Honda Civic Factory Service Manual US 1996 1997 1998 1999 2000 96 97 98 99 00

GeneralInformation
Chassis 1-2
and PaintGodes.'.'..'.....'..'..'.."
ldentificationNumberLocations'..'.'. " 1-2O
Warning/CautionLabelLocations'..'..'1-21
Under-hoodEmissions
ControlLabel.......... ......1'25
Lift and Support Points
1-21
Lift and SafetyStands.'..".'..'..'.'.'.".'
FloorJack 1'28
....,..................
Towing '.'....'1-29
Chassisand PaintCodes
U.S.1996Model l2-door Hatchback)
2AG 00001
D16Y7:1600SOHC16-valves
2HG: HONDAOF CANADA SequentialMultiport
Fuel-injected
Engine
A4RA:4-speedAutomaticTransmission
S40 : s-speedManualTransmission
GY-16P Midori GreenPearl

H: AllistonPlant,Ontario,Canada NH-503P GranadaBlackPearl
Destin.iions NH.583M New VogueSilverMetallic
R-97 RomaRed
Vehicle ldentification Number Paint Code

and FederalMotor Vehicle
Safety Standard Certification COLOR
GY.l6P
t-z
.\a
U.S. 1996Model {4-doorSedanl
J H ME J 65 2 * T S 0 0 0 0 0 1
D16Y7:1600SOHC16-valvesSequential
Multipon Fuel-injected
Engine
D16Y8;1600SOHCVTEC16-valves Sequential
MultiportFuel-injected
Engine
JAPAN:D16Y7.D16Y8- 1300001-
U.S.A : D16Yt,D16Y8- 1500001-
Lino, Body 8nd EngineTyp€

EJ6: CIVIC4-door/Dl6Y7
EJ8: CIVIC4-door/D'16Y8
Body Typo and TransmissionType A4RA:4-speedAutomaticTransmission
5: Sedan/s-speed Manual S40 : s-speedManualTransmission
S4C : s-soeedManualTransmission
A4RA{U.S.A.) : 5000001-
S40.SaC(JAPAN):1000001-
3: DX with Ay'C
4: DX with ABS,EX
5: DX with ABS and A,/C
6: LX
7; LX with Ay'C
8: LX with ABS
B-73M CycloneBlueMetallic
9: LX with ABS and A,/C
G-82P CypressGreenPearl
Ch€ckDigit
NH-538 FrostWhite
Model Year
NH-503P GranadaBlackPearl
T: 1996
NH-583M New VogueSilverMetallic
R-95P lslandCoralPearl
L: EastLibertv.Ohio Plant,U.S.A.
S: SuzukaPlant.Mie Prefecture,Japan
H: AllistonPlant,Ontario,Canada PaintCode
COLOR
Vehicle ldentification Number B.73M
Safety Standard Cortification
1-i
U.S. 1996Model (2-doorCoupe)
l H G E J 61 2 * T L 0 0 0 0 0 1
D16Y5:1600SOHCWEC-E16-valves
SequentialMultiport
Fuel-injected
Engine
Dl6Y7: 1600SOHC16-valves
SequentialMultiport
Lino, Body and EnginaTypc Fuel-injected
Engine
EJ6; ClvlCz-door/D16Y7 D16Y8:1600SOHCVTEC16-valves
EJ7: ClVlC2-door/D16Y5 SequentialMultiport
EJ8: ClVlC2-door/D16Y8 Fuel-injected
Engine
Body Type and Tranrmission Type
JAPAN:D16Y5- 1300001-
U.S.A.: D16Y7.D16Y8- 15OOO01-
3; OX with ABS, HX with ABS

4: DX with Ay'C,HX with Ay'C,EX
5: DX with ABS and Ay'C,HX with ABS
and A"/CEX with ABS
ChockDigit
A4RA : 4-speodAutomaticTransmission
Modol Year
S40,S4C:s-speedManualTransmission
T: 1996
M4VA ; ContinuouslvVariable
Transmission(CVT)
L: EastLiberty,Ohio Plant,U.S.A.
A4RA:5000001-
s40,s4c
M4VA:1000001-
Vehicle ldentification Number
Safety Standard Certification
G-82P CypressGreenPesrl
NH.5O3P GranadaBlackPearl
NH-538 FroslWhite
B-81 MilanoRed
R.95P lslandCoralPearl
PaintCode
COLOR
G-82P
1 -4
CANADA1996Modell2-doorHatchbackl
a
2 H GE J 6 3 2 * T H0 0 0 0 0 1 D16Y/- 1700001
Line, Body and EnginoTyps

EJ6: ClVlC3-door/D16Y7
Body Type and TransmissionType
A4RA:,t-speedAutomatic Transmission
S40 :s-soeedManualTransmission
CheckDigit
Modol Ysar
T: 1996
H: AllistonPlant,Ontario,Canada
GY-T6P Midori GreenPearl

Vehicle ldentification Number NH.583M New VogueSilverMetallic
and CanadianMotor Vehicle R-97 Roma Red
PaintCode
COLOR
GY.16P
1-5
CANADA 1996Model (4-doorSedan)
lHG EJ653*TL 800001
SequentialMultiport
Fuel-injected
Engine
Lino, Body and EnginoTyp6

Body Typo and TransmissionTypo
5; Sedan/s-soeed Manual
A4RA;4-speedAutomaticTransmission
S40 : 5-soeedManualTransmission
4; LX with ABS
5: LX with ABS and A,/C A4RA:5000001-
6: EX S40 :1000001-
7: EXwith ABS
CheckDigit
Model Year
T: 1996
L: EsstLiberty,Ohio Plant,U.S.A.
B-73M
G-82P
NH-503P
CycloneBlueMetallic
CypressGreenPearl
GranadaBlackPearl
w
NH-538 Frost White
VehicleldentificationNumber NH-583M New VogueSilverMetallic
andCanadian MotorVehicle
Safety StandardGertification
PaintCode
COLOR
8.73M
.'rr
F'.i!
1-6
CANADA 1996Model (2-doorCoupel
1 H GE J 61 2 * T L 0 0 0 0 0 1
1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
1600SOHCWEC 16-valves
SequentialMultipon
Lins, Body and EngineTypa Fuel-injected
Engine
EJ6: ClVlC2-door/D16\'/
EJ8: ClVlC2-doo./D16Y8
Body Typ6 and Transmi3sionType
TransmissionNumber
A4RA- 5000001
Transmissionl
A4RA I 4-soeedAutomaticTransmission
3: Si with ABS s40,s4c:s-soeedManualTransmission
5: DX with ABS SerialNumbor
ChockDigit A4RA :
Model Yeat s40,s4c:
T: 1996
G-82P CypressGreen Pearl

VehicleldentificationNumber NH-503P GranadaBlackPearl
andCanadian MotorVehicle NH-538 Frost White
SafetyStandardCertification NH-583M New VogueSilverMetallic
R-81 MilanoRed
R-95P lsland Coral Pearl
PaintCode
COLOR
NH-538
1-7
U.S. 1997Model (2-door Hatchback)
a
2 H GE J 63 2 * V H 1 0 0 0 0 1
Type ol Vohicl€ D16Y7i1600SOHC16-valves

SequentialMultipon
Fuel-injected
Engine
Lino, Body and EnginoTypr

Body Typo rnd Tranrmission Typc
A4RA:4-sDeed AutomaticTransmission
B4RA:4-speedAutomaticTransmission
3: CX with Ay'C
4: DX A4RA: 600000'l-
5: DX with Ay'C B4RA:6000001-
6: DX with ABS S40 : 1000001-
7: DX with Ay'Cand ABS
Chcck Digit
Model Yoar
V; 1997
q
H; AllistonPlant,Ontario,Canada
NH.503P GranadaBlackPearl
NH.583M New VogueSilverMetallic
Pg-l 4P DarkAmethyst Pearl
R-97 RomaRed
Safety Standard Certification Paint Code
COLOR
NH.583M
1-8
U.S. 1997Model l4-door Sedanl
J H ME J 6s 2 * V S 0 0 0 0 0 1
Dl6Y/: 1600SOHCl$valves Sequentisl

Engine
D16Y8:1600SOHCWEC 16-valvesSequential
Engine
JAPAN:D16Y7,D16Y8- 2300001-
U.S.A.: D16Yt,Dl6Y8 - 2500001-
Lino, Body snd EngineTypo

EJ6: ClVlC4-door/D16Y/ A4RA: 4-soesdAutomatic Transmission
EJ8: ClVlC4-door/D16Y8 B4RA: 4-spe6dAutomatic Transmission
Body Typo and TrsnsmissionType M4RA:4-speedAutomaticTransmission
5: Sedan/s-sDeed Manual S40 :s-speedManualTransmission
A4RA(U.S.A.): 6000001-
B4RA{U.S.A.): 6000001-
M4RAUAPAN): 2000001-
S40(JAPAN) : 1000001-
3: DX with Ay'C
4: DX with ABS,EX
5: DX with ABS and Ay'C
7: LX with Ay'C
8: LX with ABS
9; LX with ABS and Ay'C
B.73M CycloneBlueMetallic
ChockDigit
Modol Ycsr G-82P CypressGreenPesrl
V: 1997 NH-538 Frost White
L: EastLibertv,Ohio Plant,U.S.A.
Japan R.96P lnzaRed
S: SuzukaPlant,Mie Prefecture.
H: AllistonPlant.Ontario,Canada
Vehicle ldentification Number Paint Code

and FederalMotol Vehicle
Safety Standard Certification COLOR
8.73M
1-9
Vehicle ldentification Number EngineNumber

a
'tHG
E J 61 4 * V L 0 0 0 0 0 1 D16Y5- 2300001
Manutaqturer,Make and EngineType

Type ol Vehicle D16Y5:1600SOHCWEC-E16-valves
lHG: HONDAOFAMERICA SequentialMultiport
M F G , I, N C . Fuel-injected
Engine
HONDAPassenger D16Y7:1600SOHC16-valves
vehicle SequentialMultiport
Line, Body and Engine Type Fuel-injected
Engine
EJ6; ClVlC2-door/D16Y7 D16Y8:1600SOHCVTEC16-valves
EJ7: ClVlC2-door/D16Y5 SequentialMultipon
EJ8: ClvlC2'door/D16Ya Fuel-injected
Engine
Body Typ€ and TransmissionType Serial Numb€r
1: Coupe/s-speed JAPAN:Dl6Y5 - 2300001-
M an u aI U.S.A.: D16Y7,D16Y8- 2500001-
2; Coupe/4-speedAutomatic, CVT
Vehicle Grade
2: DX, HX
3: DX with ABS,HX with ABS
TransmissionNumber
4: DX with A,./C, HX with A,./C.
EX A4RA- 6000001
5: DX with ABS and A,iC,HX with ABS
and A'lC,EX with ABS TransmissionType
Chsck Digit A4RA: 4-speedAutomaticTransmission
ModelYear
a
B4RA: 4-speedAutomaticTransmission
V: 1997 S40 :s-speedManualTransmission
FactoryCode M4VA:ContinuouslyVariable
L: EastLiberty,Ohio Plant,U.S.A. Transmission
{CVT)
Serial Number Serial Number
A4RA: 6000001-
B4RA: 6000001-
Vehicle ldentification Number S40 :1000001-
and FederalMotor Vehicle M4VA:2000001-
NH.5O3P GranadaBlackPearl
NH-538 Frost White
R-81 N4ilanoRed
Paint Gode
COLOR
G.82P
1-10
CANADA 1997Model (2-door Hatchbackl
2 H GE J 63 2 * V H 0 0 0 0 0 1
D16fr: 1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
Line, Body lnd Engin€Typo

EJ6; ClVlC3-door/D16Y7
Body Type and TransmissionType
B4RA:4-sDeedAutomaticTransmission
S40 : s-sDeedMsnualTransmission
Vehicle ldentification Number NH-503P G.anadaBlackPearl

and GanadianMotor Vehicle NH.583M New VogueSilverMetallic
Safety Standard Certification PB-74P DarkAmethyst Pearl
R-97 RomaRed
Paint Code
COLOR
NH-503P
1-11
7
Chassisand PaintGodes
1 H GE J 6 5 3 + V L 8 0 0 0 0 1
D16\.t: 1600SOHC16-valves
SequentialMultiport
FueliniectedEngine
Lino, Body and EngineTyps

EJ6: ClVlC4-door/Dl6Y7
Body Type and TEnlmLrion Type
5: Sedan/s-soeed Manual
84RA:4-speedAutomaticTransmission
S40 : s-sDeedManualTransmission
4: LX With ABS
5: LX with ABS and ly'C
7: EX with ABS
8: EX with ABS and !y'C
L: EastLibertv,Ohio Plant,U.S.A.
B-73M CycloneBlueMetallic
G.82P CypressGreenPearl
VehicleldentificationNumber NH-538 FrostWhite
andCanadian MotorVehicle NH-583M NewVogueSilverMetallic
SafetyStandardCertification
Paint Code
COLOR
B-73M
v-
1-12
CANADA 1997Model (2-doorCoupel
l H G E J 61 2 * V L 8 0 0 0 0 1
D16Y7:1600SOHC16-vslves
SequentialMultiport
Engine
Fuel-injected
D16Y8:1600SOHCWEC 16-valves
SequentialMultipon
Lino. Eody and Engins Type Engine
Fuel-injected
EJ6: CIVIC2-doorlD16W
EJ8: ClVlC2-door/D16Yg
Body Type lnd Tran3missionType
44RA: 4-speedAutomatic Transmission

3: Si with ABS B4RA:4-speedAutomaticTransmission
5: DX with ABS S40 :s-speedManualTransmission
6: OX with ABS and Ay'C
7: Si with ABS and Ay'C A4RA:6000001-
B4RA:6000001-
S40 :1000001-
L: East Liberty, Ohio Plant. U.S.A.
Vehicle ldentif ication Numbel NH-503P GranadaBlackPoarl
and CanadianMotor Vehicle NH-538 FrostWhite
Safety Standard Certification NH-583M New VogueSilverMetallic
R-81 MilanoRed
Paint Code
COLOR
NH-538
1-13
U.S. 1998Model (2-doorHatchbackl
2HGEJ632 *WH 1 00001
SequentialMultiport
Fuel-injected
Engine
Line, Body and EngineType

EJ6: ClvlC3-door/D16Y7
Body Type and TransmissionTyp€
B4RA;4-speedAutomaticTransmission
3: CX with Ay'C
B4RA:7000001-
4: DX
S40 : 1000001-
5: DX with Ay'C
6: DX with ABS
7: DX with Ay'Cand ABS
CheckDigit
Mod€l Year
W: 1998
H: AllistonPlant.Ontario.Canada
NH.592P
NH-583M
FlamencoBlackPearl
New VogueSilverMetallic
t
PB-74P DarkAmethystPearl
R-97 RomaRed

Safety Standard Certificataon Paint Codo
COLOR
NH.583M
{i"
1-14
U.S. 1998Model (4-doorSedanl
J H M E J 65 2 * W S 0 0 0 0 0 1
EnginoTyp€
D16Y/:'1600SOHC16-valves Sequential
Engine
D16Y8;1600SOHCVTEC16-vslvesS€quential
Engine
JAPAN:D16Y7.D16Y8- 3300001-
U.S.A : D16Y7,Dl6Y8 - 3500001-
Line, Body and EngineType

EJ6: CIVIC4-door/D16Y7 84RA: 4-soeedAutomaticTransmission
EJ8: ClVlC4-door/D16Y8 M4RA:4-sDeedAutomaticTransmission
Body Type and TransmissionType S40 : s-soeedManuslTransmission
5: Sedan/5-speed Manual
B4RA(U.S.A.): 7000001-
M4RA(JAPAN): 3000001'
S40(JAPAN) : 1000001-
3: DX with A"/C
4: DX WithABS,EX
5: DX with ABS and Ay'C
7: LX with A,/C
8: LX with ABS 8.73M CycloneBlueMetallic
9: LX with ABS and Ay'C CypressGreen Pearl
NH-578 TaffetaWhite
NH-592P FlamencoBlackPearl
R.96P lnzaRedPearl
S: SuzukaPlant,Mie Prefecture,Japan Paint Code
000001:JAPAN,U.S.A.
COLOR
500001:CANADA 8.73M
VehicleldentificationNumbel
1-15
I
Ghassisand PaintCodes
EngineNumber
1 H GE J 6 1 2 + W L 0 0 0 0 0 1
D16Y5- 3300001
Engins Typ€
D16Y5:1600SOHCVTEC-Et6-vatves
SequentialMultipon
Fuel-injected
Engine
D16Yr:1600SoHC 16-valves
SequentialMultiport
Lin., Body and EnginaTypo Fuel-injected
Engine
EJ6: ClVlC2-door/Dt6y7 D16Y8:1600SOHCWEC l6-vatves
EJ7: ClVlC2-door/D16y5 SequentialMultipon
EJ8: ClVlC2-door/Dt6y8 Fuel-inject€d
Engine
Body Type and Transmbsion Type Serial Numbor
1:Coupe/s-speed JAPAN:D16Y5 - 3300001-
Manual 016Y8- 350OOO1-
U.S.A.: D16Y7,
2: Coupe/4-speed
Automatic.CVT
3: DX with ABS,HX with ABS

4: DX with !VC, HX with A,/C.EX
5; DX with ABS and Ay'C,HX with ABS
and Ay'C.EX with ABS
ChackDigit
Model Year B4RA: 4-speedAutomaticTransmissron
W: 1998 S40 :s-speedManualTransmission
M4VA:ContinuouslyVariable
(CVT)
Transmission
B4RA;7000001-
S40 :1000001-
M4VA:4000001-
VehicleldentificationNumber
and FedoralMotor Vehicle
SafetyStsndardCertification
CypressGreenPearl
NH-592P FlamencoBlackPearl
NH-578 TaffetaWhite
NH.583M New VogueSilverMetsllic
R-81 MilanoRed
PaintCode
COLOR
G-82P
1-16
CANADA 1998Model l2-door Hatchbackl
2HGEJ632 *WH 000001
Manufactur€r.M!ke and
Typ€ ot V6hicle D16Y7:1600SOHC16-valves
MFG.,INC. Fuel-injected
Engine
HONDAPassenger
vehicle
Lins, Body 8nd EnginoTypo
EJ6: ClVlC3-door/Dl6Yt
Body Typo and Transmi$ion Typ6
3: Hatchbacld5-speed
Manual
4: Hatchbacl(4-speed
Automatic B4RA:4-speedAutomaticTransmission
Vchiclo G18d. S40 :s-speedManualTransmission
2: CX
3: CX-G B4RA:7000001-
Chock Digit S40 :1000001-
Modol Yoar
W;1998
FactoryCodo
Sarial Number
FlamencoBlackPeafl
New VogueSilverMetallic
Vehicleldentification Numbsr DarkAmethyst Pearl
and CanadianMotor Vchicle RomaRed
Srfoty StandardCertification
Paint Code
COLOR
NH.592P
1-17
T Chassisand PaintCodes
,
\-
2HG EJ6 53 +W H 900001
Manutacturei. Make and

Type of Vehicle D16Y7:1600SOHC16-valves
M F G . I, N C , FuelinjectedEngine
HONDAPassenger
vehicle 3750001-:
U.S.A.
JHM: HONDAMOTORCO.. 3700001-:
JAPAN
LTD.
HONDAPassenger
vehicle
Line. Body and Engine Type TransmissionNumber
EJ6: ClVlC4-door/Dl6Y7
Body Type and TransmissionType B4RA- 7000001
5: Sedan/s-speed Manual
6: Sedan/4-speed TransmissionType
Automatic B4RA: 4-speedAutomaticTransmissron
VehicleGrade M4RA:4-speedAutomaticTransmission
0: EX S40 : s-speedManualTransmission
3: LX Ssrial Number
4: LX with ABS B4RA(U.S.A.): 7000001-
5: LX with ABS and A,/C M4RA(JAPAN):3000001-
7: EX with ABS S40(JAPAN) : 1000001-
8: EX with ABS and Ay'C
ChockDigit
Model Yoar
W: 1998
FactoryCode
H: AllistonPlant,Ontario,Canada B.73M CycloneBlueMetallic
S: SuzukaPlant,Mie Prefecture,
Jaoan G.82P CypressGreenPearl
SerialNumb6r NH.592P FlamencoBlackPearl
800001-:JAPAN NH-s78 TaffetaWhite
900001-:CANADA NH.583M New VogueSilverMetallic
Paint Code
and CanadianMotor Vehicle
COLOR
B-73M
1-18
t
CANADA1998Model (2-doorGouPe)
a
1 H GE J 6 1 2 * W L 8 0 0 0 0 1
SequentialMultiPort
Fuel-injected
Engine
D16Y8:1600SOHCWEC 16-valves
SequentialMultiport
Line, Body and Engin€Type Engine
Fuel-injected
EJ6: ClVlC2-door/D16Y/
EJ8: ClvlC2-door/D'16Y8 D16Y7:3750001-
Body Type and TlansmissionTyPe D16Y8:3780001-
Vehicle Grade
2: DX, Si
3: Si with ABS
5: DX with ABS B4RA:4-speedAutomaticTransmission
6: DX with ABS and AVC S 4 0 : s - s p e e dM a n u aT
l ransmission
7: Siwith ABS and A,/C
CheckDigit 84RA:7000001-
Modsl Yoar S40 :1000001-
W: 1998
L: EastLibertv,Ohio Plant.U.S.A.
VehicleldentificationNumber NH-592P FlamencoBlackPearl
and CanadianMotor Vehlcle NH-578 TaffetaWhite
Safety Standard Gertification NH.583M New VogueSilverMetallic
R-81 M i l a n oR e d
PaintCode
COLOR
NH-578
1-19
ldentificationNumberLocations
V6hicl6 ldontification
NumborlVlN) \_
Transmission
Numb6r
*:.,
Numb€l Y-
1-20
Warning/CautionLabelLocations
A: CABLEREELCAUTIONA C: DRIVERMOoULEDANGER
DANGER
REFERTO SERVICEMANUAL FOR DETAILEDINSTRUC. EXPLOSIVE/FLAMMABLE
noNs. CONTACTWITH ACID, WATER OR HEAVY METALSSUCH
AS COPPER, LEADORMERCURYMAY PRODUCEHARMFUL
AND IRRITATINGGASES OR EXPLOSIVECOMPOUNDS.
a: DRIVERMODUTIWARNING MUST NOT EXCEED2OO"F
STORAGETEMPERATURES
{l(x}"CI, FORPROPERHANDLING,STORAGEAND DISPOS.
WARNING AL PROCEDURES REFEi TO SERVICEMANUAI- SRS SUP-
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN. PLEMENT.
TALLYDEPLOYED, HURTOR KILLYOU.
CAN SERIOUSLY POTSON
. DO NOT USE ELECTRICALTESTEOUIPMENTOR PROB' CONTAINSPOISONOUSSOOIUMAZIDEAND POTASSIUM
ING DEVICES, NITBATE.
THEYCAN CAUSEACCIDENTAL DEPLOYMENT. FIRSTAID:
o NO SEnVICEABLEPARTSlNSlOE.DO NOT OISASSEM' IF CONTENTSARE SWALLOWED,INDUCEVOMMNG, FOR
8tE. EYECOI{TACT.FLUSIJEYESw|TH WATERFOR15 MINUIES.
. PLACEAIBBAGUPRIGHTWHENREMOVED. IF GASES(FROMACIO OR WATERCONTACI) ARE INHAI.ED,
. FOIIOW SERVICEMANUAL INSTRUC'TIONSCAREFULLY. SEEKFRESHAIR. IN EVERYCASE,GET PROMPTMEDICAL
ATTENNON.
KEEPOUT OF REACHOF CHILDREN.
{cont'd)
1-21
Warning/CautionLabelLocations
(cont'dl (
E
o.E
l----_l
=-+:
) F
D: DRIVERINFORMATION:
CANADAMODEI- U.S. mod.l 198modell
WASNING
4!8q{Gt ALwAYsWEARyouR SEATBELT DEATHOR SERIOUSINJURYCAN (rcCUR.
. THISCAR IS EOUIPPED WITH A DRIVERAIRBAGAND A . CHILDREN12 AND UNDERCAN BE KII-LEDBY THE
FRONTSEATPASSENGER AIFBAGTAS A SUPPLEMEN- AIRBAG.
TAL RESTRAINT SYSTEMISRSI. . THEBACKSEATlS THESAFESTPLACEFOBCHILDREN.
. IT IS DESIGNEDTO SUPPLEMENT THESEATBELT. . N E V E RP U T A R E A R . F A C I N G
C H I L DS E A T I N T I I E
' Exc6mCANADACX FRONT.
. SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG.
. ALWAYS USE SEAT BELTSAND CHILDRESTRAINIS.
E: SRSINFORMATION:
U.S. modol {96,9? mod.l) . THESRS MUST BE INSPECTED TEN YEARSAFTER1TIS
INSTALLED.
cAunoN . THE OATEOF INSTALLANONIS SHOWNON THE DRIV.
TO AVOID SERIOUSINJURY: ER'SDOORJAMB.
. FORMAXIMUM SAFEW PROTECNONIN ALL TYPESOF
CMSHES. YOU MUST ALWAYS WEAR YOUB SAFETY
BELT.
. DO NOT INSTALLREARWARD-FACING CHILDSEATSIN
ANY FRONTPASSENGER SEATPOSITION.
. DO NOT SIT OR LEAN UNNECESSARILY CLOSETO THE
ANBAG.
. DO NOI PLACEANY OBJECTSOVEn THE AIRBAGOR
BETWEENTHEAIRBAGANO YOURSELF.
. SEETHE OWNER'SMANUAL FORFURTHERINFORMA.
TION AND EXPLANATIONS.
. THE SRS MUST BE INSPECTEDTEN YEARSAFTEN|l |s
INSTALLED.
. TTIEDATE OF INSTALLATIONIS SIIOWN OF THE DRIV.
ER'SDOORJAMB,
1-22
F: ASSISTANTINFORMATIONT
US MOOEL{96,97 modell J: SRSWARNINGIHOODI
AIRBAGSEEOTHERSIDE. SUPPLEMENTAI- RESTRAINTSYSTEMISRSI

THIS VEHICLEIS EOUIPPEDWITH DNIVERAND FBONT
U.S. model 198modell SEATPASSENGER AIRBAGS*.
ALL SRS ELECTRICAL WIRINGAND CONNECTORS ARE
COLOREDYELLOW.
AIRBAGWARNING TAMPERINGWITH, OISCONNECTING OR USING ELECTRI.
FLIPVISEROVER CAL TEST EOUIPMENTON THE SRS WIRING CAN MAKE
THE SYSTEMINOPERATIVEOR CAUSEACCIDENTALFIR.
G: STEERING
COLUMNNOTICE ING OF THEINFLATOR.
WARNING
NOTICE THE AIRBAG INFLATORIS EXPLOSIVEANO. IF ACCIDEN-
TO PREVENTSRS DAMAGE, REMOVESTEERINGWHEEL TALLY OEPI-OYED.
CAN SERIOUSLYHURT YOU. FOLLOW
BEFOREREMOVING STEERINGSHAFT CONNECTING SERVICEMANUAL INSTRUCTIONS CAREFULLY.
BOLT.
' Exc.et CANADACX
H: MONITORCAUTION f: PASSENGER AIRBAG CAUnON

U.S.rnodol198mod.l)
NONCE
. NO SERVICEABLE
PAFTSINSIDE. WARNING
. REFERTO SERVICEMANUAL FOR DETAILEDINSTRUC. CHILDRENCAN BE KILLEDOR INJURED 8Y PASSENGER
TtoNs. AIRBAG.
THE BACKSEAT IS THE SAFESTPLACEFORCHILDREN12
I: FRONTSEATPASSENGER
MODULEDANGER AND UNDER,MAKE SUREALL CHILDR€NUSE SEATBELTS
OR CHILOSEATS.
DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATER OR HEAVY METALSSUCH
AS COPPER,LEAD OR MERCURYMAY PRODUCEHARM.
F U L A N D I F R I T A T I N GG A S E S O R E X P L O S I V EC O M -
POUNDS.STOBAGETEMPERATURES MUST NOT EXCEED
2OO"FIlOO"CI.FOR PROPERHANDLING.STORAGEAND
DISPOSALPROCEDURES REFERTO SERVICEMANUAL,
SRSSUPPLEMENT.
POTSON
CONTAINSPOISONOUSSODIUM AZIDEANO POTASSIUM
NITRATE.
FIRSTAID
IF CONTENTSARE SWALLOWED,INDUCEVOMITING.FOR
EYE CONTACT,FLUSH EYES WITH WATER FOR 15 MIN.
UTES,IF GASES IFROMACID OR WATER CONTACTIARE
INHALED,SEEKFRESHAIR IN EVERYCASE.GET PROMPT
MEDICALATTEiITION.
KEEPOUT OF REACI{OF CHILDREN.
WARNING
THE AIBBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN.
TALLYOEPLOYED, CAN SERIOUSLYHURTOR KILLYOU.
o DO NOT USE El-ECTRICAL
TESTEOUIPMENIOR PRO&
ING DEVICES.
THEYCAN CAUSEACCIDENTAL DEPLOYMENT.
. NO SERVICEABLE PARTSINSIDE.OO NOT DISASSEM.
BLE,
. PLACEAIRBAGUPRIGHTWHENREMOVEO.
. FOLLOWSERVICEMANUAL INSTRUCNONSCAREFULLY.
(cont'd)
1-23
Warning/CautionLabel Locations
(cont'd) I
1-24
Under-hoodEmissionsControlLabel(19!16,
1997modell
EmissionGroupldentification Engineand EvaporativeFamilies
Example: EngineFamily: V H N1 . 6 V J G K G K
tsF COOUNI, USE 'o'EO SOLUTION Model Ysar

T: 1996
V; 1997
Manufacturer
H N :H o n d a
Di3placomont
VACUUMHOSEROUTINGDIAGRAM Clsss
V: Light Duty Vehicle/PassengerCar
Fuol Systsm and Numbsr of Valvo3
J: ElectronicSequentialMultipon Injection
(threeor more valvesper cylinder)
Fuol Typ€
G: Gasoline
Standard
F; 49 or 50 StatesTier 1
K: 49 or 50 StatesTier 1
VEHICLE
EMISSION INFORMATION
CONTROL 1: CaliforniaTier 1
FAM|LY
ENGlrlE vHNl6vJcrcr ls90.F}q?
D.SB-ACEME{T O0 CIVIC
EvApoMtrvt
FAMrry
vHNroTTByMAc p:9
2: CaliforniaTLEV
CATALYST rwcHo2s{2)sFl 3: CaliforniaLEV
'N.oRMA
Hrr.n u stcv'ct MA\uArro' aDoflror{A, ro\. ff-Tl
TUN!LPCO\DNOIIS: ENGIN!ATNOFMAI OPFMTING
TTM'EqA-U8!. I I|rf '
4: CaliforniaULEV
ALtACCESSoRTESTUq{Eo FAN
oFf,CooUNG oFf,
TiANSMISSION INNEUIML
Catalyst
N0 ollrEFaDJUSTT,TENTS
NE!DEo. oBD CERTtftED E, F, G, H: Three Way Catalyst
IOLESPEED
TMNSMISSION
OBD
12"l I3TDC K - T: OBDEquipped
T!
e+l rr _9.,.' Evaporative Family: V H N 1 0 7 7B Y M A C

THISVTHICLE
CONFORMS
IO U.S.EPAANOSIAIE
OFCALIFO8NIA
MOOELYEAN
REGULAIIO1TS
NEI1MOTON
APPLICAELE
VEHICIES.
TO1997
ililulIl ModetYsar TT
T: 1996 |
CEBT]FICANON NtR1
IN.USE NEA1FUTL V:1997
112 nE-N2 H0N0AMOTO8
C0.,tTD. Manutaqturer ]
HN: Honda
Storage System
50ST {50 States}: 1:Canister
THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF Canirtor Wolking Caprcity lgrEmsl
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 7
CanisterContigurstion
MODELYEARNEWMOTORVEHICLES.
A: PlasticHousing(ClosedBottom)
B: PlasticHousing{OpenEottom)
49ST (49 States/Fodoral):
Fu€l System
THISVEHICLE CONFORMS TO U.S.EPAREGULATIONS Y: FuelInjection
APPLICABLE TO 1997MODELYEARNEW MOTORVEHI- Fuel Tank
M: Metal
Standard
CAL (Californis):
A: Current Evap
THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF E: EnhancedEvap
C A L I F O R N IR
Wild Card
M O D E LY E A R N E W P A S S E N G E C R A R SP R O V I D E D
THATTHISVEHICLE IS ONLYINTRODUCED INTOCOM.
MERCEFORSALEIN THESTATEOF CALIFORNIA.
(cont'd)
1-25
ControlLabel(1998modell
Under-hoodEmissions
(cont'd) Engineand EvaporativeFamilies
EmissionGroupldentification L
EngineFamily: W HNX V 01.6JL2
Example:
Model Y6ar
W: 1998
Manutacturer
H N X :H o n d a
Type
V: LightDutyVehicle/Passenger
Car
Displac€ment
VEHICTE
EMISSION INFORIVIATION
CONTROL SequenceCharaqters
STAT€OFCALTORNLARECULATIONSAPPLICABLE
TO 1933MOOELYEAR
NEWTLFVPASSENGEfr EvaporativeFamily: W H N X E0065 AAD
INTBOOUCEOINTO FORSALE N TNE
COMMERCE
Mod€lYear
CATALYST
two1r02s1?tEcR/sFt/0B0
| cEBTtF
E0
W: 1998
VAIV€LASH
Manufacturar
HNX:Honda
Type
E: EVAP
CaniaterWork Capacitylgrams)
NONDAMOTORCO
LTD S€quoncaChrract6ls
50ST{50 States):
THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF
C A L I F O R N IR
A E G U L A T I O NASP P T I C A B LTEO I 9 9 8
MODELYEARNEWMOTORVEHICLES.
49ST(49 States/Fed€ral):
THISVEHICLE CONFORMS TO U.S.EPAREGULATIONS
APPLICABLE TO 1998MODELYEARNEWMOTORVEHI.
LLEJ.
CAL (Calilornial:
THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF
C A L I F O R N IR
M O D E LY E A R N E W P A S S E N G E C R A R SP R O V I D E D
THATTHISVEHICLE IS ONLYINTRODUCED INTOCOM-
MERCEFORSALEIN THESTATEOF CALIFORNIA,
1-26
Lift and SupportPoints
Lift and SafetyStands
@ When heavy rear compon€nts such as suspension, fu€l tank, spar6 tir€, hatch, and trunk lid ara to bo
romovod, placa ldditional woight in the luggage rrea before hoisting. Whon substantial woight b ramovod from the r6a1
ot thc vohlcle,tha center of gravlty mty changa and can caussthe vehiclo to tip forwsld on tho hoist.
NOTE:
. Sinceeachtire/whe€lassemblyweighsapproximately30 lbs {14 kg). placingthe front wheelsin the luggageareacan
assistwith the weight distribution.
. Usethe samesupportpointsto supportthe vehicleon safetystands.
1. Placethe lift blocksas shown.
2 . R a i s e t h eh o i s t a f e w i n c h e (sc e n t i m e t e rasn) d r o c k t h e v e h i c l e t o b e s u r e i t i s f i r m l y s u p p o r t e d .
3. Raisethe hoisttolull height,and inspectlift pointstorsolidsupport.
REARSUPPORTPOINT
(cont'd)
1-27
Lift and SupportPoints
(cont'dl
FloorJack
l. Set the parkingbrakeand blockthe wheelsthat are Alway3 u3a safoty stand3 whcn working on 01 undol
not beinglifted. anv vchiclo that b 3upportod by only a iack.
Nover attompt to uso a bumper iack for lifting or
When liftingthe rearof the vehicle,put the gearshift supporting tho vohicl€.
lever in reverse (Automatic transmission/CW in E
position).
Raisethe vehicle high enough to insert the safety

stands.
Adjust and place the safety stands so the vehicle

will be approximatelylevel.then lower the vehicle
onto them.
Center the jacking

bracket in the middle
of the jack lift platform.
LIFT PLA
REAR:
Center the jack

b.acketin the middle
of the jack lifr plattorm.
k-
1-28
l l
Towing
It the vehicleneedsto be towed,call a professional tow- Front:

ing service.Nevertow the vehiclebehindanothervehi-
cle with just a ropeor chain,lt is very dangerous,
Em6rgencyTowing
Thereare threepopularmethodsof towing a vehicle:
Flat-bedEquipment- The operator loads the vehicle on

the backof a truck.This is the bestway oftransponing the
vehicle.
Wh6d Lift Equipmont- The tow truck usestwo pivoting

a.ms that go underthe tires (frontor rear)and liftsthem
o f f t h e g r o u n d .T h e o t h e r t w o w h e e l s r e m a i no n t h e
ground,
Sling-typ6 Equipm€nt- The tow truck uses metal cables

with hookson the ends.Thesehooksgo aroundpartsof
the frame oJ suspension,and the cableslift that end of TIE OOWN HOOKS
the vehicleoff the ground.The vehicle'ssuspensionand
body can be seriouslydamagedit this methodof towing
is attemDted.
lf the vehiclecannotbe transportedby flat-bed,it should

be towed with the front wheelsoff the ground.lf due to
d a m a g e ,t h e v e h i c l e m u s t b e t o w e d w i t h t h e f r o n t
wheelson the ground,do the following:
ManuslTransmission and CVT

. Releasethe parkingbrake.
. Shiftthe transmissionto neutral(CVTto E position).
AutomaticTransmission Roar:
. Releasethe parkingbrake.
. Startthe engine.
. Shiftto lpl position,then E position.
. Turn off the engine.
CAUTION:
. lmproper towing propantion will damsgo the trans-
mi3sion, Follow tho above procodur€ €x6ctly. It you
cannot 3hift the lransmission 01 start th€ engine
(automltic trsnsmissionl.your v€hicl9 mu3t be trang
portod on a ffot-b€d.
It is best to tow tho vshicls no farthol th.n 5{t mibs
(80 km), lnd kosp tho sp€ed bdow 35 mph (55 km/h).
Trying to lift or tow your vehicle by ths bumpeB will
causa sorious damage. The bumpers are not d*ignod
to support tho vohicl6'3 weight.
TOWING
1-29
Specifications
Standardsand ServiceLimits .............. 3-2
D e s i g nS p e c i f i c a t i o n.s. . . . . . . . . . . . . . . . . . . .3. -. .15
....
Body Specifications .......... 3-18
Standardsand ServiceLimits
Cylinder Head/Valve Train - Section
arlilil,r(rrr 6
o
MEASUREMENT STANOARD
{NEW} SERVICE
UMIT /
Compression 250 rpm and wide open throttle
'1,270
kPa (kgf/cm',psi) Nominal {13.0,184)
Minimum 930 (9.5,135)
Maximumvariation 200 Q.0,2al
Cylinder h6ad Warpage 0.05 {0.002)
Height o* - gs.orta.arr- r.66gt
Camshaft Endplay 0.05- 0.15(0.002- 0.006) 0.5{0.02)
oil clearance
Camshaft-to-holder 0.050- 0.089(0.002- 0.004) 0.15(0.0061
Total runout 0.03(0.0 0 1 ) m a x . 0.04(0.0021
Cam lobeheight D16Y7 lN 35.29911.3897)
EX 37.24111.4678)
D16Y5 IN Primary 38.127 1 1 . 5 1 2 9 )
4l
S€condary 3 2 . 1 9 3i1.267
38,78411.5269)
D16Y8 IN Primary 36.77411.4479)
Mid 38.21111.50681
Socondary 37.06511.4592)
38.00811.4964)
(Cold)
Valveclearance IN 0.18- 0.22{0.007- 0.009}
EX 0.23- 0.27(0.009- 0.0111
Valvestem O.D. IN 5.48- 5.19(0.2157 - 0.2161) iEi.rtnut
EX 5.45- 5.46(0.2146 - 0.2150) 5.12 10.21341
Stem-to-guideclearance IN 0.02- 0.05(0.001- 0.002) 0.08{0.003)
EX 0.05- 0.08 (0.002- 0.003) 0.11(0.004)
widrh IN 0.85- 1.15(0.033- 0.045) 1.6(0.063)
EX 1.25- 1.55(0.049- 0.061) 2.0{0.079}
Stem installedheight IN 53.17- 53.6112.093- 2.112) 53.49Q.1221
EX 53.17- 53.64(2.093- 2.112) 53.89(2.122)
Vslvespring Freelength Dl6Yt 57.9(2.28)
D16Y5 IN 56,512.221
EX 57.9(2.28)
D,I6Y8 IN
EX
58.0(2.28)
58.7(2.31)
L {
Valveguide l.D. IN 5.51- 5.53(0.217- 0.218) 5.s5(0.219)
EX 5.51- 5.53(0.217- 0.218) 5.55{0.219}
Installedheight IN 17.45- 18.35(0.703- 0.722)
18.65- 19.15(0.734- 0.754)
Rockerarm Arm-to-shaftclearance IN 0.0r7- 0.050(0.0007
- 0.0020) 0.08(0.003)
EX 0.018- 0.054 - 0.0021
10.0007 ) 0.08(0.003)
t r
3-2
Unitot length:mm (in)
EngineBlock- Seaion 7
MEASUREMET'lT STA]TDARD INEWI SERVICE
UMIT
Cylinderblock Warpageof decksurface 0.07(0.003)
max. 0.10(0.001)
Eore diameter 75.00- 75.02(2.953- 2.954) 75.07(2.956)
Bore taPer 0.05(0.002)
R€boringlimit 0.5(0.02)
Piston SkirtO.D. at 5 mm (0.2in) 74.940- 74.990t2.9520- 2.95241 (2.9516)
74.970
from bottom of skirt
Cloa16ncein cylindor 0.010- 0.040{0.0004- 0.0016) 0.05{0.002)
Groovewidth {tor ring) Top 't.020- 1.030(0.0402- 0.0406) 1.05{0.041)
Second 1.220- 1.230(0.0480- 0.0484) 1.2s(0.049)
oil 2.805- 2.820(0.1104- 0.1110) 2.85(0.112)
Pislonring Ring-to-grooveclearance
Top 0.035- 0.060 - 0.0024)
{0.0014 0.13(0.005)
Second 0.030- 0.055{0.0012
- 0,0022) 0.13(0.005)
Ringend gap Top 0.15- 0.30(0.006- 0.012) 0.60 (0.024)
Second 0.30- 0.45(0.012- 0.018) 0.70 (0.028)
oil 0.20- 0.70 (0.008- 0.028) 0.80(0.03r)
Pistonpin o.D. 18.994- 19.000(0.7478- 0.7480)
Pin-to-pistonclearance 0.010- 0.022(0.0004 - 0.0009)
Connecting Pin-to-rodinterlerence 0.014- 0.040(0.0006- 0.0016)
roo Small end bore diameter 18.96- 18.98{0.746- 0.747}
Largeend borediameterNominal 48.0(1.89)
End play installedon crankshaft 0.15- 0.30(0.006- 0.012) ororo.o'tur
Crankshatt Mainjournaldiameter 54.976- 55.000(2.16,14 - 2.1654)
Rodiournaldiameter 44.976- 45.000/.1.1701 -1.17171
Taper 0.0025(0.0001) m6x. ooosto.ooort
Out-ot'round 0.0025(0.0001)max. 0.005{0.0002)
Endplay 0.10- 0.35(0.004- 0.014) 0.45{0.018)
Totalrunout 0.03{0.001)max. 0.04(0.002)
Bearings Main bearing-to-journaloil clearance
No. 1 and 5journals 0.018- 0.03610.0007- 0.00'14) 0.05 (0.002)
N o . 2 . 3a n d4 j o u r n a l s 0.024- 0.042(0.0009- 0.0017) 0.05 (0.002)
Rod bearing-to-journ8loil cl€arance 0.020- 0.038(0.0008- 0.0015) 0.05 (0.002)
EngineLubrication Soction 8
MEASUREMENT (NEW)
STANDARD SERVICE
LIM]T
Engineoil Capacity f (uS qt, lmp ql) D16Y7 4.3(4.5.3.8)tor engineoverhaul
3.6(3.8,3.2)foroil change.includingfilter
3.3 (3.5,2.9)foroilchange.withoutfilter
Dl6Y5, D16Y8 3.7 (3.9,3.3)for engine overhaul
3.3 (3.5,2.9)for oil change,includingfilter
3.0 (3.2,2.6)Ioroil change,withoutfilter
Oil pump lnner-to-outerrotor radial clearance 0.02- 0.14(0.001- 0.006) 0.20{0.008)
Pumphousing-to'outer rotorradialclearance 0.10- 0.18(0.004- 0.007) 0.20{0.008)
Pump housing-torotor axial clearance 0.03- 0.08(0.001- 0.003) (0.006)
0.'15
Reliofvalve Pressuresettingwith oil temperature176'F (80'C)
kPa (kg7cm,,psi) at idle 7 0( 0 . 7 . ' 1 0 ) m i n .
at 3,000rpm 340(3.5,50)min.
3-3
Cooling- Section 10
MEASUREMENT STAiIDAROINEWI L i
Radiator Enginecoolantcapacity , (US qt, lmp qt) Mll 4.2 (4.4,3.7)tor overhaul
includingengin6,heater,cooling 3.1 (3.3,2.7)tor coolsnt change
line and reservoir Nf D16Y/
Rosorvoircapacity: 4.1 (4.3,3.6)tor overhaul
0.41 (0.42US qt,0.35lmpqt, 3.0(3.2,2.6)torcoolantchange
D16Y8
4.3 (4.5,3.8)for oveIhaul
3.2 (3.3,2.8)for coolantchange
CVT 4.3(4.5,3.8)foroverhaul
3.2 (3.3,2.8)tor coolantchango
Radiatorcap Opening pressure kPa (kgf/cm'.psi) 93 - 123{0.95- 1.25,13.5- 17.8}
Thermostat Start to opening 'F ('C) 169- 176(76 - 80)
Fullyopen 'F ('C) 194(90)
valve lift al tully open 8 . 0( 0 . 3 1 1 m i n .
'196- 203 (91 - 95)
Coolingfan Thermoswitch"ON" temperature .F (.C)
"ON" temperatur€
Thermoswitch"OFF" t6mperature "F (.C) Subtract5 - 15 (3 - 8) from actual
FuelandEmission- Section11
MEASUREMENT STANDARD
{i{EWI
Fuel pr6ssu16 Pressurewith fuel pressureregulatorvacuum hose 260- 310 (2.7- 3.2,38 - 46)
regulator disconnected kPa {kg7cm',psi)
Fuoltank CaDacity / (USqal,lmp gal) 1 5( 1 1 . 9 , 9 . 9 )
Engine ldle speed rpm M/T (neutral) M or CVr (E or E position)
u.s.A. Canada u.s.A. Canada
016Y5 670r 50 700I 50
D16\.' 670I 50 750r 50 700r 50 750+ 50
D16Y8 670I 50 750i 50 700f 50 750r 50
ldleCO % 0.1 m€x. L .
Clutch- Section12
MEASUREMENT STA'{DANDINEW) SERVICE
UMIT
Clutchpedal Pedalheight to floo. (6
165 1/2)
Stroko 130- 140(5 1,4- 5 1/2)
Pedalplay 12- 21l1t2- 13t161
Disengaggmentheight to floor 83 t3 r/4)
to carpet 44(1 3/4)min.Reterence
Clutchsurfac6runout 0.05{0.002}max. 0.15 (0.005)
clutchdisc Rivet head depth - 0.07)
1.3- 1.9{0.05 0.2(0.01)
Thickness 8.5- 9.1{0.33
- 0.36) 5.510.221
plat€
Pressure Warpage 0.03(0.001)max. 0.15(0.(X)61
Diaphragmspringfingersalignment 0.6{0.02}max. 1.0(0.04)
ti."
3-4
Unit of length: mm (inl
ManualTransmission Section 13
MEASUREMET'lT STANDAND
INEWI SERVICE
Ui T
Transmission
oil Capacity f (US qt, lmp qt) 1.9(2.0,1.7)for overhaul
1.8(1.9,1.6)fo. oilchangs
Mainshaft Endplay . 0.r1-0.18(0.004- 0.007) Adjust
Diameterof ball bearingcontactarsa A - 22.000(0.8656
21.987 - 0.8661) 21.930(0.8634)
(Transmissionhousingsids)
Diameterof 4th, sth gear contactarea B 26.980- 26.993(1.0622- 1.0627) 26.930(1.0602)
Diameterof 3rd gear contactar6aC 33.984- 3..000fi.3380- 1.33861 33.930t1.3358)
Diameterof ball bearingcontac'tarea D 25.917- 25.99011.0221- 1.02321 25.920(1.0205)
lClutchhousingsidel
Runout 0.02{0.001)max. 0.05(0.002)
Mainshaft3rd and t.D. 39.009 - 39.025{1.5358- '1.5364) 39.07(1.538)
4th gears Endplay 3rd 0.06- 0.21{0.002 - 0.008) 0.33{0.013}
4th 0.06- 0.19{0.002 - 0.007) 0.31(0.012)
Thickness 3rd 30.22- 30.2711.190 - 1.1921 30.15(1.187)
4th 30.'t2- 30.17(1.186- 1.188) 30.05(1.183)
Mainshaft5th t.0. 37.009 37.025t1.4510- 1.15711
- 37.07(1.459)
gear Endplay 0.06- 0.19{0.002- 0.007) 0.31(0.012)
Thickness 24.42- 28.17t1.119- 1.1211 28.35(1.1161
Countershaft Diameterof needleb6aringcontactarea A 30.000- 30.015(1.1811- 1.1817) 29.950{1.1791)
Diameterof 1st gear contactarea B 35.98,1-36.000(1.4167- 1.4173) 35.930(1.4146)
Diameterol ball bearingcontact areaC 24.980- 24.993(0.9835- 0.9840) 24.930(0.98151
Runout 0.02(0.001)max. 0.05{0.002)
Countershaftlst l.D. 41.009- 41.025t1.6145- 1.6152) 41.07{1.617)
g€ar Endplay(Whentightenedbylhe specifl€dtorque) 0.03- 0.10{0.001- 0.004} 0.22{0.009}
Thickness 30.41- 30.44(1.197- 1.198) 30.36(1.195)
Countershaft2nd t.D. 44.009- 44.025(1.7326 - 1.7333) 44.07(1.735)
gear Endplay(Whentightenedby the spociti€d
torque) 0.04- 0.12{0.002- 0.@5) 0.24(0.009)
Thickness 31.91- 3'1.96
(1.256- 1.258' 31.85(1.254)
Spacercollar LD. 33.000-33.0r0 fi.2992- 1.2996) 33.04 fi.3011
(Countershaft2nd o.D. 38.989-39.000{1.5350 - 1.535,r) 3{'.93(1.533)
g€ar) Length 32.03- 32.06(1.261- 1.262) 32.01 (1.260t
Spacercollar t.D. 27.002- 27.012(1.0631- 1.0635) 27.05{1.065)
(Mainshaft4th o.D. 4th 33.989- 34.000(1.3381- 1.3386) 33.93(1.336)
and sth goar) 5rh 31.989- 32.000(1.2594- 1.2598) 31.93(1.257)
Length ath 22.83- 22.86t0.899- 0.9(X)) 22.81(0.898)
5rh 23.53- 23.56{0.926- 0.928) 23.51(0.926)
Reverseidlergear t.o. 15.016- 15.043t0.59'12- 0.5922) 15.08{0.594)
Gear-to-revsrs6gear shaft clearance 0.032- 0.077{0.0013- 0.0030) 0.r4 (0.006)
Synchroring Ring-to-gearclearance{Ring pushedagainstgear) 0.73- 1.'r8(0.029- 0.046) 0.4(0.016)
Shitt fork Forktinger thickness lstnnd 6.2 - 6.1 1O.211-O.2521
3rd/4th 7.4 - 7.6 (0.291- 0.299)
Fork-to-synchrosleeveclea16nce 0.35- 0.65(0.014-0.026) to roonr
Reverseshift fork Fork pawl groove width 12.7- 13.0(0.50- 0.5'l)
Fork-to-rev€rseidler gear cl€arance 0.5- 1.1(0.020- 0.043) 1.8(0.07)
L-groovewidth 7.15- 7.35(0.281- 0.289)
Fork-to-5th/reverse shift oi€c6oin cl6a16nce 0.05- 0.35(0.002- 0.014) 0.5(0.02)
Shiftarm A Inner diameterof shift arm C contactpoint 13.05- '13.'t3
(0.514- 0.517)
Shift arm A-to-shiftarm C clearance 0.05- 0.23 (0.002- 0.009) 0.35{0.014}
Shift arm B Inner diameterof shift arm B shaft contact point 13.973 - 14.000 - 0.5512}
{0.550r
Shift arm B-to-shaftclearance 0.013- 0.070{0.0005 - 0.0028) 0.16(0.006)
Shift arm B-to-shittpiece clearance 0.2- 0.5(0.008 - 0.020) 0.62(0.02441
Diam6terot shift Diececontact Doint 12.9- 13.0(0.508-0.512) 't2.78(0.5031)
Finaldrivengear Backlash 0.07- 0.130{0.0028 - 0.0051) 0.180(0.007r)

Differentielcarrier Pinion shaft boro diam€ter 18.010 - 18.028 - 0.7@81
(0.7091
Carrier-to-pinionshaft clearance 0.023- 0.057t0.0009 - 0.0022) o.ogu
to.ooot
Driveshaftbore diameter 26.025 - 26.04s (1.0246
- 1.0254)
CarrieFto-driveshaftclearance 0.045- 0.086(0.0018 - 0.0034) 0.11{0.006)
Differentialpinion Backlash 0.05- 0.15{0.002 - 0.006}
gear Piniongear bore diameter 18.042 - ' I8.066 - 0.7113)
{0.7103
Piniongear-to-pinionshaft cl6aranca 0.055- 0.095(0.0021 - 0.0037) 0.15(0.006)
Set ring.to-bearingorrterrace 0 - 0.1(0- 0.004) Adjust with shim
3-5
Automatic Transmission-- Section
ctl;ttt t t 14
t.l
Transmission
MEASUREMENT
Capacity f {US qt, lmp q0
STANDARO
{NEWI
5.9(6.2,5.2)toroverheul
SERVTC€
UM]T L {
fluid 2.7{2,9,2.4}lorfluidchange
Hydraulic Line pressureat 2,OOorpm in E or E position 830- 880 (8.5- 9.0,120- 130) 780 (8.0,110)
pressure lst clutch pressureat 2,000rpm in Pll position
'124)
.2nd clutch pressureat 2,000rpm in E position 800- 850 (8.2- 8.7, 120- 760 (7.7,110)
(kgtcm', psi) with linearsolenoidconnector with linsar solenoid
disconnected conn€ctordisconnected
0 - 1 5 0( 0 - 1 . 5 , 0 - 2 1 ) 1 5 0{ 1 . 5 2, 1 )
with linear solsnoidconnectedto with lin€ar solenoid
batteryvoltage connectedto baftory
voltage
at 2,000rpm in lQl posi'
3.d and4thclutchpressure 810- 860 (8.3- 8.8.1' 18
- 125) 760 (7.8,111)
tion with linear solenoidconnector with linearsolenoid
disconnected connectordisconnocted
0-150(0-1.5,0-21) 1 5 0( 1 . 5 , 2 1 )
with linear solenoidconnecledto with linear sol€noid
batteryvoltage connecteclto battery
voltage
Stallspeedrpm (Ch€ckwith vehicleon levelground) 2,700 2,550- 2,450
Clutch Clutchinitialclearance lst, 2nd 0.6s - 0.85 (0.026- 0.033)
3rd, 4th 0.40- 0.60(0.016- 0.024)
Clutch return spring free longth
{A4RA,B4RATransmission) lst 32.0(1.26) 3 0 , 0{ 1 . 1 8 )
2nd,3rd,4th 30.5{1.20) 2a.st1.12)
(M4RATransmission) lst 31.1 11.22) 2 9 . 1( 1 . 1 s )
2nd,3rd,4th 30.5(1.20) 28.5fi.12)
Clutch disc thickness 1.88- 2.00(0.074- 0.079) Untilgrooveswornout
Clutch plate thickness lst 1.55- 1.65(0.061- 0.065) Discoloration
2 n d , 3 r d , 4 t h 1.95- 2.0510.077 - 0.081)
Clutchend plate thickness Mark 1 2.05- 2.10(0.081- 0.083) Discoloration
(A4RA,B4RATransmission) Mark2
Mark 3
Mark 4
2.15- 2.20(0.085- 0.087)
2.25- 2.30{0.089- 0.091)
2.35,2.40(0.093- 0.094)
II L (
Mark 5 2.{5 - 2.50 (0.096- 0.098}
Mark6 2.55- 2.60(0.100- 0.102) l
Mark7
Mark8
Mark9
2.65- 2.70(0.104- 0.106)
2.75- 2.80(0.r08- 0.110)
2.85- 2.90(0.112- 0.114)
I
Discoloration
Clutchend platethickness Mark1 2.3 - 2.4 (0.091- 0.094) Discoloration
{M4RATransmission) Mark2 2.4-2.510.094-0.098)
Mark3 2.5- 2.6 (0.098- 0.102)
Mark 4 2.6- 2.7 (0.102- 0.r06)
Mark5 2.7- 2.8 (0.106- 0,110)
Mark6 2.8- 2.9(0.110- 0.114)
Mark 7 2.9- 3.0 (0.114- 0.118)
Mark8 3 . 0- 3 . 1( 0 . 1 1-8 0 . 1 2 2 )
Mark9 3.1- 3.2 (0.122- 0.126)
Mark 10 3.2- 3.3(0.126- 0.130)
M a r k1 l 2.0 - 2.1 (0.079- 0.083)
M a r k1 2 2.r ,2.2 (0.083- 0.087)
Mark13 2.2- 2.3(0.087- 0.091)
M a r k1 4 3.3- 3.4{0.130- 0.134}
Mark15 3.4- 3.5{0.134- 0.138)
Mark'16 €.5 - 3.6(0.138- 0.1421
Mark 17 3.6- 3.7 (0.142- 0,146)
Mark 18 3.7- 3.8 (0.146- 0.150) Discoloration
\-
3- 6
unit of l€ngth:mm (in)
AutomaticTransmission Section 14
MEASUREMEifl STANDAND NEWI LIM]T
SERVICE
Transmission Diameterof needlebearingcontsct arsa
on mainshaftstator shaft bearing 22.980- 22.993(0.9047- 0.9052) Wearor damage
On mainshaft2nd gear 3s.97s- 3s.991(1.4163 - r.4169)
On mainshaft4th gear collar 31.975-31.991(1.2589 - 1.2595)
On mainshaft1stgearcollar 30.975- 30.99'l(1.2195- 1.2201l-
On countershaft(left side) 36.004- 36.017(1.4175 - 1.4180)
On countershaft3rd gear collar 35.980- 35.996(1.4165 - 1.4172)
On countershaft4th gear 27.980- 27.993(1.1016 - 1.1021)
On countershaftr6versegear collar 31.975-31.991(1.2589 - 1.2595)
On count€rshaftlst gear collar 31.975- 31.99' (1.2589-
] 1.2595)
On reverseidler gear shaft 13.990- 14.000(0.5508 - 0.5512) Wearor damage
lnside diameterof noodlebearingcontactarea
On mainshaft1stgear 35.000- 35.016(1.3780- 1.3786) Wearor damage
On mainshaft2nd gear 41.000- 41.0't6(1.6142
- 1.6148)
On mainshaft4th gear 38.000- 38.016(1.4961- r.4967)
on countershatt1st gear 38.000- 38.016(1.4961- 1.4967)
On countershaft3rd 96ar 41.000- 41.016(1.6142- 1.61481
On countershaft4th gear 33.000- 33.0r6(1.2992- r.2998)
On countorshaftreversegear 38.000- 38.016(1.4961- 1.43671
On reverseidler gear 18.007- 18.020(0.7089- 0.7094)
On stator shaft (ATFpump sid€) 29.000-29.01311.1411 - 1.14221
On stator shaft (statorside) 27.O00- 27.021(1.0630- 1.0638)
Reverseidler gear shaft holder l.D. 14.416- 14.434(0.5676- 0.5683) W€aror damage
Endplay
Mainshatt1stgear 0.08- 0.19{0.003- 0.007)
Mainshaft2nd gear 0.05- 0.13(0.002- 0.005)
Mainshaft4th gear 0.075- 0.185(0.003- 0.0071
Countelshaft1st gear 0.'1- 0.5 (0.004- 0.020)
Countershaft3rd gear 0.05- 0.17(0.002- 0.007)
Countershaft4th gear 0.10- 0.18(0.004- 0.007)
Reverseidler gear 0.05- 0.18(0.002- 0.007)
Countershaftreversegear 0.10- 0.25(0.004- 0.010)
Selectorhub O.D. 5r.87- 51.90(2.042- 2.0€) wuu, o, du-"n"
Mainshaft4th gear collar l€ngth 45.00- 45.03fl.771- 1.773)
Mainshatt4th gear collar flange thickness 4.435- 4.525(0.1746 - 0.178' l) Wearor damage
Mainshatt1stgearcollarlength 27.00- 27.15{1.063- 1.069}
Countershaftdistancecollar length 38.87- 38.90 1.530- 1.5311
38.92- 38.95 1.532- !.533)
38.97- 39.00 1.534- 1,535)
39.02- 39.05 1.536- 1.537)
39.07- 39.'t0 1.538- 1.539)
39.12- 39.15 1.540- 1.541)
39.'17- 39.20 1.542- 1.543)
39.22- 39.25 1.544- 1.545)
39.27- 39.30 1.546- 1.547)
Countershaft3rd gear collar length '96, '97 models 21.15- 21.20(0.833- 0.835)
'98 model 20.65- 20.70{0.813- 0.825)
Countershaftreverssgear collar length 14.5- 14.6(0.571- 0.575)
Countershaltreversegear collar flange
thickness 2.4- 2.6{0.094- 0.102) Wear or damage
Countershaft1st gear collar length 14.5- 14.6(0.571- 0.575)
Countershaft1st gear collar flange thickness 2.4- 2.6{0.094- 0.102) Wear or damage
(cont'd)
3-7
Automatic Transmission {cont'd} Section 14
MEASUREi'ENT STANDARD
INEWI SERVICEUMIT
Taansmission Mainshaft2nd g€ar thrust washgrthicknegs 3.97- 4.00(0.r56- 0.157) Wearor damage
4.02-
4.07-
4.12-
4.05(0.158- 0.159)
4.10(0.160- 0.161)
4.15(0.162- 0.163)
1I
4.17- 4.20(0.164- 0. t651
4.22- 4.25(0.166- 0.' t67)
4.27- 4.30 (0.168- 0.1691
4.32-
4.37-
1.12-
4.35{0.170- 0.171}
4.1010.172 -0.1131
1.15 10.171-0.1751
I
Wear or damage
Thrust wash6r thickngss
Mainehsfl ball boaring loft side 2.95- 3.05(0.116-0.120)
Mainshaft 1st gear
Counte6haft3rd g€arsplinedwasher '96,'97 models
One-wayclutch contactarea
Countershaftlst gea. l.D.
'98 model
2.€ - 2.50(0.096-0.098)
4.15- 4.50(0.175
- 0.177)
4.95- 5.00(0.195
- 0.197) ;""i":,":",
Parkinggear O.D. 83.339- 83.365{3.2810- 3.282r) Wear or damage
Mainshaftleed pipe A, O.D.(at 15 mm (0.59in) trom 66.685- 66.698(2.6254- 2.6259) W€sr or damag€
end) 8.97- 8.98t0.353- 0.354) 8.95 (0.3s2)
Mainshaftfoed pipe B. O.D.(at 30 mm {1.2in)trom end} 5.97- 5.98(0.2350- 0.2354) 5.95 (0.234)
Countershaftfeed pipe O.D.{at 15 mm (0.59in}trom 7.97- 7.98(0.3138- 0.3142) 7.95(0.313)
€ndl 1.87- r.97{0.074- 0.078) 1.80{0.071)
Mainshattsealingring thickness
( 2 9m m ( 1 . 1i n ) a n d3 5 m m ( 1 . 4i n ) ) 6.018- 6.030(0.2359
- 0.2374) 6.045(0.2380)
Mainshaftbushingl.D. 9.000- 9.015{0.3543
- 0.3549) 9.03 (0.356)
Mainshaftbushingl.D. 8.000- 8.015 - 0.3156t
{0.3150 8.03(0.316)
Couni6rhaft bu6hing l.D. 2.025- 2.075(0.0797
- 0.04171 2.08 (0.082)
Mainshaftsealingring goovo widlh
Rogulstor Sealingring contactargo LD. - 35.025t1.3780
35.000 - 1.3782) 35.050(1.3799)
valve body
Shifting deviceand Reverseshift fork finger thickhoss 5.90- 6.00(0.232
- 0.236) s.40{0.213}
parking br6kecon- Parkingbrakopawl
trol Parkingggar or otherdefect
lWear
Servo body Shift fork shaft bore l.D. 14.000- 14.010{0.5512- 0.5516)
Shift tork shaft valvo bore i.D. 37.000- 37.039(1.4567- 1.4582) 37.045{1.4585}
ATFpump ATF pump gear side clearance 0.03- 0.05{0.00t- 0.002) 0.07 (0.003)
ATF pump gear-to-bodyclearance Drive 0.r050- 0.1325{0.0041- 0.0052}
Drivan 0.0350- 0.0625(0,00'14
- 0.0025)
ATF pump driven gesr l.D. 14.016- 14.034{0.5518- 0.5525} Wearor damage
ATF pump driven g€ar shaft O.D. r3.980- 13.990(0.5504- 0.5508) Wearor damage
DiffersntlaI Pinion shaft contactaroa l.D. 18,010- 18.028{0.7091- 0.7098)
catnot Carier-to-pinioncle616nc6 0.023- 0.057(0.0009- 0.0022) 0.1(0.004)
Driveshaftcontscl 8re LD. 26.02s- 26.045{1.0246- 1.0254)
Carrier-to-driveshatt
cloaranco 0.045- 0.086{0.00r8- 0.0034} 0.12{0.005)
Diffsrential Eacklash 0.05- 0.15t0.002- 0.006)
piniongear l.D. 18.042 - 18.066 - 0.7113)
(0.7103
Piniongear-to-pinion
shrftclearance 0.055- 0.095(0.0022- 0.0037) o"r to.ooot
Set ring-to-bsaringout6r race clearance 0 - 0.15{0- 0.006} Adjusr
L
Unit ot length:mm {in)
Automatic Transmission - Seqtion ltt
(NEWI
STANDARD
MEASUREMENT
Springs Regulatorvalve spring A 1.8(0.071) 14.7(0.584) 87.8(3.4s7) 16.5

Regulator valvespringB 1 . 8( 0 . 0 7 1 ) 9.6(0.381) 44.0(1.732) 11.0
Stator reactionspring 4.5(0.177) 35.4(1.407) 30.3(1.193) 1.9
Modulatorvalvespring 1.4(0.055) 9.4(0.374) 35.0(1.378) 10.9
Torqueconvonercheckvalvespring 1.0(0.039) 8.4(0.334) 33.8(1.331) 8,2
Coolerreliefvalvespring 1.0(0.039) 8.4{0.334) 3 3 . 8{ 1 . 3 3 1 )
Relielvalve spring 1.1{0.043) 8.6{0.342) 3 7 . 1{ 1 . 4 6 1 ) 13.4
2nd orifico control valve spring 0.7(0.028) 6.6(0.262) 34.8{1.370) 22.0
1-2shift valve spring 0.9{0.035) 7.6{0.302) 4'1.3('1.626)
2-3shiftvalvespring 0.9(0.03s) 7.6{0.302) 57.0 t2.2441 26.8
3-4 shift valve spring 0.9(0.035) 7.6(0.302) 57.0 12.2441 26.8
1st accumulatorspring 2.1(0.083) 16.0{0.636} 89.1 {3.508)
4th accumulatorspring B 2.3(0.09r) r0.2 {0.402} 51.6{2.031) 13.8
4th accumulator springA 2.6(0.102) r7.0 (0.676) a1.0 13.4251 14.2
2nd accumulalorspringA 2.4(0.094) 29.0(1.152) 39.0(1.535) 2.9
3rd accumulator springA 2.8(0.110) 17.s(0.695) 89.3(3.5161 15.6
2nd accumulator springI 1.6(0.063) 9.0(0.3s8) 20.7{0.815) 6.1
3rd accumulatorspring B 2.2(0.087) 3 r . 01 1 . 2 2 0 ) 35.1(1.382) 2.4
2nd accumulator springC 2.210.0811 14.5{0.576} 68.0(2.677) 13.9
Lock-upshilt valve spring 0.9{0.035) 7.610.3021 73.7 12.9021 32.0
Lock-uptiming v6lv6 spring 0.9(0.035) 8.1 (0.3' 19) 80.7(3.r77) 45.8
Lock-upcont.ol valve spring 0.7(0.028) 6.6 (0.262) 38.0(1.4961 14.1
3-4 orifico controlvalve spring 0.7(0.028) 6.6 (0.262) 37.5( 1.4751 21.6
Servo control valve 6pring 1.0(0.039) 8.1 (0.322) 52.1{2.051) 20.4
CPCvalve spring 0.6(0.024) 5.6(0.223) 12.2{0.480) 5.5
CPBvalve spring 0.9(0.035) 8.1 (0.322) 47.211.858) 18.3
0.9(0.0351 6.1t0.2421 36.4(1.433) 19.5
cw Sostion14
MEASUBEMENT STANDABD
INEWI SERVICELIMIT
Transmiasion Capacity f (US qt. lmp. qr) 6.4 (6.8,5.6)for overhaul
fluid 3.9{4.1,3.4)for fluid change
Hydraulic Forwardclutch pr€ssureat 1,500rpm in Lqlposition 1.4- 1.75114.3 - 17.A.203 - 2531
pressure brakepressur€
Reverse at 1,500rpm in El position 1.4 - 1.75 114.3- 17.8, 203- 2331
MPa 0 . 2- 0 . 71 2 .-01 . 1 , 2 8- 1 0 1 1
(kg7cm,,psi) Drive pulley pre$ure at 1,500rpm in E position
Drivgn pulley pressureat 1,500rpm in Lll position 1.5- 2.3(15.3- 23.5.218- 334)
Lubricationpressureat 3.000rpm in E position Above0.2(2,30)
Stall sp€6d rpm {Ch6ckwith vehicle on levsl ground)
E position 2,500 2.350- 2,650
E, E, B positions 3,000 2,800- 3,100
Clutch Clutch initisl clearance Forwardclutch 0.6- 0.8(0.024- 0.031)
Start clutch 0.5- 0.7{0.020- 0.028)
Reversebrake 0.45- 0.75(0.018- 0.030)
Clutch return spring lree length Forwardclutch 3 0 . 5( 1 . 2 0 1 ) 28.5 t1.122)
Start clutch 40.9{1.6' t0) 38.9(1.531)
Reversebrake 29.4 t1.1571 27.4 11.O79J
Clutchdisc thickn€ss Forwardclutch 1.88- 2.00{0.074- 0.079) Until groovesworn out
Stan clutch 1.88- 2,00(0.074- 0.079)
Rovers€brake 1.94- 2.06{0.076- 0.081} Untilgroovesworn out
Clutch plate thickn€ss Forwardclutch 1.95- 2.05(0.077- 0.081) Oiscoloration
Start clutch 2.25- 2.35{0.089-0.093} Discoloration
Roversebrake 1.90- 2.00(0.075- 0.079) Discoloration
(cont'd)
3-9
CvT {cont'dl - Section 14
IiIEW} SERVICELMTT
\-- {
Clutch Forwardclutch end piate thickness Mark 1 or 15 3.4- 3.5(0.134- 0.138) Discoloration
vlark2 or'16 3.5- 3.6(0.138- 0.142)
Mark3 or 17 3.6- 3.7(0.r42- 0.r46)
Mark4 or 18 3.7- 3.8 (0.146- 0.150)
Mark5 or 19 3.8- 3.9(0.150- 0.1s4)
Mark6 or 20 3.9- 4.0{0.154- 0.157)
M a r k 7o r 2 l 4 . 0 - 4 . t ( 0 . 1 5-7 0 . 1 6 1 )
Mark8 or 22 4.1- 4.2(0.161- 0.165)
N4ark9 or 23 4.2- 4.3{0.165- 0.169}
Mark 10or 24 4.3- 4.4(0.169- 0.1731
Mark11or 25 4.4- 4.5(0.173- 0.' 177)
Msrk '12or 26 4.5- 4.6(0.177- 0.r81)
Mark13or 27 4.6- 4.7(0.r81- 0.185) Discooralron
brakeendplatethickness
Reverse 3.55- 3.65 (0.140- 0.'|44) Discootalton
U::I I 3.75- 3.85(0.1€ - 0.152)
vlark3 3.95- 4.05(0.r56- 0.1591
vlark4 4.15- 4.2s(0.r63- 0.t67)
Vlark5 4.35- 4.45{0.171- 0.175)
vlark6 4.55- 4.65(0.r79- 0.1831
t4ark7 4.75- 4.85(0.187- 0.1911
vlark8 4.95- 5.05{0.19s- 0.199) Discoloration
ATF pump ATF pump drive gear shaft O.D. 9.98- 9.99 (0.3929- 0.3933) Woar or damaged
ATF pump drivengearshaftO.D. 9.98- 9.99 {0.3929- 0.3933} Wsar or d€mag€d
ATF pump body bushing LD. Driv€ g€ar shaft 10.000 10.015(0.3937- 0.3943) Wear or damaged
Drivengearshaft 10.000- 10.015t0.3937- 0.3943) W6ar or damagad
ATFpump gearsideclearance 0.015- 0.035{0.0006 - 0.0014} 0.050(0.0021
ATF pump gear-to-bodyclearance Drive gear 0.035- 0.0505{0.0014-0.0020)
Orivengear 0.035- 0.0505(0.0014-0.0020)
Transmission Diameterof needlebearingcontactare
lnout shaft - flvwheel side 19.987- 20.000(0.7869- 0.7874) Wear or damaged
Input shaft - forward clutch side 19.987- 20.000(0.7869- 0.7874) Wear or damaged
Drive Dullevshaft - start clutch side 43.981- 43.991{1.7315- 1.7319)
Drive pulley shaft - flywheel side
Drive oullev shaft - forward clutch side
24.007- 24.020(0.945- 0.946)
24.007- 24.020(0.945- 0.946)
Wear or damaged
Wearor damagod
Wearor damagod
L {
Thrust clearance
Carrierand ring gear 0.050- 0.r 10 (0.0020- 0.004:))
Driven pulley shaft and start clutch hub 0.000- 0.130(0.000- 0.005)
Input shaft and ATF pump drivon sprocket 0.370- 0.650{0.015-0.026}
Secondarygoar shaft and flywheel ball bearing 0.00- 0.1s(0.00- 0,006)
L (
3-10
Unit of length:mm (in)
cw Saction 1 4
MEASUREMENT STANDARO
INEWI SERVICE
UMTT
_.an3mission Thrustshim.25x 31 mm thickness 1.02- 1.05(0.040- 0.041) or oamageo
conld) 1.09- 1.12(0,043- 0.044)
' 1 . 1-6 1 . 1 9( 0 . 0 4 6 - 0 . 0 4 7 )
1.23- 1.26(0,048- 0.050)
1.30- 1.33(0.051-0.052)
1.37- 1.40(0.054- 0.055)
1.44- 1.47{0.057- 0.058)
1.51- 1.54(0.0s9- 0.061)
1.58- 1.61{0,062- 0.063)
1.65- 1.68(0.065- 0,066)
1.72- 1.75(0.068- 0.069)
1.79-' !.82 (0.070- 0.072)
1.05s- 1.085(0.0415 - 0.0427)
1.125- 1.155(0.0443 - 0.0454)
1.195- 1.225(0.0470 - 0.0482)
1.265- 1.295(0.0498 - 0.0510)
1.335- 1.365(0.0s26- 0.0537)
1.405- 1.435(0.0553 - 0.0565)
1.475- 1.505(0.0580 - 0.0593)
1.545- 1.575(0.0608- 0.0620)
1.615- 1.645(0.0636 - 0.0648)
1.685- 1.715(0.0663 - 0.0675)
1.755- 1.785{0.0691 - 0.0703) or damaged
Cottelslhickness -
2.87 2.90 (0.113 - 0.114) Wearor damaged
2.97- 3.00(0.117- 0.118)
3.07- 3.10(0.121- 0.122)
3.17- 3.20(0.125- 0.126) Wear or damaged
ATF pump drive sprocketthrust shim, 22 x 28 mfi 1.12- 1.15(0.044 - 0.04st Wearor damagsd
thickness 1.37- 1.40(0.054
1.62- 1.65{0.064
- 0.055)
- 0.065)
+
r.87- 1.90(0.074 - 0.075) I
2.'t2- 2.15(0.083
2.37- 2.40(0.093- 0.094)
- 0.085) I
Wearor damaged
Secondarygear shaft thrust shim, 25 x 35 mm 2.80- 2.85{0.110 - 0.112) or damaged
thickngss 2.90 - 2 . 9 5( 0 . 1 1-40 . 1 1 6 )
3.00- 3.05(0.118 - 0.120)
3 . 1 0- 3 . 1 5( 0 . 1 2-20 . 1 2 4 )
3.20- 3.25(0.126 - 0.128)
3.30- 3.35(0.r30- 0.1321
3.40- 3.4510.134 - 0.136t
3.50- 3.5s10.138 - 0.140)
3.60- 3.65(0.142 - 0.1441
3.70- 3.7510.146 - 0.148)
3.80- 3.85(0.150 - 0.1521 or oafiaqeo
Input shaft l6ed pip€ O.D.
Drivs pulloy leed pipe 6.97- 6.98(0.274-0.275) 6.95(0.274)
Forwardclutch feed pipe 11.47- 11.48(0.4516
- 0.4520) 11.45(0.45' I)
Inputshaftbushingl.D.
Drivepull€yfoed pipebushing - 0.2762)
7.000- 7,015(0.2756 7.030 10.2171
Forwardclutch feed pip€ bushing 11.500- 11.518(0.4528
- 0.4535) 11.533(0.454)
Drivenshaft teed pipe O.D.
Start clutch f66d pipe (right side cover side) 6.97- 6.98(0.274- 0.275) 6.9510.27{}
Drivenpulleyteed pip€ 11.47- 11.48(0.4516 - 0.4520) 11.45{0.451)
Start clutch feed pipe (flywhe€lhousing side) 8.97- 8.98 (0.353- 0.354) 8.95{0.352}
DrivenpullsyshaftbushingLO.
Start clutch feed pip6 (right side cover sidel 7.000- 7.015{0.2756 - 0.2762) 7.030(0.277)
Drive pulley feed pipe 11.500- ' t1.518(0.4528
- 0.45351 1'1.533(0.454)
Stan clutch feed pipe (fl)'wheelhousing sido) 9.000- 9.015{0.3s4- 0.355) 9.03 (0.3561
Secondary drivengearsealingring groovewidth 2.50- 2.65{0.098- 0.104) 2.655(0.105)
Stan clutch e-ndplate l.D. 88.900- 88.935(3.500- 3.5011 Wear or damaged
Inputshaftsealingring groovewidth 2.00- 2.10{0.079- 0.083) 2.105(0.083)
Drivepulleyshaftl.D.at sealingring 24.007- 24.020(0.945- 0.946) Wear or damagsd
Shifting device Parkingbrakocone W6ar or other defect
and parking Parkingbrakepawl Wear or other daf€ct
brakecontrol Parkinggear Wear or other defect
(cont'd)
3-11
I
CW {cont'd} - Sectaon14
MEASUREMEiTT STANDARD
{NEW} SERVICE
LIMTT
Diffe rontiaI Pinionshaft contactarea l.D. 18.010- 18.028(0.7091 - 0.7098)
L i
carier CarrieFto-pinion cl6arance 0.023- 0.057(0.0009- 0.0022) 0.1(0.004)
Drive shaft contactarea l.D. 26.025- 26.045(1.0246- 1.0254)
Carrier-to-driveshaft
clearance 0.045- 0.086(0.0018- 0.0034) 0.12(0.005)
Differentialpinion Backlash -
0.0s 0.15 (0.002 - 0.006)
gear t.D. r8.042 - 18.066 (0.7103 - 0.71r3)
Piniongear-to-pinion
shaftclearance 0.05s- 0.095(0.0022 - 0.0037) nru to.oout
Set ring'to-bearingouter raceclearance 0 - 0 . 1 5( 0 - 0 . 0 0 6 ) Adjust
MEASUREMENT Wir. Dia. o.D. FJ.. Longth No. of Coilt
Springs PH 169ulatorvalve spring 1.2t0.0471 9.0(0.354) 25.7{1.051} 10.0
PH control valvo spring 1.7(0.067) 13.4(0.528) 39.4(1.5511 4.7
PL 169ulatorvalve spring 0.9{0.035) 7.2 t0.283') 14.6(0.5751
PH-PLcontrolvalvespring 1.0(0.039) 10.0(0.391) 31.4{1.236) 8.6
Clutchr€ducingvalvespring 1.9(0.075) 16.8{0.661} 41.4 i'1.7481 8.0
Lubrication valvespring 1.6t0.063) 13.4(0.528) 51.6{2.031} 11.6
Shift valve spring 1.4{0.055} 8.2(0.323) 34.1(1.343) 13.0
Shift control valve spring 1.0{0.039) 7.4{0.29r) 19.3{0.760}
Start clutch control valve spring 0.4(0.016) 4 . 1{ 0 . 1 6 1 ) 12.1(0.476) 6.8
Pitot regulatorvalve spring 0.6(0.024) 5.710.2211 9.5(0.374) 5.0
Start clutch valve accumulatorspring 1.2{0.047) 8.3(0.327) 29.8('t.173) 12.3
Rgversecontrol valv6 spring 1.2(0.047) 9.4(0.370) 31.4(1.236) 11.0
Shift inhibitor valve spring 1.3{0.051) 13.2(0.s20) 48.3{1.902) 10.6
Steering- Section 17
MEASUREMENT (NEwl
STANDARD
Steeringwheel Play at steeringwheel circumference 0-10{0-0,4)
Starting load at steeringwheel circumference
N {kgt. lbf)
lvlanualsteering 15(1.5,3.3)
Powersteering Enginerunning 29 {3.0,6.5) \ - l
G6arbox Angle of rackguide screw loosened M/S 2015"
trom lockedposition 20 Max
Preloadat pinion gear shaft N.m (kgf.cm,lbtin) M/S 0.5- 1.7{5 - 17,4.3- 14.8)
0 . 6 - 1 . 2( 6 - 1 2 , 5 . 2 -0 1 0 . 4 2 )
Pump Pump pressurewith valve closed 6,400- 7,400(65- 75, 920- 1.070)
{oiltemp./speed: 40'C (105'F)min.,4dle.
Do not run for morethan5 seconds).
kPa{kgflcmr,psi)
Powerstee ng Recommendedpower steeringtluid HONDAPowerSteeringFluid-Vor S
fluid Fluid capacity f (US qt, lmp qt) 0.85(0.90,0.75) at disassembly
Reservoir 0.4{0.42,0.35)
Powersteering Deflectionwith 98 N ('10kgf, 22 lbt) 10.5- 14.0{0.4'l- 0.55)with usod belt
belt* betweenpulleys 7.5 - 10.0(0,30- 0.39)with new belt
Tonsion measuredwith belt tension gauge
N (kgt. lbf) 816A2 EngineTyp€ only 390 - 540 (40- 55, 88 - 120)with used belt
OtherEngin€Types 340- 490 (35- 50, 77 - 110)with used belt
816A2EngineTypeonly 740- 880 (75 - 90, 170- 200)with new belt
Othor EngineTypes 640 - 780 {65- 80, 143- '176}wirh new belt
M/S: Manual steering,P/S:Powersteering
*: When using a new belt, adjust deflectionor tensionto new values.Runthe
enginefor 5 minut6sthen turn it off.
Readjustthe deflectionor tonsionto used belt values.
3-12
Unit ot lgngth: mm (in)
Suspension Sestion18
I EWI SERV|CE
UitlT
Camber Front 0.00' l '1"
alagnment Rear
Caster Front 1.40' r 1.
Totaltoe Front In 1.0t 2.0(1/16t 1/16)
Rear In 2.0:i3 {1/1611/15)
Frontwheelturningangle Inwardwheel 39"50'
Outward wheel 33'10'(Reference)
Rim runout Aluminumwheel Axial 0- 0.7{0- 0.03) 2.0(0.08)
Radial 0- 0.7(0- 0.03) 1.5{0.05}
Steelwheel Axial 0- 1.0(0- 0.04) 2.0(0.08t
Radial 0- 1.0(0- 0.04) 1.5(0.06)
Wheel bearing Endplay Front 0- 0.05(0- 0.002)
Rear 0- 0.05(0- 0.0021
Brakes Section 19
MEASUREMENT STANDANO
INEWI SERV|CEUi,llT
Parkingbrake Play in strokeat 196 N (20 kgf. 44 lbfl lover force To be lockedwhen pulled
lever 6 - 9 notchos
Foot brake Pedalhoight(withfloormatrefioved) M/T 156.5(6.16)
pedal A,/T,CW 161(6 5/16)
Freeplay 1-5(1/16-3/16)
Mastercylinder Piston-to-pushrodcl€arance 0 - 0.4(0- 0.02)
Disc brake Discthickness Front 20.9- 21.8(0.82- 0.86) 19.0{0.75}
Oiscrunout Front 0.1s,(0.004)
Rear 0.10(0.004)
Discparallelism Frontand rear 0.015(0.00061
Padthickness Front 9.5- r0.5r1 1.6{0.06)
8.5- 9.5*' 1.6(0.06)
Rearbrake t.D. 2000 .a7l 201(7.911
drum Lining thickness 4.0(0.16) 2.0 (0.08)
*1. 5410Stampedon the caliperbody.
*2. 2056Stampedon the caliperbody.
- Section22
Air Conditioning
MEASUREMENT STANDARD {l{EW)
Lubricanttype: SP-'10(P/N38897- P13- AoIAH or 3889 - P13- A01l{ForretrigerantHFC-134a (R-134a})
Conditioning Lubricantcapacity Condenser 20 l2/3 0.71
m? lll oz,lmp oz) Evaporator 45 112f3, 1.61
Line or hose 10 (1/3,0.4)
Feceiv€r 1 0( 1 / € , 0 . 4 )
Compressor Lubricanttype: SP-10
Lubricantcapacity mf (ll oz, lmp 02) 130- 1s0(4 r/3- 4.6,5.0- 5.3)
Fieldcoil resistanceat 68"F{20'C} o 3.05-3.35
Pulley-to-pressureplate clearance 0.5r 0.15(0.020r 0.006)
Compressor Deffectionwith 98 N (1Okgf,22lbtl 7.5 - 9.5 {0.30- 0.37)with used belt
belt* betweenpulleys 5.0- 6.5 {0.20- 0.26)wilh new bolt
Belt tension N (kgf, lbf) 340 - 490 (35 - 50, 77 - '110)with usod belt
Measuredwith belt tension gauge 690 - 830 (70 - 85, 150- 190)with new b€lt
*: When using a new belt. adjust deflectionor tensionto new values.Run the engin€tor 5 minutesthen turn it off.
Roadjustdeflectionor tension to used belt values.
3-13
Electrical- Section 23
INEWI
lgnitioncoil Ratedvoltage V 12
at 68'F(20'C) 0
Primarywindingresistance
HITACHI 0,45- 0.55
TEC 0.63- 0.77
S€condarywinding resistanceat 68'F (20"C) kO
HITACHI 22.4- 33.6
12.4- 19.2
lgnitionwire Resistanceat 68"F(20"C) k0
Firingorder 1-3-4-2
Sparkplug Tvpe Seesection23
Gap 1,0- 1,1(0.043_ioo.)
lgnitiontiming Ar idle 12+2
" BTDC(Red)
Alternatorbelt* Oetlectionwith 98 N 11okgl,22lbf'l 8.0- 10.5{0.31- 0.41)with usodbelt
betlveenpulleys 6.0 8.5 (0.26 0.33)withnew belt
Belt tension N lkgf, lbf) 340- 490(35- 50,77 - 110)with usedbelt
Measuredwith belt tension gauge 540- 740 (55- 75, 121- 165)with new belt
(NEWI
STANDARD SERVICE
UM]T
Alternator Output 13.5v at hot A
(MITSUBISHI} Coil resistance(rotor) at 68'F 120"C) k0 3.4- 3.8
Slip ring O.D. 22.7 t'.agl | 22.210.87)
Brushlength 1qnro76l |t -5 0
- {' 0 . 2 0 )
Brushspringtonsion g (oz) 300- 450(10.6- 15.9)
Startermotor Type Gear reduclion
(MITSUBA Commutator mica depth 0.4- 0.5 (0.016- 0.020) 0.15(0.006)
1.0kw Commutatorrunout 0 - 0.02 (0 - 0.0008) 0.05(0.002)
1.2kW) CommutatorO,D. 2 8 . 0- 2 8 . 1( 1 . 1 0-2 1 . 1 0 6 ) 27.5(1.083)
Brush l.ngth 15.8 16.2(0.62- 0.64) 11.0(0.43)
Brushspringtension(new) 15.7- 17.7
N (ksl, lbf) (1.60- 1.80,3.5- 4.0)
*: When using a new belt, adjust deflectionor tensionto new values.flun the enginelor 5 minutes then turn it off. {
Readjustdeflectionor tension to used belt values.
L {
3-14
DesignSpecifications
Unit ot lengthi mm {in)
I
a DIMENSIONS
lTEM
OverallLength 2 door Coupe/+door Sedan
2-door Hatchback {1996,1997)
METBIC
4,445mm
4,170mm
ENGUSH
'175.0
in
164.2in
NOIES
(1998) 4,180mm 164.6in

OverallWidth 1,705mm 67.1in
OverallHeight 2-door Coupe/2-door 1.375mm 54.'1in
Hatchback
tl-door Sedan 1,390mm 54.7in
Wheelbase 2,620mm 103.1in
Track FronvRear 1,47511,175mm 58.1/58.1in
'150mm 5.9in
GroundClearance
SeatingCapacity
WEIGHT(USA) GrossVehicleWeight Rsting {GVWR)
2-door Coupe DX, HX M/I 3,290lbs
HX A,/T 3,330rbs
EX 3,440tbs
HX CVT(1996) 3,220tbs
HX CVT(1997) 3,330lbs
2-doorHatchback CX.DX (1996,1997) 3,285tbs
DX with ABS (1998)sMT 3,290tbs
4AT 3,300lbs
4-door Sedan OX, LX M/T, LX Ay'T 3,330lbs
LX A,/Twith ABS, EX 3,460lbs
WEIGHT(CANADA) GrossVehicleWeight Rating{GVWR)
2-door Coupe DX (1996) 1,500kg
DX (1997) 1,510kg
si(1996) 1,560kg
si(1997) 1.570kg
2-doorHatchback cX (1996), cX-G (1996) 1,495kg
cx (1997),CX-G(1997) 1,505kg
cx (1998),DX {1998) 1,510kg
4-door Sedan LX, EX M/T 1,510kg
't,540kg
EX A/T
ENGINE wat6r-cooled,+stroke SOHC*',SOHC *,: Dl6Y7
VTEC'3,SOHCWEC-E*1gasolineengine *3:Dl6Y8
CylinderArrangement Inline 4-cylinder,transverse *+:D'|6Y5
Bore and Stroke 75.0x 90.0mm 1 2.95x 3.54in
'1,590
cm3(m/) 97.0cu-in
Displacement 1
Compression Ratio D16Y7,Dl6Y5 9.4
016Y8 9.6
ValveTrain Beltdriven,SOHC4 valveper cvlind€r
LubricationSystem Forcedand wet sump, trochoid pump
Oil Pump Displacementat 6,800engine rpm 33.4f {35.3US qt,29.4lmpqt)/minute
Water Pump Displacement
at 6,000engine rpm 1251(132US qt, 110lmp qt)/minut€
FuelRequired UNLEADEDgasolinewilh 86 Pump
OctaneNumbsror higher
STARIER Type/Make gA
Gearreduction/MITSU
NormalOutput 1.0kw, 1.2kw
NominalVoltage 12V
HourRatino 30seconds
Directionof notation Clockwiseasvigwedfrom gearend
(cont'd)
3-15
DesignSpecifications
(cont'dl
STARTER(cont'd) Weight
|TEM
MITSUBA1.0,1.2kW
METRIC
3.4kg
ENGLISH
7.5 tbf
NOTES L !
CLUTCH ClutchType Mlf Single plate dry, diaphraomspring
Torque converter
CW Multi plateswet sanp, hydraulic
ClutchFacingArea 160crn' | 25 sq-in
TRANSMISSION TransmissionType Synchronized5-speedforward, 1 reverse
4-speedautomatic,1 reverse
CW Non-stagespeedforward, 1 reverse
PrimaryReduction Direct 1 : 1
TRANSMISSION Manualtransmission Enginetyp€
D16Y5 D16r' D16Y8
GearRatio 1st 3.250 3.250 3.250 *1: 2'doorHatch
2nd 1.742 1.182 1.909 oacx
Jro 1.172 1.172 1.250 *2: 2-doorCoup6,
4th 0.909 0.909 0.909 and 4-door
5th 0.102 0.102 0.702 Sedan
Beverse 3.153 3.153 3.153
FinalReduction Gearratio 3.722 3.722'' 11.034*' 4.250
G€artYPe Single helicalgear
Automatictransmission Enginetype
D,I6Y' D16Y8
GoarRalio lst 2.600 2.722
2nd 'L468
3rd 0.926 0.975
4th 0.638 0.638
Reverse 1.954 1.954
Final Reductaon Gear ratio 1.35"1 4.357
Geartype Singlehelicalgear
cw
Gear Ratio Low - O.D. 2.466- 0.449 L J
Revelse 2.466
SecondaryReductionGear Ratio
FinalRgductionGearRatio 4.357
AIR Cooling Capacity 3,530Kcal/h 14,000
BTU/h
CONDITIONING Compressor Type/Make Scroll/SANDEN
No. of Cylinder
Cspacity u5,/ mt/tev I i.zz cu-rn/rev
Max.Speed 10,000rpm
LubricantCapacity '130mf 4 1/3ll oz. sP-10
|
| 4 . 6 l m po z
Condenser Type fin
Corrugated
Evaporator Type Corrugatedfin
Blower Type SiroccoIan
Motor Input 200w112v
SpeedControl 4-speedvariable
Max. Capacity 460 m3/h | 16.200cu-Vh
Tgmp€ratureControl
CompressorClutch Type Dry. single plate,poly-V-belldrive
PowerConsumption 40 W max./12V at 68'F (20'C)
Refrigerant Type HFC-134a (R-134a)
Ouantity 6sohs 22.9 -laoz
L {
3-16
Unit of length mm lin)
ITEM METRIC ENGLISH NOTES

STEEBING Type P/S P o w s r a s s i s t e d r, a c ka n d p i n i o n
SYSTEM M/S S a c ka n d p i n i o n
OverallRatio P/S:17.7,lt4/Sr20.3
Turns,Lock-to-Lock P / S : 3 . 6 ,M / S : 4 . 1
SteeringWheelDia. 380rnm i 15in
SUSPENSION Type Front and Rear I n d e p e n d e ndt o u b l ew i s h b o n e ,c o i l s p r i n s
S h o c kA b s o r b e r F r o n ta n d R e a r T e l e s c o p i ch, y d r a u l i cn i t r o g e ng a s f i l l e d
WHEEL Camber Front 0.00'
ALIGNMENT Rear
Caster Front 1'40'
TotalToe Front I n 1 . 0m m l / 1 6i n
Bear I n 2 . 0m m I n 1 / 1 6i n
BRAKESYSTEM Power-assistedsel{-adiusting
ventilated disc
Rear Powe.assisted self-adjusting solid disc Unit:mm (in)
3 7 . 5c m , \ 2 5 . 8s q - i nx 2 5,110Stamped on ths
4 4 . 1 c m ,x 2 6 . 9 4s q - i nx 2 2 0 5 6S t a m p e do n t h e
caliper body
Rear 6 7 . 2c m , x 2 10.4sq-inx2 O r u m l . D . : 2 0 0( 7 . 9 )
5 0 . 2c m , x 2 7 . 8 s q - i nx 2 D r u m l . D . : 1 8 0( 7 . ' ! )
Parking Brake Type l,lechanicalactuating,rear Nvo wheel brakes
TIRE Size Front and Rear 2-door Coupe P175D0R18 3 2 S :D X
P 1 8 5 / 6 5 R ' 1845 S :E X , H X ( U S A ) ,S i ( C a n a d a )
2-door Hatchback P 1 7 5 t 0 R 1 38 2 S :C X , D X ( U S A ) ,C X G { C a n a d a )
4 - d o o rS e d a n P 1 7 5 t 0 R r 3 8 2 S :D X ( U S A ) ,L X ( C a n a d a )
Pl85/65R1485S: LX/EX (USA),
EX (canada)
S p a r eT i r e T 1 0 5 / 8 0 D 1C 3 a r sw i t h o u t A B S E x c e p t
2 - d o o rC o u p eE X ( u S A ) ,S i
(Canada)
T 1 0 5 t 0 D 1 42 ' d o o r C o u p eE X ( U S A ) ,S ;
( C a n a d aC ) a r sw i t h o u t A B S
T 1 1 5 / 7 0 D 1D 4 X ( U S A ) ,4 ' d o o r S e d a nL X l U S A ) ,
2 - d o o rC o u p eD X ( C a n a d aC ) ars
t with ABS
T 1 2 5 r 0 O 1 4C a r sw i t h A B S 2 d o o r C o u p e ,
4 d o o r S o d a nL X , E X ( U S A ) ,
4 ' d o o r S e d a nE X ( C a n a d a ) ,
2 - d o o rC o u p eS i ( C a n a d aC ) ars
with ABS
WASHER Capacity| (uS qt, lmp qt) 2-doot coupe 2.5 l.2.6,2.21 USAmodel
RESERVOIR 4'door Sedan 4.5 {4.8, 4.0} Canadamodel
2 - d o o rh a t c h b a c k2 . 5 ( 2 . 6 ,2.2) DX
4 . 5 ( 4 . 8 ,4.0) ExceptOX
ELECTRICAL Batt€ry 12 V - 38AH/5HR
Staner 1 2 V - 1 . 0k W , 1 . 2k W
12V-154
I n U n d e r d a s h F u s e / R e l aB y ox 7 . 5 A , 1 0A , 1 5A , 2 0 A
In Under-hood Fuse/RelayBox 7.5 A, 10 A, 15 A, 20 A,30 A, 40 A, 80 A
In Under-hood ABS Fuse/RelayBox 7 . 54 , 2 0 A , 4 0 A
Headlights HighAow 12V-60AsW
F r o n tT u r n S i g n a l / P a r k i nLgi g h t s 12V 21tsW
R e E rT u r n S i g n a lL i g h t s
't2v - 21W
Brek€/Taillights 12V-21/5W
I n n e rT a i l l i g h t s * ' 12V5W
H i g h M o u n t B r a k €L i g h t 12V_ 18W*" 21Wrl.+3
Back up Lights 12V-21W
License Plate Lights 12V 5W
C e i l i n gL i g h t 12V- 8 W (Withmoonroof)
12V-5 W (Witholtmoonroof)
T r u n kL i g h t s
G a u g eL i g h t s 12v-1.4W,3W
Indicator Lights 1 2 V - 1 . 1 2 W1 ,. 4W
l l l u m i n a t i o na n d P i l o tL i g h t s 1 2 V - 0 . 8 4 W1 ,. 4W
Heater Control Panel Lights 12V-1.4W
P/S:Powersteering,M/S:Manualsteering
*l: 2-doorCoupe *2: 2-doorHatchback *3: 4-doorSedan
*4: USA (HAM),Canada(HCM)produced
*5:JAPANoroduced
3-17
Body Specifications
L
2-door Coup€: : m( i n )
U n i tm
3-18
\,
2-door Hatchback:
lr'tgl91e'l
3-19
Body Specifications(cont'd)
L r '
4-door S6dan: Unit:mm (in)
3-20
Maintenance
LubricationPoints ............4-2
MaintenanceSchedulefor 1996Model
NormalConditions ........4-4
SevereConditions 4-6
.........
SevereConditions 4-10
.........
SevereConditions .........4-14
LubricationPoints
\-
For th6 details of lubrication points and types of lubricants to b€ applied, rsfsr to the lllustrated Index and various work
proc€durss(such as Asssmbly/Reassembly,Replacement,Overhaul,Installation,etc.)contained in each section.
No. LUBRICANONPOINIS LUBRICANT

'I Engine API ServiceGrade:Use SJ 'Energy Conserving"
grade oil.
The oil containerm8y alsodisplsythe APICenificationmark
I
shown below. Makesure it says "For GasolineEngines,"
SAEViscosity:Se6chart below.
2 Transmission Manual GenuineHondaMTF*1
Automatic GenuineHondaPremiumFormula
AutomaticTransmissionFluid(ATF)*,
CW GenuineHondaCVTFluid'3
3 BrEkaLing GenuineHond8DOT3BrakeFluid*.
1 clutch Lin€ GenuineHondaDOT3BrskeFluid'a
c Pow€r ste€ring gesrbox StesringgreaseP/N08733- 8070E
6 Shift leverpivots{manualtransmission) Gressewith molvbdenum disulfide
7 Releasetork (manualtransmission) Super High Temp Urea Grease{P/N08798- 9002)
I Steering boots
o Tailgate hinges and latches(2-door Hatchbackl
10 Steeringball joints
Multi-purposegrease
11 Shift lever (sutomatictransmission)
12 P6dallinkage
13 Braks mast6r cylind6r pushrod
l'[ Trunk hingesand lstch(,|-doorSedanand 2-door
Couoe)
15
16
Door hinges upper and lower
Door opening dstents
Honda White Lithim Grease
L q
17 Hood hings and hood latch
18 Fuelfillor lid
19 Clutch m8st6r cylinder pushrod
20 Throttlecabl€ond and thronl6linksge grease
Multi-purpose
21 Rear brakg shoe linkages
22 Steeringwheel (backside)
23 Caliper piston seal,dust seal,
caliperpin, piston Siliconsgrease
21 Throttle cable end (dsshboardlower Danel)
25 Pow6r st66ring system (for cars with P/Sl GenuineHondaPowerSteeringFluid-Vor S'5
26 Air conditioningcomprsssor Comoressoroil:
SANDEN:SP-10P/N38At - P13-A01AH or3@9- P13-A01
(ForR6frigsrant: (R-f34a))
HFC-1348
API SEFVICELABCL API CERTIFICAIIOII SEAL Recornmendod
EngineOil
ffi r ,--;--i------
Engineoil viscosityfor
ambrenttempe€tureranges
NOTE: Th€ following information as marked *1, *2, 13, *4 and 15 on above chart details for 1997model.
t
Il: Alwsys use GenuineHonda MaoualTransmissionFluid (MTF).Using motor oil can causestiffer shifting becauseit
dogs not contain the propor additiv€s,
*2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can affect
shift quality.
*3: Us6 Genuin6HondaCVTfluid only. Using other fluid csn aftecttransmissionoperationand may reducetransmissionlif6. (
r,l: Always uss GenuineHonda DOT3BrakeFluid. Using a non-Hondabrakefluid can causecorrosion and decressethe life
ot the system.
:5: Alwsys use Gonuine Honda Pow6r Stooring Fluid-V or S. Using 8ny other type of pow6r stssring fluid or sutomstic
transmissionfluid can causeincr€assw€ar 8nd poor steoringin cold weathsr.
4-2
\
@ (4{oo. s.d.n) @
NOTE:Lubricateall hinges,latchesand locksoncea year.

In corrosiveareas.more frequentlubricationis necessary.
We recommendHondaWhite LithiumGrease.
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4-15
Engine
EngineRemoval/lnstallation ......".'.'....
5-1
CylinderHead/Valve 6-1
Train ........'..'.'."..
EngineBlock.......... .....'.'..'7-1
EngineLubrication ...........
8-1
lntakeManifold/ExhaustSystem ........9-1
Gooling 10-1
.........
EngineRemovaUlnstallation
Removal .......5-2
fnstalfation ...5-12
Removal {
@
.
4. Remove the battery and battery base.
Mako surs iacks and 3atety stands ar6 placed properly
and hoist brackets aro attached to ihe corroct posi- I x 1.25mm
tions on th€ engine. 21 N.m l2.1kgl.m, 17 lbf-ftl
. Mako surc the brehiclowill not roll olf rtands and fall
whilo you are working und.r it.
CAUTION:
. Uso tandar covors to ayoid damaging painted sur-
face.
. Unplug the wiri||g connoctorscarefully whilo holding
the conn6ctor poiion to ayoid damago.
. Mrrk all wiring and hosss to lvoid misconnoction.
Abo, be sur6 that thoy do not contact other wiring or
hos€s or interf?ro with othor parts,
1, Securethe hood as oDenas possible.
2.. Disconnectthe batterynegativeterminalfirst, then

the positiveterminal.
3. Disconnectthe battery cables from the under-hood

fuse/relaybox and battery positive terminal.
the connectorsfrom the ECM/PCM.

Disconnect I (
BATTERYCABLES
the main wire harnessconnsctor.
Disconnect
MAINWIREHARNESS
CONNECTOR
TERMINAL
ECM/PCM
5-2
\}
7. Removethe intakeair duct and air cleanerhousing. D16Y5,Dl5Y8 engines:
D16Y7enqine: a. D i s c o n n e c t h e I A T s e n s o r c o n n e c t o r ,t h e n
removethe intakeair duct and air cleanerhous-
a. Removethe resonatorand intakeair duct. In g .
6x1.0mm 6x1.0mm INTAKE AIR

9.8N.m {1.0kgt.m,7.2lbt.ft) OUCT
INTAKE AIR
DUCT
RESONATOR
L
IAT SENSOR
CONNECTOR
o. Disconnectthe intakeair temperature(lAT)sen-
sor connector,
then removethe air cleanerhous- 8. Disconnectthe engine wire harnessconnector
ing. the leftside of the enginecompartment.
6x1.0mm
AIR CLEANER 9.8 N.m 11.0kgf.m, t.2lbtft)
(cont'd)
5-3
EngineRemoval/lnstallation
Removal (cont'dl
9. Relievefuel pressure(seesection11), 11. Removethe brakeboostervacuumhose,fuel return
hoseand vacuumhose.
!@ uo not smot(ewhde working on th€ tuol
system. Kogp open flams or spark away from tho D16Y7engine:
work arga.Drainfuel only into an approvedcoDtainer.
10. Removethe evaporativeemission (EVAp)control

canisterhoseand fuel feed hose VACUUMHOSE
D16Y7engin€:
Dl6Y5, D16Y8engines:
FUELFEEDHOSE
Dl6Y5. D16Y8engines:
BANJOEOLT
33N.m(3.4kg{.m,
2s tbf.ftl
5-4
I
12. Removethe throttlecableby looseningthe locknut, 1 3 . R e m o v et h e g r o m m e t a n d w i r e h a r n e s sc l a m p s ,
then slip the cable end out of the acceleratorlink then pull out the ECM/PCM connectors.
age.
NOTE: 6x1.0mm
a Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one.
. Adjustthe throttlecablewhen installing(seesec-
t i o n 11 ) .
D16Y7engine:
LOCKNUT
1 4 . Removethe mountingbolt and lockbolt,then remove

the powersteering(P/S)pumpbeltand pump.
NOTE:Do not disconnect

the P/Shoses.
NUT
MOUNTINGBOLT
8 x 1.25mm
24 N.m (2.4kgf.m, 17 lbf.ftl
[ocK aoLT
LOCKNUT 8 x 1.25mm
24N.m(2.4kgf.m,17lbt.ftl
(cont'd)
5-5
Removal(cont'dl
1 5 . L o o s e nt h e i d l e r p u l l e yc e n t e rn u t a n d a d j u s t i n g 1 7 . R e m o v et h e c l u t c h s l a v e c y l i n d e r a n d l i n e / h o s e
bolt, then remove the air conditioning(A/C)com- assembly(M/T).
pressorbelt.
NOTE:
. Do not disconnectthe pipe/hoseassembly.
IOLERPULLEYCENTER . Do not operatethe clutch pedal once the slave
NUT
10 x 1.25mm cylinderhasbeenremoved.
4,r N'm 14.5ksf.m.33 lbl.ftl . Takecarenot to bendthe line.
6x f.0mm 8x1.25fifi
,t N.m (t.1 kg ,m, 21N.m l2.1kgr.m,
6 tbr.ft) 17lbnftl
1 6 . Remove the transmission g r o u n d c a b l ea n d h o s e

clamp.
6x1.0mm
18. Removethe shiftcable(CVT).
HOSECLAMP
LOCKNUT
WASHER 29 N.m {3.0 kgt m, 22 lbtft)
PLASTIC
GROUNDCABLE
SHIFTCABLE
, 5- 6
1 9 . D i s c o n n e c t h e p o w e r s t e e r i n g p r e s s u r e( P SP ) 23. Drain the engine coolant (see page 10-6),Loosen
s w i t c h c o nn e c t o r ,a n d r e m o v et h e w i r e h a r n e s s the drainplug in the radiator.
clamp. 24. Drainthe transmissionfluid. Reinstallthe drainplug
usinga new washer(seesection13.14).
25. Drainthe engineoil. Reinstallthe drain bolt using a
new washer(seepage8-5).
26. Removethe shift rod and extensionrod (M,/T).
SHIFTROO
8 x 1.25mm
20. Remove the radiator cap. 22 N.m(2-2kgf.m,16lbf,ft)
use care when removing the radiator 27. Removethe A,/Ccompressor.
E@@
cap to avoid scalding by hot coolant or steam.
NOTE:Do not disconnectthe A,/Choses.
2 1 . Raisethe hoistto full height.
and splashshield.
22. Removethe front tires/wheels
8 x 1.25mm A/C COMPRESSOR

2,r N.m {2.{ kgf.m, 17 lbf.ft}
6x1.0mm SHIELD
9.8 N.m (1.0kd m,
7.2 rbl.ft)
(cont'd)
5-7
Removal(cont'd) L
28. Removethe shiftcable(A,/T). 29. Removeexhaustpipe A.
NOTE: D16Y5,D16Y7engines:
. Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
8 x 1.25mm
one, 22 N.m (2.2 kgt m, 16 lbl.ftl
l . Adjust the shift cable when installing(see sec- Replace.
tion14).
I x 1.25mm
22 N.m12.2kgd.m.
16lbtft)
SELF-LOCKING
8 x 1.25mm
16 N.m 11.6kgt.m,
12 tbf'ft|
Replace. SELF.LOCKING NUT
PIPEA 10 x 1.25m.n
33 N.m (3.4kgtm,
25 tbt.ftt
Replace.
{
Dl6Y8 engine:
6x1.0mm 8 x ' 1 . 2 5m m
14 N.m {1.4kgf.m. 10 lbf.ft) 22 N.m 12,2kgf.m, 16lbtftl
GASKET
Feplace.
SELF.LOCKING NUT
8 x'1.25mm
16 N.m (1.6kg'i.m,'12lbf'ftI EXHAUST
Replace. PIPEA
SELF,LOCKING NUT
10 x 1.25mm
5{ N.m {5.5kgt.m,,10lbf.tt}
Replace.
\
5-8
30. Removethe damperlorks (seesection'18). Lowerthe hoist.
Jt, D i s c o n n e ctth e s u s p e n s i o nl o w e r a r m b a l l j o i n t s 34. R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e sa n d

(seesection18). heaterhoses.
Removethe driveshafts.
CAUTION:
o Do not pull on the driveshaft, the CV ioini may RADIATORHOSE
com€ apart.
. Use care when prying out the assembly.
Pull il straight to avoid damaging the difterential
oil seal or intermediats shaft dust seal.
N O T E ; C o a t a l l o r e c i s i o n - f i n i s h esdu r f a c e sw i t h
cleanengineoil. Tie plasticbagsover the driveshaft
enos.
35. R e m o v et h e A T F c o o l e rh o s e s ,t h e n p l u g t h e ATF
coolerhosesand Dipes(Ay'T).
HOSES
(cont'd)
5-9
Engine RemovaUlnstaflation
Removal(cont'd)
36. Attachthe chainhoistto the engine,
HOISTINGBRACKET
lnstall on the cylinder head
witha8xl.25mmbolr.
5-10
37. Removethe left and riqhtfront mount and bracket. 39. Removethe uooerbracket.
UPPER
4 0 . R e m o v et h e t r a n s m i s s i o nm o u n t b r a c k e t ,t h e n
removethe transmissionmount.
TRANSMISSIOt{
MOUNT
TRANSMISSION
T
MOUNT
FROI{T BRACKET
MOUNT/BRACKET
Replace.
38. Remove the rear mount bracket.
4 1 . C h e c kt h a t t h e e n g i n e / t r a n s m i s s i o
i snc o m p l e t e l y
free of vacuum hoses,fuel and coolant hosesand
electricalwirino.
42. Slowly raise the engine approximately 150 mm (6 in).

Check once again that all hoses and wires are discon-
nectedf rom the engine/transmission
43. R a i s et h e e n g i n e a l l t h e w a y , a n d r e m o v e i t f r o m t h e
car,
5-11
t'
Installation
I
BracketBolts Torque Specifications:
10x 1.25mm 10 x 1.25mm

44 N.m {4.5kgf.m,
54 N.m (5.5kgf.m,
33 rbtft) a0 lbf.ftl
D16Y5.O16Y8enginGs(M/Tl:
10 x 1,25mm
REARSTIFFENER 44 N.m {4.5 kgl.m,
33 tbtft)
8 x 1.25mm
24 N.m 12.4kgf.m, 17 lbtft) 10 x 1.25mm
ALTERNATOF /t4 N.m {4.5kgf.m,
EXCEPTD16Y5, D16Y8 engines {M/T): BRACKET 33 rbtft)
STIFFENER
Tightenthe boltson the stiffener
in the numberedsequenceas shown
(O-O). e)8x1.25mm
24 N.m(2.4kg[.m.
17rbt.ftl
\ {
10 x 1.25mm
,14N.m {4.5kgt m,
O 10 x 1.25mm 33 rbtftl
44 N.m {4.5 kgf.m.
33 rbf.ft) 8 x 1.25mm
24 N.m {2.4kgf.m,
17 rbf.ft)
A/C COMPRESSOR
BRACKET
D16Y5.O16Y8
engine3lM/Tl:
FRONT
STIFFENER
10x 1.25mm
44 N.m {i1.5kgf.m, {
8 x 1.25mm 33 tbtft)
10x 1.25mm
24 N.m {2.4kgf.m, 44 N.m (4.5kg,tm.
17 tbf.ftl 33 rbf.ft,
E 4 6
c-tz
Engine Installation: ExceptCw:
Installtheenginein the reverseorderof removal. TRANSMISSION 1 2x l 2 5 m m

Reinstallthe mount bolts/nutsin the followingsequence. MOUNT 64 N.m {6.5kgf.m,
Failureto follow these proceduresmay causeexcessive 17 tbt.ftl
noiseand vibration,and reducebushinglife.
1. I n s t a l lt h e t r a n s m i s s i o nm o u n t a n d b r a c k e t t, h e n
tightenthe boltson the frameside.
NOTE: Do not tighten the bolts/nutson the trans-

missionside.
CW:
38 N.m 13.9kgf.m,28 lbf.ftl
2. lnstall the upper bracket,then tighten the nuts in

t the numberedsequenceshown (O - @).
(412x1.25mm (il 12 x 1.25mm

?4N.m{7.5kgtm, 74 N.m 17.5kg{.m,
54 tbf.ftl 54 rbf.ftl
UPPER
BRACKET
TNANSMISSION
MOUNTBRACKET
(cont'd)
5-13
Installation(cont'd)
Installthe rearmount bracket,then tightenthe bolts 4 . T i g h t e nt h e b o l t / n u t so n t h e t r a n s m i s s i o nm o u n t
in the numberedsequenceshown (O - @). bracketin the numberedsequenceshown (Ot- @).
cvT:
O 12 x 1.25mm
59 N.m (6.0kgJm, O 12x t.25mm
(} rbtfrl 74N.m{7.5kg{.m,5il lbtft)
Replace.
12x 1.25mm
59 N.m 16.0kgt'm,
a:l lbt ft)
Replace.
O 12 x 1.25mm
59 N.m 16.0kgJm,
€ tbf.fr)
Replace.
Except CVT:
't2 x 1.25mm
O
59 N.m 16.0kg{.m.
$ tbt.ft) 12x 1.25mm
Replace. 64 N.m (6.5 kgt.m,
47 tbtftl
5. Tightenthe boltson the rightfront mounvbracketin

the numberedsequenceshown(O - O).
CW:
O14xt.5mm O to x t.zsmm
tB N.m 18.5kgf.m, 54N.m15.5kgt.m,
61 tbf.ftl /r0 lbf.ftl
Replace.
5-1 4
I
-
ExceptCVT:
7. Performthe following:
Cleanthe areaswhere the driveshaft(s) and the

intermediateshaft contactthe transmission(dif-
ferential)thoroughlywith solvent or carburetor
cleaner.and drv with compressedair.
Checkthat the set rings on the ends of the drive-
shaftand intermediate shaftclickinto Dlace.
CAUTION: Use new set rings.
a Adjustthe shift cable(seesection'14,.
a Adjustthe throttlecable(seesection11).
a Adjustthe cruisecontrolcable(seesection23).
a Refillthe enginewith engineoil (seepage8-5).
a Refillthe transmissionwith fluid (seesection13,
14).
Refillthe radiatorwith enginecoolant(seepage
10-6).
Bleedair from the coolingsystemwith the heater
valveopen(seepage10-6).
10 x L25 mm Cleanthe batterypostsand cableterminalswith
a4 N.m 14.5kgf.m,
sandpaper.assemblethem, then apply greaseto
33 tbt f0
prevenrcorroston.
Inspectfor fuel Ieakage(seesection11).
Afterassemblingthe tuel line,turn on {ll)the igni-
tion switch(do not operatethe starter)so that the
fuel pump runs for approximatelytwo seconds
Tightenthe bolts/nuton the left front mount in the and the fuel line pressurizes. Repeatthis opera-
numberedsequenceshown (O - O) tion two or threetimes,then checkfor fuel leak-
O 1 2 x 1 . 2 5m m age at any point in the fuel line.
83 N.m (8.5 kgl.m, 61
@ 12 x 1.25mm
59 N.m 16.0 kgt.m,
43 lbf'frl
44 N'm 14.5 kgt.m, Replace.
33 rbf.ftl
(cont'd)
5-15
(cont'd)
Installation
Mount and Eracket Bolts/Nuts Torque Value Specifications:
A: 10x '1.25mm
64 N.m (6.5 kgf.m,47 lbnft)
B r 1 0x 1 . 2 5m m
44 N.m (4.5 kgnm,33 lbift)
C : 1 2x 1 . 2 5m m
83 N.m (8.5kgf.m,61lbl.ft)
D : 1 2x 1 . 2 5m m
59 N.m (6.0kgt m, 43 lbl.ft)
Replace.
SIDEENGINE
MOUNT
RIGHTFRONT
MOUNT
5-16
SpecialTools
\ g
Rel. No. Tool Number Description oty PageRetsrsnce
o OTHAH- PJTOlOB ValveGuideReamer,5.5 mm 6,43

@ 07JAA- 001010A Socket,17 mm
@ 07JAB- 0010204 H o l d e rH a n d l e
@ OTLAJ. PR3O2OB Air Stopper 6-8,10
@ 07NAB- 0010404 HolderAttachment,50 mm
@ 07NAJ- P07010A PressureGaugeAdapter 6-4
o 07406- 0020201 A/'I PressureHose 6-4
orO-1 OTMAJ- PY4O1 1A A"/TPressureHose,2.210mm 6-4
I andO-2
@
o
OTMAJ PY4O120
07406- 0070300
0 7 7 4 2- 0 0 1 0 1 0 0
A/T PressureAdapter
A/f Low PressureGaugeW/Panel
V a l v eG u i d eD r i v e r , 5 . m
5m
6-4
6-4
6-41,42
e='T------_ts
o
\ - J
@ @ @
@
\ a
6-2 .;*'
VTECControl System
Troubleshooting Flowchart
toolindicates TroubleCode(DTC)Pl259:A problemin theVTECPressure
Diasnostic Switchcircuitor
tFl2Egl
---- Il"-:1"".
VItC Solenord Valve crrcuit.
Refer to page 11 38 through 11'55 before troubleshooting.
The MIL has beenreportedon.

DTCP1259is stored.
Checkthe VTECControl System:

1. Do the enginecontrolmodule
(ECM)/powertraincontrol mod * RoadTest:
ule (PCM)ResetProcedLrre (see A c c e l e r a t ei n l s t g e a r t o a n e n g i n es p e e do v e r 3 , 0 0 0r p m
section11). (D16Y5engine)or 6,000rpm (D16Y8engine).
2. Startthe engine. Holdthat enginespeedfor at leasttwo seconds.
3. Warm up the engineto normal lf the DTC P1259is not repeatedduring the first road test,
operalingtemperature(cool- repeatthistesttwo moretimes.
ingfan comeson).
4. Do the RoadTest.*
Intermittent failure. system is OK
at this time.
l s D T C P 1 2 5 9i n d i c a t e d ?
Check tor poor conneqlionsor
loose wires at VTEC oressure
switch. VTECsolenoid valve and
ECM/PCM.
VTECPRESSURE
SWITCH
CONNECTOR
Test the VTECPresslre Switch:

'1. Turnthe ignitionswitchOFF.
2. Disconnectthe VTECPressure
swrtchconnector.
3. Checkfor continuitybetween
VTECpressureswitchconnec-
tor terminalNo. 1 and No. 2.
TERMINALSIDEOF MALE
TERMINALS
ls there continuity? fleplace the VTEC pressrre switch.
vTM
{sr-ulelrt
/Ta
fll
T6st the VTEC Pressur€ Switch
Wi16:
\3-l I
1. Turnthe ignitionswitchON (ll). I
2. Measurethe voltag€between {9)
VTECpressureswitchconnec' Y
tor No. 1 and body ground. I
-L
WIFE SIOEOF FEMALE
Inspect for an open oa short to TERMINALS
ground in the wir€ betweon tho
VTECpressureswitch and ECM/
ls thereapprox.12V? PCMtCls).
It the wire is OK. sub3titute a
YES known-good ECM/PCM rnd
rech6ck.
(To page6-4)
(cont'd)
6-3
VTECControlSystem
TroubleshootingFlowchart(cont'dl
(Frompage6-3) SWITCH
VTECPRESSURE
CONNECTOR
Tost the VTEC Pt.ssure Switch

Wire:
Measurevoltageacrossthe VTEC
pressureswitchconnector.
Ropair open in the wire batwe'€n WIRESIDEOF FEMALE

VTEC Dr€66ureswitch and A10 or TERMINAL
A23 ot tho ECM/FCM.
ls thereapprox.12V? ll the wire ia OK, 3ubstilut€ a
known-good ECM/PCM .nd
rochock.
Test the VTECSolonoidValve: A/T LOWPRESSURE
1. Turnthe ignitionswitchOFF. W/PAiIEL
2 . R e m o v et h e V T E Cp r e s s u r e 07406-0070300
switch and installthe special
tool as shown,then reinstall
the VTECpressureswitch.
3. Connecta tachometer(seesec-
L-
t i o n1 1 ) .
4. Startthe engine.
5 - W a r m u p e n g i n et o n o r m a l
operating
fan comeson).
temperature (cooling
.-,,-t
6. Checkoii pressureat the fol- A/I PRESSURE HOSE
lowing enginespeeds:D16Y5 07i106- 0020201
e n g i n e :1 0 0 0a n d 3 0 0 0r p m , N O T E : K e e p m e a s u r i n gt i m e a s s h o r t a s
Dl6Y8 engine:1000,3000and possiblebecauseengineis runningwith no
5000rpm. load(lessthan one minute). A/T PRESSURE HOSE,
2-210mm
07MAJ - PY4O11A and
PRESSURE GAUGE A/T PRESSURE ADAPTER
ls pressurebelow 49 kPa
Insoectihe VTECsolenoidvalv6. ADAPTER OTMAJ- PY|{}l20
{0.5kgflcm' ,7psi)? 07NAJ - P07010A
IOW PRESSUREGAUGE WPANEL

Test the VTECSolenoidValvel 07406-O070300
1. Turnthe ignitionswitchOFF.
2. Disconnect the VTECsolenoid
valveconnector.
3. Attach the baftery positiveter
minal to the GFNIYELtermi'
nal. A/T PRESSURE HOSE
4. Startthe engineand checkthe 07406- 0020201
oil pressureat the following
e n g i n es p e e d :D 1 6 Y 5e n g i n e A/T PRESSURE HOSE,
3000rpm, D16YBengine5000 2,210nn
rpm. 07MAJ - PYlOltA .nd
A/T PRESSURE ADAPTER
OTMAJ- PYO12O
ls the pressureabove:D16Y5
engine:250kPa(2.5kgvcm?, In3oocttha VTECsolonoidvalve.
36 psi),D16Y8enginer390kPa PRESSURE
(4.0kgf/cm' ,57psi)? GAUGEADAPTER
07NAJ- P07010A
(Topage6 5)
6-4
lFrom page6-4) ECMCONNECTORS
A (32P1 c (3rP)
T6t lhe VTECPr6.sure Switch:
1. Turn the ignitionswitchOFF.
2. Reconnectthe VTEC pressure
swrtchconnector,
3. Staftthe engine.
4. With the batterypositiveter-
minal connectedto the VTEC
solenoidvalve,measurevolt-
age betweenC15 and A'10or
A.23
WIRESIDEOF FEMALE
TERMINALS
ls thsre approx. '12V above
5,000rpm? R€plac€the VTECpressureswitch.
VTECSOLENOID
VALVE
CONNECTON
Testth. VTECSolenoidValve: tT------ I

2. Disconnectthe batterypositive
terminalfrom the VTECsole-
l[-]f-r I
noidvalve,
3. Checkfor continuitybetween I
the VTECsol€noidvalve con-
neclorterminal No. 1 and body I-L
grouno.
TERMINALSIDEOF MALE
TERMINAL
ls there14- 30 O? ReDlacethe VTECsolonoid valve.
VTECSOLENOID ECMCONNECTOR
VALVE A (32P1
CONNECTOR
Tosi tho VTEC Solenoid Valv€
Wi.e:
ws
Checkfor continuity betweenthe {GRN/YELI
VTECsolenoid valve connector
terminalNo. I andA8.
WIRESIOEOF FEMALE
R€pair open in the wiro botweon TERMINALS
ls therecontinuhy? the ECM/PCM{48} and VTECaote-
noid valvoconnoclor. VTECSOLENOIDVALVE
CONNECTOR
Tost tho VTEC Solenoid Valvo

Whe:
r=
Checkfor continuity between the I t--l I
VTECsolenoidvalveconnectorter-
min6lNo. 1 and bodyground. I
r5'
Y
ls therecontinuity?
RoDair 3hort in the wire betwoon
rho €cM/PcM (A8land VIEC sot€-
I
noid valv6 connoctor, WIRESIDEOF FEMALE
TERMINAL
Sub3tituto a known-good ECM/

PCM and roch6ck.lf symptom/
indic.tion goo3 away, .oplace
th. originel ECM/PCM.
6-5
VTECSolenoid Valve
Inspection
'1. Disconnect 'lP If the filter is not clogged,push the VTECsolenoid
the connectorfrom the VTECsole- 4.
noid valve. valvewith your fingerand checkits movement.
2. Measureresistancebetweenthe terminaland body . lf the VTECsolenoidvalve is normal,checkthe

grouno. engineoil pressure.
Resistance:14 - 30 O
6x1.0mm
12 N.m (1.2kgtm,8.7 lbtftl
lf the resistanceis within specifications, removethe

V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m t h e c y l i n d e r
head.and checkthe VTECsolenoidvalve filter for
cloggrng.
. l f t h e r e i s c l o g g i n g r, e p l a c et h e e n g i n eo i l f i l t e r
a n dt h e e n g i n eo i l .
VTECSOLENOIDVALVEASSEMBLY
VTECSOLENOID
VALVEFILTER
Replace.
6x1.0mm
12 N.m {1.2 ksf.m,8.7 lbf.tr} {
o-o
VTECRockerArms
ManualInspection(D16Y5engine) (D16Y8engine)
ManualInspection
Setthe No. 1 pistonat TDC. '1.
1. Setthe No. I pistonat TDC.
2. Removethe cylinderheadcover. 2. Removethe cylinderheadcover.
NOTE:Referto page 6-46when installingthe cylin- NOTE:Referto page6-46when installingthe cylin-

der headcover. der headcover.
lvlovethe intakesecondaryrockerarm on the No. 1 3 . Pushthe intakemid rockerarm on the No, I cylin-
c y l i n d em
r anually. d e rm a n u a l l y .
Checkthat the intakesecondaryrockerarm moves Checkthat the intakemid rockerarm movesindepen-

independentlyof the primaryintakerockerarm. dently of the primary and secondaryintakerocker
arms.
MID ROCKER
ARM
SECONOARY
SECONDARY ROCKERARM
PBIMARYROCKER
PBIMARY ARM
ROCKERARM
ROCKER ARM
. Pushandpull.
C h e c kt h e i n t a k es e c o n d a r yr o c k e ra r m o f e a c h
cylinderat TDC. Checkthe intakemid rockerarm of each cylinderat
TDC.
. lf the intakesecondaryrockerarm does not move,
removethe primaryand secondaryintakerocker . l f t h e i n t a k e m i d r o c k e ra r m d o e s n o t m o v e ,
armsas an assemblyand checkthat the pistonsin removethe mid, primary and secondaryintake
t h e s e c o n d a r ya n d p r i m a r yr o c k e ra r m s m o v e rockerarmsas an assemblyandcheckthatthe pis-
smoothly. tons in the mid and primary rockerarms move
. lf any rockerarm needsreplacing.replacethe pri- smoothly.
maryand secondaryrockerarmsas an assembly. . lf any rocker arm needs replacing,replacethe
primary,mid, and secondaryrockerarms as an
assemoly.
6-7
VTECRockerArms
Inspection (D16Y5engine)
Using SpecialTools
CAUTION: 3. Remove the sealing bolt trom the inspection hole
. Eelore using the Valve Inspection Tool. make sure and connect the Valve Inspection Tool.
that the air pressuregaugs on the air compressor
indicatesover iloo kPa {4 kgt/cm', 57 psil.
10 x 1.0mm
a tnspectthe valve clearancebgfore rocker arm inspec-
SEALINGBOLT
tlon. 20 N'm {2 0 kgf'm, 14lbf'ft}
. Coverthe timing belt with a shop towalto protect the
belt. AIR STOPPER
. Checkthe intakepdmary rockerarm of eachcylinderat OTLAJ- PR3O2OB
TDC.
1. Removethe cylinderheadcover.
NOTE:Referto page6-46when installingthe cylin-

der headcover.
Plugthe reliefhole with the specialtool.
VALVEINSPECTION
TOOL
l0 x 1.0 mm (Commercially
TNSPECTTON
HOLE
ADAPTER available)
Y' . P u l l t h de i a a
turnto adjust,
Loosenthe regulatorvalve on the valve inspection

l nd
tool and apply specifiedair pressureto the intake

rockera.m timing piston.
OTLAJ_ PR3O2OB
SpecifiedAir Prossure:
250 kPa {2.5 kgt/cm,, 36 psil
6-8
5. With the specifiedair pressureapplied,push up the 6. Stop applyingair pressureand push up the timing
timing plate;the synchronizingpiston will pop out plate;the synchronizingpistonwill snap backto its
and engagethe intakesecondaryrockerarm. originalposition.
Visuallycheckthe engagementof the synchronizing Visuallycheckthe disengagementof the synchro-
piston. nizingpistons.
NOTE: NOTE:
. The synchronizing pistoncan be seen in the gap . When the timing plate is pushedup, it releases
betlveenthe secondaryand primaryrockerarms, the timing piston,lettingthe returnspring move
. W i t h t h e t i m i n g p l a t ee n g a g e di n t h e g r o o v eo n the synchronizingpistonto its originalposition.
t h e t i m i n g p i s t o n ,t h e p i s t o n i s l o c k e di n t h e . Replacethe intakerockerarms as an assemblyif
pushedout position. eitherdoes not work correctlt.
TIMI]TGPLATE
TIMII{GPLATE
TIMII{G
PLATE otL PASSAGE--il.
SPRII{G
PRIMARYROCKER SECO'{OAFY
ARM ROCKERARII
TIMINGSPRIIIIG RETURIT
SPRI G
SY CHRONIZING
PISTON
TIMINGPISTO
SECONDARY
ROCKERARM
1. Removethe specialtools.
After inspection,
checkthat the malfunctionindicator
lamp (MlL)does not comeon.
A|R PNESSURE $
PRIMARY
ROCKEBARM
TIMING
SYNCHRONIZI''IG
PISTON
TIMINGSPRING
6-9
I
VTECRockerArms
Using SpecialTools(D16Y8engine)
Inspection
CAUTION: 3. Removethe sealing bolt from the inspectionhole
. Before using the Valve Inspection Tool, make sure and connectthe ValveInspectionTool.
that the air pressuregauge on the air compressor
indicales over il00 kPa (4 kgt/cm,, 57 psi).
a Inspectthe valve clearancebelore rocker arm inspec.
tion, 1 0x 1 . 0m m
. Cover the timing belt with a shop towel to protect SEALINGBOI-T
20 N.ln 12.0kgt.m, 14 lbf.ft)
the belt.
. Checkthe intake primary rocker arm of each cylinder
at TDC.
NOTE:Referto page6-46when installingthe cylinder

neaocover.
Plugthe reliefholewith the specialtool.
Y ' TOOL
(Commercially
available)
. P u l l t h ed i a la n d
turn to adlust,
RELIEFHOLE
OTLAJ- PR3O2OB
\ q
6-10
4. Loosenthe regulatorvalve on the valve inspection Removethe specialtools.
tool and apply the specifiedair pressureto the rocker
arm synchronizingpistonAVB. 7. U s e a 1 0 m m d i a m e t e rr o d t o d e p r e s se a c h l o s t
motionassemblythroughits full movement.
SDecifiedAir Prsssure: Replaceany lost motion assemblythat does move
250 kPa {2.5 kgf/cm,. 36 psi) smoothly.
PRIMARY
ROCKER MIDROCKER SECONDARY
ARM ARM ROCKER
ARM
TIMING
PISTON
SYNCHRONIZING
SYNCHRONIZING
PISTON
A PISTON
B
Make sure that the intake primary and secondary
rockerarms are mechanicallyconnectedby the piston
and that the mid rockerarm does not move when
pushedmanually.
ASSEMBLY
After inspection,checkthat the MIL does not come

on.
lf any intakemid rockerarm moves independentlyof

the primary and secondaryrocker arms. replacethe
rockerarms as a set.
6-11
Valve Clearance
Adjustment \ {
NOTE: 5. Loosenthe locknut,and turn the adjustmentscrew

. V a l v e ss h o u l d b e a d j u s t e do n l y w h e n t h e c y l i n d e r until the feeler gauge slides back and forth with a
headtemperatureis lessthan 100"F(38"C). s l i g h ta m o u n to f d r a g .
. Alter adjusting,retorquethe crankshaftpulley bolt
(seepage6-16). D16Y7engine:
'1. Removethe cylinderheadcover. CAUTIONTDo not overtighten the locknuts; the

rockgrarms are madeol aluminum.
NOTE;RefertopageG46wheninstallingthe cylinder andExHAUST
INTAKE VALVE
neaocover. LOCKNUTS
18 N.m (1.8kgt m, 13 lbf.ftl
Removethe uppercover(seepage5-19).
"UP" mark on the cam-

Set the No. 1 pistonat TDC.
shaft pulleyshouldbe at top, and TDCmarksshould
align with the cylinderhead surface.
"UP" MARK
TOCMARKS
D16Y5, Dl6Yg engines:
INTAKEand EXHAUSTVALVE {
LOCKNUTS
20 N.m 12.0kgf.m, 14 lbnft)
4. Adiustvalveson No. 1 cylinder. Adiusting 3crew locations:

INTAKE
Intake: 0.18- 0.22mm 10.007- 0.009in) No.4 No,3 o.2
Exhaust:0.23- 0.27mm (0.009- 0.011inl
\ "/
t6 at^
o-tz
6. Tightenthe locknut,and checkthe clearanceagain. 8. R o t a t et h e c r a n k s h a f t1 8 0 " c o u n t e r c l o c k w i s teo
Repeatthe adjustmentif necessary. b r i n g N o . 4 p i s t o nt o T D C .B o t h T D C g r o o v e sa r e
onceagainvisible.Adjustvalveson No. 4 cylinder.
FEELER
GAUGE
7. Rotatethe crankshaft180"counterclockwise (cam- 9. Rotatethe crankshaft180"counterclockwise to bring

shaftpulleyturns 90").The "UP" mark shouldbe on No. 2 pistonto TDC.The "UP" mark should be on
the exhaustside.Adjustvalveson No. 3 cylinder. the intakeside.Adjustvalveson No. 2 cylinder.
.UP'MARK -UP" MARK
6-13
Valve Seals
Replacement(Cylinderhead removalnot required)
N O T E :C y l i n d e rh e a d r e m o v a li s n o t r e q u i r e di n t h i s lntake Valve Sealsi
procedure.
6, Selectthe 7/8 in diametershort compressorattach-
The procedureshown below applieswhen usingthe in- ment,and fastenthe attachmentto the No. 4 hole of
c a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h the leverarm with the speedpin supplied.
YA8845 2A7l8" attachment).
7. lnsertan air adaptorinto the sparkplug hole.Pump
Alway wear approved eye protection when air into the cylinderto keep the valve closedwhile
!@
usingthe in-carvalvespringcompressol. compressingspringsand removingthe valve keep-
ers.
'l
1. Turn the crankshaftso that the No. and the No. 4
pistonsare at top deadcenter(TDC). Positionthe lever arm underlhe crossshaft so the
leveris perpendicular to the shaftand the compres-
2. Removethe cylinderheadcoverand the rockerarm sor attachmentrests on top of the retainerfor the
assemoty. spring being compressed.Use the front position
slot on the leveras shown.
NOTE:
IN-CARSPRINGCOMPRESSOR
. R e f e rt o p a g e 6 3 0 f o r r o c k e r a r m a s s e m b l y
removal.
W h e n r e m o v i n go r i n s t a l l i n gt h e r o c k e ra r m
a s s e m b l yd, o n o t r e m o v et h e c a m s h a f th o l d e r
b o l t s .T h e b o l t s w i l l k e e pt h e h o l d e r s ,s p r i n g s
and rockerarmson the shaft.
Referto page 6-46 when installingthe cylinder
headcover.
3. Removethe fuel injectorsand the wire harness.
Uslngthe 8 mm bolts suppliedwith the tool, mount

t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
c a m s h a l th o l d e r s .T h e u p r i g h t sf i t o v e r t h e c a m -
shaftas shown.
N O T E : P u t s h o p t o w e l s o v e r t h e o a l p a s s a g e st o
prevent the valve keepers from falling into the cylin-
OIL PASSAGES
5. Insertthe cross shaft through the top hole of the

two uPflghts.
q
OIL PASSAGES
6- 1 4
L
J
9. Using a downward motion on the lever arm. com- 15, Using a downward motion on the lever arm, com-
pressthe valvespringand removethe keepersfrom pressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
sPring. spnng.
1 0 . Removethe valveseals(seepage6-38). 1 6 . Removethe valveseals(seepage6-38).
1 1 . Installthe valveseals(seepage6-43,. 1 7 . lnstallthevalveseals(seepage6-43).
1 2 . Installthe springs,the retainersand the keepersin 1 8 . Installthe springs,the retainersand the keepersin
reverseorderof removal. reverseorderof removal.
ExhaustValve Seals: 1 9 . Repeatsteps6 to 18 on the othercylinders,
t5. Selectthe 7/8 in. diametershort compressorattach-

ment,and fastenthe attachmentto the No.2 hole of
the leverarm with the speedpin supplied.
1 4 . Positionthe lever arm underthe crossshaft so the

leveris perpendicular to the shaftand the compres-
sor attachmentrests on top of the retainerfor the
spring being compressed.Use the front position
slot on the leveras shown.
N O T E :P u t s h o p t o w e l s o v e r t h e o i l p a s s a g e st o
preventthe valvekeepersfrom fallinginto the cylin-
der head.
IN.CABSPRINGCOMPRESSOR
7/8 in SHORTA
6-15
CrankshaftPulleyand PulleyBolt
Replacement
W h e n i n s t a l l i n ga n d tightening the pulley, follow the 1. Tightenthe pulleybolt to the specifiedtorque.
procedurebelow,
Torque: 20 N'm (2.0 kgf.m, 14 lbf.ftl
C l e a n ,r e m o v e a n y o i l , a n d l u b r i c a t ep o i n t s s h o w n
below. Use a felt tip pen to mark the pulley bolt head and
O: Clean wasner.
x: Removeany oil
a: Lub.icate
CRANKSHAFT
TIMINGBELT
GUIDEPLATE
Crankshaftpull€y bolt siz€ and torque value:

14 x 1.25mm
20 N.m (2.0 kgf'm. lil lbf'ft] + 90" EMBOSSINGMARKS
NOTE:Do not usean impactwrenchwhen installing.
3. Tightenthe pulleybolt an additional90'.

}IOI.DERHANDII
o'JAB- tD1020A
HOLDERATTACHMENT.50 mm
07 AB - 00100A
SOCKET,17 mm
o'JAA - @1010Aot
lComm.rcillly rv.ihbl.)
MARKING
\
t^ at^
o-to
L-
Timing Belt
lllustrated Index
NOTE:
. Referto page6-20for howto positionthecrankshaft
andpulleybeforeinstalling
the belt.
. Mark the direction of rotation on the belt before removing.
a Do not use the upper cover and lower cover for storing removed items.
. Clean the upper cover and lower cover before installing.
. Replacethe camshaft seals and crankshaft seals if there is oil leakage.
. Referto page 6-16 before installing the timing belt.
CYLINDERHEAD
COVER
Referto page6 46
when installing.
HEADCOVERGASKET
Replace when leaking,
damagedor deterioraled.
Applyliquidgasketat
the tour cornersof the
recesses.
TIMINGBELT 8 x 1.25mm
Inspectaon,page6-18 37 N.m (3.8 kg{.m.27 lbf.ftl
@y Adjustment,page6-18 Applyengineoil to the bolt
Removal,page6-19 threads.
@ page6,20
lnstaliation,
CRANKSHAFTSPEEDFLUCTUATION
ICKF)SENSOR
page6'22
Replacement,
UPPER
COVER
6x1.0mm
9.8 N.m 11.0kgf.m,
1.2 tbl.trl
RUBAERSEALS
Replace when damaged
or deterioratod.
LOWERCOVER
RUBBER
PLUG
CRANKSHAFTPULIEY
page6-16
Replacement,
PULLEYBOLT
1a x 1.25mm
20 N.m {2.0kgl.m,
lia lbf.ft) + 90'
Replacement, page6-16
Do not use an impact
TIMINGBELT wranchwhen installing.
DRIVEPULLEY
page6-16
Replacement, 6x1.0mm
O.RING 6 x 1 . 0 m m 9.8 N.m ll.0 kgf.m,
10r 1.25mm Replace.1 2 N m 1 1 . 2 k g l ' m , 7.2 tbtftt
4,1N.m {4.5 kgf.m, 33 lbtft) 8.7 lbf.ftl
6-17
Timing Belt
Inspection TensionAdjustment
1 . Removethe cylinderheadcover. CAUTION: Always adiust the timing belt tension wiih
th€ engine cold.
. Referto page6-46when installing.
NOTE:
Removethe rtppercover(seepage6-19). . The tensioneris spring-loaded to applytensionto the
belt automaticallyafter makingthe following adjust-
? Inspectthe timing belt for cracksand oil or coolant menr.
soaking. . Alwavs rotatethe crankshaftcounterclockwise when
v i e w e df r o m t h e p u l l e ys i d e .R o t a t i n gi t c l o c k w i s e
NOTE: may result in improper adjustmentof the belt ten-
. Replacethe belt if oil or coolantsoaked. sion.
. Removeany oil or solventthat gets on the belt. . Inspectthe timing belt beforeadjustingthe belt ten-
ston.
1 . Removethe cylinderheadcover,
. Referto page6-46when instslling.
Removethe uppercover(seepage6-19).
Rotatethe crankshaftfive or six revolutionsto set

the belt.
4. Setthe No. 1 pistonat TDC(seepage6-2'1).
5. Loosenthe adjustingbolt 180'.
ADJUSTINGBOLT
44 N.m {4.5kgf m,
33 tbtft)
Rotatepulley
and inspectbelt.
After inspecting,retorque the crankshaftpulley bolt

(seepage6-16).
Rotatethe crankshaftcounterclockwise
three teeth
on the camshaftpulley.
7. Tightenthe adjustingbolt.
\
After inspecting,retorquethe crankshaftpulleybolt
(seepage6-16).
Removal
NOTE: 5. Removethe dipstick,then removethe upper cover
. Replacethe timing belt at 105.000miles{168,000km) and idler pulleybracket.
accordingto the maintenanceschedule(normalcon-
ditions/severe condition). NOTE: Do not use the upper cover to store removed
lf the vehicleregularyis driven in one or more of the |tems.
followingconditions,replaceth€ timing belt at 60,000
miles(U.S.A.)100,000km (Canada). UPPERCOVER
. In very high temperatures(over110'F,43"C).
. In very low temperatures{under-20"F,-29"C). 6x1.0mm
9.8N.m {1.0kgf.m,
. Turn the crankshaftpulley so the No. 1 piston is at 7.2
top dead center(TDC)beforeremovingthe belt (see
p a g e6 - 2 1 ) .
. Inspectthe water pump before installingthe timing
belt {seepage10-12).
1 . Removethe splashshield(seepage5-7).
Loosenthe mountingbolt and lockbolt.then remove

the powe.steering(P/Slpump beltand pump.
IDLER 8 x 1.25mm
MOUNTINGEOLT 24 N.m l2.il kgf.m. 17 lbf.ft)
8 x 'l.25mm BRACKET
24 N m {2.4 kgf.m, 17 lbt.ft)
6. Removethe upperbracket(seepage6-29).
NOTE:
. Usea jackto supponthe enginebeforethe upper
bracketis removed.
a Make sure to place a cushion between the oil
pan and the jack.
P/S PUMP 7. Removethe crankshaftpulley(seepage6-'16).

BELT
8. Removethe lower coverand dipstickpipe.
8 x 1.25mm NOTE: Do not use the lower cover to store removed

24N.m(2.4kgfm, 17lbnftl tems.
L o o s e nt h e i d l e r p u l l e yc e n t e rn u t a n d a d j u s t i n g
bolt, then remove the air conditioning(A,/C)com- LOWER
pressorbelt (seepage 5-6).
Loosenthe mountingnut and lockbolt,then remove

the alternatorbelt.
ALTERNATOR LOCKBOLT
BELT 8 x 1.25mm
2ir N.m 12.4kgt.m,
17 tbt.ft)
5xl.0mm
9.8Nm(1.0kgf.m.
7.2 tbt.ftl
MOUNTINGNUT (cont'd)
10 x 'l.25mm
44 N.m (4.5ksf.m,
33 tbtft)
6-19
Timing Belt
Removal(cont'dl Installation 'i
9. Removethe CKFsensorfrom the oil oumo. Installthe timing belt in the reverseorderof removal;
Only key pointsare describedhere.
1. Set the timing belt drive pulleyso that the No. 1 pis-
ton is at top deadcenter(TDC).Align the grooveon
the timing belt drive pulleyto the pointeron the oil
oumo.
TDCMABK FOINTER
12 N.m lr.2 kglm,

8.7 tbt.trl
TIMING BELT KEY

1 0 . Loosenthe adjustingbolt 180".Pushthe tensioner ORIVEPULLEY
Clean.
t o r e m o v e t e n s i o n f r o m t h e t i m i n g b el t , t h e n
retightenthe adjustingbolt. 2. Set the camshaft pulley to TDC. Align the TDC
marks on the camshaft pulley to the cylinder head
surface.
ADJUSTINGBOLT
+l N.m 14.5kgl.m,
33 tbtftt
11. Removethe timing belt.

a 3. Installthe timing belttightly in the sequenceshown. 9. Checkthat the crankshaftpulley and camshaftpul-
oTiming belt drive pulley(crankshaft) j@Adjusting ley are both at TDC.
pulley-)@Waterpump pulley'-r@Camshaft pulley.
CRANKSHAFTPULLEY:
N O T E :M a k es u r et h e t i m i n g b e l t d r i v e p u l l e ya n d
camshaftDullevare at TDC.
(WHITEI
CAMSHAFTPULLEY:
"UP" MARK
Loosenand retightenthe adjustingbolt to tension
the timing belt.
Installthelowercoverand uppercover.
N O T E :C l e a nt h e u p p e r a n d l o w e r c o v e r sb e f o r e
installation.
6. Installthe crankshaftpulley,then tightenthe pulley

bolt (seepage6-16).
7. Rotatethe crankshaftpulley about five or sjx turns

counterclockwiseso that the timing belt positions TOC MARK
on the pulleys.
Adjustthe timing belt tension(seepage6-18). '10. l f t h e c a m s h a f to r c r a n k s h a f p

t ulleyis not posi-
tioned at TDC, remove the timing belt and adjust
the positionfollowingthe procedureon page 6-20.
Then reinstallthe timing belt.
' It . After installation,

adjustthe tensionof eachbelt.
. See section23 for alternatorbelt tensionadjust-

ment.
. See section22 fot NC compressorbelt tension
adJustment.
. Seesection 17for P/Spump belt tensionadjust-
ment.
6-21
CrankshaftSpeedFluctuation
(CKF)Sensor
Replacement
NOTE:Referto page6 46 when installing.
Removethe crankshaftpulley(seepage6 16).
R e m o v et h e u p p e r c o v e r a n d d i p s t i c k / p i p e( s e e
p a g e6 1 9 ) .
R e m o v et h e l o w e r c o v e r a n d i d l e r p u l l e yb r a c k e t
(seepage6-19).
Disconnectthe CKFsensorconnector,then remove

the CKFsensor.
CKFSENSOR
CONNECTOR
CKFSENSOR 6x1.0mm
12 N.m {'1.2kgf.m,
8.7 tbtftl
6. InstalltheCKFsensorin reverseorderof removal.
6-22
CylinderHead
lllustratedIndex
CAUTION:
. To avoid damage, wait until the engine coolant temperature drops below 100"F138'Clbetore removing the cylinder
head.
. When handling a metal gaskel, take care not to told it or damagethe contact surface.
NOTE:Usenew O-ringsand gasketswhen reassembling.
6x1.0mm
9.6 N.m (1.0kgf.m,7.2lbtft)
WASHER Applysoapsuds to threadsand cylinderhead
Replace when damaged contactsurfacewhen replacingthe rubber
or deteriorated. seal,then remove any soapsudsafter install-
ing rubberseal.
CYLINDERHEAO
COVEB RUBBERSEAI.
Beferto page6-46,when Replacewhen damaged
installingcylinderheadcover. or deteriorated.
CYLINDERHEADBOLT
10 x 1:25mm
67 N.m 16.8kgt.m, a9 lbf.ftl
Tightening,page&46
HEADCOVERGASKET Applyongin6oilto the threads.
Replace when leaking,
damagedor det6riorated.
Apply liquidgasketat
the four cornersofthe
recesses.
OISTRIBUTOR
Seesection23.
CYLINDER
HEAD
8 x 1.25 mm CYLINDER HEAD

24 N.m {2.4 kqf.m, GASKET
17 tbf.ftl Replace.
8 x 1.25mm
24 N.m (2.,0kgf.m, 17 lbfft)
OOWEL
PINS
{cont'd)
6-23
Cylinder Head
lllustratedIndex(cont'dl
Priorto.reassembling,
cleanall the partsin solvent,dry them and applylubricantto any contactparts.
D16Y7engine:
I x 1 . 2 5m m
20 N.m 12.0kgf.m, 14 lbf.ftl
Applyengineoil 10the
ROCKER ARM
ASSEMELY
Bemoval,page6-30 6x1.0mm
page6-35
Inspection, 12 N.m (1.2kgf.m, 8.7 lbf.ft)
Applyengineoil to the
threaos.
VALVEKEEPERS
c" B
AKE VALVE
SPRING
OIL CONTROL
ORIFICE AKEVALVESEAL
Clean. Replace-
VALVESPRING
O-RING SEAT
Replace. INTAKEVALVE
GUIDE
VALVEKEEPERS
SPRINGRET
EXHAUSTVAL
SPRING
EXHAUSTVALVE
SEAL
Replace. 8 x 1.25mm
37 N.m (3.8kgtm,
VALVESPRING 27 tbt.ftl
SEAT Applyengineoil to
the threads.
EXHAUSTVALVE
GUIDE
page6-39
Inspection,
Replacement,page6-41
Reaming,page6,43
EXHAUST Removal,page6 27
VALVE Warpage,page 6-40
INTAKEVALVE Valveseatreconditioning,
page 6-40
Removal,page6-38
page6-43 page6 45
Installation,
Installation,
, 6-24
D16Y5engine:
8 x 1.25mm
20 N.m 12.0kg{.m, 14 lbf.ft)
Apply engineoilto the
threads,
ROCKERARM
ASSEMBLY 6x1.0mm
Removal,page6-30 12 N.m {1.2kgf.m.8.7 lbf.ftl
page6-34
Inspection, Apply engineoilto the
threads,
CAMSHAFT
Inspection, page6-36 VALVEKEEPERS
6x1.0mm
12 N.m 11.2
8.7 rbt.ftl SPBINGRETAINER
wEc solENoro INTAKEVALVE

VALVE SPRING
INTAKEVALVESEAL
Replace.
VALVESPRING
SEAT
INTAKEVALVE
VTECSOLENOID GUIDE
VALVEFILTER CAMSHAFT
Replace. PULLEY
OIL CONTROL
ORIFICE
Clean.
VALVEKEEPERS
SPRINGRETAINER
EXHAUSTV
SPRING
EXHAUSTVALVE 8 x 1.25mm
SEAL 37 N.m 13.8kgf.m,
Beolace.
' 27 lbl-ltl
VALVE Replace. Applyengineoilto
SEAT the threads.
GUIDE
page6 39
Inspection,
Reaming,page6-43
EXHAUST OIL SEAL
VALVE Replace.
INTAKEVALVE HEAD
Removal,page6-38 Removal,page6'27
page6-43
Installation, Warpage,page6-40
Valveseatreconditioning,
page 6-40
page6-45
Installation,
(cont'd)
6-25
CylinderHead
lllustrated Index (cont'd)
'E Priorto reassembling,
creanallthe partsin sorvent,dry them and apply rubricantto any contactparts.
D16Y8engine:
I x 1.25mm
2 0 N . m { 2 . 0k g f . m , 1 4 l b f f t l
LOSTMOTION Apply engine oil to the
ASSEMBLY threads.
6x1.0mm
12 N,m 11.2kgf m, 8.7 lbl ft)
Applyengineoil to the
threads.
ROCKERARM
ASSEMBLY
Bemoval,page6 30
Inspection,
page6-34
CAMSHAFT
lnspection,
page6 36
6x1.0mm
12 N.m (1.2
8,7 tbf.fil
VAI-VEKEEPERS
SPRINGRETAINEF
"E
F
INTAKEVALVE
SPRING
INTAKEVALVESEAL
Replace.
WEC SOLENOID VALVESPRING
VALVEFILTER SEAT
Replace. \$
INTAKEVALVE
GUIOE
OIL CONTROL
ORIFICE
Clean.
VALVEKEEPERS
SPRINGRET
EXHAUSTVALVE
SPRING
@
EXHAUSTVALVE
SEAL
Replace.
EXHAUSTVALVE O-R|NG 8 x 1.25mm
cUtDE Reptace 37 N.m 13.8kgtm.
lnspection,
page6-39 21 tbt.ftl
Replacement,page6-41 A p p l ye n g i n eo i l t o
Reaming,page6-43 the threads_
otL
Replace.
INTA(E VALVE EXHAUST CYLINDERHEAD

Removal,page6 38 VALVE Removal,page6-27
Installation,
page6,43 Warpage,page6 40
Valveseatreconditioning,
page6'40
lnsta,'ation,page6-45
6-26
Removal
Engineremovalis not requiredfor this procedure. 8. Removethe throttlecableby looseningthe locknut,
then slip the cableend out of the throttlelinkage.
@ Make surs lacks and safety stands are
placed properly and hoist brackets are aftached to the NOTE:
corrcct positions on ihe engins, . Takecarenot to bendthe cablewhen removingit.
Alwaysreplaceany kinkedcablewith a new one.
CAUTION: . Adjustthe throftlecablewhen installing(seesec-
. Uso fonder covers lo avoid damaging painted sur- tion11).
facss.
. Unplug the wiring conneqtorscarefully while holding D16Y7engine:
th9 conngctol portion to avoid damage.
. To avoid damaging the cylinder head, wait until the
e n g i n e c o o l a n l t e m p o r a t u r od r o p s b e l o w 1 0 0 ' F LOCKNUT
(38"G)before looseningthe retaining bolts,
NOTE:
o Mark all wiring and hoses to avoid misconnection.
Also. be surethat they do not contactother wiring or
hoses.or interferewith other parts.
. Inspectthe timing belt before removingthe cylinder
head.
. Turnthe crankshaft pulleyso thatthe No. 1 pistonis at
top deadcenter(seepage6-21).
L Disconnect
the negativeterminalfrom the battery.
Drainthe enginecoolant(seepage10-6).
. Removethe radiatorcapto speeddraining.
Removethe intakeair duct and air cleanerhousing

(seepage5-3).
R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t , t h e n
remove the power steering (P/S) pump belt and
pump (seepage5-5).
L o o s e nt h e i d l e r p u l l e y c e n t e rn u t a n d a d j u s t i n g
bolt, then remove the air conditioning{Ay'C) com-
pressorbelt (seepage5-6).
L o o s e nt h e m o u n t i n g n u t a n d l o c k b o l t . t h e n
removethe alternatorbelt (seepage6-19).
7. Removethe P/Spump bracket{seepage5-12).
{cont'd)
6-27
CylinderHead
Removal(cont'dl
\
9. Relievefuel pressure(seesectionl1). 11. Removethe brakeboostervacuumhose,fuel return
hoseand vacuumhose(seepage5-4).
E@ Do not smokewhile working on the fuel
systgm. Keep op€n flame or 3park away from th9 12. Removethe water bypasshose and positivecrank-
work area. Drain tuel only into an approved containgr. caseventilation(PCV)hose.
10. Removethe evaporativeemission (EVAP)control D16Y7engine:

canisterhose,fuel feed hoseand breatherhose.
WATEBBYPASS
D16Y7engine:
BANJOBOLT
33 N.m{3.4kgf.m,
25tbtftl
BREAIHERHOSE
D15Y5, D16Y8 engines:
BANJO BOLT
33 N.m 13.4kgf.m, PCVHOSE
2s tbf.ft)
6-28
1 3 . R e m o v e t h e u p p e r radiatorhose, heater hose and 1 5 . R e m o v et h e s p a r kp l u g c a p sa n d d i s t r i b u t ofrr o m
water bypass hose. the cylinderhead.
16. Removethe upperbracket.

WATER
BYPASS
HOSE NOTE:
UPPER . U s e a j a c k t o s u p p o r tt h e e n g i n eb e f o r et h e
RADIATOR upperbracketis removed.
HOSE . M a k e s u r e t o p l a c ea c u s h i o nb e t w e e nt h e o i l
pan and the jack.
12x 1.25fim
7{ N.m (7.5kgt m,
54 tbf.ftl
UPPER
BRACKET
HEATER
HOSE
1 4 . R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r s
and
wire harnessclampsfrom the cylinderheadand the
intakemanitold.
a Fourfuel injectorconnectors
a E n g i n ec o o l a n tt e m p e r a t u r e( E C T )s e n s o rc o n - 17. Removethe cylinderheadcover.
nector
a ECTswitchconnector
a ECTgaugesendingunit connector
a Throttlepositionsensorconnector
M a n i f o l da b s o l u t ep r e s s u r e( M A P )s e n s o rc o n
nector
P r i m a r yh e a t e do x y g e ns e n s o r( p r i m a r yH O 2 S )
connector
S e c o n d a r yh e a t e do x y g e n s e n s o r ( s e c o n d a r y
HO2S)connector(D16Y7engine)
Exhaustgas recirculation(EGR)valve lift sensor
connector(D16Y5engine)
VTECsolenoid valve connector(Dl6Y5, D16Y8
engrnes)
VTECpressureswitch connector(D16Y5,D16Y8
engrnes,
ldle air control(lAC)valveconnector
(cont'd)
6-29
',l
CylinderHead RockerArms
Removal(cont'd) Removal \
1 8 . Removethe timing belt (seepage6-19). 1. Loosenthe adjustingscrews.
1 9 . Removethe camshaftpulleyand backcover. ADJUSTINGSCREWS
CAMSHAFT
PULLEY
Cleanwhen installing.
8 x 1.25mm
6xl.0mm 37 N.m {3.8kgf.m,
2't tbftr)
f:,f'In:J$::'"''n"
2. Unscrewthe camshaft holder bolts, then remove
20. Removethe exhaustmanifold(seepages9-5and9-6). the rockerarm assembly.
21. Removethe intakemanifold(seepages9-2thru 4). NOTE:

. Unscrewthe camshaftholderboltstwo turns at a
22. Removethe cylinder head bolts, then removethe time, in a crisscrosspattern,to preventdamag
c y l i n d e hr e a d . ing the valvesor rockerarm assembly.
. When removingthe rockerarm assembly,do not
CAUTION:To prev€nt warpage, unscrew the bolts removethe camshaftholderbolts.The bolts will
in sequencel/3 turn at a time; repeat the sequence keep the camshaftholders,the springsand the
until allbolts are loossned. rockerarms on the shaft.
CYLINDERHEADBOLTSLOOSENINGSEOUENCE: CAMSHAFTHOLDERSOLTSLOOSENING
SEOUENCE:
6-30
Disassembly/Reassembly
NOTE:
. ldentifypartsas they are removedto ensurereinstallation
in originallocations.
. Inspectrockershaftsand rockerarms (seepage6-35).
. Rockerarms must be installedin the samepositionif reused.
. When removingor installingtherockerarmassembly,do not removethecamshaftholderbolts.The boltswill keepthe
holders,springsand rockerarmson the shaft.
cleanall the partsin solvent,dry them and apply lubricantto any contactpoints.
Priorto reassembling,
INTAKE ROCKER INTAKEROCKER
D16Y7 engine: ARM B ARMA
(4 pl.corl
la pl.c$l
INTAKEROCKER
Letter "8" is stamped
on rockerarm. II
i
ROCKERSHAFT
COLLAR
14placesl
B A \ " A
ofrdT*,.\ft
ffi*
"' r' lJll--
t.l G t I
No.3CAMSHAFT| | No.2CAMSHAFTIl
HoLDER Lal HoLDER _
I ru
t
[6] i
; n] [n, ,d"h] H
UTU
" l ^
\d*hl a A B
R(rcKERSHAFT
SPRING
(4 plac.Bl
(cont'd)
6-31
RockerArms
(cont'd)
\
NOTE:
. ldentifypansastheyareremoved to ensurereinstallation
in originallocations.
. Inspectrockershaftsandrockerarms(seepage6-34).
. Rockerarms must be installedin the same positionif reused.
. When removingor installingthe rockerarm assembly,do not removethe camshaftholderbolts.The boltswill keepthe
holders,springsand rockerarms on the shaft.
/E P r i o r t or e a s s e m b l i ncgl ,e a na l l t h e p a r t si n s o l v e n td, r y t h e ma n da p p l yl u b r i c a n t t oa n yc o n t a cpt o i n t s .
INTAKE SHAFT
ROCKER
D16Y5engine:
ROCKERARMS
ROCKERSHAFT
COLLAR
No. 5 CAMSHAFT
HOLOER
[u
Hlw
€ l'l
EXHAUSTROCKER I EXHAUST
ARM 8
{4 placesl I
IR SHAFT
ROCKERARM A
14placesl
EXHAUSTROCKERSHAFT
Letter"8" is stamped Letter "A" is stamped

on rockerarm.
6-32
D16Y8engine:
INTAKEROCKERSHAFT
ROCKERSHAFT
COLLAB
INTAK€
ROCKERARMS BOCKERARM
ASSEMBLY
"o,_.-o" RUBBERAAND
/ coLLAR
,mil
\
fla tre /
H+nllf{
-
lu!4u 0lluIJllt
LF
Etue t rs,urtg
]
I
J l-
,fxll^\
rvni<
No. 4 CAMSHAFT No. 3 CAMSHAFT No. 2 CAMSHAFT NO,1 CAMSHNFT
HI I
HOLDER HOLDEB HOLDER H.LDER
r-{W
l-t -
fll
l-Jf )rJfiF
I
FOCKEBSHAFT
SPRING
(4 place3)
t v t
\
€XHAUST
ARM B ROCKEBA8M
-.\ {4 placesl
EXHAUSTROCKERSHAFT
"B" "A"
Letter is stamped Letter is stamped
6-33
RockerArms and Lost Motion Assemblies
(D16Y5,
Inspection D16Y8enginesl \. \
N O T E :W h e n r e a s s e m b l i n gt h e p r i m a r y r o c k e ra r m , D16Y5engine:
c a r e f u l l ya p p l y a i r p r e s s u r et o t h e o i l p a s s a g eo f t h e
rockerarm. NOTE:Set the timing plate and returnspring as shown
1. Inspectthe rockerarm piston.Pushit manually.

- lf it does not move smoothly,replacethe rocker
arm assemory. RETURN
D16Y5engine:
PRIMARYROCKERARM
TIMINGPISTON
TIMI G SPRING
SYNCHRO ENG
PISTOI{
CAMSHAFTHOI.DER
D16Y8engine:
.{
2. Removethe lost motion assemblyfrom the holder
and inspectit. Test it by pushingthe plungerwith
your finger.
- l f t h e l o s t m o t i o n a s s e m b l yp l u n g e rd o e s n o t
move smoothly,replaceit.
MIOROCKEBARM
Pu!h
PRIMARYROCKER t LOSTMOTONASSEMBLY
sYt{cHRof$ztlrlc
PISTONA
NOTE:
. Apply ojlto the pistonswhen reassembling.
a Bundlethe rockerarms with a band to preventthem {
from separating.
6-34
RockerArms and Shafts
lnspection
Clearance
Measureboth the intakerockershaft and exhaustrocker 3. Measurethe insidediameterof the rockerarm and
shaft. checkfor an out-of-roundcondition.
1. Measurethe diameterof the shaftat the first rocke. RockerArm-to-Shaft Clearance:

tocauon. Standard lNew):
Intake: 0.017- 0.050mm
(0.0007- 0.0020in)
-
Exhaust: 0.018 0.054mm
(0.0007- 0.0021in)
ServiceLimit:0.08mm (0.003in)
2. Zerothe gaugeto the shaftdiameter.
Inspectrockerarm
Reoeatthesemeasurements on all the rockers.

- lf the clearanceis overthe servicelimit, replacethe
rockershaftand all overtolerancerockerarms.
6-35
r,
Camshaft
Inspection 'u
NOTE: Seatthe camshaftby pushingit toward the rear of
. Do not rotatethe camshaftduring inspection. the cylinderhead.
. Removethe rockerarms and rockershafts.
Zerothe dial indicatoragainstthe end ofthe camshaft.
L Put the camshaftand the camshaftholderson the Push the camshaftback and forth, and .ead the end
cylinderhead,then tightenthe boltsto the specified olav.
torque.
Camshaft End Play:
Spocifiodtorqu€: Standard{New):0.05- 0.15mm
8 mm bolts: 20 N.m 12.0kgf.m 14 lbf'ft) (0.002- 0.006in)
Apply engine oil to the threads. ServiceLimit: 0.5 mm (0.02in)
6 mm bolts: 12 N.m (1.2 kgf.m 8.7 lbf.ft)
Apply engine oil to the th.eads.
6 mm bolts:@, @ @, @
.g
Removethe bolts.then removethe camshafthold-

ers from the cvlinderhead.
- Lift the camshaftout of the cylinderhead,wipe it
clean. then inspect the lift ramps, Replacethe
c a m s h a f ti f a n y l o b e s a r e p i t t e d . s c o r € d ,o r
excesslvely worn.
- Cleanthe camshaftbearingsurfacesin the cylin-
der head,then set the camshaftbackin place.
- Placea plastigagestrip acrosseachjournal.
Installthe camshaftholders,and tightenthe boltsto

the soecifiedtorque.
6-36
6. Remove the camshaft holders,then measurethe 8. Checkthe cam lobe heightwear.
widestportionof the plastigageon eachjournal.
Cam lobe heightstandard{New)
U n i tm m ( i n )
Camshaft-to-HolderOil Cloarance:
Standard {New}:0.050- 0.089mm INTAKE EXHAUST
{0.002- 0'004 in) D 16Y7engine 35.299{1.3897) 37.281(1.4678)
SorviceLimit: 0.15mm (0.006in)
D16Y5 PRI 3 8 . 4 2 7( 1 . 5 1 2 9 )
38.784(1.5269)
engine sEc 32.193\1.2674l
PRI 36.77411.44191
D16Y8
MID 38.274(1.5068) 38.008(1.4964)
engrne
37.065(1.45921
PRI:Primarycam lobe,SEC:Secondarycam lobe.
MID:Mid cam lobe,T/B:Timing belt.
lN: Intake,EX:Exhaust
PRIMIDSEC
7. lf the camshaft-to-holder oil clearanceis out of tol-

EX tN EX
erance: ,/a IIB
- A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d , + Dl6YS engine - D16Y8engine
you must replacethe cylinderhead,
- lf the camshafthas not beenreplaced,first check
the total runout with the camshaftsuDDortedon
V-blocks.
CamshaftToial Runout:
Standard {N€w): 0.03 mm {0.001in) max.
ServiceLimit: 0.0,t mm {0.002in)
C h e c kt h i s a r e a f o r w e a r .
Botatecamshaft
while measuring.
- lf the total runout of the camshaitis within toler-

ance,replacethe cylinderhead.
- lf the total runout is out of tolerance,replacethe
camshaftand recheck.lf the bearingclearanceis
still out of tolerance,replacethe cylinderhead,
6-37
Valves,ValveSpringsand lalve Seals
Removal
N O T E :l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e 3. Installthe valveguidesealremover.
removedso that eachitem can be reinstalledin its origi-
nal position.
SEAL REMOVER VALVEGUIDESEALREMOVER
1. socketand plasticmal- LISLEP/N 57900or KD3350
Using an appropriate-sized available)
let, lightlytap the valve retainerto loosenthe valve
keepersbeforeinstallingthe valve spring compres-
sor.
PLASTICIIIALLET
VALVE SEAL
SOCKET \
4. Remove the valve seal.
Installthe spring compressor.Compressthe spring
and .emovethe valvekeeper.
VALVE SPRINGCOMPRCSSOR
SnlD-on CF7'lI or KD-383
rYlth t32 JAWS
6-3 8
ValveGuides
ValveMovement
Measurethe guide-to-stemclearancewith a dial indi-
cator while rockingthe stem in the directionof normal
thrust (wobblemethod).
Intake Vslve Stem-to-GuideClearance:

Standard{Newl: 0.04- 0.10mm
(0.002- 0.004in)
ServiceLimh: 0.16mm {0.006inl
ExhaustValve Stem-to-GuideCl€arance:
StandardlNewl: 0.10- 0.16mm
(0.00i1- 0.fi)6 in)
ServiceLimit: 0.22 mm {0.009inl
Valveextended10 mm out from seat.
Intake Valve Dimensions

A Standard(New): 29.9- 30.1mm
{ 1 . 1 8- 1 . 1 9i n l
B Standard lNewl: 117.Q.- 117.72mm
(4.623- il.635 in)
C Standard {NBw): 5.'18- 5.49 mm .:I
10.2157 - 0.2161in)
C ServiceLimit: 5.,t5mm {0.2146in}
D Standard (New): 0.85- 1.15mm
{0.033- 0.045inl
D ServiceLimil: 0.65 mm (0.026inl
ExhaustValveDimensions
. l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t .
A St8ndard(Newl: 25.9- 26.1mm
recheckusinga new valve.
(1.02- 1.03inl
l f t h e m e a s u r e m e nits n o w w i t h i n t h e s e r v i c e
B Standsrd lNew): 114.60- 114.90mm
limit,reassembleusinga new valve.
14.512- 4.521in1
l f t h e m e a s u r e m e n st t i l l e x c e e d sr h e l i m i t .
C Standard {Newl: 5.45- 5.'16mm
(0.2146- 0.2150inl recheckusing the alternatemethod below. then
replacethe valveand guide,if necessary.
C ServiceLimit: 5.42mm 10.213,[ in]
D Standard (New): 1.05- 1.35mm
NOTE:An alternatemethod of checkingguide to
l0.0il1- 0.053inl
stem clearanceis to subtractthe O.D.of the valve
D ServiceLimit: 0.95mm (0.037in)
stem, measuredwith a micrometer,from the l.D.of
the valve guide, measuredwlth an inside
micrometeror ball gauge.Takethe measurements
i n t h r e e p l a c e sa l o n g t h e v a l v e s t e m a n d t h r e e
places inside the valve guide. The differencebe-
t w e e n t h e I a r g e s tg u i d e m e a s u r e m e n ta n d t h e
smalleststem measurementshould not exceedthe
servicelimit,
Int8ke Valve Stem-to-GuideClearancs:

Standard (Nsw): 0.02- 0.05 mm
{0.001- 0.002inl
ServiceLimit: 0.08 mm 10.003in)
ExhaustValve Stem-to-GuideClearance:
Standard (New): 0.05- 0.08 mm
(0.002- 0.003inl
ServiceLimit 0.11mm 10.004 in)
6-39
GylinderHead ValveSeats
Warpage Reconditioning
N O T E : l f t h e c a m s h a f t - t o - h o l d eori l c l e a r a n c e s( s e e 1. Renewthe valve seatsin the cylinderhead using a
page6-36)are not within specification, the cylinderhead valveseatcuner.
cannotbe resurfaced.
NOTE: lf the guides are worn (seepage 6-39),
lf the camshaft-to-holder
oil clearances
are within sDeci- r e p l a c et h e m ( s e e p a g e 6 - 4 1 )b e f o r e c u t t i n g t h e
fications.checkthe cylinderheadfor warpage. valveseats.
lf warpageis lessthan 0.05 mm (0.002in), cylin- VALVESEAT

der headresurfacingis not required. CUTTER
lf warpage is between 0.05 mm (0.002in) and available)
lCommercially
0.2 mm (0.008in), resurfacethe cylinderhead.
M a x i m u m r e s u r i a c el i m i t i s 0 . 2 m m ( 0 . 0 0 8i n )
basedon a heightot 93 mm (3.66inl.
o --\
.,o
:-e>
s
/-.\O
C a r e f u l l yc u t a 4 5 " s e a t , r e m o v i n g o n l y e n o u g h
materialtoensurea smoothand concentricseat,
3. Bevelthe upperedge of the seatwith the 30'cutter

and the lower edge of the seatwith the 60' cutter.
Checkthe width of the seatand adjustaccordingly.
Make one more very light passwith the 45" cutter to

removeany possibleburrs causedby the other cut-
ters.
Valv€ Seat Width:

Standard lNow):
Intake: 0.85- 1.15mm 10.033- 0.0,15in)
Exhaust 1.25- 1.55mm (0.0/l!'- 0.061in)
ServiceLimit:
Measurealongedges,and threeways acrosscenter. Intake: 1.6 mm {0.06i1inl
Exhaust: 2.0 mm {0.079in)
Cylinder Head Height:

Standard {Nowl: 92.95- 93.05mm
(3.669- 3.66i1inl
5. After resurfacingthe seat, inspectfor even valve
s e a t i n g :A p p l y P r u s s i a nB l u e c o m p o u n dt o t h e
valve face, and insertthe valve in its originalloca
tion in the head,then lift and snap it closedagainst
the seatseveraltimes.
6-40
ValveGuides
Replacement
1. As illustratedbelow, use a commercially-available
air-impactvalve guide driver attachmentmodified
to fit the diameter of the valve guides.In most cases,
the same procedurecan be done using the special
VALVE tool and a conventionalhammer.
SEAT
VALVEGUIDEDRIVER
(Commercially
available)
PRUSSIANBLUECOMPOUND 5.3 mm
The actualvalve seatingsurface,as shown by the
bluecompound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve steml, you
tr_r
!
must make a second cut with the 60" cutter to
move it down, then one more cut with the 45"
cutter to restoreseat width.
t- 87 mm -]+-
13.43inl |
s7 mm
i'2,24 inl 1 O . 8m m
I . lf it is too low (closer to the valve edge), you

must make a second cut with the 30'cuuer to or
10.42inl
move it up, then one more cut with the 45'cutter VALVEGUIDEDRlVEn,5.5 mm
to restoreseat width. 077i+2- 0010100
NOTE:The final cut shouldalwavsbe madewith Selectthe properreplacement guides.and chillthem

the 45' cutter. in the freezer section of a refrigerator for about an
hour.
7. Insertthe intakeand exhaustvalvesin the headand
measurethe valvestem installedheioht. Use a hot plate or oven to evenlyheatthe cylinder
headto 300'F(150'C).Monitorthe temperaturewith
Intako. ExhaustStem Installed Height: a cookingthermometer.
Standard{Newl: 53.17- 53.6i1mm
12.W3- 2.112inl
ServiceLimh: 53.89mm (2.122in)
lf the valvestem installedheight is over the service

limit, replacethe valve and recheck.lf its still over
t h e s e r v i c el i m i t , r e p l a c et h e c y l i n d e r h e a d ;t h e
valveseat in the headis too deeD.
CAUTION:
. Do nol use a torch; it may warp the head.
Do not gst the head hottor than 300'F (150'C);
excessivehaai may looson the valvc seats.
To avoid burns, use heavy gloves when handling
the heatod cylinder hoad.
(cont'd)
6-41
ValveGuides
Replacement(cont'd)
Workingfrom the camshaftside.use the driver and 7. Apply a thin coat of clean engineoil to the outside
an air hammerto drivethe guideabout2 mm {0.1in} of the new valve guide. Installthe guide from the
towards the combustionchamber.This will knockoff camshaftside of the head; use the specialtool to
someoJthe carbonand makeremovaleasier. drivethe guide in to the specifiedinstalledheight.lf
you haveall 16guidesto do, you may haveto reheat
GAUTION: the head,
. Always wear safety gogglesot a tacs shieldwhon
driving valve guides.
. Hold the air hammer ditectly in line with iho
valve guido to prevent damaging tho driver.
Turn the headover,and drive the guide out toward

the camshaftside of the head.
Valvo Guide Install€d Height:

lntake: 17.85- 18.35mm 10.703 - 0.722inl
Exhaust:18.65 - 19.15 mm - 0.754in)
(0.734
VALVEGUIDE
lf a valve guide still won't move, drill it out with a

8 mm {5/16in) bit,then try again.
CAUTION: Drill guides only in extremo cases; You

could damag€the cylinder head il the guide breaks.
6. Removethe new guidesfrom the treezer,one at a

time, as vou needthem.
6-42
Valves
Reaming Installation
NOTE;For new valveguidesonly. l. Coat valve stems with engine oil. Insertthe valves
in the valveguides.
1. Coat both the reamerand valve guide with cutting
orl, NOTE: Make sure the valves move up and down
smoothly.
2. Rotatethe reamer clockwisethe full length of the
valve guide bore. 2. Installthespringseatson the cylinderhead.
3. C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e 3. I n s t a l lt h e v a l v e s e a l su s i n gt h e v a l v e g u i d e s e a l
removingit lrom the bore, installer.
4. Thoroughlywash the guide in detergentand water NOTE:Exhaustand intakevalvesealsare not inter-

to removeany cuttingresidue. changeable.
WHITE BLACK
Checkthe clearancewith a valve(seepage6-39). SPRING SPRING
Verifythat the valve slides in the valve guide with-
out exenrngpressure.
Turn reamerin
clockwisedirection
INTAKEVALVESEAL EXHAUST
VALVESEAL
REAMER VALVEGUIDESEAL
INSTALLER
KD2899(Commercialtv
avaitable)
NOTE:UsesmalltD end ot
o-.:
-c)
REAMER.5.5 mm
OTHAH- PJ'OIOB
(cont'd)
6-43
______---
Arms and
Camshaft/Rocker
Valves CamshaftSeal/Pulley
lnstallation (cont'd) lnstallation
I n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r ,t h e n CAUTION:
installthe valve spring compressor.Compressthe . Mske sure that all rockers are in alignm€nt with theil
springand installthevalvekeepers. valves whon torquing ths rockor a3semblybolts.
. Valve locknuts should be loosgngd .nd sdiusiing
NOTE:Placethe end of the valvespringwith close- screws backed off belore installation.
ly wound coilstowardthe cylinderhead. . To prevent the rocksr arm as3ombly tlom coming
apart, leavs the camshaft holder bohs in the holde6.
1. After wiping down the camshaft.camshaftsealand

j o u r n a l si n t h e c y l i n d e rh e a d ,l u b r i c a t eb o t h s u r
facesand installthe camshaft.
Clean and install the oil control orifice with a new

O-ring.
OIL CONTROLORIFICE
I
VALVESPRING COMPBESSOR
{Commerciallyavailable)
Snao-on CF711or KD- 383
with *32JAWS
Lightlytap the end of each valve stem two or three
times with a plasticmalletto ensureproperseating
of the valveand valvekeepers.
NOTE:Tap the valvestem only alongits axisso you

do not bendthe stem.
CAMSHAFTSEAL
Sealhousingsurfaceshouldbe dry.
Applya lightcoat of oil to camshaft
a n d i n n e rl i p o f s e a l .
3. Turn the camshaft until its keyway is facing up (No. 1
piston TDC).
\'
6-44
CylinderHead
Installation
4. Apply liquidgasket(PartNo. 08718- 0001or 08718- Installthecylinderheadin the reverseorderof removal:
0003)to the head maling surfacesof the No. '1and
No. 5 camshaftholders. NOTE:
- Apply liquidgasketto the shadedareas. . Alwaysusea new headgasket.
. C y l i n d e rh e a d a n d c y l i n d e rb l o c k s u r f a c em u s t b e
c l e an .
. " UP" markon the camshaftpulleyshouldbe at the top.
. Turn the crankshaftso the No. 1 pistonis at TDC(see
p a g e6 2 0 ) .
. Cleanthe oil controlorificebeforeinstalling.
a Do not use the uppercover and loweacoverto store
removeorlems.
Clean the upper cover and lower cover before instal-
taton.
No. 1
1 . Cylinder head dowel pins must be aligned.
Set the rockerarm assemblyin place and loosely CYLINDERHEAD

installthebolts.
- Makesurethat the rockerarms are properlyposi-
tionedon the valvestems.
Tighteneachbolt two turns at a time in the sequence

shown belowto ensurethat the rockersdo not bind
on the valves.
Spocitiedtorque:
I mm bolts:20 N.m (2.0 kgf.m. 1'l lbf.ft)
Apply engineoilto the threads.
5 mm bolts: 12 N.m (1.2 kgil.m,8.7 lbf.ft)
Apply engine oil to the threads.
6 mm bolts:O, @, @, @
+
@ o o € /6\
o PINS
't
7. Installthe backcover,then installthe camshaftpul-

tey. (cont'd)
6-45
CylinderHead
Installation(cont'dl
2. Positionthe camshaftcorrectly(seepage6-20). 7 . Installthe timing belt lsee page6-20).
3. Tightenthe cylinderhead bolts sequentiallyin four Adjustthe valveclearance{seepage6-12).

steps.
9. Installthe head cover gasketin the groove of the
lsr step: O - @ 20 N.m {2.0 kgt'm, 14 lbl.fr} c y l i n d e r h e a d c o v e r . S e a t t h e r e c e s s e sf o r t h e
2nd step: G) - @ 49 N.m {5.0 kgf.m, 36 lbf.ftl camshaftfirst, then work it into the groove around
3rd srop: O - @ 67 N'm 16.8kgf.m, 49 lbf ftl the outsideedges.
,lth step: o, o 67 N.m (6.8 kgf.m, 49 tbt.ftl
NOTEI
NOTE: . B e f o r ei n s t a l l i n gt h e h e a d c o v e r g a s k e t ,t h o r -
. W e r e c o m m e n du s i n g a b e a m - t y p et o r q u e oughlycleanthe sealand the groove.
wrench. When using a preset-typetorque wrench, . When installing,make sure the head cover gas-
be sureto tjghtenslowlyand not to overtighten. k e t i s s e a t e ds e c u r e l y i n t h e c o r n e r s o f t h e
. lf a bolt makesany noisewhileyou aretorquingit, recesses wrtn no gap.
loosenthe bolt,and retightenit from the 1ststep. CORNERS OF
THERECESS
HEADCOVERGASI(ET
CYLINDERHEADBOLTSTOROUESEOUENCE:
rxe iicess covER

1 0 . Apply liquid gasketto the headcover gasketat the
four cornersof the recesses.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001or08718
- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
Installthe intakemanifoldand tightenthe nuts in a . Do not installthe parts if five minutesor more
crisscrosspatternin two or three steps,beginning h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e r .
with the innernuts (seepages9-2thru 9-4). Instead,reapplyliquid gasketafter removingold
residue.
. Alwaysusea new intakemanifoldgasket. o After assembly,wait at least30 minutesbefore
fillingthe enginewith oil.
Installthe exhaustmanifoldand tightenthe nuts in
a crisscrosspatternin two or three steps,beginning
with the innernut (seepages9-5 and 9-6).
. Alwaysusea new exhaustmanifoldgasket.
I n s t a l lt h e e x h a u s tm a n i f o l d b r a c k e t .I n s t a l lt h e
exhaustpipeA andthe bracket, then installthd cover,
6-46
11. When installingthe cylinder head cover, hold the 12. Tightenthe nuts in two or three steps.In the final
headcovergasketin lhe grooveby placingyour fin- step,tighten all bolts, in sequence.to 9.8 N.m (1.0
gers on the camshaft holder contacting surfaces kgf.m,7.2lbf.ft).
(top of the semicircles).
Settho sparkplug sealon the sparkplug pipe. NOTE: After assembly,wail at least 30 minutes
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r beforefillingthe enginewith oil.
head,slidethe cover slightlybackand forth to seat
the headcovergasket.
NOTE:
. Beforeinstallingthe cylinder head cover,clean
t h e c y l i n d e r h e a d c o n t a c t i n gs u r f a c e sw i t h a
shop towel,
. Do not touch the parts where liquid gasketwas
aDolied.
. Take care not to damage the spark plug seals
when installingthe cylinderheadcover.
. Visuallycheckthe sparkplug sealsfor damage.
. Replacethe washer when damaged or deterio-
rated.
6x1.0mm
9.8 N.m 11.0kgf.m, 7.2 lbf.ftl
tl After installation,check that all tubes, hoses and

connectorsare installedcorrectly.
SEAL
6-47
I
EngineBlock
SpeciafTools .............7-2 Cylinder Block
lllustratedlndex ...................................
7-3 lnspection ..............
7-13
Flywheel and Drive Plate BoreHoning ..........7-11
Replacement .........7-G Piston Pins
Connecting Rod and Crankshaft Removal .................
7-14
EndPlay .................
7-6 lnstallation .............
7-15
Main Bearings Inspection ..............
7-16
Cfearance -7
..,,,,,,,,,....7 Connecting Rods
Selection ................
7-8 Seleetion ................
7-15
Connecting Rod Bearings Piston Rings
^ Clearance ...............
7-B EndGap .................
7-17
|J Selection ................
7-9 Repfacement .........7-11
Pistons and Crankshaft Ring-to-GrooveClearance...............
7-18
Removal .................
7-9 Alignment ..............
7-18
Crankshaft Crankshaft Oil Seal
fnspection ..............7-11 Installation .............
7-19
Pistons Crankshaft
fnspection .,,,,.,,,....,7-12 fnstaffation .............7-2O
Installation .............
7-20 Oil Pan
fnstaffation .............7-22
Oil Seals
lnstaffation .............7-24
SpecialTools
Raf. No. Tool Numbor DBcription (Ny I Pag6 Rotorence

o 07LAB- PV00100 RingGearHolder 1 7-6
@ 07749- 0010000 Driver 1 7 -19,25
@ 079i17- S800200 SealDriver 1 7-24
@ 07948- S800101 Driver Attachment 1 7-'t9,25
@ 07973- P800200 PilotCollar 1 7-141 ,5
@ 07973- PE00310 PistonPin DriverShaft I 7-14.15
o 07973- PE00320 Piston Pin Driver Head 1 l-14,15
o 0t913 - PE00400 Piston Pin Base lnsen
I
1 l - ' 1 4 ,1 5
@ 07973- S800100 Piston BaseHead 1 7 - 1 4 ,1 5
@ 07973- 6570500 Piston Base 1 7-'t4,15
@ 07973- 5570600 PistonBaseSpring 1 7-'t4.15
@ o @
\
o
0
o o
c,
@ @
L
t-1
!
lllustrated lndex
D16Y7engine:
Lrori""t" "tl internalpartswith engineoil during reassembly.

I
NOTE:
. Applyliquidgaskettothematingsurfaces
ofthe rightsidecoverandoil pumpcasebeforeinstalling
them.
. Use liquidgasket.part No. 08718- 0001or 08718- 0003.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit. 6 x 1 . Om m
DRAINBOLT 12 N.m {1 .2 kgf.m,
44 N.m (4.5 kgf.m, 33 lbf.ftl 8 7 lbt'ftl
"i'.''
o[ rlt cnsrer
Hii,ilJ \ 'y" FLYwHEELcovER
6 x 1.0mm ,::::T:Î \\
12 N.m (1.2 kgt.m, 8.7 lbt.ft) y"::::-
ffi::: I $5./
fR..r'
OIL PAN .*"'" I gNliJ'J.f--
Refetto page7-22 ,t/,oksf'm,87
rbt'ttr
when installing. ><-BL %S
Apply liquidgasketto
@ff
these points.
1 1x 1 . 5m m
51 N.m
(5.2kgt m,3E
Applyengineoilto the bolt
threads.
NOT€: After torquing
each cap, turn the crankshaft
to checklor binding.
MAI BEARINGCAP
MAIN BEARINGS
Selection,page7-8
NOTE:New main bearingsmust
be selectedby rnatchingcrank
and block identilicationmarkings.
CRANKSHAFT
page7-'11
lnstallation,
6 x 1 . 0m m CRANKSHAFT OIL SEAL
1'l N.m (1.1 kgf.m, 8 lbf.ft) lnstallation,
pages7-19and 7-25
OII SCREEN
6 x 1.0 mm \{ePlace
1 1 N . m l 1 . 1 kgf.m, a lbt.tt) 6 x 1 . Om m
1'l N.m (l .1 kgf.m,
GASKET 8 tbt.ftl
Replace.
OIL PUMP RIGHTSIDECOVER
Overhaul.page8-9 DOWELPIN Apply liquidgasker
Removal/lnspection, to m6ting surface.
page8-10.
WASHERS
Groovedsides face outward.
NOTE:Ihrusr washerthickness
CRANKSHAFTSEAL /.\ is fixed and must not be changed
lnstallation,pages7-24--rS) BR€ATHINGPORT COVER by grindingor shimming.
MOUNT BOLTS
Replace. 6 x 1 . Om m
DOWELPIN 11 N.m 11.1 kgf.m, I lbt.ft)
6x1.0mm (cont'd)
1 1 N , m 1 1. 1 kgt.ni, O-RING Apply liquidgasketto
8 tbr.ftl Replace. the bolt threads.
7-3
lllustrated Index
(cont'dl
rubricatealt internalpartswith engineoil duringreassembly.
I
NOTE:
. Apply liquidgaskettothe matingsurfacesofthe right sidecoverand oil pump casebeforeinstallingthem.
! Use liquidgasket,pan No. 08718- 0001or 08718- 0003.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit.
OII.PAN
D16Y5.Dl6Y8 engin"", WASHER Apply liquid gaskerto Relerto page7-23
DnAtNBoL,
39 N.m 14.0kgf'm, these potnts, wheninstalling.
29 tbf.f!) FLYWHEELCOVER
\ IM/T)
\
\,-,
12 x 1.0mm
6r1.omm \% 1 1 8N . m
12 N.m (1.2kgf'm, (12.O kst.m, 87 lbl.ftl
8.7 lbf.trl
1 1 x 1 . 5m m
51 N.m
\s
15.2kgt m, 38 lbf.{t)
Applyengineoilto the bolt FLYWHEELIM/TI
threads.
NOTE:Aftertorquing
each cap, turn crankshaft OIL PAN GASKET
to checklor binding. Replace.
DRIVEPLATECOVER
MAIN
BEARING
lA/T or CVTI
1 2 x 1 . Om m
MAIN BEARINGS 74 N.m
Selection,page7-8 (7.5 kgf.m, 54 lbf.ft)
NOTE:New main bearingsmust
be selectedby matching crank
DRIVEPLAYE(A/T or CVTI
Checkfor cracks.
6 x 1.0 mm
1 1 N . m 1 1 . 1k g t . m ,
8 tbf.frl
6 x 1.0 mrn
1 1 N . m { 1 . 1 k g t . m ,8 l b f . f r l CRANKSHAFTOIL SEAL
pages7-19and 7-25
OIL SCREEN Replace.
GASKET RIGHT SIDE COVER

Replace. Apply liquidgasket
OIL PUMP to mating surface.
Overhaul,page I 9
Removal/lnspection, DOWEL PIN
page 8-10
Apply liquidgasket
to mating surface. THRUSTWASHERS
Groovedsidesface outward.
NOTE:Thrust washerthickness
is fixed and must not be changed
by grindingor shimming.
CRANKSHAFT SEAL DOWEL PIN BREATHINGPORT COVER

Installation,pages7-24 MOUNT BOLTS
a n d8 - 1 1 6 x 1.0mm \
Feplace. 11 N.m {1.1 kgf.m, 8 lbf.frl
'1 Apply liquidgasketto
6 x .0 mm
' 1 1N . m 1 1. 1 k g f . m , the bolt threads.
I lbt.fr)
7-4
NOTE:New rod bearingsmust be selectedby matchingconneclingrod assemblyand crankshaftidentificationmarkings
(seepage7-9).
PISTONINSTALLATIONDIRECTION:
Lubricate all internal parts with engine oil during
reassemblv. EXHAUST
4\A6\/A
l o o l t . - l . t l
v\y\7v
INTAKE
tl,^t , PISTONRINGS
w,
*al pase7-18
olisnment,
@ )
PISTONPIN
Removal,page7-14 PISTON
page7-15
Installation, page7-12
Inspection,
hspection,page7-16 NOTE: Belore removing piston, inspectthe
top of the cylinderborefor carbonbuild,upor
ridge. Removeridge il necessary,page 7-'10
CONNECTING ROD
End play, page7-6 ENGINEBLOCK
S e l e c t i o n ,p a g e 7 - 1 5 page7-13
Cylinderboreinspection,
page7-'13
Warpageinspection,
Cylinderborehoning,page7'14
CONNECNNGROD
BEARINGS
Clearance.page 7-8
Selection,page 7-9
Inspecttop of each cylinder bore

for c6rbonbuild-upor ridge
before removing piston.
Removeridge if necessary,page7-'10
CONNECNNGRODCAPNUT
CONNECTING ROOBEARING 8 x 0,75mm
page7-20
lnstallation. 3 1N m ( 3 , 2 k g f . m ,
NOTE: Installcaps so the 23 tbt.ft)
bearing recessis on the Applyengineoil to
same side as the recess the bolt threads.
in the rod. NOTE: After torquing each bearing
cap, rotatecrankshaftto
checktor binding.
7-5
GonnectingRod and
Flywheel and Drive Plate Crankshaft
Replacement EndPlay
Manual Transmission: Conn€GtingRod End Play:
Removethe six flywheel bolts, then separatethe fly- Standard(New):0.15- 0.30mm {0.006- 0.012inl
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 , ServiceLimit: 0.,[|)mm {0.016inl
tightenthe bolts in a crisscrosspattern.
Htr
RINGGEARHOLDER--4T-1
07LAB- PV00100
ENGINEBLOCK
RINGGEAR
Inspectring gear 12 x 1.0mm
teeth for wear or 118 N,m 112.0kgtm,87 lbl.ftl
damage.
I
I
. ll out-of-tolerance,installa new connectingrod.
. lf still out-of-tolerance.replacethe crankshaft(see
pages7-9 and 7-20).
Pushthe crankshaftfirmly away from the disl indicator,

and zerothe dial againstthe end of the crankshaft.
Then
pull the crankshaftfirmly backtoward the indicator;dial
readingshouldnot exceedservicelimit.
RINGGEARHOLDER
07LAB- PV(x'l00
Automatic Transmission:
Removethe six drive plate bolts,then separatethe drive
platefrom the crankshaftflange.After installation,
tight-
en the bolts in a crisscrossoattern.
CrankshaftEnd Play:
Stsndard {N€w): 0.10- 0.35 mm {0.004- 0.0lit in}
ServicELimit: 0.45 mm (0.018inl
. lf end play is excessive,inspectthe thrust wsshers

and thrustsurfaceon the crankshaft.
Replacepans as necessary.
NOTE:Thrustwasherthicknessis fixed and must not be

changedeitherby grindingor shimming.
Thrust washersare installedwith groovedsidesfacing
outward.
1 2x 1 . 0m m
74 N.m {7.5kgf m,54lblftl
7 -6
Main Bearings
Clearance
1. 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.
C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l t w i t h a
cleanshop towel.
Piaceone strip of plastigageacrosseach main jour-

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

the main cap down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plasti-
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 i n ga t a
lf the plastigagemeasurestoo wide or too narrow,
time.
(removethe engineif it's still in the carl. removethe
crankshaft,and removethe upper half ol the bear-
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
ing. Installa new, completebearingwith the same
bolts.
color code (selectthe color as shown on the next
page),and recheckthe clearance.
lst step: 25 N.m 12.5kgf'm, 18 lbf'ft)
Final step: 51 N'm 15.2kgl.m, 38 lbf'ft)
CAUTION: Do not file, shim, or sqape the bearings
or the caps to adiust clearance.
NOTE:Do not rotatethe crankshaftduring inspec-
tton.
7. It the plastigageshows the clearanceis still incor-
rect,try the next largeror smallerbearing(thecolor
Removethe cap and bearing again. and measure
listedaboveor belowthat one),and checkagain.
the widest pad of the Plastigage.
NOTE: lf the oroper clearancecannot be obtained
Main Bearing-to-JournalOil Clearance:
by usingthe appropriatelargeror smallerbearings'
Standard lNew):
replacethe crankshaftand startover.
No. 1,5 Journals:
0.018- 0.036mm (0.0007- 0'001,+inl
No- 2, 3, i[ Jou]nals:
0.02/t- 0.0,[2mm {0.0009- 0.0017in)
Ssrvice Limit: 0-05 mm {0.002inl
Main Bearings ConnectingRod Bearings
Selection Clearance t
CAUTION: lf the codes are indeciDherablebecauseof an 1, Removethe connectingrod cap and bearinghalf.
accumulationot dirt and dust, do not scrub them with a
wire brush or scraper.Clean them only with solvent or 2. C l e a nt h e c r a n k s h a frto d j o u r n a la n d b e a r i n gh a l f
detergent. with a cleanshop towel.
CrankshaftBore Code Location 3. Placea strip of plastigageacrossthe rod journal.
Lettershave beenstampedon the end of the blockas a 4. R e i n s t a lt lh e b e a r i n gh a l f a n d c a p ,a n d t o r q u et h e

codefor the sizeof eachof the 5 mainjournalbores. nuts.
Use them, and the numbersstamDedon the crankshaft
(codesfor main journalsizel,to choosethe correctbear- Torque
inos. 31 N.m (3.2 kgf.m. 23 lbf.ftl
NOTE:Do not rotatethe crankshaftduring inspec-

tton. I
Removethe rod cap and bearinghalf,and measure
the widestpart of the plastigage.
Conn€ctingRod Eearing-to-JouJnalOil Clearance:

StandardlNewl: 0.020- 0.038mm
(0.0008- 0.0015in)
ServiceLimit: 0.05 mm (0.(X)2in)
I
Main Joulnal Code Location(Numbers)
I
PLASTIGAGESTRIP
lf the plastigagemeasurestoo wide or too narrow,

removethe upper half of the bearing,installa new,
completebearingwith the same color code (select
the color as shown on the next page),and recheck
Bearing ldentification the clearance.
Colorcodeis crankoore
on the
edge of CAUTION:Do not lile, shim. or scrapethe boarings
the bearing.
B c D or the caps to adiust clearance.
Smallerbearing{thicker)
7. lf the plastigageshows the clearanceis still incor-
Il l f-i--l I Red Pink
rect,try the next largeror smallerbearing(the color
G.een
--Jl l i s t e da b o v e o r b e l o wt h a t o n e ) ,a n d c h e c kc l e a r -
tt l t. .3 - lt l Green
Gr€en Brown
Black
a n c ea g a i n .
+ tn t + Green Brown Elack Blue NOTE; lf the prooer clearancecannot be obtained

Smaller Smaller by usingthe appropriatelargeror smallerbearings,
main bearing replacethe crankshaftand stan over. \
journ8l (thicker)
7-8
Pistonsand
Crankshaft
Selection Removal
CAUTION:lf the codes are indecipherablebecauseof 1. Removethe oil pan assembly.
an accumulationol dirt and dust, do not scrub them
with a wire brush or scraper,Clean them only with sol- Removethe right sidecover.
vgnt or detorgent.
ConnectingRod Code Location
Numbershave been stampedon the side of each con-

necting rod as a code for the size of the big end. Use RIGHT SIDE
COVER
them, and the lettersstampedon the crankshaft(codes
for rod journalsize),to choosethe correctbearlngs.
Halfof the numberis

stampedon bearing
capand the other
hall is stampedon the
rod.
connecting Rod Journal code Locations lLettersl
OIL SCREEN
B€aring ldentif ication

Colorcodeis on the Larger big end bore
edge of
the bearing. 2 3 4
Smallerbearing{thicker)
I F;.'l I Red Pink Green

Erown
O-RING
RePlace
l l B o r l l l l Pink Green
ll .-.------.ll
I I Corlll | | Green Brown Black
l - l
Blue Remove the oil pump.
I l D o , r lr+r r
Gr€en Brown Black 4.
Smaller Smaller
rod bearing
iournal (thicker)
7-9
Pistonsand Crankshaft
Removal(cont'dl
5. Removethe boltsand the bearingcap. Removethe upper bearing halvesfrom the connect-
ing rods and set them asidewith their respectivecaps.
CAUTION: To prev6nt warpago, unscrew the bohs
in soquencel/3 turn at a tims; rgpoat the sequenco Reinstallthe main capsand bearingson the engine
until 8ll bolts ara loosonsd. In properorder.
MAIN BEARINGCAPBOLTSLOOSENINGSEOUENCE '10. you

lf canfeela ridgeof metalor hardcarbonaround
t h e t o p o f e a c h c y l i n d e r ,r e m o v e i t w i t h a r i d g e
reamer.Follow the reamer manufacturer'sinstruc-
tions.
CAUTION: lf the ridgo is not removed, it may dam-

age tho plstons as they are pushed out.
Removethe rod caps/bearings and main caps/bear-

ings.Keepall caps/bearings
in order 't1.
Use the wooden handle of a hammer to drive the
pistonsout.
7. Lift the crankshaftout of the engine,being careful
not to damagejournals.
12. Reinstallthe connectingrod bearingsand capsafter

removingeachpiston/connecting rod assembly.
CRANKSHAFT 1 3 . Mark each piston/connecting

rod assemblywith its
cylindernumberto avoid mixup on reassembly.
NOTE:The existingnumber on the connectingrod

does not indicateits position in the engine,it indi- \
catesthe rod bore size.
7-10
Grankshaft
Inspection
. Cleanthe crankshaftoil passageswith pipe cleaners Out-of-Roundand Tapel
or a suitablebrush.
. Measureout-o{-roundat the middle of each rod
. Checkthe keywav and threads. and main journalin two places.
Alignmont . The differencebetweenmeasurementson each

journalmust not be more than the servicelimit,
. 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 Out-ot-Round:
Standard (Now): 0.0025mm (0.0001inl max.
. The differencebetweenmeasurementson each ServiceLimit: 0.005mm (0.0002inl
journalmust not be more than the servicelimit.
CrankshaftTotal IndicatadRunout:
Standard {Nowl: 0.03 mm 10.001in} max.
SorviceLimh: 0.04 mm 10.002in)
DIAL INOICATOR
Rotate lwo complete round at middle.
revolutions.
MeasurelaPer
at edges.
Suppon with lathe

lype tool or V-blocks.
. Measuretaper at edges of each rod and main

journal.
. The differencebetlveenmeasurementson each

journalmust not be more than the servicelimit.
JournalTaper:
Standard{Newl:0.0025mm (0.0001in) max.
ServiceLimit: 0.005mm 10.0002in)
7-11
Pistons
Inspection
1. Checkthe pistonfor distortionor cracks. 3. Calculatethe difference between the cvlinder bore
diameter(seepage7-131and pistondiameter.
NOTE:lf cylinderis bored,an oversizedpistonmust
be used. Piston-to-Cylind€rClearanca
Standsrd {New): 0.010- 0.0i|()mm
2. M e a s u r ep i s t o n d i a m e t e ra t d i s t a n c eA t r o m t h e (0.000'l- 0.0016inl
bottom of the skirt. ServiceLimit: 0.05 mm {0.002inl
A: 5 mm (0.2in)
Piston Diameter:
Standard (N€w): 74.990- 74.990mm
12.9520- 2.952itinl
ServiceLimh: 7i1.970mm {2.9516in}
SKIRTDIAMETER
lf the clearanceis near or exceedsthe servicelimit,

inspectthe piston and cvlinderblock for excessive
wear.
Oversiz€Piston Dismatel
0.25175.23-75.21mn (2.9618- 2.9622inl
0.50:75.48- 75.49mm 12.9716- 2.9720in)
7-12
Cylinder Block
Inspection
'1. Measure .
wear and taDerin directionsX and Y at th ree lf measurementsin any cylinderare beyondthe
levelsin eachcvlinderas shown. OversizeBoreServiceLimit,replacethe block.
. lf the block is to be rebored.refer to PistonClear-

anceInspection (seepage7 12)afterreboring.
NOTE;Scoredor scratchedcylinderbores must be

honed.
ReboringLimit: 0.50 mm (0.020in)
2. Checkthe top of the blockfor warpage.

Measurealong the edgesand acrossthe centeras
shown.
SURFACES
TO 8E MEASURED
Cylinder Bore Size

Standard {New): 75.00- 75.02mm
(2.953- 2.95,1in)
S€rvicoLimit: 75.07mm {2.955inl Engine Block Warpage:
Standard(New):0.07mm (0.003in) max.
OvsFize ServiceLimit: 0.10 mm 10.004in)
O.25t75.25- 75.27mm (2.9626- 2.963,[in]
0.50:75.50- 75.52mm 12.9721-2.9732in1
PRECISION
STRAIGHTEDGE
Bore Taper
Limit (Differencebetwoen tirst and third measure.
m6nt) 0.05 mm (0.002in)
7-13
).
GylinderBlock Piston Pins
BoreHoning Removal
l. Measurecylinderboresas shownon page7-13.lf the 1. Assemble the specialtool as shown.
blockis to be reused,honethe cylindersand remea-
surethe bores. PISTONBASEHEAD
07973- SB00100
Honecylinderboreswith honing oil and a fine (400 f t
grit) stonein a 60 dagreecross-hatch
pattern.
PISTONPIN BASE
NOTEi INSERT
. Use only a rigid hone with 400 grit or tiner stone 07973- PE00a00
such as Sunnen,Ammco,or equivalent.
. Do not usestonesthat are worn or broken.
g
E.
g\
Y .,rro")". rr*,"o
079?3- 6570600
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 metal particles.Wash the cylin-
der bores with hot soapy water, then dry and oil 2. Assembleand adjust the length of the piston p t n
immediatelyto preventrusting. driverand shaftto 53 mm (2.1in) as shown.
PISTON PINDRIVER
HEAD
NOTE:Neverusesolvent,it will only redistribute
the 07973- PE00320
grit on the cylinderwalls. Pres3
lf scoring or scratchesare still presentin cylinder

bores after honing to the service limit. rebore the
+ 53 mm(21 in)
cylinderblock,
NOTE:Some light verticalscoringand scratchingis PISTONPIN

acceptableif it is not deep enoughto catchyour fin- DRIVERSHAFT
0?973- PE00310
gernailand does not run the full lengthof the bore.
PILOTOOLLAR
CYLINDERBLOCK 07973- PE00200
CYLINDERHONE
NOTE|Usea hydraulicpress.
When pressingthe pin in or out,
makesure that the recessed
NOTE: ponionofthe pistonaligns
. After honing,cleanthe cylinderthoroughlywith with the lips on the collar.
soapy waler.
. Only a scoredor scratchedcylinderbore must be Placethe piston on the specialtool and press the
noned. pin out with the specialtoolsand a hydraulicpress.
7-14
GonnectingRods PistonPins
Seleetion Installation
Eachrod falls into one of four toleranceranges(from 0 to 1. Usea hvdraulicDressfor installation.
+ 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002in)
incrementsldependingon the sizeof its big end bore.lt's a When pressingthe pin in or out, be sure you posi-
then stampedwith a number 11,2, 3, or 4l indicatingthe tion the rscessedflat on the piston againstthe lugs
ran9e. on the baseattachment,
Y o u m a y l i n d a n y c o m b i n a t i o no l 1 , 2 , 3 , o r 4 i n a n y
engine.
The arrow must face the
timing belt side ol the
Normal Bore Size: ,18.0mm (1.89inl engineand the connecting
rod oil hole must face the
NOTE: rear of the
ReferencenumbeG are for big end bore sizeand do
NOTindicatothe positionof the rod in the engine,
Inspectconnectingrod for cracksand heatdamage.
PISTOI{P|r{DRIVERHEAD
07973- PEOO320
Adjust the length of the

piston pin driver to
53 mm (2.09in)
PISTO PII{ DRIVERSHAFT

07973-PE00310
PFroI{Prr{
ffi--Z PILOTCOTLAR
07973- PEq)200
PISTOI{PINBASE I SERT
07973 - PCOO400
PISTOI{BASEHEAD
07973 - SB(xtl (xt
7-15
)
PistonPins
Inspection \ {
'1. Measurethe diameterot the pistonpin. 3. Measurethe pistonpin-to-piston
clearance.
Piston Pin Diamcter: NOTE:Checkthe pistonfor distortionor cracks.

Standard (New): 18.994- 19.000mm
(0.7,078- 0.7{80 inl lf the piston pin clearanceis greaterthan 0.024mm
OveIsiz€: 18.997- 19.003 ( 0 . 0 0 0 9i n ) , r e m e a s u r eu s i n g a n o v e r s i z e dp i s t o n
{0.7,u9 - 0.7,181in) pin.
pistonpins are oversize.

NOTE:All replacement Piston Pin-to-PistonClsarance:
Standard {Newl: 0.010- 0.022mm
{0.0004- 0.0009inl
Checkthe differencebetweenthe pistonpin diame-

ter and the connectingrod smallend diameter,
2. Zerothe dial indicatorto the pistonpin diameter.
Piston Pin-to-ConnectingRod Int€rferonc€:
Standard (New): 0.014- 0.040mm
10.0006- 0.0016inl
7-16
PistonRings
EndGap Replacement
1 . Using a piston, push a new ring into the cylinder 1 . Usinga ring expander,removethe old pistonrings.
bore 15- 20 mm (0.6- 0.8 in) trom the bottom.
2. Cleanall ring groovesthoroughly.
Measurethe pistonring end-gapwith a feelergauge:
NOTE:
. lf the gap is too small,checkto see if you have . U s e a s q u a r e d ' o f fb r o k e nr i n g o r r i n g g r o o v e
the properringsfor your engine. cleanerwith bladeto fit pistongrooves.
. lf the gap is too large,recheckthe cylinderbore . Top ring grooveis 1.0mm (0.039in) wide.
diameteragainstthe wear limits on page7-13. . Secondring grooveis 1.2mm (0.047in) wide.
lf the bore is over the servicelimit. the cvlinder . O i l r i n gg r o o v ei s 2 . 8m m ( 0 . 1 Ii n )w i d e .
blockmust be rebored. . Filedown the bladeif necessary.
Piston Ring End-Gap: CAUTION:Do not uso a wire brush to clean ring
Top Ring lands, or cut ring lands doeperwith cleaningtool.
St8ndardlNswl: 0.15- 0.30mm
{0.006- 0.012in) NOTE:lf the pistonis to be separatedfrom the con-
ServiceLimit: 0.60 mm 10.024inl nectingrod, do not installnew ringsyet.
SecondRing Installnew rings in the proper sequenceand posi-

Standard lN6wl: 0.30- 0.,l5mm tion {seepage7-18).
{0.012- 0.018inl
ServiceLimit: 0.70 mm (0.028inl NOTE:Do not reuseold pistonrings.
Oil Ring RINGEXPANDER

Standard lNewl: 0.20- 0.70 mm {Commercially
available)
{0.008- 0.028inl
SorviceLimit: 0.80 mm (0.031in)
15-20 mm
{0.6 -O.8 inl
7-17
PistonRings
Clearance
Ring-to-Groove Alignment
After installinga new set of rings, measurethe ring-to- 1, Installthe ringsas shown.
grooveclearances:
Top Ring Clearance

TOPBINGlchromo)
Standard lNew): 0.035- 0.060mm
{0.0014- 0.0024in}
Servic. Limit: 0.13 mm (0.005inl
SecondRing Clearance
Standard (Now): 0.030- 0.055mm
(0.0012- 0.0022io)
ServiceLimit: 0.13 mm 10.005inl
Piston Ring Dimensions:
r-T- f
I l r '
I I '
| . - !
A
Top Ring (Standatd):

A: 2.6 mm {0.10in}
B: 1.0mm (0.0/tin)
Second Ring {Standard):

A: 3.0 mm (0.12inl
B: 1.2mm (0.05inl
NOTE: The manufacturingmarks must be facing

upward.
,orrrno--"-@
SECONORING.>
7-18
CrankshaftOil Seal
lnstallation
2. Rotatethe rings in their groovesto make sure they The sealsurfaceon the blockshouldbe dry.
do not bind. Apply a light coatof oil to the crankshaftand to
the lio of the seal.
Positionthe ring end gaps as shown
1. Drivethe crankshaftoil seal into the right side cover
usingthe specialtools.
DO NOTpositionany rrnggap
SECONDRINGGAP at pistonthrustsurfaces, NOTE:Drivethe crankshaftoil sealin squarely.
DRIVER
07749- 0010000
Approx. 90"
TOP RINGGAP
DO NOTpositionsny ring gaP

in linewith the pistonpin hole. OIL RINGGAP
Installseal with the

part numberside
facing oui.
Confirmequal clearanceall the way around with a

feelergauge.
0.5- 0.8 mm {0.02- 0.03inl

Clearance:
0 . 5- 0 . 8 m m
10.02-O.03in)
NOTE:Referto pages'I-24and 8-11for installation

of the oil oumo sidecrankshaftoil seal.
7-19
I
Pistons Crankshaft
lnstallation lnstallation
\ {
Beforeinstallingthe pistons,applya coat of Betoreinstallingthe crankshaft,
apply a coatot
engineoil to the ring groovesand cylinder engineoil to the main bearingsand rod bear-
bores. ings,
1. lf the crankshaft is already installed: 1. Installthe thrust washersin the No. 4 journal of the
. Set the crankshaftto BDCfor each cylinder. cylinderblock.
. Removethe connectingrod caps.and slip short
sectionsof rubber hose over the threadedends Insertbearinghalvesin the cylinderblockand con-
of the connectingrod bolts. nectingrods.
. Installthe ring compressor,checkthat the bear
ing is securelyin place,then positionthe piston Holdthe crankshaftso the rod journalsfor cylinders
i n t h e c y l i n d e r a. n d t a p i t i s u s i n gt h e w o o d e n No. 2 and No.3 are straightdown.
h a n d l eo f a h a m m e r .
. Stop after the ring compressorpops free, and Lowerthe crankshaftinto the block,seatingthe rod
checkthe connectingrod-to-crank journal align- j o u r n a l si n t o c o n n e c t i n gr o d s N o , 2 , N o . 3 . I n s t a l l
ment beforepushingthe pistoninto place. the rod capsand nutsfinger-tight.
. Installthe rod capswith bearings,and torquethe
nutsto:
31 N.m 13.2ksl.m,23 lbf.ti)
Apply engineoil to the bolt threads.
2. lf the crankshaftis not installed: -

. R e m o v et h e r o d c a p s a n d b e a r i n g s i,n s t a l lt h e l- rrn
---1l
-'--tllf -l
)- t--l
ring compressor,then positionthe piston in the
cylinderand tap it in usingthe woodenhandleof ltll
a hammer. THRUST WASHERS
. Positionall Distonsat top deadcenter.
The arrow must face
Groovedsidestace
L {
the timing belt side
of the engjne. Rotatethe crankshaftclockwise.seat journals into
connectingrods No. 1 and No.4. lnstallthe rod caps
and nutsfinger-tight.
NOTE:Installthe caps so the bearingrecessis on

the sameside as the recessin the rod.
Check rod bearing clearancewith plastigage(see

page7-8).then torquethe capnuts.
RUBEER Torque:
NOTE:Maintaindownwardforce on the ring com- 31 N.m (3.2 kgf.m,23 lbf,ft)
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 f o r e Apply engineoil to the bolt threads.
enteringthe cylinderbore.
RING NOTE: Referencenumbers on the connectingrod
COMPRESSOR
(Commercially
available)
are for big-endbore toleranceand do not indicate
the positionof the pistonin the engine.
\'
Lineup the markswhen
installingthe connectingrod d
cap.
7-20
7. Installthemain bearingcaps. 8. Apply liquid gasketto the block mating surfaceof
Checkclearanceswith plastigage(see page 7-7), the right side cover, then install it on the cylinder
then tightenthe bearingcap bolts in 2 steps. block.
Fi6t st6p: 25 N'm (2.5 kgf'm. 18 lbt.ft) NOTE:

Secondstsp: 5t N.m (5.2 kgf.m, 38 lbf,ft) . Use liquidgasket,part No. 08718- 0001or 08718
- 0003.
NOTE: Coat the thrust washer surfacesand bolt . Checkthat the matingsurfacesare cleanand dry
thresdswith oil. beforeapplyingliquidgasket
. Apply liquidgasketevenly,b6ingcarefultocover
MAN BEAHNG CAP BOLTSTIGHTENINGSEOUENCE allthe matingsurface.
. To preventoil leakage.apply liquidgasketto the
innerthreadsof the bolt holes.
. Do not install the parts if five minutes or more
haveelapsedsinceapplyingthe liquidgasket,
Insteadreapplyliquid gasketafter removingthe
old residue,
. After assemblv,wait at least 30 minutes before
RIGHTSIDECOVEB
CAUTION: Whenever any crankshaft bearing or

connecting rod bgajing is rgplacad, it is neces3ary
aft6r roassemblyto run the ongino at idling spood
until it reachesnormal operating temperalure, thon
continuo to run it for approximalely 15 minutes.
6 x 1.0mm
1 1 N . m { 1 . 1kgl.m,
8 tbt.ftl
DOWEL PIN
(cont'd)
7-21
Crankshaft O i l Pa n
Installation(cont'd) Installation
9. Apply liquid gasketto the oil pump mating surface O16Y7enginc:
o f t h e b l o c k t, h e n i n s t a ltl h e o i l p u m p o n t h e c y l i n -
der block. 1. Apply liquid gasketon the oil pump and right side
covermatingareasas shown below.
Apply greaseto the lipsof the oil seals.
T h e n ,i n s t a l tl h e o i l p u m p w h i l e a l i g n i n gt h e i n n e r NOTE:
. hen the pump is in
r o t o r w i t h t h e c r a n k s h a f tW . Use liquidgasket,part No.08718- 0001or 08718
place,clean any excessgreaseoff the crankshaft, - 0003.
then checkthat the oil seallips are not distorted. . Checkthat the matingsurfacesare cleanand dry
. Apply liquid gasketas an even bead. centered
betweenthe edgesof the matingsurface.
. lo preventoil leakage,apply liquid gasketto the
Apply laquidgasket . Do not installthe parts if five minutes or more
alongthe broken h a v e e l a p s e ds i n c ea p p l y i n gt h e l i q u i d g a s k e t .
old residue.
. After assembly,wait at least30 minutes before
CYLINOER
Br_ocK
Apply liquid gasket
OIL PUMP HOUSING to these pornts.
NOTE:
. Apply a light coat of oil to the crankshaftand to L
t h e l i po f t h es e a l .
. U s e n e w O - r i n g sa n d a p p l y o i l w h e n i n s t a l l i n g
them.
1 0 . I n s t a ltlh e o i l p u m pa n d o i l s c r e e n .
6 x 1.0mm
11 N.m {1.1kgf.m,
6x1.0mm a tbt.{t}
11 N.m {1.1kgf.m,
OII- SCREEN
Apply liquid gasket

to these pornts,
DOWEL PIN
DOWELPIN
6 x 1.0mm
11 N.m O-RING
{'l.1 kgl.m, 8 lbf,lt} Replace. {
.,
r -zz
,.t ,.i
2. I n s t a ltlh e o i l p a ng a s k eat n d o i l p a n . D16Y5,D16Y8engines:
NOTE: 1. I n s t a ltlh e o i l p a ng a s k eot n t h e o i l p a n .

