Honda Prelude 5th Gen (97-99) Service Manual

ce Soave WrtnlINTRODUCTION How to Use This Manual This manual contains information for the 1997 ~ 1999 PRELUDE and divided into 24 sections. The first page of each section is marked with a black tab that lines up with its corresponding thumb index tab on this page and the back cover. You can quickly find the first age of each section without looking through a full table of con tents, The symbols printed at the top corner of each page can also be used as a quick reference system, Each section includes: 1. Atable of contents, a an exploded view index showing: © Pans disassembly sequence. Bolt torques and thread sizes. Page references to descriptions in txt Disassembly/assembly procedures and tools. Inspection. Testing/troubleshooting. Repair Adjustments Special Information FERRER srcestos« strong possiitty of severe persona injury (ross of Hef instructions are not followed. ‘CAUTION: Indicate damage if instructor NOTICE) ‘The purpote of these messages it to help prevent damage to the vehicl, other property, or the environment. possibility of personal injury or equipment not followed. NOTE: Gives helpful information CAUTION: Detailed descriptions of standard workshop procedures, safety rote that some spe: muy, ‘ways in which ‘not recommended by HONDA, might be done, jus consequences of every conceivable ‘way, nor could HONDA investigate all such ways. Anyone using service procedures or tools, whether or not recommended by HONDA, must satisfy himself thoroughly that neither personal safety ‘nor vehicle safety wil be jeopardized. Al information contained in this manual is based on the uct information available at the time of printing. We the Tight to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or trans rittes, in any form by any meen: copying, recording, oF otherwise, written permis: sion of the publisher. This includes text, figures and tables. General Info Ce. Specifications E co Maintenance Em Engine Electrical Engine Ea Cooling ca Fuel and Emissions ca *Transaxle bom *Steering Ez Suspension ie (Including |ABS)) Body La [*Heater and Air Conditionin: vee atoning MO |*Body Electrical | raSUPPLEMENTAL RESTRAINT SYSTEM (SRS) ‘The Prolude SRS includes a driver's airbag located in the steering wheel hub and a passenger's airbag located in the dashboard above the glove box. Information necessary to safoly sorvice the SRS is included in this Service Manual toms markod with an asterisk (*} on the contents page include, or are located near, SRS components. Servicing, dis- assembling oF replacing these items will require special procautions and tools, and should therefore be done by an authorized Honda dealer. ‘® To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. '* Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional activation of the airbags. # Do not bump the SRS unit. Otherwise, the system may fail in case of a coll ‘when the ignition switch is ON (I). «© All SRS electrical wiring harnesses are covered with yellow insulation. Related components are located in the ‘steering column, front console, dashboard, dashboard lower panel, and in the dashboard above the glove box. Do not use electrical test equipment on these circuits. jon, or the airbags may deployGeneral Information Chassis and Paint Codes Identification Number Locations Warning/Caution Label Locations .. Under-hood Emissions Control Label ... Lift and Support Points Lift and Safety Stands Floor Jack .. Towing . Service Precautions Parts Marking Locations . - 1-20Chassis and Paint Codes U.S. 1997 Model JH BBB 14*V.Co00001 || ‘Type of Vehicle JHM: HONDA MOTOR CO., LTD HONDA, Passenger vehicle Line, Body and Engine Type. ‘BBE: PRELUDE/H22A4 Body Type and Transmission Type 1: 2-door Coupe's-speed Manual 2: 2-door Coupelé-speed Automatic Vehicle Grade (Series) 4: Prelude 5: Prelude Typo SH check Digit — ‘Model Year V: 1997 1-2 -- Engine Number Engine Type Ho2Aa: ‘Sorial Number Protude: 1422A4- 1900001 .2 1 DOHC VTEC Sequential Multiport Fuel-injected engine 11000001 ~ Prelude Type SH: 1500001 ‘Transmission Type [— Transmission Number Mavs. 1000001 M2Y4: 6-speed Manual MBHA: 4-spoed Automatic Serial Number -- Paint Code Paint Code a Color 69M Nordic Mist Metallic Gasp Eucalyptus Groon Pear! NH-592P Flamenco Black Pear! R94 San Marino Red Vehicle Identification Number and Federal Motor Vel Safety Standard Certification. COLOR LABEL, INT. COLOR TYPE F EXT. COLOR B-83M KA $30 Ad A Paint coseU.S. 1998 Model Vehicle Identification Number barter ake one | ‘Type of Vehicle | {JHM: HONDA MOTOR CO., LTD HONDA, Passenger vehicle Line, Body and Engine Type ‘BBS: PRELUDE/H22A4 Body Type and Transmission Type —! 1: 2-door CoupeyS-speed Manual 2; 2-door Coupo/é-speed Automatic Vehicle Grade (Series) —— 4:Prolude 5: Prolude Type SH Chock Digit ———_—_! Model Year —— Ww: 1998 Factory Code ——~ C: Saitama Factory in Japan (Sayama} Serial Number — Vehicle Identification Number —— JHM 886 14*W.c000001 Engine Type — ——_1 H22Aé: 2.2? DOHC VTEC Sequerti Prolude: Prelude Type SH: 2500001 ~ jected engine 2000001 ~ [- Transmission Number way - 2000001 ‘Transmission Type M2¥é, M2U4: 5 speed Manual MaHA: 4-speed Automatic Serial Number — -- Paint Code Paint Code coor | BeaM Nordic Mist Metall GaaP Eucalyptus Groon Pearl NH-692P Flamenco Black Pear! NHe03P ‘White Diamond Peart Ros San Marino Red and Federal Motor Vehicle COLOR LageL, INT. COLOR TYPE F EXT. COLOR B-83M KA $30 Ad A Paint Code 1-3Chassis and Paint Codes U.S. 1999 Model Vehicle Identification Number T es 1 ji 000001 ‘Type of Vehicle —— {JHM: HONDA MOTOR CO., LTD HONDA, oe | Line, Body and Engine Type ‘886: PRELUDE/H22A4 Body Type and Transmission ome | 1: 2-door Coupe/S-speed Manual 2: 2-door Coupe!4speed Automatic Vehicle Grade (Series) — 4: Prolude. 5: Prolude Type SH ‘check Digit Model Year x: 1999 Factory Code CC: Saitama Factory in Japan (Sayama) ‘Serial Number Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certificat 14 p- Engine Number e204. 3000001 Engine Type ——_______— H22A4: 2.2 ¢ DOHC VTEC Sequential Multiport Fuel injected engine Serial Number Prolude: ‘3000001 — Prelude Type SH: 3500001 ~ ‘Transmission Type M2Y4, M2U&: 5-speed Manual MGHA: Serial Number ‘speed Automatic Color Crystal Blue Silver Metallic Nighthawk Black Pear! Ficus Green Pearl Metallic Premium White Pear Milano Red ‘coLoR LABEL INT. COLOR TYPE F EXT. COLOR B-91M KA S30 Ad A Paint CodeCanada 1997 Model Vehicle Identification Number JHM BBs 14*V 800001 VT J Manufacturer, Make and Type of Vehicle {JHM: HONDA MOTOR CO., LTD HONDA, Passenger vehicle i | Line, Body and Engine Type 'BB6: PRELUDE/H22A4 Body Type and Transmi 1: 2door Couper5-spe 2: 2door Coupelt-speed Automatic Vehicle Grade (Series) 4: Prelude 5: Prelude Type SH Check Digi Model Year ~— Manual vv: 1997 Factory Code C: Saitama Factory in Japan (Say yinJepan Savers) | Serial Nuumbar — Vehicle Identification Number —— and Canadian Motor Vehicle ye | Safety Standard Certification BRS VIG (- Engine Number H22A- 1000001 Engine Type H22A4: 2.2 ¢ DOHC VTEC Sequential Multiport Fu Sorial Number — Prelude: 1000001 - Prolude Type SH: 1500001 - [— Transmission Number Maya - 1000001 ramiion os | ora acs Man sev ure — Paint Code — | Paint code Col - Beam ‘Nordic Mist Metalic G-s3P Eucalyptus Green Pear! NH-592 Flamenco Black Pear! Roe ‘San Marino Red COLOR LABEL INT. COLOR TVPEF EXT. COLOR B-83M Ke sa0cec aint CodeChassis and Paint Codes Canada 1998 Model Vehicle Identification Number HM BB6 1.4*WC800001 MtcorMateans | | Type of Vel JHM: HONDA MOTOR CO., LTD HONDA, Passongor vehicle Line, Body and Engine Type 'BB6: PRELUDE/H22A4 Body Type and Transmission Type 1; 2-door Coupet6-speed Manual 2: 2-door Coupe/4-speed Automatic Vehicle Grade (Series) 4: Prelude 5: Prelude Type SH Check Digit Model Year W: 1998 Factory Code : Saitama Factory in Ja Serial Number Vehicle Identification Number —— and Canadian Motor Vehicle 1-6 HezAs- 2000001 ~T! cone te, H22A4: 2.2 € DOHC VTEC Sequential Multipor Fue!-injected engine Serial Number, Prelude: 2000001 ~ Prelude Type SH: 2500001 ~ -— Transmission Number Maya. 2000001 | M2Y4, M2Ué: 5-speed Manual Mt Spc eta Sor Humbe " r— Paint Code rent Code | calor ram | ws Wi tate Coxe Evrae reo oa wosssor | Ramon lc pon ners Ut Damen Pa R96 San Marino Red coLon LABEL. INT, COLOR TYPE F EXT. COLOR B-83M KC $30 C4 C Paint CodeCanada 1999 Model Vehicle Identification Number Manufacturer, Make and ‘Type of Vehicle — “iil: HONDA MOTOR CO, LTD HONDA, Passenger vehicl Line, Body and Engine Type ——— ‘BB: PRELUDE/H22A4 \ Body Type and Transmission Type — 1: 2,door CoupelS-speed Manual 2: 2-door Coupe!s-speed Automatic Vehicle Grade (Series) 4: Prolude 5: Prolude Typo SH check Digit ‘Model Year —— x: 1999 Factory Code ©. Saitama Factory in Japan (Sayamal Serial Number, Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification. Engine Type — [— Engine Number H22Ad: 2.2 ¢ DOHC VTEC Sequenti: Prolude Type SH: 3500001 - 2244 - 3000001 Jo [> [- Transmission Number ‘Transmission Type ——— M2Y4, M2U4: 5-speed Manual Maye. 3000001 Rat MBHA: speed Automatic Serial Number /— Paint Code Paint Code Color BoM Crystal Blue Silver Metallic B92P Nighthawk Black Pear! NH624 Premium White Pear! Milano Red (COLOR LABEL INT. COLOR TYPE F EXT. COLOR B-91M KC $30 C4 C Paint Code 1-7Identification Number Locations Vehicle Mdentiication Number [VIN] ‘Vehicle identification Number (VIN) _— See ee Transmission Number Automatic)Warning/Caution Label Locations \ A: CABLE REEL CAUTION A C: DRIVER MODULE WARNING 15Rs| INSTALLATION OF THE SRS CABLE REEL IS CRITI- CAL TO THE PROPER OPERATION OF THE SRS SYS- TEM, REFER TO THE SERVICE MANUAL FOR DETAILED INSTALLATION INSTRUCTIONS. 