f t ) 6x1.Omm
B 14 N.m (1.4 kg-m, 10 lb-ftl 6x l.Omm
14-89
lllustratedIndex
TorqueConverterHousing
\l il
q
IU
@.-. I
lL? a
@
' @
l
&P
14-90
OATF STRATNER FEEDPIPE
@MAGNET BALL
@OILFEEDPIPE TERReplace.
@otl FEEDP|PE PIN
@4THACGUMULAToR covER FEEDPIPE
@o-Rlltc Reohce. VALVEBODY
OLOCKwAsHERReotace. PUMPDRIVENGEARSHAFT
@sERvoDETENT BASE PUMP DRIVEGEAR
@sERvoBoDY PUMP DRIVENGEAR
@SERVO SEPARAToR PLATE SHAFT
@cHEcKBALL SPRIiIG
@SECoI{DARY vALvE BoDY ARM
@DOWEL PIN ARM SHAFT
@SECoNDARY SEPARAToR PLATE PIN
@AccuMULAToRBoDy covER SEPARATORPLATE
@lsT AccuMUrAToRcHoKE NEEDLE
BEARIM!
@cHEcKBALL GUIDEPLATE
@1sT/2 D ACGUMULAToR BoDY SHAFT BALL EEARING
@THROTTLE vALvE BoDY GUIDEPLATE
@THRoTTLE SEPARAToR pt-arE SEAL
@oowEt- PrN COiITROLSOLEI{OID
FILTER/GASKET
Replace.
€!THROTTLE COTTROL SHAFT COiITROLSOLEI{OID
VALVEA$SEMBLY
@ERINGReplace. -UPCONTROLSOLENOID VALVEASSEMBLY
@FILTER Replace. HOLDER
@REGULATOR VALVEBODY -UPCOTIITROL
SOLENOID
FILTER/GASKET
@O-RllJGReplace. Replacs.
@STATOR SHAFT @TOROUECONVERTERHOUStt{c
@STOPPEB SHAFT 6)II'AINSHAFTBALL BEARING
@TOROUE COiTVERTER CHECKVALVE @OlLSEAL Replace.
@TOROUE CONVERTER CHECKVALVESPRING
1 2 N . m ( 1 . 2k g . m , I l b - f t ) 6x1.0mm
18 N.m (1.8 ksFm, 13 ltsft) 8 x 1.25mm
14-91
RightSide Cover
Removal
NOTE: L Removethe elev€nbolts s€curingthe right sido covet,
. Clean all parts thoroughly in solvent or carburetor then removethe right sidecover.
cleanersnd dry with compl€ssedair.
. Blow out allpasssges. NOTE:
. When removing the transmission right side cover, h is not necessarv to remove ths right side covsl
replacethe following: protector.
, Rightsidecover gasket
. Lock washers Slipthe specialtoolonto th€ mainshsft.
. Transmissionhousinggasket MAII{SHAFTHOLDER
. O-rings 07GAB-PF5010O or
. Eachshatt locknut and conicalspringw8sher 07GAB-PF50lOl
. Sealingwsshers
LOCKNUT
cott|cAl sPRlltG
WASHER
R6phc€. PARKIT{GGCAN
IDLERGEAR
COUNTERAHAFT
RIGHTSIDECOVER
IDLERGEAR
REVERSE
SHAFTHOLD€R
ERAKEPAWL
W- "o rNGBBAKE
LEVER
I
n p
\
V--
TRA]{SM|SS0i{HOlrSlNo
RIGHTSIDE BOLTS
COVERGASKET
R€place.
TRANSMISSION TRANSMISSO HOUANG
HANGER
ATF LEVELGAUGE
IDLERGEAR
REVERSE
E x 1 . 0m m
BOLT
HOUSII{G
TRA SMISSIO|{
GASKET
R6Dlsco.
ATF COOLER
PIPES
}IOUSII{G
CO VERTER
TOROUE
JOINTBOL
SEALII{GWASHERS
Rophc6.
14-92
J. Engagethe parkingbrake pawl with the parkinggear. 12. Removethe reverseidlergear shaft holder.
4. Cut the lock tabs of each shaft locknut usinga chisel NOTE;
as shown. Then remove the locknuts and conical The steel ball does not pop out becsuseit is stsked in
springwashersfrom esch shaft, the shaft.
NOTE: 13. Move the reverse idler gear to disengageit trom the
. Mainshaftlocknut has left-handthreads. countershaftand mainshsftreverseg€arsas shown.
. Cleanthe old locknuts; they are used to installthe
press fit idler gearson the mianshaftand secondary NOTE:
shaft andthe parkinggearon the countershaft. The transmissionhousingwill not separate from the
. Always wear safety glasses, torque converter housing if the reverse idlsr gesr is
not removed.
CAUTION:
Keep all of ths chiselod particlos out ot tho REVERSE IDLERGEAR
tranamission. MAINSHAFT Moveinthisdirsction.
LOCKTAB
,! o_ -:.-.:{>,
a \!r'
Rsmove the special tool from the mainshaft after
removingthe locknuts. l l
i \
o. Remove the parkinggear using a puller f.om the
countershaft as shown. Then remove the idler gesrs COUNTERSHAFT
usinga pullerfrom the mainshaftand secondaryshaft.
14. Align the spring pin of the control shstt with the
transmission housing groove by turning the control
shaft.
15. Install the speci8l tool on the transmission housing,

then removethe housingas shown.
HOUSINGPULLER
Remove the countershaft idler gear, needle besring.

thrust needle bearing. and thrust washer from the
countershaft.
8. Removethe parkingbrake pawl, spring,shaft. and

stopperfrom the housing. GROOVE
9 . Removethe throttlecontrolleverand springfrom the

throttle control shaft.
1 0 . Removethe ATF coolerpipe mountingboh from the

transmissionhanger.
1 1 .Removethe transmissionhousingmountingbotts.
SPRINGPIl{
CONTROLSHAFT
14-93
TransmissionHousing
Removal
TRANSMISSIONHOUSI G
Removal 14-92
2ND GEAR
COUNTTERSHAFT
COUiITERSHAFTREVERSEGEAR
I{EEDLEBEARII{G
TRANSMISSO
HOUSlttc REVERSE HUB
SELECTOR
GASKET
Replace. SHIFTFORK
SELECTOR
BEVERSE
MAII{SHAFT
COUITTERSHAFT
SUB.ASSEMBLY
4TH GEAR
THRUSTWAS}GB
BEARIiIG
THRUSTI{EEDLE
COUTYTERSHAFT SECONDARYSHAFT
SUB.ASSEMBLY 2'{D GEAR
BEANI GS
NEEDLE
THRUST]{EEDLEBEARIiIG
SPLII{EDWASHER
SECOI{DARY
SHAFT
SUB-ASSEMBLY
DIFFEREICTI,AL
ASSEMBIY
HOUSING
TOROUECOIWERTER
14-94
NOTE:
. Cl€8n 8ll parts thoroughly in solvent or carburetor
cleansrand dry wilh comDressedair.
. Blow out all passsges.
. Whsn r€moving the transmissionhousing, roplace the
following:
. Trsnsmissionhousinggaskst
. Lock w8sh6r
1. Removethe trsnsmissionhousing(seepage14-94.
2, Rsmove the reverse idler g€ar from the transmission

housing.
3. Removs ths count€rahaft 2nd go8r, reverse gear,

socondaryshaft 2nd gear, thrust wash€r, and thrust
ns€dl€ besring togsther from the countershaft and
secondaryshaft.
4. Remove the lock bott socuring the shift fork, then

romovs ths fork with tho rav€rse s€lector from the
countershaft.
5. R€move tho n66dle besrings,thrust nesdle besring,

8nd splinedwasher from the socondaryshaft.
6. Romovethe secondsryshaft sub-Ess8mbly,
7. Removethe msinshaftsub-ass€mbly.
8. Removethe countershaftsub-assembv.
9. Removethe differentialass6mbv.
14-95
Torque ConverterHousing/ValveBody
Removal
O.RING
THROTTLE
COI.ITROL Roplace,
SHAFT.
\
\
^3a
fi nllltn
\s ll llUlfllle
o r FEED
P'PE
\
F \
f,
a
ATF STRAINER
i l r i l , H |t J i l _
1 s' 1!1 ;HROTTLE
VALVE
II U I BODY
4TH ACCUMULATOR
COVER
E-R.NG fl S1 rHRorrLGsEpARAroR
Replace.
. ll >[nN PLATE
\ - u - * /
LOCKWASHER
\ REGUtAroBvAtvE Replac6.
ff n
SEBVODETENT
STOPPERSHAFT BASE
O-RING
Rephce. I
TOROUECONVERTER STATORSHAFT
CHECK
VALVE SERVOBODY
OETENTARMSHAFT
CHECKVALVE
SPRING DETENTARM SEBVOSEPARATOR
PLATE
colvrRoL CHECKBALLS
OIL FEEDPIPE SHAFT
VALVE
SECONDARY
BODY
DOWELPIN
MAIN VALVE
BODY SECONDABY
SEPARATOR
OILPUMPDRIVEN
GEARSHAFT
OILPUMP ACCUMUI.ATOR
BODY
DRIVEGEAR COVER
OILPUMPDRIVEN
GEAR
IST/2NDACCMULATOR
MAIN SEPARATOR BODY
PLATE
DOWELPIN
TOROUECONVERTERHOUSING
14-96
NOTE: 9 . Romovethe ststor shsft snd stopper shaft.
. Cl€sn all parts thoroughly in sotuent or carbur€tor
cle8n€rand dry with compressedair. 1 0 . Romov€the dstsnt spring from ths dstsnt arm, thsn
. Blow out all p8ss8g€8, remove the control shaft trom the toroue converter
. Whsn removingthe vslve body, replscethe following; housing.
. O-rings
. Lock w88h6rs 1 1 .Rsmov€the detent arm snd detent srm shalt from the
m8inv8fus body.
1. Removsthe two bohs securingthe servo detent base,
th€n rsmovs ths aervo detent bass. 12. Removoth€ four bohs securingtho main valve body,
th6n r€moveth€ mainvalve body.
2. Removsthe two bohs sgcuringth6 ATF strsiner,then
removs th€ ATF strainsr. 1 3 . Remove the six bofts securing the lst/2nd accumu-
lstor body, th€n rsmovs the 1st/2ndaccumulatorbody.
3. Remove the oil fe6d pipes from the s€rvo body and
mainvalve body. 1 4 . Remove the oil pump drivon 968r shatt, then remove
the oil pump gears.
4. R€movethe three bofts securingthe 4th accumulator
covsr, thsn removethe 4th accumulatorcov€r. 1 5 . Rgmov€ th6 main seDarator Dlat6 with three dow6l
Dins.
NOTE;
Ths 4th accumulator covsr is spring loaded, to
prsvsnt strippingthe threads in the s€rvo body, press
down on tha accumulstorcover while unscrewingthe
bohs in a crisscrossDsttern.
5. R6movethe seven bohs securingth8 servo body, then

removs the sarvo body snd s6parstor plats.
6. Removethe secondsryvalve body and soparstorpl8te.
7. Rsmove the seven bohs securing th€ throttle valve

body, then remove the throttle valve body and
soparatorplata.
8. Rsmove the boh securing the regulator vslve body,

then removethe rsgulatorvElvebody.
14-97
Valve Body
Repair
NOTE: Remov€the #600 paper.Thoroughlywash the entire
This repair is only necessary if one or more of the vavs body in solvent,then dry with compressedair.
valves in a valve body do not slide smoothly in their
bores.You may use this ptocedule to free the vaves 6. Cost the vslv€ whh ATF, then drop it into its bor8. h
in the valve bodies. shouH droD to thg bottom of the bore under its own
weight. ll not, ropeat step 4, then retest.
Soak a sh€et of $600 abrasive paper in ATF for
about 30 minutes,
Carefully tap the vatve body so the sticking vslve

droDsout of its bore. VALVE
CAUTION:
h may bo necossaryto us€ a 3mal3crewd vor to plY
tho valve fioo. Be carsful not io scratch the bot€
whh ths sclowdrlvor.
InsDectthe vave tor any scutf marks. Use the ATF-

soaked #60O paperto polishotf any burrs that are on
the valve, then wash the vatue in solvent 8nd dry it
with compressed8ir. VALVE
BODY
ffi
Rotl up h€lf a sheet of ATF-soaked f60O paper and
insert it in the valve bore ot the stickingvalve.
Twist ths paper slightly,so that it unrollsand fits the t
boretightly,then polishthe boreby twistingthe paper
as you push it tn and out.
CAUTION:
Th6 valve My is aluminum and doosn't roquito
much polshing to remove any bulls.
7. Romovs tho vslve 8nd thoroughv clean it 8nd the

valve body wilh solvent. DrY 8ll parts with
comDroasedair, then reassemble using ATF 8s a
lubricant.
snl
[ssYi
vV/fJ
,.llJ'"-Q)
14-98
Valve
Assembly
NOTE: Sst the springin the valv6 and installth6m in tha valvs
Cost all psns with ATF before assembly. body. Push th€ spring in with 8 scrowdrivor, th6n
instsllthe springssat.
. lnstallthovalvs, valve springandcap in the vavo body,
and secur€with ths rollsr.
VALVEBODY
ROLLER
14-9!)
Valve Caps
Description
Caps with one projocted tip and one flat end are Caos with hollow ends ar6 installedwith the hollow
installedwith the flat end towsrd the inside ot the awav trom the insideof the valve body.
valve body. CaDswith notched ends are instslledwith the notch
Caps with a projectod tip on €ach end are instslled toward the insideot the valve body,
with th6 smsller tip toward th8 inside ot the valve Caps with flat gnds and a hole through the center are
body. The smslltip is I springguide. installsdwith the smallerhole towsrd the insideof the
vave body.
TOWARDOUTSIDEOFVALVEBODY TOWARDOUTSIDEOFVALVEBODY
EEEA
TOWARDII{SIDEOFVALVESODY TOWAROI SIT'EOFVALVEBODY
Caps with one projected tip snd hollow end sre

instslledwith the tip toward tho inside oJ the valve
body. Th6 tip is I springguide.
TOWARDOUTSIDEOFVALVEEODY
TOWARD INSIDEOF VALVE BODY
14-100
Oi l Pu mp
lnspection
1. Install the oil pump gears 8nd oil pump driven gear Measurethe side clearsnceof the oil pumDdrive and
shsft in the mainvslve bodv. driven g€ars.
OilPump Ga.lE Side (Radial)Cloalance:

Standard(New)l
Oil Pump Ddva goal
0.210-0.265 mm (0.0083-0.0104 inl
Oll Pump Drlvan g6al
0.035-0.063 mm (O.OO14-O.0O25in)
OILPUMP
ORIVEGEAR
Inspectt€ethlor
wearor damage.
3. Remove the oil pump driven gesr shaft, Measurethe

thrust clearanceof the oil pump driven gear-to-valv€
body.
OllPump Drlvo/DrivonG6sr Thrust (Axiall Clearance:

Standard(Now): 0.03-0.05 mm (0.001-0.002 in)
Selvico Limit: 0.07 mm (O.0O3in)
STRAIGHTEDGE
MAIN VALVE BODY
14-101
MainValve Body
Disassembly/lnspection/Reassembly
NOTE:
. Clean8ll parts thoroughlyin solvent or carburetorcleaner,and dry with compress€d8ir. Blow out all psssages.
. Replacevalve body as an assemblyif any parts are worn or damaged'
. Check allvav€s tor free movement.lf any fail to slidefreely, seeVafueBody Repairon page1+98.
CAUTION:
Do not use a magnotto tomovo tho ctrock balb; it may magnotizotho bak.
MODULATOR
VAIVE
CPCVALVE
3-2 K|CK-DOWN OIL FEEDPIPE

VALVE FILTER
R6phc6.
SEAT lnstsll in this diroction-
\n
U
SHIFT
CHECK
BALLS DETENTARM
3pcs.
1_2 SHIFTVALVE
VALVECAP
R
u
2_3 SHIFTVALVE
ROLLER
MAIN VALVE BODY

Inspectlor scoring
or domag€.
MANUAL VALVE
14-102
FILTER
Rephce.
CHECKBALLS
MAIN VALVE BODY

(S€ctionalView)
DETEN|T
ARMSHAFT
SPRINGSPECIFICATIONS
Unit:mm (in)
Standard(New)
No. Spring
Wire Di8. o.D. Free Length No. ot Coils
o Lock-up control valve spring o.70(0.028)

o.90 {0.035)
6.60(0.260)
7.60(0.299)
38.00(1.496)
73.70 .2.9021
14.1
32.O
@ Lock-up shift valve spring 't7.o
@ Coolerrelist valve spring 1.10(0.043) 8.40(0.331) 46.80(1.8431
o Modulatorvalve spring 1.40(O.O55) 9.40{0.370) 33.OO(1.299) 10.5
o CPCvatuespring 1.40(0.055)
1.20(O.O47t
9.40(0.370)
7.10{O.2m)
33.00{1.299)
46.90{1.846)
10.5
20.6
@ 3-2 kick-downvatuespring
o 1-2 shitt valv€spring
2-3 shift valve spring
1.00(0.039)
o.90(0.035)
8.60(0.339)
7.60(0.299)
41.30(1.626)
57.@t2.2441
16.9
26.8
@
14-103
SecondaryValve Body
NOTE:
. Clesnall parts thoroughlyin solv€nt or carburetorcleansr,and dry with compressod8ir. Blow out all passages.
. Check allvalvesfor lree movsment.lf sny fail to slidefreely, seeVave Body Rep8iron page1+98.
. Coat all parts with ATF befor€ assembling.
. Replacethe vave body as 8n assemblyif any pans 8re worn or damaged.
CAUTION:
Do not uso a mrgnoi to romova th€ chock balls;h may magnatizotho bak'
3_4 SHIFTVALVE
o
0 l
,n4u % CHECKBALLS
7 pcs.
SECONOARY
VALVEBODY
Inspectfor scoring
or damag6.
-p^ \
'cqtcrco-
21{DOR|F|CECOI{TROL /
VALVE
/ /"%
SLEEVE
14-104
L
CHECKBALLS CHECKSALLS
n
LJ
rV1 nU nl-l- l-_\)v, r.,f7
SECO DARYVALVEBODY
CHECKBALLS (SoctionslVisw)
SPRITIIG
SPECIFICATIONS
Unh:mm(in)
Stsndard(llew)
No, Springs
Wir€ Dia. o.D. Free L€ngth No, of Coils
O 4th sxhsust valve spring 0.90(o.o35t 7.10(0.2&) 60.e (2.394) 4.9

@ 3-4 shift vatuespring 0.90(o.o35) 7.@ (0.299) 57.@ l.2.244l. 26.8
@ 3rd kickdown vslve spring 1.10(0.043) 7.60{0.299) 48.30(1.902) 4.3
o Sarvo controlvalva spring 1.@(0.039) 8.10(0.319)
6.60(0.260)
52.60l2.O71l 22.4
@ Orifice control vslve spring 0.s to.031) 52.&12,06,7l 33.O
@ 2nd orifice controlvalve spring 0.60(0.024) 6.@ (0.260) 5A30 (2.295) 15.8
14-105
RegulatorValve Body
NOTE:
. Cleanatlparts thoroughlyin solvent or carburetorcleaner,and dry with comprsssadair. Blow out all p8ssages.
. Replacevalve body 8s an assemblyif any parts are worn or dsmaged.
. Ch6ck 8llvalvesfor tree movement.lf 8ny tailto slidefreely, see Valve Body Repairon page1+98.
1. Holdthe regulatorspringcap in plscewhile removingthe stopper boh. Oncethe stopper bolt is removed,releasethe spring
c8p slowty.
CAUTION:
Th€ rogulatorspllng cap can pop oui whon tho lock boh is romovod.
2. R8assemblyis the revers€ordgr of disassembly.
NOTE:
. co8t 8ll parts with ATF.
. AliSnthe hole in the rogulatorspringcap with the hole in th€ valve body; thsn pressthe spring c8p into the valve body
and tight€n the stoppor boh.
REGULATOR
SPRINGCAP
STOPPER BOLT
6x1.0mm
12 N.m(1.2ks-m,9 lb-ft)
VALVE
REGULATOB
FILTER
Rophce.
LOCX.UPTIMINGVALVE
E BOOY
Inapgctfor w6ar. scratchos
or scorng.
TOROUECONVERYER
CHECK
VALVE
ROLLER
SPRINGSPECIFICATIOTSS
Unit:mm (in)
Standard(New)
No. Springs
Wire Di8. o.D. FreeLength No. of Coils
O Regulatorvalve springA F22A1 engine 1.O (0.O71) 14.70(O.579) 86.50(3.406) 16.5

H23A1 engine 1.80(0.071) 14.70 (0.579) 88.60{3.488) 16.5
t Regulatorvalve springB r.s (0.071) 9.60 (0.378) rr4.oo(1.732) 12.7
i Stator reactionspring 4.50(0.177) 35.40(1.394) 30.30(1.193) 1.92
't4.7
3 Lock-uptlming vaVe spring o.s {o.o31) 6.60 (0.260) 51.10(2.012) 't2.o
ra Torque converter check valve spring 1.10(0.043) 8.40(0.331) 36.rto(1.433)
14-106
Throttle Valve Body
Disassembly/lnspection/R€assembly
NOTE:
. Cleanall parts thoroughlyin solvent or carburetorcleaner,anddry with compross€dair. Blow out all passagas.
. Check allvalvesfor free movement,It any failto slidefreely, see Valve Body Repairon page14-98.
. Coatallpartswith ATF beloreassembling.
. Replacethe valve body as an assemblyif any parts are worn or damaged.
AOLT
5r0.8
8 N m(0.8k s m , 5 . 8 l b - f i )
\
\
\
THROTTLE
SHORTVAIVE B
THROTTLE
LOI{GVALVE
THROTTLE
CAM
STOPPER
THROTTLE
ADJUSTING
BOLT
CAUTION: Do not loosen or remove.
RELIEF
VALVE
THROTTLE VALVEBOOY
InsDect
lor wear,
scratches
or scoring.
SPRINGSEAT
SPRINGSPECIFICATIONS
Unit:mm (in)
Stsndard{New)
No. Springs
Wire Dia. o.o. FreeLength No. of Coils
o ThrottlevalveB spring 1.40{O.O55) 8.so(0.335) 41.50(1.634) 10.5

1.40{O.O55) 8.50(0.335) 41.50(1.6341 11.2
1./tO(O.Oss) 8.50(0.335) 4 1 . 6 0( 1 . 6 3 8 ) 't2.4
Throttle vaVe I adjustingspring 0.& (0.o311 6.20tO.2Ml 3 0 . 0 0( 1 . 1 8 1 ) 8.O
Relietvalve spring 1.OO(O.O39) 8.40(O.331) 39.10(1.539) '15.1
@
14-107
Servo Body
NOTE:
. iiel"n attp"rts t6oroughlyin sofuentor carburetorcl6aner,anddty whh compt6ss€dEir.Blow out all passag.s.
. n"ptt"" itt" ""*o body as an assemblyil anYparts are worn or damsg€d'
. ReplaceATF strainet if its inlet openingis clogged.
. Cost all Dartswith ATF before assembly.
TORCOVER
MAG[{ET
Clean.
(<
\j
ATF STRAINER
Cleanor roplac€.
4TH ACCUMULATOR
PISTON
BASE
SERVODETET{T
OILFEEDPIPE
SERVOBODY
Inspoctlor woar
scratchg8or scoing.
O.RING
Replace,
SHIFTFONKSHAFT/SERVO VALVE
Inspoctfor sco ngor dama€|o.
3RD ACCUMULATOR
PISTON
SPRINGSPECIFICATIONS Unit: mm (in)
Stsndard(New)
No. Springs
Wire Di8. o.D. FreeLengrth No. of Coils
ot\ 4th accumulatorsPring 2.90(O.114) 22.@ (0.866) 90.10(3.547) 10.9

4.OO(0.157) 25.@ (0.984) 64.702.5/.71 7.3
1st-holdaccumulatorspring (4.114)
2.60 (O.102) 17.50(0.6€9) 104.50 18.O
3rd accumulatorspring
14-108
1st/2nd AccumulatorBody
NOTE:
. Cleanall parts thoroughlyin solvont or carbur€to.claaner,and dry with comprsssadair, Blow out all passsges.
. Cost sll psns with ATF b€fore sssembly.
CAUTIO : Do not usa r mrgnot to temoya the cfiack bal!; h may megnotlzo tho bals.
ACCUMULATOR
EODYCOVER
CHECKBALL
lST ACCUMULATOR
PrsTot{
2I{DACCUMULATOR
PISTON
sPRtt{GSPEC|F|CAT|O
S
Unit:mm (in)
Standard(Nsw)
No. Springs
Wire Di8. o.D. FreeLength No. ol Coils
o lst accumulatorsprim 1.e (o.o71) 16.30to.64a 115.40 (4.543) 18.6

@ zrd accumulatorspring 3.30to.130) 22.@ (0.866) 84.90 (3.343) 11 . 1
14-109
Mainshaft
NOTE:
. Lubricateallpartswith ATF duringreassembly.
.Instellthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher.
. Inspectthrust needle and needlebearingsforgallingand roughmovement.
. Before instsllingthe O-rings,wrap the shaft splineswith tape to prevent damageto the O-rings.
LOCKNUT{FLANGENUT}
Replace.
NOTE: Lotr-handthr6ads
23O N m (23O ks-m , 166 lb-ft}
+O )
170 N.m (17.0 ks-m.123 lb-ft)
CONICALSPRINGWASHER
R6place.
IOLERGEAR
TRANSMISSION
HOUSINGBEARING
SNAPRING
COLLAR
BEARING
THRUSTNEEDLE
4TH/REVERSE
GEAR
NEEDLEBEARINGS
O-RINGS THRUSTNEEDLEEEARIiIG
Replaco.
4THE GEARCOLI.AR
3RO/4THCLUTCH
ASSEMBLY
MAINSHAFT
Ch€ck splinesfor excessive
w6ar or oamage,
Check beadngsurtacetor
scorang,scratchesor 3RD GEARCOLLAR
?I{RUST EEDLEBEARING
NEEDLEBEARING
3RDGEAR
THBUSTNEEDLEBEARING
SEALINGRINGS.35 mm
RING,29 mm
NEEDLEBEARING
SET RING,23 mm
14-110
Countershaft
NOTE:
. Lubricateallparts with ATF duringreassembly.
.Installthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher,
. Inspectthrust needle and needlebesringstor gallingand rough movement.
. Before installingthe O-rings,wrap the shaft splineswith tape to prevent damageto the O-rings.
2ND GEAR
LOCKNUT(FLA'IIGENUTI
Replace.
230 N.m (23.0 ks"m , 166 lFft)
--r O -)
1 7 0 N . m( 1 7 O k s - m , 1 2 3h - t t l
REVERSE
SELECTOR NEEOLEBEARING
CONICALSPRINGWASHER
RsDhca.
REVERSE PARKII{G
GEAB
SELECTOR
THRUSTNEEDLE
BEARII{G
4TH GEAR
NEEDLE
BEARING IDLER
GEAR
COLLAR.
32 mm
COTTERS,
29 mm EEDLE
BEARING
DISTANCECOLLAR THRUST EEDLE
BEARhIG
3RO GEAR
THRUST
WASHER
TRAl{SMtSStot{
HOUSII{GBEARING
ONE-WAYCLUTCH
1STGEAR
COUI'ITERSHAFT
Ch6ck splin€sfor excessive
w€ar or damage. 1ST GEARCOLLAR
Check b€aringsurtacetor
scoring.scratchesor
lST-HOLD CLUTCH
ASSEMgLY
14-111
Countershaft
Removal
1. Using a press, press out the countershEft while
supponingth€ lst-hold clutch.
NOTE:
Place an attachment betwoen the press 8nd
countershaftto prevent dsmagsto the shalt.
14-112
lnstallation
NOTE: 4. Align the shaft splin€s with thoso of 3rd gaar, then
Lubricateall parts with ATF duringEssembv. pressthe countershaftinto 3rd gearwith a press.
1, Instslltwo new O-ringson the countershaft,

NOTE:
NOTE; . Also align the shaft splines with those of th€ lst-
Before installingthe O-ring6,wrap ths shaft splines hoH clutch when pressingthe countershaft into the
with tape to prsvent dsmagsto the O-rings. 3rd gear.
. Use 8n attachment between the shaft and a press
2. Assemblsthe 1st-holdclutch assembly,lst gearcollar, to provant damageto the countershatt.
thrust washer, needl€ bearing, lst gaar, one-way . Stop pressingthe countershaJtwhen the 1st-hold
clutch, thrust needlebearingand 3rd gear. clutch contacts the finaldrive gear.
PRESS
3RDGEAR
THRUST'{EEDLE
BEARIl{G
1ST-HOLDCLUTCH
O]TE-WAY CLUTCH
lnstallinthisdirection.
lST GEAR
I{EEDLEBEARING
THRUSTWASHER
lST GEANCOLLAR
1ST-HOLDCLUYCH
ASAEMBLY
3. Installth8 above assemblvon the countershaft.
14-113
One-wayClutch
Disassembly/lnspection/Reassombly
1. Separatecountorshstt 3rd g€ar from countershaft 1st 3. Inspectthe parts as follows:
gear by turning3rd g€arin the directionshown,
COU]YTERSHAFT
3RDGEAR
Inspsct3rd gear
for wear oascoring-
Inspoct the thaust
V
noodls bearing tor
damage or faulty
mov€mgm.
COUNTEBSHAFTIST GEAR
Remove the one-way clutch by prying h up with the

ffi.- Inspectth€ ono-way
clutch for damagoor
fauhy movement.
Inspect lst gear

tor w€ar or scoring.
end of a screwdriver,
ONE.WAYCLUTCH
After the Dartsare sssembled,holdcountershatt

1st gesr and turn countershatt 3rd gear in
directionshown to be sure it turns Ireelv.
3RDGEAR
COUI{TERSHAFT
1ST GEAR
COUT{TERSHAFT
14-114
SecondaryShaft
NOTE:
. Lubricstesll parts with ATF duringreassembly,
o lnstalltho thrust needlebesringswith unrollededgeof bearingretaineffacingwasher.
. Insp€ctthrust needle and needlebesringstor galling8nd rough movement.
. BsJoreinstallingthe O-rings,wrap the shatt splineswith t8pe to pravent damageto ths O-rings.
LOCKNUT{FLANGENUT}
Roplsc6.
23ON.m(23,0kg-m, 166 |tsft)
-JO-)
170 N.m(17.0ks-m.123lb-ft)
CONICALSPRING
WASHER
Replsco.
GEAR
IDLER
TRAI{SM|SS|OI{
HOUSTG
BEARII{G
THRUST
WASIGN
THRUSTNEEDLE
BEARING
2NDGEAR
SECONDARYSHAFT NEEDLE
BEARI]IIGS
Check splin€sfor oxcossive
w6ar or d6magE.
Chgck bearingsurfacofor
scoring,scrotchesor THRUSTNEEDLE
BEABII{G
excosstvowoat.
SPLIT{EDWASHER
p€rt
Sol6ctiv€
THRUSTNEEDLEBEARII{G
I{EEDLEBEARIMi
1STGEAR
DISTANCECOLLAR.5 mm
COTTERS,
29 mm
COTTER
RETAINER
SNAPRING
SEALING
RINGS,
32 mm
14-115
SecondaryShaft
Inspection
. CbarancaMaasurement 4. Messure2ndgearsaxialclearancewhile moving2nd
gear,
NOTE:
Lubricst€all parts with ATF duringsssemblv. 0.07-0.15 mm(0.003-O.0O6in)
STANDARD:
1. R€move the secondsry shaft bearing trom the NOTE:

transmissionhousing(seepsgo 1+129). Takemeasurements in at loastthlee plscos,anduse
the averageasthe actuslclearance.
2. Assomble the s6condsry shEft sssembly without
O-rings.Instsllth6 idler gear usinga press,then to.qu€
the 36cond8rythaft locknut to
30 N.m (3.0 ksFm, 22 lb-tt)
NOTE:
Do not instsllthe O-ringsduringinspection.
LOCKITUT
5. It the clearanceis out of tolerance,removethe splinsd

washer and measurethe thickness.
3. Attach the disl indicatorto 2nd gearas shown. SPLINEDWASHER
No. Pari l{umbol fhbknols

DAL INOICATOR
90406- PX4- 700 4.05 mm 1O.159in)
90407-PX4-7@ 4.10 mm(0.161in)
90408- PX4- 700 4.15 mm(0.163in)
4 90rto9- PX4- 700 4.20 mm(0.165in)
5 90410-PX4-7@ 4.25 mm (0.167 in)
o 90411-PX4-7m 4.30 mm {0.169 in)
90412-?X4-70o 4.35 mm 10.171in)
8 90413-PX4-700 4.2!Omm {0.173 inl
I 90414-PX4-700 4.45 mm {0.175in)
2ND GEAR 6. After r8plscingthe splinedwashsr, make sur€ that the

clearanceis within tolgrance.
14-116
Clutch
lllustratedIndex
3RD/4TH CLUTCHASSEMBLY
SI{AP RII{G
CLUTCHEI{DPLATE
ct uTcHDrscs
Stshdardthickness:
1.94 mm {0.076 inl
CLUTCH PLATES
Standard
thicknoss:
2.30 mm(0.091in)
nEruRNsPuu'rc---'--@
SNAP RII{G
srRrnc
aeurnea.-(C)
SPRI]TGRETAINER
s APRTNG--o
RETURNSPRII{G
PISTON
CLUTCHDISCS O.RINGS
Standardthickn6ss: Rsplacs.
'l
.94 mm (0.076 inl
CLUTCHDRUM
(cont'd)
14-117
Clutch
1ST/2NDCLUTCHASSEMBLY:H23A1 Ensino
CLUTCHENDPLATE
SPRINGRETAINER
SPRINGRETAINER
CLUTCHENDPLATE
SNAP RING
2ND CLUTCHDRUM
lST CLUTCHDRUM
14-118
L
1ST/2NDCLUTCHASSEMBLY:
F22A1Enstn€
O-RINGS
Replace.
CLUTCH PLATES
----.....-__----l/
PrsroN Standard
thicknoss:
Xtt
v
2.60 mm(0.102in)
qfluansrnrNcre
SPRTNG -=...._<> Y) smr nnc--..-...- -l-,,

RErarr{ER
sPRr
GRETATNEB----__.._<>
SNAPRtNG--___..v-)
& RETURNSPRING
DISCSPRING
2ND CLUTCH
DBUM
1ST CLUTCHDBUM
{cont'd}
14-119
Clutch
1ST-HOLDCLUTCHASSEMBLY
CLUTCHE O PLATE
CLUTCHPLATES
thicknsss:
Standard
2.00 mm(0.079inl
-----------....
sr{APR|NG 13
------..-..-<>
RETATNER
SPRTNG
RETURN
DISCSPBING
PISTON
O-RllrlcS
B6placs.
CLUTCHDRUM
14-120
Disassembly
1. Remove the snap ring, then remove the clutch end Installthe specialtoolsas shown.
plate,clutch discs and plates.
NOTE: For lst-hold clutch
NOTE: For a clutches
CLUTCHSPBING
COMPRESSOR
ATTACHMENT
SNAP RING oTLAE-PX40100
CLUTCHSPRING
COMPRESSOR
ATTACHMEI{T
SCBEWDRIVER 07HAE-P150100
Removethe discspring.
NOTE: For 1st-hold€nd 2nd clutches

NOTE: For 1st,2nd,3rdand4th clutches.
DISCSPRING
CLUTCHSPRING
COMPRESSOR
ATTACHMEiIT
OTLAE-PX/[O1OO
CLUTCHSPNNG
COMPRESSOR
ATTACHMEIYT
07HAE-P150100
CLUTCHSPRING
COMPRESSOR
AOLT ASSEMBLY
07GAE-PG40200
{cont'dl
14-121
Clutch
(cont'd)
Disassembly
CAUTION: Removethe snap ring.Then remove the spscialtools,
It olthor ond of tho comproraor attachmont i! 3ot ovel an springretainer8ndretrunspring.
aroa ol the sprlng rotalner which ls unsuppo od bY the
rsturn sprlng.the rotalnor may be d8magod.
Do not s6t hore.
NOTE: SteDs4 thru 6 are for allclutches.

Wrap a shop rag aroundthe clutchdrum and apply8ir
Compr€ssthe returnspring. pressureto the oil passageto removethe piston.Plsco
a tingertip on the other €nd while appving air pres6ure.
14-122
t
Reassembly
NOTE: 4. Installthe piston in the clutch drum. Apply pressure
. Clean sll parts thoroughly in solv€nt ot carburetor and rotate to ensureproper seating.
cleangr,and dry with compressedarr.
. Blow out all psssages, NOTE:
. Lubricateall parts with ATF beJoreassembv. . Forallclutches
. Lubricate the piston O-ring with ATF before
1. Inspectthe piston for a loosecheck vslve, if the check installing.
valve is loose,replaceth€ p;ston.
CAUfION:
Do not dnch O-ringby instaling the ],iston whh force.
CHECKVALVE
PISTON
PISTON
Be sure that the disc springis securelystaked.
NOTE: CLUTCHDRUM
For 1st, 3rd and 4th clutches
Installnew O-ringson the piston. Installthe return springand springretainerand position

the snapringon the retainer.
O-RINGS
NOTE: For allclutches
(cont'd)
14-123
Clutch
Reassembly(cont'd)
6. as shown.
Installthespecialtools CAUTION:
lf otthor end of lho comprslsol attachmcnt b 8ct
NOTE: For 1st-holdclutch ovor an lroa of the sp ng lelalnor whlcft k
unrupportod by tha toturn sprlng.tha rctalnel may b€
dam!god.
CLUTCHSPRIiIG
COMPRESSOR
ATTACHMEiTT
07LAE- PX40100
CLUTCHSPRI G
COMPRESSOR
ATTACHMENT
oTHAE- Pl601 00
Do not set h6ro.
CLUTCHSPRING
COMPRESSOR
BOLTASSEMBLY
07GAE-PG402q)
NOT€: Steps 7 thru I 8re for allclutches.
7. ComDresathe retuln sPring.

NOTE: For 1st, 2nd, 3rd and 4th clutches
CLUTCH SPRING
COMPRESSOR
ATTACHMEITT
07LAE- PX40lOO
CLUTCHSPRI G
COMPRESSOR
ATTACHMET{T
oTHAE-P150100
CLUTCHSPRING
COMPRESSOR
SOLTASSEMALY
OTGAE PG4O2OO
14-124
8. Installthe snap ring. NOTE: Steps11 thru 15 aretor allclutchos.
11. Soak the ctutch discs thoroughv in ATF tor I mini-

mum ot 30 minutes.
12. Starting with I clutch plats, ahernately instsll ths

clutch platesand discs,Installthe clutch end platewith
flat sidetoward the disc.
NOTE:
Before installingthe platss snd discs, mske sure the
insideof the clutch drum is free of dirt or other forsign
mattot.
CLUTCHENDPLATE
CLUTCH
Dtsc
9 . Removethe specialtools.
1 0 . Installthe disc spring.
NOTE:
. For 1st-holdand 2nd clutches
. Installthe disc springin the directionsnown.
13. Installth€snspring.
Dtsc SPRI{G
SCREWDBIVEB
(cont'dl
14-125
Clutch
Reassembly(cont'd)
14. Measurethe clearancebetween th€ clutch snd plate

1E It the clearanceis not within th€ service limits,select a
8ndtop discwith a dislindicator. new clutch €nd platefrom the followingtable'
Zero the dial indicstor with the clutch end plste
lowered and lift it up to the snap ring. The distancs NOTE:
that the clutch end plate moves is the cleatance It the thickest clutch €nd plst€ is installsd but the
botween th€ clutch end plate8nd top disc. clearanceis still over the st8ndatd,roplacethe clutch
discs 8nd clutch plstes.
NOTE:
Measureat three locations. CLUTCHENDPLATE
Clutcfi End Plato-to-TopDisc Glearance: Phte Part Number Thlckncrs

t{o. mm (lnl
Clutch Seryico Llmh 1 22551-PX4-@3 2.10(0.o&')

2,562-PX4-m3 2.n lo.oaTl
1st 0.65-0.85 mm(0.o26-O'033in) 3 22553-PX4-OO3 2.30(0.091)
2nd 0.65-0.85 mm(0.026-0.033 in) 4 22554-PX4-0o3 2.40 to.og4l
3rd 0.40-0.60 mm(0.016-0.024 in) 5 22555-PX4-@3 2.50(0.098)
4th 0.40-0.60 mm(0.016-0.024 in) o 22556-PX4-@3 2.60(0.102
1st-Hold O.&-1.0O mm(0.031-0.039in) 22557-PX4-@3 2.70(0.106)
I 22558-PX4-003 2.& (0.110)
9 22569-PX4-003 2.90(0.114)
TOPDISC
CLUTCHENDPLATE
14-126
TorqueConverterHousingBearings
MainshaftBearing/Oil
SealReplacement
1. Driv€ out th€ mainshaftbearingand oil seal, usingthe 3. Installthe n€w oils6alflush with the housing,usingthe
sDecisltoolsas shown, sDscialtools as shown.
DRIVER
07749-OOTOOOO
DRIVER
07749-001o(xro
ATTACHMEIYT
07947- 6340500
ATTACHMEI\IT.
72x75mm
07740-(x)lo6{x,
TOROUE
COI{VERTER
HOUSIT{G
Orive in the new mainshaftbsaringuntil it bottoms in

the housing,usingthe specialtoolsas shown.
DRIVER
07749-OOl(xXX'
ATTACHMENT,
62x68mm
07746-(xrlos(x,
14-127
TorqueGonverterHousingBearings
CountershaftBearingReplacement ShaftBearing
Secondary Replacement
1. Remove the countershaft bearing using the special 1. Remove the secondary shaJt bearingby heating the
toolas shown. torque converter housing to 212oF {10O"C) with a
heat gun, then tap the housinguntil the bearinglalls
our.
Comrnarclaly CAUTION:
AvoiLbL Do not hoat tho case in excsss of 212oF (1OOoCl.
3/8 ln, r 16 throad./ln.
![de hammai
ADJUSTAELE
BEARII{G
PULLER,
25-4O mm COUTttTERSHAFT
07736-AO1000A NEEDLEBEARII{G
/-\.=\-\
\, _-,/-_--_\,
Installthe oil guideplate. 2. Installthe oil guideplate,

Drive th6 new bearing into th€ housing, using the 5. Drive the new bea.ing into the housing, using the
specialtoolsas shown. specialtoolsas shown.
DRIVER
07749-(x)lOqro DRIVER
07749-OO10000
ATTACHMEifT,
62x88mm
07746-0010500
BEARING
BEARING
0 -0.03
l0 0.01inl O-0.03 mm
(0-0.01 In)
HOUSING
HOUS[{G
OII GUIDEPLATE OIL GUIDEPLATE
14-128
HousingBearings
Transmission
1. To r€rnovsths mainshait,countershsft and secondary Expsnd€ach snap ring with snap ring pliers,insert
ins the
shaft bearingslrom the tranamissionhousing,expand :he pliors.
new b€aringpart-way into it. then releasethe
each snap ring with snap ring plisrs, thon push th€ Push the bearingdown into the transmission I until
u the
bearingout. ringsnapsin placaaroundit,
NOTE: NOTE:
Do not remove th€ snap rings unlessit's necesaaryto Inst8llwith groove side o{ the housingfacing inside
ins the
cl€anthe groovesin the housing. transmissionhousing.
lnstali
I
I
Remov€
After installingth6 bosringverify the following:

. The snap ring ls se8tedin the bearingand housing
hol
groovas.
. Th6 snap ring operatesproperly.
. Ths ring6nd gap is correct.
P: 0-7mm
(O-o.28 in)
SNAP RING
14-129
Transmission
Reassembly
NOTE:
. Coat all parts with ATF.
. Replace the partsbelow:
.O-rings
. Lock washers
. Gaskets
. Locknutsandconicalspring washers
. Sealingwasher
. Torquethe 6 x 1.Omm Bohs:
1 2 N . m( ' 1 . 2k s m , 9 l b - f t ) 6xl,Omm
2 Bohs
Tluffir
e:'1
THROTTLE ATF STRAINER
CONTROL
SHAFT
Iw
4TH ACCUMULATOR
COVER
8x1.Omm
2 Bohs
1 Boh LOCKWASH€R
F;flilf":-. VALVE
REGULATOR
BODY
Reolace.
SERVODETET{T
O-Rlf{G 7
BASE
STOPPER
Replace.
TOROUECOIWERTER SERVOSODY
CHECKVALVE STATORSHAFT
CHECKVALVE SPRING DETEI{T ARM S}IAFT

SERVOSEPABATOR
DETENf ARiI PLATE
OIL FEEDPIPE cot{TRoL

SHAFT CHECKBALLS
6x 1.0
1 Boh VALVE
SECOI{DARY
BODY
8 x 1.25mm
'18N m (1.8ks-m
'13lb-ftl
SECONDARYSEPAFATOR
MAINVALVEBODY PLATE
OIL PUMPDRIVEN 6 x l.O inm

GEARSHAFT
V 6 Eohs
OIL PUMP DRIVENGEAR OILPUMPDRIVEGEAR ACCUMULATOR

BODYCOVER
MAIN SEPARATORPLATE lST/2ND

ACCUMULATOB
EODY
DOWELPIN
TOROUECO VERTERHOUSIT{G
14-130
L Installthe main sepa.ator plate with three dowel pins 8. Installtho s€condarysaparator plate with two dowol
on the torque converter housing.Then install the oil pins on the mainvalve body.
pumpgearsandoil pumpdrivengearshaft.
Installth€ control shali in the housingwith the control
NOTE: shaft and msnualvafuetogether.
Installthe oil pump driven gear with its grooved and
chamteredsidefacingdown, 1 0 . Installthe d€tent arm and alm shatt in the main valve
body, then hook the detent springto tho detent arm.
OIL PUMP DRIVEN
GEARSHAFT
\ SERVOSEPARATOR
PLATE
\ rr-'rr
orl PUMP \ 11 ll
DRIVEGEAR \ II II
\U GRoovE
|
SECO DARYVALVEBOOY
OII PUMP
DRIVEN CHAMFER
GEAB
Grooved€nd chamfer6d COIVTBOL
SHAFT
aidefac€s separatorplats.
Installthe main vafue bodv whh tour bohs. Maks sure

the oil pump drive gear rotates smoothly in the normal
operating direction and oil pump driven gsar shaft
movss smoothly in the axial and normal operating
directions. DETEI{TSPRING
lf the oil pump drive gear and oil pump driven gear
shatt do not move treely, loosenthe main valve body
bohs, realignthe oil pump driven gear shatt, and th8n
retightento the specifiedtorque.
CAUTION:
Failuro to align tho oll pump drlvan goEr shaft
correctly wlll rosuh In a seizadoll pump drlva getl 01 MANUALVALVE
oil pump driven gear shalt.
1 1 . Installthe secondaryvslve body, servo separatorplate

and servo body with seven bohs.
't2. Installth6 oil fosd pipe in tho servo body, then install
the 4th 8ccumulatorcover whh three bohs.
OIL PUMPORIVEN 12 Installth6ATF strainerwith two bohs.

GEARSHAFT
14. Installthe servo dotont base with two bohs and new
lock w8shers.
:/
)
1 5 . Inst8llthe lst/2nd sccumulstorbody with six bohs.
OIL PUMP
OIL PUMP DRIVENGEAR 1 6 . Installtwo oil ts6d pipes in the main valv€ body and
DRIVEGEAR th€ pipe in the servo body,
4. Installthe stator shaft and stoDDershaft.
5. Install the two dowel pins, torque converter check

vafue and torque converter check valve spring in the
mainvalve body.
Installthe.egulator valve body with the bolt on the

mainvalve body.
7. Installthe two dowel pins and separator plate on the

regulator vatue body, then install the throttle vave
bodv with seven bohs. (conr'd)
14-131
Transmission
Reassembly(cont'd)
17. Install the differential assembly, countershaft sub- 20. Turn the shitt tofk shaft so the largechamferedhole is
assembly, mainshatt sub-sssembly, and secondary facingthe fork bott hole.Th€n installthe shift fork and
shaft sub-assemblvin the torque converter housing. the lock boh with a new lock washer, and torque
Bendthe lock tab againstthe boh head
MAINSHAFT
SUB-ASSEMBLY COUNTERSHAFT
SUB-ASSEMBLY
SH|T FORKBOLTHOLE
SCCONDARYSHAFT
SUB.ASSEMBLY
LOCKWASHER
R€plac6.
LOCKBOLT
6x1.Omm
14 N.m{1.4 kg-m,
10 rb-ft)
SHIFTFOBKSHAFT
BOLTHOLE
Largechsmt€redhole
facssthisway.
TOROUE
COi|vERTER
HOUSING
1 8 . Installthe splined washer, thrust needle besring 8nd 2 1 . lnstsll the secondary shaft 2nd gear, thrust needle
needlebearingson the secondaryshaft. boaring and thrust washer on the socondary shalt.
Installthe countershaft reverse gear and 2nd gear on
1 9 . lnstall the needle bearings. countershaft 4th gear, the countershaftas shown.
reverse selector hub, and reverse selector with the
shift fork on the countershaft.
NEEDLE
BEARING THRUSTWASHER COU TERSHAFT
21{DGEAR
REVERSE
SELECTOR SHIFTFORI(
THRUST
REVERSE NEEDLE
lnsta in this direction. BEARIMi
COUUTERSHAFT
REVEBSE
GEAR
SECONDARY
EEDLE SHAFT
BEARINGS 2NDGEAR
COUNTERSHAFT
COUNTERSHAFT
THRUST 4TH GEAR SECONDARY
NEEDLE SHAFT
BEARING NEEDLE
BEARIiIG
COUNTERSHAFT
SECOI|I'ARY SHAFT
14-132
22. Slipthe r€verseidlsr gearinto the transmissonhousing m. hstall the trsnsmissionhousingbolts and t.ansmission
€s snown. hanger,then torque the bolts to 55 N.m (5.5 kg-m, rlo
lb-ft) in two or more steps in the pattern shown.
,Adlafu
v|>=l
R@P
23. Align the spring pin of the control shaft with the
transmission housing g.oove by turning the control
shaft. 27. Engagethe reverse idler gear to the countershaft and
mainshattreverse gesrs, then installthe reverse idler
24. Install thr6€ dowel pins and a new gasket on thg gesr shaft holderon the transmissionhousing,
torqus converter housing,
25. Plscs ths transmission housing on the torque

convert€r housing. 6x1.0mm
12 N.m (1.2 ks-m ,
CONTROL
SHAFT I lb-ft)
1 0r 1 2 5 m m
55 N'm (5.5 kg-m ,
40 b-ftt
DOWELPI P
hE
28. Install the parking brske lever on the control shaft,

then torque the lock bolt loosely with a naw lock
wasner.
NOTE:
Do not tighten the lock boh to the specifiedtorque and
bendthe lock t8b in this steD.
DOWELPIN
14-133
Transmission
Reassembly(cont'dl
the mainshaft.
29. Sliothe sDecialtoolonto 35. Placea 24 mm socket on the parkinggeEr,and instslla
10 x 1.25 mm boh in the count8rshaft. Then engage
MAINSHAFTHOLDER the parking brake pawl with the parking gesr by
OTGAB-PF50100ol movingup the parkingbrake pawl.
07GAB-PF50101
CAUTlOltl:
K€ap anof tho particlosout of tho transmissionwhon
insialllng a bolt.
36. Tightenthe boh and lightlyseat the parkinggear.
NOTE:
Do not drive the parkinggearon whh a hammer.
37. Removethe boh and socket.
38. Use the old locknut to tighten the press fit parking
gearto the specifledtorque, then loosenit.
TOROUE:230 N'm {23.Oks-m,166 lb-ft)

30. Installthe mainshaftidlergear.
21 Installthe old locknut on the mainshaftto seat the idler SOCKET.24mm
gear.
PARI(INGGEAR
NOTE:
. The mainshaftlocknut has left-handthresds,
. Do not drive the idlergearon with a hammer.
TOROUE:230 N m (23.Oks-m, 166 lb-ft)
32. Installthe secondaryshaft idlergear on the secondsry

shaft. 10 x 1.25 mm
BOLT
33. Installthe thrust wash€r, thrust needlebearing,needle
bearing,countershatt idler gear and parking gear on PARKINGBRAKE
the countershatt. PAWL
34. Installthe old locknut on the secondaryshaft. Tighten 39. Remove th€ old locknuts, th8n install new conical
the old locknut to seat the secondaryshaft idler ge81 springwashers8nd new locknutson each shstt'
while holdingthe countershsJtidlergear.
CAUTION:
NOTE: Insts[ th€ conical spfng washora In tho di]octlon
Do not drive the idlergearon with a hammer. shown,
T O R O U E :2 3 0 N m ( 2 3 . 0 k s - m , 1 6 6 l b - t t ) MAINSHAFTLOCKNUT
Left-h8ndthr€ads
PARKII{GGEAR COUMTERSHAFT
LOCK'{UT
St€mp siJs
CONICALSPRING
WASHERS
hstall in this
diroction.
SECONDARYSHAFT
IOLERGEAR
14-134
40, Tightenthe locknutsto sp€cifiedtorque. 42. S€t rhe psrking brake lever in tne lT-l position, thon
verity that the parkingbrake pswl ei-gagesthe parking
TOROUE: 9ear.
Mainrhaft 170 N'm {17.Okg-m, 123 lb-Jt)
4i,. lf th€ pswl doss not engagefully, check the psrking
Countorshaft 170 N.m (17.0 ks-m , 123 lb-ftl brake pawl stopper clearanceas describedon page
1+136.
't70
Secondaryshaft N.m (17.0 ks-m, 123 lb-ft)
44. Tightenthe lock boh, and bendthe lock tab againstthe
NOTE: bolt head.
Themainshsftlocknuthaslelt-handthreads
PARKIMiBRAKE
LEVERROLLER
TOROUEWRENCH
SECONDARYSHAFT PARKINGBRAKE PAWL

IOLERGEAR PAWLSHAFT
45. lnstallthe right sidecover.

41. Stake each locknut into its shsJt using a 3,5 mm puncn.
TOROUE: 12 N'm {1.2 kg-m, 9 lb-ftl
0.7-1.2 mln
10.o3-0.05Inl
46. InstalltheATF cooler pipeswith new sealingwashers.
TOROUE:29 N'm (2.9 ks-m , 21 lb-ft)
47. Installthe ATF levelOauge.
14-135
V
RightSideCover ParkingBrakeStopper
FeedPipeInstallation Inspection/Adjustment
Installthe feed pipes in the right side cover with new 1. Set the parkingbrakeleverin thel P lposition.
O-,ings,aligningthe lugs with the grooves in the right
side over. 2. Measurethe distancebetween the psrkingblake pawl
shaJtand the parkingbr8ke lever roller pin as shown.
Installthe snap rings,
STANDARD:64.5-65.5 mm {2.54-2 58 in)
PARKINGBRAKE
PARKINGGEAR LEVERROLLERPIN
LOCK BOLT
6xl.0mm
14 N.m (1.4 kg-m ,
10 tb-ft)
Distanc6
PARKINGBRAKE
STOPPER
PARKINGBRAKELEVER
Fififtflllf* PARKTNGBRAKE
NGHTSIDECOVER
ff the measuremant is out oJ tolerance, select and

installthe sppropriateparkingbrakestopperfrom the
tablebelow.
,- '.l r - - f f i - T , , .
--Tr I r lr \ , l\ ,l , / |
\ \t-l /
,/r>
PARKINGBRAKESTOPPER
BRAKESTOPPER
PARKING
Mark Part Numbor Ll Lz
I 24537-PA9-OO3 11.0Omm 11.00mm

(0.433 in) (o.433in)
2 24538-PAg-m3 1O.8Omm 10.65 mm

(0.425 in) (0.419 in)
24539-PAg-OO3 10.60mm 10.30mm

(0.417in) (0.400in)
After replacingthe parkingbrakestoppor,make sure

the distanceis within tolerance.
14-13 6
TorqueConverter
Disassembly
ErlOm.r| DRIVEPLATE
75 N.m{7.5kem , 54 b-ftl for crackg.
lnsD€ct
TOROUECO VERTER
GEAR
ASSEMBLY/RI'{G
1 2x 1 . 0m m
75 N.m(7.5kgtsm , 54 b-ft)
Torquoin crisscrogsDattgrn.
14-137
Transmission
lnstallation
1 . Flush ths ATF cooler as describedon psges 14-142 5. Installth€transmissionhousingmountingbolts.
and 143.
2. lnstall the stsrter motor on the torque converter

housing,and inst8llthetwo 14 x 20 mm dowel pinsin
the torque converter housing,
45 N.m 14.5 kg-m , ATARTERMOTOR

33 tuft)
DOWEL
'14x 20 PIN
mm
TRAI{SMISSION HOUSIG
MOUiITING BOLTS
12 r '1.25mm
65 N.m(6.5 kgtsm
,47 lb-ft)
DOWELPIN
14r20mm
Roplaca.
TOROUECONVERTER
ASSEMBLY o. Tighten the front engine mount bracket bolts to
sp6cifiedtorque.
Place the transmission on I jack, and raise to th€
engine8ss€mblylevel.
FROT{TEI{GII{EMOUNf
4. Attach the transmissionon the engine,then installthe BRACKETBOLTS
transmission housing mounting bolts, raar engine 10 x 1.25 mm
mountingbohs and intake maniJoldbracket botts. 39 N.m (3.9 ksFm, 28 lb-ft)
INTAKEMANIFOLD
ERACKETBOLTS
I x 1.25 mm
2. N.rn 12,2 kg-m ,
I1{TAKEMANIFOLD
BRACKET 16 tb-ft)
TRANSMlsSION
HOUSING
MOUNTINGBOLTS
12 r 1.25 mm
65 N.m (6.5 kg-m ,
47 tb-ft}
FNOI{T E GINE
MOUNTBRACKET
FROI{TE'{GINE
MOUl{f
TRAfISMISSK)NJACK REARENGINEMOUNfiNG
BOLTS
12 x 1.25 mm
R€plac€.
55 N.m (5.5 ks-m ,40 lb-ft)
14-138
Installthe transmissionmount. Tighten the bott then 10. lnstafi the control lsvsr with the shift cable on the
tighten the nuts to specifiedtorque, and retightenthe control shaft,
boh to specifiedtorque.
NUTS CAUTION:
1Ox 1.25mm Tak6 cara not to bondtho shlft cEHo.
39 N'm(3.9kem,28 b-ft)
11. lnstallthe lock boh with a new lock washer,then bend
ths lock tab.
12. Instsll the toroue converter cover and shift cable

covar.
SHIFTCABEL
cot{TRoL
LEVER
LOCK
WASHER
R6plsc€.
CONTROL
SHAFT
SHIFTCABLE
COVER
8 x 1.25 mm
18 N.m (1.8 kg-m ,
TOROUE
LOCI(BOLT COI{VERTER 13 lb-ftl
1 2 r 1 , 2 5m m 6x1.Omm COVER
65 N.m {6.5 kgim , 47 h-ft) 14 N'm (1.4ks-m, 0 x 1.0 nvn
10 b-ft) 12 N.m (1.2 kg-m,9 lb-ft)
8. Removethe transmissionjack.
13. Installthe rightradiusrodanddamperfork.
o Attach the torque converter to the drive plats with
eight bolts, snd torque to 12 N.m (1.2kg-m, 9lb-ft). NOTE:
Rotate the crankshsJt 8s necessary to tighten th€ Checkfor dotsriorationor damageof the radiusrod
'll2 rubberbushings.
botts to of the specifiedtorque, then linaltorque,
in I crisscrossDattern.
After tightening the last bolt, check thst the SELF.LOCKING NUT
crankshaft rotstes freslv. 1 2 x 1 . 2 5m m
DAMPEBPINCHBOLT 55 N.m {5.5 kg-m ,40 b-ft}
1Ox 1.25 ftm R6place.
6x1.Omm 44 N.m(4.4kem,32 b-tr)
75 N'm (7.5 kgtsm. 54 h-ft) Roplace.
RUBBER
BUS}IINGS
RADIUSROD
l2 x 1.25 mm
105 N.m (10.5 kgFm.76 lb-ft)
Roplaco.
{cont'dl
14-139
Transmission
1 4 . Instsllnew set ringson th€ end of th€ drivsshsfts' 19, Installthe vehicle speed sensor/powersteeringspeed
ssnsor and roar stiffoner. Conngcl the vehiclo spe6d
1 5 . Installthe right snd left driveshafts. sensorconnecror.
SPECIALBOLT
6x1.Omm
NOTE:
12 N'm(1.2kgFm.9b-ft)
Turn the right 8nd lelt steeringknucklesfully outward,
and axisllv into th€ difterential until you f8sl th€ set
ring engageth€ sidegear.
to. lnstallths damDerfork to the lower arm. Thsn instsll

the bslljoint to the lower arm. Usethe castls nuts whh
new cotter olns.
POWER
STEERIl{G
SPEED
SE\lsqR
10x 1.25mm O-RING

21 N'm (2.'lks-m, R6pbc6.
15 tb-ft)
REARSTIFFENER
1 O r 1 , 2 5m m
39 N.m(3.9 ks-m, 28 lb-ft)
SELF-LOCKING NUT
12 r 1.25 mm n. Connoctth€ ATF cooler hosesto the ioint pip6s.
65 N.m {6.5 kem , 47 b-ft} COTTERPI
R6phco. Replaca. 21. Connect the lock-up control solenoid, shift control
CASTLEIUT solsnoid vslve connectors, 8nd the throttle control
l2 x 1.25mm cabls.
65 N.m16.5ks-m, 47 h-ft)
22. Connectths msinshaftsp66dsenaorconnector.
17. Installth€ rear beamstiff€ner 8nd center be8m. SOLEM)IDVALVE

col{t{EcToRS
CEI{TERBEAM
1 0x 1 . 2 5m m
39 N.m{3.9 ks-m. 10 x 1.25mm
28 b-ft) 60 N.m{6.0 krm ,
43 tb-ft) Installthe ground
18. hstat the solashshield. cablein step 26.
,t 14-140
B . Connectthe countershaitsoeedsensorconnector. 27. Install the intske control vacuum tank and intake
control vacuum tank brscket, then connect the
24. Connectth€ starter motor cables. connecror.
NOTE:
When installingthe starter cable, mak€ sur6 that the 28. lnstallthe air cleanerhousingand intake air duct.
crimped side ot the ring terminal is facing out (see
section 23). 29. Refillthetransmissionwith ATF (see page14-74.
COUI{TERSHAFT
SPEED 30. Connect the battery positive (+) and negative (-)
SEITISOR
CONNECTOR cablesto the battery.
31. Start the engine.Set the parkingbrake,and shitt the

trsnsmissionthrough all gears three times. Check tor
proper shift cablesdjustment.
32. Check 8nd adjust the front wheel alignment (see

section 18).
33, Let the enginereach operatingtemperatur!_lthe

ralie-torf8ncom€son)with the transmission inI N I or
I P I position,thenturn it off andch6cktluidl8vel.
34. Roadtest as describedon pages1+68 thru 14-7O.
35, R8setths radiostations.
36. Loosenthe tront enginemount bracket botts after the

CABL€S road test, and retightenthem to specitiedtorque.
25. lnstallthe bsttery bsseand basestay.

26. Connect the ground cable to the body and the
transmission. FRONTENGINE
MOUNTERACKET
GROUND
CABLE BOLTS
1Ox 1.25 mm
39 N.m(3.9 ks-m, 28 lb-ft)
FROl{f ENGINE
MOUiff
BATTERYBASESTAY
14-141
I
Transmission
CoolerFlushing
7. With ths water and air valves oft, attach the wat€r
To prcvent iniury to faco and eyes, always woar salety to the Jlusher,(Hot water it svailsbl8.)
8nd air suDDlies
glasses 01 a laco shleld when using tho lransmlssion
tlusher,
NOTE: OFF
This procedureshouldbe performedbefore reinstallingthe
transmission.
1. Checktool andhosesfor wear or cracksbeforeusing.

It wear or cracks are found, replacethe hoses betore
using.
2. Usingthe measuringcup, fillthe tank with 21 ounces

(approximately23 full)of biodegradable tlushingfluid
(J35S44-20). Do not substitute with any other tluid.
Followthe handlingprocedureon the tluid container.
3. Securethe flusherfiller cap and pressurizethe tank

w i t h c o m p r e s sa i r t o b e t w e e n5 6 0 - 8 4 5 k p a { 5 . 6 -
8.45ks/cm,,80- 120 psi).
Turn on the flusher water vave so water will flow
NOTE: throughthe oilcoolerfor 10 seconds
The air line should be equippedwith a water trap to
ensureI drYair system. NOTE:
lf wster doos not flow through the oil cooler it is
4. Hsngthe tool underthe vehicle. completoly plugged.cannot be flushed, and must be
reolaced.
5. Attach the dischsrgehose of the tank to the return
lineot the transmissioncooler usinga clamp, 9. Depressthe trigger to mix the flushing fluid into thg
water flow. Usethe wire clip to holdthe triggerdown.
6. Connect the drain hose to the inlet line of the
transmissioncooler usinga clamp. 1 0 . While flushing with the wat6r and flushing fluid {or 2
minutes,turn the sir valveon for 5 secondsevery 1S
IMPORTANT: 20 secondsto create a surgingaction.
Securelyclampthe oppositeend of the drain hose to a AIR PRESSURE; MAX 845 kp8 (8.45kg/cm', 120 psi)
bucketor floordrain,
11. Turn the water vave off. Releasethe trigqer,then
reversethe hosesto the cooler so you can tlush in the
oppositedirection.Repeatsteps I through 1O.
12, Releasethe trigger and allow wster only to rinss the

cool€r with water tor one minule
13. Turn the water vslve ofl 8ndturn off the water supply.
14. Turnthe air vslveon to dry the systemout with airJor

two Jull minutes or until no moisture is visible leaving
the drainhose.
CAUTION:
Rosldual moisturo In the oil coolor or plpo3 can
damagethe tiansmlssion.
15. Removethe flusherfrom the coolerline.Attach the

drainhose to a oil container,
16. Install the transmission and leave the drain hose

attachedto the coolor line.
TRANSMISSIONCOOLER
FLUSHER
J38405-A
14-142
L
1 7 . Make sure the transmissionis inl P lposition. TOOL MAINTENANCE
Then tillthe trsnsmissionwith ATF and run the engine
for 30 secondsor until approximately0.95 0 (1.0 US 1. Emotyandrinseatter eachuse.Fillthecan with watsr
qt.,O.8lmpqt.l is discharged. and pressurizethe can, Flush the discharge lino to
ensurethat the unit is clean.
1 8 . Remove the drain hose and reconnect the cooler 2. lf dischargeliquiddoes not foam. the orifice may be
return hose to the transmission. blocked.
tcl Refillthe transmissionwith ATF to the orooer level 3. To clean,disconnectthe plumbingtrom the tank at the
(seep89e 1+74. largecouplingnut.
4. Remove the inline tiher from the dischargeside and

cleanif necessary.
5. The Jluidorifice is locatedbehindthe fiher.

Cleanit with the pick stored in the bottom of the tank
handleor blow it cleanwith air. Securelyreassembleall
DArtS.
FILLERCAP
14-143
E
t shift cable
1. Removethe front console{seesection 2O}'
. Make suro llfts, lacks and sat€ty stands aro dacod Z. Stritt to I tttl position, then remove the lock pin from
plopelly, and hobt brackots ars attachod to the corroct the cabte-adiuster.
positlon on the englne{se6sectlon 1).
. Apply parklng brake and block roar whoob, so car wlll
3. Removethe bohs securingthe bracket.
not lol olf stands and fal on you whllo working undorh.
CAUTION:
. A SRS olectllcal wiring harnorsos aro coverod whh
LOCK PI
ydbw oui61 imulaiion.
. Boforo dlsconnectingthe SRS who harness, Instal tho 6 x 'l.Omm
short conn€ctor(s)on the aiftag(sl. 10 N.m (1.0 kg.m , 7 luft)
. Roelacetho 6nthe aft€ctod SRS harn63sa$cmbly lf h
has an opon circuh or damag€dwiring.
BRACKET
ADJUSTER
4. Removethe shitt cablecover.
Remove the lock boh securingthe control lever,

removethe control lever with the shift cable'
SRSMAIN HARI{ES8
COt{TROLLEVER
6x1.Omm
1 2 N . m( 1 kem , I lb-lt)
SHIFTCABLE
sHtFT LOCKBOLT
CABLE 6x1,0mm '10lb-ftl
COVER 14 N'm 11.4kem ,
8 x 1.25 mm
18 N.m (1.8 ks-m, 13 b-ft)
14-144
6. Removeth€ exhaust pipeB and heat shiell. 8. Removethe cotter pin and lock pin, then separatetho
control l€ver from the shift cable.
SELF.LOCKING NUT
34 N'm(3.4 kem . 25 b-ft)
R6pl8c€.
SHIFTCABLE
SELF.LOCKING NUT
56 N.m (5.5 k$m ,40 b-ft)
HEAT SHIELD
COTTERPIN
Rspbca.
EXHAUSTPIPEB
9. lnstallth8 shift cabl€in the reverseorder of removal,
GASKET
R6phc€.
10. Check the cable adiustment after instsllingthe shift
cable (seepage1+146).
7, Romovethe cablsguideand grommet.
Exl.Omm
12 N.m (1.2 ksFm,I b-ft)
14-145
Shift Cable
Adjustment
CAUTION: 4. Check that the hole in the adiusteris pertectv sligned

. All SRS oloctlical wirlng harno3sos alo covorod whh with the holein the shift cable.
ydbw ouier insulation.
. Befolo disconneclingtho SRS who harn6ss, lnllall tho
short connoctor (s) on tho ai6ag (s).
. Replscsthe sr iro 8fiect6d SRs halno$ Esrembly lf h
has an open circuit or damag€dwiring.
AIT'USTER
Cabh Cabl€ Exact

Too Shon Too Long Alignm€nt
Stan the engine.Shift to reverseto see il the reverse

gear engages.lf not, reJerto Troubleshootingon page NOTE:
There are two holesin the end of the shift cable.They
1+64 thru 67.
are Dositionad9Ooapart to allow cable adiustmentsin
1/4turn increments.
With the engine off, remove the tront console (sae
section 20). lf not pertectly alignod,loosenthe locknut on the shift
cable,and sdiust as required.
Snit to I tt l position, then remove ths lock pin from
the cable-adjuster, 6. Tightenthe locknut.
Installtho lock pin on the adiuster.lf you tesl the lock
pin bindingas you reinstall it, the cable is still out of
adjustmentand must be readiusted.
Move the shift lever to eachgearand verify that the

A/T gear position indicator follows the A/T gear
positionswitch.
l'. Start the engineand check the shift lever in allgears.lf

any gear does not work properV, reler to trouble-
shootingon page14-64 thtu 67,
1 0 . Insertthe ignitionk€y into the key cylinderon the A/T

g€ar indicatot panel,8nd verify that the shift lock lever
is released.
SHIFTCABLE
LOCKNUT
7 N'm lO.7kg-m
5.1 tb-it)
AOI'STEN
14-146
E.
GearshiftSelector
CAUTIOI{:
. A[ SRS olectrlcal wlrlng hamossos alo cove]ad with
yellolYouter inlulation.
. Baloro dlsconnectlng tho SRS who harn6ss, Instsll
the short connector (s) on the alrbsg (sl.
. Raplacotho entilo affectsd SRS harnoss assombly lf
it h!3 an opon circuit or damagedrylrlng.
SRS MAIN HARI{EAS

SELECTLEVERKNOB
,,J:::$ 3 N.m(0.3 ks-m, 2.2 b-ft)

AppV non-hardening
locksoalsnt.
thre8d
A/T GEARPOSITION
INDICATORPANEL
-Gl
ICONEGREASE
LEVERCOVER
10 N.m ('1.0kgFm, 7 h-ft)
MOUNTBRACKET
SELECTOR
14-147
A/T GearPositionIndicatorPanel
Adiustment
CAUTIO : 1 . With the transmissionin I N I position, chsck that the
r Al sRS clectrlcd wl ng h!m.rsc! ar. covoled wlth index msrk on the indicst-oralignswith ths N mark on
yalow outcr lmuhlon. the A/T gosr plgtion indicator panel when th€
. Bcforo dtconncctlng th. SRS wlr. harn33s, lmtal tha t.ansmissionis in Lll position.
rhort comoctor bl on tha ahbrg lsl.
. Replrct th..ntlrc eff.ct.d SRS harn.3. assombly lf h
lf not sligned,rsmovs the front conaole (sso section
ha! an opan drcuh or damagpdwlrlng.
2ol.
3. Remove the A/T gear position indicstor pansl

mountingscrews, and adiustby movingth8 pansl'
NOTE:
Whenever the A/T g€8r position indicstor panel is
removed,.sinstallths psnelas d6scribedabovo.
A/T OEARPOSITIOI{
II{IXCATORPAI{EL
14-148,
ThrottleControlCable
Inspection
NOTE: 3. Check that there is plsy in the throttle control levsr
Before inspecting the throttle control cable, make sure while depressingth€ accGlerator pedal to the fulF
that: throttle oosition.
. Throttle cablefree Dlayis correct {seesection 11),
. ldlespeedis correct(seesection11).
. You warm up the engineto normal operating temper-
ature{theradiatortan comeson),
1. Verify that the throttle control lever is synchronizsd

with the th.ottle linkagewhile depressinoand releasing
the acceleratoroedal.
2. ff the throttle control lever is not synchronizedwhh

the throttle linkage.ad.iustthe throttle controlcable.
THROTTLELINKAGE
Remove the cable end oJ the throttle control cablo

trom tho throttls controllavsr.
5. Check that the throttle control lsv6r moves smoothly.

THROTTLECABLE
THROTTLECONTROLLEVER
THROTTLECOI\ITROLLEVER
1 4 -14 9
Throttle ControlCable
Adiustment
NOTE: 4. Tightenthe locknuts.
Beforeadjustingthe throttle controlcable,make sure that:
. Throttle cablefree play is correct (seesection 11).
. ldlespeedis correct(s€esection11).
. You warm up the engine to normal operatingtemper-
ature(theradiatorfan comeson l,
1. Verify thst the throttle linksge is in the fully-closed

oosition.
THROTTLE LEVER
CONTROL
LINKAGE
THROTTLE 5. A{ter tightening the locknuts, inspect the synchro-
nization8ndthrottle control lever movemsnt.
NOTE:
Loosenthe locknut on the throttle control cableat the To tailor the shift/lock-up characteristicsto 8 particular
throttle control lever. customer's driving exp€ct8tions, you can adiust the
throttle control cabl€up to 2mm {0.078inl shorter thsn tho
"synchronized" point.
Removethe free play in the throttle control cablewith
the locknut, whil6 pushingthe throttle control lav€t to
the tullv-closedDoshionas shown.
THROTTLECOI{TROLLEVEB
Pushin this direction.
14-150
t-
Differential
ManualTransmission
............................
15-t
AutomaticTransmission
.......................
15-10
Differential(ManualTransmissionl
SpecialTools.......... ...........15-2
Differential
lllustrated Index.................................
15-3
Backlash Inspection ......15-4
FinalDrivenGearReplacement ........15-4
TaperedRollerBearing
Replacement .......................................
15-5
Oil SealRemoval ...........
15-5
BearingOuterRace
Replacement .......................................
15-6
TaperedRollerBearingPreload
Adjustment ....................
15-7
OilSeallnstallation .......15-9
SpecialTools
Re{.No. I Tool Numblr

15-9
o 07GAD- PG40'100 Driver Attachment
PreloadInspectionTool 15-7
@ 07HAJ - PK40201
o 07JAD- PH80101 Driver Attachment
15-9
@ 07JAD- PH80400 Pilot.28 x 30 mm
Attachment,40 x 50 mm l.D. 15-5
07LAD- PW50601
Attachment,52 x 55 mm 15-6
@ 07746- 0010400 '|5-6
o 07746- 0010500 Attachment.62 x 68 mm
Attachment,72 x 75 mm 15-6
@ 07746- 0010600
15-6,I
@ 07749- 0010000 Driver
@
o
,6
@ a
@ o
15-2
lllustratedlndex
NOTE:lf the ' mark partswere replaced,the taperedrollerbearingpreloadmust be adjusted(seepage15-9).
.BEARIT{GOUTERRACE
OIL SEAL
Removal,page 15-5 Replacsment,page 15-6
Installation,p8ge 15-9 Inspecttor wear and damage,
.TAPEREDROLLER
BEARING
Inspgctfor wear and damag€.
'TAPERED ROL1IR BEARING
Inspoctfor wear and damagg.
TBEABINGOUTEB RACE
Replgcement,page 15-6
Inspectfor wear and dam6ge.
t -
I
I
(@o..._
.THRUST
Sel6ct,Adjustment,page 15-7
10 x 1.25lnm
103 N.m 110,3kg-m,7a lb-ftl
Left-handthreads. DRIVENGEAR
Replacementpage 15-4
Inspectfor wear and damage.
r;-
ITHRUSTSHIM
CAFBIER
Inspectfor cracks.
Remov€1,page 15,5
lnstallation,
pag€15-9
15-3
BacklashInspection FinalDrivenGearRePlacement
1. Placedifferentialassemblyon V-blocksand inst8ll 1, Remove the bolts in a crisscrosspattern in several

both driveshafts. steps,and removethe final drivengearfrom the dit-
ferentialcarrier.
2. Measurethe backlashof both piniongears.
NOTE: The final driven g€ar bolts have left-hand
Standard {Newl: 0.05- O.'15mm threads,
10.002- 0.006in)
Chamferon inside diametor

of final driven goar facoscarraer'
PINIONGEARS
DIAL INDICATOR
10 mm EOLT
103 N.m (10.3kg-m, 74lb-ft|
Installthe final driven gear by tighteningthe bolts

in a crisscrossDatternin severalsteps.
lf the backlashis not within the standard,replace

the differentialcarrier.
15-4
t
TaperedRollerBearing Oil SealRemoval
Replacement
1. Removethe differentialassembly.
NOTE:
. T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e 2. Removethe oil sealfrom the transmissionhousing.
shouldbe replacedas a set.
. Inspectand adjustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced.
. Checkthe taperedrollerbearingsfor wear and rough
rotation.lf taperedrollerbearingsare OK, removalis OIL SEAL
not necessary. Replace.
1. Removethe taperedroller bearingsusinga bearing

puller.
BEARINGPULLER
3. Removethe oil sealfromthe clutchhousinq.
Installnew taperedroller bearingsusingthe special CLUTCHHOUSING

tool as shown.
N O T E ;D r i v et h e t a p e r e dr o l l e r b e a r i n g so n u n t i l
they bottomagainstthe differentialcarrier.
ATTACHMENT,
40 x 50 mm l.D.
07LAD - PWSo€ol
otl sEAt_
Replace.
15-5
BearingOuterRaceRePlacement
NOTE: 3. After installingthe thrust shim. install 8n bearing
. T h e b e a r i n go u t e r r a c e a n d t a p e r e dr o l l e r b e a r i n g outer race in the transmissionhousing and clutch
shouldbe replacedas a set. housingusingthe specialtools as shown.
. Inspectand adlustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced. NOTE:
. Installthebearingouter racesquarely.
1. Removethe oil sealsfrom the transmissionhousing . Check that there is no clearancebetween the
a n dc l u t c hh o u s i n g( s e eP a g e ' 1 5
5) bearing outer race,thrust shim, and transmis-
sion housin9.
2. Drivethe bearingouter raceand thrust shim out of TRANSMISSION
t h e t r a n s m i s s i o nh o u s i n g ,o r r e m o v et h e b e a r i n g HOUSING:
outer race and thrust shim from the transmission DRIVER
077a9- (xn(xx)o
h o u s i n gb y h e a t i n gt h e t r a n s m i s s i o nh o u s i n gt o
a b o u t2 1 2 " F( 1 0 0 ' Cw ) i t h a h e a tg u n .
CAUTION: Do not reus€ the thrust shim if the

ATTACHMENT,
outer racGwas driven out. fi:l x 68 mm
077i16- (x)los(x)
N O T E : D o n o t h e a t t h e t r a n s m i s s i o nh o u s i n gi n
excessof 212'F(100'C).
TRANSMISSION ORIVER
HOUSING: 07749- OOl(Xno
ATTACHMENT, THNUSTSHIM
52x55mm
07715- (X)10400
THRUSTSHIM
CLUTCH
HOUSING:
DRIVER
- 00tqx)0
BEARING
:'----J)-4
OUTEFRACE
ATTACHMENT.
72xt5mm
07746 - 0011}600
EEARING
OUTER
THRUST
4. Installthe oil seal{seepage15-9).
THRUSTSHIM
OUTERRACE
15-6
TaperedRollerBearingPreloadAdjustment
NOTE: lf any of the items listed below were replaced, After installingthe thrust shim, installthe bearing
bea
the taperedrollerbearingpreloadmust be adjusted. outer race in the transmissionhousing (see re page
t
15-6).
. Trsnsmissionhousing
o Clutchhousing NOTE:
. Differentialcarrier . Installthe bearingouter racesquarely.
o Taperedrollerbearingand bearingouter race . C h e c kt h a t t h e r e i s n o c l e a r a n c eb e t w e e nthe
between
. Thrustshim bearingouter race,thrust shim and transmis transmission
nousrng.
1. R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m
from the transmissionhousing(seepage 15-6). 4. W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e moov' e d ,
i n s t a l lt h e d i f f e r e n t i a al s s e m b l y ,a n d t o r q uee t h e
NOTE:Installthe thrust shim onlv on the transmis- clutchhousingand transmissionhousing,
sion housingside.
TOROUE:10 x 1.25mm:45 N.m
CAUTION: Do not reusothe thru3t shim it the boar- ('1.5kg-m, 33 lb-ft|
ing outer rrco wls drivcn out, 8 x 1.25mm: 28 N.m
(2.8 kg-m, 20 lb-ft1
NOTE:Let the transmissioncool to the room tem-
perature if the bearing outer race was removed by N O T E : l t i s n o t n e c e s s a r yt o u s e s e a lI inngg a g( e n t
heatingthe transmissionhousing befo.e adjusting betlveenthe housings.
the taperedfoller bearingpreload.
5. Rotatethe differentialassemblyin both directions
direct
2. F i r s tt r y t h e s a m e s i z et h r u s t s h i m t h a t w a s r e - to seatthe taperedrollerbearings.
moved.
6. Measurethe startingtorque of the differential
rent|al as-
CAUTION: Use only ono thrust rhim. semblywith the specialtool and a torquewrench.
wrenc
STANDARD:1.4- 2.6 N.m

114- 26 kg-cm,12 - 23 lb-inl
THRUSTSHIM NOTE:
. M e a s u r et h e t a p e r e dr o l l e r b e a r i n gp r e rl ooaa oA I
normSlroom temperature.
a M e a s u r et h e t a p e r e dr o l l e r b e a r i n gp r e l o a oi n
I both directions.
C
WRENCH
TRANSMISSIONHOUSING
TOOL
PRELOADINSPECTION
07HAJ- PK40201
{ c o n td I
15-7
Differential{ManualTransmission)
Tapered Roller BearingPreloadAdiustment {cont'dl
7. ll the tapered roller bearing preload is not within 9. How to selectthe correctthrustshim:
the standard,selectthe thrust shim which will give - 1 ) C o m p a r et h e t a p e r e d r o l l e r b e a r i n gp r e l o a d
the correcttaperedroller bearingpreloadfrom the you get with the thrust shim that was removed,
followingtable. with the specifiedpreloadof l4 - 26 kg cm ('12
- 23lb-in).
NOTE: Changingtho thrust shim to the next size -2) lf your measuredtaperedrollerbearingpreload
w i l l i n c r e a s eo r d e c r e a s et a p e r e d r o l l e r b e a r i n g is lessthan specified.subtractyours irom the
preloadabout3 - 4 kg-cm(2.60- 3.47lb-in). specified.
l f y o u r s i s m o r e t h a n s p e c l f i e ds, u b t r a c t h e
THRUSTSHIM specitiedfrom your measuremenl.
Part Numb€r Thickneee For examplewith a 2.17mm thrustshim:

41381- PXs- 000 1.90mm (0.075in)
@ specified 26 kg-cm(23 lb-in)
B 41382-PX5-000 1 . 9 3m m ( 0 . 0 7 6i n ) you measure 6 kg-cm(5 lb-in)
c 41383-PX5-000 1.96mm {0.077in) 2 0 k g - c m{ 1 8 l b - i nl)e s s
'1.99mm (0.078in)
41384-PXs-000
@ you measure 34 kg-cm(30 lb'in)
E 41385-PX5-000 2.02mm (0.079inl - specified 26 kq-cm(23 lb-in)
F 41386-PXs-000 2.05mm (0.081in) 8 kg-cm(7 lb-in)more
41387-PXs-000 2.08mm (0.082in)
-3) Eachshim size up or down from standard
H 41388-PXs-000 2 . 1 1m m ( 0 . 0 8 3i n ) makesabout 3 - 4 kg-cm (2.60- 3.47 lb-in)
41389-PX5-000 2 . 1 4m m ( 0 . 0 8 4i n ) differencein taperedrollerbearingpreload.
J 41390-PXs-000 2 . 1 7m m { 0 . 0 8 5i n }
. In exampleA, your measuredtaperedroller
K 4 1 3 9 1- P X 5 - 0 0 0 2.20mm (0.087in) b e a r i n g p r e l o a dw a s 2 0 k g - c m l e s s t h a n
L 41392-PXs-000 2.23mm (0.088in) s t a n d a r ds o y o u n e e d a t h r u s t s h i m f i v e
sizesthickerthan standard(try the 2.32mm
M 41393-PXs-000 2.26mm (0.089in)
thrustshim,and recheck)
N 41394-PX5-000 2.29mm {0.090in) . In exampleB, yours was 8 kg-cm more than
o 41395-PXs-000 2.32mm (0.091in) s t a n d a r d ,s o y o u n e e d a t h r u s t s h i m t w o
s i z e st h i n n e r( t r y t h e 2 . 1 1m m t h r u s ts h i m ,
P 41396-PXs-000 2.35mm (0.092in) and recheck).
o 41397-PX5-000 2.38mm (0.094in)
'10.After adjustingthe tapered roller bearingpreload,
R 41398-PXs-000 2 . 4 1m m ( 0 . 0 9 5i n )
assemblethe transmissionand installthe transmis-
41399-PX5-000 2.44mm (0.096in) sion housing(seepage'13-3'l).
T 4' 1400-PX5-000 2.47mm (0.097in)
TOROUE:10 x 1.25mm: 45 N'm
{,[.5kg-m, 33 lb-ftl
8. the taperedrollerbearingpr€load.
Recheck 8 x 1.25mm: 28 N'm
(2.8kg-m, 20 lb-ft|
1 1 . Rotatethe differentialassemblvin both directions

to seatthe taperedrollerbearings.
15-8
Oil Seallnstallation
lnstallthe new oil seal flush with the transmission 2. Installthenew oil sealinto the clutchhousingusing
housingusingthe specialtools as shown. the sogcialtoolsas shown,
CLUTCH
HOUSING
TRANSMISSloN
HOUSING
DRIVER DRIVER
077it9- 001qxto 077a9- 001o{xlo
OR]VERATTACHMENT DRIVERATT
otGAD - FG('lrX) 07JAD- PHgtl01
OIL SEAL OIL SEAL
Replace. Roplace.
PILOT,2E x 30 mm
07JAD - PHE0/00 PILOT,28 x 30 mm
07JAD - PH8o4{r0
15-9
Differential(AutomaticTransmissionl
SpecialTools.......... 15-12
...........
Differential(AutomaticTransmission)
lllustratedlndex .......... .. 15-13
Backlash Inspection ......15-14
BearingReplacement .........................
15-14
Inspection/Disassembly ....................
15-15
Reassembly ....................
15-16
Oil SealRemoval 15-17
........,..
TaperRollerBearingPreload
Adjustment ....................
15-18
BearingOuterRaceReplacement.....15-20
Oil SealInstallation .......15-20
SpecialTools
R€{.No. I Tool Number Do3cription oty j Poge Refercncc
o 07GAD- SD40101or DriverAttachment 1 15-20

07GAD- SD40100
,l
@ 07HAJ - PK40201 PreloadInspectionTool 1E_14
o 07HAD- SF10r00 Driver Attachment 1 15-19

@ 07JAD- PH80101 Driver Attachment I 15-20
o 07JAD- PH80400 P i l o t , 2 8x 3 0 m m 1 15-20
@ 07LAD- PW50601 Attachment,40 x 50 mm I 1 5 -1 4
o 07749- 0010000 Oriver 1 15-19,20
@ 07947- SD90200 DriverAttachment 1 15-20
@ @ > a @
IT @ I I
@ t9
cro) @
o @
15-12
lllustratedIndex
THRUSTSHIM
page15-18
Selection,
OUTERRACE
10 mm BOLT
103 N.m 110.3kg-m,7a lb-ft1
eg Left-handthreads
9" TAPER ROLLEB BEARING

lnspectfor f6ultymovement.
FII{ALORIVENGEAR
Disa6s6mbly,page 15-15
Inspgctaon,psge 15-15
Insp6ctfor exc6ssive
lnstall in this direction.
DIFFERENNALCARBIER THRUSTWASHEB
lnsoocttor cracks.
PINIONWASHER
TAPERROLI..ER
SPRINGPIN
PINIONGEAR
page15-14
inspection,
Backlash
PINIONSHAFT
BEARIiIG OUTERRACE Inspgct{or wear or
damage.
15-13
BacklashInspection BearingReplacement
' t . P l a c et h e d i f f e r e n t i a a
l s s e m b l yo n V - b l o c k s NOTE:Checkthe bearingsfor wear and rough rotation.
installboth axles. lf the bearingsare OK, removalis not necessary.
Checkbacklashof both side gears. Removethe taper r o l l e rb e a r i n g su s i n ga b e a r i n g

puIer.
StandardlNowl: 0.05- 0.15mm BEARING PULI.IR
10.002- 0.006in.l
DIALINDICATOR SIDEGEARS
TAPER BEARING
ROLLER
Installthe new taper roller bearings.usingthe spe-

cialtool and a pressas shown,
3. lf out of tolerance,disassemble
the differentialand
selectnew pinionwashersfrom the table below. NOTE:
. Drivethe bearingson until they bottom.
PINIONWASHEB . Usethe specialtool:
. large end for torque converterhousing side
Part Numbcr Thickness
bearing.
4 1 3 5 -1P G I - 0 0 0 0.70mm (0.028n ) small end for transmissionhousingside bear-
4 1 3 5 2- P G 1- 0 0 0 0.75mm (0.029n ) Ing.
4 1 3 5 3- P G 1- 0 0 0 0.80mm (0.031n ) ATTACHMENT,
4 1 3 5 4* P G 1- 0 0 0 0.85mm (0.032n ) ,(t x 50 mm
4 1 3 5 5- P G 1- 0 0 0 0.90mm (0.035n ) 07LAD- PW5o601
41356-PGl-000 0.95mm (0.036n )
4 1 3 5 7- P G 1- 0 0 0 1.00mm (0.039n )
4 1 3 5 8- P G 1- 0 0 0 1.05mm (0.041n )
NOTE:
. The bearingand outer race should be replaced
as a set.
. lnspectand adjustthe bearingpreloadwhenever
a bearingis replaced.
. Drivein the bearingssecurelyso that there is no
clearancebetweenthe bearingsand differential
carner.
15-14
Inspection/Disassembly
Removethe final driven gear and inspectteeth for 3, Remove the pinion shaft, pinion gears, washers,
wear or oamage. thrustwashers,and side gears.
NOTE: The final driven gear bolts have left-hand

threads,
FINAL DRIVENGEAR
PINIONGEARS
SIDEGEAR
CARRIER
DIFFERENTIAL
Wash the pans thoroughlyin solventand dry them

Driveout the springpin with a pin punch. with compressedair. Inspoctall pans for wear or
damageand replaceany that are defective.
5.0 mm PIN PUiICH
15-15
Reassembly
'1. Installthe side gears,with thrustwashersin tho dif- Rotatethe gears until the shaft holes in the pinion
ferentialcarrier. gearsIine up with the shaft holesin carrier.
NOTE: Coat all gears with molybdenum disulfide Insertthe pinionshaftand alignthe spring pin holes
greaseon all sides. in one end with the matchinghole in the carrier.
Alignthe holes.
5. Drivein the springpin with a pin punch.

THRUSTWASHER
Set the pinion gears in the place exactlyopposite

each other in mesh with side gears,then install a
pinion washer behind each one. Wsshersmust be
of equalthickness.
NOTE: Selectthe correct Dinion washer from the

tableon page15-14.
Checkbacklashof both piniongearsagain.
Standard {New}: 0.05- 0.15 mm

{0.lxt2- 0.006in}
It still out of tolerance,replac€both thrustwash-

ers.
lf still out of tolerance.replacethe side and pin-

ion gears,and recheckbacklash.
lf still out of tolerance,replacethe carrierassem-

ory.
15-16
Oil SealRemoval
7. Installthe final driv€n gear.Torquethe boltsto 103 1 . Removeth€ differentialass6mbly.
N.m (10.3kg-m,74 lb-ftl.
Removethe oil sealfromthe transmissionhousing.
NOTE:The final driven gear bolts have left-hand
th.eads.
FINAL DRIVENGEAR
Chamf6ron innsr side

ot final driven gear fac6s
cSrner.
10 mft EOLT
103 N,m 110.3kg.rn, 74 lb-ftl
Lett-h8ndthreads OIL SEAL TRANS|tsstotrl
HOUSI G
Remove th€ oil seal from the toroue conv€rter

housing.
TOROUECONVERTER OIL SEAL

HOUSING Replace.
15-17
Differential{AutomaticTransmissionl
TaperRollerBearingPreloadAdjustment
NOTE: lf the transmissionhousing, torque converter Selectthe thrust shim from the table below so that
housing,differentialcarrier,taper roller bearing.outer theirtotal thicknessis 2.60mm (0.102in).
raceor thrust shim were replaced,the bearingpreload
must be adjusted. CAUTION: Do not use mor€ than two shims to
adiust tho bearing prelosd.
1. R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m
BEARINGOUTER
from the transmissionhousingby heatingthe hous- RACE
ing to about212"F(100'C)with a heatgun.
CAUTION;
. Do not h6at tha houling in oxcass ol 212'F
{100"c1.
. Roplacothc tapsr rollor bearing when tho outer
race is to bs rgplacad.
. Do not uso a ghim on the torqug convsrt9r hou3-
ing sid6.
N O T E :L e t t h e t r a n s m i s s i o nh o u s i n gc o o l t o t h e
r o o m t e m p e r a t u r eb e f o r e a d j u s t i n gt h e b e a r i n g
preroao.
HEATGUN
THRUSTSHIM
No. Part Numb6r Thickncss
41441- PK4- 000 2.20mm (0.087in)
B 41442-PK4-000 2.25mm (0.089in)
41443-PK4-000 2.30mm (0.091in)
D 41444-PK4-000 2.35mm (0.093in)
E 41445-PK4-000 2 . 4 0m m ( 0 . 0 9 4i n )
F 41446-PK4-000 2.45mm (0.096in)
G 41447-PK4-000 2.50mm (0.098in)
n 41448-PK4-000 2 . 5 5m m ( 0 . 1 0 0
in)
41449-PK4-000 2 . 6 0m m ( 0 . 1 0 2
in)
J 41450-PK4-000 2 . 6 5m m ( 0 . 1 0 1i n l
K 4 1 4 5 1- P K 4 - 0 0 0 2 . 7 0m m ( 0 . 1 0 6i n )
L 41452-PK4-000 2 . 7 5m m ( 0 . 1 0 8i n )
M 41453-PK4-000 2 . 8 0m m ( 0 . 1 1 0i n )
N 41454-PK4-000 2 . 8 5m m { 0 . 1 1 2i n )
o 41455-PK4-000 2 . 9 0m m ( 0 . 1 1 4
inl
41456-PK4-000 2 . 9 5m m ( 0 . 1 1 6i n )
41457-PK4-000 3 . 0 0m m ( 0 . 1 ' 1i8n )
R 41458-PK4-000 3 . 0 5m m ( 0 . 1 2 0i n )
* Standard shim
15-18
3. After instaliingthe thrustshim, installthe outer race 6, M e a s u r et h e s t a r t i n g t o r q u e o f t h e d i f f e r e n t i a l
in the transmissionhousing,usingthe specialtools assemblywith the specialtool and a to.que wrench.
as snown.
STANDARD:
CAUTION: Now bosrings: 2.8 -,[.0 N'm
. Install the outsr .ace squaraly in tho trsnsmi!. 128- ,l|) kg-cm, 2,1- 35 lb-inl
sion housing. Rculod bslrings: 2.5 - 3.7 N.m
. Check that thero is no cloaranco bciwocn th, (25 - 37 kg-cm, 22 - 32 lb-in)
outsr race,shim and t ansmissionhousing.
. Install tho gasket whon chocking pr6lo6d.
07?49- qlrqtoo
,'l
PRELOADINSPECTIONTOOL
07HAJ - PKIO201
NOTE:
! Measu.ethestartingtorqueat normalroomtem-
p6.ature
in bothdirections.
lf out of spec,selecttwo thrust shimswhich will
give the correct preload,and repeatsteps 1 - 6.
Changingone of the shims to the next sizewill
increaseor decreasestaningtorque about3 - 4
kg-cm(2.60- 3.,17lb-ln).
T o i n c r e a s et h e s t a r t i n gt o r q u e , i n c r e a s et h e
t h i c k n e s so f s h i m s . T o d e c r e a s et h e s t a r t i n g
With the mainshaft,countershaftand secondarv torque,decreasethe thicknessof shims.
shaft removed,installthe differentialassemblyand
torquethe transmissionhousing.
TOROUE:55 N.m 15.5kg-m. /r0 lb-ft|
Rotatethe differentialassemblyin both directions

to seatthe bearings.
15-19
BearingOuterRaceReplacement Oil SealInstallation
Removethe bearingouter racefrom the torquecon- 1. I n s t a l lt h e o i l s e a l i n t h e t r a n s m i s s i o nh o u s i n g ,
v e r t € r h o u s i n g b y h e a t i n gt h e h o u s i n gt o a b o u t u s i n gt h e s p € c i a tl o o l s a s s h o w n .
212"F(100"C)with a heatgun.
CAUTION: Do not hcat the hou3ing in excassof

212"F(100"c). DRTVER
07749- 00ltXXtO
NOTE:
. Replacethe bearingwith a new one whenever
the outer raceis to be replaced.
. Do not use shims on the torque converterhous-
ing side.
. Adjust preloadafter replacingthe bearingouter
raceand bearing.
TAPERROLLER HEATGUN
OIL SEAL
2. Drivethe oil seal into the torqueconverterhousing,

usingthe specialtools as shown.
I n s t a l lt h e n e w b e a r i n go u t e r r a c ef l u s h w i t h t h e
housingusingthe specialtools.
07749 - 001(xXlO
DRIVERATTACHMENT
07GAD- SO|O101or
o]GAD - SD.O100
15-20
Driveshafts
S p e c i aTl o o l s . . . . . . . . 16-2
Driveshafts
Removal 16-3
Disassembly 16-5
Disassembly/lnspection 16-6
Reassembly 16-7
Installation 16-9
IntermediateShaft
R e p l a c e m e n. t. . . . . . . . . . . . . . 16-11
Disassembly 16-12
Disassembly/lnspection 16-13
Reassembly 16-14
SpecialTools
Rel. No. I Tool Numbel
o
6\
oTGAD-PH70201 Oil Seal Driver
Hub Dis/AssemblyBase
16 - 1 4
1 6 - 1 2 ,1 4
oTGAF-SD40700
/?\ oTMAC-SLOO100 BallJoint Remover,32 mm I o-J
o7746-OO10200 Attachment,37 x 40 mm 1 6 - 12
@ 16-14
rA 07746-O010400 Attachment,52 x 55 mm
07746-OO30400 Attachment,35 mm LD. 16-14
\of
o7749-OO'OOOO
l Driver 1 6 - 1 2 ,1 4
@
\
re ,;A
l---:z-----.1
I
@ @
tll
@ ct_@
o
16-2
Driveshafts
Removal
INSPECTION 5. Remove the damper tork nut, bolt and damper

pinch bolt.
Drivoshaft Boot
Check the boots on the driveshaftfor cracks,damage, 6. Removethe damperfork.
leakinggreaseor loose boot bands. OAMPERPINCH BOLT
It any damageis found. replacethe boot. (SELF.LOCKINGBOLT)
10 r 1.25mm
Spline Looseness
Turn the driveshaftby hand and make sure the spline
and joint are not excessivelyloose.
It damageis found, replacethe inboardjoint.
Twisted or Crscksd
Make sure the driveshaftis not twisted or cracked.
Replaceif necessary.
l. Raisethe car and placesatety standsin the proper

locations(seesection 1).
OAMPEB
Removethe tront wheels. ISELF.LOCKING NUTI
1 2 x 1 . 2 5m m
Replace. DAMPERFORK BOLT
Dralnthe transmissionoil or fluid.
7, Removethe cotter pin from the lower arm balljoint
4. Raisethe lockingtab on the spindlenut and remove castle nut and removethe nut.
rt,
8. Installa 14 mm hex nut on the ball joint, Be sure
that the 14 mm hex nut is flush with the ball joint
pin end. or the threadedsectionot the balljoint pin
might be damagedby the ball joint remover.
9. Use the ball ioint remover, 32 mm as shown on

FRONTWHEEL page 18-13 to separatethe ball joint and lower
arm.
1O, Positionthe specialtool between the knuckleand

lower arm as shown, then separdtethe lower arm.
CAUTION: B€ careful not to damag€ the ball ioinr

boot.
CASTLEXUT
SPINOLENUT
24 r 1.5 mm
Replace.
14 mm H€X NUT
Replace.
(cont'd)
16-3
Driveshafts
Removal(cont'd)
11. Pry the driveshaftassemblywith a screwdriveras - with lntermediateShaft:

shown to force the set ring at the driveshaftend Removethe left driveshaftfrom the bearingsup-
past the groove, pon by tapping the inboardjoint of the driveshaJt
with a Dlastichammer.
CAUTION:
a Do not oull on the driveshaft. as the CV joint
may come apan.
a Use care whsn prying out the assembly and pull
it stlaight to avoid damaging the diffelsntial oil
s€al.
12. Pullthe inboardioint and removethe driveshaftand

CV joint Jromthe ditferentialcase as an assembly.
13, Pulltheknuckleoutward and removethe driveshaft

outboard ioint from the front wheel hub using a
olastichammer.
KNUCKLE
OUTBOARDJOINT
INBOARDJOINT
16 -4
I
Disassembly
CAUTION: Do not try to disass€mble the outboard Removethe inboardjoint and rollers.
joint.
Removethe circlip.then removethe spiderusinga
1. To r€movethe boot band, pry up the lockingtabs commerciallyavailablebearingremover.
with a screwdriverand raisethe end of the band.
NOTE: Before disassembly,mark the spider and
CAUTION: Tak€ care not to damage the boots. driveshaftso they can be reinstalledin their original
positions.
NOTE: Carelullv clamp the driveshaft in a vise
with solf jaws.
BEARINGREMOVER
STOPPERRING
INBOAROJOII{T
16-5
Driveshafts
Disassembly/lnsPection
NOTE:
a Mark the rollersand rollergroovesduringdisassemblyto ensureproperpositioningduting reassembly.
a Beforedisassembly,mark the spiderand driveshaftso they can be reinstalledin their originalposilions.
a The inboardjoint must be removedto .eplacethe boots.
a lf the boot band is the welded type, cut off as shown.
CAUTION: Take care not to damag€ tho boots.
DRIVESHAFT
INAOARDJOINT SPIOEB
Checksplinestor wear or damage.
Check insideborelor wear.
Inspectfor cracks,
SET R|NG __571

Replace. ROLLER
LEFT
INBOARDJOINT
STOPPERRING
lYvith int6rmodlato INBOARD BOOT
Checksplineslor wear or damage. lor cracking,
Check insidebore for wear.
Inspect
Inspect for cracks.
splittingand wear.
CIRCLIP
BOOTBAND
DYI{AMIC OAMPERBAND Replace.
(A/T mod.b, loft ddvosh.ft onlYl
Replace. AOOTBAND
Replace.
------.,
OUTBOAROJOINT
Inspect Ior faulty movement and wear.
Inspect ball bearings whilo rotaiang
Do not try to disassemble
BOOTBANO
Replace. OUTAOARORING
OUTBOARD EOOT Checkfor damage.
Inspectfor cracking,
splittingandwear. DRIVESHAFT
16 -6
Reassembly
Cleanthe driveshattsbeforereassemblv. 6. Pack the outboard joint with the joint gr€ase
cluded in the new driveshaftset.
Wrap the splineswith vinyl tape to preventdamage
to the boots and dynamicdamper(A/T models,l€tt crease Ouantity. 130-140 9 (4.6-4.9 ozl
driveshaftonly).
Installthe outboardboot, dynamicdamperand in-

board boot to the driveshaft,then removethe vinyl
IADE.
BOOT
OUTBOARO
VIf{YL TAPE
DYNAMICDAMPER
lA/T modob,
loft ddvGhaft onlvl
INBOARD
BOOT
Fit the rollersto the spiderwith their high shoulders
Installthe stopperring into the driveshaftgroove, facing outward.
Rotatethe stopperring in its grooveto be sure it is
fully seated. CAUTION:
a Rainstalltho rollor3 in their o ginal posilions on
4. Installthe spider on the driveshaftby aligningthe the sDidel.
marks on the spiderand end of the driveshaft. a To prsv€nt it from talling off, hold tho drlveshatt
assembly so th€ spidor and lollor point up.
Fit the circlipinto the driveshaftgroove.Rotatethe
circlip in its grooveto be sure it is fully seated,
CIRCLIP
b
"""@ SPIDER
STOPPERRING
1S7
Driveshafts
Reassemblylcont'd)
8. Packthe inboardioint with the ioint greaseincluded 1 1 .lnstall new boot bands on the boot and bend both
in the new driveshaftset. sets ot locking tabs
GroasoOuantity: 130-140 g (4.6-4.9 oz) 1 2 . Lightlytap on the doubled-overportionsto reduce

A/T mod€ls, Laft ddveshaft their height.
120- 130 g 14.2-4.6 ozl
9. Fit the inboardioint onto the driveshaft.
CAUTION: To provant it from falling oft, hold tho

drivoshaft assomblYso tho inboard joint points up.
ManualTransmission OnlY:
INBOARDJOINT Align the holder direction of the rollers
toward the slot of inboard joint as
13. Positionthe dynamicdamperas shown below.

a Install a new dynamic damper band and bend
HOLOER
down both sets of lockingtabs.
1 0 .Adjust the length of the driveshafts to the tigure a Lightly tap on the doubled-over portion of the
below. then adjust the boots to halfway between band to reduceits height.
full compressionand Iull extension.
NOTE: The ends oJ boots seat in the grooveof the

driveshaftand joint.
DYNAMIC OAMPEB
R i g h r :5 0 7 . 9 - 5 1 2 . 9 m m ( 2 O . O O - 2 0 . 1 9i n )
Left: 175 r 2 mm 16.9a O.l In)
. A/T modelg
8 6 2 . 9 - 8 6 7 . 9 m m ( 3 3 . 9 7- 3 4 . 1 7 i n l
DAMPERBAND
. M/T models
52O.9- 525.9 mm (2O.50-20.7O inl
16 -8
t
lnstallation
1 . Installtheoutboardjoint in the knuckle,then loose-

ly installthe spindlenut.
Apply 1 .O- 1 .5 g (O.O4-O.O5 oz) of specified

grease to the whole spline surface of the in-
termediateshatt,
NOTE: Atter applyinggrease,remove the grease

from the splinegroovesat intervalsof 2-3 splines
and Jromthe set ring grooveso air can bleedfrom
the inboardjoint.
J. Installthe new set ring onto the driveshaftor in-

termediateshaft groove.
CAUTION: Always use a new set dng whon6va? NOTE: Atter applying grease, rcmove)ve the
grease from the spline grooves at tntervats
int(
th6 drivoshatt is being installod. g groove,
ot 2-3 splines and trom the set ring g
4. Installthe inboardend of the driveshaftinto the dit-

ferentialor intermediateshaft.
NEWSETRIIIG
INTERMEDIATE
SHAFT
SETRINGGROOVE
INBOARDJOINT
SET RING
RIGHT LEFTDRIVESHAFT
Make sure the right driveshaft locks in the dit{eren- Insert the le{t driveshaft CV joint sub-axle anto (cont dI
tial side gesr groove, and the CV ioint sub-axle the intermediate shaft until the intermediate shaft
bottoms in the ditterential. set ring locks in the groove in the lelt driveshaft.
16-9
Driveshafts
5. Installthe damperfork overthe driveshaJtand onto 8. Tightenthe new spindlenut

the lower arm. Install the damper in the damper
tork so the aligningtab is alignedwith the slot in 9, lnstsll the wheels with the wheel lug nuts.
the damperfork.
NOTE: Before installing the wheel, clean the
6. Looselyinstallthe damperpinch bolt, and the new mating surtaceof the brakedisc and insideof the
damoerfork nut and bolt. wheel.
NOTE: The bolts and nut shouldbe tightenedwith

the vehicle'sweight on the damPer. WHEELLUG NUT
FRONTWHEEL 1 2 x 1 . 5m m
DAMPERPINCH BOLT 1 1 ON ' m
{SELF-LOCKING BOLTI (11 kg-m,
10 x 1.25mm 80 tb-ft)
44 N'm 14.4 kg-m, 32 lb-ft)
DAMPERFORK
TSELF-LOCKING NUTI
1 2 x 1. 2 5 m m SPINDLE NUT24 x 1.5 mm
65 N.m 16.5kg-m,47lb-ft| 25o N.m 125kg'm, 'l8l lb-ft}
NOTE:Aftertightening, usea dritl
l. t",i"tbtrf,+r"knuckle on the lower arm, then tighten to stakespindlenut shoulder
the castlenut and installnew cotter pln. againstthe d veshatt.
CAUTION:
a 8e calotul not to damago tho ballioint boot.
a Torque the castle nut to the lowol torque 1 0 .Tightenthe damperpinch bolt and the new damper
specitication, thon tightsn it only far snough to tork nut with the vehicle'sweight on the damper.
align tho slot with ths pin hol€. Do not 8li9n tho
nut by loosening. 1 1 .ReJillthe transmissionwith recommendedoil or
tluid.
1 2 .Check the tront wheel alignment and adjust if

necassary(seepage 18-4).
CASTLENUT
14 x 2.0 mm
COTTERPIN 5 0 - 6 0 N ' m ( 5 0 - 6 . 0 k9_m'
On reassembly, 36-43 tb-ftI
bendthe cotter pin
16-10
IntermediateShaft
Replacement
1 . Drainthe transmissionoil or fluid. 5. Installin the reverseorder of removal.
2. Remove the left driveshstt assembly (see page

16-4). FLANGEBOLT
39 N.m 13.9kg-m,
Removethe flange bolt and hex bolts. 2a |b-fr)
\ HEXBOLTS
I
39 N.m 13,9kg-m,
\ 28 tb-ftl
t -
HEX BOLTS
p ,a\,
Removethe intermediateshaft assemblyfrom the

differential.
CAUTION: To prevent damage to th€ diftersntial

oil s€81,hold ths intormediate shaft horizontal until
it is clear ot tho diffsrontial.
rrrrnme6lhrrsxlrr
16-11
lntermediateShaft
Disassembly
NOTE: Be carefulnot to damagethe metal ringson the 5. Removethe internalcirclip.

intermediateshaft during disassembly
1. Removethe set ring.
2. Removethe intermediateshaft outer seal from the

bearingsupport.
3. Removethe externalcirclip.
EXTERNALCIRCLIP
{)
\J
l
OUTERSEAL SET RII{G
Replace. R€place. 6. Press the intermediate shaft bearing out oJ the
bearingsuppon usingthe specialtoolsand a press.
4. Press the intermediate shatt out to the shaft bear-
ing using the specialtools and a press.
NOTE: Positionthe specialtools so they do not

damagethe metal ring on the shafr. Pres!
INTERMEOIATESHAFT BEARING
I
HUB DIS/
ASSEMBLYBASE
07GAF-SD40700
16-12
Disassembly/lnspection
INTERMEDIATESHAFT RING
Checkfor damageor distonion.
INTERMEDIATESHAFT
Checkfor damage.
BEARINGSUPPORTRING
Check tor damage or distortion.
HEXBOLTS
FLANGEBOLT
INTERITALCIRCLIP
@,, @ d^
I
BEARINGSUPPORT
Checktor damage.
INTERMEDIA
EEARING
Replace. I
ATE !SHAFT
EXTERNAL
CIRCLIP
0\
SET RING
Replace.
OUTERSEAL
Repl.ce.
16-13
IntermediateShaft
Reassembly
NOTE: Be carefulnot to damagethe metal ringson the Seat the external circlip in the groove of the in
intermediateshalt during reassembly termediateshaft.
1. Pressthe intermediateshaft bearinginto the bear- CAUTION: Installthe circlip with the taperedend
ing supportusing the specialtools and a press tacing out,
Pre3s
5 , Pressthe outer seal into the bearingsupportusing
the specialtools and a Press.
DRIVER
o7749-OO10000 I CAUTION: Do not damage the lip on outer seal
duringinstallation.
NOTE: Press the seal flush with the bearing