. Usea new oil pan gasket.
. Installthe oil pan no morethan five minutesafter NOTE:
applyingliquidgasket. . Use liquidgasket,part No. 08718- 0001or 08718
, 0003.
OILPAN . Checkthat the matingsurfacesare cleanand dry
o A p p l y l i q u i dg a s k e ta s a n e v e n b e a d .c e n t e r e d
betweenthe edgesof the matingsurface.
. To preventoil leakageapply liquid gasketto the
Apply liquid innerthreadsof the bolt holes.
gasketto . Do not installthe parts if five minutesor more
these poants.
haveelapsedsinceapplyingthe liquidgasket.
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least 30 minutesbefore
filling the enginewith oil.
OIL PAN
PAN
GASKET
to thesepoints. Replace.
3. Tightenthe bolts and n u t sf i n g e rt i g h ta t s i x p o i n t s

as shown below.
OIL PAN
GASKET
Replace.
Tightenall boltsand nuts,startingfrom boltO, clock-

wise in threesteps.
NOTE:Excessive tighteningcan causedistonionof

oil pan gasketand oil leakage.
Torque:12 N.m (1.2kgl.m,8.7lbt.ft)

(cont'd)
7-23
Oil Pan Oil Seals
Installation(cont'd) Installation
2. Apply liquid gasketto the block mating surfaces, NOTE:
t h e n i n s t a l tl h e o i l p a n .A p p l y l i q u i dg a s k e t o t h e . Engineremovalis not required.
shadedareas. . The crankshaftoil sealhousingshouldbe dry.
Apply a light coat of greaseto the crankshaftand to
the lips of the seals.
1. Usingthe specialtool, drive in the timing pulley-end

sealuntilthe driverbottomsagainstthe oil pump.
When the seal is in place,cleanany excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.
OIL PAN
3. Tighten the nuts finger{ight at six points as shown

L
o a o
07947-SB00200
lnstallseal with the
part number side
facingout.
4. Tightenall boltsand nuts,startingfrom nut O, clock-

wise in threesteps.
NOTErExcessive tighteningcan causedistortionof

oil pan gasketand oil leakage.
Torque:12 N.m (1.2kgf'm,8.7lbl.ft)
t-z+
2. Measurethe flywheel-endsealthicknessand the oil
seal housingdepth.Usingthe specialtool. drive the
flywheel-endseal into the rear cover to the point
where the clearancebetweenthe boftom of the oil
seal and the right side cover is 0.5 - 0.8 mm (0.02-
0.03in) (seepage7-191.
NOTE:Align the hole in the driver attachmentwith

the pin on the crankshaft.
07749-0010000
DRIVERATTACHMENT
07948-S800101
lnstallseal waththe
part numberside
facing out.
7-25
IHI
/
SpecialTools
t
Ref.No. I Tool Numbel Description Oty PageRoforance
o 07746- 0010400 Attachment.52x 55 mm 1 a-12

07749- 0010000 Driver I a-12
a2) 07912- 611000' ] Oil FilterWrench 1 8-7
I {
8-2
lllustrated Index
NOTE: CAUTION: Do not overtighten the drain bolt.

o Usenew O-ringswhen reassembling.
ENGINEOIL PRESSURE SWITCH
. Apply oil to O-ringsbeforeinstallation. 18 N.m {1.8ksf m, 13 lbf.ft)
. Use liquid gasket,Part No. 08718- 0001 or 08718- 1/8in. BSPT(Eritish
0003. StandardPipeTaper)
. Cleanthe oil pan gasketmatingsurfacesbeforeinstall- 2Slhreads/inch.Use
properliquidsealant.
In g .
. Apply liquidgasketto the recessesof the oil pan gas-
ket (seepage7-22).
D16Y7engin€:
OILPUMP
Overhaul,page8-9 O-RING OIL BREATHER
Inspectaon,page8-10 Replace. CHAMBER
Applyliquidgasket 6x1.0mm
to the matingsurface 1 1 N . m{ 1 . 1kst.m,
of the block. 8 lbl.fr)
OIL FILTER
Replacement,
page8-7
O.RING
Replace.
Apply liquidgasketto
6x1.0mm thesepornts.
11 N.m (1.1kgl,m,
8 tbf.ft)
OILPAN
GASKET GASKET
Replace. Replace.
PAN
Befertopage7 22
when installing.
6x1.0mm 6 x 1.0mm
1l N.m {1.1kgf.m, Apptvtiquidqasketro 12 N m (1.2kglm, 8.7tbf.ftl
8lbf ft) rhesepoints.
DRAINBOLT
44 N.m 14.5kgf.m,33 lbtftl
Do not overtighten.
(cont'd)
8-3
lllustrated Index
(cont'd) t.
NOTE: CAUTION: Do not overtighten the dlain bolt.
. Usenew O-ringswhen reassembling.
. Apply oil to O-ringsbeforeinstallation.
. Use liqu;d gasket,Part No. 08718- 0001 or 08718-
0003. ENGINEOIL PRESSURE SWITCH
. Cleanthe oil pan gasketmatingsurfacesbeforeinstall, 18 N.m 11,8kgf.m, 13 lbt.ft)
ing. 1/8in. BSPT(British
StandardPipeTaper)
28 Threads/inch.Use
D16Y5,D15Y8engines: properliquidsealant.
OILPUMP
Overhaul,page8-g
Inspection,page8-10 DOWELplN
Applyliquidgasket
to the matingsurface
of the block.
6x1,0mm
11 N.m 11.1kgf.m,
8 tbf.ttl
page8,7
Replacement,
6x1.0mm
11 N.m 11.1kgt m.
8 tbf.ftl
BAFFLEPLATE
OILPAN
SCREEN GASKET
Replace.
6x1.0mm 6x1.0mm
11 N.m 11.1kgf.m. 11 N.m 11.1kgl.m, OIL PAN
8 tbf.ft) 8 tbf.ftl Referto page7-23
when installing.
39 N.m {,r.0kgl.m, 29 lbf.ft}

Do not overtighten.
urr.o-*tn
12 N'm 11.2kgl.m,8.7 lbf.ftl
8-4
En g i neO il
Inspection Replacement
1 . Parkthe vehicle on level ground, and turn off the CAUTION: Removo lhe drain bolt car€fully whilo tho
engine.Allow the oil a few minutesto drain back engine is hot; tho hct oil may cau36scalding,
into the oil pan so the dipstickwill show the actual
level. 1. Warm up the engine.
Make cenainthat the oil level indicatedon the dip- 2. Drainthe engineoil.
stickis betweenthe upperand lower marks.
DRAINBOLT Beplace.
a,l N.m14.5kgt'm, 33 lbf.ft)
Do notovertighten.
D16Y5.Dl6Y8 6ngines:
lf the level has droDpedclose to the lower mark,

add oil until it reachesthe uooermark.
CAUTION:Insertthe dipstickcarefullyto avoid bend-

ing it.
DRAINBOLT
39 N.m (,1.0kgl'm, 29 lbt frl
Donot ovenighten.
(cont'd)
EngineOil
Replacement
{cont'd)
3. Reinstallthe drain bolt with a new washer, and refill
the enginewith the r€commend€doil.
Requirement
API ServiceGrade:Use an "Energy
Conserving"SJ gradeoil or an
"EnergyConserving
ll" SH gradeoil,
SAE 5W - 30 preferred.
You can alsousean oilthat bearsthe
API CERTIFICATION mark.
Capacity D16Ytengine: API CERTIFICATION

MARK
3.6f (3.8US qt, 3.2 lmp qt)
at change,includingfilter.
3.3f (3.5US qt, 2.9 lmp qt)
at change,without filter.
4 . 3 1 ( 4 . 5U S q t , 3 . 8l m p q t )
afterengineoverhaul.
3.3/ (3.5US qt. 2.9 lmp qt)
at change,includingfilter.
62\"'
3.0/ (3.2US qt, 2.6 lmp qt)
at change.without filter.
3.7/ (3.9US qt,3.3 tmp qt)
afterengineoverhaul.
API SERVICELABEL
Change Every7,500miles (12,000km) or
12 months(NormalConditions).
Ev6ry3,750miles(6.000km) or
6 months (SevereConditions).
NOTE:Under normalconditions,the oil filter should be Fill the enginewith oil up to the specifiedlevel,run
replacedat everyotheroil change. the enginefor more than three minutes,then check
fof oil leakage,
Undersevereconditions,the oil filter shouldbe replaced
at eachoil change.
The numbersin the middle of the Apl Servicelabel tell
you the oil's SAE viscosityor weight. Selectthe oil for
your car accordingto this chart:
Ambienl Temperature
-30 20
A n o i l w i t h a v i s c o s i t y o f 5 W - 3 0 i s p r e f e r r e df o r
improved fuel economy and year-roundprotectionin the
car.You may usea 10W- 30 oil if the climatein your area
is limited to the temperaturerangeshown on the chart.
\
8-6
Oil Filter
Replacement
Installtheoil filter by hand.
Aft€r the engine has been run, the exhaust pipe will
be hot; be careful when working around the exhaust Afterthe rubbersealseats,tightenthe oil filterclock-
pipe. wise with the oil filterwrench.
Be careful when loosening the drain bolt while the
engine is hot. Burns can result becausethe oil tem. Tighten: 7/8 turn clockwise.
perature is very high. Tighteningtorque:22N.m (2.2kgf.m,16lbt.ftl
1. Removethe oil filter with the oil filter wrench.
2. Inspectthe threadsand rubbersealon the new filter.

Wipe oif the seaton the engineblock,then apply a
lightcoat of oil to the new filter'srubberseal.
NOTE: Use only filters with a built-in bypass sys-

rem.
Apply oil to rubberseal

beforeinstalling.
8-7
Oil Filter Oil Pressure
(cont'dl
Replacement Testing \
Usethis procedureto tightenthe filter if eight num- lf the oil pressurewarninglight stayson with the engine
bers(1 to 8) are Drintedon the surfaceofthe filter. running,checkthe engineoil level.lf the oil levelis cor
rect:
1) Makea markon the oil filterbaseunderthe num,
ber that shows at the bottom of the filter when 1. Connecta tachometer.
the rubberseal is seated.
2. Removethe engineoil pressureswitch,and installan
2) Tightenthe filter by turning it clockwiseseven orl pressuregauge.
numbersfrom the markedpoint. For example,if a
markis madeunderthe number2 whenthe rub-
ber seal is seated,the filter shouldbe tightened
untilthe number1 comesup to the markedpoint.
ENGINEOIL PRESSURE
SWITCH
MOUNTINGHOLE
7,€ turn
clockwise.
MARK
Numberwhen rubber Numberaftertightening.

seal is seated,
Numberwhen rubber
4 5 6 7 at
sealis seated
ADAPTER OIL PRESSUREGAUGE
{1/8'r28, BSPT} lCommerciallv
available)
Numberaftertightening 8 2 3 4 5 6 7 (Commercially avsilable)
CAUTION:Using any procedureolher than those Stan the engine.Shut it off immediatelyif the gauge
shown could r€sult in seriousengine damsge due registersno oil pressure.Repairthe problembefore
to oil leakage. contrnurng.
5. Afterinstallation,fill the enginewith oil up to the spec- 4. Allow the engineto reachoperatingtemperature(fan
ifiedlevel,run the enginefor morethanthreeminutes. comeson at leasttwice).The pressureshouldbe:
then checkfor oil leakage.
EngineOil Temperature:176'F(80.C1
EngineOil Pressure:
Ar ldle: 59 kPa10.7kgf/cm,,10 psi)
minimum
At 3,000rpm: 3,t0 kPa (3.5 kgt/cm,, 50 psi)
minimum
lf oil pressureis within specifications, replacethe

oil pressureswitchand recheck.
lf oil pressureis NOTwithin specifications, inspect
t h e o i l p u m p( s e ep a g e8 1 0 ) .
8-8
Oil Pump
Overhaul
NOTE:
a Usenew O-ringswhen reassembling.
. Apply oil to O-ringsbeforeinstallation.
. U s el i q u i dg a s k e tP, a r tN o . 0 8 7 1 8 - 0 0 0 o
1r08718-0003.
. The rotorsmust be installedto the samedirection.
. After reassembly, checkthat the rotorsmove without binding.
PUMPHOUSING 6x1.0mm
Inspection,Page8-10 7 N.m (0.7kgf m, 5 lbt'ft)
Applyliquidgasket OUTERROTOR
to mating surfaceof page8_10
Inspection,
the cylinderblock
when installing.
INNERROTOR
page8_10
lnspection,
DOWELPIN
PUMPCOVER
O-RING
Feplace.
6x1.0mm OIL SEAL

11 N.m (1.1 kgt m. 8 lbt.ft) Replace. Valvemust slidefteely
page8-11
Installation, in hous,ngbore.
Replaceit scored.
SPRING
g
@ .Hwlsren
E -
-/SEALING BOLT
39 N.- l{o kgf.m,
29 tbtftl
8-9
Oil Pump
RemovaUlnspection/lnstallation
'L
D r a i nt h e e n g i n eo i l . 1 0 . Removethe screwsfrom the pump hausing,then
separatethe housingand cover.
2. Turn the crankshaftand align the white groove on
the crankshaftpulley with the pointeron the lower 1 1 . Checkthe inner-to'outerrotor radial clearanceon
cover. the pump rotor.lf the inner-to-outer rotor clearance
e x c e e d st h e s e r v i c el i m i t . r e p l a c et h e i n n e r a n d
3. Removethe cylinderheadcoverand uppercover. ourerrorors.
4. R e m o v et h e p o w e r s t e e r i n gp u m p b e l t ,a i r c o n d i , Inner Rotor-to-OuterRotor RadialCl€arsnce

tioner beltand the aiternatorbelt. Standard(New):0.02- 0.14mm
{0.001- 0.006inl
Removethe crankshaftpulleyand removethe lower ServiceLimit: 0.20 mm {0.008in)
cover.
OUTER
ROTOR
6. Removethe timing belt.
7. Removethe drive pulley.
8. Removethe oil pan and oil screen.
O.RING
DOWELPIN Replace.
INNERROTOR
1t Cneclithe housing-to-rotoraxial clearanceon the
pump rotor, lf the housing-to-rotoraxial clearance
exceedsthe serviceIimit, replacethe set of inner
and outer rotorsand/orthe pump housing.
Housing-to-RotorAxial Clearance
Standard(New):0.03- 0.08mm
(0.001- 0.003inl
ServiceLimit: 0.15mm {0.006in)
OIL SCREEN
9. Remove the oil pump.
ROTORS
8-10
13. Checkthe housing-to-outer ' 1 7 .R e a s s e m b lteh e
rotorradialclearance. o i l p u m p ,a p p l y i n gt h r e a dl o c kt o
It the housing-to-outer
rotor radialclearanceexceeds the pump housingscrews.
the servjcelimit, replacethe set of inner and outer
rotorsand/orthe pump housing 1 8 . Checkthat the oil pump turnstreely.
Hoqsing.to.OutorBotor RadialClearance: 1 9 . Apply a light coatof oil to the seallip.

Standard{New):0.10- 0.18mm
(0.004- 0.007in) 20. Installthe two dowel pins and new O-ringon the oil
ServiceLimit: 0.20 mm (0.008in) pump.
HOUSING
2 1 . Apply liquidgasketto the cylinderblockmatingsur-
faceof the oil pump.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001or 08718
- 0003
. Checkthat the matingsurfacesare cleanand dry
. Apply liquidgasketevenly,in a narrowbeadcen
teredon the matingsurface.
. To preventoil leakage,apply liquidgasketto the
. Do not installthe pans if five minutes or more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t .
old residue.
. After assembly,wait at least 30 minutes before
1 4 . Inspectboth rotorsand the pump housingfor scor- fillingthe enginewith oil.
ing or otherdamage.Replacepartsif necessary.
1 5 . Removethe old oil sealfrom the oil pump.
to. Usingthe specialtool, gentlytap in the new oil seal Apply liquidgasket
alongthe brokenline.
until the driverbottomsagainstthe pump.
NOTE:The oil seal alone can be replacedwithout

removingthe oil pump. DRtvER
- 0010000
0?7i19
ATTACHMENT.
52x55mm
07746- 0010i100
(cont'd)
8-11
O il Pu mp
RemovaUlnspection/lnstallation
(cont'd)
22. Installthe oil pump on the cylinderblock.
Apply greaseto the lip of the oil pump seal.
Then,installtheoil pump onto the crankshaft.
Whenthe pump is in place,cleanany excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.
6x1.0mm
11 N.m 11.1kgf m,
I rbt.ftt
6 x'l.Omm 11N.m(1.1kgf.m,
11N'm(1.1kgtm, 8lbfftl
8 tbt.ftl
23. l n s t a ltlh e o i l s c r e e n .
24. I n s t a l l t h eo i l p a n( s e ep a g e7 , 2 2 ) .
NOTE:Cleanthe oil pan gasketmatingsurfaces.
8-12
IntakeManifold/ExhaustSystem
lntakeManifold
Replacement ..........
-............................
9-2
ExhaustManifold
Rep|acement 9-5
.......................................
ExhaustPipeand Muffler
Replacement .......................................
9-7
ThreeWay CatalyticConverter(TWC)
Inspection ......................
9-9
HeatedOxygenSensor{HO2S)
Replacement .......................................
9-9
IntakeManifold
Replacement
NOTE:Use new O-ringsand gasketswhen reassembling,
CAUTION:
. Ch€ckfor lolds or scratcheson the surtaceof the gasket.
. Replacewith a new gasket if damaged.
D16Y7engine:
8 x 1.25mm
22 N.m 12.2kgl.m, 16lbfftl
INTAKEMANIFOLO
Replaceif crackedor
it matingsurtacesare
oama9eo,
8 x 1.25mm
23 N.m (2.3kgt.m,
1? tbt.ftl
INTAKEMANIFOLD
ERACKET
E x 1.25mm
2a N.m 12./tkgf.m, 17 lbtftl
g-2
D16Y5engine:
6x1.0mm
12 N.m l'1.2kgt.m,8.7 lbtftl
EGRCHAMBER
INTAKEMANIFOLD
Replaceif crackedor
if mating surfacesarc 8 x 1.25mm
oamageo. 21 N.m {2.1 kgf.m,
15 tbf f0
EXHAUSTGAS
INTAKEAIR CONTROL RECIRCULATION
IIAC}VALVE (M/TI {EGRIVALVE
8 x 1.25mm
22 N.m (2.2 kqf.m, 16 lbf.ftl
INTAKE MANIFOLD
BRACKET 8 x 1.25mm
22 N.m (2.2kgf.m,
8 x 1.25mm 16 tbt tr)
23 N.m 12.3kgf.m,
17 tbf.frl
(cont'd)
9-3
Intake Manifold
(cont'dl
Replacement
NOTE:Usenew O-ringsand gasketswhen reassembling.
CAUTION:
. Checkfor folds or scraichss on the surfaceof the gasket.
. Replacewith a new gasket it damaged.
D16Y8engine:
INTAKEMANIFOLD
Replaceit crackedor
il mating surfacesare
oamageo.
INTAKEAIR CONTROL
{IAC)VALVE(M/T) N $"^
GASKET
Replace.
THROTTLE
BODY
See section 11.
I x 1.25mm
23 N.m {2.3 kgf.m,
17 rbt.ftl
INTAKEMANIFOLD
BRACKET
9-4
ExhaustManifold
Replacement
NOTE:Usenew gasketsand self-lockingnutswhen reassembling.
CAUTION:
. Checkfor folds or scraicheson the surtace of lhe gasket.
. Replacewith a new gaskei if damaged.
D16Y5,D16Y7engines:
PRIMARYHEATED
OXYGENSENSOR
{PRIMARYHO2SI
I x 1.25mm 44 N.m (4.5kgf.m, 33 lbt.ft)
24 N.m {2,4 kgtm, 17 lbf,ft} Replacement, page9 9
10 x 1.25mm
44 N.m 14.5kgt.m,
33 tbf.ftl GASKET
Feplace.
8 x 1.25mm
31 N.m 13.2kgf.m.
23 tbt.ft)
Replace.
THREEWAY CATALYTIC
CONVERTER {TWC)
page9'9
Inspection,
MANIFOLD SECONDARY HEATED

BRACKET OXYGENSENSOR
6x1,0mm ISECONDARY HO2S}
11 N.m (1.1kgf.m,8lbtft) 4zlN.m 14.5kgf.m, 33 lbl.ftl
Beplacement, page9-10
{cont'd)
9-5
)
ExhaustManifold
Replacement(cont'd)
NOTE:Usenew gasketsand self-lockingnutswhen reassembling.
CAUTION:
. Checktor lolds or scratcheson thg surfac6ol the gaskgt.
o Replacewith a new gasket if damaged.
D16Ygsngine:
8 x 1.25 mtn
2a N.m {2.4 kgf.m,
t7 tbf.ft)
E x 1.25mm
3l t&m13.2kgf.m,
23 tbt'ftt
R€placs.
PNIMARYHO2S
14 N.m 14.5kgt.m, 33 lbt.ft)
EXXAUSTMANIFOLD
BRACKET 10 x 1.25mm
44 N.m (4.5kgf.m,33 lbf.ft,
9-6
ExhaustPipe and Muffler
Replacement
NOTE:Use new gasketsand self-lockingnutswhen reassembling.
D16Y5,D16Y7engines:
EXHAUSTPIP€NP
MUFFI.ER
6 x 1.0 m.n
9.8 N.m {1.0 kgt.m, 7.2 lbf.ftl
HEAT SHIEI.I)
"e*......------------ 8 x 1.25mm
22 N.m 12.2kgt.m.
16 tbf.frl
Replace.
6xt.0mfi
s Tightenthe boltsin
steps,alt€.naling
side-to-side.
9.EN.ft (1.0kst'm, 7.2 lbl'ftl
8 x 1.25mm
22 N.m {2.2kgf.m, 16 |bfftl
Replace.
Tightenthe bolts in steps,
akernatingside-to-side.
------------->@
Replace.
GASKET
Replace.
SELF.I-OCKING NUl
SEI.f.LOCKINGNUT 8 x 1.25mm
10 x 1.25mm 16 N.m (1.6kg .m. 12 lbf.tt)
33 N.m 13.4kgtm, Replace.
25 tbt ftl
Replace.
(cont'd)
9-7
)
ExhaustPipe and Muffler
Replacement(cont'd)
NOTE: Use new gaskets and self-locking nuts when reassembling.
Dl6Yg engine:
EXHAUSTPIPETIP
MUFFLER
I
o.4/
GASKET
Replace.
-6r1.0mm
9.8 N.m {1.0kgf.m, 7.2 lbf.ftl
8 x 1.25mm
22Nm12.2kgtm,
16 tbt.ft)
Feplace.
Tightenthe boltsin
stePs,alternating
HEATSHIELD side-toside.
6x1.0mm
9.8 N.m {1.0kgf.m, 7.2 lbt.ftl
L
SELF.LOCKING NUT
l0 x 1.25mm
EXHAUSTPIPE 33 N.m {3.4kgf.m,
25 tbt.ft)
Replace.
SECONDARY H()2S
a4 N.m (4.5kgf.m, 33lbf.ftl
page9-10 GASKET
Replacement,
Replace.
TWC
page9-9
Inspection,
GASKETS
Replace.
8 x 1.25mm
EXHAUSTPIPEA 22 N.m (2.2kgt.m, 16 lbf.ftl
Replace.
Tightenthe boltsin steps,
alternatingside-to-side.
SELF.LOCKING NUT
t0 x 1.25mm
54 N.m 15.5kgtm,40 tbtftl \
16 N.m {1.6kgl.m, 12lbt.ft)
Replace. Replace.
9-8
TWC HO2S
1. Usinga flashlight,makea visualcheckfor plugging, Primary HO2S:
meltingand crackingof the catalyst.
1. Removethe primaryHO2S.
D16Y5,D16Y7enginss:
D16Y5,D16Y7engines:
a. Disconnectthe primary HO2Sconnector,then

removethe cover.
8 x 1.25mm
a-
2ilNm12.4kgt'm,
/)
D16Y8 engine:
FLASHLIGHT
b. Removethe primaryHO2S.
I
l
I
PRIMARYH02S
44 N.m 14t kgf.m, 33tbtftl
(cont'd)
9-9
A
HO2S
(cont'dl
Replacement
Dl6Y8 engine: SocondaryHO2S:
a. Disconnectthe primary HO2S connectorthen 1. Removethe secondaryHO2S.

removethe primaryH02S.
Dl6Y5, Dl6Y7 engin6:
a. D i s c o n n e c t h e s e c o n d a r yH O 2 Sc o n n e c t o r ,
then removethe secondaryHO25.
()2 SENSOR
WRENCH
(Commercially
PRIMARYHO2S
4,0N.m {4.5kgI.m, 33 lbt.ftl
2. lnstallthe DrimarvHO2Sin reverseorderof removal.
D16Y8engine:
a. Removethe grommet,and pullout the secondary

HO2Sconnector,then disconnectthe secondary
HO2Sconnector.
SECONDABY
HO2S
CONNECTOR
9-10
a
b. Removethe secondarvHO2S.
02 SENSORWRENCH
available)
lCommercially
SECONDARY HO2S
{rr N.m (4.5 kgf.m, 33 lbf.frl
2. I n s t a l lt h e s e c o n d a r yH O 2 S i n r e v e r s eo r d e r o f
removal.
9-1
Cooling
flfustrated lndex........... "." 10-2
Radiator
Replacement ........................ " " I 0-5
"."......
EngineCoolantRefillingand
Bleeding 10-6
........"".......'.'
CapTesting 10-8
...........'....'..'
Testing .'..'.10-8
Thermostat
Replacement " " 10-9
"......
........................'..
Testing "....10-10
EngineGoolantTemPerature
(ECT)Switch
Testing ....'.10-10
WaterPump
lllustratedIndex .....".'. .. 10-11
fnspection .10-12
Replacement 10-12
.......................'.'.'.......'."
lllustratedIndex
!@@ system is under high pressurewhen the CAUTION:lf any engine coolantspills on painted por-
engine is hot. To avoid danger of releasingscalding tions ol the body, rinse it off immediately.
enginecoolant,removethe cap only when the engineis
coor. NOTE:
. Checkall coolingsystem hosesfor damage.leaksor
Total Cooling System Capacity ncluding heater and deteriorationand replaceif necessary.
reservoir{0.41 (0.,12
US qt,0.35 lmp qt))l: . Checkall hoseclampsand retightenif necessary.
. Use new O-ringswhen reassembling.
M/I 4 . 2f ( 4 . 4U S q t , 3 . 7l m p q t )
4 . 1 i ( 4 . 3U S q t , 3 . 6 l m p q t ) * 1
Afi
4 . 3 f { 4 . 5U S q t , 3 . 8 l m p q t ) * '
CVT 4 . 3f 1 4 . 5U S q t . 3 . 8l m p q t )
* 1 :D 1 6 Y 7
engine BADIATORCAP
x 2 :D 1 6 Y ge n g i n e
Pressuretest, Page10-8 6x1.0mm
9.8N.m (1.0kgt m,
RADIATOR 7.2 tbt.ftl
Enginecoolantrefillingand bleeding, \
page10 6
Leaktest,page10-8 \
Inspectsolderedjointsand
UPPEN seamsfor leaks, \
RADIATOR Blowout dirt from between
HOSE corefinswith compressed air. COOLANT
lf insects,etc.,are clogging RESERVOIR
radiator,washthem off with \
-E-
low pressurewater,
5x0.8mm
5.4N.m {0.55kgtm, 4.0lbffi}
6x1.0mm
7.2N.m {0.73kgJ.m,
5.3 tbf.f0
LOWER
CUSHION
O-RING
DRAIN Replace.
PLUG
Referto sectionl4
when installing.
, 10-2
EngineHose Connoction3:
Dl6Y7 engin€:
IACVALVE
HEATER
HEATER VALVE
HOSES
(cont'd)
10-3
,.l
lllustratedIndex
(cont'dl
EngingHosgConnections:
D16Y5,D16Y8engines:
tAc vAtvE
IA/T)
CONNECTING
PIPE
Replace.
WATERBYPASS
HOSE
IAC VALVE
IM/T) THEBMOSTAT
HOUSING
O.RING
Replace.
\
\
\
\
rn
/
CONNECTING
PIPE
O.RING HEATEB
Replace. VALVE
H€ATER
HOSES
10-4
Radiator
Replacement
1 . Drainthe enginecoolant. 5, Removethe fan shroudassembliesand other parts
from the radiator.
2. R e m o v et h e u p p e ra n d l o w e r r a d i a t o rh o s e s ,a n d
ATFcoolerhoses. Installthe radiatorin the reverseorderof removal:
3. Disconnect
the fan motor connector. NOTE:
. Setthe upperand lower cushionssecurely,
4. Removethe radiatorupper bracket,then pull up the . F i l l t h e r a d i a t o rw i t h e n g i n ec o o l a n ta n d b l e e d
raqtalor. the air.
6x1.0mm
RAOIA 9.8 N.m (1.0kg[.m,
7.2 tbl.trl
ATF COOLER
HOSES{A/TI
Referto section
when installing.
UPPERRADIATORHOSE
6x1.0mm
7.2 N.m (0.73kgt.m,
5.3 tbl.fr) RESERVOIR
TANK
LOWEBCUSHION
DRAINPLUG
O.RING
Replace.
LOWERRADIATORHOSE
10-5
Radiator
EngineCoolantRefillingand Bleeding
CAUTION:When pouring engine coolant, be sure to Apply liquid gasketto the drain bolt threads,then
shut the rolay box lid and not to let coolant spill on the reinstallthe bolt with a new washer and tighten it
sl€cirical parts or thc paint. ll any coolant spills. rinse it securery.
off imm€diatslv.
Tightenthe radiatordrain plug securely.
1. Slide the heatertemperaturecontrol lever to maxi
mum heat. Make sure the engine and radiatorare 7 . Remove,drain and reinstallthe reservoir.Fill the
cool to the touch, tsnk halfwayto the MAX mark with water,then up
to MAX the markwith antifreeze.
2. Removethe radiatorcao.
3. Loosenthe drain plug, and drainthe coolant.
ORAINPLUG
4. Removethe drain bolt from the cvlinderblock. MAX MARK
</on
7E N.m 18.0kgl m, 58 lbf ft)
10-6
8. M i x t h e r e c o m m e n d e da n t i J r e e z w
e ith an equal 9. Pour coolantinto the radiatorup to the baseof the
amountof water in a cleancontainer. filler neck,and installthe radiatorcap looselv.
NOTEI
. Useonly genuineHondaantifreeze/coolant.
. For best corrosion protection,the coolant con-
c e n t r a t i o nm u s t b e m a i n t a i n e dy e a r - r o u n da t
50% minimum. Coolantconcentrations lessthan
5 0 % m a y n o t p r o v i d e s u f f i c i e n tp r o t e c t i o n
againstcorrosionor freezing
. C o o l a n tc o n c e n t r a t i o n gs r e a t e rt h a n 6 0 % w i l l
i m p a i r c o o l i n g e f f i c i e n c ya n d a r e n o t r e c o m -
menoeo.
CAUTION:
. Do not mix differcd brands of antifreeze/coolants.
. Do not use additional rust inhibitors or anti.rust
produsts; thcy may not be compatible with the
coolant.
Engine Coolant Refill Capacity Iincluding reservoir

(0.4f 10.42US qt, 0.35lm' qt)ll.
M/I 3 . 8{ { 4 , 0U S q t , 3 . 3l m p q t ) 1 0 . Startthe engineand let it run until it warms up (the

3.7/ (3.9US qt,3.3 lmp qt)*' radiatorfan comeson at leasttwice).
A/T
3 . 9/ ( 4 . 1U S q t , 3 . 4l m p q t ) * ,
1 1 . Turn off the engine.Checkthe level in the radiator.
CVT 3 . 9{ ( 4 . 1U S q t , 3 . 4l m p q t ) add coolantif needed.
* 1 : D 1 6 Y 7e n g i n e
* 2 : D 1 6 Y 8e n g i n e Put the radiatorcap on tightly,then run the engine
againand checkfor leaks,
10-7
)
Radiator
CapTesting Testing
'1.
1. Removethe radiatorcap, wet its seal with engine Wait until the engine is cool, then carefullyremove
tester.
coolant,then installit on the Dressure t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e
coolantto the top of the filler neck.
Attachthe pressuretesterto the radiatorand apply

a pressureof 93 - 123 kPa(0.95- 1.25kgt/cm?,'14
-
18 osi).
RADIATOR
ADAPTOR
(for32 mm neck,low profile)
RAOIATORPRESSURE
TESTER
(Commercially
available)
ADAPTOR
{for32mm neck,low Profile)
Apply a pressureof 93 - 123kPa(0.95- 1.25kgflcm' .

1 4- 1 8 p s i ) .
Checkfor a d.op in pressure.
lf the pressuredrops.replac€the cap.
Inspectfor enginecoolantleaksand a drop in pres-

sure.
4. Removethe testerand reinstalltheradiatorcap.
NOTE: Checkfor engine oil in the coolant and/or

coolantin the engineoil.
10-8
Thermostat
Replacement
NOTE:Usea new O-ringwhen reassembling.
THERMOSTAT
Installwithpin up.
RUEBERSEAL
THERMOSTAT
THERMOSTAT
HOUSING
TEMPERATURE
IECTI
swtTcH 6xl.0mm
24 N.m 12.{ kgt.m, 17 lbl.ftl 12 N.m 11.2kgf.m,8.7tbtft)
10-9
Thermostat ECTSwitch
Testing Testing
Replacethe thermostatif it is open at room temperature. @ Removingthe EcT switch while the engine
is hot can causethe coolant to spray out, seriouslyscald-
To test a closedthermostat: ing you. Always let the engine and radiator cool down
betore removing the ECTswitch,
'L Suspendthe thermostatin a containerof water as
shown. NOTE:Bleedair from the coolingsystemafter installing
the ECTswitch{seepage10-6}.
1. Removethe ECTswitch from the thermostathous-

THERMOMETER ing (seepage10-9).
Suspendthe ECTswitch in a containerot water as

shown.
THERMOSTAT
tl
Heat the water, and checkthe temperaturewith a

thermometer.Checkthe temperatureat which the
thermostatfirst opens.and at which it is fully open.
CAUTION:Do not let the thermometertouch the Heat the water, and checkthe temperaturewith a
bottom ot the hot container. thermometer.
M e a s u r el i f t h e i g h t o f t h e t h e r m o s t a tw h e n f u l l y CAUTION:Do not let lhe thormometertouch the

open. bottom of the hot container.
STANDARDTHERMOSTAT 4. Measurethe resistancebetweenthe A and B termi-

Lift height: above8.0 mm (0.31in) nalsaccordingto the table.
Startsopening: 169'- 176"F(75"- 80"C)
Fullyopen: 194"F(90'C) Terminal
\ B
Op"r"ffi
196"- 203"F
ON O_
SWITCH 5" - 15.F(3"- 8"C)

O F F lower than the tempera-
turewhen I goeson
10-10
Fueland Emissions
SpecialTools ..............
11-2 ldle ControlSystem
Component Location3 System Description .................11-122
lndex . . .1 1 . 3 Troubl€shootingFlowchart3
Systom Description ldle Control System . . . . .1. 1 - 1 2 4
Vacuum Connections 11.8 ldle Air Control Valve 11-126
Electricrl Connaqtions 11-19 Starter Switch Signal . ..11-130
I 1.29
SystemConneqtors.........................,,.,..,...,.,. AirConditioningSignsl .................................
11-131
Troubleshooting AlternatorFRSignal ......................................
t1-133
Troubfsshooting Procoduro!...............,........
71.42 Brake Switch Signal 11-13i1
EngineContlol Module/Poworftain Power Stoaring PressurcSwitch Signal ......11.135
Control Module Terminal A/T Gear Position Signal .... 11-137
Arrangement 11-'19 ClutchSwitch Signal .......... 11-139
DiagnosticTroubl€CodeChart ....................11-53 ldle SpeedSetting 11-141
1f -59
How to ReadFlowcharG...............................
Fuel Supply System
PGM-FlSystem Fuel Lines t 1-1i[5
Systom Description 11.60 Fusl Tube/Ouick.ConnectF ittin9s................,.... 11-117
TroubleshootingFlowcharts System Description........ 1t-150
EnginoControl Module/Pow€rtrain Fuel PressurG.........,. 11-150
Control Module 11.(x'
Fuel Iniectors ....... 11-152
Msnifold Absolute Pre3sureSen3or.............11-67
FuelPressureRegulator.....,.,.............,..,...,..,..... I 1-15i1
Intak€ Air Temp€raturoSensor 11-73
Fuel Fiher . . . . . . . . . . . . . . . . . . . .1. .1. ._. 1. .5. .5
EngineCoolant TemperatureSensor ...........1I-76
Fuel Pump . . . . . . . . . . . . . . . . . . . .1. .1. .-.1. 5. .6.
ThrottlePositionSensor ...............................
11-79
PGM-FlMain Relay . . .1 1 - 1 5 7
Prim8ryHeatedOrygen Sensor(Sensor1) ... 11-8'l
FueTl ank................... . . . . . . . . . . . .1. .1. .-.1 6 0
Socondrry Hoat€d Orygon Sonsor
lSensor2)................ 11-95
HeatedOxygen Sensor Heatel 11-98 Intake Air System
Fuel Supply System 11-103 System Description t1-161
Misfire Detectod in One Gylinder 11-105
Random Misfire 11-108
Knock Sensot 11-109
CKP/TDC/CYP Sensor.......................-....-.-.....
1 1 - 1t 0
VehicloSpesdSensor,......,...,....,.....,.,...........
11-'112 Emission Control System
Barometric PressureSen3or 1t-113 Syst€m Description 11-167
ElectricalLoad Detectol 11-115 Tailpipe Emission 11-167
CKFSensor 11-117 Three Way Catalytic Converter 11-167
EGM/FCMInternalCircuit .............................
11-120 ExhaustGasRecirculation System ...................
11-169
A/T Sisnal[rvlA/TMB] ..................................
11-121 PositiveCrankcaseVentilation System ..-......-..11-171
EvaporativeEmissionControls..........................
I 1-178
Speci a l To ols
t {
SpecialTools
Rsl. No. Tool Number Description Oty I PageRefel€nc€
't1-171,112,145,
o A 9 7 3 X - 0 4 1_ X X X X X 0 - 30 in.Hg
VacuumPump/Gauge, 1
186,188,192.193
07JAZ- 0010008 Vacuum/PressureGauge,0 - 4 in.Hg 1 1 1 - 1 9 21, 9 3
6 07PAZ- 0010100 SCSServiceConnector 1 11-42
o 07sAz - 0010004 BackprobeSet a 11-44
1 1 - 1 5 01,5 r , 1 5 4
07406- 0040001 FuelPressureGauge 1
07406- 0040304 FuelPressureAdapter,6x 15 mm 1 11 - 1 5 0
I (^
./.
u ),
11- 2
ComponentLocations
lndex
D16Y5engine:
THROTTLEPOSITIONITPI MANIFOLDABSOLUTE
SENSOR PRESSURE IMAPI SENSOR
page11 79
Troubleshooting, page'l 1-67
Troubleshooting,
EXHAUSTGAS NECIRCULATION
{EGR)VALVEand EXHAUSTGAS IDLEAIRCONTROL IIACIVAI-VE
RECIRCULATION IEGR}VALVE {M/TI
LIFTSENSOR page11-126
Troubleshooting,
pagel1 170
Troubleshooting,
EXHAUSTGAS RECIRCULATION
IEGR'CONTROLSOLENOID
INIAKE AIR TEMPERATURE
valvE tcwt
page11 I70
Troubleshooting,
IIAT} SENSOR
page11-73
Troubleshooting,
EVAPORATIVE EMISSION
ELECTRICALLOAD {EVAP}PURGECONTROL
DETECTOR IELD){USA model) SOLENOIDVALVE
page11-115
Troubleshooting, pag€11-190
Troubleshooting,
POWERSTEERINGPRESSURE
CRANKSHAFT swlTcH{usal
tPsP)
POStTTON/ page11-135
roubleshooting,
TOPDEADCENTER/ 1 = -
CYLINDER KNOCKSENSOR{KSI
POStTtON (cw)
(CKP/TDC/CYP} page11-109
Troubleshooting,
(Buikinrothe distributor)
T r o u b l e s h o o t i npga,g e1 1 - 1 1 0. /
CRANKSHAFT SPEED
VEHICLESPEEDSENSOR FLUCTUATION ICKFISENSOR
page1'l 112
Troubleshooting. page1'1117
Troubleshooting,
ENGINE
TEMPERATURE IOLEAIR CONTROL(IAC)VALVE
SENSOR
{ECT) tcwt
page11-76
Troubleshooting, page11-128
Troubleshooting,
WAY CATALYTIC
CONVERTER
ITWC}
PRIMARYHEATED paget 1-168
Troubleshooting,
SENSOR(PRIMARYHO2SI
{SENSOR1) {M/Tt
page1'1-88
Troubleshooting,
PRIMARYHEATEDOXYGEN
SENSOR{PRIMARYHO2S'
{SENSOR1t {CWl SECONDARY HEATEDOXYGEN
page11-84
Troubleshooting, SENSORISECONDARY HO2SI
{SENSOR2l
page11-95
Troubleshooting,
(cont'd)
11-3
Component Locations
Index(cont'dl
THROTTLEPOSITIONITP}
D16Y8engins: SENSOR
page11 79
Troubleshooting, MANIFOLOABSOLUTE
INTAXEAIRTEMPERATURE PRESSURE {MAPISENSOR
IIAT} SENSOR page11 67
Troubleshooting,
page1'1-73
Troubleshooting, IOLEAIR CONTROLIIACIVALVE
EI."ECTRICAL
LOAO {M/T}
page11-126
Troubleshooting,
DETECTOR{ELDI(USAI
pageI1-t15
Troubleshooting, EVAPORATIVE
EMISSION
IEVAP)PURGE
CONTROL
SOLENOIDVALVE
CRANKSHAFT page11-185,
Troubleshooting, 190
POStTtON/
TOPDEADCENTER/ POWERSTEERINGPRESSURE
CYLINOEF {PSP|SWTTCH{USA)
POStTtON page11-135
Troubleshooting,
(CKP/TDC/CYP} SENSOR
l8uilt into the distributori KNOCKSENSOR{KSI
Troubleshooting, page11'110/' page11-109
Troubleshooting,
CRANKSHAFTSPEED
FLUCTUANON ICKFISENSOR
page11-'l17
Troubleshooting,
VEHICI."E
SPEEDSENSOR
page11-112
Troubleshooting, IDLEAIRCONTROLIIACIVALVE
IA/TI
page1'l-128
Troubleshooting,
TEMPERATURE PRIMARYI{EATEDOXYGENSENSOR
tEcTtsENson (PRIMARYHO2SIISENSOR1}
page11 76
Troubleshooting,
THREEWAY CATALYTIC
CONVERTER {TWCI
page1l'168
Troubleshooting,
t?\..==.-- - --L------ --- - ----:
SEOONDARY HEATEDOXYGEN
SENSOB
ISECONDABY HO2S}{SENSOR2I
page11 95
Troubleshooting,
11-4
THROTTLEPOSITIONITPI MANIFOLOABSOLUTE
SENSOR PRESSURE (MAP)SENSOR
D16Y7engin6: page11-79
Troubleshooting,
VEHICLESPEEOSENSOR{VSSI INTAKEAIR TEMPERATURE
page1!-112
Troubleshooting, {IATISENSOR
page11 73
Troubleshooting,
ELECTRICAL
LOAD
DETECTORIELDIIUSAI
page11''1'!5
Troubloshooting, POWERSIEERINGPRESSURE
--....- {PSP)SWTTCH|USA}
CRANKSHAFT
-
page11-135
roubleshooting,
POStTtoir/
TOPDEADCENTER/
CYLINDER
POSTT|ON IDLEAIR CONTROL{IACIVALVE
r o u b l e s h o o t i n g ,p a g e 1 1 ' ! 2 8
ICKP/TDC/CYPI SENSOR
{Builtintothe distributor)
Troubleshooting. page11-110i
CRANKSHAFT SPEED
FLUCTUATION {CKF}SENSOR
page11 117
TroLrbleshooting,
ENGINECOOLANT PRIMARYHEATEDOXYGEN
TEMPERATURE SENSORIPRIMARYH02SI
IECTISENSOR lsENsoR
1)
page11-76
Troubleshooting, page11 84
Troubleshooting,
EVAPORATIVE EMISSION THREEWAYCATALYTIC
IEVAP)PURGECONTROL SECONDARY H€ATEDOXYGEN CONVERTER{TWC)
SOLENOIDVALVE SENSORISECONDARY HO2SI pageI 1-168
Troubleshooting,
page'l1-190
Troubleshooting, {SENSOR 2t
page11-95
Troubleshooting,
CLUTCHSWITCH{D16Y56ngine PGM.FIMAIN RELAY

M,/T) RelayTesting,page11-157
pag€11-158
Troubleshooting.
t2Pl ENGINECONTROLMODULE
Selt-diagnosticProcedures, IECMI/POWERTRAIN
page 11-42 Procedures,
Self-diagnostic
page11-42 CONTROLMODULE{PCM}
page11-63
Troubleshooting,
(cont'd)
11 - 5
ComponentLocations
Index(cont'dl \
'96 Dl6Y8 engine
{coupe),
'97 Dl6Y7 engiDs(coupe:KL mod€|, sedan: KL
{LX) modell,
'97 Dl6YBengine(coupo:all models,sedan:KL modell,'98-all
models:
FUELVAPORPIPE FUELGAUGESENDINGUNIT FUELPUMP
FUELFEEOPIPE Testing,seesection23 Testing,page11-156
FUELFILTER Replacement,page11-156
page11-155
Replacement.
EVAPORANVE EMISSION
IEVAPICONTROLCANISTER
VENTS}IUTVALVE
page'l1-185
Troubleshooting.
IEVAP)CONTROLCANISTER
page11-1
Troubleshooting,
FUELTANK
page11-160
Replacement,
APORATIVEEMISSION
{EVAPIBYPASSSOLENOID
VALVE
T r o u b l e s h o o t i n g .p a g e ' l 1 - ' 1 8 5
FUELINJECTORS TIVEEMISSION
page11-152
Roplacement, {EVAPITWOWAYVALVE
page11-193
Testing,
TANKPRESSURE
FUEI SENSOR
REGULATOR page11-181
Troubleshooting,
Testing,page'll-154 FUEL
R e p l a c e m e n t ,p a g e 1 1 - 1 5 4 FITTINGS
page11 147
Precautions,
page11 147
Disconnection,
page11-148
Connection,
'96 Dl6Y5
engino,'96 Dt6Y7 lngin€,'96 Dl6Y8 €ngin. {sedan),
'97 D16Y5.ngine, '97 D16Y7
ongine (coupe:KA, KC mod6ls,
sedan: KA, KC, KL {DX) mod€ls, hatchback:8ll mod€lsl.
'97 D16Y8engine (sed!n: KA, KC
mod€ls): FUELVAPORPIPE
FUEL
FUELFILTER FUELPUMP
page11155
Replacement, Testing,page11 156
Replacement,page I 1-156
IEVAPICONTROLCANISTER
page11-190
Troubleshooting,
FUELFILL
CAP
FUELTANK
page11-160
Replacement,
TIVE EMISSION
IEVAP)TWO WAY VALVE
Testing,page11 193
TUBE/OUICK.CONNECT
FITTINGS
FUELPRESSURE page11-147
Precautions,
REGULATOR page1'1147
Disconnection,
Testing,page11-154 page11 148
Connection,
Replacement,pageI 1-154
11-6
D16Y5,D16Y8engine:
TITROTTLEBODYITB}
page11-164
Inspection, THROTTLECABLE
R e m o v a l ,p a g e 1 1 - 1 6 5 Inspection/Adjustment,
page11-'162
AIR CLEANERIACL) D i s a s s e m b l y ,p a g e 1 l 1 6 6 page11,163
Installation,
Replacement,
VENTILATION{PCV}VALVE
page I1-177
Inspection,
D16Y7engine:
THROTTLECABLE
page1'l-162
Inspection/Adjustment,
AIR CLEANER{ACL} page1l 163
Installation,
page11-'162
Replacement,
RESONATOR POSITIVECRANKCASE THROTTLEBODY(TBI

VENIILATION{PCVIVALVE page'l1-16,4
Inspection,
page'l1-177
Inspection. Removal,page11'165
Disassembly.page11 166
11-7
SystemDescription
VacuumConnections
D16Y5engine{'96,'97 models):
To EvAPORATIVE
EMISSION
{EVAPI MANIFOLO
TWOWAYVALVE ABSOLUTE
PRESSURE(MAPI
SENSOR
EXHAUSTGAS RECIRCULATION
(EGRICONTROLSOLENOIO
VALVEIA/TI
\
EVAPORATIVEEMISSION \
IEVAP)PURGE
CONTROLCANISTER \ ^ \
Tre) l.--
EXHAUSTGAS RECIRCULA
M
-.'ry \
(EGRIVALVEand EXHAUSTGAS
RECIRCULATION{EGRIVALVE
LIFTSENSOR
(A/TI
EVAPORA
EMISSION(EVAP} To CRUISE
PURGECONTROLSOLENOID CONTROL
VAI-VE DIAPHRAGM
FRONTOF VEHICLE (withcruisecontroli
REGULATOR
O: VacuumhoseNo.
11-8
D16Y5ongine1,98modell:
EVAPORATIVE
EMISSION{EVAP)
CONTROLCANISTER
VENTSHUTVALVE
To EVAPORATIVE
EMISSION
To EVAPORATIVE
€MISSION (EVAP}
{EVAPITHREEWAYVALVE EXHAUSTGAS RECIRCULATION
TWOWAYVALVE and EXHAUST
IEGRIVALVE GAS
IEGRIVALVE
LIFT SENSOR
tatfl
EXHAUSTGAS RECIRCULANON
{CVTonlyl {EGRICOiITROLSOLENOID
VALVE
EV nvE
i,ff------\-
EMISSION{EVAP} I M, lin.;rrdio- - --
PURGECONTNOL I SP llesolure
CANISTER PURGE L..-..-..-..-r PRESSURE
tMAPI
SENSOR
JOINT
I
I
I
To CRUISE
CONTROL
EVAPORATIVE DIAPHBAGM
EMISSION{EVAP' (withcruisecontrol)
PURGECONTROLSOLENOID FRONTOF VEHICLE
VALVE
FUELPR€SSURE
REGULATOR
O: VacuumhoseNo.
(conr'd)
11 - 9
SystemDescription
VacuumConnections(cont'd)
D16Y8engine:
EVAPORATIVE EMISSIONIEVAPI
CONTROLCANISTER
VENTSI{UT VALVE
('96 coup., 37 coup.: all models,
'97 aed.n: KL model, 'g8-modelsl
To EVAPOnATVEEMISSION
{EVAPITHFEEWAY VALVE
'97 To EVAPORATIVE
EMISSION
l'96 coupo, coupo:all mod6b,
'97 sedan:KL model, 'g8-modols) IEVAPI
TWO WAY VALVE
EVAPORATIVE
EMISSIONIEVAPI
PURGECONTROL
CANISTER
{'96coupe, 37 coupe:ell modek,
3edan:KL model)
FUELPRESSURE
MANIFOLD
AESOLUTE
REGULATOR (MAP}SENSOR
PRESSURE
EVAPORANVEEMISSION
IEVAPIPURGE
CO]TTROLCANISTER
('96 3.d.n, 37 r.drn: KA,
KC mod.lrl
EVAPORATIVE
EMISSION{EVAP}
PURGECONTROLSOLENOID
VALVE
FNONTOF VEHICLE
Qo To CRUISE
CONTROL
OIAPHRAGM
(withcruisecontrol)
11 - 1 0
D16Y7ongine l'96 modek,'97 coups: KA, KC models.'97 sedsn: KA, KC.KL {DX} models,'97 hatchback:all modolsl:
FUEL
EVAPORATIVE PRESSURE
EMISSION
IEVAP' REGULATOR
PURGECONTROL
To EVAPORATIVE MANIFOLD
AASOLUTE
EMISSION(EVAPI PRESSURE
IMAP)
TWOWAYVALVE SENSOB
To CRUISE
CONTROL
DIAPHRAGM
{withcruiso
control)
EVAPORATIVE
EMISSIONIEVAPI
PURGECONTROL
CANISTER FRONTOF
vEHtcl-E
(cont'd)
11-11
r
SystemDescription
VacuumConnections(cont'dl
Dl6Y7 engine('97coupe:KL modcl,'97sedan:KL {LX)model,'98models}:
EVAPORATIVEEMISSION(EVAPI
CONTROLCANISTER
VENT SHUTVALVE
To EVAPORATIVE
EMISSION To EVAPORATIVE
EMISSION
IEVAPITHREEWAY VALVE IEVAP)
TWOWAYVALVE
FUELPRESSURE
REGULATOR
MANIFOLDAASOLUTE
PRESSUREIMAPI SENSOR
EVAPORATIVE
EMISSIONIEVAPI \
PURGECONTFOL
CANISTER
To CRUISE
coNTROt
DIAPHRAGM
(withcruis€control)
EVAPORATIVE
EMISSION(EVAPI
PURGECONTROLSOI."ENOID
VALVE
FRONTOF VEHICLE
11-12
D16Y5enginenl'95,'97 modelsl:
,r;---l
I ENGINEI
i COOLANTi
l(D l+ |
t/6r IUI t
iLffii
i -I]Fn- i
L l-r- I
l-,4 I
:l: Vacuum ho3oNo.

': CVT only
o PRIMARYHCATEDOXYGENSENSORIPRIMARYHOzS, @ FUELTANK EVAPORATIVE

EMISSIONIEVAP}VALVE
SENSOR 1l
6i SECONDARY
a
(D
AIB CLEANER
HEATEOOXYGENSENSORISECONDARY RESONATOR
HOzS.SENSOR2l @ POSITIVECRANKCASEVENTILAIION{PCVIVALVE
aal MANIFOLDABSOLUTEPRESSURE (MAP}SENSOR €0 EXHAUSTGAS RECIRCULANON
IEGRICONTROL
@ ENGINECOOLANTTEMPERATURE IECTISENSON SOLENOIDVALVE
INTAKEAIR TEMPERATURE{IATISENSOR @)EXHAUSTGAS RECIRCULANON
{EGRIVALVE
KNOCKSENSORIKS} EXHAUSTGAS RECIRCULANONIEGRIVALVELIFT
o CRAITIKSHAFTSPEEDFLUCTUATION(CKFISENSOR SENSOR
@ IDLEAIR CONTROL(IACIVALVE @ EVAPORANVEEMISSION{EVAPIPURGECONTNOL
6\ THROTTLE BOOY(TBI sottNotDvALvE
[E FUELINJECTOR a EVAPORATIVE
EMISSION{EVAPICONTROLCANISTER
o FUELPULSATIONDAMPER @ EVAPORATIVE
EMISSIONIEVAPITWO WAY VALVE
@ FUELFILTER 6 THREEWAY CATALYTICCONVERTEFITWCI
@ FUELPRESSURE REGULATOR
(0 FUELPUMP(FP)
@ FUELTANK
(cont'd)
11 - 1 3
SystemDescription
\
D16Y5enginel'98 model):
-: Vacuum hoaoNo.
*: CW only
O PRIMARY HEATED OXYGENSENSOR (PRIMARYHO2S. @ posrnvEcRANKcasE

vENnLATtoN
{pcvtvALvE
SENSOR 1l @ EXHAUSTGAsRECIRCULATIoN
IEGn)coNTRoL
O SECoNDARY HEATED oxYGENsENsoRISEGoNDARY SOLENOID
VALVE
HO2S.SENSOR 2) @ EXHAUST GAs RECIBCULATIoN{EGRIvALvE
O MANIFoLD ABSoLUTE PRESSURE |MAP}sENsoF @ ExHAUsrGAs REctRcuLATtoN {EGRtvalvE L|FT
(' ENGINC COOLANT TEMPERATURE ICCI)SENSOR SENSOR
O INTAKE AIFTEMPERATUBE {IAT}sENsoR @ EVAPoRATIVE EMISSIoNIEVAPIPUnGEcoNTRoL
G) KNOCK SENSOR IKSI SOLENOID
VALVE
O CRANKSHAFT spEEDFLUCTUAT|oN tcKFtsENsoR 8] PURGEJOTNT
@ IDI.EAIRcoNTRoL{IACIVALVE @ EVAPoRATIVE EMIsstoNIEVAPIcoNTRoLCANISTER
O THRoTTLE BoDYtrBl @ EvApoRATtvE EMrsstoN(EvAp)BypAsssoLENoD
(O FUELINJECToR VALVE
O FUELPULSATION DAMPER @ EVAPoRATIVE EMtssIoN{EVAP)THREEwAY vALvE
@ FUELFILTER @ EVAPoRATIVE EMISSIoNIEVAPIcoNTRoLCANISTER
(} FUELPRESSURE REGULAToR VENTSHUTVALVE
(} FUELPUMP{FP) @ FUE|-TANKpREssuRE sENsoR
@ FUELTANK @ EVApoRATtvE EMtsstoNtEvAp)two wAy valvE
@ FUE|-TANKEvApoRATtvE EMtsstoNtEvaplvALvE @ THREE wAY cATALYTICcoNvERTER ITwcI
@ AIRCLEANER
@ RESoNAToR
'97 '98 models):
D16Y8engine('96coupe,'97coupe:all models, s€dan:KL model,
{M/T)
| - : - l
iI ( ' l
F@, i
i liiffis r
:.. --''--- I
{A/T)
- -l
E-NGim
6)toofl'!
O PRIMARY HEATED oxYGENsENsoRIPRIMARY Hozs, (1-6)AIR CLEANER

SENSOR 1l o RESONATOR
€) SECoNDARY HEATED oxYGENsENsoR{SECoNDARY @ POSITIVECRANKCASEVENTILATION{PCV)VALVE
HO2S.SENSOR 2r @ EVAPORATIVEEMISSIONIEVAPIPURGECONTROL
O MANIFoLD ABSoLUTE PRESSURE IMAP)sENsoR SOLENOIDVALVE
@ ENGINE COOLANT TEMPERATURE IECTISENSOR @ EVAPORATIVEEMISSION{EVAP)CONIROLCANISTER
O INTAKE AIRTEMPERATURE (IAT)sENsoR E1lEVAPORATIVE
EMISSIONIEVAPIEYPASSSOLENOID
@ KNocKsEt{soRtKs) VALVE
O CMNKSHAFT spEEDFLUcruATroN(cKFlsENsoR @ EVAPORATIVE
EMISSIONIEVAPITHREEWAY VALVE
@ |DLEAtRcoNTnoLltacl vALvE @ EVAPORATIVE
EMISSION{EVAPICONTROLCANISTER
@ THRofiLEBoDYITB) VENT SHUTVALVE
@ FUELINJEcToR @ FUELTANK PRESSURE
SENSOR
O FUELFILTER c! EVAPORATIVEEMISSION{EVAPITWO WAY VALVE
@ FUELPRESSURE REGULAToR adTHREEWAY CATALYTICCONVERTER(TWC)
G) FUELPUMP{FP)
@ FUELTANK
@ FUELTANKEVAPORATIVE EMISSION(EVAP)VALVE
(cont'd)
SystemDescription
VacuumConnections(cont'dl
Dl5Y8 engine ('96 sedan,'97 sedan: KA, KC modets):
IM/T)
I-@-l
ir'ffii
'_._:_..i
l,'
\
.' PRIMARY HEAIEDOXYGEN SENSOR IPfiIMARYHO2S, @ FUELPRESSURE REGULATOR

SENSOn lt @ FUELPUMPIFPI
€] sEcoNDARyHEATED oxycEN sENsoRrsEcoNDABy @ FUELTANK
HO2S.SENSOR 2l @ FUELTANK EVAP,ORATwE EMISSION{EVAPIVALVE
O MANIFoLD ABSoLUTE PRESSURE (MAPIsENsoB @ AIR CLEANER
O ENGINE cooLANTTEMPERATURE tEcD sCNsoR (xRESONATOR
O INTAKE AIRTEMPERATURE IIATIsENsoR @ POSITIVECRANKCASEVENNIANON {FCV} VAIVE
@ KNocKsENsoR{Ksl @ €VAFORATIVEEMISSIONIEVAP}PURGECONTROL
O CRANKSHAFf spEEDFLUcruATtoN{cKFtsENsoR SOLENOIDVALVE
@ |DLEAtRcoNTRoLflActVALVE @ EVAPORATIVEEMISSON IEVAPI CONTBOLCANIS1ER
O THROTTI.I BODYITBI @ EVAPORATIVE EMISSION(EVAP}TWO WAY VAVE
@ FUELINJECToR @ IHREE WAY CATALYTICCONVERTERITWC}
@ FUELFILTER
11-16
-
D16Y7enginel'96 models,'97coupe:KA, KC modets,'97sedan:KA, KC,KL (DXl models,'97h8tchback:all models):
COOLANT
O PRIMARY HEATED OXYGENSENSOR {PRIMARYHO2S, @ FUELPUMPIFPI

SGNSOR 1l @ FUELTANK
O sEcoNDARyHEATED oxyGENsENsoR(sEcoNDARy (}FUELTANK EVAPORATIVE EMISSION(EVAP)VALVE
HO2S.SENSOR 2) @ AIR CLEANER
O MAN|FoLD ABSoLUTE pREssuRE (MAptsENsoF @ RESONATOR
€) ENGINECOOLANT TEMPERATURE {ECTISENSOR all
POSITIVECRANKCASE VENTILATION{PCV)VALVE
@ INTAKE AIRTEMPERATURE (IAT)sENsoR @ EVAPOMTIVEEMISSIONIEVAPIPURGECONTROL
@ CRANKSHAFT SPECD FLUCTUANON ICKF}SENSOR SOLENOIDVALVE
O |DLEAtRcoNTRoL{tActvALvE @ EVAPORATIVE EMISSIONIEVAP)CONTNOLCANISTER
@ THRoTTLE BoDYITBI @ EVAPORATIVE EMISSIONIEVAP}TWO WAY VALVE
@ FUELINJEcTon THREEWAY CATALYTICCONVERTER {TWC)
@ FUELFTLTER
O FUELPRESSURE REGULAToR
(cont'd)
SystemDescription
D16Y7ongine l'97 coupe: KL modol, sed8n:KL (LX) model, g8.modols):
--[-
O PRIMARY HEATED oxYGCNsENsoRIPRIMARY Ho2s, @ RESONATOR

SENSOR 1) @ POSMVECRANKCASEVENTILATION(PCVIVALVE
O SEGoNDARY HEATED oxYGENsENsoR{SECoNDARY EMISSION(EVAPIPURGECONTROL
@ EVAPORATIVE
HO2S,SENSOR 2l SOLENOIDVALVE
O MANIFoLD ABSoLUTE PBESSURE IMAPIsENsoB EMISSION(EVAP)CONTROLCANISTER
@ EVAPORATIVE
@ ENGINE cooLANTTEMPERATURE tEcTIsENsoR @ EVAPORANVEEMISSION{EVAPIBYPASSSOI.-ENOID
O INTAKE AIRIEMPERATURE {IATIsENsoR VALVE
@ CRANKSHAFT SPEED FLUCTUATION (CKFISENSOR @ EVAPORANVEEMISSION(EVAP)THREEWAY VALVE
O IDLEAIRCONTROL |IAC)VAI.VE @ EVAPORANVEEMISSIONIEVAPICONTROLCANISTER
@ THRoTTLE BoDy tTBt VENTSHUTVALVE
O FUELINJECToR @ FUELTANK PRESSURESENSOR
@ FUELFILTER @ EVAPORATIVEEMISSIONIEVAPITWO WAY VALVE
O FUELPRESSUFE REGULAToR @ THREEWAY CATALYTICCONVERT€RIIWC}
.IA FUELPUMP{FP)
{9 FUELTANK
Ii4 FUELTANKEVAPORANVE EMISSION{EVAP}VALVE
f,, AIRGLEANER
11 - 1 8
ElectricalConnections
-9
I
!
lo C*iCA6OR Cl,UlCtt F€IAY

lo A./CPfiC8dUiE a|lrTCH
ECr SW'ICtl
CHEC|(
.2: AII (Dlovt, Dr6Y8.neln.l
ra: AfI.nd OioYt.hgl..

r5: El€Dt A/I.n<l Dr6Y7 ft9ir.
r?: CVTlDi6Y5 ooln.l .nd O16Y3.nsin.

ra:96
96 Di6Yadgln. Ic@p.|, 37 Dl6Y3.n9ln.
Dl6Y3.t O i liIIEES
n UCHI
lco!p.: .ll mod.l." t d.n: XL mod.il '$ Ol6Y5 .n9in., O tAC(
tâ lr? lt.6 A,i N., 13fUEL tlr$t lll Al
o xox
rAt
o tAtttl t'|. rt &lEr|{AlOi A?*i.3oi tr.aAl
'10: M/I lD16Y5mdn.l orct llo. 3t 6ta8fEi stol{^t tt.6 at
11l: Eropt M/r OlaY5 .tr!4..1 r: h ii. lndr.lb.d lr-/nld 5.r
.12: DiCY5,DltYgmdn.
'15: '9t Dl6lt d9ln. (@qp.: K- mo.Ll, ..d.n: {cont'd)

KL lLxl mod.ll, 16 D16rt .nein.
11 - 1 9
System Description
ElectricalConnections(cont'dl .l
T:I
FUEL
PACITST'R€
sEt{Bon
gEN90fi
EGN
EGN
tnAt(Ctt{ltcH
{
lo f,lEnJOCK
@fttiot utrtt
A: EVA' tUiG€ clr||liol aorliloo VAIVE

a: EvAr cotltioa c tr*slEi wm $(rr vavE
qEv P av?ats aolEioo valvE
O: CCi Coraliol Sotlltlolo VAIVE
E: VIEC 6otli|oa V IVE
t: r,iEAns{r(EilOrOV IVE
c: LOO(.I P Ot Ltxt! SOt'lilOlO VAYE A
tt toc(.(t@ lf,ot aot.€iloD vAlvE I
r SHfT @tvtioi, aottlllxt v^lvE A
J: at||f @lvriol8OlIiIXt VAIVE !
2; A/t lolart, Olava rCDl

ra: AfI .nd Dlart ddn.
15: Espr A/T.nd Dttr, dsa.
.7: CVI iD'lav6milDl.nd DilV,.ndd
r3: ga Ol6Y3 dct lcoup.), '97 DtaYS .|'|tu
- r------t - ldD...t mort lr..d..: l(l n .Ul, ! DtaYE osl..,
{
Lll.J' 1t!r!]J l' ? l
l6 r r D 11 |
'ror M/r tDrat6 oCn l
t,'r,, st llll rll: Erc.pl M/T lDlaYt .nsl..l
'12: D'laY5, DlaYa..dD
rl5: It Oiart ddm ldrp.: IL h.d.l,..d.n:
11-20 xL lL]xlhodJ','S Dlart odd

MAP S€i60f,
EGi VAVE
cl'!t uF sENsoB
""fi""-_l- s€ivtcE cHEcx

cot{NEcToi
I
stu
l__.!-sru/YEL a6scoNriol u r,
@l{t{€cToi
(cont'd)
11-21
SystemDescription
ElectricalConnections{cont'dl
ro?aF c.,l
8lx/YyHTl
so2SHTC
ltvwHT,
cl3r ca46
iED/YEL"I
sEcotD aY
HO2S iSE|!SOR 2l
FOzSHTC.x PAIMANY
sol.E|lo|D
cror
.2: a/t IOl6Yt, Dl6Y, .n!in.l .10: M/t lDl6YE osin.l
.lr: Erc.rt MtI lot5Y5 min.l
\i
.a: a/I .nd OlaYt .n!i.. rl2: ol6Yt, Dl6Yaogin.
.6 Esoi Art.d Dt6r, .n!ln.
.7: CW (Oia\6 ociml.nd DI6YS.nciM .t5: 9? D16Ytdgi..ldp.: KL tFd.l. t d.n;
.3:'94 OlaYl ncin. l.o{Fl, !7 ol6Ya 6ci.. lG ltxl mod.D,'93 O|6YT.nsim
tcour:.amod.lr..d.n: Xtmod.ll,'9aOl6Y5.ngh,
11-22
:rva --f|:F-l
wtfii l-,1 /ffi|
| | L__.dJ I
8LX'-1FJ I
LT GAiYWHT
CAI'IISTEAVEM
SHUTVALVE{.i$
N C D /- U
' ' _ _ _ - __ _ _ '''-'- _ - _ __ __ -
F--+,
Ks"-I
-
aeo'--
8rx-- Jl---l
1t+l
clurcH swrrcHn.
{cont'd)
11-23
System Description
ElectricalConnectors(cont'd) .a
scr{90fi
rDc
s€t€ofi
cr(?
BLX
H?,H,?,"iI t30
BFN/IL(I
BRN/BIXI
BA/
alx1
r* &
L ]t . l
lTop.l.tt-2al
r1:USAmod .9i D'16Y5 mgim
.2: Arr tD'r6\r, Dr5Y3dsin. l0: Mfl lDl6Y5.rsitul
.3: C\/T tot6y6 net..l .11: €r..ct M/I lD'laY5 osim)
.a: A/I .nd Dl6r, .nC,. r12: OtaY5, OtSYt .natr.
.E: Erc.ptA/T.nd Oi6Y'.ryin. .13: DltYa osin. {
.arA/t tDt6y8 dctn.t rla: DlaYt.nlln.
.7r CVt (Dl6V6 .nelal .nd DiOYs .ncin. 116:t7 Dl6ft .n!Nm l@p. XL nod.l, ..d..:
'0:'96Dl5Y0.nc.{dp.l,37Di6Y3.nsim |(!tlxlh.d.ll,'!cDlaftosid
lcoup.:.llmod.L,..d.n:Klmod.ll,'9aot6Y5.nrin.,
11-24
MAINSHAFI SPEED SENSOf,"
t3
BtU'
COUNT:RSHAFI
SPIEDSENSOR-
c121
ll e
3
l I
l l |
(cont'd)
11-25
System Description
ElectricalGonnectors(cont'dl
cr3r caa6 orrr c*,2
oll0 cSlta
GRT/ATI: T
d YCL
I
rr GFl{l ----
Brx/Bru
-
w{F-
T*- FEo
-
l
GRN --
I
uru,-
1
fi
a/r GE i fo6no|l swTcll
NtEn|-OCX
coifliot uttr
;., -
--.1
cnr'--
l .lc
ilr mffimi#
t'i --
BLU/BEB-- - - f
arun:u-- j' ro ^/c s$rcH
U
cr3r c/r46
'2: A/T (Dl6Y7,Dl6Y3.ngin.t .10: Mlt loloY5.ncitul

.i'l: Erc.Dr M/r ID|6Y5 ddn.l
.a: A/T .nd Di6rr.ncitu
rt: Erc.pt Alt .nd Dl6Yt .nsi..
'rA DiAY5,Dli\,t melm
,
.t: Cw lol6Y5 6ein.l ..d D16YO .nsin. r15: 'et Dl6rt oslo loop.: KL mo.bl,..d.n:
.8i'96 Ot6yt.ntin. l6uD.l, 97 Dt6Y3.nCln. xl lDo m.<bll,'S olsYt.ncln.
tcoup.: .ll mod.lr..d.n: xt mod.ll,'96 o16Y5.n!in.,
11-26
WHT/BLU
lcr l/toal
]lonx tl6al
A/C CTUTCH
REIAY
["*
--o_ Fr,ISE/REI.AY
BOX
FCir-Fl
I'AIN REIAY
No. 3l STABTEn
srct{ar (7.5al
1-27
f-
System DescriPtion
ElectricalConnectors(cont'dl
- tT GRn
GR /ALK'
o|or c555
ii F YEUBI-U
ITGRts-
t- GA /a|.x
AUUWHI
t 3LU'-
t:l t"-l
TT
[t
FED/ FED
GRN
VREFI
wxT/nED, F
F l " l
F
clit5
Hiriffi+€
BEAXf,SWTTCX
.2: A/T {Or6Y?,Dl5Y8.nsin.l

'3: Cvr {Dl6Y5.ngi.€}
.4: A/T .nd Dl€Yr.ngin.
.5: Ex€Dt A/T tnd Dl6Y7.ngin.
.5: A/T {D16Y8.ngln.l
17rCW tDtoYs!ngln.) lnd ol6YE .ngin.
r8:'96 Dl5Y8.nsin. {coupol,37 Dl6Y8!.sin.
'98 D16Y5.nsin.,
lcouo.r .ll mod.b, ..d.o: Nl mod.tl,
'$O16Y8login.
.9: D16Y5.ngin.
'10: Mff lDr6Y5.ngin.l
.tt: Exc.pi M/r {Dl6Y5.nein.,
.t2: Dl6Y5,Dt6Ya.ngin.
.13: D16YE..gin.
'15:,97 O'16Y7.ngin.lcoup.r XL mod.l ..d.n:

11-28 KL {LXlood.ll,'98 Dl6Yt msin.
SystemConnectors[FuelPumpl
c792+r.*'5
,
c565 c792r.,r1s
tlr
c793r3.rE *2: USA model
t
A/T {D16Y7,D16Y8engine}
*3: CvT {D16Y5enginel
E ffi fr
l
*4: A/T and Dl6Y7 engine
I
@
*5: ExceptA/T and D16Y7enginc
16:A/T lDl6Y8ensine)
*7: CVT {D16Y5engine}and D16Y8engine
*8: '96 D16Y8engine{coupel,'97D16Y8engine
I
{coupe:all models,sedan:KL model),
'98 D16Y5engine, '98
O'16Y7engine
'9: D16Y5engine
*10:M/T {D16Y5enginel
IITYT!BLU-___l *11:ExceptM/T (D16Y5engine)
I"TGRN/BLx- *12:D16Y5,D16Y8engine
f'li-BN' - *13:Dl6Ygengine
'14: D16Y7.ngine
*15:'97D16Y7enginelcoupe:KLmod6l.s€dan:
KL {LX)modell,'98D16Y7en9in6
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKI

and YEUBLK,are not the same).
O: Belatedto Fueland EmissionsSystem.
. - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline)rView from wire side
(cont,d)
11-29
SystemDescription
SystemConnectors[EngineGompartmentl(cont'dl
D16Y5,D16Y8sngine:
11 - 3 0
c101 c102 oo c104
.",t c105 c106
(Canada,
F'fftt l- Irl f'frf

l.l.l
.l
ItrlwHr/RED,--l lolwHr,nED"
Fl8iNiB.,. I ttlBLvyEL -
Ec" 1
16lBLrr,f ItlwHlBLrJ-
c10? c109r. cl10 c'|13+1 cl1a
r'ft]
16loRN---l
l€)lYEUsrK' I
bIBLX/BLtl-
ffiffi
c136.. c137r' c138r5 C1,r2r'
fr
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguish

them (for example,yEUBLKT
O: Relatedlo Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline):
View from terminalsroe
- Connectorwith femaleterminals
{singleoutline):View from wire side
(cont'd)
11-31
System Description
SystemConnectors[EngineCompartmentl(cont'dl
D16Y5,D16Y8engine:
c14113 c112
cl23
11-32
c111 c112 ct15 c116 c117
fr r'tra
l a 8LK
FfBL{-l
YEUBLKI i9, B L K ' i?l8L|(YEL I
G) Y E U B L K ' ELKI f3-l-surwHr -
@ YEVE!KI 8LK'
YEUBLII .!3 E L K I
,!] Y E V B L K ] !l B L K '
YEUELK' SLK
cl20 c122 c125
c118*' c123 c124"
fr ffi fr ffi
--__l
lDlGRr,P o YEVGAN
ti|wHr FED.__l
I]l
lEl-Lur-- - 8LU5 tJ) RED5
fiTGRN/BLF
o BIK'
l-3_ELK.YELl]]lI
YELI BLU
5 10 ElxrYEL
lalir-r1wii'
c126r' c121" c12E.' c139* c14{}*f clalrl
ffi
-_Et_
F I'I fr E fr FT'I
FT-wHr-7---l |6FED,--__-l
l_l l6lELU/vEL-l 16lcRr.yYEL;_l trTBLF---__-] tilLr cnvwnl
Il
lDlFEp. I lSlwHl lETcRr^rHil l ? l n eo , I I-IBLKCi
glnn ;c;*
A l r l 2 l 3 l
l-t
l 1l , I t f ; l
['lrl.) tiT l L4 6l;I;l
v
16]wHrigLa_--l It'|wHr/BLx_l ----_--.l .- wH si_l
EBrx,r/yf,p I5T l-T- f-Fr 6 BL'q^/rf__l
l?liFN/BIK,
---1I ll? GFN/BLKr I l2lBtK l6lwHT l l2 wHTBLU a w ' r TB . l r I l 2 BtUl/vHT 7 - |
ItrItEUBLU I aTYELisLt- I3 GFN,ELK' 7 BL(' I I3 ItH] GRN 9 WFTCFN I I1 WFIBLK S W H IG R N I
lelBra-----l
-1 l4lwHl' 8lqED" I 14 8-k 10 - | l! w H rB L K e wrrl I
F T _
j6FNF -_- I. *"' "co
-1 BL-\/r-
| |u l e rr c a r o
f6-wrr Rro f---
c35{'1
r'ft] -.l
fclBtKi,,iHr
loleLK--'-ll]l
1olGRNFEo
NOTEI. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,yEUBLKI
and YEVBLK,are not the same).
O: Relatedto Fueland EmissionsSvstem.
o - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)
11 - 3 3
System Description
SystemGonnectors[EngineCompartment](cont'd) V., J
D16Y7engine:
11-34
c10l c102 C'loil c105
9,''on {C.nada)
r,frt r+
| 1 l 2 l r'1rtr ffi
|jIJ
-l
lSlwHr/RED;_l 16lwHr/RED"
---1
16TBuNsLKr--l
_-l ETBLX/vEr -'1
EfBLUmEo. lTlwHrsru
c106 c107 c108 c112
ffi ffi Etr ffi
c113*!
t=t
/ 1 \
\2
I6ERN--l ll
Idfsr-r---
NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1

O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside (cont'd)
11-35
System Description
SystemGonnectors[EngineCompartment](cont'dl
D16Y7sngine:
11 - 3 6
c109 c'|10 c114 c115 cl16
r'ff;r fr
l BLK
fSloRN---__l
IaIYEUBLK, I .1) YEUELKI BLK'
lb]-Bar<,jLu I ttl Y E V B L K ' o BLK'
YEVBLK' BLKI
Y€UBLK' BLK'
o'| YEUELK' BLK'
YEUBLK' BLK'
cI17 cl18 (A/Tl cl23
r'frfl ffi ffi

lllBLr----l
lt ELK,YEL_-l I
I-TBLUIrvHT
ffi fiil RrD ,vHr--
IdIGBIvBLK' I
c12r lalf I c125 c126lA/T) c127(A/Tl c12A |dfil c141.r5
ffi FF-'
lrl2l
['l.l
fr ffi -t+-t
IrI2l l ' l zI
-l
ftERN/Br-r;_-lI6liHT/REo'-_-l ItrlwHr'--__l l6lwHr' ITTTBLI YEL--I lEl LicRN^,Hrl
lElYEL;---_-l lolREo,YEF-_-l lOlBEp. I l@lREo, I l.afcrll-NlrHT,ll l6fsar<'EL I
lofBr-r</YEL I
lSlBLK/wHTi-l
c35{*'
l 1 l 2 l 3 l
16lBL&l"Hr__-l
l6lBLK I
lO cRNiREo I
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKT

and YEVBLK'are not the same).
O; Relatedto Fueland EmissionsSystem.
. - Connectorwith maleterminals(doubleoutline):View from terminalside
11-37
SystemDescription
SystemConnectorslDashand Floorl
11-38
m
6 l 7 l 8 l et 0 t 1 1 12 12 1 3 15
BLU,rv€L
c'15
ottT'r
-r=l- ,-F- |
l[TTtT;ll lr l, I t
l l . | 5 | 6| 7I l I
ll BL(vEr. I la FFo' I
TiTsuqv/ir---'l
---l litEli l
ftl B.u,"Ep
lOlwHr,€Lr I
t.8lx I
tilwHr/6RN I 11
': scu.rYarrmsFtem YEL
0125 ct|:|5
lwnhout crui! contolt (wtth ctuir controll
-F- F€-
,|
ffiffi
a 5 6 7 E 9 10
't2 1 3 t a 1 5 1 6 1 l 1E 20
I !'IGRNAI/HF I I 1 LLTGiN I 't2

ll WHI/GRN I 12 GnY I BLX'EL
13 | lO cFNeHr' I
f.T_ - ltrlwHT/GRN-
1)
o 3
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEL,/BLK1

. - Connectorwith maleterminals{doubleoutline):Vjew from terminalside
(cont'd)
11 - 3 9
SystemDescription
SystemConnectors[Dashand Floor](cont'dl \
c412 C131 C135

c446
11-40
c130
t 5 6 7 I t0
't'l 12 l 3 l 5 1 6 1 7 ta 't9 20
lD16Y5, Dl6Ya.ngin6l
YEL
cr32 tEcM/PCM-A) Ct33., (FCM-B) cr3a{EcM/PcM-ct
5 6 7 8 9 t0 1l
12 t 3 lit t 5 l 6 t t I E t 9 2l 23 2a
25 27 2a 29 30
cr!5 tEcM/FcM-Dl
ffi r'TftI;I fr
fiTwr/Brt- l ItTniKrysr I-l I
-l l-"rlcnN^v'tr
TtltErnrx Itmsrneo l
lfsri------l I]]l f.. ErlwHr'--l
rnwHr
flwHrnEF l
aaFlBa( I
Cr|]lil
! a l 5 E 9 to
ffi rfir
tl 't2 1 3 't1 t 8 1 9
ITFI
l-tlwr/nEd-
I;TcRN^,Nr--l
lrfttK,/,/H
lilBrx,v/Hr l
NOTE:. Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1

. - Connectorwlth maleterminals(doubleoutline):View from termlnalside
11-41
Troubleshooting
TroubleshootingProcedures
How To BeginTroubleshooting
Whenthe MalfunctionIndicatorLamp(MlL)has beenreportedon. or there is a driveabilityproblem,usethe appropri-
ate procedurebelowto diagnoseand repairthe problem.
A . W h e nt h e M I Lh a sc o m eo n :
'1. Connectthe HondaPGMTesteror an OBD ll scantool to the 16PDataLink Connector{DLC}locatednearthe left

k i c kD a n e l .
2, Turn the ignition switch ON (ll).
Check the DTC and note it. Also check and note
the treeze frame data.
Refer to the Diagnostic Trouble Code Chart and
begin troubleshooting.
NOTE:
. Seethe OBDll scantool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
. The scantool or testercan readthe DiagnosticTroubleCodes(DTC),freezeframe data,currentdata.and other
EngineControlModule(ECM)/Powertrain ControlModule(PCM)data
. Freezeframe data indicatesthe engineconditionswhen the first malfunction,misfireor fuel trim malfunctior
was detected.lt can be usefulinformationwhen troubleshootino.
B . Whenthe MIL hasnot come on , but there is a driveabilityproblem,reterto the SymptomCharton page11-46.
c. DTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp(MlL)with the SCSserviceconnectorcon-

nected.
Connectthe SCS serviceconnectorto ServiceCheckConnectoras shown. (The 2P ServiceCheckConnectoris
locatedunderthe dashon the passenger's
sideof the vehicle.)Turn the ignitionswitchON {ll}.
OBD ll SCANTOOLor
HONDAPGM TESTER
SERVICECHECK SCSSERVICECONNECTOR
CONNECTOR I2P} 07PAZ- 001011X'
DATA LINKCONNECTOR
{16PI
11-42
ll. ControlModule(PCM)ResetProcedure
EngineControlModule(ECM)/Powertrain
Eitherof the followingactionswill resetthe ECM/PCM.
. Usethe OBDll scantool or HondaPGMTesterto clearthe EcM's/PcM'smemorv.
NOTE:Seethe OBDll scantool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
. Turn the ignitionswitch OFF,Removethe BACKUP (7,5A) fuse from the under-hoodfuse/relaybox for 10 sec-
onds.
NOTE:Removingthe BACKUP {7.5A) fuse cancelsthe clockand the radio presets.Make note of the customer's
oresetsso vou can resetthem.
lll. FinalProcedure(thisproceduremust be done afterany troubleshooting)
1, Removethe SCSServiceConnectorif it is connected.
the MIL will stay

NOTE:lf the SCSserviceconnectoris connectedand there are no DTCSstoredin the ECM/PCM,
on when the ignitionswitchis turned ON (ll).
2 . Do the ECM/PCMResetProcedure,
Turnthe ignitionswitchOFF. (cont'd)
11-43
Troubleshooting
Troubleshooting (cont'd)
Procedures
lf the inspectionfor a particularcode requiresvoltageor resistance
checksat the ECM/PCMconnectors,removethe right
kick panel.Pull the carpetbackto exposethe ECM/PCM.Removethe ABS control unit if so equipped.Unboltthe ECM/
PCM bolt. Turn the ignition switch OFF,and connectthe backprobesets and a digital multimeteras describedbelow.
Checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon the followingpages.
l
)
KICK PANEL
How to Use the BackprobeSets
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire insula-

tion as a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectortrom the wire side
until it comesin contactwith terminalend of the wire.
BackproboAdapter
BACKPFOBE SET
07SAZ- 001000AlTwo
OIGITALMULTIMETER
{Commcrcially.vaitablelor
KS-AHM-32-003
1 1-4 4
CAUTION:
. Puncturingthe insulation on a wire can causepoor or intermittcnt elesttical connestions.
. Bring th€ tester probe into contaqt with the terminal lrom the terminal sid6 of wire harnossconnectors in the enging
compadment. For Ismale connectors,iust touch lightly with ihe tester probe and do not ingert the probe.
RUBBERSEAL TESTERPBOBE
TERMINAL
{cont'd}
11-45
Troubleshooting
TroubleshootingProcedures{cont'd)
Symptom Chart
Listedbeloware symptomsand probablecausesfor problemsthat DO NOTcausethe lvlalfunction indicatorLamp(MlL)to
c o m eo n . l i t h e M I L w a sr e p o r t e d
o n ,g o t o p a g e ' 1 1 - 4 2 .
Troubleshooteachprobablecausein the order listedlfrom left to right)until the symptomis eliminated.
The probablecauseand troubleshooting pagereferencecan be found below.
SYMPTOM PROEABLECAUSE
Enginewill not start 4 , 2 , 3 , 5 , 2 01, 4 ,1
Hardstaning 2,4.11,16,13,'t9
Coldfast idle too low 7, 8, 6, 16
Cold fast idle too high 7 , 8 ,1 0 , 9
ldle speedtluctuates 7 , 8 ,1 0 , 9
M i s f i r eo r r o u g hr u n n i n g Troubleshoottor misfireon pages11-105,108
Low power 2 ,9 , 1 0 , ' t 2 1
, 1 ,1 6 ,1 8 ,2 0
E n g i n es t a l l s 2 , 4 , 1 1 , 7 ,2 0 ,A , 5 , 1 5
OtherProbableCausesfor an enginethat will not start:

- Compression - Startingsystem
- Intakeair leakage - Overheating
- Enginelockedup - Battery
- Timing belt
ProbableCauseList (Forthe DTCChart, see page 11-531

\
ProbableCause Page System
1 I t-oJ EngineControlModule(ECM)/Powertrain
ControtModule(PCM)
1' t - 1 5 01,s 1 Fuelpressure
1I -157 PGM-Flmain relay
4 Section23 lgnitionsystem
Crankshaft
Position/Top
DeadCenter/Cylinder
Positionsensorcircuit,CKFsensor
1 1 - 1 1 10 1, 7
circuit
6 11-73 IntakeAir Temperature{lAT)sensorcircuit
7 11-'t26,128 ldle Air ControlValve(IACV)
11-141,142,
8 ldle speedadjustment
143,144
9 1t-164 Throttle body
10 11-162 Thronlecable
't1
11-67 ManifoldAbsolutePressure(MAP)sensor
12 1' t-79 ThrottlePosition(TP)sensor
IJ 1 11 1 3 Barometricpressure(BARO)sensor
14 Section14,1'l-139 A/T gear posilionsignal(seepage'1'l-137)
or clutchswitchsignal
11 -1 3 4 Brakeswitchsignal
11-162 AirCleaner
11 Intakeair pipe
18 1l-168 Three Way CatalyticConverter(TWC)
19 11-181 emission(EVAP)control
Evaporative
20 Contaminated fuel
11-4 6
ECM/FCMData
By connectingthe OBD ll scantool or the HondaPGM Testerto the 16Pdata link connector(DLC),variousdata can be
retrievedfrom the ECM/PCM. The itemslistedin the table belowconformto the SAErecommendedpractice.
The HondaPGMTesteralso reads databevondthat recommendedby SAE.
Understanding this datawill helpto find the causesof intermittentfailuresor engineproblems.
NOTE:
a The "operatingvalues" given below are approximatevaluesand may be differentdependingon the environmentand
the individualvehicle.
. Unlessnotedotherwise,"at idle speed" meansidlingwith the enginecompletelywarmed up, A//Tin pe5ition@ or @,
turnedoif.
M/T in neutral,and the A/Cand all accessories
Data Description OperatingValue FreezeData

Diagnostic lf the Ecl\4/PcM derectsa problem,it will storeit as a lf no problemis detected,
TroubleCode code consistingof one letterand four numbers. there is no output.
(DTC) Dependingon the problem,an SAE-detined code (P0xxx) YES
or a Honda-defined code (P1xxx)will be outputto the
rester.
E n g i n eS p e e d The ECM/PCM computesenginespeedfrom the signals Nearly the same as
sentfrom the CrankshaftPositionsensor. tachometer indication.
YES
This data is usedfor determiningthe time and amountot
fuel injection.
VehicleSpeed convertspulsesignalsfrom the Vehicle
The EClvl/PcM Nearlythe sameas
YES
SoeedSensor(VSS)into speeddata speedometerindication
Manifold The absolutepressurecausedin the intakemanifoldby With enginestopped:
Absolute engineload and speed. Nearlythe sameas atmo-
Pressure(MAP) sphencpressure
YES
At idle speed:
24 - 37 kPa(180- 280
m m H g ,7 . 1- ' 1 1 . i0n H g )
EngineCoolant The ECTsensorconvenscoolanttemperatureinto volt- With cold engine:
Temperature age and signalsthe ECM/PCM.The sensoris a thermistor Sameas ambienttemper-
(ECT) changeswith coolanttempera-
whose internalresistance atureand IAT YES
ture.The ECM/PCMusesthe voltagesignalsfrom the With enginewarmedup:
'176 194.F(80- 90"C)
ECTsensorto determinethe amountof iniectedfuel.
HeatedOxygen The HeatedOxygenSensordetectsthe oxygencontent 0 . 0- 1 . 2 5V
Sensor(H02S) in the exhaustgasand sendsvoltagesignalsto the At idle speed:
(Primary, ECM/PCM. Basedon thesesignals,the ECM/PCM con a b o u t0 . 1- 0 . 9V
S e n s o r1 ) trols the airfuel ratio.Whenthe oxygencontentis high
NO
(Secondary {thatis. when the ratiois leanerthan the stoichiometric ( S e n s o1r )
Sensor2) ratio),the voltagesignalis lower.
Whenthe oxygencontentis low (thatis, when the ratio
is richerthan the stoichiometricratio),the voltagesignal
is hioher.
(cont'd)
11-47
Troubleshooting
(cont'dl
Data Description Operating Value FreezeData
"open" or "closed". At idle speed:closed
HO2S Loopstatusis indicatedas
Feedback Closed:Basedon the HO2Soutput,the ECM/PCM deter-
LoopStatus minesthe airlfuelratioand controlsthe amountof inject-
ed fuel. YES
Open:lgnoringHO2Soutput,the ECM/PCMrefersto sig-
nalsfrom the TP,MAP,and ECTsensorsto controlthe
amountol iniectedfuel.
Shon Term The airfiuelratiocorrectioncoefficient
for correctingthe ! 20%
F u e lT r i m amountof iniectedfuel when HO2Sfeedbackis in the
closedloop status.Whenthe signalfrom the HO2Sis
weak,shortterm fuel trim getshigher,and the ECM/PCM
increases the amountot injectedfuel.The airlfuelratio YES
graduallygets richer,causinga higherHO2Soutput.
Consequently, the shortterm lueltrim is lowered,and
the ECM/PCMreducesthe amountot injectedfuel.
This cvclekeeDsthe airlfuelratiocloseto the stoichio-
metricratiowhen in closedloop status.
LongTerm Longterm luel trim is computedfrom shortterm fuel + 200/o
FuelTrim trim and indicateschangesoccurringin the fuel supply
systemover a long period. YES
l f l o n gt e r mf u e lt r i m i s h i g h e tr h a n 1 . 0 0t,h e a m o u n to f
injectedfuel must be increased.lf it is lowerthan 1.00,
the amountof injectedfuel must be reduced.
InlakeAir The IATsensorconvertsintakeair temperatureinto volt- With cold engine:
Temperature age and signalsthe ECM/PCM. When intakeair tempera- Sameas ambienttemper-
YES
(IAT) of the sensor
ture is low, the internalresistance atureand ECT
increases, and the voltagesignalis higher.
Throttle Basedon the accelerator pedalposition,the opening At idle speed:
YES
Position anqleof the throttlevalveis indicated. approx.10 %
lgnition lgnitiontiming is the ignitionadvanceangleset by the At idle speed:12't 2"
Timing ECM/PCM. The ECM/PCMmatchesignitiontiming to the E' I UL Wtrn rne 5L5 Ser- NO
drivingconditions. viceconnectorconnected.
Calculated from the MAP data.
CLVis the engineload calculated At idle speed:
LoadValue 15-35%
YES
(CLV) At 2,500rpm with no load:
12 - 30%
Engine/Powertrain
ControlModuleTerminalArrangement
ECM/PCMCONNECTOR
A {32P)
1 2 a 5 6 7 8 I 10 t1
I N J 4 INJ3 INJ2 I N J l LG1 PGl IGPl
1 2 't3 1 4 1 5 1 6 1 7 1 8 1 9 20 22 21
ACV PCS FLR acc MIL AtTC tcM LG2 PG2 IGP2
25 21 2a E 30
vsv SLU
Wiresideof femaleterminals
ECM/PCMCONNECTOR
A {32P1
NOTE:Standardbattery voltage t s
Sig.al
YEL l N J 4 { N o a F U E LI N J E C T O B } D r i v e s N o .4 i u e l n i e c r o r . W i t h e n g i n ef u n n n 9 : p u l s e s
2 BLU l N J 3 ( N o . 3 F U E LI N J € C T O R I
3 FED lNJ2(No,2 fUEL INJECTOR) Drives No. 2 fuel injecto..
88N I N J I 1 N o .1 F U E L I N J E C T O F ) O n v e sN o . 1 l u e l ' n t e c t o r
SO2SHTC(SECONOARY HEATED Drives secondary h€ated oxygen sensor W i i h i g n i l i o ns w i t c hO N ( l l ) : b a n e r yv o t a g e
5 BLI(WHT OXYGENSENSOFHEATERCON W i l h i u l l y w a r m e d u p e n g i n er u n n i n g :d u t y c o n r f o t t e d
TSOL)
PO2SHTCIPSIMARYHEATED Drives prihary heated orygen s6nsor Wirh ignitio. swhch ON (ll): batery vohage
6 BLK^/VHT OXYGENSENSOEHEATER W i l h t J l l / w a r m e du p e n g i l e . r 1 . n S .d J r \ ,, o r t . o l e o
CONTROL)
E S O LI E G FC O N T R O L Orives EGF conto solenoid valve. W n 5 E G Ro o - , d r ' n 9d u . i r S d i v i a g w r F . J f y w a ' r - d
FED*3 SOLENOIO VALVEI up engine: duty controlled
W i l h E G Rn o r o p e r a t i n q : 0V
E EGR W i l l - F C F o p e r a f i n gd u ' , n 9 d r ' v , rg w r h t u l l y w d n p d
! p e n 9 r n ed r ulycontrolled.
W l h E G Rn o t o p e r a t i n q : 0V
WS (W€C SOIENOID VALVE) Drives VTECsoleno d valve. W i l h e n g i n ea t l o w e n g i n es p e e d : 0V
GBN/YEL
Wilh enqine at hlqh enqine sD6ed:batre.vvokaoe
9 BRN/BLK L G 1( L O G I CG 8 O U N D ) Ground for lhe ECi!4/PCM conlrolclrcuit. L e s sl h a n I 0 V a t a r lr i m e s
IO BLK PG1 (POWERGBOUNO) G ' o u n d l o r t h e E C M / P C Mp o w e r ( t r c ! f .
IGPl (POWERSOURCE) Pow6rsource tor the ECM/PCMco.trol Wlth ignit on swilch ON (ll): batrerv vo taqe
ll YEUBLK
w i t h r g n n i o ns w h c h O F F : 0V
12" SLVALU IACV(IDLEAIR CONTAOLVALVE) W i l h e n g i n er u . n i n g : p u l s e s
ORN IACV N lIDLE AI8 CONTROL Drives lhe IAC valve lnegai ve side).
VALVE NEGATIVESID€)
IACV P (IDTEAIR CONTFOL D ' i v e sI A Cv a l v el p o s r t r v €
srde).
BLVBLU
VALVE POSITIVESIDE)
PCS {EVAPPUsGE CONTROL Orives EVAP purge contro soleno d vaive. W l l h e n g i n er u n n i n g ,e n g i n ec o o l a n tb e o w 1 5 4 F
15 FEOTYEL SOLENOIDVALVE) (64'Cl: battery vohage Wilh engine running eng ne
cocrant above 154'F {68'C): 0 V
F L R{ F U E LP U M PF E L A Y ) Drvestue pump relay. 0 v for ndo *(onds dier rJ .{ g 'gr't on sw ! h oN
16 GRNAEL
A C C( A , / C
C L U T C HF E L A Y ) DrivesA,/C
clulch.etay. w r t h c o m p r e s s oO
r N:0 V
17 BLK/FED
Wth compressorOFF: battery vohaoe
MILlMALFUNCTIONINDICATOR W i i h M l L r u r n e dO N : 0 V
18 G8N/ORN
W i l h M l L t u r n e dO F F : b a t t e r yv o h a s e
ALTC (ALTEFNATOBCONTNOL) Sends alle.nator cohtrol signa Wilh lully warmed up engine running: b.ftery voltsge
WHI/GFN
Du.ingdrivingwilhsmallelectrcalload:0V
rclvr0GNrI|oNcoNTfloL With ignition switch ON (ll):baltery voltage
20 YEVGRN t!'IODULE) W t h e n g i n er ! n n i n g : a b o u t 1 0 V ( d e p e n d i n go n
22 BRN/ALK L G 2( L O G i CG F O U N D ) Ground fof lhe EC^4/PCMconrrolcncuil L o s s t h a nl . 0 V a r a l l i i m o s

23 BLX PG2IPOWER GFOUND) G r o u n df o r l h e E C M / P C Mp o w e f c i r c u i t .
I G P 2( P O W E RS O U F C E ) Powe. source fof rhe ECM/PCMcont.ol Wirh igniiion switch ON (lll: banery vohage
YE|J€LK
W i t h i 9 n i t i o ns w i t c hO F F : 0V
V R E F( R E F E N E N CVEO T T A G E ) Provides rslerencevo ltage to TCM. W i t h i g n i t i o ns w i t c hO N ( l l ) : a b o L t5 V
25'3 WHf/BED
W i t h l g n i l i o ns w i l c h O F F : 0V
FANC iRAOIATOSFAN Orives radiarorfan relay. Wiih radiato. f8n running: 0 V
27'r GRN
CONTFOL) Wirh radialor tan stopped: banery vohaoe
2WBS (EVAPBYPASS Drives EVAP bypass sol6nord valve w n h i g n i t i o ns w t c h O N ( l t ) : b a l l e r yv o t r a g e
8LU
SOIENOID VALVE)
VSV {EVAPCONTBOLCANISTEB Drives EVAP control canisrer v6nish!t With ignilron swilch ON lll): battery vohage
VENI SHUT VATVE)
S!U (lNTEELOCKCONTROL Derecb lnter ock convol unit sisnal. W t h i s n t i o n s w i i c h O N { 1 1 ) a n bd r a ( e p e d a l
UNIT) d€pressed:batieryvohaae
*2: A/T (D16\./. Dl6YSensine) r 1 0 : M / T ( D 1 6 Y 5e n g i n e )

* 3 : C W ( 0 1 6 Y 5e n g i n e ) . 1 1 : E x c e p lM / I ( 0 1 6 Y 5e n g i n e )
14: A"/Tand D16Y7 ensine i 1 2 : O 1 6 Y 5D , 1 6 Y 8e n g i n e
'5:Except A/T and 016\./ engine
16: AtlTlD16Y8 engine)
r T r C V T( O 1 6 Y 5o n q i n e )a n d D l 6 Y B e n s i n e ' 1 5 : ' 9 t 0 1 6 Y 7e n g i n e( c o u p € :K L m o d e s e d a n rK L {cont'd)
'8:'96 016Y8ensine {oupel. 97 Dl6YSensine (coupe:all modols, '98 D16Y7 , lLXl modet),
sd.niKl moder), engine
'98 D'I6Y5
sngin€,'98 016Y8 engine
11-49
Troubleshooting
ControlModuleTerminalArrangement(cont'dl
Engine/Powertrain
Wirg sideof femaleterminals

PCMCONNECTOR
B {25P)*'
NOTE: Standard battery voltage is l2
Telminal Wire Terminsl
numoer color De3cription Signal
LS- (LINEAR
SOLENOID Groundtor linearsolenoidvalve. With ignitionswitchON (ll):pulses
1 WHT
VALVE_ SIDE)
LS+(LINEARSOLENOID Driveslinearsolenoidvalve. With ignitionswitchON (ll):pulses
2 RED
VALVE+ SIDE)
SHA(SHIFTCONTROL DrivesshiftcontrolsolenoidvalveA. With enginerunningin 2nd,3rdgears:
SOLENOID VALVEA} batteryvoltage
3 BLU/YEL
With enginerunningin 1st,4thgears:
about0 V
4 LCB (LOCK.UPCONTROL Driveslock-rrpcontrol solenoid With lock-upON: batteryvoltage
GRN/BLK
SOLENOID VALVEB) valveB- With lock-upOFF:0 V
LCA (LOCK.UPCONTROL Driveslock-upcontrolsolenoid With lock-upON:batteryvoltage
5 YEL
SOLENOID VALVEA) With lock-upOFF:0V
8 PNK ATPD3IA,/TGEARPOSI- DetectsA,/Tgear positionswitch InEposition:0V
TIONSWITCH) srgnat. In any otherposition:batteryvoltaqe
SHB(SHIFTCONTROL Drives shift control solenoid valve 8. Wathenginerunningin 1st,2nd:baftery
1t GRNA/VHT SOLENOID VALVEB) voltage
With enginerunningin 3rd,4th:about0 V
(INTERLOCK
WHT/RED SLU CON- Drivesinterlockcontrolunit. With ignitionswitchON (ll)and brake
TROLUNIT} pedaldepressed:0 V
D4 IND(D4INDICATOR DrivesD4 indicatorlight. With D. indicatorlighrrurnedON:batter),
GRN/BLK LIGHT) voltage
With E indicatorlightturnedOFF:OV
NMSG(MAINSHAFT Groundfor mainshaftsoeedsensor.
14 WHT
SPEEDSENSORGROUND)
NM {MAINSHAFT SPEED Detectsmainshaftspeedsensor With enginerunning:pulses
RED
SENSOR) srgnal,
ATPR{!VT GEARPOSI- DetectsAy'Tgear position switch InEposition:oV
WHT
TIONSWITCH} signal In any otherposition:batteryvoltage
ATP2(A"/TGEARPOSI- DetectsAy'Tgear position switch InAposition:0V
17 8LU
TION SWITCH} srgnal, In any otherposition:batteryvoltage
NCSG{COUNTERSHAFT Ground lor countershattspeed
22 GRN
SPEED SENSOR GROUND) sensor.
BLU NC {COUNTERSHAFT Detectscountershaftspeedsensor With ignitionswitchON {ll),and front
SPEEDSENSOR} srgnal. wheelsrotating:pulses
ATPD4{A"/TGEARPOSI- DetoctsA./Tgear position switch In El position:OV
24 YEL
TION SWITCH) srgnal. In any otherposition:5 V
25 LT GRN
ATPNPiAlT GEAFPOSI- DetectsA.rTgear position switch ln m orE position: OV
TIONSWITCH) srgnal. ln anyotherposition:battery
voltage
*1: USA model '9: 016Y5engine
*2: A,/T{D16Yr,Dl6Y8 engine) *10:M/T lD16Y5engine)
*3: CVT(D16Y5engine) *11:ExceptM/T (D16Y5engine)
*4: A*/Tand Dl6Yl engine * 12:D16Y5,D'|6Y8engine
*5: ExceptA,rf and 016Y, ongine *13rDl6Y8engine
*6r IVT {D16Y8€ngine} i14: Dl6Y7engine
*7: CW (D16Y5engine)and D16Y8engine *15:'97016Y7engine{coupe:KL model,sedan:KL (LX)model),
* 8 : ' 9 6 D 1 6 Y 8e n o i n 6( c o u p e ) , ' 9 7D 1 6 Y 8ehgine {coupe:all '98D16Y7 engine
models. sedan:KL model),'98 D16Y5engine,'98 D16Y8
on9ine
11 - 5 0
ECM/PCMCONNECTOR
C 131PI
1 2 a 1 a 9 10
CKfP CKPP TIrcP ACS sTs scs TMA vBu
11 12 13 1 4 15 16 1 7 18
CKFM vTM ALTf vss
21 25 z) 30
lP+ TMB
Wire sideof femaleterminals
ECM/PCMCONNECTOR
C {31PI
NOTE:Standardbatteryvoltageis 12 V,
Torminal T6rminal
numbot Description Signrl
l BLU/RED CKFP{CKFSENSORP SIDE} Detects CKF sensor. W i t h e n g i n er u n n i n g :p u l s e s

2 BLU C K P P( C K PS E N S O RP S I D E ) Detects CKP sensor. pulses
Withonginerunning:
3 GRN TDCP{TOCSENSORP SIDE} DetectsTDCsensor, With engine running: prils6s
YEL CYPP{CYPSENSORP SIDE) DetectsCYP s€nsor. puls€s
Withenginerunning:
ACS (P,/CSWITCHSIGNAL) OetectsAy'Cswitch signal. With,!y'C switch ON: 0 V
5 BLU/RED
With ,y'C switch OFF: battery voltage
6 BLU/ORN
STS {STARTERSWITCH Detects starter switch signal, With starter switch ON (lll): battery vollage
SIGNAL) With starler switch OFF: 0 V
S C S( S E R V I CC EHECK Detectsservicecheck connector signal With the connector connected: 0 V
1 BRN ( t h es i g n a l c a u s i n ga D T Ci n d i c a t i o n )
SIGNAL) With the connector disconn6ct6d: 5 V
8 LT8LU K - L I N E( D L C ) S e n d sa n d r e c e r v e ss c a nt o o l s i g n a t , W i t h i g n i t i o ns w i t c h O N ( l l ) :a b o u t 5 V
D a t ac o m m u n i c a t i o nw i t h T C M : E C M W i t h i g n i t i o ns w i t c hO N ( l l ) :p u l s 6 s
GRY
c o n t r o l d a t ao u t p u t
VBU(VOLTAGE
BACKUP) Power sourc6 for the ECM/PCM 8.ttery voltage at alltimos
10 WHT/BLU control circuit. Power source for the
DTC memory
CKFI\4{CKF SENSOB M G r o u n df o r C K Fs e n s o rs i g n a l .
t1 WHT/RED
SIDE)
CKPI\4(CKPSENSORM G r o u n df o r C K Ps s n s o rs i g n a l .
SIOE}
RED TDCM(TDCSENSORM G r o u n df o . T D C s e n s o rs i g n a l .
SIDE)
C Y P M( C K PS E N S O RI V G r o u n df o r C Y Ps e n s o rs i g n a l .
14 BLK
SIDE)
BLU/8LK
VTM {VTECPRESSURE DetectsVTEC pressure switch signal. With engine at low6n9in6 sp€€dr0 V
swrTcH) With engineat high engin€speed:batteryvoltEge
P S P S W( P / SO I L P R E S S U R E Detects PSPswitch signal. At idle with steering wheel in sk6ight ahaad
,I6 SWITCH) p o s i t i o n i 0V
GRN
At rdle with st6€ring whsel at full lock: battery
voltage
ALTF(ALTERNATOE
FR Detects alternator FR signal, Withfullywarmedup 6nginerunning:
17 WHT/RED SIGNAL) 0V- batteryvoltage{depsnding
on electrical
load)
18 VSS(VEHICLE
S P E E DS E N . DetectsVSS signal. W i t h i g n i t ' o ns w i t c h O N { l l ) a n d f r o n t w h e e l s
BLU/WHT soR) rotating:cycles0V-5V
23'to BLK l P +( H O 2 SP U M PC E L L+ ) C o n t r o l sH O 2 Sp u m p c e l l . W r t h r g n i t i o ns w h c h O N t l l ) :a b o u t 0 . 5 - 5 . 3 V
IP-, VS- {HO2SCOMMON) R e f e r e n c ev o l t a g es u p p l y , With fully warmed up 6ngin6 at idle:
RED
a b o u t 2 . 6 - 2 . 8V
25* ta VS+(VSCELLVOLTA6E) DetectsVS cell voltage. W i t h i g n i t i o ns w i t c h O N ( l l ) :a b o u t T V
ATPNP{4,/TGEARPOSI. Detectspy'Tgear position switch signal. I n E o r E p o s i t i o n :V0
LTGRN*3
TroNswrTcH) ln any otherposition:batteryvoltage
29
CLSW (CLUTCHSWITCH) Detects clutch switch signal. With clutchpedalreleas€d: about5 V
BED*r0
With clutch oedaldeoressed:0 V
30 TM8 D a t ac o m m u n i c a t i o nw i t h T C M : W i t h i g n i t i o ns w i t c h O N { l l ) :p u l s e s
PNK
E C Mc o n t r o ld a t a i n p u t
*1: USAmod€l * 9 : D 1 6 Y 5e n g i n e
+2rAlT(Dl6Yl,D16Y8 engine) r 1 0 : M / T { D 1 6 Y 5e n g i n e )
'3: CVT(D16Y5engine) * 1 1 : E x c e p tl v l / T( 1 6 Y 5e n g i n e )
'4: A,/Tand D16Y7engine ' 1 2 : D 1 6 Y 5 ,D 1 6 Y 8e n g i n e
'5: ExceptA,/Tand Dl6Yl engine * 1 3 : D 1 6 Y ge n g i n e
*6: Ay'T(D16YBengine) ' 1 4 : O 1 6 Y 7e n g i n e
*7: CVT(016Y5engine)and D16YBengine * 1 5 : ' 9 7 D 1 6 Y 7e n g i n e ( c o u p e : K L m o d e l , s e d a n : K L ( L X ) m o d e l ) ,
*8:'96 D16Y8engine(coupel,'97 D16Y8engine(coupe:all models, '98D16Y7
engine
sedan:KLmodel),'98 D16Y5 engine,98 D16YBongine {cont'd)
11-51
Troubleshooting
Engine/Powertrain (cont'dl
ControlModuleTerminalArrangement
ECM/PCMCONNECTOR
O {16P)
ECI BXSW
a lo
KS
13 11 15
EL
D (16P}
ECM/PCMCONNECTOR
NOTE:Standardbatteryvoltageis 12 V.
Terminal Wire T€.minal
Description Signal
I RED/BLK IPS (THROTTLE

POSITION DetectsTPsensorsignal. With throttlefully open:about4.8V
SENSOR) With throftletully closed:about0.5V
(ENGINE
2 RED^^/HT ECT COOLANT DetectsECTsensorsignal. With ignitionswitchON(U): about0.1- 4.8V
TEMPEFATURE SENSOB (depending on enginecoolanttemperature)
MAP (MANIFOLDABSO- DetectsMAPsensorsignal. With ignitionswitchON(ll):about3 V
3 RED/G
BN LUTEPRESSURE SENSOR) At idle:about1.0V
(dopending on enginespeed)
YEURED
vccl (SENSOR
VOLTAGE) Powersourcefor MAPsensor. W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u r 5 V
W i t h i g n i t i o n s w i t c h O F F r0 V
5 EKSW(BRAKE
SWTCH) Detectsbrakeswitchsignal. With brakeDedalreleased:0 V
GRNîVHT
With brakepedaldepressed:batteryvoltage
6*? RED/BLU KS (KNOCKSENSOR) DetectsKS signal. With engineknocking:pulses
PH02S(PRIMARY HEAT Detectsprimary heatedoxygen With thronlefully openedfrom idlewith
ED OXYGENSENSOR, sensor{sensor1) signal. fully warmedup engine:above0.6V
1 SENSOR 1) Withthrottlequicklvclosed:below0.4V
LABEL DetectsLABELresistance. With enginerunning:about0.3- 4.9V
8 IAT(INTAKEAIRTEM, DetectsIATsensorsignal. With ignitionswitchON {ll):about0.1-
BED/YEL
PERATURE SENSOR} 4.8V (depending on intakeairtemperature)
(EGRVALVELIFT
9* WHT/8LK EGRL DetectsEGFvalvelift sensorsional. At idlewithoutvacuum:about1.2V
SENSOR} With 27 kPa(200mmHg,8 in. Hg):about4.3V
10 YEL/BLUVCC2(SENSOR VOLTAGE) P r o v i d e ss e n s o r v o l t a g e , With ignitionswitchON(ll):about5 V
With ignitionswitchOFF:0 V
ll GRN/BLK (SENSORGROUNDi Sensorground. L e s s t h a n1 . 0V a t a l l t i m e s
12 GRNAr'VHT SG1(SENSORGROUND) Groundfor MAPsensor. Lessthan 1.0V at alltimes
SHO2SG(SECONDARY Ground for secondaryheatedoxy-
GRN/8LK+I'
HEATEDOXYGENSEN. gen sensor{sensor2),
REDt/EL*14
SOF,SENSOR2 GROUND)
SHO2S(SECONDARY Detectssecondaryheatedoxygen With throttle fully openedfrom idle with
14 WHT/RED HEATEDOXYGENSEN- sensor(sensor2) signal. tully warmedup engine:above0.6V
SOR,SENSOR
2) With thronlequicklvclosed:below0.4V
LT GRN
PTANK(FUELTANKPRES- Detectsfuel tankoressuresensor, With fuel fill caDooen€d:about 2.5 V
SURESENSOR)
EL (ELD) DetectsELDsignal. With parkinglightsturnedon at idle:about
16*, GBN/RED
With low beamheadlights turnedon at
i d l e :a b o u t1 . 5 - 2 . 5V
*1: USA model r9: D16Y5engine
*2: IVT {D16Y7,D16Y8ensine) * 10rM/T (D16Y5engine)
*3: CW (D16Y5engine) *11:ExcoptM/T (Dl6Y5engine)
*4: ,VTand D16Y76ngine *12:D16Y5,D16Y8engine
+5:ExceptAy'Tand D16W engine *13:D16Y8engane
*6: A/T 1D16Y8 engine) '14: Dl6Y7engine
*7: CW (O16Y5engine)and 016Y8engine *15:'97 016Y7engine{coupe:KL model,sedan:KL (LX)
1 8 : ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) , ' 9 7D 1 6 Y 8e n g i n e( c o u p o :a l l '98D16Y7 modet),
engine:
m o d e l s ,s e d a n :K L m o d e l ) , ' 9 8D 1 6 Y 5€ n g i n e ,'98 D16Y8
engrne
11-52
DiagnosticTroubleCode(DTC)Chart
DTC
(MlLindicationr) D€tection ltem ProbableCause Page
ManifoldAbsolute . Vacuum connection

P0106*15 (5) PressureC:rcuit . MAP sensor 1167
Range/PerformanceProblem
ManifoldAbsolute Openor short in MAP sensorcircuit
(3) PressureCircuit MAP sensor
P0'107 1169
Low Input ECMiPCt\,4
TCM*I
ManifoldAbsolute Open in MAP sensorcircuit
P0108 (3) PressureCircuit MAP sensor 11-71
H i g hI n p u t ECM/PCM
IntakeAir Temperature . IAT sensor
P 0 11 1 + r ,*41. 5{ 1 0 ) Circuit 11-73
Range/PerformanceProblem
IntakeAir Short in IAT sensorcircuit
P01't2 (10) TemperatureCircuit IAT sensor 1l-74
Low Input ECM/PCM
lntakeAir Openin IATsensorcircuit
P01' t3 (10) TemperatureCircuit IAT sensor 11-75
E n g i n eC o o l a n t . ECTsensor
P0116 (86) TemperatureCircuit . Coolingsystem 11-76
Range/Performance Problem
EngineCoolant Shortin ECTsensorcircuit
P0117 (6) TemperatureCircuit ECTsensor 11-17
Low Input ECM/PCM
E n g i n eC o o l a n t Open in ECTsensorcircuit
P0118 (6) TemperatureCircuit ECTsensor l1-78
ThrottlePosition Openor shon in TP sensorcircuit
(71 Circuit TP sensor
P0'122 11-79
Low Input ECM/PCM
TCM*1
ThrottlePosition Openin TP sensorcircuit
P0123 t7l Circuit TP sensor I 1-81
High Input ECMiPCM
PrimaryHeatedOxygenSensor Short in PrimaryHO2S{Sensorl)circuit
CircuitLow Voltage PrimaryHO2S(Sensor1)
P0131*' (1) ( S e n s o1r ) 11-84
Fuelsupplysystem
ECM/PCM
PrimaryHeatedOxygenSensor Openin PrimaryHO2S(Sensor1) circuit
PO132+' (1) CircuitHighVoltage PrimaryHO2S(Sensor1) 11-86
(Sensor1) ECtVr/PCM
PrimaryHeatedOxygenSensor . PrimaryHO2S(Sensorl)
P0133*' (61) Slow Besponse ' E x h a u s ts y s t e m 11-8J
{SensorI )
PrimaryHeatedOxygen . Openor short in PrimaryHO2S
SensorHealer ( S e n s o1r ) h e a t e cr i r c u i t
P0135*' (41) . ECM 11,98
CircuitMalfunction
(Sensor'l)
*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp (MlL)with
the SCSserviceconnector
connected
* 1 : D l 6 Y 5e n g i n e( C V T )
*2: ExceptDl6Y5 engine(M/T) (cont'd)
*14: '97 model
* 1 5 : ' 9 6m o d e l
*16:'98 model
11 - 5 3
Troubleshooting
DiagnosticTroubleCode(DTC)Chaft (cont'd)
DTC
Detection ltem ProbableCause Page
{MlL indication)
Secondary HeatedOxygenSensor HO2S(Sensor
Shortin Secondary 2) circuit
P0137 (63) CircuitLowVoltage Secondary HO2SlSensor2) 11-95
(Sensor 2) ECM/PCM
SecondaryHeatedOxygenSensor Openin SecondaryHO2SiSensor2)circuit
P0138 (63) CircuitHigh Voltage SecondaryHO2S(Sensor
2) 11-96
(Sensor2) ECt\4/PCM
SecondaryHeatedOxygenSensor SecondaryH02S (Sensor2)
P0139 (63) SlowResponse 11-97
(Sensor
2)
SecondaryHeatedOxygen Sensor Open or short in SecondaryHO25 (Sensor
(65) Heater 2) heatercircuit 1 19 8
P0141
CircuitMalfunction ECM/PCM
(Sensor2)
SystemToo Lean Fuel supply system
PrimaryH02S (Sensor1)
lvlAPsensor
P0171 {45) 11-103
Contaminatedfuel
Valveclearance
Exhaustleakage
System Too Rich Fuel supply system
PrimaryHO2S(sensor1)
P0172 (45) MAP sensor 11,103
Contaminatedfuel
Valve clearance
P0300*16 RandomMisfire lgnitionsystem
and Fuelsupplysystem
someof MAPsensor
P0301 EGRsystem 11 -1 0 8
P0302 l#\
P0303 l 7 3 l
IACvalve
Contaminated fuel
P0304 \741 Lackof fuel
- Cylinder1
tr\
P0301 Fuel Injector
- Cylinder2 Fuel Injectorcircuil
P0302 - Cylinder3
P0303 lgnitionsystem 11-105
173| - Cylinder4 Low compressron
P0304 \741 Misfire Detected Valveclearance
KnockSensor(KS)Circuit Open or short in KnockSensor(KS)circuit
P0325'3 (23) Maltunction KnockSensor(KS) 11,109
ECM/PCM
Crankshaft
Position CrankshaftPositionSensor
P0335 (4) SensorCircuit CrankshaftPositionSensorcircuit 11-110
Mallunction ECM/PCM
Position
Crankshaft . CrankshaftPositionSensor
P0336 . Timingbeltskippedteeth ' 11 - 1 1 0
{4) Sensor
Range/Performance
ExhaustGas
P0401.1 (80) Recirculation . E G Rl i n e 11-170
lnsufficient Flow Detected
CatalystSystem . Three Way Catalyticconverter
P0420 (67) EfficiencyBelow . SecondaryH02S 11-168
Threshold
*3r Dl6Y5engine(CVT)andDl6Y8engine
*4: D16Y5engine
* 1 6 : ' 9 8m o d e l
11-54
DTC
(MlLindicationl Detection ltem Probable Cause Page
EvaporativeEmissionControl EVAPPurgeControlSolenoidValve
System lnsufficient Open or short in EVAPPurgeControl
PurgeFlow SolenoidValvecircuit
P0441*5 {92) 11-'190
EVAPControlCanister
Vacuum lines
ECM/PCM
FuelTankPressure
SensorCircuit Shortin FuelTankPressure
Sensorcircuit
P0452*6 (91) Low Input FuelTankPressureSensor 11 -1 8 1
ECM/PCIV
FuelTank PressureSensorCircuit Openin Fu€lTankPressureSensorcjrcuit
P0453*6 (91) H i g hI n p u t FuelTankPressureSonsor 11 -1 8 3
ECM/PCM
VehjcleSpeed VehicleSpeed Sensor
P0500.1, (17) SensorCircuit VehicleSpeed Sensorcircuit 11-112
lvlalfunction ECM
VehicleSpeed VehicleSpeedSensor
P0501*13 (17) SensorCircuit VehicleSpeedSensorcircuit 1 1112
Range/Performance PCM
ldle ControlSystem . IAC valve
P0505 (14) 11-124
Malfunction . Throttle Body
P0700*E Automatic
and some of Transaxle
P0715
P0720
P0730 (70)* Section 14
P0740
P0753
P0758
P0700*1 AutomaticTransaxle
and {70)* Section 14
P0725
BarometricPressure . bCM/PCM (tsarosensorl
Circuit 11 1'13
Range/Performance
Problem
Barometric . ECM/PCM{8aro sensor}
P1107 (13) PressureCircuit ' '| 14
LowInput
Earometric . ECM/PCM(Barosensor)
P1108 (13) PressureCircuit 11-1't4
H i g hI n p u t
ThrottlePositionLowerThan . TPsensor
Pl121+M.+16 17)
Expected 11-82
ThrottlePositionHigherThan . TPsensor
P 1 1 2 2 * 1 4* 1 5 l 7 l 11-83
Expected
ManifoldAbsolutePressure . MAP sensor
P 1 1 2 8 * 1 4* '.6 ( 5 1 11-72
Lower Than Expected
Manilold AbsolutePressure . MAP sensor
HigherThan Expected 11-72
*: The
LD.jindicatorlight and the MallunctionIndicatorLamp (MlL) may come on simultaneously.
*1: D16Y5engine (CVT)
*5j '96 D16Y5engine,D16Y7engine,Dt6Y8
engine (sedanl,,97 O1dy5engine,O16y7engine (coupe:KA, KC models,sedan:KA,
KC,KL (DX) models,hatchback:a models),D16yg engine (sedan:KA;KC models)
*6:'96 D16Y8engine (coupe),'97D16Y7
engine {coupe:KL modet,sedanrKL (LX) model),'97 D16y8 engine (coupe:all models,
sedan:KL model), '98-allmodels
*12: ExceptA/T (D16Y7,D16Y8enginel
*'13:A"/T(D16Y7,D16Y8engine)
+14:'97modet
*T6: ,98 model
{cont'd)
11 - 5 5
Troubleshooting
TroubleCode(DTGIChart(cont'dl
Diagnostic
DTC Detection ltem Probable Cause Page
{MlLindication}
PrimaryHeatedOxygenSensor . Openor shortin PrimaryHO2Slsensor1
. PrimaryHO2S(Sensorl) '1188
P1162*1 (48) (Senso1r )Circuit
Mal{unction
PrimaryHeatedOxygenSensor PrimaryHO25 (Sensor1)
P1163*' (61) (Senso1r )Circuit 11-87
Slow Response
PrimaryHeatedOxygenSensor . PrimaryHO2S(Sensor1)
P1164*' i61) (Sensor'l) CircuitRange/ 11-92
Performance Problem
PrimaryHeatedOxygenSensor PrimaryHO2S(Sensor1)
P1165*? (61) (Sensor'1)CircuitRange/ 11-92
PerformanceProb em
PrimaryHeatedOxygenSensor Open or short in PrimaryHO2S(Sensor'l)
(Sensor1) HeaterSystem Electrical heatercircuit
P1166*? (41) 11-100
Problem PrimaryHO2S(Sensor1|
ECM/PClvl
PrimaryHeatedOxygen Sensor HO2S(Sensor
Openin Primary liVS+ circuit
P1167*1 (41) (Sensor1) HeaterSystem PrimaryHO2S(Sensor1) Heater 11-102
Malfunction PrimaryHO2S(Sensor1i
PrimaryHeatedOxygen Sensor . Shon in PrimaryHo2S (Sensor1) LABEL
P1 1 6 8 * ? (48) ( S e n s o r1 ) L A B E LL o w I n p u t carcuit
PrimaryHeatedOxygen Sensor . Open in PrimaryHO2S(Sensor1) LABEL

'11-94
P1169*7 (48) { S e n s o r1 ) L A B E LH i g hI n p u t circuit
. Short in ground circuit
VTECSystem Malfunction VTECSolenoidValve
Open or short in VTECSolenoid
Valve circuit
P1259*3 \22) v I tL PressureSwttcn Section6
Open or short in VTECPressureSwitch
crrcurt
ECM/PCM
ElectricalLoad ElectricalLoad Detector
P1297*' (20) DetectorCircuit ElectricalLoad Detectorcircuit 11-115
Low InPut ECM/PCrvl
ElectricalLoad ElectricalLoad Detector
P1298*' (20) DetectorCircuit ElectricalLoad Detectorcircuit 11-116
H i g hI n p u t ECM/PCIV
R a n d o mM i s f i r e lgnitionsystem
and Fuelsupplysystem
someof MAPsensor
P0301 1 7 I1 EGRsystem 11 -1 0 8
P0302 prl IACvalve
P0303 l73l contaminated fuel
P0304 \ 74 l Lackol fuel
*7: D16Y5engine (M/T)
*8: D16Y5,D16Y8engine
*9: USA model
* 1 4 r' 9 7 m o d e l
+ 1 5 r' 9 6 m o d e l
11 - 5 6
DTC
Detoction hem Probable Cause Page
lMlL indicrtionl
CrankshaftSpeed . CKFsensor
P1336 (54) FluctuationSensor 11 117
Intermiftent Interruption
CrankshaftSpeed CKFsensor
P1337 (54) FluctuationSensor CKFsensorcircuit 11 117
No Signal ECM/PCM
CrankshaftPosition/Top CKP/TDC
sensorcircuit
P1359 (8) DeadCenterSensor 1 11 1 9
Disconnected
Top DeadCenter . TDCsensor
P1361 (8) SensorIntermittent 1 11 1 0
Interruptron
Top Dead Center TDCsensor
P1362 (8) SensorNo Signal TDCsensorcircuit 11-110
ECM/PCM
CylinderPositionSensor . CYPsensor
P1381 (91
IntermiftentInterruption 11-' '10
]
CylinderPositionSensor CYPsensor
P1382 (9) No Signal CYPsensorcircuit 11 1 1 0
ECM/PCM
Evaporative
Emission
Cont.ol F u e lf i l l c a p
(FuelTank
SystemLeakDetected Vacuum connection
Area) Fueltank
Fueltank pressuresensor
P1456*6 (90) EVAPbypasssolenoidvalve 11-185
EVAP two way valve
EVAPcontrol canistervent shut valve
EVAPcontrol canister
EVAPpurge control solenoidvalve
Evaporative
EmissionControl Vacuum connection
SystemLeakDetected(EVAP EVAPcontrol canister
ControlCanister
Area) Fueltank pressuresensor
(e0) EVAPbypasssolenoidvalve
P1457+6 11,185
EVAP two way valve
EVAPcontrol canistervent shut valve
FuelTank
EVAPpurge control solenoidvalve
*6:'96 Dl6Y8 engine (coupe),'97 D16Y7engine (coupe:KL model, sedan: KL
1LX)model),'97 D16Y8engine (coupe:all models,
sedan:KL model),'98-allmodels
{cont'd)
11-57
Troubleshooting
DiagnosticTroubleCode(DTC)Chart(cont'dl
DTC Probablc Cause Pags
Detection ltem
lMlLindicationl
EGRValve EGRvalve (with lift sensor)
Lift Insufficient EGRvalve lift sensorcircuit
Detected EGRcontrol solenoidvalve (4,/T)
P1491*. l12l EGRcontrol solenoidvalve circuit 11-171
EGRvalve circuit (M/T)

ECIV
EGRValve EGRvalve lwith lift sensor)
P1498*. \12) Lift Sensor EGRvalve lift sensorcircuit 11 - 1 7 6
High Voltage ECt\4
ldle Air ControlValve IAC valve
P1508*'0 (14) CircuitFailLrre IAC valve circuit 11-126
ECM
ldle Air ControlValve Openor shon in IACvalvecircuit
P1s09*11 114) C i r c u iF
t ailure IACvalve 11'128
ECM/PCt\,,|
EngineControl . ECM/PCM
Module/PowenrainControlModule
P1607 lnternal
11-120
P1655*1 (30) TMA,/TMBSisnal Line Failure Open or short in TMA/TMBcircuit 11-121

P1705 AutomaticTransaxle
P1706
P1 7 5 3
P1758
P1768
P1785
P1790
P1791
P1793 (70)* Section14
P1870
P1873
P1879
P1885
P1886
P1888
P1890
P1891
*: The[D!]indicatorlightandthe Mallunction Lamp(MlL]maycomeon simultaneously.
Indicator
*1: D'16Y5engine(CVT)
*4: D16Y5engine1N4/T)
*10:ExceptA/TandD'16Y7 engine
*11:A,/TandD16Y7engine
11 - 5 8
How to ReadFlowcharts
A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware:
lf you go off the "map" anywherebut a "stop" symbol,you can easilyget lost.
ISTARN Describes
the conditionsor situationto starta troubleshootinq
{boldtype) flowchart.
jAcroNl Asksyou to do something;performa test.set up a conditionetc.
QE!E]!!, Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting

direction.
fsro-l The end of a seriesof actionsand decisions,describesa final repairactionand sometimesdirectsyou to

(boldtype) an earlierpan ot the flowchartto confirmyour repair.
NOTE:
. The term "lntermittentFailure"is used in thesecharts.lt simply meansa systemmay have had a failure,but it checks
out OK at this time. lf the MalfunctionIndicatorLamp {MlL)on the dash does not come on, checkfor poor connectrons
or loosewires at all connectorsrelatedto the circuitthat you are troubleshooting
(seeillustrationbelow).
. Most of the troubleshootingflowchartshave you resetthe EngineControlModule (ECM)/Powertrain ControlModule
{PC[/)and try to duplicatethe DiagnosticTroubleCode(DTC).It the problemis intermittentand you can't duplicatethe
code,do not continuethoughthe flowchart.To do so will only resultin confusionand, possibly,a needlesslvreDiaced
ECM/PCM.
o "Open" and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an acci-
dentalconnectionof a wire to ground or to anotherwire. In simple electronics, this usuallymeanssomethingwon't
work at all. In complexelectronics(likeECM'S/PCM'S), this can sometimesmeansomethingworks,but not the way it's
suoDosed to.
LOOSE
PGM-FISystem
SystemDescription
ENGINE L O D U L E( E C M ) i
C O N T R OM
INPUTS POWERTRAIN CONTROL MODULE(PCM) OUTPUTS
CKP/TDC/CYP Sensor
CKFSensor FuelInjectors
MAP Sensor PGMFl Main Relay{FuelPump)
ECTSenso. MIL
IATSensor IAC Valve
TP Sensor A,/CCompressorClutch Relay
EGRValveLiftSensor*1 RadiatorFanRelay*'
PrimaryHO2S F*l |.r*a"r.Tl.il g ""d Dr*i";l Condenser FanRelay
Secondary HO2S ALT*?
VSS rcM
EAROSensor E r""t'.','l" ldb c-o-l*il EVAPPurgeControlSolenoid
ELD*'
KS*3
StarterSignal F,h*J--r---l Fr"*il] PrimaryHO25Heater
SecondaryH02SHeater
ALT FRSignal EGRControlSolenoidValve*7
Air Conditionjng
Signal Effi;r"sc;;il EGRvalve*6
A,/TGearPositionSignal EVAPBypassSolenoidValve*a
BafteryVoltage(lGN.1) EVAPControlCanisterVent Shut
SrakeSwitchSignal FcM/PcMB""k,upFr*,or'sl
PSPSwitchSignal VTECSolenoidValve*5
FuelTankPressure Ssnsor*a DLC
VTECPressureSwitch*t Lock-upControlSolenoidValve*3
ClutchSwitchSignal*6 ShiftControlSolenoidValv6*3
CountershaftSpeedSensor*3 LinearSolenoidValve*3
Mainshalt SpeedSensor*3
'1: D16Y5engine
*2:USAmodel
*3rCW (D16Y5 engineland
016Y8 engine
*4: '96016Y8engine{coupe},'97
D16Y7 engine{coupe:
KLmodel,sedan:KL{LX)model),'97 engine(coupe:
D16Y8 all models,
sedan:KL
model).'98'all
models
15:Dl6Y5,Dl6Y8engine
*6:M/T(016Y5 engine)
*7:CVT(D16Y5 engine)
*8:A/T(D16Y7,D16Y8 ensine)
*9:'96 Dl6Y5engine,'96
D16Y7 engine,'96D16Y8engine(sedan),'97
D16Y5engine,'97
D16Y7engine(coupe:
KA,KCmodels, sedan:
KA,KC,KL(LX)models,hatchback:
all models),'97
D16Y8engine(sedan:
KA,KCmodels)
PGM-FISystem
The PGM-Fisystemon this model is a sequentialmultiportfuel injectionsystem.
Fuol inisstor Timing and Duration
The ECM/PCMcontainsmemoriesfor the basicdischargedurationsat variousenginespeedsand manifoldair llow rates.
The basicdischargeduration,afterbeing readout from the memory,is further modifiedby signalssentfrom varioussen-
sorsto obtainthe final dischargeduration.
ldlo Air Control
ldle Air ControlValve(lACValve)
Whenthe engineis cold,the Ay'Ccompressoris on, the transmissionis in gear,the brakepedalis depressed, the P/Sload
is high,or the alternatoris charging,the ECM/PCM controlscurrentto the IACValveto maintainthe correctidle speed.
lgnition Timing Co||trol
. The ECM/PCMcontains memorieslor basic ignition timing at various engine speedsand manifold air flow rates.
lgnitiontiming is also adjustedfor enginecoolanttemperature.
. A knockcontrolsystemwas adoptedwhich setsthe idealignitiontimingfor the octaneratingof the gasolineused.*3
Other Control Functions
1. StaningControl
Whenthe engineis started,the ECM/PCMprovidesa rich mixtureby increasingtuel injectorduration
2. FuelPumpControl
. When the ignitionswitchis initiallyturned on, the ECM/PCMsuppliesgroundto the PGM-FImain relaythat sup-
pliescurrentto the tuel pump for two secondsto pressurize
the fuel system.
. When the engine is running,the ECM/PCMsuppliesground to the PGM-FImain relay that suppliescurrentto the fuel
pump.
. When the engineis not runningand the ignitionis on, the ECM/PCMcuts groundto the PGM-FImain relaywhich
cutscurrentto the fuel pump.
11-60
3. FuelCut-offControl
. Duringdeceleration with the throttlevalveclosed,currentto the fuel injectorsis cut off to improvefuel economyat
speedsoverthe {ollowingrpm:
. D16Y5engine(M/T):850 rpm
. D16Y5enginelCVT),D16Y8engine(USAM/T)r920 rpm
' D16Y8engine(USAA,/T),Dl6Y7 ensine(USAA"/T):910 rpm
. D16Y8engine(CanadaM//T),Dl6Y7 engine(Canada):990 rpm
. D'16Y8 engine(CanadaM/T):1,000rpm
. Fuelcut-offactionalso takesplacewhen enginespeedexceeds6,900rpm (D16Y5,Dl6Y7 engine;D16Y8engine:
7,000rpm),regardlessof the positionot the throttlevalve,to protectthe enginefrom over-rewing.
Ay'CCompressorClutchRelay
When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom
beingenergized, and enrichesthe mixtureto assuresmoothtransitionto the Ay'Cmode.
5 . Evaporative Emission(EVAP)PurgeControlSolenoidValve+s
Whenthe enginecoolanttemperatureis above '154.F(68"C).the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid
valvewhich controlsvacuumto the EVAPpurgecontrolcanister.
Evaporative Emission(EVAP)PurgeControlSolenoidValve*a
Whenthe enginecoolanttemperatureabove 154"F(68"Ci,intakeair temperatureabove32"F(0"C)and vehictespeeo
above 0 mile 10 km/h)or [A,/Ccompressorclutchon and intakeair temperatureabove 160"F141.C)1, the ECM/PCM
controlsthe EVAPpurgecontrolsolenoidvalvewhich controlsvacuumto the EVAPpurgecontrolcanister.
6. ExhaustGasRecirculation (EGR)ControlSolenoidValve*?
When EGRis requiredfor controlof oxidesof nitrogen(NOx)emissions.the ECMcontrolsthe EGRcontrolsolenoid
valvewhich suppliesregulatedvacuumto the EGRvalve.
7 . AlternatorControl
The systemcontrolsthe voltagegeneratedat the alternatorin accordance with the electricalload and driving mode,
which reducesthe engineloadto improvethe fuel economV.
€CM/PCMFail-safe/Back-upFunctions
'L Fail-safe
Function
when an abnormalityoccursin a signalfrom a sensor,the ECM/PCN4 ignoresthat signsl and assumesa pre-pro-
grammedvaluefor that sensorthat allowsthe engineto continueto run.
2. Back-upFunction
When an abnormalityoccursin the ECM/PCMitself.the fuel injectorsare controlledby a back-upcircuitindependent
of the systemin orderto permitminimaldriving.
3. Self-diagnosis Function[r4alfunctionIndicatorLamp(MlL)]
When an abnormalilyoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the MIL and storesthe DTC
in erasablememory.When the ignitionis initiallyturned on, the ECM/PCMsuppliesgroundfor the MIL for two sec-
ondsto checkthe MIL bulb condition.
4. Two Trip DetectionMethod
To preventfalse indications,the Two Trip DetectionMethodis usedfor the HO2S,fuel metering-related,idle control
system,ECTsensor.EGRsystem and EVAPcontrol systemself-diagnostic functions.When an abnormalityoccurs,
the ECM/PCMstoresit in its memory.When the same abnormalityrecursafterthe ignitionswitch is turned OFFand
ON (ll) again,the ECM/PCMinformsthe driverby lightingthe MlL. However,to easetroubleshooting, this functionis
cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelvwhen an abnormalitv
occurs.
5. Two (or Three)DrivingCycleDetectionMethod
A "DrivingCycle"consistsof startingthe engine,beginningclosedloop operation,and stoppingthe engine.lf misfir-
ing that increasesemissionsis detectedduringtwo consecutivedrivingcycles,or TWC deteriorationis detecteddur-
ing three consecutivedrivingcycles,the ECM/PCMturns the l/lL on. However,to easetroubleshooting, this function
is cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelywhen an abnormalitv
occurs.
(cont'd)
11-61
PGM-FISystem
SystemDescription(cont'd) \.
LoanEurn Control(D16Y5enginerCVT)
SENSOR
TDC/CKP/CYP
MAP SENSOR
CKFSENSOB
Comparison of currentair
fuel ratio to target ratio
SelectionoI basicfuel
iniectionduration
ECM
The lean burn controlsystem is basedon the characteristic which occursin

increasein crankshaftangularacceleration
when the air-fuelratiogets leaner.
The CKFsensor,which is mountedon the crankshaft,monitorsenginespeed.lf crankshaftangularacceleration falls below
a certainlevel(targetair-fuelratiolevel),the amountof injectedfuel is reduced.
lf crankshaftangularacceleration exceedsthis level.the amountof fuel is increased.
This system improvestuel economyand driveabilityby controllingthe amount of iniectedfuel in the lean burn range
immediatelybeforecombustionstartsto deteriorate,
11-62
EngineGontrolModule/PowertrainGontrolModule{ECM/PCM)
NOTE:lf this symptomis intermittent,
checkfor a looseluse No. 25 llrETER7.5A) in the
The Maltunction Indicato. Lamp underdash fuse/relaybox, a poor connectionat ECN4/PCM terminal Al8, or an intermit,
{MlL) nover com.s on {even to. tent openin the GRN/ORN wire betweonthe ECM/PCM (Al8) and the gaugeassembly.
two secondsl .tter ignition i!
tutned on.
Turnthe ignitionswitchON (ll).

- Rgpair short or open in tho
wire betwo.n No. 25 (METER)
(7.5A)fusc rnd gauge r$om-
ls the low oil pressurelight on?
blv.
- ReplecoNo.25 IMETERI17.5
A)tu...
Try to stan the engine.
A (32P}
ECM/PCMCONNECTOR
PGl {BLKI
Ch6cklor an open in the wiros

(PGlineslr
1. Turn the ignitionswitchON (ll).
2. Measurevoltage between
body ground and ECM/PCM
connectorterminalsA10 and
A23individually.
Checkfor an open in th6 wire or
bulb lMlL lino):
1. Turnthe ignitionswitchOFF. Repair opon in thc wi..l3)
2 . C o n n e c t h e E C M / P C Mc o n ls therelessthan 1.0V? botwe€n ECM/PCM and c10l
nectorterminal 418 to body lloc.ted at tho tharmostat hous-
groundwith a jumperwire. inglthrt had more th.n 1.0V.
3. Turnthe ignitionswitchON (ll).
Substitute . known-good ECM/

PCM and rechock. lf 3ymptom/
indication goo3 away, rcplac6 ECM/PCMCONNECTOR
A {32PI
tho o.iginal ECM/PCM.
- Repai. open in tha wire3

ls the MIL on? betweon ECM/PCM(A181.nd
gaugc a$ombly.
- Reolacethe MIL bulb.
Substituto a known-good ECM/

PCM and rechsck. lI symptom/
indicetion goo3 away, replaco Wire sideof femaleterminals
the odgin.l ECM/PCM.
(cont'd)
PGM-FISystem
ControlModule(ECM/PCMI(cont'd)
EngineControlModule/Powertrain
NOTE:
The Malfunction lndicator Lamo . When there is no DiagnosticTrouble Code (DlC) stored,the MIL will stay on if the SCS
lMlLl stays on or comos on after serviceconnectoris connectedand the ignitionswitch is on.
. lf this svmptomis intermittent, checkforl
- A looseFl E/M{15A) fusein the underhoodfuse/relay box
- A l o o s eN o .1 3 F U E L P U M P f u s e ( 1 5i A
n t)h e u n d e r ' d a sf hu s e / r e l abyo x
- An intermittentshortin the wire betweenthe ECM/PCM(C7)and the servicecheck
- An intermittentshort in the wire between the ECM/PCM(A18)and the gauge

C h e c kt h e D i a g n o s t i cT r o u b l e
Code(DTC): - An intermittentshort in the wire betweenthe ECM/PCM(D4land the MAP sensor
1. Connecta scantool or Honda - An intermittentshort in the wire betweenthe ECM/PCM{D10},the TP sensor,the
PGMTester. EGRvalve lift sensor (D16Y5engine)and/or the Fuel tank pressuresensor ('96
2. Turnthe ignitionswitchON {ll). 016Y8engine(coupe),'97Dl6Y7 engine(coupeiKL model,sedan:KL (LX)model),
3. Readthe DTC with the scan '97 D16Ygenginelcoupe:all models,sedan:KL model),'98-tllmodels)
tool or HondaPGMTester. - PGM-FI mainrelay
. See the O8D ll scantool or HondaPGMTesteruser'smanualsfor specificoperating
Instructrons.
Go to troubl6hooting proc€dures.
{3eepag611-53)
Ch6ckthe DTCby MIL indication:

2. Connectthe SCSservicecon'
n e c t o rt o t h e s e r v i c ec h e c k
connector.
R€pair opon or short in wire

between the EcM/PcM {c8)
Doesthe MIL indicateany DTC? and Oata Link Connector.
Go to troublashooting p.oce-
dure. (s6epage 11-531. C I31PI
ECM/PCMCONNECTOR
scs (BRNI
Try to stan the engine.
Doesthe enginestan?
C h e c kl o r a s h o r t i n t h a w i r e (To page11-65)
ISCSlinel:
'L Disconnectthe SCS service
2. Stop the engineand turn the

ignitionswitchON (ll).
3. N4easure voltagebetweenthe
ECM/PCMconnectorterminal
C7and bodyground.
Repair 3hoft to body ground in

ls thereapprox.5 V? th€ wire botwoen ECM/PCM{C7)
tnd se ice checkconn€ctor.
(Topage11-65)
11-64
(Frompage11-64)
Ch.ck to. . 3hort in the wirc {MlL

linol:
2. Disconnecrthe ECM,/PCi!4 con-
nectorA (32P).
3. Turn tho ignitionswitchON (ll).
Roptir ahort to body ground in

th6 wir. b.twoon the ECM/PCM
lAl8l snd MlL.
Substitute a known-good ECM/

PCM and rech.ck. ll 3ymptom/
indication goes away, replace
the original ECM/PCM.
(From page 11-64)
InspectFl E/M ('10A) fuse in the

undeFhoodtuseJrelaybox.
R.prir 3hort in thc wi..

b€tw.en Fl E/M 115 A) luse
and PGM-FIm.in iolay.
Ropl.co Fl E/M (15 A)fu.e.
InspectNo. 13 FUELPUMP115A)
fuse in the undeFdashfuse/relay
box.
- Repair short in the wire
betwoen No. 13 FUEL PUMP
{15 Al tus6 and PGM-FIm.in
retay,
- ReplaceNo. 13 FUELPUMP
115A) luse.
Ch€cktor a short in a son3or:
'1. Turn
the ignitionswitchON (ll).
2. Disconnectthe 3P connector
from eachsensorone at time:
. TPsensor
. EGRvalve litt sensor{Dl6Y5
engtne)
. F u e l t a n k p r e s s u r es e n s o r
('96 D16Y8engine {coupe),
' 9 7 D 1 6 Y 7e n g i n e ( c o u p e :
K L m o d e l , s e d a n :K L ( L X )
m o d e l ) ,' 9 7 D 1 6 Y 8e n g i n e
( c o u p e :a l l m o d e l s .s e d a n :
KL model'98-allmodels)
(Topage11-66)
{cont'd)
1-65
PGM-FISystem
EngineControlModule/PowertrainControlModule(ECM/PCMI
(cont'dl
\
lFrompage11-651
ECM/PCMCONNECTOR
D {16PI
Rapbce the ranaor thrt cau3od
Does the MIL go OFF? VCC1(YEL/RED)
th6 light to go out,
Chect tor r short in th6 wiras

{VCClin.3l:
1. T{rrnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e E C M / P C M
connectorD (16P).
3. Checkfor continuitybetween Repair ahon to bodY g.ound
body ground and ECM/PCM in th. wire batwaon ECM/
connectorterminals D4 and PCMlD4l snd MAP s.n.or. Wire sideof femaleterminals
D10individually. R.pair .hort to body ground
in tho wi.e botwoen ECM/
PCM lD10l, th. TP sensor,the
EGR v.lve lift son.or {D16Y5
.ngin.l and/or thc Fu.l tsnk A I32P}
ECM/PCMCONNECTOR
pra33u.escnso. ('96 D16Y8
onginc {coup.l,'97 D16Y7
6 n g i n 6 { c o u p o :K L m o d e l , ,I
IGP
Check tor en opcn in th. wire3 3odan: KL lLXl modcll, '97 (YEL/BLK)
llGP linosl: D16Y8ongino lcoupc: all
1. Disconnectthe fuel inioctors model3,seden:KL modol, '98- 2 a a l0 11
and IACvalveconnectors. all modobl, 12 t 3 t5 t 5 1 1 t8 20 22 2a
2. Turn the ignitionswitchON (ll). 25 21 2A 29 30
body ground and ECM/PCM IGP2
connectorterminalsA11 and (YEL/8LKI
A24 individually.
- Rapail opan in the srire{31
botwo.n ECM/PCM (A11.
A24l .nd PGM-FImrin roby.
- Check lor poor connaction3
or loo3. wirc! .t th. PGM-FI
main ralay.
- Tert lho PGM-FImain r.lay LGl
Check for an opon in the wirg! l3ecpag611-1571. IERN/
ILG line.l:
BLK}
1. Reconnect all sensorconnec-
rors, a !l to !l
2. Reconnectthe ECM/PCMcon- 12 t 3 t a t 5 t 6 7 7 t 8 t9 20 23 2a
nectorD (16P). E 21 2A 23 3 0
3. Turn the ignitions,witchON {ll).
4 . N 4 e a srue v o l t a g e b e t w e e n LG2
body ground and ECM/PCM IBRN/
connectorterminals A9 and BLKI
A22 individually.
Rapair op.n in the wiro(rl

ls there lessthan '1.0V? b€tween ECM/PCM lA9, A22l and
G101that had morothln 1.0V.
Sub.titute . known-good ECM/

PCM and lochock. lf .ymptom/
indic.tion 9o€. awry, roplace
the origin.l ECM/PCM.
11-66
ManifoldAbsolutePressure(MAP)Sensor
The scan tool indicatesDiagnosticTrouble Code (DTC)P0106:A mechanicalproblem (vacuumleak) in the
ManifoldAbsolutePressure(MAP)Sensorsvstem.
The MAPsensorconvertsmanifoldabsolutepressureinto electricalsignalsand inputsthe ECM/pCM.
OUTPUI
VOLTAGE
tvt3.5
3.0
2.5
2.O
1.5
1,0
o ,5 tq. rs. 10 .25 30 lin. Hg) GAUGE

- The MIL has bo6nr€poned on. READI'{G
- lqt 2|x) 3(x) i(X, 5OO 600 7ql
OTCP0106is stored. lln]n Hgl
- Or from ProbableCauseUrt.
Problemverilication:
I 1. Do the ECM/PCMResetPro-
cedure.
2. Start the engineand keep
enginespeedat 1,000rpm for
one minutewith the transmis,
sion in P or I position(M/T
in neutral).
ls DTCP0106indicated?
C h e c kf o r v a c u u m l e a k a g eo r
blockagebetweenthe MAP sen-
Ch6ckthe MAP sensoroutput:
sor and throttle body.
2. Turnthe ignitionswitchON lll).
3. Checkthe MAP with the scan
tool.
ls there leakageor blockage?
Checkthe MAP sonso. outputr

1. Stopthe engine.
tool.
(To page11-68) {To page11-68)

(cont'd)
ManifoldAbsolutePressure(MAPISensor(cont'dl
(Frompage11-67) lFrompagel1-67)
Check{or poor r6ponse: Ch6ckfor poor response:

1 . S t a r t t h e e n g i n e .H o l d t h e 1 . S t a r t t h e e n g i n e .H o l d t h e
engineat 3,000rpm with Iy'T in engineat 3,000rpm with lVT in
E or E] position, M/T in neu- E or E position,M/T in neu'
tral untilthe radiatorfan comes tral untiltheradiator lan comes
on, then turn the ignition on, then turn the ignition
switchOFF. switchOFF.
2. Stanthe engine. 2. Start the engine.
3. Checkth€ MAP with the scan 3. Checkthe MAP with rhe scan
tool. tool.
ls a MAP of 40.0 kPa 1300 mmHg,

1 2 . 0 i n . H g )o r l 6 s s i n d i c a l e d w i t h i n
one second after startingthe
engine?
ls a MAPot40.0kPa{300mmHg,
12.0in.Hg)or lessindicated
within
The MAP sensor is OK at this tims. one secondafterstartingthe
engine?

PCM and recheck.It symptom/
indication go6s awsy, roplace
the originsl ECM/PCM.
11-68
The scan tool indicatesDiagnosticTrouble Code (DTC)P0107:A low voltage (high vacuum) problem in the
ManifoldAbsolutePressure(MAP)sensor.
The MIL has b€6n reooned on.

DTC P0107 is stored.
'1. Turnthe ignitionswitchON (ll).
tool.
Intermittent f.ilure, svslem b OK

at this tirne. Chock to. poor con-
nactionsor loose wiroa at C111
IMAPs€nsorland ECM/PCM.
Checkfo. an open or short in th€

MAP sensor:
2. Disconnectthe MAP sensor
3P connector.
3. Turnthe ignitionswitchON {ll).
tool.
MAP SENSOR3P CONNECTOR

ICTI'tI
vccl
{YEL/REDI
Checktor an open in wi.e {VCCI
lin6l:
M e a s u r ev o l t a g e b e t w e e nt h e
MAP sensorconnectorNo, 1 ter
minaland No. 2 terminal.
ls thereapprox.5V? Repair opeo in the wire b€twoen

ECM/PCMltxl and MAP 3€mor.
Checktor . short in the TCM:

2. Disconnect the 22Pconnector
from the TCM.
3 . T u r n t h e i g n i t i o ns w i t c hO N
flr).
tool.
(To page11-70)
(cont'd)
11-69
PGM-FISystem
ManifoldAbsolutePressure(MAPISensor(cont'd)
MAP SENSOR3P CONNECTOR

IC111}
C h o c kl o r . s h o r t i n t h o w i J e
(MAPlinel:
1. Turnthe ignitionswitchOFF. MAP
2 . D i s c on n e c t t h e E C M / P C M (RED/GRNI
connectorD (16P).
the MAPsensorconnectorNo.3
terminaland body ground.
ReDair 3hort in the wire bstween

ECM/PCM{D3l and MAP sensor.
Substitute a known-good EGM/

PCM, and rechock. It norrnal MAP
b indiceted, replaco the o.iginal
ECM/PCM.
11-70
The scan tool indicatesDiagnosticTroubleCode (DTC)P0108:A high voltage (low vacuum)problem in the
ManifoldAbsolutePressure(MAP)sensor.
Tho MIL has b€€n reported on.

OTCP0108is sto.ed.
Problemverification:
l . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (Ay'Tin E or E position,
M/T in neutral)untilthe radia-
tor fan comeson,then let h idle.
tool.
Intormittont lailwo. 3yst6m ir OK
ls 101kPa(760mmHg,30.0in.Hg) at thia timc, Ch.ck tor poor con- MAP SENSOR3P CONNECTOR
{CI11I
or higherindicated? noctions or looaa wira! at Cllt
(MAP!€nrorl and ECM/PCIV|,
Check for an open in the MAP
1. Turnthe ignitionswitchOFF-
2 . D i s c o n n e ctth e M A P s e n s o r
3P connector,
3. Installa jumper wire between {RED/GRNI
the MAP sensor3P connector JUMP€R
WIRE
terminals No.3 andNo.2.
4. Turnthe ignitionswitchON llll. Wiresideof temaleterminals
tool.
ls 101kPa{760mmHg,30.0in.Hg}
or higherindicated? vccl
(YEL/REDI
Check Ior an open in wirs (SGl

linel:
1. Removethe iumperwire.
2. Measurevoltagebetweenthe
MAP sensor3P connectorter-
minalsNo. 'l and No.2.
ls thereapprox.5 V? Repairopen in tho wir6 bctwaon

ECM/PCMlDl2l .nd MAP sonror. CCM/PCMCO NECTORD I16PI
JUMPERWIRE
Check for an open in lhe wire MAP
IMAPlinel: IRED/GRNI
2 . C o n n e c tt h e E C M / P C M
con-
nectorterminalsD3 and 012
with a iumPerwire.
3. Turnthe ignitionswitchON (ll). sG1
4. Checkthe MAP with the scan {GRN/WHTI
tool.
Wire side of femaleterminals
ls 10'1kPa(760mmHg,30.0in.Hg) R.pair op€n in tha wir63 botwocn
or higherindicated? ECM/PCMlD3l .nd MAP.onsor.

PCM .nd rechock.ll normal MAP (cont'd)
is indicated, .oplace the originel
ECM/PCM.
11-71
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor(cont'd)
The scantool indicatesDiagnosticTroubleCode (DTC)P1128;ManifoldAbsolutePressure(MAP)lower than
expected.
- The MIL hes been.eoorted on.

- DTC Pl128 is stored.
Problamv€rific.tion:
ls 54.1kPa(406mm Hg, 16.0 Intermittont tailurc, system b OK

in. Hg)or higherindicated? at thk time.
The scantool indicatesDiagnosticTroubleCode (DTC)P1129:ManifoldAbsolutePressure(MAP)higherthan

exoected.
- The MIL h.s beenreportedon.

- DTCPl'129is stor6d.
Probl6mveritication:
1 . S t a r tt h e e n g i n e .H o l d t h e
load (A,/Tin E or E position,
tor tan comes on, then let it
idle.
tool.
ls 43.3kPa{325mm Hg, 12.8 lntermittent failure, 3y3temi3 OX

in. Hg)or lessindicated? at lhis time.
11-7 2
IntakeAir Temperature(lATlSensor
The scantool indicatesDiagnosticTroubleCode (DTC)P0111: A range/performance
problemin the lntakeAir
Temperature(lAT) Sensor circuit.
The IAT Sensoris a temperaturedependantresistor(thermistor). ot the thermistordecreasesas the intake

The resistance
air temoeratureincreases
as shown below.
- Th6 MIL has beenroportedon. RESISTAI{CE

ft01
- DTCP011t is stored,
- O. from Probabl. C.us€ List.
Probl€mvoritication:
1. Turnrhe ignitionswitchOFF.
2. Disconnect the IAT sensor2P
connector,
3. Removethe IAT sensor. -a 32 X rO. t1a 212 24a t.jl
4. Reconnectthe IAT sensor2P -20 0 20 /|o ao ao !00 t2o trcl
connector. II{IAXE AIR TEI/IPERATURE
5. Leavethe IAT sensorexposed
to ambienttemperature.
7. Checkthe IAT with the scan
tool,
Reolacetho IAT sensor.
Checkthe IAT s€nsoroutput:

1. Warm the IAT sensorwith a
hairdryer.
tool,
Didthe IATrise2"F(1"C)or more Interrnittentlailure, system is OK

from the ambienttemperature? at this time.
Reolacothe IAT sensor.
(cont'd)
1-73
PGM-FISystem
IntakeAir Temperature(lAT)Sensor{cont'd}
The scantool indicatesDiagnosticTroubleCode(DTC)P0112:A low voltage(hightemperature)problemin the
IntakeAir Temperature{lAT)sensorcircuit.
- The MIL he3 b6en Eoortcd on. RESTSTANC€

ll0l
- DTC P0112 b 3tor.d.
lo
to
I
Problamvo.ification:
tool,
. aa aa ro. tra 2t2 a{ frt

- 20 0 ro :|o ao ao t00 r20 tlcl
ITTAXEAN EMPERATURE
ls 302'F (150"C)or higher (or
H-Limit*rlindicated?
Replacethe IAT sensor.
Intormittent failurg, 3y3temis OK

at thb tims. Chackfor Door con-
ncctions or looac wi.as at C112
(lAT sonsorl .nd ECM/PCM.
Checklor . .horl in the IAT s6n-

sot:
1. Oisconnectthe IAT sensorcon-
nedot,
tool.
ls 302'F (150'C)or higher (or

RoplacGtho IAT senio..
H-Limit*1)indicated?
IAT SENSOR2P CONNECTOR
{Cl12I
Chockfor. short in the wiro llAT

lin.l:
--+-r
l l l 2 l
2. Disconnectthe ECM/PCMcon-
nectorD 116P). + IAT
3. Checktor continuitybetween
the IATsensor2Pconnectorter-
@ IRED/YELI
minalNo.2andbodyground. =
Wiresideof femalerermtnats
Rgpairlhort in tho wire betweon
ECM/PCMlDSl and IAT sensor.
Sub3titute e known-good ECM/

PCM and recheck. It normal IAT
is indic.lad, replaco the original
ECM/PCM.
* 1 : With HondaPGMTesterin Hondamode.
*2. lfthe engineis warm,it will be higherthanambienttemperature.
11-74
The scantool indicatesDiagnosticTroubleCode(DTC)P0113:A high voltage(low temperature)problemin the
lntakeAir Temperature(lAT)sensorcircuit.
- The MIL has beenreport€don.

- DTCP0113is stor€d.
Ploblem veriticationi
tool,
Inte.mittent lailura, system is OK

at this time. Checktor poor con-
neclionsor loose wires at C112
{lAT sensorl and ECM/PCM.
Checkfo. an open in the IAT sen-

(C112)
IAT SENSOR2P CONNECTOR
sor:
1. Disconnect the IAT sensor2P
connector,
2. Connectthe IATsensor2P con-
----F--
t l
n e c t o rt e r m i n a l sN o , ' l a n d I ' l r IAT
l
No.2 with a jumperwire. sG2 ffi
3. Checkthe intakeair tempera- (GRN/BLnI I (RED/YEL)
ture with the scantool.
JUMPER
wtEE
Wire sideoI lemaleterminals
D (16PI
ECM/PCMCONNECTOR
Checklor an op€n in the wires
{lAT,SG2 lines):
2. ConnectECM/PCMconnector
t e r m i n a l sD g a n d D l 1 w i t h a
3. Turnthe ignitionswitchON (ll). sG2

4. Checkthe IAT with the scan IAT(RED/YELI IGRN/8LK}
tool.
JUMPERWIRE
Repairopen in th€ wires between Wire sideof femaleterminals

ECM/PCM(D8, D11)and IAT sen-

PCM and recheck. It normal IAT
is indicated. replace the o.iginal
ECM/PCM.
*r With HondaPGMTesterin Hondamode.
PGM-FISystem
EngineCoolantTemperature{ECTISensor
The scan tool indicatesDiagnosticTrouble Code (DTC)P0116:A range/performance problem in the Engrne
CoolantTemperature(ECT)Sensorcircuit.
The ECTSensoris a temperaturedependantresistor(thermistor).
The resistance
of the thermistordecreases as the enoine
coolanttemperatureincreasesas shown below.
RESISTANCE
tkol
THERMISTOR a 3 2 6 E1 0 a1 a 0 1 7 62 t 2 2 a 8( . r )
-20 0 20 ao o I to !20 Ic)
ENGINE COOLANT TEMPERATURE
NOTE:lf DTCP0117and/or P0118are storedat the same time as DTCP0116,troubleshootthose DTCSfirst, then trou-
bleshootDTCP0116.
PossibleCausa
. ECTsensordeterioration
. Malfunctionin the coolingsystem
TroubleshootingFlowchart
- The MIL has b€en rcportodon.

- DTCP0116k stored.
1. Start the engine.Hold the
load {A"/Tin E or El position,
M/T in neutral)until the radia-
tor tan comes on, then let it
idle.
2. With the scan tool, checkthe
ECT.
Intermittent failure, system is OK

et this time. Checkthe cooling
Chock the cooling systom. lf the

cooling alElam i3 OK, replacothe
ECTsensor.
11-76
The.scantool indicatesDiagnosticTroubleCode(DTC)P0117:A low voltage(hightemperature]problemin the
:Ipfln7'l E n g i n eC o o l a nTt e m p e r a t u r{eE C Ts) e n s o r c i r c u i t .
The MIL hes b€en reooned on.

DTC P0117 is sto.ed.
Problomveriticrtion:
1. Turnthe jgnitionswitchON (lli.
2. Checkthe ECTwith the scan
tool.
Intormittent failure,lvstem k OK
at thi3 time. Checkfor poor con-
nection3 or loo3o wirg! at Cl22
IECT3.n3or)and ECM/PCM.
Chocktor a short in the ECTson-
1. Disconnect
the ECTsensor2P

tool.
ls 302"F(150"C)
or higher(or
H-Limit*)indicated?
ECTSENSOR2P CONNECTOR
{C122I
Chock tor a sho.t in the wire

{ECTline):
nectorD (l6P).
3. Checkfor continuitybetwoen
the ECTsensor2Pconneclorter
minalNo. 1 and bodyground.
Wiresideof fomaleterminals
Reoairshort in th6 wir6 botwoen
ECM/PCMlD2l and ECTsensor.
Subrtituto r known-good ECM/

PCM and rochock, f nolmal ECT
i3 indicated, r6plac€ tha origin.l
ECM/PCM.
*r With HondaPGMTesterin Hondamode.
(cont'd)
11-77
PGM-FISystem
(ECTISensor(cont'dl
EngineCoolantTemperature
The scantool indicatesDiagnosticTroubleCode{DTC)P0l l8: A high voltage(low temperature)problemin the
EngineCoolantTemperature(ECT)sensorcircuit.
The MIL hrs boon reported on.

P.oblemveritication:
L Turnthe ignitionswitchON (ll).
tool.
Intormittent tailuro, svstem is OK

at this time. Chock tor poor con-
nestions or loose wires at C122
{ECTsonsorland ECM/PCM.
ECTSENSOR2P CONNECTOR
{C122I
Checktor an opon in the ECTsen-
1 . D i s c o n n e c t h e E C Ts e n s o r ECT
2P connector. {RED/WHTI
2 . C o n n e c tt h e E C Ts e n s o r2 P JUMPENWIRE
connectorterminalsNo. 1 and
No.2 with a j!mperwire. sG2
3. Checkthe ECTwith the scan IGRN/BLK)
tool.
ECM/PCMCONNECTOR
D {16P)
JUMPERWIRE
Checklor an opon in th6 wir6s
{ECT,SG2 linesl:
2. ConnectECNI/PCM connector
ECT
(RED/WHTI
L ---l
l 3 l a l
sG2{GRN/BLKI
t e r m i n a l sD 2 a n d D 1 1w i t h a
6 1 I 9 to 12
3. Turn the ignitionswitchON (ll). l3 t5 t6

tool.
Wire sideoJfemaleterminals
Repeiropen in the wires botween

ECM/PCM{D2,Dl1) snd ECTsen-
Substiluto a known-good ECM/

PCM and rocheck.It normal ECT
is indic.ted, .splac. the original
ECM/PCM.
*: With HondaPGMTesterin Hondamode.
11-7 8
ThrottlePosition{TPlSensor
scantool indicatesDiagnosticTroubleCode {DTC)P0122:A low voltageproblemin the ThroftlePosition
tFo-,
- .Tj_:
t I l-l sensorcrrcull.
The TP Sensoris a potentiometer. lt is connectedto the throttlevalve shaft.As the throttlepositionchanges,the throttle
positionsensorvariesthe voltagesignalto the ECM/PCM.
OUTPUTVOLTAGE{VI
- The MIL has been reDortedon.
- DTCP0122is stored. 5
4
Problomve.ification: 1 THROTTLE
1. Turnthe ignitionswitchON (ll). OPENING
0
2 . C h e c kt h e t h r o t t l e p o s i t i o n FULL
with the scantool- THROTTLE
TP SENSOF3P CONNECTOR
{Cl1OI
ls thereapprox.10%whenthe Inlermittent tailure,system is OK
throttle is fully closedand et this time. Checklor Door con-
approx.90%when the throttle nectionsor loose wires at Cl10
is fullyopened? ITPsenso.land ECM/PCM.
sG2 vcc2
IGRN/BLK} (YEL/BLU)
Ch6ck for an opcn in lhe wire

(VCC2linell
2. Disconnectthe TP sensor3P
connector. Waresideof femaleterminals
4. N,4easure voltage between
the TP sensor3P connectorter-
minalsNo.'l andNo.3.
D Il6PI
ECM/PCMCONNECTOR
ls thereapprox.5 V?
Checkfor an op6n in wire IVCC2

line):
Measurevoltage betweenECM/ SG2 (GRN/BLKI
PCMconnector terminalsD10and
D1' ]. Wire side of female terminals
Checktor an open or 3hort in TP
sensoa:
Repairopen in lhe wire between
2, At the sensorside, measure ls thereapprox.5 V?
ECM/PCM(D10)and TP sonsor.
resistancebetweenthe TP sen-
sor terminalsNo. 1 and No. 2
with the throttlefullyclosed.
PCM and rechock. It orescribed
voltage is now available, replac€
(Topage11-80)
the originel ECM/PCM.
Terminalsideof maleterminals
(cont'd)
PGM-FISystem
ThrottlePosition(TP)Sensor(cont'dl
(Frompage1'179)
ls thereapprox.0.5- 0.9k0? TP SENSOR3P CONNECTOR
YES
CheckIor an open or short in the

TP sensori
Measureresistancebetweenthe
T P s e n s o rt e r m i n n a lN o . 2 a n d
No.3 withthe throftlefullyclosed.
ls thereapprox.3.6- 5.4kO? TerminalsideoI maleterminals
Checklor an open in the ECM/

PCM{TPSline): ECM/PCMCONNECTOR
O Il6PI
1 . R e c o n n e ct th e T P s e n s o r3 p
lh f f"i
2. Turnthe ignitionswitchON {ll). TPS(RED/ sG2(GRN/BLKI
3. Measurevoltage between BLKI
ECM/PCM connectorterminals
D 1a n dD 1 l .
7 I 9 10 l l 12
13 l a ta
ls thereapprox.0.5 V whenthe Sub3titute a known-good ECM/

throttle is tully closedand PCM and recheck. It oroscribed Wiresideof t6m6leterminals
approx.4.5 V whenthe throttle voltago is now availabl6, aeplace
;s fullyopened? the original ECM/PCM.
(D16Y5engine
f -l
Checktor a short in rhe TCM:
L Turnthe ignitionswitchOFF.
from the TCM.
4. MeasurevohagebetweenECM
BLKI
l1rtt"
TPS (RED/ sG2IGRN/BLKI
c o nn e c t o rt e r m i n a l sD 1 a n d
D11. 8 9 r0lrt 12
l a 1 5 l lrG
ls thereapprox.0.5V when the

throule is fully closedand
approx.4.5 V whenthe throttle
is fullyopened?
Repairshort in the wire betwe€n

ECM/PCM{Dll, TCM and TP s6n-
11-80
The scantool indicatesDiagnoslicTroubleCode (DTC)P0123:A high voltageproblemin the ThrottlePosition
(TP)sensorcircuit.
- The MIL has been.eoorted on.

- DTC P0123 is stored.
Problemveritication:
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
ls there approx.10%when the Intermittent failure, system b OK TP SENSOR3P CONNECTOR

ICl lOI
throttleis fullyclosedand at this tim6. Checktor poor con-
approx.90%whenthethrottle neciionso. loose wires at C110
is fullyopened? (TPsensor]and ECM/PCM.
sG2 vcc2
(GRN/BLKI IYEL/BLU)
Checklor en open in the TP sen-
2. Disconnectthe TP sensor3P
connector,
3. Turnthe ignitionswitchON {ll). Wiresideof femaleterminals
4. At the harnessside,measure
voltagebetweenthe TP sensor
3P connecterterminalsNo. 1
a n dN o . 3 .
ls thereapprox.5 V? Replacethe thronle body.
ECM/PCMCONNECTOR
D I16P)
Chock for dn open in the wire
(SG2line):
Measure voltage between ECM/
P C M c o n n e c t o rl e r m i n a l s 0 1 0 a n d
D]1.
SG2{GRN/8LKI
ls thereapprox.5 V? Repairopen in the wire between

ECM/PCM(D11)and TPsensor.
Wire side of female terminats

PCM and recheck. ll presc.ibed
vohag€ is now available,replace
the originalECM/PCM.
11 - 8 1
PGM-FISystem
ThrottlePosition(TP)Sensor
P1121 | The scantool indicatesDiagnosticTroubteCode(DTC)p'I12j:Throttleposition(Tp)lowerthan exeected.
- The MIL has been reported on.

- DTC Pl121 is stor€d.
Problomve.ification:
1. Turnthe ignitionswitchON (lll.
with the scantool.
ls TP* % or higherindicated Intoimiftent tailure, systam i3 OK

whenthe throttleis fully opened? at this time.
* : 1 1 . 8l D 1 6 Y e
5nginei
12.91D16Y e n7 g i n e )
12.2(D16Y8engine)
11-82
[Fil22-l Position(TP)higherthan expecred.
Th" """n tool indicatesDiagnosticTroubleCode{DTC)P1122:Throttle
- The MIL hes been reported on.

P.oblemverification:
with the scantool.
ls TP* % or lessindicatedwhen Intermittent tailurc, ay3tem is OK

the throttleis f!lly closed? at this time.
*r 16.5{Dl6Y5,D16YBengine)
16.9{D16Y7engine)
11-83
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (ExceptDl6Y5
engine(M/Tl)
The HeatedOxygenSensor(HO2S)detectsthe oxygencontentin the exhaustgas and signalsthe ECM/PCM. In operation,
the ECM/PCMreceivesthe signalsfrom the sensorand variesthe durationduring which fuel is injected.To stabilizethe
sensor'soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin the exhaustmanifold.
HO25:
SENSOR VOLTAGE{VI
ztRcoNrA
HEATER RICH. AIN- - LEAN

TERMINALS FU€L
RATIO
tFor3I The scan tool indicatesDiagnosticTroubleCode (DTC)P0131:A low voltageproblem in the Primary Heated
OxygenSensor{H02S)(Sensor1) circuit.
- The MIL has bo€nreportedon.

- DTCP013'lis storod.
Problomveritication:
1. Do the ECM/PCMFeset Pro
cedure.
2 . S t a r t t h e e n g i n e .H o l d t h e
load (A/rfin E or E position,
M/T in neutral)untilthe radia
tor fan comeson.
3. Test drive with the A/T in E
positionlM/T in 4th geari
4. Check the Primary HO25
(Sensor1) output voltagewith
the scantool during accelera
taonusingwide openthrottle.
Intormittent failure, systom i3 OK

Does the vohage stay at 0.1 V
at this time. Checkfor poor con-
nections or loos€ wires rt C123
or less?
l P r i m a r yH O 2 S ,. 6 n 3 o r 1 | a n d
ECM/PCM,
lTo page11-85)
\-
11-8 4
(Frompage11-84)
Chockfor a shon in the HOzS:

2. Disconnect the PrimaryHO2S
(Sensor1l 4P connector.
3. Stan the engineand let it idle.
4. Check the Primary H02S
lSensor1)outputvoltagewith
the scantool.
Doesit stayat 0.1V or less? PRIMARYHO2S(Sen3or1l aP CONNECTOR

lC123l
Pr{o2s T--
{wHTrI- I--]
Check for a short in the wir€
f-l 1 2l
IPHO2Sline): 6\z r r__i_l
l s l r l
1. Turnthe ignitaon switchOFF.
2. Disconnect the ECM/PCM con, L
nectorD (16P).
3. Checkfor continuitybetween Wire sideof femaleterminals
the PrimaryHO2S(Sensor1)
4 P c o n n e c t o tre r m i n a lN o . 1
andbodyground.
R€pairshort in the wire betwoan

ls there continuityT ECM/PCM{D7)and PrimeryHO2S
{Sensor11.
Substitut€ a known-good ECM/

PCM and rocheck.It symptom/
indicstion goos awey, replacethe
original ECM/PCM.
{cont'd)
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1) {ExceptD16Y5
engine{M/Tll (cont'dl
The scan tool indicatesDiagnosticTroubleCode (DTC)P0'132:
A high voltageproblemin the PrimaryHeated
:[FO13t OxygenSensor(PrimaryHO2S)(Sensor1) circuit.
The MIL hes be€n reooned on.

DTCP0132 b stored.
Problemvedfication:
'1. Do the ECM/PCMResetPro-
cedure.
load {A,/Tin E or E position,
tor fan comeson,
3. Test drive with the Arr in E
position (M/T in 4th gear).
4. Check the Primary HO2S
(Sensor1) outputvoltagewith
the scantool duringdecelera-
tion using completelyclosed
throttle.
Intermittent failuro, system b OK
Doesthe voltagestayat 1.0V at this time. Checktor ooor con- PRIMARYHO2Slsensor 1l ,lP CONNECTOR
or more? nections or loose wires at C123
lPrimary HO2S,Sonsor 1) and
ECM/PCM.
PHO2S sG2
Ch€ckfor an op€n in the Primary {WHT) {GRN/
H02S: BLKI
(Sensor1l 4P connector.
3 . C o n n e c tt h e P r i m a r yH 0 2 S
(Sensor1) 4P connectortermi- Wiresideof femaleterminals
n a l sN o . ' l a n d N o . 2 w i t h a

(Sensor1l output voltagewith
the scaniool.
lsthere1.0V or more?
C h e c kt o r . n o p e n i n t h e w i r e
IPHO2Sline):
2. ConnectECM/PCMconnector D {16PI
ECM/PCMCONNECTOR
terminalsD7 and D11 with a
JUMPERWIRE
PHO2S(WHTI sG2(GRN/BLKI
(Sensor1) output voltagewith
the scantool. ffi
I l0 1 1 12
Repai. open in thc wire betwoen t3 t6
ls there1.0V or more? E C M / P C M ( D 7) e n d P r i m e r y
HO2S{Son3or1} .
Subltituto . known-good ECM/
PCM and roch.ck. lf 3ymptom/
indic.tion goe3 away, replace
the originel ECM/PCM.
11-86
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l
scantool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the PrimaryHeated
tFols3-lThe
OxygenSensor(PrimaryHO25)(Sensor1) circuit.
The scantool indicatesDiagnosticTroubleCode (DTC)P1163:A slow responseproblemin the PrimaryHeated

P1163
l OxygenSensor(PrimaryHO25)(Sensor1)circuit.
DescriDtion
By controllingthe airlfuelratiowith a PrimaryHO2S(SensorI ) and a SecondaryHO2S(Sensor2), the deteriorationof the
PrimaryHO2S{Sensor1) can be evaluatedby its feedbackperiod.When the feedbackperiodof the HO2Sexceedsa cer,
tain valueduringstabledrivingconditions,the sensorwill be judgedas deteriorated.
Whendeterioration hasbeendetected duringtwo consecutive
trips,the MILcomeson and DTCP0133or P1'163*
will be stored.
NOTE:lf DTCP0131,P0132and/orP0'135 are storedat the same time as DTCP0133,troubleshootthose DTCSfirst, then
troubleshootDTCP0133.lf DTCP1'162,P1168and/orPl 169are storedat the sametime as DTCP1163,troubleshootthose
DTCSfirst.then troubleshootDTCP1163.
PossibloCause
. P r i m a r yH O 2 S( S e n s o1r ) D e t e r i o r a t i o n
o PrimaryHO2SHeater(Sensor1)Deterioration
. Exhaustsystemleakage
- The MIL has beenreoortedon.

- DTC P0133and/o. P1163.is
stored.
ProblemVorification:
1. Do the ECM/PCMResetPro-
cedure.
2. Connectthe scantool.
engineat 3,000rpm with no
load (A"/Tin E or E position,
tor fan comeson.
4. Connectthe SCSservicecon-
nector.
5 . T e s t - d r i v eu n d e r f o l l o w i n g
conditaons.
- 55 mph (88 km/hl steady
speed
- A/T in E position(M/T in
5th gear)
- Until readinesscode comes
Intermittent tailur6, sysiom i! OK

at this timo. Chgckfor pooa con-
nections or loose wi.ss at C123
lC1/|5)*(PrimaryHOzS.Sensor1)
and ECM/PCM.
*: P1163tD16Y5engine1M/T))
11-87
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (D16Y5engine
(M/Tt)
The scan tool indicatesDiagnosticTrouble Code lDTC)P1162:A malfunctionin the PrimaryHeatedOxygen
y O 2 S () S e n s o1r ) c i r c u i t .
S e n s o (r P r i m a r H
Description
The PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1) operatesover a wide airlfuelrange.The PrimaryHO2S
( S e n s o1r ) i s i n s t a l l e idn t h e e x h a u sm
t anifold.
SENSOR HEATER
ELEMENT TERMINALS
SENSOR
TERMINALS
NOTE:lf DTCP1162is storedat the sametime as DTCP1167,troubleshootDTCP1162first,then troubleshootDTCP1167.
- The MIL has been.eported on.

Problomverilication:
1. Dothe ECMResetProcedure.
2. Startthe engine.
3. Wait at leasttwo minutes.
Test'drivefor severalmiles with

ls DTC Pl162 indicated? the transmissionin 3rd gear.Hold
the enginespeedat 1,500rpm.
Intermittent tailure, system is OK
at this time. Ch6ckfor poo. con-
ls DTCP'l162indicated? nections or loose wires at C145
{ P r i m a r yH O 2 S ,S e n s o r1 ) a n d
ECM,
Check for an open in the wire

(lP+line): ECMCONNECTOR
C 131PI
PRIMARYHO2S
1. Turn the ignition switch OFF.
{SENSOR1} 8P
2. Disconnect ECM connector C
CONNECTOR (C1,15)
( 3 1 P ) f r o mt h e E C M .
3, Disconnect the 8P connector
from the Primary HO2S (Sen-
'l
sor ).
4. Check for continuitv between
the Primary HO2S (Sensor 1)
8 P c o n n e c t o rt e r m i n a l N o . 7
and ECM connector terminal
c23. female terminals of female
Iermrnats
Repeiropen in the wire between

E C M l C 2 3 )a n d P r i m a r y H O 2 S
(Sensor1).
Inspectfor poor terminalto telmi-

nal contact at the Primarv HO2S
lsensor 1) connectorand ECM.
lf terminal conlact is OK, replace
the PrimaryHO2S(Sensor1).
(Topage11'89)
11 - 8 8
ECMCONNECTORS
(Frompage11-88)
c {31P} o {16P}
Chcck th. ECM input vohego {lP-/

VS- lino):
2 Turnthe ignitionswitchON {ll). sG2
3. Measurevoltage between {GRN/BLI(}
ECMconnectorterminalsC24
a n dD ' ] 1 . IP-/VS- {REDI
female terminals
3 a 5 6 1 8 9 l0
ls there more than 0.5 V? Ch6ckthe ECM: 1 1 12 t 3 1a 15 l6 11 18 22
2. DisconnectECM connectorC 23 21 25 27 2t z) 30
{31P)from the ECM. o-\ rP-/vs-
3. Checkfor continuitybetween 7 rneot
b o d y g r o u n da n d E C Mc o n
nectorterminalC24.
- Repair open in the wire
between ECM lc24l and Pri-
mary HO2S(Sensor'l I.
- Substitutea known-goodECM
and .ach.ck. It symptom/indi-
cation goes awey, replacethe
originalECM.
Chocktor s short in the wire (lP-l 1 2 3 1 5 8 t0

V9- linel:
1. Disconnectthe 8P connector 1 1 l 2 1 3 1 4 1 5 1 6 1 7 1 8 ,/ ?2
from the PrimaryHO2S(Sen' 23 2a 25 21 2A a 30
sor'l).
body ground and ECMconnec- fr) {RED}
tor terminalC24.
R6pairshort in the wi.e between

the Primarv HO2S{Sensor'l) and
ECMtc24t.
Repl.c. the Primary HO2S {Sen-

so.1).
Chock tho ECM output voltage

IVS+linol:
Measurevoltage between ECM
connectorterminalsC25and D'11.
Checkfor a sho.l in tho wire {VS+

linel: 1 I 8 10
1. Turnthe ignitionswitchOFF-
2. DisconnectECMconnectorC 1 1 12 13 14 15 16 1 7 1 8 22
ls theremorethan0.5V?
(31P)fromthe ECM. 23 21 25 21 2a 8 30
3. Check for continuity between
b o d y g r o u n da n d E C M c o n - O) vs*
nectorterminalC25. ! twHTt
{cont'd)
(To page11-90) (To page11-90)
11 - 8 9
I
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (Dl6Y5 engine
(M/Tl) (cont'dl
lFrompage11-89)
Substitut€ a known-good ECM

and rccheck. lf symptom/indica-
tion goes away, replaco tho origi-
nal ECM.
Check for a short in tha wiro {lP+ I 2 3 6 1 E 9 l0

linel: l 1 12 r3 l5 t6 11 r8 22
1. Disconnect the 8P connector
from the Primary HO2S (Sen
2. Check for continuity between p lfi. w;,".ia"or

body ground and ECM connec- I r e m a r el e t m t n a
tor terminalC25.
R€pairshort in th6 wire between

ls therecontinuityT the PrimaryHO2S{Sensor1l and
ECMtC25).
Replacethe Primary HO2S {Sen-

sor 11.
ls theremorethan 5.0V? Checkthe EcM:

2, Disconnectthe 8P connector
from the PrimaryHo2S {Sen-
sor'l).
3. MeasurevoltagebetweenECM
connectorC25and D11.
Replace the Primary HO2S lSen-

ls theremorethan 5.0V?
sor 11.
Checkthe ECMinput vohago(lP-/ Substitut€ a known-good ECM

vS- linel: and recheck. lf symptom/indica-
1 . S t a r t t h e e n g i n e .H o l d t h e tion goes away, replac€th6 origi-
engine at 3,000rpm with no nslECM.
load (M/T in neutral)until the
radiatorfan comeson, then let
it idle.
connectorterminalsC24 and
01' j.
1 t 2 3 5 t 9 10
ls there2.6- 2.8V? Check the ECM output voltage 12 t 3 t5 t 6 rl
{VS+ line):
Measure voltage between ECM
connectorterminals C25 and D'11. VS+ sG2
(WHT} (GRN/8LKI
2 3
to tl 't2
t5 16
( T op a g e1 1 - 9 1 ) ( T op a g e1 1 - 9 1 )
11 - 9 0
l F r o mp a g e1 1 - 9 0 ) lFrompage11-90)
ls thorelessthan 2.8V? Roplacothe Primary HO2S (S6n-

sor 11.
Substitute a known-good ECM

and recheck. lf symptom/indica-
tion go€s away. replacethe origi-
nal ECM.
c (3rP) D t16Pl
Check the ECM output voltage
llP+line):
connector terminalsC23and D'11.
sG2
(GRN/BLKI
lP+
IBLK) Wire side of
Substiluta a known-good ECM femaleterminals
YES and recheck. It symptom/indica-
ls theremorethan 0.4V? 2 3 a
tion goes aw.y, rcplacethe o.igi- 6 t I t0
nalECM. 1 1 12 r3 t a 15 16 1 7 t8 22
23 21 25 29 30
Checkthe ECM:
1. Turnthe ignitionswitchOFF. I lP+
2. DisconnectECM connectorC IBLK)
(31P)fromthe ECM. Check for an open in lh6 wire h
3. Checkfor continuity between llP+line):
1. Turnthe ignitionswitchOFF. ECMCONNECTOR
C 13lPI
b o d y g r o u n da n d E C M c o n -
nectorterminalC23. 2. Disconnectthe 8P connector PRIMARYHO2S
from the PrimaryHO2S(Sen- tsENsoR118P
s o r1 ) . coNNECTORtCl{st
the PrimaryHO2S{Sensor1)
8P connectorterminal No. 7
and ECM connectorterminal lP+
c23. IBLKI lP+ Wire side
IBLK} of female
femaleterminals termrnats
NO R€pairopen in tho wi.o bstween

E C M ( C 2 3 ) . n d P r i m a r yH O 2 S
lsensor ll.
Checktor a short in the wir€ (lP+ Subsiitute a known-9ood ECM

linel: and rocheck. lt symptom/indica'
1. Disconnectthe 8P connector tion goes eway, replacethe origi-
from the PrimaryHO2S(Sen nal ECM.
sor'll.
b o d y g r o u n da n d E C M c o n 2 3 I 5 6 8 I 10
nectorterminalC23. 1 1 12 13 1 4 16 11 18 22
23 21 25 29 30
R.pair shon in th6 wirc b€tween
th€ Primary HO2Slsonsor 1) and 6\ lP+
ECM{C23). jjl {8LKl
Replecethe Primary HO2S ls6n-

{cont'd}
sor 1).
11-91
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1) (Dl6Y5engine
(M/T)l (cont'd)
lptrEl The scan tool indicatesDiagnosticTrouble Code (DTC)P1164:A range/performance
problem in the Primary
: HeatedOxygenSensor(PrimaryHO2S)(Sensor1) circuit.
- The MIL h.3 be€n .sportod on.

- DTC Pl16il ii rtorcd.
ProblGmVerific.iion:
'1. Do the ECMResetProcedure.
l o a d u n t i l t h e r a d i a t o rt a n
3. Connectthe SCS servicecon

nector,
4. T€st-drivein 4th gear. Staning
at 1,600rpm, accelerateusing
wide op€nthrottlefor at least5
seconds.Then deceleratefor at
least 5 secondswith the throt-
tle complot6lyclosed.
Intermittent frilurc. sy3tam b OK

at this time. Ch€cktor poo. con-
ls DTCP]164indicated? nections or loos6 wire3 at C145
{Prima.y HO2S,Sensor 1) .nd
ECM.
R€pl.c. tho Primary HO2S (Sen-

3or 11.
The scan tool indicatesDiagnosticTrouble Code (DTC)P1165:A range/performance

problem the Primary
HeatedOxygenSensor (Primary
H02S) (Sensor1) circuit.
Th6 MIL has becn ooorlcd on.

DTCP1165b 3to.ed.
ProblomV.ritidtion:
1. Do the ECMResetProcedure.
2. Start the engine.Hold the
6ngine at 3,000rpm with no
l o a d u n t i l t h e r a d i a t o rf a n
3. Connectthe SCS servicecon-
4 . T e s t ' d r i v eu n d o r f o l l o w i n g
conditions.
- 55 rnph steadyspoed
- Transmission in 5th gear
- Untilreadinesscod€ comes
Intormitteni failure, sy3tsm ia OK

at thia tim6. Check tor poo. con-
ls DTCP1165indicatod? nections or looso wiroa at c145
lPrimary HO2S. Sentor 1l .nd
ECM.
Rsplrc6 th6 Primary HO2S lson-

aor 11.
11-9 2
lpi,';;l The scan tool indicatesDiagnosticTroubleCode (DTC)P]168:A low voltage problem in the PrimaryHeated
|gjgggg!ggg
OxygenSensor(PrimaryHO2S)(Sensor1) LABELcircuit.
The MIL has boon ..ported on.

DTC Pl168 is stored.
Problemvedficalion:
2. Startthe engine.
3. Waitat leasttwo minutes.
IntermittGotlailuro, 3yst.m is OK
al this tim6. Chocktor poor con-
ls DTCP1168indicated? n€ction3 or loo3e wiros at C145
{Primary HO2S, Sensor 1) and
ECM.
ECMCONNECTOR
D {16PI
LABEL{WHTI
Checkthe ECM:
2. Disconnectthe ECM connec-
tor D (16P).
E C M c o n n e c t o tr e r m i n a lD 7
and bodyground. Wire sideof femaleterminals

.nd rcchack. lf aymptom/indica-
tion goes swsy. r6placeth6 origi-
nal ECM.
LABELIWHT}
Check for a short in the wires

(LABELlin.l:
(Sensor1) 8Pconnector-
2. Check for continuity betlveen
ECM connector terminal D7
and body ground.
ls therecontinuity? Replaceth6 Primary HO2S lsen-

sor 11.
Ropair short in thg wir6 botweon

tho Pfimary HO2S(Sensor1l and
ECMtD7).
(cont'd)
11 - 9 3
)
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2S){Sensor1l (Dl6Y5engine
(M/Tl)(cont'dl
[ti,r;ol The scan tool indicatesDiagnosticTroubleCode {DTC)P1169:A high voltageproblemin the PrimaryHeated
L]g OxygenSensor{PrimaryHO2S}{Sensor1)LABELcircuit.
The MIL hs3 b€en r6Dorted on.

DTC P1169 is stor6d.
Probl€mveritication:
1. Do the ECMResetProcedure-
2. Startthe engine-
3, Wait at leasttwo minutes,
PRIMARYHO2SISENSON1} 8P CONNECTOR
I145I
Intormittent failure, system is OK

at thi3 time. Checkfor ooor con-
ls DTCP1169indicated? nections or loose wi.es at C145
{ P r i m a r yH O 2 S ,S e n s o rl l a n d
ECM.
Wire sideof
femaleterminals
Check for an op€n in thg wiro
ILABELlinel:
1- Turnthe ignitionswitchOFF.
2. Disconnectthe Primary HO2S
(Sensor1i 8P connector.
ECMCONNECTOFD {16PI
Primary HO2S(Sensor1) 8P ,|
connectorNo. 4 terminaland 2 3 1
bodyground. 6 8 9 t0 1 l 12
1 4 15 16 sG2
IGBN/8LKI
ls thereapprox.5V? Check for an open in the wire sideof
lSG2line): le terminals
female (11
1. Turnthe ignitionswitchOFF. \9
2. DisconnectECM connectorD
(16P)from the ECM.
3. Checkfor continujtybetween I
_l
2 3
;G2
{GRN/8LK}
1
ECM connectorterminal D11
Repai open in tho wir€s bstw€en
and PrimarvHO2S(Sensor1) 6 8
the Piimary HO2Slsensor 1) and
8P connectorterminalNo. 3.
ECM(D71.
Repairopen in the wire betwe€n

th. Primary HO2S(Sen3or1l and
ECMtD11l.
11-94
SecondaryHeated Oxygen Sensor (SecondaryHO2S)(Sensor2l
scantool indicatesDiagnosticTroubleCode(DTC)P0137:A low voltageproblemin the SecondaryHeated
lTol3ji]l lh"
.: OxygenSensor(Secondary HO2SI(Sensor2) circuit.
- The MIL h.3 bo6n reported on.

'1. Do
the ECM/PCMResetPro
cedure,
load {A/Tin E or E position,
tor fan comeson.
3. With the scan tool, checkthe
S e c o n d a r yH O 2 S( S e n s o r2 )
outputvoltageat 3,000rpm.
Intermittont failuro, sy3tem is OK
at thi3 time, Checktor poor con-
nections or loose wiao6at C131'
Does the voltage stay at 0.3 V (locrtod under right 3ide ot da3hl.
or less?
C432r {located und.r middle of
dashl, C125 (C782lt (Secondary
HO2S)lsonlor 2l and ECM/PCM.
Ch€ck fol a short in the Second!ry

HO2SI
Turnthe ignitionswitchOFF.
Disconnect he Secondary
HO2S(Sensor2) 4P connector.
Startthe engine.
C h e c kt h e S e c o n d a r yH O 2 5
(Sensor2) outputwith the scan
tool.
SECONDARYHO2S(S.n.or 2l
/aPCONNECTOR
1C125,C7E2r)
C h e c kl o l . 3 h o n i n t h . w i r o
{SH()2Slinel:
2 . D i s c o nn e c t t h e E C M / P C M
connectorD 116P).
the SgcondaryHO25 (Sensor Wire sideof femaleterminals
2) 4P connectorterminalNo. 1
and body ground.
Rco.ir 3hort in the wire bdtw.en

ECM/PCM lDl4l and Secondary
HO2Slsonsor 21.
Substitute . known-good ECM/

PCM and r.check. lf symptom/
indication go03 away, replaco
tho original ECM/PCM. (cont'd)
*: D16Y8engine
11 - 9 5
PGM-FlSystem
SecondaryHeatedOxygenSensor(secondaryHO2SI(Sensor2l (cont'dl
The scantool indicatesDiagnosticTroubleCode{DTC)P0138:A high voltageproblemin the SecondaryHeated
OxygenSensor(SecondaryH02S)(Sensor2) circuit.
The MIL has been reDorted on.

1. Do the ECM/PCMFeset Pro-
cedure.
load (A/Tin E or E position,
torfancomeson,
3. With the scantool, checkthe
S e c o n d a r yH O 2 S( S e n s o r2 )
outputvoltageat3,000rpm.
Intermittent failure, 3ystem b OK HO2Slsontor2)
SECONDAnY
at this time. Checkfor poor con- C125(C782lr
4PCONNECTOR
nections or loose wires st C131'
Does the voltage stay at 0.6 V
llocatedundor right side of dashl. JUMPERWIRE
C432i (localed undor middle ol
da3h),C125 (C?82)*lsocondary sH02s sH()2sG
HO2SSensor2) and ECM/PCM. (YEL/RED}
IWHT/REOI
Checkior an op€n in the Seclndary (GRN/BLKIT
HO2S:
2 . D i s c o n n e c tt h e S e c o n d a r y
HO2S(Sensor2) 4P connector. Wire side of female terminals
3. Connectthe SecondaryHO2S
(Sensor2) 4P connectorter_
m i n a l sN o . 1 a n d N o . 2 w i t h a
iumperwire.
5 . C h e c kt h e S e c o n d a r yH 0 2 S D Il6PI
ECM/PCMCONNECTOR
{Sensor2) outputvoltagewith
the scantool,
ls there0.6V or more?
sHo2sG
(YEL/RED)
I I sHo2slwHT/REol
(GRN/BLKP
Check tor an open in th€ wire JUMPERWIRE
(SHO25line):
1. Turnthe ignitionswitchOFF. Wiresideof femaleterminals
terminalsDl4 and D13with a
3. Turnthe ignitionswitchON (lli.

4 . C h e c kt h e S e c o n d a r yH O 2 S
( S e n s o r2 ) o u t p u t v o l t a g e
with the scantool.
Repairop6n in the wire betweon

ls there0.6V or more? ECM/PCM{D13and,/orD14}and
SecondarvHO2S{Sensor2).

PCM and recheck.It symptom/
u)t
indicaiion goes away. replace
*: Dl6Yg engine
11 - 9 6
a
TroubleCode{DTC)P0139:A slow responseproblemin the SecondaryHeated
The scantool indicatesDiagnostic
OxygenSensor(HO2S){Sensor2) circuit.
- Thc MIL haa bccn rcponed on.

- DTCP0139i3 3iored.
P.obl6m vo.ificalion:
c60ure,
load (A"/Tin E or E position,
tor fan comes on,
3. With the scantool, checkthe
SecondaryHO2S{Sensor2)
outputat 3,000rpm.
Intermittent lailure, system is OK

at this time. Checkfor poor con-
Doesthevoltagestaywithin nections or loose wires at C13'l*
0.3-0.6 V tor two minutes? llocatedunder right side ol dash),
C432' {locatedunder middle of
dashl C125 {C7821*{Secondary
HO2SI{Sensor2l and ECM/PCM.
11-97
PGM-FISystem
HeatedOxygenSensor(HO2S)Heater \,, .a
The scan tool indicatesDiagnosticTrouble Code (DTC)P0135:An electricalproblem in the Primary Heated
fFor35lOxygenSensor(PrimaryHO2S)(Sensor1) Heatersvstem{ExceptD16Y5engine(M/T))'
TroubleCode(DTC)P0141:A problemin the SecondaryHeatedOxygenSensor
tool indicatesDiagnostic
lFot+ilThe scan
(Secondarv
HO2S)(Sensor2) Heatercircuat.
- The MIL haa bgon teDorted on.

- DTC m135, and/or P0141a.e
stored.
Problomvorification:
cedure, lntermittont failure, swtem i5 OK
2. Startthe engine. at thb time. Checkfot poor con' PRIMARYHO2S{S.n.ot l)]|P CONNECTOR
noction3 or loose wiros at SECONDARYHO2s (S6nto12)4P CONNECTORT
C131** {located under right 3ide
ol dashl, C432** {located under
middle of d.sh), C123 (P.imary
HO2S,Sensor 1l C125 {C7821**
lSecondary HO2S, Sensot 2)*
and ECM,/PCM.
Checkfoi en opon or short in the
HO2S:
2. Disconnect the HO2S(Primary Terminalsidoot maleterminals
or Secondary*)lSensor 1 or
Sensor2)4P connector.
3 . A t t h e H 0 2 S s i d e ,m e a s u r e
resistancebetween the HO25
4P connectorterminalsNo. 3
a n dN o . 4 . /
ls therel0 - 40 0?
C h e c kf o r c o n t i n u i t y b e t w e e n (Cl23I
b o d y g r o u n d a n d t h e H O 2 S4 P PRIMARYHO2SISENSOR1) 'P CONNECTOR
c o n n e c t o rt e r m i n a l sN o . 3 a n d sEcoNDARY HO2STSENSOR 2) rP COI{NECTORlcl2s}*
No.4 individually.
_l=._1
i|iru I t z leozsxrc.
sozsxrc
YELI I- T-- IBLK/WHTI
l - l
L--Cp
Wi16 side of f6male terminals
Checkfoi an open or short in the
wire IPO2SHTC, SO2SXTC*lino):
1. Turnthe ignitionswitchoN (ll).
2. Measurevoltage between the
HO254P connectorterminals sEcoNoAnY 2l
Ho2slsENsoR
(C782)*.
lP CONNECTOR
No. 3 and No.4.
so2sHTc tG1
(BLK/WHT) {BLK/WHTI
(To page11-99) *r P0141

**: D16Y8engine
(To page11-99) Wire sideof lemaleterminals \, I
11-98
PRIMARYHO2SISENSOR1) ilP CONNECTOR
(cr23t
SECONDARYHO2S(SENSOR2l irP
coNNECTOR(C12s)r
Checktor an open or short in the 1 1 2 l

wire (lG1linell - r l
M e a s u r ev o l t a g e b e t w e e nt h e tL_r__.r.____J
3t { l
HO2S4P connectorterm;nalsNo.3 lcl
( D 1 6 Y ge n g i n e N
: o.4)and body |BLK/ O)
- Ropair open or short in the YELI Y
ground-
wire between Prim.ry HO2S
{Sensor1), (No. 15 ALTERNA-
TOR SP SENSORI17.5A) tuie Wire sideot femaleterminals
and SoconderyHOzS,Scnsot
2l+,
- RoDlac.the No. 15 ALTEBNA-
Check fo. an open in the wire TOR SP SENSORl7.s Al tuso.
{PO2SHTC, SO2SHTC*linel: SECONDABYHO2S
1. Turnthe ignitionswitchOFF. {SENSOR2I {P CONNECTOR
2. Reconnectthe HO2S4P con- tc782t*r
3. Disconnectthe ECM/PCMcon
nectorA (32P).
5. Measurevoltage between the -l.
IGl {BLK/WHTI
ECM/PCM connector terminals
46 andA10(A5andA10)*. (v)
Repairopen in the wire betweon
Y
ls there0.1V or less? ECM/PCM{46, A5lt and HO2S Wirosideof femaletorminals
{Primary,Secondary*1.
ECM,/PCM A I32PI
CONNECTOR
Substituta a known-good ECM/
PCM and recheck.lt 3ymptom/ pozsxrc E/
the original ECM/PCM. so2sHrcIIBLK/WHTI ^
tBLK/wHn-Jr-----{vF PG1
IBLK)
T-r
'11 6 rl lalglro ll
{Frompage 98}
12 t 3 t5 t 6 ta t 0 20 21 23 2a
27 2A a 3o
Wire side ol female terminals

Chock lor a short in lhe wire
{PO2SHTC, SO2SHTC.lino):
2. Disconnectthe ECM/PCM con-
nectorA {32P).
the ECM/PCMconnectortermi-
so2HTClBtX/WHTtr FO2SHTCIBLK/WlfTl
nalA6 (A5)*and bodyground.
ReDairshort in tho wi.s bstween

ls therecontinuity? ECM/PCM(46, As*l and HO2S
lPrimary,S.condary.l.
Subslitute r known-good ECM/

PCM and recheck.lf symptom/
indication goes away. r€place
the original ECM/FCM.
*: P0141
**: D16Y8engine
11 - 9 9
PGM-FISystem
HeatedOxygenSensor(HO2S)Heater(D16Y5engine(M/Tll t
The scan tool indicatesDiagnosticTrouble Code (DTC)P1166:An electricalproblem in the PrimaryHeated
OxygenSensor(PrimaryHO2S)Heatersystem.
- Th€ MIL h.3 bean reoon.d
- DTCP1165b stored.
2. Startthe engine.
Intermittent tailur., 3vt.m is OK
et thii time (te3i drive may bo
ls DTCP1166indicated? nccossaryl. Chock for poor con-
noctions oa looie wkas bgtween PRIMARYHO2SISENSOR1} 8P CONNECTOR
C145 (Priftary HO2S,Sonsor 1)
and ECM.
Chockth6 Primery HO2S{S6nso1
'll re3btance:
lSensor1) 8P connector.
3 . A t t h e P r i m a r yH O 2 S( S e n -
s o r 1 ) , m e a s u r er e s i s t a n c e Terminal side of
betweenNo. 1 and No. 2 ter maleterminals
mrnal.
ls there2 - 13 O?
Check for a shortsd Prima.y

HO2Slssn3or'll:
C h 6 c kf o r c o n t i n ! i t y b e t w e e n
body groundand eachterminal.
ls therecontinuity?
Ch.ck lor . 3hort6d Primery

HO2Slsensor 1):
Checkfor continuity betweenter-
minal No. 1 and terminalsNo.3,
4, 6, 7 and 8 individually.
Replacctho Primary HO2S (Scn-

sor 11,
( T op a g e1 1 - 1 0 1 )
11-100
(Frompage11-100) PRIMARYHO2SISENSOR1l8P CONNECTOR
{Clirsl
PO2SI{TC
{BLK/WHTI
ch6ck the Po2sHTc circuir:
1. Start engineand keep engine
rpm at idle.
2. At the engine wire harness,
m e a s u r e v o l t a ge b e t w e e n
P r i m a r yH O 2 S( S e n s o r1 i 8 P
connectorterminalNo. 1 ter-
minaland bodyground.
Chsck for en open'in th6 wire PO2SHTC

(PGlinel: (BLK/WHT)
ls theremorethan 5 V? MeasurevoltagebeNveenPrimary
HO2S{Sensor1) 8P connectorter'
minalsNo. 1 and No.2.
Ropairopen in the wire between

ls theremorethan 5 V? thc HO2S.nd Gl01 llocated at
thermostat housingt.

and .echock, lf symptom/indice- PO2SHTC
V lion goes rw.y, repl.c€ the origi- IBLK/WHTI
Check ror a 3hort in the wire nel ECM. f)
(PO2SHTClinel:
1. Turntho ignitionswitchOFF. ECMCONNECTOR
A
2. DisconnectECNIconnectorA
(32P)from the ECM. 6 , 9L 10
12 l 3 t a r5 l a t 0 1 9 2\ 221 23 2a
E C M c o n n e c t o rt e r m i n a l4 6 25 21 2a 4 30 |,-.'
and body ground.
Iemaleterminals
Repair3hon in th6 wiae between
the ECM (A6l and the Primary
HO2Sls.nso.'l).

(PO25HTClin.l:
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM connectorterminal46 and
the PrimaryHO2S(Sensor1) 8P
connectorterminalNo, 1,
Repairopen in the wirc between

ECM lA6l and the Prim.ry HO2S
lsen3or 'l ).
L
Substiiuto . known-good ECM
and r.ch.ck. lf symptom/indica- (cont'd)
tion 90e3.wry, ..pl.c€ the origi-
n.l ECM.
11 - 1 0 1
PGM-FISystem
HeatedOxygenSensor{HO2S)Heater(D16Y5engine(M/Tl) (cont'd)
DisgnosticTrouble Code (DTC)P1167:A system malfunctionin the PrimaryHeated
scan tool in^dicates
lTlLtl lh"
.....-''.--.......
Oxygen Sensor (Primary HO2S)(Sensor1) Heatercircuit.
The MIL he! bcofl ..oort.d on.

DTC P1167 b stored.
Problomveffication:
load 1A,/Tin N or E position,
M/T in noulral)untilthe radia-
tor fan comeson.
Intermittent failure, systom k OK
at this time. Checkfor poor con- PFIMARYHO2S(SENSOR1) 8P CONNECTOR
ls oTC1167indicated? noctions or looie wi.es at C145 lClil5l
lPrimary HO2S, Sen3or 1l and
ECM.
Ch6ck for an op.n in the wire

{VS+lin.):
(Sensor'1) 8P connector.
4. Measurevokage between the ECMCONNECTOR
C {3.IPI
P r i m a r yH O 2 S( S e n s o r1 l 8 P
connectorterminalNo, 6 and
body ground.
1 2 a 6 7 8 9 r0
check rhe EcM: 't3
1 1 12 t 4 1 5 1 1 61 1 l 8
ls theremorethan5 V? M e a s u r ev o l t a g e b e t w e e nt h e
ECMconnectorterminalC25and 23 21 25 2i 30
body ground.
VS+
(WHT) Wire side of female
terminals
Repairopen in thc wire ECM{C25}

ls theremorethan 5 V?
and PrimaryHO2Slsensor 11.
Sub3tilute a known-good ECM

and recheck, lf symplom/indica-
tion goes eway, leplaceth€ origi-
nal ECM.
11-1 0 2
PGM-FISystem
HeatedOxygenSensor{HO2S)Heater(D16Y5engine(M/Tl) (cont'd)
DisgnosticTrouble Code (DTC)P1167:A system malfunctionin the PrimaryHeated
scan tool in^dicates
lTlLtl lh"
.....-''.--.......
Oxygen Sensor (Primary HO2S)(Sensor1) Heatercircuit.
The MIL he! bcofl ..oort.d on.

DTC P1167 b stored.
Problomveffication:
load 1A,/Tin N or E position,
M/T in noulral)untilthe radia-
tor fan comeson.
Intermittent failure, systom k OK
at this time. Checkfor poor con- PFIMARYHO2S(SENSOR1) 8P CONNECTOR
ls oTC1167indicated? noctions or looie wi.es at C145 lClil5l
lPrimary HO2S, Sen3or 1l and
ECM.
Ch6ck for an op.n in the wire

{VS+lin.):
(Sensor'1) 8P connector.
4. Measurevokage between the ECMCONNECTOR
C {3.IPI
P r i m a r yH O 2 S( S e n s o r1 l 8 P
connectorterminalNo, 6 and
body ground.
1 2 a 6 7 8 9 r0
check rhe EcM: 't3
1 1 12 t 4 1 5 1 1 61 1 l 8
ls theremorethan5 V? M e a s u r ev o l t a g e b e t w e e nt h e
ECMconnectorterminalC25and 23 21 25 2i 30
body ground.
VS+
(WHT) Wire side of female
terminals
Repairopen in thc wire ECM{C25}

ls theremorethan 5 V?
and PrimaryHO2Slsensor 11.
Sub3tilute a known-good ECM

and recheck, lf symplom/indica-
tion goes eway, leplaceth€ origi-
nal ECM.
11-1 0 2
FuelSupplySystem
]TO17il Th" """n tool indicatesDiagnosticTroubleCode(DTC)P0171:The fuet systemis too lean.
I P0172 The scantool indicatesDiagnosticTroubleCode(DTC)P0172:The fuel systemis too rich.
D6scription
By monitoringthe LongTerm FuelTrim, longterm malfunctionsin the fuel systemwill be detected.
It a malfunctionhasbeendetectedduringtwo consecutive
trips,the MILwill come on and DTCP0171and/orP0172will be
stored.
NOTE:lf some ot the DTCSlistedbeloware storedat the sametime as DTCP0171and/orP0172,troubleshootthose DTCS

first,then troubleshootDTCP0171andlotP0172.
P0106-8. *5rMAP Sensor

P1128-9*3.
P0135:PrimaryHO2SHeater
P0137-8:
SecondaryHO2S
P0141:SecondaryHO2SHeater
P0401:EGRFlow lnsufficient*1
P0441:EVAPSystemInsuificientPurgeFlow*6
P1259:VTECSystem*,
P1491rEGRValveLift Insuflicient*l
P1498:EGRValveLift SensorHighVoltage*1
* 1 ;D 1 6 Y 5e n g i n e
+,: D16Y5,D16Y8engine
*3:'97 model
*a:'96 model
*5:'98 model
*6:'96 Dl6Y5 engine,'96D16Y7engine,'96 D16YBengine(sedan),'97D16Y5engine,'97D16Y/engine(coupe:KA,KC mod
els,sedanKA.KC,KL (DX)models,hatchback:
all models),'97Dl6Y8engine(sedan:KA,KCmodels)
PossibleCause
D T CP 0 1 7 1 FuelPumpinsufficient flovpressure
FuelFeedLineclogged,leaking
FuelPressureRegulatorstuckopen
FuelFilterclogged
FuelInjectorclogged,air inclusion
Gasolinedoesn'tmeetOwner'sManualspec.
PrimaryH02S (Sensor1) deteriorated
MAP Sensorrange/performance*a
EGRSystemmalfunction(too much flow)*1
ValveClearance
Exhaustleak
DTCP0172 FuelPressureRegulatorclogged,stuckclosed
FuelReturnPipeclogged
FuelInjectorleaking
Gasolinedoesn'tmeetOwner'sManualspec.
PrimaryH02S (Sensor1) deteriorated
MAP Sensorrange/performance+4
EGRSysteminsufticient
flowrl
EVAPPurgeControlSolenoidValveleaking,stuckopened
ValveClearance
{cont'd}
11 - 1 0 3
PGM-FISystem
FuelSupplySystem(cont'dl
- The MIL has been reoortedon.

- DTCP0171and/or P0172are
stored.
ls the fuel pressureOK?
ls the luel pressuretoo high Chock the fucl p.caaure reguletor

and fuel rcturn pip€.
Checkthe P.imary HO2SI

Checkthe fuel pump, luel fe.d
engine at 3,000rpm with no pipe, fuel lilter, and fuel pressu.e
load (.A/Tin N or E position,
regulator.
tor fan comeson,
2 . C h e c kt h e P r i m a r yH O 2 S
( S e n s o r ' l )o u t p u tw i t h t h e
scantool.
Doesit stayat lessthan 0.3V YES

or morethan 0.6V?
NO
Check for a sticking or leaking

E V A Pp u r g c c o n t r o l s o l e n o i d
With a vacuumpump,applyvacu-
u m t o t h e E V A Pp u r g e c o n t r o l
s o l e n o i dv a l v e f r o m t h e i n t a k e
manifoldside.
Does it hold vacuum?
Checkthe MAP sensoroutputl

1. Turnthe ignitionswitchON ill).
2. Checkthe l,4APwith the scan
tool,
YES
Check the response of the MAP

Sensot:
1. Stanthe engine.
tool.
ls a MAPof40.0kPa(300mmHg,
12.0inHg)or lessindicatedwithin
one secondafter startingthe
engine?
L v
- Checkth6 valve clearance,
- Checkthe EGRswt6m (D16Y5
en9inel.
- It they are OK, replacethe luel
inlecto.s.
11-104
Misfire Detectedin One Cylinder
I P0301 The scantool indicatesDiagnosticTroubleCode(DTC)P030'1:
Cylinder1 misfiredetected.
I P0302 ths s636tool indicatesDiagnosticTroubleCode(DTC)P0302:cylinder2 mistiredetected.
119393-.1Th"""untool indicatesDiagnosticTroubleCode{DTC)P03O3r
Cylinder3misfiredetected.
P0304 i ths 56sntool indicatesDiagnosticTroubleCode{DTC)P0304:Cylinder4 misfiredetected
Description
Mistiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft.
lf misfiringstrongenoughto damagethe catalystis detected,lheMIL will blinkduringthe time ot its occurrence,
and DTC
P0301,P0302,P0303or P0304will be stored.Then,afterthe misfirehasceased,the MIL will come on.
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on, and DTC
P0301.P0302.P0303or P0304will be stored,
NOTE:lf some of the DTCSlistedbelow are storedat the sametime as a mislireDTC,troubleshootthose DTCSfirst,then
troubleshootthe misfireDTC.
P0106rMAP sensor
P0131,P0132:HO2S
P017'1, P0172tFuelsupplysystem
P0335,P0336:CKFsensor
P0401,P1491,Pl498:EGRsystem
P044'l:EVAPsystemInsufficientpurgeflow*6
P 1 3 5 9P, 1 3 6 1P, 1 3 6 2T: D Cs e n s o r
P l 3 8 1 ,P l 3 8 2 :C Y Ps e n s o r
* 6 : ' 9 6D ' 1 6 Ye5n g i n e , ' 9 6
D 1 6 Y 7e n g i n e , ' 9 6 e n g i n e( s e d a n ) , ' 9D
D16YB 7 1 6 Y 5e n g i n e , ' 9 7
D 1 6 Y 7e n g i n e( c o u p eK: A ,
KCmodels,sedanKA,KC,KL (DX)models,hatchback: all models),'97D16Y8engine(sedan:KA,KCmodels)
PossibleCause
. Fuelinjectorclogging,fuel leakage,air leakage
. Fuelinjectorcircuitopenor shorted
. Sparkplug carbondeposits,fouling,malfunction
. lgnitionwires open.leaking
. Distributormalfunction
a Compressionlow
. Valveclearanceout of spec
. VTECsystemmalfunction{D16Y5,D16Y8engine)
. HO2S
. HO2Scircuit
)/
(cont'd)
11 - 1 0 5
PGM-FISystem
Misfirein DetectedOneCylinder(cont'dl I
Troubl€shootingFlowchart
- The MIL hra boenreDortedon.

- oTc P0301,P0302,P0303,o.
P0304i3 indicatsd.
Chocktho luol injector tunction:

Slartthe engine,and listenlor a
clickingsoundat the fuel injector
in the problemcylinder.
Checkfor an openor shortin the

harnessbetweenECM/PCMand
the fuel injector.
Repairopen or short in the wire.
- Replacethe fu6l injoctoi.

- Subslitute a known-good
E C M / P C Ma n d r e c h o c k .I t
symptom/indicrtion goos
aw.y, rcplac€tho originsl ECM/
PCM.
Problemvorilicationi NOTE:
1. After checkingthe freezedata, 'lI thore is no lreezedata oI misliring,
do the ECM/PCMResetPro- just clearthe DTC.
ceoure, . lf there is no freezedata of misfir;ng,
2. Exchange the sparkplug from test drives under various conditions
the problemcylinderwith one
of anothercylinder.
nector.
4. Test'drivethe vehicleseveral
times in the rangeofthe lreeze
oala.
(To page11-1071
11 - 1 0 6
/
{Frompage11-106}
ls DTCP0301,P0302,P0303, Intermittent mistire due to spark

plug fouling, etc- lfiring is OK al
or P0304indicated?
this timel.
Doesthe misfireoccurin the

othercylinderwhosesparkplug Replacelh6 faulty spark plug.
was exchanged?
Ch6ck for fuol injector malfunc-

tion:
1 . E x c h a n g et h e f u e l i n i e c t o r
trom the problemcylinder
with one lrom anothercylin'
der,
2. Letthe engineidlefor two min- NOTE|It there is no lreezedata of mis
utes, f;ring,test drives under variouscondi
3. Test drive the vehicleseveral tions are necessary,
times in the rangeot the freeze
data.
T ls DTCP0301,P0302,P0303, Inte.mittont misfiro due to bad

contact in the fuel injector con-
or P0304indicated?
necto.lfiringis OK at this time).
Doesthe mislireoccurin the

othercylinderwhosefuel injector R€plac€ the faulty luel iniector.
was exchanged?
Chockfollowing items
- Cylinderleak{own
- Comoaession
- Crank3heft soeed fluctuation
ICKFI3ensor
11-107
PGM-FISystem
RandomMisfire
*' The scan tool indicatesDiagnosticTrouble Code (DTC)
l*' o' fFl3ool*'' "nd P0301
[Fo3oo P 0 3 0 0 * so r P 1 3 0 0 + *31 a n d s o m e o f P 0 3 0 1- P 0 3 0 4 :
Randommisfire.
Dgscription
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft.
lf misfiringstrongenoughto damagethe catalystis detected,the MIL will blink duringthe time of its occurrence,and DTC
P0300*5 or and some of DTCSP0301through P0304will be stored.Then,after misfirehas ceased.the MIL will
c o m eo n .
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on. and DTC
P0300*5 or P1300*3. *a and some of DTCSP0301through P0304will be stored.
NOTE:lf some of the DTCSlistedbelow are storedat the sametime as a misfireDTC.troubleshootthose DTCSfirst,then
troubleshootthe misfireDTC.
MAP sensor
P 0 1 3 1P. 0 1 3 2H: O 2 S
P0171,P0172tFuelmetering
P0401,Pl491,Pl498:EGRsystem*r
P0505:ldle ControlSystem
P1253;VTECSystem*,
Pl361.Pl362:TDCsensor
Pl381.P1382:CYPsensor
P1508:IACvalve
PossibleCauso
. Fuelpump insufficientfuel pressure,amountofflow
. FuelIineclogging,blockage,leakage
. Fuelfilter clogging
. Fuelpressureregulatorstuckopen
. EGRsystemmalfunction*r
. Distributormalfunction
. lgnitioncoil wire open,leakage * 1 : D 1 6 Y 5e n g i n e
. lgnitioncontrolmodulemalfunction *2: D16Y5,D16Y8engine
. MAP sensorrange/performance, poor response*1 *3; '97 model
. Valvescarbondeposit *4: '96 model
. Compressionlow *5: '98 model
. IACvalvemalfunction*a
! VTECsystem malfunction*,
. Fueldoes not meetOwner'sManualspec..lackoffuel
. HO2S
. HO2Scircuit
Troubleshooting
By test-driving,determinethe conditionsduring which misfireoccurs.Dependingon these conditions,test in the order
describedin the table below.
Possiblecause Crankshaft
\ E GR * 1 position(CKP)
Fuel Distributorand
tcM
rAc MAP
\, system pressure lgnitionwires Clearance Valve
,;;; sensor sensor
11 - 1 5 0 ,
Condition 1l-170 section6 section23 section 23 section 6 1't-126 11-67
\
Only low rpm and
toao o @ @ o @
Onlyaccelerating o @ @
Only high rpm and
toaq
ra\ o @ @ @
Not specific o @ @ @ @ U
NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owner,smanual
spec,lackof fuel, carbondepositson sparkplug,etc.
11 - 1 0 8
J
KnockSensor(KS)(Dl6Y5engine{CVTIand D16Y8enginel
The scantool indicatesDiagnosticTroubleCode(DTC)P0325:A malfunctionin the circuitof the KnockSensor
{KS).
- Th€ MIL hes been reooned on.

- DTC m325 is stored.
Problemv6rification: DIAPHRAGM
1. Do the ECM/PCM ResetProce-
dure-
load (A/Tin N or E position,
tor fan comes on, then let it
idle.
3 . H o l d t h e e n g i n e a t 3 , 0 0 0-
4,000 rpm for at least 60 sec-
onds.
Intormittenl tailure. system is OK
at this time ltest drive mev be
Ch6ck lor poor conncclions or
loose wi.es between C137(knock
sensorlKSl) .nd ECM/PCM.
Checktoi a shon in the wir. (Ks
linell
ECM/FCM D (16P1
COtrl]\|€CrOB
2, Disconnectthe knock sensor KS
2Pconnector,
3 . D i s c o nn e c t t h e E C M / P C M
IRED/
ALU)
connectorD {16P}.
4. Checktor continuity between
E C M / P C Mc o n n e c t o rt e r m i
nalsDOand body ground.
Wir€ side of femal€ terminals
Repairshort in tho wire between
ECM/PCMlD6| and knock sen-
sor. KS 2P CONNECTOR
tcl37l
KS
Chock lor an open in the wire IRED/BLUI
(KSlinel:
t 1
ou1
ECM/PCM connectorterminalD6
and knock sensor 2P connector
terminalNo. 1.
Rapairopen in the wire b€two6n € s ide of fgm al€

ECM/PCMlD6) .nd knock sen- terlninil t s
Substitutea known-goodknock
sensorand recheck.
1 2 3 a 5
KS 't0 1 1
IREO/ 7 8 12
BLU) 13 1 a 16
Replacetho originalknock s6nsor.