8: DRIVER MODULE DANGER DANGER EXPLOSIVE/FLAMMABLE CONTACT WITH ACID. WATER OR HEAVY METALS SUCH AS COPPER, LEAD OR MERCURY MAY PRO: DUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS. STORAGE TEMPERA TURES MUST NOT EXCEED 200°r (100°C), FOR PROPER HANDLING, STORAGE AND DISPOSAL PROCEDURES REFER TO SERVICE MANUAL, SRS SUPPLEMENT. POISON CONTAINS POISONOUS SODIUM AZIDE AND POTAS- SIUM NITRATE first AD IF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EVE CONTACT, LUSH EVES WITH WATER FOR To MINUTES IF GASES (PROM ACID OR WATER CON TACT ARE INHALED. SEEK FRESH AIR Il EVERY | CASE, GET PROMPT MEDICAL ATTENTION. | KEEP OUT OF REACH OF CHILDREN ‘2S WARNING ] ‘THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCI- DENTALLY DEPLOYED, CAN SERIOUSLY HURT OR. KILL YOU, ‘¢ DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROBING DEVICES. ‘THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. ‘¢ NO SERVICEABLE PARTS INSIDE. DO NOT DIS. ‘ASSEMBLE. ‘© PLACE AIRBAG UPRIGHT WHEN REMOVED. ¢ FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. (cont) 1-9Warning/Caution Label Locations (cont'd) 1-101D: SRS WARNING (HOOD) U.S. model (98 model) ‘SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ‘THIS VEHICLE IS EQUIPPED WITH DRIVER AND FRONT SEAT PASSENGER AIRBAGS. ALL SAS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. ‘TAMPERING WITH, DISCONNECTING OR USING ELECTR. CAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE ‘THE SYSTEM INOPERATIVE OF CAUSE ACCIDENTAL FiR- ING OF THE INFLATOR, WARNING ‘THE AIRBAG IVFLATOR IS EXPLOSIVE AND, IF ACCIDEN- ‘TALLY DEPLOYED, CAN SERIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. ; STEERING COLUMN NOTICE ‘NoTice ‘TO PREVENT SRS DAMAGE, REMOVE STEERING WHEEL BEFORE REMOVING STEERING SHAFT CONNECTING BOLT. F: MONITOR NOTICE wonice (Shs) ‘+ NO SERVICEABLE PARTS INSIDE. {2 REFER TO SERVICE MANUAL FOR DETAILED INSTRUC: THON, ‘A WARNING (DEATH OR SERIOUS INJURY CAN OCCUR. ‘¢ CHILDREN 12 AND UNDER CAN BE KILLED BY THE ‘AIRBAG, ‘THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN. NEVER PUT A REAR-FACING CHILD SEAT IN THE FRONT. SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG. [ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS. ‘THE SRS MUST BE INSPECTED TEN YEARS AFTER IT 1S INSTALLED. ‘© THE DATE OF INSTALLATION IS SHOWN ON THE DRIV. ER'S DOORJAMB, (Canada mode! (99 mode!) caunion TO AVOID SERIOUS INJURY: ‘= FOR MAXIMUM SAFETY PROTECTION IN ALL TYPES OF ‘CRASHES, VOU MUST ALWAYS WEAR YOUR SAFETY ber. ‘© DO NOT INSTALL REARWARD-FACING CHILD SEATS IN ‘ANY FRONT PASSENGER SEAT POSITION. ‘¢ _DONOT SIT OR LEAN UNNECESSARILY CLOSE TO THE AIRBAG. ‘= DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OF. [BETWEEN THE AIRBAG AND YOURSELF. ‘¢- SEE THE OWNER'S MANUAL FOR FURTHER INFORMA. ‘TION AND EXPLANATIONS, -PASSENGER INFORMATION (U.S, modell (7, 98 model US, model (99 model) [ AIRBAG SEE OTHER SIDE. US. model (99 model) "AIRBAG WARNING FLIP VISOR OVER. SRS INFORMATION (US.8 Canada model (97 model) {Canada modal) (98 model) cAUTION TO AVOID SERIOUS INJURY: ‘¢ FOR MAXIMUM SAFETY PROTECTION IN ALL TYPES OF CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY BELT. DO NOT INSTALL REARWARD-FACING CHILD SEATS IN [ANY FRONT PASSENGER SEAT POSITION. ‘© _DONOT SIV OR LEAN UNNECESSARILY CLOSE TO THE AIRGAG. ‘+ DO NOT PLACE ANY OBJECTS OVER THE AIREAG OR BETWEEN THE AIRBAG AND YOURSELF. ‘+ SEE THE OWNER'S MANUAL FOR FURTHER INFORMA. ‘TION AND EXPLANATIONS. ‘©THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS INSTALLED. ‘+ THE DATE OF INSTALLATION IS SHOWN OW THE DRIV. ER'S DOORJAMB. ‘A, WARNING. [DEATH OR SERIOUS INJURY CAN OCCUR, CHILDREN 12, AND UNDER CAN BE KILLCO BY THE AIRBAG. ‘THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN, [NEVER PUT A REAR-FACING CHILD SEAT IN THE FRONT. SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG, ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS. (cont'd) 1-11Warning/Caution Label Locations (cont'd) |: FRONT SEAT PASSENGER AIRBAG MODULE DANGER (37 model) 2A DANGER: EXPLOSIVE FLAMMABLE CONTACT WITH ACID, WATER OR HEAVY METALS SUCH [AS COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL ‘AND IRRITATING GASES. OR EXPLOSIVE COMPOUNDS. ‘STORAGE TEMPERATURES MUST NOT EXCEED 200° (100°C). FOR PROPER HANDLING, STORAGE AND DISPOSAL PROCEDURES REFER TO THE SERVICE MANUAL, SRS SUP. PLEMENT. POISON, CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE, FIRST AID | CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT, FLUSH EVES WITH WATER FOR 15 MIN. UTES. IF GASES (FROM ACID OR WATER CONTACT) ARE INHALED, SEEK FRESH AIR, IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN. ‘WARNING: THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN- ‘TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. ‘© DONOT USE ELECTRICAL TEST EQUIPMENT OR PROB- In Devices, THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. ‘© NO SERVICEABLE PARTS INSIDE. 00 NOT DISASSEMBLE. © PLACE AIRBAG UPRIGHT WHEN REMOVED, | 1-12 {FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY, (98, 99 model) 2 DANGER EXPLOSIVE/FLAMIMABLE ‘STORAGE TEMPENATUNCS MUST NOT EXCEED 200°F [85.C), FOR PROPER HANDLING, STORAGE AND DISPOSAL, PROCEDURES REFER TO THE SERVICE MANUAL, SRS SUP. PLEMENT. RST AID IF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MIN: UTES. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN. A WARNING ‘THE AIRBAG INFLATOR 1S EXPLOSIVE AND, IF ACCIDEN: TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU. ‘¢ _DO.NOT USE ELECTRICAL TEST EQUIPMENT OR PROB. ING Devices, HEY CAN CAUSE ACCIDENTAL DEPLOYMENT. ‘¢ NO SERVICEABLE PARTS INSIDE. DO NOT DISASSEMBLE. ‘© PLACE AIRBAG UPRIGHT WHEN REMOVED. ‘¢_ FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. 4: PASSENGER AIRBAG CAUTION US. modo 98, 99 model “WARNING CHILOREN CAN BE KILLED OF INJURED BY PASSENGER, ‘AIRBAG. ‘THE BACK SEAT iS THE SAFEST PLACE FOR CHILDREN 12, AND UNDER. MAKE SURE ALL CHILDREN USE SEAT BELTS, (OR CHILD SEATS. porce oresENGINE COOLANT INFORMATION. senvice INFORMATION (Under-hood | Emissions Control Label) BATTERY CAUTION. RADIATOR CAP cauTion, “TRE INFORMATIONUnder-hood Emissions Control Label Emission Group Ident (1997 model) Engine and Evaporative Families Example: Engine Fami VHN22vJGKH TTITITT TRGUO HGEE ROUTING DASHA mode'vor | every commen 1987 | | Saleeeoa var runoe row sen mee io HN: Honda anaten XR uct ness Displacement ———________| ea ln a EWAN VALE V Light Duty Vehicl/Passenger Car | Fuel System and Number of Valves —— | “I Electronic Sequential Mutiport jection three or more valves por evlinder) Fuel Type = asoling Standard Eanconrna —“? 49 of 80 Stats Tor 1 cet X: 49 or 60 States Tier 1 1! California Ther VEHICLE EMISSION CONTROL INFORMATION EASON 2: calforia THEY a calf ULE —— Wy Cotayst a eat = NDP URE 1 AF MOE ARNE TONES. zane Evaporative Famil Y we ronaa wpcanoranco 0 Model Yesr — ve i997 Wanidaststee ————___— 0ST (50 States: TN Honda I HIS VEMICLE CONFORMS TO US. EPA AND STATE OF | guurtye Siete ——_____ | CALIFORNIA REGULATIONS. APPLICABLE TO 1997 pa oan | MODEL YEAR NEW MOTOR VEHICLES. Canister Working Capacity grams) —— Canister Contguretan | 4957 (49 States/Federa: 1: Poac Housing (Closed dorom) ‘Ths VENICLE CONFORMS TO U.S. EPA REGULATIONS B:Plestic Housing (Open Botom) APPLICABLE TO 1997 MODEL YEAR NEW MOTOR Ve! | puereyersge CUOlOPEN Bowery cues Pus! jeation Fuel Tank — CAL (Catforna: wn Metal His VEHICLE CONFORMS 70 US.ePA AND TATE OF | gulag’ CALIFORNIA REGULATIONS APPLICABLE TO 1987 Setar Evan MODEL YEAR NEW PASSENGER CARS PROVIDED en THATTHIS VEMCLEIS ONLY INTRODUCED INTO.COM. | iment MERCE FOR SALE IN THE STATE OF CALIFORNIA, 1-14Emission Group Identification Engine and Evaporative Families (1998 model) Example: Engine Famil EL ge) LEVAP PURGE CONTROL, ae Manufacturer stata aitoma ee ear Sr ae Evaporative Family: WHINX E 0030 AAC Met Yor | verses we —_] wn Hons Canister Work Capacity (grams) EG SON COMO FONWATON Seaquense Charters CATALYST fan®" W 50ST (50 States): THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES. 49ST (49 States/Federal) THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS. APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHI- cues. CAL (California): THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW PASSENGER CARS PROVIDED ‘THAT THIS VEHICLE IS ONLY INTRODUCED INTO COM MERCE FOR SALE IN THE STATE OF CALIFORNIA. 1-15Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families (1999 model) Example Engine Family: X HK Vo2.2 Sat _J ‘VACUUM HOSE ROUTING DIAGRAM Model Year Tuer: x: 1989 cy THEVA Manufacturer 'V: Light Duty Vehicle/Passenger Car Displacement ———— ‘Sequence Characters —— Evaporative Fat ward x: 1999 Manufacturer HNX: Honda Type R: EVAP/ORVR Canister Work Capactty (grams), VEACLE ENISSION CONTROL FORMATION ‘Sequence Characters. ——— CATALYST Bia NX R010 AAF 50ST (50 States): THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW MOTOR VEHICLES. 49ST (49 States/Federal): ‘THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS, ‘APPLICABLE TO 1999 MODEL YEAR NEW MOTOR VEHI- CLES. CAL (California): THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW PASSENGER CARS PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED INTO COM- MERCE FOR SALE IN THE STATE OF CALIFORNIA, 1-16Lift and Support Points Lift and Safety Stands rr When heavy rear components such as suspension, fuel tank, spare tire and trunk lid are to be removed, place additional weight in the trunk before hoisting. When substantial weight is removed from the rear of the vehicle, ‘the center of gravity may change and can cause the vehicle to tip forward on the hoist. NOTE: Since each tirelwheel assembly weighs approximately 30 Ibs (14 kg), placing the front wheels in the trunk can assist with weight distribution, 1. Place the lift blocks as shown. 2, Raise the hoist a few inches (centimotors), and rock the vehicle to be sure its firmly supported. 3, Raise the hoist to full height, and inspect the lift points for so support. NOTE: Use the same support points to support the vehicle on safety stands. _ LS Ono FRONT SUPPORT POINT LIFT BLOCKS REAR SUPPORT POINT 1-17Lift and Support Points Floor Jack 1. Set the parking brake, and block the wheels that are not being lifted. oan 5 use safety stands when working on or under ‘any vehicle that is supported by only a jack. 2. When ifting the rear of the vehicle, put the aearshift '¢ Never attempt to use @ bumper iack for liftina or lever in reverse (Automatic in P] position) supporting the vehicle. 3. Raise the vehicle high enough to insert the safety stands 4 Adjust and place the safety stands so the vehicle will be approximately level, then lower the vehicle conte them. Front: center the jack ACK LIFT PLATFORM bracket inthe middle ofthe jack it platform. 