ATTACHMENT support.
52x55mm
07746-OO10400
Packthe interiorand
lip of the outer seal.
2 . O - 3 . 5 g ( O . 0 7- 0 . 1 2 o z l
HUB DIS/
oTGAF-SD40700
2. Seatthe internalcirclipin the grooveof the bearing

supPort.
3. Pressthe intermediateshaft into the shaft bearing

using the specialtool and a Press.
Pr6ss
F-t
F4
m
n
+*:-+ Installthe new set ring in the intermediateshaft
F | .,-.t
6,
groove.
ATTACIlMENT,
35 mm l.O.
46-0030400
HUB DIS/
07GAF-SD40700
16-14
Steering
SpecialToofs . . . . . . . . . . . . . . . .1. 7 - 2 Power Assist Chsck

General lnformation w i t h C a rP a r k e d . . . . . .1 7 - 7 9
4 W S S e r v i c eI n f o r m a t i o n. . . . . . . . . . . . . . . . . . , . .1,7. - 3 A s s i s tC h e c ka t R o a dS D e e d. . . . . . . . . . , . . . . . . 1. .7 - 8 O
Component Location Power Steering Speed Sensor
I n d e xl 2 W S i 4 W S ) . . . . . . .1 7 - 5 Replacement . . . . . . . . . .1 7 - 8 0
Component Location Steering Wheel
I n d e x( 4 w s l . . . . . . . . . . . . .1. 7 - 6 R e m o v a, l. . . . . . . . . , . . . . , . . . .1 7 - 8 1
System Descliption D i s a s s e m b l y / R e a s s e m. .b.l.y. , . . . . . . . . . . . . . . .1.7. - 8 3
FluidFlow Diagram 1 7- 7 Installation
Steering Pump 1 7- 8 2 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .7. -. 8 . .4. . . .
F l u i dR e s e r v o i r / F i l t.e.... . , , ., .- . . . . .-. . . . . . . . .... . ' t 7- 9 4 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 7 . .-.8. .6. . . .
4-way Valve 1 7- 1 0 SteeringColumn
k n l o a d eSr y s t e m . . . . . . . . . . . . . . . . . . .1. .7- 1 2
F u l l - l o cU R e m o v a.l. . . . . . . . . . . . . . . . . . .1 7 - 8 9
PowerSteeringSpeedSensor 1 7- 1 2 fnsoection . . . . . . . . . . . . . . . .1. 7 - 9 2
ElectronicallvControlled Installation . . . . . . . . . . . . . . .1. 7 - 9 3
P o w e rA s s i s t e d4 W S . . . . . . . . . . . . . . . . . . . . . . 1. .7. - 15
Troubleshooting (Power Steering SteeringPump
System) Beolacement 17-96
G e n e r aTl r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . . . . - 1 . .7- - 2 5 P u l l eR y e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . .1. 7 . .-.9. .6
Noissand Vibration ..,.. 17-24 Flow Control Valve Insoection
F f u i dL e a k s . . . . . . . . . . . . . . .1. 7 - 2 9 and Rsplacement 17 -97
Troubleshooting l4WS) Disassemblv 17-99
C o m p o n e nL to c a t i o n. . . . . . . . . . . . . . . . . . . . . . . 1. .7. -. 3 . .0 lllustratedIndex 17-102
C o n n e c t oLr o c a t i o n s. , . . , . . , . . , . , . . . . . . . . . . . . .17-31 ... Ass6mblv 17 - 1 0 3
Cilcuit Diagram 17-32 Steering Gearbox
4WS CONTROLUNIT Terminal l n d e x. . . . . . . . . . . . . . . . . . . . . . . .1 7 - 1 0 5
Arrangement 17-34 V a l v eB o d yU n i r . . . . . . . . . .1 7 - 1 0 6
DiagnosticTroubleCode(DTCI 17-36 G e a r b o xR e m o v a l . . . . . . .1 7 - 1 1 4
Precautions 17-37 l l f u s t r a t sfdn d e x . . . . . . . . . .1 7- 1 1 7
S y m p t o m - t o - S y s t sCmh a r t. . . , . . . , . . . . . . . . . . .1. .7 - 3 8 O v e r h a u.l. . . . . . . . . . . . . . . . . .1 7 - 1 1 8
4 W S I n d i c a t oLr i g h tC i r c u i t. . . . . . . . . . . . . . . . . . .17-42 .. fnstallation . . . . . . . . . . . . . . .1. 7- 1 3 4
DiagnosticTroubleCodes {DTCS): Rear Steering Actuator (4WS)
1 0 , 1 2 ,r 6 17-45 f f f u s t r a t efdn d e x . . . . . . . . . .1 7 - 1 3 7
DiagnosticTlouble Codes (DTCsl: R e m o v a. l. . . . . . . , . . . . . . . . . . ,1 7 - 1 3 8
1 1 , 1 3 ,1 7 17-50 Disassembly . . . . . . . . . . . . .1. 7 - ' l 4 O
DiagnosticTiouble Codes (DTCsl: Asssmbfv . . . . . . . . . . . . . . .1. .7. - 1 4 1
2 0 ,2 2 ,2 4 , 2 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .7. .- .5.5. fnstallation . . . . . . . . . . . . . . .1. 7- 1 4 4
Diagnostic Trouble Codes (DTCsl: 4WS Control Unit
2 1, 2 3 . 2 5 , 2 9 17-59
R e m o v aal n dl n s t a l l a t i o n. . . . . . . . . . . . . . . . . . . . . ' l7 - 14 5
DiagnosticTroubleCodes (DTCsl:
30,34 ............... 17-63 Tie-rod End Boot
DiagnosticTlouble Codes (DTCSl: Replacement . . . . . . . . . . . . .1. 7 - 1 4 5
3 1 .3 5 . . . . . . . . . . . . . . . 17-64
Diagnostic Troubls Codes (DTCs): 4WS System Inspection
32,36 ............... 17-66 E l e c t r o n iN l h e c k . - . . - - . . . . . - . . - . . - . . -1.7. .- 1 4 6
c e u t r aC
DiagnosticTroubleCode(DTCI:33 .......... 1 7 - 6 8 4WS System Adiustment
DiagnosticTroubleCode(DTC):50 .......... 1 7- 7 0 4 W S S y s t e mA d j u s t m e n t. . . . . . . . , . . . . . , , . . , . . .7. '-l 15 1
D i a g n o s t iTcr o u b l eC o d e{ D T C } 5 : 1 . . . . . . . . . .1 7- 7 1 Sub SteeringAngle Sensor
DiagnosticTroubleCodes {DTCS}: Adjustment . . . . . . . . . . .1 7 - 1 5 3
6 0 , 6 1, 6 2 , 6 3 1 7- 7 1
Maintenance
P u m pB e l tA d i u s t m e n t. . . . . . . . . . . . . . . . ........ . . .17 - 74
On-Car Checks
R a c kG u i d eA d i u s t m e n t. . . . . . . . . . . . . . . . . . . . . . 1. .7.- 75
FluidReplacement ,..,.. 17-77
P u m pP r e s s u rCeh e c k. . . . . , . . . . . . . . . , . . , , . . ,1.7, -. 7 .4
.
S t e s r i n gW h e e fS o t a t i o n aPl l a y. . - . . . . . . - . . - . 1. .7 - 7 9
S p e ci a l To ols
Ref. No. Tool Numbel DoscriDtion Oty Page Relerence

I
o
(;\
OTGAF SD40TOO
oTJGG-OO10100
Hub Dis/AssemblyBase
Belt TensionGauge
1
'I
17 - 1 0 8
17-74
aa) OTLAG_SM401OA PistonSeal Ring Guide 1 1 7- 1 2 5
OTLAG SM402OA PistonSeal RingSizingTool 1 1 7- 1 2 5
@
OTLAG SM403OA CylinderEnd Seal Slider 1 1 7- 1 2 6
Lcf
o7t\4AA-SLOo20A LocknutWrench, 43 mm I 17 15,76, 132
@
1 7- ' t1 4 , 1 3 4
o oTMAC-SLOO200
'IA
BallJoint Remover,28 mm
P/S Joint Adapter {Pump)
I
1 17-74
@ O T N A K S R 3 O1
,G) OTNAK_SR3012A P/S Joint Adapter(Hose) 1 1778
oTNAB-SSOO100 Rack Hold€r I 1 7- 1 4 0 , 1 4 2
@
o OTNAJ_SSOO2OA RearSteeringCenterLock Pin 1 17-4,144, 150,
15 6 . 1 5 7
07406-OO10101 BypassTube Joint I 17-80
@
( l n c l u d e dw i t h 0 7 4 0 6 - 0 0 1 O O 0 1l
o7406-OO10001 P/S PressureGauge 1 17-78
@
o7406-oo10300 PressureControlValve 1 1 7- 7 I
@-1
07406-OO10400 PressureGauge 1 1 7- 7 4
@-2 '17-96
o7725-OO30000 UniversalHolder 1
@
(t o7746-0010200 Attachment,37 x 40 mm 1 17-103
07746 0010300 Attachment,42 x 47 mm 1 1 7- 1 2 0 , 1 2 3
@ 1 7- ' t2 3
07749-OO l OOOO Driver I
@ 17-103
o7947-6340500 DriverAttachment 1
@
o7974-6920500 Hub AssemblyGuideAttachment 1 17,145
@
/g)
\Z'cfp
@
/t-\
i=
@@
7-2
GeneralInformation
4WS ServiceInformation
On modelsequippedwith the electronicallycontrolledpower assisted4WS (4-wheelsteeringsystemi, note the foliow-
ing specialprecautionsbefo.e service.
a After performingthe following operations,check and adiustthe 4WS systemto be sure that it is electronicallyand
mechanicallyin neutral(all 4 wheels in properalignment).
Check for Checkfor

Relerence
Operation mechanical electronic
page
neutral neutral
Rack guide adjustment o 1 77 6

Steeringwheel removal/installation o o 1 7 - 8 ' ,l 8 6
Steeringwheel replacement o o 17-86
Steeringcolumn removal/installation o o 17 89, 93
Front steeringg€arboxremoval/installation
or
dissssemblv o o 17 - 11 8 , 13 1
Rearactuatorremoval/installation o o 17 137
Ffont/rearsub steeringangle sensor
removal/installation
o 1 7 - 1 1 7 1, 3 7
Front msin steeringangle sensor

removal/installation o o 1-t -92
Rearmain steeringanglesensor
removal/installation
o 17 137
a Th6 4WS Systemmust be ( l ) mechanicallyand (2) electronicallyin neutralfor Woperoperation.Performthe following

mechanicalneutralcheck on the system and adjustas necessaryfirst, then performthe followingelectronicneutral
check and adjust as necessary.(4WS system adiustmeni:see page 17-151 )
(l) Mechanicallyneutrsl:
Be surethat the front and rearwheelsalignpfoperlywith the steeringwheel in the straightdrivingposition(i.e.dif
ferencein computerizedfour wheel alignmentequipmentreadingbetweenthe right and left wheels is within 0.5
mm/O.02 inl.
{2) El€ctronicneutral:
in neutralwith the steeringwheelin the straightdrivingposition.
Be surethat the tollowingsensorsare electronically
Electronicneutralpositionis indicatedby blinkingor lightingof the 4WS indicatorlight.
Front Main SteeringAngle Sensor

Front Sub SteeringAngle Sensor 4ws tNDtcaToRLtcHT
Rear Main SteeringAngle Sensor I
RearSub SteeringAngle Sensor
I
. ,.. at{rt4-
( c o n t ' d)
7-3
Generallnformation
4WS Service lnformation (cont'd)
o It the spokesngleof steeringwheel is not atthe designatedanglewhiledrivingstraight,checkwhetherit was caused
simply by an improperlyinstalledsteeringwheel or by the misalignmentof the lront and rear wheels. Check the
wheels for properalignmentbefore adjustingthe steeringwheel spoke angle.
Installtherearsteeringlock pin in the rearactuatorand. with the steeringwheelin the straightdrivingposition,check
the wheelsfor properalignment(i,e.differencein computerizedfour wheelalignmentequipmentreadingbetweenthe
right and left wheels is within 0.5 mm/0.02 in).
Checkthe sensorsfor electronicneutralto be sure that the rearwheels are in correctsteeringanglewhile driving.
a Do not contaminatethe front and rea. sub steeringanglesensors,front and rearmain steeringanglesensors,and the
rear steeringactuatormotor terminalswith mud, oil, and grease.
a Thephrase"the steeringwheel in the straightdrivingposition" meansthat the front wheels are in the straightdriving
positionwith the steeringwheel spokesat a horizontalangle.
a lf the power to the 4WS controlunit was shut down for the followingoperations,start the engineand turn the steer-
ing wheel tully right and left before checkingand adjustingthe 4WS system.
- Battery removal/installation
- 4WS control unit removal/installation
- No,43 fuse CLOCKRADIOremoval(in the under-hoodfuse/relaybox)
CAUTION;
a The roar whoel steoring angle is not controlled when the engine is OFF. When the engine is staned, the rear
whaels aro ste6r6d to an angle in accordancewith the front whoelangle. We recommendthat the steering system
b6 sorviced wilh the steering whoel set in th6 straight driving position,
a Do not st8n the engino with the lock pin sot in the rear acluator. The rear actuator might be damaged whsn the
rear whools aro steorod. Bo surs to removs ths lock Din after service.
CAPBOLT
22 N.rn SEALINGWASHER
12.2kg-m.16 tb-ftt Replace.
17-4
ComponentLocation
Index (2WS/4WS)
NOTE: lf an intact driver's airbag assemblyhas been removedfrom a scrappedcar or has been found defectiveor
damagedduringtransit, storageor service,it shouldbe deployed{seesection23}.
STEERINGWHEEL
Removall2WS/4WS).page 17'81
Disassembly/Reassembly, page 17-83
Installation{2WS}, page 17-84
Installation{4wS}, page 17-86
STEERINGCOLUMN
Removal,page 17-89
Inspection,p6ge 17-92
Installation,page'l7-93
FRONTMAIN STEERING
ANGLE SENSOR{4WSI
Adiustment,page 17-15'l
IGNITIONSWITCH
Steering Lock Replacomentand
Swirch Test, see ElectricalSection
STEENI G GEARBOX
RackGuideAdiustment(2WS/4WS),pago 17-75
Removal,p€ge 17-114
Index,page 17-1 17
Ov€rhaul,page 17-118
POWERSTEERINGSPEEDSENSOR
Rgplscement,pag€ 17-8O
TIE.RODENO
VALVEBODYUNIT BallJoinr Eoot
Ovsrhaul,page 17-106 Replacement,
FROI{T SUB STEERING p g a e1 7 - 1 4 5
ANGLE SENSORI4WS)
Adiustment,
p a g e1 7 - 1 5 3
FLUIORESERVOIR
FluidReplacement,
page 17 77
STEERINGPUMP
Pump Belt Adjustmenr,page 17 74
FluidRepfacement, page 17-77
PumpPressureCheck,page 17-78
Pump Replacement, page 17-96
page 17-97
ControlValve Inspectionand Replacement,
Disassembly,page 17-99
Reassembly, page 17-103
17-5
GomponentLocation
Index (4WSl
4WS COTTROL UI{IT

page | 7-145
Removal/lnstallation,
4WS SYSTEM I SPECTION.nd ADJUSTMET{T
Insp€ction,page 17-15'l
RACK EI{O REARSUB STEERINGANGLE SENSOR

Removal,page 17-138 Adjustmenl,page 17 155
page 17-144
Installation, Romoval,page 17 138
page 17-141
Installation,
REARMAIN STEERINGANGLE SENSOR

R e m o v a lp, a g e1 7 1 4 1
fnstaflation,page 17'1 42
TIE-RODEND
Boot Replacement,
p a g e1 7 | 4 5
REARSTEERINGACTUATOR
lllustratedIndex,page 17-137
ActuatorRemoval,page 17-138
Actuator Dissssembly, Page 17-140
17-6
SystemDescription
FluidFlow Diagram
The reservoirsuppliespower steeringtluid to the pump; the pump pressurizes the fluid and deliversit through a high
pressurehose to the valve body unit on the gearbox.
The 4-way valve {in the valve body unit) controlsthe directionof the turn by shiftingfluid to the left or right side of the
piston on the rack {in the power cylinder).
The gain control valve jn the valve body unit controlsthe amount ot the assistby regulatingthe stroke of the 4 way
valve.The operationot the gain controlvalveis atlectedby the fluid pressure,which is regulatedby the pressurecontrol
valve, sensororifice and power steeringspeed sensor.
Constant pressureis generatedby the pressurecontrol valve. This pressureis used as a referencepressuretor the
responseto the car speed.By introducingthis pressureto the power steeringspeedsensorthroughthe sensororilice,
the pressuredownstreamol the orificeis changedaccordingto the speedof car. This pressureis then used to operate
the gain control valve.Two orificesare pfovidedaroundthe circumferenceof the gain controlvalve.Theseorificespro-
vide th€ steplessreductionof the pressuretrom the pump accordingto the changesin the car speed.The reduced
pressu.eis then sent to the reactionchambers.Theretorethe assistvariesby regulatingthe lluid pressurein the valve
body unit accordingto the speedot car.
FIuidretrrrninglrom the power cylinderflows back throughthe 4-way valveand out to the reservoirthroughthe cooler.
VALVE EODY UNIT ------l

tr----------
PRESSURE
CONTROL
SENSORORIFICE
VALVE
RESERVOIR
GAIN CONTROLVATVE
REACTIONPLUNGER
a-say y4s-ys{
GEARBOX
I
I
CYLINDER
FLOW CONTROLVALVE
lhas s built-in reliel valvel
WHEEL
STEERING
7-7
System Description
Construction
The pump is a vane-typeincorporatinga tlow controlvalve(with an integratedreliefvalve)and is drivenby a V-beltfrom

the crank pulley.The pump features1Ovanes.Eachvane performstwo intake/discharge operationslor every rotationof
th€ rotor. This meansthat the hydraulicfluid pressurepulse becomesextremelysmall duringdischarge.
FLOW CONTROLVALVE
DRIVESHAFT
Operation
pressureis appliedto
The belt-drivenpullevrotatesthe rotor throughthe drjve shaft. As the rotor rotates,the hydraulic
being pushed onto the innercircumference of the cam rlng'
the vane chamberof the rotor and the vaneswill rotatewhile
extended portion with respect to the centerof the shaft, so the rollers
The inner circumterenceof the cam ring has an
directionas the carrier
rotates.As a resultof this rollermovement, the internalvolume of the
move downward in the axial
vane chamberwill change,resultingin fluid intake and discharge
START OF FLUID INTAKE FLUID INTAKE FLUIDMOVEMENT FLUIDDISCHARGE
INLET
POBT
The volume of the The sucked-in fluid moves As the vanes return to the
The vanes are pushed onto
chamber increases so t h a t toward the discharge port, their original position on the
the inner circumferenceof
tluid is suckedin. inner side, the volume of the
the cam ring.
vane ch6mber decreases so
the fluid is discharged from
the discharge pon.
17-8
Fluid Reservoir/Filter
Flow Control A one-piecereservoirand filter is attachedto the tender

apron on the left side of the enginecompartment.The
Fluidtrom the pump runs through a meteringorificeto fluid and the filter/reservoirshould be replacedif the
the valve body unit. This createsa pressurediJference system is openedfor repairs,or if the fluid gets water or
between the pump and valve body unit sides of the dirt in it.
orifice.When pressurein the pump side is higherthan
the force ot the spring holdingthe flow control valve CAUTION: Use only Honda Powsr sleering
closed, it pushesthe valve down (openl, and excess Fluid-V,The use ot othel fluid such as A.T.F., or
fluid returnsto the Dumoinlet. The combinedetiect ot othor manufacturor's power stsering fluid. will
the metsringoriJiceand the flow controlvalve provides cause damago to the system.
a relativelyconstantflow of Jluidto the valvebody unit.
METERING
ORIFICE
<-
To Valve bodv Unit
Steering
ProssureRelief SpeedSensor
As pr€ssureon the valve body unit side builds up, it

pushes the relief valve ball (inside the tlow control From Valve body Unit
valve)up againstits spring,and excessfluid returnsto
the pump inlet. As the pressureunderthe flow control
valve drops,the reliefvalve ball is closedby its spring,
<r
and the flow control valve is forced down again.allow- To Steering Pump
ing excesslluid from the pump side to returnto the in-
let. This tlow control valve-reliefvalve cylinder keeps
pump output pressure between TOOO-8OOO kPa
( 7 O - 8 0 k g i c m ' .9 9 5 - 1 , 13 8 p s i ) .
RELIEFVALVE OPEN
RELIEFVALVE EALL
1 7- 9
System Description
4-Way Valve
Mountedon ihe lower sideof the gearboxis a 4-way valvethat is movedhorizontallyby a pin on the pinionholderto shift
tluid pressureto the right or left side of the power cylinderwhen the steeringwheel is turned.
It has thrust pins at both ends, and two inter-connected reactionchambers,one on each side.
Eachreactionchambercontainsa pair of spring-loaded plungersthat rise againstright and lelt thrust pins.
The valve body fluid passagesare controlledby the 4-way valve.
Fluidpressurein the reactionchambersis reducedby the gaincontrolvalvein orderto changethe amountof the assistin
accordancewith the changein the car's speed
VALVE BODY UNIT
SENSORORIFICE
RESERVOIR
GAIN CONTROLVALVE
4-WAYVALVE+
I matl ontrtce
l r >
i ----------JJ-l-
POWERCYLINDER
L________
FLOW CONTROLVALVE
lha! I built-ln toliot valvo)
+WAY VALVE
17-10
In the power steeringunit, the methodusedto directa singlesourceot fluid pressurein eitherof two directions(for left or
"message" oJ directionto the tluid in the 4-way valve
right turns) involvesthe piniongear transferringa
The pinion is mountedslightlyoff-center in a pair ot bearings,which are in turn mountedin a pinionholdercylinderthat
rotates,centeredin its own outer bearings.At the bottom ol the PinionHolderis a pin, which fits in a slot in the 4-way
valve.
As the pinionis turned (to turn lett or right),becauseit is off-center.it alsomovesslightlyalongthe rack.This movement
is transferredto the holder.The pin in the holderthen movesthe 4-way valve,to directfluid pressureto eithersideof the
rack in th€ power cylinder.
The bsck edgesot the pinionholder(facingaway lrom the rack)hit the stopscast into both sidesof the gearhousingto
avoidpushingthe 4-way valvetoo far in eitherdirsction,The tront edgeof the pinionholdercuts off assistat full lock as
describedon the next page.
POWERCYLINDERS
NEEDLEROLLER
BEARIG
STEERINGRACK
BALL BEARING
Plt{
+WAY VALV€
HOLOEB
RACK
4.WAYVALVE
1 7- 1 1
System Description
Full-lockUnloaderSystem Power SteeringSpeedSensor
The 4-way valveshifts the directionof fluid flow when The power steering speed sensor is a trochoid-rotor,
the steeringwheel is turned right or left. hydraulicpump combinedwith a reliefvalveand a one-
However,when the wheel is turned to the right or left way valve. lt is driven by the speedometergear shatt
lock at parking speed, the edge of the pinion holder which in turn is driven by a helical gear on the
ridesup on the end of the rack, movingthe pin in the op- differential.
posite directionwhich pulls the 4-way valve back to
nsutral.
This keeps pump pressure from building up (which
could cause idl€ speedto drop), and improvessteering
leel by increasingresistanceat left and right lock.
INNERROTOR
OUTERROTOR
ONE-WAYVALVE
Controlin "assist" position
SPEEDOMETER
GEAR
The power steeringspeed sensorturns only when the

car is moving.controllingthe gain control valve.
The constant pressureis generatedby the pressure

conlrol valve.
This pressureis used as a relerencepressurefor the

response to the car's speed. Bv introducing this
pressureto the power steeringspeed sensor through
the sensor oritice, the pressuredownstream of the
4-way valve moves back to "neutral" position orifice is changedaccordingto the speedof the car.
PRESSURECONTROLVALVE
To power steeringspeedsensor
Pressurein response
to vehiclespeed
FEEOSIDEORIFICE
17-12
With the engine running at idle in a parked car, fluid When the car is moving at high speed, the sensor
flow through the sensor rotors is blockedbecausethe reducesthe pressureturther and the gain control valve
rotors are not turning.Theretorethe gain control valve moves furthsr to the right. The orifice pressureon the
movesto the left. On the gain controlvalve.the oritice pump side is low and the pressureon the reservoirside
resistanceis high on pump side, while it is low on the is high,the fluid pressurein the reactionchamberis also
reservoirside, with the resultthat pressurein the reac- high giving the steeringwheel less assist.
tion chambe,is loweredand steeringassist is high.
Hydraulic prossurein response
to the car's speed(Lowl
Hydraulic pressurein
FEEDSIOEORIFICE responseto thg car's
speed{High}
RESERVOIRSIDE OiIFICE
RETURl{
GAr{ CO|{TRO|-
RETURN VALVE
Pressurein reaction
chamber(Low)
As th€ car is driven.the rotorsstart turningand the fluid

returns to the reservoir, reducing the fluid pressure at
the gaincontrolvalve.Theretore,the gain controlvalve
bsginsto move to the right. The orifice resistanceon
the pump and reservoirsidesis appropriatelybalanced,
with the result that the reaction chamber is in the
mediumrangeand the steeringresistanceis moderate.
HvdraulicPressurein reaponse
ro the car'ssDeed(M€dium)
SIDEORIFICE FEED
RESERVOIR
REACTIONCHAMBER
(cont'd)
17-13
System Description
PowerSteeringSpeedSensor(cont'd)
One-wayValve(ln PowerSteeringSpeed ReliefValve (ln PowerSteeringSpeedSensorl
Sonsorl
When the car is moving in reverse,the power steering
Wh6n the car is moving at high speed, negative speed sensor also turns backward and pumps tluid in
pressure develops at the sensor inlet because the the oppositedirection.To avoid buildingup pressurein
power steeringspeedsensoris pumpingfasterthan the the reactionchambersthat would increasesteeringef-
fluid can be supplied.To compensatefor this, the outlet ton while driving in reverse,the inlet and outlet-ports
and inlet ports are connectedinternsllyby a passage are connectedby a secondinternalpassagecontaining
containinga one-way valve that lets output tluid recir a relief valve that allows the tluid to recarculate.
culate to the inl€t pon to equalizepressure.
Driving at Hlgh Speed: Driving in Reve.se:
ONE.WAYVALVE
ROTORS
RELIEFVALVE
17-1 4
ElectronicallyControlledPower Assasted4WS
Outline
The electronicallycontrolledpower assisted4WS (4-wheelsteeringsystem)consistsof the hydraulicpower steering

systemthat steersthe front wheels,the rearactuatorthat steersthe rearwheels,the 4WS controlunit, and the sensors
that detectthe car's speedand othersteeringconditions,The front steeringgearboxandthe rearactuatorare connected
by a wire harness.The rearsteeringangleis controlledelectrically,allowingthe rearwheelsto be set at any desigrated
steeringangle.
FRONTMAIN STEENINGANGLE SENSOR

VEHICLESPEED
17-15
System Description
ElectronicallyControlledPower Assisted 4WS (cont'd)
System Operation
The 4WS control unit receivesinput from the VehicleSpeedSensor(VSS),front main steeringanglesensor,and the
f.ont sub steeringanglesensor.The 4WS controlunit calculatesthe vehiclespeed,steeringturningangle,steeringspeed
and steeringdijectionto determinethe best angleto steer the rear wheels.
(System op€ration flow)
VSS ggrves the soeedmeter as

Front main st66dng angle sgnsol
well.
Front gub stooring angl€ sonaol
Calculation of the C.lculation ot steor-

car's apggd ing rotation speed
Calculation ot stooring angle lor toar whgels
4WS Control unit
17-16
The rear wheels are turned by a motor built into the rearsteeringactuator.The motor is activedby the power circuit in
the 4WS controlunit. The actualsteeringangleof the rearwheelsis detectedby the rearmainsteeringanglesensor,and
the rearsub steeringanglesensor.The 4WS controlunit adjuststhe angleaccordingto the differencebetweenthe sens-
ed steeringangle of the rear wheels and the targetedsteeringangleof the rear wheels.
FRONTMAIN STEERING
ANGLESENSOR
SENSOR REARSUB STEERING

ANGLESENSOR
4WS CONTROLUNIT REARMAIN
FRONTSUB STEENING
ANGLE SENSOR STEERINGANGLE
SENSOR
( c o n t ' d)
1 7- 1 7
System Description
ElectronicallyControlledPower Assisted 4WS {cont'd)
System Operation
Featuresol rear wheol steering:

The electronicsllvcontrolledpower assisted4WS sets the rear wheels at the best steeringanglelor the car's speed,
steeringrotationspeed,steeringwheel angle,etc.
a Car speed
When the car is travelingat low speed,the 4WS systemturns the rearwheelsin the reversedirectionof the front wheels
in proportionto the rotationangleof the steeringwheei. When the car is travelinga higherspeed,the system increases
the steeringangle of the rear wheels in the same directionas the front wheels.
Changingthe steeringangleperformanceof the rearwheelsin relationto the car's speedgivesthe car improvedhandling
characteristics.
a Steeringspeed 18 mph (3O km/h) or above

The rear wheel steeringanglevarieswith how rapidlythe steeringwheel is rotated.See graph
lSto6ring angl€/sp€ed
portoamancocuwol
Slow st€6.ing
Rapid stooring
0. 5
200 300 400
0
100
-0. 5
17-18
Component Function & Operation
Roa?actuator:
The rearactuatoris mountedat the rearoI the car to steerthe rearwheels.The motor, built into the actuator,is madeup
of a stato. with a permanentmagnet. a rotor. and brushesthat pass electricjtyto the commutators.The motor is
mountedon the sameaxis as the steeringshaft screw, makingthe rearactuatorcompactand light in weight. The rearac-
tuato. also containsthe rear main steeringanglesensorand the rear sub steeringanglesensor.
The 4WS control unit drivesthe electricmotor with DC current.lt switchesthe currentpolarityto changethe motor's
direction.Two strong return springs,one at each end ot the actuator,providea centeringaction.They returnthe rear
wheelsto the straight-aheadpositionwhenevercurrent is cut to the motor.
REARSUB STEERING
ANGLESENSOR
ACTUATORHOUSING
STATOR
REARMAIN STE€RING
ANGLESENSOB RETURNSPRING
STEERII{GSHAFT SCREW COMMUTATOR
BRUSHES
ROTOR
RECIRCULATING
BALL SCREW
<RETURN SPRINGOPERATION>
Mov6s to l€ft: Moves to right:
The return spring compresseswhen the steeringshaft

screw moves to right or left. When the motor is OFF,
the stesring shaft screw is held in the straight ahead
(neutral)positionby the force oJ the return spring.
{cont'd)
17-19
Maintenance Back-upLight Switch
Transmission
Oil Replacement
NOTE:Checkthe oil with the engineOFF,and the car on NOTE:Checkthe switchseesection23.
levelground.
1. Disconnectthe back-uplight switch wire connec-
1. Removethe oil tiller plug, then checkthe level and rors.
conditionof the oil.
2. Removethe back-uplight switch,
WASHEN
Replace.
ProperLevel.
OILFILI.IRPLUG
45 N.m(4.5kg-m,33lb-ftl
2. The oil levelmust be up to the fill hote.lf it is below

the hole, add oil until it runs out. then reinstallthe
o i l f i l l e rp l u g .
3. l f t h e t r a n s m i s s i o no i l i s d i r t y , r e m o v et h e d r a i n
p l u ga n dd r a i nt h e o i l .
4. R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r ,a n d
refillthe transmissionoil to the properlevel.
NOTE:The drain plug washershouldbe replacedat

everyoil change. 3. Installthenew washerand back-uplight switch,
5. Reinstallthe oil filler plug with a new washer.
Oil Capacity
1.9/ 12.0US qt, 1.7lmp qtl ar oil chango.
2.0 / {2.1 US qt, 1.8 lmp qtl at overhaul.
Useonly SAE 10 W - 30 or 10 W - 40,SF or SG grade.
OIL FILLERPLUG
'15N.m (4.5kg-m. 33 lb-ft)
WASHER
Feplace.
13-3
System Description
ElectronicallyGontrolledPower Assisted 4WS (cont'd)
Component Function & OPeration

Front main stso.ing anglg sensor:
The front main steeringanglesensoris mountedin the
stee,ing column. lt sens€sthe directionand angle of
steering wheel {otation and converts it to electrical
signalsthat are sent to the 4WS control unit.
CIRCUIT MR ELEMENT HALL IC
Roal main ste€dng angle 9en9o1:

The rear main steeringanglesensoris mountedon the HALL IC MR ELEMENT
rear actuator. lt sensesthe directionand angle of the
rear wheels and sendssignalsto the 4WS control unit.
The 4WS controlunit usesthis informationas feedback
to determineif the actual rear wheel positionmatches
the desiredDosition.
17-20
Front tub stoering angl€ s€nsor:
The front sub steeringangle sensoris mountedon the
front stgering gearbox. lts purpose is to detect the posi
tion of the front wheels and convert this inJormationto
an slectrical signal for the 4WS control unit.
The front sub steering angle sensor uses a spring-

loadedplungerthat ridesin a slopedgroovein the rack.
As ths rack turns the tront wheels,the plungerridesup
the slope and is pushed into the differential transformer
assembly.The plunge.'spositionis used to determine
how tar the rack is turned.
FROI{T SUB STEERINGANGLE SENSOR
STEERINGRACK
Rgar sub gtoodng anglg aensor:

Th6 r6a. sub steeringangle sensor is mounted on the
rear actuator spring cover. lts detects the position oI
the rear wheels as a feedbacksignalfor the 4wS con-
trcl unit. lt ogerates in exactlv the same wav as the
front sub steering angle sensor.
11-21
System Descripton
ElectronicallyControlled Power Assisted 4WS {cont'd)
Componont Function & Operation (cont'dl

a Average moving curent control
The 4WS controlunit monitorsthe averagemovingcurrentol the motor to protectthe system.Whenthe averagemov-
ing currentexceedsa given value,the 4WS control unii lowers the currentto changesteeringangleof the rear wheels
graduslly(approximately6 degrees/3osecondsl.When the averagemoving currentto the motor is below the given
value,the rear wheels returnto the designatedsteeringangle slowly {approximately6 degrees/2minutes).
a Over-voltage control
An increasein battery voltage (due to a voltageregulatorfailure,for example)could causeexcessiveactuationof the
motor and grraticcontrolof the r€arwheels.To preventthis, the 4WS controlunjt monitorsthe voltage.lI it exceedsa
givenvalue,the 4WS controlunit slowly returnsthe rearwheelsto the straightaheadpositionby reducingvoltageto the
motor and turns the 4WS indicatorlight ON.
17-2 2
Fail-sat€Function:
When the 4WS controlunit sensesa tailurein the system,it switchesto fail-safemode. In this mode, it powersthe tail-
safe and damper relays.The fail-salerelay cuts power to the rear steeringmotor, while the damper relay slows the
motor's returnto neutral.As a result,the rearwheelsreturnslowly to the straightaheadpositionand then remainthere.
The car then drives like conventional2WS.
When the 4WS control unit switchesto fail-safemode, it storesa DiagnosticTroubleCode(DTC)and turns on the 4WS
indicatorlight to notify the driver of a problem.This code can be read by connectingthe servicecheck connectorter
minals with a iumoerwire under the dash. The code is read as blinksof the 4WS indicatorliqht.
4WS INDICATORLIGHT
/
/
..
I
;=; .
-'Puf
Flr,\-n-
=' -
i .
="1 :
- -
-:- :a.
JUMPERWIRE
Damper Control:
When the system goesinto fail-safemode,it cuts power to the motor by poweringthe fail-saferelay.Without sometype
of damping,the returnsspringswould turn the rearwheelsto the straight-aheadpositiontoo rapidly,adverselyatlecting
the car's handling.
To counteractthis, the 4WS control unit also powersthe damperrelay.The armatureo{ the now deactivatedmotor is
spun by the movementof the steeringshaft. This causesthe motor to act as a generator.The voltagegeneratedby this
action is appliedback to the motor throughthe damperrelay.This causesthe motor to resistthe force ot the returnspr-
ings. allowingthe rear wheels to go back to the straightaheadpositionslowly.
1 7- 2 3
System Descripton
ControlledPowerAssisted4WS (cont'dl
Electronically
Componont Function & Operation (cont'dl
a El€ctronic neutral Position
ln other
For the 4WS system to work correctly,it must be in el€ctronicalignmentas well as mechanicalalignment
w o r d s , t h e s Y s t e m , s ' r o n t a n d r e a l s e n s o r s m u s t S i g n a | t h a t t"electronic
hewhee|sarepointedstraightaheadwhenthewhee|sare
mgchsnicallypointedstraightahead.The techniciancan test tor straightahead" by connectingthe service
ch6ck connector terminals with a iumper wire and turning the front and rear wheels'
17-24
Troubleshooting(PowerSteeringSystem)
GeneralTroubleshooting
Check the following betoreyou begin:
a Has the suspensionbeen modifiedin a way that would affect steering?

a Are tire sizesand air Dressurecorrect?
a ls the steeringwheel originalequipmentor equivalent?
a ls the power steeringpump belt properlyadjusted?
a ls steeringfluid reservoirfilledto properlevel?
a ls the engineidle speedcorrect and steady?
HardSteering
Littleor no assistin both directions Assislin one directiononly, littleor

with car parked. no assistin the olher.
Check for bubbles in power steer- Remove the valve body unrt and
ing fluid. check the pinion pin for free move-
ment. lf OK, check lhe 4 way valve
for free movement (see page
1/,107|.
It there are bubbles, check the
l{ there are no bubbles, check i{ reservoir inpul side hoses and
Repair as necessary.
assist improveswhen engine speed pump front seallor air leaks.
is increasedlC| 3,O00 rpm. Repairas necessary.
lf assistimproves,checkthe pump lI assist does nol improve,check

flow control volve lor internal leak' tluid pressure,using power steer-
ing, and clean or replace as ing pressure gauge with shut off
necgssary(seepage 17-98). lf the valve closed(seepage 17-78).
valve is OK, replacethe steering
Fluid pressurebelow 7,000 kPa Fluid pressure7,00O 8.O00 kPa

(7O kglcm2, 995 psi). l 7 o - 8 0 k s l c n ' . 9 9 5 - 1 .1 3 8 p s i ) .
Checkthe pump flow controlvalve The pump is OK. Measurethe force

Ior internal leaking,and clean or requiredto turn the wheel with the
replace 6s necessary {see page speed sensor hose plugged and the
17-98). lf the valve is OK, replace
car parked (see page 17 79).
the pumP.
Steeringeffort above30 N (3.0 kg, Steeringeffon below 30 N (3.o kg,

6.6 lbs)- Check the pressurecon' 6.6 lbs).The power steeringspeed
trol valve for stickingor a clogged sensoris leakinginternallyireplace
orifice; clean or replacethe valve the power steeringspeed s€nsor
as necessary(seepage 17'107). lf ( s e ep a g e1 7 B 0 ) .
the pressurecontrol valve is OK,
checkthe pinionpin for free move_
ment. lf seizedor bindingoverhaul
the steeringgearbox,
(cont'd
17-25
GeneralTroubleshooting(cont'd)
Adiustthe belttension.Replace
Beltslippingon the pulley. the belt,iJ necessary(seepage
17-141.
Checkgaincontrolvalve;clean
or replacethe gaincontrolvalve
or valvebodyunit.
lI the enginestallswhen wheel

is turnedwhilecar is stoppedor
ldle speed low or erratic.
movingat low speed,adjustidle
speed(seefuel section).
rough ataering.
Check power steeringfuid level,

lf levelis excessivelylow. check
Air in reservoirtank, o. low for leaks in the system. Add
powersteeringlluid level.
tluid to the soecitiedlevel.
It fluid levelis OK, check O-rings

and sealson both ends ot the
pump inlet hose, and the oil
pump housingmatingsurfaces
tor suctionleaks.ReDlace Darts
as necessarv.
Adjustthe rackguide(seepage
1 7 75 r ' .
lf the rack guide adjustmentis

OK, check the pinion bearings
for wear or damage. Replace
them as necessary.
7-26
Pump belt slipping on pulley Adiustthe belttension(seepage
(pump stops momenlarily). 17-74)or replacebelt.
Shock or vibrationwhen wheel

turned to tull lock.
Set the powersteeringpressure The pump pressureshould be
gauge.Closethe shut-offvalve 7,000 8,000 kPa (70 80
fully and measurethe pump k g / c m ,9, 9 5 - 1 , 1 3 8p s i )w i t h
p.essure(seepage17 781. needle fluctuation of t 5OO
k P a ( t 5 k g / c m , ,a 7 0 p s i )o r
l e s s .l l t h e n e e d l ef l u c t u a t i o n
exceeds :t 5O0 kPa (t 5
kg/cm' ,:t 70 psii checkthe
f l o w c o n t r o vl a l v e ,o f t h e J l o w
controlvalve is OK, replace
the pump.
Measureforce requiredto turn lf below, check gain con

wheel with bypass tube joint trol/pressure control valves
Assist (excessivelylight steering)at
installed, and car parked on and valve body unit and
high speed:
dry paved surface (see page replace parts as necessary.
17-80).
Adjust the belt tension (see

page 17 74l' or replacebelt.
Steering kicks back during wide Sticking gain control valve or Replace the gain control valve
turns. valve body unit. or valve body unit.
Rackguideadjustedtoo loose. Adjust the rack guide (see

page 17 751.
Readjustthe front wheel align,

Wheel will not return shoothlv. ment or replace parts as
necessary.
1 7- 2 7
Noiseand Vibration
-4oF or colder)is normal
NOTE:PumDnoise in first 2-3 minutesafter starting in cold weather (-2o'c,
Hummingdue to pulsationof fluid is normal,particularlywhen wheel is turned

wilh car stopped.
lf equipped with autolnalic Confirm by temporafily removrng

the hum couldbe tor-
transmission, pump bert.
que converter or pump noise,
High p.€ssure line touching lhe

R e p o s i l r o nl h e f i n e .
lrame.
Pinion shaft seal nol lubricatod
Horn contact nol lubricaled, or Grease the conlacl, or bend rl to

reduce tne pres3ure.
"clunk" maY bo e notmal amount of linkageclearance'To

NOTE: A sangte
distinguishthis lyp€ ol clunk, turn th€ wl|€el back and lorth with lhe engineOFi
Tighten or replace pulley

Loosc pump pull€y. ll sh6lt is loose, raplacelh€ pump.
Rattle or chr(e.ing
Loos6 sleerinO shtfl conn6ctor, ti6_ Check and tighlen, or teplace gans
rod, or ball pant.
Columnshaft wobbling. Replacethe columnassemblY.
Lines or hoses from the valve bodY

unit louching each other.
Noise from valve body unil.
NOT€: Pump noise up to 2-3

mrnutes afler starting in cold lf pump noise is abnormallyloud,
Pump gea. norse weather (-2OoC, -4oF or colde.) check the pump ball bearingand
any parts.(seepage 17-102).
Compere pump norse at ope.atrng
lemperalure to another car
Check llurd level
l l l o w , f r l l r e s e r v o r rl o p r o p e r l e v e l .
and check for leaks
Gratrngdorselrofi pump Trghten or replace as necessatY
Check lo. crushed suclron hose o.

a loose hose clamp allowrng ar Inio
Trghten of replace as necessary
17-28
Fluid Leaks
NOTE: When tluid leaks lrom one

side of the rack the balance tube
Bemove the 4 way valve and in-
transfers the fluid to the other
spect the 11 mm O-ring and rhe
side, giving the appearance that
port housing bore for pits, burrs or
both sides are leaking. To
s c r a t c h e s( s e e p a g e 1 7 1 0 7 ) .
troubleshoot, remove both boots,
Repair as necessary.
clean the rack and locate the leak.
lf no abnormalrty is found, replace

the O ring, reseal the gearbox and
Inspect the steeflng rack seaiing
surface lor burrs or scratches be
tween the steenng rack gear teelh
and the piston. Inspect the seal re
Resealgearbox and inspect the tainer bore in the gearbox housing
rack sealingsurfacebetweenthe for proper chamfer and sharp
steeringrack piston and the righl e d g e s ( s e ep a g e 1 / 1 1 7 1 .
e n d { s e ep a q e 1 7 1 1 7 ) .
Trghten attachrng bolls or replace

valve body or port housrng.
Sreeflng gearbo'(
Leaking l.om erlher side of valve Replace all valve body unit seals
and O-rings.
Replacethe valve body.
Replace the front seal.
Replace housing O rngs.

Pump housrng leaks et €ither end ll lhe housrng st|ll leaks, replace
the pump
R e s e r v o i ro v e r l i l l e d
Leaking from around cap, Pullolt the hose and drarnto proper
Air leak in
s€4r,.
lhrgh pressure)
Lealrng because ol damage,

LO\/vpfessure hoses delefioralron, or rmproper as. Replac€or repar as necessary
Tighten connector. lf still leaking.

the prpeor vaive bodv unrt.
Leaking at gearbox connection

{at O ring jojnt).
1 7- 2 9
Troubleshooting(4WS)
ComponentLocation
NOTE:
The radio may have a coded theft protectioncircuit.
Be sure to get the customer'scode number betore
- Removingthe No. 43 CLOCK.RADIO (1O Al fuse.
After service,reconnectDowerto the radioand turn it on.
When the word "CODE" is displayed,enter the cus-
tomer's 5-digit code to restoreradio operation.
CLOCK,RADIO(10 AI FUSE ANGLE

REABMAIN STEERING
SENSOR
UNDER'HOOD
FUSE/RELAYBOX
ABS CONTROLUNIT
REARSUB STEERING
ANGLESENSOR
FRONT MAIN STEERING

ANGLE SENSOR
REARACTUATOB
UNDER,DASH
BOX
FUSE/RELAY
VEHICLESPEEOSENSOR
{vss)
ANGLE
FRONTSUB STEERING
SENSOR
SERVICECHECK CONNECTORI2P}
Behindthe cenler console
No. 22 4WS tto Al FUSE
17 -3 0
ConnectorLocations
ABS CONTROLUNIT CONNECTOR

4WS CONTROLUNIT POWERTERMINAL
G 503 \ 4WS CONTROLUN|T CONNECTOR{4p)
4WS CONTROLUNIT
CONNECTOR{18P)
VEHICLESPEEDSENSOB
CONNECTOR I3P)
CONTROLUNIT CONNECIORI12PI
SERVICECHECKCONNECTOR {2P}
Behind the conler console.
1 7- 3 1
CircuitDiagram
wffi--------*--
UNO€R.HOOD
FUSENELAY
BOX FUSENo. FUSELABELNAME
23 ECU
F/CMIRNOR
METER
1WS
UNDER-OASH
80X
FUSEiRELAY LIGHT
SYSTEM
CI'IARGING
IGNITION
SWITCH
l|G1l
VEHICI.E
SPEEDSENSOR GRNETD
41., ,ro*
\ ll^ ,/ LEVEL
*1- swrcr
SUBSTEERING FRONTSUB
REAR STEERING
ANGLE
SENSOR ANGLE
SENSOR A
-=
G301
-+YELtsLU
V'/HTALU€-
BLK+YEUBI(
B[K/r{HI------O- GRY
ANGTE
SITIRING
FRONTMAIN SENSOR WHTELU-.+GRYmt
BLK---.€- GRY/BLK
*l
SENSOR
MAINSIIERINGAMNGLE
REAR
cIr
GO2
G101
17-32
SERVICE
CHECK
CONNECTOR
IGNITION
SW]TCH
l|G2)
ABSCONNOL
UNII
IGRt{nED
l--':*ln'"-Io'j
(lL ,
PARKTNG
rr\
anlxeY'
91,v116gJ-
IWSCONTROL
UNIT
POWER
TERMINAT
I8PCONNECTOR 12PCONNECTOR
1 4 7 U 1 9 20 21 23
10 't2 1 4 1 5 16 1 7 1 8 27 28
IWSCONTIOL
UNIT
CONNECTOR interiorside
17-33
UNITTerminalArrangement
4WS CONTROL POWERTERMINALID}
(AI (B)
12P CONNECTOR (C)
4P CONNECTOR
18P CONNECTOB
l 2 3 4 5 6 7 8 192 0 22 2 3
10 13 14 1 5 16 17 18 24 2 5 26 1 , / 2 8
View from controlunit terminalside
con- Check
con_ Termanalname Measuremt
necror W i r ec o l o r Measurement Normal
necror voltage termimals
No. condition
While the wheel is 1- 2 4
G R Y / R E D R e a rr i g h tp u l s e 5V-OV
being rotated slowly
Engine ON Batteryvoltage.
2 WHT/BLU Charge 2-24
EngineOFF O V
While the wheel is 5 V-O 3-24
3 GRY/WHT Rear left pulse being rotated slowly
IG SW ON Battery voltage
BLK/YEL lgnition 2 4-24
IG SW O V
OFF, ACC, START
Rearmain steering O V 5 -ground
5 RED IG SW ON
angle sensorground
Rearmain steerang While actuatormotor 5V-OV 6-24
6 WHT/GRN is runningslowly
angle sensorA phase
Light ON O V
1 PNK Warning 1
Lisht OFF Battery voltage
Front main steering While steeringwheel 5V-OV 8-24

I GRN
angle sensorA phase is being rotated slowlY
I
Short OV
10 B R N / W H T Service check signal 10-24
Open 5V(AT:1lV)
1 1
Front main steerlng While steeringwheel 5V-0V 12,24
1') BLU is being rotated slowlY
angle sensorZ phase
Rearmain steerrng While actuatormotor 5V€OV
13 BLU/GRN
angle sensorB phase is runningslowly
ON O V
G R N / R E D Parking brake 1 4- 2 4
14 Battery voltage
OFF
Front main steerlng While steeringwheel 5 V-0 15,24

I D YEL/RED is being rotated slowlY
angle sensorB phase
BLK Ground2 IG SW ON O V 16-ground
Rearsub steering Analogtester DC approx. 1 7- 2 4

17 GRY/YEL range 2 . 5V
anble sensorcenter
WHT/YEL I Back up Power source At all times Battery voltage 18- 24

18
s w i t c h ,A C C :accessory{'l position)
17 -34
18P CONNECTOR
IAI 12P CONNECTOR
IB} {c)
CONNECTOR
1
t0
3 4
12 1 3 1 4 l 5
6 7
16 17 18
t9 20
24 25 26
21 2 2
2 829
ffi
Eqql
View from control unit terminalside interior side
con- Ch e c k
con-
nector Wire color Terminalname Measurement Normal Measuremt
nector
No. condition voltage rermtmats
'19 ORN Vehiclespeed sensor
While front wheel is
5 V*O 19-24
being rotated slowly
Rearmain steering While actuator motor
20 GRN 5 V.,O 20 24
angle sensorZ phase asrunningslowly
Front sub steering Analog tester AC Left CenterrRight
21 YEL/BLK 21 26
angle sensor left range s.ovT2svb.o v
Front sub steering Analog tester AC Left Right
YEL/BLU 22 26
angle sensorright range 2 . OV 2 . 5 V 3 . 0 v
Light ON O V
23 PNK Warning 2 23 24
Light OFF Battery voltage
B
24 BLK Ground 1 IG SW ON O V 24 gtound
IGSW ON Baltery voltage

25 YEL/RED lgnition 1 25 24
I G S W O F F ,A C C O V
Front sub steering Analog tester DC approx.
YEL/GRN )6 ?4
angle sensorcenter range 2.5 V
27
Rearsub steering Analog tester AC Left Cen! Right
2S GRY/BLK 2A 17
angle sensorleft range 2 . OV 2 . 5 V 3 . 0v
Rearsub steering Analog tester AC Left Right
29 GRY 29 17
angle sensorright range 3 . 0v 2 . 5V 2 . OV
31
32
Resistancerange Continuity
YEL Damper 33- 34
Disconnect4P
connector. Momentarilyopen, control untt
34 BLU Damper Start the engine no conI|nutry Iermtnal
WHT Motor power source At all times Battery voltage A ground
FI BRN power (motorl ground IG SW ON O V B ground

D
O V
RED Motor terminal C ground
Start the engine Battery voltage
D BLK Motor terminal D -- ground
The normalvoltage is the value when the system is working properly.
17-35
agnOSIlC Trouble
Diagnostic Code(DTC)
I rOUOle UOOe tu I l-f -
To display the DiagnosticTrouble Code (DTC)

( 1 ) Pullout the servicecheck connector(2P) locatedbehindthe centerconsoleand connectthe two terminalsof the
connectorwith a iumper wire.
(3 P)
DATA LINK CONNECTOR
NOTE:
Do not attach
the jumper wire.
,-->,/
' _ \
JUMP€R SERVICECHECK
coNNECIOR (2Pt
(2) Turn the ignitionswitch ON. but do not start the engrne.
( 3 ) Watch as the 4WS indicatorlight blinksto displaythe code
{4) Recordthe codes.
NOTE:
a Be sure to recordthe code. lf you do any oI the following, the code will be erased.
- Disconnectthe battery terminals
- RemoveNo. 43 CLOCKRADIO (10 A) fuse from the under-hoodfuse/relaybox
- Disconnectthe 4WS control unit connector.
IndicatorLamp (MlL) will stay on

a It the engineis started with the serviceconnectorjumped, the N,lalfunction
DTCindicationpattern Main - sub --+'
l'.""i11,n"i"" sub * 5'u" --" Main
V.fv6 t+ #12, t--- #22 --, signsl F-#22=, t<-# 12
chock 3.0
o.g 0.4 0.8 o.g o.4
0.8 0.4 0.8 0.4

The 4WS indicatorlight displaysa code by a seriesof long and short blinks.This indicatorlight can displaymultiplecom-
ponent problemsby blinkingseparatecodes,one after another.The numberof long blinksequalsthe lirst d;git of the
code. the numberof short blinksequalsthe seconddigit. When there are multiplecodes,there is a two secondpause
betweenthe codes.
System problemscan be detectedby both the main and sub centralprocessingunits (CPUS)in the 4WS control unit
Each CPU can memorizeup to 1O codes. lf both CPUshave stored codes, the 4WS indicatorlight will:
a Blink quickly once as an indicatorlignt check, (this happensonly when the ignitionswitch is first turned on).
a Pausetor three seconds.
a DisDlavthe codes stored in the main CPU.
a Pausefor 1.6 seconds.
a Blink rapidlytor three secondsto indicatethe switch betweenthe main and sub CPU.
a Pausefor 1.6 seconds.
a Displaythe codes stored in the sub CPU.
a Pausefor three seconds,then repeatthe cycle.
This cycle will continueuntil the ignitionis turned OFF.
NOTE:
a Be su.e to check both CPUsfor at least 10 codes betoreturning OFF the ignitionswitch
a lf the main and sub CPUSdisplaythe same codes,those codes need only be checkedonce.
7-36
Precautions
DiagnosticTrouble Code (DTC):
The DTC is memo.izedwhen the 4WS control unit detects an abnormality,even if it was a temporarycondition.To
troubleshoot,ask the customerin detailaboutthe conditionswhen the 4WS indicatorlight cameon, and try to duplicate
those conditionsduringthe test drive.lt the 4WS indicatorlight does not come on duringthe test drive,do not continue
to troubleshoot;the system is OK at this time, The troubleshootingproceduresassumethat the symptom is occuning.
Check for loose connectionsor poor contacts at the connectorsby wigglingthe harness.etc.
The 4WS indicatorlightcomeson when the 4WS controlunit detectsa problemin the system.Dependingon the problem,
the 4WS indicatorlight may be canceledby turningthe ignitionswitch ofl, or it might requireremovingthe CLOCK,RA-
DIO (10 A) tuse in the under-hoodfuse/relaybox. It a problemis detectedin the main steeringangle sensorsystem,
you must removethe CLOCK,RADIO{1O A) fuse to cancelthe 4WS indicatorlight. lI a problemis detectedin any other
part of the system, turningthe ignitionswitch off will canceithe 4WS indicatorlight.
NOTE: It the 4WS light comes on becauseof a temporaryproblemin the main steeringanglesensorsystem, it cannot
be canceledby simply removingthe causeof the problemand cyclingthe ignitionswitch; the CLOCK,RADIO (10 A)
fuse must be removed.
The 4WS indicatorlight does not come on when the DTC is 71 , 72, ot 73. However.the 4WS indicatorlight will flash
these codes when the servicecheck connectoris iumoed.
TemporaryDriving conditions:
Whenthe vehicleis operatedunderextremelyharshor abnormalconditions,the 4WS controlunit interpretsit as a problem

and memorizesthe DTC.
DTC Operation 4WS IndicarorLight
70 The ignitionis turned from OFF to ON while driving. ON

The car is driven aggressivelywith the driver and three passengerson
71 board. or the steeringwheel is turned with a rear wheel blocked by
the curb, etc.
The engine is started while quick-charging the battery.
Drivingthe car with the parkingbrake ON. ON 5 minutes
74
after detection
Fail-safecontrol:
When the fail-safe conditions are met, the 4WS control unit stops the 4WS control and returns the rear wheels to the
straight driving position slowly.
17-37
Troubleshooting(4WSl
Symptom-to-SystemChart
FAIL SAFE(F/S)ITEM AFFECTED

l5
l
F
z a
z It
z
c
4 t
z
i
z
= l f (r F
I o
F -LE
> o F
t 2
o t F X
t-- ; o o o F IE ACTION
& z -'z .rr nr T c E E o
tr9 F
z i 3; ) a a= zz.
A H
Z t-z = z F
z
F
z
f
t- F
(,
o:l
z ,,, 6 = F14
> 6
> ; o
C)
(J <(r nfr z
lr =
F z
;E
z = Eul 2=, crii'i
o l(l. < D < i < A 2e F
36
O O
- i z i z
tr< t < [ <
riz aa
E t1) t a
c0 3 # 5 R+
Go to
NO
code
7 +23 o trouble
shoo!ng
18
25 Go to
No o
code
o o trouDte 1 74 2
2 snoorng
Go to
22 o
10 FRONT o o 1 14 5
snoorng
Go to
1t REAR
17
o o a) 1750
snoorng
Go to
FRONT o o trouole 1 74 5
snooflng
Go to
11
REAR
2a
c) o trouble 1750
o snooflng
v,
Replace
14
(,
FRONT o
z
(9
z Replace
tr REAR o
trolunrt
F
at)
l 22 Go to
16 FRONT 26 o o 1t 45
21 shootrng
Go to
17 REAR 17 o O ,-l trouble 17 50
2a snoorng
Repiace
18 4WScon
17-38
FAIL-SAFE(F/S)ITEM
(9
4
(E
lDz
F q
z )
i z
tr<
rroLrble- 17 59
Go to
1 7- 3 9
Symptom-to-SystemChart (cont'dl
FAIL-SAFE{F/S)ITEM AFFECTED
(9
F
= o (9
2 t t
l z i = z z
l o = l ) E F
l5
E -.lE
I o
F o l ;o ; o o F z
E Z t;i
-'z o F E
E 2 ACTION
@ z - z
E l o
la
t z t z F d)
F p
tD F^ 2
x z
a ) <1, < = z.z
= 6 E"'
z
o
z
o
F
o
< E z
(9
4
z
z,,, Ful O cc
<5
F
F
z
o ;fr
Z:!
i z s:
z i
O ltr
. TL
<tr *E co
iE
3 <E ; 5^ P $ i
o(J tr< aa<E < E
Go to
REAR 3 o o o trouble- 1 7 - 6 8
33 R/L 'l
snoorng
Go to
34 o FRONT 19 o o o 17-63
REAR L 3 o o o 17-64
I
= REAR R I o o o o 17-66
shooting
Replace
37 REARL o 4WS con-
Replace
VEHICLE
SPEED
o 4WS con
trol unrt
40 CONTROL o
UNIT
41 CONTBOL o
UNIT
L
42 z CONTROL o
:) UNIT
o
43 F
z
o
o UNIT
o
44
=
o
UNIT
45 o
UNI-T
4WS
46 CONTROL o
UNIT
Go to
C +
o o a 1770
z o
C + o o o 1 7- 7 1
5 t 6 D _
17-40
Go to
trouble' 11-11
shooting
1 77 1
1 7- 4 1
Troubleshooting (4WSl
4WS IndicatorLight Circuit
4WS CONTROLUNIT 18P/12PCONNECTORS
The 4WS indicarorlight does noi

como on whon ignition switch is
first turned ON.
Connect
View from terminal side.

Turn the ignition switch ON and
pull the parking brake.
c h e c k t h e N o . 1 3 M E T E Rf u s e
Does the brake indicator light
1 1 0A ) i n t h e u n d e rd a s hf u s e k e '
ls the luse OK? Reolaceth€ fuso and rocheck.

Connectthe 4WScontrolunitNo.
7 terminal(PNK)and No. 23 ter-
minal(PNK)wire to body ground. ReDairopen in the YEL wire b€
tw€€n rhe No. 13 METERtuso 110
Al .nd the 4WS indicator light.
Does the 4WS indicator light
Reolacerhe 4WS control unft.
The 4WS indicator light does not

go oft alier stariing €ngineand no
DTC is shown.
Start the engine and check the

charging system light.
Does the light go off?
Turn the rgnrlronswitch OFF.
Checkthe No. 43 CLOCK,RADIO

fuse (10 A) in the under_hood
ls the fuse OK? Reolace the fuse and recheck,
{ T op a g e1 7 4 3 )
17-42
lFrom page 17-42)
Checkthe No. 22 4WS luse (10

A) in the undeFdashluse/rel8y
box.
ls the fuse OK? Replacoth. lulc 6nd rochock.
checktheNo.I R/c MlRRoRluse

(15 Alin theunder-d8sh
fuse/re-
tayDox.
Roolacotha fula and rochock.
Disconnectthg 4WS controlunit

'l8P connector and 12P con-
nector.
Repalrihort in tho Pf{K wlrc! b6-

tw6en tho 4WS cont.ol unit and
tho indicrtor light.
Connect lhe 4WS contiol unit 4WS CONTROLUNIT 18P CONNECTOR

18P connoctor and 12P con'
nector,
8aft6ry Voltsgo?

4WS controlunitNo. 18 terminal
(WHTrY€L)and body ground.
Ropalrop.n in WHT|'EL wlro bo-

ls there bsttery vollage? twcon tho 4WS control unit .nd
undor-hood fuaa/rolay bor.
{To page 17-44}

(4WS)
Troubleshooting
4WS IndicatorLight Circuit (cont'd)
(Frompage 17-43) 4WS CONTROLUNIT CONNECTOR
12?

4WS control unit terminals:No.
'|8 (WHTryEL)and No. 16 (BLK),
and botw€enNo. 18 (WHT,ryEL)
and No. 24 (BLK). View lrom terminalside
Ropairtho poor ground lcso'l) o.

oDon in BLK wir6 bolwesn tho
4WS control unit and body
ground.
Measure voltag€ between the

4WS controlunit No. 25 terminal
(YEL/RED)and body ground,
Reprir op6n in tho YEL/REOwlr6

ls there battery voltageT b€tw6€n the 4WS conlrol unh and
und€r-d6ahfuse/rolav box. 4WS CONTROLUNIT CONNECTOR
18P 12P
Measure voltage betwe€n the

4WS control unit No. 4 terminal
and body ground,
{BLK/YEL) v V ) Bsttory
Ropairopen in tho 8LK/YELwir6 View from terminal side.

ls there battery voltage? botwoon tho 4WS control unit and
tho under-dashtusoholay box.

{WHT/BLU)and body ground.
Ropairop€nin th6 WHT/BLUwir6

b€twoon tho 4wS conttol unit and
tho undor-dashfuso/rolav box.
Roplacoth6 4WS control unit.

DiagnosticTroubleCodes(DTCs):10, 12, 16
-Thc 4WS indicoro. light has

boan roDortodon.
-With sorvico ch6ck conn6ctor
irmpod codos 10. 12, 16 610in-
dlc.tcd.
Disconnectthe front sub steering

anglesensorconnector,
Measur€resistancebetween the
No. 1 terminal {BLK)and No. 2
terminal{WHT/BLU}ot the sensor
side connector.
l s t h e r e8 . 4 - 1 2 . 2 O ?
Measureresistancebgtween the
No. 2 terminal {WHT/BLU)and
No. 3 terminal(BLKMHTI ot rhe
senaor side connector.
ls rhere8.4- 12.2O? ANGLESENSOR

FNONTSUB STEERING
SENSONAIDE CONNECTOR
Checkfor continuity between the

sensor side connsctor No. I te.- Continyity?
minal (8LK)and body ground.
8.4-12.2 A?
View from terminalside.
(To page '17-46)
1 7- 4 5
(4WSl
Troubleshooting
DiagnosticTroubleCodes {DTCs): 10, 12,16 {cont'd)
lFrom page 17-45)
FRONTSUB STEERINGANGLESENSOR
Measurethe voltsge betweenthe
4WS CONTROLUNIT SIDECONNECTOR
4WS control unit side of the ssn-
sor connector No. 1 torminal
(YEL/BLK)and body ground. i+_I-}
/J\ z.svr
Y
Disconnectthe 4WS controlunit
ls there approximat€ly2.5 V? 12P connector.
4WS CONTROLUNIT 12P SENSORSIDECONNECTOR
Checktor continuity between the

4WS controlunitNo.21 terminal
{YEL/8LK)and body ground.
Vi€w from terminalside.
R.o.li short in the YEL/BLKwire

botwoontho 4WS controlunil and
tho front sub steering angle
sonsor.
Connect the 4WS control unit

12P connector.
4WS CONTROLUNIT 12P CONNECTOR
Measurevoltag€between the No.

21 terminal{YEL/BLKIol the 4WS
control unit and body ground.
ls there approximarely2.5 V? R6plac6 the 4WS conlrol unit.
lfo page 17-471

Ropairop6n in tho YEL/BLKwiro
botwoon tho 4WS control unit and
th€ tront sub stooring anglo
30nsot.
17 -46
(Frompage 17-46)
Measurethe voltage belween the 4WS CONTROLUNIT SIOECONNECTOR
4WS control unit side of the sen-
sor connector No. 2 terminal
rlTf-\
w
IYEL/GRN)and body ground. (V) 1 25 v?
Y
Disconnectthe 4WS control unit

ls there app.oximately1.25 V?
12P connector.
4WS COI{TROLUNIT 12P SENSORSIDECONNECTOR
Checktor continuity between lhe Continuity?

{YEL/GRN) and body ground.
View trom terminalside.
Ropairshort in the YEL/GRNwire

botw66n the 4WS control unit and
tho sub steeJingangle sensor.

12P connector.
Measur6 voltage betwoen the

{YEL/GRN)and bodv ground.
ls there approximatoly1.25 V? Rool6c6the 4ws control unit.
{To page 17-481

R6pai opon in tho YEL/GRNwire
borwoon tho 4ws contol unit and
tho front rub staering anglo
aonaot.
17 -47
DiagnosticTroubleCodes (DTCs):10, 12, 16 (cont'd)
lFrcnr,page 17'471
4WS CONTROLUNIT SIDE CONNECTOR
Messurethe voltage betweenthe

4WS control unit side ol the sen- ( v )2 . 5 V l
sor connector No, 3 termi-
nsl(YEL/BLU) and body ground.
:r
ls lhere approximately2.5 V? Disconnectthe 4WS control !nit

12P connector,

4WS controlunit No. 22lerminal
(YEL/8LU)and body ground.
Ropai.shorl in the YEL/BLUwiro

b,6two6nth6 4WS contiol unh 6nd
3ub stooring 6n9lo sonsor.

12P connector.

(YEL/BLU)and body ground.
ls there approximately2.5 V? Raolac6tho 4wS control unit.
(To page 17 49)

Rop6iropon in tho YEL/BLUwiro
botrYoontho 4WS control unh ald
the front sub 3t66ring angl6
sonsor.
17 -48
(Frompage 17-48)
Conneclthe front sub steeringan-

gle sensorconnector.
List6d Voltage?
View from terminalside-
FRONTSUB STEERINGANGLESENSORTERMINALVOLTAGE
IREFEBENCE}
STEERING
WHEEL
LEFT CENTER RIGHT
P0stTt0N
Whileturningthe steeringwheel, approx approx approx
measurevoltagebetweenNo. 22 Voltage
(YEL/BL|)and No. 26 (YEL/GRN) 2 . OV 2 . 5V 3 . 0v
terminalsol the 4WS control unit Analog tester AC range
usingAC rangeof analogtester.
Does voltage change as

shown in the table?
Check the neutral point of the

front sub steeringanglesensor.
{ s e ep a g e1 7 1 4 6 ) .
Adtust the noul.al point ot tho

ls the neutralpoint OK?
troni 3!b steering sensor.
ReDlacoth6 4WS control unit
17-49
Troubleshooting(4WS}
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7
-Th6 4WS indicator light has

boon toDorled on.
-With sorvic6 chock connoctor ANGLESENSOR
'l7 are in- REARSUB STEERING
iumpod cod6s 1l, 13, SENSORSIDECONNECTOR
dicatod.
l|l 12.3L-
/-\rFP /z\ -r_
ur\u ua\ lr /^\
Disconnectthe rear sub steerang \"/ \"/ Ir,/ Continuitv?
\ ..r/
anglesensorconnector.
a . 4 - 1 2 . 2A ? +

Measure resistancebetween the
No. 1 terminal {BLKMHT), and
the No. 2 terminal{WHT/BLU}oI
th€ sensorsadeconnector'
l s r h e r e8 . 4 - 1 2 . 2 0 7
Measure rosistancebetween the

No. 2 terminal (BLK,ryVHT),and
th6 No. 3 terminal (BLK)of the
sensor sadeconnector,
l s t h e r e8 . 4 1 2 . 20 ?
Chock for continuity between the

sensorside connectorNo. 3 ter
minal (BLK)and ground.
llo page r /-5l l
17-50
lFrom page 17-5Ol
REAR SUB STEERINGANGLE SENSOR
4WS CONTROLUNIT SIDECONNECTON
r-Ffi-r
Measurethe voltage bGtweenthe
4WS control unit side of the sen- (V) z.svz
sor connector No, 1 terminat Y
(GRYI and body ground.
ls there approximately2.5 V? Disconnectthe 4WS conlrolunit

12P connector.
fl-ll rarfT l
Check for continuity between the
wrl continuiry
(GRY)and body ground. I
YES RoDairshort in the GRY wiro be-

tween the 4WS control unit and
the rearsub steeringanglesonsor.

12P connector.

4WS controlunit No.29terminal
(GRYIand body ground.
View from terminalsrde,
ls there approximately2.5 V?
fio page 17-52l,

R6pairopon in tho GRY wir6 b6-
twoon the 4WS control unit and
tho roar sub stooring anglo aonsor.
17 - 5 1
D i a g n o s t i cT r o u b l eG o d e s( D T C s ) :1 1 , 1 3 ' 1 7 ( c o n t ' d l
( F r o mp a g e 1 7 - 5 1 )
REARSUB STEERINGANGLESENSOR
Meas!re the voltage betweenthe 1.25V?

4wS control unit side of the sen-
sor connector No, 2 terminal
{GRY|Y€L)wire and body ground.
View lrom terminalside.
'1.25V? Disconnectthe 4WS control unit

ls there approximately 18P connector.
4WS CONTROLUNIT 18P SENSOBSIDECONNECTOB
Check for continuitv between lhe

4WS controiunit No. 17 terminal
{GRY/YEL) and bodv ground.
Reoahshort in the GRY/YELwire

betwoontho 4WS conttol unit and
the rearsub stG€ringanglesensor.

18P connector.

4WS controlunitNo. lTterminal
(GRY/YEL)and body ground.
'1.25V? Roolaceth6 4WS control unit.

ls there approximatelv
(To page 17-53)

Ropairopen in the GRYI/EL tYire
b6lwo6n tho 4WS control unit and
tho roar sub steoring englo sonsor.
17-52
(Frompage 17-52)
REARSU8 STEERINGANGLESENSOR
(3.1 I !
M€asurethe voltage betwoen the (V) z.svz
4WS control !nit sido of the sen-
sor connector No. 3 terminal Y
(GRY/BLK)and body ground.
View trom terminalside

ls there approximately2.5 V?
12P connector,
Checklor continuity between the

4WS controlunir No. 28 terminal
{GRY/BLK) and body ground.
Repai.shon in the GRY/8LKwiro

hw€6n the 4WS controlunitsnd
tho rotr sub st€oringanglosonsor.

12P connector,
4WS CONTROLUNIT ,I2P CONNECTOR

{GRY/BLK)and body ground.
ls there approximatelv2.5 V? Reolace4WS control unit.
{To page 17-54)

Ropairop.n in tho GRY/BLKwire
between $€ 4WS control unit and
th€ roaasub Stseaingangle sensor.
17-53
Troubleshooting(4WSt
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7 { c o n t ' d )
(Frompage 17-531
4WS CONTROLUNIT'I8Pi12P
CONNECTOR
Connectthe rear sub steeringan-

gle sensor connector-
ANGLESENSORTERMINALVOLTAGE
REARSUB STEERING
(REFEREI{CE)
WHEEL
STEERING
LEFT CENTER RIGHT
P0stTt0N
While turning the steering whool
and measurevoltagebetweenNo. approx approx approx
and No. 29 (GRY) Voltage
17 lGRY,ryELl 3 . 0v 2.5V 2 . OV
terminalsof the 4WS controlunit
using AC range ot an analog Analog tester AC
tester.
Doos voltage change as

shown in the table?
Checkthe neutralpoint ot the rear

sub steering angle sensor (sse
page 17-1461.
Aqu3t dre iratural point of tt|€ tolr

ls the neutral point OK? aub ltoailng aanlor.
Replacotha 4WS control unit
17 -54
DiagnosticTroubleCodes (DTCsl: 20, 22, 24,28
-Th6 4WS indicator light has

bggn reDortodon. FRONTMAIN STEEBINGANGLESENSOR
With service chock conngctot 4WS CONTROLUNIT SIDECONNECTOR
iumpod codes 20. 22, 24. 28
are indicated.
Disconnectthe front main steer- BsnoryVoltago?

Ing anglesensorconnector,

Turn the ignitionswilch ON.
Measure voltage between the FRONTMAIN STEEBINGANGLESENSOR

4WS controlunit sideconnector 4WS CONTROLUNIT SIDE CONNECTOR
No. 1 terminal {BLK/YEL}and
body ground.
fT-fFlt
-X-
Ropair op6n in th6 harnoss wiro ( V.)c.svr
betwoen tho No. 22 4WS tuso :r
and tho tront main stoering angle
sonsor. View from ierminalside.
Measurethe voltage between the

4WS controlunit sideof the sen-
sor connectorNo. 4 terminal(LT
GRN)and body ground. 4WS CONTROLUNIT 18P
SENSONSIDECONNECTOR
ls there approximately4.5 V7 Disconnectthe 4WS controll unit

18P connector.

4WS control unit No. 8 terminal View from terminalside.
(GRN)and body ground.
Rooairshort in tho GRN wiro be-

twoon tho 4WS control unit and
th6 main ste€dng angle aonsor.

18P connector.

(GRN)and body ground.
ls there approximately4.5 V? Roolaceth6 4WS cont.ol unit.
( T op a g e1 7 - 5 6 )
Ropah open in the GRN wiro be-
tweon the 4WS control unit and
the front main sloo.ing anglo
17-55
DiagnosticTroubleCodes (DTCs):20, 22, 24, 28 (cont'd)
{Frompage 17-55)
FRONTMAIN STEERINGANGLESENSOR
Measurgthevoltage between the

aor connoctorNo.3 terminal(BLU)
and body ground.
ls there approximately4.5 V? Disconnectthe 4WS control unit

18P connector. 4WS CONTROLUNIT 1AP
SENSORSIDECONNECTOR
Check tor continuity between the

{BLU}and body ground.
View lrom terminalside.
R.Dair short in tha BLU wire b6-

twoon tho 4WS cont.ol unit and
the main stooring angl€ aonsor.
Conn6cl the 4WS control unit

18P connector.
Moasure voltage between the

(BLU)and body ground.
ls there €pproximatoly4.5 V? Roplsce the 4WS control unit.
(To psge 17-57)

Repair opon in tho BLU wiro be-
twoon th6 4WS control unit 6nd
th6 front main stoodng anglo
30n3('t.
17-56
{Frompage 17-56}
FRONTMAIN STEERINGANGLESENSOR
Megsureth€ voltago between the

sor connectol No. 2 t€rminal
(YEL/REDIwire and bodyground.

ls th6re approximat6ly4.5 V?
18P connector. 4WS CONTROLUNIT 18P
SENSORSIDECONNECTOR

{YEL/RED) and body ground.
View from terminalside,
Ropairshon in tho YEL/REDwire

botweon lhe 4WS control unit and
tho main st€ering sngle s€nsor.

18P connector.

{YEL/BEO)and body ground.
ls there approximately4.5 V? Reolacethe 4WS control unit.
Ropairopon in th6 YEL/REDwire

botwo6n tho 4WS control unit and
th6 front main sto6.ing angle
lTo page 17-58) aon30r.
1 7- 5 7
Diagnostic Trouble Codes IDTCs):20, 22, 24, 2A (cont'd)
(Frompage 17-57)
FRONTMAIN ST€EBINGANGLESENSOR
Check for voltage between the

No.2 terminalIYEL/RED) and the [T'T-TT;I
No. 5 terminalIELK)of the 4WS l ^
control unit side connectorof the \:/ 4.5 V?

front main steeringanglesensor.
View from terminalside

Rcpair tho poor ground lG 4Ol,
402, 4041or oDenin rhe BLKwiro
ls there approximately4.5 V? botwo€n th6 front main atooring
anglo 3onsor and body ground.
Reconnectth€ front main steering

anglesensor5P connector,
While turning the steeringwheel,

check for the signalsbetweenthe
following 4WS control unit termi' 4WS CONTROLUNIT 18P CONNECTOR
nals and the body ground with an
analogvoltmoteron the DC range.
A-phase:
Betwsentho No. 8 terminal(GRN)
and body ground: should pulse
O-4.5 V rspidly {every2o) 0-4 . 5 v ? ( V ) ( V ) (V
B-phas6:
Between th€ No. 15 terminal
(YEL/RED)and body ground:
shouldpulse0e4.5 V rapidly(ev
€ry 2o) View from terminalside
Z-ph8se:
Bgtween the No. 12 terminal
IBLU) and body ground: should
pulse0*4.5 V onceper steoring
wheel revolution
Are the signalsavailablebe-

tween the resp€ctive terminal
and the body ground?
Checkthe Z-phaseneutralposi'
t i o n ( s e ep a g e1 7 - 1 4 6 ) .
adjust the front main stooringan-

ls the Z'phasein the straight glo sonsor noutral poaition
drivingposition?
{soo pago 17-15)
YES Srraight
l revolustion
Podormtroublgshootinglor OTCa
1 0 . ' 1 2 1. 6 .
{3e6pag6'17451. A-phase
o
4.5
B-phase
0
4.5
Z-phase
---------------- Time
L-
17 -58
DiagnosticTroubleCodes (DTCs):21 , 23, 25,29
REARMAIN STEERINGANGLESENSOR
-Th6 4WS indicalor light hss
b6on rooorlod on,
-V\fth sorvica check connecto. \\.) JJ
.iumpodcod6s 21 , 23. 25, 29 t..t tlt I
w
ato indicatod.
\:/ Battery voltaqo?
I
Disconnectthe rear main steering

angresensorconnector. View from terminalside

4WS CONTBOLUNIT SIDECONNECTOR
4WS conlrol unit side connector
No. 1 terminal (RED)and body
grouno.
Ropair open in thg hahoss wire

ls there battery voltage? bolweon tho No.22 4WS fuse
and the reaamain gtoering tngla
YES sensot. View from terminalside
Measurethe voltage between the
4WS control unit side No.3 termi 4WS CONTROLUNIT 18P
nal {WHT/GRN}and body ground. SENSORSIDECONNECTOR
ls there approximately4.5 V? Disconnecl the 4WS control unit

18P connector.
YES
Checktor continuity belwoen the View from terminalside

(WHI/GRN)and body ground.
Repairshort in the WHT/GRNwire

ls there continuity? betwecn tho 4WS controlunit and
the main steering angle sensor,
NO
Connect the 4WS control unit 4WS CONTROLUNIT 18P CONNECTOR
18P connector.

{WHT/GRN}and body ground.
ls there approximately4.5 V? ReDlacothe 4WS control unir.
Repairopon in th6 WHT/GRN wi.o

botwoon the 4WS contol unit and
the aoaa main stooring angle
sensot.
lTo page I7-60)
I
J
17-59
DiagnosticTroubleCodes (DTCs):21, 23, 25, 29 lcont'd)
{Frompag6 17-59)
REAR MAIN STEERINGANGLE SENSOR

Measur€the voltage betw€en the

4WS controlunit side No 4ler-
minal (ORN) wire and body
9rouno.
View from lerminalside

ls ther€ €pproximately4.5 V? Disconnectth€ 4wS control unit
12P conneclor. 4WS CONTROLUNIT 12P
SENSORSIDECONNECTOR
l--T--fl nr lEf-l
ffiwx)
Checklor continuity between the (p
Continuitv?
{ORN)snd body ground.
RoDairshon in ths ORN wiro bo-

tweon tho 4WS control unit 6nd
tho .oar main stoering anglo
80n8('t.
Connoct the 4WS control unit

12P connector.
12P CONNECTOR
CONTROL,UNIT
Measure voltage belwoen the

r'.l-H-tD
ff
4WS controlunitNo. 20terminal
(V) +.svr
{ORN)snd body ground :r
ls there approximately4.5 V? Roplacotho 4WS conttol unit
{ T o p a g 61 7 - 6 1 ) Ropairopon In tho OBN wi.c bo_

twoon tho 4WS conttol unit and
the roar main 3loaring angle
30nlot.
1 7 -6 0
{Frompage 17 601
.-rnfl-
a / F
Measurethe voltage betweon the vl5,l,/t )
4WS control unit side No. 6 ter
m i n a l ( B L U / G R N )a n d b o d y ( V ) a . sv r
gtouno, Y
ls there approximately4.5 V? Disconnectthe 4WS controlunit

18P connector. 4WS CONTROLUNIT 18P
SENSORSIDECONNECTOR
Checktor continuity between the

4WS controlunit No 13 terminal
{BLU/GRN) and body ground.
View from terminal side
ReDai.short in the BLU/GRNwire

YES betweenthe 4WS controlunit and
the rear main stgoring angle
sensor.

l8P connector. 4WS CONTROLUNIT 1AP CONNECTOR

(BLU/GRN)and body ground.
ls there approximately4.5 V? Raolace the 4WS control unit.
{To page 17-62)

R6pai.op.n in the BLU/GRNwire
botween tho 4WS control unit and
tho ioaa main Stoaring anglg
sensor.
1 7- 6 1
DiagnosticTroubleCodes(DTCs):21' 23, 25, 29 lcont'dl
(Frompage 17-611
REAR MAIN STEERINGANGLE SENSOR
M€asure voltsge betwson the

No,6 terminsl {BLU/GRNIand the
No. I terminal (RED)of the 4WS
contrcl unit aide connector ot the
reat main steedng angle sensor.
R.p.l opcn In th. RED wir. bo- View from terminalside

twocn tho 4WS cont?ol unit and
ls there €pproximately4.5 V? tha ra.] maln ltooting anglo
Itn!o1,
Rsconngctthe rear main ateering

sngle sonsot 8P connector.
While turning th€ steering whe€|,

check for the signalsbetwe€nthe 4WS CONTROLUNIT 18P/12P
following 4WS conttol unit termi- CONNECTOR
n6ls and the body ground with an
analogvoltmeteron the DC range. I l2oHl I
A-phase:
Eetween the No. 6 terminal ri+ffi M
(WHT/GRN)ahd body ground:
O-4 . 5v ? ( V v (v)
shouldpulseO-4.5 V rapidlylev- Y
ery 2o)
B-phase:
Between thc No. 13 terminal
(BLU/GRN) and body ground: View from terminalside
shouldpulseO-4.5 V rapidly(ov'
ery 2ol
Z-phaae:
Betwesn the No. 20 terminal
IORN) and body ground: should
pulsoO€4.5 V once per ste6ring
wheel revolution
Are the signals availablebe-

tween lhe resDectiveterminal
and the body ground?
Check the Z-phase neutral Posi-

tion {seo page 17-'146).
ls the Z-phase in the straighi

driving position?
Porform trouble.hooting of
the DTCs 11, 13, 17. (.o6 psgo 4.5
A-phase
t7-501 o
4.5
B-phase
0
4.5
Z-pha86
0
---------------- Time
17-62
DiagnosticTroubleCodes (DTCsl: 30, 34
vehicle speed sensor (VSS)

NOTE: DTC 34 may have been memorizedon 4WS control unit after the using ALB checker.
It so, disconnectNo. 43 CLOCK,RADIO(10 A) fuse in under-hoodtuse/relavbox to reset the 4WS control unit.
-Tho 4WS indicator light has

boon roDortedon.
-With aervice check connector
iumpod codos 30 and 34 are
indicated.
Disconnectlhe No.43 fuse{'l0 A)

in the undeFhoodfuse/relaybox.
Tesl drive the car.
Sy3tom is OK at trrb tims. Inlpoct

Do codes 30 and 34 appear? tho vohicle spoed sonso. tominal
connecrots.
Does the speedometer

operate properly?
(Go to pago 23-1181
Disconnectthe 4WS controlunit 4WS CONTROLUI{IT 12P SENSORSIOECONNECTOR

12P connector,
Measurevoltage betweenthe No.

l9 terminal(ORN)of sensorside View from terminalside
connector ot 4WS control unit
and body ground.
Rool6c6 the 4WS control unit

ls there more than 5 V?
lwhon tho symplom rocurrod.)
Repaii opon or short in the ORN

wh€ to body ground betwoen the
vehiclospeedsensorand rhe 4WS
contol unil.
17-63
(4WS)
Troubleshooting
DiagnosticTroubleCodes(DTCs):31, 35 (cont'd)
-Tho 4WS indicator light ha6 4WS CONTROLUNIT 18P CONNECTOR

boon ropott6d on.
-With asivico chock connoctol
jumpod codos 31 and 35 oro
indicatod.

Does the ABS indicator light Go to pago 19-54
stay ON? Problem in ABS rystom
Stop the engine.Then turn the ig-

nition switch back ON.
With the loft rear wheel raisedoll

ground, slowly rotate the wheel
while checking {or voltage be
tween the 4WS control unit No.
3 terminal{GRYMHT) and body
ground.
Record lhc DTC rnd clear the
4WS contiol unit. Tost drive th6
car, if th6 DTC doo3 not roaPpear,
Does the voltage alternate from chock tho to.minal connoctions ol
zero to approximately 5 V? th€ 4WS co.rtrol unii 18P conn€c-
'l4P
tor and tho A8s contiol unit
connoctor.
(Topage1 7 - 6 5 )
7-64
l F r o mp a g e1 7 - 6 4 )
Turn the ignitionswitch OFF. 4WS CONTROLUNIT 18P SENSORSIDECONNECTOR

connectorand the ABS control
unil connector,

Checklor continuitybetweenthe
(GRY/WHT)and body ground.
Repeirshon in tho GBY,^/HT wire

bctwoon tho 4WS control unh and
tho ABS control unit.
4WS CONTROLUNIT lAP CONNECTOR
Measurevoltagebetween the No.

3 terminalof the 4WS control unit
connectorand body ground. View from terminal sade
ls there approximately5 V? Rophco tho 4WS control unit.
ABS CONTROLUNIT 14P SENSORSIDECONNECTOR

Measure voltage betweon the No.
3 terminal (GRY/WHT) of sensor
side connector oI ABS control unit
14P connector and body ground.
Rsp.ir opsn in tho GRY/WHTrYiro View from terminalside

botwoon tha 4WS control unh snd
th€ ABS control unit.
R6olacothe ABS control unit.

(4WSI
Troubleshooting
DiagnosticTroubleCodes(DTCs):32, 36
-Th. 4WS indlcator light h$

baan ropo.tgd on. 4WS COI{TROLUNIT IAP CONNECTOR
-Yvlth lowica chack connoctor
iumpod code. 32 and 36 sro
indiclt.d.

YES co to p!9.'19-54
ftoblem in ABS .y.t.m
Stop the engine.Then turn the ig-

With the right rear wh€ol .aised

off the ground. slowly rotate the
wheel while checking for voltag€
betweenth€ 4WS contrclunit No.
1 terminal IGRY/RED)and bodv
grouno.
Rocord tha DTC .nd cl..t th.
4l rS control unll. l.al driv. tho
c.r, it tha DTC dodc not ro.ppaat,
Does the voltage alte.nate trom
afFck tra tarmind connacdonr ot
zero to approximstely 5 V?
d|. 4WS cont ol unit 18P cofir.c_
toi and th. ABS control unit l4P
NO
connoqtoi.
{To page 17-67}
17-6 6
(Frompage 17-66)
Turn the ignitionswitch OFF. 'I8P SENSORSIDE CONNECTOR

4WS CONTROLUNIT

connector and the ABS control
unit connoctor,
Vi€w from terminalside

Check tor continuity between the
{GRY/REO} and body ground.
Rap.i. .hon In th. GRY/REDwi?o

bltwa.n th.4WS conltol onh and
th. ABS conlrol unit.
4WS CONTFOLUNIT 18P CONNECTOR
Moasurevoltagebetweenthe No.
1 terminal (GRY/REDlotth€ 4wS View trom terminalside
conlrol unit conneclor and body
ground.
ls there approximately 5 V? Rcplscr lh. 4WS control unii
ABS CONTROLUNIT 14P SENSORSIOECONNECTOR
Measurevoltag€between the No.

1 terminsl IGRY/RED)of sensor
sideconnectorof ABS controlunit
14Pconnectorand body ground.
Rcplli opcn in th! GBY/REDwite

b.twran th.4WS coiltol unh lnd
th. ABS control unit.
Roplacalhc ABS conttol unit.
17-67
DiagnosticTroubleCode(DTCI:33
NOTE: Problemcode 33 is memorizedwhen the front wheelsare turned at a speedot 30 km/h for 2 minuteswith the
lront wheels raisedoff the ground and the rear wheels blocked.(Parkingbrake must be off to test this code.)
-The 4WS indicator light has 4WS CONTROLUNIT 18P CONNECTOR

boon roDortodon.
-Whh sorvic6 chack connoctor
3
iumpod codo 33 ir indicsted.
V V 0-5 V?

Perfo.m troubleshooting ol tho ABS system
Does the ABS light stay ON? (pag6 '19-541
Stop the engino.Then turn the ig-

Rotate the rear left wheel slowly

and check for voltage b€tween
the 4WS unit control No. 1 termi-
nal IGRY/RED) and body ground,
and betweenthe No. 3 terminal
(GRYA HT) and body ground.
Record tho DTC and clear th6

4WS control unit. T6st driv€ th€
Doesthe voltage from both rear car, if th6 DTC doos not rsappoar,
wheel sensorsalternatefrom chock tho torminal3 connoctions
zero to approximately5 V? ot tho 4WS control unit 18P con-
nector and tho ABS control unlt
14P connoctor.
(To page 17-69)
17-68
(Frompage 17-68)
'I8P SENSORSIDECONNECTOR
4WS CONTROLUNIT
Disconnoctthe 4WS control unit

connector and the ABS control
untl connectol,
Chockfor continuity between the

4WS control unit No. 1 terminsl View from terminalside
(GRY/RED) and body ground.
Ropai.shorl in tho GRY/REDwire

botwoen 4WS control unit and the
ABS control unit.
Check for continuity between the
{GRY/WHT)and body ground.
Ropairlhon in th6 GRY/WHT wiro

between tho 4WS control unit snd
tho ABS control unit.
4WS CONTROL UNIT 18P CONNECTOF

(GRY/RED)and body ground.
ls there approximately5 V? Roplac6ths 4WS control unit.
YES
{To page 17'70)
17-69
(4WSl
Troubleshooting
TroubleCode(DTCI:33 (cont'dl-DiagnosticTroubleCode{DTC}:50
Diagnostic
{Frompage 17-691 4WS CONTROLUNIT 18P CONNECTOR
Measure voltage between thg

IGRYMHTI and body ground.

ls there approximately 5 V? Beolaco tho 4WS control unit.
ABS CONTROLUNIT 14P CONNECTOR
Measure vollage between the

No. 7 terminal{GRY/RED} ot the
14Pconnectorof the ABS control TERMINAL
unit and body ground. 9;;;
ls there approximstely 5 V? Ropairop€n in th6 GBY/REDwiro.
'I4P CONNECTOR
ABS CONTROLUNIT

No. 8 tgrminalof the 14Pconn6c-
tor of the ABS control unit and
body Oround.
View from interiorside

ls there approxinately 5 V?
Baplaco the ABS control unit. REARACTUATOR MOTOR TERMINAL
Diogno.tic Trouble Cod6 (DTCI: 50
-The 4WS indicato. light hes

boon rcooned on.
-with aoavico Ghock connectol
iumped codo 50 is indicolod.
Start the engine. Turn the stoeF

ing wheel and check the rear
ste€ring motor lor function,
Cloa. tho 4WS control unit and

Does it operate properly? rotort, if tho DTC roccouB, then
.6placo tho contlol unit. 8LK MOT _
l
Roplacotho r6aaactuator motot. R E DM O T +
I
BRN GND
l
WHT+B
17-70
Code(DTCI:51-Diagnostic
Trouble
Diagnostic Codes(DTCsl:
Trouble 60, 61, 62, 63
Diagnostic Trouble Codo {DTC}: 51
I -Tho 4WS indicstor light ha8

boon rgportod on.
-Wlth s6rvico chock connoctoi
iump6d codo 51 is indicatod.
Start the engine. Turn the steer

ing wheel and check the rear
steeringmotor for function.
Th6 DTC 51 blinkt whon lhg roar
whoals cannot bo atoerod bg-
cause th6y aia blockad wfth tho
Does it operate properly? cuab, otc.
ll tho DTc 51 blink! aftor rhr rg3t
drivo, tho control unit i. taultY.
R€olacoth6 roar actuatoamolor. 4WS CONTROLUNIT POWERTERMINAL
Diagnostic Troubl€ Codes {DTCS):60, 61, 62, 63

B.tt.ry Voltago?
-Th6 4WS indicator light h.s
Batt.ry Voltage?
boen roportod on.
-With sorvico chock connoctor
iumpod codos 60, 61,62, 63
aro indicatad.
check the No.38 4ws fuse

(60 AI in the under-hoodfuse/re- Battory Volrage?
View from interiorside
Roplaco th€ turo lnd rccheck
Measure voltage between the A

rarminal(WHTI of the 4WS con
trol unit powerterminalandbody
grouno.
Ropairopon in th6 WHT wi.a bo-

two.n thq undo,-hood fute/tol.y
box and tho 4WS control unlt.
Measure voltage between the B

terminallBRN)of the 4WS control
unit power torminal and body
grouno.
Rop.lr tho poor gtound lG5O2l or

opon in ths ERltl wiro balw.dr lh6
4WS cont.ol unlt and bodY
ground lG5O2l.
Startthe engineand immediately

(withinapproximately 2 seconds
after starting the engine) check Roplsco th6 4WS control unit.
for voltage between the C termi
nal {RED)of the 4WS controlunit
pow€rterminaland bodyground.
7-7
DiagnosticTroubleCodes(DTCs):60, 61, 62, 63 (cont'd)
l F r o mp a g €1 7 - 7 1 )
Stop the engineand turn the ig_

nition switch ON.
Measure voltage between the D

terminal (BLK)ot rhe 4WS control
unit power terminal and body
groundimmediatelyafter {wilhin
approximately2 seconds)starting
the engrne.
Roplacolh€ 4WS control unit
Measure voltage between the C

terminal(BED)of the rear actu
ator motor and body ground
immediatelyafter{withinapprox-
imately 2 seconds)startingthe
engine.
Repair opsn in the RED wi.o be-

ls there battery voltage? twoen tho 4WS control unit and
tho roar actuator motor.
Measurevoltagebetweenthe D
rerminal{BLK}of the rearactua
tor motor and body ground
immediatelyalter {withinapprox'
imately 2 seconds)startingthe
engine.
Ropair opon in the BLK wir6 be-

ls there battery voltage? tween tho 4WS control unit and
the rcar actuator motor.

No. 33 terminal{YEL}of the rear ACTUATORMOTORTERMINAL
actuatormotor and body ground
immediatelyafter lwithin approx-
imalely 2 secondslstartingthe
engine.
D U P + N O .3 3 I Y E T I
(To page 17 73)
Battery Voltag6?
17-72
lftonl. page 17-721
ls there battery voltage? Raolacotho rsar actuato. motor.

ACTUTOR MOTOR TERMINAL

No. 34terminal(8LU)of the rear
actustor motor and body ground
immodiatelyafter (within approx-
imately 2 secondsl slarting the
engrn9.
ls there battery voltage? Roplacotho roar actuator motor.
Meaaure voltsge between the

controlunitNo. 33 terminal(YEL)
and body ground immediatelvaf-
ter (within spproximately 2
seconds) starting the engine.
Ropair op.n in tho YEL wir6 bo-

two6n the 4WS cont.ol unit and
tho roar actuator motot.

control unit No. 34 terminal (8LU)
and body ground immediatelyat- 'rT\
ter (within approximstely 2
seconds) starting the €ngine.
ffi
( v ) ( vBattory
) Voltago?
Y:T
Repaii opon in the BLU wir6 b6-
ls there baftery voltage? twoon th6 4ws control unil and
the ioai actuator motoi. View from terminalside
Roplacs lhc 4wS control unit.