PCM and r.check. lf symptom/
indication goos away, 16plac6
thc originrl ECM/PCM.
11 - 1 0 9
PGM-FISystem
GrankshaftPosition/TopDeadCenter/Cylinderposition(CKp/TDC/Cyp)
Sensor
il'oggslThe scantool indicatesDiagnosticTroubleCode(DTC)P0335:A matfunctionin the Crankshaftposition(CKp)
sensorcircuit.
The scantool indicatesDiagnosticTroubleCode(DTC)P0336rA range/performance

problemin the Crankshaft
fFffi6l Position(CKP)sensorcircuit.
The scantool indicatesDiagnosticTroubleCode(DTC)pl36.l: lntermittentinterruotionin the Top DeadCenter

tPr36rI {TDC)sensorcircuit.
tn362l The scantool indicatesDiagnosticTroubleCode (DTC)P1362:No signalin the Top DeadCenter(TDC)sensor

circuit.
The scantool indicatesDiagnosticTroubleCode{DTC)P1381:Intermittentinterruptionin the Cvlinderpositaon

tFtu8Tl
(CYP)sensorcircuit.
tPJ382lThe scantool indicatesDiagnosticTroublecode (DTC)P1382:No signalin the cylinder position(cyp) sensor

circuit.
Doscription
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up{cranking)and when crankangle is abnormal.The CyF Sensordetectsthe
positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKpiTDClCyp
Sensoris built into the dastribu_
ror.
NOTE:lf DTCPl359 is storedat the sametime as DTCP0335,P0336,P1361,Pi362,pi381 and/orp1382,troubteshoot

DTC
P1359first. then troubleshootthose DTCS. Ot6y5ongin.: Di6y7,D16y8ongin6:
- Th. MIL hs. b..n roportld on.

- DTC P0335, P0336, Pl361.
P1362,P1381.nd/or P't382ero
storod.
CKP CYP
Problcmv.riticetion: TDC CKP
SENSOR SENSOR
1. Do the ECM/PCMResetProce- SENSOR SENSOR
SENSORROTOR ROTOR ROTOR ROTOF
dure.
2. Stan the engine, ROTOR
DISTRIBUTOR
lOP
coNNECTORtC120t TDCP
Intgrmittont failuro, systam is OK
b DTCm35, P0336.P1361,P1362. et this time. Chockfor Door con-
P1381and/orP1382indicated? nections or loose wires at C120
ldbtributo.l and ECM,/PCM.
Chocktor an open in th. CKP/

TDC/CYP..nror:
2. Disconnectthe distributor 10P CYPM{BLK)
connector.
3. Measureresistancebetween
th€ lerminals of the indicated
sensor(rseetable).
S E N S O R oTc SENSOR ECMPCM W I R E

ls there 350 - 700 O? R.pt.ce the di.tributor ignition ERMINALIERMINAL COLOR
ho6in9 (3Gesoction23).
CKP P0335 2 c2 8LU
m36 6 c12
TDC P1361 3 GRN
P1362 7 cr3 RED
CYP P1381 c4 YEL
1 1 - 11 0 P1382 cl4 BLK
-
v
( F r o mp a g e1 1 - 1 1 0 )
DISTRIEUTOR
Chock tor e 3hort in the CKP/ 10PCONNECTORtcl20l
TDC/CYP3en3or:
C h e c kf o r c o n t i n u i t y t o b o d y TDC P IGRNI
ground on both terminalsof the
i n d i c a t e ds e n s o r i n d i v i d u a l l y
('seetable).
Replace the distributor ignition

housing (see section 231.
CheckloJ an opgn in th6 wire3

ICKP/TDC/CYP linesl: TDC
1. Reconnect the distributor10P
connecror,
nectorC (31P).
3. Measureresistancebetween Terminalsideof
the terminalsof the indicated maleterminals
sensoron the ECM/PCMcon
nector('seetable).
Repai. open in the indicated sen- ECM/PCMCONNECTORS

C {31P|
ls there350- 7000?
sor wiles ('see tabl€).
CKPP TDCP CYPP
\, {BLUI IGRN} (YELI
Chock tor a 3hort in the wires

{CKP/TDC/CYP linosll
body ground and EcM/PcMcon-
nectorterminalsC2, C3 and/or C4
individually.
M
ls therecontinuity?
Ropair short in tho indicated 3on- {WHT) Wiresid6of
sor wiros ('see tablel. femaleterminals
TDCP cYPP
Subitituto a known-good ECM/
PCM, and recheck. lt 3ymptom/ CKP P
indicdtiongo6s away, replecothe IBLUI
origin!l ECM/PCM,
11-111
PGM-FlSystem
VehicleSpeedSensor(VSSI
The scan tool indicatesDiagnosticTrouble Code (DTC)P0500:A malfunctjonproblem in the VehicleSDeed
Sensor(VSS)circuitlexceptAy'T(D16Y7,D16Y8engine)].
The scan tool indicatesDiagnosticTrouble Code (DTC)P0501:A range/performance

problem in the Vehicle
LP@ SpeedSensor (VSS)circuitlA/T (D16Y7,D16Y8engine)1.
The MIL has boonreDortedon.

DTCP0500or P0501is stored. ECM/PCMCONNECTORS
A l32P) lcl
Problem verificationi IBRN/BLKI
1 . T e s t - d r i v et h e v e h i c l e .
2. Check the vehicle speed with
the scan tool, 1 I ! 9 t0 ll
12 l 3 t 5 15 t 3 t 9 20 2a 2a
Intermittent f.ilure, 3ystem is OK E 27 2A 4 30
ls the correctspeedindicated? at this time. Checktor Door con-
nections or loose wircs at C117
(VSS)and ECM/PCM.
CheckIor an open in the ECM/

PCM: c t3lPt
r. r urn Ine rgnrt|onswrtchut-t-.
2. Elockthe rearwheelsand set
the parkingbrake. I I tro
3. Jack up the front ot the vehicle 1t 12 13 t a t 5 1 6 t t I E
a n d s i r p p o r ti t w i t h s a f e t y
stands.
4. Turnthe ignitionswitchON (ll). VSS{BLU/WHTI
5. Blockthe right front wheel and
s l o w l y r o t a t et h e l e f t t r o n t
Wire side ot f€ma16tgrminals
E C M / P C Mc o n n e c t o rt e r m i
nalsC18and A9.
Substituto a known-good ECM/

Doesthe voltagepulse0 V PCM and recheck. lf symptom/
and 5 V? indication90e3 .way, replacetho
originalECM/PCM.
Check for a short in the ECM/ LGl

PCM: (BRN/BLKI
'1.
Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connectorC (31P). 6 I 9 t0 tt
3. Turnthe ignitionswitchON (ll). 12 t t t 6 'It ! t m 22 2a 21
4 . B l o c kt h e r i g h t f r o n t w h e e l E 27 2t 22 30
and slowly rotatethe left lront
ECM/PCMconnectorterminals
C18andA9.

Doesthe voltagepulse0 V PCM and rech6ck.lf symptom/
and 5 V? indication 9o6s away, replsco
NO 3 5 6 a 9 l0
- Bepair 3hort in the wire t 1 1Z l 3 t a | l 5 ] t 6 i 1 7 ta
betwe€n ECM/PGMlC18)and
vss,TcM.
- Repair open in the wire vss (Btu/wHTl
between ECM/PCM{C181and
vss.
- lf wiie is OK. rest the VSS
{seepag€23-120).
11-112
BarometricPressure(BarolSensor
The scantool indicatesDiagnosticTroubleCode(DTC)P1106:A range/performance
problemin the Barometric
Pressure(Baro)Sensorcircuit.
Th6 MIL has been rooortod on.

DTC P1106 b.tor.d.
1. Do the ECM/PCMresetproce-
dure,
load (A/T in E or E position,
M/T in neutral)until the radia-
tor fan comes on, then let it
idle.
3. Connectthe SCSServicecon-
nefior.
4. Test-drivewith the A/T in E
position(M/Tin 4th gear).
5. Acceleratefor live seconds
usingwide openthrottle.
lntermitteni tailuro.system is OK
st this timo.
I Subslitute a known-good ECM/

PCM end recheck. ll symptom/
indication goss away. .cplaco
(cont'd)
11-113
PGM-FISystem
BarometricPressure{BarolSensor(cont'd}
lTilOil Th"""untool indicatesDiagnosticTroubleCode(DTC)Pl107:Alowvoltage problemin the Barosensorcircuit.
c r o u b l eC o d e( D T C )P 1 1 0 8A: h i g h v o l t a g ep r o b l e mi n t h e B a r os e n s o r
T h e s c a nt o o l i n d i c a t e sD i a g n o s t i T
-l P , i l O C l crrcutl.
- The MIL has beenreportedon.

- DTCPl107or Pl108is 3tored.
1. Do the ECM/PCMResetPro
ls DTCP1'107
or P1108indicated? Intermittent tailure, 3ystemis OK
at this time.
Substitute e known-good ECM/

PCM and r6check. lf symptom/
indication go€s away, replace
11-114
) ElectricalLoadDetector(ELDI
The scan tool indicatesDiagnosticTrouble Code (DTC)Pl297; A low voltage problem in the ElectricalLoad
Detector(ELD)circuit.
- DTCP1297is slored.
Problemverificationi
cedure,
2. Startthe engine.
3. Turnon headlights.
Intermittent feilure, svdam k OK
at this time. Ch€ckto. poor con-
ls DTCP1297indicated? noctions or looso wir.s at C131
{locatedunder right 3id€ ot dashl.
Cil54{ELD}and ECM/PCM.
Check for an op€n in the wire EID 3P CONNESTOR{qtsill

{lGl linel:
1 . T u r n t h e i g n i t ; o na n d h e a d
lightsOFF.
2 . D i s c o n n e ctth e E L D 3 P c o n -
nector,
4. Measurevoltagebetweenbody
ground and the ELD3Pconnec'
tor terminalNo.1.
Wire sideof lemaleterminals
Ropairopen in the wire between
No. 15 ALTERNATOR SP SENSOR
) 17.5Al tuse in thc undor-dash
tuse/relaybox and ELD.
f t ,
Checktor short in the ELO:
Measurevoltage between body
-T
L l l 2 l 3 l
groundand the ELO3P connector
t e r m i n aNl o . 3 - O) IGRN/RED}
Y
ls thereapprox.4.5V2
Checktor a short in the wi.e (EL D (16PI

ECM/FCMCONNECTOR
linel:
2. Disconnect the ECM/PCM con-
nectorD (16P).
3. Check{or continuitybetween
b o d y g r o u n da n d E C M / P C M
connectorterminalD16.
Repairshort in the wire betwcon

ls therecontinuity?
ECM/PCM{D161and ELO. Wire side of temale terminals
Substituter known-goodECM/
PCM and recheck. Ifsyrnptom/
indication goes away. roplace
t the original ECM/PCM.
(cont'd)
1 1 - 11 5
PGM-FISystem
ElectricalLoadDetector(ELDI{cont'd)
The scan tool indicatesDiagnosticTroubleCode {DTC)P1298:A high voltage problem in the ElectricalLoad
Detector(ELD)circuit.
1. Do the ECM/PCMResetPro
cedure.
2. Startthe engine.
3. Turnon headlights.
Intermittent failuro, 3y3tem is OK

at thb time. Checklor ooor con-
ls DTCP1298indicated? ELD3P CONNECTOFlc3sil,
nection3 o. loose wire3 at C131
(locrted undcr right side of dashl,
C354lEtDland ECM/PCM.
Check lor rn open in the wire

(GNDlinell
1. Turn the ignition switch and
headlights OFF.
2 . D i s c o n n e ct th e E L D 3 P c o n , Wire sideof femaleterminals
necror,
3. Checklor continuitybetween
body ground and the ELD 3P
connectorterminalNo, 2,
nepair opcn in the wirc between

El-Dconnectorand G4l)2. EL {GRN/REO)
YES
Chackfor an opon in ihe wi.e (EL

line):
Checktor continuity between the
ELD3P connectorterminalNo. 3
and ECM/PCMconnectortermi
n a lD 1 6 .
Repairopen in lhe wire betwo€n Wire sideol femaleterminals

ECM/PCM{D16)and the ELO.
Chcckfor a malfunctionin tho ECM/PCMCONNECTORS

ELD:
1. Reconnectthe ELD 3P con-
2. Start the engine and allow it

to idle.
3. While measuring voltage
b e t w e e n E C M / P C Mc o n n e c t o r
t e r m i n a l s D ' 1 6a n d A 9 , t u r n
the headlightson (low).
Wire sideof temaleterminals
Does the voltage drop?
Substitutea known-goodECM/ {
PCM and r€ch6ck. lf symptom/
indication goes away, replaco
1 1 - 11 6
L
a CrankshaftSpeedFluctuation(CKFISensor
tPtg36-lThe scantool indicatesDiagnosticTroubleCode(DTC)P1336:Intermittentinterruptionin the Crankshaft

Fluctuation(CKF)sensorcircuit.
SDeeo
tP-s37 The scantool indicatesDiagnostic

sensorcircuit,
TroubleCode(DTC)P1337:No signalin the Crankshaft (CKF)
SpeedFluctuation
Description
The diagnosticsystemhasa pulserrotor on the crankshaftand a pulsepick-upsensoron the engineblock.The ECM/PCM
monitorsthe crankshaftspeedfluctuationbasedon the CKFsensorsignal,and judgesthat an enginemisfireoccurredif
the fluctuationgoes beyonda predeterminedlimit,
- The MIL ha3 t€en reDortodon.

- DTC P1336and/or P1337are
ltored.
P.oblemvelitication:
dure.
T 2. Startthe engine.
Intermittont failure, system i3 OK
at this time. Chack for poor con-
nections or loose wires ai C102
(CKFsensorl and ECM/PCM,and
mak6 sure CKF sensor mounting
bolt is tigt|t.
Checklor an open in the CKFsen-

301:
2. Disconnect the CKFsensor3P
connector, CKF SENSOR 3P CONNECTOR
3 . M e a s ur e t h e r e s i s t a n c e
between the CKF sensor 3P f' ----i l
connectorterminalsNo. 1 and iffil
No.3. 1 1 l 2 1 3 l
cxrrrrf--fc*r "
lwHrl L,,dJ |BLU)
ls there1.6 3.2kO? g/
Terminalsideof maletermanals
Checkfo. a rhort in tho CXFson-

3('t:
Check for continuity betwe€n
body groundand the CKFsensor l--l
3P connectorterminalsNo. 1 and -1
I-T--
No.3 indavidually- lll 2 3ll
CKF M
{WHT)
.Yt XY CKF P
(8t_ul
I I
( T op a g e1 1 ' l 1 8 ) {cont'd)
11-117
PGM-FISystem
GrankshaftSpeedFluctuation(CKFISensor(cont'dl
{ F r o mp a g e1 1 - 1 1 7 }
Chcck for an op.n in the wires

(CKFlines):
1. Reconnect the CKFsensor3P
2. Disconnectthe ECM/PCMcon- C {31PI

ECM/PCMCONNECTOR
nectorC (31P). CKFP
3, Measureresistancebetween (BLU/REDI
E C M / P C Mc o n n e c t o ri e r m i -
n a l sC 1a n dC 1 1 .
IT
a 6 1 8 I 10
1 2 1 3 1 4 1 5 l 6 1 7 '18
Repeiropen in tho wire between
ls there1.6- 3.2k0? ECM/PCM(C1,Cl'll end the CKF 23 21 25 21 2a z) 30
sensol.
CKFM
IWHT/RED} Wire sideof female
Ch€ck tor a short in the wire terminals
ICKFlin6):
body groundand ECM/PCMcon-
nectorterminalC1.
Ropairshort in the wire between

ECM/PCMlcl) and the CKFsen- CKFP
(BLU/REDI
\.
PCM, end rech€ck. lf 3ymptom/
indicrtion 90e3away, replacolhe
origin.l ECM/PCM.
\4
11-118
I CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYP)
Sensor
TD; aEol The scantool indicatesDiagnosticTroubleCode (DTC)P'1359:
Ll=!g
A problemin the CrankshaftPosition/TopDead
Center/CvlinderPosition{CKP/TDC/CYP)sensorcircuit.
The MIL ha3 been roportad on.

2. Stan the engine.lftheengine
won't start,Crankit for at least
10seconds,
Intermittem tailure, system is OK.

ls DTCP1359indicated? Ch6ck for Door connection3or
loose wires at C120 {distributorl
.nd ECM/PCM.
C h e c kf o r p o o r c o n n e c t i o n so r
loose wires betweenthe distribu-
tor and the EcM/PcM_
I Substituto a known-good ECM/

PCM, and recheck. lf symptom/
indication go6s awaV, rgplace
ths original ECM/PCM.
11-119
PGM-FISystem
InternalCircuit
ECM/PCM
I P1607 The scantool jndicatesDiagnosticTroubleCode(DTC)P1607:An ECM/PCMInternalCircuitProblem.
- The MIL has beenreportedon.

- DTCP1607is stored.
1. Do the ECM/PCMResetPro'
cedure,
3. Wait 10 seconds.

PCM and recheck.lf syrnptom/
indicationgoes away, replacethe
originalECM/PCM.
1-120
l/ A/T Signal(TMA/TMB){D16Y5engine(CVT))
I P1655 iThe scantool indicatesDiagnosticTroubleCode(DTC)Pl631:TMMMB signallinefaiture.
ECMCONNECTOR
C {31P)
TMA IGRY}
Problomverilication:
1. Dothe ECMResetProcedure.
2. Drive the vehiclefor several
milesat varyingspeeds.
Wire sideot temale

termrnats
Intermittent failure,sysl€m is OK
at this timo. Chockfor Door con-
ls DTCP1655indicated? nections or loose wires at C131
(locatedunder right side of dash),
C4:t8{TCMI,nd ECM.
fcu22P
Ch6ck tor an open in the wire CONNECTOR
{TMA linol:
2. DisconnectECM connectorC
{31P)from the ECM.
E C M c o n n e c t o tr e r m i n a lC g Chcck lor a short in the wire
and bodyground. ITMA line):
Measurevoltage betweenTCM
22PconnectorterminalNo. 7 and
I ls there batteryvoltage? body ground.
ls there batteryvoltage? RoDairshort in the wire between

lhe ECM{C9land th6 TCM.
Chock tor rn open in tho wir€
(TMB line):
1. Turnthe ignitionswitchOFF. fcu 22P
2. ReconnectECM connectorC Repairopen in the wire between
the ECMlcg, and the TCM. CONNECTOR
(31P).
from TCM.
4. Turntho ignitionswitchON (ll).
5 , M e a s ur e v o l t a g e b e t w e e n
TCM 22P connectorterminal
No.6 and bodyground.
C h e c kf o . a 3 h o r t i n t h e w i r e
{TMB line}:
ls there batteryvoltage? Measurevoltage between ECM
connoctorterminalC30and body
grouno. { 6 1 8 I 10
11 1 2 1 3 l 4 1 5 1 6 1 7 l 8
23 21 25 29 30
Substitute r known-good ECM
and rccheck. lt 3ymptom/indica- TMBT
Wire sideof female
tion goe3away, roplacelhe origi- terminals
{PNK)
nal ECM.
Repairshort in the wire between

the EcM lc30) and the TcM.
Reprir open in the wi.e bstwe€n

rhe EcM {c30) and rhe TcM.
11-121
ldle Control System
SystemDescription
The idle speedof the engineis controlledby the ldle Air Control(lAC)Valve.
The valvechangesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledby the
ECM/PCM. Whenthe IACValveis activated, lhe valveopensto maintainthe properidle speed.
D16Ys,D16Y8ensine(M/T): , :::/ __ _<

, BLK T *f,T.ir;tJ
MAINRELAY
I - T
- r )
VARIOUS
SENSOnS
aLk
IROTARY}
IACVALVE EIVGINE
COOLANT
INTAKEMANIFOLD
D16Y5(CVTI,D15Y8engine(A/T):
;[i- <l;litf,U''j
vARtous
D16Y7engine: SENSORS
11-1 2 2
a
1 . After the enginestarts,the IACvalveopensfor a certaintime, The amountof air is increasedto raisethe idle speed
about 150- 300rpm.
When the coolanttemperatureis low, the IAC valve is openedto obtain the propertast idle speed.The amount of
bypassedair is thus controlledin relationto the enginecoolanttemperature.
IOLE SPEED
lrpml
Et{Gt1{E
COOLANTTEMPERATURE
176 (oF)
80 toc)
1. When the idle speedis out of specification and the scantool does not indicateDiagnosticTroubleCode{DTC}P0505
or P1508,checkthe followingitems:
. A d j u s t h e i d l es p e e d( s e ep a g e1 1 , 1 4 1 )
. S t a r t esr w i t c hs i g n a (l s e e p a g e l l - 1 3 0 I
. A i r c o n d i t i o n i nsgi g n a (l s e ep a g e1 1 - 1 3 1 )
. ALT FRsignal(seepage11 133)
' Brakeswitchsignal{seepage1'l-134)
' PSPswitchsignal(exceptCanadamodel)(seepage11-135)
. A/T gear positionsignal(seesection'14,D16Y5engine(CVT):
p a g e1 l - 1 3 7 )
. Clutchswitchsignal(D16Y5engine(M/T))(seepage 11-139)
. Hosesand connections
. IACvalveand its mountingO-rings
lf the aboveitemsare normal.substitutea known-goodIACvalveand readjustthe idle speed(seepage 11-141).
lf the idle speedstill cannot be adlustedto specification(and the scantool does not indicateDTCP0505or P1508)
after IAC valve replacement,substilutea known-goodECM/PCMand recheck.lf symptom goes away, replacethe
originalECM/PCM.
11-123
ldle ControlSystem
ldle ControlSystem
lT05O5l Th" """n toot indicatesDiagnosticTroubleCode{DTC)P0505:ldle controlsystemmalfunction.
NOTE:lf DTCP1508or P1509is storedat the sametime as DTCP0505,troubleshootDTCP1508or P1509first,then trou-

bleshootDTCP0505.
Possiblecause
. IACvalvemechanicalmalfunction
. Throttlebody cioggedport, improperadiustment
r lntakemanifoldgasketieakage
. Intakeair hoselooseleakage
. V a c u u ml e a k
. ECTsensorincorrectoutput
. ThrottlePositionsensorincorrectoutput*1
Tloubleshooting Flowchart
- Th6 MIL has beenreoortodon.

- DTC P0505is stored.
Problsm vorificationl
load 1A,/Tin E or E position,
M/Tin neutraliuntiltheradiator
fan comeson, then let it idle.
*1 -Wi*i
t2. tne scan toot, checLtt e-l
- Throttleposilionshouldbe
approx.10%with the throt'
tle {ully closed.
- E n g i n ec o o l a n tt e m p e r a -
ture shouldbe 194- 205'F
(90- 96'C).
lf they are not within the
spec.,repairthe faultysen-
L sol9!!9'llj:-.-.-.- - l
3 . C h e c kt h e e n g i n e s p e e d a t
idle with no-loadconditions:
h e a d l i g h t sb, l o w e rf a n , r e a r
defogger,radiatorfan, and air
conditionerare not operating
(seepage11 139).
Intermitt€nt failure, system is OK

ls the idlespeedOK?
et this time.
ls it 550 rpm or less?
(Topage11-125) { T op a g e1 1 - 1 2 5 )
* 1 : ' 9 6m o d e lo n l y
11 -1 2 4
{Frompage11-124}
(A,/Tand D16Y7engine)
I
Checkthc IACvrlvo:
Disconnectthe 3P connectortrom
the IACvalve.
- - - - D'|6Y8
' {Dl6Y5, - - - t engin€with M/T)
Chcckth. IAC valve:

D i s c o n n e c tt h e 2 P c o n n e c t o r
from the IACvalvo.
Doesthe enginespeeddrop or
the enginestall?
_ l
Dl6Y5, Dl6Y8 ongin€:

Adi6t thc lbasll idle 3pa6d ls6c
p.9€ 11-1391. UPPER
ll it'. impo$ible,
cl6an th€ ports in tha throttle
body.
lFrompage I1-124)
Putyour fingeron the upperport

in the throttle body.
Chack for vacuum laakr. make Dl6Y7 engine:

Doeslhe engin€speeddrop? 3u.c th. throitla valvc is com-
plctaly closrd, .nd ropair I nec-
ca3ary.
Adiust tho idlo sp..d (3€e pag.

11-139).It it'5 impo$iblo, r.placo
tha IAC Yalve.
11-125
ldle GontrolSystem
ldle Air Control(lAClValve(Dl6Y5,Dl6Y8 enginewith M/T)
(lAC)valve
The scan toot indicatesDiagnosticTrouble Code (DTC)P1508:A problem in the ldle Air Control
crrcurt.
The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in
order to maintain the proper idle speed.
- The MIL has b€6n reDortgd on.

- DTC P150a is stor.d.
Problomvorification:
cedure.
2. Startthe engine,and warm it
up to normal operatingtem-
perature.
vat_vE
lntc.mittent tailure, svslem i5 OK
et thb time. Check for poor con-
ls DTCP1508indicated? noction3 or 10036wirg3 st C138
llAC v.lvel .nd ECM.
Check to..n open in tho wi.o IAC VALVE2P CONNECTOR

ICl38}
llGPl lin6l:
2. Disconnectthe IAC valve 2P /T\'--'J rcpr
connector, t rYCLrBtXl
\ 2 J -
4. Measurevoltagebetweenbody
s r$,
ground and the IAC valvo 2P
connectorterminalNo.2.
Y=
Wire sid6ot femaleterminals
Reprir opsn in the wiro bstwcen
ls there batteryvoltage? IAC valvo and PGM-FImain rcltY.
Chacklor rn open o. short in the A I32PI

ECMCONNECTOR
wirc {lACv linel:
1. Turn the ignition switch OFF
and reconnectthe IAC valve to
I 3 5 6 ! 1 9
connecror,
12 l 3 1 5 i 6 't, t l t9 ao 2a 2a
2. Disconnectthe ECMconnector
A (32P). tAcv lzsVlztl lz.lzelnl/l | .,'
3. Turn the ignilionswitchON lll). IBLK/ $
4 . M e a s u r ev o l t a g e b e t w e e n BLUI
b o d y g r o u n da n d E C Mc o n -
nectorterminalA12.
(To page 11-127)
11 -1 2 6
(Frompage11-126)
Ropairopen or short in the wiro

ls ther€ batteryvoltage? b.tw€en ECM lA12l and IAC
Checkthe IAC valvelunction:

MomentarilyconnectECM con-
n e c t o rt e r m i n a l sA 1 2 a n d A ' 1 0
with a iumoerwire severaltimes,
Wire side of female t€rrhinals
Doesthe IACvalveclickT
Substitute . known-good ECM

and rocheck. lt 3ymptom/indica-
tion 906 away, .oplaco tho origi-
n.l ECM.
11-127
ldle Gontrol System
ldle Air Control(lAClValve (A/T and Dl6Y7 engine) v
lTi509l TroubleCode(DTC)P1509:Aprobleminthe idleAirControl(lAC)valvecircuit.
Th""""ntool indicatesDiagnostjc
The (Rotary)IAC Valvechangesthe amount ot air bypassingthe throttle body in responselo a currentsignaltrom the
ECM/PCM in order to maintain the proper idle speed.
BIMElAL
The MIL has beenreooned on.

DTCPl 5'lx)is sto.ed.
Problomverification:
1. Do the ECM/PCMResetProce-
dure,
2. Turnthe ignitionswitchON (ll). SHAFT VALVE STOP?ER
Intermittent failuro, svstem ia OK
ls DTCP1509iodicated? at lhis time. Check for poor con-
nections or 10036wires at C109
{lACvalve) end ECM/PCM.
ECM/PCMCONNECTOR
A I32P}
Checkfor an open in the wires PGl (BIK}
IPGlin6):
Measurevoltage between body
ground and ECM/PCMconnector
terminalsA10 and A23 individu
Repair op6n in lhe wires between

ls theremorethan 1.0V? ECM/PCM and G101 {locat6d ar \3
the thermostat housing.l
Wire sid€ ol temale terminals
Check the ECM/PCM inpul volt-
age:
2. Disconnect ECM/PCM connec-
tor A (32P)from the ECM/PCM- 2 I 8 10 1'l
3. Turnthe ignitionswitchON (ll). 1 2 l 1 31 a 1 5 1 6 1 7 t8 t9
4 . M e a s u r e v o l t a ge b e t w e e n
m 22 23 2a
connectorterminalsA14 and tAcv N {oRNt. . l 27 28 29
IACVP IBLK/BLU}
3o
A13+individually. O)
ls therebafteryvohage? (Topage11129)
Check the IAC valve:

1. Turn the ignition switch OFF.
IAC VALVE3P CONNECTOB
2. Disconnect the IAC valve 3P
connector.
3. Measure resistance between
IAC valve 3P connector termi'
IACV N IACV P
n a l N o . 2 a n d t e r m i n a l sN o . 1
and 3 individually.
ls there16- 28 O? IGP
Terminalsideof male
Iermtnals
Substiluto a known-good ECM/
PCM and rocheck.lf symptom/
indicalion goes away, replace
*: IACV N line
11 -1 2 8
{ F r o mp a g e1 l - 1 2 8 }
IAC VALVE3P CONNECTOR

{CIOI}
Check tor an open in the wire

(lGPline):
1. Turnthe ignitionswitchOFF. IGP {YEL/BLKI
2. Disconnectthe IAC valve 3P
connector.
4. At the wire harness,measure
voltage between IAC valve 3P
connectorterminalNo. 2 and
body ground.

ls therebatteryvohage? lh6 IAC valvo and PGM-FImain
relav.
Checkfor an open in tho wires

(IACVP, IACV N' lines):
2. Disconnectthe ECM/PCMcon
nectorA (32P).
IAC valve3P connectortermi
nal No. 3 and ECM/PCMcon'
n e c t o r t e r m i n a lA 1 4 ( a n d
betweenIAC valve 3P connec- IACV N
tor terminal No. 1 and ECM/ toRNl* ' t 2 3
IACV P
PCMconnector terminalA13)*. IBLK/BLUI
ECM/PCM
Repairop€n in tho wire bctwoen A t32Pl
CONNECTOR
the IAC v.lve end ECM or PCM
(A14,A13*1. IACV P
(BLK/BLU)
I 7 E 9 lo tt
Check tor a short in th€ wires
(IACV P, IACV Nr linesl: 12 l 3 1 a t 5 l 6 1 7 ta t 9 2A u 2a
Check tor continuity between 25 21 2a 29 30
b o d y g r o u n d a n d E C M / P C Mc o n '
nector terminals A14 and 413* Wire sideof femaleterminals
individually.
Repairshort in the wire between

tho IACvalveand ECM/PCM1A14.
A13*).
I 3 a 6 a 9 t0 tl
t 2 t 3 lil t 5 t 6 1 7 l a t 9 20 24
Sub3titute a known-good ECM/
PCM and reched( lf syrYFtom/indi-
cation goes away, replac€th6 o.igi-
n.l ECM/PCM.
': IACVN line
tacv N toRNl.
Lry,"*"YYO
l,
11-129
ldle ControlSystem
StarterSwitch Signal
This signalsthe ECM/PCM
when rhe engineis cranking.
NOTE:
. A/T:Transmission
in E] or @ posnion.
. M/T: in neutral
ECM/PCMCONNECTORS
Chockfor an open or ihort in the A I:PPI LGl c t3lPt
wire {STSlinol: sTstELu/oFNt
Measurevoltage betweenECM/
PCMconnectorterminals Ag and 3 E 9 't0
I 7 1' | 3 a 5 7 t 9 t0
C6 with the ignition switch in the t 2 l 3 t 4 1 5 1 6 t 7 ta r 9 20 22 23 2a t t 12 r3 t a t5 t6 1 l 't8
start(lll)position.
25 27 ut 29 30 2a 2a E 29 30
Wire side ot female terminsls
Inspecttho No. 31 STARTERStG,

NAL {7.5A) fuse in the undeFdash
Iuse/relaybox.
- Raplir rhon in thc wiro

b.tw..n the ECM lC6) and
St.rior switch sign.l b OK. tho No. 31 STARTERSIGNAL
(t.5 Al lu3. or th. PGM-FI
main relsy.
- ReDhcotho No, 31 STARI€R
SIGNAL17.5A1tu3..
v
Rapair open in tha wire batwatan
tho ECM/PCMlC6|and th. No.31
STARTER SIGNAL17.5Al tu!..
\,
11-130
Air ConditioningSignal
when there is a demandfor coolingtrom the air conditioningsystem.
ECM/PCMCONNECTORS
A l32Pl c t3lPl
LGl IBRN/BLK} ACSIBLU/REDI

2 I 8 9 l0 It I 2 a 5 1 E 9 10
1 2 1 3 ta 't5 't6 1 7 t 8 1 9 a) 22 23 2a 't'l 12 t 3 1 l t 5 t 5 1 7 t 8
Check lor a ahort in th6 wir€ 25 27 2a xt 30 23 2a 2a z, 30

{ACSlinel:
Wiresideof lemaleterminals
2. Disconnectthe A/C pressure
switch 2P connector(see sec-
t i o n2 2 ) .
E C M / P C Nc4o n n e c t o rt e r m i -
nalsC5 and A9.
Chockfo. a short in the wire IACS ACS{BLU/RED}

linol:
ls thereapprox.5V?
nectorC (31P).
connectorterminalC5,
Repairshort in the wire botw€sn

the ECM/PCM (Csl .nd the A/C
pro3suraswitch.
- Substitute a known-good
Chock tor an open in the wire
ECM/PCM and r€chock, lf pro-
IACClin.l:
1. Turnthe ignitionswitchOFF. acribgd vohago i3 now aveil-
.ble, replace the original ECM/
2, Reconnectthe A/C pressure
PCM.
switch 2P connector. -
3. Turnthe ignilionswitchON (ll). See the sir condhione. insp€c-
tion l.oc s.ction 22). LGTIBRN/BLKI
4. Momdntan'ly connect ECM/
PCM connectbrterminalsA9 - r l
and A17 with a iumper wire
severaltimes. 1 2 3 a ; l s l r I l s l s l ! ol r r l
12 l 3 t a 1 5 1 6 1 lnltslil/1zzl ze I z+ |
(To page11-132)
25
ACC
27
w-z-
IBLK/REDI JUMPERwlRE
{cont'd)
1 1- 1 3 1
ldle Control System
Air ConditioningSignal (cont'dl
( F r o mp a g e1 1 - 1 3 1 )
UNDER.XOODFUSE/RELAY
Check for an open in the wir€ BOX9P CONNECTOBtc3s2t
{ACCline):
ls therea clickingnoiselrom Momentarilyconnectunder-hood t 2 3 a
the A,/Ccompressorclutch? fuse/relaybox 9P connectorter
5 6 / 8 9
minal No. 5 to body groundwith
a jumperwire severaltimes. JUMPER
WIRE ACC IBLK/REOI
IBLK/RI
Wire side
side ot
ot female
tefmrnalS
ls therea clickingnoisefrom See air conditioner inspection

the A/Ccompressor clutch? lsee section22).
Repairopen in the wire between

i h . E C M / P C Ml A 1 7 ) a n d t h 6
under-hood tu3e/relay box 9P
connector{C3521.
ECM/PCMCONNECTORS
A (32Pt
Check tor the operation of the LGT c (31Pt
A/C: (BRN/ALKI
1. Startthe engine.
ACSIBLU/REDI
2. Turnthe blowerswitchON. I 6 7 8 9 l0 tl I 8 I 'to
3. Turn the A"/Cswitch ON. 12 1 3 t a t 5 t 6 1 7 I E 1 9 zo 22 23 2a t t 12 t4 lf, 1 7 't8
25 27 E 30 2a 2a 29 30
WiresideoI femaleterminals

{ACSlin6):
PCMconnectorterminalsAg and
Air conditioningsign.l is OK.

R€prir open in tha wire bstween
ls therelessthan1.0V? the ECM/PCM lcsl .nd th. A/C
swhch.
- Substiluta. known-good
E C M / P C Ma n d r e c h o c k .l I
symptom/indicationgoes
a w a y , r e p l a c et h o o r i g i n a l
ECM,/PCM,
- Seethe air conditionerinspec-
tion (seesection22).
11 -1 3 2
I Alternator(ALT)FRSignal
when the Alternator(ALT)is charging.
lnspectionot ALI FRSignal.

ECM/PCMCONNECTORS
A t32Pl c t31Pl
LG1
(BRN/BLKI
Ch6ck for a sho.t in the wire {ALT
F line):
1. Disconnectthe 4P (3P)*con-
nectorfrom the ALT.
2. Turnthe ignitionswitchON (ll). ALT F
3 , M e a s ur e v o l t a g e b e t w e e n Wire sideot temaleterminals
{WHT/BEO)
E C M / P C Mc o n n e c t o rt e r m i -
nalsC'|7and A9.
Check tor a short in the wire IALT
F linel: I 2 3 a 5 6 l 7| 8 9 't0
2. Disconnectthe negativebat
1 1 12 1 3 l 4 1 5 l 6 rlrl/ ,/ / ,/
tery cablefrom the battery. 23 21 E 30
ls thereapprox-5 V? 3. Disconnectthe ECM/PCMcon
nectorC (31P). (wHr/FED)
4. Checklor continuitybetween 0) ALrF
b o d y g r o u n da n d E C M / P C M
connector terminalC17.
Checkthe operation ot the ALT:
2. Reconnectthe ALT 4P (3P)*
connectorto the ALT. Repair shon in the wire between
ls therecontinuity?
3 . S t a r t t h e e n g i n e .H o l d t h e the ECM/PCM{C17)endthe ALT.
load {A,/Tin E or E position,
tor fan comes on, then let it Substitute a known-good ECM/
idle. PCM and recheck. It prescribed
4 , M e a s ur e v o l t a g e b e t w e e n voltage is now available,replace
ECM/PCMconnectorterminals the originalECM/PCM.
Cl7 andA9.
D o e s t h e v o l t a g e d e c r e a s ew h e n
h e a d l i g h t sa n d r e a r d e f o g g e r a r e ALT FR signal i3 OK.
ALT CONNECTORS
lcloirl
4P 3Pr
Chec* lor an opeo in the wire IALT
F lin€): -+r
1 1 2| 2 3
1. Turnthe ignitionswitchOFF. ffi
2. Disconnectthe 4P (3P)*con
nectorfrom the ALT. l 3 l ll JUMPER ALT F
rr-r r -lr JUMPER WIRE (WHT/RED'
4. Measurevoltage between the rwHr/(V) WIRE
ALT 4P {3P}*connectortermi REot Y
n a l N o . 4 ( N o .1 ) * a n d b o d y Wire side of female terminals
ground.
Repair open wire between the

ls thereapprox-5 V?
ECM/PCM{Cl7).nd the ALT.
':Canadamodel
11 - 1 3 3
ldle Control System
BrakeSwitch Signal
when the brakepedalis depressed.
This signalsrne ECM/PCM
Inspcctionol &ak€ Swhch Signal.
Are the brakelightson without

depressingthe brakepedal?
Inspectthe HORN('15A) fu6e in

Do the brakelightscomeon? the under hoodtuse/ relaybox.
- ngpaif shorl in the wire

betwoen thc br.k6 3whch and
the HoRN l't5 A) tuse.
- R.placo the HORN{7.5Al tuse.
Repair open in the wire

bgtw6cn the brrke iwitch and
thc HORN115Altuse.
Inspoci tho b.ake switch lsoe
Boctionl9l.
Check lor an op.n in th€ wiro
IEKSWlin6l: ECM,/FCMCONNECTORS
1. Depressthe brakepedal.
2. Measurevoltage betwoen D tl6Pl BKSW
A t32P) taRnu IGRN/
ECM/PCN4 connectorterminals
A9 and D5 with the brakepedal WHT}
depressed. 1 2 t I 6 8 I 10 tl I 3 a 5
1 2 1 3 1 4 't5 l6 1 ' l8 t9 20 22 23 21 6 8 I 10 1 1 12
25 27 2A a 30 13 t4 15 16
Wir€ sid6 of lemale terminals

Rop.il open in the wi.6 botween
tha ECM/PCMlDs) rnd thc b.ako
lwitch,
8r.ke 3witch 3ignal ia OK.
11-134
)
PowerSteeringPressureIPSP)Switch Signal(USAI
This signalsthe ECM/PCMwhen the power steeringloadis high.
ECM/PCMCONNECTORS
lNp€ction of PSP3witch rignal.
Ch.d( for .n op.n in the wi.. (PSP

SW lin.l:
1. Turn the ignitionswitchON {ll}.
2 . M e a s u 1 6v o l t a g e b e t w e e n
Wire side of femalo terminals
E C M / P C Mc o n n e c t o rt e r mi '
n a l s A 9a n dC ] 6 .
Chockfor .n op€n in lhe wire (PSP
SW linol: PSPSW]TCH2PCONNECTOB
2. Disconnect the PSPswitch2P PSPSWtcBf{l
connecror,
3. Turn the ignitionswitchON lll).
ls therelessthan 1.0V? 4. At the harnessside, connect JUMPER T-1 rJJ
the PSPswitch 2P connector w r F E- 2 /
t e r m i n a l sN o . 1 a n d N o . 2
with a jumperwire. GND IBLKI
ECM/PCMconnectorterminals Wir€ sid6 of temale terminals
Ag andC16.
t
- Bepair opon in the wire
betwocn th6 ECM/PCMlcl6l
and the PSPswitch.
ls therelessthan 1.0V? -
Ch6ck thc opo.ation ot th6 PSP Ropeir open in BLK wir€
rwhch; b€tween the PSP 3wiich .nd
1. Stanthe engine G101.
2 . T u r n s l e e r i n gw h e e l t o I u l l
lock.
EC 4,/PCMconnectorterminals
Ag and C'|6.
ls there bafteryvoltage?
PSP .whch tignal i3 OK. { T op a g e1 1 - 1 3 6 )
I (cont'd)
1 1- 1 3 5
ldle Control System
(PSPISwitch
PowerSteeringPressure Signal(USA)(cont'dl u
(Frompage11-135)
C h e c kt o r € s h o . t i n t h 6 P S P ECM/PCMCONNECTORS
switch:
from the PSPswitch.
4 . M e a s ur e v o l t a g e b e t w e e n
E C M / P C l vc lo n n e c t o rt e r m i -
n a l sA 9 a n dC 1 6 .
Checkfor a shon in the wir6 {PSP

1 1 6 7 8 9 10
SW linel:
1. Turnthe ignitionswitchOFF. 1 t 12 13 14 15 1 6 1 7 18
nectorC (31P).
23 21 25 E 30 \-
b o d y g r o u n da n d E C M / P C M PSPSW {GRN}
connectorterminal C16. o
Rep.ir short in th6 wire between

ls therecontinuity? the ECM/PCM{C16)and rhe PSP
switch.

PCM and recheck.lf p.escribed
voltage is now available,replace
11 - 1 3 6
AutomaticTransaxle(CW) GearPositionSignal(D16Y5engine)
s inE or E position.
T h i ss i g n a l st h e E C Mw h e nt h e t r a n s m i s s i oi n
Check the ope.ation of th€ A/T

gear position switch:
2. Observethe A"/Tshift position
indicatorand selecteach posi
tronseparately.
Seethe A/T g6ar position indica-

tor inspection{seesection 141.
ECMCONNECTORS
Ch6ckfor a short in ihe wir€ (ATP

NP linel:
from the gaugeassembly.
) 3, Disconnectthe 26P connector
lrom the TCM.
5. MoasurevoltagebetweenECl/l Wire sideof Iemaleterminals ATP NP
c o n n e c t o tre r m i n a l sA 9 a n d {LT GRN)
c29.
Checkfor a shon in the wire IATP

NPline): I 5 7 8 9 10
1. Turnthe ignitionswitchOFF. 1 1 12 13 1 a 1 5 16 1 7 18
2. Disconnectthe ECM connec'
ls thereapprox.5V?
t o rC ( 3 1 P ) . 23 21 29 30
b o d y g r o u n da n d E C Mc o n ATPI N P
nectorterminalC29. o I
ILT GRNI
Checklor .n open in th€ wiro IATP
NP linel:
2. Reconnect the l4P connector Repairshort in the wire between
to the gaugeassembly. ls therecontinuity? the EcM {c29)and rhe gau96
3. Reconnect the 26Pconnector assemblv.
to the TCM.
4. Startthe engine.
5 . M e a s u r ev o l t a g e b e t w e e n
ECM connectorterminalsA9
a n d C 2 9w i t h t h e t r a n s m i s -
sion in E and E position.
and recheck.ll prescribadvolt-
ege is now available,replacethe
originalECM.
(Topage11-138)
I (cont'd)
1 1-137
ldle Control System
AutomaticTransaxle(CWl GearPositionSignal(D16Y5engine)(cont'd)
( F r o mp a g e1 1 - 1 3 7 )
- Repair open in the wire
b€tween the ECM lc29l and
the gaugaa!3ombly.
l s t h e r e l e s s t h a n 1 . 0V ? - Repair open in the wire
between the gaugo assembly
rnd the A/T gear position
switch.
Checkfor a short in the wire IATP

NP linel:
connectorterminalsA9 and C29
with the transmission in gear.
ATP NP
Wire side ol female torminals ILT GRNI
ls there batteryvoltage? Repairshort in the wire between
ECM(C291and gauge assembly.
A/T gear po6ilion signel is OK.
11 - 1 3 8
ClutchSwitchSignal(Dl6Y5engine(M/Tll
This signalsthe ECMwhen the clutchis engaged.
Inap€ction of clutch .witch signal. ECM COITNECTORS

A t32Pl LGl IBRN/BLK}
Ch.ck for rn opcn in the wiro

(CI..SWlin.l:
1. Turnthe ignitionswitchoN (lll.
A9.
Wire sid6of femaleterminals (REDI
Checkth. clutch 3witch:

trom the clutch switch.
ls thereapprox.5V?
4. Measurevoltageb€tweenECM
A9.
ls thereapprox.5V?
Check lor a shorl in tha wire

(CLSWlinel: 1 5 7 8 9 't0
1. Turnthe ignitionswitchOFF. t t l 2 ! 3 1 a l 5 t 6 l 7 1E u
2. Disconnectthe EcM connec-
tor C (31P)fromthe ECM.
Chock tor an opcn in the wiro
(CLSWlinel: 3. Checklor continuity between cLsw
(REDI
1. Depressthe clutchpedal.
ECM connectorterminal C29
and body ground.
a
2. MossurevoltagebetweenECM
connectortermin6lsC29 and
A9.
Ropairshort in the wiro botwe.n
tho ECM {C29} rnd tho clutch
swhch.
{To page11-140} Subititute a known-good ECM

and rcch6ck. ll pGacribcd vohrge
h now availabla,replacothe otig-
inrl ECM.
{cont'd)
11-139
ldle ControlSystem
ClutchSwitch Signal(Dl6YSengine(M/Tl) (cont'dl
(Frompage11,139)
CLUTCHSWITCH2P OONNECTOR
Chockthg clutch switch:
ls voltagelessthan '1.0V? Irom the clutch switch.
the clutch switch connector
terminalsNo. 1 and No.2 with
the clutch pedaldepressed.
Terminalsideof male
terminals
- Adiu.t the clutch switch.

- Roplecothe clutch .witch.
CLUTCHSWITCH2P CONNCCTOFlcillTl
r-+-r
t l t 2 l
Checktor an opon in the wiro: LJ_J
1. Turnthe ignitionswitchON (ll). I
2. Measurevoltagebetweenthe clsw
clutch switch connectortermi- (REDI 1;\
nal No. 1 and body groundwith Y
the clutchpodaldepressed.
Wire side of female
terminals
Rcpril opon in the wirc betwocn

ls there approx. 5 V? th6 EcM lc29) .nd tha clutch
switch.
R.prir open in BLKwira batwaon

th. clutch 3witch snd G/O1.
Outch 3witch signal i3 OK.
11-1 4 0
ldle SpeedSetting
Inspection/Adiustment Adjustthe idle speed,if necessary,by removingthe
cap and turningthe idle adjustingscrew.
'96,'97 D16Y5,'96-'98Dt6Y8engine
{M/T}
NOTE: After adjustingthe idle speed in this step,
NOTE: recheckthe ignitiontiming (seesection23).
. B e f o r es e t t i n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g lf it is out of spec,go backto step4.
items: IDLE
- The MIL has not beenreponedon.
- lgnitiontiming
- Sparkplugs
- Air cleaner
- PCVsystem
o ( C a n a d aP) u l l t h e p a r k i n gb r a k el e v e r u p . S t a n t h e
engine.then checkthat the headlightsare off.
'1.
Startthe engine.Hold the engineat 3,000rpm with
no load {transmissionin neutral)until the radiator
Connecta tachometer.
Disconnect
the IACvalveconnector.
Turn the ignitionswitchOFF.
7 . Reconnectthe 2P connectoron the IAC valve,then

do the ECMresetprocedure.
Restartand idle the enginewith no-loadconditions

for one minute,then checkthe idle speed.
N O T E : ( C a n a d aP
) u l l t h e p a r k i n gb r a k el e v e r u p .
Startthe engine, then checkthat the headlightsare
off.
ldle speed should be:

670 t 50 rpm {USA}
750 t 50 rpm lcanadal
ldle the enginefor one minutewith headlights(Low)

ON.and checkthe idlespeed.
ldl8 sp€€d should bo:

lf the enginestalls,restartthe enginewith the accel- 750 I 50 rpm
eratorpedalslightlydepressed. Stabilizethe rpm at
1,000,then slowly releasethe pedaluntil the engine 1 0 . T u r n t h e h e a d l i g h t so f t . l d l e t h e e n g i n ef o r o n e
idles. minute with heaterfan switch at Hl and air conditioner
on,thenchecktheidlespeed.
Checkidlingin no-loadconditions:headlights,blower
fan, rear defogger,radiatorfan. and air conditioner ldle speed should be:
are not operating. 8101 50 rpm
ldl€ 3p€€dshould be: NOTE:lf the idle speed is not within specification,
il50 t 50 rpm seeSymptomCharton page 11-46. (cont'd)
11-141
ldle ControlSystem
ldle Speed Setting (cont'd)
'96, '97 Dt6Y5
engino {CvT), '96-'98 Dl6Y8 engine lA/T) D16Y5,D16Y8engine:
rnd '96-'98 D16Y7engine
Adjustthe idle speedusing a HondaPGM Testerif pos-

sible.lf not, usethe followingprocedure:
NOTE:
. Leavethe IACvalveconnected.
. B e f o . es e t t i n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g
items:
- The MIL hasnot beenreportedon.
- l g n i t i o nt i m i n g
- Sparkplugs
- Air cleaner
- PCVsystem
1. Connecta tachometer.

no load (A/T in N or E position, M/T in neutral)
until the radiatorfan comeson, then let it idle, Dl6Y7 engine:
NOTE:When you removethe ACL housing,do not
Checkthe idle speedwith no-loadconditions:head- disconnectthe IAT sensorconnector.
lights,blower fan, rear defogger,radiatorfan, and
air conditionerare not operating.
ldlc speed should be:
USA:
Dl6Y5 engine {CVT),D16Y7engine (A/T). Dl6Y8

.ngino lA/T):
700 i 50 rpm (in S or p position)
Dl6Y7 engine{M/T):
670 I 50 rpm
Crnada:
A i t e r t u r n i n g t h e i d l e a d i u s t i n gs c r e w 1 / 2 - t u r n ,
D15Y8engine,D16Y7engine: checkthe idle speedagain.lf it is out of spec,turn
MIT 750t 50 rpm the idle adiustingscrew1/2-turnagain.
NOTE: Do not turn the idle adjustingscrew more
AIT 750i 50 rpm {in E or E position) than 1/2-turnwithout checkingthe idle speed.
l d l e t h e e n g i n e f o r o n e m i n u t e w i t h h e a t e rf a n
Adjustthe idle speed,if necessary, by removingthe switch at Hl and air conditioneron, then checkthe
c a p a n d t u r n i n gt h e i d l e a d j u s t i n gs c r e w 1 / 2 - t u r n idle soeed.
clockwiseor counterclockwise.
MN 810t 50 rpm
A/T. CVT 8 1 0 1 5 0 r p m ( i nE o r E p o s i t i o n )
NOTE:
. Do not turn the idle adjustingscrewwhen the air
conditioneris on.
t lf the idle speed is not within specification,
see
SymptomCharton page 11-46.
11- 1 4 2
Inspection/Adiustmeni lf necessary.adjust the idle speed. by removing the
c a p a n d t u r n i n g t h e i d l e a d j u s t i n gs c r e w .
'98 D16Y5engine(M/T)
After adjusting the idle speed recheck the ignition
NOTE:Beforesettingthe idle speed,checkthe follow- timing (see section 23). lf it is out of spec, go back
Ing trems; to step 4. |DLE
- The MIL hasnot beenreportedon.
- S p a r kp l u g s
- Aircleaner
- PCVsystem
1 . Startthe engine.Hold the engineat 3,000rpm with

no load (transmissionin neutral)until the radiator
2. Connecta tachometer.
Disconnect
the IACvalve2P connectorand the EVAP
purgecontrolsolenoidvalve2Pconnector.
Turn the ignitionswitchOFF.
7 . Reconnectthe 2P connectorsto the IAC valve and

the EVAPpurge controlsolenoidvalve,then do the
ECMresetprocedure.
8 . Restartand idle the enginewith no-loadconditions

for one minute,then checkthe idle speed.
ldle speedshouldbe: 6701 50 rpm

EVAPPURGE
CONTROL
SOLENOIDVALVE NOTE:lf the idle speed increasesto 810 t 50 rpm,
this meansthe EVAPsystemis purgingthe canister.
lf the enginestalls,restartthe enginewith the accel- T o s t o p t h e p u r g i n gt e m p o r a r i l yr,a i s et h e e n g i n e
eratorpedalslightlydepressed.Stabilizethe rpm at speed above 1,000rpm with the acceleratorpedal,
1,000,then slowly releasethe pedaluntil the engine then slowly releasethe pedal.
idles.
l d l e t h e e n g i n eI o r o n e m i n u t ew i t h h e a d l i g h t s
Checkidlingin no-loadconditions: headlights,
blower (Low)ON, and checkthe idle speed.
fan, rear defogger,radiatortan, and air conditioner
are nor operalrng. ldle speedshouldbe:
750 I 50 rpm
450 I 50 rpm 1 0 . T u r n t h e h e a d l i g h t so f f . l d l e t h e e n g i n ef o r o n e
minute with heatertan switch at Hl and air condi-
tioneron, then checkthe idle speed.
ldle speedshouldbe:
810t 50 rpm
l f t h e i d l e s p e e d i s n o t w i t h i n s p e c i f i c a t i o ns, e e
SymptomCharton page11-46. {cont'd)
11-143
ldle ControlSystem
ldle Speed Setting (cont'dl
'98 D16Y5engine (CVTI
6. Removethe cap and turn the idle adjustingscrew
1/2-turnclockwiseor counterclockwise.
Adjustthe idle speedusing a HondaPGM Testerif pos- IDLE
sible.lf not, usethe followingprocedure:
NOTE:
. Leavethe IACvalveconnected.
. B e f o r es e t t l n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g
items:
- The MIL hasnot beenreponedon.
- Sparkplugs
- Air cleaner
- PCVsystem
l. Connecta tachometer.

no load (transmission
in N or E position)until the
radiatorlan comeson, then let it idle.
C h e c kt h e i d l e s p e e d u n d e r n o - l o a dc o n d i t i o n s :
head lights,blower fan, rear defogger,radiatorfan, 1. Afterturningthe idle adjustingscrew'll2-turn,check
and air conditionerare not operating. the idle speedagain.lf it is out of spec,turn the idle
adjustingscrew1/2-turnagain,
ldle speed should be: 700 I 50 rpm
NOTE: Do not turn the idle adlustingscrew more
. lf the idle speed is within the specification,the than 1/2-turnwithoutcheckingthe idle speed.
procedureis complete.
. lf the idle speedis out of specification,
go to step 4. Turn the ignition switch OFF,Reconnectthe EVAP
purge controlsolenoidvalve 2P connector,then do
4. l f t h e i d l e s p e e di s 8 1 0 1 5 0 r p m , t h i s m e a n sr h e the ECMresetprocedure.
EVAPsystem is purging the canister.To stop the
purgingtemporarily,raisethe enginespeed above Stan the engine.ldlethe enginetor one minutewith
1,000rpm with the accelerator pedal.Slowly release heaterfan switch at Hl and air conditioneron. then
the pedal,and recheckthe idle speed. checkthe idlespeed.
. lf the idle speed is within the specification,the
procedureis complete. ldl6 speed should be:
. lf the idle speedis out of specification, go to step5. 810 1 50 rpm (in @ or @ position)
Disconnectthe EVAPpurge control solenoidvalve l f t h e i d l e s p e e d i s n o t w i t h i n s p e c i t i c a t i o ns, e e

2P connector. SymptomCharton page 1l-46.
SOLENOIDVALVE
1 1-1 4 4
Fuel Supply System
FuelLines
NOTE:Checkfuel systemlines,hoses,tuel filter,and other componentsfor damage,leaksand deterioration,
and replace
if necessarv.
22 N..n
12.2kgl.m, 16lbt.ftl
lD16Y5engin€:28N m
2.8 kgl m, 21 lbf.fil
(conr'd)
11-145
FuelSupplySystem
FuelLines(cont'd)
NOTE:Checkall hoseclampsand retightenif necessary.
FUELTUBE/
OUICKCONNECT
FUEL
PUMP
PRESSUBE
NEGULATOR
FUEL
TANK
s\s\s\s\t\
Replace.
Clampin the middle
Clamp in the middle
1 0 - 1 6m m
10.39- 0.63 inl
11-1 4 6
)
Fittings
FuelTube/Ouick-Connect
Plecautions Disconnection
@ Do not smok€ while working on the fu€l @ Do not smoke while working on the luel
systom. Kosp open tlamsg away from your work area. systgm. Keepopen tlames away from your work aroa.
The fuel tube/quick-connect fittings assemblyconnects 1. R e l i e v feu e lp r e s s u r (es e ep a g e s1 1 - 1 5 01,5 1 ) .

the in-tankfuel pump with the fuelfeed pipe.For remov-
ing or installingthe fuel pump and fuel tank, it is neces- 2. Checkthe tuel quick-connectfittings for dirt, and
sary to disconnector connectthe quick-connect fittings. cleanif necessary.
Payattentionto tollowing:
3. Hold rhe connectorwith one hand and pressdown
. The fuel tube/quick-connect fittings assemblyis not the retainertabs with the other hand,then pull the
h e a t - r e s i s t a nbt ;e c a r e f u ln o t t o d a m a g ei t d u r i n g connectoroff.
weldingor other heat-generating procedures.
NOTE:
o The fuel tube/quick-connect fittings assemblyis not o Be carefulnot to damagethe pipe or other parts,
acid-proof;do not touch it with a shop towel which Do not usetools.
was used for wiping batteryelectrolwe.Replacethe . lf the connectordoes not move,keepthe retainer
tuel tube/quick-connect fittings assemblyil it came tabs presseddown, and alternatelypull and push
into contactwith electroiyteor somethingsimilar. the connectoruntil it comesoff easilv.
. Do not removethe retainerfrom the pipe; once
. W h e n c o n n e c t i n go r d i s c o n n e c t i n gt h e f u e l t u b e / removed,the retainermust be replacedwith a
q u i c k - c o n n e cf it t t i n g s a s s e m b l y ,b e c a r e f u ln o t t o new one.
bendor twist it excessively. Replaceit if damaged.
LOCKINGPAWL
A disconnected quick-connectfittingcan be reconnected,
but the retaineron the mating pipe cannot be reused RETAIiIERTAA
once it has been removed from the pipe. Replacethe
retainerwhen
! Replacing the fuel pump.
. Replacingthe tuel feed pipe.
. lt hasbeenremovedfrom the Dioe. CONNECTOR
. lt is damsged. Pressdown.
ACCESS PANEL
Checkthe contactareaof the pipe for dirt and dam-

age.
. lf the surfaceis dirty,cleanit.
. lf the surface is rusty or damaged,replacethe
fuel pump or fuel feed pipe.
PIPE
(cont'd)
11-147
FuelSupplySystem
Fittings(cont'dl
FuelTube/Ouick-Connect
5. To prevent damage and keep out toreign matter, Connection
c o v e r t h e d i s c o n n e c t e dc o n n e c t o ra n d p i p e e n d
with plasticbags. @ Do not smoke while working on the fuel
systom. Keepopen flames away lrom your work ars!.
1. Checkthe pipe contact area for dirt and damage.

and cleanif necessary.
CONTACTAREA
PLASTICBAGS
Insert a new retainer into the connector if the retainer

is damaged, or after
. replacing the fuel pump.
. replacing the fuelfeed pipe.
. removing the retainer from the pipe.
NGw RETAINER
(lnsertinto
the connector.)
11 -1 4 8
Beforeconnectinga new {uel tube/quick-connectfitting 4. Make sure the connection is secure and the pawls
assembly,removethe old retainerfrom the matingpipe. are firmly lockedinto place;checkvisuallyand by
pullingthe connector.
With the
tabs pulled
apan,romove
and discardthe
retainer
RETAIiIER
Reconnectthe bafterynegativecable.and turn the

New FUELIUBE/
i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l r u n f o r
OUICK4ONNECT a b o u t t w o s e c o n d s .a n d f u e l p r e s s u r ew i l l r i s e .
FTTTINGASSEMALY Repeattwo or three times, and checkthat there is
no leakagein the tuel supplysysten..
3. Align the quick-connect fittings with the pipe, and
align the retainerlockingpawls with the connector
grooves.Then pressthe quick-connect fittingsonto
the pipe until both retainerpawls lock with a click-
i n gs o u n d .
NOTE:lf it is hard to connect,put a small amount

of new engineoil on the pipe end.
Connectionwith new reiainer:
I
11-149
FuelSupplySystem
SystemDescription
The fuel supply system consistsof a fuel tank, in-tank Inspeqtion
high pressurefuel pump, PGM-Flmain relay,fuel filter,
fuel pressureregulator.fuel injectors,and fuel delivery 1. Relievefuel pressure.
a n d r e t u r nl i n e s .T h i s s y s t e md e l i v e r sp r e s s u r e - r e g u -
latedfuel to the fuel injectorsand cuts the fuel delivery Removethe servicebolt on the fuel filterwhile hold-
w h e nt h e e n g i n ei s n o t r u n n i n g . ing the banjo bolt with anotherwrench.Attachthe
specialtool.
FuelPressure('96model)
Relieving FUEL
PNESSURE
Beforedisconnectingfuel pipes or hoses,releasepres- GAUGE
sure from the system by looseningthe 6 mm service 07405 - 0040001
bolt on top of the tuel filter.
FUELPRESSURE
. Do not smoke while working on the fuel system, AoAPTER,6x15mm
Keep open flames or sparks away lrom your work 07(}6 - 00{0304
area.
. Be suie to relieve fuel pressurewhile the ignition
switch is off,
'1. Write down the frequenciesfor the radio's preset
buttons.
2. Disconnectthe batterynegativecablefrom the bat- NEGULATOB
tery negativeterminal.
3 . R e m o v et h e f u e l f i l lc a p .
4. Use a box end wrenchon the 6 mm servicebolt at Startthe engine.Measurethe fuel pressurewith the
t h e f u e l f i l t e rw h i l e h o l d i n gt h e s p e c i a b
l a n j ob o l t engineidling and the vacuumhoseof the fuel pres-
with anotherwrench. sure regulatordisconnected from the fuel pressure
5. Placea rag or shoptoweloverthe 6 mm servicebolt. regulatorand pinched.lf the engine will not start,
6. Slowly loosenthe 6 mm servicebolt one complete turn the ignition switch ON (ll), wait for two sec-
turn. onds, turn it off, then back on again and read the
fuel pressure,
Pressureshould bs:
260 - 310 kPa (2.7- 3.2 kgif/cm',38 - 46 psil
4. Reconnectvacuumhoseto the fuel pressureregulator.
Pressureshould b€:
200 - 250 kPa l2-0-2.5kgllcm2,28 - 36 psil
lf the fuel pressureis not as specitied,first checkthe

fuel pump (seepage 11-'156). It the fuel pump is OK.
checkthe following:
l f t h e l u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d ,
o A fuel pressuregaugecanbe attachedat the 6 mm inspectfor:
- Pinchedor cloggedfuel returnhoseor line.
servicebolt hole.
- Faultyfuel pressureregulator(seepage 1l-'lg).
. Alwavs reolacethe washer betweenthe service
bolt and the specialbanjo bolt wheneverthe ser- lf the fuel pressureis lowerthan specified, inspect
vice bolt is loosened. for:
- Cloggedfuelfilter.
. R e p l a c ea l l w a s h e r s w h e n e v e r t h e b o l t s a r e
- Faultyfuel pressureregulato.(seepage11-154).
removed.
- Fuelline leakage.
11 - 1 5 0
FuelPressure('97and later modelsl
R€lioving Inspec'tior
Betoredisconnecting fuel pipes or hoses,releasepres-
s u r e f r o m t h e s y s t e mb y l o o s e n i n gt h e 1 2 m m b a n j o l Relievetuel pressure.
bolt on toD of the fuel filter.
2. Removethe 12 mm banio bolt from the fuel filter
w h i l e h o l d i n gt h e f u e l f i l t e r w i t h a n o t h e rw r e n c h .
Do noi smok€ while working on tho tuel system, Attach the specialtools.
Keep open flames or sparks away from your work
area.
Bo surs to relieve tuel pressurewhile the ignition
switch is oft.
1. Write down the frequenciesfor the radio's preset FUELPRESSURE

buttons, ADAPTERBOLT,12 mm
tgflDE - PD6- 0101
Disconnect the batterynegativecablefrom the bat-
tery negativeterminal.
Removethe iuel fill cap.
4. Use a box end wrench on the 12 mm banjo bolt at

the fuel filter while holdingthe fuel filter wirh anoth-
er wrencn. REGULAIOA
Placea rag or shoptowel overthe 12 mm banjobolt. Stan the engine.Measurethe fuel pressurewith the
engineidling and the vacuum hoseof the fuel pres-
Slowfy foosenthe 12 mm banjo bolt one complete sure regulator disconnectedfrom the fuel pressu.e
IUIN. regulatorand pinched,It the enginewill not start,
12 mm EANJO turn the ignition switch ON (ll), wait for two sec-
BOLT onds, turn it off, then back on again and read the
fuel pressure.
Pressursshould be:
260 - 310 kPa (2.7- 3.2 kgf/cm,, 38 - '15psil
4. Reconnectvacuumhoseto the fuel pressureregulator.
Pressureshould bo:
200 - 250 kPa (2.0- 2.5 kgf/cm,, 28 - 35 psi)
lf the fuel pressureis not as specified,tirst checkthe

fuel pump (seepage 1'1-156).lf rhe fuel pump is OK,
N O T E :R e p l a c ea l l t h e w a s h e r sw h e n e v e rt h e 1 2 checkthe following:
mm banjo bolt is loosenedor removed.
. l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d ,
inspectfor:
- Pinchedor cloggedfuel returnhoseor line.
- Faulty fuel pressureregulator(see page 11-
1541.
. lf the fuel pressureis lowerthan specified.inspect
for:
- Cloggedtuelfilter.
- Faultyfuel pressureregulator(see page 11-
154).
- Fuelline leakage.
11-151
FuelSupplySystem
Fuellnjectors
Replacement
!@ Do not smoke when working on the luel system. Keep open flames away lrom your wotk alea.
1, Relievethe fuel pressure(seepages11-150,151),

2. Disconnect the connectorsfrom the fuel iniectors(D16Y7engine:Removethe air cleaner).
3. Disconnect the vacuumhosesfrom the fuel pressureregulator.Placea shop towel overthe fuel returnhose,then dis-
connectit from the fuel pressureregulator,Disconnectthe vacuum hosesand 2P connectorfrom the EVAPpurge
controlsolenoidvalve(D16Y5,D16Y8engine).
4. Removethe retainernuts on the fuel rail.
5. Disconnect the fuel rail.
6. Removethe fuel iniectorsfrom the intakemanifold.
D15Y5,D16Y8engine: D16Y7engine:
NOTE:lllustrationshowsD16Y8engine.
D 1 6 Y 5e n g i n ei s s i m i l a r .
12 N.m
11.2kgf.m,
8.7 tbf.ft)
'r2N.m
11.2kg{.m,
8.7tbtfr)
O.RING
ffi ffi
O-RING
Replace. ffi ffi Replace.
g E
CUSHION CUSHION
V
g
RING V E
V Y Replace. Replace.
EVAP Y
PURGECONTROL
SOLENOID
VALVE SEAL
SEAL RING
Replace.
RING
Replace.
7. Slidenew cushionringsonto the fuel injectors.

8. Coatnew O-ringswith cleanengineoil, and put them on the fuel injectors.
9. Insertthe fuel injectorsinto the fuel railfirst.
10. Coatnewsealringswith cleanengineoil, and pressthem intothe intakemanifold.
11 -1 5 2
11. To preventdamageto the O-rings,installthe tuel injectorsin the fuel rail first, then installthem in the intakemani-
fo ld.
't2. Installand tightenthe retainernuts.
1 3 . Connectthe vacuum hosesand fuel return hoseto the fuel pressureregulator.Connectthe vacuum hosesand 2P
connectorto the EVAPpurgecontrolsolenoidvalve(D16Y5,D16Y8engine).
1 4 . Installtheconnectorson the fuel injectors(D16Y7engine:Installthe air cleaner),
Turn the ignitionswitchON (ll),but do not operatethe starter.Afterthe fuel pump runsfor approximately two seconds,
the fuel pressurein the tuel line rises.Repeatthis two or threetimes,thencheckwhetherthereis anyfuel leakage.
11 - 1 5 3
FuelSupplySystem
FuelPressureRegulator
Testing Replacement
!@ Do not smoke during the test. Keep open @ Do not smoke while working on fuel sys-
tlamesaway lrom your work area. tem. Keepopsn llame away from your work area.
1. Attachthe specialtool(s)to the servicepon on the 1. Placea shoptowel underthe fuel pressureregulator,
f u e lf i l t e r( s e ep a g e s1 1 ' 1 5 01, 5 1 ) . then relievefuel pressure(seepages11-150,
151).
Pressureshould be: 2, the vacuumhoseand fuel returnhose.

Disconnect
260 - 310 kPa {2.7- 3.2 kgf/cm', 38 - 46 psi}
{with the fuel pressureregulator vacuum hose 3. Removethe two 6 mm retainerbolts and the fuel
disconnectedand pinched) pressureregulator.
CLAMP
FUEL
PRESSURE
TOR
FUELPRESSURE
REGULATOR
12 N.m
(1.2kg{.m,
8.7 tbtft)
2. R e c o n n e ctth e v a c u u mh o s e t o t h e f u e l p r e s s u r e
regulator. Replace.
3. Checkthat the fuel pressureriseswhen the vacuum

hosefrom the fuel pressureregulatoris disconnected
a g aIn .
l f t h e f u e l p r e s s u r ed i d n o t r i s e . r e p l a c et h e f u e l
pressureregulalor.
Apply cleanengineoil to a new O-ring,and carefully

installit into its properposition.
I n s t a l lt h e f u e l p r e s s u r er e g u l a t o ri n t h e r e v e r s e
orderof removal,
11-1 5 4
Fuel Filter
RoplEcement ,96 MODEL:
r!@
Do not smoke while working on fuel systsm. K6op
12 mm
BAt{JO
open fbme away from your work area. AOLT
While roplacing th€ tusl filtar, be careful to keop a 33 N.m
{3.4 kg{.m,
safo distance betwssn battGry tgrminals and any 25 rbf.ftl
tools.
T h e f u e l f i l t e r s h o u l d b e r e p l a c e dw h e n e v e rt h e f u e l
pressuredrops belowthe specifiedvalue 1260- 310 kPa
12,7- 3.2 kgtlcm,,38 - 46 psi)with the fuel pressurereg-
u l a t o rv a c u u m h o s e d i s c o n n e c t e ad n d p i n c h e d la f t e r
making sure that the tuel pump and the fuel pressure
regulatorare OK,
' 1 . Place
a shop towel underand aroundthe fuel filter.
Relievefuel pressure{seepages11-150,151).
9.8 N.m
R e m o v et h e 1 2 m m b a n j o b o l t a n d t h e t u e l f e e d .0 lg{ m,
pipetrom the fuel filter,while supponingit with the 7.2rbt.ftt
anotherwrench.as shown, (3.8ksf.m,
27 tbf.ftl
Removethe tuel filter clampand fuel filter.
I n s t a l l t h e n e w f u e l f i l t e r i n t h e r e v e r s eo r d e r ,97 AND LATERMODELS:

removal,and notetheseitems:
. When assembling.use new washersas shown.
. C l e a nt h e f l a r e d j o i n t o t h i g h p r e s s u r eh o s e s 12mm
thoroughlybeforereconnecting them. BANJO
BOLT
33 N.m
(3.4*gf.m,
25 tbf.ftl
N.m
ll.0 kg(.rn,
37 N.m 1.2 tbt.trl
13,8kgt m,
27 tbtftl
11 - 1 5 5
FuelSupplySystem
FuelPump
Testing R€olacement
Do not smoke during the test. Keep oPen !!@ Do not smoke while wotking on luel 3Y3-
@
tlame away trom you. work atea. tem, Koopopen tlam€s away from your work area.
lf you suspecta problemwith the fuel pump, checkthat the 1. Removethe seatcushion(seesection20).
fuel pump actuallyruns;when it is ON (ll),you will hear
somenoiseif Vouholdyour earto the fuelfill portwith the 2. Removethe accesspanelfrom the floor.
fuel fill cap removed,The fuel pump should run for two
secondswhen ignitionswitchis first turnedON (ll).lf the ACCESSPANEL
fuel pump does not make noise,checkit as follows:
1. Removethe seatcushion(seesection20).
2. Removethe accesspanelfrom the floor.
3. Make sure the ignition switch is OFF,then discon-

nectlhe fuel tank2P connector.
4. Connectthe PGM-Flmain relay7P connectortermi-

nal No. 4 and No. 5 with a jumperwire. 5.9N-m
10.6kgt m.
{.3 tbr.ftl
PGM-FIMAINRELAY7PCONNECTOR
{C,a,|3)
\,
FUELPUMP IGN 1
{YEL/ (YEL/GRNI
GRNI
JUMPERWIRE
Wiresideof temaletorminals
Checkthat batteryvoltageis availablebetweenthe

fuel pump connectorterminalNo. 1 and body ground
whenthe ignitionswitchis turnedON (ll).
CONNECTOR
{c56sl
tr:
I
FUELPUMP
(YEL/GRNI
I l----r
El d, 3. the 2Pconnectorfrom the tuei pump.
Disconnect
Y Wire side of
female terminals 4. Removethe tuel pump mountingnuts.
Removethe fuel pump from the fuel tank,
checkthe tuel pump

lf batteryvoltageis available, Installpartsin the reverseorderof removal.
ground.lf the groundis OK,replacethe fuel pump.
lf there is no voltage.checkthe wire harness(see
p a g e1 ' l - 1 5 8 ) .
L
1 1 - 15 6
PGM-FIMain
Relay
Descliption RelayTesting
The PGM-Flmain relay actuallvcontainstwo individual
relays.This relay is locatedat the right side of the cowl. NOTE:
One relayis energizedwheneverthe ignitionis on which . It the enginestartsandcontinues
to run,the PGM-Fl
suppliesthe batteryvoltageto the ECM/PCM,power to main relayis OK.
the fuel injectors,and power for the secondrelay.The . U s et h e t e r m i n anl u m b e r sb e l o w ;
secondrelayis energizedfor two secondswhen the igni- ignorethe terminalnumbersmoldedinto the relay.
tion is switchedON (ll),and when the engineis running,
'1. Removethe PGM-FImain relay.
to supplypowerto the fuel pump.
2. Attachthe batterypositiveterminalto the No. 2 ter-
minal and the batterynegativeterminalto the No. 1
FGM.FI terminal of the PGM-Flmain relay.Then checkfor
MAITI RELAY continuitybetweenthe No. 5 terminaland No.4 ter-
minalof the PGM-FImain relay.
. lfthere is continuity.go on to step3.
. lf there is no continuity.replacethe PGM-Flmain
relayand retest. No. 2
No.3
No. 1
FUELPUMP No. No.7

N o , 5 No. 6
To lGN. To BAT @
To GROUND
To ECM,/PCM
{A1'1,A24}
To ST. SWITCH
To ECM/PCM(A To FUELPUMP
Attachthe battervDositiveterminalto the No. 5 ter-
minal and the batterynegativeterminalto the No, 3
terminalof the PGM-FImain relay.Then checkthat
there is continuitybetweenthe No, 7 terminaland
No. 6 terminalof the PGM-FImain relav.
. lf thereis continuity,go on to step4.
. lf there is no continuity,replacethe PGM-Fimain
relayand retest.
Attachthe batterypositiveterminalto the No. 6 ter-
minal and the batterynegativeterminalto the No. 1
terminalof the PGM-Flmain relay.Then checkthat
there is continuitybetweenthe No. 5 terminaland
No. 4 terminalof the PGM-Fimain relay.
. lf thereis continuity,the PGM-Flmain relayis OK.
ll the fuel pump still does not work,go to Harness
Testingon the nextpage.
. lf there is nocontinuity,replacethePGM-Flmain
relay and retest. {cont'd)
11-157
FuelSupplySystem
PGM-FIMain Relay(cont'dl
Circuit Troubleshooting
- Engine will not siart.

- Inspection ot PGM-FI main
relay and relay harness,
PGM.FIMAINRELAY7PCONNECTOR
lca,Bl
Check for an open in the wiro
IGNDline):
2. Disconnectthe PGM-FImain
relay7P connector.
3- Checkfor continuitybetween
the PGM-FImain relay7P con'
nectorterminalNo.3 and body
ground.
the PGM-FIm.in relay and G101.
Checkfor an open or short in the

wire (BATlinel:
PGM'Flmain relay 7P connector
terminalNo. 7 and body ground.
- Repair open or short in tho
wire b€tw6€n th6 FGM-FImain
r6lsy and the Fl E/M 115Al
fu3o.
- ReDlecothe Fl E/M l'15Alfus6
in th6 und€r-hood tuso/r.lay
box.
Checkfor an open or short in th6
wir€ (lGl line):
2. Measurethe voltage between
the PGM-Flmain relay7P con-
nectorterminal No.5 and body
ground,
- Ropair open o1 short in thg
wire b€nrvo€nth€ PGM-FImain
r6layand the No. 13 FUEL
ls there battery voltage? PUMP{15A} tusc.
- Roolac€ the No. 13 FUEL
PUMP115A) fus6 in th€ under-
dash fuso/rolay box.
Checklor an open 01 short in the
wi.e {STSline):
1. Turnthe ignitionswitchto the
START(lll) position.
NOTE:
. M/T: Clutch pedal must be sls IBLU/WHTI
depressed. 2 3
. A"lT:Transmissionin E or
a 5 E 7
E position.
2, Measurethe voltage between
t h e P G M - F Im a i n r e l a y 7 P
connectort€rminalNo, 2 and
body ground.
( T op a g e1 1 - 1 5 9 )
11 - 1 5 8
(Frompage11-158| PGM-FIMAIN RELAY7P CONNECTOR
IC'4|II
- Fcprir opono.3hon in tho FLR

wirc baaw6.n the ftiu.Fl main rcRNNEL]
6lry .nd tho No. 31 STARTER
SIGNAL17.5A tuso.
- Roplecotho No. 31 STARTER 2 3
1
SIGNAL {7.5 A} fuse in tho
a 6
undor-dalh fu3o/rclaybox. o
Ch.ck to. an op6n in thG wir. FLR
IFLRlin6l: IGRN/YEL) ECM/PCMCONNECTOR
A t32Pl
2. Oisconnectthe ECM/PCMcon,
nectorA (32P).
I 2 3 5 I ll
the PGM-FImain .elay 7P con- 12 t l t 5 l 6 t 7 ta t 9 20l,/ 22 23 2a
nectorterminalNo, 1 and ECN4/ 2t 21 2A 4 l 3 0 l /
PCMconnectorterminalA16.
Wirosideof lemalelerminals
Raprir op6n in the wire bgtwaen
t h o E C M / P C Ml A 1 6 ) a n d i h 6
PGM-FImain ..lay.
Chack for an open in the wiro3 PGl (BLKI

{lGPl. lGP2line3l:
1. Reconnect the ECM/PCM con- 5 8 9
nectorA (32P).
2. Reconnectthe PGM-Flmain
l2 t 3 t5 t6 1 1 tl t 9 20 22 z tI r l
relay connector. n 2A 4 30
4. Measur€voltage between IGP2
ECM,PCMconnectorterminals IYEL/BLKI
A 1 1 a n d A 1 0 ,a n d b e t w € e n
A24and A10.
R.pair opon in th. wi.e bet-

ls there batteryvoltage? w.€n th. ECM/FCM{A11,A24l
.nd thc PGM-FImain lolay.
R.pleo. tho PGM-FImain relay.
FLR
Ch.ck for sn opon in th. ECM/ IGRN/YEL) PGl IELK}
PCM:
'1. Turn
the ignitionswitchOFF.
2 l s o l r l l e l e lr r 11
2 . M e a s ur e v o l t a g e b e t w e e n
12 I t l a l 5 t6 ta l 9 20 221 23 2a
ECM/PCMconnectorterminals 21 2a 30
A16and A10whenthe ignition
switchis firstturnedON (llltor
two seconds.
Sub.titut. ! known-good ECM/

ls there'1.0V or less? PCM and ..check. lf orcacribod
voltaga ii now rv.il.ble, rcplace
thc origin.l ECM/PCM.
Ch.ck lhe PGM-FI main rel.y

lroo pagc 11.1571.
11 - 1 5 9
FuelSupplySystem
FuelTank
Rsplacement
@ Do not smokewhile working on fuel system.Keepopanflame away from your work aroa.
1. Relievethe fuel pressure(seepages11-150,151).

2. Removethe seatcushion(seesection20).
3. Removethe accesspanelfrom the floor.
4. Disconnectthe 2P (C565)and 3P (C564)connectors(96 D16Ygengine{coupe)'97 Dl6Y7 engine(coupe: KL model,
sedan:KL (LX) model),'97D16Y8engine(coupe:all models,sedan:KL model '98-allmodels):and 6P (C568)connec-
torl.
5. Disconnect the hoseand quick-connect fittings(seepages11-146,147).
6. Jackup the vehicle.and supportit with jackstands.
7. Removethe fuel tank cover('96.'97 model)orthefuel hosejoint protector.
8. Bemovethe drain bolt, and drainthefuel into an approvedcontainer.
9. Disconnect the hoses(seepage 11-146). Slidebackthe clamps,then twist hosesas you pull,to avoiddamagingthem,
10. Placea jack,or othersuppon.underthe tank,
11. Removethestrapnuts,and let the strapsfall free.
12. Removethe fuel tank, lf it stickson the undercoatappliedto its mount.carefully pry it off the mount.
13. Installthe drain bolt with a newwasher,thencoatthedrain bolt with Noxrustl24B,Allowthe Noxrustdryfor20 min-
utes.
14. Installtheremainingpartsin the reverseorderof removal.
BASEGASKET
Replace.
38 N.m
(3.9kgl.m,
28 tbtft) BASEGASKET
Replace.
WASHER
Replace.
TANK
STRAPS
DRAINBOLT
4t N.m {5.0kgl.m, 36 lbf.ttl
11 - 1 6 0
IntakeAir System
SystemDescription
The systemsuppliesair for all engineneeds.lt consistsof the intakeair pipe,Air Cleaner(ACL),intakeair duct,Throttle
Body {TB),ldle Air Control(lAC)Valveand intakemanitold.A resonatorin the intakeair pipe providesadditionalsilencing
as air is drawn into the svstem.
Dl6Y5, Dl6Y8 angine (M/Tl
YEL/ - From PGM-FI

BLK _ MAIN RELAY
VARIOUS
SENSORS
BLK
IROTARYI ENGINE
IACVALVE COOLANT
D15Y5engine{CWl, D16Y8enginelA/T)' lrutne umrrrolo
YEL/ - From PGM-FI

BLK I MAIN RELAY
ORN
D16Y7sngin€: VARIOUS
BLK/
SENSORS
8tu
BLK
(ROTARYI
RESONATOR
IAC VALVE
11 - 1 6 1
lntakeAir System
Air Cleaner(ACLI ThrottleCable
NOTE; Do not cleanthe ACL elementit with com- Inspection/Adiustmont
pressedair (exceptdry type). 1. Startthe engine.Hold the engineat 3,000rpm with
no load(ly'Tin E or @ position,Mff in neutral)until
Dl6Y5,D16Y8engino: the radiatorfan comeson,then let it idle.
2. Checkthat the throttlecableoperatessmoothlywith
ACL ELEMENT no bindingor sticking.Repairas necessary.
Normal conditionsi
Replacgair cleanerelement every
3. Checkcable free play at the throttle linkage.Cable
30,000milos (48,000kml or 24 deflectionshouldbe 10- 12 mm l3/8- 1/2in.l.
months whichovercomes first.
Sova.c conditionr: D16Y5.D16Y8engine:
(Usenormalschedule
except in dusty conditions)
Replaceevery 15,000 CABLE
miles (24,000km) or '12months
whichevercomesfirct.
DEFLECTION
1 0 - 1 2m m
13l8- 112inl
HOUSING
Dl6Y7 engine:
LOCKNUT
Dl6Y7 engine: AIUUSTING
DEFLECNON
10-12mm
B l a - 1 1 2i ^ l
ACL ELEMENT
Normrl condhion3:
Replaceair cleanerelementevery
30,000mil6s(48,000 km) or 24
months whichevercomes first.
Sovorocondhion3:
(Usenormalschedule except
in dustyconditions)
Replace every'15,000
whichever comesllrsl. It de{lection is not within specs, loosen the locknut,

turn the adjustingnut untilthe deflectionis as speci-
fied,then retightenthe locknut.
With the cableproperlyadjusted,checkthe throttle
valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe throt-
tle valve to be sure it returnsto the idle position
L
wheneveryou releasethe accelerator pedal.
11 -1 6 2
lnstallation 4. S e t t h e l o c k n u to n t h e c a b l e b r a c k e t .A d j u s t t h e
adjustingnut so that its free play is 0 mm.
'L Openthe throttlevalvefully.then installthe throttle
, n d i n s t a l lt h e c a b l e
c a b l ei n t h e t h r o t t l el i n k a g e a 5. Removethe cablesheathfrom the throttle bracket,
housingin the cablebracket. resetthe adjustingnut and tightenthe locknut.
D16Y5,D16Y8engine: Dl6Y5,D16Y8engin€:
CABLE LOCKNUT
NUT
ADJUSTING
D16Y7€ngine:
ADJUSTING 9.8 N.m

NUT {1.0kgf.m,
7.2 tbt'ttl

no load(A,/Tin E or E position,M/T in neutral)until
the radiatorfan comeson, then let it idle.
Hold the cablesheath,removingall slackfrom the

caore.
11-163
IntakeAir System
ThrottleBody
Doscription Inspection
The throttlebody is eithera single-barrel side-drafttype
{ D 1 6 Y 5D, 1 6 Y 8e n g i n e )o r a d o w n - d r a f t y p e ( D 1 6 Y 7 1 . C h e c kt h a t t h e t h r q t t l ec a b l e o p e r a t e ss m o o t h l y
engine).The lower portionof the throttlevalve is heated without bindingor sticking.
b y e n g i n e c o o l a n t f r o m t h e c y l i n d e r h e a d .T h e i d l e
adjustingscrewwhich regulatesthe bypassair is locat- It thereare any abnormalities, checkfor:
ed on the top of the throttlebody. . Excessive wear or play in the throftlevalveshaft.
. Stickyor bindingthrottieleverat the fully closed
position.
. Clearancebetweenthrottlestop screwand throt-
tle leverat the fully closedposition.
D16Y5,Dl6YB engine:
THROTTLESTOP SCBEW
{Do not adiust.}
D16Y7 engine:
{Do not adiust.)
Replacethe throttlebody it there is excessiveplay in the

throttlevalveshaftor if the shaftis bindingor sticking.
11-1 6 4
Removal
D16Y5,D16Y8engine:
D15Y7engine:
IAT SENSOR
AIF CTEANEF
IACLI
MAP SENSOB
22Nm
12.2*gl.m,
16tbf.ftt
GASKET
Repl6ce.
THROTTLECAALE
NOTE:
. Do not adjustthe throttlestop screw.
o After reassembly, adjustthe throttlecable(seepage11-162).
. The TP sensoris not removable. (cont'd)
11 - 1 6 5
IntakeAir System
ThrottleBody(cont'dl
Disassembly
Dl6Y5,Dl6Y8 engine: 2.1 N.m

(0.21kgf.m, 1.5 lbf.ftl
MAP SENSOR
page'1167
Troubleshooting,
TP SENSOR
O-RING
IDLEADJUSTING
SCREW
IAC VALVE
3.5N.m 10.35
kgf.m,2.5lbtftl
D16Y7engine:
2.1 N.m MAP

10.21kgf.rn, SENSOR
1.5lbt.ft) p6ge11-67
Troubleshooting,
11 - 1 6 6
EmissionControlSystem
SystemDescription ThreeWayCatalyticConverter
(TWC)
The emissioncontrol system includesa Three Way Cata-
lytic Converter(TWC),ExhaustGas Recirculation {EGR) Description
system*, PositiveCrankcaseVentilation(PCV)system and The Three Way CatalyticConverter(TWC) is used to
Evaporative Emission{EVAP)Controlsystem.The emis- conven hydrocarbons(HC),carbonmonoxide(CO),and
sion control system is designedto meet federaland state oxides of nitrogen(NOx) in the exhaustgas to carbon
emissionstandards. dioxide(CO?), dinitrogen(Nr)and watervapor.
*: D16Y5engine
Dl6Y5, Dl6Y7 engine:
ENGINESIDE
TailpipeEmission
Inspection
E@ Do not smoke during this procodure.Ke€p

any open flam€ away from your work area.
1. Stan the engine.Hold the engineat 3,000rpm with

no load (Ay'Tin E or E position,N4/Tin neulral)until
the radiatorfan comeson. then let it idle.
Connecta tachometer.
D16Y8engine:
Checkand, if necessary.adjustthe idle speed (see
p a g el l - 1 4 1 ) .
HOUSING
Warm up and calibratethe CO meteraccordingto the
metermanufacturer's instructions.
Checkidle CO with the headlights.heater blower,

rearwindow defogger,coolingfan,and air condition-
er off.
N O T E :( C a n a d aP
) u l l t h e p a r k i n gb r a k el e v e r u p .
Stan the engine,then checkthat the headlightsare
off.
CO metershouldindicate0.1%maximum.
NOTE:'98 D16Y5engine- lf the idle speedincreas-

es to 810 f 50 rpm, this meansthe EVAPsystemis
purgingthe c8nister.To stop the purgingtemporari-
ly. raisethe enginespeedabove 1.000rpm with the
accelerator pedal.then slowly releasethe pedal.
(cont'd)
11-167
ThreeWayCatalyticConverter(TWC)(cont'dl
TroubleCode(DTC)PO42O:
] P0420 I tne scantool indicatesDiagnostic Catalystsystemefficiencybelowthreshold.
Description
This systemevaluatesthe catalyst'scapacityby meansof the HO2S(Primaryand Secondary) outputduringstabledriving
conditions.lf deterioration
has beendetectedduringtwo consecutive
drivingcycles,the MIL comeson and DTCP0420will
be stored.
NOTE:lf some of the DTCSlistedbelow are storedat the same time as DTCP0420,troubleshootthose DTCSfirst, then
troubleshootDTCP0420.
P0137,P0138:SecondaryHO2S(Sensor2)
P0141:SecondaryH02S (Sensor2) Heater
PossibleCause
. TWC Deterioration
. Exhaustsystemleakage
- The MIL hes beenreoortedon.

- DTC P0420b stored.
Problgmverfficationi
1. Do the ECM/PCMResetProce'
dure.
load (A/Tin E or E position,
tor fan comeson.
nector.
4 . T e s t - d r i v e4 0 - 5 5 m p h f o r
a p p r o x .t w o m i n u t e s .T h e n
deceleratefor at least 3 sec
o n d s w i t h t h e t h r o t t l ec o m
pletely closed. Then reduce
the vehiclespeedto 35 mph,
and try to hold it until the
readiness codecomeson,
Intelmitlent trilure, ayrlom ia OK

at thi3 timc.
Ch.ck the TWC {seesection9}.

lf nocessary,roplacethe TWC.
1 1 - 16 8
{EGR)System(Dl6Y5enginel
ExhaustGasRecirculation
Description
The EGRsystemis designedto reduceoxidesot nitrogenemissions{NOx)by recirculating exhaustgasthroughthe EGR

valveand the intakemanifoldinto the combustionchambers.lt is composedof the EGRvalve,EGRvacuumcontrolvalve,
EGRcontrolsolenoidvalve,ECMand varioussensors.
The ECMcontainsmemoriesfor ideal EGRvalve litts for varyingoperatingconditions.The EGRvalve lift sensordetects
the amountof EGRvalvelift and sendsthe intormationto the ECM.The ECMthen comparesit with the idealEGRvalvelift
which is determinedby signalssentfrom the other sensors,lf there is any differencebetweenthe two, the ECMcuts cur-
rent to the EGRcontrolsolenoidvalveto reducevacuumaooliedto the EGRvalve.
EGRCONTROL
cVT. SOLENOIO VALVE
BLK
4
EGRVALVELIFTSENSOR
BLK
1-16 9
(EGR)System(D16Y5engine){cont'dl
The scantool indicatesDiagnosticTroubleCode(DTC)P0401:Insufficient
flow in the ExhaustGasRecirculation
(EGR)svstem.
DescriDtion
Deterioration(clogging,leakage,etc.)in the EGRline or EGRvalve is detectedby meansof the changesin MAP before
and afterthe operationof the EGRvalve.
It deteriorationhas been detectedduring two consecutivedriving cycles,the MIL will come on and DTCPO4O1
will be
stored.
PossibleCauses
. Clogging,leakagein the EGRline
. FaultyEGRvalve
- The MIL has been.eoortadon.

- DTC P0401b stored.
Problomveriticetion:
nector,
3. Testdriveunderthe following
conditions.
- Withoutany electdcalload
- D e c e l e r a t fer o m 5 5 m p h
{88 km/h)for at least 5 sec
onds
Intermittont tlilure, sy3tcm is OK

at thb time.
Cledn th6 intake mrnifold EGR

port with calburetor deana..
Clean the passag€inside the
EGR valve with carburetor
cleanerot toplac€the velve.
11-170
The scantool indicatesDiagnosticTroubleCode (DTC)P1491:A malfunctionin the ExhaustGas Recirculation
(EGR)system.
CvT (M/T seepao€ 11-174):
- Tha MIL h'3 boan.eDortedon.

- DTCP1,191is sto.od.
Probl.m verificstion:
2. Conn€ctthe SCS servicecon-
nector.
3 . S t a r t t h e e n g i n e .H o l d ! h e
engineat 3,000rpm with no
load (transmissionin E] or E
position) until the radiator fan
comeson.
4. Drivethe vehicleon the road
for approx. 10 minutes.Try to
keepthe enginespeedin the
'1,70O - 2,500rpm range.
Intermittgnt failure, systom is OK

at thb tirno. Checktor Door con-
ngctions or looaa wire3 at, C144
{EGRvrlvol and ECM,
YES
Ch.ck tor vacuum to the EGR
1. DsconnecttheNo.16hosetrom
th€ EGRvalve.
2 . C o n n e c ta v a c u u m p u m p /
gaugeto the hose.
3. Stanthe engineand let it idle.
EGRVALVE
LIFTSENSOR #16 HOSE
Ch.ck tor a mrlfunction in tho

EGRcomrcl lolonoid v.lv.: l T o p a g e1 1 - 1 7 2 )
1 . D i s c o n n o ctth e E G Rc o n t r o l
solenoidvalve2Pconnector.
2. R€checkthe No. 16 hose for
PUMP/GAUGE,0-30in.Hg
A973X-fi1 -XXXXX
Check vacuum hose .outing ot

ls there6ny vacuum? the entirs EGR 3y3tom. lf hose
routing is OK, .eplsce the EGR
control solenoidvrlve.
VALVE
Subrtitute a known-good ECM
.nd r€check.lf lymptom/indica-
tion goar aw.y, r.placa th6 oJigi-
nll ECM.
(cont'd)
11-171
ExhaustGasRecirculation(EGR)System(D16Y5engineGWI (cont'dl
( F r o mp a g e1 1 - 1 7 1 )
#16HOSE
,w;
VACUUM
- 30in.Hg
PUMP/GAUGE,0
A973X-041-XXXXX
*nj-
Check tor a malfunction in the
EGRvalve:
1. Movethe vacuumpump/gauge
to the EGRvalve.
2. With the engineat ;dle,apply
26.7kPa{200mmHg,8.0 in.Hg)
ofvacuumto theEGRvalve.
Doesthe enginestallor run

roughand doesthe EGRvalve
hold vacuum?
\
Checkthe vacuum routing:
1. Reconnect tho vacuumpump/ EGRCONTROLSOLENOIOVALVE
gaugeto the No. 16 hose.
2P CONNECTOR
2. Startthe engineand let it idte.
3 . A t t h e E G Rc o n t r o ls o l e n o i d
valve side, connectthe baftery
positiveterminal to the EGR
control solenoidvalve connec-
torterminalNo,1, li;El
4 . W h i l ew a t c h i n gt h e v a c u u m
g au g e , c o n n e c tt h e b a t t e r y
negativeterminalto the EGF
controlsolenoidvalve2P con-
E
lo el
nectorterminal No.2.
Terminalsideol
maleterminals
ls thereapprox.26.7kPa(200
mmHg,8.0 in.Hg)of vacuum
whhin l second?
Checkthe vacuum ho3€a:
1. Turnthe jgnitionswitchOFF.
2 . I n s p e ct th e N o . 1 6 a n d N o .1 0
hosestor leaks,restrictionsor
mrsrout|ng.
\
(Topage11-173)
11-172
( F r o mp a g e1 1 1 7 2 )
EGRCONTROLSOLENOID
VALVE2P CONNECTOR
{Cl42I
Checkfor an open in the wire {E Wire side

ESOL
SOLlinel: of female
terminals IFEDI
from the EGRcontrolsolenoid
ECM
3. Disconnect the ECMconnector CONNECTOR
ESOL
A (32P)Iromthe ECM. A t32Pl IREDI
E C M c o n n e c t o tr e r m a n a4l 7
and the EGRcontrolsolenoid
v a l v e2 P c o n n e c t otre r m i n a l
No.2.
Wire side
oI female
Repeirop6n in lhe wire b€'twe€n terminals
the EGR control 3olenoid valv6
and the ECM lA?).
Ch€ck tor a short in the wir€

(ESOLline):
Checklor continuitybetweenthe
EGRcontrolsolenoidvalve2P con
nectorterminal No. 2 and body
ground,
Repril short in th€ wi.e betwcen

th€ EGR control solenoid valve
and the ECMlA7l.
Check for an op6n in the wire

(GND linel:
Check {or continuity between the
EGR control solenoid valve 2P con
'1
nector terminal No. and body
ground,
GND
{8LKI
Bopair open in the wir€ betwoen
tho EGR control sol€noidvalve
and G101.
Substitute e known-good ECM

and recheck. lf symptom/indica-
tion goes away, replacethe origi-
nalECM.
(cont'd)
1 1-173
SystemlD16Y5enginel(cont'd)
M/T:
- The MIL has be€nroportodon,

- OTCPl{)l is stor€d.
Probl6mvorification:
nector.
enganeat 3,000rpm with no
load (transmission in neutral)
untilthe radiatorfan comeson.
4. Drive the vehiclo on the road
for approx. 10 minutes.Try to
keepthe enginespeedin the
1,700- 2,500rpm rang€,
EGRVA|V: 6PCOI{NECTOR
lC14,a)
Intermittont frilur., ry3tem i! OK
l s D T C P 1 4 9 1i n d i c a t e d ? at this timo. Checktor poor con- 1 2 3
n.c{ion3 or looa6 wiros at Clil4
IEGRvllve) lnd ECM. 1 6
G101 PNK
Check tor r mallunction in the IBLKI IE.EGNI
EGRvalve:
L Startthe engineand let it idle.
2. Measurevoltage between th6 Wire side of mal€ torminals
EGRvalve 6P connectortermi
nal No. 4 and No. 6.
rr-
EGRVALVE 5P CONNECTOR
Chockthe EGRv.lv.:
2. Disconnectthe EGRvalv6 6P
connector.
3. Connectthe battery positive
terminalto EGRvalve6P con'
Sub3titute r known-good ECM nectorterminalNo,6.
and rcch.ck. lf symplom/indica- 4. Stan the engineand let it idle,
tion goe3.wey, replaceth€ origi- then conn6ctlh€ battery nega-
nal ECM. tive terminalto EGRvalve 6P
connectorterminal No. 4.
Wire side of fem.lo terminrls
( T op a g e1 1 - 1 7 5 )
11-174
(Frompage11-174)
EGRVALVE
6PCONNECTOR
tcla,al
1 2
I E.EGF
a
Chockfor an op6n in the wire {E -
IorurrWire side
EGRlinel: of lemale
2. Disconnectthe ECMconnector
A (32Plfromthe ECM.
E C M c o n n e c t o tr e r m i n a l4 7
t32Pl
2 3 a
_j E-EGR
IPNKI
8
tsrminals
't0 11
and the EGRvalve6P connec- 12 1 3 1 4 t 5 t6 1 7 1 8 1 9 20 22 23 21
tor terminalNo.6.
25 21 n a 30
Wire side
Repairopon in tho wir6 betwcon of female
tho EGRvalvc and tho ECM lA7l. terminals
Chock lor rn opgn in tho wir6

IGNDlinol:
Checklor continuity betveen the
EGRvalve6P connectorterminal
No.4 and body ground. 1 2 3
Repsir op€n in the wir€ b€twe€n {
ls therecontinuity? th. EGR control 3ol€noid v.lve
and G101. I G101
0) ter-xt
Subrtituta r known-good ECM
.nd rcchock. lt 3ymptom/indica-
lion go.3 away, .apl.ca tha origi-
nd ECM.
(cont'd)
1 - 175
System(D16Y5engine){cont'dl
The scan tool indicatesDiagnosticTrouble Code (DTC)P'1498:A high volrage problem in the ExhaustGas
(EGR)valvelift sensorcircuit.
Recirculation
- The MIL has boen reportedon.

- DTCP14)8 is sto.ed.
Problemvs.iticstionl
1. Do the ECMBesetProcedure.
2. Startthe engine.
lntermitt€fi failuro. 3y3tem i3 OK

at thL tim.. Chcck to. ooor con-
noctions o. loo3. wire3 at Cl/14
IEGRvalv.l and ECM.
Check tor an op6n in the EGR

valve lift sonso.: EGRVALVELIFTSENSOR3P lM/T: SPlCONNECTOR
{Ct14l
1. Turnthe ignitionswitchOFF. cw:
2. Disconnectthe EGRvalve lift
sensor3P {M/T:6P)connector. vcc2
4, Measurevoltage between the
IYEL/BLUI
EGRvalve lift seosor 3P (M/T:
6P)connectorterminalsNo. 3
a n dN o . 2 . SG2IGRN/BLKI
ls thereapprox,5 V?
sG2 vcc2
(GRN/ (YEL/
BLK} ALUI
Chock tor opcn in the wire lSG2
linel;
connector terminalsD10and D11.
Wiro side of female teaminals

Ropairopon in th. wirg bctwoon
ls thereapprox.5 V? ECM(D11)and EGRvalv.litt.cn-
sor.
€cM CoNNECTOR
O tl6Pl
and recheck. ll symptom/indica-
tion goe3away, replac€the origi-
nal ECM.
vcc2 sG2
(YEL/BLUI (GRN/BLKI
Wire side of female te.minals
11-176
Ventilation(PCV)System
PositiveCrankcase
D€scription Inspgqtion
T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s y s t e m i s 1. Checkthe PCVhosesand connectionsfor leaksand

designedto preventblow-by gas trom escapingto the clogging.
atmosphere.The PCV valve contains a spring-loaded At idle,makesurethere is a clickingsoundfrom the
plunger.When the enginestarts,the plungerin the PCV PCVvalve when the hose betweenPCVvalve and
valve is lifted in proportionto intakemanifoldvacuum intakemanifoldin lightly pinchedwith your fingers
and the blow-by gas is drawn directly into the intake or olters.
manifold.
D16Y5,D16Y8ongine:
O16Y5,D16Y8engine:
Gentlypinchhere.
PCVVALVE
D16Y7engine:
D16Y7engine:
Gently pinch here.
:: ELOW-BYVAPOR
e: FRESHAIR
VALVE
l f t h e r e i s n o c l i c k i n gs o u n d ,c h e c kt h e P C Vv a l v e
grommetfor cracksand damage.lf the grommet is
OK,replacethe PCVvalveand recheck.
11-177
EmissionGontrolSystem
EvaporativeEmission(EVAP)Controls
Dsscripiion
The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The
systemconsistsof the followingcomponents:
A. EvaporativeEmission (EVAP)Control Canister

An EVAPcontrolcanisteris usedtor the temporarystorageof luel vapor until the fuel vapor can be purgedfrom the
EVAPcontrolcanisterinto the engineand burned.
B. Vapor PurgeContfol System

EVAPcontrolcanisterpurgingis accomplished by dr6wingfreshair throughthe EVAPcontrolcanisterand into a pon
on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve.
EVAPPURGECONTROL
SOLENOID VALVEDUTYCON.
TROLLED
AFTERSTARTINGENGINE
I ' 9 6O 1 6 Y 5e n g i n e , ' 9 6D 1 6 Y 7e n g i n e , ' 9 6D 1 6 Y 8 '97 D16Y7

l ' 9 6 D 1 6 Y 8e n g i n e ( c o u p e ) , engine
e n g i n e( s e d a n ) , ' 9 D7 1 6 Y 5e n g i n e , ' 9 7D ' 1 6 Y 7 ( c o u p e :K L m o d e l ,s e d a n :K L ( L X ) m o d e l ) , ' 9 7
engine (coupe:KA, KC models,sedan: KA, KC, D16Y8engine(coupe:all models.sedan:KL model,
K L ( D X ) m o d e l s ,h a t c h b a c ka: l l m o d e l s ) , ' 9 7 '98-allmodelsll
D16Y8engine(sedan:KA, KCmodels)l
ENGIN€COOLANTTEMPERATURE
ABOVE154'F(68"C) ENGINECOOLANTTEMPERATURE ABOVE154"FI68"C)
INTAKEAIRTEMPERATURE ABOVE32"F(O'C)
ano
VEHICLESPEEDABOVE0 MILE(0 km/h) \
or
A./CCOMPRESSOR
CLUTCHON
and
ABOVE160"F(41"C}
INTAKEAIRTEMPERATURE
C. FuelTank Vapor Control System

Whenfuel vapor pressurein the fuel tank is higherthan the set valueof the EVAPtwo way valve,the valveopensand
regulatesthe flow of fuel vaporto the EVAPcontrolcanister.
11-178
'96 D16Y8
engine lcoupe), '97 D16Y8 engine {coupe: all models, sedan:KL model). '98 Dt6Y5 engine (all models}, '98
D16Y8engine(allmodelsl:
From
9:I' No. 15
ALTERNATOR
EVAPPURGE
r
SP SENSOR
CONTROL (7.sa)
FUEL SOLENOIDVALVE
TANK 7'
PRESSURE YEL/
SENSOR BLU
tLl THREE €VAPCONTROL . LT GRN
\ VENT SHUT VAI . GRN/
VAL BLK
EVAP
BYPASS
SOLENOID BLU
VALVE
LT GRN/
WHT
EVAP RED/
TWOWAY YEL
VALVE
BLK
FUELTANK
INTAKE
MANIFOLD
'97 Dl6Y7 engine
{coupe:KL model, sedsn: KL ILX) mod6l},'98 D16Y7engine:
From
9ii '-< No. 15

ALTERNATOR
YEL/ SP SENSOR
BLU t7.5Al
LT G'
FUEL GRN/
TANK BLK
PRESSURE
SENSOR
BLU
LT GRN/
WHT
EVAP
RED/
BYPASS
YEL
SOLENOID
VALVE BLK
EVAPCONTROL
EVAP CANISTER
TWOWAY
VALVE FUELFILL
CAP
FUELTANK
(cont'd)
11-179
EvaporativeEmissionControls(cont'dl
'96 D16YSengine,'96 D16Y8engine '97 '97
lsedanl, D16Y5engine, D16YBenginelsedan:KA, KC models):
EVAP
PURGE
EVAP CONIROL
TWO WAY sot_ENotD
VALVE VALVE
MANIFOLD \
'96 D16Y7engine,'97 D16Y7engine (coupe:KA, KC mod6ls, sedan: KA, KC, KL IDX) models, hatchback:all models):
From
No. 15
----- { ALTERNAToR
i:1"
EVAP SP SENSOR
PURGE
CONTROL
SOLENOID
VALVE
VARIOUS
SENSORS
BLK
J-
\,*ro..
MANIFOLD
11 - 1 8 0
FuelTank PressureSenso. I'96 D16Y8engine {coupe),'97D16Y7€ngine (coupe:KL mod6l, sedan:KL (LXl modet),'97
D16Y8engins(coupe:allmodels,sodan:KL model,'98-allmodels)l:
The scan tool indicates Diagnoslic Trouble Code (DTCI P0452:A low voltage problem in the Fuel Tank Pressure
sensor.
The fuel tank pressuresensorconvertsluel tank absolutepressureinto electricalsignalsand inputsthe ECM/PCM.
OUTPUT
VOLTAGE
tv)
4.5
Th6 MIL has b€en .eported on.

DTC P0452 b stored,
0.5
Ch€ckthe vacuurnlinos: -7 kPr +t kP8
C h e c kt h e v a c u u ml i n e s o f t h e (-50 mmHg, (50 mmHg,
fueltankpressuresensorfor mis- -2 in.Hgl 2 in.Hgl
r o u t i n g ,l e a k a g eb, r e a k a g ea n d
clogging. PRESSURE
Are the vacuumlinesOK?
ECM/PCMCONNECTOR
D Il6PI
Problemvorilication:
1. Do the ECM/PCM ResetProce'
dure.
2. Removethe fuel fill cap.
4. Monitorthe FTPSensorvolt-
a g e w i t h t h e H o n d aP G M
T e s t e r ,o r m e a s u r ev o l t a g e PTANK
b e t w e e nb o d y g r o u n d a n d Intermittent tailur6,systom is OK {LTGRN'
ECM/PCM terminalD15. at thb time. Checktor ooor con-
nections or loose wire3 at C131 Wiro side ol temale terminals
{locatedunder right sid6 of dashl,
ls thereapprox.2.5V? C401 (located above unde.-daah
tuse/relay boxJ. C568 llocatod FUELTANK
under acce3s prnel), C792 (tuel PRESSUBESENSOB
tank pre33uresonsorl and ECM/ 3P CONNECTOR
tC792)
Chockfor an opon in wire {VCC2 FCM.
linel:
2. Reinstall the fuelfill cap. vcc2
(YEL/BLU)
3. Disconnect the fuel tank pres-
suresensor3P connector.
5, Measurevoltage between the
fuel tank pressuresensor3P
connectorNo, 1 terminaland
No.2 terminal.
Wire sideof femalet€rminals
Repairopen in the wire belween
ls thereapprox.5V? tho tueltank pre3sur6sen3o.and (cont'd)
the ECM/PCMlD10l.
YES
(Topage11-182)
11 - 1 8 1
EmissionControl System
EvaporativeEmissionControls(cont'dl \
{ F r o mp a g e1 1 - 1 8 1 }
FUELTANK
PRESSURESENSOR
3P CONNECTOR{C7921
C h e c kt o r a s h o r t i n t h e w i r e PTANK
(LTGRN)
IPTANKline):
fueltank pressuresensor3P con-
nectorNo. 3 terminaland No. 2
rermtnat,
sG2
{GRN/BLK)
ls thereapprox.5 V? Wire sideof femaleterminals
Check for a Short in the wire

(PTANKline):
2. Disconnect the ECM/PCM con
nectorD (16P).
the fuel tank pressuresensor
3P connectorNo. 3 terminals
and body ground.
ReoairShort in the wire between

the fueltank oressurcsensorand
ECM/PCMtD15).
Sub3titut6 a known-good ECM/

PCM and recheck.ll symptom/
orisinal ECM/PCM.
11-1 8 2
FuelTank PressureSensorf96 D16Y8ongine {coups),'97D15Y7ongins lcoupe:KL model, sedan:KL (LX} model},,97
D16Y8enginelcoupe:all models,s6dan:KL model,'98.allmodelsll:
The scantool indicatesDiagnosticTroubleCode(DTC)P0453:A high voltageproblemin the FuelTankPressure

sensor.
Th6 MIL has beenroportodon.

OTCP(X53 is stored.
Chackthc vacuum lines:

C h e c kt h e v a c u u m l i n e s o f t h e
fuel tank pressuresensorfor mis-
routing, leakage,breakageand
cloggrng.
Are the vacuumlinesOK?

ECM/PCM CONNECTORD (T6P}
Problcmverificetion:
dure,
2. Removethe fuelfill cap.
4. Monitor the FTPSensorvolt, PTANK
age with the HondaPGM ILTGRNI
T e s t e r ,o r m 6 a s u r ev o l t a g e
b e t w e e nb o d y g r o u n d a n d Intermittont tailu.e, sy3tem b OK Wiresidsof f6malsterminals
ECM/PCM terminal015. at this tim6. Chcck to. poor con-
noctions or loo.g wiros at C131
{locatodunder right side ol d.!h}, FUELTANK
ls thereapprox.2.5V? C401 llocrtod abovo und.r-dash
PRESSUAE
SENSOR
tuse/rolay boxl, C56Ellocatod
undor accossD6ncl),C792 (fuel
3PCONNECTOR
tC792)
tank prossurc s6n3or) and ECM/
Chock for rn opon in the wire FCM.
lSG2linol: vcc2
1. Turnthe ignitionswitchOFF. (YEL/3LUI
2. Reinstallthe fuelfill cap.
3. Disconnect the fuel tank pres-
suresensor3P connector,
sG2
5, Measurevoltagebetweenthe
fuel tank pressuresensor3P
IGRN/BLKI
connectorterminals No. 1 and Wir6 side of temale terminals
No.2.
Repai. op€n in thc wirc botwc€n

ls thereapprox.5V? the tuel tank pa633ure36nsorend
ECM/PCM(D111.
Check tor an open in the wiro

(PTANKlinal:
fuel tank pressuresensor3P con-
nector No. 3 terminaland No. 2 1 2 3
termanal. sG2 PTANK
IGRN/BLKI IGRN/NEDI
ls thereapprox.5 V?
(To page11-184) (cont'd)
11 - 1 8 3
EvaporativeEmissionControls(cont'd) \
(Frompage11 183)
D (16PI
ECM/PCMCONNECTOR
{PTANKline}:
P C M c o n n e c t o rt e r m i n a l sD 1 5
a n d0 1 1 .
PTANK SG2IGRN/BLK)
Rcp.ir open in th6 wir6 betweon ILT GRNI
ls thereapprox.5V? E C M / P C M{ D 1 5 )a n d f u e l t a n k
pt033utesensol. Wire side of fsmal€ terminals
Sub3litute a known-good ECM/

PCM .nd rech€ck.lf symptom/
indicationgoes away, replaceth6
originalECM/PCM.
11-1 8 4
['96 Dl6Y8 engine(coupe],'97Dl6Y7 sngine{coupe:KL model,sedan:KL {LX}modeU.'97Dl6Y8 engine(coupe:alt mod-
els, sedan:KL model, '98-all modolsll:
scantool indicatesDiagnosticTroubleCode(DTC)P1456:EvaporativeEmission(EVAP)conlrolsystemteak
tPEs6l The
detected(fuel tank system).
(DTCIP1457:Evaporative
tPl45?-lThe scantool indicatesDiagnosticTroubleCode
detected(EVAPcontrolcanistersystem).
Emission(EVAp)controlsystemreaK
PossibloCauso
. Fuelfill cao
. VacuumConnections
. FuelTank
. EVAPControlCanisterVentShutValve
. EVAPControlCanisterVentShutValveCircuit
o EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPBypassSolenoidValve
. EVAPBvDassSolenoidValveCircuit
. FuelTankPressureSensor
. FuelTankPressureSensorCircuit
. EVAPControlCanister VACUUM
. Throttle Body PUMP/GAUGE,0-30in.Hg
4973X- 041-
Troubl€shootingFlowchart
xxxxx
EVAP
- CONTROL
Th. MIL has bo.n reDoned CANISTER
- VENT
DTCP1456or P1457i. storcd. SHUT
VALVE
Ch6ck the EVAP control c.nbtet
v.nt lhut valva: O.RING
1. Disconnectthe vacuum hose Replace.
from the EVAPthree way
valve and connecta vacuum
pumpto the hose.
2 . R € m o v e t h e E V A Pc o n t r o l
canistervent shut valvelrom
the canister.
3. Turnthe ignitionswitchON (ll). Chock tor a short in the wiro
4. Applyvacuumto tho hose. {VSV linol:
Disconnectthe 2P connectorfrom
the EVAPcontrol canister vent
Doesthe valve hold vacuum?
Rop.ir 3hort in the wirc betw€en
Doesthe valve hold vacuum? lh6 EVAP control caniste. v€nt
Check tho EVAP control crnialc. shut valvo and the EcM/PcM
vont 3hut valvo: la29l.
ECM/PCMCONNECTOR
A I32P)
2. ConnectECM/PCMconnector Roplrce the EVAP control cani.-
terminal429 to body ground tcr vont rhut valvo, I 2 a 7 a 9 to ll
with a jumperwire.
12 t 3 t5 t3 t t r8 t 3 20 2 23 2a
4. Applyvacuumto the hose. 6 21 a 4t 30
{LT GRN/WHTI I JUMPERWIRE

Doesthe valv€hold vacuum?
Wiresideof lemaleterminals
(cont'd)
{To page11-186) (To page 1l-186)
11 - 1 8 5
EmissionGontrolSystem
EvaporativeEmissionControls(cont'dl
(Frompage11-185) (Frompage'1'l-185)
EVAPCONTROL
CANISTER
VENTSHUT
VALVE2PCONNECTOR
{Cl41I
Check lor an op.n in th. wi.e

(lG1linel: tGl
1. Turnthe ignitionswitchOFF. IBLK/YEL)
from the EVAPcontrolcanis-
ter v0nt shutvalv€.
3. Turnthe ignitionswitchON (ll). Wire side of f€male torminal6
4. Measurevoltage betwe€n the
EVAPcontrolcanistervent shut
valve 2P connectorterminal
No.2 and bodyground.
Rcpair opon in tha wirc batwoon
tho EVAP control crnirtor vont
lhut vdw rnd tho No. 15 ALTER-
NATORSP SENSOR{7.5Al tu!..
Ch.d( ior an op.n in tho wirr IVSV ECrir/FcM@NNECTOfiA {32P1

lin l:
1. Turnthe ignitionswitchOFF. PGl (BLK)
2. Roconnectthe 2P connector
to the EVAPcontrol canister I -J-
'|
vent shutvalve.
2
12 l 3 t5
I ' l ' l I' l r l r l r o I r r I
rrlrrlllll @ l / l z l a l u l
4 , M e a s u r ev o l t a g e b e t w e e n
E C M / P C Mc o n n € c t o rt 6 r m i
a ,JAA_]{
nalsA29and A10.
vsv (LTGRN^Vlff)
Wiro sid€ ot lomsle
t6rminals
Rapairop6n in thc wh6 batwaan

iho EVAP control caniatar vant
shut vrlvo end th. ECM/PCM
tA29t.
Raolaccth6 EVAP cont.ol canis-

ter vant rhut valva.
Ch6cktho vacuumwhan cold:

1. Disconnectth€ vacuum hos6
shown from the EVAPcontrol
canrsterand connecta vacuum
gaugeto the hose.
2. Stan the engineand allow it VACUUM
to idle. PUII'P/
GAUGE,0 - 30in.Hg
N O T E :E n g i n ec o o l a n tt e m -
peraturemust bo below 154"F A973X-
(68'C)or Iy'Cswitch OFF. 041- xxxxx
3. Ouicklyraisethe engine spegd
to 3.000rpm.
(Topage11-187)
1 1 - 18 6
(Frompage11-186)
Ch.ck the EVAP purge control
robnoid velvol
from the EVAPpurge control
solonoidvalve.
2. Orricklyraisethe enginespeed
to 3,000rpm.
Inspectv.cuum hoaerouting.
lf OK, replaco lho EVAP purge
contrcl solonoidvalve.
Chcck tor a short in the wir. EVAPPURGECONTROLSOI:NOID

VALVE2P OONNECTOR
lC11,al
{PCSlincl:
Chacktha vrcuum whcn hoti 1. Turnthe ignitionswitchOFF.
1. Turnthe ignitionswitchOFF. 2. DisconnectECM/PCMconnec-
2. Block the rear wheels and set tor A 132P).
the parkingbrak€. 3. Check for continuity botween
3. Jack up tho front ot the vehi- the EVAPpurge controlsole' Wiro side ot
cle and support it with salety noid valve 2P connectortermi- temale
slands. nal No. 2 and body ground. t€rmrna|s
4 . S t a r t t h e 6 n g i n e .H o l d t h e
engin€ at 3,000rpm with no Repairshort in the wira bgtween
loed {A/r in E or E position, the EVAP purga control solonoid
WT in neutral)untilthe radiator valvo and rhe EcM/PcM lA15l.
lan comeson, then let it idle.
5. Ch6cktor vacuum at the vac'
uum hos6 with lransmission Sub3titut. a known-good EGM/
in ge6r {A/T in B position, PCM lnd r.ch.ck. lf symptom,/
M/T in 1st gear) after starling indication eoo3 away, raplacc th.
the €ngine. o.iginrl ECM/FCM.
6. Ouicklyraisotho ongine sp66d
to 3,000rpm.
Chock th6 EVAP purg. control
.olonoid valvoi PCS
l. Turnthe ignitionswitchOFF. {RED/YELI
from the EVAPpurgo control
solenoid valve and worm it
up to normal operatingtom
peratureagain it necessary.
3. Startthe engine.
4. At the ha.nessside. moasure
v o l t a g e b e t w e e nt h e E V A P
purgo control solenoidvalve
2P connectorterminsl No. 1
a n dN o . 2 .
Intp€ct vacuum hoa! routing.

ls there batteryvohage? It OK, roplace EVAP purg6 con-
trol solonoidv6lvo.
Chcck for an opcn in th6 wire

llcl linoll
At the harnossside.measurcvolt- tGl
ago b€twoenthe EVAPpurge con- IBLK/YEL}
trol solenoidvalve 2P connector
terminal No. 1 and body ground.
Ropai. open in the wiro lrotwean
EVAPpurga control 3olcnoid valv.
ANdthC NO. 15 ALTERNATORSP
SENSOR{7.5Al fu36.
(cont'd)
{Topage11-188) (To page11-188|
11-187
EvaporativeEmissionControls{cont'd} |5
( F r o mp a g e ' 1 1 ' 1 8 7 ) (Frompage11 187)
A {32P)
ECM/PCMCONNECTOR
PGI
{BLKI

{PCSline}:
2. Reconnect the 2Pconnectorto
the EVAPpurge controlsole_
noidvalve.
4, Measurevoltage between PCS
{RED/YELI wire sid€ ot
ECM/PCMconnectorterminals
female
A 1 5a n dA 1 0 .
!ermrnatS
Repairopen in the wire botween

th6 EVAP purga cont.ol solenoid
v.lve and the EcM/PcM lA15l.
EVAP TWO WAY
Subrtitute a known.good ECM/

PCMand ratest. It symptom/indi-
cation goe3 away, replace the
original ECM/PcM.
Checkthe EVAPtwo way valvsl

See EVAPtwo way valve test (see
p a g e1 1 ' 1 9 3 1 . PUMP/
GAUGE.0-30 in.Hg
4973X- EVAPBYPASS
Repl.c€the EVAPtwo way v.lve. 041- SOLENOIDVALVE
xxxxx
Checkthe EVAP bypa$ solenoid
1, Disconnectthe vacuum hose

from the EVAPtwo way valve
and connecta vacuumpump
to the hose.
U
2. Turnthe ignitionswhchON (lli.
3. Applyvacuumto the hose. Check tor a short in the wi.€ O.RING
I2WBSline): Replace.
Disconnect lrom
the 2P connector
Doesthe valvehold vacuum? the EVAPbypasssolenoidvalve. EVAPTWOWAYVALVE
Rooair3hort in tho wirc botween

Does the valve hold vacuum? EVAP bypass 3ol.noid valve and
rhe EcM/PcM {A281.
l T o p a g 61 1 - 1 8 9 1
\
11-188
(Frompage11-188)
Checkthe EVAP bypasssolenoid ECM/PCMCONNECTOR

A I32PI
terminalA28and bodyground 5 I I lo
'12 t 3 r5 t 6 It tl 1 9 2A 23 2a
with a iumperwire.
3. T!rn the ignitionswitchON (ll). Check for an opon in tha wire 25 27 2A 29 3 0
llGl linel:
2, Disconnectthe 2P connector 2WBS Wire sid€ of
from the EVAPbypass sole IBLUI femal6
Does valve hold vacuum? terminals
JUMPER
3. Turnthe ignitionswitchON (ll). WIRE
EVAP bypasssolenoidvalve
2 P c o n n e c t otre r m i n a lN o . 1 EVAPBYPASSSOLENOID
and body ground. VALVE2P CONNECTOR
{C79i}l
tG1 Wire sido of

(BLK/WHTI
lemale
terminals
Ropai. open in the wirc botwoon

EVAPpurg6 control solonoid valve
snd the No. 15 ALTERNATORSP
SENSOR17.5A) tu36.
A (32PI
ECM/PCMCONNECTON
PGl (BLK}
{2WBSlin6l:
2. Reconnectthe 2P connector = -J--
to the EVAPbypasssolenoid l r l l . l e l r oI i r I
12 l 3 t6 1a 1 1 tt tolal.lal za l yl
3. Turnthe ignitionswitchON (ll). 6 21 a
4, Measurevoltage between
ECM/PCMconnectorterminals 2WBSIBLUI
A28andA10.
wirs side of female
l6fmrn6ls
Check the following part3 lor
l e a k a g e t o a t m o s p h e r e .a n d
repair or rcplaceit necessary: Ropai. opon in the wiro between
' tucl till c.p ls there batteryvoltage? tha EVAP byp.33 3olenoid valv.
. luel tank .nd tho ECM/PCM lA28|,
. tuel vapor pipe
. EVAPtwo wav vslve
. EVAPbypasssolenoidvalve
. Iuel tank pressuresensoa
. EVAPcontrol cenkter
. EVAPcontrol canistcr vant
shut valve
. EVAP pu196 control solenoid
. vacuum hososand connoctions
(cont'd)
11 - 1 8 9
EvaporativeEmissionControls{cont'd} \
'96 Dl6Y5 engine,'96Dl6Y7 engine,'96Dl6Y8 engine
{sedan},'97Dl6Y5 engine,'97D16Y7enginelcoupe:KA, KC mod-
els, sedan: KA, KC, KL (DX)models, hatchback:all models),'97 Dl6Y8 €ngine (sedan:l(A, KC models):
- The scan tool indicatesDiagnosticTrouble Code (DTC)P0441:EvaporativeEmission(EVAP)control system
I P0441 | ;n"r11;";.ntouroeftow.
Description
By monitoringthe purge line vacuum with the MAP sensor,the ECM/PCMcan detectinsufficientEVAPcontrol system
purgeflow.
PossibleCause
. EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPControlCanister
. V a c u u mL i n e s
. ECM/PCM
- Tho MIL has b6onreportedon,

- DTCP(X4t is stored.
Problsmve.itication:
enganeat 3,000rpm with no
load (A,/Tin N or E poskion,
M/T in neutral)untilthe radia'
tor tan comeson.
2. Do the ECM/PCMResetProce-
oure,
nector.
4. Test-driveunderfollowingcon-
ditionson the road.
- Withoutany eloctricalload
- A/T in $ or E position
(M/Tin 3rd-5thgear)
- Engine speed between
1,200- 2,400rpm.
- Decelerate from 50 mph (80
km,4')to 15 mph 124km/h)
Intorrnittenttailu.e, 3wtem i3 OK EVAPPURGECONTROL
at thi3 timo. Chock for poor con- SOLENOIOVALVE2P
ls oTC P0441indicated? n€ctions or 10036wir$ at C144 CoNNECTORtctla)
(EVAP purge control solenoid
valve)andECM/PCM.
r+_r
' l ' l
Ch€ck for an op€n in the wir€ (lcl
linell
1. Turnthe ignitionswitchOFF. lrci oixrv..r
2 . D i s c o n n e ctth e E V A Pp u r g e rv)
nector,
Y
3. Turn the ignitionswitchON {ll).
4. Measurevoltagebetweenbodv wir6 side of lemslo
g r o u n da n d t h e E V A Pp u r g e terminals
control solenoidvalve 2P con-
nectorterminal No. 1.
Ropair open in th€ wiEs botwoon
the EVAP purgo control rolenoid
valve and th. No. 15 ALTERNA.
TORSP SENSOF17.5Al fuse.
{ T op a g eI 1 - 1 9 1 )
1 1 - 19 0
{ F r o mp a g e1 1 - 1 9 0 } D (32PI
ECM/PCMCONNECTOR
PG1IALK)
Chock tho EVAP purge control

30lenoidvalv6:
'1.Reconnec
t h e E V A Pp u r g e
controlsolenoidvalve2P con
nector.
2. ConnectECM/PCI,connector
terminalsA'15and A10 with a JUMPERWRE
Wire sideoI tomaleterminals
Does the solenoid valve click

Chockfol rn op6n or 3hort in th6
wirc IPCSlin6l:
when the jumper is connected?
PCMconnectorterminalA15 and PCS{RED/YELI
bodyground.
Ch6ckfor a shon in the wire IFCS

ls therebaneryvoltage? lin€):
nectorA {32P).
3 . D i s c o n n e ctth e E V A Pp u r g e
nector.
t body ground and ECM/PCM

connectorterminalA15,
ReD.ir 3hort in the wire! bdtween

the EVAP purge control 3olgnoid ls therecontinuity?
vtlve .nd ECM/PCM(415).
Ropair opon in the wires bstwson

Chocktho vacuum lines:
the EVAP purge control solenoid
Checkthe vacuumlinesof EVAP
valveand ECM/PCM{Al5}.
systemIor misrouting,leakage.
breakageand clogging.
Ar€ the vacuumlinesOK?
I 2 6 I E 9 10 ll
12 l 3 'l'a t 5 l 6 1 7 I E t 9 20 23 21
25 27 26 A 30
O) Pcs {RED/YEL}
t (cont'd)
{To page11-192)
11 - 1 9 1
EvaporativeEmissionControls(cont'd)
l F r o mp a g e1 1 - 1 9 1 )
D16Y5engine: D15Y7,D16Y8€ngine
Check the EVAP purge control

solenoidvalve:
1. Disconnectthe vacuum hose VACUUM
from the EVAPcontrolcanister. VACUUM
PUMPI PUMP/
2. Connectthe vacuumpump to GAUGE,
the hoseandapplyvacuum. GAUGE,
0-30 in.Hg 0 - 30 in.Hg
4973X - A973X- 041 -
041 - xxxxx
xxxxx
Doesit holdvacuum?
EVAPCONTROL
CANISTER
Checkthe EVAPcontrol canister: ECM/PCMCONNECTOR

D I32P}
1, Reconnect the vacuumhoseto
the EVAPcontrolcanister. PG1IBLKI
2, Connectthe vacuum/pressure
9augeto the purgeair hose.
terminals415 and 410 with a
4. Start the engine.

5. Checkthe vacuum.
JUMPERWIRE
D16Y7,Dl6YBengine:
Check the EVAP two way valve

lseepage11 193).
0oesthe EVAPtwo way valve

Replacethe EVAPtwo way valve.
D16Y5engine:
VACUUM/
PRESSURE
GAUGE0- 4 in.Hg
Substitute a known-good ECM/ 07JAZ- 0010008
PCM and recheck.lf svmptom/
original ECM/PCM.
VACUUM/PRESSURE
GAUGE
0 - il in.Hg
07JAZ- 0010004
11-192
EvaporativeEmission(EVAP)Two Way ValveTesting f96 D16Y5engine,'96D16Y7engine,'96D16Y8engine
I'96 Dl6Y8 engine{coupel,'97Dl6Y7 engine(coupe:KL (sedanl,'97D16Y5engine.'97D16Y7engine(coupe:KA.
model,sedan:KL (LX)model),'97 D16Y8engine{coupe: KC models,sedan:KA, KC, KL (DX) models.hatchback:
all models,sedan:KL model,'98-allmodelsll: all modelsl,'97D16Y8engine(sedan:KA. KC models)l:
1 . R e m o v et h e f u e lf i l l c a p .
1. R e m o v et h e f u e lf i l l c a p .
2. R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
valve, and connectit to a T fitting from a vacuum 2. R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
g a u g ea n d a v a c u u mp u m pa s s h o w n . valve on the fuel tank, and connectit to a T-fitting
f r o m a v a c u u mg a u g ea n d a v a c u u mp u m p a s
VACUUM/PRESSURE
GAUGE VACUUM/
0 - 4 in.Hg PFESSURE GAUGE,
07JAZ- 0010008 0 -4 in.Hg
o?JAZ- 0010008
VACUUM
PUMP/GAUGE,
0 - 30 in.Hg
A973X-041-XXXXX
T.F|rTING
T-FITTING
3. Applyvacuumslowlyand continuouslywhile watch- 3. A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l yw h i l e
ing the gauge.The vacuumshouldstabilizemomen- w a t c h i n gt h e g a u g e .T h e v a c u u ms h o u l ds t a b i l i z e
t a r i l ya t 0 . 8- 2 . 1k P a( 6- 1 6m m H g ,0 . 2 0 . 6i n . H g ) . m o m e n t a r i layt 0 . 7 2 . 0k P a( 5 - 1 5 m m H g , 0 . 2- 0 . 6
l f t h e v a c u u m s t a b i l i z e s( v a l v eo p e n s l b e l o w i n .H g) .
0 . 8 k P a ( 5 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k P a l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w
( 1 6m m H g , 0 . 6i n . H g )i,n s t a lal n e wv a l v ea n d r e t e s t . 0 . 7 k P a ( 5 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 0 k P a
( ' 1 5m m H g ,0 . 6i n . H g )i,n s t a lal n e wv a l v ea n d r e t e s t .
4. Move the vacuumpump hosefrom the vacuumfit-
ting to the pressurefitting, and move the vacuum 4. Move the vacuum pump hose from the vacuumfit-
gauge hose from the vacuum side to the pressure ting to the pressurefitting, and move the vacuum
sideas shown. gauge hose from the vacuum side to the pressure
side as shown. f-E-
i
5. Slowly pressurize the vapor line while watchingthe

Slowly pressurize the vapor line while watchingthe gauge.The pressureshouldstabilizeat 1.3- 4.7 kPa
gauge.The pressureshouldbe stabilizemomentari- ( 0 - 3 5 m m H g ,0 . 4 1 . 4i n . H g ) .
l y a b o v e 1 . 0k P a( 8 m m H g , 0 . 3i n . H g ) . . l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e sl v a l v e
'1.4
. l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e o p e n s )a t 1 . 3- 4 . 7 k P a( 1 0- 3 5 m m H g ,0 . 4
o p e n s )a b o v e 1 . 0 k P a ( 8 m m H g , 0 . 3i n . H g ) t, h e in. Hg),the valveis OK.
valveis OK. . ll the pressurestabiljzes below 1.3kPa(10 mmHg,
. lf the pressurestabilizesbelow 1.0kPa(8 mmHg, 0.4 in.Hg)or above4.7 kPa(35 mmHg, 1.4in.Hg),
0.3 in.Hg),installa new valveand retest. installa new valveand retest.
11 - 1 9 3
Transaxle
Clutch 12-1
M a n u aTl r a n s m i s s i o" .n' . . . . . ' . . . " " " " ' 1 3 - 1
AutomaticTransmission ...'..."""""' 14-1
D i f f e r e n t i a .l . . . . 15-1
Driveshafts 16-1
I
Clutch
S p e c i aTf o o l s . . . . . . . . "".--- 12-2

flfustrated Index ........ ."' 12-3
clutch Pedal
Adjustment ..."""'.-"" 12'4
Clutch Master Cylinder
Removal/lnstallation
Slave Cylinder
'." 12-5
"" 12-6
#
PressurePlate
Removal/lnspection -'." 12-7
Clutch Disc
Removal/lnspection .'." 12-8
Flywheel
Inspection ' 12-9
R e p l a c e m e n. .t . . . .". . . . . ." . . . . ' . . . . . .".. 12 - 9
Clutch Disc, PressurePlate
Installation ...".....'.'...1 . 2-10
ReleaseBearing
Removal/lnspection ..." 12-11
lnstallation 12-12
rf,'
l l ,
)
SpecialTools
Ret. No. I Tool Number D€scliption Oty I P89e Reference

o
l
OTJAF_PM70 11
A Clutch AlignmentDisc 1 't2-7
OTJAF_PM7O124 Clutch AlignmentShaft 1 12-7A , , 1 0 ,1 1
/6 OTLAB- PVOO1OOor Ring Gear Holder 1 12-7S , , 1 0 ,1 1
o7924-PD20003
@ 07746-0010100 Attachment, 32 x 35 mm 1 12-10
,A 07749-O010000 Driver 1 12-10
@ 07936-3710100 Handle 1 1 2 - 7, 8 , 1 0 , 1 1
12-2
lllustratedIndex
NOTE:
a Wheneverthe transmissionis removed,clean and greasethe releasebearingslidingsurface.
a It the parts markedwith an asterisk(*) are removed,the clutch hydraulicsystem must be bled (see page 12-6).
a Inspectthe hosesfor damage,leaks,interlerence,and twisting.
/6t-^
@ *REsERvorR
r
@
ASSTST
t=/
ov g*______-__=
Fn \ ,,'
*CLUTCHLIN€
15 N.m {1.5kgl.m,
W.*ra
11 tbt.Ir)
TCLUTCHLINE
19 N.m ll.9 kgl'm,
14 rbt.ttl
PEDALPIN
'CLUTCH MASTERCYLINOER
'12
Removal/lnstallation,
Page 5
\F fl
CLUTCH PEDAL
Adjustment,page 12-4
I x ' 1 . 2 5m m
\ 25 N.m (2.6 kgf.m,
19 tbf.fi)
RELEASEBEARING
Removal/lnspection, page 12-11 FLYWHEEL
lnstallation,page 12'1 2 page12'9
Inspection,
CLUTCH DISC
Removal/lnspection, page 12_8
Installation,page 12-10
1 2 x 1 . Om m
118 N.m {12.0 kgf.m, 86.8 lbf.tt}
PRESSUREPLATE
Removal/lnspection, page 12 7
Installation,page 12-10
6 x 1.0mm
9.8 N.m (1.0kgf,m,
7.2 lbt.Ir)
8 x 1.25mm
22 N.rn 12.2 kgf.m, 16 lbl.ttl
*SLAVE CYLINDER
page 12-6
*CLUTCHLINE
15 N.m {1.5kgl.m.11 lbf.{r)
12-3
Clutch Pedal
Adjustment
NOTE: 5. Turn the clutchswitch {or adjustingbolt) in an addi-
a To check the clutch interlock switch and clutch tional 3/4 to 1 full turn.
switch, see section 23.
a The clutch is sell-adjusting
to compensatefor wear. 6. Tighten locknut A.
CAUTION: ll thefe is no clearance between the 7. Loosenlocknut B on the clutch interlockswitch.

master cylinder piston and push rod, the leleaso
bearingis held against the diaphragm spring, which 8. Measurethe clearancebetweenthe floor boardand
can resultin clutch slippageor other clutch problems, clutch pedal with the clutch pedallully depressed.
'1. '15-20 mm (O.59
Loosenlocknut A, and back off the clutch switch 9 . R e l e a s teh e c l u t c hp e d a l 0.79
(or adjustingbolt) until it no longertouchesthe clutch in) from the tully depressedpositionand hold it there.
oedal. Adjustthe positionof the clutchinterlockswitch so
that the enginewill startwith the clutchpedalin this
2. Loosenlocknut C, and turn the push rod in or out postuon.
to get the specifiedstroke(@)and height(O) at the
clutch pedal. '10.
Threadthe clutch interlockswitch an additionalin
3/4 to 1 full turn.
3. Tighten locknut C.
1 1 . T i g h t e nl o c k n u tB .
4. Threadin the clutch switch (or adjustingbolt) until
it contacts the clutch pedal
assjyear.lc
-@{
{P/N LOCKNUT 8
9.8 N.m (1.0 kgt.m,7.2 lbf.ttl
PUSH ROO
CLUTCH MASTER CYLINDER INTERLOCKSWITCH
CLUTCH SWITCH
{or ADJUSTING BOLTI
LOCKNUTA
9.8 N.m (1.0 kgf.m, 7.2 lbl.lt|
LOCKNUTC
1 8 N . m ( 1 . 8 k g f . m ,1 3 l b l . f t )
@ (STROKE a t P E D A L )1: 3 0 - 1 4 0 m m 1 5 . 1 2 - 5 . 5 1 i n )
€) {fOrll Clufcx PEDALFREEPLAYI:12-21 mm 1o.47-0.83 in) includethe pedalplay 1-1o mm {0.o4-0.39 in)
ao |CLUTCHPEDALHEIGHT):165 mm (6.50 in) to the flool
o) {CLUTCHPEDALDISENGAGEMENT HEIGHT):83 mm 13.27 in) minimumto the floor
12-4
Clutch Master Cylinder
CAUTION: 4. Removethe clutch mastercylinder.
a Do not spill brake fluid on the vehicle;it may damage
the paint; if brake fluid does contact the paini, wash
it off immodiately with water.
a Plugthe end ot the clutch line and reservoirhose with
a shop towelto pleventbrakefluid from comingout.
1. The brake fluid can be removed from the clutch

mastercylinderreservoirwith a syringe.
2. Disconnectthe clutch line and reservoirhose from

the clutch master cylinder.
CLUTCHLINE
1 9 N . m( 1 . 9 k g t ' m ,
14 tbI.ft)
CLUTCHMASTERCYLINDER
5 . Installthe clutch mastercylinderin the reverseor-

derof removal.
NOTE: Bleed the clutch hydraulic system {see

(. page12-6).
3 . Pry out the cotter pin, and pull the pedalpin out of
the yoke. Removethe nuts.
NUTS
8 x 1 . 2 5m m
13 N.m (1.3 kgf.m, 9.4 lbf,ftl
12-5
Slave Cylinder
CAUTION: 3. Install the slave cylinder in the reverseorder ol
a Do not spill brake fluid on th€ vohiclo; it may damagc removat.
the paint; it brake fluid doos contact tho paint. wash
it ott immsdiatoly whh water. NOTE: Make surethe boot is installedon lhe slave
a Plug the end of the clutch line with a shop towel to cylander.
prevent brake tluid from coming out. CLUTCHLINE
15 N.m (1.5 kgf.m,1'l lbt.ttl
-.El: S u p e r H i g h T e m p U r e a G r e a s e { P iN
08798 9002).
-=-t"*'.]:].:Brake Assembly Lube or equivalentrubber SLAVECYLINDER
grease.
'1. Disconnect
the clutch line lrom the slavecylinder.
-C.
(P/N 08798 -9002)
8 x 1.25mm
22 N.m 12.2 k9l.n,
16 tbf'ttt
.:;?L.
-=-s!!rqil
(BrakeAssembly
Lubel
Bleedthe clutch hydraulicsystem.
a Attach a hoseto the bleederscrew, and suspend

the hose in a containerof brake fluid.
a Make surethere is an adequatesupplyof fluid ar
the clutchmastercylinder,then slowly pumpthe
clutch pedaluntil no more bubblesappearat the
bleederhose.
a Refillthe clutch mastercylinderwith fluid when
done.
a Always use GenuineHonda DOT 3 BrakeFluid.
2. Removethe slavecylinderfrom the clutch housing. Using a non-Hondabrakefluid can causecorro-
sion and dec.easethe liJeof the system.
a Contirmclutch operation,and check for leaking
fluid.
12-6
PressurePlate
Removal/lnspection
1 . Inspectthe Jingersof the diaphragmspringfor wear Inspectthe pressureplatesurlacefor weaf, cracks,
at the releasebearingcontact area. and burning.
Check the diaphragmspring tingers tor height us- 6. Inspectfor warpageusinga straightedge and feel-
ing the specialtools and a feelergauge. er gauge.
StandardlNew): 0.6 mm (0.02 inl max. NOTE: Measureacrossthe pressureplate at three

ServiceLimit: 1.0 mm (O.O4in) points.
FEEL€RGAUGE
Standard(New): O.O3mm (0.0O1inl max.
S€rvicoLimit: O.15 mm (0.0O6inl
STRAIGHTEDGE
CLUTCH ALIGNMENTOISC
OTJAF_PM7O11A
CLUTCH ALIGNMENTSHAFT
OTJAF-PM7O12A
HANDLE
07936_3710100
lf the height exceedsthe servicelimit, replacethe
pressureplale.
3. Installthe specialtools.
PRESSUBEPLATE
lf the warpageexceedstheservicelimit,replacethe
pfessureplate.
RING GEAR HOLDER OTJAF_PM7012A

071A8-PV00100 HANDLE
ot 07936-3710100
07924-PD20003
GEARHOLDER
ENGINE
BLOCK NUT
ADJUSTER BOLT
4. To prevent warping, unscrew the pressureplate

mounting bolts in a crisscrosspattern in several
steps, then removethe pressureplate.
12-7
Clutch Disc
Removal/lnspection
1. Removethe clutch disc and specialtools. 4. Measurethe depth lrom the lining surfaceto the
rivets, on both sides.
CLUTCH DISC Rivet Depth:

Standatd(New):1 .3 - 1 .9 mm {0.O5-O'O7in} min'
S€rviceLimit: O.2 mm (O.01 inl
07936-3710100
Inspectliningof the clutchdisc tor signsof slipping

or oil. lf it is burnedblack or oil soaked,replaceit.
Measurethe clutch disc thickness.
Clutch Oisc Thickness:

S t a n d a r dl N e w ) : 8 . 5 - 9 . 1 m m ( 0 . 3 3 - 0 . 3 6 i n l
ServiceLimit: 5.5 mm (0.22 in)
CLUTCH DISC
lI the depthis lessthan the servicelimit,replacethe

clutch disc.
lf the thicknessis lessthan the servicelimit,reolace

the clutch disc.
12-8
Flywheel
1. Inspectthe ring gear teeth tor wear and damage. 1. Installthe sDecialtool.
2. Inspect the clutch disc mating surface on the

flywheel for wear, cracks, and burning. FLYWHEEL
3. Measurethe flywheel runout using a dial indicstor

through at least two full turns. Push againstthe
flywheeleachtime you turn it to take up the crank,
shaft thrust washer clearance.
NOTE: The runoutcan be measuredwith enginein-

stalled.
Standard{Now}: O.O5mm (0.OO2in) max.

ServicaLimir: O.15 mm (0.006 inl
,
FLYWHEEL
MOUNTING
BOLTS
RI[{G GEAR HOLOER

071A8 -PV00100
ot
07924-PO20003
2 . Removethe flywheelmountingbolts in a crisscross

patternin severalsteps as shown, and removethe
flywheel.
lf the runout exceedsthe servicelimit, reolacethe
flywheel. Removethe ball bearingfrom the flywheel.
Turn the innerraceof the ball bearingwith your fin-

ger. The ball bearingshouldturn smoothlyand qui-
etly. lf the inner race does not turn smoothly and
q u i e t l y .r e p l a c et h e b e a r i n g .C h e c kt h a t t h e b a l l
bearingouter racefits tightly in the flyweel.lf it is
loose.replacethe ball bearing.
FLYWHEEL
BALL BEARING {cont'd)
12-9
ClutchDisc,
Flywheel PressurePlate
Replacement(cont'dl Installation L
4. Drivethe new ball bearinginto the flywheel using 1. Installth€ specialtool.
the sDecialtools as shown.
ON|vER
07749-OOtO(xX)
clurcH olsc
07936-37ioioo
ATTACHMENT,
32x35mm
07746-0010r00
FLYWI{EEL
(P/n 08798-90{'21
RING GEAR HOLDER
07LAB-PVOOIOO
ot CI.UTCH ALIGNME T SHAFT
07924-PD20003 OTJAF_PM7012A
BEARII{G
5 . Align the hole in the flywheel with the crankshaft lnstallthe clutch disc using the specialtools.
dowel pin and installthetlywheel.Installthemount-
ing bolts fingertiqht. Installthe pressureplate.
o. Install the specialtool, then torque the flywheel

mountingbolts in a crisscrosspattern in severalsteps
as shown.
MOUNTING BOLTS
1 1 8N . m 1 1 2 . 0k s t ' m ,
87 tbf'ft)
YWHEEL RINGGEARHOLDER O7JAF.PM70l2A

oTLAB-PVOO100 HANDLE
ol 07936-3710100
07924-PD20003
RINGGEARHOLDER
oTLAB-PV00100
ol
07924-PD20003
12-10
ReleaseBearing
Removal/lnspection
4. Torquethe mountingbolts in a crisscrosspatternas 1 . Remove the release fork boot from the clutch
shown. Tighten them in severalsteps to prevent housing.
warping the diaphragmspring.
Removethe releasefork from the clutch housingby
squeezingthe releasefork set springwith pliers.Re-
move the releasebearing.
@ MoUNTING BOLTS
8 x 1 . 2 5m m
25 N'm 12.6kgf.m,19 tbt.ft)
R€LEASEFORK
3 . Checkthe releasebearingfor play by spinningit by

hand.
CAUTION: The lelease bearing is packed with

grease. Do not wash it in solvent
RINGGEARHOLDER CLUTCHALIGNMENT
oTLAB-PVOo100 OTJAF_PM7O12A
ol HANDLE
o7924,PD20003 07936- 3710100
lf there is excessiveplay, replacethe releasebear-

ing with a new one.
12-11
ReleaseBearing
Installation
NOTE: Use only Super High Temp Urea Grease 3. Movethe releasefork rightandlelt to makesurethat
(P/N 08798 9OO2). it fits properlyagainstthe releasebearing,and that
the releasebearingslidessmoothly.
1. Wilh the release fork slid between the release bear
i n g p a w l s , i n s t a l lt h e r e l e a s eb e a r i n g o n t h e m a i n
shaft while insertingthe releaselork through the hole
in the clutch housing.
29 N.m 13.0 kgf.m, 22 lbl.fr) --6i

oa798-9002)
4. Installthe releasefork boot;makesurethe boot seals

aroundthe releasefork and clutch housing.
(P/N08798-9002)
0 . 3- 0 . 9 g { 0 . 0 1 - 0 . 0 3o z }
2 . Align the detentoJ the releasefork with the release

{ork bolt,then pressthe releasefork overthe release
lork bolt sequarelv.
12-12
ManualTransmission
SpeciafTools ......... 13-2 Shift Fork Assembly

Maintenance Index............. ....13-25
T r a n s m i s s i oOni l . . . . . . . . . . . . . . . . . . . .1. .3. - 3 C l e a r a n clen s p e c t i o n . . . . . . . . . . . . . . . .1. .3 - 2 6
Back-upLight Switch MBS Shift PieceInspection......... 13-27
Replacement ....... 13-3 SynchroSleeve.SynchroHub
Troubfeshooting ..... 13-4 Inspection/lnstallation ................13-27
TransmissionAssembly Synchro Ring, Gear
Removal . . . . . . . . . . . .1. 3 - 5 Inspection .........1 . 3-28
lnstallation ...... ... 13-8 Shift Rod
l l l u s t r a t el nd d e x . . . . . . . . . . . . . . . . . . . . . .1.3. .-.1. 0 Removal . . . . . . . . . . .1. .3 - 2 9
TransmissionHousing Differential
Removal . . . . . . . . . . .1. .3 - 1 2 l n d e x. . . . . . . . . . . . . . . . .1 3 - 3 0
Reverse S h i f tH o l d e r Backlash I n s p e c t i o n. . . . . . . . . . . . . . . . .1. 3
. -30
C l e a r a n cIen s p e c t i o .n. . . . . . . . . . . . . . .1. .3 - 1 3 B e a r i n gR e p l a c e m e n. t. . . . . . . . . . . . . .1. .3 - 3 1
Reverseldler Gear FinalDrivenGear Replacement .... 13-31
Removaf . . . . . . . . . . . .1. 3 - 1 4 T h r u s tS h i mA d j u s t m e n t. . . . . . . . . . .1. 3 - 3 2
Mainshaft, Countershaft,Shift Fork Clutch Housing Bearing
Disassembly . . . . . . .1 3 - 1 4 Replacement . . . . . . .1 3 - 3 4
Mainshaft Assembly Mainshaft Thrust Shim
I n d e x. . . . . . . . . . . . . . . . .1 3 - 1 5 Adjustment . . . . . . . .1. 3 - 3 6
C l e a r a n cIen s p e c t i o .n" . . . . . . . . . . . . . .1. 3. - 1 6 Transmission
Disassembly . . . . . . .1 3 - 1 7 Reassembly . . . . . . . .1 3 - 3 9
Inspection .........1 . 3-18 OilSeals
Reassembly . . . . . . . .1 3 - 1 9 Replacement . . . . . . .1 3 - 4 3
CountershaftAssembly GearshiftMechanism
fndex............. .... 13-20 Overhaul . . . . . . . . . . .1. 3 - 4 4
C fe a r a n c efn s p e c t i o n. . . . . . . . . . . . . . . .1. 3 . -21
Disassembly . ... ... 13-22
lnspection ....... ... 13-23
Reassembly ..... ... 13-23
Ref. No. I Tool Number Description Oty I Page Relerence
o oTGAJ-PG20110 MainshaftHolder 1 13-38
@ oTGAJ-PG20120 Collar 1 13-37
o
.@
07GAJ-PG20130 MainshaftBase 1 13-37
07736-AO10004 AdjustableBearingPuller,25 40 mm 1 13-34,35
,3) o7746-0010300 Attachment,42 x 47 mm I 1 3 - 3 4 ,3 5
@ o7746-0010400 Attachment. 52 x 55 mm I 1 3 - 3 4 ,3 5
(j) o7746-0030100 D r i v e r ,4 0 m m l . D . I 13-19,24,
31,32
(q) o7746-0030300 Attachment, 30 mm LD. I 13-19,24
€) o7746-OO30400 Attachment, 35 mm LD. 1 13-19,24
@ o7749-O010000 Driver 1 13-343 , 5,43
(, 07JAD-PH80101 Driver Attachment 1 13-43
@ 07JAD-PH80200 Pilot, 26 x 30 mm 1 13-43
@ 07947-6110501 Seal DriverAttachment 1 13-43
07947-6110500
n Must be used with commerciallyavailable3/8 " -'16 Slide Hammer.
ll (1] at\ \,
/;i
o
\
@ (9
13-2
Maintenance Back-upLight Switch
Transmission
Oil Replacement
NOTE:Checkthe transmissionoil with the engine OFF NOTE: To test the back-uplightswitch, seesection23.
and the vehicleon levelground.
1. Disconnectthe connector,then removethe back up
1. Removethe oil fille. plug, then check the leveland light switch connectorlrom the connectorclamp.
conditionof the oil.
OILFILLERPLUG 2. Removethe back-uplight switch.
44 I{.m (4.5 kgt.m, 33 lbl.ftl
ProperLevel
WASHER
Replace.
The oil level must be up to the filler hole. lf it is
below the hole, add oil until it runs out, then rein-
stall the oil filler plug with a new washer.
lf the transmissionoil is dirty, removethe drainplug

and drain the oil.
Reinstallthe drainplug with a new washer,and refill

the transmissionwith the recommendedoil to the
properlevel. 25 N'm 12.5 kgf'm, 18lbt.tt) Replace.
NOTE: The drainplugwashershouldbe replacedat

3 . Installthe new washer and back-uplight switch.
every oil change.
Connectthe back-uplight switch connector.
Reinstallthe oil filler plug with a new washer.
Oil Capacity
1.8 f (1.9 US qt, 1.6 lmp qtl at oil change
1.9 t l2.O US qt, 1 .7 lmp qtl at overhaul
Always use GenuineHonda Manual Transmission

Fluid (MTF).Using motor oil can causestiffershift-
ing becauseit does not contain the proper addi-
ttves.
13-3
Troubleshooting
ReverseGear Noise ReductionSystem
Wheneverthe clutch pedal is depressedto shift into reverse,the mainshaftcontinuesto rotate becauseof its inertia.
The resultingspeed differencebetween mainshaftand reverseidler gear producesgear noise.
The reversegearnoisereductionsystememploysa cam platewhich was addedto the reverseshift holder.When shifting
into reverse,the sth/reverseshift piece,connectedto the shift lever,rotatesthe cam plate.This causesthe sth synchro
set to stop the rotatingmainshaft.As there is no speeddifterencebetweenmainshaftand reverseidler gear,there will
be less gear noise.
NOTE: This system is not a fully-synchronized gear noise reductionsystem.

Therelore,you may hear gear noise when
!) you shift inlo reversewith the vehiclenot yet completelystopped
i2) you shift quickly into reverseduring fast idling.
Gearnoiseis presenlwhen shift-

ing into reverseafler lhe engine
rs slarleo.
ls the gear noisepfesentwhen Replacetho sth synchto hub and

shilting into sth gear? sEeve as a sel.
Measurethe clearancebetween
sth shift fork and 5th synchro \
sleeve{seepage 13 26).
ls the clearance1.0 mm (0.04

in) or iess?
Measure the MBS shift piece pin

( s e ep a g e 1 3 - 2 7 ) .
l s i t 6 . 8 m m { 0 . 2 7 i n }o r m o r e ? Roplacethe MBs shitt piece.
Reolace the revsrso shift holder.
13 -4
TransmissionAssembly
Removal
Disconnectthe vehiclespeedsensor(VSS)connec-
@ 6.
tor.
Make sure jacks and satety stands are placed proper-
ly, and hoist bracksts are attached to correct pos;lion
on the engine. vss
Apply parking brsko and block rea. wheels so cal will CONNECTOR
nol ,oll oft stands and lall on you whils working
under it.
CAUTION: Use fender covers to avoid damaging

painted surlacas.
1 . Disconnectthe negative(-) cable first, then the

positive(+ l cable from the battery.
Draintransmissionoil (seepage13-3).
Removethe intakeair tube, intakeair duct and air

cleanerhousingassembly(seesection5).
Disconnectthe starter motor cables,transmission

groundwire and back-uplight switchconnector,
7. Removethe clutch line bracket,clutch line clamp,
and slavecylinder.
CAUTION:
6xl .O mm a Do not operate the clutch pedal once the slave
9.8 N.m (1.0 kgt.m, 7.2 lbf'ft) cylinder has been removed.
a Take care not to bend the clutch line.
b
ARTER
8t1.25 mm
8.8 N.m (0.9kgf.m,6.5lbl.ttl
5. Removethe wire harnessclamos.
(cont'd)
13-5
Removal(cont'd)
8. Removethe driveshafts(seesection 16). 10. Removethe shitt rod and extensionrod.
NOTE: Coatall the precisionfinishedsur{aceswith

cleanengineoil or grease.Tie plasticbags over the
drivesha{tends. SHIFTROD
SET RING
1 0 x 1 . 2 5m m
43 N.m (4.4 kgl.m,
DRIVESHAFT
8x22mm
SPRINGPIN
Replace.
\
1 l. Removethe enginestiffenersand clutch cover'
Dl6Y5, Dl6Yg onginos:
10 x 1.25mm 8 r 1.25mm
COTTERPIN 24 N.m (2.4 kgf.m
Replace 44 N.m {4.5 kgl.m,
17 tbt.trl
12 x '1.25mm Replace.
33 tbhlrt
4 9 - 5 9 N . m l 5 . O 6 . 0 k g f ' m , 12 x 1 .25 mrn
36 43 tbt.ft) 64 N.m 16.5 kgt.m.47 lbt.ftl
L Remove exhaust pipe A.
GASKETS
Replace.
COVER
ruur.-@
sELF-LocKrNG EXHAUST
Replace. PIPEA
I x 1 . 2 5m m SELF-LOCKING NUT
1 6 N . m 1 1 . 6k g t ' m , Replace.
12 tbf.ftl D16Y5, Dl6Y7 engin€s: 8 x 1.25mm
SELF.LOCKING NUT 1 0 x 1 . 2 5m m
24 N.m (2.4 kgl'm,
Replace. 33 N.m (3.4 ksl'm, 25 lbI'ttl '| 7 tbl.trl
8 x 1.25mm D16Y8 engine:
22 N'nt. 12.2 kgl'm, 10 x 1.25mm
16 tbf.fr) 54 N.m (5.5 kgf.m,40 lbt'ft}
13-6
O16Y7 engine: 1 4 . R e m o v et h e r i g h t l r o n t m o u n tb r a c k e t .
1 O x 1 . 2 5m m
4 4 N . m 1 4 . 5k g f. m ,
33 tbf'fr)
8 x 1.25mrh
24 N.m (2.4 kgf.m,
17 tbf.fr)
ENGINE
STIFFENER
1 0 X 1 . 2 5m m
44 N.m 14.5kgl.m,33 lbt.ttl
Installthe bolts in the cylinderhead and attach a

RIGHTFRONT
chainhoist to the bolts,then lilt the engineslightly ' 1 2x 1 . 2 5 m m MOUNT/BRACKET
to unloadthe engineand transmissionmounts. 64 N.m (6.5 kgt.m,47 lbt.ttl
CHAINHOIST
1 5 . P l a c ea j a c k u n d e rt h e t r a n s m i s s i o n .
16. Removethe transmission

mountbracketand mount.
TRANSMISSION TRANSMISSION
MOUNT BRACKET
1 3 . B e m o v et h e s p l a s hs h i e l d .
SPLASHSHIELD
(cont'd)
13-7
Removal(cont'd) Installation
17. Removethe threeuppertransmission mountingbolts Installthetransmissionassemblyin the reverseorderol
and the lower starter mountingbolt. removal.
a Beforeinstalling,check that the two dowel pins are

i n s t a l l e di n t h e c l u t c hh o u s i n g .
a When installingthe startercable,make surethat the
crimped side of the ring terminalis facing out {see
s e c t i o n2 3 ) .
a Apply greaseto the parts as shown, then installthe
r e l e a s ef o r k a n d r e l e a s eb e a r i n g .
NOTE:Use only Super High Temp Urea Grease

( P / N0 8 7 9 8- 9 0 0 2 ) .
RELEASEFORKEOLT
STARTER 1 2 x 1 . 2 5m m
29 N.m {3.0 kgt.m,
tPiN 08798-9002)
MOUNTING TRANSMISSION
BOLT 22 tht.trl
MOUNTINGBOLTS
1 0 x 1 . 2 5m m 1 2 x 1. 2 5 m m
44 N.m {4.5 kgl.m, 64 N.m (6.5kgf.m,47 lbt,tt)
33 tbt.trl RELEASE
FORK
1 8 . R e m o v et h e r e a rm o u n tb r a c k e bt o l t sa n dt r a n s m i s BOOT
sion mountingbolts
spEcrALBoLT
Replace.
1 4 x ' l . 5m m
12 x 1.25mm a 4 N . m { a . Sk g f . m , 6 1 t b f , t t l \
6 4 N . m 1 6 . 5k g f . m , 4 7 l b f . f t )
{P/N08798 9002)
RELEASE
FORK
lP/N08798-9002)
0 . 3 0 . 9s
{ 0 . O -10 . 0 3 o z )
WASHER
SPECIALBOLT
Replace.
14 x 1.5mm
84 N'm 18.5 kgl.m, 61 tbf.ft)
'1 Pull the transmission away from the engine until it

9.
c l e a r st h e m a i n s h a f t ,t h e n l o w e r i t o n t h e t r a n s m i s -
sion jack.
CAUTION: Take care not to bend the clutch line.
13-8
a Torquethe mountingbolt and nuts in the sequence a Apply greaseto the slave cylinderpush rod.
shown.
NOTE: Use only Super High Temp Urea Grease
A 1 2 x 1 . 2 sn m ( P / NO 8 7 9 8 9 0 0 2 ) .
64 N.m {6.5 kgf.m, a ) 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m, 6 x 1.0mm
47 tbI.tt) 9.8 N'm (1.0kgt.m,
7 .2 tbt.ltl
CLUTCH 8 x 1.25mm
PIPE 22 N.m 12.2 kgl.m,
@ 1 2 x 1 . 2 5m m tP/N08798_9002) 16 tbt.fl)
7 4 N ' m 1 7 . 5k g f . m , Turn the breathercap so that the "F" mark pointsat
54 lbt.tt) the front of the car as shown.
a Check that the bushingsare not twisted or offset.
a Installthe clip as shown.
FRONT
SHIFTROD 8 x 1 . 2 5m m
22 N.m 12.2 kgt,m, 16 lbt.ftl
gx22mm
I -/:'.G
SPBING
PIN
Replace.
,// EXTENSTON
BOD | ^
/.t***rrm"'i@ Retill the transmission with the recommended oil

(seepage 13-3).
,z-s;c,r oown
).,, Connect the positive (+ ) cable first, then the nega-
tive {- ) cable to the battery.
a Check the clutch operation.
a Shift the transmission and check for smooth
operation.
'18).
a Turn the boot so the hole is facing down. Check the front wheel alignment (see section
a Make sure the boot is installedon the shift rod.
lllustratedIndex
Referto the drawing below for transmissiondisassembly/reassembly

Cleanall the parts thoroughlvin solvent and dry with compressedail
I LuOricateall the parts with oil belore reassembly.
NOTEI
a This transmission usesno gasketsbetweenthe maiorhousings;useliquidgasket{P/N0871 I - 0001 or 08718 - OOO3)
( s e ep a g e 1 3 - 4 ' l ) .
a Always clean the magnet@ wheneverthe transmissionhousingis disassembled.
a Inspectall the bearingsfor wear and operation.
I
+v
d b +
;- 6
\"
u
/
6
13-10
Torqu€ Value
A - 15 N.m {1.5kgf'm.11 lbf.ft)
B - 27 N.m (2.8kgim,20 lbf.ft)
C - 31 N.m (3.2kgf.m,23 lbf.ft)
O BALLBEARING(*1I @ 3RD/.TH SHIFr FoRK @ 72 mm THRUSTSH|M t'1)

ANGULAR @ 5TH/REVERSE sHIFT FoRK 80 mm THRUSTSHIM {*2)
BALL EEARINGIT2) O 52 mm SNAP RING Selection,page 13-33
@ sTH sYNcHRo HUB @ 65 mm THBUSTSHIMl*11 @ DIFFERENTIAL ASSEMBLY
O 5TH SYNCHRoSLEEVE 70 mm THRUSTSHIM l*21 Seepage 13-30
@ SYNCHROSPRING Selection,page 13-36 @ 14 x 25 x 17.5mm OtLSEAL
@ SYNCHRO RING @ OIL GUIDEPLATE Replace.
@ 5TH GEAR @ WASHERReplace. @35x56x8mmOlLSEAL
@32xazxz:.5mm @ BAcK.uP
LrcHT
swrrcH Replace.
NEEDLEBEARING 25 N.m (2.5 kgt'm, 18 lbf.ft) @sHrFrRoD
@ SPACERcoLLAR @ sETscREw @ BOOr
@3lx3gxz3mm 22 N.m (2.2 kgt.m, 16lblftl @ oIL GUIDEPLATE
NEEDLEBEARING @ WASHERReplace. @30xlzx2tmm
@ 4TH GEAR @ SPRINGL.31.6mm (1.24in) NEEDLE BEARING ('1}
O SYNCHRoRING @ STEELBALL (5/16 in) 3 0 x 5 5 x 2 1m m
@ SYNCHROSPRTNG @ BACK.UPLIGHT NEEDLE EEARING IT2)
@ 3RD/4THSYNGHRoSLEEVE SWITCHHARNESSSTAY @ COUNTERSHAFT
@ 3RD/4THsYNcHRo HUB @ TRANSMISSIONHANGER @ 3 6 x 4 1x 2 5 . 5m m
@ 3RD GEAR @ 32 mm SEALINGBOLT NEEDLE BEARING
@34x39x27.5mm 25 N.m (2.5 kgf.m, 18 lbt,ft) Check for wearand
NEEDLEBEARING @ OIL SEAL ooeralton.
@ MAINSHAFT Replace. @ lsT GEAR
@ WASHER @ OII DRAINPLUG @ FRICTION DAMPER
@ SPRINGWASHER 39 N'm {4.0 kgf.m, 29 lbf.ftl @ sYNcHRoR|NG
@ BALL BEARING @ WASHERReplace. @ sYNcHRoSPRTNG
Checkfor wear and @ OIL FILLERPLUG @ 1ST/2NDsYNcHRoHUB
operalron. 44 N.m (4.5 kgf.m. 33 tbf'ft) @ REVERSE GEAR
@26x42x7mmOlLSEAL @ WASHERReptace. @ SYNCHRO SPRTNG
Replace. @ TBANSMISSIONHOUSING @ SYNCHRO FING
@ 28 mm PLUGBOLT @ RELEASEPIPESTAY @ FRICTION DAMPER
54 N.m {5.5 kgt.m, 40 lbf.ft) @ OIL GUTTERPLATE @ SPACER
@ 1ST/2NDSELECTSPRING @ REVERSELocK cAM @39xllx2zmm
L. 36.26mm (1.428inl @ REVERSESELECTSPRING NEEDLE BEARING
@ SHIFT ARM SHAFT L. 63.4 mm l2.i€6 in) @ 2NDGEAR
@ CLUTCHHOUSTNG @ REVERSESELECTRETAINER @ 3RDGEAR
@ INTERLoCKGUIDEEoLT @ SHIFTARM c @ 4THGEAR
39 N.m 14.0kst.m, 29 lbf.ft) @ SHIFTARM B @ 5THGEAR
@ REVERSESHIFTHOLDER @ INTERLOCK @ EALLBEARTNG {*1)
@ REVERSEIDLERGEAR @ COLLAR NEEDLE BEARING I*2I
@ REVERSETDLER GEARSHAFT @ SHIFI ARM A @ BALLBEARING
@ 5 x 22 mm SPRINGPIN @ SPBINGWASHER @ SPRING WASHER
Replace. @ MAGNET @ LoCKNUT Reptace.
@ 3RD/4THSHIFI PIECE @ SETEALL SPRINGBOLT 1 0 8+ 0 * 1 0 8N . m
@ sTH/REvEnsESHIFTPIECE 22 N.m (2.2 kgl.m, 16 lbf.ft) f r r . o* o * 1 1 . 0k g f . m , l
@ MBS SH|FTP|ECE @ r4 x 20 mm DOWELPIN lrs.e* o- 79.6tbtft |
@ lsT/zNo SHIFI FoRK
r 1 : D l 6 Y 7€ n g i n .
12: D16Y5.D16Y8engines
13-11
Housing
Transmission
Removal
NOTE:Placethe clutch housingon two piecesof wood Loosenthe transmissionhousingattachingbolts in
t h i c k e n o u g ht o k e e p t h e m a i n s h a f tf r o m h i t t i n g t h e a crisscrosspattern in severalsteps.then remove
workbench. them.
1. Removethe back-uplight switch. 5. Removethe 32 mm sealingbolt.
2. Removetransmissionhanger. Expandthe snap ring on the countershaftball bear-

ing, and remove it from the groove using a pair of
TRANSMISSION snap ring pliers.
HAt{GER
32 mm SEALINGBOLT
SNAP RIIIG
Removethe setting screws,washers,springs,and Separatethe transmissionhousingfrom the clutch

steelballs. housing,and wipe it cleanol the sealant.
Removethe thrust shim,oil guide plate,and oil gut-

ter plate{rom the transmissionhousing.
STEELBALLS
D.5/16in
SPRING
L . 3 1 . 6 m m 1 1 . 2 4I n l
TRANSMISSIONHOUSING
13-12
ReverseShift Holder
ClearanceInspection
1 . Measurethe clearance
betweenthe reverseshiftfork 3. Measurethe clearancebetweenthe reverseidlergear
and sth/reverseshift Dieceoin. a n d t h e r e v e r s es h i f t f o r k .
Standard: 0.O5-O.35 mm (O.OO2-0.O14

in) Standardr 0.5-1.1 mm {O.02-0.04 in}
ServiceLimit: 0.5 mm {0,02 inl S e . v i c eL i m i t : 1 . 8 m m ( 0 . 0 7 i n t
IDLEBG€AB
REVERSE
REVERSE
REVERSE
SHIFTFOBK
2 . lf the clearancesare more than the service limit, lf the clearanceis morethan the servicelimit,meas-
measurethe widths of the groovein the reverseshift ure the width of the reverseshift fork.
fork.
S t a n d a r d 1: 2 . 7- 1 3 . O m m ( 0 . 5 0 0 - 0 . 5 1 2 i n )
Standard:7.15- 7.35 mm (0.281- 0.289inl
REVERSE
SHIFTFORK
SHIFTHOLDER
REVERSE
REVERSE
SHIFTHOLOEB
lf the widths of the grooves are not within the
standard,replacethe reverseshift holderwith a lf the width is not within the standard,replace
new one. the reverseshift holderwith a new one.
lf the width of the groovesare within the stan- lf the width is within the standard,reDlacethe
dard, replacethe sth/reverseshift piece with a reverseidler gearwith a new one.
new one.
13-13
Mainshaft,Countershaft,
Reverseldler Gear Shift Fork
Removal Disassembly
1. Remove the reverse shift holder. 1 . Remove the interlock guide boh trom under the
REVERSESHIFT clutch housing.
HOLDER SHIFTARM8
ATTACHINGEOLT
SPRING
WASHER
CLUTCH
HOUSING
2. Removethe reverseidlergearshattand reverseidler

geat.
GUIDEBOLT
II{TERLOCK
2 . Removethe shift arm B attachingbolt.
Removethe mainshalt and countershaft assemblies

REVERSEIDLER with the shift lork trom the clutch housing.
GEARSHAFT
NOTE: Belore removingthe mainshalt and counter-

tape the mainshaftsplinesto pro-
shaft assemblies.
tect the seal.
Tape the mainshaft

sp nes.
WASHER
SPBING
WASHER
13 - 1 4
MainshaftAssembly
Index
Notethe followingduring reassembly:
. The 3rd/4thand sth synchrohubs are installedwith a press.
. Installthe angularball bearingwith the thin-edgeouter racefacingthe sth synchrohub.
. Installtheball bearingwith the bsll cagefacingup.
cleanall the partsin solvent.dry them and applylubricantto all contactsurfacesthe 3rd/i[th
Priorto reassembling.
and sth svnchrohubs,
Ball cage faces up.
BALLBEARING{T1}
3RD/4THSYNCHROSLEEVE ANGULARBALLBEARING('2I
p a g e1 3 2 7 Checkfor wearand operation.
Note the directionof installation.
SYNCHROHUB
sTH SYNCHRO
SLEEVE
page13 27
lnspection,
SYNCHROSPRING SPRING
SYNCHRORING
Inspection, SYNCHRORING
p a g e1 3 - 2 8 Inspection,page 13'28
5TH GEAR
I n s p e c t i o np,a g e 1 3 - 1 7
NEEOLEBEARING
3RO GEAB Checkfor wear and
Inspection,page 13'16 CHAMFER operation.
SPACERCOLLAR
34 x 39 x 27.5 mm Inspection,page 13-'t6
NEEDLEBEARING 34x39x23mm
Checkfor wear NEEDLEEEARING
ano operalron. Check for wear
ano operalton.
MAINSHAFT 4TH GEAB

I n s p e c t a opna, g e 1 3 - 1 8 I n s p e c t i o np,a g e 1 3 - 1 6
RING
Inspection,page 13-28
SPRING
D16Y7engine
D16Y5,D16YBengines
13-15
MainshaftAssembly
Inspection
Clearance
NOTE: lI replacementis required,always replacethe 3. Measurethe clearancebetween 4th gear and the
svnchrosleeveand hub as a set. soacercollar.
1. Measurethe clearancebetween2nd and 3rd oears. Standard: 0.06-o.19 mm (O.OO2-O.OO7

inl
ServiceLimit: O.31 mm {0.012 in}
Standaid: 0 . 0 6 - O . 2 1 m m { O . O 0 2 - O . O Oi8n }
Ssrvice Limit: O.33 mm (O.O13inl
4TH GEAR
: --, / /hm
t l,- €
r[Jl] i
[nI
q l
2ND GEAR
r tl-lll
\- cltl-l
\ \-,l-LJ 3RD GEAB 5TH GEAR
lf the clearanceis morethan the seryicelimit,meas-

ure distance@ on the spacercollar.
Standard: 22-82-22.86nm
{ 0 . 8 9 8 - O . 9 O 0i n }
ServiceLimit: 22-81 mm (0.898 in)
2 . lf the clearanceis morethan the servicelimat.meas-
ure the thicknessof 3rd gear. 4TH GEAR
stoE
Standard: 30.22-30.27mm
{ 1 . 1 9 0 - 1 . 1 9 2i n l
S e r v i c eL i m i t :3 0 . 1 5 m m ( 1 . 1 8 7 i n l SPACEB
COLLAR
lf distance@ is lessthan the servicelimit, replace

3RO GEAR
the spacercollar with a new one.
lf distance@ is within the servicelimit,measurethe
thicknessof 4th gear.
Standard: 3 O . 1 2- 3 0 . 1 7 m m
1 1 . 1 8 6 -1 . 1 4 8i n )
Ssrvicelimit: 30.05 mm {1.183 in)
4TX GEAR
a lf the thicknessot 3rd gear is lessthan the serv-

ice limit, replace3rd gear with a new one-
a lf the thicknessof 3rd gear is within the servrce
limit,replacethe 3rd/4thsynchrohub with a new lf the thicknessof 4th gearis lessthan the serv-
one. ice limit, replace4th gear with a new one.
It the thicknessof 4th gear is within the service
llmit, replacethe 3rd/4th synchro hub with a new
one.
13-16
Disassembly
6. Measurethe clearance
betweenthe spacercollarand 1 . R e m o v et h e b a l l b e a r i n gu s i n ga b e a r i n gp u l l e ra s
sth gear. shown.
BEARINGPULLER
S t a n d a r d : O . 0 6 - O . 1 9 m m ( 0 . 0 O 2 - O . O O 7i n l (Commercially
S6rvicelimit: O.31 mm (0.O12 in) available)
4TH GEAR
DIAL
INDICATOR
t
*3'4>
--t
sTH GEAR
1 . lf the clearanceis morethan the servicelimit.meas-

ure distance@ on the spacercollar.
(0.926-0.928 inl
Servics Limit:23.51 mm (0.926 in)
CAUTION: Removethe synchrohubs usinga piess

and steel blocks as shown. Use of a.iaw-type puller
sTH GEAR can causedamageto the gear teeth,
stoE
2. Support4th gearon steelblocks,andpressthe main'
lf distance@ is less than the servicelimit, replace shaft out of the sth synchro hub as shown.
the sDacercoliar with a new one.
lf distance@ is within the servicelimit, measure
thicknessof sth gear.
Standald: 28.42-28.47mm
( 1 . 1 1 9 -1 . 1 2 1i n l
ServiceLimit: 28.35 mm l1 . l 16 in)
sTH GEAR
It the thicknessof sth gear is lessthan the serv-

ice limit, replace5th gear with a new one.
lf the thicknessof sth gear is within the service
limit,replacethe 5th synchrohub with a new one.
{ c o n t ' d}
13-17
MainshaftAssembly
(cont'dl
Disassembly Inspection
3. Supportthe 3rd gearon steelblocks,and pressthe I. Inspectthe gear surtaceand bearingsurfacefor wear
mainshaltout of the 3rd/4thsynchrohub as shown. and damage,then measurethe mainshaftat points
A, B, C, and D.
Standard: A: 21 .987-22.OOO mm
{0.8656-0.8661 in}
B: 26.980-26.993 mm
11.0622- 1 .0627 inl
C: 33.984-34.OOO mm
( 1 . 3 3 8 0 - 1 . 3 3 8 6i n )
D: 25.977-25.990 mm
11.0227 -'l .0232 inl
ServiceLimit: A: 21.93O mm (O.8634 inl
B : 2 6 . 9 3 0 m m { 1 . 0 6 0 2i n }
C : 3 3 . 9 3 0 m m { 1 . 3 3 5 8i n }
D : 2 5 . 9 2 0 m m { 1 . 0 2 0 5i n }
Checktor wearanddamage
lf any part of the mainshaftis lessthan the servicelimit,

replaceit with a new one.
2. Inspecttor runout.
Standald: O.O2mm {O.0O1in} max.

Ssrvico Limit: 0.05 mm {0.0O2 inl
NOTE: Suooort the mainshaft at both ends as

snown.
lf the runout is more than the servicelimit, replacethe

mainshaftwith a new one.
13-18
Reassembly
CAUTION: When installing the 3rd/,lth and 5th synchro 3. Installthe sth synchrohub using the specialtools
hubs, support the shaft on steel blocks. and instsll the ano a oress.
synchro hubs using a press.
NOTE:Referto page 13-15for reassemblysequence.

DRIVER,40 mm l.O.
1. Support 2nd gear on steel blocks,then install the 07746 - 0030100
3rd/4thsynchro hub using the specialtools and a
press,
ATTACHMENT,
30 mm LD.
o7746-0030300
sTH SYNCHROHUB
ORIVER.40 mm l.D
o7746 -0030100
ATTACHMENT,
35 mm LO.
o7746 -OO30400
Installthe ball bearingusingthe specialtools and a

press.
2ND GEAR
2. I n s t a l lt h e 3 r d l 4 t hs y n c h r os l e e v eb y a l i g n i n gt h e
stopsof the 3rd/4thsynchrosleeveand hub.
NOTE:After installing,checkthe operationof the

3rdl4thsynchrohub set.
SYNCHROSLEEVE
*1: D'16Y7
engine
*2r D16Y5,D16YBengines
13-19
GountershaftAssembly
Index
NOTE:The 3rd, 4th,and sth gearsare installedwith a press,
3 Prior_to
reassembling,cleanall the partsin solvent,dry them and apply lubricantto all contactsurfacesexceptthe
3rd.4th,and 5th gears.
Snap ring groove laces up.
OCKNUTReplace.
108-0- lOgN.m
I 1 1 . 0 - 0 - . 1 1 . 0k g f . m l
| 79.6- 0- 79.6 lbnlr I
WASHER
BEARING
Checkfor wear and
operation.
/ BALL EEARTNG (* 1)
I NEEDLEBEARTNG (*2)
SYNCHROSPRING
Check for wear
and operation.
SYNCHRORING
Inspection,page 13-28 GEAR
4TH GEAR
FRICTIONDAMPER
3RO GEAR
lST GEAR 2ND GEAR
l n s p e c t i o np,a g e 1 3 2 1 , 2 8 lnspection,page 13-21, 28
39x44x27 mn
NEEDLEBEARING
Checktor wear and
operation.
SPACERCOLLAR
FRICTIONDAMPER
SYNCHRORING
36 x 41 x 25.5 mm
NEEOLEBEARING
Check for wear and operation. SYNCHROSPRING
I n s p e c t i o np,a g e 1 3 - 2 3 REVERSE GEAR

page 13-27
lnspecta.on,
1ST/2NDSYNCHROHUB
*1: D16Y7engine
'2: D16Y5,D16Y8engines
13-20
ClearanceInspection
NOTE: lf replacementis required,always replacethe 3. M e a s u r et h e c l e a r a n cbee t w e e n2 n d a n d 3 r d q e a r s
synchrosleeveand hub as a set.
S t a n d a , d : O . O 4 - O . 1 2m m ( 0 . 0 0 2 - 0 . 0 0 5 i n )
1 . M e a s u r et h e c l e a r a n c eb e t w e e nt h e c o u n t e r s h a f t ServiceLimit: 0.24 mm {0.009 in)
and lst geaf.
3RD GEAR
S t a n d a l d : O . O 3 - O . 1 Om m ( 0 . 0 O 1- 0 . 0 O 4 i n )
ServiceLimit: 0.22 mm {0.0O9 in} FEELER
GAUGE
SPACER 2NO GEAR

COLLAR
lf the clearanceis morethan the servicelimit,meas-

ure the thicknessot the spacercollar.
Standard: 3 2 . 0 3 - 3 2 . 0 6m m
11.261- 1.262 inl
GAUGE ServiceLimit: 32.01 mm l1 .260 inl
2. lf the clearanceis morethan the servicelimit,meas-

u r e t h e t h i c k n e s so f 1 s t g e a r . SPACER
COLLAR
{ 1 . 1 9 7 - 1 . 1 9 8i n }
S e r v i c eL i m i t : 3 0 . 3 6 m m ( 1 . 1 9 5 i n )
5 . lf the thicknessis lessthan the servicelimit. reDlace

the spacercollar with a new one.
lf the thicknessis within the servicelimit, measure
1 S TG E A B the thicknessof 2nd gear.
Standard: 31.91- 31.96mm

11.256- 1.258inl
S.rvicoLimit:31.85mm (1.25i1in)
/-?:- 2rlDGEAR
/ t \ -N/ /
A-
f - l
L'rz::---h_l
t
i I t h e t h i c k n e s so f 1 s t g e a ri s l e s st h a nt h e s e r v lf the thicknessot 2nd gear is lessthan the serv-
i c e l i m i t ,r e p l a c e1 s t g e a r w i t h a n e w o n e . i c e l i m i t ,r e p l a c e2 n d g e a rw i t h a n e w o n e .
lf the thicknessof l st gear is within the service lf the thicknessof 2nd gear is within the service
limit,replacethe 1st/2ndsynchrohub with a new limit,replacethe 1st/2ndsynchrohub with a new
one. one.
13-21
GountershaftAssembly
Disassembly
CAUTION: Remove the gears using a pr6ss and st€el 4. Suppon4th gearon steelblocks,and pressthe coun-
blocks as shown. Use of a iaw-type pullor can damage tershaftout of sth and 4th gearsas shown.
the gear toeth.
1 , S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.
2. Raisethe locknuttab from the groove of the coun-

tershaft,then remove the locknut and the spring
wasner. 4TH GEAR
Support 1st gear on steel blocks,and pressthe coun-

tershaftout of 3rd gear as shown.
WOODBLOCKS
3, R e mo v e t h e b e a r i n g su s i n g a b e a r i n gp u l l e ra s
shown.
BEARINGR'LLER
13-22
Inspection Reassembly
t. Inspectthe gear surfacesand bearingsurfacesfor CAUTION:
wear and damage,then measurethe countershaft . Prcssthc 3rd. 4th, and 5th gelrs on thc cour*crshaft
at pointsA. B. and C. whhoul lubrication.
. When installing the 3rd, 4th, and sth gea.5, support
Standard: A: 30.000- 30.015mm the shaft on 3te6l blocks and install the gas.r uring a
{ 1 . 1 8 1-1 1 . 1 8 1 i7n l prass.
B: 35.984- 36.000mr'
{1.4167- 1.4r73inl NOTE: Referto page 13-20for reassemblysequence.
C: 24.980- 24.91t3mm
10.9835- 0.9840in) 1. Installtheneedlebearingon the countershaft.
S€rviceLimh: A: 29.950mm (1.1791in)
B: 35.930mm (1.41i[6in] 36 x 41 x 25.5 rnm
C: 2/+.930mm (0.9815inl NEEDLEBEARII{G
COUNTERSHAFT
Check oil passages

for clogging.
2. Assemblethe Dartsbelow as shown.
NOTE:Checkthat the fingersof the frictiondamper

are securelyset in the groovesof the 1sv2ndsyn-
chro hub.
. lf anv oart of the countershsftis less than the
servicelimit, replaceit with a new one. 2 D GEAR
2. lnspectfor runout. 39r44x27mm

I{€EOLE BEARIIIG
Standard: 0.02 mm {0.001in) max.
SPACERCOLLAB
SorviceLimh: 0.05 mm 10.002in,
FRICTIOII DAMPER
SY'{CHRO RING
SYI{CHROSPNING
REVERSEGEAB
lST/21{D
SYNCHNOHUB
SY]TCHROSPRING
SYNCHRORING
FRICTIONDAMPER
1ST GEAR
I . lf the runout is more than the servicelimit. replace

the countershaftwith a new one.
3. Installthe oarts on the countershaft.
(cont'd)
CountershaftAssembly
(cont'd)
Reassembly
4. SuoDortthe countershafton a steelblockas shown 7. Installthe bearingsin the directionshown usingthe
and install 3rd gear using the specialtools and a specialtoolsand a press.
oress,
CAUTION: Install the b€arings with a maximum
pr€ssureof 7.8 kN (8m kd. 5.786lbf).
DRIVER,40 mm l.D.
o7746-0030100
ATTACHMENT,
35 mm LO.
07746 -OO30400
w Snapring
faces up,
Ball cage faces up.
5. Install4th gear usingthe specialtools and a press.
DRIVER,40 lnm
07746-0030100 *1: D16Y/engine
+2:D16Y5,D16Y8engines
ATTACHMENT,
35 mm l.D. TH GEAR S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
07746-OO3O/IOO benchvisewith wood blocks.
LOCKNUT
108*0-108N.m
111.0* 0 * 11.0kgf.m,79.6+ 0+ 79.6lbf.ft)
LOCKNUT
Replace.
6. Installsth gear usingthe specialtoolsand a press.
DRlvER,40 mm l.O.
07746-0030100
ATTACHMENT,
30 mm l.O.
07746-0030300 sTH GEAR
a Installthe spring washer,tighten the locknut,then

stakethe locknuttab into groove.
13-24
Shift Fork Assembly
lndex
---'rl
'f
cleanall the partsin solvent,dry them,andapplylubricantto anYcontactparts
erlorto reassembling,
3RO/4THSHIFTFORK
5TH/REVERSE
SHIFTFORK
1ST/2NDSHIFTFORK
MBS SHIFT
PIECE
5TH/REVERSE
SHIFTPIECE
3RO/4lH
SHIFTPIECE
'13-25
Shift ForkAssembly
ClearanceInspection
NOTE:The synchrosleeveand the synchrohub should 3. Measurethe clearancebetweenthe shift oiece or
be replacedas a set. shiftfork and the shift arm B.
1. Measurethe clearancebetweeneach shift fork and Standard: 0.2 - 0.5 mm (0.008- 0.02 in)
its matchingsynchrosleeve. ServiceLimit: 0,62 mm {0.024ifin)
Standard: 0.35- 0.65 mm (0.014- 0.026in)

ServiceLimit 1.0 mm (0.0{ in)
SHIFTARMB ".
lf the clearanceis more than the servicelimit, mea-

surethe grooveof the shift pieceor shiftfork.
lf the clearanceis more than the servicelimit, mea-
surethe thicknessof the shiftfork finqers. Stsndard:13.2- 13.4mm {0.520- 0.528in}
Siandard;
3rd/,fth: 7.4 - 7.6 mm {0.291- 0.299in)
lst/2nd, 5th: 6.2 - 6.,f mm (0.244- 0.252in)
SHIFTFORK
lf the groove of the shift piece or shift fork is not

within the standard, replacethe shift pi€ce or
lf the thicknessof the shift fork fingers is not shift fork with a new one.
within the standard, reDlacethe shift fork with a lf the groove of the shift piece or shift fork is
new one. within the standard,reDlacethe shift arm B with
lf the thicknessof the shift fork fingers is within a new one.
the standard.replacethe synchrosleevewith a
new one.
13-26
SynchroSleeve,
SynchroHub
MBS Shift PieceInspection lnspection/lnstallation
1. Measurethe width of the MBS shilt piece. 1. I n s p e c tg e a r t e e t h o n a l l s y n c h r o h u b s a n d s y n c h r o
s l e e v e sf o r r o u n d e d o l f c o r n e r s ,w h i c h i n d i c a t e
Standard: 6.9-7.1 mm (O.272-O.2aO in)
SoryiceLimit: 5.8 mm (O.268 inl
I n s t a l le a c h s y n c h r o h u b a n i t s m a t l n g s y n c h r o
sleeve, and check for freedom oI movement.
N O T E : l f r e p l a c e m e n ti s r e q u i r e d , a l w a y s r e p l a c e
the synchro sleeve and synchro hub as a set.
SYNCHRO
SLEEVE
lf the width of the MBS shift pieceis lessthan

servicelimit, replacethe MBS shift piece. When assemblingthe synchrosleeveand synchro
hub, be sureto matchthe three sets of longerteeth
(120 degreesapart)on the synchrosleevewith the
three sets ol deepergrooves in the synchro hub.
CAUTION: Do not install the svnchro sleove with

its longer leeth in the synchro hub slots because it
will damagethe spring ring.
LONGERTEETH
13-27
SynchroRing,Gear
Inspection
I n s p e c t h e s y n c h r or i n g a n d g e a r . SYNCHRO
A r I n s p e c t h e i n s i d eo f t h e s y n c h r o r i n g l o r w e a r .
8: lnspectthe synchro sleeveteeth and matching

teeth on the synchro ring for wear (rounded off). SYNCHRO
GOOOWORN
oo
C: Inspectthe synchro sleeve teeth and matching
teeth on the gear for wear (rounded off).
/\... ,,-\.
\---l (rl
GOOOWORN
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe cone surfacefor wear and roughness.
F : I n s p e c t h e t e e t ho n a l l g e a r sf o r u n e v e nw e a r ,
s c o r i n gg, a l l i n ga, n dc r a c k s .
2. Coatthe cone surfaceof the gear with oil, and place

t h e s y n c h r or i n g o n t h e m a t c h i n gg e a r .R o t a t et h e
synchroring, makingsurethat it does not slip.
M e a s u r et h e c l e a r a n c eb e t w e e nt h e s y n c h r or i n g
a n dg e a ra l l t h e w a y a r o u n d .
NOTE: Holdthe synchroring againstthe gear even-

l y w h i l em e a s u r i n tgh e c l e a r a n c e .
Synchro Ring-to-GearClearance
Standardi 0.73-1.18 mm (0.029-O.046inl
ServiceLimit: 0.4 mm (O.O2inl
l f t h e c l e a r a n cies l e s st h a nt h e s e r v i c el i m i t ,r e o l a c e
the synchroring and synchrocone.
13-28
shift Rod
Removal
N O T E :T h es t e e bl a l l s a r e aol lf t h e s a m e s i z e ( 5 / 1 6 i n ) . 6 . R e m o v es h i f ta r m sC a n d B , a n dt h e i n t e r l o c kt,h e n
r e m o v et h e r e v e r s es e l e c ts p r i n ga n d r e t a t n e r .
1. Removethe diff;rential assemory.
7 . R e m o v et h e s h i f t a r m A a t t a c h i n gb o l t ,t h e s e t b a l l
2. Removethe 28 mm plug bolt and 1st/2nd select s p r i n gb o l t , s e t s p r i n g ,a n d s t e e lb a l l .
spring.
8 . R e m o v et h e s h i f tr o d ,t h e n r e m o v et h e s h i f ta r m A .
3 . Removethe shitt arm C attachingb o l t .
9 . Removethe reverselock cam.
Removethe shilt arm shalt.
1 0 . R e m o v et h e m a g n e t .
NOTE: Be careful not to lose the s t e e l b a l l .
5 . Removethe steel ball, spring,and c o a r .
REVESSE
LOCKCAM
SHIFTARM C
I SELECTRETAINER
REVERSE
,Y/
SHIFTARM B
INTERLOCK
\s S€LECT SPRING
L. 63.4 mm (2.50 inl
SPRINGL. 21.4 mm
{0.843 in)
SET BALL
SHIFTARM A SPRINGBOLT
COLLAR SPRING
14x20 L . 2 5 . 6 m m 1 1 . 0 1i n )
DOWELPIN
CLUTCH
HOUSING
ASSEMBLY
DIFFERENTIAL
^s* \
6p* \ ssrrrinru spnrr OIL SEAL
Replace.
\ \',)r,r*o
\ "r..", "r*,*o
L . 3 6 . 2 6 m m { 1 . 4 2 8i n l SHIFTBOO
\
28 mm PLUG BOLT
13-29
Differential
Index BacklashInspection
1. Placedifferentialassemblyon V-blocks,and install
both driveshafts.
PINIONGEARS
A
:'ylT'Y:-1.91"*4w
checktorwear^;Ul
2 . Measurebacklashof both pinion gears.

BALL AEARING Standard{Newl:0.05-O.15 mm (O.0O2-O.006in)
Check lor wear and damage.
10x 1.0 3 . It the backlashis not within the standsrd,reolace

1 0 1 N ' m 1O.3 kgl.m, 74.5 tbt'ft1 the ditterentialcarrier.
Left-hand threads
13-30
BearingReplacement Final Driven Gear Replacement
't
NOTE: Check bearingsfor wear and rough rotation. . Remove the bolts in a crisscross pattern in several
the bearingsare OK, removalis not necessary. steps, then remove the final driven gear from the
differential carrier.
1. Remove the ball bearings using a bearing puller as
NOTE: The final driven gear bolts have left-hand
threads.
PULLER
(Commercially
available) FINALDRIVENGEAR
Chamferon ansidediameterol
final drivengear faces carrier.
BALL BEARING
2. Installnew ball bearingsusing the specialtool as

shown.
1 0 x 1 . 0m m B O L T
NOTE: Drivethe bearingssquarelyuntil they bot- 101 il.m (10.3kg{'tn,74 5 lbl'tt)
tom againstthe carrier. Left-hand threads.
DRIVER,40 mm l.O.
7746- 0030100
2. Installthe final driven gear by tighteningthe bolts

in a crisscrosspattern in severalsteps.
BALL BEARING
13-31
Differential
Thrust Shim Adjustment
1 . I n s t a ltlh e d i f f e r e n t i aals s e m b l ym
, a k i n gs u r ei t b o t - 3 . Installthe transmissionhousing(seepage 13-41).
t o m s i n t h e c l u t c hh o u s i n gu, s i n gt h e s p e c i a l t o oal s
sh o wn . NOTE: Do not applyliquidgasketto the matingsur-
tace of the clutch housing.
Tighten the transmissionhousingattaching bolts

( s e ep a g e 1 3 - 4 2 ) .
8 x 1 . 2 5m m
27 N.m (2.8 kgt'm, 20 lbf.to
5. Usethe specialtool to bottom the differentialassem-

bly in the clutch housing.
DRIVER,40 mm l.D.
07746 -0030100
I n s t a l tl h e t h r u s ts h i m .
N O T E : I n s t a l tl h e s a m es i z et h r u s ts h i m t h a t w a s
removed.
6. Measureclearancebetweenthrust shim and bear-

i n g o u t e r r a c ei n t r a n s m i s s i ohno u s i n g .
13-32
7. ll the clearanceis more than the standard,selecta 8 0 m m T H R U S TS H I M :D 1 6 Y 5 ,D l 6 Y 8 e n g i n e s
n e w t h r u s ts h i m f r o m t h e f o l l o w i n gt a b l e . Part Numbe? Thickness
NOTEr lf the clearancemeasuredin step 6 is within 4r441-PL3-800 1 . 0 m m ( O . O 3 9 4i n )

t h e s t a n d a r dg, o t o s t e p 1 O . 41442-PL3 BOO 1 1 m m ( O . 0 4 3 3i n )
41443 PL3 800 1 .2 mm lO.O472in')
: -0.1O mm l0-0.OO4 in)
S t a n d a r dO
41444-PL3-800 1 . 3 m m ( O . O 5 1 i2n )
72 mm THRUSTSHIM: Dl6Y7 engine 41445 PL3 800 1 . 4 m m { O . O 5 5 i1n )
'1.5
Part Number Thickness 41446- PL3 800 m m ( O . O 5 9 1i n )
4t441 PL3 AOO 1. 0 m m ( O . O 3 9 4i n ) 41441 PL3 BOO 1 . 6 m m ( O . 0 6 3 0i n )
41442 PL3 AOO 1. 1 m m ( O . O 4 3 3i n ) 41448- PL3 BOO 1 . 7 m m ( 0 . 0 6 6 9i n l
41443-PL3-A00 1.2 mm lO.0472 tn) 41449-PL3- 800 1 . 8 m m ( 0 . 0 7 0 9i n )
41444 PL3-AOO 1 . 3 m m { O . 0 5 ' 1i2n ) 41450 PL3-800 1. O 5 m m ( 0 . 0 4 13 i n )
41445-PL3-AOO 1 . 4 m m ( O . O 5 5 i1n ) 4 1 4 5 ' t- P L 3 - B O 0 1. 15 m m ( O . O 4 5 3i n )
41446-PL3-AOO 1 . 5 m m { 0 . 0 5 9 1i n ) 41452 PL3-BO0 1 . 2 5 m m ( O . O 4 9 2i n )
41447 PL3 AOO 1 . 6 m m ( 0 . 0 6 3 0i n ) 4 1 4 5 3 - P L 3- B O O 1 . 3 5 m m ( O . O 5 3 2i n )
41448-PL3-AOO 1 . 7 m m ( 0 . 0 6 6 9i n ) 41454 PL3-BO0 1. 4 5 m m { O . 0 5 7 1i n )
41449-PL3,AOO 1 . 8 m m ( 0 . 0 7 0 9i n ) 41455 PL3-BO0 1 . 5 5m m { 0 . 0 6 1 0i n )
41 450- PL3- AOO 1. 0 5 m m ( 0 . 0 4 1 3 i n ) 41456 PL3,B00 1 . 6 5 m m { 0 . 0 6 5 0i n )
4 1 4 5 ' 1, P L 3- A O O 1. l 5 m m ( O . O 4 5 3i n ) 41457 PL3 BO0 1 . 7 5 m m ( 0 . O 6 8 9i n )
4 14 5 2 - P L 3- A O O 1 . 2 5 m m { O . O 4 9 2i n )
' 1 . 3 5m m ( O . O 5 3 2i n ) 8 . Removethe bolts and transmissionhousing.
41453-PL3-A00
'1
41454-PL3 A00 . 4 5 m m { O . O 5 7 'i1n ) 9 . Replacethe thrust shim selectedin step 7. then
41455-PL3-AOO 1. 5 5 m m ( 0 . 0 6 ' 1 0i n ) recheckthe clearance.
4 14 5 6 - P L 3- A O O 1 . 6 5 m m { 0 . 0 6 5 0i n ) 'lO. Removethe bolts and transmissionhousing.Apply
'1
41457 PL3 A00 . 7 5 m m ( O . 0 6 8 9i n ) liquidgasketto the surfaceo{ the transmission
hous-
ing and reassemble.
13-33
Clutch HousingBearing
Replacement \J
Mainshafl 3. Drivethe new oil sealinto the clutch housingusing
the sDecialtools as shown.
1 . R e m o v et h e b a l l b e a r i n gu s i n gt h e s p e c i atl o o l a s
s h o wn .
ATTACHMENT, 42 | 47 mm
07746-0010300
\ '
Drivethe ball bearinginto the clutch housingusing
ADJUSTABLE EEARING the specialtools as shown.
PULLER,25-40 mm
07736-A01000A
) Remove the oil seal trom the clutch housing.
CLUTCH
HOUSING
Replace.
13-34
J
Countershatt 2. I n s t a ltlh e o i l g u i d ep l a t e t, h e nd r i v et h e n e e d l eb e a r -
i n g i n t o t h e c l u t c hh o u s i n gu s i n gt h e s p e c i atl o o l s
1. Removethe needlebearingusingthe specialtool as as shown.
shown, then removethe oil guide plate.
NEEDLEBEARING
)
GUIDEPLATE
25-40 mm
PULLER. * 1 : A T T A C H M E N T4,2 x 4 7 n n
07736-AOtOOOA 07746-0010300
*2: ATTACHMENT.52 x 5s mm
o7746 -0010400
OIL GUIDEPLATE
*1: Dl6Y7 €ngin6

+2: D16Y5, Dl6Yg onginos
13-35
MainshaftThrust Shim
Adjustment
I. Removethe thrust shim and oil guideplatetrom the 5. S e l e c t h e p r o p e rs h i mo n t h e b a s i so f t h e f o l l o w i n g
t r a n s m i s s i ohno u s i n g . calculatrons:
N O T E : U s e o n l y o n e t h r u s ts h r m
THRUSTSHIM :.____
( B a s i cF o r m u l)a
( B ) + ( C ) - O . 9 5 = s h i mt h i c k n e s s
1)/t' i':
OIL GUIDE
PLATE
''7 Exampleof calculation:
D i s r a n c e@ ( 2 . 0 Om m ) + D i s t a n c e ' e ( O . 0 9m m )
= 2.09mm
TRANSMISSION s u b t r a c t h e s p r i n gw a s h e rh e i g h t( 0 . 9 5m m ) = t h e
HOUSING f e q u i r e dt h r u s ts h i m ( 1. 14 m m )
2 . Installthe 3rd/4th synchro hub, spacercollar, 5th
synchrohub, ball bearing,and thrust washeron the 65 mm THRUSTSHIM: Dl6Y7 engine
mainshaft.Installthe assemblyin the transmission Part Numbet Thickness
housrng. 23931 PL3 A10 0.60 mm {0.0236 in}
B 23932 PL3 410 0 . 6 3 m m 10.0284 in)
c 23933 PL3 A10 O . 6 6m m { 0 . 0 2 6 0 ; n }
D 23934 PL3 A10 0 . 6 9 m m { 0 . 0 2 7 2i n }
@ gnolcru sYncHRoHUB E 23935 PL3 Ar0 0 . 7 2 m m ( 0 . 0 2 8 3i n )
F 2 3 9 3 6- P L 3- A 1 0 0 . 7 5 m m ( 0 . 0 2 9 5i n )
23937 PL3 A10 O . 7 8 m m ( O . O 3 Oa7n l
THRUSTWASHER H 23938 PL3 A10 O . 8 1 m m ( 0 . 0 3 1 9i n )
23939 - PL3-A' t O O . 8 4 m m 1 0 . 0 3 3 1i n )
SPACERCOLLAR J 2 3 9 4 0 -P L 3- A 1 0 0 . 8 7 m m 10.0343 inl
K 23941 PL3 A10 O . 9 0 m m 1 0 . 0 3 5 4i n )
L 2 3 9 4 2- P L 3- A 1 0 O . 9 3 m m { 0 . 0 3 6 6i n }
5TH SYNCHROHUB M 23943 PL3 A10 O . 9 6m m ( O . O 3 7 8 in)
N 23944 PL3 A10 O . 9 9m m ( O . O 3 9 O in
o 23945 PL3 ArO 1 . O 2m m ( O . O 4 Oi2n
BALL EEARING 23946 PL3 A10 1 . 0 5 m m ( 0 . 0 4 1 3i n )
o 23947 PL3 A10 1 . 0 8 m m ( 0 . 0 4 2 5i n )
3 . Measurethe distance@ between the end of the R 23948 PL3-A10 1 . 11 m m ( 0 . 0 4 3 7i n )
transmissionhousingand thrust washer. 23949 PL3-A10 1 4 m m O.0449 in)
T 23950 PL3 A10 1 . 1 7m m 1 0 . 0 4 6 1 in)
23951 PL3 A10 1 . 2 0 m m ( 0 . 0 4 7 2i n )
NOTE:
23952 PL3 A10 l 2 3 m m l O . O 4 8 4i n )
a Use a straight edge and verniercaliper. 23953 PL3 A10 L 2 6 m m { 0 . 0 4 9 6i n )
a Measure at three locations and average the X 2 3 9 5 4 - P L 3- A 1 0 L 2 9 m m { 0 . 0 5 0 8i n )
readings. 23955 PL3 A10 1 . 3 2m m { 0 . 0 5 2 0i n }
2 3 9 5 6 P L 3- A 1 0 1 . 3 5 m m { O . O 5 3 Ii n )
4. Measurethe distance@ betweenthe surfacesot the 2 3 9 5 7- P L 3- A 1 0 1 . 3 8 m m ( 0 . 0 5 4 3i n )
AB 2 3 9 5 8- P L 3- A t O 1 . 4 1 m m { 0 . 0 5 5 5i n }
clutch housingand bearinginner race.
AC 23959 PL3-A10 1 . 4 4 m m 1 0 . 0 5 6 7i n )
AD 23960-PL3 A10 1 . 4 7 m m ( 0 . 0 5 7 9i n )
NOTE: AE 23961-PL3-A10 . 5 0 m m ( O . 0 5 9 1i n )
a Use a straightedge and depth gauge. 2 3 9 6 2- P L 3- A 1 0 - 5 3 m m 0 . 0 6 0 2i n )
a Measure at three locations and average the AG 23963 PL3 A10 . 5 6 m m ( O . 0 6 1 4i n l
readlngs. AH 23964- PL3-A 10 . 5 9 m m ( O . 0 6 2 6i n )
ENDOF CLUTCHHOUSING 23965 PL3-A 10 L 6 2 m m ( 0 . 0 6 3 8i n )
2 3 9 6 6- P L 3 , A 1 0 ' t . 6 5m m
0.0650 in)
AK 23967-PL3-A10 L 6 8 m m { 0 . 0 6 6 1i n }
2 3 9 6 8- P L 3- A 1 0 7 l m m 0.0673in)
23969 PL3 A10 1 . 7 4 m m { 0 . 0 6 8 5i n i
23970 PL3 A10 1 . 7 7 m m ( 0 . 0 6 9 7i n )
AO 23971 PL3 A10 1. 8 0 m m ( 0 . 0 7 0 9' n )
INNERRACEOF EALL BEARING
13-36
70 mm THRUSTSHIM: D16Y5. D16Y8 enqines 7. Installthe thrust washer and spring washer in the
Part Number Thickness mainshaft.
A 23931 PL3 BOO 0 . 6 0 m m { 0 . 0 2 3 6i n }
a 23932 PL3- BOO 0 . 6 3 m m { 0 . 0 2 8 4i n i
23933-PL3 BOO O . 6 6 m m { 0 . 0 2 6 0' n )
D 23934 PL3 800 0 6 9 m m ( 0 . 0 2 7 2i n )
E 23935 PL3 800 0 . 7 2m m ( 0 . 0 2 8 3i n )
F 23936 PL3 800 0 . 7 5 m m ( 0 . 0 2 9 5I n ) THRUSTWASHER
G 23937 PL3 B00 0 . 7 8 m m ( 0 . 0 3 0 7i n )
SPRINGWASHER
H 23938 PL3 800 0 . 8 1 m m ( 0 . 0 3 1 9i n )
23939 PL3 800 0 . 8 4 m m ( O . 0 3 3 1i n )
J 2 3 9 4 0- P L 3 B O O 0 . 8 7 m m ( 0 . 0 3 4 3i n )
23941-PL3 BOO O . 9 0m m ( O . 0 3 5 4i n )
23942 PL3 BOO O . 9 3m m { O . 0 3 6 6i n )
M 23943 PL3 BOO O . 9 6m m { 0 . 0 3 7 8i n )
N 23944 PL3 BO0 0 . 9 9 m m { 0 . 0 3 9 0i n } 8 . Installthe mainshaftin the clutch housing.
o 23945 PL3 800 LO2 mm {0.0402 inl
23946 PL3- 800 1. O 5 m m ( 0 . 0 4 13 i n ) 9 . Placethe transmissionhousingover the mainshaft
o 23947 PL3 800 1 . O 8m m { 0 . O 4 2 5i n ) and onto the clutch housing.
R 23944 PL3 800 1 . 11 m m ( 0 . 0 4 3 7i n )
S 23949 PL3 800 '] 14 mm (O.O449 in) 1O. Tightenthe clutch and transmissionhousingswith
T 23950 PL3-800 1 . 1 7m m ( 0 . 0 4 6 1i n )
23951 PL3 800 1 . 2 0 m m ( 0 . 0 4 7 2i n )
severalI mm bolts.
23Ss2 PL3 BOO L23 mm {O.O484 in}
23953 PL3 800 1 . 2 6 m m { 0 . 0 4 9 6I n ) NOTE: lt is not necessaryto use sealing agent
23954 PL3-BOO l 2 9 m m { 0 . 0 5 0 8i n } between the housings.
23955 PL3- 800 1 . 3 2m m { 0 . 0 5 2 0i n l
z 23956 PL3- 800 1 . 3 5 m m ( 0 . 0 5 3 1i n ) I x 1 . 2 5m m
23957 PL3 800 1 . 3 8 m m 1 0 . 0 5 4 3i n )
27 N'm (2.8 kgf.m. 20 lbf.ftl
AB 23958 PL3-800 1 . 4 1 m m ( 0 . 0 5 5 5i n )
AC 2 3 9 5 9- P L 3 - 8 0 0 1 . 4 4 m m ( O . 0 5 6 7i n )
AD 23960 - PL3- 800 1 . 4 7 m m ( O . 0 5 7 9i n ) t i t h a p l a s t r ch a m m e r .
1 1 . T a p t h e m a i n s h a fw
AE 23961 PL3 800 L 5 0 m m ( 0 . 0 5 9 1i n )
23962 PL3 800 L 5 3 m m { 0 . 0 6 0 2I n ) 12. Checkthe thrust clearancein the mannerdescribed
AG 23963-PL3-800 . 5 6 m m { 0 . 0 6 1 4i n } below.
AH 23964 PL3- BO0 1 . 5 9 m m { 0 . 0 6 2 6i n }
23965- PL3- BO0 L 6 2 m m { 0 . 0 6 3 8i n )
23966 PL3 800 1 . 6 5 m m 1 0 . 0 6 5 0i n l CAUTION: Measurementshouldbe made at room
AK 23967 - PL3 BOO 1 . 6 8 m m ( 0 . 0 6 6 1i n ) temperalute.
23968-PL3 BOO . 7 ' l m m ( O . 0 6 7 3i n )
23369 PL3 800 1 . 7 4 m m ( O . 0 6 8 5i n ) a. Slidethe mainshaftbase and the collarover the
AN 23970- PL3,800 1 . 7 7m m 1 O . 0 6 9 7 in) mainshaft.
AO 23971 PL3 800 1 . 8 0 m m ( O . 0 7 0 9i n )
6. Installthe oil guide plate and selectedthrust shim

CLUTCH
in the transmissionhousing. HOUSING
NOTE:
a Cleanthe thrustwasher,springwasherandthrust
shim thoroughlybefore installation.
a Install the thrust washer, spring washer and
thrust shim properly. MAINSHAFT BASE
:---.._ 07GAJ- PG20't30
THRUSTSHIM COLLAR
i,I '"9
"): oTGAJ-PG20120
O I LG U I D E
a',/,
PLATE
TRANSMISSION
HOUSING
---[
{cont'd}
13-37
--
MainshaftThrust Shim
Adjustment (cont'd)
b. Attach the mainshaltholderto the mainshaftas e. Zero a dial gauge on the end of the mainshalt
lollows:
NOTE:
Back-outthe mainshaftholderbolt and loosenthe
two hex bolts.
F i t t h e h o l d e r o v e r t h e m a i n s h a f ts o i t s l i p i s
toward the transmission.
Align the mainshaftholder'slip aroundthe groove
at the insideof the mainshaftsplines,then tighten
the hex bolts.
MAINSHAFTHOLDER
EOLT
MAINSHAFTHOLDEF
07GAJ-PG20t 10
MAINSHAFT f . Turn the mainshalt holderbolt clockwise;stop

. HOLD€R turningwhen the dialgaugehas reachedits max-
07GAJ-PG20110 imum movement,The readingon the dial gauge
is the amount ot mainshaltend play.
CAUTION: Turning tho mainshatt hold6t bolt

mor6 than 60 dogroosatter the needls of the dial
gaugs stops moving may damage th6 trans-
missioo.
Seat the mainshaftfully by tappangon the end s . lf the readingis withinthe standard,the clearance
with a Dlastichammer. rs correcr.
d . Threadthe mainshalt holderbolt in until it just lf the readingis not within the standard,recheck
contactsthe wide surfaceof the mainshaftbase. the shim thickness.
: . 1 1 - O . 1 8 m m { O . O O 4 - 0 . O Oi7n )
S t a n d a . dO
13-38
Transmission
Reassembly
N O T E :T h es t e e bl a l l s a r e aol lf r h e s a m e s i z e ( 5 / 1 6 i n ) . 6 . Insertshift arm shatt in the clutch housing
1 . I n s t a l tl h e m a g n e ta n d r e v e r s el o c k c a m . 7 . Installthe collar,spring,and steelballinto the case.