1-18Towing If the vehicle needs to be towed. call a professional tow. ing service. Never tow the vehicle behind another vehicle with just a rape or ehain. It is very dangerous. Emergency Towing ‘There are three popular methods of towing a vehicle. Flat-bed Equipment — The operator loads the vehicle on the back of a truck. This isthe best way of transporting the vehicle. Wheel Lift Equipment — The tow truck uses two pivoting farms that go under the ties (front or rear) and lifts them off the ground. The other two wheels remain on the ground. the vehiole cannot be transported by flat-bed, it should bbe towed with the front wheols off the ground. If due to damage, the vehicle must be towed with the front Wheels on the ground, do the following: Manual Transmission ‘# Release the parking brake. ‘¢- Shift the transmission in Neutral, Automatic Transmission ‘© Release the parking brake, Start the engine. Shift to. position, then fl position. © Turn off the ongine. cauTion: ‘© Improper towing preparation will damage the transmission, Follow the above procedure exactly. If you cannot shift the tranemiecion or start the engi automatic transmission), the vehicle must be trans. ported on a flat-bed. «© Its best to tow the vehicle no farther than 50 miles (80 km), and Koop the speed below 35 mph (56 km/h. ‘© Trying to lift or tow the vehicle by the bumpers wil cause serious damage. The bumpers are not designed ‘to support the vehicle's weight. TOWING HOOKS ans TIE DOWN BRACKETS Rear “TW NOWN BRACKET 1-19Service Precautions Parts Marking Locations To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts will have self-adhesive labels or labels attached with a break-off bolt. Replacement body parts will have self-adhesive labels, and replacement engine and transmission parts will be stamped with a code for spare parts. NoTe: '* Be careful not to damage the parts marking labels during body repairs, and mask the labels before repainting. ‘© Labe! location letters without parenthesis indicate original parts. Letters with parenthesis indicate replacement parts. Label Locations Aor (Ak: Engine Bor (B): Transmission Cor (Ck: Front Bumper Dor iD): Hood Eoor (El: Trunk Lid For (F): Rear Bumper G or (G): Front Fender (Left and Right) Hor (H\: Front Door (Left and Right) lori): Outer Side Panel ¢ 1-20Specifications Standards and Service Limits Design Specifications Body Specifications ....Standards and Servi fe Engine Electrical — Section 4 e Limits MEASUREMENT an cai Teted voltege Vv Ka [STANDARD (NEW) Commutator mica dopth ‘Gommutator runout ommirator 0.0. Brush length Brush spring tension (new) _N kg th 822 Nest) Primary winding resistance at 68°F (20°C) Secondary winding fesistance at 68°F (20°C) Tanition wire Resistance at 68 (20°C) ko Spark lua Type ignition ting ‘BIDE (Red! Alternator Output 135 Vat hot Coll resistance rotor at 68°F (20°C), kn Sli ring OD. Brush length Brush spring tension _N (ka, I) ‘Starter Manufacturer Output staNaRo new | -senvceunaT | See Secion 4 Seetiase—o04 | 10a STANDARD NEW senvice ua wWwoA na Boo ‘tes Hopes isbn) Ss 29-35 (0.30036, 066 ~0.79) MITSUBA 1oKW 04-08 (0016-0020), 0.15 0.006) 0-002(0-a000) 0.05 (0.002) 280-28. (1.102~ 1.106) 27511083), 16.8 162,002-0.68) 1100.43) 16-18 (18-18,35~40) "Tio not edlual the aap, replace the spark wlva Wits out of service limi. 2-2| Cylinder Head/Valve Train — Section 6 Wat eaten) MEASUREMENT STANDARD (NEW! SERVICE LMT Compression 350 rpm ana Nominal 9mm 30.185) wide open theo Minimar 830 9.5, 135) Pa ati’ os ‘Maximum variation | 200 (2.0, 28) Gylinderhead | Warpage —— ] 8:05 (0.002) Heian. 146.95 - 147.06 6.785- 5.709) | —— Camshaft End play ‘005-015 0.002 - 0.006) 050.0%) Cemenst to-holder ol clearance 1.050 0.089 10.0020 -0.0035) | 0.750.006), Total runout (0.030.001) max. 0.08 yo.002), Cam lobe height Proiude IN Primary | 34.083 41.3402) —_ Mia 96.856 1.4510) — Secondary | 34971 (1.3763) — © Primary | 33.745 (13285) - Mic 136.323 (14300) — Secondary | 34.683 (1.3658) — Prelude Typo SH In Primary | 38.041 (13400) — wie 37229 (1.4657) = Secondary | 34871 (1.3768) — BK Primary | 33.745 (13285) — Mid 36.706 (1.4450) as Secondary | 34683 (1.3655) — Vane Valve clearance (Gold) IN | 0.15-0.1910.008- 0.007% — Ex | 017-021 0.007 -0.008)"° — Valve stom 0.0. WW | 5475-5485\02186-0.2189) 5.448 (0.2144), Ex | 5475-5455 (02156-02159) || 5445/0148) Stomto-guide clearance Iw | 0025-0055 0.0010 0.0022) | 0.08 10.005) x | 0.050 - 0.80 0.0020- 0.0031) _| 0.110.004) Valve seat With WW | 130- 15010051 005s) 2.00 0.079), Ex | 125-188 0.019061) 2.00 (0.078), ‘tom installed height ww | 5-427 (1673-1680) 4295 1.691), Bx | 439-401 (1728- 1.738) 144.35 1.745 Valve spring IN Outer | 45.16 1.7781" ams 25:75 1.302)" — tomer | 41.78(3.685)°* —_ av75 (neu) — © Outer | 46:72 (1.059)¢" — 46.74 (1840) — Inner | 39.32 (1.548)¢" — 39.28 (1 546)" — Prelude Type SH Ww ower | 40011578) — Tnaee | 4387 (1719) — EX Outer | 44581758) — a tnwoe [ators Valve ude iB in | ss10-ssenz169-02177) | s 5510210) ex | s835—s555 02179-02187) | 560{0.220) Installed height in | 14859 - 15005 (0.579 ~ 0.599) — ex | 1495 15.45 0.589 - 0.608) — Rocker aim “Aumto-shaft clearance in} 01025-0052 10.0010 o.0020) | 0.08 0.008) x | 1025 0.082 0.0010 0.0020) | 0.08 0.003), "7 CHUO HATSUJO manuTectured valve spring 2: NIKON HATSUUO manufactured valve sping. “3 Measuring point between camshaft and rocker arm, 2-3Standards and Service Limits ; Engine Block — Section 7 MEASUREMENT STANDARD (NEW) SERVICE LMT Cylinder block | Warpaye of deck surece ‘0.07 (0005) wan 2.10 (0008 Bore diameter Aor £87.010-87-020{3.4256 -3.<260) | 87.070 (4279) Borll {87.000 87.010(3.4252- 3.4256) | 87.070.3.4279) Bore taper = 10.05 ¢.002), Reboring iit == 0.250.010), Piston ‘Skin 0.0. Jat 1S mm {08 im) from) Noletier | 8G999—@7.006(a.4240-a.4254) | 66.960.@.4244) bottom of sk. Lett 186.983 — 88.996 (2.4245 3.4250) | 86.970 2.4240) Clearance it cylinder (0.008 0.027 '0.0002-0.0011) | 0.08 0.002) Groove wicth For ring) Top 4.240-1.255 0.0488 0.0894) | 1.276,00502) Second 1230-1.245 (0.0488 -0.0%90) | 1.265 (0.0898) ol 205-2825 0.1104-0.1112| | 2.85(0.112) Piston ring | Fing-1o-wroove clearance Top (0.056 0.085 (0.0022 - 0.0033) | 0.13 (0.05) Second 0.040 0.070 (0.0018-0.0028) | 0.13 0.005) Ring end gap Top 025-035 (0.010~-o.0r4) 0.80 0.028), Second 0.80 -0.75 0.024 -0.030) 9:90 (0.095), on 0.20-0.70 (0.008 0.023) ‘0.80 00311") 7 0-20-0150 (0.006 0.020)" 0.80 (0.024): Piston pin 00. 21.961 -71.965 0.8846 -0.8648) | 21.983 (0.0643) “ Pin-to-pston clearance “0.003 ~ 0.006 (-0.0001 -0.0002)_| 0.609 0.0008) Connecting rod | Pirtovod clearance 10.008 -0.018 0.0002 - 0.0006) 0.002 0.0008) Sinallend bore diameter 21.870 ~21976 (0.8649 0.8582) | —— Large ond bore diameter Nominal | SL.0 201) a End play installed on crankshaft 0.15030 10.008-0.012) 0.4070.016), Cranicha "Main journal diameter No.1 and/No. 2journala | 49.976 90.000 1.9676 - 19685) | —— ‘No. 3 journal 49.872~ 45.996 (19674 1.9683) | ‘No. § journal 49.984 50.006 (19679-19688) | ‘No, 8 journal 49.988 — 50.012 (1 3680-19690) | —— Rod journal diameter 447876 — 48.000 (18888-18399) | ——— Taper 0.005 (0.0002) max. 0.006 0.0002) Out-ofroune 0.008 (0.0002) max. ‘0.006 (0.0002) End ply 0.10-0.35 0.008-0.014) 0.45 (0.018), Funout 1.03 (0.0031 max. 0.08 (.002), Bearings Main bearing t Journal ol No, TandNo.2journals | 0.021 0.048 0.0008 0.0018) | 0:050,0.0020) No. 3 journal 0.025 -0.049 (9.0010 0.0019 | 0.088 0.0022) ‘No. 4 journal 0.013 0.037 (0.0005 0.0075) | 0.050 10.0020) ‘No. 8 journal (0.009 -0.033 (0.0004 0.0013) 040 0.0036), Fos bearing to journal oil clearance (0.027 - 0055 (0.0011 0.0022) | 0.06 0.002) Balancer shat | Journal diameter No. 1 fron journal A272 42 734 (1.6820 ~ 1.6824) | 42.71(1.88) No.1 rear journal 20,888 - 20.960 (01824308248) | 2092/0824) No. 2rontand rearjournals | 38712-38.724(1.5241-1.5246) | 3870(1524) NNo.Stront and rearjournals | 34722 34.734(1:3670- 1.3676) | 34.71(1.367) Journal taper (0.005 (0.0002) max. — End play 0,100.40 (0.004 0.016) = 2.04 0.15 (0.002 0.008), —_ Total runout 0.02 0.000) ‘2.03 200) Shaf-1o-bearing oll clearance No. Nfront,No.3 font and rear journals | 0.066-0.098 0.0028 0.0028) | 0.120.008), No. 1 rear journal (0.050 0.075 (0.0020-0.0030) | 0.090.004) No. 2frant and rear journals 0.676 -0.108(0.0030-0.0043} 0.13 (0.008) Balancer that | 10. ‘No.1 front journal “42.800 - 42.820 (1.6860 - 1.6358) | 12.83 /.686) beoring No.1 rear journal 24.000 21.013 (0.8268 - 08273) | 21.02 (0.828) No. 2front and reat journsls | 38.600 38420(1.5276~ 1.5263) | 98.83(1.529) No.3 front andrear journals _| 34.800 34820(1.37011.3709)_| 9489:1.979) i: RIKEN manufactured piston rng, 2: TEIKORU PISTON RING manulactured piston tng 24— Engine Lubrication — Section 8 Unit of langth: rm find MEASUREMENT | stanoanoiwew) | __Senvice LMT | Engine oit ‘Capacity | TUS at tmp at £5962, 52) for engine overaul 413161, 42 fr ol enange, reusing fier - - 415148, £0) for lchange, without iter ‘Sion ipnerto-ouer rotor earance {02-016 (0001-008) 02010008 ‘ii Rousing oct rover cleorance Ofbrae wo cw O21 ooo Purnp housing toto axial Sa2-corlac0t 0.008) | 0.21008) Fatotvaie | Pressure seing at engine ot temp. TE (0°) Wate si ato | 69007, 10) mn, 3000 om | 940135, 50) min — Cooling — Seetion 19) $$$_$_$_$_$_$_$_$$$ [ MEASUREMENT STANDARO NEW) Radiator Coolantcapaciy€ (US aim a WR — including engi, hese, 89173, 61 for oveshul coin toe end vverval 33138, 29) for coolantchange Foverol capecty 0.87 10.0 US 05 imp at wer Prlude type St 63172, 60 for overhaul 3215.4.22 for cool hange ANT: 68172 60 for overhaul $224.28 forcoolantchange Faditorcop | Opening pressure Pa gon ps 361231095175, 14- 18) Therma Stato open FC) 169 — 17670 80 Fully open“ CCl t94i90 Vat tra ly open 4100 10:0) in Zoalington | Thormoswtch A “ON femperature FFE) 19820862 - 98) ‘Thormoswich A-OFF* temperature_"FC) Subvast 4 1312 ~7 from actual "ON" temperature ;— Fuel and Emissions — Section 11 MEASUREMENT - SSTANDARO (NeW) Pesan | emarewhrpiaervewmtoredizometed | yp yo.a9-95 07-80 “Fuoitank opacity 1 (US gal imp ga woes, 32) —_— —— Fraine le speed wth heaghs and cooling fon oF wit ote ‘pm imin) - : 7660 700: 50 Festi pm 54002 700, Wdoc0_% 0.4 max 2-5Standards and Service Limits (- Clutch — Section 12 (MEASUREMENT 'STANDARO (NEW) ‘SERVICE LIMIT | Clutch pedar Pedal height tovioor | 189 78) = a] Stroke 138-145 6.915.711 — play 9-15 (08-08) — py 10-7.01004-0.28) — ngagament height tafloor | 9318.7) min. — Fiywheol ‘Clutch surace runout | 0.08 vo.002i max. 0.15 (0.008), ‘Cutch aise Rivet head depth 1.2-1.7(005-007) 02001) | Trickness 83-90 (033-035) 60 (0.24) Pressure plate | Warpage (0.080.001) max. (0.360.006 Diaphragm spring finger alignment 0.50.02) max. 08 (0.03) [- Manual Transmission — Section 13 MEASUREMENT STANDARD INEW) [SERVICE UNIT Transmission ail | Capacity # WSat.imp qd | M2VATransmission | 19 120, 1.7) forollchange: 2.012. 