Maintenance
Pump Belt Adjustment
NOTE: When using a new belt, first adiustthe deflec- 2, Loosen the power steering pump mounting bolt,
tion or tensionto the valuesfor the new belt.then read nuts and adjustingbolt locknut.
just the deflectionor tensionto the valuesfor the used
belt after runningenginefor tive mjnutes. 3. Turn the adjustingbolt to get the properbelt ten
sion, then retightenthe adiustingbolt locknut and
1 . A p p l ya l o r c eo f 1 0 ON ( 1 Ok g , 2 2 l b s )a n d m e a s u r e mountingbolts.
the deflectionbetween the power steeringpump
and the crankshaftPulleys. 4. Start the engineand turn the steeringwheel lrom
Doflection: lock-to-lockseveraltimes,then stop the engineand
U s 6 db e l t : 1 3 . 5 - 1 6 . 5 m m { 0 . 5 3 - 0 . 6 5 i n l recheckthe deflectionof the belt
New belt: 9.5-11.5 mm (0.37-0.45 in)
NOTE: lf there are cracks or any damageevident POWERSTEERING
on the belt, replaceit with a new one. MOUNTING BOLT
POWERSTEERING PULLEY 22 N.m 12.2kg-m,16lb-ftl
AOJUSTING BOLT LOCKNUT

15 N.m 11.5 kg-m, 1 1 lb-tt)
Measurewith Belt TensionGaugel

Attach the belt tension gauge to the belt and
ADJUSTING
measurethe tension of the belt.
POWERSTEERING
T6nsion: MOUNTINGNUTS
U s € db o l t : 3 5 0 - 5 O O N ( 3 5 - 7 0 k g , 7 7 - 1 1 Ol b s l 2 2 N ' m ( 2 . 2k s ' m , 1 6 l b - t t )
Now belt: 7oo-9oo N {70-90 kg, 154-198 lbs}
NOTE: lf there are cracks or any damageevident
on the belt, replaceit wilh a new one.
Follow the manufacturer'sinstructionslor the ten-
srongauge.
PULLEY
POWERSTEERING
CRANKSHAFTPULLEY
17-74
On-CarChecks
RackGuideAdjustment
CAUTIONTwhen servicing,be careful not to damage

the power steering fluid linss with the special tool.
RACK GUIOESCREW
NOTE: Adjust the rack guide at the center ol the rack
stroke.
2WS:
'1.
Removethe gearboxshield.
2. Loosen the rack guide screw locknut with the

specialtool.
3. Tighten,loosenand retightenthe rack guide screw

two times to 4 N.m (O.4kg-m, 2.9 lb-ft) then back
*
it oft 20 3".
4. T i g h t e nt h e l o c k n u tt o a b o u t 2 5 N . m ( 2 . 5 k g - m ,
18 lb-ft) while holdingthe guide screw.
5. Checkfor tight or loosesteeringthrough the com-

plete turning travel.
6. R e c h e c ks t e e r i n ga s s i s t( s e ep a g e1 7 7 9 ) .
1 7- 7 5
On-CarChecks
Rack Guide Adjustment {cont'd)
4WS: 4. Loosen the rack guide screw locknut with the

'1. Removethe gearboxshield. specialtool.
2. Cut wire tie trom the cover, then removethe cover 5. Tlghten.loosenand retightenthe rack guidescrew
from the front sub steeringangle sensor, two times to 4 N.m (O.4kg-m, 2,9 ib-ft) then back
*
it olf 20 !'.
CAUTION: Cut the wire tie with carefullv,so as
not to damago the harness. 6. Tighten the locknut to about 25 N.m (2.5 kg-m,
18 lb-ft) while holdingthe rack guide screw.
7. Check for tight or loosesteeringthrough the com-

SENSORWIREHARNESS plete turningtravel.
8. Rechecksteeringassist (seepage l7-79i.

cot{t{EcToR
COVER
zo.3'
ANGLESENSOR
FRONTSUBSTEERING
3. Removethe sub steeringanglesensorwire harness

from the clamDand disconnectthe connector. LOCKNUTWRENCH,43 mm
07MAA-S10020A
RACKGUIDESCREW
LOCKNUT RACKGUIDESCR€W
9. Reconnectthe connector and secure the sensor

wire harnesswith the clamp and installthe cover.
NOTE:
a Be sure the sensor wire harness dois not in-
terfere with the stabilizer and other moving
parts.
a Be certain that the sensor wire harnessis not
twisted before connectingit.
1O. Set the cover on the tront sub steerangangle sen-

sor. Securethe cover with the new wire tie.
NOTE: After rack guide adjustment,perform the

electrical check on the 4WS system (see page
17-146).
17-76
On-CarChecks
Fluid Replacement
Fluid Level Inspection FluidReplacement
Check the power steeringfluid level with the engine 1. Raisethe reservoirand disconnectthe hose that
cold and the car parkedon levelground.Make surethe goes to the oil cooler.
fluid levelis betweenthe UPPERand LOWERlevellines
on the reservoir.lf the level is near or below the lower 2. Connecta hose of suitablediameterto the discon-
level line, check the system for leaks.lf the system is nected hose that goes to the oil coolerand put the
not le€king.and fluid levelis low, add fluid to the upper hose end in a suitablecontainer.
level line.
3. Startthe engine,let it run at idle,andturn the steer-
ing wheel from lock-to-lockseveraltimes When
RESERVOIR tluid stops running out ol the hose, shut off the
engine.
Discardthe fluid.
4. Reconnectthe return hose to the reservotr.
Fill the reservoirto the upoer levelline.
NOTE: Take care not to spill the fluid on the body

and parts. Wipe oll the spilledat once,
CAUTION: Uso only Honda Power Stsering

Fluid-V. Using other fluids such as ATF or othor
manufactuer's pow6r steering fluid will damagethe
syst€m.
System Capacity:
1 . 7 l i t e r( 1 . 8 0 U S q t , 1 . 5 o l m p q t l 8 t c h a n g o
RosorvoirCapacity:
O.5 liter 10.53 US qt, 0.44 lmp qt)
Start the engine and run it at idle, then turn the

steeringfrom lock-to-lockseveraltimesto bleedair
from the system.
7. Recheckthe fluid leveland add some if necessary.
CAUTION: Do not fill the reservoirbeyondthe up-

oer lovgl line.
1 7- 7 7
On-GarChecks
Pump PressureCheck
l
Check the fluid Dressureas follows to determine O p e nt h e s h u t o f f v a l v ef u l l y .
whether the trouble is in the pump or gearbox.
5 . Open the pressurecontrol valve fully.
NOTE: First check the power steeringtluid level
and pump belt tension. 6 . Start the engineand let it idle.
'1.
CAUTION: Dlsconn€ct tho high plossule hosa Turn the steeringwheel from lock-to-lockseveral
carofully, so as not to spill tho power steering tluid times to warm the fluid to operatingtemperature.
on thg trame and other parts.
8. Close the shut oft valve, then close the pressure
1. Disconnectthe outlet hose from the pump outlet control valve gradually until the pressuregauge
Jifting, and install the pump joint adaptor on the needleis stable.Readthe pressLrre.
pump outlet.
9. l m m e d i a t e loyp e nt h e s h u t o l f v a l v ef u l l y .
2. Connectthe hoseioint adaptorto the power steer-
ing pressuregauge,then connectthe outlet hoseto CAUTION: Do not keep the shut-oft valve closed
the adaotor. mol€ than 5 secondsor the pump could be damag-
ed by over-heating.
3. Install the power steering pressuregauge to the
pump joint adaptoras shown. l l t h e p u m p i s i n g o o dc o n d i t i o nt,h e g a u g es h o u l d
r e a d a t l e a s t7 , O 0 O - 8 , O O 0k P a ( 7 0 8 0 k g / c m ' ,
9 9 5 1 , 1 3 8 p s i ) .A l o w r e a d i n gm e a n sp u m p o u t -
put is too low for full assist. Repairor replacethe
pump.
P/S JOII{T ADAPTOR{PUMPI P/S JOINT AOAPTORIHOSE)

oTNAK-SR30l1A 07NAK-SR3012A
VALVE
SHUT-OFFVALVE
17-78
SteeringWheel RotationalPlay Power Assist Check with Car
Parked
1 . Placethe lront wheels in the straight ahead posi- '1.
Check the power steering fluid level and pump beil
tion and measurethe distancethe steeringwheel Iensron.
can be turned without movingthe front wheels.
2, Start the engine.allow it to idle, and turn steering
2 . lf the play exceedsthe servicelimit.checkall steer- wheel from lock-to-lockseveraltimes to warm up
ing components. the Jluid.
3. Attach a spring scaleto the steeringwheel. With

the engineidling and the car on a clean.dry floor,
0- 10 mm (O-0.4 inl pull the scale as shown and read it as soon as the
tires begin to turn.
SPRING
SCALE
The scaleshouldread no more than 30 N (3.O kg,

6.6 lbs).
lf it readsmore or less,go on step 5.
Stop the engine. Disconnectthe hose from the

power steeringspeedsensorand plugthe hoseand
the sensorfitting as shown.
POWERSTEERING
SPEEDSENSOR
o. Start the engineand let it idle.
a I t t h e r e a d i n gi s n o w 3 0 N ( 3 . 0 k g , 6 . 6 l b s ) o r
less. replacethe power steeringspeed s e n s or ,
see page 1 7-8O.
a lf the readingis still more than 30 N

6 . 6 l b s ) ,c h e c kt h e g e a r b o xa n d p u m p
17-79
On-CarChecks
Assist Check at Road Speed P o w e r S t e e r i n gS p e e d S e n s o r
Replacement
'1. Removethe rear mountingbracketstay.
Check the power steering fluid level lsee page 1.
17-771and pump belt tension (see page 17 74).
2. Disconnectthe sensor wire connector trom the
2 . Sta.t the engine,let it warm up to normaloperating power steenngspeeo sensor.
temperature(the cooling fan comes on), and turn
the steering wheel lock-to lock a few times to 3 . Remove the sensor mounting bolt and pull the
warm up the fluid. power steeringspeed sensorlrom the diflerential
nousrng.
Stop the engine.To simulatespeedsabove 50 mph
(80 km/h), disconnectthe hoses from the power 4. Disconnectthe sensorhosesand plug the tittings.
steering speed sensor and connect them to the
bypasstube joint. PIugthe end of the bypasstube
joint. BYPASSTUBEJOINT SENSORMOUNTINGBOLT
07406-0010101 6 x 1 . Om m
(lncluded with 19 N.m POWERSTEERING
07406-0010001) (1.9 kg-m, 14 lb-ft) SPEEDSENSOR
NEARMOUNTING HOSES
BRACKETSTAY
Plugs.
4. Attach the springscaleto the steeringwheel.With

the engineidling and the car on a clean,dry floor,
pull the scale as shown and read it as soon as the
tires beginto turn. 10 x 1.25mm
21 N.m O-RING
( 2 . 1k s - m ,1 5 l b - f t I Replace.
'l
10 r .25 mm
39 N.m
(3 9 kg-m' 28 lb-ftl
Alter installinga new power steeringspeedsensor,
turn the steeringwheellock to lock with the engine
idlingto bleed air lrom the system.
6 . Checkthe reservoirand add fluid if necessary(see

p a g e1 7- 7 7 1 .
lf the scalereadsa normal50 N (5.o kg, 1 1 lbs),

or more the assistproblemat high speedsis be-
ing caused by reduced power steering speed
sensoroutput.
Replacethe power steeringspeed sensor.
l f t h e s c a l er e a d sl e s st h a n 5 0 N ( 5 , Ok g , I 1 l b s ) ,
the power steeringspeed sensoris OK and the
problemis in the sensorleed line, the pump, or
lhe valve body unit.
Seeif the feed line is pinchedor bent then check
pump-
See GeneralTroubleshooting(seepage 17-25).
17-80
SteeringWheel
- Removal
with sRs: Disconnectthe negative and positive cable from

the battery.
!@ store a removed driver's airbag
assemblywith the pad surlace up, i{ lhe airbaqis a Removethe accesspanel from the steeringwheel
impropelly stored face down, accidentaldeploy- lower cover, then remove the short connector
ment could propel tho unit with enough lorc€ to (RED).
cause sedous injury.
Disconnectthe connectorbetweenthe airbagand
CAUTION: c a b l er e e l .
a Eefore removing the steering wheel, align the
front wheels straight ahead. 4. Connect the short connector (RED)to the airbag
a Do not installused SRS parts Jrom anolhercar. side ot the connector.
When repairing,use only new SRS parts.
a Caretully inspecl the airbag ass€mbly belore in-
stalling. Do not install an airbagassemblythat
shows signs of being dropped or imp.oparly
handled,such as dents, cracks or deformation.
a Always keep the shon connector(s)on the air-
bag(s)when the harnessis disconnected.
a Do not disassembleor tamper with the airbag
assembly.
NOTE:
The radio may have a coded theft protectioncir- ACCESSPANEL
cuit. Be sure to get the customer's code number
betore
- Removing t h e N o . 4 3 ( 1 OA ) t u s e l i n t h e u n d e r -
hood fuse/relaybox). Removethe covers.
- Removingthe radao.
After service, reconnect power to the radio and Remove the two TORXo T3O bit bolts, then
"CODE" is displayed, removethe driver's airbagassembly.
turn it on. Whenthe word
enter the customer's s-digit code to restoreradio
ooeration. DRIVER'SAIREAGASSEMBL
I
t
1..-\
& \
I\T
TORXO
Replace.
SRSMAIN HARNESS
(cont a
17-81
SteeringWheel t-
Removal(cont'd)
7. Disconnect the connectors from the horn and Without SRS:

- Removethe emblemand steeringwheel nut'
cruisecontrol set/resumeswitches connector'
NOTE: Be carefulnot to damagethe emblemand steer-

ing wheel.
CRUISECONTROL
SET/R€SUMESWITCHES - Remove the steering wheel by rocking it slightly
from side-toside as you pull steadily with both
hands.
STEERINGWHEEL EMBLEM
NUT
Replace.
II
V
bo
STEERINGWHEEI.
- Removethe steeringwheel nut
- Remove the steering wheel by rocking it slightly

Irom side-to-sideas you pull steadily with both
hands,
17-82
@ store a rsmoved driver's airbag assombly CAUTION:

with the pad su.face up. ll the airbsg is improperly a Carelullyinspectths driver'sairbagass6mblybetore
stored faco down. accidental deploymont could propol installing.Do not installthe driver'sairbagassembly
th€ unit with 6nough forc6 to cause serious inlury. that shows signs ol being dropped o. impropo.ly
handled,such as dents, cracks or deformation.
NOTE: lf an intact driver's airbag assemblyhas been a Always keep the short connector{s}on the airbag(s}
removedfrom a scrapoedcar or has beenfound defec- when the halnessis dioconnected.
tive or damaged during transit, storage or service, it o Do not disassembleor temper, with the d.ivsr's air-
shouldbe deploved(seesection 23). bag assembly.
<With SRS:>
STEERING WHEELNUT
5ON'm
(5.Oks-m, 36 lb-ft)
\ @ WHEEL
STEERING
-Rg p^
roRx@
BoLr \ -
ii#I'i" b $q>
\*.R= I
DRIVER'SAIRBAG
ACCESSPANEL
<Without SRS:>
Qlt
@
@
I
I
EMBLEM
7 -83
SteeringWheel
lnstallation
2WS/With SRS: 2. Installthe steeringwheel and tighten the steerang
wheel nut.
CAUTION:
a B€fore installing the stearing wheel, align the NOTE: Be sure the steeringwheel shaft engages
front wheels straight ahead. the pins of the cable reel.
a Be suro to install the ha.ness wires so that they
CABLEREEL
are not pinched or interfering with other ca.
pans.
a Do not replace the original steering wheel with PIN
any othor d€sign, since it will make it impossible
to properly install the airbag. lOnly use gsnuine
HONDA replacement pans)
a Aftel ieassembly, contirm that the wheels are
still straight ahead and that steering wheel STEERING WHEEI
NUT
spoke angle is co ect. lf minor spokeangle ad- 50 N.m
iustm€nt is necessary, do so only by adiustment l5.O kg-m, 36 lb-ft)
of tho ti€ rods, not by lemoving and lsposition-
ing the stesring wheel.
l@ conlirm that ths driver's airbag

assembly is socutely attached to lhe steering
whe6l; othorwise, sgvgie personal iniury could
result during airbag dgploYment
1. Before installing the steering wheel, center the

cable reel,
Do this by first rotatingthe cablereelclockwiseun- WHEEL
til it stops.
Then rotate it counterclockwise(approximately lnsert the cruise control set/resume swltches con-
two turns) until: nector to the steering wheel clips.
- The yellow gear tooth lines up with the align-
ment mark on the cover. Connect the horn connector.
- The arrow mark on the cable reel label points
straight uP.
ALIGNMENTMARK
17-84
5, Install the driver's airbag assembly with new 9. Connect the battery positive terminal and then
TOBXo bolts. connectthe negativeterminal.
'10. After installingthe driver's airbagassembly,con

DRIVER'SAIRBAGASSEMBLY
firm propersystem operation:
a Turn the ignition to ll position:the instrument
p a n e l S R S i n d i c a t o rl i g h t s h o u l dc o m e o n f o r
about six secondsand then go off.
a Confirmoperationof horn buttons.
a Confirm operationof cruise control set/resume
S\/!r'rrcns.
a Turn the steeringwheel counterclockwiseand
m a k e s u r e t h e y e l l o w g e a r t o o t h s t i l l I i n e su p
with the alignmentmark.
TORX@ BOLT TORX@ BOLT

lO N.m {'l.O kg-m, 7 lb-ft| 10 N.m 11.0kg-m, 7 lb-ftl
6. Disconnectthe short connector(RED)from the air-

bag connector.
7, Connect the airbag connector and cable reel

connector.
8. Attach the short connector {BED) to the access

panel, and installthe accesspanelon the steering
lower cover.
YELLOWGEAR TOOTH
CAELE REEL
CONNECTOR
SHORTCONNECTOR
17-85
SteeringWheel
2ws/without SRS: 4WS/With SRS:
1. Installthe steeringwheel and tighten the steering
wheel nut. CAUTION:
a The tront main steeringangle sensor with the
NOTE: Align the slots on the steeringwheel and neutrallock mechanismis mounted on the col-
tabs on the turn signalcancellingsleeve. umn shall ot the car. When the steeringwheelis
removed,the rotationpart oJ the sensoris lock-
2. Installthe emblem. ed at the electricallyneutral position,and it is
unlock€dwhen the steelingwheel is inserted to
the specifiedinstallationposition.
WHEEL
STEERING a lf the spokeangleis not at the designatedangle
SIGNAL
while driving straight, check the front and rear
wheelsfor properalignmentbeforeadjustingthe
spokg angle.
Pertorm the electronic n6utral check ot the 4WS
systemto be surethat the rearwheelsare at the
correct steedng angle while driving {see page
17-146).
a B6fore installingthe steering wheel. align the
f.ont whsels straight ahead.
STEERINGWHEEL a B€ su.e to installthe harnesswiles so that they
EMBLEM aie not pinched or interfering with other car
J
oarts.
a Do not replacethe originalsteeringwheel with
any other design,sinceit will make it impossible
to properlyinstallthe airbag.lOnly use genuine
HONDA replacementparts)
!@ confirm that the airbag assemblyis

securelyattachedto the steedngwheel;otherwise,
sevorepersonalinjury could tesult during later air-
STEERING WHEELNUT bag dsployment.
50 N.m
{5.Oks-m, 36 lb-ft| 1. Beforeinstallingthe steeringwheel, centerthe ca
ble reel.
Do this by first rotating the cable reel clockwise
until it stops.
Then rotate it counterclock w ise (approximatelv
two turns) until:
- The yellow gear tooth lines up with the align
ment mark on the cover.
The arrow mark on the cable reel label points
strarghtuP.
ARROWMARK
ii.
fr.
l
CABLEREEL
ALIGNMENTMARK
17-86
2 . Temporarilyinstall the steering wheel aligning it 6. Reinstall the steering wheel in the straight ahead
with the column shaft serration. d r i v i n g p o s i t i o n ,b e i n g c a r e f u ln o t t o m a k e i t o f f t o
either side from the position set in step 3.
Turn the steeringwheel fully to the right and left
and set the steering wheel in the center of the NOTE:
rangewhere the front wheels move (i.e.centerthe a A l i g n t h e h o l e i n t h e s l e e r i n gw h e e l w i t h t h e p i n
steeringrack). of the cable reel.
a Align the steering wheel with the sefiations
NOTE: which makes the spoke angle closest to
a Be sure that the tront wheels are in the straight horizontal.
aheaddrivingposition.
a Be sure the steering wheel shaft engagesthe
Dinsof the cable reel.
\,'
CABLEREEL
e /^\ i rj
tE#
ffi 7. lf the spoke angle is not horizontal, adjust the steer
ing wheel slightly right or left, without pushing in
I
\rD,, the steering wheel too deep.
STEERING WHEELNUT
4. Removethe steeringwheel.
) 50 N'm
{5.0 kg-m, 36
Check whether the yellow paint mark of the tront
main steering angle sensor rotor is facing down
(i.e. in neutral lock position where the rotor does
not turn).
NOTE: lf the paint mark is not facingdown, adjust

as tollows.
1) Temporarilyinstallthe steeringwheel with the

spokesat a horizontalangle.
2) Turn the steeringwheel until the mark is facing With the spoke angle set at the horizontal, then
down. push the steering wheel in fully. Tighten the steer
3) Returnthe steeringwheel spokesto the horizon- ing wheel nut while pushing the steering wheel
tal angle set in the step 1, being carefulnot to
push in the steeringwheel. Removethe steering NOTE: Do not turn the steering wheel when
wneet. pushing the steering wheel.
8. Check the four front and rearwheelsfor alignment

and perform the electronic neutral check on the
FRONTSTEERINGANGLE 4 W S s y s t e m ( s e e p a g e 17 1 4 6 ) .
sEilsoR
ICOn: -
17-87
SteeringWheel
lnstallation{cont'd)
9. Insertthe cruisecontrol set/resumeswitches con- 1 1 . D i s c o n n e ct th e s h o r tc o n n e c t o(rR E D f)r o m t h e a i r
nector to the steeringwheel clips. bag connecror.
Connectthe horn connector' '12.
Connect the airbag connector and cable reel
connector.
SWITCHES
SET/RESUME 13. Attach the short connector (RED)on the access
panel,and installthe accesspanel on the steering
lower cover.
IREDI
14. Connectthe batterypositiveterminalandthen con
nect the negativeterminal,
10. Install the driver's airbag assembly with new
TORX@bolts.
15. After installingthe driver's airbag assemblY,con
lirm ProPersYstemoPeration:
a Turn the ignition to ll positionl the instrument
panel SRS indicator light should come on for
ORIVER'SAIREAGASSEMBLY about six secondsand then go off.
a Confirm operationof horn buttons.
a Contirm operationot cruise control set/resume
switches.
a Turn the steeringwheel counterclockwiseand
make sure the yellow gear tooth still lines up
with the alignmentmark.
TORXO EOLT
BOLT 10 N.m 11.0kg-m, 7 lb-ftl
10 N.m {1.O kg-m
7 rb-ft1
17-88
SteeringColumn
Removal
Wirh 4WS: 1 . Removethe driver's airbagassemblyand steering
w h e e l( s e ep a g e 1 7 - 8 1 ) .
CAUTION: Th6 front main steering angle sonso.
with the neutral lock machanism is mounted on the Remove the steeringjoint bolt and toothed lock
column shaft ol the car. When the steering wheelis washer (from the enginecompartment).
removed, the rotation part ol the ssnsof is locked
at tho olectrically nautral position, and it is unlock-
€d whgn the stooring whoel is inserted to th€
spociliod installation position. TOOTHEDLOCK WASHER
with sRs:
CAUTION:
a All SRS glsctrical wiring hamossas are coversd
with yellow outer insulation.
a Before disconnocting thg SRS wire harness in-
stall th6 $hort connector(s) on the airbag(s)(s6e
page 23-290|.
a R€place tho entire affected SRS harnass
assembly it has an open circuit or damagsd
wiring.
NOTE:
The radio may have a coded theft protectioncir-
cuit. Be sure to get the customer'scode number
betore
- Removingthe No. 43 (1O A) fuse lin the under-
Remove the dashboard lower cover and driver's
hood Juse/relaybox). knee bolster.
Removingthe radio.
After service, reconnect power to the radio and
"CODE" is disolayed,
turn it on. When the word
enter the customer's s-digit code to restoreradio DRIVER'SKNEEBOLSTER
oDeratlon.
OASH BOARD
LOWERCOVER
SRSMAIN HARNESS
(cont'd)
17-89
SteeringColumn
Removal(cont'd)
4. Removethe upper and lower column covers. 6. Removethe cable reel assembly(SRSonly).
CABLEREELASSEMBLY
Removethe cable reel harnesslrom the underside 7. Removethe turn signalcancelingsleeve,combina-

oJ the column bracket by removingthe clip (SRS tion switch assemblyand front main steeringangle
onlv). sensor(4wS only) by removingthe circlip
NOTE: After removingthe combinationswitch as-

sembly, place it on the floor gently so that it does
not hinderyou in service.Do not disconnectthe ca-
bles from the combinationswitch assembly.
CIRCLIP
@! \
TURNSIGNAL
CANCELING
SLEEVE
CLIP
SRS WIRE HARNESS
FRONTMAIN STEERING
ANGLESENSOR
(4WS Only)
17-90
8. Removethe air duct. 1O. Disconnectthe ignitionswitch wtre connecror.
1 1 . Removethe steeringcolumnassemblyby removing

the attachingnuts. bolts and column holder.
COI-UMNHOLDER
AIR OUCT
9. Removethe steeringjoint cover.
STEERINGJOINT
COVER
1 7- 9 1
SteeringGolumn
Inspection
Replace
NOTE: Checkthe tilt mechanism,steeringioint bearingsand steeringshaft for propermovementand damage
as an assemblyif damagedor faulty.
CAUTION: Do not apply an impact load to the column shaft in the axial direction
Front Main Stooring Angle Sensor (4WS): FRONTMAIN STEERING

Checkwhether the Yellowpaint mark of the front main ANGLESENSORI4WS ONLY}
steering angle sensor rotor is facing down {i.e in
neutral lock position where the rotor does not turn).
This indicatesthat the front main steeringanglesensor
YELLOWPAINTMARK
is electronicallyin neutral.
CAUTION: It th€ tront main steering angle sensor is

unlocked onca, turn it to tho locking position and lock
RETAINING
sgcu16ly. COLLAR
Checkfor damage.
STEERINGCOLUMN I
rN-\
@ qt
FRONTMAIN STEERING
ANGLE SENSOR
t4ws oNLY)
FLANGENUT
I x 1 . 2 5m m
't6 t{.m
('1.6kg-m, 12lb-ft)
tr
,,,\
colur'rr ttot-DER
,{g
FLANGEBOLT (2.2 kg-m, 16 lb-tl)
39 N.m (3.9 kg-m, 28 lb-fil
SPRINGSCALE
a Check the tilt mechanismfor propermovement
and damage. TILT LOCKBOLT
- Attach a springscaleto the knob of the tilt lever. -6.1

Measurethe preloadrequiredto move the lever. STOPPER
Prsload:7O-9O N U-9 kg, 15-20 lbs)
- lJ the preload measured is not within the

specification.removethe 6 mm bolt and stop-
per. Then adjust the preload by tightening or
looseningthe tilt lockboltat the lever pulledup.
- Reinstall the stopper and 6 mm bolt, then
recheckthe preloadagain.
CAUTION: Do not loosen the tilt lover when set- 6 mm EOLT

1 0 N . m { 1 . 0 k g - m ,7 l b - f t l
thg dp ltoppor and when iightening the bolt.
17-92
lnstallation
NOTE: 4. Installthe steeringjoint cover with the clampsand
a Be sure the pinion shaft and the steeringshaft are cliP.
aligned;the joint should sllp on freely.
lf not, repositionthe steering rack to correct the
misalignment.
a Coat the interiorof the steeringjoint grommet with
grease.
1. Guidethe steeringshaft through the enginecom-

partmentbulkhead.Align the bolt hole in the steer-
ing joint with the slot in the steeringshaft, and in-
sert the shaft into the steeringjoint.
STEERINGJOINT BOLI
Bolt rnust line up with lhe
tlat on shaft-
22 N.m
STEERINGSHAFT (2.2 kg-m, 16 lb-fi)
JoINT CLIP
COVER
5. Install the front main steering angle sensor (4WS
o n l y ) , c o m b i n a t i o ns w i t c h a s s e m b l ya n d t u r n s i g n a l
c a n c e l i n gs l e e v e w i t h a c i r c l i p .
NOTE:
a Be sure the wires are not caught or pinched by
SREERIITG JOINT any parts when connecting the combination
Slip the upperend of the steeringjoint onto the steering switch and the cable reel.
shafi (lineup the bolt hole with the groovearoundthe shaft) a A l i g n t h e s l o t s I n t h e t u r n s i g n a lc a n c e l i n gs l e e v e
and inslallthe steeringioint bolt.
w i t h t h e t a b s o n t h e f r o n t m a i n s t e e r ; n ga n g l e
Installthesteeringcolumnassemblywith the nuts, sensor,
bolts and column holder. FRONT TURNSIGNALCANCELING
MAIN STEERING SLEEVE
Connectthe ignitionswitch connector.
COMBINATION
SWITCH
16 N.m
11.6kg-m, 12 lb-ft)
HOLDER 39 N.m
13.9kg-m,28 lb-ftl
FRONTMAIN STEERING
ANGLESENSOR
l4WS Onlyl
tconl c
17-93
SteeringGolumn
6. Installthe cable reel assemblY(SBSonlv). 8. Installthe upper and lower column covers
NOTE: Align the slot in the cancelingsleevewith

the projectionon the cable reel (2wS only).
UPPERCOLUMNCOVER
2WS:
PROJECTION
FROI{T MAII{ STEERINGANGLE SENSOR
9. Installthe air duct.
Connect the cable reel harness and SRS wire

harness,then attach the cable reel harnesson the
undersideot the column bracket with the clip.
AIR DUCT
SRS WIRE HARNESS
17-94
1O. Install the driver's knee bolster and dashboard
tower cover.
DRIVER'S
BOLSTER
6 mm BOLT
WASHER
1 ON . m
(1.O kg-m, 7 lb-ltl
DASH BOAND
LOWERCOVER
1 1 . I n s t a l l t h e s t e e r i n gw h e e l a n d d r i v e r ' s a i r b a g
a s s e m b l y( s e ep a g e 1 7 8 4 o r 8 6 ) .
17-95
SteeringPump
Replacement PulleyReplacement
NOTE: Beforedisconnectingthe hosesfrom the pump, Hold the steeringpump in a vise with soft jaws, and
place a suitablecontainerunder the car. hold the pulleYwith the specialtool, and remove the
p u l l e yn u t a n d P u l l e Y
1. Orainthe tluid from the system (seepage 17-77).
N O T E : P u l l e yn u t h a s l e l t - h a n dt h r e a d s .
2. Removethe belt by looseningthe power steering
mountingbolt, nut and adjustingbolt
HOLDER
UNIVERSAL
3. Disconnectthe inlet and outlet hoses from the 07725-O030000
pump and plug them.
NOTE: Take care not to spill the fluid on the body

and parts. Wipe oft the spilledat once
4. Removethe power steeringmountingbolt and nut,

then removethe pumP. ADJUSTING
o9llEr eolr
BOLT
't 't N.m
11.1kg-m, 8 lb-ft)
PUMP ASSEMBLY
O.RING
Replace.
HOSECLAMP
PULLEYNUT
Left-handthread
STEERING
MOUNTINGNUTS
22 N.m
12.2kg-m, 16 lb-ftl
Reinstallthe pulleyin the reverseorder ol removal
INLET HOSE
NOTE: Installthe pulleyas shown
POWERSTEERINGBELT
PULLEY NUT
PULLEY
65 N'm (6.5 kg-m,47 lb-ft)
POW€R
MOUNTINGBOLT
22 N.m
(2.2 ks-m. 16 lb'ft)
NOTE: Do not turn the steeringwheel while the
pump removeo.
5. Looselyinstalla new pump on the bracket.
6. Connectthe inlet and outlet hosesto the pump.
7. lnstalland adiust the belt (seepage 17-741.
CAUTION:
a Mak€ sure that the powel steering belt is
securoly on the groove of tho pulleys
a Do not get powor ste€ring fluid or groase in the
powsr steeiing belt or pulley {aces.
Cl€an ofl any fluid or gloase bsforo installation.
8. Fill rhe reservoirwith new fluid to the UPPERlevel Check that the pump turns smoothly by turning the
fine on the reservoir{see page 17 -771 pulley.
17-9 6
Flow Control Valve Inspectionand Replacement
Removethe controlvalve cap by removingthe two 4. Slip the flow control valve back in the pump and
tlange bolts. check that it moves in and out smoothly.
Removethe flow controlvalve,springand O-rings.
FLOWCONTROLVALVE FLOWCONTROLVALVE
SPRING
| "o"r*o,- uo.u. "o,
@-'@h,
,q/@
lf OK. go on to step 5; if not. replacethe flow control

vatve:
a The originalvalvewas selectedfor a precise{it in the

pump housingbore, so make sure the new one has
the same identificationmark.
IDENTIFICATION
Check lor wear, burrs, and other damageto the

edges of the groovesin the flow control valve,
Mark Part Name S i z em m ( i n )

FLOW CONTROL 1 7 . 9 9 1- 1 7 . 9 9 6
VALVE A (o.7083-O.7085)
FLOW CONTROL 17.996-18.OO1
B (o.7085-O.7087)
VALVE B
lconl dI
17-97
SteeringPump
Flow Control Valve Inspectionand Replacement(cont'd)
Attach a hose to the end of the flow control valve 7. ClamDthe bottom end of the {low controlvalvein a
as shown. vise with sott jaws.
8. Unscrewthe seal in the top end of the tlow control

valve, and removeanv shims,the reliefcheck ball,
'%
relief valve and relief valve spring.
RELIEFCHECKBALL
RELIEFVALVE
| "*,",.,
11.3kg-m, 9 lb-ft)
FLOW CONTROLVALVE
Clamp this end in
a visg with sott jaws.
SPPING
9. Clean all the parts in solvent, dry them olf then
reassembleand retest the flow control valve.
NOTE: lf necessary.relief pressureis adjustedat

the factory by adding shims under the check ball
Submergethe llow control valve in a containetof seat. It you found shims in your valve, be sureyou
power steering fluid or solvent. and blow in the reinstallas many as You took out.
hose. lf air bubblesleak through the relief valve. 'lO. lnstallthetlow controlvalve in the reverseorderof
reDlaceor repairit as Jollows.
removal.
NOTE:
a Coat the tlow control valve with power steering
fluid, then installit and sPring.
AIR PRESSURE
a When replacingthe flow control valve, be sur€
No mor6 than 20 kPa
{0.2 kg/cm2, 0.3 plll the replacementflow controlvalvehasthe same
identificalionletter as the originalflow control
VALVE
a-fuh,
J contnoL vlle clp
**@'.
FLANGEBOLT
11N.m
(l .1 kg-m, a lb-ft|
22.1 x 1.9 mm O-RING 5.8 x 1.9 mm O'RING
17-9 8
Disassembly
CAUTION: The pump components are made ot alumin- 6 . Remove the pump cam ring from the
um. Be careful not to damago th€m wh6n sorvicing. housing.
1. Removethe pump from car (seepage 17-96).

PUMP CAM RING
2. Removethe pulley (seepage 17-96).
3. Removethe flow control valve (see page 17-971.
4. Removethe inlet joint and 13 x 1 .9 mm O-ring.

HOUSING
INLETJOINT
1 3 x ' 1 . 9m m
O-RING
Replace.
5. Remove the pump cover and O-ring. 7. Removethe pump rotor and pump vanes.
PUMP VANES
68.5 x 1
O-BING
"d
Replace. f..!
PUMP COVER
(cont'dt
7-99
SteeringPump
Disassembly(cont'd)
8 . Removethe two rollersfrom the side plate. 11. Remove the circlip. then remove the drive shaft
from the pump housingusing a plastic hammer.
9 . Removethe side plate and preloadspring.
12. Removethe pump seal spacerand oil seal.
ROLLER
x 26.8 mm
CIRCLIP
SIOE PLATE
A
- : . ' ' - . . ., -OAtVe
-
U,s-
e) / sHAFf
ff
t-\v1t
\a__-/
Il
U -.ryv:jjAr
A1/sP^cER
\:/ orr sFA
OIL SEAL
Replace.
PUMPHOUSING
1O. Removethe O-ringsfrom the side plate.
1 3 .Inspectthe bearingby rotatingthe outer raceslow-

ly. lf any play or roughnessis felt, it must be replac-
ed. Performstep 14 and 1 5
1 6 . 8x 1 . 9 m m
O-RING
Replace.
Sx1.9mm
O.RING
Replace.
SIOE PLATE
BEARING
17-100
14. Remove the bearing using the special tool and
pressas shown.
Pross
HUB OIS/ASSEMBLYBASE
OTGAF-SDi+O7OO
15. Installthe new bearingusingthe pressand special

tool as shown.
Plo!!
+
Blacksealside.
Red seal side.
HUB DIS/ASSEMBLYBASE
oTGAF-SD40700
NOTE:Hold the innerrace
with the tool securely.
17-101
SteeringPump
lllustlated Index
CAUTION: Pump components aro made ot aluminum, Be careful not to damago lhem when servicing'
NOTE:
a Cleanall of the disassembledparts thoroughly.
a Replaceall O-ringsand seals.Do not dip new O-ringsand sealsin solvent; coat O-ringswith power steeringfluid
before installation,and make sure they stay in placeduring reassembly.
a lf any part denotedwith an asterisk(*) is worn or damaged,replacethe completepump.
NEEDLEROLLEREEARING
FLANGEBOLT
20 N.m iPUMP CAM RIf{G
(2.0kg-m,14
Check lor damage
and wear,
'PUMP VANES
(10 platBl
PUMP COVER Checkfor damage
Check for damage to
sealingface.
ROLLER
4.5 x 49.8 rnm 88.5x 1.9 mm
O.RING
R€place.
16.8x 1.9 mm
.PUMP HOUSING
O.RING
Chock {or damage to Replace.
s€alingfaces.
-6.l
OIL SEA
Replace.
1 3x 1 . 9 PUMP SEAL
o-Rtt{G SPACER
Rgplace. ORIVE
SHAFT
Checkfor damage PULLEY
and wear. Checkfor distortion
--(cL and cracks.
FLANGEBOLT
11 N.m (1.1 kg-m, 8 lb-ft}
*{@
IT{LETJOINT
B1.2'""'-"
f^@'
FLOW CONTROLVALVE
Check lor pressure BEARING
leak.
Checklor
22.1 x 1.9 mm O-Rl 6 -'>Q
excessive
ptay. PULLEYNUT
65 .m
16.5 ks-m, 47 lb-ft)
FLANGEAOLT CONTROLVALVE CAP
11 N.m (1.1 kg-m, 8 lb-lt)
17-102
Assembly
'I . Coat the lip of the new oil sealwith steeringgrease o. Installthe preloadspringin the pump housing.
{ H o n d aP / N0 8 7 3 3 - B o 7 o E ) .
7 . Set the 4.5 x 49.8 mm rollerin the 4.5 mm hole in
2. Install the new oil seal in the pump housing by the pump housing.
hand.
8 . Set the side plateover the rollerand installit on the
Installthe pump seal spacer,then installthe drive pump housrng,
shaft in the pump housingusingthe specialtools.
o Set the 5 x 26.8 mm rollerin the 5 mm hole in the
Installthe circlipwith its taperedside facing out. side plate.
5 x 26.8 mm
ROLLER
CIRCLIP
)
DRIVERATTACHMENT
07947 -6340500 4.5 x 49.8 mm
9=-o*,ve ROLLER
ruI\ sHAFr
ATTACHMENT, 37 x 40 mm Y
07746*0010200 FI purrrp
senl
SPAGER HOUST G
Jl PRELOAD
x
\v
SPRING
4.5 mm HOLE
10. Assemblethe pump rotor to the drive shaft with

the "O" mark on the.otor facing upward.
5 . Coat the side plate grooves with power steering 1 1 . Set the 1O vanes in each groove in the rotor.
fluid, then positionthe 16.8 x 1 .9 mm and 54 x 1.9
mm O-ringson the side plate. NOTE: Be sure that the round end of the vanes is
in contact with the slidingsurfaceol the cam ring.
16.8x 1.9 mm
O-RING
,,O" MARK
/E PUMP ROTOR
O 54 x 1.9 mm
O.BING
Round 6nd
4o
VANE
{cont d
17-103
SteeringPump
Assembly{cont'dl
'17
1 2 .Set the pump cam ring over the two rollerswith the . S e t t h e 1 3 x 1 . 9 m m O - r i n go n t h e i n l e tj o i n t ,ano
" : " m a r ko n t h e c a m r i n g u p w a r d . installthe inlet joint on the pump housing,
1 3 . Apply clean power steeringfluid to the vanes and

pump cam flng.
PUMPCAM RING
INLETJOINT
FLANGEBOLT
11 N'm
(1.1 kg-m, 8 lb-ftl
18. Installthe flow control valve (seepage 17-98).
1 4 . I n s t a l lt h e 6 8 . 5 x 1 . 9 m m O - r i n go n t h e p u m p 19. Installthe pulley (see page 17-96) and check that

cover. the pump turns smoothly by turning the pulley.
1 5 .Align the rollerset holesin the pump cover with the

rollers.
Align the projectionon the pump housingand the

projectionon the pump cover,then tightenthe tour
bolts.
FLANGEBOLT
20 N.m
(2.O kg-m, 14 lb-ft)
68.5 x 1 . 9 m m
O-RING
ROLLEBS
17-104
SteeringGearbox
Index
CAUTION: Betore diEassamblingthe gsarbor, wash it oll with solvent and a brush.
€--=.- ss t.-
13.9 kg-m, 28 lb-ft)
VALVEBODYUNIT
page17'106
Overhaul,
GEARBOXSHIELD
lr.O tg-m, 7 lb-ftl

RIGHTMOUNTING
BRACKET RACKEND
AIR BOOTBAND 65 N.m 16,5kg-m,47 lb-ft)
CLAMP neptace.
TIE.ROD \
LOCKNUY 8o,or \s
45 N.m
(4.5 kg-m, 33 lb-ftl
\ =K\ \)
TIE.RODEND \
MdNNry:
\
TUBE CI-AMP
TRANSFERHOSE
TRANSFERHOSE
9-- CLAMP
a
50-60 N.m
(5.0-6.0 kg-m,
36-43 tb-ft)
Ss'..t -ArR HOSE BAND RUBBER
I
t AIR HOSE BAND
/-
I
COTTER-PIN
Replace.
17- 105
SteeringGearbox
Valve Body Unit
Romoval Removethe two I mm flangebolts and removethe

valve body unit from the gearbox.
1. Drsin the power steeringfluid (seepage 17-77).
6. Remove the O-rings and port orifices trom the
2. Removethe gearboxshield. gearbox.
9.8 x 1.9 mm
O.RING
Replace.
PORT
ORIFICE
45.5 x 2 mm
O.RING
Replace.
GEARBOXSHIELD
8 mm FLANGEEOLT
Usingsolventand a brush.wash any oil and dirt off
the valve body unit, its lines, and that end of the
gearbox.Blow dry them with compressedair. UNIT
UsingJlarenut wrenches,disconnectthe four lines

Jrom the valve body unit.
A: To oil cooler: 17 mm wrench

8: To power st€qring spsed sensor: 12 mm wrench
C: To reservoir:12 mm wrench
D: From pump: 14 mm wronch
17-106
Valve Body Unit
Disassembly 4. Checkthe Dressurecontrol valve:
1. Removethe three 6 mm flange bolts, then remove Inspectits surfacefor scoringor scratchss.
the valve body cap trom the valve body.
Slip it back into the valvebody. and makesure it
2. Removethe cap seal trom the valve body cap. slides smoothly without drag and without slde
play.
VALVEBODY
PRESSURE CONTROL VALVE
Checkfor scoringor
scratches,and rough
opgration.
6 mm FLANGEBOLT
NOTE: lf the valve body is damaged,replacethe

valvebody unit (valvebody, pressurecontrolvalve.
gain control valve,4-way valve)as an assembly.
Removethe pressurecontrolvalveand valvespflng 5 . Remove the gain control valve and valve spring
from the valve body. irom the valve bodv.
VALVE BODY VALVE BODY
\, .la
\(C
4*
VALVESPRING
VALVE SPRING
(conl ct
17-107
SteeringGearbox
Valve Body Unit (cont'd)
6. Checkthe gain control valve: 9. Remove the rollers from the 4-wav valve bv
pushingthe valve out one side of the valve body,
a Inspectits surJaceJor scoringor scratches. and then the other.
a Slip it back into the valve body and make sure it NOTE: When removing the rollers, hold the
slides smoothly without drag and without side plungerswith your linge.s to keep them ffom pop-
pray. prng our.
GAIN CONTROLVALVE
Checkfor scoring,
scratches,or rough
operation.
PLUNGERS
NOTE: lf the valve body is damaged,replacethe 1O. Remove the plungers, return springs and 4-way
valvebody unit (valvebody, pressurecontrolvalve, valve from the valve body.
gain control valve, 4-way valve) as an assembly.
11. Removethe 11 mm O-ringt.om the 4-way valve.
Separatethe valve body and port housing.
12. Check the plungers.
Removethe port seal and dowel pins trom the port
housing. a Inspecttheir surfacefor scoringor scratches.
a Slip each plungerinto the valve body, and make

sure it slides smoothly, without drag or side
play.
lf any plungeris damaged.replaceit.
VALVEBOOY
PLUNGERS
PLUNGERS Check lor scoring or
Check for scoring or scratches, and rough
scratches, and rough sliding.
sliding.
DOWEL PIN
17-108
'13.
Checkthe 4-way valve.
Inspectits surfacefor scoringor scratches.
Slip it into the valve body, and make sure

slidessmoothly.without drag or side play,
4.WAY VALVE
Checkfor scoring,
scratches, or rough
operation,
(
NOTE: lf the valve body is damsged,replacethe

valvebody unit (valvebody, pressurecontrolvalve,
gain control valve,4-way valve)as an assembly.
1 4 . Using a 3 mm (1/64") drill bit, removethe sensor

oriJiceand 3.4 m O-ring,
gh
PORTHOUSING
17-109
SteeringGearbox
Valve Body Unit
Assembly
lllustrat€d lnd€x
1, Throughlycleanthe disassembledparts shown below.
2. Coat the plungers,pressurecontrol valve, gain control valve and 4-way valve surfaceswith power steeringfluid.
3, Beassemblethe pans in the reverseorder of disassembly.
CAUTION:
a Replacothe O-rings and ssals with n€w onos,
a Do not dip tho O-dngs and saals in solvent.
a Apply tb€ power ste€dng fluid in the e€al groovos to keep tho leals in pl8cs,
. -6f : STEERING GREASE(Pa.t Numb€rO8733-BO?OE|
45.5 x 2 mm
O.RING
PORTHOUSING Replace.
1l mm O-RING
DOWELPII{S
PRESSURE
cof{TRoL
VALVE
uo.u."r*nol trN
VALVE EODY
6 mm FLANGEBOLT
I N.m lO.9 kg-m, 7 lb-ft)
PLUNGERS
S*"MS^"..'.
.' \ / l i l
"/)H
--
^qq
d
\
\\
+ w r vv t v e
oo,n"onrro.
vALvE
1 \sENsoR
oRtFtcE
SPRINGS \
3.4 m]n O-RING
ROLLER R6place.
NOTE: lf the valve body is damaged,replacethe valve body unit (valvebody. pressurecontrolvalve,gain control
valve, 4-way valve)as an assembly.
17-1 1 0
4. Coat the surface of the 4-way valve with power 7. Coat the pressurecontrol valve and gain conttol
steeringfluid, and installinto the valve body. valvewith power steeringfluid, and installthemin-
to the valve body,
5 . Coat the surfaceo{ the plungerswith power steer-
ing tluid, and install the plungers,return springs 8. Installthe valve springs.
and rollerson the valve body.
VALVEBODY
1 1 mm
SPRINGS
I
r0
VALVE SPRINGS PRESSURECONTROLVALVE
E
PLUNGERS
E 9. Coatthe cap sealwith power steeringfluid, and in-

stall it in the groove ot the valve body cap.
6. Coatthe port sealwith power steeringfluid, and in-
stall it the grooveof the port housing.Then install 1O. Installthe valve body cap on the valve body with
the valve body and port housing. 6 mm flange bolts.
CAUTION: Maka sure the mating surface ot th6

valve body and cap are flush at the uppor sid6.
VALVE BODY
PORT HOUSING
6 mm FLAIIGE BOLT
9 N.m (0.9 kg-m, 7 lb-ft)
VALVEBODYCAP
rol
{cont 6
17-111
SteeringGearbox
Valve Body Unit (cont'd)
'I 1. Make sure the 4-way valve moves smoothly,and lnstallation
returnsto neutrSlDosition.
1. Coatthe 9,8 x 1.9 mm O-ringswith power steering
fluid, and installthem togetherwith the orifices.
2. Installthevalvebody unit on the gear housingwith

the two 8 mm bolts.
CAUTION;
a When installing, be caleful not to hil th€ pinion
holderpin.
a Mak€ sure the O-rings are in place and not
pinchad,
PINIONHOLDERPIN
-6l 9.8 x 1.9 mm

O-RINGS
E
PORTORIFICES
45.5 x 2 mm
O.RING
BODYUI{IT
22 N'm 12.2ks-m' 16 lb-lil
Connectthe four linesto the valve body unit, using
flare nut wrenches.
A: To oil coolor: 17 mm wrench

29 N.m {2.9 kg-m, 21 lb-ftl
B: To power ste€ring spoed aensor:
12 mm wrench
13 N.m (1.3 kg-m, 9 lb-lt)
C: To rgsorvoir: 12 mm wrench
13N.m (1.3 kg-m, 9 lb-ft)
D: From pump: 14 mm wrench
38 N.m (3.8 kg-m, 28 lb-tt)
17-1 1 2
Fillthe reservoirwith power steeringfluid and bleed
air from the system by turning the steeringwheel
from lock to lock severaltimes with the engine
warm lsee page 17-771.
Make sure there are no fluid leaks,then installthe

gearboxshield.
o. Recheckthe fluid level in the reservorr.
GEARBOXSHIELO 1 ON . m
(1.0 kg-m, 7 lb-ftl
17-113
SteeringGearbox
GearboxRemoval
NOTE: Beforeremovingthe steeringgearbox,alignthe 7 . Removethe selfJockingnuts that connectthe ex-

front wheels straightahead. haust pipe A to the three way catalyticconverter,
and the exhaustoiDeA to the exhaustmanitold.
1. Drainthe power steeringfluid as describedon page
17-77. 8. Disconnectthe heated oxygen sensor connector
(H23A1 and H22A1 engine)and remove the ex-
2. Raisethe front o{ car and supporton safety stands haust pipe A,
in the properlocations(see sectjon 1).
CAUTION: Replac€ tho oxhaust gaskot and salf-
3. Removethe front wheels. locking nuts when you loinstall ths pipe.
4. Remove the cotter pin lrom the castel nut and

removethe nut.
Installa 12 mm hex nut on the ball joint. Be sure

that the 12 mm hex nut is tlush with the ball joint
pin end, or the threadedsectionof the ballioint pin
NOTE: Removethe ball joint using the Ball Joint

Remover.Referto page 18-13 tor how to use the
ball joint remover.
Separatethe tie-rodballjoint and knuckleusingthe

s p e c i atl o o l .
CAUTION: Avoid damagingthe ballioint boot. EXHAUST PIPEA
q
Automatic transmissiononly.
a Removethe shift cable holder and disconnect

ihe shift cablefrom the shift control shaft.
SHIFT CONTROLSHAFT
12 mm HEX NUT
SHIFTCABLEHOLDER
17-114
1 0 .Removethe center beam. 1 2 .Usingsolventand a brush,wash any oil and dirt ofl
the valve body unit, its lines, and the end ot the
NOTE: Replacethe self-lockingbolts if you gea.box. Blow dry them with compressedair.
easilythread them in.
CAUTION: Aftel disconnecting the hoses and
pipes,plug or sealthe hosesand pipeswith a piece
of tape o. equivalent to paevent foreign material
lrom entering the valve body unit.
1 3 .Usingtlare nut wrenches,disconnectthe four lines

trom the valve body unit.
A: To oil cooler: 17 mm wrench

B: To power stssring speed sensor: 12 mm wrench
C: To reservoir:12 mm wrench
D; From pump: 14 mm wrench
11. Removethe gearboxshield.
4WS:
14. Cur the wire tie from the cover, then removethe
cover from the front sub steeringanglesensor,
CAUTION: Use care when cutting the wire tie so

as not to cut into the wire harness,
15. Removethe sensor wire harnessfrom the clamp

and disconnectthe connector.
CONNECTOR
COVER
GEARBOXSHIELD
WIRETIE
Replace. FRONTSUB STEERING
ANGLESENSOR
17-115
SteeringGearbox
gearDox Removallcont
Gearbo llemoval q,
lcont'd)
16. Lock the steeringshaft with ignition key to keep 1 9 . Removethe left-tie rod end, then slidethe rack all
the steeringshaft position. the way to the right.
17. Removethe steeringjoint bolt, and move the joint 20. Pull the steering gearbox assembly all the way
toward the column. down to clear the Dinionshaft lrom the bulkhead.
STEERINGJOINT
21 . Move the steeringgearboxassemblyto the right so
the left rack end clearsthe rear beam-
Hold the steeringgearboxassemblyand slide the

rack all the way to the left. Placethe left rack end
below the rear beam.
Move the steeringgearboxassemblyto the left and

tilt the left side down to removeit from the car.
LOCKWASHER
TOOTHED
18. Remove the left mounting bracket first, then
removethe right mountingbrackets.
A
RAq
In6ta
innoa
STEERINGGEARBOXASSEMBLY
35.
o{
R.!
CAUTION: Bo calsful not to bond or damage the
four power aleedng lines when lomoving the gear-
box aasemblv. z<
AIR HOSE CLAMP
17-1 1 6
lllustratedIndex
a Thoroughlyclean all disassembledparts.

a Always replaceo-rings and seals.
a Replaceparts with damagedslidingsurtaces.
a Do not dip sealsand O-ringsin solvent;coat O-ringswith power steeringfluid or steeringgrease,makesurethey stay
in positionduring reassembly,and use the appropriatespecialtools to installlhem where necessary.
-!56{ : STEERING GREASE{P/N08733 BoToEl
FRONTSUB STEERING
ANGLESENSOR
l4wsl
Adjustment
page 17-132
RACKGUIDESCREW
(2WSl
SEAL RETAI'{ER SPRING

AALL
BUSHINGSTOPPER CYLINDERCAP BEARING
.- RACK
.@] cutDE
o -: -GEAR
HousrNG
t
RETAIT{ING
ffi
AE5<-- PrNtoNHoLDER
\-+-- pr roNHoLDER
WASHER
Beplsce. 9.8 x 1.9 mm _-.,t

o-RTNGS--- J
H
ffi"k
""'!kr
#.'=....-#
PORTORIFICES
ser.
ersron
BING
Feplace BALLBEARTNG
35.5 x 2.4 mm
&---
(nlr- SAf{P R|NG
R'.
iJillitt.l"l3T-0"-","
i:11T,""*,
)d'ffi"oCYLINDER Inspect lor damage to CYLIIIIDER
SNAP RING
;rd$;t inner surface ,sPRlNG
-";tJilhre$m''L,NDER
--=.:=\/V\\-- fiI.;!,?,T I::X'"T:U:'*""
\ -5ffiq \ /'e- '-
O-RING
Replace.
CYLINDERBOLT
22 N.m
12.2 kg-m, 16 lb-trl
17-117
SteeringGearbox
Overhaul
1. Removethe two 8 mm flangebolts and removethe 4WS:

valve body unit trom the gearbox. 5. Loosen the locknut and remove the rack guide
screw/front sub steeringangle sensorassembly.
2. Remove the O-rings and port orifices from the
gearbox. 6. Removethe spring and rack guide from the gear
housing.
8 m m FLANGEBOLT
45.5 x 2 mm
O-RING
Replace.
9.8 x 1.9 mm
O-RINGS RACK GUIDE
Replace.
Loosen the locknut and remove the rSck guide 7, Removethe rack guide screw, O-ringand locknut
5Crew. from the front sub steeringangle sensor.
Removethe spring and rack guide trom the gear

housing.
LOCKNUT
RACKGUIDE
17-118
8 . Csretully clamp the gearbox in I vise with soft 1 1 .Hold th€ steeringrack with I wrench and unscrew
jaws. the rack end with a wrench.
9 . Removethe tie-rod end.

RACK END LOCK WASHER
TIE.RODLOCKNUT
\ ,
@-=-47'
,^@
1- r_------_1,
V \
TIE.RODEND
1 0 . Bemovethe boot bands and tube clamps. Pull the 1 2 . Removethe dust cover.
dust sealsaway from the ends of the gearbox.
1 3 .Removethe gear housingcap from the gear hous-
ing by removingthe four 6 mm flange bolts.
1 4 . Remove the steering pinion seal from the gear

housingcap.
DUST COVER
STEERINGPINIONSEAL
Replace.
GEAR HOUSINGCAP
46 r 1.5mm
O.RING
Replace.
TUBE CLAMP
(cont'd)
17-119
SteeringGearbox
Overhaul(cont'd)
15. Pushthe right end ot the rack back into the cYlinder a Removethe ball bearingusing a commercially
housing so the smooth surtace that rides agsinst availablebearingpuller.
the seal won't be damaged.
Install the ball bearing on the pinion using a

p.ess and the specialtools.
to. Checkthe ball bearingot the pinionfor play; if it is

good, go on step 17,
lf the bearingis noisyor hasexcessiveplay,replace
the bearing.
a Removethe snap ring.
BALL BEARING
17-120
a Installthe snap.ing on the pinion. 19. Remove the cylinder end seal from the cylindel
housing.
NOTE: Useyour tingersor a woodenstick to avoid

damagingthe housing.
PINION
@
II
END
CYLINDER
ENDSEAL CYLTNDER
HOUStt{G
17. Removethe four cylinderbolts from the end of the 20. Removethe cylinder,sealretainer,cylindercap and
cylinder housing, then slide the housing off the steeringrack from the gear housing.
tacK.
18. Remove the O-ring. back-up ring, steering rack

bushingA and cylinderspring.
CYI-INDER
GEARHOUSING
17-121
SteeringGearbox
Overhaul(cont'd)
I
!
21. Removethe retainerwasherJromthe gearhousing. a Removethe pinionholdertrom the gearhousing. t

a Check the needle roller bearingsin the pinion
holderand gear housingfor damage;if oK, pack
the needlerollerbearingwith grease.lf the bear-
ings are damaged.replacethem as a set.
PINIONHOLDER
GEAR I{OUSING
22, Check the pinion holder for tree movement, ex- a Checkthe ball bearingfor damage;it it is good.
cessiveplay and rough movement;if it is good 90 go on step 23.
on steD 23.
lf it is damaged,or if dirt has gone past the sealinto a Remove the pinion ball bearingfrom the gear
the grease,replacethe bearing. housing.
a Removethe circlipfrom the pinion holder.
BALL BEARING
PINIONHOLOER
17-122
a Drivethe new ball bearinginto the gear housing a Reinstallthe circlip with its taperedside facing
using the specialtools. ouI.
NOTE: Circlip ends must be alignedwith the flat

area.
ORIVER
07749-OO10000
47 mm
CIRCLIP
a Installthe pinion holderin the gear housing.
PINIONHOLDER
23, Removethe cylindercap and sealretainerfrom the
steeringrack.
CYLINDERCAP/
SEAL RETAINER
NEEDLEROI-LER
BEARINGS
STEERINGRACK
GEARHOUSING
{cont d,
17-123
SteeringGearbox
Overhaul(cont'd)
24. Removethe O-ringand snap ring ftom the seal re- 28. Carefullypry the piston sealting and O-ringoff the
tainer.then removethe cylindercap from the seal olsron,
retalner.
25. Removethe O-ringstrom the cylindercap.
29.7x 1.9 mm
O.RING
43.3 x 1,5 mm
Replace.
O.RINGS
Replace.
II
SEAL RETAINER
(\s
CI
SNAP RING
PtSTON
SEALRI[{G
CYLINOERCAP R€Place.
NOTE: Befo.e reassemblingany parts, inspect

Remove the bushing stopper ring lrom the seal
retainer. them as describedon page 17-'l17 and mak€ sure
they are clean. Replaceworn or damagedparts
2 7 . Removethe cylinderend seal and rack bushingB.
BUSHINGSTOPPER
SEAL RETAINER
RACK BUSHINGB
SEAL
17-124
29. Install a new O-ring on the piston with Its narrow 32. Coat the piston seal ring and insideof the special
€dge facing out. tool with power steeringfluid.
33. Carefullyslidethe tool onto the rack and ove. the

pistonsealring, then rotatethe tool as you move it
up and down to seat the piston seal ring.
30. Coat the pistonseal ring guide with power steering

fluid. then slide it onto the rack, big end fifst.
31. Positionthe new piston seal ring on the special 34. Coat new O-ringswith powe. steeringfluid and in-
tool, slideit down onto the big end of the tool, then stall them on the cylindercaD.
pull it otf into the piston groove on top of the O-
ring.
43.3 x 1.5 mm O-RINGS
STEERINGRACK
(cont'dr
17-125
SteeringGearbox
Overhaul(cont'd)
35. Slidethe cvlindercap onto the seal retainer. 38. Gr€asethe slidingsurfacesot the new cylinderend
sealand the specialtool.then placethe sealon the
36. Installthe snap ring on the seal retainerand coat specialtool with its grooved side facing opposite
new O-ringwith power steeringfluid and installit the slider.
on the seal reta,ner.
29.7 x 1,9 mm
S[{AP RII{G O-R|NG BACK.UPRING
\ t Make sure the back-up

ring is seated in the
\ l cylinde.end seal.
\.-6
^@"\
* \ !
@'f \
cYtlt{DERcAP
CYLINOERENO SEAL
lnstall end soal with its grooved
side facing opPosite
\ seal slider.
I
SEALRETAINER
CYLINDEREND
SEALSLIDER
07LAG-SM/tO30A
37. Greasethe sliding surface of the rack bushingB.

and installthe bushingon the steeringrack. 39, lnstallthe specialtool and cylinderend seal.
-Gl
RACK BUSHING
17-126
40. Separatethe cylinder end seal from the special 4 2 . Push the rack bushing B toward the seal retainer by
tool, then removethe specialtool from the fack. hand until the cylinderend seal is seatedin the re-
tainer.Fit the bushingstopperring in the grooveot
the sealretainersecurely.Then greasethe steerinq
racK.
CYLINDEREND
SEAL SLIDER
07LAG-SM4030A
AUSHINGSTOPPERRING
SEAL RETAINER
RACK SUSHINGB
RAC( BUSHINGB
41. Fit the seal retaineron the steeringrack. 43. Installthe retainerwasher on the gea. housing.
SEAL RETAIT{ER
GEAR HOUSING
{cont'dl
17-127
SteeringGearbox
Overhaul(cont'd)
44, Placsthe gea. housingon the work bench and in- 48. Coat the insidesurfaceof the cylinderwith power
sert the sealretainerand steeringrack into the gear steeringfluid and installthe cYlinderend seal with
housing. its groovedside Jacingout.
45. Coat the insidesurfaceof the cylinderwith powet

steeringfluid, slideit overthe rack and into the gear
housing;press it into the housinguntill il seats' GROOVES
STEERINGRACK
CYLINDEREND SEAL
SEAL RETAIITER
E
CYLINDER
ENO SEAL
49. Coatthe new O-ringwith grease.then installtheO-

ring and back-upring into the gear housing.
50. Carefullypositionthe cylinderon the gear housing

HOUSING
and looselyinstallwith four cylinderbolts.
CAUTION: Bo cartul not to damagetho 6nd se€l in

the cylinder housing.
46. Installthe cylinderspringover the rack, then coat

CYLINDERHOUSING
the rack bushingA with greaseand installit on the
sp.ing.
4 7 . Wrap the end of the steeringrack with vinyl tape.

Coat the tape with grease.
-6q ,6Q
A_e2
RACKBUSHTNG
A)
CYLINDERSPRING -.9
STEERINGRACK --F\ d
Vinyl tape
59 x 2.4 mm
O.RING
-6ll
-Gl
17-128
51. Removethe vinyl tape from the steeringrack. 55. Greasethe sealinglip ot the steeringpinion seal.
and installit on the gear housingcap.
52. Tightenthe four cylinderbolts.
56. Wrap the spline area of the steering pinion with
NOTE: Beforetighteningthe bolts, make sure the vinyl tape and greasethe surfaceoi the tape.
mating surfacesof the cylinderand gearhousingfit
properly by pushing them together; hold them 57. Greasethe new O-ring and install it in the gear
togetherwhile tighteningthe bolts. housing.
58. Slidethe gear housingcap over the steeringpinion,

being carefulnot to damagesealinglip or dislodge
the springof the steeringpinionseal.
59. Removethe vinyl tape.

6mm DUST
FLANGEBOLT
CYLINDERHOUSING 1'l N'ln {1.1 kg-m, 8 lb-ft} /
:ERINGPINION
-6i
CYLINDENBOLT
22 N.m
12.2kg-m, 16 lb-Ill HOUSINGCAP
'
Make sure the O-ring
-61 46 x 1.5 mm O-RING
is in placeand not Vinyl tape
pinched.
HOUSING
53. Insert the steeringrack into the cylinderhousing,

being caretul not to damage the steering rack
slidingsurface.
54. Installthe pinion in the pinionholder.

Install the circlip securely in the pinion holder
6 0 . Screw each rack end into the steeringrack while
groove.
holdingthe lock washer so its tabs are in the slots
in the steeringrack.
NOTE: Installthe circlip with its taperedside fac-
Ing our.
Hold the steeringrack with a wrench and tighten
t h e r a c ke n d t o 6 5 N . m ( 6 . 5 k g - m , 4 7 l b - f t ) .
RACK ENO
PINIONHOLDER
STEERINGRACK
{conl d
17-129
SteeringGearbox
Overhaul{cont'd)
62. After tighteningthe rack end, stske the four sec- 6 3 . Apply greaseto the circumlerenceof the rack end.
tions of lock washer with a dritt,
6 4 . Coat the tie-rodgrooveand insideoJ the boot with
siliconegrease.
AVAILABLEDRIFT
COMMERCIALLY SILICONEGREASE
(Roll Pln Ddft, SnsPOn No. PPfi8l Cost the sliding
surface ot the rack
end. -6,1
RACK END
GROOVE
NOTE: This drift has a tlat,

to prevent punctunng
the metal washer.
6 5 . lnstall the boots on the rack end with the tube
qamps.
NOTE: Checkthat the boot joint piece(i.e.air hose

ioint) is not clogged with grease.
LOCK WASHER
Wood
block
1.0- 1.3mm
(0.04-O.05 inl
Check the lock wssher
diameter aft€r staking.
I'
I
TUBE
CLAMP
17-130
66. Installthe right and l€ft tie-rod6nds. 70. Adiust the rack guide at the center of the rack
stroke.
71. Tighten the rack guide screw until it compresses

the spring and seats againstthe rack guide, then
loosenrt.
TIE-ROOLOCKNUT 72. Retightenit to 4 N.m (O.4kg-m, 2.9 lb-ft), back it

Final to.que: 45 N.m {4.5 kg-m, 33 lb-ft| off about 20 + 5; then installthe locknuton the rack
guide screw.
73. Tightenthe locknut with the specialtool to about

25 N.m (2.5 kg-m, 18 lb-ft) while holdingthe rack
guide screw.
LOCKNUT WRENCH,43 mm RACKGUIDESCREW
oTMAA-SLOO20A
NE.RODEND
6 7 . Greasea new O-ringand instsll it in ths groovs in

the rack guide sctew.
6 8 . Coat the rack guide slidingsurfacewith grease,. 4WS:

74. Installthe locknut on the front sub steeringangle
6 9 . Installthe rack guide, spring and rack guide screw sensor.
on the gear housing.
75. Greasea new O-ringand installit in the groove in
GEAR HOUSII{G
the front sub steeringanglesensor.Installthe rack
guide screw.
SPRING
RACK GUIDESCREW
LOCKNUT
GUIDE
t*F
Loosolyinslall.
(cont d
SteeringGearbox
Overhaul{cont'd}
76. Coat the rack guide slidingsurfacewith grease. 81 . Coat the 9.8 x 1 .9 mm O-ringswith power steering
Jluid.and installthem togetherwith the orifices.
77. Installthe rack guide, spring, O-ringand the .ack
guide screw/frontsub steeringanglesensoron the 82. Coat the 45.5 x 2 mm O-ringand pinionholderpin
gear housing. Then adjust the rack guide at the with grease,then installit in the valve body unit.
center of the rack stroke.
83. Installthe valve body unit on the gear housingwith
the two 8 mm bolts.
CAUTION:
a Whon installing. b€ carolul not to hit the pinion
holderpin.
a Make sute the O-rings ale in place and not
pinched.
LOCKNUT
RACK GUIOE
8 mm BOLT
O.RING 22 N.m '16
(2.2 kg-m, lb-ftl
-6,1
RACKGUIDESCREW
ANGLE
FRONTSUBSTEERING
SENSOR
78. Tighten the rack guide screw until it compresses

the spring and seats againstthe rack guide. then
loosenit.
79. Retightenit to 4 N.m (O.4kg-m, 3lb-ft). back it otf

+
about 20 3' and install the locknut on the rack
Ee?H",. 45,5 x 2 mm
O.RING
guide screw with the specialtool.
9.8 x 1.9 mm
80, Tightenthe locknut to with the specialtool about O.RINGS
25 N.m (2.5 kg-m, 18 lb-tt) while holdingthe guide
screw.
17-132
NOTE: Install the boot band with the rack in the 8 7 . lnstallthe air hose cliDas shown.
straight ahead position (i.e. right and left tie-rodsare
equal in length). 8 8 . lnstallthe bandcushionand air hoss band;Dosition
the band as shown then tighten it. Installthe air
84. lnstallthe boot bandso that the lockingtabs of the hose,
band (stakepointsl are in the rangeshown below.
(Lockingtabs shouldtace up and slightlyforward.) 8 9 . After assembling,slidethe rack right and left to be
cenain that the boots are not deformedor twisted.
85. Installnew boot bandson the boot and bend both
sets of lockingtabs. NOTE: After installation, perform the electrical
check on the 4wS system (seepage 17-146).
86. Lightlytap on the doubled-overponions to reduce
their height.
CAUTION:
a Stako the band locking tabs firmly.
a When staking. be car€tul not to damag€ the
boot.
AIR HOSECLIP AIR HOSE BAf{O

(Viewedlrom the right side) (Viewed lrom the right side)
Clamp 6mm
AIR HOSE
CLIP
atRHosE
NOTE: Connect with the
protector side toward
th6 gearbox,
AIN HOSE BAND
45i5o
LOCKINGTA&S
TUBE The locking tabs (stake
JOINT points) should be in this
range.
Front +
Bandwinding
direction.
OFFSET
SHAFT 10a50
LINE
CENTER
LEFTBOOTBAND RIGHT BOOT BAND

(Viewedfrom the lelt side) (Viewed from the right side)
17-133
SteeringGearbox
lnstallation
Slidethe rack all the way to the right. 7 . Positionthe steeringrack centerof its strokes.
Pass the right side of the steering gearbox Make sure that the cable reel of the driver'sairbag
assemblyabove and through the right side of the system is centeredas follows:
rear Deam,
a Turn the steering wheel left approx. l50
Hold the steeringgearboxassembly8nd slide the degrees,to check the cable reel position with
rack all the way to the right. indicator.
a lf the cable reel is centered,the yellow gear
4. Raisethe left sideot the steeringgearboxassembly tooth lines up with the aljgnmentmark on the
above and th.ough the left side ot the rear beam. cover.
a Return the steering wheel right approx. 150
degreesto position the steering wheel to the
straightaheadposition.
Looselyinstallthe left and right mountingbrackets

with the six mountingbolts,
Tighten the mounting bolts on the left mounting

bracket ti.st, then tighten the mounting bolts on
the right mountingbrackets.
\ <L6tt
\
LEFTMOU NNG YELLOW
GEAR
BRACKET
9. Slip the lower of the steeringjoint onto the pinion
shaft (line up the bolt hole with the groovearound
the shaftl and looselyinstallthe steeringjoint bolt.
NOTE:
39 N.m a Connectthe steeringshatt and pinionwhen the
(3.9 kg-m, 28 lb-ftl cable reel and steeringrack are centered.
<Bight Sido:> 44 N.m a Be sure that the steeringjoint bolt is securelyin
{4.4 kg-m, 32 lb-ft| the groove in the pinionshatt.
STEERINGJOINT BOLT
BOLTHOLE 22 N.m 12.2 kg-m, 16lb-ft)
STEERINGJOINT
MOUNTIT{G
BRACKET
NOTE: The arrow on the
FGHT MOUNTING brscket points toward
TNACKET the front.
AIR HO 39 l{.m
CLAMP 13.9 ks-m, 28 lb-ft)
17-134
1 0 .Connectthe four linesto the valvebody unit, using Fill the reservoir with power steering fluid and bleod
flare nut wrenches. air from the system by tufning the stesring whesl
from lock to lock several times with the engine
A: To oil cooler: 17 mm wrench warm (see page 17-77l..
29 N.m (2.9 kg-m, 21 lb-ftl
B: To powgr stoedng speod sen3of: 1 4 . Make sure there afe no tluid leaks,then installthe
12 mm wranch gearboxshield,
13 N.m {1.3 kg-m, 9 lb-ft}
C: To rsseryoir: 12 mm wrench Recheckthe fluid level in the reservoir.
1 3 N . m ( 1 . 3 k g - m ,9 l b - t t )
D: From pump: 14 mm wronch
38 N.m {3.8 kg-m, 28 lb-ft)
1 1 .Reconnectthe connector and secure the sensor

wire harnesswith the clamp and installthe cover.
{1.0 kg-m, 7 lb-ft}
NOTE: GEARBOXSHIELD
a -Be sure the sensor wire harnessdoes not in-
terferewith the stabilizeror other moving parts. 15. Install the center beam.
a Be certain that the sensor wire harnessis not
twisted betore connectingit.
Set the cover on the front sub steeringangle sen-

sor. Securethe sensorwire harnessand cover with
a new wire tie.
CONNECTOR SENSORWIRE
60 N'm
60 N'm
WIRETIE CI-AMP SUB STEERING {6.0 kg-]n,4.:lb-ft1
NOTE: After rack guide adjustment,perlorm the

electrical check on the 4WS system (see page {cont d
17-146],.
17-135
SteeringGearbox
16. Automatictransmissionmodel only. 18. Reconnect the tie-rod ends to the steering
knuckles.tightenthe castlenut to the specifiedtor-
a Connectthe shift cable end to the shift control que, and instailnew cotter pins.
shaft. and installthe cable holder.
CAUTION: Torque the castle nut to the lower tol-
qu€ sp6citication, th6n tighton it onlY tar €nough to
atign the slot wilh the pin hol6. Do not align the nut
SHIFT CABLE by loosening.
CASTLENUT
50-60 N.m
(5.0-6.O kg-m.
36-/13lb-ft)
CABLE tl.4 kg-ln, 10 lb-ftl

1 8N ' m
1 1 . 8k g - m ,1 3 l b ' f t |
COTTER PIN
17. Installthe exhaustpipe A with a new gasket.then On reassembly,bond
tighten the new self-lockingnuts. Connect the the cottgr pin as shown.
heated oxygen sensor connector (H23A1 and
H22A1engine).
'19.
Adiust the front toe (seesection 18).
NOTE: lf the steeringwheel and rack are notalign-

ed centered,reDositionthe serrationsat lower end
of the steeringjoint.
20. Fillthe system:

a Fill the reservoirwith new Honda Power Steer-
i n g F l u i d - V{ s e ep a g e 1 7 - 7 7 ) .
21. After installation,perform the following ch€cks

a Stan the engineand let it run at idle, then turn
the steering wheel trom lock-to-lock several
times to bleed air from the system (see page
55 N.m 15.5kg-m,40 lb-ftl EXHAUST PIPEA 1 7- 7 7 t .
a Check the fluid again, and add more if
necessary.
a Check the gearboxfor leaks.
a Check the tront toe (seesection 181.
a Check the steeringwheel spoke angle.
a Checkthe 4WS system {4WS only).
7 -136
RearSteeringActuator
lllustrated Index
CAUTION:
a Do not strlks tho rack end and shaft scrow.
a Us€ the spocial tool when removing the rear stee ng actuator. Tho special tool should remain installed excopt whon
tha aciuator ia inspected tor tunction, stc.
a Do not try to disasEambletho rear stoering actuator. lf the actuator is taulty, roplace it a3 an assembly.
a Whon disassemblingand sorvicing. do not let dust, din. and for€ign matelials snter tho rgar ats€ring actuator.
a Wh€n eithor th€ roar sub stoering anglo sonsor or th6 roar main st6o.ing angle sensor are removsd, pertorm Inspgction
and adiustmont ot the raar sub stee ng angle sensor aft€r installing ths rear steering actuator.
a Lock th€ shatt scrow using th6 r6ar steoring lock pin special tool betole removal/installstion and
dlsassembly/r€assemblyof tho real steering actuator assembly.
5O-60 N.m
15.0-6.0 kg-n, 36-43 lb-ft)
\
t
LOCKNUT
45 .m
14.5kg-m,33 lb-lrl
RACK
55 N.m
(5.5 kg-m, 40 lb-ftl
BOOTBAI{D
Replace.
I TORX@ BOLT
d%
'10t{.m (1.O
kg-m, 7 tb-ft|
w O.RING
Replace.
NOTE: Do not let dust, dirt,
and {oreign materials enter
the actuator.
Replace.
REARSUB
ANLGE SENSOR
Adjustmenl. page 1 7 - 15 5
LOCKNUT
25 N'm (2.5 kg-m, 18 lb-ft) I
REAB STEERING SHAFT SCREW
ACTUATOR
17-137
Removal
1. Raisethe rear of car and supporton safety stands 5. Removethe rear steeringactuatorcover.
in the properlocations(seesection 1).
NOTE: When the engineis OFF,the shaft screw of

the rearsteeringactuatoris held in the neutralposi-
tion (straightaheaddriving position)by the return
springtension.
CAUTION: Do not start the €ngin€ with the real

st€ering lock pin set in lhe roal stoering actuator. lf
the ste€ring whsal is tumed with the engina runn-
ing, the rear 6te€ringactuator will oporate, damag-
ing th€ rear stoering actuator.
2 . Remove the cotter pin from the castel nut and

removethe nut.
Installa 12 mm hex nut on the ball joint. Be sure

that the 12 mm hex nut is tlush with the ball joint
pin end. or the threadedsectionot the balljoint pin
NOTE: Removethe ball joint using the Ball Joint

Remover.Referto page 18-13 for how to use the REARSTEERING
ACTUATOR
COVER
ball joint .emover.
Separatethe tie-rodballjoint and knuckleusingthe 6. Disconnectthe ground cable connectorsand ter-

specialtool. minalsfrom the rear steeringactuator.
CAUTION: Avoid damaging th6 ball ioint boot.

12 mm HEXNUT
3.P CONNECTOR
TERMINALNUTS
NOTE: Do not contaminatethe terminal bolt and

nut with grease.Cleanthem if necessary.
17-138
7. Removethe rearsteeringactuatorby removingthe
four mountingbolts and bracket.
MOUNTINGERACKET
MOUNNNG AOLTS
17-13!l
Disassembly
1. Removethe tie-rod ends, 3. Using a soft hammer,drive in th€ sp€cialtool be-

tween the actuator housing and stopper washer
with the flat side of the specialtool toward the
housing.
4. Straightenthe tie-rod lock washer.
TIE.RODEND
RACKHOLDER LOCKWASHER
O7NA8-SSOo1OO Reolace.
Removethe boot bands and tube clamDs.Pullthe 5. Hold the shaft screw end with the spscialtool and
boots awav trom the ends ot the rack end. unscrewthe rack end with a wrench,
RACKEND
TUBE CLAMP
6. Removethe specialtool.
17-140
Assembly
7 . Removethe rearsub steetinganglesensorfrom the 1 . Installthe locknut on the rear sub steeringangle
actuatorhousing. sensor,then greasea new O-ringand installit.
Screw the rear sub steeringangle sensorinto the

actuator housingfully by hand, back it off about
REARSUB STEERING 1/2 turn, and looselytighten the locknut.
ANGLE SENSOR
REARSUBSTEERIITG
AI{GLESENSOR
Screw in the resr sub stgering

angle sonsor until se6ted, thgn
back it oft about 1/2 turn.
LOCKNUT
ACTUATOR HOUSING
LOCKl{UT
8. Removethe rear main steeringangle sensorfrom

the actuatorhousing.
ACTUATOR HOUSII{G
REARMAIN STEERING
NOTE: Adiust the rear sub steeringangle sensor
(seepage 1 7-155) after instsllingthe rear steering
actuatoron the car.
CAUTION: Aftor disassembly, attach a pioco of

tape or equivalent materialon each port andioint ot
tho r6ar stooring actuator to protoct it trom dust.
dirt, and foraign matoriala. {coltl c
17-117
Assembly(cont'd)
3. Greasea new O-ringand installit in the .ear main 5 . Using a soft hammer, drive the special tool be-
steering angl€ sensor, then install the rear main tween the housing and stopper washer with the
steeringangle sensor. tlat side of the specialtool toward the housing.
REARMAIN STEERING o. Tightonthe rack end securely,then bend the lock

ANGLE SENSOR washer back against the tlat on the flange as
snown.
TORXO EOLT
1O lt'm
{1.Oks-m, 7 lb-ttl ACTUATOR HOUSING
-611
o-Rrr{G
DOWEL PINS
55 N.m
15.5kg-m,rto lb-ftl
CAUTION:
a Tako exfiomo car6 not to apply axisl impact and
fotational tolc€ on the shaft screw.
Screw each rack end into the shaft screw while a S€t th€ projoction ot the lock washer in the
holdingthe lock washerso lts tabs are in the slots groove in the lack securely. After tightoning the
the shaft screw end. rack ond, bend th6 tabs of ths washer sgainst
the tlats secur€ly.
NOTE: Install the stopDer washer with the
chamferedside tacing out. 7 . Removethe specialtool,
8 . Apply greaseto the circumferenceof the rack end

STOPPERWASHER housing.
o Coat the rack end groove and insideot the boot

with siliconegrease.
:-
GREASE
Coar the sliding
surtace of the rack
end.
BOOT
TUBE CLAMP
17-142
1O. lnstallnew boot bands, 11. Installthe right and left tie-rod ends on the right
and lsft rack ends.
- Installthe boot band so that th€ lockingtabs oJ
the band (stake points) are in the range shown
below.
{Tabsshouldface up and slightlyforward.)
LOCKING
TABS
RIGHT SOOT BAI{D
Front lr
LEFTBOOT
Th€ locking tsbs

(stake points)
should bs in this
range.
The locking tsbs (stske

points) should be in this
ran9e.
- Install new boot bands on the boot and bend

both sets of locking tabs.
- Lightly tap on the doubled-overponions

reducetheir height,
CAUTION:
a Siako tho band locking tabs firmly.
a Whan staking, bo careful not to damago the
boot.
LOCKINGTAB{i
17-14:l
lnstallation
Installthe rear steeringactuator with four mount- NOTE: Do not contaminatethe terminal bolt 8nd
ing bolts and bracket. nut with grease.Cleanthem iJ necessary.
NOTE: Installthe bolts looselyfirst, then tighten Connect the ground cable, connectots and ler'
them. minalsto the rear steeringactuator.
NOTE: Be surethe wires are not caughto. pinched

MOUNTINGCUSHION
by any parts.
,-9
II MOUNTINGSRACKET
The arrow on the
44 N.m bracketpoint up.
(4.4 kg-m, 32 lb-ft)
39 N.m (3.9 kg-m,28 lb-ft|
2. Reconnectthe tie-rod ends to the rear steering

knuckles,tightenthe castlenut to the specifiedtor
que, and installnew cotter Pins.
CAUTION: Torquethe castls nut to the lower tol-

que specitication, then tighten it only tar enough to
align the slot with the pin hole. Do not align the nut
by loosening.
4. Adjustthe rearsub steeringanglesensor(seepage
1 7 - 15 5 1 .
CASTLENUT
50-60 N'm NOTE:
l5.O-6.0 kg-m,
36-43 lb-ft} a Be sure that the tront sub steeringanglesensor
and front main steering angle sensor are in
neutral8nd the steeringwheel is in the sttaight
aheaddrivingposition,
a Bs sur€ that the rear steeringlock pin {special
tool) is set in the rear actuator.
lnstalltheterminalcover and rearsteerlngactuator

COTTERPIN cover,
On reassembly,bend
lhe cotter pin as shown,
TIE-RODEND
17-144;
4WS ControlUnit Tie-rod End Boot
Removaland Installation Replacement
1 . Removethe rear seat back {seesection 20}. Removethe boot.
, Disconnectthe terminalwires and connectorsf.om 2 . Packthe interiorof the boot and lip with grease.
the 4WS control unit.
Wipe the greaseoff the slidingsurfaceof the ball
Removethe 4WS control unit. pin, then pack the lower area with lresh grease.
CAUTION:
a Koep groase otl the boot installation s€ction and
UNIT
4WS CONTROL th6 tapersd section of the ball pin.
a Do not sllow dust, din, or othar foreign
mat€rials to onter the boot.
-\P
BOOT INSTALLATTON
SECTION
and
BALL PIN TAPERED
SECTION
BLK wire. 4. Installthe new balljolnt boot usingthe specialtool

as shown below.
7 N.m lO.7 kg-m, 5 lb-lt)
NOTE: After driving the boot onto the ball joint,
apply sealantbetweenthe tie-rod end and boot.
REDwire.
BRNwire.
TIE.RODEND
4. Installin the reverseorderof removal.

CAUTION: After installing the boot, check the ball
NOTE: Turn the ignitionswitch ON and check the pin tapered section fol grease contamination and
4WS indicatorlight operation. wipe it if necossary.
17-145
4WS System Inspection
ElectronicNeutral Gheck
Preparation NOTE: The sDecificationsare the measurements

on the outer circumferenceof the steeringwheel.
NOTE:
a lf the power of the 4WS control unit was shut
down tor the following operations,start the
engine and turn the steering wheel lully right
and left.
- Batteryremoval/installation
- 4WS control unit removal/installation a18 mm l!0.7 inl Florn
- N o . 4 3 f u s e C L O C KR A D I Or e m o v a l{ i n t h e MARK
CENTER
under-hoodfuse/relaybox) a9 mm 110.4inl From
MARK
CENTER
a Before performingthe electronicneutralcheck
on the 4WS system check the following items.
Be surethat the steeringwheelspokeangleis
at the designatedanglewhile drivingstraight
aneao.
- Be sure that the rear wheels are not steered
to the right or left, but in the straight ahead
drivingposition,
Jack up the car and placethe tour wheelsslowly in

the ceriterof the lurning radiusgaugeturn tables.
Placea pieceof maskingtape or equivalentapprox-

imately 3OOmm {12.O in) long on the top edge of
the steering wheel. Place a mark on the tape at
each of the following measurements:
a Center (highestpoint of the steeringwheel).
a 9 mm {O.4 in) right and lell oI center (Forfront
main steeringanglesensor).
a 18 mm {O.7in) right and left of center(Fortront Fashiona pieceof stift wire (coathanger)and place
sub steeringangle sensoradjustment). it on top of the dashboard.Positionthe wire so the
a 55 mm (2.2 in) right and left of center(Forfront indicatingtip is closeto the marks on the steering
sub steeringangle sensorinspection). wheel and tape the wire down securely.
4. Set the steeringwheel in the straightaheaddriving

positionand set the wire at the centermark on the
steeringwheel.
17-146
5. Take out the service check connector (BLU 2P) Front sonsors insoection:
trom behind the center console.Connect the ter- 7. Checkthe front main steeringanglesensorwith the
minals with a piece ot jumper wire. ignitionswitch on (engineoff),
- From the straight ahead driving position, turn
NOTE: the steering wheel to the left, then turn the
a The 4WS indicator light will not indicate that steering wheel slowly to the right beyond the
sensorsare in the neutralpositionwhen display- straight aheaddriving position.Do not turn the
ing stored problemcodes. steeringwheel inversely.
a Check and verify any problemcodes displayed - Turn the steeringwheel to the left, then turn to
beforecheckingthe neutralposition. the right beyondthe straightaheaddrivingposi-
tion. Repeatthis operation severaltimes until
vou tind the position where the 4WS indicator
light starts to come on steady.
4WS INDICATOR
LIGHT
t
' -Br
'11\
,r9 mm (t0.4 in/:!3of -: --=- rll !

F.omCENTER MARK
JUMPERWIRE SERVICECHECK
CONNECTONIBLU 2P}
!1i
o- Pullup the parkingbrakeleverfully and turn the ig-

nition switch on (engineoff) to turn the parking
brske indicatorlight on. This sets the front sensors
in the insoectionmode.
The 4WS indicatorlight should start to come on

within the rangeof i9 mm (1O,4 in/a3") from the
center mark on the steeringwheel.
NOTE;
a The 4WS indicator light might look as if it is
blinkingat a point nearthe ends of the specilied
range.
a To determinethat the 4WS indicatorlight is oo
and not blinking,be surethat the 4WS indicator
light stays on for more than 2 seconds.
- Adjust the 4WS system if the indicatorlight
startsto come on at a ooint outsidethe mark-
ed range on the steering wheel (see page
17-151l.
(cont'd)
17-147
ElectronicNeutral Check (cont'd)
8. Checkthe front sub steeringanglesensorwith the Rsal sgnsols insDection:
ignitionswitch on {engineoff), 9. Releasethe parkingbrakeleverfully to turn off the
- From the slraight ahead driving position. turn parkingbrakeindicatorlight. This sets the rearsen-
the steeringwheelto the right,then turn it slow- sors in the insDectionmode.
ly to the left beyond the straight aheaddriving
position. Do not turn the steering wheel
inversely.
- Turn the steeringwheelto the right,then turn to
the left beyondthe straightaheaddriving posi-
tion. Repeatthis operationseveraltimes until
you find the centerpoint of the rangewhere the
4WS indicatorlight blinks(at the intervalsof O.2
seconds).
4WS INDICATORLIGHT
'I
O. Turn the ignitionswitch off.
1 1 .Removethe cap bolt and sealingwasher from the

rear steeringactuator.and screw the specialtool
into the rear steeringactuatoras far as it will go.
NOTE: Do not start the engine with the special

tool set in the rear steeringactuator.
The centerpoint shouldbe within the rangeof t55

mm l!2.2 ini11 6,50 ) from the centermark on the
steeringwheel. After adjustingthe front sub steer-
ing anglesensor,however,the centerpoint should
b e w i t h i n t h e r a n g eo f 1 1 8 m m ( 1 0 . 7 i n / 1 5 . 5 " )
from the center mark.
- It the center point is outsidethe markedrange

on the steeringwheel. adjustthe front sub steer-
ing anglesensor(see page 17-153).
17-148
'12.
Set the steeringwheel in the straightaheaddriving 14. Set the steeringwheel in the straightahesddriving
positionto preventthe rearwheelsfrom steeringif positionto preventthe rearwheelsfrom steeringit
the engineis started in error. the engineis startedin error.
13. Turn the ignition switch on (engineoff) to check 15. Turn the ignitionswitch on (engineoff) and check
the rear sub steeringanglesensor. the rear main steeringanglesensor.
- Push the rea. left wheel fully to the .ight by - Pushthe rearleft wheel fully to the left by hand,
hand, then push it slowlv to the lett. then push it slowly to the right.
- The 4WS indicatorlight shouldblink at intervals - The 4WS indicatorlight should turn ON when
of O.2 secondswhen the rearwheel is oushedto the rear wheel is pushedto the right.
the lett.
. 4WS INDICATOR
4WS If{DICATORLIGHT
ra,.!?.' " """""ffi--- uear
1_.-1) 1
REARLEFTWHEEL
TURNTO LEFT TURN TO RIGHT
Froni Front
NOTE: The 4WS indicatorlight blinks in a narrow NOTE:

range.Take care not to overlookit a The 4WS indicator light turns on in a narrow
range.Take care not to overlookit.
- lf the 4WS indicatorlight does not blink, adjust o The 4WS indicator light might look as it it is
the rear sub steering angle sensor (see page blinking at a point near the ends oI the range
1 7 - l5 5 ) . where the light is on.
a To determinethat the 4WS indicatorljght is nor
blinking. be sure that the 4WS indicator lighr
stays on tor more than 2 seconds.
a lf the 4WS indicator light does not turn on,
removethe rear main steeringanglesensorand
check it for damage.
17-149
ElectronicNeutral Check {cont'd)
16. Turn the ignitionswitch oJt.
17. Removethe specialtool from the lear steeringac-

tuator, and installthe cap bolt and the new sealang
washer on the rear steering actuator'
REARSTEERII{G
ACTUATOR
18. Removethe jumper wire from th€ ssrvice check
connectorterminals{BLU 2P).
19. Returnthe connectorbehindthe center console.
20. Reinstallthe removedparts.
17-150
4WS System Adjustment
Adjust the 4WS system usingthe followingprocedure, a Check whether the yellow paint mark ot the
tront main stseringangle sensorrotor is facing
NOTE; down (i.e. in neutral lock position where the
a lf the Dower ot the 4WS control unit was shut rotor does not turnl. This indicatesthat the front
down for the Jollowing operations,start the main steering angle sensor is electronicallyin
engine and turn the steeringwheel tully right neutral.
and left.
- Battery removal/installation NOTE: lf the paint mark is not facing down, adjust
- 4WS control unit removal/installation as instructedin step 5, (1) through (3) on page
- N o . 4 3 f u s e C L O C KR A D I Or e m o v s l{ i n t h e 't7 -87
.
under-hoodfuse/relavbox)
FRONTMAIN STEERING
1, Jack up the car and placethe wheelin the centerof
the turning radiusgaugeturn tables.
a Installthe steeringwheel, aligningit with the

serrationwhich makes the spoke angle closest
to horizontal.
- lf the spokeangleis not horizontal,adjustthe
RADIUS
TURNING GAUGE steering wheel slightly right or left. being
TURNTABLE careful not to push in on the steeringwheel.
Set the steeringwheelso that it is positionedin the
WHEELNUT
STEERING
centerof the rangewhere the steeringwheelturns
5ON.m
fully to the right and left. (This centers the tront {5.0 ks-m, 36 lb-ft)
steeringrack.l
lf the steering wheel spoke angle is not at the

designatedanglewith the steeringwheel set in the
positionexplainedin step 2. adjustthe tront main
steeringanglesensorand spoke angleas follows.
a Set the steeringwheelin the straightaheaddriv-
ing position,then removeit.
STEERINGWHEEL a With the spoke angle set at horizontal,then

push the steeringwheel in fully.
Tighten the steefing wheel nut while pushing
the steeringwheel in.
NOTE:
a Do not removethe steeringwheel until adjust-
ment is completed.
a Do not turn the steeringwheel when pushing
the steeringwheel.
tcont c
17-151
4WS System Adjustment (cont'd)
4. Be sure that the rear wheels are not steeredto the Checkthe sub and main steeringanglesensorsus-
right or left, but in the straight ahead driving ing the table shown below (seepage 17-146).
Dosition,
NOTE:
a Turn the ignition switch on (engine off ) to
check.
a The 4WS indicatorlight does not indicatethe
electronicneutralpositionwhen it is indicating
problemcodes.
a Check the sensors by turning the specified
wheel in the specifieddirection shown in the
table below, The sensorsare adiustedproperlyif
the 4wS indicatorlight turns on in the specilied
range on the steeringwheel, or if the center ot
the rangewhere the 4WS indicatorlight blinksis
Take out the service check connector (BLU 2P) within the specifiedrangeon the steeringwheel.
trom behind the center console.Connectthe ter-
Sensor Parkingbrake lever
minalswith a pieceof jumper wire. Check
type l Pull *2 Release
Frontmain
steering Turn front .2 0N
angre wheelsto right
sensor
Front sub
steering Turn front *3 Blinks
angle wheels to left
sensor
Rearsub '4 Turn rear
steering '3 Blinks
wheelsto
angle
lefl
sensor
Flearmain *4 Turn rear
steering *2 Blinks
wheelsto
angle
ngnt
sensor
*'1:Be sure that the parking brake indicatorlight operates
properly.
'2: The 4WS indicatorlight might look as if it is blinkingat a
point near the ends oI the range where the light is ON.
*3: The 4WS indicator lighl blinks in the intervalsof O.2
seconds.When the indicatorlight is indicatingthe main
steeringanglesensorcondition{lightON),indicationot the
sub steeringanglesensorcondilionby blinkingis canceled.
*4: Turn the rear wheel slowly by hand with the specialtool
(rear steering center lock pin) sel in the rear steering
actuator,
17-152
Sub Steering Angle Sensor
Adjustment
7 . lf the sensors are not sdiusted properly. adjust Front Sub SteeringAngle Sensor
eacn sensof.
a It the front main steeringanglesensoris not ad- NOTE: Before adjusting the sub steering angle
iusted properly, start with the step 2. sensor. check that the front main steeringangle
a Front sub stee,ing angle sensor adiustment: see senso. is adjustedproperly(see page 17-146).
psge17-153.
a Rear sub steerlng angle sensor: see page 1. Jack up the ca. and raise all four wheels off the
17-155. ground.Placethe salety stands in the properloca-
tions to supportthe car (seesection 1).
NOTE: The rsar main steeringanglesensorcannot
be adjustsd.lf the rear main steeringangle sensor 2. Set the steeringwheel in the straightaheaddriving
is sbnormal,removeit and check it tor damage. oosttton.
3. Take out the service check connector (BLU 2P)

from behind the center console.Connect the ter-
minals with a piece of iumper wrre.
NOTE:
. The 4WS indicatorlight will not indicatethat the
sensors are in the electronic neutral oosition
when displaying stored Diagnostic Trouble
C o d e s( D T C ) .
a Check and verify problem codes displayed
betorecheckingthe electronicneutralposition.
4. Set the parking brake lever and turn the ignition

switch on {engineofl). Be sure that the parking
brakeindicatorlight turns on,
Turn the ignitionswitch oJf.
17-1!i :l
Sub SteeringAngle Sensol Adjustment (cont'd)
6. Cut the wi.e tie from the cover, then remove the 9, Turn the ignitionswitch on {engineoff).
cover Jromthe front sub steeringanglesensor.
10. Set the steeringwheel in the straightaheaddriving
CAUTION: Uso car6 whon cutting lhe wire tie so position.Set the front main steeringangle sensor
as not to cut into the wiro harnsss. electronicallyin neutral (4WS indicator light is
blinking)this time.
7, Removethe sensor wire harnessfrom the clamp
and disconnectthe connector. NOTE: Hold the steeringwheel in this positionun-
til adjustmentis completed,lJ the steeringwheel is
moved in effor. repeat the adjustment procedure
starting with step 10.
CONI{ECTOR
COVER
/w
" \ '
WIRETIE
R6place.
11. Turn the front sub steering angle sensor slowly

clockwise. and check the range Jrom where the
4WS indicatorlight startsto blinkto where it stops.
12. Loosenthe front sub steeringanglesensor.Repeat

the step 11 severaltimes to set the sub steering
anglesensorin the centerof the rangefrom where
Loosenthe locknut. Tighten the locknut fully by the 4WS indicatorlight starts to blink to where it
hand, back it off about 3/4 turns and connectthe srops.
connector. ] CENTER
LIGHT STABTS
TO BLINK LIGHT OFF
FRONTSUB STEERING
LOCKf{UT ANGLE SEIISOR
TURNINGDIRECTIOI{
NOTE:
a Turn the front sub steering angle sensor
clockwiseto makethe 4wS indicatorlight blink.
a lf the sub steeringangle sensorwire is twisted
excessively,turn the ignitionswitch ott, discon-
nect the connector,and straightenthe wire.
17-154
13. Tighten the locknut while holding the front sub RearSub SteeringAngle Sensor
steefingangle sensorwith a wrencn.
1. Jack up the car and raise all four wheels off the
NOTE: Take carenot to turn the tront sub steerino ground.Placethe safety slands in the properloca-
angle sensor. tions to supportthe car (see section 1).
LOCKNUT FRONTSUB STEERING 2. Take out the service check connector (BLU 2Pl
25 N'm 12.5 kg-m, ANGLE SENSOR
from behind the center console.Connect the ter-
18 tb-ftl
minalswith a pieceof jumper wire.
NOTE:
a The 4WS indicatorlight will not indicatethat the
sensor is in electronic neutral oosition, when
displaying stored Diagnostic Trouble Codes
(DTC).
a Check and verify problem codes displaved
SENSOR beforecheckingthe electricallyneutralposition.
WIREHARNESS
'I
4. Disconnectthe front sub steeringanglesensorcon-
nector to straightenthe sensorwire harness.
Reconnectthe connecior.
NOTE: Do not contaminatethe front sub steering

angle sensor connector terminals with mud, oil,
and grease.
'15.
Check that each sensoris electronicallvin neutral
{ s e ep a g e 1 7 - 1 4 6 ) .
NOTE: Be sure that the centerof the rangewhere

the 4WS indicatortighr btinks (indicatingthat the JUMPERWIRE
front sub steeringangle sensoris electronicaltyin
n e u t r a l l ,i s i n t h e r a n g e : t 1 8 m m ( a 0 . 7 i n / r s . 5 0 )
from the center mark on the steeringwheel.
t(rir' 3 . Releasethe parkingbrakeleverfully and turn the ig-
i18 mm lao.7 in) Frorn ///{\ nition switch on (engineotf). Be surethat the park-
CENTERMARK ' ' . . ing brake indicatorlight goes olt.
4. Turn the ignitionswitch off.
PARKINGBLAKE LEVER
16, Reconnectthe connectorand securethe sub steer-

ing angle sensorwire harnesswith the clamp and
installthe cover.
NOTE:
a Be sure the sensor wire harnessdoes not in-
terferewith the stabilizeror other movingparts.
a Be certain that the wire is not twisted before
connectingit.
17. Securethe cover with a new wire tie. (cont'd)
17-155
Sub SteeringAngle SensorAdjustment lcont'dl
Removethe fear steeringactuatorcover 9. Set the steering wheel in the strsight ahead driving
position to prevent the rear wheels trom steering if
o. Remove the cap bolt and sealing washer from the the engineis startedin error.
rear steeringactuator.Sc.ew the specialtool in as
far as it will go. 1O. Turn the ignitionswitch on (engineotf).
SEALIT{GWASHER 11. Push the rear left wheel tully to the left by hand,
then push it slowly to the right to turn the 4WS in-
dicatorlight on (i.e..ear main stee.inganglesensor
is electronicallvin neutral).
REARLEFTWHEEL
TURNTO
STEERING
LOCKPIN
CENTER
REAi STEERING
07NAJ-SSOO20A Frcnt
7. Remove the rear sub steering angle sensor wire

from the clamp and disconnectthe connector'
NOTE:
8. Loosen the locknut. Tighten the locknut tully by a The 4WS indicator light turns on in a natrow
'l12 turn and connect
hand, then bsck it oft about range.Do not ovetlookit.
the connector' a Work with ca.e so as not to move the real
wheels from this neuttal position.
LOCKNUT
17-156
12. Turn the ignitionswitch on {engineoff}. 16. Disconnectthe rear sub steeringanglesensorcon-
necto. to straighten the wire. Reconnect the
13. Turn the .ear sub steering angle sensor slowly connector.
counterclockwise,
and checkthe rangelrom where
the 4WS indicstorlight starts to blink. to where it NOTE: Do not contaminatethe rear sub steering
srops. angle sensor connector terminals with mud, oil,
ano grease.
14. Tightenthe rear sub steeringangle sensora little.
Repeatthe step l3 severaltimes to set the sub 17. Checkthat each sensoris electronicin neutral(see
steering angle sensor in the center of the range p a g e1 7 - 1 4 6 ) .
from where the 4WS indicatorlight starts to blink,
to where it stops. I CEIITER 18. Turn the igntion switch olf. Removethe special
LrcHToFF I tool from the rear steeringactuator,and installthe
cap bolt and the new sealingwasher on the reat
LIGHT STARTS steeringactuator.
TO BLII{K
TURI{ING 19, Installthe rear steeringactuatorcover.

DIRECTION
CAPBOLT SEALINGWASHER
22 N.m
{2.2 kg-m,16 lb-ft)
NOTE:
a Turn the rear sub steering angle sensor
counterclockwiseto make the 4WS indicator
light blink.
a lf the rear sub steering angle sensor wire is REARSTEERING
twist€d excessively,turn the ignitionswitch off, ACTUATOR
disconnectthe connector, and straightenthe
REARSTEERINGCENTERLOCK PIN
15. Tighten the locknut while holding the rear sub 07NAJ-SSOO20A
steeringangle sensorwith a wrench.
NOTE: Take care not to turn the rearsub steering

angle sensor.
REARSUB STEERING
ANGLESEI{SOR
Suspension
SpecialTools ......... 18-2 Front Damper
ComponentLocation Removaf .............18-22
l n d e x. . . . . . . . . . . . . .... 18-3 Disassembly/lnspection .............. 1A-22
Wheel Alignment Reassembly ........ 18-24
S e r v i c e1 n f o r m a t i o n , , , . . . . . . . . . . .1. .8.-, 4, lnstallation ......... 18-25
Camber . . . . . . . . . . . . .1. 8 - 5 Rear Suspension
C a s t o r. . . . . . . . . . . . .... 18-5 Torque Specifications ................ 18-26
Front Toe Inspection/ Knuckle/Hub
Adjustment ..... 18-6 llfustratedIndex ..................... 1A-27
RearToe Inspection/ Removal ......... 18-28
Adjustment ..... 18-7 lnstallation ...... 18-31
Turning Angle Inspection/ Suspension Arms
Adjustment ..... 18-8 Removal/lnspection ................18-33
Wheel Measurements Installation ...... 18-34
B e a r i n gE n d P l a y. . . . . . . . . . . . . . . . . . . .1. .8. - 9 BallJointBootReplacement ......... 18-35
R u n o u t. . . . . . . . . . . .... 18-9 LowerArm BushingReplacement .... 18-35
Front Suspension Rear Damper
Torque Specifications ................18-10 Removal .......... 18'36
Knuckle/Hub Disassembly .... 18-37
lllustrated I n d e x. . . . . . . . . . . . . . . . . . 1
. .8. - 11 Inspection ....... 18-37
Removal . . . . . . . . .1 8 - 1 2 Reassembly ..... 18-39
Hub Unit and Wheel Bearing lnstallation ...... 18-40
Replacement ... 18-15 D a m p e rD i s p o s a.l. . . . . . . . . . . . . . . . . . .1. .8. - 4 1
lnstallation ...... 18-17
Suspension Arms
Removal/lnspection ................18-19
lnstallation ...... 18-20
Ball Joint Boot Replacement....... 18-21
Lowerarm BushingReplacement .... 18-21
SpecialTools
Rcf. No. I Tool Number Desc ption O'ty I Pag. Refcrcnce
o oTGAF-SD40700 Hub Dis/Ass€mblyBase

Hub Dis/AssemblyTool
2
r
1A-'t5
1 8 - 1 5 1, 6 , 1 7
@ oTGAF-SEOo100
oTGAF-SEOO200 Hub Assembly Guide Attachment 1 L18-17
07GAG-SD40700 Ball Joint Boot CliDGuide 1 | 1 8 - 2 13, 5
@
@ oTHAD-SG00100 Driver Attachment r I ra-ro
07MAC-5100100 Ball Joint Remover,32 mm 1 | 18-14,30
@
@ oTMAC-S100200 Ball Joint Remover,28 mm r I ra-ra,14,so,36
@ oTNAD-SS00100 BushingDriver 1 | 1 8 - 2 1 .3 5
@ 07746-OO10500 Attachment, 62 x 68 mm r I rg-rs
@ 07749-0010000 Driver r Jr1 8e- -1 r6 ,sr1 7e,
o 07965-SD90100 support Base
BallJoint Boot Clio Guide
1
1 I 1 8 - 2 1 ,3 5
@ 07974-SA50800
I 6
H F1
{--ru
:,.--l
| l
tr I(J v
/ \
o @ @ @@
/-]
l , r a l
V
---G-1
F N
W @
@ @o @ @
n
hJ
w
H
l_,
@ @
8-2
Component Location
lndex
@ The tront and real dampe.s contain nitrogon gas and oil undor presauro,The prsssuro must be raliov€d
betore disposal to provent oxplosion and possiblo iniury whon scrapping.
Wheel Alignment,page 18-4
Front Suspension: FROI{T UPPERARM

. Removal/lnspection, page 'l8-19
. Installation,page 18-2O
FRONTDAMPER
. Removal, page 18-22
. Disassembly/lnspection, page 18 22
. Reassembly,page 18-24 STABIUZER BAR
. Removal/lnspection,
page18-19
. Installstion,page 18-25 . Installation,
page18-20
. Disposal,page 'l8-41
FBOI{T KNUCKLE/HUB
. Removal,page 18-12
FRONTLOWERARM . BearingReplacement, Page 18-15
. Removal/lnspection, page 18-19 . lnstallation,page 18-17
. Installation,page 18-20
t l /
RADIUSROD ,/
. Removal/lnspection.
p6ge18-19
. Installation,
page18-20
Roar Suspension:
BEAR UPPERARM
REAR OAMPER . Removal/lnspection,page 18-33
. Removal,page 18-36 . Installation.page 18-34
. Disassembly,page 18-37
. Inspection,pago 18-37
. Reassembly, page 18-39
. Installation,page 18-40 REARKNUCKLE/HUB
. Oisposal,page 18-41 . Removal, page18-28
. Installation,
pago18-31
REAR LOWEA ARM

. Removal/lnspection, Page 18-33
TRAILINGARM
. Removal/lnspection,page '18-33
1&3
Wheel Alignment
Service Information
NOTE: For proper inspection/adjustment of the wheel
alignment, check and adiust the following before check-
ing the alignment.
a Check that the suspension is not modified.

a Check the tire size and tire pressure
a Check the runout oJ the wheels and tires.
a Checkthe suspensionballjoints. (Holda wheel with
your hands and move it up and down and right and
left to check for wobbling.)
wheel alignment adjustment procedure Adiust cambet

Each of the wheel alignment elements relates to the
other, Theretore, the total adjustment of the lront/rea.
wheel alignmentis requiredwhenevereitherone of €le- Adiust caster
ments (i.e.camber.caster.toe, snd/orturningangle)is
adiusted.
Adiust toe
Adiust turning angle
R€adjust camber
Read,ustcaster
Roadiusttoe
Readjustturning angle
18 -4
Camber Caster
lnsp6ction Inspection
NOTE: Use commerciallyavailablecomputerizedfour ;ommerciallyavsilablecomputerizedfour

NOTE: Use commercially
wheel alignmentequipmentto measurewheel alignment wheel alignment equipmentto measurewheel alignment
ent equipmer
(i.e. caster, camber,toe, and/orturning anolel. Follow (i.e. caster, camber,
ramber,toe, and/orturning angle).Follow
the equipment manufacturer's instructions. the equipment manufacturer'sinstructions.
rt manufact!
1. Check the tire pressure. 1. Turn the front wheels to the straight aheadposition.
2. Turn the Jront wheels to the straight ahead position. Check the
te caster angle.
3. Check the camber angle. ngl€: 20,

Caster angl€: 2o4O' 1 1"
Cambel angle, Front: 0oO0' t 10 ll adjustment required,recordthe casterreading,

nent is r€
Roar: -Oo45't 10 (2WSl then go too step 4
4, lf adjustment is not required, re-
-oo45' r 30' (4ws) gnment(equipment.
move alignment
4. Front: lf out of specitication.check for damagedsus- :aster an

NOTE: Caster angle can be adjusted by increas-
pensroncomponents. ing/decreasing
lasingththe numberol the sdjustingshims.
install the radius rod each time the
Remove and inst
Rear (2wsl: lJ out oJ specification, ch€ck for rgle is a(
caster angle adjusted.
damagedsuspensioncomponents.
4. end of the car and placesafety stands
Raisethe front en(
(4WSl: - lf adiustment is requared,go to step in the proper locations(see section 1).
oper locr
- i no adjustmentis required,remove 5. Removethe selfiocking nut on the end of the radius

the selfi(
alignmentequipment. rod.
Rear Camber Adjustment (4WSl b. radiusrod attachingbolts at the lower

Removethe radiu
5, Hold the adiustingbolt and loosenthe self-locking arm, then removethe radiusrod (page 18-19).
n remov{
nut.
Adiust the
e caster angle by increasing/decreasing
the
o. Adjust the rear camber by turning the adjusting bolt adjustingI shims.
shims.
until camberis co.rect.
- One adjusting
djustingshim changesthe casterangle by
7. Installthe new self-lockingnut and tighten while 40' and caster anglecan be adjustedby I o20'
d the cas
holdingthe adjustingbolt. maxtmum.
- One adjusting s h i m i s 3 . 2 m m ( O . 13 i n l i n
thickness.
ADJUSTING SHIM
BADIUS ROO
SELF.LOCKING NUT
55 N'm {5.5 kg-m,!
Replac€.
SELF.LOCKIIIGNUT
12 x 1.25mm
Rgplace.
NOTE:
65 N.m 16.5 kg-m, use more than two adjustingshims.
a Do not ul
47 tb-ft} ADJUSThIG BOLT re adjustment. tighten the self-lockingnur
a After the
speci{ied torque.
to the sD
18€
Wheel Alignment
Front Toe Inspection/Adiustment
NOTE: Use commerciallyavailablecomputerizedfour Loosenthe tie-rod locknutsand turn both tie-rods
wheelalignmentequipmentto measurewheelalignment in the same directionuntil the lront wheels are in
{i.e. caster,camber,toe. 8nd/or turning angle),Follow straightaheadposition.
the equipmentmanufacturer'sinstructions.
Turn both tie-rodsequallyuntil the toe is correct.
1. Check the tire pressure.
6. After adjusting,tighten the tie-rod locknuts.
2. 2WS: Set the tront wheels to the straight ahead
posation. NOTE: Repositionthe tie-rod boot if it is twisted or
4WS: Set the front main steering angle sensor in displaced.
the neutral position and jump the service check con-
nector to turn the 4WS indicator ON (see page
1 7 - 15 6 ) .
NOTE:Maintainthis conditionduringinspectionand TIE-RODLOCKNUT

adjustment. 14 r 1.5 mm
45 lrl'm {4.5 kg-m, 33 lb-ft) TIE.ROD
4WS INDICATOR
Check the lront toe.
Front toe: 0 t 2.O mm lO a O'O8in)
- lt adjustment is required, go on to step 5. ,
- lf no adjustment is required. remove alignment

equipment.
8-6
RearToe Inspection/Adjustment
NOTE: Use commercially available computerized tour 4. 2WS:
wheel alignmentequipmentto measurewhe6l alignment a Hold the sdjusting bolt on the rear lower arm B
(i.e. caster,camber,toe, and/or turning angle).Follow and loosen the self-locking nut.
the equipmentmanufactur€r'sinstructions.
a Adjust the rear toe by turning the adjusting bolt
1. 4WS only: Checkthe rear main steeringanglesen- until toe is correct.
sor is in the neutralpositionand jump the service
checkconnectorto turn the 4WS indicatorON (see a Installthe n€w self-lockingnut andtighten while
psge17-156). holdingthe adjustingbolt.
NOTE:Maintainthis conditionduring inspection.
4WS INDICATOR
4WS:
a Loosenthe tie-rod locknuts and turn both tie-rods
in the samedirectionuntil the rearwheelsare in
the straight ahead position.
NOTE: Make sure the 4WS indicatoris ON
Releaseparkingbrake. a Turn both tie-rods equally until the toe is cortect.
Check the rear toe. a After adjusting.tighten the tie-rod locknuts.
NOTE: NOTE:Rspositionthe tie-rodboot it it is twisted

a Measureditferencein toe measurementswith the or disDlaced,
wheels pointed st.aight ahead.
45 N.m (4.5 kg-m, 33 lb-ft|
o lf the parkingbrakeis engaged,you may get an
incorrectreading.
Reartoeln: 2.O ! 2.O mm (O.08r O.OBin)
- lf adjustment is required, go to step 4,
- lf no adjustmentis required,removealignment
equrpmenr.
TIE.ROD
1*7
Wheel Alignment
TurningAngle Inspection/Adjustment
NOTE: Use commercially available computerized four 4. It the measurementsare not within the specifica-
wheel alignmentequipmentto m€asurewheel alignment tions, adiust as required by turning the tie-rods.
(i.e. caster,camber,toa, and/orturning angle).Follow
the equipmentmanufacturer'sinstructions. NOTE:After adiusting, recheck the front wheel toe
and readiustif necessary.Repositionthe tie-rod boot
1, Jack up the tront of the car. Set the turningradius it twisted or displscad.
gaugesbeneaththe front wheels. then lower the car.
TIE-ROD LOCKNUT
2, 2WSt Jack up the rearof the car. Placeboardsthat 1 4 x 1 . 5m m
are the same thicknessas the turningradius 45 N.m (4.5 kg-m,33lb-ft) llE-ROD
gaugesunderthe rearwheels,then lower the
car.
4WS: Jack up the rear of the car. Set the turning
radiusgaugesbeneaththe reat wheels,then
lower the car.
NOTE:Foraccuratereadings.the car must be level.
3. Turn the wheel right and left while applying the

brake. Measure the tutning angle oJ both front
wheels, and both rear wheels (4WS models).
Front turning angl€:

lnwa.d whsol: 36o20' ! 2o
Outward whaol: 29o4O' (roloronca)
Raar tuming anglo (4WSlr

lnward wheel: 6000' 1 10
Outward whcsl: 6020' (.otoronce)
18-8
Wheel Measurements
Bearing End Play Runout
1. Raisethe car and support it with safety stands in the 1. Raisethe car and support it with safety stands in the
proper locations(seesection 1,. proper locations(see section I l.
2. Removethe wheels, then reinstallthe lug nuts. 2. Check tor b€nt or deformedwheels.
3. Attach the dial gauge as shown. 3. Attach the dial gauge as shown.
4. M€asurethe bearingend play by movingthe disc in 4. Measurethe wheel runout by tuming the wheel.
and out.
Front and Raar Wheel Axial Runout:
front wheol End Play:
Standard:
Standard:0-O.O5 mm {O-O.002 inl St6ol l|haol: 0- 1 .O mm (O-O.O4 in)
AluminumWhool: O-O.7 mm {0-0.03 in}
Se.vlce Limitr 2.O mm {0.O8 inl
Rear Who6l End PlsY: Front and Rear Wheel Radial Runout:
Standard:0-0.05 mm (0-0.002 in) St.ndard;

Stoel Whool: 0-1.0 mm (O-O'O4 inl
Aluminum Wh.ol: O-O'7 mm (O-O.O3 inl
Scrvico Limlt: 1.5 mm (0.06 inl
lf the bearingend play measurementis more than lf the wheel runout is more than the servicelimn
the standard,replacethe wheel bearing. reolacethe wheel.
1&9
Front Suspension
TorqueSpecifications
CAiJ-f€N,
a Reiface the s€lf-lockingnuts after rsmoval.
a Beplacotho solt-lockingbolts it you can aasily thlaad a non-soll-lockingnut past th6ir nylon locking lnsotts.
{lt shoub requir€ 1 N'm (0.1 kg-m. O.7 lb'ft) ot torqus to tuln thc nut on tho bolt}'
a The vehtg|es-houldb€ on th€ groundbeloreany bolts or nuta connoctedto rubbermountsor bushingaro tighten6d.
a Torqueihe castlenut to th€ low6r torquespocification.thon tighton lt only far onoughto aligntho slot with tho dn
holo. Do not align the nut by loosening.
NOTE:Wipe off the greaseb€loretighteningthe nut at the balljoint.
INSERT
SELF.LOCKIT{G NUT
1 0 x 1 . 2 5m m
30 N'm (3.0 kg-m,22 lb-ftl NUT
Replace.
1 0 x 1 . 2 5m m
SELF-LOCKII{G 1{UT 39 N'm 13.9kg-n. 28 lb-tt)
12 r 1.25 ]nm
65 ltl.m 16,5kg-m, 47 tb-ttl
Replace. CASTLENUT
lO r 1.25mm
SELF.LOCKII{G NUT 4O-48 N'm
1 0 x 1 . 2 5m m l4.O-4.8 kg-tn,29-35 lb-ft}
30 t{.m {3.0 ks-m, 22 lb-ftl
Reolace.
DAMPERNNC'.IEOLT
(SELF.LOCKII{G EOLTI
1 0 x 1 . 2 5m m
44 N.m 14.4kg-m,32 lb-ft}
SELF.LOCKII{G BOLT CASTLENUT
1 2 x 1 . 2 5m m 12 , 1,25rnft
55 N'm (5.5 kg-m, 50-6{, ]t.m 15.O-6.0 kg-m,
40 tb-ftl 36-43 tb-frl
t{ur
sPtt{Dt"E
SELF-LOCKING t{UT 24 x 1.5 mm
1 2 r 1 . 2 5m m 25ON'm (25 kg-m,
55 N.m(5.5kg-m, r81 tb-ft|
40 tb-ft) Raplacs.
Replace. NOTE:Aftsr tightoning,usoI drift to
nut ahouldsrag6rnst
stakgths apindlG
tho spindle.
SELF.LOCKI]TG BOLT
1 2 x 1 . 2 5m m
105 N.m(10,5 kg-m, DAMPB FORKt{UY
76 lb-ft {SELF.LOCKII{G NUTI
1 2 r 1 . 2 5m m
NUT 65 'm (6.5 kg-m,47 lb-ft)
SELF-LOCKING Beolace.
12 x '1.25
mm
55 N'm 15.5kg-m,40 lb-ttl CALIPER BRACKET
MOUNTINGBOLT CASTLCNUT
Replace. 1 2 x 1 . 2 5m m 14 r 2.o mm
11ON.m(11 ks-m,80 lb-ft| 50-60 I{'m{5.0-6.0 ks-m,
36-43 tb-ftt
18-10
Knuckle/Hub
lllustrated lnd6x
NOTE:
a Use only genuineHondawheel weights for aluminumwheels.Non-genuinewheel weights may corrode8nd damsge
the aluminumwheels.
a Before installing the brake disc, cleen the mating surfacas of the front hub and inside ot tbe brake disc.
a Beforeinstallingthe wheel, clean the mating surfacesof the brake disc and insideof the wheel.
K1{UCKIE KNUCKLEPROTECTOR
Checkfor dam8ge. Ch6cktor damage.
BOLT-WASHER
6 x 1 . Om m
10 N.m (1.Okg-m, 7 lb-ft)
K UCKLERING COTTERPIl{
Checkfor damag€, Roplace.
WHEEL AEARING
Replace.
psge 18-15
Replacament,
CIRCLIP
SPLASH GUARD
Check tor bending
or damage.
BALLJUNT EOOT
Checkfor doteiorstion
or damago.
CIRCLIP----"""i€)
:3J.'ff*.--.......€ SCREW
10 'm (1.0 kg-ft, 7lb-fil
FROI{THUB
Ch€ckfor d6mag6or
cracKs.
BRAKEDISC
Chsck for w6ar or rust.
Inspoction,soction 19
LUG UT
1 2 x 1 . 5m m
1 10 N.m 111 kg-rn, 80 b-trl
I lnm EnAKEDISC
RETAII{INGSCREW
10 'm (1.0 ks-m,7 lb-ft| atl a
1&t I
Front Suspension
Knuckle/Hub(cont'd)
Removal 7. Removethe 6 mm brake disc retainingscrews.
Loosenthe wheel nuts slightly. 8. Screwtwo 8 x 1 .25 mm bolts into the disc to push
it away from the hub.
Raisethe Jrontof car and supporton safety stands
in properlocations{seesection 1). NOTE:Turn each bolt two turns at a time to prevent
cockingthe disc excessively.
Removethe wheel lug nuts and front wheel.
9 . Removethe b.ake disc from the knuckle.
4. Raisethe lockingtab on the spindlenut. then remove
the nut.
x 1.25 mm BOLTS
6 mm SRAKEDISC
SCREWS
RETAINING
1 0 .Removethe wheel sensorwire bracket,then remove

the wheel sensorfrom the knuckle.
Removethe brake hose mounting bolts. NOTE:Do not disconnectthe wheel sensor wire.
6 . Removethe caliperbracket mounting bolts and hang

the csliperassemblyto one side.
CAUTION: To provont accidantal damago to the

calip€r assomblyor brako hos€. us€ a short piece ol
wire to hang lhe calipel sgombly from lhe und€r-
cariago.
CAIIP€R ARAO(ET MOUNTING BOLTS

12 r 1.25mm
18-12
NOTE:Use ballioint remover,to separatethe balljoints 1 6 .Once the tool is in place,turn the sdiustingbolt as
from the suspensionor steeringarm. necessaryto make the jaws parallel.Then hand-
tighten the pressurebolt and recheckthe iaws to
CAUTION: B€ calotul not to damEgothe ball ioint boot' make sure they are still parallel.
1 1. Cleanany dirt or greaseotf the ball joint.
12. Apply greaseto the specialtoolon the areasshown.