Compressthe ball and insert the shift arm shaft.
2. S e t s h i f t a r m A o n t h e c l u t c hh o u s i n gt,h e n i n s t a l l
the shiftrod. 8 . Installshift arm C in shitt arm A, then insertthe shift
arm shalt.
3 . Installthe springwasherand shitt arm A attaching
bolt. 9 . Installthe reverseselectretainerand reverseselect
spring onto shitt arm shaft.
Installthe steelball,spring,and set ball springbolr.
1 0 .lnstallthe differentialassembly.
5 . Installshitt arm B in the interlock,then set it on the
clutch housing.
6 x 1 . 0m m
A:8x'l.Omm SHIFTARM C 1 5 N . m { 1 . 5 k g t . m ,1 1 l b l . f t l
31 N.m 13.2 kgf.m, 23 lbf.ft,
/ REVERSE
LOCKCAM
sHtFTARM " ___\..-
ITNTERLOCK,\
NTERLOCK.
-.-.-.-...uK,
-b
K REVERSESELECTRETAINER
REVERSESELECTSPRING
L. 63.4 mm 12.50inl
MAGNET
f!ir"---
10.843 in)
SET BALL SPRINGBOLT
SHIFTARM A
22 N.m 12.2 kgt.m, 16 lbf.ltl
COLLAR SPRING
L. 25.6 mm ('l.Ol inl
CLUTCH
HOUSING
OIFFERENTIAL
ASSEMBLY
OIL SEAL
Replace.
SHIFTARM SHAFT
SHIFT ROD
BOOT
(cont'd)
13-39
Transmission
Reassembly(cont'dl
11. Positionthe 36 mm springwasherand washeronto 15. lnstallthe reverseidler gear and reverseidler gear
the mainshaftbearing. shaft.
MAINSHAFT/COUNTERSHAFT
SHIFTFORKASSEMBLIES
IDLER
REVERSE
GEARSHAFT
Tape the mainshaft
splrnes.
WASHER
1 2 .Installthe mainshaft,countershaft.and shift fork

GEAR
assemblies.
NOTE: Align the finger ot the interlock with the

groove in the shitr fork shaft.
16. Installthe reverseshift holder.
Installthe springwasher and shi{t arm B attaching
bolt.
8 x 1 . 0m m REVERSE
SHIFT
31 N'm 13.2kgl'm, 23 lbl'ltl
1ST/2NOSELECTSPRING
L . 3 6 . 2 6 m m 1 1 . 4 2 8i n )
28 mm PLUGEOLT
54 N.m {5.5 kgl.m,
GUIDEEOLT
40 tbf.Irl
39 N.m 14.0 ksf.m,29 lbf.ftl 6x1.Omm
1 4 . I n s t a ltlh e 1 s t / 2 n ds e l e c ts p r i n g ,2 8 m m p l u g b o l t . 15 N.m {1.5kgl'm,
and interlockguide bolt. 11 lbI.fr)
N O T E : A p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 - O O O 1o r
08 7'l I 0003) to the threadsof the 28 mm plugbolt
and interlockguide bolt.
13-40
1 7 . I n s t a l tl h e o i l g u t t e rp l a t e 2O. lnstallthedowelpinsand the transmissionhousing.
21. Lower the transmissionhousingwith the snap ring

pliers,and set the snap ring into the groove of the
OIL GUTTERPLATE
countershaftbearing.
NOTE: Checkthat the snap ring is securelyseated

in the groove of the countershaftbearing.
32 mm SEALINGEOLT
25 N.m {2.5 kgf.m, 18lbf.ttl
TRANSMISSION
HOUSING
1 8 . Installtheoilguideplateandthrustshimon the trans-

missionhousing.
1 9 . Apply liquidgaskel to the surfaceof the transmis-

sion housing mating with the clutch housing as
shown.
NOTE:
. Use liquid gasket (P/N O8718-OOO1 or
o8718-O003).
4.6 -8.3 mrr|
a Removethe dirty oil from the sealingsurface.
10.18 0.33 in)
a lf 5 minutes have passedafter applying liquid
gasket.reapplyit and assemblethe housings.
a Allow it to cure at least20 minutesafter assem-
bly before tilling the transmissionwith oil.
Liquid gasker
2 2 . I n s t a l tl h e 3 2 m m s e a l i n gb o l t .
N O T E : A p p l y l i q u i dg a s k e t( P / NO 8 7 1 8 - O O O 1
t 0 8 7 1 8 - O O O 3 )t o t h e t h r e a d s .
(cont'd)
13-41
I -
Transmission
Reassembly(cont'dl
23. Tightenrhe rransmissionhousingattachingbolts in 2 5 . I n s t a l lt h e b a c k - u pl i g h t s w i t c h a n d l r a n s m r s s r o n
the numberedsequencein several steps shown hanger.
oetow.
8 x 1. 2 5 m m
Totqnet 27 N'm (2.8 kgf.m, 20 lbl'fr) 8 x 1 . 2 5m m
27 N.t 12.8 kgt.m, 20 lbf.frl
BACK,UPLIGHTSWITCH
HARNESSSTAY
le
25 N.m {2.5 kgl'm, 18 lbf,ftl

24. Installthe steel balls,springs,and set screws.
SPRING
L . 3 1 . 6 m m ( 1. 2 4 i n l
SETTINGSCREW
22 N.m l'2.2 ksf.m, 16 lbt.tt)
13-42
Oil Seals
I Replacement
TransmissionHousing: Clutch Housing:
L Bemovethe oil sealfrom lhe transmissionhousing. 1. Removethe oil seal from the clutch housing.
2 . Installthe oil sealinto the transmissionhousinqus- Installthe oil seal into the clutch housingusingthe
ing the specialtools as shown. soecialtools as shown.
DRIVER
DRIVERATTACHMENT
S€AL DRIVER oTJAD-PH80101
ATTACHMENT
07947-6110501 ot
07947-6110500 otL sEAt
neplace.
OIL SEAL
Replace.
13-43
GearshiftMechanism
Overhaul v
NOTE:
replaceany worn or damagedparts.
a Inspectrubberpartsfor wearanddamagewhendisassembling;
a Installthe clip as shown.
a Turn the boot so the hole is facing down as shown.
a Make sure the boot is installed on the shift rod.
EXTENSION
BOLT
SHIFTLEVERKNOB
7.8 N.m (0.8 kgl.m,5.8 lbf.ftl )
EXTENSION
xx'tt" .,,,"1"I
cuErfl
iiJ?t
ffi
U &_ e:---g exrrfusror
noo END ExrENsroN
BUsHrr{c
ENocoLLAR
3$i^\@ ffi)'o"o*h--:l+:l
:r'.n Y Y9 ,-,r:- \\ i!l,1t'^- cL'P
Ant;:n;r ,:1i",""""""",, \ J
sH,FrRoD
5ii_-.ry
@
f
r*H \\
exrertror,r o.n^c\\ ex r.zs.- ,._, r.,or.rr, I ffiW
lii,€i"r**,
se^LB d""
fi+L-w^sHER
A'?''"
*tlp;t{^
-' % \o ,, _
- _
Boor
I 1
;#""*,\**
REARJo,Nr",i""YEo
:rr,'"'iyss.
\
aÂ
iKlp-dffi
NUr
sELF.LocKrNG | /oown \ \a[ffi=
:"
Replace. / CLIP t
6 x 1 o mm
9.8 N.m l1.Oksf.m,7.2 lbt.frl sinttc ptt't \
neoraci. HOLE
13-44
AutomaticTransmission
."' 14-1
AutomaticTransmission.'.'......'."....
ContinuouslyVariableTransmission
(cwl .......... 14-161
t
Automatic Transmission
SpecialToofs .............-.-....-......14-2ATF Pump

Description .............,.,.,..,......,.. 14-3 Inspection .......................... 14-109
PowerFlow ........................ 1i1.6 Main ValveBody
ElestronicControlSystem ..,............................. 14.13 Disassembly/lnspection/Rea$embly ......,......, 14-110
HydraulicControl .............. 14-18 SecondaryValve Body
HydrauficF|ow...... .,.....-..... 14-23 Disassembfy/lnspection/Reassembly ......-.-..-.. 11-112
Lock-upSystem .-......-....-.-. 1+32 RegulatorValv€ Body
EleqtricalSystem Disassembly/lnsp€ction/Reassembly .......,....,.1{-'t13
ComponentLocations.......,..,....,.,......... ................. 1i1"39 Servo Eody
PCMCircuit Diagram Disassembly/lnspection/Beassembly .............. 14.114
{A/T ControlSysteml ......................................... 1il.40 Lock-upValve Body
PCMTerminsl Voltage/MeasuringConditions Disassembly/lnspection/Reassembly .............. 14.115
A/T ControlSystem ..-.......14-42 Mainshatt
Troubleshooting Procedures...........................,..,.,. 14-44 Disassembly/lnspection Rsassembly............... 1,t"116
Symptom-to-ComponentChart
Inspection ........................,. 1+117
ElectricalSystem .....,.....,.,. l il-il8 Countershaft
ElectricalTroubleshooting
Dissssembly/lnspection/Reassembly .............. 14-119
Troubleshooting Flowcharts............................. 14.50
Disassembly/Reassembly ................................. 14-120
Lock-upControl Solenoid Valve A/B Assambly
fnspection .........-.-.............. 14-121
Test ...................... ............. 14-71 One-way
Clutch
Repfacement ...........-.-....,.., 11-74 Disassembly/lnspection/Reassombly .....,,....... 1,[.123
Shift Control Solenoid Valve A/B Assembly
Clutch
Test ...................... . . . . . . . . . - . - . 1 4 - 7 5 lllustratsd
lndex {A'lRA.BitRATransmission}... 1Gl24
Replacement .......,.............. lil-75 lllustrated lndex IM4RATransmission) .........-.. 14.126
Linear SolenoidAssemblV
Disassembly... 11-128
Test ...................... . . . . . . . . . .1. 4
. .- 7 6
Reassembly ........................ 14-130
Reofacement ......,.,.,,,,.,.,,,,. 11-77 Differential
a Mainshaft/Counter3haftSpeedSensors lllustrotedIndex ................ 1+13/t
t Repfacement ...................... 1+77 BacklashInspection .......... 14-135
Hydraulic Systcm
B€aringReplacement.............,.........,........,........ lil-l35
Symptom-to-ComponentChart
DitferentialCarrierReplacement..........,........... 1il.136
HydraulicSystem ...........-.- 11-78 Oil S€alRemovsl ............... 14.137
RoadTest ................................ 14-82 Oil SealInstallation/Side Clea.anc€................. 14-137
Stall SDeed
Torque Converter Housing Bsarings
Test ...................... ............. 1/t-85 Mainshaft Bearing/OilS€al Replacement........1,t-1,m
Fluid Level
CounteEhaftBearingReplacemsnt................. lil-li[f
Checking/Changing .......... lil-86 TransmissionHousing Bearings
PressureTesting ......,.............. 1il-87 Mainshaft/CountGrshaftBearings
Transmission Repfacement -..........,.,.,, 11-112
Transmission Reverseldl€r Gear
R e m o v a .l . . . . . . . . . . . . . . . . . . . . . . . . .1. .4.. 9 0 Installation ..,,.................,.,. l+t/*l
lllustrated Index Parking BrakeStop
Transmission/Right SideCover ..............,..,.,.... 1+g4 Inspection/Adiustment ..,.......................,,...,...... lil-li(|
Transmis3ion Housing....,......,........................,.. 14-96 Transmission
TorqueConverterHousing/ValveBody ..,....,... 14-98 Rea$embly........... ............. 14-144
Right Side Cover TorqueConv€rter/Drive Plate ...................,.,..,....... 14-150
Removal................ ............. 14-100 Transmission
TransmissionHousing Installation ......................... 14-151
Removaf................ ............. 1+102 CoolerFlushing ................. l il-155
Torque Converter Housing/ValveBody Shift Cable
Removal...........,.... .......,..,.. 14-10i1 Removal/lnslallation........................,................ 14-157
Valve Caps Adiustment ........................ lil-158
Description ......................... 14-106 Shift Lever ............................... 1a-t5g
Valve Body Shift Indicator Panel
Repai. .................... .--........-. 1+107 Adiustment . . . . . . . . . . . . . . . . . . .1. .{.-.1. .6. 0
.
alve ATF Cooler Hoses
SpecialTools
v
Ref. No. I Tool Number Description Oty I Prgo Reforenc.
o 07GAB- PF50101 MainshaftHolder 1 1 4 -1 0 1 ,1 4 8

't 4-128,'t31
07GAE- PG40200 ClutchSpringCompressorBoltAssembly 1
ar 07HAC- PK40' l0AHousingPuller 1 14-103
@ 07JAD- PH80101 DriverAttachment I 14-139
07JAD- PH80200 Pilot,26 x 30 mm I '14- 139
07LAE- PX40100 'l
@ ClutchSpringCompressorAttachment 14-124,131
@ 07PAZ- 00'10100 SCSServiceConnector 1 l4-45
@ 07sAz - 0010004 BackprobeSet 14-46
o OTMAJ_ PY4O11A A"/TOil PressureHose,2210mm 't 4-47
@ 07MAJ- PY40120 A,/TOil PressureHose,Adapter 14-87
@ 07406- 0020400 A,/TOil PressureGauge Set w/panel I 14-87
@ 07406- 0070300 Ay'TLow PressureGaugew/panel 1 14-87
@- 07736- A010004 AdjustableBearingPuller,25 - 40 mm 1 14-140,14' 1
@ 07746- 0010500 Attachment,62 x 68 mm 1 14-140,141,142
@ 07746- 0010600 Attachment,72 x 75 mm I 14-'t40,142
@ 07746- 0030100 Driver40 mm l.D. 1 '14-121. 135,137,138
@ 07749- 0010000 Driver I 14-139,140,141,'142
07947-611501 'I
@ DriverAttachment,68 mm 14-139
*Must be usedwith commerciallv-available
3/8" - 16 slidehammer.
I o
Edttltr-€
6, @
\l
g
\,
@ @ o @
@ @ @ @ @
t
14-2
Description
controlled
The automatictransmissionis a combinationof a 3-elementtorque convenerand a dual-shaftelectronically
automatictransmissionwhich provides4 speedsforwardand 1 reverse.
Torque Converter,Geats and Clutches

The torqueconverterconsistsof a pump.turbineand stator,assembledin a singleunit.They are connectedto the engine
crankshaftso they turn togetheras a unit as the engineturns.Around the outsjdeof the torque converteris a ring gear
which mesheswith the starterpinionwhen the engineis being started.The entiretorqueconverterassemblyservesas a
flywheelwhile transmittingpowerto the transmissionmainshaft.
The transmissionhas two parallelshafts:the mainshaftand the countershaft. The mainshaftis in line with the engine
crankshaft.The mainshaftincludesthe 1st,2nd and 4th clutches,gearstor 2nd, 4th, reverseand 1st (3rd gear is integral
with the mainshaft,while the reversegear is integralwith the 4th gear).The countershaftincludesthe 3rd clutch,and
gearsfor 3rd, 2nd. 4th, reverse,1stand parking.The gearson the mainshaftare in constantmesh with those on the coun-
tershaft.When certaincombinationsof gears in transmissionare engagedby clutches,power is transmittedfrom the
mainshaftto the countershaft to providep, E, E, and E positions.
ElectronicControl
The electroniccontrol system consistsof the PowertrainControl Module (PCM),sensors,a linear solenoid and four
controlledfor comfonabledriving underall conditions.The PCMis
solenoidvalves.Shiftingand lock-upare electronically
locatedbelowthe dashboard,underthe front lower panelon the passenger's side.
HydraulicControl
The valvebodiesincludethe main valvebody,the secondaryvalvebody,the regulatorvalvebody,the servobody and the
separatorplates,Theyare boltedon the torqueconverterhousing.
lock-upvalvebody throughthe respective
The main valve body containsthe manualvalve,the 1-2shift valve,the 2nd orificecontrolvalve,the CPB(ClutchPressure
, Back-up)valve,the modulatorvalve.the servocontrolvalve,the reliefvalve,and ATF pump gears.The secondaryvalve
body containsthe 2-3shift valve,the 3-4shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalveand the CPC(Clutch
PressureControl)valve.The regulatorvalve body containsthe pressureregulatorvalve,the torque convenercheckvalve.
the coolerreliefvalve,and the lock-upcontrolvalve.The servo body containsthe servovalvewhich is integratedwith the
reverseshift fork, and the accumulators.The lock-upvalve body containsthe lock-upshift valve and the lock-uptiming
valve.The linearsolenoidand the shift controlsolenoidvalveAy'Bare boltedon the outsideof the transmissionhousing,
and the lock-upcontrolsolenoidvalve!y'B is boltedon the outsideof the torque converterhousing.Fluidfrom regulator
passesthroughthe manualvalveto the variouscontrolvalves.The clutchesreceivefluid from their respective ieed pipes
or internalhydrauliccircuit.
Shift Control Mechanism

Inputfrom varioussensorslocatedthroughoutthe car determineswhich shift controlsolenoidvalvethe PCMwill activate.
Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shift valveto move.This pressurizes a line
to one of the clutches,engagingthat clutchand its correspondinggear.The shift controlsolenoidvalvesA and B are con-
trolledby the PCM.
Lock-uoMechanism
In E position,in 3rd and 4th, and in E positionin 3rd, pressurized
fluid is drainedfrom the backof the torqueconverter
through a fluid passage,causingthe lock-uppistonto be held againstthe torque convertercover.As this takesplace,the
mainshaftrotatesat the same as the enginecrankshaft. Togetherwith hydrauliccontrol.the PCMoptimizesthe timing of
the lock-upmechanism.The lock-upvalvescontroltherangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and
B, and linearsolenoid.When lock-upcontrolsolenoidvalvesA and B activate,the modulatorpressurechanges.The lock-
uo controlsolenoidvalvesA and B and the linearsolenoidare controlledby the PCM.
t
(cont'd)
14-3
Description
(cont'd)
Gear Sel€ction
The shift leverhassix positions:E PARK,E REVERSE,
E NEUTRAL,E 1stthrough 4th gear ranges,E 1stthrough3rd
gear ranges,P 2nd gear.
Position Description
E PARK Frontwheelslocked;parkingbrakepawl engagedwith parkinggearon countershaft.

All clutches
reteaseq,
E REVERSE gearand 4th clutchlocked.

Reverse;reverseselectorengagedwith countershaft.everse
E NEUTRAL All clutchesreleased.
E] DRIVE Generaldriving;stansoff in 1st,shiftsautomatically

to 2nd.3rd,then 4th, dependingon vehicle
(1stthrough4thl speedand throttleposition.Downshiftthrough3rd,2nd and 1ston deceleration to stop.The Iock-up
mechanismcomesinto operationin E positionin 3rd and 4th gear.
E DRIVE Usefor rapidacceleration at highwayspeedsand generaldriving;up-hilland down-hilldriving;starts

(1stthrough3rd) to 2nd,then3rd,dependingon vehiclespeedandthrottleposition.
off in 1st,shiftsautomatically
Downshifts through2ndto 1ston deceleration to stop.The lock-upmechanismcomesintooperation
in 3rd gear.
E SEcoND Usefor enginebrakingor bettertractionstartingoff on looseor slipperysurfaces;staysin 2nd

gear,does not shift up and down,
Startingis possibleonly in E and N positionsthroughthe useof a slide-type.neutral-safety

switch.
Automatic TransaxlslA/T) Gear Position Indicatot

The Ay'Tgear positionindicatorin the instrumentpanelshowswhich gear has beenselectedwithout havingto look down
at the console,
Clutch€s
The four-speedautomatictransmissionuseshydraulically-actuated clutchesto engageor disengagethe transmission gears.
When hydraulicpressureis introducedinto the clutchdrum, the clutchpiston moves.This pressesthe frictiondiscsand
steel platestogether.lockingthem so they don't slip. Power is then transmittedthrough the engagedclutch packto its
hub-mountedgear.Likewise, when the hydraulicpressureis bledfrom the clutchpack,the pistonreleases the frictiondiscs
and the steelplates,and they are free to slide past each other. This allowsthe gear to spin independentlyon its shaft,
transmittingno power.
. 1st Clutch
The lst clutchengages/disengages lst gear,and is locatedat the end of the mainshaft,just behindthe right sidecover.
The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft,
. 2nd Clutch
The 2nd clutchengages/disengages 2nd gear, and is locatedat the middle of the mainshaft.The 2nd clutch is joined
back-to-back to the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circuitconnect-
ed to the internalhydrauliccircuit.
. 3rd Cluich
The 3rd clutchengages/disengages 3rd gear, and is locatedat the end of the countershaft.
The 3rd clutchis supplied
hydraulicpressureby its ATFfeed pipe within the countershaft.
. 4th Clutch
The 4th clutchengages/disengages 4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The I
4th clutch is joined back-to-back
to the 2nd clutch.The 4th clutch is suppliedhydrauiicpressureby its ATF feed pipe
within the mainshaft.
14-4
One-way Clutch
The one,wayclutchis positionedbetweenthe countershaft1stgearand the parkinggear,with the parkinggearsplinedto the
The
countershaft. lst gear providesthe outer race and the parkinggear providesthe inner racesurface.The one-
surface,
'1st
way clutch locksup when power is transmittedfrom the mainshaft gear to the countershaft1st gear.The 1st clutch
and gearsremainengagedin the 1st,2nd,3rd, and 4th gear rangesin the E, E or @ position
However,the one way clutchdisengageswhen the 2nd,3rd, or 4th clutches/gears are appliedin the D., o or E position.
"speedrange" of the
This is becausethe increasedrotationalspeedof the gearson the countershaftoverridesthe locking
one-wayclutch.Thereafter, the one-wayclutchfree-wheelswith the 1stclutchstill engaged.
2ND CLUTCH 4TH CLUTCH
1STCLUTCH
MAINSHAFT
COUNTERSI{AFT
ONE-WAYCLUTCH
PABKINGGEAR
3AD CLUTCH
OUTSIDEOF ONE.WAY
CLUTCH
The sprags engage/
INSIDEOF ONE,WAY disengageoutside
CLUTCH and inside of the
Splinedwilh counter one way clutch.
shaft
LOCKINGCONDITION OVER.FIDING
LOCKINGSPEEOCONDITION
14-5
t-
Description
PowerFlow
1STGEAR 2ND GEAR 3RD GEAR 4TH

TOROUE REVERSE PARKING
\enr 1sT 2ND 3RD
CONVERTER GEAR GEAR
POSMON\. CLUTCH CLUTCH CLUTCH GEAR CLUTCH
E o o
E o o o
E o
o 4,2
2ND o o*i o
D-a 3 R O o o*, o
4TH o o*! o o
o o*,
[o] 2ND a o*' o
3RD o o*' o
E o o*1 o
O: Operates,x: Doesn'toperate.
*1: Althoughthe 1stclutchengages,driving power is not transmittedas the one-wayclutchslips.
*2: The one-wayclutchengageswhen accelerating, and slipswhen decelerating.
,, 14-6
I
El Position
Hydraulicpressureis not appliedto the clutches.Poweris not transminedto the countershaft.
E Position
Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft
The countershaftis lockedby the parkingpawl interlockingthe parkinggear.
TOROUECONVERTER
1ST CLUTCH
FINALDRIVE
GEAR
3RD CLUTCH
(cont'd)
14-7
Description
Power Flow (cont'd)
lst Gear {lP!lor .D3lposition)
tn [D.]or lal position,the optimum gear is automatically

selectedfrom 1st,2nd,3rd and 4th gears,accordingto conditions
suchas the balancebetweenthrottleopening(engineload)and vehiclespeed.
1. Hydraulicpressureis appliedto the 1st clutch,which rotatestogetherwith the mainshaft,causingthe mainshaftlst

gear to rotate.
2. Poweris transmittedto the countershaftlst gear,which drivesthe countershaft

via the one-wayclutch.
3. Poweris transmittedto the final drivegear,which drivesthe final drivengear.
TOROUE
CONVEETER
MAINSHAFT1ST GEAR
1ST CI-UTCH
MAINSHAFT
ONE-WAYCLUTCH
FINAI.DRIVEGEAR
PARKINGGEAR
COUNTERSHAFT
1ST GEAR
FINAL DRIVEN GEAR
14-8
Znd Gear {[0!, or or @ positionl
E Positionis providedto drive only 2nd gear.

'1. Hydraulicpressureis appliedto the 2nd clutchon the mainshaft,and power is transmittedvia the 2nd clutchto the
mainshaft2nd gear.
2. Powertransmiftedto the mainshaft2nd gear is conveyedvia the countershaft2nd gear, which drivesthe counter-
shaft.
3. Poweris transmittedto the final drive gear,which drivesthe final drivengear.
NOTE:Hydraulicpressureis also appliedto the 1st clutch.but sincethe rotationspeedof the 2nd gear exceedsthat
of 1stgear,powerfrom 1stgear is cut off at the one-wayclutch.
TOROUE
CONVERTER
2ND CLUTCH
MAIIISXAFT
COUNTERSHAFT
2ND GEAR
(cont'd)
14-9
Description
PowerFlow {cont'dl
3rd Gear ([ll or lg.l position)
'1. Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft
3rd gear.
2. Poweris transmiftedto the final drive gear,which drivesthe final drivengear.
NOTE:Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 'lst
gear,powerfrom lst gear is cut off atthe one-wayclutch.
TOROUECONVERTER
MAINSHAFT3RD GEAR
MAINSI{AFT
COUNTERSHAFT
3RD GEAR
3RD CLUTCH
FINALORIV€NGEAB
14-10
4th Gear {[t] position)
1. Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,causingthe mainshaft4th

gear to rotate.
2. Poweris transmittedto the countershaft4th gear,which drivesthe countershaft.
Poweris transmittedto the final drive gear.which drivesthe final drivengear.
NOTE:Hydraulicpressureis alsoappliedto the 1stclutch.but sincethe rotationspeedof 4th gear exceedsthat of 1st
gear,powerfrom 1stgear is cut off at the one-wayclutch.
TOROUE
4TH GEAR
4TH CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALDRIVENGEAR
(cont'd)
14-11
Description
Power Flow (cont'd)
E Position
l Hydraulicpressureis switchedby the manual valve to the servo valve.which moves the reverseshift fork to the
reverseposition.The reverseshift fork engageswith the reverseselector,reverseselectorhub, and the counte.shaft
reversegear.
2 Hydraulicpressureis also appliedto the 4th clutch.Power is transmittedfrom the mainshaftreverseoear vta the
reverseidler gearto the countershaftreversegear.
The rotationdirectionof the countershaftreversegear is changedvia the reverseidlergear.
4. Poweris transmittedto the final drive gear,which drivesthe final drivengear.
TOROUE
MAINSHAFT
COUNTERSHAFT
COUNTERSHAFT
REVERSE
GEAR
REVERSE
SELECTOR
HUB
REVERSE
SELECTOR
FINALORIVENGEAR REVERSE
SHIFT
FORK
SERVOVALVE
14-12
ElectronicControlSystem
The electroniccontrolsystemconsistsof a PowertrainControlModule{PCM),sensors,a linearsolenoidand four solenoid
valves.Shiftingand lock-upare electronicallycontrolledfor comfortabledriving underall conditions.The PCMis located
belowthe dashboard.under the front lower panelon the passenger'sside.
PGM-FI
Conirol Sy3tem
A/T Control SFtem
Shift Control
Lock-uDControl
(cont'd)
14-13
Description
ElectronicControlSystem(cont'dl
Shift Control
The PCM instantaneously determineswhich gear should be selectedby varioussignalssent from sensors,and actuates
the shift controlsolenoidvalvesA and B to controlshifting.Also,a GradeLogicControlSystemhas beenadoptedto con-
trol shiftingin io.rpositionwhile the vehicleis ascendingor descendinga slope,or reducingspeed.
Shil't Control Solenoid Shift Control Solenoid

Position Gear
Valve A Valve B
1st OFF ON
Dr Dr 2nd ON ON
3rd ON OFF
rq! 4th OFF OFF

l 2nd ON ON
E- Reverse ON
*See page 14-30forreverseinhibitorcontroldescription.
Lock-uoControl
From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol
solenoidvalveA and/orB accordingly.The combinationof driving signalsto lock-upcontrolsolenoidvalvesA and B and
the linearsolenoidpressureis shown in the table below.
Lock-up Control Lock-upControl Linear Solenoid

Lock-up Conditions
Sol€noid Valve A Solenoid Valve B Pressure
Lock'upOFF OFF OFF High
Dutyoperation
L o c k - u pH, a l f ON
OFF- ON
L o c k - u pF, u l l ON ON H i gh
LOCX-Up Dutyoperation
ON Low
duringdeceleration O F F* O N
14-14
. GRAOELOGICCONTROLSYSTEM
How it works:
The PCMcomparesactualdrivingconditionswith drivingconditionsmemorizedin the PCM,basedon the input trom the
vehiclespeedsensor,the throttlepositionsensor.the barometoricpressuresensor,the enginecoolanttemperaturesensor,
the brakeswitchsignaland the shift lever positionsignal.to controlshiftingwhile a vehicleis ascendingor descendinga
slope,or reducingspeed.
SIGNALSOETECTED
Judgemenl ot Controlling ArGa
OrivingRt3ktrncc
{Fuzzylogicl
' GradualA3cendingmode
' Steop Ascondingmode
. D6c€nding mode
. GradualOoscondingmode
. Si€ep Odcending mode
(cont'd)
14-15
Description
ElectronicControlSystem(cont'dl
. AscendingControl
When the PCMdeterminesthat the vehicleis climbinga hill in El position,the systemextendsthe engagementarea of
2nd gear and 3rd gear to preventthe transmissionfrom frequentlyshiftingbetween2nd and 3rd gears,and between3rd
and 4th gears,so the vehiclecan run smooth and have more power when needed.Thereare two ascendingmodeswith
different3rd geardrivingareasaccordingto the magnitudeof a gradientstoredin the PCM.
NOTE:
. The PCMmemorycontainsshift schedulesbetween2nd and 3rd gears,and between3rd and 4th gearsthat enablethe
PCM'sIuzzylogicto automatically selectthe most suitablegearaccordingto the magnitudeof a gradient
. Fuzzylogic is a form of artificialintelligencethat lets computersrespondto changingconditionsmuch like a human
m i n dw o u l d .
. DescendingControl
When the PCM determinesthat the vehicleis going down a hill in E position,the shift-upspeedfrom 3rd to 4th gear
when the throttleis closedbecomesfasterthan the set speedfor flat roaddrivingto widenthe 3rd geardrivingarea.
This, in combinationwith engine brakingfrom the decelerationlock-up,achievessmooth driving when the vehicleis
descending. Thereare two descendingmodeswith differentdownshift(4 - 3) schedulesaccordingto the magnitudeof a
gradientstoredin the PCM.When the vehicleis in 4th gear,and you are deceleratingon a gradualhill. or when you are
applyingthe brakeson a steephill,the transmissionwill downshiftto 3rd gear.Whenyou accelerate, the transmissionwill
then returnto 4th gear.
ASCENDINGMODE DESCENDING
MOOE
,lTH SHIFTING
CHARACTERISTICS
CONTROLAREA
ir'.ff}", vehicre
speod v.hicre3pe€d
ir'.111,",
. DecelerationControl
Whenthe vehiclegoes arounda corner,and needsto first decelerateand then accelerate,

the PCMsetsthe datafor deceleration
controlto reducethe numberof timesthe transmission shifts.When the vehicleis decelerating
from speedsabove26 mph
(41km/h),the PCMshiftsthe transmission
from 4thto 2ndearlierthan normalto copewith upcomingacceleration.
14-1 6
CircuitDiagramand TerminalLocations
IGNITION
SWITCH
PG2 LOCK-UPCONT8OL
OVALVE
SOLENO A
IGPl
IGP2
vcc2 LOC( UPCONTFOL

TPS SOLENOIDVALVEB
sG2
SNIFTCONTSOL
SOLENOIDVALVEA
SHIFICONTFOL
VALVEB
SOLENOID
LNEIFSOLENOID
POSITONF
14-17
Description
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump.valves,accumulators, and electronicallycontrolledsolenoids.
The ATF pump is drivenby splineson the end of the torqueconverterwhich is attachedto the engine.Fluidfrom the ATF
pump flows throughthe regulatorvalveto maintainspecifiedpressurethroughthe main valve body to the manualvalve,
directingpressureto each of the clutches.The valve body includesthe main valve body, the regulatorvalve body, the
lock-upvalve body, the secondaryvalve body, the servo body. the linear solenoid,the shift control solenoidvalve Ay'B
assembly,and the lock-upcontrolsolenoidvalveA,/Bassembly.The shift controlsolenoidvalveA,/Bassemblvand the lin-
ear solenoidare bolted on the outsideof the transmissionhousing,The lock-upcontrol solenoidvalveAy'Bassemblyis
boltedon the outsideof the torqueconverterhousing.
SHIFTCONTROL
SOLENOIDVALVEA/B
ASSEMBLY
LINEARSOLENOIO
VALVE
VALVEBODY
ATFPUMPGEARS
14-1 8
Main Valve Body
The main valve body houses the manual valve, the 1-2 shift valve, the 2nd orifice control valve, the CPB valve, the modu-
lator valve, the servo control valve, and the relief valve. The primary functions of the main valve body are to switch fluid
pressure on and off and to control the hydraul;c pressure going to the hydraulic control system
2NOORIFICECONTROL
VALVE
1.2 SHIFTVALVE
MOOULATOFV VE
MANUALVALVE
RELIEFV VE
CONTROL
MAIN V
VALVE
BODY
SecondaryValve Body
The secondaryvalvebody is locatedon the main valve body.The secondaryvalvebody housesthe 2-3 shift valve,the 3-4
shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalveand CPCvalve
3.4 SHIFTVALVE
2-3 SHIFTVALVE
4TH EXHAUSTVALVE
CPCVAL
VALVE
3.4 ORIFICECONTBOL
VALVE
(cont'd)
14-19
Description
HydraulicControl (cont'd)
RegulatorValve Body
The regulatorvalve body is locatedon the main valve body.The regulatorvalve body consistsof the regulatorvalve,the
torqueconvertercheckvalve,the coolerreliefvalve,and the lock-uocontrolvalve.
REGULA
VALVE
COOI.ERRELIEFVALVE
CONTROLVALVE
Lock-upValve Body
The lock-upvalvebody with the lock-upshift valveand the lock-uptiming valveis locatedon the regulatorvalvebody.
LOCK-UPSHIFTVALVE
TIMINGVALVE
BODY
14-20
RegulatorValve
The regulatorvalve maintainsa constanthydraulicpressurefrom the ATF pump to the hydrauliccontrol system,while
alsofurnishingfluid to the lubricatingsystemand torqueconvener.The fluid from the ATF pump flows through B and B'.
The regulatorvalve hasa valveorifice.The fluid enteringfrom B flows throughthe orificeto the A cavity.This pressureof
the A cavitypushesthe regulatorvalveto the right side,and this movementof the regulatorvalve uncoversthe fluid port
to the torque converterand the reliefvalve.The fluid flows out to the torqueconverter,and the reliefvalveand regulator
valve movesto the left side.Accordingto the levelof the hydraulicpressurethrough B, the positionof the regulatorvalve
changesand the amountof the fluid from B' through D and C also changes.This operationis continued,maintainingthe
ltnepressure.
NOTE:When used,"left" or "right" indicatesdirectionon the illustrationbelow.

ENGINENOTRUNNING ENGINERUNNING
To TOROUECONVERTER Lubrication
STATOBSHAFTARM
Stator ReactionHydraulicPressureControl
Hydraulicpressureincreasesaccordingto torque,are performedby the regulatorvalve using the statortorque reaction

The statorshaft is splinedwith the statorin the torqueconverter.and its arm end contactsthe regulatorspringcap.When
the vehicleis accelerating or climbing(TorqueConverterRange),the statortorque reactionacts on the statorshaft,and
the statorarm pushes the regulatorspringcap in the directionof the arrow in proportionto the reaction.The statorreac-
tion spring compresses, and the regulatorvalve movesto increasethe line pressurewhich is regulatedby the regulator
valve.The line Dressurereachesits maximumwhen the statortorque reactionreachesits maximum.
TOROUECONVERTER
VALVE
REGULATOR
TORSPRINGCAP
'..- _..-7
3f
ATORSHAFTARM
STATORSHAFT
{cont'd)
14-21
Description
HydraulicControl(cont'd)
Servo Body
The servo body is locatedon the secondaryvalve body.The servo body containsthe servovalvewhich is integratedwith
the reverseshift tork,and the accumulators
2ND ACCUMULA
SERVOBODY
lST ACCUMULATOR
3RDACCUMULATOR
SERVOVALVE/SHIFT
FORKSHAFT
14-22
.J HydraulicFlow
Gen€r8lChart of Hydraulic Pressure
ATFPump- RegulatorValve -; LinePressure ModulatorPressure--
;LClutch
LinearSolenoid
Pressure
l TorqueConverterPressure
L LubricationPressure
Distribution of Hvdraulic Pr€ssure

. RegulatorValve- TorqueConvenerPressure
f LubricationPressure
L To requlateLinePressure
. ManualValve-- To selectLinePressu.e ClutchPressure
. ModulatorValve ModulatorPressure Shift ControlSolenoidValves

l Lock-upControlSolenoidValves
LinearSolenoid
. 1-2 Shift Valve Il]l

. 2-3 Shift Valve ClutchPressure
l
. 3-4 Shift Valve
NO. DESCRIPTION
OF PRESSURE N O . DESCRIPTION
OF PRESSURE N O . OF PRESSURE
DESCRIPTION
MODULATE
'1 LINE 6B (SHIFT
CONTROL
SOLENOID 4 1 4THCLUTCH
VALVEB)
MODULATE
LINE (LOCK-UPCONTROL LINEARSOLENOID
SOLENOIDVALVEA)
MODULATE
1" LINE 6D (LOCK-UPCONTROL 90 TOROUECONVERTER
SOLENOIDVALVEB)
MODULATE
2 LINE 6D' (LOCK-UP
CONTROL 91 TOROUECONVERTER
SOLENOIDVALVEB)
LINE 7 LINE 92 TOROUECONVERTER
LINE 8 LINE/CPC 93 ATF COOLER
LINE LINE 94 TOROUECONVERTER
LINE 10 1STCLUTCH LUBRICATION
LINE 20 2ND CLUTCH 96 TOROUECONVERTER
4' LINE 204 2ND ACCUMULATOR 97 TOROUECONVERTER
cPc 25 LINE 99 SUCTION
MODULATE 30 3 R DC L U T C H X DRAIN
MODULATE
6A (SHIFTCONTROL
SOLENOID 40 4TH CLUTCH
VALVEA)
(cont'd)
14-23
Description
HydraulicFlow (cont'dl
N Position
(ATF)is drawn from (99)and dis-
As the engineturns,the ATF pump also startsto operate.Automatictransmissionfluid
(1) line pressure(1) is regulated
chargedinro (1).Then,ATF flowing from the ATF pump becomesthe line pressure The
(94) of the torque converter through the lock-up
by t;e regulatorvalve.The torque converterinlet pressure{92)enters
valve prevents the torque converter pressure from rising'
shift valveand dischargesinto (90).The torqueconvertercheck
Underthis condition,the hydraulicpressure is not appliedto the clutches'
"|eft" or "right" indicatesdirectionon the hydrauliccircuit'

NOTE:When used,
14-24
E Position
The line pressure(1)flows to the manualvalveand the modulatorvalve.The line pressure(1) changesthe line pressure
(4) and (25)at the manualvalve,and changesto the modulatorpressureat the modulalo.valve.But the modulatorpres-
sure (6) does not flow to each shift valve becauseshiit control solenoidvalvesA and B are turned ON by the PCM.The
line pressure(4) passesthrough the CPBvalveand the CPCvalve,and changesto the line pressure(5),then flows to the
1-2shift valve.The line pressure(5)from the 1-2shift valvechangesto the 2nd clutchpressure{20)at the 2-3 shift valve.
The 2nd clutch pressure(20) is appliedto the 2nd clutch,and the 2nd clutch is engaged.The line pressure(4) passes
throughthe 1-2shift valve and the orifice,and changesthe 1st clutchpressure,The 1st clutchpressure(10)also flows to
the 1stclutch.However,no power is transmittedbecauseof the one-wayclutch.
NOTErWhen used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
(cont'd)
14-25
Description
HydraulicFlow (cont'd)
El or lOi Position
1. lst Gear
The flow of fluid throughthe torque convertercircuitis sameas in N position.The line pressureflows to the manual
valveand the modulatorvalve.The line pressurechangesto the modulatorpressure(6) at the modulatorvalveand to
the line pressure(4)at the manualvalve.The modulatorpressure(6)flows to the left end of the 1-2shiftvalveand the
3-4 shift valvebecauseshift controlsolenoidvalveA is turnedOFFand B is turnedON by the PCM.The l-2 shift valve
'lst
is movedto the right side.The line pressure(4) changesto the clutchpressure110)at the 1-2shift valve and the
orifice.The 1st clutchpressure('t0)is appliedto the lst clutchand the 1st accumulator;consquently, the vehiclewill
move as the enginepower is transmitted.
"right" indicatesdirectionon the hydrauliccircuit.
NOTE:When used,"|eft" or
2. 2nd Gear
As the speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveA is turned ON by meansof the

PCM.The modulatorpressure(64l in the left end of the 1-2 shift valve is releasedby turning shift control solenoid
valveA ON. The 1-2 shift valve is moved to the left side and uncoversthe pon to allow line pressure(5) to the 2-3
shift valve.The line pressure(5)changesto the 2nd clutchpressure(20)at the 2-3 shift valve.The 2nd clutchpressure
(20)is appliedto the 2nd clutch,and the 2nd clutchis engaged.
Fluid flows bv wav of:

- Line Pressure(4)- CPBValve- LinePressure(5)- 'l-2ShiftValve- LinePressure(5)- 2-3 ShiftValve
- 2nd ClutchPressure(20)t 2nd Clutch
The hydraulicpressurealsoflows to the 1stclutch.However,no power js transmittedbecauseof the one-wayclutch.
NOTE;When used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
(cont'd)
14-27
Description
HydraulicFlow (cont'd) \
3. 3rd Gear
As the speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalve B is turned OFFby meansof the
pCM. Shift control solenoidvalve A remainsON. The modulatorpressure(6) tlows to the right end of the 1-2shift
valve and the left end of the 2-3 shift valve.The 2-3 shift valve is moved to the right side by the modulatorpressure
{68),The 2-3 shift valvecoversthe port to stop line pressure(5)to the 2nd clutchand uncoversto the 3-4 shift valve
as the 2-3 shift valve is moved to the right side.The line pressure(5) becomesthe 3rd clutchpressure(30)at the 3-4
shiftvalve.The 3rd clutchpressure(30)is appliedto the 3rd clutch,and the 3rd clutchis engaged.
Fluidflows by way of:

- Linepressure(4)- CPBValve- Line Pressure(5)- 1-2ShiftValve- LinePressure(5)+ 2-3 Shift Valve
- LinePressure{5)- 3-4 Shift Valve- 3rd ClutchPressure(30}* 3rd Clutch
The hydraulicpressurealso flows to the 1st clutch.However,no power is transmittedbecauseof the one-wayclutch
a s i n 2 n dg e a r .
When used,"left" or
14-28
i*. 4th G6ar ( qr Positionl
Asthe speedofthevehicle reachesthe prescribedvalue,shiftcontrolsolenoidvalveA is turnedOFFby meansof the

PCM.Shift control solenoidvalv6 B remainsOFF.The modulatorpressure(6) flows to the left end of the 1-2 shift
valve and the left end of the 3-4 shift valve.The modulatorpressure(64) in the left end of the 1-2shift valveequals
the modulatorpressure(68) in the right end of the 1-2 shift valve,the 1-2shiit valve remainsat left side by the ten-
sion of the valvespring.
The 3-4 shift valveis movedto the right side by the modulatorpressure(5A).The 3-4 shift valvecoversthe port to the
3rd clutchand uncoversthe port to the 4th clutchas this valveis movedto the right side.The 4th clutchpressure(41)
from the 3-4 shift valve becomesthe 4th clutch pressure(40) at the manual valve.The 4th clutch pressure{40} is
appliedto the 4th clutch,and the 4th clutchis engaged.
Fluidflows by way of:

- Linepressur€(4)- CPBValve- LinePressure(5)+ l-2 Shift Valve- LinePressure(5)- 2-3 ShiftVarve
- LinePressure(5)* 3-4 ShiftValve- 4th ClutchPressure(41)+ ManualValve- 4th ClutchPressure(40)
+ 4th Clutch
The hydraulicpressurealsoflows to the 1stclutch.However,no power is transmittedbecauseof the one-wayclutch

as in 2nd and 3rd gear.
NOTE:When used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
(cont'd)
14-29
Description
HydraulicFlow(cont'dl
lll Position
The flow of fluid through the torque convertercircuitis the same as in E position.The line pressure(1) changesto the
line pressure(3)and flows to the 1-2shift valve.The line pressure(3)changesto the line pressure(3')at the 1-2shift valve
and flows to the servovalve.The servovalve is movedto the right side (Reverserangeposition)and uncoversthe pon to
allow line pressure(3") to the manualvalve.The line pressure(3')from the 1-2shift valveflows throughthe servovalveto
the manualvalve and changesthe 4th clutchpressure{40).The 4th clutchpressure(40)is appliedto the 4th clutch,and
the 4th clutchis engaged.
ReverseInhibitor Control
Whenthe E positionis selectedwhile the vehicleis movingforwardat speedsover 6 mph (10 km/h),the PCMoutputsthe
1stspeedsignalto shift controlsolenoidvalvesA and B; shift controlsolenoidvalveA is turnedOFF,shift controlsolenoid
valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe port to stop line pressure{3') to the
servo valve.The line pressure(3') is not appliedto the servovalve,and the 4th clutchpressure{40)is not appliedto the
4th clutch,as a result.power is not transmittedto the reversedirection.

NOTE:When used,"|eft" or
14-3 0
E Position
The flow of fluid through the torque convertercircuitis the same as in E position.The line pressure(11changesto the
line pressure(3)and flows to the 1-2shift valve.The line pressure(3)changesto the line pressure(3')at the 1-2shift valve
and flows to the servovalve.The servovalve is movedto the right side {Reverserangeposition)and uncoversthe port to
allow line pressure(3")to the manualvalveas in E position.The line pressure(3")from the servovalveis interceptedby
the manualvalve.However,hydraulicpressureis not suppliedto the clutches,and the power is not transmitted.
When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
14-31
Description
Lock-upSystem
Lock-upClutch
1. Operation(clutchon)
With the lockup clutchon, the fluid in the chamberbetweenthe torqueconvertercoverand the lock-uppistonis drained
off,and the converterfluid exertspressurethroughthe pistonagainstthe torqueconvertercover.As a result,the convert-
therebyplacingthe vehiclein directdrive.
er turbineis lockedto the convertercover.The effectis to bypassthe converter,
LOCK-UPPISTON DAMPERSPRING
The power flows by way of:
TOROUECONVERTER
Engine COVER
I
Driveplate
t
Torque convertercover
t
Lock-uppiston
t
Damperspring
t
Turbine
I
lvlainshaft
MAINSHAFT
Operation(clutchoff)
With the lock-upclutch off, the fluid flows in the reverseof "clutch on." As a result.the lock-uppiston moves away from
the convertercover,and the torque converterlock-upis released.
TURBINE
TOROUE
Engine COVER
t
Driveplate
{
Torqueconvenercover
t
Pump
t To ATF coolel
Turbine
t
lvlainshaft
MAINSHAFT
14-32
In igd position,in 3rd and 4th, and D3-position in 3rd,
pressurized fluid is drainedfrom the back of the torque
converterthrough a fluid passage,causingthe lock-up
pistonto be held againstthe torque convertercover.As
this takesplace,the mainshaftrotatesat the same speed
as the engine crankshaft.Together with the hydraulic
c o n t r o l ,t h e P C M o p t i m i z e dt h e t i m i n g o f t h e l o c k - u p
system. Under certain conditions,the lock-upclutch is
appliedduring deceleration, in 3rd and 4th gear.
The lock-upsystemcontrolsthe rangeot lock-upaccord-

ing to lock-upcontrol solenoidvalvesA and B, and the
linearsolenoid.When lock-upcontrol solenoidvalvesA
TOROUECONVERTER and B activate.modulator pressurechanges.Lock-up
control solenoidvalvesA and B and the linearsolenoid
a r e m o u n t e do n t h e o u t s i d eo f t h e t o r q u e c o n v e r t e r
housing,and are controlledby the PCM.
Lock-up Conditions/Lock-up Control Solenoid Valves/

Linear Solenoid Pressure
Lock-upControl Linear
Lock-up Solenoid Valve Solenoid
Conditions
A B Pressure
Lock-upOFF OFF OFF High

Duty operation
Lock-up,Half ON
OFF- ON
Lock-up,Full ON ON High
LOCX-Up
Duty operation
during ON
IOROUECONVERTER OFF- ON
deceleration
CHECKVALVE
MODULATORPRESSURE
RELIEFVAL
LOCK.UPTIMING
VALVE
<- LINEARSOLENOIDPRESSURE
",
.X,COOLER
RELIEF
VALVE
ATFPUMP
(cont'dl
14-33
Description
Lock-upSystem(cont'dl
No Lock.up
. Lock-uoControlSolenoidValveA: OFF
. Lock-uoControlSolenoidValveB: OFF
. LinearSolenoidPressure:
High
The pressurized fluid regulatedby the modulatorworks

on both ends of the lock-upshift valve.Underthis condi-
tion, the pressuresworking on both ends of the lock-up
shift valve are equal,the lock-upshift valve is moved to
the right side by the tension of the valve spring alone.
The fluid from the ATF pump will flow through the left
side of the lock-upclutchto the torque convener;that is,
TOROUECONVERTER the lock-uoclutchis in OFFcondition.
NOTE:When used,"left" and "right" indicatesdirection

on the hvdrauliccircuit.
-r
TOROUECONVERTER
I
CHECK VALVE
MOOULATORPRESSURE
RELIEFVALVE
LOCK-UPTIMING
VALVE
LINEARSOLENOIDPRESSURE
$ I L--r COOLERRELTEF
VALVE
ATFPUMP
Half lock-up
. Lock-upControlSolenoidValveA: ON
. Lock-upControlSolenoidValveB: DutyOperation
OFF* ON
. LinearSolenoidPressure:
Low
The PCMswitchesthe solenoidvalveA on to releasethe

modulatorpressurein the left cavity ot the lock-upshift
valve.The modulatorpressurein the right cavity of the
lock-upshift valve overcomesthe spring force;thus the
lock-upshiftvalve is movedto the left side.
The line pressureis then separatedinto the two pas-
TOROUECONVERTER
sagesto the torque convener:
T o r q u eC o n v e r t e rI n n e r P r e s s u r ee: n t e r si n t o r i g h t
sideto engagelock-upclutch
Torque ConverterBackPressure:entersinto left side
to disengagelock-upclutch
The back pressure(F2)is regulatedby the lock-upcon-
trol valve, whereas the position of the lock-uptiming
valve is determinedby the linearsolenoidpressureand
LOCK,UPCONTROL tensionof the valvespring.Also the positionof the lock-
SOLENOIDVALVE up control valve is determinedby the back pressureof
the lock-upcontrolvalve,torque converterpressurereg-
ulatedbv the torque convertercheckvalve,and modula-
t tor pressuredeterminedby the lock-upcontrolsolenoid

valve B. The PCM switchesthe lock-uDcontrol solenoid
valve B on and off rapidly(duty operation)undercertain
conditionsto regulatethe backpressure{F2)to lockthe
torqueconverterproperly.
NOTE:When used,"left" and "right" indicatesdirection

TOBOUECONVERTEFI on the hydrauliccircuit.
CHECKVALVE
MODULATOR
PRESSURE
RELIEF VALVE
LOCK.UPTIMING
VALVE
^r
,. r* cooLERRELTEF
VALVE
ATFPUMP
(cont'd)
14-35
Description
Lock-upSystem(cont'd) {
Full Lock-up
. Lock-upControl Solenoid Valve A: ON

. Lock-upControl Solenoid Valve B: ON
. LinearSolenoidPressure:High
When the vehicle speed further inc.eases,the linear

solenoid pressureis increasedto high in accordance
with the linearsolenoidcontrolledby the PCM.
The lock-uptiming valve overcomesth€ spring force
and moves to the left side. Also. this valve closesthe
fluid port leading to the left side of the lock-up control
TOROUECONVERTER Under this condition,the modulatorpressurein the left

s i d e o f t h e l o c k - u pc o n t r o l v a l v e h a d a l r s a d y b e a n
releasedby the lock-up control solenoid valve 8; the
lock-upcontrol valve is moved to the left side. As this
LOCK-UPCONTROL t a k e s p l a c e ,t h e t o r q u e c o n v e r t e r b a c k p r e s s u r e i s
VALVE releasedfully, causingthe lock-upclutchto be engaged
fully.
NOTE:When used,"|eft" and "right" indicat€sdirection

LOCK.UPCONTROL
SOLENOIDVAI.VE on the hvdrauliccircuit,
MODULATORPRESSURE
RELIEFVALVE
LOCK-UPTIMING
VALVE
^
1,,__.r'cooLERRELTEF
vALvE
ATFPUMP
14-36
DecelerationLock-up
. Lock-upControlSolenoidValveA: ON
. Lock-upControlSolenoidValveB: DutyOperation
OFF- ON
. Low
LinearSolenoidPressurer
The PCM switchessolenoidvalve B on and off rapidly

. h e s l i g h t l o c k - u pa n d h a l f
u n d e r c e r t a i nc o n d i t i o n sT
lock-upregionsare maintainedso as to lock the torque
converterproperly.
"right" indicatesdirection
NOTE:When used,"left" and
TOROUECONVEATER
on the hydrauliccircuit.
LOCK-UPCONTROL
SOLENOIOVALVE
,o*oua"otua"rlil
CHECKVALVE
MODULATORPFESSURE
RELIEFVAL
LOCK.UPTIMING
VALVE
PRESSUBE
LINEARSOLENOID
^r
s ---r'1 COOLERRELIEFVALVE
ATF PUMP
14-37
ComponentLocations
CONTROL
POWERTRAIN
MOOULEIPCM}
TICTRANSAXLEIA/TI
GEARPOSITIONSWITCH
COUNTERSHAFT
SPEEDSENSOR
i:.
i\\.i.'.
(- tr',\i,
',
V'.:t
SOLENOIDVALVE
ASSEMBLY
SOLENOIDVALVE
ASSEMBLY
14-39
PCM Circuit Diagram(A/T ControlSystem)
-HOODFUSE/REIAY
UNOEfl BOX
No.41(80A) No.42l40A) (l5A)

No.13
UNOER DASH
FUSE/RELAY
BOX
N o . 4 7{ 7 . 5A )
/8tu BtK BLK

c10 A10 423
L
ArpNp l o r ^ o ] s L ul n r r n lSlt l6lt lor*
'96: 824 l88 I817
BLU/RED YEL96:GRN BLU
'97,'98:
GRN/BLK
G A U GA
ES S E M E L Y
A/TGEAR
POSITION
INDICATOR
',u,,,,tro "I f T T T
,at BLKETU
38-'cFN/BLK wHT YEL GRN BLU
F- BIK/BLU
|--wHT
I-- GRN
N D, I
NorE:rf :To5v I
r T o1 2 V
T
14-40
VEHICLE
SENSOR
SPEEO
V
l'1Fr
. SERVICE CONNECTOR
CHECK
rlP
I
II YEUBTURED/BtK
BLUMHT RED/WHT
l.', 02 010 D1
s23
I" 83 |811
l"
l"'
REO BLU GRN
I
RED BLU/ryELGRN,4A/HT
I
122
I
I
GRN/BLKBRN/BTK
_l__L f_l_ _l__l-

_l__l_
Tt lT I T T T
t
Lcl
l TTTT
p*8
MAINSHAFT
SPEED
SENSOR SP€EoSENSoR L|NEARSOLENo|D
-UP CONTROL
LOCK
VALVE
SOLENOIO
ASSEMBLY
Locations
rcM TeminBl
14-41
PCMTerminalVoltage/Measuring
Conditions
A/T ControlSystem
The PCMterminalvoltageand measuringconditionsare shown for the connectorterminalsthat relateto the A,/Tcontrol
system.The other PCN4
terminalvoltageand measuringconditionsare describedin section1L
A l32P)Connector I (25PlConn€crol C (3lPlConnector D {16P)Connector
PCMCONNECTOR
A {32P}
TerminalNumber Signal Description Measuring Condiiions/Terminal Voltage
41 to A8 see section 11 -
A9 LGl Ground
A't0 PGl Ground
411 IGPl Powersupplysystem With ignitionswitchON (ll):Batteryvoltage
With ignitionswitchOFF:0 V
A.12ro 421 - seesection11-
422 LG2 Ground
L
423 PG2 Ground
424 IGP2 Powersupplysystem With ignitionswitchON (ll):Batteryvoltage
With ignitionswitchOFF:0V
A25 to A32 - seeseclion11
PCMCONNECTORB {25PI
TerminalNumber Signal Description Measuring Conditions/Telminal Voltage
B1 LS- Linearsolenoidpower supply l g n i t i o ns w i t c hO N { l l } :P u l s i n gs i g n a l
negativeelectrode
82 LS+ Linearsolenoidpower supply l g n i t i o ns w i t c h O N t l l ) :P u l s i n gs i g n a r
positiveelectrode
SHA Shift control solenoid valve A In 2nd gear and 3rd gear in id, Ei position,
control and in El, E position:Batteryvoltage
In lst gearand 4th gear in D3l,Bll position:OV
B4 LCB Lock-upcontrolsolenoidvalve B When full lock-up:Batteryvoltage
control W h e nh a l fl o c ku p : P u l s i n gs i g n a l
B5 LCA Lock-upcontrolsolenoidvalveA When lock-upis ON: Batteryvoltage
control With no lock up: 0 V
86 to 87 Not used
B8 ATP D3 Ay'Tgear positionswitch !c posi- position:0 V
In .[D;]
tion signalinput In otherthan D3lposition:Batteryvortage
89to 810 Not used
14-42
PCMCONNECTORB (25P)(cont'd)
Terminal Numbel Signal Description Measuring Conditions/TerminalVoltage
811 SHB Shift controlsolenoidvalveB In 1stgear and 2nd gear in El, E position,
control and in E position:Batteryvoltage
In 3rd gearand 4th gear in E, lp! position:0 V
SLU lnterlockcontrol When ignitionswitchis ON (ll).brakepedal
depressedand accelerator pedalreleased:0V
B13 D4IND D4 Indicatorlight control When ignitionswitchis first turnedON (ll):

Battery voltage for two seconds
In iDaposition:Batteryvoltage
814 NMSG Mainshaftspeedsensorground Always:0 V
NM Mainshaftspeedsensorsignal Dependingon enginespeed:Pulsingsignal
Input When engineis stopped:0 V
B16 ATP R A,/Tgear position switch @ InEposition:0V
positionsignalinput In otherthan E position:Batteryvoltage
817 AJP 2 A/T gear positionswitchP posi- InEposition:0V
tion signalinput In otherthan E position:Batteryvoltage
8 1 8t o 8 2 1 Not used
B22 NCSG Countershaftspeed sensorground Always:0 V
B23 NC speedsensorsignal
Countershaft Dependingon vehiclespeed:Pulsingsignal
Inpur Whenvehicleis stopped:0 V
824 ATP D4 A/T gear position switch Pj posi- In -Drlposition:0V
tion signalinput In otherthan E! position:5 V
B25 ATP NP A/'f gear positionswitchE and In E and El positions:0 V
N positionsignalsinput In other than E and N positions:Batteryvoltage
C {31P)
PCM CONNECTOR
Terminal Number Signsl Description MeasuringConditions/Terminalvoltage
Cl to C6 - seesection11 -
c7 Servicechecksignal With ignition switch ON (lll and servicecheck

connectoropen:5 V
With ignition switch ON (ll) and servicecheck
connectorconnectedwith specialtool: 0 V
C8 to C9 - seesection11-
c10 VBU Back-uppower system Always battery voltage

Cl 1 to C31 - seesectionI I -
PCM CONNECTORD (16P)
TerminalNumber Signal Description Measuring Conditions/TerminalVoltage
D1 to D4 - seesection1 l -
D5 STOPSW Brakeswitchsignalinput Brakepedaldepressed:Batteryvoltage

Brakeoedalreleased:0 V
D Ot o D 1 6 - seesection11-
14-43
Checkingthe DiagnosticTroubleCode{DTC)
with an OBD ll Scan tool or Honds PGM Testel
When the PCM sensesan abnormalityin the input or output systems,the ql indicatorlight in the gaugeassemblywill
blink When the 16PData Link Connector(DLC)ilocatedunder the dash on the driver'sside) is connectedto the oBD ll
ScanTool or HondaPGM Testeras shown,the scantool or testerwill indicatethe DiagnosticTroubleCode (DTC)when
t h e i g n i t i o ns w i t c hi s t u r n e dO N I ) .
when the E ] indicatorlight has been reportedon, connectthe oBD ll scan Tool conformingto SAEJ197gor HondapGM
Testerto the DLC(l6P). Turn the ignitionswitchON {ll), and observethe DTCon the screenof the OBD ll ScanTool or
HondaPGMTester'After determiningthe DTc, referto the electricalsystemSymptom-to-component chart on pages14-48
and 14-49.
NOTE:Seethe OBD ll ScanTool or HondaPGMTesteruser,smanualfor specificinstruction.
OBD ll SCANTOOLor
HONDAPGM TESTER
(16P}
DATA LINKCONNECTOR
14-44
Checkingthe DiagnosticTroubleCode (DTC)
with the ServiceCheckConnestorand SpecialTool
Whenthe pCM sensesan abnormalityin the inputor outputsystems.the itj indicatorlight in the gaugeassemblywill blink
When the ServiceCheckConnector(locatedunderthe dash on the passengerside) is connectedwith the specialtool as
TroubleCode(DTC)when the ignitionswitchis turnedON (ll).
shown,the lD1indicatorlight will blinkthe Diagnostic
Whenthe @ indicatorlight has beenreportedon, connectthe ServiceCheckConnectorwith the specialtool.

Thenturn ON (ll)the ignitionswitchand observethe [o! indicatorlight
GAUGEASSEMBLY
'i''
.-.=-.-..--- . . .-'
\.....-,-..-.""r .-
c ,
a:
CONNECTOR
SERVICECHECK
07PAZ- (x)'10t00
CONNECTOR I2P}
a seriesof long and short

codes 1 through9 are indicatedby individualshort blinks.codes 10 and aboveare indicatedby
to determinethe code After deter-
blinks.one long blink equals10 short blinks.Add the long and short blinkstogether
Charton pages 14-48and 14-49'
miningthe code,referto the electricalsystemSymptom-toComponent
Short blink {once}
See DTC 1
See DTC2
Long blink Short blinks lfive times)
See DTC 15
(cont'd)
14-45
{cont'd)
1. side (seesection20).
Removethe kickpanelon the passenger's
2. Removethe PCM,and turn the PCMover.
Inspectthe circuiton the PCMaccordingto the troubleshooting

ter as shown.
llowchartwith the specialtools and a digitalmultime- L
How to Use the BackprobeSet
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cords to a multimeter.Using the wire

insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side until it comesin contactwith the terminalend of the wire.
EACKPROAE
BACKPROAE SET
07sAz- 001000A
(tworequired)
OIGITALMULTIMETER
(Comm€rciallyavailable)
-aHM-32-003
or equivalent
14-46
. PCM RasetProcadure
1. Turnthe ignitionswitchoff.
2. Removethe BACKUP fuse (7 5 A) from the under-hoodfuse/relaybox for 10 secondsto resetthe PCM'
NOTE:
. Disconnectingthe BACKUP fuse also cancelsthe radio presetstationsand clock setting.Make note of the radio
presetsbeforeremovingthe tuse so you can resetthem.
o The PCMmemorycan alsobe clearedby usingthe OBDll ScanTool or HondaPGMTester'
BACKUP
(7.5A) FUSE
. Final Procedurg
NOTE:This proceduremust be done after any troubleshooting
2. Resetthe PcM.
tool from
3. Disconnect the OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector,or removethe special
the ServiceCheckConnector.
4. Turn the ignitionswitchON (ll),and set the radiopresetsand clocksetting
14-47
Symptom-to-Component
Chart
ElectricalSystem
Diagnostic
TroubleCode El Indicator Symptom PossibleCause
Referto
(DTC)* Light Page
Lock-upclutchdoes not engage. Disconnected lock-upcontrolsolenoid

P1753 Lock-upclutchdoes not disen valveA connector
(1) Blinks gage. Shortor open in lock-upcontrol l4-50
solenoidvalveA wire
Faultylock-upcontrolsolenoidvalveA
Lock-upclutchdoes not engage. Disconnected lock-upcontrolsolenoid
P1758 valveB connector
Blinks Shortor open in lock-upcontrol 14-52
t2l
solenoidvalveB wire
Faultylock-upcontrolsolenoidvalveB
. Failsto shiftotherthan 2nd - 4th . Short in Ay'Tgear positionswitchwrre
P1705
(s) Blinks gears. . FaultyA4 9"", Oositionswitch 14-54
. Lock-upclutchdoes not engage.
. Failsto shiftotherthan 2nd - 3rd Disconnected A/T gear positionswitch
P1706 - 4th gears. connector
(6) OFF . Lock-upclutchdoes not engage. 14-s6
Open in A"/Tgear positionswilchwire
FaultyAy'Tgear positionswitch
. Failsto shift (between1st- 4th, Disconnectedshiftcontrolsolenoid
P0753 o r 2 n d- 3 r d g e a ro n l y ) . valveA connector
Blinks . Failsto shift (stuckin 4th gear). Shortor open in shift controlsolenoid
t7I r4-58
FaultyshiftcontrolsolenoidvalveA
Failsto shift (stuckin 1stor 4th Disconnected shiftcontrolsolenoid
gears). valveB connector
P0758
Blinks Shon or open in shiftcontrolsolenoid '14-60
(8)
valveB wire
Faultyshift controlsolenoidvalveB
. Lock-upclutchdoes not engage. Disconnectedcountershaftspeedsen-
PO120 sor connector
(9) Blinks Shon or open in countershaft
speed 14-62
sensorwrre
Faultycountershaftspeedsensor
(DTC)*:The DTcs in parentheses are the numberof the E indicatorlight blinkswhen the servicecheckconnecrorrs con-
nectedwith the specialtool (SCSserviceconnectorl.
14-48
Diagnostic Referto
Indicator
TroubieCode E Symptom PossibleCause
Page
(Drc). Light
'96,'97 models . Lock-upclutchdoes not engage. Disconnectedmainshaftspeedsensor

connector
P07r5 OFF
Shortor open in mainshaftspeedsen- 14-64
(1 5 ) '98 model
sor wtre
Blinks
Faultymainshaftspeedsensor
. Transmission jerkshardwhen Disconnected linearsolenoidconnector
P1 7 6 8 shifting.stuckin 4th gear. Shortor open in linearsolenoidwire
14-66
(16) Blinks . Lock-upclutchdoes not engage. Faultvlinearsolenoid
Disconnected or loosedPGterminal
P0740 . Lock-upclutchdoes not engage. . Faultylock-upcontrolsystem
14-68
(40)
Failsto shift (between1st- 2nd, . Faultvshift controlsystem
1st- 4th. 2nd - 4th,znd - 3rd, 3rd
P0730 - 4th, 1st- 2nd - 3rd, 1st-3rd -
OFF 14-69
(41) 4th or 2nd - 3rd - 4th gearsonly).
Failsto shift (stuckin 1stor 2nd
gears).
Any automatictransmissionproblem,
P0700
To eliminateDTCP0700,troubleshootthe other automatictransmissionprob-
(none)
lem(s)accordingto the DTC(S)indicated.
(DTC)*:The DTCSin parentheses are the numberof the E indicatorlight blinkswhen the servicecheckconnectoris con-
nectedwith the sDecialtool(SCSserviceconnector).
NOTE:When the OBOll ScanTool or HondaPGMTesterindicatethe DTC(S) for the automatictransmissioncontrolsys-

Code P0700meansdetectionof some automatic
tem, the scan tool or tester also indicatescode P0700simultaneously.
transmissionoroblemon the PGMFl controlsystem.
Ei!]indicatorlight does not blink,performan inspectionaccordingto the table below.

lf the self-diagnostic
Symptom Inspection Ref. page
E indicatorlight does not come on tor two secondsafter ignition 14-70

switchis first turnedON (ll).
E indicatorlight is on constantly(not blinking)wheneverthe ignition 't 4-12
switchis ON (ll).
Shift levercannotbe movedfrom E positionwith the brakepedal Inspection 14-13
oeoresseo,
NOTE:lf a customerdescribesthe symptomfor code P1706(6),it will be necessary

to recreatethe symptom by test-driv-
ing,then recheckthe DTC.
14-49
ElectricalTroubleshootin
g
TroubleshootingFlowchart- Lock-upGontrolSolenoidValveA
. OBD ll ScanTool indicatesCode PossibleCsuso

P1753. . Disconnectedlock-up cont.ol
. Sell-diagnosi3 i-tl indicatol
solenoid valve A connector
light blinks once. . Short or opon in lock-upcontrol
3olenoidvalve A wire
. Faulty lock-up control solenoid
valvo A
PCMCONNECTORS
Checkfor e Short to Power:

2. Disconnect the A {32P)and B
( 2 5 P )c o n n e c t o r sf r o m t h e
PCM.
the 85 and A9 or A22 termi-
nals.
WIRESIDEOF FEMAI.f TERMINALS
Ropairshort to power in the wirc

betweon the 85 terminal and the
lock-upcontrol solenoidvalve A. L
Measur€ Lock-upControl Sole-

noid Valve A R*istanc€:
2, Measure the resistance
betweenthe 85 and Ag or A22
terminals.
Check tor loose P1CMconnectoJs.

12- 25 0?
ls the resistance It necossary, substituto a known-
good solenoid v.lvo assomblyor
PCM and r6chock.
To page14-51 \
14-50
From page14-50
PCMCONNECTORS
Check Lock-up Control Solenoid A (32P)

Valve A for a Shon Circuh:
1, Disconnectthe 2P connector
from the lock-upcontrolsole-
noid valveassembly.
the 85 and Ag or A22 termi-
nals,
WIRESIDEOF FEMALETERMINALS
Repair3hort to ground in the wire

ls therecontinuity? between the 85 t6rminal and the
lock-uD conttol solenoid vahre A.
LOCK.UPCONTROL
SOLENOIDCONNECTOR
*T
. - F
ItrTt
M6asu.e Lock-uo Control Solo- YEL
noid Valve A Rosistance at lho (o)
SolenoidConnector:
Measure the resistancebetween
the No. 2 terminalof the lock-up
I
control solenoid connectorand
body ground. TERMINALSIDEOF
MALETERMINALS
Check for open in the wire

12- 25 0?
ls the resistance b€twe€n the 85 terminel .nd the
lock-upcontrol solenoid valve A.
Replece the lock-up control sole-

noid valve assembly.
14-51
ng
ElectricalTroubleshooti
TroubleshootingFlowchart- Lock-upGontrolSolenoidValveB
OBD ll Scan Tool indicli.. Code Po..iblo C!u&

P1758. . Diaconnacted lock"up control
Selt-disgnolb E indicltor light rolanold valv. B connector
blinks twice. . Short oi opon In lock-upcom.ol
rolgnoid v.lva B wiro
. F ulty lock-up contol rolanoid
valva B
FCM CONNECTORS
Chockfor a Short to Power:

1. Turn thg ignitionswitchOFF. A t32P)
2. Disconnact the A (32P)and A
PCM.
4. Measurethe voltagg b€tween
nals,
WIRESIOEOF FEMALETENMNALS
Rapair rhort to powar in tha wirc

brftv.en th. Ba tormin.l rnd th.
lock-upcontrol aolanoidvalva B.
Me!!u.e Lock-up Conlrol Sole-

noid Valvo B Rcrictlncc:
2. Measure the resistance
b e t w e e nt h e B 4 a n d A g o r
A22terminals.
Ch.ck tor loo.. PrCi, conn.c'lor3,

12- 25 O?
ls the resistance It n6ca3t!ry. subttihrta r known-
good rolanoid valvo a$ombly or
PCM lnd rcch.ck.
To page14.53
14-52
From page 14-52
PCMCONNECTORS
Chack Lock-up Control Solenoid

Vslve B to. a Short Citcuit:
trom the lock-upcontrol sole-
noid valve assembly.
nals,
Rapair3hort to ground in th€ wir€

betwaen the 84 torminal and th€
lock-up control solenoid valvo B.
LOCK-UPCONTROL
SOLENOIDCONNECTOR
Mea3ura lock-up Control Sole-

IFT']
t-
noid Vrlvc B Ro3irtrnc. at the cnNreLxI

SolonoidConnoc{or: (o)
the No. 1 terminalof the lock-up T
I
control solenoid connectorand
bodyground.
TERMINALSIDEOF
MALETERMINALS
Chock for opon in the wir€

12- 25 0?
ls the resistance botwo€n th. 84 torminal and the
lock-up control aolonoidvalva B.
R.phc. tha lock-up cont.ol solo-

noid valvc $!.mbly.
14-53
Troubfeshooting
Flowchart- AIT GearPositionSwitch (shortl
. OBD ll ScanTool indicatesCode PossibleCause

P1?05. . Shorl in A/T 96ar position switch
. SelI-disgno3isE indicrror light
blinks tive tim6. . FaultyA/T geal po3ition switch
NOTE:Code Pl705 (5) is causedwhen
t h e P C M r e c e i v e st w o g e a r p o s i t i o n
Observeth6 A/T Gear Po3ition ,nputsat the sametime-
Indicator:
2. Observethe A,/Tgear position
i n d i c a t o r ,a n d s h i l t t o e a c h
posttlon.
Do any indicatorsstayon The system is OK at this time.

whenthe shiftleveris not in Check the wile harnessfo. dam-
thosepositions? age. PCMCONNECTORS
MeasureATP R Voltage:
1. Shittto all positionsotherthan
E.
2. Measurethe voltagebetween
nals,
Check for short in the wire
betweenthe Bl6termineland the WIRESIDEOF FEMALETERMINALS
A/T gear position swilch or A/T
gear position indicator. lf wire is
OK, check lor loose PCM connec-
tors. It noceasary,substitute a
known-goodPCMand recheck.
MeasureATP NP Voltage:
1. Shiftto all positionsotherthan
Nor@.
the 825 and Ag ot A22 te(mi
nals,
Check tor short in the wire
b€tweentho 825 terminal and the
A/T goar position indicator, o. a
shon in the wiaes beiween the
ls therebatteryvoltage? A/T gear position indicator and
the A/T gear posilion switch. It
wires are OK, check for loose
PCM conneclors. lf nec€ssarv,
substitute a known-good PCM
MeasureATP 04 Voliage: end rechock,
O..
nals.
Check for sho.t in the wiro

betweenthe B24terminaland the
ls thereapprox.5 V? A/T ge.r position switch. lf wire
is OK, check lor loose PCM Gon-
nectoE. ff necessary,substituto a
known-goodPCMand recheck.
To page14-55
14-54
Frompage14-54 PCMCONNECTORS
M.tsuro ATP D3 Vohage:

'1. Shift to all positionsother than
E.
nats.
WIBESIDEOF FEMALETERMINALS
Ch6ck for short in tho wire
batwe€n tho 88 terminel and the
A/T gear position switch ot A/T
ls there batteryvoltage? gea. position indicator. It wire i3
OX, check for loos6 PCM connec-
lors. lf neces3ary, substitute a
known-good PCMand techeck.
BRN/ALK
Morsure ATP2vohage:
tr.
2. lvleasurothe voltage between
the 817 and A9 or 422 termi
nats.
BRN/BLK
Check for sho.t in the wire

b€twe€nthe 817 terminal .nd thc
A/T goar position switch or A/T
gear position indicalo.. tf wire is
OK. check for loos6 PICMconnec-
tors. lf necessary,substitute a
known-goodPCM.nd racheck.
Chockfor loo3o PCMconnGctors,

lf nccossrry, 3ubsthuto a known-
good PCM tnd r6chock.
14-55
TroubleshootingFlowchart- A/T GearPositionSwitch (Openl
. OBD ll ScanTool indicat$ Code PGsibl. Causo

P1706. . DisconnectodA/T goal po3iilon
. Self-di.gnosisq indicatorlight 3witch connector
blinks six iim*. . Open in A/l gear position awitch
. Fauhy A/T go.r position switch
PCMCONNECTORS
Me8ure ATP R Voltage: BRN/BLK

2. Shiftto E position.
3, Measurethe voltagebetween
nals,
BRN/BLK
Bepair open in the wile bstwaton
the 816 torminal and tha A/T goar
po3hion switch.
BRN/BLK
1. Shiftto N orE position.
the 825 and Ag or A22 termi
nals,
Ropail open in the wiae betweon

the B25torminal and the A/T g.at
position indicstor oi the A/T gear
Dositionswitch.
BRN/BLK
MeasureATP D4 Voltage:
8RN/BLK
Repairopen in the wire be4wcen

the 824 terminal and tho A/T gcrt
oosition swhch.
To page14-57
14-56
From pag€ 14-56
PCMCONNECTORS
Mqllurt ATP D3 Volt gt:

1. Shift to @ position.
2. Measurethe voltagg betwe€n
nats.
Rapair opan In th6 wira b3twocn

tha 88 t.rminll snd tha A,lT go!1
Dolition .witcb.
Ma.$ra ATPz Voltaga:

1. Shift to E position.
2. Measurs th€ voltage betwesn
th€ Bl7 8nd Ag or A22 tsrmi-
nals.
Rop.ir opln in tha wir. b.twocn

th. Bl7 tlrminrl .nd tho A/T
gatr polhion switch.
Chack tor looaa PCM connactoB.

It nacoaaary, tubtihuta ! known-
good FCM .nd r.ch.ck.
14-57
g
TroubleshootingFlowchart- Shift ControlSolenoidValveA
. OBD ll ScanTool indicatosCode PossibleCeuse

m753. . Disconngcledshift cont.ol solenoid
. Sof-di.gno.is D; indicrtor llght
valve A connoctot
blinks 36v6ntimes. . Short or open in shift control sole-
noid valve A wire
. Faulty shift control 3olenoid valve A
PCMCONNECTORS
BLU/YEL
Ch.rckfo. a Short to Powel:

2. Disconnect rhe A {32P)and B
PCM.
3. Turnthe ignitionswitchON (ll). BRN/BLK
4. Measlre the voltagebetween
the 83 and Ag orA22 terminals. WIRESIDEOF FEMALETERMINALS
Ropairshort to power in the wire

between the 83 t6.minal and tho
shift control3olenoid valve A.
M€ssure Shift Control Solenoid

Vrlve A Rosidance:
betweenthe 83 and Ag or A22
Iermrnats.
Chocktor loose PCM connoctors.

It nace33ary,substitut€ a known-
12- 25 O?
ls the resistance
good solenoid valve assemblyor
PCMand .echeck.
To page14-59
14-58
-
Frompage'14-58
PCMCONNECTORS
Chock Shilt Control Sol.noid

Velv. A lor a Short Circuit:
l. Disconnectthe 2P connector A {32P)
from the shift control solenoid
valve assemblv.
2. Chgck for continuity between
the 83 and Ag or A22terminals.
Ropairlhort to ground in the wire

betweon the lIt torminal and lho
rhift control solenoid v6lvo A.
SHIFTCONTROLSOLENOID
CONNECTOR
Me.sure Shift Control Solonoid

Valv. A R6btanco .t the Solonoid
Connoctor: BLU/YEL
the No. 1 terminal oI the shitt con-
trol solenoid connectorand body
ground.
TERMINALSIDEOF MALETERMINALS
Chack lor opon in lhe wire

12- 25 O?
ls the resistance betwoen the 83 termin.l and tho
rhift control solenoid valv6 A.
14-59
TroubleshootingFlowchart- Shift ControlSolenoidValveB
. OBD ll ScanTool indicatosCode Possibl6Cause

P0758. . Disconnoctod shift contlol solenoid
. Selt-diagnosisEi indicator ligln velve B connector
blinks oight time6. . Short or ooen in shift control sole-
noid valve B wire
. Faulw shift control solenoid valve B
PCMCONNECTORS
Chockfo. a Short to Power: l32Pl

l. Turnthe ignitionswitchOFF.
2. Disconnectthe A {32P}and B
(25P)connectors from the PCM.
3. Turnthe ignitionswitchON (lli.
the 8'11and Ag or A22 termi
nals.
Repairshort to power in th6 wire

between the 811 termin.l and
the shift conlrol solenoidvelve B.
Measure Shift Control Solenoid

Valve B Resistance:
b e t w e e nt h e 8 1 1 a n d A g o r
A22terminals.
Ch6ckfor looso PCMconnectors.

lf nocessary,3ubitituta a known-
ls the resistance
12 25 0? good sol6noid valvo a$ombly ol
PCMand rechock.
From page14 60
PCMCONNECTORS
C h € c kS h i f t C o n t r o l S o l e n o i d BRN/BLK
Valve B tor a Short Circuit:
lrom the shift control solenoid
valveassembly.
nars, BRN/BLK
Repairshort to ground in the wira

ls therecontinuity? betweenthe 811 ierminal and the
shitt control solenoidvalve B.
SHIFTCONTROLSOLENOID
CONNECTOR
li; tt
I GRN,/WHT
Measure Shift Control Solenoid (o)
Velve B Resistanceat the Solo- Y
noid Connec'tor: I
Measure the resistancebetween I
the No.2 terminalofthe shiftcon-
trol solenoidconnectorand body
oround, TERMINALSIDEOF MALETERMINALS
Check for open in the wire

l s t h e r e s i s t a n c el 2 - 2 5 0 ? between the Bll terminal and the
shift control solenoid valve 8.
14-61
TroubleshootingFlowchart- CountershaftSpeedSensor
I . OBD ll Scrn Tool indicat€s Code Po$ible C.u3o
PO720. . t"a* ". t*rlty ""."""t1*
. Solt-diagnosis Dj indicator botwoen the PCM .nd c.r har-
light blinks ninc times, noss
. Disconnectodcountarshaft
soeodson3orconnector
. Short or open in countorsh.ft
sp6ed sensor wirc
. F ulty count€.shrft speod 3en-
ls the countershaftspeedsensor
installedproperly?
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
t'-tt
TT
Measure Countorsh.ft Soeed Sen-
sor R6istanc€ al ths Senror Con-
9t ll
nectot:
1. Disconnectthe 2P connector L I
from the countershaftsDeed
sensofconnector, TERMINALSIDEOF MALETESMINALS
2, Measurethe resistance oI the
countershaftsDeedsensor,
ls the resistance400- 600 0?
PCMCONNECTOR
B {25P)
Chack Coume6hatt Spo€d Sensor

for a Short Circuit:
1 . D i s c o n n e ct th e B ( 2 5 P )c o n
nectorfrom the PCM.
2. Checklor continoitybetween
the body groundand the 823
t e r mi n aI a n d 8 2 2 t e r m i n a l
individually.
Repairshort in the wires belwe€n

the 823 and 822 torminals and
the countershaft soeed sensor.
To page14-63
14-62
Frompage14-62
PCMCONNECTOR
B {25PI
Maasure CruntoFhaft Speod Son-

sor Rosbtrnce:
1. Connect the countershaft
speedsensor2Pconnector.
between the 823 and B22 le''
minals,
SIOEOF FEMALETERMINALS
Ropair loose terminal or open in
tho wiies bstw66n tho B23 and
ls the resistance400- 600 O?
822 termin.ls and tha countor-
shaft speodsensor.
Check tor loos6 PICMconnectors.

lf necass{ry, substihJtg a known-
good PCMrnd roch.ck.
14-63
TroubleshootingFlowchart- MainshaftSpeedSensor
N O T E : C o d e P 0 7 1 5 ( 1 5 )o n t h e P C M
. OBD ll ScanTool indicatosCode Posible Ceuse
doesn't always mean there's an electrical
P0715. ' DI*.""."1"d -"l".h"ft .*.d problem in lhe mainshafl or countershaft
. S e l t - d i a g n o s i sE i n d i c a t o l 3en30t conn€ctot s p e e d s e n s o r c i r c u i t : c o d e P 0 7 1 5 1 1 5m
) at
light indic.t6 Cod€ 15. . Short or op6n in main3hatt also indicatea mechanicalproblem in the
speed sensorwire transmtsston.
. Faulty mainshaft speodsensol
Checkthe mainshaftand counter'

shaftspeedsensorinstallation.
Are the mainshaftand countershaft

speedsensorinstalledproperly?
MAINSHAFTSPEED
SENSORCONNECTOR
MeasureMainshrft SpeedSensor
Resistanceat the Sensor Con-
nector:
from the mainshaftspeedsen'
sor connector.
2. Measurethe resistanceof the
majnshaftspeedsensor. TERMINALSID€OF MALETERMINALS
ls the resistance400- 600 {}?
PCMCONNECTOB
8 I25P}
Check MainahaftSpeed Sensot

for a Short Circuit:
1. Disconnect the B (25Piconnec-
tor from the PCM.
bodygroundand 815terminal
and the 814 terminalindividn-
ReDairshort in the wires between
ls therecontinuity? the 815 and Blil terminals and
lhe meinshrft soeedsensor.
To page14'65
14-64
Frompage14-64
8 (25PI
PCMCONNECTOR
MeasureMrinshaft SpeedSensor
Resistance:
1. Connectthe mainshaftspeed
sensor2P connector,
betweenthe 8'15and 814 ter-
mt n a l s .
Run iho Elect ical Troubleshooling

Flowchartfor code m720 l9l.
400- 600o?
ls the resistance Checktor loose PCM connectors.
It n€cossary,substitute a known-
good PCMand recheck.
MAINSHAFT SPEED SENSOR
CONNECTOR
CheckNM Wire Continuity:

from the mainshaftspeedsen-
sor connector.
the 815terminaland the No. 1
terminal of the mainshaft
speedsensorconnector,

ls therecontinuity? the 815 terminal and the main'
shaft speedsensor.
CheckNMSG Wire Continuity:

Checkfor continuitybetweenthe
814 terminaland the No. 2 termi-
nal of the mainshaftspeedsensor
Bepair op6n in th€ wire between

ls therecontinuity? th€ 814 terminal and the main-
3haft sDeeds€nsor.
Checklor loos€ PCMconnectors.

It nocessarv,substitute a known-
good PCMand recheck.
14-65
g
TroubleshootingFlowchart- LinearSolenoid \
. OBD ll ScanTool indicat6 Codo Po$ible C.Ge

P176a. . Oisconnectedlin€ar solonoid
. Self-diagnosis [d indic.tol
light indicatesCode 16. . Short or op6n in linear solonoid
. F.uhy linorr 3olonoid LINEARSOLENOIDCONNECIOR
trTt
-r-r
Msasure Linoar Solanoid Rosi3t-
anco at tho SolonoidConnector:
rdl
2. Disconnectthe 2P connector Yt Il
from the linearsolenoidcon-
nector,
t_i
3. Measuretho resistance ofthe
linearsolenoid. TERMINALSIDEOF MALE TERMINALS
ls the resistance
aoorox.5.00?
B (25P)
PCMCONNECTOR
WHT RED
Ch6ckLinor. Sol.noid for a Short
Circuit:
l Disconnectthe B (25P)connec,
tor from the PCM.
2. Checktor continuity between
the body ground and the 81
terminaland 82 terminalindi-
vidually.
Repairsho.t in the wire3 bgtwoon

tho 81 and 82 termin.ls rnd th6
lineal solonoid.
Me.iuie Linoar Solenoid Rcai3t-

ance:
1 . C o n n e c t h e l i n 6 a rs o l e n o i d
connector.
2 . M € a s u r e t h e r e s i s t an c e
betweenthe 81 and 82 termi-
nals,
Ropair loo3o terminsl or open in

ls the resistance
approx.5.0O? tho wirgs bgtween the B1 and 82
torminrl! rnd the linoar sol6noid.
To page14-67
14-66
Frompage14 66
PCMCONNECTOR
A I32P}
Ch6cktho Ground Cilcuit:

Checkfor continuity between the
Ag and A10terminals.
. Rgpair open in the wire

between tho torminal3 A9 .nd
A 1 0 . n dG 1 0 1 . WIRESIDEOF FEMALETERMINALS
. R6pair loo3o junction connector.
. Ropairpoor ground (G1011.
Chgckloi loo3a PCMconnecto.s.

lf necellrry, 3ubstituto a known-
good PCMand rochock.
14-67
TroubleshootingFlowchart- Lock-upControlSystem \
OBD ll Sc{n Tool indicatss Code Poitible Cru..

m740. Faulty Lock.up control ryitcm
Self'diagnosis ErJ indicdor light
indicatB Code /U).
Chockfor Another Code:

Checkwhether the OBD ll scan
t o o l o r t h e E i n d i c a t o rl i g h t
indicatesanothercode.
Doesthe OBDllscantoolor Perform tho Troubla3hooting

the E! indicatorl;ghtindicate Flowch.rt tor tho indic.t.d
anothercode? Codols). Rocheck tol codo P0740
l40l after troublG.hooting.
NOTE:Do not continuewith this troubleshootino

until th€ causesof any
other DTCShave beencorrected.
Test Lin€ Piessure:
M e a s u r et h e l i n e p r e s s u r e{ s e e
page14-87and 14-88).
ls the linepressurewithinthe Repai. tho hydrrulic sy3tom a.

servicelimit? necdsrry l3os pago'14-E61.
R e p l a c et h e L o c k - u p C o n t r o l \
Solenoid Valve Assembly end
Recheck:
1 . R e p l a c et h e l o c k - u pc o n t r o l
solenoidvalve A/B assembly
(seepage14-74).
2. Turn the ignition switch OFF
and resetthe PCM by remov
ing the BACKUP {7.5A) tuse
in the under-hoodfuse/relay
box tor more than '10seconds.
3. Using the scan tool, checkto
be sure that the enginecool-
a n t t e m p e r a t u r ei s i n 1 7 6 " F
{80'C)and above.
4. Drive the vehicle at 55 mph
(88 km/h)constantlyfor more
than one manute.
5- Recheck for codeP0740(40).
DoestheOBDll scantool
indicatecodeP0740(401? The syltom ii OK at thb timo.
14-6 8
TroubleshootingFlowchart- Shift GontrolSystem
' OBD ll Scan Tool indic.t6 cod. PorsibleCauso

m730. F.ulty shitt contol systom
' s.lf-di.gno.i. E indicator
lig]|t Indicat . Code 41.
Chacklor Anoth.r Codo:

Checkwhether the OBD ll scan
t o o l o r t h e E i n d i c a t o rl i g h t
indicateanothercod6.
Parform the Troubl.shooting

Doe3the OBD ll scantool or Flowchrrt tor th6 indicatod
the E indicaro.lightindi- Codo(s).Rochockfor cod! m730
cste anothercode?
{41| rft ol troubl.ihooting.
NOTE:Do not continu€with this troubleshootinguntil the causesof any
other DTCghave beencorrected.
Tcat 13t, znd, 3rd and 4th Clutch

Prctauro:
Measurethe lst, 2nd, 3rd and 4th
clutch pressure{see page 14-87
thru'14-891.
ls each clutch pressurewithin Rcpair tha hvdraulic aystom ra

the servicelimit? nacaa3ary laaa p.g. 14-88 lnd
1a-891.
Repl.c. Shift Control Sol.noid

V.lYe A*rembly, Linorr Solonoid
A$.mbly .nd B.check:
1. Replacethe shift control
solenoidvalve A/B ass6mblv
(seepage14-?5).
2 . R e o l a c et h e l i n o a r s o l e n o i d
assembly(seepage 14-771.
3. Turn the ignirionswitch OFF
and rsset th€ PCMmemory by
romovingthe BACKUP (7.5A)
fuse in the under-hood{use/
r e l a yb o r I o r m o r e t h a n 1 0
seconos.
4. Drive the vehicle at ovgr 12
mph (20 km/h) in lst, 2nd. 3rd
and 4th geal,lor more than 30
secondsat [8d oosition.
5, Recheckfor code PO73O (41).
Do6sthe OBD ll scantool or

the E indicatorlight indi- Tho sydem b OK rt this time.
cate code P0730(41)?
14-69
TroubleshootingFlowchart- D.-lndicatorLight DoesNot GomeOn
Th6 E indicator light doos not

come on when the ignition switch
is lirst turned ON lll). {lt should
come on Ior about two 36conds.)
Checkthe ServiceCheckConnec-
tor:
Make sure the specialtool (SCS
SetuiceConnector)is not connect-
ed to the servicecheckconnector.
ls the specialtool(SCSService Disconnectthe soecial tool from

Connector) connectedto the ser- the se.vice chock connoctor and
vice checkconnector? rachock.
Checkth€ E indicator Light:

Shiftto E position.
Checkto. loose PCM connectors.

lf nec€asary,substitute a known.
good PCMend iecheck.
A (32P)
PCMCONNECTOR
Checklhe Ground Circuit:
2. Disconnectthe A (32P)connec'
tor fromthe PCM.
t h e A g t e r m i n a la n d b o d y
ground and the A22 terminal
and body ground.
Repair opon in the wires botwoen

tho A9 or A22terminalsand G101.
Repairpoor ground(Gl01).
T o p a g e1 4 7 1
14-70
Frompage14-70 A I32P}
PCMCONNECTOR
Moasure Powo. Supply Circuit

Voltage:
2. Measureth€ voltage between
t e r m i n a l sA g a n d A 1 1 a n d
b e t w e e nt e r m i n a l sA 2 2 a n d
424.
R.p.ir open or short in the wire
botwoen the A11 tnd lor A2l ter-
ls there bafteryvoltage? minals,the PGM-FImain .elay,
aod the fu3e box.
MoasuroD4 IND Voh.ge:

2. Connectthe A (32P)connector
to the PCM.
3. Connecta digital multitester
to the 813 and A9 or A22 ter-
mtnals,
4. Turnthe ignitionswitchON (ll) BRN/8LK
'96: BLU/RED
and makesure that the vokage '97, '98: GRN/BLK
is availablefor t\ivoseconds.
Check tor open in the wire

between the 813 lermintl and
the gauge as3embly.lf wiro is
OK, chock for a taulty E indic.-
tor light bulb or s faulty gsuge
r33embly printod circuit board.
Checkfor loo3o PCMconnedots.

Checkthe A/T ge.. position
switch. ll nec6$ary, substitute a
known-good PCMand recheck.
14-71
TroubleshootingFlowchart- E IndicatorLight On Constantly
The E indic.tor light b on con-

3lently {not blinking}whenever
the ignition switch b ON {lll.
PCMCONNECTOR
B I25PI
Me.sure Dil IND Voltage:
2. Disconnectthe B (25P)connec-
tor from the PCM.
t h e 8 1 3t e r m i n a a
l ndbody
ground.
Repairshort to power in the wire

betweon the 813 terminal and
the gauge a$embly.
MeasuraATP D{ Voltage;
2. Connectthe B (25Piconnector
to the PCM.
4. Shiftto any positionotherthan
D;.
t h e 8 2 4 t e r m i n a la n d b o d y
ground.
Checkfor a short to ground on the

wire. ff wire is OK. ropl.c€ the A/T
gearpositionindicator.
14-72
TroubleshootingFlowchart- BrakeSwitch Signal
Symptom
Shift lav6r crnnot be movod liom
E porition whh the bt.ko Pedal
Ch.ck Brr*. Light Op.r.tion:

Oeoressthe brakepedal.
Rapairtaulty brake switch circuit

Are the brak€lights ON? l3oor€ction 231.
PCMCONNECTORS
M.arur. STOP Sw voh.gc:

2. Disconnoctth€ A (32P)and D
{ 1 6 P )c o n n e c t o r sf r o m t h e
PCM.
3. Measurethe voltage betw€en
the D5 and Ag or A22 termi-
nals with the brake peclal
depress€d.
WINES|DEOF FEMALETERMINALS
Rop.ir opan in thc wiro b€twcen

ls there battoryvoltsge? th. D5 terminal lnd tha brako
swit*,
. 8..1. rwitch rign.l i. OK.

. Chad( to? looaa PCM connactoB.
It nacarlary, aubatituta a known.
goodFC .nd t!d|!ck.
. Inrp.ct th. brtlr .witch citcuit
{t . ..ction 23}.
14-73
Lock-upGontrolSolenoidValveA/B Assembly
Test Replacement
1. Disconnectthe 2P connectorfrom the lock-upcon NOTE:Lock-upcontrolsolenoidvalvesA and B must be
trol solenoidvalveAy'Bassembly. removed/replaced
as an assembly.
TERMINAL
SIDEOF 1. R e m o v et h e m o u n t i n g b o l t s a n d l o c k - u pc o n t r o l
MALETERMINALS solenoidvalveA,/Bassembly.
6 x 1.0mm
12 N.m {1 .2 kgt.m, 8.7 lbl.ltl
FILTER/GASKET Cleanthe mountingsurface

Replace. and fluid passages.
LOCK.UP
CONTROL
SOLENOID
VALVEA/B
ASSEMBLY
2. Cleanthe mounting surfaceand fluid passagesof
Measurethe resistancebetweenthe No. 2 terminal t h e l o c k u p c o n t r o ls o l e n o i dv a l v e a s s e m b l ya, n d
( s o l e n o i dv a l v eA ) o f t h e l o c k - u pc o n t r o ls o l e n o i d installa new lock-upcontrolsolenoidvalveA,/Bwith
valveconnectorand body ground,and betweenthe a new filter/gasket.
No. 1 terminal{solenoidvalveB} and body ground.
Checkthe connectorfor rust,dirt or oil, and recon-
12 - 25 O
STANDARD: nectrt securely.
Replace t h e l o c k - u pc o n t r o ls o l e n o i dv a l v ea s s e m -
bly if the resistance is out of specification.
lf the resistanceis within the standard,connectthe

No. 1 terminalof the lock-upcontrolsolenoidvalve
connectorto the bafterypositiveterminal.A clickjng
soundshouldbe heard.Connectthe No.2 terminalto
the batterypositiveterminal.A clickingsoundshould
be heard.Replacethe lockup controlsolenoidvalve
assemblyif no clickingsoundis heard.
Shift ControlSolenoidValveA/B Assembly
Test Replacement
1. Disconnectthe 2P connectorfrom the shift control NOTE: Shift control solenoidvalves A and B must be
solenoidvalveA'lBassembly. removed/replacedas an assembly.
1. Removethe mountingboltsand shiftcontrolsolenoid

valve4!/Bassembly.
6x1.0mm
12 N.m BRACKET
CONNECTOR
{1.2ksl.m,8.7 lbt'ft}
SHIFTCONTROL
VALVEA/8
SOLENOID FILTER/GASKET
ASSEMBLY Replace. Cleanthe mountingsurface
and fluid passages.
'1
2, Measurethe resistancebetweenthe No. terminal
(solenoidvalveA) of the shift controlsolenoidvalve
connectorand body ground,and betweenthe No. 2
terminal(solenoidvalveB) and body ground 2. Cleanthe mounting surfaceand fluid passagesof
t h e s h i f t c o n t r o l s o l e n o i d v a l v e a s s e m b l y ,a n d
12- 25 O
STANDARD: installa new shift controlsolenoidvalveA,/Bwith a
new filter/gasket and the clamp bracket.
Replacethe shift controlsolenoidvalve assemblyif
the resistanceis out of specification. 3. Checkthe connectorfor rust, dirt or oil, and recon-
nectit securely.
lf the resistanceis within the standard,connectthe
N o . 1 t e r m i n a lo f t h e s h i f t c o n t r o ls o l e n o i dv a l v e
connectorto the batterypositiveterminal.A clicking
sound should be heard.Connectthe No. 2 terminal
t o t h e b a t t e r yp o s i t i v et e r m i n a l .A c l i c k i n gs o u n d
should be heard.Replacethe shift control solenoid
valveassemblyif no clickingsound is heard.
14-75
LinearSolenoidAssembly
Test
I
1. Disconnect
the linearsolenoidconnector. lf not, removethe linearsolenoidassembly.
6. Checkthat the linearsolenoidfluid passagefor dust

or qrn.
LINEARSOLENOID
7. C o n n e c t h e N o . 2 t e r m i n a lo f t h e l i n e a rs o l e n o i d
connectorto the batterypositiveterminaland con
nectthe No. 1 terminalto the batterynegativetermi,
nal.Checkthat the valvemoves.
8. Disconnectone of the batteryterminalsand check

that the valvereleases.
NOTE: You can see the valve movement through

the fluid passagein the mountingsurfaceof the lin-
ear solenoidassembly.
LINEAR
SOLENOID
2. Measurethe resistancebetweenthe No. 1 and the

N o .2 t e r m i n a l o
s f t h e l i n e a rs o l e n o i dc o n n e c t o r .
\
STANDARD:approx. 5 O
lf the resistanceis out of specification,replacethe ,.-,.

linearsolenoidassembly.
Connectthe No. 2 terminalof the linearsolenoidcon- VALVE

nectorto the batterypositiveterminaland connect
the No. 1 terminalto the batterynegativeterminal.A
clickingsoundshouldbe heard.
9. lf the valve binds. or moves sluggishly, or the linear

solenoid does not operate, replacethe linear solenoid
assemory.
14-76
Mainshaft/Counter-
shaft SpeedSensors
Replacement Replacement
1. Remove the mounting bolts and the linear solenoid 1. Removethe 6 mm bolt and the countershaftspeed
assemDly. sensorfrom the right sidecover
Cleanthe mountingsurface 6x1.0mm

and fluid passages. 12 N.m {1.2kgJ.m, COUNTERSHAFT
8.7 rbr.frl SPEEDSENSOF
5x1.0mm O.RING
12 N.m (1.2kgf.m, Replace.
8.7 tbf.ftl
MAINSHAFT
SPEED
SENSOR
@
@
MAINSHAFTSPEED
LINEAR SENSOEWASHER 6x1.0mm
GASKET 12 N.m 11.2kgl.m,
SOLENOID {D16Y7engine)
ASSEMBLY 8.7 tM.ft)
Cleanthe mountingsurfaceand fluid passageof the R e m o v et h e 6 m m b o l t a n d t h e m a i n s h a f ts p e e d

linearsolenoidassemblyand transmissionhousing. senso.from the transmissionhousing.
Installa new linear solenoidassemblywith a new Repiacethe O-ringwith a new one beforeinstalling
gasket. speedsensoror the mainshaftspeed
the countershaft
sensor.
NOTE:Do not pinch the gasketwhen installingthe
linearsolenoid;makesurethat the gasketis installed NOTE:Installthemainshaftspeedsensorwasheron
properlyin the mountinggroove of the linearsole- the mainshaftspeed sensor.The mainshaftspeed
nord. s e n s o rw a s h e ri s u s e d o n m o d e l sw i t h t h e D 1 6 Y 7
engine.
4. Checkthe linearsolenoidconnectorfor rust,dirt or
oil, and connectit securely.
14-77
Chart
HydraulicSystem
\
SYMPTOM Checktheseitemson the Checktheseitemson

PROBABLE CAUSELiSt the NOTESList
Engineruns,but vehicledoes not move in any gear. 1,2,3,5,6,'t,36,38 K,L,R,S
Vehiclemovesin p. E, but not in pel,@, position. 6, 8, 9, 10,30, 54 c,M,o
Vehiclemovesin E, E, E. but not in E position. 6,11,12,24 C,L
Vehiclemovesin E, E, E, but not in E position. 4 , 6 ,1 4 ,1 5 c,L,o
Vehiclemovesin E position. 10, 12,13,14,16,29, 33,34. 35 C,D
Excessive
idle vibration. 1 , 2 , 1 9 , 3 2 , 3 64, 5 ,4 7, 4 8 B.K.L
flareson startingoff in ro.. @ position
Pooracceleration;
Stallrpm high in lDl, E, El position. 1 , 2 , 3 , 6 , 3 A4, ' l K.L,R
Stallrpm high in E, l,- position. 6, 8, 10 C,D
Stallrpm high in E position. 6,12 C,D
i Stallrpm is in specification. 14 N
Stallrpm low. 17, 32, 45,47. 48 R
No shift 't9,20,40,
48,49 G,L
Failsto shift in @, @ position;from 1stto 3rd gear 22, 49
Failsto shift in pl, @ position;from 'lsrto 4th gear 22, 23, 4A
Erraticupshifting.
1-2upshift,2-3 upshift.3-4upshift 58
1-2upshift 21, 48
2-3 uDshift 22, 49
_ 3-4 upshift 23, 48 \
Harshupshift{1,2). 1 2 ,1 9 ,2 0 , 2 9 ,5 0 , 5 1 , 5 ,15 8
Harshupshift{2-3). 13,19,20,24,21,29,50,51,57,58 C,D,E,H,L
Harshupshift(3-4). 14, 19,20,25,28,29,50,51. 57,58 C ,D ,E ,I , L
Harshdownshift(2-1) 1 9 , 2 0 , 2 44, 3 ,5 4 , 5 7, 5 8 o
Harshdownshift(3-2). 12,'19,20,25,43,55,57, 58 C,D.E,H
Harshdownshift(4-3). 13, 19,20,26, 43,56,57,5A C, D, E, I
Flareson 2-3 upshift. 1 3 ,1 9 ,2 0 , 2 4 ,2 7 , 5 1
Flareson 3-4 upshift. 14, 19, 20, 25, 2A,5'l E,L,N
Excessive
shockon 2-3 uDshift. 13,19,20,24,27, 43,50,51, 58 E,L,N
Excessive
shockon 3-4 upshift. 14, 19,20,25,28,43,50,51, 58 E.L,N
Lateshift from E positionto E or lE! position. 1 0 ,3 0 M
Lateshift from E positionto E positron. 4,14,21,53 o
Noisefrom transmissionin all shift leverpositions. 2,37 K,L,O
Vehicledoes not acceleratemorethan 31 mph (50 km/h). 17
Shift leverdoes not operatesmoothly, 6, 39 P
Failsto shift;stuckin 4th gear. 19,48, 49
Transmission will not shiftintoparkinggearin E] position. 6, 18.39 P
Stallrpm high; all clutchpressuresare in specification. 41 D.K.O
Lock-upclutchdoes not disengage. 19, 44,45,46,47,50,51, 58 F I
Lock-upclutchdoes not operatesmoothly. '19,4't,

44, 45, 46,47, 50, 51, 58 L
Lock-upclutchdoes not engage. 't9,
41,44,45,46,47,50. 51,57, 58 E,L
Vibrationin all positions \
36
14-78
.
PROBABLE
CAUSE
2 ATF pump worn or binding. 42 Foreignmaterialin separatorplate.

Regulator valve stuck. 43 CPBvalvestuck.
Servo valve stuck. 44 Lock-uptiming valvestuck.
5 Mainshaftworn/damaged. 45 Lock-upshift valvestuck.
6 Shiftcablebroken/outof adjustment. 46 Lock-upcontrolvalvestuck.
7 Finalgearsworn/damaged. 47 Lock-uppistondefective.
I One-way{sprag)clutchworn/damaged. 48 ShiftcontrolsolenoidvalveA defective.
1stgearsworn/damaged(2 gears). 49 ShiftcontrolsolenoidvalveB defective.
10 1st clutch defective. 5U Lock-uDcontrolsolenoidvalveA defective.
l1 2nd gearsworn/damaged(2 gears)- Lock-uocontrolsolenoidvalveB defective.
2nd clutch defective. 52 Servocontrolvalvestuck.
3rd clutchdefective. 53 1staccumulatordefective.
14 4th clutch defective. 54 Foreignmaterialin 2nd exhaustorifice.
tc Reversegearsworn/damaged(3 gears). Foreignmaterialin 3rd exhaustorifice.
16 ExcessiveATF Foreignmaterialin 4th exhaustorifice.
17 Torqueconverterone-wayclutchdefective. MainshaftsDeedsensordefective.
18 Pakingmechanismdefective. 58 Countershatt sDeedsensordefective
19 Linearsolenoidassemblydefective.
20 CPCvalve stuck.
21 1-2shiftvalvestuck.
2-3 shiftvalvestuck.
3-4 shift valve stuck.
2nd accumulatordefective.
3rd accumulatordefective.
4th accumulatordefective.
27 2nd orificecontrolvalvestuck.
28 3-4 orificecontrolvalvestuck.
29 Foreignmaterialin main orifice.
30 Foreign material in 1st orifice.
31 Foreignmaterialin reverseorifice.
32 Engineoutput low,
33 Needlebearingworn/damaged.
34 Thrustwasherworn/damaged.
Clutchclearanceincorrect.
Driveplatedefectiveor transmissionmisas-
sembly.
Torqueconverterhousingor transmlsslon
housingbearingworn/damaged.
38 ATFstrainerclogged.
Joint in shift cableand transmissionor body
40 Modulatorvalvestuck.
(cont'd)
14-79
Ghart
HydraulicSystem (cont'dl
\
The followingsymptomscan be caused Check

theseitemson the
PROBABLE Items on the
by improperrepairor assembly CAUSEDUETO
IMPROPER NOTES List
REPAIRList
Vehiclecreepsin N position. R 1 ,R 2
Vehicledoes not move in .S or @ position. R4
Transmissionlocksup in E position R 3 ,R 1 ' 1
Excessive
drag in transmission. R6 K,R
Excessive
vibfation,rDm related, R7
Noise with wheels moving only. R5
Main sealpops out. R8 s
Variousshiftingproblems. R 9 ,R 1 O
PROBABLE
CAUSEDUETO IMPROPER
REPAIR
R1 lmproperclutchclearance.
R2. lmproper gear clearance.
R3. Parkingbrakeleverinstalledupsidedown.
R4. One-way(sprag)clutchinstalledupsidedown.
R5. Reverseselectorhub installeduDsidedown.
R6. A T Fp u m pb i n d i n g .
R7. Torqueconverternot fully seatedin ATF pump.
R8. Main seal improperly installed.
R9, Springsimproperlyinstalled.
R10. Valvesimproperlyinstalled.
R11 Shiftfork bolt not installed.
14-80
NOTES
Seeflushingprocedure,page14-155and 156.
B, set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in engine
section of this manual.
c. lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining'
D. worn, inspectthe otherclutchesfor wear,and checkthe orifice
lf the clutchpackis seizedor is excessively
controlvalves,CPCvalveand linearsolenoidlor free movement
E. lf the linearsolenoidis stuck,inspectthe clutchesfor wear.
lf the l-2 shift valveis stuckclosed,the transmissionwill not upshift lf stuckopen,the transmissionhas
no lst gear.
H. lf the 2nd oriticecontrolvalveis stuck,inspectthe 2nd and 3rd clutchpacksfor wear.
t. It the 3-4orificecontrolvalveis stuck,inspectthe 3rd and 4th clutchpacksfor wear'
J, lf the clutchDressurecontrolvalveis stuckclosed,the transmissionwill not shift out of 1stgear'
K. lmproperalignmentor main valvebody and torqueconverterhousingmay causeATF pump seizure.The
symptomsare mostlyan rpm relatedtickingnoiseor a high-pitchedsqueak-
L. lf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differential
pinion shaft. lf both are OK and no cause for the contamination is found, replace the torque convener.
l f t h e l s t c l u t c h f e e d p i p e g u i d e i n t h e r i g h t s i d e c o v e r i s s c o r e d b y t h e m a i n s h a f t , i n sbpeeacrtitnhge b a l l
for excessivemovementin the transmissionhousing.lf oK, replacethe right sidecoveras it is dented.The
O-ringunderthe guide is probablyworn
N. , Replace the mainshaftif the bushingfor the 4th feed pipeis looseor damaged.lf the 4th feedpipeis dam-
agedor out of round,replacethe rightsidecover.
. Replace the mainshaftif the bushingfor the 1stfeed pipeis looseor damagedll the 1stfeedpipeis dam
agedor out of round,replaceit. _
o. A worn or damagedspragclutchis mostlya resultof shiftingthe transmissionin iD1or lDapositionwhile
the wheelsrotatein reverse,suchas rockingthe vehiclein snow.
P, Inspectthe lrame for collisiondamage.
o. Inspectfor damageand wear:
1. Reverseselectorgearteethchamters
2. Engagement teethchamlersoI countershait4th and reversegear'
3. Shifttork for scuffmarksin center.
4. Differentialpinionshaftfor wear underpiniongears
5. Bottomof 3rd clutchfor swirl marks
makesa clicking,grindingor whirringnoise,
Replaceitems1, 2, 3 and 4 if worn or damaged.lf transmission
afsorepfacemainshaft4th gear,reverseidlergear,and countershaft 4th gearin additionto 1,2,3 or 4'
pinionshaftis worn, overhauldifferential
lf differential assembly, replaceATFstrainer,andthoroughly
and
cleantransmission, cooler
Ilushtorqueconverter, and lines
lf bottomof 3rd clutchis swirledandtransmission makesgearnoise,replacethe countershaftandfinaldriven
gear.
Be very carefulnot to damagethe torqueconverterhousingwhen replacingthe main ball bearing.You
may alsodamagethe ATF pump when you torquedown the main valvebody.This will resultin ATF pump
seizureif not detected.Usethe propertools.
S. Installthe main sealflush with the torqueconverterhousing.lf you push it into the torqueconverter
housinguntil it bottomsout, it will blockthe fluid returnpassageand resultin damage'
14-81
RoadTest
NOTE:Warm up the engineto normaloperatingtemperature(the radiatorfancomeson).
'1.
Apply parkingbrake and block the wheels.Start the engine,then shift to E positionwhile depressingthe brake
pedal.Depressthe accelerator
pedaland releaseit suddenly.The engineshouldnot stall.
2. Repeatsametest in E position.
Test-drivethe vehicleon a flat road in the E] position.Checkthat the shift pointsoccurat approximatespeeossnown
on a flat road.Also checkfor abnormalnoiseand clutchslippage.
NOTE:Throftlepositionsensorvoltagerepresents
the throttleopening.
a. Unboltthe PCMfor roadtesting;referto page 14-46.

b Set the digital multitesterto checkvoltagebetweenD1 (+) terminaland A9 {-) or A22 l. l terminalof the pCM for
the throttlepositionsensor.
BACKPROBE
ADAPTER
BACKPROBE SET
07sAz- 001000A
Itwo requiredl
DIGITALMULTIMETER
lCommerciallyavailablel
KS-AHM-32-003.
or equivalent
PCMCONNECTORS
B {2sP) c {31P)
&l Position: Dl6Y7 engine
Upshift
Throttle Opening Unit of speed lsl + 2nd znd * 3rd 3rd - ilth Lock-upON
mpn 9-12 28-32 2 1- 2 4

Throttlepositionsensor
voltage:0.75V km/h 15- 19 1t _ a'f 45-52 34-39
Throttlepositionsensor mph 21-25 40-45 59-65

v o l t a g e : 2 . 2V5 km/h 34-40 65-73 9 5- 1 0 4 99 - 108
Fullyopenedthrottle mph 33-38 101- 112 99 - 109

Throttlepositionsensor ' t76
km/h 53-61 102- 115 163 180 159-
voltage:4.5V
Downshift
Throttle Opening Unit of sDeed Lock-upOFF 4th * 3rd 3rd + 2nd 2nd * lst
throttle
Fully-closed mpn 19-22 1 7- 2 0 6-9(3rd-1st)
voltage:0.5V km/h 30-35 10- 15 (3rd* 1st)
Fully-openedthrottle mph 9 5- 1 0 5 85-95 54-61 25-30

voltage:4.5V km/h 1 5 3- 1 6 9 1 3 7- 1 5 3 87-98 40-48
-9. Position: D16Y8engine
Upshift
Throttle Opening Unit of speed lst * 2nd 2nd + 3rd 3rd + 'lth Lock-upON
mph 9-12 20-23 28-32 2't- 24

voltage:0.75V km/h 15-l9 32-37 45-52 34-39
mph 40-45 62-67
voltage:2.25V km/h 34-40 65-73 9 5- 1 0 4 99 - 108
'107 9 5- 1 0 6
Fully-openedthrottle mph 62-70 96 -
km/h 52-60 1 0 0- 1 1 3 155- 172 1 5 3- 1 7 0
voltage:4.5V
Downshift
Throttle Opening Unit of speed Lock-upOFF ilth - 3rd 3rd - 2nd 2nd - lst
Fully-closed throttle mph 19-22 1 1- 2 0 6-9(3rd- 1st)

Throttlepositionsensor ' 1 0- 1 5 ( 3 r d-
km/h 30-35 lstl
v o l t a g e : 0 .V
5
Fully-openedthrottle mpn 91 101 85-95 54-61 25-30
voltage:4.5V km/h 1 4 7- 1 6 3 1 3 7- 1 5 3 87-98 40-48
NOTE:
o Lock-uOp N : T h el o c k - u p c o n t r so ol l e n o i dv a l v eA t u r n sO N .
. Lock-uoOFF:Thelock-upcontrolsolenoidvalve A tu rns OFF.
(cont'd)
14-83
RoadTest
(cont'dl
Accelerateto about 35 mph (57 km/hl so the transmissionis in 4th, then shift from E positionto @ position.The
vehicleshouldimmedistelybeginslowingdown from enginebraking.
CAUTION: Do not shift trom E or E position to E position at speeds ovcr 6:l mph (100 km/hl; you mly dlmlge
the tJansmission.
Checkfor abnormalnoiseand clutchslippagein the followingpositions
E (2nd cear) Position

a. Accelerate
trom a stop at full throttle.Checkthat there is no abnormalnoiseor clutchslippage.
b. Upshiftsand downshiftsshouldnot occurwith the selectorin this oosition.
E (Reverse)Position
Accelerate
from a stop at full throttle,and checktor abnormalnoiseand clutchslippage.
Test in E {Parking)Position
Parkthe vehicleon slope{approx.16'),applythe ps.kingbrake,and shift into E position.Releasethe brake;the vehi-
cle shouldnot move.
Stall Speed
Test
CAUTION:
. To prevent transmission dEmage,do nol test stall sPeedtol more than 10 secondgat 8 time.
. Do not shift th€ l€ver whils raising th€ sngine spoed.
. Bs sure to rsmove ths pressuregauge beforg l€gting stall sPeed.
'1. Engagethe parkingbrake,and blockthe front wheels.
2. Connecta tachometerto the engine.and startthe engine
3. Makesurethe IVCswitchis OFF.
4. Afterthe enginehaswarmed up to normaloperatingtemperature{the radiatorfan comeson), shift into E position.
5. for 6 to 8 seconds,and noteenginespeed'

Fullydepressthe brakepedaland accelerator
6. Allow two minutesfor cooling,then repeatthe test in E and E positions.
NOTE:
. Stallspeedtestsshouldbe usedfor diagnosticpurposesonly
. Stallspeedshouldbe the same in E, E and E positions.
Stall Speed RPM:

Spocmcation:2,700rpm
ServiceLimit: 2,550- 2,850rpm
TROUBLE PROEABLECAUSE
stall rpm high in ld, El and E positions Low tluid levelor ATF pump output
CloggedATF strainer
Pressureregulatorvalvestuckclosed
Slippingclutch
Stallrpm high in E position . Slippageof 4th clutch
Stallrpm high in E position . Slippageof 2nd clutch
Stallrpm high in E position . Slippag€of lst clutchor 1stgear one-wayclutch

stall rpm low in E, E and E Positions . Engineoutputlow
' Torqueconvenerone-wayclutchslipping
14-85
FluidLevel
Checking/Changing
CAUTION: While checking 8nd changing, bo sure not to Changing
allow du3t and other foreign particles to €nter into the
transmission. CAUTION: Keop all of the toreign particles out of the
transmiasion,
Checking
1. Bringthe transmissionup to operatingtemperature
CAUTION: Keep all of th€ loreign particles out of th€ b y d r i v i n g t h e v e h i c l e .P a . k t h e v e h i c l eo n l e v e l
transmission. g r o u n d . t u r n t h e e n g i n e o J f ,t h e n r e m o v e d r a i n
ptug.
NOTE:Checkthe fluid level with the engine at normal
operatingtemperature{the radiatorfan comeson}. NOTE:lf a coolerflusheris to be used,seepage 14-
1 5 5a n d 1 5 5 .
l. Parkthe vehicleon level ground. Turn off the
engrne. 2. Reinstallthe drain plug with a new sealingwasher,
2. Removethe dipstick(yellow loop) from the trans- then refill the transmissionwith the recommended
mission,and wipe it with s cleancloth. fluid* to the uppermark on the dipstick.
I\
Automatic Transmi$ion Fluid Capacity:
2.7 I 12.9US qa,2-1lmp qt) at chang.
5.9 / {6.2 US $, 5.2 lmp qt} at overhaul
\ \ RecommendedAutomatic Transmisrion Fluid:

Genuine Honda Pr€mium Formula Autometic
\\ l Vl TransmissionFluid (ATF)..
TRANSMISSION
RIGHTSIOECOVEF
tl
0- UPPERMARK
LOWERMARK
OIPSTICKIYELLOWLOOPI
3 . Insertthe dipstickinto the transmission.

4. R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l ,l t
shouldbe betweenthe upperand lower marks.
lf the levelis belowthe lower ma.k, pour the recom-
mendedfluid+ into the filler hole to brino it to the
uppermarK.
Insertthe diDstickback into the trsnsmissionin the DRAINPLUG
directionshown. 1 8x 1 . 5m m SEALINGWASHEE
FRONT 49 N.m {5.0kgf.m,36lbttr) Replace.
* Alwaysuse GenuineHondaPremiumFormula
AutomaticTransmissionFluid (ATF).Usinga non-
Honda ATF can affect shift qualitv.
Installthedipstickin the extent

ol the directionshown.
PressureTesting
@
. While tosting, be careful of the rotating tront wheels
. Maks sur€ lifts, iacks, and saloty stands are placed properlY{seesoction 11.
CAUTION:
. Betoretesting, bs sure the transmissiontluid is tilled to the proper level.
. Warm up the engine befote tssting.
1. Raisethe vehicle(seesection1).
2. Warm up the engine,then stop the engineand connecta tachometer.
3. Connectthe oil pressuregaugesto eachinspectionhole.
TOROUE:18 N.m {1.8 kgf'm, 13 lbf'ftl
CAUTION: Connect the oil pressuregauges securely;be sure not to allow dust and other foreign particles to €nter
th€ inspection holes.
A/T OIL PRESSUBEGAUGE A/T OIL PRESSURE HOSE

SETWPANEL ADAPTER
07406 - 0020400 07MAJ - PY,(}l20
(4 roquirodl
A/T LOWPRESSUBE GAUGE A/T OIL PRESSUREHOSE

SETWPANEL 2.10 mm
07'r()6- 0070300 07MAJ - PYiOllA
{{ rsquirodl
Startthe engine,and measurethe respectivepressureas follows

a Line Pressure
. 1stClutchPressure
. 2nd.3rd and 4th ClutchPressure
Installa new washerand the sealingbolt in the inspectionhole,and tightento the specifiedtorque.
TOROUE:18 N.m (1.8kgf.m,13 lbf'ft|
NOTE:Do not reuseold sealingwashers;alwaysreplacewashers
(cont'd)
14-47
PressureTesting
(cont'd)
a Line Pressure/1stClutch PressureMeasurement
1. Setthe parkingbrake,and blockboth rearwheelssecurely.
2. Runthe engineat 2,000rpm.
3. Shiftto E or E posltion,then measureline pressure,
are made in shift leverpositionsotherthan E or fl posi-

NOTE:Higherpressuremay be indicatedif measurements
tion.
4. Shiftto E position,then measurelst clutchpressure.
1STCLUTCHPRESSURE
INSPECTION HOLE
(Markedwith "L")
LOCK.UP
CONTROL
VALVEA/B
SOLENOID
ASSEMELY
VALVEA/B ASSEMBLY
I
SHIFTLEVER FLUIDPRESSURE
PRESSURE SYMPTOM CAUSE
PROBABLE
POStTtON Standard S€rvic€Limit
Line Eo.E No {or low) Torqueconverter, 830 - 880 kPa 780 kPa
lrnepressure ATF pump, pres- (8.5- 9.0 kgf/cm' , {8.0kgf/cm,,110psi)
sure regulator, 1 2 0- 1 3 0p s i )
torqueconverter
checkvalve
'1st Noor low 1st 1 s tC l u t c h
Clutch E
pressure
14-88
2nd, 3rd rnd 4th Clutch Ptassurc Mclrurcmanl
LINEARSOLENOID
1 . Set the psrking brake,and block both tear wheels

sscurely.
2. Disconnectthe linsarsolenoidconnector.
3. Startthe sngine,and run the engineat 2,000rpm.
4. Shift to E position,and measureeachclutchpres-

sure,
5. Connectbattery voltage and ground lo the linear

solenoid connect€rtgrminals,then msasure each
clutch pr6ssure.
1THCLUTCH
INSPECTIONHOI.I
(M.rkedwith "4")
PRESSURE
CLUTCTI
HOLE
INSPECTION
PRESSURE
FLUIDPRESSURE
SHIFTI.EVER
PfiESSURE SYMPTOM PROBABI.E
CAUSE
POSmON Standard ServiceLimit
2nd Clutch E No or low 2nd 2nd Clutch 800 - 850 kPa 760 kPa
pressure (8.2- 8.7 kg7cm', (7.7kgf/cm,,110psil
120- l2il psi) with the linearsolenoid
with the linearsolenoid disconnected
disconnec'ted
0- 150kPa Above 150 kPa

(0-1.5kgflcm' , {1.5kg?cm,,2l psi)
0 - 21 psi) with the linearsolenoid
with the linearsolenoid connectedto battery
connectedto battery vollage and ground
voltageand ground
3rd Clutch E No or low 3rd 3rdClutch 810- 860 kPa 765 kPa
pressure (8.3- 8.8 kgflcm', (7.8kgf/cm' ,111psi)
1 1 8- 1 2 5p s i ) with the linearsolenoid
with the linearsolenoid disconnected
disconnected
ilth clurch No or low 4th 4th clutch
pressure
0 - 150kPa Above 150 kPa
(0-1.5kgf/cm' , (1.5kgf/cm' .21 psi)
ts Servo Valve or 4th 0 - 21 psi) with the linearsolenoid
Clutch with the linearsolenoid connectedto battery
connectedto battery voltage and ground
voltageand ground
14-89
Transmission
Removal
@Make suie lifts, 4. Removethe transmissiongroundcable,and discon-

iacks and safety stands are placed nectthe lock up controlsolenoidconnector.
properly, and hoist bracket are aftached to the col-
rect positionon the engine(seesection11.
Apply paiking brske and block rear wheels so vehicle
will not roll off standsand lall on you while working
undel it.
CAUTION: Use fender covers to avoid damaging paint-

ed surfaces.
1. D i s c o n n e ct th e b a t t e r yn e g a t i v e( - ) t e r m i n a lf r o m
the battery,then removethe positive(+)terminal.
2. Removethe intakeair duct.
D16Y7engine:
Removethe intakeair duct and resonator.
D16Y8engine:
R e m o v et h e i n t a k ea i r d u c ta n dt h e a i r c l e a n e hr o u s -
ing assembly.
R e m o v et h e s t a r t e rc a b l e sa n d c a b l eh o l d e rf r o m
the startermotor.
5. Disconnectthe vehiclespeedsensor(VSS)connec,
tor and the countershaft
speedsensorconnector.
MOTORCABIE
VEHICLE
SPEED
MOTOECABLE
14-90
6. Removethe transmissionhousing mounting bolts 8. R e m o v et h e d r a i n p l u g , a n d d r a i n t h e a u t o m a t i c
and the rearenginemountingbolt. t r a n s m i s s i o nf l u i d ( A T F ) .R e i n s t a ltlh e d r a i n p l u g
with a new sealingwasher.
DRAINPLUG
1 8x 1 . 5m m
49 N.m (5.0 kgf.m,36 lbf ftl
7. Disconnect the shift controlsolenoid,the linearsole-

noid.and the mainshaftsDeedsensorconnectors.
9. Remove the splash shield.
SHIFTCONTROL LINEARSOI.ENOID
SOLENOIOCONNECTOR CONNECTOR
SPLASHSHIELD
CONNECTOR
BRACKET
(cont'd)
14-91
Transmission
Removal(cont'dl
10. Removethe cotter pins and castlenuts.then separate 16. Removethe shift cablecover,then removethe shift
the balliointsfrom the lowerarms(seesection18). cableby removingthe controllever.
DAMPER PINCH BOLT
CAUTION: Take care not to bend the shift cable.
SHIFTCABLE
CONTROL
:\ SHAFT
NUT
FORK COTTERPIN
FORK BOLT Replace.
WASHER
1 1 . R e m o v et h e r i g h t d a m p e rf o r k b o l t ,t h e n separate
r i g h td a m p e rf o r ka n d d a m p e r .
12. Prythe rightand leftdriveshafts

out of the differential. 1 1 . Removethe rightfront mount/bracket.
P u l lo n t h e i n b o a r dj o i n ta n dt h e r i g h ta n d l e f td r i v e - 1 8 . R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r
shaftslseesection16). lines.Turn the ends of the ATF cooler hosesup to
preventATF from flowing out, then plug the ATF
1 4 . Tie plasticbagsover the driveshaftends. coolerhosesand lines.
NOTE:Coatall precisionfinishedsurfaceswith clean N O T E :C h e c kt o r a n y s i g n o f l e a k a g ea t t h e h o s e

e n g i n eo i l . joints.
Removethe exhaustpipeA. ATF COOLER

LINE
N O T E :D ' 1 6 Y 8e n g i n e i s s h o w n ; D 1 6 Y 7e n g i n ei s
s i mi l ar .
Y;
"€):
,
*S9e,
SELF.LOCKING
NUT
Replace. RIGHTFRONT
MOUNT/BRACKET HOSE
EXHAUSTPIPEA
Replace.
14-92
1 9 . R e m o v et h e e n g i n es t i f f e n e ra n d t h e t o r q u ec o n - 23. Placea jack under the transmission,and raise the
vertercover. transmissionjust enoughto take weight off of the
mounts,lhen removethe transmisslonmount.
TRANSMISSION
MOUNTBRACKET
STIFFENER
CONVERTER
20. R e m o v et h e e i g h t d r i v e p l a t eb o l t s o n e a t a t i m e
while rotatingthe crankshaftpulley.
n o u s i n gm o u n t i n gb o l t s
2 4 . R e m o v et h e t r a n s m i s s i o h
2 1 . Removethe distributor. a n dt h e r e a re n g i n em o u n t i n gb o l t s .
2 2 . Attacha hoistingbracketto the engine.then lift the 25. Pull the transmissionaway from the engine until it
e n g i n es l i g h t l y . clearsthe 14 mm dowel pins, then lower it on the
transmissioniack.
REARENGINE
TRANSMISSIONHOUSING MOUNTINGBOLTS
MOUNTINGBOLTS Replace.
26. lf necessary,removethe torque convener and the

stanermotor.
14-93
lllustrated lndex
Transmission/Right
SideCover
(,ROLLER @ RIGHTSIDECOVER
@ COLLAR @ lsT cLUTcHFEEDPIPE
O o-RtNGReplace. @ o-RlNGsReplace.
@ FEEDPIPEFLANGE @ FEEDPIPEFLANGE
O o-RINGReplace. @ SNAPRING
@ SNAPRING @ MA|NSHAFTLoCKNUT(FLANGENUTI21 x 1.25mm
O 3RDcLUTcH FEEDPIPE Replace.
@ COUNTERSHAFT LOCKNUT{FLANGENUT) @ CONICALSPRINGWASHERReplace.
23 x 1.25mm Replace. @ lsT cLuTcH ASSEMBLY
O CONICALSPRINGWASHERRepIace, @ o-RlNGs Replace.
@ PARKINGGEAR @ THRUSTWASHER
@ ONE-WAYCLUTCH @ THRUSTNEEDLEBEARING
@ COUNTERSHAFT 1STGEAR @ NEEDLEBEARING
@ NEEDLEBEARING @ MAINSHAFTlST GEAR
@ COUNTERSHAFT 1STGEARCOLLAR @ MAINSHAFTlST GEARCOLLAR
@ o-RlNGs Replace. @ ATF COOLERLINE
@ RIGHTSIDECOVERGASKETRep|ace. @ SEAL|NGwAsHERs Reptace.
@ DowEL PINS @ JoINT BoLT
@ PARKINGBRAKEPAWLsToP @ ATF DTPSTICK
@ LocK WASHERReptace. @ ATF COOLERLINE
@ PARKING BRAKESTOPSelectivepart @ JOINT BOLT
@ PARKINGBRAKELEVEB @ SEAL|NGWASHERSReptace.
@)PARKINGERAKELEVERSPRING @ VEHICLE SPEEDSENSOR
@ DRAINPLUG @ O.RINGReplace.
@ SEALINGWASHERRepIace.
@ o-RINGReplace.
@ COUNTERSHAFT SPEEDSENSOR
@ PARKINGBRAKEPAWL
@ PARKINGBRAKEPAWLSPRING
@ PARKINGBRAKEPAWLSHAFT
@ LINEARSOLENOTD ASSEMBLY
@ LTNEAR SOLENOID GASKETRepIace,
TOROUESPECIFICATIONS
Bolt/Nut No. Torque Value Size Remarks

6A 12 N'm (1.2kgim,8.7 lbf.ft) 6 x 1 . 0m m
'14 '10
6B N'm (1.4kgf.m, lbf'ft) 6x1.0mm
'1.2m 5m
8F 22 N.m (2.2kgim, 16 lbf.ft) 8x
12A' 28 N.m (2.9kgf.m,21lbf.ft) 1 2x 1 . 2 5m m Joint bolt
18D 49 N.m (5.0kgf.m,36lbf.ft) 1 8x 1 . 5m m D r a i np l u g
21M 78 N.m (8.0kgim,58 lbf.ft) 2 1 x 1 . 2 5m m Mainshaftlocknut:Left-handthreads
1 0 3N . m( 1 0 . 5k g n m , 7 5 . 9
lbf.ft) 2 3 x 1 . 2 5m m Countershaft locknut:
Left-handthreads
14-95
lllustratedIndex
Transmission
Housing
6A
I
o
14-96
b
ill LOCKWASHERReplace. 89 THRUSTNEEDLEBEARING
(A REVERSE SHIFTFORK @ MAINSHAFT
@ couNTERSHAFTREVERSE GEARCOLLAR 60 SEALINGRINGS,35 mm
.' COUNTERSHAFT REVERSEGEAR 6DSEALINGRING,29 mm
@ NEEDLEBEARING 6!) NEEDLEBEARING
(O REVERSESELECTOR @ SETRING
O REVERSESELECTORHUB @ SHTFTCONTROLSOLENOIDVALVEA/B ASSEMBLY
@ COUNTERSHAFT 4TH GEAR @ HARNESSCLAMPBRACKET
O NEEDLEBEARING 6DsHtFT CONTROLSOLENOTD FTLTER/GASKETReptace.
@ DISTANCE COLLAR,28 mm Selectivepart @ CONNECTORBRACKET
@ COUNTERSHAFT 2ND GEAR .O TRANSMISSIONHANGER
@ THRUSTNEEDLEBEARING @ BREATHER cAP
[3 COUNTERSHAFT 3RD GEAR @ MAINSHAFT sPEEDsENsoR
(iI NEEDLEBEARING @ MAINSHAFTSPEEDSENSORWASHER{O16Y7ENgiNEI
.(3 COUNTERSHAFT 3RD GEARCOLLAR @ o-RINGReplace.
(D THRUSTNEEDLEBEARING @ SNAPRING
(' SPLINED WASHER @ MAINSHAFT TRANSMISSION HOUSINGBEARING
@) 3RD cLUTcH ASSEMBLY (5] COUNTERSHAFTTRANSMISSION HOUSINGBEARING
@ o-RlNGsReplace. @ REVERSE IDLERGEARSHAFTHoLDERASSEMBLY
@ COUNTERSHAFT €D NEEDLEBEARING
@ SNAPRING 6, olL SEALReplace.
@ THRUSTWASHER @ SETRING,80 mm Selectivepart
@ THRUSTNEEDLEBEARING €d]TRANSMISSIONHOUSTNG
@ MAINSHAFT4THGEAR/REVERSE GEAR @ REVERSE IDLERGEAR
@ NEEDLEBEARINGS @ DOWELPINS
@ THRUSTNEEDLEBEARING @ TRANsMtssloNHoustNG GASKETReptace.
€) MAINSHAFT4TH GEARCOLLAR @ DIFFERENTIAL ASSEMBLY
@ 2ND/4THcLUTcH ASSEMBLY @ olL SEALReplace.
@ o-RlNGsReplace. 62TOROUECONVERTER HOUSING
@ THRUSTWASHER,36.5x 55 mm Selectivepart
6] THRUSTNEEDLESEARING
@ MAINSHAFT 2ND GEAR
@ NEEDLEBEARING
Bolt/Nut No. TorqueValue Size Remarks

6A '12
N.m 1l.2kgf.m,8.7lbf.ft) 6x1.0mm
'14
6B N . m( 1 . 4k g f . m 1
. 0lbnft) 6x1.0mm
10A 44 N m (4.5kgnm,33lbnft) 1 0x 1 . 2 5m m
14-97
lllustrated Index
TorqueConverterHousing/ValveBody
'98 mod.l
i lll
iH
t -
14-98
- - \
T) ATF FEEDPIPE @ ATF MAGNET
O ATF STRAINER @ COUNTERSHAFT TOROUECONVERTER HOUSTNG
@ SERVOBODY BEARING
@ sERVo SEPARAToRPLATE @ ATF GUIDEPLATE
.' SECONDARYVALVE BODY Q] TOROUECONVERTER HOUSING
a6)DowELPrNs @ olL SEALReplace.
O SECONDARYSEPARATORPLATE (.} MAINSHAFTTOROUECONVERTER HOUSING
@ SERVODETENTBASE BEARING
O ATF FEEDPIPES @ olL SEALReplace.
(o) ATF FEEDPIPES @ LOCK.UPCONTROLSOLENOIDFILTER/GASKET
O SHAFTsToP Replace.
@ coNTRoL SHAFT @ LocK-UPcoNIRoL SoLENoIDVALVEA/B ASSEMBLY
(} DETENTARM SPRING @ CONNECTOR BMCKET
(D DETENTARM
@ DETENTARM SHAFT
@ FILTERReplace.
O CHECKBALLS
[o) TOROUECONVERTER CHECKVALVESPRING
@ TOROUECONVERTER CHECKVALVE
@ DOWELPINS
@ LOCK-UP VALVEBODY
@ LOCK.UPSEPARATORPLATE
@ REGULATOR VALVE BODY
@ DowELPrNs
@ COOLERRELIEFVALVE SPRING
@ COOLERRELIEFVALVE
@ o-RINGReplace.
@ STATORSHAFT
@ STOPSHAFT
@ ATF FEEDPIPE
@ MAIN VALVE BODY
O ATF PUMPDRIVENGEARSHAFT
@ ATF DRIVENGEAB
@ DOWELPINS
@)ATF PUMPDRIVEGEAR
@ MAIN SEPARATORPLATE
@ SUCTIONPIPECOLLAR a

6A 1 2 N . m { 1 . 2k g f . m , 8 . 7l b f . f t ) 6x1.0mm
14-99
Right Side Cover
Removal
NOTE:
. Cleanall partsthoroughly
in solventor carburetor
cleaner,
anddrywithcompressed
air.
. Blowoutall passages.
. When removingthe right sidecover,replacethe following:
O rings
- Mainshaftand countershaftlocknuts
- Conicalspringwashers
- Rightsidecovergasket
Lockwasher
S e a l i n gw a s h e r s
RIGHTSIDE
COVEB
ARAKELEVER
WASHER
lST GEABOOLLAR
JOINT BOLT COUNTERSHAFT
SEALINGWASHERS
14-100
'13 5. Removethe specialtool from the mainshaftafter
1 . Removethe bolts securingthe right side cover.
then removethe right sidecover. removingthe locknuts.
Slipthe specialtool onto the mainshaftas shown. 6. Removethe 1stclutchand mainshaftlst gearassem
bly and mainshaftl st gearcollarfrom the mainshaft.
MAINSHAFT HOLDER 7 . Removethe parkingbrakepawl.springand shaft.

o'GAB- PFs0'101
8 . R e m o v et h e p a r k i n gb r a k el e v e rf r o m t h e c o n t r o l
shaft.
Usinga universaltwo jaw puller,removethe parking

g e a r . o n e - w a yc l u t c h a n d c o u n t e r s h a f t1 s t g e a r
assemoty.
PULLER
(Commerciallyavailablel
PARKII{GGEAR
J. E n g a g et h e p a r k i n gb r a k ep a w l w i t h t h e p a r k i n g
gear.
Cut the locktabs of the mainshaftand countershaft

locknutsusing a chisel as shown, then removethe
locknutsand conicalspringwashers.
CAUTION: Keep all of the chisoled particles out of

tho transmiS3ion.
'10. R e m o v et h e n e e d l eb e a r i n ga n d t h e c o u n t e r s h a f t
NOTE:
. Mainshaftand countershaftlocknutshave left- 1stgearcollarfrom the countershaft.
handthreads.
. Always wear safety glasses. 1 1 . Removethe ATF coolerlinesand ATF dipstick.
CHISEL
LOCKNUT
LOCKTA8
14-101
Transmission
Housing
Removal
TRANSMISSIONHOUSING
MOUNTINGEOLTS
18 Bolts
TRANSMISSION
HANGER
TRANSMISSIONHOUSING
MAINSHAFT
SUB.ASSEMBL
MAINSHAFT
SENSORWASHER
(D16Y7engine)
SPEED
SENSOR
TRANSMISSION
HOUSINGGASKET
TOROUE
CONVERTER
HOUSING
14-102
-
NOTE: Removethe countershaftreversegear with the col-
r C l e a na l l p a r t st h o r o u g h l yi n s o l v e n to r c a r b u r e t o r lar and needlebearing.
cleaner,and dry with compressedair.
. Blow out all passages. Removethe lock bolt securingthe shift fork. then
. W h e n r e m o v i n gt h e t r a n s m i s s i o nh o u s i n g ,r e p l a c e removethe fork with the reverseselectorfrom the
the following: countershaft.
- O-ring
- Transmissionhousinggasket 7. R e m o v et h e c o u n t e r s h a fst u b - a s s e m b l ya n d t h e
* Lockwasher mainshaftsub-assembly together.
' t . Removethe mainshaftspeedsensorfrom the trans-

missionhousing.
MAINSHAFT COUNTERSHAFT
SUB,ASSEMBLY
2. Removethe transmissionhousing mounting bolts SU8-ASSEMBLY
ano nanger.
Align the spring pin on the control shaft with the

transmissionhousinggrooveby turning the control
shaft,
8. Removethe differentialassemblyfrom the torque

converterhousing.
HOUSINGPULLER
- PKa010A
07HAC
lnstallthe specialtool on the transmissionhousing,

then removethe housingas shown.
CAUTION: Make sure the mainshaft speed sensol

has been removed trom the transmission housing
before removing ihe transmission housing lrom the
torqug converter housing.
14-103
TorqueConverterHousing/ValveBody
Removal
6x1.0mm
1
ATF FEEDPIPE
x 1.0mm
PIN 2 Bolts
LOCK-UPVAL
BODY 6x1.0mm
IOCK-UPSEPARATOR SEBVODETENT TF STRAINER

PLATE BASE
ATF FEED
REGULATOR
VALVEBODY
CONTROL
DOWEL SHAFT
COOLERRELIEFVALVE OETENT x 1.0mm

ARM SHAFT 7 Bolts
DETENT
TOROUE ARM
CHECKVALVE SERVOSODY
SERVOSEPARATOR
PLATE
ATF FEEOPIPE
6x1.0mm 6x1.0mm
5 Bolts 3 Bolts
MAIN VALVE
BODY SHAFT VALVEBODY
ATFPUMP STOP
GEARSHAFT PIN
ATF PUMP ATF PUMP
DRIVEN ORIVEGEAR SECONDARY
MAIN SEPARA SEPARATORPLATE
PLATE
TOROUE
CONVERTER
HOUSING
14-104
NOTE: 1 3 . C l e a nt h e i n l e t o p e n i n go f t h e A T F s t r a i n e rt h o r -
o Clean all parts thoroughly in solvent o. carburetor oughly with compressedair, then checkthat it is in
cleaner,and dry with compressedair. good condition,and the inletopeningis not clogged.
. Blow out all passages.
. When removingthe valvebody, replacethe O-ring.
1. Removethe ATF feed pipes from the servo body,

secondaryvalvebody and main valvebody.
2, Remove the ATF strainer and servo detent base

(two bolts).
3. Removethe servo body and servo separatorplate

(seven boltsl.
Removethe secondaryvalve body, shaft stop and

INLETOPENING
secondaryseparatorplate(threebolts).
Removethe lock-upvalve body and separatorplate

{sevenbolts),
Removethe regulatorvalvebody {one bolt).

1 4 . Test the filter by pouring clean ATF fluid through
7 . Removethe stator shaft and stop shaft, t h e i n l e t o p e n i n g .R e p l a c et h e A T F s t r a i n e ri f i t i s
cloggedor damaged.
Removethe detentspringfrom the detentarm. then
remove the control shaft from the torque converter NOTE:The ATF strainercan be reused if it is not
housing. croggeo.
Removethe detentarm and detentarm shaft from

the main valvebody.
1 0 . Removethe main valvebody (fivebolts).
NOTE:Do not let the eight checkballsfall outofthe

m a i n v a l v e b o d y w h e n r e m o v i n gt h e m a i n v a l v e
body.
1 1 . Removethe ATF pump driven gear shaft,then remove

the ATF pump gears.
12. Removethe main separatorplate and two dowel

prns.
14-105
ValveCaps
Description
Caps with one projected tip and one flat end are Capswith hollow ends are installedwith the hollow
i n s t a l l e dw i t h t h e f l a t e n d t o w a r d t h e i n s i d e o f t h e end awayfrom the insideof the valvebody.
valve body. CaDswith notchedends are installedwith the notch
Caps with a projected tip on each end are installed towardthe insideof the valvebody.
with the smaller tiD toward the inside oI the valve Capswith llat ends and a holethroughthe centerare
b o d y .T h e s m a l l t i p i s a s p r i n gg u i d e . i n s t a l l e dw i t h t h e s m a l l e rh o l e t o w a r dt h e i n s i d eo f
the valvebodv.
Toward outside of valve bodv. Toward outside of valve bodv.
EflE
Toward inside of valve bodv. Toward inside of valve bodv.
C a p s w i t h o n e p r o j e c t e dt i p a n d h o l l o w e n d a r e Capswith flat ends and a groovearoundthe cap are

installedwith the tip toward the inside of the valve installedwith the groovedside toward the outsideof
body.The tip is a springguide. the valvebodv.
---'gJfr
Toward outside of valv6 bodv. Toward outside ol valve body.
GROOVE
./
\:7
Sectional view.
Toward insideot valve bodv Toward inside ol valve body.
14-106
E.
Valve Body
Repair
NOTE:This repair is only necessaryif one or more ot 5. Removethe #600 paper and thoroughly wash the
the valvesin a valve body do not slidesmoothlyin their entire valve body in solvent,then dry it with com-
bores.You may use this procedureto free the valvesin pressedarr.
the valvebodies.
6. Coatthe valvewith ATF,then drop it into its bore.
1. S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r It should drop to the bottom of the bore under its
about30 minutes. own weight.lf not, repeatstep4, then retest.
2. C a r e f u l l yt a p t h e v a l v eb o d y s o t h e s t i c k i n gv a l v e
dropsout of its bore.
C A U T I O N :l t m a y b e n e c e s s a r yt o u s e a s m a l l
screwdriver to pry the valve free. Be carelul not to
scratchthe bore with the screwdriver.
3. Insoectthe valvefor anv scuff marks.Use the ATF-

soaked#600 paper to polish off any burrs that are
on the valve,then wash the valvein solventand dry
it with compressedair. VALVE EODY
Roll up half a sheetof ATF-soaked paper,and insen

it in the valvebore of the stickingvalve.
Twistthe paperslightly,so that it unrollsand fits the
b o r e t i g h t l y ,t h e n p o l i s ht h e b o r e b y t w i s t i n gt h e
ffiFS'
paperas you push it in and out.
CAUTION:The valve body is aluminumand doesn't

require much polishing to remove any burrs.
ATF-so6ked
#0OO abrasivo papet
7. Removethe valve,then thoroughlyclean it and the
v a l v e b o d y w i t h s o l v e n t .D r y a l l p a r t sw i t h c o m
pressedair, then reassembleusing ATF as a lubri-
cant.
14-107
Valve
Assembly
NOTE: . Set the spring in the valve and i n s t a l il t i n t h e v a l v e
Coatall partswith ATF beforeassembly. b o d y . P u s ht h e s p r i n g i n w i t h a s c r e w d r i v e rt,h e n
installthe springseat.
. I n s t a l tl h e v a l v e ,v a l v es p r i n ga n d c a p i n t h e v a l v e
body and securewith the roller.
ROLLER
SPRINGSEAT
SPRING
VALVE BODY
\
VALVE BODY
Installthe valve,springand cap in the valvebody.

P u s ht h e c a p ,t h e ni n s t a ltlh e c l i p .
ROLLER
VALVE BODY
VALVE
SPRING
CAP
14-108
ATFPump
lnspection
'L lnstallthe ATF pump gears and ATF pump driven 2. Measurethe side clearanceof the ATF pump drive
gear shaftin the main valvebody. and drivengears.
NOTE: ATF Pump Geais Side (Radiallclearance:

. Lubricateall partswith ATF during inspection. Standard (New):
. I n s t a l l t h e A T Fp u m pd r i v e rgr e a rw i t h i t s g r o o v e d ATF Pump Drive Gear
and chamferedsidefacingup as shown. 0.105- 0.1325mm {0.00/t- 0.005in)
ATF PumpDrivenGear
0.035- 0.0625mm (0.0014- 0.0025in)
ATFPUMPDRIVENGEAR
Groovedand chamfereds cie MAIN VALVEEODY
ATF PUMP
ATF PUMP Inspectteethfor wear and damage.

DRIVEGEAB
I n s p e c tt e e t h f o r w e a r a n d d a m a g e -
3. Removethe ATF pump driven gear shaft. Measure

the thrust clearanceof the ATF pump driven gear-
to-valvebody.
ATF Pump Drive/D ven GoarThrust lAxial)Clearance:

MAIN VALVE BODY Standard (Newl: 0.03- 0.05 mm 10.001- 0.002inl
ServiceLimit: 0.07 mm 10.003in)
14-109
Main Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner.and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any pans are worn or damaged.
. Checkall valvesfor free movement.lf any fail to slidefreely,seeValveBody Repairon page 14-,|07.
. Coatall pans with ATF duringassembly.
CAUTION: Do not uss a magnet to remove the check balls; it may magnetizethe balls.
1-2 SHIFTVALVE
VALVECAPCLIP
2ND ORIFICE
CONTROLVALVE
{*4 CHECKBALLS,8
1STACCUMULATOf,CHOKE
MOOULATOR
VALVE
du:
RELIEFVALVE VALVE
MAIN VALVEBODY
Inspectfor wear,scratches
and scoring.
SERVOCONTROLVAL
VALVECAP
14- 1 1 0
CHECKBALL
CHECKBALLS
CH€CKBAI.LS
SPRINGSPECIFICATIONS U n i t :m m ( i n )
Standard (Newl
No. Springs
Wire Dia. o.D. FreeLength No. of Coils
o Reliefvalvespring 1 . 1( 0 . 0 4 3 ) 8.6 (0.342) 3 7 .t { 1 . 4 6 1 ) 13.4

Modulatorvalvesprang 1 . 4( 0 . 0 5 5 ) 9.4 {0.374} 3 5 . 0( 1 . 3 7 8 ) 10.9
\9/ CPBvalvespring 0.9(0.035) 8 . 1( 0 . 3 2 2 ) 47.2{1.858) 18.3
'1-2 0.9(0.035) 7.6 (0.302) 4 1 . 3( 1 , 6 2 6 ) 16.3
@ shiftvalvespring
2nd orificecontrolvalvespring 0.7(0.028) 6.6 (0.262) 34.8(1.370) 22.0
Servocontrolvalvespring 1.0(0.039) 8.1 (0.322) 5 2 . 1( 2 . 0 5 1 ) 20.8
14-111
SecondaryValve Body
Disassembly/l
nspection/Reassembly
NOTE:
o Cleanall pans thoroughlyin solventor carburetorcleaner,and drywith comp.essedair. Blow outall passages.
. Replacethe secondaryvalvebody kit, P/N27700- P4R- 305 (Thesecondaryvalvebody kit includesthe linearsolenoid
assembly)if any partsare worn or damaged.
. Checkallvalvesfor free movement.lf anyfail to slidefreely,seeValveBody Repaironpage'14-107.
. Coatall partswith ATF duringassembly.
. The CPCvalveis installedin the secondaryvalvebody, held in placeby the lockbolt.
2.3 SHIFTVAI.VE
3.4 SHIFTVALVE
LOCKBOLT
CAUTION: Oo not move.
SECONOARY VALVEBODY
and
scofing.
3-4 ORIFICE
CONTROLVAL
VALVE
ROLLER
SPRINGSPECIFICATIONS
U n i t :m m ( i n )
Standald lNewl
No. Springs
Wire Dia. o.D. Free Lenglh No. oI Coils
o
6,
3-4 shift valvespring 0.9(0.035) 7.6 (0.302) 51.0 12.2441 26.8
2-3 shift valvespring 0.9{0.035) 7.6 (0.302) 51.0 \2.244) 26.8
4th exhaustvalvespring 0.9(0.035) 6.1 (0.242) 3 6 . 4( 1 . 4 3 3 ) 19.5
@ 3-4 orificecontrolvalvespring 0.7(0.028) 6.6 10.2621 3 7 . 5( 1 . 4 7 6 ) 24.6
14-1 1 2
RegulatorValveBody
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damaged
. checkall valvesfor free movement.It any {ail to slidefreely,seevalve Body Repairon page 14-107.
1. Holdthe regulatorspringcap in placewhile removingthe stop bolt. Oncethe stop bolt is removed,releasethe sprang
cap srowry.
CAUTION: Thc regulator spring cap can pop out when the stop bolt is removed'
2. is the reverseorderof the disassemblyprocedure

Reassembly
NOTE:
. Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe springcap into the valve
body,and tightenthe stoPbolt.
STOPBOLT
6x1.Omm
1 2N . m( 1 . 2
REGULATOR VALVEBODY
Inspectfor wear, scratches
and scortng,
REGULATOR
VALVE
SPRINGSPECIFICATIONS U n i t :m m ( i n )
Standard(New)
No. Springs
Wire Dia. o.D. Free Length No. of Coils
o RegulatorvalvespringA 1 . 8( 0 . 0 7 1 ) 14.7(0.584) 87.8(3.457)

1' I.0
RegulatorvalvespringB 1 . 8( 0 . 0 7 1 ) 9 . 6( 0 . 3 8 1 ) 44.0l'1.7321
Statorreactionspring 4 . 5( 0 . 1 7 7 ) 3 s . 4( 1 . 4 0 7 ) 3 0 . 3( 1 . 1 9 3 ) 1.9
@ Coolerreliefvalvespring 1 . 0( 0 . 0 3 9 ) 8.4 (0.334) 3 3 . 8{ 1 . 3 3 1 ) 8.2
Torqueconvertercheckvalvespring 1.0(0.039) 8.4 {0.334) 3 3 . 8( 1 . 3 3 1 ) 8.2
Lock-upcontrolvalvespring 0.7 {0.028) 6.6 (0.262) 38.0(1.496) 14.1
14-113
ServoBody
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damageo.
. Replacethe O rings.
SERVOBOOY
lnspectfor wear,scratches
and scoring.
"----.-'g
2NDAccuMULAroR
==p
O-BING
g;li:':-Y
Beplace.
-^'":::#, 1STACCUMULATORPISTON
3RDACCUMULATORPISTON
4TH ACCUMULATOBPISTON
SNAPRINGS
U n i t :m m ( i n )
Standard (New)
No. Springs
Wire Dia. o.D. FreeLength No. of Coils
o 1staccumulatorspring 2.1(0.083) 16.0{0.636) 89.1(3.508) 16.2
4th accumulato.springA 2 . 6( 0 . 1 0 2 ) 17.0(0.676) 87.0(3.425) 14.2
4th accumulatorspringB 2 . 3( 0 . 0 9 1 ) 10.2{0.402) 5 1 . 6( 2 . 0 3 1 ) 13.8
A) 3rd accumulatorspringA 2 . 8( 0 . 1 1 0 ) 17.5(0.695) 89.3(3.516) 15.6
lJl 3rd accumulatorspringB 2.2(0.087) 3 1 . 0{ 1 . 2 2 0 ) 35.1(1.382) 2.4
@ 2nd accumulatorspringC 2.2(0.087) 1 4 . 5( 0 . 5 7 6 ) 68.0(2.677) 1? O
o 2nd accumulatorspringA 2.4(0.094) 2 9 . 0( 1 . 1 5 2 ) 39.0(1.535) 2.9

@ 2nd accumulatorspringB 1 . 6( 0 . 0 6 3 ) 9.0 (0.358) 20.7(0.815)
14-114
Lock-upValve Body
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair, Blow out all passages.
. Replacethe valvebody as an assemblyiJany partsare worn or damaged.
. Checkall valvesfor free movement.lf any fail to slidefreeiy,seeValveBody Repairon page14-107.
. Coatall pans with ATF duringassembly.
LOCK.UPSHIFTVALVE
LOCK-UP VALVEBODY
Inspect
for wear,scratches VALVECAP
ano sconng,
LOCK.UPTIMINGVAL
\uo.*.or.,-,,
U n i t :m m { i n )
Standard (New)
No. Springs
Wire Dia. o.D. Free Length No. of Coils
o Lock-upshiftvalvespring 0.9(0.035) 7.6(0.302) 73.1|'2.902) 32.0

Lockup timing valvespring 0.9(0.035) 8 . 1{ 0 . 3 1 9 ) 80.1t3.1771 45.8
14-115
t- Mainshaft
NOTE:
. Lubricateall partswith ATFduring reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement.
. Beforeinstallingthe O-rings.wrap the shaftsplineswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
LOCKNUT(FLANGENUTI
2 1 | 1. 2 5 n f i
78 N.m 18.0 kgl.m,58 lbl.ftl
Replace.
Lelt-handthreads
SNAP RING CONICAL SPRINGWASHER
Replace.
lST CLUTCH
ASSEMBLY
THRUST WASHEN
O.FINGS
Replace.
THRUSTNE€DLE
BEARING THRUSTWASHER
THRUSTNEEDLE
4TH GEAR BEARING
MAINSHAFT BEANING
Check splinestor excessive NEEDI-EBEARINGS
,IST GEAR
wear and damage.
Check bearingsurfacefor scoring,
scratchesand excessivewear.
THRUSTNEEDLE
EEARING
4TH GEAR COLLAR TRANSMISSION

HOUSINGEEARING
2ND/4TH CLUTCH
ASSEMBLY
O.BINGS
Replace.
THBUST
WASHER,
36.5 r 55 mm
Selectivepart.
THRUSTNEEDLE
BEARING
SEALINGRINGS,
35 mm 2ND GEAR
Inslallthe sealingring BEARING

matlng faces as shown,
NEEDLE
RING, BEARING
29 mm
lti NEEDLEBEARING
SET RING
14-1 1 6
L.
Inspection
. ClearanceMeasurement 3. Torquethe mainshaftlocknutto 29 N'm (3.0 kgf'm,
22 lbf.ft).
NOTE:Lubricateall partswith ATF during assembly.
NOTE:Mainshaftlocknuthas left-handthreads.
1. Removethe mainshaftbearingfrom the transmis-
sion housing(seepage l4-142).
2. Assemblethe partsbelow on the mainshaft.
NOTE:Do not assemblethe O-ringsduring inspec-

tion.
LOCKNUT CONICALSPRINGWASHER
,IST CLUTCH ASSEMELY Hold 2nd gear againstthe 2nd clutch,then measure
the clearancebetween2nd gear and 3rd gear with a
feelergauge.
THRUST WASHEB
NOTE:Take measurementsin at leastthree places,
1ST GEABCOLLAR and usethe averageas the actualclearance.
TRANSMISSION STANDARD:0.05- 0.13 mm {0.002- 0.005in)

HOUSINGBEARING
SNAP RING
THRUSTWASHER
4TH GEAR COLLAR
2ND/4TH CLUTCH
ASSEMBLY
THRUSTWASHER
36.5 x 55 mm
Selective part.
TI{RUST NEEDLE
BEARING
2ND GEAR
NEEOLEBEARING
THRUSTt{EEDLE
BEARING
MAINSHAFT
(cont'd)
14-117
Mainshaft
Inspection(cont'd)
5. l f t h e c l e a r a n c ei s o u t o f t o l e r a n c e ,r e m o v et h e
thrustwasherand measurethe thickness.
6. Selectand installa new washer.then recheck.
THRUSTWASHER36.5x 55 mm
No. Part Number Thickness

1 9044' -t P4P- 010 4 . 0 0 m m ( 0 . 1 5 7i n )
2 90442-P4P-010 4 . 0 5m m ( 0 . 1 5 9i n )
90443-P4P-010 4 . 1 0m m ( 0 . 1 6 i1n )
4 90444-P4P-010 4 . 1 5m m ( 0 . 1 6 3
in)
5 90445-P4P-010 4 . 2 0m m { 0 . 1 6 5i n )
6 90446- P4P, 010 4 . 2 5m m ( 0 . 1 6 7i n )
1 90447-P4P-010 4 . 3 0m m ( 0 . 1 6 9
in)
8 90448-P4P-010 4 . 3 5m m ( 0 . 1 7 1
in)
90449-P4P-010 4 . 4 0m m ( 0 . 1 7 3i n )
10 90450-P4P-000 4 . 4 5m m ( 0 . 1 7 5i n )
7. A f t e r r e p l a c i n gt h e t h r u s t w a s h e r ,m a k e s u r e t h e
clearanceis within tolerance.
14-1 1 8
Gountershaft
NOTE;
. Lubricateall parts with ATF before reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement.
. Beforeinstallingthe O-rings,wrap the shaitsplineswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
LOCKNUT(FLANGENUTI
23 x 1.25mm
103 N.m
{10.5 kgf.m, 75.9 lbI.ft)
Replace.
REVERSEGEAR Left-hand threads
CONICALSPRING
WASHER
Replace-
NEEDLEBEARING
SELECTOR
HUB
BEARING
4TH GEAR
NEEDLEBEARING ST GEARCOLLAR
DISTANCECOLLAR,
28 mm
Selectivepart.
2ND GEAR
THBUSTNEEDLE
COUNTERSHAFT EEARING
Checksplines{or excessive
wear and damage, 3RD GEAR
Check bearingsurfacefor scoring,
scratchesand excessavewear.
NEEDLEBEARING
3RD GEARCOLLAR
THRUSTNEEOLEBEARING
SPLINEDWASI.IEB
3RD CLUTCHASSEMBLY
Replace.
14-119
Gountershaft
1. Using a hydraulicpress,pressout the countershaft 2. Assemblethe parts on the countershaftas shown
while supporting4th gear. Delow.
NOTE: Placean attachment between the press and NOTE:

to preventdamageto the shaft.
the countershaft . Lubricateall pans with ATFduring assembly.
. Beforeinstallingthe O-rings,wrap the shaft splines
CAUTION: Do not allow the countershaftto fall and with tapeto preventdamagingthe O-rings.
hit the ground when Press€dclear.
4TH GEAR
NEEOLEBEARING
DISTANCECOLLAR, 28 mm
Selective part.
2ND GEAR
THRUST NEEDLEBEARING
3RD GEAR
NEEDLEB€ARING
3RDGEARCOI.LAR
TI{RUSTNEEDIEAEABING
SPLINED
WASHER
3RDCLUTCHASSEMBLY
14-120
lnspection
3. lnstallthe reverseselectorhub on the countershaft a Clearance
Measurement
sub-assembly, and then pressthe reverseselector
hub usingthe specialtool and a pressas shown. NOTE:Lubricateall partswith ATFduringassembly.
'L Removethe countershaftbearingtrom the trans-
missionhousing(seepage 14 142).
2. Installthe partsbelowon the countershaftusingthe

specialtooland a pressas describedon this page.
NOTE:Do not assemblethe O-ringsduring inspec

tron.
REVERSESELECTOR
DRIVER 40 mm l.D.
HUB
07746 -OO30tOO
4TH GEAR
NEEDLEBEARING
DISTANCECOLLAR, 28 mm
Selectivepart.
2ND GEAR
THRUSTNEEDLEBEARING
3RD GEAR
NEEDLEBEARING
3RD GEARCOLLAR
THRUSTNEEDLEBEARING
SPLINEDWASHER
3RD CLUTCHASSEMBLY
{cont'd)
14-121
Gountershaft
Inspection {cont'd) \
3. I n s t a l lt h e p a r t s b e l o w o n t h e c o u n t e r s h a fst u b , 4. M e a s u r et h e c l e a r a n c eb e t w e e nt h e 2 n d g e a r a n d
a s s e m b l yt,h e n t o r q u et h e l o c k n u tt o 2 9 N . m ( 3 . 0 the 28 mm distancecollarwith a feelergauge.
kgf.m,22blf.ft).
NOTE:Takemeasurements in at leastthree places,
NOTE:Countershaft
locknuthas left-handthreads. and usethe averageas the actualclearance.
0.10- 0.18mm (0.004- 0.007inl

STANDARD:
Left-handthreads
CONICALSPRING
WASHER
PARKINGGEAR/ONE-WAY
CLUTCH/1STGEAR
ASSEMELY
NEEDLEEEARING
OISTANCECOLLAR.28 mm
1ST GEAECOLLAR
TRANSMISSION
HOUSING
BEARING
REVERSEGEAR
COLLAR
COUNTERSHAFT 5. lf the clearanceis out of tolerance,removethe 28

SUB-ASSEMELY mm distancecollarand measurethe width.
6. S e l e c ta n d i n s t a l la n e w d i s t a n c ec o l l a r ,t h e n
recnecK.
DISTANCECOLLAR.28 mm
No. PartNumber width

,] 90503-PCg-000 3 9 . 0 0m m ( 1 . 5 3 5
in)
2 90504- PCg, 000 3 9 . 1 0m m ( 1 . 5 3 9i n )
3 90505- PCg 000 3 9 . 2 0m m ( 1 . 5 4 3i n )
4 90507-PCg-000 3 9 . 3 0m m ( 1 . 5 4 7i n )
5 90508-PCg-000 3 9 . 0 5m m ( 1 . 5 3 7
inI
6 90509-PCg,000 3 9 . 1 5m m ( 1 . 5 4i1n )
7 90510-PCg-000 3 9 . 2 5m m i 1 . 5 4 5i n )
8 9 0 5 1 1- P C g 0 0 0 3 8 . 9 0m m ( 1 . 5 3 1I n )
9 90512-PCg-000 3 8 . 9 5m m ( 1 . 5 3 3i n )
1. A f t e r s e l e c t i n ga n e w d i s t a n c ec o l l a r ,r e c h e c kt h e
c l e a r a n caen d m a k es u r ei t i s w i t h i nt o l e r a n c e .
14-122
One-way Clutch
nspection/Reassembly
Disassembly/l
1. S e p a r a t ec o u n t e r s h a f1t s t g e a r f r o m t h e p a r k i n g 3. Inspectthe partsas followsl
g e a r b y t u r n i n gt h e p a r k i n gg e a r i n t h e d i r e c t i o n
shown. PARKING
GEAR
Inspectthe parkinggear
for wear and scoring,
PARKINGGEAR
ONE-WAYCLUTCH
COUNTERSHAFTlST GEAR Inspectthe one-way
clutch for damageand
faultVmovement.
2. Removethe one-wayclutchby prying it up with the
end of a screwdriver.
ONE.WAYCLUTCH
COUNTERSHAFT
1STGEAR NOTE:Installin this direction.
.IST GEAR
Inspectcountershall'l
for wear and scoring,
4. Afterthe partsare assembled,hold countershaft1st

g e a r a n d t u r n t h e p a r k i n gg e a r i n t h e d i r e c t i o n
shownto be sure jt turns freely,Also makesurethe
parkinggeardoes not turn in the oppositedirection.
ONE.WAY CLUTCH
COUNTERSHAFT,IST GEAR
COUNTERSHAFT
lST GEAR
SCREWDRIVER
14-123
Clutch
lllustratedIndex(A4RA,B4RATransmissionl
3RDCLUTCH
CLUTCH O-RINGS
DRUM Replace. C L U T C Hp t S T O N
DISC SPRING
CLUTCHPLATES
Standardthickness:
2 . 0m m ( 0 . 0 7 i9n )
CLUTCHEND
PLATE
SNAPRING
lST CLUTCH \
CLUTCHEND
TE cLurcsorscs
Standardthickness:
'1.94mm
{0.076in)
SNAPRING
SPRINGRETAINER
RETURNSPNING
DISCSPRING
o-"'"cs
!,L"urlcf
I tleptace.
I CLUTCHDRUM
CLUTCHPLATES
Standardthickness:
1.6mm 10.063 in)
CHECKVALVE
\
14-124
2ND/4THCLUTCH
{
SNAPRING
CLUTCHPLATES
CLUTCHPISTON
SNAP DISCSPRING
SPRINGRETAINEB
RETURNSPRING
O.RINGS
Replace. 4TH CLUTCHDRUM
CLUTCHPLATES
StandardthicknessrO-RINGS
2.0mm {0.079in) Reptace.
CLUTCHEND PLA
SNAPRING
14-125
Clutch
lllustratedIndex(M4RATransmissionl
3RDCLUTCH
CLUTCH
ORUM
CLUTCHPISTON
OISCSPRING
CLUTCHEND
PLATE
SNAPRING
1STCLUTCH
CLUTCHEND
SNAPRING
rll
CHECKVALVE
14-126
g
SNAPRING
2ND/4TH-CLUTCH
CLUTCHPLATES
Standardthickness:
VALVE 2.0 mm (0.079in)
\---
2ND CI-UTCH
DNUM
CLUTCHPISTON
RETURNSPRING
O-RINGS
Replace.
SNAPRING
\---
SNAPRING
14-127
Clutch
Disassembly
1. Removethe snap ring, then removethe clutch end 3. Installthe specialtoolsas shown.
plate.clutchdiscsand olates.
CLUTCHSPRING
COMPRESSOR
SCREWORIVER
ATTACHMENT
07LAE- PX40100
SNAP RING
;= _=:_-.-----
CLUTCHSPRING
COMPRESSOR
2. Removethe discspring. ATTACHMENT
07LAE- PX40100
ol
NOTE:Except2nd clutch. 07HAE- P150100
CLUTCH
COMPRESSOR
BOLTASSEMBLY
OISCSPRING 07GAE- PG40200
ol
OTGAE- PGIO2OA
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
t
CLUTCHDRUM
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
li 07LAE- PX40100
CLUTCHSPRING
ll COMPRESSOR 07HAE- P150100
BOLTASSEMBLY
07GAE- PG40200
OI
OTGAE_ PG4O2OA
14-128
g -
CAUTION:It eitherend of the specialtool issetoveran 5. Removethe snap ring.Thenremovethe specialtools,
area of the spring retainer which is unsupported by the springretainerand returnspring.
return spring, the retainer may be damaged. Be sure the
specialtool is adiusted to have tull contact with the
spring retainer.
SPECIALTOOL 6. Wrap a shop rag aroundthe clutchdrum. and apply

air pressureto the ATF passageto removethe pis-
ton.
P l a c ea f i n g e rt i p o n t h e o t h e r e n d w h i l e a p p l y i n g
a r rp r e s s u r e .
OSHA-APPROVED
SPRING RETAINER
4. Compressthe returnspring.
PISTON
14-129
Glutch
Reassembly \
NOTE: 3. Installthe pistonin the clutchdrum. Apply pressure

. Clean all parts thoroughly in solvent or carburetor and rotateto ensureproperseating.
cleaner,and dry them with compressedajr.
. Blow out all passages. NOTE:Lubricatethe piston O-ringwith ATF before
. Lubricateall partswith ATF beforereassembly. installing.
1. Inspectthe checkvalve;if it's loose,replacethe pis- CAUTION: Do not pinch th8 O.ring by installing the
ton, piston with too much force.
CLUTCHDRUM
CHECK VALVE
PISTON
2. Install new O-rings on the clutch piston.

I n s t a l lt h e r e t u r ns p r i n g a n d s p r i n g r e t a i n e r a
, nd
positionthe snap ring on the retainer.
O-RINGS
SNAP RING
SPRINGRETAIN€R
RETURNSPRING
CLUTCHDRUM
PISTON
14-130
5. lnstallthe soecialtools as shown. CAUTION:ll either end ot the special tool is set
over an ar6a of the spring retainer which is unsup-
ported by the return spring, the retainer may be
CLUTCHSPRING damaged. Be sure the specialtool is adiusted to
COMPRESSOB have tull contact with the spring retainsr.
ATTACHMENT
07LAE- PX40100
CLUTCHSPRING
COMPRESSOR
ATTACHMENT Do not s6t hore.
07LAE- PX40100
SPRING ot
07HAE- PL50'100
SPECIALTOOL
OTGAE- PG4O2OA
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
oTLAE-PX40100 6. Compressthe returnspring.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
CLUTCHSPRING 07HAE- PL50100
COMPRESSOR
BOLTASSEMBLY
07GAE- PG40200
ot
OTGAE- PG4O2OA (cont'd)
14-131
Clutch
(cont'd)
Reassembly
7. lnstallthe snap ring. '10. Soak
the clutchdiscsthoroughlyin ATF for a mini-
mum of 30 minutes.
1 1 . staning with a clutch plate, alternatelyinstall the

clutch platesand discs.Installthe clutch end plate
with flat sidetowardthe disc.
NOTE:Beforeinstallingthe platesand discs,make

sure the insideof the clutch drum is free of din or
otherforeignmatter.
CLUTCH EI{D PLATE

Installin this direction.
SNAP RING
9. Installthe discspring.
N O T E : I n s t a l lt h e d i s c s p r i n g i n t h e d i r e c t i o n
shown,except2nd clutch.
DISC SPRING
12. Installthe snap ring.
SCREWDRIVER
SNAP RIIIG
!tf
14-132
-
13, Measurethe clearancebetweenthe clutchend plate ENDPLATE
CLUTCH
and top discwith a dial indicator.Zero the dial indi-
cator with the clutch end plate lowered and lift it up A,[RA,B4RATransmission:
to the snap ring. The distancethat the clutch end
olatemovesis the clearancebetweenthe clutchend Plste No. Part Numbe. Thicknoss
plateand top disc,
1 22551- P4R- 003 2.1mm (0.083in
2 22552- P4R,003 2,2 mm (0.087in
22553-P4R-003 2 . 3m m ( 0 . 0 9 1
in
and usethe averageas the actualclearance.
22554-P4R-003 2 , 4m m { 0 . 0 9 4
in
22555-P4R-003 2.5 mm (0.098in
Clutch End Plate-to-TopDisc Clearanco:
6 22555-P4R-003 2 . 6m m ( 0 . 1 0 2
in
7 22557-P4R-OO3 2 . 7m m ( 0 . 1 0 6
in
Clutch Sowico Limit 22558-P4R-003 2 . 8m m ( 0 . 1 1 0
in
8
1st 0.65- 0.85mm (0.026- 0.033in) I 22559-P4R-003 2 . 9m m ( 0 . 1 1 4
in
2nd 0.65- 0.85mm (0.026- 0.033in)
3rd 0.40- 0.60mm (0.016- 0.024in) M4RATransmission:
4th 0.40- 0.60mm (0.016- 0.024inl
DIAL INDICATOR Plaie No. Part Number Thicknoss

1 22551- PCg- 000 2.4mm (0.094in
2 22552-PCg-000 2.5mm {0.098in
tl 22553-PCg-000 2 . 6m m ( 0 . 1 0 2i n
22554-PCg-000 2 . 7m m { 0 . 1 0 6 I n
E 225ss-PCg-000 2 . 8m m ( 0 . 1 1 0in
6 22556-PCg-000 2 . 9m m ( 0 . ' 1 1i 4n
7 22557-PCg-000 3 . 0m m ( 0 . ' 1 1i 8n
8 22558-PCg-000 3 . 1m m ( 0 .1 2 2i n
9 22559-PCg-000 3 . 2m m ( 0 . 1 2 6in
10 22s60-PCg-000 3 . 3m m ( 0 . 1 3 0in
11 22561- PCg- 000 2.'l mm (0.082in
CLUTCHEND 12 22s62-PCg-000 2.2mm (0.086in
PLATE Clearance '13 22563-PCg-000 2.3 mm (0.090in
14 22574-P4V- 003 3 . 4m m ( 0 . 1 3 4in
CLUTCHDISC 15 22561- P4V- 003 3 . 5m m ( 0 . 1 3 8in
16 22562 - P4V- O03 3 . 6m m ( 0 . 1 4 2i n
17 22563-P4V-003 3 . 7m m ( 0 . 1 4 6i n
18 22564-P4V-003 3.8 mm (0.150in
15. After replacingthe clutchend plate,make sure that

1 4 . l f t h e c l e a r a n c ei s n o t w i t h i n t h e s e r v i c el i m i t s , the clearanceis within tolerance.
select a new clutch end plate from the following
table.
NOTE; lf the thickesiclutch end plate is installed,

but the clearanceis still over the standard,replace
the clutchdiscsand clutchDIates.
CLUTCHEND PLATE
14-133
Differential
lllustratedlndex
SET RING, 80 mm
BOLT
10 x 1.0 mm
lol N.m (10.3 kgt.h,74.5 lbf.ftl
Lett-hand threads
FIiIIAL DRIVENGEAR
Inspectfor excessivewear.
Installin this dlrection.
lnspectlor taulty movement.
DIFFERENTIALCARRIER
Insoectlor cracks.
5x 10mm
SPEEDOMETER DRIVE
GEAR
SNAP RING
Installin this direcrion.
BALL EEARING
Inspectfor faulty movement. \
14-134
BacklashInspection BearingReplacement
1. Placedifferentialassemblyon V-blocksand install NOTE: Checkbearingsfor wear and rough rotation.
both axles. bearingsare OK. removalis not necessary.
1. Removebearingsusinga bearingpuller.
BEARINGPULLER
(Commercially
availablel
Checkbacklashof both piniongears.
Siandard(Ncwl:0.05- 0.15mm (0 002- 0.006in)
lf backlashis out of tolerance,replacethe differen-

tial carrier. 2. Installnew bea.ingsusingthe specialtool as shown.
DRIVER40 mm l.O.
07746-OO30100
14-135
Differential
DifferentialCarrierReplacement
1. Removethe final driven gear from the differential Align the hookedend of the snap ring with the pin-
carner. ion shaft as shown,then installthe snap ring in the
differentialcarriergroove.
NOTE: The final driven gear bolts have left-hand
threads. SNAP RING
Hooked end Installin this direclion.
2. Prythe snap ring off differentialcarrier,then remove
the speedometer drivegearand 5 x 10 mm roller.
SNAP RING
PINIONSHAFT
SPBING
Installthe final drivengear,then tightenthe boltsto

the specifiedtorque,
TOROUE:101 N.m 110.3kgf.m, 74.5 tbf.ft)
NOTE: The final d.iven gear bolts have left-hand

threads.
3. Installthe5 x 10 mm rollerin the differentialcarrier.

BOITS
10 x t.0 mm
SPEEDOMETER 1Oi N'm 11O.3kgl.m,
DRIVEGEAR 74.5 tbf.ttl
Installin this Left-hand threads
direction.
FINAL ORIVEN
GEAR
Installin this
direction.
OIFFERENTIAL
Frlr CARRIER
tril 4. Installthe speedometerdrive gear with its cham-
fered side facingthe carrier.Align the cutout on the
bore of the speedometerdrive gear with the 5 x lO 7. Install a new ball bearing (see page'14-'l3S).
mm ro er,
14-136
Oil SealRemoval Oil SealInstallation/SideClearance
1, Removethe differentialassemblv. 1. Installa 2.50mm (0.098in) set ring,80 mm in trans-
missionhousing.
2, Removethe oil sealfrom the transmissionhousing,
NOTE:Do not installthe oil sealvet.
RING,80 mm
TRANSMISSION
OIL SEAL HOUSING
Replace.
R e m o v et h e o i l s e a l f r o m t h e t o r q u e c o n v e r t e r
housing. Installthe differentialassemblyinto the torque con-
verterhousingusingthe specialtool as shown.
TOROUE
CONVERTER
HOUSING
I n s t a l lt h e t r a n s m i s s i o nh o u s i n ga n d t i g h r e n t h e
TOROUECONVERTER bolts(seepage 14-146and 14-147).
HOUSING
(cont'd)
14-137
Differential
Oil Seal Installation/SideClearance(cont'd) \
4. Tap on the transmissionhousingside of the differ- 5. Measurethe clearancebetweenthe 80 mm set ring

entialassemblvwith the soecialtool to seatthe dif- and outer race of the ball bearingin the transmis-
ferentialassemblyin the torqueconverterhousing. s i o nh o u s i n g .
0 - 0.15mm (0 - 0.006inl
STANDARD:
DRIVER40 mm LD.
-0030100
TRANSMISSION
HOUSING
6. lf the clearanceis more than the standard,selecta

new set ring from the table,and insta :
SETRING,80 mm
Part Number Thickness

90414 689- 000 2.50mm (0.098n )
90415- 689 000 2 . 6 0m m ( 0 . 1 0 2n )
90416-689-000 2 . 7 0m m ( 0 . 1 0 6n )
90417 689- 000 2 . 8 0m m ( 0 . ' 1 1 0
n)
90418-689-000 2 . 9 0m m ( 0 . ' 1 1 4
n)
90419- PH8 000 3 . 0 0m m ( 0 . ' 1 1 8
nl
NOTE:lf the clearancemeasuredin step 5 is stan-

dard,it is not necessary
to performsteps7 and 8.
7. Removethe transmissionhousing.
8. Replacethe 2.50mm (0.098in) 80 mm set ring wjth

the one of the correctthicknessselectedin step6.
ti{
t
\
14-138
9. lnstallthe new oil seal flush with the transmission
housingusing the specialtools as shown.
ORIVER
0?7/tg- 00'10000
PILOT, DRIVERATTACHMENT,68 mm
26x30mm 07947- 6110501
07JAD- PH80200
1 0 . l n s t a l lt h e n e w o i l s e a lf l u s h w i t h t h e t o r q u ec o n -
verterhousingusingthe specialtools as shown.
DRIVER
07749- 0010000
14-139
TorqueGonverterHousingBearings
MainshaftBearing/OilSeal Replacement
1. R e m o v et h e m a i n s h a t tb e a r i n ga n d o i l s e a l u s i n g 2. Drivein the new mainshaftbearinguntil it bottoms
the specialtools as shown. in the housingusingthe specialtools as shown.
3/8'-I6 SLIDEHAMMER
( C o m m e r c i a l l ya v a i l a b l e ) DBIVER
07749- 0010000
ATTACHMENT,
62x68mm
077{6 - 0010500
ADJUSTABLEEEARING
PULLER,25 - 40 mm
07736- A01000A
3. Install the new oil seal flush with the housinq u s rn g

the soecial tools as shown.
ATTACHMENT,
l;'.r 72 x75 tnm
07746- 0010600
fri
14-140
CountershaftBearing Replacement
1. Removethe countershaftbearingusing the special
tools as shown.
3/81T6SLIDEHAMMER
(Commercially
available)
AOJUSTABLE
BEANING
PULLER,
25-40mm
07736- A01000A
t
2. A T Fg u i d ep l a t e .
Installthe
3. D r i v et h e n e w b e a r i n gi n t o t h e h o u s i n gu s i n gt h e
specialtools as shown.
0 - 0.03mm
{0 - 0.001in)
ATF GUIDEPLATE
1+141
Transmission
HousingBearings
Mainshaft/CountershaftBearingsReplacement
\
1. To removethe mainshaftand countershaftbearings Expandeach snap ring with snap ring pliers,insert
from the transmissionhousing,expand each snap t h e n e w b e a r i n gp a r t - w a yi n t o t h e h o u s i n gu s i n g
ring with snap ring pliers,then push the bearingout the specialtools and a press as shown. Installthe
usingthe specialtools and a pressas shown. bearingwith the groovefacingoutsidethe housing.
N O T E rD o n o t r e m o v et h e s n a p r i n g s u n l e s si t , s NOTE:Coatall parrswith ATF.

necessary to cleanthe groovesin the housing.
Releasethe pliers.then push the bearingdown into
PRESS t h e h o u s i n gu n t i l t h er i n gs n a p si n p l a c ea r o u n di t .
\ 07749- 00r0000
ATTACHMENT,
62x68mm
07146 -
ATTACHMENT
. Mainshaft Bearir|gRemovaluse:
ATTACHMENT,72 x 75 mm
07745- 0010600
. CountershaftBearing Removal use:
MAINSHAFTBEARING ATTACHMENT,62 x 58 mm
07746- 0010500
DRIVER
07749- 00r0000
4. After installingthe bearingverilythe following:
ATTACHMENT . The snap ring is seatedin the bearinqand hous-
Ing grooves.
. The ring end gap is correct.
ENOGAP:0-7mm
{0 - 0.28inl
ATTACHMENT
. Mainshaft B6aring Installation use:
ATTACHMENT,72 x 75 mm
077'16- 0010600
. CountershaftBearing Installation use:
ATTACHMENT.62 x 68 mm SNAPRING
07745- 0010500
14-142
Reverseldler Gear ParkingBrakeStop
Installation Inspection/Adjustment
1. Installthe reverseidler gear. 1. Set the parkingbrakeleverin the E posrrron.
2. M e a s u r et h e d i s t a n c eb e t w e e nt h e p a r k i n gb r a k e
pawl shaft and the parkingbrakelever roller pin as
STANDARD:72.9- 73.9 mm (2.87- 2.91 inl
'2:\
Measuring
Installthe reverseidler gear shaft holderand needle

bearinginto the transmissionhousing.then tighten -.
the bolts. BRAK€
PARKING
PAWLSHAFT
6 x 1.0mm
12 N.m (1.2kgf.m, lf the measurementis out of tolerance,selecl and
8.7 tbf.ftl
installthe appropriateparkingbrakestop from the
table below.
PARKINGBRAKE
STOP
PARKINGBRAKESTOP
Mark Part Number Lr L2
I mm
24537-PAg-003 1 1 . 0 0 11 . 0 0m m
(0.433in) (0.433 in)
'10.80mm 1 0 . 6 5m m
2 24538-PAg-003
( 0 . 4 2 5i n ) ( 0 . 4 1 9i n l
3 2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m 10.30mm
( 0 . 4 1 7i n ) (0.406in)
After replacingthe parking brake stop. make sure

the distanceis within tolerance.
14-143
Transmission
Reasembly
NOTE:
. Coatall partswith ATF.
. Replacethe followingpans:
- O-rings
- Lockwashers
- Gaskets
- Mainshaftand countershaftlocknutsand conicalspringwashers
- Sealingwashers
TOROUE:12 N.m (1.2kgf.m,8.7tbf.ft)
6x1.0mm
7 Bolts ATF FEEDPIPE:A
6x1.0mm
2 Bolts
LOCK-UPVALVE
BOOY
ATF STRAINER
LOCK-UPSEPARATOR ATF FEEO
PLATE PIPES:
B
REGULATOR
EODY
VALVE
o r9 l SERVODETENT
il BASE
DOWELPINS.2 CONTROLSHAFT
DETENT
li lf: ln
l 6x1.0mm
cooLER RELrEFvALVe -----------E ARM SHAFT Yl l 7 Bohs
DETENT
ARM SERVOBODY
TOROUECONVERTEB
CHECKVALVE
SERVOSEPARATOR
STATORSHAFT
PLATE
O-RING
SECONDARY
VALVE
STOPSHAFT BOOY
ATF FEEDPIPE:H
6x1.0mm i l PINS,2
5 Bolts
, ATFFEED
MAIN VALVEEODY
PIPES:
ATFPUMP SECONDARY
GEARSHAFT
\l SEPARATOR
PLATE
ATF PUMPDBIVEN
GEAR CONTROL
SHAFT
MAIN SEPARATOR ('98model)
PLATE
DOWELPINS,
2
14-144
1 . lnstallthe ATF magnetand suctionpipecollarin the 8. I n s t a l lt h e s e r v o b o d y a n d s e p a r a t o p
r l a t eo n t h e
tgrqueconverterhousing.if necessary. secondaryvalve body (seven bolts).
2 . lnstallthe main seoaratorDlateand the two dowel
pins on the torqueconverterhousing. L lnstall the servo detent base and the ATF strainer
3 . Installthe ATF pump drive gear, ATF pump driven Itwo bolts).
gear and ATF pump driven gear shaft on the torque
convenernousrng. 1 0 . Tightenthe five bolts on the main valve body to l2
N.m (1.2kgim, 8.7 lbf.ft).
N O T E :I n s t a l lt h e A T F p u m p d r i v e n g e a r w i t h i t s Make surethe ATF pump drive gear and ATF pump
groovedand chamferedsidefacingdown. drivengear shaftmove smoothly.
ATF PUMP 1 l . It the ATF pump drive gear and ATF pump driven
GEAR
gear shaft do not move freely,loosenthe live bolts
on the main valve body. and disassemble the valve
bodies.
Realignthe ATF pumpdrivengearshaftand reassem-
ATF PUMPDRIVEN ble the valve bodies,then retightenthe bolts to the
GEARSHAFT specifiedtorque.
ATF PUMP CAUTION: Failureto slign lhe ATF pump driven

DRIVEN gear shaft correctly will result in a seizedATF pump
drive gear or ATF pump driven gear shaft.
Grooved and chafitered
side faces separalot MAIN SEPARATOR
plate. PLATE
Looselyinstallthe main valve body with five bolts.

Makesurethe ATF pump drivegearrotatessmoothly
in the normaloperatingdirectionand the ATF pump
driven gear shaft moves smoothly in the axial and
normaloperatingdirections.
Install the secondaryvalve body, separatorplate
and two dowel pins on the main valvebody.
NOTE: Do not installthe bolts.
Installthe controlshaft in the housingwith the con- /

trol shaftand manualvalvetogether. ATF PUMP
DRIVENGEAR DRIVENGEAR
7. l n s t a l lt h e d e t e n ta r m a n d a r m s h a f t i n t h e m a i n
SHAFT
valve body, then hook the detentarm sprangto the
detentarm. 12. Installthe statorshaftand stop shafi
PLATE
SERVOSEPARATOR 1 3 . lnstallthe bolts and the shaftstop on the secondary
valvebody,then tightenthe bolts (threebolts).
DETENTARM
SHAFT
1 4 . lnstallthe torqueconvertercheckvalve,coolerrelief
valveand valvespringsin the regulatorvalvebody,
t h e n i n s t a l lt h e r e g u l a t o vr a l v e b o d y o n t h e m a i n
valvebody (one bolt).
DETENTAFM SPRING Installthe lock-upvalvebody on the regulatorvalve

OETENTARM body (sevenbolts).
1 6 . Installthe ATF feed pipes in the main valve body,

the threeATF feed pipesin the secondaryvalveand
MANUAL VALVE the four ATFfeed pipesin the servobody.
(cont'd)
14-145
I
I
Transmission
Reassembly(cont'dl
TRANSMISSIONHOUSING
TRANSMISSION MOUNTINGBOLTS
HANGEB 1 0x 1 . 2 5m m
44 N.m (4.5 kg{.m,33 lbf.trl
TRANSMISSIONHOUSTNG
MAINSHAFT
SUE.ASSEMBLY
MAINSHAFTSPEED
SENSORWASHER COUNTERSHAFT
(D16Y7engine) SUB.ASSEMELY
MAINSHAFT
SPEEDSENSOR
DIFFERENTIAL
ASSEMBLY
TRANSMISSION
HOUSINGGASKET
TOROUECONVERTER
HOUSING
14-146
1 7 . I n s t a l lt h e r e v e r s ei d l e r g e a r a n d t h e g e a r s h a f t 2 1 . Install the needle bearing, countershaft reverse gear
h o l d e r( s e ep a g e1 4 - 1 4 3 ) . and reverse gear collar on the countershaft.
1 8 . Installthe differentialassemblyin the torque con- 2 2 . Align the spring pin on the control shaft with the
vener housrng. transmission housing groove by turning the control
shaft.
1 9 . A s s e m b l et h e m a i n s h a f ts u b - a s s e m b l ya n d t h e SPRINGPIN
c o u n t e r s h a fst u b - a s s e m b l yt ,h e n i n s t a l lt h e m CONTROLSHAFT
togetherin the torqueconverterhousing.
COUNTERSHAFT
SU8-ASSEMBLY
Installthe two dowel pins and a new gasketon the

torqueconverterhousing.
24. Placethe transmissionhousingon the torque con-

vener nousrng.
CAUTION: Make sule that the mainshaft speed

s€nsor is not installed on the transmission housing
before installingthe transmissionhousing on the
20. Turn the shift fork so the large chamferedhole is torque converter housing.
facing the fork bolt hole, then install the shift fork
with the reverseselector,and torque the lock bolt. 25. I n s t a l lt h e t r a n s m i s s i o nh o u s i n gm o u n t i n g b o l t s
Sendthe locktab againstthe bolt head. a l o n g w i t h t h e t r a n s m i s s i o nh a n g e r .t h e n t i g h t e n
the bolts in two or more steps in the sequenceas
snown.
SHIFTFORK TOROUE:44 N.m {4.5 kgf.m, 33 lbt.ft,

TRANSMISSION
LOCKWASHER HANGEB
Replace.
6 x 1 . Om m
a -&)H@
14 N.m
(1.4 kgf.m, '10 lbf'ft)
V G ' -_F
|
Large chamfered hole
"fl:
o @
1+117
Transmission
Reassembly(cont'd)
26. Slip the specialtool onto the mainshaftas shown. 3 1 . I n s t a l lt h e m a i n s h a f t' 1 s tg e a r c o l l a ro n t h e m a i n ,
shaft.
MAINSHAFTHOLOER
- PF50101 32. Wrap the shaft splineswith tape to preventthe O-
rings,then installnew O-ringson the mainshaft.
33. Assemblethe thrust washer.thrust needlebearing,

n e e d l eb e a r i n g a
, nd mainshaf1
t s tg e a r i n t h e 1 s t
clutchassembly,then installthemon the mainshaft.
34. lnstallnew conicalspring washersand locknutson

eachshaft.
CAUTION: Install ihe conical spring washers in lhe

dirsction shown.
2 7 . lnstallthe parkingbrakeleveron the controlshaft.
MAINSHAFT
28. Assemblethe one-wayclutchand the parkinggear LOCKNUT
with the countershaft1stgear{seepage 14 '|.23). Left-hand
threads
29. Installthe countershaft1st gear collar,needlebear

i n g , a n d t h e c o u n t e r s h a f t1 s t g e a r / p a r k i n gg e a r
assemblyon the countershaft.
lSTCLUTCH PARKING
ASSEMBLY GEAR PAWL
COUNTERSHAFT
LOCKNUT
Left handrhreads.
CONICAL SPRING WASHEBS

Installinthisdirection-
35. Tightenthe locknutsto the specifiedtorque.
NOTE:
. D o n o t u s e a n i m p a c t w r e n c h .A l w a y s u s e a
torquewrenchto tightenthe locknut,
30. Installthe parking brake pawl shaft, spring, pawl, . Mainshaftand countershaftlocknuts have left-
and pawlstopon the transmission h o u s i n g t, h e n handthreads.
e n g a g et h e p a r k i n gb r a k ep a w l w i t h t h e p a r k i n g
aear. TOROUE:
MAINSHAFT 78 N.m {8.0 kgt.m, 58 lbl.ft}
COUNTERSHAFT103 N.m {10.5kgt'm, 75.9 lbt ft)
14-148
36. Removethe special tool from mainshaft,then stske 40. Installthe right side cover with two dowel pins and
eachlocknutusinga 3,5 mm punchas shown. I new gasket(thirteenbolts).
TOROUE:12 N'm 11.2kgt.m, 8.7 lbt'ft)
RIGHT
SIDECOVER
3 7 . Set the parkingbrakelever in the E position,then
verifythat the parkingbrakepawl engagesthe park- 4 1 . Insrallrhe ATF cooler lineswith new sealingwash-
ing gear. ers.
lf the pawl does not engagetully, checkthe parking TOROUE:28 N'm (2.9 kgt.m, 21 lbf.ft)
brakepawl stop clearance(seepage 14-143).
Installthe ATF dipstick.
Tightenthe lockbolt and bendthe locktab.
6 r 1 . Om m
1 4 ' m 1 1 . 4k g t . m , 10 lbt'frl
PAR(ING BRAKE PAWL
14-149
TorqueConverter/DrivePlate
6 x 1 . Om m
12 r 1.0 mm
74 N.m 17.5 kgt.m, 54 lbl.ftl
Torque in a crisscross Dattern,
E PLATE
lirl
14-150
Transmission
Installation
L Flushthe ATF cooler as describedon page 14-155 6. lnstallthe transmissionmount bracket.
and 14-156.
2, Installthe torque converterassemblysecurelywith

a new O-ringon the mainshaft.
45 N.m 14.5kgf.m,
STARTERMOTOR
1a mm DOWELPIN
12 x'l.25 mm MOUNT
7il N.m (7.5kgl.m,
I n s t a l lt h e s t a r t e rm o t o r o n t h e t o r q u e c o n v e r t e r 54 tbf.ftt
housing,then installthe tlvo 14 mm dowel pins in
the torqueconverterhousing. 7. lnstallthe remainingtransmissionhousingmount-
ing boltsand remainingrearenginemountingbolt.
Placethe transmissionon a iack,and raiseit to the
WASHEB
engineassemblylevel.
REARENGINE
MOUNTINGBOLT WASHER
5. Aftach the transmissionto the engine,then install 14 x 1.5rnm
two transmissionhousingmounting bolts and two 8i] N.m 18.5kgt'm,
rearenginemountingbolts. 61 rbf.n)
REARENGINE Replace.
MOUNNNGBOLTS
14x 1.5mm
TRANSMISSIONHOUSING 83 N.m 18.5kg 'm, G1lbtft)
MOUNTINGBOLTS Replace.
12 x 1,25 mm
64 N.m 16.5 47 tbf.ftl
HOUSING
MOUNTINGBOLTS
ENGINE 12 x 1.25mm
MOUNTING 64 N.m (6.5kgf.m, 47 lbf.ftl
BRACKET
8. Remove the transmission iack.
{cont'd)
JACK
14-151
Transmission
Installation(cont'd)
9. Attachthe torque converterto the drive plate with 14. Installthe control lever with a new lock washerto
eight drive plateboltsand torqueas follows: the controlshaft,then installthe shiftcablecover.
Rotatethe crankshaftpulleyas necessary to tighten
the bolts to 1/2 of the specifiedtorque,then to the CAUTION: Tako care not to bend the shift cable.
finaltorque,in a crisscrosspattern.
After tighteningthe last bolt, checkthat the crank- SHIFTCABLE
shaft rotatesfreely.
TOROUE:12 N.m (1.2 kgf'm, 8.7 lbf.ftl
10 x 1.25mm
44 N.m 14.5kgl.m, 33 lbf.ft)
LOCKWASHER
Replace.
6x1.0mm
12 N.m {'1.2kg{.m, 8 x 1.25mm
8.7 tbf.ftl 22 N.m
{2.2 ks{.m, 16lbf.ftl
SHIFTCABLE
COVER 6x 1.0mm
1{ N.m11.lkgf.m,
8 x 1.25mm 10tbtftt
24 N.m {2.4kgf.m,
17 tbf.ftt CONVERTER 15. Installthe exhaustpipeA.
COVER
NOTE:D16Y8engineis shown;D16ft engineis sim-
1 0 . I n s t a l lt h e t o r q u e c o n v e r t e cr o v e r a n d t h e e n g i n e ilar.
stiffener.
1 1 .Tightenthe crankshaftpulley bolt, if necessary(see
section6).
1 2 . Connectthe ATFcoolerhosesto the ATFcoolerlines
(seepage14-160).
ATF COOLER
LINE
J
Replace.
SELF.LOCKING NUT
Replace.
,4 " GASKET 10 x 1.25 mm
1 0 x 1 . 2 5m m
Replace. 5,1N.m 15.5kgf.m,
44 N.m {4.5kgt.m, 40 rbf.ftl
33 lbf.f0
RIGHTFRONT 12 x 1.25mm SELF.LOCKING NUT NUT
MOUNT/BRACKET64 N.m {6.5 kgf.m, Reolace. ReDlace.
47 lbI.ft) 8 x 1.25mm 8 x 1.25mm
22 N.m (2.2kgt.m. 16lbf.ft) 16 N.m ('1.6kgf.m,
12 tbf.ftt
13. Installtherightfront mounvbracket.
14-152
16. lnstalla new set ring on the end of eachdriveshaft. 20, Connectthe mainshaitspeedsensor,the linearsole-
17. Installtheright and left driveshafts(seesection16). noid and the shiftcontrolsolenoidconnectors.
CAUTION:While inslalling the driveshaftsin the
difforGntial,be sure not to allow dust and olher for-
oign particlos to enter into the transmission.
SHIFTCONTROL
SOLENOID LINEAR
SOLENOIO
NOTE: CONNECTOR CoNNEcToR
. Cleanthe areaswherethe driveshaftscontactthe
transmission(differential)thoroughly with sol- 5x1.0mm
, nd dry with com-
v e n t o r c a r b u r e t o cr l e a n e r a 12Nm(1.2kgf.m,
pr€ssedatr. 8.7 rbf.ft)
. Turn the right and left steeringknucklefully out-
ward, and slide eachdriveshaftinto the differen-
tial until you teel its set ring clip engagethe side
gear.
18. Installthe damperfork,then installthe right and left
ball jointsto the eachlower arm with the castlenuts
and new cotteroins.
DAMPERPINCHBOLT
10 x 1.25mm
a3 N.m {4.4 kd.m,
32 tbnft)
MAINSHAFT
CONNECTOR
ERACKET SPEEDSENSOR
CONNECTOR
2 ' t . Connectthe countershaftspeedsensorand the vehi-

cle speedsensor(VSS)connectors.
VEHICLE
SPEED
SENSORCONNECTOR VSS
\
COTTER
SELF-LOCKING NUT CASTLENUT
Replace.
12 x 1,25mm 1 2\ 1 . 2 5n n
6ir N.m (6.5 kgf.m, il7 lbf.ftl 49 - 59 N.m
Replace. (5.0- 6.0 kgf.m, 36 - $ lbtftl
19. Install
lnstall the
the splash
solash shield,
shi
COUNTERSHAFT
SPEEDSENSOR
SHIELD
CONNECTOR
6r1.0mm
12 N.m (1.2kgt'm,8.7 lbf'ft)
(cont'd)
14-153
Transmission
22. Connectthe lock-upcontrolsolenoidconnector,and 24. Installtheintakeair duct.
installthe transmissiongroundcable.
D16Y7engine:
Installtheint6keair duct and the resonator.
6x1.0mm
12N.m{1.2kgtm,8.7lbtftl
D15Y8engine:
Installthe intakeair duct and the air cleanerhous-
ing assembly.
Refillthe transmissionwith ATF (seepage 14-86).
Connectthe positive(+) cablefirst. then the nega-

tive {-) cableto the battery.
27. Checkthe ignitiontiming {seesection23).
Stan the engine.Setthe parkingbrake,and shiftthe

transmissionthrough all gears.three times. Check
the shift cableadjustment{seepage14-158).
Checkthe front wheelalignment{seesection181.
30. L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
cooling fan comes on) with the transmissionin E
or E position,then turn it off and checkthe fluid
Connectthe startercableson the startermotor, and levet.
installthe cableholder.
3 1 . Roadtest as describedon pages14-82thru 14-84.
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 rc a b l et e r m i n a l ,
makesurethat the crimpedside of the ring terminal
is facingout (seesection23),
6xl.0mm
12 N.m 11.2kgtm,8.7 lbt.ft)
{0.9 kgf.m.7 lbI.ft}
STARTERCAALE
lllri
lltl
14-154
CoolerFlushing
@ To prevent iniury to lace and eyes, always 7. With the water and air valves off, aftach the water and
wear safety glassesor a face shield when using the air suppliesto the tlusher. (Hot water if available.)
transmissionllusher.
NOTE:This orocedureshouldbe oerformedbetorerein-

stallingthe transmission.
1 . Checktool and hoses for wear and cracksbefore

using.lf wear or cracksare found,replacethe hoses
beforeusing,
Usingthe measuringcup,fill the tankwith 21 ounces

( a p p r o x i m a t e l2y/ 3 I u l l l o t b i o d e g r a d a b lfel u s h i n g
fluid {J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
container.
3 . Securethe flusherfiller cap,and pressurizethe tank

with compressedair to between550- 829 kpa {5,6- 8 . Turn on the flusherwater valve so water will flow
8.45kg?cm' ,80 - 120psi). throughthe coolerfor 10 seconds.
NOTE:The air line shouldbe equippedwith a water NOTE:lf water does not flow throughthe cooler,it
trap to ensurea dry air system. is completelyplugged,cannotbe flushed,and must
be replaced.
4. H a n gt h e t o o l u n d e rt h e v e h i c l e .
Depressthe triggerto mix the flushingfluid into the
5. Attach the tank's dischargehose to the return line waterflow. Usethe wire clipto holdthe triggerdown.
of the transmissioncoolerusinga clamp.
1 0 . W h i l ef l u s h i n gw i t h t h e w a t e ra n d f l u s h i n gf l u i df o r
Connectthe drain hoseto the inlet line on the trans- two minutes,turn the air valve on for five seconds
m i s s i o nc o o l e ru s i n ga c l a m p . every 15- 20 secondsto createa surgingaction.
AIR PRESSURE: MAX 845 kpa (8.45kgf/cm,,120psi)
IMPORTANT:
Securelyclampthe oppositeend ofthe drainhoseto a 1 1 . Turn the water valve off. Releasethe trigger,then
bucketor floor drain. reversethe hosesto the coolerso you can flush in
the oppositedirection.Repeatsteps8 through 10.
1 2 . Releasethe trigger,and rinsethe coolerwith water

o n l yf o r o n e m i n u t e .
Turnthe watervalveoff,andturn offthewatersupply.
1 4 . Turn the air valveon to dry the systemout with air

for two full minutesor until no moistureis visible
leavingthe drain hose.
CAUTION: Residualmoisture in the cooler or pipes

can damagethe transmission.
{r water
Removethe flusherfrom the coolerline.Attachthe
drain hoseto a container.
TRANSMISSIONCOOLER
FLUSHER
(Commerciallyavailablel I n s t a l tl h e t r a n s m i s s i o na,n d l e a v et h e d r a i n h o s e
BUCKET Kent-MooreJ38405-A attachedto the coolerllne.
or oquivalent
(cont'dI
14-155
Transmission
CoolerFlushing(cont'd) \,
1 1 . Makesurethe transmissionis in the E position. TOOL MAINTENANCE
F i l lt h e t r a n s m i s s i ow n i t h A T F ,a n d r u n t h e e n g i n e
f o r 3 0 s e c o n d so r u n t i la p p r o x i m a t e0l y. 9 5I ( 1 . 0U S 1. Emptyand rinseaftereachuse.Fillthecanwith water
q t . ,0 . 8l m p q t . ) i sd i s c h a r g e d . and pressurizethe can. Flushthe dischargeline to
ensurethat the unit is clean.
1 8 . B e m o v et h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r
r e t u r nh o s et o t h e t r a n s m i s s i o(ns e ep a g e' 1 4 ' 1 6 0 ) . 2. lf dischargeliquiddoes not foam,the orificemay be
blocked.
'19. Refillthe transmission
with ATF to the proper level
( s e ep a g e1 4 - 8 6 ) . 3. To clean,disconnectthe plumbingfrom the tank at
t h e l a r g ec o u p l i n gn u t .
FILLERCAP
FILTER
COUPLING
I{UT
\
\ I
- 0 - - \D -sq I
II \
ORIFICE
O-RING
4. Removethe in-linefilterfrom the dischargeside and

cleanit necessary.
5. The fluid orificeis locatedbehindthe filter.

Clean it with the pick stored in the bottom of the
tankhandleo , r b l o w i t c l e a nw i t h a i r . S e c u r e l y
reassemble all parts.
14-156
Shift Gable
f!!@ Makesure lifts are placedproperly(see Removethe shift cableholder.

section11.
5. Removethe shift cablecover.
1. Removethe front console(seesection20).
6. R e m o v et h e c o n t r o l l e v e r f r o m t h e c o n t r o ls h a f t ,
2. Shift to N position,then removethe lock pin from then removethe shift cable.Takecare not to bend
the adjuster. the cablewhen removing/installing it.
8 x 1.25mm
22 N.m SHIFTCABLEHOLDER
12.2kgt.m,
16 tbf.ftl SHIFTCABLE
6x1.0mm
SHIFTCABLE 12 N.m
COVER LOCKWASHER {1.2kgf.m,
Replace. 8.7 tbt.ftl
6x1.0mm
CONTROLLEVER 14 N.m
(1.4kgf.m.10lbtft)
7. Install the shift cable in the reverse order of removal.

SHIFTCABLE
8. Check the cable adjustment on reassembly (see
7 N.m page 14-158).
10.7ksf.m.s lbt.ft)
3. Removethe shift cablebracket.
SHIFTCABLE 6x1.0mm
BRACKET 9.8N.m
11.0kgl.m.7.2lbf.ft)
14-157
Shift Cable
Adjustment
!@ Make sure litts are placed properly (see 3 . C h e c kt h a t t h e h o l e i n t h e a d j u s t e ri s p e r f e c t l y
section1). a l i g n e dw i t h t h e h o l e i n t h e s h i f t c a b l e .T h e r ea r e
two holes in the adjuster.They are positioned90'
1. Removethe front console(seesection20). a p a r tt o a l l o w c a b l ea d j u s t m e n itn 1 / 4 t u r n i n c . e -
ments.
2. Shift to E position,then removethe lock pin from
the adiuster.
Cable Cable Exact

Too Shorl Too Long Alignment
4 . lf the hole is not perfectlyaligned,loosenthe lock- \

nul on the adjusterand adjustas required.
5 . Tightenthe locknutto 7 N.m (0.7kgf.m,5 lbf.ft).
6 . I n s t a l tl h e l o c k p i n o n t h e a d j u s t e rl.f y o u f e e l t h e
lock pin binding as you reinstallit, the cable is still
out of adjustmentand must be readjusted.
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d j u s t e r
securety,
8 . Move the shift leverto eachgear,and verifythat the

7 N m 1 0 . kgf.m,
7 shift positionindicatorfollows the automatictrans-
5lbtft) axle gear positionswitch.
S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
gears.It any gear does not work properly,refer to
t r o u b l e s h o o t i n( sge ep a g e1 4 - 7 8t h r u 1 4 - 8 1 ) .
1 0 . Insertthe ignition key into the key cylinderon the

Aft gear positionindicatorpanel,and verifythat the
shift lockleveris released.
Ir
t'l
14-158
Shift Lever
PUSHKNOBSPRING
LEVERKNOB
SCREW
N.m {0,3 kgnm. 2 lbI.ft)
Applynon hardeningthreadlocksealant.
SCREW
SILICONEGREASE 3 N.m (0.3kgf.m, 2 lbl.ft)
GEANPOSITIONINDICATORPANEL
COVER
BUSHING
SHIFTINDICATORLAMP
-Gt
LEVER SILICONEGREASE
SHIFTLOCK
SCREW
LEVERASSEMBLY
3 N.m {0.3
2/'o"*"'
g
5x1.0mm
,@__------
9.8 N.m 11.0kgf.m,
7.2 tbt.fr) Gar \oo.,rar.*
A/T GEARPOSITION
PI-ATE
A/T GEARPOSITIONSWITCH
SHIFTI-EVERERACKETBASE
SHIFTLEVER
BASECOLLAR
6x1.0mm
9.8 N.m (1.0kgl.m,7.2lbf.h)
14-159
Shift Indicator Panel ATFCoolerHoses
Adjustment Connection
1 . C h e c kt h a t t h e i n d e x m a r k o n t h e i n d i c a t o a
r ligns l. Connectthe ATFcoolerhosesto the ATFcoolerlines
with the E mark on the shift indicatorpanelwhen and ATF cooler,and securethem with the clips as
t h e t r a n s m i s s i oi ns i n N E U T R A L . shown.
INDEXMARK
TRANSMISSION CLIP
3 N'm (0.3 kgf.m,2lbf.ft) PANEL

ATF COOLER
lf not aligned.removethe front console(seesection HosEs
201. aoo'itoa
2-4 mm
Removethe shift indicatorpanel mounting screws 1 0 . 1 - 0 . 2i n )
and adjustby movingthe panel.
NOTE:Wheneverthe shiftindicatorpanelis removed.

the panelas described
reinstall above.
f "
14-160
-
(CVT)
VariableTransmission
Continuously
S p e c i aTl o o l s . . . . . . . . . . . .. . . 1 4 - 1 6 2 TransmissionHousing/
'14-163 LowerValveBodyAssemblY
Description .....................
R e m o v a. l. . . . . . . . . . . . . . .....'14-246
Clutches/Reverse Brake/Planetary
Gear/Pulleys . . . . . . . . . .1 4 - 1 6 6 TransmissionHousing/Flywheel Housing
P o w e rF l o w . . . . . . . . . . . . . .1 . .4. .1. 6
.8 R e m o v a.l. . . . . . . . . . . . . . . . ........14-244
E l e c t r o n iCco n l r oS l y s t e m. . . . . . . . . . . . . . . . . . . . 1. .4. 1 7 1 RightSideCover/lntermediate Housing
H y d r a u f iC control ...... 14-173 R e m o v a.l. . . . . . . . . . . . . . . . ........14-250
H y d r a u l iF cfow ......... 14-177 M a n u aV l a l v eB o d y
P a r k i nBg r a k eM e c h a n i s .m. . . . . . . . . . . . .... . . .1 4 ' 1 8 7 Disassembly/lnspection/Reassembly ....... 14'252
ElectricalSystem ForwardClutch
C o m p o n e nLt o c a t i o n s , . . . . . . . . . . . . . . , . . . . . ... . . .1. .4. .-.' .t .8.9. l l l u s t r a t eldn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .4. -. 2 . .5. .3. . . . . .
T C MC i r c u iD t iagram ..... 14-190 Disassembly . . . . . . . . . . . . .1 4 - 2 5 4
TCM Terminal Voltage/ Reassembly . . . . . . . . .... . . . . 1 4 ' 2 5 6
M e a s u r i n g C o n d i t i o.n. s. . . . . . . . . . . . . . . . . . . . . . 1. .4. .-.' .1 9 2 SecondaryGearShaft
Troubleshooting Procedures ....... . ... . . .. ..... . 14 194 25 x 35 mm ThrustShim Selection. . ..... . . 14 260
Symptom-to-Component Chart Differential
Electrica Sly s t e m . . . . . . . . .1.4 - 1 9 8 lflustrate l ndd e x. . . . . . . . . . . . . . . . . . . . . . . . . . .1 4 - 2 6 1
Electrical Troubleshooting BacklashInspection . .,..14-261
T r o u b l e s h o o t i nFgl o w c h a r t.s. . . . . . . . . . . . . . . . .1. 4 . .- 2 0 0 B e a r i n gR e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . . . ..... . .1. .4. '.2. 6 2
LinearSolenoids/lnhibitor Solenoid D i f f e r e n t iC a la r r i eR r e p l a c e m e n. .t. . . . . . . . . . .1. '4 - 2 6 2
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . ........14-223 Oil SealRemoval ........... 14-263
DrivePulley/Driven Pulley/Secondary Gear O i l S e a ll n s t a l l a t i o n / S iCdlee a r a n c .e. ...14-263
ShaftSpeedSensors F l y w h e eHl o u s i n gI n p u tS h a f tO i l S e a l
'14'224
Replacement .......... ...... Replacement . . . . . . . . . . .1 4 - 2 6 5
StartClutchControl T r a n s m i s s i oHno u s i n gB e a r i n g s
StartClurchCalibrationProcedure........... 14-225 DrivenPulleyShaftBearing
HydraulicSystem R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4. .-.2. .6. 6 .......
Symptom-to-Component Chart SecondaryGearShaftBearing
HydraulicSystem ..... . .14'226 Replacement . . . . . . . .. 1 4 - 2 6 1
R o a dT e s t . . . . . . . . . . . . . . . . . . . .1. 4
. .-.2. .2. .4 F l y w h e eHl o u s i n gB e a r i n g
StallSpeed SecondaryGearShaftBearing
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . ........14'230 R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . . ......... .1.4. .- .2. 6 . .7
FluidLevel R i n gG e a rB e a r i n g
.. ..14'231 Replacement . . . . . . . . . . . . .1. 4 - 2 6 8
Checking/Changing
P r e s s u rTee s t i n g ............14-232 ControlShaftAssembly
Removal/lnstallation ....14-268
LowerValveBodyAssembly
Replacement . . . . . . . . . ... . 1 4 ' 2 3 4 Transmission
Reassembly . . . . . . .. . . . . . 1 4 - 2 1 0
ATF Filter
R e m o v a l / l n s t a l l a t i o n . . . . . . . . . . . . . . ...............1. 4 . -235 F l y w h e e l / D r iP v el a t e. . . . . . . . . . . . . . . . . . . . . . ...' . .........1.4 - 2 7 9
Transmission Transmission
lnstattaton . . . . . . . . . . . . . . .1. .4. -. .2. 8 0
Transmission
........14-236 CooleF r lushing . . . . . . . . . .1 4 - 2 4 4
R e m o v a.t. . . . . . . . . . . . . . . .
lllustratedIndex Shift Cable
Removal/lnstallation .'.,.14-246
Transmission/Lower ValveBody
Assembly . . . . . . . . . . . . .1. 4 ' 2 4 0 Adjustment . . .. . ... .. . .. :.. .
...:.. .. . .. .. .. .. .. .. . . .. . ... 14-2aj
Transmission Housing/ s h i f tL e v e r . . . . . . . . . . . . . . . . . . 1. .4. .-.2. .8 8
F l y w h e e l H o u s i n.g. . . . . . . . . . . . . . . . . .....,.,.... 1 4 - 2 4 2 Shift IndicatorPanel
RightSide Cover/ Adjustment ..............1 . .4 - 2 8 9
l n t e r m e d i a tHeo u s i n 9. . . . . . . . . . . . . . . . . . . . . .1. 4. .-.2 4 4 ATFCooler/Hoses
lnstallation .............. ........14-289
SpecialTools
Ref. No. I Tool Number Description (hy I PageReferenco

o 07GAE- PG40200 ClutchSpringCompressorBoltAssembly ,l
14-254,257
07JAD- PH80200 Pilot,26 x 30 mm 1
o 07LAE- PX40'100 ClutchSpringCompressorAttachment 1 14-254,25'l
@ 07PM- 0010100 SCSServiceConnector 1 14-195,225
p, 07sAz - 0010004 BackprobeSet 2 14-196,228
07TAE- P4V0110 ReverseBrakeSpringCompressor 'l
14-251,271
o 07TAE- P4V0120 Start ClutchRemover 1 14-249
o 07TAE- P4V0130 Start ClutchInstaller 1 14-274,275
6r OTMAJ_ PY4OIlA A/T Oil PressureHose,2210mm 4 14-232
@ 07MAJ- PY40120 A,rIOil PressureHose.Adapter 14-232
@ 07406- 0020400 A,/TOil PressureGaugeSet Wpanel 1 14-232
@ 07406- 0070300 A,/TLow PressureGaugew/panel 1 14-232
@- 07736- A010004 AdjustableBearingPuller,25 - 40 mm 1 14-261
(D 0 7 7 4 6- 0 0 1 0 1 0 0 Attachment,32x 35 mm I 14-265,268
@ 07746- 0010500 Aftachment,62 x 68 mm 1 14-267
@ 07746- 0010600 Attachment,72 x 75 mm 1 14-266,261
@ 07746- 0030100 Driver40 mm l.D. 1 14-262,263
(D 07749- 0010000 Driver '1 't4-265,266,
267,
@ 07947- 611050't DriverAttachment,68 mm I 14-265

@ 07941 - 6340201 DriverAttachment,58 x 72 I 14-265 I
I
*Must be usedwith commercially-available
3/8" - 16 slidehammer.
E.!rnt!!---€
g \ l
l,
o
fi
@ o @ @ @ @
\
@ @ (9 @)
14-162
Description
The ContinuouslyVariableTransmission(CVT)is a electronically

controlledautomatictransmissionwith drive and driven
pulleys,and a steelbelt.The CVTprovidesnon stagespeedsforwardand one reverse.The entireunit is positionedin line
w i t ht h e e n g i n e .
Transmission
Aroundthe outsideof the flywheelis a ring gearwhich mesheswith the staner pinionwhen the engineis being staned.
The transmissionhasfour parallelshafts:the input shaft,the drive pulleyshaft,the drivenpulleyshaft and the secondary
gearshaft.The input shaft is in linewith the enginecrankshaft.
The drive pulleyshaftand the drivenpulleyshaftconsistof
movableand fixedface pulleys.Eoth pulleysare linkedby the steelbelt.
The input shaft includesthe sun gear.The drive pulleyshaft includesthe torwardclutchwhich mountsthe carrierassem-
bly on the forwardclutchdrum.The carrierassemblyincludesthe piniongearswhich meshwith the sun gear and the ring
gear.The ring gear hasa hub mountedreversebrakedisc.
The driven pulleyshaft includesthe startclutchand the secondarydrive gear whjch is integralwith the parkinggear.The
secondarygear shaft is positionedbetweenthe secondarydrive gear and the final drivengear.The secondarygear shaft
includesthe secondarydriven gear which servesto changethe rotationdirection,becausethe drive pulleyshaft and the
d r i v e np u l l e ys h a f t r o t a t et h e s a m e d i r e c t i o nW
. h e n c e r t a i nc o m b i n a t i o n os f p l a n e t a r yg e a r si n t h e t r a n s m i s s i o a
nre
engagedby the clutchesand the reversebrake,power is transmittedfrom the drive pulleyshaftto the driven pulleyshaft
to provideE, E, d, and E.
ElectronicControl
The electroniccontrolsystemconsistsof the TransmissionControlModule (TCM),sensors,three linearsolenoids,and a
inhibitorsolenoid.Shjftingis electronically
controlledunderall conditions.
The TCM is locatedbelowthe dashboard,behindthe kickoanelon the driver'sside.
HvdraulicControl
The lower valve body assemblyincludesthe main valve body,the PressureLow (PL)regulatorvalve body,the shift valve
body, the start clutch control valve body, and the secondaryvalve body. They are positionedon the lower pan of the
t r a n s m i s s i ohno u s i n g .
The main valvebody containsthe PressureHigh (PH)controlvalve,the lubricationvalveand the pitot regulatorvalve.
The secondaryvalve body containsthe PH regulatorvalve,the clutch reducingvalve,the start clutchvalve accumulator
and the shift inhibitorvalve.The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrol valve
which is joined with the PH-PLcontrol linearsolenoid.The inhibitorsolenoidvalve is bolted on the PL regulatorvalve
DOOy.
T h e s h i f t v a l v eb o d y c o n t a i n st h e s h i f t v a l v ea n d t h e s h i f t c o n t r o lv a l v e ,w h i c h i s j o i n e dw i t h t h e s h i f t c o n t r o ll i n e a r
solenoid.The stan clutchcontrolvalve body containsthe start clutchcontrolvalve,which is joined with the start clutch
controllinearsolenoid.The linearsolenoidsand the inhibitorsolenoidare controlledby the TCM.The manualvalvebody
which containsthe manualvalveand the reverseinhibitorvalve,is boltedon the intermediatehousing.
The ATF pump assemblyis locatedon the transmissionhousing,and it is linkedwith the input shaft by the sprocketsand
the sprocketchain.The pulleysand the clutchreceivefluid from their respective
Ieed pipes,and the reversebrakereceives
f l u i df r o m i n t e r n ahl y d r a u l icci r c u i t .
Shift ControlMechanism
I n p u tf r o m v a r i o u ss e n s o r sl o c a t e dt h r o u g h o u t h e v e h i c l ed e t e r m i n e sw h i c h l i n e a rs o l e n o i dt h e T C M w i l l a c t i v a t e .
Activatingthe shift control linearsolenoidchangesthe shift controlvalve pressure,causingthe shift valveto move.This
pressurizes the drive pulley pressureto the drive pulleyand the driven pulley pressureto the driven pulleyand changes
their effectivepulleyratio.Activatingthe startclutchcontrollinearsolenoidmovesthe startclutchcontrolvalve.The start
clutchcontrolvalveuncoversthe port, providingpressureto the startclutchto engageit.
(cont'd)
14-163
I
Description
(cont'd)
Gear Sel€ction
The shift leverhassix POSitiONS:

E PARK,F] REVERSE,
E NEUTRAL,
E DRIVE,E SECOND,
ANdE LOW.
Position Description
E PARK Frontwheelslockedjparkingbrakepawl engagedwith the parkinggearon the drivenpulleyshait.
The startclutchand the forwardclutchreleased.
E REVERSE Reverse;reversebrakeengaged.
E NEUTRAL Neutral;the startclutchand the forwardclutchreleased.
{d DRrvE Generaldriving;the transmissionautomaticallyadjuststo keepthe engineat the bestspeedfor

drivingconditions.
E] SECOND For rapidacceleration

at highwayspeeds;the transmissionshiftsinto a lower rangeof ratiosfor
betteracceleration
and increasedenginebraking.
E LoW For enginebrakingand powerfor climbing;the transmissionshiftsinto the lowestrangeot the

rataos.
Staningis possibleonly in @ and N positjonsrhroughthe useof a slide-type,neutral-safety

switch.
Automatic Transaxle{A/T) Gear Position Indicator

The A/T gear positionindicatorin the instrumentpanelshowswhich gear has beenselectedwithout havingto look down
at the console.
14-164
L )/
BING GEAR ?
FLYWHEEL
STEELBELT
STARTCLUTCH
INPUTSHAFT
DRIVEPULLEY
FORWARDCLUTCH
REVERSE
BRAKE
ARY GEARSET
ATF FILTER
14-165
Description
Clutches/Reverse
Brake/Planetary
Gear/Pulleys
Clutch€s/ReverseBrake
T h e C V T u s e st h e h y d r a u l i c a l l y - a c t u a tcel u
d t c h e sa n d b r a k et o e n g a g eo r d i s e n g a g et h e t r a n s m i s s i o ng e a r s .W h e n
hydraulicpressureis introducedinto the clutchdrum and the reversebrakepistoncavity,the clutchpistonand the reverse
brakepiston move.This pressesthe frictiondiscsand the steel platestogether,lockingthem so they don,t slip. power is
t h e nt r a n s m i t t e d
t h r o u g ht h e e n g a g e dc l u t c hp a c kt o i t s h u b - m o u n t e gd e a r ,a n d t h r o u g he n g a g e dr i n g g e a rt o p i n i o n
gears.
Likewise,when the hydraulicpressureis bledfrom the clutchpackand the reversebrakepistoncavity,the prstonreteases
the frictiondiscsand the steelplates,and they are free to slidepast each.This allowsthe gearto spin independently on its
shaft,transmittingno power.
Start Clutch
The stan clutch,which js locatedat the end of the drivenpulleyshaft,engages/disengages
the secondarydrive gear.
The stan clutchis suppliedhydraulicpressureby its ATFfeed pipeswithin the drivenpullevshaft.
Forward Clutch
The forwardclutch,which is locatedat the end of the drive pulleyshaft,engages/disengages
the sun gear.
The forwardclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the drive pullevshaft.
ReveFe Brake
The reversebrake,which is locatedinsidethe intermediatehousingaroundthe ring gear,locksthe ring gear in
@ posi-
tion The reversebrakediscsare mountedto the ring gear and the reversebrakeplatesare mountedto the intermediate
housing.The reversebrakeis suppliedhydraulicpressureby a circuitconnectedto the internalhydrauliccircuit.
PlanetaryGear
The planetarygearconsistsof a sun gear,a carrierassembly,and a ring gear.The sun gear is connectedto the Inputshaft
with splines The pinion gearsare mountedto the carrierwhich is mountedto the forward clutch drum. The sun gear
inputsthe enginepower via the input shaftto the planetarygear,and the carrieroutputsthe enginepower.The ring gear \
is only usedfor switchingthe rotationdirectionof the pullevshafts.
In @, $, and E positions(forwardrange),the pinion gears don't rotate and revolvewith the sun gear, so the carrier
rotates ln S position(reverserange),the reversebrakelocksthe ring gear and the sun gear drivesthe prntongearsto
rotate.The pinion gearsrotateand revolvein the oppositedirectionfrom the rotationdirectlonof the sun gear,and the
carrierrotateswith piniongear revolution.
Pulleys
Eachpulley consistsof a movabletace and a fixed face, and the effectivepulley ratio changeswith enginespeed.The
drive pulleyand the drivenpulleyare linkedby the steelbelt.
To achievea low pulley ratio, high hydraulicpressureworks on the movableface of the driven pulley and reducesthe
effectivediameterot the drive pulley,and a lower hydraulicpressureworks on the movableface of the drive pulleyto
eliminatethe steelbelt slippage.To achievea high pulleyratio,high hydraulicpressureworks on the movableface of the
drive pulleyand reducesthe effectivediameterof the drivenpulley,and a lower hydraulicpressureworkson the movable
faceof the drivenpulleyto eliminatethe steelbelt slippage.
14-166
ATF PUMP ATFPUMP
DRIVENSPROCKET
DRIVEPULLEY FORWARDCLUTCH
REVERSEBRAKE
RING GEAR PISTON REVERSEBRAKE
FLYWHEEL CARRIEB
RINGGEAR
DRIVEPLATE
PLANETARY
PINIONGEARS
INPUTSHAFT
ATFPUMP
DRIVECHAIN
ATF PUMP
DRIVESPROCKET
DRIVENPULLEY
SHAFT
STARTCLUTCH
FINALDRIVEGEAR
ORIVENPULLEY
SECONDAFYGEAR STEELEELT
SHAFT
a'- ORIVEGEAR
SECONDARY
PARKINGGEAR
14-167
Description
PowerFlow
E Position
. StartClutch:released
. ForwardClutch:released
a ReverseBraketreleased
Hydraulicpressureis not appliedto the startclutch,forwardclutch,and the reversebrake.Poweris not transmatted

to the
secondarydrive gear.
E Position
. Stan Clutch:released
. ReverseBrake:released
Hydraulicpressureis not appliedto the stan clutch,forwardclutch,and the reversebrake.power is not transmitted
to the
secondarydrive gear'The secondarydrive gear is lockedby the parkingbrakepawl interlockingthe parkinggear.
FLYWHEEL FORWARD
INPUTSHAFT
SUN GEAR
STARTCLUTCH
DRIVENPULLEY
FINAL DRIVE SECONDARY

GEAR
GEAR SHAFT
i{
B$
PARKINGGEAR
14-16A FINALORIVENGEAR
E, E, 8nd E PGitions (Forward Range)
. StartClutch:engaged
. ForwardClutch:engaged
. ReverseBrake:released
1. The hydraulicpressureis appliedto the forward clutch and the stan clutch,and the sun gear drives the forward
clutch.
2. The forwardclutchdrivesthe drive pulleyshaft,which drivesthe drivenpulleyshaftlinkedby the steelbelt.
3. The drivenpulleyshaftdrivesthe secondarydrive gear,via lhe sta.t clutch.
4. Poweris transmittedto the secondarydrivengear.which drivesthe final drivengear.
NOTE:The workinghydraulicpressureon the movablefaceof eachshaftdependson the throttleopeningposition.
DRIVEPULLEY
FLYWHEEL
CLUTCH
SUN GEAR
START CLUTCH
DRIVEN
SECONDARY
GEAR
(cont'd)
FINAL DRIVEN GEAR
14-169
Description
Power Flow (cont'd)
E Po$ition
. StartClutchtengaged
. ReverseBrake:engaged
1. The hydraulicpressureis appliedto the reversebrakeand the startclutch.The sun gear drivesthe pinrongears,and
the piniongearsrevolvearoundthe sun gear.The carrierassemblyrotatesin the oppositedirectionfrom tne rotatron
directionof the sun gear.
2 The carrierassemblydrivesthe drive pulleyshaft via the forward clutchdrum, and the drive pullevshaft drivesthe
drivenpulleyshaft linkedby the steelbelt.
3. The drivenpulleyshaftdrivesthe secondarydrive gearvia the startclutch.
4. Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear.
DRIVEPULLEY STEELBELT
DRIVE BEVERSEBRAKE
PULLEY
CARRIERASSEMBLY
INPUTSHAFT
STARTCLUTCH
FINALDRIV€
SECONDARY
DRIVEN
GEAR
!il
FINALDRIVENGEAB
14-170
ElectronicControlSystem
The electroniccontrolsystemconsistsof the TransmissionControlModule (TCM),sensors,three ljnearsolenoids,and a
controlledunderall conditions
inhibitorsolenoid.Shiftingis electronically
The TCM is locatedbelowthe dashboard,behindthe kickpanelon the driver'sside
The TCM controlsthe transmtsston to reduceenginespeedand retainthe engine'scoolingefficiencywhen the vehicleis

drivenwith full throttleacceleration
t h, e T C M r e g u l a t e st h e p u l l e yh y d r a u l i cp r e s s u r et o
y r i v e na t f u l l t h r o t t l ea c c e l e r a t i o n
l f t h e v e h i c l ei s c o n t i n u o u s l d
increasethe pulleyratio,which, as the result,reducesthe engine speed and retainsthe designedcoolingefficiency.After
the vehiclehasbeendrjvenat a lowerengine speed for a while, the TCM increases the pulleyratioto the originalratio
For smooth starting in the E position, the TCM sends a signal to the ECM to cut off the A,/Cclutch{if the IVC is on} and
increases the enginespeedto 900 rpm when the transmissionis shiftedto the E position
The start clutchfunctionsto make smooth startingpossible.To let the start clutchfunctionproperly,the TCM regulates
the startclutchhvdraulicpressurebasedon the engine'snegativepressurememorizedin the E position.
=
I
z
z
S@ond.ry Gelr Sh.tr
(cont'd)
14-171
Description
ElectronicControl System (cont'd)
Circuit Diagram and Terminal Locations
IGNITION
SWIICH
L]NEANSOLENOIO
SIAFTCLUICNCONTsOL
LINEAFSOLENOID
3 SC1
SIlIFTCONTROL
6 L]NEARSOLENOID
F TXD/NXD
=
I rM8
sNAKESWIICN
l\__ +B
8RA(EL]GHT
i\- rcr
2 3 5 1 I I 10 t l 12 1 2 5 6 I I s to
14 16 11 20 23 25 12 '14
1 7 l8 20
\
14-172
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump,the valves,and the solenoids.The ATF pump is drivenby the
input shaft.The ATF pump and the input shaft are linkedby the ATF pump drive chain and the sprockets.The inhibitor
solenoidvalveand the linearsolenoids,which are locatedon their valve body, are controlledby the TCM. Fluidfrom the
ATF pump flows throughthe PH regulatorvalveto maintainspecifiedpressureto the drive pulley,the driven pulley,and
the manualvalve.
The lower valve bodv assemblyincludesthe main valve body,the PL regulatorvalve body,the shift valve body,the start
clutchcontrolvalvebody,and the secondaryvalvebody.
Main ValveBody
The main valvebody containsthe PHcontrolvalVe,the lubricationvalve,and the pitot regulatorvalve.
PH Control Valve
The pH controlvalvesuppliesPHcontrolpressure(PHC)in accordance with the PH-PLcontrolpressure(HLC),and sup-
plies pH control pressureto the PH regulatorvalve,which also regulatesPH pressure.At kick-down,it increasesPH
controlpressurewhich increases the high (PH)pressure.This shonensthe shift speedby releasingthe reverseinhibitor
pressurelRl)from the inhibitorsolenoidvalve.
LubricationValve
The Iubricationvalvecontrolsthe lubricationpressureto eachshaft and maintainslubricationpressure.Whenthe pres-
This movesthe lubricationvalveand opensthe fluid leakpassage.
sureis too high,the spring is compressed.
Pitot RegulatorValve
with the enginespeed,when the electron
The pitot regulatorvalvecontrolsthe startclutchpressure{SC)in accordance
ic controlsvstemjs faulty.
LOWERVALVEBODY
ASSEMELY
TION VALVE
1+173
Description
HydraulicGontrol(cont'dl
SecondaryValve Body
The secondaryvalve body containsthe PH regulatorvalve,the clutchreducingvalve,the start ciutchvalve accumulator,
and the shift inhibitorvalve.
. PH Regulatol Valve
The PH regulatorvalve maintainshydraulicpressuresuppliedfrom the ATF pump, and suppliesPH pressureto the
hydrauliccontrolcircuitand the lubricationcircuit.PH pressureis regulatedat the PH regulatorvalve by the PH control
pressure(PHC)from the PHcontrolvalve.
Clutch ReducingValve
The clutchreducingvalve receivesPH pressurefrom the PH regulatorvalveand regulatesthe clutchreducingpressure
valvesuppliesclutchpressure(CR)to the manualvalveand the startclutchcontrolvalve,and
lCR).The clutchredLrcing
suppliessignalpressureto the PH-PLpressurecontrolvalve,the shift controlvalve,and the inhibitorsolenoidvalve.
Start Clutch Valve Accumulator

the hydraulicpressurethat is suppliedto the startclutch.
The startclutchvalveaccumulatorstabilizes
Shift lnhibitor Valve

The shift inhibitorvalveswitchesthe fluid passageto switchthe startclutchcontrolfrom electroniccontrolto hydraulic
controlwhen the electroniccontrolsystemis faulty.lt alsosuppliesclutchreducingpressure(CR)to the pitot regulator
valveand the pitot lubricationpipe.
STARTCLUTCHVALVE \
VALVE
SECONDARY
BOOY
SHIFTINHIBITORVALVE
CLUTCHREDUCINGVALVE
VAL
PH REGULATOR
fi
1i
1 4- 1 7 4
L
PL RegulatorValve Body
joined with the PH-PL
The pL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrolvalve,which is
valve
controllinearsolenoid.The inhibitorsolenoidis boltedon the PL regulator body
PL RegulatorValve
The PL regulatorvalvesupplieslow pressure(PL)to the pulleyto eliminatesteelbelt slippage'
The PL pressureis controlledby the PH-PLcontrolpressure(HLC).
PH-PLControl Valve
The pH-pLcontrolvalve controlsthe PL regulatorvalve accordingto enginetorque.The PH-PLcontrolvalve supplies
pH-pLcontrolpressure(HLC)to the PH controlvalveto regulatePH pressurehigherthan PL pressure.The PH-PLcon-
trol valveis controlledby the PH-PLcontrollinearsolenoid,which is controlledby the TCM'
lnhibitorSolenoid
The inhibitorsolenoidcontrolsthe reverseinhibitorvalveby turningon and off, Also,the inhibitorsolenoidcontrolsPH
controlpressure(PHC)by applyingreverseinhibitorpressure(Rl)to the PH controlvalve The inhibitorsolenoidis con-
trolledby the TCM.
Start Clutch Control Valve Body

The startclutchcontrolvalve body containsthe start clutchcontrolvalve.Both are ioinedto the startclutchcontrollinear
solenoid.
. Start Clutch Control Valve

The startclutchcontrolvalvecontrolsstartclutchengagementaccordingto the throttleopening.The start clutchcon-
trol valveis controlledby the stan clutchcontrollinearsolenoid,which is controlledby the TcM.
STARTCLUTCHCONTROL
LINEARSOLENOID
STARTCLUTCHCONIROL
VALVE
INHIBITORSOLENOID
PL REGULATOR
VALVEBODY
LOWERVALVEBOOY
ASSEMBLY
PL REGULATOR PH.PLCONTROL
VALVE LINEARSOLENOID
(cont'd)
14-175
)
Description
HydraulicControl (cont'dl
Shift Valve Body
The shiftvalvebody containsthe shift valveand the shift controlvalve.Bothare joined
to the shift controllinearsotenoid.
e Shift Valve
The shift valve is controlledby shift valve pressure(SV)from the shift
control valve.The shjft valve distributespH
pressureand PL pressureto drive pulleyand the drivenpulley,
to shift the transmission.
. Shift ControtValve
The shift controlvalve controlsthe shift valve in accordancewith the throftle
openingand vehiclespeed.The shift
control valve is controlledby the shift control linearsolenoid,which is
controlledoy tne rcv. wnen tne electronic
controlsystemis faultv,the shift controlvalveswitchesthe shift inhibitor
valveto uncoverthe pon leadingthe pitot
regulatorpressureto the startclutch.
SHIFTCONTROL
LOWERVALVEBODY CONTROLVALVE
ASSEMBLY
VALVEBODY
Manual Valve Body

The manualvalvebody containsthe manualvalveand the reverseinhibitor
valve.The manualvalvebody is boltedto the
i n t e r m e d i a theo u s i n g .
. ManualValve
The manualvarvemechanicatyuncovers/covers
the fruid passageaccordingto the shift reverposition.
. ReverseInhibitor Valve
The reverseinhibitorvalve is controlledby the reverseinhibitorpressure(Rt).
lt interceptsthe hydrauliccircuitto the
reversebrakewhile the vehicleis movingforwardat speedsover approximately
6 mph (10km/h).
REVERSE
INHIBITOR
MANUALVALVE
BODY
14- 1 7 6
HydraulicFlow
GeneralChart of Hydraulic Pressure
. Shift Valve
. ShiftlnhibitorValve
,,/ SHIFTVALVE
PL REGULATOR
VALVE
PH REGULATOR
VALVE
NO. OF PRESSURE
DESCRIPTION NO. OF PRESSURE
DESCRIPTION
CLUTCHCONTROL PP PITOTPIPE
coL ATF COOLER PR PITOTREGULATOR
CR REDUCING
CLUTCH RCC RECIRCULATION
DN DRIVENPULLEY RI INHIBITOR
REVERSE
DR DRIVEPULLEY RVS REVERSE
BRAKE
FWD FORWARD
CLUTCH STARTCLUTCH
HLC PH-PLCONTROL sl S H I F TI N H I B I T O R
LUB LUBRICATION SUC SUCTION
PH P R E S S U RHEI G H SV SHIFTVALVE
PHC PHCONTROL X LEAK
PL PRESSURE
LOW
(cont'd)
14-177
L
Description
llj Position
As the engineturns,the ATF pump also startsto operate.Fluidfrom the ATF pump flows to the PH regulatorvalveand the
clutchreducingvalve.The PH regulatorvalveregulateshigh pressure(pH),and send,it to the shift valveand the pL regu-
lator valve.The high pressure(PH)flows to the movableface of the driven pulleyvia the shift valve,and turns into low
pressure(PL)at the PL regulatorvalve.The low pressure(PL)flows to the movableface of the drive pulleyvia the shift
valve.At this time, the pulleyratio remainslow.
The high pressure(PH)becomesthe clutchreducingpressure{CR)at the clutchreducingvalve.The clutchreducingpres_
sure{CR)flows to the startclutchcontfolvalve,the manualvalve,the PH-PLcontrolvalve,and the shift controlvalve,and
is interceptedby thosevalves.
Underthis condition,hydraulicpressureis not appliedto the clutchesand reversebrake.
1 4-1 7 A
E position, at low speed range
position.The
The flow of fluid up to the drive pulley.the drivenpulley,and the clutchreducingvalve is the same as in E
pulleyratio is low becausethe drivenpulleyreceiveshigh pressure (PH),and the drive pulieyreceives low pressure {PL).
in" "tut"t reducing pressure (CR) flows through the manual valve to the forward clutch,then forward clutchis engaged.
The forwardclutchthen drivesthe drive pulleyshaft,which drivesthe drivenpulleyshaft'
pressure(CC).
Also, clutch reducingpressure(CB)flows to the start clutch control valve, and becomesclutch control
(CC) pressure(SC) at the shift inhibitorvalve. Start clutch pressure (SC)is
Clutchcontrol pressure becomesstart clutch
aooliedto the startclutchto engagethe start clutch
(contd
14-179
Description
lll position, at middle spe€d range
As the speedof the vehiclereachesthe prescribedvalue.the shift controllinearsolenoidis activatedby the TCM.The shift
controllinearsolenoidcontrolsthe shift controlvalveto activateshift valve pressure(SV).Clutchreducingpressure(CR)
from the clutchreducingvalvebecomesshift valvepressure(SV)at the shift cont.olvalve.Shift valvepressure(SV)flows
to the left end of the shift valve,the shift valveto the right side and positioningit in the middleof its travel.The shift valve
coversthe port to stop high pressure(PH)to the pulleys.and uncoversthe port leadinglow pressure(PL)to the pulleys.
The drive pulleyand the drivenpulleyreceivelow pressure(PL).At this time, the pulleyratiois in the middle.
Pressureremainsto applythe forwardclutchand the stan clutch.
NOTE:When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
14-180
E position, at high speed range
As the speedof the vehiclereachesthe prescribedvalue,the shift controllinearsolenoidmovesthe shift controlvalveto

increaseshift valvepressure(SVl at the left end of the shift valve.The shift valve movesto the right side comparedto its
positionat the middle pulteyratio.The shift valve uncoversthe port leadinghigh pressure(PH)to the drive pulley and
uncoversthe pon leadinglow pressure(PLlto the driven pulley.The drive pulleyreceiveshigh pressure(PH)and the driv-
en pulleyreceiveslow pressure(PL).The pulleyratio is high
Pressureremainsto applythe forwardclutchand the startclutch.
"|eft" or "right" indicatesdirectionon the hydrauliccircuit

NOTE:When used,
(cont'd)
14-181
Description
\
lll position
The flow of fluid up to the drive pulley,the driven pulley,and the clutchreducingvalve is the same as in E position.The
pulleyratio is low becausethe drivenpulleyreceiveshigh pressure(pH)and the drive pulleyreceiveslow pressure(pL).
The manualvalve is shiftedinto the E position,and it uncoversthe port that leadsreversebrakepressure(RVS)to the
reverseinhibitorvalve.The inhibitorsolenoidturns off by meansof the TCM,and reverseinhibitorpressure(Rl)is applied
to the right end of the reverseinhibitorvalve.The reverseinhibitorvalvemovesto the left side,and uncoversthe pon that
leadsreversebrakepressure(RVS)to the reversebrake.Clutchreducingpressure(CR)becomesreversebrakepressure
{RVS)at the manualvalve,and flows to the reversebrake.The reversebrakeis engaged,and it locksthe ring gear.
NOTE:When used,"1eft"or "right" indicatesdirectionon the hvdrauliccircuit.
14-182
Lll position
FeveBe lnhibitor Control
lf the E positionis selectedwhile the vehicleis moving forward at speedsover 6 mph (10 kmlh),the inhibitorsolenoid
doesn,tturn off by meansof the TCM. Reverseinhibitorpressure(Rl) is not appliedto the reverseinhibitorvalve as the
reverseinhibitor solenoidturns on. The reverseinhibitor valve is kept on the right side, and coversthe port to stop
(RVS)is not appliedto
reversebrakepressure(RVS)to the reversebrakefrom the manualvalve.Reversebrakepressure
the reversebrake, and Dower is not transmjttedto the reverse
direction.