18) for averhaul M2UtTranemission | 2.1 (22.1.8) for oll hangs 221233, 18) for overhaul Mainshate End play 0-10 0.18 (.008 - 0.006) ‘st Diameter of bal bearing contact area (clutch side) | 27.977 -2789011.1015~ 1.1020) | 77:94(.100) Diameter of needle bearing contact area 37.984 30.000 (14954-14961) | 37.53 (1.493), Diameter of bal bearing contacter mission housing side) 27.987 - 28.000 (1.1018 1.1024) | 27-96 1.100) 0.02 (0.001) max. 005.002), ‘Maina re and 145.009 - 43.025 (18053 1.6899) | 43.090 (1.6980) 4th goars 0.08 -0.21 (0.002 ~ 0.008) 030100121, ard gear | 9492-3497 41.75- 1377) 348037) ngear | 3142 —31.47 (1757-1239), aaaz Mainehat mh 148,008 — «3.025 (1.6953 - 1.6839) | «3.080 (76861) esr 10.08 0.21 10.002 - 0.008) 03 00%) Thickness 2092-3097 (1.217 1219) 308(12) Countershaw Diameter of noodle bearing contact area "38.000 - 98.015 (1.4961 - 14967) | 37-95 (1.494 Diameter of bal Bearing and needle Dearing contact | 24987 25.000 0.9837 -0.9843) | 74.94 (0982) of Ist gear contact ate 39.984 ¢0.000(1.5742- 19749) | 399515721 2.02 0.001) max 0.05 (0.002), 2-6Unit of ength: mm /— Manual Transmission — Section 13 MEASUREMENT STANDARD (NEW) SERVICE LMT Gounterahat tat | 1. ‘6009-46 05 n.a11¢— 18120) | aeOR TATA) ear End play 0,060.23 (.002 ~0.008) 0.23 (0.009), 7 Thickness $32.96 - 53,00 (1.297 1.290) Gountershatt 20d | 1. “7-008 47.025 (1.8607 - 1.9514) | 47.08 11854) ‘ear End play 0.10-0.15 (0.004 - 0.06) 0.18 10.007), Thickness 292-2097 (1.199 1.141) ‘Spacer collor 10. "3.000 — 31 072 (1.2208 - 1.2208) | 31.08 (1223) (anchor sth | 0. $37 989 — 36.000 (1.4955 14961) | 37.94(1.498) fandsth geers) | Length A | 5545-5655 (2.222 -2.726) @ | 26.03 - 26.08 1.025 - 1.027) 2601 (1020) Reverse ior ar | UD. 70.016 20.043 (0.7880 - 0.7881) | 20.09 0.7900) ™ Geer-to-reverse gear shat clearance 0.036.084 0.0018-0.0038) | 0.160 (0.0063) ‘ynehra rng Ring to-gear clearance [ring pushed against gear) | 0851.10 (0.038 - 0089) ‘0.4(0.02) ual cone Clearance (ring pushed against gear synchte (Outer synchro ring to synchro cone 05 1.0(0.02-0.08) 03001) SSynenra cone-t0.ge 05-1.0/002~ 0.041 Outer synch tingto-gear 0.95 1.88 (0.037 - 0.006) Shift fork Finger thiexness| “rajath ahiW Tork | 747.6 (020-0301 Except above | 626.4 (0280.26) Forkto-syneheo 0.35 -0.85 (0.014 - 0.026) Reverse sniftfork | Paw groove width 180-133 (051-052) —— Farkto reveree ior goor clearance 05~1.1 002-008) ra) Groowe width"! ata | 1.06 7.25 (0.278 -0.286) — MB | 78-77 1023-030) Fore to-Stvreverco aif ata’ | 005-035 (0.002 - 0.014) at8" | 04-08 1002-0031 | stam 10, 4597316000 (0 6289 0.6290) Shit armc-aaf clearance ‘ons 0.09 (0.0002 0a023), Shit fork diameter at contot aes ‘a8 x20 (808-0512) Shit am to-shi fork shot sleronce 02" 05 10.000-0.020 Sele ver Shaft outer diameter saa 15.68 06776-08287) Sharm cover dlearance (8.0920 102(0.00¥3 0.0080) Shite Oo. 18.941 15.968 (06276-06287) Transmission housing larance Shit everside | 0012 ~0.122 (0005 00088) ° Shitloverand_| 0921-8, 102 0.0006 0.0040 irtrock Bore diameter 1600-1605 690-0321 Si arm slearance - ‘220.109 (0.00%3 - 00089) | oer Pinion shaft contact oea 1D. 18.000 18.018 (07087 - 0.7004) carrier Carertorinion sat clearance ‘047-0147 (0.0007 0.0018) DSriveshas intermediate sat eontact aaa UD. 28008 -28.025(%,4020 11090) Canter todiveshat clearance a1t25~0096 0.0010 0.0026 Cantor to-iarmchate shaft eearance 8.055 0.081 .0022 00038) Dien Backs (005 -0.15 (0.002 0.006) pinion gear to. Ya.oa2~ 1.086 07908 -0.71%) Pinion gearto-inin shat casrance 1085 0095,0.0022~ 0.0037) Differeiial tapered roller bearing peloed 14-25 (14-26. 12-20) Stating terqun Aim of, in) 1: Meosuring points 2: Measuring pont a ® ® 2-7Standards and Service Limits (- Automatic Transmission — Section 14 MEASUREMENT [STANDARD (NEW) SERVICE LMT Transmission Capacity 1 (US qt. mp att 6.1 (64, 84) at overhaul fd 255 (26, 22) at fluid chango a Hydraulic Line pressure at 2,000 rpm in [for [P) position ‘860-910 "800 18.2, 120 pressure 17 ~33, 120-190) _ Pa tkatfem?, psi) | ath clutch proseure at 2000 rpm in [De position [edo 920 (86-9.4, 120-130) | 7801. 120) {3 oluteh pressure at ZUW0 rpm in [Ds postion | 2d clutch pressure at 2,000 tpm in(2] postion a “st cluten pressure at 2.000 rpm in position ‘ual peed pm (Cheek with vehicle on level ground) 2.500 — 2.380 2,680 ‘luton ‘Cutch inital clearance 1.15-1.35 (0.048 - 0.053) —_— 119-12 10039-0.087) — 06 -08,0.024- 0031) a 4-06 0016-0024), ‘Clutch return spring free length 45.7 (1.80) | 87107 335 (132) S13itz@ Clutch disc thickness 1.88 - 2.000.074 0.079), Until grooves worn out Clutch plate thickness 1195-205 (0.077 -o.c81) Discoloration 1155 1.65 (0.061 0.065), 285 266 [0.100 0.104) 2.25 2.35 (0.089 - 0.099) Diecoldration {luich era plate thickness '305=3.10 0.120-0.122) Discoloration 1st 2nd clutches, 3.15~320 0.124 0.126) 3.25 3.30 (0.128 0.130) 3353.40 0.132~0.138) 2.55 2.60 [0.100 0.102) 2.65 2.70 0.104 0.106) 275-20 0.108 0.110) 2.85 - 2.90 0.112 0.114) 2.95 3.00 0.116 0.118) ‘lotch end pate thickness 2052.10 0.081 ~ 0.083) ra, ath elutohes 2.18 2.20 (0.085 - 0.087) 2.25- 2.3010.088 - 0.091) 235-240 (0.093 0.094) 2.48 2.50 (0.096 0.098) 2555-260 (0.100 0.102), 2.65 270 0-108 0.105), 275~280(0-108-0.110), 285-290 (0.120.114) Dizcaloration Veweboay “Stator shaft noodle bearing contaat LD. “Torque eonverter side 27.000~-27.021 (1.0830 1.0638) | Wear or damat ATF pump side 2,000 - 29.021 (1.1417 1.1426), ATE pump gear thrust clearance 0.03 - 0.05 0.001 0.002) 0.07 (0.003) [ATE pump gear-to-body elearance rive | 0210-0266 (0.0083-o.0108) | Driven | 0.070 0.125 (0.0028 - 0.0048) ATE pump driven goat LD. 14016-14034 (05518 -0.5525) | Wear or damage [ATE purnp driven gear shaft 0. 12.980 13.990(0.5504 0.5608 | Wear ot damage Thifing device | Rovorse shit fork finger thickness 5.90 - 600 (0.232 -0.736) 54010219) land parking brake | Parking brake paw! — Wear or " Parking brake Qear — ther defect | Servo body ‘Shift fork shatt bora LD. 74.000~ 14.010 (05512-05516) Shift ork shaft valve bore LD. ‘37.000 37.039 11.4567 — 1.4582) | 97.095 (1.4885) | Regulator vaive | Sealing ring contact 10, "32.000 ~ 32.026 1.2588 12608) | 32.050 (1.2618) body - _ ‘Accumulator body | Sealing ring contact 1D. ‘36,000 ~ 36.095 (1.3760 1.3768) | 36.08 (1.3798) [Stator shat ing ring contact. "29,000 79.021 (1.1417 1.1426) | 29.050 (1.1437) 2-8;- Automatic Transmission — Section 14 (MEASUREMENT STANDARD (NEW) Unit of fenath: mm tn SERVICE IMT Tranomioion | Mainahaft rd goar thrust eh 4172 mm thickness 22 6. (024m 0.2600) 15.37 ~6.40 (0.2508 0.2520) 6.42 6.45 (02828 -0.2530) 6.47 6.50 (0.2547 -0.2588) {552 6.55 (0.2860 -0.2570) 8.57 6.60 (02587 ~ 0.2538) thickness ‘Mainahaft th gear thrust washer, 2747 mm “4.95 5.00 (0.1949 0.7965) thickness “Secondory shaft splined washer, 38 x56. mim 6826.85 (0.269 0.270) {887 ~6.90 (0.270-0.272), 8926.95 (0272-0274) 597 - 7.00 (0274-0276) 702-705 (0.780.278) 7.07 7.10 10278 0.280) ‘Sesondary shaft thrust shim, 37 65 mim thickness “487-490 0192 0.198) 492-495 (0.194-0.195) 4497-500 0.198 0.1971 5025.05 (0.198 0.199) 507 5.10 0.000.201) 5,125.15 [0.202 0.203) 5.17 - 520 (0.204 0.205) Woar or damage Mainshaft th gear colferlenath “Mainshat th g Cotor thickness Mainchat ath elutch feed pipe 0.0. Mainehat 3¢dclute feed pipe 0.0. ‘Secondary shat foed pipe 0. ‘Secondary shaft bushing LD. ‘Onmainenat of stator shaft (On mainshat oF Sed goa (On mainsnat of sth goat collar (On eountershaft of sth goar On eountershaft 2nd geer On eountershat of L side (On parking geer (On Secondary shat of 1st gear (On secondary shat of 2nd gear (On secondary shaft of L. side (On reveree idler goar shalt ‘contac area LD, (ear shaft holder LD, or hub 0.0, Inside Osemeter Mainsnat ed gear Moinshat th gear CCountershat th gear CCountershat idler gear CCountershat reverse gear Reverse fer gear Secondary shaft st gear Secondary shaft 2nd gear collar lange thickness CCourtershatt distance colar length ‘Sevondery shaft sealing ring, 95 mm thickness [Mainshatt sealing ving, 32 mim thickness ‘Mainshef sealing ring, 28 mm thickness Mainshat sealing ring groove width ‘Secondary shaft sealing ring groove width -Mainsnf sth clutch feed pipe bushing LO IMainehat 31d olute feed pips bushing LD. Diameter of needle bearing contact area “Tranamigsion housing of reverse ilar gear shaft ‘ad 0950 (1.945 1.940) 435-450 0.171-0.177) 5042 50.46 (1.965 1.987) 1199-2002 (0.078 0.080), 41990 - 1950 0.074 0.077) 11850 1.950 0.073 0.077) 11.50 1.960 (0.073-0.077) 2.025 ~ 2060 [0.080 0.081) 2.025 - 2060 [0.080 0.081) 1a ~ 11.48 (0.4516 - 0.4520) 597 5.98 (07350 0.2354) 797 -7.98 (0.3138 0.3142) 11.500 11.518 (0.4828 ~ 0.4536) 6.018 6.030 [0 2369-02374) 18.000 -€.015 10.3160 0.3156), 22.984 - 23.000 (0.9048 - 0.9055) 55.075 55.991 (22037 2.2044) 33.975 53.991 (1.3376 - 1.3382) 33.975 33.991 (1.3376 ~ 1.3382) 39.979 - 40.000 (1.8740 — 1.5748) [38.005 — 26.015 (1.4175 ~ 1.4779) {61.966 41.980 (18821 — 1.6528) 7.978 37,999 (14952 ~ 1.4958), 39.975 53.900 (13376 13385), ‘34.000 ~ 24.073 (13386-13391), 114965 ~ 15.000 0.5900 - 0.5908) + 4.B00 - 14.86 (0.5827 0.5834), 14.800 14.826 (05827 ~ 0.5806) 95.87 ~ 5590 (21998 -2.2008) 61.000 61.019 (2.4016 2.4023), 40,000 — 40.016 (15748-15754) 40.000 - 40.018 (15748 1.5754) 50,000 - 50.016 (19685 ~ 19691), 46.000 86.016 (18110-18116) 20.007 ~ 20.020 (0.7877 0.7882), “44.000 — 48.016 (17323-17328), 40,000 — 40.016 1.5748 1.5750) Wear or damage 1-800 (0.071) 11800 (0.071) 11809 (0.071) 2.080 (0.082), 2.080 (0.082) 1145 0.4508), 5.95 (02545), 7.95 (0.3130), 115530 (0.4839) 15.045 (0.2360) 8.030 0.3161) w or damage ‘Wear of damage ‘Wear or damage Wear or damage Wear or damage: Wear of damage (cont'd) 2-9Standards and Service Limits — Automatic Transmission (cont'd) — Section 14 (MEASUREMENT [STANDARD (NEW) (cone Malnshatt 34 goa 9.30.11 (0.001 - 0.004) —— Mainehat th goa 0.10-0.22(0.008 - 0.08) == Countershaft tst gear 0.00 0.330.000 -0.013) —_ CCountershaft&th geat 0.04 0.280.002 0.011) — CCountershaft ier gear 2015-045 (0.001000) =| —— Countershaft reverse gear 0.10--0.25 (0.000.010) — Reverse idlr gear 0-20-0185 (0.008 -0.022) — | Secondary shat ist gear 0.07 0.15 (0.003 -0.008) = Secondary shaft 2nd gear 0,080.12 0.002 - 0.005) — Differential Pinion shaft contact area. veo10- 16.028 (0700-0710 | —— carrier 0.023 - 0057 (0.001 - 0.002), 0.1 0.004) 28.025 - 26.045 (1.103 - 1.108) 0.045 - 0.086 (0.002 - 0003) 0.120.008), Cariersto-imarmediate shaft ch 1.065 0.111 10.003 0.008) 0.120.008), Diorential Baekaeh 10.050—0.780 (0.002 0.006) — Pinion gear 1b. 18.042 -18.066(0710-0711) | —— Pinion gear-to-pinion shaft learanco_ 0.055 ~ 0.095 0.002 - 0.008) 0.720.005), Differential tapered roller bearing pretoad Fornew bearing | 27-39 (28 40,2435) ‘Adjust Staring toraue Nm dkgem, tin) Forused bearing | 28-3.8(25-37,22~ 321 ‘aust stat ena LL INDARD (NEW) — Wire Die. 00. Free Length | No.of Colls ‘opine Fegulator valve spring A 19007) | wa7(0S7) | 77.4G0e7 162 Regulator valve spring B ‘87 model 118100089) 9210362) | 44.011.732) wo "98 "99model | 1.8 (0.063), 920362) | 48.0(1.732) 125 Stator reaction spring a5io17m | 35.4130) | 30.3(1.193) 182 Modulator valve spring Ysi008 | T0.41040) | sa5U1310) os Torque converter chock valve spring 1.110.043) aaoasn) | 36300350) u2 Relief valve spring 09 (0036), 5(0260) | 30.8(1.557) 204 Cooler check valve spring 05 10028) 58027) | 16510871) 68 Shit valve A spring 08 0031) 7410280) | 40.4(0.581) 169 Shift valve 8 spring 03 (003) rite) | 40.4591) 169 Shift valve C spring 03003) 6610260) | 49.117.993) 27 Shift valwo spring 07 (0028) 66,0260) | 32211268) ise lock-up shift valve spring 0.9 (0.038) Toi020) | sso) | ae Lock up timing valve speing (065 10.026) 610.260, | 34811370) 156 Lock up contol valve spring 07 (0028) 60260) | aza(rasa) | Shift valve O spring 07 jo0z— 6610260) | 35.71.4081, 172 Serva contel valve spring 07 jaz 6640260) | 357 (1408), 2 Reverse CPC valve spring 07 jooze) 611020) | 78,0700) 19 CPC valve spring A 07 (002m 811024) | 17.810701) 19 