This will esse installationot the tool and prevent
damageto the pressurebolt threads.
Apply greasehere. PRESSURE

BOLT
BoLT
ADJUSTING
13. Removethe cotter pin Jromthe steering arm and re-
move the nut. ;i
14. lnstalla 12 mm hex nut on the balljoint. Besurethat

the hex nut is flush with the balljointpin end to pre-
vent damageto the threadedend of the ball joint. 1 7 . With a w.ench, tighten the pressurebolt until the
ball joint shaft pops loose from the steeringarm.
15. Use the ball ioint removeras shown.
Insert the jaws carefully,making sure you do not l!@ w6ar eye protsction. The ball ioint
damagethe ball joint boot. Adjust the iaw spacing can brsak loose suddenly and scatto. dirt or othgl
by turning the pressurebolt. debris in your oyos.
NOTE:It necessary,apply penetratingtype lub.icant 1 8 . Removethe tool. then removethe nut lrom the end
to loosenthe ball joint. of the ballioint and pullthe balljoint out ol the steer-
jng/suspension arm. Inspectthe ball ioint boot and
replaceit if damaged.
12 mm HEX
{cont c
1&13
Front Suspension
(cont'dl
Knuckle/Hub
19. R€movethe cotter pin and lowef arm balljoint nut. 22. Remove the knuckle protector,
20. Installa 14 mm hex nut on the balljoint.Be surethat 23. Removethe cotter pin and the upper balljoint nut.
the hex nut is flush with the ballioint pin end, or the
thresded section of the ball joint pin might be 24. Installa 1O mm hex nut on the ball joint.
damagedby the ball joint remover. Be sure that the hex nut is tlush with the ballioint
pin end, or the threadedsectionot the balljoint pin
21. Use the balljoint .emoveras shown on page 18-13 might be damagedby the ball joint.emover.
to separatethe ball ioint and lower arm-
25. Use the balljoint removeras shown on page 18-13
NOTE:lf necess8ry,apply penetr€tingtype lubricant to separatethe ball joint and knuckle.
to loosenthe ball ioint.
NOTE:lJ necessary,apply penetrstingtype lubricant
to loosenthe ball joint.
BA1I JOIITT
oTMAC-StOO200
1..
\ r',
10 mm HEx NUT
CASTLE
BAI.I JOINT 10 x 1.25 ]nln COTTER PII{
REMOVER,32 mm R€place,
07MAC-SLOOTO0 26. Pulltheknuckleoutwa,d and removethe driveshaft
outboardjoint Jromthe knuckleusinga plasticham-
mer. then removethe knuckle.
KNUCKLE
18-14
Hub Unit and Wheel BearingReplacement 29. Remove the circlip and tho splash guErd from tho
knuckle.
NOTE:Replacethe bearingwith a new one after removal.
27. Separatethe hub from the knuckleusing the spe-

cial tools and a press.
cAuT|O:
a Take cars not to distort th6 splash guard,
a Hold onlo the hub to k6ep it trom talling whon
pressod clear.
30. Pressthe wheel bearingout ofthe knuckls using tn€

special tools and a Press.
HUBDIS/ASSEMBLY
TOOL
oTGAF-SE00tOO
28. Removethe knucklering trom the knuckle.

ho!t
ORIVEB
07749-OOIOOOO I ATTACHME'{T.
KNUCTLE 82 x 88 mtt
07744-(xr1oBm
@
HUBDIS/ASSEMBLYBASE
07GAF-SD/()7OO
(cont'dl
18-15
Front Suspension
Knuckle/Hub {cont'dl
31. Pressthe wheelbearinginnerracef rom the hub us- NOTE: Wash the knuckle and hub thoroughly in high
ing the specialtools and a commerciallyavailable tlash-point solvent b€fore reassembly.
bea.ingseparalor.
32. Pressa new wheel besringinto the hub using the
specialtools shown and a press,
HU8 DIS/ASSEMELY
TOOL
07GAF-SEOOIOO
praaa
BEARII{G
SEPARATOR DRNE' I
ATTACHMET{T
INNERBACE oTHAD-SGOO100
WHEEL
BEARII{G
SUPPORTBASE
07965-SD90100
33. Install the circlip secur€ly in th€ knuckle groove.
34. Install the splash guard and tighten the screws.
18-16
3 5 . Installthehub on the knuckleusingthe specialtools lnstallation
shown and a Dress.
CAUTIOIII:
CAUTION:Tak€ car6 not lo diston tho splarh guard. a B€ csrotul not to damage ths ball irint boot.
a Torquo tho castlo nut to th€ lowor torquo specitica-
HUBASSEMBLY tion, thon tlghton it only lar enough lo align the slot
GUIDEATTACHMENT
07cAF-SEOO200 with tho pin holo, Do not allgn the nut bY loo8cning-
37. Installthe knuckleon the driveshaft.
38. Installtheknuckleon the lower arm and the tie-rod,

then tightsn the castle nuts and install new cotter
Dtns.
COTTER PII{
On reassembly,
bond the cofte. pin
BASE CASTLEI{UT
1 2 t 1 . 2 5m m
50-60 N'm
{5.o-6.o ks-m,
36, lnstallthe knucklering on the knuckle. 36 - 43 tb-frl
CASTLENUT
14 x 2.0 mm
50-60 N'm (5.0-6.0 kg-m,36-43 lb-ft|
39. Installthe knuckleon the upper arm, then tighten
KNUCKLE
RING
the castle nut and install a new cotter pln.
40. lnstall the knuckle protector with the 6 mm bolt.
@ K UCI(LE
PNOTECTON
COTTENPIN
On reassembly.
bgnd the cotter pin
10 N.m (1.Okg-m' 7lb'frl
CASTLENUT
10 x 1.25mm
(cont'd)
rlo-rt8 N'm (4.0-4.8 kgn, 29-35 lb-ft)
18-17
Front Suspension
Knuckle/Hub (cont'd)
41. Installthe wheel sensorwith the sensormounting 44. Install the brake caliper with the calipel bracket
bolts. mounting bolts.
NOTE:8e careful when installingthe sensorsto 45. Installthe brakehose with the brakehosemounting
avoid lwisting wires. bolts.
BRAKEHOSE
MOUNTING BOLTS
lo N'm (t.o kg-m,7 lb-ft1
42. lnstall the sensorwire with the two bolts.
10 N.m SENSORMOUNTING
(1.O 7 tb-fr) BOLTS
22 N.Jn
12.2 ks-m, 16 lb-ft)
'l '10N.m (11 kg-m.80 lb-ftl
46. Tightenthe new spindlenut.
WHEEL SENSOR NOT€:Betoreinstallingthe wheel,cleanthe mating

surlace of the brake disc and inside ot the wheel.
43. lnstallthe brakedisc with the 6 mm brakedisc re-
taining screws. 47. Installthe wheel with the wheel lug nuts.
WHEEL LUG NUT

12 x 1.5 mm
t10.in
{11 kg-m. 80 lb-fr}
24 x 1.5 mm
250 'm {25 kg-m, 181 lb'ftl
NOTE: After tightening, use a drift
6 mm BRAKEDISC to stake sDindlenut shoulder
RETAII{II{G
SCREWS againstthe spindle.
10 N.mll.0 kg-m,7 tb-fr)
44. Check the front wheel alignment and adjust if neces-

sary (see page 18-41.
8 -18
SuspensionArms
Removal/lnspection
GAUTION:
a Roplacetho salt-lockingnuts aftor removal.
a R€placothe salf-lockingbolts it you can oasilythiead a non-selt-locking nut past thoir nylon lockingins6n8.
(lt shouldr€quire1 N'm (0.1 kg-m, O.7 lb-ft) of to.qus to turn lho nut on th€ bolt).
a Bo car€fulnot to damagethe ballioint boots.
SELF.LOCKINGNUT
12 x 1.25mm
Replace.
UPPERARM ASSEMBLY
Checkfor bendingor damage.
NOTE:Do not disassemble.
BALLJOINTBOOT
Checklor detorioration
or damage.
SELF-LOCKINGBOLT
12 x '1.25 rn''rjf
STABIUZER BAR
Checkfor bendingor
damage.
RADIUS ROD WASHERS
SELF-LOCKINGNUT
12 x 1.25mm
Replace.
STABILIZERLINK
RUBBERBUSHING
Check Ior delerioration
or damage.
LOWERARM
Checktor damage.
OAMPERPINCH BOLT
ISELF.LOCKINGBOLT)
t0 x 1.25mm
SELF.LOCKINGNUT DAMPERFORK NUT

12 x 1.25mm {SELF-LOCKING NUTI
Replace. RADIUS ROD
12 x 1.25 rnm
Replace.
DAMPERFORK
CheckIor damage.
SELF-LOCKINGNUT
8 x '1.25mm
Replace.
ADJUSTING SHIM
NOTE:Adjustthe casterangleby increasing/decreasing

the adjustingshims (seepage 18-4).
'aqa a
1&19
Front Suspension
SuspensionArms {cont'd)
Installation
CAUTION: Th6 vehicle should bs on th€ glound bstoro any bolts or nuts conn€ct€d to rubbol mounts or bushing are
tightened.
NOTE:
a Wipe off the greasebefore tighteningthe nut at the ball joint.
a The right and left dampertorks 8re not symmetrical.The left damperfork is markedwith "SL" while the right damper
tork is markedwith "SR". Do not inte.changethem.
a The right and left upper arms are not symmetrical,The left upper arm is markedwith "SL" while the right arm is
markedwith "SR". Do not interchangethem.
a AJter installingthe suspensionarm. check the wheel alignmentand adjust it necessary.
a When installingthe radius rod washers,the "FR" mark faces the front of the car.
SELF"LOCKINGNUT
'12 x 1.25
mm
65 N'm (6.5 kg-m, 47 lb-ft)
UPPERARM ASSEMBLY
SELF.LOCKINGBOLT
1 2 x 1 . 2 5m m
55 N.m (5.5 kg-m, /rc lb-fr)
SELF-LOCI(INGNUT
12 x 1.25mm
55 N.m (5.5 ks-m,40 tb-ft)
STABILIZEBBAR
BOLT
I x 1.25mm
22 N.m 12.2 kg-m, l6 lb-ftl
SELF-LOCKIG NUT
12 x 1.25 fi.n
55 .m (5.5 kg-m, tlo lb-ft)
RUBAER
RUBBERAUSHING
stLrcoNE .@]
GREASE stLtcoNE
GREASE
DAMPER PINCH BOLT

ISELF.LOCKINGBOLTI
10 x 1.25mm
SELF-TOCKING BOLT tt4 N.m (4.4 kg-m, 32 lb-ftl
12 x 1.25mm
105 N'm {10.5kg'm,
76 rb-ftl DAMPER FORKNUT
(SELF-LOCKING NUT)
12 x 1.25mm
65 N.m {6.5 ks-m, 47 lb-ft}
DAMPERFORK
FRONT:GD, SELF-LOCKINGNUT
8 x 1.25mm
18 N'm {1.8 kg-m, 13lb-ftl
Align the marKs.
CAUTIOII: Do not interchange the radius lod rubbor bushings.
1a-20
Ball Joint Boot Replacement Lower Arm BushingReplacement-
'1. Adjust the bushingdriverso that it matchesthe outside
Removethe set ring and the boot.
dimensionof the lower arm bushing,Pressthe lowerarm
CAUTION: Do not contaminate the boot installation bushingusing the specialtool and a press.
section with gf6as6.
NOTE:When installingthe lower arm bushing,press it
Pack the interiorof the boot and lip with grease. so that its leadingedges are llush with the lower arm.
BALL PIN TAPEREDSECTION
SOCKETBOL 'l
BOOT INSTALLATIONSECTION BOOT INSTALLATION
SECTION
Wipe the greaseoff the slidingsurfaceof the ball

pin and pack with fresh grease.
CAUTION: <+
a Koep gloase oll the boot installation s€ction and
tho tapored soction of tho ball pin.
a Do not allow dust. dirt, or othor toreign mata.i-
als to enter tho boot.
4. Installtheboot in the grooveot the boot installation

section securely,then bleed air.
Installthe upperand lower balljointboot clipsusing

the specialtools as follows:
Lower balljoint: Adjust the specialtool with the ad-

iusting bolt until the end ol the tool alignswith the
grooveon the boot. Slidethe set ring over the tool
and into position.
Upper ball joint: Hold the tool over the ball joint,
then slidethe clip over the tool and into position.
BALL JOINT
BOOT CLIP ADJUSTING BOLT
GUIDE Adjust the depth by
turning the bolt. ARM BUSHING
UPPERBALL
JOINTBOOT:
o7974-SA50aOO
LOWERBALL 6ET RING

JOINTBOOT:
OTGAG-SO/rO7O0
40 mm CIRCLIP
CAUTION: Afler installing tho boot, chock the ball
gin tapel€d s€ction tol greas€ contaminalion and
wipo it if necossary,
1&21
Front Damper
Removal Disassembly/lnsPection
1 . Removethe brake hose mounting bolts from the Disassembly
oamper. 1. compressthe damperspring with the spring com-
pressoraccordingto the manufacturer'sinstructions,
2 . Removethe damper pinch bolt. then removethe self-lockingnut.
Removethe damperfork nut, bolt and removethe CAUTION: Do not compress th€ spling more than
damperfork. necessary to remove tho nut.
BRAKEHOSEMOUI{TINGBOLT
OAMPERPINCHBOLT (8x 16 SELF-LOCKINGNUT
BOLT) 1 0 x 1 . 2 5m m
ISELF-LOCKING
Replace.
BRAKE HOSE
MOUNTING BOLT
(8 x 20 mml
STRUT SPRING
COMPRESSOR:
Cornmordally Avallablo
BRANICKOT/N MST-sAOA
o. oouivalont
2. Removethe springcompressorthen disassemblethe

DAMPERFORK
damperas shown on the next page.
Inspection
DAMPERFORK NUT DAMPEn 1. Reassembleall parts. except the spring.
NUTI
{SELF-LOCKING
Replac6.
2. Push on the damperassemblvu" "hi-n.
3. Check for smooth operationthrough a full stroke.

4. Removethe damperby removingthe three nuts. both compressionand extension.
NUTS NOTE:The dampershould move smoothly. lf it does

1 0 x 1 . 2 5m m not (no compressionor no extension),the gas is leak-
ing. and the damper should be replaced.
4. Checkfor oil leaks,abnormalnoisesor bindingdur-

ing these tests.
NOTE:See page 18-41 for damperdisposal.
8-22
Inspection
SELF.L(rcKING ]{UT
1 0 x 1 . 2 5m m
30 N'm (3.0 kg-m,22 lb-ft|
ReDlacs.
DAMPERMOUNTINGWASHER
Checkfor wgakness.
\ , /
DAMPERMOUNTII{G
@z
a@\,/
RUBEEB
DAMPERMOUNTING
*{ COLLAR
DAMPERMOUNTI'{G
Rueeei
(92' BUMP STOP PLATE
BUMP STOP ,/
Check tor weakness o, ,/
damage.
_\
-.-..t.@@
vH
\J
SPRINGMOUNTING BUBBER
Check for damag€.
-----@
DUSTCOVERPLATE
P
l l
lY l
OUSTCOVER
Checkfor bendingor damage.
OAMPERUNIT
. Check tor leaks and
faulty operation.
. Check tor rust.
1a-23
Front Damper
Reassembly
Installthe damper unit on a spring compressor. 4. Compressthe damperspringwith the spring com-
Dressor.
NOTE:Follow the manufacturer'sinstructions.
CAUTlOltl: Do nol comptess tho spring more than
Assemblethe damDerin reverseorderof disassem- necosaary to install lhe nut.
bly except the dampermounting washer and self-
locking nut. Installthedampermountingwasher.then looselyin-
stall the new seltlocking nut.
NOTE: Align the bottom of the dsmperspringwith
the spring lower seat as shown, 6. Hold the damper shatt and tighten the new self-
lockingnut.
Positionthe dampermountingbase on the damper
unit as shown.
SELF.LOCKINGNUT
10 x 1.25mm
<LEFT:>
30 N.m 13.0 kg-m, 22lb-l1l
STUDBOLT
STRUT SPRII{GCOMPRESSOR:
CommorciollyAvail.blo
BRANICKOT/N MST-sAOA
SPRINGLOWERSEAT
18-24
Installation
1 . Loosely install ths damper on thg trame with the 2 . Installthe damperfork over the driveshaftand onto
sligningtab tacing inside. the lower arm. Installthedamperin the damperfork
so the aligningtab is alignedwith the slot in the
dampertork.
a Hand-tightenthe bolts and nuts.

NUT
1 0 x 1 . 2 5m m
39 N.m 13.9kg-n, 28 lb-ftl 4. Raisethe knucklewith a tloor jack until the car just
litls otJ the salety stand.
NOTE:The bolts and nuts shouldbe tightenedwith

the vehicle'sweight on the damper.
5 . Tightenthe damperpinch bolt.
Securethe dampertork bolt with I new selflocking

nut.
Securethe damperassemblyto the frame with the

flange nuts.
8. lnstall the brske hose mounting bolts.
BRAKE HOSE MOUNTII{G EOLT

{8 x 16 rml
22 N.m 12.2kg-m. 16 lb-ft)
BRAKEHOSE
MOUNTING BOLT
(8 x 20 mm)
22 N.m
12.2 16 tb-frt
DAMPER BOLT
(SELF-LOCKING BOLT)
10 x 1.25mm DAMPER FOBK AOLT
44 N.m (4,4 kg-m, DAMPERFORK NUT
32 rb-ftt {SELF-LOCKING NUT}
12 x 1.25mm
65 N'm (6.5 kg-m, 47 lb-ft)
18-25
RearSuspension
Torque Specifications
CAUTIOIT:
a R.C.cr tho 3olt-locking nuts aftor removal.
a RaDLc. tho rett-locklng bohs It you can easily throad a non-salf-locking nut past thair nylon locklng in3.rls.
{h.houH r.quko 1 N'm (0.'l kg-m, 0.7 lb-ft) of torque to tuln tho nut on tho bolt}'
a lta v€hlcla should bo on th6 ground botore any bolts or nuts connoctedto rubbor mounls or bushings 8re tightenod,
a Torquc th! casdo nut to tha lower torquo epoqlllcatlon, then tight6n lt only far enough to align tho llot wfth the dn
hole. Do not allgn thc nut by loosoning.
NOTE:Wipe off th€ greasebetore tighteningthe nut at the ball joint.
SEIF.LOCKINGNUT
10 r 1.25mm
30 N.m l3.O kg-m, 22 lb-frl
Rgolace.
NUT
1 0 x 1 . 2 5m m
39 N'm {3.9 ks-m. 28 lb-ft)
SELF.LOCKINGNUT
12 x 1.25mm
OE .m 16.5 kg-m, 47 lb-ft|
Roploce.
CASTLEttIUT
1 0 x 1 . 2 5m m
40-48 N.m {4.0-4.8 kg-m,
29-35 tb-ft|
BOLT
8 x 1,25 lnm
22 N.m {2.2 kg-m. 16 tb-ft)
'l NUT
l
sELF-LocKtt{c
10 x 1.25mm
45 N.m (4.5 ks-m, 33 lb-ft)
Replace.
/
SELF.LOCKII{G ]{UT CASTLENUT
1 2 x 1 . 2 6m m 12 x 1.25mm
65 t{.m (5.5 kg-m,40 lb-ftl 50-60 tl.m 15.0-6.0 ks-rn,
Rgoloce. 36-43 tb-ftl
SPI]TDLEfIUT
22 x 1.5 fim
185 N.m
{18.5 kgn, 134 lb-tt}
Replac6.
NOTE: After tightoning, use I drift to
stske the spindlo nut shouldor against
the spindle.
CASTLE NUT
14 x 2.0 mm
50-60 N.m {5.0-6.0 ke-m,
SELF.LOCKINGBOLT 36-43 tb-ft|
12 x 1.25 mrn CALIPERBRACKETMOUNTII{G BOLT
65 N.m 16.5 kg-m, 47 lb-ftl 12 x '1.25lrxn
39 N'm (3.9 ks-m, 28 lb-ftl
18-26
Knuckle/Hub
lllustrated lndex
NOTE:
a Use only genuineHondawheel weightsfor aluminumwheels. Non-genuinewheel weights may corrode8nd dsmsge
the aluminumwheels.
a Beforeinstallingthe brake disc, cleanthe mating surfacesot the rear hub and insideof the brakedisc.
a Beforeinstallingthe wheel, cleanthe mating surtacesof the brake disc and insideof the wheel.
SELF-LOCKINGBOLT COTTERPIN
10 x 1.25mm Replace.
44 N.m 14.4 kg-m, 32 lb-tll
\--q, KNUCKLEPROTECTOR
Ch6ckfor damago.
BOLT
6 x 1 . 0m m
10 N.m ll.O kg-m, 7 lb-frl
SPLASHGUARD
b Checkfor bending
REAR or damago.
SPINDLEASSEMBLY
Check for damage. 10 N'm l1.O kg-m, 7 lb-ft)
p
s- \ COTTERPIN
Replace.
REARWHEEL
HUB UNIT
Check for cracking
or damags.
WASHER
SPINDI..E
tan^l
ae
BRAKE OISC
Check for wear or rust.
Inspection, section 19
6 mm BRAKEDISC
RETAININGSCREWS
10 N.m (1.0 kg-m, 7lb-ft| WHEELLUG NUT
12 x 1,5 mm
110 N'm 111 kg-m,80 lb-frl
(cont'dl
18-27
RearSuspension
Knuckle/Hub(cont'dl
Removal 8 . Removethe 6 mm brake disc retainingscrews
1. Loosenthe wheel nuts slightly. 9 . Screw two 8 x 1.25 mm bolts into the disc to push
it away from the hub.
2. Raisethe rearof car and support it with safety stands
in properlocations(seesectjon 1). NOTE:Turn each bolt two turns at time to prevent
cocking the disc excessively.
3. Bemovethe wheel lug nuts and rear wheel.
1 0 .Removethe brake disc.
4. Pull the parking brake lever up.
5. Removethe hub cap, then raisethe lockingtab on

the spindlenut, then removethe nut.
HUBCAP I x 1.25 mm BOLTS
Replace.
NOTE| Take care not to damagethe hub
BRAKEOISC 6 mm
5 EBAKE DISC
MM ERAKE
RETAINIT{GSCREWS
S
1 1. Remove the hub unit from the knuckle,
o. Removethe brake hose mounting bolts.
7. Removethe caliperbracketmountingboltsand hang

the caliperassemblyto one side.
CAUTION: To prevent accidental damage to the

caliper assemblyor brake hoss, use a shon pisce ot
wir€ to hang th€ calip€r as$mbly lrom th6 und6.-
cardag6.
BRAKEHOUSEMOUNTING
BOLT
TRAILINGARM
CALIPERASSEMBLY
CAUPERARACKETMOUNTING BOLT
18-28
12. Removethe splssh guard from the knuckle. 1 5. Removethe rear spindleassemblyfrom the knuckle.
SELF-LOCKINGNUT
10 x 1.25mm
Replace.
ASSEMBLY
13. Removethe parkingbrakecabletrom the knuckle. 1 6 .Hold the ball pin of the stabilizertink with a hex
wfench and loosenthe self-lockingnut.
14. Removethe wheel sensorwire bracket.then remove
the wheel sensorfrom the knuckle. Removethe selflocking nut, then disconnectthe
slabilizerlink from the stabilizerbar.
NOTE:Do not disconnectthe wheel sensorwire.
WHEELSENSOR
PARKINGBRAKE CABLE
1 2 r 1 . 2 5m m
Replace.
{cont'd)
18-29
l'-
Rear Suspension
Knuckle/Hub {cont'd)
18. Remove the cotter pin from the tie-rod end (4WS) 24. Removethe knuckleProtector.
or lower arm B (2WS) 8nd removethe castle nut.
25. Removethe cotter pin and the upperbsll joint nut.
19. lnstalla 12 mm hex nut on the ballioint. Besurethat
the hex nut is flush with the balljointpin end. or the 26. lnstall a 1O mm hex nut on the ball joint.
threaded section of the bsll joint pin might be Be sure that the hex nut is flush with the bsll ioint
damagedby the ball joint remover. Dinend, or the threadedsectionot the balljoint pin
might be damagedby the ball joint removar.
20. Usethe balljoint removeras shown on page | 8-13
to separate the ball ioint and knuckle. 27. Usethe balljoint remove.as shown on page 18-13
to separatethe balljoint and knuckle,then remove
NOTE:lf necessary,apply penetratingtype lubricant the knuckle.
NOTE:lf necessary,apply penetratingtype lubricant
COTTERPIN to loosenthe ball joint,
Replace.
BALLJ()|NT
REMOVER. 28 mm
oTMAC-SLOO200
BALL JOINT
REMOVER,28 mm
oTMAC-SLOO200
21 . Removethe cotter pin and lower arm balljoint nut. K UCKLEPROTECTOR
22. Installa 14 mm hex nut on the balljoint.Be sutethat

the hex nut is flush with the balljoint pin end, or the
threaded section of the ball joint pin might be
damagedby the ball joint remover.
23. Usethe balljoint removeras shown on page 18-13

to separatethe ball joint and lower arm.
NOTE:lf necessary,apply penetratingtype lubricant R€place.

,a,-,",
mm HEX NUT
CASTI.ENUT
14 x 2.0 mm
EALLJOINT
REmOVER,32 mm
-slooro0
oTmac
18-30
lnstallation 33. Installthe whe€l sensor, wheel sensor wire bracket
and parkingbrake cable on the knuckle.
28. Connectthe lowe. arm, lower arm B (2WSl or tie-
rod end (4WS) 8nd upper arm with the knuckle, then NOTE:Be careful when installingthe sensorto avoid
tighten the castle nuts, twisting the wire.
22 .m {2.2 kg-m, 16lb-ftl
29. Installthe naw cotter oins.
30. Installthe knuckleDrotectorwith the bolt.
31. Connect the knuckle and the stabilizerbar, then

tighten the new selflocking nut.
CASTLENUT
1 0 x 1 . 2 5m m
40-/t8 N.m 14.0-4.8 kg-ir,
29 - 35 tb-tr)
COTTERPIT{
On roa$ombly,
bondth€ cott€r pin
SELF.LOCKING I{UT 22 N.m 12.2kg-m, 16 lb-ft)

1 2 x 1 . 2 5m m
55 .m 15.5 ks-m,40 lb-ttl
CASTLEITUT 34. Installthe splashguard with the bolts.

14 x 2.0 mm
50-60 N.m(5.0-6.0 kg-m,
36-43 tb-ft|
COTTERPIN
CASTLE NUT
1 2 x 1 . 2 5m m
50-60 .m (5.0_6.0 kg.h,
36_43 tb-ttt
32. Installthe rearspindleassemblyon the knuckle,then

tighten the new self-locking nuts.
SEI.F.LOq(NGIIUTS
lO r 1.25mm
45 N.m (4.5 kg{n, 33 lb-ftl
10 N.m(1.0 kg{, 7 |tsft}
18-31
RearSuspension
Knuckle/Hub (cont'dl
35. Install the hub unit and spindle washer on the 37. Installthe caliperassemblywith the caliperbracket
knuckle. mounting bolts.
38. Installthebfakehosewith the brakohosemounting

bolts,
BRAI(EHOSEMOUI{TINGBOLT
22 N.m 12.2 16 tb-ft|
ASSEMBLY
CALIPER
MOUNTII{GBOLTS
39 N'm 13.9kg-m,2a lb-ft)
SPi DLE WASHER

39. Installthe new spindlenut, then tighten the nut'
40. Installthe new hub cap.
41. Installthe rear wheel with the wheel lug nuts.

ito. lnstallthe brakedisc with the 6 mm brakedisc re-
taining screws. NOTE:BeJoreinstsllingthe wheel,cleanthe mating
surfaceof the brakedisc and insideo{ the wheel.
REANWHEEL
SPI DLE ]{UT

22 x 1.5 mm WHEELLUGNUT
185 N,m (18.5 kg-m. 134 lb-ft| 1 1 0N . m
NOTE: After tightening, uss a drift to
(l I kg-rn,80 lb-ft}
stake the spindle nut shouldgr against
the spindl6.
6 mm BRAKE DISC
RETAII{INGSCNEWS 42. Checktherearwheelalignmentand adjustif neces-
10 N.m (l.o kg-m, 7 lb-ft| sary (seepage 18-4).
18-32
SuspensionArms
Removal/lnspection
GAUTION:
a R€placetho selllocking nuts afte.;emoval.
a Roplacethe self-locking bolts it you can oasily thread a non-solt-locking nut past thoir nylon locking insons,
(lt should roquire 1 N.m (O.1 kg-m, O.7 lb-ft) of torque to turn the nul on tho bolt).
a B€ caroful not to damage the balljoint boots.
SELF.LOCKINGNUT
12 x 1.25mm UPPER ARM ASSEMBLY
Replace. Checklor bending
or damage.
NOTE:Do not disassemble. )
SELF-LOCKINGNUT
10 x 'l.25 mm
Replace.
l2wS only)
SELF.LOCKINGNUT
12 x 1.25mm
Roplace.
{4wS only)
bo
SELF.LOCKINGBOLT
14 x 1.5 mm
(2wS only)
STAAILEER BUSHII{G
Check lor deterioration
SELF-LOCKIf{G or damag6.
12 x 1.25mm
""\;\^.J
LOWERARM B
Replace. Check tor b€nding
or damage.
,aar-ao"*,no"oa\ (2WS only)
RUBBER BUSHING
Checktor deterioration
or damage.
SELF-LOCKINGBOLT
12 x 1.25mm
TRAILINGARM
BUSHING {cont'd)
Check for deterioration
or damage.
18-33
Rear Suspension
SuspensionArms (cont'dl
Installation
CAUTION: Tho vohiclo ehould be on the ground bofor€ any bolts or nuts connectod to rubb3r mounls or bu3hlng arc
tlghtcnod.
NOTE;
a Wipe ofJ the grease before tightening the nut at the ball joint.
a The right lower arm B is identiJiedby white paint.
"L" while the right 8rm is markod
a The right and left upper arms are not symmetrical. The left upper arm is marked with
with "R". Do not interchangethem.
a After installing the suspension arm, check the wheel alignment and adiust if necesssry.
SELF.LOCKINGNUT
12 x 1.25mm
65 N.|n (6.5 ks-m, 47 lb-ft1
-\
_rrat
v UPPERARM ASSEMBLY
SELF.LOCKINGT{UT
10 x 1.25mm
55 N.m 15.5 kg-m,
4{' tb'ft|
(2WS onlyl
SELF-LOCKIT{G NUT
12 x 1.25mm
65 N.m (6.5 kg-m, 47 lb-ft| BOLT
(4wS only)
10 x 1.25 rn.n
44 .m {4.4 kg-rn, 32 lb-ftl
\
SELF-LOCKINGBOLT
14 x 1.5 mm
85 N'.n 18.5ks-m, 61 lb-ft)
(2WSonlyl
BOLT I
8 r 1.25mm
22 N.m 12.2kg-m, 16 lb-ft|
22 N.m 12.2kg-m,
16 tb-ft}
SELF-LOCKINGNUT LOWERARM B
12 x 1.25 tnm onlyl
55 N'm {5.5 kg-m.
/to lb-ft)
LOWERARM
SELF-LOCKINGBOLT
12 x 1.25mm SELF-LOCKI]TG BOLT
65 i.in 16.5 kg-m, 47 lb-ft} 1 2 | 1 . 2 5m m
TRAILIT{GARM 65 N.m 16.5kg-m,47 lb-ftl
18-34
Ball Joint Boot Replacement Lower Arm Bushing Replacement
Removethe set ring and the boot. Adjust lhe bushing driver so that it matches the outside
dimensionof the lower arm bushing.Pressthe lower arm
CAUTION: Do not contaminate ths boot installation bushingusing the specialtool and a press.
soctlon with giease.
NOTE:When instsllingthe lower arm bushing,press it
Pack the interiorof the boot and lip with grease. so that its leadingedges are tlush with the lower arm.
BALL PIN TAPEREDSECTION
Pr9!a
t
BUSHITIG
DRIVER
o7t{AD-SSq)lOO
BOOT INSTALLATIOI{SECTION
BOOTINSTALLATIOT{
SECTION
3. Wipe the greaseotf the slidingsurfaceof the ball
pin and pack with tresh grease.
a Keep g.oas€ off the boot inatallationssction and

ths tapered soction of tho ball pin.
a Oo not allow dust, dirt, or other foroign mat6d-
als to ont€J the boot.
4. Installthe boot in the grooveof the boot installation

section securely.then bleed air.
5. Installthe upperand lower balljointboot clipsusing

the sDecialtools as Jollows:
Lower balljoint:Adjust the specialtool with the ad-

justing bolt until the end of the tool alignswith the
grooveon the boot. Slidethe set ring over the tool
and into position.
Upper ball ,oint: Hold the tool over the ball joint.
then slidethe clip over the tool and into position.
BALL JOINT AOJUSTII{G BOLT

BOOT CLIP Adjust the depth bV
turning the bolt.
GUIDE
UPPERBALL
JOINTBOOT:
07974-SA50800
LOWERBALL SET RING
JOINTBOOT:
07GAG-SD/rO700
40 mm CIRCLIP
CAUTION: Attor installing the boot, ch€ck tho ball

pin tapered soction tor greaso contaminatlon and
wipe it it nscossary.
18-3s
Rear Damper
Removal
1 . Jack up the rear of car and support on satety stands 9 . Remove the damper mounting bolt.
in properlocationslsee section 1).
1 0 . Lower th8 raar susp€nsionand remov€ the dampgr
Remove the rear wheel. assemblv.
t Removethe trunk side trim.
4. Removethe two nuts,
NUTS
10 x 1.25rfn
Removethe knuckleprotector.
6. Remove the cotter pin and the upper ball ioint nut.
7. lnstalla 1O mm hex nut on the ball ioint.

Be sure that the hex nut is flush with the ball joint
Dinend, or the threadedsectionof the ballioint pin
might be damaged by the ball joint remover. MOU TINGBOLY
(SELF.LOCKIl{G
BOLT)
8 . Usethe balljoint .emoveras shown on page 18-13 1 2x t . 2 6 m m
to separatethe ball joint 8nd knuckle.
NOTE:lf necessary,apply psnetratingtype lubricant

1o loosenthe ball joint.
BALL JOINT
BEMOVER,28 mm
10 mm H€X UT oTMAC-SLOO200
KNUCKLEPROTECTOR
CASTLEl{UT
1 0 x 1 . 2 5m m
COTTEBPIIT BOLT
Replaco. 6x t.Omm
18 -3 6
'b'--
Disassembly Inspection
1 . Compress th€ damper spring with the spring com- Reassembleall parts, except the spring.
pressoraccordingto the manufacturer'sinstructions,
Push on the damper assemblyas shown.
CAUTIO : Do not compr.rs th6 sprlDg mora than
noceaaaryto ramovo tho sclt-locking nut. J. Check for smooth operation through a full stroke.
both comoression and extension.
Remove the selflocking nut trom the damper as- NOTE:The damper should move smoothly. lf it does
s€mbly, not (no compressionor no extensionl,the gas is leak-
in9, and the dampershould be replaced.
STRUT SPRINGCOMPfiESSOR:
Commo.d.lly Av.illbl.
BRANICKOT/t{ MST.5g)A
or oquivrlant
3. Remove the spring compressor and disassembly the 4. Checkfor oil leaks.abnormalnoisesor bindingdur-
damper as shown on the next page. ing these tests.
NOTE:See page 18-41 for damperdisposal.
(cont'dl
18-37
RearDamper
Inspection (cont'd)
SELF-LOCKINGNUT
10 x 1.25mm
Reolace.
30 N.m (3.0 kg-m, 22 lb-ft|
DAMPER ./
MOUTTTTNG ^r'
WASHER -_ --.f.:, g
Ch6cktor DAMPER MOUT{TING
woakness. \Y RUBBER
DAMPER DAMPCRSPRII{G
MOUI'IN G BASE Check for weakened
compresspnor oamage.
F
DAMPERMOUl{TrirG ll l*----.-
iUBBER t---^6
ooio" "ornr,ro
\r' -- BUMPSTOPPLATE
',/
w
,ffi,
t
*r'
SPf,INGMOUNTING
RUBBER
Check lor damago
or cracKs.
DUSTCOVERPLATE
DUSTCOVER
Chocklor bending
or damage.
DUSTCOVERAOOT
Ch6ckfor detorioration
or damage.
DAMPER UITIT
. Check tor leaks and
faulty operation.
. Check tor rust.
18-3 8
Reassembly
w
1 . Install th€ dampel unit on 8 spring compressor. 4. Compress the damper spring with the spring com-
pressor.
NOTE: Follow the manutacturer's instructions.
GAUTION: Do not compross ihe spring more than
AssemHe the damper in revsrse order of disassem- necesaary to Install tho nut.
bly except the damper mounting wash€r and sel{-
locking nut. Installthe dampermounting washer, then loosely in-
stall the new selflocking nut.
NOTE:Align the bottom ot the damperspringwith
th6 spring lower seat as shown, 6 . Hold the dampershaft and tighten the self-locking
nut.
a Position the damper mounting base on the dsmp€r
unit as shown.
SELF-LOCKII{G lrluT
<LEFT:> <RIGHT:
> 1 0 x 1 , 2 5m m
30 tl.m l3.Oks-m, 22 ltFftl
OAMPM
WELDED UT WASHER
STRUTSPRII{GCOMPRESSOR:
Commrrd.lly Avdllbl.
BRAt{lCKoT/1{MST-580A
SPfiING LOWERSEAT
18-39
Rear Damper
Installation
I
1 . Lower the rear suspensionand set the damperas, 4. Connectthe upper arm and knuckle,then tighten the
semblv. castle nut.
2 . Connectthe damperassemblyand the lowe. arm, 5. Installthe knuckleprotectorwith the bolt.

then looselyinstallthe dampermounting bolt. I
NOTE:The damp€. mountingbolt should be tight-

ened with the damDerunder vehicleload.
KNUCKLEPROTECTOR
COTTERPIN
On reassembly,
..:-.'l"t' bend the cotter pin
DAMPER
MOUNTING BOLT
(SEI"F-LOCKING
BOtTI
1 2 r 1 . 2 5m m
- { 4
I
CASTLE NUT COTTERPIN
1 2 x 1 . 2 5m m
40-48 N'm l0 . m { 1 . Ok g - m , 7 l b - f t l
{4.O-4.8 kg-m,
29 - 35 rb-frl
WELDEDNUT
Raisethe rearsuspensionwith a tloor jack until the
weight ot the car is on the dampe,.
Tightenthe two nuts.
7 . Tightenthe dampermounting bolt
NUTS
l O x 1 . 2 5m m
39 N'm (3.9 kg-m,2a lb-trl
DAMPEB
MOU]IINNG AOLT
{SELF.LOCKING
BOr-Tl
12 x 1.25mm
65 N.m 16.5 kg-m,
47 tb-ftl
8. Checkthe rearwheelalignmentand adjustif neces-

sary (seepage 18-4).
18-40
Damper Disposal
a Ths dampors contain nitrog€n gas and oil under p(€3-

sur6. Tha prossur6must b6 roliovod boforo disposal
to provent explosion and possible hiuly whon
scrapping.
a Always wear oye protsction to avoid getting motal
shavings in your eyes whon the gas dampel pr€ssuro
is rolieved.
Placethe damperon a levelsur{acewith its rod extend-

e d a n d d r i l la h o l eo t 2 . 0 - 3 . 0 m m { 0 . O 8 - 0 . 1 2 i n l d i -
ameter in the body to release the gas.
( Front Damper:>
Drill here.
( Rear Damper:>
Drill here.
18-41
Brakes
Conventional Brakes...... 19-1
A n t i - L o c kB r a k eS y s t e m( A B S I . . . . . . . . . . .1 9 - 3 1
ConventionalBrakes
SpeciafToofs .......... 19-2 RearDisc Brakes

l l l u s t r a t eIdn d e x . . . . . . . . . . . . . . . . . . . . . , . .1. 9. .-. 3 T o r q u e / l n s p e c t i .o. n. . . . . . . . . . . . . . . . . 1 9 - 1 7
PedalHeight RearBrake Pads
Adjustment ......... 19-4 Inspection/Replacement ..............19-18
ParkingBrake RearBrake Disc
Adjustment ......... 19-5 R u n o u It n s p e c t i o n , . . , , . . . . . . , , . . . . ,1,9. .-.2 0
Flont Brakes Thicknessand Parallelism
T o r q u e / l n s p e c t i .o. n. . . , . . . . . . . . . . . . .1. .9. - 6 Inspection ....... 19-20
Front Brake Pads RearCaliper
Inspection/Replacement ..............19-7 Disassembly ....... 19-21
Front Caliper Reassembly ........ 19-24
Disassembly ....... 19-9 BrakeHoses/Pipes
Reassembly . . . . . . . .1 9 - 1 0 fnspection ...,,,,,.. 19-27
Front BrakeDisc BrakeHoseReplacement .............19-28
R u n o u It n s p e c t i o .n. . . . . . . . . . . . . . . , , . 1. .9. - 11 ParkingBrake
Thicknessand Parallelism Disassembly and Reassembly...... 19-29
Inspection ....... 19-11
Bleeding . . . . . . . . . . . . . . 1. .9 - 1 2
Master Cylinderand Brake Booster
Removal/lnstallation ...................19-13
Master Cylinder
Inspection .........1 . 9-14
Brake Boostel
Tests............ .....19-15
PushrodClearance Adjustment..... 19-15
SpecialTools
Rol. No. I Tool Number

oTHAE-SGOO100 BrakeSpringCompressor 19-22, 19-25
oTJAG-SD40100 Pushrod Adjustmenl Gauge 19-l5
o7914-SA50000 Snap RingPliers 19-22, 19-25
o7916-6390001 LocknutWrench 19-21, 19-26
@ an
19-2
lllustratedlndex
FRONTBRAKES REARDISC BRAKES

Torque/lnspection,page 19-6 Torqu6/lnspsction,p8g€ 19- l7
Front Brsk€ Pads. page 19-7 PARKINGBFAKE R6arBrak6P8ds,psgs 19-18
Front Csliper, pag6 19-9 Adjustmont, pago | 9-5 R6ar Brak€ Disc, page 19-20
FrontSrakeDisc,page 19-11 Diaa$embly 6nd Reassombly, R6ar Calip€r, page 'l9-2'l
p6go 19-29
ERAKEPEDAL
Adjustmont,psg€ l9-4
MASTER CYLIT{DER AND BRAKEBOOSTER

Rgmoval/lnstallation,psge 19-13
MastsrCylinder,page 19-14 BRAKEHOSES/PIPES
BrakgBooster19-15 Inspoclion,pag€ 19-27
Brake Hoso Replac€m€nt.p6g€ 'l 9-24
19-3
PedalHeight
Adjustment
'I
. Disconnectthe brakeswitch connector,loosenthe 4. Screw in the brake switch until its plungeris fully
brakeswitch locknutand back off the brakeswitch depressed(threadedend touching the pad on the
until it is no longertouchingthe brake pedal. pedal arm). Then back otf the switch 1/4 turn to
make O.3 mm {0.O1 in} of clearancebetween the
2 . Measurethe pedalheight from the left side center threadedend and pad. Tightenthe locknut tirmly.
of the Dedalsurface. Connectthe brake switch connector.
CAUTION: Ch6ck that the brak€ lights go oft

BRAKE
swtrcH whon ths psdsl is l€leased.
PAD
BrEke Podal Froe Play Inspection:

Stop the engine and inspect the play by pushingthe
pedalby hand.
A: Podal Freo Play
1-5 mm (1/16- 13/64in) BrakeP€dalFreePlay: 1-5 mm {1/16-13/64 inl
B: Standard P€dal Height (with floor mat
removed) CAUTION: It tho pedal freo play is insufficient, it
MT: 165 mm (6.5 inl minimum may ro3ult in brak€ drag.
AT: 186 mm (7.3 in) minimum
3 . Loosenthe pushrodlocknutand screw the pushrod
in or out with pliersuntil the standardpedalheight
from the floor is reached.After adjustment.tighten
the locknut firmlv,
PUSHRODLOCKNUT
l5 N.m 11.5kg-m, 11lb-fll tor cai. without ABS
19 .m {1.9 kg-m, 14 lb-ftl for cars with ABS
19-4
bsnmrr
ParkingBrake
Adjustment
NOTE: After rear brake caliper servicing,loosen the E Tighten the adjusting nut until the rear wheels drag
parking brake adiusting nut, start the engine and slightly when turned.
depressthe brake pedal severaltimes to set the self-
adjustingbrake beforeadjustingthe parkingbrake.
@ Bbck the flont wheots beforo iacking up

the loar of the car-
1. Raisethe rear wheels off the ground.
2. Make sure the lever of the rear brake calipercon-

tacts the pin ot the brake caliper.
o. Rel€asethe parkingb,ake lever and check that the

r€ar wheels do not drag wh€n turned. Readjustit
nScessarv.
With the equalizer properly adjusted, the rear

brakes should be tully applied when the parking
brake lever is pulledup 6 to 1O clicks.
3 . Pull rhe parkingbrake lever up one notch.
Removethe tront consoleand centerconsole(see

p a g e2 O - 5 1 ) .
19-5
Front Brakes
Torque/lnspectaon
a Nevgl us€ an air hos6 or dry brush to cl€an braks assamblies.

a Use an OsHA-spproved vacuum cl6aner, to avoid breathing brake dust,
a Contaminated brake discs or pads reduce stopping ability.
CAUTION:
a Do not spill brake tluid on tho car; it may damagethe paint; it brakefluid does contact tho paint, wash it ott immediate-
ly with water.
a To prevont spills, cover the hose loints with rags or shop towels.
a Cl€8n all pans in brake lluid and air dry; blow out all passageswith compross€dail.
a B€tore reassembling.chcck that all parts ar€ free of dust and oth€r toreign particlas.
a Replaceparts with new ones whcn€vel specitisd to do so.
a Make sure no dirt or othor lor€ign matt€r is allowed to contaminato th6 brako fluid.
a Do not mir different brands of braks fluid as th€y may not b6 compatible.
a Do not reuse the drained tluid. Us6 onlv clean DOT 3 or 4 brake fluid.
NOTE:
a Coat piston, piston seal, and caliperbore with clean brakefluid.
a Reolaceall rubberoarts with new ones wheneverdisassembled.
-ffi: Brakecyrindergrease(P/N:08733-Bo2oE) or equivalentrubbergrease. ..6|t, siliconegrease.
INNERPAD SHIM B WEAR INDICATOR OUTERPAD SHIM

Checklor wear or lnstallinnerpad with Check tor wear or
oamage. atswear indicatorupward. oamage. 1 2 x 1 . 2 5m
Apply Molykoteo N477ptt{ B 1 1 0 N . l n ( 1 1 . 0k g - m ,
Apply Molykoteo M77
to pad side of shim. Checkfor bendingor 80 lb-ftl
to shim A sadeol shim.
\ damage.
\/L ,.
I r t \ -41 Ptt{BooT
Replace.
{ ( /? tI , -6l
\"--'--\
^t t
INNERPAD SHIM A /
CheckIor wear or
\ ( i /
I 4-
damage. ,/
Apply Molykoreo M77 BUSHING
to both sidesof shim.
-6,l
10 x 'l.O mm BRAKEPADS
50 N'm {5.0 kg-m, rinins
check thicknes.
36 tb-ftl
yN
q{
6 P t o . /
< Check for bending or
'iN.-_ damase.
u afl _G1
naEih
ffi,.--- RETAIl{ER
BLEEDSCBEW
I N.m
Nv Yl(o,6
-N/ffiL
Checkfor
damage.
/
I \V--\.-_
(0.9 kg-m, 6.5lb-fr)
CALIPERBODY
/
PrsroNSEAL PISTONBOOT
I Replace.
CheckIor scoring
on cylinderwall-
."o,,nn
8'n"i"?nfo,
on srlrface.
19-6
Front BrakePads
Inspection/Replacement
4. Removethe pad shims, pad retainersand pads.

a Nevar us€ an air hoss or dry brush to cl€an blake
assemblies. Using vernier calipers,measurethe thickness of
a Use an OsHA-approved vacuum cleanet, to avoid each brakepad lining.
broathing brako dust.
Brako Pad Thickness:
1. Loosenthe front wheel lug nuts slightly,then raise Standard:
the car and supporton safety stands, F22A1 and H23Al sngine: 12.5 mm (O.49in)
Removethe front wheels. H22A1 engin€: 1 1.O mm {0.43 in)
Servic€ Limit:
2. Removethe caliperbolt and pivot the caliperup out 1.6 mm {0.06 inl
of the way.
CALIPERSOLT
NOTE: Measurementdoesnot includepad backing
plate thickness.
CALIPER
BODY
6. Cleanthe caliperthoroughly;removeany rust, and
3. lf the brake pad thicknessis lessthan servicelimit check for groovesor cracks.
at step 5, replacethe front pads as a set.
Installthe pad retainers.
Front BrakePads
(cont'd)
8 . Apply Molykote@ M77 compound to the pad 1 1 .P ivotthe caliperdown into position,then installthe
shims and the back of the pads. Wipe off excess. caliperbolt (flangebolt).
9 . lnstallthe brake pads and pad shims correctly. NOTE: Make sure the pin is clean before installa-
tion, then applya cleansiliconegreaseto the inside
@
a Wh6n reusing th€ pads, always leinstall tho
ot the boot and the Din.
brake pads in their original positions to pravent

loss ot braking efticiency.
a Contaminated brake discs or pads reduce stop-
ping sbility, Ke€p greas€ oll the discs and p8ds.
NOTE: Installthe pad with the wear indicatoron

the inside.
CALIPER
50 N.m
{5.Okg-m,
36 rb-ft|
PISTON
INNERPAD SHIM A
Apply Molykote@
M77 to borh
sidesof shim.
Apply Molykoteo
M77 to inner
side of shim.
12. Depressthe brakepedalseveraltimesto make sure
N
t l
the brakeswork. then road-test.
t ' \
INNERPAD SHIM B
E i
Apply Molykote@ NOTE: Engagementof the brake may requi.e a
M77 to inner
sadeof shim.
INNERBRAKEPAD V greater pedal stroke immediatelyafter the brake
pads have been replacedas a set. Severalapplica-
indicator) OUTERBRAKEPADS tions of the brake Dedalwill restore the normal
1O. Pushin the pistonso that the caliperwilltit overthe oedal stroke.
pads. Keepthe boot in positionto preventdamag-
ing the boot when pivotingthe caliperdown.
19-8
FrontCaliper
Disassembly
lf necessary,apply compressedair to the caliper

a N6vor uso an air hose or dry brush to clean brake fluid inlet to get the piston out. Placea shop rag or
ass€mbli9s. wooden block as shown to cushion the oiston
a Use an OSHA-approved vacuum clgan€r to avoid when it is exoelled.
broathing brake dust. Use low pressureair in short spurts.
Removethe piston from the caliDer.
CAUTION:
a Do not spill brak€ fluid on the ca1;it may d8mag€the
paint; il brake fluid do€s contact the paint, wash it a Do not placo your fingsrs in front of th€ piston.
ofl immediatoly with wat6r. a Do not use high air pressuls; use an OSHA-
a To plevent spills, cover the hose ioints with rags or approvsd 30 PSI nozzle.
shop towels.
a Clean all parts in brak6 tluid and air dry; blow out all
passages with comprossed air.
1. Removethe banjo bolt and disconnectthe brake

hose from the calioer.
2. Removethe caliperbolts, then removethe caliper.
4. Removethe piston boot and piston seat.
CAUTION: Take care not to damago the cylindel

SEALING
bore,
WASHERS
Replace. CALIPERBOLT
19-9
Front Caliper
Reassembly
CAUTIOt{l 4. Lubricatethe calipercylinderand pistonwith brake

a Do not spill brako fluid on the ca.; it may damagethe fluid, then installthe piston in the cylinderwith the
paint; if brake fluid do6s contact th€ paint, wash it dishedend facing in,
off immediately with water.
a Bofore reassgmbling,chock that all parts are troe ot
dust and othol toreign pa.ticles.
a Raplacepans with new ones whgn6vo. spocitied to
do so.
a Make suls no di.t or othor loroign mattor is allowod
to contaminate the brak€ tluid.
a Do not mix different brands ot brake tluid as they
may not be compatible,
a Do not reus€ tho drain€dfluid. Use onlv cloan DOT 3
or 4 brakefluid.
1. Cleanthe piston and caliperbore with braketluid

and inspectfor wear or damage.
2. Coal a new piston sealwith siliconegreaseand in-

stall it in the cylindergroove.
5. Install the brake pad retainersand brake pads in
their originalpositions(seepage 19-8).
3. Apply brakecylindergrease(P/N:08733-BO2OE)
or equivalentrubbergreaseto the sealinglips and
@ Always r€install the brake pads in
insideof a new piston boot, and installthe boot in
their o.iginal positions to prevent loss ol braking
the cylindergroove.
ofliciancy.
6. Installthecaliperon the caliperbracketand tighten

the caliperbolts.
7 . Connect the brake hose to the calipe. with new

sealingwashersand tighten the banio bolt.
BANJO BOLT
35 t{.m {3.5 kg-m,
25 tb-ftt
,:^" PISTONSEAL
#-i!!r9ul
RUBBERGREASE -611
SILICONEGREASE
SEALING
WASHERS
CALIPER BOLT
50 .m (5.0 kg-m,
36 tb_trl
8. Fill the brake reservoir up and bleed the brake

s y s t e m{ s e ep a g e1 9 1 2 ) .
19-10
Front BrakeDisc
Runout lnspection Thicknessand Parallelism
Inspection
Loosenthe front wheel lug nuts slightly,then raise Loosenthe front wheel lug nuts slightly,then raise
the car and supporton safety stands. the car and support on safety stands.
Removethe front wheels. Removethe front wheels.
2. Removethe brake pads (seepage 19-7). 2 . Removethe brake pads (see page 19-7).
3. Inspectthe disc surfacefor cracks,and rust. Clean Using a micrometer, measure disc thickness at
the disc thoroughlyand removeall rust. eight points, approximately45o apartand 1O mm
(O.4 in) in trom the outer edge of the disc.
4. Use lug nuts and suitableplainwashefsto holdthe
disc secu.elyagainstthe hub, then mount a dial in-
dicatoras shown and measurethe runoutat IO mm
(O.4 inl from the outer edge oJ the disc,
Brak6 Disc Runout:

Scrvlc. Limlt: O.10 mm (0.004 in)
5. lf the disc is beyond the servicelimit, refinishthe

rotor with an on-car brake lathe. The Kwik-Lathe
producedby Kwik-WayManufacturingCo. and the
"Front Brake Disc Lathe" offered by Snap-onTools
Co. are appfovedfor this operation.
MEx. RefinishingLimit: 21.0 mm (0.83 in)
Brako disc thickness:

Standard:23.O mm {0.91 inl
O.O15mm (0.00OOin) mar.

BrakoDisc Parallelism:
NOTE; This is the maximum allowabledifference

between any thicknessmeasurements.
4. lf the disc is beyondthe servicelimit for parallelism,

refinishthe rgtor with an on-car brake lathe. The
Kwik-Larheproducedby Kwik-Way Manufacturing
Co. and the "Front BrakeDisc Lathe" offered by
Snap-onTools Co. are approvedfor this operation.
NOTE: A new disc should be retinished if its
runout is greaterthat O.l O mm {O.OO4in}. Max. R€finishingLimit: 21.O mm (0.83 in)
19-11
Bleeding
cAUTtOt{: FRONT:
o Uso only clsan DOT 3 or 4 brake fluid,
a Mako suro no dirt 01 oth€l toreign mattor i5 allowod
to contaminate ths brake tluid.
a Do not mix diflorent brands of brako fluid as they
may not be compatible.
a Do not spill brake fluid on tho car; lt may damags the
paint; it brake tluid does contact the paint, wash it
ofl immadiately with wator.
NOTE: The reservoiron the master cvlinder must be

full at the stan ot bleedingprocedure,and checked
after bleedingeach brakecaliper.Add fluid as required.
Use only clean DOT 3 or 4 brakefluid.
BLEEDING
SEOUENCE:
REAR:
O Fronr Right O Roar Rlght
BI-EEDSCREW
a Front Loft a R..r L.fi
1 . Have someone slowly pump the brake pedal

severaltimes, then apply steady pressure.
Loosenthe brake bleed screw to allow air to escape

from the system. Then tighten the bleed screw
securelv.
3. Repeatthe procedurefor each wheel in the se-

quence shown above, until air bubblesno longer
appearin the fluid,
4. Check brake performanceby road testing.
19-12
Master Cylinderand BrakeBooster
CAUTION:
a Be calelul not to bend or damago tho brake pip€s whsn removing tho mast6r cylindor and boostef.
a Do not spill brako fluid on the cai; it may damag€the paint; if brake fluid do€s contact th€ paint. wash it oft immediate-
ly with wat€r.
o To prevsnt spllls, cover the hose ioinis wiih rags or shop tow6ls.
a Before lesssembling, check that all parts als tree ol dust and oth€r toreign particlos.
a Mako sur6 no din or oth6r foroign matter is allowod to contaminat€ th€ brake tluid.
a Do not mir dift6r6nt brands ot brak€ tluid as they may not bo compatibls.
a Do not raus€ th6 drain€d fluid. Us€ only closn DOT 3 oi 4 brake fluid.
a Whon connecting the b18k€pipes, msko suro that thor6 is no intoderenco botwoan tho brake pipos and othor parts.
a Do not disass€mbletho mastor cylindor or boost6r, Roplacoth€m as complots assomblies.
1. Drainthe brakefluid from the mastercylinder.

2. Disconnectthe brakefluid level switch connectors.
3. Disconnectthe brake pipesJromthe mastercylinder.
4. Removethe mastef cylindermountingnuts and the mastercylinder.
5. Disconnectthe vacuum hose from the boosterand removethe vacuum hose bracket.
6. Removethe thfottle/cruisecontrolcableb.acket,then.emovethe throttlecableg.ommetfrom the enginecompart-
ment bulkhead,
7 . Removethe intake air temperaturesensorfrom the intakemanifold. PUSHBOD LOCKNUT
8 . Loosenthe pushrodlocknut. and removethe cotter pin and joint pin. 15 N.m ll.5 kg-m,11 lb-ftltor carswithoutABS
q
Removethe boostermountingnuts and clevis, 19 N.m 11,9kg-m, 14lb-ftl tor cars with ABS
1 0 . Removethe brak€ booster(seenext page). COTTER.PIN BRAKEBOOSTER
8 x 1.25mm Do not disassemble.
13 N.m
11.3kg-m, 9 lb-ft|
JOII{T PIN
-6l
DUALPROPORTIONING
To right- VALVE
rcar blako Oonot disassemble.
x 1,25
To left-.e6r b.ako l5 N.m
( 1 . 5 k g - m ,1 1 l b - f t )
\
---
19 N.m
{1.9 kg-m, 14lb-ft)
l O r 1 . Om m
19 N.m ,/
{1.9 kg-m, t4 lb-ftl To .ight-tront brako
11. Installthe brake boosterand mastercvlinderin the reverseorder oI removal.
NOTE: Beforeinstallingthe mastercylinder,check and adjustthe pushrodclearance(seepage 19-15).
12. After installation,check and adjustthe brakepedal height (seepage

- 19-4).
1 3. Fill and bleedthe brake system {see page 19-12). (cont'd)
19-13
Master Cvlinder and Brake
Booster Master Cylinder
(cont'dl
Removal/lnstallation Inspection
Boorter Replacement CAUTION:
a Do not splll brak6 tluid on the car; it may damagc the
1. Pull th8 brak6 booster torward. then turn it to th6 palnt; il brak€ fluid doos contact th€ paint, wash lt
right until the oporating rod is clear of the bulkhead ofl immediately with vvater.
as shown below. a B€foro roassambling,check thst all parts ar€ treo ot
dust and other fo?olgn particles,
2. Move the ope.sting rod beyond the left dampe. a Do not try to disasssmblo th6 maEtar cylindef
bas6 by turningthe brake booster. assembly, Beplaco tho ma3t€r cylindor assombly
with a now part it necessary.
EFAKEBOOSTER ROD
OPERATII{G a Make sura no dirt or othof toloign matter is allowed
to contaminate tho blako tluld.
Frcnt
/
LEFTDAMPERBASE
Continue to turn the brak8 booster until the

ope.ating rod points forward,
R€move the brake booster from the engin€ com-

partmont with the front cylinder shell sid8 of the
b18k€boosteruDw8rd.
FRONTCYLII{DERSHELL
CYLINDER
SILICONEGREASE Checkfor loaksor damags.
OPERATINGROD
19-14
BrakeBooster
Tests PushrodClearanceAdjustment
Functlonal Test NOTE: Master cylinder pushrod-to-pistonclearance
1, With the enginestopped.depressthe brake pedal must be checkedand adjustmentsmade, if necessary.
severaltimes,then depressthe pedalhardand hold b€fore installingmastercylinder.
that pressurefo. 15 seconds.lf the pedalsinks,the
master cylinder, brake line or a brake caliper is 1. Set the specialtool on the master cylinderbody;
taulty. push in the center shaft until the top ot it contacts
with the end of the secondarypistonby turningthe
2. Start the engine with the pedal depressed.lf the sdjustingnut.
pedal sinks slightly,the vacuum booster is work-
PUSHBODADJUSTMENT
GAUGE
ing. lf the pedalheightdoes not va,y, the boosteror 0TJAG-SD40100
check valve is faulty.
Lesk T6st
1. Deprsssthe b,ake pedal with the enginerunning, ADJUS?ING NUT
then stop the engine.It the pedal height does not
vary while depressedfor 30 seconds,the vacuum
booster is OK, lf the pedal rises, the booster is
taulty.
CAUTION: Do not try to disa$ombl€ th€ boosto..

Replac€the boostor assembly with a new ono. MASTER CYLINOER
SECONDARYPISTON
CENTERSHAFT
2. With the enginestopped,depressthe brake pedal
several times using normal pr€ssure.When the
pedal is first depressed,it should be low. On con- Without disturbingthe center shaft's position,in-
secutiveapplications,pedalheight shouldgradual- stall the specialtool upsidedown on the booster.
ly rise. lf the pedal positiondoes not va,y, check
the boostercheck valve. Install the master cylinder nuts and tighten to the
specified torque.
Check Valve Tost
1. Disconnectthe brake boostervacuum hose at the 4. Connectthe booster in-linewith a vacuum gauge
booster. 0-760 mm HS (O-30 in Hg) to the booster's
engine vacuum supply, and maintain a engine
2. Stsrt the engine and let it idle. There should be speed that will deliver 500 mm Hg (2O in Hg)
vacuum available.lf no vacuum is available.the vacuum.
check valve is not working correctly.
Replacethe check valve and retest. 5 . With a feeler gauge. measurethe clearancebe-
tween the gauge body and the adjusting nut as
snown.
CHECKVALVE
Cloaranc6:
C81swithout ABS: O-0.4 mm {O-0.O2 in}
Car8 with ABS: O-O.2 mm (O-O.01 inl
VACUUM GAUGE
0-760 mm Hg lO-3O in Hgl
(Commercially
Available)
15 N.m 11.5kg-rn,
1 1 tb-ft}
]{UT
ADJUSTING (cont'd)
1 9 - 15
BrakeBooster
PushrodClearanceAdjustment (cont'd)
NOTE: lf the clearancebetween the gauge body and 7 . Adjust the pushrodlength as shown ii the booster
adjustingnut is 0.4 mm (0.02 in) [cars with ABS: 0.2 is removed.
mm (0.01 inll, the pushrod-to-pistonclearanceis 0
mm. However,the clearancebetweenthe gauge body
and adjusting nut is O mm, the pushrod-to-piston 1 1 6r 0 . 5 m m
clearanceis O.4 mm (O.O2inl lcars with ABS: O.2 mm (4.6 t 0.02 in)
(O.O1in)l or MOBE.Therefore,it must be adjustedand
rechecked.
6. lf the clearanceis incorrect:

- Cars without ABS: loosenthe star locknut and
adjustthe clearanceby turningthe adjusterin or
out while holdingthe pushrod.
Tightenthe star locknut to the specifiedtorque
and removethe sPecialtool.
NOTE:
a Adjustthe clearancewhile the specifiedvacuum
is appliedto the booster,
a Hold the cleviswhile adjusting,
LOCKNUT
O-O.4 mm (0-0.02 inl 15 N.m
STARLOCKNUT (1.5 kg-m,
22 N.m PUSHROD 11 tb-ftt
12.2kg-m,l6lb-ft|
8. lnstallthe mastercylinder(seepage 19-13).
o After installation,perform the following inspec-

tions and adjustil necessary.
a Brakepedal height {seepage 19-4}
. Brakepedalfree play (seepage 19-4)
- Cars with ABS: removethe specialtool and ad-

just the clearanceby turning the adjusterin or
out while holdingthe output rod.
O - O . 2m m 1 0 - 0 . 0 1i n l
19-16
RearDisc Brakes
Torque/lnspection
a Ngver use an air hose or dry brush to clean btake assemblies.

a Use an OSHA-approvedvacuum cleaner,to avoid breathingbrakedust.
a Contaminated brake discs or pads reduce stopping ability.
CAUTION:
a Do not spill blake tluid on the car; it may damagethe paint; il brske fluid does contact the paint, wash it oft immediato-
ly with watsr.
a To prevent spills, cover the hose ioints with rags or shop towels,
a Clean all parts in brako fluid and air dry; blow out all passagewith compr€ss€dair.
a Batore reassembling,check that all parts ar6 free of dust and other toreign panicles.
a Replacs parts with new ones whenevei sDeciliedto do so,
a Make sure no dirt o? other loreign mattet is allowgd to contaminate the blake fluid,
a Do not mix different brands of brake fluid as they may not be compatiblo.
a Do not reuse the drained lluid. Use onlv clean DOT 3 or 4 brake fluid.
NOTE:
a Coat piston, piston seal, and caliperbore with cleanbrakefluid.
a Replaceall rubberparts with new ones wheneverdiassembled.
-{Z-aiiif-{ : Brakecylindergrease(P/N:08733-Bo2oE) or equivalentrubbergrease. .-6f , Siliconegrease.

BRAKEPADS RETAINER OUTERPAD SHIM
Checkliningthick- Checkfor weakness Checkfor wear. '10x 1.25 mrn
or oamage, Apply Molykoteo M77 to 39 N.m
INNERPAD SHIM pad side of shim. (3.9 kg-m, 28 lb-ftl
Checktor wear.
Apply Molykoreo M77 ro
pad side of shim.
CALIPER
BRACKET
CheckIor
cracks.
PARKINGNUT
10x1.25mm
28 N.m (2.8 kg-m.
20 tb-frl
SPRING
CAM BOOT
Replace.
PAD SPRING -
-.'j@Ell PINBOOTS
cr,."t r". *.* or Replace.
damage,
\
I SLEEVE PlsroN
I Checkfor wear
f or damaoe.
',.'' KX( I check ror wearor PISTONASSEMBLY

1 lniir- I d"maqe. Checktor scoringon
D S^ J I
'''ry9 the surface,
CALIPERBODY
Checkfor scoring
O-RING'-
Reolace.
=^"
c:_9!!a!$l
.,,- cuP ./
Replace.
A-^
._=i!!l!iil
BEARTNGA
Check for damage
'y"P"M
cfRcLrP
/
(nl,--/
/
/
/r,"ron
Replace.
I 4..
"oo,
on cylinderwall. ADJUSTING
SPRINGB Replace.
8 mm FLANGEBOLT tor SPBING
Check
23 N.m (2.3 kg-m, 17lb-ftl Checkfor damage.
19-17
RearBrakePads
lf liningthicknessis lessthan servicelimit at step 5,
@
a iloyor uae an alr hose 01 dry blush to cloan brake .eplace the rear pads as a set.
assamblies.
a Us6 an OsHA-approvod vacuum cloanor, to avoid
breathing brake dust.
1. Block the front wheels, loosenthe rear wheel luq.

nuts slightly, support the rear of car on satety
stands.then removethe rear wheels.
Releasethe parkingbrake.
2, Removethe calioershield.
CALIPER
SHIELD
Remove the two caliper mounting bolts and the 4. Removethe pad shims, pads and pad retainers.
calipertrom the bracket.
Using vernier calipers,measurethe thickness of
CAUTION: each brakepad lining,
a Thoroughly cloan ths outsido ot tho calipsr to
prevont dust and dirt ttom ontodng insid6. B.ako Pad Thicknass:
a Support the calipel with a pleco ot wilo 5o that it Standard: 9.O mm (O.35 in)
does not hang trom tho brako hose. ServicoLimii: 1.6 mm (0.06 inl
CALIPERMOUNTING
NOTE: Measurementdoesnot includepad backing

Dlatethickness.
19-18
o. Cle6nthe caliperthoroughly;removeany rust, and 9. Rotatethe caliperpistonclockwiseinto placein the
check lor groovesor cracks. cylinder,then alignthe cutout in the pistonwith the
tab on the inner pad by turningthe piston back.
7. Make surethat the pad retainersare installedin the
correct Dositions. CAUTION: Lubricats the boot with silicone groaso
to avoid twisting the piston boot. lf piston boot is
twisted, back it out so it sits proporly,
1O. Installthe caliperon the caliperbracketand tighten

the calipermountingbolts.
BRACKET
8. Install the brake pads and pad shims on caliDer

bracket. CALIPERMOUNTING
BOLTS
23 .m (2.3 kg-m,
t 7 lb-ft1
a Whon rousing tho pads, always reinstall the
blake pads in their original poaitions to prevent
loss ot braking sfficioncy.
PISTONBOOT
a Contaminated brako discs or pads reduco stop-
ping abillty. Ko€p greaseoft tho disca and pads. =^"
#.!!!4t!x
11. Installthe calipershield.
NOTE:
a Apply Molykote@ M77 to the pad side of the
shims. Wipe excessgreaseoff the shims.
a Install the inne. pad with its w€ar indicator fac-
ing upwa.d.
12. Depressthe brakepedalseveraltimes to make sure

the b.akeswork, then road-tesr.
NOTE; Engagementof the brake may require a

gr€ater pedal stroke immediatelyatter the brake
pads have been replacedas a set. Seve.alapplica-
tions ot the brake pedal will restore the normal
REARBRAKEPADS pedal stroke.
19-19
RearBrakeDisc
Runout Inspection Thicknessand Parallelism
Inspection
Loosenthe rear wheel lug nuts slightly,then raise 1. Loosenthe rear wheel lug nuts slightly,then raise
the car and supporton safety stands. the car and supporton safety stands.
Removethe rear wheels. Removethe rear wheels.
2 . Removethe brake pads (see page 19-181. Removethe brake pads (seepage 19-18).
InsDectthe disc surlace tor grooves,cracks, and Using a micrometeJ.measure disc thickness at
rust, Cleanthe disc thoroughlyand removeall rust. eight points, approximately45o apart 8nd 1O mm
(0.4 in) in from the outer edge of the disc.
4. Use lug nuts and suitableplainwashersto hold the
disc securelyagainstthe hub. then mount a dial in-
dicatoras shown and measurethe runoutat 1Omm
(O.4 inl from the outer edge of the disc.
Brake Disc Runout:

Selvics Limit: 0.1O mm (0.O04in)
lf the disc is beyondthe servicelimit, refinishthe

rotor,
Max. RslinishingLimit: 8.O mm lO'32 in)
Blake Disc Thickness:

Standard:1O.Omm (O.39in)
O.O15mm (O.O006inl max.

BrakeDisc Parallelism:
NOTE: This is the maximum allowablediJference

WHEELNUT between any thicknessmeasurements.
1 1 ON ' m
tl1 kg-m'80 lb-ft| 4. It the disc is bevondthe servicelimit tor parallelism,
.efinishthe totor.
NOTE: A new disc should be refinished if its
runout is greatetthan O.1Omm (O OO4in). Max. Refinishing Limit: LO mm {0.32 in)
19-20
RearCaliper
Disassembly
ren
5 . Removethe pad springfrom the caliperbody.
a Never use an air hose or dly brush to clean brake
assemblies. 6. Remove the piston by rotating the piston
a Use an OsHA-apprgved vacuum clganer to avoid counterclockwisewith the specialtool and remove
bleathingbrake dust. the Distonboot.
CAUTION: CAUTION: Avoid damaging the piston.

a Do not spill brake fluid on the car; it may damago th€
paint; it brake fluid does contact the paint, wash it
off immediately with water. PISTONBOOT
a To prevent spills, cover the hose ioints with rags or
shoo towels.
a Clean all parts in brake tluid and air dry; blow out all
passages with complessed air.
1. R e m o v et h e c a l i p e sr h i e l d( s e ep a g e1 9 - 1 8 ) .
2. R e m o v et h e l o c k p i n a n d c l e v i sp i n .
Removethe cable clip and disconnectthe parking
brake cable trom the arm.
LOCK PIN
LOCKNUTWRENCH
07916-6390001
7. Removethe piston seal.
CAUTION: Take cars not to damage th6 cylinde.

bole.
3. Removethe banjo bolt and two sealingwashers.
4. Removethe two calipermountingbolts and caliper

body from the bracket.
MOUNTING
CALIPER EOLT
Replace.
SEALING
WASHERS (cont'd)
Replace.
19-21
RearCaliper
Disassembly(cont'd)
8. Install the specialtool between the calipet body 1 1. Lower the locknutslully and tighten the locknuts
and spflng cover. securely.
CAUTION: Be careful not to damag€ th€ inside of NOTE: Keepthe locknutsin this positionuntil you
tho calipor cylinder du ng calipGrdisa$€mbly. reinstallthe citcliD.
9. Positionthe locknutsas shown, then turn the shaft

until the plate just contactsthe caliperbody,
NOTE: Do not compress the spring under the

spring cover.
LOCKNUTS
PLATE
BRAKESPRING
COMPRESSOR
oTHAE-SGOOIOO
12. Removethe circlipwith snap ring pliers.
SNAP RING
PLIERS
07914-SAs(Xxro
1O. Turn the shaft clockwise 1/4-112 turn to com-
pressthe adiustingspring B in the caliperbody.
CAUTION: To plsv€nt damags to ths inn€r com-

pononts, do not turn thg shaft more than 1/2 tutn.
19-22
13. Hold the plate with your fingersand turn the shatt 1 6 . Removethe sleevepiston,and removethe pin from
counterclockwise.Remove the sDecialtool from the cam.
the caliper.
SLEEVE
PISTON
17. Removethe return spring.
18. Removethe parkingleverand cam as an assembly

from the caliperbody.
1 4 . Removethe adjustingbolt. CAUTION: Do not loos€n the parking nut with tho
cam installod in tho calipar body. It the lever and
Remove the spring cover, adjusting spring B, shaft must b6 sopa.ated, hold the levsr in a viso
spacer,bearingA and cup trom the adjustingbolt. and looson tho parking nut.
19. Removethe cam boot.
RETURN
SPRIlTG
PARKINGLEVER/
CAM ASSEMBLY
PARKI G NUT
19-23
RearCaliper
Reassembly
CAUTION: Z^" : Commarcially.vailabl€
a Do not spillbrakotluidonthe car; it may damagothe #jlqqil ..'embtv tube
paint; if blake fluid does contact the paint, wash it
RETURN
oft immsdiatoly with water.
a Botore reassembling,check thst all pa.ts aro floa ol
dust and oth€r forsign panicles.
a Roplaceparts with new ones when€ve. sp€cifisd to
do ao.
a Make sure no din or other for€ign matter is allowed
to contaminato the brak€ tluid.
a Oo not mix different brands of brske fluid as thoy
may not be compatibl€.
a Do not reuse th€ drained tluid, Uso only cloan DOT 3
or 4 brakefluid.
'I . Pack all cavitiesof the needle bearingwith com-
merciallyavailableassemblylube.
2. Coat the new cam boot with commercially

availableassemblylube and installit in the caliper
DOOy.
3. Apply commerciallyavailableassemblylube to the

pin contactingarea of the cam and installthe cam
and lever assemblyinto the caliperbody.
4. Installthe return spring.
CAUTION:
a When the cam and leve? wa.e separatgd, bo lnstsllthe pin in the cam.
sure to assemblothsm betoro installing the cam
in th€ caliper body. Install tho l€vsr and 3p ng Installa new O-ringon the sleevepiston.
washer, apply locking ag€nt to ths threads, and
tighten the parking nut whib holding lhe lovor lnstallthe sleeveDistonso the holein the bottom of
with a viso. the piston is alignedwith the pin in the cam, and
a Avoid damaging the cam boot since it must be two pins on the pistonare alignedwith the holesin
installed botore the cam. the caliDer.
a When installing the cam, do not allow the cam
boot liDs to tu]n outsid€ in.
HOLES
SLEEV€nSTOf{
19-24
8. Cost a new cup with brake cylindergrease (P/N: 11. Check that the tlared end of the spring cover is
08733-BO2OE) or equivalentrubber grease,and below the circlipgroove.
instaltit with its groovefacingthe bearingA sideof
the adiusting bolt. 12. Installthe circlip in the groove, then remove the
specialtool.
9. Fit the bearingA, spacer, adjustingspring B and
springcover on the adjustingbolt. and installthem NOTE: Check that the circlip is seated in the
in the calipercylinder. groove properly.
SI{AP RING
PLIERS
SPRING
COVER
@-S";X""'Y"
@+SPACER
+__EEARINGA
e
l<ro'lusrnc
/15
\=z
{=="r"
=^^
r:4i!!l!!,il
'lo. Installthe specialtool on the springcover and tu.n 13. Coat a new pistonseal with siliconegreaseand in-
the shaft until the locknut contactsthe olate. stall it in the caliper.
14. Apply brakecylindergrease(P/N:08733-BO2OE)

or equivalentrubber greaseto the sealinglips and
inside of a new piston boot, and install it in the
calioer.
PISTONSEAL
-Gr
PISTONBOOT
tzt=-1"=-- "
.4-$q!!n
RUBBER GREASE (cont,d)
19-25
RearCaliper
Reassembly(cont'd)
15. Coat the outsideof the Distonwith brakefluid and 19. Installthe caliperon the caliperbracketand tighten
install it on the adjusting bolt while rotating it the calipermountingbolts.
clockwisewith the sDecialtool
20. Connect the brake hose to the caliper with new
CAUTION: Avoid damaging the piston and piston sealingwashersand tighten the banjo bolt.
boot.
CALIPERMOUNTINGBOLTS
23 .m (2.3 kg-m, l7 lb-ft)
CALIPERBRACKET
BAI{JO
BOLT
35 N.m 13.5kg-m.
25 rb-ft|
EXTENSION
8AR
Commercially
available CALIPER
16. Installthe pad spring on the caliper. 21. Insen the parkingbrakecablethroughthe arm and
connect the parkingbrake cable to the lever with
the clevis pin and lock pin.
Installthe cable clip securely.
PAD SPRING
LOCK PIN
PARKINGBRAKE
CABLECLIP
22. Fill the brake reservoir up and bleed the brake

17. Installthe brake pad retainersand brake pads. s y s t e m( s e ep a g e1 9 - 1 2 ) .
18. Align the cutout in the pistonwith the tab on the tn- 23, Operatethe brakepedalseveraltimes, then adiust
n e r p a d { s e ep a g e 1 9 - 1 9 ) . the parkingbrake (seepage 19-51.
19-26
BrakeHoses/Pipes
Inspection
1. Inspectthe brake hosesfor damage,leaks,interferenceor twisting.
2. Ch€ckthe brakelines tor damage,tipping, rustingor leakage.Also check ior bent brakelines.
3. Check fo. leaksat hose and line joints or connections.and retightenif necessary.
CAUTION: Roplacotho brako hose clip whonever the blake hos6 is servicod.
BBAKE LINE.TO.ARAKEHOSE
15 N.m {1.5 lg-m, 1l lFftl
BRAKELII{E.TO.BBAKE HOSE
15 N.m 11.5kg-m,11 lb-ftl
MASTER CYLIT{DER-TO.BRAKE LINE
19 .m {1.9 ks-m. 14 lb-ft)
BLEEDSCREW BLEEDSCREW
9 N.m (0.9kg-m,6.5lb-ftl 9 N.m lO.9 kg-m,6.5 lb-ftl
BRAKEHOSE.TO.CALIPER BRAKEHOSE.TO.CALIPER
IBANJOBOLTI IBANJO BOLT)
35 .m {3.5 kg-m.25 lb-ft| 35 N.m {3.5 kg-m,25 lb-ft}
19-27
BrakeHoses/Pipes
Brake Hose Replacement
cAuTro :
BNAKEHOSE CLIP
a Bofo.. reassembling,ch€ck that all parts are free ol
Roplace.
dust and othel toraign particles.
Roplaceparts with new ones whenev€l spocitiod to BRAK€ HOSE MOUNTING
do so. SOLT
a Uss only cl€an DOT 3 oi DOT 4 braks fluid. (8 x 16 mml
a Mako suro no dirt or otho. toroign mattar is allowod 22 N.m 12.2 kg-m,
to contaminate th€ blake tluid. 16 tb-frl
a Do not mix diff€r€nt brands of brako fluid 8s thoy
may not be compatibl€.
a Do not spill brake fluid on the car; it may damagethe
paint; it brake tluid doos contact the paint, wash it
oft immediately with wator.
1. Replacethe brake hose if the hose is twisted,

crackedor if it leaks. BRAKEHOSE
MOUNTING BOLT
2. Disconnectthe brakehose from the brakeoioe us- 1 8x 2 0 m m ) l
ing a 1O mm flare nut wrench. 22 N.m 12.2
16 lb-fr)
BRAKE P'PE
BANJO BOLT
1 0 x 1 . Om m HOSE
35 N.m MOUNTINGBOLT
13,5kg-m, 25 lb-tt) 10 N.m (1.0kg-m,
7 tb-ftl
6. Installa new brakehose with the brakehoseclamo
bolts.
7 . Connectthe brakehoseto the caliperwith the ban-

jo bolt and new sealingwashers.
8. Installa new brake hose clip on the brakehose.
9 . Connectthe b.ake hose to the brakepipe.
Removeand discardthe brake hose clip from the

brake hose.
4. Removethe banjo bolt and disconnectthe brake

hose from the caliper.
Removethe brakehose clamp bolts and the brake

hose.
BRAKEHOSECLIP
1 0 .After installingthe brake hose, bleed the brake

system (see page 19-121,check the hose and line
joints for leaks.and tighten if necessary.
19-28
ParkingBrake
and Reassembly
Disassembly
CAUTION: Tho parking brak€ cables must not be bont or distorted. This will load to stift operation and prematurr cablo
tailure,
PARKINGBRAKECABLES
Check for laulty movomont.
"
ds
/ \
/ \
/ \
CLEVISPIN LOCK PIN
Replace.
EOUALIZER
(Sliding
surface)
Disconnectthe pa,king brake cable from the lever on

the caliperby removingthe lock pin and clevispin, and
removethe cable from the arm by removingthe clip.
cLEVtSnN
19-29
Anti-lockBrakeSystem(ABSI
SpecialTools .......... 19-32 Modulator Unit
l l l u s t l a t oIdn d e x . . . . . . . . . . . . . . . . . . . . . . . .1. 9
. .-. 3 3 Removal/lnstallation............... .... 19-8.2
Anti-lock Brake System (ABSI lndex/Torque ....... 19-83
Featules/Construction/ Solenoids
Operation ........ 19-34 LeakTost ............19-84
CircuitDiagram ....... 19-46 Pump
Wiring/ConnoctolLocations ............ 19-5O PressureSwitch Replacement...... 19-84
ALB Checker Accumulator
FunctionTest ...... 19-51 Disposal ..............19-85
Wheel Sensor Signal Bleeding . . . . . . . . . . . . . . .1. .9 - 8 6
Gonfirmation ... 19-53 Electronic Components
Troubleshooting ABS ControlUnit Replacemont..... 19-87
Anti-lock Brake System (ABSI RelayInspection ... 19-87
IndicatorLight .. 19-54 Puleers/WheelSensors
Symptom-to-SystemChart .......... 19-56 Inspection ...........19-88
Flowcharts ......... 19-57 WheelSensorReplacement ..........19-89
Hydraulic System
Index HydraulicConnections........ 19-80
Relieving Accumulator/
LinePressure ... 19-81
Sp e ci a l To ols
Ref. No. I Tool Numbel Description Oty Page Reference
o OTHAA-SGOO101 or BleederT-wrench 19 - 5 7 . 1 9 - 6 4 ,
't9-81.19-86
oTHAA SG00r O0
,a\ O T H A J - S G O OOl A o r ALB Checker 1q_ql 1q_A?
OTHAJ_SGOOlOB r 9-86
oTHAJ-SGOO200 ALB Checker(Canada)
ffi?n
tr
-T- +{
i-l
E
ll
II
tl
u
U
o i.?,,
19-32
"
lllustratedIndex
@ The accumlator contains high-pressure nitrogon gas, do not puncture, expose to tlame or altempt to
disassernblethe accumlator or it may explode; severe personal injury may.osuh.
BRAKEHOSES/PIPES
REARWHEEL SENSOR fnspection, page 19-27
MODULATORUNIT Inspection,page 19-88 BrakeHose Replacement,
HydraulicConnection,page 19-80 Replacement, page 19-89 page 19-28
page 19-82
Removal/lnstallalion,
page 19-83
Index/Torque,
Accumulator,page 19-85
HYDRAULICSYSTEM
RelievingAccumulator/Line PARKINGBBAKE
Pressure,page | 9-81 Adjustment,page 19-5
Bleeding,page 19-86 Disassemblyand
ABS CONTROLUNIT
page 19-87 Roassembly,page 19-29
Replacement,
FRONTERAKES
Torque/lnspection,page 19-6 REARDISC
Front BrakePads,page 19-7 page 19-17
Torque/lnspection,
Front Caliper,page 19-9 RearBrakePads,page 19-18
Fronl BrakeDisc,page 19_11 RearBrakeDisc, page 19-20
RearCaliper,page 19-2't
WHEELSENSOR
Inspeclion,page 19-88
MASTERCYLINDERAND BRAKEBOOSTER Replacement, paqe 19-89
HydraulicConneclion,page 19_8O
MasterCylinder,page 19 14
BrakeBooster,page 19 15
19-33
Anti-lockBrakeSystem (ABSI
Features/Construction/Operation
In a conventionalbrakesystem, iJ the brakepedalis depressedvery hard,the wheelscan lock beforethe vehiclecomes

to a stop. In such a case,the stabilityof the vehicleis reducedif the rearwheelsare locked,and maneuverability
of the
vehicleis reducedif the front wheels are locked,creatingan ext.emelyunstablecondition.
The Anti-lock BrakeSystem (ABS)modulatesthe pressureof the braketluid appliedto each front caliperor both rear
caliperstherebypreventingthe lockingof the wheels,wheneverthe wheelsare likelyto be lockeddue to hardbfaking.lt
then restoresnormalhydraulicpressurewhen there is no longerany possibilityof wheel locking.
F6atures
a Increasedbrakingstabilitycan be achievedregardlessof changingd.ivingconditions.
a The maneuverabilityot the vehicleis improvedas the system preventsthe front wheels from locking.
a When the anti-lockb.ake system goes into action, a kickbackis felt on the brakepedal.
a The system is equippedwith a self-diagnosisfunction.When an abnormalityis detected.the ABS indicatorlight
comeson. The locationoi the system'stroublecan be diagnosedfrom the frequencyof the systemindicatorlight
blinks.
This sYstemhas individualcontrolot the lront wheels and commoncontrol ("Select Low") lor the rear wheels.
"Select Low"
means that the rear wheel that would lock first (the one with the lowest resistanceto lock-uo)
determinesanti-lockbrake system activationtor both rear wheels.
The system has a fail-safefunction that allows normal braking if there's a problemwith the anti-lockbrake
svstem.
Construction
In additionto the conventionalb.aking system, the anti-lockbrake system consistsof: gear pulsersattachedto the
rotating part of individualwheels; wheel sensors,which generatepulsesignalscorresponding to the revolutionof the
gear pulsers;ABS controlunit, which controlsthe workingof the anti-lockbrakesystemby performingcalculationsbas-
ed on the signalsfrom the individualwheel sensorsand the individualswitches; modulatorunit, which adjuststhe
hydtaulicpressureappliedto each caliperon the basisot the signalsreceivedfrom the ABS controlunit; an accumulator,
in which high-pressurebrake lluid is stored, a pressureswitch, which detects the pressurein the accumulatorand
transmits signalsto the ABS control unit; a power unit, which suppliesthe high-pressureworking fluid to the ac-
cumulatorby meansof a pump; a motor relayIor drivingthe power unit; {ail-saierelays.which cut off the solenoidvalve
ground circuit when the fail-safedevice is at work; and, an ABS indicatorlight.
ABSCONTROL MASTER CYLINDER
WHEEL SENSOR
PULSER SENSOR
19-34
Master Cylinder
1. Construction
A tandemmastercylinderis usedto improveth€ safety of the brakingsystem.In addition,centervalvesara usodso
as to match the anti-lockbrakesvstem oDeration.
The mastercylinderhas one reservoirtank which is connectedto the cylindersectionsby two smallholes.lt hastwo
pistons:primaryand secondary,which are crisscrossconnectedwith the cslipersso that the fluid pressureworks
separatelyon each system (front right wheel & rear left wheel, and front left wheel & resr right wheell.
A stop bolt for controllingmovementof the primarypistonis providedat the sideof the mastercylindetbody. A r€€d
switch for detectingthe braketluid volume is also providedin the cap of the reservoi,tank.
2. Ooeration
When the brakepedalis depressed,the secondarypistonis pushedthroughthe brakeboosterand the contervalveB
is closedso that fluid pressureis generatedon the secondaryside.At the sametime, the p,imarypistonis push6dby
the sscondaryfluid pressureand the centervalveA is closedso that brakingfluid pressureis generatedboth on th€
primaryand secondarysides.
When the brake pedal is released,the primaryand secondarypistonsare returnedto the originalpositionby the
brakefluid pressureand piston spring.
CENTERVALVEB
(cont'dl
19-35
(cont'd)
3. Responseswhen fluid is leaking

(1) In case of leakingtrom the primarysysteml
Sincethe fluid pressureon the primaryside does not rise,the primarypiston is pushedby the fluid pressureof
the secondarypiston and the tensionof the pistonspringuntil the end hits on the cylinder.The brakingis per-
formed bv the fluid oressureon the secondarvside.
FRONT-LEFT
t 2 l In case of leakingfrom the secondarysystem:

The secondarypiston does not producefluid pressure,keeps moving ahead,hits on the end surlace of the
primarypistonso that the primarypiston is pushedunderthe sameconditionas an ordinaryrod. Theretore,the
brakingis conductedby the fluid pressureon the primaryside.
1 9 -3 6
Wheel Sensor
The wheel sensoris a contactlesstype that detectsthe rotatingspeedof a wheel.lt is comprisedof a permanentmagnet
and coil. When the gear pulsersattached to the rotating parts of each wheel (front wheel: outboard toint of the
driveshaft,rear: hub bearingunit) turn, the magneticllux aroundthe coil in the wheel sensoralternates.generaling
voltageswith frequencyin proportionto wheel rotatingspeed.Thesepulsesare sentto the ABS controlunit and the ABS
control unit identifiesthe wheel speeds.
PERMANENT
MAGNET
\ l
\lrrral
/ JJ"-'-c-- ou*ur
, f -
t
GEAR PULSER
at HIGHSPEED
"-', at LOW SPEED

VOLTAGE
ABS ControlUnit
The ABS controlunit consistsof a main functionsection,which controlsthe operationof the anti-lockbrakesystem,and
"self-diagnosis"
subfunction,which controlsthe pump motor and
'1. Main Function
The main lunction sectionof the ABS controlunit performscalculationson the basisof the signalslrom each wheel
sensor and controlsthe operationof the anti-lockbrake system by putting into action the solenoidvalves in the
modulatorunit for each front brakeand lor the two rear brakes.
2. Sub-tunction
"selt-diagnosis"signals,necessary
The sub-functionsectiongivesdrivingsignalsto the pump motor and alsogives
for backingup the anti-lockbrakesystem.
ABS CONTROLUNIT soLEf{orD

VALVES
WHEEL MAIN FUNCTION
SENSORS
PRESSURESWITCH SUB-FUNCTION
. FAIL-SAFE
PUMPMOTOR . PUMPMOTORCONTROL
PARKINGBRAKE . SELF-DIAGNOSIS
swtrcH
MAIN FUNCTION
SUB.FUNCTION
. FAIL-SAFE
. PUMP MOTOR CONTROL
. SELF.DIAGNOSIS
19-37
Anti-lock BrakeSystem (ABS)
(cont'dl
1. Sell-diagnosticFunction
Sincethe anti-lockbrakesystem modulatesthe brakingpressurewhen a wheel is about to lock, .egardlessol the
driver's intention,the system operationand the braking power will be impairediJ thsre is a malfunctionin th€
system. To preventthis possibility,at speedsabove 6 mph (1O km/h). the selt-diagnosis function,p.ovidedin the
sub-tunctionof the ABS control unit. monitorsthe main system functions.When an abnormalityis detected,tho
ABS indicatorlight goes on. Thereis alsoa check modeof the self-diagnosis systemitself;when the ignitionswitch
is tirst turned on, the ABS indicatorlight comeson and stays on for a Jew secondssfter the enginestarts,to signify
that the self-diagnosis system is functional.
2. Fail-safeFunction
When abnormalityis detectedin the controlsystem by the self-diagnosis,the solenoidoperationsare suspendedby
turningoft the relaysItail-saterelays)which disconnectthe groundlinesof all the solenoidvalvesto inhibitanti-lock
brakesvstem operations,Underthese conditions,the brakingsystemfunctionsjust as an ordinaryone, msintaining
the necessarybrakingfunction. When the ABS indicatorlight is turned on, it meansthe tail-safeis Junctioning.
ModulatorUnit
Modulatorsfor each wheel and solenoidvalvesare integratedin the modulatorunit.

The modulatorsfor front and rearbrakesare ot independentconstructionand are positionedverticallyfor improvedmain-
tainability.The modulatorsfor rearbrakesare providedwith a PCVfunction(Proportioning ControlValve)in ordelto pre-
vent the rear wheel from locking when the anti-lock brake system is malfunctioning or the anti-lock brake system is not
actrvated.
The solenoidvalve featuresquick response(5 ms or less).
The inlet and outlet valves are integrated in the solenoid valve unit. There are three solenoid valves provided, on€ fol
each front wheel, and one for the rear wheels.
SoLENOtO
To Pump
Aas6mbly
F.om M..t r Cylnd.r

Pl.tor
M..l.r CyLd.t
Prlrnary Plrto|r
To Lcft-f.ont
Brakc Cdllpol
From
Pump
Ar36mbly To Rlght-rea.
B]rk. Callp€r
19 -3 8
Accumulator
The accumulatoris a pneumatictype which accumulateshigh-pressure brakefluid fed from the pump incorporatedin the
power unit. When the anti-lockbrakesystem operates,the accumulatorand the power unit supplyhigh-pressure brake
Jluidto the modulatorvalve via the inlet side ot the solenoidvalve.
ACCUMULATOR
ALADDER
PressureSwitch
The pressureswitch monito,sthe pressureaccumulation(pressurelrom the pump)in the accumulatorand is turnedoff
when the pressurebecomeslower than a prescribedlevel.Whenthe pressureswitch is turnedoft, the switchingsignalis
sent to the ABS control unit. Upon receivingthe signal,the ABS controlunit activatesthe pump motor relayto operate
the motor. lf the pressuredoesn't reachthe prescribedvalue,the ABS indicatorlight comes on.
ODeration
When the pressurein the accumulatorrises,the Bourdontube in the pressureswitch deformsoutwards.When the
free end of the Bourdontube movesmore than the prescribedamount,the micro-switchis activatedby the force of
the spring attachedto the sensinglever. When the pressurein the accumulatordecreasesdue to anti-lockbrake
system operations.the Bourdontube moves in the directionopposileto the one describedabove, and the micro-
switch is eventuallyturned off. Upon receivingthis signal,the ABS controlunit activatesthe motor relayto operate
the motor.
SENSINGLEVER
(cont'd
19-39
Anti-lockBrakeSystem (ABS)
(cont'd)
Power Unit
The power unit consistsof a motor, filter, guide, piston rod and cylinderbody. Sincea guide is positionedoftset to the
centerof the motor shalt, the rotationof the motor and cylinderbody providesthe reciprocating motionto the piston,od,
The brakefluid is thus pressurizedand fed to the relief valve. accumulatorand modulator,
As the pressurein the accumulatorexceedsthe prescribedlevel,the pressureswitch is turnedon. Approx.O.5 s€conds
after receivingthe ON-signal.the ABS control unit stops the motor relayoperation.In this state, the pressurein the ac-
cumulatorreaches23000 kPa (23Okg/cm' , 327O psi).
lf the pressuredoesn't reachthe prescribedvalueafter the motor has operatedcontinuouslytor a specitiedperiod,the
ABS control unit stoDsthe motor and activatesthe ABS indicatorliqht.
ACCUMULATOR
PRESSUBE
swlTcH To Modulator
Roliot V.lvo
valv6 Rod
cylindor Eody Pisron Rod

lRotationl (ReciptocaringMotionl
Anti-lock BrakeSystem (ABSI IndicatorLight
This warningsystemturns on the ABS indicatorlight when one or moreof the belowdescribedabnormalitiesis detected.
This is onlv a oartiallist.
a When the operatingtime of the motor in the power unil exceedsthe specitiedperiod.
a When vehiclerunningtime exceeds30 secondswithout releasingthe parkingbrakelever.
a When one of the rear wheels is lockedduring running,
a When absenceot speedsignalsfrom any of the tour wheel sensorsis detected.
a When the activationtime of all solenoidsexceedsa given time or an open or short circuit is detectedin the
solenoidsystem.
a When solenoidoutput is not detectedin the simulatedanti-lockbrakesystemoperationcarriedout duringrunning
at speedsof 6 mph (1O km/h) or more.
To checkthe ABS indicatorlight bulb.the light is activatedwhen the ignitionswitch is turnedon. lt is turnedoff after the
engrneis startedif there is no abnormalityin the system,
19-40
Operation
1. OrdinaryBrakingFunction
In ordinsrybrakeoperations,the cut-off valvein the modulatoris open,transmittingthe hydraulicpressurefrom the
maste. cylinderto the brake calipersvia chamberA and chamberB.
ChamberC is connectedto the reservoirthroughthe outlet valve,which is normallyopen.lt is alsoconnectedto the
hydraulicpressuresource (pump,accumulator,pressureswitch, etc.)via the inlet valve.which is normallyclosed.
ChamberD servesas an air chamber.Underthese conditions,the pressuresol chambersC and D are maintainedat
about atmosphericpfessure,permittingregularbrakingoperations.
CHAMBERO
RESENVOIR
SLIOE
PISTON
CUT.OFF CHAMBERB
VALVE
CHAMBERA
CALIPER
ACCUMULATOR
CHAMBERC
19-41
Anti-lockBrakeSystem (ABS)
(cont'd)
It brake inputs (torceexened on brake pedal)are excessivelylargeand a possibilityof wheel lockingoccu,s, the ABS
control unit operatesthe solenoidvalve, closing the outlet valve and openjngthe inlet valve. As a result, the high
pressureis di.ectedinto chamberC, the piston is pushedupward,causingthe slidepistonto move upward and the cut-
off valveto close.As the cut-oft valvecloses,the tlow from the mastercylinderto the calipetis interrupted,the volume
ol chamberB. which is connectedto the caliper,increases.and the fluid pressurein the caliperdeclines,
When both of the valves,inletand outlet, are closed(whenonly the outletvalveis activated)the pressurein the caliperis
maintainedconstant.
When the possibilityof wheel lockingceases,it is necessaryto restorethe pressurein the caliper.The solenoidvalve is
thereforeturned off (outletvalve: open, inlet valve: closed).
Process CaliperPressure Outlet Valve InletValve
Electric Hydraulic Electric Hydraulic

Power Circuit Power Circuit
Caliperpressuredeclining ON Close ON Open

Caliperoressureconstant ON Close OFF Close
Caliperpressureincreasing OFF Open OFF Close
MASTER
RESERVOIR CHAMBERD
CHAMBER8
CHAMBERA
CALIPER
ACCUMULATOR CHAMBERC
r 19-42
2. SlidePistonFunction
When the car is used on roughroadswhere the tires sometimesloseadhesion,the antilock brakesystemmay func-
tion excessively,causinga very largevolumeof brakefluid to flow into chamberC. When this occurs,the piston is
moved excessively,resultingin an abnormalloss of pressurein chamberB. In orderto overcomethis problem.the
slidepiston is kept in properpositionby springforce to preventthe pressurein chamberB from becomingnegative.
CHAMBERC
(cont'dl
19-43
(cont'dl
Features/Gonstruction/Operation
3. Kickback
When the anti-lockbrakesystem is functioning.the pistonmovesupward.the volumeof chamberB increases,and
the fluid pressureon the caliperside is reduced.At the sametime. the volumeof chamberA is reducedandthe brake
fluid is returnedto the mastercylinder.Whenthe braketluid is pushedbackto the mastercylinder,the drivercanfeel
the functioningof the anti-lockbrakesystem becausethe brakepedalis kickedback.
4. PCV {Proportioning ControlValve) Function

ln the modulatorfo. the rearwheels.the diametersof the pistonandthe slidepistonare distinctlydifterent.This pro-
vides a PCV (Proportioning ControlValve) function to preventthe rear wheelsfrom lockingduringan emergency
stop.
{ 1 ) B e f o r et h e T u r n i n gP o i n t :
1)When the fluid pressurelrom the master cylinderis below the turning point. the cut off valve is always
pusheddownward by the force of the slidepiston and its spring,
Underthese conditjons,there is a gap betweenthe cut-off valve shoulderand the sleeve.ChamberA and
chamberB are theretoreconnectedthrough the gap. The pressurefrom the mastercylinderflows into the
rear calipersthrough chamberA and chamberB.
MASTER
CHAMBERC
19-4tr;
2) When the fluid pressuretrom the mastercylindefreachesthe turningpoint,the force on the slidepistonover-
comes the torce ot the spring,causingthe slidepislon to travel upward.
The cut-ofI valve,previouslybeingin contactwith the bottom of the slidepiston,then movesupwardandthe
cut-otl valveshoulderhits the sleeve,blockingthe fluid passages(the fluid pressureat this point is calledthe
turning point).
E3
6E
Hi
CHAMBERC
(2) After the turning point:

As the lluid pressurefrom the mastercylinderincreases,the pressurein chamberA becomeshigher,causinga
force to push down the largediamelerportionot the piston. Consequently, the slide piston comesdown. the
cut-off valve is pusheddownward by the bottom of the slide piston, allowingchambersA and B to connect
momentarily.As this occurs, pressurein chamberB increases,the slide piston is pushedupward, the cut-off
valve goes up. and the connectionbetweenchamberA and chamberB is blockedagain.As describedabove,
when the pressurein the mastercylinderis abovethe lurning point,the slidepistonreducesthe pressurein the
rear caliperto the prescribedamount by repeatingihis process.
1945
CircuitDiagram(2WSl
FUS€ No. FUSE
TAEELNAME
ECU
't3 MElrR
BATTERY
RrcMIRROR
sumL-f
UNO€R.HOOD
FUSENEIAY
8OX
UNDEfiOASH
FUSENELAY
8OX A
GL*,,,n,.uf
CHASGING UGHT
SYSIEM
tGs:w(50Al
88ATE
SYSIEM
UGHT
II
sTotHoRN
lr5A) A8SINDICATOR
UGI{T
A \ I
.-.1U'-
88AIG
$,$fCH
-
YE$c+
A8Si,lOT0R YEUGRT{-ar-
Al
150
A8SUr{rI05 A}
WHTETU
I sLuau(*l
REOAVHT
l r u I ABS
PUMP
MOTON
Y BU(
GRN
t
8U(
+
G|03
-o-
-=
Gr0l
Gt02
GOl
19-46
ECM
,\o
,rrtrr l-
SERVICE
CHECK
IGR{NEO CONNECTOR
,A
GRMED ttl-t,-l{,F_YEL+sLK-a
ERAKE
FI.UID PREssuRE =
EVrI srvrrin 3i3;
swtTcH Gl01
t9 WASN
2
5 WARtir ABSINSPECTION
^ WHIELj(
s0[rNolDs
FRONT.R
3 fl-ot T
RLW{+l
11 R.tN
6 ROW
18P CO[{NECTOR 12P CONNECTOR
30 29 28 21 l1 't0 8
21 2 0 1 9 1 8 1 7 1 6 1 5 1 4 1 3 7 o 5
,/ 1
ABS CONTROLUNIT COIINECTOR ABS CONTROLUNIT CONNECTOR

View t.om terminal side. CASE View trom terminalside.
GSOUND
1947
Circuit Diagram(4WS)
FUSE
No. FUSE
LABET
NAIVE
SAMRY 13 MFTEfi
9 R/CMIFROR
UNDER.HOOD
FUSENEIAY
BOX
UNDEROASH
FUSENEIAY
BOX
rGsw{50a)
STOP
HORN
{15A}
>_
wHr-{
EvnED_f-
ABSMOTOR
{50A}
A8SUNIT{?.54)
r-
JJm
WHI,ATU
I sLu,sLX_reL
8TD/WHT
A8SPUMP
MOTOR
BEAR
GRN SLK
FAII--SAFE
I RELAY
BtK
J-
+G103
-=
G101
G102
GOI
19-48
A8SCONTROT
' TC|V(SCS) ECM
. ECMISCS)
4
x,a
glgl,rrgf-l
s€8vtcE
cHEcK
IGRMEO CONNECTOR
Â
GRMTD nL*t,i[9-YEL+8LK-a
BRAK€
FTUID
LEVEL
Tt::$E
swrlcH .*
b*,
swtTcH Gt0l
18WARN
2
ABSINSPECIION
-J
s0tEN0tDs
IRONT-R
R L W ( +1) 7
8RP 7
RLP 8
2OPCONNECTOR
34 33 30 28 2 6
25 24 2322 212 0 19 1 8 17 15
ABS CONTROLUNIT CONNECTOR CASE ABS CONTROLUNIT CONNECTOR
View from terminalside. GROUND View from terminalside.
19-49
Wiring/ConnectorLocations
UNDER.HOOD
BOX
FUSE/RELAY ABS UNIT
ABS 82 II5 A} (7.5 A} FUSE
FUSE
STOP/HORN ABS
{'l 5 A} MOTOR
FUSE RELAY
ABS 81 (20 A} FUSE
{1(x' A}
EATTERY
FUSE
iTGHT.BEAB
WHEELSEI{SOR
ABS MOTOR ABS COI{TROL
(50 A) FUSE rG sw {50 Al FUSE UNIT
U1{IT
MODULATOR LEFT-REAR
WHEELSENSOR
RIGHT.FRONT
WHEELSENSOR
RIGHT.FRONT FAIL.SAFE
WHEELSENSOR RELAYS
LEFT-FROl{T
WHEEL SENSOR WHEELSENSOR
CONNECTOR
19-50
F.
ALB Checker
FunctionTest
NOTE: NOTE; Placethe vehicleon level ground with the

a The ALB checker is designed to confirm proper wheels blocked,out the transmissionin neutraltor
operation of the anri-lockbrake system (ABS) by manualtransmissionmodels,and in @ positionfor
simulatingeach system function and operatingcon- automatictransmissionmodels.
dition. Before using the checker, contirm that the
anti-lockbrakesystem (ABS)indicatorlight is not in- Stan the engineand releasethe parkingbrake,
dicating some other problemwith the system. The
light shouldgo on when the ignitionis first turnedon 5. Operatethe ALB checkeras follows:
and then go off and stay off one second after the ( l ) T u r n t h e M o d e S e l e c t o sr w i t c ht o " 1 " .
engineis started. (2)Pushthe Start Test switch:
a The checkershouldbe used through modes 1-5 to - The test in progresslight shouldcome ON.
confirm properoperationof the system in anv one of - In one or two more seconds, all four monitor
the following situations: lights should come on (lf not the checker is
- After replacingany ABS component. faultv).
- After replacingor bleedingthe system fluid {0 - The ABS indicatorlight shouldnot come ON.
mode not necessaavl.
- After any body or suspensionrepair that may NOTE: When the test in progressindicatorlight is
have affectedthe sensorsor their wiring. ON, don't turn the Mode Selectorswitch.
a The procedure{or modes 1-5 are on this page and
19-52, mode "O" {wheel sensorsignal)is on page
19 - 5 3 .
@ Disconnoct the ALB checker belore driv- Monlror Lights

ing the car, A collision can rosult tlom a roduction, or
completo loss, of braking ability csusing aevo.o per-
sonal injury or doath.
4W ALB CHECKER
1. With the ignitionswitch off , disconnectthe ABS in-
spectionconnector(6P) from the connectorcover
located on the cross-member under the pas- Taal ln prog.art
senger's seat and connect the ABS inspection
I
I
connector(6P) to the ALB checker. )
o
Porval Ol{ Start Tcat Modo S€lscro.
4. Turn the Mode SelectorSwitch ro "2"
A
oTHAJ-SGOO108
See poge 19-32 for othe. applicablecheckers.
{cont'd)
19-51
ALB Checker
FunctionTest (cont'd)
Depress the brake pedal firmly and push the Start Inspection points:
'1. The ABS indicatotlight comes ON.
Test switch.
The ABS indicatorlight shouldnot go on while the a Check the DiagnosticTrouble Code and go to
Test in P.ogress light is ON. There should be the troubleshooting,se8 page 19-55.
kickbackon the brakePedal.
2. The.e is no or liftle kickbackin modes 2 through 5
NOTE: The operation sequence simulated by and the ABS indicatorlight does not come ON'
Modes 2. 3, 4 and 5: a Air in the high Pressu.eline
a Restricted high Pressureline.
a Faultvmodulatorunat.
Aboul 30 racond3
"3", "4" and

6. Turn the Mode Selectorswitch to
"5" .
Perform step 5 for each oJ the test mode positions.
Mode 1 :
S8ndsthe simulateddrivingsignalO mph (O km/h)
* 1 1 3 m p h ( 1 8 0 k m / h l - 0 m p h { Ok m / h )o f e a c h
wheel to the ABS control unit. Thereshouldbe NO
kickback.
Mode 2:
Sendsthe drivingsignalot each wheel, then sends
the lock signal of the left .ear wheel to the ABS
control unit. There should be kickback.
Mode 3:
S€ndsthe drivingsignalof each wheel, then sends
the lock signal of the right rear wheel to the ABS
control unit. There should be kickback.
Mode 4:
Sendsthe drivingsignalof each wheel, then sends
the lock signal of the left front wheel to the ABS
control unit. There shouldbe kickback.
Mode 5:
Sendsthe drivingsignaloJ each wheel. then sends
the lock signalot the right ftont wheel to the ABS
control unit. There shouldbe kickback.
Mode 6:
Not used on this model.
WheelSensorSignalConfirmation
"O") to contirm
NOTE: Use the ALB checker (mode Monitor Lig}lt3
properwheel sensoroperation.
1. Disconnect the ABS inspection connector {6P) 4W ALB CHECKER

from the connector cover located on the cross-
member under the passenger'sseat and connect
the ABS insDectionconnector (6P) to the ALB Toat In Prog6ss
checker. I
I
t
Powot ON Start Te3t Modo Scbctot
5 . With the transmissionin neutral.rotate

rota each wheel
briskly (one revolutionper secondl
ndl by hand, and
conJirm that its respectivemonitor
ritor light on the
checkerblinks as the wheel rotates.
NOTE:
a Rotatinga wheel too slowly willill produce
p only a
weak blink of its monitor light that
thl may be dif-
Jicultto see.
a In bright sunlight.the monitor light
ligl may be dif-
Jicultto see. Performtests in ar shaded
st area.
a In some instances,it may not bee possible
p( to spin
07HAJ-SGOo10B the tront wheelsfast enoughtoI get
ge a monitorin-
Seepage19 32 for otherapplicable
checkers.
dication.It necessary,stan the engine
en{ and slow-
ly accelerate and decele.ate the
he front wheels.
The monitor lights should blink,
ink, indicating a
good wheel sensorsignal.
lf any monitor light fails to blink,

blin check the
susPected sensor, its air gap and its
wiring/connectors.
Raisethe car so that all lour wheels are ott the

ground and supporton safety stands.