NOTE:When used,"left" or
(cont'd)
14-183
Description
HydraulicFlow(cont'dl
El position
The flow of fluid up to the drive pulley,the driven pulley,and the clutch reducingvalve is the same as in E position.
Clutchreducingpressure(CR)flows to the stan clutchcontrolvalve,th€ manualvalve,and the shift controlvalve.and is
interceptedby thosevalves.
Underthis condition,hydraulicpressureis not appliedto the clutchesand reversebrake.
14-144
E po3ition. when the electroniccontrol system is taulty.
When the electroniccontrolsystem(linearsolenoidsand sensors)is faulty,the transmissionusesthe pitot pipe pressure

(PP)to allow the vehicleto drive.
When all linearsolenoidsand sensorsare off becauseof a faulty electroniccontrolsystem,clutchreducingpressure{CR)

flows to the startclutchcontrolvalve,the manualvalve,the PH-PLcontrolvalve,and the shift controlvalve.Clutchreduc-
ing pressure(CR)becomesshift valve pressure(SV)at the shift controlvalve,and shift valve pressure(SV)is appliedto
the left end of the shift valve and the right end of the shift inhibitorvalve.The shift valve movesto the right side,and
uncoversthe port that leadshigh pressure(PH)to the drive pulleyand uncoversthe port that leadslow pressure(PL)to
the driven pulley.At this time, the pulley ratio is high. The shift inhibitorvalve movesto the left side,and uncoversthe
port that leadsshift inhibitorpressure(Sl)to the pitot lubricationpipe and the pitot regulatorvalve.The pitot lubrication
pipe dischargesfluid insideof the pitot flange,and dischargedfluid entersinto the pitot pipe and it is appliedto the left
end of the pitot regulatorvalve.The pitot regulatorvalve movesto the right side,and uncoversthe pon that leadspitot
regulatorpressure(PR)to the shift inhibitorvalve.Pitot regulatorpressure{PR)becomesstart clutchpressure(SC)at the
shift inhibitorvalve.and is appliedto the start clutch.The start clutch is engaged.The forward clutch pressure(FWD)is
appliedto the forwardclutch,and the forwardclutchis engaged.This allowsthe vehicleto drive.
(cont'd)
14-185
Description
E position, when the electroniccontrol system is faulty.
The flow offluid up to the drive pulley,the drivenpulley,and the startclutchis the sameas in E position.
The manualvalve is shiftedinto the E position,and it uncoversthe port that leadsreversebrakepressure(RVS)to the
reverseinhibitorvalve.Reverseinhibitorpressure(Rl)is appliedto the right end of the reverseinhibitorvalve becauseof
a faulty inhibitorsolenoid.The reverseinhibitorvalve moves to the left side, and uncoversthe port that leadsreverse
brakepressure(RVS)to the reversebrake.Clutchreducingpressure(CR)becomesreversebrakepressure(RVS)at the
manualvalve,and flows to the reversebrake.The reversebrakeis engagedand locksthe ring gear.This allowsthe vehi-
cle to drive in reverse.
14-186
ParkingBrakeMechanism
The parkingbrakemechanismlocksthe transmissionby engagingthe parkingbrakepawl with the parkinggear which is
integralwith the secondarydrive gear.The secondarydrive gear engageswith the secondarydrivengear which engages
with the final drivengear.
Shiftingto E positioncausesthe parkingcone (installedat the end of the parkingbrakerod) to pressthe parkingbrake
pawl onto the parkinggear. Even it the end of the parkingbrakepawl rides on the top of the parkinggear teeth,slight
movementof the vehiclewill causethe parkingbrake pawl and the parkinggear to mesh with each other completely
becausethe parkingbrakecone receivesthe tensionfrom the parkingbrakerod spring.The parkingbrakepawl receives
the tension(whichactsto separatethe parkjngbrakepawl from the parkinggear)from the parkingpawl spring.
ART CLUTCH
PARKINGGEAR
PARKINGBRAKEROD
PARKINGBRAKE
PAWL
PARKINGBRAKE
RODSPRING
14-187
ComponentLocations
BRAKESWITCH
AUTOMATICTRANSAXLE{A/T)
GEARPOSITIONSWITCH
SECONOARY
GEARSHAFT MANIFOLDABSOLUTE
SENSOR
SPEED PRESSURE{MAP)SENSOR
THROTTLEPOSITIONITPI
SENSOR
INHIBITORSOLENOID
STARTCLUTCHCONTROL PH-PL CONTROL

LINEARSOLENOID L I N E A RS O L E N O I D
SHIFTCONTROL
LINEARSOLENOID
14.1A 9
TCMCircuitDiagram
\
UNDER-HOOD
FUSE/RELAY
BOX
N o . 4 1l 8 0 A ) N o . 4 7 ( 7 . 5 A )
PARKING
BRAKE
SWITCH I G N I T I OCNO I L
YI I V
UNDER-DASH
FUSE/RELAY
BOX
I I
II II
BLU
oul
lGl
To12v
5V
REGULATOS
G A U GA
ES S E M B L Y
A/I GEARPOSITION
INDICATOR L TG R N
8LK/8LU
_ RED
GRN/8LK
-GflN-
_ BLU
BLK
[,
II
I: \
G401
G404
14-190
l A 4 l A 1 7l A 1 3 l A 2 6
BRN/BL( | 8l,K I
I BRN/BLK I BLK
L--.1 L---l
RED/BLU
T ;i, T ,,t,,.T ?t T l
I J , T*t* I *-I*T*^,T,* GRN/BLK
I --l+--++ wHT I WHT/REDI
'lFr 'i Fl
PNK/8LK I PNK/BLU I GRNTYELI
t - t a
I
;I. T".T"T 1P 1ts
Tt lTTI TI T| T| T.,^T,,T I I I P K/BLK I PNK/8LU I GRNIYEL I G8N/BLK
| | I I I t.l- 8RN/BLK BLK
LOJ L C @ @ @ @ l F l ,rr,r,.o, I i s0LEN0r0

SHIFT
| L
DNNEPULLEY DRIVEN SECONDARY PH_PT
PUI-LEY START t l
SPEEO
SENSORSPEEDSENSOR GEAR
SHAFT CONTROL CLUTCH CONTROT
I.INEAR
_o _o_
SENSOR LINEAR
SPEED CONIROL : - :
SOLENOID LINEAR SOLENOID
SOLENOID G101 G101
TCMTerminalLocations
X
1 ,, 4 E 7 8 I 10 11
,l t,
I 2 6 7 8 9 10
14 1 5 l6 1 7 20 23 2 5 26 13 14 t 5 16 18 20
T C M- A { 2 6 P ) C o n n € c t o r T C M - Bl 2 2 P ) C o n n e c l o r
14-191
TGM TerminalVoltage/MeasuringGonditions
TCM Torminal Locations

--r- a
1 2 3 4 1 I r 0 i 1 112 I 2 I 6 7 10
la 15 16 11 20 23,/ 26 1 2 14 15 1 7 l8 20 L)
TCM-A(26P1Connoctor TCM.Bl22PlConnector
TCM CONNECTOR A {26P}
TerminalNumbor Measuring Conditions/Terminal Voltage

Start clutch control linearsolenoid E n g i n ei d l i n g ,E p o s i t i o n :
Aoorox. 0.4 V
PH PL control linear solenoidpower Engineidling,lll positionl
A p p r o x . 0 . 7V
Shift control linear solenoidpower E n g i n ei d l i n g ,E l p o s i t i o n l
inerunningP
: u l s i n gs i g n a l
Ay'Tgear positionswitch L! position In i!.1position:0 V

In other than E position:
A/Tgearpositionswitchlg position I nE Jp o s i t i o n :V0
s i g n a li n p u t ln otherthanE position: Approx.1OV
A,/TgearpositionswitchE position I nL l l p o s i t i o n :V0
In otherthanE position:Approx.1OV
410 Ay'Tgear positionswitchE or E I n E o r E p o s i t i o nor V
In other than N or E position:Approx. 1OV
411 gear positionswitch E position
A,,/T I n L Ep I o s i t i o n : 0V \
I n o t h e rt h a n E p o s i t i o nA
: p p r o x .1 OV
With ignition switch ON 1ll):Batteryvoltage
wirh switch OFF|0 V
A13
Start clutch control linearsolenoid E n g i n ei d l i n g ,
A15 PH-PLcontrol linearsolenoidDower E n g i n ei d l i n g ,

A o p r o x . 5 . 0V
A16 Shift control linearsolenoidpower E n g i n ei d l i n g , posation:
ADorox.6.0 V
417
A18
A19
E indicatorlighr control indicatorlight comes on: Approx. 10 V

indicatorlight OFF:0 V
Always banery voltage

424
With ignitionswitch ON (ll): Batteryvoltage

With ignition switch OFF|0 V
426
14-192
{
B (22P)
TCM CONNECTOR
Terminal Number Me6suring Conditions/Terminal Voltag€
B1 With inhibitorsolenoidONr Batteryvoltage

W i t h i n h i b i t o rs o l e n o i dO F F : 0V
82 Manilold AbsolutePressure(MAP) W i t h i g n i t i o ns w i t c hO N ( l l ) :A p p r o x . 2 . 5V
sensorsignal input With engine idling: Approx. 1.0V (dependingon
e n g i n es p e e d )
B3
B4 Throttle PositionlTP) sensorsignal With ignitionswitch ON (ll) and throttlefully open:
input 4 . 1 4- 4 . 4 2V
With ignitionswitch ON (ll) and throttlefully
closed:0.44- 0.56V
B5 With ignitionswitch ON (ll) and rotatingfront
wheelsi0-SVcycle
B6 Data communicationwith ECMI With ignition switch ON (ll):Pulsingsignal
Transmissioncontrol data oLltput
B7 Datacommunicationwith EcM: With ignition switch ON (ll)rPulsingsignal
PGIM-Flcontrol data input
B8
Driven pulley speedsensorsignal I n o t h e rt h a n E a n d E p o s i t i o nP
: u l s i n gs i g n a l
Drive pulley speedsensorsignal ln other than position;Pulsingsignal

810
B tl
812 Brakeswitch signal input With brakepedal depressedrBatteryvoltage
With brake V
released:0
813 with ignitionswitchoN (ll):Approx.5.0v
814 SCS I Servicechecksignal With ignition switch ON (ll) and servicecheckcon

nectoropen: Approx. S V
With ignition switch ON (ll) and servicecheckcon-
nectorconnectedwith specialtool: 0 V
815 Secondarygear shaft speedsensor Dependingon vehiclespeed:Pulsingsagnal
s i g n a li n p u t When vehicleis stopped:0 V
816 Secondarygear shaft speedsensor
817
818 Parkingbrakeswitch signal input p a r k i n gb r a k el e v e rp u l l e d : 0V
rkinq brakelever released: voltage
819
820 W i t h i g n i t i o ns w i t c hO N ( l l ) :A p p r o x . 5 .
821
822
14-193
Procedures
Troubleshooting
l. How To Begin Troubleshooting

When the E indicatorlight has been reportedon, use the appropriateprocedurebelow to diagnoseand repairthe
proorem.
A. Whenthe E indicatorlight hascome onl
1. Connectthe HondaPGM Testeror an OBD ll ScanTool to the 16PData Link Conneclor(DLC)locatednearthe left
k i c kp a n e l .
3. Checkthe DTC and note it. Also checkand note

the freezetrame data.
Referto the DiagnosticTrouble Code Chan and
begintroubleshooting. o0\-/oo
INOICATOR
LIGXT
NOTE:SeetheOBDll ScanToolor HondaPGMTesteruser'sman uals for specificoperatinginstructions.
Some PGM-Flproblemswill also makethe E indicatorlight come on. After repairingthe PGM-Flsystem,disconnectthe
BACKUPfuse (7.5A) in the under-hoodfuse/relaybox for more than 10secondsto resetthe TCM memory,then recheck.
NOTE:Disconnecting the BACKUP tuse also cancelsthe radio presetstationsand the clock setting,Make note of the
radiopresetsbeforeremovingthe fuseso you can resetthem.
OBDtl SCANTOoL or
HONDAPGMTESTER
I16PI
OATALINKCONNECTOR
14-194
B. DTCSwill be indicatedby the blinkingof the E indicatorlight with the SCSserviceconnector connected.Connect
the SCS serviceconnectorto ServiceCheckConnectoras shown. (The ServiceCheckConnector(2P)is located
underthe dashon the passenger's side of the vehicle.)Turn the ignitionswitchON (ll)
CONNECTOR
I2PI CONNECTOR
07PAZ- @101tX)
Codesl through9 are indicatedby individualshort blinks.Codes10 and aboveare indicatedby a seriesof long and shon
blinks.One long blink equals10 short blinks.Add the long and shon blinkstogetherto determinethe code.After deter-
miningthe code,referto the electricalsystemSymptom-to-Component Charton pages14-198and 14-199.
Shon blink {onc.l
S.. DYCI
S.c DlC2
Long blink Sho.t blinkt {fiv. tim6l
S.c DTC15
Some PGM-Flproblemswill also makethe E indicatorlight come on. After repairingthe PGN4-Fl system,disconnectthe
BACKUP fuse (7.5A) in the under-hoodfuse/relavbox for more than 10 secondsto resetthe TCM memory,then recheck.
(cont'd)
14-195
(cont'd)
C. lf the inspectionfor a particularcode requiresvoltageor resistancechecksat the TCM connectors,removethe
driver'sside kickpanel.Unboltthe TCM.Turn the ignitionswitchOFF,and connectthe backprobesetsand a digital
multimeteras describedbelow.Checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)
listedon the followingpages.
How to use the BackprobeSet
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire

insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side untilcomesin contactwith the terminalend of the wire.
BACKPROBE SET
07sAz- (x)1000A
(two roquiredl DIGITAL
MULTIMETER
rv.ilablol
lCommcrcirlly
KS-AHM-32-003,
or equivalent
ADAPTER
CORD
14-196
ll. TCM ResetProcedure
1. Turn the ignitionswitchoff.
2 . R e m o v et h e B A C KU Pf u s e( 7 . 5A ) f r o m t h e u n d e rh o o df u s e / r e l abyo x f o r l 0 s e c o n d s t or e s e t t h e T C M .
NOTEI
. Disconnectingthe BACKUP fuse also cancelsthe radio presetstationsand the clocksetting.Makenote of the radio
presetsbeforeremovingthe fuse so you can resetthem
BACKUP
(7.5A) FUSE
. The TCM can also be clearedby usingthe OBDll ScanTool or HondaPGMTester.
OBO ll SCAN TOOL ol

PGMTESTER
DATALINKCONNECTOB
I16P)
lll. FinalProcedure
NOTE:This proceduremust be done afterany troubleshooting.
1. Turn the ignitionswitchoff.
2. Resetthe TCM.
3. Disconnect the OBD ll ScanTool or HondaPGMTesterfrom the DataLink Connector(16P),or removethe specialtool
from the ServiceCheckConnector.
4. Turn the ignitionswitchON (ll),and set the radiopresetsand clocksetting.
14-197
Chart
ElectricalSystem \
Diagnostic
Indicaror
TroubleCode E Symptom PossibleCause
Referto
(DTC)* L i gh t Page
E n g i n er p m d o e s n o t i n c r e a s e . Disconnectedthrottleposition(TP)
Transmission does not kick- sensorconneclor
P1790
(3) Blinks Shortor open in TP sensorwire 14-200
Transmission does not change FaultyTP sensor
to higher ratio.
. No specificsymptomappears. Disconnectedvehiclespeedsensor
P1791 (VSS)connector
(4) Blinks 14 201
Shortor open in VSSwire
FaultyVSS
P'1705 . Transmission shiftssameas E Shortin A/T gear positionswitchwire
Blinks 14 202
15) positionin any positions. FaultyA"/Tgear positionswitch
. Transmission shiftssameas @ DisconnectedA/T gear positionswitch
P'1706 positionin any positions. connector
(6) OFF 14-204
Openin A,/Tgear positionswitchwire
FaultyAft gear positionswitch
Pooracceleration,
flareson Disconnected ignitioncoil connector
P0725
( 11 ) Blinks starting off. Shortor open in ignitioncoil wire 14-206
F a u l t yi g n i t i o nc o i l
No speciticsymptomappears. Disconnected manitoldabsolutepres,
P1793 sure(I/AP) sensorconnector
Blinks 14-207
\121 Shon or open in MAP sensorwire
FaultyMAP sensor
. Pooracceleration,
flareson Disconnected solenoidharnesscon-
P1870 startingoft. necror
(30) Blinks Shortor open in shift controllinear 14-208
solenoidwire
Faultyshift controllinearsolenoid
Pooracceleration,
flareson Disconnected solenoidharnesscon-
staningoff. nector
P1873 't4-209
( 3 1) Blinks S h o no r o p e ni n P H - P L
c o n t r ol i n e a r
solenoidwire
FaultyPH-PLcontrollinearsolenoid
Pooracceleration,
flareson Disconnected solenoidharnesscon
startingoff. nector
P1 8 7 9 Shortor open in startclutchcontrol 't4-210
(32) Blinks
linearsolenoidwire
Faultystartclutchcontrollinear
solenoid
No specificsymptomappears. Disconnected solenoidharnesscon-
P1882 nector 't4-2't1
(33) Blinks
Shon or open in inhibitorsolenoidwtre
F a u l t yi n h i b i t osr o l e n o i d
{DTC)*:The DTCSin parentheses are the numberof the E indicatorlight blinkswhen the servicecheckconnectoris con-
nectedwith the specialtool (SCSServiceConnector).
14-198
Diagnostic Referto
E Indicator Symptom PossibleCause
TroubleCode Page
Light
(DTCT
flareson
Pooracceleration, Disconnected drive pulleyspeedsen-
startingoff. sor connector
P1885 Shon or open in drive PulleYspeed 14-212
Blinks
(34) sensotwire
Faultydrive pulleyspeedsensor
. Pooracceleration,
flareson Disconnecteddrivenpulleyspeedsen-
starting off. sor connecror
P1886 Shon or open in drivenPUlleyspeed 14-213
Blinks
(35) sensorwire
Faultydrivenpulleyspeedsensor
. Poor acceleration,flares on DisconnectedsecondarY gear shaft
starting off. speeclsensorconnecror
P1888 Shortor open in secondarygearshaft 14-214
Blinks speedsensorwtre
(36)
Faultysecondarygearshaftspeed
sensor
. Poorcreepingpowerwith brake Shortor open in TMA wire between
pedalreleased. 87 terminaland ECIVI
P1655 Shon or open in TMB wire between86 14-215
Blinks t e r m i n aal n d E C M
l31l
FaultyECM
FaulryTCM
P1890 flareson
Pooracceleration, . Faultyshift controlsystem
Blinks 14-217
\421 startingoff.
P1891 Poor acceleration,flares on start- Faultystartclutchcontrolsystem 14-214
Blinks
(43) ing otf.
(DTC)*:The DTCSin parentheses are the numberol the E indicatorlight blinkswhen the servicecheckconneclorrs con-
nectedwith the specialtool (SCSServiceConnector).
E indicatorlighr does not blink,performan inspectionaccordingto the table below

lf the self-diagnostic
SymPtom Inspection Ref. page
E indicarorlight does not come on lor two secondsafterignitionswitch 14-220

is firstturn on {ll).
@ indicatorlight is on constantly(not blinking)wheneverthe ignition 14-222
switchis on (ll).
NOTE:
. It a customerdescribedthe symptomfor code P1706(5),it will be necessary to recreatelhe symptom by test driving,
then recheckthe DTC.
. Sometimethe E indicatorlight and the MalfunctionIndicatorlamp (MlL)may come on simultaneously. lf so, repairthe
p G M - F ls y s t e ma c c o r d i n gt o t h e D T c , t h e n r e s e tt h e m e m o r y b y r e m o v i n gt h e B A C KU P f u s e i n t h e u n d e r - h o o d
(50 km/h),then
fuse/relaybox for more than 10 seconds.Drivethe vehiclefor severalminutesat a speedover 30 mph
recheckthe DTC.
14-199
)
TroubleshootingFlowchart - Throttle Position (Tp) Sensor
. OBD ll ScanTool indic.les Code PossibleCause

P1790. . Disconnoct€dthrottle Dosition
. Sef-diagnosisE indicaior light (TP)sensorconnecior
blinks threo times. . Short or open in TP sensorwire
. FaultvTP sonsor
CheckIor Anothe. Code or MIL

Blinking:
'1. Turn
the ignitionswitchON (ll).
2. Checkwhetherthe OBD scan
tool indicatesanothercode or
the MalfunctionIndicatorLamp
lMlL)blinks(seesection11).
Doesthe OBDllscan tool indicate

anothercode
or isthe MILblink Repairthe PGM-Flsystem lse€
ing? section111.
MeasureVREFVohage: TCM CONNECTORS

'L Turn
2. Disconnect the A (26P)and B
l26Pl
1 2 2P ) c o n n e c t o r sf r o m l h e
TCM.
3 . T u r n t h e i g n i t ; o ns w i t c hO N
flr).
4. Measurethe voltagebetween WHT/RED
the 820 and A13 or 426 termi-
nals, WIRESIDEOF FEMAI-ETERMINALS
Repair op6n or short in the wir6

ls thereapprox.5 V? betweenthe 820 terminal and the
ECM.
Measu.e TPS Voltagel RED/BLK

Measurethe voltage between the
B4 and A13 or A26 terminals.
ls there0.4-0.6V? Repairopen in the whe betwoen

the 84terminal and the TP sensor.
Chocklor loos6 TCM connectoB.

ff necossary,substitute a known-
good TCM and recheck.
TroubleshootingFlowchart- VehicleSpeedSensor(VSSI
. OBD ll Scan Tool indicare. Codo PossibleCause
P1791. . Di3connected vehicls sPeed
. Sor-di.gnotb E indhttor light ienaor (VSSIconnectol
blink3lour tim.i . Short or ooan in VSS wile
. Faulty VSS
Refol to s.ction 23 tor vehicle

spood 3ensor {VSSI t6t.
check rh. vss voh.go:

1. Raisothe vehicle. . Mak6 3ure lifts, iacks,and salety stands aro plsced properly lseo section 1l
2. Shift the transmissionto E . Set tho pa*ing brake socurgly,and block the rear wh6el3.
posrt|on.
. Jack up the front of the vehicl€,and supPort it with salety 3tands'
3. Disconnectthe A 126P)and B
( 2 2 P )c o n n e c t o r sf r o m t h e TCM CONNECTORS
TCM.
4. Turnthe ignitionswitchON lll)
5. Rotate the tront wheel and
checkfor the voltage between
nals.Blockthe otherwheelso
it does not turn.
Check lor open in the wiro

botwean tho 85 torminal and the
vehiclo speod sen30r (vSSl. lf
wire is OK, chock the VSS (see
3€ction23).
Chack for loo3o TCM connoctoG.

ll nacaaarry,aubltituto t known'
good TcM rnd rechock.
14-201
g
TroubleshootingFlowchart- A/T GearpositionSwitch (Shortl
. OBD ll ScanTool indicatesCodo PossibleCause

P1705. .Short in A/T gear position
. Selt-diagnosis@ indicator tight
switch wire
blinksfive timos. . FeuttyA/T gear pGition switch
NOTE:Code5 is causedwhen the TCM

two gear posilioninputsat the
recerves
Observethe A/T 9€.r position
indicator:
1 . T u r n t h e i g n i t i o ns w i t c hO N
( ).
2. Observethe A/T gear position
a n d i c a t o ra, n d s h i f t t o e a c h
positionseparately.
Do any indicators stay on when the The syslem is OK at this tim€. TCM CONNECTOR
A I26P}
shift lever is not in that position? Checkthe wire harnesstor dem-
age.
Mersure ATP R Voltagel

1. Shittto all positionsothe.than
tr.
the Al 1 and A13or 426 termi-
nals.
WIRESIOEOF FEMALETERMINALS
Check for short in lhe wi.e
betwoenthe A11terminal and tho
A/T gear position switch or A/T
ls thereapprox.10V? gear position indicator. ll wire is
OK, check for loose TCM connoc-
tors. lf nocessary,substitute a
known-goodTCM and .echeck.
Measure ATP NP Voltagei
1. Shift to all positions other
t h a nE o r E .
the 410 and A13 or 426 termi,
nals,
Check for short in th6 wiro
between lhe A10 terminal and
the A/T g€ar position indicator.
or a short in tho wires botween
ls thereapprox.l0 V? th€ A/T gear position indicator
and the A/T gear position
switch. lI wires are OK, check for
loose TCM connectors. ll neces-
sary, substilute a known-good
TCM and roch€ck.
MeasureATP D Vohago:
E,
the A9 and A13 or 426 rermi-
nals.
Check for short in the wire

bstwoon the Ag terminal and the
ls thereapprox.10V? A/T gear position switch. ll wiro
is OK, check lor loose TCM con-
nectoG. lf neces3ary,substitute a
known-goodTCM and r€check.
To page14'203
14-202
A (26P}
TCM CONNECTOR
Frompage14-202
M.ssur6 ATP S Vohage:

1. Shjftto all positionsotherthan
ts.
the Ag and A13 or A26 termi
nals.
Check lor sho* in the wire
between tho A8 tolminal and the
A/T 9o.r po3ilion switch or the
ls thereapprox.10V? A/T goar position indicrtor. lf wirc
is OK, check for loose TCM con-
n€ctors. ll necessery,substitute a
known-goodTcM and roch€ck
MoasureATP L voltager
1. Shittto all positionsotherthan
E.
the A7 and A13 or A26 termi-
nats,
Check for short in the wile

betwoen the A? terminal and the
A/T gear po3ition switch or the
ls thereapprox.10V? A/f gear pGition indicttor. lf wile
is OK, check for loo3o TCM con-
nectors. lf noc€asi.ry.subditute a
known-goodTCM and rc.ch.ck.
Checktor looso TCM connoctors.

It neco$ary, substitute a known_
good TCM and rechock.
14-203
Electrical
Troubleshooting
TroubfeshootingFlowchart- AIT Gear positionSwitch (Open)
\
. OBD ll Scan Tool indicatesCode PossibleCause

P1706. . OisconnectedA/T geer position
. Self-diagnosisE indicator tight
switch connector
blinks six times. . Openin A/T gearpositionswitch
. Faulty A/T gear position switch
MeasureATP R Voltage:
t h eA 1 1a n dA 1 3o r 4 2 6 t e r m i
nals,
Repairopen in the wire botween
lhe A11 terminaland the A/T
gear position switch.
1. Shiftto E or E position.
t h eA 1 0a n dA 1 3o r 4 2 6 t e r m i -
nals.
Bepair op6n in the wire between

the A10 termineland the A/T
gea. position switch.
MeasureATP D Voltage:
the Ag and Al3 or 426 termi
nals.
Repairopen in tho wire between

the Ag torminal and the A/T gea.
Dositionswitch,
Ii
To page14 205
14-204
Frcm page 14-204 A {26P}
TCM CONNECTOR
MeasuroATP S Voltage:
1. Shittto E position.
the Ag and A13 or A26 termi_
nals.
Repairopen in lhe wire between
the A8 terminal and the A/T gear
oo3iiion swilch.
MeesureATP L Voltage:
the A7 and A13 or A26 termi_
nals.

the A7 termin.l and th€ A/T goar
oosition switch.
Checkfor loose TCM connectors.

lf necessary,sub3titute a known'
14-205
TroubleshootingFlowchart - lgnition Goil
. OBD ll ScanTool indicat€sCode PosFiblsCause

P0725. . Oisconnectedignition coil con-
' Selt-diagn6is E indicaior tight
ngctor
indicat6sCod6 'l 1. . Short or op6n ignition coil wire
. Faulty ignition coil
Maasu.oNE Voltag6:
1. Disconnectthe A l26p) con-
nectorfrom the TCM.
2. Startthe engine.
the A5 and A13 or 426 termi,
nals.
Repair open or short in the wiro

between the A5 torminal and ths
ignition coil. f wire is OK, chsck
the ignhion coil tost {see section
23l..
Chock tor loose TCM connector.

It nec$sary, sub3titute a known-
Ii
14-206
TroubleshootingFlowchart- ManifoldAbsolutePressure(MAP)Sensor
. OBOll ScanTool indicat$ Code Po$iblo Causo
P1793. . Dilconnoctodmanitold absolute
. Self.diagno.i3E indicator light prG3u.a {MAP} sensor connoc_
indicat* Cods 12. lol
. Short or opan in MAP 3on3o.
MAP s€nsol
Check tor Anolhor Coda or MIL

Blinking:
2. Checkwhetherthe OBOll scan
tool indicatesanother code or
IndicatorLamP
the Malfr.rnction
(MlL)blinks(seesection11).
DoestheOBDllscantool indicate Repair PGM-Fl syltem 13663ec'

anothercodeoristhe MILblink- tion 111.
ing?
TCM CONNECTORS
Mca3uroVREFVohtge:
l. Turnthe ignitionswitchOFF
2. Disconnect the A (26P)and B
( 2 2 P )c o n n e c t o r sJ r o m t h e
TCM,
the 820 and A13 or A26 termi- WHT/REO
nals.
WIRESIOEOF F€MALETERMINALS
R6pai. opon ot short in ths wire

ls thereapprox.5 V? botw.on the 820 tolminal and
rhe ECM.
Moasur. MAP (PBlvoltago:

Measurethe voltage betweenthe
82 and A13or 426 terminals.
Repair open or shon in the wire

ls thereapprox.3 V? botween tho 82 terminal and tho
MAP s€nsor.
Ch€cktor loo3eTCM connectors.

lf n6ce$ary, 3ubstitut6 a known'
good TCM and rech6ck.
14-207
TroubleshootingFlowchart - Shift Control Linear Solenoid
. OBD ll ScanTool indicatesCode Possibl€Cau3e

P1870. . Disconnectedsolenoid harness
. Selt-diagnosisE indicator light
connector
indicetesCod€ 30. . Short or op6n in shift cont.ol
linear solonoidwire
. Faulty shift control linear solc- SOLENOIDHABNESS
noid 8P CONNECTOR
8LU/WHT
MeasureShift ControlLine.r Sole-
noid Resistanceat lhe Solenoid
HarnessConnector:
fromthe solenoidharnesscon-
nector.
2 , M e a s ur e t h e r e s i s t a n c e
beNveenthe No. 3 and the No. GRN/YEL
7 terminalsofthe solenoidhar
nessconnector. TERMINAL
SIDEOF MALETERMINALS
ls the resistance
3.8 6.8O?
TCM CONNECTOR
A I26PI
o GRN/YEL
I 3 a 7 8 9 l 0 1 1 12
Check Shift Control Linear Sole-
noid for a Shon Circuit:
11 l5 16 1 7 20 23 26
1 . D i s c o n n e ct th e A ( 2 6 P )c o n BLU/YEL
nectorfrom the TCM.
o
body ground and the 43 ter-
m i n a la n d t h e A 1 6 t e r m i n a l
individually.
WIBESIDEOF FEMALETERMINALS
Repairshorl in the wi.es be'tween

ls thereconlinuity? the A3 and A16 terminals and the
body ground.
GRN/YEL
''
M a a s u r eS h i f t C o n t r o l L i n e a r 11 2 4 5 I I 1 0 1 t 1 2 13
SolenoidR6istance:
1. Connectthe 8P connectorto t'Ft 17 m 23 25 26
the solenoidharnessconnec BLU/YEL
tor.
rJetween the A3 and A16 ter-
mt n a l s .
Repair loose terminal or open in

3.8- 6.8g?
ls the resistance the wires between the A3 and
A16 terminals and the solenoid
harnessconnector.
Checklor loose TCM connectors.

ll nece$ary, substitute a known-
14-208
Flowchart- PH-PLControlLinearSolenoid
Troubteshooting
OBD ll ScanTool indicat€sCodo Po$ib16Cau3e

P1873. . Disconnectedsolonoid hatn8s
Self-diagnosisE indicrtor light connectol
indicat€sCodo 31. . Short or opon in PH_PLcontol
linear 3olenoidwire
. FaultyPH-PLcontrol linear sole_
noid
SOLENOIDHARNESS
Mgasure PH-PLControl Lineet 8P CONNECTOR
Solenoid Rgsistancaal th6 Sole- GRN/WHT
noid Harne3sConn6ctor:
from the solenoidharnesscon-
nector.
betweenthe No. 2 and the No.
6 terminals of the solenoidha.
nessconnector. PNK/BLK
TERMINAL
ls the resistance3.8- 6.8 0?
A (26P)
TCM CONNECTOR
o PNK/BLK
Check PH-PLControl Linoar
Sol.noid tor a Short Circuit: 1 1 5 8 I 1 0 1 1 12 1 3
1. Disconnectthe A (26P)con-
nectorfrom the TCNI. 11 15 11 20 23 25 26
body ground and the A2 ter_ LGRN/WHr
minaland the A15terminal
iodividually. o
R6pair 3hort in the wires

between the A2 and 415 tormi-
nals and the body ground.
Mea3ure PH-PLControl Linear

- l PNK/BLK
_J()l-
Solsnoid Ro3istance:
1. Connectthe 8P connectorto t , t . 3 a 8 9 t 0 11 12 1 3
the solenoidharnessconnec- 20 23 25 26
tor. u1l] 16 1 7
2. Measure the resastance GRN/WHT
betweenthe A2 and A15 ter-
manals,
Ropair loosa terminel or opon in

ihe wires between the A2 and
3.8- 6.80?
ls the resistance A'15torminals and the solonoid
haJnessconn6ctor.
Ch.ck for loosa TCM connectors.

It nece$ary, substhuto a known_
good ICM and rech€ck.
14-209
TroubleshootingFlowchart- Start ClutchControlLinearSolenoid
. OBOll Sc.n Tool indicst$ Code PossibleCrule
P1879. . Disconnectodsol.noid harno33
. Selt-diagnosisE indicator light
connoctot
indicatesCode32. 'Sho.l or opan in 6tart clutch
control lineff solonoidwire
. Faulty 3tart clutch control lineat
solenoid
SOLENOIDHARNESS
Measuro Slan Clutch Control 8P CONNECTOR
Lin€arSolenoidRosistanceat the YEL
Solenoid HarnessConnoqtor:
nector,
betweenthe No. 4 and the No.
8 terminalsofthe solenoidhar-
nessconnector. PNK/BLU
ls the resistance3.8 - 6.8 O?
TCM CONNECTOR
A I26P)
o PNK/BLU
Check Start Clutch Control Lin-
ear Solonoidtor a Shori Circuitr
1. Disconnectthe A (26P)con- 1 2 3 I 5 7 E 9 1 0 1 1 12 1 3
nectorfrom the TCM. 1 a t5 1 6 20 23 25 26
2. Checkfor continuity between
body ground and the A1 ter- IYEL
minaland the A14terminal
individually.
0)
R6pair short in the wir6s
betwoen th6 Al and A1{ lermi-
nals and the body grcund.
Measu.6 51.n Clutch Cont.ol PNK/BLU

LinoarSolenoidRo3istance:
1. Connectthe 8P connectorto
the solenoidharnessconnec-
tor.
F
Jr
2 3 il 5
a 15 1 6 1 7
7
20
8 9 10
23
12 1 3
25 26
betweenthe A1 and 414 ter- I YEL
mrnals.
Repair looae tormin.l o. open in

ls the resistance3.8 - 6.8 O? ih. wir6s botwoen th€ Al snd
414 terminals and tho solenoid
htanos3connectot.
Checkfor loos€ TCM connsctors.

lf necossary,substitute a known-
14-210
TroubleshootingFlowchart - lnhibitor Solenoid
. OBD ll ScanTool indicatesCode Po$ible Cause

P1882. . Disconnectedsolenoid harn6s3
. Self-diagnosisE indicator light connectol
indicatesCode33. . Short or open in inhibitor sol.'
noid wi.e
. F.ultv inhibhor solenoid
M€asureInhibitorSolenoidRe3ist' SOLENOIDHARNESS
a n c e a t l h e S o l e n o i dH a r n e s s 8P CONNECTOR
Connector:
1. o;sconnectthe 8P connector
f r o m t h e s o l e n o i dh a r n e s s
connector.
2 . M e a s ur e t h e r e s l s t a n c e
betweenthe No. 5 terminalof
the solenoidharnessconnec_
tor and body ground-
TERMINAL
11.7- 21.0A?
lsthe resistance
TCM CoNNECTORB l22p)
Check Inhibitor Solenoid for a

Short Circuit:
1 . D i s c o n n e ct th e I ( 2 2 P )c o n -
nectorfrom the TCM.
t h e B ' 1t e r m i n a la n d b o d y
ground.
WIRES|OEOF FEMALETERMINALS
Repair3hort in the wire between

the B1 and the body ground.
MeasurelnhibhorSolenoidResisl'
ance:
1. Connectthe 8P connectorto
the solenoidharnessconnec_
IOr.
2 , M e a s ur e t h e r e s i s t a n c e
betweenthe B1 and body
ground.
ReDairloose terminal or open in

11.7-21.0{l?
ls the resistance the wire between the Bl and the
solenoidharnessconnectoa.
Checktor loose TCM connectors.

lI necessarv,substitute a known-
14-211
g
TroubleshootingFlowchart - Drive pulley Speed Sensor
\
. OBD ll ScanTool indicatosCode Po$iblo Cause
P18a5. . Dbconnectod drivo pulloy lpocd
. Selt-diagnosisEl indicator tight
30n301connectot
indicat$ Codo3{. . Shon or op.n in diiv. pulley
tpasd sonaorwire
. Faulty drivr pull.y sp..d ron-
soa
ls the drivepulleyspeedsen-
sor installedproperly?
ORIVEPULEY SPEED
SENSOR2P CO NECTOR
Measurc D.iv6 Pulloy Spe€d Sen-

sor Rasistlnce st the SorBor Con-
n€ctoJ:
t|;Trl
*r-r
from the drive pulley speed
sensorconnector,
2. Measurethe resistance
drivepulleyspeedsensor.
ofthe
t9
LJ
TERMINALSIDEOF MALE TERMINALS
ls the resistance350 - 600 O?
\
B (22P}
TCM CONNECTOR
Check Driv6 PullGySpood S.n- RED/BLU
sor for s Short Ci.cuit:
1. Disconnectthe B (22p)connec-
torfromtheTCM.
2 4 5 6 , E 9 t0
2. Checkfor continlity between
body groundand the Bl0 t€r, 12 t3 1 1 t5 1 6 1 ' 1 8 m
m i n a la n d 8 1 7 t e r m i n a il n d i -
GRN
vidually.
t,
nepair shon in th. wiags botween
the B10.nd 817 torminals 6nd
the driv6 pulley sp€€d 3onso.. WIRESIOEOF FEMALETERMINALS
MeasuroDrivo PulloySpood Sen-

sor R6ktanco;
1. Connectthe drive pulleyspeed
sensor2P connector,
betweenthe 810 and 817 ter- REO/BLU
minals.
I 2 a 5 iTiT;f;Fdz
ls the resistance350 - 600 0?
RepaL looro toiminal or open in
tha wiro3 betw6on tho Bto rnd
12 1 3 1 a t5 16 ,I,ElVdVV
817 t.rminak .nd the driv6 oul- GRN
lay !p6od a€n3or.
Chock lor looso TCM connestor.

lf necessary.sub3titute e known-
14-212
Troubleshooting Flowchart - Driven Pulley Speed Sensor
' OBD ll ScanTool indicat€sCode PossibleCause

P1846. . D i s c o n n e c t e dd t i v e n P U l l e y
. Solt-diagnosisE indicator light 3pegdsensorconnec'tor
indicatesCode 35. . Short or open in driv6n PulleY
so6€dson3orwire
. Faulty driven pulley speed sen_
Checkthe driven Pulley sPeed

s e n s o r i n s t al l a ti o n ,
DRIVENPULLEYSPEED
ls the drivenpulleyspeedsen- SENSOR2P CONNECTOR
sor installedproperly?
t- r-_- l
MeasureDrivenPulloySpeedSen-
-T-r
l t1 | 2 |
lL +
sor Resistanceat the SensorCon-

nector:
1. Disconnectthe 2P connectol
lt @
l
from lhe driven PUlleYspeed
sensorconnector- t_.1
2. Measurethe resistance of the
drivenpulleyspeedsensor, TERMINALSIDEOF MALETERMINALS
350 6000?
ls the resistance
B (22P)
TCM CONNECTOR
WHT
Check Driven Pulley Speed S€n- 0 o
sor for a Short Citcuit:
1. Disconnect the B (22P)connec'
torfromtheTCM. a 5 6 8 10
2. Checkfor continuitybetween 12 13 14 15 1 6 1 7 1 8 20
body ground and the 88 ter
minaland 89 terminalindivid-
uaIy.
Reoairshort in the wir€s bgtween

ls therecontinuity? th€ 88 .nd 89 terminals and the WIRESIDEOF FEMALETERMINALS
driven pulley spoedsensor.
MeasuleDrivenPulloySpeodSon- RED/BLUI WHT

sor Resistance: Al
1 . C o n n e c t h e d r i v e nP U l l e Y \j/
speedsensor2Pconnector.
2 , M e a s ur e t h e r e s i s t a n c e 2 a 6 8 10
1
betweenthe 88 and Bg termi
nals, 12 1 3 1 4 1 5 1 6 1 7 1 8 20
Eepair loose t€rminal or opon in

th€ wires botween the 88 and Bg
350 600O?
ls the resistance
lerminals and the driven Pulley
soeedsensoJ,
Check lor loose TCM connector.

lf necessarv,substitute a known'
good TcM and recheck.
14-213
TroubleshootingFlowchart - SecondaryGear Shaft Speed Sensor
. OBD ll ScanTool indicatesCod€ PossibleCause

P1884. . Disconnecled3econdarygea.
. Self-diagnosisE indicalor light
shaft speedsonsorconn€ctot
indicatesCode36. . Short or open in s€condarygear
shaft speedsonsorwire
. Faulty secondary 9ea1 3haft
Check the secondary gear shatt

speed sensor installation.
SECONDARY GEARSHAFTSPEED
ls the secondary
gearshattspeed SENSOR2P CONNECTOR
sensorinstalledproperly?
lT- T ---1
t l l 2 l
Measur€SecondaryGear Shaft -T--T-
ta
Speed Sonsor Resistanceat the
Sensor Connectoa:
from the secondarygearshaft t l
speeosensorconnector.
2. Measurethe resistanceofthe
L__l
secondarygear shaft speed TERMINAL
350- 600O?
ls the resistance
B (22PI
TCM CONNECTOR
Ch6ck Count€rsheft Speed Sen-
sor for a Short Circuitl
1. Disconnectthe B (22P)connec, 1 a 5 6 8 9 10
tor from the TcM. 12 1 3 '14 1 5 1 6 1 7 1 8
20
body groundand the 815 ter-
WHT/REDT '1 ORN/BLU
m i n a la n d 8 1 6 t e r m i n a il n d i
vidually. o) (o
Ropairshort in the wires betwoen
ls there continuity? the 815 end 816 terminals and WIRESIOEOF FEMALETERMINALS
the socondary g6ar 3haft speed
sensor.
MeasureSeconderyGoar Shaft
Sp€edSensorResistance:
1 . C o n n e c t h e s e c o n d a r yg e a r 2 1 8 10
shaftspeedsensor2P connec- 12 13 14 15 16 1 7 l8 20
tor,
betweenthe 815 and 816 ter-
mtnals.
WHT/REI
A
I
ORN/BLU
Bepair loose terminal or oDen in

350- 600O?
ls the resistance the wires b€tween the 815 and
816 terminals and the secondery
gearshaft speedsensor.
Check tor loose TCM connector.

It nocessary,substitute a known-
14-214
TroubleshootingFlowchart- TMA and TMB Signals
. OBOll ScanTool indicate3Code Po$ible Csuse

P1665. . Short or open in TMA wire
. Seff-dirgnosisE indicator light between B? terminal and ECM
indicstosCod€37. . Short or oDenin TMB wire
B I22P)
TCM CONNECTOR
beiwoen 86 terminal and ECM
. Faultv ECM GRY
' F.ultv TCM o
CheckTMA Wire ContinuitY: a 6 t 7 8 10
I 2 I
2. Disconnectthe B (22P)con- 1 2 't3 1 a 1 5 1 6 1 7 1 8 20
nectorfrom the TCM.
3 . D i s c o n n e ctth e C ( 3 1 P )c o n
nectorfrom the ECM. C 131P)
ECMCONNECTOB
4. Checkfor continuitybetween GRY
t h e 8 7 t e r m i n a lo f t h e T c M
and the Cg terminalof the 2 3 1 sJs;lI I
ECM.
1 1 12 t 3 t 4 16 17lle/t./ 22
// // l2s
R€pairopen in the wiro between WIRESIDEOF F€MALETERMINALS

the TCM and the ECM.
GRY
I
ChockTMA wite lor a Shorl Ci.-
cuiti 1 1 5 7 8 I 10
Checklor continuitybetweenthe
87 terminalof the TCM or the Cg 12 13 1 4 1 6 1 7 18 20
t e r m i n a lo f t h e E C M a n d b o d y
ground.
C {31P)
ECMCONNECTOR
ls therecontinuity?
GRY
Checkthe ECM:
1 . R e c o n n e ctth e C { 3 1 P )c o n
nectorto the ECM,and the B
{22P)connectorto the TCM. 1 2 I 5 6 7 8 10
2. Turnthe ignitionswitchON (ll). t 5 1 7r 8
11 12 1 3 1 4 t/
t h e c 9 t e r m i n a lo f t h e E c M 4r 30
and body ground.
Checkfo. loose ECM connectors.

ls thereapprox.10V? ll necessary,substitute a known'
good ECMand r€check.
To page14-216 {cont'd)
14-215
TroubleshootingFlowchart - TMA and TMB Signals (cont'dl
ftom page 14 215
TCM CONNECTOR
B I22P}
CheckTMB Wire Continuity:
2. Disconnect the C 13'1P) connec
PNK
o
tor from the ECM.and the B
{22P)conneclorfrom the TCM.
3. Checkfor continuitybetween I 2 4 I | 9 10
t h e 8 6 t e r m i n a lo f t h e T C M 12 1 3 1 4 l 5 17 18 20
a n d t h e C 3 0t e r m i n a lo f t h e
ECM. ECMCONNECTOR
C {31P}
1 2 4 sl67 I 9 10
1 12 t 3 l 4 16 1 1 81/r,/)/
ls therecontinuity? Repeir open in the wi.o between
the TCM and th6 ECM. LA WU 14+
PNK I
WIRESIDEOF FEMALET€RMINALS
CheckTMB Wire tor a Short Cir-

cuit:
PNK
Checkfor continuitybetweenthe o
8 6 t e r m i n a lo f t h e T C M o r t h e
C 3 0t e r m i n a lo f t h e E C M a n d
body ground. 2 4 5 7 8 10
1 2 1 31 a 1 5 1 6 1 7 1 8 20
ls therecontinuity?
check th6 TcM:

1 . R e c o n n e ctth e B ( 2 2 P )c o n -
PNK
nectorto the TCM, and the C
(31P)connectorto the ECM.
2. Turnthe ignitionswitchON {ll}.
3, Measurethe voltage between 1 2 4 6 1 8 9 't0
t h e 8 6 t e r m i n a lo f t h e T C M 12 1 3 11 '15 16 17 l8 20
and bodyground.
ls thereapprox.5 V?
CheckIor loose TCM connectors.

lf nece3sery,substituto a known-
good TCM and r€check.
14-216
TroubleshootingFlowchart- Shift ControlSystem
. OgD ll Sc.n Tool indiclt6 Codo PoasiblaC.uta
P1890. . Faulty shitt control rystom
. S.lt diagno.b E indicator ligl|t
indic.tG Codo 42.
Ch6ckfor Anoth.r Cod.:

check wh€ther the E] indicator
light indicatessnother code.
Parlorm lha Troubl63hooting

lsthe E indicatorlight indi- Flowch.rt tor thc indicttcd
cato anothercod6? Codolrl.
Ch.ck Stlll Spo.d RPM:

M e a g u r et h e s t a l l s p e e d R P M
(seepag6 14-230).
ls the stall speedover 3,500rpm?
lsthe stallsoeedb€low 2,000rPm?
T.!l-drivo .nd Ch.ok Engina

Spa!d:
t. Driv€ the vehicle at 30 mPh
(50 km/h) constantly for sev-
eral minutes,
2. Checkthe enginesps6d.
ls th6 engino speedwithin tho

spocification(se6 page 14-228
and 1+229)?
14-217
TroubleshootingFlowchart - Start Clutch Gontrol System
. OBD ll ScanTool indicatesCode PossiblGCause

P1891. . Feulty start clutch control sys-
. Selt-diagn€b E indicator tight
tem
indicatesCode43.
Checkfor Another Code:

C h e c kw h e t h e rt h e E i n d i c a t o r
light indicates anothercode.
ls the E indicatortightindi P e r l o r mt h e T r o u b l e s h o o t i n g
cateanothercode? Flowchart for the indicatod
Code(sl.
Test Start Clutch Operationl

2. oisconnectthe 8P connector
3. Startthe engine,and shift to

E position.
4 . C h e c kw h e t h e r t h e v e h i c l e
moves,
ooes the vehiclemoveT Replacothe stan clutch,assemblv.
CheckCreepingSpeed:
2. Reconnect the 8P connectorto
the solenoidharnessconnec,
tor.
3. Stan the engine,and shift to
E position.
4 . C h e c kw h e t h e r t h e v e h i c i e
creeps,and checkthe creep,
ing speed.
Doesthe vehicle move and is

the creeping speed approx. 3
mph (5 km/h)?
To page 14-219
14-218
Frompage14-218
ChockStall SpeedRPM:
Measurethe stallsooedRPM(see
page14-230).
ls the stall sDeedover 3,500rpm?
Warm Up Eogine and Roch€ck

F.ilure:
1 . W a r m u p t h e e n g i n et o n o r
mal operating'aemperature
lthe radiatorfan comeson).
2. Checkwhetherthe startclutch
problemappearsagain.
The syst6m k OK rt this time.
a
14-219
g
TroubleshootingFlowchart- E] IndicatorLight DoesNot ComeOn
The E Indicator tight does not

come on whon lhe ignition switch
is first turned ON (lll. (lt should
come on tor about two seconds.l
Checkthe ServiceChockConnec-
tot:
Make sure the specialtool 1SCS
S e r v i c eC o n n e c t o r i)s n o t c o n
nectedto the servicecheckcon-
nector,
ls the specialtool (SCSService Disconnsctth6 sDecialtool trom

Connector) connected to the ser- the sgrvice chgck connector and
vicecheckconnector? recheck.
Checkth€ E Indicator Light:

Shiftto E position.
Does the E indicator light Chocktor loosc TCM connector3.

ff n6cess6ry,3ubstituta e known-
good TCM and rachock.
A (26P)
TCM CONNECTOR
BLI i r ( [ ,
Checkthe Ground Circuit:
2 . D i s c o n n e ct th e A ( 2 6 p )c o n -
nectorfrom the TCM. 1 a 8 9 1 0 t 1 12 a
l-
t h e A 1 3 t e r m i n a la n d b o d y
14 15 16 1 7 20 23 25 a
ground and the 426 terminal BLK
and body ground.
(o
WIRE SIDE OF FEMALE TERMINALS
. Repair opan in the wi.€s

ls there continuity? botwean lho A13 or A26 termi-
nalsand G101.
. Repairpoor ground ic101).
Io page 14 221
From page 14 220
A (26PI
TCM CONNECTOR
BLK/WHT I BLK
Measure Power SuPPIYCircuil
Voltege:
(v)
1. Turnthe ignitionswitchON (ll). YI
2. Measurethe voltagebetween 1 2 I 5 I 9 '10 l t 1 2
terminalA s 1 2a n dA 1 3 a n d
b e t w e e nt e r m i n a l sA 2 5 a n d t a 15 16 1 7 20 23 25 26
426.
)
BLK/WHT BLK
Repairopen or short in the wiro
between the Al2 and/or A25 ter-
ls Ihere banery voltage? minals and the undeFdashfuse
box.
MeasureO IND Voltag6:

2. Connectthe A 126P)connec'
tor to the TCM.
3. Connecta digital multilester
10the A20 and A13 or A26ter
mrnals.
Turnthe ignitionswitchON (ll),
and makesure that the voltage GRN/BLK
is availablefortwo seconds
Check tor oDen in the wire

b€tween the A20 terminal and
lhc gauge assembly. lf the wire
is OK, check for a faulty El indi-
cator lighl bulb or a faulty gauge
assomblyprinted circuit boa.d A (26P}
TCM CONNECTOR
CheckD IND lor an Short Ci.ctlit:
1. TLrrnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e A ( 2 6 P )c o n
nectorfrom the TCM.
the A20terminalandthe No.I
terminalof the gaugeassem-
bly connectorlseesection23).

ls there continuity? the A20 terminal and the gauge
essemblY,
WIEESIDEOF FEMALETERMINALS
Checktor loose TCM connectors.
C h e c kt h e A / T g e . r p o s i t i o n
switch. lf necessary.substitute a
known-good TCM and recheck.
14-221
TroubleshootingFlowchart- El IndicatorLight On Constantly \
Tho llj indicator light b on con-

stantly {not blinking}whenev.r
the ignition switch b ON (ll).
TCM CONNECTOR
A I26PI
Mea3ureD IND Voltag6:

1. Turnthe ignitionswitchOFF. 1 2 3 { 7 8 9 10 t l 12 13
2 . D i s c o n n e ct th e A ( 2 6 P )c o n - t4 15 1 5 1 7 20 23 25 26
nectorfrom the TCM.
3. Turn the ignitionswitchON {ll). GRN/8LK
t h e 4 2 0 t e r m i n a la n d b o d y
ground.
Repairshort to powsr in the wir.

botwoon tha A20 t6rminal .nd
lhs gaug€ essombly.
Me.3ur6 ATP OVohage:

2. Connectthe A (26P)connec-
tor to the TCM.
3. Turn the ignitionswitch ON (ll). 2 3
1 I 5 E 9 l0 I t 12 1 3
4. Shiftto any positionotherthan
E. ta l5 1 6 1 1 20 23 E 26
t h e A S t e r m i n a la n d b o d y
ground.
Chock tor a short lo ground on

the wire. It wiro i3 OK, roplaco
the A/T goar pGition indic.tor.
rd
14-222
LinearSolenoids/lnhibitor
Solenoid
Test
'L
Disconnect
the 8P connectorfrom the solenoidhar- 7. lf all of the resistancesare within the standard,a
nessconneclor. c l i c k i n gs o u n d s h o u l db e h e a r dw h e n c o n n e c t i n g
the batteryterminalsto the solenoidharnesscon
2. M e a s u r et h e r e s i s t a n c o
e f t h e s h i f t c o n t r o ll i n e a r nectorterminalsbelow:
solenoidbetweenthe No. 3 and No. 7 terminalsof
the solenoidharnessconnector. . Shift control linear solenoid
No.3: Battervpositiveterminal
3. lMeasurethe resistanceof the PH-PLcontrol linear No.7: Batterynegativeterminal
solenoidbetweenthe No. 2 and No. 6 terminals. . PH-PLcontrol linear solenoid
No.2: Baftervoositiveterminal
Measurethe resistanceof the start clutch control No.6: Batterynegativeterminal
linearsolenoidbetweenthe No. 4 and No. 8 termi- . Start clutch control linear solenoid
nals. No. 4: Battervoositiveterminal
No. 8: Batterynegativeterminal
3.8- 6.8 o
STANDARD: . lnhibitorsolenoid
No. 5: Batterypositiveterminal
M e a s u r et h e r e s i s t a n c eo f t h e i n h i b i t o rs o l e n o i d Bodyground:Batterynegativeterminal
betweenthe No. 5 terminaland body ground.
11.7- 21.00
STANDARD: SOLENOIDHARNESSCONNECTOR
SOLENOID
HARNESS
CONNECTOR
8. l f n o c l i c k i n gs o u n d i s h e a r d ,r e p l a c et h e l o w e r
valvebody assembly.
N O T E |l f t h e l o w e r v a l v e b o d y a s s e m b l yr e p l a c e -
ment is required,see Lower Valve Body Assembly
Replacement {page'1 4-234).
ATF DIPSTICK
6. Replacethe lowervalve body assemblyif any of the

solenoidsresistance
is beyondthe standard.
14-223
Drive Pulley/DrivenPulley/SecondaryGear Shaft Speed
Sensors
Replacement
\ ,
CAUTION: While replacingthe speed sensor,be sure not to allow dust and other loreign particles to enter into the ttans-
mission.
1. the drive pulley,the drivenpulley,or the secondarygear shaftspeedsensorconnector.

Disconnect
2. Removethe 6 mm bolt from the transmissionhousing,and removethe drive pulley.the driven pulley,or the sec-
ondarygear shaftspeedsensol.
3. Replacethe O-ringwith a new one beforereinstallingthe drive pulley,the driven pulley,or the secondarygear shaft
sDeedsensor.
6x1.0mm
12 N.m {1.2kgf.m, 8.7 lbl.ftl
DRIVENPULLEY
SPEEO
SENSOR
6x1.0mm
12 N.m (1.2kgf.m,
8.7 tbf fr)
14-224
Start ClutchControl
Start Clutch CalibrationProcedure
NOTE:When the following partsare replaced,the TCM S h i f t i n t o E o r E p o s i t i o n .T o s t o r e t h e e n g i n e
must memorizethe teedbacksignalfor the start clutch negative pressure in memory, let the engine idle in
control. E or E position for one minute under the follow-
ing conditionsl
o TCM
. Transmission assembly . With the brake pedal depressed.
. Startclutchassembly . With the A,/Cswitch OFF.
. Lowervalvebody assembly . Wilh the combination light switch OFF.
. Engineassemblyor overhaul . With the heater fan switch OFF.
. Turn OFF all other electrical systems.
'96
Mod€l Only
NOTE: Start step 5 w;thin 60 seconds after the radi-
CAUTION:Do not use this procedureon'97 -'98 mod. ator Ian goes off.
els or you will damagethe transmission.On'97 -'98
models, the TCM memorizes the feedbacksignals when Shift into E position, and let the engine idle lor two
you drive the vehicle. minutes to store the feedbacksignal in memory
under the same conditions as in step 5.
1 . E n g a g et h e p a r k i n gb r a k e ,a n d b l o c kt h e f r o n t
wheelssecurely. 7. Connect the Honda PGM Tester. Check that the TCM
has completed the start clutch calibration.
2. Connectthe SCS serviceconnectorto the Service
C h e c kC o n n e c t o ra s s h o w n . ( T h e S e r v i c eC h e c k NOTE:
C o n n e c t o r( 2 P )i s l o c a t e du n d e r t h e d a s h o n t h e o The TCM will not storethe feedbacksignalwhen
passenger's side of the vehicle.) the CVTfluid temperatureis below 40'C (104'F)
even il the engine coolanttemperaturereaches
the normaloperatingtemperature.
a R e p e a t h e s e p r o c e d u r e su n t i l t h e s t a r t c l u t c h
calibrationis completed.
8. D i s c o n n e ctth e S C S s e r v i c ec o n n e c t o rf r o m t h e
ServiceCheckConnector.
'97 - '98 Models
The TCM memorizesthe feedbacksignalwhen you

drivethe vehicleas follows:
A f t e r w a r n i n g u p t h e e n g i n e( t h e r a d i a t o rf a n
(2PI
CONNECTOR CONNECTOR c o m e so n ) .
07PAZ- 0010100 Shift into E position.
a Turn OFFall electricalsystems.
a D r i v et h e v e h i c l eu p t o t h e s p e e d3 7 m p h { 6 0
km/h).
Start the engine,and warm it up to normal operat A f t e r t h e s p e e d r e a c h e s3 7 m p h ( 6 0 k m / h ) ,
ing temperature(the radiatorfan comeson twice). releasethe accelerator for 5 seconds.
4. Fullydepressthe brakepedaland accelerator

for 20
secondsin the E position.
14-225
Symptom-to-Gomponent
Chart
HydraulicSystem
SYMPTOM Checktheseitemson the PROBABLE
CAUSEList
Engineruns,but vehicledoes not move in anv position. 1 , 2 , 3 , 4 , 5 , 6 , 1 , 89,, 1 0 ,2 0 ,3 4 ,3 5 ,3 6 ,3 8 ,4 1
Vehicledoes not move in @, [, S positions. 10,11,12,20,41
Vehicledoes not move in B position. 5 , 1 0 ,1 1 ,1 2 ,1 1, 1 a ,1 9 , 2 0 , 3 94, 1
No shift to higherratio. 9 , 1 3 ,1 4 ,1 5 ,1 6 ,3 5 , 3 7 4
,0
Poor acceleration. 9 , 1 3 ,1 4 ,1 s ,1 6 , 2 0 , 3 5 , 3 7 , 3 a , 4 0
F l a r e so n m o v i n g . 9, 10,20,21,35,36, 38, 40,42
Excessiveshockwhen depressingand releasing
pedal.
accelerator 9 , 1 0 ,2 0 , 2 1 , 3 5 , 3 6 , 3 84,2
N o e n g i n eb r a k i n g . 9, 20,21, 35,36,3A
Vehicledoes not accelerate
in E position. 9, 17, 18,19,20, 35,36,38
Vehiclemovesin N position.
(Shiftcableadjustmentis proper). 10,22,23
Lateshiftfrom @ positionto D position,and from @

positionto E position. 10,11,12,22,41
Lateshiftfrom N positionto E position,and from E ' t 1 ,1 2 ,

positionto @ position. 1 7 ,1 A , 2 2 , 4 1
Enginestopswhen shiftedto @ positlonfrom N position. 9, 10,20,35,37,3A

42,
Enginestopswhen shiftedto E positionfrom E position. 9, 18,19,20,25, 26.35,31,38,42
Noisefrom transmissionin E position.*1 5 , 1 1, 1 8 ,1 9 ,2 5 , 2 6
Excessive
idle vibration.
Noisefrom transmissionin E and E positions.
2 , 3 ,8 , 2 1, 2 8
2 , 3 ,1 9 , 2 4 , 2 5 , 2 A
I
H u n t i n ge n g i n es p e e d . 16,35,37,38
Vibration in all position. a, 2a
Shift leverdoes not operatesmoothty. 1 1 , 2 9 ,4 ' l
Transmissionwill not shift into E positionor transmis-
sion cannotbe removedfrom p position. 11, 29,30,31,32,33
Vehicledoes not accelerate
to more than a certainsDeed. 9 , 1 0 ,1 4 ,1 5 ,1 6 , 2 0 , 3 5 , 3 1
Excessive
shockon staningoff. 38, 42
Flareson acceleratingat low speed. 20,21,34,42
vibrationin @, p, p, @ posirions.
Excessive 20,21,3A,42
Low enginespeedin [, [, p, @ positions. 2 0 , 2 1 , 3 84, 2
S t a l ls p e e dh i g h . 1 0 ,2 0 , 3 8
Stallspeedlow. 9 , 2 0 ,2 1, 3 7, 3 a
Judder on starting off. 20,43
*1: Somegear noiseis normalin the
E positiondue to planetarygear actton.
4-226
a CAUSELIST
PROBABLE
1 Low CVTfluid tevel
2 ATF pump worn. AT gearsworn or damaged.Foreignmaterialin ATF pump.
3 ATFpump chain/ATFpump sprocketworn or damaged.
4 I n p u t s h a f tw o r n o r d a m a g e d .
5 Sun gearworn or damaged.
F i n a ld r i v e n g e a r w o r n o r d a m a g e d .
1 drivengearworn or damaged.
Secondarydrive gear/secondary
8 plateworn or damaged.
Flywheel/drive
9 housingassemblyworn or damaged.
Intermediate
10 Forward clutch defective.
11 Shift cable broken/out of adiustment.
12 M a n u a l e v e rp i nw o r n .
t5 ATFfeed pipe (pulleypressure)worn or damaged.
14 pulleyspeedsensordefective.
Drivepulleyspeedsensor/driven
Vehiclespeedsensordefective.
TCM defective.
17 Reverse brake defective.
18 Reversebrakepistonand relatedpartsworn or damaged.
19 P l a n e t a rgye a rw o r n o r d a m a g e d .
20 Start clutchdefective.
21 ATFteed pipe lstartclutchpressure)worn or damaged.
22 Clutch clearance/reversebrake clearance incorrect.
23 Reversebrake return spring/retainerworn or damaged-
24 Needlebearingon input shaftworn or damaged.
25 r o r no r d a m a g e d .
T h r u s tn e e d l eb e a r i n go n c a r r i ew
Thrustwasheron carrierworn or damaged.
,1 E n g i n eo u t p u t l o w .
2a Flywheel assembly def ective.
29 C o n t r o ll e v e rw o r n o r d a m a g e d .
30 Parkingbrakepawl/parkingbrakepawl shaftworn or damaged.
brakerod assemblyworn or damaged.
Detentlever/parking
32 Parking gear worn or damaged.
Parkingbrakepawl springworn or damaged.
34 filter clogged.
ATFstrainer/ATF
35 Lower valve bodv assemblv defective.
36 Lowervalvebody assemblydefective(PLregulatorvalvebody assemblydefective).
37 Lowervalvebodv assemblvdefeclivelshiftvalvebody assemblydefective).
38 Lowervalvebodv assemblVdetective(startclutchcontrolvalvebody assemblydefective).
Lowervalvebodv assemblvdefectivelinhibitorsolenoiddefective).
40 Solenoid harness worn or damaged.
41 M a n u a lv a l v e b o d y w o r n o r d a m a g e d .
42 PBfeedbacksystemdelective,
43 CVTfluid deteriorated.
RoadTest
NOTE:Warm up the engineto normaloperatingtemperature{the radiatorfan comeson).
1, Apply the parkingbrakeand block the wheels.Start the engine,then shift to the E positionwhile depressingthe
brakepedal.Depressthe acceleratorpedaland releaseit suddenly.The engineshouldnot stall.
2. T e s ti n E p o s i t i o n
Parkthe vehiclein a slope (approx.16"),apply the parkingbrake,and shift into E position.Releasethe brake;the
vehicleshouldnot move.
3. Test-drivethe vehjcleon a flat road in the positionshown in the table,Checkthat the enginespeedsmeetthe approx-
imatevehiclespeedsshown in the table.
NOTETThrottlepositionsensorvoltagerepresentsthe throttleopening,To monitorthe throttlepositionsensorvolt-

age,useone of the followingmethods:
A. Connectthe HondaPGMTester,and go to the PGM-FIDataList.

OBo ll SCANTOOLoI
HONOAPGMTESTEB
B.'!. Removethe kickpanelto exposethe TCM for roadtesting;referto page 14-194.
2. Setthedigitalmultitesterto checkvoltagebetlveenthe 84 (+)terminalandA4(-) or A17 (-)terminaloltheTCM

for throttlepositionsensor.
I TCM
84 T6rmin.l
DIGITALMULTIMETER
BACKPROBE SET
II
lCommelcielly.v.ilabl.)
07sAz- 001000A KS-AHM-32-003
{two raquirad} or oquivilont
I BACKPROBE
AOAPTER
l STACKINGPATCH
CORD
TCM CONNECTORS
[''
I WIRESIDEOF FEMALETERMINALS
14-228
. E position: Engine Speedrpm
Vehicle Soeed
ThrottleOpening
25 mph (40 km/h) 37 mph (60km/hl 62 mph 1100km/hl
Throttlepositionsensorvoltage:0.75V 1,250 1,650

Throttlepositionsensorvoltage:2.25V 2,500 3,r 00 2,6s0 3,250 2,700 3,300
Throttlepositionsensorvoltager4.5 V 4,650 5,250
3,950 4,550 5,200 5,800
Fullthrottleposition
. E position:EngineSpeed.pm
Vehicle Speed
Throttle Opening
2s mph (40 km/h) 37 mph 160km/hl 62 mph (100km/hl
Throttlepositionsensorvoltage:0.75V 1,800- 2,200 2,200- 2,AOO 3,550- 4.150
Throttlepositionsensorvoltage:2.25V 2,950- 3,550 3,250- 3,850 4,050- 4,650
Throttlepositionsensorvoltage:4.5V 5,900- 6,500
4 , 1 0 0- 4 , 7 0 0 5,100- 5,700
positaon
Fullthroltle
. E position:EngineSpeedrpm
Vehicle SDeed
Throttle Opening
25 mph (40km/hl 37 moh 160km/h) 62 mph (100km/hl
Throttlepositionsensorvoltage:0.75V 3,' l00- 3,700 3,650- 4,250 4,450- 5,050

Throttle position sensor voltage: 2.25 V 3.500- 4,100 4,050- 4,650 4,800 5,400
Throttlepositionsensorvoltage:4.5 5,900- 6.500
4,100 4,700 5 , 1 0 0- 5 , 7 0 0
Fullthrottleposition
14-229
Stall Speed
Test
CAUTION:
. To preventtransmissiondamage,do notteststall speedfor more than 10 secondsat a time.
. Do not shift the lever while raising the engine speed,
. Be sure to remove the pressuregauge before testing stall speed.
. Stall speed tests should be used for diagnostic purposesonly.
1 . E n g a g et h e p a r k i n gb r a k ea, n d b l o c kt h e f r o n tw h e e l s .
2. Connecta tachometerto the engine,and startthe engine.
3. Makesurethe IVC switchis OFF
4. After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan comeson),shift into E position.
5. Fullydepressthe brakepedaland accelerator

for 6 to 8 seconds,and note enginespeed.
6. Allow two minutesfor cooling,then repeatthe test in E, E, and E positions.
Stall SpeedRPMin @ position:

Specilication:2,500rpm
ServiceLimit: 2,350- 2,650rpm
Stall SpeedRPMin p. I and @ positions:

Specification:
3,000rpm
ServiceLimit:2,800- 3,100lDm
TROUBLE PROBABLE
CAUSE
S t a l lr p m h i g hi n E , E , E , a n dE p o s i t i o n s Low fluid levelor ATF pump output
CloggedATF strainer
PH regulatorvalvestuckclosed
Slippageof forwardclutch
Faultystan clutch
S t a l lr p m h i g hi n @ p o s i t i o n Slippageof reversebrake
Faultystart clutch
Stallrpm low in Dl, p, [, and @ positions E n g i n eo u t p u tl o w
Faultystart clutch
Stuckshift valve
14-230
FluidLevel
Checking/Changing
CAUTION:while checkingand changing,be sure not to Changing
allow dust and other foreign particles to enter into the
transmission, 1. Bringthe transmissionup to normaloperatingtem-
perature(the radiatorfan comes on) by driving the
Checking . a r kt h e v e h i c l eo n t h e l e v e lg r o u n d ,a n d
v e h i c l eP
NOTErCheckthe fluid level with the engine at normal turn oif the engine.
operatingtemperature(the radiatortan comes on iust
2. Removethe drain plug,and drainthe CVTfluid.
1. P a r kt h e v e h i c l eo n t h e l e v e lg r o u n d .T u r n o f f t h e NOTE:ll a coolerflusheris to be used,see page14-

engine. '14-285.
284 and
2. Removethe dipsrick(yellow loop) from the trans-
mission,and wipe it with a cleancloth. 3. Reinstallthe drain plug with a new sealingwasher,
t h e n r e f i l l t h e t r a n s m i s s i o nw i t h G e n u i n eH o n d a
N O T E :C h e c kt h e t r a n s m i s s i o fnl u i d 6 0 t o 9 0 s e c - CVTFluidto the uppermarkon the dipstick.
onds aftershuttingoff the engine.
AutomaticTransmission FluidCapacity:
3. Insenthe dipstickinto the transmission.
3.9? 14.1US qt, 3.4 lmp qtl at changing
6.4{ (6.8US qt,5.5lmp qtl at overhaul
DIPSTICK{YELLOWLOOPI
RecommendedAutomaticTransmissionFluid:
GenuineHondaCVTFluid.
U s eG e n u i n eH o n d aC V Tf l u i do n l y .U s i n go t h e rt l u -
i d s c a n a f f e c t t r a n s m i s s i o no p e r a t i o na n d m a y
reducetransmissionlife.
l ChangeInterval:
NormalCondition:30,000miles(48,000kml
SevereCondition:30,000miles {48,000kml, but if
you drive at high speedsin high
4. R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l .l t t90"F {32"C1and abovel temper'
a t u r e s ,t h e t r a n s m i s s i o nf l u i d
shouldbe betweenthe upperand lower mark.
should be changed every 15'000
miles {24,000km).
5. lf the level is below the lower mark. add fluid rnto

t h e f i l l e r h o l e t o b r i n g i t t o t h e u p p e r m a r k .U s e DRAINPLUG SEALINGWASHER
G e n u i n eH o n d aC V TF l u i do n l y . 1 8x 1 . 5m m Replace.
49 N.m 15.0kgI m, 36lbfttl
Insenthe dipstickinto the transmission.
14-231
PressureTesting
L
. While testing, be careful of the rotating tront wheels.
. Make sure lifts, iacks, and safety stands are placed properly {seesection 11.
CAUTION:
. Belore testing, be sure the transmissionfluid is lilled to the proper level.
. Warm up the engine to normal operating temperature before testing.
. While testing, be sure not to allow dust and other foreign particles to enter into the transmission.
1. Raisethe front of the vehicle,and supportitwith safetystands(seesectionI).
2. Setthe parkingbrake,and blockboth rearwheelssecurelv.
3. Allow the front wheelsto rotatefreely.
Warm up the engine(the radiatorfan comeson),then stop and connecta tachometer.
5. Connectthe specialtoolto each inspectionhole.
TOROUE:18 N.m (1.8kgf.m,13 tbf.ft)
CAUTION:
' Connectthe oil pressureg.uge securely,be sure not to allow dust and other toreign particles to enter the inspec-
tion hole.
. When troubleshooting by the E indicator light indicatesa problem, you must use an oil pressuregauge that mea
sures 4,900kPa {4.90MPa, 50.0 kgflcnf, 711 psil or more when measuringdrive pulley pressureand driven pulley
Dressure.
NOTE:
. Drivepulleypressuremay be above3,430kPa(3.43MPa,35.0kgf/cmr,498psi)when there is a transmissionprob-
lem that causesthe TCM to go into the fail safemode.
. U s e a c o m m e r c i a l lay v a i l a b l eo i l p r e s s u r eg a u g et h a t m e a s u r e s4 , 9 0 0k p a ( 4 . 9 0M p a , 5 0 . 0k g t c m r ,7 1 1 p s i )
or
more,and the A,/TOil PressureHose,22j0 mm (071\itAJ - py40j 1A).
A/T OIL PRESSURE A/T PRESSURE HOSE A/T PRESSURE HOSE

GAUGE A/T LOW PRESSURE ADAPTER 2210 rnfi
SETw/PANEL GAUGEW/PANEL 07MAJ - PY40120 OTMAJ- PY4O11A
07406- 0020400 07406- 0070300 (4 Requirad) (4 Bequired)
FORWARDCLUTCHPRESSURE DRIVEPULLEYPRESSURE
INSPECTION HOLE REVERSEBRAKEPRESSURE
INSPECTION
( M a r k e dw i t h " F " ) lMarkedwith "DR") INSPECTION
HOLE
oJ.. ATF OIPSTICK

LUBRICATION PRESSUBE DBIVENPULLEY STARTCLUTCHPRESSURE
PRESSURE INSPECTION
INSPECTION HOLE HOLE
( M a r k ew
d ith " L U B " ) INSPECTION HOLE (Markedwith "SC")
(Ma.kedwith "DN")
14-232
Stan the engine.
rpm.
7 . shift to the respectiveshift leverpositionas in the table,and measurethe followingpressuresat 1,500
. ForwardClutchPressure
. ReverseBrakePressure
. DrivePulleyPressure
. DrivenPulleyPressure
8 . Shiftto E position,and measurethe lubricationpressure.at 3.000rpm
FLUIDPRESSURE
SHIFTLEVER
PRESSURE SYMPTOM PROBABLECAUSE
POStTtON Standard/ServiceLimit
'1.4- 1.75MPa
Forward E No or low for- Forward Clutch
Clutch ward clutch (14.3- 17.8kgtcm' , 203- 253psi)
pressure
Reverse E No or low ReverseBrake 1 . 4- 1 . 7 5M P a
Brake reversebrake (14.3- 17.8kgf/cm' ,203- 253psi)
a pressure
Drive E No or low ATF pump,PH reg- 0.2- 0.7 MPa
Pulley drive pulley ulatorvalve,PL (2 - 7.1 kgflcm' ,28- 101psi)
pressure regulatorvalve,
Shiftvalve
)a Drivepulley
pressuretoo
h i gh
PH regulatorvalve,
PL regulalorvalve,
Shiftvalve,Shift
controllinear
solenoid
Driven No or low ATF pump,PH reg' 1 . 5- 2 . 3M P a
Pulley drivenpulley ulatorvalve,Shift (15.3- 23.5kgficm' ,218- 334Psi)
pressure valve.Shiftcontrol
linearsolenoid
Drivenpulley PH regulatorvalve
pressuretoo
h i gh
Lubrication No or low ATF pump, Above0.2 MPa
lubrication Lubricationvalve (Above2 kgf/cm' ,30 psi)
pressure
q the specialtool afterpressuretesting.

Disconnect
1 0 . Installthe sealingbolt with a new sealingwasherin the inspectionhole,and tightento the specifiedlorque
TOROUE:18 N.m (1.8 kgf'm. 13 lbt'ft)
CAUTION: Koep all ol the foroign particles out of the transmission.
14-2?:t
LowerValveBody Assembly
Replacement
!@ Make sure lifts, jacks, and safety stands 7. Removethe ATF cooleroutletpipe.
are placed properly {seesection 11. 8. Removethe ATFcoolerDipebracketbolt.
9. Removethe ATF pan (fourteenbolts).
C A U T I O N :W h i l e r e m o v i n ga n d i n s t a l l i n gt h e l o w e r 10. Removethe ATF strainer(two bolts).
valve body assembly.be sure not to allow dust and 11. R e m o v et h e o n e b o l ts e c u r i n gt h e s o l e n o i dh a r n e s s
other toreign particlesto enter into the transmission. connector.
' 1 2 .R e m o v e
t h e l o w e r v a l v e b o d y a s s e m b l y ( e i gh t
1. Raisethe front of the vehicle,and suoDortit with bolts).
safetystands{seesection1}. JOINT BOLT
28 N.m (2.9 kgtm, 2l lbf.ft)
SEALING
Set the parkingbrake,and block both rear wheels Replace.
securely.
ATF COOLEE
OUTLETPIPE
3. R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
R e i n s t atl h
l e d r a i np l u g w i t h a n e w s e a l i n gw a s h e r
(seepage14-231).
CAUTION: Keep all ol other foreign particles out of O.RING

the transmission. Replace
SOLENOID
HARNESS
4. Disconnectthe 8P connectorfrom the solenoidhar CONNECTOR
nessconnector.
DOWELPIN
R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r 6x1.0mm
pipes,Turn the ends of the ATF cooler hosesup to 12 N.m {1.2kgl.m,
O-RING 8.7 tbf.tt)
preventATF from flowing out, then plug the ATF ATF Replace.
cooternoses. STRAINER
LOWERVALVE
BODYASSEMBLY
CAUTION: Keep all of other foreign particles out ot
the transmission. 6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbtft)
6. Removethe right front mounvbracket.
6x1.0mm ATF PAN GASKET
'10x 1.25mm Replace.
12 N.m 11.2kgt m,
44 N.m (,1.5kgtm, 33 lbnftl 8.7 rbtftl
ATF COOLERINLET
DOWELPIN PIPEBRACKETBOLT
RIGHTFRONT I x 1.25mm
MOUNT/BRACKET 26 N.m (2.7kgt.m,
/ 20 tbl.ft)
ATF COOLERPIPE 6x1.0mm

ATF PAN
12 N.m (1.2kgf.m,8.7lbl.ft)
1 3 . I n s t a l lt h e n e w l o w e r v a l v e b o d y i n t h e r e v e r s e
orderof the removalprocedure
CAUTION: Keep all of other toreign particles out of
the transmission.
C NOTE:
'10x 1.25mm
. Replacethe followingparts:
54 N.m (5.5kgt.m, - O - r i n g so n t h e s o l e n o i dh a r n e s sc o n n e c t o r
40 tbt.ft)
and the ATFstrainer
l-
- ATF pan gasket
S e a l i n gw a s h e r s
. l f t h e A T F c o o l e r i n l e t p i p e b r a c k e ti s b e n t o r
ATF COOLERHOSE warped,put it backto the originalposition.
1 4 . P e r f o r mt h e s t a r t c l u t c hc a l i b r a t i o np r o c e d u r eo n
p a g e1 4 2 2 5 .
14-234
ATFFilter
Make sure lifts, iacks, and safety stands 6. Removethe ATF cooleroutletpipe
@@
are placedproperly lsee section 11. 7. Removethe ATF coolerpipe bracketbolt.
8. Removethe ATF pan (founeenbolts).
CAUTION: While removing and installing the ATF filter, 9. Removethe ATF coolerinlet pipefrom the ATF pan
be sure not to allow dust and other foreign particles to {threebolts).
enter into the transmission. 10. Removethe ATFfilter,and cleanit.
11. Checkthat the ATFfilter is in good condition
1. Raisethe front of the vehicle,and support it with 12. Replacethe ATFtilter if it is clogged.
saletystands(seesection1).
JOINT BOLT
2. Ser the parkingbrake,and block both rear wheels 28 N.m 12.9kgl m, 2'l lblftl
securely. SEALING
Replace.
3. R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
Reinstallthe drain plug with a new sealingwasher ATF COOLEROUTLET
(seepage'14231). ATF COOLERINLET
6 x 'l.0mm PIPEBRACKETBOLT
12 N.m (1,2kgf m, I x 1.25mm
CAUTION: Keep all of other foreign particles out of
8.7 tbtft) 26 N.m (2.7kgt m,
the transmission.
R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r
Di9es.Turn the ends of the ATF cooler hosesup to
preventATF from flowing out, then plug the ATF
coolerhoses.
DOWEL
CAUTION: Keep all of othet loreign particles out ot
the transmission.
5. Removethe rightfront mounvbracket.
1 0x 1 . 2 5m m ATF P
44 N.m (4.5kgt'm,33lbfftl GASKET O.RING
Replace. Replace.
ATF PAN
RIGHTFRONT
MOUNT/BRACKET
6x1.0mm
12 N'm {1.2 kgl m, 8 7 lbf'ft}
't3. l n s t a l l t h e A T F f i l t e r i n t h e r e v e r s e o r d e r o f t h e
removal procedure.
10 x 1.25mm CAUTION: Keep all foreign particles out of the

54 N.m (5.5 kgf'm,
40 rb{ft1 transmission.
NOTEI
. Replacethe O-rings, the ATF pan gasket and
sealing washers.
ATF COOLERHOSE . lf the ATF cooler inlet pipe bracket is bent or
warped, put it back to the original position.
14-235
Transmission
Removal
@@
Make
4. Disconnect the solenoidharnessconnector,the drive
sure lifts, iacks, and safety stands are placed pulleyspeedsensorconnector,and the groundcable
pfoperly, and hoist bracket are attached to the cor- terminals.
rect position on the engine (seeseqtion 1).
Apply parking brake and block rear wheels, so the GROUNDCABLE
vehicle will not roll off stands and fall on vou while TERMINAL
GROUNDCABLE
working under it.
CAUTION:Use fender coversto avoid damaging painted

surfaces.
'L
Disconnectthe battery negative(-) terminal from
lhe battery.then removethe positive{+)terminal.
2. R e m o v et h e i n t a k ea i r d u c ta n d a i r c l e a n e h
r ousing
assemDty.
3. R e m o v et h e s t a r t e rc a b l e sa n d c a b l eh o l d e rf r o m
the startermotor.
DRIVEPULLEY
SPEEDSENSOR
CONNECIOR
STARTERMOTON SOLENOIOHARNESS
CONNECTOR
5. Removethe clip,then separatethe shift cablefrom

the controllever.
GAUTION:Take care not to bend the shift cable.

SHIFICABLE
WASHER
WASHER
STARTERCABLE
Ft CONTROLLEVER
14-236
6. Disconnectthe vehiclespeedsensor(VSS)connec- 8. R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V Tf l u i d .
tor, the driven pulleYspeedsensorconnector,and Reinstall the drainplugwith a new sealingwasher'
the secondarygear shaftspeedsensorconnector.
CAUTION:while installingthe drain plug, be sure
SECONDAFYGEAR DRIVENPULLEY not to allow dust and other foteign particles to
SHAFTSPEED SPEEDSENSOR
SENSOR enter into the transmission
CONNECTOR
F(A --
. . ,
,fi .
' - 1-
DRAINPLUG SEALINGWASHER
18x 1.5mm Replace.
SENSOR(VSSt irg N.m {5.0kgl m.36lbt'ft)
CONNECTOR
7. Removethe transmissionhousingmountingbolts.
9. R e m o v et h e s p l a s hs h i e l d .
(cont'd)
14-237
Transmission
Removal(cont'dl
10. Removethe cotterpinsand castlenuts,then separate 16. Remove the right front mount/bracket.
the balljointstrom the lowerarm (seesection18).
TF COOLERPIPE
ATFCOOLER
HOSE
1 t . Removethe right damper fork bolt, then separate 1 1 . R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r
r i g h td a m p e rf o r ka n d d a m p e r . pipes.Turn the ends of the ATF cooler hosesup to
preventCVT fluid from flowjng out, then plug the
1 2 . Prythe right and left driveshaftsout of the differen- ATFcoolerhosesand pipes.
tial.
NOTE: Checkfor any sign of leakageat the hose
Pullon the inboardjoint and the right and left drive, joints.
shafts(seesection16).
't Removethe enginestiffenersand the flywheelcover.
4. Tje plasticbagsoverthe driveshaftends.
NOTE:Coatall precisionfinishedsurfaceswith clean

e n g i n eo i l .
t5, Removethe exhaustpipe A.
r")
ENGINESTIFFENER
SELF-LOCKING
NUT r9. Remove the eight drive plate bolts one at time while
Beplace. rotating the crankshaft pulley.
SELF-LOCKING
NUT
Replace. EXHAUSTPIPEA
14-238
20. Removethe distributor. 2 3 . R e m o v et h e t r a n s m i s s i o nh o u s i n gm o u n t i n gb o l t
and rearenginemountingbolts.
t1 Attacha hoistingbracketto the engine,then lift the
e n g i n es l i g h t l y . REARENGINEMOUNTING
TRANSMISSIONHOUSING BOLT
MOUNTINGBOI-T
lP.-
WASHER
24. Pull the transmissionaway from the engine until it

22. Placea jack under the transmission,and raise the clearsthe 14 mm dowel pins, then lower it on the
transmissionjust enoughto take weight off of the transmissioniack.
mountbracket
mounts,then removethe transmission
MOUNT
TRANSMISSION
14-239
lllustratedIndex
Valve Body Assembly
Transmission/Lower \
14-240
O) ATF DIPSTICK
@ o-RINGReplace.
O SOI-ENOIDHARNESSCONNECTOR
O LowER vALvE BODYASSEMBI-Y
O DowEL PIN
O JoINT aoLT
€) ATF COOLERINLETPIPEBRACKETSOLT
@ A'F COOLERINLETPIPEASSEMBLY
o SEALINGWASHERReplace.
G, ATF COOI-EROUTLETPIPE
@ o-RING Replace.
Ci)ATF FILTER
@ o-RINGReplace.
G) ATF PAN
(9 DOWELPtN
@ O-RINGReplace.
€) ATF STRAINER
G} ATF MAGNET
@ ATF PAN GASKETReplace.
€) ATF MAGNET
@ DRAINPLUG
@ SEALINGWASHERBepIace,
Boh/Nut No. Torque Value Sizs Remarks
6A 12 N m (1.2kgf.m,8.7lbf'ft) 6x1.0mm
8F 26 N.m (2.7kgf.m,20lbf.ft) 8 x 1 . 2 5m m
'12x 1.25mm Joint bolt
12J 28 N.m (2.9kgf.m,21lbi'ft)
18D 49 N.m (5.0 kgnm, 36 lbf.ft) 1 8x 1 . 5m m Drainplug
14-241
lllustratedIndex
Transmission
Housing/Flywheel
Housing \
8G
I
P
14-242
af O-RINGReplace. !d O-RINGReplace.
le oll sEAl- Replace. LA STARTCLUTCHATF FEEDPIPE
:O FLYWHEEL HOUSING e3 o-RING Feplace.
i4l FLYWHEEL HOUSING GASKETReplace. 8 FEEDPIPEFLANGE
.1'-DIFFERENTIAL ASSEMBLY .O SNAPRING
G,IATF PASSAGEPIPEASSEMBLY @ CONNECTOR BRACKET
?l o-RINGReplace. €A BALI BEARING
i8')DOWELPIN @ SNAPRING
.' ATF PUMPASSEMBLY @ COTTERRETAINER
iio DOWELPlN, 18 x 10 mm @ COTTERS, 25.5 mm Selectivepart
ll O-RINGReplace. @ STARTCLUTCHASSEMBLY
a1aOOWELPlN, 22 x 10 mm 6I SECONDARY DRIVEGEARASSEMBLY
O ATF PUMPoRIvE CHAIN @ o-RINGSReplace.
.iOSNAPRING @ DIFFERENTIAL COVER
i9 THRUSTsHlM,22x 28 mm Selectivepan @ THRUSTsHlM, 25 x 35 mm selecrivepart
(10) ATF PUMPDRIVESPROCKET .4i SECONDARY GEABSHAFT
.1I PITOTFLANGE 6DPABKINGBRAKEPAWLSHAFT
.O ATF PUMPDRIVESPROCKET HUB @ PARKINGBRAKEPAWLSPRING
'O PARKINGBRAKEPAWL
i!i) THRUSTWASHERS
6i PIToT PIPEBRACKET @ TONGUEDWASHERRepIace.
iz:i,PITOTLUBRICATION PIPE {3 PARKINGBRAKERODHOLDER
., PITOTPIPE €I BALLBEARING
ag OILSEALReplace. io o-RINGReplace.
ari SET BING,80 mm Selectivepart .4!)VEHICLESP€EDSENSOB
29 ATF PASSAGEPIPEHOLDERASSEMBLY 60 OILSEALReplace.
TOROUE SPECIFICATIONS
6A 12 N.m ('1.2kgim,8.7 lbf'ft) 6x1.0mm

' l . 2 5m m
8A 22 N.m 12.2kgf.m,16lbf.ft) 8x
8F 26 N.m (2.7kgf.m,20lbnft) 8 x 1 . 2 5m m
8G 29 N.m (3.0kgtm,22 lbf.ft) 8 x 1 . 2 5m m
14-243
lllustratedIndex
Right Side Cover/lntermediateHousing
8B
I
tr
g
.i) RIGHTSIDECOVER (t TRANSMISSIONHOUSINGGASKETReplace
(.] ATF FEEDPIPE @}DOWELPIN
i3. DOWELPIN @ ATF FEEDPIPE
O O-RINGReplace. @ O-RINGReplace.
i5) FEEDPIPEFLANGE 6t o-RING Replace.
€] FEEDPIPEFLANG€PLATE .45)DRIVEPULLEYSPEEDSENSOR
Ol'RoLLER (? TRANSMISSION HANGER
iq,]INTERMEOIATE HOUSINGASSEMBLY (O SNAPRING
O CONTROLSHAFTASSEMBLY pa(
e0 THRUSTSHIM,25x 31 mm Selective
1_oI TRANSMISSION HouSlNG 6i BALLBEARING
.11) SHIFTCABI-EBRACKET O RINGGEAR
iO BREATHER CAP 69 SNAPRING
O olL SEALReplace. 6l REVERSE BRAKEEND PLATESelectivepan
(4 CONTROI-LEVER @IREVERSE BRAKEDISC
(3 LOCKWASHERReplace. 69 REVERSE BRAKEPLATE
ii6-iSECONDARY GEABSHAFTSPEEDSENSOR 6! D|SCSPRTNG
Ji DRIVENPULLEYSPEEDSENSOR @ THRUSTWASHER
(8_' O-RINGReplace. 6J'THRUSTNEEDLEBEARING
t!9 SNAPR|NG 63 THRUSTWASHER
.9 TBANSMISSIONHOUSINGDRIVENPULLEY @ CARRIER ASSEMBLY
SHAFTROLLERBEABING 6) THRUSTWASHER
2i RIGHTSIDECOVERGASKETFEPIACE. @ THRUSTNEEDLEBEARING
(2?jO-RINGReplace. @ SUN GEAR
POMANUALVALVEBODYLINEA @ SEALINGRINGReplace.
.]i MANUALVALVEBODYLINE8 69 NEEDLEBEARING
a3 o-RINGReplace. @ INPUTSHAFT
,! DETENTSPRING @ NEEDLEBEARING
!]) ATF FEEDPIPE @ SEALING RINGReplace.
Q0O-RINGReplace. 69 SEALINGRINGIRUBBER)Replace.
EI MANUAL VALVEBODY @ ATF FEEDPIPE
13o]DOWELPIN
51)MANUALVALVEBODYSEPARATOB PLATE
34 SNAPRING
$) FORWARDCLUTCHASSEMBLY
gl o-RINGFeplace.
69 SNAPBING
(30SPRINGRETAINEB/RETURN SPRINGASSEMBLY
O REVERSE BRAKEPISTON
(381O-RINGReplace.
r SNAPRINGRETAINER
.4!)ATF FEEDPIPE
6A 12 N.m (1.2kgf.m,8.7lbf'ft) 6x1.0mm

6B 1 4 N . m( 1 . 4k g n m ,1 0 l b i f t ) 6x1.0mm
8B 37 N.m (3.8kgim,27 lbf'fti 8 x 1 . 2 5m m
8F 26 N.m 12.7kgf.m,20lbf.ft) 8 x 1 . 2 5m m
8G 29 N.m (3.0kgf.m,22lbnft) 8 x 1 . 2 5m m
14-245
TransmissionHousing/LowerValveBodyAssembly
Removal
NOTE:
o Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair.
. When removingthe lowervalvebody, replacethe following:
- O-rings
- ATF pan gasket
- Sealingwashers
O.BING
Replace.
SOLENOIDHARNESSCONNECTOR
OOWELPIN 6 x 1.0mm BOLT
LOWERVALVEBODYASSEMBLY
6 x 1.0mm EOLT
ATF PAN GASKET

Feplace.
ATF COOLERINLETPIPE
ATF STRAINER BRACKETBOLT
8 x 1.25mm
ATF COOLERINLETPIPE
6 x 1.0mm BOLT
6 x 1.0mm EOLT
ATF PAN
14-246
1. Removethe ATFcoolerinletpipe bracketbolt.
2. Removethe ATFcooleroutletpipe.
3. Removethe ATF pan (founeenbolts).
4. Removethe ATFstrainer(two bolts).
5. Removethe one bolt securingthe solenoidharness

connector,then pushthe connector,
6. Removethe lowervalvebody (eightbolts).
7. Cleanthe inletopeningof the ATFstrainerthoroughly

with compressedair, then checkthat it is in good
condition,andthe inletopeningis not clogged.
ATF STRAINES
the ATFstrainerif it is cloggedor damaged.

Replace
NOTE:The ATF strainercan be reusedif it is not

clogged.
14-247
Housing/Flywheel
Transmission Housing
Removal
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair.
. When removingthe transmissionhousingflywheelhousing,replacethe followingl
- O-rings
- Secondarydrive gear assembl,
- Stan clutchassembly
- Flywheelhousinggasket
ATF PASSAGEPIPE
HOLOERASSEMBLY 8 x 1.25mm BOLT
CONNECTOR
BRACKET
FLYWHEELHOUSING
O.RING
fl B g fl
Replace.
DOWELPIN
ASSEMBLY
OIFFERENTIAL FLYWHEELHOUSINGGASKET
Reolace,
SNAPRING
COTTERRETAINER ATF PASSAGE
COTTERS, 25.5 mm PIPEASSEMBLY
Selectivepart O-RING
Replace. 6 x 1.0 mm BOLT
STARTCLUTCH
ASSEMBLY
Replace. O-RING
Replace.
THRUSTSHIM, ATF PUMPDRIVECHAIN

25x35mm SNAPRING
Selectivepart THRUSTSHIM,22 x 28 mm
Selectivepart
6 x 1.0mm BOLT
SECONDARY
GEARSHAFT ATF PUMP DRIVE
SPROCKET
SECONDARYDRIVE PITOTFLANGE
GEARASSEMBLY
Replace. ATF PUMPDRIVE
SPROCKETHUB
PARKINGBRAKE
PAWLSI{AFT THRUSTWASHERS
PARKINGBRAKEPAWL
SPRING
INPUTSHAFT
PARKINGBRAKEPAWL
TRANSMISSIONHOUSING
ORIVENPULLEYSHAFT
14-248
1 . Removethe ATF passagepipe holderassembly. 10. Setthe specialtool on the startclutch,and attachthe
pawl of the specialtool to the parkinggear securely
Removethe flywheelhousing(twentybolts). as snown.
Removethe ATF passagepipe assembly(onebolt). CAUTION:

. Do not place the pawl ol the special tool on the
Removethe ATF pump drive sprocket(threebolts), start clutch guide. lf the pawl of the special tool
then removethe ATF pump drivecharn. contacts the slart clutch guide. the start clutch
guide may be damaged.
Move the pitot flange toward its cutout, then remove . Be sure not to allow dust and other toreign par-
the pitot flange. ticles to enter into the driven pulley shaft.
STARTCLUTCH
REMOVER
07TAE- P4V0120
STARTCLUTCH
ASSEMBLY
Replace.
PITOT PIPE
1 1 . R e m o v et h e s t a r t c l u t c ha n d t h e s e c o n d a r yd r i v e
gear assemblyusing the specialtool, then remove
the secondarygearshaft.
Removethe snap ring securingthe ATF pump drive
sprockethub, then remove the 22 x,28 mm thrust START CLUTCH
REMOVER
shim,the ATF pump drive sprockethub and the thrust 07TAE- P4V0120
washers.
7. Removethe difterentialassembly.
Removethe parkingbrake pawl shaft,the parking

brakepawl spring,and the parkingbrakepawl.
Removethe snap ring securingthe startclutch,then

remove the cotter retainerand the cotters.
PARKING GEAR
14-249
)
Housing
RightSideGover/lntermediate
Removal
NOTE:
. Cleanall partsin solventor carburetorcleaner,and dry with compressedair.
. Elow out all passages.
. When removingthe right sidecover/intermediate housing.replacethe followingparts:
- O rings
- Rightsidecovergasket
- Transmissionhousinggasket
- S e a l i n gr i n g s
- S e a l i n gw a s h e r s
8 x 1.25mm BOLT
SNAPRING
6 x 1.0mm BOLT
REVERSE BRAKE
{u
END PLATE
Dtsc
PLATE
DISCSPRING
SNAP RIGHTSIDECOVER
GASKET
THRUSTSHIM. Replace.
2 5 x 3 1m m
Selective pan
RINGGEAR
DOWELPIN
THBUSTWASHER
THRUSTNEEOLE 8 x 1.25mm BOLT

BEARING
THRUSTWASHER
CARRIERASSEMBLY
THRUSTWASHER
THRUSTNEEDLE
SEARING
SUN GEAR TRANSMISSION
HOUSINGGASKET
INPUTSHAFT Replace,
SNAPRING
CLUTCHEND
PLATE
FORWARDCLUTCH
ASSEMBLY
SEALINGRING(BUBBER} DOWELPIN
Beplace.
SNAPRING
TRANSMISSION
HOUSING
SPRINGRETAINER/
RETURNSPRINGS
14-250
1 . R e m o v et h e r i g h t s i d e c o v e r ( t h r e e6 m m b o l t s , 11. Compressthe returnsprings.then removethe snap
eleven8 mm bolts). ring.
2. Removethe manualvalvebody linesA and B. C A U T I O N :l f t h e s p r i n g l e t a i n e r t a b i s o n t h e

leverse brake piston, the spring retainer may be
3 . Removethe snap ring securingthe ring gear,then damaged.Be sure the spring retainertab is not on
removethe thrustshim and the ranggear. the piston.
SPECIALTOOL
R e m o v et h e s n a p r i n g s e c u r i n gt h e r e v e r s eb r a k e
discsand plates,then removethe reversebrakeend
plate,brakediscs,brakeplates,and discspring.
Removethe carrierwith the thrust washersand the

thrustneedlebearing,from the forwardclutch.
6 . Removethe sun gear and the input shaft as a sub

assemblyby pullingir.
The sun gear is pressfittedtightly into input shaft. SPRINGRETAIiIER
TAA
7 . Removethe snap ring securingthe forward clutch, 12. R e m o v et h e s p e c i a tl o o l , t h e n r e m o v et h e s p r i n g
and removethe snapringsecuringthe forwardclutch retainer/return springassembly.
end plate,then removethe forwardclutchend plate. Removethe sealingbolt securingthe reversebrake
pressureinspectionhole.
8 . R e i n s t a ltl h e c a r r i e ro n t h e f o r w a r d c l u t c h ,t h e n 1 4 . Apply air pressureto the inspectionhole to remove
securethe carrierwith the snap ring on the forward the reversebrakepiston.
ciutchend plate. SPRNG RETAINER/
RETURNSPRING
9 . R e m o v et h e f o r w a r dc l u t c ha n d c a r r i e ra s s e m b l y ASSEMBLY
together.
REVERSEBRAKE
PISTON
1 0 . I n s t a l lt h e s p e c i a lt o o l t o r e m o v et h e s n a p r i n g
securingthe reversebrakereturnspring retaineras
snown.
o-Rt Gs
Replace.
REVERSE BRAXE
SPRINGCOMPRESSOR
07TAE- P4V01r0
REVERSE
BRAXE
PRESSUR€INSPECNON
HOIT
SEALING
WASHER
Replace.
8 x 1.25 mm
18 N.m {1.Ekgl.m, 13 lbf.ftl
15. Removethe snap ring retainerfrom the drive pulley

shaft.
16. Removethe manualvalvebody (fivebolts).
'17 Removethe roller,and Dushthe controlshaftassem-
bly toward the outsideof the transmissionhousing,
then removethe intermediate housing(fourbolts).
14-251
ManualValveBody
NOTEI
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages,
o Coatall partswith CVTFluidduringassembly,
SPRINGSEAT
R€VERSEINHIBITOR
VALVESPRING
INHIBITOR
REVERSE
VALVE
N'
MANUAL VALVE
MANUALVALVEBODY
andscoring.
14-252
I
ForwardGlutch
lllustrated Index
CLUTCHORUM
\
\ DISCSPRING
\ _
RETURNSPRING
RETAINER
SNAPRING
CLUTCHPLATES
Standardthickness:
2.00mm (0.079in)
CLUTCHEND PLATE
CLUTCHPISTON
clurcH Dlscs
Standardthickness;
1 . 9 4m m ( 0 0 7 6 i n )
SNAPRING
14-253
ForwardClutch
Disassembly
1. Remove the snap ring, then remove the clutch end 3. Installthe specialtools as shown.
plate, clutch discs, and plates.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
SNAP RING
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
OTHAE PLsO,IOO
2. Removethe discspring. CLUTCH SPRING

COMPRESSOR
BOLT ASSEMBLY
oTGAE-PG40200
DISC SPRING
CAUTION: lf either end ot the specialtool is set over
an area ol the spring retainor which is unsupported
by the return spring, the retainer may be damaged,
Be sure the specialtool is adiustedto have full con-
tact with the spring retsiner.
Do not s€t h€re.
SPECIALTOOL
SPRINGRETAINER
14-254
4. Compressthe returnspring. 6. Wrap a shop rag aroundthe clutchdrum, and apply
air pressureto the fluid passage
to removethe piston.
Placea fingertip on the otherend while applyingair
pressure.
OSHA.APPROVED
30 p3i NOZZLE
5. Removethe snapring.Then removethe specialtools,

springretainer,
and returnspring.
SPRINGRETAINER
14-255
ForwardClutch
ReassemblY
pressure
3. lnstallthe pistonin the clutchdrum Apply
NOTE: and rotateto ensureproperseatlng'
. Clean all parts thoroughly in solvent or carburetor
cleaner,and dry them with compressedalr' NOTE: Lubricatethe piston O-ring with
CVT Fluid
. Blow out all Passages. beforeinstalling
. Lubricateall partswith CVTFluidbeforereassemDly'
the
the prs- CAUTION: Do not pinch the O-ring by installing
1. Inspectthe checkvalve;i{ it's loose'replace piston with too much lorce
ton.
CHECKVALVE
PISTON
2. Installnew O-ringson the clutchpiston' and

l n s t a l lt h e r e t u r ns p r i n g a n d s p r i n g r e t a i n e r '
positionthe snap ring on the retainer'
O.RINGS
SNAP RING
SPRINGRETAINER
RETURNSPRING
CLUTCHDRUM
PISTON
14-256
5. Installthespecialtools as shown, 6. Compressthe returnspring.
CLUTCHSPRING
COMPBESSOR
ATTACHMENT
OTLAE PX4OlOO
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
oTHAE-P150100
CLUTCHSPRING 7. I n s t a l l t h es n a p r i n g .
COMPRESSOR
EOLTASSEMBLY
07GAE-PG40200
CAUTION: lf either end ot the specialtool is set over

an area ol the spring retainor which is unsupported
by the return spring, the retainer may be damaged.
Be sure the specialtool is adlusted to have full con-
tact with the spring retainer.
SNAP RING
Sot here.
Do not set h€re.
SPECIALTOOL
RETAINER (cont'd)
14-257
/
ForwardClutch
Reassembly(cont'dl
9 . I n s t a ltlh e d i s cs p r i n g . 1 2 . I n s t a ltlh e s n a pr i n g .
NOTE: Installthediscspringin the directionshown.
DISC SPRING
SNAPRING
\ ".urr* o.r*
1 0 . Soakthe clutchdiscsthoroughlyin CVT Fluidfor a

m i n i m u mo f 3 0 m i n u t e s .
1' ]. Starting with a clutch plate, alternatelyinstall the

clutch platesand discs.Installthe clutch end plate
with flat sidetoward the disc. 13, Verifythat the snap ring end gap is correct.
NOTE:Beforeinstallingthe platesand discs,make CLUTCH

sure the insideof the clutch drum is free of dirt or DRUM
otherforeignmatter.
M i n i m u m7 . 9m m { 0 . 3 1i n )
CLUTCHEND PLATE
14-254
I
i
14. Measu.ethe clearanc€betweenthe clutchend plate
andtop discwith a dial indicator. Zerothe dial indica-
15. lf the clearance selecta new clutch
is out of tolerance,
end platefrom the followingtable.thenrecheck.
tor with the clutch end plate lowered,and lift it up to
I
the snap ring.The distancethat the clutchend plate NOTE:It the thickestclutchend plateis installedbut
moves is the clearancebetweenthe clutch end Dlate the clearanceis still over the standard,replacethe
andtop disc. clutchdiscsand clutchplates.

and usethe averageas the actualclearance. PLATE I{UM8ER Thicknoss
Clutch End Plate-to-TopDisc Clearance:
STANDARD:0.6 - 0.8 mm (0.024- 0.031in)
CLUTCH END PI-ATE
FORWARDCLUTCHEND PLATE
Plale No. Part Numbel Thickness

1or15 22561- P4V- 003 3 . 5m m ( 0 . 1 3 8i n )
2ot16 22562-P4V-003 3 . 6m m ( 0 . 1 4 2i n )
3or17 2 2 5 6 3 - P 4 V - 0 0 33 . 7m m ( 0 . 1 4 6i n )
4ot18 2 2 5 6 4 - P 4 V - O O 33 . 8m m ( 0 . 1 5 0i n )
'19
5 or 2 2 5 6 5 - P 4 V - 0 0 33 . 9m m ( 0 . 1 5 4i n )
6or20 2 2 5 6 6 - P 4 V - 0 0 3 4 . 0 m m ( 0 . 1 5 7i n )
7ot21 22561 -P4V OO3 4 . 1m m ( 0 . 1 6 1i n )
8ot22 2 2 5 6 8 - P 4 V - 0 0 34 . 2m m ( 0 . 1 6 5i n )
9or23 2 2 5 6 9 - P 4 V - 0 0 3 4 . 3m m ( 0 . 1 6 9i n )
'10 24 22510 P4V OO3 4 . 4m m ( 0 . 1 7 3i n )
or
1 1o r 2 5 225't1 P4V , OO3 4 . 5m m ( 0 . 1 7 7i n )
or 225-72-PAV-OO3 4 . 6 m m ( 0 . 1 8 1i n )
or 22573 - P4V - OO3 4 . 7 m m ( 0 . 1 8 5i n )
After replacingthe clutchend plate,make surethat

the clearanceis within tolerance.
14-259
r'
SecondaryGearShaft
25 x 35 mm Thrust Shim Selection
1. Measurethe distancebetweenthe flywheelhousing 4. Calculate25 x 35 mm thrust shim thicknessbv fol-
surfaceand the ball bearing as shown, then note lowingformula.
the measurement(Measurement A).
FLYWHEEL FORMULA:
HOUSING
--"i<t='' 25 x 35 mm Thrust Shim Thickness
= Measurement A - Measurement B + Flywheel
HousingGasketThickness:0.5 mm (0.020in)
fi-i"r*,.goi.r".."\ I
ExamDle:
MeasurementA:32.7mm (1.287in)
MeasurementB:30.1mm (1.185in)
25 x 35 mm Thrust Shim Thickn€ss

= 32.7mm 11.287 inl -30.1 mm {1.185in}
+ 0.5 mm (0.020in)
= 3.1 mm 10.122in)
Select 25 x 35 mm Thrust Shim D.
5. Selectthe 25 x 35 mm thrust shim from the follow-

ing the table.
THRUSTSHIM,25 x 35 mm
BALL FLYWHEEL
BEARING HOUSING No. Part Number Thickness
Installthe secondarygear shaft in the transmission 9 0 5 5 '-1P 4 V - 0 0 0 2 . 8m m ( 0 . 1 1 0

in)
housrng. B 9 0 5 5 2 - P 4 V - 0 0 0 2 . 9m m { 0 , 1 1 4i n )
c 9 0 5 5 3 - P 4 V - 0 0 0 3 . 0m m ( 0 . 1 1 8i n )
M e a s u r et h e d i s t a n c eb e t w e e nt h e t r a n s m i s s i o n
h o u s i n gs u r f a c ea n d t h e t h r u s t w a s h e rm o u n t i n g 9 0 s 5 4 - P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2 2i n )
surfaceof the secondarygear shaft as shown,then E 9 0 5 5 5 - P 4 V - 0 0 0 3 . 2m m { 0 . 1 2 6
in)
notethe measurement{Measurement B).
F 9 0 5 5 6 - P 4 V - 0 0 0 3 . 3m m ( 0 , 1 3 0
in)
SECONDARY
9 0 5 s 7 - P 4 V - 0 0 03 . 4m m ( 0 , 1 3 4i n )
GEARSHAFT
H 9 0 5 5 8 - P 4 V - 0 0 0 3 . 5m m ( 0 . 1 3 8i n )
9 0 5 5 9 - P 4 V - 0 0 0 3 . 6m m ( 0 . 1 4 2i n l
J 9 0 5 6 0 - P 4 V - 0 0 0 3 . 7m m ( 0 . 1 4 6
in)
K 90561- P4V- 000 3 . 8m m { 0 . 1 5 0i n )
14-260
Differential
lllustratedlndex BacklashInspection
1. Placethe differential
assemblyon V-blocks,
and install
AOLTS
10 r 1.0mm both axles.
101N.m {10.3kgf.m.
74.5 |bfit) 2. Checkthe backlashof both piniongears.
Left'handthreads
Standard(Newl:0.05- 0.15mm {0.002- 0.006inl
PINIONGEARS
FINALORIVENGEAR
BALLBEARING
lf the backlashis out of tolerance,replacethe differ-

entialcarrier.
14-261
Differential
BearingReplacement DifferentialCarrier Replacement
NOTE:Checkthe bearingsfor wear and rough rotation. 1. Removethe final driven gear from the differential
lf the bearingsare OK, removalis not necessary. carrier.
1. Removethe ball bearingsusinga bearingpuller, NOTE: The final driven gear bolts have left-hand
threads.
BOLTS
1 0x 1 . 0m m
98 N.m {10.0kg{.m,
72 tbf.ft)
Left-hand threads
BALLBEARING
I
Installthe new ball bearingsusing the specialtool

with a pressas shown. DIFFERENTIAL
CARRIEN
2. Installthe final driven gear with its chamferedside
on the innerborefacingthe differentialcarrier.
Torquethe boltsto the specifiedtorque in a crisscross

panern.
TOROUE:98 N.m {10.0kgf.m, 72 lbf.ftl
p BALLBEARING
14-262
Oil Seal Removal Oil Seal Installation/SideClearance
1. Removethe differentialassembly. 1 . I n s t a l la 2 . 5 0m m { 0 . 0 9 8i n ) t h i c k8 0 m m w i d e s e t
r i n gi n t h e t r a n s m i s s i ohno u s i n g .
2. Removethe oil sealfrom the transmissionhousing.
NOTE:Do not installthe oil sealyet.
SETRING,
80 mm
Seleclivepart
TRANSIflSStON
HOUSING
TRANSMISSION OIL SEAL
HOUSING Replace.
3. Remove the oil seal from the flywheel housing. Installthe difterentialassemblyinto the transmis-
sion housingusingthe specialtool as shown.
HOUSING
(cont'd)
14-263
,l
Differential
Oil Seal Installation/SideClearance(cont'd) \
3. l n s t a l l t h ef l y w h e e l h o u s i n g ,a n d t i g h t e nt h e b o l t s . 4. Measurethe clearancebetweenthe 80 mm set ring

a n d o u t e r r a c eo f t h e b a l l b e a r i n gi n t h e t r a n s m i s -
s i o nh o u s i n g .
8 x 1.25mm 0 - 015 mm (0 - 0 006 inl

STANDARD:
29 N m (3.0kgtm,22 lb{ft}
uH fs
TRANSMISSION
HOUSING
DIFFERENTIAL
ASSEMBLY FLYWHEEL
HOUSING
FLYWTIEEL
HOUSINGGASKET
lf the clearance is more than the standard, select a

new set ring from the table, and install it.
SET RING, 80 mm
PartNumber Thickness
90414-689-000 2 . 5 0m m ( 0 . 0 9 8
in)
90415- 689 000 2 . 6 0m m ( 0 . 1 0 2
in)
90416-689-000 2 . 7 0m m 1 0 . 1 0i6n )
90417-689-000 2 . 8 0m m ( 0 . 1 1 0
in)
90418-689-000 2 . 9 0m m ( 0 . 1 1i4n )
90419-PH8-000 3 . 0 0m m 1 0 . 1 1i8n )
NOTE|lf the clearancemeasuredin step 4 is stan

to performsteps7 and 8
dard.it is not necessary
6. Removethe flywheelhousing.
1. Replacethe 2.50mm (0.098in) set ring,80 mm with

the one of the correctthicknessselectedin step5
h
14-264
FlywheelHousing
InputShaftOil Seal
Replacement
8. Installthe oil seal in the transmissionhousingusing 1. Removethe input shaft oil seal from the flywheel
the sDecialtools as shown. houstng.
DRIVER
07749- 0010000
Installrhe oil seal in the flywheelhousingusingthe

q
Installthe oil seal in the flywheelhousingusingthe specialtools as shown.
soecialtools as shown.
FLYWHEEL
Installed depth:
2.5 - 3.5 mm
PILOT,
26r30mm
,"rf
fo"rrr'l,i.ttl,
ATTACHMENT,
DRIVER
ATTACHMENT,5E x 72 mm
07JAD- PH80200
t@ 32x35mm
07746- 0010100
079{?- 6340201
14-265
Transmission
HousingBearings
Driven Pulley Shaft Bearing Replacement
\
'1. To
removethe driven pulleyshaft bearingfrom the Expandthe snap ring with snap ring pliers. insert
t r a n s m i s s i o nh o u s i n g ,e x p a n dt h e s n a p r i n g w i t h the new bearing part-way into the housing using
s n a p r i n g p l i e r s ,t h e n p u s h t h e b e a r i n go u t u s i n g the specialtools and a press as shown. Installthe
the specialtoolsand a pressas shown. bearingwith the groovefacingoutsidethe housing.
NOTE:Do not removethe snap ring unlessit's nec- N O T E :C o a ta l l p a n sw i t h C V TF l u i d .

essaryto cleanthe groovein the housing.
Releasethe pliers.then push the bearingdown into
the housinguntil the ring snaps in placearound it,
u s i n gt h e s p e c i a l t o o lass s h o w n .
07749- 0010000
ATTACHMENT,
72x75mm
BEARING 07746 - 0010600
GBOOVE
SNAPRING
ATTACHMENT.
4. After installingthe bearingverifythe following:
72x75mm
07746- 0010600 . The snap ring is seatedin the bearingand hous-
Ing gfooves.
. The snap ring operatesproperly.
. The ring end gap is correct.
ENDGAP:0-9mm
(0- 0.35in)
BEARING HOUSING
SNAPRING
14-266
FlywheelHousing
Bearing
SecondaryGear Shaft Bearing SecondaryGearShaft Bearing
1. Removethe secondarygear shaft bearingusingthe 1. Removethe secondarygear shaft bearingusingthe
s p e c i a l t o o lass s h o w n . soecialtool as shown,
3/8" - 16 SLIDEHAMMER
lCommerciallyavailablel
GEAR ADJUSTABLEBEARING
SECONDARY - 40 mm
PULLER.26
ADJUSTABLE BEARING SHAFTBEARING
- ,10mm 07736- A01000A
PULLER,25
07?36- 4010004
Installthe new secondarygear shaft bearinguntil it lnstallthe new secondarygear shaft bearinguntil it
bottomsin the transmissionhousing,usingthe spe- bottoms in the flywheel housing,using the special
c i a l t o o l sa s s h o w n . tools as shown.
DRIVER
07749- 0010000
ATTACHMENT,
72 x 75 mrn ATTACHMENT.
07746- 0010600 62x68mm
07746- 0010500
14-267
RingGearBearing ControlShaft Assembly
Replacement RemovaUlnstallation
1. R e m o v et h e r i n g g e a r b e a r i n g . 1. Remove the bolt and lock washer.
CONTROLSHAFT
ASSEMBLY
TRANSMISSION
RING RINGGEAR
Installthe new ring gear bearinguntil il bottoms in

the ring gear,usingthe specialtools as snown.
6x1.0mm
14 N.m (1.4kgf.m, CONTROL
10 tbf.ttl LEVER
DRIVER LOCKWASHER
0?749- 0010000 Replace.
Removethe controlleverfrom the controlshaft.
3. Removethe controlshaftassembly.
Installthe controlshaftassemblyin the transmission

nousrng.
5. Installthe controlleverto the controlshaft.
6. Installand tightenthe bolt with a new lockwasher.
b
14-268
Transmission
Reassembly
\
be sure not to allow dust and other foreignparticlesto enter into the transmission.
CAUTION:Whilereassembling,
NOTE:
. Coatall partswith CVTFluid.
. Replacethe followingparts:
- O-rings
- S e a l i n gr i n g s
- S e a l i n gw a s h e r s
- Gaskets
- Stan clutchassemblyand Secondarydrive gear assembly
8 x 1.25mm
37 N.m {3.8kgl.in, 27 lbt.ft)
SNAPRING 6x1.0mm
12 N.m lI.2 kgf.m,8.7lbnftl
MANUAL VALVE
REVERSEERAKE
ENDPLATE RIGHTSIDECOVER
olsc DOWEL
PIN
PLATE
O.RINGS RIGHTSIDECOVEBGASKET
DISCSPRING
6x1.0mm
THRUSTSHlM.25x 31 mm 12 N m (1.2kgf.m.8.7lbf.ftl
part
Selective
SNAP
RINGGEAR RING 8 x 1.25mm
29 N.m 13.0kgt ln.22lbtftl
THRUSTWASHER MANUAL
THRUSTNEEOLE VALVE
BEABING BODY INTERMEDIATE
HOUSINGASSEMBLY
THRUSTWASHER
CARRIERASSEMBLY
THRUSTWASHER ROLLER
THRUSTNEEOLE
BEARING
SUN GEAR ATF FEEDPIPE
INPUTSHAFT O.RINGS TRANSMISSION

HOUSINGGASKET
SNAPRING
FORWARDCLUTCH
CONTROLSHAFT
ASSEMBLY
SNAP AING
SPRINGRETAINER/
RETURNSPRING
ASSEMBLY
DOWELPIN
REVERSE
BRAKEPISTON
O.RINGS
HOUSING
SNAPRINGRETAINER
ATF FEEDPIPES
14-270
1. Installthe ATF feed pipe in the transmissionhous- Compressthe return springs.then installthe snap
ing, and installthe three ATF feed pipeswith new ring in the intermediatehousing above the spring
O - r i n g si n t h e t r a n s m i s s i ohno u s i n g . retarner.
2 . Installthe two dowelpinsand newtransmission hous-
ing gasketon the transmissionhousing. 1 0 . Verifythat the snap ring end gap is correct
? Pushthe controlshaft assemblytoward the outside
M i n i m u m1 5m m ( 0 . 5 9i n )
of the transmissionhousing,then installthe inter-
mediatehousingassembly(fourbolts).
lnstall the manual valve body separatorplate and ,a7 "-,,,,.
/,.' \.,
the two dowel pins on the intermediatehousing.
'
ir
then installthe manual valve body with the detent ir ',
spring (fivebolts). / / /
Put the controlshaft assemblyback,then installthe ,'t . :''
rollerin the intermediatehousing. SNAPRING

Installthe reversebrake piston in the intermediate
housing. 1 1 . S o a k t h e r e v e r s eb r a k e d i s c st h o r o u g h l yi n C V T
7 . lnstallthe springretainer/retu.n spring assemblyon F l u i df o r m i n i m u m3 0 m i n u t e s
the reversebrakePaston.
Installthe discspringon the reversebrakepiston.
NOTE:Installthereturnspringson the springguides
oJthe reversebrake piston securelY t5. S l a r t i n g w i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
installthe reversebrakeplatesand discs lnstallthe
Installthe specialtool to compressthe returnsprlng reversebrakeend piate,and the snap ring
as shown.
1 4 . Measurethe clearancebetweenthe reversebrake
REVERSEBRAKE end plateand the top discwith a dial indicator.Zero
SPRING
COMPRESSOE
o?TAE- P4V0110 t h e d i a l i n d i c a t o rw i t h a r e v e r s eb r a k ee n d p l a t e
lowered,and lift it up to the snap ring.The distance
that the reversebrakeand plate moves is the clear-
ance between the reverseend plate, and the top
disc.
NOTE:Take measurements in at leastthree places,

and usethe averageas the actualclearance
0.45- 0.75mm (0.018- 0.030in)

STANDARD:
CAUTION:lf the spring letainer tab is on the reverse

brake piston, the spring retainer may be damaged.
Be sure the spring retainertab is not on the piston.
SPECIALTOOL BRAKE
REVERSE
(cont'di
14-271
Transmission
Reassembly(cont'd)
lf the clearance is not withinthe standard,removethe 22. Verily that the outside diameter of the snap ring is
reversebrakeend plateand measureits thickness. correct.
S e l e c ta n d i n s t a l la n e w r e v e r s eb r a k ee n d p l a t e ,
then recheck. Maximum4l 4 mm 11.63in)
N O T E : l f t h e t h i c k e s tr e v e r s eb r a k ee n d p l a t e j s
installed,but the clearanceis still over the standard,
replacethe reversebrakediscsand plates.
REVERSE
BRAKEENDPLATE
""^rr,""()
PlateNo. Part Number Thickness
2 3 . I n s t a l lt h e i n p u t s h a f t a n d t h e s u n g e a r a s a s u b
22551 - P4V 003 3 . 6m m ( 0 . 1 4 2i n )
assembly.
2 22552 - P4V 003 3 . 8m m ( 0 . 1 5 0i n )
3 22553-P4V OO3 4 . 0 m m ( 0 . 1 5 7i n ) 2 4 . I n s t a l lt h e t h r u s t n e e d l e b e a r i n g a n d t h e t h r u s t
washer on the sun gear.
22554- P4V 003 4 . 2m m 1 01. 6 5i n )
5 2 2 5 5 5 - P 4 V - 0 0 3 4 . 4m m ( 0 . 1 7 3i n )
CARRIERASSEMBLY
6 2 2 5 5 6 - P 4 V - 0 0 34 . 6m m ( 0 . 1 8 1i n )
7 22551-P4V -OO3 4 . 8m m ( 0 . 1 8 9i n )
8 2 2 5 5 8 - P 4 V - 0 0 3 5 . 0m m ( 0 . 2 0 0i n )
1 7 . After replacingthe reversebrake end plate, make THRUST

s u r et h a tt h e c l e a r a n cies w i t h i nt h e s t a n d a r d .
1 8 . R e m o v et h e s n a p r i n g , r e v e r s eb r a k ee n d p l a t e ,
dascs,plates,and discspring.
1 9 . l n s t a l lt h e s n a p r i n g r e t a i n e ro n t h e d r i v e p u l l e y THBUSTNEEDLE
BEARING
shaft.
20. Wrap the drive pulleyshaftsplineswith tapeto pre-
v e n t d a m a g et o t h e O - r i n g s ,t h e n i n s t a l ln e w O -
flngs.
Installtheforwardclutchassemblyon the drive pul
ley shaft,then installthe snap ring.
SNAPBIT{G
O.RINGS
SNAP RING
RETAINER
25. Installthe carrierassemblyon the forwardclutch.
14-272
26. Installthe thrust washer,the thrust needlebearang, 30. lf the clearanceis out of tolerance,removethe 25 x
and the thrustwasheron the carrierassembly. 31 mm thrustshim and measureits thickness.
THRUSTSHIM,
SNAPBING 2 5 x 3 1m m 3'|. Selectand install a new 25 x 3'l mm thrust shim,
Selective part then recheck.
THRUSTSHIM.25 x 31 mm
RINGGEAR
No. Part Number Thickness
90451- P4V- 000 1.05mm (0.011in)
THRUSTNEEDLE THRUSTWASHERS B 90452 P4V- 000 1 . 1 2m m ( 0 . 0 4 i4n )
BEANING
c 90453 P4V- 000 1 . 1 9m m ( 0 . 0 4 i7n )
D 9 0 4 5 4 - P 4 V - 0 0 0 1.26mm (0.050inl
E 9 0 4 5 5 - P 4 V - 0 0 0 1.33mm {0.052in)
F 9 0 4 5 6 - P 4 V - 0 0 0 1.40mm (0.055in)
'1.47mm (0.058in)
G 90457-P4V-000
H 9 0 4 5 8 - P 4 V - 0 0 0 1.54mm (0.061in)
9 0 4 5 9 - P 4 V - 0 0 0 1.61mm {0.063in)
J 9 0 4 6 0 - P 4 V - 0 0 0 1.68mm (0.066in)
K 90461- P4V 000 1.75rnm {0.069in}
27. Installthe ring gearand the 25 x 31 mm thrustshim.
then installthe snap ring. L 90462 P4V- 000 1.82mm (0.072in)
M 9 0 4 8 0 - P 4 V - 0 0 0 1.085mm (0.0427
in)
28. Verifythat the outsidediameterof the snap ring is in)
N 9 0 4 8 1 - P 4 V - 0 0 0 1.155mm 10.0454
correct.
o 9 0 4 8 2 - P 4 V - 0 0 0 1.225mm (0.0482
in)
m0 . 7m m( 12 1i n )
Maximu3 P 9 0 4 8 3 - P 4 V - 0 0 0 1.295mm (0.0510
in)
F - 1 o 9 0 4 8 4 - P 4 V - 0 0 0 1.365mm {0.0537
in)
't'":' \ R 90485 P4V- 000 1.435mm (0.0565 in)
/./ \\
/l rl 9 0 4 8 6 - P 4 V - 0 0 0 1.505mm (0.0593
in)
i\ l\ r ,
' T 9 0 4 8 7 - P 4 V - 0 0 0 1.575mm (0.0620
in)
, / _ 9 0 4 8 8 - P 4 V - 0 0 0 1.645mm (0.0648
in)
SruEP
RING,
9 0 4 8 9 - P 4 V - 0 0 0 1.715mm (0.0675
in)
'1.785
29. M e a s u r et h e c l e a r a n c eb e t w e e nt h e 2 5 x 3 1 m m 90490-P4V-000 in)
mm {0.0703
thrustshim and the snap ring.
32. After replacingthe 25 x 31 mm thrust shim, make
STANDARD:0.05- 0.11 mm 10.0020- 0.00/B inl sure that the clearanceis within toleranceand the
snap ring outsidediameteris correct
Installthe discspringin the directionshown.
34. S t a r t i n g w i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
i n s t a l lt h e r e v e r s eb r a k eD l a t e sa n d d i s c s .l n s t a l l
selectedreversebrake end plate. then install the
snapflng.
REVERSEBRAKE
END PLATE Dtscs
OISCSPRING
REVERSEBRAKE lnstallin this direction
PLATES
'! ttl.
,*"ua{t",",
RINGGEAB (cont'd)
14-273
Transmission
Reassembly(cont'dl
35. Verifythat the snap ring end gap is correct. 39. Installthe parkingbrakepawl, spring,and shaft on
t h e t r a n s m i s s i o nh o u s i n g ,t h e n m o v e t h e c o n t r o l
M i n i m u m1 8m m ( 0 . 7 1i n ) leverto any gearotherthan E position.
--
t\ SNAPRING
I'J .\i COTTER
.,.. THRUSTSHIM, RETAINER
1' r t , COTTERS,
SECONDARY 25.5mm
sruapntruc-/ \ . : : ,/ GEABSHAFT pan
Selective
36. I n s t a l tl h e m a n u a lv a l v eb o d y p i p e sA a n d B w i t h
new O-ringson the manualvalvebody and the inter- PABKINGBRAKE STARTCLUTCH
mediatehousing. PAWLSHAFT ASSEMBLY
6x1.0mm
8 x 1.25mm 12Nm(1.2kgf.m. SECONDARY
37 N.m (3.8kgI.m,27 lbt.ft) 8.7 tbt.ftl DRIVEGEAR
ASSEMBLY
t'tl\
f, E
" J \ O-RINGS
E P
9>- E
PARKINGBRAKE
PAWLSPRING
PARKING
RIGHTSIDE ORIVENPULLEY
COVERGASKET SHAFT
DOWELPINS
O.RINGS
40. Installthe secondarygear shaft with selected25 x
3 5 m m t h r u s ts h i m( s e ep a g e1 4 - 1 0 0 ) .
MANUAL VALVE 4 1 . W r a p t h e d r i v e n p u l l e ys h a f ts p l i n e sw i t h t a p e t o
BODYPIPEA preventdamageto the O-rings,then installnew O-
nngs.
42. Assemblethe secondarydrive gear assemblyin the
startclutchassemblv. then installthem on the driven
oullevshaft.
43. P u l lt h e h a n d l eo f t h e s p e c i a tl o o l u p , t h e n i n s t a l l
the tip of it into the driven pulleyshaft hole,and set
the soecialtool on the startclutch-
ATF FEEO
PIPES CAUTION:While installing the start clutch and the
secondarydriv€ gear assemblyusing the special
tool, be sure not to allow dust and other toreign
MANUALVALVE particlesto enter into the transmission.
BODY
STARTCLUTCH t r , ,n u n a ' " .
37. Installthe two dowel pins and new right side cover INSTALLER I
g a s k e to n t h e i n t e r m e d i a t eh o u s i n g ,t h e n i n s t a l l 07TAE- P4V0130
new O-ringson the ATFleed pipes.
38. Installthe right sidecover (three6 mm bolts,eleven

8 mm bolts).
N O T E :I n s t a ltlh e n i n e 8 m m b o l t si n t h e r i g h ts i d e
cover (two 8 mm bolts remainin the right side
cover)then tightenthe eleven8 mm bolts.
14-2 7 4
44. Pushthe handleof the specialtool, then tightenthe 4't. It the clearanceis not within the standard.remove
nut to seat the secondarydrive gear assemblyon the cottersand measureth eir thickness.
the drivenpulleyshaftsecurely.
48. Selectand installnew cotters,then recheck.
S?ART CLUTCHINSTALLER
coTTERS,25.5mm
No. Part Numbel Thickness
9 0 4 2 9 - P 4 V - 0 0 02 . 9m m { 0 . 1 1 i4n )
B 9 0 4 3 0 - P 4 V - 0 0 0 3 . 0m m ( 0 . 1 1i8n )
c 90431- P4V- 000 3 . 1m m { 0 . 1 2 2i n )
D 9 0 4 3 2 - P 4 V - 0 0 03 . 2m m { 0 . 1 2 6i n )
49. After replacingthe 25.5mm cotters,make surethal

the the clearanceis the standard.
50. I n s t a ltlh e c o t t e rr e t a i n ear n dt h e s n a pr i n g .
Verifyrhat the outsidediameterof the snap ring is

correcI.
n
Minimum33.9mm 11.33in)
HANOLE
45. Pull the handleof the specialtool up, and remove "no"*,/\--/
the specialtool-
52. I n s t a l tl h e t h r u s tw a s h e r s t, h e A T F p u m p d r i v e
46. Installthecotters,then measurethe clearancebetween sprockethub and the 22 x 28 mm thrustshim on the
the cottersand the slart clutchguide. input shaft,then installthe snap ring.
0 - 0.13mm {0 - 0.005in)
STANDARD: SNAPRING\
THRUSTSHIM,22 x 28 mm
NOTE|Takemeasurements anat leastthfee places, Selectiveoan
and usethe averageas the actualclearance. ATF PUMPDRIVE
SPNOCXETHUA
THRUSTWASHENS
25.5mm
COTTERS,
GAUGE
li l)
lf
STARTCLUTCH
STARTCLUTCH ( c o n td )
GAUGE
14-275
,l
Transmission
(cont'dl
Reassembly
53. Verifythat the outsidediameterof the snap ring is 5 1 . After replacingthe 22 x 28 mm thrust shim, make
correct. sure that the clearanceis within toleranceand the
snap ring outsidediameteris correct
r5
M a x i m u m2 6 . 3m m { 1 . 0 4i n )
58. Installthe pitot flange using its cutout as shown to

clearthe pitot pipes.
INPUTSHAFT
54. Measurethe clearancebetween the 22 x 28 mm

thrustshim and the snap ring.
STANDARD;0.37- 0.65 mm 10.015- 0.026in)

Eq lnstall the ATF pump drive sprocket.and put the

ATF pump drive chain on the ATF pump drive and
driven sprockets.then lnstall and tighten the bolts
(threebolts),
THFUSTSHIM,
PUMPORIVECHAIN
22x28 mm
6 x 'l.0mm
12 N.m
lf the clearanceis out of tolerance,removethe 22 x (1.2kgf.m,8.7lbtft)
28 mm thrustshim and measureits thlckness.
ATF PUMP DRIVE
56. Selectand install a new 22 x 28 mm thrust shim, SPROCKET
then recheck.
PITOTFLANGE
THRUSTSHIM.22 x 28 mm
No. Part Number Thickness ATF PUMP
c 90573-P4V-000 1.'1m
5 m {0.045
in)
D 9 0 5 7 4 - P 4 V - 0 0 0 1.40mm (0.055in)
E 9 0 5 7 5 - P 4 V - 0 0 0 1.65mm (0.065in)
F 9 0 s 7 6 - P 4 V - 0 0 01 . 9 0m m ( 0 . 0 7 5i n )
9 0 5 7 7 - P 4 V - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n )
H 9 0 5 7 8 - P 4 V - 0 0 0 2.40mm (0.095in) INPUTSHAFT
14-276
60. Installthe differentialassembly.
61. Installthe ATF passagepipe assemblywith new O-rings(one bolt).
62. Installthe three dowel pins and new flywheelhousinggasketon the transmissionhousing
63. Installthe flywheelhousingand connectorbracket(twentybolts).
I 64. InstalltheATF passagepipe holderassembly(two bolts).
6x1.0mm
12 N.m {1.2kgf.m,
8 x 1.25 mm
29 N.m (3.0k91.m,22lbl'ftl
8.7 tbI.ft)
arF PAssAGEPIPE
HOLDER ASSEMBLY
I
I
I R E {u FLYWHEELHOUSING
\ €
\n
f-{
\A
[tr1
o-RrNG-___\S/
CONNECTOR
ERACKET
ATF PASSAGEPIPE
DOWEI.PIN
6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbtftl
DIFFERENTIAL
ASSEMBLY
DOWELPIN
DOWELPIN
FLYWHEEL
HOUSING at":
GASKET
,):/;[
ri-{e
TRANSMISSIONHOUSING
( c on t ' d)
14-277
Transmission
(cont'dl
Reassembly
65. Installthe solenoidharnessconnectorwith a new O-ring{one bolt},then installthe lower valve body assemblywith
threedowel pins (eightboltsl.
66. Installthe ATFstrainerwith a new O-ring(two bolts).
assemblethe ATF pan,ATFfilter,and the ATF coolerinlet pipe(seepage'14-235).

67. lf necessary,
68. Installthe ATF pan with the two dowel pins and a new ATF pan gasket(fourteenbolts).
69. Installthe ATFcoolerinlet pipe bracketbolt.
70. lnstalltheATFcooleroutletpipe with the joint bolt and new sealingwashers.
6x1.0mm
12 N.m 11.2kgf m,
8.7 tbt.ftl
DOWELPINS
ATF STRAINER
O-RING
ATF COOLEROUTLETPIPE
OOWELPINS
ATF PAN/ATFFILTER/
ATF COOLERINLET
PIPEASSEMEI-Y
SEALING
WASHERS
O-RING JOTNTBOLT
28 N.m {2.9ksf.m, 21 lbf.ft)
HARNESS
CONNECTOR
5x1.0mm
12 N.m {1.2kgt.m,
8.7 tbf.ftl
6x1.0mm LOWERVALVEBODY
12 N.m 11.2kgf.m, ASSEMBLY
8.7 tbf.ttl 6x1.0mm
12 N.m 11.2kgt m,
8.7 tbf.ft)
ATF COOLEFINLET
PIPEERACKETBOLT
8 x 1.25mm
26 N.m (2.7kgf.m,20 lbf.ftl
14-278
Flywheel/DrivePlate
DRIVEPLATE WASHER
6nKn,
teethot the ring gearfor excessive
wear.
1 2x 1 , 0m m
74 N.m {7.5kgI.m, 54lbl.ftl
Torque in 6 crisscrosspattern.
14-279
Transmission
Installation
l Flushthe ATF cooleras describedon pages'14-284 6. Placethe transmissionon a jack,and raise it to the
a n d1 4 ' 2 8 5 . e n g i n ea s s e m b l lye v e l .
2. R e m o v et h e u s e d g r e a s ei n t h e f l y w h e e lh u b c a p 7. Attach the transmissionon the engine,then install

and flywheelsplines. the transmission h o u s i n gm o u n t i n gb o l t a n d r e a r
e n g i n em o u n t i n gb o l t s .
3. Fillthe insideof the flywheelhub cap,andcoatthe fly
wheelhub splineswith SuperHighTempUreaGrease
(P/N08798- 9002)as shown. REARENGINEMOUNTING
TRANSMISSION HOUSING BOLT
MOUNTINGBOLT Replace.
64 N.m (6.5kgt.m, '12x 1,25mm
41 59 N.m (6.0 kgf.m, 43 lbtftl
SPLINES
Apply SUPERHIGHTEMP WASHER
UREAGREASE
{P/N 08798- 90021
SUPERHIGHTEMP .:_11
UREAGNEASE
{P/N 08798- 90021
1.5- 2.5 g (0.05- 0.ogozl
8. lnstallthe transmissionmount bracket Tightenthe

long bolt loosely,and tighten the nuts and bolt on
4. Instalal n e w s e a l i n gr i n g ( r u b b e r o
) n the input t h e m o u n t b r a c k e t o t h e s p e c i f i e dt o r q u e .T h e n
shaft,and installtwo 14 x 20 mm dowel pins in the tightenthe long bolt to the specifiedtorque.
llywheelhousing.
1 2x 1 . 2 5m m
lnstallthe flywheelsecurelyon the input shaft,then 64 N.m {6.5kgl.m, 47 lbl.ft)
installthestartermotor on the flywheelhousing.
44 N.m
(4.5kgf.m.33 lbf.ft)
INPUTSHAFT
STARTER
14x20mm
rtl DOWEI-PIN
I S E A L I N GR I N G
{RUBBER)
14 x 20 mm DOWELPIN
FLYWHEEL
MOUNT
12 x L25 mm
74 N.m {7.5kgl.m,54lbtft}
14-280
9. Installthe remainingtransmissionhousingmount- 13. Tightenthe crankshaftpulleybolt, if necessary(see
ing bolts. section6).
PRIMARYOXYGENSENSOR 1 4 . Connectthe ATF cooler hosesto the ATF cooler pipes

(seepage 14-2891.
CAUTION: While connecting the ATF cooler hoses,

be sure not to allow dust and other loreign parti-
cles to enter ioto the transmission.
Installthe rightfront mounvbracket.
10 x 1.25mm
4{ N.m (,1.5kgl m, 33 lbf ftl
RIGHTFRONT
MOUNT/EFACKET
ATF COOI.IRPIPE
'10x 1.25mm
1 0 . Removethe transmissionjack and the hoist, then
54 N.m 15.5kgt m,
removethe hoist bracketfrom the engine. {0 rbf.ft)
1 1 . Attach the flywheel to the drive plate with eight

boltsand torqueas follows:
Rotatethe crankshaftpulleyas necessary to tighten ATF COOI.ERHOSE
the bolts to half of the specifiedtorque,then to the
final torque,in a crisscrosspattern. 16. Install the exhaust pipe A.
A f t e r t i g h t e n i n gt h e l a s t b o l t , c h e c kt h a t t h e
crankshaftrotatesfreely. EXHAUSTPIPEA
1 2 . Installthe flywheelcoverand the enginestiffeners.

6x1.0mm
12 N.m
11.2kotm. ENGINE 10 x 'l .25 mm
DRIVE TE e.zruittt STIFFENER ,14N.m (4.5kgf.m,
33 tbt.ftl
GASKET
8 x 1.25mm Replace.
24Nm
(2.6 kgf.m,
17 tbf.ftl
@
\
oo"*ar-@ SELF.LOCKING NUT
Replace. Replace.
DRIVEPLATEBOLT
6x1.0x14mm SELF.LOCKING 10x 1.25mm
12 N.m {1.2kgt m, Beplace. 54 N.m (5.5kgf m,
8 x 1.25mm 4r) tbt.ftt
8.7 tbl.ft| 26 N.m 8 x 1.25mm
FLYWHEEL 22 N m {2.2kgf.m,16lbtftl SELF.LOCKING NUT
12.7kgl..n. Replace.
ENGINE STIFFENER 20 rbf.ft)
8 r 1.25 mm
10 x 1.25mm 16 N.m 11.6kgf m,
8 x 1.25mm 44 N.m (4.5kgf.m,
24 N.m (2.4 kgf'm, 17 lbt ft) 12 tbf.ft) (cont'd)
33 rbtft)
14-281
Transmission
Installation(cont'd) \
1 7 . Installa new set ring on the end of eachdriveshaft. 20. Installthe splashshield.
1 8 . Installtheright and left driveshafts(seesection16).
CAUTION:While installing the drivcshalts in the

diflerential, be sure not to allow dust and other for-
eign particlesto enter into the transmission.
NOTE:
I Cleanthe areaswherethe driveshaftscontactthe
transmission ( d i f f e r e n t i atl h) o r o u g h l yw i t h s o l -
v e n t o r c a r b u r e t o cr l e a n e r ,a n d d r y w i t h c o m
pressedarr.
. Turn the right and left steeringknucklefully out-
ward, and slideeach driveshaftinto the differen-
tial until you {eel its set ring clip engagethe side
gear.
1 9 . Installthe damperfork,then installthe right and left 6 x 'l.O mm SPLASHSHIELD

9.8 N.m {1.0kgf.m,
b a l l j o i n t st o e a c h l o w e r a r m w j t h t h e c a s t l en u t s
7 .2 tbl'ttl
and new cotterprns.
2 1 . C o n n e c t h e v e h i c l es p e e ds e n s o rc o n n e c t o rt,h e
driven pulley speed sensorconnectorand the sec-
10 x 1,25mm
43 N.m ondarygear shaftspeedsensorconnector.
(4,4kgf.m,32 lbf.ftl
VEHICLESPEEO
SENSOR 6x1.0mm
'12N.m
CONNECTOR {1.2kgf.m, 8.7 lbl.ft}
DRIVENPULLEY
SPEEOSENSOR
CONNECTOR
SELF-LOCKING NUT ./*:,

Replace. ./ cbr-rERPtN
12x 1.25nm
64 N.m
CASTLENUT
1 2x 1 . 2 5m m
Beplace. a'.
{6.5 ks{.m,47 lbf.ftl 4 9-- 5 9 N m 1 5 . 0 - 6 . 0 k g f . m ,
36 43 tbf.ftl
SECONDARYGEAR
SHAFTSPEED 6x1.0mm
SENSORCONNECTOR 12 N.m 11.2kgl m, 8.7lbf.ftl
14-282
22. Installthe shift cableend on the control lever,and 25. Connectthe startermotor cableon the startermotor,
installthe shift cableon the shift cablebracket. and installthe cableholder.
Takecarenot to bendthe shift cable.

CAUTIONT NOTErWhen installingthe startermotor cable,make
s u r e t h a t t h e c r i m p e ds i d e o f t h e r i n g t e r m i n a li s
2 3 . I n s t a l l t h ce l i pi n t h e d i r e c t i o sn h o w n . facingout (seesection23).
LOCKNUT
SHIFTCABLE 29 N.m (3.0 kgl.m, 22 lbfftl STARTERMOTOR
SHIFTCABLE
BRACKET
WASHER
IPLASTIC}
STARTER
B TERMINAL MOUNTINGNUT
I N.m 10.9kgt.m, 7 lbtft)
CONTBOL
LEVER
26. Installall removedconnectorsand clamps.
24. Connectthe solenoidharnessconnector,the drive 27. Inslallthe distributor.
p u l l e y s p e e d s e n s o rc o n n e c t o r ,a n d t h e g r o u n d 2 8 . I n s t a l tl h e i n t a k ea i r d u c t a n d a i r c l e a n e rh o u s i n g
c a b l et e r m i n a l s . assemDty.
2 9 . R e f i l l t h e t r a n s m i s s i o nw i t h t h e r e c o m m e n d e d
6x1.0mm GROUNDCABLE G e n u i n eH o n d aC W F l u i d( s e ep a g el 4 - 2 3 1 ) ,
12 N.m {1.2kglm, TERMTNAL 6x1.0mm
12 N.m 11.2kgl.m,
8.7 tbt.f0
8.7 rbf.ftl CAUTION:While lilling the CVT Fluid,be sure not to
allow dust and other toreign particles to enter into
the transmission.
30. Connectthe battervpositive(+) terminalfirst, then

the negative{-) terminalto the battery.
Checkthe ignitiontiming (seesection231.
a ) Startthe engine.Setthe parkingbrake,and shiftthe
t r a n s m i s s i otnh r o u g ha l l g e a r st h r e et i m e s .C h e c k
shift cableadjustment(seepage14-287).
33. Checkthe front wheelalignment(seesection18).
DRIVEPULLEY 3 4 . L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
SPEEDSENSOR
CONNECTOR r a d i a t o fr a n c o m e so n ) w i t h t h e t r a n s m i s s i oinn E
or E position,then turn it of{ and checkfluid level.
3 5 . P e r f o r mt h e s t a r tc l u t c hc a l i b r a t i o np r o c e d u r eo n
page 14-225.
36. Roadtest as describedon pages14 228 and 14-229.
14-283
Transmission
CoolerFlushing \
!@ To prevent iniury to face and eyes, always 7. With the water and air valves off, attach the water and
wear satety glassesor a face shield when using the air suppliesto the flusher. (Hot water if available.)
transmissionflusher,
NOTE:This procedureshouldbe performedbeforerein-

stallinqthe transmission.
1. C h e c kt o o l a n d h o s e sf o r w e a r a n d c r a c k sb e f o r e
using.lf wear or cracksare found, replacethe hoses
be{oreusing.
2. Usingthe measuringcup,fill the tankwith 21 ounces

(approximately213tulll ot biodegradableflushing
fluid (J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
container.
3 . Securethe flusherfiller cap,and pressurizethe tank 8. Turn on the flusher water valve so water will flow
with compressedair to between550- 829 kpa (5.6- throughthe coolerfor 10 seconds.
8.45kgf/cm,,80- 120psi).
NOTE:lf water does not flow throughthe cooler,it
NOTE:The air line shouldbe equippedwith a water is completelyplugged,cannotbe flushed,and must
trap to ensurea dry air system. be replaced.
4. Hangthe tool underthe vehicle. 9. Depressthe triggerto mix the flushingfluid into the
waterflow. Usethe wire clipto holdthe triggerdown.
5. Attach the tank's dischargehose to the return line
of the transmissioncoolerusinga clamp. 10. While flushingwith the water and flushingfluid for
two minutes,turn the air valve on for five seconds
6. Connectthe drain hoseto the inlet line on the trans- every '15- 20 secondsto createa surgingaction.
missioncoolerusinga clamp. AIR PRESSURE: MAX 845 kpa(8.45kgtcm,, 120psi)
IMPORTANT: 11. Turn the water valve off. Releasethe trigger,then

Securelyclampthe oppositeend ol the drain hoseto a reversethe hosesto the coolerso you can llush in
bucketor floor drain. the oppositedirection.Repeatsteps8 through 10.
Releasethe trigger,and rinsethe coolerwith water

o n l yf o r o n e m i n u t e .
Turn the water valveoff, and turn off the water supply.
1 4 . Turn the air valve on to dry the systemout with air

for two full minutesor until no moistureis visible
leavingthe drain hose.
CAUTION: Residual moisture in the cooler or lines

can damagethe transmission.
1 5 . Removethe flusherfrom the cooler line.Attachthe

drain hoseto a container.
1 6 . I n s t a l tl h e t r a n s m i s s i o na,n d l e a v et h e d r a i n h o s e
attachedto the coolerline.
{Commerciallyavailablel
Kent-MooreJ384O5-A
or equivalent
14-284
't1. Makesurethe transmissionis in the position. TOOL MAINTENANCE
E
w i t h C V T F l u i d ,a n d r u n t h e
F i l lt h e t r a n s m i s s i o n
'1. Emptyand rinseaftereachuse.Fillthe canwith water
enginefor 30 secondsor until approximately0.95/
( 1 . 0U S q t . , 0 . 8l m p q t . )i s d i s c h a r g e d . and pressurizethe can. Flushthe dischargeline to
e n s u r et h a tt h e u n i ti s c l e a n .
'18. R e m o v et h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r
returnhoseto the transmission(seepage l4 287). 2. lf dischargeliquiddoes not foam,the orificemay be
blocked.
1 9 . Refillthe transmissionwith CVT Fluidto the proper
l e v e l( s e ep a g e ' 1 42 3 1 ) . 3. T o c l e a nd , i s c o n n e ct ht e p l u m b i n gf r o m t h e t a n k a t
t h e l a r g ec o u p l i n gn u t .
FILLERCAP
couPLlf{G
NUT
I I
-@q
\
ORIFICE
Removethe in-linefilterfrom the dischargeside and

cleanif necessary.
The tluid orifice is located behind the filter. Clean it

with the pick stored in the bottom of the tank han
dle, or blow it clean with air. Securely reassemble
all parts.
14-285
Shift Cable
Removal/lnstallation \
!@ Make sure lifts, iacks and salety stands ale 3. Removethe air cleanerhousingassembly.
placed properly (seesection 1).
Removethe clip from the control lever,and loosen
1. Removethe front console(seesection20). the locknut.
CLIP SHIFTCABLE LOCKNUT
2. Shift to ffi position,then removethe lock pin from 29 N.m {3.0 ksf.m, 22 lbtft)
the adiuster.
Tr(>
WASHER
SHIFI CABLE
BRACKET
CONTROLLEVER
\
Removethe shift cable from the control lever,the
shift cablebracket,and the clamp.
Removethe shift cablebracketbolts and nuts,then

remove the shift cable.Take care not to bend the
shift cablewhen removing/installing
it,
SHIFTCABLEBRACKET
( 0 . 7 k g f . m ,5 l b f . f t l
ADJUSTER
{1.2 kgt.m,8.7 lbl.ft)
! 1.
8.
Installthe shiftcablein the reverseorderof removal.
Checkthe cableadjustment(seepage 14-2871.
14-286
Adjustment
@ Make sure lifts,lacks and safety stands are 3. Checkthat the holein the adiusteris perfectlyaligned
placed properly {seesestion 11, with the holein the shiftcable.Therearetwo holesin
the adjuster.They are positioned90" apartto allow
1. Removethe front console(seesection20). cableadiustmentin 1/4turn increments.
2. Shift to E position,then removethe lock pin from

the adjuster.
lf the hole is not perfectlyaligned,loosenthe lock-

nut on the adjusterand adjustas required.
Tightenthe locknutto 7 N.m {0.7kgf.m,5 lbnft}.
Installthe lock pin on the adjuster.lf you feel the

lock pin binding as you reinstallit. the cable is still
out of adjustmentand must be readjusted.
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d j u s t e r
SHIFTCABLE
10.7 kgf'm, 5 lbf'ftl securely.
Movethe shift leverto eachposition,and verifythat

the shift position indicatorfollows the automatic
transaxlegear positionswitch.
q
S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
positions.If any gear does not work properly.reier
to troubleshooting (seepage14-226and l4-227J.
Insen the ignition key into the key cylinderon the

A//Tgear positionindicatorpanel,and verifythat the
shift lockleveris released.
14-287
Shift Lever
PUSHKNOBSPRING
,l
PUSHKNOB
-6r
SILICONEGREASE
SHIFTINOICATORLAMP
LEVERCOVER
SHIFTLOCK
SOLENOID BUSHING
LEVERCOVER
..@]
SILICONEGREASE
SCREW
SHIFTLEVERASSEMBLY
3 N.m {0.3 kgt m, 2 lbtft)
EJ
@'""'-rccretn
ADJUSTER
6xl.0mm
9.8N.m {1.0kgl m, -6.,1
1.2 tbt.ltl SILICONEGREASE
A/T GEARPOSITION
PLATE A/T GEARPOSITIONSWITCH
3 N.m {0.3kgf.m,
2 tbf.ftl
SHIFTLEVERBRACKETBASE
SHIFTLEVERBRACKET
BASECOLLAR
6x1.0mm
9.8N.m (1.0kgf m,7 2lbtft)
14-288
Shift IndicatorPanel ATFCooler/Hoses
Adjustment lnstallation
1 . C h e c kt h a t t h e i n d e x m a r k o n t h e i n d i c a t o a
r ligns 1. I n s t a l lt h e A T F c o o l e r ,A T F c o o l e r p i p e a s s e m b l y
with the E mark on the shift indicatorpanelwhen and the ATFcoolerhoses.
t h et r a n s m i s s i oi n
s in NEUTRAL.
6x1.0mm
ATF COOLERPIPEASSEMBLY
ATF COOLERHOSE
RADtAfoR
/,/'
6xl.0mm
9.8N.m (1.0tgl m,7.8 lbf ftl
MOUNTINGSCREW TANEL
3 Nm {0.3kgt.rn.2lbtft} HOSES
ATFCOOLER
lf not aligned, remove the front console (see section C o n n e c t h e A T F c o o l e r h o s e st o t h e A T F c o o l e r

20). linesand ATF cooler,and securethem with the clips
a ss h o w n .
Remove the shift indicator panel mounting screws
and adjust by moving the panel.
RADIATOR
NOTE: Whenever the shift indicatorpanel is removed,

reinstallthe panel as described above,
/
I &)
\-6-gmm
(0.2- 0.3in)
6-8mm
(0.2- 0.3 in)
33-35mm
( 1 . 3- 1 . 4i n l
2-4mm
10.1- 0.2 inl
I
14-289
Differential
seetion13
......................
ManualTransmission
AutomaticTransmission section14
.................
d
Driveshafts
SpecialTools.......... """.."' 16-2
Driveshafts
Inspection 16-3
..."...'.'..'....'...
Removal ....16-3
Disassembly 16-5
..".'...."....."
Reassembly 16-7
......."...'."....
lnstallation 16-11
..'........'..'.'..'.
SpecialTools
Ref. No. I Tool Number
BallJoint Remover,28 mm
16-2
Driveshafts
Inspection Removal
Drivoshafi Boot 1 . Loosenthe wheel nuts slightlY.
Checkthe boots on the driveshaftfor cracks,damage,
leakinggreaseand loose boot bands.lf any damageis Raisethe tront of the vehicle,and support it with
found,replacethe boot and boot bands safetystandsin the properlocations(seesection1).
Loose Splines Removethe wheel nuts and front wheels.

Turn the driveshaftby hand and make sure the splines
and ioint are not excessivelyloose lf any damage as
found.replacethe inboardjoint.
Twisted or Cracked
Makesurethe driveshaftis not twistedor cracked.
ReDlace it if necessary.
Drainthe transmissionfluid (seesection13 or 14).
R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut,
a Removethe self-lockingnut and flangebolts.
FLANGEEOLT
10 x 1.25mm
BOOT BANDS
12 x 1.25mm
Replace.
7. Remove the damper fork.
(cont'd)
16-7
Driveshafts
Removal {cont'd)
8. Removethe cotter pin from the lower arm ball joint 1 2 . P u l l t h e i n b o a r dj o i n t , a n d r e m o v et h e d r i v e s h a f t
castlenut, and removethe nut. from the differentialcase as an assembly.Do not
pull on the driveshaft;the inboardjoint may come
apart.Use carewhen prying out the assembly,and
pull it straightto avoid damagingthe differentialoil
seal.
07MAC- St_00200
9 . I n s t a l la 1 2 m m h e x n u t o n t h e b a l l j o i n t . B e s u r e
that the hex nut is flush with the ball joint pin end,
or the threadedsectionof the ball joint pin might be SCREWDRIVER
damagedby the specialtool.
1 0 . Usethe specialtool as shown in section18,to sepa- 13. Pullthe knuckleoutward.and removethe driveshaft
rate the ball ioint and lower arm. Be carefulnot to o u t b o a r dj o i n t f r o m t h e f r o n t w h e e l h u b u s i n g a
damagethe ball joint boot, olastichammer.
NOTE: lf nece'ssary,apply penetratingtype lubri-

cantto loosenthe bsll joint.
1 1 . Pry the driveshaftassemblywith a screwdriver,as

shown, to force the set ring at the driveshaftend
pastthe groove.
SCREWDRIVER
3.5mm
ORIVESHAFT
16-4
Disassembly
- It the boot band is double loop type, raise the
1. Caretullyclamp the driveshaftin a vise with soft
jaws, then remove the set ring from the inboard band bendas shown.
joint.
To removethe boot band, pry up the lockingtabs

with a screwdriverand raise the end of the band.
Takecarenot to damagethe boot. DOUB1I I.OOPBAND
R6place.
Mark each roller and inboard ioint to identify the

locations of rollers and grooves in the inboard joint.
Then remove the inboard joint on the shop towel.
Be careful not to drop the rollers when separatang
them from the inboard joint.
SETRING
Replace.
- lf the boot band is the welded type, cut it off as
INBOARDJOINT
snown. Checksplineslor wear or damage
Checkinsideborefor wear'
BOOTBAND Inspect{or cracks.
Replace.
- lf the boot band is the crimpingtype, pry up the

end of the bandwith a screwdriver.
BOOTBAND
Replace.
Mark3
{cont'd)
16-5
Driveshafts
(cont'dl
Disassembly \
4. Mark the rollersand spiderto identifythe locations 9. Wrap the splineson the driveshaftwith vinyltapeto
of rollerson the sDider,then removethe rollers. preventdamageto the bootsand dynamicdamper.
INBOARD BOOT
for cracking,BOOTBAND DYNAMICOAMPER
Inspect
splitting
andwear. R e p l a c e . BAND
Replace.
OYNAMICDAMPER
Checkfor damage.
OUTBOARDBOOT
Inspectfor cracking,
splittingand wear.
1 0 . Removethe boot band and inboardboot.Takecare
not to damagethe boot.
1 1 . R e m o v et h e d y n a m i cd a m p e rb a n d a n d d y n a m i c
damper,if equipped.Takecare not to damagethe
dynamicdamper.
12. Removethe boot bsnds and outboard boot, then

removethe vinyltape.
1 3 . Inspectthe outboardjoint for faulty movementand

wear. lf any roughnessor excessplay is felt, replace
Removethe circlip. the outboardjoint.
Mark the spider and driveshaftto identitythe posi-

tion of the spideron the shaft.
7. Removethe spiderusinga bearingremover.
Removethe stop ring (exceptJapanproduced).
OUTBOARDJOINT
16-6
Reassembly
Notetheseitemsduring reassemblyl
. Cleanthe disassembledpartswith solvent,and dry them throughlywith compressedair. Do not wash the rubberparts
with solvent.
. -,.6l : Thoroughlypackthe inboardjoint and both joint bootswith the ioint greaseincludedin the new driveshaft
Greasequantity:
' 1 1 0- 1 2 0g { 3 . 9- 4 . 2o z )
Japan Produced
lnboardJoint '120- 130g
ExceptJapanProduced {4.2- 4.6ozl
JapanProduced 70 - 80 g (2.5- 2.8 oz)
OutboardJoint
ExceptJapanProduced 1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z )
SCTRING INBOARDJOINT
Replace.
\zn ROLLER
STOPRING{ExceptJapan producod}
B(rcT
INBOARD
- - -
Packcavitywith grease. --" &l
Packcavity with groase.
DYNAMICDAMPER
BOOTBANDS
Replace.
DRIVESHAFT
OYNAMICDAMPERBAND
Replace.
OUTBOARDBOOT
-611
Packcavity wrtn grease.
(cont'd)
16-7
Driveshafts
Reassembly(cont'dl
1. Wrap the splineswith vinyl tape to preventdamage 4. I n s t a l lt h e s t o p r i n g i n t o t h e d r i v e s h a f tg r o o v e
to the bootsand dvnamicdamoer. {exceptJapan produced),Always rotate the stop
ring in its grooveto be sure it is fully seated.
V;
APE
OUTBOAROBOOT \zr|<-C|RCL|P
DYNAMIC
DAMPER
Installthe spider on the driveshaftby aligningthe
INAOARD BOOT markson the spiderand end of the driveshaft.
2. I n s t a l lt h e o u t b o a r db o o t , d y n am i c d a m p e r a n d
i n b o a r db o o t t o t h e d r i v e s h a f tt.h e n r e m o v et h e Fit the circlip into the driveshaftgroove. Always
vinyl tape.Take care not to damagethe boots and rotatethe circlip in its groove to be sure it is fully
dynamicdamper. seated.
Packthe outboardjoint with the joint greaseincluded 7. Fit the rollersto the spiderwith their high shoulders
in the new driveshaftset, facingoutward,and notetheseitems:
. Reinstallthe rollersin their originalpositionson
Greasequantity: the spiderby aligningthe marks.
Japan Produc€d: 7o- 80g (2.5- 2.aozl . H o l d t h e d r i v e s h a f tp o i n t e du D t o prevent the
ExceptJapan Produced:115- 1359 (i1.0- 4.8ozl rollersfrom tallingoff.
16-8
8. Packthe inboardioint with the joint greaseincluded 10. Adjust the length of the driveshaftsto the figure
in the new driveshaftset. below, then adiust the boots to halfway between
f u l l c o m p r e s s i o na n d f u l l e x t e n s i o nT h e e n d s o f
Greasequantity: bootsseatin the grooveof the driveshaftand joint.
Jaoan Produced: 110- 120g (3.9- 4.2ozl
ExceptJapan Produced:120- 130g (4.2- 4.6 ozl Left driveshaft: 774- 779 mm 130.5- 30.7in)
Right driveshaft:501- 506 mm 119.7- 19.9in)
1L Positionthe dynamicdamperas shown below.
Left:
Fit the inboardjoint onto the driveshaft,and note Without "SRl" mark:94 :t 2 mm 13.7t 0.1 in)
thesertems: With "SR1" mark: 75 t 2 mm 12.9i 0.1 in)
. Reinstallthe inboardjoint onto the driveshaftby Right5: 5 1 2 m m ( 2 . 2t 0 . 1i n l
a l i g n i n gt h e m a r k so n t h e i n b o a r dj o i n rw i t h t h e
markson the rollers.
. Holdthe driveshaftso the inboardjoint pointsup
to preventit from fallingoff.
INBOARD
JOINT
DYNAMICDAMPERBAND
{cont'd)
16-9
Driveshafts
(cont'd)
Reassembly
\
12. Set the doubleloop band onto the boot and dynam- Threadthe free end of the band through the nose
ic damperwith the band end toward to front of the sectionoJ the boot band tool and into the slot on
vehicle. the winding mandrel.
Placea wrenchon the winding mandrslof the boot

band tool, and tighten the band until the mark you
madeon the bandmeetsthe edgeof the clip,
AOOTBAND
TOOL
(KD-3191
or equivalent) Markon band.
Pullup the slackin the band by hand.
1 4 . Mark a positionon the band 10 - 14 mm (0.4- 0.6

in) from the clip. 1 7 . Raiseup the boot band tool to bend the free end of
the band90 degrees,then center-punch
the clip,
cuP
HAiIMER
16-10
lnstallation
18, Unwindthe boot bandtool, and cut oft the excess5 1. Installthe new set ring onto the driveshaftgroove.
- l0 mm 10.2- 0.4 in) from the cliP. Always use a new set ring wheneverthe driveshaft
is beinginstalled.
5-10mm
(0.2- 0.4 in)
INBOARDJOINT
SETRINGGROOVE
'19. Securethe end of the boot band by tappingit down
with a hammer,
2. Installthe outboardjoint into the knuckle.
KNUCKLE
Notetheseitemsafter reassembly:
. Make sure the band and clip does not interferewith
anythingand the band does not move.
! R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r r o u n d i n g JOINT
OUTBOARD
surtaces.
(cont'd)
1 6 - 11
Driveshafts
(cont'd)
Installation
Cleanthe areas where the driveshaftcontact the 5. Installthe damperfork over the driveshaftand onto
transmission(differential)thoroughlywith solvent t h e l o w e r a r m . I n s t a l lt h e d a m p e ri n t h e d a m p e r
or carburetorcleaner.and dry with compressedair. f o r k s o t h e a l i g n i n gt a b i s a l i g n e dw i t h t h e s t o t i n
Insertthe inboardend of the driveshaftinto the dif- the damoerfork.
ferentialuntil the set ring locksin the groove.
FLANGE BOLT
INAOARD
JOINT 10x 1.25mm
(3 N.mla.akgf.m.32lbf.trl aLtGNtNG
TAB
DIFFERENNAL
Installthe knuckleon the lower arm. Be carefulnot
d a m e g et h e b a l l j o i n t b o o t . W i p e o f f t h e g r e a s e
before tighteningthe nut at the ball joint. Torque
SELF.LOCKING NUI
the castlenut to the lowertorquespecification. then 12 x 1.25mm
tighten it only far enoughto align the slot with the fl N.m (6.5 kgf.m, it7 lbf'ltl
pin hole.Do not alignthe nut by loosening. Repiace.
6. Loosely install the flange bolts and the new self-

locking nut.
7 . Apply oil to the seating surface of the new spindle
nur.
FRONTWHEEL
WHEELNUT 12 x 1.5mm
108 N.m {11.0kgt m, 80lbt ftl
COTTERPIN
Replace.
CASTLE On reassembly,
12 x 1.25 mm bend the cotter pin
alt - 59 N.m 15.0- 6.0 kg{.m, 36 - ail lbl.ftl
SPINDLENUT 22 x 1.5 mm
181N.m 118.5kg{.m, 134lbf.tt)
NOTE: After tightening,use a drift to
stake
thespindlenutshoulder
against
thedriveshaft.
8. Installa new spindlenut,then tightenthe nut.
9. Cleanthe mating surfacesof the brakedisc and the
wheel, then installthe front wheel with the wheel
nutS,
10. Tighten the flange bolts and the new setf-locking
nut with the vehicle'sweighton the damper.
11. Refillthe transmissionwith recommended fluid (see
f, section13 or 14).
'12. Check
the front wh;eltlbnment
essarv(seesection18).
'il and adjust if nec-
16-1 2
Steering
Tools
Speciaf .............17-2 Inspestion and Adiustment
17-30
SteeringOperation..........................
ManualSteering Power Assist Check
ComponentLocations 17-30
With VehicleParked ....................
fndex ................ .......17'3 SteeringLinkageand Gearbox .......17-31
Inspection and Adiustment Pump Beft ..............
17-32
SteeringOperation.......................... 17-4 RackGuideAdjustment ................... 17-33
RackGuideAdjustment................... 17-5 17-33
FluidRep|acement...........................
'Steering Wheel PumpPressure 17-34
Check......................
(Seepower steering sec'tion) *Steering Wheel
*SteeringColumn Removal 17-35
.................
(Seepower steering sectionl lnstallation .............
17-35
Steering Gearbox Disassembly/Reassembly I 7-36
...............
Removal 17-5
................. 'Steering Column
Disassembly 17'7
........... 17-37
Removal/lnstallation.......................
Reassembly ............
17-9 Inspection ..............
17.38
lnstallation .............
17-13 Power Steering Hoses,Lines
Fluid LeakageInspection.................17-39
PowerSteering Replacement ..........17-39
Component Locations Power SteeringPump
lndex ................ .......17-15 17-tlo
System Description Disassembly ...........
17-41
FluidFlow Diagram.......................... 17-16 fnspection ..............17-42
17-17
SteeringPump .................................. Reassembly ............17-44
Steering Gearbox 17-20
............................. SteeringGearbox
Troubleshooting Removaf 17-47
,,,,.,...........
GenerafTroubleshooting................ 17-22 Disassembly 17-lt!l
...........
Noiseand Vibration......................... 17-26 Reassembly ............
17-55
Ffuid Leaks .............17-28 lnstallation .............
17-65
Ball Joint Boot Replacement..........17-68
SpecialTools
Ref. No I Tool Number Description Oty PageReferenco

I
a 07GAF- PH70100 P i l o tC o l l a r 11-54
07GAG- SD40l0Aor PistonSealRing 17-59
07GAG- SD40100
aal 07GAG- SD40204or PistonSealRingSizingTool 17-59
07GAG- SD40200
@ * 0 7 J G G- 0 0 1 0 1 0 A BeltTensionGauge 1
07MAC- S100200 B a l lJ o i n tR e m o v e r , 2 m
Sm 'l
17-6,47
OTNAD- SR3O2OA CylinderEnd SealRemoverAttachment I 17-51
o 07NAG- SR3090Aor PistonSealRingSizingTool 1 17-56
07NAG- SR30900
@ 0 7 R A K- 5 0 4 0 1 1 0 P/SJoint Adaptor(Pump) 17-34
ao'r 07RAK- 5040121or P/SJoint Adaptor(Hose) 't]-34
07RAK- 5040120
@ 07406- 0010004or P/SPressureGauge 17-34
07406- 00'10001
o 07725- 0030000 UniversalHolder 17-42,46
@ 07746- 0010100 Attachment,32x 35 mm 17-57,58
@ 07746- 0020'100 Driver,22 mm l.D. l 7 -1 0
@ 07746- 0030300 Attachment,30 mm l.D. 't7-44
@ 07749- 0010000 Driver 17-57
@ 07916- SA50001 LocknutWrench,40 mm
@ 07965- SA50500 FrontHub Dis/Assembly Tool 17-68
@ 07974- SA5020Aor SleeveSealRingSizingTool 17-51
07974- SA50200
@ 07974- SA50800 EallJoint BootClip Guide 17-57,68
* Includedin the BeltTensionGaugeSet,07TGG-
001OOOA.
g/ @
o
,g
=fu* (o)
l:1
@
o @
0 (D @
7-2
ComponentLocations
lndex
ManualSteering
NOTE:
. lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has beenfound defectiveor damageddur-
ing transit,storageor service,it shouldbe deployed{seesection24)'
. Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel
. After installingthe gearbox,checkthe wheelalignmentand adjustif necessary.
and proceduresin the SRS

SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
section{24}beforeperformingrepairsor service
STEERINGWHEEL
page17-35
Removal/lnstallaiion,
page17'36
Disassembly/Reassembly,
DRIVER'SAIRBAGASSEMBLY
seesection24
Bemoval/lnstallation,
STEEBINGCOLUMN
Page17 37
page'17-38
Inspection,
CABLEREEL
seesection24
Femoval/lnstallation,
IGNITIONSWITCH
Seesection23
STEERINGGEARBOX
RackGuideAdjustment,Page17-5
R e m o v apl ,a g e ' 1 7 - 5
Disassembly, page17-7
Beassembly, page'179
Installation, page17 13 TIE.RODENOBALLJOINT
page17-68
BallJoint BootFeplacement,
17-3
Inspectionand Adjustment
SteeringOperation \
SteeringWheel Rotational Play Steering Eftort Check

Placethe front wheels in a straightahead positionand Raisethe front wheelsoff the ground.
measurethe distancethe steeringwheel can be turned Turn the steeringwheelwith a springscaleand checkits
without movingthe front wheels. reaoIng.
PLAY:0 - 10 mm (0 - 0.4 in)

ROTATIONAL Standard:15 N {1.5kgf,3.3 lbfl maximum
lf the play exceedsthe servicelimit, perform rackguide l f i t r e a d sm o r e , p e r f o r mr a c k g u i d e a d j u s t m e n (t s e e

adjustment(seepage17'5). page 17-5).
lf the play is still excessiveafter rack guide adjustment,
inspectthe steeringlinkageand gearbox as described
BOTATIONALPLAY
\ -J -
TJ
TIE.RODLOCKNUT
Checkfor looselocknut.
BOOT
I n s p e c tf o r d a m a g e a n d d e t e r i o r a t r o n
COLUMN
for loosecolumn
InsPect
STEERING JOINTS
mountingboltsand nuts
Checkfor looseioint bolts.
PINIONSHAFTGROMMET
for damageand deterioration
BALLJOINT BOOT
Inspectfor damageand deterioration.
END BALLJOINT
Seepage17-68for replacement.
Inspectfor faultymovement
ano oamage.
MOUNTING
GEARBOX
l n s p e c tf o r d e t e r r o r a t l o n
GEARBOX ASSEMBLY
\
Inspectfor loosemountingbolts.
17 -4
SteeringGearbox
RackGuide Adjustment Removal
N O T E : P e r f o r mt h e r a c k g u i d e a d j u s t m e n tw i t h t h e NOTE:Using solventand a brush.to wash any oil and
wheelsin the straightaheadposition. dirt off the gearbox.Blow dry with compressedair.
1. Loosenthe rack guide screw locknutwith the spe- 1. Raisethe front of vehicle,and support it on safety
cialtool, then loosenthe rackguidescrew. standsin the properlocations(seesection1).
2. Removethe front wheels.
3. Removethe steeringwheel (seepage 17-35).
4. Removethe steeringioint cover
STEEBINGJOINTCOVER
07916- SA5000l
Tightenthe rackguidescrewuntil it compressesthe

springand seatsagainstthe rackguide,then loosen
it.
Retightenthe rackguide screwto 4 N.m (0.4kgf'm,

2.9lbtft), then backit off to specifiedangle.
5. Removethe steeringjoint lower bolt, and discon-
SpecitiedReturn Angle: 30' max. nect the steeringjoint by moving the joint toward
t h ec o l u m n .
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw. STEERINGJOINT
Checkfor tight or loose steeringthrough the com-

pieteturningtravel.
Rechecksteeringeffort (seepage 17-4).
{cont'd)
SteeringGearbox
Removal (cont'dl
Removethe cotter pin from the castlenut ('96-'97 13, Removethe mountingbracket.
model)or nut ('98 model)and removethe nut.
COTTERPINS
Replace.
7 . Installthe 10 mm hex nut on the balljoint.

Be surethat the 10 mm hex nut is flushwith the ball
joint pin end,or the threadedsectionof the ball joint
pin mightbe damagedby the balljoint remover.
NOTE:Removethe ball joint usingthe specialtool.

R e f e rt o s e c t i o n1 8 f o r h o w t o u s e t h e b a l l j o i n t 1 4 . Pull the steeringgearboxall the way down to clear
remover. the pinionshaftfrom the bulkhead,then removethe
pinionshaftgrommet.
Separatethe tie-rodball joint and knuckleusingthe
specialtool. Move the steeringgearboxto right so the left rack
end clearsthe rearbeam,then tilt the lelt sidedown
CAUTION: Avoid damaging lhe ball ioint boot. to removeit from the car.
Removethe left tie-rod end, then slide the rack all

the way to the right,
1 0 . Separatethe exhaustpipeA or TWC (seesection_9). PINIONSHAFTGROMMET
1 1 . Disconnectthe shift linkage(seesection13 or sec-

tion14).
12. Removethe stiffenerplate,
STEERINGGEARBOX
17-6
Disassembly
l. Placethe gearbox in a vise with a soft jaws, then 5. Pushthe right end of the rackbackinto the cylinder
c l a m p t h e g e a r b o xa t t h e m o u n t b r a c k e to r g e a r housing so the smooth surfacethat rides against
noustng. the sealwon't be damaged.
CAUTION: Be car€ful not to distort the gear hous- 6. L o o s e nt h e l o c k n u t ,a n d r e m o v e t h e r a c k g u i d e

ing by clamping it too tight in the vise incorrectly. screw.
2. Removethe tie-rodend and locknut. 7. Remove the disc washer, spring and rack guide
from the gear housing.
3. Removethe boot bands and tie rod clips. Pull the
bootsawayfrom the ends of the gearbox.
SPRING
OISCWASHER
LOCKNUT FACKGUIDE
SCREW
8. R e m o v et h e p i n i o nd u s t s e a la n d t h e 3 5 m m s n a p
E-RODC L I P
ring.
BOOT I
Replace.
I 9. Holdthe pinionshaftwith a visesecurely.
R e m o v et h e p i n i o n b y t a p p i n ge v e n l ya r o u n dl h e
@ flanged sectionof the gearboxwith a plasticham
m er .
4. H o l d t h e s t e e r i n gr a c k w i t h o n e w r e n c h , a n d
unscrewthe rackend with anotherwrench. CAUTION: Do not tap on the steering rack.
CAUTION:Be caretulnot to damagethe rack sur- NOTE:Do not reusethe removedpinaon.

face with the wrench. PINIONOUSTSEAL
STEENINGRACKENO Repl6ce.
SNAPRING,35 mm
STEERINGPINION
Feplace.
17-7
SteeringGearbox
Disassembly(cont'dl
10. Slidethe steeringrackout of the cylinderhousing. the gearboxmountingcushionif necessary:
12. Replace
CAUTION: Be caretul not to damagethe bushing in To removethe cushion,usea sharpknifeand make

the cylinderhousing. a cut downthe lengthof the cushion.Becarefulnot
to damagethe painton the outsideof the cylinder
housing.Removethe old cushion.
Apply weatherstripadhesiveto the insideof the
new cushion.Installthe cushiononto the cylinder
housingand positionit 20- 22 mm (0.79- 0.87in)
from the end of the cylinderhousingas shown.
N O T E :A f t e r i n s t a l l i n gt h e c u s h i o n ,w i p e o f f a n y
e x c e s sa d h e s i v et h a t m a y h a v e d r i p p e d i n t o t h e
i n s i d eo f t h e c y l i n d e hr o u s i n g .
1 1 . R e m o v et h e r a c ke n d b u s h i n g .
GEARBOX
MOUNTINGCUSHION
20 - 22 mm 10.79
- 0.87in)
RACKENOBUSHING
Inspectinnerwall for wear or damage
1 7 -A
Reassembly
NOTE:
. Cleanthe disassembled partswith solvent,and dry them with compressedair. Do not dip the rubberpartsin solvent.
. Alwaysreplacethe non-reuseable partswith new ones beforeassembly.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe steeringgearbox.
PINIONDUSTSEAL
RACKENO BUSHING
-6r Replace.
GEARBOXMOUNTINGCUSHIONS
\
t_ M."^pR,NG.3smm
r@
-R4
-$d
\ \
RACKGUTDESCREW
DISCWASHER
RACKGUIDE
(cont'd)
17-9
SteeringGearbox
Reassembly(cont'd)
't.
Apply a thin coat of greaseto the insidesurfaceot 5. Drivein the steeringpinion in the gear housingwith
the rackend bushing. t h es p e c i a l t o o l s .
Greasequantity:1 - 3 g (0.04-0.1 oz)

PINIONDUST
SEAL
CAUTION:Do not fill the slots with greas€;they Replace.
DRIVER,
must remain open to serve as air passages. 22 .rlml.D.
07146-
2. I n s t a ltl h e r a c ke n d b u s h i n gb y a l i g n i n gt h e r o u n d 0020t00 SNAPRING,35 mm
projectionon the bushingwith the hole in the cylin- Vinyltape
d e rh o u s i n g
STEERING
PINION
6 . I n s t a l lt h e 3 5 m m s n a p r i n g s e c u r e l yi n t h e g e a r
nousrnggroove.
1 . Apply vinyl tape to the pinion shaft,then coat the

v i n y l t a p ew i t h g r e a s e .
8. Installthe piniondust sealon the gear housinguntil

it seatsproperly,then removethe tape.
3. Greasethe steeringrackteeth.
9 . G r e a s et h e s l i d i n gs u r f a c eo f t h e r a c k g u i d e ,a n d
4. I n s t a l lt h e s t e e r i n gr a c k i n t o t h e c y l i n d e rh o u s i n g i n s t a lilt o n t o t h e g e a rh o u s i n g .
c a r e f u l ltyo a v o i dd a m a g i n g t h e r a c ke n d b u s h i n g .
'10.
Installthe spring,discwasherand rackguide screw
o n t h e g e a rh o u s i n g .
NOTE:Installthe disc washerwith its convex side

f a c i n gi n .
DISCWASHER
SPRING
RACKGUIDESCREW
LOCKNUT
CYLINDERHOUSING '11.
Adjustthe rackguide screw(seepage 17-5).
17-1 0
12. I n s t a l lt h e n e w l o c k w a s h e r i n t h e g r o o v e i n t h e 16. Apply grease around the outside of the rack end
steeringrack. houstng.
IJ. Installthe steeringrackend into the rack.
RACKEND 54 N.m 15.5kgifm, 40 lbtftl
LOCKWASHER
Repiace.
t;J"' "
TAB .=-!!!r9i!l
SILICONE GREASE
RACK END
1 7 . A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
1 4 Hold the steering rack with a wrench and tighten grooveson the rackends,
the rackend with another.
CAUTION: Be carelul not to damage the rack sur- 1 8 . I n s t a l lt h e b o o t s i n t h e r a c k e n d w i t h t h e t i e - r o d
tace with the wrench. clrps.
t 5 , After tightening the rack ends, stakethe four sec-
tions of the lock washer with a roll pin drift and a NOTE: Install the boot band with the rack in the
mallet. straight ahead position (right and left tie-rods are
. Placethe wood blockon the presstable,then set e q u a li n l e n g t h ) .
the lock washer section of the rack end on the
wood blocksecurely.
. Be sure the tool is alignedwith the flat sections
of the steeringrackend beforepressing
. S t a k et h e l o c k w a s h e ri n t h e c e n t e ro f t h e f l a t NOTE:Wipe greaseoff
sectionof the steeringrackend. the threadsection.
ROLLPIN ORIFT:
(Commorciallyavailablel
Snap-OnNo. PPR8or equivalent
Press
NOTE:This dritt hasa flat

tip, to preventpunctunng
CLIP
TIE.ROD
nncxl
srrenrruc
woooENELocK (cont'd)
17-11
SteeringGearbox
Reassembly(cont'd)
1 9 . Installthe boot band so that the lockingtabs of the 22. Slide the rack right and left to be certainthat the
band (stakepoints)are in the rangeshown below. bootsare not deformedor twisted.
(Tabsshouldface up and slightlyforwaro.J
20. Bendboth setsof lockingtabs.
2 1 . Lightlytap on the doubled-overportionsto reduce

t h e i rh e i g h t .
CAUTION:Stakethe band lockingtabs firmly.
Stakepoints
+ Front
L6ft Boot Band Right Boot Band

(Viewedfrom the left side) (Viewedfrom the right sidei
17-12
lnstallation
1. Slidethe rackall the way to the right. 4. I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x
mountingboltsand stiffenerplateattachingbolts.
2 Installthe pinion shaftgrommet,and insertthe pin- N O T E rI n s t a l lt h e b o l t s l o o s e l yf i r s t , t h e n t i g h t e n
ion shaftup throughthe bulkhead. them securelv.
PLATE
STIFFENER
NOTE:Align the notch in the pinion shaft grommet
with the tab on the gear housing.
PINIONSHAFTGROMMET
GEARBOX MOUNTING BOLTS

43 N.m(4.{kgf.m,32 lbf.ft)
STEERINGGEARBOX
5. Centerthe steeringrackwithin its stroke,
6. Slip the lower end of the steeringjoint onto the pin-
3. Installthe mountingbracketswith the two gearbox ion shaft{line up the bolt hole with the groove
mountingboltson the cushion. aroundthe shaft),and tightenthe lower bolt.
NOTE:
. Connectthe steeringshaft and pinion with the
steeringwheel and steeringrackcentered.
B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t i s
securelyin the groove in the steeringgearbox
p r nr o n .
lf the steeringwheel and rack are not centered,
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringjoint.
JOINT
STEERING
14.0kgl.m,29lbtftl
NOTE:The arrowon the bracket
pointtowardthe front. STEERINGJOINT
LOWERBOLT
22 N.m
12.2kgt m, 16 lbf.ftl (cont'd)
17-13
SteeringGearbox
'1. 9. Reconnect the tie-rodendsto the steeringknuckles,
Centerthe cable reel by first rotating it clockwise
until it stops,Then rotate it counterclockwise then tighten the castlenut ('96 -'97 model)or nut
(approximatelytwo turns) until the arrow mark on {'98 model)to the specifiedtorque,and installnew
the label points straight up. Reinstallthe steering cotter Dins.
wheel (seepage 17-35).
NOTE:Betoreconnectingthe tie-rodends,wipe off
Installthe steeringioint cover with the clamps and a n y g r e a s ec o n t a m i n a t i o nf r o m t h e b a l l l o i n t
clros. taoeredsectionand threads.
CAUTION:Torquethe csstle nut to the lower torque

spocification,th€n tightsn it only fsr enough to
Elign th€ slot with the pin hol6. Do not align the
nut by loosoning {'96 -'97 modol only}.
JOINT COVER
STEERING
TIE-ROD
COTTERPINS
Replace.
On reassembly, bend
!=-
the cotterPlnas shown.
'95 - '97 model: 38 model:
NUT
,10- 48 N'm 4,1N.m
(4.5 kgf'm,
(ir.o- 4.8 kgt m.
33 lbf.frl
29 - 35 rbl.ftl
Installthe exhaustpipeA or TWC(seesection9)'
1 1 . Connectthe shift linkage(seesection13 or section

14).
12. Installthe front wheels.
After installation,performthe followingchecks'
. Adjustthe front toe (seesection18).

. Checkthe steeringwheel spokeangle'Adjust by
turningthe right and lefttie-rods,it necessary'
NOTE:Turn the right and lefttie-rodsequally'
1 7 -1 4
ComponentLocations
lndex
Power Steering:
NOTE:
. lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has beenfound detectiveor dsmageddur-
ing transit,storageor service,it shouldbe deployed(seesection24).
a Betoreremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel.
. After installingthe gearbox,checkthe wheelalignmentand adjustif necessary.

section(24)beforeperformingrepairsor service.
STEERING WHEEL
page17-35
page17 36
DRIVER'SAIRBAGASSEMBLY
seesection24
STEERING GEARBOX
RackGuideAdjustment,page17 33
Removal,page17-47
Disassembly, page17-49
Reassembly, page17-55
page17'65
Installation,
VALVEBODYUNIT
Overhaul,page17 52
COLUMN
page17-37
page17-38
Inspection,
CABLEREEL
seesection24
IGNITIONSWITCH
Seesection23
POWERSTEERINGPUMP TIE.RODEND BALLJOINT

PumpBeltInspection,page17'32 page17-68
BallJointBootReplacement,
PumpBeltAdiustment,page17-32
PumpPressureCheck,page17 34
page17-40
Bemoval/lnstallation,
page17 41
17-15
SystemDescription
FluidFlow Diagram
The systemis a compactrotary-valve,type power steering,connectedto the steeringgearbox.The fluid pressureis pro-
vided by a vane-type pump which is driven by the enginecrankpulley.The amountof fluid and pressureis regulatedby
the flow controlvalvebuilt into the pump.The fluid pressurefrom the pump is deliveredto the valvebody unit aroundthe
pinjonof the steeringgearbox.The valveinsidethe valvebody unit controlsthe hydraulicpressureand changesthe direc-
tion of the flow. The fluid then flows to the power cylinder,where rackthrust is generated.Fluid returningfrom the power
"filtered"and suppliedto the pump again'
cylinderflows backto the reservoir,wherethe fluid is
RESERVOIB
VALVEBODYUNIT
SUB.VALVE
FLOWCONTROLVALVE GEANBOX
STEERING POWERCYLINDER
17-16
SteeringPump
Construction
The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is drivenby a POLY-V-belt
from the crank pulley,The pump features10 vanes.Eachvane performstwo intake/discharge operationsfor every rota-
tion of the rotor.This meansthat the hydraulicfluid pressurepulsebecomesextremelysmallduringdischarge.
FLOWCONTROLVALVE
ROTOR VANE CAM RING
Operation
The belt,drivenpulley rotatesthe rotor through the drive shaft.As the rotor rotates,the hydraulicpressureis appliedto
the vanechamberof the rotor and the vaneswill rotatewhile beingpushedonto the innercircumference of the cam ring.
The inner circumferenceof the cam ring has an extendedportionwith respectto the centerof the shaft,so the vanes
move downwardin the axialdirectionas the rotor rotates.As a resultof this roller movement.the internalvolume of the
r i l l c h a n g er,e s u l t i n ign f l u i di n t a k ea n dd i s c h a r g e .
v a n ec h a m b ew
STARTOF FLUIDINTAKE: FLUIDINTAKE: FLUIDMOVEMENT: FLUIDOISCHARGE:
T h e v a n e s a r e p u s h e do n t o The volumeof the vanecham T h e s u c k e d - i nf l ui d m o v e s As the vanes return to the

the innercircumference of the ber increasesso that fluid is towardthe dascharge pon. t h e i ro r i g i n ap
l o s i t i o no n t h e
c a mr i n g . suckedin. inner side, the volume of the
v a n e c h a m b e rd e c r e a s e s o
t h e f l u i d i s d i s c h a r g e df r o m
the dischargeport.
(cont'd)
17-17
SystemDescription
SteeringPump(cont'dl L
The flow control valve and sub-valvein the pump per- FLOWCURVE
forms the following stepsO through @ to control the
flow of fluid, that is to increasethe dischargevolume
when enginespeed is low. and to decreaseit when the l"
e n g i n es p e e d i n c r e a s e sT, h e a s s i s t a n c teh r u s t o f t h e I J
s t e e r i n gg e a r b o xc h a n g e si n c o m p l i a n c ew i t h t h e t r r
changein the dischargevolume.
;
-..}
PUMPR.P.M.
o When the engine starts,fluid dischargedfrom the To STEERINGGEARBOx

SUB-VALVE
dischargeport stans to flow through oil passageA,
the fixed orificeand the variableorificeto the steer-
ing gearbox,When the engine speed is extremely
low, the return port is closed by the flow control
valve.
Fluid pressuredischargedfrom the dischargeport
is appliedto the top of the sub-valve,and the fluid
Bottom //l'.€zRx \
pressurethat passedthroughoil passageA is applied
to the bottom of the sub-valve.When this happens,
the pressuredifferencebetweenthe ends of oil pas-
=K.Aq
sage A, which is causedby the resistanceoil passage o'.io"l^LKq;OY
11\t/./
A w h e n t h e f l u i d f l o w s t h r o u g h t h e p a s s a g e ,i s
appliedto the sub-valve.However,the pressuredif-
ferenceapplied to the sub-valve.that is the force
t h a t p u s h e st h e s u b - v a l v ed o w n , i s t o o s m a l l t o
overcomethe springforce,and the variableorificeis
fully openwhen the enginespeedis e)dremelylow,
FLOWCONTROLVALVE
Becausethe fluid volume flowing throughthe fixed To STEERINGGEARBOX
oriticeand variableorificeincreases, a pressuredif- SUB-VALVE
ference is createdbetweenthe ends of these ori-
fices, and it increasesin proportionto the engine
speed.As the lluid pressurethat passedthe fixed
orificeand variableorificeis directedto the bottom
of the flow control valve, a pressuredifferenceis
createdbetweenthe top and bottom of the valve,
ORIFICE
w h i c h D u s h e sd o w n t h e f l o w c o n t r o l v a l v e a n d
opens the return port. As a result,part of the fluid 1 ) l
dischargedfrom the dischargeport returnsto the vr-
pump suction port, keepingthe dischargevolume
conslanl,
In this condition,the sub-valvedoes not move, and
the variableorificestaysfully open.
FLOWCONTROLVALVE
17 -1 8
To STEERINGGEARBOX
O The fluid volumethat flows thoroughoil passageA

and the pressuredifferenceappliedto the sub-valve
i n c r e a s ei n p r o p o r t i o nt o t h e e n g i n e s p e e d .T h e
sub-valvelowers overcomingthe spring force,and
it startsto closethe variableorificeto regulatethe
dischargevolume,Whenthis happens,the fluid vol-
/z/ffi\\
ume flowing to the steeringgearboxdecreasesas
the engine speed increases.At the same time. the
+/A<Y?il
flow controlvalvecontinuesto controlthe fluid vol- o',-lorlo[5o
zit)Y
-et27
ume to the returnDort.
\ \
FLOWCONTROLVALVE
To STEERINGGEARBOX
SUB.VALVE
@ As the enginespeedincreasesfurther,the pressure
differenceat the sub-valveincreases furtheras well.
The sub-valvethen closesthe variableorificecom-
p l e t e l y ,r e g u l a t i n gt h e d i s c h a r g ev o l u m e f u r t h e r .
W h e n t h i s h a p p e n s t. h e f l u i d v o l u m e d i s c h a r g e d
from the pump to the steeringgearboxis regulated /X
€TI-p..\
a n d m a i n t a i n e da t a g i v e n l e v e l u n t i l t h e e n g i n e
speedreachesthe high speed range.The flow con-
LT€J6("4")il
trol valve functions continuesto control the fluid o"'ro"iio't?2ia)f
volumeto the returnDort. 11"QJtYl
FLOWCONTROLVALVE
PressureRelief
P r e s s u r ea t t h e d i s c h a r g es i d e o f t h e f i x e d o r i f i c e i s
directedto the bottom of the flow control valve.When
the pressurebuilds up, the reliefvalve in the flow con-
trol valveopensto releasethe pressureat the bottom ot
t h e v a l v e .T h i s a l l o w s t h e f l o w c o n t r o l v a l v e t o b e
pushed back by the pressuredifference.and the fluid
volumeto the pump returnport increases.
As explained above,the system keepsthe pump dis-
charge pressure (relief pressure)from exceedingthe
given level by controllingthe volume of the fluid to the
pump returnpon.
FLOWCONTBOLVALVE
DAMPINGORIFICE RELIEFVALVE (Openl

(Decreasesexcessive
vibration in the valve.l
17-19
SystemDescription
SteeringGearbox
The rackand-piniontype steeringgearboxhas a valve body unit incorporatedwith the pinionlo controlthe steeringfluid
pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve body unit and is sentthroughthe cylin
der line to the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylin-
der returnsthroughthe cylinderline and valvebody unit to the reservoir.
VALVEBODYUNIT
LINE
CYLINDER
To RESERVOIR+
From PUMP ri
POWERCYLINDER
Valve Body Unit
Insidethe valve body unit is the valve.which is coaxialwith the pinionshaft,and controlsthe steeringfluid pressure.The
valve housingis connectedwith the fluid line from the pump, the returnline to the reservoir,and the two cylinderlines
from the respectivepower cylinder.The pinion shaft is double- structuredwith the input shatt connectedto the pinion
gear,both of which are interconnected wlth the torsionbar.
The pin insertedin the valveand the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the
valve.Becauseof this construction, the differencein anglein the circumferential directionbetweenthe input sh8ftand the
valvebecomeslargeraccordingto the torsionalstrengthof the pinionor steeringresistance. However.maximumtorsion
betlveenthe shafts is regulated by the engaged splinesof the shaftsat the pin engagement sectionto hold the torsionbar
within the setvalue.
This allowsthe steeringsystemto functionas an ordinaryrack-and-pinion type steeringif the steeringfluid is not pressur-
izedbecauseof a faulty pump.
VALVE
Diflerencein angle between the
input shaft and pinion shaft
PINION SHAFT
la
-l
INPUTSHAFT INPUTSHAFT
B
17-20
PressureControl
Low assistat higherspeeds:

When steeringresistanceis low, such as when driving at high speeds,or when driving straightahead,the input shaft is
nearor in the neutralposition,so there is littleor no flow to any of the power cylinderorifices.N4ostof the feed pressure
from the pump is bypassedto the reservoir.Becauseof this,the pressurestaysthe same in both sidesof the power cylin-
der, resultingin low or no assist.
VALVE From PUMP
RETURNPASSAGE
lTo RESERVOIR)
VALVEBODY
UNIT
. A SECTIONA.A
POWERCYLINDER
GEAREOX
High assistat lower speeds:

When steering resistanceis high, such as when driving at low speeds,or when turning the wheel with the vehicle
stopped,the differencein anglecreatedbetweenthe input shaft and the valve opensthe fluid passageon one side, and
closesthe fluid passageon the other side. at each pair of orifices,The fluid pressureincreasesin the side of the power
cylinderfed by the largerfluid passage.This increasedpressurepusheson the rackpiston,allowingthe steeringwheelto
be turnedwith light effort.On the otherside of the powercylinder,the returnpassageopensallowingthe steeringfluid to
returnthrough the input shaft to the reservoir.The fluid passagesto the power cylinderautomaticallychange in size,
increasingas the steeringresistanceincreases.In other words. the passagesbecomelargerand power assistincreases
when the steeringeffort would normallybe high, (for example,when parkingor making low speedturns),and the pas-
sagesbecomesmallerand power assistdecreaseswhen the steeringeffort would normallybe low, (for example,when
drivingat high speedsor straightahead).
FLUIDPASSAGETO
POWEBCYLINDER From PUMP
---------\\
r - /
SECTIONA-A
(High lluid pressur€l
17-21
Troubleshooting
GeneralTroubleshooting
Checkthe followingbeforeyou begin:
. Hasthe suspensionbeenmodifiedin a way that would affectsteering?
. Are tire sizes,tire varietyand air pressurecorrect?
. ls the steeringwheel originalequipmentorequivalent?
. ls the powersteeringpump belt properlyadjusted?
. ls steeringfluid reservoirfilledto properlevel?
. ls the engineidle speedcorrectand steady?
HardSteering(Checkthe powerassist,seepage'17-30.
lflhe forceis over 29 N 13.0kgf,6.6lbf),Precedewith this troubleshooting.)
Checkthe pump fluid pressure

(seepage17-34).
Abnormal
Measuresteadystate fluid pres Iluid pressure C h e c kt h e l e e d a n d r e t u r n c i r c u i t l i n e s a n d h o s e
sure while idling with the both b e t w e e nt h e g e a r b o xa n d p u m p f o r c l o g g i n ga n d
{fluidpressure
valvesfully open. is too high) delormation.
It shouldbe 1,500kPa(15kgvcm,,
213psi)or below.
Normalline
a n dh o s e
Normal
Faultyvalvebody unit
C h e c kt h e p u m p { l u i d p r e s s u r e
{seepage17-34). Checkthe tlow control valve (seepage 17-42).
M e a s u r ep u mp r e l i e f p r e s s u r e Reliefpres- . Checkthe valvefor smooth movementin the hous-
while idling with the pressurecon- ing.
trol valveIully closed. ' Checkthe reliefvalvefor leaks.
It should be 6,400- 7,400kPa165-
75 kgflcm',920- 1,070psi)
Normalreliefpressure Abnormal
Go to page17 23 Faultypump assembly Faultyflow control valve

(Replace the pump as an
assembly)
1 7- 2 2
Checkthe lorce requiredlo turn
the wheol(seepage17-30).
Startthe engineand measurethe
force required to turn the wheel
to the right and left. Differenceof
t h e f o r c e r e q u i r e dt o t u r n t h e
wheel to the right and to the left
shouldbe 2.9 N (0.3kgl, 0.7 lbt)
Normal Checkfor bent rack shaft.
Checkpump tluid pressure(see

page17-34). Check rack guide adjustmgnt (see AdjustmentOK
Turn the steeringwheelfully to the page 17'33).
right and left while idling wirh the
pressurecontrol valvg Iully open,
and measurethefruid pressure. Faultyvalvebody unit
lr shouldbe 6,400-7,400 kPa(65-
75 kgflcm,,920- 1,070psi).
Abnormal - Faultygearbox
Checkthe gearbox.
Removethe gearbox and mea-
Checkthe parts othor than the gearbox-relatedparts lor
surethe piniontorque.
Drooerrotation.
Thetorqueshouldbe; . lmproperrotationofthe steedngcolumn-relatsd part(s)
* 0.7- 1.2N.m (7 - 12 kgf'cm,6 -
. Faultysteeringjoint
10 lbl.in) with the steering rack . Faultyrackend ie-rodend ballioints
in th6 straightdrivingposition. . Interferencein the steeringsystem
1 1 . 3 N . m ( 1 3 k g f . c m 1, 1 . 3l b f i n )
with the steering rack in any
other position.
Abnormal
Adjust the rack guide (see Page

1 7 - 3 3 ) a, n d r e c h o c kt h e p i n i o n Normal - lmproperlyadiustedrackguide
torque.
Abnormal
Faultygearbox
(cont'd)
17 -23
Troubleshooting
GeneralTroubleshooting (cont'd)
lf the problem is not correctedby

Assist (excossivelylight steering)at Checkthe rack guide for proper adjustingthe rack guide, adjust
highspeed. adiustment(seepage17-33). the lront whe€l alignment (see
soction18).
Shockor vibrationwhen wheelis Checkthe rack guide tor proper

turnedto full lock. adjustment(seepage17-33).
Adjustthe rackguide.
Rackguideis adiustedproperly.
lf the problom is not correctedby
adiustingthe rack guide,replace
Checkthe belt tor slippageand the gearbox.
adjust as necessary(see page
17-321.
Steeringwheelwill not roturn

smoothly.
A a n d I c y l i n d e rl i n e sa r e n o r -
mal. checkwheel alignment(see W h e e l a l ; g n m e n ti s a b n o r m a l ,
soctionl8). adjust as needed.
' l t s h o u l db e 0 . 7- 1 . 2N . m ( 7 -
1 2 k g f . c m , 6- 1 0 l b t . i n )o r
Wheelalignmentis normal. below with the steeringrack in
R e m o v et h e g e a r b o xf r o m t h e the straightaheaddrivingposi-
f r a m e a n d m e a s u r et h e p i n i o n tion.
torqueon the gearbox. . 1.3 N.m (13 kgf.cm,11.3lbf.inl
w i t h t h e s t e e r i n gr a c k i n a n y
otherposition.
lf the measurementsare out of

s p e c i f i c a t i o n sa, d j u s t t h e r a c k
gurde.
f'' lf the problemis not correctedby

adjlsting the rackguide,replace
the gearbox.
17-24
I
Unevenor roughsteering, Mjust the rackguide(seepage17-33).
lf the problom is not coftected bY

adjustingthe rackguide,roplace
the gearbox.
Adiustthe belttension.Replacethe
(seepage17-321.
belt,if necessary
lfthe enginestallswhen the wheel

is turn€d while car is stoppodor
ldle speed low or erratic. moving at low speed,adjustthe
idle speed(seeseclion11).
Checkpower stoeringfluid level.lf

Air in resgrvoir,or checkpowor the level is excessivelylow, chock
steeringfluid level. tor leaks in the system.Add fluid
to the sp€cifiedlevel.
lf lluid level is OK, check O-rings

8 n d s e a l so n b o t h o n d s o f t h e
pump inl€t hose,and the P/S
pump housing mating surfaces
and the pump shaft oil seal for
suction leaks. Replaceparts as
Stoeringwheelkicksback P!mp belt slippingon pulley Adlustthe belt tension{seePage

duringwid€ turns. {pumpstopsmomentarily). 17-32)orreplacebeh.
Checkit pump pr€ssureis normal

and the gaugeneedletravel is 500
Installthe power steeringpressure k P a ( 5 k g f l c m ' ,7 1 p s i ) o r l e s s .
gauge.Closethe pressurocontrol Checkthe flow controlvalve if the
valvelully and measurethe pump needle travel exceeds500 kPa 15
pressure(seepage 17-34). kgt/cm,,71 psi).lf the flow control
valve is normal,replacethe pump
as an assembly,
17 -25
Troubleshooting
NoiseandVibration
NOTE:Pumpnoisein first 2 - 3 minutesafterstaningin cold weatheris normal.
H u m mj n g Humming due to pulsationof fluid is normal, particularlywhen the wheel is

turnedwith the vehiclestoooed.
lf equippedwith automatictrans-
r n i s s i o nt,h e h ! m c o u l d b e t h e Confirm by temporarily removing
torqueconverteror pump noise. the pump belt.
High-pressureline touching the

frame. Repositjonthe line.
Rattleor chattering Loosesteeringshaft connector, C h e c ka n d t i g h t e n , o r r e p l a c e

tie-rod,or ballioint. parts as necessary.
Columnshaftwobbling. Replacethe columnassembly.
Checkthe rack guide lor proper

adjustment(seepage17-33). Adjust,if necessary.
Rattlingsoundand feelingwhen turningthe steeringwheelright and leftwith the

engineOFFis a soundwhen the valvebody unit contactsthe stoo.This is normal.
Pump noise,though not loud,from the valve body unit can be heardwhen turn-
ing the steeringwheelright or left.This is normal.
CAUTION: When inspecting, do not hold the steering wheel 8ll the way to
the right or the left.
f''
17-26
Checkthe fluid lev€1.
Gratingnoise Cavitationcausedby air bubbles l f l o w , f i l l t h e r e s e r v o i rt o t h e
Pumpnoise from pump in the fluid. propor level,and chockfor leaks.
Tighten or r€placeas necessary.
Checkfor a crushedsuctionhose
or a loose hose clamp allowing
air inlo the suction side ol tho
system.
Tightgn or replace8s necessary.
NOTE: Pump noise uP to 2 - 3 ll pump noiseis abnormallyloud,

m i n u t e sa f t e r s t a r t i n gi n c o l d removeand inspectthe pump tor
Pumpgearnoise weatheris normal. wear and damage(see page 17-
Comparepump noiso at operating 41t.
temperature to simularvehicle.
,Ou"u,,nn
Tighten or roplacethe pull€y.