CPC valve spring B 07 (0028) siz) | eo | 79 ‘st accumulator spring 35j0139 | we(or2 | 617429) 98 ara accumulator spring 3510139 | rs6(0772 | 61.7 2.429) 36 4th accumulator spring 35 (0139 | 1980072) | B17 @4z9) 96 2nd accumulator spring A 2eior10 | 216(0850) | 6822605) 89 2nd accumulator spring 8 26.0102 | 14s(os67 | 51.02.0081, no | Active Torque Transfer System (ATTS) — Section 15 MEASUREMENT STANDARD (NEW? ATTS (moment — | Capacity (US at. Imp ad TAIT, 12) at overhaul ‘contd unit Hud 0.95 1.0, 0.84) st fluid change 2-10— Steering — Section 17 Unit of length: mm tn} | (MEASUREMENT ‘STANDARD (NEW) “Steering wel” | Goratona play arsewring wheel chewrnfonmae | = 100-038) Starting fond steering whe! ereumforence Neg Engine running | 29130, 66) Gearbox “Angle of ack guide screw loosened from locked | 20°25 postion [Pump | Pump prossur with shutoff valve closed 900-7500 (7077, 1.000 1,101 | atte oh * Power steering | Recommended Wud Honda Power Storing Fd Wor 5) ‘id Fluid capacity For overnaut | 124127, 106) S usar meat Feta chaage | 041042038) ower seeing | Deflection wth 310 ta 22D 140-165 (051 0.65) with used bolt bot” between pulleys 85~11.0(035 0.49) wrth new belt Beltersion Ng bf 300 540 (40-85, 88 120) wih vod bat Measured with bl onion gouge 140 60 175-90, 170200) with new bot | ‘When using a naw bel, adust defection or tension to naw value Run the engine for 5 minutes then turn ito Fendjist deflection or tension to used bolt values. - Suspension — Section 18 MEASUREMENT [STANDARD INEW) Whee Camber Front voor ~ alignment Rear ors Prelude Caster Front age Fetal too Front O22i04 110) Re W222 (1162 176) Front wheel turning angle Inward wheel | 38°20" 2 = Outward whee! | 25°40 reference) ‘Wheel ‘Camber Front corny aiigrimen re oases Prelude Type sH | Coster Front Prelude payey Prelude Type SH | 4°20 45° Total toe Front 02210: 16) Rear Inz=2 (18+ 110) Front wheel turning angle Inward wheel | 34°50" 2° Outward whes! | 28°50! (roferonce) ‘STANDARD INEW) SERVICE Whee! Rio runout Aluminum whee! Axil 0-07 0-003) 2.01008) Facial 0-070 003), 151006), 2-11Standards and Service Limits Brakes — Section 19 (MEASUREMENT STANDARD (NEW) SERVICE LIMIT Faving brake | Playin rake ot 196 120 gt 41 Tver fore To be osked wren pulled @~ TO noice lover Foot brake pedal | Podal bight with carpet removed MT 7616576) = wt 185169781, = Freeplay 151118316) == Master cvinder | Piston-o-pushrod ck 0=02 (0-001) Disc brake Die thickness Front 730.08) Toum Rear 501035) Bo1030) Disc runout Front aot 0.100.045, Rear — 0:10:0.008 ise parallelism Frontand rear | —— 0.05 (0.0006) Pad thickness Front Tro ress) 18,006) eae 9.01035) 1810.08) — Air Conditioning — Seetion 22. $$ $a ama MEASUREMENT STANDARD (NEW) Tir conditioning | Lubricant ype system SP-10 (PIN 38897 - P12 AOTAH or 38809 - P13 ~ AT] Lubricant capacity Condenser | 25 56, 0.8) it Ifo, Imp o2! Evaporator | 4011 1,14) Line orhose | 1011.04) Receiver | 101173.0.8) Compressor Tabricant ype SP. (PN 807 - PIO ADYAH oF 38699-P13 -AD1) | Cobncant capacity mt cz imp oa) 1907 (6 8 72 46-71 Stator coil resistance ot 63°F (20°C) 525355 L Palloytoprossure pate clearance 0150.18 10020 = 0.006) ompressor bell | Deflection with 98 N 10 ka 2 bf {95-125 (037-048) with used bet tween pulleys $5. 151022~0.20) ith now bel jttension _N ka. bt) 300-540 0-65, 66 121) with used bot assured with bel tension gauge 801,090 (90 105, 198-231) with new belt When using # new belt, adjust deflection or tonsion to now values. Run the engine for S minutes then turn off Readlust deflection or tension to used belt values. 2-12Design Specifications rem meme enous noves DIMENSIONS] Ove Leth 2520000 Teen Overltwtn ‘0 mm coin Overal Hight 1218 San Wcebase 236 mn wen Mex front | gas mm toon Seating Capacity Four WEIGHT TSA | Groes Veh Weigh Rating TGVWAT — 36 bs WEIGHT (CANADAT_| Gros Veni Weight Rating (GVWR Tae == 1 ENGINE ype Water coued «sake DOWE ‘7ee pasos engine Cynder sangeet Inve chide rarer Bore and Sree 101007 mmf 330387 in aplacent 7 an teecuin Comprcron Rao wo vove Wain salt driven, DOHC VTEC “vate pa evindr Lubrication Sytem Foreed and wet somp,roahold pump tum Bspecrment a 6000 enginespm | 91 F625 Jat 320 Imp rime nr PompDsstnmen a 8otDengerpm | 42S" (SOUS, Re Imp amine Pt Ronet iettom UNLEADED gave _ 1 un Ontane Number oho STARTER ye eat Fediction Noval Output Tsk Nowra Voge ev hecrantog seconde Direction of Rotation | clockwise avd rm gor end cluTeH Guten Type Want | Single plate dry, elapvogr sping an Tove coer uch Facing rea fi | asec ee Le scin : TRANSMISSION | Tranarission Type MIT | Sytroned ape Toward, ever an ‘tleconcaly cnaed speed automo, troverse Primary Redvton Oren Manual Teer oor ato 1 2.285 ns 188 oa 13a a 08 sh one “Final Redon Geartype | Single etl gar Sears i268 ‘ora Wenaion Geeta 1a ase FA ose tn oesa fovea 1503 Final Redon ont Shae lal gm Soares me (cont'd 2-13Design Specifications r- (cont'd) mem METRIC ENGLISH aR Gooling Capacity 390 Keath aan ATU CONDITIONING TypaiManvtacturer ‘Sro1CENAIN No. of Cylinder x“ Capacity 85.7 mtiov | §23cusintey Max. Sper 10,000 rpm Lubricant Capscity 130 mi ager Liubrisnt Type _|SP-10 (P/N 38897-P13-AOYAH or 38899-P13-A01) Condenser Type. Corrugated fn Evaporator Type. Corrugated fin Blower Type Sirocco fan Motor input za0wnv ‘Speed Contr! “speed Max. Capacity 80mm | 16.950 cu fh Temperature Control ‘Bicmix ype Compressor Cuich ‘Type Dry, single plat, poly-V-belt dive __ Power Consumption s2Wmaxit2V Refrigerant Te THFC-Y3te (9-134) Quanity 70a | ___268.{s02 STEERING Tye Powe assisted, rack and pinion Overall Ratio Prelude "8275 Prelude Type SH 1361 Turns, Loekto-Lock Prelude 289 Prolude Type SH 278 Steering Whoo! Diameter 380mm | 1500 ‘SUSPENSION Type Front Independent double wishbone, ail spring with stabzer Rear | Independent double wishbone | ‘cll spring with stabilizer Shock Absorber Front and fear “eloscopie, hysraulic nitrogen gos ied ‘WaeEL Camber Froat 00 ALIGNMENT Feat 0°48 Caster Front Prelude as Prelude Type SH 20 Total Too Front mm on eat | tazmm In Bin BRAKESYSTEM | Type Front Power asisiod slfadusting ventilated dise Fear Power assisted sol adjusting solid disc Pod Surface Arca Front Stemin2 | 78} eain? Fear 279cm x2 432 sain x2 Parking Bea Type ‘Mechanical actuating, rear two wheel brakes TRE ‘Sie and Prossure See tire labe 2-14mem STANDARD ores ELECTRICAL Bowory 72V—SRANE HR St 2V-16KW ‘Alternator s2¥-1008, Fuses in under dash fuseielay box T3A,10A, 188 208,308 Fuses in under-hood fuse/elay Box 15A.10A 1A. 20A,30, 404, SOA, 1008 Headlights 525565 Ww | Front Turn Signal Lights yv-aW || Front Parking Lights 2V-BW. || Front Sida Marker Lights wev-3cr Fear Side Marker Lights 12V-5W orc. Fear Turn Signal Lights 12v-21W | BrokeTodlights 1v-2V8W Tailights i2V-5Worsce Back up Lis v-aw License Pate Light wv ace High Mount Brake Light v-21w ‘Bub type wv-L60, LD ype ailing LightSpotight nv-sw Trunk Light wv-5W Gauge Lights s2V-14W, 300, 112 icator Lights lumination and Plot Lights 12V-056W, 084 w 120.56 W, 0.84 W, 14W, LED. 2-15Maintenance Lubrication Points ... Maintenance ScheduleLubrication Points For the details of lubrication points and type of lubricants to be epplied, refer to the illustrated index and various work procedure (such as Assembly/Reassembly, Replacemant, Overhaul, Installation, etc.) contained in each section. No. LUBRICATION POINTS LUBRICANT [| Engine {API Service Grado: Use SJ “Enorgy Conserving” grade oil. The oil container may also display the API Certification seal shown below. Make sure it says “For Gasoline Engines.” SAE Viscosity: See chart below. Genuine Honda MTF ‘Transmission ‘Automatic TeanarmIssiGhi Genuine Honda Premium Formula Automatic jo = Transmission Fluid (ATF)*? ATTS unit Brake line (includes ABS line) Genuine Honda DOT 3 Brake Fluid®? Genuine Honda DOT 3 Brake Fluid*® si Release fork (Manual transmission) Shift and select cable ends (Manual transmission) Throttle cable end (Dashboard lower panel hole) _| Silicone grease Throttle cable end (Throttle link) 11 | Brake master eylinder pushrod 12 | Clutch master eylinder pushros Multi-purpose grease 13 | Battery terminals 14 | Fuel fill id 18 | Hood hinges and hood latch 36 | Trunk hinges and latch 17 | Door hinges, upper end lower 18 | Door opening detent 19 | Rear brake calipers Honda White Lithium Grease 20 | Power steering system | Air conditioning compressor ‘Compressor oll: SP-10 (P/N 38897 ~ P13 - ADIAH or a ‘38899 - P13 AO) For Refrigerant: HFC-134a (R-134a) ‘API SERVICE LABEL. ‘API CERTIFICATION SEAL. Recommended Engine Oi! Engine ol viscosity for ambient temperature ranges -20 00 -30-20 10 ‘1: Always use Genuine Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it 9 proper additives. 1@ Honda Premium Formula Automatic Transmission Fluid (ATF). Using @ non-Honda ATF can affect dove net contain *2: Always use Gen shift quality *3: Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. *"& Always use Genuine Honda Power Steering Fluid-V or S. Using any other type of power steering fluid or automatic transmission fluid ean cause increased weer and poor steering in cold weather. 3-2NOTE: Lubricate all ninges, latches, anc locks once a year. In corrosive areas, more frequont lubrication is necessary. We recommend Honda White Lithium Grease. 3-3‘Le pu ¢-¢ sobed uo anpoyas soueualuleW suoIpuCD B10A9g oy: MOI!04 ;s}9POW EPELED 104 Taishe yaeniar jewvawaydane odeuy aioe Soon po = SE ae eran a elelelelelelele sone Se | |— aR RETR mows oe [vee fooler [ee | | a | smow 7 sion fac et eae ae aor sia aaa oe ero ar Loe [aan 3-5Maintenance Schedule for 1997 Model Severe Conditions ‘suonypvea esey Jo 610U1 10 240 wy usa s: Aen ao.4on 24 (ePEUED) UA OO0-OL CN #8) GOD‘ E “io. ere . e ny era 22erd9y sou s2ye1q 268) pue 04 1>edsu, . . . imu wun sii eoerdey . . . ny uorsswusuenn aneou . . . weyoos eusun aoerdny e ‘peods op eau . ° . 