"O".
Turn the Mode Selectorswitch to
19-53
Troubleshooting
Anti-lock BrakeSystem (ABS) IndicatorLight
Tomporary Driving Conditions: ABS Indicatol Light Circuir:
1. The ABS indicatorlight comeson and the ABS con-
trol unit memorizesthe diagnostictrouble code CAUTION: Us6 only the digital multimet€r to chsck th.
(DTC)under certainconditions. syst6m.
NOTE: The DTCSare explainedon page 19-56. 1 . The ABS indicato.light does not go on when the ig-
nition switch is turned on.
a The tire(s)adhesionis lost due to excesslvecor-
neringspeed. Check the following items. lf they are OK, check
DTC: 5, 5-4, 5-8. the ABS control unit connectors.lf not loose or
o The vehiclelosestraction when startingftom a disconnected,substitutea known-goodABS con-
stuck condition on a muddy, snowY, or sandy trol unit and recheck:
road.
DTC: 4-1 . 4-2, 4-4, 4-4. . Blown ABS indicatorlight bulb.
a When the patkingbrakeis appliedfor mofe than a Open circuit in YEL wire between the No. 13
30 secondswhile the vehicleis being driven. METER('lO A) fuse in the under-dashfuse/relay
D T C :2 - 1 . box and gaugeassembly.
a The vehicle is driven on an extremely rough a Open circuit in BLU/REDwire between the
road. gauge assemblyand ABS cont.ol unit,
a Poot ground connection between the ABS con-
The ABS js OK. it the ABS indicatorlight goes off trol unit and the body.
atter the engineis testarted.
The ABS indicatorlight remainsON after the engine
is started.howeverthe ABS indicatorlight does not
blink any DTC. Check the following items:
a Looseor poor connectionof the wire harnessat

the ABS control unit.
. Faulty ABS 82 (15 Al Juse in the under-hood
fuse/relaybox.
a Open circuit in WHT wire betweenthe ABS 82
(15 A) fuse in the undet-hoodfuse/telaybox and
ABS control unit.
ABS INDICATORLIGHT a ODencircuitin BLK/YELwire betweenthe No. 9
R/C MIRROR (15 A) fuse in the under-dash
fuse/relaybox and ABS control unit.
a Short circuit in BLU/REDwire between gauge
lf you receivea customer'sreportthat the ABS in- assemblyand ABS control unil
dicator light sometimes comes on, check the a ODen circuit in WHT/BLU wire between alter-
system using the ALB checkerto contirm whether nator and ABS control unit.
there is any trouble in the system.
S e e p a g e1 9 - 5 1 . lf the Droblemis not found, substitute a known-
good ABS control unit and techeck whether the
The ABS indicatorlight will come on and the ABS ABS indicatorlight remainsON.
control unit will memorizea DTC when there is in-
sulficient battery voltageto the ABS control unit.
An examplewould be when the batteryis so weak
that the car must be iump-started Aftet the battery
is sufficiently recharged,the ABS indicator light
will work normallyafter the engineis stoppedand
restarted.
However, after rechargingthe battety, the DTC

must be cleared from the ABS control unit's
memory by disconnectingthe ABS 82 {15 A) luse
in the under-hoodfuse/relaybox ior at least three
seconds.
1 9 -5 4
Oiagnostic Troubl€ Cod€ {DTCI:
1. Disconnectthe servicecheck connectorfrom the connectorcover locatedbehindthe tront of the centerconsole.
Connectthe two terminalsof the servicecheck connectorwith a jumper wire.
2. Turn the ignitionswitch on. but do not start the engine.
3, Recordthe blinkingfrequencyof the ABS indicatorlight.
The blinkingfrequencyindicatesthe diagnostictroublecode (DTC).
CAUTION: B€foro starting the engine, disconnact the lumper wire from tho sorvico ch6ck connoctor, o. els€ the
MalfunctionIndicatorLamp (MlL) will stay on with tho engine.unning.
DTC indication oatto.n
Tum the lgnition DTC.4-2 DTC: 1 Dfc| 7 -2

switch on MainCode:4 Main Cod6: 1 Mlin Code:7
A8S Sub-Codo:2 Sub-Cods: none Sub-Cod!:2
Indicator -, -.
light on
ABS
lndicator
light oft
2 1 5 Socond 5 Sacond
Conngct tho Second Socond pau30 pauro Socond
iumpor wi.e pauso p6u30 paulo
1 Socond
NOTE:
a The ABS control unit can indicatethree DTCS(one,two or three problems).
of ABS IndicatorLight Circuitpage 19-54.
a lf the ABS indicatorlight does not light, see Troubleshooting
a lf you miscountthe blinkingtrequsncy,turn the ignitionswitch off then on to cyclethe ABS indicatorlight again.
a After the repairis completed.disconnsctthe ABS 82 {15 A) fuse in the under-hoodfuse/relaybox for at least
three secondsto erasethe ABS control unit's memory.Then turn the ignitionkey on agsin and recheck.
a The memoryis erasedit the connectoris disconnectedfrom the ABS controlunit or the ABS controlunit is remov-
ed from the bodv.
a AJter recordingthe DTC (if applicable),referto the Symptom-to-System Chart.
SERVICECHECX DATA LINK CONNECTOR(3PI

CONNECTOR I2PI NOTE: Do not attach
the jumperwire.
ABS INDICATORLIGHT
19-55
Troubleshooting
Symptom-to-SystemChart
DIAGNOSTIC
TROUELECODE PROBLEMATIC AFFECTED
(DTC) OTHER
COMPONENT/ PAGE PAGE
COMPONENT
MAIN SUB. SYSTEM FRONT FRONT REAR REAR
CODE CODE RIGHT LEFT RIGHT LEFT
Solenoid
ABS pump motor 1 9 - 5 7 ABS pump motor
over-tun Pressureswitch
ABS motor relay
ABS pump motot 19-59 ABS unit tuse 19-87
{3} circuit problem ABS motor fuse
.tt!
High pressure 1 9 - 6 2 Solenoid{s) 19-84
\7 leakage
Pressure 19-63
it)
switch
Accumulator 19-64
{t}
'.'- I
| gas teakage
Parkingbrake I I BrakeJluidlevel
/*\ -
x,. switch-related I 19-64 I switch,
problem I I BrakesYstemlight
tu Wheel sensor
{3} o Pulser(sl o 19-88
installation
o o o
o o
{i}
J.;\
Wheel sensor
o 19-65
o
tqt
o o Modulator
\:l o Wheel sensorls) o 19-67 Rear brake drag
rD o
o o 19-87
\9r o Fail-salerelay o 19-69 (Function

Test)
{1} o
{u o 19-75
ABS 81 fuse
Front Jail-saferelaY
r:\
v.. rt Solenoid related
problem
o
!) o o 19-78 Rear tail-safe relay
19-56
Flowcharts
Diagnostic Trouble Code (DTC) 1: ABS Pump Motol Over-run (2O seconds)
CAUTION: Uso only tho digitsl multimetor to chock tho systom'
Pro-l€at st6p:
a Check tor tluid leaksfrom the tunctionalparts and teplacethe faulty pans it there is a leak'
Functional pans: View lrom underhood lusekelav box

a Modulatorunit terminal side.
a ABS Pump assembly
a High pressurehose/pipe
FmnffiffirflFTr;l
- With onglno running, ABS in- IUffilluffillE:l
dicotor llght ls Oil.
- \ tith Bewic€chsck connocto.
iumpod lsoe pago 19-55),
DTC 1 b lndlcat6d.
Bleed high pressure fluid from

the maintenance bleeder with
the EleederT-wrench {see p6go
19-81).
Connect the No. 29 and 30 ter-

minals using a jumpe. wire lor UNDER-HOOD
about eighl seconds. FUSE/BELAYBOX
Pump runr with a conatant 3oft

Doesthe ABS pump motor run touno:
loud,
with an increasingly Blo.d sl. trom anil-lock b.ako
raspy sound? lyttam uling the procoduto on
p6go 19-86 and chock the pump
round again.
Check the accumulator fluid

quantity by bleeding the high
pressureline with the BleederT'
UNOER.HOODFUSE/RELAYBOX CIRCUITDIAGRAM
70 cc (UPPERuMlTl
ls there40-70 cc? (To page 19-59)
40 cc {LOWERLlMlTl
(To page 19-58) {cont ct

T-WRENCH
BLEEOER
oTHAA-SGOO101
19-57
Troubleshooting
Flowcharts (cont'dl
(Frompage 19-57) {Frompage 19.571
Connectthe No. 29 and No. 30

terminalsusinga jumperwire for
about 1O seconds.
Check if there is any changein

the fluid level in the reservoir
tank.
Faulty ABS pump motor {Rell6t
ls there anV change? velve i3 dofective and ooenl.
Replace tha ABS pump a$em-
blv.
F.uhy.olonoid (loak.g6l.
R6plac6lho modulator unit.
Connect the No. 29 and No. 30

terminalsusinga iumperwire for
about 1O seconds.
Disconnect the pressure switch Continuity?

2P connectorand checkthe con-
tinuity betweenthe No. 1 (YEL) View from terminalside.
and No. 2 {YEL)terminals.
TIE v.r|.ch b OK at thb timo.
19-5 8
DiagnosticTroubleCode (DTCI l-2: ABS Pump Motor CircuitProblem
CAUTION: Use only the digital multimeterto check the system.
NOTE: l{ a malfunctionis detected,this code appearsand the fail-safelunction is activated.The ABS indicatorlight
the ABS 82 (15 A) fuse in the under hood
comesON after restartingthe engineuntil the DTC is erased{by disconnecting
fuse/relaybox for three seconds).
Pre-test stgps:
a Check ABS MOTOR \5O A) iuse in the under-hood luselle\aY box
a Check ABS UNIT {7.5 A) fuse in the under hood {use/relaybox.
a Check for loose under-hoodfuse/relaybox connectors.
- Wirh engine running, ABS in-

dicator light is ON.
- With s€ruicecheck connector
iumped lsee Pago 19'551,
DTC 1-2 is indicated.
Checkthe ABS pumPmotor relaY

(seepage 'l9-87).
Does it work Proporly?
View from underhood luse/relaybox

Connectthe No. 29 and No. 30 terminalside.
terminals using a iumPer wlre.
ffilffilffil
l _?9lgl91l-l _ ll
l___q1_1_
Doesthe ABS oumpmotor run? ( T op a g e1 9 - 6 1 )
Removerhe ABS UNIT (7.5 A)

Iuse in the underhoodfuse/relaY
box.
(To page 19-60)
JUMPERWIRE
UNDER.HOODFUSE/RELAYBOX CIRCUITDIAGRAM
19-59
Troubleshooting
Flowcharts (cont'd
19-59t
Check tor voltage belween lhe

underhood fuse/relavbox ABS
UNIT fuse No. 31 terminal and
body groLrnd.
Repairopen in WHT/BLK wire be-

tween the ABS UNIT (7.5 Al luse
ls there battery vollage?
in ihe und€r-hoodluse/r€laYbox
and ABS contaolunit.
Reinstallthe fuse in the under'

hood fuse/relaybox.

lrom the ABS pump molor-

ABS pump molor relay No. 30
terminaland body ground.
UNDER-HOOD Batteryvoltago?
FUSE/RELAY
AOX
ls therebatteryvoltage?

No. 32 termjnal and body
ground.
R€pair opon in BI-K/YELwire be-

twsen the No. S R/C MIRROR
ls therebatteryvoltage? (15 Al fuso in the undeFdash
l2WSl
18P CONNECTOR
fusa/relav box and ABS PumP
motor a€lav.
30 29 2a 27 t!J 2 5 2 4 23
22 21 20 1 9 1 8 1 7 1 6 14 13
Disconneclthe
'l8P
{4wS: 2OP) B.ttery uon"n",
Qf )r,-,r.o
connectorfrom the ABS control I IPMR}
unit.
View from ABS controlunit terminalside
Check {or voltage between the

ABS control unit connectorNo 20P CONNECTORl4WSl
18 {4WS: No. 21 ) (YEL/RED)
ter
minal and body ground. 34 32 3 1 lul 30 2A 21
't5
24 2 1 20 1 9 1 8 1'1
Ropairopsn in YEL/REOwire be'
ls there battery voltageT tween iho ABS pump motor relay
and ABS control unit.
YES
Battery vorr"e"z$)
\tu"o t'"t'
View from ABS conlrolunit terminalside

trcl rrir dd recheck
19-60
lFrompag619 59)
Cheek tor vollago bgtwoon the

No.29 terminal and body
ground.
HARt{ESS-SIDECONNECTOR
BLK (GROUNDI WHT/BLU IMOTOR RELAYI

Irom the ABS pump motor.
Check for voltagg b€tween the

No, 1 (WHT/BLUIt€rminal and
body ground.
Rogah op€n in WHT/BLU wiro

ls th€ro batt€ry voltage? bctwaan th6 ABS pump motor
rohy and ABS pump molor.
HARNESS-SIDECOI{NECTOR
BLK {GROUNDI WHT/ALU IMOTOB

Ch6ck for voltage betwe€n the
'l (WHT/BLU) terminal and
No.
No. 2l8LKl tsrminal.
86ftery Voh.g€?
R€pairopen in BLK wlro botwoon

ls there battery voltago? tho AgS pump moto. and g.ound
or pool ground 1c403).
Fauhy ABS pump motor.

Roplac€ tho ABS pump a.tom'
blv.
19€1
Troubleshooting
Flowcharts (cont'd)
Diagnosric Troubl€ Code (DTC) 1-3: High Pr6$ur€ Leakag6
CAUTIOI{: Uso only th€ digital multimetor to check tho syEtam.
Pre-test steps:
a Check reservoirfluid level. and if necessa.y,fill to the MAX level line.
a Check for tluid leaksfrom the lunctionalparts and replacethe faulty parts if there is a leak.
Functional parts:
a Modulatorunit View trom undeFhood fuse/relay box
a ABS Pump assembly terminalside.
a High pressurehose/pipe +
il-fnntrT-ll ll-Tl-f-Tlll I l'.ll
- Whh 6ngino running, ABS in-
IUffil[Iml|[[_trl
- With soryice chock conngctor
jumpod (s6o pag6 19-55),
DTC 'l-3 is indicatod,
Bleed high pressure lluid lrom

the BleederT-wrenchlsee p6ge
19-81).
Connectthe No. 29 and No. 30

terminals using a iumper wire lor
about 10 seconds.

AAS PUMP AAg UiIIT I7.5AI
from the pressureswitch.
Alter 30 minutes, check for con-

tinuiry belween the No.1 {YEL) UI{OER-HOODFUSE/RELAYBOX CIRCUITDIAGRAM
and No.2 {YELIterminalson the
switch side of connector. SWITCH SIDE CONNECTOR
The v.hicL l. OK rt thb tlmo.
Continulty?
Frrty .oLnoid (leakago).

Ragaac. tha modulator unit. View from terminal side.
19-62
J ! ' . r t i t . d .
Dlagnostic Trouble Code (DTC) 1-4: Pressur€Switch Circuit
CAUTION: Uso only tho digit8l multim6tor to chock tho systom.
- Wlth.nglno iunnlng, ABS in-

dlcator llghi 18ON.
- With solvico check connoctor
iumped (3e€ p.go 19-551,
DTC t-4 k indicatod.
8le€d high pressure fluid trom

the Bleeder T-wrench {soe page
19-81).
SWITCH.SIOECONNECTOR
Oisconnect the 2P connector
from the pressureswilch.
Continuity?
Chock ths continuiiy ol pr€ssur€
switch b6twe6n the No.l (YEL)
and No.2 (YEL)terminals.
HARNESS.SIO€CONNECTOR
Check for continuity between

the No. 1 (YEL) terminal and
body ground on lh€ harness sade
connsclor.

Ropairlhort In YEL wl.o ttotwoen
tho ABS control unit and P]€t-
aur6 lwitch.
Chock for looao ABS control unii

connactor!. lf noc6ara.y, lubati-
tuto a known-good ABS control
unlt and r6chock.
(conl d,
19-63
Troubleshooting
Flowcharts (cont'd)
Diagnostic Troublo Codo {DTC) 1-8: Accumulator Gas Leakage

Chock tho tollowing itoms:
a The relief plug is loose.
a The reliet plug O-ringis out ol place.
a Bleedthe high pressureline with the BleederT-wrench.Operatethe ABS pump motor for 10 secondsand bleedthe
high pressureline againwith the BleederT-wrench.lf no tluid or more than 70 cc of lluid come out, replacethe ABS
pump assembly.
BLEEDERT.WRENCH
07HAA-SGOOIO'l or
07t{AA-SG00100
RESERVOIR
ABS PUMP ASSEMELY
Diagnostic Trouble Code {DTC) 2-1: Parking Brake Stvitch Related Problom
lf the parkingbrakehasbeenreleased.the followingitemsare possiblecauses.lf they are OK, checkthe ABS controlunit
connectorsfor good connection.lf not looseor disconnected,substitutea known-goodABS control unit and recheck.
NOTE: BeforetroubleshootingDTC 2-1, removethe ABS 82 {15 A) fuse in the under-hoodfuse/relaybox for three
secondsto clearthe ABS control unit's memory,then test drive the car.
lf the ABS indicatorlight stays otf, the probabilityis that the car was drivenwith the parkingbrakeapplied.
a The parkingbrake is appliedfor more than 30 secondswhile driving.

a The brakefluid level in the mastercylinderis too low.
a GRN/REDwire is shortedbetweenthe brakesystem light and parkingbrakeswitch.
a GRN/REDwire is shoned betweenthe brake system light and brakefluid levelswitch.
a The brakesystem light is blown
a GRNiREDwire has an open betweenthe brakesystem light and the ABS control unit.
'
Diagnostic Troublo Code {DTC} 4-1 to 4-8: Wh6el Sensor
CAUTION: Us€ only th6 digital multimeter to ch€ck ths systsm.
NOTE: lf a malfunctionis detected,this code sppearsand the fail-safefunctionis activated.The ABS indicatorlight may
come ON after restartingthe engineuntil the DTC is erased(by disconnecting the ABS 82 (15 A) fuse in the under-hood
fuse/relavbox for three seconds).
-
18PCONNECTOR
{2WSl
With ongine running, ABS in-
dicator light is oN. BRN:FL O GRN:FRO GRN/BLU:
FL @
- With servico chgck conneclor GRN/BLK:FR @
ju.npod (s66 pag. l9-551,
DTCa 4-1, 4-2, 4-4 andlol
4-8 a.e indicaled.
GRN/YEL:RR @
Disconnectthe 18P 14WS:20P) cRy: RL O BLU/YEL:RR O LT/BLU: BL @
connectorfrom the ABS control
unil. Vi6w from ABS control unit terminal side.
20P CONNECTORl4WSl
Check the rcsistance of each
sensor between the positive and BRN:FL O GRN:FR O GRN/BLU:FL O
negatave:
. GRN/BLK:Front Right Positive
34 33 32 3 1 Lq 30 2A 27
GRN: Front Right Negative
. GRN/BLU:Front LeIt Positive 24 23 21 19 1 8 17 1 6 1 5
BRN:Front Left Negative
. GFN/YEL:RearRightPositive GRN/YEL:
BLU/YEL:RearRight Negative GBY: RL O BLU/YEL:RR O LT/BLU: RL O
. LT ELIJ: Rear Left Positive
GRY: Rear LeIt Negative View lrom ABS control unit terminal side
ls there
Front: 70O-11OO O,
Rear r 10OO 1600 o?
R€psir short in Senaor wire ol

Roplacotho whool ren3or.
Disconnoct the 2P connector of
the wheel sensor.
CONNECTOR
SENSOR-SIOE
Check for loose ABS conttol unit
connoctors. Chock thai th6 son- FRONT REAR
3o. is installod p.operly. ll _/r-l\- I|Ell
nocoslary. substitulo g known- //---\\ 5--/
good ABS control unit and
rsch€ck.
(l zTI'|)
r-t tl
rFSb
\+# .LOr
-
ls there
Front:7O0- 1
'1000, @
700- l too o? 1000-1600 0?
Rear: 1OO0- 1600 0?
Viewfromterminal
side.
(To page 19-66)
19-65
Troubleshooting
Flowchart {cont'd)
(Frompage19-65)
HARNESS.SIDECONNECTOR
'l8P (4WS: 2OP)
Roconnectth€
connector to the ABS control FRONTLEFT FRONTRIGHT
unit.
Check each wire for continuity

belween the whoel sensor
ffi"U""'os4ffiffin's l\-/l
terminalsand body
harness-side
ground.
@
+ o
+ @
+ I6
Contlnuity?
REARLEFT REARRIGHT
cRY: /=\ _LT8LU: BLU/YEL:_ GRN/YEL:
Rapalr opan lo wlr! hrmaaa.
o-tFlfl-gf
-t-
@ o lHgf o
-tF'tl_-
Chock tor looao whool 3onaot

connoctoE. It nocolltry, tubati-
Positivs:3.3 k0 a 15% is OK. 0
I -
0L 0I I
0
Nggrtivo:Lessthon 1 O i6 OK.
iuto a known-good ABlt control
unit and rochock. Contlnulty?
Visw from terminal side.
19-6 6
""hi r r! $Hl L,lllft&trrt,
Dbgnctic Troublo Code (DTC) 5 to 5-8: Wheol S€nsor(s)
CAUTlOttl: Use only th€ digltal multimotor to chock tho syEt€m.
NOTE: lt I malfunctionis detected,this code appearsand the iail-safefunctionis activated.The ABS indicatorlight may
come ON sfter restartingthe engineuntilthe DTC is erased{by disconnecting the ABS B2 (15 A} fuse in the under-hood
box tor three seconds.)
18PCONNECTOR (2WS)
- Wlth onglnc running, ABS in'
dc or llght l! ON.
- Wlih lowlco chock connoctor 30 2a 27 t!!J 26 25 24
iump.d {roe paga t9-55), 21 20 1 9
'18
1 1 16 1 5 1 4
DTC. 5, 54 or 5-8 l! in-
dlcrtod.
:RLO \ LTBLU:RLE
RRO
BLU/YEL:
Disconnectthe 18P(4ws: 2OP)
Vi€w {rom ABS control unit t6rminal sido'
connoctorlrom the ABS control
un|t. 20P CONNECTOR
{4WSl
34 32 uJl 30 26
Chock th€ .esistance ot each 25 24 23 21 20 1 8 't7 1 6
sonsor between th€ positive and
n6gativo:
. GRN/YEL:Rsar Right Positive
SLU/YEL: Rssr Right Negarive GRY: R L O \ LYELU:RL@
. LT BLU: Rear Left Positive BLU/YEL:
RRO RRO
GRN/YEL:
GRY: Rear Left N€gative
Vigw from ABScontrolLrnittsrminalside.
ls thero 1OO0- 1600 07
Rcprlr rhort In lonlor wiro ot

Rapbco tha whaol lonaor.
R€connect the l8P (4WS: 2OP)

Disconngct lhe wire hamgss connsctor to the ABS control
trom wheel sensor. unit.
Connoct the ALB checker to tho

ABS insDeclionconnector.
Chock Ior resistance botween

ths sensor terminals. Ch€ck for ABS lunction in mode
2 and 3.
Do€s it work prop€.ly?
SENSOR.SIOE
CONNECTOR
Check to, rctr bt.k6 dr.g. ll OK, REAB
sub.ftut6 a known-good ABS
control unlt and .ochgck.
ls there 1OO0- 1600 O?
YES 1000- 16000?

Viewfromterminalside. (conl.d)
(To pag€ 19-681
19-67
Troubleshooting
Flowcharts {cont'd)
Reconnecrthe 18P l4WS: 2OP) HARNESS.SIDE

CONNECTOR
connoclor to th€ ABS control REARLEFT REARRIGHT
unit.
GRY:\ /=\ lT BLU: BLU/YEL:^ GRN/YEL:
e_HE{_e o_r$Lo
Check each wire for continuity
between the wheel sensor l:l l,*,I
harness-sidetorminals and body
ground.
9
+ +9 +9 +0
Contlnulty?
Rrpdr op.r| lo whr h.rnaar, Vi6w trom torminal sido.
Chock lor looig whool lenaoi Positivs: 3.3 k0 a 15% is OK.

conn6ctorE.It nocoraary, aubati- Nogative: Less th6n 1 O is OK.
tut6 a known-good ABS control
unlt and rochock.
1 9 -6 8
Diagnostic Trouble Code (DTCI 6-1 : Front Fail-SafeRelay Cilcuit
CAUTION: Use only the digital multim€tel to check tho systom.
Ple-test steDs:
a Check ABS B1 (2O A) tuse in the under-hoodfuse/relaybox.
a Check for loose under-hoodfuse/relavbox connectors.
FAIL.SAFERELAYS
- With engine running, ABS in-
- With so.vic6 chock connector
iumped lsee pags'19-551.
DTC 6-1 is indicated.
Wire colors oI the laifsate relay conneclor

Removethe lronl faifsale relay
FTONT:BRN/BLK,BLK/YEL,YEL/GRN,BLK
from under the gauge assembly.
Rear: BLU/8LK,BLK/YEL,YEL/GRN,8LK
Check relay function lsee page

19-87).
Doesrt work properly? R6plac. thc tront f.ll-..f. r.hy.
Check for voltage between the HARNESS-SIDECONNECTOR

fail-saferelay connector No. 1
(BLK/YEL)termanal and body
ground,
Rep€iropen In 8LK/YEL wlre be-

tween the No. 9 R/C MIRROR
ls there batte.y voltage? {15 A} fuso In the unde.-da.h
tuao/rolay box and lront tald-a€to
reley.
Disconnectthe 10P connector

from the solenoids.
B.ttoryVoltago? Continuity?
the fail safe relayconnectorNo.
2 (BRN/BLK)terminal and bodv
ground.
{ T op a g e1 9 7 0 )
{cont'd)
19-69
Troubleshooting
Flowcharts (cont'd)
(Frompage19-691
R.pai. rhon In BRN/BLK wlro

botwoon thg aolenold and lront
tlil€al. rolry.
Check each wire {or continuity

between the solenoid terminals
and body ground
No.4 {BRN/BLK): Front Right
No. 6 (BRN/BLU):Front LeIt
View from t€rminal sid6.
F.uhy lol.nold llhortl.

RapLca tha modulator unh.
12P CONNECTOR(2WS)
REO/8LU RED/BLK
tFL-r ) tFR-rN)
YEUBLK
IFR.OUTI
YEUBLU
{Ft-our}
Continuity?
Vi€w trom ABS control unit terminal sid6.
14P CONNECTOR(4WSl
Disconn€ct the connectors lrom RED/BLU RED/BLK
the ABS control unit. (FUINI {FR.IN)
YEUBIT(
(FR.OUTI
Check each wire for conlinuitY
between the ABS control unit
connectot and body ground.
RED/BLK:Front Rightlnlet YEL/BLU
YEUBLK:Front RightOutlet (FL.OUT)
RED/BLU:Front LeIt Inlel
YEL/BLU:Fronl Left Outlet
Contlnulty?
F.p.h lhon In wi . b.twgln tho Vi€w from ABS control unit terminal side.
roLoold lnd A&S cont.ol unh:
RED/BLK:Froot Right InLl
YEUELK: Front Rlglrt Outht
RED/8LU: Front L.ft Inlot
YEUBLU: Froot L.ft Outlct
{ T op a g e1 9 - 7 1 )
. ",r-,.:,i .:dt til{ril

(Frompage19-7O)
'l8P CONNECTOR(2WS)
30 29 2A 27 llJ 26 25 24
21 20 1 9 1 8 1 1 14
c o n t i n u i t v r( C l ) ' Y E U G R N

the No. 17 (4WS: No. 19) View {rom ABS control unit terminal side.
(YEL/GRNIterminal and body
ground.
20P CONNECTORt4WSl
34 33 31 tlJ 30 2a 27
25 24 21 20 't9 1 8 1 7 1 6 1 5
r'3*:::,,
I
Rcoair rhon in YEUGRN wire
bctwaon tho ABS control unit View from ABS controlunit terminalside.
rnd tront l.ll-.afo rol6y,
'l8P CONNECTORl2WSl
30 E 2a 27 tlJt 26 25 2 1
Reinstallthe tront lail-sale rolay.
22 2 1 20 1 9 1 8 1 7 1 6 14 13
Turn th€ ignition switch ON.

Batteiy "o,,un"r
(V)',tt"t{f*n
Check lor voltafe b€tween the

ABS control unit connector No. View from ABS controlunit terminalside.
17 l4WS: No. 19) {YEL/GBN)ter-
minaland body ground.
20P CONNECTOR{4WSt
34 uJl 30 2A 27
25 21 20 1 9 1 8 11 15
,""ili*' (V
Roplir op.o in YEUGR wi o 8att6.y Voltago?
ls there batlery voltage? bot$,6on tha front lall-aalo rolay
and ABS control unlt. View from ABS controlunit terminalside.
Chock to. looso ABS cont.ol unit

connoctor3. ll n6c63sary, sub-
stituto a known-good ABS con-
trol unit snd .ochock.
19-71
Troubleshooting
Flowcharts (cont'd)
Diagnostic Troublo Codo (DTC) 6-4: Re81Fail-SafoRolay Cilcuit
CAUTION: Use only digital multimetar to chock tho system.

FAIL.SAFERELAYS
- Whh engine running, ABS in-

dicator light ie ON.
- With sorvice chock connoctol
iumpod lsee pago 19-55).
DTC 6-4 is indlcated.
Wire colors of the tsil-s9te relay connector

Remove the rear lailsafe relay Front:BRN/BLK,BLK/YEL,YELiGRN,BLK
from underthe gaugeassembly. Rear: 8LU/BLK,BLK/YEL,YEL/GRN,BLK
Check relay function (see Page

19,87).
Does ir work prop€rly? R€placethc r6at fall_3aferolaY.
HARI{ESS.SIDECONNECTOR
Turn th6 ignition switch ON.

fail-saferelay connector No. 1
(BLK/YEL) terminal and body
ground.
R.plir opon In BLK/YEL wlro bo-

two€n th. No. 9 B/C MIRRoR
(15 Al fute In th! und.i-dalh
lu$/roby bor and ttont f.ll-lafo
lollY.
BlttoryVoh.go? Cootinuity?
Turn tho ignition switch OFF.
Vi6w from t€rmin6l side.
Disconnectthe lOP connector

from the solenoids.
Check Ior continuity between

the fail-safe rclay connector No.
2 {BLU/BLK)terminal and boclv
ground.
Ropai. 3hon in BLU/BLK wlro b.-

twoon tho iolonold and torr fail-
aalo rglav.
NO
( T op a g e1 9 7 3 )
19-72
:i
(Frompage19-72) CONNECTOR
SOLENOID-SIDE
Chcck to. continuity bslwoon

th€ solenoidNo. 5 IERN/WHT)
terminalsnd body ground.
Faulty lolondd {rhortl.

Roolacctha modulalor unit.
Disconnect the connectors from

the ABS control unit.
Check each wire tor continuity

betwegn the ABS control unit
connector and body ground,
RED/WHT:Rearlnlet RED/WHT
IR.IN)
YEUWHT; Rear Outlet
View from ABS controlunit terminalside.
14P CONNECTOR
l4WSl
RED/WHT{R.INI
12 []t 1 l 10 9
8 7 6. 413 1
YEL/WHT I
O O Continuity?
Repairrhort in wlre b.twoon tho

aolanoidond ABS control unit:
RED/WHT:Rear Inlot
YEI/WHT: Roar Outlot
lTo page19-74)
(cont'dl
19-73
Troubleshooting
Flowcharts (cont'd)
(Frompage19-73)
laP CONNECTORl2WS)
30 29 2A [Jl 26 25 24 23
22 21 20 1 9 1 8 1 1 15 14
Continuity?
o tFsR)
rhe No. l7 (4WS: No. 191
(YEL/GRN)terminal and bodv View lrom ABS control unit terminal side.
ground.
20P CONNECTORt4WS)
34 33 3l tllj 30 28 26
24 22 20 1 9 1 8 1 7 '16 1 5
Fop.lr lhort In YEL/GRN wito

b€two€n tho ABS contlol unit
,'.:1;"'
e
Continuity? =L.
and '.ar lail3ata rclay.
View from ABS control unit terminal side.
Reinstallthe rear laifsate relay.

18P CONNECTOR{2WS}
30 29 2A 27 uJ 25 2 1
Turn the ignitionswilch ON. 't9 1 8 't7 1 6 1 5 1 1
22 21 20
Check for vollage between the

ABS control unat connector No. (V)
vorr"e"z ;:;;
17 (4wS: No. 19) (YEL/GRN) ter-
minal and body ground.
View from ABS control unit terminal side
20P CONNECTORl4WS)
34 33 3l tlJl 30 2A 27 26
25 24 2'l 20 1 9 1 8 1 7 1 6 1 5
YEL/GHN t \l
tFsRt \-r-
ganeryVoltage?E
Repair op6n in YEL/GRN wito
ls there battory vollage? b6twcan thc toar fail-3at6 rel6Y View from ABS controlunit terminalside.
and ABS cont.ol unil.
ch€ck lor looso ABS cont.ol unlt

connoctors, It necesaary, sub-
rtituts a known-good ABS con_
trol wrh snd rocheck.
19-74
, .d.'{Fi.FFn-.r-,,q.iiillilnryl&_
Diagnostic Trouble Code {DTC) 7-1 and 7-21 Front Solonoid RolatedProblom
CAUTION: Uso only tha digital mullimeter lo chsck tho systom.
Pr6-test steps:
. Check ABS B1 (20 A) fuse in the under-hoodtuse/relaybox.
a Check for loose under-hoodluse/relaybox connectors.
- wlth ongino running, ABS in-

lcator light is ON.
- Wlth sorvico ch6ck connocto.
SOLENOID-SIDECONNECTOR
,ump€d lloo pa96 t9-551,
DTCa 7-1 6nd/or 7-2 ir in- RED/BLU{FLIN) RED/BLK(FR-INI
dic.tod,
oisconnect the lOP connoctor

from the solenoids.
Check for resistance between

the solenoidterminal:
N o . 1 ( R E D / B L Ka) n d N o . 4 1-3 0?
{ARN/BLK): FrontRight Inlet
N o . 3 { R E D / B L Ua) n d N o . 6
(aRN/BLU):Front LeIt Inlet
ls there 1 -3 0?
Check lor resistance between

the solenoid terminals:
N o . 8 ( Y E L / B L K a) n d N o . 4
(8RN/BLK):Fronr Right Outlel
No. 1O (YEL/BLU)and No. 6
IBRN/BLU):Front Left Outlet
t-30?
'l
ls there -3 O? Viewfromterminal
side.
{Topage19-761 (cont dI
19-75
Troubleshooting
Flowcharts (cont'dl
(From page 19-75) HARNESS-SIOE (2WSI
CONNECTOR
RED/BLU
IFL,IN)
Disconnectthe 12P (4WSr 14Pl
connector from the ABS control
unit, View from terminalside.
YEL/BLU
YEL/BLK
(FR-OUTI IFL,OUTI
Check each wire lor continuity
belween lhe ABS cont.ol unit Continuiiy?
and front solenoid.
RED/BLK:Front Righr Inlet RED/ALUIFI--IN)
YEL/BLK:Front Right Outlet
RED/BLU:Front Lelt Inlet
YEL/BLU:Front Left Ourlet
tFR-OUtl
View lrom ABS controlunit terminalside.
HARNESS-SrOE
CONr{ECTORt4WS}
REO/SLK REOiBLU
{FR-INI IFL{NI
View lrom lermanalside.
YEL/BLU
YEUALK (FL,OUT)
(FR-OUTI
Contlnuhy?
RED/8IU (FL.II{}
YEL/8LK
IFR-OUTI
Rapdr opan h vri a batwaan tha View from ABS conirolunil terminalside.
|oldrold ..d ABS coitrol unh:
REDrSL|(: Froit Rlght lnbt
YEUBLK: F oni Rlght OutLt
REO/8LU: Front L.ft InLt 12P CONNECTOR
t2WS)
YEUBLU: F or L.ft OutLt
REO/8LU REDiBLK
{FL-IN) {FR{NI
Check each wire tor continuity

and body ground.
RED/BLK:Front Right Inlet
YEL/BLK:Fronl Right Ourlet
1
11 llJ 10 I
3 2
8
1n x YEL/BLK
IFR-OUTI
RED/BLU:Fronl LeIt Inler

YEL/BLU:Front Lelr Ourlet
o ;l:tt$€ .o) (o.
Continuity?
(To page19-77) View lrom ABS controlunit terminalside.
1 9 -7 6
" -ffit4!{r"{?flFqrr+*' "'frf,!ffiru..
14P COI{NECTOR{4WS)
(Frompage19-76)
RED/BLU(FL-IiI} RED/BLKIFR.INI
12 tlJ 1 1 1 0 I )
I 7 6 5 4 3. 2 YEL/BLK
IFR-OUTI
Conrlnulrv?
/ |
6 oXo
c)| ['.:-6'r'Y'
View from controlunit terminalside.
Ropalrrhort In wlre baiwaen th€
lolonold and ABS contrcl unlt: FAIL.SAFERELAYS
RED/BLK:Fronl Rlght Inlot
YEL/BLK:F.oot Rlght Outht
RED/BLU:Front Lolt lnlor
YEUBLU: F ont L6ft Outl.t
Wiro colors of the tail-saIe r€lav connecror

Remove the lront foil-sate i€lav FTONT:BRN/BLK,BLK/YEL,YEL/GRN,BLK
from under the gauge assembly. Rear: BLU/8LK. 8LK/YEL, YEL/cRN, BLK
Check for relay function (s€e

pago 19-87).
Ooes it work propedy? R.placc thc fronl tall-..fo .elay.
HARNESS-SIDECONNECTOR
Ch€ck for continuity betwoen

th€ fail-sato rglsy connectoi No.
4 terminal and body ground.
Roprli opcn In BLK wire betwe€n

tho fall-aafo l6lay and g.ound or
poo. ground lG4O1, G4O2,
G/rO4l.
View from terminalside. =

Check BRN/BLK wirs for con-
tinuity bgtwoonthe aolonoid3and HARNESS.SIDECONNECTOR
front failsate relay.
BRN/BLK
Rcpair opon In BRN/BLKwl.o b.-
twean tho rolanolda and f.ont
lall{ol. relay,
Chack tor looae ABS control unh

connactota. lf nocolaaty.
.ublthuto . known-good ABS
contrcl unh ond rechock.
View Irom terminalside.
19-77
Troubleshooting
Flowcharts(cont'd)
Dllgnostic Troublo Code (DTCI 7-4: Roar Solenoid Problem
CAUTION: Uso only tha digltal multimolol to ch€ck the syst€m'
- YVhh.nglno runnlng, ABS In- REDAAIHT

dcator fight ir ON. tR-rNl
- Whh raNico chqck conneclol
jurnp.d (te6 pag€ 19-551,
BRN/WHT
DTC 74 l. indlc.lod.
YEL/WHT
{R-OUT}
Oisconnect the lOP connector
from the solenoids. 1-3 0?
View from tsrminal 9ido.

Check for registance between
the solenoid terminals: HARNESS.SIOECOI{NECTORI2WSI
N o . 2 ( R E D / W H TaI n d N o . 5
(BRN/WHI: RearInlet
N o . I ( Y E L f l V H TaI n d N o . 5
(BRN/WHT):Rear Outlst
tgrminal 3ide.
ls thete 1 -3 O? YEL/WHT
(R-OUTI
Co lnuhy?
(R.IIU
RED/WHT
Disconnectthe 12P (4WS: 14P)

connector trom ABS control unit.
Check each wt€ {or continuity

botween the ABS control unit View Irom ABS control unit terminal gide
and r6ar solenoid:
RED/WHT: Rear Inl6t HARNESS-SIDECONNECTOBI4WSI
YEL/WHT: Rear Outlet
Raprlr opan In wlra botwaan tho

rolonold .nd ABS cont.ol unlt:
REO/WHT:R.at Inl.t
YEL/WHT: Redr Outlot
Condnuity?
(R.INI
REDAATHT
YEL/WHT{R-OUTI
View from ABS control unit terminal side'
(To page19-79)
1 9 -7 8
{Frompage19-781 (2WSl
12PCONNECTOR 14P CONNECTORt4WSl
RED/WHT{R.INI REON/HT IR-INI
Check each wi.e tor continuity
and body ground:
RED/WHT:RoarInl6t
YEUWHT: Roar Outlet
IR-OUTI
View trom ABS control unit terminal side. View from ABS controlunit terminalside.
FAIL-SAFEBELAYS
Roolir lhort ln wlre b€twocn iho
lolgnold and ABS cont.ol unlt:
REO/WHT:Roar Inlot
YEL/WHT: R6or Outlct
Wire colors ot tho fail-safe relay connector

Remove the rear lail-safe relav F.ONI:BRN/BLK.BLK/YEL,YEL/GRN,BLK
Irom under the gauge sssembly. Rear: BLU/8LK,BLK/YEL,YEL/GRN,8LK
Check for rglay lunction {s€e

page 19-87).
Does it work properly? RapLco tho rorr tril-lafo roaly.

HARNESS.SIDECONNECTOB
Check for continuity betweon

the tail-safe rclav connector No.
4 (BLK) terminal and bodY
grouno.
Raprlr opon in BLK wl.o botw66n

tho hll-refe rcl.y and ground o.
poo. ground lc4o1, G402,
G/ro4l.
Check BLU/BLK wire tor con- View from terminalside.

tinuity betwsen th€ solenoidand
r€ar tail-safe r€lay.
HARNESS.SIDECONNECTOR
Ropalrop6n In BLU/BLKwi.o b.-

twaen lhe 3oLnold rnd roar fail- BLU/BLK
lrtc rohy.
Chock for loote ABS cont.ol unlt

connecioaa. lf nccoraary, aub- Continuity?
Btitute a known-good ABS con-
t.ol unh and rochock.
19-79
HydraulicSystem
Index/HydraulicConnections
CAUTIOI{: Do not spill brsks tluid on tho car; it may damage the paint; if brake fluid does contact the paint, wash it oft
im.nadillcly tYith water.
RESERVOIR TANK
BrakeFluidDraining, ' 1 0x 1 . 0 m m
page19-81
1 9 N . m 1 1 . 9k g - m ,
't 4 tb-ft)
To right-l.onl
brako
To lolt-tiont
to agnr+eat,// 7'
br.ke
,/
To loft-roar brake
MODULATORUNIT 10 x 1.0 mm
page 19'82
Removal/lnstallation, 1 9 N . m ( 1 . 9k g - m ,
page 19-83
Index/Torque, 14 tb-ft}
19-80
RelievingAccumulator/LinePressure
@ Use the BloederT-wrench before disassemblingthe parts shaded in th€ illustration,
1. Ooen the hood.
2. R€movethe red cap from the bleederon the modulatorbody.
3. Installthe specialtool on the maintenancebleederand turn it out slowly 90" to collecthigh-pressure

fluid into the
reservoir.Turn the specialtool out one completeturn to drainthe brakefluid thoroughly.
4. Retightonthe maintenancebleederand discardthe fluid.
5. Reinstsllthe red cao.
ReservoirBrake Fluid Draining

1. Drainingbrakefluid from modulatortank:
The brake fluid may be sucked out through the top of the modulatortank with a syringe.lt may also be drained
through the pump joint after disconnectingthe pump hose.
2. Drainingbrakefluid from mastercylinder:

Loosenthe bleed screw and pump the brake pedalto drainthe brakefluid from the mastercylinder.
a High-p.ossul€ tluid u,ill squirt out if th6 shadod hoso and pip€ are removod.
a To drain high-prossursbrake tluid. follow the procodure on this page.
19-81
ModulatorUnit
CAUTION:
a Ba carsful not to bond 01 damage tho brako pipos when romoving tho modulator unit'
a Do not spill brake lluid on th€ car; it may damag€the paint; if brak€ fluid do€s contact the paint, w88h it ofl immodiate-
ly rYilh tYatel,
a To pravont spills, covol tho hose ioints with lags or shop towels'
a Bofore reassembling,ch6ck that all pans are free of duEt and oth€r fo?sign particlss'
a Do not mix diffarsnt brands ot brako tluid as thoy may not b€ compatibl€'
a Do not reus6 the dtain€d fluid. Uso only clean DOT 3 01 4 brake fluid'
a Whan connocting tho brak€ pipos, mako sula that thelo is no intorf€lonce betwaon th€ braka pipos and othor panE'
1. Drainthe brakeJluidIrom the mastercylinder.

2. Relievethe high pressurefluid (seepage 19-81) when the high pressurehose is to be disconnected,
3, Removethe intake air duct
4. Disconnectthe solenoid,pump motor and pressureswitch connectors'
5. Disconnectthe six brakepipesJromthe modulatorunit.
6.Loosenthetwo|owermount|ngbo|ts,andremovetheuppermountingbo|tsndthemodu|atorunitlromtheframe.
7. lnstallthe modulatorunit in the reverseorder ot removal.
8. After installation, till and bleed the hydraulic system.
UPPERMOUI{TII{G BOLT
8 x 1.25 mm
SOLENOIDCOI{NECTOR 22 N.m 12.2kg-m, 16 lb-tt)
MODULATORUNIT
PRESSURE
swlTcH
CONNECTOR
(
\ LOWERMOU'{TING BOLTS
I x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)
Loos€n.
10 x 1.0 mm
19 N.m 11,9 kg-m,
14 tb-ft)
1 2 x 1 . Om m
'19 N.m ll.9 kg-m,
14 tb-ft)
19-A2
slrrr{EriE.a..
Index/Torque
@ Before removing tho modulatol-to-pump high-pressurelino, bo sur€ to reliove ths tluid ptossure trom th.
maintenanc€bloeder{se€ page 19-81).
CAUTION:
a Do not spill brake tluid on th6 car; it may damagetho paint; it brake fluid does contact the paint, wash it oft immodiato-
ly with watel.
a To pr€vent spills, cover the hose ioints with rags or shop towols'
a Befora roaassmbling.chock that all parts are freo ol dust and othor foreign particlos.
a Do not mix diffsront brands of brato fluid as thoy may not b€ compatible.
a Do not rous€ the drainod tluid. Use only cl6an DOT 3 or 4 brako fluid.
a Do not dissssembl€tho modulator unit, Replacotho modulator unit as an asssmbly if it is defectiv€.
a Do not disassomblsthe pump (oxcept plsssuro switchl,
6 r 1.0mm
1O N'm (1.O kg-m.
7 lb-ft|
MODULATORASSEMBLY
Do not disassemble.
CONNECTOR
BRACKET
SEALINGWASHERS
Replace.
SOLENOIDS
LeakTest,page19-84
BANJO BOLT
35 N.m {3.5 kg-m.
25 tb-ft)
I x 1.25rnm
1 5 N . ml l . 5 k g - m , PUMPEBACKET
lt tb-frl
6x1.Omm
1 0 N . m 1 1 . 0k g - m ,
7 tb-tt)
MODULA
ARACKET
6 r 1 . Om m
1O N.m {1.O kg-m,
7 tb-ft) ACCUMULATOR
Disposal,psgo 19-85
EANJOBOLT
35 N.m 13.5kg-m,
HOSE CLAMP rb-ft)
SEALINGWASHERS
Str.O^,'/ Replace.
1 0 N . m 1 1 . 0k g - m , PRESSURE
SWITCH PUMP ASSEMELY
7 tb-til Do not disassemble.
19-83
Solenoids Pump
LeakTest PressureSwitch Replacement
NOTE: lf a sol€noidleaks excessively,the brake fluid Removal

level in the modulator reservoirtank will rise when '1.
operatingthe ABS pump motor. The modulatorreser- Securethe pump assemblyin a vise.
voir may also overtlow.
2. R€movethe banjo bolt, then removethe pressure
1. Disconn€ctthe pump motor and ptessureswitch switch from the pump housing
connectors.
2. Connsct an ohmmeter between the YEL and YEL

BANJOBOLT
terminalsof the pressur€switch connector. 35 N.m 13.5kg-m,25 lb-ft)
3. Attach the positive(+) leadoJ a fully charged12 V

battery to the RED/WHTterminal ot the motor con-
I
nector and negative(-) lead to the GRN t€rminal,
and install a switch between negative lead 8nd
/@
GRNterminalas shown. o@ /1
4. Turn the switch on to allow sutficient gr€ssure to
build uo within the accumulatorand checkfor con-
tinuity. lf ths ohmmete.shows continuity(pressure
switch turned on), run the motor for 1O seconds
mors, then turn the switch off
lnstallation
lnstall the pressure switch with the banjo bolt and
sealingwashers,then tighten the bolt.
a CheckiJ the solenoidhissesor squeaks.Replsce

the modulatorif the solenoidhissesor squeaks.
a Check the pressure switch for continuity within
30 minutes,lt is normalif there is continuity' ll
there is no continuitv, a solenoid is taulty or
high-pressure line leaks.
19-84
Accumulator
Disposal
reL
@ The accumulatol containa high pr€ssur€
nltrogen gas. Do not puncturo. oxpose lo the flamo, or
attomot to disassomblotho accumulatol or it may €x-
plode and a€var6 porsonal injury may l€sult.
1. Securethe pump assemblyin a vise and remove

the accumulator by turning it counterclockwise
with a 19 mm oDen-endwrench.
ACCUMULATOR
Securethe accumulatorin a vise so that the reliet

plug points straightup.
Slowly turn the plug 3-112 turns and then wait

three minutestor all pressureto escape.
4. Remove the plug completely and dispose ot the

accumulator.
19-8s
Bleeding
CAUTION:
4. Start the engine and allow it to idle for a iew
a Do not spill brake fluid on the car; it may damagetho
minutes,then stop it. Check the fluid level in the
paint; it brako fluid does contact the paint, wash it
modulatorreservoirand refillto the MAX levelline
off imm€diataly with water.
if necessarv.
a Make sure no dirt or other loreign mattsr is allowed
to contaminato tho brake fluid. Bleed high-pressurefluid from the maintenance
a Do not mix dilferent brands of brake fluid as they
bleederwith the specialtool.
may not be compatible.
a Do not rous€ ths drained tluid. Use only clean DOT 3
or 4 blake fluid. T.WRENCH
BLEEDER
oTHAA-SG00101
1. Placethe vehicleon level ground with the wheels
blocked.Put the transmissionin neutralior manual
transmission models, and in @ position for
automatictransmissionmodels. Releasethe park-
ing brake.
2, Disconnect the ABS inspection connector (6P)

irom the cross-memberunderthe passenger'sseat
and connectthe ABS inspectionconnector(6P) to
the ALB checker.
CONNECTOR
o. Start the engine and allow it to idle lor a few

minutes,then stop it. Check the fluid level in the
modulatorreservoirand refillto the MAX levelline
if necessary,
Turn the Mode Selectorswitch of the checkerto 2.

Seepage19-32lor other
applicablo
chockers.
8 . While d€pressingthe brake pedal fitmly, push the
Start Test switch to operatethe modulator.There
should be kickback on the brake pedal. lf not.
fepest steps 5 to 8.
3. Fill the modulator reservoirto the MAX level ltne
and installthe reservoircap.
NOTE: Continueto depressthe brakepedalfirmly
when operatingthe checker'
9. Turn the Mode Selectorto 3, 4. and 5

MAX LEVELLINE Performstep 8 for each oJthe test mode positions.
1O. Refillthe modulatorreservoirto the MAX levelline

snd installthe reselvoircaP.
@ Disconnect the ALB checker botors driv-

ing tho car. A collision can result tlom a teduction ol
compl€t6 loss ol braking ability, causing sevsrs p€r-
sonal iniury or death.
19 -8 6
ElectronicComponents
ABS Control Unit Replacement Relay Inspection
1 . Removethe right quartertrim panel. 1. Removethe fail-saferelaysand motor relay (loca-

t i o n : p a g e1 9 - 5 0 1 .
2 . Disconnectthe ABS control unit connectors.
2. Check for continuity betweenthe terminalsC and
J. Removethe ABS control unit attachingbolts, then D.
removethe ABS control unit. Thereshouldbe continuity.
ABS CONTROLUNIT 3. Check for continuitybetweenthe terminalsA and

B.
There should be continuity when the battery is con-
nected betweenthe terminalsC and D.
There should be no continuity when the baftery is
disconnected,
<Fail-sate Relay:>
lnstallthe ABS control unit in the reverseorder of

r€movar.
<Motor R€lay:>
19-87
Pulsers/Wheel
Sensors
Inspection
Front Rear
1. Checkthe pulserfor chippedor damagedteeth and 1 . Removethe rear caliDerassemblY.

replaceif necessary.
2 . Removethe rear brakedisc.
2. Measurethe air gsp betweenthe sensorand pulser
all the way aroundwhile rotatingthe driveshaftby Checkthe rearpulserfor chippedor damagedteeth
hand. and replaceif necessary.
Standard:o.4- 1 .0 mm (0.02-0.04 in) 4. Measurethe air gap betweenthe sensorand pulser

all the way around while rotatingthe hub bearing
NOTE: lf the gap oxceeds1.Omm (0.04 in) 8t any unit by hand.
point, the probabilityis a distortedknuckle,which
should be replaced. Standard:O.4- 1.O mm {O.O2-O.O4in}
NOTE: It the gsp exceeds1 .O mm (O.O4in) at any

point, the probabilityis a distortedknuckle.which
should be reolaced.
FRONTWHEELSENSOR
REARWHEELSENSOR
19-88
Wheel SensorReplacement
Front
6r1.Omm
E '10N.m ll.0 kg-m,
NOTE:
a Be carefulwhen installingthe sensorsto avoid
e 7 tb-fr)
twistingthe wires.
ftI
a After sensorreplacement,contirm properoperation fr
( s e ep a g e 1 9 - 5 3 1 .
6 r 1 . Om m 8 x 1 . 2 5m m
10 N.m (1.0 kg-m, 22 N.m 12.2 kg-m,
7 tb-ftI 't6 tb-frl
6 r 1.0mm
Rear lO N.m (1.0 kg-m,
7 tb-ft)
NOTE:
a Be carefulwhen installingthe sensorsto avoid
twistingthe wires.
a After sensorreplacement, confirmproperoperation
( s e ep a g e1 9 - 5 3 ) .
\ l
* ) 3
l\h
"Y
8 r 1.25 mm ,/ 6 x 1.0 mm
22 N.m 12.2 kg-m, 16 lb-ft) 1 0 . r n ( 1 . Okg-m, 7 lb-trl
19-89
Body
Bumpers Roof Molding/Side
SillPanel
FrontReolacement ...............,.,,....,.
2G58 Reolacement .......2G68
FrontDisassembly...............,,.,,..,,,.
2G60
RearReplacement 2G61
.............,............ Seats
....20-62
RearDisassembly....................... FrontRemoval .....2G38
FrontReplacement 2G38
..,.,.,..................
*Carpet FrontSeatCoverReplacement...,2G4O
Reolacement .......2G 48 2G41
RearReo|acement,.........................
*Consoles Seat Belts
Replacement .......2G5O FrontReplacement 20-43
.........................
RearReolacement ..................,,.,,...
2045
*Dashboard lnsoection ............2G46
.........2O-5'l
ComDonent ChifdSeatAnchor Plate.............
....fu47
Replacement .......2G55
Sub-frame .......20-71
Doors
1ndex fuz Sunroof
.................................................
DoorPanel/Plastic lndex.................. ...2$ 28
2Gg
CoverReolacement,............... Troubfeshootin9 ..............................Tn
OuterHandleReplacement........2G5 SlidingPanelHeightAdiustment ...2G29
LatchRep|acement .....................
20-6 RearEdgeClosingAdjustment......2G3O
Replacement...2G7
Glass/Regulator SunroofLinerand SlidingPanel
OuterMoldingReplacement......2Gg ReDlacement ...2G30
WeatherstripsReplacement.....2G9 SunroofRepair/lnstallation ............
2G31
.2G10
GlassAdjustment.................,........ Motor, DrainTube,and Frame
PositionAdjustment.......................
2Gl 1 ReDlacement ... fu32
StrikerAdiustment.........................
*12 PanelStay/Slider.Lifter and
GuideRailsReplacement ............
2G33
*FrameRepairChart...............
n-72 OpeningDragCheck
(MotorRemovedl........................ 20-34
FuelLid ClosingForceCheck
Ooenerand FuelLid (MotorInstalledl 2G35
..........................
Latch Reolacement 2C167
.....................
OpenerCableReplacement........... 2G66 TrunkLid
Repfacement/Adjustment .....,,.,,,,,.
2G64
Headliners OpenerReplacement 2G67
......................
Replacement .......2G36 Trunk Lid LatchReolacement.......2G65
OpenerCableReplacement........... 2G66
Hood OpeningWeatherstrip/License
Replacement/Adjustment..............
2G63 2G69
PlateTrim Replacement.............
Openerand Latch Replacement ....2G63 Trunk SpoilerReplacement...........2G7O
HoodEdge
ProtectorReplacement ......2G69
Window/
Windshield/Rear
lnteriorTrims OuarterGlass
Reofacement ,...,,.n'37 fndex......,............ ...20-14
Windshield
Mirrors Removal ...........
2G15
Power DoorMirrorReplacement..2G12 lnstallation ........2G16
............
MirrorHolderReplacement 2G13 RearWindow
RearviewMirrorReolacement.....,2G13 Removal ...........2O-2O
lnstaffation ........2G21
RearEmblem OuarterGlass
lnstaflation ...........2G7O Removal ...........2G25
fnstallation .'.....2G25
Doors
lndex
CENTERSASHGUIDE
R€phcofirom,so€pags2O7
GLASS
RBOTTATOR Roplacofirorlt, s6g pr€6 2G7
R.pboe.v|6m,s€s p.g€ 2OB OUTER]IIOLDING
Adjustnrsnt, soo pago 20l0 so6ps€B2G9
Replacemont,
GLAsSRUN
CHAiT{EL
J
CEI{TERCHAI{]{EL
R6placom€at,
sse pagp2Og
r(D
a
(U TXX)R
Adjustm€,n,
-$
s6epa€€2G11
POWEAWNDOWMOTOR
^ d P
LocK cYLr D€R------&
ftto
Rophcemont,
CJfs t ba
r
sso p6gE2G5
OUTERH/\I{DLE
Rsplaceinent, @RJ
Ee6p.!B 2Gs
*^r.r3:
Adjuatmont,
DETEiITROD
o \
HIiIGE
s€'6psfle n-12c
PLASTICCOVER
I]U{ER HA DLE
ARMREATPOCKET
POWERDOOR
MIRRORSwlTCH
I I{ER HA DLE
TRIM PA EL
I'OOR PAI{EL
FOWERDOOR R€plac€m€nt,
LOCKSWTTCH s66 psc|e2G3
POWERWNDOW
swtTcH
SPEAKER
COVER
20-2
._-
CoverReplacement
DoorPanel/Plastic
Pry the cap, thon r€movethe scrow. NOTE;
Removsth6 clips 8nd disconnoctth€ connectors,thon Romovethe doorpanslwith aslittleb6nding8s possibl€
to
remov6tha innerhandletrim oan8l. or breakingit.
svoidcroasing
NOTE: . 95 mm(3.74In)
. Remove ths hook by slidingthe innsr hsndle trim
panel bsckward whil6 pulling the handle, then -1
'\ l - - -
|
12 hm
ramoveths innerhandletrim panel.
. Tak6 care not to scrachthe innerhsndlotrim psnel' CLIP io-;;7;1''-L---tu
REiIOVER
>: Clp bcttlon
sltAPO ---fr-
HOOK *a177
N ENHA DLE r * n l , F
TRIMPA EL Il{l{ERHANDLE {o.oahl I l____l
45 mm
irr.-F-
{1.77In}
5. Rsmove the screws and clips bee clip tetnover)

attachingthg door pansl,
Rsmovethe door panslby pullingh upward.
Disconnoctthe oowsr door mitror awitch conn6ctor.
SCREW
> : Clp bc.tloru l9l

POWERDOOR
LOCKSW]TCH
CONiECTOR
POWERWtl{DOW
slvrTcH coi[{EcToR
DOORPAI{EL
1".,,
F
l*"Yl
Pry the c8p and ramovo the acrew, then rsmovo tha
armr€st Docket. \__ F{
Pry th6 cap.
SCREW Pry tho cap.
SCREW
SCREW
POWEFTXX'F
MIRROFSWITCH
Pushher€.
COT{NECTOR
(cont'd)
Doors
(cont'd)
GoverReplacement
DoorPanel/Plastic
4. Remove th€ grommats, bracket and door lock unit, Apply sdhesivoalongthe edge where necessaryto
thsn carefuly removethe plasticcover. maintain8 continuousaealand DrsvsntwEtsr l6aks.
GROMMETS
GROMMETS
BRACKET DOORLOCK
UMT
lnstallth6 door Daneland olastic cov€r in th€ revarae

ordel ol removal.
NOTE:
. Maka sure the door harnsssssand connoctors are
lastenedcorrsctly on the door.
(D: tlarno$ ctp locltloo! . Before tighteningth6 door psnel mounting screwa,
mako sur6 tho door harnesaesare not pinchod,
.flEl-..
OuterHandleReplacement
NOTE: Prv the lock cvlinderrod out, then removetho out6r
Rais€th€ glassfully. handle,
1. R6movs; NOTE:
o Door panel(seepage2G3) Takecarenot to bendthe lockcvlind€rrod,
. Plasticcover (ses page2G4)
P66loff ths accesshol€ soal.
3 . Removs ths mounting bohs and clip, then pull the

out€r handlsout.
CAUTION:
Uro protac{lve tapo lround tho outll handlo to
prevrnt damage.
NOTE:
Do not drop th€ rnountingbohs 8nd clip insideth€ door.
OUTERHA]IDLE
PROTECTME
TAPE
MOUI{TINGBOLTS
6r1.Omm
5 N.m(0.5kem . 3.6 b-ft)
OUTER
HAI{DLE
6. Pu[ out the ret8inerclip,then removethe lock cylinde].
LOCKCYLINDER
ROD
4. Pry the outer hsndlerod out ot its ioint usingI flat tip
screwdriver.
CAUTIOI{:
Whon prylng whh a llat tip lcrawd vsr, wrap h whh
prot€ctlvo tapo to pravont damlge,
L(rcKCYLII{DER
NOTE:
. To eas6 rosssembly,note the location @ of the
outer handlerod on the joint before disconnectingit.
. Tske ca.e not to damagethe joint.
7. Installationis the reverseof the removalprocedure.

Doors
Latch Rephcement
NOTE: Disconnectthe connector and harness clip from the
R8iseths glassfu[y. door, Removethe mountingscrews, then remove the
latch throughthe hole in the door.
1. Removs:
r Door panel(seepage2G3) NOTE;
. Plasticcovor (seepage2G4) Take care not to bendthe lods.
. Center sssh (8€€page2G7)
. Out€r handls{seepage2G5)
OUTERHAM'LE
ROD
2. Disconnoctthe inner handlerod and lock rod from the
inner handleand lock crank.
Rsmovethe scrsws, then removethe innerhandleand
lock crank,
NOTE:
Tak6 care not to bendthe rods.
FASTEI{ER
iloul{Tllrlc SCREWS
6 r 1 . Om m
5 N.m (0.5 kg-m ,
3,8 b-frl
HARNESSCLIP
is the reverseof the removalDrocedur€.

4. lnstallation
NOTE:
Make sure the rods and connectorare fasten€d
correctly.
20-6
Replacement
Glass/Regulator
R€move: 5. Csrefullypullthe 9l8ssout throughtheI window slot.
. Door psnel(soepage2G3)
. Plasticcover (sse page2G4) NOTE:
Take csre not to drop tho glassinsidethe
I door,
Low€r th€ glassf ully.
GUIDEPIf{
Peeloff the sssh guidecovsr and remove the gcrewa,
then .emove the cent€r sashguid€from the door. \ \ LI GLASS
CEI'IIERSASHGUIDE
GLASSMOU]\ITI[{GBOLTS
6r1.0mm
6 N'm10.6ks-m, 4.3 b-ftl
. Check th€ guide pin for damag€, and replaco it

nec€ssary.
SASH GUIDE
COVER NOTE:
NOTE:
Whon inataling,
Sclib€ E line aroundth€ guide pin to show
s th6 original
appv tho doublo-faced location,
adh$ivo tapo to the
sashguid6covor.
PIN
GUIDE
4, Caretulv movs the glasauntil you can 8oe th€ thss

mountingbolts,then looa€nthe glasamountingbohs.
Slid€tho guid€to the rear.then ramov€tho glaaa.
R..r.ldo: From aHa:
GUIDEPI
+ l___@.)l +
GUII'EPIN
MOU TI[{GBOLT c[
6rl.0mm
3 N'm(0.3 ks.m, 2.2 lb-ft) SEAL
{cont'd}
20-7
Doors
Glass/Regulator (cont'd)
Replacement
P66lth€ glassrun channolout of the front chsnnel. MOU]TTING BOI-TS
8r1,Omm
R€move the mounting bolts, then remove the front 8 N.m(0.8ks<n, 5.8 b-ftI
channol8nd center chsnnel. BEGULATOB Loosenthe bohs.
NOTE:
After instslling,mak€ sur6 th€ ghss run chsnnolis not
BOLLER
twisted. FROl{I
CHANNEL
n
OLASSRUN
MOUNTINGBOLTS
8x1.0mm Sxl.Omm
I N.m {O.8kg-m , 5.8 lb-ft) I N.m (0.8 ko-m . 5.8 lb-ft)
q
Greaseall th6 slidingsurtaces oJ th6 regulatorwhere
snown.
1 0 . Before removingthe powar window motor, mark tho

location by scribingI line across th6 s€ctor gear and
MOU TII{G BOLTS r€gulator.
6r1.Omm Install using th6 motor mounting bohs. Move th€
I N.m (0.9 ks-m ,6.5 lb-ft) regulatorto tho originsl position by conecting I 12 V
NOTE: battsry to tho power window motor {seos6ction 23).
To install.fit the glassrunchannelintothe front andcsnter
chann€lsas shown. SECTONGEAR
CEl{TER GLASS RUI{ FROI{T

CHA NEL CHANNEL CHANNEL
NOTE:
Apply tho adhssivoto th6
shadowodar6s.
Removothe two mountingbolts, two roll€rguidebolts

and loos€n the two mounting bolts. Disconnect the
conector. Remove th€ regulator through the center POWERwlI{DOW
holein the door. MOTOR
is thg rovorss of ths removalorocsdurs.
l l . lnstEllEtion
NOTE:
Scrib€ a line around the roller guide boh to show the 12. Roll the glass up and down to so6 il it moves frsev
originsladjustment, without binding. Also make sur€ that there is no
ROLLER GUIDEBOLT clearance between the glass 8nd glass run channol
when the glass is closed. Adjust the position of th6
glassas necesssry(seepage2Ol0).
Attach the door hsrness to th6 door correctly (see

psgs 2G4).
1 4 . When reinstallingthe plastic cov€r, apply adhesive

8long the edge wh6r6 nocc€ssary to msintain a
continuousssal and prevsnt watsr lgaks{seepag€2G
4t.
20-8
{'!ficarfr-
OuterMoldingReplacsmont WeatherstripsReplacement
Remove; > : Clp bc.rlon
. Door pansl(s66pass 2O3l
. Plasticcover (ss€ page2G4)
. Door mirror (seepagea,Aj-.lA
. Glass(se6pase2G7)
> : Clp locrilon.
WEAY}ERSTRIP
WEATHERSTRIP
cLtP16l
NOTE: rnside f
Takecarenot to twist or scratchthe outsrmoHing.
OUTER MOLDIG
Staningst tho reEr,prythe outormoHingup .rd
detachthe clps.thon.6movotho out6rmolding.
CI.ASsRUl{CHA EL
lnstsllationis the reversaof ths removalprocodure.

WEATHERSTRIPS
NOTE:
. ll nsces,sary,rsplscs any dsmagodclips.
. When instslling,slign ths r88r €dgs of tho outsr NOTE:
moldingwith the resr edgoof the door, . Before instEllingth6 w68th6rstrip, sppv cle8r s68l8ntto
ths @ ar€asof th€ door as shown.
e lf necessary,replac6any damag€dclips.
S!.hm: Comcdlnc # 85OO
20-9
Doors
GlassAdjustment
NOTE: Maks surs tho glassgoss up anddown smoothv.
. Placsthe vshiclo on I tirm, l€val surtsco when sdiusting
tha dass. 6. lf n€csssaly, sdjust the front channgl and c6ntor
. Check th6 weathorstrip 8nd glEss run channel for channel,
dsnrsgaor doteriorstion8nd r€pl8ceil nsccoasary.
1. R6movsth6 door p8n€l8ndps6loff the plasticcovsr

(sa6pagss2G3,4).
FROIIITCHAiTIEL
2. Conn6ct th€ powor window switch connoctor to the
door harna9aconngctor.
3. Loosenth€ rollor guide bolts and sdju$ the glassso h

is p8rall6lwith ths glassrun chann6l.
NOTE:
Mak6 sure the guid6pin i9 in ths centst sashguide.
CE]|TERCXAiT{EL
GUE'EPIl{
7. Rsisath€ giasstully snd check for g6ps.
OLASS RUl{ CHAi'IEL
WEAT}fRSTN|P
S"\
ROLLERGUDEAOLTS & Chockgbssoporstion,

Loos6n,
NOTE:
Chockthst tho ghss contactsthe ghss run channel
R8issth€ glassas far up 8s possiblaEndhold it sgainst evsnlv.
th€ gbss run chann€|,
Thon tbhten the rollerguid6bolts.
20-10
'F1rfrtryl-.
PositionAdjustment
9. Checklor watorl6aks. NOTE:
Place the vehicle on I tirm, level surface when adiustine
NOTE: the doors.
Donot usshighprossure
water.
Aft6r instsllingthe door, check tor a flush fh with the body,
thgn check for equalgapsbstween the front and rear, and
top 8nd bottom door edgssand the body,
Th€ door and body edgesshouldalso b€ p8rall8l,Adjust 8t
the hing€s8s shown.
GAUTION:
Plec6a shop towol on tho ieck to prevent damagoto lho
door whcn the mountig bohs are bosen€d for adiuttmem.
DOONMOUI{TINGBOLTS
I x 1.25mm
30 N'm(3.0 lg-m , 22 lb-ft)
Loosonthe door moumingbohs slkthtv to
movotho door lN or OUT until it's tlush
with tho body.tf nocoas€ry,youcaninstall
a shim b€hindoo€ hingEto m6k6the doo.
odgssPARALLEL whh tho body,
y"i-6,
HINGEMOUNTII'IG BOLTS
1 0 . Routg the door harnossssand connectors and faston 8 x 1.25mm
them to ths door (ss6 pag82G4). 30 N.ml3.Oks-m. 22 lb-ft)
Loos6n th€ hing€ mounting
1 1 . Attsch ths plastic cover, rhen install the door p8n6l HINGE bohs, 6nd move tho door
(soepEgss2G3.4), BACKWARDor FORWARD.
Low6r the gla8s. UP or DOWNos n6cossaryto
th€ gaps.
eqraliz6
SHOP TOWEL
Tho door and body 6dg6sshouHb6 p€ralle..
NOTE:
Chsckfor waterleaks.
20-',1
Doors Mirrors
Striker Adjustment PowerDoorMirrorReplacement
Make su.e the door latchessecurelywithout slsmming. 1 . Pry out the cov€r panol with I flat tip scrswdrivor,
lf it needs adjustment: then removethe covGrpanel.
Disconnectthe connector.
1. Drawa linearoudthe strikertor reference.
2. Rernovethe mounting scrows while holdingtho door
2. Loosenthe mountingscrews and move the striker lN mirror.
or OUT to make the latch fit tighter or looser. Move
the striker UP or DOWN to align it with the latch
opening,Then lightlytighten the mountingscrews and
recheck. DOORMIRROR
STRIKER
MOUrrnG SCReWS
I x I.25mm COVER PAI{EL
1 8 N.m {1.8 kg-m .
1 3 b-ft)
2 Installationis the revers€of ths removalprocedure.
4. Checkfor water leaks.
NOTE:
Do not use high pressur€wat6r.
NOTE:
. Holdthe outer handleout and push the door against
the body to be sure the striker allowsa tlush Jit.
. Do not tap the striker with a metal hammer to
adiustthe position.
lf the door lstches properly, tighten the mounting

screwsandrecheck.
NOTE:
R€placethe strikor it it is cracked.
20-12
Mirror HolderRoplacement RearviewMirrorReplacement
1, Pry the mirror hoher from the bottom until you can 1. Carstullyremoveths cover with a flat tip screwdriv€r.
seethe actuator,th€n detachth€ hooks usinga flat tip
screwdriv€ras shown. 2. Loosen the lock boh, then slide the mirror stay from
th€ lug.
NOTE:
Tak6 care not to scratchth€ mirror housing.
ADIfSIVE TAPE
REARVIEW
MIRROR
ffirSr MIRRORSTAY
FJ
COVER
ACTUATOR
Disconnectthe hooks and connector,then remov€th€ Removethe lock boft, th€n r€move th€ toothed lock
mirror hoHer from the actuator. washsr 8nd hoH springfrom the mirror stay.
ACTUATOR
LOCKBOLT
Loft-h6nd th16ads
TOOTHED
LOCKWASHEN
HOLDSPRING
-ld HOOKPLATE
.:I;) ,"i
MIRRORSTAY
MIRRORHOLI'ER
3. Installationis the reverseof ths rsmovalprocedure. 4. lnstallationis the revarseof the .ernovalDrocedure.
20-13
Windshield,RearWindow, O,uarterGlass
lndex
( ):Ouanthyof part us€d.
CENTER (1)
FASTE]TER
(Clip-typ€)
ffndd{dd: UPPERFASTENER
I2I
(Clip-typ€)
CORNEBCLIP{2}
cLrP{6)
(8I
RETANER
V
WINDSHIELD
Removsl, s66p8g€2G'15
v DAMS
RUBBER
s66pago2G16
Instoll€tion,
UPPER FASTEiIER (2}

(solf-adhosive.typo)
FASTEER(1}
CENTER
(Solf-adh68iv6-tYP6)
GLASS
BRACKET12}
--=-Tr"-;;
MOLDIMi
R.ar Wlndow:
RUBBER
DAMS
REARWINDOW
Romovsl,roo pag62O2O
Instslldtion,s€opag62G21
Ouortor GLrr:
q.
OUARTERGLASS
\*r I nuesen
DAM
SV-p\
\
\
s
\
\
GLAss'
GLASS
LOWERMOLDtitG
MOLDII{G HOLOER(7)
BRACKET{2)
Romovsl,soe p8g€2G25
Installation,soe pagE2G25
20-14
Windshield
Removal
CAUTION: 4. Pulldown the front ot the front headlin€r(seepsgG
. Woar glov63to remove and Instal the windlhiald. 2G36).
. Use aeat covols to avoid damagingany surfaces.
CAUTION:
1. To removethe windshield,first removethe: Take caro not to bond the h6adln6r oxcosrivev.
r Rearviewmirror (seepsge2G13)
. Sunvlsors(seepage2G36) 5. Remove the other retainers and Jast€nersfrom the
. Front pillartrim (seepage2G37) body.
. Front wipers snd air scoop {seesection 23)
6, Apply p.ot€ctiva tape alongthe edgoof the dashboard
2. Detach the clips from the retainers,then remove the and body as shown.
side sectionof the windshieldmoldingas shown. Usingan awl, mske a holethroughthe rubberdam and
sdhesive from inside the car. Push the oiano wire
NOTE: throught the hole and wrap each end aroundI pieceof
lf necessary,replsce8ny dsmagedclips. wood.
PROTECTIVE TAPE
3, Peeloff the upper section ol the windshieHrnolding.
NOTE:
Wh6n the upper section of the windshield molding
removalis difficutt, cut oll the windshieldmolding.
WINDSHIELD WINDSHIELD
MOLDING MOLDING
\
\)v/ l\..n'
# @Y CORNERCLIP
7.
TAPE
PROTECTIVE
With € helpe. on the outside, pull the piano wire back

and forth in a sawing motion and careJullycut through
the adhesive around the entire windshield, then
carefullyremovethe windshield.
CAUTION:
HoH tho plano wlre as closo to tho wlndshioH as
possiblo to pr6vent damago to tho body 8nd
dashboard.
PI,ANOWIRE
/Zh ;Erl
WINOSHIELD
(
/ / '
RETAINER
GLASSBRACKET
NOTE:
removethe screw,thenreplacethe ghss
It necessary,
bracket.
20-15
Windshield
lnstallation
1. Scrape the old sdhssiv€ smooth with a knile, to I 4. Glue the rubber dams to the inside faca of th€
thicknsss of sbout 2 mm (0.O8 in) on tho bonding windshieldas shown, to contain the sdhssiv€ durim
surlaca aroundthe entir€ windshieHoponingtlangs. installation,
NOTE; NOTE;
. Do not scrape down to the p8intsd surface of the Be careful not to touch th€ windshieldwhsro adhssivg
body; damsged psint will interfere with prop8r willbe aeplied.
bonding. 65 mm 326.5 mm
. Remove the rubber dsm and fsst€ners from the 12.56In) {12.a5In}
bodv.
o Mask of{ surroundingsurfacesbstore p8inting. RUEBER
DAMS 95 mm(3.74hl
2. Clean tho body bonding surfscs with a sponge

damDenedin slcohol.
9mm
NOTE: 10.35Inl
After cleaning,keep oil, greaseor water from gatting
on the sulfaca.
3. ]f ths old windshieH is to be reinstslled,use I putty

knife to scraDs off all trscss of oH 8dhesiv8, thon
clean the wlndshisldsurfac€ with slcohol wh6re new
sdhesiveis to be appliad.
NOTE: WIiDSHIELD
Mak€ sure the bondingsutfecs ia kept 1166ot watsr,
oilandgre8se.
CAUTION:
Avoid s€tilng tho wlrdshl.H on h3 edlps; tmd.filpE
may hsr dovobp Into clrckt.
NOTE:
Cleanthe shadowed8reE. WI DSHIELD
5. Glu6the csntor and upp€r fastsn€rs to the insidetaco

ol tho windshislJas shown,
66 mm 326.5mm
(2.56Inl h2.85 Inl
I,,PP€R
FASTEiER 95 mm 13.74lnl
(2)
CE TER
FASTET{ER
WhIDSHELD
WINDSHIELD FASTEI{ERS
WINDSHIELD
20-16
6, Inst8llthe glEssbrackets,retainersand fastenersto With 8 sponge, apply a light coat of glass primer
the bodyasshown, around the edge of the windshield as shown, then
lightlywipe it off with gauzeor cheesecloth.
NOTE:
Donottightenthe glassbracketmountingsclews. NOTE:
. Do not apply body primer to the windshield,and do
FASTENER not get body and glassprimerspongesmixed up.
. Nevertouch the primedsurfaceswith your hands.lf
l;-\ \
lfiftm?
vou do, the adhesive may not bond to the
windshield properly, causing a leak atter the
I L\_r= windshieldis installed.
\_.: . Keepwster, dust. and abrasivematerislsaway from
the primedsurface.
/////f : Agply slast$lmd h6ro. CENTER
UPPERFASTE ER FASTEI{ER
CENITER
FASTENER{1} I mm 10.35in)
326.5mm
11285Inl
RUBEERDAM WINDSHIELD
UPPERFASTENER
RETAII{ER
{8I
(2}
GLASSBBACKET
WINDSHIELD
7. Set the windshieldupright on the glassbrackets,then 9. With a sponge,apply a light coat of body p.imer to tho
center it in the windshieH opening. Mske slignment origin8l adhesive remaining around the windshield
marks across the windshieldand body with I grease openingflsnge. Th€ windshieldshould be installed10
D€ncilat the four points shown. minutesafter you applythe body primer,
NOTE:
11 mm 10.43Inl . Do not appv glass primer to the body. and be
carefulnotto mix up gl€ssandbody primersponges.
ALIGNMENTMARKS . Nevertouch the primedsurfaceswlth your hands.
. Mask off the dashboardbefore paintingthe flange.
'//Z
I Apd,t bod,t Nlmor horo.
WII{DSHIELD
30 mm ('1.18inl
WINDSHIELD
GLASS BRACKETS
NOTE:
Adjust th6 glsss brack€ts
'l until
th6ro is 6 sap ol 1 mm (0.4 in)
botwesn ths uppgr sdge ot the
windshieh snd the l€adingedgs of
th€ rool, th6n tight€n the (conl d\
mountingsct6ws.
20-17
Windshield
1 0 . Thoroughv mix the adhssiveand hardenartogether on 13. Uso suction cup8 to hold tho windshiold over tho
a glassor rnetalplatewhh a putty knife. opening,alignh with the slignrnontmarks mad€in stsp
7 and sst it down on the sdhssive.LightlYpush on th€
NOTE: windshi€Huntil h8 edg6is fullv seatedon the sdhosiv6
. Clesn 8 glass or metal plate with a sponge and sllths wav around.
slcoholbefore mixing.
. Folow the instructionsthat come with the adhesive. NOTE:
. Do not closs or opgntho doors until adhesivois dry.
. Mako surothe fastonela are fastensd correctlY.
1 1 . Before filling a carttidge,cut the €nd ot the nozzl€as
shown.
WII{DSHELD ALIG MEiT il|ARK8
cut nozzleend
10 mm (0.39ln}
7 mm10.27In)
12. Pack adhssiveinto the cartridg€ without air pockots

to ensure continuous delivery' Put the csnridge in a
calking gun and run a bead of adhesivo around the
edgeof the windshieldas shown.
NOTE:
AppW the sdhesivewithin 30 minutes alter sppving
the glassplimer. 14. Installtho clips on tho windshioldmolding.
2 mm (o.OgInl
-Tr Make s slghtly thickor bo.d
at 6ach corn€r d upp€r.
Fffi,I\:AD}IESNE
t
8mm
10.31in)
l Emm lmm
(o.31 lnl (0.04 'l
CET{TER
FASTEIIER
At +cslvE
RUBBER
OAM
WI DSHELD
WII{DSHIELD
20-18
Scrape or wips ths 6xc63s 8dh68iveoff whh a putty 1 7 . Let ths adh6siv6dry for 8t l68st one hour, than sprsy
knife or tow6l, wat€r over the windshisH and ch6ck for l€aks,Mark
loakingErsassnd l6t th6 windshielddry, then sesl with
NOTE: saalant.
To r6mov6 adhssivs from I Daintedsurface or the
windshieH, wipo with 8 solt shop towel damp6n€d NOTE:
whh alcohol. . Lot th€ car stand for at l€ast four hours aftsr
windshisH install6iton,ll th6 c81 h8s to bs ussd
1 6 . Installth6 windshioHmoHing. within th€ first four hours,it muat b6 driv€n slowly.
. K66p ths windshi€H dry for th6 first hour sttol
NOTE: installstion.
. Wh6n instslling,make surs th6ra aro no twists in the . check rhst the snds ol tho windshieldmoHing are
molding. sat underths air scoop.
. Install th€ windshield molding by starting Et th6
upper corn9r. 1 8 . Reassembls8ll r6mov6dp8rts.
. Gluethe upper soction with the Edh83iv8.
NOTE:
lnstallth6 r6srvi6w mirror after the adh6siv6has dri6d
throughly.
> : Clp, r.l!h.r bcltlonr
WIl{DSHIELD e
- WINDS]iELD
MOLDIT{G MOLDIT{G
\k <'.fr
4 # I
R ETAIT{ER
{4} cLrP(31
20-19
RearWindow
Removal
cAuTto : 4. Peeloff th6 roar window molding.
. War llovaa !o lamovo rnd ln3td thc loal wlndow.
. Do not drmrgc tho dctrortcr grld lnos. NOTE:
o When th6 rosr window moldingremovslis difficuh,
1. To rorbvo the rsar window, first romove: cut the 168rwindow mold:ngwhh 8 knife.
. Trunk lid (seepage2G64) . lf ngcossary,remov6the screw, th6n replacetho
o Rearshelf (seepage2G37) glas.sbrsckets'
. Resr pillartrim panel{seepags2G37) REARwlMrcW
Disconnoct ths dofrosler l8ads, and r€move th€il l^ 1"7'*

(W
2.
holdars. REARWINDOW
MOLDIIIG
NOTE:
Avoid scrstching the r€8r window whh ths cutter "-\-
blade.
I ,L
3. Remove the moldinghoHers, thon rorrove the lowel \ ADHESIVE
molding.
Ronrovoth6 r6ar hosdlinerls6o p8g€2G36).
CAUTIO :
Td(. cr?c not io b.nd thc h3l ml .rcosllvclY'
Apply protectiv8 tap6 to slom the odgeof ths bodYas

shown.
Usim En awl, mak€ a holethrough the rubb€r d8m and
adh6siv6from insidothe car. Push pisno wira thlough
tha hole Endwrsp each and s;ound a pi6coof wood.
HAM)WNE
Moldng hoHot rcmovel:
1) Removeor loo8snthe screw. V*

a Plscothe screw in tho screw
grommst agEinldo not screw
it in) and Drsssit down.
Affi***-
'
S\ts,ro.or*
\r HoLDER
3) Pull the screw with th8
molding hoHer o|'n of tns 10 ,,.,
,R{s
bodY.
riigEb--
lnstallation
With a help€l on ths outside, pullthe piano wire back Scrape the oH adhesiv€ smooth whh s knil6, to !
8nd torth in a sawing motion Endcarefullycut through thickness of about 2 mm (0.08 in) on the bondim
the adhesivesroundthe ontire rear window. surfsc€ aroundthe €ntir€ rear window oponingfhnga.
CAUTION: NOTE:
Hold the pl8no who ar dolo to tho rlar wlndow ss . Do not scrape down to the painted sur{ace of tho
posslbb to provc damagoto tha body. body; dsmased paint will intsriers whh proper
bonding.
. Remove the rubbsr dam and fastenars from the
PIANOWIRE REARWINDOW body.
. Mask otf surrounding surfaces before applying
orimer.
Clean the body bonding surfacs with a aponge

damponedin alcohol.
NOTE:
After clesning.keep oil, greaseor wat6r from gEtting
on th6 surface.
It the old rear window is to bs rsinstallsd,use I putty

knile to scrape oft all trac€s of oH adhesive,th€n
clgan the resr window aurtaca with alcohol whsre
new adhesiv€is to be appli6d.
NOTE:
Make sure the bondingsurface is kept fr€e of wst6r,
oil andgrssse.
CAUTION:
Avold sottlng the resr wlndow on h3 edgas; smal
chip€ may h davalopinio cracks.
8. Carefullvremovoths rsar window.
NOTE:
Cleanthe shsdowedarss.
REARWI DOW
(cont'd)
20-21
RearWindow
(cont'd)
Installation
4. Gbo rha rubber dams to the inside lsce of ths roar 6. Installth€glassbrack€tsandfasten€rsto the body8s
window as ahown, to contain th€ adhssive during snown,
instalrtion.
NOTE:
NOTE: Donot tightenthe glsssbrscketmounting8crews.
Bs careful not to touch the roar window wh€ra
sdh6sivewill b6 sDoli€d.
REABWINDOW
Glu6th€ side and uppar tastenersto the insid6fsce oJ

r6ar window as shown.
GLA88BRACKETS
{2}
FAETENER
BUBBER
DAM 7. Set the rear window upright on the ghss brsckots,
than cent€r it in the opening.Make alignrnontmarks
acroaathe roar window 8nd body with E greasep€ncil
at the tour ooints shown.
ALIGNMENTMARKS
UPPERFASTEI{ER(2} ALIGNMEIfTMARKS
DAM
RUBBER 10 lnm (039 Inl
H
Nft
. - I
I
FASTENER
{4)
SIDEFASTENER(2}
NOTE:
Adiustths brsck€tsto centerthe rsar windowin the
REARWII{DOW opening,thentightenth€ mountingscrews.
20-22
8. With a spongo, apply a light coat ot glass primer 1 0 . Thoroughlymix the 8dhesiveand hardenertogother on
around the edge of the rear window as shown, then a glass or m€tal plate with a putty knife. Follow th8
lightlywipe it off with gauzeor cheesecloth. instructionsthst came with the adhesive.
NOTE: NOTE:
. Do not apply body primer to the rear window, and CleanI glassor metal plste with s spongeand alcohol
do not get body andglassprimerspongesmixed up. before mixing.
. Nevertouch the primedsurfaceswith your hands.lf
you do, the adhesive may not bond to the r6ar 1 1 . Before filling I cartridge,cut the end of the nozzleas
wlndow properly, causing a leak after the rear snown,
window is instslled.
. Keep w8ter, dust, and abrasivematerialsaway trom
the primedsurface.
Cut nozzle end
as snown.
'////z mm {0.39 In)
t apply snrt wl^", hcr..
9 mm(0.35inl
LJ
I I GLAss
f-l | ,/ 7 mm(O,27In)
Ndffi-/
IDAM
RUBEER
12. Pack adhesiveinto the csrtridge without 8i. pockets
to ansure continuous delivery. Put the canridge in a
calking gun and run a bead of adhesive around the
edgeof the rear window as shown.
NOTE:
Apply the sdhesive within 30 minutes after applying
ths glassprim€r.
9 . With a sponoe,apply a light coat oJ body primer to the 2 mm10.08in)

original adhesive remalningaround the rear window
openingflange.The rear window shouldbe installed1O Mak€ I slightly thicksr
minutessfter you appV the body primer. :ADHESIVE
bead at each corner
ano upp9r,
NOTE: .'f.ffi,T\
. Do not apply glass primer to the body, snd be
carefulnot to mix up glassand body primersponges.
. Nevertouch the primedsurtaceswith you. hands. UPPER
8mm FASTEI{ER 8mm
20 mm (0.31 In) 1031 In)
/////t ; Appiv body pdmor horo. {0.79 in}
tG mm 10.63lnl 7.4 mm{o.29in}
ADHESIVE
RUAEEBDAM
(cont'd\
20-23
RearWindow
13. Us€ suction cups to hold the reat window over the 16, Installthe moldingholderon the low€r molding.
oponing,align it with the alignmentmarks madein step
7 and s€t it down on the adhesiv€.Lighttypush on the
raar window until its edges are fully sested on the
sdhosiveallthewaV around.
NOTE:
I Do not closeor open the doots until adhesiveis dry.
. Mske sure the fastenersare Jastenedcorrectly'
ALIGNMENTMARKS REAR
wtt{oow
CUPS
1 7 . lnstsll the lower moHing, then tighten the mounting
1 4 . Scrapeor wipe excess adhesiveotf with a puttY knile screws,
or tow€|.
NOTE:
To removeadhesivefrom I paintedsurfsce or the rear
window, use a sott shop toweldampsnedwith alcohol'
ta. lnstsllthe rear window molding.
NOTE:
. When installing,make sure thsre are no twists in the
rear window molding.
. First instaltthe upper section, th€n install the each
l1
side.
. Gluethe upper sectionwith the adhesive'
REARWII{DOW
MOLDNI{G
18. Let th€ adhosivedry for at lesst one hour, then sprsy
wate. ovst the tear window 8nd check for leaks M€rk
l€8king areas and let the rear window dry, than seal
with s68l8nt.
NOTE:
Let the csr stsnd for 8t least fout houts after l€ar
;indow installation ff the cat has to be used whhin
the first four hours,it must be driven slowv
19. Rssssomble8ll removedParts.
20-24
OuarterGlass
Removal lnstallation
CAUTION: l. Scrape the old adhosive smooth with a knife, to s
. Woar 9bv63 to lomovo and In3ial th€ gbar. thicknoss ot about 2 mm (O.O8in) on the bonding
. U3osoat covors to lvold damaglngany aurlecor. aurfacearoundthe entire quarterglassopeningflango.
NOTE: NOTE:
Replacethe qu8rterglasswith new one when removingit. . Do not scrape down to the painted surface of th€
body; damagod paint will interfero whh proper
1. To r€rnovethe quartergl8ss,first removeth6: bonding.
. Rearpillartrim pan€llsoe pago2G37) . M€sk ofJ surrounding surtacas before applying
. Ousrter t.im (s6epage2G37) onmar.
. Ousrter trim panellsee pag€2G37)
2. Clean ths body bonding surtace with a sponge
dampsnedin alcohol.
UseI knite to cut thloughth€ Edhssivefrom inside
thoc8r,allthewayaround. NOTE:
After cleantng,keep oil, greaseor water from gatting
NOTE: on the surface,
the quarte,grassandbody,
Tak€carenotto damage
3. Clean the new quarter glass surface with slcohol
OUARTERGLASAMOLDI G where adhesiveis to be applied.
Make sure the bondingsurtace is kept free of wat€r,

oilandgrease.
CLIP
it /
Cl€an tho shadow€d sr6s all
the way around.
3. Removethe qus.ter glass.
20-25
OuarterGlass
', with E spong3, sppv a light coat of glass prirn€r to the 5. With a sponge,apply 8 light coat oI bodv primerto the
insilo tEco ot tho qusrtsr glass 8s shown, then lightly o.iginal adhesive remainingaround the quarter 91888
wipe it off with gauzeor chaesecbth' openingfl8nge.Ths quarter glassshouldbe installed10
minutesafter you spply the bodYprim€r.
NOTE:
. Do mt sppv body prinrel to ths quarter ghss, and NOTE:
do not gpt body 8nd glass primer spong€a mixed up. . Oo not apply glass primer to the body, and be
. l{ov€r touch ths primodsurtacoswith your hsnds.ll careful not to mix up glsss8nd body primersponges.
you do, the adhesivsmay not bond to the quErter . Nevertouch the primedsurfaceswith your hands'
gl€ssproperly,causinga leak sfter ths quartsr gl€as '/f
is instsllod. ; Applybody prlmethte'
. Kegp w8ter, dust, and sbrasivomsteriab away from
the Drimedsurfaco. 38 mm {1.49In}
r'///////, : Af,y fit stmr hen.
11 |fxn
lo4:l hl
38 mm (1.49In)
OUARTEBGTASA
6. Throughv mix the adhesiveand hardenertogether on

a gbss or metal plste with I puttY knife.
NOTE:
o Clean a glass or metsl plate with a sponge and
alcoholbefore mixing.
. Folbw the instructionsthat came with the adhesive.
7. Befor6 tiling a cartridge,cut the end ot the nozzle8s

shown.
cut nozzb end

63 gttown.
10 lnm (0.39Inl
7 mm {0.27 In}
20-26
8. Pack adhesiveinto the cartridge without air pockets 9. Use suction cups to hold the quarter glsss over tt|€
to ensure continuous delivery. Put th€ cartridge in a opening,alignit with the clip setting points and s€t it
calking gun and run a bead of adhssive around the down on the adheisive,Lightly push on the quaner
edgs of the quarterglassas shown. glassuntil its edgesare fully seatedon the adhesivea[
the way around.
NOTE:
Apply the adhesivewhhin 30 minutes after applying NOTE:
the glassprimer, Do not oDen or close the doors until the adhosivois
drv.
CLIP
2 mm (0,08Inl
-Tr
13 mm
{O.51Inl
n:ADHEsrvE
H
8mm
Msk€ a slghtv thicker
boadat 6ach coln6r.
{0.31 Inl
6 mm (O23 In)
- t
i , l T ,
- H
fz_) i i ,L=_** r_ - _ SUCTK)N
CUPS
CLIP
1 0 . Scrspe or wipe the excess adhesiveoff wlth a putty

knifeor towel,
NOTE:
Use a soft shoD towel damDenedwith alcohol to
remove adhesive from a painted surlace or quaner
gEss.
1 1 . After the adhesive is dry, spray water over the

OUARTERGLASSMOLDI G quarter glassand check for leaks. Mark leakingareas
and let the quaner glassdry, then sealwith sealant.
NOTE:
Let the car stand for at least four hours after ouarter
glassinstallation.It the car has to be used within the
first four hours,it must be driven slowly.
12. Reinstall removedparts.

allremaining
20-27
Sunroof
lndex
SUNROOFPANEL
Adiustmont, s6e pa€E2G29
Rsplac€mofi,seepagpan31
SUI'IROOFSEAL
REARSEAL HOLDER
FRONTSEAL HOLDER
SIDESEALTOLDER
SUNROOFLINER
Roplacemont.s6e pag€20.30
OUTER CABLEASSEMBLY
sse pag€2G33
Rsplscom€nt.
MOTOR
Repl6coment, s€e p6g6 2G32
PANELBBACKET
€ .^*--,^,e b'=-n*o""r,
ttottt* ]
",,,or --# llniRt on",.o"
,*ER--& Y^*J"\ REARDRAIN
CHAI{NEL
ggygtr-4
FROTTDRAIN
CHANNEL
FAONT
STOPPER
FRAMESEAL
REARDRAII{TUBE
FRAiIE
Roplacamont, soe ps€B2G32
20-24
dtrr..-.
Troubleshooting
Symptom ProbablaCauso
Water leaks 1 . Cloggeddraintube.

GapbetweensunroofsealandrooJpanel.
J . Defectiveor improperlyinstalledsunroof seal.
4 . GaDbetwa€n frame sealandroof Danel,
Wind noise 1. ExcessivecleSrancebetwaen sunroof sealand roof Danel,
Motor noise 1, Loosemotor.

2. Worn gearor besring.
3. Outer cabledeformed,
Sunroof Danal does not move, but 1 . Clutch out of adjustment.

motor turns Foreignmatter stuck b€twoen guiderailand slider,
a lnnercableloos€.
4. Outer cablenot attached properly.
Sunroof Danel do€s not move and 1. Blowntuse.

motor does not turn lsunroof panel 2. Fauhyswitch.
can be moved with sunroot wrench) 3. Battery run down,
4. D€tective motor,
5. Fsulty relay.
Sunroof PanelHeight Adjustment
Boot panel should be even with the sunroof seal to

within 1.9 t 0.5 mm (0.o7 + 0.02 in) 8ll the w8y
around.lf not, tih the sunloot panelfully,and:
1.9t o.5mm SUNROOFSEAL

ROOFpA EL {0.07t O.02Inl
SHIMS
PANELBRACKET
1. Removeths sunroof liner (seepage2G3O).
Loosen the sunroof panel mounting nuts and

instsll shims between sunroof panel and panel
bracket as shown.
Shlm thlcknos!: 1.O mm (O.O4in)

Adlustmont: max. 2.0 mm (0.O8in)
Repeaton oppositesids if necessary.
20-29
Sunroof
RearEdgeClosingAdjustment SunroofLinerandSunroofPanel-
Replacement
ODenthe sunroof Danslabout a foot, then closeit to check l. Removethe front of the root trim.
where rear edg€beginsto rise. lf it risestoo soon and s€ats
too tightty agEinstthe roof panel.or too late and does not Align the locstion @ position ot tho fram6 to the
sest tithtv enough,adjust it. mountingscrew.
MOUI{TINGSCREW
1. Remove the sunroof liner, then remove the sunroof sut{RooF
panel. LINER
2. Chock that the position ot the litter is the same on

eachside.
NOTE:
It the position difters from sids to side, remove tha
motor (seepage2G32),then adjustthe positionof the
lifter on each side.
3. Loosenthe mountingscrews. Align the panelbracket

to the same positionon each side.
l. Removsthe mountingscrews 8nd clips. then slideths

sunroot linerslightlytorward.
NOTE:
Take care not to scratchtho sunroof liner.
> | CIp bcltlott!

AU ROOF
LINER
lnstall the sunrool panel. ClosBthe sunroot panol, then

check the alignment between the rool panel and
sunroot panel.
NOTE:
Adjust the sunrool panel right 8nd l€ft bY using the
oanelbracket mountingholes 4. Slidethe sunroof linerbackward,th€n romovoit'
SU ROOFPAI{EL
With the sunroof panel closed fully, check for water
leaks.
NOTE:
Do not use high Pressurawater.
SUNROOFLINER
20-30
Sunroof SealRepair
5. Rsmovethe mountingnutsfromthe panelbrackatson ff a sunroof sealis leaking,or if it is to be replaced,proceod

bothsides,thenrernovethe sunroofpanelby liftingup. as follows:
NOTE: 1. Removethe sunroof liner (seepage2G30).

the roof panel.
Donot damage
2. Removethe sunroof panel.
3. Removethe sealholder,Carefullypeelthesealoff the

SUNROOF
PANEL sunroof panel.
SUNROOF
> : Scrow,nut locttlon! SEAL
r ' 9
c
t, 6
c,A
SU R(X)F SEAL
I N'm (0.9 ksFm,6.5 h-tt)
Fillwirh adhesive.
o. lnstallationis the reverseof the removalprocedure. PANEL

SUNROOF
NOTE; 4. Cleanthe sunroof sealattachingsurfaceswith a clean

. Before installingthe sunroof liner,close the sunrool cloth dampenedin alcohol.
panel fully, then check fo. closing slignment, lf
necessary,adjust the sunroot panel alignment{see NOTE:
page2G3Ol. After cleaning,keep oil, greaseor wster from getting
o When inst€llingthe sunroof linar, make sure the on the surface.
sunroot liner is fast€ned correctly with the clips and
holder. 5. Fill the sunroot seal groove with adhesive.Coat the
sunroof seal att€ching surfaces of the sunrool panel
Check tor water leaks. with the sam€ adhesive.
NOTE: 6. Fit the sunroot seal onto the sunrool panel evenly all
Do not us€ highpressur€water, the way around.
7. Wlpe off excess sdhesive with a clean cloth

dampenedwith alcohol.
8. Allow the sdhesiveto cure tor st leastfour hours atter

sunroot seal installation 8nd before operating the
sunroof panel.
9. Checkfor water leaks.
NOTE:
Do not use highpressurewater.
20-31
Sunroof
Motor, DrainTube, and Flame Replacement
cAuTto :
Be c'rfirl ]pl to damagoth€ soats or oth6l intorlor trim.
1. Rornovethe headliner(seepage2G36).
2. Disconnectthe motor connector;removathe clips securingthe ceilinglight wire harness'
NOTE:
When removingthe motor, removethe two mountingbohs andthree nuts.
3. Removethe sunroolpanel(seepage2G31).
4. Disconnectthe draintubes.
5. Removethe 10 mountingbolts and rear hooks,then removethe frame from the car'
NOTE:
You mav requireassistancewhen removingthe lrame.
DRAhITUBE
To instsl,sid6ths drsintubs ovorth€
trsrnsnozzl€st loast10 mm (0.4in).
GUIDEPIiI
DRAI TUBE
REART()OK (2}
FRAMCSEAL
I x 1.On||n
10 N'm (1o kgFm.
7 b-ft)
NOTE:
lf you n6ed to remov6 a drain
tubo, tie a string to th6 ond ot
it so h can bs roinstall€d.
REARDRAINTUBE
FRAME \g
/-:\
MOTOR
M6ko su.o th€ lft6.s 6re
pal.l6l when instarng th6
motor.
FRONTDRAINTUBE
@
To install,ins€rt ths Jrama'sfear hooks into th€ body hol€s,then installparts in the reverseorder of removal.
NOTE:
. Installrhe tube clips with the 6ndsfacingto the sideto esse instsllstionof the headliner.
. Cleanthe surfaceol frame.
. Checkthe frame seal.
. Check tor wster leaks.
20-32
Panel
rerrvr Stay/Slider
v.etrv Lifter and Guide
RailsReplacement
1. Rsmovothe frame (seepage2G32). Removsthe motor (page2G32).
2. Removethe front drainchannel, o. Remove the mounting screws @, then remove the
guide rail. Remove the mounting screw @, then
remov€the outer cableassemblv.
6r1,Omm
10 N.m(t.Oks-m,7 lb-ft) NOTE:
Tske care not to bendthe cableDiDos.
GROMMET
NOTE;
MOUiITING To install,fill the groove in 6ach
SCREW grommotwhh seahnt,
CABLE
FROI{TDRAIN PIPE
CHANNEL
PANEL
STAY
OUTER
CABLE
ASSEMSLY
GUIDERAII.
Slide the p8n6l stay backwsrd, than remove it from

Romovethe rear drainchannel. the guiderail.
Romovethe resr railholder. 8. Remove the lift€r Jrom the inner cable end, then
separats the panel stsy, lifter, slide stoppet link 8nd
slider.
NOTE:
To install,apply muhi-purposegreaseto the lifter and
slidestopper link.
6x1.Omm
10 N.m (1.0 kg-m ,
7 b-ft)
SLIDESTOPPER
LINK
{co.rt d
Sunroof
Panel Stay/Slider, Lifter and Guide OpeningDrag Gheck
RailsReplacement(cont'd) (Motor Removed)
9. Tu,n the hook ol the snchor rod with I flat tip Betor€ inEtallingthe motor, measure stfon required to
screwdriver, then remove the anchor rod and anchor open sunroof panelusinga springscaleas shown
springfrom the guidersilby slidingit backward.
cAuflo :
NOTE: wh.n rFlng a cp ng scals. proiect the loadingodgo ot tho
To install,apply muhi-purposegreaseto the hook. sunroof panelwhh a lhop towol.
lf load is over 1O kg (22 lbs), check side clearanceand

sunroot panelhoightadiustment{s€€page2G29).
ANCIIORSPRING
ltooK
At{cHoRROD
SHOPTOWEL
is tha revetseot the r€movalprocedure.
10. Installation
NOTE:
the guiderail,appv the calkingto
. Beforeinstalling
guiderailmountfacesof the frame.
GUIDERAIL
FRAME
. Damagedparts shouldbe replaced'

. Apply greaseto the slidingportion.
. Belore installingthe motor, adiust the litter to the
samepositionon each side.
20-34
GlosingForceCheck
(Motor Installedl
1. After installingall removed parts, hav€ a helper hold
the switch to close the sunroof panel while you
measure force required to stop it. Attsch a spring
scaleas shown. Readthe torce as soon as the sunroof
panel stops moving, then immedistely releasa the
switch and springscale.
CAUTION:
When udng a spring scale. protest th€ badng adgo
of tha 3unroof panelwhh a 3hoptowel.
ClosingForce: 20-30 ks {/t4-66 lbs)
SPRINGSCALE
SHOPTOWEL
lf force is not within sDociJication,install I new bck

washer,sdjust the tension by turningthe motor clutch
adjusting nut, and bend th€ lock washer agsinst the
motor clutch adjustingnut.
t ocK
WASHER
20-35
Headliners
Replacement
> : Clp b.rtlo.!
'
wwzz t6l
-lN- i
-w(:
v lr.#IlE I *_) @)
) - )
'_- /
CAUTION:
When prying whh a flat tip scrowdrlvor, wrap it whh protcctlve tapo to pravent damago.
NOTE:
. Remov€the front se8ts (seepage2G38).
. Tako care not to bendor scratch the flont and rear hoadliners.
o Keep water away Jromths front 8nd rsar headlinets.
. Be caretul not to dsmagethe dsshbosrdand other interiortrim'
JOtitT
OROOFTRIM
OFRONT
IEADLII{ER @REARHEADLII'IER
€)HOLDER
t
Looaoh th6 bohs.
O}iGH-MOUT{T
BRAKELIGHT
@suNvtsoR (DCEILIIIG
OHIGH.MOUiII
LIGHT BRAKELIG+IT
Dbconnoct tho OLE S
COVER
connoctol.
REARPILLAR
TRIM PA EL
NOTE:
Removethe headlinerfrom the passenger'ssids dool opening'
l|stallationis the reverseol the removslproc€dure.
NOTE:
. V,lt\en \nsta\\ng the lront and tsar head\nsrs, be csrstu\ r\ot to lo\d or bsnd R' A\so, be cqrelu\ not to scrstch ths bodY'
. Ch€ckthat boih sidesof the tront and rearheadlinersare sscurelyattschadto the body and rear pillartrlm panol'
. Whon installingthe root trim, installthejoint towards the rear.
. It nocessary, replaceany damagedclips.
20-36
lnteriorTrims
Replacement
> : Clp bcltlon.

A I B " 1 "
t N t | | 6 l
v_trj
-r-)r-
Disassemblein number€ds€quence.
#l M\ryi
l
H I
_:)_
ffii - )
CAUTION:
Whan prylng whh a tlrt tlp 3crcwdrlvel, wrap h with protoctivo tapo to prevont damago. l, (#"" @'
NOTE:
ldB.t
Takecarenot to b€ndor scratchthe trimsandpanels.
OREARPILLAR
TRIMPAI{EL
C)qUARTER TRIii \\--""-T
Firstromov€the roar
(s6spsg62G36).
headlinor OSEATLOCKCOVER
(soepa€62G42
@DOORTRIM @REARSHELF
Fhst rsmov€ th€ spoakors
(s6€s€ction23) and 166lsoat
upp€rtrim panells€e psf|eMA.
u OTRUNKTRIM
OOOORSILL
MOLDING :z @RIGHTTRUNKFRO]'IT
PANEL
First rgmov€the r6ar
s6at {soepags2G41).
@RIGHI TRUNKSIDE
OiIGTITKICKPA EL
oSPARETIRELID
C)REARTRIM PANEL
is the revelseof the removalprocedure.

lnstallation
REARUPPERPANEL
NOTE:
clips.
replace8nydamaged
lf nocessary,
20-37
Seats
Front Removal Front Replacement
NOTE: NOTE:
TSkecare not to scrStchthe sest covers and body. Take care not to scratch the seal covers and bodv.
1. Removethe mountingbolts covers. 1. Removethe front s6at, then take it out from the doot
oPening.
2. Remove the mounting bohs and disconnect the
connector.then removethe tront seat. 2. Remove the screws and knobs, then removo the
reclinecover,
RECLII{E
COVER
FRONTSEAT
@scREw
MOUiTTNGAOLTS r(
@< xroa
1Ox 1.25 mm \oulmonv
ito N.m l4.O ks:m . KNOB
ORECLII'E
29 tb-tt)
Disconn€ct th6 aeat Removeth€ screws, then removethe center coval.

hgAtorconnoctor 3.
(canadaI SR 4WS/
sR-v).
a.
\,
a
iV*
i,OUI{TI G
BOLT
Disconnectths COVER
connector
(drivor'sonly).
MOUI{TING BOLTS
10x 1.25mm R€movethe lower clips and Jastenerslrom the asat-
/O N'ml4.OkgFm,29 b-ft) back, then Joldthe sest cover back.
> : Clp locltlont

3. Instalhtionis the reverseof tho rsmoval procedure.
SEA-AACK
Foldthe s6at-b8ckcover 8nd pad back until you can > | Cllp locltlom
see the seat-backmountingbolts.
NOTE:
Tsks care not to damagethe pad.
R€move the seat-back and s68t cushion mounting

bolts and pivot nut, thon remove the soat-backEnd
seat cushionfrom the inn€rand outsr ssat tracks.
PlvorNur Pvor wAsHER
b4;;- SEAT-BACK
,/'wqP
w^sHER O: Clp loo.tloB
il SEATHEATERUNIT
BUSH
REAR
SEAT
PIVOTI{UT accEas
I x 1.25mm CABLE
2 N'mlz2 ks-m, 16 b-ft) To 86at bolt
buckh.
lo rast-back.
SEAT
cusHtof{
SEATCUSHK)]T MOUNTIiIGBOLTS
10 x 1.25mm To so6t-back. SEAT CUSHION
43 N.m(4.3 kg-m,31 b-ft) Diaconnoct th6 r6ar RECLIiE
366t aCCgSll AII'USTER HoatedSoat {C6nada:SR 4wS/SR-V)
cabb.
SEAT.BACK MOUNIT|NGBOLTS
1Ox l,26 mm
43 N.m (4.3 kem .31 b-ft)
INNERAEAT
TBACK
SEATCUSHIONMOUI{TINGBOLTS
1Ox 1.25mm
43 N.m{4.3 kg-m.31 b-ft}
JOINT
ROD
NOTE:
Take c6re not to
b6ndth€ rod. OUTERSCATTRACK
7. lnstallstionis the rsverse of the romovalprocodule.
NOTE:
. To prevent wrinkles when installing8 seat-backcover, makg aurs tho materialis stlgtched evsnly ovel ths frame bsfore
securingsllthe clips.
. Apply gteaseto the movingsurfaces.
20-39
Seats
FrontSeatCoverReplacom€nt
CAUTION: t
Wora gbv€! to lomov€ and iNtal the sgat-backand seat cushion covols. I;f.:fo:Sffi*. or. crp'rmovlr:
NOTE:
Take cars not to tear the ssamsor damsgethe seat-backand ssat cushioncovers.
Soat-backcover romoval:
1. Removethe s€at-b8ckfrom the innerand out6r seat trscks.
2. Removethe rea. seat acc€sstrim and lumbarsupport knob (6xcept S modsl:Driver's).
3. Remov€the ssat-backcovsr by releasingallth€ insidesprings,
SEAT-BACKCOVER
\\ ^n- I
"OU
il#ss\\K;,i-l
'w,
Seal curhlon covar ramovsl:
1. Removeth6 s6at cushionfrom ths inn6r andouter s6at tracks,
2. Removsall clipsfrom undsrths ssat cushion,thsn loossnthe ssat cushioncovar,
3. Pullback th6 6dgoof the seat cushioncov6r allthe way around,th6n rsloasoth6 pad clips and insidssprings.
SEAT
custto
COVER
FRAME
SEAT CUStflOil COVER
Clp Inrtllrtlon:
UPK)LSTERY RING
PLIERS
hstsllstion is the reverseof the removalorocedure, Commgrciatry
sv.ilablo.
NOTE:
. To prevent wrinkles, mak€ sure ths mat€rialis stretched
EW CLIP
6venv over the lrsme b6tor€ securingallthe clips and insidesprings.
. ll necsssary,replaceany damagedinsidesprings. WIRE. PAD
. RoDlacethe cliDs. lCovors kl6l
WIRE(P.dsidsl
20-40
..
RearReplacement
Disassomblein numboredssquencs.
G)HOOKt2l
OLEFTSEAT-8ACK
@10x 1.25mm
/tO N.m14.0ksFm, 29 b-ft|
)
(_
r 6l
----v
Push the roat cushion.

Pull th€ knob. th6n dirconnoct th6 hook.
PulluDsnd fomovo tho 3aat cu3hion.
CARPET
€)N|GHTSEATCUAH|oN OLEFTSEATCUSHION
2041
Seats
(cont'd)
RearReplacement
Dbsssofi$b in numboredsequsnce. Rrlr aeat btch/Lock cylndor rgmoval:
SEAT LOCK COVER
REAR SEATLOCK
AHELF COVER
OG r 1.0mm
10 Nm 11.0ks.m,7 b-ft)
Pry h6re.
6x1.0mm
10 N'm (1.0 kgFm
7 b-ftl
NGHT PNOT LOCKCYLI]'IDER
BRACKET R6movo tho rear
shotf{seepag62G32.
t ocK RoD
ORIGHTsEAT. NOTE:
BACK LEfT PIVOT Tak€ car€ not to
BRACKET bsndtho bck rod.
6x1.Omm
10 N'm (1O ksm ,7 tr-ft)
Hq)KS I t 1.0 rnm
10 N'm (1O kg|.m. 7 b-ft)
RIGHTPIVOTBRACKET LEFTPIVOTBRACKET
Removo ths ouanortrim R6movotho soatcorltea
pansl(so. ps€a2G37). p€d(se€psgo92.
hstEllationis the revsrs6of the r€movalprocodur€. > : Clp bcltlonr
NOTE: A l B l
TN\\\\\\\$ I ]
. Bolore sttsching the sest-back and sgat cuahion,
,n8ke surathere ar€ no twists in th6 seat b€h.
. Whon instsllinsthe ssat cushion, poshion the seat
N i + i
behs correctly. _-__) \)
20-42
Seat Belts
Front Replacement
CAUTIOITI:
Chock tho 5o!t bohs for damago and roplaco thom ll necossary. B€ carelul not to dsmago thom durlng removd and
inslalation.
1. Remove:
o Front seat (seepage2G38)
o Rearseat (seepage2G41)
. Door trim (seep8g€2G37)
o Rearshelf (seepage2G37)
. Rishttrunk front panellsee page2G371
. ouarter trim panel(seepag€2G37)
2. Removethe sest boh quideand centor cover.