Rattleor chattering l f s h s f t i s l o o s o , r e P l a c el h e
pump.
17-27
,l
Troubleshooting
Fluid Leaks
. Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points,dependingon locationof the
rings.Checkthe followingbeforeremovinglhe gearboxfrom the frame.
faultyoil seals/seal
Leakingfrom the oil seal on the Replacethe valve oil seal from
SteeringGearbox top of the valvehousing. the valvehousing.
Leakinglrom cylinder end into Replacothe valve oil seal from

left tie rod boot. the pinionshaft.
Replacethe cylinderend sealon

the g€arhousingside.
Leakingfrom cylinder end into Replacethe cylinderend sealon

right tie-rod boot. the cylinderend side.
Leakingfrom the shaftupperend

sectionor pin engagemenlsec- Replacethe valve body unit.
tion of the pinionshaft.
Tighton th6 connector. lI it's still

Leakinglrom cylinderline A or B
(atflarenut). leaking,replaceth€ lino,cylinder
connections
or valvehousingunit.
L e a k i n gc a u s e db y a d a m a g e d
ReplacecylinderlineA or B.
cylinderlineA or L
Leakingfrom feed line and return Tightenthe connector.lf it's still

linejoint fittingon the valvebody leaking,replacethe line,joint fit-
unit (atflare nut). ting or valvehousing.
17 -28
Replace the housingO-rings.
lf the housingstill leaks,replace
the pump.
Reservoiris ov6rfilled.
Pull off the hose and drain the
reservoirto the proper lev€1.
Air leak in suctionside ot the sys-

lem {res€rvoir,inlet hose,{ront
pump seal).
Tighten the fining. It it's still leak-

Pumpoutletline Leakingat the lhreadedlitting.
(high-pressure) in9, replacothe O-ringor feed line.
Leakingat the swsggedjoint.
af
Leakingbecauseof damage.dete- Replaceor ropairas necessary.
Pumpinletline rioration,or improperassombly.
(low-pressure)
Steering Operation PowerAssistCheckwith
VehicleParked
Placethe front wheels in the straight ahead position,
a n d m e a s u r et h e d i s t a n c et h e s t e e r i n gw h e e l c a n b e 1. Checkthe power steeringfluid level (see page l7-
turnedwithout movingthe front wheels. 33) and pump belttension(seepage 17-32).
ROTATIONALPLAY:0 - 10 mm l0 - 0.39 inl 2. Startthe engine,allow it to idle, and turn the steer-
ing wheel from lock-to-lockseveraltimes to warm
lf the play exceedsthe servicelimit, perform rackguide up the fluid.
adjustment(seepage 17-33).
lf the play is still excessiveafter rack guide adjustment, 3. Attacha springscaleto the steeringwheel.With the
inspectthe steering linkageand gearboxas described engine idling and the vehicleon a clean,dry floor,
on the next page. Dull the scaleas shown and read it as soon as the
tires beginto turn.
ROTATIONALPLAY
7 t l
The scaleshould read no more than 29 N (3,0 kgf,

6 . 6 l b f ) . l f i t r e a d sm o r e , c h e c kt h e g e a r b o xa n d
oumo.
17-30
SteeringLinkageand Gearbox
TIE.RODEND BALLJOINT
Insoectfor faultvmovement
and damage.
BOOT
Inspect damage and deterioration.
JOINTS
Checkfor loosejoint bolts.
a
SHAFTGROMMET
TIE.RODLOCKNUT
for looselocknut.
STEERINGGEARBOX
Inspectfor loosemountingbolts.
GEABBOXMOUNTINGCUSHIONS
lnsoecttor deterioration.
3ALL JOINT BOOT
See p49e 17-68for replacement.
17-31
PumpBelt
NOTE:When usinga new belt,first adjustthe deflection Adiustment
or tensionto the valuesfor the new belt, then readjust
the deflectionor tensionto the valuesfor the used belt 1. Loosenthe power steeringpump mountingbolts.
a f t e rr u n n i n ge n g i n ef o r l i v em i n u t e s .
Inspection PUMPMOUNTINGBOLT
24 N m 12.4kgt m, 17 lbffrl
Attachthe specialtool to the belt and measurethe ten
sion of the belt.
Tensionr
used Belr: 340- 490N {35- 50 kgf. 77 - 110tbt)
New Belt: 640 - 780 N {65 - 80 kgl, 143- 176 tbfl
NOTE:
. lf thereare cracksor any damageevidenton the belt,
replaceit with a new one.
. Followthe manufacturer's instructionsfor the tension
g au g e .
BELTTENSION GAUGE POWER
07JGG _ 001010A PUMP
PUMPMOUNTINGBOLT
24 N.m {2.4kgf.m, 17 lbr.ft)
2. Adjust the belt tensionby moving the power steer-

ing pump with a 1/2" drivebreakerbar to obtainthe
p r o p e r b e l t t e n s i o n ,t h e n r e t i g h t e nt h e m o u n t i n g
bolts.
3. Start the engine and turn the steeringwheel from

Inspectthe pump beltfor cracksor any damage. lock-to-lockseveraltimes,then stop the engineand
Replacethe beltwith a new one if necessary. recheckthe deflectionof the belt.
Measurementwithout Belt TensionGauge:

Apply a force of 98 N (10 kgl,22 lbt) and measuret h e
d e f l e c t i o nb e t w e e nt h e p o w e r s t e e r i n gp u m p a n d t h e
c r a n k s h apf tu l l e y s .
Detlection:
UsedBelt: 10.5- 14.0mm (0.41- 0.55in)
New Belt: 7.5- 10.0mm (0.30- 0.39inl
17-32
RackGuideAdjustment FluidReplacement
NOTE:Performrack guide adjustmentwith the wheels Checkthe reservoirat regularintervals,and add fluid as
in the straightaheadposition. necessary.
CAUTION: Always use Gonuin€ Honda Powsr Steering
1. '96 - 97 model: Fluid-V or S. Using any oth.r type ot pow 3toering
Loosenthe rack guide screw locknutwith the spe- fluid or sutomatic lrsnsmis3ion fluid can cause
cialtool, then loosenthe rackguidascrew. increasedwear and poor steoring in cold woather.
SYSTEMCAPACITY:
0.85 litor 10.90US. qt, 0.75 lmp.qtl
at dkassembly
RESERVOIR CAPACITY:
0.4 liter {0.42US. qt, 0.35 lmp.qt)
UPPERLEVELLINE
LOWERLEVELLINE
'98 modol: 1 . Raisethe reservoir,then disconnect the returnhose

tl Removethe old sealantoff of the threadedsection, a Connecta hose of suitable diameter to the discon-
then apply new sealantto the first three threads. nectedreturn hose,and put the hose end in a suit-
Looselyinstalltherackguidescrew. ablecontainer.
CAUTION:Taks car. not to spill tho lluid on tho
Tightenthe rack guide screwto 25 N'm (2.5 kgf m, body and parts. Wipe off any spilled fluid at once.
18 lbf.ft),then loosenit.
Retightenthe rackguidescrewto 3.9 N.m (0.4kgf'm,

2.9 lbf.ft),then back it off to specifiedangle.
SpecifiedRetuh Angle: 20" max.
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.
Checkfor tight or loose steeringthrough the com-

pleteturningtravel.
Performfollowinginspections: HOSE
. Steeringoperation(seepage17-30). Startthe engine,let it run at idle,and turn the steer-

. Powerassistwith vehicleparked. i n g w h e e l f r o m l o c k - t o - l o cske v e r a lt i m € s .W h e n
f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
engine.Discardthe fluid.
4. Reinstallthe returnhoseon the reservoir.
Fillthe reservoirto the uoDerlevelline.
Startthe engineand run it at fast idle,then turn the
steeringfrom lock-to-lock severaltimes to bleed air
from the system.
7. Recheck the fluid leveland add some if necessary.
CAUTION: Do not fill the reservoir beYond the
upper lovel line.
17-33
Inspectionand Adiustment
PumpPressureCheck
C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e 6. Startthe engineand let it idle.
whetherthe troubleis in the pump or gearbox.
7. Turn the steeringwheel from lock-to-lockseveral
NOTE: First check the power steering fluid level and timesto warm the fluid to operatingtemperature.
pump belttension.
8. Measuresteady-state fluid pressurewhile idling. lf
CAUTION: Disconnectthe high pressurehose with care t h e p u m p i s i n g o o d c o n d i t i o nt,h e g a u g es h o u l d
so as not to spill the power steering fluid on the ftame readlessthan 1500kPa(15 kgflcm' ,213psi).
and other parts. lf it readshigh, checkthe outlet line or valve body
unit (seeGeneralTroubleshooting 17-22).
1. Disconnectthe outlet line from the pump outlet fit-
ting, then jnstallthe P/Sjoint adaptor{pump)on the 9 . C l o s et h e p r e s s u r ec o n t r o l v a l v e ,t h e n c l o s et h e
pump outlet. shut-off valve gradually until the pressuregauge
2. Connectthe P/S joint adaptor(hose)to the power needleis stable.Readthe pressure.
steering pressuregauge, then connectthe outlet
hoseto the adaptor. 10. lmmediatelyopenthe pressurecontrolvalvefully.
3. Installthe power steeringpressuregaugeto the P/S
joint adaptor{pump)as shown. CAUTION: Do not k€€p the pressure conlrol valve
closed more then 5 seconds or the pump could be
6 x 1.0mm BOLT damaged by over-heating.
OUTLETHOSEFTTNNG
lf the pump is in good condition,the gaugeshould
P/S JOINTADAPTORIHOSE) read at least 6.400- 7,400kPa(65 - 75 kgflcn',920 -
07MK - 5040121
1.070psi).A low readingmeanspump outputis too
oa
07RAK- S040r20 low for full assist.Repairor replacethe pump.
P/SPRESSURE GAUGE
07405- 001000A P/S PRESSURE GAUGE
ol 07{06 - 00'llD0A
07,106- q)l0001 ot
lPart of tooll
1 1N . m
(1.1 ksf.m, I lbt'ft)
PRESSURE
CONTROLVALVE
.OFF
VALVE
PUMPOUTLET
FITTING
SHUT.OFFVALVE
6 x 1.0mm BOLT
(Partot tooll
1 1N m
(1.1ksf.m,8lbtft)
Openthe shut-offvalvefully.
5. Openthe pressurecontrolvalvefully.
17-34
SteeringWheel
Removal lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e CAUTION: Do not tap on the steering wheel or steering
SRScomponentlocations,precautions,and procedures columnshaft when installingthe steeringwheel.
in the SRSsection(24)beforeperformingrepairsor ser-
vice. N O T E :B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,a l i g n t h e
front wheelsstraightahead.
N O T E :B e f o r er e m o v i n gt h e s t e e r i n gw h e e l ,a l i g n t h e
front wheelsstraightahead. 1. B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e rt h e
cable reel. Do this by first rotating the cable reel
' 1 . R e m o v et h e d r i v e r ' sa i r b a ga s s e m b l yf r o m t h e clockwiseuntil it stops.Then rotateit counterclock-
steeringwheel(seesection24). wise approximatelytwo turns. The arrow mark on
the cablereellabelshouldpointsstraightup.
2. D i s c o n n e ct th e h o r n c o n n e c t o ar n d c r u i s ec o n t r o l
switchesconnector.
CABLEREEL
2. lnstall the steeringwheel with the steeringwheel

I nut.
N O T E :B e s u r e t h e s t e e r i n gw h e e l s h a f t e n g a g e s
3. Remove the steering wheel nut. the cablereel and cancelingsleeve.
STEERING WHEELNUT
Replace.
3. Attachthe cruisecontrol switchesconnectorto the

steerinw
g h e e lc l i P .
4. Connectthe horn connector.
5. I n s t a l lt h e d r i v e r ' sa i r b a ga s s e m b l y a, n d c o n f i r m
propersystemoperationlsee section24).
4. Remove the steering wheel by rocking it slightly from
side to side as you pull steadilywith both hands. 6. C h e c kt h e h o r n a n d c r u i s e c o n t r o l s w i t c h e sf o r
properoperations.
17-35
SteeringWheel
Disassembly/Reassembly \
*@*&*W
-:<z<z
%
17-36
SteeringColumn
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e 9. Installationis the reverseof the removalprocedure.
SRScomponentlocations,precautions,and procedures NOTE:
in the SRSsection(24)beforeperformingrepairsor ser- . Makesurethe steeringjoint is connectedas follows:
vice. a. Insertthe upper end of the steeringjoint onto the
NOTE: Before removing the steeringcolumn for SRS, steeringshaft (lineup the bolt holewith the flat on
removethe driver'sairbagassemblyand cablereel (see the shaft),and looselyinstallthe upperjoint bolt.
section24). b. Slip the lower end of the steeringjoint onto the
1. Removethe steeringwheel (seepage17-35). pinion shaft (line up the bolt hole with the groove
2 . R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d a r o u n dt h e s h a f t ) .a n d l o o s e l yi n s t a l lt h e l o w e r
driver'skneebolster(seesection20). joint bolt.
3. Removethe combinationswitchassemblvfrom the Be sure that the lower joint bolt is securelyin the
steeringcolumn shaft by disconnecting the connec- groovein the pinionshaft.
rors. c . P u l l o n t h e s t e e r i n gj o i n t t o m a k e s u r e t h a t t h e
4. Disconnect the ignitionswitchconnectors. steeringjoint is fully seated.Thentightenthe joint
5. Removethe steeringjoint cover bolts.
6. Removethe steeringjoint bolts. . Be sure the wires are not caught or pinchedby any
7 . D i s c o n n e ct th e s t e e r i n gi o i n t b y m o v i n gt h e j o i n t partswhen installingthe column.
toward the column,and removeit from the column . Make sure the wire harnessis routed and fastened
shaft. properly,
8 . R e m o v et h e s t e e r i n gc o l u m n b y r e m o v i n gt h e . Makesurethe connectorsare properlyconnected.
attachingnuts and bolt.
UPPER STEERINGCOLUMN
RETAININGCOLLAR COMBINATIONSWITCH
t NOTE:Takecarenot to letthe
retainingcollarfall out of
positionduringinstallation.
ASSEMBLY
STEERINGJOINT BOLTS
22 N.m {2.2 kgt m, 16 lbl.ftl
FLANGEBOLTS
22 N.m 12.2kgl'rn,
15lbl tr)
UPPERJOINT BOLT
Bolt must line up COLUMNCOVER
on shaft.
Groove.
JOINTCOVER
CLIP
JOINT BOLT
Bolt must line up with
g.oove around on shaft.
17-37
SteeringColumn
Inspection
NOTE:The tilt steeringcolumn type is shown; the con-
v e n t i o n asl t e e r i n gc o l u m n i s s i m i l a re x c e p tf o r t h e t i l t
mechanism.
Checkthe steeringcolumn ball bearingand the steer-

ing joint bearingsfor play and proper movement.lf
there is noiseor if there is excessiveplay,replacethe
steeringcolumnas an assembly.
C h e c kt h e r e t a i n i n gc o l l a rf o r d a m a g e .l f i t i s d a m -
aged,replacethe retainingcollar.
Checkthe absorbingplates,absorbingplate guides ABSORBINGPLATES
and slidingcapsulesfor distonionor breakage.
Replacethe steeringcolumn as an assemblyif they ABSORBINGPLATEGUIDES
are distortedor broken.
COLUMNBALLBEARING RETAINING COLLAR
BEARINGS
\
SLIDING
IGNITION
This part is attached
Seesection23.
to the column bracket
with the plastic injections.
'1. lMovethe tilt lever from the loose positionto lock

p o s i t i o n3 t o 5 t i m e s ; t h e n m e a s u r et h e t i l t l e v e r
p r e l o a d1 0m m ( 0 . 4i n )f r o m t h e e n do f t h e t i l t l e v e r .
Preload:70 - 90 N {7 - I kgl. 15-20 lbf)
2. l f t h e m e a s u r e m e ni ts o u t o f t h e s p e c i f i c a t i o n ,
a d j u s t h e p r e l o a du s i n gt h e f o l l o w i n gp r o c e d u r e s . TILT LOCKBOLT
Tightenthe lockbolt
a. Loosenthe tilt lever,and set the steeringcolumn the tilt leverraised.
in the neutralposition.
b. Removethe 6 mm lock bolt and removethe stop.
c. Adjustthe preloadby turningthe tilt lockbolt left
or ngnr.
d. Pullup the tilt leverto the uppermostpositionand
i n s t a l tl h e s t o p .C h e c kt h e p r e l o a da g a i n .l f t h e
measurementis still out of specitication,repeat
"a" "c" to adiust.
the aboveprocedures through
CAUTION: Be calelul not to loosen the tilt level

when installing the stop or tightening the 6 mm
lock bolt.
9 . 8N . m{ 1 . 0k g l m , 7 l b l f t )
17-38
PowerSteeringHoses,Lines
Fluid LeakageInspection
HOSESand LINES
. I n s p e c th o s e sf o r d a m a g e ,l e a k s ,i n t e r f e r e n c eo r VALVEBODYUNIT-Io-CYLINoER LINES
rwrsI|ng. 1 7N . m1 1 . 7 12 tbf ft,
. Inspectfluid linesfor damage,rustingand leakage.
vALVE BODYUNIT-to-FEED/RETURN LINES
. Inspectfor leaksat hose and line joints and connec
Feedline: 14 x 1.5 mm flare nut
trons. 37 N.rn 13.8kgf.m, 27 lbl.ft)
POWERSTEERINGPRESSURE SWITCH Rdurn Line Joint: 16 x 1.5 mm flare nui
12 N.m (1.2ksf.m,9 lbthl 28 N.m (2.7kgt m, 20lbf.ftl
CYLINDERHOUSING-to-CYLINDER LINES
28 N.m {2.7kg{.m,20 lbf.ft)
BOOT
for leaks.
Check
GEARBOXand VALVEBODYUNIT
Checkfor leaksat the matingsurface
and flare nut conneclions.
OUTLETHOSE
1 1N . m
(1.1kgf.m,8
(DoubleRingType)
C h e c kf o r l e a k s a t t h e p u m p
seal, inlet and oudet fittings.
Replacement
NOTE: CAUTION: Check all clamps for deterioration or defor-
. Connecteachhoseto the corresponding pipesecurely mation; leplace with the clamps new ones it necessary.
until it contactsthe stop on the line. Installthe clamp
or adjustableclamp at the specifieddistancefrom the
hoseend as shown.
. Add the power steeringfluid to the specifiedlevelon
the reservoirand checkfor leaks.
ADJUSTABLEHOSECLAMP: HOSECLAMP:
. P o s i t i o nt h e a d j u s t a b l eh o s e c l a m p s a t t h e p o i n t s . P o s i t i o n t hh
e o s ec l a m p sa t t h e p o i n t si n d i c a t e{db ) i n
indicated(a) in the drawingabove. the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop. . Slidethe hoseoverthe line until it contactsthe stop.
tqtT-f*r-
--!-t__1
g-
/Z\\\
@ - f f_lli
_tr
2.5- 5.5mm 2 . 0 - 4 . 0m m 2.5- 5.5mm
(0.01- 0.22inl 10.08 - 0.'16inl {0.01- 0.22in}
17-39
PowerSteeringPump
RemovaUlnstallation
NOTE:Beforedisconnecting the hosesf.om the pump, Connectthe inlet hose and the outlet line. Tighten
placea suitablecontainerunderthe car. the pump fittingssecurely.
1. Removethe belt by looseningthe pump mounting Looselyinstallthe pump in the pump bracketwith
bolts. mountingbolts.
11 N.m {1.1kgt.m,
7. Installthe oump belt.
PUMPMOUNTINGBOLT
2{ N.m {2.4kgf.m, 17 lbf ft) CAUTION:
. Mako suro that the power 3teering belt is prop-
erly positioned on the pulleys.
. Do not get power siesring fluid or gresse in the
power steering belt or pulley fac$. Cleanofl any
fluid or grcase before installation.
8. Adjustthe pump belt (seepage17-32).
Fill the reservoirto the upper level line (see page

PUMPMOUNTING EOLT 11-33t.
2il N.m{2.4kgf.m,1?lbt.ft)
Coverthe A,/Ccompressorwith severalshop towels

to protectit from spilledpower steeringfluid.
Disconnectthe inlet hose and the outlet line from

t h e p u m p ,a n d p l u gt h e m .
NOTE:Takecare not to spill the fluid on the body

or parts.Wipe off any spilledfluid at once.
Removethe pump mountingbolts,then removethe

pump.
NOTE:
. Do not turn the steeringwheel with the pump
removed.
. Wrap the opening of the pump with a piece of
tape to prevent foreign material from entering
I n ep u m p .
17-40
Disassembly
CAUTION: The power steering components are made of aluminum. Avoid damaging the componsnG during assembly.
NOTE:
. Cleanthe disassembledpartswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a sol-
vent.
a Always replacethe O-ringsand rubbersealswith new ones beforeassembly,
. Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe powe. steeringsystem.
. Replacethe pump as an assemblyifthe pans indicatedwith asterisk(+)are worn or damaged.
FLANGEEOLTS
20 N.m (2.0 kgf.m.
14 tbtft)
4.5mm ROLLEB
PUMPCOVERSEAL
Replace.
*OUTERSIDEPLATE
PUMPCOVER
5 mm ROLLER
*PUMP FOTOR
.SIDE PLATE
3 t
SNAPRING 13 x 1.9mm O-RING
Replace.
.PUMPHOUSING
,SUB-VALVE
51 x 2.{ mm O-RING
Replace.
15.2x 2.4mm O-RING PUMPSEAL

Beplace.
Replace.
PUMPSEALSPACER
INLETJOINT
BALLBEARING
FLANGEBOLTS Inspection
and Replacement,
11 N,m {1.1kgf.m, seepage17-43
8 rbf.ft)
a0 mm CIRCLIP
*FLOWCONTROLVALVE
Insoection
and Overhaul. PULLEY
seePaselT"
fi '-tlu"i:3;'n^ô'^''o PULLEY NUT
spnrruc/ d 64N.m{6.5kgt.m,
FLOWCONTROLVALVECAP 47lbt.ft)
4It N.m {5.0 kgf.m,
36 tbtft)
(cont'd)
17-41
PowerSteeringPump
Disassembly(cont'd) Inspection
1 . Drainthe fluid from the pump. Flow Control Valve:
Hold the steering pump in a vise with soft jaws, 1. Checkthe flow control valve for wear, burrs, and
hold the pulley with the specialtool, and remove other damage to the edges of the grooves in the
the pulleynut and pulley. valve.
CAUTION: Be carelul not to damage th6 pump FLOW

CONTROLVALVE
housing with thc iaws ot the viso and extension bar.
UNIVERSALHOLDER
C h e c kf o r
damage to edges.
Inspectthe bore the flow control valve for scratches

or wear.
Slip the valve back in the pump, and checkthat it

movesin and out smoothly.
D \
Loosenthe flow controlvalvecap with a hex wrench

and removeit.
Removethe O-ring,flow controlvalveand spring.
Removethe inletjoint and O-ring.
Removethe pump coverand pump coverseal.
7 . Removethe outer side plate,pump cam ring, pump

rotor,pump vanes,side plateand O-rings,
lf OK, go on step 4; if not, replacethe pump as an
Removethe snap ring, then removethe sub-valve assembly,The flow control valve is not available
from the pump housing. separately.
Removethe circlip, then remove the pump drive Attacha hoseto the end of the valveas shown.
shaft by tappingthe shaftend with the plasticham-
mer.
VALVE
FLOWCONTFOL HOSE
1 0 . Removethe pump sealspacerand pump seal.
17 -4 2
5. Submergethe valve in a containerof power steer- Ball Bearing:
ing tluid or solvent.and blow in the hose.lf air bub-
b l e s l e a kt h r o u g h t h e v a l v e a t l e s st h a n 9 8 k P a 1. Inspectthe ball bearingby rotatingthe outer race
{1.0kgflcm,,14.2psi),repairit as follows. slowly. lf any play or roughnessis felt, replacethe
ball bearing.
BALLBEARING
<-- POWERSTEERING
FLUIDor SOLVENT
Hold the bottom end of the valve with a open end

wrench.
7. Unscrewthe seat in the top end of the valve, and 2. Removeand discardthe ball bearingusing a press
.{ removeany shims.the reliefcheckball, reliefvalve as snown.
D and reliefvalvespring.
Installthe new ball bearingusinga pressas shown.
RELIEFVALVE
RELIEFCHECK BALL Ball Bearing Replacement:
SEAT
9 N.m
{0.9kgl.m.6.5lbtft)
C l a m pt h i se n d i n
a openeno wtencn. FLOWCONTROLVALVE
8. C l e a na l l t h e p a r t s i n s o l v e n t ,d r y t h e m o f f , t h e n
reassembleand retestthe valve.lf the flow control
valve tests OK, reinstallit in the pump. lf the flow
control valve still leaksair, replacethe pump as an lnstallwith the
assembly.The flow control valve is not available red shieldedside
separately. facing down.
NOTE: It necessary,relief pressureis adjusted at NOTE:Supponthe innerrace

the factory by adding shims under the check ball with the toolsecurely-
seat.lf you found shims in your valve,be sure you
reinstallas manv as vou took out.
17-43
PowerSteeringPump
Reassembly
1. Align the pin of the sub-valvewith the oil passage Coat the pump cover seal and the cover bushing
in pump housing,and push down the sub-valve. with the power steeringfluid, then installthe pump
Installthesnap ring properly. coversealinto the groovein the pump cover.
OIL PASSAGE
Align the pin of
Installthe outer side olateoverthe two rollers.
sub valve with
the oil passage.
ROLLERSET HOLES
OUTERSIDEPLATE
4.5 mm ROLLER
5 mm ROLLER
PUMPHOUSING
SNAPFING
2. Installthe new pump seal in the pump housingby

hand,then installthe pump sealspacer.
NOTE: Insertthe pump seal with its grooved side

I f a c i n gi n . PUMPCOVER ,rr","oE \
Positionthe pump drive shaft in the pump housing, 7 . Setthe pump cam ring over the two rollerswith the
then drive it in usinga specialtool as shown. " " " mark on the cam ring
upward.
Installthe 40 mm circlipwith its radiusedside fac-

Ing out. 40mm CtRCLtp
PUMPCAM RING
ATTACHMENT,30mm H
- oososob
ozzls q:D
BALLEEARING PUMPDRIVESHAFT
ROLI.IR SET HO|'.CS
PUMPSEALSPACER
ROLIIRS
17-44
Assemblepump rotor to the pump cover with the Coatthe O-ringwith power steeringfluid, and posi-
" o " markson the rotorfacingdown. tion it into the pump housing.
9 . Setthe 10 vanesin the groovesin the rotor. 1 3 . Installthe pump cover assemblyin the pump hous-
Ing.
NOTE:Be surethat the round ends of the vanesare FLANGEBOLTS
in contactwith the slidingsurfaceof the cam ring. 20 N.m {2.0 kgl.m,
r4 tbf.ftl
PUi'P VANES
PUMP ROTOR (10 plrt .)
aE
nn
't4. Coat the flow control valve with power steering

fluid.
D
1 5 . I n s t a l lt h e f l o w c o n t r o l v a l v e a n d s p r i n g o n t h e
1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gl l u i d . a n d p u m ph o u s i n g .
installit into the groovesin the side plate.
1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gt l u i d . a n d
1 l . Installthe side plateon the cam ring by aligningthe installit on the flow controlvalvecap.
rollerset holesin the side platewith the rollers.
't] . Installthe flow cont.olvalvecap on the pump hous-
I
ing, and tighten it.
SIDE PLATE E
15-2 | 2.1 mm O-RING r
Replace. SPRING E
Mv (64
ROU.€R SET HOll 15.2x 2.4rnm O-RING
Replace.
SET HOIf
\tbry
\
FLOWCONTROL
VALVECAP
49 N.m (5,0kgl.m,
36 rbtft)
ROU"EBS
(cont'd)
17-45
PowerSteeringPump
Reassembly(cont'dl
1 8 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d 21. Holdthe pulleywith the specialtool, and tightenthe
installit into the groovesin the inletjoint p u l l e yn u t .
PULLEYNUT
1 9 . I n s t a ltlh e i n l e tj o i n to n t h e p u m ph o u s i n g UNIVERSALHOLDER 64 N.m {6.5 kgtm,
15.2x 2.4
Beplace.
11 N.m (1.1kgl.m,
8 tbtfr) E Checkthat the pump turns smoothlyby turnrngrne
p u l l e yb y h a n d .
2 0 . l n s t a l lt h e D u l l e va s s h o w n b e l o w , t h e n l o o s e l y
I n s t a l tl h e p u l l e yn u t . H o l d t h e s t e e r i n gp u m p i n a
visewith softjaws.
CAUTION:Be carelul not to damagethe pump hous-

ing with the iaws of the vise.
17-46
SteeringGearbox
Removal
NOTE:Usingsolventand a brush,wash any oil and dirt 7. Removethe cotterpin from the castlenut ('96-'97
off the valve body unit its lines,and the end if the gear- model)or nut ('98 model)and removethe nut.
box. Blow dry with compressedair.
1, Drainthe power steeringfluid as describedon page END

TIE.ROD
1 7- 3 3 .
Raisethe front of vehicle,and support it on satety

standsin the properlocations(seesectionl).
Removethe front wheels.
Removethe driver'sairbagassembly,and steering

wheel(seepage17-35).
Bemovethe steeringjoint cover.
Installthe 10 mm hex nut on the balljoint.

D Be surethat the 10 mm hex nut is flush with the ball
j o i n t p i n e n d , o r t h e t h r e a d e ds e c t i o no f t h e b a l l
joint pin might be damagedby the specialtool.
NOTE:Removethe ball joint usingthe specialtool.

R e f e rt o s e c t i o n l 8 f o r h o w t o u s e t h e b a l l j o i n t
remover.
Separatethe tie-rodball joint and knuckleusingthe

6. Removethe steeringjoint lower bolt, and discon- specialtool.
nect the steeringjoint by moving the joint toward
t h ec o l u m n . CAUTION: Avoid damaging tho ball ioint boot.
1 0 . Removethe lefttie-rodend,then slidethe rackall the

way to the right.
1 1 . Separatethe exhaustpipeA or TWC (seesection9).
shiftlinkage(seesection13or section
Disconnectthe
141.
(cont'd)
17-47
,l
SteeringGearbox
Removal(cont'dl
Loosenthe 14 mm flare nut and disconnectthe feed 17. Removethe mountingbrackets.
l ne,
1 4 . Loosenthe adjustablehose clamp and disconnect

the returnhose.
Loosenthe 16 mm flare nut and removethe return

hose iointfrom the valvebodv unit.
CAUTION: After disconnecting the hose and line,

plug or seal the hose and line with a piece of tape
or equivalsnt to prevent foreign materials from
entering the valve body unit.
N O T E : D o n o t l o o s e nt h e c y l i n d e r l i n e A a n d B
betweenthe valvebody unit and cylinder.
ADJUSTABI.EHOSE
CLAMP
1 8 . Pull the steeringgearboxall the way down to clear

the pinion shaftfrom the bulkhead,then removethe
pinionshaftgrommet.
1 9 . Move the steeringgearboxto right so the left rack

end clearsthe rearbeam,then tilt the left side down
to removeit from the vehicle.
14 mm FLARENUT
CAUTION:Be careful not to bend or damage the
leed line and cylinder linss wh€n r€moving th6
Removethe stiffenerplate. gearbox.
NOTE:Some stiffenerplateattachingbolts are also

used as gearboxmounting bolts.The gearboxwill
tilt to sidewhen theseboltsare removed.
STIFFENERPLATE STEERING
GEARBOX
ATIACHING BOLTS
17 -48
Disassembly
Steoring Rack Disassombly 5. Holdthe steeringrackwith a wrench{'98 model:left
end onlv), and unscrewthe rack end with another
NOTE: wrench.
. Beforedisassemble the gearbox,wash it off with sol-
vent and a brush. CAUTION: Bo caroful not to damage tho rack sur-
. Do not dip sealsand O-ringsin solvent. fac€ with tho wrench.
1. Removethe st€eringgearbox(seepage l7-47). NOTE:'96 -'97 model is shown.
2. Removethe tie-rodend and locknut. STEERINGRACKEND
3. Removeairtube and clips.
STEERINGRACK
.l
Removethe boot bands and tie-rod clips, Pull Loosen the locknut, then remove the rack guide
bootsawayfrom the endsof the gearbox. screw('98 model)and O-ring{'96-'97 model only).
7. Removethe springand the rackguidefrom the gear

housrng.
RACKGUIDE
scREws
BOOT
TIE-ROOCLIP
(cont'd)
17-49
SteeringGearbox
Disassembly(cont'dl
8. Remove cylinder lines A and B from the gearbox 1 1 . D r i l la 3 m m { 0 . 1 2i n ) d i a m e t e rh o l ea p p r o x i m a t e l y
2 . 5- 3 . 0 m m ( 0 . 1 0- 0 . 1 2i n ) i n d e p t hi n t h e s t a k e d
p o i n to n t h e c y l i n d e r .
CAUTION:
. Do not allow metal shavings to enter the cylin'
der housing.
. After removing the cylinder end, remove any
burrs at the staked Point.
Deprhr2.5- 3.0mm {0.10- 0.12in)
LINEB
CYLINDER CYLINDERLINE A
9. Drain the fluid from the cylinder fittings by slowly CYLINDER

moving the steering rack back and forth
10. Remove the two flange bolts, then remove the valve
body unit from the gearbox. (See page 17 52 for
valve body unit disassemblY.)
1 2 . H o l d t h e s t e e r i n gg e a r b o xu s i n g a C - c l a m pa s
VALVE BODYUNIT FLANGE BOLT shown.
,
I
'96 - '97 model:

32 mm SHIMS
'98 modol:
WAVE WASHER
13. Loosenand removethe cylinderend.
17-50
'18. Removethe l2 mm bolt and nut from the steering
14. Assemblea '12x 1.25mm flangenut onto a 12 x 175
mm grade 10flangebolt as shown. rack.
1 9 . R e m o v et h e c y l i n d e re n d s e a l f r o m t h e s t e e r i n g
N O T E :W r a p t h e f l a n g e p o r t i o n o f t h e b o l t w i t h rack.
vinyl tapeto protectthe cylinder. CYLINDER HOUSING
CYLINDER ENDSEAL
Repiace,
l " \s-,'
r
|t " . .
tP/N 90177- SLo- 0001
It ^
I n s t a l tl h e f l a n g eb o l t i n t o t h e e n d o f t h e s t e e r i n g
r a c k u n t i l i t b o t t o m s i n t h e h o l e , t h e n b a c kt h e I o-tfl
f l a n g eb o l t o u t 1 / 4t u r n . H o l d t h e f l a n g eb o l t , a n d Q)*
tightenthe flangenut againstthe rackby hand. lol 3/8" drive extensionand the spe-
20. Inserta 24" long,
Installthe bearingseparatoron the gearboxhousing th cylinderfrom the gearboxs r d e .
cialtool into the
as shown. N O T E :M a k )e sure
s that the specialtool is securely
'12x 1t5 mm Press positionedon t backupring edges.
n the
FLANGEBOLT CAUTION: Be careful not damage to inner surtace
of the cylinderhousingwith the specialtool.
BEARINGSEPARATOR
o- 4112"I
21. Set the gearboxin a press,then pressout the cylin-
(commerciallvavailablel der end sealand backupring from the gearbox.
r-,,' CAUTION:
. Keepthe tool straightto avoid damagingthe cylin'
der wall. Checkthe tool angle,and correctit if nec-
essary,when removingthe cylinderend seal.
. Use a press to rcmove the cylinder end seal. Do
not try to remove the seal by striking the tool. h
will break the backup ring, and the cylinder end
sealwill remainin the gearbox.
Press
STEERINGRACK 24 "LONG 3/8" DRIVEEXTENSIONI

{Commerciallyavailable)
CYLINOER
END SEAL
17. Setthe gearboxin a pressso the gear housingpoint

upward,then pressthe cylinderend seal and steer-
ing rackout of the gearbox. BACKUPRING
NOTE:Holdthe steeringrackto keepit from falling

when pressedclear. CYLINDERENOSEAL
CAUTION:
. Be carelul not damage to inner surtace of the CYLINDERENOSEAL
REMOVERATTACHMENT
cylinderhousingwith the tlangebolt. 07NAO- SB3020A
. Do not place your lingers under the steering
rack. (cont'd)
17-51
SteeringGearbox
Disassembly(cont'dl
22. Carctullypry the pistonseal ring and O-ringoff the Valve Body Unit Disassembly
prslonracK.
2 3 . B e f o r er e m o v i n g t h e
v a l v eh o u s i n ga, p p l y v i n ytla p e
CAUTION:Be carefulnot to damagethe inside ot to splinesof the pinionshaft.
seal ring groove and piston edgeswhen temoving
the sealring. 24. Separatethe valve housingfrom the pinion shaft/
valveusrn9a press.
VALVEHOUSING
Vinyl tape
PINIONSHAFT
Replace.
2 5 Checkthe innerwall of the valvehousingwherethe

seal ring slideswith your finger.lf there is a step in
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valvehousing.
NOTE;
T h e r em a y b e t h e s l i d i n gm a r k sf r o m t h e s e a l
r i n g o n t h e w a l l o f t h e v a l v e h o u s i n g .R e p l a c e
the valvehousingonly if the wall is stepped.
When the valve housingis replaced,installnew
shim(s)on the bearingsurfaceof the housingto
adiustthe thickness.
Checkthe insideof valvehousing
whetherthe wall is stepped.
L t ,
17-52
2 6 . C h e c kf o r w e a r , b u r r s a n d o t h e r d a m a g et o t h e 28. Usinga cutteror an equivalenttool, cut and remove
edgesof the groovesin the sleeve. the four sealringsfrom the sleeve.
NOTE:The pinion shaft and sleeveare a precision CAUTIONTBe careful not to damage the edges of
m a t c h e ds e t . l f e i t h e rt h e p i n i o n s h a f t o r s l e e v e the sleeve groovos and out6r sufaca whon romov-
must be replaced,replaceboth parts as a set. ing the 3eal rings.
SLEEVESEALRINGS
SLEEVE
Checklorpeeloffor
damage.
Using a cutter or an equivalenttool. cut the valve

27. Removethe circlipand pinion shaft sleevefrom the seal ring and O-ringat the groovethe pinion shaft.
3 f Removethe valvesealring and O-ring.
pinionshaft.
CAUTION: Be caretul not to damage the odges of

the pinion shaft groove and outor 3urfac€when
r€moving ths valve seal ring 8nd O-ring.
Cuftingslot Position.
VALVESEALRING
Replace.
(cont'd)
17-5 3
)
SteeringGearbox
Disassembly(cont'd)
30, Removethe valveoil sealand backupring ('96-'97
model)or wave washer('98 model)from the pinion
shaft.
NOTE:
Inspectthe ball bearingby rotatingthe outer race
slowly.lf there is any excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
The pinion shaft and sleeveare a precisefiu do
not intermix old and new pinion shaftsand
sleeves.
BALLBEARING
'96 - '97 model:

BACKUPRING
Replace.
3 1 . Pressthe valve oil seal and roller bearing{'96 -'97
model)or bushing('98 modell out of the valve
h o u s i n gu s i n g a h y d r a u l i cp r e s sa n d s p e c i a tl o o l
shown below.
N O T E :D o n o t u s e a h a m m e r ;i t w i l l d a m a g et h e
specialtool.
'96 - '97 model:

PILOTCOLLAR
07GAF- PH70100
VALVEOIL SEAI-
Replace.
ROLLERBEARING
Beplace.
PILOTCOLLAR
07GAF- PH701(x)
VALVEOIL SEAL
Replace.
BUSHING
Replace.
t,,
17-54
Reassembly
NOTE:
. Cleanthe disassembled partswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a sol-
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly,
. Apply the recommendedpower steeringfluid to the pans.indicated in the assemblyprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem.
. Usethe appropriatespecialtools where necessary.
CYLINDERLINE A
CYLINDERLINE B
VALVEHOUSING
VALVEOIL SEAL
Replace.
FLARENUTS
17 N m 11.7kgt.m, 12 lbt.ft)
Replace -S-.- BEARING

--=-..--
SEALRINGS.-.--------..--
SLEEVE
S€ ",r"a,,
.o'S RePIace
VALVEOIL SEAL.
CYLINOER ENDSEAL Replace.
Replace. \ $<-----sueve
BACKUP -.$}-S:"_------;T;i,',Tl"t',
- " - v >
Replace. valvESEAL
-;;oi;"*. RING
itoilJoril."."
wAvEwASHER -_____
p***t.----..--..-
CYLINDERHouslNG
----_
I ll
GEARHOUSING
\ \ - - - - . - W - - - P t . t t o ' r s " n modol

n only:
S,----'96-'97
S-- 32 mm SHIMS
'96 - '97
mod6l only:
O.RING
'98 modol: Replace.
CYLINDEREND
63 N'm {7.0 kqf.m,51 lbftll
{cont'd)
17-55
SteeringGearbox
(cont'd)
Reassembly
Valvs Body Unit Rsassembly 8. Apply power steering fluid to the surface of the
v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n
1. Apply vinyl tape to the steppedportion of the pin- shaft.
ion shaft,and coat the surfaceof the vinvl taDewith 9. Apply power steeringfluid to the insideof the spe-
the power steeringfluid. cial tool. Set th€ largerdiameterend of the special
2 . I n s t a l lt h e b a c k u pr i n g ( ' 9 6 - ' 9 7 m o d e l )o r w a v e tool overthe valvesealring.
washer ('98 model)with its taperedside as shown 10. Move the specialtool up and down severaltimesto
makethe valvesealring fit in the pinionshaft.
3. C o a tt h e i n s i d es u r f a c eo t t h e n e w v a l v e o i l s e a l 11. Removethe specialtool,
with powersteeringfluid. 12. Turn the specialtool over,and setthe smallerdiam-
4. Slidethe valve oil seal over the pinion shaft,being eter end of the specialtool over the valveseal ring.
carefulnot to damagethe sealinglip. Move the specialtool up and down severaltimes to
Vinyl tape m a k et h e v a l v e s e a l r i n g f i t s n u g l y i n t h e p i n i o n
lStepped ponion) '96 - '97 modal: shaft.
Taperedposition.
PISTONSEALRING
EACKUPRING Grooveside. SIZINGTOOL
OTNAG- SR3G'OA
surethe springis or
seatedin the oil seal. 07NAG- SR3o900
PINION SHAFT S6aling lip
E
mvewAsHERt
t
CAUTION: Instsllthe valve oit sealwhh its grooved

side facing opposite the bearing.
Apply vinyl tape to the splinesand steppedportion

of the shaft, and coat the surfaceof the vinyl tape
with the powersteeringfluid.
Fit the new O-ringin the grooveof the pinion shaft.
Then slide the new valve seal ring over the shaft
(w(ffi
Use the larger diameter
end of the special
Makethe valvesealring
fit snuglyin the pinion
and the groovein on the pinionshaft. tool first to make shaftusingthe otherend
7. Removethe vinyltapefrom the pinionshaft. the valve seal ring (smallerdiameterend)of
fit in the pinion the specialtool.
shaft.
VALVESEALRING
Replace
Do not over-expand.
17-56
Apply power steeringfluid to the surfaceof the spe- 18, Apply power steeringfluid to the surfaceof the pin-
cialtool. Setthe new sealrings over the specialtool ion shaft.Assemblethe sleeveover the pinionshaft
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l . a n d b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e
expandthe seal rings. Do two rings at a time from sleevewith the cutout in the shaft.Then installthe
eachend of the sleeve. new circlipsecurelyin the pinionshaftgroove.
NOTE: NOTE:
. Do not over-expand the sealring. Installthe resin o B e c a r e f u l n o t t o d a m a g et h e v a l v e s e a l r i n g
seal rings with care so as not to damagethem. when insertingthe sleeve.
After installation.be sure to contract the seal .Install the circlipwith its radiusedsidetowardthe
rings usingthe specialtool(sizingtool). sleeve.
. There are two types of sleeve seal rings: black
and brown. Do not mix the different types of
sleevesealringsas they are not compatible.
1 4 . Setthe specialtool in the groovesin the sleeve,and

set each ring in eachgroovesecurely.
NOTE: After installation,compressthe seal rings

with your fingerstemporarily.
1 9 . Apply power steeringfluid to the seal ring lip of the

valveoil seal,then installthe seal in the valve hous-
i n g u s i n g a h y d r a u l i cp r e s s a n d s p e c i a lt o o l s a s
) shown.
CAUTION:lnstallthe valveoilsoalwith its grooved

side facing the tool.
15. Apply power steeringfluid ro the seal rings on the
sleeve,and to the entire insidesurfaceof the spe- ATTACHMENT,
32x35mm
cialtool. 07746- 0010100
16. Insertthe sleeveinto the specialtool slowly.
1 7 , M o v e t h e s l e e v ee a c h d i r e c t i o ns e v e r a lt i m e s t o
makethe seal ringssnuglyfit in the sleeve.
NOTE:Besurethat the seal rings are not turned up.
fr SLEEVESEALRING
SIZINGTOOL
07974- SA5020Aor
07974- SA50200
VALVE OIL SEAL

Replace.
spring is in the
oit seat. {cont.d)
17-57
SteeringGearbox
(cont'd)
Reassembly
20. P r e s st h e n e w b e a r i n g1 ' 9 6- ' 9 7 m o d e l ) o r n e w 2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
bushing('98 model) into the valve housingusing a pressas shown.
hydraulicpressand specialtool as shown.
N O T E : C h e c kt h a t t h e p i n i o n s h a f t / s l e e v e
turns
NOTE:Placethe roller bearing('96 -'97 model)or smoothlyby turningthe pinionshaft,
bushing('98 model) on the valve housingwith the
s t a m p e dl e t t e r f a c i n g ( ' 9 6 - ' 9 7 m o d e l o n l y ) u p
towardsthe valveside.
DRIVER ATTACHMENT.
Pres3
07749-0010000
+ 32x35mm
077i16- 0010100
'96 - '97 model:

ROLLERBEARING
Letterstampedface
upward,
21. Apply vinyl tape to the pinion shaft,then coat the

vinyltapewith power steeringfluid.
Sealing lip lace.

VALVEOIL SEAL
VALVEHOUSING
PINION
r
SLEEVE SEALRINGS
E
Replace.
Be surethat the
searfingsare not
turnedup, then
anstall.
22. Insertthe pinionshaft into the valvehousing.
CAUTION: Bo carotul not to damage the valve seal

rin9s.
23. Removethe vinyl tapefrom the pinionshaft.
17-58
Steering RackRoassembly 31. Wrap vinyl tape aroundthe rackteeth and rackend
edges.then coat the surface of the tape with the
25. Coatthe pistonseal ring guide with power steering powersteeringfluid.
fluid,then slideit onto the rack,big end first N O T E :M a k e s u r e t h a t t h e v i n y l t a p e i s w r a p p e d
carefullvso that there is no steppedportion.
26. Positionthe new O-ringand new pistonseal ring on
the specialtool, then slide them down toward the
b i g e n do f t h e t o o l .
NOTE:
. Do not over expand the resin seal rings. Install
the resin seal rings with care so as not to dam-
age them. After installation,be sure to contract
t h e s e a lr i n gu s i n gt h e s p e c i a l t o o(ls i z i n g
tool)
. Replacethe piston'sO-ringand sealring as a set.
27. Pull the O ring off into the piston groove,then pull
the pistonsealring off into the pistongrooveon top
of the O-ring. 32. Coatthe insidesurfaceof the new cylinderend seal
with powersteeringfluid.
33. Installthe cylinderend seal onto the steeringrack
PISTON
with its groovedsidetowardthe piston.
CAUTION:when inslalling the cylinder ond seal.
be careful nol damago the sealing lip face of the
seal with th€ edges or teeth of the steering rack.
I PISTON
GUIDE
SEALRING
07GAG- SD,OloAor CYLINDEREND SEAL

07GAG- SDIO100
O.RING
Replace
PISTONSEALRING
Replace-
28. Coatthe piston seal ring and the insideof the spe-
cialtool with powersteeringfluid
29. Carefullyslide the tool onto the rack and over the
pistonsealring.
30. Move the specialtool backand forth severaltimes Groovedsrde.

to makethe pistonsealring fit snuglyin the piston.
PISTON Makesurethe
Replace. sPringis in the cylinder
r
eno seal
E
34. Remove the vinyl tape from the steering rack
NOTE| Remove any residue oftape adhesive
(cont'd)
17-59
SteeringGearbox
Reassembly(cont'd)
35. Install the new backup ring on the steering rack. Installthe flange bolt into the end of the steering
then placethe cylinderend sealto piston. r a c k u n t i l i t b o t t o m s i n t h e h o l e .t h e n b a c kt h e
f l a n g eb o l t o u t 1 / 4 t u r n . H o l d t h e f l a n g eb o l t a n d
BACKUPRING tightenthe flangenut againstthe rackby hand.
Installthe cylinderend seal into the bottom of the

c y l i n d e rb y p r e s s i n go n t h e b o l t w i t h a p r e s sa s
shown.
CAUTION: Do not push on the boft with sxcessive

lorca as it may damagetha cylinder €nd seal.
Pre33
12 x 175mm FLANGEBOLT
(P/N 90177- SLo- 0001
36. Greasethe steering rack teeth, then insert the steer- 12 mm FLANGENUT
ing rackinto the gear housing.
CAUTION: Be careful not to damage to inner sur-

faco ot tho cylinder housing with tho rack edgB.
CYLINDERHOUSING
R e m o v et h e f l a n g e b o l t , a n d c e n t e rt h e s t e e r i n g
rack.
40. W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s .a n d
coatthe surfaceof the tape with the power steering
fluid.
N O T E :M a k e s u r e t h a t t h e v i n y l t a p e i s w r a p p e d
carelullyso that there is no steppedportion.
17-60
4 1 . Coatthe insidesurfaceof the new cylinderend seal 46. C o a t t h e i n s i d es u r f a c eo f t h e c y l i n d e re n d w i t h
with power steeringfluid. power steeringfluid,then installthe cylinderend by
screwingit into the cylinderhousing
Installthe cylinderend seal onto the steeringrack
with its grooved side toward the piston, 4 7 . Removethe C-cl8mpfrom the steeringgearbox.
43. Pushin the cvlinderend sealwith your finger. 48. After tighteningthe cylinderend, stakethe point of
t h e c y l i n d e rh o u s i n gs h o w n b e l o w .F o r ' 9 8 m o d e l
CAUTION:Wh.n irstalling the cylindsr ond 3eal, go to step51.
b6 csreful not damage the sealing face ol th€ seal
with the threads and burrs at the stakad position of NOTE: Stakethe cylinder in the position opposite
the cylinder housing. from where the stakewas removed during disas-
semblY.
E CYLINOER
Replace.
ENOSEAL
Makesurethe spring
Stakepoint.Deplh:1.0mm 10.0{inl
is in the cylinderend seal

mm {0.16in}
CYLINDEEEND
Staked
posr!on,
Groovedside
END
CYLINOER CYLINDEBEND
SEAL 69 N.m {7.0 kgt m, 5l lbf.ft)
Be careful not to damage
44. Removethe vinyl tapefrom the steeringrack. the bushing when insening
the cylinder end.
NOTE:Removeany residueof tape adhesive. 49. Selectthe 32 mm shim(s)('96-'97 model only).
45. Holdthe steeringgearboxusinga C-clampas shown. N O T E :O n l y r e i n s t a ltl h e o r i g i n a l3 2 m m s h i m ( s )

when the steeringgearboxis reassembledwithout
replacingthe pinion shaft,valve housing,and gear-
box housingwith new ones.
l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x
housingare replaced,selectthe new shimls)as fol-
GEARBOX lows.
Shim selestion:
a. Setthe four 32 mm shims on the bearingsurfaceof
t h e g e a r b o xh o u s i n g .T o t a l t h i c k n e s so f t h e t o u r
shimsshouldequalno more than 0,70mm.
Shim set: four 32 mm shims (Thickness: 0,10 mm,
0.15mm, 0,20mm, 0.25mm respectively)
CAUTION; Tho four 32 mm shims do not havo

thickness identification ma1k3.Measuro iho thick-
nass of each shim using a micromster,and mark
the shim for identitication.
(cont'd)
17-61
SteeringGearbox
Reassembly(cont'dl
l n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x ,a n d Example:
tightenthe flangeboltsto the specifiedtorque. lvleasurement is 0.28mm (0.011in):
FLANGEBOLT 0 . 7 0- 0 . 2 8 = 0 . 4 2m m ( 0 . 0 2 8 - 0 . 0 1 1 = 0 . 0 1i n7)
VALVEBODYUNIT
20 N.m {2.0kgtm, l4lbfft}
T h e s e l e c t e ds h i m s s h o u l db e 0 . 2 5m m ( 0 . 0 1 0i n ) a n d
0 . 1 5m m { 0 . 0 0 6i n } i n t h i c k n e s s .
g
l f t h e r e q u i r e ds h i m t h i c k n e s si s 0 . 1 0 m m o r l e s s ,n o
snrmsare necessary.
50. Set the selected32 mm shims on the bearingsur-

faceof the gearboxhousing.
VE EODYUNIT
O.RING
Replace.
M e a s u r et h e c l e a r a n c eb e t w e e nt h e g e a r b o xa n d
valvebody unit usinga feelergaugeas shown.
-61
NOTE: Measurethe clearanceat the point midway
betweenthe two mountingbolts.
32 mm SHIMS
BEARING
NEEDLE
--6'
Coatthe new O-ringwith grease,and carefullyfit it
on the valvehousing.
Apply greaseto the needlebearingin the gearbox

housrng.
d. D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m Installthe valve body unit on the gearboxhousing

s h i m sb y s u b t r a c t i ntgh e c l e a r a n coeb t a i n e di n t h e by engagingthe gears.
step "c" from the total thicknessof the four shims
( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( c l e a r a n c e )= NOTE: Note the valve body unit installationposi-
R e q u i r etdh i c k n e sosf t h e s h i m s tion (directionof line connection).
NOTE:Selectthe shims so that the total thickness Tightenrhe flangeboltsto the specifiedtorque
is closeto, but lessthan,the requiredthickness.
\
[ ,
17-62
55. InstallthecylinderlinesA and B. 6 0 . l n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e
NOTE: steeringrack.
. C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e sA a n d B 61. Screweachrackendsinto the rack.
thoroughly. The joints must be free of foreign 62. Holdthe steeringrackwith a wrench('98 model:left
material. end only),and tightenthe rackends.
. Instaltthe cvlinderlinesA and I by tightingthe CAUTION: Be careful not to damags tho rack sur-
flare nuts by hand first, then tighten the fla.e facr whh the wrench,
nutsto the specifiedtorque. NOTE:'96 -'97 model is shown
STEERINGRACKEND
17 N.m {1.7kgl.m,12lbtft) 5il N.m 15.5kgf.m, 40 lbf'ft)
LOCKWASHER
28 N.m {2.?kgf.m, 20 lbl.ft}
STEERINGRACK
CYLINOERLINEB CYLINDERLINEA
56. Greasethe sliding surfaceof the rack guide, and

installit onto the gear housing.
'97 model:
57. '95 - 63. After tighteningthe rack ends, stakethe four sec-
Apply a thin coat of greaseto the new O-ring,and tions of lockwasherwith a drift and a mallet.
installit on the rackguide screw. Placethe wood blockon the presstable,then set
'98 model: the lock washer section of the rack end on the
Remove the old sealant off of the threaded section, wood blocksecurely.
then apply new sealantto the firct threethreads. Be sure the tool is alignedwith the flat sections
Installthe spring,rack guide screw and locknuton of the steering rack end before pressing.
the gear housing. Stake the lock washer in the centet of the flat
59. Adjustthe rackguide screw(seepage 17-33). sectionof the steeringrackend.
NOTE:After adjusting,checkthat the rack moves
smoothlyby slidingthe rackright and left.
..-6ll
O.RING
Replace.
'96 - .97 model:
NOTE:Thisdrift hasa flat,

to preventpuncturing
STEERINGRACK
RACKGUIDE WOODENELOCK
LOCKNUTS scREws
{cont'd)
17-63
SteeringGearbox
(cont'd)
Reassembly
64. Apply greaseto the circumferenceot the rack end 67. Adjust the air hose fitting positionof the boots by
housing. turningit as shown below.
LEFTBOOT RIGHTBOOT
(Viewedfrom the {Viewedfrom the
leftside) rightside)
=_.
:!4AEn
SILICONEGREASE
AI8 HOSEFITTING
65. A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
grooveson the rackends.
l n s t a l lt h e b o o t s i n t h e r a c k e n d w i t h t h e t i e - r o d
clrps. 68. Installnew boot bandson the boot, and bend both
setsof lockingtabs.
NOTE:Installthe boots with the rack in the straight
ahead position (right and left tie-rodsare equal in CAUTION: Stake the band locking tabs firmly.
length).
RACKEND
a-.
.:!!!!t!H 69. Lightlytap on the doubled-overportionsto reduce
SILICONEGREASE
t h e i rh e i g h t .
@ Slide the rack right and left to be certainthat the

bootsare not deformedor twisted.
\
\
!'
TIE-ROO
17-64
lnstallation
7 1 , C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t CAUTION: Be caletul not to bend or damag€ ths tood
boot. line and cylinder linos when insialling tha gearbox.
72. Installthe clipspn the cylinderlines,then clampthe 1. Beforeinstallingthe gearbox,slide the rack all the
air tube with the clips. way to right.
2. Installthe mounting cushion on the steeringgear-

oox.
CYLINDERLINE A
3. Installthe pinionshaftgrommet,then insertthe pin-
ion shaft up throughthe bulkhead.
NOTE:Align the notch in the pinionshaft grommet

with the tab on lhe valvehousing.
CLIP
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t i n g
cushion,then installtwogearboxmountingbolts.
MOUNTINGBRACKET
N O T E : I n s t a l lt h e b r a c k e t {4.0 kgf.m, 29 lbl ft)

with the arrow pointing
(cont'd)
17-65
SteeringGearbox
Installation (cont'd)
l n s t a l l t h e s t i f t e n e rp l a t e w i t h t h e t w o g e a r b o x 9 . Centerthe steeringrackwithin its stroke.
mountingboltsand stiffenerplateattachingbolts.
1 0 . Slip the lower end of the steeringjoint onto the pin-
CAUTION: Be sure the air tube is not caught ol ion shaft(lineup the bolt hole with the groove
pinched by stiftener plate. aroundthe shaft),and tightenthe lower bolt.
N O T E :I n s t a l lt h e b o l t s l o o s e l yf i r s t , t h e n t i g h t e n NOTE:
them securely. . Connectthe steeringshaft and pinion with the
cablereeland steeringrackcentered.
Besurethatthe lowersteeringjoint bolt is securely
in the groovein the steeringgearboxpinion.
STIFFENER
PLATE lf the steeringwheel and rack are not centered.
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringjoint.
STEERING
JOINT
ATTACHINGEOLTS
38 N.m (3.9 kg,f.m.28lbl.ftl
GEARBOXMOUNTINGBOLTS
,€ N.m ({.4 ksl.m, 32 lbl.fr}
Installthe returnhosejoint by tighteningthe l6 mm

flare nut.
\
1. Connectthe return hose securely,and tighten the
a d j u s t a b l eh o s e c l a m p f r o m t h e e n g i n ec o m p a r t -
ment.
8. Connectthe feed ljne and tighten the 14 mm flare

nut.
STEERINGJOINT
NOTE: Makesure that there is no interference LOWER BOLT
betweenthe fluid lines,the rear beam or any other 22N.m(2.2kgf.m,16lbl.ft)
pans.
ADJUSTAELEHOSE 15 mm FLARENUT
CLAMP 28 N.m {2.7 kgf.m.20 lbtft)
(seepage17-39i 'I
1. Centerthe cable reel by first rotating it clockwise
until it stops.Then rotate it counterclockwise
FETURNHOSE (approximatelytwo turns) until the arrow mark on
the label points straight up. Reinstallthe steering
wheel(seepage17-35).
1{ mm FLARENUT
37 N.m (3.8kgtm,27 lbf.tt)
17-66
12. Installthe steeringjoint coverwith the clampsand a 1 4 . Installthe exhaustpipe A or TWC (seesection9).
clip.
1 5 . Connectthe shift linkage{seesectionl3 or section
14).
lnstallthe front wheels.
1 7 . Fill the systemwith power steeringfluid. and bleed

air from the system(seepage 17-33).
1 8 . After installation. performthe followingchecks,

. S t a r tt h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e
steeringwheelfrom lock-tolockseveraltimes to
warm up the tluid. Ch€ckthe gearboxfor lesks
(seepage17-39).
. Adjustthe tront toe (seesection18),
Reconnect the tie-rodendsto the steeringknuckles, . Checkthe steeringwheel spokeangle.Adjust by
tighten the castlenut ('96 -'97 model) or nut {'98 turningthe right and lefttie-rods,if necessary.
model)to the specifiedtorque,and installnew cotter
prns. NOTE:Turn the right and lefttie-rodsequslly.
NOTE: Before connectingthe tie-rod ends, wipe off

any greasecontaminationfrom the balljoint tapered
sectionand threads.
CAUTION: Torquethe castlenut to the lower torque

specification, th€n tighten it only far enough to align
the slot whh the pin hole. Do not align the nut by
,97 modd onlyl.
looeening('96-
NE.RODENO
COTTERPINS
Replace.
On reassembly, bend
the cotterpin as shown.
CASTLE NUT NUT

,+0- ,18N'm il,l N.m
(4.5kgl'm,33 lbffrl
14.0- 4.8kgt'm,
29- 35lbf.fr)
17-67
Balljoint BootReplacement
'96 - '97 modol: '98 modol:
L Removethe boot set ring and the boot. CAUTION: Do not contaminatetho boot instsllation sec.
tion with grease.
GAUTION:Do not contaminatethe boot installa-
tion section with gtease. 1. Removethe boot from the tie-rodend, and wioe the
old greaseoff the ball pin,
2. Packthe interiorof the boot and lip with grease.
2. Packthe lowerareaofthe ball pin with freshgrease.
3. Wipe the greaseoff the sliding surfaceof the ball
pin,then packthe lower areawith freshgrease. 3. Packthe interiorof the new boot and liD with fresh
grease.
CAUTION:
. Keep grsase off th6 boot installation section and GAUTION:
the tapered s6stion ot the ball pin. . Ke€p grgaseofftha boot installation soction and
. Do nol allow dust. dirt, or othar foteign matori- lhe tapered soction if the batl pin.
als to enter the boot. . Do not allow dust, dirt. or othor foroign materials
to enter ths boot,
LIP BALLPIN TAPERED
SECTION
Wipe off the grease.
BOOTINSTALI."A \
BOOTINSTALLATION sEcnoN
SECTION Wipe offthe grease.
SECTION Wipeoff the grease.
Wipeoff the grease-
4. Installthe boot in the grooveof the boot installation
sectionsecurelv,then bleedthe air from the boot.
Installthe new boot usingthe specialtool as shown
ADJUSTINGBOLT oerow,
Adjustthe depth
by turningthe bolt.
NOTE: The boot must not be a gap at the boot instaf
lation sections.
FRONTHUB
DIS/ASSEMBLYIOOL
0796s - SA5o500
, . .^'
,'
,;i
. -,.-.:.-
SETRING
Adjust the specialtool with the adjustingbolr until

the end of the tool aligns with the groove on the
boot. Slidethe set ring over the tool and into posi-
Iron.
ir
f'
CAUTION: After installing tho boot, chock the batt
pin tap€rod section tor gtsase contamination and
CAUTION: Aft€r installing the boot, chock the ball
pin taperod sgction for gr€ase contamination, and
wipo il if necess8ry. wipo it il nocessary.
17-68
Suspension
SpeciafToofs 18-2
............. Front Damper
ComponentLocations Removal 18-16
.................
lndex ................ ......18'3 Disassembly/lnspection "..' 1A-17
........'....
Wheel Alignment Reassembly 18-18
...........
Caster,.............. ...,,,18'4 Installation 18-18
.............
Camber 18-4
.................. RearSuspension
Front Toe Inspection/ SuspensionArms Replacement.....18-20
Adiustment ......'.18-5 Hub BearingUnit Replacement......18-21
RearToe Inspection/ Upper Arm BushingReplacement. 18-22
Adiustment ........18-5 RearDamper
18-6
TurningAngleInspection...............' t8-23
.................
Removal
Wheel/HubInspection Disassembf ".' 18'24
y/lnspection ..............
1a'7
BearingEnd Play.........................."" 18'25
...........
Reassembly
Wheel Runout .......18-7 Installation 18-26
.............
Front Suspension
SuspensionArms Replacement.....18-8
Knuckle/HubReplacement..'.......'.' 18-9
Lower Ball Joint Replacement.......18-15
Ball Joint Boot Replacement..........18-16
1
SpecialTools
Ref. No. Tool Number Description Oty PageReterence
o 07GAF- SE00200 Hub AssemblyGuideAttachment 1

'I
18-14
@ 07GAF- SE00401 Hub Dis/Assembly Base 18-13
at\ 07GAG- SD40700 B a l l J o i n tB o o tC l i pG u i d e 1 18-16
' 1 81- 3
@ 0 7 J A F- S H 2 0 1 1 0 Hub Dis/Assembly Pilot,38 mm I
OTJAF SH2O120 Hub Dis/Assembly Shatr,22.4x25.4 mm 1 18-13
!o, 07JAF- SH20200 BallJoint RemoverBase 1 18-15
'1,
o 0TiilAC- S100200 B a l lJ o i n tR e m o v e r2, 8 m m 1 18-1 1 2
@ 07746- 0010500 Attachment,62 x 68 mm 1 18-13
6l 07749- 0010000 Driver I 18-13
@ 07947- 6340201 DriverAttachment 1 1 8 -1 4
o 07965- S800100 BallJoint Remover/lnstaller 1 18-15
@ 07965- S800200 B a l lJ o i n tl n s t a l l eBr a s e 1
@ 07965- SD90100 SupportBase 1 18-14
@ 07974- SA50700 B a l lJ o i n tB o o tC l i pGu i d e 1 1e 1R 16
o o.(} o
@,@
@ @
8-2
ComponentLocations
Index
Wheel Alignment, page 18-4
Front SusDension:
FRONTDAMPER
' Removal,page18-16
. Disassembly/lnspection,
page'18'17 UPPERARM
. Reassembly, page18 18 . Replacement,
page18-8
. lnstallation,
page18'18
KNUCKLE/HUB
. Replacement,
page18 9
. WheelBearingReplacement,
page18.13 STABILIZERBAR
. L o w e r E a l l J o i n t R e p l a c e m e n t ,p a g e 1 8 - ' 1 5 . Replacement,
page18-8
LOWERARM
. Replacement,
page18-8
RearSuspension:
REABDAMPER
' Removal,page18 23
. Disassembly/lnspection,
page18-24
. Reassembly, page18-25
. Installation,
page18-26
UPPERARM
' Replacement,
page18-20
LOWERARM
. Replacement,
page18-20
TRAILINGARM
. Replacement,
page18 20 . Replacement,
page18-20
18-3
WheelAlignment
Caster Camber
NOTE| For proper inspection/adjustment of the wheel Inspection
alignment checkand adjustthe following before check-
ing the alignment. N O T E :U s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z efdo u r
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n -
. Checkthat the suspensionis not modified. m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
. Checkthe tire sizeand tire pressure. the equipmentmanufacturer's instructions.
. Checkthe runoutof the wheelsand tires.
. Checkthe suspensionball joints. (Holda wheel with 1. Checkthe camberangle.
your handsand move it up and down and right and
leftto checkfor wobbling.) Camb6rangle:
Front: 0'00' I 1'
R e a r -: 1 " 1 1 '
2. lf out of specification,checkfor bent or damaged

suspensioncomponents.
Inspection
N O T E :U s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z efdo u r
m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equipmentmanufacturer's instructions,
1. Checkthe casterangle.
Casterangle:1"40't 1"
2. lf out of specification,checkfor bent or damaged

suspensron componenrs.
D=r$*
18-4
FrontToe Inspection/Adjustment RearToe Inspection/Adjustment
N O T E :U s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z e fdo u r N O T E :U s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z efdo u r
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n - w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n -
m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equipmentmanufacturer's instructions. the equipmentmanufacturer's instructions.
'1. Checkthe tire pressure. 1. Releaseparkingbrake.
2. Centersteeringwheelspokes. NOTE:
. M e a s u r ed i f f e r e n c ei n t o e m e a s u r e m e n tw
sith
3, C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t the wheelspointedstraightahead.
ahead. . lf the parkingbrakeis engaged.you may get an
incorrectreading.
Fronttoe: lN 1 t 2 mm (lN 1/16l: 1/16in)
Reartoe-in:2 1i mm ttlte:ljl8 int
- lf adjustmentis required,go on to step 4.
- lf adjustmentis required,go to step2.
- lf no adjustmentis required.remove alignment
equipment. - lf no adjustmentis required,remove alignment
equipment.
4. Loosenthe tie-rod locknuts,and turn both tie-rods
in the same directionuntil the front wheels are in Beforeadjustment,note the locationsof adjusting
straightaheadposition. boltson the right and left compensatorarms.
Loosenthe adjustingbolts. and slide the compen-

TIE.RODLOCKNUT
satorarm in or out, as shown,to adjustthe toe.
1 4x 1 . 5m m
{,1 N.m (,1.5kgt m, 33 lbtftl
ADJUSTINGBOLT
1 0x 1 . 2 5m m
64 N.m {6.5kgt.m. 47 lbtftl
IN ARM
COMPENSATOR
Turn both tie-rodsequally until the toe readingon
the turning radiusgaugeis correct. 4. Tightenthe adjustingbolts.
After adjusting,tightenthe tie-rodlocknuts. . Example:

A f t e r t h e r e a r t o e i n s p e c t i o n t, h e w h e e l i s 2 m m
NOTE:Repositionthe tie-rodboot if it is twisted or (0.08in) out of the specification.
displaced. - M o v e t h e a r m s o t h e a d j u s t i n gb o l t m o v e s 2 m m
(0.08in) inwardfrom the positionrecordedbeforethe
adjustment.
- The distancethe adjustingbolt is moved should be
equalto the amountout-of-specification.
18-5
WheelAlignment
TurningAngleInspection
N O T E :U s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z efdo u r
m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the eouiDmentmanufacturer's instructions.
1. Turn the wheel right and left while applying the

brake,and measure the turning angle of both
wheels.
Turningangle:
lnward wheel: 39"50'
Outward wheol lreferencel:33"10'
2. l f t h e t u r n i n ga n g l eis not within the specifications,

c h e c kf o r b e n t o r d a m a g e ds u s p e n s i o nc o m p o -
nenrs.
18-6
Wheel/HubInspection
BearingEndPlay WheelRunout
1. Raisethe vehicleoff the ground.and supportit with 1. Raisethe vehicleoff the ground,and suppon it wjth
safetystandsin the properlocations(seesection1). safetystandsin the properlocations(seesection1).
2. Removethe wheels,then reinstallthe wheel nuts. Checkfor bent or deformedwheels.
3. Aftachthe dial gaugeas shown. 3. Attachthe dial gaugeas shown.
4. lMeasurethe bearingend play by movingthe disc in Measurethe wheel runoutby turningthe wheel.
or outward.
Front and R€arwheel Axial Runout:
Front/Rear: Stand8rd:
Standsrd:0- 0.05mm {0 - 0.002inl Steel Wheel: 0 - 1.0 mm (0 - 0.0/tinl
Aluminum wheel: 0 - 0.7 mm {0 - 0.03in)
Service Limit: 2.0 mm 10.08inl
Front and RearWheel RadialRunout'

Standard:
i SteelWheel: 0 - 1.0mm (0 - 0.0/tinl
AluminumWheel:0 - 0.7 mm (0 - 0.03in)
ServiceLimit: 1.5mm (0.06inl
Measureend playat centero{

t h e h u bc a p .
lf the bearing end play measurement is m o r e t h a n 5. lf the wheel runout is more than the servicelimit,
t h e s t a n d a r d ,r e p l a c et h e w h e e l b e a r i n g . replacethe wheel.
18-7
I
FrontSuspension
Suspension
ArmsReplacement
CAUTION:
. Replacetho selt-lockingnuts after removal.
. The vehicle should be on the ground betore any bolts or nuts connectedto rubber mounts or bushings are tightened.
NOTE:
. Wipe off any dirt, oil from greaseon the threadsbeforetighteningthe fasteners.
. The right and left damper forks are not interchangeable. The left damper fork is markedwith "AL" while the right
dampertork is markedwith "AR .
. The right and left upper arms are not interchangeable.The left upperarm is markedwith "SO1-L"while the right arm
i s m a r k e dw i t h " S O 1 - R " .
. Beforetighteningthe upperand lower mountingnuts on the stabilizerlink,adjustthe locationof the link with the sus-
p e n s i o nu n d e rv e h i c l el o a d .
. When installingthe radiusarm washers,the "FR" markfacesthe front of the vehicle.
. After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary(seepage 18 4).
STABILIZER
FLANGEBOLTS STABILIZER BAR BUSHING
1 0 x 1 . 2 5m m Alignthe stabilizermark
54 N.m {5.5 kgl.m, with end of stabilizer
bushi
40 tbf.ft) UPPERARM
Checkthe bushingfor deterioration
anddamage.
BALLJOINT BOOT
STABILIZER END . C h e c k f o r d e t e r i o r a t i o na n d d a m a g e .
RUBBER BUSHING . See page 18 16 for boot replacement.
Checkfor deterioration
ano oamage,
STABILIZER BAR
FLANGEBOLT Checkfor bendingand damage.
l i l x ' 1 . 5m m
103N.m 110.5kgtm, \
76lbfftl \
FLANGEBOLT
8 x 1.25mm
22 N.m 12.2kgt.m, LOWERARM
16 tbf.ftl RUBBER BUSHING 1 4x 1 . 5m m
. Checkfor deterioration Replace-
ano oamage. 83 N.m 18.5kg{.m,61 lbtft}
1 4x 1 . 5m m
89 N.m (9.1kgf.m,66lbf ft)
SILICONEGREASE
RUBBER BUSHINGS
FLANGEBOLT
10 x 1.25mm
SELF-LOCKING NUT 8 x 1.25mm i|i} N'm 14.4kgl'm.
22 N.m (2.2kgl.m, 16 lbf.ft) 32 rbf ft)
Replace.
SELF-LOCKING NUT
12 x'1.25mm
Replace.
64 N.m (6.5kgf.m, {7 lbnft}
RUBBER BUSHING
. Checkfor deterioration
and damage
SILICONEGREASE
STABILIZER ENDRUBBER BUSHINGS
Notethe direction
ot the bushings.
18-8
Knuckle/HubReplacement
CAUTION:
. Replacethe selt-lockingnuts after removal.
. The vehicle should be on the ground before any bolts or nuts connectedto rubber mounts or bushings are tightened.
. Torque the castle nut to the lower torque specification,then tighten it only far enough to slign the slot with the pin
hole.Do not alignthe nut by loosening.
NOTE:
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weightsmay corrodeand damage
t h e a l u m i n u mw h e e l s .
. On the aluminumwheels,removethe centercapfrom the insideof the wheelafter removingthewheel.
o Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc.
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakediscand wheel.
. Wipe off the greasebeforetighteningthe nut at the balljoint.
CALIPERMOUNTINGBOLT CASTLENUT
12x 1.25mm 10 x 1.25mm
108N.m (11.0kgt m,80 lbnftl 39 - 47 N.m 14.0- 4.8 kgf.m, 29 - 35 lbtft)
COTTERPIN
Replace.
WI{EELBEARING
Replace.
page18-13
Replacement,
GUARO
CIRCLIP
LOWERBALL SCREW
Inspectfor faulty 5x0.8mm
movementand wear. 4.9N.m {0.5kgtm.3.6lb{.ftl
Replacement, page18 15
FRONTHU8
SET C h e c kf o r d a m a g e 6 n d
COTTERPIN Replacement,
BALLJOINT BOOT Replace. page l8-10
ano oamage. SPINDLENUT
22 x 1.5mm
CASTLENUT 181N.m 118.5kgt.m, 134lbf.tt)
12 x 1.25mm Replace.
49 - 59 N m 15.0- 6.0 kgf m, 36 - iB lbf.ft) NOTE:
. Betoreinstallingthe spindlenut,apply
engineoilto the seatingsurfaceofthe nut.
. Aftertightening,usea driftto stakethe
spindlenut shoulderagainstthe driveshaft.
ERAKEDISC
C h e c kf o r w e a r a n d
rust.
R e p l a c e m e n t ,p a g e ' 1 8 ' 1 0
I n s p e c t a o ns, e c t i o n 1 9 ,
WHEELNUT
1 2x 1 . 5m m
't08 N.m
{11.0ksf.m,80lbf.ft)
6 mm BRAKEDISCRETAININGSCREW
9.8 N.m 11.0ksf m, 7 lbtft)
{cont'd)
18-9
FrontSuspension
Knuckle/HubReplacement{cont'd}
1. Loosenthe wheel nuts slightly. 7. Removethe 6 mm brakedisc retainingscrews.
2. Raisethe front of vehicle, and support it with safety

standsin the properlocations(seesection 1).
3. Removethe wheel nuts and wheel.

WHEELNUT 6 mm BRAKEDISC
108N.m RETAININGSCREWS
{11kgtm.80 lbf.ftl 9.8 N.m ll.0 kgl.m, 7 lbf.ft)
8 x 1.25mm BOLTS
8. Screwtwo 8 x 1.25mm bolts into the discto push it
awayfrom the hub.
SPINDI.fNUT
181N.m {r8.5kgf.m,134lbtft) NOTE:Turn eachbolt two turns at a time to prevent
Replace. cockingthe discexcessively.
NOTE:Beforeinstallingthe spindlenut, apply
engineoil to the seatingsurfaceof the nut.Atter
tightening,use a dritt to stakethe spindlenut 9 . Removethe brakediscfrom the knuckle.
shoulderagainstthe driveshaft
1 0 . Checkthe front hub for damageand cracks.
Raisethe locking tab on the spindle nut, then remove
the nut. 't1. Remove
the wheel sensorfrom the knuckle(for cars
5. Remove the brake hose mounting bolts. with ABS).
BMKE HOSEMOUNNNG BOLT
8 x 1.25mm NOTE:Do not disconnectthe wheel sensorconnec-
12 N.m 11.2ksI.m,8.7 lbtftl ror.
9.8N.m
CAI-IPERMOUNTINGBOLTS {1.0kgf.m,
12 x 1.25mm
7 rbr.ft)
108N.m (11.0kgf.m,80lbl.ft)
6. R e m o v et h e c a l i p e rm o u n t i n gb o l t s a n d h a n g t h e
caliperassemblvto one side.
MOUNTING
CAUTION;To prevent accidentaldamage to th€ BOLTS
'+
caliper assemblyor brake hose, use a short piece ot 9.8N.m
wire to hang the caliper from the undercarriage. 11.0kgf.m,7lbf.ftl
18-10
NOTE: Use the specialtool to separatethe ball ioints 17. Oncethe specialtool is in place,turn the adjusting
from the suspensionor steeringarm bolt as necessaryto make the jaws parallel.Then
h a n d - t i g h t e nt h e p r e s s u r eb o l t , a n d r e c h e c kt h e
CAUTION: Be careful not to damagethe ball ioint boot. jaws to makesurethey are still parallel.
1 2 . Cleanany dirt or greaseoff the balljoint.
1 3 . Removethe cotter pin from the steeringarm and

removethe nut.
1 4 . Apply greaseto the specialtool on the areasshown.

of the tool and prevent
T h i s w i l l e a s ei n s t a l l a t i o n
damageto the pressureboltthreads.
ADJUSTINGBOLT
PRESSURE
BOLT
NOTE:After making the adjustmentto the adjust-

ing bolt, be sure the headof the adjustingbolt is in
this positionto the allow the jaw to pivot.
18. With a wrench,tighten the pressurebolt until the

balljoint shaft pops loosefrom the steeringarm.
l 1 0 m m h e x n u t o n t h e b a l l j o i n t .B e s u r e
I n s t a la
that the hex nut is flush with the ball joint pin end to @ wear eye protection. The ball ioint
p r e v e n td a m a g et o t h e t h r e a d e de n d o f t h e b a l l can break loose suddenly and scatter dirt or other
Jornt. deblis in your eyes,
I n s t a l lt h e s p e c i a lt o o l a s s h o w n . I n s e r tt h e j a w s 19. Removethe tool, then removethe nut {rom the end

carefully,makingsure you do not damagethe ball of the balljoint and pull the balljoint out of the
j o i n t b o o t . A d j u s tt h e j a w s p a c i n gb y t u r n i n gt h e steering/suspension arm. Inspectthe ball joint boot
pressurebolt. and replaceit if damaged.
N O T E :l f n e c e s s a r ya,p p l y p e n e t r a t i n g
type lubri-
cantto loosenthe ball joint.
COTTER.PIN
Replace.
On reassembly,
bendthe cotterpin
CASTLENUT
10 x 1.25mm ';" .
39 - 47 N.m
(4.0- 4.8 kgf.m, CASTLENUT
xei ruur
Replace. BALLJOINT REMOVER,28 mm
07MAC- SL00200 {cont'd)
1 8 - 11
FrontSuspension
Knuckle/HubReplacement{cont'dl
20. Removethe cotterpin from the lower arm ball joint 23. Removethe cotterpin from the upperball joint cas-
castlenut, and removethe nut. tle nut. and removethe nut.
COTTER.PIN
Replace.
On reassembly,
bendthe cotterpin
CASTLENUT
1 2x 1 . 2 5m n
49 - 59 N.m {5.0- 6.0 kgf.m, 36 - /H lbtftl
12 x 1.25mm
39 - 47 N.m
{4.0- 4.8 kgt m,
29 - 35 tbtft)
12 mm HEXNUT
24. Installthe 12mm hex nut on the ball joint.

Be sure that the hex nut is flush with the ball joint
pin end, or the threadedsectionof the ball joint pin
might be damagedby the balljoint remover.
Usethe specialtool as shown on page 18-11to sep-

aratethe ball joint and knuckle.
NOTE: lf necessary.apply penetratingtype lubri-

cantto loosenthe ball joint.
CASTI-ENUT BALLJOINT REMOVER,28 mm 26. Pullthe knuckleoutwardand removethe driveshaft

1 2x 1 . 8 m m 07MAC- 5100200 outboardjoint from the knuckleby tappingthe drive-
shaft end with a plastichammer,then removethe
knuckle.
KNUCKLE
2 1 . I n s t a l la 1 2 m m h e x n u t o n t h e b a l l j o i n t . B e s u r e Checkfor damage.
that the hex nut is flush with the ball joint pin end,
or the threadedsectionof the ball joint pin might be
damagedby the ball joint remover.
2 2 . Usethe specialtool as shown on page 18-11to sep-

aratethe balljoint and lowerarm.
N O T E :l f n e c e s s a r ya,p p l y p e n e t r a t i n g
type lubri-
c a n tt o l o o s e nt h e b a l l j o i n t .
18-12
NOTE: Replacethe bearingwith a new one after removal. 2 9 . P r e s s t h e w h e eble a r i n go u t o f t h e k n u c k l eu s i n g t h e
soecialtoolsand a pressas shown.
27. Separatethe hub from the knuckleusingthe special
tools and a hvdraulicpress. Press
CAUTION:
DRIVER
07749- 00'10000
+
. Take care not lo disto.t the splash guard. ATTACHMENT,
. Hold onto lhe hub to keep it from falling when KNUCKLE 62x68mm
preised clear. 07746- 0010500
a To prevenl damage to the tool. make Sure ihe
threads are fully engagedbefore pressing.
HUBDIS/ASSEMBLY
PILOT,38 mm
07JAF- SH20r10
l
KNUCKLE I
HUBDIS/ASSEMBLYBASE WHEELBEARING
07GAF- SE0040r Replace.
3 0 . P r e s st h e w h e e l b e a r i n gi n n e r r a c e f r o m t h e h u b
using the specialtools, a bearing separator, and a
pressas shown,
HU8 DIS/ASSEMELY
SHAFT.22.4x 25.4mm
07JAF- SH20120 Pres3
HUB DIS/ASSEMBLY
BEABING
SEPARATOR
0 - 1112in.
I PILOT,38 mm
07JAF- SH20110
(Commercially
available)
Removethe circlip and the splash guard from the
knuckle.
Checkfor bending and damage.
HUBDIS/ASSEMBLY
SHAFT,22.4x 25.4mm
07JAF- SH20120
j
l
l
(cont'd)
18-13
FrontSuspension
Knuckle/HubReplacement(cont'd)
N O T E :W a s h t h e k n u c k l ea n d h u b t h o r o u g h l yi n 34. Installthe hub on the knuckleusingthe specialtools
highflash point solventbeforereassembly. shownand a hvdraulicDressas shown.
Pressa new wheel bearinginto the knuckleusing CAUTION:Takecare not to distort the splashguard.
the specialtools and a pressas shown.
NOTE:Placethe wheel bearingon the knucklewith

the Dackseal (metal color) toward the inside. Be HUB/ASSEMBLY
GUIDEATTACHMET'rT
carefulnot to damagethe sleeveof the packseal. 07cAF- SEqt200
Press
HANDLE OOUBLELIPSEAL
o7749- IBLACKCOLOR)
DRIVER
ATTACHMENT
58x72mm
07947- 6340201 FRONTHUB
WHEEL
BEARING ., SPLASHGUARD
I
I
I
KNUCKLE
SUPPORT BASE
07965- SO90100
32. Installthecirclipsecurelyin the knucklegroove.

35. lnstallthe knucklein the reverseorder of removal,
33. Installthesplashguardand tightenthe screws. and pay particularattentionto the followingitems:
B e c a r e f u ln o t t o d a m a g et h e b a l l j o i n t b o o t s
scREws when installingthe knuckle.
4.9N.m(0.5kgf.m,4lbtft) Torque all mounting hardwareto the specified
t o r q u ev a l u e s .
Torquethe castlenuts to the lower torque speci-
fications.then tighten them only far enoughto
align the slot with the pin hole, Do not align the
castlenut by loosening,
Install new cotter pins on the castle nuts after
torquing.
Avoid twisting the sensorwires when installing
the wheelsensor.
Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel,cleanthe matingsur-
faceof the brakediscand the insideof the wheel.
Checkthe lront wheqlialignment,and adjustit if
*_l necessary{seepage{S0.
,:1S
18-14
LowerBallJoint Replacement
1. Removethe knuckle(seepage18 10). 8. Installthe ball joint boot and set ring usingthe spe
c i a lt o o l ( s e ep a g e1 8 - 1 6 ) .
2. Removethe boot by pryingthe set ring off.
3. and damage,
C h e c kt h e b o o t f o r d e t e r i o r a t i o n
replaceif necessary. ADJUSTINGBOLT
Adj!st the depthby
I n s t a ltlh e s p e c i atlo o l so n t h e b a l li o i n t a n dt i g h t e n turningthe bolt.
the castlenut.
5. P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s
shown, then set the assemblyan a vise. Pressthe
ball joint out of the knuckle.
SALLJOINTREMOVER/INSTALLER
07965- 5800100
CASTLENUT
(
- -
BALLJOINT REMOVERBASE
07JAF- SH20200
6. Placethe ball joint in position by hand.
7. Install the special tools over the ball joint as shown, 9. Installthe knucklein the reverseorder of removal,
t h e n p r e s st h e b a l l j o i n t i n . and pay particularaftentionto the followingitems:
BALLJOINT INSTALLERBASE . B e c a r e f u ln o t t o d a m a g et h e b a l l i o i n t b o o t s
w h e n i n s t a l l i ntgh e k n u c k l e .
BALLJOINT REMOVER/
INSTALLER
r Torque all mounting hardwareto the specified
07965- 5800100 torquevalues.
. Torquethe castlenuts to the lower torque speci-
f i c a t i o n st,h e n t i g h t e nt h e m o n l y f a r e n o u g ht o
a l i g nt h e s l o tw i t h t h e p i n h o l e .D o n o t a l i g nt h e
castlenut by loosening.
. Install new cotter pins on the castle nuts after
torquing.
. Avoid twisting the sensorwires when installing
the wheelsensor.
. Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel,cleanthe matangsur-
faceof the brakediscand the insideof the wheel.
Checkthe front wheel alignment,and adjustit if
BALLJOINT HOUSINGSURFACE
necessary(seepage 18-4).
18-15
FrontSuspension FrontDamper
Ball Joint Boot Replacement Removal
Removethe set ring and the boot. ' 1 . Remove
the front wheels(seepage 18-10).
CAUTION:Do not contaminatethe boot installa- R e m o v et h e d a m p e r p i n c h b o l t f r o m t h e t o p o f

tion section with grease. damperfork,
Packthe interiorof the boot and lip with grease.
BALLPtN TAP€REDSECTTON OAMPERFORK

LtP
DAMPER
FORK
BOLT
BOOTINSTALLANONSECTION
Wipe ofl the grease. Wipe otf the grease.
3. Wipe the greaseoff the sliding surfaceof the ball DAMPER

pin and packwith freshgrease. PINCH SELF.LOCKING
NUT
BOLT 12x 1.25mm
GAUTION: 1 0x 1 . 2 5m m Replace.
. Keep greaseoff the boot installation section and
the taper€d section of the ball pin. Removethe damper fork bolt and self-lockingnut
. Do not allow dust, dirt, or other loreign matcri- from the bottom of the damper fork, then remove
als to enter the boot. damperfork.
lnstallthe boot in the grooveof the boot installation Removethe damperby removingthe two nuts.
sectionsecurely,then bleedair.
5. lnstallthe upper and lower ball joint boot set rlngs

usingthe specialtools as follows:
OAMPER
L o w e r b a l l j o i n t : A d j u s t t h e s p e c i a tl o o l w i t h t h e
adjustingbolt until the end of the tool aligns with
the groove on the boot. Slide the set ring over the
tool and into position.
ADJUSNNG BOLT
BALLJOINT
Adiust the depth by
aooTcLrP turningthe boh.
GUIOE
UPPERBALL
JOINT BOOT:
07GAG- SDr0700
LOWERBALL
JOINT BOOT:
07974- SA50700
CAUTION: Aftei installing the boot, check rhe batl

pin tapered section for greasecontaminationand
wipe it il necessary.
18-16
Disassembly/lnspection
""----------------g
Disassembly
1. Compressthe damper spring with the spring com-
io'i'i'"?Tllo
29 N m 13.0kg{.m,22 lbtftl
p r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r 'lsi n s t r u c - Replace.
tions,then removethe self lockingnut. DAMPERMOUNTINGWASHEB
CAUTION: Do not compress the spring more than

neceaaeryto remove the nut.
10 mm SELF-
LOCKINGNUT BASE
Replace. DAMPERMOUNTING
RUBBEB
C h e c kf o r d e t e r i o r a t i o n
and oamage,
OAMPERSPBING
STRUTSPRING Checkfor weakenedcompression
COMPRESSOR: ano oamage.
lCommerciallyavailablel SPRINGMOUNTINGRUBBER
ERANICKo T/N MST.58OA,T/N 7200, Checkfor deterioration
or eouivalent ano oamage,
BUMPSTOP
Releasethe pressurefrom the spring compressor, Checkfor weaknessand
damage.
then disassemblethe damperas shown in the next BUMPSTOPPLATE
column. DUSTCOVER
PLATE
Inspection
1. Reassemble all parts,exceptthe spring.
2 . P u s ho n t h e d a m p e ra s s e m b l a
y ss h o w n .
DUSTCOVER
Checkfor bendingand damage.
DAMPEBUNIT
3 . C h e c kf o r s m o o t ho p e r a t i o nt h r o u g ha stroke,
both compressionand extension.
N o T E r T h e d a m p e rs h o u l d m o v e s m o o t h l y l f i t
does not (no compressionor no extension),the gas
i s l e a k i n ga, n dt h e d a m p e rs h o u l db e r e p l a c e d .
4. C h e c kf o r o i l l e a k sa, b n o r m anl o i s e so r b i n d i n gd u r -
ing thesetests.
18-17
FrontDamper
Reassembly Installation
1 . lnstallthe damperunit on a springcompressor. L Loosely install the damper on the frame with t h e
a l i g n i n gt a b f a c i n gi n s i d e ,t h e n l o o s e l yi n s t a l lt h e
2. Assemblethe damper in reverseorder of removal two flangenuts.
exceptthe damper mountingwasherand self lock-
i n gn u t . FLANGE NUTS
10x 1.25mm
49 N.m(5.0kgf.m,36 lbf.ft)
N O T E :A l i g n t h e b o t t o mo f d a m p e rs p r i n ga n d
spnng towerseatas shown.
DAMPERASSEMBLY
STRUTSPRING COMPRESSOR:
(Commarciallyavailablol
BRANICKO T/N MST.58OA,T/N 7200,
or equivalent
SPRINGLOWERSEAT
Positionthe damper mountingbaseon the damper

u n r ta s s n o w n .
Compressthe damperspring.
5. Installthe dampermountingrubber,dampermount-
ing washerand a new 10 mm self-lockingnut.
Hold the dampershaft and tighten the 10 mm self-

lockingnut.
SELF.LOCKING
NUT
10x 1.25mm
29 N.m {3.0kgf.m, 22 lbf.ft)
MOUNTINGWASHER
18-18
2. Installthe damperfork over the driveshaftand onto
t h e l o w e r a r m . l n s t a l lt h e f r o n t d a m p e r i n t h e
damperfork so the aligningtab is alignedwith the
slot in the damDertork.
DAMPER
FORK
BOLT
ALIGNINGTAB
DAMPER
PINCH
BOLT
SELF.LOCKING NUT
10 r 1.25mm
€ N.m 14.4kgf m, 32 lbf.ft) 1 2x 1 . 2 5m m
64 N.m {6.5 kgt m, 47 lbf,ft)
Replace.
? Looselyinstallthe damper pinch bolt on the top of

the damperfork.
Looselyinstallthe damperfork bolt and a new self-

lockingnut on the bottom of the damperfork.
5. Raisethe knucklewith a floor jack until the vehicle

just liftsoft the safetystand.
@ The floor iack must be securely posi'

tioned or personal iniury may r€suli.
6. Tightenthe damperPinchbolt.
nut.
7 . Tightenthe damperfork bolt and self-locking
8 . Tightenthe flangenuts on top of the damper.
9. lnstallthe brakehose mounts with the brakehose

mountingbolts.
10. lnstallthefront wheel.
18-19
RearSuspension
SuspensionArms Replacement
@ when the suspensionarms 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 causing the car to tip for-
ward.
CAUTION:
. Replacethe self-lockingnuts after removal.
. The vehicle should be on the ground before any bolts or nuts connectedto rubber mounts or bushings are tightgn.
NOTEI
a Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection.
. " t U P L " o r " i U P L H G " o r " l U P L K " o r " t U p L S . ,i s s t a m p e do n t h e l e f tu p p e ra r m a n d , , t U p R , , o r , , t U p R H
" t U PR K " " t G , ,o r
or U P R S " o n t h e r i g h tu p p e ra r m .
. The right and left compensatorarm are symmetrical.lnstallso the "l UP" markstampedsidefacesforward.
. After installingthe suspensionarm,checktherearwheelalignment,and adjust if necessa (seepage .18-4).
ry
FLANGEBOLT
10x 1.25mm
54 N.m
15.5kgt.m, 40 lbl.ft)
ADJUSTINGEOLT
(FLANGEBOLT)
10 x 1.25mm
UPPER
ARM INNER
47 tbf.ft) BUSHING
C h e c kf o r d e t e r i o r a t i o n
ano oamage, DAMPERMOUNTINGBOLT
-.- SILICONE {FLANGEBOLT)
.d@l cREAsE 10 x 1.25mm
sil N.m
{5.5 kgt m, 40 lbt.ft)
10 mm FLANGEBOLT
N.m 14.0kgf.m,29 lbt.ft)
UPPERARM
Checkfor bending
i damage.
FLANGEBOL
'10x 1.25mm
TBAILINGARM
COMPENSATOR ARM 54 N.m FI-ANGEBOLT
Checkfor bending I (5.5kgf m, 40 lbtft) 10 x 1.25mm
ano oamage. 54 N.m
{5.5kgt m, 40 lbtftl
COMPENSATOR ARM
INNERBUSHING
,-- S|L|CONE
*@l cnense
a n dd a m a g e .
LOWERARM EUSHING
LOWERARM ...- SILICONE
FLANGEBOLT Checkfor cracks ,4@] GREASE
10 x 1.25mm ano oamage. Checkfor deterioration
64 N.m {6.5kgf.m. FLANGEBOLT
12x 1.25mm ano oamage.
47 tbf.ftl
64 N.m 16.5kgl m,
rl7 lbf.ft)
18-20
HubBearingUnit Replacement
NOTE:
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weightsmay corrodeand damage
t h e a l u m i n u mw h e e l s .
. Onthe aluminumwheels,removethe centercap f rom the insideofthewheel after removingthewheel.
. Beforeinstallingthe brakedrum,cleanthe matingsurfacesof the rear hub and the brakedrum.
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakedrum and wheel.
SPINOLENUT
22 x 1.5 rnm
181N.m 118.5kgf.m,134lbt.ft)
Replace.
TRAILINGARM NOTE:Aftertightening,usea drift
Checkfor cracking punchto lockthe spindlenut shoulder
ano oamage. BNAKESHOE intothe spindle.
WASHER
SPINDLE
BACKINGPLATE
FLANGEBOLT
1 0x 1 . 2 5m m
5,1N.m (5.5 kgtm,,l0 lbtft)
REARWHEEL
HUBBEABINGUNIT
Checktor cracking
and oamage.
BRAKEDRUM
Checkfor wear
ano oamage.
WHEELNUT
1 2x 1 . 5m m
108N.m (11.0kgf'm,80lbtft)
(cont'dl
18-21
RearSuspension
Hub BearingUnit Replacement UpperArm BushingReplacement
(cont'dl
1. Loosenthe wheel nuts slightly. 1. R e m o v et h e u p p e ra r m b u s h i n ga n d i n n e rb u s h i n g
2. Raisethe rear of vehicle,and supportit with safety as shown.
standsin the properlocations(seesection1).
3. Removethe wheel nuts and rearwneel. UPPER
ARMINNERBUSHING
SPINOLE NUT
22 x 1.5mm
181N.m {18.5ksf.m,134lbth)
Replace.
NOTE:Aftertightening,usea drift to
stakethe spindlenut shoulderagainst
the spindle.
REARUPPERARM
2. N 4 a r ak s c r i b el i n e o n t h e u p p e ra r m i n n e rb u s h i n g
so that it is in line with the bolt mountinosurface.
3. Mark on the upper arm at two points so that they

a r e i n l i n e a n d m a k ea r i g h ta n g l ew i t h t h e a r m a s
shown.
MARK
REARWHEEL
HUBCAP
Replace.
NOTE:Takecarenot to damagethe hub bearingunit
on disassembly. WHEELNUT
1 2x 1 . 5m m
108N.mfi1.0 kgf.m,g0tM.ftl
4. Pullthe parkingbrakeleverup.
5. Removethe hub cap. BOLTMOUNTING
6. Raisethe lockingtab on the spindlenut,then remove SURFACE
the nut. Drivein the upperarm innerbushingwith the marks
7. Releasethe parkingbrakelever. aligned.
8. Removethe brakedrum, hub bearingunit and spin
d l ew a s h e r . 5. D r i v et h e u p p e ra r m b u s h i n gi n t ot h e u p p e ra r m .
N O T E rD r i v ei n t h e u p p e ra r m b u s h i n ga n d i n n e r
bushinguntil their leadingedgesare flush with the
HUB BEARINGUNIT
Checktor cracksand damage
BRAKEORUM
SPINDLEWASHER
9. Installin the reverseorderof removal.
18-22
RearDamper
Removal
1. Remove the rearwheels(seepage 18-22). 6. and removethe damper.
Lowertherearsuspension,
2. Removethe speakercoverand speaker(Hatchbackl.

Sedanand Coupe:Removethe trunk side panel(see OAMPER
section20).
3. Removethe two flange nuts.
FLANGENUTS
10 x 1.25mm
4. Removethe flangebolt from the damper.
FLANGEBOLT
1 0x 1 . 2 5m m
FLANGEBOLT
1 0x 1 . 2 5m m
Removethe flangebolt that connectsthe lower arm

to the trailingarm.
18-23
RearDamper
Disassembly/l
nspection
Disassembly lnspection
L Compressthe damper spring with the spring com- 1. Reassemble
all parts,exceptthe spring.
p r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r ' isn s t r u c ,
tions,then removethe self-lockingnut. 2. Pushon the damperas shown.
CAUTION: Do not compress the spring more than

necessaryto remove the selflocking nut.
WOODENBLOCK
STRUTSPRINGCOMPRESSOR: Checkfor smooth operationthrough a full stroke.

(Commerciallyavailablel both compressionand extension.
BRANICI(@
T/N MST-580A,T/N 7200,or equivatent
N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l y .l f i t
does not (no compressionor no extension),the gas
Release the pressure from the spring compressor, asleaking,and the dampershouldbe replaced.
then disassemble the damper as shown on page 18-
Checkfor oil leaks.abnormalnoisesand bindingdur-
ing these tests.
I
18-24
Reassembly
SELF-LOCKINGNUT--------------- gr 1. I n s t a ltlh e d a m p e ru n i to n a s p r i n gc o m p r e s s o r '
10 x 1.25mm Y
29 N.m (3.0kgt.m, 22 lbl.ft)
instructions.
NOTE:Followthemanufacturer's
DAMPER
MOUNTING 2. Assemblethe reardamperin reverseorderof disas
WASHER s e m b l ye x c e p tt h e d a m p e rm o u n t i n gw a s h e ra n d
OAMPERMOUNTING s e l f l o c k i n gn u t .
RUBBER
Checkfor N O T E rA l i g n t h e b o t t o mo f d a m p e rs p r i n ga n d
deterioration
ano oamage. springlower seatas shown.
DAMPERMOUNTING
COLLAR 3. Positionthe dampermounting base on the damper
DAMPER unit as shown.
MOUNTINGBASE STRUTSPRINGCOMPRESSOR:
DAMPERMOUNTING MOUNTING(Commerciallyavailable)
DAMPER
BRANICKO T/N MST-580A.T/N 7200,
RUBBER or equivalent
Checkfor
deterioration
ano oamage, DAMPERSPRING
Checkfor weakness,
compressionand damage.
SPRING
RUBBER
ano oamage.
BUMPSTOP
Checkfor weakness
a n oo a m a g e .
DUSTCOVERPLATE
DUSTCOVER
Checkfor bending
SPRINGLOWERSEAT
Compressthe damper spring with the spring com-
pressor.
5. I n s t a l tl h e d a m p e rm o u n t i n gw a s h e r ,a n d l o o s e l y
installa new self-locking nut.
6. Holdthe dampershaftwith a hex wrench and tighten

DUSTCOVERBOOT nut.
the self-locking
Checkfor deterioration SELF-LOCKING NUT DAMPER
a n oo a m a g e , '10x 1.25mm
MOUNTING
29 N.m {3.0kgf.m,22lbfft} WASHER
Replace.
DAMPERUNIT
18-25
RearDamper
Installation
L Lowerthe rear suspensiona , n d p o s i t i o nt h e
damperwith the springstop pointedtoward the left
sideof the vehicle. ,i
:..
SPRINGSTOP
2. Looselyinstallthetwo flangeNUIs.
FLANGENUTS
10x 1.25mm
49 N.m {5 kgl.m, 35 lbf.ftl
Tightenthesenuts in
Step7.
Looselyinstallthe flangebolt.
FLANGE BoLT
10x 1.25mm
' 54 N.m {5.5 kgl.m,40 lbf.ftl
i ' a - -: a
as'.( r'
I
I
FLANGEBOLT
10 x 1.25mm
54 N,m 15.5kgt.m,
40 rbf.ft)
Raisethe rearsuspensionwith a floor jack until the
vehicleiust liftsoff the safetvstand.
@ The floo. iack must be securely posi-

tioned or personal iniury may result
5. Tightenthe flangebolt.
Tightenthe two flangenuts on top of the damperto

the specifiedtorque.
7. Checkthe rearwheel alignmentand adjustit neces-

sary (seepage 18-41.
18-26
Brakes
ConventionalBrakes ........19-1
Anti-lockBrakeSystem(ABS).............
19-31
GonventionalBrake
SpecialTools .............
19-2 Rear Drum Brake
ComponentLocations fndex/fnspection ..............................
19-21
lndex ................ ......19-3 Inspection ..............
19-25
Inspection and Adiustment BrakeShoe Disassembly................. f 9-26
Brake System Rubber Parts ErakeShoe Reassembly.................. 19-26
and BrakeBooster...........................
19-4 BrakeHoses/Lines
BrakePedal ............
19-5 Inspection/TorqueSpecffications..... 19-28
ParkingBrake ........19-6 HoseReplacement ...........................
19-29
Bleeding .................
19-7 ParkingBrakeCable
Front Brake Pads Inspectionand Replacement..........19.30
Inspectionand Replacement..........19-8
Front BrakeDisc
DiscRunoutInspection...................19-12
DiscThicknessand Parallelism
fnspection ..........19-12
Front BrakeCaliper
Disassembly ..........
19-13
Reassembly ...........
19-16
MasterCylinder/BrakeBooster
19-21
PushrodClearanceAdiustment ......19-22
BrakeBoosterInspection..............,, 19-23
SpecialTools
Ret. No. I Tool Number Description Oty I Pag€Retorencs
o 07JAG- SD40100 PushrodAdjustmentGauge 'l 't9-22
9-2
ComponentLocations
lndex
BRAKEPEDAI- BRAKEHOSESLINES
Inspection
and Inspection/Torquespecifications,page 19-28
page19-5
Adjustment, HoseReplacement, page'19-29
MASTERCYLINDER/ARAKE BOOSTER
page19-21
PushrodClearanceAdiustment,page19_22
page19'23
BrakeBoosterInspection,
PARKINGBRAKECABLE
and RePlacement,
Inspection
page19-36
PARKINGBRAKE
Adjustment,page19 6 REARORUMERAKES
FRONT page19-25
Inspection,
NOTE: There are two types of front brakecalipers: Page19 26
ErakeShoeReplacement,
"5410"
The calipertypescan be identitiedby the
or "2056" stamp€don the caliperbody.Checkthe
type ol the brakecaliperbelore servicing
FrontBrakePads
5410Type:page19-8
2056Type:page19-10
FrontBrakeDisc,page'19-12
FrontBrakeCaliper
5410Type:page19'13
2056Type:page19-14
19-3
andAdiustment
Inspection
BrakeSystemRubberPartsand BrakeBooster
@ BrakeBoostel Brake Hoses
Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signsof fluid leakage.
lf the brakesdo not work properly,checkthe brake Replacethe brakehosewith a new one if it is dam-
booster.Replacethe brakeboosteras an assembly agedor leaking.
if it does not work properlyor if there are signs of
leakage. o Caliper Piston Seal and Piston Boots
Checkbrakeoperationby applyingthe brakes,
€) Piston Cup and PressureCup Inspeqtion Visuallycheckfor damageor signsof fluid leakage.
. Checkbrakeoperationby applyingthe brakes. lf the pedal does not operateproperly,the brakes
Visuallycheckfor damageor signs of fluid leak- drag. or there is damageor signs of fluid leakage,
age. disassembleand inspectthe brakecaliper.Replsce
R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f the boots and sealswith new ones wheneverthe
the pedal does not work properly or if there is brakecaliperis disassembled,
damageor signsof fluid leakage.
@ Wheel Cylinder Piston Cup and Du3t Cover
. C h e c kf o r a d i f f e r e n c ei n b r a k e p e d a l s t r o k e Checkbrakeoperationby applyingthe brakes.
b e t w e e nq u i c k a n d s l o w b r a k e a p p l i c a t i o n s . Visuallycheckfor damageor signsof fluid leakage.
Replacethe master cylinder if there is a differ- It the pedal does not operateproperly,the brakes
encein oedalstroke. drag, or there is damageor signs of fluid leakage,
disassembleand inspectthe wheel cylinder.lf nec-
essary,replacethe wheelcylinderas an assembly.
19-4
Brake Pedal
PedalHeight 4. Screw in the brake switch until its plunger is fully
L Disconnectthe brakeswitch connector,loosenthe depressed(threadedend touching the pad on the
brake switch locknut, and back off the brake switch oedal arm). Then back off the switch 1/4 turn to
until it is no longertouchingthe brakepedal. m a k e 0 . 3 m m ( 0 . 0 1i n ) o f c l e a r a n c eb e t w e e nt h e
threadedend and pad. Tightenthe locknutfirmiy.
2. At the carpetcutout,measurethe pedalheightfrom Connectthe brakeswitchconnector.
the right sidecenterof the pedalpad.
CAUTION: Make sure that the brake lights go off
PUSHROD when th€ p€dal is relea3ed.
LOCKNUT
BRAKESWITCH
LOCKNUT
I 0.3 mm
{0.0'lin)
5. Checkthe brakepedalfree play as describedbelow.
PedalFreePlay
MEASURING 1. With the engine off, inspectthe play on the pedal
POINT{CUTOUT} pad by pushingthe pedalby hand.
Standsrd PedalHeight (with carpet removedl: FreePlay:1 - 5 mm (l/16 - 3/16 in)

M/T: 156.5mm (5.15inl
A/T, CW: 161mm 16 5/16 inl 2. lf the pedalfree play is out of specification,
adjust
the brakeswitch.
I
3. Loosenthe pushrodlocknut,and screwthe pushrod
in or out with pliers until the standardpedal height CAUTION: lf the pedal froe play i3 insufficient, it
from the floor is reached.After adjustment,tighten may result in brake drag.
the locknutfirmly.
N O T E : D o n o t a d j u s tt h e p e d a l h e i g h t w i t h t h e
oushroddeoressed.
BRAKEPEDALPAO
PUSHRODLOCKNUT
15 N.m
11.5kg{.m.11 lbf.ftl
19-5
i-
ParkingBrake
Inspection Removethe rearconsole{seesection20),
1. Pullthe parkingbrakeleverwith 196N (20kgf.44 lbf)
force to fully apply the parkingbrake.The parking Pullthe parkingbrakeleverup one notch.
brake lever should be locked within the sDecified
notches. Tightenthe adiustingnut until the rearwheelsdrag
slightlywhen turned.
Levsr LockedNotches:6 - I
Pulledup with 196 N (20kgf,44 lbf)
AOJUSTINGNUT
2. Adjustthe parkingbrakeif the lever notchesare out
of specification.
Releasethe parkingbrakeleveriully, and checkthat
Adiustment the rear wheelsdo not drag when turned.Readjust
if necessary.
NOTE:After rear brakeshoe servicing,loosenthe park-
ing brake adjustingnut, $tart the engine, and depress Make sure that the parkingbrakesare fully applied
the brake pedal severaltimes to set the self-adjusting when the parkingbrakeleveris pulledup fully.
brakebeforeadjustingthe parkingbrake.
7. Reinstallthe rearconsole.
1. Raisethe fear wheels off the ground, and support
the vehicleon safetystands.
@ Block th€ tront wheers before iacking

up the rear ol the vehicle.
9-6
Bleeding
CAUTION: FRONT:
. Always use GonuinoHondaDOT3 BrakeFuid. Using a
non-Honda brake tluid can cause corro3ion and
d€cr.ase th. liis ot tho 3wtam.
. Mako suro no dirt or other foroign matter is allow€d
to contaminato tho brake tluid.
. Do not spill brako tluid on the vohicle.it may damage
the paint; if brake tluid does contact tho paint. wash
it off immediatoly with wator.
NOTE:The reservoir'onthe mastercylindermust be at

the MAX (upper)level mark at the start of the bleeding
p r o c e d u r ea n d c h e c k e d a f t e r b l e e d i n g e a c h b r a k e
caliper.Add fluid as required.
1. Makesure the brakefluid levelin the reservoiris at

the MAX (upperllevelline. BLEEDSCREW
I N.m 10.9kgl m, 6.5 lbf.ftl
MAX {UPPERILEVEL REAR:

LINE
RESERVOIR
MASTERCYLINDER
Havesomeoneslowly pump the brakepedalseveral

times,then applysteadypressure.
/ i
Loosenthe brakebleedscrewto allow air to escape
f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w
s€curetv.
BLEEDSCREW
7 N.m10.7kgl.m,5 lbf.ftl
4. Repeatthe procedurefor each wheel in the sequence
shown below until air bubblesno longer appearin
the fluid.
Refillthe mastercvlinderreservoirto the MAX (up-

oer)levelline.
BLEEDINGSEOUENCE:
O F ont Risht O RearRight
O Front Left O Re.r Left
1 e t*
Front BrakePads
Inspectionand Replacement
NOTE:Therearetwo tvpesof front brakecalipers: 4. Removethe pad shim. pad retainersand pads.
"5410"or
T h e c a l i p e rt y p e s c a n b e i d e n t l f i e db y t h e
"2056" stamped on the caliperbody 8s shown below. NOTE:When the caliperis equippedwith on outer
, pad shim, replacethe shim togetherwith the pads
Checkthe type of the brakecaliperbeforeservicing.
as a ser.
5410Typo:
see page
NOTE:For 2056type disassemblyprocedures,
19-10.
@
. N€ver use an air ho3e or dry brush to clean brako
assemblies.
Use 8n OSHA approved vacuum cl€aner io avoid
breathing brake dust.
1. Loosenthe front wheel nuts slightly,then raisethe

vehicle. and support it on safety stands. Remove
the front wheels.
Removethe brakehosebracketfrom the knuckle. . e a s u r et h e t h i c k n e s so f
U s i n g v e r n i e rc a l i p e r s m
Removethe caliper bolt, and pivot the caliper up eachbrakepad lining.
out of the wav.
Brake PadThicknss:
Standard: 9.5 - 10.5mm (0.37- 0.,t1 inl
ServicoLimit: 1.6 mm (0.06in)
NOTE:Measurementdoes not includepad backing

CALIPERBOLT platethickness.
lf the brakepad thicknessis lessthan servicelimit,

f i NOTE:Checkthe hosesand pin boots for damage replacethe front padsas a set.
P and deterioration.
19-8
7 . Cleanthe caliperthoroughly;removeany rust.and 12. Pushin the pistonso that the caliperwill fit overthe
checkfor groovesand cracks, pads. Make sure that the piston boot is in position
o . Checkthe brakediscfor damageand cracks. to prevent damaging it when pivoting the caliper
Installthe pad retainers. down.
CALIPERBOLT
N.m {3.3ksl.m, 24 lbnftl
rl
ii
10. Apply greaseto the points indicatedby the arrows i
in the foilowingillustration:
NOTE:Use the pad greaseincludedin the pad set

or Molykote M77 grease,and apply a thin coat of
greaseevenlyto the designatedpoints.
. Pistonend and inner pad contactsurface

. Padand caliperbracketcontactsurface
. Outerpad and caliperbody contactsurface 1 3 . P i v o tt h e c a l i p e rd o w n l n t o p o s i t i o n ,t h e n i n s t a l l
. OuterDadshim and outer oad contactsurface caliperbolt and tightenit.
. Outerpad shim and caliperbody contactsurface
CAUTION: Be careful noi damage tho pin boot
when pivoting tho caliper down.
1 4 . Installthebrakehosebracketon the knuckle.
WEARINDICAIOS NOTE: Inspectthe brake hose for interferenceor

twisting.
OUTER
PAOSHIM 1 5 . DeDress the brakeDedalseveraltimes to makesure
the brakeswork,then test-drive.
]
N O T E : E n g a g e m e n ot f t h e b r s k e m a y r e q u i r ea
INNERPAO
A
5...1
greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplica-
OUTERPAD ur t i o n s o f t h e b r a k ep e d a l w i l l r e s t o r et h e n o r m a l
11. Installthe brakepadsand pad shim correctly. pedalstroke.
1 5 . After installation,checkfor leaksat hose and line

Whon reusing the pads, always reinstall the jointsor connections,and retightenif necessary,
brake pads in thoir original positions to prevent
loss of braking efficiency.
Contaminat€d brake disca or pads reduce stop-
ping ability, Keopgreaseoff the discs snd pads.
NOTE: lnstall the pad with the wear indicator on

the inside.
(cont'd)
19-9
FrontBrakePads
Inspectionand Replacement(cont'dl
2056 Type: 5, Using vernier calipers, measure the thickness of
eachbrakepad lining.
@Nev6r usg an air ho3e or dry brush to cloan brakg Brake P8dThickness:
sssembligs. Standard: 8.5 - 9.5 mm (0.33- 0.37 in)
Usg an OSHA approved vacuum cleanor to avoid ServiceLimit: 1.6 mm (0.06in)
breathing brako dust.
1 . Loosenthe front wheel nuts slightly,then raisethe

vehicle,and support it on safety stands. Remove
the front wheels.
t Removethe brake hose bracketfrom the knuckle.
Removethe caliperbolt B, and pivot the caliperup
out of the wav.
BRAKEHOSEARACKET
BACKING PLATE
NOTE:Measurementdoes not includepad backing

olatethickness.
6. lf the brakepad thicknessis lessthan servicelimit.

CALIPER replacethe front pads as a set.
BOLTB 7. Cleanthe caliperthoroughly;removeany rust, and
NOTE;Checkthe hosesand pin boots for damage checkfor grooves and crscks.
and deterioration. 8. Checkthe brakediscfor damageand cracks.
9. lnstalltheoad retainers.
Removethe pad shim, pad retainersand pads,
NOTE:When replacingthe pads. replacethe shim

togetherwith the as a set.
OUTER
PADSHIM
Check
forwear.
INNER PAD
PAORETAINERS
Checkfor weaknessand
damage.
OUTERPAD
19-10
10. Apply greaseto the points indicatedby the arrows 12. Pushin the pistonso that the caliperwill fit over the
in the followingillustration: pads.Make sure that the piston boot is in position
to preventdamaging it when pivoting the caliper
NOTE:Use the pad greaseincludedin the pad set oown.
or lvolykote M77 grease,and apply a thin coat of
greaseevenlyto the designatedpoints. PISTON
. Pistonend and inneroad contactsurface

. Padand caliperbracketcontactsurface
. Outerpad and caliperbody contactsurface
. Outerpad shim and outer pad contactsurface
CALIPERBOLTB
. Outerpad shim and caliperbody contactsurface 26 N.m {2.7kgl.m,
20 tbt.ftt
WEARINDICATOR
OUTERPAD
OUTER
PADSHIM 1 3 , P i v o tt h e c a l i p e rd o w n i n t o p o s i t i o n ,t h e n i n s t a l l
caliperbolt B and tightenit.
1 4 . lnstallthe brakehosebracketon the knuckle.
NOTE:lnspectthe brakehose for interferenceand

twistrng.
1 5 . Depressthe brakepedalseveraltimes to makesure

the brakeswork,then road-test.
N O T E :E n g a g e m e n o t f t h e b r a k e m a y r e q u i r ea
11. Install the brake pads and pad shim correctly. greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplica-
t i o n s o f t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l
o When reusing the pads, always reinstall the pedalstroke.
brake pads in their original positions to prevent
loss of braking efficiency. After installation,checkfor leaksat hose and line
. Contaminat€d brake discs or pads reduca stop- jointsand connections. and retightenif necessary.
ping ability. Keepgrea3€off the discs and pads.
N O T E :I n s t a l lt h e p a d w i t h t h e w e a r i n d i c a t o ro n
the inside,
1 9 - 11
FrontBrakeDisc
DiscRunoutInspection DiscThicknessand Parallelism
Inspection
t. Loosenthe front wheel nuts slightly,then raisethe
vehicle, and support it on safety stands.Remove 1 . Loosenthe front wheel nuts slightly.then rsisethe
the front wheels. vehicle. and support it on safety stands, Remove
the front wheels.
Removethe brakepads(seepage19-8).
Removethe brakepads(seepage 19-8).
I n s p e c tt h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoroughlyand removeall rust. U s i n g a m i c r o m e t e r ,m e a s u r ed i s c t h i c k n e s sa t
eight points, approximately45" apart and 10 mm
4, Use wheel nuts and suitableplain washersto hold (0.4in) in from the outer edgeof the disc.
the disc securelyagainstthe hub, then mount a dial
i n d i c a t o ra s s h o w n , a n d m e a s u r et h e r u n o u t a t
'10mm (0.4in) from the outeredgeof the disc.
Brake Disc Runout:

ServiceLimit 0.10 mm {0.00,1in)
BrakeDisc Thicknsss:
Standard:20.9- 21.8 mm {0.82- 0.86 in)
W{EEL NUT AND Max. RefinishingLimil: 19.0mm (0.75in)
PLAINWASHER
108 N.m
(11kgf.m,80lbtft) NOTE:ReDlacethe brakedisc if the smallestmea-
surementis lessthan the max. refinishinglimit.
Erake Di3c Parallelism:0.015mm 10.0006inl max.
lf the disc is beyond the servicelimit, refinishthe NOTE: This is the maximum allowabledifference
brake disc with an on-car brake lathe. The Kwik- betweenthe thicknessmeasurements.
Lathe produced by Kwik-way manufacturingCo.
and the "Front BrakeDisc Lathe" offeredby Snap- lf the disc is beyondthe servicelimit for parallelism,
on ToolsCo.are approvedfor this operation. refinishthe brake disc with an on-car brake lathe.
The Kwik-Latheproduced by Kwik-WayManufac-
"Front ErakeDisc Lathe"offered
M8x. RetinishLimit 19.0mm (0.75inl turing Co. and the
by Snap-onTools Co. are approvedfor this opera-
NOTE:A new disc shouldbe refinishedif its runout tron.
is greaterthan 0.10mm (0.004in)
NOTE:Seesection18for brakedisc replacement.
19 -1 2
Front BrakeGaliper
Disassembly
NOTE:Therearetwo typesof front brakecalipers: 3. R e m o v et h e c a l i p e rp i n s a n d p i n b o o t s f r o m t h e
"5410"or calioerbracket.
T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e
"2056" stampedon the caliper body as shown below. PINB
CALIPER CALIPER BRACKET
Checkthe type of the brakecaliperbeforeservicing.
5410Type:
see page
NOTE:For 2056type disassemblyprocedures,
'19-13. CALIPERPIN A
lf necessary,apply compressedair to the caliper

fluid inlet to get the pistonout. Placea shop rag or
Nsv€r use an air hose or dry brush to clean brake wooden blockas shownto cushionthe pistonwhen
assemblics. it is expelled.Use low pressureair in shortspurts,
Use an OSHA approved vacuum clganer to avoid
breathing brake dust.
. Do not place your fing€rs in froni ot tho piston.
CAUTION: . D o n o t u s e h i g h a i r p r e s s u r e ;u s G a n O S H A
. Do not spill brske tluid on the vehicle; il may damage approved 30 PSInozzle.
the paint; if braka fluid does contact the paint. wssh
it off immediately with water.
. To prcvent spills, cover the hose ioints with rsgs or
shop towels.
. Clesn all parts in brake fluid and air dry; blow out all
passageswith compressedair.
L Removethe banjo bolt, and disconnectthe brake

hosefrom the caliper.
CALIPER
EANJO SOLT
Removethe pistonfrom the caliper,and checkthe
pistonfor scoring.
Removethe boot clip,pistonboot and pistonseal.
CAUTION:Take care not to damagethe cylinder

bore.
PISTONSEAL
Replace.
SEALING
Replace. CALIPERBOLTS BOOTCLIP
Beplace.
Removethe caliperbolts, then remove the caliper
\ ,
from the bracket. t l
( \
U PISTONBOOT
CALIPERBODY
Checkfor scoring
Replace. {cont'd)
19-13
L
Front Brake Caliper
(cont'dl
Disassembly
2056Type: 4. R e m o v et h e p i n b o o t , s l e e v eB a n d s l e e v eboot
from the caliperbody.
@
. Never use an air hose or dry brush to clean brake
CALIPER SODY
Checkfor scoring
on cytinder wall.
assembli€s.
. Use an OSHA approved vacuum cleaner to avoid
breathing brak€ dust,
CAUTION:
. Do not spill brake fluid on tha vohicle; it may dsmage
the paint; if brake tluid do€s contaqt the paint. wash
it otf imm€diately with water.
. To prevent spills, cov6r tho hose ioints with iag3 or
shop towels,
. Cleanall parts in brake tluid and air dry; blow out all /
1.
pasragoswith compressedair.
Removethe banio bolt, and disconnectthe brake

hosefrom the calioer.
SEALINGWASHERS
Replace.
SLEEVEI
Replace.
st EEVE
I
d
Checklor damage.
lf necessary,apply compressedair to the caliper
fluid inlet to get the pistonout. Placea shop rag or
wooden blockas shownto cushionthe pistonwhen
it is expelled.Uselow pressureair in shortspurts.
a Do not plac€ your tingers in front of the piston.

a Do not us€ high 8ir prossur€; usc an OSHA
approved 30 PSInozzle.
Removecaliper bolt B, pivot the caliper up out ol

the way, then removethe caliperfrom the bracket.
Removethe guide pin boot from sleeveA on the

caliperbracket.
Checkfor damage.
Removethe pistonfrom the caliper,and checkthe

GUIDEPIN BOOT piston for scoling.
Replace.
CALIPERBRACKET
! CheckIor cracks.
19-1 4
7. Removethe boot clip, pistonboot and pistonseal.
CAUTION:Take care not to damage the cylinder

bore.
800T cLtP
Replace.
SEAL
PISTONEOOT
Replace.
Front BrakeGaliper
Reassembly
5,110Type:
NOTE;For 2056type reassemblyprocedures.

seepage 19-18,
o Never use an air hose or dry brush lo cl€an brske t$embliss.

. Use on OSHA approvsd vacuum cleanerto avoid breathing brako dust,
. Contaminatedbraks discs or pads reducestopping ability.
. when teusing the pads, always reinstall the brake pads in their original positions to prevent loss ot braking cfficiancy.
CAUTION:
. Do not spill brak€ lluid on the vehicle; it may damage tho paint; if brrke lluid does contact the paint, wash it off imme-
diately with water.
. Cleanall parts in brake fluid 8nd air dry; blow out all pa$ages with compr63sedair.
. Bofore rea$embling, checkthai all parts a.o froo of dust and other lorsign particlog.
. Roplacepart3 with n€w onss whenever spscifiedto do so.
. Make sure no dirt or othe. foreign mattor is allowed to contaminste tha brake fluid.
. Alway3 us€ Genuine Honda DOT 3 Brrke Fluid. Using a non-Hondabrako fluid c8n caus€ corrosion and decroasethe
lifs of the system.
NOTE:
. Coatthe piston,pistonseal.and caliperbore with cleanbrakefluid.
. Replaceall rubberpartswith new oneswheneverdisassembled.
#r-anrrsr-H:
Userecommendedrubbergreasein the cslipersealset.
-61' Userecommendedsealgreasein the calipersealset.

BEAKEPAOS CALIPERBRACKETMOUNTINGBOLT
PIN BOOTS
rMA Replace.
TOR
WEABINDICATOR
(ln
|trf,
t \ ' \ \J q l c A
\\r li
_41
BRACKET
oUTER PADSH|M
ta,
R ---+-s' -
caupeaetNa/ @
PADRETAINERS
=..
.H!!q9ril
PISTONSEAL
Replace. PISTONBOOT
Replace.
-6r
/ eoorcue
Replace.
BLEEDSCREW f
9 N m (0.9kgr.m,6.5 lbf.ft)
CALIPEBBOOY
A
wo]
19-16
1 . Cleanthe piston and caliperbore with brakefluid, Apply the recommendedseal greasein the caliper
and inspectfor wear and damage. seal set to the sliding surfaceof the pins and the
Coat the new Diston seal with the recommended insideof the new Dinboots,
rubbergreasein the caliperseal set.and installthe Installthe pin boots into the groovesin the caliper
sealin the cylindergroove, bracketproperly.
CALIPERBRACKET
Apply the recommendedseal greasein the caliper PIN BOOT\
seal set to the sealinglips and insideof a new pis- Replace. - \
ton boot. and secureinstallit in the caliperwith the CALIPER
new boot clio.
.@]
CAUTION: 8o carelul not to damage the caliper PINB
CALIPER
cylinder wall.
PIN BOOTS
Replace.
PISTONSEAL
Replace.
=^.
,->---!!!!!Lil
RUBBER GREASE
-6,l
CALIPEFPIN
7. Insertpin A and pin B into the caliperbracket.

8. Installthe pin boots into the grooves in the pins
properly.
PISTONBOOT 9. Installthe brakepads in their originalpositions(see
Replace.
page 19-9).
.,'.{@l 10- Pushin the pistonso that the caliperwill fit overthe
SILICONEGREASE pads,and installthecaliper.
11. Tightenthe caliperbolts.
12. Connectthe brakehoseto the caliperwith new seal-
ing washers,and tightenthe banjobolt.
BANJO BOLT SEALINGWASHERS
34 N.m (3.5kgl.m.25lbf ft) Replace.
L u b r i c a t et h e c a l i D e ra n d p i s t o nw i t h b r a k ef l u i d .
then installthe pistonin the cylinderwith the dished
end facingin.
CALIPERBOLT
32 N.m {3.3ksf.m,24lbf.ft}
1 3 . Fill the brakereservoirand bleedthe brakesvstem

{seepage 19-7).
1 4 . Performthe followingchecks.
. Checktor leaksat hose and line joints and con-
nections,and retightenif necessary.
. Checkfor brakehosesfor interferenceand twisting.
(cont'dl
Front BrakeCaliper
(cont'd)
Reassembly
2056Type:
. Ngver uso an air hose or dry brush to clean brake assemblies.

. Uss an OSHA approved vacuum cleanerto avoid breathing brake dust.
. Contaminatedbrake discs or pads reducestopping ability.
. When reusing the pads. always reinstall ths brake pads in their original positions to prevent loss of braking efticisncy.
CAUTION:
. Do not spill brake fluid on the vehicle; it may dsmage th€ paint; if brak€ fluid does contact the paint, wash it off imme.
diately with water.
. Cl€anall parts in brake fluid and air dry; blow out all passageswith compre$€d air.
. Betore reassembling,checkth8t all parts are free of dust and other toreign particles.
. R€placeparts with new ones whenever specifiedto do so.
. Make sure no dirt or othsr forgign mattsr is allowed to contaminate the brake tluid.
. Always use Genuine Honda DOT 3 Erake Fluid. Using a non-Hondabrakc fluid can cause corrosion and decreasethe
lite ot the system.
NOTE:
. Coatthe piston.pistonseal.and caliperborewith cleanbrakefluid.
o Reolaceall rubberDartswith new oneswheneverdisassembled.
c''-"{@: Use recommendedrubbergreasein the calipersealset.
-Gr, use recommendedseargreasein the caliper searset.

_.-cALrpER ERACKET MoUNTTNG BoLT
@f "\ toe ru'- {tt.o kg{.m.80rbtft)
BRAKE
BNAKE
PADS
PADS
N \ A-t -- .ALTPER
BRA.KET
OUTERPAO
WEARINDICATOR
ir*l;r**t,;;ll;-fn *6ry-- 'ADRETA,NER

h \
culoEP,NBoor \\
M lll'l r) Pl
/ H, I ll I l' I
\ l lt l d 6
% . -t'.---.-
"""-,t"oo*tJ*,
o . , " , ""'*nW
* u..(b
**-y
--\_^ \l SLEEVEA
BLEEDSCREW \
s N.mro.s
ksr.m,6.s
tbr.ft)
'-b#\S"^.(*r1 tr.€_ \ 6"1
,o,,,,"o,,"/
/\
26N.m{2.7ksf.m.2orbftt}
W
I
^/-^^..
Tffi
YffA"
\Uf->"
mFZ\
-
| l(// )A{
-,P,sroNBoor
Reorace.
;if;rqq
80()TcLtP
Replace.
l.'
19-18
'1.
Cleanthe piston and caliperbore with brakefluid, 4. Lubricatethe caliper and piston with brake fluid,
and inspectfor wear and damage. t h e n i n s t a l l t h e p i s t o n i n t h e c y l i n d e rw i t h t h e
dishedend facingin.
Coata new pistonsealwith the recommendedrub-
ber greasein the calipersealset,and installthe seal
in the cylindergroove.
Apply the recommendedseal greasein the caliper

seal set to the sealinglips and insideof a new pis-
ton boot, and secureinstallit in the caliperwith a
new boot clip.
CAUTION: Be caretul not to damage the calipel

cylinder wall.
BOOTCLIP
Replace.
5. Apply the recommendedseal greasein the caliper

seal set to the sliding surfaceof sleeveB and the
insideof the new pin and sleeveboots.
6. Installthe new sleeveand pin boots and sleeveB

on the caliper.
NOTE:Be sureto installthe boots into the grooves

in the caliperand sleeveB properly.
BOOT
SLEEVE
Replace. Replace.
re---.
-e1 - :-!!!r!ail
RUBBER GREASE
SILICONEGREAS€
SLEEVEB
Y
P IN BOOT
Replace,
(cont'd)
19-19
Front BrakeCaliper
(cont'd)
Reassembly
7 . Apply the recommendedseal greasein the caliper 1 1 . Connectthe brake hose to the caliperwith n"w a6al-
seal set to the sliding surfaceof sleeveA and the ing washers.and tightenthe banjobolt,
insideof a new guide pin boot.
12. Tightenthe caliperbolt B.
I n s t a l lt h e g u i d e p i n b o o t i n t o t h e g r o o v e i n t h e
sleeveA. BANJOBOLT
34 N.m{3.5kgf.m,25lbt.ftl
Make sure that the brake pad retainersand brake
padsare in their originalpositions{seepage 19-10).
26 N.m(2.7kgf.m,20 lbt.frl
1 3 . Fill the brakereservoirand bleedthe brakesystem

(seepage19-7).
1 4 . Performthe followingchecks.
10. Installthe caliperonto sleeveA, and pivot it down o Checkfor leaksat hose and line joints and con-
into position. nections,and retightenif necessary.
. Checkfor brake hoses for interferenceand twist-
NOTE:Installthe guide pin boot into the groove in In g .
the caliperproperly.
SLEEVEA
_ 1
19-20
MasterCylinder/BrakeBooster
I RemovaUlnstallation
CAUTION: 9. Removethe four boostermountingnuts
. 86 carefulnot to bend or damagethe brake lineswhen 10. Pull the brake booster forward until the clevis is
removingthe mastercylinder. clearof the bulkhead.
. Do not spill brake fluid on tho vehicle; it maY damage 11. Removethe brake booster from the engine com-
the paint; if brake tluid doas contaqt the paint, wash panmenr.
it off immediately with water. 12. lnstallthe brakeboosterand mastercylinderin the
. To prevent spill3, cover thg hose ioints whh rags or reverseorderof removal.
shop towels.
CAUTION:
1 . Disconnect the brakefluid levelswitchconnectors. . When connecting the brake lines, make sure
2 . Removethe reservoircap trom the mastercylinder. that lhere is no int€rterence between the brake
? The brakefluid may be suckedout throughthe top lines and other Parts.
of the mastercylinderreservoirwith a syringe. . Be caretul not to bend or damagethe brake lines
Disconnect the brakelinesfrom the mastercylinder' when installing the master cylinder.
5. R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d
wasners. N O T E : l f r e p l a c i n gt h e m a s t e rc y l i n d e ro r b r a k e
6. Removethe mastercylinderfrom the brakebooster' b o o s t e r ,c h e c ka n d a d i u s tt h e p u s h r o dc l e a r a n c e
7. Disconnectthe vacuum hosefrom the brakebooster' beforeinstallingthe mastercylinder(seepage 19-22\.
8. Removethe cofterpin and clevispin from the clevis'
, n d b l e e dt h e
1 3 . F i l l t h e m a s t e rc v l i n d e rr e s e r v o i r a
CAUTION: Do noi disconnect the clovis by remov' brakesystem(seePage19-7).
ing it from ths operating rod of the brake booster' lf 1 4 . After installation,checkthe brakepedal height and
the clevis is loosenod, adiust the pushrod length brakepedal free play (see page 19-5)and adjust if
before installingthe brake booster (seepage 19-221 necessary.
BRAKE BOOSTER
(WithABS:7" . S" tandembrakeboosier)
-6ll BRAKEFLUIDLEVEL
CLEVIS PIN SWITCHCONNECTORS
MASTEFCYLINDER
VACUUM HOSE
To RearWheelCylinders
13 N.m {1.3kst m,9 lbtft)
To FrontCaliper
(WithoutABS)
.---
15 N.m (1.5kgf.m,
11 tbt.ft)
CONTROLVALVE
PROPORTIONING
15 N.m (1.5ksf'm,11lbfft)
(WithABSTTomodulatorunit)
19-21
MasterGylinder/Brake
Booster
PushrodClearance
Adjustment
NOTE: N O T E :l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y
. Mastercylinderpushrod-to
pistonclearance
mustbe 8nd adjustingnut is 0.4 mm 10.02in), the pushrod-
checkedandadjustmentsmade,if necessary,
before to-pistonclearanceis 0 mm. However,if the clear-
installingmastercylinder. ance betweenthe gauge body and adjustingnut is
ABStype is shown,conventional
braketvpe is similar. 0 mm, the pushrod-to-piston clearanceis 0.4 mm
(0.02in) or more.Thereforeit must be adjustedand
l. Setthe specialtool on the mastercylinderbody; push rechecked.
in the centershaft until the top of it contactsthe end
of the secondarypistonby turningthe adjustingnut. 6. lf clearanceis incorrect,loosenthe star locknutand
turn the adiusterin or out to adjust.
PUSHRODADJUSTMENTGAUGE
07JAG- SD'(}l00
NOTE:
Adjust the clearancewhile the specifiedvacuum
SECONDARY is appliedto the booster.
PISTON Holdthe cleviswhile adiusting.
ADJUSTING
NUT 7 . Tightenthe star locknutsecurely.
CENTER
SHAFT 8. Removethe specialtool.
0 - 0 . 4m m{ 0 - 0 . 0 2i n l
MASTERCYLINDER
STARLOCKNUT
22 N.m
12.2kgt m, 16 lbf.ft)
2. Withoutdisturbingthe centershaft'sposition,install CLEVIS

the specialtoolupsidedown on the booster.
Installthe mastercylinder nuts and tighten to the
sDecified toroue.
Connectthe boosterinline with a vacuumgaugeO-
101 kPa (0 - 760 mmHg, 30 in.Hg)to the booster's
e n g a n ev a c u u m s u p p l y ,a n d m a i n t a i na n e n g i n e
PUSHROD
speedthat will deliver66 kPa(500mmHg,20 in.Hg)
ADJUSTMENTGAUGE
vacuum. 07JAG- SD40100
With a feelergauge,measurethe clearancebetween 9. Adjust the pushrodlength as
the gaugebody and the adjustingnut as shown. ts removed.
'11610.m
5 m
Clearance:0 - 0.4 mm (0 - 0.02 in)
(4.5710.02in)
VACUUM GAUGE
{Commerciallyaveilable)
0 - 101kPe
{0- 760mm Hg,30 in.Hgl
AOJUSTINGNUT
HOSE
Connecta hoseof
suitablediameter.
PUSHROD
CYLINDEB
NUT LOCKNUT
FEELERGAUGE 1 5 N . m 1 1 . 5k g f . m , 1 1 l b f f i ) 15 N.m (1.5kgl.m,11 lbf.ft)
1 0 . lnstall the master cylinder (see page l9-21).
19-22
BrakeBoosterInspection
FunctionalTest
'1. With
the engine stopped.depressthe brake pedal
severaltimes to depletethe vacuum reservoir,then
depressthe pedalhard and hold it for 15 seconds.lf
t h e p e d a l s i n k s ,e i t h e r t h e m a s t e r c y l i n d e rl s
bypassinginternally,or the brake system (master
c y l i n d e r ,l i n e s ,m o d u l a t o r ,p r o p o r t i o n i n gc o n t r o l
valve.or caliper)is leaking.
2 . S t a n t h e e n g i n ew i t h t h e p e d a ld e p r e s s e dl.f t h e
pedalsinksslightly,the vacuumboosteris operating
n o r m a l l y .l f t h e p e d a l h e i g h t d o e s n o t v a r y , t h e
boosteror checkvalve is faulty.
3. With the engine running,depressthe brake pedal
l i g h t l y .A p p l y j u s t e n o u g h p r e s s u r et o h o l d b a c k
a u t o m a t i ct r a n s m i s s i o nc r e e p .l f t h e b r a k ep e d a l
s i n k sm o r e t h a n 2 5 m m { 1 . 0i n . ) i n t h r e e m i n u t e s ,
t h e m a s t e rc y l i n d e ri s f a u l t y .A s l i g h t c h a n g ei n
pedal height when the A/C compressorcycles on
a n d o f f i f n o r m a l . ( T h e A / C c o m p r e s s o rl o a d
changesthe vacuumavailableto the booster.)
Leak Test
1. Depressthe brake pedal with the engine running,
then stop the engine. lf the pedal height does not
varv while depressedfor 30 seconds,the vacuum
b o o s t e ri s O K . l f t h e p e d a l r i s e s .t h e b o o s t e ri s
faultv.
2. With the engine stopped,depressthe brake pedal
s e v e r a lt i m e s u s i n g n o r m a l p r e s s u r e W
. hen the
pedal is first depressed,it should be low. On con-
secutiveapplications, the pedalheight shouldgrad-
ually rise.lf the pedal positiondoes not vary, check
the boostercheckvalve.
Booster CheckValve Test

1. Disconnectthe brake boostervacuum hose at the
booster.
2. Startthe engineand let it idle.Thereshouldbe vac-
uum. lf no vacuum is available,the checkvalve is
not working properly. Replacethe brake booster
vacuumhoseand checkvalve,and retest.
BRAKEBOOSTER
VACUUMHOSE
( C h e c kv a l v e
built-in)
19-23
RearDrumBrakes
Index/lnspection
a N6v€r use an air hos€ or dry brush to clean brako assemblies.

a Use an OSHAapproved vacuum cleanerto avoid brealhing brake dust.
a Contaminatedbrake linings or drums reducesiopping ability.
a Block thc front wheels before iacking up the rear of ihe vehicle.
' 1 . Blockthe front wheels,
loosenthe rearwheel nuts slightly,supportthe rear of vehicleon safetystands,then remove
the rearwheels.
2. Releasethe parkingbrake,and removethe rearbrakedrum.
WHEELCYLINOER
Inspectfor leakage.
I N.m {0.9 kgt m, 6.5 lbf.ftl It necessary,replaceas an assembly.
u-cLtP UPPERRETURNSPRING
Replace. Checkfor weakness
@
I ano oamage.
PIVOTPIN
/ €{-l
^ "*'"i
TENSIONPIN
/ ,.to,n.*.r*,"n
/ , Install securely on
10 mm BOLT tensionpin.
| /
II &- d / /
64 N.m {6.5 kgf.m,
47rbf.ft)
ts
cLEV'sB
( r
/
AOJUSTEREOLT
Checkratchetteeth
{or wear and damage. LOWERRETURN
SPRING
Checklor weakness
BRAKESHOE and damage-
seepage19 30
lnspection,
lf brakeshoesare to be
reused,markand reassemble
in sameposition. SELF.ADJUSTER
SPRING
Checkfor weakness
ano oamage,
19-24
Inspection
1. Checkthe wheelcylinderJor leakage. 6. M e a s u r et h e i n s i d ed i a m e t e ro f t h e b r a k ed r u m
usingthe insideverniercalipers,
2. Checkthe brake liningsfor cracking,glazing,wear
and contamination, Drum lnside Diamet€r:
Standard: 199.9- 200.0mm (7.870- 7.874in)
3. Measurethe brakeliningthickness. ServicsLimh: 201.0mm (7.913in)
Brake Lining Thicknoss: INSIDEVERNIERCALIPERS

Sisndard: /1.0mm (0.157in)
ServiceLimit: 2.0 mm (0.08in)
WHEELCYLINDER
7. lf the inside diameter of the brake drum is more

than servicelimit, replacethe brakedrum.
8. C h e c kt h e b r a k e d r u m f o r s c o r i n g ,g r o o v e sa n d
NOTE: Measurementdoes not include brakeshoe cracks.
thickness, \
l f t h e b r a k e l i n i n g t h i c k n e s sr s l e s s t h a n s e r v i c e
limit, replacethe brakeshoesas a set
5. Checkthe bearingsin the hub unit for smoothoper-

ation.lf defective,referto section18.
RearDrumBrake
Brake Shoe Disassembly
1. R e m o v et h e t e n s i o np i n s b y p u s h i n gt h e r e t a i n e r 6, Removethe wave washer,parkingbrakelever and
springsand turningthem. pivot pin from the brakeshoe by.emoving the U-
cliD.
PARKINGERAKE
L€VER
WAVEWASHER
/
@G
RETAINER
SPRINGS
I
u'cLrP
Replace.
Lower the brake shoe assembly,and remove the

lower returnspring.
BrakeShoeReassembly
NOTE:Be carefulnot to damagethe dust cover on
the wheelcylinder. 1. Apply brake cylinder grease (P/N:08733- 8020E)or
equivalentrubber greaseto the sliding surfaceof
Removethe brakeshoe assembly. the pivot pin, and insertthe pin into the brakeshoe.
Disconnectthe parkingbrakecablefrom the parking Installthe psrkingbrakelever and wave wasneron

brakelever. the pivot pin and securewith U-clip,
Removethe upper returnspring,self-adjuster lever NOTE: Pinchthe U-clip securelyto preventthe pivot
a n d s e l f - a d j u s t esr p r i n g .a n d s e p a r a t et h e b r a k e pin from coming out ofthe brakeshoe.
shoes.
ADJUSTERBOLT UPPERRETURNSPRING
Checkratchettoeth tor Checkfor weakness
wear ano damage. ano oamage.
rr\
\'
io
I
//
.:l
I' SPRING
19-26
C o n n e c tt h e p a r k i n g b r a k ec a b l e t o t h e p a r k i n g Cleanthe threadedponionsof clevisesA and B.
brakelever. Coat the threads of the cleviseswith grease.To
shortenthe clevises,turn the adjusterbolt.
Apply greaseon eachslidingsurface.
6. Hook the self-adjusterspring to the self-adjuster
contaminated brake linings reduce leverfirst,then to the brakeshoe.
@
stopping ability. Keep greaseor oil off the brake lin'
ings. Wipe any excessgr€aseoft the parts. 1 . Installthe clevisesand upper return spring noting
the installationdirection,
. Apply brakecylindergrease(P/N:08733- 8020E)
or equivalentrubber greaseto the sliding sur- NOTE;Be carefulnot to damagethe wheel cylinder
facesas shown. dust covers.
8. Installthelower returnsPring.
-|a Slidingsurface 9. Installthe tensionpins and retainingsprings.
UPPERRETURNSPRING CLEVISB
CLEVISA
SELF-ADJUSTER
SPRING
. Apply Molykote44MAto the brakeshoeendsand
oppositeedgesof the shoesas shown.
+a Opposite edge of the shoe

-)o Brake shoe ends
1 0 . Installthebrakedrum.
1 1 . lf the wh6el cylinderhas been removed.bleedthe

brakc system (see page l9-6), and checkfor leaksat
brakeline connections,and retightenif necessary.
1 2 . Depressthe brake pedal severaltimes to set the

self-adjustingbrake.
1 3 . Adjusttheparkingbrake(seepage l9-6).
19-27
BrakeHoses/Lines
Inspection/Torque
Specifications
1. Inspectthe brakehosesfor damage,deterioration,
leaks,interference
and twisting.
2. Checkthe brakelinesfor damage,rustingand leakage.Also checkfor bent brakelines.
3. Checkfor leaksat hoseand linejointsand connections,

and retightenif necessary.
4. Checkthe mastercylinderand ABS modulatorunit for damageand leakage.
CAUTION: Replacethe brake hose clip wheneverthc brake hose is serviced.
ABSMODULATOR UNIT-Io-BRAKE
L|NE
19N.m11.9kgtm. 1albtftl
PROPORTIONING CONTBOLVALVE.
Io.BRAKELINE
15 N.m (1.5kgf.m, 11 lbf.ft)
MASTERCYLINDER.TO.ARAKE LINE
15 N.m {1.5 ksf.m, 11 lbf.ft}
aRAKELINE-Io-WHEEL CYLTNDER
15N.m11.5kgf.m,11lbtft)
BLEED SCREW
7 N.m{0.7kgtm, 5 lbl.frl
SRAKELINE-Io-BMKEHOSE
15 N.m (1.5kgf.m, 1r lbnftl
BRAKELINE-IO.BRAKE HOSE
15 N'm {1.5kgf.m,11lbf ftl
BRAKEHOSE-io-CALIPEB
IBAIUJOBOLT}
3l N.ln(3.5ksf.m,25lbf'ft}
19-28
HoseReplacement
CAUTION: 6, lnstall the brake hose bracketand brake hose on the
o Before reas3embling,check that all parts are free ol knucklefirst, then connect the brake hose to the
dust and other toreign particles. caliperwith the baniobolt and new sealingwashers
. Replaceparts with new ones whenever sp€cified to
do so.
. Do not 3pill brak€ fluid on the vehicle; it may damage
the paint; il brake fluid does contact the paint, wash
it off immediately with water.
1. ReDlace the brakehoseif the hoseis twisted,cracked,

or if it leaks,
6 mm HOSEERACKET
Disconnect the brakehosefrom the brakeline using BOLTS
9.8 N.m
a 10 mm flare nut wrench.
FLARE NUT {1.0 ksf.m, 7 lbf'ft)
(Commercially
available)
BRAKE LINE
BANJO BOLT
3,1N.m
(3.5 kgf.m.25 lbf.ft)
7. lnstallthe brakehose on the upper brakehose bracket

with a new brakehoseclip.
15Nm
{1.5 kgf.m, 11 lbf.ft)
Removeand discardthe brake hose clip from the
brakehose.
Connectthe brakelineto the brakehose.
9 . After installingthe brakehose,bleedthe brakesys-

t e m ( s e ep a g e ' 1 9 - 7 ) .
4. Removethe banjo bolt, and disconnectthe brake
hosefrom the caliper. 1 0 . Performthe followingchecks.
. Checkthe brakehose and line joint for leaks,and
5. Removethe brakehosebracketfrom the knuckle. tightenif necessary.
. Checkthe brakehosesfor interferenceand twist-
Ing.
19-29
ParkingBrakeCable
Inspectionand Replacement
CAUTION: The parking brake cables must not be bent or distortad. Thi3 will l€ad to stiff operation and premature cable
failure.
PARKINGBRAKECABLE
Checkfor faultymovement.
PARKINGBRAKESWITCH
Removethe parkingbrakecablefrom the backingplate

usinga 12 mm offsetwrenchas shown,
BACKINGPLATE
19-30
Anti-lockBrakeSystem(ABS)
SpecialTools 19-32
...'......... Wheel Sensor ........19-52
19-33
ComponentLocations....."..............'... Solenoid 19-54
.................
Anti-lock Brake System (ABSI 19-56
ABS PumpMotor .............................
19-34
Features/Construction.....'...'.......... Main Relay ..........."19-59
Operation 19-35
'.............. lgnition Voltage .... 19-60
GircuitDiagram .........19-38 CentralProcessingUnit (CPU)........19-61
ABS Control Unit Terminal Modulator Unit
Arrangement .........19-40 19-62
TroubfeshootingPrecautions....,.." " " 19-42 ABS Control Unit
DiagnosticTroubleCode (DTG) Replacement .....'...19-6:l
.. Diaonostic Trouble Gode (DTCI Pulsers/WheelSensors
a lnaication 19-44
........... Inspection ..........."'19-63
DTCErasure 19-45
........... Wheel SensorReplacement.......'....19-64
Symptom-to SystemChart .....'....... 19-46
Troubleshooting
ABS Indicator Light Does Not
ComeOn 19-48
............
ABS IndicatorLight DoesNot
19-50
Go Off ............................................
SpecialTools
Rsl. No. Tool Number Description Oty Page Retorence
o - 0010100
07PAZ SCSServiceconnector 1 19-44
19-32
ComponentLocations
SERVICECHECKCONNECTOEI2PI RIGHT-REAR
WHEEL
SENSORCONNECTOR
MODULATOBUNIT ABS CONTROLUNIT
RIGHT.REAR
WHEELSENSOR
UNOER.HOOO ABS
BOX
FUSE/RELAY
LEFT.REAR
WHEEL
SENSOFCONNECTOR
FUSE/RELAYBOX
UNOER.OASH
WHEEL
LEFT.FRONT LEFT-FRONT
WHEELSENSOR
SENSORCONNECTOR
FUSE/RELAYBOX
UNDER-HOOO
rcl (40A' FUSE
nnn
-r n -fl
LIJn
'-
rr
LJ
rr
LJ
flI]
ft l ft l nt l t
I-
Q!! ,
ABS INDICATORLIGHT (15A) FUSE

HORN/STOP
BOX
FUSE/RELAY
UNDER.DASH BOX
ABS FUSE/RELAY
UNDER-HOOD
METER{7,5A} FUSE ABS +B {20 A} FUSE PUMPMOTORI40 A) FUSE
0000n
[0000 0 0 0 0u
[ 0000 0000[[
PUMPMOTORBEI-AY
RRDEFRLY{7.5A) FUSE MTRCHECK{7,5AI FUSE
19-33
Features/Construction
when the brakepedalis depressedduringdriving,the wheelscan lock beforethe vehiclecomesto a stop. In sucha case.
the maneuverability of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the
rearwheelsare locked.creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate ot the wheelsto
ensurethe grip forceof the tires,and it therebyensuresthe maneuverbility and stabilitvof the vehicle.
Judgingthe vehiclespeed,the ABS calculatesthe slip rate of the wheelsbasedon the vehiclespeedand the wheetspeed.
then it controlsthe brakefluid pressureto attainthe targetslip rate.
Grip Force ol Tire and Road Surface
COEFFICIENT
OF
FRICTION
TARGETSLIPRATE STOPPOINT
A: Distancewithout slio
B: Slipped distance
C: Actual distanceto stoo
SLIPRATE nnre=f
sr.re
19-34
Operation
ABS Control Unit
Main Control
The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle
speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring decelerationbasedon the
rateof deceleration.
T h e A B S c o n t r o lu n i t c a l c u l a t etsh e s l i p r a t e o f e a c hw h e e l ,a n d i t t r a n s m i t st h e c o n t r o ls i g n a lt o t h e m o d u l a t o ru n i t
s o l e n o i dv a l v ew h e nt h e s l i pr a t ei s h i g h .
The pressurereductioncontrolis a three modesystem,that is pressurereduction,pressureretainingand pressureintensi
fvino modes.
ABS CONIFOLUN T
Function
Sell-diagnosis
The ABS controlunit is equippedwith a main CPUand a sub CPU,and the CPUScheckeachother.
The CPUScheckthe circuitof the system.
"systemdown mode" or the "controlinhibitionmode".
Whenthe CPUsdetectfailure,they shift to the
MAIN SOLENOID DTC

MODE A B SI N D I C A T OLRI G H T CPU Restartcondition
RELAY VALVE
SYSTEM No Drive lgnition
ON Operation'l O F F- O N Memory
DOWN operation inhibition switch
CONTROL No Drive
ON Operation Automatic lMemory
INHIBITION operation inhibition
+ 1 : E x c e p tC P U f a i l u r e
The self-diagnosis can be classifieldinto thesefour categories.
O r I n i t i adl i a g n o s i s
@: ExceptABS control
O : D ur i n gA B Sc o n t r o l
( D :D ur i n gw a r n i n g
On-board DiagnosisFunstion
The ABS controlunit is connectedto the data linkconnector(16P)
The ABS systemcan be diagnosedwith the HondaPGMTester'
(cont'd)
19-35
Operation {cont'd)
ABS Modulator
The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the
d a m p i n gc h a m b e r .
The modulatorreducesthe caliperfluid pressuredirectly.and it is alsoreferredto as a circulating
type becausethe brakefluid
circulates throughthe caliper,reservoirandthe mastercylinder.
The hydrauliccontrolhasthreemodes:pressurereduction,pressureretainingand pressureintensifying.
The hydrauliccircuitis the independent four channeltype, one channelfor eachwheel.
SOLENOIDVALVE
PUMPMOTOR
RF LF
Pressureintensiiyingmodel Inletvalveopen,outletvalveclosed lN: INLETVALVE( N O F M A L L YO P E N )

OUT: OUTLETVALVE (NOFl\,4ALLY CLoSED)
lvlastercylinderfluid is pumpedout to the caliper.
Pressureretainingmode: Inletvalveclosed,outletvalveclosed
Caliperfluid is retainedbv the inletvalveand outletvalve.
Pressurereductionmode: Inletvalveclosed,outletvalveopen
Caliperfluid flows throughthe outletvalveto the reservoir.
Motor operationmode: Whenstaningthe pressurereductionmode,the pump motor is ON.
When stoppingABS operation,the pump motor is OFF.
The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master
cylinder.
19-36
Wheel Soeed and Modulator Control
SPEED
VEHICLE
VEHICLESPEED
REFERENCE
WHEELSPEED
OUTLET
VALVE
ON
OFF
INLET
VALVE
ON
OFF
MOTOR
ON
OFF
Whenthe wheelspeeddropssharplybelowlhe vehiclespeed,the inletvalveclosesto retainthe caliperfluid pressure.

When the wheel soeeddrops further,the outletvalve opens momentarilyto reducethe caliperfluid pressureThe pump
motor startsat this time.
As the wheel speedis restored,the inletvalveopensmomentarilyto increasethe caliperfluid pressure.
Wheel Sensol
The wheelsensorsare the magneticcontactless type.

As the gear pulserteeth rotatepastthe wheel sensor'smagneticcoil,AC currentis generated.The AC frequencychanges
in accordance with the wheel speed.The ABS control unit detectsthe wheel sensors;gnalfrequencyand therebydetects
the wheelspeed.
Thereare four wheelsensors,one for eachwheel.
The gear pulserhas50 teeth.
GEARPULSER
o at LOW SPEED
19-37
CircuitDiagram
UNDEF.OASH
LEFI.FBONTSOLENOIO
-Fm-Feiu
.-..@u* YE!8IK-1
F GHi.FRONTSOLENOID
REDDTU
YELTLU
- F € O-
-YTL-
BtKa
ABSFUSE/RELAY
UNDER.HOOD BOX UNOEF DASH FUSE,/BELAY
BOX M O D U L A T OU
RN I T1 O PC O N N E C T O R
3PCONNECTOR(a) number) 20P CONNECTOR(C number) (C number)
I 2 3 l l 2 5 6
t0 11 ll 15 18 1920
UNDER.HOOD
ABSFUSE/RELAYBOX UNDEB.DASHFUSE/RELAYBOX
2PCONNECTORi! number) 1 8 PC O N N E C T O R( f n l m b e r )
a 1 , f 1 2 3 alr,:15 6 P U M PM O T O R2 P C O N N E C T O R
(fl n!mber)
9 t0 Il 21314/ 1 6 t7 ,/
GAUGE ASSEMBLY
5PCONNECTOR
(O numbsr)
fl"
l 1 l / 3 5 l
WIRESIDEOFFEMALE
TERMINALS
19-38
fi
I
E C MI P C M I S C S )
GF|//vvHI--GR^L&Hr V
8tK
rB
rL
V cor, coz
'n-, '_ l n A ^ n IoaTALNK

rr6P)
la 3
I? l3lcoNNEcroF
t'-
BTK
4
cot, ctoz
wln/GFN---E
-"**d
RIDE!I]
YtlrBlll
B!!/YEt
Tep*'
GNDl
;--l
*l:,1.J l
cnoic.oz cnoicloz
l
ABS CONTROLUNIT26P CONNECTOR SERVICE

CHECK W H E E LS E N S O R
(C number) (2P)
coNNECTOF 2P CONNECTOF]
FRONT
2 3 6 / : a 9 10 t2 tl
15 11 t9 ./ zt / 123 25 2E llllrh
ABSCONTROL UNIT22PCONNECTOR DATALINK
(l number) coNNECTOB (16P) REAR
4 /",/lt /), l0 tt lT,

l-rl
tTl
12 1 i / 1 9 / 21 22
T E R M I N AS
L I O EO F
W I R ES I D EO F F E M A L ET E R M I N A L S MALETERMINALS
19-39
ABSGontrolUnit TerminalArrangement
ABSCONTROL
UNIT26PCONNECTOR
-
7-rt-Il:
I
;:, I .li
WIRESIDEOF FEMALETERM
VB: BatteryVoltage
Voltago
Terminal Wire Tormind sign
numbel color Description Condition3
ITermin.l namol Output voltagg
tafininlb (lgnition Switch ON (lll)
PCOt\4 Powersourcetor the solenoid ON OV
1 GRN^r'VHI (Primary valveandpumpmotor. 1-GND ON
common) 6 OFF AC:3-6 V
scoM Power sourcelor the solenoid OFF
2 BLIqWHT (Secondary 2.GND theSCSservice]
lConnect Approx.3 V
common) \ connector l
3 BLK/BLU Detects ignition switch 2
(lgnition2) signal.{Systemactivatesignal) 3-GND VB
RRO Detects right-rear wheel
BLU//EL (Rear-right 53mVorabove on
0) sonsorsrgnal. digitaltester
Whenthe wheelis {AC
RLO Detectsleft-rearwheelsensor (Referance)
GRY (Rear-left
0) s r g nla. turnedat 1 turn/second. range)
150mvtrporabove
FRO Detects right-front wheel onoscilloscope
8 GRN (Front-right0) 8-21
sensorsrgnal. Stops ADprox.2.5V
STOP Detects
brakeswitchsignal. Erakepedal depressed. VB
I GRNA/VHT (Stop) 9-GND
unnecessaryABS
{Prevents operation) Erakepedal released. OV
Detects left-front wheel sensor 53mVorabove on
signal. Whenthe wheelis digitsltester{AC
10 FLO
BRN^/vHT(Front-left turnedat 1 turn/ rangel (ffeferance)
0) 10-23 secono. 150mvpporabove
onoscilloscope
Stops Approx.2.5 V
Drivesleft-rearoutlet solenoid '5
RL-OUT ON OV
12 YEL (Rear-left 12-GND ON -9
outlet)
AC:3-6 V
RR-IN Drivesright-rearinlet solenoid uJ
OFF
REO/vVHT (Rearright I3-GND SCSservice]
lConnectthe A p p r o x . 3V
inlet) \ connector I
14 B1 Powersourcefor the solenoid
(Battery1) valveandpumpmotor. 14-GND
Power sourcefor the solenoid
VB
r'VHT/GRN (Battery 15,GND
2) valve and pump motor.
16 BLK GND2 Ground for the ABS control
(Ground2) unit. 16.GND Below0.3V
17 RR1
GRN/YEL(Rear-right Detects right-rear wheel
1) sensorsignal. 53 mV or above
R L l Detectsleft-rearwheel sensor on digital tester
19 LT BLU (Rear-left'l 19,6 When the wheel is turned (AC range)
) signal.
at 'l turn/second. (Referance)150
)1 FR1 Detects right-front wheel mVp-p or above
GRN/BLK(Front-righr 21-A
1) sensorsignal. on oscilloscope
23 FLI Detects left-front wheel sensor
(Front-left1) signal. 23-10
Stops A p p r o x . 2 .V5
Drivesleft-rear
inletsolenoid '6
ON OV
valve. ON
RL-IN OFF AC:3-6V
RED (Rear-left 25.GND
inlet) OFF
theSCS
lconnect seNicel Approx.3 V
I Connector l
26 BLK GND3 Ground for the ABS control

(Ground
3) unit. 26-GND Below0.3V
19-40
UNIT22PCONNECTOR
ABSCONTROL
VB: BatteryVoltage
Voltage
Tsiminal WiJe Terminal sign
Doscription Conditions
numb6r cotol lTo]minal nomsl (lgnition Switch ON lll)l Output voltago
tef|ninak
Drivesright-frontinlet '6
ON OV
solenoidvalve. ON
FR.IN OFF AC:3-6 V
I RED/BLU (Front-right 1-GND o
inlet) OFF
lconnsct SCS
the servicel Approx.3 V
\ connedor I
Detectsservicechecksignal SCS service connector
OV
(Diagnostictrouble code connecleo.
BRN (Service check 4-GND
indicationl SCSserviceconnector
signal) Approx.5 V
disconn6cted,
DrivesABSlndicatorIight{The Indicator
lightoN Approx.2 V
indicatorlightgoesoff when
7 BLU/RED (Warning ABS controlunit outputsbat-
7-GND
ramp, Indicatorlight OFF VB
tery voltage).
FL-OUT Drives left-tront outlet ON OV
10 YEUSLK (Front-left solenoidvalve. 1O-GND
ON
outlet)
OFF AC:3'6 V
Drivesleft-frontinlet solenoid
FL-IN
11 RED/BLK (Front-let 11.GND
inletl
uJ OFF
FR-OUT Drivesright-frontoutlet theSCSseruiceJ
/Connect Approx.3 V
YEUBLU (Front-right solenoidvalve. 12-GND \ conneclor I
outlet)
DLC Communicateswith Honda
l4 LT BLU (Data link PGM Tester. 14-GND Approx.5 V
connector)
Detectspumpmotordrive Pump ON VB
MCK 1 7G N D motor
17 BRN/VEL (llotorcheck) s r g n a l .
relay OFF OV
Drivespumpmotorrelay. ON OV
ON
PMR OFF AC:3-6 V
19 YEVRED (Pump motor I9-GND
retay, OFF
servicq
theSCS Approx,3 V
lconnect
\ connefior l
Drivesright-rear
outlet Pump ON OV
solenoidvalve. ON motor
RR-OUT reray OFF AC:3-6 V
BLU {Rear-right 21-GND
outlet) OFF
theSCS
lconnect seNicq A p p r o x . 3V
\ connedor I
GND2 Ground for the ABS control 22-GND Below0.3V
BLK (Ground2) unit.
19-41
TroubleshootingPrecautions
ABS Indicato. Light

1. The ABS indicatorlight comeson when the ABS control unit detectsa problemin the system.However,eventhough
the system is normal.the ABS indicatorlight can come on. too, under the following conditions.To determinethe
actualcauseof problem,questionthe customerabout the problem,taking the following conditionsinto considera-
I|on.
. Signaldisturbance
. W h e e ls p i n
. Only drivewheelsrotate
. Battery voltage Iluctuates
2. When a problemis detectedand the ABS indicatorlight comes on, the indicatorlight can stay on until the ignition
switchis turnedoff, or it can automaticallygo off, dependingon the mode.
. Lightstaysonuntil the ignitionswitchisturned off: Whenthesystemis inthesystem down mode.
. Lightautomatically goesoff: Whenthe systemis in the controlinhibitionmode.
(refer to symptom-to-systemchart)
3. The ABS indicatorlight stayson when the systemis reactivated without erasingthe DTC,but it goes off after starting
the car.
When the wheel sensorsystem is faulty and the ABS indicatorlight comes on, the algorithm of the system automatically
turns off the ABS indicatorlight after the wheel speedsignal returnsto the normal speed.While,when the DTCis erased.
the CPUis resetand the ABS indicatorlight goes off when the systemcheckedout normal by the initial dlagnosis.
Therefore,test-drivethe car afterservicingthe wheelsensorsystem,and be surethat the ABS indicatorlight does not
come on.
4. Whenthe ABS controlunit outputsbatteryvoltageto gaugeassembly.the ABS indicatorlight goesoff,
DiagnosticTroublo Code (DTCI

1. The diagnostictroublecode (DTC)is memorizedwhen a problemis detectedand the ABS indicatorlight does not go
off, or when the ABS indicatorlight comeson.
The DTCis not memori?edwhen the ABS indicatorlight comeson unlessthe CPUis activated.
2. The memorycan hold any numberof DTCs.However,when the same DTCis detectedtwice or more,the laterone is
writtenover the old one.
Therefore,when the sameproblemis detectedrepeatedly, it is recordedas one DTC.
3. The DTCSare indicatedin the orderof ascendingnumber,not in the orderthey occur.
4. The DTC$are memorizedin the EEPROM(non-volatile memory).
Therefore,the memorizedDTCScannotbe canceledby disconnecting the battery.Performthe specifiedproceduresto
erase.
Self-diagnosis
1. The self-diagnosiscan be classifieldinto thesefour catego.ies.
. Initialdiagnosis: Performedright afterthe enginestarts and untilthe ABS indicatorlight goesofJ
. ExceptABS control:Performedwhen the ABS is not functioning.
. DuringABS control:Performedwhen the ABS is functioning.
. Duringwarning; Performedwhen the ABS indicatorlight is ON.
2. The systemperformsthe followingcontrolswhen a problemis detectedby the self-diagnosis.
! ABS indicatorlight ON
. Memory of DTC
. Modechangeto the "systemdown mode" or the "controlinhibitionmode".
MAIN SOLENOID
MODE ABS INDICATOR
LIGHT CPU Restartcondition DTC
RELAY VALVE
SYSTEM No Drive lgnition
DOWN
ON
operatron inhibition Operation*1 OFF* ON Memory
swatch
CONTROL No Drive
ON Operation Automatic Memory
INHIBITION opera on inhibition
*1: ExceptCPUfailure
19-42
Kickbsck
1. The motor operateswhen the ABS is functioning,and the fluid in the reservoiris forcedout to the mastercylinder
causingkickbackat the brakepedal.
2. The ABS controlunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosis.You may
hearthe faint solenoidvalveoperationsoundat this time, but it is normal.
Pump Motor
1. The pump motor operateswhen the ABS is functioning.
2. The ABS control unit checksthe pump motor operationduring acceleration.

You may hearthe faint operationsound
at this time, but it is normal.
Brake Fluid Replac€ment/AirBleeding

1. Brakefluid replacement and air bleedingproceduresare sameas conventionalbrakes.
Troubleshooting
1. The troubleshootingflowchartsexplainthe procedureson the assumptionthat the causeof the problemis still pre-
sent and the ABS indicatorlight is still on.
Notethat troubleshooting followingthe flowchartwhen the ABS indicatorlight does not come on can resultin jncor-
rectjudgment.
Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions
for troubleshooting.
Self-diagnosisis made at varioustimes such as the initialdiagnosis,exceptABS control,during ABS control,during
acceleration,during the specifiedvehiclespeed,etc. Therefore.the symptom cannot be checkedunlessthe check
conditionsmatchwith the problemconditions.
When the ABS indicatorlight does not come on duringthe test-drive,but the troubleshootingis performedbasedon
the DTC,checkfor the looseconnectors,poor contactof the terminals,etc,beforetroubleshooting.
erasethe DTCand test-drivethe car. Be surethat the ABS indicatorlight does not come on.
Aftertroubleshooting,
The connectorillustrationsshow the femaleconnectorswith a singleoutlineand the male connectorswith a double

ouI|tne.
The connectorterminalcavitiescontainingfemaleterminalsare alwaysnumberedby lookingat the connectorfrom

the wire side,and the cavitiescontainingmale terminalsare alwaysnumberedby lookingat the connectorfrom the
terminalside.
19-{f
TroubleCode{DTC}
Diagnostic
DiagnosticTroubleCode{DTG)Indication
NOTE:This operationcan also be carriedout with HondaPGMTester.
1. side kickpanel
Connectthe SCSserviceconnectorto the servicecheckconnectorinsidethe passenger's
2, Turn the ignitionswitchON (ll),but do not startthe engine

NOTE:Do not depressthe brakepedalwhen turningthe ignitionswitch.
3. Recordthe blinkingfrequencyof the ABs indicatorlight.The blinkingfrequencyindicatesthe DTc.
4. Turn the ignitionswitchOFF,and removethe SCSserviceconnector.

NOTE;The MalfunctionIndicatorLamp (MlL)will stay on after the engine is startedif the SCSserviceconnectoris
connected.
5. Erasethe DTC.
condiiions for DTCindication

. The car is stoDDed.
. The SCSserviceconnectoris connectedbeforethe ignitionswitchis turned ON (ll).
. The brakepedalis released.
. The SCSserviceconnectorremainsconnectedduringthis procedure
The DTC indication stops and the ABS control unh executesthe software tunction if at least ono of the tollowing condi'
tions is satisfied,
. The car is not stopped.
. TheABScontrolunitreceivesthenormalsignal(whichisfortheABS controlunit)from a HondaPGMTester.
. The SCSserviceconnectoris disconnected duringthis procedure.
u.s.A.
@
CANADA
ABS INDICATORLIGHT
o r c| 1 2
LIGHT
A8S INDICATOR
. 3sec.
0. 3s€c.
8ff'?,1i'*"n Sscond
x : Eulbch€ckmc'd€
. When ignitionswitchis turnedON (ll),the ABS indicatorlight comeson to checkthe bulb. Do not count it as a DTC.
. The ABS controlunit can memorizeany numberof DTCs.
. The new DTCis not memorizedwhen the ABS controlunit has alreadymemorizedthe same DTC.
.lftheDTCisnotmemorized,theABSindicatorlightstaysONafteritgoesoftfor36seconds'
19-44
DTCErasure
1. side kickpanel.
Connectthe SCSserviceconnectorto the servicecheckconnectorinsidethe passenger's
2. Depressthe brakepedal.
3. Turn the ignitionswitch ON (ll) while holdingthe brakepedsl, but do not start the engine.The ABS indicatorlight
goes off after two seconds.
4. Afterthe indicatorlight goesoft, roleasethe brakepedal.The indicatorlight comeson afterfour seconds.
5. After the indicatorlight comes on. depressthe brakepedal again.The indicatorlight goes off again after four sec-
onds.(the brakepedalis still depressed.)
6. Afterthe indicatorlight goesoff, releasethe brakepedalagain,
,t 7. Afterfour seconds,the indicatorlight blinkstwice for 0.3secondand the DTCis erased.
8. Confirmthe DTCindication,and checkthat the DTCwas erased.
NOTE; Always maintain these steps. lf you disconnectthe SCS service connector and/or fail to operate the brake pedal
accordingto the indicatorlight indication,the DTCwill not be erased.
Conditions tor DTCorasuro

. The car is stopped.
o The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON (ll).
. Thebrakepedalis depressedbeforethe ignitionswitchis turnedON {ll).
. The SCSserviceconnectorremainsconnectedduringthis procedure.
The DTCerasurs stops and ABS control unit €xacutostho software tunction if 8t least ons of the following conditions is
satisli€d.
. The car is not stopped.
. The SCSserviceconnectoris disconnected duringthis service,
. The ABS controlunit receivesthe normalsignal(whichisfortheABS controlunit)from a HondaPGMTester.
. The brakepedalis not operatedaccordingto the indicatorlight indication,
. The DTCerasureis finished.
0.3sec.
ABSINDICATOR
LIGHT
OFF
DEPRESS
BRAKEPEDAL
RELEASE
lqnilionswitch
oN ( )
19-45
)
TroubleGode(DTCI
Diagnostic
Chart
Symptom-to-System
OETECIIONTIMING
>7
orc s< xkY= oTAGNOSTS/
SYMPTOM
2
Z E zz
PROBAELE
CAUSE
EXts 48"
16> x€EeP86az i:Y
Open in the power source circuitfo.the ABS indacatorlight

ABS indicEto. lisht do6s Elown ABS indicator lightbulb
nor come on whon ignirion Op6n in the ABS andicato.light drive circuit.
swirch is turnod on (ll) Shorrio powo. in th6 WALP ci.cuit
NO F6ultv ABS codtfol unit
Drc
Opsn in th€ lG2 cncuit
ABS indacatorlight doos
Opsn in lh€ +B circuit
ON not go ofi aftsr€ngine is
Opsn and/or shon to body srcund in rhe WALP circuit
FaultYaBS controluoil
1l Op6n, shonto body sround and/orshonto pow6r inrhe wh€el
Whe6l s6nsor (op6r'/shon
oNr O o o o
15 Faulty aBS contrclunit
11 RL
12 Shon io who6l sonsor (0)circuit inth€ who€l scnsor (1)circuit
Faulty wheel sensor inst8ll6tion
oN' (chipp6d pulssr g€a/noise) o o o Faulty AgS controlunit

16
1E RL
FR IN op€n, shonto body ground and/or shonlo pow€r inthe
32 F8.OUT
Opsn in lhe COM circuit
33 FLIN
3,r Sol6noid {op6 sho.tio FL.OUT Faulty AaS contrclunit
ON o o o
35 FA IN
RR-OUT
37 RT-IN
3a RI.OUT
Op.n in th6 motor poworsourco ci.cuit
Op6n in rh€ motor GNDcarcuit
51 ON o o
Fautty AAS oontrol u.it
Open in lh€ COM, PMF and/or MCK circuit

Op6n.nd/or blown fus6 in th€ undeFhood ABS fus6/r6l6y box
52 ON o o
Faulty pump motor rBlay
Fault ABS cont.ol unil
Shonto body ground in the PMB circuii
Shortto power in the pump motor power sou@ circuit
53 ON o Faulty pump motor rcl.y
Faultv ABS cont.olunit
Opon, shorito body sround dncyor blown fuss in the B1 or 82
54 ON o o o Shonro body g.ound andlorshonto powor in rh€ COM circuit

Fsulty modulalor unit
F a ! l t v A B Sc o n t r o l u n i t
Cono€ction oltho 24v battery for engine start
lgoilion voltago ilow voh' o o o o Faulrycharuinq sy8tem
6'I ON
Op€n in th6lG2 circuit
FaultvABS controlunit
Extem€l feto sj can b€ lho c!u!€(s) ol the preblem

F a u l t y A B Sc o n t r o l u n i t
81 ON CPU o o o o
r: It DTCSt 1 18 (whool ssnsor codos) wsre detocredth6 last time th6 ca, w.s drav6n,the ABS indicator light will 3ray on unril the ignilion switch is tLrrnodoN (ll), 6nd the
conlrol unit confirms that th€ wheel sensoF arc OK,
19- 4 6
MANAGEMENT
F€FER
CONDITIONFOR DETECTION DURING EXCEPT TO
A8S CONTROL ASSCONTROL PAGE
19€
19-50
Th€ ABS indicalor light comes on when vehicl€ is stopped and wheelsensora giv€n voltag€ does not
1952
The ABS indjcalorcomes on underrhe following conditions.

. When more than one ol wheels ar€ at a srandstill and the velocitY ofth. fasr€si wheel reachesa
. When the v€l@ity ol the faste$ wheel reachesor erc@ds a givsn sp*d, and ifthere a.e som€ whels 19,52
whos€ v€lo.ity is slowerthan a ce.lain parc€nlaqeol the fastel wheelsp€€d tor a given period.
. Whsn there aretempor.ry open orshort ctcuits of lhe wheel sensor, chippod pulsof gear, o. signal
The main relay repeats ON/OFFswitching aialltimes.

. When the main relav is ON, a shorttest pulse is sentto each valve.lfthere is some discrepancy,the
ABS indicalo. liqht comes on.
. Wh€n ti€ main r6lav is OFF,a shontest puls€ is soni ro each valve.lt lhe solenoid drive voltage is
oul of a given range, the ABS indicator light comes on. 1954
. Th€ pump motor is aclivated once or twice afterevery ignition switch ON (ll)operation while lhe
vehicle acceleral€s,thon lhe moror drive vollag€ ischocked. Whan lhe voltags is abnormal,lhoABS '19,56
indi@ror light comes on.
.AfterABS conrrol comglerion, lhe motorswirchgd is ofiand the main CPU chects the motor drivo
voltaqe. Wh€n rhe voltaqe is abno.msl,tho ABS indicator lightcomas on
During an active mororresl or AaS cont.ol, the main CPU checksthe supply voltaqe to lhe motor.
W h e n t h e v o l t a g €i s a b n o r m a l , l h e A B Si n d i c a r o lri g h t c o m e so n .
19-56
lf the moro. driv€ voltage indicates motor operarion when lhe main CPU does notswilch the motor
oN, rh€ ABS indicalorcomes on. 19-56
. When a solenoid valve failure is detected,rhe CPU checksrhe vottag€ ofrhe main relay output lfth€
vottage is lowe.than a given vohage, the AgS indicator lighl comoson.
. The main relay r€peats ON/oFF switching atalltim€s- whon the main relay is oft, a shon test pulse t9 59
is sent lo each valve. The CPU monito.s tho relerencevoltage, lflh€ vollage is out ot 3 given rang€.
the aBs indicator liohr comes on.
Whenrhe isnition voltaoe is lower or higherthan a given voltage, the CPU inhibirs ABS contoland
swirches offrhe main relay, and the ABS indicator lighr comes on. when the ignition vollage recovers l9-60
lo no.mal r.nge, ABS inhibition is canceled.
The main CPU.nd sub CPU check each other under certsin condirions. when the CPUSdetectthe lol_
lowing d iscrepansies,lhe ABS indicaror light comes on.
'When there is discrepancyin thecalculaled wheelspeed velocitylhatconiinuesfo. morethan a given
1 96 1
. Wh€nrh6re is discrepancyin the phase informarion thatcontinues for morethan a givon p€riod
. When thors is discreoancyin the calculstedconnolparameter.
'when the warch dos control pulse is faalslor a given period.. whsn rho checksum ofthe ROM is tails
.When there is discrepancyin ths dara r€adins and wrilins procadu.e of FAM.
19-47
Troubleshooting
ABSIndicatorLight DoesNot ComeOn
The ABS indicator light does not come on when ignhion switch is turned ON {ll)
Th€ ABS indicator light doos not

come on wh€n ignhion switch is
turned ON llll.
NOTE:All indicatorlights exceptthe charg-

check the MEIER (7.5A) luse in ing systemlight will not come on when the
the under-dash
fuse/relay
box. METER17.5A) fuse is blown.
Boplacothe tu3e and recheck.
YES
NOTE:
Reinstallthe
fuse it it is OK.
Chocklor .n open in tho lcl cir- GAUGEASSEMBLY5P CONNECTOR

cuit:
1. Disconnect the gauge assem-
bly 5P connector. IG1IYEL)
3, Measurethe voltage between
the gauge assembly5P con-
nectortermin6l No. 5 and
body ground.
. Repair opcn in the wira
between the METER 17.5 Al
tus€ and gauga aitombly,
. Rookca lhe undor-dr3hfu3./
rolay box. (Opcn circuit insido
tho box.
c h e c k t h e A B s i n d i c a t o rl i g h t
bulb in the gaugeassembly.
Checklor a shon to oower in tho

WALPcircuit:
Measurethe voltagebeNveen the
g a u g e a s s e m b l y5 P c o nn e c t o r
Ropairshort to powo. in the wiro

ls there batteryvohage? between the gaugo a33omblv
and ABS comrol unit.
(To page19-49|
19-48
(Frompage19-48)
Checktho gaugo .$smbly:

2. Conn€ctthe gauge assembly GAUGEASSEMBLY5P CONNECTOF
5Pconnector,
3. Connectthe terminalNo. 3 to
b o d y g r o u n dw i t h a j u m p e r
Doesthe ABS ind;cator Roplacethe ABS indic.tor light

lightcomeon? drive cilcuit in tha grugg a33em-
blv.
.Ropair opon in tho wire

botwaen the g.uge ei3ambly
and body ground.
. Ropair pool ground lc,lo1.
cl{)2t.
19-49
Troubleshooting
ABSIndicatorLight DoesNot Go Off
Thc ABS indicator light does not 90 off after the 6ngine is slarted.
- With engine.unning, ABS

indic.tor light is ON.
- With the SCS s€rvice connec-
tor connocted (s6o pago 194,11,
no DTCis indicrted.
check the RRDEFRLY(7.5A) luse

in the under-dashfuse/relaybox.
Raolacotho fuso and Jachock.
YES NOTE:Reinstallthe
fuse it it is OK.
Checkthe ABS +B (20 A) fuse in

the under-hoodfuse/relaybox.
Replacetho tuse and rech6ck.
YES NOTE: Roinstallthe

fuse if it is oK. ABS CONTROLUNIT 26P CONNECTOR
IG2 {BLK/BLU}
Checkfor an opcn in the lG2 cir-
cuh:
the ABS controlunit 26Pcon-
WIRESID€ OF FEMAI-ETERMINALS
n e c t o rt e r m i n a lN o . 3 a n d
body ground.
Ropairopon in tha wira bstwaan

ls there battery voltage? the RR DEF RLY 17.5Al tu30 rnd
ABS contrcl unh,
ABS CONTROLUNIT 26PCONNECTOR
Checkfor .n open in the Bl and

82 ci.cuit:
M e a s u r et h e v o l t a g e b e t w e e n 81 IWHT/GRNI
bodygroundand terminalsNo. 14
and No. 15individually.
Reprir opon in the wir6 brtwaan

ls there bafteryvoltage? the ABS +B 120Al furo snd ABS WIR€ SIDEOF FEMALETERMINALS
control unh.
{To page19-51)
19-50
(Frompage19 50)

Checkfor a short to bodY ground
in the WALPcircuit: WALPIBLU/REOI
2 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pand gaugeassemblY
5Pconnectors.
the ABS controlunit 22Pcon- WIRESIDEOF FEMALETERMINALS
n e c t o rt e r m i n a lN o . 7 a n d
bodyground.
Repairshor! lo body ground in

the wire botween th€ ABS con'
trol unit and gauge assemblY. ABS CONTROLUNIT 22PCONNECTOB
WALP (BLU/REO)
Check the ABS control unat:

1. Connect the ABS control unit
22Pconnector.
2 . T u r n t h e i g n i t a o ns w i t c h O N ( l l )
3. Measure the voltage between
the ABS control unit 22P con
nector terminal No. 7 and ABS CONTROLUNIT 26PCONNECTOR
body ground.
Checklor an open in th€ GND2
circuit: t 2 3 4 6 ,/8 I r0 12113
1. Connectthe ABS controlunit
1 4 t 5 1 61 7 / ' , 1 s./ 21 26
26PconnectorterminalNo 16
to body groundwith a jumper JUMPERGND2(8LK)
WIRE
the ABS controlunit 22Pcon WIRESIOEOF FEMALETERMINALS
n e c t o rt e r m i n a lN o 7 a n d
body ground.
. Repairopen in the wire between

the ABS control unit and bodY
ls there batteryvoltageT ground.
. Repair poor ground {Gilo1,
G402).
Checkfor loose ABS control unit

connectors, It necessary.substi-
tute a known-good ABS control
unit and recheck.
Ch€ckfor an open in the WALP
circuit; GAUGEASSEMELY5P CONNECTOR
Measurethe voltagebetweenthe
g au g e a s s e m b l y5 P c o n n e c t o r
Repairopen in th€ wire betwoen

the ABS control unit and gauge
assemblv. WIRESIDEOF FEMALETERMINALS
Replacethe ABS indicator light

driv6 ci.cuit in the gauge assem'
blv.
19-51
Troubleshooting
Wheel Sensor
DiagnosticTroubleCode(DTCI11-18:WheelSensorDiagnosis
NOTE:TheABS indicatorlightcomeson when onlythe drivewheelsareturning.signaldisturbance is detected.etc.Therefore,
test-drivethe car at a speed of 12 mph (20 km/h) or more after turning the ignition switch from OFFto ON 0l). and if the ABS
indicatorlight does not come on, the systemis OK.
- With tho ignition switch ON
llll, ABS indicltor lisht does RRO
not go off. IELU/YELI
- After dliving, ABS indicator
light comes on.
- With the SCS serviceconnec- AppropriateTerminal
tor connocted ls€€ page 1$501, DTC
(O)SIDE (1)SIDE
DTCa11-18ar€ indicated. 1 1 ,l 2 ( R i g h r - l r o n t ) N o . 8 : F R o N o . 2 1 :F R l
RRl {GRN/YELI FLl {GRN/ORNI
13, 14 (Left-front) N o 1 0 : F L o N o . 2 3 :F L l
1 5 ,1 6( R i s h t - r e a f ) No.4: RBo N o . 1 7 :R R 1 RL1ILT 8LU) FRl {GRN/BLKI
'17,
Checkthe wh6ol sensorcircuit: 18 {Left-rear) N o . 6 : R L o N o . 1 9 :R L ' l WIRESIDEOF FEMALETERMINALS
l Disconnectthe ABS control
unit 26Pconnector.
betweenthe appropriatewheel
sensor10)and (1)circuittermi-
. Roplir opcn in the l0l or ('l) cir-

ls the resistanceOK? cuit wire, or ahort to tho (0, cir-
- cuit wir. in thc (1) circuit wire
/Front:750 1050o/20.c,68"F\ betwoon tha ABS control unit
850- 1150020'C,68"F/
lRear. and appropriatawheal son3or.
' Roplacetho approprirto wh.el
3an30r,
Checktor a shon to body ground

in the wheel sensorcircuit:
Checkfor continuitybetweenthe
ABS control unit 26P connector
appropriatewheel sensor(0) cir
cuitterminal*and body ground.
' Rspair 3hort to body ground in
the l0) or {11 circuit wire
ls therecontinuity? between the ABS control unit
and appropriatowheel s€nsor,
. Replacethe appropiiate wheel
Checktor a short to power in the

wheel sensorcircuitl
1. Reconnect the ABScontrolunit
26Pconnector.
2. Startthe engine.
the ABS controlunit 26Pcon-
nectorappropriate wheelsen NOTE:Judgementvaluetor short to
s o r ( 0 ) c i r c u i tt e r m i n a l a n d
body ground.
Repair shon to powor in the (01
ls there4 V or more? or {l) circuit wiro b€tween the
ABS control unit and appropriate
NO
NOTE
. Normalvoltage:Approx.2 V
. 0 V: Replacethe ABScontrolunit.
. 4 V or more indicatesa shortto power.
(To page 19-53)
19-52
(Frompage19-52)
Checkfor chippedpulsergear.
Ropl.ce the driverhrft or hub

unit. (Chippedpuls€t goerl
DTC 11. 13. 15, 17: Roplscothe

ABS control unit,
DTC 12, 1ir, 16, 't8: The ABS con-
trol unit may have dotected sig'
nil dbturbanco.
19-53
Troubleshooting
Solenoid
DiagnosticTroubleCode{DTC)31-38:SolenoidDiagnosis ABS CONTROLUNIT 22PCONNECTOR
FL-OUT{YEL/BLK}
- With the ignition switch ON
(ll). ABS indicatorlight does
not go off, or ABS ifldicator
light comes on while ABS is
tunctioning.
- With the SCS sewice connec-
DTC
tor connoctodlsoepage1$50). Terminal
DTCS31-38 are indicated. 3 1 : F Rl N 22P No.1
32:FR-OUT 22P No. 12
3 3 r F Ll N 22P N o .1 1
Chocktor a short to pow€r in the 34i FL-OUT 22P No.10
solenoidcircuit: 35:RR-lN 26P No. 13 WIRESIDEOF FEMALETERMINALS
1 . D i s c o n n e ctth e A B S c o n t r o l 36: RR-OUT 22P No.21
unit 22Pand 26Pconnectors. ABS CONTROLUNIT26PCONNECTOR
37iRL'IN 26P No.25
2. Startthe engine.
3, Measurethe voltage between 38:RL-OUT 26P No.12
RL.OUTIYEL}
the ABScontrolunitconnector
a p p r o p r i a t es o l e n o i dc i r c u i t
terminal*and bodyground.
R 6 p a i rs h o r t l o p o w e r i n t h e
appropriate solenoid circuit wire
between the ABS control unit
and modulator unh,
check lor a 3hort to bodY ground

in the solenoid circuili wlRE SIDEOF FEMALETERMINALS
Check {or continuity betlveen the
appropriate solenoid circuit termi
nal* and body groLrnd.
. Repairshon to body ground in

the appropriatosolenoid circuit
wire between tho ABS control
unit end modulator unit.
. Replacethe inodulator unit.
oTc Terminal
Checkthe ABS control unit: 3 1 :F R I N No. 2: SCOM
1. Turnthe ignitionswitchOFF. RL.OUT{YELI
2. Connectthe ABS controlunh 32:FR-OUT No.2:SCOM
22Pand 26Pconnectors. 33:FL-lN No. 1: PCO[,
3. Connectthe SCSservicecon- 34:FL-OUT No. l: PCOM
nector, 3 5 iR Rl N No. 1:PCOM
36:RR'OUT No. 1: PCO[,
the ABS controlunit 26Pcon- 3 7 : R LI N No. 2: SCOM
nectorappropriateCOMcircuit 38:RL-OUT No. 2: SCOM
terminal**and bodyground.
Chocklor loose ABS control unit

ls thereapprox.3 V? conneclors. lf oecessary,substi-
tule a known-good ABS control
YES unit and recheck.
(Topagel9-55) PCOM
(GRN/WHTI
19-54
{Frompage19-54) ABS CONTROLUNIT 22PCONNECTOR
FL.OUTIYEL/BLK)
Appropnale Appropriate
DTC Terminal
Connector
3 l : F Rl N 22P No. l
32:FROUT 22P No. 12
33: FL]N 22P No. 1'l
34i FL-OUT 22P No.10
35: RR lN 26P No. 13
Checkfor an open in th. solenoid 36:RROUT 22P No.21

circuit: 37:RLIN 26P N o .2 5
Measurethe voltage betweenthe 38:RL.OUT 26P No.12
ABS control unit connedor aPPro_
priatesolenoidcircuitterminal*
and bodyground. WIRESIDEOF FEMALETERMINALS
. Repair open in the appropriate
COM circuit wire betwe€n the
ABS cortrol unit and modulator
unit. ABS CONTROLUNIT 26PCONNECTOR
ls therespprox.3V? . Repair open in the applopriate
solenoidcircuil wite bstween RL.OUT(YEL)
the ABS control unit rnd modu-
lator unit.
. ReDlacethe modulato. unit.
Checkfor looso ABS control unit

connostors, lf nocGaary, sub3ti'
tute 6 known-good ABS control
unit and recheck.
19-55
Troubleshooting
ABS PumpMotor
DiagnoeticTrouble Cod6 (DTC)51-53: ABS Pump Motor Diagnosis
- With rhe ignition 3wilch ON

{lll, ABS indic.tor light do..
not 9o ott.
- With the SCS s€rvice conn.c-
tor connoc{€d 13€€pegg 19-50},
DTCa5l-53 .rc indlstod.
checktheMTRcHEcK0.5 A)tuse.
Rcplacothe tus6 and r6ch6ck.

yES N O T E : S h o r t t h e P M Rt e r m a n a t o b o d y
NOTE:Reinstall groundfor a moment,and recheckthe fuse.
l 1 8 / 1 0t l
the fuse it it is OK. lf the fuse is blown, checkfor a short to body
groundin the MCKcircuit. l4 ,/117 1 9 1 , / 21
PMRIYEL/RED}
I JUMPER
I wrRE
Repl.co the fuso and .scheck.
YES N O T E : S h o r t t h e P M Rt e r m i n a l t o b o d y
groundtor a moment,and recheckthe tuse.
NOTE:Reinstall
thefuseif it is OK. lf the fuse is blown, checkfor a shon to body
ground in the wire be&veenthe underhood
ABS tuse/relaybox and pump motor.
Replacctho pump motor .alay.
Check th€ pump motor powet

sourcecircuit:
Turnthe ignitionswitchON (ll).
Check tor a short to powoJ in tho

Doesthe pump motor operate? pump motot powar sourcocirc{it:
Removethe pump motor relay.
Repair3hort to powar in tha wile

Doesthe pump motor operate? botwoon the under-hood ABS
tu3o/rolay box and ABS pump
motot.
Chocktor loose ABS control unit

connector!. lf nece$sry, subsli-
tute a known-good A8S control
unit and recheck.
(Topage19-57)
19-56
T
I
UNDER-HOOD ABS
{Frompage19-56) FUSE/RELAYBOX
JUMPERWIRE
Checkthe pump motor circ!it:

1. Removethe pumpmotorrelay
2. Turnthe ignitionswitchON (ll)
3. Connectthe PUmPmotorrelay
connector+B and MOTORter_ Checkfor an open in the PumP
minalswith a jumperwire for motor +B circuit:
a momenl. 1. Turnthe iOnitionswitchOFF.
2 . D i s c o n n e ct th e p u m p m o t o r
2P connector.
3. Turnthe ignitionswitchON (ll). TERMINAL TERMINA.
Doesthe pump motoroperate? 4. Connectthe pump motorrelay
connector+B and MOTORtet' PUMP MOTOR2P CONNECTOR
minalswith a iumPerwire.
5. Measurethe voltagebetween MOTOR+B (WHTl,S
the pump motor 2P connector
rv) -
terminalNo. l and bodY Y
ground.
TERMINALS
WIRESIDEOFFEMALE
Repairopen in the wire betwoen

ls there baftery voltage? the under-hoodABS fus€/relav
box and pump motor.
MOTOR+B iRED) MOTORGNDIBLKI

Check the pump molor opera'
tion:
Connectthe battery(+)termanalto
the pump motor 2P connectorter
minaN l o . ' 1a, n dt h e( ) t e r m i n a l t o
theterminalNo.2 for a moment.
Beolacethe modulator unit.

Doesthe pump motor oPerate? {Fallty pump motorl
Checkfor a short to body ground Repah open in the wita between

in the PMRcircuit: the pump motor rnd bodYground,
or poor ground (G/o31. ABS CONTROLUNIT 22PCONNECTOR
unit 22Pconnector.
t e r m i n a lN o . 1 9 a n d b o d y
ground.
Repairshort to body ground in

th6 wire betweenlhe und€r-
ls lhere continuity? h o o d A B S t u s e / r e l a yb o x a n d WIRESIDEOF FEMALETEFMINALS
ABS control unit.
(cont'd)
(To page19-58)
19-57
Troubleshooting
ABSPumpMotor (cont'dl
(Frompage19-57)
Check loi .n open in the PCOM

circuit: ) t-1E
tr
1. Turnthe agnitionswitchOFF.
2 . R e c o n n e ctth e A B S c o n t r o l r.l
unit 22Pconnector.
nector,
5. Measurethe vokagebetween
t h e p u m p m o t o r r e l a yc o n -
n e c t o r P C OM t e r m i n a l a n d
body ground.
Bopair open in the wire betwoen

ls thereapprox.3 V2 tha under-hoodABS tuse/reley
box and ABS cont.ol unit. ABS CONTROI-UNIT 22PCONNECTOR
Chocktor an open in ihe PMRcir- 7 8 10 t l

cuit: 12 / 14 11 21 22
PMR{YEL/RED)
terminalNo. 19and bodyground.
Ropairopen in the wire betwaen

ls thereapprox.3V? WIRESIDEOF FEMALEIERMINALS
the under-hoodABS fuse/relay
box and ABS control unit.
Check tor an open in the MCK

circuit:
2 . D i s c o n n e ctth e S C S s e r v i c e
connector.
4. Measurethe voltage betlveen
the ABS controlunit 22Pcon
n e c t o rt e r m i n a l N o . 1 7 a n d
body ground while connect-
ing the pump motor relay
connector+B and MOTORter
minal with a jumper wire for
moment.
Repairopen in the wire betwoen

ls there battery voltage? the under-hoodABS fuso/r€l.y
box and ABS control unit.
Checktor loose ABS control unit

connectors, It necessary,substi-
tuto a known-good ABS control
un;t and recheck.
Main Relay
DiagnosticTrouble Code (DTC)54: Main R€layDisgnosis

{ll}, ABs indicator light do.s
not go off.
- With the SCS 3oruics connec-
tor conn.ctod h6e Psgc 19601,
DTCg b indcst d.
check the ABs +B (20A) fuse.
Raplac!lha fuso snd lachock.

YES
N O T E :R e i n s t a l l
the fuse if it is OK.
Ch6ck for .n open in thc 81, 82 B1

circuh: (WHT/GRNI
M e a s u r et h e v o l t a g e b e t w e e n
body ground and the ABS control
unit 26Pconnectorterminal No. 14
and No.15individually.
Ropairopen in th. wi.o bdtw.en
ls there batteryvoltage? tho ABS control unit and under'
hood ABS tuse/rol.y box.
Checklor a ihon to body Itound

in the PMRcitcuit: ABS CONTROLUNIT 22PCONNECTOR
2, Removethepump motor relay.
3. Disconnectthe ABS control
unit 22Pconnector.
t e r m i n a lN o . 1 9 a n d b o d y
ground.
Ropair short to bodY ground in

tho wiro botwean th. undel' WIRESIDEOF FEMALETERMINALS
ls therecontinuity? hood ABS fu3e/.ehY box tnd
ABS control unil.
Checkfor a short lo bodY ground PCOM SCOM

in the PCOM,SCOMcilcuit: {GRN/WIIT) {BLK/WHTI
unit 26Pconnector.
body ground and the ABS con- . Repairshort to bodY ground in
trol unit 26PterminalsNo l the PCOM circuit wirs bctween
andNo.2 individually. tho ABS control unit and undor_
t6 17
hood ABS t6o/r.lay box.
. R€pair3hon lo bodY ground in
ls therecontinuity? th6 PCOMoJ SCOMcilcuit wiro
botwoen the ABS control unit
end modulator unit.
' R o p l a c et h e m o d u l t t o r u n i t .
(Short circuh in3ideth6 unitl
(Topage19-60)
(cont'd)
19-59
Troubleshooting
Main Relay(cont'd)
\
(Frompage19,59)
PCOM
{GRN/WHT}
Checklor a rhort to power in the
PCOM,SCOMcircuit:
1. Stanthe engine.
body groundand ABS control
. Rcp.i. 3hort to powor in the
unit 26P connectorterminals
No. l and No.2 individualty. PCOM circuh wirc bqtwaen tho
ABS control unit and undoa-
hood ABS fuso/relaybor.
. RopaiJshorl to powor in th6
ls there8 V or more?
PCOM or SCOM circuit wir.
botwoen tha ABS control unit
and modulato. unit.
. Repl.co the modulator unit.
Turn the ignhion switch OFFand
conn.ct thc SGS sorvics connoc- lshorl to powol inside tho unitl
lo.. Then tuJn the ignition rwitch NOTE: 8 V or more indicatesa short to
ON lll) rnd m.rsuro th. voltago
betwcen the PCOM and SCOM
tt.minals and body ground. lf
there i3 0 V, rephco the ABS|con-
trol unit.
19-60
lgnition Voltage
DiagnosticTrouble Code {DTC)61: lgnition Voltage Diagnosis
- With the engine running, ABS

indic.lor light is ON.
- With the SCS serviceconnoc-
tor connected (saepage 19-501,
OTC61 is indicded.
Problemve.ification:
1. Erasethe DTC.
2. Startthe engine.
3. Make sure that the ABS indi
catorlight comeson and DTC
61 is indicated.
ls DTC61 indicated? The swlern is OK at this time.
Chcckthe lG2 circuit: IG2IBLK/BLU}

Me6surethe voltagebetweenthe
ls there18V or above? WIRESIDEOF FEMALETERMINALS
ff the vohage is 0 V, check tor an

ooenin the lG2circuit.
lf there h 12 - 17 V, substitute a
known-goodABS control unit rnd
r€ch€ck.
9-61
Troubleshooting
CentralProcessingUnit (CPU)
DiagnosticTroubl€ Code {DTC}81: CPU Diagnosis

(ll), ABS indicato. light doos
not go off.
- Wrth the SCS s€rvice connec-
tor connoctod lsee page 19601,
DTC81 i! indieted.
Ploblem v6dtication:
1. Erasethe DTC.
2. Test-drivetho vehicle.
3. M6ke sure that the ABS indi-
cator light comes on and DTC
81 is indicated.
RopbcGtho ABS control unil.
The syitom b OK rt this time.
19-62
ModulatorUnit
CAUTION:
. Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immedi-
ately with water.
. Take care not to damage or deform the brake lines during lemoval and installation.
. To Drevent the brake fluid from flowing, plug and cover the hose ends and ioints with . shop towal or equivalent
material.
NOTE:Tightenthe flare nutsto 15 N.m ( 1.5kgf m, 11 lbf'ft).
Removal
1. the modulatorunit 10Pand pump motor 2P connectors

Disconnect
2. the brakelines,then removethe modulatorunit

Disconnect
lnstallation
1. Installthe modulatorunit,then connectthe brakelines.

'l0Pand pump motor 2P connectors
2. Connectthe modulatorunit
3. Bleedthe brakesystem.
4. Startthe engine,and checkthat the ABS indicatorlight goesoff.
PUMPMOTOR
2P CONNECTOR
ffi
t'
TORUNIT
'%
19-63
Pulsers/Wheel
ABSControlUnit Sensors
Replacement Inspection
1. Removethe right side kickpanel. 1. Checkthe front and rear pulserfor chippedor dam-
agedteeth.
2. Disconnect
the ABS controlunit connectors.
2. Measurethe air gap betweenthe wheel sensorand
3. Removethe ABS controlunit. pulserall the way aroundwhiie rotatingthe pulser.
4. Installthe ABS control unit in the reverseorder of Standard:0.4- 1.0mm (0.02- 0,04inl
removal.
N O T E : l f t h e g a p e x c e e d s1 . 0 m m ( 0 . 0 4i n ) , t h e
p r o b a b i l i t yi s a d i s t o r t e ds u s p e n s i o na r m w h i c h
shouldbe replaced.
Front
0.4- 1.0mm
{0.02- 0.04inl
CONNECTORS
0.4- 1.0mm
(0.02- 0.04in)
19-64
Sensor
Pulsers/Wheel
WheelSensorReplacement
NOTE:
. Be carefulwhen installingthe sensorsto avoidtwistingthe wires.
. The torquevalueof the bolts is at 9.8 N'm (1.0kgf m, 7 lbift)
Front
WHEELSENSOR
1. Removethe hub bearingunit (seesection18).

2. Removethe four backingplatebolts
to disconnectthe
pull the backingplateawayfrom the trailingarm, then removethe wheelsensor.lt is not necessary
b r a k el i n e .
''-----_l'-
19-65
I
Body ('96 model)
Doors
FrontDoorIndex(4D) .-'2O-2
RearDoorIndex(4D) ..'..20-8
DoorfndexlzDl3Dl ."""20'14
Emblems
fnstallation 20'118
Exterior
G o m p o n e n Lt o c a t i o nI n d e x ' . . . . . . . " . . 2
. .0. - 9 3
*FrameRepairGhart ........,. 2O'12O
*lnterior
ComponentLocationIndex....".'.....'.20-58
Mirrors
MirrorReplacement ...."...'."...'..". " "' 20-24
MirrorHofderReplacement ""'.'.""..' 20-25
MirrorCoverReplacement "."""'."". 20-25
RearviewMirrorReplacement '..-""" 20'25
Moonroof
l n d e x, . . . . . . . . . ..'......'.'.....'.'.20'50
OpenerCable/Opener and Latch/
WiperandWasher
ComponentLocationIndex..'.......'. ". 20-1oj
Seatsand SeatBelts
ComponentLocationIndex..'..'.... "".20'73
Sub-frame ."' 20-119
Windshield, RearWindowand OuarterGlass
fndex......'.'. '..'.".'."""'.'.' 20'26
Body ('97 modell .............

...""."20-123
Body ('98 model) ......... .....'....20-131
Doors
FrontDoor Index
ilD:
SASHTRIM
WEATHERSTRIP
OETENT
o obn
ROO
fu-P 'aer7a
[q-/
POWERWINDOW
SWITCH
DOOR
Adjustment,page
20-23
DOOR
PROTECTOR
c€ \f
R--2''
7t'<
DOOR DOOR
GRIP GRIP
DOOBPOCKET
COVER r-\
"rrd*r,
-."v ef'
COVER
20-2
GLASS
Replacement,
page 20'6
Adjustment,
page 20-20
CENTERLOWER
CHANNEL
CYLINOER REGULATOR
PROTECTOR Replacement,
LOCKROO
pa9e20-6
PROTECTOR .^@
\lzl
dD
ô
STRIKER
Adjustment,
page20-23
e'
I \".ou.oro,
\ t l LOCK
CYLINDEB
RETAINER
CLIP
R e p l a c e m e n t ,p a g e 2 0 - 5 HANOLE
\ (
INNER HANOLE ROD
A (
V*#a
* POWERDOOR
LOCKSWITCH
(driver'sonly)
CYLINDER
ROD
/
LATCH
Replacement,
LATCH
PROTECTOR
-w fi6* $@
20-6
INNER
HANDLE
20-3
Doors
Door PanelRePlacement
4. Releasethe clips that hold the door panel Remove
NOTE:Takecarenot to scratchthe door paneland other
the door panelby pullingit upward
pans.
NOTE:Removethe door panelwith as littiebending

1. Remove:
. Innerhandle(seePage20-3) as possibleto avoidcreasingor breakingit
. Mirror mount coverpanel(seepage20'24l'
95 mm 13.74inl
ll applicable, remove the regulator handle by pulling .L

the clip out with a wire hook 12 mm
TRIM PAD {0.47in} T-
TORHANDLE
REMOVER
WIREHOOK (Commercially
available) /t4-
Snap-on , ./zn nu"
#4171,or 1mm L,-- |
equivalent 10.04in)
45 mm
{1.77inl
>: Cliplocations,5
Removethe door grip coverand speakercover,then

i
3.
removethe screws.
POWERWINDOW
J:lt{ [ i
5
>: Sctewlocations, swlTcH
ltN i
cL,P l\ i
REMoVERi I i
-E/
D i s c o n n e c tt h e
s p e a k e rc o n n e c l o r '
5. Installationis the reverseof the removalprocedure'
20-4
OuterHandleReplacement
NOTE:Raisethe glassfully. 4. Pull out the outer handle.Pry the outer handle rod
out of its joint usingdiagonalcutters.
1. Remove:
a Door panel NOTE:
. Plasticcover {see page 20-21 . To easereassembly, note location@ ofthe outer
handlerod on the joint beforedisconnectingit.
2. Pullout the retainerclip. . Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
CYLINDERPROTECTOR door.
OUTERHANDLE BUSHING
ROD Replace.
DIAGONAL
€l
CUTTERS
\
,1rl'.
LOCKCYLINDER
RETAINER
CLIP
Removethe bolts,then removethe cylinderprotec-

tor, lockcylinderand outer handle.
>: Bolt locations,2
I
r$\'* 6 x 1.0mm i
\Af@ g.aN.mtr.otsr.m, I
?.2 tbI.ft) )
-_-_--/
CYLINDER
SHOP
TOWEL
5, lnstallationis the reverseof the removalprocedure,
NOTEj Makesurethe door locksand opensproperly.
LOCKCYLINDER
ROD
CYLINOER
20-5
Doors
LatchReplacement Replacement
Glass/Regulator
' t . Remove:
NOTE:Raisethe glassfully.
. Door panel(seepage20-4)
1. Remove: . Plasticcover(seepage20-2)
. Plasticcover(seepage20-21 Carefullymove the glassuntil you can seethe bolts,
. Outerhandle(seepage20-5) t h e n r e m o v et h e m . C a r e t u l l yp u l l t h e g l a s so u t
throughthe window slot.
2. Removethe bolt, then move the center lower channel
forward. NOTE:Takecarenot to dropthe glassinsidethe door.
3. Disconnectthe connector,and detachthe harness

>: Boltlocations.
2
c l i p f r o m t h e d o o r . R e m o v et h e l a t c ht h r o u g ht h e
hole in the door.
NOTE:Takecare not to bend the inner handlerod,

outer handlerod, cylinderrod and lock rod.
>: Screwlocations,3
GLASS
LOCKROD
REGULATOR
6x1.0mm
I N.m {0.8kgf.m,
6 tbf.ft)
4. Installationis the reverseof the removalprocedure.
NOTE:
. M a k e s u r e t h e i n n e r h a n d l erod and connector
are connectedproperly.
. lvlakesurethe door locksand opens properly.
20-6
3. Disconnectthe connector,and detachthe harness 4. Greaseall the slidingsurfacesof the regulatorwhere
c l i p ,t h e n r e m o v et h e r e g u l a t otrh r o u g ht h e h o l e i n shown.
t h ed o o r .
>: Bolt locations
a>,4 8>,3
6x1.0mm 6x1.0mm
REGULATOR
REGULATOR
MOTOR
5. Installationis the reverseof the removalprocedure
NOTE:Rollthe glassup and down to see if it moves

freelywithout binding.Also make sure that there is
no clearancebetweenthe glassand glassrun chan-
nel when the glassis closed.Adjust the positionof
the glassas necessary(seepage20-20).
a: Nut locations,3
I
l
AR 6x1.0mm
@ rgt -,
e ru.- 1o.a
i 6rbf ft)
L-r REGULATOR
(Manualtype)
20-7
Doors
RearDoorIndex
4D:
OUTER
WEATHERSTRIP
INNER
WEATHERSTRIP
...-\\\
DOOR
iD\\ Adjustment,
page20-23
\b\ fu4 R'r"'

\\
S"'P
Y-*^
HINGE
oooR
PROTECTOR
20-8
n
(2
REARCHANNEL\
\4\
\ \ \
\\ \
t\
Qll
a@ lll
"ro."*o""..*
coLLAB I jl
\ J I
*-@\l'
REGULATOR
HANDLE \
OUTERHANOLE
page20-11
Replacement, >-9
\n'
POWERWINDOW
MOTOR
LOCKROD
PROTECTOR
Replacement,
page20-12
POWERDOOR INNER
LOCKACTUATOR HANDLE
ROD
20-9
Doors
Door PanelReplacement
NOTEjTakecarenot to scratchthe door paneland other 3. Releasethe clips that hold the door panel.Remove
parts. the door panelby pullingit upward,
'1. Remove:
NOTE:Removethe door panel with as little bend-
. Innerhandle{seepage20-9) ing as possibleto avoid creasingor breakingit.
. Regulatorhandle(seepage20-4)
2. Removethe door grip cover,then removethe screws.

.L
1 2m m
TRIM PAD {0.47in) T-
REMOVER
(Commercially
available) /={
Snap-on t ./t ' , cs"
44177,ol 1fim -i-,.--t I
6quivalent 10.04inl I L ,
45 mm
{1.77inl
>: Cliplocalions,7
4. Installationis the reverseof the removalorocedure.
\20-10
e--'
OuterHandleReplacement
NOTE:Raisethe glassfully. 4. Pull out the outer handle.Pry the outer handlerod
'1. Remove:
. Door panel NOTE:
. Plasticcover(seepage20-8) . To easereassembly, note location@ of the outer
handlerod on the joint beforedisconnecting it.
2. Removethe screws. . Takecarenot to bendthe outer handlerod.
>r Screwlocations,
3 ooor.
6x1.0mm I
6 N.m (0.6kgt m, ) BUSHING
4 rbf.ft)
Replace.
.41
:'"*',Yt:
DIAGONAL \
ft_-..p
^\ r r---t--J-
4 t---\---
pS\.. \]
\ \-V
OUTER
HANDLE
ROD
3. Move the latch down, and remove the bolts.
>: Bolt locations,2 |
I
----,!Sl/ s't.o--
6@.1 g.a N.m i
)
11.okd m,7 .2 tbt'ft| /
SHOPTOWEL
5. Installationis the reverseof the removalDrocedure.
NOTE:Makesurethe door locksand opensproperly.
20-11
Doors
LatchReplacement RePlacement
Glass/Regulator
NOTE:Raisethe glassfully. 1 . Remove:
1. Remove: . Plasticcover{seepage20-8)
r Door panel(seepage20-10)
. Plasticcover{seePage20-8) 2. Carefullymove the glassuntil you can seethe bolts,
. Outerhandle(seepage20-11) then removethem.
2. Removethe iockcrankand cliP. NOTE:Takecarenot to dropthe glassinsidethe door.
>: Screwlocation,1 >:Clip location,1 2

>: Boltlocations,
fi s'r.o-- |
@ 9.8N m tl.o kgtm, J
- L2 tbl.tlt , ,,-----/,/
Removethe rearchannelcollar.
NOTE:Takecare not to bendthe lock rod and inner

handlerod.
REARCI{ANNEL
LATCH
3. C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d
screwtrom the rearchannel,then removethe glass
\i trom the rearchannel.
NOTE:Takecarenotto dropthe glassinsidethe door.