499 anu znfpe pue eds - oust 8 . . . . olefolefofelo] ite muce aay 2 Ue FO oes Sry But 10) eden | ONO 0 (wy OOO SIN OBL" ASKS 30va “le lalele le Savow poe 3H0N za [oo | vr fort | e6 | a | wv ooo eu] Nousas oz: [sor] os | po | | oe Boo" x29;0| (¢ 689) svonpue Burmug 218495 249 Jo e104 10 uO ep {TNIV UBNUP 81 APNEA 3-6se pur s998,@ JOPUN ATINOISYII0 UEAUP SI 489 841 1 “3LON -€ sofed uc ainpayog eoueUaIUIEW) SUOHIPUOD JEON aun MO}IO} pINOUS NOA ‘suomypuoo snoulewunous uy Bulaup 40 ‘10209 dor ‘BulAup 08:pue-doxs jo spoued Guo) 10 Buyp! aaisuara ‘suo}tipu0a J. 08 800] 104 Ajouranxa ut BuIAua ‘du sad (uy 91) seu ob UeUL Ss0] Buynup‘seumesadwier Bu) luser-Buo} aunsue 01 poued abe: Uuoissiue 5,soworsno plOa 10U Jo001 ayy ye peuoyied 9q 5 Pee SweH eyt UO eoueUETUIEW WOLed OF ‘osapoid awe Beek OF ‘onus pue swOi7 | _suonseuuos pu sou ong | sated ene eee e ee oe cot woqoeuuc pe wey met BuN08D Tera = , emuEHa Ped eR OR no pny FE sspsounpaonus quan on 9951'72L91 | yen oy 30a) Poe afm Jo V8 sora edd Pr 0 wpe put wma IY swuevoduros vorsuadeng, ‘suUOU 9 20 (24 D00'2 us 905'¢ 93 ‘1000 ue 09 1008 Bur98K spuD pO? StL ‘sway, Buyono} a 20d AYES co 1880) 38 vompuo9 pue won 006'1 Atos 6 ra eRe ERT elele _— - - see a foo p me Le ue 310N zor | or | vi | ozt | 96 | zx | er NoUsas: ‘ozt | so1| 06 | <2 | 09 | ar | of 3-7Normal Conditions Maintenance Schedule for 1998 Model "de puopuas Jono ut Bhd eds 84 294401408 on 10U 00 Ze "ve 9}001 pu yaueues woamion wrod BuuneNor te or yon an wun a pox votes utr Sy S10 18 BOE ans Teena pan opemeTa aT] ne cien ieee or | elelelelolelele =a ° pesmi emo Ze | ceume ms coanes so 20 . permission sou tS | rae | ed bony } i woupeeanrerce = . . . -1ug}009 euj6us soeiday eae eT we Tao Somme aa nmee |e aaa eo} fel fe] fe sa ae rin peg Guy sana am ° eo er ° son yeas eeu risen eee — are e-owiorne mess |e] le) lel lo cove een owing otter = SR aE RD . Baan Pee : 8 SRGET SOUS 287, | swuow 2120 en 000720) yo ouBuo oserday Se [ala lelel= lea] ame asaus ee 340n zecfanfrecfocr| oe [er | m [we | “eootri | nmaumaun lotto Nous zt [so [06 [se [on | sr | oe | st | 0001 x son eeospu a ‘ode ou op 11-€ pu® O1 € s060d uo ajspagag saueUeILIeH ALONIBUCD STANRG Bin Ut pEYiDadS SuorpUGD BuIA O10A08 aLL-€ PUP O1-€ sebed uo ainpayos soueuayUIeYY SUORIPUED a19n9g a4R Mo}|O4 ;}opOW EpeUED 404 ‘Au pewuoped aq saoues soueuaiulew ie YR spuoWUOD9: epUo} ‘IeneMO},'s ‘Ue Ulm poxsew sure! 242 Uo 2ouBueU!eUs UHiCHad 02 94n|e} ‘sUONe|NBaL [esepay pue LEIS 0} BuIp109y ue suonneuu0s 2800) UaIUBNeL, ° seu pus ye @Bewep. 7 || ] T | “svomseuvos pu £90 sumnsAs13Nep Suoqpouuos pue sasoy wass Buyoog yuo M01 pins #4620 Jo wonpoa yenay 3504) ‘voupuae pue s sye9} 10) 1Pa4D PUP SP PINTS abauep 19) 78HD "51009 0 uoRUCR RUD say On ju Seu pu s=50%) 100 WEUSSNIG ueduoo uojsuedsng eu ‘3009 pue ~o9 1208 6u1s8916 pus pO! (oy aus Bade ATTA — ova ole maveu | poe a0N 96 senayoiy au Nousas poiest [oe [ar [oe | st 3-9Maintenance Schedule for 1998 Model Severe Conditions peor 000004 (Sf) Su 00 8 ct porn oe oTelepepeper aa SO ORT AES ° e ny oye widen sso 90 uy 000 sm Gos Mn soe 661 pu 8a sea. e| le . °| prow aun SLL oe eat ee . . pimy worsen soedny so ee . tujo0s abu aoe aaa eS RI UI Foo SRT ee coco aommmeawnmn | | @ oe new | a . . . . seg anu pe pus toda, . w Er00= «EOF t ter supambaoeNa0 ° | | ves 1 8000-000) 120 . . . . ul 2000 = 900) 6D eloleloleloie me ia Ja eT HD PIE TOD ue uuu 920 G00) sn 818 mr 7) — | ole a] pus ion 7 se | a Nou3as mi atate {LL-€ #686) suon;pueg Bulag 210N06 eX j0 #10u 10 640 nun AINIY UBAUD spy Bu 1paY9g SOUEURRUTEW SUOMIPLOD B1ON9s By MOIO4 3-10ee pur 8-£ SaBed Uo ainpoyos soUBUaTUIEWY SUOMpUDD |ELLION a4 MO}IO} PINOYS NOA ‘uoMIPUED ,2saK9s, © 19PUN ATTYNOISYIIO YORU $1 409 94 JI :3LON ‘wn pepuauuios9: oy 10 pouroyied 2q se21AI9s soUEUSIUIOW jI0 104A sPUBWWOD9: ePUOH “J9REMOH seNUELIEN Uuo|ssi.wa s s0WoIsn9 PIOA 10U IIA (4) YSUOISE UE UMA PayZeW SWI! B41 UO aoUEUETUIEW WO}ed 0} aunjIe} ‘suONNE|nB9: {e9Pe) pue o}eI8 0} BuIps0D9y T Teomapun wiaNah ‘jonuos pue sé suoqpeuu0s pe 50 _watshs enews suoneuvos pve sasoy worsks Bujoo9 sesu zen EEL SOL ‘imu 40 worspve9 pue sie Iw | | [sav Spr oa pu Beso OOS ‘00 Wyeuseag ‘suauodiuo> uossuadsns, sow 910 (49 opo'zt| soy 008s 943, eu ‘1009 pue 0a 1608 Bunions spue Pos OL, — suo Buoy} an 266s Agen, — (12 00020 san oss Ase 1999118 volupuo> pur U ree elelelelelelele. sbimpuesioa ova 36 | ve | ex | 0s | or | vc |e mae] pve 310N zat | esr [om [oz] 96 | zx | ay | ve | ooo xu nowaas ozs | so | 06 | se | 09 | sr | oF | St | ono xsomu aves a 3 21019§ 3-11Maintenance Schedule for 1999 Model Normal Conditions (wn 000) sa a's Ana sm oie . . ra elelelele iu in ove ero eelelele ‘sbyeq eas pu wou weds, . | | Pinu wun Si sero . | por vorssuen somo . . . tweens euve esse (uonisod 6 au we 08 +007 worsuvER (aaa a dg 05 i ponds ape pode woe wee . . . . snipe pur ter ovo ne ° tradeo] pup oa over og Bu 9rd wer . Syd eds oe 69 le 100 Avo oy oven an . el Ta ov "Bye 01 ORD Bue ONAL EAD | dow ony ua Tuejoes pus yo au 20) 8 elele 72g Suu weed 2 bsntsyey | 8 war obut oy AisedeD 9 eubue soe cou so ue 310N Nouns 3-12“GU-€ ue FL-€ SaBed Uo ainpaung soueuarUieWy suOMPUED 810n95, ‘moliod ‘s}apous epeueg 104 soueuowieu ‘wioyiad 0} aanyie} ‘suonejnBau jexapay pue 2124s 01 Gulpios2y Tied pabauep how seydor T pue suo19¥u09 e800] unYBned ‘He 0) OU ‘sounj0n pu eye0|"OBewIEP 10} 294m 5°8 _|_pue oxi nex ‘pos weny seu0H09 ARIE BU OUD uowered0 v8 18 -Suonn@Uu09 pu 8 m4 versie asnepg suopoeuuos pue eosoy wershs BuN1009 Pini 0 vompucs pue sian pn i | Sey Supnpouy souy pue soy oye1e si00q weUsoniG suouodusea uojsuedsng, ‘009 pue og 1896 Sunde spue pos oi, - —__] "si Bapmoyoy ayy vada MeN a0ve me lw [aloe lelr[a| smo pue 310N ast [oor [ver oer] 96 | ex | er | vz | oo xun Nowoas oer [sor | 06 | sx | 09 | oe | oe | at | coor xsonu 3-13Maintenance Schedule for 1999 Model bnjavieds out easy de au oni vu og ‘xpos pu yoysveo ueoNysa lod CUUNeEEAL 1, eT ote 7 UVB 8S ele oe ele Tiaiipr me Bee S| . pny 21a oer [stow 91 ooo 21 anu os Kana oye 00 pu 0 008 spuoy suuep up ebueya.o peduiree ognow 760 | © . ° ° Prion Sy mou Ty roy unaigwpadg sun ea stung nj ibd ev snza2VeeLiNIeN nen | © ° . . Pinu vossnseuea aoe sbomyaioj bar ¢ | WSHOD 264 wALA “LW ebuoy austen Sopot 76d Bu 15 E60 7949 | vw dujez won 7s) 7s wont snuory fuga weno 72S aah, apmesg so Geauieewense jee . . . ume ourbue aceon | 7 aT AT OS LL RIE ——..| s Cu pba. sermon rr ° : pasos ap 86 im zoze =e 0.) 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Starter Brush Holder Test .. Starter Brush Inspection Overrunning Clutch Inspection Starter Reassembly 4-12 Performance Test 413 inition System Component Location Index Ad Circuit Diagram oe ws 4-15 Ignition Timing Inspectio 416 a7 4-18 Distributor Replacement Distributor Overhaul Ignition Control Module (ICM) Input Test Ignition Wire Inspection and Tost .. eo pve MeO Ignition Coil Test 4-20 Spark Plug Inspection 421 419 Charging System Component Location Index ... Circuit Diagram ... Troubleshooting Alternator Replacement . Alternator Overhaul .. Rectifier Test Alternator Brush Inspection Rotor Slip Ring Test Stator Test A/C Compressor (Alternator) Belt Inspection and Adjustment ....... 4-33 Cruise Control Component Location Index... 434 Circuit Diagram . 435 Control Unit Input Test nnn 436 Main Switch Test/Replacement ..... 4-38 Set/Resume Switch Test/ Replacement Actuator Test ... - 4-40 Actuator Replacement ... 4-41 Actuator Cable Adjustment 441 Clutch Switch Test .. sone Mo Brake Switch Test seve M2 Actuator Solenoid Test... Actuator Disassembly... sees ABSpecial Tools 2 07JGC 0010108, Bolt Tension Gouge > OTPAZ - 0010100 SCS Service Connector * Included in the Belt Tension Gauge Set, T/N 07JGG ~ 0010004, Ref. No. Tool Number Description © ‘AQTSX 041 -XXXXX | Vacuum Pump/Gauge, 0 - 30 ina, 4-2Starting System Component Location Index STARTER CUT RELAY STARTER Test, page 45 Solenoid Tost, page 46 Foplocement, page 7 Overhaul page 48 Reassombly, page 4-12 BarTeRy Test, soction 23 AIT GEAR POSITION SWITCH IAT! “Test, section 14 Replacement, section 14 4-3Starting System Circuit Diagram Lwoes-toonruseRELAYBOX TON SaTEN arte No3Z 083 EON or I 8 NNT TAS Oy sar vee ak Wired WHT eure ur Bw euxiai mmosuzes conan SIRO” 44+ ENGINE Starter Test NOTE: The air temperature must be between 69 and 100°F (18 and 38°C) before testing, Recommended Procedure: © Use a starter system tester. © Connect and operate the equipment in accordance with the manufacturers instructions. ‘© Tost and troubleshoot as described. Alternate Procedure: 1+ Use the following equipment: —Ammeter, 0-400 A — Voltmeter, 0-20 V (accurate within 0.1 volt) — Tachometer, 0— 1,200 epm ‘© Hook up voltmeter and ammeter as shown, oye tea | [ev NEGATIVE TERMINAL, NOTE: After this test, or any subsequent repair, reset the ECM to clear any codes (see section 11), Check Starter Engagement 1. Remove No, 4 (10 A) fuse from the under-dash fusejrelay box ‘Turn the ignition switch to START {lll with the shift lever in [¥] or [position (A/T) or with the clutch pedal depressed (MIT), The starter should crank the engine. If the starter does not crank the engine, go to step 3. ‘© fitcranks the engine erratically or too slowly, go to "Chock for Wear and Damage” on the next page. Chock the battery, battery positive cable, ground, starter cut relay, and the wire connections for loose. noee and corrosion. Tost again. if the atarter still does not crank the engine, go to stap 4. Unplug the connector (BLKWHT wire and solenoid terminal} from the starter. Connect a jumper wire from the battery positive (+) terminal to the solenoid terminal. The starter should crank the engine. © In me starrer still does not crank tne engine, remove it, and diagnose its internal problem. ‘© Ifthe startor cranks the engine, goto stop 6. BLK/WHT ‘SOLENOID WIRE TERMINAL Check the ignition switch. Check the starter cut relay. Check the A/T gear position switch (A/T) or clutch interlock switch (M7). Check for an open in the WHT/RED wire between the ignition switch and starter cut relay, and check {for an open in the BLKWHT wire between the starter cut relay and starter. (cont'd) 45Starting System Starter Test (cont'd) (Cheek for Wear and Damage The starter should crank the engine smoothly and steadily, I the starter engages, but cranks the engine erratical ‘and inspect the starter drive gear land torque converter ring gear or flywheel ring gear for damage Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive ‘gear held, If damaged, replace the gears. Check Cranking Voltage and Current Draw Cranking voltage should be no less than 8.5 volts. Current draw should be no more than 380 amperes. If cranking voltage is too low, or current draw too high, cheek fe *© Dead or tow battery © Open circuit in starter armature commutator seg ments Starter armature dragging © Shorted armature winding © Excessive drag in engine ‘Cheek Cranking rpm Engine speed during cranking should be above 100 rpm. If speed is too low, check for: Loose battery or starter terminals © Excoseively worn etartor brushes © Open circult in commutator segments «© Dirty or damaged helical spline or drive gear © Detective drive gear overrunning clutch Check Starter Disengagement ‘With the shift lever in [P] or [f] (A/T) or with the clutch pedal depressed (M/T}, turn the ignition switch to START (Ill, and release to “ON (ll). The starter drive tgesr should disengage from the torque converter ring ‘gear when you release the key. IW the drive gear hangs up on the torque converter ring gear, check for: © Solenoid plunger and switch matfunction «© Dirty drive gear assembly or damaged ovartunning elutch 4-6 Starter Solenoid Test 41. Check the holdin coil for continuity between the S terminal and the armature housing (ground). The coll is OK if there is continuity. wir z ARMATURE HOUSING (GROUND) AMT: ARMATURE House (GROUND) 2. Check the pullin coil for continuity between the S ‘and M terminals. The eoil is OK if there is continuity PULLINCOR ——-HOLD.INCOILStarter Replacement 1. Mako sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the bettery negative cable, then disconnect the positive cable, and wat at leat thrae minutes. 