Remov€ th€ all three anchor bohs, retractor bolt and ret.actor mounting bolt, then remove the segt belt 8nd seat belt
buckle.
NOTE:
Wh€n removingth€ anchorbohs and retlactor boh, use a 17 mm socket or box-andwrench.
TUPPERANCHORBOLT
7/16-20 UNF
33 N.m (3.3 kg-m , 24 b-ftl
SEATBELTGUIDE
SEATBELTGUIDE
MOU Tllrlc BOITS
6xl.0mm SEATBELT
10 N.m (1.0 kem. 7 b-ft)
RETRACTOR
BOLT
6x1.Omm RETRACTOR
10 N m (1.0 ksm .7 lb-ft)
REiRACTORBOLT
7/16-20 UNF
33 N.m (3.3 ks-m . 24 b-ft)
SEATBELT LOWERAI{CHORBOLT
EUCKLE 7/16-20 UNF
33 N'm (3.3 ks-m , 24 lb-.ft)
CEI{TERCOVER
(seepag620-38)
ANCTIORCAP
LOCK
TOOTHED
WASHER
Disconn€ctthe connoctor
ldriv6r'sonlyl.
\\\
ICE TEB ANCHORBOLT

7/16-20 Uf{F
33 N m (3.3 ksFm.24 b-ft)
(cont'd)
2043
Seat Belts
(cont'd)
FrontReplacement
Aarchoabolt coft.lructlon :
LOCK WAVEWASHEF
WASHER
LOCK
BEARING WASIER
LOWERAITICHOR \
BOLT
J'Jil \
*/
\
WASHER TOOTHED EEARNG PLAII{ TOOTIIED

LOCK WASHERS LOCK
WASHER WASHER
4. ChBckthat the retractor lockingmechanismtunctions as describedon pago2G46.
5. lnstallationis the revors€of the removalproceduro'
NOTE:
. Make sure you assemblethe washers8nd collsls on the upp€r and low6l dnchorbolta aa ahown.
. Before attschingthe quartertrim pan6l,maks sure th€ra are no twists or kinks in the ssEtb6lts.
. On reassembly,r€pl8cethe upper anchorboh and center anchorbolt {') and u86liquidthr68d lock'
20-44
RearReplacement
CAUTION:
Chsck tho roat bolts tol damago and roplaco them ll necesrary. 8o careful nol to damage tham du ng lemoval and
in3talation,
1. Remove:
. Front s6st (seepage2G381
. Rearseat (8e€pagp2G41)
. sest center pad (s€,epage*42!.
r Rearshetf (seepage2G37)
. Center console(seepsg82G51)
. Door trim (Esepsse 2G37)
. Righttrunk front panel(seepage2G37)
. Ouarter trim panellsee pags 2G37)
. H€sdliner(ses psge2G361
. R€arpillartrimpanel{seepage2G37}
Detschth€ seat belt guids.
J. Remov€ th6 all thrss anchor bohs, retractor bolt and retractor mounting bolt, thsn remove the s€at belt snd se8t beh
buckle.
NOTE:
When removingthe snchor bohs and retractor boft, us€ a 17 mm socket or box-endwrench.
TUPPER AI{CHOR BOLT

7/16-20 U]{F
33 N.m(3.3 kg-m, 24 b-ft) \ n ,-,.' SEATBELT
f;l,?- curDE
-)I,lb
'llll
It6\
IW
.U\
RETRACTOR BOLT
7/16-20 UNF
33 N.m(3.3 kem .24 h-ftl
RETRACTORMOUNTING LOWER AI{CHOBBOLT

BOLT 7/ta-20 UNF
Exl.Omm 33 N.m(3.3 ks-m. 24 lb-fr)
10 N'm (1O kg-m, 7 b-tt)
\
Ar{cHoRBotr ---------9.
TcENTER
Anchor bolt conrtructlon: UPPER
3l'i-?:Tn-.ro,"n, ANCHOR
"*r"b
BUCKLE
4. Checkthat the retrsctor lockingmschanismfunctionaas

describsdon psge 2G46.
lnstsllationis the r€verseof the removalprocedul€.
NOTE;
. Belore attachingthg rear pillartrim paneland .ear seat,
make sure thsre are no twists in the seat bett. .CE TERA CHOR
. On raassembly,replacethe upper and cent€r anchor BOLT
bofts (') snd use liquidthroad lock.
2045
Seat Behs
Inspection
RciEcto? hapoctlon On-tho-CarSost Beh Inlpoction
1. B€tor6 installingtho retractor, check thst ths ssat b€h 1. Check thst the s6st belt is not twisted or caught on
can be pulledout fr66ly. anything.
2. M€ko sur€ that ths ssat beh does not lock when th€ 2. After installingthe anchors.check for Jree movement
retractor is l6an€dalowly up to 15" flom the mountod on the anchor bohs. lf necessary,remove the anchor
oosilion.Th€ seat beh shouldlock when ths ratractor bohs and check thst the washers and other Dartsare
is leanedov€r 4.0o. not damsgador improperlyinst8lled.
GAUTlOlt: Check the sest behs for damage or discoloration.

Do not attempt io dls$romble tho lotraclor. Cl68nwith a shop towel if necessary
r: Mountld Poitloti CAUTION:
Uso only 3oap and wator to clean.
NOTE:
Dirt build-upin ths metal loops of the upper anchors
can causetha seat behs to retract slowly.
WiDs the inside of the loops with 8 cl€8n cloth
dampon€din isopropvlalcohol.
Check that the seat belt does not lock when pulledout
slowv. The 8€8t beh is designedto lock only during a
t, suddenstop or impact.
Make sur€ that the seat belt will tetract sutomaticslly

wh6n r€lgasad.
6. ReDlscsthe seat beh with 8 new one if there is any

I abnormality.
Forwlrd - hrld.
RETBACTOR
Forw!.d h.ld.
Replaceth€ s6at belt with 8 now ons if thers is anY

abnormality,
20-46
ChildSeat Anchor Plate
Attachment points are provided for a rear seat mounted

childrestraintsystem which usesa top tethe.,
The attachment points are located on the rear sholf, iust
behindthe rear sest-b8ck.
When usinga childsest with a top tether, use a razor blade
or sharp knife to carefully cut 8 1 inch diamster circle at
tho location ot the attachment points and installthe child
seat ancho. Dlatesecurelv,
15Omm {5.9Inl
ATTACHMET{TPOItYfS
8 x 1.25 mm
22 N.m 12.2ks-m , 16 lb-ft}
CHILDSEAT TOOTHED
WASHER
ANCHORPLATE
NOTE:
. Do not remove the toothed washor from the child seat
anchor plate, Use the child sest anchor plste with the
tooth€d wssher attachedto it.
. When installinga child seat on the rear seat, follow the
instructionsof the manutacturorof the childseat,
. Additionslsnchor Dlatesare avsilable.
r So not \3q i\q t*{\d sst\ a\{i\sr $Er\c ls\ N\ tl\\6\

purpos6;it ls dosignadexchsivolY for Instanatbn ol a
child so8t.
. Mako eurs tha lear soat-back ie locksd fhmlY whon
Insta$ng a chlld seat.
2047
Carpet
Replacement
SRSwire harnessesare routod neat the carpet.
CAUTION:
. Al SRS cloctlical whing halnosses ale covorad whh
yolow outer iNubtlon.
. Bofor! disconnocting the SRS wiro halnos3, Inltal
thc short connoctol(s)on tho airbag(s).
. Reg|lco the entiro affocted SRS hrrnoss alscmblY if
ll has an opon chcuft or damagedwitlng.
NOTE:
The radio may hsve a coded th€ft protection circuh. Bo
sureto get the customer'scode numberbefore
-Removing the l,lo.43 (1OA) fuse
(inthe under-hoodfuse/relaybox).
Atter service, reconnect power to the radio and turn it
"CODE" is displayed,enter the
on. When the word
customer's Sdigit code to restore radiooperation.
1. Remove:
. Front se8ts (seepage2G381 o opener cover (seepsge 2G67)
' . Consols(seepage2G50) . Front seat beh lower anchor(seepage2G43)
. Centerpanel{seepage2G51} . Door sill moldingand door trim (seepage2G37)
. Dashboardlower cover, knee bolster . Kick panel(s€€psse 2G37)
(seepago2GtB) . RMt trunk front panaland quart€rtrim panel
. Glovs box (seepsge2GS) (seepage2G37)
. Rearseat {seepage2G41) . Footrest
. Seat center pad (seepage&2)
2. Pry out the clips and removethe retainorfrom the door silltlange.
Detachthe fsst€nar in the driver's side carpet,thsn pull back ths carpot at ths bottom of heat€r.
4 . Removethe carpst by slidingh r€srward.

NOTE:
Take care not to damage,wrinkle or twist th€ carpet,
20-44
>:Cllpbcationr
Fq)TREST
FASTEI{ERS
OUARTERTRIM DOORSILL MOLDING

(s6e page 2G37)
PAI{EL
{se6psgp2G37)
SEAT HARI{ESSES
DOORSILLMOLDING
(s6epage2G37)
SEAT HARI{ESS
DOOR A|LL
MOLDII{G
5, Installationis the reverseoJ the removalprocedure.
NOTE:
. Take care not to damage, wrinkle or twist the
carDet.
. Make sure the seat harnessesare routed correctlY.
DOOR SILL FLAI{GE
2049
Consoles
Replacement
areroutednearthe tront console.
SRSwire hsrness€s
CAUTlo :
. Al SRS€lrctrbal whlng harnessosare covotadwfth
yclow outorlmuhion.
8.fo.o dsconnoctlng the SRS who halno3s, Install
th. 3hort connoctorb) on the alrbag(sl.
Rcpbc. tho entir€ affoctod SRS harness assomHy lf
h hrs an opon chcuh 01damagodwl ng.
il""ll!'S sF
SRS UNIT
CAUTIO :
. To plevenl damageto tho 3hlfl bvot knob ard shlft Indicatort m rlng, wrap thom whh a shop towol'
. When prying whh a th tip sclowdllver, wlaP h whh plotostlvo tape to prevent dEmago.
NOTE:
. Take ca.e not to scrgtchthe front and center consolesand dashboard.
. Slidethe front sest fully to the rear.
Auiomlllc trantmllllor modal:

> r Clp locltlon!
SHFT II{DICATOR SHIFT II{DICATOR

TRIM RING TRIM RII{G
FROiIT
COI{SOLE
r
Manual t]antr alloo mod.l:
SHIFTLEVER
KI{OB
FROi'T CONSOLE
hstElation is the reverseof the removalplocedure.
20-50
.L
Dashboard
ComponentRemoval/lnstallation
SRS wire hsrnesses8r€ routed near the dashboardand
steeringcolumn.
CAUTION:
o AI SRS oloctrlcal tyhlng harnossea!rc covor€d whh
yolow outor insulatlon.
. Botole dkconnectlng th€ SRS wlro hamesr, Inrtafi
tho rhort connoctor(s)on the alrbag(sl,
. Roplscotho ontlre alfeaed SRS harnols astombly lf
h has an opon drcuh or damlged whlng.
. Aftor Inrtalrtlon ol ths gauge a$ombly. iochock the
oFrEtlon of tho SRSIndcator lght.
NOTE:
. The radiomay h8v€ a codedthett protectioncircuit. Be sure to gat ths customer'scode numbarbofore
- Rsmovingthe No. 43 (10 A) tuso {inths under-hoodfuse/r€hy box).
- Romovingthe radio.
"CODE" is displaysd,ent€r tha customsr'a Sdigit
After service,reconnect power to the radioand turn it on, Wh€n th6 word
code to restora radiooDeration.
. Tak€ care not to scratchthe dsshboardand rslsted p8rts.
. Do not drop the screws insidethe dashbosrd.
cAUTrOil:
Whon prylng whh a flat tlp screwdrlvel, wlap h wlth protoctiv6 tape to pravolrt damlgo,
ATEREO
RADK)/
CASSETTE
Looaenths bolts.
Disconnoctthe
conn6ctols.
scREws
CENTERPANEL
Removoth€ front
coneole (see palp 2G5O). (cont'd)
20-51
ClutchOverhaul
Removethe centernut while holdingthe armature 3. Removethe snap ring B with a snap ring pliers.
plate.
NOTE:
. Oncethe snap rjng B is removed,replaceit with
a new one.
CENTERNUT a Be caretulnot to damagethe compressorbody
18N.m11.8
kg-m,13lb-ft1 and rotor pulleyduring removal/installation.
A,/CCLUTCHHOLDER
Commorcirlly av6ihble
Robin.ir: P/N 10204
Kent-Moore:P/N J3?872
A
\/
: ROTOR
PULLEY
@)
Removethe armatureplateby pullingit up by hand. Removethe rotor pulleyfrom the shaftwith a puller
lf you can not remove it by hand, attach the fly- and the specialtool.
wheel pullerto the armatureplate,screwthe bolt in
the centerand removethe armatureplate. NOTE:Putthe clawsofthe pulleron the backofthe
r o t o r p u l l e y ,n o t o n t h e b e l t a r e a ;o t h e r w i s et h e
rotor pulleycan be damaged.
FLYWHEELPULLER
07935-8050003
SEAL DRIVER
07945-4150200
(cont'd)
22-37
Compressor
ClutchOverhaul(cont'dl
5. Removethe snap ring A with a snap ring pliers. 7. lnstall in the reverseorder of removal, and:
Releasethe field coil connector from the connector
holder,and disconnectthe connectorand field coil
groundterminal.
. Clsan the rotor pulley and compressorsliding
surfacaswith non-Detroleumsolvent.
. Installth6 snap rings with the chamferedside
I
Removethe field coil from the comDresso.. facing out and make sure the snap rings are in
the groov€ complgtoly.
NOTE: . After installing,mak€ sure that the rotor pulley
. Oncethe snap ring A is removed.replaceit with turns smoothly.
a new one. . Routeand clamp the wir€s properlyor they can
. When installingthe field coil. align the boss on be damag6d by the rotor pulley.
the tield coil with the hole in the comDressor.
6. Positionthe rotor pulleysquarelyoverthe field coil.

Pressthe rotor pulley onto the compressorboss
with the soecialtool.
lf the rotor pulley does not presson straight,
remove it and checkthe rotor pulleyand compres-
sor bossfor burrsor damage,
CAUTION: Maximum press load: il00 kg (882lbsl

SHAFTRING
REMOVEROTJAC_ SH2O3OO
Vv
22-38
ThermalProtestorReplacement
1 . Removeth6 bolt,tield coil terminal,and retsiner, Removal
Removethe thermal protector. NOTE: Make sure the suction and dischargeports are
Removethe rssidueof siliconsssalantfrom the top pluggedwith caps.
of thermal orotector.
1. Removethe three bolts,heat insulator.reliefvalve,
and O-ring.
NOTE:Be sure to use the right O-ringsfor R-l34a

to avoid leakage.
CAUTION: Be caretul not to spill comprGssor oil,

lnd mlb gura there is no foreign matter in the 3y3-
t.|n.
HEAT !2 N.m {1.2ks-m,I lb-ftl
II{SULATOfi
RELIEF
VALVE
New p.rt (R-134.1
10 N.m (1.0kg-m,
7 tb-ftl
O.RING
NGwp.rt (R-134.)
Replace.
to the top of the thermalpro-

Apply siliconesea18nt
tector. lnstrllation
1' Cleanoff the reliefvalvematingsurface,
ReplaceO-ringwith new one at the reliefvalve,and

a p p l y a t h i n c o a t o f r e f r i g e r a n to i l ( S P - 1 0 : P / N
38899-Pl3-0031beforeinstallingit.
NOTE:
. Oo not return the oil to the containeronce dis-
pensedand nevermix with other refrigerantoils
to avoidcontamination.
. lmmediatelyafter using the oil, replacethe cap
o n t h e c o n t a i n e ra n d s e a l i t t o a v o i d m o i s t u r e
absorption.
. Do not spill the refrigerantoil on the car; it may
SILICOI{ESEALAN' damagethe paint; if the refrigerantoil contacts
th€ paint,wash it off immediately,
Tightenthe reliefvalve.
4, lnstallin the reverseorderof removal. Checkthe relief valve for leaksand cap the relief
valvewith the valveseal.
Belt Adjustment
1. Apply a torce of 100 N (10 kg, 22 lbs) and measure Measurewith BeltTensionGauge:
rhe deflection betweenthe alternator and crankshaft Attachthe belt tensiongaugeto the belt and mea-
DUIeY. surethe tensionof the belt.
Comp.6so. Beh CompresgorBglt

Moction: Tension:
U.cd Eolt: 10.0- 12.0mm 10.39- 0.,17in) Used Bsh: 450 - 600 N {i[5 - 60 kg,99 - 132 lbs]
N.w B€h: 4.5 - 7.0 mm (0.18- 0.28 in) New Belt: 950 - 1t5O N
{95 - 115 kg, 2Og- 254 lbs)
P/S Pump Belt
Usod Bolt: 13.5- 16.5mm (0.53- 0.65 in) P/S B€lt
Now Bslt: 9.5 - 11.5mm (0.37- 0.,15in) Used Beh: 350 - 500 N {35 - 50 kg, 77 - 110 lbs}
Nsw Eolt: 700 - 900 N (70 - 90 kg, t5'l - 198 lbs)
NOTE:
. lf there are cracksor any damageevidenton the NOTE:
belt,replaceit with a new one. . lf there are cracksor any damageevidenton the
. "Used belt" means a belt which has been used belt,replaceit with a new one.
for five minutesor more. a Seethe instructionsfor the tensiongauge.
. "New belt" means a belt which has been used
for lessthan five minutes.
BELTTENSIONGAUGE
07JGG- (x)l010A
THBOUGHAOLT
THROUGHBOLT il5 N.m {i1.5kg-m, 33 lb-ft)
45 N.m 1,1.5
kg-m, 33 lb-ft)
\
CRANKSHAFT
PULI-EY
ADJUSTMENT
LOCKNUT
22 N.m {2.2kg-m, 16lb-ft|
2. Loosenthe through bolt and alternatorn"t.
A/C COMPRESSOR 3. Turn the adjustingbolt to obtainthe properbeltten-

s i o n , t h e n r e t i g h t e nt h e a d j u s t m e n tl o c k n u ta n d
through bolt.
Recheck
the deflectionof the belt.
Condenser
Replacement
1. Recoverthe refrigerant(see page 22-251. o. Removethe two mounting bolts, then lift out the
condenseras shown.
2. Disconnectthe Ay'Cpressureswitch 2P connector,
then removethe receiverline A. CAUTION:Do not damage tho radiator and con-
denserfins when removing the condenser.
3. the dischargeIinefrom the condenser.
Disconnect
CAUTION:Cap the opon fittings immediatcly to

keop moi3ture 8nd dirt out ot tho sy3l6m.
DISCHARGE LINE
Now prrt (R-134.1
O.RING
Now pa.t {R-13,lal
R6place.
CONOENSEB
MOUNT CONDENSER
MOUNT
CUSHION
RECEIVERLINE A
O.RING
SWITCH
A/C PRESSURE N.w p.rt lR-134r1
2 P CONNECTOR
6x1.0mm
10N'm{1.0kg'm,7lb-ft|
Removethe two bolts and Ay'Chose bracket

'l.O mm
6 r
Removethe four bolts and radiator upper mount 10 N.m {1.Okg-m, 7 lb-ftl
brackets.
6x1.0mm
10N.m11.0kg-m,7 lb-ft)
6x1.0mm
RADIATORUPPEF 10 N.m 11.0kg-m, 7 lb-ft)
MOUNT BRACKET
Iil 7. Installin the reverseorderof removal.and:

. lf you're installinga new condenser,add refriger-
a n t o i l ( S P - 1 0 :P / N 3 8 8 9 9 P 1 3 - 0 0 3 )( s e ep a g e
22-21).
I f *oo,oto*,"".t o ReplaceO-rings with new ones at each fitting,
]
MO,UNTBRACKET a n d a p p l ya t h i n c o a t o f r e f r i g e r a not i l ( S P - 1 0 :
P/N38899-P13-003) beforeinstallingthem.
N O T E : B e s u r e t o u s e t h e r i g h t O - r i n g sf o r
R-134ato avoid leakage.
Be sureto installthe condensermount cushions

securelyinto the holes.
Charge the system (see page 22-431and test its
performance(seepage 22-261.
6x1.0mm
10 N.m 11.0kg-m,7 lb-ttl
22-41
A/C System Service
Evacuation
Onry !se service equipmentthat is U.L.-listedand is
ce(tt€d to meet the requirements ol SAE J2210 to remove R.cov.rylR.cycling/Ghrrging Sptcm
e '34a trom the air conditionersystem.
C A U T I O N :E r p o g u r e l o a i r c o n d l t i o n a r
.etrigeranl and lubricant vapot ot mlgl can
irrilale eyes, nose end throat. Avold broathlng
the ai1 conditioner relrlgeranl and lubrlcanl
vapor or migt.
ll accidentalsystem dischargeoccurs,ventilatework area
beloreresumingservice.
B - 1 3 4 a s e r v i c ee e u i D m e not r v e h i c l ea i r c o n d i t i o n e r
systemsshouldnol be pressuretested or leak l€sted with
compressedarr.
E@ some mixture of atr and
R-134ahave been shown to ba combustlble8l
elevaied pressures and can rslull in flre or
exploslon causing iniury or property damags.
Never use compressed alr lo pre3sura trlt
R.134a servlce equlpmsnt or vchlclo alr
condilloner gyslama.
Additionalhealth and salety inlormationmay be obtained
from lhe refrigerantand lubaicantmanufaclurers.
When an Ay'CSvstem has been opened to the atmo-

sphere,such as during installationor repair,it must
be evacuatedusing a R-134arefrigerantRecovery/
Recycling/ChargingSystem.(lf the systemhas baan
open for severaldays,the receiver/dryer should be
replaced.)
Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystemto the car as shown followingthe
equiomentmanutacturer'sinstructions.
NOTE: lf low pressuredoes not reach more than

700 mm H9 (27 in-Hg)in 15 minut€s,there is proba-
bly a leakin the system.Partiallychargethe system
and checkfor leaks{seeLeakTest).
22-42
Gharging
Only use service equipmenlthat is U.L.-listedand is R.coyrry/Rlcyclin g/Charging Syst€m
of SAE J2210 lo remove
certiliedto meet the requirements
R-134atrgm lhe air conditionersystem.
C A U T I O N :E x p o 3 u r c t o e i 1 c o n d l l l o n e r
rofrlgcrant and lubricanl vapor or mlll can
lrltalo €ye!, no3e and thloat. Avold bruathlng
lhc alr condllloner ratllgoranl and lubrlcanl
vapor or ml3t.
It accidentalsystem dischargeoccurs,ventilatework area
b€lore resumingservice. Additionalhealth and salely in'
lormationmay b€ obtainedkom the relrig€rantand lubri-
cant manulacturers.
Rctriglrlnt crpacity: 650* g 1231oz)
CAUTTON:Oo not ovrrchrrgc tha tYstcm; th! comp.t!'

3or will ba drm!g!d.
C o n n e c t a R - 1 3 4 8r s f r i g e r a n t R e c o v e r y / R e c y c l i n g /
C h s r g i n gS y s t e mt o t h e c a r a s s h o w n f o l l o w i n g t h e
aquipmentmanufacturer's instructions
22-43
A/C SystemService
LeakTest
Only use service equipmentthat is U.L.-lisledand is Rccov.rylRrcycling/Chrrging Syltlm

cenrliedto meet the requirementsol SAE J2210 to remove
R'l34a lrom the air conditioner
syslem.
C A U T I O N :E x o o s u r e t o e i . c o n d i l i o n e r
,etrigerant and lubricant vapor or mist can
irdtale eyes, nose and throgt. Avoid breathing
lh€ air condltloner retrlgerani and lubrlcant
vapqr or migl.
It accidentalsystem dischargeoccurs,ventilatework area
beforeresumingsetuice.
t r v e h i c l ea i r c o n d i l i o n e r
R - 1 3 4 as e r v i c ee o u i o m e n o
syslemsshouldnot be pressuretested or leak tested with
compressedarr.
E@ some mixture ol air and

R.134ahave been shown to be combustibleat
glevated pressureg and qan resull In fire or
explosion causing injury or property damags.
Never use compressed air to pressure lgsl
R.134a servlce equipment or vehicle ail
conditionersystems.
Additionalheallh and salely informationmay be obtained
from the relrigerantand lubricantmanufacturers.
l. Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystemto the car as shown followingthe
eouiomenlmanufacturer'sinstructions.
NOTE:Be sure to installthe same amount ot new

r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o r e
c h a r gI n g .
Open high pressurevalve to chargethe system to

about 100 kPa (1.0 kg/cm?.14 psi), then close the
suppryvarve.
Checkthe systemtor leaksusing a R-134arefriger- HIGHPRESSURE

SIDE
ant leak detector with an accuracvof 0.5/oz.per
vear or better.
l f y o u f i n d l e a k st h a t r e q u i r e t h e s y s t e m t o b e
opened (to repair or replacehouses.fittings, etc.).
r e c o v e rt h e s y s t e m a c c o r d i n gt o t h e R e c o v e r
Procedureon page22-25.
5. After checkingand repairingleaks,the systemmust

be evacuatedlsee SystemEvacuationon page 22-
42t.
22-4
Electrical
Lights, Exterior
Back-upLights ........... 23-192
Troubleshooting Brake/HighMount Blake Lights ..............23-194
T i p s a n d P r e c a u t i o n .s. . . . . . . . . . . . . . . . ...... . . . . . . , 2
. 3-3 Hoadlights . . . . . . . . . . . . . . .2 . .3 - 1 8 3
Five-step T r o u b l e s h o o t i n.g, . . . , . . , . . . . . . . . . . . . .2. ,3. - 5 L i c e n s eP l a t eL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. .- 1 4 8
P a l k i n gL i g h t s . . . . . . . . . . .2. 3 - 1 8 6
How to Use This Section SideMa*erLights................ 23-185,188
Schematic Symbols T a i f f i g h t s. . . . . . . . . . . . .......23-147
Wire Color Codes T u r n S i g n s lL i g h t s . . . . . . . . . . . . . . . . . . . . . . . . . . - .2. 3 . .-.1 8 5
Lights, Interiol
Relayand Control Unit Locations . . . . . . . . . . . . .2. 3 - 1 9 0
C e i l i n gL i g h t
E n g i n eC o m p a r t m o n .t . . . . . . . . . . . . . . . . , ,....,,, , . , . . ,2 3 - 7 ' Dash Lights BlightnessControl ...............23-201
Dashboard . . . . . . . . . . . . . . . . . .2. .3 - 8
E n r l yL i g h r ................23-173
Dashboard/Seat ............ 23-11
l g n i t i o nK e y L i g h t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .-. 17 3
F l o o r. . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3 - 1 2
TlunkLighr . . . . . . . . . . . . . . .2.3 - 1 8 9
*Lighting System -.--..--...-.23-174
Index to Circuits and Systems
Airbag ............... . . . . . . . . . . .2 3 - 2 4 7 PGM-FISystom Soction 11
Air Conditioner ....... Section22 Powel Antenna ..,..,,...,..,23-213
Anti-lock BrakeSystem {ABS) .............Ssction 19 Power Distribution .......... 23-51
+ P o w s rD o o r L o c k s. . . . . . . . . . . . . . . . . . . , . . , . . , . . . . .2. .3. .-.2 5 5
Automatic TransmissionSystem ......... Section 14
*Powsr Mirors -,..-...,,.,,..,23-242
Battery.............. ..........2 . 3-66
Blow€l Controls ...... Section21 Power Windows ...--..-...-.23-248
C h a r g i n gS y s t s m ...........23-102 Radiatorand CondanserFan Controls .,,...,., 23-'115
* C i g s r e t t eL i g h t o l . . . . . . . . . . . . . . . . . . . - . . . . . . . - . . . - 2 + R e a rW i n d o w D e f o g g o r. . . . . . . . . . . . . . . . . . . . . . . . . .2.3. .- 2 2 7
. .3- .-.2- 2 4
*Clock................ - . . . - . . - . .2- 3 - 2 1 8 RefayLocations ,..,..,,..,..,23-7
C o n t r o lU n i t L o c a t i o n s. - . . . - . . - - . - - . . . - . . - . . . . .2. -3. -. .7 S e a tH e a t s r s{ C a n a d s }. . . . . . . . . . . . . . . . . . . . . . . . - -2. -3--. 2 3 2
' C r u i s eC o n t r o f *Side Mark€r/Turn Signal/Hazard
. . . . . . . . . . , . , ,2. 3 - 2 7 2
FlasherSystem .......... 23-196
DaytimeRunningLights (Canada)...............23-180
S p s r kP l u g s . . . . . . . . . . . . . . . . .2. .3 - 1 0 1
F u s lP u m p . . . . . . . . . . . .S. c c t i o n1 1
StartingSystem .............23-76
Fuses * S t e r e oS o u n dS y s t e m . , . . . . . . , . . . , . . , . . , . . , . . , . .2. .3. -, 2 0 6
U n d € r - d a sF h u s e / R € l aByo x . . . . . . . . . . . . . . . . .2. .3 - 4 8 * S u n r o o f. . . . . . . . . . . . . . . . . . . . . . . . 2. 3 - 2 3 7
U n d e r - h o oF d u s e / R e l aByo x . . . . . . . . . . . . , . . . .2. .3 - 4 6
+Gauges SupplementalRostrainlSystem (SRS)......... 23-287
V e h i c l eS D e e dS e n s o r( V S S I. . . . . . . . . . . . . . . . . . . .2. 3. - 1 3 8
C i r c u i tD i a g r a m .........23-126
Wiper/Washer . . . . . . . . . . . . . . .2.3 - 2 6 3
Engine Coolant Temperature {ECT)
G a u g e. . . . . . . . . . . . . . . . ...23-123 wires, Harness. and Connectors
F u e lG a u g e . . . . . . . . . . . . . .2. 3 - 1 2 3 Connector ldontitications and
W i r e H a r n e s sR o u t i n g. . . . , . . , . . . . , . . . . . . . 2 . .3. - 1 3
Spoedometer . . . . . , . . . . . ,2. 3 - 1 2 4
Wi ng Diagram .......... 23-332
Tachometer - . . . - . . - . . - .2 . .3 - 1 2 4
Ground rRead SRSprecautionson page 23-294, than installlh6
Distribution . . . . . . . . . . . . . . . . . . . .2. 3. - 5 9
short connecior on the airbag before wolking in these
Locations . . . . . . . . . . . . . . .2 . .3 - 1 3
areas.
HeaterControls ...... Section21
*Horns ............... ,.,..,,..,2 . 3-220
r l g n i t i o nS w i t c h . . . . . . . . . . . .2. 3 - 7 3
r l g n i t i o nS y s t e m . . . . . . . . . . . .2. 3 - 9 0
l g n i t i o nT i m i n gC o n t r o l . . . . . . . . . . . . . . . . . . . . . . . . . 2 . .3. .- 9 3
Indicators
* A / T G e a rP o s i t i o nl n d i c a t o r. . . . . , , , . . . . , . . . ,2. .3 - 14 4
H i g hE e a mfn d i c a t o r. . . . . . . . . . . . . . . . . . . . . . . . . 2 . .3. .- 1 3 2
* S a f e t yI n d i c a t o l . . . . . . . .2 3 - 1 5 1
T u r n S i g n a fn d i c a t o r . . . . . . . . . . , . , , . . . . . . . . . . .2.3. .- 13 2
*fntsgratedControl Unit ,..23-164
t l n t e d o c kS y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3.-. 1 .5 8
SpecialTools
Rcl. o. Tool Numbol Doscription Oty I Pago Roloronco

.lr KS-AHM-32-003 DigitalMultimete. I 23-99,293
'2, oTJGG-001010A Eelt TensionGauge I 23-1' 13,1't4
o 07JAA*OO10008 Antenna Wiench 23-214
o- oTHAZ-SGOO400 OeploymentTool 1 23-322
07MAZ-SLOO500 Test Harness A 1 23-303
@-' oTMAZ-SPOO500 Test HarnessB I 23-306
o. oTLAZ-S140300 Test HarnessC I 23-222, 274, 30'l
@' oTLAZ-SL40400 Test Ha.nessD 1 23-309
,l
@ A 9 7 3 X _ 0 4 1 _ X X X X XVacuum Pump Gauge 23-243
': lncludedin SRS Tool Set OTMAZ-SMSOOOA
* *: lncludedin SRSTool Set OTMAZ-SLoOlOA
@ @
(, @
@
I 23-2
Troubleshooting
Tips and Precautions
Betol€ Troubloshooting Nevertry to disconnectconnectorsby pulling on their
a Checkapplicabletuses in the appropriatefuse/relay wires; pull on the connectorhalvesinstead.
DOX. Always reinstallPlasticcovers.
a Check the battery for damsge, state ot chsrge, and
clean and tight connections.
a Check the alternatorbelt lension.
CAUTION:
a Do not quick-chargoa battory unlosslhe banory
ground cable has bs6n disconnoctod.
Otherwiseyou will damagath6 ahomator diod63.
a Do not att€mpt to crank the ongino with the bat-
t6ry ground cable loosely conn€cted or you will
seveloly damag€ tho widng.
Befoaeconnectingconnectors,make sure the ter-
Handling Connectors minalsare in olace and not bent.
a Make sure the connectorsare cleanand have no loose
wire terminals.
a Mske sure multiple cavity connectors8re pscked with
grease(exceptwatertight connectorsl.
a All connectorshave push-downreleasetype locks.
a Check lor looseretainerand rubberseals.

Some connectors have a clip on their side used to 8t-
tach them to a bracketon the bodv or on anothercom-
ponent.This clip has a pull type lock.
R€TAINER
Some mounted connecto.s cannot be disconnected
unlessyou first releasethe lock and remove the con-
necto. from its bracket.
The backs of some connectors are packed with

grease.Add greaseif necessary.lf the gresseis con-
taminated,replaceit.
ERACKET
{cont'd}
23-3
Troubleshooting
Tips and Precautions(cont'dl
a Insertthe connectorall the way and make sure it is a Seat grommetsIn lheir groovesproperlv.
securelylocked.
a Position wires so that the open end ol the cover
f a c e sd o w n .
Fac6 NOT GOOO
A
open ond
-M/
V
Hsndling Wilos and Halnossos
a Securewires and wire harnessesto the frame with
their respectivewire ties at the designatedlocations.
-Y-
l
Testing and Repairs

l
--P\
a Do not usewiresor harnesses

l r
with brokeninsulation.
Replacethem or repairthem by wrappingthe break
with electricaltape.
a Removeclips caretully;don't damagetheir locks. a After installingparts, make sure that no wires are
pinchedunder them.
a When using electricaltest equipment, follow the
manufacturer'sinstructionsand those describedin
this manual.
a lf possible.insert the probe of the tester from the wire
side (exceptwaterproofconnector).
Slippliersunderthe clip baseand throughthe hole at an a Use a probe with a tapered tio.
angle,then squeezethe expansiontabs to releasethe
cxp.
SNAP.RINGPI-IER
After installing harness clips, make sure the harness ReIerto the instructionsin the HondaTerminalKit for
doesn't inter{ere with any moving parts. identification
andreDlacement of connectorterminals.
Keep wire harnesses away from exhaust pipes and
other hot parts, lrom sharp edges of brackets and
holes. and from exposed screws and bolts.
23-4
Five-StepTroubleshooting
1 . Vofly Tho Complaint 4. Fix Tho Problom
Turn on allthe componentsin the problemcircuitto Once the speciticproblemis identiJied.make the
verifythe customercomplaint.Notethe symptoms. repair. Be sure to use proper tools and safe
Do not begindisassemblyor testing until you have proceoures.
narowed down the oroblemarea,
5. Make Suro Tho Ci.cuit Works
Analyze The Schomatic Turn on all componentsin the repairedcircuit in all
Look up the schematicfor the problemcircuit. De- modesto make sure you've Jixedthe entire problem.
termine how the circuit is supposedto work by trac- It the problemwas a blown fuse, be sure to test all
ing the currentpaths from the power feed through of the circuits on the fuse. Make sure no new
the circuitcomponentsto ground.lf severalcircuits problemsturn up and the originalproblemdoes not
fail at the same time, the fuse or ground is a likely recur,
cause.
BSssdon the symptomsand your understandingof

the circuitoperation,identifyone or more possible
causesof the Droblem.
3 . lsolate Tho Problom By Tosring Th6 Circuir

Makecircuittests to checkth€ diagnosisyou made
in step 2. Keep in mind that a logical,simple pro-
cedure is the key to efficient troubleshooting. Test
for the most likelycauseof failurefirst. Try to make
tests at points that 8re easilvaccessible.
23-5
How to Use This Section
Schematic Symbols
AATTERY GROUND FUSE cotl, soLE otD CIGARETTELIGHTER
Groundterminal Componentground
E I
At
r
RESISTOR
A
VARIABLE
:
II
RESISTOR
II
I.:
THERMISTOR
S.-O-
IGNITIONSWITCH
t-Al
+
BULB
t+J
HEATER
+ ilHH + fr J)-
T-
MOTOR PUMP CIRCUITBREAKER HORN DIODE SPEAKER.EUZZER
+ + D
I
$ H
Mast
ANTI:NNA
I
TRANSISTOR(TI)
Wire Color Codes
Y II
The following abbreviationsare used to identify wire
colors in the circuit schematics:
W H T . . . . . . . . . . .W . hite
Y E L . . . . . . . . . . . . .Y. e l l o w
B L K . . . . . . . . . . . . .B. l a c k
B L U . . . . . . . . . . . .B. .l u e
RELAY lln no rmal po.itlon) CONDENSER G R N . . . . . . . . . . . .G . reen
Normallyopon r€lay Normally closed relay R E D . . . . . . . . . . .R . . e. d
GI - T - I I O R N . . . . . . . . . . . .O . range
P N K. . . . . . . . . . . .P. .i n k
B R N. . . . . . , . . . . .B. ,r o w n
t i l T G R Y . . . . . . . . . . . .G . ray
P U R. . . . . . . . . . . . .P. u r p l e
l-t^f L T B L U . . . . . . . . .L i g h tB l u e
L T G R N . . . . . . . . .L i g h tG r e e n
SWITCH {ln nrrrm6l positionl TIGHTEMTTNITG
DIODE
Normallyopen Normally closed ITEDI
switch switch The wire insulationhas one color or one color with
I /rn\
I t l anothercolor stripe. The secondcolor is the stripe.
/f'[\
\Y./
00 tti I
$/I
CONNECTION CONNECTOR
I T T
REEDSWITCH
9--wHr/BLK
t , /
/ t
/
-___----{
Input I Output
. / l
vY lJ r- +>-
A
ttit
-
R
/
I V tt
! Y
Relay and Control Unit Locations
EngineCompartment
WII{DSHIELDWIPERINTERMITTEI{T RELAYtB-rypo)
I Wir. colorr: BLK,BLU^/HT, I CONDENSER FAN NELAY
I BLU/nED,GR /aLK,snd cR /REDI
I Wirocolo.s:YEIA tHT, WHT/GRN,I
I BLU/RED, and BLU|'EL I
'l r Wirc color3:YEL/WHT,WHl, r
BLU,and BLUrYEL I
ABS MOTOR RELAY {A-typo)
RAOIATORFAN RELAY
lA-typo)
DIMMER RELAY
(a-typol
FUSE/RELAY
BOX
RELAY
A/C COMPRESSOR
CLUTCH NELAY
I Wiro colorr: YEL/BLK,YEL/BLK,
I RED/BLU. and RED
*Ii Wire coloc: BLK|'EL,BLK^/EL,
NED/BLU. 6nd RED
IEST TACHOMETER
COl{NECTOR
r: Wlrh OFflONAL A/C
23-7
Dashboard
CIGARETTELIGHTER
RELAY lA-typ.)
Wir6 colors: YEL/RED,,
WHT/BLU,BLK, I
and WHT/BED I
HOBN RELAY IA-Typo}
SUNROOFCLOSERELAY (B-typol
-'
Wir. colors: WHT/YEL,
;ii,[iic
I ;tir/Rl=d I
I and BLK I
OPENRELAY
SUI{BOOF TURN SIGNAL/
HAZARD RELAY
wrNDow
RELAY (A-typel
{i ' -
'rl wtNDow
r"'tE DEFOGGER
RELAY(A-typcl
CONTROLUNIT
INTEGRATED
BLOWERMOTORRELAY
tA-typ6l
FUSE/RELAY
BOX PGM-FI MAII{ RELAY
ABS REAR FAIL.SAFE

ABS FRONTFAIL.SAFE RELAY (A-typ.)
nELAYlA-typol , Wire colors: 8LU/BLK, ,
, Wir. colo.3:BRN/BLK,, IBLK/YEL,YEL/GBN, I
I BLK/YEL, YEL/GRN, I I and BLK I
I ond BLK I
23-A
DASH LIGHTS BRIGHTNESS
CONTROLUNIT
DAYTIME
RUNNINGLIGHTS
CONTROL UNIT
(Canada)
RADIATORFAN
COI{TROLMODULE
23-9
Dashboard(cont'dl
TRA SMISSIOT{CONTROL
MODULE (TCMI
23-10
Dashboard/Seat
ORIVER'SSEAT HEATERRELAY (Ctntda)
SEAT HEATERMAI]II
RELAY {C.n!dal
, Wir. color.: WHT/BLK,'
BLK/GnN,I
IYEL/BLK,
l6nd BLK I
PASSENGER'SSEAT HEATERRELAY (Can.d.l
COiJTROL
II{TERLOCK UNITIA/T)
23-1
Relayand ControlUnit Locations
Floor
23-12
Connector ldentificationand Wire HarnessRouting
How to ldentify Connectors:
"C" for connectors,
ldentiticationnumbershave beenassignedto all connectors.The numberis precededby the letter
"G" for ground terminalsor "T" for non-groundterminals.
Location OthoB (Floor. Dool,

Engine Companment Dashboard
Harnsss Trunk, and Roof)
Starter cables f1, T2, and +
Batteryground cable T3
G l a n d-
Engineground cable T4 and T5
Enginewire harness C1 0 1t h r uC 1 3 9
T'l O1 thru T'l 03
G1 0 1
Right enginecompartmentwire C201thru C2l I
harness G201
Left enginecompartmentwire C301thru C326
harness G301
Main wire harness C420 thru C435 C401thru C419
and C484 C436 thru C483
G 4 0 1 ,G 4 0 2 . G 4 0 3 ,
and G4O4
Right side wire harness C501 thru C514
T5O1 thru T5O9
G501,G502,G503,
G504, G505
Lefl side wire harness C521 thru C543
G521 G522
Rear wire harness C551 th.u C559
G5 5 1
Dashboardwire harness C6O1 thru C622
Roof wire harness C651 thru C655
SRS main harness C701 thru C7O7
G701
Driver'sdoor wire harness C721 thru C731
Passenger'sdoor wire harness C741 thru C748
Rear window defoggerground wire c801 G801
A/C wire harness C381 thru C386
G381
23-1
Startor Cablos
Connector or Numborot
Location ConnoctEto Notes
Terminal Cavitias
T1 Right side ot engine compartment Unde.-hoodfuse/relaybox
r2 Right side of engine compartment Starter motol
@ Battery Battery positive terminal
Battery GroundCables
Connector ot Numbor ot
Location Connocts to Notes
Torminal Cavities
T? Middle of engine compartment T16nsmissionhousing
Right side of engine compartment Body ground, via battery gfound
cables
Battery Battery negativ€ terminal
EngineGround Cables
Connoctor or Number of
Location Connects to Notos
Torminal Cavitios
T4 Middle ot engine compartm€nt Engine mount bracket
T5 Middl€ of engine compartmant Valve cover
G2 Left side of engine companment Body glound, via engineground
cables
23-14
BATTERY
POStTtVE
TERMINAL
BATTERY
t{EGATIVE
TEBMINAL
BATTERYGROU]TDCABLES ENGINEMOUNTBBACKET
EI{GINEGROUT{DCABLES
( )
23-15
Connector ldentification and Wire Harness Routing
Errq\ne \Nne Rursess \AZZAI' Errg\rre. 2.2 t SSRQ.\
Connector or Numbor of
Location Connects to Notos
T€lminal Cavitios
c101 4 Left side of engine compartment Alternator
c 102 Middle of engine No. 'l fuel injector
c103 2 Middleof engine No. 2 fuel injector
c l04 Middleof engine No. 3 fuel injector
c105 Middle of engine No. 4 fuel injector
c106 Middle of enginecompartment Idle air control (lAC) valve
c107 6 Left side of enginecompartment Injectorresistor
c 108 Middle of enginecompartment Intake air temperature(lAT) sensor
c110 Middle of enginecompartment Power steeringpressure(PSP)switch
,l
c111 Middle ot engine Enqineoil pressureswitch
c113 Middle of enginecompartment Throttle position (TP)sensor
c114 4 Middleof engine Heatedoxygen sensor{HO2S)
c115 Middle of engine Vehiclespeed sensor (VSS)
c116 Middle of engine Countershaftspeed sensor Aft
c117 Middle of engine EGRvalve litt sensor
c118 2 Middle of engine Enginecoolanttemperature(ECT)
switch A
c119 I Middle of engine Back-uplight swirch (-) Mrf
cl20 1 Middle of engine Back-uplight switch ( + ) M/T
c121 4 Middle of engine lgnition coil
c122 Middle of engine Enginecoolanttemperature{ECT)
sensor
c123 Middleof engine Enginecoolanttemperature(ECTI
sendingunit
cl24 I Middle of engine Staner solenoid
c125 I Middle of engine TDC/CKP/CYP sensor
c126 Middle of engine lgnition control module {lCM)
c't 27 2 Middle of engine Enginecoolant temperature(ECT)
switch B
c128 Middle of engine Mainshaftspeed sensor Arf
c129 Middle of engine Lock-upcontrol solenoidvalve A/T
c130 Middle of engine Shift control solenoidvalve NT
c131 10 Right side of enginecompartment Junction connector
2 Right side of enginecompanment Main wire harness(C428)
L I S J 14 Right side of enginecompartment Main wire harness{C425)
c134 10 Right side of enginecompartment Main wire harness{C426)
LtSC 10 Right side of enginecompartment Main wire harness{C432) NT
LIJC 4 Right side of enginecompartment Main wire harness(C432) M/T
Lt50 14 Right side of enginecompartment Main wire harness(C433)
Tl01 Right side of enginecompartment Under-hoodJuse/relaybox
r't02 Left side of enginecompartment Alternator
G1 0 1 Middle of engine Engineground,via enginewire
harness
23-16
THEBMOSTAT
HOUSING
c104 c108
cl13 .t
cl 9 r /" r o .
cl35 C136 26 c r z rI c 1 J 7
23-17
EngineWire Harness(H22A1Engine:2.2 I VTECI
c101 4 Left side ot enginecompartment Alternator

cl02 Middle of engine No. 1 fuel iniector
c 103 Middle of engine No. 2 fuel injector
c104 Middle of engine No. 3 fuel injector
c105 Middleof engine No. 4 fuel injector
c106 Middle of enginecompartment ldle air control (lAC) valve
c107 6 Left side of enginecompartment Injectorresistor
c108 2 Middle of enginecompartment Intakeair temperature{lAT) sensor
c109 Middle of enginecompartment Intake air bypass (lAB) control sole-
noid valve
c110 Middle of engine compartment Power steering pressure (PSPI switch
c 11 2 Middle ol engine Knock sensor (KS)
c 11 3 3 Middle of enginecompartment Throttle position (TP) sensor
c114 4 Middleof engine Hested oxygen sensor (HO25)
c 1l 5 Middle of engine Vehiclespeed sensor(VSS)
c117 3 Middleof engine EGRvalve lift sensor
c 11 8 2 Middle of engine Enginecoolant temperature{ECTI
switch A
c119 Middleof engine Back-uplight switch ( - )
c'120 Middleof engine Back-uplight switch { + )
c121 Middleof engine lgnitioncoil
c122 Middle of engine Enginecoolant tempersture(ECT)
sensor
c123 Middle of engine Engine coolant temperature (ECT)
sendingunit
c't24 Middleof engine Starter solenoid
c125 Middleof engine TDC/CKP/CYPsensor
c126 Middle oJ engine lgnitioncontrol module (lCM)
Middle ol engine Enginecoolanttemperature(ECT)
switch B
c131 Right side ol enginecompanment Junction connector
c132 Right side of enginecompartment Main wire harness(C429)
c133 Right side of enginecompartment Main wire harness(C425)
c134 Right side ot enginecompanment Main wire harness(C426)
Lt55 Right side of enginecompartment Main wire harness(C432)
c136 Right side of enginecompartment Main wire harness(C4331
c137 Middleof engine VTEC pressure switch
c138 Middle oJ engine VTEC valve
c139 Right side of enginecompartment Main wire hsrness(C484)
T1 0 1 Right side of enginecompartment Under-hood fuse/relay box
T102 Left side of enginecompartment Alternator
Tl 03 Middle ot engine Engineoil pressufeswitch
23-1A
c113
ct31
cl32
ct 33
c1
c139
cl
ct
c123
c1
23-19
EngineWire Hamess (H23A1 Engine:2.3 f DOHCI
Connoctor 01 Number ol
Location Connects to otes
T.rminal Cavities
c101 4 Lett side of engine compartment Alternator
c102 Middleof engine No- 1 fuel injector
c103 2 lvliddleof engine No. 2 fuel injector
c104 Middleof engine No. 3 tuel injector
c105 2 Middleof engine No. 4 tuel iniector
c106 2 Middleof enginecompanment ldle air control {lAC) valve
cl07 o Lett side of engine compartment Injector resistor
c108 Middle ot engine compartment Intakeair temperature{lAT) sensor
c109 2 Middleof enginecompartment lntake air bypass (lAB) control sole-
noid valve
c110 2 Middle of engine compartment Power steering pr€ssure (PSPI switch
c112 Middle of engine Knock sensor(KS)
c113 Middle of engine compartment Throttle position {TP) sensor
c114 4 Middle of engine Heatod oxygen sensor (HO25)
c115 3 Middle of engine Vehicle sp€ed sensor (VSS)
c 11 6 Middle ol engine Countershaft spe€d aonaor ATT
c117 3 Middle of engine EGR valve lift sensor
c118 2 Middle ol engine Engine coolant temperature {ECT}
switch A Mrr
c119 1 Middle ot engine Back-up light switch ( - ) M/T
cl20 1 Middle of engine Back-up light switch { + )
c'121 4 Middl€ of engine lgnitioncoil
Middle of engine Engine coolant temperature (ECT)
sensor
cl23 1 Middle of engine Engine coolant temperature (ECT)
sending unit
cl24 1 Middle of engine Starter solenoid
c'125 I Middle ot engin€ TDC/CKP/CYPsensor
c126 2 Middle of engine lgnitioncontrol module (lCM)
c127 Middle of engine Engine coolant temperature {ECTI
switch B
c128 Middle of engine Mainshaft soeed sensor A/T
c129 2 Middle of engine Lock-uo control solenoid valve A/T
cl30 Middleof engine Shift control solenoid valve A/T
c131 10 Right side of engine compartment Junction connector
c132 2 Right side of sngine compartment Main wire harness(C428)
c133 't4 Right side of enginecompartment Main wire harness1C425)
c134 10 Right side of engine compartment Main wire larness (C426)
LIJI 10 Right side of enginecompanment Main wire harness1C432) ATT
c135 4 Right side of engine compartment Main wire harness1C432) M/T
Lt5t' 14 Right side ot engine compa.tment Main wire harness{C433}
T101 Right side ot engine compartment Und€r-hood fuse/relay box
r102 L€ft sids of engine compartment Alternator
T103 Middle oJ engine Engine oil pressure switch
G1 0 1 Middle of engine Engineglound. via engine wire
nSrness
23-20
THERMOSTATHOUSING
06 El WIRE HARI{ESS
oa
:109cl
cl15C118 c1o3 /
c133
cl1
cl
cl1
cl22
c123
c1
c1
c1'14 T103
10 12
23-21
Right Engine Compartment Wire Harness
Conn6ctor ol Numborot
Location Connocts to l{ot6s
Torminal Cavities
Middle ot enginecompartment Right horn
2 Middle oI enginecompartment Left horn
Middle oJ engine compartment A/C pressure switch
c204 Behindright front side marker Right front side markor light
light
c205 2 Behind lront bumoer Right tront turn signal light
c206 2 Behindfront bumper Right front fog light OPTION
c207 Behindright headlight Right headlight (High b6am)
c208 Middle ot engine compartment Radiator fan motor
c209 Behindright headlight Right headlight (Low beam)
c210 Behindright headlight Right lront parking light
c211 22 Behindright kick panel Main wire harnesslC4Ol )
Right side of enginecompanment Body Oround,via main wire
harness
23-22
9<P
23-23
Left Engine Compartment Wire Harness
Connoctor 01 Numbsrof
Location Connocts to Notas
Torminal Cavitlos
c301 2 BehindleJt front side marker light Left front side markerlight
c302 2 Behindfront bumoer Left front turn signallight
LSUJ 2 Behindfront bumDer Left front fog light OPTION
c304 Behindleft headlight Left headlight(High beaml
c30s 1 Middle of enginecompadment A/C compressor clutch Alc
c306 2 Behindradistor Condenserfan motor A/C
c307 Behindleft headlight Left headlight(Low beam)
c308 4 Left side ot engine compartment Cruisecontrol actuatot
c309 I Lett side of engine compartment A/C wire harness(C381) OPTIONAL
c310 Left side of engine compartment EGR control solenoid valve

c311 Left side of enginecompartment Left front wheel sensor ABS
c312 4 Left side of engine compartment A/C compressor clutch relay Atc
c313 Left side of enginecompartment Condenserfan relay A/C
c314 4 Left side of sngine compartment A/C diode A/C
c315 Behindfront bump€r Windshield waaher motol
c316 2 Behindleft headlight Left lront parkinglight
c317 Lett rear of engine companment Windshieldwiper motor
c318 1 Left side ot engine compartment Brake fluid level switch ( - |
c319 1 Left side ot engine compartment Braketluid level switch (+ I
c320 Middle of enginecompartment MAP sensor
Middle of enginecompartment Evaporative emission (EVAP) purge
control solenoid valve
c322 6 Left side of €ngine compartment Windshield wiper intermitt€nt relay
c323 Under middle of enginecom- 4WS front sub steering angle sensor 4WS
panment
c324 20 Behind left kick panel Main wire harness(C4621
c325 22 Behindlett kick Danel Main wire harness(C463)
c326 20 Behindleft kick Danel Junction connector
G301 Left side ot engine companment Body ground, via left enginecom-
oartment wire harnoss
23-24
LEFT E GINE COMPARTMENTWIRE HARNESS
23-25
A/C Wire Harness {With optional A/Cl
Connoctor ol Numb€r ol
Location Connocts to Notos
Torminal Cavitios
c381 I Lelt side of engine compartment Left engine compartment wire har-
ness (C3O9l
c382 4 Under left side of dash A/C diode
c383 4 Und6r left side of dash Cond€nser fan relsy
c384 4 Under left side of dash A/C compressor clutch relay
c385 2 Under l€ft side oJ dash Condenser fan motor
c386 Under l€ft side of dash A/C compressor clutch
G381 Left front of engine compartment Body ground, via A/C wire harness
23-26
23-27
Gonnectorldentificationand Wire HarnessRouting
Main Wire Harness(Right side of engine compartmentbranchl
Connector ol Number of
Location Connects to Not6s
Torminal Cavitios
c420 Right side of enginecompartment Under-hoodfuse/relavbox (C945)
a Right side of enginecompartment Under-hoodfuse/relaybox (C946)
Right side of engine compartment Under-hoodfuse/relavbox (C947)
c423 I Right side ot enginecompartment Under-hoodfuse/relaybox (C948)
c424 Right side ot enginecompartment Underhood fuse/relaybox (C9491
c425 14 Right side ot enginecompartment Enginewire harness(C133)
c426 10 Right side of enginecompartment Enginewire harness(C134)
c427 Right side of enginecompartment Test tachometerconnector
c42a Right side of enginecompartment Enginewire harness(C132)
c429 2 Right side of enginecompartment Intakeair control solenoidvalve DOHC
c430 Right side of enginecompartment Right front wheel sensor ABS
c431 10 Right side ol engine compartment ABS solenoids
c432 10 Right side of engine compartment Enginewire harness(C135) A/T
4 Right side ol enginecompartment Enginewire harness{C135) M/T
c433 14 Right side of enginecompartment Enginewire harness(C1361
c434 Right side of enginecompartment ABS pressureswitch
Right side of enginecompartment ABS motor
c4a4 I Right side ot enginecompartment Enginewire harness(139) VTEC
23-28
lcontinuos on prgo 23-3'l l
UNOER.HOOD FUS€/RELAY
BOX
lviow lrom bolow)
MAII{ WIRE HARNESS
c427
c42A
c|+84
c429
(cont'd)
23-29
Main Wire Harness(Right side of dash and floor branch) (cont'dl
c401 Under right side of dash Right enginecompartmentwire harness

(c211)
c402 to Under right side of dash Right side wire harness(CsO1)
c403 20 Under right side of dash Right side wire harness (C5O2l
c404 20 Under right side of dash Dashboardwire harness (C62O)
c405 6 Under right side of dash Passenger'sdoor wire harness (C742)
c406 10 Under right side ol dash Passenger'sdoor wire harness(C741)
c407 Under right side of dash Blower resistor
c408 2 Under right side ot dash Evaporatortemperatura sensor
c409 4 Behind glove box Recirculationcontrol motor
c410 26 Behindright kick panel Transmission control module (TCM)
c411 22 Behindright kick panel Transmission control module (TCM)
c412 20 Behindright kick panel Junction connector
c413 Behind glove box Blower motot
c414 20 B€hindright kick panel Junction connector
c415 Under right side ot dash ECM
c416 16 Under right side ol da8h ECM
c417 22 Under right side ol dash ECM
c418 14 Under right side of dash Daytime running lights control unit Canada
c419 20 Under right side of dash Junction connector
c436 I Under light side ot dash Radiator fan control module
c437 3 Under middleof dash Shift lock solenoid
c438 4 Under middleoJ dash Cigarefte lighter
c439 to Under middleot dash Heater control panel
c440 Under middleof dash Blower fan switch
c441 16 Under middleot dash Stereo radio/cassette player
c442 2 Under middleof dash Servic€ check connector
c443 Under middleof dash Dsta link connector (DLC)
c444 2 Under middleoJ dash A/T gesr position console light
c445 12 Under middleol dash A/T gear position switch
c446 3 Under middleot dash A/T gear position switch (Back-up light
switch)
c447 Behind middle ol dash Junction connector
c448 Behind middle ol dash Mode control motor
B€hind right side ol dash Body ground, via main wire harness
Under middleof dash Body ground, via main wir6 harnasa
Under middleot dash Body ground,via main wire harness
Under middleot dash Body ground, via main wirs harn€ss
23-30
MAIN WIREHARNESS
, Continuoa on I
Ipaee 23-33 | I Continuo! on
I paso 23-29
c418
I
c413
c414
{cont'd)
23-31
Main Wire Harnesa(Left side of dash and floor branchl {cont'd}
Connac-tor or Numbol ot
Location Conn€cts to Notos
TcrmlnEl Cavities
c449 20 Under left side of dash Junction connectof
c450 I Under lett side of dash lgnitionswitch
c451 Under left side ot dash lgnitionswitch
c452 5 Under lett side ot dash Combinationlight switch
c453 8 Under lett side oJ dash Driver'sdoo. wire harness(C7221
c454 14 Under left side of dash Driver'sdoor wire harness(C721)
c455 10 Under left side of dash Front main steeringangle sensor 4WS
c456 Under left side of dash Lights-onchime
c457 I Under left side of dash lnterlock control unit Afi
c458 Under left side of dash Clutch interlockswitch M/T
c459 J Under l€ft side of dash Clutch switch CRUISE
c460 20 Under lett side ot dash Junction connector
c461 20 Under leli side oI dash Lett side wire harness{C522}
c462 20 Under left side of dssh Left engine compartment wire
harness(C324)
c463 22 Under lett side ot dash Left engine compartment wire
c464
c465
,:l Under left side of dash
Under left side of dash
harness(C325)
Dashboardwire harness(C602l
Front tog light relay OPTION
c466 r i Under left side of dssh Under-dashtuse/relaybox 1C918)
c467 4 l Under left side of dash Under-dashtuse/relaybox {C922}
c468 e l Under left side of dash Under-dashJuse/relaybox {C920}
c469 14 1 Under left side of dash Under-dashJuse/relaybox (C915)
c470 14 | Under left side of dash Underdashjuse/relaybox {C914}
c471 2 J lUnder left side of dash Under-dashtuse/relaybox {C916)
c472 c l Under left side of dash Under-dashluse/relaybox {C919}
c473 16 I Undsr left side ot dash Integratedcontrol unit
c47 4
c475
c476
1
4
l Under left side ot dash
Under left side of dash
l Under left side of dash
Starter cut relay
Cigarette lighter relay
Horn relsy
M/T
sRs
c477 14 | Under left side of dash Cruisecontrol unit
c478 4 l Under left side of dash SRS main harness{C706l sRs
c479 4 l Under lett side ot dash Brake light switch cRulsE
c479 2 Under left side ol dash Brake light switch
c480 4 Under left side of dash ABS front fail-safe relay
c481 4 Under left side ot dash ABS rear fail-safe relay
c4a2 4 Under left side of dash Seat heater main relay Canada
c483 Under lelt side of dash PGM-Flmain relay
23-32
(Continuoson page 23-31)
MAIN WIRE HARNESS
/ c453 c;54
c456
UNDER.DASH
FUSE/RELAY
BOX
c469
c46a
c467
INTEGRATEDCONTROL
23-33
Righr Side Wire Harness
Coon€ctor ol Numborof Not6s

Location Connocts to
Tcrminal Cavities
c501 16 Jnderright side of dash Main wire harness(C4O2)
c502 20 Jnder right side of dash Main wire harness(C403)
c503 to Jnder right side of dash Dashboardwire harness(621)
c504 6 light side of tloor ABS inspection connector ABS
LCUS 14 iight quarter panel ABS control unit 4WS
c505 12 light quaner panel ABS control unit
c506 20 light quarter panel ABS control unit 4WS
c506 18 light quaner panel ABS control unit
c507 20 light quarter panel Junction connector
c508 4 -elt front of trunk 4WS control unit 4WS
c509 18 Left front of trunk 4WS control unit 4WS
c510 12 Left front o{ tiunk 4WS control unit 4WS
c51 1 lnside ol right rear wheel Right rear wheel sensor ABS
c512 2 Inside ot right rear wheel Le{t rear wheel sensor ABS
L5t5 Under middle oI trunk 4WS rear di{ferential trans{ormer 4WS
c514 I Under middleoI trunk Rear main steering angle sensor 4WS
Tsol Right side ot engine compartment Under-hood fuse/relay
Ts02 Let-tfront of trunk 4WS control unit 4WS
T503 Left lront oJ trunk 4WS control unit 4WS
T504 Lett front of trunk 4WS control unit 4WS
T505 Left front of trunk 4WS control unit 4WS
T506 Under middle ol trunk Rear steering motor 4WS
T507 Under middleof trunk Rear steering moto. 4WS
T508 Under middleof trunk Rear steering motor 4WS
T509 Under middleof trunk Rear steering motor 4WS
G501 Right side ol rear tloo. Body ground, vi8 right side wire
harness
G502 Middle tront of trunk Body ground, via right side wire
narness
G503 Middle front ol trunk Body ground, via right side wire
nSrness
G504 MiddleJ.ont of trunk Body ground,via right side wire
narness
G505 Under middleof trunk Body ground, via right side wire
harness
23-34
II
i
T502
T503
T5()4
T505
T5o8
Tsor
REABSTEERING
MOTORI4WSI
lt, RIGH?SIDE
WIRE HANNESS
FUSE/REI.AYBOX
ABS COI{TROL
U1{IT
(N
23-35
Left Side Wire Harness
Location Connects to Notss
Trrminal Cavities
c521 14 Under left side of dash Dashbosrd wire harness lC603)
c522 20 Under left side of dash Main wire harness(C461)
c523 16 Behindlett kick panel Under-dashfuse/relaybox 1C917)
c524 o Middle of center floor Hazard wsrning switch
c525 1 Middle of center floor Parking brake switch
c526 6 Middle of center floo. Passengor'sseat heater switch Canada
c527 6 Middle of center floor Driver's seat heater switch Canada
c52A 18 Left front ol trunk Rearwire harness{C5511
c529 Right side of floor Passenger'sseat heatel Canada
c530 2 Left side oJ floor Driver'a seat h€ater Canada
c531 Left side of floor Driver's seat belt switch
'I
Right quarter panel Passenger'sdoor switch
c533 I Left quarter panel Driver's door switch
c534 20 Lett quarter panel Junction connectol
c535 20 Left side ol rear shelf Roo{ wirs harness{C651}
c536 5 Fueltank Fuel gauge sending unit
c537 2 Fuel tank Fu€l pump
c538 Right side of rear shelf Right rear spssker
c539 Middle ot rear shelt Trunk light
c540 Left side of rear shelf Left rear apeaker
c541 2 Behindrear consolepanel Wootsr sDeakel VTEC
c542 10 Behind rear console panel Woofer amplifier VTEC
c543 20 Let't side ot floor Junction connoctor VTEC
G521 Lett side ot floor Body ground, via left side wile
halnsss
Right quarter panel Body ground, via left side wire
natneas
23-36
c535
c52a
E
4
' l rl
UNDER.OASHFUSE/RELAYBOX
RearWire Harness
Connoctor 01 Number of
Location Connects to otos
Terminal Cavitios
c551 18 Left front of trunk Left side wire harness{C528}
c552 Middle of trunk Left license light
2 Middle of trunk Trunk latch switch
c554 Middle of trunk Right licenselight
c555 8 Left side of trunk Left taillight
c556 Left side of trunk Left rear side markerlight
c557 Right side ot trunk Right rear side marker light
c558 3 Right side of trunk Power antenna motor
c559 8 Right side ot trunk Right taillight
G551 Middle of trunk Body ground, via rea. wire
narness
Roof Wire Harness
Connector ol Numbor ot
Loc€tion Connocts to Not6s
Torminal Cavities
LO5 | L€ft side oJ rear shelf Left side wire harness (C535)
c652 1 Rear of roof Rear window defogger
c653 2 Rear of roo{ Sunroof motor
c654 Rear of roof Ceilinglight
5 Rear of roof High mount brake light
Rear Window Defogger Ground Wire
Connector ot Number of
Location Connocts to l{ot.!
Torminal Cavhios
c801 1 Rear of roof Rear window defogger
G801 Rear of root Body ground, via rear window
detogger ground wire
23-38
BOOFWIREHAR ESS
REARWINDOW OEFOGGERGROUND
23-39
Dashboard Wire Harness
Connector ol Numbel of
Location Connects to Notog
Tsrminal Cavitios
c601 to Bshindleft kick oanel Under-dashfuse/relay box (C9O7)
c602 Under leJt side of dash Main wire harness(C464)
c603 14 Under left side of dash Left side wire harness{C521)
c604 5 Under leJl side of dash Dash lights brightnesscontroller
c605 6 Under leJt side ot dash Cruisecontrol main switch CRUISE
c606 5 Under leJ-tside ot dash Sunrool switch
c607 1 Under left side oJ dash Left front tweeter
c608 I Under left side ot dash Left front tweete.
c609 20 Under left side ot dash Junction connector
c610 10 Behindmain gauge assembly Main gaug6 assembly
c611 5 Behindmain gauge assembly Main gauge assembly sRs
c612 16 Behindmain gauge assembly Main gauge assembly
c613 10 Behindsub gauge assembly Sub gauge assembly
c614 30 Behindsub gauge assembly Sub gauge assembly
c615 5 Behindsub gauge assembly Clock
c616 6 Behindmiddleot dash Dash lights brightnesscontrol unit
'I Under right side ot dash Right tront tweete.
c618 1 Under right side oJ dash Right tront tweeter
c619 20 Under right side ot dash Junction connector
c620 20 Under right side of dash Main wire harness (C4O4)
c621 16 Under right side of dash Right side wir€ harness{C5O3)
c622 10 Under left side ol dash Front fog light switch OPTION
23-40
DASHBOARDWIRE HARNESS
I
' 19
C6i4 C615 C616
2'1
C602 C6O3 r--r e
UI{DER-DASHFUSE/NELAY
BOX
23-41
SRS Main Harness
Location Connocts to t{otos
Tarminal Csvities
c701 Behind left kick panel Under-dashtuse/r8l8ybox (C931)
c702 Under left side of dash Lett dash sensor
c703 2 Under right side ot dash Right dash sensor
c704 18 Middle ot floor SRS unit
c705 Under right side of dash Passenger'sairbag assembly 4WS, VTEC
c706 4 Under left side oJ dash Main wire harness(C4781
c707 o Under left side ot dash Cable reel
G701 Middle of floor Body ground,via SRS main hsrness
23-42
-lnL
t--l-E
Fi-r-EF
r-:-l
lE=
.ml
[ffiEHflHflHHil
23-43
Driver's Door Wire Harness
Cooncctor 01 Numb.r ot
Location Connocts to otos
Torminal Caviti6s
c721 14 Driver'sdoor Main wire hsrnsss (C454)
c722 8 Driver'sdoor Main wire harness(C4531
c723 Driver'sdoor Dfiver's door soeaker
c724 4 Driver'sdoor Driver's Dower window motol
c725 6 Driver'sdoor Driver'sdoor lock actuatot
c726 18 Driver'sdoot Power door lock control unit
2 Driver'sdoor Power mirror defogger switch Canada
c728 10 Driver'sdoor Power mi.ror switch
c729 Driver'sdoor Driver's Dower miror actuator USA
c729 6 Driver'sdoor Driver's oower mirrot actuator Canada
c730 Driver'sdoor Driver'sdoor lock switch
10 Driver'sdoor Master oower window switch
Passenger's
DoorWire Hamess
Connector or l!umb6. of
Location Connocts to l{ote!
Terminal Cavitios
c741 10 Passenger'sdoor Main wire harness (C4O6)
c7 42 o Passenger'sdoor Main wire harness (C4O5)
c743 Passenger'sdoor Passenger'sdoor speakel
c744 Passenger'sdoor Passenger'spowel window motor
c 74 5 o Passenger'sdoor Passenger'sdoor lock actuator
c746 5 Passenger'sdool Passenger'spower window switch
c7 47 Passenger'sdoor Passsnger'sdoor lock switch
c74A 5 Passenger'sdool Passonger'spower mirror actuator USA
c 74 8 6 Passenger'sdoor Passenger'spower mirror actuator Canada
c745 c744
PASSENGER'SOOOB WIRE HARNESS
23-45
Fuses
Under-hoodFuse/RelayBox
tr47f,E46fC45lE44 fE43 lC42fC41ftr4oftr3s l

tr4efC48f
E sllEsof
c941
lTo ABS motor rohyl
c942
[To ].di.tor tan r.llyl
4WS CONTROL UNIT

c943
I To right sld. wiro I lTo dimrn.rrCryl
I hern63s ll5ol) I
BATTERY
cautes
[ [oretoncr 1 ALTERNATOR lfo h.!d[ght r.hyl
I To onginowtr. I
r ha.n€.r{T101},1
c945
I To mainwire I
t harne$ tC42O)|
c946
I To mainwlro
r harn$3(C4211
c947
I To mrin wir. h.m.s. I
. tc422l I
23-46
Fuse
Numbor Amps Wlro Colol Circuits and Components Ptotact€d
al 50A ABS motor relav

32 1 0 0A Power distribution
33 50A WHT lgnitionswitch {BAT)
34 40A BLK/GRN Rearwindow deJoggerrelay
Jb 40A WHT Blower motor relav
50 40A WHT/RED Seat heaters(Canada),PGM-FImain relay
404 WHT/BLU Sunrootsystem, power window system, daytime runninglights control unit
(Canadal
38 60A WHT 4WS control unit
39 1 5A WHTTYEL Turn signal/hazardrel8y, hazard warning lights
40 1 5A WHT ABS control unit (82)
41 1 5A WHT/YEL Horns, horn relay, brake lights, brake light signal
42 20A' REO/GRN Parkinglights, dash lights
43 1 0A WHTA/EL Clock { + B), stereosound system, 4WS control unit, ECM, transmissioncontrol
module ITCM)
44 1 5A WHT Power door lock control unit
45 1 5A WHT/GRN Condensertan motor, radiator tan control module
46 1 5A WHT/BLU Ceilinglight, cigarettelighter rel8y,ttunk light, ignitionkey light
47 1 5A RadiatorJan motor
4A 7.5 A WHT/BLK ABS control unit
49 204 WHTi GRN ABS control unit {B1l
50 20A RED/GRN Right headlight
c l 20A- REDryEL Left headlight, high beam indicator light
23-47
Fuses
Under-dashFuse/RelayBox
Front Vi.w {... p!96 23-50 lor bsck viowli
C901 [To turn signal/hazardroloy]
C903 [To blower molor rolayl
C9O4 [To pow.r window rol6y]
c905 CgOGITo roar wlndow dologgor rolayl

Ir To aunroof
openI
r
rclay
c907 CgOB tTo SRS luso block (C933)l
ITo da.hboard I
t wir6 ham6s tC6Olll c931
lTo sRsm6ln I
AUXILIARY I harno.r{C701}|
FUSE HOLDER
(4WSl c932
lTo ignitionrwltchl
c909 F,
I To combinrtionI n tnl
@@@q
I light switch I 23 24
U IUI
- nnrjl
-I | 1 a1 92 0
UUU
nr:In|:lnnnnn
91011121314'1516t
Sporo fuso UUIJIJUUUUT c933
l:lnnnr:rrj]nElr lTo und.r{!.h
box (C9O8)l
turc/rclly
1 2 3 4 5 6 7 8
UUIJUIJUIJIJ
SRSFUSEBLOCK
C910 loptionl
C91 1 loptionl
C912 loptionl
C913 loptlonl
23-4a
Fuso
Number Amps Wiro Colol Circuit! and Compononts Prolocted
Not used
7.5 A BLU/RED ECM, PGM-Flmain relay, sub gaug€ (brakecheck circuit)
5 1 5A BLU/RED Fronttog lights (option)
1 0A YEL/BLU PGM-Flmain relay
Not used
o 1 5A WHT/BLK Seat hester svstem (Canada)
7 30A lnternal Sunroof open relay, sunroof close relay
connecI|on
8 1 0A RED/GRN Daytimerunninglights control unit {Can8d8)
I 1 5A lnternal ODtion2 connector,blow€r motor relay
connect|on
BLKiYEL Heater control panel, power mirror systsm, ABS control unit, tadiator fan control
module, Mode/recirculation control motor
10 Not used
l1 1 0A lnternal Rearwindow defoggerrsl8y, integratedcontrol unit,
connection
YEL/BLK Seat heate. main relay (Canadal,A/C compressorclutch relay, ECM
12 7.5 A YEL/RED Daytimerunninglights control unit (Csnada)
t 5 1 0A YEL Gaugeand indicatorlights, clock, back-uplights
14 7.5 A BLK/RED Cruise control system
t 5 20A. WHT/BLK Driver's Dower window system
to 20A BLU/BLK Passenger'spower window system
17 30A GBN/BLK Windshieldwip€r system
18 1 0A lnternal Option 4 connector
connection
YEL/RED Stereo radio/cassette plaYer, cigarette lighter
l o Not used
20 Not used
*21 Not used
'22 1 0A YEL/RED 4WS control unit
*23 1 5A BLK/YEL PGM-Flmain relay, transmissioncontrol module (TCM), radiatorfan control module
PNK SRS unit
*24 1 0A RED SRS unit
' 2 1 . 2 2 : A U X I L I A R YF U S EH O L D E R( W i t h4 W S )
*23, 24: SRS FUSEBLOCK
(cont'dl
23-49
Fuses
Brck Vhw {.!. p.gr 2348 to. tront vi.wl:
lTo m.ln wl.. h.ma$ lc470ll c915

lTo mlin wlr! h!rno!. {C469)l
c916
lTo D.ln wlrc h.mct. (C471ll
c917
[To l.tt rid. wl.. h.rn.r. (C523ll
c918
lTo m.ln who hlrnr.r lc466ll c920
lTo m.ln wiro ha]nor! {C468ll
c919
lTo mainwlr. hrrru.t (C472ll c922
lTo inlin wlr. h.]no!. (c/t67)l
c921
lTo Intcgrr$d control unltl
23-50
Power Distribution
Circuit ldentification
BATTEBY
r-F-q-* BLK- motor

Startor
I SOX
FUSE/REI.AY
U DER-HOOO
No.38{60A)
i' wHT- 4WScontrolunit
tlo.39l15A)
WHT,"YEL- Tumsional/fuiardrclay
Hazrrdwaminglighls
No,40{1541
ABScontrol
unitlB2)
&akolightB,&Ekesigml
N0.49l20Al
wm/Gnl1 ABScontrolunit{BI }
ABScontrolunit183)
0.1€17.54)
ABSMOTOB
RELAY
ALTERNATOR
Y_,.-
-
GRN/8LK ECM
-r"*
G4o'l
G4o2 +l$l','13l!:ltlT
G404
BLvcRN "*'
+ [Tl"['13-%P"ooo'^
*'n* "*'
h:o$5lJ59',0'i
wrrneo *t
$ HloollAoltfrTu""'*t
WHT/BLU t'
+ HtX'&-rol%i""tt*'
fro p.g€23- 521
{cont'd}
23-51
PowerDistribution
Circuit ldentification (cont'dl
lFromp4o23- 51|
Sters rdio/clssott€dayor
Pow6l6nt6nn6 motor
Clockl+ Sl
4WScontrclunh
Tra miaiioncontrolmodul€ITCM)
ECM
Powatdooabck control utit
WHT/GR-+ ndidor f.n conrolmodul€

L C.ndo|tg€rl.|r motorMatth,,/Cl
Clgrott.lQht6.
lgnilionkoylight
Keyintodock lohndd la,/Tl
Intagratadconttolunil
Trunkk t
C€ih|ofght
oat! linkcortrroclor
{oLCl
RADIATON
FAN
MODUI.!
COI{TROL
BIUEU( - Rrdiatorf8nmotor
I
YEL
raunm ENGTNE
cooLAt{T
TEMP€MTURE
$
{Top.g623- 53, 541
23-52
USA:
- HOOD
UND€R FUSE/NELAY
BOX
. HIGH BEAM
INDICA]ORLIGHT
. RIGHT HEADUGHT
(Hiohborml
. LEFT HEADUGHT
{Highbo3ml
RED/GRN- Right headlight{Lorvb€em)

L Risht h€adlishtlHish beeml
No.51(20A1
bft h€6dlghl{Lowb6.rhl
Lrft h6ad[tt[ {Highboaml
coMEINAT|oN Highb€6mindicrtorhht
FOGUGI{T UGHT
SWTCH Foglightr6lry(oprionl
st /tTcH
(Optionl
DIMMER
>G-
I
ORN
"-1 PASSING
_I
G401 tot ^ Grc1
G102 G102
BIUiNED G404
i\3
i oFF
2
(;--r
RED/8t(
Riohttritight
F ont p.*ing lights
Roa aidemerkorlights
Lhons6pht6 fEhts
Int6grstadcontrol unit
Daehhhts
DEshlights brightnosscontrol unit
{Oplion O conrpclot)
Ljghts lin dim modoltor
clock, A,/Tg€!. po*ion
indicrior rd cru&aaadic8lor
toft tdxght
Power Distribution
Circuit ldentification(cont'd
Canada:
-HOODFUSE/REI.AY
UNDEN BOX
--..+
RED/GRN Rightheadlighl
llow b.rm)
, HIGH BEAM
INDICATORLIGHT
L+> 359g5115Pôuu*"
. RIGHT HEADUGHT
Hiohb€ehl
. LEF.IHEADTIGHT RED/YEL---- Lrtl hoedli0htllow borml
{Highb66m) F Highb€amindic3torlight
F Foglight rchy loFion)
LD>36#S11"llf'*uo*
i8ilfl8sil3il
FOGLIGHT
swtTcH
l0ption) I.OO DIMMER
onN
'"1_ '"-l_
G401
G402
G404
II
I
Riohtrdffghr
Fmntprltin€ lightg
r REO/GRiI DAYTIME
RUNI{ING
LIGHTS
{ORI.)
COMTROL
R€rrs&remafiorlights
Lic.ns.pletoliohs
kt grrtodcontrolunit
D.!h li$ts
REDTYEI D!,.hlightsbrighhGscor .ol udt
UNIT (OptionO conn€ctorl
GRI.I/RED Light3{indimmodolfor
YEURED
< lf;l;'Jl?illtT, cbcl A'/Tgcsrposition
indicdorrM cruis€iMicrtor
l.ft trtlghl
REo/cRN lH;'Jl3fliSE,,
t
GRI'I/RED
<
BLK
I
6301
23-54
No.33{504)FUSE
pqo23- 511
{From BLOC(
SRSFUSE
r-----------------'l
IGNITION
SWTTCH
Y
t l
T No.24ll0A)
.,i- I N0.23{15A1
,' ^lcz
O
+
poc23- 571
BLK/YEL
-
8LK/YEL*
F
PGM- Fl mainmlly
Radiltor fan control modulo
Inraka.it comol .olsnoilv6tuo{DOHC}

EGR cnntol aol€noid vdv6
l- Evroorutivc oinisioi IEVAPI
Putgscontrollol€noillv6fuo
BLKIYEL- ch.rgino3y3t.mlightlsobo go)
BLK'YEL- conrlotmodur€
] Trsnsmblion FcMl
|-,
F V€hiclospo€d!€n3or{VSS)
F Voh.gote! btorllcl)
F lflata aitbypre!llA8lcontrcl
I sol€nollv!tu. {DOHCI
I N- ELouNlT
a? fioPry2s-stt
tlo.l3{1041
YEt ......- GtugE36ndlMic3tor lghtt
llntomdconnoctionl
co(rtrolunit
Intagrsl€d
SWITCH
TURNSIGNAT
YEt ..+ Brck- uPlight3

l- shift lockrohnoidlA/Tl
No.l417.5A)
B["f\iRED- Crui!6 cotttol mrn switch
lF Crubo contol unh
GRNiELK* Wndshiold wipd int.minont rcl6y

l- Windshioldwip€r notot DleY
WIPE&WASHER
WINDSHIED SWTCH
BLKryEL- lgritioncrtl
Btt,ryEL
AUXIUARYFUSE
HoL.DER
t4WS)
YEUREo- 4lVSfiont main.raing lngh 36[eot

F 4WScontrolurtt
L /tWSr6srmeinslo€tingtngie$nsor
{cont'd)
23-55
Power Distribution
Circuitldentification(cont'd
DASHFUSE/RELAY
UNDER_ BOX
-/---'-r
F-_..-/ |
t t
loption O connctorl
Cirlrfft hhtor r6ley
Sters ndio/crcaott!dryor
Wootd iinD[fr6r
Wrthlavan!0€ak6rr)
No.gl15A) 0ntermlconnoctionl
lOptbn @ connectorl
BI.I(Y€L lloltar conlroi p8n€l
BLK/YEL Powd mkror &lurtor!
powor
mlrord.io0e6r
i;' i
Modacontrol motor
a8s fril- "f. trby
il;;' i
ABScontrclunh
No.35lrcAlFUSE ABSi|lp€cti)n conn&lor
p.9.23- 51I
lFrom 4WSconttolunh
Rldirtortln
lln controlnroduk
modllo
Rrcirdhtbn controlmolor
f-
_-i.-
' 'j- fif,HlSlBll'
:
G401
G402
G404
SluAvHr- 8bw6.moior
ilo.1217.5Al r\ DAYTIME RUNMIGUGHIS

-{11)>
YEURED CoMTRoL UN|T
f (Top!0.23- 54,
ib.1l ll0Al
YEUBIX - S..t h.tt.. mlin |!hy
E ,VC compllasof ctxdr ralty
No.34140A,
A,SE l|l|tern.lcorlarcctionl
lFrcmpa!623-511 Irtogrltod conlrol u|t|:t
YEUGRN- f,6lr wirdoyr drfo0[pr 3yritch
4I(GRX - n !r window datogoar
23-56
tGNtTtoN
swrTcHlsll
- 551
p.ge23
lFrom
,a
;!^,Girr 6.[ -l
-jt-
TMTERLoCK
cLuTcH swrrcH ++
G10l
G402
G404
BLX/RED EU(/IVI{I- strrrorsol€noid
-
I
__________r
BUoi/t{T - strd6f solonoid
UNOEF-DASHFUSE/RELAY
BOX
BLUif,ED* €CM
L FGM_ Flmainr6leY
BtuiRED- Subgru!6 l&rk d€ck

No.36llOA)FUSE
lFrcmp.g€23-51)
llntlmal connaclion)
loprionO conmctor)
-
BIUiRED Foghht3 loptionl
-
YEUBLU PGM- Flm3inroky
wm/Buf solth..!orlrLy
i;'J
(cont'd)
23-57
Power Distribution
Circuit ldentification (cont'd)
_ DASHFUSSRETAY
UNDER BOX
INTEGRATID
COMTROL
UNIT
V
Y
I '"--f,_
No.37{404}FUSE
pag623-51}
{From
G4ot
G402
I G104
I tlo.15(20A1
WffT/BtX - Malter pow.. window lwhdl
E orivo/t @war window motor
BtU/BLK - P!3!€ng€/! powar window motor
--->
GRN/RED suilRooF
slyncH
GRiI/RED- glnmot moior
nrtnr, -$ su nooF
slvrTcH
GRNY€|- smrool r|oto,
Bt(
-p
',o,c"r ', .o*'
liFlfl,#itT*f
A-:
i
G40l
G402
G404
I
I __i
23-s8
GroundDistribution
Circuit ldentification
- housing
Transmission
,l
T.': E Valvscovor
r
-l
G2
I-rot-fiT/rilIl-t
Main.hft sp6ed {#w"ttstu-1 i|
s€nsorlA/T) l--l!l0RN/BLU -r liorr,r,u
|
- ILTransmission
controlmodub
| _ | lfTCMl
Co(litolshaft sp€€d
r_i!lBr-u,^YEL
-l
.€nsor lA/Tl +DIBIU/GRN +j
Hostodoxygens6mor IHO2S) -14 | wHT-

Knocks€nsor{KS)
conlrolmodul€(TCMI
Transmbsion
r.* -{--.8rl* ECM
Vohiclesp€€ds6nsorIVSS)
Engino
coola tomperature
IECTI
Cl'nk3haftposilion 1-i4lsLurenir
{CKPIsonsor l-{ElarurrcL
- l
TDCa6mor 1-i!JonNBLu
L+lOwrniBLU
I
I
<f-Elont
ORN
po3rtion
Cylindor r - I
ICYPI$nsor L-t!;lwHT WHT
8LK/RED
Transmi$ion
contrclmoduloITCM)
DEta
linkconnoctor
{DLcl
BU(_ WECpmssure
switch{VTECI
"^-1,-.'E r*
T riX_o,."*r,
Bt-( * PowerstE€ringprossurcIPSPI
switch
I
l- Engin€coolanttBmperature
{ECTI
switchA
j
G10l E i Battorygrcundcables El Mdnnke hsmess
tr :: Emine
groundcablss ------- S h i ew
l dh e
E Enginowirohanesg
(cont'd)
23-59
Ground Distribution
Gircuit ldentification (cont'd)
8t-K FIgt|rfrcnt parldng

light
BI.K trghttronttumsignallight
BL( ftglt fiont skJsmffkorlight
B|.l( Radbtorfanmotor
8U(- lronltugrghtloption)
Right
BU(- Rightl
r I h€.dftgh
lLowbeam)
BU(+{olpjrx elx -l F--lFlBU(su( -
l-lFl t-6rr
r!ft J
| - | . -
,u.J
Bu( Crukacontrolactuator
8tx Condonlor
f6nriotor
8u( trft ftlnt foghht {optiml
Btx L6ftlronrdd,.ma*6rlight
Btl( bft trontrumlign.l kht
BU(- &*o ffrkl l€vslswhch
BIJ( - L.ft fmnt prtjrE fght
BU(- Wri$iald wipormotor
BU(- Wri$bld wahd morot
BU(- nlay
Wind$i.H rviporintonnitt€nt
CondeNorfln molor(Wth optionalA./Cl
: Right6ngin6comprt||rafit wira hdtL!.

: Lrft onginocompitrnant wira h!fiLd
i A/C wir6 hrm63afwrthot{ronrl A/Cl
23-60
P&!rneo/! doorbck Ectuatot
doorbck switch
Praagngar'!
l-;;;;;;;il;;;-l
runninglghrt contolunil
Daytlma I
I L- - - - - - - - - - - - - - - - - I
I tcr dr)
F fhltar codrolpl|rl
l- pd; ff q6ncon1;6lmodug
BK- !t* ] A8st;t-r"f","r*
F haar J
L AESDreiijra lwitch
8tl( - Cru|..contll unit
F llnorlockcodrolunhlA/I)
L lurloo poCtlon.witch
BLX- DimmrtlLv
Bt( EL! unh

-
l- lightor
Ciger€no
Homr€by
Fro||tminltsring d|gl€ saNot
{v/lrtt
odva/! porv6.minordotog[€rlcantdal
Powotminorlwilch
Masterpowe wlndowrwitdr
)
Ddvor',powarwindowmotor
Bt( - Powddoorlockcontolunh
F orlvor'sdoorlocl lwhch
l- Odvlr'adoorbcl rcturtor
B.* "
Ht?'$"-rolUu,'n'*'
+
8LK- St6r€oradio/ca8atl.plryar
G4o4
E .M6inwho hanoss [ : P!t!aar0a/t d@awi! htrs

tr' Ddver'sdoorwir€hamoss []: RlghtCd. win hrrs
(cont'd)
23-61
GroundDistribution
Gircuit ldentification(cont'dl
UNDER-OASH
FUSE/REI-AY
80X
au j Subgarg. !8!.muy
Maingatrg6allamtt
Slnrooflrvhdl
BLX tug light3witchloptionl

8rI ordr liohtshhttn rs comrclunh
'I
8Ll(
8r( I Mdnga{€ rlsembt
SunrcofclosorErry 8t.K Cruilomdnswitch

grb gmgoaslombv
Sunrcofopon l6l6y
8U(- Clod
'nrfrr*.ofttot unfl
#Tum
Powarwindownlay
Blowarnotor rdrv
Combinalionligfrt lwhdl nd windCli.ld wiper/yra$or,witdr
s|.K-D G521fio p!0.23- 61t
#deu
BI.K Clu!$ swlth lwth cruL contol)

8tJ( Clurdtlm.dod(rwirdl lM/Tl
G404{Frcmp.g€23- 8l ) Bl-K ........- Ljght -on chim.
b Sart lbdar min lthy
lgrilionk y rwhch
Oo'rtl.lietn.. rllrt
:]---
BU( - lhrt r ft|l .tyitdl
ABSrbtor
G403
E
tr :: oashboerdwir6ham.ss
tr [!ft sid€r,ir€hanost
23-62
PoworlmotorlgoundT504
l4WSco rclunitl
7-:i:
--^^
R6.rst .ing motor ffneO

{+l
Rearlt€.ringmotor ffarf
v-:::
l-t
G505
rTl vFl
Raarito€dnorrotor
{oamper fu;tion +}
Radrlacrimmotor
lDempdl funclion- I
ffau
8tK
- ) lws comrorunir
El : Rightsidcwir6ham$3
(conl d)
23-63
GroundDist
Circuit
Drivor'ssoat hoatars
Ddvar'3s6tt h6atd rol€y
Ddvor's3ort hoatd 3witch

Paaaong6r'ssost hoatoa3
Paasang€r'ss6!t hostor r6lay

P6ssongor'ssert hortor lwitch
FuolpumplFPl
Btx -#| - s1x-] - eu(-

l-{M-l HishmountblskoFght
| L f -
c€ilim lisht
| - r. -
--! su t* -T
lHlu :Yt ] rc.N€Drst6
rohtt
Lln r
l-
L frunk letchrwhclr
Driv..'r r6st b6h awitch
Woof.. lmplfi€r
fwith s.wn sDoako6)
Fuollandingunit
E , L"ft slde,ire t'*ness

E : Foofwit..
E : Rear wirahamcss
23-64
Rioht
- r
| tdltqhr
Lsft r
Rioht l
reea$o€ m€ncr ||gnt
L!-ft J
Poworantonnanrotor
tt*-I"'unn
I
Re.r window defogg6{
otot
E : Rearwnehmess
@ : sRsmainhan€ss
E : R€$windo\N groundwir€
dofoggor
23-65
Battery
@
a Baftery tluid (olectrolyt€l contains sulfuric acid. tt may causo aavolo burns if it gots on your skin ol In your 6yoa.
Wear protoclivo clothing and a face shiold.
- lf oloclrolyta g6ts on your skin or clothos. nae it off with wat€r immediatoly.
- It electrolyta gots in your €yes, flush it out by splashingwatar in your oy63 tor at least 15 minutes; call a physician
imm€diatoly.
a A batto.y gives off hydrogan gas. ll ignit6d, tho hydlogan will oxplode and could crsck tho battory caro and aplattol
acid on you. Keep sparks, tlames. snd cigatettes away flom tho battory.
a Overchargingwill raiso tha tamperature ot tho oloctrolyte. Thb may forco ol6ctroly'toto splay out of tho battory vontE'
Follow the chargor manufactulor's inatructions and chargo tho battory at a propol tato.
Use eithef a JCI or BearARBSTtester. and follow the manufacturer'sproc€dures.l{ you don't have one oJ these com-
puterizedtesters,follow this conventionaltest procedure:
To get accurateresults,the temperatureot the electrolytemust be between TOoF l21oCl and IOOoF (38oC).
lJ the case is cracked or the terminals are

loose, replace the baftery.
lf the indicator shows low electrolvte,

distilledwater it Dossible.
Test Load Capacity(# 1l

. Apply 300 amp load for 15 secondsto remove
surfacecharge.
. Allow 15 secondsrecovetyperiod.
. Apply test load {see Test Load Chart).
. Recordvoltage at the end oJ 15 seconds.
Voltage stays above 9.6

volts; battery is OK,
23-66
Chargeon High Setting (4O amps)
Chargsuntil EYEshows chargeis OK; plus an
additional30 minutesto assuretull charge.
NOTE:lf the battery cha,ge is very low, it
may be necessary to bypass the charger's
polarity protection circuitry.
lf the EYEdoes not show chargeis OK within
three hours, the baftery is no-good; replace it.
Write down how long the battery was
charged.
Test Load Capacity( # 2)

Apply 30O amp load lof 15 secondsto removesurfacecharge,
Allow 15 secondsrecoveryperiod.
Apply test load (see Test Load Chart).
Recordvoltage at the end of 15 seconds.
Voltage stays abov€ 9.6 volts; battery is OK. Voltage drops below 9.6 volts; battery is
no-good.
80D26L-MF
TI
I_ BATTERYCODE
TEST LOAD CHART
Use the test load ot 112the cold crankingamps (CCA)print-
ed on the labelon the top ot the baftery. lf neitheris indicat-
ed, use the informationbelow:
BATTERY COLDCRANKING LOAD
CODE AMPS (CCA) I (amps)
80 550 270
70 440 220
55 405 200
23-67
3. Removethe dashboardlower cover, knee bolster,

a All SRS elect cal wiling halnesses are covered with
yellow outer insulation. and heaterduct,
a Belorodisconnectingthe SRSwirs harnoss,installthe
short connecto.(s) on the airbag(sl (see page 23-2941,
a Roplac€th€ ontile aftected SRS harn$s assembly if
it has an opon ci.cuit or damaged wiring.
NOTE: The radiomay havea codedtheJtprotectioncir-

cuit. Be sureto get the customer'scode numberbeJore
- Removingthe No. 43 (1O A) fuse.
(ln the under-hoodfuse/relavboxl
After service.reconnectpower to the radioand turn it on.
DASHBOARDLOWERCOVER
4. Remov€the door sill moldingand left kick panel
Removal:
1. Disconnectboth the negative cable and positive
cable from the battery.
2. Removethe driver's foot rest.
23-68
5. Disconnectthe 16-Pconnectorfrom the integrated Installatioo:
control unit. 1. Reconnectthe connectorsto the fuse/relaybox.
o. Remove the mounting bolts and pull the fuse/relay NOTE: To reinstallthe SRSmain harnessconnector,
box away from the kick panel. push it into positionuntil it clicks, then closethe con-
nector lid.
UNOER-DASH
FUSE/RELAYBOX 2. Installthe under-dashfuse/relaybox.
3. Reinstallthe kick panel and door sill molding.
4. Reinstallthe knee bolster and dashboardlower

cover.
Connectboth the negativecableand positivecable

to the battery.
6. Confirmthat all systems work properly.
Disconnectthe fuse/.elaybox connectorsand take

out the tuse/relaybox.
BOX
FUSE/RELAY
UNDER-DASH
SRS MAIN
HARNESS
NOTE: The SRSmain harnessconnecto.is double-

locked.To removeit, first lift the connectorlid,then
pressthe connectortab down and pull the connec-
tor out.
23-69
Power Relays
RelayTest {A-tYPe)
NOTE: See page 23-198 for the tu,n signal/haz8rd .e-
lay input test and see page 23-236 for the seat heater a Seat heater main relaY
relav test, a ABS front fail-s8ferelay
a ABS rear fail-saferelay
1. Removethe power relay from its socket.
2. Check continuitybetween relay terminals.
a Thereshouldbe continuitvbetweenthe C and D ter-

minals.
a Thereshouldbe continuitybetweenthe A and B ter-

minalswhen power and groundare connectedto the
C and D terminals.Thereshouldbe no continuitv when
oower is disconnected.
a Starter cut relay

a Horn relay a Condenserfan relay
a Cigarettelighter relay a A/C comoressorclutch relav
a Power window relay
a Blower motor relay
a Radiatorlan relay
23-70
a Hsadlightrelay
a R6ar window defogger r8lay
a ABS motor relav
23-71
Power Relays l1
Relay Test (B-typel
Remove the power relay from its socket. a Windshieldwiper intermittentrelay
Check continuity between relay terminals,
Thereshouldbe continuitvbetweenthe A and C ter-

minalswhen power and groundare connectedto the
D and E terminals.
Thereshouldbe continuitybetweenthe B and C ter-
minals when Dower is disconnected,
I
a Dimmerrelay
a Sunroof open .elay

a Sunroofclose .elav
D B E
A C o
E+,6
7"-'
23-72
lgnition Switch
Test
CAUTION: 3, Checkfor continuitybetweenthe terminalsin each
a All SRS oloctrical wi ng harnassesar6 covorod wlth switch positionaccordingto the table.
yellow out€l insulation.
a Boforedisconnectingtho SRSwira hsmess. instsll the
shon connsctor(s) on the airbag(s) {soe page 23-29a1. rernrnsl WHT/ BLK/ YEL BLU/
a Roplacothe ontire affected SRS harne$ assembly it
\ BLK WHT YEL flG2t WHT
it has an open cilcuit or damagad wiring, Position tAcc) IBAI) Gl) {sT)
0
-o
tl o-- -o
Il o- --o
SRS MAIN HARNESS
1 . Removethe dashboardlower cover, left kne€ bol-

tE,
ste.. and left kick panel (see page 23-68).
Disconnectthe 5-P connectorfrom the under-dash

fuse/relavbox and disconnectthe 3-P connector
from the main wire harness.
3-P CONNECTOR
(Main wire harnessside)
ST IBLK/WHT}
3.P CONNECTOR
UNDER-DASH
BOX
FUSE/RELAY
5.P CONNECTOB
SOCXET
23-73
lgnition Switch
ElectricalSwitch Replacement
CAUTION: 3. Disconnectthe 5-P connectorJromthe under-dash

a All SRS €lectlical wiring harnossrr are covorod with fuse/relav box and disconnect the 3-P connector
yollow outor insulation. from the main wir€ harness.
a Boforo disconnocting the SRS wir6 h.mo$, install th€
shon connoctor on the airbag{sl (3oo pag6 23-2941.
a Replacethe entilo affactod SRS hEmossa$ombly it
it has an open circuit or damagsd wiring. 3.P CONNECTOR
(Main wiro harness sid6l
NOTE: The radiomay havea codedthett protectioncir-
cuit. Be sure to get the customer's code number before
- Removingthe No. 43 (1O Al fuse.
{ln the under-hoodfuse/relaybox) 3-P COl{ ECTOR
After se.vice,reconnectpower tOthe radioand turn it On.
4. Insert the key and turn it to "O",
Removs thg cover screw and ths cover.
SRSMAIN HARNESS R€move the two mounting scrsws and replaco the
'1. Remove switch.
the dashboard lowsr cover and let't knee
bolster.
2. Removethe steeringcolumn covers.