>: Bolt.screwlocations
A'1 t't
@@!iT,--,,-, ,J @
i
II
6w.ftt _-,/./ _
6x1.0mm
INm(0.8kgf.m,
D i s c o n n e c tt h e
6 tbf.ft) connector. B, 1 6r1.0mm
4. Removethe latchthroughthe hole in the door. I N.m 10.8kgt m,6lbf ftl '
,,<\
t"<1'
Fllt--n]nTl
5. Installationis the reverseof the removalprocedure. )
,/
NOTE: Makesurethe door locksand opensproperly.
20-12
4. Caretully remove the glass from the window slot.
CLIP
Greaseall the slidingsurtacesof the regulatorwhere
shown.
NOTE:
a lf necessary,remove the power window motor
from the regulator.
REAR . Beforeremovingthe powerwindow motor,scribe
CHANNEL a line acrossthe sectorgearand regulator.
COLLAR
SECTORGEAR REGULATOF
B
5. Removethe outer molding,then removethe quar-
ter glass.
OUARTER
wtNDow
>: Bolt locations.3

POWER
wtNDow
MOTOR
6x1.0mm
7 N.ml0.7kgf.m,
5 tbf.ft)
6. Disconnectthe connector,and detachthe h a r n e s s

clip, then removethe regulatorthrough the h o l e i n REGULATOR
the door. 8. lnstallationis the reverseof the removalorocedure.
>: Boli locations
B> . 2 NOTE:Rollthe glassup and down to see if it moves
a>,2
6 x 'l.0mm
I
| 6x1.0mm
I freely without binding.Also make sure that there is
El sN-{o.a*gr.m, 8Nmlo.8ksfm, no clearancebetweenthe glassand glassrun chan-
ff o rrr.rt 6 tbtftt ) nel when the glassis closed.Adjustthe positionof
the glassas necessary(seepage20-20).
20-13
Doors
DoorIndex \
2Dl3Dl GLASSGUIDE
CLIP
I sAsH
S 61P \ \ 1
\
\ T a_\
\
OUTER
WEATHERSTRIP
:
h\>l\\-,-'\ \ ",Ro,--"ou",
r\J \.l+-- PANEL
covER
9,, i i <an
@
[-\r ffi*'"o'
, \
\i ft{351'"'
INNERHANDLE
TRIM
S tuf
{h
-re
(with powerdoor locks)
\ eowenooon INNER
HANDLE ".o.*.r\ oooR
LOCKSWTTCH tRtM - |
\ Adjustment,
\ \ {withoutpower Cf-
-. I
,.JL Pase20'23
ts1.,h.*
-\Q'-Qh.\\-*<y
tls!^
| W
\J' (t!5t \\
ARMRE'T \R]
POCKET +..-ooon
PROTECTOR
ARMREST
POCKET
1-O-14
GLASS
Replacement,
page20-19
Adiustment,
page20-20
GLASSRUN
CHANNEL
3ill,'î,i"**\N
\
\\
\\\\ REGULATOR
pas€20.19
\\\\ Reptacement,
l\\\\ \ z
trq\\\t v.
,6@
POWER
MOTOR
CYLINDER
PROTECTOR
e'
\".or.oro*
HANDLE
RETAINER page20-17
Replacement,
LOCK
CLIP
CYLINDER
w RODPROTECTOR
HANDLEBOD
FRONTLOCK
ROD
REARLOCK
ROD
LATCH
PROTECTOR
20-15
Doors
DoorPanelReplacement \
N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d 5. Releasethe clips that hold the door panel.Remove

other parts. the door panel by pulling it upward.Disconnectthe
soeakerconnector.
1. Remove:
! Innerhandletrim (seepage20-14) NOTE:Removethe door panelwith as littlebending
. Mirror mount cover panel{seepage20-241 as possibleto avoid creasingor breakingit.
2. l f a p p l i c a b l e r. e m o v el h e r e g u l a t o rh a n d l e b y
pullingthe clip out with a wire hook. 95 mm 13.74inl
-L
12 mm
HANDLE
REGULATOR TRIM PAD 10.47in) 1-
WIREHOOK REMOVER
(Commercially
available)
Snap-on
/t1-
*4177,or 1mm L---'"t/lf'
equival€nt to.o4inl I : -]
I
45 mm
(1.77in)
>: Clip location3,
il_
Remove the armrest pocket,then disconnectthe
oower window switch connector.
JF
=l$
INOS
t\
-------l I
cr_rp
REMoVER
F?
rI
DOORPANEL
ARMREST
POCKET
4. Removethe soeakercover.then removethe screws.
>i Screw localions,3

|
6hD:"
L"
.i CONNECTOR
6. Installationis the reverseof the removalDrocedure.
COVER
20-16
Outer HandleReplacement
NOTE:Raisethe glassfully. 4. Pull out the outer handle.Pry the outer handlerod
l. Remove:
. D o o rp a n e l NOTE:
. Plasticcover(seepage20-14) . To easereassembly, note location@ of the outer
handlerod on the joint beforedisconnecting it.
2. P u l lo u t t h e r e t a i n ecr l i p . . Takecarenot to bendthe outer handlerod.
PROTECTOR
CYLINDER door.
BUSHING
Replace.
,w,
LOCKCYLINDER
OIAGONAL
CUTTERS \
CLIP
3 . Removethe bolts,then removethe cylinderprotec

tor, lockcylinderand outer handle.
>: Eolt locations.2
SHOP
TOWEL
5. Installation is the reverse of the removal procedure.
NOTE: Make sure the door locks and opens properly.
LOCKCYLINDER
CYLINDERROD
20-17
Doors
Latch Replacement
NOTE:Raisethe glassfully. 3. Removethe boltsand movethe centerlowerchannel.
l. Remove: NOTE:Take care not to bend the inner handle rod

. Door panel(seepage20-16) and lockrods.
. Plasticcover(seepage20-14)
. Outerhandle(seepage20-17)
2. Removethe rod protector. >: Screw locataons
A>,3 8>,3
5x1.omm i
[v) ) 4 p 6 N m { 0 . 6 k e f m , i
@
l
4 tbt.h)
) _)
CENTERLOWER
CHANNEL CBANK
HOLDER
PROTECTOR
6xl.0mm
8 N.m {0.8 kgf.m,
6 rbr.ftl
R e m o v et h e i n n e r h a n d l e ,t h e n r e m o v et h e l a t c h
throughthe hole in the door.
lnstallationis the reverseol the removalprocedure.
NOTE:Makesurethe door locksand opensproperly.
20-18
Replacement
Glass/Regulator
1. Remove: 3. Disconnectthe connector,and detachthe harness
. Door panel(seepage20-16) clip, then removethe regulatorthrough the hole in
. Plasticcover{seepage20-14) the door.
2. Caretullymove the glassuntil you can seethe bolts, NOTE:Scribea line aroundthe rearrollerguidebolt
then loosenthem. Slidethe guide rearward.remove to show the originaladlustment
t h e g l a s s f r o m t h e g u i d e , a n d c a r e f u l l yp u l l t h e
glassout throughthe window slot.
>: Bolt locations
NOTE:Takecarenot to dropthe glassinsidethe door.
A>,4 B>,2
6x1.0mm 6x1.0mm
I N.m10.8ksl.m, I 8 N m {0.8kst.m, I
>: Bolt localions,2 6|lofttt 6 rbrft
LOOSen.
|
6x1.0mm
9.8N.m11.0kg{.m,I )
E
,* 7.2tbrft) |
€l Loosen.
/
ROLLER BEGULATOR
BOLTS
GUIDE
(cont'd)
20-19
Doors
Glass/Regulator (cont'dl
Replacement GlassAdjustment
Greaseall the slidingsurfacesof the regulatorwhere NOTE:
shown. . Placethe vehicleon a firm, levelsurfacewhen adjust-
ing the glass.
NOTE: . Checkthe weatherstrips and glassrun channelfor dam-
a lf necessary,remove the power window motor age or deterioration,and replacethem if necessary.
from the regulator.
. Beforeremovingthe powerwindow motor,scribe 1. Remove:
a line acrossthe sectorgearand regulator. . Door panel(seepages20-4,10,16)
SECTORGEAR . Plasticcover(seepages20-2,8,14)
2. Adjustthe glass.
REGULATOR
4D:
a, R a i s et h e g l a s sf u l l y .
o. L o o s e nt h e g l a s sm o u n t i n gb o l t s ( f r o n td o o r )
and regulatormountingbolts.
c. Push the glass rearward (front door glass)or

forward (rear door glass).
>: Bolt locations, 3 d. Tighten the glass mounting bolts (front door)
and regulator mounting bolts.
q(])
6xr.om;- ] A >: Glassmountingbolt
locations.
POWERWINDOW
B >: R€gulato.mouting
bolt locations.
Front:
; l L //
- ^ ->
\
5. Installationis the reverseofthe removalprocedure.
NOTE:Rollthe glassup and down to seeif it moves

freely without binding.Also make sure that there js REGULATOR
no clearancebetweenthe glassand glassrun chan
nel when the glassis closed.Adjust the positionof
the glassas necessary.
20-20
Rear:
GLASS
A
u +
REGULATOR
e. Loosenthe front channelmounting bolts (tront 2DI3D:

d o o r ) o r r e a r c h a n n e lm o u n t i n gb o l t ( r e a r
door). Raisethe glassas far up as possible,and hold
it againstthe glassrun channel.
f. Lowerthe glass.
o. L o o s e nt h e r o l l e rg u i d e b o l t s ,a n d a d j u s tt h e
g. P u s h t h e f r o n t o r r e a r c h a n n e l sa g a i n s tt h e glassso it is parallelwith the glassrun channel.
glass,then tightenthe mountingbolts.
GLASSRUN
>r Fiontandrear CHANNEL
channel mounting
bolt locations
Front:
ROLLERGUIDEBOLTS
(cont'd)
20-21
Doors
GlassAdjustment(cont'dl
c. Tightenthe rollerguide bolts. 6. Checkfor water leaks.
d. Loosenthe front channelbolts. Spray water over the roof and on the sealingarea
as shown.
e. Lowerthe glass.
NOTE:
f. Push the front channelagainstthe glass,then . Adjustthe water pressureas shown.
tightenthe mountingbolts. . Do not squeezethe tip of the hose.
GLASS
12 mm {0.47inl
hd
Y
HOSE
300mm (11.8in)
MOUNTING
BOLT
3. Checkthat the glassmovessmoothly.
4. Raisethe glassfully and checkfor gaps.
5. Checkthe glassoperation, 7. Attachthe plasticcover,then installthe door panel

(seepages20-4,10, 16).
NOTE:Checkthat the glasscontactsthe glass run
c h a n n eel v e n l y . lnstallthe regulatorhandleso it pointsforward and
up at a 45 degreeanglewith the glassclosed.
WEATHERSTFIP
Forward
20-22
g
PositionAdjustment StrikerAdiustment
NOTE: Placethe vehicleon a firm. level surtacewhen Makesurethe door latchessecurelywithout slamming.
adjustingthe doors. lf it needsadjustment:
After installingthe door, checkfor a flush fit with the N O T E rT h e s t r i k e r n u t s a r e f i x e d . T h e s t r i k e rc a n b e

body.then checkfor equal gaps betweenthe front, rear, adjusted1.5mm (0.059in) up or down,and 3 mm (0.1in)
a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d tn or out.
body edgesshouldalso be parallel.Adjust at the hinges
asshown. 1. Loosenthe screws,then inserta shoptowel between
the body and striker.
CAUTION:Placea shop towel on the lack to prevent
damageto the door when looseningthe door and hinge
mounting bolts lor adiustment.
DOORMOUNTING BOLTS
8 x ' 1 . 2m
5m 1 . 5m m 1 . 5m m
28 N.m{2.9kgt.m,21 lbf.ftl (0.059in) {o.059in}
Loosenthe door mountingboltsslightly Inserta shop towel
to movethe door lN or OUT until between the body and
it's flushwith the body.lf necessary,
you can installashim behindone
hingeto makethe door edges PLASTIC
PARALLEL with the body. HAMMER
HINGEMOUNTINGBOLTS
8 x 1.25mm
28 N m {2.9 kgf.m,21 lbf.ft)
Removethe innerfender,
loosenthe hingemounting
bolts,and movethe door
BACKWARD or FORWARD,
UP or DOWNas necessary
to equalizethe gaps.
Lowerthe glass.
8 x 1.25mm
l8 N.m {1.8kgl m, TOWEL
r3 tbf ft)
2. Lightlytightenthe screws.
3. Wrap the strikerwith a shop towel, then adiustthe

strikerby tappingit with a plastichammer.
CAUTION: Do not sttike the striker too hard.
NOTE:Holdthe outer handleout, and pushthe door

againstthe body to be surethe strikerallowsa flush
The door and body edgesshouldbe parallel. fit.
4. lf the door latchesproperly,loosenthe screws,then

removea shop towel.Tightenthe screwsand recheck
,lJl:ril:x;T9#
NOTE:Checkfor water leaks.
20-23
Mirrors
Mirror Replacement \
NOTE:Takecare not to scratchthe mirror, mirror base 3. Removethe mirror mounting nuts while supporting
coverano ooor. the mrrror.
I L o w e rt h e d o o rg l a s s .
a: Nut locations,
3
2. Carefullypry out the mirror mount cover panel by
nano.
Power milror:
€)coNNEcToR
(Mirrorside)
MIRROR
{Doorharness
side)
CONNECTOR
MIRROR
MOUNT
PANEL
COVER
Manualmirror: Installationis the reverseot the removalprocedure.
Removethe cap, screwand knob,then removethe NOTE:Make sure the connectoris connectedprop-
mirror mount cover panel. erly.
MIRRORMOUNT
KNOB
20-24
Mirror Holder Replacement RearviewMirror Replacement
CAUTION: Wear gloves to remove and install the mir- l. Removethe rubberdamper.
ror holder.
2. Pry the cover off using the end of a flat tip screw-
' 1 . C a r e f u l l yp r y o u t t h e m i r r o r h o l d e rw i t h a f l a t t i p dnver.
screwdriveras shown.
CAUTION: When prying with a flat tip screwdriver,
PIVOT wrap it wilh a shop towel to prevent damage.
JOINT PIN -6r 3. Removethe screws,then removethe rearviewmir-

--Gl ror.
lnstallationis the reverseof the removalprocedure
SCREW
5x0.8mm
4 N,m {0.{ kgf.m,
3 tbf.ftt RUBBERDAMPER
JOINT PIN
-6,l
MIRRORHOLDER
SHOPTOWEL
2. lnstallationis the reverseof the removalprocedure
NOTE: Apply greaseto the locationsindicatedby

tne arrows.
REARVIEW
MIRROR
MirrorCoverReplacement
>: Screw locations
A>.3 s>,2
d\.nri''i.'.'i.i-. ] d\.,.,',r.,+.
\{ P#'/u2
II
':::_)
)
To removethe screws, -ln=T-
pullthe sealaway.
VIf.
.ll) |U
._.[__
SHOPTOWEL
MIRRORBASE
20-25
Windshield,RearWindow and OuarterGlass
Index
NOTE:The numbersafterthe part namesshow the quantitiesof the partsused.
Windshield(2Dl3D/4D):
MOLDING
UPPERRUBEEF
RearWindow {2Dl4D}:
FASTENER, 4
REARWINDOW (Selt-adhesive-type,
glassside)
Removal,page20-32
page20-33
Installation, I FASTENER,4
/
/ body side}
{Self-adhesive.rype,
* . /
d
SPACER,
w
g
@
20-26
RearWindow {3D):
FASTENER, ,T
glassside)
lSelf-adhesive-type,
SPACER,
| ,o.r.".*, n
I
Iff'".*-.Y'e'bod'side)
DAM,2
RUBBER
Removal,page 20-36
tI \
page20-37
Installation, \
SEALA, 1
SEAL8 , 2
Ouarter Glassi
3D: UPPERCLIP
2Di
(Self-adhesive-type)
OUARTERGLASS OUATERGLASS
Removal,Page20-40 Removal,page20-45
Page20_41
lnstallation, OUARTER page20 46
Insrallation,
h\f
GLASSTRIM
(Selt adhesive-type,
rr-il
body side)
(--/ /:=
\il n FASTENER
type,
{Sell-adhesive
glassside)
LOWERCLIP
(Self-adhesive
type)
LOWERCLIP
LOWERRUBBER (SelI-adhesive
type)
DAM
20-27
Windshield
Removal
\
CAUTION: 4. Apply protectivetape along the edge of the dash-
. Wearglovesto removeand installthe windshield. b o a r d a n d b o d y a s s h o w n . U s i n ga n a w l , m a k e a
. Use seat coversto avoid damaging any surfaces, h o l e t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ef r o m
i n s i d et h e c a r . P u s ht h e p i a n ow i r e t h r o u g ht h e
1. To removethe windshield,first removethe: hole,and wrap eachend arounda pieceof wood.
. Rearviewmirror (seepage20 25)
. Sunvisorsand holders(seepage20 64)
. F r o n tp i l l a rt r i m ( s e ep a g e s2 0 - 5 9 , 6 0 , 6 1 ) PIANOWIRE PROTECTIVE
. Windshieldwiper arms and cowl cover(seepage UPPER tit'
RUBBER
I
20 113\
DAM
WINDSHIELD
2. Peel oll the molding, and removethe glass brack
ets. ADHESIVE
NOTE: When molding removal is difficult,cut the

moldingwith a knife.
MOLDING
PROTECTIVE
TAPE
wlNDSHIELD
DASHBOARD
aoxesrir lowEB DEFOGGEB
BUBBER SEAL
OAM
5. W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n ow i r e
backand forth in a sawingmotion,and carefullycut
t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ea r o u n dt h e
entirewindshield.
CAUTION: Hold the piano wire as closeto the wind-

shield as possible to prevent damage to the body
and dashboard,
3. Pull down the front of the headliner{see page 20-

64).
CAUTION: Take care not to bend the headliner

excessively.
6. Carefully remove the windshield.
20-28
lnstallation
1. Using a knife,scrapethe old adhesivesmooth to a 4. G l u e t h e r u b b e rd a m a n d f a s t e n e r st o t h e i n s i d e
thicknessof about2 mm (0.08in) on the bondingsur faceof the windshieldas shown.
Iacearoundthe entirewindshieldopeningtlange
NOTE:Be carefulnot to touch the windshieldwhere
NOTE: adhesivewill be applied.
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding.
. Removethe rubberdams and tastenersfrom the
body.
. Maskoff surroundingsurfacesbeforepainting.
2. Cleanthe body bondingsurfacewith a spongedamp-

enedin alcohol. {0.53inl ALIGNMENT
\._- - !41Ks _
N O T E :A f t e r c l e a n i n g k, e e p o i l , g r e a s ea n d w a t e r
ALIGNMENT
from gettingon the surface. MARK
3 . lf the old windshieldis to be reinstalled,use a putty

knife to scrapeoff all traces of old adhesive,then
c l e a nt h e w i n d s h i e l ds u r f a c ew i t h a l c o h o lw h e r e
new adhesiveis to be applied. '13.smm
10.53in)
NOTE: Make sure the bonding surlaceis kept free
of water,oil and grease. LOWERRUBBER
DAM
CAUTION:Avoid setting the windshield on its edges;
small chips may later developinto cracks. WINDSHIELD
NOTE: 5. Align and glue the molding to the edgeof the wind
. Cleanthe shadowedarea. shield.
o Cleanarea@ as shown.
lnside NOTE: Be careful not to touch the windshield where
JL
WINDSHIELD
WINDSHIELD Apply primer(3M N 200,or equivalent)

to edge (cont'd)
of the windshield.
20-29
Windshield
Installation (cont'dl \
Installtheglassbracketsand fastenersas shown. 9. With a sponge,apply a light coat of glass primer

aroundthe edge of the windshieldas shown, then
NOTE:The numbersafterthe part namesshow the lightlywipe it off with gauzeor cheesecloth.
quantitiesot the partsused.
NOTE:
. Do not apply body primerto the windshield,and
do not get body and glassprimerspongesmixed
up.
. Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the wind-
shieldproperly,causinga leakafterthe windshield
is installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface. Applyglassprimer
/fu
, apptygt .. primerhere.
9.5mm
{0.37in)
RUBBERDAM
FASTENER
WINDSHIELD
GLASSBRACKETS,
2
MOLDING
7. Set the windshieldon the glass brackets,then cen

ter it in the opening.Make alignmentmarksacross
the windshieldand body with a greasepencilat the
four pointsshown. WINDSHIELD
10. With a sponge,apply a light coat of body primer to
NOTE:Be carefulnot to touch the windshieldwhere t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e w i n d -
adhesivewill be applied. shield openingflange. Let the body primer dry for
at least10 minutes.
NOTE:
. Do not applyglassprimerto the body.and be care-
ful notlo mix up glassand bodyprimersponges.
. Nevertouchthe primedsurfaces with your hands.
. Maskoff the dashboardbeforepaintingthe flange.
)./////
/////// : Applr bodv wime. here.
6mm 16mm 5mm 16 mm
(0.2{in) {0.63in} 10.2in) In)
BRACKETS
NOTE:Adjustthe glassbrack-
etsto centerthe windshieldin
the opening,then tightenthe
SCREW
8. R e m o v et h e w i n d s h i e l d .
20-30
1 1 . Thoroughlymix the adhesiveand hardenertogether 14. Use suction cups to hold the windshield over the
on a glassor metalplatewith a putty knife. opening,align it with the alignmentmarks made in
step7, and set it down on the adhesiveL . ightly
NOTE: push on the windshielduntil its edge is fully seated
. Cleanthe platewith a spongeand alcoholbefore on the adhesiveall the waYaround.
mrxrng.
. Followthe instructionsthat come with the adhe- NOTEI Do not openor closethe doorsuntil adhesive
sive. is dry.
ALIGNMENTMARK
12. Beforelilling a cartridge,cut the end of the nozzle

as shown.
C u t n o z z l ee n d
10 mm (0.39in)
7 mm (0.27inl
1 5 . Scrapeor wipe the excessadhesiveoff with a putty

Packadhesiveinto the cartridgewithout air pockets knifeor towel.
to ensurecontinuousdelivery.Putthe cartridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d NOTE:To removeadhesive from a paintedsurfaceor
the edgeof the windshieldas shown. wipewith a softshoptoweldampened
the windshield,
with alcohol.
NOTE|Apply the adhesivewithin 30 minutesafter
applyingthe glassprimer. 1 6 . Letthe adhesivedry for at leastone hour,then spray
water over the windshieldand checkfor leaks.Mark
12mm (0.47in)
-tl
the leakingareas,let the windshielddry, then seal
1 Make a slightly thicker
with sealant.
i .,1 aouestvr bead at each corner.
NOTE:
,T"Irr,,,", 5mm . Letthe car standfor at leastfour hoursafterwind
(0.2in)
MOLDING
-_rr shieldinstallation.lf the car hasto be usedwithin
the firstfour hours.it must be drivenslowly.
. Keepthe windshielddry for the first hour after
-/lr:.-,j.'o'.uo
\--.. installation.
/ \ . Checkthat the ends of the side molding are set
/
WINDSHIELD
w underthe air scoop.
LOWER 1 7 . Reinstallall remainingremovedparts.

RUBBER
FASTENER OAM NOTE:
. Installthe rearviewmirror rubber damper after
LOWER
RUBBER the adhesivehasdriedthoroughly.
DAM . Advisethe customernot to do the following things
for two to three days:
10.04inl
- S l a m t h e d o o r sw i t h a l l t h e w i n d o w s r o l l e d
up.
- T w i s t t h e b o d y e x c e s s i v e l y( s u c h a s w h e n
WINDSHIELD
going in and out of drivewaysat an angle or
drivingover rough,unevenroads).
20-31
RearWindow
Removal
2DI1D: 4. Apply protectivetape alongthe edge of the body as
shown. Usingan awl, makea hole through the
CAUTION: adhesivefrom insidethe car. Push the piano wire
a Wgar gloves to remove and install the rear window. t h r o u g ht h e h o l e ,a n d w r a p e a c h e n d a r o u n da
. Use seat coversto avoid damaging any surfacss. pieceof wood.
. Do not damage the rear window defogger grid lines,
window antenna grid lines, and terminals. PIANOWIRE
1. To removethe rearwindow,first removethe: ADHESIVE

. Trunk lid REARWINDOW
. Rearseatcushion(seepages20-79.81)
. Rearseatside bolsters(4D,seepage20-791
PEOTECTIVE
. Rearseat-back(2D,seepage20-81) TAPE
. Rearshelf(seepages20-59,61)
. Rearpillartrim (4D,seepage20-59)
. Sidetrim panel(2D,seepage20-61)
. Ouartertrjm panel(2D,see page20-61)
. Rearroof trim (seepage20-65)
2. D i s c o n n e ctth e r e a r w i n d o w d e f o g g e rc o n n e c t o r
from eachside. PIANOWIRE
3. Peeloff the molding.

PROTECTIVE
NOTE:When molding removal is difficult.cut the TAPE
moldingwith a knife.
ADHESIVE
MOLOING
With a helper on the outside, pull the piano wire

backand forth in a sawing motion,and carefullycut
il"*t, t h r o u g ht h e a d h e s i v ea r o u n dt h e e n t i r er e a r w i n -
dow.
^D.HE:tyE
._ --,/// CAUTION: Hold the pisno wire as close to the rear
REARWINOOW window as possibleto prevent damageto the body.
S
MOLOING
6. Carefullyremovethe rearwindow.
20-32
lnstallation
1. Using a knife,scrapethe old adhesivesmooth to a 4. Apply the double faced adhesivetape (NITTO501,
t h i c k n e s so f a b o u t2 m m ( 0 . 0 8i n ) o n t h e b o n d i n g or equivalent)to the edge of the rearwindow,then
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g installthe moldingaroundthe edge of the rearwin
flange. dow as shown.
NOTE: N O T E : B e c a r e f u ln o t t o t o u c h t h e r e a r w i n d o w
. Do not scrapedown to the paintedsurfaceof the w h e r ea d h e s i v w
e i l l b ea p p l i e d .
b o nd i n g ALIGNMENT
MARK
. Maskotf surroundingsurfacesbeforepainting. ADHESIVETAPE
. R e m o v et h e f a s t e n e r sa n d s p a c e r sf r o m t h e 867mm {34.1in)
DOOy.
5mm
C l e a nt h e b o d y b o n d i n g s u r f a c ew i t h a s p o n g e (0.2inl
dampened in alcohol. ADHESIVE
TAPE
N O T E :A f t e r c l e a n i n g k, e e po i l , g r e a s ea n d w a t e r Thickness:
0.'16mm {0.006inl
from gettingon the surface.
MOLDING
3. usea putty
lf the old rearwindow is to be reinstalled, ALIGNMENT
knifeto scrapeoff all tracesof old adhesiveand the MARK
rubberdam,then cleanthe rearwindow surfacewith
alcoholwherenew adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free MOLOING

of water,oil and grease.
WlNDOW
CAUTION:Avoid setting the rear window on its
edges;small chips may later develop into cracks.
NOTE:Cleanthe shadowedarea. 5. Gluethe fastenersand spacersto the insideface of

the rearwindow as shown.
N O T E : B e c a r e f u ln o t t o t o u c h t h e r e a r w i n d o w
w h e r ea d h e s i v w
e illbeapplied.
MOLDING >: Fastener,spacer

loc6tions
A >. 4 FASTENER
--=,
I ALIGNMENT
\ M MARKS
A
B> , 2
Outside
REARWINDOW
(cont'dl
20-33
RearWindow
(cont'd)
Installation
6. Gluethe fastenersto the body as shown. 9 . W i t h a s p o n g e ,a p p l y a l i g h t c o a t o f g l a s sp r i m e r
aroundthe edgeof the rearwindow as shown,then
Fastenerlocations,4 lightlywipe it off with gauzeor cheesecloth.
FASTENER
NOTE:
\ e l . Do not apply body primer to the rear window,
4i< ) and do not get body and glass primer sponges
mixed up.
l Y l
F_L^NGE
NycH,/,/
lf you do, the adhesivemay not bond to the rear
window properly, causing a leak after the rear
window is installed.
from the primedsurface.
'//f
, appty gtassprimerhera.
10 mm 10.39in)
GLASS All around.
t
I
MOLDING
1. Set the rear window, then centerit in the opening.

Make alignmentmarksacrossthe rear window and FASTENER
bodywith a greasepencilat the four pointsshown. REARWINDOW
10. With a sponge,apply a light coat of body primerto

t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n d t h e r e a r
ALIGNMENT
MABK window openingflange.Letthe body primerdry for
at least10 minutes.
NOTE:
. Do not applyglassprimerto the body,and be care-
ful notto mix up glassand bodyprimersponges.
S
''/fu7.
, oort, Aoa,orimerhere. 1 6m m
{0.63inl
16 mm 7mm
In, 10.28in)
8. Removethe rearwindow.
20-34
'14. Use suctioncups to hold the rear window over the
1' t. Thoroughlymix the adhesiveand hardenertogether
on a glassor metalplatewith a pufty knife opening,align it with the alignmentmarksmade in
step7, and set it down on the adhesiveL . ightly
NOTE: p u s h o n t h e r e a rw i n d o w u n t i l i t s e d g e sa refully
. Cleanthe platewith a spongeand alcoholbefore seatedon the adhesiveall the way around
mrxrng.
. Followthe instructionsthat came with the adhe NOTE:Do not openor closethe doorsuntilthe adhe-
sive. siveis dry.
1 2 . Beforefilling a cartridge,cut the end of the nozzle SUCTION ALIGNMENT

as snown. CUPS MARK
10 mm 10.39inl
7 mm {0.27inl
1 3 . Packadhesiveinto the cartridgewithout air pockets

to ensurecontinousdelivery.Put the canridgein a
c a u l k i n gg u n , a n d r u n a b e a do t a d h e s i v ea r o u n d
the edgeof the rearwindow as shown.
1 5 . Scrapeor wipe the excessadhesiveoff with a putty
NOTE:Apply the adhesivewithin 30 minutesafter knifeor towel.
applyingthe glassprimer.
NOTE:To removeadhesivefrom a paintedsurface
Make a slightly thicker or the rear window, use a soft shop lowel damp-
12 mm 10.47inl bead at each corner. enedwith alcohol.
GLASS
oo"r'u. 1 6 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
[/
-+- s p r a y w a t e r o v e r t h e r e a r w i n d o w a n d c h e c kf o r
8 mm (0.31in) leaks.Mark the leakingareas,let the rear window
dry, then sealwith sealant.
NOTE:Let the car sland for at leastfour hoursafter

re4window installation.lf the car has to be used
within the first four hours,it must be drivenslowly.
1't. Reinstallall remainingremovedparts.
NOTE:Advisethe customernot to do the following

thingsfor two to threedays:
. Slamthe doorswith all the windows rolledup.

. Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough,unevenroads).
20-35
RearWindow
Removal
3D: Upperportion:
CAUTION:
. Wear gloves to remove and install the rear window.
. Use seat coversto avoid damaging any surlaces.
. Do not damagethe real window defoggergrid lines.
. Take care not scratch the rear window molding.
t . t o removethe rearwindow,first removethel

a Rearcentershelf(seepage20-60)
a H a t c h u p p e r t r i m , h a t c ht r i m p a n e l a n d h a t c h
sidetrim (seepage20-63) TAPE
Rearwindow wiper arm {seepage20-115)
Hatchspoiler(seepage20-101) Side portion:
D i s c o n n e ctth e r e a r w i n d o w d e f o g g e rc o n n e c t o r GLASS
from eachside.
3. Apply protectivetape to the inner edge of the tail

gare.
4. From insidethe hatch,usea knifeto cut throughthe

rearwindow adhesiveall the way around.
NOTE:
. lf the rear window is to be reinstalled,take care
not to damagethe molding. Lower Dortion:
. lf the molding is damaged,replacethe rearwin
dow and moldingas an assembly
MOLDING
HATCH
's>
G^Yb\ x ADHESIVE
Carefullyremovethe rearwindow.
NOTE:Checkthe moldingfor damage,and replace

the rearwindow if necessary.
BEARWINDOW
20-36
lnstallation
'1. 4. Glue the rubberdams to the insidetace of the rear
Using a knife,scrapethe old adhesivesmoothto a
t h i c k n e s so f a b o u t 2 m m ( 0 . 0 8i n ) o n t h e b o n d i n g window, as shown, to containthe adhesiveduring
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g and gluethe fasteners,spacerand seals
installation,
flange. as shown.
NOTE: NOTE:
. Do not scrapedown to the paintedsurfaceof the . Gluethe rubberdams usingthe printeddots as a
body; damaged paint will interferewith proper g ul d e .
bonding. . Be careful not to touch the rear window where
. Removethe rubberdams, spacersand fasteners a d h e s i vw
e illbeapplied.
from the hatch. >: Fastener, spacer6ndseal
. Mask off surroundingsurfacesbefore applying locations
primer. a >,4 B > ,1
FASTENER SPACER
2. C l e a nt h e h a t c h b o n d i n g s u r f a c ew i t h a s p o n g e
dampened in alcohol.
N O T E :A f t e r c l e a n i n g ,k e e p o i l , g r e a s eo r w a t e r
D> , 2
l f t h e o l d r e a r w i n d o w i s t o b e r e i n s t a l l e du, s e a
Insid.
putty knife to scrapeoff all tracesof old adhesive,
t h e n c l e a nt h e r e a r w i n d o w s u r f a c ew i t h a l c o h o l
where new adhesiveis to be applied.
NOTE:Makesurethe bondingsurfaceis keptfree of

water,oil and grease.
-d' -f--At
RUBBER
CAUTION:Avoid setting the rear window on its
edges;the molding can be psrmanently deformed.
NOTErCleanthe shadowedarea.
REARWINOOW
FASTENER PRINTEDDOTS
REARWINDOW
RUBBER
DAM
MOLDING
(cont'd)
20-37
RearWindow
lnstallation {cont'd)
Installthe fastenersto the hatchas shown. 8. With a sponge, apply a light coat of glass primer
around the edge of the rear window, then lightly
>: Fastener
locations,
4 wipe it oif wirh gauzeor cheesecloth.
NOTE:
. Do not apply body primer to the rear window,
and do not get body and glass primer sponges
mixed up.
Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the rear
window properly, causing a leak after the rear
window is installed.
Keep water, dust. and abrasivematerialsaway
V//////7, , eppv stassc,im6, h6r6.
Insido I
V, llsmm
I W-- ]10.59 inl
N r t
/
AN I \\
*
cr-l'ss \
SPACER
REARwlNOOW \
Set the rearwindow uprighton the hatch,then cen-

ter it in the opening.Make alignmentmarksacross
the rear window and body with a greasepencil at
the four pointsshown.
NOTE: Be carefulnot to touch the rearwindow where

adhesive
will be applied.
7. Removethe rearwindow.
20-38
9. With a sponge,apply a light coat of body primer to 12. Packadhesiveinto the cartridgewithout air pockets
t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n d t h e r e a r to ensurecontinuosdelivery.Put the canridgein a
window openingflange.Letthe body primerdry for c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d
at least10 minutes. the edgeof the rearwindow as shown.
NOTE: NOTE:Apply the adhesivewithin 30 minutesafter

. Do not applyglassprimerto the body,and be care- applyingthe glassprimer.
tul not to mix up glassand bodyprimersponges.
///////l ' aooV roay primerhere.

i:EI^,T_/:aDHEs,vE
8mm
{ 0 . 3 1i n l
l6 mm
{0.63in)
--_Jr--
DZT ro.ornr
tEt
JI\
, / N \SPACER
GLASS
REARWINDOW
22 Jnm
1 0 . Thoroughlymix the adhesiveand hardenertogether

on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mrxrng.
. Followthe instructionsthat came with the adhe-
sive,
11. Beforefilling a cartridge,cut the end of the nozzle MOLDING

as shown.
GLASS -----ll
Cut nozzle
'10mm
{0.3Sin) f\-L,-- int
to.oe
ffi-f
MOLDING,-
,,.17
\
7 mm {0.27in)
(cont'd)
20-39
RearWindow OuarterGlass
Installation (cont'd) Removal
13. Use suctioncups to hold the rear window over the 3D:
o p e n i n ga, l i g ni t w i t h t h e a l i g n m e nm
t a r k sm a d ei n
step6, and set it down on the adhesive.Lightlypush CAUTION:
on the rear window until its edgesare fully seated a Wear gloves to remove and install the quarter glass.
o n t h e a d h e s i v ae l l t h ew a y a r o u n d . a Use seat coversto avoid damaging any surfaces.
NOTE:Do not openor closethe doorsuntilthe adhe- 1. To removethe quarterglass,first removethe:

siveis dry. . Rear seat-backand rear seat cushion (see page
20_80)
SUCTION . Rear center shelf and rear side shelf (see page
cuPs 20-60)
R e a rt r i m p a n e la n d s i d e t r i m p a n e l ( s e ep a g e
20-60)
l Upper anchorbolts from the front and rear seat
.J 2.
belts{seepages20 86, 89)
Ouanertrim panel(seepage20-60)
From insidethe car, use a knifeto cut through the

quarterglassadhesiveall the way around.
NOTE:
. lf the clip on the rear edge is broken,the quarter
glasscan be reinstalled usingbutyltape(seepage
20-421.
. Apply protectivetape alongthe edgeofthe entire
quarterglassopeningflange.
1 4 . Scrapeor wipe the excessadhesiveoff with a putty \

knifeor towel.

or the rear window, use a soft shop towel damp-
enedwith alcohol.
L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
s p r a y w a t e r o v e r t h e r e a r w i n d o w a n d c h e c kf o r
leaks.Mark the leakingareas,let the rear window
NOTE:Let the car standfor at leastfour hoursafter

rear window installation.lf the car has to be used
1 6 . Reinstallall remainingremovedpans.

thingsfor two to threedays: GLASS
. Slam the doorswith allthe windows rolledup.

i n a n d o u t o t d r i v e w a y sa t a n a n g l e o r d r i v i n g
20-40
Installation
Upper portion: Using a knife,scrapethe old adhesivesmooth to a
t h i c k n e s so f a b o u t 2 m m ( 0 . 0 8i n ) o n t h e b o n d i n g
s u r f a c ea r o u n dt h e e n t i r e q u a r t e rg l a s s c p e n i n g
tlange.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
RUABER
DAM
bonding.
. Removethe rubberdamsfrom the body.
ADHESIVE . lf any of the clips are broken,removethem from
the body.
PROTECTIVE . Mask off surroundingsurfacesbefore applying
TAPE pnmer.
Lower portion:
2. Cleanthe body bondingsurfacewith a spongedamp-
enedin alcohol.
N O T E :A f t e r c l e a n i n g k. e e p o i l , g r e a s ea n d w a t e r
PROTECTIVE
TAPE
3. lf the quaner glass is to be reinstalled,use a putty
cleanthe quarterglass surfacewith alcoholwhere
ADHESIVE
adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free

of water,oil and grease.
Pillar portion:
CAUTION:Avoid setting the quarter glass on its
OUARTER edges;small chips may later develop into cracks.
GLASSTRIM
NOTE:Cleanthe shadowedarea.
ADHESIVE
CLIP
3. Carefullyremovethe quarterglass.
N O T E :C h e c kt h e q u a r t e rg l a s st r i m a n d c l i p s f o r
damage,and replacethem if necessary.
(cont'd)
20-41
OuarterGlass
Installation {cont'dl
Gluethe upperand lower rubberdams to the inside 6. lf the old quarterglass is to be reinstalled(and the
face of the quarterglass,as shown, to containthe c l i p o n t h e r e a r e d g e i s b r o k e no f f ) , a p p l y a l i g h t
adhesiveduring installation. coat of primer (3M C-100,or equivalent), then apply
butyl tape to the quarterglass.as shown. and seal
N O T E :B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s the body holewith pieceof urethanetape.
where adhesivewill be applied.
>: Alignment mark NOTE:
'o""tton" o Be careful not to touch the quarter glasswhere
oao""
UPPER
OUARTER
t
--f-_1_- l adhesivewill be applied.
RUBBERDAM
GLASS r-'J--.i.. . Do not peelthe separatoroff the butyl tape.
mml tT-
13.5 I
i l 0 . 1 i4n l I '//////7r,
RUBEER : eug tape tocstions(3M8628,or equivelent)
\ Thickn*s:3.2mm 10.13 inl
\ DAM
Width:6.4mm 10.25 inl
LOWER
BUBBER
DAM
Installthe quarter glass trim on the quarter glass,

then gluethe upperand lower clipsas shown.
\
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
where adhesivewill be applied.
UPPER OUARTER
GLASSTRIM
NOTE:Contactthe clipsagainstthe
quarter9lasstrim at the areas
indicatedby the arrows.
20-42
7. With a sponge,apply a light coat of glassprimerto 8. With a sponge,apply a light coat of body primerto
the insideface of the quarterglass,as shown,then the originaladhesiveremainingaroundthe quarter
lightlywipe it off with gauzeor cheesecloth. glassopeningflange.Let the body primer dry for at
least10 minutes.
NOTE:
. Do not apply body primer to the quarter glass, NOTE:
and do not get body and glass primer sponges . Do not apply glass primer to the body, and be
mixed up. c a r e f u ln o t t o m i x u p g l a s sa n d b o d y p r i m e r
. Nevertouchthe primedsurfaceswith your hands. sponges.
It you do, the adhesivemay not bondto the quar- . Nevertouchthe primedsurfaceswith your hands.
ter glassproperly,causinga leak afterthe quar . Maskoff the rearside trim panel beforepainting
ter glassis installed. t h ef l a n g e .
from the primedsurface. ////////7 : aootvbodv odmerhere. 1 6m m
(0.63inl
//////// ' eooV st.,. primerhere.
21 mm 15 mm
lo.tB io) {0.59inl
OUARTER
GLASSTRIM
Thoroughlymix the adhesiveand hardenertogether

on a glassor metalplatewith a putty knife.
NOTE:
mr x r n g .
. Followthe instructionsthat came with the adhe-
stve.
15 mm 30 mm 10. Beforefilling a cartridge.cut the end of the nozzle

{0.59in) lr.2 in) as shown.
C u t n o z z l ee n d
in)
10 mm 10.39
7 mm 10.27in)
(cont'd)
20-43
OuarterGlass
Installation {cont'd)
11. Packadhesiveinto the cartridgewithout air pockets 12. Use suctioncups to hold the quarterglassover the
to ensurecontinuousdelivery.Putthe cartridgein a opening.alignthe clips,and set it down on the adhe
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d sive.Lightlypush on the quarterglassuntil its edges
the edgeof the quarterglassas shown. arefully seatedon the adhesiveall the way around.
NOTEI N O T E : D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
. lf the old quarterglass is to be reinstalled,peel adhesiveis drv.
the separatoroff the butyl tape afterapplyingthe
adhesive.
. Apply the adhesivewithin 30 minutesafterapply-
ing the glassprimer.
li.;l,l/:ADHE','E
8mm
{0 3'l inl
22.5nm
OUARTER {0.89in)
GLASSTRIM
CLIP
UPPER
RUBBER
DAM
Scrapeor wipe the excessadhesiveoff with a putty
knifeor towel.
BUTYL
TAPE
or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
spray water over the quarter glass and checkfor
leaks.Mark the leakingareas,let the quarter glass
LOWER
NOTE:Let the car standlor at leastfour hoursafter
RUBBER
DAM quarterglass installation.lf the car has to be used
1 5 . Reinstallall remainingremovedparts.

thingsfor two to three days:
. Slam the doorswith all the windows rolledup.

RUBBER
DAM i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
20-44
Removal
2Di Upper portion:
CAUTION:
. Wear gloves to remove and install th€ quarter glass.
. Use seat coversto avoid damaging any surfaces,
1. To removethe quaner glass,first removethe:

. Rear seat-backand rear seat cushion (see page
20-81)
. Sidetrim panel(seepage20-61)
ADHESIVE
. Rearshelf(seepage20-61)
o Upper anchor bolt from the front seat belt (see
page20 86)
. Ouanertrim panel(seepage20-61) PROTECTIVE
TAPE
2. Ftom insidethe car, use a knifeto cut through the Rear edge portion:
quarterglassadhesiveall the way around-
NOTE:
. lf the quarterglassis to be reinstalled,take care
not to damagethe molding.
. Apply protectivetape alongthe edgeofthe entire
quarterglassopeningflange.
a
Pillar portion:
TAPE
GLASS
Carefullyremovethe quanerglass.
NOTE:Checkthe moldingfor damag€,and replace

it if necessary.
20-45
OuarterGlass
Installation \
' t . Using a knife,scrapethe old adhesivesmooth to a 4. Installthe molding around the edge of the quarter
t h i c k n e s so f a b o u t 2 m m ( 0 . 0 8l n ) o n t h e b o n d i n g glassas shown.
s u r f a c ea r o u n d t h e e n t i r e q u a r t e rg l a s s o p e n i n g
flange. NOTE:
. It the old molding is to be reinstalled,scrapeoff
NOTE: t h e o l d a d h e s i v et a p e f r o m t h e m o l d i n g ,a n d
. Do not scrapedown to the paintedsurfaceof the c l e a nt h e m o l d i n g s u r f a c ew i t h a l c o h o lw h e r e
body; damaged paint will interferewith proper new adhesivetape is to be applied.Apply the
bonding. double-facedadhesivetape to the molding and
. Removethe fastenerfrom the body. quarterglassas shown.
. lf any ot the clips are broken,removethem from . Be carelul not to touch the quarter glasswhere
the body. adhesivewill be aDDlied.
o Mask off surroundingsurfacesbefore applying
primer. Adhesivetape A {3M 4215,or equivalentl
Thickness:0.4 mm (0.02inl
Cleanthe body bondingsurfacewith a spongedamp- Width: 5 mm 10.2in)
enedin alcohol. Length:440mm (17.3in)
NOTE: After cleaning,keep oil, greaseand water Adhesivetape B (NITTO501, or equivalontl

from gettingon the surface. Thickness:0.16 mm (0.006inl
Width: 8 mm 10.3inl
lf the quaner glass is to be reinstalled,use a putty Length:'140mm (17.3in)
cleanthe quarterglass surfacewith alcoholwhere Adhesivetape C {3M '1213,or equivalentl
adhesiveis to be applied. Thickness:0.8 mm (0.03inl
Width: 5 mm (0.2in)
NOTE: Make sure the bonding surfaceis kept tree Length:30 mm (1.2in)
of water,oil and grease. ADHESIVE
CAUTION:Avoid setting the quarter glass on its

edges;small chips may later develop into cracks.
NOTE:Cleanthe shadowedarea.
20-46
5. lf the old quarterglass is to be reinstalled,glue the 7. With a sponge,apply a light coat of glassprimerto
upperand lowerclipsand fasteneras shown. the insideface of the quarterglass,as shown,then
lightlywipe it off wjth gauzeor cheesecloth.
N O T E :B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
where adhesivewill be applied. NOTE:
. Do not apply body primer to the quarter glass,
>: Clip,tastenerloc.tions and do not get body and glass primer sponges
a>,2 B> , 1 mixed up.
ALIGNMENT 2.5mm . Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bondto the quar-
ter glass properly,causinga leak after the quar-
ter glassis installed.
t///////1 ' aooV wav orime,hero.
15.5mm 10 mm
MOLDING {0.61in) (0.39in)
6. Gluethe fastenerto the body as shown.
>: Fastener
locstion.1
ALIGNMENT
(cont'd)
20-47
OuarterGlass
Installation (cont'd)
With a sponge.apply a light coat ol body primer to 11. Packadhesiveinto the cartridgewithout air pockets
the originaladhesiveremainingaroundthe quarter to ensurecontinuousdelivery.Put the cartrigein a
glassopeningflange.Let the body primer dry for at c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d
least10 minutes. the edgeof the quarterglassas shown.
NOTE: NOTE:
. Do not apply glass primer to the body, and be . lf the old quarterglass is to be reinstalled.peel
c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r the separatoroff the butyltape afterapplyingthe
sponges. adhesive.
. Nevertouchthe primedsurfaceswith your hands. . Peel the separator off the adhesivetape after
. Maskoff the rear side trim panel beforepainting applyingthe adhesive.
the flange. . Apply the adhesivewithin 30 minutesafterapply-
ing the glassprimer.
t///////7, , epptyroay erimerhere.
1 . 5m m
i;.Ii^,/: ADHE'T'E
8mm
(0.31in)
CLIP
9. Thoroughlymix the adhesiveand hardenertogeth,

er on a glassor metalplatewith a putty knife.
NOTE:
mixing.
. Followthe instructionsthat came with the adhe
sive.
10. Beforefilling a cartridge,cut the end of the nozzle

as shown.
Cut nozzleend
10 mm {0.39in)
20-48
12. Use suctioncups to hold the quarterglassover the
o p e n i n g ,a l i g n t h e c l i p s , a n d s e t i t d o w n o n t h e
adhesive.Lightlypush on the quaner glassuntil its
edges are fully seatedon the adhesiveall the way
around.
N O T E :D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
adhesiveis dry.
CLIP
1 3 . Scrapeor wipe the excessadhesiveoff with a puny

knifeor towel.

or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
s p r a yw a t e r o v e r t h e q u a r t e rg l a s sa n d c h e c kf o r
leaks.Mark the leakingareas,let the quarterglass
dry,then sealwith sealant.
NOTE:Letthe car standfor at leastfour hoursafter

quarterglass installation.lf the car has to be used
within the firstfour hours,it must be drivenslowly.
Reinstallall remainingremovedparts.

thingsfor tlvo to three days:
. Slamthe doorswith all the windows rolledup.

. Twist the body excessivelylsuch as when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
20-49
Moonroof
lndex
SWTTCHPLATE
Adiustment,page20-56
=-.
CABLEASSEMBLY
page20-55
Replacement,
SUNSHADE
page20 52
Replacement,
INNERCABLE
RAIL HOI-DERB
SLIDER
RAIL HOLDERA
REARDFAIN
TUBE
, /
?<^
/ \ ?'''
UBE ll /
LfP ll ,
U 6
a"w
REARDRAIN
VALVE
FRONTDRAINTUBE
20- 5 0
Troubleshooting
Symptom ProbableCause
'1. Cloggeddraintube.
Waterleaks
2. Gap betweenglassweatherstripand roof panel
3. Defectiveor improperlyinstalledglassweatherstrip
4. Gap betweendrainsealand roof panel.
Wind noise 1. Excessiveclearancebetweenglassweatherstripand roof panel.
Motor noise 1. Loosemotor.
2. Worn gear or bearing.
3. Cableassemblydeformed.
'1. Clutchout of adjustment.
Glassdoes not move.but motor turns
2. Foreignmatterstuckbetweenguide rail and slider.
3. Innercableloose.
4. Cableassemblynot attachedproperly.
Glassdoes not move and motor does not turn 1. Blownfuse.
(glasscan be movedwith moonroofwrench) 2. Faultyswitch.
3. Batteryrun down.
4. Defectivemotor.
5. Faultyrelay.
GlassHeightAdjustment
The roof panel should be even with the glassweather
s t r i p , t o w i t h i n 1 . 7 l l t f m m ( 0 . 0 7l 3 & ' i n ) a l l t h e w a y
around.lf not, openthe glassfully, and:
1.7rl.3mm
{0.0713:3i
in)
1. Removethe bracketcover.
Loosenthe nuts, and installthe shims betweenthe

glassframe and glassbracketas shown.
Shim thickness:Frontmax.3 mm {0.12inl

Rearmax. 2 mm (0.08inl BRACKET 6x1.0mm
6xl.0mm
9.8 N m (1.0kgl m, COVER 9.8 N.m {'1.0kgI.m.
Repeaton oppositeside if necessary 7.2lbl.ltl 7.2lbtft)
20-51
Moonroof
Glass,GlassBracketand SunshadeReplacement \
1 . C l o s et h e g l a s sI u l l y . 6. R e m o v et h e d r a i n c h a n n e l .
2. Slidethe sunshadeall the way back. DRAINCHANNEL
3. Removeboth bracketcovers.
BRACKETCOVER
SCREW
Forward
4. Remove the nuts trom both glass brackets.
GLASSBRACKET 7. Remove the holder cover, then remove the

h o l d e rB .
NUT
6x1.0mm
9 N.m {0.9 kgf.m,
7 rbf.frl
{itt'za
6 x 'l.0mm
9.8N.m{1.0kstm,7.2lbfft)
Removethe glassby lifting up and pulling forward RAILHOLDERB

as shown. Usingthe moonroofwrench,move the glassbracket
to the positionwherethe moonroofnormallypivots
NOTE| Do not damagethe roof panel. down, and removethe screws.
GLASS
scREws
20-52
9. Removethe rail holderA. 12. Slidethe sunshadeforward,then removeit.
NUT
6x1.0mm
9 N.m {0.9 kgf m,
1 3 . Installationis the reverseof the removalprocedure.
NOTE:Checkthe glassheight(seepage20-51).
1 4 . Checkfor water leaks.
water'
NOTE:Do not use high-pressure
DRAINCHANNEL ROOSTOP
asshownto removeit fromtheguiderail.
Rotate
10, Removethe drain channelrod slider by moving the

cablesliderforwardusingthe moonroofwrench.
'11. Detachthe drain channelrod stop from the cutout
of the guide rail as shown,
I 20-53
I
Moonroof
Motor, DrainTubeand FrameReplacement
GAUTION:
. Wear gloves to remove and install the ftame.
. Be careful not to damagethe seats, dashboardand other interior trim.
1. Removethe headliner(seepage20-64).
2. Disconnect
the motor connectorand glasspositionswilch connector.
NOTE:when removingthe motor,detachthe connectorfrom the frame,removethe bolts and nuts.then removetne
motor.
3. Removethe glass{seepage20-52).
4. Disconnect
the draintubes,and detachthe ceilinglight harness.
5. Removethe frame mountingbolts.
NOTE:
. An assistantis helpfulwhen removingthe bolts.
. Removethe front bolts last.
6. Detachthe rearhooksby movingthe frameforward,then removethe frame.
Removelast,
BOLT
6x1.0mm
9.8Nm(1.0kgl.m,
7.2 tbl.tll
6 x 1.0mni
9.8 N.m 11.0kgf.m,7.2tbtfo
20-54
Guide Rails/CableAssemblY
Replacement
7. Pullthe draintubesout the front and rearpillars
CAUTION: Wear gloves to remove and install the guide
NOTE:Beforepullingout the draintube,tie a string railsand cableassembly.
to the end ot it so it can be reinstalled.
1. Removethe frame.
2. Removethe motor and glassbracket(seepage20 52)'
3. Removethe nuts, and liit off each guide rail, then

removethe cableassemblywith slidersattached'
NOTE:Take care not to bend the cable tubes and

g u i d er a i l s .
REARDBAIN
VALVE
lnstallationis the reverseof the removalprocedure'

GROMMET
NOTE:
. Beforeinstallingthe frame,clearthe drain tubes
and drainvalvesby usingcompressedalr. 4. Installationis the reverseof the removalprocedure'
. Checkthe frame seal.
. Cleanthe surfaceof the frame. NOTE:
. When installingthe trame, first attach the rear . Damagedpartsshouldbe replaced
hooksinto the body holes. . Greasethe slidingportionwith SuperHighTemp
. When connectingthe draintube, slide it over the UreaGrease,P/N08758- 9002.
frame nozzleat least10 mm (0.39in) . Fillthe groovein eachgrommetwith sealant.
t u b ec l i Pa s s h o w n .
. Installthe
Upward
I TUBECLIP
I
I DRAINTUBE
a lnstallthe frame sealsecurelY
a Beforeinstallingthe motor, makesure both slid-
9. Checkfor water leaks.
ers are parallel.
water.
NOTE:Do not use high-pressure Beforeinstallingthe motor, installthe trame and
glass,then checkthe openingdrag (seepage20-
57).
I
f 20-55
Moonroof
Switch PlateAdjustment(FullyClosedPositionl \
1. Removethe headliner{seepage20-64).
2. Usingthe moonroofwrench,closethe glassfully.
NOTE:Checkthe glassfit to the roof panel.
3. Usingan open-endwrench,loosenthe switchplatemountingbolts.
4. Adjustpositionof the switchplate(switchcam) as shown.
5. Checkthe operationof the glass(fromtilt-up positionto fully closedposition,from the fully open positionto the fully
closedpositjon)by operatingthe moonroofswitch.
NOTE:Checkthe glassheight{seepage20-51}.
SWITCHPLATE
GUIOE
PLATE
Vt,
,
I cneclthe
Checkrr switchplatecontactsthe
ccable
ao r eo r
bracket.
I
l c CABLE
, ERACKET
SWITCHCAM INNER CAELE END
While movingthe switchplate little by little,securethe switch

plate at the positionwherethe switchcam contactsthe switch
A (a faintclickis heard).
Closethe glassfully, and checktor water leaks.
NOTE: Do not use high-pressure

water.
2 0- 5 6
OpeningDragCheck ClosingForceCheck
(Motor Removed) (MotorInstalled)
Beforeinstallingthe motor, measurethe effort required 1 . A f t e r i n s t a l l i n ga l l r e m o v e dp a r t s ,h a v e a h e l p e r
to openthe glassusinga springscaleas shown. hold the switch to close the glasswhile you mea-
sure the force requiredto stop it. Attach a spring
CAUTION: When using a spring scale.plotest the l€ad- scaleas shown. Readthe force as soon as the glass
ing €dge of the glasswith a shop towel. stops moving,then immediatelyreleasethe switch
and springscale.
lf load is over 40 N (4 kgf,9 lbf),checkthe side clearance
a n d g l a s sh e i g h t( s e ep a g e2 0 - 5 1 ) . CAUTION: When using a spring scale, protect the
leading edge ol the glass with a shop towel.
Closing Force:200 - 290 N

SHOPTOWEL (20 - 30 ksf, /14- 66 lbf)
SCALE
lf the force in not within specification, installa new

lockwasher,adjust the tension by turning the motor
c l u t c h a d j u s t i n gn u t , a n d b e n d t h e l o c k w a s h e r
againstthe motor clutchadjustingnur.
LOCK
WASHEB
Replace.
aI COUNTER-
cLocKwtsE
To decrease
20-57
lnterior
ComponentLocationIndex
SRScomponentsare locatedin the pans areasmarkedwith an asterisk(*). Reviewthe SRScomponentlocauons,precau-
tions,and proceduresin the SRSsection(24)beforepertormingrepairsor service.
2D l3D llDl
FRONTPILLAR
CENTERPILLAR TRIM
(seepages20'59,60,61i
UPPERTRIM
CENTERPILLAR
LOWERTRIM PANEL {seepage20 59)
(seepage20 59)
REARPILLAR
TRIM
(seepage 20-59)
REAR
(seepage20-59)
TRUNK
TRIM
(seepage20-62)
SEAT ComponentRemoval/lnstallation,
SIDETRIM page20-68
(seepage20-59)
Removal,page20-70
TCARPET
page20-66
Feplacement,
PANEL
Replacement.page 20-67
3D: OUARTER 2Dl OUARTER

TRIM PANEL TRIM PANEL
(seepage20 60)
REARROOFTRIM
(seepage20 65) REARROOF
TRIM
HATCH {seepage20,65}
UPPER
TRIM
(seepage20 63)
REARCENTER
SHELF
(seepage 20-60)
REAR
PANEL
SIDETRIM
{seepage20-60} REAB
(seepage20-60) PANEL
(seepage20-62)
REAF
TRIM PANEL SIDETRIM (seepage20-6'1)
(seepage 20'63) PANEL
(seepage 20-60)
2 0- 5 8
lnteriorTrim
Replacement
CAUTION:
. Wear gloves to remove and install the trim and panels.
. When prying with a tlat tip screwdriver,wrap it wilh protective tape to prevent damage.
NOTE:Takecarenot to bend or scratchthe trim and panels
4D:
>: Clip locations

a>,2 8>,6 c>,21 o>,2 E> , 2
CLIP
retu n>( |
\Zl\ J
^f CLIP
REARSHELF
LOCKCYLINDERTRIM
FRONTPILLAR
TRIM
CENTERPILLAR
LOWERTRIM
PANEL
+ SEAT
BELTUPPER
ANCHOR
Disconnectthe
high mount brake
lightconnector.
(seepage20 85)
RIGHT KICK
PANEL
T SIOETRIM
Removethe rearseatcushionand rear
seatsidebolster(seepage20 79i.
lnstallationis the reverseof the removalprocedure.
NOTE:
. lf necessary,replaceany damagedclips.
. Beforeinstallingthe front seatbelt upper anchor
and rear shelt, make sure there are no twists or
kinksin the seatbelts.
(cont,d)
20-59
InteriorTrim
(cont'dl
Replacement
3D:
>: Clip locations >: Screw, bolt locations

a>,2 B>.3 c>,8 D>,3 E> , 8 a>,3 B>,6
CLIP
A i f , n \ l e
n l-,
rr,\\F\
i ## s qHP Y l*@
_ _ -/ _ 7 / \
,\\ \ \ ul\ / l c > .1 D> , 2
_ _ - CLIP ,r+n
/
F > ,1 { G>,2 H>,2
REARSEATBELT
l@@
I N '.,. ] rcig \ - - \--
N i 4 ) i @ i UPPERANCHOR
{seepage20-89)
|_) _t),t
)_w/ REARSIDE
SHELF
SIDETRIM
PANEL
Removethe rearseat-backand
FRONTSEAT rearseatcushion(seepage20-80)
EELTUPPER Disconnectthe rearspeaker
ANCHOR connector(bothsides,
(seepage20-86) for somemodels).
REARTRIM
PANEL
SIDETRIM PANEL
PROTECTOB
SIDETRIM
REARCENTER
SHELF
FRONT SEAT BELT
LOWER ANCHOR
(seepage 20 86) SPABETIRE
H
LID
Installationis the reverseof the removalprocedure.
NOTE:
. Beforeinstallingthe anchorbolts,makesurethere
are no twistsor kinksin the seatbelts.
20-60
2D:
>: Clip locations >: Screw locations,4
a>,2 B> , 3 c>, 14 D> , 3 E>,2
TRIM
F>,8 G>,4 H>,2

,. I r$H
N,tU ffi
FRONTPILLAR
SIDETRIM PANEL
Removethe rearseat-back
and
rearseatcushion(seepage
2 08 1 ) .
LOCKCYLINDER
TRIM
FRONTSEAT
EELTUPPER
ANCHOR
{seepage20-86)
SIDETRIM PANEL
the high
Disconnect
mount brakelight
connector.
SIDETRIM
PIVOTBRACKET
(seepage20-81)
SEATBELT
w' A LOWERANCHOR
(seepage20-86)
@
, \ .
/ " c NOTE:
ntoirrrcx . lf necessary.
replaceany damagedclips.
a . Beforeinstallingthe anchorbolts and rear shelf,
LEFTKICK makesurethereare no tvvistsor kinksin the seat
PANEL belts
20-61
TrunkTrim
Replacement
CAUTION:
. Wear gloves to remove and install the trim and panels.
. Whon prying with a flat tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:
. Takecarenot to bend or scratchthe trim and panels.
. When removingthe trunk sidetrim or trunktrim panel,fold the seat-back
torward.
Japan-produced: >: Clip locations

REARTRIM
a >,6
PANEL
4D: RIGHTTRUNK NOTE:Do not push
SIDETRIM the innerclip in too far.
I s CLIP
R-.--\ra I
I l'€3{aQ'F-
s:'\ " |NNER
I B
|
\\-
B>,6
cll
, -
t -
\--
i J
/tt
!l
i ) :Hook locations
TRUNKMAT Ai-), t
B t-'),2
2D:
TRUNK TRIM
(
NOTE:
. lf necessary, replaceany damagedcl;ps.
. To installthe A clips,pull the innerclip up, install
the clip,then pushthe innerclip until it'sflush.
20-62
HatchTrim
Replacement
CAUTION:
. Wear gloves to remove and install the trim.
. When prying with a flat tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:Takecarenot to bend or scratchthe trim and panel.
>: Cliplocations
a >' 2 I B> , 7 c>,13
NOTE:Do not pushthe I i
innerclip in too far. I r- r -N-l
IS]
M cr-rp.
54@-,1 vr:/ I
Y , /
",/
g * - \ |
:?- INNER ]
ct!,/
'Pr-u
a
c l
.rt-ATa-a-a
;--'"[1" c c
LEFTHATCH
SIDETRIM
HATCH
UPPERTRIM
Installation is the reverse of the removal procedure.
NOTE:
. lf necessary,replace any damaged clips.
. To install the A clips, pull the inner clip up. install
the clip, then push the inner clip until it's flush.
20-63
Headliner
Replacement
CAUTION: When prying with a flat tip screwdriver. 2. Remove the sunvisor and holder from each side.
wlap it with protective tape to prevent damage.
NOTE:
. Takecarenot to bendand scratchthe headliner.
. Be careful not to damagethe dashboardand other
interiortrim.
'1.
Remove:
4D:
a Frontpillartrim (bothsides,see page20-59)
a Centerpillarlowertrim panel(bothsides,seepage
20-59)
Upper anchorbolt from the front seat belt (both
sides,seepage20-85) 3. Removethe grab handlesand coathanger.
Centerpillaroutertrim and centerpillaruppertrim
(bothsides,seepage20-59)
a Ceilinglight (seesection23)
Rearviewmirror (seepage20-25) ACCESS
LID
3D:
. Frontpillartrim (bothsides,see page20-60)
. Right rear seat-backand rear seat cushion (see
page20-80)
. Rearcentershelf(seepage20-60) ACCESS
o R e a rs i d e s h e l f a n d s i d e t r i m p a n e l( r i g h ts i d e , LID scREws
seepage20 60)
. Upper anchorbolts from the front and rear seat
belts{right side,seepages20-86,89)
. Ouartertrim panel(rightside,see page20-50)
. Ceilinglight (seesection23) COATHANGER
. Rearviewmirror (seepage20-25) BRACKET
2Dl
. Frontpillartrim (bothsides,see page20-61)
. Right rear seat-backand rear seat cushion (see
page20-81)
. Sidetrlm panel(rightside,seepage20-61)
. Upper anchorbolt from the front seat belt (rlght
side,see page20-86)
. Ouartertrim panel(rightside,see page20 61)
. Ceilinglight (seesection23)
. Rearviewmirror (seepage20-25)
20-64
4. Remove the rear root trim and clips, and remove 2Dl
the roof trim and socket plug (moonroof model)
>: Clip locations

A> 20l40,7 B > With moonrool,1
3D,5 Withoutmoonrool,3
l
)At EE
% ) & )
2D l3D l4Dl
REARBOOF REAR
PILLAR
TRIM OUARTER
HEAOLINEB TRIM PANEL
5. 4D: Lowerthe rearpillartrim on both sides.

3D: Removethe upper anchor bolts from the front
and rearseatbelts(seepages20-86.89i,then lower
the quanertrim panelon left side.
2 D : R e m o v et h e u p p e ra n c h o rb o l t t r o m t h e f r o n t
seat belt (see page 20-86),then lower the quarter
trim panelon left side.
6. L o w e rt h e h e a d l i n e r .
7. Carefullyremovethe headlinerthroughthe passen-

ger'sdoor opening(2Dl4D)or hatchopening(3D)
8. Installationis the reverseoI the removalproceclure.
NOTE:
3D: . W h e n i n s e r t i n gt h e h e a d l i n etrh r o u g ht h e o p e n -
ing, be carefulnot to fold or bendit. Also,be care-
tul not to scratchthe body.
. C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e
securelyattachedto the trim.
. W h e n i n s t a l l i n gt h e r o o f t r i m , i n s t a l lt h e j o i n t
towardthe right side (moonroofmodel)
20-65
Carpet
Replacement
SRScomponentsare locatedin this area.Reviewthe SRS 4. Removethe footrestand parkingbrakelevermount-
componentlocations,precautions,
and proceduresin the ing bolts,and detachthe clips,then removethe car-
SRSsection(24)beforeperformingrepairsor service. pet.
1. Remove: >: Clip locations, >: Bolt locations

. Frontseat(seepage20-74l A>,2 B>.2
. Rearseatcushion(seepages20-79,80,81)
rft I O 6x'l.0mm
Kickpanel(seepages20-59,60, 61) \ t l 9s l / tf I e.sN.mt1.oksrm,

E / 7 2 tbrftl
Centerpillarlowertrim panel(4D.seepage20,59)
a Frontseat belt lower anchor(2Dl3D,see page20- 2Dl3Dl4D:
86) FOOTREST
a Sidetrim {seepages20-59,60, 61)
a Frontand rearconsoles
a Consolepanel
Removethe SRSunit covers.
3 . Cut areas@ and @ in the carpet,then pull it backas

snown.
>: Cliplocetions,
2
--.ils
- I
-llp -
l@l
|
LEFTSRS
UNIT COVER
2D l3Dl
SIDETRIM
NOTE:
. Takecarenot to damage,wrinkleor twist the car
pet.
. Make surethe wire harnessesare routed correctly.
. Slip the carpet under the seat side trim (4D) or
sidetrim panel(2Dl3D)on eachside properly.
. Reattachthe cut areas@ and @ in the carpet
with wire ties.
20- 6 6
Panel
Consoles/Console
Replacement
NOTE:Takecarenot to scratchthe front and rearconsoles,front seatand relatedparts.
Disassemble
in numberedsequence.
>: Screw locations >: Clip localions

A>,8 A>./t A>,2 B>,2
-f
D7777777v-r
i
0F* @@'
: ) " ) _ : )
(' FRONTCONSOLE
Remove the shif! lever knob {M,/T).
o REARCONSOLE
lwith armrest)
^\
Installation of the removalprocedure.

is the reverse
NOTE:
. replaceany damagedclips.
lf necessary,
. Makesurethe wire harnessesare not pinched.
. Makesurethe connectoris connectedproperly.
20-67
Dashboard
ComponentRemoval/lnstallation
CAUTION:when plying with a flat tip screwdriver,wrap Driver'sdashboardlower cover and knee bolster removal:
it with protectivetape, and apply protectivetape around
the related parts,to prevent damage. SRScomponentsare locatedin this area.Reviewthe SRS
and proceduresin the
componentlocations,precautions,
NOTE:Takecarenot to scratchthe dashboardand related SRSsection{24}beforeperforming repairsor service.
parts.
1. R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n
Instrument panel removal: r e m o v e t h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r .l f
equippedwith power mirrorsand moonroof,discon-
1. Lowerthe steeringcolumn. nectthe connectors.
2. Removethe screws,and detachthe clips,then care-

fully removethe instrumentpanel.
>: Screw,bolt locations
a >,3 B>,2
>: Screw locations,2 >: Clip locations.2 --'4.i
***\Y /D,- ox lomm
((n1lfl )e.8 N m (l.o kgtm,
"[] I \)- 7.2tbf.ftl
p 1 >: Clip locations

a>.2 B>, 1
l J
d
F-,,
POWERMIRROR
SWITCHCONNECTOR
(for somemodels)
PANEL
3. lnstallationis the reverseof the removalDrocedure.
MU(,NTIUUI-
swtTcH
CONNECTOR
models)
DRIVER'S
DASHBOARD
LOWERCOVER
2. Removethe bolts,then removethe kneebolster.

Glove box removal: Center dashboardlower covsr:
'1.
Removethe bolts,then removethe glove box. Remove:
. Driver's dashboard lower cover
>: Boltlocations,
2
. Glove box
5xo.8mm I
9 N m lO.9ksf.m,I 2. Remove the screws and bolt. then remove the cen
'::" ter dashboard lower cover. Disconnect the accesso-
)
ry socket connector.
>: 8olt, scrsw locations

A>, I B>,5
A ,ro.r-- A
6:u;q9 Q,
lnstallationis the reverseot the removalorocedure.
Side air vent/Side defogger trim removal:
SIDEDEFOGGER
TRIM
C a r e f u l l yp r y r t a t t h e s i d e e d g e .
HOOKS
SIDEAIR VENT CENTERDASHBOARO

Removethe driver'sdashboardlower LOWERCOVER
cover,or openthe glovebox, CLIP
then pushthe clipstrom each
openingby hand,and pullit
out. Disconnectthe connedors HOOKS 3. Instgllation is the reverse of the removal procedure
(driver'sside).
DASHLIGHTS
BRIGHTNESS
CONTROLLER
l- [3LT'-""'31r",.,
CRUISECONTROL
MASTERSWITCH
CONNECTOR
(forsomemodels)
(cont'd)
20-69
Dashboard
ComponentRemoval/lnstallation Removal
(cont'd)
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
Center panel removal: SRS componentlocatlons,precautions,and procedures
in the SRSsection(24)beforepreformingrepairsor ser-
'1. Remove: vtce.
. Centerdashboardlowercover(seepage20-69)
. Radio(seesection23) NOTE:
. An assistanlis helpfulwhen removingand installing
2. Removethe rear window defoggerswitch and haz t h ed a s h b o a r d .
ard warningswitch,then disconnectthe connectors. . T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d y a n d
relatedparts.
>: Screwlocations,5 >: Cliplocations 1. Remove:

A>,4 B> , 3
. Frontand rearconsoles(seepage20-67)
i'Y . Consolepanel(seepage20-67)
6tr'
CENTER
@-Y-r . Driver'sdashboardlower cover and knee bolster
(seepage20-68)
. Glovebox {seepage20-69)
. Centerdashboardlowercover(seepage20-69)
2. Lowerthe steeringcolumn(seesection17)
@@ To avoid accidentaldeployment and

possiblo iniury, always disconnsct the driver's
airbag connector before lowering the steering col-
umn lsee section 2,1).
/w4,
ew
I
NOTE:To preventdamageto the steeringcolumn,
wrap it with a shoptowel.
HAZARD
I
WARNING
swrTcH
wI
N<4
Mtx
CONTROL
CABLE
3. Disconnectthe dashboardwire harnessconnectors,
remove the nuts, then move the under-dashfuse/
relay box. Disconnectthe antennalead and moon-
roof relayconnectors.
REAR
WINDOW MOONROOF oasHeolno 9LlPs SRSMAIN
CONTROL RELAY FRAME HARNESS
DEFOGGER
SWITCH UNIT CONNECTORS
(for somemodels)
Disconnectthe air mix controlcable,and removethe

screws,then pull out the centerpanel.
4. Disconnectthe connectorsfrom the heatercontrol

unrt.
is the reverseof the removalprocedure.

Installation
UNDER.DASH
NOTE: FUSE/RELAY
a Makesurethe connectorsare connectedproperly. BOX
. Adjustthe air mix controlcable(seesection21).
ANTENNA
LEAD
OATA DASHBOARO 6x1.0mm

CONNECTOR WIREHARNESS 9.8 N.m 11.0kg{.m,
Detach. CONNECTORS 7.2 tbt.tll
20-70
4. Removethe following partslrom the dashboard.
. Driver'sdashboardsidecover
. Passenger'sdashboardlower cover
. Dashboardcenterlid
5. the connectorsand air mix controlcable.

Disconnect
!!!@ To avoid accidental deployment and possible inlury, always disconnect the flont passenger'sai.bag
connector when the SRSmain harnessis disconnested(seesection 241
>: Bolt, screw localions

A>,7 B>,1 c>,1 D>,1
8x1.25mm I ,,{\ I x 1.25mm I l\- 6x1.0mm I

22 N-m 12.2kgl.m, )
16 tbt ftl
l[!,P 22N.m{2.2ksrm, I LBJIP e.6N rn11.s
,"-- _,J
1s1m,I @
/ : _:_'_"o'nt ___ L
>: Clip locations
A>, 1 B>,1 c>,5
OASHBOARD
,Jiill I .ll I vt)
ft,ffits
"ffi j M,i
/ffi) M
WT DASHBOARD
' | . 1 , / - - t t / - - - J
AIR MIX CONTROL
UNOER.OASH
FUSE/BELAY
PROTECTIVE BOX
PLATE
Loosenthe bolt.
r
I
PASSENGER'S
DASHBOARD
LOWERCOVER
6. Removethe bolts,then lift and removethe dashboard.
CAUTION: Use protective platss on the bottom ol the front pillar trim.
(cont'd)
20-71
Dashboard
Removal (cont'dl
7. removethe dashboardframefrom the dashboard
lf necessary,
>: Screw locations a: Nut locations,3

a>,21 B>,4
.4\
]r45 s'r.o--
ksf.m,
\Gt"/ s.8N.m_11.0
INSTRUMENT
I( . -€Fu'
-
lft))@
!v \- r1,b,ft
PANEL >: Clio locations
DASHBOARD
DASHBOARD
FRAME
DASHBOARD
WIREHARNESS
STRIKEB
DASHBOABD BRACKET
SIDECOVER
8. Installation is the reverse of the removal procedure.
NOTEi
. Before tightening the bolts, make sure the dashboard wire harnessesare not pinched
. Make sure the connectors, antenna lead and air mix control cable are connected properly'
20-72
Seatsand Seat Belts
2Dl3Dl1D:
SHOULDER ANCHOR REAnSEATBELT12Dl,lDl
ADJUSTER I4DI page20-88
Replacement,
lseepage20-85) page20-91
Inspection,
REARSEATBELTBUCKLE/
CENTERBELTTONGUE{2DI4DI
(seepage20'90)
FRONTSEATBELT
Replacement,pages20 85,86
page20-91
Inspection,
REABSEAT(2Dl4D)
FRONTSEATS Removal,pages20-79,81
Removal,page20'74
Seat-backLatchReplacement,page 20 82
Replacement,page20-75 page20-83
SeatCoverReplacement,
HarnessWiringand Becline
CableLocations,page20 77
SeatCoverFeplacement,page20 77
BELTBUCKLES
(seepage20-87)
3D:
REARSEATBELTBUCKLE/
CENTERBELTTONGUE
(seepage20 90)
REARSEATBELT
page20 91
Inspection,
REAR SEAT
Removal,page 20 80
S e a t b a c k L a l c h B e p l a c e m e n t ,p a g e 2 0 8 2
S e a t C o v e r R e p l a c e m e n t ,p a g e 2 0 8 3
20-73
FrontSeat
Removal
CAUTION: when prying with a flat tip screwdrivol,wrap 2. Lift the driver'sfront seat,then disconnectthe seat
it with proteqtivetape to preventdamage. belt switch connector.
NOTE: Takecare not to scratchthe seatcoversand body.
'1. Removethe seat track end cover,then removethe

bolts.
)
Removethe headrest.
Carefullyremove the front seat through the door

openrng.
FRONTSEAT Installationis the reverseof the removalprocedure.
NOTE:Make sure the connectoris connectedprop-

erly.
BOLT
10 x 1,25 mm
39 N.m (4.0kgf.m,
29
BOLT
I x 1.25mm
22 N.m 12.2kgl.m,
16 rbf.ftl
8 x 1.25mm
22 N.m 12.2kgl.m,
16 tbt.ftt
20-74
Replacement
CAUnON: When prying with a flat tip screwdriver,wrap it with protective tape to provent damage.
NOTE:
a Takecarenot to scratchthe seatcoversand body.
. Removethe front seatthroughthe door openang.
Drivel's:
NOTE:Referto page20-77for the seatbelt switchharnesswiring location. HEADREST
SEAT.BACK
PIVOTNUT
SEATCUSHION
8 x 1.25mm
22 N.n i'2,2
16 lbf.ft)
vI
CENTER
1 0x 1 . 2 5m m
,17N.m {4.8 kgt m,
10x 1.25mm
47 N.m (4.8kgt.m,
35 tbt.fr)
RECLINEAOJUSTER
LOWER CAP
t
1 0x 1 . 2 5m m
& RECLINE
CONNECTING WIRE
To connect,twist 180'.
OUTERSEAT
TRACK
8 x 1.25mm
Installationis the reverseof the removalprocedure,
20 N.m (2.0 kgf.m,
1/rlbf.ft)
NOTE:
. M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e
installedproperly.
. T o p r e v e n tw r i n k l e sw h e n i n s t a l l i n gt h e s e a t -
back cover. make sure the materialis stretched
evenlyoverthe pad.
. Greasethe slidingportion. (cont'd)
20-75
FrontSeat
Replacement(cont'dl
Passenger'slwith recline cablel:
NOTE:Referto page20-77for the reclinecablelocation.
HEADREST
SEAT.BACK
PIVOTNUT
I x 1.25mm
22 N.m(2.2kgf.m,
rbr.ftl
SEATCUSHION
PIVOT
WASHER
l0 x 1.25mm
LOWER
47 N.m (4.8 kgf.m,
CAP
10 x 1.25mm 35 tbnfr)
47 N.m {4.8 kgf.m,
35 tbf.ftl INNERSEAT
RECLINE
rowER CAP
i
b
10x 1.25mm
47 N.m ({.7 kgf.m,
35 tbf.ft)
OUTERSEAT WIRE
TRACK T o c o n n e c t ,t w r s t 1 8 0 .
8 x 1.25mm NOTE:
20 N.m (2.0kgf.m, . M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e ra r e
14 tbtft) installedproperly.
. To preventwrinkleswhen installingthe seat-back
cover,makesurethe materialis stretchedevenly
overthe pad.
. Adjustthe reclinecable.
. Greasethe slidingportion.
20-76
HarnessWiringand Recline SeatCoverReplacement
CableLocations
CAUTION: Wear gloves to remove and install the seat
NOTE:When installingthe seat cushion,make sure the GOVetS.
seatbelt switchharness,connectorand reclinecableare
NOTE:Take care not to tear the seamsor damagethe
fastenedcorrectlyon the seatcushionframe.
seatcovers.
Driver's: >: Clip locations Seat-backcover removal:
1. Releasethe hook.and fold backthe seat-backcover.
HEADREST
2. Releaseall inside springs,then foid back the seat-

(with reclinecablel: DacKcover.
Passenger's
3. Removethe headrest.
Removethe headrestguide,then removethe seat-
DacKcover.
TRACK
NOTE:To preventwrinkleswhen installinga seat-
backcover. makesure the mateial is stretchedevenly
over the pad beforesecuringthe insidespringsand
hook.
(cont'd)
20-77
FrontSeat
SeatCoverReplacement(cont'dl \
Seat cushion cover removal: 4. Installationis the reverseof the removalprocedure.
1. Removethe seatcushion(seepages20-75,76). NOTE:

. To preventwrinkleswhen installinga seatcush-
2. Removethe clipsfrom underthe seatcushion,then ion cover, make sure the material is stretched
loosenthe seatcushioncover. evenlyover the pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.
>: Clip locations
NEWCLIP
SEATFFAME
COVER
Pull backthe edge of the seatcushioncover all the

way around,then releasethe clips,and removethe
seatcushioncover.
>: Cliplocations
20-78
RearSeat
Removal
NOTE:Takecarenot to scratchthe seatcoversand body.
4D:
::-):Hooklocations,2
c>,1 D>,1
>: CliplocatioG,14
I
@
---------8tr--
Fq
EU )
-w ,/
V r>t
CENTER r--r
PIVOT
BRACKET
B
RIGHTSEAT-BACK
SEATCUSHION
SEAT.BACK
Pivot bolt construction:
TOOTHED
LOCK
WASHER
BUSHING
PIVOTBOLT ERACKET
Installationis the reverseof the removalprocedure. 8 x 1.25mm
22 N.m {2.2 kgtm, 15 lbf.ftl
Apply liquidthreadlock.
NOTE:
a Beforeaftachingthe seat-backand seatcushion,make sure there are no twists or kinks in the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seat cushion.
. N4ake surethe seat-backlockssecurely.
adjustthe seat-backlatch(seepage20-82)and seat-back.
o lf necessary, (cont'd)
20-79
RearSeat
Removal(cont'd)
3D:
>: Bolt locations (:) : Hook locations,2 >: Clip locations,14

A>,6 8 > ,1 c>,1
v@n
6x1.0mm ffi 6x1.0mm
':*2 6x1.0mm FE
9.8 N.m (1.0kst m,l I 22 N.m |.2.2kgl.m)
16tbt'-ft')
E
e e
E/ )
It
- -J)
SEATCUSHION
STRIKER STRIKER
Removethe sidetrim TRUNK
panel(seepage20 60). T
6 x 1.0mrn STRIKER
9.8Nm(1.0kgf.m,
1.2 tbt.ftl
A
A
CENTER
PIVOT
B
BRACKET
PIVOT
BRACKET
LEFT
SEAT.BACK
TOOTHED
LOCK
SEATCUSHION WASHER
BUSHING
PtvoTBoLT BRACKET
8 x 1.25mm
22 N.m {2.2kgf.m,16lbtft)
Installationis the reverseof the removalprocedure. Apply liquidthreadlock.
NOTE:
. Beforeattachingthe seat-backand seat cushion,make sure there are no twists or kinksin the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushion.
. Makesurethe seat-backlockssecurely.
. lf necessary,
adjustthe strikerand seat-back.
20- 8 0
2Di
>: Bolt locations i) : Hooklocations,2 >: Cliplocations,lil

A>,6 B>,1 c>,1
6x1.Omm R l 6 x 1 . o m m I ,\ff8 , u " , , 0 - -

,r@?r,
FF
9.8Nm11.0ksf.m,;
':*'
I 22N m t2.2kgtm,'
16tbfitt
S.eN m tr.Oksf-,
7.2rbr.tt)
E E )
) ) E
SEATCUSHION
SEAT-8ACKMAT
vv
V
PIVOTBRACKET
--v-.
CENTER
PIVOTBRACKET
RIGHTSEAT-BACK
|\
TOOTH€D
LOCK
WASHER
BUSI{ING
PIVOT
SEATCUSHION PIVOTBOLT BRACKET
8 x 1.25mm
'..' 22 N m (2.2kgI.m, 16 lbf.ft)
NOTE:
. Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinksin the rearseat belts and
centerbelt.
. Makesurethe seat backlockssecurely.
adt'ustthe seat-backlatch(seepage20-82)and seat-back.
. lf necessary,
20-81
RearSeat
Seat-backLatchReplacement \
2Dl1.D: 3D:
R e m o v et h e l o c k c y l i n d e rt r i m . t h e n r e m o v et h e r e a r Pullthe trunk mat awayfrom the seat-back(seepage20-

shelf(seepages20-59,61). 80).
NOTE:Takecarenot to bend eachlockrod.

>: Bolt. screw locations
a>,2 B>,1
>: Boh, scrow locrtions
A>,4 B> , 2 /-\ 6x1.0mm
ffifu s.aN.. tt.or,sf.-. @ i
G
Ei
ort.o--
g.sw m tt.otot.-.
-
r g l Y 11'11 )
E 7.2tbr.ft, ) : l
c 7 /
SEAT-BACK
LOCKCYLINDER
TRIM
nstallationis the reverseof the removalprocedure.

BACKLATCH
NOTE:
Installationis the reverseof the removalprocedure, . Makesurethe seat-backlockssecurelyand opens
propeny.
NOTE:
a Makesureeachlock rod is connectedsecurely.
. M a k e s u r e e a c h s e a t - b a c kl o c k s s e c u r e l ya n d
opensproperly.
. lf necessary. adjustthe seat-backlatch.
20-82
Seat Gover Replacement
CAUTION: Wear glov€s to remove and install the seat 4. Installationis the reverseot the removalprocedure.
covels.
NOTE:
NOTE; Takecare not to tear the seamsor damagethe seat . To preventwrinkleswhen installinga seat cush-
covers. ion cover, make sure the material is stretched
evenlyover the pad beforesecuringthe clips.
Soat-backcover removal: . Replacethe releasedclipswith new ones.
2DI4D: 3D:
'1.
L Removethe seat-back(seepages20-79,81). Removethe seat-back(seepage20-80).
2. L o o s e nt h e s e a t - b a c kc o v e r b y r e l e a s i n ga l l t h e 2. coverby releasingallthe clips.

Loosenthe seat-back
clrps.
>: Cliplocations NOTE:Removethe lock knob, lock collar and latch
cover.
>: Cliplocations
SEAT.BACK
COVER
LEFTSEAT.BACK RIGHTSEAT.BACK
COVER COVER
3. Pull back the edge of the seat-backcover all the way
around. then releasethe clips.
>: Clip locations 3. Pull backthe edge of the seat-backcoverall the way
around,then releasethe clips.
>: Cliplocations
SEAT.BACK
COVER
RIGHT
NOTE:
. To preventwrinkleswhen installinga seat-back
cover,makesurethe materialis stretchedevenly
overthe pad beforesecuringthe clips.
(cont'd)
20-83
RearSeat
SeatGoverReplacement(cont'dl
Seat side bolster cover r€moval l,lDl: 2Dl3Dl
1. Removethe seatside bolster(seepage20-79).

-
2. Loosenthe seat side bolstercover by releasingall
V EF*aa-bF-E< \
the clips,then removeit. f.I--l f ,
lm n r -r_I--t
>: Clip locations rt=r/ { lr (!, .t=!l
SEATSIDE COVER
BOLSTER
COVER Pull back the edge of the seat cushion cover all the
way around, release the clips, and remove the seat
cushron cover.
>: Clip locations
4D:
NOTE:
a To preventwrinkleswhen installinga seat side
bolstercover,makesurethe materialis stretched
evenlyoverthe pad beforesecuringthe clips. 20 l3Dl
Seat cushion cover removal:
1. R e m o v et h e s e a tc u s h i o n( s e ep a g e s2 0 - 7 9 , 8 0 , 8 1 ) .
2. Loosenthe seat cushioncover by releasingall the

clrps.
COVER
>: Cliplocations
4D: 4. Installationis the reverseof the removalprocedure.
NOTE:
. To preventwrinkleswhen installinga seatcush-
a o nc o v e r ,m a k e s u r e t h e m a t e r i a li s s t r e t c h e d
evenlyover the pad beforesecuringthe clips.
_ - / - /.)
v,la UPHOLSTERY RINGPLIERS
-.lL J lL--Jl '.n lCommerciallv
available)
SEATFRAME
20-84
Front Seat Belt
Replacement
CAUTION: Check the tront seat belts for damage, and Removethe centerpillaruppertrim (seepage20-59).
replacethen if nacessary.B9 careful not to damage then
during removal and installation, 6. Removethe shoulderanchoradjuster.
Fronl seat belt removal {,[D):
1 . Slidethe front seatforwardfully.
2. Removethe centerpillar lowertrim panel(seepage

20-59).
I x 1.25mm
Removethe upper anchorcover and lower anchor
23 N.m (2.3 kgf m,
cap. 17 tbf.ft)
UPPERANCHORBOLT
7/16-20UNF
32 N,m (3.3kgf.m, ANCHOR
24 rbf.ftl ADJUSTER
UPPERANCHOR NOTE:
COVER
. Checkthat the retractorlockingmechanismfunc-
FRONTSEA tions as describedon page20-91.
BELT
. Makesureyou assemblethe washersand collars
RETRACTOR on the uoDerand lower anchorbolts as shown.
MOUNTINGBOLT . Beforeinstallingthe anchorbolts,makesurethere
6x1.0mm are no twists or kinksin the front seatbelt.
9.8 N.m (1.0 kgf.m,
7.2 tbf.ftl
Upper anchorboh construqtion:
UPPER UPPERANCHOR
RETRACTOR ANCHOR BOLT
COLLAR Apply liquidthread
RETRACTOR BOLT
7/1&20UNF
32 N.m (3.3 kgt.m,
2a tbtft)
+I
LOWENANCHORBOLT I
7,/16-20UNF
32 N.m (3.3 kgf.m, 24 lbf ftl
II BEARING
LOWERANCHOR
CAP
Removeall the anchorbolts and the retractorbolt,

remove the retractormounting bolt. then remove
the front seatbelt and retractor.
(cont'd)
20-85
Front Seat Belt
Replacement(cont'dl \
Lower anchor bolt construction: Front seat belt romoval (2Dl3D):

SPRING
WASHEF
1. Slidethe front seatforwardfully.
2. Remove:
. Rearseat-backand rear seatcushion(seepages
2 08 0 , 8 1 )
. R e a r c e n t e rs h e l f a n d r e a r s i d e s h e l t ( 3 D ,s e e
page20-60)
. Reartrimpanel(3D,seepage20-60)
. Sidetrim panel(seepages20-60,61)
3. Removethe upperanchorcoverand loweranchorcap.

COLLARS WASHERS LOWER BEARING
ANCHOR UPPER ANCHORBOLT
7/r6-20UNF
32 N.m 13.3kgt.m,
FRONTSEAT 24 rbf.ft)
R€tractor bolt construction: BELT
RETRACTOR
BOLT
I
llrrtnn-ffi\
RETRACTOR
MOUNTINGBOLT
\Y **rss,t
6x1.0mm
9.8 N.m {'t.0kgt.m,
7.2 tbf.ftl
I
RETRACTOR
LOWER
ANCHOR
CAP
I
I
t
o
RETRACTOR BOLT
7/16-20UNF LOWERANCHORBOLT
32 N.m (3.3kgl.m, 7/16-20UNF
24 tbI.ft) 32 N.m {3.3kgt m,24 lbf.ftl
4. Removeall the anchor bolts and the retractorbolt,

removethe retractormountingbolt,then removethe
front seat belt and retractor.
2 0- 8 6
5. Installation of the removalprocedure.
is the reverse Seat beh buckle removal:
NOTE: 1 . R e m o v et h e f r o n t s e a t t h r o u g ht h e d o o r o p e n i n g
. Checkthatthe retractor
lockingmechanism
func- (seepage20 74).
tionsasdescribedon page20-91.
Makesure you assemblethe washersand collars 2. Removethe centercover(seepages20-75,76).
on the uoDerand lower anchorboltsas shown.
Beforeinstallingthe anchorbolts,makesurethere Removethe centeranchor bolt, then removethe seat
are no twists or kinksin the front seat beit. beltbuckle.
Upper anchor bolt construclion: SEATBELT

BUCKLE
WASHERS
SPRING ANCHORBOLT
BEARING
WASHER
CLIP 32 N'm {3.3kgfm, 2't lbfft)
Lower anchor bolt construction:
SPRING 4. Driver's:Detachthe seat belt switch connectorand
WASHER BEARING harnessclip from the seatcushion(seepage20-77).
Removethe seat cushion mounting bolts from the
COLLARS innerseattrack{seepage20-751, and movethe inner
seattrack,then pull the seatbeltswitchharnessout.
NOTE:Takecarenot to damagethe hingebracket.
Center anchor bolt construction:
CENTERANCHOR
BOLT
WASHERS LowER LOWERANCHOR
LOCKWASHER ANCHOR BOLT
Retractorbolt construction:
TOOTHEO RETBACTOR
LOCKWASHER
b
SPRING WASHER
WASHER
NOTE: Make sure you assemblethe washers and

bearingon the centeranchorbolt as shown.
RETRACTOB
20-87
RearSeat Belt
Replacement
GAUTION:Checkthe rear seat belts for damage,and 3. Installationis the reverseof the removalprocedure.
replacethen if necessary,Be careful not to damage then
during removal and installation. NOTE:
Rearseat belt removal l2DllDl:. tions as describedon page20-91.
. Make sure you assemblethe washersand collar
1. Remove: on the upperanchorbolt as shown.
. Rearseatcushion(seepages20-79,81) . Beforeinstallingthe anchorbolt, make surethere
. Rearseat-back{2D,see page20-81) are no twists or kinksin the rearseat belt.
. Sidetrim panel(2D,seepage20 61)
r Rearshelf(seepages20-59,61) Upper anchorboh construction:
. Reartrim panel(seepage20-62)
. Trunksidetrim, Japan-produced
(seepage20-62)
. Trunktrim panel,USA-produced(seepage20-62)
2. Removeall the anchorbolts and retractorbolt, then

removethe rearseat belt and retractor.
UPPERANCHOR
BOLT
7/16-20
UNF
TOOTHED
RETRACTOR BOLT LOCKWASHER
7/16-20UNF
32 N.m {3.3kgf.m,
24 rbf.ft)
Lower anchor bolt construction:
LOWERANCI{OR
BOLT
LOWERANCHOR
Retrastor bolt construqtion:

7/1S20UNF
32 N.m 13.3kgI.m,24lbl.ftl
/7-'\ 177--7,
trv-*q
,/Rr /i\ ntz ll l \
/ \ \
TOOTHED RETRACTOR RETRACTOR
LOCKWASHER BOLT
20-88
Rearseat belt removal l3Dl: 4. Installationis the reverseof the removalprocedure.
1. Remove: NOTE:
. Rear seat-backand rear seat cushion (see page . Checkthat the retractorlockingmechanismfunc-
20_80) tions as describedon Page20-91
. Rear center shelf and rear side shelt (see page . Makesureyou assemblethe washersand collars
20-601 on the upperanchorbolt as shown
. Reartrim paneland sidetrim panel(seepage20- . Betoreinstallingthe anchorbolt, makesurethere
60) are no twistsor kinksin the rearseatbelt.
2. Removethe upperanchorcover Upper anchorboh construqtion:
SPRING
UPPERANCHORBOLT
7/16-20UNF
32 N.m {3.3kgl m.24lbf ftl
UPPERANCHOR WASHER TOOTHEO

RETRACTOB BOLT BOLT LOCK
7/16-20UNF WASHER
32 N.m (3.3kgf.m,
Lower anchorbolt construction:
LOWEBANCHOB
7/15-20UNF
32 N.m (3.3kg{.m,24lbfft) TOOTHED
LOCKWASHER
Retraqtorboh conslruction:
3. Removeall the anchorboltsand retractorbolt.then €

removethe rearseat belt and retractor'
TOOTHED
LOCKWASHER
BOLT
(cont'd)
20-89
RearSeat Belt
Replacement(cont'd) \
Soat belt buckle/Canterbelt tongue removal: Centel anchor bolt construction:
1. Removethe rear seat cushion(seepages20-79,80,

81).
2. Removethe center anchor bolts, then remove the

seatbelt bucklesand centerbelttongue.
CENTERANCHOR
2DI4'D:
CENTER
BELT
BUCKLE
7/16-20UNF TOOTHEO
LOCKWASHER
Installationis the reverseof the removalDrocedure.
NOTE: Beforeattachingthe seat-backand seat cush-

ion, make sure there are no twists or kinks in the cen-
ter belts.
CENTERBELTTONGUE
3D:
CENTERANCHORBOLTS
7/16-20UNF
32 N.m {3.3 kgf.m,
24 tbtftt
CENTERBELT
20-90
Seat Belts
Inspection
Retractor Inspection 3D:
'1.
Beforeinstallingthe retractor,checkthat the seatbelt
can be pulledout freely.
lvake sure that the seat belt does not lock when the
retractoris leanedslowlv up to 15'from the mounted
position.The seatbelt shouldlockwhen the retrador
is leanedover40".
CAUTION:Do not attempt to disassemblethe retrac-

tor. RETRACTOR
Forward
*: Mounted Posilion
Front:
4D:
3. Replacethe seatbelt with a new one if there is any

abnormality.
On-the-CarSeat Belt Inspection
1. Checkthat the seat belt is not twisted or caughton

anyrnrng,
2. After installingthe anchors,checkfor free move-

Forward lnside ment on the anchorbolts.lf necessary.removethe
anchorbolts and checkthat the washersand other
2DI3D: partsare not damagedor improperlyinstalled.
3. Checkthe seatbeltsfor damageor discoloration.

Cleanwith a shop towel if necessary.
CAUTION: Use only soap and water to clean.
NOTE:Dirt build-upin the metal loops of the upper

anchorscan causethe seat belts to retractslowly.
Wipe the insideof the loopswith a cleanclothdamP
enedin isopropylalcohol.
lnside
Checkthat the seat belt does not lock when pulled
Rear: out slowly. The seat belt is designedto lock only
duringa suddenstop or impact.
2Dl lDl
Makesurethat the seatbeltwill retractautomatically
when released.
For each passenger'sseat belt, make sure that the

l o c k i n gm e c h a n i s mi n t h e s e a t b e l t r e t r a c t o rw i l l
engagewhen the seatbelt is pulledall the way out.
7. Replacethe seat belt with a new one if there is any

abnormality.
J Forward lnside
20-91
Seat Belts
GhildSeat Anchor Plate
Attachmentpointsare providedfor a rear seat mounted
childrestraintsystemwhich usesa top tether.The attach- 8 x 1.25mm
22 N.m (2.2kgf.m.16lbf.ftl
ment points are locatedon the rear shelf or rear trim
panel,just behindthe rearseat-back. When usinga child
seatwith a top tether,installthe chjld seatanchorplates
securely.
2Dl4Dl
N O T E : R e m o v et h e p l u g c o v e r sf r o m t h e a t t a c h m e n t
pointsof the rearshelf.
CHILDSEAT
ANCHOR WASHER
PLUGCOVERS
PLATE
NOTE:
. Do not removethe toothedwasherfrom the childseat
anchorplate.Usethe child seatanchorplatewith the
toothedwasherattachedto it.
. When installinga child seat on the rear seat,follow
the instructions
of the manufacturerot the childseat.
. Additionalanchorplatesare available.
Do noi use the child seat anchor plate for any other
purpose;it is designedexclusivelytor installation of a
child seat.
Make sure the rear seat-back is locked tirmlv when
installinga child seat.
REARSHELF
3D:
NOTE:The reartrimpanelhasperforations ateachattach-

ment point, Cut the rea. trim panel along the perforations
to makea hole.
REARTRIM
PANEL
20-92
a
Exterior
r a n u a l 1, 9 9 6M o d e lS e r i e sP, / N . 6 1 5 0 3 3 0 , f o r t hheo o d , t r u n kl i d a n d h a t c hr e m o v a l
N O T E :R e f e tr o t h e C i v i cB o d yR e p a i M
2D t3DtlD:
SIDEWINDOW LICENSEPLATE
MOLOINGS TRIM TRUNKLID
ROOFMOLDING Replacement, Replacement, Adjustment,page20 97
Replacement, page 20-102 page20 't00 TorsionBarRemoval,
page 20 1O2 20 99
HOOD
Adjustment,Page20-96 TRUNKLID
HoodEdgeProtector WEATHERSTRIP
page20-99 Replacement,
page20-100
REARBUMPER
Replacement,
page20'95
REARAIR OUTLET
Feplacement,
page20-106
PIPE
PROTECTOR
Replacement,
page20-106
FENDERWELLTRIM
FRONTGRILLE page20 106
Replacement,
(seepage20 99) DOORand SIDEMOLDINGS
page20 103
Replacement,
SILLPANEL
R e p l a c e m e n t ,p a g e 2 0 - 1 0 5
INNER
Replacement,
page 20-106
3D:
HATCHSPOILER
Removal,page20-101
HATCH
WEATHERSTRIP
HATCH
Adiustment,
page20 98
LICENSEPLATETRIM
page20 100
Replacement,
REARAIR OUTLET
page20'106
Replacement,
20-93
FrontBumper
Replacement
CAUTION:Wsa.glovesto removeandinstallthe front bumper.
NOTE: >: 8olt, screw locations >: Clip

. An assistant
is helpfulwhenremovingthefrontbumper. a >,2 B>,2 locations,7
. Takecarenotto scratchthefrontbumperandbodv.
c>,4 D> , 4
t165
ldb !J,J:ff,ry-"_. 6x1.0mm
9.8 N.m {'1.0kgf.m,
\I/ _r6rbrftl 7.2 tbf.ft)
FRONTBUMPERBEAM _g
ABSOREER
IA

FRONTEUMPER
NOTE: SIOESTIFFENER
. Make sure the front bumper engagesthe front
bumperside stiffeneron eachside securely.
. lf necessary,adjust the front bumper side stiffener
to obtainthe propergap.
20-94
RearBumper
Replacement
CAUTION: Wear gloves to remove and install the rear bumpet.
NOTE:
is helpfulwhen removingthe rearbumper'
. An assistant
. Takecarenot to scratchthe rearbumperand body.
. 2D and 4D shown here;3Dremovalproceduresare the sameas 4D.
>: Screw, bolt locaiions
A>,2 B >, 4 >: Clip locations,7
A
i,,A
\r9{
R
,9iiffiF=*-..f
REARBUMPERBEAM
REARBUMPER
NOTE:
. lf necessary,
. Makesurethe rearbumperengagesthe side clip on eachside securely.
20-95
Hood
Adjustment
NOTE:Beforeadjustingthe hood,looseneachbolt slightly.
1. Adjustthe hood hingesright and lefr,as well as fore and aft, by usingthe elongatedholes.
2. Turn the hood edgecushions,as necessary,

to makethe hood fit flush with the body at front and sideedges.
3. Adjustthe hood latchto obtainthe properheightat the forwardedge.
4. After adiustment,tighteneachbolt securely.
HOOD
\\"'
6x1.0mm )
9.8N.m {1.0kgf,m, ,/
1.2lbl.ttl
_ _ _ , / CUSHION
NOTE:Move the hood latch rightor leftuntilthe striker
is centeredin the hood latchasshown.
6x1,0mm
9.8 N.m 11.0kgf.m,
7.2 tblfrl
2 0- 9 6
TrunkLid
Adjustment
NOTE:Beforeadjustingthe trunk lid, looseneachbolt slightly
1. Adjustthe trunk lid hingesrlght and left,as well as fore and aft, by usingthe elongatedholes.
2. to makethe trunk lid fit flush with the body at the rearand side edges
Turn the trunk lid edgecushions,as necessary,
3. Adjustthe fit betweenthe trunk lid and the trunk lid openingby movingthe striker'
4. After adjustment,tighteneachbolt securely.

TRUNKLIDEDGE
CUSHION
21"
( i €r/-\\
\ V,,'' / TBUNKLID
NOTE: Take care not \ rY ./ srrucrs
to hit the rear window
when loosen ng the
bolts.
\-2/\
- -)
:> ---
6x1.0mm
9.8 N.m 11.0kgl.m,7.2lbf.ftl
/
the rearshelflseepases20-59,61).
NOTE:Remove
//
NOTE:Move the strikerright or left until it's centeredtn

the trunk lid latchas shown.
6x1.0mm
9.8 N.m (1.0kgf.m,
STRIKEB
20-97
Hatch
Adjustment
NOTE:
. Beforeadjustingthe hatch,looseneachbolt and nut slightly.
o The supportstrutsshouldbe removed.
. To adjust,removeboth hatchsidetrim {seepage20-63)and the rearroof trim (seepage20-65).
1. Adjustthe hatchhingesright and left,as well as fore and aft, by usingthe elongatedholes.
2. Turn the hatchedgecushions,as necessary,

to makethe hatchfit flush with the body at eachside.
3. Adjustthe hatchfit to the hatchopeningby movingthe striker.
4. After adjustment,tighteneachbolt and nut securely.

HATCH
6x1.0mm EDGECUSHION
9.8N.m (1.0kgt.m,
HATCH
HINGE
Rearward
HA
EDGE
CUSHION
@
HATCH
\ HINGE
STRIKER
10 x 1.25 coVER
38 N.m {3.9kgl.m,
2.8 rbf.ft) HATCH
EDGE
CUSHION
NOTE:Move the strikerright or left until it's centeredtn

the hatchlatch,as shown.
6x1.0mm
9.8N.m {1.0kgf.m,
7.2 tbl.ttl
FrontGrille/HoodEdge TrunkLid Torsion
Protector Bars
Replacement Removal
Fronl grille: CAUTION:Wear gloves to remove and installthe torsion
bars.
NOTE:Takecarenot to scratchthe front bumper.
NOTE:Takecare not to damagethe body.
Removethe front bumper (seepage20-94).Removethe
clips and screws.then slide the front grille forward by Removethe torsion bars with the torsion bar assembly
detachingthe hooks. t o o lw h i l eh o l d i n gt h e t r u n kl i d a s s h o w n .
>: Screwlocations,4
j
A I
A l
:Y/
CENTERCLIP
Hoodedgeprolector:
NOTE:
. When removing the clips, use a clip remover.
. lf necessary,replace any damaged clips.
Installation is the reverse of the removal procedure.
>: Cliplocarions,lS
NOTE:
. Adjustthe torsionbarsfore or aft with the tor
sionbarassembly toolasshown.
HOOOEDGE
a = Normalposition
a = H i g h e tre n s i o n
Make sure the trunk lid opens properly.
20-99
Trunk Lid/Hatch
Weatherstrip LicensePlateTrim
When installingthe trunk lid/hatchweatherstrip,align it CAUTION: Wear gloves to remove and install the license
with the alignmentmarkon the trunk lid/hatchopening. plate trim.
NOTE: NOTE:Takecarenot to scratchthe trunk lid/hatch.

. Makesurethereare no wrinklesin the weatherstrip.
. Checkfor water leaks. 1. Removethe ljcenseplate.
2D l4Dl 2. 3D: Removethe hatchtrim panel(seepage20-63).
ALIGNMENTMARK 3. Removethe nuts and clips,and detachthe clip,then

removethe licenseplatetrim.
NOTE:Takecarenot to drop the nuts insidethe trunk

lid/hatch.
a: Nut locations,2 >: Clip locations,3
I
ffisxo.amm I nA
IEL
L
- 1.8N.m{0.18kstm.l
\Y9l,/ @ta9@
13 tbtfr) ,/
WEATHERSTRIP
ALIGNMENT
MARK
4. Installationis the reverseofthe removalprocedure.

STEEL
CORE NOTE:lf necessary,
ALIGNMENT
MARK (2Dl4D)
BODY
20-100
HatchSpoiler
Removal
NOTE:Takecarenot to scratchthe hatchand body. 4. removethe spoilertrim from the spoiler
lf necessary,
frame.
1. Removethe hatchuppertrim (seepage20-63).
NOTE:The hatchspoilertrim for Canadaproduced
2. Removethe nuts, and detachthe clip, then Iift the carscannotbe disassembled.
hatchspoilerup.
>: Clip locations
a: Nut localions,4
6x1.0mm l
9.8N m 11.0 ksf.m.I
7.2
\t.to - _J/ >: Screw
locations,4 l
GROMMET
"ig \ l
6
i
HIGHMOUNT BRAKE
LIGHTCONNECTOR v /
SPOILER
CENTER
SPOILER TRIM
SIDETRI
NOTE:
ACCESSCAP
. lf necessary, replaceany damagedclips.
a M a k e s u r e t h e c o n n e c t o ra n d w a s h e rt u b e a r e
connectedproperly.
3. Disconnect the high mount brakelightconnectorand

r e a rw i n d o w w a s h e rt u b e ,t h e n r e m o v et h e h a t c h
spoIer.
20-101
SideWindow Moldings RoofMolding
CAUTION: Wear gloves to remove and install the side CAUTION;Whsn prying with a flat tip sc.ewdriver,wrap
window moldings. it with protective tape to prevent damage,and use pro-
tective tape on the body.
NOTE:
. Takecarenot to scratchthe body. NOTE:Takecarenot to scratchthe bodv,
. Removethe screw,and pull the side window molding
by hand.
>: Clip locetions

A>, 13
K
(Bodyside)
WINDSHIELO
MOLDING I
)
Screw locations,
I
*@ )
ARACKET
NOTEi
. Takecarenot to damagethe windshieldmolding.
. Makesurethe roof moldingis installedsecurely.
MOLDING
ROOFMOLDING
NOTE:lf necessary,
20-102
Doorand SideMoldings
Replacement
CAUTION: When prying with a tlat tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:
. To removethe front side molding,removethe innerfender(seepage20-106).
. To removethe door molding,removethe door panel(seepages20 4, 10, l6) and plasticcover.
. To removethe rearside molding,removethe sidetrim panel(seepages20-60,61).
. Takecare not to bendthe door moldings.
. Before.eassembling, cleanthe door bondingsurfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface
4D:
2Dl3Dl
REARSIDE
MOLDING
>: Clip locations a: Plasticnut location, 1

A >: ,lO,11 B> , 3 c>.2
2013r),7
@)
_/
(cont'd)
20-103
Doorand SideMoldings
Replacement(cont'dl
Door moldingremoval: Door moldinginstallation:
The following materialsand tools are requiredto repair L G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g s a s

t h e d o o rm o l d i n g s . shown.
N\\N\l : Adhesivetape locations

NOTE:Followthe manufacturer's
instructions- 60 mm
t2.1
820mm 132.3inl
Materials:{Reference}
. Striperemover
3M 08907
. Stripeadhesiveremover Forward L
3M 08908 MOLDING CLIP
HOLDER
. Adhesivetape 40 mm
3M SuperAutomotiveAttachmentTape (1.6in)
Tools:
. Protectivetape . Film
. Knifeor Cutter . Puttyknife Forward L
. Spongeor Shoptowel . Alcohol
. Infrareddryer
2Dl3Dl
CAUTION: Wear gloves to remove and install the dool
1,050mm {41.31inl
moldings.
1. R e m o v et h e d o o r p a n e l ,a n d p u l l b a c kt h e p l a s t i c
cover.
2. Apply protectivetape on and aroundthe molding.
5 mm {0.2in)
ADHESIVETAPE
Thickness:1.2 mm 10.05inl
2. I n s t a ltlh e c l i p so n t h e m o l d i n g .
3. Releasethe clips from insideof the door. Carefully
cut the adhesivetape with a knife or cutter while 2 H e a t t h e b o n d i n g s u r f a c eo f t h e d o o r a n d d o o r
pullingthe edgeof the moldingaway from the door moldingwith an infrareddryer.
as shown. Door: 104- 140'F(40- 60'C)
Molding:68 - 86'F (20- 30'C)
NOTE:Take care not to scratchor bend the mold-
Ing NOTE: Use care when heatingto preventdeforma-
KNTFE
t i o no t t h e m o l d i n g .
4. Align the molding with the clip locations,and set

the molding. Lightly push on the molding until its
edgeis fully seatedon the adhesivetape.
NOTE: Do not spray water on the molding within

the first 24 hoursafterinstallation.
OOOBMOLDING all removedparts.

Reassemble
20-104
SideSill Panel
Replacement
NOTEI
. Takecarenot to scratchthe body.
. 4D shown here;2Dand 3D removalprocedureis the sameas 4D.
>: Clip locations >: Screw locations,4
A>,3 B>,7
I
I
NOTE:Loosenthe screw, SIDECLIP

then removethe lowerclip Removethe sideclipsfrom the body
usinga clip remover. by turningthem 45'
NOTE:When removingthe side

sill panel,the sideclipswill
stayin the body.
SIDE SILL PANEL

Remove the lower clips,
then remove the side sill panel
by sliding it forward.
To installthe sidesill panel,removethe sideclipsfrom the body, installthem on the side sill panel,then installthe sidesill
oaneo l n t h ec a r .
NOTE:
. Takecarenot to twist the side sill panel.
. lf necessary,
replaceany damagedside and lower clips.
20-105
InnerFender,FenderwellTrim, FuelPipeProtectorand Rear
Air Outlet
Replacement
NOTE:lf necessary,
lnner fender:
>: Screwlocations,
4
6h*l
: , /
>: Clip locations,7
CLIP
Fenderwelltrim/Fuel pipe protector/Rearair outlet:
NOTE:
'@
. Takecare not to bendthe tenderwelltrim. >: Clip locations
a>,4 B>,4 c>.2
. Betoreinstallingthe fenderwelltrim, cleanthe body
d
bondingsurfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseor water from gettingon
the surface.
+
. To removethe fuel pipe protector,first removethe rear
wheel(seesection18).
. To remove the rear air outlet, first remove the rear
bumper(seepage20-95).
STEEL FENDERWELL
20-106
OpenerCable/Openerand Latch/Wiperand Washer
zDl3Dl4Dt
wrPERaRMs
*TNDSHTELD
page20-1
Replacement, 13
page20-1
Adiustment, 17
WINDSHIELD
WASHERNOZZLES
Adjustment,page20-117
FUELLIDOPENER
CABLE
(seepage20-108)
TNUNK LID OPENER

CABLE
(seepage20 108)
LID/FUEL
LIDOPENER
{seepage20-111)
REI."EAS€HANDLE
(seep6ge20-110)
3D:
REARWINDOW
wlPER REARWINDOW WASHER TUBE
REARWINDOW (seepage20 1161
ARMrnd MOTOR WASHERNOZZLE
page20-'l15
Eeplacement, Adiustment,page20-117
page20-'l17
Adjustment,
HATCH/
FUELLIDOPENER
{seepage20-111)
FUELLIDOPENER
CABLE
{se€page20-'110)
(seepage20 111) HATCI{OPENER

CABLE
(seepage20-110)
20-107
J
OpenerCables
Replacement \
NOTE: Trunk lid/Fuellid openercable(2Dli[D):

. When removingthe clips,usea clip remover.
. Takecarenot to bendthe openercables. NOTE:Removethe following partsfrom the left side of
the vehicle.then pull the carpetback,as necessary{see
Hood open€r cable: page20-66).
NOTE:Removethe front bumper (see page 20-94)and . Rearseatcushion(seepages20-79,81)

innerfender(seepage20-106). . Rearseatside bolster(4D,seepage20-79)
. Rearseat-back{2D,see page20-81)
. Centerpillarlowertrim panel(4D,seepage20-59)
>: Clip locations
A>,5 BD,1 . Lower anchor bolt from the front seat belt (2D,
#l
page20-86)
. Sidetrim (seepages20-59,61)
@
o Seatsidetrim (4D.seepage20-59)
. Sidetrim panel(2D.seepage20-61)
. Trunk mat and sparetire lid
HOODRELEASE . Trunksidetrim, Japan-produced (seepage20-62)
HANDLE . Trunktrim panel,UsA-produced (seepage20-62)
{seepage20-110)
>: CliD.
cablecushion
locations
a>,4 I>,4D,r c >, 1 {4D)
# l B
_ L ) _-__l ffi \ _,)
D> , 3 E> , 4 D ,1
2D,2
Routethe opener
cable through the
hole in the body.
NOTE:
. Make sure the hood openercable is routed and
connectedproperly.
. Makesurethe hood opensproperly.
20-108
TRUNK LID LATCH
(seepage20 112)
4D:
To trunklid
latch,
TRUNKLID/FUEL
LIOOPENER
( s e ep a g e2 0 ' 1 1 1 )
To trunklid
latch.
a
A \ TRUNKLID
OPENERCABLE
FUELLIO
OPENERCABLE
TRUNKLIO/FUEL
LID OPENER
( s e ep a g e2 0 - 1 1 1 )
(cont'd)
20-109
OpenerCables Openerand Latch
Replacement(cont'dl Replacement
Hatch/Fuellid opener cable (3D): NOTE:Takecarenot to bendthe openercables.
NOTE:Bemovethe following parts,then pull the carpet Hood releasehandle:

backas necessary(seepage20-66).
N O T E :R e m o v et h e k i c kp a n e l( s e ep a g e s2 0 - 5 9 . 6 0 , 6 1 ) .
. Rearseatcushionand rearseat-back {seepage20-80}
>: Boll locations,2 |
. Lower anchorbolt from the tront seat belt (seepage I
20-86) 6 x 1 . 0 m mi HOOOOPENER
. Sidetrim (seepage20-60) 9.8N.m I CABLE
. Sparetire lid {seepage20-108)
. Rearcentershelfand rearsideshelf(seepage20-60)
. Sidetrim panel(seepage20-60)
>: Clip,c.ble cushionlocations

A>,9 B>,1 c>,1 D>,5
#)
HOODRELEASE
*i l
HANDLE
Hood latch:
Routethe opener
cablethroughthe NOTE:Removethe front bumper(seepage20-94).
hole in the body. FUELLID LATCH
(seepage20-112)
FUEL LID
STRIKER doo OPENER
--\," CABLE
o/l
HATCH
OPENERCABLE
HATCH/FUEL
LID
OPENER
Installationis the reverseof the removaiprocedure.

NOTE:
. N4akesure each openercable is routed and con NOTE:
nectedproperly, . Makesurethe openercableis connectedproperly.
. Makesurethe hatchandfuel lid openproperly. . M a k e s u r e t h e h o o d o p e n s p r o p e r l ya n d l o c k s
securely.
20-110
Trunk lid or Hatch/Fuellid opener: Striker l3D):
NOTE:Removethe sidetrim (seepages20-59,60.61). NOTE: Removethe reartrim panel(seepage20-601.
>: Boltlocrtions,
2
OPENERLOCK >: Bolt locations.2
a@-\ CYUNDER
6x1.0mm
9.8N.m la//tzDt4Dl
L-.-^
(1.0kgt.m, HATCH
7.2 tbl.ftt 6x1.0mm OPENERCABLE
9.8N.m (1.0kgf.m, I (seepage20-110)
':-!, J
TRUNKLID,/HATCH
OPENERCABLE
{see 2 0 - 1 0 81, 1 0 )
To trunklid latch
or striker.
To fuel lid latch. \
lnstallation is the reverse of the removal procedure.
NOTEi
FUELLID
OPENERCABLE a Makesure each openercableis connectedprop'
(seepages20-108,110) erlY.
. M a k e s u r e the hatch opens properly and locks
securely.
NOTE:
. Makesurethe openercableis connectedproperly.
. Makesurethe trunk lid or hatchand fuel lid open
properly.
(cont'd)
20-111
Openerand Latch
(cont'dl
Replacement
Fuel lid latch: Trunk lid latch/Lock cylinder:
NOTE:Removethe followingparts.
2Dl4Di >: Bolt locations

A>,3 B > ,1
. R e a rt r i m p a n e l{ s e e p a g e 2 0 6 2 )
. Rear edge of the trunk side trim or trunk trim p a n e l
(leftside,seepage20-62)
3D:
. Accesspanelon the sidetrim panel
>: Bolt locations, 2

5 x 1.0mrn
,-*Y:EiI::Y FUELLID LATCH TRUNKLID

LATCH
CYLINDER
ROD
LOCK
CYLINDER
FUELLID
After installingcheckfor
a flushfit with the body.
CONNECTOR
Disconnect.
a-
I
I
FUEI-LID LATCH
FUELLIDOPENER
CABLE
(seepages20'108,1'10i
@ LOCK
CYLINDER
Removethe fuel lid latch

by turningit 90'
Installationis the reverseot the removalprocedure.
NOTE:
NOTE: . Greasethe trunk lid latch.
. Make sure each openercableis connectedprop- . Makesure the trunk lid opensproperlyand locks
erly. securely.
. Make sure the fuel lid opens properlyand locks . M a k e s u r e t h e c o n n e c t o ra n d c y l i n d e rr o d a r e
secureiy.
20-112
WindshieldWiper Arms
and Linkage
Replacement
Hatch latch/Lock cylinder: CAUTION: Wear gloves to remove and inslall the wind-
shieldwiper linkage.
NOTE: Remove the hatch trim panel (see page 20-63).
NOTE:Takecarenot to scratchthe hood and body.
>: Bolt locations l R e m o v et h e w i n d s h i e l dw i p e r a r m s ,t h e n r e m o v e

A>,3 8>, 1
the hood sealand cowl cover.
6x1.0mm 6x1.0mm
9.8 N.m 11.0kgf.m, 9.8N m (1.0kgf.m,j >: Clip locations
7.2 tbt.ft) 1.2tbttij
/ a >,9 I >,9
I t L.-.-=-
HATCH
LATCH
1 0x ' 1 . 2 5m m
l8 N.m (1.8kgf.m.
i ?(lb L\--:.-a t r
t)
COWLCOVER
Disconnectthe connector,then remove the wind-

s h i e l dw i p e rl i n k a g ea s s e m b l y .
Japan/Canada-produced:
NOTE:
. Greasethe hatchlatch.
. M a k e s u r e t h e h a t c ho p e n sp r o p e r l ya n d l o c k s
securely.
. Makesurethe cylinderrod is connectedproperly.
(cont'd)
20-113
WindshieldWiperArms and Linkage
Replacement(cont'dl
USA-produced: USA-produced:
>: Boll locations,3 NOTE:Scribea line acrossthe link and windshield

wiper motor to show the o.iginaladjustment.
WINDSHIELD
WIPERLINKAGE
l@.',,.0-- >: Bolt locations,2
ASSEMBLY E 9.8N.mn.o ksf.m,
7 2 rbr'ftl 6x1.0mm NUT
\_q. R I 10 x 1.25mm
tf I N.mto.skstm,I
18 N.m 11.8kgf.m,
P,:!-Y ) 13 rbf.ft)
S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d -
shieldwiper motor.
Japan/Canada-produced:
NOTE:Scribea line acrossthe link and windshield

wiper linkageto show the originaladjustment.
WIPERMOTOR
WIPERMOTOR
'10x 1.25
mm
18 N.m (1.8kgt.m,
rbrftl
SPRING Installationis the reverseof the removalprocedure.
WASHER
NOTE:
. li necessary, replaceany damagedclips.
. I n s t a l lt h e w j n d s h i e l dw i p e r a r m s a s d e s c r i b e d
o n p a g e2 0 - 1 1 7 .
. Checkthe windshieldwiper motor operation.
. Greasethe moving parts.
WIPERMOTOR
WIPERLINKAGE
20-114
RearWindow wiper
Arm and Motor WasherReservoir
1. Removethe hatchtrim panel(seepage20-63). 1. Removethe front bumper(seepage20 94).
2, R e m o v et h e r e a rw i n d o w w i p e r a r m a n d w l p e r Disconnectthe connectorsand washertubes from

motor as shown. the washermotors,
>: Boll locations,

3
/)^ Gxl.o mm
Ql(S) s.eNmtt.orsr'm.
\-/ 7.2 tbf.f
- - '/)
H*?H"[*
Routethe washer tubes
to the washerreservoir
5x1.0mm
9.8 N.m {1.0kgf.m,
7.2 tbf.ft)
WIPERMOTOR
MOTOR WASHER MOTOR

3. lnstallationis the reverseof the removalprocedure. (3D,for somemodels)
NOTE:
a Makesurethe connectoris connectedproperly. 3. Removethe bolts, then remove the washer reser-
a Installthe rearwindow wiper arm as describedon voir.
page20-117.
. Checkthe rearwindow wiper motor operation. lnstallationis the reverseof the removalprocedure
. Greasethe moving parts.
NOTE:
. M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d
washertubesare connectedproperly.
. Checkthe washermotor operataon.
20-115
WasherTube
Replacement
>: Washer nozzle, clip and cushion locations
NOTE: A>,2 B>,3 c>.1
. To removethe windshieldwashertube, removethe
wtwospteloI
left innerfender(seepage20-'106). wrsren =--S1
. To removethe rearwindow washertube (3D).remove
the followingpartsfrom the leftsideof the vehicle.
-
-
I n n e rf e n d e r( s e ep a g e2 0 - 1 0 6 )
lNozzLE CE
i
\- \f
@ |g" |
,
-,J:n
-+3
<:/1+-
Kickpaneland sidetrim (seepage20-60) D>,1 E>,1 F>, 11

- Rearseat backand rearseatcushion(seepage20 -f7!
c
80)
-
Sparetire lid
Rearcenlershelf and rearside shelf lsee page 20-
]\N
60)
- \ \ \
Reartrim panel and side trim panel (seepage 20-
60) WINDSHIELD
TUBE
Ouartertrim panel{seepage20 60)
- Rearrooftrim {seepage20-65) A
* REARWINDOW
Hatchspoiler(seepage20 101) WASHERTUBE
Routethe washertubes
to the washerreservoir
Routethe washertubes
a
I
underthe wire harness.
(seepage20-101).
REARWINDOW
WASHERTUBE
(forsome models)
Installation
NOTE:
. Takecarenot to pinchthe washertubes.
. lf necessary,replaceanydamagedclips.
. After installing,adjustthe aim of the washernoz
zles(seepage20-117).
20-116
Wiper Arms/WasherNozzles
Adjustment
Windshield Wiper/washer: Rear Window Wiper/Washer (3D):
1. Adjust the wiper arms so that their park positions l. Adjust the rear window wiper arm so that its park
matchthe illustration. positionmatchesthe illustration.
View from front to rear View from rear to front
Centerline
REARWINDOW BLACK
WIPEFARM CERAMIC
EDGE
B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y ,
WINDSHIELD
ARMS
WIPER adjustthe washer nozzleso that it aims at position
C as shown in the illustration.
2. B y i n s e r t i n ga t a c k a n d m o v l n g r t a s n e c e s s a r y , NOTE:The fluid jet should hit within a 50 mm (2.0

adjustthe washer nozzlesso that they aim at posi- i n ) r a d i u sa r o u n dp o i n tC .
t l o n sA . A ' , B , a n d B ' s h o w ni n t h e i l l u s t r a t i o n .
NOTE:The tluid jets should hit within a 50 mm (2 0

in) radiusaroundeachof pointsA, A', B, and B'
Distance from center from black

Nozzleaim \ II n e ceramic edge
A a n dA ' 4 0 0m m ( 1 5 . 7i n ) 255mm (10.0in)

B a n dB ' 11 5 m m ( 4 . 5i n ) 322 mm 112.1inl
20-117
Emblems
Installation
Apply the emblemswhereshown.
NOTE:
o Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface.
Attachment Points {Relerencel: U n i t :m m ( i n )
CIVICemblem
TRUNK LID
V€Bion emblem Version emblem Version embl€m
20-118
Sub-frame
Sub-flame Torque Sequence:
CAUTION: Aftel looseningthe sub-frame mounting bolts, be sure to replacethem with new ones'
BOLTS
1 4x 1 . 5m m
90 N.m {9.1 kgf.m,
10 x 1.25mm 66 rb{.ft)
Replace-
38 N.m 13.9kgf.m;
28 tbf.ft)
20-119
FrameRepairChart
Unit:mm (in)
6: Innerdiameter
oETATLAREA:ll
> =
POINTd3
o15{0.591
Transmisaion
Mount Point
20-120
I l:3D
SECTIONAA
UpperArm
o12 10.471
POINT
Upper
a12lo.0l
a25
-o20
{0r8) Locate
o8( Hole
otN' Tank POINT w
Strap
LOCA
Point o20 10.8)LocateHole
Hole SECTION8B
Damoer Lower Bush Center
20-121
Body {'97 model}
FrontSeat Belt
Removal/lnstallation ....20-128
RearSeat
Removal/lnstallation .".20-126
WasherTube
Repfacement .................. 20-129
Windshield
lndex .......... 20'124
I
I
i
i
'97 Model Changes

Outline of
The moldingsidesealwas added.
The methodof installingthe rearseatcushionwas changed.(2Dl3D)
(2Dl3D)
A middlefloor gussetwas addedand the methodof detachingthe seatbelt retractorwas changed.
The installationpositionof the washertube was changed.
Windshield
Index
NOTE:The numbersafterthe part namesshow the quantitiesof the pans used.
UPPERRUEBER
WINDSHIELO DAM
MOLDING
FASTENER, 2
(Selt-adhesive-type,
glassside)
FASTENER,
2
WINDSHIELD
20-124
MoldingSideSeal
lnstallation
Gluethe moldingside sealto the windshieldmoldingon
eachside.
20-125
RearSeat
3D:
>: Boll locations

A>.6 B>,1 c>,1
i
I
tQ6't.o-- | 6x1.0mm I
ps.a ru'-{r.orgr.-, 22N-m 12.2kgf -,]
E 7.2 tbf.ftt 16 tbf.ft)
,)
,/
STRIKER
Bemovethe sidetrim
panel(seepage20 60). STRIKER
6xl.0mm
9.8 N.m {1.0kgt m,i
1.2tbt-ltl !
V v
V Yvt
PIVOT
BRACKET PIVOT
v
RIGHT BRACKET
SEAT
--\--------
>: Cliplocations.14
SEATCUSHION I
; ,-------\
HOOK lMwm
I F E
A I
\_
F
!t
F
Pivot bolt construclion:
WASHER
SEAT.BACK
PIVOTBOLT BRACKET
8 x 1.25mm
Installationis the reverseof the removalprocedure. 22 N.m (2.2 kgf.m, 16 lbnftl
NOTE:
. Beforeattachingthe seat backand seat cushion,make sure there are no twists or kinks in the rear seat belts and
centerbelt.
. When installingthe seatcushion.slipthe seatbelt bucklesthroughthe slits in the seat cushion.
. lf necessary,
adjustthe strikerand seat-back.
i 20-126
I-!
I
8(-). t
2D:
>: Bolt locations

A>,6 B>,1 c>,1
ii @
93;mr,
ksf.m,' v
g 7.2tbrftt ) MIDDLEFLOOR
CENTER
GUSSET
>: Clip locations,14 SEAT-BACKMAT

I
@ni
------irl|H--|
E E )
qr
,/
PIVOTERACKET
RIGHTSEAT-8ACK
i i l
TOOTHED
LOCK
WASHER
BUSHING
PIVOTBOLT BRACKET
SEATCUSHION 8 x 1.25mm
22 N.m (2.2kgtm. 16 lbf.ft)
NOTE:
. Beforeattachingthe seat-backand seat cushion,make surethere are no twists or kinksin the rear seatbelts and
centerbelt.
. lf necessarV,
adiustthe seat-backlatchand seat-back.
20-127
FrontSeat Belt
RemovaUlnstallation
2D l3Dt 4. Removethe upper anchorcover and lower anchor
cap.
1. Slidethe front seatforwardfully.
UPPERANCHORBOLT
7/16-20UNF
2. Remove: 32 N.m {3.3 kgf..n,
. Rearseat-backand rear seat cushion(seepages 24 tbtftl
20-126,1271
. R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D . s e e
page20 60)
@'a--- 'PPERANcHoR
. Reartrim panel(3D,seepage20-60)
. Sidetrim panel(seepages2G60,61)
3. Pull backthe carpetas necessary,and removethe RETRACTOB

MOUNTINGAOLT
bolts.then removethe middlefloor gusset. 6x1.0mm
9.8 N.m (1.0kgt m,
7.2 tbl.ftl
>: Boh locations,8
l-owER
10 x 1.25mm ANCHOR
38 N.m (3.9kgf.m. CAP
I
28 tbt f0
I
+
o
RETRACTOR BOLT
7/16-20UNF LOWERANCHORBOLT
32 N.m (3.3kgf.m, 7/16-20UNF
24 rbnft) 32 N.m 13.3kgl.m, 24lbl.ftl
Removeall the anchorbolts and the retractorbolt,

remove the retractormounting bolt, then removethe
tront seat belt and retractor.
Installationis the reverseof the removalorocedure.
NOTE:
tions as describedon page20-91.
. Makesureyou assemblethe washersand collars
on the upperand lower anchorboltsas shown.
. Beforeinstallingthe anchorbolts,makesurethere
are no twists or kinksin the front seat belt.
20-128
WasherTube
Replacement
NOTE:To removethe windshieldwashertube, removethe left innerfender(seepage20 106).
>: Washernozzle.clip and cushionlocations

a>,2 B>,'l Ct',1 D>,1 E>,1 F>,1 G>,1
ffi,"td-<g *.\ |
wtNDSHtELD .--7 l -r'v!
\T
|
iJ ',',,4
,,
W,'i | '*V
1
.<a>t,
| I
@t"(
\3t / -----J _*)
\\\
E -/ _'' _-/ REAR
l
_ WINDOW
_J
REABWINDOW I wasHERTUBE
9)
WASHERTUBE I \
behind the EcM/PcM bracket.
WINDSHIELD
TUBE REARWINDOW
WASHERTUBE
A
\;
Routeihe washertubes
to the washerreservoar

Installation
NOTE:
. Takecarenot to pinchthe washertubes.
. lf necessary,
(seepage20-117).
adjustthe aim of the washernozzles
. Afterinstalling,
(cont'd)
20-129
WasherTube
(cont'd)
Replacement
NOTE:To removethe rearwindow washertube (3D),removethe followingpartsfrom the leftside of the vehicle.
- Innerfender(seepage20-106)
- Kickpaneland sidetrim (seepage20-60)
- Rearseat-back and rearseatcushion(seepage20-80)
- Sparetire lid
- Rearcentershelfand rearsideshelf(seepage20-60)
- Reartrim paneland sidetrim panel(seepage20-50)
- Ouartertrim panel(seepage20-60)
- Rearrooftrim (seepage20-65)
- Hatchspoiler(seepage20-101)
>: Washernozzle,clipandcushionlocations
A > ,9 B>,2 c>,1
./'-:.1
-?) K) a/j
_____J
To rear window
washernozzle
(seepage20-101).
Installationis the reverseof the removalDrocedure.

motor.
NOTE:
a Takecare not to Dinchthe washertubes.
. lf necessary,
replaceanydamagedclips.
. Afterinstalling.
adjustthe aim of the washernozzles(seepage20-1j7).
20-130
Y
Body ('98 modell
Openerand Latch
Replacement .................. 20'132
'98 Model Ghanges

Outline of
. The hood latch cover was added.
. The hatch handle was added. (3D)
Openerand Latch
Replacement Hatch Handle
HOODLATCHCOVER 1. Removethe hatchtrim panel(seepage20 63).
NOTE:Takecarenot to the hood latchcoverand body. 2. Removethe hatchhandlebolts.
>: Bohlocations,2
I
6x1.0mm
HOODLATCHCOVER 9.8 N.m {1.0kgf.m,I
HOODLATCH "'o::___,/
HANDLEROD
i 20-132
HatchLatch/LockGylinder
4. Notethe positionof the joint on the handlerod (A). 1 . Removethe hatchtrim panel(seepage20-53).
Pry the handlerod of the joint using diagonalcut-
t e r s ; t a k e c a r e n o t t o b e n d t h e r o d . R e m o v et h e Removethe hatchlatchscrews.
hatchhandle.
>: Screw locations.3
6x1.0mm
9,8 N.m {1.0kg{.m.
7,2 tbtttl
EUSHING
Replace. D i s c o n n e ctth e l o c k r o d , t h e h a n d l er o d , t h e l o c k
cylinder rod, and the connector,then remove the
hatchlatch,
l n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e
theseitems: LOCK
. Makesurethe handlerod is connectedproperly. ROO
. Beforeinstallingthe hatchtrim panel,makesure
the hatchopensproperly.
{'
LOCKCYLINDER
RoD
I
/)< /
...Ly'; CONNECTOR
{cont'd)
20-133
Openerand Latch
(cont'dl
Replacement
Pullthe lockrod out.
LOCK
5. removethe lockcylinder.
It necessary,
>: Bohlocation,1
6x1.0mm I
I
9.8N.m 11.0kgf.m,l
!!,b,!)__J
l n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e
thesertems:
. Apply greaseto the hatchlatch.

. Beforeinstallingthe hatchtrim panel,make sure
the hatchopensproperlyand lockssecurely.
20-134
Heaterand Air Conditioning
Heater """""'21-1
A i r C o n d i t i o n i n g' . ' . . . . . . . . . "' 22-1
SYSTEM(SRS}
RESTRAINT
SUPPLEMENTAL
(exceptsome
The civic sRS includesa driver'sairbag locatedin the steeringwheel hub. ln addition,all models
modelsfor Canada)havea passenger's airbaglocatedin the dashboardabovethe glove box'
(*)
lnformationnecessary to safelyservicethe sRS is includedin this serviceManual.ttemsmarkedwith an asterisk
disassembling or replacingthese
on the contentspage include,or are locatednear, SRS components.servicing,
itemswill requirespecialprecautionsand tools,and shouldthereforebe done by an authorizedHondadealer.
@
-;;Gia rendsring the SRS inoperative, which could lead to petsonal iniury or death in the event ol severs
flontal collision, all SRSservicework must be pertormed by an authorized Honda dealer'
personal
. lmproper service procsdures, including incolrect removal 8nd installation of the sRs, could lesd to
injury causedby unintentional activation ol the airbags.
o Do not bump the sRS unit. otherwise, the system may tail in case of a collision, or the airbags maY dsploy
when the ignition switch is ON (lll
. All sRs electrical wiring harnessesare covered with yellow insulation. Related components are locatod in thg
glove box.
steeling column, tront console, dashboald, dashboard lower panel, and in the dashboard above the
Do not use el€stricalt€st equipment on these circuits.
T
tI
Heater
21-2
fffustratedlndex ................................... Temperature Control
CircuitDiagram ,,,,,....21-3 Adiustment ............21-23
Troubleshooting Mode Control Motol
21-4
SymptomChan ............................... Test ................. .......21-24
HeaterControl PanelInput/Output Repfacement .........21-24
21-5
Signals..........................................RecirculationGontrolMotor
Flowcharts Test ................. .......21'25
BlowerMotor Speed ...................21-6 Repfacement ,.,,,.,,.21-25
21-8
BlowerMotor ............................... Relay
ModeControlMotor ....................21-11 Test ................. .......21-26
RecirculationControl Motor ,,,....21-14 Heater Fan Switch
Blower Unit Test ................. .......21-26
Replacement .........21-16 Mode Control Switch
Overhaul ................21-17 Test ................. ..,.,..21-27
* HeaterUnit
* Read SBS precautions before working in
Replacement .........21-18
Overhauf ................21-20 this area.
HeaterControl Panel
Repfacement .........21-21
Overhauf ................21-22
lllustratedIndex
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions.and proceduresin the SRS

section{24)beforeperformingrepairsor service.
BLOWERUNIT
Replacement,page21'16
Overhaul,page21 17
HEATEBUNIT
Feplacement,page21,18
Overhaul,page21-20 BLOWER
RESISTOR
Test,page21-7
CONTROLMOTOR
Test,page21-25
page21-25
Replacement,
A/C SWTTCH
{with A/c)
HEATERVALVECABLE
MODECONTROL
MOTOR
Test,page21-24
R e p l a c e m e n t ,p a g e 2 1 2 4
TER FAN
swrTcH
AIR MIX CONTROLCABLE Test,page21-26
Adiustment,page21'23
Replacement,page21 22
MODECONTROL HEAIERCONTROL
swtTcHEs PANEL
lest, page21-27 Replacement,page21-21
Ovethaul,page21-22
TEMPERATURE CONTROL
LEVER
page2123
Adjustment,
Defroster-aqtivatedA/C System
Turningthe defrosteron activatesthe A,/Cand sets the air flow mode to FRESH.It is possibleto turn the Ay'Coff or to
changethe air flow to RECIRCULATE by pressingthe Ay'Cbuttonor the FRESH/RECTRCULATE button.
21-2
CircuitDiagram
a UNDEN'HOOD BOX
FUSE/RETAY
UNDEsOASH
FECIRCULATION
BLOWEF
a 17
II
I
BLU/RED
i,fi*r.,{ ?r,l -tr'-?

eil+ji'^*'l-fl
Lf:}
| | Ieff{+jir*'It-} Lr_l il:Y
?r
HEATERCONTROL
PAN€L
a I
G401
DASHLIGHTS
SRIGHTNESS
G'102 CONTNOLLEF
21-3
{
Troubleshooting
SymptomGhart
NOTE:
. Checkthe enginecoolantlevel,and allowthe engineto warm up beforetroubleshooting.
. Any abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurements needed,usea multimeterwhen testing.
. Beforeperformingany troubleshootingprocedurescheckl
._ Fuses*1No.47 \1.5 A), *1No.55 {40A}, *,No. 17 (7.5A)
- G r o u n d sN o .G 4 0 1 c, 4 0 2
- Cleanliness and tightnessof all connectors
*rr In the under-hoodfuse/relaybox
*' : In the under-dash fuse/relaybox
Symptom Remedy
Hot air flow is low. Blowermotor runs,but one or more Performthe proceduresin the flowchan(seepage21 6).
speedsare inoperative.
Blowerruns properly. Checkfor the following:
. Cloggedheaterduct
. Cloggedheateroutlet
. lncorrectdoor position
No hot air flow. Blowermotor does not run at all. Performthe proceduresin the flowchart(seepage21-8).
Blowermotor runs. Checkfor the following:
. Cloggedheaterduct
. Cloggedbloweroutlet
. Cloggedheatervalve
. F a u l t ya i r m i x d o o r
. Heatervalve cable adjustment(see page 21-23l,
' Air mix controlcableadjustment(seepage21-23)
. Faultycoolingsystemthermostat(seesection10)
' Cloggedevaporator(with air conditioning)
. Frozenevaporator(with air conditioning)
Mode controlmotor does not run, or one or more modes Performthe proceduresin the flowchart(seepage21-l 1).
are inoperative.
Recirculation
controldoor does not chanqebetween Performthe proceduresin the flowchart(seepage2'l-14).
FRESHand RECIRCULATE.
I
II 21-4
r-
HeaterControlPanelInput/OutputSignals
HEATERCONTNOLPANEL14PCONNECTOR
Terminal Wire Terminal Wire

Signal Signal
No. color No. color
YEL HEAT/OEF INPUT 8 YEURED VENT INPUT
BLVYEL tG2 INPUT GRN/YEL HEATA/ENT INPUT
INPUT '10 BLK GROUND OUTPUT

WHT/BLU +B
YEUBLU DEF INPUT BLU/RED A.iC THERMOSTAT INPUT

DASHLIGHTS
RED OUTPUT 12 GRN/WHT FRESH INPUT
BRIGHTNESS
CONTROLLER
LIGHT
COMBINATION
6 RED/BLK INPUT 13 GRN/RED RECIRCULATE INPUT
SWITCH
7 BLU^r'r'HT HEAT INPUT 14 GRN HEATERFAN SWITCH OUTPUT
21-5
Troubleshooting
Blower Motor Speed
Blower motor runs. but one or

more sp€edsare inoperalive.
Check for a 3hort or an open in

the wire(s):
Turn the ignitionswitch ON (ll),
and the heaterfan switch OFF.
Doesthe blowermotor run?
HEATERFAN SWITCII6P CONNECTOR

Checkfor a shon in the wi.e{s}:
2, Disconnectthe blower motor
2P connector,
3. Removethe centerdashboard
lower cover (see section20),
and disconnect the heaterfan
switch6P connector,
4. Disconnectthe blower resis
tor 4Pconnector,
the No. 2, 3, 4 and 5 terminals
o f t h e h e a t e rf a n s w i t c h 6 P
connectoa r nd bodyground
individually.
Replace the heater f'n switch.
Repair short in the wirels)

between the blower resbtor, the
heater fan switch and the blower
6A tl\
z t-r,
- .
Frompage2'l-6
Checkth6 blower r€sistor: BLOWEBRESISTOR

'1. Turnthe ignitionswitchOFF
2. Disconnectthe blower resis
tor 4P connector,
3. Measure the resrstance
betweenthe No. 2 and No. 4
terminalsof the blower resis'
tor.
ls thereapprox.2- 3 ohms?
Checktor an open in thg witelslr HEATERFAN SWITCH6P CONNECTOR

1. Reconnect the blower.esistor
4Pconnector. BLU/WHT
2. Removethe centerdashboard
lower cover (see section20i, BLU/BLK
and disconnect the heaterf€n 2
switch 6P connector. JUMPER
3. Turnthe ignitionswitchON (lli. 1 6
WIRE
4. Ground each of these termi- BLUI IBLU/Y
nals individuallyin the follow-
ing order;No.4, 2, 5 and 3.
WIRESIDEOFFEMALETERMINALS
Does the blower motor run at Beolaco the heator fan switch.
p r o g r e s s i v e l yh i g h e r s p e e d s ?
Repairopen or causeof excessive

r e s i s t a n c ei n i h G a p p r o P . i a t e
wirels) between the blower resis-
tor and tho heaterlan switch.
21-7
Troubleshooting
Blower Motor
Blower motor does not run al ell.
Checkthe No.55 {40A)tuse in the

undeFhoodfuse/relaybox, and
t h e N o . 1 7 ( 7 . 5A ) f u s e i n t h e
under-dashfuse/relaybox.
Roplacothe lu3o(!1,rnd rochock.
BLOWERMOTOR2P CONNECTOR
Checktho blowcr motor:

1. Connectthe No. 2 terminaloI F
the blower motor 2P connec- l l l
tor to body ground with a

l-,1
ruueeif6rureu
wrRE
1
Doesthe blowermotor run? To page21'9
WIRESIDEOF FEMA1TTERMINALS
Checktor an open in the wire: glulwxr

1 . D i s c o n n e ctth e j u m p e r w i r e F
and the blowermotor 2P con- L'--r'|--]
nector.
2. Measurethe voltagebetween L1J d)
the No. l terminal and body
ground,
I
ls there batteryvoltage?
Chackthe blower motor relay:

2 . R e m o v et h e b l o w e r m o t o r
rolayffom the under-hood
fuse/relaybox, and test it (see
page21-26).
Rcpltc€ tho blowo. motol r.l!y.
To page21-10
21-8
Frompage21-8
Checklor an open in the wite:

1. Turn the ignitionswitch OFF, HEATERFAN SWITCH6P CONNECTOR
a n d d i s c o n n e ct th e j u m P e r
2, Removethe centerdashboard
lower cover (seesection20),
and disconnect the heaterfan
switch6P connector.
l nd body
t h e N o . 3 t e r m i n aa
ground.
Ropair open in the wire between
ls there battery voltage? the blower motor and the heatol
lan switch.
Checkfor an open in the wire:

the No. l terminaloftheheater
fan switch 6P connectorand
bodyground.
Replacethe heaier fan switch.
Check lor an oDen in the wire

between the h6ater tan switch
and body ground.It the wir€ is OK,
checklor poor ground at G401and
G&2.
(cont'd)
21-9
Troubleshooting
BlowerMotor (cont'dl
Frompage21 8
Check the under-hood fuse/relay BLOWERMOTORRELAY4P SOCKET

box:
Measure the voltage beNveen the
No. 3 terminal of the blower
motor relay 4P socket and body
ground.
rD
{
Chockfor an open in the wi.e: rl- ,

'1. Turnthe ignitionswitchON (ll).
l 2 1 1 l
2, Me6surethe voltage between r r -
t h e N o . 4t e r m i n a l o f t h be l o w l r l 3|
er motor relay 4P socketand IBLK/YEL
body ground.
o)
Y
Repairopcn in the wire between
the No. 17 luse and the blowe.
motor reley.
Checktor an opon in the wire:

2. Check for continuity betlveen
the No. 2 terminal of the blow-
er motor relay 4P socketand
body ground.
Check to. an oDen in the wiie

between lhe blowor motor relev
and body glound. lf the wire is
OK. check for poor ground at
G{01 .nd G{02.
R e p a i ro p o n i n t h e B L U / W H T
wiae bolwean the blower motor
relav snd the blower motor,
21-1 0
Mode ControlMotor
Mode control motoa does nol run,

or one or more modes are inoPen_
tive.
check the No. 17 (7.5A) fuse in

the under'dashfuse/relaybox.
ReDlacethe lus€, and rech€ck. MODECONTROLMOTOR7P CONNECTOR
f
ChscktoJ an open in the wire:
1. Disconnectthe mode control 3 I 5
motor7P connector, BLK/YEL
2. Turn the ignitionswitch ON (ll).
the No. l terminal and body
grouno.
Repairopen in the wi.e between WIRESIDEOF FEMALETERMINALS

ls lhere battery voltage? the No. 17 fuse and the mode
control motor,
_ l T
Checktor an open in the wite:
1. Turnthe ignitionswitchOFF. 1 I 6 7
2. Checktor continuitybetween BLK
the No.7 terminalofthe mode
control motor 7P connector {l
and bodyground.
Check for an opon in the wire

h$ro6n the modc control motor
and body ground.lllho wire is OK,
check lor poor gaoundtl G,Ol and
G402.
Test the mode control motor (soe

page21-24).
Check the mode control linkage
and doors:
1 . R e m o v et h e m o d e c o n t r o l
lsthe modecontrolmotor OK? motor (seepage21 24).
2. Checkthe mode controllinkage
and doors for smooth move-
ment.
To page21-12
Do the mode control iinkage

and doors move smoothly?
Roolacethe mode control motor.
(cont'd)
21-11
Troubleshooting
Mode Control Motor (cont'd)
F r o mp a g e2 1 - 1 1 HEATERCONTROLPANEL1{P CONNECTOR
Check for a short in the wire{sl:

1. Remove the center dashboard
Repeir any short in the wire(sl

between the mode control motol
and the heatercontrol panel.
Checkfor a short to Dower:

Checkthe samewiresfor voltaoe.
Repairshort to power in the wir6

betweon the mode control motor
ls thereany voltage? rnd the heater control oanel.
(This short damages the heatel
control oanel.l
T o p a g e2 1 - 1 3
2 1- 1 2
Frcm page21-12 HEATERCONTROLPANEL14PCONNECTOR
Ch6ckfor an open in tho wirolsl:

followingterminalsof the mode
control motor 7P connectorand
the heatercontrolpanel14Pcon'
nector,
7P: 14P:
No.2-No.4
N o . 3 - N o .1
N o . 4 - N o .7
No.5- No.I
No.6- No.8
MODECONTROLMOTOR7P CONNECTOR
Ropeir lny op€n in tha wilolsl

b€iwe6n tho modo conlrol motor
and th6 haaie. contol P.nal.
Ch6ck lo. looso wiro3 ot Pool

connoc'tion3 at iha haatcr conttol
prn6l l/aP conncctot. ll tho con-
nactions !.o good, rcplace tho
hgel€r control pancl.
21-13
Troubleshooting
Recirculation
ControlMotor
Recirculation control door does

not change b€tween FRESHand
RECIRCULATE.
Checkthe No. 17 (7.5Al {use in

the under-dashfuse/relaybox.
Roplacethe lus6, aod rscheck.

RECISCULATION
CONTROLMOTOR
4P CONNECTOR
Checkfor an open in th6 wi.e:

1 . D i s c o n n e ctth e r e c i r c u l a t i o n 1
control motor 4P connector.
2. Turnthe ignitionswitchON (ll). BLK/YEL
3. Messurethe voltagebetween
t h e N o . ' 1t e r m i n a a
l nd body
ground.
Repairopen in tho wirc botweon WIRESIDEOF FEMALETERMINALS

the No. 17 tuse and lhe recircula-
tion control motor.
Check the recirculationcontrol

motor:
2. Test the recirculationcontrol
motor (seepage2l 25).
Check the rccirculation control
linkagoand door:
1. Removethe recirculation con-
trol motor (seepage2l-25).
2. Checkthe recirculationcontrol
linkageand door for smooth
To page 21 'l5
Oothe recirculation
controllink- Repairthe recirculationcontrol
ageand door move smoothly? linkage or door.
21-14
F r o mp a g e2 1 - 1 4 HEATEFCONTROLPANEL14PCONNECTOR
1 2 ;-? 4
CheckIor a short in the wite(s): 7 8 9 'olx 11 12 r3 14
1. Removethe centerdashboard GRN/wHr GRN/REO

lower cover (seesection20), | |
and disconnedthe heatercon
trol panel14Pconnector'
oo
2. Checkfor conlinuitybetween
the No. 12 and No 13 termi-
nalsand body groundindivid WIRESIDEOF FEMALETERMINALS
R6air short in the wilo(a) bstween

the r€drculaiion conttol motor rnd
tfte heater control Panel.
1 2 4
t ?
1 8 1 0| 11 12 1 3 1 4
Checkfor a short io powar:
GRN/WHT GRN/RED
Checkthe samewiresfor voltage
v)(v
Repairshort to Powsr in the wir€

between the recirculstioncontrol
motor and tho heator control
penel. lThis short damagesthe I
h6ater control pan6l'l
1 2 ''l 1 5 6
Checklor an opon in tho wire{s}: 7 8 9 10I 1 1 1 2 't3 1 1 I

tollowing terminalsof the recircu GRN/W -tl GRN/RED
lation control motor 4P connector
t-
A
and the heatercontrolPanel14P
I
4P: 14P:
o
I
N o . 2 - N o .l 2
N o . 4- N o .1 3
I_
GRN/WHT \ r - iRN/RTiD
Repair open in the wire(sl

,lr\/ 4
between the recitculationcomrol

motor and lhe heeter conttol CONTROLMOTOR
RECTRCULATION
oanel. 4P CONNECTOR
Check for loose wiles or Poor
connectionsat the heater control
oanel l,lP connector. ll tha con-
nections are good, replace the
heater control Panel.
21-15
BlowerUnit
Replacement
NOTE:The blower motor, recirculationcontrol motor With Air Conditioning
and blower resistorcan be replacedwithout removinq 3-b. Removethe evaporator(seepage22-25).
the blowerunit (seenext page).
1. Remove the glove box {see section 20). 6x1.0mm

9.8 N.m
2. Remove the self-tapping screw and the passenger,s 7.2 tbt tll
dashboard lower cover. Remove the bolt, the nut
and the knee bolster, then remove the five bolts and
the glove box frame.
I :r-
KNEE iCIi1,
6x1.0mm
9,8N.m(1.0kgf.m,7.2
tbtf
Disconnectthe connectorsfrom the blower motor,

blowerresistorand recirculationcontrolmotor.
Removethe wire harnessclip from the recirculation
GLOVEBOX FRAME controlmotor,and releasethe wire harnessfrom the
clamp on the blower unit. Removethe two mount-
ing bolts,the mountingnut and the blowerunit.
Without Air Conditioning 6x1.0mm

3-a. Removethe wire harnessfrom the heaterduct,then 9.8 N.m {1.0 kgf m,
7.2 tbf.tr)
removethe two self-tappingscrewsand the heater
quct.
tr
tr 6xl.0mm
9.8N.m(1.0kgf.m,
7.2tbl.ttl
Installin the reverseorder of removal.Make sure
that there is no air leakage.
HEATERDUCT
6a ^ t\
za-tr,
Overhaul
NOTE:
. Beforereassembly, controldoor and linkagemove smoothlywithout binding'
makesurethat the recirculation
control motor, make control door
sure its positioningwill not allow the recirculation
. when attachingthe recirculation
to be pulledtoo far.
control motor, connectpower and ground,and watch the movementof the recircula-
. After attachingthe recirculation
tion controldoor.
21-17
HeaterUnit
Replacement
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e 4. the heaterhosesfrom the heaterunit.
Disconnect
SRScomponentlocations.precautions,and procedures
in the SRSsection124)beforeperformingrepairsor ser- CAUTION:Enginecoolant will damage paint.
vice, Ouicklyrinse any spilled sngine coolantftom painted
surtaces.
1 . Disconnect
the negativecablefrom the battery.
NOTE| Enginecoolantwill run out when the hoses
2. When the engine is cool, set the temperaturecon- drain it into a cleandrip pan.
are disconnected;
trol leverto MAX. HOT(openthe heatervalve),then
drain the enginecoolantfrom the radiator{seesec-
tion10).
HEATERHOSE
!@ Do not remove the radiator cap when {OUTLETSIOEI
the engine is hot; the engins coolant is under pres-
sure and could severelyscald you.
3. Open the clamp, then disconnectthe heatervalve

cablefrom the heatervalvearm
CLAMP
5. Removethe mountingnut from the heaterunit.
NOTE:When removingthe mountingnut, takecare

n o t t o d a m a g eo r b e n d t h e f u e l p i p e s ,t h e b r a k e
pipes,etc.
HEATERVALVE ARM
8 x 1.25mm
HEATERVALVECABLE 22 N.m (2.2kgl.m, 16lbf.ft)
21-14
Removethe dashboard(seesection20).
7. Removethe heaterduct (seepage 21-16)or evapo-

rator(seepage22-251.
8. Disconnectthe connectorfrom the mode control

motor, and removethe wire harnessclips and wire
harnessJromthe heaterunit. Removethe clip from
the heater duct, then remove the two mounting
nutsand the heaterunit.
6x1.0mm
9.8N m 11.0kgf'm,7.2lblft)
TERDUCT
HEATER
UN]T
9. lnstallin the reverseorderof removal.Makenote oi

the followingitems.
a Apply sealantto the grommets.

a Do not interchangethe inlet and outlet heater
hoses.Makesurethat the clampsare secure.
R e f i l lt h e c o o l i n g s y s t e mw i t h e n g i n e c o o l a n t
(seesection101.
Connectall cables,and makesurethey are prop-
erly adjusted(seepage21-23).
Makesurethat there is no air leakage.
21-19
HeaterUnit
Overhaul
1. Removethe two self-tappingscrewsand the heater Pullout the heatercorefrom the heaterunit.
corecover.
NOTE: Be careful not to bend the inlet and outlet
Pullout the grommetfrom the heatercore pipes. pipesduring heatercore removal.
Removethe self-tappingscrewand the clamp. Assemblein the reverseorderof disassembly.
HEATERCONECOVER
21-20
HeaterControlPanel
Replacement
'1. Remove the driver's dashboard lower cover, the
glove box and the center dashboardlower cover
(seesection20).
Disconnect the air mix controlcablefrom the heater
unit (seepage21-23).
Removethe rearwindow defoggerswitch,the hazard
warningswitchandthe audiounit (seesection23).
Disconnectthe connectorsirom the heatercontrol
panel.Removethe five self-tappingscrewsand the
centerpaneltogetherwith the heatercontrolpanel.
NOTE:The lockingtabs are on the bottom of the

connectors,
AIR MIX CONTROL

CABLE
5. Remove the four self-tapping screws and the heater

controlpanel,
HEATER PANEL
CONTROI.
Installin the reverseorderof removal.Adjustthe 8ir

mix control cable and the heatervalve cable (see
page 21-231.
21-21
HeaterGontrolPanel
Overhaul
\n4.---
^Jj- 6:B
ffi ^gvry AIR MIX CONTROLCABLE
Adiustment,page21'23
f f i \
g HEATERFAN SWITCH
Test,page21-27
Air Mix Control CableReplacement
1. Cut the innercableon the leverside ofthe cableholder,then removeboth piecesofthe innercable.
2. Usinga sharpknife,cut completelylhroughthe end of the cablehousingat the two locations.
3. Slidethe largesectionofthecable housingoutofthecable holder,beingcarefulnot to damagethe cablestops.
4. Carefullyremovethe cut piecesof the cablehousingwith a smallflat tip screwdriver.
5. Hookthe tip of the new air mix control cableto the temperaturecontrol lever,then push the cable housinginto the
cableholderuntil it locksinto place.
AIR MIX CONTROLCABLE
CAALEHOLDER
TEMPERATURE
CONTFOLLEVER
re controlleverslidessmoothlythroughthe full strokefrom rightto left.

NOTE:Afterassembly,checkthat the temperatu
21-22
Control
Temperature
Adjustment
1. Under the hood, disconnectthe heater valve cable 6. Underthe hood, move the heatervalve arm to the
from the heatervalve. f u l l v c l o s e dp o s i t i o n t, h e n a n a c ht h e h e a t e rv a l v e
cableto the heatervalvearm.
CLAMP
TER
VALVE
HEATERVALVEA8M CABLE HEATER
VALVE
CABLE
2. Under the dash, disconnect the air mix control cable HEATERVALVE ARM
housing from the cable clamP.
7. H o l d t h e h e a t e rv a l v ea r m i n t h e c l o s e dp o s i t i o n ,
and gentlypull on the heatercableouter housingto
take up any slack,then installthe heatervalvecable
h o u s i n gi n t ot h e c a b l ec l a m p .
3. Setthe temperaturecontrolleverto MAX. COOL
With the air mix control cable attachedto the air

mix controlarm, gently pull on the outer cable
housingto fully closethe door and to removeany
slackin the cable.Don't pull to hard,or the temper-
aturecontrolleverwill move.
Hold the air mix control arm againstthe stop, then

s n a p t h e a i r m i x c o n t r o l c a b l e h o u s i n gi n t o t h e
c a b l ec l a m p .
21-23
ModeControlMotor
Test Replacement
1 . Disconnectthe 7P connectortrom the mode control 1 . Disconnectthe 7P connector from the mode control
motor. motor.
2. Connectbattery power to the No. 1 terminal, and Removethe rod from the arm of the mode control
g r o u n dt h e N o ,7 t e r m i n a l . motor.
CAUTION: Never connect the battery in the oppo- Bemovethe two self-tappingscrewsand the mode
site direction. controlmotor.
U s i n ga j u m p e r w i r e , c o n n e c t h e N o . 7 t e r m i n a l
individuallyto the No. 2, 3, 4, 5 and 6 terminalsin
that order. Eachtime the connectionis made' the 7P CONNECTOR
mode controlmotor shouldrun smoothlyand stop.
NOTE:It the modecontrolmotor does not run when

jumping the first terminal,jump that terminalagain
afterjumpingthe otherterminals.The mode control
motor is OK it it runs when jumping the first termi-
n a la g a i n .
MOOECONTROLMOTOR
Installin the reverseorderof removal.After installa-

t i o n , m a k es u r e t h e m o d e c o n t r o lm o t o r r u n s
smoothlv.
4. lf the mode control motor does not run in step 3,

removeit, then checkthe mode control linkageand
doorsIor smoothmovement.lf they move smoothly,
replacethe modecontrolmotor.
21-24
I
I
RecirculationControlMotor
Test Replacement
1 . Disconnectthe 4P connectorfrom the recirculation 1. Disconnectthe 4P connectorfrom the recirculation
controlmotor. c o n t r o l m o t o r , a n d r e m o v et h e w i r e h a r n e s sc l i p
from it.
2. Connectbattery power to the No. 1 terminal. and
groundthe No. 2 and No. 4 terminals;the recircula- Removethe two self-tappingscrewsand the recir-
tion controlmotor shouldrun smoothly. culationcontrolmotor.
CAUTION: Never connect the battety in the oppo-

site direction.
Disconnect the No. 2 or No. 4 terminalsfrom ground;

controlmotor shouldstop at FRESH
the recirculation j
or RECIRCULATE.
NOTE: Don't cycle the recirculationcontrol motor

for a long time.
CONTROLMOTOR
RECIRCULATION
CONTFOLMOTOR
Installin the reverseorder of removal.After installa-

tion, make sure the recirculationcontrol motor runs
smoothly.
4. controlmotor does not run in step

lf the recirculation
controllink-
2. removeit, then checkthe recirculation
age and door lor smooth movement.lf they move
smoothly,replacethe recirculationcontrolmotor.
21-25
Relay HeaterFanSwitch
Test Test \
Thereshouldbe continuitybetweenthe No. I and No. 3 Checkfor continuityb€tweenthe terminalsaccordingto

terminalswhen power and ground are connectedto the the table below.
No. 2 and No. 4 terminals,and there shouldbe no conti-
nuitywhen power is disconnected. Terminal ,1 a
o 4 3
Position
OFF
o o
o- -o
o- --o
o- o
rH [ Fa
' r t
1 2 -
ffi
"++
IF.=qI
l l
21-26
Mode ControlSwitch
Test
Checkfor continuitybetweenthe terminalsaccordingto
the table below.
Terminal
10 7 1 8 I
Position
Heat o- -o
HeaVDef o -c
Def o- -o
Vent o- -o
Heawent o- -o
7 8 9 ;l t
21-27
l
T
I
;
Air Conditioning
SpeciafTools Evaporator
"'.......".22'2
22-3 Replacement
lffustratedIndex .........................'---...". .-."....22-25
Wiring/ConnectorLocations'.............' 22-4 Overhaul ................22-26
Description Gompressor
outfine ............ """' 22'5 Repfacement -......-.22-27
....'....22'6 22-29
fffustratedfndex "........'.....'..."..'.."..
Circuit Diagram
Tloubleshooting ---22'30
Clutch Inspection...............'.....'.'.'
22'7
SymptomChart ...................."..'---..' ...".. 22-31
Cfutch Overhaul'.....'..'........"....
" ". 22-8
CondenserFan ....."......'.".........., Thermal Protector Replacement .... 22'33
Compressor ."'...-'.'22'11 RefiefValve Replacement.....-......". 22'33
A/C System ..---.."'.22-15 A/C GompressorBelt
A/C Thermostat Adiustment .-."'..--..22-34
Test ............"'.. ..""'22'14 Condenser
Relay Repfacement -......'.22-35
Test ...'............. .......22-14 A/G System Service
A/C ServiceTips and Precautions....'.22-19 Evacuation ........,....22'36
A/C System Torque Specifications ...-22-2O Charging "'......".....22-37
A/C System Service LeakTest ....'..........22-37
Recovery ...".'...-.""22'21
22-22
PerformanceTest .....................'..',,'.
...."' 22'24
PressureTest Chart ..'.......""....
SpecialTools
Ret. No. Tool Numbor Description Oty I PageReference
o *07JGG- 001010A BeltTensionGauge 1 22-34

o 07sAz - 0010004 BackprobeSet 2
'I
22-12,14
Ar 07947- 6340300 DriverAttachment 22-3'l
@ 07965- 6920500 Hub AssemblyGuideAttachment 't
* Includedin the BeltTensionGaugeSet,07TGG-001000A.
e @
,a
o
I
22-2
lllustratedIndex
A/C PRESSURE SWITCH

Whenthe refrigerant pressureis below200kPa(2.0kgtcm' ,
28 psi) due to refrigerantleakageor above 3200kPa 132kgflcm',
EVAPORATOR
page22-25 455 psi) due to refrigerantblockage,the A,/Cpressureswitch
Replacement,
opensthe circuhto the A/Cswitchand stopsthe air conditioning
Overhaul,page22-26
to protectthe compressor.
SERVICEVALVE
ILOW.PRESSURESIOE}
Test,page22 18
CONDENSER RECEIVER,/DRYER
page22-35
Replacement,
page22'27
Replacement,
22-3
Wiring/ConnectorLocations
DIODE,
CONOENSER FAN RELAY,
COMPRESSOF CLUTCHRELAY
{Locatedin the underhoodfuse/relav
box}
FAN
CONDENSER
CONNECTOR
COMPARTMENT
WIREHARNESS
CONNECTOR
22-4
Description
Outline
The air conditionersystemremovesheatfrom the passengercompartmentby circulatingrefrigerantthroughthe system
as shownbelow.
High-temperature/ High-temperature/ High-temperature/

h i g h - p r e s srue g a s h i g h - p r e s s u rlei q u i d h i g h - p r e s s ulri q
euid
t r a p so e D f l s ,
ano removes
Suction and compression Radiationof heat motsture
coMpREssoR RECEIVER/DRYER
-CoNDENSER-
Less moisturized Moreliquidified
low-pressurevapor low-pressurevapor
Absorption of heat
E VAT\JhA I UN \
EVAPORATOR
RECEIVERLINE
LINE
DISCHARGE
SUCTIONLINE
RECEIVER/DRYER
COMPRESSOR
This car uses HFC-134a

{R-'134a) Pay attentionto the following
refrigerantwhich does not containchlorofluorocarbons,
servtcertems:
(R-134a)They are not compatible.

CFC-12(R-12)and HFC-134a
a Do not mix refrigerants
Use only the recommendedpolyalkyleneglycol(PAG)refrigerantoil (SP-10)designedfor the R-134acompressor.
Intermixingthe recommended{PAG)refrigerantoil with any other refrigerantoil will resultin compressorfailure.
All Ay'Csystemparts(compressor, dischargeline,suctionline,evaporator,condenser,receiver/dryer, expans'onvalve.
O-ringsfor joints)haveto be properfor refrigerantR-134a.Do not confusewith R-12 parts.
a Usea halogengas leakdetectordesignedfor refrigerantR-134a.
R-12and R,134arefrigerant servicingequipmentare not interchangeable,Useonly a Recovery/Recycling/ChargingSystem
is
that U.L.,listedand is certified
to meet the ot
requirements SAE J2210to R-134a
service air systems.
conditioning
Alwaysrecoverthe refrigerantR-'134a with an approvedRecovery/Recycling/Charging Systembeforedisconnecting any
A,/Cfitting.
22-5
CircuitDiagram
U N D E R - H O OFDU S E / B E LB
AOYX UNDER DASH
FUSE/RELAY
8OX
N 0 . 4 1i 8 0 A ) N 0 . 4 2( 4 0 A ) N o . 1 7( 7 . 5 4 1
No.56l20A)
4
I
COMPRESSOR
CLUTCH
RELAY
j 1
BLU/ryVHT
I
iS. rc
(,r ) PRESSURE
\.:J./ SWITCH
CONDENSER COMPRESSOR
FANMOTOR cLUTcH REsrsToR
.N..i.._-)
BIK
I
22-6
Troubleshooting
SymptomGhart
NOTE:
. Any abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurements needed,usea multimeterwhen testing.
o Beforeperformingany troubleshootingprocedurescheck;
. 7 ( 7 . 5A ) , * 1 N o . 5 6( 2 0A ) , * , N o .1 7 ( 7 . 5A l
_ F u s e s* 1 N o 4
- GroundsNo. G401,G402,G751
- Cleanliness and tightnessot all connectors I
*r: In the under-hoodfuse/relaybox I
*2:In the under-dashfuse/relavbox I
Symptom Remedy !
s
Condensertan does not run at all. Performthe proceduresin the flowchart(seepage22-8).
Compressorclutchdoes not engage Performthe proceduresin the flowchart(seepage22-11)
A,/Csystemdoes not come on (compressorand tan). Performthe proceduresin the flowchan(seepage22-15).
22-7
Troubleshooting
CondenserFan
Condens€a
lan does noi run at ell.
Removethe condenserfan relay,

and test it {seepage22-18).
Replacethe condensertrn relay.
CONDENSER
FAN RELAY4P SOCKET
Checkthe unde.-hoodIuse/r€lsy
box:
No. 3 terminalof the condenser
f a n r e l a y 4 P s o c k e ta n d b o d y
ground.
Checktho conden3e.tan:
Connectthe No. 'l and No. 3 ter
minafs of the condensetlan rclay
4P socketwith a jumper wire.
Doesthe condenserfan run? To page22'9
To page22-10
22-8
Frompage22 8 FAN RELAY'P SOCKET
CONDENSER
wHTa------l
1 l
I r--------------1
Checkfor an open in the wire: l t 3 l
1. Disconnect the iumperwire. l f f i
2. Disconnect the condenserfan
2Pconnector. I l n l ' l
3. Checkfor continuitybetween 6
\:/
\ -
the No. 1 terminalol the con-
denserfan relay4Psocketand
II r- r
the No. 1 terminalof the con-
denserfan 2Pconnector.
L-r,T;l
wHT t-----l-----J
CONDENSERFAN 2P CONNECTOR
Repairop€n in the wire betwoen WIRESIDEOF FEMALETERMINALS
tho condenser fan relay and the
condensertan.
Checkfor an op.n in the wire:

Checkfor continuity beNveenthe
No. 2 terminal ol the condenser
fan 2P connector and body
ground.
ls therecontinuity? RsDlacethe condenserfan motor,
Chock Ior an ooen in lhe wile

between the condenser tan and
body ground. ll the wire i3 OK,
chsck for poor ground at G751.
(cont'd)
22-9
Troubleshooting
Fan(cont'dl
Condenser
Frompage22-8
Checkthe diode:
1. Disconnect the jumperwire.
2 . R e m o v et h e d i o d e f r o m t h e
under-hood fuse/relaybox.
3. Checkfor currentflow in both
directionsbetweenthe A and
B terminals.
ls therecurrentflow in only a o--J(-----o n

one direction?
22-10
Compressor
Removethe compressorclutch
relay,and test it (seepage 22-18)-
CLUTCHBELAY4P SOCKET
COMPRESSOR
Checkthe under-hoodfuse/relay
box:
No. 3 terminalof the compressor
clutch relay 4P socketand body
ground.
ls there battery voltage?
JUMPER
WIRE
Checktho compr*sor clutchl
Connectthe No. 1 and No. 3 termi'
nalsotthe compressorclutchrelay
4Psocketwith a iumoerwire.
Doesthe comoressorclutchclick? fo page22-12
Checklor.n oponin the wir€:

1. Disconnect the jlmper wire.
2 . D i s c o n n e ctth e c o m p r e s s o r
clutch1Pconnector.
the No. 1 terminalof the com-
pressor clutch relay 4P socket
and the terminal of the com
pressorclutch1Pconnector,
Rapairopen in tho wite botwoen

ls therecontinuity? tha compa6sor clutch aelay ,nd
tho compressorclutch.
COMPRESSOR CLUTCH1P CONNECTOR
WIRESIDEOF FEMALETERMINAL
Insp€ct tho compressor clutch
(s€epago 22-301.
(cont'd)
22-11
Troubleshooting
Compressor(cont'dl
t u o mp a g e 2 2 - 1 1 COMPRESSOR
CLUICH RELAY4P SOCKET
Checkfor an open in the wi.e:

1. Disconnect the jumperwire,
the No. 4 terminalof the com
pressor clutch relay 4P socket
and body ground.
Is there batteryvoltage?
A (32PI
ECM/PCMCONNECTOR
Chocktor an open in thg wira:

1. Turn the ignitionswitch OFF,
then reinstallthe compressor
clutch relay.
2. Nlakesure the A/C and heater
tan switchesare OFF,then turn
the ignitionswitchON lll).
3. Using a *BackprobeSet (T/N
07SAZ- 001000A),measure
the voltagebetweonthe No. 17
terminal of the ECWPCMcon,
nector A {32P) and body WIRESIOEOF FEMALETERMINALS
groundwith the ECM/PCMcon-
n6ctorsconnected.
Repairopen in the wiro between

ls therebatteryvoltage? the compressor clutch .elay snd
rhe ECM/PCM.
fo page22-13 *How to usethe backorobe sets

Connectthe backprobeadaptersto the stackingpatchcords,and
connectthe cordsto a multimetor,Usingthe wire insulationas a
guldefor the contouredtip ot the backprobeadapter,gentlvslide
the tip into the connectorfrom the wire side untalit comesin con-
tactwith theterminalendofthe wire lseesection11).
22-12
Frcm page22-12
SWITCH2P CONNECTOR
A/C PRESSURE
Chocklor an opon in tha wira;

2. Disconnoctthe Ay'Cpressure
switch 2P conneclor.
th€ No. l terminal and body
grouno.
Rsprir open in the wire between
lh6 condanser fan relav and th6
A/C oro$ure switch.
A/C PRESSURE
SWITCH
Ch6ckthc A/C pressuJorwitch:

2. Check for continuity betwesn
th€ No. 1 and No.2 terminals
of th€ NC Dressureswitch.
To page 22-14
Checktor Ay'Csystem pressure.
Rop.ir the A/C pr.3suroploblem.
Replaccth. A/C pr4sute swhch.
(cont'd)
22-13
Troubleshooting
Compressor{cont'd)
Frcmpage22 13
ECM/PCMCONNECTOR
C 131P)
Checkfor an op6n in the wire:
1. Reconnectthe ,a/Cpressure
swilch 2P connector,then turn
the ignitionswitchON {ll).
2. Using a *BackprobeSet {T/N
07SAZ- 001000A),measure
the voltage betweenthe No. 5
terminal ol the EcM,rrPcMcon-
nector C {31P) and body
groundwith the ECM,PCMcon-
nectorsconnected.
Ropairopon in the wire between

ls there batteryvoltage? the A/C oresure switch and the
ECM/PCM.
Check lor loos6 wires or poor

c o n n e c t i o n sa t t h e E C M / P C M
connectorsA {32P}and C 131Pl.It
the connec,tionsare good, substi-
tute a known-good ECM/PCM,
and recheck. lf the symptom/
the oriqinal ECM/PCM.
*How to usethe backprobe sets
Connectthe backprobeadaptersto the st6ckingpatchcords,and
connectthe cordsto a multimeter.Usingthe wire insulationas a
guidetor the contouredtip of the backprobeadapter,gentlyslide
the tip into the connectorfrom the wire side until itcomes in con-
tactwith the terminalend of the wire {seesection11).
22-14
I
l
A/C System
A/C aYstem does not come on

(compressotand fanl.
C h e c kt h e N o . 5 6 f u s e i n t h e
under-hoodfuse/relaYbox and
the No. 17 fuse in the under-dash
Iuse/relaybox.
Replacethe tuse(sl,and recheck.
FAN RELAY'P SOCKET

CONDENSER
Checkfor an open in the wi.e:

1 , B e m o v et h e c o n d e n s e rf a n
relayfrom the under-hood
fuse/relaybox.
3. i/leasurethe voltage between
the No. 4 terminalof the con-
d e n s e rf a n r e l a y 4 P s o c k e t
and body ground.
Ropairopgn in the wile botween

the No. 17 tuso and the con'
donssrlan relay.
Checkth€ under-hoodfuso/relaY
box:
No. 3 terminal of the condenser
f a n r e l a y 4 P s o c k e ta n d b o d y
grouno,
3P CONNECTOR
A/C THERMOSTAT
ChecktoJ an opon in lhe wire:

1. Turn the ignitionswitch OFF,
a n d r e i n s t a l tl h e c o n d e n s e r
Ian relay.
2. Disconnectthe NC thermostat
3P connector.
3. Turn the ignitionswitchON (ll)
4. Measurethe voltage betlveen
the No. 3 terminal and body
ground. WIRESIDEOF FEMALETEBMINALS
Repairopen in the wite betwe€n

the No. l? fuse and tho A/C thet-
mostal.
(cont'd)
To page22 16
22-15
Troubleshooting
A/C System{cont'dl
Ftom page 22-15
Ch6ckfor an open in the wirsi

No. 1 terminalof the A"/Cthermo,
stat 3P connector and body
grouno,
Repai. open in the wire botwaen

the condonser fan rolay and th6
A/C thermGt.t.
Ch€cklhe A/C thermostat:

2. Reconnectthe Py'Cthermostat
3P connector, . -t-
3. Connectthe No. 2 terminalto lu----r---u
1 l 2 l 3 l
groundwith a iumperwire.
4. Startthe engine. JUMPER
I BLU/RED
wrRE l
I
Do both fansrun and doesthe
compressorclutchengage?
HEATERCONTROLPANEL,I4PCONNECTOR
Checklor an open in the wire:
r , r u r n r n e r g n r t r osnw n c hu t - t - ,
t h e n d i s c o n n e ctth e j u m p e r
1 2 3 ''|
f
a 5
2. Flemovethe centerdashboard
lower cover (see section20), 8 9 lol It 12 1 3 14
and disconnect the heatercon
trol panel14Pconnector.
4, Measurethe voltagebetween
the No. l1 terminaland body
ground.
WIRE SIDE OF FEMAI,TTERMINAU;
Ropair open in tho wire b€ttt oon

ls there batteryvoltage? the A/C th.rmGt.t.nd th. hertor
conlrol panol.
To page 22-17
22-16
Frompage22-16 HEATERCONTROLPANEL1'P CONNECTOR
Chocktor en opon in the wire: 1 2 ;--? I 5 5

2 . D i s c o n n e c tt h e h e a t e r f a n
switch 6P connector.
8 9 10 X 11 1 2 1 3 1 4
GRN
3. Check for continuity beNveen
the No. 14 terminal of the
heatercontrolpanel 14Pcon-
nectorand the No. 6 terminal
2
ofthe heaterfan switch6P con-
nector, GRN
4 5 6
R€pairopen in tho wire bstwoon HEATERFAN SW]TCH6P CONNECTOR

tho hoater control pan€l and the
hoater f.n switch.
Chocklor an op6n in the wir6:

No. 1 terminal of the heaterfan
switch 6P connector and body
ground.
Ch6ck for an opon in the wirs

botwecn tho hsator fan switch
and body ground. lf the wire is OK,
check lor poor ground .t Gl01 and
G102.
Test the heater fan switch lsee

page21-26).
ls the heaterfan switch OK? Replacethe hedter fan swiich.
Chgck lor loo!€ wires or Poor

connectionsat thg ho.ler coBtrol
panol 14P connecto.. It the con_
noction3 arg good, replace the
herler contlol Danol.
22-17
A/C Thermostat Relay
Test Test
Connectbatterypower to the No. 3 terminal,groundthe Thereshouldbe continuitybetweenthe No. 1 and No.3
No. 2 terminal,and connecta test light betweenthe No. 1 terminalswhen power and ground are connectedto the
and No. 3 terminals. No. 2 and No. 4 terminals,and there shouldbe no conti-
nuitywhen power is disconnected.
NOTE:Usea 12V, 3 W - 18W test tight.
Dip the !y'Cthermostatinto a cup filled with ice water, and

checkthe test light.
Serpentinetype evaporator ,t YI I
t>
The light shouldgo off at 36 - 39'F{2 - 4"C)or less,and
shouldcome on at 39 - 41"F(4 - 5"C)or more. .l nI lo
I
Laminatetype evaporator
The light shouldgo off at 39 - 43.F{4 - 6.C) or less,and
shouldcome on at 43 - 45"F(6 - 7"Clor more.
l f t h e l i g h t d o e s n ' tc o m e o n a n d g o o f f a s s p e c i f i e d ,
replacethe Ay'Cthermostat.
12v,3w-18W
1.,
rE-],,'
I A
Llt i|
\ 1 \ .,,fl--$-....
A/C ServiceTips and Precautions EI
The air conditionersystemusesHFC-134a (R-134a)
refrigerantand polyalkyleneglycol (PAG)refrigerantoil*' which are not
compatible with 6p6-12 1n-tZ) and
refrigerant mineral oil. Do not use R-12 or
refrigerant mineraloil in this system,and do
not attemptto useR-12servicingequipment;damageto the air conditionersystemor your servicingequipmentwill result.
*SandenSP-10:
. P/N38897- Pl3 - A01AH:120mf (4 fl'oz.4.2 lmp'oz)
. P/N38899- P13- A01:40 ml 11lBIl'oz, 1.4lmp'oz)
Use only serviceequipmentthat is U.L. listedand is certifiedto meet the requirementsof SAE J2210to removeR-134a
from the air conditionersystem.
CAUTION:Exposureto air conditioner r€ftigerant and lublicant vapor or mist can irritatg eyes, nose and lhroat. Avoid
breathing the air conditioner refrigerant and lubticant vapor or mist.
lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice'
R-134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor Ieaktestedwith compressed

air.
@ Some mixtures ol air and R.i34a havs been shown to b9 combusiible at elevated pressuresand can resuh
iiTiiffiiplo"ion causing iniury or property damage. Nevet use compresscd air to pressuretest R-13/+aservica equip-
ment or vehicle air conditionor systems.
Additionalhealthand safetYinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers'
t. Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningparts.
2. Keepmoistureand dust out of the system.When disconnecting any lines,plug or cap the fittings immediately;don't
removethe capsor plugs untiljust beforeyou reconnecteachline.
3. Beforeconnectingany hoseor line,apply a few drops of refrigerantoilto the O-ring'
4. Whentighteningor looseninga titting,usea secondwrenchto supportthe matchingfitting'
a 5. When dischargingthe system,use a R-134arefrigerantRecovery/Recycling/charging

ant into the atmosphere
6. Add refrigerantoil after replacingthe followingparts:
system; don't releaserefriger-
NOTE:
. To avoidcontamination, do not returnthe oil to the containeronce dispensed,and nevermix it with other refriger-
ant oils.
. lmmediatelyafterusingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption
. Do not spillthe refrigerantoil on the vehicle;it may damagethe paint;ifthe refrigerantoil contactsthe paint,wash
it off immediatelY.
Condenser .......20m/ (2/3fl'oz' 0.7 lmp'ozl
ils m I 11213tl'oz' 1.6lmp'ozl
Evaporator........................................
Lineor hose........... 10 ml (1/3fl'oz.0.4 lmp'oz)
Receiver/Dryer 10 ml (1/3 fl'oz, 0.4 lmp'oz)
Leakagerepair 25 m/ (5/6 ll'o2, 0.9 lmp'ozl
compressor .., For compressot teplacement, subtract the volume of oil drained {rom the
r€movedcomDressorfrom 130 m/ (4 1/3 fl'oz, '1.6tmpoz), and drain the calculated
volum€ of oil from the new compressor:130 m0 l'l l/3 floz, 4'6 lmp'oz)- volume
of removedcomprgssot= Volume to drain from new compressor'
NOTE:Even if no oil is drainedfrom the removedcompressor,don t draln more
than 50 m/ \1 2/3tl'o2,1.8lmp'oz)from the new compressor.
REMOVED NEW
COMPRESSOR COMPRESSOR
6(C
w re
f f i f f i
w
I I l6_dr omrr,rrruc
l
uver-.ffir volunae 130 16rmP
m{t41/3rr'oz' ozr
h['-saue ]
22-19
A/C SystemTorqueSpecifications
O Dischargehoseto the compressor(6 x i.0 mm) ............... ........................

9.SN.m 0.0 kgf.m,7.2 lbf.ft)
@ Dischargohoseto the condenser(6 x 1.0mm)................... .......................
9.8 N.m 0.0 kgf.m,7.2 tbf.ft)
@ Condenserpipe to the condenser{6 x 1.0mm|................... ......................
9.8 N.m fl.0 ksf.m,7.2 lbf.ft)
@ Condenserpipeto tho receiver/dryer {6 x i,0 mm)......... ..........................
9,g N.m (1.0kgt.m,7.2 lbr.ft}
@ Receiverpipe A to the roceiver/dryer(6 x 1.0mm)...,..... .....................,....
9.8 N.m 0.0 kgf.m,7.2 tbf.ft)
@ Receiverpipe B to the receiverpipe A t3 N.m {1.3 kgt.m, 9.4 tbf.ft)
O Receiverpipe Cto the receiverpipe B t3 N.m (1.3 kgf.m,9.it lbf.ft)
@ Receiverpipe C to the evaporator(6 x 1.0mm) ............... .........................
9.8 N.m 0.0 kgf.m,7.2 lbf.ft)
O Suctionpipe B to the evaporatol(6 x 1.0mm)................ ..........................
9.8 N.m {1.0kgf.m,7.2 tbf.ft)
@ Suctionpipe A to the suctionpipe B ...........................
31 N.m {3.2kgf.m,23 tbf.ftl
@ Suctionhoseto tho sustionpipe A... ...........................
3t N.m {3.2kgt.m,23 lbf.ft)
@)Suctionhoseto the compressor(6 x 1.0mm),..............,... ........,,..............
9.8 N.m {i.0 kSf.m,7.2 lbf,ft}
@ Compressorio the comp.essorbracket(8 x 1.25mm).., .......,..,.......-....,,..-
24 N.m {2.4kgl.m,17 lbf.ft}
@ Compressorbracketto the cylindorblock {10x 1.25mm} ..................................................._......
/14N.m (4.Skgr.m,33 tbf.ft)
@ Compressorbracketio the left front enginemount {12x t.2S mm) ..........................................
59 N.m (6.0kgf.m,43 tbr.ft)
22-20
ru
A/C SystemService
Recovery
Useonly serviceequipmentthat is U.L-listedand is cer-
tifiedto meetthe requirements of SAEJ2210to remove
HFC-134a (R-134a)from the air conditionersystem
g/Charging system
Recovery/Recyclin
CAUTION: Exposure to air conditioner r€frigersnt and
lubricant vapol or mist c8n irritate syes, nose and
ihroat. Avoid breathing the air conditioner lgfrigerant
and lubricant vapol or mist.
lf accidentalsystemdischargeoccurs,ventilatework
areabeforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersys-

tems shouldnot be pressuretestedor leaktestedwith
comDressed atr.
!@ some mixtures of air and R-134ahave been

strown to be combustible at elovatedpressuresand can
resull in fire or explosioncausing inlury or prope y dam'
age. N€ver use compressedair to pressure test R'i34a
s€rviceequipment ot vehicleair conditionsr systems.
Additionalhealthand safetyinformationmay be obtained

from the refrigerantand iubricantmanuJacturers.
1 . Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystemto the vehicle,as shown,following
the equipmentmanufacturer'sinstructions.
Measurethe amountof refrigerantoil removedfrom

the A,/Csystem after the recoveryprocessis com-
pleted.
NOTE: Be sure to installthe same amount of new

refrigerantoil backinto the ly'C system before charg-
Ing.
22-21
A/G System Service
Performance
Test
The Derformance test will helo determineif the air con-
ditionersystemis operatingwithin specifications.
Recovory/Recycling/chargingSystom
Useonly serviceequipmentthat is U.L.-listed and is cer-
tified to meet the requirementsof SAEJ2210to remove
HFC-134a (R-134a) from the air conditionersvstem.
CAUTION: Exposure to air conditioner relrigerant and

lubricant vapor ol mist can irtitate eyes, nose and
throat. Avoid broathing the air conditioner retrigerant
and lubricant vapor or mist.
lf accidentalsystem dischargeoccurs, ventilate work

areabefore.esumingservice,

tems should not be pressuretested or leak testedwith
compressedair.
!@ som€ mixtures of air 8nd R-134ahave been

shown to b€ combustible at elevated p.essuresand can
result in fire or explosion causing iniury or property
damage. Nev6r uss compressed air to pressuretogt R.
134a sarvice equipment or vohicl€ air conditioner sy3-
tems.

from the refrigerantand lubricantmanufacturers.
1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n R
t ecover/Recycling/
ChargingSystemto the vehicle.as shown, follow-
ing the equipmentmanufacturer's instructions.
2. l n s e r t a t h e r m o m e t e ri n t h e c e n t e r v e n t o u t l e t .
Determinethe relative humiditv and air temDera-
ture.
Testconditions:
. Avoid directsunlight,
o Openhood.
. Openfront doors.
. Setthe temperaturecontrolleverto MAX. COOL,
the mode control switch on VENTand the recir-
culationcontrolswitchon RECIRCULATE.
. Turn the IVCswitchon, and the heaterfan switch
on MAX.
. Runthe engineat 1,500rpm.
. No driveror passengers in vehicle
After running the air conditioningfor 10 minutes

under the above test conditions,read the delivery
temperaturefrom the thermometerin the dashvent
and the high and low systempressurefrom the !y'C
gauges.
5. To completethe charts:
. Markthe deliverytemperaturealongthe verticalline.
o Markthe intaketemperature(ambientair temperature)alongthe bottom line.
. Drawa line straightup from the air temperatureto the humidity
. Mark a Dointone line aboveand one line belowthe humiditylevel(10%aboveand10%belowthe humiditylevel).
. Fromeachpoint,draw a horizontalline acrossthe deliverytemperature.
. The delivervtemoeratureshouldfall betweenthe two lines
. Completethe low side pressuretest and high side pressuretest in the sameway.
. Anv measurements outsidethe line maYindicatethe needfor further inspection
kPa
lkgf/cm'l
lpsil 80/o
2900- 307o
(30t
t€0t
2500-
t25) DELIVERY
t3601 PRESSURE
2000- 80vo
t20)
kPa
1280t
{kgt/cmz) "F
tpsil {"c}
1500- 400 - 85
lI
t15t l,ll {30t
t2101 t57l
DELIVERY
PRESSURE
980 - 300- 77
{10) t3) l25l INTAKE
11lol li(}l
PRESSURE
200- 68
ll
tzl (20t
I2Al
100 59
{11 tlst
INTAKE lt 4l
PRESSURE
0 - 50
l
{10}
DELIVERY
DELIVERY TEMPERATURE
TEMPERATURE
11
(5t
ri
"F
6 a n a 6 95 104
l20l (251 t30) (35) (,r01 fC)
INTAKETEMPERATUFE
22-23
A/C SystemService
PressureTestChart
\
NOTE:Performance
Test is on page22-22.
Test results Relatedsymptoms Probablecause Remedy

D i s c h a r g(eh i g h ) After stoppingcompressor,pres- Air in system Recover,evacuate,and
pressureabnor, suredropsto about200kPa rechargewith specifiedamount.
m a l l yh i g h {2.0kgflcm,,28psi)quickly.and Evacuation:see page22-36
t h e nf a l l sg r a d u a l l y . Charging:seepage22-37
R e d u c e do r n o a i r f l o w t h r o u g h . Cloggedcondenserfins Clean.
condenser . Condenserfan not work- Checkvoltageand fan rpm.
ing properly Checkfan direction.
Lineto condenseris excessively Restricted flow of refriger Restricted
lines
hot. ant in system
Dischargepres- Highand low pressuresarebal . Faultycompressordis- Replacethe compressor.
s u r ea b n o r m a l l y ancedsoon afterstoppingcompres- chargevalve
sor.Lowsideis higherthannormal. . Faultycompressorseal
Outletof expansionvalveis not . Faultyexpansionvalve . Replace.
frosted,low pressuregaugeindi- . Moisturein system . Recover,evacuate.and
catesvacuum. rechargewith specified
amount.
Suction(low) Expansionvalveis not frosted,and Frozenexpansionvalve Replacethe expansion valve.
pressureabnor- low pressureline is not cold.Low Faultyexpansionvalve
m a l l yl o w pressuregaugeindicates vacuum.
Discharge temperature is low,and Frozenevaporator Runthe fan with compressor
the air flow from ventsis restricted. off, then checkA,/Cthermostat.
Expansionvalveis frosted. Cloggedexpansionvalve Cleanor replace.
Receiver/dryeroutletis cool,and Cloggedreceiver/dryer Replace.
inletis warm (shouldbe warm
11lr9i!99!:!. _
Suctionpres- Low pressurehoseand check . Expansionvalveopentoo Repairor replace.
s u r ea b n o r m a l l y joint are coolerthan the tempera l on g
high tu re aroundevaporator. . Looseexpansioncapillary
tube
Suctionpressureis loweredwhen
Excessive refrigerantin sys- Recover,evacuate,and
condenseris cooledby water.tem recharge
with specifiedamount.
l-l,gh""d l"* pr""sureare equal- . Faultygasket Replacethe compressor.
izedas soon as the compressoris . Faultyhigh pressurevalve
stopped,and both gaugesfluctu ] . Foreignparticlestuckin
a t ew h i l er u n n i n g . high pressurevalve
S""tl""""d d'; l Reducedair flow throughcon- I . Cloggedcondenserfins Cleancondenser.
cnargepres- denser. . Condenserfan not work- Checkvoltageand fan rpm.
suresabnormally ing properly Checkfan direction.
nrgn
Suctionand dis- Low pressurehoseand metalend Cloggedor kinkedlow pres- Repairor replace.
chargepressure areasare coolerthan evaporator. sure hoseparts
abnormallylow
Temperaturearoundexpansion Cloggedhigh pressureline Repairor replace.
valveis too low comparedwith
that aroundreceiver/dryer.
Refrigerant leaks Compressorclutchis dirty. Compressorshaftsealleaking Replacethe compressor.
Compressorbolt{s)are dirty. Leakingaroundbolt(s) Tightenbolt(s)or replacecom-
pressor.
gasketis wet with oil.
Compressor Gasketleaking Replacethe compressor.
22-24
Evaporator
Replacement
'] Removethe battery. 6. Disconnectthe connectorfrom the A,,/C thermostat,
and removethe wire harnessfrom the evaporator'
2. Recoverthe refrigerantwith a Recovery/Recycling/ Removethe four self-tappingscrews,the mounting
ChargingSystem(seepage22 21). b o i t a n d t h e m o u n t i n gn u t . D i s c o n n e ctth e d r a i n
hose.then removethe evaPorator.
3, Removethe bolts,then disconnectthe suctionand
receiverlinesfrom the evaporator.
NOTE:Plug or cap the lines immediatelyafter dis-

connectingthem to avoid moisture and dust con-
ORAINHOSE
taminatron.
SUCTIONLINE
:1i
6x1.0mm
9.8N.m (1.0kgl.m,
7.2tbt.ftt ., i, I
THERMOSTAT
CONNECTOR
EVAPORATOR
1 . 0m m
RECEIVERLINE N.m {1.0kgl.m.7.2lbtft}
Removethe glove box (seesection20).

7. Installin the reverseorder of removal.Make note of
Removethe self-tappingscrewand the passenger's the followingitems.
d a s h b o a r dl o w e r c o v e r .R e m o v et h e b o l t ,t h e n u t
and the kneebolster,then removethe five boltsand lf you'reinstallinga new evaporator,add refriger-
the glove box frame. ant oil (SP-10)
(seepage22-191.
Replacethe O-ringswith new onesat eachfitting,
.1...
and apply a thin coat of refrigerantoil before
,;1 ,, installingthem.
-;1t'i
i1:-.....
r'l--.;:,i,, i', NOTE: Be sureto use the right O-ringsfor HFC-
,. i 134a{R-134a) to avoid leakage.
a Apply sealantto the grommets.
a Makesurethat there is no air leakage.
a Charge the system (see page 22-311,and test its
performance(seepage22-22J.
22-25
Evaporator
Overhaul
1. Pull out the Ay'Cthermostatsensorfrom the evapo- 5. Assemblein the reverseorderof disassemblv.
Make
ratorfins. noteof followjngitems.
2. Removethe self-tappingscrews and clamps from Replacethe O-ringswith new onesat eachfitting,
the housings. a n d a p p l y a t h i n c o a t o f r e f r i g e r a not i l b e f o r e
installingthem,
3. Carefullyseparatethe housings,then remove the NOTE:Be sure to use the right O-ringsfor HFC
evaporator. 134a(R-134a) to avoid leakage.
Installthe expansionvalve capillarytube so that
lf necessary,
removethe expansionvalve. it is in direct contactwith the suction line.Then
wrap wrth tape.
NOTE:Whenloosening the expansion valvenuts,use Reinstallthe Iy'Cthermostatsensorto its original
a secondwrenchto hold the expansionvalveor the location.
evaporatorpipe.Otherwise,they can be damaged.
1 2 0 15 m m TAPE
6th fin trom inlet side {4.710.2 in) UPPERHOUSING Replace.
Makesurethereis no foreignmatterstuckbetween
Serpentinetype: the capillarytube and outletline.
a
Laminatetype: EVAPOBATOR
6015mm blow dirt out of tins
12.1! 0,2 inl with compressed air. N.m {0.8 kgl.m,
rbr.ftl
6th fin from outlet side

CAPILLARY
TUBE
EXPANSIONVALVE
N.m {2.itkg{.m,
A/C THERMOSTAT
Testpage22 18
LOWERHOUSING
22-26
Compressor
Replacement
'1. 7. L o o s e nt h e c e n t e rn u t o f t h e i d l e r p u l l e ya n d t h e
I t t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er, u n t h e
e n g i n e a t i d l e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r adjustingbolt,then removethe Ay'Ccompressorbelt
work tor a few minutes,then shut the engineoff. from the pulleys,Removethe two mounting bolts
from the left front engine mount, then removethe
2. the negativecablefrom the battery.
Disconnect A,/Ccompressorbelt by passingit through the gap
betweenthe body and the leftfront enginemount.
Recoverthe refrigerantwith a Recovery/Recycling/
ADJUSTINGBOLT
ChargingSystemlsee page22-211.
CENTERNUT
Removethe bolts,then disconnectthe suctionand
dischargelinesfrom the compressor.
NOTE:Plug or cap the lines immediatelyafter dis-

tamination.
6x1.0mm
LINE
DISCHARGE
LEFTFRONT
1.0x125mm
a4 N.m {4.5kg{.m,33 lbtftl
8. Remove the four mounting bolts and the compressor. J
SUCTIONLINE II
COMPRESSOR
5. Removethe condenser(seepage22-35).
NOTE:Do not disconnectthe dischargehose from

lhe condenser-
6. Removethe power steeringpump belt {seesection

171.
2il N m 12.4kg[.m, 17 lbf.ftl
(cont'd)
22-27
Compressor
(cont'd)
Replacement
9. removethe compressorbracketas fol-
lf necessary, 10. lnstallin the reverseorderof removal.Makenote of
tows. the followingitems.
- Removethe nut and the washer. lf you're installinga new compressor,drain all
the refrigerantoil from the removedcompressor,
NOTE:When tighteningthe nut of the left front and measureits volume.Subtractthe volume of
enginemount,makesurethe washeris set prop- drainedoil lrom 130mf 14 1B fl.oz,4.6 lmp.oz);
erly on the leftfront enginemount as shown. the result is the amount of oil you should drain
from the new compressor(throughthe suction
- Removethe four mounting bolts and the com- fitting).
pressorbracket. Replacethe O-ringswith new ones at each fit-
t i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l
beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFC-
134a(R-134altoavoid leakage.
12 r 1.25mm Use refrigerantoil (SP-10lforR-134aSandenand
59 N.m {6.0 kgl.m, Hadsysspiraltype compressorsonly.
43 tbf.ftl
To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
COMPRESSOR with other refrigerantoils.
BRACKET lmmediatelyafter using the oil, replacethe cap
on the container.and seal it to avoid moisture
absorption.
Do not spill the refrigerantoil on the vehicle;it
may damagethe paint;if the refrigerantoil con-
tactsthe paint,wash it off lmmediately.
Adjust the Ay'Ccompressor belt (see page 22-341
and the power steeringpump belt {seesection17).
Charge the system (see page 22-371,and test its
WASHER performance(seepage22-22').
LEFTFRONT
1.0x 1.25mm ENGINEMOUNT
a{ N.m 14.5kgt m.33 tbf.ft)
22-28
lllustratedIndex
CENTER
NUT
Replace.
ARMATUREPLATE
page22-30
Inspection,
sHrM{s)
Replace.
Replace.
ROTORPULLEY
page22-30
Inspection,
SNAPRINGA
Replace.
FIELDCOIL
page22-30
Inspection,
q\
q \
_-2 RELTEF
vALvE
a- page22-33
Replacement,
COMPRESSOR
{Do not disassemble.)----"-}l
THERMALPROTECTOR
Replace.
page22-30
Inspection,
a
22-29
Compressor
Clutch Inspection
Checkthe platedpartsof the armatureplatefor color . Releasethe field coil connectorfrom the holder,then
c h a n g e sp, e e l i n go r o t h e r d a m a g e .l f t h e r e i s d a m - disconnectit. Checkthe thermal protectorfor conti-
age,replacethe clutchset. n u i t y . l I t h e r e i s n o c o n t i n u i t y r. e p l a c et h e t h e r m a l
Drotector.
Checkthe rotor pulleybearingplay and drag by rotat-
ing the rotor pulley by hand. Replacethe clutch set
with a new one it it is noisyor hasexcessive
play/drag.
Checkresistance
of the field coil.
Measurethe clearancebetweenthe rotor pulley and FieldCoil Resistance:3.2

t 0.15ohms at 68"F{20"C1
the armature plate all the way around. lf the clear-
ance is not within specifiedlimits,the armatureplate lf resistanceis not within specifications,
replacethe
must be removed and shims added or removed as field coil.
required,followingthe procedureon page22-31.
Clearanca:
0.5t 0.15mm {0.02010.006in}
NOTE: The shims are availablein four thicknesses:

0 . 1m m , 0 . 2m m . 0 . 4m m a n d0 . 5m m
22-30
II
i
Clutch Overhaul
1. Removethe centernut while holdinqthe armature 3. Removesnap ring B with snap ring pliers.
olatewith the tool.
NOTE:
CENTERNUT
17.6N.m {1.8kg{.m, 13 lbf.ft} a B e c a r e f u ln o t t o d a m a g et h e r o t o r p u l l e ya n d
compressorduring removal/installation.
o
A/C CI-UTCH HOLDER . Once snap ring B is removed,replaceit with a
(Commercially available)
new one,
Robinai.: P/N 10204
Kent-Moore: P/N J37872
-..::::.:...-
2. Removethe armatureplateby pullingit up by hand.
4. Remove the rotor pulley from the shaft with a puller

ARMATURE
PLATE and the special tool.
NOTE: Put the claws of the puller on the back of the

rotor pulley, not on the belt area; otherwise the
rotor pulley can be damaged.
/t,
.\\
.)'
.l t
(cont'd)
22-31
Compressor
ClutchOverhaul(cont'd)
5. Removethe screwfrom the field coil groundtermi- 7. A s s e m b l ei n t h e r e v e r s eo r d e r o f d i s a s s e m b l y .
nal,then disconnecthe field coil connector. Make noteof the followingitems.
R e m o v es n a p r i n g A w i t h s n a p r i n g p l i e r s ,t h e n
removethe field coil, . Installthe fieldcoilwith the wire sidefacingdown.
. C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g
NOTE: surfaceswith non-pet.oleumsolvent,
. Be carefulnot to damagethe field coil and com- . Make sure the snap rings are fully seatedin the
pressorduring remove/installation. groove.
. Once snap ring A is removed,replaceit with a . Make sure that the rotor pulley turns smoothly
new one. after it's reassembled.
. When installingthe field coil, align the boss on . Routeand clamp the wires properlyor they can
the field coil with the hole in the compressor. be damagedby the rotor pulley.
SNAP RING A
Replace.
6. Positionthe rotor pulleysquarelyover the field coil.

Pressthe rotor pulley onto the compressor boss
w i t h t h e s p e c i a tl o o l . l f t h e r o t o r p u l l e yd o e s n o t
press on straight, remove it, and check the rotor
pulleyand compressorbossfor burrsor damage.
CAUTION: Maximum press load: 39,200 kPa

(400kgt/cm', 5,690psil
Preit
T HUB ASSEMBLY
GUIDEATTACHMENT
07965 - 6920500
FOTOR
PULLEY
22-32
-
Thermal Protector Replacement ReliefValve Replacement
1. Bemovethe bolt. the groundterminaland the hold- 1. Removethe reliefvalveand the O-ring,
er. Disconnect
the field coil connector.then remove
the thermalprotector. NOTE:
. Do not let the compressoroil run out.
. Make sure that no foreign matterentersthe sys-
7.{ N.m {0.75kgl.m, 5,4lbf.ftl
tem.
THERMAL
PROTECTOR Q t)
.Y,/
RELIEF
VALVE
, 9.8 N.m (1.0kgt m,
7.2 rbnft)
O.RING
Replace.
Cleanthe matingsurfaces.
Replacethe O-ringwith a new one at the reliefvalve,

Replacethe thermal protectorwith a new one, and a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e
apply siliconesealantto the top of the thermalpro- installingit.
tector.
NOTE:
. To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
. lmmediatelyafter using the oil, replacethe cap
on the container,and seal it to avoid moisture
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint;if the refrigerantoil con-
tactsthe paint,wash it off immediately.
Installand tightenthe reliefvalve.
SILICONESEALANT
5. Charge the system (see page 22-311,and test its
performance(see page 22-221.
3. lnstall in the reverse order of removal.
22-33
A/C CompressorBelt
Adjustment \
Deflection Method Tension Gauge Method
1. Apply a force of 98 N (10 kgf, 22 lbf), and measure '1. Attach

the specialtool to the Ay'Ccompressorbelt as
the deflectionbetweenthe A,/Ccompressorand the shown below,and measurethe tensionof the belt.
crankshaftpulley.
A/C ComprossorBelt
A/C CompressorBelt Used Belt: 340 - it90 N (35 - 50 ksf, 77 - 110 lbfl
UsedBelt:7.5- 9.5 mm 10.30- 0.37in) New Belt: 690 - 830 N (70 - 85 kgf, 150- 190 lbf)
New Belt: 5.0- 6.5 mm (0.20- 0.26in)
NOTE:
NOTE: o Follow the manufacturer'sinstructionstor the
. lf there are cracksor any damageevidenton the belttensiongauge.
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. . "Used belt" means a belt which has been used
. "New belt" means a belt which has been used for iive minutesor more.
for lessthan five minutes. . "New belt" means a belt which has been used
for lessthan five minutes.
2. Loosenthe centernut ofthe idlerpulley,
2. Loosenthe centernut ofthe idlerpulley.
3. Turn the adjustingbolt to get properbelttension.
3. Turn the adjustingbolt to get properbelttension,
4. the centernut ofthe idlerpulley.
Retighten
4. the centernut ofthe idlerpulley.
Retighten
5. Recheckthe deflectionof the Ay'Ccompressorbelt.
5. Recheckthe tensionof the Ay'Ccompressorbelt.
22-34
Condenser
Replacement
1. Recoverthe refrigerantwith a Recovery/Recycling/ 4. Removethe bolt from the suctionhose bracket,and
ChargingSystem(seepage22 21). removethe two bolts and the upper mount bracket.
Removethe condenserassemblyby liftingit up
2. Disconnectthe condenserfan connectorfrom the
A/C wire harness,then removethe Ay'Cwire harness NOTE:Be carefuinot to damagethe condenserfins
from the condenserfan shroud. when removingthe condenserassembly.
MOUNTBRACKET
UPPER
6x1.0mm
9.8 N.m (1.0kgf.m.7.2lbfftl
CONDENSER
FAN 6x1.0mm
CONNECTOR 9.8N.m 11.0kgl.m,7.2lbI.ftl
A/C WIREHARNESS
3. R e m o v et h e b o l t s ,t h e n d i s c o n n e ctth e d i s c h a r g e
and condenserlinesfrom the condenser.
5. lnstallin the reverseorder of removal.Make note of
NOTE: Plug or cap the lines immediatelyafter dis- the followingitems.
ramlnaton. . lf you'reinstallinga new condenser,add refriger-
6x1.Omm ant oil (SP-10) (seePage22-19).
L|NE 9.8 N.m 11.0
DTSCHARGE . Replacethe O-ringswith new ones at each fit-
t i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l
beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFc-
1344(R-'134a) to avoid leakage.
a B e c a r e f u l n o t t o d a m a g et h e c o n d e n s e rf i n s
when installingthe condenserassembly.
. Chargethe system{seepage 22-37).and test its
CONDENSER
performance{seePage22-221
6x1.0
9.8 N.m {1.0kgf.m, 7.2 lbf ft)
22-35
A/C System Service
Evacuation \
Use only serviceequipmentthat is U.L.-listed and is cer

tified to meet the requirementsof SAEJ2210to remove
HFC-134a {R 134a)trom the air conditionersystem. g/Charging System
Recovery/Recyclin
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irrilate eyes, nose and throat.
Avoid breathing the air conditioner refrigerant and lubri-
cant vapor or mist.
lf accidentalsystem dischargeoccurs,ventilate work

areabeforeresumingservice.

tems should not be Dressuretested or leaktested with
compressedarr.
@ some mixtures ot air and R-134ahave b€€n

shown to be combustible at elevat€d ptessuresand can
result in tire or explosion causing iniury or property
damage. Never use compressed air to pressure test R-
134a service equipment or vehicle air conditioner sys-
Iems.

from the refrigerant
and lubricantmanufacturers.
'1.
When an Ay'CSystemhas beenopenedto the atmo-
sphere,such as during installationor repair,it must
be evacuatedusing a R-134arefrigerantRecovery/
Recycling/ChargingSystem.(lf the systemhas been
open for severaldays,the receiver/dryer should be
replaced,and the system should be evacuatedfor
severalhours.)
2. Connecta R-134arefrigerantRecoverylRecycling/
ChargingSystemto the vehicle,as shown, follow-
ing the equipmentmanufacturer's
instructions,
NOTE:lf low pressuredoesnot reachmorethan 93.3

k P a( 7 0 0m m H g , 2 7 . 6i n . H g )i n 1 5 m i n u t e st,h e r ei s
probablya leak in the system.Partiallychargethe
system,and checkfor leaks(seeLeakTest).
22-36
Charging LeakTest
Use only serviceequipmentthat is U.L.-listed and is cer- Use only serviceequipmentthat is U.L.listedand is cer-
titied to meet the reouirementsof SAEJ22,!0to remove tified to meetthe requirementsof SAEJ2210to remove
HFC-'134a (R-134a) from the air conditionersystem. HFC-'134a (R-134a)from the air conditionersystem.
CAUTION:Exposureto air conditionerrefrigerantand CAUTION:Exposureto air conditionerrefrigerantand

lubricant vapor or mist can irritate eyes, nose and lubricant vapor or mist can irritate eyes,nose and throat.
thloat. Avoid breathingthe air conditionerretrigerant Avoid breathing the air conditioner retrigerantand lubri-
and lubricantvaooror mist. cant vapor or mist.
l f a c c i d e n t asl y s t e md i s c h a r g eo c c u r s ,v e n t i l a t ew o r k l f a c c i d e n t asl y s t e md i s c h a r g eo c c u r s ,v e n t i l a t ew o r k
a r e a b e f o r e r e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t h a n d areabeforeresumingservice.
safetyinformationmay be obtainedfrom the refrigerant
and lubricantmanufacturers. R l34a serviceequiDmentor vehicleair conditionersys-
tems should not be pressuretested or leak testedwith
Refrigerantcapacity:550:goI {22.9:qs oz) compressedair.
CAUnON: Do not overchargethe system;the compressor ![@ some mixtures ot air and R-13,1ahave
will be damaged. been shown to be combustibleat elevatedpressures
and can result in fire or explosion causing iniury or
Connecta R-134arefrigerantRecovery/Recycling/Charging property damage. Never use compressedail to pressure
Systemto the vehicle,as shown,followingthe equjpment test R-134aservice equipment or vehicle air conditioner
manufacturer'sinstructions. systems.