3. Remove the engine wire harness and radiator lower hhose from the bracket on the starter motor 4. Disconnect the starter cable from the B terminal on the solenoid, then disconnect the BLK/WHT wire from the $ terminal wire, wr: 101.25 mm 46 Nem (5 kof, 331 STARTER CABLE 8x1.25mm 0x 1.25 mm 98m (09 kat, 44Nim (45 kgm, Tee abt ar 10125 mm {44m 169 bgt, 93 eR) BLK wuT WIRE 10 1.25mm {44 Nom (45 kof, 33 fF) 2841.28 mm 8 Nem 0.8 kot, 7 it) 5, Remove the two bolts holding the starter, then remove the starter. 6._Install in the reverse order of removal NOTE: When installing the starter cable, make sure that the crimpod side ofthe ring terminals facing out Chimps side of ring Connect the battory positive cable and nogative eable to the barery Enter the anti-theft code for the radio, then enter the customer's radio station presets. 47Starting System Starter Overhaul CAUTION: Before removing the starter, disconnect the negative cable from the battery. STARTER SOLENOID SOLENOID LevER OVERRUNNING (CLUTCH ASSEMBLY ‘BRUSH Be Coen Inspoction, page 4-11 ARMATURE Inspection and Test, page 19 nut Nem (0.9 kot, 7A) ARMATURE HOUSING SOLENOID MEER asker movBoeNum @ STARTER SOLENOID Test page ¢6 GEAR HOUSING ON ‘OVERRUNNING (CLUTCH ASSEMBLY Inspection, page 412 4-8Armature Inspection and Test 1. Inspect the armature for wear or damage due to can: tact with the permanent magnet. IF there is waar or place the armature damage, Inspect for damage 2, Check commutator surface and diameter. ‘Ifthe surface is itty or burnt, resurface with emery cloth or a lathe within the following specifications, fF recondition with #500 oF 9600 sandpaper. COMMUTATOR © If commutator diameter is below the service limit, replace the armature. Commutator Diameter ‘Standard (NEW) Serviee Limit 28.0-28.1mm 275mm (1.102 ~ 1.108 in) (7.083 in) ‘VERNIER CALIPER ‘CORMUTATOR 3. Measure the commutator runout. © If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments © If the commutator runout is not within the ser Vie limit, replace the armature, Commutator Runout Standard NEW) | __ Service Limit 0-002 mm 0.05 mm (0-0.001 in} ¢0.002 in DIAL INDICATOR ‘COnMUTATOR (cont'd) 49Starting System Armature Inspection and Test (cont'd) 4, Check the mica depth. if necessary, undercut the ‘mica with 2 hacksaw blade to achieve proper depth. If the service limit cannot be maintained, replace the armature Hic Mica NoTGooD ‘Commutator Mica Depth Standard NEW) ‘Service Limi 5. Check for continuity betwoen the segments of the ‘commutator. If an open circuit exists between sny segments, replace the armature. ‘COMMUTATOR SEGMENT 4-10 6 Place the armature on an armature tester. Hold @ hhacksaw blade on the armature core, ARMATURE TESTER. HACKSAW BLADE ARMATURE I the blade is attracted to the core or vibrates while ‘the core is turned, the armature is shorted. Replace the armature. Check with an ahmmoter that no continuity exists between the commutator and armature coll core, and between the commutator and armature shaft. If continuity exists, replace the armature, ‘SHAFT cOlLcORE = COMMUTATOR= ENGINE Starter Brush Holder Test 1. Chock that there is no continuity between the ® and © brush holders. If there is continuity, replace the brush holder assembly, © anUsH HOLDER © BRUSH HOLDER © BRUSH HOLDER @ BRUSH HOLDER 2. Insert the brush into the brush holder, and bring the brush into contact with the commutator, then attach 2 spring scale to the spring. Measure the spring tension at the moment the spring lifts off the brush, SPRING SCALE \- (Commereialy ‘vaisble) spr rusia —*] ‘Spring Tension: Spring Tens 157-177 N | 1.80 kof, 3.53 ~ 3.97 1b) Starter Brush Inspection Measure the brush length. If it is not within the servic holder assembly. limit, replace the brush Brush Length Standard (NEW) ‘Service Limit 158-162 mm 11.0 mm (0.62-0.64 inh (0.43 i) NOTE: To seat new brushes after installing them in their holders, slip a strip of #500 or #600 sandpaper, with the frit side up, over the commutator, and smoothly rotate the armature, The contact surface of the brushes will be sanded to the same contour as the commutator. 4-11Starting System Overrunning Clutch Inspection 1. Slide the overrunning clutch along the shaft. Does it move freely? if not, replace it 2, Rotate the overrunning clutch both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it (CLUTCH GEAR DRIVE GEAR 3, Ifthe starter drive gear is worn or damaged, replace the overrunning olutch assembly; the gear is not available separately. 4 Check the condition of the flywheel or torque con verter ring gear if the starter drive gear teeth are damaged. 4-12 Starter Reassembly NOTE: Use the illustration on page 4-8 as reference for reassembly, 1. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, ‘and release the spring to hold it there, 2, Install the armature in the housing. Next, pry back Until it seats against the commutator, then release the spring against the end of the brush. Y 3, Install the end cover on the brush holder. BRUSH HOLDER END COVER" ENGINE Performance Test NOTE: Before starting the following checks, disconnect, the wire from terminal M, and make a connection as described below using 3s heavy a wire as possible (preferably equivalent to the wire used for the vehicle) Pullin Coll Test: Connect the battery as shown. If the starter pinion pops ‘oul, itis working properly CAUTION: Do not leave the battery connected for more ‘than 10 seconds, (GROUND) Disconnect the vive. Holdin Coll Test: Disconnect the battery from the M terminal. Ifthe pinion does not retract, the hold-in coil is working properly. CAUTION: Do not leave the battery connected for more ‘than 10 seconds, ) ‘00¥ (GROUND) Retracting Test: Disconnect the battery also from the body. Ifthe pinion retracts immediately, its working properly CAUTION: Do not leave the battery connected for more than 10 seconds, ® Bopy IGROUNO} 1. Clamp the starter firmly in a vise, 2. Connect the starter to the battery as deseribed in the diagram below, and confirm that the motor starts and keeps rotating. a STARTER nv BATTERY 3. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly Specifications: {80 A oF less (Electric current), 2,800 rpm or more (Motor: speed) 4.13Ignition System Component Location Index IGNITION TIMING CONTROL SYSTEM Inspection, page 416 IGNITION wines ‘TEST TACHOMETER CONNECTOR Ingpection and Test, page #20 pistasJTOR SPARK PLUG Replacoment, page 17 Inspection, page £21 Overhaul page 4-18 Janition Cantro! Module (CM) Input Test, page 419 Jgntion Col Tost, pages «20Circuit Diagram ee ure Tosa Nes OH Gea 4 wae wate sari | cm mate yes = Vv SUISL ZI |X| as uooare Al Al [4A * ‘TRANSMISSION la Ber cu —_ ACTIVE TORQUE Seat BASS (OVP Cynder pseton ie 4-15Ignition System Ignition Timing Inspection 1 Check the idle spood, and adjust it if necessary (see section 11). ull out the eervice check connector 2P (GRNBLK and REDMWHT wires) from the connector holder under the dash on the front passongor side, then connect the SCS service connector (TIN O7PAZ ~ 0010100) to it. Star the engine. Hold the engine speed at 3,000 rpm with ne load (A/T in [Por [Xl] position, M/T in neutral) ntl the radiator fan comes on, then let it idl. Connect a timing light to the No. 1 ignition wi Remove the rubber plug from the “window” in the fiywheel/drive plate housing. While the engine idles, point the timing light toward the pointer on the flywshaal (MIT) or drive plate (AZT) "TIMING LIGHT window 4-16 ‘Check the ignition timing in no load conditions: headlights, blower fan, rear defogger, and air condi- tioner are not operating, Ignition Timing: 1B" = 2° BTOC (RED) during idling in neutral 18° £ 2 BTOC (RED) during ialing in|) or Bl wr aT NOTE: The illustration shows AT. Wr maRK (roc) Lan RED MARK rive PLATE It the ignition timing is incorrect, replace the ECM [there is no way to adjust ignition timing) Disconnect the special tool from the service check connector+ ENGINE Distributor Replacement Removs 1. Disconnect the connector from the distributor. 2. Disconnect the ignition wires from the distributor ignition (DI) cap. 3. Remove the mounting bolts from the distributor, then remove the distributor from the eylindar head. DISTRIBUTOR END CAMSHAFT END NEW O-RING moUntinc sour 22Naw (22 kgf, 16 bt) Installation: NOTE: Before you install the distributor, bring the No. 1 piston to compression stroke TOC. 1. Coat a new O-ring with engine oil, then install it 2. Slip the distributor into position. NOTE: The lug an the end of the distributor and its ‘mating grooves in the camshaft end are both offset 10 eliminate the possibility of installing the dist ‘oF 180° out of time. 3. Install the mounting bolts, and tighten them lightly. 4 Connect the ignition wires to the distributor ignition {Dl} cap as shown. No.2 No.1 Not No.3 Connect the connector to the distributor. Inspect the ignition timing (see previous page! After inspecting the ignition timing, tighten the ‘mounting bolts. 4-17Ignition System Distributor Overhaul heck for damage. O ae pisTRIRCrTOR IGNITION (01) ROTOR on sve senson Replace. ‘oubleshooting, section 11 Donat IGNITION coNTROL MODULE cM) Troubleshooting, section 11 Input Tes, page & pistr@uTOR IGNITION (00, Check for evacks ‘nd damage. 4.18Ignition Control Module (ICM) Input Test NoTE ‘© See section 11 when the malfunction indicator lamp MIL) comas on. ‘© Perform an input test for the ianition control module ICM) after finishing the fundamental tests for the ignition system and the fuel and emissions systems. ‘© The tachometer should operate normally iFthe ICM is Ok. 1. Remove the distributor ignition (Di) cap, the distri tutor ignition {Dl} rotor, and the leak cover. 2. Disconnect the wites from the ICM. eM Lu wir Gan wine ‘BLA)VEL WIRE 10. Turn the ignition switeh ON (Il). Check for voltage between the BLK/YEL wire and body ground. The should be battery voltage. '# If there is no battery voltage, check the BLKIYEL ‘wire between the ignition switch and the ICM If there is battery voltage, go to step 4, Turn the ignition switch ON (Il, Check for voltage between the GRN wite and body ground. There ‘should be battery voltage, 12 Ifthore is no battery voltage, check = ignition coil. — GRN wire between the ICM and ignition coil '© If there is battery voltage, go to step 5 Disconnect the A (32P) connector from the ECM, ‘and check for continuity on the YEL/GRN wire between the ICM and ECM. There should be cont- uity, Check for continuity on the YELIGRN wire to body ‘ground. There should bo no continuity Recannact the FCM A (32P) connector. Disconnect the 16P connector from the gauge assembly, and check for continuity on the BLU wire between the ICM and tachometer. There should be continuity, Check for continuity on the BLU wire fo body ground. There should be no continuity. Wall the tests are normal, reconnect the 16P connec: tor to the gauge, and replace the ICM. 4-19Ignition System Ignition Wire Inspection and Test CAUTION: Carefully remove the igni pulling on the rubber boots. Do not bend the wires; you ‘might break them inside. 