UPPERCOLUMN COVER
MOUI{TING SCREWS
23-74
Steering Lock Replacement
CAUTION: 4. Centerpunch each of the two shearbolts and drill

a All SRS eleclrical wiring hslnossos aro covated wlth their h€ads off with a 5 mm (3/ 16 in.) drill bit
yollow outar insulation.
a Bololo disconnocting the SRS wile hamoss. install tho CAUTION: Do not damage tho switch body whon
short connoclor(slon tho airbag(sl(saopage 23-294). romoving the shoar bolts.
a Roplacoth€ ontiro aftect€d SRS harneasassembly lf
it has an open cilcuit or damagad wiring'
NOTE: The radio mav have a coded thett protection cir-

cuit. Be sureto get the customer'scode numberbefore
- Disconnecting lhe battery.
- Removingthe No. 43 (1O Al fuse.
{ln th€ under-hoodfuse/relaybox)
After service,reconnectpower to the radioand turn it on.
"COOE" is displaved,enter the cus-
When the word
tomer's 5-digit code to restoreradio operation,
5. Remov€ the shear bolts trom the switch body.
6. Installth€ new steering lock without the key in-

sened.
Loosely tighten the new shear bolts.
8 . Insert the ignition key and check for proper opera-

tion o{ the steeringwheel lock and that the ignition
key turns freely.
:
9 . Tighten the shear bolts until the hex headstwist oft.
Removethe dashboardlower cover, left knse bol-

ster, and lett kick panel (see page 23-68).
SHEAR BOLT
Disconnectthe 5-P connectorfrom tho under-dash

fuse/relaybox and the 3-P connectorfrom the main
wire harness.
Remove the steering column covers {see page

23-74t.
lll
TWIST-OFFPORTION
23-75
StartingSystem
ComponentLocation Index
A/T GEAR POSITION

swtTcHtA/Tl
{!nd NEUTRALPOSITIONSW|TCHI
Test. page 23-148
Replacoment. pago 23-149
BATTERY
Test. page23-66
i:T:i,Ii5i?* sw'rcH
rM/rl
Switch PositionAdjustment,s€ction 12
STARTER
T6st, page 23-79
Solenoid Test, pag€ 23-83
Overhaul, page 23-82
Reassembly,page 23-87 _lEr_
f-l-D
CUTRELAY(M/TI
STARTER
Wir6 color': BLK/WHT,
BLKAA'I{T,BLK/GNN,
--f--r
lnd 8LK/RED
Test, page 23-70
r-:-r lFl
-L-----l
--:--rl
r-rr1
l|
*
rfltll'l
l]0mmm[[|l
|Jmm[0[D0lj
23-76
Description
Startsr Intorlock Syslom {M/T):
The starter interlock system prevents the engine trom starting unless the clutch pedal is fully depressed.
The clutch interlockswitch turns on at the positionwhere the clutch disengages:15-20 mm {O.59-0.79 in) from the
fully depressedpositionoJ the clutch pedal.
NOTE: A full stroke of the clutch pedal is 135-145 mm (5.3-5.7 in) from the fully releasedposition
CLUTCH INTERLOCKSWITCH
135- 145 mm
{5.3-5.7 inl
Fully D6pro$od
Posidon
23-77
StartingSystem
Circuit Diagram
- HOODFUSE/RELAY
UNO€R 8OX t6Nfir0N
swTcH
$/Hr-o
l;\
crj
\87
I
BLl(A,t/l{T
{A/n I
r--------------------------r
NEUTMI-
POStTtoN
swtTcH
/ InA/Tg€er \
\ po€itionBwilch /
BLXNEO
I
T-r--'l
| )u.z luNo€F-oAsH
I k {7,5A)|RSEinELAYSOX
r I I
I
8t-u/RED
I
f7
. ECM
' PGM- FIMAIiIREI.AY
. BSAKECHECK CIRCUIT
STATTER
23-7a
StarterTest
'1.
NOTE: The air temperaturemust be between 59 "F and Disconnectthe 4-P connector from the ignition
10O oF (15 oC 8nd 38 oC) betoretesting. coil.
Rccommandod Procedure:
a Use a starter systsm tester

a Connect and oporate ths equipment in accor-
dance with manutacturer's instluctions.
a Test and tloubl€shoot as d€scribed.
Altornat€ Procedura:
Use the followingequipment:

- Ammeter,O-4O0 A
- Voltmeter, O-2O V {accurate within O.1
volt)
- Tachometer,0- 12OOrpm
Hook up voltmeterand ammeteras shown.
Check the starter engagement:

Pressthe clutch pedalall the way in (M/T).and turn
"START". The startershould
the ignitionswitch to
crank the engine.
NOTE: On carsequippedwith manualtransmission,

the enginewill not crank unlessthe clutch pedalis
fully depressed.
a lf the starter does not crank the engine,check the

battery, battery positive cable. ground, €nd the
wire connections for looseness and corrosion.
a Test again.
lf the starter still does not crank the engine,
bypassthe ignitionswitch circuit as follows:
Unplug the BLK/wHT wire trom the solenoidter-
minal. Connecta iumper wire ttom the battery
Dositive(+ ) terminalto the solenoidterminal.The
starter should crank the engine.
NEGATIVETERMII{AL
NOTE: After this test, or any subsequent repair,

resetthe ECMto clearany codes (seesection 1 1).
{cont'd)
23-79
StartingSystem
StarterTest (cont'd)
- lf the staner still does not crank the engine, re- Check crsnkingrpm:
move the starter and diagnose its internal Enginespeedduringcrankingshouldbe above 1O0
problems. rom.
- lf the starter cranksthe engine,check for an open lf soeed is too low, check tor:
in the BLKMHT wire and connectorsbetweenthe
starter and ignitionswitch. a Loose battery or starter terminals.
Check the ignitionswitch. a Excessivelyworn starter brushes.
On cars with automatictransmission,check the a Open circuit in commutatorsegments.
A/T gear positionswitch (neut.alpositionswitch). a Dirty or damagedhelicalsplineo. drive ge8r.
and connectors. a Defectivedrive gesr overrunningclutch.
On cars with manual transmission.check the
starter cut relay, clutch interlockswitch, and con- o. Check the starter disengagement:
necrors. Pressthe clutch pedalallthe way in {M/T},turn the
ignitionswitch to "lll" and releaseto "ll" position.
NOTE; Checkthe No. 33 (50 A) fuse in the under- The starter drive gear should disengagefrom the
hood Juse/rel8ybox and the starter cut relay, flywheel ring gear.
Check for wear or damage: lJthe drivegearhangsup on the flywheelring ge8r,

The startershould crank the enginesmoothly and check for:
steadilv.
a Solenoidplungerand switch malfunction.
lf the starter engages, but cranks the engine errati- a Dirty drive gear assembly or damaged overrun-
cally, removethe startermotor. Checkthe starter, ning clutch.
drive gear, and flywheel ring gear for damag€.
Check the drive gear overrunning clutch for binding
or slippingwhen the armatureis rotated with the
drive gear held. Replscethe gears if damaged.
Check crankingvoltage and current draw:

Voltageshould be no less than 8.5 volts.
Currentshould be no more than 38O amoeres.
lf voltage is too low, or current draw too high, check
for;
a Low batterv.
a Open circuit in starter armature commutator
segments.
a Starterarmaturedragging,
a Shortedarmatur€winding.
o Excessivedrag in engine.
23-80
Clutch InterlockSwitch Test (M/Tl Starter Replacement
Remove the dashboard lower cover and knee NOTE: The radiomay havea codedtheft protectioncir-
bolster, then disconnectthe 2-P connectortrom cuit. Be sureto get the customer'scode numberbeJore
the switch. - Disconnectingthe battery.
- Removingthe No.43 (10A)fuse.
Check for continuitv b6tween the terminals accord- (ln the under-hoodfuse/relavbox)
ing to the table. - Removingthe radio.
Atter service,reconnectDowerto the radioand tu.n it on,
"CODE" is displsyed,enter the cus-
When the word
\ Terminsl tomer's 5-digit code to restoreradio operation.
A B
.*.n*o]---\ 1. Disconnectthe negativecable trom the battery,
RELEASEO
Removethe enginewire harnessfrom the harness
PUSHEO G- o 2.
clip on the starter motor.
3, Disconnectthe startercabletrom the B terminalon

the solenoid,8nd the BLKMHT wire trom the S
terminal.
NOTE: In case of an A/T model, the starter cable

slso has to be removed from the bracket on the
transmissionhousing.
4. Removethe two mountingbolts holdingthe start-

er, then remove the starter molor.
? lJ necessary, r€pl8ce th€ switch or adjust the

switch Dosition{sse section 121.
fl
9 N.m lO.9 kg-m, 6.5 lb-ftl
23-41
StartingSystem
Starting Overhaul
CAUTION: B€toro l€moving th6 starta., disconnect tho
ground cable from the battory.
BRUSHHOLDER
ARMATURE OVERRUNIIII{G
CLUTCH ASSEMBLY
ENO COVER
\-s
?
>*'N-
with PERMANENT
MAGNET
GEARHOUSING
@
l
\
LABYRINTH
TUEE
NUT
9 N.m (0
GEARHOUSING
COVER
soLEt{otD
Test, page 23-83
Wq )o.*o'o
m"r"
23-82
Starter SolenoidTest
'|, Removethe stsn€r solenoid.
2. Checktor continuitybetweenthe terminalsin each PULL.INCOIL COIL

HOLD.IN
solenoidplungerpositionsccordingto th€ table,
\ Terminal
R M s GITUUNU
Position
RELEASED
PUSHED o-
SOLENOIOHOUSI G IGROUT{D)
23-83
StartingSystem
Armature lnspectionand Test
1. Inspectthe armaturesurfacefor wear or damage. Commutator Runout
Standard{Now}; 0-0.02 mm {0-0.0008 in)

Inspecl tor
SsrvicsLimit : 0.O5 mm (0.002 inl
damage.
A dirty or burnt commutatorsuriacemay Deresur-

faced with emerycloth or a lathewithin the tollow- COMMUTATOR
ing specificstions.
Commutator Diametot
lf the commutatorrunout and diamet€rare within
limits,checkthe commutatorfor damageor tor car-
Standard(Newl: 28.0-28.1 mm
bon dust or brasschips betweenthe segments.
{ 1 . 1 O 2 -1 . 1 O 6i n l
SoruiceLimit ;27.5 mm (1.O8inr
4. It the suriaceis dirty, reconditionit with a #SOOor
#600 sandpap€r. Then, check mica deDth. ll
necessary, undercut the mica with a hacksaw
blad6to achieveproperdepth.
VEBNIERCALIPER
Commutator Mica D€pth
S t a n d a r d( N e w l : 0 . 4 - O . 5 m m ( 0 . 0 1 6 - 0 . 0 2 0 i n )
ServiceLimit : 0.15 mm {0.006 in}
23-a4
5 . CheckJor continuitybetweenthe segmentsof the 7 . With an ohmmete.,checkthat no continuityexists
commutator.lf an open circuitexists betweenany between the commutatorand armaturecoil core,
segments.replacethe armature. and betweenthe commutatorand armatureshaJt.
lf continuitvexists, replacethe armature.
COMMUTATOR
COILCORE COMMUTATOR
6. Placethe armatureon an armaturelesler. Hold a

hacksawblade on the armaturecore.
ARMATURETESTER HACKSAW BLADE
ARMATURE
I
It the bladeis attractedto the coreor vibrateswhile

the core is turned,the armatureis shorted.Replace
the armature.
23-85
StartingSystem
Starter Brush HolderTest Starter BrushInspection
1. Check that there is no continuity betweenthe @ Measurebrush length. It not within the service limit,
and O brushholders. replace the armature housing and brush holde.
lf continuity exists, replace the brush holder assemblv.
assembly.
Brush Length
Standa.d(Newl: 15.8-16.2 mm (0.62-0.64 in)
O EBUSHHOLOER O BRUSHHOLDER Sarvice Limit : 1O.Omm {O.39 in}
@ BRUSHHOLDER @ ERUSHHOLOER
2. Insertthe brushinto the brushholder,and bringthe

brush into contact with the commutator,then attach
a springscaleto the spring.Measurethe springten-
sion at the moment the spring lifts off the brush. NOTE: To seat new brushes after installingthem in
their holders, slip a strip of #5OO or #600 sandpaper,
with the grit side up, over the commutator, and
SpringTension smoothly rotate the armature, The contact surface of
16-18N the brusheswill be sandedto the same contouras the
[/ itsuba
( 1. 4 K W ) commutator.
{1. 6 - ' l . 8 kg, 3.5-4.O lbs)
Mitsuba 1 6 - 1 8N
{1.6KW) {1 . 6 - 1 . 8k g , 3 . s - 4 . O l b s )
SPRINGSCALE
23-86
OverrunningClutch Check Startel Reassembly
trI
1 . Check that the overrunning clutch moves along the Reassemblethe starter in the reverse order of
shaft frsely. lf not, replace it. disassembly.
Checkthat the overrunningclutch locks in one direc- l. Pry back each brush spring with a screwdriver,
tion and rotates smoothly in reverse. lf it does not then position the brush about haltway out of its
lock in eitherdirectionor it locks in both directions, holder,and releasethe springto hold it there.
reDlaceit.
2. Installthe armaturein the housing.Next pry back

each brush spring againand push the brushdown
until it seats against the commutator, then release
the springagainstthe end ot the brush.
Checkthe starterdriv€ gear for wear and damage.

lf the gear is worn or damaged, replacethe overrun-
ning clutch assembly; the gear is not available
separately.
NOTE: Check the condition ot the flywheel or tot-

que conv€rter ring gear if the starter drive gear teeth
aw
are damaged.
3. Installthe end cover on the brush holder.
BRUSHHOLDER
23-87
Starting System
PerformanceTest
NOTE: Beforestarting the following checks, disconnoct Retlactlng Test:

the wire from terminal M,8nd make a connectionas Also disconnect the battery from the body. lf the pinion
describedbelow usingas heaw a wire 8s possible(prefer- retracts immediately, it is working properly.
ablv equivalentto the wire used tor the car).
NOTE: Do not l6avethe battery connectedJor more than
Pull-in Coil Test: 10 seconds.
Connect the baftery as shown. lf the pinion protrudes,
it is working properly.
NOTE: Do not leavethe battery connectedfor more than

1O seconds,
Hold-in Coil T€sl:

Disconnect the battery from the M torminal. lf the pin-
ion does not retract, the hold-in coil is working proporly.
NOTE: Do ;ot bave the batt€ry conn€ctodfor moro than

1O seconds.
23-88
Start.l [tlo-loadTest:
1. Clamp the stsrter firmly in a vise.
2. Connect the starter to the battery as described in

the diagrambelow and confirm that the motor starts
and keeps rotating.
3. lf the electric current and motor soeed meet the

specifications when the battery voltage is 8t 1 lV,
the staner is working prop€rly.
Spocitication6:
Mitruba: 80 A 01 los! (aloclric currsnt),

(1.4KW) 2600 rpm 01 mote (motor spoodl
Mitsuba: 80 A or less (el€ctric curont),

{1.6KW) 2600 lpm or mor. {moior spccd}
23-89
lgnition System
ComponentLocation Index
IGNITIONTIMIITGCONTROLSYSTEM
. Description,page 23-91
. Troubleshooting,section 11
.Inspection and S€tting,page 23-93
TESTTACHOMETER
DISTRIBUTOR
Top End Inspection,page 23-95
page 23-95, 97
Removal/lnstallation,
IGNITIONCOIL
Test, psge 23-1O0
Overhaul,page 23-96
Reassembly,page 23-99
lgnirioncontrol Modu16{lcM) SERVICECHECK COT{NECTOR
{2.P)
Troubleshooting, section 1 I
ICM Input Test, Page 23-98
IGNITIONWIRES
Inspection and Test, page 23-99
SPARK
Inspection,page 23- 1O1
23-90
Description
lgnllion Timing Control:
The programmedignition (PGM-|G)used in this engineprovidesoptimum control oJ ignitiontiming. A microcomputer
determinesthe timing in responseto engine speed and manifoldvacuum. The input signalsare transmittedby the
TDC/CKP/CYPsensor,throttle position (TPl sensor,enginecoolanttemperature(ECT)sensor,and MAP sensor.This system,
which is not dependenton a governoror vacuum diaphragm,is capableof sefting leadangleswith complicatedcharac-
teristicswhich cannot be providedby conventionalgovernorsor diaphragms.
Enginecoolanttemperature(ECT)com-
pensation
Basic Control:
The controlunit has storedwithin it the optimumbasicignitiontiming for ope.atingconditionsbasedupon enginespeed
and intakemaniJoldpressure,With compensstingsignalsfrom sensors,the system determinesoptimum ignitiontiming
and durationfor ambientconditionsand sends vottagepulsesto the lCM.
Compensationof ignitiontiming:
Compensationltem RelatedSensorand Information Description
ldling TDC/CKP/CYPsensor lgnitiontiming is controlledto the ta.get speed

MAP sensor with compensationaccordingto the idling speed.
Comoensationat warm-up ECTsensor Lag angle is adjustedaccordingto warm-up con-
ditions to bring about a good balancebetween
operatingperformanceand exhaustgas level.
ECT compensation ECT sensor Compensationfor lead angle at low engine
coolant temperatureand lag angle at high engine
coolanttemDerature.
Control at Start:
lgnitiontiming is fixed at 7o BTDCJorcranking.The crankingis detectedby the TDC sensor(crankingrpm) and slarter signal.
23-91
lgnitionSystem
CircuitDiagram
- HOODFUSEiRELAY
UNOER BOX
""7
rcNtTtof{
swfTcH
ECM
IGNITION
COIL
DISTTIBUTOR
ASSEMELY
il:-,
TDC/CKPrcYP
SENSOR
-.-:1_-
| *,*t1*u
++ . TACHOMFIER
. TnANSMISSION
CONTROL
MODULEfICM)
' CRUISECOMTROT
UNIT
23-92
GaugeAssembly
CircuitDiagram
- HooD
u DER FtSEÊLAY
Box ittilfl8'I
T'ffi;ffi*"l
( + )+.-c'\-o.<\o+wtn-to
6),, BtK,YEt
\_/ rco/-
UI{DER.DASH
FUSSRELAY
80x
r- BUVYEI
-iet'-
I TMNsMtsstoN
I COMTRO|
No.6lt20a)
l2O I MoDULE
{rCM)
FUSE
Y lt w
l l GRNiORN
R EOTYEI YEL I
I YEr, I
MAINGAUGE
ASSEMSIY
-[r-]^' ll:'
++++
l t l
=;;;-
HIGH
BEAM GAUGE INDICATOR
POSITION
INDICATOR LIGHTS DIMMING
CIRCUIT
UGHT {3Wx5l
l1.4Wt
$ RED/BLU
l"
Btt(
l82
I
RED
I
II
I
I
D MEN
FELAY
Y
DASHUGHTS
BRIGIITNESS
couTRot
UNIT
G10t
G40z
G404
23-126
t
I
tcn|T,oN
CONTROL
MOOULE
0cMl
\--7
I
BLU
183 '---l
snmn I
MOTOR
. 4WSCONTBoLUNTT I
. TnANSMTSSTON I
PNK COMTROL {TCMI ORN
MOOULE
I
. CRUISE
CONTROT
UNIT
. ECM
-r_ J_ Y_",_
4WS
COMTROI
UNIT
23-127
GaugeAssembly
CircuitDiagram(cont'd)
COMBINATION No.2(7.5A)
LIGHT
SWITCH FUSEISTsigml)
Y
II
RED/BTK
Y
BLU/REO
cRursE
CONTROL
UNIT
23-128
l
I
t
t - - - - - - - - l
; LIGHTTUBE
FLUOBESCENT
L______________---____J
FUEU€NGINE TEMPEMTURE
COOIATIT IECT]
COMTROI.CIRCUIT
D4
t-+
|
\---J
I
I t
F+t
I INTEGMTED
coNrRoLUNlT
I
8\ ENGINEo|L
!. , PiESSURE
:I/ SWTCH
A8SCONTROL
UNIT
23-129
GaugeAssembly
Removal
CAUTION: 2. Removethe screws and the instrumentpanelvisor.

a All SRS el€ctrical wi ng harnossesar€ covered with
ysllow outor insulation.
o Before disconnecting th6 SRS wire harn6ss, install
the short connoctor(s) on th6 airbag(s) (see page
23-294t.
a Roplacothe entir€ affected SRS harnossassembly if
it has an open cilcuit or damaged wiring.
. After inst8lling tho gauge a$embly, rechock tho
op€ration ot the SRS indicator light.
NOTE: The radiomay havea codedtheft protectioncir-

- Disconnectingthe battery,
- R e m o v i n gt h e N o . 4 3 ( 1 OA ) f u s e .
(ln the under-hoodfuse/relaybox)
Removingthe radio.
Aiter service,reconnectDowerto the radio and turn it
on. When the word "CODE" is displayed,enter the
customer's 5-digit code to restoreradio operation. t Removo th€ screws and the black face pan6l, then
disconn6ct the 6-P connector fiom ths clock reset
switch.
cot{t{EcToR
BLACTFACEPANEL
1. Removethe tweeter covers trom the dashboaad,
covERs
23-130
Main Gauge Assembly: Sub Gaugs Assembly:
4. Remove the four screws from the main gauge 6, Remove the four screws from the sub gauge
assembly. assemblv.
MAIN GAUGEASSEMBLY
Place a cloth over the dashboard to prot€ct the 7. Placea cloth over tho dsshboardto protect the sub
gauge assembly,then pull the assemblyout and
main gauge assembly,then pull the assemblyout
and disconnectits connectors. disconnect its connectors.
23-131
GaugeAssemblY
BulbLocations
Main Gaugo Ass€mblyi
HIGH BEAM II{DICATORLIGHT II.4 W}
rl{DtcaToRLTGHT
t1.4 W)
RIGHTTURN SIGNAI-IT{DICATORLIGHT (1.4 W}
sRs tNDtcatoF UGHTtl.4 Wl
4WStNDtCATOn (1.4Wl
LTGHT
GAUGEucltTs {3 w r 5l
23-132
Sub Gaugs Assombly:
LOW FUELINDICA?ORLIGIIT 13 WI
CRUISELIGHT I3.2 W)
LIGHT(3 WI
ABSIT{DICATOR
I
l
BNAKESYSTEMLIGHT13W}
INDICATOR
LIGHT13W)
{Caogda) SEATBELTREMII{DERLIGHT(3 WI
CHARGIXGSYSTE'{ UGHT 13 WI
BRAKEBULB Tnu x r{lxcAToR
tf{DtcAToRIIGHT 13Wl LIGHi (3 Wl INDICATORLIGHT {3 WI
LOW OIL PRESSURE
MALFUNCTIONINDICATOR
LAMP (MIL}
(3 Wl
23-133
GaugeAssembly
Disassembly
Main Gsug€ Assembly: SRSINDICATOR
MOUNTINGSCREWS
(x2)
NOTE:
a Handle the terminals and Drinted circuit boards
carefullyto avoid damagingthem.
a lf either the speedometeror the tachomet€r is faulty,
reolacethem both as a unit.
SPEEDOMETER
ilil0iltltil
lt0tl||Tilil
[0ffi[
L0l
MOU TI c SCREWS
lx3l
PRINTEDCIRCUITBOARD C
HOUSTNG
G ODO/TRIPMETER
6- sd page23-136
ra
/
r{e)
SRS INDICATORPANEL
FACEPAITEL
TACHOMETEB
Specificstion, page 23-124
PNI TED CIRCUITBOARD B

{-'2\:.
PRINTEDCIRCUITAOAROA
Sp€cificstion,
page 23-124
vtsoR
23-134
Sub Gaugs Assembly:
NOTE: Handle the terminals and printed circuit

boardscarefullyto avoid damagingthem.
PRINTEOCIRCUITBOARD/REARCOVER
MOU TI[{G SCREWS(x 161
FUEL/ENGINECOOLANT
TEMPEBATUREIECTI
GAUGE
Test, p€ge 23-139, 142
PNI EO CIRCUIf BOARO BOX PRII{TEDCIRCUIT
FROIIT HOUSING
23-135
Meter/Odometer
Speedometer/Trip
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.
Item to be inspected
:
a 'i
9>. @
{ o -
a 3 c
- .c. c
3
!
E : P E
z E E 'E v x
o:-
?i o)
3 f @
E i o
Symptom l/, (L ; d
Odometerand trip meter work, but speedometerdoes

n01.
1
Speedometerworks, but odmeterand trip meter do

not. 1 2 3
Speedometer,odometer,and trip meter do not work. 2
N O T E : V S S g r o u n di s v i a E C M ( G 1 O 1 ) .
VSS Input Test (At hahess side of 3-P connGctorl

No. Wire Test condition Tost: DosirEdl€sult Possiblecause il .esult is not obtained
BLK Underall conditions Checkfor continuityto ground: . An open in the wire.
Thereshould be continuity. . P o o rg r o u n d( G 1 0 1 ) .
BLK/YEL lgnitionswitch ON Checkfor voltageto ground: . B l o w nN o . 2 3 { 15 A ) f u s e
Thereshouldbe battery . Short to ground
voltage.
3 ORN lgnitionswitch ON Check for voltageto ground: . Short to ground
There shouldbe about 5 V . An open in the wire.
NOTE: A short to ground in the ORN wire can be causedby a short in anv comDonentconnectedto it.
VSS Test View from terminal side

Speedometer does not woIk.
lnspect No. 23 (15 A) luse in CONNECTOR

undeFdashfuse/relaybox before
testing.

BLK/YELwire terminal and the
BLK wire terminalin the harness
sadeol the 3 P conneclor.
(To next page)
23-136
(FrompreviousPage)

ls there battery voltageT the BLK terminal and body
ground.
Measure voltage belween the Repair op6n between VSS and

oRN and rhe BLK wire terminals. ground G101 via ECM.
Ropairop6n in tho BLK/YELwiro,

ls thereabout5 V? botwoen tho VSS and th€ undor-
d6sh lus6/relay box.
Raise the lront oI the car and Repatuopon in ths ORN wi.s or
supportil with stands. shon to body grcund.
Touch a probe to the ORN wire

and connect it to body ground
througha voltmeter.
Slowly rotateone wheelwith the

other wheel blocked.
DoesvoltagepulselromOto Roplaca the vss (soe Page

about 12 V? 23-138).
Disconnectthe 16-P connector

at the speedometer,
Touch a probe to the ORN wire

and connect it to body ground
through a voltmeter,
Slowly rotate one wheel with the

other wheel blocked.
Repairop6n in tho ORN wir€ be-

Doesthe meterindicate tw6€n the VSS and the sp6odo-
pulsingvoltage? meter.
EngineLow Oil Pressure
VehicleSpeedSensor(VSS) IndicatorSystem
Replacement Switch Test
Disconnect the 3-P connector from the vehicle 1. Remove the YEL/REDwire from the engine oil
speedsensor (VSS). pressureswitch.
Removethe mountingbolts, then removethe VSS. 2. Checkfor continuitybetweenthe positiveterminal

and the engine (groundl,
NOTE: The VSS drive link is a very small part, be
careful not to lose it. a There should be continuity with the engine
stopped.
a There should be no continuitywhen the engine
runs.
3-P CONNECTOR
ENGINEOIL PBESSURESWITCH
18 N.m (1.8 kg-m, 13.0 lb-ftl
1/8 in. BSP(EritishStandard
PipeTaper)28 threads/inch.
OIL FILTER Use proper liquid sealant.
3. Installin the reverseorder of removal.

POSITIVETEBMINAL
YEL/REDWIRE
3. lf the switch fails to operate,check the engineoil

level.lf the engineoil levelis OK, checkthe engine
oil pressureand, it necessary,inspectthe oil pump
(seesection 8).
23-138
FuelGauge
GaugeTest
NOTE: Reterto page 23- 129 for the circuitdiagramof Turn the ignition switch OFF. Connect a iumper
the fuel gauge. wire between the YEL/GRN and YEL/WHT
terminals.
1. Check the No. 13 {1O A) fuse in the under-dash
tuse/relaybox beforetesting. CAUTION: Do not connect power and ground to
th€ lerminals; it will damage th6 luel gaugs.
2. Open the trunk,
7 . Turnthe ignitionswitch ON, and checkif the gauge
"F"
3. Removethe fuel tank accesspanel. indicates
4. Disconnectthe 5-P connectorfrom the fuel gauge CAUTION: Disconn€ct the iumpor rYireas soon as
"F", or you will damags the
sendingunit. the gaugs r6aches
gau9e.
a ll the fuel gaugedoes not work at all, replaceit.

a lf the fuel gaugeis OK, inspectthe sendingunit
YEL/GR CONNECTOB
-L
I r t,---t I
Fi!.-1---1
I'--'-r---
l l t I
YEUWHT
5. Connect the voltmeter positive probe to the

YEL/GRNterminaland the negativeprobeto body
ground,then tu.n the ignitionswitch ON.
There shouldbe between 5 and 8 V.
a lf the voltage is as specitied,go to step 5.

a lJ the voltageis not as specitied,check for:
- An open in the YEL or YEL/GRNwire.
- Looseor disconnectedterminals.
- Faultytuel gauge.
23-139
FuelGauge
SendingUnit Test
@ Do not smok€ whils working on ths fuol b. Check the resistancebetween the B and C ter-
systom. Ko6p open flame away flom th€ work aroa. minals.lt shouldchangeevenlyas you changethe
positionof the tloat.
1. Open the lrunk.
a lf it does not change evenly, replacethe fuel
2. Removethe fuel tank accesspanel- sendingunit.
a lf it changesevenly, go to step 7.
3. With the ignition switch OFF. disconnectthe 5-P
connectorfrom the fuel gauge sendingunit. 7 . Support the sending unit on a workbench in the
positionshown.
4. Removethe five nuts. then take the sendingunit
assemblyout of the fuel tank,
Top ot tho wortb.nch (Bottom ol tho tuel tank)
8. Measurethe resistancebetween the B and C ter-

minals by moving the float to the distanceslisted
Jor E (EMPTY),1/2 (HALF FULL).and F (FULLl.
Float Position E 1t2 F

ResistancelO) 16-32 1 1 6 - 1 8 8 2 3 9- 3 1 4
E F
Measure the resistance between the A and B
20.5 mm 73.6 mm 126mm
terminals.
( O . 8 0i n ) (2.90in) l'4.7 inl
a It it is more than about 27O-33O O, reDlacethe
tuel sendingunit.
. lf it is within about 27O-33O O, go to step 6. 9. lf unableto obtain the above readings,replacethe
fuel gauge sendingunit.
23-140
Low Fuel IndicatorSystem
Indicator Light Test
NOTE: Referto page23-127 for the diagramof the low 4. Removethe fuel tank accesspaneland disconnect
fuel indicatorcircuit. the 5-Pconnector{rom the fuel gaugesendingunit.
Connect the GRN/WHTterminal to the BLK ter-
Parkthe car on level ground. minal with a iumper ware.
Do not smoke whil€ working on the It the light comeson, the problemis the sending
E@
tusl system. Keep open flamo away lrom tho wolk unlt.
area. Drain tuel only into an apploved container. lf the light does not come on, the problemis an
ooen in the GRN/WHT wire to the gsuge
Drainthe fuel tank into an approvedcontainer. assemblv,no power to the gauge,a bad bulb, or
Then installthe drain bolt with a new washer. poor ground.
A d d l e s st h a n 9 . Ot 1 2 . 4U . S .G a l ,2 . Ol m p . G a l )o f
fuel and turn the ignitionswitch ON.
The low luel indicatorlight shouldcome on within
four minutes.
til
LOWFUELINDICATOR LIGHT
(ln the subgaugeassemblyl
a lf the light goes on within four minutes,go on to

step 5.
a lf the light does not go on within four minutes,
go on to step 4,
5. Add one more gallonof fuel [approx.4 f ( 1.1 U S.

G a l ,O . 9 l m p . G a l ) 1 .
The light should go off within four minutes.
23-141
(ECTIGauge
EngineCoolantTemperature
GaugeTest SendingUnit Test
NOTE: Reterto pag€ 23- 129 tor the circuitdiaglamof 1 . Disconn€ctthe REDwire from the sendingunit.
the enginecoolanttemperature(ECTIg8ugs.
2 . With the snginecold, use an ohmmeterto measure
'1.
Check the No. 13 (10 A) tuse in the under-dash r€sistanceb€tween the positive terminal and the
tuse/relaybox beforetesting. engine (ground),
2. Make sure the ignitionswitch is OFF,then discon- --------.____/

nect the REDwire from the ECT sendingunit 8nd
ground it with a jumper wire.
REO
WIRE
POSITIVETERMINAL ECT SENDINGUNIT
REDWIRE ECT SEI{DII{GUNIT Checkthe temoeratureof the coolant.
4. Run the engine and measu.e the change in

resistancewith the engine at operatingtempera-
Turn the ignition switch ON. Check that the ture (.adiatorfan comes on).
segmentsof the ECT gauge light up.
CAUTION: Turn tho ignition switch OFF lm- Coolant 1 3 3 0 F( 5 6 . C ) 1 8 5 0 F { 8 5 0C ) -

m€diately after the ssgmsnts light up. Failuroto do Tempgrature (Enginecold) 2't20F t1000cl
so may damag€ the gaug6. 'l42
Resistance(O) 49-32
a lf the segmentsdo not light up, check for an
open in the YEL or REDwire. lf the wire is OK, 5. lf the readingsyou get are substantiallydifterent
replacethe ECT gauge. from the speciticationsabove,replacethe ECTsen-
a lf the segmentslight up, checkthe sendingunit. ding unit.
23-142
BrakeSystem Light
ParkingBrakeSwitch Test BrakeFluid Level Switch Test
Removethe floor consoleand disconnectthe con- Remove the reservoir cap. Check that the float
nectof from the switch. movesup and down freely;if it doesn't, replacethe
reservoircap assemblY.
Checkcontinuitybetweenthe positiveterminaland
body ground. Check Jor continuity between the terminalswith
the tloat uD and down,
a There should be continuitY with the brake lever
uo. a There should be continuity with the float down
a There should be no continuity with the brske a Thereshouldbe no continuitvwith the float up
lever down. Replacethe resetvoircap assemblyif necessary.
RESERVOIRCAP
BRAKELEVER
a blilt-in
lHas ]
\ magner l
DOWN POSITION
contacts closed
when float drops.
UP POSIIION
Switch contacts open, at
properfluid level.
Canads:
NOTE: lf the parkingbrakeswitch is OK, but the brake

system light does not work, performthe input test for
the daytime running lights control unit {see page
23-180).
23-143
A/T GearPositionIndicator
Component
LocationIndex
CAUTION:
a All SRS olectdcal wi ng harnsssss are covorad with
yellow outer insulation.
a Betore disconnecting the SRS wile ham6ss, install
the short connector(sl on the airbag{sl (see page
23-2941.
a Roplacethe €ntile atfocted SRS hamoss assembly it
it has an open ci.cuit or damaged wiring.
a Aftel installing tho gaugo assembly, recheck th€
operation ol the SRS indicator light.
MAIN GAUGE ASSEMBLY

Removal,p6ge23-130
Disassembly,p6ge23-134
INTERLOCKSYSTEM
See page 23 158
A/T GEAR POSITION

INDICATOR
Input Test, page23-146
Bulb Replacemenr, page 23-1
TRANSMISSIONCONTROLMODULE (TCMI
See Automatic Transmission,
section 14
A/T GEAR POSITIONSWITCH

Test, page23-148
23-144
CircuitDiagram
. ECM
HOOD
UNDER-
. TMNSMISSION
BOX
FUSE/RELAY
*€t-r"T UNDER_DASH
80X
FUSE/REI.AY
COMBIiIATION
LGHTSWlTCH
TRANSMISSION
COMTFOL
MODULE(TCM)
CONTNOL
MODUIE
ITCMI
I
I-TGRN
llnthomalngruo.a$omblyl
AITGEAR OIMMING
INDICATOR
POSITION CIRCUIT
II
t -
TNANSMISSION 10
CONTNOL
(TCM)
MODULE
INTERLOCK T(
UNIT
CONTROL
VI
GRNAVIfi
COMBINATION
LIGHT
SWITCH
VI
AITGEAR
POStTT0N \ t /
CONSOLE \ t / z
LIGI{T
{r.4w) E-.'-1,i,,,,'---Jn
AITGEAR
PostloN swlrcH
G4o1 G401
G402 G402
G404 G(X
23-145
A/T GearPositionlndicator
IndicatorInput Test
CAUTION:
a All SRS €lectrical wiring harnossesa.e coveled with
y€llow outor insulation.
a Betoro disconn€cting the SRS wirs harnoss, install
the shon connectorls) on the airbag{s} {see page
23-294t.
a Feplace tho entire atfoctod SRS hamoss assembly if
it has an open circuit or damag€d wiring.
a After installing the gauge ssssmbly, r6check tho
operation of tho SRS indicatol light.
1. Removethe main gauge assemblyfrom the dash-

b o a r d{ s e ep a g e2 3 - 1 3 O ) .
2, Disconnectthe 16-P and 1O-Pconnectorsfrom it.

SRSMAIN HARNESS
3. Inspectthe connectorand socket terminalsto be

sure they are all makinggood contact.
a lf the terminals afe bent, loose, o. corroded,

repair them as necessary, and recheck the
sysrem.
a lf the terminalslook OK, make the loltowing in-
put tests at the connector.
- lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input tests prove OK, the indicator
must be faulty; replacethe gaugeassembly.
NOTE: Different wires with the same color have

been given a number suflix to distingujshthem
{YELj and YEL2are not the same).
View from wire side
23-146
Test condition Tost: Desiled result Possiblocaus€ il rosult is not obtainod
1 BLK Under all conditions. CheckJor continuityto ground: . Poorground{G401,G4o2,G404).

There shouldbe continuitY. . An ooenin the wire.
YELI lgnitionswitch ON. Checktor voltageto ground: . B l o w nN o . 1 ( 1 OA ) f u s e .
There shouldbe bsttery (ln ths under-dashfuse/relayboxl
voltage. . An open in the wi,8.
GRN/WHT Shift lever in E. Check for continuity to ground; Faulty An gear position switch.
NOTE: Don't push the Thereshould be continuity. Poor ground (G4O1,G4O2,G4041.
brake pedal. NOTE:Thereshouldbe no An ooen in tho wire.
continuityin any other
GRN/RED Shift lever in @.
position,
GRN Shift lever in [.
GRN/BLU Shift lever in E.
GRN/YEL Shift lever in @.
LT GRN/ Shift lever in [.
WHT
REDand Combinationlight switch Check for voltagebetween . Faultydash lights brightnesscon-
4
RED/BLK ON and dash lights RED/BLKand REDterminals: trol system.
brightnesscontrol dial or There shouldbe battery . An open in the wire.
full bright. voltage.
Check for voltageto ground: . F8ultytransmissioncontrol module
GBN/ORN lgnitionswitch ON and
shift lever in any Posi- Thereshould be bsttery (TCM).
voltage fof two seconds after . An open in the wire.
tion except @.
the ignitionswitch is tutned
ON, and less than 1 V two
secondslater.
YEL' lgnitionswitch ON and Check for voltageto ground: . FsultyTCM.
6
shift lever in any posa- Thereshouldbe lessthan 1 V . An open in the wire.
tion except E. tor two secondsafter the igni-
tion switch is turned ON, 8nd
more than 5 V two seconds
later.
lgnitionswitch ON. Check for voltageto ground: . FaultyECM or TCM.
7 LT GRN
There shouldbe more than . An open in the wire.
1 1V .
23-147
A/T GearPositionSwitch Test
CAUTION:
a All SRS ol6ctrical wiring harnessosare coverod with
yallow outor insulation.
a Botore disconnoctlng the SRS wiro halnass, install
tho short connoctor(s) on th6 airbag(sl (s6o pagg
23-2941.
a Roplacoth€ ontire Effoctod SRS halness assombly if
it has an opon circuit or damaged wiring,
a Aft€r imtalling th€ gaug6 asEembly, rocheck tho
op.ration ot tho SRS indlcator lighr.
1. Removeths console,then disconnectthe 12-Pand

3-P connectorsfrom the switch.
2. Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.
a Move the lever back and forth at each oosition

without touchingthe push button, and checkfor
continuitywithin the rangeof tree play.
a lf there is no continuitywithin the rangeof free
play, adjust tho position ot th€ switch as
describedon the next page.
A/T Goar Back-up l{eutral

Posltlon Light Positlon
Switch Switch Switch
T6rminal
\ 8 I 2 5 o 7 ll 9 t0 t3 15
ffi;-------l
a -o
lTl
o- --{} --o
tr o- --{} --o
E --o
E o- --o o- *-o
tr o- --o o- _O
E o- --o o- --o
23-148
A/T GearPositionSwitch A/T Gear PositionSwitch
Adiustment Replacement
1 Shift to the lll positionand loosenthe switch nuts. Removethe console,then disconnectthe 12-Pand
3-P connectorstrom the switch.
Slidethe switch rearwardlup to 2.0 mm (0.O8in)l
until there is continuitybetween No. 8 and No. 11 Remove the two mounting nuts and remove the
terminalswithin the range of free play of the shift switch.
lever.
3, Recheck for continuity between each of the SWITCH SLIDERlln po3ition LLI)
termtnals.
SHIFT LEVER
NOTE:
a li adiustmentis not possible,check ior damage
to the shift lever detent and/or bracket,
lf there is no damage,replacethe A/T gear posi-
tion switch.
a The engineshouldstart when the shift leveris in
position@ anywhere within the range of free
play.
-Fre€ play
]tl
@t
ll\''--
q---------.__- GEAR POSITION
LOCK PIN swtTcH
Positionthe slideron the new switch to positionE

as shown above.
"Neutral". then slipthe switch in-
Shift the leverto
to position,
5- Attach the switch with the two mountingnuts.
6 . Test the switch in the @ and $ positions.
NOTE: The engine should start when the shift

leveris in positionfl anywherein the rangeof free
ptay.
Adjust rearward Connectthe 12-P and 3-P connectors,clamp the

lup to 2.0 mm (O.O8in)l harness.and installthe console.
23-149
Bulb Replacement
CAUTION:
a All SRS oloctrical wiring hamesses are coverod with
a Before disconn€cting tho SRS wir6 ham6ss, install
the shon connector(s) on th€ 8i|bag(s) {see page
23-294t.
a Replacothe €ntire affectod SRS harness assembly if
it has an opon ci.cuit or damaged wi.ing.
a Afior installing tho gaug€ assombly, roch6ck tho
opelation of th€ SRS indicator light.
1. Remove the main gauge assembly (see page

23-130t.
2. Disassemblethe main gauge assembly(see page

23-134!.
3. Remove the bulb from the A/T gear position in-

dicator circuit board.
B U L BI 1 . 1 2W I
4. Installtheindicatorin the reverseorderof removal.
23-150
SSlisul&
Safety Indicator
ComponentLocationIndex
CAUTION:
a All SRS el€ctrical wiling hamossos aro covared with
yellow outof insulation.
a Botor€ disconnecting th6 SRS wite harness, install
the short connector(e) on tha airbag(s) (see page
23-2941.
a Replacoihe €ntiro aftocted SRS harnossassombly il
it has an open cilcuit or damagod wiring.
a After installing tho gauge assembly. rocheck ths
operation of tho SRS indicator light.
SAFETYINDICATOR(ln the sub gauge sssemblyl

Troubleshooting.pag€ 23-1 56
Removal,page23-130
fnput Test, page 23-154
Bulb Replacement, page23 133
CEILINGLIGHT
Test/Replacement.page 23-1 90
HIGH MOUNT BRAKELIGHT
p a g e2 3 - 1 9 5
BRAKESWITCH PASSENGER'SDOOR SWITCH
Test, page23-195 Test. page 23-191
TNUNK LIGHT
est, page 23-199
RIGI{T BRAKELIGHT
AILURESENSOR
Test, page 23-157
DRIVER'SDOOR
Test, page 23- 191
LEFTBRAKELIGHT LATCH SWITCH

FAILURESENSOR Test/Replscement,page 23-189
Test,page23-157
Safsiy lndicator Systsm:

Bulbsare usedto indicatewhen the trunk lid or a door is not fully closed,or when a brakelight is faulty. The bulbswill re-
main ON Jor about two seconds after the ignition switch has been turned ON to show that the system circuit is
functioning.
Blako Light Bulb Fallule Indicatot:

lf all brakelight bulbs are OK, the indicatorlight stays off becausethe WHT/GRNwire is constantlybeinggroundedby
the two brakelight tailuresensorsconnectedin series.With the brakelight ott, the groundis providedthroughthe diode,
the failuresensorrelaycoil, and the bulb filaments.With the brakelight on, alltour relays(threein the leit sensor.one in
the right sensor),connectedin series,supplyground.lJ eitherof the two bulbsis not working.the chainis brokenand the
WHT/GRNwire is not being grounded.The indicatorlight comes on.
23-1
Safety Indicator
Circuit Diagram
-HOOD
UNDER
FUSE/R€TAY
BOX
WHT/YEL
| 'Mreoncreo
| ,*rn*tro
|| .POWER
38lY*0'I| 8fi|l*o'
POWER
| 00oRtocK I D00R
rocK
| 8fii[*'' | 8Rifl*'
|H .Y,| "Y,
q*,*,Q*,,,n.,,,
l8fi,?f., lDooRsw'TcH
t l
1
: -:- 1
23-15.2
*tt"r,J
. ECM
+-
V +BNlwHT GRt{/l
, TRANSMISSION
CONTROL
MODULE(TCMI
' CRUISE
CONTROLUNIT
' ABSCONTROL
UNIT
LEFT !-
T A I T L I G H T ,:
BRAKE
LIGHI
t43CPl
BLK
BLK
{
G521
23-153
Safety Indicator
IndicatorInputTest
a All SRS eloclricsl widng ha]nossesare coverod with

yollow out€r insulation.
a Bofole disconnecting the SRS wira ham€ss, install I
ths short connoctor(s) on the airbag(s) lsee page
23-294t. I
a Replacothe sntir€ affectad SRS harness assembly il
it has an opon circuit or damagod wiring.
a Aftor installing th6 gaug€ a$ombly, lochock ths
operation of the SRS indicator light.
1. Removethe sub gauge assemblyfrom the dash-

board (seepage 23-130).
2 . Disconnectthe 30-P connectorfrom the sub gauge

assembly.
Inspectthe connectorand socket terminalsto be

sure they are all makinggood contact.
a lf the terminals are bent, loose, or corroded,

sysrem.
a lf the terminalslook OK. make the following in-
- It a test indicatesa problem,find and correct
- lf allthe input tests prove OK, the printedcir-
cuit board must be faulty; replaceit.
Viow lrom wire side
GRN/BED
SUBGAUGEASSEMBLY
23-154
Tosi condition T6str Desired rssult Possibl€cause it result is not obtained
1 BLK Under all conditions. Checkfor continuityto ground: . Poor ground {G4Ol, G4O2,G4O4l.
Thereshould be continuitv.
YEL lgnition switch ON. Check for voltageto ground: . B l o w nN o . 1 3 ( 1 OA ) I u s e .
There shouldbe battery (ln the underdashfuse/relaybox)
voltage. . An open in the wire.
3 WHT/GRNBrakepedal pushed. Check for continuityto ground: B l o w nN o . 4 1 ( 1 5 A ) f u s e .

Thereshouldbe lessthan 4 kO. Faultybrakeswitch.
Blown brakelight bulb.
Faultybrakelight failuresensor.
P o o rg r o u n d( G 5 2 1 .G 5 5 1 ) .
An open in the wire.
4 GRN/BLK Trunk lid open. Check for continuityto ground: Faultytrunk latch switch.
There shouldbe continuity. P o o rg r o u n d( G 5 2 1 ) .
NOTE:Beforetesting, remove An open in the wire.
N o . 4 6 ( 15 A ) f u s e i n t h e
under-hoodfuse/relaybox.
BLK/WHT Ceilinglight switch in Connectto ground:Ceiling E l o w nN o . 4 6 ( 1 5 A l f u s e .
MIDDLEposition. light shouldcome on. Faultyceilinglight.
GRN/BLU Driver'sdoor oDen. Check for continuityto ground: . Faultydoor switch.
Thereshouldbe continuity. . An open in the wire.
NOTE: Beforetesting. remove
GRN/RED Passenger'sdoor open. N o . 4 4 ( 15 A l a n d N o . 4 6 ( 15
A) fuses in the under-hood
fuse/relaybox.
23-155
_
Safety Indicator
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence
Item to be inspected
c
a; < +
rr:
o f 3
{ d
o c
z 3 z a 3 -9 - c
c g ; G
I t 3
9 c
<t F
Symptom
G401
No indicatorsooerate. G402 Y E L
G404
Indicator lights do not come on when the
ignition switch is turned to ON.
Door indicatorlight does not come on with GRN/BLK
J 1
ooors open. GRN/RED
Trunk indicatorlight does not come on with
2 3 1 G521 GRN/BLK
trunk lid open.
Brakeindicatorlight does not come on with
2
blown brake light bulb. WHT/GRN
Brakeindicatorlight remainson with good or GRN
1 G551
brake light bulbs.
Ceilinglight does not come on with door open BLKiWHT
(with switch in MIDDLEposition). 2 3
23-156
i,,,
Brak
raKeLight Densor Test
rallure Sensor
Llgnr Failure I Gsr -
1 . Firstmake sure the brakelights come on when the 4. Open the taillightaccesspanelto the left taillight.
brake oedal is gressed. Remove the bulb socket housing. watch the
trTARnAMFl light when the ignition switch is
a lf all the brake lights come on. go to step 2. turnedfrom OFFto ON with the B (GRN)wire ot the
a lf one of the brake lights does not come on. 6-P connectorgroundedand the brakepedalpress-
check whether the bulb is blown. lf the bulb is eo.
OK. go to step 2.
a lf none oi the brake lights come on, check the LEFTFAILURESENSOR
brake light circuit {see page 23-153).
Open the trunk lid and the taillightaccesspanelto

the right taillight.Removethe bulb sockethousing.
Watch the TBRARE-IAMFI light in the safety in-
dicat( , when the B {WHT/GRN)wire of the 4-P con-
nectoris groundedand the ignitionswitch is turned
t r o m O F Ft o O N .
a It the BRAKELAMP I light comes on and stays

on, there is an open in the B (GRNIwire between
the le{t failure sensor and the right failure sen-
sor.
r tt ttre lEnnfELAME light does not stay on, go
to step 5.
a lf the IBRAKELAMP light comes on and stays
5 . Warch rhe trRAK-E LAMFI light when the ignition
on, check tor an open in the B (WHT/GRN)wire
switch is turned from OFF to ON with the F (BLK)
between the safety indicator and the right
wire ot the 6-P connectorgroundedand the brake
failuresensor. pedal pressed.
r tf the i gnnre- LAtt,tpI tight does not sray on. go
to steD 3. r tt ttre I aR-AKaLAMPI light comes on and srays
on, replacethe left tailuresensor.
3, watch ttre f aRAKaLAMt light when the ignition o tt tne IaRAKaLAMPI light does nor slay on,
switch is turned from OFFto ON with the D {GRN)
check for an open in the F {BLK)wire between
wire of the 4-P connectorgroundedand the brake
the left failuresensorand ground,and checkJor
pedal pressed.
a p o o rg r o u n da t G 5 5 1 .
o It the [6nAre LAMpllight comes on and stays
on, replacethe right failuresensor.
o tt ttre IERAKELAMpllight does not stay on, go
to step 4.
23-157
InterlockSystem
CAUTION:
a All SRS sloctrical wiring hamosses ar€ cove?edwith
yollow outer insulation.
a Botolo disconnectlng ths SRS wira hamoss, install
the short connector(sl on the airbag{sl, then dlscon-
nect the wire harnesa (soo page 23-294).
a Rsplac€the sntile affected SRS hamass assembly if
It has an opon clrcuit 01 damaged wiring.
a Aftor inEtalling ths gaugo assombly. rechock th6
opelation ol th€ SRS indicator light.
A/T GEAR POSITIONII{OICATOR

So€ page23-144
INTERLOCK CONTROLUNIT KEY INTERLOCKSOLEI{OID SHIFT LOCK SOLENOID

InputTest,page23-161 and KEY INTERLOCKSWITCH Test, page 23-163
(ln thg steering lock assembly) Replacement, page 23'163
Test, p€ge 23-162
A/T POStTtON
swtTcH
T€st, page23-148
Repl€cement,psg€ 23-149
23-158
Description
The car is equippedwith the following devicesto preventinadvertentshifting:
a Shift lever with shift lock

a Key cylinderwith interlockedignitionkey
Shilt Lock Systom:

The shift tock system preventsthe shitt leverfrom movingto @ or p from the @ unlessyou step on the brakepedal.
NOTE:
a The shift lever cannot be shifted when the brakepedaland the acceleratorare steppedon at the same time.
a In caseof svstem malfunction,the shift levercan be releasedby pushinga key into the releaseslot nearthe shift lever.
Key Intorlock System:

When the shift leveris in any
The ignitionkey cannot be removedtrom the ignitionswitch unlessthe shift leveris in L?.1.
positionother than @. a solenoidis activated,makingit impossiblefor the key to be removed untilthe leveris movedto
the lP l.
I ne sntn tever rs In Ll:l
INTERLOCKLEVER
SOLENOID
IOFFI
KEYCYLINDER
The shilt lever is in any position except l-P-l
SOLENOID
(oNt
23-159
InterlockSystem
GircuitDiagram
NOTE: Different wires with the same color have been given a number suffix to distinguish them (GRN/WHTl and
GRN/WHT' are not the same).
- HOODFUSEiRELAY
UNOER 8OX
WHT/YEI.
HORN
CIRCUIT
DASH
UNOER- GRNMIfT I
FUSEiRELAY
8ox
SHIFT
LOCK
s0LE otD
loN:UNLoCK)
. ERAKEUGHTS
. cRutsE
c0t{rRoL
{
G40l
G402
G404
23-160
ControlUnit InputTest
Oisconnectthe 8-P connectorfrom the interlockcontrol
untr.
Inspectthe connectorand socket terminalsto be sure
they are all makinggood contact.
a lJ the terminalsare bent, loose, or corroded,repair

them as necessary,and recheckthe system.
a lt the terminalslook OK, make the following input
tests at the connector.
- lf a test indicatesa Droblem,find and correctthe
CONTROLUNIT
INTERLOCK
cause,then recheckthe svstem.
- lf all the input tests prove OK. substitute a
known-goodcontrol unit and recheckthe system.
lf the check is OK, the controlunit must be faulty;
reDlaceit. WHT/GRN
NOTE: lf the shift lock solenoidclickswhen the ignition

switch is turned ON and you step on the btake pedal
{with the shift leverin LLI),the shift lock system is elec-
tronically normal; if the shift lever cannot be shifted
from LBl, test the A/T gear position switch as desctibed
View from wire side
on page 23-148 and see section 14.
Shift Lock System:

No. Wile Test condilion Test: Dosired result Possiblocause if result is not obtained
1 WHTiGRN lgnition switch ON. Check for voltage to ground: Blown No. 41 (15 A) tuse.
Brakepedal pushed. There shouldbe battery Faulty ECM.
voltage. Faulty brakeswitch.
Faultythrottle position (TP,sensor.
lgnition switch ON, Checkfor voltageto ground:
brake pedsl and ac- Thereshouldbe lessthan bat-
celeratorpushedat the tery voltage.
s a m et i m e .
GRN/WHT' Shift lever in @. Checkfor continuityto ground: FaultyA/T gear positionswitch.
Thereshouldbe continuity. Poorground (G4O'1.G4O2,G4O4).
GRN lgnitionswitch ON. Checktor voltageto ground: Blown No. 13 {10 A) fuse.
There shouldbe battery Faultyshift lock solenoid.
voltage. An open in the wire.
K6y Int6 ock System:

No. Wire Test condition T€st: Desired result Possiblecause it lesult is not obtained
1 BLK Under all conditions. Checkfor continuityto ground: . P o o rg r o u n d{ G 4 O 1 G

, 4 0 2 ,G 4 O 4 )
There shouldbe continuity. . An open in the wire.
GRN/WHT' Shift lever in E. Check for continuityto ground: FaultyA/T gear positionswitch.
There shouldbe continuity. Poor ground (G4O1, G4O2,G4O4).
WHT/RED lgnitionswitch turned to Check for voltageto ground: B l o w nN o . 4 6 ( 1 o A ) f u s e .
ACC (l) and the key There should be battery Faultysteeringlock assembly(key
WHT/BLU pushedall the way in. voltage. interlocksolenoid).
23-161
InterlockSystem
' Key I esl -
SolenoidTest
InterlockDolenolq
Kev IntenOCK
CAUTION: 3. Checkfor continuitvbetweenthe terminalsin each

a Alt SRS elactrical wiring harnessosare covor€d with switch position according to the table.
Bolore disconnecting ths SRS wira ham€45, inatall
the shon connectorls) on tho airbag(s) lsee page
23-2941.
Replacothe €ntiro aftoctod SRS hamess assembly if \___------1"-'"d A B
it has an opon cilcuit or damaged wiring. Po8ition
lonition Koypush€d
in. o-
iwitch
ACCfl) Koyr€lossod. (J- --o
4. Check that the kev cannot be removed with powe.

and ground connectedto the A and C terminsls.
a lf the key cannot be removsd, th€ ksy interlock

solonoidis OK.
a It the key can be removed, roplace the ste8ring
lock assemblv (the key intetlock solsnoid is not
SRSMAINHARNESS availabl€separstely).
'1.
Remove the dashboard lower cover and knee
bolster.
2. Disconnectthe 8-P connectortrom the main wire

narness.
View trom wire side
23-162
Shift Lock SolenoidTest/Replacement
Test:
1. Removethe console,then disconnectthe 3-P con-
nectorof the shift lock solenoidfrom the main wire
narness. NUTS
Replace.
NOTE: Do not connectpower to the B l-) terminal 1Ot{'m
{reversepolarity}or you will damagethe diode in-
side the solenoid.
Connect batterv oower to the A terminal and

ground to the B terminal momentarily.Check the
solenoidto see if it works. lf it does not work,
replaceit.
NOTE:
a When the shift lock solenoidis ON, check that
there is a cleafanceol 2.9 ! O.5 mm {0.114 t
0.020 in) between the top corner of the shift
\ack\e\e\ andthe \ock p\n qroo\e \see c\earance
check on this paqe).
lnstall the new shift lock solenoid in the reverse
a When the shift lock solenoidis OFF, make sure
order of removaland adjust its position.
that the lock pin is blocked by the shitt lock a when the shift lock solenoidis ON. check that
tever.
e J 2 . 9 t O . 5 m m ( O . 1 1 4a
t h e r ei s a c l e a r a n c o
a lf it is not, adjust the positionof the shift lock
0.O2O in) between the top corner of the shift
solenoid.
lock lever and the lock pin groove, and tighten
the self-lockingnuts.
NOTE: Use brand-newselflocking nuts.
2.9 r 0.5 mm
(0.'114r O.O2OInl
SHIFT LOCK
LEVER
LOCK PIN
GROOVE
when the shift lock solenoidis OFF,make sure

that the lock pin is blocked by the shift lock
tever.
Rsplacement:
1. Removethe solenoidpin.
2. Remove the self-locking nuts and shift lock

solenoid.
23-163
IntegratedGontrolUnit
CircuitDiagram
Descdption
An integrated control unit, located in the left kick panel, integrates the tunctions of the key - in/seat beh reminder,
side marker light f lasher, wiper/washer, lights - on reminder, rear window defogger timer, entry light timer, power
window k€y -off timer, and engineoil pressureindicatorflashercircuits.
NOTE: Different wir€s with the same color have be6n given a number suffix to distinguish them (for example,
GRN/RED1 and GRN/RED'are not the samel.
UNDER-
HOOD
FUSE/RELAY
BOX
N0.32{1004) No.46ll5Al
IGNITION
SWITCH
WINOSHIELD
WIPER/
WASHER
SWITCH
WASHER COMBINATION
swftcH IMT UGHTSWTCH
I
BLKffEL
Y
IMTEGRATED
CONTNOT
UNIT
II'ITERMITTENT
I . SAFETY
*f
wrPER RELAY I INDICATOR
I POWER CIRCUIT
*Y, I o00RLocK . POWER

DOORLOCK
,' r,r,!"rt,8filI*o' UNIT
CONTROI,
Prsft
I v"
++
RED/B].U
FROI'IT
SIDE
'
BI-UiWHT MARKER iilF-*lJ
",.gFI
@i'fl"* (
UGI{T DRIVER'S
J {3CPt SEATBELT
swtTcH
B LK BI..K BLK BLK
WINDSHIELD INTERMITTEMT
MOTOB WIPER
WIPER REI-AY
4 4 4 I
_l.L
-
G301 G20t G401 G522
G402
23-164
' TRUNKUGHT
, CIGARETTE
LIGHTER
. CEILING
UGHT
, KEYINTERLOCK
SOTENOID
REAR REAR
wtNDow wtNDow
OEFOGGER
DEFOGGER
RELAY INDICATOR
'Y
\--7
I
E I YEUGRN
;l_
b
,.
I 812
fl EITGINE
,k4
Bu( 0rL
t
PRESSURE
swtTcH
G4ot
G402
G{Ol
23-165
IntegratedControl Unit
Input Test
CAUTION:
a All SRS electrical wiring halnesses are covered with
a Before disconnecting the SRS wira harness, install
th€ shon connector(s) on the airbag{sl (see page
23-2941.
a Roplacethe entire affectsd SRS harnessassembly if
it has an open circuit or damaged wiring.
1. Remove the left kick panel. then disconnectthe

16-P connectortrom the integratedcontrol unit.
2. Remove the underdash fuse/relay box, then

removethe integratedcontrol unit.
3. Inspectthe connectorand the socket terminalsto

be sure they are all makinggood contact.
a li the terminals are bent, loose, or corroded,

NOTE:
repair them as necessary, and recheck the a Different wires with the same color have been
system. given a number suffix to distinguishthem {Jor
a lf the terminalslook OK, make the followingin- example,GRN/RED1 and GRN/RED' arenot the
put tests at the connectorand the socket. same).
lf a test indicatesa problem,find and correct a Do not disconnect any connectors from the
the cause,then recheckthe system. under-dashfuse/relavbox exceDtthe one fof the
- lf allthe input tests proveOK, the controlunit
integratedcontrol unit.
must be faulty; replaceit
It-..-t..-
|.-z\
REO/BLU
23-166
GRN/WHT BLU/WHT, GRN/BLK
View trom terminal side of lhe
under-dashluse/relaybox socket View from wire side of the harnessconnector
Wiper Systsm:
No. Terminal Tost condition Test: Desirod result Possiblecause if result is not obtained
B1 Under all conditions, Check for continuityto ground: . Poor ground (G4Ol, G402. G4O4l
2 B2 lgnition switch ON. Check for voltageto ground: B l o w nN o . 1 7 ( 3 OA ) f u s e .
Thereshould be battery (ln the under dash fuse/relaybox)
voltage. Faulty intermittentwiper relay.
3 810 lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 1 7 { 3 0 A ) f u s e .
and wiper switch at Thereshould be battery (ln the under-dashtuse/relaybox)
INT position. voltage. Faulty wiper switch.
4 B'l 1 lgnitionswitch ON Check tor voltageto ground: B l o w nN o . 1 7 ( 3 OA ) f u s e .
and washer switch There shouldbe battery (ln the under-dashfuse/relaybox)
oN. voltage, Faultywiper switch.
B3 lgnition switch ON. Check for voltageto ground: Blown No. 17 (30 A) tuse.
Thereshouldbe battery (ln the under-dashfuse/relayboxl
voltage. Faultyintermittentwiper relay.
Faultywindshieldwiper motor.
Engine Oil PressuroIndicatol FlasherSyst€m:

No, T€rminal Tsst condition Tost: Desired result Possiblecause il result is not obtain€d
1 B1 Underall conditions. Check for continuityto ground: . Poor ground (G4O1, G4O2,G4o4).
B9 lgnition switch ON. Check for voltageto ground: . B l o w nN o . 13 ( 10 A ) t u s e .
Thereshouldbe battery (ln the under-dashfuse/relayboxl
B6 Headlightswitch ON. Checkfor voltageto ground: B l o w nN o . 4 2 ( 2 0 A ) f u s e .

Thereshould be battery (ln the under-hoodfuse/relayboxl
voltage. Faultycombinationlight switch.
4 87 lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 1 3 ( 1 OA ) f u s e .
and turn signalswitch It shouldchangefrom (ln the under-dashfuse/relayboxl
to "Left". O-12 O V repeatedly. Faultyturn signal/hazard relay.
5 814 lgnitionswitch ON
and turn signalswitch
to "Right".
GRN/WHT Connectthe 85 ter- Check front side markerlight Blown bulb.
minal to the GRN/ operation:Lett (or Right)front P o o rg r o u n dI G 3 O 1( o r G 2 O 1 ) l
7 GRN/RED1 HT (orGRN/RED1)
W side ma.ker light shouldcome An open in the wire.
terminal. on as the battery is connected.
{cont'd}
23-167
IntegratedControlUnit
Input Test (cont'd)
813 811 89 GRN/WHT BLU/WHT' GRN/BLK
View from terminalside of the

underdash fuse/relaybox socket View from wire side oI the harnessconnector
K€y-in/Seat Eelt Rsminder System:

No. Terminal Test condition Test: Desired result Possiblecause if result is not obtained
1 B1 Under all conditions. Check tor continuityto groundl . Poor ground (G4O1,c4O2, G4O4).
B8 Driver'sdoor open. Checkfor continuityto ground: . Faultydriver'sdoor switch.
NOTE: Betoretesting, remove
No. 46 (15 A) fusein the
BLU/WHT' lgnition key is in- Check for voltageto ground: Faultyignitionkey switch.
serted into the igni- It shouldbe 1 V or less. Poorground (G4O1,c4O2, G4O4).
tion switch. An open in the wire.
4 RED/BLU lgnitionswitch ON Checkfor voltageto ground: Faultyseat belt switch.
and driver's seat belt It shouldbe 1 V or less. P o o rg r o u n d( G 5 2 2 ) .
unbuckled. An open in the wire.
5 B9 lgnition switch ON. Check for voltageto ground: . B l o w nN o . 1 3 ( 1 OA ) f u s e .
Thereshould be battery (ln the under-dashfuse/relayboxl
Power Window Key-oft Time. System:

No, Terminal Test condition Test: Desired tesult Possiblecause it .esult is not obtained
1 B1 Under all conditions. Check for continuityto ground: . P o o rg r o u n d{ G 4 O l , c 4 O 2 , G 4 O 4 } .
Thereshouldbe continuity. . An open in the wire,
2 B5 Underall conditions. Check tor voltageto ground: . B l o w nN o . 4 6 ( 1 5 A ) f u s e .
The.e should be battery {ln the underhood fuse/relaybox)
B8 Driver'sdoor open. Check for continuityto ground: ' Faultydriver'sdoor switch.
NOTE: Beforetesting, remove
N o . 4 6 { 15 A ) t u s e i n t h e
G R N / R E D ' Passenger'sdoor Check for continuityto ground: . Faultydoor switch.
open. There shouldbe continuity. . An open in the wire.
NOTE: Beforetesting. remove
No. 46 (15 A) fuse in the
under-hoodtuse/relaybox.
5 G R N / B L K Connectthe 85 ter Check window operationl Faulty power window relay.
minal to the GRN/BLK Power windows shouldwork Poor ground lG4O1, c4O2, c4O4).
terminal. with the key OFF. An open in the wire.
23-168
WHTiBLUJ
ORN
8ED/BLU
GRN/WHT BLUiWHT' GRN/8LK
View from terminal side ot the

under'dash fuse/relay box socket View from wire side of the harnessconnector
Entry Light Timer System:

No. Terminal Test condition Test: Desired result Possiblecaus€ i{ result is not obtained
1 B1 Under all conditions. Check for continuityto ground: . P o o rg r o u n d{ G 4 O l , G 4 O 2 ,G 4 O 4 } .

2 B5 Underall conditions. Checkfor voltageto ground: . B l o w nN o . 4 6 ( 15 A ) f u s e .

Thereshouldbe battery lln the under hood fuse/relaybox)
voltage. . A n o p e ni n t h e w i r e .
WHT/BLK Under all conditions. Attach to ground: lgnition key . Blown bulb.
light should come on. . An open in the wire.
4 B8 Driver'sdoor open. Check Ior continuityto ground: . Faultydriver'sdoor switch.

NOTE: Beloretesting, remove
N o . 4 6 { ' l5 A ) I u s e i n t h e
Lights-on ReminderSystem:
No. Terminal Test condition Test: Desired result Possiblecause if result is not obtained
1 B1 U n d e ra l l c o n d i t i o n s . Check Ior continuityto ground: . P o o rg r o u n d{ G 4 O 1 G. 4 O 2 ,G 4 O 4 ) ,

Thereshould be continuity. . A n o p e ni n t h e w i r e .
2 B6 Headlight switch ON. Check for voltageto ground: B l o w nN o . 4 2 l 2 O A J f u s e .

Thereshould be battery (ln the under-hoodfuse/relaybox)
B9 l g n i t i o ns w i t c h O N . Check for voltageto ground: . B l o w nN o . 1 3 ( 1 OA ) f u s e .
There shouldbe battery (ln the underdash fuse/relaybox)
voltage. . A n o p e ni n t h e w i r e .
B8 Drjver'sdoor open. Check for continuityto ground: . Faultydriver'sdoor switch.

There shouldbe continuity. . A n o p e ni n t h e w i r e .
NOTE: Beforetesting, remove
N o . 4 6 ( 1 5 A ) f u s ei n t h e
under-hoodIuse/relaybox.
5 ORN lgnition switch ON Check chime operation:Chime . F a u l t yc h i m e .
and connect the 89 should activateeach time the . An open in the wire.
terminal to the ORN battery is connected.
termtnal,
(cont'd)
IntegratedControl Unit
InputTest(cont'd)
View from terminalside of the

under-dashtuse/relay box socket View from wire side o{ the harnessconnector
Rear Window Defogger Timer Circuit:

No, Terminal Test condition Test: Desired result Possiblecause if result is not obtainod
1 B1 Underall conditions. Checkfor continuityto ground: . Poorground (G40'1. G402. G4O4l.
813 Defoggerswitch Check for continuityto ground: Faultydefoggerswitch.
pushed. There shouldbe continuityas Poor ground {G4O1,c4O2, c404}.
the switch is pushed. An open in the wire.
812 lgnitionswitch ON. Attach to ground: Blown No. 34 (40 A) fuse.
Rearwindow defoggershould (ln the under-hoodfuse/relayboxl
work and the defoggerswitch Faultydefoggerrelay.
indicatorlight shouldcome on. Blown LED.
4 B9 lgnitionswitch ON. Check for voltageto ground: . B l o w nN o . 1 3 ( 1 OA ) f u s e .
Thereshould be battery (ln the unde.-dashfuse/relayboxI
voltage. . An open in the wire,
Engins Oil P.assur€ Indicator FlashorSvstem:

No. T€rminal T€st condition Tsst: Dosired tosult Possiblecause il result is not obtained
I B1 Under all conditions. Check lor continuityto ground: . Poor ground (G4O1. G4O2,G4O4t.
B9 lgnition switch ON. Checkfor voltageto ground: . B l o w nN o . 1 3 ( 1 OA ) f u s e .
Thereshouldbe battery (ln the under-dashfuse/relaybox)
WHT/BLUl Enginerunning. Check for voltageto ground: . Faultychargingsystem.
Thereshould be battery . An open in the wire.
voltage.
4 YEL/RED lginition switch OFF. Check for continuityto ground: . Faultyengineoil pressureswitch.
Theie should be continuity. . An open in the wire.
lgnition switch ON. Check indicarorlight. lf the . B l o w nb u l b .
light does not come on, attach . An open in the wire.
the YEL/REDterminalto
ground:The light shouldcome
on as the ignitionswitch is
turned ON.
Start the engine. Check tor voltageto ground: Insulficientoil.
Thereshould be battery lmp.operlubrication.
voltage. Faultyengineoil pressureswitch.
23-170
Liqhts-onReminder
Key-inReminderSystem Sy-stem
lgnition Key Switch Test Chime Test
NOTE: Refer to page 23-164 tor the diagram oJ the NOTE: Refer to page 23-165 tor the diagramof the
key-in beep€r circuit, and page 23-168 for the input lights-onremindercircuit, and page 23-169 for the in-
test of the beepercircuit. put test of the circuit.
"O" position and
When the ignitionkey is not removed,the key-inbeeper When the ignition key is turned to
in the integratedcontrolunit sensesgroundthroughthe removed. with the lights on, voltage is appliedto the
closedignitionkey switch. when you open the driver's remindercircuit on the integratedcontrol unit. When
door,the beepercircuitsensesgtoundthroughthe clos- you open the driver's door, the circuit sensesground
"BLU/WHT2" and through the closeddoor switch.
ed door switch. With ground at the
"88" terminals,the beepersounds. "86" terminal,groundat the "88"
With voltageat the
"B9" terminal,the chime
terminaland no voltageat the
1. Remove the dashboard lower cover and knee soundsto remindthe driverto turn off the lights.
bolster (seepage 23-68).
1. Bemove the dashboard lower cover and knee
2. Disconnectthe 8-P connectorfrom the main wire bolster.
harness.
2. Disconnectthe 2-P connectorfrom the main wire
harness.
8-P CONNECTOR
2-P CONNECTOR
Check continuitybetweenterminalsA and B Test the chime by connectingbatterypower to No.

1 terminal,groundingto No. 2 terminal,and cycling
a Thereshouldbe continuitywith the key in the ig- the power on-off repeatedly.
nition switch.
a There should be no continuity with the key 4. lf the chime fails to sound every time power is cy
removgd. cled, replaceit.
23-17 1
Seat Belt ReminderSystem
Description SeatBeltSwitch Test
NOTE: Refer to page 23-164 for the diagramof the Slide the f.ont seat all the wav forward then
seat belt beeper/timercircuit. disconnect the 2-P connector from the seat belt
switch.
With the ignitionswitch in "Run" or "Start", voltageis
appliedto the beeper/timerof the integratedcontrol
unit. When you unbuckle the driver's seat belt, the
beeper/timercircuil sensesground.With voltageat the
"89" terminaland ground
at the "RED/BLU" terminal.
the seat belt beeper sounds and the timer contacts
closeand open.This causesthe seat belt reminderlight
to ilash on and off. After five secondsthe alarmstoos
and the contacts .emain oDen. t
Ch€ck continuitv between terminals A and B.
a There should be continuity with the seat belt

unbuckled.
a Thereshouldbe no continuitywith the seat belt
is buckled.
23-172
! l
Entry Light Timer System I

lgnition Key Light Test lgnition Key Light Replacement
Remove the dashboard lower cover and knee 1, Remove the steering column covers lsee page
bolster (see page 23-68). 23-741.
Disconnectthe 8-P connectorfrom the main wire 2. Removethe bulb/socketfrom the key light housing
narness. by turning the socket 45o counterclockwise.
There should be continuity between the A and B

termlnals.
It there is no continuity,replacethe light.
23-173
LightingSystem
DRL INDICATORLIGHT lcanadol

(ln the sub gaug€assembly) HIGH BEAM INDICATORLIGHT
Bulb Locations,page 23-133 {ln the main galge assembly)
BufbLocations,page23-132
COMBINATION
LIGHT SWITCH
Test, page 23-178
Repfacement,page 23-182
DAYTIME RUNNINGLIGHTS
CONTROLUNIT (Canadal
Test, page23-180
BOX
FUSE/RELAY
UNDER.HOOD
HEADLIGHTS
Adjustment,page 23-184
FRONT Replacement,page23-183
tAt----TAt:-,
I4A4A4I4A4!=Y -- LIGHT
|ililil[|aL_Jat--l Page23-186
Beplacement, FRONTTURN
(f, t(:) (:) to k:i - | I| | SIGf{AL LIGHT
Replacement, page23-185
SIDE
MABKERLIGHT
(B-type)
Test, page 23-72
(A-typel
Test, page 23-71
23-174
PASSENGER'SDOOR SWITCH
Test, page 23-191
TRUNK LIGHT
CEILINGLIGHT
Test, page 23-189
Test, page 23-190 page 23'189
page23-190 Replacement,
Replacement,
LICENSEPLATELIGHTS
page23-188
Replacement,
DRIVER'SDOOBSWITCH
T€sr,page23-'l91
TAILLIGHTS
Repalcement,Page 23'1 87
REARSIOE MARKERLIGHT BulbReplacement,page 23-187
page 23-188
Replac€ment,
23-175
LightingSystem
CircuitDiagram(USA)
- HOOO
UND€R FUSE/RELAY
8OX
BLK
COMEINATION
UGIfTSWITCH
BU( BLK
t l
t l
rr-.' I
\ / I
L.TAII.I]GHT I
I
. DASH LIGHTS
BRIGHTNESS
CONTROLTER
. DASH LIGHTS
, SIOEMARKER
UGHTS
. R,TAILTIGHT
, TICENSEPTATE
IIGHTS
. INTEGRATED
CONTROL UNIT
. FRONT PARKING
UGTTTS
' HEATER CONTROL
PANETLIGHTS
G201 G40l G401

G442 G4o2
G40+ G40,1
23-176
GircuitDiagram(Canada)
No.32ll00Al No.42{20A}
DNLINOICATOR
LrGHT{3.0W1
REDffVHT
{/o+ Btu
DAYTIME
RUI.INING
UGt{rs
CONTROL
UNIT
Ln**nroT.RN/RED
GRN/RED
BRAKE
FLUID
|.lVEL
SWTCH
23-177
LightingSystem
CombinationLightSwitch Test
CAUTION:
a All SRS electrical wiring halnessos ara covered with
a Bofore disconnocting tho SRS wilo harnoss, install
th€ sho.t connector on th6 ai1b8g{se€ paga 23-2941,
a Roplacetho entire aftected SRS harno$ assembly it
it has an opon circuit or damagod widng.
NOTE: The radiomay havea codedtheft Drotectioncir-

cuit. Be sureto get the customer'scode numberbetore
- Oisconnectingthe battery.
- Removingthe No. 43 (1OA) fuse.
(ln the under-hoodtuse/relaybox)
SRS MAIN HARNESS
After service,reconnectpower to the radio and turn it
on. When the word "CODE" is displayed,enter the
customer's5-digit code to restoreradio operation.
1. Remove the dashboard lower cover and knee

bolster.
2. Disconnect the connectors from the main wire

narness.
3. Inspectthe connectorterminalsto be surethey are

all making good contact.
a lf the terminals are bent, loose. or corroded,

sysrem.
a lf the terminalslook OK, check for continuity
betweenthem in eachswitch positionaccording
to the tabl6s.
2O-PCONNECTOR
5.P CONNECTOR
View from wire side
DAHSBOARDLOWERCOVEF
KNEEBOLSTER View trom wire side
23-178
Headllght/Dlmmor/Pa$ing Switch
11 23
\ Terminal
a 1l l4 23
Position
OFF
\J
Headlight
sw|Icn a'\
LOW
a
o--
HIGH
o
OFF
Passinq switch
siitch "OFF")
{Headlisht ON
-----o
Passingswitch
switch"."}
{H€sdlight ON o ---o
Tum Siqnal Swltch
{See pa-ge23 - 197 fol turn signal circuit dlagraml
\ Tsrminsl '12
o I
Position \
RIGHT
--o
N€ut18l
LEFT ar ---o
23-179
LightingSystem
Daytime RunningLights Control Unit Input Test lCanada)
CAUTION:
a All SRS elsctrical wiring harnessesare covor€d with
ycllow out€r insulation.
a Botors disconnocting the SRS wire harnoss, inatall
th€ short connoctor on th6 airbag lsoo page 23-2941.
I
a Rcplacetho ontire affected SRS halness ass€mbly it
It has an open circuit or damaged wiring.
1. Pullthe front passenger'scarpetaway and remove

the kick Danel.
2. Disconnectthe 14-P connectorfrom the davtime

runninglights control unit.
3. Inspectthe connectorterminalsto be surethev are

all making good contact.
a lf the terminSls are bent. loose, or corroded,

r€pair them as necessary, and recheck the
svstem.
a lf the terminalslook OK, make the following in-
- lf a test indicatesa problem,find and correct
- lf all the input tests proveOK, the controlunit
must be faulty; replaceit.

been given a number suffix to distinguishthem
(RED/GRN1 and RED/GRN,are nor the same).
14.P CONNECTOR
RED/GRNI
RED/WHT REO/YEL BLK GRN/WHT
View from wire 3id€
BLU I RED/ORN GRN/RED

RED/BLU
14-P CONNECTOR RADIATORFAN

CONTNOLMODULE
23-180
No, Wils Test condition Test: Desired result Possiblecaus€ it result is not obtainod
Check for continuityto ground: . Poor ground (G4O1, G4O2,G4O4).

1 BLK Under all conditions.
There shouldbe continuitY. . An open in the wire.
2 R E D / G R N ' Under all conditions. Check for voltageto ground: Blown No. 37 (4o A) fuse.
Thereshould be battery (ln the under-hoodfuse/relaybox)
voltage. B l o w nN o . 8 { 1 OA ) f u s e .
(ln the under-dashtuse/relaybox)
Check for voltageto ground: . FaultyheadlightrelaY.
BLU/RED Under all conditions.
There should be batterY . An open in the wire.
voltage.
Check for voltageto ground: . B l o w nN o . 1 2 ( 7 . 5 A ) t u s e .
4 YEL/RED lgnitionswitch ON.
Thereshould be batterY (ln the under-dashfuse/relaybox)
votrage. . An open in the wire.
RED/GRNl Passingswitch ON. Check for voltageto ground: Faulty passingswitch.

Thereshould be battery Faultydimmerrelay.
voltage. Fsulty headlightrelay.
Blown No. 50 (20 A) fuse.
6 RED/YEL (ln the under-hoodfuse/relaybox)
B l o w nN o . 5 1 ( 2 OA ) f u s e .
7 RED/BLU Passingswitch ON. Check for continuityto Faultycombinationlight switch.

ground:Thereshouldbe con- Faultydimmerrelay.
a ORN Combinationlight
tinuity. An open in the wire.
switch OFF.
q Check for continuitYbetween . Blown headlightbulb (high beam).
RED/WHT Combinationlight
the terminals: . An open in the wire.
' l o RED/ORN switch OFF.
There shouldbe continuitY.
DRL indicatorlight should . Blown bulb.
1l BLU lgnition switch ON.
come on. . An open in the wire.
Brakesystem light should . Blown bulb.

1 2 G R N / R E D lgnitionswitch ON.
come on, . An open in the wire.
Check lor continuityto ground: . Faultyparkingbrakeswitch.

1 3 GRNiWHT Parking brake lever
Thereshouldbe continuitY. . An open in the wire.
up.
23-141
LightingSystem
GombinationLight Switch Replacement
CAUTION: 2. Removethe steeringcolumn covers.

a All SRS olectrical wiring harneasesaro covered with
a Botore disconnecting th€ SRS wir€ ham6ss, install
COLUMNUPPERCOVER
the short connector{s} on the ailbag{s} (see page
23-2941.
a R6placothe €ntire aftect€d SRS harnessassembly il
it haa an opon circuit or damag€d wiring.
COLUMNLOWERCOVER
Remove the dashboard lower cover and knee

bolster. Disconnectthe connector from the combination
light switch assembly, then remove the two
screws and the switch.
COMBINATION
OASHBOAROLOWERCOVEN
4. Installin the reverseorder of removal.
23-182
Headlights
Replacement
CAUTION: o. Disconnect the 2-P connectots from the headlight
a Halogen hsadllghts can becomo vory hot In urc; do bulbs.
not touch thom or tho attaching hardware im-
modiatsly alter thcy have boon tumad oft' Remov€ the mounting bolts and headlight
a Do not try to replacc or claan tho headlights tYith tha ass€mbly.
lights on.
1. Removea screw, then removethe tront turn signal 2-P CONNECTORS

light (see page 23-185).
2. Remove a scr€w, th6n remove the flont side

markerlight (seepage 23-185).
3. Disconn€ct the connectors from the tlont turn

signallights and frqnt sids ma.ker lights.
4. Remove ths front bumper (see section 2Ol.
8. After installing the hsadlights, adiust them to local

requlremenls.
Disconnect the 2-P connector from the front park-

ing light, and remove the light by removing the
mounlrngscrew.
23-183
Headlights
Bulb Replacement Adjustment
CAUTION:
a Halogen hoadlights can become very hot in use; do a Halog€n headlights can become v€ry hot in us€; do
not touch them or the attaching hardwaro im- not touch them or the attaching hardware im-
modiately aft€r thoy have b6on turn€d off. mediately attsr they havs bsen tuhod otf,
a Do not try to roplace or clean the headlights with ths a Do not try to replace or clean the headlights with ths
lights on. lights on.
NOTE: 1, Adjust the headlightsto localrequirementsby turn-

a Before disconnecting the left side connectors, ing the adjusters,
removethe washer reservoirfiller neck {one bolt).
a Before disconnecting the right side connectors,
removethe batteryand the enginecoolantreservoir. VERTICAL HORIZONTAL
ADJUSTER ADJUSTER
Disconnect the 2-P connector(s) from the

headlight.
Turn the bulb holder(s) counterclockwiseand

removethe bulb{s}.
EULBHOLDERS
Do not touch the giass
BULEt55 Wt
auLB{65 W}
2.P CONNECTORS
23-184
Front Side Marker Lights FrontTurnSignalLights
Removethe screw and pull th€ front side marker 1, Removethe screw and pull the front turn signal
light assemblyout of the front bumper. light assemblyout ot the front bumper.
FRONTTURN SIGNAL LIGHT
Disconnectthe 2-P connectorfrom the light. Disconnectthe 2-P connectorfrom the light.
To reDlacethe bulb, turn the bulb socket 45o To reolace the bulb, turn the bulb socket 45o
counterclockwiseand removeit trom the housing. counterclockwiseand removeit from the housing.
FRONTTURN SIGNAL LIGHT

FRONTSIDE MARKERLIGHT
BULB
BULB t32 CPI
t3 cPl
23-185
Front ParkingLights
Replacement
1 . R€move the screw and s€parate the parking light Turn the bulb socket 45o counterclockwise and
from the headlight ass€mbly. remove it from the housing, then replace the bulb.
NOTE: Be carefulnot to damagethe hoadlightand

the tront fender.
2 . Disconnectthe 2-P connectorfrom the light.
@'1 I
\
\ BULB15WI
BULBSOCKET
FRONTPARKII{GLIGHT
23-186
Taillights
Replacement Bulb Replacement
1, Oo€n the trunk lid and removethe tear trim panel. 1 Open the trunk lid and removethe taillightaccess
panel.
Removethe screws and the bulb holderpanel.
ACCESSPANEL
BULBHOLDER
PANEL
Oisconnectthe 8-P connector from the taillight

assembly.
Remove the six mounting nuts and the taillight Removethe faulty bulb by pushingit in and then
assembly. turning it 45o counterclockwise.
O BRAKELIGHT/TAILLIGHT BULB{43/3 CP)

@ TURN SIGNAL LIGHT BULB (45 CP}
8-P COf{NECTOR O B A C K . U L
P I G H TB U L B( 3 2 C P)
ASSEMBLY
NOTE:
a Inspect the gasket; replace it if it is distorted or
stays compresseo.
a After installingthem, run water over the lights
to make sure they do not leak.
23-147
LicensePlateLights RearSide Marker Lights
Removethe two screwsfrom the licenseplatelight Removethe screw from the rear side marker lioht
assembly. assembly.
Pullthe light out and disconnectthe 2-P connector Carefullypry the light out of the rear bumper and
f.om it. disconnectthe 2-P connectorfrom the light.
NOTE: Be carefulnot to damagethe rear bumper.
LICENSEPLATE
LIGHT
3. Take the lens off, then replace the bulb.
3, Remove the bulb socket by turning ir 450

counterclockwise.
23-1AA
-t
Trunk Light and Latch Switch

Trunk LightTest/Replacement LatchSwitch Test/Replacement
Pry ofl the trunk light lens from the housing. Open the trunk lid and disconnectthe 2-P connec-
tor from the trunk latch.
Pry out the light.
CheckcontinuitybetweenterminslsA and B. There
Disconnectthe 2-P connectorfrom the housing. should be continuity.
BULA(3.4Wl
LENS
4. Make sure that the bulb is oK
Check for continuity between A (+) and B (-)
terminals.
NOTE: This light has a diode in it. To get an ac-

curate reading,eithertest it with a volt-ohmmeter
a lJ necessary,remove the three bolts and pull the
that comDensatastor diodes, or make sure you
connect vour t€st leads to match the polarity latch ou1ot the trunk lid, then disconnecttho lock
snown. rod from the latch,
4. Disconnectthe trunk openercable from the latch.
{3.4W1
From
rr*rffi
FUSE
23-189
CeilingLight
Replacement Test
Turn th6 c€iling light switch OFF. Check for continuitv between the terminals in ea'ch
Pry ofl th€ lens.
\ Torminal
AorA' !ot6 D
P""- \
OFF o- @ --o
/\
MIDDLE G- \:.,.
ON o- A
\:/ -o
From 0.46 (l5Al FUSE

A
t8w
t l
)
)'\
ON ,l OFF
., Bb c
I
A'B'
Remove the two acrews from the c€iling light

housing.
Disconnect th6 3-P connsctor and r€mov€ th€

housing.
23-190
DoorSwitch Test
1 . Removethe screw and pull the door switch out.
2 . Disconnect the 1-P connector and temove the

switch.
Checkfor continuitybetweenthe terminalsin sach

\ rermnal
O TERMINAL BASEPLATE
Poshion \
CLOSE
OPEN o
e) TERMINAL
SCREW
23-191
Back- up Lights
CircuitDiagram
- HOODFT'S€/RELAY
UNDER BOX
MAIiIWIRE
A,rTGEAR
POSTT|oN
- uplioht ENGINE
WIRE
MAINWIR€
IIFT SIDEWR€HARNESS
)
)
*.*-r-l
ucr{Ts I
t32oh2t t
t
REAR
WIRE
HARNESS
23-192
Back-upLights
Switch Test
Manual Transmission: Automatic Tmnsmission:

1. Turn the ignition switch ON and move the shift 1. Turnthe ignitionswitch on and move the shitt lever
lever to LBJ.The back-uplights shouldcome on. to LB-1.
The back-uplights shouldcome on.
It a back-uplight does not go on, check for: lf a back-uplight does not go on, check for:
- Blown bulb in the taillightassembly. - Blown bulb in the taillightassembly.
lf both back-uplights do not go on. check tor: lf both back-uplights do not go on. check for:
- Blown No. 13 (10 A) fuse in the under-dash - Blown No. 13 (1O A) fuse in the under-dash
fuse/relaybox. fuse/.elaybox.
lf the fuse and bulbs are OK, go to step 2. It the fuse and bulbs are OK, go to step 2.
Disconnectthe connectorstrom the back-uplight 2 . Disconnectthe '12-Pconnectorfrom the A/T gear

switch, positionswitch (back-uplight switch).
A (YELI
swtTcH
25 .m {2.5 kg-m,
1E rb-ftl
This washermust
always be r€placed
for the switch to
lunction properly
and to preventoil View trom wire side
reaKs.
Move the shiit lever back and lorth in E without

touchingthe push button, and checkfor continuity
Check for continuity between the A and B between No. 9 and No. 1O terminals.
terminals. Thereshouldbe continuitywithin the rangeof tree
play of the shift lever.
a There should be continuity only with the shilt
lever in @. a lf there is no continuitywithin the rangeof free
a lf there is no continuity,replacethe switch (see play, adjustthe positionof the A/T gearposition
s e c t i o n1 3 ) . s w i t c h ( s e ep a g e2 3 - 1 4 9 ) .
a lf there is continuity.but the back-uplights do a l{ there is continuity,but the back-uplights do
not go on. check for: not go on, check tor:
- An open in the YEL or GRN/BLKwire. - An open in the YEL or GRN/BLKwire.
- P o o rg r o u n d( G 5 5 1 ) . P o o rg r o u n d( G 5 5 1 ) .
23-193
BrakeLightsand High Mount BrakeLight
CircuitDiagram
, ECM
. TRANSMISSION
COMTROT
MODUI.E
ITCM)
. crursE
coNTnoLuNn
. A8SCoilrnot
UN|T
L€Fr !-'
TAII"TIGHTi F
I ",F*l, 1 ,
7 f ? njT
\ BRAXE
) I UGHI
/ ErcPI
L.
8u(
G551
23-194
BrakeSwitch Test High Mount Brake Light/Bulb
Replacement
1 . lf one of the brakelightsdoes not go on. checkthe 1 . Removethe cover.
bulb in the taillightor the high mount brake light.
Inspectthe bulbsand replacethem if they are burn-
2 . lf none of the brakelights go on, checkthe No. 41 ed out.
(1 5 A) fuse in the under-hoodtuse/relaybox.
\,
lf the tuse and bulbs are OK, disconnectthe 4-P
connectorfrom the brakeswitch.
A B
il+
"JE={"
l i
4-P CONNECTOR COVER
2 ll the light is taulty, removeits two mountingbolts.
4. Disconnectthe 3-P connectorand removethe light.
Check for continuity between the B and C ter-

minals.There should be continuitvwith th€ brake
pedal pushed.
a lf there is no continuity,adjustthe pedal height

(seesection 19), and recheck.
a It there is still no continuity,replscethe switch.
HtGHttiouNT BRAKELrcHT
a lf there is continuity,but the brakelightsdo not
go on, check for: lnstallin the reverseorder of removal,
P o o rg r o u n d( G 5 5 1 ) .
- An ooen in the WHT/YELor GRN/WHTwire. NOTE: Clean the rear window glass first. and
- Faulty brake light failure sensors (see page make sure the rubber seal on the light is touching
23-157t. the glassall the way around.
23-195
SideMarker/TurnSignal/HazardFlasherSystem
ComponentLocationlndex
CAUTION:
a All SRS ol€ctdcal widng ham€sses aro covered with
ycllow outel insulation.
a B€for€ dlsconnecting the SRS wire hamoss, install
the short connector on the 8i1b89{sl,thon diEcon-
noct the wke hamess (so€ page 23-2941-
o Replacotho ontiro aftocted SRS hamess assombly
il it has is an open ciicuit or damagod wiring.
SRS MAIN HARNESS
UI{DER.DASH
FUSE/RELAYBOX TUNNSrcNAUHAZARD
BELAY
InputTest,page23-198
SIDE MARKERLIGHT FLASHERCIRCUIT

{ln the integrated control unit)
HAZARD WARI{II{G SWTTCH

TURI{ SIGIIAL II{DICATOR Romoval, page 23-2OO
UGHTS Tosr, page 23-2OO
(ln the gauge assomblyl
Bulb Locations, page 23-132
coMBll{A LIGHT/TURN SIGT{AL

swtTcH
Test, psge 23-178
Repfacoment, page 23-182
23-196
CircuitDiagram
6;\ **n" No.13l10A)

-J"-l conn€ctionl
{lntornal
T 'u7-
coMBlNATror,{
.-..J^._.
l
R€D/BII(
whr/ttl
UGHTSWITCH
v l _ l
WHTTYEI
-l
lg lo
C
HAZARD I
WARNING I
sw[cH II
tA
wtfl /YEL TURN
L / l \ R SIGNAL
swlTcH
frl
€
GRN/YEL
DASHIG}TTS COMBINATION
BRIGITTI{ESS 3 t-tcHtswtTcH
COMTROTUNIT
TURNSIGMU
R€I-AY
HAZARD
VI
6 4
llm.md connoction
I
SIDEMARKER FI-ASHER
CIRCUIT
llntamelconn€ction
I llntheintagdt6d
contrclunit)
ALUGHTS
TTFI]URNSIGN I ^,0*r uo
ru*r'ono,
-1
HTS
T
RI{/8[U GRN/BLUGRNIBIU GRN
GRN,"YEL GRN/YELGRN/ryEL MHT GRI{,frED
tt
\?-^"V-" rs\
t l I ( t t
urtfim
liiTii' li5)lin I ll.{
t t 9*r*''%
t t l',lHls
n.'9r*-
:P)
[/
l(45cP)
I
h,o'Y i* v
I S|DE I SrDr
I I MAixea
MABKER
{T
P)
BLK BLK BT.K 8I.(
[.( Bl-K
BI.K BLK
rl t
t t
l l
l
I I I
: - : :
f , T l
G201 G55l G301 G201 G40
FlasherSystem
Side Marker/TurnSignal/Hazard
RelayInputTest
Turn Signal/Hazard
CAUTION:
a All SRS electrical wlring harnessosare covared with
yollow outor insulation,
a When disconnecting tho SRS wiro harness. inslall
th€ short connectol on tho airbag(s). lhsn discon-
noct the wiro ha.ness (soo page 23-294).
a Replac€the €ntiro aft6ct6d SRS hamess ass€mbly it
it has is an open circuit or damagod wlring,
Removethe driver's side kick panel.then remove

the turn signal/hazardrelay from the under-dash
fuse/relaybox.
Inspectthe socket terminalsto be sure they are all

makinggood contact.
a lJ the terminals are bent, loose, or corroded,
sysrem.
put tests at the socket.
- lJ a test indicatesa problem,find and correct
- lf all the input tests provB OK, the turn
signal/hazard relay must be faulty; replaceit.
1 2 3
9ee
aEo
4 5 6
lerminal side
23-198
No. T€rminal Tost condition Tost: Desirad rosull Possibls cause if result is nol obtainod
1 4 Under all conditions. Checktor continuityto ground: . Poor ground {G4O1, G4O2,G4O4).
There shouldbe continuitv. . An ooen in the wire.
Underall conditions. Check for voltageto gtound: . B l o w nN o . 3 9 ( 1 5 A ) f u s e .

There should be battery (ln the under-hoodfuse/relayboxi
voltage. . An open in wire,
1 Hazardwaring switch CheckJor voltageto ground: . Faultyhazardwarning switch.

oN. There should be battery . An ooen in the wire.
lgnitionswitch ON voftage. B l o w nN o . 1 3 { 1 OA l f u s e .
and turn signalswitch {ln the under-dashfuse/relaybox)
in Right position. Faultyturn signalswitch.
4 Hazardwarning Ch€ck for voltageto ground: . Faultyhazardwarningswitch.
switch ON. There should be baftery . An oDenin the wire.
lgnitionswitch ON voltage. B l o w nN o . 1 3 ( 1 OA l f u s e .
and turn signalswitch (ln the under-dashfuse/relaybox)
in Left position. Faultyturn signalswitch.
An ooen in th€ wire.
5 3 . 2 Connectthe No. 3 Rightturn signallights should Blown bulb.
terminalto the No. 2 come on whgn the terminals P o o rg . o u n d( G 2 O 1 G
, 551)
terminal. are connected. An open in the wire.
b 3.6 Connectthe No. 3 Left turn signallights should Blown bulb.
terminalto the No. 6 come on when the terminals P o o rg r o u n d( G 3 O 1 G
, 5 5 1l
terminal. are connectgd. An open in the wire.
23-199
Side Marker/TurnSignal/HazardFlasherSystem
HazardWarningSwitch Replacement HazardWarningSwitchTest
CAUTION: Be careful not to damage the console 1 . Removethe hazardwarningswitch from the center
pan€ls. consolepanel.
1. Removethe front consolepanel (seesection 20). 2 . Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table,
2. Remove the screw and turn the hazard warning
switch slowly in the directionshown and removeit
from the center console. Te.minal
\ E
3. Disconnectthe 6-P connectorfrom the switch. il----\
-o
ON
o- /1 -o o- t_r_ -o
\:,/
OFF
CENTERCONSOLE
6.P CONNECTOR
23-200
Dash Lights BrightnessControl
Component Location Index
a All SRS olect cal wiring harnessesare covel€d with

a Betor€ disconnecting the SRS wire harnoss, install
the short connector{s) on the airbag(s) (see page
23-2941.
a Roplaccthe entiro atfected SRS harnessass€mbly if
it has an open cilcuit or damaged wiring.
a Alter installing the gaugo assombly, rechock the
oD€rationof tho SBS indicator light.
\
sRsMAIN HARNESS
DASH LIGHTS BRIGXTNESSCONTROLUNIT

Test, page 23-2O4
DASH LIGHTS
BRIGHTNESS
CONTROLLER
Test, page 23-203
23-201
Dash Lights BrightnessControl
CircuitDiagram
BATTERvrv!98:!999l99sEsr9 g3ilfl$$H3il
No.32ll00Al No.a2
I t20A)
|
'\_./ r-r '
\_--
23-202
I
I
I
ControllerTest
Carelully pry the switches out of the dashboatd,
then disconnectthe connectorsfrom them.
Measureresistancebetweenthe C and E terminals.
Resistanca:8- 12 kO
NOTE: Resistancewill va.y slightlywith tempera-

IUTE.
Measure resistance between the D and E terminals

while rotatingthe adjustingdial.
Resistanceshouldvary from O to 1O kO as the dial
is rotated.
t T -
4. Turn the controlleroft (clickingsound) and check
continuity betwe€n the B and F terminsls.There
should be no continuity.
i- "l(
I cANcEL\./
\ ucrtr
) t0.Bwtl
lJ the controller is faulty, remove the two screws I I

and reDlaceit.
23-203
DashLightsBrightnessControl
Control Unit Input Test
CAUTION:
a All SRS electrical wiriog harness€sare cov€r€d with
yellow out€l insulation.
o Befora disconnecting tho SRS wire harness. install
the short connector{s) on the airbag(s) (see page
23-294t.
a R€placeth€ entire aflectod SRS hahoss assombly if
it has an open circuit or damagod wiring.
a After installing tho gauge assembly, rocheck th6
opo.ation ot th€ SRS indicator light.
1 . R e m o v e t h e s u b gauge assembly {see page

23-131).
2. Disconnect the 6-P connector trom the control

unit.
3. Inspectthe connectorterminalsto be surethey are

all makinggood contact.
a lf the terminals are bent, loose. or corroded,

repair them as necessary. and recheck the
svstem.
a l{ the t€rminalslook OK. make the following in-
Dut tests at the connector.
- It a test indicatesa problem,find and correct
- lf all input tests prove OK, the control unit
must be faulty; replaceit
RED/BLU
23-204
No. T6st condition Test: D€siled r€sult Possiblocaus€ it r6sult is not obtainad
BLK Under all conditions. CheckJor continuityto ground: . Poorground {G401. G402, G404).
There shouldbe continuitv. . An oosn in the wire.
2 RED/BLK Combinationlight switch Check for voltageto ground: Blown No. 42 {2O A) fuse.
oN. There should be battery (ln the under-hoodtuse/relayboxl
An ooen in the wire.
5 RED Combinationlight switch Attach to ground:Dash lights . An open in the wire.
oN. should come on full bright.
4 RED/GRNAdjustingdial rotating. Checktor resistancebetween . Faultycontroller.
or the REDiGRNand RED/WHT . An open in the wires.
RED/WHT terminals:Thereshouldbe
8- 12 kO at all times,
5 RED/BLU Adjustingdial rotating. Check for resistancebetween
ano the RED/BLUand RED/WHT
RED/WHT terminals:lt shouldvary from
O- 10 k0 as the dial is rotated.
23-205
StereoSoundSystem
CAUTION:
a All SRS oloctrical wiring hamssses ara cov6r6d with
yellow outof insulation,
a B€lore disconnocting the SRS wire hamoss, install
th€ short conn€ctor{s} on tho airbag(sl (soo pago
23-2941.
a Replacethe ontile aftoct6d SRS harne$ assombly it
it has an op€n circuit or damagod wi.ing,
NOTE: The radio may have a coded theft protection cir-

cuit. Be sure to get the customer'scode numberbefore
- Removingthe No. 43 {1O A) fuse.
After service,reconnectDowerto the radio8nd tu.n it
on, When the word "CODE" is displayed,enter the
customer's5-digit code to.estore radio op€ration.
DRIVER'S
DOORSPEAKER
Rspfacament,
page23-215 TWEETERS
Replacement,
psge 23-216
DOORSPEAKER
Repfacement,gae 23-215
STEREO PLAYER
Removal,page23-210
Termioals, page 23-21 1
WOOFERAMPLIFIER
Removal,pae 23-212
fetminal, page 23-212
23-206
Doscliption:
For the desc.iption of a factory-instslled stereo radio/cassette player, please see the owner's manual.
The oower antennais controll€dby the .adio ON/OFFswitch. lt will extendfully wheneverthe radioswitch and the igni-
tion switch are on at the same time. When the radioor the ignitionis shut off, the antennaretractsfully. The antenna
motor has a built-inrslay together with a limit switch for this function.
A]{TEI{NA
page23-214
Repfacment,
23-207
StereoSound System
CircuitDiagram(ExceptSevenSpeakersSystem)
UNOER-HOOD
FUSE/RELAY
BOX
UNDER_DASH
FUSE/RETAY
BOX
COMBINATION
LIGHT
swtTcH
j"ffi**i
I I BI-U/GRN
L--------------_J
{Wrthsixsp€.kaE)
o
RAoro/o
srER€o
CASS€TTE
PI.AYER
-_____-__l I RED/GRN t
I l-t4 I
8RN/B].X IIIRIGHT :
I I I ITWEETER
i
I
ANTENNA
ITAD
l7sLu/yer
+fl,en
I Al5 lllnEAR
_ GRY&Hr_l_\l SPEA(ER
AT'ITENNA
IIAD
GROUND REOTYEI RIGHT
2 A 6 416 REAR
YEL/{VXT BRNAVHT SP€AKER
POWER ANTENNA MOIOR

(Withtheantonna
r6tlect6dfullvl
I
G401
G402
G404
23-204
CircuitDiagram{WithSevenSpeakersSystem)
OASH
UNDER-
8OX
FUSEJREI,AY
DRIVER'SPASSENGER'S
000R DooR
SP€AKEFSPEAKER
YEUWTiT
AI{T€NNA
tlA0
YEUWIfI
AMPLIFIER
WOOfER
IIAD o @
rcWERAi.ITENNA MOTOR
{Wrthlhalnr6nnsctractodfully)
StereoSound System
Unit Removal
CAUTION; 2. Remove the four mounting screws and pull the
a All SRS oloctrical wiring hah€sses al€ cov€rad with radio panel assemblyout part of the way.
yallow outor inEulation,
a Befors disconnecting th€ SRS wilo harness, install
the short connsctor(s) on th€ airbag(s) {s6o pag€
23-294t.
a Replacotha entiro affected SRS harness sssembly if
it has an op6n circuit or damagsd wiring.
NOTE: The radiomay have a codedtheft protectioncir-

cuit, Be sureto get the customer'scode numb€rbefore.
- Disconnectingthe battery,
Removingthe No. 43 (1O Al fuse.
(ln the under-hoodfuse/relayboxl
After service.reconnectpower to the radio and turn it
on. When the word "CODE" is displayed.enter the
customer's 5-digit code to restoreradiooperation.
RADIO PANELASSEMBLY
Disconnectthe connectorsand antennalead,then

removethe assembly.
4. Removethe two mounting screws. then temove

the ster€o radio/cassette player from the panel
assamblv.
Removethe 1Omountingscrews,then removethe

tront console.
23-210
Stereo Radto/CassettePlayer
Terminals
A9 - - - - ----> A16
Connectato
A1 RED/GRN Right tront speak€r @

A2 BLU/GRN Le{t lront speaker (E
A3 RED/BLK Lights-on signal
WHT/YEL Constant power {Tuning memoryl
A5 YEL/RED ACC
A6 YEL/WHT Radioswilched pow€r
A7 BLU/YEL Left roar speaker @
A8 RED/YEL Right rear speaker O
A9 BRN/BLK Rightfront speakerO
A10 GRY/BLK Left lront speaker O
A11 {Not used}
al2 (Not used)
A13 (Not usedl
A14 BLK Ground(G4O1,G402, G4O4)

A15 GRY/WHT Le{t rear speaker O
A16 BRN/WHT Right rear speaker O
23-21
Stereo Sound System
Woofer Amplifier Removal Woofer Amplifier Terminals
1 . Removethe rga. seat (sees€ction 20).
Removethe rear seat csnter pad (seesection 20).
Removethe three screws and disconnectthe 1O-p

connectorfrom the amplifier,then removelr.
WOOFERSPEAKER
Connocts lo
.81 BLU/YEL Lett rearspeaker(E
82 GRY/WHT Left rearspoakere
BRNAA,/HT Right rear speaker O
84 RED/YEL Right rear spoaker (E
WOOFERAMPLIFIER 10-P COI{NECIOR
YEUWHT Radio switched Dower
YEUEED ACC
87 {Not used)
B8 8LK Ground(G522)
B9 RED Wooterspeaker(D
810 WHT Wooler spoaker O
23-212
PowerAntennaMotor Test
. Removethe trunk right side trim panel. 5. lf the motor fails to operateproperly.replaceit.
l. Disconnectthe 3-P connectorfrom the motor. and

ANTENNA MAST
removethe connectorfrom its clamp.
3. First, check power to the motor at the connector

termrnals:
a There should be battery voltage between the

WHT/YEL(+) and BLK {-) terminalsallthe time
a There should be battery voltage between the
YEL/WHT (+) and BLK {-) terminalsonly with
the ignitionand radio switched ON.
View from wire side
l_ 1*
ilT
I r t flr I
Sticking Ant€nna:
The antennasticks in eitherthe up or down position.
1. Usingthe antannanut wrench. removethe special

nut, spacer,and bushing(see next pagel,
2. Clean the antenna mast housing threads, then

reinstallthe spacerand bushing.
PLASTICSLEEVE ANTENNA MAST
Viewfromwireside
4. Tesl motor operation:
EXTEND: Connectbatterypower to the No. I and

No. 2 terminalsand groundto the No. 3
5. Usethe antennanut wrench and torquethe special
terminal.
nut to 2.3 N.m (0.23 kg-m. 1 .7 lb-tt). lf the special
nut is over-torqued,the antennamay stick. It stick-
RETRACT:Then disconnectpower trom the No. 2 ing occurs. back the nut off until the antenna
terminal. moves freelv.
23-213
Stereo Sound System
AntennaMast Replacement
NOT€: The antenna mast alone can be replaced Hold the new antenna so the teeth on the drive
without havingto removethe power antennamotor. cable face in the directionshown, and insen the
drive cable into the antennahousino.
1. Removethe specialnut, spacer,and bushing.
2. Carefullywithdraw the antennamast while exten-

ding it by turning the radio switch ON.
g.- SPECIALtIUT
(3
\,.- SPACER
BUSHII{G
ANTENNA MAST DRIVE CAELE
ANTENNAwRENcH
/ ,-/ oTJAA-OO10{)08
4. Check for engagsment of the cable teeth to the

drive gear by carefully moving the cable up and
down,
Turnthe radioswitch "OFF", and let the motor pull

the drive cable insidethe ant€nnahousing.
o- Cleanthe threadson the antennamast housing.

SPECIALNUT
2.3 N.m 10.23ks-m,1.7 lb-ftl Insert the antenna mast into the antenna housing,
install the bushing and spacer, and tighten the
TEETH sp€cialnut to 2.3 N.m (O.23kg-m. 1.7 lb-ft).
NOTE: It th€ specialnutis overtorqued,the anten-

n8 may stick, lf sticking occurs, back the nut off
until thg antonna moves lrselv.
8 . Check thst th6 sntenna mast retracts and extends

fully wh€n th€ radio switch is turned ON and OFF
repeatedly.
POWENANTENNA
MOTOR
23-214
PowerAntennaMotol DoorSpeakerRePlacement
Replacement
Remove the trunk right side trim panel. Remov€ the door panel.
Disconnect the 3-P connector and antenna lead 2 . R€mov6the tour screws, then disconnectthe 2-P
from the motor, th€n remove the special nut and connoctor from the speak€r, and remove the
mounting nut, and take out the motor with the soeaKer,
antennamast,
OTJAA-OOIOOOA (0.23 kg-m, 1.7 lb-ft)
SPACER
ANTENT{A
LEAD
colrr{EcToR
DRAIN HOSE
MOTOR
BRAC(ET
MOUNTING
NUT
When installing the new antenna, tightsn the

special nut first, thon tighten the mounting nut on
the motor brack€t.
23-215
StereoSoundSystem
RearSpeakerReplacement Tweeter Replacement
1. Removethe three nuts from insidethe trunk, then 1. Carefully pry the tweeter cover out of the
disconnectthe connectorand removethe speaker dashboard.then disconnectthe connectorsfrom
assembly. the soeaker.
/
LEFTREARSpeeren lsseireLv
LEFTTWEETER
COVER
Removethe two screws and removethe tweeter

from the cover.
2 Removethe three screws from the adapter,then

removethe speakercover.
Removethe three screws,then removethe soeaker

f.om the adaDter,
23-216
Woofer Replacement
Removethe rearseat uppertrim panel(seesection
201.
REARCONSOLEPANEL
Remove the four screws and disconnectthe 2-P

connector from the speaker. then replace the
sDeaKer,
WOOFERSPEAKER
2-P CONNECTOR
23-217
Clock
GircuitDiagram
FUEIdd EilGlNECooLAi{T
TEIIIP€MruNEIECT1
COMTROL CIRCUTT
COi'|EI{ATON
UGXTS1VITCH
VI
I
REO/Bt.K
r vaa i llFla httd! on thd lwltdt do mt

8t'|( tlLr to th. v*iclo loood lartsr.
G401
G402
G404
23-218
I
Removal/Terminals
CAUTION:
a All SRS ol6ct cal widng hamosses are qovorod with
yollow outef insulation.
a Betor€ disconnecting tho SRS wire hahoss, inslall
the short connector(sl on th€ airbag(s) (see page
23-2941.
o Reolacotho entire affectod SRS harness assembly it
it has an open circuit or damagod wiring.
a Aft6r installing tho gauge assombly, rechock tho
oporation of th6 sRs indicator light.
Romoval:
I . Removethe right tweeter cover (seepage23-130).
2. Remove the instrument panel visor (see page

23-130).
3. Removethe black Jacepanel (seepage 23-130).
4. Remove the sub gauge assembly (see page

23-131).
F5<- - -Fl
Yry
Terminals: T€rminal Connocts to

Tsrminal wira Connectato Ground
F1 BLK Ground .,OO" SET
F2 RED/BLK Combinationlight switch , , H ' 'U P

G3 __
F3 LT GRN Displayconttol circuit ___--__-.---
G4
F4 YEL lG1 (Main clock power supplyl ,,M" UP
G5
F5 WHT/YEL Constantpower (Time memorY)
NOTE: Theseletters on the switch do not refer to the

VehicleSoeedSensor.
23-219
Horns
a All SRS olectrical wiring hah€sses aro coverod with

a Beforo disconnecting the SRS wire ham€ss, install
tha short connecto.{s} on the airbagls) {see page
23-2941.
a Roplacothe ontire afloctod SRS harnossassombly il
it has an open cilcuit or damag€d wifng.
. HORNS
fesi, page 23-221
HORN SWITCHES
Tesr, page 23-222
I
t
REEL
fesr, page 23-222
23-220
CircuitDiagram Test
BATTERY 1. Disconnect ths 2-P connector and remove the

norn.
I 2. Test the horn by connecting batte.y power to one

terminaland groundingthe oth€r. The horn should
tf*";l sound.
WHT,^YEL
- WHT/YEL
+
HORN
UGTIT 2-PcOlrllrlECTOR
3, lf it fails to sound; replaceit.
23-221
Horns
Switch Test
cAUTtOt{: 5. Installthe short connectoron the airbagconnector.
a All SRS oloct cal whlng hamosaeaa.o coyorod whh
yellow outer insulstion,
a B€loro disconnocting the SRS wlro h!me3s. insiall
iho shon connector(sl on tho alrbag(ll (rce page
23-2941.
a Replacothe €ntirr aftectod SRS hamoss a$embly it
it has an open clrcuit or damagod widng,
NOTE: The radio may havo a coded theft protection cir-

cuit. Be sure to get the customer's code number before
- Removingthe No. 43 (1O Al tuse. AIR BAG
(ln the under-hoodfuse/r6laybox) CONNECTOR
After servica, reconnect pow€r to the radio and turn it
on.
When the word "CODE" is displayed, ent6r the
customer's 5-digit cod€ to restore r8dio operation. SHORT/ ACCESSPANEL
6 . Romove the dashboard lower cover.
7. Disconnectthe cable reel 6-P connectorfrom the

SRS main harness, then connect Test HarnessC
onlv to the cable reel side of the 6-P connector.
Disconnect the baftery negative cable, and then

positive cable.
Make sure the wheels are turned straight ahead.
Remove the two scrows and accoss panel, th6n

remove the short connector trom the acc6ss Danel,
4. Disconnsct the airbag conn€ctor and cabl€ reel

connector.
23-222
8 . Checkfor continuitybetweenthe No 3 terminalof 1O. Remove the two TORXo bolts using a TORX@
the 8-P connector of Test Harness C and body T3O bit, then removethe driver'sairbagassembly.
ground with the horn switch pressed.
TEST HARNESSC
OTLAZ- SL/O3oo
?
CONTINUITY
AIRAAG
ASSEMALY U3o a TOBXo T30 blt
CRUISECONTROL
SET/RESUME
a lf there is continuity,the horn switch is OK
swlrcl{ covER
a lf there is no continuity,go to step 9.
9. Carefullyremove the cruise control SET/RESUME 11. Checktor continuitybetweenthe horn positiveter-
switch cover by prying between the cover and minal and steering shaft with the horn switch
switch in the sequenceshown. pressed.
cRutsE
cot{TRoL
SET/RESUME HORf{
swtTcH TERMII{AL
POSITIVE
cRursE
CONTBOL
SET,/RESUME
swtTcx covER
STEERING
SHAFT
a lf there is continuity;
- Checkthe cable reel.
- check the SET/RESUME switch.
a lf the.e is no continuity,replacethe horn switch
(seesection 17).
23-223
GigaretteLighter
CIGARETTELIGHTER
Repfacement, page 23-226
CIGARETTELIGHTER
RELAY{A-tyD€l
fwrc cotolt:Veuneo,wxrlglu)
IBLK,.nd WHT/RED I
'2
\esr, page 23-70
-rl
-D
r-:-r
- L - l f---l
----------rl
* ccL___J
,__"_
nllfl|.|
l1[0mm[[il]
ummmml
23-224
CircuitDiagram
FUSE/REI.AY
U DER-HOOD BOX tct{utoN
swtTcH _ DASHFUSE/RELAY
UNOER 8OX
6i\\
adf**'* YEURED
I
wHIiBLUTwHr/BLU I
V
STEREO
RADIO/
PITYER
CASSETTE
Bu(
BI.K
I
G40t
G402
G404
G40r
G402
G404
23-225
GigaretteLighter
Replacement
CAUTIO : 3. Disconnect the thermofuse housing flom the
a All SRS olsctdcal widng hamesses arc covsrsd with socket.
y6llow outer insulation.
a Boloro disconnecting the SRS wire hamess. install CIGARETTE
iha short connector(s) on tho airbag(s) (see page LIGHTER
23-2941.
a Replacatho ontira affoctod SRS harness arsombly if
it has an open circuh or damaged wiring.
NOTE; The radio may have 8 coded theft protection cir-

- Removingthe No. 43 (10 A) fuse.
(ln the under-hoodfuse/.elaybox)
After service, reconnect power to the radio and turn it
on.
When the word "CODE" is displayed, enter the
customer's 5-digit code to restoreradioopgration.
UGHT{1.4W
4. Remove the ring nut and s€parate the cigar6tta

lighter socket trom the th€rmal protector.
Wh6n installing the cigarette lighter, align €ach lug

on th€ face pansl, illuminstion ring, and cigarette
lighter socket with the groove in the hole, then
position the bulb housing on ths thermal protector
hw66n ths stops in the radio panel,
SRS MAII{ HARI{ESS
6 . Mak€ sure that the ground wire, bulb sock6t, and

thermofuse housing are sested against the
l. Removethe front console{seesection 2O}.
cigar€tte lightsr assembly.
Remove the radio panel assembly (see page
23-210t.
23-226
RearWindow Defogger
CAUTION:
a All SRS electdcal wi ng hahosses ale covared with
a Beforo disconnecttng the SBS wile harne$, install
the short connactor on tha airbag(3), then discon-
nect the wiro hamess (se€ page 23-294).
a Replacoth6 entira aft6ct€d SRS harnessassembly il
k has an open circuii 01 damagod wi ng.
REARWINDOW
sRsMAII{ HAR]TESS
DEFOGGERSWITCH
Test, page 23-230
Replacement, 23-230
UNDER-DASHFUSE/RELAYBOX
wftDow
DEFOGGER RELAY
(A-Typ6l
Test, psge 23-7'l
REAR OEFOGGER
Function Test, page 23-231
DEFOGGER CIRCUIT
{ln the integrated control unit}
fnput Test, pago 23'170
The rear window defoggeris controlledby the integratedcontrol unit. When the defoggerswitch in th€ heatercontrol
panelis pushed,it sendsa signalto the defoggertimer in the integratedcontrolunit and the defoggerstayson for about
25 minutes,or until the ignitionis switchedoff.
The indicatorlight in the switch comes on when the defoggeris ON.
RearWindow Defogger
Circuit Diagram
IGNITION
UTIDER-
IIOODFUSE/NELAY
8OX swncH
UiIDER_
DASI{FUS€]REI,AY
8OX
ll .m.lconrEtfunl
COMBINANON
UGHTS1ITTCH
HEANNCOiITROL
PAiIET
BTJqGRN
+ BU(
I
G801 G4o1
G402
G401
G102
DASHUGI{TS
ERIGTTT
UNIT
ESS
COMTROL
G404 G10,1
23-228
Troubleshooting
NOTE: The numbsrsin the table show tho troubleshootingsequence.
Item to be insDected ?
;
ID !
6 9 E e ! l t o
3; G S ,:o 5o-
{ a
a.: a e <€ g o 3
o+ o+
o
T8 o x
o
v i - 9 !l- o o lo
(t o,;
i i E
.FE: a .E
--c
ot
2 t z a z 1 z a o)
o E
c 9 r 9 c q 9 o c g o
3
o
. ! ; i 3 i c F 3 i
9 c o c 9 c o c
Symptom
6 o co o- 5E
Defogger works, but indicator BLK/YEL'
1 3 YEL/GRN
light dogs not go on.
Oefogger does not work and 3 1 YEL
indicator light does not go on.
Defoggor doas not work, but G401
BLK/GRNI,
indicatorlight goes on. G402
2 I 5 5 4 YEL/WHT
G404
BLK/GRN'
G801
Defogger-on time too long or G401

too short compared with the I G402 YEL/WHT
normalON time (25 minutes). G404
23-229
RearWindow Defogger
Switch Replacement Switch Test
1. Removethe front console(seesection 201. Removs th€ heater control Danel.
2, Remove the stereo radio/cassette player (s66 page Check for continuitv between th€ terminals accord-
23-21Ol. ing to the table.
3. Disconnectthe air mix cable from the heater.
\ Terminal
t1 14 l6 l2
t".*"__\
ON
-o
OFF
BEARYVITDOW
DEFOGGERSWITCH
ASSEMBLY
Remove the two mounting screws and diaconnect

the connectors, then remove the hester control
paner.
Install in the reverse order of removal.
o. After installing the control panel, connect the air

mix cable (see section 22), and mak€ sure the
temperature control function works correctly.
23-230
FunctionTest DefoggerWires Repair
CAUTION: Be careful not to scratch or damago tho NOTE: To make an effective repair, the broken section
defogger wires with ths toster p1ob6. must be no longerthan one inch.
1. Check for voltage between the positive te.minal 1. Lightly rub the srea around the break with tine steel
and body ground with the ignition switch and wool, then clean it with alcohol.
deloggerswitches ON.
There should be battery voltage. 2, Car€fully mask above and bslow the broken portion
ot the defogge. wire with cellophanetape.
a lf there is no voltage,check for:
- Faulty defogger relay.
- Faultydefoggerswitch.
- Faulty integrated control unit.
- An ooen in the GRN/BLKwire.
a lf there is battery voltage, go to st€p 2.
POSMVETERMIIIAL
TAPE
Using a small brush, apply a heavy coat of silver

conductivepaint extendingabout 1/8" (3 mm) on
both sidesof the break.Allow 30 minutesto dry.
NOTE: Thoroughlymix the paint before use.
Check for continuity between the negative terminal

and body ground.
It there is no continuity, check for an open in the
defoggerground wire.
Touch the voltmeter positive probe to the halfway

point of each defogger wire and negative probo to
the negativeterminal.
There should be app.oximately 6 V with the igni-
tion switch and detogger switch ON.
a lf the voltage is as specified, the defogger wire

is OK.
a lf the voltage is not as specified, repair the
defogger.
- lf it is more than 6 V, ther€ is a break in the
negativehalf of th€ wire.
- lf it is l€ss than 6 V, there is a break in the
Dositivehalf of the wire. 4. Check lor continuityin the repairedwire.
Apply a second coat of paint in the same way Let it

drv three hours before removing the tape.
23-231
SeatHeaters(Canadal
SEATBACKHEATER
Test,page23-236
SEAT HEATERRELAY
Test, page 23-236
SEATHEATERMAIN RELAY
lA typ6l
Test,page23-70
SEATCUSHIOT{
HEATEN
Test, pago 23-236
SEAT HEATERSWITCH
Test, page 23-235
Replacement.page 23-235
Description
Two heatersare providedin each front seat; one in the seat cushion and another in the seat back. In normal use,
temperatureis automaticallycontrolledby the thermostat[OFFabove104oF {40oCl] built into eachseatcushionheater.
Breaker1 [OFF above 'l22oF (50oC)l and breaker2 IOFFabove 158"F (70"C)1cut ott the circuitto preventabnormal
temoeraturerise.
23-232
CircuitDiagram
BOX
FUSEfrELAY
UNDER.HOOD IGNITION
SWITCH
BOX
OASHFUSE/RELAY
UNDER-
MAINRELAY
SEATHEATER
R.SEAT
HEATER
SWTCH
l 1
-t 8LK
TI
BLK
C R,SEAT REI.AY
HEATER
t l l - l
I
8 LK
I lr- |
rr t.----J I
i Ii i1
r >
i|
r r < l
r r l l
ii ii 9l ! 8t 8 , I'
| | O l I
I r i
f o**..IJ i
L.SEAT
CUSHION BACK
L,SEAT CUSHION
R.SEAT
R.SEATHEA]ER
BLK
I
_lr
-
I OFFdbove122'F lSOc)l
BRI : BREAKER G521
:
TH1 THERMOSTAT IOFF above1O4oF{4Oc)]
BR2: EREAKERI OFFabove158oF(7Oc)l
23-233
SeatHeaters(Ganadal
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence,
Item to be insDected o
o o o
! so
9 <
r 6
< € < E o
^ O < c v ; o
3 6 ;
o
o f
F
- 7
:
3
(r)6 CI
(D o o (D
Z J z t z ) ro
o 'oE
c q --c
3 i i
Symptom 9 c @
o
6 = Co o o o <t o*g
Seat heaters work, but indicator light
does not go on. 1 BLK
Seat heaters do not work and indicator G401
light does not go on. G402 WHT/BLK,
BLK/GRN
I 5
G404 YEL/BLK,
WHT/RED
G521
Seat heaters do not GRN/WHT,WHT/GRN,
wo.k, but indicator Left or right seat 1 BLU,WHT/RED,
light goes on. WHT/BLU
Seat cushion heater or seat back hearer
does not work, but indicator light goes 1 BLU, GRN
on.
23-234
Switch Replacement Switch Test
1 . Pry the switch out ol the center consolepanel. 1. Remove the seat heater switch Jrom the
console.
Disconnectthe 6-P connectortrom the switch.
2. Check to, continuitybetweenthe terminalsaccor-
ding to the table.
6-P CONNECTOR
Torminal
I o
Position
ON o- a\
\7
--o
OFF o- Z\
\7
--o
6t
NOTE: Left and right seat heaterswitches are the

same.
6
INDICATOR
t|Gt{T
l0.84wl
23-235
Seat Heaters(Canada)
HeaterTest Seat Heater RelayTest
1. Disconnectthe 6-P and 4-P connectorsas shown Remove the soat, then rsmove the relav from the
below. bottom of ths seat.
NOTE: Left front seat is shown. Rightfront seat is Check continuity between relav terminsls.
similar. a Ther8 should be continuity between the F and A
terminals, and the C and D terminals when
power and ground are connected to th€ F 8nd E
wire side terminals.
a Th6rs should be continuity between the F and D
t6rminals when power is disconnected.
6-P
CONNECTOR
S€AT HEATER
RELAY
r!+41
To FLOOR
HARNESS
F+P
D E F
wire side
Soat cushion hoata.: NOTE: Left and right ssat heater relavs are the
Check for continuitybetweenthe No, 2 and No. 3 same.
terminals(R x 103scale).
Thsre shouldbe continuity.
Seat back hoatel:

Check for continuitybetweenthe D and No. 8 ter-
Irr ( J
'T t_i ,y'
minals(R x 103scale).
rT
There shouldbe continuitv. t-F---------to <f -
23-236
I
Sunroof
a All SRS olsctricsl wiring harnossesaro coveled wlth

a Botob disconnecting tho SRS wire ha;noss, install
ths short connector(s) on tho airbag(s) (soe pag6
23-294t.
a Replacetho entiro affsctod SRS harnessassembly if
h has an op6n circuit or damaged widng.
SUNROOFMOTOR
Test, page 23-241
SUNROOF
CLOSE RELAY
{B typo}
Test, Pag€ JD
l
sut{RooF r:-l I
OPEI{RELAY
(B-typ.)
Tost, page 23-72 CC
r llfll-l
m[[[[I]
|lm[
llm[mmm|]
23-237
Sunroof
CircuitDiagram
COMEINATION
UGHTSWTCH
V
II
nED/Bu(
I
I
l.
I A
I
RqD
OASHUGHTS
ERIGHTNESS
CONTROL
UNIT
23-23A
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence'
Item to be inso€cted
sE>
;,d Q
bg o- g @
o!D ID gE
6 8 9 5 b 6 >
E o o
= ! o < E ( a
aeg
Y 6 I
b= 6t' 5 8 (t;
3
o o -
.o . 65 e
F.6
Y
r.. !
- l 9 g g E 3
2
v xF !. Y
2 z a z ) z ) ; ID - c
=-c ; ! c!P 6
9i b i ! ; 0)
-9c 9 c
Symptom d 6 6 rL o a o (L
Sunroof does not move, but motor 1

tuns.
With either WHT/BLU,
Sunroot does not G401
switch. BLK/YEL,
move and motor does 4 6 G402
GRN/YELor
not run (sunroof can G404
GRN/RED
be moved with
sunrootwrench). With OPEN GRN/YELor
1
switch. GRN/REO
with cLosE GRN/REDor

1
switch. GRN/YEL
23-239
Sunroof
Switch Test/Removal
'1.
Caretullypry the switches out of the dashboard, 3. Ch6ck for continuity between the terminals in each
then disconnectthe connectorsfrom them. switch position sccording to the table.
\ rormrnal
A I D
Position \
OFF o o
OPEN G" @ -o o -o
ctosE G
A -o
A
B
c
D
E
2. Removethe sunrool switch from the switch o8n6l.
)t) ucHT
t1.1wl
23-240
Motor Test
Removethe high mount brake light cover'
Remove the headliner,then disconnect the 2-P

connectotfrom the sunrooJmotor.
Test the moto. by connectingpower and groundto

the 1 and 2 terminalsaccordingto the table. The
motor shouldrun smoothlY.
NOTE: Motor clutch test is in section20
No. 1 terminalto ground

OPEN No. 2 terminalto Power
No. 1 terminalto Power
CLOSE No, 2 terminalto the ground
2.P CONNECTOR
wire sid6
2.P CONNECTOR
lf the motor does not run smoothly,replaceat
23-241
PowerMirrors
CAUTIOT{:
a All SRS olectrical wi ng harnsssos a.e coverod with
y6llow outol insulation.
a When disconnecting th€ SRS wiro harness, install
the short connector on th8 Eirbag(s)then disconnect
tho wire hamess lso€ pago 23-2941.
a Replac€the ontirs affected SRS hamess assembly if
POWER T'IRRORSW|TCH
Test, psge23-245
POWERMIRRORS
Test,page23-247
Repfacement, page23-247
23-242
CircuitDiagram(USA)
UNDER.HOOO
8OX
FUSSRELAY
ryIl' fffi,'' ffi,'oo;l --*-{$S,lfSl

eF["*lT -f
- OASH
UNDEN
FUSgREtAY
BOX
POWEN SWTCH
MIRNOR
r l l i
__________Jr
/tt-----_---_-------:tl\
R.rcWER
MIRROR
Grc1
G,to2
G1o4
23-243
PowerMirrors
CircuitDiagram(Canada)
- r.tooD
uriDER
R,SE/REIAY
BOX
*rrr |.*-;iôJ;l
I tr00A) t50At I
tt)-flo<\!twdT-l
r/ aXr \ rcnrlor
\ lG2 , sl{lrcH
\l-/
I
/EL
I lm lili,tf,"e$"
BIJ(/YEL
POWER
MIRRON
SWTCH
OErcGGER
DOWN
23-244
SwitchTest
1. Remove the switch as described under
,,FUNCTIONTEST".
2. Checkfor continuitybetweenthe terminalsin each

switch Dositionaccordingto the table.
Mirror SrYitch
\ lermlnal
I 10 5 7
Position \
OFF o- -o
o- -o
UP
o- -{.} _o
G- _o
UP
o- -o
R DOWN
----
I NIGHT
o- LEFT T
I
tEFI
o- -o
o- -o
RIGHT
G- -o
OFF o- -o r l l l
LL__-___IJ
o- -o
UP
o- -{.} =o
o- L l l R L l I R
o- -o
L DOWN
o- -o
LEFT
o- -o
o- _o
RIGHT
o- -o
UP
oeroccen
( \y' swrTcH ,{l RIGHT
Dofoggor Switch(Canada) Il "'i i

I
z \ l -
\ lermlnal
l0 lv
I OEFOGGER
I
I i
Position
ON
\
o- -o
I rNDlCAloR
| (rED)
L
;}T l*-- J
OFF o- --o T-;-f

E ;f,
, ? ' 1 ,. ? ' 1 ,
23-245
Power Mirrors
FunctionTest
Carefullypry the switch out ot the door panel. a lf the mirrorneithertilts down nor swings left, repair
thE YEL/BLU\,virE.
Oisconnectthe connectorsfrom the switch, a lf the mirrorworks properly,checkthe mirrorswitch.
Right mirlol inopemtiv€:

Connectthe BLK/YELterminalot the 1O-pconnectorto
the GRN/BLUterminal and the BLU/ORN{or BLU/BLK}
terminalto body ground with jumper wires.
The right mir.orshouldtilt down (or swing left) with the
ignitionswitch ON.
a It the mirror does not tilt down (or does not swing
left), removethe right door panel and check for an
open in the BLU/ORN(or BLU/BLK)wire betweenth€
---) right door mirror and the switch
ll the wire is OK, check the right door mirror motor,
a lf the mirrorneithertilts down nor swings lsft, repair
the GRN/BLUwire.
a lf the mirrorworks properly,checkthe mirrorswitch.
Defogger test (Canadsl
NOTE: Checkthe No. 9 {15 A) Iuse in the under-dash

lcansda) Juse/relaybox betore testing.
vi€w trom wire side.
1. Check for voltage between the BLK/YELterminal of

the 2-P connectorand body ground with the igni-
MirrorTest tion switch ON.
There should be battery voltage.
One or both inoporative: a It the.e is no voltage, check for an open in the
1. Check for voltage between the BLK/YELterminal BLK/YELwire between the under-d8shJuse/
and body ground with the ignitionswitch ON. felay box and the detoggerswitch.
The.e should be battery voltage. a lf there is bsttery voltage, go to step 2.
a lf there is no voltage,check for;
- Blown No. 9 (15 A) tuse in the under-dash 2. Connectthe BLK/YELterminalof the 2-p connector
fuse/relaybox. to the ORN terminalwith a jumper wire.
- An open in the BLK/YELwire. Both the right and left mirro.s should g.adually
a lf there is baftery voltage, go to step 2. warm up with the ignitionswitch ON.
a It neitherwaJms up, repairthe ORN wire.
2. Checkfor continuitybetweenthe BLKte,minaland a It only one fails to wa.m up, check its mirror
body ground. defogger ef€ment lsee page 23-2471.
There shouldbe continuity. a lf both warm up, check the switch,
a lf there is no continuity,check for;
- An open in the BLK wire.
- Poor ground (G4O1.c402, G404).
Loft mirror inoDorativ€:

Connectthe BLK/YELterminalot the 1O-pconnectorto
the YEL/BLUterminat.and the BLU/ORN(or YEL/GRNI
terminalto body ground with jumper wrres.
The left mirrorshouldtilt down (or swing leftl with the
ignitionswitch ON.
a lf the mirror does not tilt down (or does not swing
left), remove the left door panel and check tor an
open in the BLU/ORN{or YEL/GRN)wire betweenthe
left door mirror and the switch.
lf the wire is OK. check the left door mirrormotor.
23-246
PowerMirrorMotor Test PowerMirrorReplacement
1. C8r€fullypry out the window corneJpanel with a NOTE: Be{ore removing the mirror, lower the window
flat tip screwdriver. tully.
2 . Removethe door panel. 1. Carefully pry out the window corner panel with a
flat tip screwdriver.
Disconnect the 3-P or 6-P connector from the
mirrot. 2. Removethe door Panel.
3. Disconnect the 3-P or 6-P conn€ctor from the

mirlor.
4. While holdingthe mirrorwith one hand,removethe

three mountingscrews with the other.
@-
3-PCONNECTOR 6-P CONI{ECTOR
tusAl (Canadal
4. Test actuato. operation:
TILT UP Connect batterv power to the No.