1, Check the condition of the wire terminals. f any terminal is corroded, clean it, and if itis broken or dis- torted, replace the wire. ‘check for broken, corroded, of bent terminals. 2. Connect ohmmeter probes and measure resistance. Ignition Wire Resistance: 25 kOl max. at 68°F (20°C) 3, resistance exceeds 25 k0, replace the ignition wire, 4-20 in Coil Test Ignit 1. Turn te ignition switch OFF 2, Disconnect the 4P connector and ignition coil wire. SECONDARY WINDING TERMINAL 4 CONNECTOR 3. Using an ohmmeter, measure resistance between the terminals. Replace the coil if the resistance is not within specifications. NOTE: Resistance will vary with the coil tempera: ‘ture; specifications are at 68°F (20°C) Primary Winding Resistance (Between the A and C terminal 0.64 -0.78 0 ‘Secondary Winding Resistance (Between the A and secondary winding terminals): 144-218 kD a e © ‘SECONDARY winoING. TERMINAL 4. Check for continuity between the A and B terminals, Roplace the coil f share is no continuity+ ENGINE Spark Plug Inspection 1, Inspect the electrodes and ceramic insulator for: Worn or deformed + Improper gap Soilouing | 1 Cracked eater ‘Burned or worn electrodes may be caused by: © Advanced ignition timing Loose spark plug Plug heat range too hot Insufficient cooling Fouled plug may be caused by: ‘© Retarded ignition timing © Oil in combustion chamber = Incorrect spark plug aa ‘¢ Plug heat range too cold ‘¢ Excessive idjingllow speed running © Clogged air cleaner element © Deteriorated ignition coil or ignition wires 2 Do not adjust the gap of platinum tip plugs: replace the spark plug if the gap is out of specification or if the centar electrode is rounded, Electrode Gay Standard | 1.183. mm (0,043°Z.ain) 1.3 mm (0.051 in) Sorviee Limit Platinum tp plu: Do not adjust the gap: replace the spark pug ithe is out of spec Replace the plug at the specified interval, or if the center electrode is rounded as shown below: ROUNDED ELECTRODE NOTE: Use only the spark plugs listed below. ‘Spark Plugs NGK’ PZFROF-A1 DeNSO PRIZOCR-LIT Apply @ small quantity of anti-seize compound to the plug threads, and serow the plugs into the cylin der head fingor-tight, Then torque thom to 18 Nem (1.8 kghm, 18 IbFfe. 4-21Charging System Component Location Index ‘CHARGING SYSTEM LIGHT {ln the gauge assembly! “est, section 23, LUNDER-HOOD FUSE/RELAY BOX Has builtin ELECTRICAL LOAD DETECTOR (ELD) UNIT BATTERY Test, section 23, ALTERNATOR ‘Alterator and Regulator Test, page 4.27 Replacement, page ¢-2 Overhaul, page 430 [A/C COMPRESSOR {ALTERNATOR} BELT Inspoction and Adjustment, page 433 4-22ry ENGINE Circuit Diagram UNDER 000 FUSERELAY 80% No.2 1008) oo ns) wat | open wat | eee ate ssrectsomo. a) wa racer Pt win L 1 ai 4-23Charging System Troubleshooting It the charging system light does not come on or does not go off, ar the battery is dead oF low, test the f the order listed below: lowing items in Battory (see section 23) Charging system light Voltage Alternator control system Alternator/regulator ‘Charging System Light Test (Charging System Light Check: ake sie te charging system Tight comes on / Does the charging system NO. tat come ont zi {he WHY BLU or BUX/VEL wir ght Check CZ. Dows no charging system YES [perform te Attomator equator (ta go oft ‘est ne page +27 ALTERNATOR 4P CONNECTOR No Wire sida of WT ssreiy female terminals P Vohtage cheek ‘Measure the voltage atthe No. 1 terminal of the 4 connector with the fanicon switch ON Gh, — ~ wo | Repair the open in the BLK/YEL << twtnere battery voltage? >— ‘ite between the alternator and — a ‘under dash fuse/relay box. ves (To next page) 4.24+ ENGINE ‘From previous page) ALTERNATOR 4P CONNECTOR ect for an open inthe Li | Tu de igon ste OFF 2) Disconnest the AP connector fromthe atrnator. 3. Ground the No.2 terminal of thea? connector. | 4 Turn tho ignition witch ON (. /~ o08 the charging system NO_| Repair the open in the WHT/BLU < tight come on? wire, Wiee side of female terminals L war /BLU) ‘hort in the L el | Disconnect the No.3 terminal of ‘he AP connector rom the ground. (Doss tne charging system light go of? ; no. ato | Repair the short to ground in the WHTTBLU wire (cont) 4-25Charging System Troubleshooting (cont'd) Alternator Control System Test NOTE: Before testing, chack proper operation of the ELD by confirming with the MIL (see section 11), BATTERY {ALTE tine) 4 Disconnect the 4? connector 2. Start tho engine, and turn tho headlights thigh bea 3. Measute voltage between the 4P connector terminal No. 2 land the positive terminal of . pal le thore 1 V ot less? Ss oe No Check for @ short in the elreult 1m) ON. CAUTION: Be sure to use a voltmeter ‘with its plus terminal connected to bat- ‘Check for thort in the wire (ALTE: 10 Turn the headlight and ign tion switch OFF 2. Disconnect the A {32P) con: ‘actor from the ECM, 3. Chock for continuity betwoon the ECM connector A 122°) terminal No. 19 8nd body [arena ves. Repair short in the wi the alternator and ECM. 4-26 between ‘ery postive (+ and its negative (+) ter- ce minal to the 4P connector terminal No. (warT/GRN) 2 ALTERNATOR {4 CONNECTOR ECM CONNECTOR A (32P) yes T2)3)4| [5 2 1/6 25/26] 27 cen tora oy Wire sige of (Check for an open in the wire | fymoie terminals {ALT tine): S Turn the bi c tion switch OFF. IWaT/GRN) 2, Disconnect the A (32P) con rector fram the ECM. 3. Check for continuity between the ECM connector A (32P) Wie side of terminal No. 19 and alternator female terminals 4 connector terminal No 2. i, ALTERNATOR 4° CONNECTOR '0_| Repair open in the wire between ves <_tethere continuity? > ‘Tat thealtenator/regulator original ECM, th ‘ternator and ECM ECM CONNECTOR A (32F) s[e]7| [ejs|wn 17] 18[ 19) 20) 7| 22) 23) 2 2526) 27A ENGINE Alternator/Regulator Test NOTE: Be sure the battery is sufficiently charged (see section 23) ‘Aiwornator/Regulator Test 4. Connect @ Sun VAT-40 (or fequivalant tester, and wen LOAD ADJUSTER the selector swteh to postion (CARBON PLE) eteting) 2, Shift to novtral [AMT in For IN) position, ang start the fengine. Hold the engine at 31000 rpm with no load unt the radiator fan comes on, then iti o 3. Raise the engine speod to 2,000 pm, and hold ves ‘Alternator/Regulator Test 2 fon 4 Roloaco the accelerator pedal, ‘and let the engine ic. 2, Make sure all ccossories aro turned off Turn the selector ‘zaiteh to postion 2 charging! 3. Remove the inductive ck up, ‘and zero the ammater. 4. Place the inductive pick-up lover the B terminal wite of the ‘alternator s0 that the arrow points away from the alterna 5, Raise the engine speed to 2,000 rm, and hold it ther, 1 Fr ‘sth voage nes than 1357 > Anply 2 load with the VAT-40 beteaen 1213.5. To next page FULL FIELD TESTER LEAD (BLU ‘CABLE (RED) TERMINAL Wire VOLTMETER NEGATIVE LEAD (BLK VOUMETER osinive LEAD (RED) NEGATIVE TESTER CABLE (BLK) (cont'd) 4-27Charging System Troubleshooting (cont'd) From previous page | i, “The charging system Isthe amperage 75 A or more? No CAUTION: The voltage will ise quickly when the alternator is fullfiekded. Do not allow Ataratraguinter ona: | _thevolage te exceed 1 ima damage the ciel syste. 1 speed still at |__2000rbm,fullfekdthe atemator, _} Wore: Auach « probe to the VAT. test load, ant insert the probe into the fal field seceas hole at the bock ofthe ‘Switch the fel selector tothe “A (Ground)” position momentarily, and check the amperage reading. REGULATOR Located insce the end cover! FULLRELD ACCESS HOLE END COVER nator output 75 Aor, NO. ves. 4-28Alternator Replacement 1, Make sure you have the antithett code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery cable, then disconnect the positive cable. 3, Discanneet the 4P connector and BLK wire from the alternator. 5x1.0mm Nm (08 kgf, 6ibe 4 Remove the adjusting bolt, locknut and mounting bolt, then remove the alternator belt and alternator. MouNTING 8oLT 10% 1.25 mm 44m (45 kam, a3 te) i Ber Locknur 84125 mm 22Nim (22 bglen, riot) ‘ADJUSTING BOLT Install in the reverse order of removal, Adjust the alternator belt tension {see page 4-33) Enter the anti-theft cade for the radio, then enter the. eustomer’s radio station presets. 4.29Charging System Alternator Overhaul NOTE: Do not remove the pulley unless the front bearing needs replacement. To loosen the pulley locknut, use 10 mm and 22 mm wrenches. If necessary, use an impact wrench. ROTOR Test, page 4.32 seanaia, ‘0mm BOX WRENCH RETAINER PULLEY LOCKNUT ‘141 Nhe (1.3 kgm, 81.7 Ib) ‘sTaToR DRIVE-END HOUSING ‘CAUTION: Do nor get grease ‘oro onthe slip ings. PULLEY LOcKNt ju HTN (14.3 kgfm, 81.7 We) VOLTAGE REGULATOR REAR BEARING DIODE (RECTIFIER) ASSEMBLY Test page 431 TERMINAL INSULATOR . 9 fi so Ee 4-30Rectifier Test NOTE: The diodes ate designed to allow current to pass in one direction while blocking it in the opposite direc: tion, Since the alternator rectifier is made up of eight diodes (four pairs), each diode must be tasted for cont nuity in both directions with an ohmmeter that has diode ‘checking capability; a total of 16 checks. 4. Chock for continuity in each direction, between the B and P, and between the E (ground) and P terminals of each diode pair. All diodes should have continuity in only one (GROUND) & Ps eo a Pm me me e 2. Wany of the eight diodes fal, replace the rectifier assembly. (Diodes are not available separately.| Alternator Brush Inspection 1. Remove the ond gover, than take out the bruch hold fer by removing its two screws 2, Measure the length of the brushes with a ve caliper Alternator Brush Length: Standard: 10.5 mm (0.41 in} Service Limit: 1.5 mm (0.06 in) ALTERNATOR BRUSHES. \VERNIER CALIPER the brushes are less than the service limit, replace the elternator brush assembly. 4-31Charging System Rotor Slip Ring Test 1. Check that there is continuity botwoen the slip rings. SUP RINGS ROTOR 2. Check that there is no continuity betwaan the alip rings and the rotor or rotor shatt 3. Ifthe rotor fails either continuity check, replace the alternator. 4-32 Stator Test 1. Check that there is continuity between each pair of leads, colt cone 2. Check that there is no continuity between each lead ‘and the coll core, 3. If tho coil fails either continuity check, replace the alternator,

Honda Prelude 5th Gen (97-99) Service Manual

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Honda Prelude 5th Gen (97-99) Service Manual

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