3 terminaland groundto the No.
4 terminal.
TILT DOWN Connect battery powel to the No.
3 terminal.
SWINGLEFT Connect batterv power to the No,
5 terminal.
SWING Connect battery Power to the No.
RIGHT 5 terminaland groundto the No.
4 terminal.
5. Checktor continuitybetweenthe No. 1 and No. 2

terminals{RX 103scale).
There shouldbe continuity.
23-247
Power Windows
PASSENGER'SWINDOW SWITCI{ PASSENGER'SWINDOW MOTOR

Test, page 23-252 Tost, page23-254
Repfacement,page 23-253 Replacement,section 20
ORIVER'SWINDOWMOTOR
Test,pago23-254
Replacement,
section20
POWERWIITDOWSWITCH
InputTest,page23-251
Tosr,pag€23-252
Repfacement,page23-253
E=E
! E1El
UI{OER.DASHFUSE/RELAYBOX
KEY.OFFTIMER CIRCUIT
{ln th€ integratod control !nit)
Inputtest, p8ge 23-168
Description
Power Window Key-olf Tim€r Oporation:
The power windows can still be operatedtor aboul 1Ominutesafter the ignitionswitch is turnedfrom the " " to the ,,1,,
or "O" positionas long as neitherdoor has been opened.This providesa convenienceto parkedoccupanrs.
23-248
I
CircuitDiagram
BOX
FUSE/RELAY
UNDER_HOOD
ernenv
llffif-ffifl
@wnolu
\:_/
wtNDow
PASS€NGER'S
WINDOWMOTOR
23-249
Power Windows
Troubleshooting
NOTE: The numbe.sin the table show the troubleshootingsequence.
Item to be inso€ctod
! !
E !
9:.\
! ! g
; !
o .E
3E 3
]
E ' o
ae ! 3 , 3 'P 3Oo
o o
(\
E .= ttt a
s 6 c\
i 3 ' i P !
..
( 9 I6
i t ID
t o 3
e E
! i :
(D 3 o 9 0
z ) i z
C;
z
; o i o 't g 8
c g
3 - c
ID o
3 ! 3 ' o 9 i
Symptom 9 c '
o .z @ o
{ , o
oc'
El= (D .o Y = o-
Neither window works. G401
1 2 G402 GRN/BLK
G404
Driver'swindow does not work. 3 4 WHT/BLK
Driv€r's window does not work in
2 a BLU
AUTO,
Passenger'swindow do6s not
work. 1 2 2 4 BLU/BLK
One or both windows do not work
within 1O minuresaft€r the ignition 1 J
switch is OFF.
23-250
I
NOTE: The control unit is built into the master power

window switch, and onlv controlsthe driver'swindow. 1O-PCONNECTOR
'1. 3-P CONNECTOR

Removethe driver'sdoor handlepaneland discon-
nect th€ 1O-P8nd 3-P connectorsfrom it.
lnsoectthe connectorterminalsto be surethey are

ELKI BLK' BLU/BLK
a lf the terminals are bent, loose, or corroded,
reDair them as necessary, and recheck the
sYstem. lrom
wire side
a It the terminalslook OK, make the tollowingin-
out tests at the 1O-Pconnectol RED/YEL
- lf a test indicatesa ptoblem,{ind and correct
- lf all input tests prove OK, the control unit WHT/BLK BLU/YEL
must be faulty; replace the master power

window switch.
No. Terminal Test condition Test: Desirsd rssult Possiblecause if rosult is not obtained
Under all conditions. Check for continuityto ground: . Poor ground (G4O1, G4O2,G4O4)
1 BLKl
There shouldbe continuity. ' A n o p e ni n t h e w i r e .
'16
WHT/BLK lgnitionswitch ON. Check for voltageto ground: Blown No. 1 5 or {2O A) fuse.
There shouldbe battery (ln the underdash fuse/relaYboxl
voltage. Faultypower window relaY.
BLU/BLK
Checkthe driver'swindow . Faultydriver'swindow motor.
RED/BLU connect the wHT/
BLK terminalto the motor: lt shouldrun. . An open in the wire.
and
RED/YEL RED/BLUterminal,
and the RED/YELter-
minalto the BLKI ter-
minal,then turn the
ignitionswitch ON.
4 BLU/YEL Connectthe BLU/BLK Checkthe passenger'swindow Faulty passenger'swindow motor.
ano terminalto the BLU/ motor: lt shouldrun. Faultypassenger'swindow switch.
BLU/GRN GRNterminal,and the An open in the wire.
BLU/Y€Lterminalto
the BLK terminal,
then turn the ignition
switch ON.
5 BLU connect the wHT/ Connectan analogohmmeter Faultypulser.
ano BLK terminalto the to the BLU and BLK2terminals: Faultydriver'swindow motor.
BLK' RED/YELterminal, The meter needleshouldmove An open in the wire.
and the BLK2terminal back and forth as the driver's
to the RED/8LUter- window motor runs.
minal,then turn the
ignitionswitch ON.
Power Windows
MasterPowerWindowSwitch Test Passenger'sWindow Switch Test
1 . Removethe driver'sdoor handlepaneland discon- '1.
Carefully remove the passenger's door handle
nect the 1O-Pand 3-P connectorsfrom it. panel from the door, then disconnect the 5-p
conneclor.
, Check{or continuitvbetweenthe terminalsin each
switch positionaccordingto the table. 2. Checkfor continuitybetweenthe terminalsin each
DRIVEB'SSWITCH
oooR HANDLEPANEL PASSENGER'S
WINDOW
OOORHANDLE PANEL
MASTER POWER
MAIN SWITCH
wtNDowswtTcH
E F G H I J
Ddvo?'s Switch
\ Terminal
I F T""ryl
\_____ B c D
Position Position
--o --o
OFF UP o-
UP o- --o OFF o- --o o- --o
DOWN o- 00wN o- -o
DowN(AUTo) o- -o
Passong6r'sSrvltch
\ rermrnal
J
PositlonI Mainswitch\
ON --o
o- -_o
OFF
OFF
o- --o
UP
ON
o-- --o
OFF o- --o
-o
DOWN
ON
o- --o
OFF o- --o
23-252
Switch Replacement
Maslcr powor window swilch: Passangor'awindow Swhch:
1. Removethe mounting screw and pry the driver's 1. Remove the mounting screw and pry th€ passen-
door handlepanelout of th€ door panel, ger's door handls panelout ot the door pan8l'
2. Disconn€ctthe 10-P and 3-P connectorsfrom it' 2. Disconnectthe 5-P and 3-P connectorsfrom it.
3.P CONNECTOR 5.P CONNECTOR
DOOR
DRIVER'S
HANDLEPANEL DOOR
PASSENGER'S
HANDLEPANEL
3. Removethe master power window switch from the 3. Removethe passenger'swindow switch from tha
door handle panel by removingthe four mounting door handle panel by removingthe two mounting
screws. screws.
MASTER POWER
wtNDowswlTcH
PASSEI{GER'SWINDOW SWITCH
DOOR HANDLE PANEL
23-253
Power Windows
Driver'sWindow Motor Test Passenger's
Window Motor Test
Motor Tast: Romove the door panel (see s€ction 20).
1. R€movethe door panel (sees€ction 20).
Disconnect the 2-P connector from the motor.
2. Disconnect the 4-P conn€ctor from th6 motor.
Tsst motor operation by connecting power and
3. T€st motor operstion by connecting battery power ground to the No. 1 and No. 2 tsrminals.Test the
to the No. 3 terminaland g.oundingthe No. 4 ter- motor in each dir€ctionby switchingthe leads.
minal. T6st the motor in each direction bv swit-
ching the lesds. 4. lf the motor do€s not run, r€Dlaceit.
4. lf the motor does not run, reolaco it.
View lrom wire sido
Pul3.r Tcst:
Connoct the test leads of an analog ohmm€tor to ths
No. 1 8nd No. 2 terminals. Run the motor by connecting
power and groundto th6 No. 3 8nd No. 4 terminals.The
ohmmeter needl€ should move back and forth Es the
motor runs. PASSoIGERS
wtN00w
Irl0TOR
23-254
Power Door Locks
CAUTION:
a All SRS aloctdcal wiring harn€ss€sare cov€r€d with
a Bofore disconnectitrg tho SRS wire harness. install
tha short connoctor on th6 airb8g(s)th6n disconnoct
tho wir€ harnoss (s8e pags 23-2941.
a Replacethe ontiro aftscted SRS hamess assembly it
it has an opsn circuit or damaged witing.
DOOR LOCK SWlTCtl

Test, page 23-262 PASSENGER'SKEY CYLINOERSWITCH
Test, page 23-26'l
PASSEI{GER'SDOOR LOCK ACTUATOR

Test. page 23-261
R€Dlacement,section 20
CONTROL U'{IT
Test, page23-258
tcl{lTrol{ KEYSWITCH
Test,page23-171
DRIVER'SOOOR LOCK ACTUATOR

and LOCKKNOBSWITCH
Test, paee23-260
Replacement,section20
23-255
PowerDoorLocks
CircuitDiagram
- HOODFUSE/BEIAY
UNOER 8OX
PoIYER
000RtocKcoNlrot u n
N 8l PASSENGER'S
3 lpAssENG€R.s
5
l,,
' I 000RKEY | 00oRtocK
I SWITCH I CYUNDER
lGNlTlot'l PASS€NGER'S
I I SWITCH
KEY
swtTcH 3fi'f;.'.| |
8LK
I
Troubleshooting
Item to be insoected
d q
! i 3
o, !n o, 3
* R I
<€ 3 3
t 5
o l r o
I
3
{ 6 o
o >
2 )
o o
- f 8€
Symptom 9 c
O Y 5 5 o o- o IL (L o €
G401
Power door lock system 2 G402 W H T
1
doesn't work at all. G404
Doorsdon't lock or G401

Both GRN/WHT
unlock with the I G402
doors or GRN/RED1
driver's power door G404
lock switch. One YEL/RED
2
ooor or WHT/RED
Ooorsdont't lock or G401

Both BLK/WHTor
uFlockwith the 1 G402
doors BLK/RED
pass€ngers power G404
door lock switch. One YEL/REO
1
door or WHT/RED
Doorsdon't lock Both G401
BLU/RED
or
with th€ driver's doors 1 z G402
BLUiWHTI
door lock knob. G404
{lgnitionkey not One YEL/RED
insert€dand doors ooor 1 3 or WHT/RED
closed.l
Doors donit lock or G401
Both BLK/REDor
unlock with the 2 1 G402
doors BLK/WHT
passenger'sdoor G404
key cylinderswitch. One YEL/RED
1 3
door or WHT/RED
Doors will lock when the kev is G 4 0 1 BLU/WHT'
still in the ignitionswitch and I G402 G R N / R E D '
the driver's door is ooen. G404 or GRN/BLU
23-257
Power Door Locks
ControlUnit InputTest
Removetha driver's door panel {see section 20)
and disconnect the 18-P connector trom the power
door lock control unit.
Inspectthe connectorterminalsto be surethey are

a It the terminals are bent, loose, or corroded,

svstem.
out test at the connectorterminals.
- lf a test indicatesa problem,Jindand correct
the cause.then recheckthe system.
- lf all ingut tests DroveOK, the control unit
must be taulty; replaceit.

beengiven a numbersuffix to distinguishthem {tor
examole, GRN/RED1and GRN/RED,are not the POWERDOORLOCK
same).
1A.P CONNECTOR
View from wi.e side
BLU/WHTI GRlII/wXT
BLK/WHT BLU/WHT'
23-258
Disconnect the 1 connecto?from the control unit.
No. Wile Test condition Test: Dosi?adresult Possibli caus6 it rosult is not obtainod
1 BLK Under all conditions. Checktor continuityto ground: . Poor ground (G401, G4O2,G4O4).
There shouldbe continuitv. . An ooen in the wire.
WHT/RED connect the YEL/RED Check door lock operation: . Fauly actuator.
ancl terminalto the WHT All doors shouldunlock. . An open in the wire.
YEL/RED terminal,and the
WHT/REDterminalto
the BLK termlnal
momentarily.
Connectthe wHT/ Check door lock ooeration:
REDterminalto the All doors shouldlock.
WHT terminal,and
the YEL/REDterminal
to the BLK terminal
momentarily.
Reconnect the 18-P connector to the control unit.
No. wiro Test condition Tost: Dosirod te8ult PosEiblocauss if result is not obtainsd
WHT Under all conditions. Chsck tor voltageto ground: . Blown No. 44 (15 Al fuse.
There should be battery (ln the under-hoodtuse/felayboxl
vo|tage. . An open in the wire.
4 GRN/WHT Driver'sdoor lock Check for voltageto ground: Faultydriver'sdoor lock switch.
switch in LOCK. Thereshouldbe 1 V or less. Poor ground (G4O1,G402, G404).
An ooen in the wire.
G R N / R E D T Driver'sdoor lock
switch in UNLOCK.
BLKi RED Passenger'sdoor lock Checkfor voltageto gfound: Faultypassenger'sdoor lock switch.
switch in LOCK. Thereshouldbe 1 V or less. Poor ground (G4O1,G402, G4O4).
BLK/WHT Passenger'sdoor lock
switch in UNLOCK.
6 BLU/WHTI Driver'sdoor lock CheckJor voltageto ground: Faultydriver'sdoor lock actuator.
knob in LOCK. There shouldbe 1 V or less. Poorground (G4O1, G402, G4O4).
An oDenin the wire.
BLUi RED Driver'sdoor lock
k n o bi n U N L O C K .
7 GRN/BLU Driver'sdoor open. Check for voltageto ground: Faultydoor switch.
Thereshouldbe 1 V or less. Poorground.
NOTE: Beforetesting, remove An open in the wire.
G R N / R E D ' Passenger'sdoor No. 46 (15 A) tuse in the
open. under-hoodfuse/relavbox.
8 BLU/WHT' lgnitionkey is in the Checkfor voltageto ground: Faulty ignitionkey switch.
ignitionswitch. Thereshould be 1 V or less. Poor ground (G4O1, G4O2,G4O4).
9 BLKi RED Passenger'sdoor key Checktor voltageto ground: Faulty passenger'sdoor cylinder.
cylinderin LOCK. There shouldbe I V or less as Poorground (G4O1, G402, G404).
the switch is turned. An oDenin the wire.
BLK/WHT Passenger'sdoor key
cylinderin UNLOCK.
To prevent damago to the motol, apply battefy voltago only mom€ntarily.
23-259
PowerDoorLocks
Driver'sDoorLockActuator Test
t _ Remove the door panel (see soction 2O), Check for continuity betw66n ths tsrminals in each
2 . Disconnect the 6-P conn€ctor from ths actuator,
\------ ry'"d 6
Position
r0cK o- -o
UNLOCK o- o
DOORLOC|(X[O8
View trom wire Sids
a Test actuator operation:
LOCK: With battery pow6r connected to the No. 4

terminal,groundthe No. 5 terminalmom€ntarily,
UNLOCK:With baft€ry power conn€cted to th6 No.

5 terminal,groundth€ No. 4 tarminalmomentarily.
CAUTION: To provont damago to thc motor, only

connocl powor momontarlly.
4. lf the actuator doea not work properly, r€placo it.
23-260
Passenger'sDoorLock KeyCylinderSwitch Test
Actuator Tost
1. Removethe door panel (seesection 201. 1 . Removethe door Danel(seesection 20),
2. Disconnect the 6-P connector from the actuator. Disconnectthe 6-P connectorJromthe actuator,
6-P CONI{ECTOR
View from wire side
6.P CONNECTOR
View from wire side
T6st actuator operation:
LOCK: With battery power connected to th€ No, 4

terminal,groundthe No. 5 terminalmomentarily,
UNLOCK:With batterv power connected to ths No,

5 t€rminal,groundthe No. 4 terminalmom€ntarily. 3. Checkfor continuitybetweenthe terminalsin each
CAUTION: To provont d€mag€ to ths motor. con-
nsct power only momontadly,
4. It the actuator does not work properly, replsce it.

\_____jy"'l I o
Position
LOCK o- ---o
UNLOCK o- --o
23-261
Power Door Locks
Door Lock Switch Test
1. Removethe door handleoanel.
3.P CONNECTOR
DOORIOCK SWTTCH
Disconnectthe 3-P connectorJromthe switch.
Check for continuity between the telminals in €sch

Terminal
\ A I
Poshion
LOCK o-
OFF
UNLOCK o- o
23-262
Wiper/Washer
WINDSHIELD
WIPER/WASHER
swtTcH
Test, page 23-266
Repfacement, page 23-267
WINOSHIELDWIPER
ARMS/BLADES
Replacement,
WINOSHIELDINTERMITTENT
WIPERPELAY l8-typo)
Test, page 23-72
WINDSHIELDWIPER
MOTOR ASSEMBLY
Test, page 23-268
Repfacement. psge 23-27 O
Ut{DER.DAS}I
FUSE/RELAYBOX
MOTOR
Test, page 23-269
WIPER/WASHERCIRCUIT
{ln the integrated control unit}
23-263
WiperMasher
CircuitDiagram
- HOOD
UNDER FUSE/RELAY
8OX DASHFUSE/RELAY
UI{DER_ BOX
INTERMITTENT
WIPERCIRCUIT
flntlF intoEnod \
BLK BLK Btx BI.J(
G30l G30r G4o1 G30l G101

G402 Grc2
m4 G40/t
23-264
Troubleshooting
Item to be
inspected
6
l! P 9 ,
3 E I -vii
G
a; E 5 6 6 E
E!'
g E! X ! t
r'. f -
o:?
i
z ) 3 E E E E o)
3
c 9
t i
E
E E
6 : o o
.2 o a) .2
9 c
Symptom ; 3 3 Z Y i5; o o- O E
Wipers ln all GRN/BLK

1 4
do not positions G301
ln INT G401 G R No r
1
G402 BLU/WHT
t
G404 BLU/YELor BLU
In LOor Hl
') BLU/YEL
ln MIST
Bladesdo not returnto
park positionwhen 1 BLU/WHT
wipers are turned OFF,
ErraticintermittentcY- G R N / B L KG, R N .
cle or wipers do not 1 BLU/WHTor
work in lNT. GRN/RED
Little or no washer fluid 4 2 G 3 0 1 BLK/YEL

is pumped.
Wipers and washer do
not work at the same I BLK/YEL
ttme.
23-265
Wiper/Washer
Wiper/Washer
Switch Test
1 . Remove the dashboard lower cover and knee
bolster.
2. Disconnectthe 5-P and 20-P connectorstrom the

main wire harness.
Checkfor continuitybetweenthe terminalsin each

positionaccordingto the table.
20-P COI{NECTOR
DASHAOARD
LOWERCOVER
KIEE EOLSTEF
U l4 15 16 11 24
Position
OFF o-
INT o- o-
t0 o-
HI G_ o
Mistswitch'0N' --o
switch'0N'
WEsher o- ---o
23-266
I
Switch RePlacement
Wiper/Washer
CAUTION: 2 Removethe steeringcolumncovers,
a Atl SRS clectrical wlring harno!343 ato covarcd whh
yollow outct Inrulatlon.
a Bators dbconnocting tha SRS wito hlmcss, lnstell COLUMNCOV€R
UPPER
th6 rhort connoctor(sl on tha sitbag(sl (sae pago
23-2941.
a Roplaco thr cnllro Effectad SRS hamcls asr.mbly lf
It has an op€n circult or dsmlgod whlng'
1. Remova the dashboard lower cover and l(nee

bolster.
Disconnectthe 8-P connector, then remove the
wip6r/washerswitch.
CONNECTOR
LOWERCOVER
DASHBOARD
23-267
Wiper/Washer
WindshieldWiper Motor Test
Open the hood and removethe cap nuts and the

wipef arms. Be caretulnot to damagethe hood. lfl (BLU/YEL}
Disconnect the 5-P connector from the wiDer B lGif{/BLt(} LO(BLU}

motor assemblv.
5. Rgconn6ct the 5-P connactor to the wio€r motor

assembly.
6 . Connsct an analog voltm€ter between the As

(BLUA /HT) 8nd the E IBLK) terminals. Fun the
motor by turning the wip€r switch ON (LO or Hl
position). Th6 voltmete. should alt€rnately indicate
O V and mors than 4 V.
5.P CONNECIOR
termanalside.
2 Test motor ooeration;
LOW SPEED:Connect battery power to the B

(GRN/BLKIterminal and ground to
the LO {BLU)te.mins..
HIGH SPEED:Connect battery power to the B
(GRN/BLK)terminal and ground to
the Hl (BLU/YEL)termtnsl.
4. lf the motor does not run. or Jailsto run smoothlv,

reolace it.
23-268
Windshield Washer Motor Test
Rsmovs the 18ft inner fendor.
Disconnect the 2-P connector from the washer

motor.
T€st the washsr motor by connecting batt€ty

oowel to the @ terminal and grounding the O
terminsl.
2-P
a lf the motor does not run, or fails to run
cot{r{EcToR
smoothly, replsce it.
a lf the motor runs smoothly, but little or no wash-
er tluid is pumped, check for a disconnscted or
blockedwasherhose,or I cloggedpump outlet.
23-269
Wiper/Washer
WindshieldWiper Motor Replacement
Open the hood and remove the caD nuts and the Removethe three mountingbolts and one nut from
wiper arms. Be carefulnot to damagethe hood. the wiper linkage,then removethe wiper motor.
Removethe windshieldlower molding,hood seal,

and air scoop by prying the trim clips out and
removingthe sctews. NUT
22 N.m {2.2 kg-m,16 lb-ftl
CAPNUT
MOUI{TIIIIG
BOLTS
10 .m {1.O kg-m, 8 lb-ft|
3, Disconnectthe 5-P connectorfrom the wiDermo-

tor, then remove the wiper harnessfrom the wiDer
linkage.
VNPERMOTOR
WIPERLII{KAGEASSEMBLY
Removethe wiper linkageassemblyby removing

the three mountingbolts.
23-270
I
WasherMotor RePlacement
1. Removethe washer filler neck.
2. R€moveth€ innerfender.
3. Disconnectthe hose and the 2-P connectortrom

the washer motor'
4. Romove the thre€ mounting bolts 8nd pull out the

washer .esetvoil.
5. Romove the washer motor from the washer

reservolr.
6. Removeths washel nozzlesand washer hose as

necessary.
7. During installationtake care not to pinch 8ny

hoses, Instsllthe hose clips tirmly.
8. After installingwasher nozzlss,check/adiusttheir

aim.
23-271
GruiseControl
CAUTION:
a All SRS elect cal wiring harnesaosalo cover€d wiih
yallow out€r insulation.
a 8ofo.e di6connecting ths SRS wire harn6ss, install
the short connector{sl on tho ai.bag{s) (see page
23-2941.
a Roplacethe entiro affectod SRS harnoss ass€mbly if
COI{TROL UNIT
fnputTesr,page23-276
CRUISECONTROLMAIN SWITCH
Test, page23,280
CAALE REET
Replacement,page 23-280 Test, page 23-278
Repfacement.pag6 23-276, 318
SET/RESUMESWITCH
Test, psge 23-278
Repf6cement. pdga 23-27 I
A/T GEAR POSINON

swtTcH
CLUTCH SWITCH Test, page 23-149, 281
Test, page 23-281 Replacoment,page 23-149
Pedal Height Adiustm€nt, section
swtTcH
T€st, pag€ 23-282
Pedal Hoight Adjustmenr, section 'l I
23-272
\
ACTUATOR CABLE
Adjustment, Page23-294
ACUUII,IRESERVOIR
SofenoidTest, page 23'282

Test, page 23-283
Replacement,Page 23-284
Disa$embfy, page 23'285
23-273
CruiseControl
CircuitDiagram
- HOOO
UNDER FUSE/RELTAY
8OX UNOER-
OASHFUSSRE!{Y c0MEtNAnoir
8OX
UGHT
SWITCH
INDICATOR
UGHT
t0.84wl
IP IP
Il
IOSET tb8h,
- rcNrnoN
lL
cot{TRot
MODUI.I
{rcMl
\7
REEL I
t
I ErlJ
l
P(
CRUISE
c0l{TRot
ACIUATOR
VEHICI.T
SP€ED
s€NsoR
{vsst
M,/T: CLUICHSWTTCH\
,,/T: MG€An I
PosrTloir
swrTcH
8u(
l^ 81-K
12,ft, D.l
I
t
{ {
G301 G401 G40t
G402 G4!2
G404 G(X
23-274
Troubleshooting
a The numbe.sin the table show the troubleshootingsequonca.

a Beforetroubleshooting.
- Check the No. 14 (7.5 Al fuse in the undsr-dashfuse/relaybox End ths No' 41 (15 A) fuse in the und€r-hood
fuse/relaybox.
- Checkthat th€ ho,ns sound.
- Check the tachometer for propor operation.
Items to be inspscted o
o o
F E;
@
3 ;
o o 6
o o
'P-
o
o T6;
3 o E -g I
'P-
o
o
q o o 3 E
; !
!l
6 o (! E 6 9
o
,E
ut
z o
3
o
o o E'g5
I <t ' o
o
P ; E
= E >
o
u, o
o o o = >
Symptom
6
F
ut
a
o
o
E
o
;: o gg ! o
o
o
o o
-q .9
BRNMHT,
LT GRN/BLK,
Cruisecontrol cannot be set' G401 BRN/BLK,BRN/RED,
G402
ORN,LT GRN
G404 BLU
LT GRN/RED,
Cruise control can be set, but GrtO1
indicatorlight does not go on. I G402 YEL,RED,RED/BLK
G404
Cruise speed noticeably highsl 1 J 2
or lower than what was set.
Excessive overshooting and/or
undershootingwhen trYingto I 3 2
set speeo.
Steady speed not held, even on
a flat road with cruisecontrol 1 4 2 3
set.
Car does not decelerateor ac-
celsrateaccordinglYwhen SET 1 2
or RESUMEbutton is Pushed.
Set speed not cancellsd when I 2 PNK
clutch pedal is Pushed(M/T).
Set speed not cancelledwhon 1 2 PNK
shift lever is moved to 1 (A/Tl.
Set soeed not cancelledwhen 'I 2 GRY, GRN/WHT
brake pedal is pushed
Set speednot cancelledwhen 2 LT GRN
main switch is DushedOFF.
Set sosed not resumed when
RESUMEbutton is Pushed(with 1 2
main switch ON, but set speed
temporarilycancelled).
23-275
CruiseControl
ControlUnit Input Test
CAUTION:
a All SRS aloctfical widng harnessosare cov6r€d with
yollow outo. insulation.
a Brtoro di3connoctlng the SRS wira hamoss, install
tho short conn6ctor(s) on the airbag(s) (see page
23-2941.
a Replacethe entiro affoctod SnS harn6ssa$ombly it
it has an opon clrcuit or damagod wiring,
1. Disconnectthe 14-P connector from the control

untr.
Inspectthe connectorand socket terminalsto be

sure they ars all makinggood contact.
a lf the terminsls are bent, loose, or corrodsd.

fepair them as necessary, and rechsck the
system,
a It the terminalslook OK, make the following in-
put t€sts at the connector,
- lf a test indicatesa p.oblem,find and correct
th€ caus€,then recheckthe svstem.
- lf allthe inputtests proveOK, the controlunit
must be faulty; replaceit.
coNrRoLuwr /
cRUrsE
r4-P CON|{ECTOR
View from wire side
23-276
't
Test condition Test: Dosir€d result Possiblocause if result is not obtain6d
BLK Under all conditions. Check for continuityto ground: . Poorground {G4Ol, G4O2,G404)
1
Thereshouldbe continuity, . An open in the wire.
LT GRN lgnitionswitch ON Checkfor voltageto ground: B l o w nN o . 1 4 { 7 . 5 A ) f u s e .

and main switch ON. There shouldbe battery (ln the under-dashtuse/relaybox)
voltage. Faultymain switch.
LT GRN/ RESUMEbutton push- Check tor voltageto ground: B l o w nN o . 4 1 ( 1 5 A ) f u s e .

BLK eo. Thereshouldbe battery {ln the under-hoodfuse/relaybox)
voltage. Faulty SETiRESUMEswitch.
4 LT GRN/ SET button pushed.
Faultycablereel.
REO
PNK M/T: Clutch pedal Check for continuityto ground: Faultyor misadjustedclutch switch
pusneo. Thereshouldbe continuity. (M/T).
A/T: Shift lever in NOTE: Thereshouldbe no Faultyor misadjustedA/T gear posi-
E,E.o,E continuitywhen the clutch tion switch.
pedal is releasedor when the Poor ground{G4O1,G4O2,G404).
A/T shift lever is in other posi- An open in the wire.
tions.
BLU Start the engine. Check for voltageto ground: . Faultyignitionsystem or ECM.
6
There should be baftery . An open in the wire.
vortage.
7 ORN lgnitionswitch ON CheckJor voltagebetweenthe Fauhyvehiclespeedsensor(VSS).
and main switch ON. ORN @ and BLK O terminals: P o o rg r o u n d( G 1 0 1 ) .
Raisethe front ot the I t s h o u l db e 0 - ' 1 2 - O - 1 2 V An open in the wire.
car, rotate one wheel repeatedly.
GRY lgnitionswitch ON, Check for voltageto ground: . Faultybrakeswitch.

I
main switch ON and Thereshouldbe O V with the . An open in the wire.
brake pedal pushed, pedal pushed, and battery
then released, voltagewith the pedalreleas-
ed.
Checkfor voltageto ground: . Faultybrakeswitch.
9 GRN/WHT Brakepedal pushed,
then released. There shouldbe battery . An open in the wire.
voltage with the pedalpushed,
and O V with the pedal releas-
ed.
10 RED lgnitionswitch ON. Connectto ground:Cruisein- Elown bulb.
dicator in the gaugeassemblY Blown No. 13 { 10 A} fuse.
comes on. (ln the under-dashfuse/relaybox)
Faultydimmingcircuit in the gauge
assemory.
1'l BRN/RED Underall conditions. Check for resistanceto . Faultyactuatorsolenoid.
ground:Thereshouldbe . An open in the wire.
80- 1200.
'12 BRN/BLK Under all conditions. Check for resistanceto
ground:Thereshouldbe
' 1o
70- 1 0.
1 3 BRN/WHT Under all conditions. Check for resistanceto
ground:Thereshouldbe
40-60 0.
23-277
CruiseControl
Set/ResumeSwitch Test/Replacement
CAUTION: 5. Installtheshort connectofon the airbagconnector.

a All SRS €lectrical wiring halnesses ar€ covorad wlth
yellow outer inaulation.
a Botoro disconnecting tho SRS wire harness, install
the 6hon connector(sl on th€ airbag(s) (sea page
23-2941. CABLE REEL
a Replacothe €ntire affected SRS harnass assembly if CONNECTOR
it has an op€n circuit or damaged wiring.
NOTE: The radiomay havea codedtheft protectioncir-

AIR BAG
Removingthe No. 43 (1O A) fuse. CONNECTOF
After service,reconnectpower to the .adio and turn it
on.
When the word "CODE" is displayed. enter the ACCESSPANEL
SHORT
customer's 5-digit code to restoreradio oDeration. CONNECTOR
(RED}
o. Remove the dashboard lower cover and knee

bolster,
Disconnect the cable reel 6-p connector from the

SRS main harness,then connect Test HarnessC
only to the cable reel side ot the 6-p connector.
Disconnectthe battery negative cable. and then

positivecable.
Make sure the wheels are turned straightahead.
Remove the two screws and access Danel,then

removethe short connectorfrom the accessDanel.
4. Disconnectthe airbag connector from the cable

reel connector.
23-278
I
L Checklor continuitybetweenthe terminalsof Test 1 0 . Remove the two screws and cruise control
HarnessC in each switch positionaccordingto the switch.
SET/RESUME
table.
SET/BESUMESWITCH
rofinrnal 1
\ L TG R N / LTGRNi
ELU/NEU
Position REO BLK
SETION) o- ---o
RESUME(ON} G- ---o
a lf there is continuity.and it matchesthe table.

the switch is OK.
a lf there is no continuityin one or both positions,

go to stsp 9.
A'
Carelullyremove the cruise control SET/RESUME B

9.
switch cover by prying between the cover and c
switch in the sequenceshown.
CRUISE
CONTROL
SET/RESUME
swtrcH 1 1 Checkfor continuitybetweenthe terminslsin each
\ Terminal
CRUISE AorA' B
cot{TRoL Position
SET.RESUME
SWITCH COVER SET(ONI G- ---o
RESUME
ION) o- ---o
lf there is no continuityin one or both positions,

reolacethe switch.
a lf there is continuitYand it matchesthe table,

replacethe cable reel.
23-279
GruiseControl
Main Switch Test/Replacement
1. Carefullypry the switches out of the instrument 3. Checkfor continuitybetweenthe terminalsin each
panel and disconnecttheir connecrors. switch positionaccordingto the table.
\ termrnal
n a E
Position \
OFF o- ,/.\
\:.,/
-o o- /:\ -o
ON o- /:\
\:.,/ -o o- a\
INDICATOR
LIGHT
t0.84w)
ti t l
7
5-P I
CONNECTOR
I CRUISECONTROL
MA|N SWtTCt{
\
2. Removethe cruise controlmain switch from the a lf there is no continuity,replacethe switch.
switch panel.
SWITCH PANEL
23-2AO
Clutch Switch Test A/T Gear PositionSwitch Test
1. Disconnect the 3-P connector from the clutch 1. Remove the tront console, then disconnectthe
switch. 12-P connectorfrom the switch.
2. Check for continuitybetween the terminalsaccor-

ding to the table.
Terminal
\ 'c*.hP;f-l B
PUSHED
BELEASED o- o
2, Checktor continuitybetweenthe terminalsin each

Terminal
5 8
Position
tr
o- ------o
tr o_- ------o
E o --o
N
tr
E
3, lI necessary,replacethe switch {seepage23-149).

lf necessary,replacethe switch or adjust pedal
height (seesection 12).
23-281
CruiseGontrol
r BrakeSwitch Test ActuatorSolenoidTest
1. Disconnectthe 4-P connectorfrom the switch. 1. Disconnectthe 4-P connectorfrom the actuStor,
BRAKESWITCH

Measure resistance between the terminals,
2. Checkfor continuitybetweenthe te.minalsaccord-
ing to the table. Resistance
VENT SOLENOID(betwo€n C and Dt:
80- 120 0
Terminal VACUUM SOLEI{OID(bstwoen I 8nd Dt:
A d D
;**;---_\ 70-t100
SAFEW SOLENOID{botwoen A and Dl:
PUSHED G- --o 40-60 0
RELEASED o- NOTE: Resistance will vary slightty with
temperature; specified resistance is at 70oF
(200c).
3. lf necessary,replacethe switch of adjust pedal
height (seesection 191. VEI{T VALVE
VACUUMVALVE
23-2a2
\
ActuatorTest
1. Disconnectthe actuator cable from the actuator With voltage and vacuum still applied,try to pull
rod and disconnectthe 4-P connector. the actuator rod out by hand. You should not be
able to pull out. lf you can. it is defective
2. Connect batterv Dower to the D terminal and
ground to the A, B, and C terminals.
3. Connecta vacuum pump to the check valve.

Then apply vacuum to the actuator.
CHECKVALVE
I/ -YF
\N7
ACTUATOR
/A@ o
/t:#r'.\
VACUUMPUMPGAUGE
o_ Disconnectground from the C terminal. The ac-
tuator rod should return. lf it does not return but
a973X-041-XXXXX the vent hose and filter are not plugged, the
solenoidvalve assemblyis defective.
Repeatsteps 2 through 5, and disconnectground

View from
terminalside trom the A terminal. The actuator rod should
return. It it does not retu.n but the vent hose and
tilter ar€ not plugged,the solenoidvalve assembly
4. The actuatorrod shouldpull in completely. is defective.
lf the rod pulls in only part-wayor not at all, check
for a leakingvacuum line or defectivesolenoid. 8 . lf you replacethe solenoidvalve assembly,be sure
to use new O-ringson each solenoid.
ACTUATOR ROD
23-283
CruiseGontrol
Actuator/CableReplacement Actuator CableAdjustment
Pull the boot back and loosen the locknut. then Check that the actuator cable operatessmoothly
disconnectthe cable from the bracket. with no bindingor sticking.
Start the engine.
t Measurethe amount of movementof the actuator

rod until the cable pulls on the acceleratorlever
=
(enginespeedstarts to increase).Freeplay should
i b e 1 1 t 1 . 5 m m ( O . 4 3t 0 . 0 6 i n ) .
ACTUATORROD
Disconnectthe cable end from the actuatorrod. LOCKNUT
Disconnectthe 4-P connectortrom the actuator.
VACUUM HOSE
LOCKNUT
FREE
PLAY:11 a 1.5 mm
(0.43r 0.06 inl
4. lf Jreeplay is not within specs,loosenthe locknut

and turn the adjustingnut as required.
VENTHOSE
NOTE: lf necessary.check the throttle cable free
play {see section 11), then recheck the actuator
rod free play.
e Retightenthe locknut and recheckthe free play.
4-P
CONNECTOR
4. Pullthe vent hose out of its grommet.
Removethe two mounting bolts and the actuator

with the bracket.
Disconnectthe vacuumhosefrom the checkvalve.
lf necessary,disconnectthe cable end from the

linkage over the acceleratorpedal, then turn the
grommet 9Oo in the bulkhead and remove the
caDle.
8. Installin the reverseorder of removal,and adjust

tree play at the actuator rod after connectingthe
cable (seenext column),
23-284
I
Actuator Disassembly
FILTERCOVER
b
SOLENOIOVALVES
Test, p€ge 23-282
--)@r
GROMMET
VACUUMHOSE
VACUUMHOSE
CHECKVALVE
6- ACTUATORBBACKET
ACTUATOR
Test, page23-283
DRAIN HOSE
ACTUATORBRACKET
23-285
..
SupplementalRestraintSYstem
(sRsl
Component Location Index'..."'.. '..'.'. 23-288
Description ' 23-2Ag
CircuitDiagram 23-290
WiringLocations 23-292
Precautions/Procedures .' 23-293
Troubleshooting .......... '.23-294
AirbagAssembly
Replacement 23-318
Disposal 23-322
CableReel
Repfacement 23-324
DashSensor
Replacement 23-324
SRSUnit
Replacement 23-330
SupplementalRestraintSystem (SRS)
CABLEREEL
page23-324
Replacement,
SRS INDICATORLIGHT
{ln the gguge assembly} TO DRIVER'SAIREAG
Troubleshooting,page 23-298 ASSEMBLY
Gsuge assembly, page 23-122
TO CRUISECOI{TROL
SET/RESUMESWITCH
FRONTPASSEI{GER'SATRBAG
ASSEMBLY
Replacamont,
page23-318
Disposal.
UNOER.DASH
FUSE/RELAY8OX
BIGHT
DASH SEITSOR
R€placement,
ORIVER'SAIRBAG psge 23-328
{lnctudingcowr s€nsorlASSEMBLY
DASH SE'{SOB Replacement, R6placement,
Replacernent, pag€ 23-330 page 23-318
page 23-328 Disposal,page 23-322
23-288
Description
The SRSis a safety devicewhich, when usedin conjunctionwith the seat belt.is designedto helpprotectthe driver{and
front passenger)in a frontal impact exceedinga certainset limit.
The system is composedof left and right dash sensors,the SRSunit (includescowl sensors),the cablereel,driver'sair-
bag and front passenger'sairbag(Si 4WS, Si VTEC: USA, SR 4WS,SR-V:Canadamodels).
SRS UNIT
AIRBAG
CABI-EREEL
OPERATION:
As shown in the diagrambelow, the left and right dash sensorsare connectedin parallel.The parallelset of sensotsis
connectedin seriesto each airbaginflatorcircuitand the car battery.In addition,a back-uppower circuitis connectedin
parallelwith the car battery.The back-uppower circuit and the cowl sensorsare locatedinsidethe SRSunit.
For the SRSto operate:

{1) One or both cowl sensorsand one or both dash sensorsmust activate.
(2) Electricalenergymust be suppliedto the airbaginftatorby the battery,or by the back-uppower circuitiJthe bat-
tery voltage is too low.
{3) The inflator chargemust ignite and deploythe airbag.
It takes about O.l secondfrom the beginningot the airbagdeploymentuntil it is completelydeflated(frontalcollision

againsta fixed wall at a speed of 30 mph t50 km/hl).
FRONT
PASSENGER'S
I l-r IAAIRBAG
|RBAG ll
t t t L . - l
Selt-diagnosissystom
A seli-diagnosis circuitis built into the SRSunit; when the ignitionswitch is turnedON. the SRSindicatorlight comeson
and goes off after about six secondsif the system is operatingnormally.It the light does not come on, or doesnot go oft
atter six seconds.or if it comeson while driving,it indicatesan abnormalityin the system.The systemmust be inspected
and repairedas soon as possible.
23-289
SupplementalRestraintSystem (SRSI
CircuitDiagram(WithoutFrontPassenger's
Airbag)
i1}358;,K%, sRsrNorcAToRcrRcurT
sRs
tNotcAToR
ctRcurT
lln theg.u€6a8!ombv)
A
( ,o'ft ) 'on't'ot'*'ttt
Y wm
J---,
I Zlfoiil**'-
II ti[*? ORIVER'S
ANEAG
INFLATOR
o
I i ir#i,
l*' o
Fl-1-,
\_-/
BATTERY
o
@
@
a
SAIrc
a
@
@
Btc @
o
GNO@
tDc @
MI @
o
@
SRSUI{ITI8 - PCONNECTOR
23-290
\
CircuitDiagram(WithFrontPassenger's
Airbagl
SRSINOICATORCIRCUIT
(lnthegaug€
83s€mbiyl
BLKffEL
,k
( ,lYt ),.*'t'orr*,..* I
Y WHT
G401
G4.02
I
I n
I ll
I tl
r l l
J----,
rtr
CABLE
REEL
SAOH
|I |I I,s,;
t#ff{,
DRIVER'S
AIRBAG
INFLATOR
o
I ln;'l-' @
a
6
BATTERY
FRONT
PASS€NGER'S
AIRBAG
INFLATOR
@
@
a
a
SADC @
a
BUC @
o
GND @
tDc @
MI @
a
a
23-291
Widng Locations
CAUTION:Mak€sureall SRSgroundlocationsare cleanand groundsare socurelyattach€d.
NOTE:
a All SRSelectrical
wiringharnesses
arecoveredwith yellowouterinsulation.
a Replacethe entireaftectedSRSharnessassemblyil it hasan opencircuitor dsmagedwiring.
OASHBOAFDWIRE HARNESS
ro SRS ItIDIcAToR LIGHT
in GAUGE ASSEMBLY
5.P CONNECTOR
SRS MAIN HARNESS

to FRONTPASSENGER,S
AIRAAG
3.P COITNECTOR
DASHBOARDWIREHARNESS
SRS MAIN HARNESS

Io UNDERDASH
FUSE/RELAYBOX
2-P
SRS MAIN
HARNESS
SRS UNIT
GROUNO SRSMAINHARITESS
ro RIGHTDASHsENsoR
2.P CONNECTOR
MAIN WIRE HARNESS
to DASHBOARDW|RE
HARNESS
2O-P CONNECTOR
SRS MAIN HARNESSSOCKET

1A.PCONNECTOR
23-292
GeneralPrecautions Airbag Handlingand Storage
a Carefullyinspectany SRS part before you install it. Do not try to disassemblethe airbagassembly.lt has no
Do not install any part that shows signs of being serviceableparts. Once an airbag has been operated
dropped or improperly handled, such as dents. (deployed),it cannot be repairedor reused.
cracks or detormation:
For temporary storage of the airbag assemblyduring
- Airbagassembly(driver'sand front passenger's). service,pleaseobservethe following precautions:
- Dash sensors,
- Cablereel. a Storethe removedairbagassemblywith the pad sur-
- SRSunit. face uD.
({,
!!!@ lf the airbag is improgerly stored face

d6ii, accidental deployment could prop€l the unit
with enough folce to cause serious iniuly.
. Use only a digitalmultimeter(KS-AHM-32-OO3) Storethe removedairbagassemblyon a secureJlat
to check the sYstem.Using an analogcircuit tester surfaceaway from any high heat source (exceeding
may cause an accidentaldeploymentand possible 212oF/'lOOoCland free oJ any oil, grease.detergent
injury. or water.
a Do not install used SRS parts Jrom another car' CAUTTON: lmproper handling or storag€ can intsr-
When makingSRS repairs,use only new parts' nally damage ths airbag assambly, making it
inoperativs.
a Exceot when performing electrical inspections, lf you suspect the airbag assembly has b6€n damag-
always disconnect both the negative cable and ed, install a new unit and refer to the Dsploy-
positivecable at the battery beforebeginningwork' ment/Disposal Proc€dules lor disposing of the
damaged airbag
a Replacement of the combination light and
wiDer/washerswitches and cruise control switch
can b€ done without removingthe steeringwheel:
- Combination light and wiper/washer switch
replacement(seePage23-182).
- C.uise control switch replacement (see page
23-2741.
a When rsinstallingthe SRS unit cover. be sure lt

snapstogetherProperlY.
23-293
WiringPrecautions
a Neverattemptto modity.spliceor repairSRSwiring. Instslling the short connector
NOTE: SRS wiring can be identified by special To avoid accidenrat deployment 8nd
@
yellow outer protectivecovering. possible injury. always install ths protective short con-
nector(s) on the driver's and passonget's airbag con-
nector(s) belore working noar any SRS wiring.
NOTE: The radio may have a s-digit coded theft pro-

tection circuit. Be sure to get the customer's code
numberbefo.e disconnectingthe battery.
l. Disconnect the battery negative cable, then

disconnectthe positivecable.
2. Installthe short connector{s)(RED):
Driver's Sido:
a Removethe access panel from the steeringwheel,
Be sure to installthe harnesswires so that they are then remove the short connector (REDI from the
not pinchedo. interferingwith other car parts. oanet.
Make sure all SRS ground locationsare clean and

groundsare securelyfastenedfor optimum metal-to-
metal contact. Poor groundingcan cause intermit-
tent problemsthat are difficult to diagnose.
Disconnectthe 3-P connectorbetween the driver's

airbagand cablereel,then lnstalltheshort connector
(RED)on the airbagside of the connector.
23-294
Front Pass6nger'sSide: Disconnecting the SRS Connector at the Fuse
a Remove the glove box, then remove the short con- Box
nector (RED)from its holder.
CAUTION: Avoid breEking tho conn€ctor; it's double-
lock6d.
FRONTPASSENGCR'S
1. First lift the connectorlid with a thin screwdriver,
AIRBAG
3.P CONNECTOR then press the connectortab down and pull the
SHOR1 CONNECTOR{RED)
connector out.
SRS MAI]II HARNESS

UI{DER.DASHFUSE/RELAYBOX
Q+
GLOVEBOX
Disconnect the 3-P connector between the front SRS MAIN HARNESS
passenger'sairbagand SRS main harness,then in-
stall the short connector (RED)on the airbag side of
the connector.
To reinstalltheconnector.push it into positionuntil

it clicks.then close its lid.
23-295
Steering-relatedPrecautions
Steering Wheel and Cable Reel Alignment SteeringColumnRemoval

NOTE: To avoid misalignmentof the steeringwheel or CAUTION:
airbagon reassembly,make surethe wheelsare turned a Eefors romoving the steering column, fitst discon-
straightaheadbetore removingthe steeringwheel. noct the conn€ctor betwoen th€ cable reol and the
SRS main harn€ss.
a It tho steeling column is going to bo removed
withoul dismounting the ste€ring wheel. lock ths
stesring by turning tho ignition key to O-LOCKposi-
tion 01 rsmova the key from ths ignition so that the
staering wh6al will not turn,
Rotatethe cable reel clockwiseuntil it stops.

Then rotate it counterclockwise(approximatelytwo
turns) until:
- The yellow gear tooth lines up with the alignment

mark on the cover.
- The arrow mark on the cablereellabelpointsstraight
up,
HARI{ESS
Do not replacethe originalsteeringwheel with any

other design,since it will m8ke it impossibleto pro-
perly install the ai.bag (only use genuine Honda
replacementpartsl.
After reassemblyconfirm that the wheels are still

turned straight ahead and that the steering wheel
spoke angle is correct. lf mino. spoke angle adjust-
ment is necsssary,do so only by adjustmentof the
tie-rods, not by removing and repositioningthe
stee.ingwheel.
NOTE: Modelswith 4WS

Test and adiust the 4WS system (seesection 17).
23-296
I
SensorInspection InspectionAfter DePloYment
CAUTION: Take extra care whan psinting ol doing After a collisionin which the airbagswere deployed,in-
body work in the area bolow the dashboard. Avoid spect the following:
dir€ct €xposule of tho sensors ol wiring to hsat guns'
welding, or spraying equiPment. 1. Inspect the dash sensorsfor physicaldamage. l{
the sensorsare damaged,replacethem.
@
-o
Disconnect both the negative and positivs battary 2. Inspectall the SRSwire harnesses.Replace,don't
cables. repair,any damagedharnesses.
a Install the short connector(s) botore working b€low
the dashboard ol near tho dash sensors. 3. Inspectthe cable reel tor heat damage lf there is
a After any degree of frontal body damage, inspect any damage,replacethe cable reel.
both dash sensors.Replacea sensorif it is dented.
cracked,or deformed. 4. AJter the car is completelyrepaired,turn the igni-
tion switch on. It the SRSindicatorlight comeson
for about six secondsand then goes ofl, the SRS
system is OK. lf the indicatorlight does not func-
tion properly,go to SRSTroubleshooting.
DASI{ SENSOR
o Be sure the sensorsate installedsecurely'
DASH SENSOR
23-297
SupplementalRestraintSystem(SRS)
Troubleshooting
Self-diagnosisFunction Short Conn€ctor Installation
The SRSunit includesa selJ-diagnosis function.lf there To avoid accidontat deploymont and
is a failurein the s€nsors,SRSunit, inflator,or their cir- @
possible injury, always install the protective short con_
cuits, the SRS indicator light in the gauge assembly nectot on the drivel's ailbag connoctor and on cars
goes ON. oquippod wlth flont paasengor,sairbag, install protac_
SRSINDICATOR LIGHT tivo short conn€ctots on thg drlver.a airbag and front
paaaonger's airbag bofore working near any SRS
wiring.
f::=
NOTE: The radio may have a s-digit coded theJ't pro-
numberbetore disconnectingthe battery.
As a system check, the SRSindicatorlight also comes
1. Oisconnect the battery negative cabl€, then
on when the ignitionis iirst turned to the ll oosition.lJ
the light goes otf after approximatelysix seconds,the
system is OK.
2. Installthe short connector(sl:
Driver'sSide:
lf the SRSindicatorlight remainson (or failsto come on
a Remove the access panel from the steering
in the systemcheckmodel, one ot the SRScomDonents
(or the wiring/connectorsin bgtween)is faultv. wheel, th8n.emove the short connector(RED)
from the Danel.
Troubloshooting Procautions
a AlwSys uso ths test hamess. Do not us€ tast probgs
DRIVER'SAIBBAG 3.P CONNECTOR
dirsctly on component connoctot tatminala ot wiros;
you m8y damsgo them or th€ SRS unit.
a Wh6n connecting any of th6 tsst hamoasos to the
system. push the connectors straight-in; do not bend
tho conn€ctot torminals.
a Boforo disconnacting any p8n ot tho SRS wire ACCESSPANEL
ha.ness, install the short connector (RED) on the
driver's airbag. On csrs equipp€d with a front
passenger's airbag, instsll shon connoctols on the
driver's airbag and the front pass€ngor,sairbag,
SRS Indicator Light Troubloshooting a Disconnectthe connecto.between the driver's

airbagand cable reel,then installthe short con-
Possibleconditions: n€ctor {RED} on the airbag side of the
1. SRS indicatorlight does not come on at all _ see connector.
page 23-3OO.
2. SRSindicatorlight stays on constantly- see page Front Passenger'sSide:
23-304. a Remove the glove box, then remove the short
3. SRSindicatorlight comeson in combinationwith a connector(REDIfrom the holder.
failure of another electricalsystem {brakesystem
light, malfunctionindicatorlamp (MlLl etc.). Check a Disconnect the connector between the front
for damage/corrosion at the under-dashfuse/relav passenger'sairbagand SRSmain harness,then
box connector. installthe short connector (RED)on the airbag
side of the connector(seepage 23-295).
NOTE:
a Before starting the applicabletroubleshooting.
check the conditionof all SRS connectorsand
ground points,
a lf the fault is not found atter completingthe ap-
plicable troubleshooting,substitute a known_
good SRS unit and check whether the indicator
light goes off.
23-298
t
Test Harnessesand Attachment Points
Test HarnessA
DRIVER'SAIRBAG
ASSEMELY
TEST HABNESSA
07MAZ- SLOOSOo
DRIVER'S
2 3 t 6
't2 t 5 1€
HARI{ESS C
o7LAz- s140300 FRONTPASSENGER'S
AIRBAG ASSEMBLY
Test Harness B
SRS MAIN HARNESS

1g.P CONNECTOR
3.P CONNECTOR
Test HarnessD
SRS MAIN HARNESS

2.P CONNECTOR
3 5 6 1 I 11 12 13 15 18
2 5 6 12 13 1 5 t6 1 1 18
ROW B {WIREHARNESSENDI
23-299
Troubleshooting
The SRS IndicatorDoes Not Light
CAUTION: Use only a digitatmulrimotel|KS-AHM-32_OO3) to chock tha system.
NOTE: The radio may have a s-digir coded thelt pro-

Dbconnoct tho bottory nog8tivo tection circuit. Be sure to get the customer,s code
cablo 6nd thsn tho Dositivo numberbefore disconnectingthe battery.
cable.
Install tho 3hort connocto.lsl on
the airbag{3|{.€e page 23-294}.
Reconnect the battery positive

cable and then the negative
cable.
Turn tho ignitionswitch ON.
Do any other indicator lights

(brake system light etc.)
Inspocttho No. 13 (10 A) tuse
come on {in tho gauge {undeFdashfus€/rclav box}
ass6mbly)?
ls No. 13luse OK?

Replir opon In drlhborrd wiro

hsmoa! bqtwoon tho l{o. 13 tulo
Disconnect the SRS main and glugo raa.mbly.
hamess18-Pconnectorfrom the
SRS UNIT
sRs MA[{
HARI{ESS
18-P CONl{ECTOR
Tho SRS unit is taultv.
{To page 23-301)
23-300
I
(From page 23-3OO)
Disconnect the SRS main

harness 4-P connector lrom the
main wire harness.
SRS MAIN HARNESS

4-P CONNECTOR
ls SRSindicatorlightON? The SRS main harnott is tauliY.
Remove the gauge assembly,

then inspect the SRS indicator
light b'.rlb.
Repl6cotho indicator light bulb.
DASHBOARDWIRE
HARNESS5.P CONNECTOR
Conn€ct a voltmeler between
the No. 3 terminalofthe 5 P con-
nector and body ground.

the No.3 terfiinal and body
ground.
{To psge 23-302}
e
BLU
Lo$ than 8.5V?
23-301
r J
- . . '
Troubleshooting(cont'dl
{Frompage 23-3OlI
Sho.t in BLU wiio ot rhe

ls therelessthan 8.5 V with
da3hboardwiro hamess. Reolace
the ignitionswitch ON?
tho dashboa.d wir6 harnoss.
HARNESS5-P CONNECTOR
Connect the voltmeter between

the No. 1 lerminal (+) and rhe
No. 5 terminal {-) oI the
dashboardwire harness 5-P con,
nector,

the No. 1 terminaland the No. 5
terminal. rr--/#l
l : l r l 3 l 4 l l l
t l
YEL BLK
lL---(I0------r
^ l
Battary vohlga?
View lrom terminal side.
Ch€ck tor continuity between

ls there battery voltage? t h e N o . 5 t e r m i n a la n d b o d y
grouno.
Ropoi. oD6n in rh€ BLK
wire lNo. 5 tominall
Turn the ignitron switch OFF.
Detwoen the gauge
a3sornbly and body
{To page 23-3031 g.ound or look to. a
poor ground (c4O1,
4021.
Rep.ir opon in the Y€L wire lNo.
1 teminall ot the de3hboardwiro
hamo3s betwgen tho 9aug6
asaembly and the No. 13 luse.
23-302
{F.omp€ge 23-302}
Reconnecteach conn€ctor to the

gauge assembly and SRS unit
then connect Test Harness A to
th€ sRs unit.
Measure the voltag€ between

tho No. 13 terminal and body
ground for six s€conds after igni-
tion is {irst tumed on.
TEST HARI{ESSA
07MAZ- S100500
2 3 6 7 8
9 lo 1 l 12 t3 1 4 1 5 16
Moro thon
SRS Indlcatot cilcuit {in tho

ls theremorethan 8.5 V? gaugo 6!.mblyl 13taulty.
23-303
Troubleshooting{cont'd
SRS IndicatorLight Stays on Conrinuously 6. Compare each reading wilh the voltage ranges
listedin the columnbelow it. lf the readingis within
1. Make a photoeopy of this page (without front a range,circlethat range.
passenger'sairbag),or the next page (with tront a lf you circledall the FailureMode rangesacross
p a s s e n g e r 'asi r b a g ) . any row, check the car for the probableFailure
Mode listedat the end of the row. (Referto the
2. Connect Test HarnessA (O7MAZ-SLOOSOOI
to letter for that Mode on the following pages).
the SRS unit as shown.
a lf you did not circle all the ranges across any
3, Turn the ignitionswitch ON. row, replacethe SRS unit with a known-good
a Voltagesin the chart assumethe car,s,,battery unit, and retest.
voltage" is about 12 volts. Less than 12 volts - lf all your voltage readingsare now Normal,
will result in differentor possiblyfalse readings. replacethe SRSunit.
a Do not disconnectthe airbag from the circuit - lf your voltage readingsare still not normal
when checkingSRS unit voltages. but they don't tit within a completerow ot
FailureMode ranges,check the conditionoi
4. First,check for voltagebetweenTest HarnessTer- the terminalsin each of the SRS connectors
m i n a lN o . 1 2 a n d g r o u n d . shown in the system diagram on page
a lf voltage is indicated,there is a poor ground
( s e ep a g e2 3 - 3 1 7 ) .
a lf no voltage is indicated,continuewith check-
ing all the other terminals.
5. Recordyour voltagereadings.tor each terminal,in

the row of blank boxes near the top of the chart.
Without Front Passonger'sAirbag:
NOTE: Do not disconnectthe airbagwhen checkingSRS unit voltages.
1 5 8 10 12 t3
SADH vcc SV SADC BUC] GND rDc
43 4 . 5 12.O 5.6 11.5 8.5 8.4

-56 - 5.5 14.3 - 7.3 - 14_5 0 - 13.6 10.9 P.obableFailureMode
2.8 4 5 12.O 3.7 11 . 5 2 0 8.4

-3.7 5.5 14.3 - 14.5 0 A Open in one cowl sensor.
4.9 8.5 - 10.9
. Open in both cowl
0 4.5 r2.0 11 . 5 2.O 8 . 4

14.3 0 0 - 8.5 10.9
t4 5
. shon to driv€f's atbag
86 4.5 12.O 11.2 Short in cowl sensor of

11.5
0
2.0 8 . 4
- 14.3 14.6 14.5 8 . 5 - r0.9 C open in both dash sen
5.7 4 . 5 12.O 11 . 5 2 0 8.4

-1.4 5 5 I4.3 14.5
0 D Open in one dash sensof.
8.5 10.9
8.6 4 . 5 12.0 11 . 5 2.O 4 . 4

0 0 c' Open n driver's anbag
5.5 14.3 I4.5 8 5 -10 9 inllaror or .able recl
43 5.6 11.5 2 . 0 8.4 Blown SRS luse {No. 24

-5 6 0 0 - 7.3 0 H
''
14.5 8.5 - to.9 1 0 A ) o r o p e ni n t h e w t e .
4.3 4.5 12.4 5.6 0

5.6 -5 5 -73 - 14.5 0 (8.5 8 . 4 I
Shon (o' open) in SRS
I4.3 10.9 In0rcalorwrre harness.
13.6
23-304
With Front Passenger'sAirbag:
NOTE: Do not disconnectthe airbagwhen checkingSRSunit voltages.
l 2 4 5 8 10 12 13 14
S A O H SAPH vcc SV SADC BUC] GND tDc
4 . 3 4.3 4.5 12.0 5.6 11.5 8 . 5 8.4 FailurcMode

-5.6 - 5.5 14.3 -14.5 0 - 13.6 10.9 Probable
Reading
2.4 2.4 4 . 5 12.O 3.7 11.5 2.O 8 . 4 A openIn onecowlsenso..

0 - 10.9
3.7 - 3.7 5.5 1 4 . 3 4.9 - 14.5
. Openin bothcowl
4.5 12.0 11.5

o 2.0 8.4
0 0 0 -8.5
5.5 ,14.3 - 14.5 10.9 . Shon$ diver's or
pass€flger's
akbsgin-
Shod in cowl $nsor or

8.6 8.6 4.5 12.O 11.2 11.5
0
2.O 8 . 4 C open in both dssh sen'
1 1 . 3- r 1 . 3 - 14.3 14.6 - 14.5 8.5 10.9
5.7 5.7 4.5 12.O 7.4 .5 2.O E.4

-7.4 - 14.5 o -8.5 - 1 0 . 9 D Open in one dash sensor.
14.3 9.7
8.6 2.9 4.5 t2.o 3.7 11 . 5 2.O 8 . 4 E Open in d'iver's anbog

- 1 1 . 3 3.7 - 5.5 14.3 -4.9 - 14.5 0 - 8.5- 10.9 -
,nllator or ceble reel.
2.9 8.7 4.5 1 2 . 0 3.7 1r.5 2.O 8 . 4 F Open

in t.onl passengers
-3.7 - 5.5 14.3 -4.9 14.5 0 -8.5 - 10.9
Open in d.iver's and

8.6 8.6 12.0 11.5
0 2.0 8.4
0
-11.3 - 5 . 5 - 14.3 14.5 8 . 5 - 10.9
4.3 4.3 5.6 |.5 2.O 8.4 BlownSRSruse(No.24

0 0 0 '|r'
-5.6 -'t.3 14.5 8.5 - r0.9 1 0 A l o r o o e ni n l h e w i r c .
0 8.4 short(oropen)in SBSin-

4.3 4.3 4.5 12.O 5.6 11.5 'I
- 5.6 0 t8.5 1 0 . 9
5.5 -14.3 14.5
13.6
dic.torwirchamess.
23-305
Troubleshooting(cont'd)
Mod€ A: Open in ono cowl s€n6or. 3. Reconnect the driver's airbag connector, thsn
checkcontinuitybetweenthe B l terminalandbody
. The SRSunit is faulty. Substitutea known-goodSRS ground, and betwesn the 87 t€rminal and body
unit and recheckthe voltagesaccordingto the chart ground.
on page 23-304.
Mode B: TESTHAR ESSB

. Shon to dfver's or passengor's ai.bag inflatol. 07MAZ- SF005q'
. Short in one dash sensor, A
. Op6n in both cowl s6nsor. B
NOTE: The radio may have a 5-digit coded theft pro-

number beforedisconnectingthe battery cables.
1. Betore disconnectingany part ot the SRS wire a lf there is continuity at eithel terminal, go to
harness.installthe short connector(sl(RED)on the step 6.
airbag(sl (see page 23-2941.
a lf ther€ is no continuity at either torminal, go 10
2. Connect Test HarnessB (O7MAZ-SP0O50O)be- steD 4.
tween the SRS unit and SRS msin harness 18-P
conneclor. 4. Reconnsct the front passenger'sairbag connector,
th6n check continuity betwe€n the B2 terminal and
body ground, and betw€en the 88 terminal and
body ground.
TESTHARI{€SSB
oTMAZ- SPdr6{X'
a lf there is continuity at either terminal, go to

step1O.
a lf there is no continuity at either terminal, go to

step 5.
23-306
- \ l
Check continuity between body ground and each 7 . Check continuity between the No, 4 terminaland
terminalof both dash sensors. body ground. and between the No. 5 terminaland
body ground.
TESTHARNESSB
07MAZ- SP00500
a lf there is continuityat any ol the terminals,go

to step12.
lf there is continuity at either terminal. go to
a lf there is no continuity at any terminal, go to step 8.
step13.
lf there is no continuity at either terminsl,the
o. Disconnectthe cable reel 6-P connectorfrom the SRS main harness is faulty. Replace it and
SRS main harness,then connect Test HarnessC recheckthe voltagesaccordingto the chart on
{O7LAZ-SL4O3OO)only to the cable reel side oI page 23-3O4.
the 6-P connector.
{cont'd)
23-307
I
Troubleshooting(s6n1'd1
8. Oisconnectthe driver's airbag3-P connectorfrom 1O. Disconnectthe front passenger'sairbag3-P con-

the cable reel, then connect Test Harness C nector from the SRS main harness,then connect
(07LAZ-SL4O3OO) to the driver's airbag 3-P Test HarnessC {07LAZ-SL4O3O0)to the airbag
connector. side of the connector.
FRONTPASSENGER'SAIRBAG
TESTHARNESSC
07LAZ_S140300
1 1 .Check continuity between the No. 7 terminaland

body ground,and betweenthe No. 8 terminaland
body ground.
Check continuity betwsen the No. 7 terminaland

body ground, and betweenthe No. 8 terminal8nd TEST HARNESSC
body ground. oTLAZ - SL403qt
TEST HAR ESS C

oTLAZ - SL4og)O
lf there is continuityat eitherterminal,the front

passenger'sairbag inflator is faulty. Replaceit
and recheckthe voltagessccordingto ths chart
on page 23-304.
It there is continuity at either te.minal, the It there is no continuity at either terminal,the

dfiver's airbag intlator is laulty. Replaceit and SRS main harness is faulty. Replace it and
recheckthe voltagesaccordingto the chart on recheckthe voltagesaccordingto ths chart on
page 23-3O4. page 23-304.
lf there is no continuity at either terminal,the

cable reel is faulty, Replaceit and recheckthe
voltagesaccordingto the chsrt on page23-304.
23-308
I
' t 2 .Connect Test HarnessD (O7LAZ-S14O400) be- lf resistanceis 3.8-4.2 Ko for both sensors,
tween the dash sensorand SRS main hatness2-P the SRS unit is taulty. Substitutea know-good
connector.Checkcontinuitybetweenthe No.1 ter- SRSunit and recheckthe voltagesaccordingto
minal and body ground,and betweenthe No.2 ter- the chart on page 23-304.
minal and body ground.
lf resistanceis less than 3.8 KO for either sen-
sor, go to step 14,
SRS MAIN
HARNESS 't4. Connect Test HarnessD (07LAZ-SL4O4OO)be-
2.P CONNECTOR
tween the dash sensor8nd SRS main harness2-P
connector.Checkthe resistancebetweenthe No.1
terminaland No. 2 terminal.
SRS MAIN
SENSOR HARf{ESS
2-P COI{IIECTOR
TESTHART{ESSD
07LAZ- SL/O4OO
TEST
HARNESSD
OTLAZ- SL/to4Oo rffir DASHSEf{SOR
? ? TESTHARNESS D
- SL/IO4{X)
a lf there is continuityat eitherterminal,the dash OTLAiZ
sensor is faulty. Replace it and recheck the
TEST
voltagesaccordingto the chart on page23-304. HARI{ESSO
OTLAZ- SL4O/IOO
a It there is no continuity at either terminal,the
SRS main harness is faulty. Replace it and
recheckthe voltagesaccordingto the chart on
page 23-304. a It rssistance is 3.8-4.2 KO, the SRS main
harness is faultv. Replaceit and recheck the
13. Checkthe resistancebetweenthe left dash sensor voftagesaccordingto the chan on page23-304.
terminalsB12 and Bl6, and betweenthe right dash
sensorterminals84 and 86. a lf resistanceis lessthan 3.8 KO,the dashsensor
is faulty. Replaceit and recheckthe voltagesac-
cordingto the chart on page 23-304.
B
TESTHAR]IIESS
07MAZ-SPOo50{'
A
I
(cont'd)
23-309
.4
Modo C: Short in cowl sgnsot. or oD€n in both dash 3. Check the resistance between the left dash sensor
s€nsors. terminals812 and 816, and betweenthe right dash
Mode D: Open in on€ dash sensor. sensorterminals84 and 86.

numberbeforedisconnectingthe bafte.y cables. TEST HARI{ESS B
oTMA;Z - SPq)sd!
1. Beiore disconnectingany pan ot the SRS wire
harness,installthe short connector(s)(RED)on the
airbag{sl(see page 23-294l..
2. Connect Test HarnessB (07MAZ-SPoO5OO)be-

tween the SRS unit and SRS main harness 18-P
connector.
a lf resistance is more than 5 Kn for either set of
terminals,go to step 4.
a lf resistance is less than 5 KO for both sets of

terminal, the SRS unit is faultv. Substitute a
known-goodSRS unit and ,echeckthe voltages
accordingto the chart on page 23-304.
TESTHAR'{ESSB
oTMAZ-SP00500
23-310
'!
4. Connect Test Harness D (07LAZ-SL404OO) be- Mode E: Open in drivsr's airbag inflator or cable re6l.
tween the dash sensorand SRS main harness2-P
connecror. NOTE: The radio may have a s-digit coded thelt pro-
Check the resistancebetween the No' 1 terminal tection circuit. Be sure to get the customer's code
and No. 2 terminal. number betoredisconnectingthe battery cables.
1. Before disconnectingany part of the SRS wire

harness,the positive cable. Installthe short con-
nector(s)(RED)on the airbsg(s)(seepage23-294).
2. Connect Test HarnessB (O7MAZ-SP005OO)be-

connector.
TESTHARI{ESSD
07LAZ - 5140400
B
TEST}IARNESS
oTMAZ-SP00500
Reconnect the driver's airbag connector, then

lf resistanceis more than 5 K0. the dash sensor check the resistancebetween the B1 and the 87
is faulty. Replaceit and recheckthe voltagesac- terminals.
cordingto the chart on page 23-304.
B
TESTHARI{ESS
It resistanceis less than 5 KO, the SRS main oTMAZ- SmO500
harnessis taulty. Replacethe SRSmain harness
and recheckthe voltagesaccordingto the chatt
on page 23-304.
a lf resistanceis more than O.2 KO, go to step 4.

a lf resistanceis lessthan O.2 KO.the SRSunit is
faulty. Substitute a known-goodSRS unit and
recheckthe voltagesaccordingto the chan on
page 23-3O4.
(cont'd)
23-311
r 'l
- - -
Troubleshooting(66n1'd1
4. Disconnectthe cable reel 6-P connectorfrom the 6, Disconnectthe d.iver's airbag3-P connectortrom
SRS main harness.then connect Test HarnessC the cable reel harness, then connect Test Harness
(O7LAZ-SL4O300Ionly to the cable reel side of C {O7LAZ-SL4O30O)to the driver's airbag 3-P
the connector. connector.
CABLE REEL
5. Measurethe resistancebetweenthe No. 4 terminal 7. Measurethe .esistance between the No. 7 terminal
and the No. 5 terminal. and the No. I terminal.
TESTHARI{ESSC TEST HAB'{ESS C

oTLAZ - S1403{tO - st4{t3dt
oTr.Aiz
lf resistanceis more than 0.2 KO,9o to step 6. a lf resistanceis more than O.2 KO, the drive.'s
airbag intlator is faulty. Replace the airbag
lf resistanceis less than O.2 KO, the SRS main assembly and recheck the voltages according to
harness is taulty. Replaceit and recheck the the chart on page 23-304.
voltages according to the chart on page 23-30'4,
a lf resistance is less than 0.2 KO,the cable resl is
faulty. Replace it 8nd .echeck the voltages ac-
cording to the chart on page 23-304.
23-312
\
Mode F: Open in lront passongot's airbag inflatol' 4. Disconnectthe front passenger'sairbag 3-P con-
nsctor from the SRS main harness,then connect
NOTE: The rsdio may have a s-digit coded theft pro- Test HarnessC (O7LAZ-S14030O) to the tront
tection circuit. Bs sure to get the customer's code passenger'sairbagside of the connector.
number before disconnecting the battery cables.
1. Belore disconnectingany part of the SRS wire

PASSENGER'SAIRBAG
airbag(s) (see page 23-2941'
2. Connect Test HarnessB (o7MAz-SPoOsoo) be-

connecror.
3. Reconnectthe front passenger'sai.bagconnector,

then measure the resistance between the 82 ter-
minal and 88 terminsl.
TESTHABI{ESSB
oTMAZ- SPOO5d'
A
a TESTHARNESSC
07LAZ-S140300
Measurethe resistancebetweenthe No. 7 terminal

and the No. 8 terminal.
It resistanceis more than O.2 K0, go to step 4.
ll resistanceis lessthan O 2 KO,the SRSunit is TEST HABNESS C

07LAz - S[/rO3o,0
faulty. Substitute a known-good SRS unit and
recheckthe voltagesaccordingto the chart on
page 23-305.
lf resistanceis more than O.2 K0, the front

passenger'sairbaginflatoris faulty. Replacethe
front passenger'sairbagassemblyand recheck
the voltages accordingto the chart on page
23-305.
lf resistanceis lessthan O.2 KO,the cablereelis

taultv. Replacethe cable reel and recheckthe
voltagesaccordingto the charton page23-305.
(cont'd)
23-313
SupplementalRestraintSystem(SRSI
Modo G: Blown SRS No. 24 fuse. or opon in the wire. 4. Reconnectthe positiveand negativecablesto the
battery.
tection circuit. Be sure to get the customer's code 5 . Measurethe voltagebetweenthe B13 te.minaland
number beforedisconnectingthe battery cables. body ground with the ignitionswitch ON.
Check the SRS No. 24 {10 A) Juse in the under-

dash fuse/relaybox. lf it's OK, go on to step 2. TESTHARNESS
B
lf it's blown, replaceit with a new 1OA tuse, then 07MAZ-SP00500
turn the ignitionswitch ON: 2 3 6 a 9 10 11 12 1 5 10 18
2 3 5 a 9 10 n 12 I6 18
a lf fuse doesn't blow, go on to step 2.
a lf the Juseblows, troubleshootas necessarvto

find the short.
2 . Before disconnectingany part ot the SRS wire lf there is batteryvoltage,the SRSunit is faulty.
harness.installtheshort connector(s)(RED)on the Replaceit and recheckthe voltagesaccordingto
airbag(s) (see page 23-2941. the chart on page 23-304.
Connect Test HarnessB (O7MAZ-SPOO5OO) be- a lf less than battery voltage, the SRS main
tween the SRS unit and SRS main harness18-P ha.ness is faulty. Replaceit and .echeck the
conneclor. voltagesaccordingto the chart on page23-304.
TEST HARNESSB
oTMAz-SPOO500
23-314
Modo H: Short or opsn SRs indicator wiro harnosa.
? BeJoredisconnectingany pan of the SRS wire
NOTE: The radio maY have a 5-digit coded theJl pro- airbag(s) (see page 23-2941.
tection circuit. Be sure to get the customel's code
numberbeJoredisconnectingths battery cables. 4. Connect Test HarnessB (O7MAZ-SPOO5OO) be-
1. Disconnsctthe SRS main harness4-P connector connecror.
from the main wire harness.
oTMAZ_SP00500
Reconnectthe battery positivecable and negative

cable.
o. Checkfor continuitybetweenthe B1 1 terminaland

body ground,
2 . Turn the ignition switch ON and wait for six

s€conds.Measulethe voltage between the No' 1
terminal8nd body groundon the SRSmain harness TESTHARI{ESSB
oTMAZ- SP(xrs(x)
4-P connectorside.
SRSMAII{ HARI{ESS
4 - P CONf{ECTOR
F-"------
F-i-rl
/JLILx
' l l-. ,\
BLU a lf there is continuitv,the SRS main harnessis
-t
ap shoned. Replacethe SRS main harness and
t_ recheckths voltagesaccordingto the chart on
page 23-3O4.
View from terminslside.
a lf th€re is no continuity,go to step 7.
a lf voltageis mote than 8.5 V, go to step 8'
a ll voltage is less than 8.5 V, go to step 3
23-315
7. Check for continuitybetween the B1l terminalof q

Turn the ignition switch ON and wait tor six
Test HarnessB (O7MAZ-SPOo5OO) and the No. 1 seconds.
terminalof the SRS main harness4-p connector. Measurethe voltage between the No. 5 terminal
and body ground.
TESTHARI{ESS
B
07MAZ-SPq)500
DASHBOARDWIRE
A HARNES95-P CONNECTOR
B
View lrom terminalside
a lf there is continuity, the SRS unit is faultv.

Replaceit and recheckthe voltagesaccordingto a lf voltageis more than 8.5 V. the SRSindicator
the chan on page 23-304. circuitis faulty (in the gaugeassembly).Replace
the SRS indicator assembly and recheck the
a lf there is no continuity.there is an open in the voltagesaccordingto the chart on page23-304.
SRS main harness. Replace the SRS main
harnessand recheckthe voltagesaccordingto a lf voltageis lessthan 8.5 V. the dashboardwire
the chart on page 23-304. harness (or the main wire harness)is faulty.
Replaceil and recheckthe voltagesaccordingto
Reconnectthe SRSmain harness4-P connectorto the chart on page 23-304.
the main wire harness.Disconnectthe dashboard
wire harness 5-P connector from the gauge
assemblv.
HARNESS5.P CONNECTOB
23-316
a lf there is continuity at either terminal, the SRS
Poor glound at SRS unit or unit mounting bolts
unit is Jaulty. Replace it and recheck the
NOTE: The radio may have a s-digit coded theit pro- voltages accordingto the chart on page 23-304
a lJ there is no continuity at either terminal,the
numberbelore disconnectingthe battery cables.
SRS unit ground, the SRS unit component
grounds, or the SRS main harness is faulty.
1. Betore disconnectingany part of the SRS wire
Check the grounds(checkthe SRS unit ground
wire and mounting bolts) and, if necessary,
airbag(s)(see page 23-294l,.
rsplace the SRS main harness. Racheck the
voftagesaccordingto the chart on page23-304,
2. Connect Test HarnessB (o7MAz-SP005oo) be-
conneclor.
sRsur{tT
SRS MAIN HARNESS

18-P CONNECTOR
HARNESSB
07MAZ-SP00500
Check for continuitybetweenthe 85 terminaland

body ground. and the 815 terminal and body
ground.
TESTHARNESS8
07MAZ - SP005q)
23-317
Airbag Assembly Replacement
E@ sro.e a rsmoved airbag assembtywith the Front Passenger'sSide:

pad surlace up. lf tho airbag is improp€rly stored face a Removethe glove box, then remove the short
down, accidental d€ployment could plopel th€ unit with connector{RED)from its holder
€nough lotce to cause satious iniury.
a Disconnectthe 3-P connectorbetweenthe front
CAUTION: passenger'sairbagand SRSmain harness.then
a Do not install used SRS parts f.om another cat. installthe short connector (RED)on the airbag
Wh€n repailing as SRS, use only n€w parts. side of the connector.
o Carelully inspect ths airbag assembly before you in_
stall it. Do not install an airbag assembly that shows
signs of being droppad or improperly handled, such
FRONTPASSENGER'S
as dents, cracks or dolotmation. AIRBAG
a Always ke€p tho short conn€ctor(sl (REDIon the air_ 3.P CONNECTOR
bag{s) whan th6 harness is disconnoctod.
a Do not disasaombls ()1 tamper with the airbag
ass€mbly.

tection circuit, Be sure to get the customer's code
number beforedisconnectingthe battery cables.
l. Disconnect the battery negative cable, then

2. Installthe short connector(s)(REDIon the airbaq

side of the connector(s):
Oriver'sSide:
a Remove the access panel from the steering
wheel, then removethe shon connecto.{RED)
trom the panel.
a Disconnect the 3-P connector between the

driver's airbag and cable feel, then insta the
short connector(RED)on the airbagside of the
connector.
GLOVEBOX
CABLE R€EL3.P CONNECTOR
DRIVER'S
AIRBAG
3-P CONNECTOR
ACCESSPANEL
SHORT
CONNECTOR
{RED}
23-318
J. Removethe ai.bag(s): Front Passenger'sSide:
a Removethe tweetet cover from the dashboard,
Driver'sSide: then removethe visor and blackface panel (see
a Remove the two TORXo bolts using a TORXo p a g e2 3 - 1 3 0 ) .
T3O bit, then remove the driver's airbag
assembly, a Remove the glove box, then remove the four
mountingnuts from the lront passenger'sairbag
assembly.
DRIVER'S
AIRBAGASSEMBLY
DASHBOABD
GLOVE BOX
TOBXO BOLT
U.. . TORX@ T3O bh
a Carefully lift the front passenger's airbag
assemblvout ot the dashboard.
(cont'd)
23-319
Airbag Assembly Replacement(cont,dl
CAUTIOI{: B€ sura to installthe SRS wi ng so thst it ie Front Passenger'sSide:

nol pinchod or intorforing with oth6r car parts. a Placethe front passenger'sairbagassemblyin
the dashboard.
4. Installthe new airbag(s).
a Loosenthe two mountingnuts on the L-bracket.
Driver'sSide: Placethe driver'sairbagassemblyin
the steeringwheel. and secureit with new TORX@ a P.essthe airbagassemblydownwardsand turn
bolts. the adjusting nuts until they touch the lower
part of the airbagassembly.
OBIVEB'S
AIRBAG a Tighten the four airbag mounting nuts, then
tightenthe two mountingnuts on the L-bracket.
ADJUSTING
NUT L-BRACKET L-BRACKET
MOUNTING NUT
10 N.m 11.0kg-m, 7.2 lb-ftl
Replace.
TORXO BOLT
10 N.m {1.Okg-m, 7.2 tb-ft)
Reolace. ASSEMBLY
U8o 6 TOBX@ T3O bit MOUNTINGNUTS
10 N.m (1.0 kg-m, 7.2 tb-frl
Replace.
23-320
5. Rsmoveand ptoperlystore the short connsctor{s), Driver'sSide:
then reconnectthe airbagconnector{s). a R€mov€ the short connector {RED)from the
driver'sairbagconnector.then connectthe air-
Front passenger'sSide: bag 3-P connector to the cable reel 3-P
a Attach the short connector(REDltothe connec- connector.
to, holder.
a Then reinst8llthe glove box, visor, and tweeter a Attach the short connector(RED)to the access
cov€r on the dashboard. panel. then reinstallthe panel on the steering
wh€el.
FRONTPASSENGER'S
AIRBAG3.P CONNECTOR CABLEREEL3.P CONNECTOB
DRIVER'S
AIRBAG
3-PCO I{ECTOR
6 . Connsct th€ battery positive cable, then the

negstivecable.
Aft6r instaltingthe ai.ba(tassembly,conJirmproper

system operaflon:
a Turn the ignition ON {lll: The instrumentpanel

SRS indicatorlight should go on for about six
secondsand then go off.
GLOVESOX a Make sure both horn buttons work.
a Take a test drivs and make sure the cruasecon-
trol set/resume switch works.
tt. Enter the code number to restore radio operation

(see page 23-206).
23-321
Ai6ag AssemblyDisposal
Beforescrappingany airbag(s){includingone in a whole Front Passongef's Alrbag:
car to be scrappedlthe airbagmust be doployed.lf the
car is still within the warrantyperiod,betoreyou deploy 4. Remove the glove box, then disconnectth6
the airbag.the Honda District Service Managermust 3_p
connector between the front passeng€r,s airbag
give approvaland/or specialinstruclons.
and SRS main harness.
Only after an airbaghas beendeployed(asthe resultol
vehiclecollision.for example),it can be scrapped.
lf an airbag(s)appearsintact (not deployedltrestit with FBONT PASSEI{GER'SAIRBAG
extremecautaon. 3-P COt{t{EcToR
Followthis Drocedure:
D€ploying the Ai|bag(s): In-CE]
NOTE: lf an SRScar is to be entirelyscrapped,its 8ir_

bag(sl should be deployedwhile still in the ca..
The airbag(slshould not b€ consideredas salvageable
part and should never be installedin anothercar.
@E confirm that th6 airbag assombty i!

secu.ely mountad; otherwiso sovoro porsonal injury
could r€sult dudng doploymont,
1. Disconnectboth the negative cable and Dositiv8

cable from the batt8rv.
2. Confirmthat the specialtoolis functioningproporly
by following the check procedure on the label of
the tool set box, or on page 23-317 5. Cut off the airbag connector, strip the ends of the
aibag. wires, and connsct the speci6l tool alligator
Drivor's Alrbag: clips to ths bar6 wires. place the special tool ap-
proximatsly thirty f€et away from the airbag.
3. Removethe accesspanel,then disconn€ctthe 3_p
connector between the d.iver,s airbSg and the
cable reel. DFIVER'SAIREAG FRONTPASSEI{GER'S
AIRBAG
ALUGATOR
CLIPS
lY.lowl
ORIVER'S
AIRBAG ACCESS
3.P CONNECTOB PANEL
23-322
\
o, Conn€ct a 12 volt battery to the tool: D6ploying tho Ai6ag: Out-of-cal'

a lf ths g.een light on th€ tool goes on, tho airbag
ignit8r circuit is defective and csnnot deploy th€ NOTE: lt 8n intact airbag assembly has b€6n removed
bag. Go to DamagedAirbag SpecialProcedure. from a scrapped car or has been found dotectivs or
a It the red light on the tool goes on, the sirbagis damagedduringtransit,storage,or service,it shouldbe
r€8dy to be d€ployed. deployedas follows:
7 . Push the tool's d€ployment switch. The airbag !@ Position tho ai6a9 aslembly faco up' out-
should deploy (deploymentis both highly audible E6EJn tlat ground at loart thlrtY feet lrom any
and visible- a loud nois€and rapidintlationof the obstacbs or Poople.
bag, tollowod by slow deflation).
. ll audible/visibledeploym€nt happensand the

gre€n light on the tool goes on, continue with
this procedure.
. It the airbagdoesn't deploy,yet the green light
goes ON, its igniter is d€fective
Go to DamagedAitbag SpecialProcedure.
1. Confirm that the specialtool is tunctioning properly
Du?ing d.ployment, rho airbag by following the check procadureon this page or on
!@
assembly can b€como hot gnough to burn you. the tool box l8bel.
Wait thirty minutos aft6r doploymont before 2. Remove tho short connactor from the Eirbag
touching the ass€mbly. connector,
3. Follow steps 5, 6, 7 and I ot th€ in-car d€ploym€nt
L Disposeof the complste airb8gassembly.No pan procodute.
of it can be reused. Place it in a sturdy plsstic bag
and seal it securelv. Damagod Airbag Special Procedure'
CAUTION: !@ lf an airbag cannot be dcployod' ir thould

a Wsar a taco shiold and glovos wh€n handling a i6Fue tteatea aa normal scrap; it lhould stlll bo con-
deploy6d Eirbag. sidorod a potontiallY explolivo dovico that can c.us€
a Wash your hands and dns6 thom wall with sarious lniury.
wat6r afior handling a doployed alrb8g.
1. It instsll€din a car, tollow the rsmovsl proc€dure
o n p a g e2 3 - 3 1 9 .
2. In allcases,make surea short connscto.is properly

installedon the airbagconngctor.
3. Packagethe airbsg in exactly th€ same packaging

that the new replacamentpart came in.
"DAMAGED AIRBAG
4. Mark the outsideof th€ box
NoT DEPLOYED"so it does not get confused with
your parts stock.
5. Contact your Honda Oistrict Service Manager lor

how and where to return it for disposal.
Doploymant Tool: Chock Plocedulo.
1. Connectthe vellow clips to both switch protoctor

handles on the tool; connact th€ tool to a baftary'
Pushthe operationswitch: greonmeanstool is OK;

red meanstool is Jsulty.
3 . Disconnect the bsttery and the yellow clips.
23-323
CableReelReplacement
@ storo a romovcd aiibag assombtywith tho 4. Installths short connector{slon the airbag(s)(se€
pld rurtrco up. lf tho airbag is lmpfoporly stored taco paga 23-2941.
down, eccldental d€ploymont could propol the unit with
lnough torc6 to cause sadous iniury.
CAUTION: CABLEREEL3.P COI{IECTOR

r Carefully insp€ct the alrbag assembly botor6 install-
ing h. Do not install an airbag asscmbly that shows
signs ot belng droppcd or lmprop. y handled, such
aa denta, cracks 01 dgtormation.
a AlwayE koop th. short connoctol(s) on tho airblg(sl
wh€n ths hames! is disconnectod.
a Do not disassomble or tamp€r with any ailbag
a8sambly. DNIVER'S
AIRBAG 3.P
cof{t{EcToR
NOTE: The radio may have a s-digit cod6d theft pro-
tection circuit. Be sure to g€t the customer,s code
numberbetore disconnectingthe battery cable.
SHORT
1. Disconnect the battery nogative cable 8nd then the cor{r{EcToR
positivecabls. (REDI accEss
PAl{EL
2. Make su,e ths wheels are facing straightahsad.
3. Remove the dashboard lower cover, knee bolst6r,

F Remove the driver,s airbag assembly trom
and air duct. tho
steoring whe€l (two T30 TORXo bolts), then
ramov€ the steering whe€l nut.
S?EERII{GIYHEELITUT
TORXO BOLT
U.. . TOnXo T3O bh
23-324
\
Disconnect the connectors from the horn and 9. Disconnect the 6-P connector between the cable
cruise control set/resume switches, then remove reel 8nd SRS main harness,then removethe con-
the cable reel 3-P connectorJrom its clip. n€ctor holder from th€ staering column.
CRUISECONTROL
HORN CONNECTOR SET/RESUME
CABLEREEL
COI{NECTORHOLDER
7. Removethe steeringwheel Jromthe column' 1O. Removethe cable reel from the column.
8. Removethe upper and lower column covers'
UPPERCOLUMN COVER
23-325
Cable ReelReplacement(cont'd)
CAUTION: 13. Installthe steeringcolumnupperand lower covers,
a Bcforo Installingth€ steofng whool. th€ front whe€lg
should be alignod straight ahead. 14. Centerthe cable reel.
a Bc aure to install the harnoss wires so that thoy ar€ Do this by first rotatingthe cablereelclockwiseun-
not pinch6d or intsrfering with other car parts. til it stoDs.
a Aftor reassembly. contirm that the whoels aro still Then rotate it counterclockwise(approximately
straight ah6ad and that the rteerlng wheel spoke two turns) until:
angle is correct (road test), lf minor spoke angle ad-
iustmont is n€cesaary, do so only by adiustment ot a The yellow geaf tooth lines up with the align-
th€ ti€-lods. not by removing and repositioning tho ment mark on the cover.
ste€ring whael. a The arrow mark on the cable reel label Doints
straight up.
11. 2WS: Align the cancel sleeve grooves with the
cable reel projections, ARROW MARK
CANCELSLEEVE CABLE RE€L
ALIGNMENTMABK
15. Installthe steeringwheel and aftach the csble reel

connectorto the cliD.
HORI{ CONNECTOR CRUISE

CONTROL
SET/RESUME
4WS: Be sure that the yellow make on the front SWITCHCONNECTOR
main steeringanglesensorrotorfacesdownwards.
It it doesn't,turn the rotortill it is in the neutrallock
position(seesection 17).
Carefullyinstallthe cable reel on the steeringcol-

umn shaft. Then attach the connectorholderto the
steeringcolumn,
1 6 . Connect the horn connector and cruise control

set/resumeswitch connector.
23-326
\
1 7 . Installthe steeringwheel nut. 20. Removeand properlystore the short connector(s)

{RED),then reconnectthe airbagconnector(s}{and
NOTE: Modelswith 4WS reinstallthe glove box).
Checkthat the 4WS system is neutral(seesection
17). WHEELNUT 2'1. Reconnect the battery positive cable, then the
STEERING
50 N.m (5 kg-m,36 lb-It) negativecable,
22. Atter installing the cable re€|, conJirm proper

system operation:
a Turn the ignition ON (ll); the instrumentpanel
SRS indicatorlight should go on for about six
secondsand then go otf
a Make sure both horn buttons work.
a Make sure the headlight and wiper switches
work,
a Go for a test drive and make surethe cruisecon-
trol set/resumeswitch work.
a Rotate the steering wheel counterclockwise to
make sure the yellow gear tooth lines up with
the slot on the cover.
TORXO BOLTS
10 N'm (1.0 kg-m. 7.2 lb-ft)
BeDlace.
U3o a TORXo T30 blt
18. Install the driver's airbag assembly'
19. Connect the cable reel 6-P connector to the SRS

main harness, then installthe air duct, knee bolster'
and dashboard lower cover.
YELLOWGEARTOOTH
23. Enter the code number to resto.e radio operation

(see page 23-206).
DASHBOARDLOWERCOVER
23-327
DashSensorReplacement
CAUTION: 3, Left Dash Sensor:
a Oo not damsgo tho sonsor wiring. Removethe footrestand left door sill molding,then
a Do not install ussd SRS parts trom anoth6. car. pull the carpet back.
Wh€n r€pairing an SRS, use only new pans.
a Raplace a sansor il it is dented, c1ack6d, ol
d€to1med.

numberbeforedisconnectingthe battery cable,
1. Disconnectthe battery negative cable, th€n the

positivecable.
2. Installthe shorr connector{s}on the airbag{s}.
CAALE REEL
3-P CONt{ECTOR
4. Right Dash Sensor:

Removethe right door sillmoldingand pull backthe
caroet. Removethe ECM.
SHORTCONNECTOR
(RED)
FRONTPASSENGER'S
AIRBAG
SRS MAIN
Remove the two mounting bolts, then remove thg

left or right dash sensor.
GLOVEBOX
BOLTS
23-328
CAUTION: 8 . Removeand properlystore the short connector(sl
a Bg sure to install the harness wil€s go thoy ar€ (RED),then reconnectto aitbag connector(s){and
not Dinch€d01 intorfering with oth6r cal parts. reinstallthe glove boxl.
a Carefully inspect the new dash sonsol(sl for
signs of being dropped or imploperly handl6d, 9 . Reconnectthe battery positive cable, then the
such as dents, cracks or deformation. negativecable.
a Fol the SRS to function proporly, the dghl and
lett sansors must b€ install€d on the propor 1 0 .After installingthe dash sensor, confirm proper
sidos. system operation:Turn the ignitionON (ll); the in-
strumentpanelsRS indicatotlight shouldgo on for
o. Installthe sensorsecurelY. about six secondsand then go off
'l 'l . Enter the code number to restoreradio operation
(see page 23-206).
DASH SENSOR
DASH SENSOR
MOUNTINGEOLTS
8 t 1 . 2 5m m
22 N'm t2.2 kg-m. 16 lb-ft)
RePlace
7. Reinstall all other removed parts.
23-329
SRS Unit Replacement
4. R€movethe left side cover trom the SRSunit, then

a Boloro disconnecting any pan ot the SRS wire disconnectthe SRS main harnesslB-p connactor
ham€ss. install the shon conn€ctor(s) on th€ from the SRS unit.
airbag(s).
a Do not damage tho SRS unit terminals or
connectors, SRS UNIT
a Oo not disass€mble the SBS unit; it has no aor-
vicoable p8rts.
a Stor€ the SRS unit in a clean, dry arsa,
a Do not us€ any SRS unit which has be€n subj€cted
to watel damage or shows signs of bsing droppsd 01
improperly handled, such as dents, cracks or
doformation.
NOTE: The radio may have a s-digit coded theft pro- SBS MAIN
HARNESS
tection circuit. Be sure to get the customer's code 1a-P COI{NECTOR TOBXO
number beforedisconnectingthe battery cable. BOLTS
Usc a TORXo
1. Disconnectthe battery negative cable. then the T30 btr
oositivecable.
lnstallthe short connector{s)on the airbag(sllsee

page 23-2941.
3 . Removethe right side cover from the SRSunit.
5. Removethe fou. SRSunit TORXo bolts, then oull

SRS UNIT the SRS unit out from the driver'sside.
_--,/ TOBXo
8()tTs
Use ! TORXo
bir
23-330
t\
\
CAUTION: Ba sur€ to install tho SRSwidng so that Removeand properlystore the short connector{sl
it is not pinch6d 01 intorfefng with othor cal pada' {RED),then reconnectthe airbagconnector(s}(and
reinstallthe glove box).
lnstallthe new SBS unit.
1 0 .Reconnect the battety positive cable, then the
negativecable,
1 1 .After installing the SRS unit. confirm proper

systemoperation:Turn the ignitionto ll; the instru-
ment panel SRS indicator light should go on for
about six secondsand then go otf
' 1 2 .Enter the code number to restore radio operation
(see page 23-206).
ToRxo BOLTS 6 mm
10 N.m tl.O kg-m,7.2 lb-ft)
ReDlace.
snsuNlr U3e a TORxo T3O bit
SRS MAIN
HARNESS
18.P CONNECTOR
TORXo SOLTS6 mm
1ON'm 110 kg-m'7.2 lb-ft|
RePlace.
Ut. a TORXo T30 blt
Connectthe SRS main harness18-P connectorto

the SRS unit; push it into positionuntil it clicks.
8. Installthe SRSunit covers (right and lett).
23-331

1993 Prelude

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I NT RO DUCT ION I G e n e ra l n fo

How to Use This Manual -

Each section includes: Specifications f,|tr

NOTE: Gives helpful information. Fueland Emissions

All informationcontainedin this manualis basedon the latest Droduct

Chassis and PaintCodes................. 1-2

M2F4: Manualwith H22A1 engine

Vehicle ldentificationNumbel Paint Code

F22A1: 2.2 / SOHC SequentialMulti

Vehicle ldentificationNumbe] Paint Code

Vehicle ldentif ication

A: CABLE REELCAUTION A D: DRIVERMODULEWARI{|]{G

C: DRIVERMODULE DANGER E: I FLATOR WARNING TAG

'E: Inflatorwarning tag (Reterto page l-5).

SUPPLEMENTALRESTRAIIIITSYSTEM ISRS) ALWAY WEARYOURSEATBELT

CAUTION ISRS DRIVER'SAIREAG INFORMATION

1. Placethe lift blocks as shown.

Raisethe ca. high enoughto insertthe safety stands'

Adjust and placethe satety standsas shown on page

ll the car needsto be towed. call a proJessional

Wheel Litt Equipmont - The tow truck uses two plvor-

Sling-type Equipmont - The two truck uses metal ca-

lf the car cannotbe transportedby flst-bed,it shouldbe

5-spe6d Manual Tlansmission

NOTICE:lmpropertowing preparationwill damagethe

f NOTICE:Tryingto lift or tow the car by the bumperswill

Gray plsting: "Dacro" type

''l: CHUO HATSUJOmanulacturedvalve sprrng.

I.l Valvo spring

250 rpm and Nominal 1 , 3 0 O( 1 3 . 0 ,1 8 5 )

Balancershatl Journaldiameter No. 1 iournal(lront) 42.722-42.734(1.6820'1.68241 4 2 . 7 ' l{ 1 , 6 8 9 }

Spacercollar LD. 36.48-36.49{1.4362-1.4366) 3 6 . 5 0( 1 . 4 3 7 1

MEASUREMENT STANDARD {NEWI SERVICELIMIT

Clutch Clutch initialclearance lst-hold 0.80-1.00{0.031-0.039}

Valve body Stator shah needlebearingcontact l.D

Final driven Backlash 0.085-o.142 {O.OO33-0.0056) o.20(o.o08l

Differential (Automatic tlansmission) Section 1 5

Finaldriv€ng€ar Escklash o.o85-o.142 {O.0033-0.0056) 0.20(o.oo8)

Pump Pump pressure with valve closed (oil temp./spoed: 1O5"F

Overall Length 4,440mm I 1 7 4 . 8j n

Type F22A1 engine Water-cooled, 4,srroke SOHC

4.062 1 4.266 1 4.266

Automatic Engine tYPe F2241 H23A1

Indexand variouswolk pro-

Transmission Manual API ServiceGrade:SF or SG

Shift lever pivots (Manualtransmission)

Selectthe oil for your car accordingto this chart:

Type Water cooled4-stroke,In-line4-cylindergasolineengine

RacingEngine VTEC Engine StandardEngine

RPM switch ovgr

*A and B cam lobes

I *The rock€r arms ere linked

Valv€ Timing ChEngeConditions

Lost Motlon Machanbm

I Hydraulic Prg$ure Contlol Machanism

The one-piececylinderhead is made of aluminumalloy to reducethe weight while increasingefficiency

Low-speedvalve timing High-speod valve timing

<F i Intok6 valva opon

TDC: Top dead center

The valve spring wire uses a moditiedcross-sectionto valve lift in a limitedsoace.

EGG SHAPE LEMON SHAPE

o The male screw is

madeoJ FRM,a composite

7.0 mm {0.28 inl