System and lubricantmanufacturers.
from the refrigerant
Recovery/Recycling/Charging
1. Connecta R-134arefrigerantRecoverylRecycling/
C h a r g i n gS y s t e mt o t h e v e h i c l e ,a s s h o w n i n t h e
previouscolumnfollowingthe equipmentmanufac-
turer'sinstructions.
NOTErBe sure to installthe same amount of new

refrigerantoil backinto the A,/Csystembeforecharg-
In g .
Open high pressurevalve to chargethe systemto

the specifiedcapacity,then closethe supplyvalve,
and removethe chargingsystemcouplers.
O 122.9:1aozl
Refrigerantcapacity:650130
3. Checkthe systemfor leaksusing a R-134arefriger-

ant leak detectorwith an accuracyof l4 g (0.5 oz)
per year or better.
4. lf you find leaksthat requirethe systemto be opened

(to repairor replacehoses,fittings,etc.),recoverthe
LOW.PRESSURE
SIDE systemaccordingto the RecoveryProcedure on page
22-21.
5. After checkingand repairingleaks,the systemmust

be evacuatedlseeSystemEvacuation on page22 36)
22-37
Electrical
,fgnition Switch .......-.-..........23-75
SpeciafToofs .." """""'23-2
lgnition System " 23-88
Troubleshooting *A/T .....
....... ........ . "" 23-133
GearPosition Indicator
Tios and Precautions..............'. " " "" 23-3 ilntegrated 23-140
Control Unit ........,.........-.-...............,..
Five-stepTroubleshooting........" """" """ 23-5 """"""""' 23-124
wire color codes "" 23-5 fnterlock System
Lighting System - """ " 23-146
SchematicSYmbols.........'.'......'. "" " 23-6
Relayand Control Unit Locations Lights, Exteriol
" """" 23-7 Bsck-upLights """"23-151
Engine Compartment .
..'.............'.
" " 23-8 Brake Lights "" " "" 23-158
Dashboard
""""' 23-12 Davtime Running Lights(Canadal...'. " "' 23-150
Door ...................... 23-151
,Airbags ...,........,... ........Sestion24 FrontParkingLights ....................... . ""
Section 2l FrontTurn Signal Lights......'......... " " 23-151
Air Conditioning ."
Headlights .. " "" " 23-151
Atternator .......,........,........,..23-98
High Mount BrakeLight ... .........."" "" 23-159
Anti-lock BrakeSvstem IABSI ... .." " " Section 19 " "" 23-156
Sestion 14 LicensePlate Lights
Automatic TransmissionSystem .. . "" " "23-153
"""""""23-77 Taillights...............
B a t t e l y. . . . . . . . . . . . . . . . . . .... """"""23-162
Section 21 fnteriorLights
Blower Controls 23-203
" """"""23'72 Moonrool .................,...........
Charging System
Powel Distribution """"""'23-57
Connestorldentification and Wire Harness """"""23-219
R o u t i n g. . . . . . . . . . . . . . . . . """"' 23-11 PowerDoor Locks
" """""""'23-2oa PowerMirrors "" """ " 23'180
cruise contlof
. " " "" 23'160 Power Retays......... """""""23-72
Dash Lights BrightnessController
....... """ " 23-111 PowerWindows " "" "'23-191
FanControls
FuelPump .........""" Section11 RearWindowDetogger.....'..........'......"""""23-176
""""""23-52 SparkPlugs ..... "" " "' 23'97
F u s e s, . . . . . . . . . . . . . . . . . . . .
"" Seqtion 11 StartingSystem ..... "" " 23-79
PGM-FIControlSystem... .................
*G.uges *StereoSoundSystem ........,......,........................' 23-167
" "" "23-116 'supplemental Restraint Systom (SRSI .....Section 24
CircuitDi.gram
"" " """"'23-126 Turn Signal/HazardFlasherSystem "" " "' 23-154
FuefGauge
" " 23-114 +Under-dash Fuse/Relay Box 23-71
...............................
Speedometer........'
...........23-65 Vehicle Speed Sensor (VSS) .
...... " " """"23"124
cround Distribution
"""" section 21 rwipers/Washers " "" 23-186
Heatet controls
*Horn ..................... .............-..23-173
NOTE:Unlessotherwisespecified.referencesto auto-
matictransmission (A,/T)in this sectionincludethe CVT'
- +
SpecialTools
Rel. No. I Tool Number Description Oty i PageReterence

o
{t*
A973X 041_ XXXXX V a c u u mP u m pG a u g e0, - 3 0 i n . H g . 23-215
0 7 J G G- 0 0 1 0 1 0 4 BeltTensionGauge 23-'t10
o OTLAJ_ PT3O2OA TestHarness 23-124,125
o 0 7 N A C- S R 2 0 1 0 0 FuelSenderWrench 23-126
07PM- 0010100 SCSServiceConnector 23-9'l
*: Includedin Belt Tension GaugeSet 07TGG- 0010004
o ri an
I \
23-2
Troubleshooting
Tips and Precautions
BoforeTroubleshooting N e v e rt r y t o d i s c o n n e c ct o n n e c t o r sb y p u l l i n g o n
. Checkagplicablefuses in the appropriatefuse/relay their wires;pull on the connectorhalvesinstead.
oox. Alwaysreinstallplasticcovers.
. Checkthe batteryfor damage,state of charge,and
cleanand tight connections.
. Checkthe alternatorbelttension.
CAUTION:
. Do not quick-chafgea battety unless the battery
ground cable has been disconnected,otherwise you
will damagethe alternator diodes.
. Do not attempt to crank the engine with the battery
ground cable loosely connected or you will severely
damagethe wiring.
Handling Connectols Beforeconnectingconnectors,make sure the termi-

. Makesurethe connectorsare cleanand haveno loose nalsare in placeand not bent.
wire terminals.
. Makesure multiplecavityconnectorsare packedwith
grease(exceptwatertightconnectors).
. All connectorshave push-downreleasetype locks.
LOCKINGTAB
. Checkfor looseretainerand rubberseals.
Some connectorshave a clip on their side used to
attach them to a mount bracketon the body or on
anothercomponent.This clip hasa pull type lock RETAINER
Some mounted connectorscannot be disconnected
unlessyou first releasethe lock and removethe con-
nectorfrom its mount bracket.
T h e b a c k s o f s o m e c o n n e c t o r sa r e p a c k e d w i t h
grease-Add greaseit necessary.lf the greaseis con-
taminated,replaceit.
LOCKING
PAWL ON
OTHER Pull to
HALF OF drsengage BRACKET (cont'd)
CONNECTOR
23-3
Troubleshooting
Tips and Precautions(cont'd)
Insertthe connectorall the way and make sure it is . Seat grommets in their grooves properly.
securelylocked.
Positionwires so that the open end of the coverfaces
down. NOT GOOO
Fsce
opon end
A & - /
-w--_w\\
ll I
Testing and Repairs

Handling Wires and Harnesses . Do not usewires or harnesses with brokeninsulation.
. Securewires and wire harnessesto the frame with Replacethem or repairthem by wrappingthe break
their respectivewire ties at the designatedlocations. with electricaltaDe.
. Removeclipscarefully;don't damagetheir locks. a A f t e r i n s t a l l i n gp a r t s ,m a k e s u r e t h a t n o w i r e s a r e
oinchedunderthem.
. W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. l f p o s s i b l e i, n s e r tt h e p r o b e o f t h e t e s t e rf r o m t h e
wire side (exceDtwaterDroofconnector).
Slip pliers under the clip base and through the hole at . Usea probewith a taperedtip.
an angle,then squeezethe expansiontabs to releasethe
c l lP .
SNAP.RINGPLIERS
After installlngharnessclips, make sure the harness Referto the instructionsin the HondaTerminalKit for
doesn'tinterferewith any moving parts. i d e n t i f i c a t i o an n d r e p l a c e m e not f c o n n e c t o tr e r m i -
Keep wire harnessesaway from exhaust pipes and nals.
other hot parts. from sharp edges of bracketsand
holes.and from exDosedscrewsand bolts.
23-4
Five-stepTroubleshooting Wire Color Codes
1. VerifyThe Complaint The following abbreviationsare used to identify wire
Turn on all the componentsin the problemcircuitto colorsin the circuitschematics:
verifythe customercomplaint.Note the symptoms W H T . . . . . . . . . . . . . . . . . . . .W . . ,h. i. t. e. . .
Do not begin disassemblyor testing until you have Y E L. . . . . . . . . . . . . . . . . . . . . Y. .e. .l.l.o. w ...
narroweddown the problemarea. B L K . . . . . . . . . . . . . . . . . . . . .B. .l.a. c. .k. . .
BLU..............................81ue
2. AnalyzeThe Schematic G R N . . . . . . . . . . . . . . . . . . . .G . . r. .e. e. .n. .
L o o k u p t h e s c h e m a t i cf o r t h e p r o b l e m c i r c u i t . R E D. . . . . . . . . . . . . . . . . . . . .R. .e. .d. . . . .
Determinehow the circuit is supposedto work by O R N . . . . . . . . . . . . , . , . . . . .O . . r. .a. n. .g. .e
tracing the current pathsfrom the power feed P N K. . . . . . . . . . . . . . . . . . . . .P. .i.n. k. . . . .
throughthe circuitcomponentsto ground.lf several B R N. . . . . . . . . . . . . . . . . . . . .B. .r.o. .w. .n. .
circuitsfail at the sametime, the fuse or ground is a G R Y. . . . . . . . . . . . . . . . . . . . .G . .r. a. .y. . . .
likelycause. P U R. . . . . . . . . . . . . . . . . . . . .P. .u. .r .p. l. e. .
L T B L U . , . . . . . . . . . . . . . . . .L. i.g. .h, .tB. l u e
Basedon the symptomsand your understandingof L T G R N . . . . . . . . . . . . . . , . .L. .i .g.h. .tG . reen
the circuitoperation,identifyone or more possible
causesof the problem. T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h
anothercolor stripe.The secondcolor is the stripe.
J. lsolateThe ProblemBy TestingThe Circuit
Makecircuitteststo checkthe diagnosisyou made
in step 2. Keepin mind that a logical,simple proce-
dure is the key to efficienttroubleshooting. Test for
the most likely cause of failure first. Try to make
testsat pointsthat are easilyaccessible. WHT/ALK
FixThe Problem
Once the specificproblem is identified,make the
repair.Be sure to use propertools and sale proce-
oures.
MakeSureThe CircuitWorks
Turn on all componentsin the repairedcircuitin all
modes to make sure you've fixed the entire prob-
lem. lf the problem was a blown fuse, be sure to
test all of the circuitson the fuse.Makesure no new
problemsturn up and the originalproblemdoes not
recur,
23-5
Troubleshooting
SchematicSymbols \
EATTERY GROUND FUSE COIL, SOLENOID CIGARETTELIGHTER

Groundterminal ground
Componenl
l,r
t""l
ril
II II <'r.-e rh A
_1 lat lTl
r
_d_
.: -
+ i7
RESISTOR VARIABLERESISTOR THERMISTOR IGNITIONSWITCH BULB HEATER
/+' A
ilHq.r + +
I
Jl- t=l
I
MOTOR PUMP CIRCUITgREAKER HORN DIODE SPEAKER,BUZZER
+ + D
I
Q c Mast
ANTI:NNA
t
TI
TRANSISTOR(Trl SWITCH lln n o.mal politionl

Normally open I Normally closed
LIGHTEMITTING
DIODE{LED)
\
'*i'"n
/c\ A+,
switch
Y I4 v Y T
t
RELAY {ln normal positionl

I
t l
CONDENSER
I
l'0\
I
CONNIicTtoN
|
i
\h/
l
CONNECTOR REEDSWITCH
Normallyopen relay Normallyclosedrelay lnput Output
--+>-
t--.--'l
fT't Gt - l - | I V J- A
It'rl
I
t i l
l r l
t i l
trf l-*'+ T -r-l- ! Y
23-6
Relayand ControlUnit Locations
EngineGompartment
ELDUNIT
UNDER.HOOD
BOX
FUSE/RELAY
t:
n
-fr@ tr
D tl
T'lrrrl
r-- --1
BLOWER
MOTOR
FAN
CONDENSER RELAY
RELAY
RADIATOR
UNDER.HOOD ABS A/C COMPRESSOR FAN RELAY
FUSE/RELAYBOX CLUTCHRELAY
23-7
Dashboard:96, 97 models
CRUISECONTROLUNIT
DAYTIME
RUNNINGLIGHTS
CONTROLUNIT DASHLIGI{TSBRIGHTNESS CONTROLLER
(Canad.) (Hasbuilt-incontrolunit)
STARTER CUTRELAY
. MOONROOFOPENRELAY Iwir6 colo]s:BLK/wHf,au/wxf,l
[wire colors:GRN/ORw.
CAru/Ae
O,l I BLU/aLK,andBLK/RED l
[WHT,YEL,andBLK I
. MOONROOF CLOSERELAY
[Wi]e colors:GRN/ORN,GRN/YEL,l
IWHT,GRN/RED, and BLK I
23-8
INTEGRATED
UNDER.DASH CONTROLUNIT
FUSE/RELAYBOX
il-trral a\{\ fi |
Fnnr-1nnnnn-r POWERWINDOWRELAY
FrJrJrJuuLluLrLJU|lJ
F-nnrr'-1nn|-1nrl
p!rrrLrLrrruLr'.uLJ|P
u_:;_:_:_l:_:_l_;E::
TURNSIGNAL/
HAZARORELAY
CONTROLUNIT
INTERLOCK
lTcM tcw)
.: Coupe
23-9
Dashboard:98model
CRUISECONTROLUNIT
DAYTIME
RUNNINGLIGHTS
CONTROLUNIT DASHLIGHTSBRIGHTNESS CONTROLLER
(Hasbuilt-incontrolunit)
{Cenada}
[Wi]e colols: BLK/WHT,etX/WXf,l

IBLU/BI-K,and BLK/RED J
Wire colors:WHT/GRN,BLU/RED,
GRYand WHT/GRN
MOONROOFCLOSERELAY
lwilo colo]s:cRN/ORru,
Cnn/Yel,l
IWHT,GRN/RED, andBLK I
23-10
POWERWINDOWFELAY
I\JJJ'IJJJIJJJ LI
CONTROLUNIT
INTERLOCK
.TCM(CvT)
': Coupc
23-11
Dashboard/Door
AUDIO UNIT
(Hasbuilt in keylessreceivercircuit)
POWEROOORLOCK
CONTROLUNIT
PGM.FIMAIN RELAY
MASTERSWITCH
(Hasbuilt-incontrolunit)
ABS CONTROLUNIT
23-12
Connectorldentificationand Wire HarnessRouting
How to ldentily Connectols: "C" for connectors'

ldentificationnumbershave been assignedto all connectors.The number is precededby the lefter
" G " f o r g r o u n dt e r m i n a l o " T " f o r n o n g r o u n dt e r m i n a l s
sr
Location Others lFloor. Door,

EngineCompartment Dashboard
Harness Trunk/Hatch, and Root)
Startercables T 1 ,T 2 a n d@
Batterygroundcable G l a n dO
E n g i n eg r o u n dc a b l eA
E n g i n eg r o u n dc a b l eB T4
G3
Under-hoodABSfuse/relaybox wire t5 ano (?
harness(with ABS)
Enginewire harness C 1 0 1t h r u C 1 4 7
T 1 0 l a n dT 1 0 2
G'r01
Enginecompartmentwlre narness C 2 0 lt h r u C 2 1 4
G201and G202
Main wire harness C 3 0 1t h r u C 3 1 0 C401thru C446
C351thru C360 G401and G402
Dashboardwire harness C501thru C520
Floorwire harness C551thru C573{C574)

G551and G552
Rearwire harness C 6 0 1t h r u C 6 1 7
G601
Driver'sdoor wire harness C631thru C639
Passenger's door wire harness C651thru C656
Left reardoor wire harness(Sedan) C661thru C664
Rightreardoor wire harness(Sedan) C671thru C674
Roofwire harness{Withoutmoonroof) C701thru C703
Moonroofwire harness(Withmoon' C 7 1 1t h r u C 7 1 8
roof)
A
Heatersub-harness C721thru C727
B
Heatersub-harness C741thru C743
A,/Cwire harness C 7 5 1t h r u C 7 5 4
Hatchwire harness(Hatchback) C76l thru C768

G761
Rearwindow defoggergroundwire c771
G77'l
Secondaryheatedoxygensensorsub- C 7 8 1a n dC 7 8 2
harness
Fueltank pressuresensorsub-harness C791thru C793
S R Sm a r nh a r n e s s C801thru C807
G801
O : 9 7 , 9 8m o d e l
23-13
Starter Cables
Connectoror Numberol
Location Connectsto Notes
Terminal Cavities
T,1 Rightside of enginecompanment Under-hoodfuse/relaybox
T2 Rightside of enginecompartment Startermotor
o Battery Batterypositiveterminal
Battery Ground Cable
Connectoror Number of
Terminal Cavities
Right front shock tower Bodyground,via batteryground
cable
o Baftery Batterynegativeterminal
EngineGroundCableA
Tgrminal Location Connectsto Notes
Cavities
T3 Leftside of engine Powersteeringpump bracket
Leftsideof enginecompartment Bodyground,via engineground
cableA
EngineGroundCableB
Connectorot Numberof
Terminal Location Connectsto Notes
Cavities
T4 Rightsideof enginecompartment Transmission
Rightside of front frame Bodyground,via engineground
c a b l eB
Under-hoodABS Fuse/RelayBox Wire Harness
Connoctoror Number of
Terminal Location Connaqtsto Notes
Cavities
T5 Rightside of enginecompartment Under-hoodfuse/relaybox
@ Battery Batterypositiveterminal
A/C Wire Harness
Connestoror Numberof
Terminal Location ConnecGto Notes
Cavities
c751 Rightsideof enginecompartment Enginecompartmentwire harness
(c209)
1 Rightside of enginecompartment Compressorclutch
2 Rightside of enginecompartment Condenserfan motor
c754 Rightside of enginecompartment Ay'Cpressureswitch
G751 Leftside of enginecompanment Bodyground,via Ay'Cwire harness
23-14
BATTERY
GROUND
CABLE
UNDER-HOOD
ABS FUSE/RELAY
BOXWIRE
HABNESS
GROUNO
CASLEB
A/C WIRE
HARNESS
23-15
EngineWire Harness(Dl6Y5,D16Ygenginesl
c 101 10 Left side of enginecompartment Main wire harness{C303)

c102 3 Middle of engine Crankshaftspeedfluctuation(CKF)sensor
c103 1 Niliddleot engine Engineoil pressureswitch
c104 Left side of engine compartment Alternator
c104 3 Left side of enginecomPartment Alternator
c105 2 Middle of engine No. l fuel injector
c106 2 M i d d l eo f e n g i n e No.2 tuel injector
c 107 2 Middle of engine No. 3luel injector
c 108 2 Middle of engine No. 4 fuel injector
c109 3 Middle of engine IAC valve
c110 3 Irliddleof engine Throttleposition(TP)sensor
c11l 3 Middle of engine Manilold absolutepressure(MAP)sensor
cl12 2 Middle oI engine Intakeair temperature(lAT)sensor
c113 2 Middle of engine Power steering pressure(PSP)switch
c114 2 M i d d l eo f e n g i n e EVAPpurge control solenoidvalve
c115 14 Middle of engine Junctionconnector
c116 14 Middle of engine Junctionconnector
cl17 3 Left side of engine comPartment Vehiclespeedsensor{VSSI
c118 2 Middle ot engine CountershaftsPeedsensor
c119 2 Middle ot engine Engine coolant temperature (ECT)switch A
c120 10 Middle ol engine Distributor
c121 1 Middle of engine Engine coolant tefiperature (ECT)sending
unii
c122 2 Middle ol engine Engine coolanttemperature(ECT)sensor
c123 Middle ol engine PrimaryHO2S{sensor1)
c123 8 Middle ol engine PrimaryHO2S(sensor 1)
c124 2 Middle o'f engine Back-uplightswitch
2 Middle ot engine Lock-up control solenoid valve
c124
c125 Middle of engine Secondary HO2S (sensor 2)
2 Middle of engine Mainshaftspeedsensor
cl26 Lin€arsolenoidvalve
c127 2 Middle ot engine
2 Middle of engine Shift control solenoidvalve
c128 Startersolenoid
c129 1 Rightside ol enginecomPartment
c130 20 Eehind right kick Panel Junction connector
c] 31 22 Under right side ot dash Main wire harness(C446)
Under right side of dash ECM/PCM
cl32 32
PCM
-,(Arr)
25 Under right side of dash
14 Under right side of dash Main wire harness(C305) Ay'T:
96 model
'14 Main wire harness{c305)
'1 (Avn:
c136 Under right side of dash
97.98
models
Under right side of dash Main wire harness(C305) AlT..
97,98
models
c 137 2 Middle of engine Knocksensor(KS)
c138 2 Middle of engine IAC valve
c139 1 Middle of engine VTECsolenoidvalve
c140 2 Middle of engine VTEC pressure switch
c141 2 Middle of engine EVAPcontrol canistervent shut valve -,{A,/T)
c142 2 Middle of engine EGRcontrol solenoidvalve
Secondarygear shaft speedsensor
-1(Arr)
c143 2 Left side of engine comPartment ., (A/r)
c144 Middle of engine EGRvalve
EGRvalve
* 1{r\,riT)
c144 Middle of engine -'(A/T)
c145 2 Right side ol engine compartment Drive pulley speedsensor
*1 (CVT)
c146 8 Rightsideof enginecomPartmenl Solenoidconnector(CVT)
.,(A/T)
c147 2 side of engine comPaftment Driven pulley speedsensor
Left side oI engine comPartment
ground,via enginewire harness

*1: D16Y5engine
'2: D16Y8engine
*3: D16Y5(A,,/T),
D16YA
engines
23-16
c132am crog c138 c113 T101
c110
12
c141
T102.
c117-
ENGINEWINE
c143 HARNESS
c't17
c144
c140
cl18 cl'r5
c139
c120 c116
c129 c137
c146
c102
c145
23-17
\
EngineWire Harness{D16Y7engine):96model
Connectorot
Terminal Location Connectsto
Cavities
c 10'1 10 Left side of engine compartment Main wire harness(C303)
c102 3 Middleof engine Crankshaft speedfluctuation(CKF)
sensor
c103 Middleof engine Engineoil pressureswitch
c104 Left side of engine compartment Alternator USA
c104 Left side of engine compartment Alternator Canada
c105 Middleof engine No. I fuel injector
c106 [/iddle of engine No. 2 fuel injector
c'107 Middleof engine No. 3 fuel injector
c 108 Middleof engine No. 4 fuel injector
c 109 Middleof engine IACvalve
c110 Middle of engine Throttleposition(TP)sensor
c111 Middleof engine Manifoldabsolutepressure(MAp)sensor
cl12 fvliddleof engine lntakeair temperature(lAT)sensor
C'113 Middleof engine Powersteeringpressure(PSP)switcn
c 11 4 Middleof engine EVAPpurgecontrolsolenoidvalve
cl15 Middleof engine Junctaonconnector
cl16 Middleof engine Junctronconnector
c117 Left side of engine compartment Vehiclespeedsensor(VSS)
cl18 Middle of engine Countershaft speedsensor
c119 Middleof engine Enginecoolanttemperature(ECT)
switchA
cl20 Middle of engine Distributor
c121 Middleof engine Enginecoolanttemperature(ECT)
s e n d i n gu n i t
Middle of engine Enginecoolanttemperature{ECT)sensor
Middleof engine PrimaryHO2S(sensor1)
Middleof engine Back-uplight switch
Middle of engine Lockup controlsolenoidvalve
Middleof engine SecondaryHO2S(sensor2)
Middleof engine Mainshaftspeedsensor
Middleof engine Linearsolenoidvalve
Middleof engine Shiftcontrolsolenoidvalve
Right side of engine compartment Startersolenoid
Behind right kick panel JunctionConnector
Under right side of dash NIainwire harness(C446)
U n d e rr i g h t s i d eo f d a s h ECM/PCM
Under right side of dash PCM
U n d e r r i g h ts i d eo f d a s h ECM/PCM
Left side of engine compartmenl
Right side of engine compartment
Middleof engine Engineground,via enginewire harness
23-18
96 model:
ENGINEWIREHARNESS
c135 C134
c133 cl32
c130
T102
c1' r7
c119
c120
c118
c129
c106
cr07 c103
t't, c"' c108
23-19
EngineWire Harness(D16Y7engine):97model
Connectoror Numberof
Terminal Location Conneqtsto Notes
Cavities
c101 10 Leftside of enginecompartment Main wire harness(C303)
c102 M i d d l eo f e n g i n e Crankshaft speedfluctuation(CKF)
sensor
cr03 1 N4iddle of engine Engineoil pressureswitch
c104 4 Leftside of enginecompartment Alternator USA
c104 3 Leftside of enginecompartment Alternator Canada
c105 2 lvliddleof engine No. 1 fuel injector
cr06 2 M i d d l eo f e n g i n e N o . 2 f u e li n j e c t o r
cl07 2 lvliddleof engine No. 3 fuel injector
cl08 2 M i d d l eo f e n g i n e N o . 4 f u e li n j e c t o r
c109 3 Middleof engine IACvalve
c110 M i d d l eo f e n g i n e Throttleposition(TP)sensor
c111 3 Middleof engine Manifoldabsolutepressure(MAP)sensor
cl12 2 M i d d l eo f e n g i n e Intakeair temperature(lAT)sensor
c113 ) M i d d l eo f e n g i n e Powersteeringpressure(PSP)switch USA
c114 2 M i d d l eo f e n g i n e EVAPpurgecontrolsolenoidvalve
14 M i d d l eo f e n g i n e Junctionconnector
14 M i d d l eo f e n g i n e Junc on connector
c117 3 Leftside of enginecompartment Vehiclespeedsensor(VSS)
cl18 , M i d d l eo f e n g i n e Countershaft speedsensor NT
cl19 2 M i d d l eo f e n g i n e Enginecoolanttemperature(ECT)
switch A
c120 10 M i d d l eo f e n g i n e Distributor
c121 'l M i d d l eo f e n g i n e Enginecoolanttemperature(ECT)
sendingunit
c122 2 M i d d l eo f e n g i n e Enginecoolanttemperature(ECT)sensor
Middleof engine P r i m a r yH O 2 S( s e n s o1r )
c124 2 M i d d l eo f e n g i n e Back-uplight switch
c124 2 Middleof engine Lock-upcontrolsolenoidvalve NT
M i d d l eo f e n g i n e SecondaryHO2S(sensor2)
2 M i d d l eo f e n g i n e Mainshaftspeedsensor Alr
c't21 2 M i d d l eo f e n g i n e Linearsolenoidvalve Alr
cl2A 2 M i d d l eo f e n g i n e Shiftcontrolsolenoidvalve A/r
c129 1 Rightsideof enginecompartment Stanersolenoid
c130 20 Behindright kickpanel Junctionconnector
c 13'r 22 Underright side of dash Main wire harness(C446)
c't32 Underright side of dash ECM/PCM
c133 25 Underright side of dash PCM
c134 Underright side of dash ECM/PCM
16 Underright sideof dash ECM/PCM
c136 8 Leftside of enginecompartment Main wire harness(C305) Alr
c137 2 M i d d l eo f e n g i n e EVAPcontrolcanistervent shutvalve
T101 Leftside o{ enginecompartment Alternator
r102 Rightsideof enginecompartment Under-hoodfuse/relaybox
G101 Middleof engine Engineground,via enginewire harness
23-20
97 model:
WIREHARNESS
ctto "',' '
23-21
EngineCompartment Wire Harnesg
Connectoror Number ol
Location Conn€ctsto Notes
Te.minal Cavities
c201 10 Leftsideof enginecompartment Main wire harness(C308)
c202 6 Leftsideof enginecompartment Main wire harness(C309)
c202 2 Leftsideof enginecompartment Main wire harness{C309}
c203 4 Lelt sideof enginecompartment Cruiseactuator
c204 2 Behindtront bumper Windshieldwashermotor
c205 Behindfront bumper Rearwindow washermotor
c206 Leftsideof enginecompartment Leftfront turn signaUparking
light
c207 1 Behindtront bumper Frontfog light Optional
c20a Leftsideof enginecompanment Leftheadlight
c209 Leftsideof enginecompartment A,/Cwire harness(C751)
c210 2 Behindfront bumper Horn
models
c210 1 Behindfront bumper Horn 98 model
c211 2 Rightsideof enginecompanment Radiatorfan motor
c212 3 Rightsideof enginecompartment Rightheadlight
c213 Rightsideof enginecompartment Rightfront turn signal/parking
light
c214 8 Rightsideof enginecompartment Main wire harness(C355)
G201 Rightsideof enginecompartment Bodyground.via enginecompartment
wire harness
G202 Leftside of enginecompartment Bodyground.via enginecompartment
wire harness
*'l: With cruisecontrol
*2: Withoutcruisecontrol
|I 23-22
I
ENGINECOMPABTMENT
WIREHARNESS
23-23
Main Wire HarnesslLeft side ol engine compartment branch)
Cavities
c301 5 Leftside of enginecompartment Windshieldwjper motor
c302 Leftside of enginecompartment Testtachometerconnector
c303 10 Leftsideof enginecompartment E n g i n ew i r e h a r n e s (sC 1 0 1 )
c304 Leftside of enginecompartment Daytimerunninglightsresistor Canada
c305 14 Leftside of enginecompanment Enginewire harness(C136)
c305 8 Leftside of enginecompanment Enginewire harness(C136)
c306 I Leftsideof enginecompartment Brakefluid levelswitch(+)
c307 1 Leftside of enginecompanment Brakefluid levelswitch(-)
c308 10 Leftside of enginecompartment Enginecompanment wire harness(C2011
c309 Leftside of enginecompartment Enginecompartment wire harness(C202)
c309 2 Leftsideof enginecompartment Enginecompartmentwire harness(C202)
c310 Leftside of enginecompartment Left front ABS wheel sensor A8S
* 1 : D 1 6 Y 5e n g i n e
*2: D16YBengine
*3: With cruisecontrol
*4: Withoutcruisecontrol
Main Wire Ha.ness(Right 3ide of engine compartment branch)
Conn€qtoror Number of
Terminal Cavities
c351 1'l Rightsideof enginecompartment Under-hoodfuse/relaybox (C9081
9 Rightsideof enginecompartment Under-hoodfuse/relaybox (C906)
5 Rightsideof enginecompartment Under-hoodfuse/relaybox (C905)
c354 Rightsideof enginecompartment Under-hoodfuse/relaybox (C907) USA
c355 I Rightsideof enginecompanment Enginecompartment wire harness(C214)
3 Rightsideof enginecompartment Under-hoodABS fuse/relaybox {C927) ABS
c357 2 Rightsideof enginecompartment Under-hoodABS fuse/relaybox (C926) ABS
c358 2 Rightsideof enginecompartment Rightfront ABS wheelsensor ABS
c3s9 10 Rightsideof enginecompartment ABS solenoid ABS
c360 Rightsideof enginecompaTtment ABS pump motor ABS
G403 Rightsideof enginecompanment Body ground, via main wire harness
23-24
UNDER-HOOD
FUSE/RELAYBOX
MAIN WIREHARNESS
(leftbranch)
23-25
Main Wire Harness (Left side of dash and floor branchl
Connectorol Nurnberof
Terminal Cavities
c401 14 Above underdashfuse/relaybox Floorwire harness(C555)
c402 4 Underleft sideof dash Floorwire harness(C554) ABS
c403 4 Underleft sideof dash Securitysystem Optional
c404 14 Underleft sideof dash Cruisecontrolunit
c405 4 Underleft sideof dash Daytimerunninglightscontrolunit Canada
c401 2 Underleft sideof dash Roofwire harness(C701)
c407 2 Underleft sideof dash Moonroofwire harness(C7'1 1)
c408 1 Underleft side of dash Frontfog light connector Optional
c409 10 Behindunder-dash fuse/relaybox lntegratedcontrolunit
c410 Underleft side of dash Dashboardwire harness{C504} Atr
c411 24 Underleft side of dash Dashboardwire harness{C502)
c412 ? Aboveunder-dash fuse/relaybox SRSmain harness(C802)
c413 l6 Underleft side of dash Datalink connector
c414 4 Underleft sideof dash Startercut relay Mtr
c415 7 Aboveunder-dash fuse/relaybox lgnitionswitch
c416 6 Underleft sideof dash Securitysystem Optional
c417 2 Underleft sideof dash Clutchswitch
c418 2 Underleft sideof dash Clutchinterlockswitch M/T
c419 18 Behindunder'dashfuse/relaybox Under-dash fuse/relaybox (C919)
c420 20 Behindunderdashfuse/relaybox Under-dash fuse/relay box (C920)
c421 18 Behindunder-dash fuse/relaybox Underdashfuse/relaybox {C922)
c422 7 Behindunder-dash fuse/relaybox Underdashfuse/relaybox (C914)
c423 6 Behindunder-dash fuse/relaybox Under'dashfuse/relaybox (C915)
c424 Underleft sideof dash Horn relay
c425 Underleft sideof dash Brakeswitch
c426 8 ln the steeringcolumncover Windshieldwiper/washerswitch
c421 6 In the steeringcolumncover Rearwindow wiper/washerswitch
c42A In the steeringcolumncover Turn signalswitch
c429 7 In the steeringcolumncover Combinationlightûrnsignalswitch
c430 3 Underleft sideof dash Cablereel
c431 8 Underleft sideof dash Interlockcontrolunit
c432 U n d e rm i d d l eo f d a s h Secondaryheatedoxygensensorsub-
harness(C781)
c433 14 U n d e rm i d d l eo f d a s h A,/Tgear position switch
c434 2 U n d e rm i d d l eo f d a s h Shift locksolenoid A/r
c435 U n d e rm l d d l eo f d a s h Parkingpin switchand IVT gear
positionconsolelight
c437 26 Underleft side of dash Transmission controlmodule(TCM) CVT
c438 22 Underleft side of dash Transmission controlmodule(TCM) cw
c439 1 Behindunder-dash fuse/relaybox Under-dash fuse/relaybox (C925) Optional
G401 Left kick panel Bodyground,via main wire harness
*2: Withoutmoonroof
*4: With moonroof
*5: M//T(with cruisecontrolor for Dl6Y5 engine)
*6: With secondaryheatedoxygensensor(H025)
23-26
1 C410
-n--r--nr-n-rnn
UUUUUUUUUUUUqIU
23-27
Gonnectorldentificationand Wire HarnessRouting
Main Wile Harness(Left side of dash and floor branchl: 98 model
Conneqtsto Notes
Location
Terminal Cavities
c401 14 Aboveunder-dash tuse/relaybox Floorwire harness(C555)
c402 Underleit sideof dash Floorwire harness(C554) ABS
c403 Underleft sideof dash Securitysystem Optional
c404 14 Underleft sideof dash Cruisecontrolunit
c405 Underleft sideof dash Daytimerunninglightscontrolunit Canada
c407 2 Underleft sideof dash Roofwire harness(C701)
c407 2 Underleft sideof dash Moonroofwire harness(C711)
c408 1 Underleft sideof dash Frontfog light connector Optional
c409 10 Behindunder-dash fuse/relaybox Integratedcontrolunit
c410 Underleft sideof dash Dashboardwire harness(C504)
c41'1 24 Underleft sideof dash Dashboardwire harness(C502)
c412 3 Above under-dash fuse/relaybox SRSmain harness(C802)
c413 16 Underleft side of dash Datalink connector
c414 Under-dashrelaybox Startercut relay Mfi
c415 7 Aboveunder-dash fuse/relaybox lgnitionswitch
c416 6 Underleft side of dash Securitysystem Optional
c417 Underleft side of dash Clutchswitch
c418 2 Underleft side of dash Clutchinterlockswitch M/T
c419 18 Behindunder-dash fuse/relaybox Under-dash fuse/relaybox (C919)
c42'l 18 Behindunder-dash fuse/relaybox Under-dash fuse/relaybox (C922)
c424 Under-dashrelaybox Horn relay
c425 Underleft sideof dash Brakeswitch
c426 I In the steeringcolumncover Windshieldwiper/washerswitch
c421 6 In the steeringcolumncover Rearwindow wiper/washerswitch
c428 4 In the steeringcolumncover Turn signalswitch
c429 7 ln the steeringcolumncover Combinationlightnurnsignalswitch
c430 3 Underleft sideof dash Cablereel
c431 8 Underleft sideof dash lnterlockcontrolunit
c432 Undermiddleof dash Secondary heatedoxygensensorsub-
harness(C781)
c433 14 Undermiddleof dash Ay'Tgear positionswitch
c434 2 Undermiddleof dash Shift locksolenoid
c435 Undermiddleof dash Parkingpin switchand A,/Tgear
positionconsolelight Atr
c431 Underleft side of dash Transmission controlmodule(TCM) CVr
c438 Underleft side of dash Transmission controlmodule(TCM) CVT
G401 Leftkickpanel Body ground, via main wire harness
*2: Withoutmoonroof
*4: With moonroof
*5: M/T (with cruisecontrolor for D16Y5engine)
*6: With secondaryheatedoxygensensor(H02S)
23-28
"n , ctza c,81
98 model:
c/(}0 c42A
I clzs
MAIN WIRE
HARNESS
c412 C411 C410
UNDEB.DASH
BOX
FUSE/RELAY
23-29
Main Wire Harnsss(Bight side of dash branchl
Conneclor or Number of
T€rminal Cavities
c440 Undermiddleof dash Heatersub-harness A (C721)
c441 Underright side of dash Servicecheckconnector
c442 20 Underright side of dash Junctionconnector
c443 7 Underright side of dash PGM-Flmain relay
c444 22 Underright side of dash ABS controlunit
c445 26 Underright side of dash ABS controlunit
c446 Underright side of dash E n g i n ew i r e h a r n e s (sC 1 3 1 )
G402 Rightkickpanel Bodyground.via main wire harness
MAIN WIREHARNESS
23-30
DashboardWire Harness
Connectoror Numberof Connectsto Notes

Location
Terminal Cavities
c501 20 Behinddashboardlower panel Under-dash fuse/relaybox (C912)
c502 24 Aboveunder-dash fuse/relaybox M a i nw i r e h a r n e s s( c 4 11 )
c503 16 Aboveunder-dash fuse/relaybox Floorwire harness(C553)
c504 12 Aboveunder-dash fuse/relaybox M a i nw i r e h a r n e s (sC 4 1 0 )
c505 5 Leftside of steeringwheel Cruisemain switch
c506 3 Leftside of steeringwheel Dashlightsbrightnesscontroller
c507 20 Belowgauges Junctionconnector
c508 5 B e h i n dg a u g e s Gaugeassembly SRS
c509 5 B e h i n dg a u g e s Gaugeassembly
c510 14 B e h i n dg a u g e s G a u g ea s s e m b l y
Behindgauges G a u g ea s s e m b l y
c512 B e h i n dg a u g e s Gaugeassembly
'10 Rightside of gauges Hazardwarningswitch
L5 t5
c5l4 5 Rightside of gauges Rearwindow defoggerswitch
c515 16 B e h i n dm i d d l eo f d a s h Audio unit {Keylessreceivercircuit)
B e h l n dm i d d l eo f d a s h Securitycontrolunit Optional
c517 B e h i n dm i d d l eo f d a s h A u d i ou n i t
c5't8 5 B e h i n dm i d d l eo f d a s h Securitysystem Optional
c519 2 Behindmiddleof dash Cigarettelighter
c520 5 B e h i n dg a u g e s G a u g ea s s e m b l y ABS
G501 U n d e rm i d d l eo f d a s h wireharness
Bodyground,via dashboard
*1: With shift-upindicatoror cruisecontrolsystem(96,97models)
With cruisecontrolsystem(98model)
cs09c511 cs10 c515
13 I C517
c520
c501 c502 c504
23-31
HarnessRouting
Connectorldentificationand Wire
Floor Wire Harnsss{Coupe/Hatchback)
box Undetdashfuse/relaY box {C923)

'16 Behindunder-dash fuse/relaY
box Under-dash fuse/relaYbox (C921)
8 Behindunder-dash fuse/relaY (C503)
box Dashboard wire harness
Aboveunder-dash fuse/relaY
c553 Main wire harness (C402)
4 Underleft sideof dash
c554
Juse/relaYbox Main wire harness(C401)
Aboveunder-dash (C631)
Lb55
Driver'sdoor wire harness
c556 25 Driver'sdoor wire harness (C63'l)
Driver'sdoor
c556 2 Driver'sdoor wire harness(C651)
Passenger's door
25 Passenger's door
cs57 Passenger's door wire harness{C651)
2 Passenger's door
Parkingbrakeswitch
1 Middleof floor
LSCO
Driver'sseatbelt switch
c559 2 Leftsideof floor
Passenger's door switch
1 Left B-piller
LeftrearABS wheelsensor
L50 r 2 lnsideof left rearwheel
Rearwire harness{C60'l)
LeftC-Piller
Rearwire harness(C602)
c563 2 LeftC-piller
Fuelgaugesendingunit
c564 Fueltank
FuelPumP
c565 2 Fueltank
RightrearABS wheelsensor
c566 2 lnsideof right rearwheel
Driver'sdoor switch
cs67 1 LeftB-Piller
Fueltank pressuresensorsub-harness
Fueltank
c568
c569 10
{c791)
Powermirrorswitch I
Bodyground.via floor wire harness
Left kick Panel
Bodyground,via floor wire harness
Leftsideof floor
*1: With Powerwindows
*2: WithoutPowerwindows
'3: 97modelD : 1 6 Y 3e n g i n e( C o u p e )
(Coupe/Hatchback'
98 model:D16Y8engine
23-32
FLOORWIREHARNESS
c552
23-33
Floor Wire Harness{Sedanl:96 model
Terminal Cavities
c55'l Behindunder-dash fuse/relaybox Under-dash fuse/relaybox {C923)
8 Behindunder-dash fuse/relaybox Under-dash fuse/relaybox (C921)
c553 Aboveunder-dash fuse/relaybox Dashboardwire harness(C503)
c554 Underleft sideof dash Main wire harness(C402) ABS
LCCC 14 Aboveunder-dash fuse/relaybox M a i nw i r e h a r n e s (sC 4 0 1 )
c556 25 Driver'sdoor Driver'sdoor wire harness{C631)
ucco 2 Driver'sdoor Driver'sdoor wire harness(C63'l)
c557 Passenger's door Frontpassenger's doorwireharness (C651)
2 Passenger's door Frontpassenger's door wire (C651)
harness
c558 1 Middleof floor Parkingbrakeswitch
c559 2 Leftside of floor Driver'sseatbelt switch
c560 1 R i g h tB p i l l e r Frontpassenger's door switch
c561 2 lnsideof left rearwheel Left rearABS wheelsensor ABS
14 LeftC-piller Rearwire harness(C601)
c563 2 LeftC-piller Rearwire harness(C602)
c564 Fueltank Fuelgaugesendingunit
c565 2 Fueltank F u e lp u m p ( F P )
2 Insideof right rearwheel RightrearABS wheelsensor ABS
c567 1 Left B-piller Driver'sdoor switch
c569 10 Leftside of steeringwheel Powermirror switch
c570 6 R i g h tB - p i l l e r Rightreardoor wire harness(C671)
c571 6 Left B-piller Left reardoor wire harness(C661)
c572 1 Leftquarterpanel Left rear door switch
c573 1 Rightquarterpanel Rightreardoor switch
G551 Left kickpanel Bodyground,via floor wire harness
G552 Leftside of floor Bodyground.via floor wire harness
*1: With power windows
*2: Without powerwindows
I 23-34
96 model:
c558 c573 c566 C564
FLOORWIREHARNESS c570
c560
23-35
Gonnectorldentificationand Wire HarnessRouting
Floor Wire Harness(Sedanl:97. 98 models
Connectorol Number of
Terminal Cavilies
l6 Behindunder-dash fuse/relaybox Under-dash fuse/relaybox {C923)
8 Behindunderdashfuse/relaybox Under-dash tuse/relaybox (C921)
c553 16 Aboveunder-dash fuse/relaybox Dashboardwire harness(C503)
c554 Underleft side of dash Main wire harness(C402) ABS
L555 14 Aboveunder-dash fuse/relaybox Main wire harness(C401)
LC50 Driver'sdoor Driver'sdoor wire harness(C631)
L55b Driver'sdoor Driver'sdoor wire harness(C631)
Passenger's door Frontpassenger's doorwire harness(C651)
c557 Passenger's door Front passenger's doorwireharness(C651)
c558 1 Middleof floor Parkingbrakeswitch
2 Left side ot floor Driver'sseatbeltswitch
c560 1 RightB-piller Frontpassenger's door switch
2 lnsideof left rearwheel LeftrearABS wheelsensor ABS
c562 16 LeftC-piller Rearwire harness(C601)
t LeftC-piller Rearwire harness(C602)
c564 Fueltank Fuelgaugesendingunit
2 F u e tl a n k F u e lp u m p{ F P )
2 Insideof right rearwheel RightrearABS wheelsensor ABS
'I Left B-piller Driver'sdoor switch
l0 Leftsideof steeringwheel Powermirrorswitch
6 RightB-piller Rightreardoor wire harness(C671)
c57r LeftB-piller Left reardoor wire harness(C661)
,l Leftquarterpanel
c512 Left rear door switch
c573 1 Rightquarterpanel Rightreardoor switch
c514 Fueltank Fueltank pressuresensorsub-harness
{c791)
Leftkickpanel Bodyground,via floor wire harness
Left side of floor Bodv ground,via floor wire harness
*1: With powerwindows
*2: Withoutpowerwindows
97.98 models:
HARNESS
23-37
RaarWire Harnoss{Hatchback)
Conneclor or Numberot
Location Connectsto Notos
Tsrminal Cavities
c601 14 Leftquarterpanel Floorwire harness(C562)
c603 2 Leftquarterpanel Left rear speaker Optional
c604 Left side of cargo area Leftoutertaillight
Rightside of cargoarea Rightoutertaillight
c606 Rightquarterpanel Rightrearspeaker Optional
c607 Rightquarterpanel Hatchwire harness(C761)
c608 2 Rightquarterpanel Hatchwire harness(C762)
G601 Middleof cargoarea Bodyground,via rearwire harness
REARwlRE HARNESS
Rearwire Harness(CouPe/Sedan)
Connectoror Number of Location Connectsto Notes

Terminal Cavities
c603 2 Leftquarterpanel Left rearspeaker
c604 Leftsideof trunk Leftoutertaillight
c605 Rightside of trunk R i g h to u t e rt a i l l i g h t
c606 2 Rightquarterpanel Rightrearspeaker
c609 1 Leftsideof rearwindow Rearwindow defogger(+)
c6'r0 2 Middleof rearshelf H i g hm o u n tb r a k el i g h t
c611 2 Middleof rearshell T r u n kl i g h t
c612 1 Rightside of rearwindow Rearwindow defogger(-)
Leftside of trunk Leftinnertaillight
c614 2 M i d d l eo f t r u n k Leftlicenseplatelight
c615 2 M i d d l eo f t r u n k Trunklatchswitch
2 lMiddleof trunk Rightlicenseplatelight
c617 4 Rightside of trunk R i g h ti n n e rt a i l l i g h t
G601 M i d d l eo f t r u n k Bodyground,via rearwire harness
REARWIREHARNESS
c617
c615
23-39
I
J--
Driver's Door Wire Harness(Couoe/Hatchbackl
Connectorol Numberof
Cavities
25 Driver'sdoor Floorwire harness(C556)
2 Driver'sdoor Leftfront door speaker
Driver'sdoor Driver'spower window motor Coupe
c634 Driver'sdoor Driver'sdoor lockactuator Coupe
c63s 2 Driver'sdoor Tweeter Coupe
c636 12 Driver'sdoor Powerwindow masterswitch Coupe
c638 5 Driver'sdoor Driver'sdoor lockswitch Coupe
c639 8 Insideof left power mirror Leftpower mirror Coupe
c640 12 Driver'sdoor Powerdoor lockcontrolunit Coupe
*'l: With powerwindows
Passenger'sDoor Wire Harness(Coupe/Hatchback)
Cavilies
c651 25 Passenger's door Floorwire harness(C557)
2 Passenger's door Floorwire harness(C557)
2 Passenger's door Rightfront door speaker
c653 2 Passenger's door Frontpassenger's powerwindow motor Coupe
c654 2 Passenger's door Frontpassenger's door lockactuato. Coupe
c655 Passenger's door Frontpassenger's powerwindow switch Coupe
c656 8 Insideof right power mirror Rightpower mirror Coupe
2 Passenger's door Tweeter Coupe
23-40
.
DRIVER'SOOORWIREHARNESS
DOORWIREHARNESS
PASSENGER'S
23-41
Driver's Door Wire Harness{Sedanl
Cavities
c632 2 Driver'sdoor Leftfront door speaker
c633 Driver'sdoor Driver'spowerwindow motor
c634 Driver'sdoor Driver'sdoor lockactuator
c636 Driver'sdoor Powerwindow masterswitch
1 Driver'sdoor Powerwindow masterswitch
c638 3 Driver'sdoor Driver'sdoor lockswitch
c639 8 Insideof left power mirror Leftpower mirror
c640 Driver'sdoor Powerdoor lockcontrolunit
Front Passenger'sDoor Wire HarnesslSedanl
Connectorol Number of
Cavities
25 Passenger's door Floorwire harness(C557)
c65l 2 Passenger's door Floorwire harness(C557)
2 Passenger's door Rightfront door speaker
c653 2 Passenger's door Frontpassenger's powerwindow motor
c654 2 Passenger's door Frontpassenger's door lockactuator
5 Passenger's door Frontpassenger's powerwindow switch
I Insideof right power mirror Rightpower mirror
*1: With power windows
i2: Without power windows
23-42
DNNEB'SDOOR
WIREHARNESS
c6:|7 c636 C633
23-43
Left Rea. Door Wire Harness{Sedanl
Connestorot Number ol
Terminal Cavities location Connectsto Notes
6 Left B piller Floorwire harness(C571)
c662 2 Left rear door Left rear power window motor
c663 Left reardoor Left rear power window switch
c664 Left rear door Left reardoor lockactuator
Right Rear Door Wire Harness{Sedan}
Conneclor or Number of
Terminal Cavities Location Connectsto Notes
c671 6 RightB-piller Floorwire harness(C570)
c672 2 Rightreardoor Rightrearpowerwindow motor
c673 5 Rightreardoor Rightrearpowerwindow swltch
c674 2 Rightreardoor Rightreardoor lockactuator
Left Rear Door:
LEFTREARDOOR
WIREHARNESS
Fight RearDoor:
RIGHTREARDOOR
WIREHARNESS
23-44
Heater Sub-harnessA
Connectoror Number of Connecisto Notes

Location
Terminal Cavities
c721 r6 Underleft side of dash Main wire harness(C437)
c722 7 Behindglove box Mode controlmotor
c723 20 Behindglovebox Heatersub-harness B (C741)
c724 3 Behindglove box AVCthermostat
c125 2 Behindglove box Blowermotor
c726 Behindglove box Blowerresister
c727 4 Behindglove box controlmotor
Recirculation
Heater Sub-halnessB
Connectoror Number ol Connectsto Notes

Location
Terminal Cavities
cl4'l 20 Behindglove box Heatersub-harnessA (C723)
c142 6 Behindmiddleof dash Heaterfan switch
c743 14 Behindmiddleof dash HeatercontrolPanel
B
HEATERSUB.HARNESS
2345
Connectorldentification
andWire HarnessRouting
Hatch Wire Harness(Hatchbackl
Connestoror Number ol
Terminal Location Connectsto Notos
Cavities
c761 6 Rightquarterpanel Rearwire harness(C607)
2 Rightquaner panel Rearwire harness(C608)
2 Rearof roof Highmount brakelight
c764 1 Rightsideof tailgate Rearwindow defogger(+)
2 Middleof tailgate Rightlicenselight
c766 2 Middleof tailgate Leftlicenselight
c767 Middleof tailgate Rearwindow wiper motor
2 Middleof tailgate Tailgatelatchswitch
G761 Middle of tailgate Body ground,via tailgatewire harness
RearWindow DetoggerGround Wire lHatchback)
Connectot or Number of
Cavities
c711 1 Leftsideof tailgate Rearwindow defogger(-)
G771 Leftside of tailgate Body ground. via rear window defogger
ground wrre
23-46
REAFWINDOWDEFOGGEB
96, 97 models: GROUNOWIRE
TCHWIREHARNESS
c768
c766
c767
REARWINDOWOEFOGGER
GROUNDWIRE
TCHWIBEHARNESS
2347
Gonnectorldentification
and Wire HarnessRouting
Roof Wire Harness(Coupe/Hatchbackl
Connestoror Number of
Terminal Csvities
c701 2 Underleft sideof dash Main wire harness(C407)
c702 2 Centerof roof C e i l i n gl i g h t
Root Wire Harness{Sedan}
Connectoror Number ot
Terminal Cavities
c702 I Centerof roof Ceilinglight (Power)
c703 1 Centerof roof C e i l i n gl i g h t( G r o u n d )
Moonroof Wire HarnesslCoupe/Sedanl
Connectoror Number ot
Terminal Location Conneststo Notes
Cavities
c712 3 Behinddashboardlower panel Under-dash fuse/relaybox (C910) Optional
c 7t 3 6 Leftsideof dashboardbracket Moonroofopen relay
c714 6 Leftside of dashboardbracket Moonroofcloserelay
c715 Leftside of steeringwheel Moonroofswitch
c716 3 Centerof roof C e i l i n gl i g h t
c't17 2 Rearof roof Moonroofmotor
c718 Rearof roof Moonroofmotor (Tiltswitch)
c719 1 Frontof roof Spot light 98 model
WIREHARNESS
23-49
RearHeatedOxygenSensorSub-harness
Cavities
c7al 4 Under middleof dash Main wire harness(C432)
c7a2 4 Undermiddleof dash Secondaryheatedoxygensensor
(Secondary HO25)
FuelTank PressureSensorSub-harness
Cavities
c79'1 6 Middleof floor Floorwire harness(C568:Coupe/
Hatchback, C574:Sedan)
c192 3 Left side of fuel tank Fueltank pressuresensor
c793 2 Left side of fuel tank EVAPtwo way valve
FUELTANK PRESSURE
SENSOR
23-5 0
a SRSMain Harness
Connectoror Numbcr ol Location Conneststo Notes

Terminal Cavities
2 Underleft side of dash Under-dash fuse/relaY box (c911)
c801
A b o v e u n d e r - d a s hf u s e / r e l a Y M a i nw i r e h a r n e s (
s C 4 12)
c802 3
DOX
c803 2 R i g h t s i d e o f u n d e r - d a s hf u s e / Memoryerasesignal(MES)connector
relaybox
c804 2 Under left side of dash Cablereel
airbagassemblY
Passenger's USA
c805 2 Underrightsideot dash
Dummy resistorconnector Canada
c806 2 Middleof floor
c807 18 Middle of floor SRSunit
G801 Middle of floor Body ground,via SRSmain harness
SRSMAIN HARNESS
23-51
Fuses
Under-hoodFuse/RelayBox
ALTERNATOR
ITo engine wire harness(T101)l BATTERY
lTo startercables(Tlll
t Er'1 r-'l
IJ
tr 47
LI
tr r'1
51
LI
tr n5 6
IJ
r'1
LI
c901 c904
ITo condensertan relayl lTo blowermotorrelayl
c903
*: Not used ITo radiator tan relayl
NOTErView from the backsideof the under-hoodfuse/relaybox.
cr06
lTo main wire hsrness(C352ll
c905
lTo mainwire harness{C353}l
lTo main wire harness{C354)l lTo main wire harness{C351)l
23-52
FuseNumber Amps Wire Colol Component(s)or Circuit(s)Protectod
41 80A Powerdistribution
40A WHT/BLK To ignitionswitch(BAT)
43 7 . 5A WHT/RED Ceilinglight,data linkconnector,trunk light

44 1 5A WHT/BLK PGM-Flmain relay
45 Not used
46 40A WHT/BLU Powerwindow motors(viapowerwindow relay)
47 7 . 5A WHT/BLU Audio unit,clock,TCM {CVT).ECM/PCM(VBU)

(headlight)
48 30A WHT No. 33 (7.5A) fuse,To combinationlight switch
49 Not used
50 30A WHT/GRN Rearwindow detogger(viarearwindow defoggerrelay)
5l 204 WHT/GRN Powerdoor lockcontrolunit, moonroofmotor
52 1 5A WHT/GRN Horn svstem,brakelights,brakesignal

WHT/BLK relay
Hazardwarninglight,turn signal/hazard
53 1 0A
54 40A WHT/RED Option{+B)
5C 40A BLU,4/VHT Blowermotor (via blowermotor relay)

WHT Condenserfan motor (via condenserfan relaYl
56 20A
RED A/Ccompressorclutch(viaA\/Ccompressorclutchrelay)
57 20A BLIqRED Radiatorfan motor (viaradiatorfan relay)
,a
23-53
Fuses
Under-dashFuse/RelayBox
c912
[Todashboard
wir6 harnesslC501ll
c913
lTo ignitionswhchl llo main wire h.rno.s lciP2)l
c915
lTo main wiro harn$3 1C423)l
- r-t r-'l - T-l Ft n El rl Fl Tt r'l

23 2a aa 26 27 2A 29 30 31 32 33
I-J LI tJ LI LI LJ LI L.J tJ TJ LI LI
r-r r"t T1 n r'r r't n |-l rt r.1 T1 r-1
12 13 ra 15 16 1a 20
17 19 21 22
LI IJ I.J LI LJ LI L-JIJ LI LI I.J I.J lTo powar window relayj
r'l r;l El r't r-r r'l |;l r-l r't I;l T1 T1
1 2 3 1 5 6 r 8 9 1 01 1
TI IJ LJ LI TJ IJ LI LI IJ LI TJ LI
a: Canada
r: Not used
O: Cg26loption l+Bll c!'17
@: C!t2?Ioption (drsh lightsll lTo turn signal/he2ardrolayl
G)r Gt28 loption lACCll
@: Cg2gloption llc2ll dotoggerrelayl
NOTE:View from the backsideof the under-dashfuse/relavbox.
C925(96,97 modebl
lTo msin wiro h.rncss (C/('g)l
lTo main wire harn*31C419)l
23-54
Fus6Numbel Amps Wire Color Componsnt{s)or Circuit(s)Protscted
Not used
Not used
10A GRN Rearwindow wiper motor,rearwindow washermotor
1 0A RED/BLU Right headlight (high beam)
5 10A RED/GRN Left headlight thigh beam), high beam indicator light
6 Not used
1 20A RED/WHT Left rear power window motor
8 204 YEUBLK Rightrearpowerwindow motor

Not used(96,97 models)
9
1 5A RED Distributor(ignitioncontrolmodule)(98model)
10 20A GRN/BLK Frontpassenger's powerwindow motor
l'l 204 BLU/BLK Driver'spowerwindow motor
12 YEUBLK relay(viaturn signal/hazard

Turn signal/hazard switch)
YEUGRN PGM-Flmain relay

13 1 5A
cRY or BLKI/EL SRSunit {VA)
14 BLKI/EL Cruisecontrolsystem.audio unit
Alternator,VSS.ELDunit {USA),EVAPpurgecontrolsolenoidvalve,
15 7 . 5A 8LK/WHT
oxygen sensors,TCM (CVT)
to 7 . 5A BLI</8LU ABS pump motor,rearwindow defogger
17 BLK/YEL l'lc system,power mirror,option (lG2)
18 7 . 5A YEUBLK Daytimerunninglightsrelay(Canada)
19 7 . 5A YEURED Back-uplights
20 10A BLK/WHT Daytimerunninglightscontrolunit (Canada)
1 0A REO,4ryHT Rightheadlight(low beam)
22 10A L
RED|YE Leftheadlight{low beam)
1 0A GRYor PNK SRSunit (VB)
24 7 . 5A GRN/ORN Moonroofrelays
7 . 5A YEL Gaugeand indicatorlights,interlockcontrolunit
Windshieldwiper motor,windshieldwashermotor.
20A. GRN/BLK
inteqratedcontrolunit {Canada)
1 5A YEUGRN Accessorvsocket (ACC)
28 10A,/15A' YEURED Audio unit,option (ACC)
29 Not used
30 7 . 5A RED/BLK Dashlights,option (dashlights)
31 7 . 5A BLU/IVHT ECM/PCM, PGM-Flmain relay.integratedcontrolunit
7 . 5A RED/BLK Frontparkinglights,taillights,licenseplatelights
WHT/GRN Interlockcontrolunit, key interlocksolenoid
*('98 ModelOnly)
23-55
Fuses
Under-hoodABS Fuse/RelayBox
lTo undor-hoodABS tuse/relav box wire harn€ssl
c926 c928
lTo main wire harnesslC357ll lTo ABSpumpmotorrelayl
cs27
lTo main wire ha.ness{C350ll
FuseNumber Wire Color Component(s)or Circuitls) Proiected

61 40A WHT ABS pump motor (viaABS pump motor relay)
7 , 5A BRN//EL ABS controlunit lmotor check)
63 20A WHT/GRN A B Sc o n t r o ul n i t( + 8 1 )
23-5 6
PowerDistribution
Circuitldentification
UNDERHOODABS
FUSEiRELAYBOX
wHTGFN-] lBs.onuo'rn,t
CONTFOL
V
I
GRNiWHT
WHT ABSpumpmolof
BFN/YEL
ABSconlrol
unrt
I
YEURED
BLK- s l a d em
r olor
UNDER-HOOD
BOX
FUSE/FELAY
wHTBLK- Hazard wan nglighl

relav
Turnsional,hazatd
(vras ilch)
ALTERNATOR
V Horn
t#i',33),5i3i
L Hornreay
ABSconlrolunrl
PCM
ECMi
TCM(CVr)
Cruise
conlrolwil
Brakeights
G R N / R E-D PCM
ECMi
I-*^
G401
l--'-
NHrts-/-2>.=""1i")iis cl'. t Ot'rSw-C- :.-
G402 WHT/FED Celinglighl

Trunklighl
lD-:
Dalalinkconneclor
InleEaledconlroluni:
WHI/BLK- P G MF L m a irne L a y
UNDERDAS-
i: '
FL.JSEIRELAV
page
(To 2: a'
TCM(CW)
ECM/PCM
23-57
PowerDistribution
Circuitldentification(cont'd)
UNDEFHOODFUSE]RELAY
BOX
UNDER.OASI,]
FUSEiRELAY
BOX
(Topage23-62)
COMBINATION LIGHTSWLTCH
(Io page23.63.64)
IJNDER.DASHFUSE/FELAY
BOX
(Topage23-64)
F\ ,UNo-EF
, . , ^ - ^DaSH
^ " - , F-Sl ql I AYBoX
t4,-TGF\ -.,i .>
>/ t apagFzrb \
V'/-- Gi\
- Powe.doorlo(l (ortro u t r
- Moonroolmolor
,"--... h\ -\DEqDAS-EUsE FE-A'Box

1,.' llo oag"2j-6n
N o . 1 (77 . 5 4F) U S E
(Frompage23 59)
BLUMHT- Bowermolor
"*-]
oot
G402
BLU/1flHT ECMiPCM(Va ArCpressure

swilch)
ELUA&HT ,nClhermoslal
lanmoloa
Condenser
llo compressor
c ulch
-
BLK/REO PCM
ECMi
BLK/RED- Fadiatorlan
motor
23-5 8
N0.42(40A)FUSE
(Frompage23'57)
UNDEFDASHFUSAFELAYBOX
IGNITIONSWITCH
-
BLKELU unit
ABsConlrol
F\ q E A RW I \ D O WD E F O G G E
FRELAV
+-l', > (V,arearsrldo$,deloqger swilcF
l,z (Topage23.51)
eN i,, I
I
l- Rearwrndow swilcll
delogger
-., ACC
I ighl
indicalor
No17(7.5A) (Fuse/relay
boxsocket)
(lG2)
Oplonalconneclor
. BLOWER MOTOR RELAY

.CONDENSER FANFELAY
' ,vc coMPREssoR
CLUTCH RELAY
. RADIATON FANRELAY
{Io page2358)
Healerconlrolpanel
A/Cthermoslat
Modeconlrolmolor
conllolmolor
Fecirculalion
.|
lefl mwe,m,r,or
actualor
|'\ DAvllMERLNN'NG
- L GH_S
YELBL( -l j> CO\TFO_UN (Caladd)
V' llo page23-64)
. 8L(YEL+ lgnilon
coil
GRN molor
Rearwndowwasher
GRN motor
Re windowwipel
N 0 . 1 (27s A )
-
YEUBLK relaY
Turnsional/hazard
(Viaswitdr)
YEUGRN_ PGM-F
firain
relay
SRSlnil (VA)
N 0 . 1 (47 . s A )
BLK/VEL-l- CrJseco"lroturl rvrama,ns\rilch)
l- I'gtl
C'LEemarrswilchlrdrcalor
l- ctcuil)
AuoioJ1,rt(ey'e9s'ece'ver
N 0 . 1 (57 . 5 A )
vss
HO2S
venlshutvalve
EVAPconlrolcanisler
BL</w--
+ :J"!i'.rT
F-"t
--
BLXMHT fTcM(cvTj
I
-
BLKtr/HT lighl
syslem
chaGing
(cont'd'
23-59
PowerDistribution
Circuit ldentification (cont'd)
UNDER,DASH
FUSE/RELAY
BOX
Back-uplighls
G F Yi o ' P N < i - S F SL r i l ( v a )
GF\.CF\ Moonroor
openreay
-
- Moolroolctose.etay
POWEH WINOOW RELAY

(Topage
23-61)
No25(7.5A) (Fuserelaybor sockel)

nlegfalpdconlro Llnil
.;. -- S ' l | r t o o ( s o r e n o o( , , - .
l- I n t e r l o c ^ c o n t o l LI nltrly r l
Gaugeassenby
SRSndlcalorlighl
ABSindicalor
light
Mqear DosronndcatofJ
ormmrng
crrc!l
Cruriendcator I
boxsocke0
{Fusgrelay
Inlegraled
conlrctunil
-
GRN/8LK Windshleldwper
molor
sw TcH(ACC)
tGNtTtoN
page
(From 23.59)
Inlegraled
conlrol!nil
(VEwindshieldwlp€rswlch)
W ndshieldu/ashermotor
(Vasrvitch)
-
YEUGRN power
Accessory (ACC)
sockel
Oplonalconneclor
(ACC)
Audiounil
N0.54(40A)FUSE
(Frompage2358) BOX
FUSEIRELAY
UNDER.DASH
ft
I
WHT/RED
(Fuse/f
elayboxsockel)
(+B)
conneclor
Oplional
No24(75A)FUSE
(Frompage2360)
N0.46(40A)FUSE
(Frompage23'57)
f-;-7
tr*a
\7I
I G401
Wl.lTiELLJ
G402
d-J ts-^ + 'oitFr wrnJo{n'o;le $ .1

l- Powefw nOOw COntO Lnrl
(viapowerwrndow masterswlcn)
GRN/BL(- ] FronlPassengers
Power
G R N / B L-KJ wn00wm0l0r
/via powerwrndow
maslersw ch\
landlronlPassengels
Power l
\wndowswilch I
':: -olor
::- i Le'lrearoowe,wrdow
'/Vla $r.oowmdsleswdch\
Pow€r
w ndowswilclr
\and ell rearPower /
:":"1 i Riohrealoowewndow-olor
'/v'a powerwlndowmasel swllcl
l
No 50 (30A)FUSE \ a r on g l t ' e dp
l o w e ' wd o w s wl c l /
(Frompaqe23'58)
vI
No16(7.sA)FUSE WHT]GRN
(Vaswilch)
(From
paqe23'59)
Rearwindow
delogqer
f,7
I
BLll/YEL
"n-f,-
G40t
G402
(cont'd)
23-61
PowerDistribution
Circuitldentification(cont'dl
(MT)
GN|T0N SWTCH{ST)
(Frompage23.59)
BLKMHI cu qELA"
i"'
-fff
"n*n'
cLUc- swlrcH
,,,,,,*
@**-f_
t-
l l i l
--T€l-
BLK4THT BLK/RED _
BLK,vHT srarrer
sotenoid G401
T
E L KRi E D
I
L-
N€UTRALPOSLT]ON
SWITCH
(Flse/relay
boxsockel)
In1egraled
conlrolunt
-
BLUI/VHI PGM-F|main
retay
_
BTUMHT ECi?VPCM
i,Y
",5
[l;'if'"od) F- ** ..............--
WI-]T/GRN Inle ockconrrotun
(Viaintedoct
swrlch)
I
r- Keyinleiocksotenord
*-,
' [\ covB NATToN LicH-swtrci
V I'o Page
2363 6',
23-62
USA:
FUSE]RELAY
UNDER'DASH BOX
COMBNATION
LIGHTSWITCH
R E D i B L -U FrghlheadlghllHrghbeam)
N0.5110A)
No48(30A) R E D T G R- N H g hb e a r ni d c a l o!rg h l
FUSE
\2358 / l nPASSTNG R E D T G R- N glrbeam)
Lellheadlighl(H
w I
to
-
REDIWHT R L g h t h e a d l{gL o wb e a m )
I
R E O I Y E-L LellheadghllLowbeam)
N o4 8 1 3 0 A )
FUSE
/ F r o mp a g e\
\2362 /
(Fuse/reay
boxsoc(el)
(Dashghls)
Oplonalconneclor
(Fuseirelay
boxsockel)
nieoraled
conlro!n
Hazard warnrn!swtchlghl
G a u gLeg h t s
Feafwndowdelogg€r swtch$h]
Cfurse man sw(ch€11
c r L t s en dc a t o r
) c m mn qc , r , r
A qeap r o s r 0 nn oc d r o r r
Dashighlsbnglrlness conlroer
-t
RED/BLK A'Tgearposlonconsoielghl
Healerconlropanelghl
REDlBLK
- l e f , | i , o n t o a 'nt ol o h t
Hqntl
FEDIELK
Hqnr
inn"'lu'gltt
r'trh1J
---:
l censo e a l el o h l s
H q N IJ
(cont'd)
23-63
PowerDistribution
UNDER.DASH
FUSEiRELAY
BOX
R E D / B L -U R g h th e a d i g h( H
t i gb
he a m )
--<
BEDiBtU REssToF(Canada)
- -
RED/GFN Nighbeamindic€lor
ighl
\23.59 / l oPASSNG
I
\7 to REDMHT FEDTGRN
T
Lenheadlghl(H,qhbearn)
I
WHT <
REs
sroRlcanada)
BEOMHT- (Lowbeam)
Fighlheadlighl
No48(30A)
FUSE
/ F r o mp a g e \ Lellheadlght(Lowbeam)
\2362 l
{Flserelayboxsockel)
RED/GBN Oplional (DashI ghls)
connector
(Fuse/reay
bor sockel)
Inlegraled
conlrclunrl
RED/BLK Hazardwarning swilchlighl

GalgeI ghls
N ol 8 ( 75 A ) N0.48(40A)
FUSE FUSE Audioun1
/Frompage\ Rearwindow deloggerswlchlghl
\23.59 J \23 58 J Crlisenan swllchlght
Cruisendcator I dlmmtng
lVTgearposilonindicalorJcrc!i1
Dash€htsbrlghhess conlroler
YELIBLK REDTBLK Mgear pos onconsoterght

-
- Healercontropanetqhl
-t
RED/BLK
) uon'
l"'l'n' 'nn'
ou"'"n
F,i6,'.E"
I l"fn,]o''.'''"'nn"
Y I ) '-"'''"n*'
h,'fn,
'|
l-.,-;
.*o^,
lt'j") '*n."o'"'"
'nn,,
ITIIFLUD ---D
FED,BLU RGHT
HEADLGHT
(Hshbeanr)
I , JI L E V E L t+
wHr/RED........+?
I'*'"l-
|
I f-llrr-t- -->
REo/GFN LEFT
HEADL
cHT(Hish
beam)
t l
BLK REDIGRN 8LK RESSTOF
I A
I Y
.
G401
G402
I
G40l
G402
GroundDistribution
Circuitldentification
Ballery
o,
Powersleerngpumpbrackel
I
i'
nous
Transnissron ng
I
i
Primary HO2S(M/T)I
(M/T)
E G Rv a l v e
| l O r s v S" n g , n . )
soenoidvave (AiT) l
BLK ECTswlch
BLK VSS
BLK PSPsw ch
BLK ( P G 1I)
fEoMTPCM
BRN/BLK BLK {PG2)l
IV s,r. -lFIpLh
' - PGMFmenleay
E1tt"'tu-'
page23 66) WEC pressure swilcfl
( D 1 6 Y 05 1 6 Y 8e n g n er 9 8m o d e)
Ballerygroundcabe E : Engineground B
cable @ nwreturness
t',la
trl groundcableA
Engine B harness
Engn€lvire
)
(cont'd)
23-65
GroundDistribution
page2365)
w
A
|l]
BRN/BLK
LG1I
l Ect,tPcM
roz J
f _{r I enNierx
L ^ F S e n s o1r
L -E={ll Erui RED
K n o cske n s o(rK S ) + i : € FED/BLU
PrmaryH02S*' - WHT
l,."
sensor-€
Manshallspeed RED
speedse.sor -1Fl
Counlershall BtU
Dl6Ygengrne
[--;'*:+il; y:1=.":*:-]
Dl6Y5,016Y7engine
-
BRN/BLK
--:'--l
I
B R N / B L _K
puleyspeed
Drive .-!l
sensor RED/BLU reo[[,]- f tcvrc*1
Drivenpuleyspeedsefsor =.j€ WHT wrr --+
S e c o n d a r y gsehaar lsl p e e sde n s o r
----1Fl |
WHTTRED WHT/RED.+J
E : Enginewre
harness Shlelding * 1: D]6Y5,
016Y8engine
: Manwre * 2: Excepl
D16Y5engine(M/T)
E harness *3:016Y5 engne(M/I)
23-66
r- Fiqhl headliqhr
BL^- ;gn'ru,. Pc,"''e'sn

l- Riqhllronl lurn signalllghl
o L ^ - - - - - ! -
l- lighl
LerllronlParking
l- Leitlrontlun gqnalight
8L< ? !',/ndshield malo'

wasrr€r
l-- Fearwndowwashef molor
cruisocontroltclualor
E , Engine hatn"ss
cotpanmentwre
(conl'd
23-67
GroundDistribution
o_^ ---- Yllnosr,eE wtcErmoro,

t_ Bra{e llLto eve swilci
6_^ ---- g1' or rev sw,lcrL
f i oata
t.. co-.ecro,
o-c,
W ndshe d wiper/washer
swilch
,r* -fi-f6 -
B,L,oc^ - "-
ud^ |
s6's7m.dels
:-'" I
Re wlfdowwiper/waslrer
swilch
oL^-- l e 1 o c hc o n r r Jo r
oaaiT on swilc,r J! i a /' r ,
l-
- ctJlci irreroc\swrtcLt lM-l
8rK Cruseconlrolunil
8LK Daylimerunnng (Canada)

ighlsconlrolunll
I_ Clllchswitch
([,]/T
wlhcrrise
conlrolor
lorD]6Y5engine)
(Fuse/relay
boxsockel)
Fearwndow relay
delogger
(Fuse/relay
boxsock€l)
Inlegraled
conlrcllnil
(Fuse/relay
boxsocket)
(Fuse/relay
borsocket)
BLK Tornsignal/hazard
relay
J ;L^ ------ 1roon.oor.wrcr
\u/
l-- oper'etay
voon.oot
G402 Mool,oolctose,etay
( To Faqe
23 69- a-1 ---- orqrrress
lasr r'gnls co'rorer
l- Key/essdoo'ockcorro,u'r
.....- tsL^--F Seculryconlto,
Jflr
oit
Crulsenrainswrlchlighl
Cluseindicalor
dimming circut
Re windowdslogger swlchlght
l/T gsalposton indicatordlmmngcncuit
BLK-+ powersockel
ACCeSSOTy
SRSindicalor
lighrcircuil
BLK Gauges
andindcaloas
BLK ABSndcatorighlcircu[
BLK Gaugelighls
@ : Englne
companmenlwre
harness E : Dashboard
wrehaness
@ Main wrehaness E : Moonroolwire
harness
rwih., I ARsr
-<
BLK caol(Fom 2,.6s)-
ease
l
(wrhA8s)
BLK- l/TiearPosition
swlch
BLK checkconneclor
Servrce
UNDER.HOOD
FUSE/RELAY
BOX
ABSplmp molor
oro,
Audioun1
G501
la BLK + Po{e! doot\od\ !oi\o\ uh\

l- Drveisdoorlochaclualof
r- Dfivers doortockswilch
I i Pow windowrraLnsw ci
tt4 )
l- Dfper s powerwrndowmolor
Fuelunl
BLK
- 5ii.?i1!"f1,.,,'"n
ttt tr : Driversdoorwireharness
fit wre harness
Dashboard L r - ! l Heater A
sub-harness
trn : Healersubharness
B
23-69
GroundDistribution
Circuitldentification(cont'd)
l-L! J--. -t:JEL^
I
t
- l
l -l"r.,ln"'nno I
l
-
lr - ' l - 1t
-d 3-{ -1_t-L: ;_K
G601 l"$$,)',r"n,"ou'.,,n'''.
I
Hghmoonlbrakelighl I
Rearwindowwiper
motor
G76l
(Halcnback
r96 97models)
t-.1-...--!"..
L. t-iin1Jtt't,ignt'
t
l
- l
l
- l l l - l -
< a_K-iJ-1: ts-h Leil ) .
rrcenePralerqn$
G60l RrghtJ
Highmounlbrakelighl
Rearwindow wipermotor
Trunklalchswilch
I
LG761
(Halchback:98
_l
m00€u
I
o*t""'u'nn"
h"'$,)
c: Lefil.
RrghlJ
L e t ll .
Innellarl||gn$
lrcensePrae{ms
G601 R qhtJ
Trunklalchswitch
Highmounltake lighl
Rearwindow delogger
(Coupe/Sedan)
Condenser
lanrnolor
oir,
Rearwindow (Nalchbach)
delogger
G77l
],,,,.'
out
B U : Rear
window ground
delogger wire * GRY: 96 97 models
rdl : GRN: 98 model
El sns main
harness
E Hatclr
wirehamess
23-70
Under-dashFuse/RelayBox
SRS componeols'rle located in this area Reviewthe lnstallalion:
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor ser- 1. C o n n e c tt h e c o n n e c t o r st o t h e u n d e r - d a s hf u s e /
vice. relaybox, then installthe under-dashfuse/relaybox
in the reverseorderof removal{seesection24).
Removal:
2. lnstallthe driver'sdashboardlower cover (seesec-
t. Disconnectthe batterynegativecable,then discon- tion 20).
nectthe positivecable,and wait at leastthree min-
utes. 3. Connectthe airbagconnectors(seesection24).
2. the airbagconnectors{seesection24)
Disconnect 4. Connectthe batterypositivecable,then connectthe
negativecable.
3. R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster(seesection20). 5. Conlirmthat all systemswork properly.
4. Removethe t\rvomountingnuts,and pull the under-

dashfuse/relaybox out from underthe dash.
UNOER.OASH
FUSE/RELAYBOX
D i s c o n n e ctth e c o n n e c t o r sf r o m t h e u n d e r - d a s h
fuse/relaybox, and take out the under-dashfuse/
relaybox (seesection24).
2?-71
PowerRelays
RelayTest \
NOTE:Seepage23-155for turn signal/hazard
relalinput o Rearwindow defoggerrelay
Le5t.
Normally-opentype:
'1.
Checkfor continuitybetweenthe terminals.
. Thereshouldbe continuitybetweenthe No. 1 and
No. 3 terminalswhen power and groundare con-
nectedto the No. 2 and No. 4 terminals.
. Thereshouldbe no continuitybetweenthe No. 1
and No.3 terminalswhen power is disconnected.
Terminal
\ 3
ao*o o,o.= *o.if'
Disconnected
Connected o o
l(-l-
h-- 5
'I
ln P
I
a Startercut relay:96,97models
. Blowermotor relay Horn relay:96,97 models
. ABS pump motor relay

Normally-opentype: Five-lerminaltyPe:
1. Checktor continuitybetweenthe terminals 1. Checkfor continuitybetweenthe terminals.
. Thereshouldbe continuitybetweenthe No. 1 and . Thereshouldbe continuitybetweenthe No l and

No. 2 terminalswhen power and groundare con No. 2 terminalswhen power and groundare con
nectedto the No. 3 and No. 4 terminals n e c t e dt o t h e N o .3 a n d N o . 5 t e r m i n a l s .
. Thereshouldbe no continuitybetweenthe No. 1 . Thereshouldbe continuitybetweenthe No.2 and
and No. 2 terminalswhen power is disconnected' No. 4 terminalswhen power is disconnected
Terminal
\ | ermrnal \ 1 2 4
2
Power(N0.3- No.4) \
t"i* r*"-, - t". u\
Disconnected o- ---o
Disconnected
Connect€d o -----o Connected o- O
( r.l
9
I {
2
Powerwindow relay Moonroofopen relaY;96,97 models
a Radiatorfan relay a Moonroofcloserelay:96,97 models
a Condenser fan relay
IVCcompressorclutchrelaY
Startercut relaY:98model
a H o r nr e l a y : 9 8m o d e l
23-73
PowerRelay
RelayTest
\
Five-terminaltype:
l. Checkfor continuitybetweenthe terminals.
. There should be continuity betweenthe No. 1

a n d N o . 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
connectedto the No. 5 and No. 3 terminals.
. There should be continuity between the No. .l
and No. 4 terminalswhen power is disconnected.
\ Terminal
1 2
Power(No. 5 - No. 3) \
Disconnected o- ----o
Connected o- --o
5
a Moonroofopen relay:98 model
a Moonroofcloserelay:98 model
I
| 23-74
L
lgnition Switch
Test ElectricalSwitch RePlacement
SRS componentsare located in this area. Reviewthe SRS componentsare locat€d in this area Reviewthe
SRScomponentlocations,precautlons,and proceoures SRScomponentlocations,precautions,and procedures
in the SRSsection{24)beforeperformingrepaarsor ser- in the SRSsection(24)beforeperformingrepairsor ser-
vtce. vice,
1. the batterynegativecable.
Disconnect 1. the batterynegativecable.
Disconnect
2. Remove the driver's dashboard lower cover and 2. Remove the driver's dashboard lower cover (see
knee bolster (seesection 20). section20).
3, Disconnectthe 5P connectorfrom the under-dash 3. Disconnectthe 5P connectorfrom the under-dash

fuse/relaybox and the 7P connectorfrom the main fuse/relaybox and the 7P connectorfrom the main
wire harness. wire harness(seeleft column).
4. Checkfor continuitybetweenthe terminalsin each 4. Removethe steering column covers (see section
switchpositionaccordingto the table. 171.
"0 (LOCK)".
Terminal (3) E (1) 5. Insenthe ignitionkey,and turn it to
\ 1
(ACC) {BAT) 0 G 1 ) Il\rZ, {ST)
,olirton-__\ 6. Removethe two screws and the electricalswitch
o {LocK) from the steeringlock.
| (ACC) o- ---o
lr(oN) o- --o
III (START) o- ---o
[ ] :7P connector
Wire side of lemale terminals
BLK/WHT(ST} WHT(BAT}
7P CONNECTOR
WHT/8LK
BLK/YEL(IGlI 7. lnstallin the reverseorderof removal

YEL{IG2)
lf the continuitychecksdo not agreewith the table,

reolacethe electricalswitch
23-75
lgnition Switch
Steering Lock Replacement
SRS componentsare located in this area. Reviewthe Insiallation:
in the SRSsection(24)beforeperformingrepairsor ser- 1. Installthe new steeringlock assemblywithout the
vice. key inserted.
Remove: 2. Looselytightenthe new shearbolts.
1. Disconnect
the batterynegativecable. 3. lnsertthe ignition key, and checkfor properopera-
tion of the steeringwheel lock and that the ignition
2. R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d keyturns freely.
kneebolster(seesection20).
4. Tightenthe shearbolts until the hex headstwist off.
3. Disconnectthe 5P connectorfrom the under-dash
fuse/relaybox and the 7P connectortrom the main
wire harness(seepreviouspage).
SHEARBOLT
4. Removethe steeringcolumn covers,then remove
the mounting bolts and nuts from the steeringcol-
umn (seesection17).
5. Lowerthe steerlngcolumnassembly.
6. Center-punch eachof the two shearbolts,then drill

their headsoff with a 5 mm (3/16in) drill bit.
TWIST-OFFPORTION
CAUTION: Do not damagethe steering lock body.
5. Installin the reverseorderof removal.
7. Removethe shearboltsand the steeringlock

ory.
Battery
Test
@
a Battery fluid (electrolytel Gontatnssulfuric acid. lt may causesevele burns if it
gets on your skin or in youl eyos weal
protective clothing and a face shield.
- lf electrolyte gets on youl skin or clothes, rinse it off with water immediately'
-||e|eqtro|ytegetsinyoureyes,||ushitoutbysp|ashingwaterinyoureyes|orat|sast15minutes;c8||aphysician
immediatelY.
.Abafterygivesof'hydlogengas.|fignitgd,thghydrogenwil|exp|od€andcou|dcrackthebatterycaseandsp|atter
acid on you. Keepsparkg.flames, and cigarottesaway lrom ths battery'
. overcharging will raise the temperatur; ths electrolyte,This may force electrolyte to spray out of the battery vents.
Fol|owthechargelmanufactuler,sinstructions,andchalgethebatteryataploper]ate.
procedures.lf you don't have one of thesecomput-

Useeithera JCI or BearARBSTtester,and follow the manufacturer's
test procedure:
erizedtesters,follow this conventional
Toqetaccurateresu|ts,thetemperatureofthee|ectroIytemustbebetweenTo.F(21.c)and100.F(38"c).
lf the caseis crackedor the postsare loose,replace

the battery.
CheckIndicatorEYEColor
lf the indicator shows low electrolyte, add distilled
TestLoadCapacity(#1)
. A p p l y 3 0 0 a m p l o a d f o r ' 1 5s e c o n d st o r e m o v e
surfacecharge.
. Allow 15 secondsrecoveryPerloo.
. Applytest load (seeTestLoadChart)
. Recordvoltageat the end of 15 seconds.
Staysabove9.6 volts;
batteryis OK.
{co'::
23-77
Battery
Test (cont'd)
Chargeon HighSening{40amps}
Chargeuntil EYEshows chargeis OK; plus an
additional30 minutesto assurefull charge.
NOTE: lf the battery charge is very low, it may
be necessaryto bypassthe charger'spolarity
protection circuitry.
lf the EYEdoes not show chargeis OK within
three hours,the batteryis no-good;replaceit.
Write down how long the batterywas
charged.
Test Load Capacity(#2)

Apply 300amp load for 15 secondsto removesurfacecharoe.
Allow l5 secondsrecoveryperiod.
Apply test load (se€Test Load Chart,.
Recordvoltageat the end of 15 seconds.
Stays above 9.6 volts; batterv is OK. Drops be]ow 9,6 volts; battery is no-good,
5582{L - MF ot
558241(St - MF
TESTLOADCHART
Usethe test loador 1/2the cold crankingamps (CCA)printedon the
labelon the top of the battery,lf neitheris indicated,usethe
informationbelow:
fr, BATTERY
CODE
*: 5sB24L(S)- MF
COLDCRANKING
AMPS(CCA)
4 0 5( * 4 1 0 )
LOAD
tamps,
200
23-78
StartingSystem
ComponentLocationlndex
STARTERCUT RELAY(M/T)
les\, page za t z, t r
Test,page 23-138
CLUTCHINTEBLOCK
swrTcH
BATTERY
Test,page23-77
STARTER
Test,page23-81
SolenoidTest,Page23-82
Replacement,Page23 86
PerformanceTest, Page23-87
23-79
Starting System
IGNITION
UNDER.HOOD
FUSETRELAY
BOX S WT C H
No41(80A) No42 (40A)
WHT]BLK
{-WHT
SLKA/VHT
I
t
BLKWHT
l
BLKMHT
A,TTGEAR
P O ST I O NS W T C H
( C l o s e d : lpno s o n N o r E )
STARTER
CUTRELAY
BLI]/8LK
I CLUTCN
swiTcll
Closed:Clulclrpedal)
lullydepressed /
BLK
STARTEF
(Permanenlmagnellype)
1
G40l
G4A2
23-80
StartingSystem
StarterTest (cont'd) Starter Solenoid Test
Checklor Wear and Damage 1. Checkthe hold-incoil for continuitybetweenthe S
T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d t e r m i n a la n d t h e a r m a t u r eh o u s i n g( g r o u n d )T. h e
s t e a d i l y l,f t h e s t a r t e re n g a g e s b, u t c r a n k st h e e n g i n e coll is OK if there is contjnuity.
erratically,removeit, and inspectthe starterdrive gear
and torqueconverteror flywheelring gearfor damage.
ARMATURE
HOUSING
. Checkthe drive gear overrunningclutchfor binding (GROUND)
o r s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e S TERMINAL
d r i v eg e a rh e l d .
- lf damaged,replacethe gears.
CheckCranking Voltage and Current Draw

C r a n k i n vgo l t a g es h o u l db e n o l e s st h a n8 . 5v o l t s .
Currentdraw shouldbe no more than 350amperes. M TERMINAL
lf crankingvoltageis too low, or currentdraw too high,

checkfor:
. deador low battery.
. o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g ,
menrs.
. stanerarmaturedraggtng.
. shonedarmaturewinding.
o excessivedrag in engine. B TERMINAL
STARTER
CheckCrankingrpm CABLE B TERMINAL
E n g i n es p e e dd u r i n gc r a n k i n g
s h o u l db e a b o v e1 0 0r p m . MOUNTINGNUT
lf speedis too low, checkfor: 9Nm(0.9kgtm,
a loosebaneryor starterterminals. 7 tbtft)
a excessively worn starterbrushes. 2. Checkthe pull-in coil tor continuitybetweenthe S
. open circuitin commutatorsegments. and M terminals.The coil is OK if thereis continuitv.
. d i n y o r d a m a g e dh e l i c asl p l i n eo r d r i v eg e a r .
. defectivedrive gear overrunningclutch.
CheckStarter Disengagement
With the shift leverin S or E position(A,/T)or with the

clutchpedaldepressed(Mff), rurn the ignitionswitchto
S T A R T( l l l ) a
, n d r e l e a s teo O N ( l l ) .
The starterdrive gear shoulddisengagefrom the torque
converteror flywheel ring gear when you releasethe
key.
lf the drive gear hangsup on the torqueconveneror fly

wheelring gear,checkfor:
. solenoidplungerand switchmalfunction.
. d i r t y d r i v e g e a r a s s e m b l yo r d a m a g e do v e r r u n n i n g
clutch.
23-82
ArmatureInsPectionand Test
1. Inspectthe armaturefor wear or damagedue to con-
tactwith the permanentmagnetor fieldwinding.
VERNIER
CALIPEB
a lf there is wear or damage,replacethe armature.
for damage.
Inspect
2. Checkcommutatorsurfaceand diameter.
. lf the surfaceis dirty or burnt, resurfacewith emery 3. Measurethe commutatorrunout.

cloth or a lathe within the following specifications,
or reconditionwith #500or #600sandpaper. . lf the commutator runout is within the service
. lf commutatordiameteris belowthe servicelimit, limit. checkthe commutatorfor carbon dust or
replacethe armature brasschipsbetweenthe segments.
. lf the commutatorrunout is not within the ser
Commutator Diamate. vice limit, replacethe armature.
Standard(NEW) ServiceLimit Commutator Runout

28.0- 28.1mm 27.5mm
Standard(NEW) ServiceLimit
( 1 . 1 0-2 1 . 1 0 i6n ) ( 1 . 0 8 3i n )
0 - 0.02mm 0.05mm
(0- 0.0008in) (0.002in)
COMMUTATOR
(cont'd)
23-83
StartingSystem
ArmatureInspectionand Test (cont'dl
4. Checktor mica depth. lf necessary,undercutmica 6. Placethe armature on an armaturetester. Hold a
with a hacksawbladeto achieveproperdepth.lf ser- hacksawbladeon the armaturecore.
replacethe armature.
vicelimitcannotbe maintained,
ARMATURE
TESTER
NOT GOOD
MICA DEPTH
Commulator Mica DeDth
ARMATURE
0 . 4- 0 . 5m m 0 . 1 5m m
(0.016 - 0 . 0 2i n ) (0.006 in)
. lf the blade is attractedto the core or vibrates

5. Checkfor continuitybetweenthe segmentsof the while the core is turned.the armatureis shorted.
commutator,lf an open circuit exists betweenany Replacethe armature.
segments,replacethe armature.
7. Checkwith an ohmmeterthat no continuityexists
betweenthe commutator and armature coil core,
and betweenthe commutatorand armatureshaft.lf
there is continuity,replacethe armature.
corl coRE COMMUTATOR
23-84
Brush Holder Test BrushInspection
't. Checkthat there is no continuitybetweenthe O and Measurethe brush length.lf not within the servicelimit,
O brush holders. replacethe brush(or brushholderassembly)
l f t h e r e i s c o n t i n u i t y r, e p l a c et h e b r u s h h o l d e r
assemDry. Brush Length
O BRUSHHOLDER 1 5 . 8- 1 5 . 2m m 1 1 . 0m m
(0.62- 0.64in) ( 0 . 4 3i n )
NOTE:To seatnew brushesafterinstallingthem in their

holders,slip a strip of #500or #600sandpaper,with the
O BRUSHHOLDER O ERUSHHOLDER grit side up. over the commutatorand smoothly rotate
the armature.The contactsurfaceof the brusheswill be
sandedto the same contour as the commutator.
2. lnsenthe brushinto the brush holder,and bring the
I brush into contactwith the commutator,then attach

a springscaleto the spring.Measurethe sprlngten-
sion at the momentthe springlifts off the brush.
ClutchInsPection
Overrunning
1 . Slidethe overrunningclutchalongthe shaft.Doesit
move freely?lf not, rePlaceit.
Rotatethe overrunningclutch both ways. Does it

l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n
SPRINGSCALE reverse?lf it dces not lock in either directionor it
locksin both directions,replaceit.
CLUTCHGEAR
BRUSH
SpringTension
15.7- 17.7 N (1.60- 1.80kgf,3 5 - 4.0 lbf)
23-85
StartingSystem
StarterReassembly StarterReassembly
't. Disconnect
the batterynegativecable. 1. Pry backeach brushspringwith a screwdriver, then
positionthe brush about halfwayout of its holder,
Disconnect the startercablefrom the B terminalon and releasethe springto hold it there.
t h e s o l e n o i d t, h e n d i s c o n n e ctth e B L K A T V H
wTi r e
from the S terminal.
MOUNTINGBOLT
44 N.m {4.5 kgf.m,32 lbf.ft)
S TERMINAL
2. Installthe armaturein the housing.Next. pry back

each brush spring again,and push the brush down
BLK/WHT until it seatsagainstthe commutator,then release
WIRE
the springagainstthe end of the orusn.
STARTER
CABLE
aw
MOUNTINGBOLT
44 N.m {4.5kgl.m, 32 lbtftl
B TERMINAL B TERMINAL
MOUNTINGNUT
9 N.m {0.9kgt m,
6.5 tbtfr)
R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r ,t h e n
remove the starter.
Installin the reverseorderof removal.

s
Installthe end coveron the brushholder.
NOTE:When installingthe stanercable.make sure

thatthecrimpedsideofthe ringterminalisfacingout.
Crimpedsideol ring
termtnal
TERMINAL
Connectthe batterypositivecableand negativecable

to the battery.
23-86
Test
Performance
NOTE:Betorestaningthe following checks,disconnect RelractingTest:
t h e w i r e f r o m t e r m i n a lM , a n d m a k e a c o n n e c t i o na s
describedbelowusingas heavya wire as possible(prefer- Disconnectthe batteryalso from the body. It the pinion
ablyequivalent to the wire usedfor the car). retractsimmediately,it is working properly.
Pull-in Coil Test: CAUTION: Do not leave the battery connectedfor more
than 10 seconds.
Connectthe batteryas shown. lf the starterpinion pops
out, it is working properly.
CAUTION: Do not leave the battery connectedfor more

than 10 seconds.
Starter No-load Test:
L Clampthe starterfirmly in a vise.
Connectthe starterto the battery as describedin

t h e d i a g r a m b e l o w ,a n d c o n f i r mt h a t t h e m o t o r
startsand keepsrotating.
Hold-in Coil Test:
Disconnect the batteryfrom the M terminal.lf the pinion

does not retract,the hold in coil is working properly.
F4
"pcr"
/'4 N
CAUTION: Do not leave the batterv connectedfor more L / J ,t-\

than l0 seconds, Y
STARTER
BATTERY
l f t h e e l e c t r i cc u r r e n ta n d m o t o r s p e e d m e e t t h e
specifications when the batteryvoltageis at 1 1.5V,
the starteris workingproPerly,
Specifications:
8 0 A o r l e s s ( E l e c t r i cc u r r e n t ) , 2 . 6 0 0r p m o r m o r e
{Motor-speed)
23-87
lgnition System
Component Location Index
IGNITIONTIMINGCONTROLSYSTEM
. Troubleshooting,section11
. ldle speedInspection/Adjustment,
section11
. lnspectionand Setting,page23-91
SERVICECHECKCONNECTOR {2PI
lwire colors:BRN and BLKI
TESTTACHOMETER
CONNECTOR
IGNITIONWIRES
and Test,page23-96
Inspection
PLUGS
page23-97
Inspection,
DISTRIBUTOR
Replacement, page23'92
Overhaul,page23-93
lgnitionCoilTest,page23-96
lgnitionControlModule(lCM)
InputTest,page23-95
23-88
lgnitionSystem
CircuitDiagram: 96,97 models
GNTION
UNDERDASH
FUSE/FELAY
HOOD
UNDEF BOX SWITCH
FUSE/RELAY
BOX
BLKYEL YELiGRN
BLI(YEL BLK/YEL YEL/GRN
^l GNT]ON
colL
i I
IGNTIONCONTROL
M O D U L(EC M )
T D C : T odpe a dc e n l e r -
CKP: Crafkshaltposilion +i wlteLu / H a sb ul l . n\
CYP CyLnder posilron I noEe l
TDC/CKPiCYP
SENSOR
TDC
CKP
CYP
BLU'
I
n
BLU' BLU
.lJl- I A
J ++ Ji[3î''l=
TACHOMETER
TCt\4{CWr
* 1 HITACH]
*2 TEC
23-89
lgnition System
C i r c u i tD i a g r a m: 9 8 m o d e l
IGNITON UNDER.OASH
UNDER
HOOD
FUSE]RELAY
BOX SWITCH FUSE/RELAY
BOX
u''"'.-* /-1\,
-un*'{_:z I-*',il] EcMipcM
BLx'EL-E_,}I,
Y
t YELiGRN
l
1
T D C r T odpe a dc e n l e r " +lBLU_

CKP:Crankshalt posilion
C Y P T Ci ny d epr o s l i o n
T D C / C K P i CSYEPN S O F
BLU'
I
liIl]'_r BLUl
t
t l
l n
l
B L UJ
++i+++| -MFCM-
I TEST
I TACHOMETER
\__7 CONNECTOR
TACHOMETER
TCM(CW)
I
X1 HITACHI
+2 TEC
23-9 0
lgnition Timing Inspectionand Setting
1 . Checkthe idle speed,and adjustit if necessary(see 6. Adjust the ignition timing if necessary,as follows.
s e c t i o n1 1 ) . Loosenthe distributormountingbolts,and turn the
distributorignition{Dl)housingcounterclockwise to
2. Pullout the servicecheckconnector2P(BRNand BLK advancethe timing, or clockwiseto retardthe tim-
wires)from the connectorholder locatedunderthe In g .
dash on the front passengerside,then connectthe
SCSserviceconnector(T/N07PM - 0010100)to it To ADVANCE
.r<,
3 . Startthe engine.Hold the engineat 3,000rpm with

no load (AfI in N or E, M/f in neutral)until the
radiator{an comes on, then let it idle
'l
Connectthe timing light to the No. ignitionwire,
then point the light towardthe pointer on the timing
belt cover.
C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s :
headlights,blower fan, rear window defogger,and
air conditionerare not operatlng.
lgnitionTiming:
MOUNTING BOLTS
1 2 ' t 2 " B T D C( R E Dd) u r i n gi d l i n gi n kgt'm,13lbfft)
18N'm11.8
neutral
1 2 "1 2 " B T D C( R E Dd) u r i n gi d l i n gi n @
M 7 . Tightenthe distributormountingbolts,and recheck
orE
r h e i g n i t i o nt i m i n g .
Disconnectthe SCSserviceconnectorfrom the ser

vice checkconnector.
POINTER
RED MARK
23-91
lgnition System
DistributorReplacement
Removal: 4. Connectthe ignitionwires to the distributorignition
( D l )c a pa s s h o w n .
1. Disconnect
the connectorfrom the distributor.
HITACHI:
2 - D i s c o n n e ct th e i g n i t i o nw i r e s f r o m t h e d i s t r i b u t o r
i g n i t i o n( D l )c a p .
No. 1
CYLINDER
3. R e m o v et h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r , MARK
then removethe distributorfrom the cylinderhead.
DISTRIBUTOR
END CAMSHAFI END
TEC:
No. 1
CYLINOER
MOUNTING BOLT
18N.m{1.8kgt.m,13lbtft}
lnslallation: No.2 No. il
NOTE:Beforeyou installthe distributor,bring the No. 1 5. Connectthe connectorto the distributor.

pistonto compressionstrokeTDC.
6. Setthe ignitiontiming (seepreviouspage).
1. Coata new O-ringwith engineoil, then installit.
7. After settingthe ignitiontiming, tightenthe mount-
2. Slip the distributorinto positiof ing bolts.
NOTE;The Iug on the end of the distributorand its

mating groovesin the camshaftend are both offset
to eliminatethe possibilityof installingthe distribu'
tor 180"out of time.
3. l n s t a l l t h em o u n t i n gb o l t s a
, n dt i g h t e nt h e m l i g h t l y .
23-92
DistributorOverhaul
HITACHI:
DISTRIBUTOR IGNITION {DOHOUSING

Checkfor cracksand damaqe.
IGNITIONCOIL
Test,page 23-96
)
section11
Troubleshooting, IGNTTIONCONTROLMODULE{ICMI
Do not disassemble. lnputTest,page23'95
CAPSEAL
Checkfor damage.
OISTBIBUTOR IGNITION(DII CAP

Checkfor cracks,wear,
d a m a g ea, n df o u l i n g .
Cleanor replace.
(cont'd)
23-93
lgnition System
Distributor Overhaul (cont'd)
TEC:
LEAKCOVER
IGNITION(DI)ROTOB
DISTRIBUTOR
CAP SEAL
C h e c kf o r d a m a g e
DISTRIBUTOR IGNITION{DIICAP
Checkfor cracks,wear,
damage,and fouling.
Cleanor replace.
IGNITIONCOIL
WHT/BLU Test, page23-96
O-RING
Replace
\ TDC/CKP/CYP SENSOR
vA
Troubleshooting,
section11
Do not disassemble.
DISTBIBUTOR
IGNITION
{DI}HOUSING
C h e c kf o r c r a c k sa n d d a m a g e .
23-94
lgnition GontrolModule (lCM)Input Test
NOTE: 3. Turn the ignition switch ON (ll). Checkfor voltage
. See section11 when the mallunctionindicatorlamp betweenthe BLK//ELwire and body ground.
(MlL)turned on. Thereshouldbe batteryvoltage.
. Performan input test for the ignitioncontrolmodule
( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atle s t sf o r t h e . lf there is no batteryvoltage,checkthe BLK/YEL
ignitionsystemand the fuel and emissionssystems. wire betweenthe under-dashfuse/relaybox and
t h eI C M .
1. Removethe distributorignition{Dl)cap,the distrib . lI there is batteryvoltage,go to step4.
utor ignition(Dl)rotor and the leakcover(TECl.
Turn the ignition switch ON (ll). Checktor voltage
2. the wires from the lCM.
Disconnect betweenthe wire*r and body ground.
Thereshouldbe batteryvoltage.
HITACHI:
. lf there is no batteryvoltage,check:
- t h e i g n i t i o nc o i l .
- t h e * r w i r e b e t w e e nt h e i g n i t i o nc o i l a n d t h e
tcM.
. lf there is batteryvoltage,go to step5.
* 1 : B L U 'w i r e ( H I T A C H I )
WHT/BLUwire (TEc)
Disconnectthe ECM/PCMconnectorA 132P).Chec.

f o r c o n t i n u i t yo n t h e Y E L / G R Nw i r e b e t w e e nt l " .
ECI\I/PCM and the lCM.
Thereshouldbe contanuity.
6. Checkfor continuityon the YEL/GRNwire to boc,

ground.
BLK/YEL Thereshouldbe no continuity.
BLU'WIRE YEL/GRNWIRE
7. C h e c kf o r c o n t i n u i t yo n t h e B L U r w i r eb e t w e e nt h e
TEC: testtachometerconnectorand the lcM.
Thereshouldbe continuity.
Checkfor continuityon the BLU'wire to bodyground

Thereshouldbe no continuity.
9. lf all the testsare normal,replacethe lCM.
BLK/YELWIRE
23-95
lgnition System
lgnition Coil Test lgnition Wire Inspectionand Test
Using an ohmmeter, measure resistancebetween the C A U T I O N : C a r e f u l l yr e m o v e t h e i g n i t i o n w i r e s b y
terminals.lf the resistanceis not within soecifications, pulling on the rubber boots. Do not bend the wires; you
replacethe ignitioncoil. might break them inside.
NOTE: Resistancewill vary with the coil temperature; 1. Checkthe conditionof the ignitionwire terminals.lf
are at 68'F (20'C).
specifications anv terminalis corroded,cleanit. and if it is broken
or distorted,replacethe ignitionwrre.
HITACHI:
Primary Winding Resistance
(Betweenthe A and B terminalsl:
0.45- 0.550
SecondaryWinding Resistance
(Eetweenthe A and secondarywinding terminalsl:
22.4- 33.6 k{r
TERMINALB {-I
TERMINALA (+
Checkfor broken,
corroded,and benl
terminals.
IGNITION
WIRE
2. Connectohmmeterprobesand measureresistance.
TEC: lgnition Wire Resistance:

Primary Winding Resistance 25 kO max. at 68'F (20"C)
{Betweenthe A and B terminalsl:
0.63- 0.770
(Betweenthe A and secondarywinding terminals):
12.8- 19.2kO
SECONDARY
WINDING
TERMINAL
@ O
IGNITION
WIRE
3. lf resistanceexceeds 25 kO, replace the ignition wire.

TERMINALA {+ TERMINALB (_)
23 -9 6
lgnition System
lgnition Coil Test lgnition Wire Inspectionand Test
Using an ohmmeter, measure resistancebetween the C A U T I O N : C a r e f u l l yr e m o v e t h e i g n i t i o n w i r e s b y
terminals.lf the resistanceis not within soecifications, pulling on the rubber boots. Do not bend the wires; you
replacethe ignitioncoil. might break them inside.
NOTE: Resistancewill vary with the coil temperature; 1. Checkthe conditionof the ignitionwire terminals.lf
are at 68'F (20'C).
specifications anv terminalis corroded,cleanit. and if it is broken
or distorted,replacethe ignitionwrre.
HITACHI:
Primary Winding Resistance
(Betweenthe A and B terminalsl:
0.45- 0.550
(Eetweenthe A and secondarywinding terminalsl:
22.4- 33.6 k{r
TERMINALB {-I
TERMINALA (+
Checkfor broken,
corroded,and benl
terminals.
IGNITION
WIRE
2. Connectohmmeterprobesand measureresistance.
TEC: lgnition Wire Resistance:

Primary Winding Resistance 25 kO max. at 68'F (20"C)
{Betweenthe A and B terminalsl:
0.63- 0.770
(Betweenthe A and secondarywinding terminals):
12.8- 19.2kO
SECONDARY
WINDING
TERMINAL
@ O
IGNITION
WIRE
3. lf resistanceexceeds 25 kO, replace the ignition wire.

TERMINALA {+ TERMINALB (_)
23 -9 6
SparkPlugInspection
1. Inspectthe electrodesand ceramicinsulatorfor: 2. Checkthe electrodegap.
! Adjustthe gap with a suitablegappingtool.

worn or deformod
. lmpropergap
. Oil-fouling ElectrodeGap
. Carbondeposits
. Crackedcenter
Standard I t . t 8 m m ( 0 . 0 4 38 o o , i n )
Damaged electrodeinsulator
gasket 'l.l mm
(0.043in)
Replacethe plug if the centerelectrodeis rounded

as shownbelow:
ROUNDED
ELECTRODE
Burned or worn electrodesmay be causedby: I r----a

ll Fq-
. Advancedignitiontiming
. Loosesparkplug
. Plug heat rangetoo low
. Insufficientcooling
EngineTypes SparkPlugs
Fouledplugs may be causedby:
. Retardedignitiontiming D16Y5 Z F R 4 F . 1 1{ N G K )
. Oil in combustionchamber K J l 4 C R - 1 1 1( D E N S O )
. lncorrectsparkplug gap D16Y7, Z F R 5 F - 1( 1
NGK)
. Plug heat rangetoo high D16Y8 KJ16CR-11 (D
1E N S O )
. Excessive idling/lowspeedrunning
. cloggedair cleanerelement
. Deteriorated ignitioncoil or ignitionwires 3. Apply a small quantity of anti-seizecompound to
the plug threads,and screwthe plugs into the cylin-
der head finger-tight.Then torque them to 18 N m
(1.8kgf.m,13lbf.ft).
23-97
GhargingSystem
CHARGINGSYSTEMLIGHT
(ln the gaugeassembly)
BATTERY
UNDER.HOOD FUSE/RELAY
i*Hasreplaceable
I DETECToR
BOX
ELECTRICAL
(ELD)
UNIT
j
LOAD
1
lest, page23-77
E]
page23-100
Troubleshooting, ALTERNAIORBELT
Replacement, page23-105 Inspection
and Adjustment,page23-110
RectifierRemoval,page23-106
Test,page23-107
Rectifier
RearBearingBeplacement,page23-109
CircuitDiagram
trr
BOX
UNDERHOODFUSEiRELAY
No41(8OA) ,.4\ No42(40A)
I
,/T\
I BAT I ON]TION
\ tcl ,t S W T C H
\3-l
I
BLKiYEL
UNDER,DASH
FUSE/BELAY
BOX
GRN]RED
I 1,,*'
WHT/GFN BLK/YEL
T"*
WHT/BLU
REGULATOR
VOLTAGE
ALTERNATOR
23-99
ChargingSystem
Troubleshooting
lf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in
the order listedbelow:
1. Battery(seepage23 771
2. Chargjngsystemlight
3. Voltage
4. Alternatorcontrolsystem(USA)
5. Alternator/regulator
ChargingSystem Light Test
ChargingSystemLight Ch€ck-1:
Make sure the charging system
lightcomeson.
Ch.ck lor a blown No. 15 {7.5Al

fuse and a blown chargingsys-
Doesthe chargingsystem
tem light bulb. lf the fu3e and
lightcome on?
bulb are OK, ropair tho opon in
the wHT/BLU wila.
Charging Systcm Light Ch6ck-2:

Startthe enoine.
Doesthechargingsystem
lightgo off? ALTERNATOR
4P CONNECTOR
{usAt
.-l1l 2l Wire sideof

I l-T;l femaleterminals
Vollage Chock:
Measurethe voltageat the No. 1
IG
{BLK/YEL) tI -
lNo.2lterminalof the 4PI3Plcon-
nectorwith the ignition switch ON (v)
flr).
T
3P CONNECTOR
ALTERNATOR
Ropair the opon in the BLK/YEL
{Canadal
wire bstwogn tho dternrtor and
under{a3h f uio/relay box.
femaleterminals
IG
(To next page) IBLK/YELI
[ ]: Canada
23-100
)
ALTERNATOR'PCONNEGTOR
(FrompreviousPage) {usAt
.-r
Chgck for an open in the L cir-

cuit-1:
-r-
l l l 2 l Wire sideof
t-T;t femaletermrnals
L
L
2. Disconnectthe 4P [3Pl con- IWHT/BLUI
nectorfrom the alternator.
3. Groundthe No. 3 terminslof
the 4P[3Plconnector.
Turn the ignition switch OFF,and 3P CONNECTOR

ALTERNATOR
Doesthe charging system repair tho opon in tho wHT/
lightcome on? gLU wile. {Crnadal
Wire sideof
temaleterminals
L
IWHT/BLU)
-+.t 2
-r-
1 1 l
l.T;l
'w"l".ur
Chock for an op6n in the L cir' l)
cuit.2:
Disconnect the No. 3 terminalot
t h e 4 P t 3 P l c o n n e c t o trr o m t h e
ground.
Doesthe chargingsystgm
lightgo ofi?
(WHT/8LUI
Turn the ignition 3witch OFF,and

rgpair tha 3hon to ground in the
WHT,/BLUwiro.
[ ]: Canada (conl'd)
23-10
ChargingSystem
Troubleshooting {cont'dl
Alte.nator Control System Tost IUSAI
NOTE:Beforetesting,checkproperoperationof the ELDby confirmingwith the MIL (seesection11).

BATTERY
Chockfor a short in tha circuit
(Al-TClinel:
1, Reconnectthe 4P connector CAUTION: Be sure to use a voltmet€r
to the alternator. with its plus terminal conn€ctedto bat,
2. Startthe engine,and turn the tery plus and i$ minus torminal to the
headlights(highbeam)ON.
c
4P connectortemrinal No. 2. {WHT/GRNI
3. Measurevoltage between the
4P connectorterminal No. 2
Wire sideof ALTERNATOR
and the positive terminal of ilP CONNECTOR
the baftery. femaleterminals
ECM/PCMCONNECTOR
A I32PI
1 2 3 1 5 8 9 , 1 0 11
ls there1 V or less? 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22 23 2a
25 26 21 30
Wire sideof ATLC
temaleterminals IWHT/GRN)
IALTClinel: ([,
1 . T u r n t h e h e a d l a g hatn d i g n i -
taonswitchOFF.
from the ECM/PCM. Wire sideof 1
_f IWHT/GRN)
2 ALTERNATOR
3. Checkfor continuitybetween femaleterminals 3 .I'UUNNEUI(,K
4
the ECM/PCM32P connector
terminalNo. 19and alternator
4PconnectorterminalNo, 2.
ls therecontinuity? Rep.i. open in tho wi.e bolwocn

the.lternator.nd ECM/PCM.
ECM/PCMCONNECTOR
A {32P}
Checkfor short in the wire {ALTC
line):
1 . T u r n t h e h e a d l i g hat n d i g n i 1 2 3 I 6 1 7 8 I 10 11
tion switchOFF. 12 13 lil l 5 1 5 1 1 1 8 t 1 9 20' 21 22123 21
from the EClvl/PcM. 25 26 30
the ECM/PCM32P connector Wire side of I ATLC
t e r m i n a lN o . 1 9 a n d b o d y femaleterminals I WXf/CnXl
grouno, []
PCM,and recheck.
ls therecontinuity? ll prescrib€dvoltage is now avail"
able, replacethe original ECM/
PCM,
Repairshort in th€ wi.e betwe€n

th€ alte.nator and ECM/PCM.
23-102
i-_*_lffi*
Alternator/BegulatorTest
NOTE:Makesurethe batteryis sufficientlycharged(seepa9e 23-77]-

FULLFIELO VOLTMETER
Alternator/Regulatorlest_'l : LOADADJUSTER TESTER NEGATIVE
1 . C o n n e c ta S u n v A T - 4 0 ( o r ICARBONPILE) LEAD IBLU} (BLK}
equivalent tester), ano lurn
the selectorswitch to Posilion
1(stanang).
2. Shift to neutral(A,/Tin E or
E ) p o s i t i o n ,a n d s t a r t t h e
e n g i n e .H o l d t h e e n g i n e a t
3,000rpm with no load until
lrffil @
.gdi
VOLTMETER
POS|TIVE
t h e r a d i a t o rf a n c o m e s o n , r[@*.: LEADIREDI
then let it idle.
3 . R a i s et h e e n g i n es P e e dt o
2,000rpm,and hold it there.
FIELD
SELECTOR
ls the voltageovor 15.1V?
NEGATIVETESTER
swtTcH CABLEIBLKI
INDUCTIVE
PICK-UP POSITIVETESTEi
Ahernator/negulatorTesl-2i {GRN) CABLE(REDI
1. Feleasethe accelerator Pedal,
and let the engineidle.
2. Makesure all accessories are
turned off. Turn the selector
switchto position2 (charging). INDUCTIVE
3. Removethe inductivePick-uP, PICK.UP
and zerothe ammeter,
4 . P l a c et h e i n d u c t i v eP i c k - u P
over the battery groLrndcable
so that the arrow points to the
baftery negativeterminal.
5 . R a i s et h e e n g i n e s p e e d t o
2,000rpm,and hold it there TIVE
TERMINAL
ls the voltagelessthan 13.5V?
Alternator/RegulatorTest-3:
Apply a load with a VAT-40until
the battery voltage droPs to
'13.5V.
between12-
To next page
)
(cont'd)
23-103
GhargingSystem
Troubleshooting(cont'dl
Frompreviouspage
ls the amperage50 A or more? The chargingsystem is OK.
CAUTION:The voltago will rise quickly when the alteinato. is tull-fielded.Do not.llow
Alternator/RegulatorTest-4: the voltage to exceed18 V; it may damagethe electricalsystem.
W i t h t h e e n g i n e s p e e ds t i l l a t
2,000rom,full-fieldthe alternator.
NOTE:Aftacha probeto a VAT 40 full fieldtest lead,and insertthe probeintothe fulj field
Switchthe Iieldselectorto the "A (Ground),.
accessholeat the backof the alternator. posi-
tion momentarily,and checkthe amperagereading.
23-104
AlternatorRePlacement
NOTE: Removethe alternatorfrom belowthe vehicle 4. R e m o v et h e a d i u s t i n gb o l t a n d t h r o u g h b o l t n u t ,
then removethe alternatorbeltfrom the pulley'
1. Removethe batterynegativecable,then disconnect
the Positivecable.
UPPERMOUNT
2. Disconnectthe 4P (or 3P) connectorfrom the alter- BRACKETEOLT
naI0r. 44 N.m {4.5kgl.m,33lblftl
ALTERNATOR
ADJUSTINGBOLT
TERMINALNUT 24 N.m {2.4 kgf'm, 17 lbf ft)
7.85 N.m (0.8kgf m, 5 79 lbtft)
)
4P lor 3P)
CONNECTOR
| ): Canada
44 N.m (4.5ksf m.33 lbIftl
LOWERMOUNT
BRACKETBOLTS
44 N.m {4.5kgf m.33 lbf ftl
3. Removethe terminal nut and the WHT wire from

the B terminal.
5. P u l l o u t t h e a l t e r n a t otrh r o u g hb o l t , t h e n r e m o v e
the alternator.
b. lf necessary,removethe mount bracketbolts, and

the upperand lower mount brackets
1. Adjust the alternatorbelt tension after installation

( s e ep a g e2 3 - 1 1 0 ) .
23-105
ChargingSystem
RectifierRemoval
1. Removethe four throughbolts. 3. Sepa.atethe rear housingfrom the drive-endhous-
ing by insertinga flat tip screwdriverinto the open-
ings and pryingthem a part. Be carefulnot to dam-
agethe statorwith the tip of the scfewdriver,
REARHOUSING
DRIVE-ENDHOUSING
S e p a r a t et h e r e a r h o u s i n ga n d d r i v e - e n dh o u s i n g
with the statorattachedto the rearhousinq.
Heatthe rear bearingseatwith a '1,000 W hair drier

for aboutfive minutes(120- 140"F,50 - 60"C),
HAIR DRIER
REAREEARING
SEAT
23-106
RectifierTest
5. Separatethe rear housing from the stator/rectifier NOTE:The diodesare designedto allow currentto pass
assemblyby removingthe four screwsand the ter- in one directionwhile blockingit in the oppositedirec-
minal nut. tion. Since the alternator rectifier is made up of nine
diodes,each diode must be testedfor continuityin both
d i r e c t i o n sw i t h a n o h m m e t e rt h a t h a s d i o d e c h e c k i n g
capability;a total of 18 checks
1. Checkfor continuityin eachdirectionbetween

- the B and P terminals.
- the B' and P terminals.
- E (ground)and the P terminals.
All diodesshould havecontinuityin only one direc-
tion.
Unsolderthe recti{ierfrom the statorleads

. To avoid damagingthe diodes with heat, pinch
the stator leads between pliers to carry heat off,
and applythe solderingiron only long enoughto
separatethe leadsfrom the rectiller.
. Use a 100W solderingiron.
lf anv of the diodesfails,replacethe rectifierassem-

bly. (Diodesare not availableseparately.l
7. lnstallthe new rectifierin the reverseorder of removal

. A p p l y t h e s o l d e r i n gi r o n o n l y l o n g e n o u g ht o
ensure a good connectionso the heat will not
damagethe diodes
. Use only a rosin core type solderor solderjoints
will corrode.
23-107
ChargingSystem
RotorSlip RingTest AlternatorBrushInspection \
1. Checkthe resistance betweenthe slip rings. 1 . Separatethe drive-endhousingfrom the rear hous-
Thereshouldbe 1.8- 3.0ohms. ing as describedon page23-106.
. lf resistancemeetsthe specification,go to step 2.
. l f r e s i s t a n c ed o e s n o t m e e t t h e s D e c i f i c a t i o n . Separatethe rear housingfrom the stator/rectifier
replacethe alternator. assemblyby removingthe four scrswsand the ter-
minal nut from the rearhousing(seepage23-,|06).
FOTORSHAFT M e a s u r et h e l e n g t h o f t h e b r u s h e sw i t h v e r n i e r
calipers.
Alternator Brush Longth:
O Standard(NEW) O ServiceLimit
19.0mm (0.75in) 5.0 mm (0.20in)
Checkthat there is no continuitybetweenthe slip

ringsand the rotoror rotor shaft.
lf the rotor fails eithercontinuitycheck,replacethe

alternator.
StatorTest
1. Checkthat there is continuitybetweeneach pair of
leads.
lf the brushesare lessthan the servicelimit, replace

them.
cotL
CORE
Checkthat there is no continuitybetweeneach lead
and the coil core.
lf the coil fails either continuitycheck,replacethe

alternator.
23-108
RearBearingRePlacement AlternatorReassemblY
1. Pulloff the rearbearing. 1. P u s ht h e b r u s h e si n , t h e n i n s e r ta p i n o r d r i l l b i t
(about1.8mm diameter)to holdthem there
. Makesure the tips ot the bearingpullerjaws are
thin enough to fit betweenthe bearingand the
slip rings.
. Do not reusethe bearing.
SLIPRINGS BEARINGPULLER
BRUSHES
REARBEARING H e a tt h e r e a r b e a r i n gs e a t i n t h e r e a r h o u s i n ga s
describedon page 23-106.After heating,continue
immediatelywith assemblingbeforethe rear bear-
ing seatcoolscompletely.
assemblyand drive-end
Put the rear housing/stator
)
Use a hand pressto installthe new bearing.Apply housing/rotorassemblytogether,tighten the four
pressureonly on the inner raceto avoid damaging throughboltsand pull out the Pin.
the bearing.
BRUSH ACCESS
BOI,T
THROUGH
REARBEARING
*,
SLIPRING
REAR
STATOBASS€MBLY
After assemblingthe alternator,turn the pulley by

hand to make sure the rotor rotatessmoothly and
without noise.
23-109
ChargingSystem
AlternatorBelt Inspectionand Adjustment
DetloctionM6thod: Belt Tension Gaug€ Method:
Apply a force of 98 N (10 kgt,22 lbf), and measurethe Followingthe gauge manutacturer,s instructions.attach
deflectionbetweenthe alternatorand the crankshaftoul- the specialtool to the belt,and measurethe tension.
Tension I 340-490N(35-50kgf,77-j10tbf)
Deflection | 8.0- 10.5mm {0.31- 0.41in}
NOTE: On a brand-newbelt (onethat hasbeen run for less
NOTE: On a brand-newbelt {onethat has beenrun for less than five minutes),the tension should be S4O-740 N
than five minutes),the deflectionshouldbe 6,0- 9.5 mm (55- 75 kgt 121- 165lbf) when firsrmeasured.lf the belt
(0.26- 0.33in) when first measured.lf the belt is worn or asworn or damaged,replaceit.
damaged.replaceit,
Measurehere. 24Nm12.4kgf.m,
CRANKSHAFT
PULLEY BELTTENSION GAUGE
07JGG- 0010'l0A
lf adiustmentis n€cessary:
l. Loosen
thelowermounting
nutandtheuppermount- lf adiuslment is n€cossary:
ing bolt.
'L
Loosenthe lowermountingnut andthe uppermount-
2. Movethe alternator to obtainthe properbelttension, ing bolt.
then retightenthe uppermountingbolt andthe lower
mountingnut to the specifiedtorques. 2. Movethe alternatorto obtainthe properbelttension,
then retightenthe uppermountingbolt and the lower
3. Recheck
the deflectionof the belr. mountingnut to the specifiedtorques.
3. Recheckthe tensionot the belt.
23-110
FanControls
. -ri -rT _tF-1tr'l RAOIATORFAN RELAY

t I r-r T-t T-l Test,page23 73
,-, LJ L_JL_JI___I
-l
tQr_-
U LJL-Jrr
CONDENSER FAN RELAY
Test,page23 73
UNOER-HOOD
CONOENSER
FAN MOTOR
FAN MOTOR
Removal,section 10
ENGINECOOLANT
TEMPERATURE(ECTI
swlTcH
Removal,section10
Test, section10
23-111
FanControls
CircuitDiagram
UNDER.DASI-1
UNDEF.HOOD
FUSEi
RELAY
BOX IGNITIONSWTCH FUSEiRELAYBOX
No4r i80A) No42(40A) l-'"----E

l
-l
-YEL-.].--o.\-F-h
BrKyEL-J
BLKi
RED
II
l,^,^,",
,J"
1,,**,
T*' twl.i-:;"
BLK
I f
BLK
II I
-: t
I
G20l G101
23- 1 1 2
GaugeAssembly
precautions'and proceduresin the sRS
sRS componentsare locatedin this area.Reviewthe sRS componentlocations,
section{24}beforeperformingrepairsor service.
6x1.0mm
9.8 N.m (1.0 kg{.m,
22 tbt.ftl
VEHICLESPEEDSENSORIVSS)
Page23 124
Troubleshooting,
FUELGAUGESENDINGUNIT
Test,page23'126
GAUGEASSEMBLY
Gauge/lndicator/Terminal
LocationIndex,Page23_114
Removal,page23-119
BulbLocation,Page23 120
Disassembly,page23-122
BRAKESWITCH
FLUIDLEVELSWITCH
SWITCH
ENGINEOIL PRESSURE
IECT)GAUGE
ENGINECOOLANTTEMPERATURE
SENDINGUNIT
23-113
GaugeAssembly
Gauge/lndicator/Terminal
LocationIndex
With tachometer:
CONNECTOR "A" "8" "C"

CONNECTOR CONNECTOR
(A/T GEARPOSITION
INDICATOR) {GAUGEand INDICATOR}
A1- - --+A6
B1----------{-Bt6 c 1- - - - - - - - - > c 1 3
lrl..::.fi|
----_..-ts|
t.t
47 - ->A14
Jililil{ililt1
JililtHililL
.' "€3{\
o
o
D1- --->D5 Fl- - --> F5
CONNECTOR "O" "E"

CONNECTOR "F"
CONNECTOR
{ABSINDICATOB} I sHrFr-up
orcRU|sE
I (SRSINDICATOB}
lrNDrcAToR I
SPEEDOMETER:
Indicates 60 km/h at 637 rpm or
6 0 m p h a t 1 , 0 2 5r p m o f t h e A/T GEARPOSITION
vehiclespeed sensor (VSS). INDICATOR
Seepage23-133
oa/ \oo
TACHOMETER:
Indicates100rpm at
200pulsesper minute
of the ignitioncontrol FUELGAUGE
m o d u l e( l C M ) . Gauge/Sending page23 126
LJnitTest,
2 3- 1 1 4
EI'
Without tachometer:
"B" "C"
"A" CONNECTOR CONNECTOR
CONNECTOR IcAUGE and INDICATORI
tA/T GEARPOSITIONINOICATOR} IcAUGEandlNDlcAToRl
8 1 . - - - - - - -- - - . - - - - - - + 8 1 6 C1-----.---.--->C13
---->414
Innrruttttttl
lilillllllL
\J (Ju gr -
A
s :
a-)
, 6
Fl--) F5
Dl--->05
"D"
CONNECTOR
IABS INDICATOR)
SPEEDOMETER:
lndicates60 km/hat 637rpm or
60 mph at 1,025rpm of the
vehiclespeedsensor(VSS).
oo/ \oo
(ECT)GAUGE FUELGAUGE
ENGINECOOLANTTEMPERATURE UnitTest,page23 126
Gauge/Sending
Seesection5
23-115
GaugeAssembly
CircuitDiagram
U N D E R . H OF
OUDS E i F E L B
AOYX
UNDER DASH
FUSEiRELAYBOX
N 0 . 3 (075 A )
FUSE
VI
RED/BLK RED/BLK
GAUGE
CHAFGING LIGHTS
SYSTEM
LIGHT l3wx4 |
l"'
WHTIBLU I l" Tt lt "
*i"' l"l'
I iI
FED BLK I RED/GRN BLK BLU
II l f
I
I
r
WHT/RED
l t l
t l
I
t+ IJ
i
v + i I
l v I
I
TEFNATOF DASHLIGHTS
ERiGHTNESS
CONTFOLLEF
L'*'-
(Wilhshillup ndicalor
tighl)
I
I
'
cRUlsE
CONTROL
UNIT I
olsyslem)
1",,-'
II
G401 G401
G402
23- 1 1 6
ECM/PCM
+
BLKAVHT
l_"'f"'
(With
lachomele0
TUFNS]GNAL'
H A Z A RW
DARNING : rc-,w'oi-_l
CoNTROL
SWITCH I I
No.5ll0A) I MODULE I
LEFT F]GHT | (cM) i
V r-7 f-7
t v I
I tt l
l
GRN/RED CRN/YEL il ,l l" ,i l GAUGA
ESSEMBLY
To
NEXT
RIGHT PAGE
TURN ENGINE
COOLANT LOWFIJEL
SIGNAL INDCATOF
INDICATOR TEMPERATUFE
{ECT) LIGHT
L GHT (3w)
GAUGE
8LK BtUtRED BLK
L
V
ABS
CONTROL ENGINE
IJNlT COOLANT
TEMPERATURE
(ECT)
SENDNGI]N T
BLK
G401
G402
o,1o,
G4A2
I
G552
{cont'd)
23-117
GaugeAssembly
CircuitDiagram(cont'dl
GAUGE
ASSEMBLY
PREVOUS
PAGE
SEAT LOWOtL MALFUNCTION
ERAKE BELT TRUNK PRESSUREINDICATOS
SYSTEM REMINDER INDICATOS INOICATOR
LGHT LIGHT LIGHT LiGHT (MrL)
(1.4w) (1.4W) 0.4w) (1.4W) 0.4w)
)
./
\
C
't
\
'./ (
\ / -
B6
I
83
( YEUFED GRN/ORN
v l ,.y."
I
_i |
PARKING ERAKE
FLUIO rRUNK | ,"",.
BFAKE
rp rlt*i'!l*,
TEVEL
,,,,,,,**,
i'iiifl
SWTCH
swiTcH
fclosedLever
up )
(Op€n Leverdown
J lolosed: Floal
down
(Open FloalLrp
folosed:Unbuckled
l
lopen :Euckled .l *.","n,
c401
G402
BLK
I
BLK
T
G552
t:
23-118
Removal
1. Removethe two screwsfrom the instrumentpanel.
2. Removethe instrumentPanel.
CAUTION: Carelully remove the instrument panel without damaging the clips'
3. Tilt the steeringwheeldown with the tilt adjustmentlever.
Spreada protectivecloth overthe steeringcolumn
5. Removethe four mountingscrewsfrom the gaugeassembly.
6. Prythe gaugeassemblyout, and disconnectall connectorsfrom it'
7. Takeout the gaugeassembly.
GAUGEASSEMBLY
INSTBUMENT
PANEL
23-119
GaugeAssembly
Bulb Locations(With Tachometerl \
TRUNKINDICATOR
(1.4W)
LTGHT CHARGINGSYSTEMLIGHTI1.4 WI
GAUGELIGHT{1.4wl
(1.4W)
LTGHT
BRAKESYSTEM
{1.4Wl LOW ENGINEOIL PRESSURE
SEATBELT HIGHBEAM INOICATORLIGHT{1,4WI
REMINOERLIGHT{1.4W} INDICATORLIGHT
{ 1 . 4W ) MALFUNCTION
LOW FUELINOICATOR
INDICATOR
LIGHT 13W}
LAMP IMIL}
t 1 . 4W l
RIGHTTURN SIGNAL LEFTTURN SIGNAL
INDICATORLIGHTI1.4WI INDICATORLIGHT{T.4WI
A/T GEARPOSITION GAUGELIGHTS{3 WI SRSINDICATOR(1.4wl

INDICATOR 11.12x 6l {Onthe printedcircuitboard)
{Onthe printed GAUGELIGHTI3.4W}
circuitboard)
aBs tNDtcAToR t1.4Wt CRUISEor SHIFT-UPINOICATOR(1.12Wl
{Ontheprinted
circuitboard) {Onthe printedcircuitboard)
23-120
E'|
Bulb Locations(WithoutTachometerl
TRUNKINOICATOR
LTGHT
tl.4 W) CHARGINGSYSTEMLIGHT(1.4WI
GAUGELIGHT{1.,1W)
GAUGELIGHTI1.{ W)
BRAKESYSTEM
LIGHT(1.{ W) LOW ENGINEOIL PRESSURE
SEATBELT TORLIGHTI1.4W)
REMINDERLIGHTI1.4WI
MALFUNCTION
LOW FUELINOICATOR INOICATOR
LIGHT(3 W) LAMP {MILI
BULB(1.4W}
RIGHTTURN SIGNAL
LEFTTURNSIGNAL
INDICATORLIGHT
INDICATORLIGHT{1.,rwl
{1.4W}
o / o V @
A/T GEARPOSITION GAUGELIGHTS13W)

INDICATOR {1,12x 6) t1.4W)
sRs tNDtcAToR
{Onthe printed {Onthe printedcircuitboard)
circLrit
board) GAUGELIGHT
ABStND|CATOR t1.4Wt 13.4Wt
circuitboard)
{OntheDrinted
23-121
GaugeAssembly
Disassembly{With Tachometer) \
NOTE: Handle the terminals and printed circuit boards

c a r e f u l l yt o a v o i d d a m a g i n gt h e m .
eg F - -.- -^^ i'\

e\J !=r c) ./ \\
o \ s\\.Q
ê'-----"' .,:
)
,'@
I u t/@
@', I ;=1 @ /+i
o 1
o,,o. ".,,Yu 7
PRINTEDCIRCUIT
d,@
,-@
ob,
.,- Il $
ts*u"El
| ""il\r
A/T GEARPOSITIONINDICA
PRINTEOCIRCUITBOARD
CRUISEor SHIFT-UPINDICATOR ABS INDICATOR
PRINTEOCIRCUITBOARD PRINTEDCIRCUITBOARD
@ FUELand ENGINECOOLANTTEMPERATURE
{ECTI
TACHOMETER AUGE
GAUGE
page23-114
Specification,
@ * lI
METERPANEL
l6$-
\ \,/
23-122
Disassembly(WithoutTachometer)
NOTE:Handlethe terminalsand printed circuit boards
carefullyto avoiddamagingthem.
oOOo -z\\
'.oo..-----..\
ID '.o.,' \(
i ; o\
, i + o l
o 6,,
,,,Y
\ [ J e
FUELGAUGE ENGINECOOLANTTEMPEMTURE
MOUNTINGSCREWS{x 3} GAUGEMOUNTINGSCREWSlx 3l
' o @
,"o
"
ôo
rmhiffi
rugF5w
.w-
-r?ft
\\''$f ,a._€d\
\
A \ A/T GEARPoslrloN lNolcara
V \ PRINTEDCIRCUIT BOARO
ABS INDICATOR
PRINTEDCIRCUTTBOARD
@
SPEEDoMETER .nd
ODO/TRIPMETER
page23'115
Specification,
ri\-
\,.j 4 D,l
\.{
FUELGAUGE
Tost, page 23-126
METERPANEL
23-123
VehicleSpeedSensor(VSSI
Troubleshooting
Beforetesting,inspectthe No. l5 (7.5A) fuse in the under-dashfuse/relaybox.
Test ths 8LK wire:

trom the vehiclespeedsensor
(vss).
2. Connect the test harness
107LAJ- PT30200)only to the
enginewire harness.
3. Connectthe REDtest harness
clip to the positive probe of a
ohmmeter.
the REDtest harnessclip and
body ground.
Repairopen in th. BLK wire vss

botwoen the VSS and G101.
Tesi tho BLK/YELWir€:

1. Connectthe WHT test harness
clip to the positive probe of a
voltmeter,and connectthe RED \
test harnessclipto the negative
probe.
Repairopen in the BLISYELwire

betwoon tho VSS and tho under-
dash tuso/.slay box.
(Tonextpage)
23-124
-
I
(From previouspage)
WHT TESTHARNESS
CLIP
Test rhe BLU/WHTwirer

C o n n e c t h e G R Nt e s t h a r n e s s TESTHARNESS
c l i p t o t h e p o s i t i v eP r o b e o f a O7LAJ. PT3O2OA REDTESTHASN€SS
voltmeter,and connectthe RED CLIP
test harnessclip to the n€gative
probe.
PROTECTIVE
Repairopen in ihe BLUMHT wire TAPE
ls thereabout5 V or more? bctween lh6 VSS and ECM/FCM,
TCM {CWl, snd ctui3€ control unit
T6st the vSS:

2. Connect the other test har-
nessconnectorto the VSS
3. Raisethe front of the vehicle,
and support it with satety
stands,
4. Putthe vehiclein neutralwith
GRNTESI HARNESSCLIP
the ignitionswitchON (ll)
5. Slowly rotateone wheel with
the otherwheelblocked
Doesvoltage pulse from 0 to

approx,5V or more?
"8"
16PCONNECTOR
GAUGEASSEMBLY
SpeodometelTost:
" B " f r o m t h e g a u g ea s s e m _
2. Toucha probeto the BLU,ryVHT

femaleterminals
wire, and connect it to body
groundthrougha voltmeter.
3. Slowly rotate one wheel with
the otherwheelblocked.
Ropairopsn in th€ BLU/WHTwire

Do€sthe meterindicatepuls- between tho VSS and the spo.d'
ing voltage? meter.
23-125
FuelGauge
Gauge/SendingUnit Test
!@s@ Do nor smoKewnre worxrngon tne ruet 7. Checkthat the pointerof the fuel gaugestartsmov-
system, Keepopen flame away from yout work area. ing toward the "F" mark.
NOTE:Referto page 23-117for the fuel gauge system CAUTION: Turn the ignition switch OFF betore the
crrcutl. pointerreaches"F" on the gaugedial. Failureto do
so may damagethe tuel gauge.
1. Checkthe No. 25 (7.5A) fuse in the under-dash
fuse/
relaybox beforetesting. NOTE|The fuel gauge is a bobbin (cross-coil) type,
hencethe fuel level is continuouslyindicatedeven
2. Removethe accesspanelfrom the floor. w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r
ACCESSPANEL movesmore slowly than that of a bimetaltype.
. lf the pointerof the tuel gaugedoes not move at

a l l ,r e p l a c teh e g a u g e .
. lf the gauge is OK, inspectthe fuel gaugesend
ingunit.
8. Removethe fuel gaugesendingunit as shown.
Japan-produced
FUELGAUGE
SENDINGUNIT
femaleterminals
IJSA. Canada-Droduced
D i s c o n n e ct th e 3 P c o n n e c t o fr r o m t h e f u e l g a u g e
s e n d i n gu n i t .
FUELGAUGE
4. Connectthe voltmeter positiveprobe to the No. 2 SENDINGUNIT
terminaland the negativeprobeto the No. 1 termi-
n a l ,t h e nt u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
Thereshouldbe between5 and 8 V.
. lf the voltageis as specified,go to step 5.

. lf the voltageis not as specified,checkfor:
- an open in the YEL/BLKor BLKwire.
- p o o rg r o u n d( G 5 5 2 ) .
6. Attach a jumper wire betweenthe No. 1 and No. 2

t e r m i n a l st h
, e nt u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
23-126
E1
9. Measurethe resistancebetweenthe No 1 and No. 2
t e r m i n a l sa t E ( E M P T Y ) ,1 / 2 ( H A L FF U L L )a n d F
(FULL)by movingthe float.
(Ceramicboardtypel:
USA,Canada-produced
FIoat Position 1/2 F

(O)
Resistance 105 108 29.5- 35.5 3.5-5
Japan-Produced{Wire-woundtype)'
FloatPosition E F
(O)
Resistance 1 0 5- 1 1 0 2 5 . 5- 3 9 . 5
T o p o t t h e w o r k b e n c h l B o t t o m o f t h e f L l e lt a n k )
lf the resistancereadingsare beyondthe range,replace

t h e f u e lg a u g es e n d l n gu n i t .
23-127
4 __r.*_
InterlockSystem
INTERLOCK
UNIT
InputTest,page23 130
KEYINTERLOCK SOLENOID
and KEYINTERLOCK SWITCH
(ln the steeringlockassembly)
Test,page23 131
6'm
, \-/ \-!J
PARKINGPINSWITCH
Test,page23-132
SHIFTLOCKSOLENOID
Test,page23-131
23-128
BOX
FUSE]RELAY
UNDER.HOOD
No41(80A) N0.42(40A)
GRN]WHT
YEL
I
ftoL{Eu'flil' t
GRN/WHT
l
GRN'1flHT
J
[o*
nrol
feurrr
sleern0
-
-]
tfl +
YELTBLK
3 NTERLOCK UN1T
CONTFOL
. BRAKE
'CRUISE
LIGHTS
CONTROT
. ABSCONTROL
. TCi,4
(CW)
UNIT
UN]T
KEYINTERIOCK
C RCUIT
r'lTGEAR
POSTION
INDICATOR
17
WHT/BLK BLK/BLU
IYr
I
BLK/BLU
A,TTGEAR
PARKNG POSITLON
PLNSWTCH SWITCH
( Co s e d I np o s r l oEn )
BLK
l'
BLK
J
G401
I
G401
G402
I
G401
23-129
lnterlockSystem
ControlUnit InputTest
t. Disconnect the 8P connectorfrom the interlockcon-
t r o lu n r t .
2 . I n s p e c t h e c o n n e c t o ra n d s o c k e tt e r m i n a l st o b e
surethey are all makinggood contact.
. lf the terminalsare bent,looseor corroded,repair
them as necessary, and recheckthe system.
. l f t h e t e r m i n a l sl o o k O K , m a k et h e f o l l o w i n g
input testsat the connector.
lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- l f a l l t h e i n p u t t e s t s p r o v e O K , s u b s t i t u t ea
known-goodcontrolunit, and recheckthe sys- WHT/BLU
tem. lf the checkis OK, the control unit must
be faulty;replaceit.
N O T E :l f t h e s h i f t l o c k s o l e n o i dc l i c k sw h e n t h e 1
ignitionswitchis turned ON (ll) and you step on the
4 5 1 I
brakepedal(with the shift leverin E), the shift lock INTERI-OCK
s y s t e mi s e l e c t r o n i c a l lny o r m a l ;i f t h e s h i f t l e v e r CONTROLUNIT
cannotbe shiftedfrom E, test the A//Tgear position wHT sLr/glu wHrlneo
switch.parkingpin switch,and seesection14.
Wire sideof
femaleterminals
Key Interlock System:
Cavity Wire Test condition Test: Desiredresult Possible cause if result is not obtained
lgnitionswitchturnedto C h e c kf o r v o l t a g e t o g r o u n d l BlownNo. 48 (30A) fuse in the under-
1 WHT/BLU A C C( l l a n dk e yp u s h e d ; n There should be batteryvoltage. hoodfuse/relay box
BlownNo.33 (7.5Aifuse in the under
dashfuse/relaybox
Faultysteeringlockassembly
5 (keyinterlocksolenoid)
An openin the wire
U n d e ra l l c o n d i t i o n s Checkfor continuityto ground: . Poorground(G401,G402)
4 BLK . An openin the wire
Theresho(,ldbe continuaty.
Shiftleverin E Checklor continuityto ground: Poorground{G401,G402)
BLI(BLU Thereshouldbe continuity. FaultyM gearpositionswitch
An openin the wire
the 8P connectorto the interlockcontrolunit.

Reconnect
Shift Lock System:
Cavity Wire Testcondition Test: Desiredresult Possiblecause if result is not obtained

lgnitionswitchON (ll) Checkfor voltageto ground: ' BlownNo. 25 (7.5A) fusein the under
2 YEL Thereshouldbe batteryvoltage. dashfuse/relaybox
. An openin the wire
lgnition switch ON (ll) Checkfor voltage to ground: B l o w n N o . 2 5 ( 7 . 5A ) f u s e i n t h e u n d e r -
There should be battery voltage. dash fuse/relay box
3 YEUBLK Faultyshift lock solenoid
A n o p e n a nt h e w i r e
ShiftleverIn E Checkfor voltage to ground: Poorground(G401,G402)
6 BLK/8LU There should be 1 V or less. FaultyA,/Tgearpositionswitch
An openin the wire
lgnitionswitchON (ll) C h e c kf o r v o l t a g e t o g r o u n d : BlownNo. 52 (15Alfuse in the under
Brakepedaldepressed There should be 1 V or less. hoodfuserelaybox
lgnition switch ON (ll) C h e c kf o r v o l t a g e t o g r o u n d : FaultyPCM
I WHT/RED B r a k e p e d a l a n d There should be batteryvoltage. Faultybrakeswitch(seesection11)
accelerator depressed at
Faultythrottleposition{TP}sensor
the same trme {seesectionl1)
An open in the wire
23-130
KeyInterlockSolenoidTest Shift Lock Solenoid Test
' 1 . R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d 1. Removethe tront console(seesection201.
kneebolster{seesection20).
the shift locksolenoid2P connector.
Disconnect
2. D i s c o n n e ctth e 7 P c o n n e c t o rf r o m t h e m a i n w i r e
harness. Connect battery power to the No. 1 terminal and
groundto the No. 2 terminalof the solenoidmomen-
rarIy,
NOTE: Do not connectpowerto the No. 2 (-) termi-

nal (reversepolarity)or you will damagethe diode
insidethe solenoid.
3. Checkfor continuitybetweenthe terminalsin each

key positionaccordingto the table.
\ -- --\
Terminal
7
;il;
lgnition Key pushedin o-- --'o
switch
ACC{r) Key released o- o
Checkthat the shift lock releaseswhen the release
4. Checkthat the key cannot be removedwith power lever is pushed.and check that it locks when the
and ground connectedto the No. 7 and No. 5 termi releaseleveris released.
n al s .
lf the solenoiddoes not work, replacethe solenoid
. lf the key cannot be removed,the key interlock
solenoidis OK.
. lf the key can be removed,replacethe steering
lockassembly(the interlocksolenoidis not avail-
able separately).
I
23-131
InterlockSystem
ParkingPin Switch Test
1. Removethe front console(seesection20).
2. Disconnectthe 4P connectorfrom the parking pin

switch.
Checkfor continuitybetweenthe No. 3 and No. 4

terminalswith:
- the shift leverany positionotherthan E. or
- the push buttonpushedin E.
Thereshouldbe continuity,
Checkfor continuity betweenthe No. 3 and No. 4

terminalswith the shift leverin E and the push but-
ton released.Thereshould be no continuity.It nec-
essary,replacethe parkingpin switch.
NOTE: Parkingpin switch 4P connectorNo. 1 and

No, 2 terminals are for A,/Tgear position console
light,referto the circuitdiagramon page23-134.
23-132
A/T GearPositionIndicator
J ComponentLocationIndex
precautions,and proceduresin the sRs
sRs componentsare locatedin this area.Reviewthe sRs componentlocations,
section(24)beforeperformingrepairsor service
A/T GEARPOSITIONINDICATOR
InputTest,Page23-136
E E
N N
E E
E E
E B
(cvr)
Test,page23-138
Page23-139
Replacement,
23-133
CircuitDiagram \
CW: IGNITION UNDER-DASH

FUSE/RELAY
UNDER.HOOD BOX SWTCH FUSEi
FELAY
8OX
N0.30{7.54)
t'*','uorl FUSE
f..*fl
I t l
\-/
. ECM
. TCM
I
YEL
I
RED/BLK
(n thegauge
A,4GEARPoSlTloNNDICATOR assenrbly)
V
I
LTGRN
A"/TGEARPOSITIONNDICATOR
DIMMINGCIFCUIT
Vt Yt Vl Yt
No30(7 5A)
V
I
NED/8LK
t,
| ,,-kg'qen
I
llqlcoNsoLEl
| | "'*'I
I Y./ LGHT I
T/TGEAR
t l l POSTTl0N
SWTCH
t'
RED BLK
II
OASH
V
LIGHTS
BRIGHTNESS G401
CONTROLLER G402
23-134
CircuitDiagram
Except CVT: UNDEF-OASH
BOX
. \ O E P H O O DL U S ER E L A B
YO X FUSE/RELAY
RED/BLK
PCM
(h thegalgeassemby)
l./TGEARPOST ONINDICATOR
A2
V
D]MI!,IING
A,TGEARPOSITON NDICATOR CIRCU]T
I
GRN]BL(
I
YEL
I RED
I
No300.54)
YYYY I
I
DASHLIGHTS
V B RG H T N E S S
CONTNOLLER
I
REDiBLK
t,
e;"'lgn
|l { ,L
t t
I
dlcoNsotEl
l Y i t e i l|
l
\ \ l t /
-
/
,t^jI
tI ' A"|tGEAR
P O ST O N
SWITCH
BLK
FED
I II
I
I-:
I DASHLIGHTS
BR]GHTNESS
G401
G402 (COnt d
CONTROLLEF
23-135
IndicatorInputTest
1. Removethe gaugeassemblyfrom the dashboard(seepage23-1'19),
and disconnect
the t4p connectorfrom rne gauge
assembly.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
. lf the terminalsare bent,looseor corroded,repair lhem as necessary, and recheckthe system.

. lf the terminalslook OK,makethe followinginputtestsat the 14pconnector.
- lf a test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the inputtestsproveOK, but the indicatoris faulty,replacethe printedcircuitboard.
"A"
14PCONNECTOR
YEL RED/BLK RED BLU BRN(*1I
A1 A2 A3 A6
A8 A9 A10 A 1 1 412 4 1 3 4 1 4
BLK WHT LT
GAUGEASSEMBLY
*1i Not used

'2: ExceprCVT
*3: CvT
23-136
\
I
Wire Test condition Test: Desiled result Possiblecauseil result is not obtained
Cavity
Checkfor voltageto ground: . Blown No.25 (7.5A) fusein the
lgnitionswitchON {ll)
YEL Thereshouldbe batteryvoltage. under-dashfuse/relaY box
A'I . An open in the wire
C o m b i n a t i o nl i g h t Checkfor voltagebetween B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e
RED/BLK and REDterminals: under-dash fuse/relaY box
A2 RED/BLK switch ON and dash
lights brightness Thereshouldbe batteryvoltage Faultycombinationlight switch
control dial on full Faultydash lightsbrightness
bright controller
A3 RED
An open in the wire
CheckIor continuityto groundl . FaultyA//Tgearpositionswitch
A4 BLU Shift leverin E or E
Thereshouldbe continuity . An open in the wire
410 GRN Shift leverin [q] or E NOTE:Thereshouldbe no
RED Shift leverin E continuityin anYother Position
A.12 WHT Shift leverin @
Shift leverin E
413 BLVBLU NOTE:Don't depress
the brakepedal.
lgnitionswitchON (ll) Checkfor voltageto ground: FaultyTCM*'
YEL*1 and shift leverin anY Thereshouldbe batteryvoltagefor FaultyPCM*'
positionexceptEl tlvo secondsafterthe ignition An openin the wire
A9 switchis turnedON (ll),and then
lgnitionswitchON (ll)
lessthan 1 V.
GRN/BLK*' and shift leverin any
positonexcept@
Checkfor continuityto ground: . Poorground(G401,G402)
U n d e ra l l c o n d i t i o n s
A8 BLK Thereshouldbe continuitY. . An openin the wire
lgnition switch ON (ll) Checkfor voltageto ground: FaultyTCM*'

LT GRN . Thereshouldbe batteryvoltage*' FaultyPCM*i
A14
. Thereshouldbe about5 V*r An open in the wire
*1: Except
CVT
*2: CVT
23-137
A/T GearPositionSwitch Test
1. Removethe front consolelseesection20).
2. Disconnect
the 14Pconnectorfrom the Ay'Tgear positionswitch.
3. Checkfor continuitybetweenthe terminalsin eachswitchpositionaccordingto the table.
. Move the shift leverbackand fonh without pushingthe shift leverat eachswitchposition,and checkfor continuity
within the rangeof free play of the shift lever.
. lf there is no continuitywithin the range of free play. adjustthe positionof the switch as describedon the next
page.
Terminal side o{ male terminals
Back- up Neutral
A/T Gear Position Switch Light Switch Position Switch
*1
\ Terminal
2 5 6 7 I 1' l3 14 3 l0 11
t**"\
(Notused) G- --o
a tr CF -_o
E E o- --o
E E o- -o
N N o- --o o- --o
tr tr o- --o o- --o
E tr o- -_o CF --o
* 1 : Withcruisecontrolsystem
23-138
A/T Gear Position Switch A/T GearPositionSwitch
Replacement Adjustment
1. Removethe lront console,then disconnectthe 14P 1. Shiftto the E position,and loosenthe nuts'
connectorfrom the A'/Tgear positionswitch
2. Slidethe switchin the directionof El or E position
Removethe two mountangnuts Iwithin 2.0 mm (0.079in.)lso that there is continu'ty
swrTcH betweenthe No. 1 and No.7 terminalsin the range
SLIDER of free play of the shift lever'
3. Recheckfor continuitybetweeneach of the termi-

nals.
NOTE:
. It adjustmentis not possible,checkfor damage
t o t h e s h i f t l e v e r d e t e n t a n d / o rt h e b r a c k e t l f
there is no damage,replacethe consoleswitch'
. The engineshouldslart when the shilt lever is in
positionS in the rangeof free play
Directiono{ IDI or E Position

6 xl.0 mm Iwithin 2.0mm (0.079in)l
9 8 N m ( 10 k g f ' m , 7 l b n f t )
" N e u t r a l "a s s h o w n
P o s i t i o nt h e s w i t c h s l i d e rt o
above.
Fre€ play
"Neutral",then slipthe switch
4. Movethe shiftleverto
into posation.
Attachthe switchwith the two mountingnuts'
Testthe switchin the E and N positionof the shift

lever.The engineshould start when the shift lever
is in positionE anywherein the rangeof free play
't.
Connectthe 14Pconnector,clamp the harness,and
installthe front console.
LOCKPIN
23-139
IntegratedControlUnit
CircuitDiagram \
UNDER,HOOD
FUSE/RELAY
BOX
+WH'I
WHT/8LK
WHT/RED
W NDSHIELD
WIPERi
WASHER9WTTCH.
OFF/INT INT
f7 f7
tt l
l
t l
t
8LU/BLK YEL/BLU
l
g
INTERMITTENT * COMBINED
WPERBELAY WIPER
WASHEH
CIRCUIT CIRCUIT
--1--
lun^r,r-r
l$'lli3fl*"'I
ELU,JWHT |
v I
i *'f--J
| wHnBLK BLK
I |
II i l
r7
WINDSHELD
WIPER
MOTOR
| ,,^v.,,
I
| __
WASHER
"oto*
_ \
* Withcombrned
wiper
washer
opeGl
on G40l
G402
(ffr)
A/TGEAR
POSITION SWITCH- -
( C l o s e dn: p o s | o nl g o r [ N ] )
t 6 gr_r<rqrl
BLKI\lvHl-
10\--l11
STARTER
CUI FELAY
BLU,BLK+[:'##"
I COMBINATION
LIGHTSW]TCH
f7
I
REDiGRN
BOX
UNDERDASHFUSE/BELAY
GRNiRED
YEL
A SEATBELT
NDER
FEII,I
LIGHT
I
UNIT
CONTROL
INTEGRATED
''o
|RED [t GRN LI
BLUi 9]
l u '
I
I ttu,.'
BLU/BED
I
A A L T
Y
')lf#,]"J
l(3ix';
I,if;',"",",..
, ,
Doorcrosed
I BLK
T
BLK
T
c552 G401
foeen
-:
G402
23-141
, l = - _
Input Test
and proceduresanthe SRS
1. Removethe driver'sdashboardlower coverand kneebolster(seesection20).
2. Disconnect
the 10Pconnectorfrom the integratedcontrolunit.
3. Removethe integratedcontrolunit from the under-dashfuse/relavbox.
4. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
. lf the terminalsare bent,looseor corroded,repairthem as necessary, and recheckthe system.

.lftheterminalslookoK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.
INTEGRATEO
CONTROLUNIT
1OPCONNECTOR
Wiresideof
femaleterminals
23-142
\
All Systems:
Wire Test condition Test: Desiredresult Possiblecauseif result is not obtained

Cavity
Checkfor continuityto ground: . Poorground(G401,G402)
Underall conditions
A14 BLK Thereshouldbe continuity . An open in the wire
Underall conditions Check for voltage to ground: Blown No. 43 (7.5A) fuse in the
There should be battery voltage under-hoodfuse/relaY box
A9
An open in the wire
Checkfor voltageto ground: . Blown No. 25 (7.5A) fuse in the
lgnitionswitchON (ll)
Thereshouldbe batterYvoltage. under-dashfuse/relaybox
A6 . An open in the wire
Intermittent Wiper SYstem:
Wire Test condition Test: Desiredrssult Possiblecause if result is not obtained

Cavity
lgnitionswitchON (ll), Checkfor continuitYbetweenthe B l o w nN o . 2 6( 2 0A ) f u s ei n t h e
BLU/BLK and windshieldwiPer BLU/BLKand BLU/WHTterminals: underdashfuse/relaybox
B1
and switchat OFFor INT Thereshouldbe continuitY. FaultywindshieldwiPerswitch
FaultywindshieldwiPermotor
82 BLU,AiVHT
An open in the wire
lgnitionswitchON (ll), Checkfor voltageto ground: B l o w nN o . 2 6( 2 0A ) f u s ei n t h e

and windshieldwiPer Thereshouldbe batterYvoltage. under-dashfuse/relaybox
B3 YEUBLU FaultywindshieldwiPerswitch
switchat INT
An open in the wire
lgnitionswitchON (ll) Checkfor voltageto ground: B l o w nN o . 2 6( 2 0A ) f u s ei n t h e

*A5 Thereshouldbe batteryvoltage under-dashfuse/relaY box
An open in the wire
. Faulty windshield washer switch
lgnitionswitchON (ll), Checkfor voltageto ground:
*84 Thereshouldbe batterYvoltage. . An open in the wire
WHT/BLK and windshieldwasher
switchON
*: With combinedwiper-washeroperation
(cont'd)
23-143
InputTest(cont'dl
al -- --- -- - --->A7
femaleterminals
A8--------.->A14 BLU/RED
Key-in/SeatBelt Reminder,Lights-on ReminderSystem:
Cavity Wire Test condition Test: Desiredresult Possiblecause it result is not obtaineo
C o m b i n a t i o nl i g h t Check for voltage to groundl B l o w n N o . 3 0 ( 7 . 5A l f u s e i n t h e
switch ON There should be battery voltage.
A8 under-dash fuse/relay box
Faulty combination light switch
An open in the wire
l g n i t i o ns w i t c hO N ( l l ) , Checkfor voltageto ground: P o o rg r o u n d( c 5 5 2 )
81 RED/BLU and driver'sseatbelt T h e r es h o u l db e 1 V o r l e s s . Faultyseatbelt switch
switchunbuckled An open in the wire
Driver'sdoor open Checkfor voltageto ground: . Faultydriver'sdoor switch
B9 GRN
Thereshouldbe i V or less. ' An open in the wire
lgnitionkey inserted Checkfor voltageto ground: P o o rg r o u n d( G 4 0 1c, 4 0 2 )
8 1 0 BLU/RE
D into the ignitionkey T h e r es h o u l db e ' l V o r l e s s . Faultyignitionkeyswitch
swrtcn An open in the wire
Bulb CheckSystem (BrakeSystem Light):
Cavity Wire Test condition Test: Desiredresult Possiblecauseil result is not obtained
l g n i t i o ns w i t c ho N ( ) , Connectto ground:Brakesystem Blown No. 25 (7.5A) fuse in the
brakefluid reservoir l i g h ts h o u l dc o m eo n . under dashfuse/relaybox
A4 GRN/RED
f u l l ,a n d p a r k i n gb r a k e Blown brakesystemlight bulb
leverdown An open in the wire
lgnitionswitchat Checkfor voltageto ground: Blown No. 31 (7.5A) fuse in the
START0 ) Thereshouldbe batteryvoltage. under-dashfuse/relaybox
A 1 3 BtU/^/VHT
Faultystartercut relay
A n o p e ni n t h e w i r e
23-144
l.r ^
LightingSystem
DAYTIMERUNNINGLIGHTS
RESISTOR(canadal
Test,page23-151
DAYNME RUNNINGLIGHTS
CONTROLUNIT (Canadal
.HEADLIGHT
'152 InputTest,page23-150
Adjustment,Page23
SIGNALLIGHT
Page23-151
Replacement,
HIGHMOUNT BRAKELIGHT
page23 159
Replacement,
LICENSEPLATE
page23-156
Replacement,
INNERTAILLIGHT
page23-153
Replacement,
OUTERTAILLIGHT
Page23 153
RePlacement,
*: Headlight and front parking/front turn signal light cannot be separated (cont'd)
23-145
LightingSystem
ComponentLocationIndex (cont'dl
HIGHBEAM INDICATORLIGHT
DASHLIGHTSBRIGHTNESS TURNSIGNALINDICATOR
LIGHT
CONTROLLER
ControllerlnputTest, COMBINATIONLIGHTSWITCH
page23-161
Test,page23 149
r- rll l......--,.'...-1F''------4 |-;----

l \
q L__.r L__Jt ' )
--:fft,1al ---l
flfl 11 f- L_J {_
O nnnnnnnnnn;n O
r _ _ r f| l
_ Lr u r,J rJ rJ [J LJ LJ rJ LJ LJ rJ |
I-nnnnrr-nnrrnn LJ !J a-
IJ I-] IJ LI tJ IJ LJ t,J U T-J U LI
r'r n rr n it rr r't rl - n r.t 11it r'l
utJlJ|'JLl|JLJLILI|.JLj|'JtJLl
TURN SIGNAL/HAZARDRELAY
InputTest,page23-155
23-146
trtt
CircuitDiagram(USA)
FUSEiRELAYBOX
UNDEB,HOOD
.\-- --- -- --'r\- --- '
-T\-" T,g,?.. To
FUSE/FELAY
I,JNDER.DASH BOX
l , l I
)
J No.5
00A)
N0.22
(104) Zltl (
N0.4
00A)
No30
(7.5A) i u',';
?
I I I I
FEDi
BLK RED/BLK
REDiGRN
II II
I H]GI-]BEAM
NDICATOR
LIGHT
(1.4w)
I
Y'
DASHLIGHTS
DASHLIGHTS
BRIGHTNESS
CONTROLLER
r?
I
PARKINGLIGHTS
TA]tL]GHTS
LICENSEPLATELIGHTS
BLK BLK BLK
I
G401
G402
oio,
I
G201
I
23-147
LightingSystem
CircuitDiagram(Canadal
UNDEF
H O O DF U S E / R E L8AOYX
REDIW H T RED RED/GNN ]T :L
L
UNDER.DASH
FUSE/FELAY
BOX
q
L_l
b i No.4
(10A)
I
)No 30
L {7.sA)
T
I
)to.:z
'r t75A)
I
N0.20 , N 0 . 1 8
(r0A) (7.54)
)
| | | | ,^,f,-,,,^,."f:",
EBAKESYSTEM
FLDGF\ cLDvF. RFoW- FFD8LU qro e.,( neoa_x ftHT YEL'BLK L GHT
INTEGFATED
CONTBOLUNIT
\-7
t t l Eiffifg.'':trio.'''0-',
| | | |
I
RED/GRN
I
""t*
FED'GRN
I | | r*.",-lT1F*,,._
3t:'r{"is-t}6}"
OAYTIME
FUNNNGLIGHTS
C O N T R OULN I T
I l)tJ-;-,
I t&Jdt&JsJ
REDi3RN REDiGFN
( e)i
Y*,0
ru$i'%H
t N c
liE;;-""' lt*.' T PARKING
BRAKE
A
| )l
I
I
I BRAKE FLIJID
ILG
l(ra
8LK
I I BL( BLK BLK
swrTcH
lclosedLever)l
upl
I L E V ES
I
BLK
Icos€d
L WT C H
. Floar
downl
I I
I
I n: I
-L
: -
G401 G2A2 G2A1 G40l
G402 G401
G402 G402
23-14A
Combination Light Switch Test
(seesection20).
1 . Removethe driver,sdashboardlower coverand steeringcolumncovers
the 4P and 7P connectorsfrom the switch.

Disconnect
Insoecttheconnectorandsocketterminalstobesuretheyarea||makinggoodcontact'
. ll the terminalsare bent,loose.orcorroded,repairthemas necessary, and recheckthe system'

tables lf there
. lf the terminalslook OK,checkfor continuitybetweenthem in eachswitchpositionaccordingto the
is no continuitybetweenany of them,checkfor continuityin the switch harness
- lf there is continuityin the switchharness'replacethe combinationlight switch'
- lf thereis no continuityin the switchharness,replacelt'
rffi]
t-l:
tAltA2!l
fl-
l a rm J l
COMBINATIONLIGHTSWITCH 7P CONNECTOB
Headlight/Dimmel/PassingSwitch :
\ Tetminal B6
B1 82 B3 *84 B5
Position \
OFF
:m: o-- - o
Headlightswitch
LOW cF- --o o- --o
=D
HIGH o- ----o o- ----o
OFF
switch
Passing ---{
ON O-
* : Canada
Turn SignalSwitch :
Terminal
A1 A2 A4
Position
RIGHT o- o
NEUTRAL
LEFT o o
23-149
LightingSystem
DaytimeRunningLightsGontrolUnit Input Test (Canadal
1. R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster(seesection20).
2. D i s c o n n e ct th e c o n n e c t o r sf r o m t h e d a y t i m er u n -
n i n gl i g h t sc o n t r o ul n i t .
3. I n s p e c t h e c o n n e c t o ra n d s o c k e tt e r m i n a l st o b e
surethey are all makinggood contact.
lf the terminalsare bent.looseor corroded,repair

them as necessary, and recheckthe system.
l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
input testsat the connector.
- lf any test indicatesa problem,find and correct
the cause,then recheckthe system.
- l{ all the input tests proveOK, the controlunit
must be faulty;replaceit.
Cavity Wire Test condition Test: Desiredrgsult Possiblecause il result is not obtained
Underallconditions C h e c kf o r c o n t i n u i t yt o g r o u n d : . Poorground (G401.G402)
B1 BLK
T h e r es h o u l db e c o n t i n u i t y . . An open in the wire
U n d e ra l l c o n d i t i o n s Checkfor voltageto groundl . Elown No. 20 (10A) fuse in the
A2 BLK /VHT Thereshouldbe batteryvoltage. under-dashfuse/relaybox
. An open in the wire
IgnitionswitchON (ll) Checkfor voltageto ground: Blown No. '18(7.5A) fuse in the
Thereshouldbe batteryvoltage. under-dashfuse/relaybox
82 YEUBLK
Faultyignitionswitch
An open in the wire
C o m b i n a t i o nl i g h t Checkfor voltageto ground: Blown No. 48 (30Al fuse in the
"=d' position
switch in Thereshouldbe batteryvoltage. under-hoodfuse/relaybox
RED
Faultycombinationlight switch
An open in the wire
C o m b i n a t i olni g h t H e a d l i g h t s( h i g h b e a m ) s h o u l d P o o rg r o u n d( G 2 0 1G
, 2 0 2G
. 401,
switchOFF;connecta come on, (andhigh beam G402)
jumperwire between i n d i c a t o rs h o u l d c o m e o n ) . Blown bulbs
A1 WHT/RED t h e Y E U B L K and Faultydaytimerunninglights
WHT/RED terminals, resistor
t h e nt u r n t h e i g n i t i o n An open in the wire
s w i t c hO N ( l l )
l g n i t i o ns w i t c h O N ( l l ) , Connectto ground:The brake Blown No. 25 {7.5A) fuse in the
brake fluid reservoir systemlight shouldcome on. under-dashfuse/relaybox
B3 GRN/RED
full, and parking brake Blown brakesystemlight
lever down An open in the wire
Parkingbrakeleverup Checkfor continuityto ground: . Faultyparkingbrakeswitch
B6 RED/GRN
Thereshouldbe continuity. . An open in the wire
23-150
Turn
Headlights/Front
Lights
Signal/Parking
DaytimeRunningLightsResistor Replacement
Test (Canada)
CAUTION: Halogen headlights become very hot in uss;
CAUTION: The davtime running lights resistor becomes do not touch them 01 the attaching hardware immedi-
very hot when the daytime running lights are on; do not atelv after they have been turned oft.
touch it or the attaching hardware immediatelyaftel
the lights have been turned oft. 1. Remove the lront bumper (see section 20).
1. the 3P connectorfrom the resistor'

Disconnect 2. Remove the mounting bolts
3. Disconnect each connector, then remove the head

DAYTIMERUNNING light/front turn signal/parking light assembly.
MOUNTING
BOLT
I
TURNSIGNAL/
HEADLIGHT,/FRONT
LIGHTASSEMBLY
PARKING
60/55W
HEADLIGHT:
LIGHT:2115W
FRONTTURNSIGNAL/PARKING
sideof male
Terminal
terminals
Measurethe resistancebetweenthe resistortermi_

'l
nals(No. and No. 2) and the powerterminalNo 3
Resistance:1,6 o i 0 08 o
Replacethe resistorwith a new one it any of the

are beyondspecilication.
resistances
23-15'
. ^
Headlights
Adjustment
Beforeadjustingthe headlights: Adjustthe headlightsto localrequirementsby turn,
ing the adjusters.
. Parkthe vehicleon levelground.
. lvlakesurethe fueltank is full. After headlightreplacement, it may be necessary
to
. The driver or someonewho weighsthe same should readjustthe horizontalindicatorgear.
sit in the driver'sseat.
. Loadthe trunk with the itemsyou usuallycarry. . Firstinstalltheheadlight,and adjustits horizontal
. Pushdown on the front and rearbumoeGseveraltimes a n d v e r t i c a al i m i n g sa c c o r d i n gt o l o c a lr e q u i r e -
to makesurethe car is sittingnormally. menIs.
. Then checkthat the arrow on the horizontalindi-
CAUTION: Halogen headlights become very hot in use; cator gear is alignedwith the mark on the hori-
do not touch them or the attaching hardware immedi- zontalindicator.
ately after they have been turned off, - lf they are not aligned,removethe screw,adjust
the indicatorgear,and retightenthe screw.
1 . O p e nt h e h o o d .
NOTE:As the outer lensesa.e made of an acryli-
2. Checkthe horizontaladjustmentindicator. coated,polycarbonatedmaterial,do not cover the
The "0" markon the horizontalindicatorgearshould headlightswhen they are turned on.
be alignedwith the markon the horizontalindicator.
HORIZONTALINDICATOR
HORIZONTAL
INDICATOR
3. l f t h e i n d i c a t o irs n o t a l i g n e dw i t h i t s " 0 " m a r k a s

described above,an adjustment canbe madeby using
a PhilliDs screwdriver.
23-152
Taillights
Replacement
NOTE: InnerTaillights(Coupe/Sedan):
. tnspectthe gaskeUreplaceit if it is distortedor stays
compressed. 1 . O p e nt h e t r u n kl i d ,t h e nr e m o v et h e a c c e s p
s anel
. After jnstallingthe taillights,run water over them to
makesurethey do not leak 2. the 4Pconnectorfrom the innertaillight
Disconnect
OuterTaillights: 3. R e m o v et h e I o u r l t h r e e ]m o u n t i n gn u t s .t h e n p u l l
o u t t h e i n n e rt a i l l i g h t .
1 . O p e nt h e t r u n kl i d / h a t c h . I l: Sedan
2. Disconnectthe 4P or 6P connectorfrom the outer Coupe:

taillight. INNERTAILLIGHT
3. R e m o v et h e f o u r m o u n t i n gn u t s ,t h e n p u l l o u t t h e
o u t e rt a i l l i g h t .
,lP or 6P CONNECTOR
Sedan:
INNERTAILLIGHT
Hatchback:
BRAKE/TAILLIGHT:2115W
TURNSIGNALLIGHT:21 W
BACK-UPLIGHT: 21W
Coupe/Sedan:
BRAKE/TAILLIGHT:2115w
TURNSIGNALLIGHT:21 W
4P CONNECTOR
BRAKE/TAILLIGHT:2115W
BACK-UPLIGHT: 21W
23-153
Turn SignaUHazard
FlasherSystem
CircuitDiagram
UNOERHOODFUSEiRELAYBOX UNDER.OASH
G NT ] O NS W I C H FIJSEiRELAY
BOX
N 0 . 1 (27 . 5 A )
"l
No30 (7.541
GRN/YEL RED/BLK
TUFNS GNALSWITCH 2 (Nolused)
GRNMHT
3 I
tr ll
RIGHTTURNSIGNALLIGHTS
I
DASHLIGHTS
BRIGHTNESS
CONTROLLER
FRONT NDCATOR INDlCATOR

(2rw) (1.4W)
BL( BLK
BLK
G601.G76t Hatchback G2A2 G201 CoOt,

GZOttlrt.nlr.t
G601 CouperSedan G40l
G601
:Coupe/Sedan G4A2
23-154
trI\
.t Turn Signal/HazardRelayInput Test
SRS componentsare located in this area. Reviewthe
in the SRSsection(24)betoreperformingrepairsor ser-
{
vrce.
{
1. relayfrom the under-
Removethe turn signal/hazard
dash box.
fuse/relay
2. Inspectthe relayand fuse/relaybox socketterminals

to be surethey are all makinggood contact.
. l f t h e t e r m i n a l sa r e b e n t , l o o s e o r c o r r o d e d ,
repairthem as necessary,and recheckthe system.
. l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
inDuttests at the fuse/relaybox socket.
- lf any test indicatesa problem'find and cor-
rect the cause,then recheckthe system.
- lf all the input tests prove OK,the turn signal/ r=\-:=
hazardrelavmust be faulty;replaceit t - l
iln nE-
,\l
' ..lll L l l
........r------
FUSE/RELAYBOX
SOCKET
J
Cavity Tesi condition Ted: Desiredresults Possible caus€ if lesult is not obtained
Hazardwarningswitch Hazardlightsshouldcome on. P o o rg r o u n d( G 2 0 1G

, 2 0 2G
, 401,
G402,G551.G552,G60' 1, G76' 1)
ON;connectthe No. 1
terminalto the No. 3 Faultyhazardwarningswitch
terminal. An open in the wire
'l . Faultyturn signalswitch
lgnitionswitchON (ll) and Rightor leftturn signallightsshould
turn signalswitchin right c o m eo n ,
or left;connectthe No. 1
terminalto the No, 3
te.minal.
Checkfor continuityto ground: ' Poorground(G401,G402)
Underall conditions
2 Thereshouldbe continuity. . An open in the wire
lgnitionswitchON (lll Connectfor voltageto ground: B l o w nN o . 1 2 ( 7 . 5A ) f u s ei n t h e

Thereshouldbe batterYvoltage. under-dashfuse/relaybox
Faultyhazardwarningswitch
An open in the wire
HazardwarningswitchON Connectfor voltageto ground: Blown No. 53 (10A) fuse in the under-
Thereshouldbe batteryvoltage hood fuse/relaybox
Faultyhazardwarningswitch
An open in the wire
23-155
Turn SignalI HazardFlasher
System LicensePlateLights
HazardWarningSwitchTest Replacement
CAUTION: Be careful not to damage the hazard warn- Sedan/Coupe:
ing switch or the center outlet panel when prying the
switch out. 1. Removethe two screwsfrom the licenseplatelight.
and pull the light out part of the way.
1. Pry the hazardwarningswitchout of the centerout
let oanel. 2. Disconnect
the 2Pconnectorfrom the light.
2. Disconnect the 10Pconnectorfrom the hazardwarn- 3. Takethe lensoff, then replacethe bulb.
ing switch.
3. Checkfor continuitybetweenthe terminalsin each 2P CONNECTOR

switchpositionaccordingto the table.
lOPCONNECTOR
Halchback:
1. Carefullypry the licenceplatelight out ofthe license

platetrim.
2. Disconnect
the 2P connectorfrom the Iight.
2P CONNECTOR
\ Terminal
.-\
_ - 2 3 4 5 6 8 I 10
rostlton \
.OFF
o o
o @ o
ON
o o
o ooo o (9 o
Terminal
No.4is not used
LENS
23-156
I
Back-upLights
CircuitDiagram
IGN]TION
BOX
FI.JSE/RELAY
UNDER.HOOD swtTcH
""'--""\9r--l
wnreLx..*wHr6-I eLx/YeL
f[,,*.iliuit*t**
YELiRED
Ilr A TG E A R
/K PosrTloN
r
Vt[{,[H.,. neosrrcn
lcLored Ell
) I
GFN/BLK
I
23-15i
BrakeLights
CircuitDiagram \
'61 UNDER.HOOD
FUSE/RELAY
BOX
\, F!_*,.
|
*l wjcPN_l
I V
H.BNSYSTEM
fi-- Pedardeoressedl
I,t'"t
GRNA'VHT
..,F.,,*,,r . ABSCONTROL
' ECi,I/PC[I
'TCM(CW)
.]NTEHLOCK
'CRUISE
UNIT
coNTRotUNT
CONTNOLUNIT
GRN,ryVHT ffi; I
I
,l. ffi,!,.,
Yr,:"'
I P } BRAKE
I
Ii t*i
r i
BLK
Li;
* 2lW Coupe/Sedan
18W Hatchback
[ ] Wilhc.uisecontro
G601,G761 Halchback
G601:Coupe/Sedan
23-158
High Mount BrakeLight Replacement
Hatchback: Coupe/Sedan:
1 . L o o s e nt h e t w o s c r e w s ,t h e n r e m o v et h e h i g h 1. Removethe rearshelf{seesection20)
m o u n t b r a k el i g h t . B e c a r e f u ln o t t o d a m a g et h e
hatchspoiler. 2 R e m o v et h e t w o s c r e w s ,t h e n r e m o v e t h e h i g h
mount brakelight from the rearshelf.
2. Removethe bulb socketfrom the light.
BULBSOCKET
TWO SCREWS
23-15
DashLightsBrightnessController
CircuitDiagram \,
FUSE/RELAY
UNDER.HOOD BOX
G401
c402
23-160
\
a ControllerInput test
NOTE:The controlunit is built intothe dash lightsbright-
nesscontroller.
1. Carefullypry the controllerout of the dashboard
2. the 3P connectorfrom the controller'

Disconnect
3. Inspectthe connectorterminalsto be sure they are

all makinggood contact.
. lf the terminalsare bent,loose,or corroded,repair

lhem as necessary, and recheckthe system
. lf the terminalslook OK,makethe lollowinginput
testsal the connector.
- lf any test indicatesa problem,find and cor
rectthe cause,then recheckthe system'
- If all the input tests prove OK, the controller
must be faultyjreplaceii.
Test condition Test: Desiredlesults Possiblecauseif result is not obtained

Cavity
C o m b i n a t i olni g h t Checkfor voltageto ground: B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e
Thereshouldbe batterYvoltage. under-dash f use/relaY box
switchON
RED/BLK Faultycombinationlight swatch
A n o p e ni n t h e w i r e
Check for continuity to ground: . P o o rg r o u n d( G 4 0 1G , 402)
Underall conditions
2 BLK T h e r es h o u l db e c o n t i n u i t y . A n o p e ni n t h e w a r e
Connectto groundl ' A n o p e ni n t h e w i r e

C o m b i n a t i olni g h t
3 RED switchON D a s hl i g h t ss h o u l dc o m eo n f u l l
bright.
23-161
InteriorLights
Component Location Index \
CEILINGLIGHT
Test,page 23-165
SPOTLIGHTS FRONTPASSENGER'S
Test,page23-166 oooRswtTcH
RIGHTREARDOORSWITCH
TRUNKLIGHT{Coup6/Sodan)
Test. page 23-166
LEFTREARDOORSwlTCH
IRUNK LATCHSWITCH
23-162
t CircuitDiagram(Without Spotlights)
BOX
FUSE/FELAY
UNDER-HOOD
W].]T/RED
CEILING
LIGHT
ON \ OFF
BLU/BLK
II
I
I &i*J,"'
I V T GRN/RED
| *tecroreo
| ,,J,,, rf--l lcoNTBotUNLT
!I I T-'.- )
BLK
BLUi 6NN LTG
A A \(
Tn':ii
Tt*:r.:,
)
ftm' I TcosedDoo'open I
closed
FRONT
PASSENGERS
DOOR
swtrcH
Dooropen
'l
LEFT
REAR
DOOR
SWITCH
folosed:Dooropen I
R]GHT
REAR
DOOR
swtTcH
fcbsed iDooropen )
l[3'&'i'
8LK
| [OPen
I
Door -] fcbsed
(Open :0oorclosed
J (Open Doorclosed J (open :Doorclosed,
I I:
G60l G761:Halchbac(
G601: Coupe/Sedai
. *1 3 4w:llsA,CanadP a roduceo
5WlJapan'Produced
* 2 8 Wr W l hm o o n r o o l
5W :Wilhoulmoonroo{
23-163
lnterior Lights
CircuitDiagram(With Spotlights| t"
UNDER-HOOD
FUSEi
BELAYBOX
WHT/REO
rhr
I I.l'-,-1
T !
I
BLU/BLK
II t
| **,,",
I'V ]NTEGRATEO
| .,J,,- CONTFOL
UNIT
I
BLU/BLK GRN LTGRN/REO
A A A
Y*,urr" Yoo*
A
Y""
I REAR
[niH,,,,,,*,,ItfuTi::.Ll
BtK li*r*.rt;:ff
l3$?rt"
-
IPASSENGEFS
I DOOF
ll3;:1"'
ao
I I- : lDoorcrosed.J
:
I(ooo
CeOt CZOI ga"f,O""k
G601:Coupe/Sedan
T
xI 3.4W:USA,Canada-pfoduced
prodlced
5W:Japan
*2 8W Wlhmoonrool
5W Wlhoul
moonrool
23-164
L
J Ceiling Light Test
1. Turn the light switchOFF. Without moonrool:
2. Pry off the lens. Coupe/Hatchback:
3. Removethe two mountingnuts (or a bolt) from the

housing,then removethe housing
4. Disconnect from the housing.

the connector(s)

rermrnar 2 3
\ I or ot 4
Position \ 2' 3'
OFF o- /a\
\:/
--o
MIDDLE o- /:\
\:./
--o
ON G_ /A
\./
-_o
BULB {5 WI
With moonroof:
3P CONNECTOR
2'
l'
23-165
InteriorLights
SpotlightsTest Trunk Light Test
1. Turn the spotlightswitchOFF. 1. Openthe trunk light coverfrom the housing.
2. Pryoff the lens. 2. Pryout the light assembly.
3. Removethe two screwsand the housing. 3. Disconnect

the 2P connectorfrom the housing.
4. Disconnect
the 1Pconnectorfrom the housing. 4. Make sure that the bulb is OK. Checkfor continuity
betweenthe No. 1 (+)and No.2 (-lterminats.
BULBITT
\ Terminal
_\ 1 2 3
*"t*
--o
o-t (9 /a\
\-.7
--o rl 3.4 W: USA, Canad!-producod
(9 --o 5 W: Japan-produced
ON o- oJ /^ --o
\,/
23-166
\.
StereoSoundSystem
t ComponentLocationIndex
and proceduresin the sRS
sRS componentsare locatedin this area.Reviewthe sRS componentlocations,precautions,
AUDIOUNIT
(SfEREORADIOTUNER)
Replacement,Page23 169
Terminals,page23 170
ANTENNAMAST RIGHTTWEETER
Replacement,
LEF1TWEETER RIGHTFRONTSPEAKER
page23-171
Replacement,
) it
LEFTFRONTSPEAKER
page23_171
Replacement,
suB
LEAD
CASSETTEPLAYER REARSPEAKERS
Page23-169
Replacement,
23-167
StereoSoundSystem
CircuitDiagram
UNDEF
DASH
U N D E R , H OF
OUDS E / F E LB
AOYX GNITON SWTCH FUSEi
RELAY
SOX
t'*'fdl
-t-'---ll
I
I
II No.30(7.5A)
V
I
ANTENNA
LEAD
WHT/BLU
I I
YEURED FED/BLK
I REDTEr
,,I;J, RED
II
H I
LEFTREAR R l G HN
T EAR LEFTFRONI I
J
SPEAKER SPEAKER DOORSPEAKER
DASHLIGHTS
BRIGHTNESS
CONTROLLER
23-16 8
J Removal
Stereo RadioTuner: CassettePlayel:
1. Removethe centerdashboardlower cover (seesec- L Removethe front consolepanel(seesection20).

tion 20).
2. Removethe DIN cord from the stereoradiotuner'
2. Removethe two mountingbolts,and pullthe stereo
r a d i ot u n e ro u t 3. Removethe lour mounting bolts,then removethe
cassettePlayer'
3. D i s c o n n e ct th e 1 6 Pc o n n e c t o r ss, u b a n t e n n al e a d
and DIN cord (with cassetteplayer)'then remove
the stereoradiotuner.
16PCONNECTORS MOUNTINGBOLTS
STEREORADIOTUNER
{t
23-169
StereoSoundSystem
StereoRadioTunerTerminals MastAntennaReplacement
F o r k e v l e s se n t r v 1. Disconnect the connectorbetweenthe antennalead
a n ds u b a n t e n n al e a d .
To OIN CORD 2. Removethe two mountingscrews,then removethe

mast antenna.
MOUNTINGSCREWS
To DIN CORD
(forsecurity MAST ANTENNA

system)
Cavity Wire
Rightfront door speaker@,
A1 RED/GRN
righttweeterO
Leftfront door speakerO,
A2 BLU
left tweeter @
A3 RED/BLK Lights-onsignal
Constantpower (tuning
A4 WHT/BLU
memory)
ACC(mainstereopower
YEURED
supply)
A7 BLUI/EL Left reardoor speaker@
A8 REDI/EL Rightreardoor speakerO
Rightfront door speakerO,
A9 BRN/BLK
righttweeterO
Leftfront door speakerO,
410 GRY/BLK
left tweeter O
Dashlightsbrightnesscon-
412 RED
troller
414 BLK G r o u n d( G 5 0 ' 1 )
415 GRYA/r'HT Leftreardoor speakerO
416 BRN,^/VHT Rightreardoor speakerO
T e r m i n a lA
s 6 ,4 1 1
J SpeakerReplacement
Front speaker: Rgarsp€aker:
1. Removethe speakercover' 1. Removethe rearsideshelf or rearshelf(seesection

20).
2. Removethe threescrewsfrom the speaker'
2. the 2Pconnectorfrom the speaker.
Disconnect
3. Disconnectthe 2P connector,and removethe door
speaker. 3. Removethe four screws,then removethe speaker.
Hatchback:
g SPEAKER
FRONT
Tweeter:
2P CONNECTOR
1. Removethe door panel{seesection20)
2. the 2P connectorfrom the tweeter'

Disconnect Coupe/Sedan:
3, Removethe mirrorgarnish. REAR
4. Removethe two screws,then removethe tweeter'
|' TWEETER
2P CONNECTOR
23-171
Horn
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions.and proceduresin the SRS
HORNASSEMBLY
Test,page 23-173
a\
\ )
\-'/"''\
\ rap
HORNRELAY: 98 modot
lWirecolors:WHT/GRN, cRy.l
IWHT/GRN, BLU/RED I
Test,page23-73
-/ l i
L-l | | I
hJrrfl a\ a\ fl f- - L--l
nFFrnn-r-rFrl'1llr-
---t | |
LrurrLr!Lrrrr.rLrUrrrr i | |
r ' rF r n n r ' rF r - n F r F r r r r l Ll LJJ
J:::::::::tJ:-t l HORNRELAY:96, 97 modots

lWiro color3:WHT/GRN,GRy,l
lwHT/cRN, BLU/RED I
Test,psge 23-72
UNDER.DASHFUSE/BELAYBOX
23-172
h-
g CircuitDiagram:96,97models HornTest:96,97models
'L Removethe tront bumper(seesection20).
BATTERY
2. the 2Pconnectorfrom the horn'
Disconnect
HORN
RELAY
LOW HORN
rt
Removethe horn.
Test the horn by connectingbattery power to one

terminaland groundingthe other.lf the horn failsto
sound,replaceit.
I
Y--
BLU/RED
I
B LK
{
I
G401
G4o2
23-173
Horn
CircuitDiagram:98 model HornTest 98 model
1 . Removethe front bumper(seesection20).
BATTERY
Oisconnect
the 1Pconnectorfrom the horn.
BRAKE
SWITCH
TERMINAL
Wlhl,eyessenry ";, \
svs€m
ir-?
lJ !--oA" 3. Test the horn by connectingbattery power to the
t v i I t e r m i n a la n d g r o u n d i n gt h e m o u n t i n gb o l t l f t h e
horn failsto sound,replaceit.
WHT/GRN
4,",,
It
I':
23-174
g Switch Test
1. Disconnect the batterynegativecable,thendisconnect R e m o v et h e d r i v e r ' sa i r b a ga s s e m b l y( s e es e c t i o n
the positivecable,andwaitat leastthreeminutes' 2 4 ) ,t h e n d i s c o n n e ctth e h o r n c o n n e c t o frr o m t h e
steeringwheel.
2. Disconnectthe driver's airbag connector(see sec-
tion 24). 7 . Checkfor continuitybetweenthe No 2 terminalof
the cable reel sub-harness3P connectorand horn
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r { s e e positive
terminal.
3.
section20).
4. Disconnect 3P connector
the cablereel sub-harness HORNPOSITIVETERMINAL
from the main wire harness.
REEL
- MAIN WIRE SUB.HARNESS
HARNESS 3P CONNECTOR CABLEREEL
3P CONNECTOR
HORNCONNECTOR
. l f t h e r e i s n o c o n t i n u i t yr, e p l a c et h e c a b l er e e l
(seesection24).
. lf there is continuity,repairor replacethe horn
switch.
Terminalsideof
maleterminals
l f a l l t e s t s p r o v e O K , r e i n s t a ltl h e d r i v e r ' sa i r b a g
assembly(seesection24), and reconnectthe cable
5. Checkfor continuitybetweenthe No. 2 terminalof reelsub harnessconnector'
t h e c a b l er e e l s u b - h a r n e sasn d b o d y g r o u n dw i t h
the horn switchPressed. 9 . Reconnectthe driver's airbagconnector,and reln-
stallthe accesspanelon the steeringwheel.
1 0 . Reconnectthe batterypositivecable,then the negative

terminal.
1 1 . After installingthe airbagassembly,confirm proper

Terminalsideol systemoPeratlon:
maleterminals
Turn the ignition switch ON (ll);the SRS indica-
tor light should come on for about six seconds
and then go off.
) a lf there is continuity,the horn switchis OK. Makesureboth horn buttonswork.
a lf there is no continuity,go to step6.
23-175
RearWindowDefogger
UNDER-DASH
FUSE/RELAYBOX
t l t t l . - :
- :--=-=-=;----------.l
o
:uuu
-n--nhnn-n;n
u ! !
uuuuuu!uluuu .-1 fl
_ | | l
REARWINDOWDEFOGGEF SWITCH
uu!uu!uu!u!u / ----t InputTest,page23-179
REARWINOOWDEFOGGER
FLrnctionTest,page 23-178
DefoggerWjre Repair,page 23-1j8
23-176
U
trt\
CircuitDiagram
**"-*9
-
IGNITION
BOX SWTCH
UNDERHOODFUSE/FELAY
No41 (80A) No42(404)
BOX
DASHFUSE/RELAY
UNDER
(7sA)
N0.30
FUSE
v
I
RED/BLK
tI
BLK]BLU
\t
+
I-
| -r]]
I ;-
I REAR
| wrNDow
I DEFOGGER
TIBLK
BLK
II
II V
I
DASHLIGHTS
I
ERIGHTNESS
CONTROLLER
rt
I --
G6ol :Coupe/Sedan
G771 HalchbacK
G40l
G402
G401
G402
ZLITT
RearWindow Defogger
FunctionTest DefoggerWire Repair
CAUTION:Be carefulnot to scratchor damagethe detog- NOTE: To make an effective repair, the broken section
ger wires with the tester probe. m u s t b e n o l o n g e rt h a n o n e i n c h .
1. Checkfor voltagebetweenthe positiveterminaland 1. Lightly rub the area around the broken section with
body ground with the ignitionswitch and defogger fine steel wool, then clean it with alcohol.
switchON.
T h e r es h o u l db e b a n e r yv o l l a g e . 2. Carclully mask above and below the broken portion
of the defogger wire with cellophane tape.
. lf there is no voltage,checkfor:
- faulty defoggerrelay. OPEN
- faulty defoggerswitch.
- a n o p e ni n t h e E L I V B L U
wrre.
. lf there is batteryvoltage,go to step2.
NEGATIVE
TERMINAL POSITIVETERMINAL
CELLOPHANE
TAPE
3. Using a small brush, apply a heavy coat of silver

c o n d u c t i v ep a i n t e x t e n d i n g a b o u t 1 / g , , o n b o t h
sides of the break. Allow 30 minutes to dry.
NOTE: Thoroughly mix the paint before use.
Checkfor continuitybetweenthe negativeterminal

a n d b o d yg r o u n d .
l f t h e r e i s n o c o n t i n u i t yc, h e c kf o r a n o p e n i n t h e
defoggerg roundwire.
Touch the voltmeterpositiveprobe to the halfway

point of eachdefoggerwire, and the negativeprobe
t o t h e n e g a t i v tee r m i n a l .
Thereshouldbe approximately6 V with the ignition
switch and the deiogger switch ON.
lJthe voltageis as specified,the defoggerwire is

oK.
lf the voltage is not as specified, repair the defog
gerwire.
lf it is more than 6 V, there is a break in the
negative half of the wire.
- lf it is less than 6 V, there is a break in the
positive hall ot the wire.
4. Checkfor continuityin the repairedwire.
5. Apply a secondcoat of paint in the sameway. Let it

dry three hoursbeforeremovingthe tape.
23-178
J Switch Input Test
CAUTION: Be careful not to damage the rear window
defoggerswitch or the center panel when plying the
switch out,
N O T E :B e f o r et e s t i n g ,c h e c kf o r b l o w n N o 1 6 ( 7 5 A )
fuse in the underdashfuse/relaybox
1. Prythe switchout of the centerpanel(seesection20)'
2. the 5Pconnectorfrom the switch.

Disconnect
3. Turnthe ignitionswitchON {ll),and checkthe voltage

betweenthe BLVBLU(+)andthe BLK{-) terminals
Thereshouldbe batterYvoltage.
. ll there is no voltage,checkfor an open in the

BLVBLUwire
. lf there is batteryvoltage,go to step 4.
RED
Wiresideof famaleterminals
4. Connecta jumper wire betweenthe BLK/BLUand

the BLU/YELterminals.
Turn the ignitionswitch ON (ll). and checkthat the

rear window defoggerworks; if it does, replacethe
rt defoggerswitch.
23-179
PowerMirrors
PowerMirror
FunctionTest,page23-182
PowerMirrorTest,page23-183
Replacement,section20
ActuatorReplacement,page23-184
POWERMIRRORSWITCH
Test,page23,183
23-180
hr-
a CircuitDiagram
GNTION
BOX
FUSE/RELAY
UNDER.HOOD swrTcH
YEL
UNDER.OASH
I lu";I FUSE/RELAY
BOX
I
BLK/YEL
*
lt f#'-_'":1:
3 5
BLUiBLK GRN/WHT
-
G551
23-181
-...
PowerMirrors
FunctionTest
CAUTION: Be caretul not to damage the mirror switch Left mirror inoperative:
or the dashboard driver's lower cover when prying the
switch out. Connectthe No. 2 (BLK/YEL) terminalof the 1Opconnec-
tor to the No. 3 (YEURED)terminatand the No. 5 (or No.
1. Pry the switch out of the driver,sdashboardlower 6) terminalto body ground with jumper wires. The left
cover. mirror shouldtilt down (or swing left)when the ignition
2. Disconnectthe 10Pconnectorfrom the switch. switchis turnedON l).
lf the mirrordoesnot tilt down (or doesnot swing left),

removethe left door panel,and checkfor an open in
t h e B L U / W H T( o r B L U / B L K w
) i r e b e t w e e nt h e l e f t
powermirrorand the switch.
- lf the wire is OK,checkthe left power mrrroracrua_
tor.
lf the mirror neithertilts down nor swings left, repair
the YEVREDwire.
lf the mirroroperatesproperly,checkthe mirrorswitch.
Right mirror inoperative:
Connectthe No. 2 (BLVYEL) te.minalof the 1Opconnector

to the No. 3 (YEURED) terminatand the No. 9 (or No. 8)
lOP CONNECTOR
terminalto body groundwith jumperwires.The rightmir-
r o r s h o u l dt i l t d o w n ( o r s w i n g l e f t )w h e n t h e i g n i t i o n
YEL/REO
switchis turnedON {ll).
BLK/YEL BLK
POW€RMIRROR
swtTcH lf the mirror does not tilt down (or does not swino
2 4
left), removethe right door panel,and checkfor ai
6 / 1 8 open in the GRN,Ar'/HT (or YEUBLK)wire betweenthe
right power mi.ror and the switch.
BLU/WHT YEL/BLK - lf the wire is OK,checkthe right power mirror actu-
ator.
lf the mif ror neithertilts down nor swings left. repair
the YEVREDwire.
l f t h e m i r r o r o p e r a t e sp r o p e r l y ,c h e c kt h e m i r r o r
switch.
Mirror Test
Both inoperative:
'1.
Checkfor voltagebetweenthe No. 2 (BLK,/YEL) ter-
minal and body groundwith the ignitionswitch ON
( ).
Thereshouldbe batteryvoltage.
. lf there is no voltage,checkfor:
- b l o w n N o . 1 7 ( 7 . 5A ) f u s e i n t h e u n d e rd a s h
fuse/relaybox.
- an open in the BLVYELwire.
. lf there is batteryvoltage,goto step 2.
2. Checkfor continuitybetweenthe No. 4 (BLK)termi-
n a la n d b o d yg r o u n d .
. lf thereis no continuity,checkfor:
- a n o p e ni n t h e B L Kw i r e .
- p o o rg r o u n d( G 5 5 1 ) .
23-182
!.\-
Switch Test PowerMirror Test
J
1. Removethe switch as describedin FunctionTest 1. Prv out the coverpanei{seesection20}
(seepage23-182).
2. Checkfor continuitybetweenthe terminalsin each cov€R

Mirror Switch:
\ rermrnal
2 3 4 5 6 8 9
Position \
UP o- o- -o -o
DOWN o- -o o- -o
L
LEFT G -o G -o
o- G -o -o
RIGHT
o- o- _o -o
UP
DOWN o- _o o- _o
Terminalsideof
LEFT o- -o o- maleterminals
)
g -o
RIGHT o- o- -o
the 8P connectorfrom the powermitrrt
Disconnect
Checkactuatoroperationby connectingpower-l
groundaccordingto the tables.
\ Terminal
-_\ 6 1 t
P*t,i""--
TILTUP o
TILTDOWN o
POWERMIRROR
swlTcH SWINGLEFT o @
S W I N GR I G H T @
I rt
23-183
PowerMirrors
Mirror ActuatorReplacement(DonnellyTypel
1. Removethe power mirror from the door (see sec- 6. Removethe two screws,cut the wire harness,and
t,on 20),and disconnectthe 8P connector, removethe actuator.
2. R e m o v et h e m i r r o r b a s e c o v e r f r o m t h e m i r r o r ACTUATOR BRACKET
housing.
MIRRORHOUSING
MIRROR
HOLDER
7. Recordthe terminallocationsand wire colors.
Removethe mirror holderfrom the mirror housing.
Gentlypull it out by hand. 8. Routethe wire harnessof the new actuatorthrough
t h e h o l e i n t h e b r a c k e t .B e s u r et o p a s st h e w i r e
Removethe three screwsfrom the actuatorand the underthe bracketclip.
t w o s c r e w sf r o m t h e b r a c k e ta t t h e b a s e o f t h e
assembly.
BRACKET
5. Removethe bracketfrom the housino.
9. Passthe connectorboot overthe wire harness.
23-184
\r-
a
10. lnsertthe terminalsinto the connectorin the origi-
n a l a r r a n g e m e n (t r e c o r d e di n s t e p 7 ) , a s s h o w n
Delow.
Left: Right:
PNK PNK
' ].
1 Apply tape to sealthe intersectionof the connector
boot and the wire harness.
Reassemble in the reverseorder of disassembly.Be

carefulnot to breakthe mirror when reinstallingit
to the actuator.
rt
1 3 . Reinstallthe mirror assemblyto the door.
1 4 . Operatethe power mirror to checkthat the actuator

workssmoothly.
rt
23-185
Wipers/Washers
WIPER/WASHER SWITCH
Test,page23-189
REARWINDOWWIPER
MOTORlHatchbackl
WINDSHIELO
WIPERARMS/BLAOES
Test,page 23,190
WINDSHIELDWIPERMOTOR
Test, page 23-189
FLUID
WINOSHIELD RESERVOIR nf-___]
l.,...--.--_
Ilfr
WASHER
MOTOR
Test,page23'190
{ - J l l l
REARWINDOW
WASHERMOTOR{Hatchb.ck)
[ ]_ll-l
Tesl, page 23-190
23-186
\
CircuitDiagram(Windshield)
UND€R-DASH
FUSEiFELAYBOX
UNDEF.HOOD
8OX
FUSE/REtAY
]NTEGRATED
CONTROL
UNT
/ HasbuiLl'in \
I intem lenl I
I wperreray I
rt
WHTiBLK
I WINDSHIELD
Y
WASHER
MOTOR
BLK BLK
BLK
\t IG2A2 G401
G402
G401
G402
,I :W]lhCOMBINED WIPERMASHER
OPERATION
23-187
Wipers/Washers
CircuitDiagram(RearWindow)
UNDER.HOOD
FUSE/RELAY
8OX
REARWINDOW
WIPER
MOTOR
REAFWINDOW ,'/-\\:---- ----l

W]PERA/VASHER
SWITCH
BLK BLK 8LK
G401
23-188
\ _
tY Wiper/Washer Switch Test WindshieldWiperMotor Test
n\
'1.
Remove the driver's dashboard lower cover (see 1. Openthe hood, and removethe cap nuts.Carefully
section20). remove the wiper arms so that they do not touch
2. Removethe steeringcolumncovers. the hood.
3 . D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e
switch, remove the two screws. and pull out the Removethe cowl cover by prying out the trim clips
switch. (seesection20).
Disconnectthe 5P connectorfrom the windshield

wiper motor.
SWITCH
WIPER/WASHER
Terminalsideof
maleterminals
windshield:
1 1 23 4 l
|t 1_- a T t|
l 5 6 j 7 8 |
RearWindow:
i l 2 3 l
li;i7-',611

\t
Windshield Wiper/Wssher Swiich:
\ | ermrnsl
1 2 3 4 5 1
rostr|on \
OFF o .o
INT
o o
oo
LO o o Test the motor by connectingbattery power a n o
groundaccordingto the table.
HI o o
l\4ist
switch"0N" o o \ Terminal -\ 1 2
Washerswitch"0N
"
o o ;;il-
LOWSPEED o o
H I G HS P E E D o @
RearWindow Wiper/WasherSwitch:
Terminal lf the motor does not run or fails to run smoothly.
\
1 2 3 6 replaceit.
t*t*---__\
o- -o o- -o Connectan analogvoltmeterbetweenthe No. 5 (+)

switch"0N" 5.
Washer "0FF"}
switch
{Wiper and No. 3 (-) terminals,and run the motor at low or
OFF o- -o high speed.
rt
ON o- -o The voltmetershould indicate0 V and 4 V or less
alternately.
o- -o G -o
" 0N'
Washer
switch
"0N")
(Wiper
switch
23-189
Wipers/Washers
RearWiper Motor Test (Hatchbackl WasherMotor Test
t. Removethe hatchlowertrim panel(seesection20). 1 . Removethe front bumper{seesection20).
2. Disconnectthe 4P connectorfrom the wiper motor 2. Disconnect

the 2P connectorsfrom the washer.
assemDty.
Test the motor by connecting battery power to the

No. 1 terminaland groundto the No.3 terminal.
3. Testthe washermotor by connectingbatterypower
lf the motor does not run or fails to run smoothly, and ground accordingto the table.
replace[.
Terminal
Reconnectthe 4Pconnectorto the wiper motor. 1 2
Battery
Connectan analogvoltmeterbetweenthe No. 4 (+) Disconnected

a n dN o . 2 ( - ) t e r m i n a l s . Connected @ o
Runthe motor by turningthe wiperswitchON.
. lfthe motor failsto run smoothly,replaceit.
. lf the motor runssmoothly,but littleor no washer
The voltmetershould indicate0 V and 4 V or less
f l u i d i s p u m p e d .c h e c kf o r a d i s c o n n e c t e do r
alternately.
blockedwasherhose,or a cloggedpump outletin
the motor.
23-190
\
PowerWindows
v ComponentLocationlndex
POWERWINDOWRELAY
Test,page23 73
P - ( ) ( ) ( ) ( ) I
FRONTPASSENGEB'SWINDOWSWITCH
Test,page23-200
BOX
FUSE/RELAY FRONTPASSENGER'S WINDOWMOTOR
Test,page 23_202
POWERWNDOW
MASTERSWITCH
(Hasbuilt-incontrolunit) RIGHTREARWINDOWSWITCH(SEdAN)
InputTest,page23-196 Test,page23-200
Test,page23-194
\t RIGHTREARWINDOWMOTOB
{Sedanl
Test, page 23'202
DRtVER'SWINOOW
Test, page23-201
LEFTREARWINDOWSWITCHlS.-
Test,page 23-200
I
I
LEFTREARWINOOWMOTOR(Sedanl
Iest. page 23-202
\t
23-191
PowerWindows
CircuitDiagram(Coupe/Hatchback) \
UNDER.HOOD
FUSEiFELAYBOX UNDER.DASH
FUSE/BELAY
BOX
BLK
BLK
PASSENGERS
G55l
t
G551 G401
G402
WiNDOWI'IOTOR
23-192
\
EfI
J CircuitDiagram(Sedan)
FUSEiFELAY8OX
UNDER.HOOD U N D E R , D AFSU
HS E / R E L8AOYX
GNT]ONSWITCH
MASTERSWTCH
PASSENGER'S
lt
c 11 8 4 B5
BLUIYEL BLU]oRN 8LK RED/YEL
4 3 I L E F TR E A F 3 I FIGHTREAR 4I 3IFRONT
WINDOW W NDOW PASSENGERS
SWITCH SWTCH WINDOW
8ru;FED I SWTCH
^| ':i"'
REDYEL RED/YEL
MOTOR I4
D R I V ESFW N D O W
RED]BLU
rffi-r
2 I
BLK BLK
\I'
lul t
G551
I
G551 G40l
LEFTREARWINDOW FIGHTFEARW NDOW FRONTPASSENGER
S G402
MOTOR MOTOR WINDOWMOTOR
2s-193
PowerWindows
MasterSwitch Test (Coupe/Hatchback)
1. Removethe master switch from the driver's door Passenger'sSwitch:
panel(seepage23-196).
Terminal
\
D i s c o n n e c t h e 1 2 P c o n n e c t o rf r o m t h e m a s t e r
switch.
P",ir"'-T-mil\A2 A5 A6 A7
ON o- --o
OFF
MAIN OFF o- --o
swtTcH
ON
o- --o
UP o- --o
OFF o- -o
G- *-o
ON
DOWN G_ --o
OFF G_ --o
AI A2 A3 A4 A5
A6 A 7 A8 412
Terminal
sideol maleterminals

switch position acco{dingto the table.
Driver's Switch:
The driver'sswitchis combinedwith the control unit so

you cannot isolatethe switchto test it. Instead,run the
master switch input test proceduresat termrnals A1, A3,
44, A8 and A12 on page 23-196.lf the tests are normal.
the driver'sswitchmust be faulty.
v MasterSwitch Test (Sedanl
1. Removethe armrest from the driver's door panel F ont Passenger'sSwitch:
(seepage23-198). Terminal
\ B1 82 Bl1 cl
2. D i s c o n n e ctth e 1 6 P a n d 1 P c o n n e c t o r sf r o m t h e t".-*Tm;\
masterswitch. ON o- --o
OFF
OFF CF --.o
o- --o
o- --o
MAIN SWITCH ON
UP
POWERWINDOW
MASTERSWITCH OFF G- --o
SWITCH
oRtvER'S
o- --o
DOWN
ON
G- --o
OFF o- --o
FRONT
PASSENG€B'S Left Rear Switch:
swlTcH
\ Terminal
814 815 Bl6
r".-*-f-m}
ON G -_o
OFF
OFF CF --o
v J=\ o- --o
ON --o
H UP
OFF o- --o
CF
c)-
Terminalsideof 00wN
ON
o- --o
maleterminals
OFF o- --o
B1 B3 B4 B5 B7
Right RearSwhch:
B8 B9 8 1 0 B r 1 ,/1,/ 8 1 48 1 5
\ Terminal
B9 810 c1
P."-b"Tmm\B8
ON G_o -o
OFF
OFF o- --o
o- -_o
o- --o
Check for continuitv between the terminals in each ON
switch position according to the tables. UP
Driver's Switch:
OFF G- --o
o- --o
The driver'sswitch is combinedwith the control unit so
DOWN
ON
o- --o
you cannot isolatethe switchto test it. Instead,run the
masterswitchinput test proceduresat terminals83, 84' OFF o- -o
85, 86 and 87 on page 23-198 |f the tests are normal,
v the driver'sswitchmust be faulty
23-195
PowerWindows
MasterSwitch Input Test (Coupe/Hatchback)
NOTE:The controlunit is built intothe powerwindow masterswitch,and only controlsd river'sdoor w jndow operations.
1. Removethe driver'sdoor panel,a nd disconnectthe I2p connectorfrom the masterswitch.
2. lnspectthe connectorand socketterminalsto be surethey are all makinggood contact.
a lf the terminalsare bent,looseor corroded,repairthem as necessary, and recheckthe svstem.

. lf the terminalslook OK, makethe {ollowinginputtestsal the connector.
- lf all the input testsproveOK,the powerwindow masterswjtchmust be faulty;replace
it.
Wire side of femalet6rminals
23-196
L-
\
!-t\
I ' I \
l-l
v
Csvrty Wire Ta3t condition To3t Desirodresult Possiblecause if result is not obttined
Checkfor continuityto ground: . Poorground (G551)
Underall conditions
A5 Thereshouldbe continuity. . An open in the wire
BLK
A8
lgnitionswitchON (ll) Checkfor voltageto ground: Blown No. 10 or 11 (20A) fuse in

A1 BLU/BLK There should be battery voltage. the under-dashfuse/relaY box
Faulty power window relaY
A6 GRN/BLK An open in the wire
Checkthe driver'swindow motor: . Faultydriver'swindow motor

connectthe BLU/BLK
to the RED/YEL It shouldrun (thewindow moves . An open in the wire
A4 RED/BLU terminal
terminal.and the RED/ down).
BLUterminalto the
BLKterminal,then turn
A3 RED/YEL the ignitionswitchON
flr).
Connectthe GRN/BLK Checkthe passenger's window Faultypassenger's window motor
ro the BLUI/EL motor: lt should run (thewindow Faultypassenger's window switch
A7 BLUI/EL terminal
terminal,and the BLU/ movesdownl. An open in the wire
ORNterminalto the
BLU/ORN the ignitionswitchON
flr).
Checkfor voltage betweenthe Faultypulser
v A't2 BLU
Connectthe BLU/BLK
terminal to the RED//EL BLUand BLKterminals:APProx.6 Faultydriver'swindowmotor
terminal,and the BLK V shouldbe indicatedas the driv- An openin thewire
terminalto the RED/ er'swindow motor runs.
BLUterminal,then
A8 BLK turn the ignitionswitch
oN0r).
\y
23-197
PowerWindows
MasterSwitch Input Test (Sedan) \
NOTE:The controlunit is built into the powerwindow masterswitch,and only controlsdriver'sdoor window opera!ons.
l Removethe driver'sarmrest,and disconnectthe 16Pand 1p connectorsfrom the masterswitch.
2. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
. lf the terminalsare bent,looseorcorroded,repairthem as necessary, and recheckthe system.

. lf the terminalslook OK,makethe followinginput testsat the connecror.
- lf all the input testsproveOK,the powerwindow maserswitchmust be faulty;replaceit.
POWERWTNOOW swtTcH
ABMREST
Wire sideot
femaleterminals
23-198
L.
ry
Cavity Wire Test condition Test: Desiredresult Possiblecausc il resuh is not obtained
Checkfor continuityto ground: . P o o rg r o u n d( G 5 5 1 )
Underall conditions
B4 Thereshouldbe continuity. . An open in the wire
BLK
c1
lgnition switch ON (ll) Checkfor voltageto ground: B l o w nN o .7 , 8 , 1 0o r 1 1 ( 2 0A )
B3 BLU/BLK Thereshouldbe batterYvoltage fuse in the under-dashfuse/relaY
box
82 GRN/BLK Faultypowerwindow relaY
An open in the wire
B8 YEUBLK
8 1 5 R€DAr'VHT
Connecrthe BLU/BLK Checkthe driver'swindow motor: Faultydriver'swindow motor

moves An open in the wire
B7 RED/BLU terminalto the RED/YEL It shouldrun {thewindow
terminal,and the RED/ down).
BLUterminalto the
BLKterminal.then turn
B5 RED/YEL the ignitionswitchON
0r ) .
Connectthe GRN/BLK Checkthe front passenger's Faultyfront passenger's
window
window motor: motor
B1 BLU//EL terminalto the BLU/YEL
terminal,and the BLU/ It shouldrun (thewindow moves Faultyfront passenger's
window
switch
v ORNterminalto the oown).
An open in the wire
8 1 1 BLU/ORN the ignitionswitchON
flr).
connectthe YEUBLK Checkthe right rearmotor: Faultyright rearwindow motor
terminal to the YELter- It shouldrun (thewindow moves Faultyright window switch
B9 YEL
m i n a l ,a n dt h e Y E U oown). An open in the wire
GRNterminalto the
8 1 0 YEUGRN the ignitionswitchON
flr).
Connectthe REDny'VHT Checkthe left rearmotor: Faulty left rear window motor
It shouldrun {thewindow moves Faulty left rear window switch
8 1 4 GRNfYEL terminalto the GRN/
YELterminal,and the oown,. An open in the wire
GRNterminalto the
816 GRN the ignitionswitchON
0l).
Connectthe BLU/BLK Checkfor voltagebetweenthe Faultypulser
terminalto the RED/ BLUand BLKterminals: Faultydriver'swindow motor
BLU
YELterminal, and the Approx, 6 V shouldbe indicatedas An open in the wire
BLKterminalto the the driver'swindow motor runs.
RED/8LU terminal,
B4 BLK then turn the ignition
switchON (ll).
{Y
23-199
PowerWindows
Passenger's
Window Switch Test
Coupe/Hatchback: Switch side ot 5P terminal:
1 . R e m o v et h e a r m r e s tp o c k e tf r o m t h e d o o r p a n e l
(seesection20).
PASSENGER'S
WINDOWSWITCH
Terminal side of
male terminals
Checkfor continuitybetweenthe terminalsin each

Terminal
\ 1 2 3 5
ilil----t
o- -o
UP
o- -o
o- -o
o- -o
OFF
5PCONNECTOR
o- -o
DOWN
2. Disconnectthe 5P connectorfrom the passenger's
window switch. o- -o
Sedan:
1. Removethe armrest(seesection20).
5P CONNECTOR
ARMREST
wtNDow
swtTcH
2. Disconnect
the5Pconnector,
thenremove
themount-
ing screw from the passenger'sswitch.
23-200
L{-
E\ I
v Driver'sWindow Motor Test

Motol Test: PulserTest:
1. Removethe driver'sdoor panel(seesection20)' 5. Connectthe test leadsof an analogohmmeterto the

No. 3 and No. 4 terminals.
6. Run the motor by connectingpower and groundto

the No. 1 and No. 2 terminalsThe ohmmeterneedle
shouldmove backand forth alternately.
Terminalsideot maleterminals
2. Disconnectthe 4Pconnectorfrom the motor'
3. Testthe motor in each directionby connectingbat-

tery power and groundaccordingto the table.
\ Terminal
2
;;;;--_l\
UP o @
DOWN @ o
CAUTION: When the motor stops running' discon-

nect one lead immedistelY.
4. lf the motor does not run or fails to run smoothly,

replaceit.
ly
23-201
PowerWindows
Passenger's
Window Motor Test
Front: Rear:
'1.
R e m o v et h e p a s s e n g e r 'ds o o r p a n e l ( s e es e c t i o n 1. R e m o v et h e p a s s e n g e r ' ds o o r p a n e l ( s e es e c t i o n
20t. 20).
2. D i s c o n n e ct th e 2 P c o n n e c t o fr r o m t h e w i n d o w 2. D i s c o n n e c t h e 2 P c o n n e c t o rf r o m t h e w i n d o w
motor. molor.
NOTE:The illustrationshowsthe right rearwindow

2P CONNECTOB
motor;the left rearwindow motor is symmetrical.
2P CONNECTOR
Terminalsideof male
terminals
Terminalsideof male
terminals
3. Checkwindow motor operationby connectingpower

and groundaccordingto the table. 3. Checkwindow motor operationby connectingpower
and groundaccordingto the tabre.
\ -_-l
Terminal
2
il;; \ Terminal
1 t
UP @ o Direction \
DOWN o o UP o @
DOWN @
CAUTION:When the motor stops running,discon-
nectone leadimmediately. CAUTION: When the motor stops running, discon_
nect ons lead immediately.
4. lf the motor does not run or fails to run smoothlv.
replaceit. 4. lf the motor does not run or fails to run smoothlv.
replaceit.
23-202
f,.!*
,
I I
Moonroof
Gomponent Location Index
MOONROOF SwrTCH
Test,page23-206
. MOONROOFCLOSERELAY
IWirr colo]s: w T, GRN/YEL, I
IGRN/ORN,BLK,lNd GNN/REDJ
Test, page 23-73,74
. MOONROOFOPENRELAY
IWir. color.: WHT,GRN/REO,l
LGRN/ORN,BLK.nd YEL I
Te6l. gage 23-73, 74
MOTOR
Test,page 23-206
\y
23-203
Moonroof
CircuitDiagram * 1 : 9 6 , 9 7m o d e l s
x 2 : 9 8m o d e l
U N D E q . - O OFDU S ER E L A B
YO X IGNITIONSWITCH
No4l (80A) N0.42(40A)
WHT/BLK
+_ WHT
UNDER.DASH
FUSURELAY
8OX
MOONFOOF
OPEN
BETAY
OPEN/CLOSESWITCH:
. DLrrinq the llinoooeraUon
(:lr[!-p - Filticlosed)
A andC lorminals ate@nnected.
MOONROOF
SWITCH ' Durm theslidnoooeraton
(Fullyilosedi Fullvop€n)
A andElermrna s arecbnnecied
TILT/CLOSESWITCH:
. Du nqthelillinOOOeratron
(-Iillui - Fulticlosed)
BLK D andF terminalsare corinpded
I
-1r
' DufirElheslidnoooeratron
(Fullyclosed-; Fltv oDen)
' D arldE lermrnals areconhecied
G401
G402
23-204
b.,1
ry FunctionTest
nl
CAUTION:8e carsftilnot to damagethe moonroofswhch Connectthe No. 1 (YEL)terminal to body ground
or the driver's dashboard lowet cover when prying the with a jumperwire,then turn the ignitionswitchON
(ll),The moonroofshouldopen.
switch out.
NOTE:Checkthe No. 51 {20 A) fuse in the under-hood . lf the moonrooiopens,checkthe switch.

fuse/relaybox and No. 24 (7 5 A) fuse in the under-dash . lf the moonroofdoes not open,checkfor:
- a n o p e ni n t h e Y E Lw i r e
fuse/relaybox, beforetestang
- faulty moonroofopen relay.
- faulty moonroofcloserelaY.
1. Pry the switch out of the driver'sdashboardlower
- p o o rg r o u n d( G 4 0 1G
, 402).
cover.
the 4P connectorfrom the switch.

Disconnect Connectthe No. 3 (YEURED) terminalto body ground
2.
with a jumperwire,then turn the ignitionswitchON
(ll).The moonroofshouldclose.
4P CONNECTOR
. lf the moonroofcloses,checkthe switch
a lf the moonroofdoes not close,checkfor:
- an open in the YEUREDor GRN/RED wire.
- faulty moonroofcloserelaY.
- faulty moonroofopen relay.
- faultytilvcloseswitch.
Connectthe No. 2 (BLU)terminalto bodygroundwith

a jumper wire, then turn the ignitionswitch ON (ll)
The moonroofshouldtilt uP.
v . lf the moonrooftilts up, checktheswitch.

. llthe moonroofdoes nottilt up, checkfor:
- an open in the BLUwire.
- faultytilvcloseswitch.
Connectthe No. 3 (YEURED) terminalto body ground

with a jumperwire,then turn the ignitionswitchON
(ll).The moonroofshouldtilt down.
lf the moonroof does not tilt down, the open/close

relay must be faultY.
7. Checkfor continuityto body ground on the No 4

(BLK)terminal.
Wire sideoI femaleterminals
. lf there is continuity.checkthe switch
. lf there is no continuity,checkfor:
- a n o p e ni n t h e B L Kw i r e
- poor ground(G401,G402)
\y
23-205
Moonroof
Switch Test Motor Test \
1. Carefullyremovethe switchfrom the driver,sdash, 1, Removethe headliner{seesection20}.
boardlower cover(seepage23-205).
2. D i s c o n n e ctth e 2 P c o n n e c t o rf r o m t h e m o o n r o o f
2. Checkfor continuitybetweenthe terminalsin each motor.
\ Terminal Terminalsideof maleterminals

l 2 3
t*,*--_\
OFF
OPEN o- --o
CLOSE o- --o
TILT o- --o
Checkthe motor by connectingpower and ground

accordingto the table.
\_ __lg.-rq I
Position
OPEN o @
CLOSE @ o
4. lfthe motor does not run, replaceit (seesection2O).
NOTE: See Closing Force Checkin section 20 for

motor clutchtest.
23-206
\
Open/Glose-Tilt/CloseSwitch Test
1. Removethe headliner(seesection20).
2. Disconnect trom the moon-

the 2P and 4Pconnectors
roo{ motor and the switch.
3. Checkfor continuitYbetweenthe terminalsin each

switchpositionaccordingto the table
Terminal
1 2 3
Position
-
CLoSE TltT o-- --o o- -_o
-
CLoSE oPEN G- -_o
4. ll thereis no continuity,adjustor replacethe switch'
\!y
23-207
CruiseControl
MAIN SWIICH
TesVReplacement,
page23 212
CABLEREEL
Replacement,
section24
. Test,page23-214
CRUISECONTROLUNIT . PedalHightAdiustment,
InputTest,page23-210 section19
swtTctltM/T) A/T GEARPOSMON

. Test,page23 214 swtTcH
. clutch PedalAdjustment, . Test,page 23-138
. Replacement, page23 139
section12
ACTUATORCABLE
VACUUM TANK
TORASSEMBLY
. Test,page23-215
. Replacement,page23-216
. SotenoidTest,page23_217
. Disassembty,
page23-218
23-20a
\ -
-.
CircuitDiagram
GN]TION
SWTCH FUSEiRELAYBOX
UNDER,DASH
U N D E R . H OF
OUDS E ] F E LB
AOYX No30{7.sA)
FUSE
No41(80A) No42(40A)
+WHT
WHT/8LK f7
I
REDJBLK
NDCATOF
LGHT
(084W)
WHTiGRN
v GAUGE
ASSEMBLY
CRNIWHT 7 10 l3
5 2 6
J 9 1l
C R US EC O N T F OULN I T
3
+ r--l
BRAKE CRUISE PNK ELL.JMHT BLK BLK
TIGHTS CONTROL
ACTUATOR
l'
A
:;i",
Yr", ) |
I
i"$L€:H;JF
I'
BLK IoN:Pedareeasedl
/
A T
\v : l
G40l
G202 G40l
G402 G402
23-209
'ry
CruiseControl
ControlUnit Input Test
and procedu.esin the SRS
1. Removethe driver'sdashboardlowercoverand kneebolster(seesection20).
2. Disconnect
the 14Pconnectorfrom the controlunit.
3. lnspectthe connectorand socketterminalsto be surethey are all makinggood contact.
lf the terminalsare bent,loose,or corroded,repairthem as necessary,and recheckthe system.

lf the terminalslook OK, makethe followinginput testsat the connector.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
CONNECTOR
Wire sideol femaleterminals

CRUISECONTROLUNIT
GRN/WHT LTGRN/RED LT GRN/BLK
;--?\
I 2 6 7
I 10 1l 12 13 l4
BRN/BLK BLU/WHT LT GRN
"-"0
v
Wire Test condition Test: Desiredtesult Possiblecau3eit result is not obtained
Cavity
Underall conditions Checkfor resistance to ground: Faultyactuatorsolenoid
9 BRN/VVHT T h e r es h o u l db e 8 0 - 1 2 0O Poorground (G202)
An open in the wire
Underall conditions Checkfor resistance to ground:
1 BRN Thereshouldbe 40 - 60 O'
Underall conditions Checkfor resistance to grouno:
11 BRN/BLK T h e r es h o u l db e 7 0 - 1 1 0O '
Checktor voltageto ground: . Faultybrakeswitch
lonitionswitchON (ll),
Thereshouldbe 0 V with the pedal . An open in the wire
riain switchoN and
2 GRY pushedand batteryvoltagewith
brakepedalpushed,
then released the Pedalreleased.
ground: . Poorground (G401,G402)
Under all condrtions , Check for continuity to . An open in the wire
BLK There should be continu'tY'
BrakepedalPushed, Checkfor voltageto ground: B l o w nN o . 5 2( 1 5A ) f u s ei n t h e

Thereshouldbe batterYvoltage under-hoodfuse/relaY box
then released
5 GRN/!VHT with the pedalpushed,and 0 V Faultybrakeswitch
with the pedalreleased. An open in the wire
Set button Pushed Checkfor voltageto ground: Blown No. 52 (15A) tuse in the
LT GRN/ Thereshouldbe batterYvoltage. under-hoodfuse/relaybox
RED Faultyhorn relaY
Faultysevresumeswitch
ResumebuttonPUshed
LT GRN/ Faultycablereel
7
BLK An open in the wire
ly lgnitionswitchON (ll) Attachto ground: B l o w nb u l b
Cruiseindicatorlight in the gauge Blown No. 25 (7.5A) fuse in the
assemblyshouldcome on. under-dashfuse/relaybox
10 RED/BLU Faultydimmingcircuitin the
gaugeassemDly
An open in the w,re
Checkfor voltagebetweenthe . Faultyvehiclespeedsensor(VSS)
lgnitionswitchON {ll)
BLUMHT O and BLKO terminals: . An open in the wire
and main switchON;
't2 BLU/VVHT raisethe front of the T h e r es h o u l db e 0 - 5 V o r m o r e
car,and rotateone -0 - 5 V or more rePeatedly.
wheelslowlywith the
otherwheelblocked.
lgnitionswitchON (ll) Checkfor voltageto ground: Blown No. 14 (7.5A) fuse in the
Thereshouldbe batteryvoltage under-dashfuse/relaY box
and main switchON
1 3 LT GRN Faultymain switch
An open in the wire
A/f: Shiftleverin E, Checkfor continuityto ground: Faulty A,rr gear Positionswitch

b'l or [f Thereshouldbe continuity. Faultyor misadjustedclutch
M/T: Clutch pedal NOTE:Thereshouldbe no conti- switch(M/T)
14 PNK
released nuitywhen the clutchPedalis Poorground(G401,G402)
depressedor when the shift lever An open in the wire
is in other positions.
'\ty
23-211
CruiseControl
Main Switch Test/Replacement Set/ResumeSwitch
Test/Replacement
Removethe driver'sdashboardlowercover(seesec-
tion 20). l. Dlsconnectthe batterynegatjvecable,then discon-
nectthe positivecable,and wait at leastthree min_
Carefullypush out the swilch from behindthe dash_ UIES.
ooarq.
Disconnectthe driver's airbag connector(seesec-
3. Disconnectthe connector from the switch. rion 24).
Removethe dashboarddriver'slowercover(seesec-
tion 20).
4. Disconnectthe cablereel sub-harness

3p connector
from the main wire harness.
MAIN SWITCH
BULBS{0.84W)
MAIN WIRE
HARNESS
3P CONNECTOR
Terminalsideof
maleterminals
Checkfor continuity betweenthe terminals of the
4. Checkfor continuitybetweenthe terminalsin each cable reel sub-harness3p connectorin each switch
switchpositionaccordingto the table. positionaccordingto the table.
Terminal \ Terminal
\ __\ I 2 3
1 3 5
t*t*-\ t^,*
OFF o- /:\
\-/
-o G- /5
\-/ -o SET(ON} o- -o
ON o /:\
\:,, o o- /5
\:./ -o (ON}
RESUME o- ---o
, n d j t m a t c h e st h e t a b l e ,
a l f t h e r e i s c o n t i n u i t ya
the switchis OK.
lf there is no continuity,reOlace
the switch. a lf there is no continuityin one or both positions,
go to step6.
23-212
llL *
Removethe two screws,then removethe switch lf all tests prove OK, reconnectthe cable reel and
6.
cable reel sub-harness connector.then reinstallthe
steeringcolumncovers.
9 . Reconnectthe driver'sairbag connector,and rein-

stallthe accesspanelon the steeringwheel'
SET/RESUME
1 0 . Reconnect the batterypositivecable,then the nega-
tive cable.
1' ]. A f t e r c o n n e c t i n gt h e a i r b a gc o n n e c t o r sc, o n f i r m
propersystemoperation:Turnthe ignitionswitchON
(ll);the SRSindicatorlight shouldcome on for about
six secondsand then go off
{y
7. Checkfor continuitybetlveenthe terminalsin switch

positionaccordingto the table.
\ lermlnal
2 3
Position \
SET(ON) o- ---o
(ON}
RESUME o-- -o
lf there is continuity, and it matches the table,
replace the cable reel.
lf there is no continuity in one or both positions,
replace the switch.
'st
23-213
CruiseControl
BrakeSwitch Test GlutchSwitch Test (M/T)
1. Disconnect
the 4P connectorfrom the switch. 1. Disconnect
the 2P connectorfrom the switch.
l-N7-rl]]ll
1lx 2 |
lffl
| 3 ,
. ll
|, I
4P CONNECTOR
CLUTCHSWITCH
BRAKE \
PEOAL
Checkfor continuitybetweenthe terminalsaccord-

ing to the table.
2. Checkfor continuitybetweenthe terminalsaccord-
ing to the table.
\ Terminal
2 3 4
tr**On----\
o- --o \ Terminal
RELEASED -\ 2
at**",
DEPRESSED o- --o RELEASED
DEPRESSED o o
3. lf necessary,replace the switch or adiust Dedal
height(seesectionl9).
3. l f n e c e s s a r yr, e p l a c et h e s w i t c h o r a d j u s t p e d a l
height(seesestion12).
23-214
\^
Y Actuator Test
1. Disconnectthe actuatorcablefrom the actuatorrod 5. With voltageand vacuumstill applied,try to pull the
and the 4Pconnector' actuatorrod out by hand.You shouldnot be ableto
pull it out. lf you can,it is defective.
2. Connectbattery power to the No. 4 terminal and
groundto the No. 1, No. 2 and No. 3 terminals
3. Connecta vacuumpump to the vacuumhose Then

applyvacuumto the actuator.
VACUUM PUMP
GAUGE,0- 30 in.Hq.
(A973X- 041 -
xxxxxt
ACTUATOR
Disconnect groundfrom the No.3 terminal The actu-

ator rod should return. lf it does not return, but the
vent hose and filter are not plugged.the solenoid
valve assemblyis defective.
iy 7. Repeatsteps 2 through 5, and disconnectground

.P CONNECTOR from the No. 1 terminal The actuatorrod should
return.lf it does not return,but the vent hose and
filter are not plugged,the solenoidvalve assembly
is detective.
8. lf vou reDlacethe solenoidvalve assembly,be sure

to usenew O-ringson eachsolenoid.
4. The actuatorrod shouldpull in completely.lfthe rod Disconnectpower and ground from the 4P connector'
pulls in only part-wayor not at all, checkfor a leak- Disconnectthe vent hose from the actuator.Connect
ing vacuumline or defectivesolenoid. a vacuumpump to the actuatorvent hose pon, and
applyvacuum.The actuatorrod shouldpull in com-
p l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n .
Reolacethe aduator.
ROD
ACTUATOR
23-215
CruiseControl
Actuator Replacement Actuator GableAdjustment
t. Pullbackthe boot,and loosenthe locknut.Then dis- 1 . Checkthat the actuator cable operatessmoothly
connectthe cablefrom the bracket. with no bindingor sticking.
2. Disconnect
the cableend from the actuatorrod. Stan the engine.Hold the engineat 3,000rpm with
no load (Aff in N or E . MfI in neutral)until the
radiatorfan comeson. then let it idle.
Measurethe amount of movementof the actuator

r o d u n t i l t h e c a b l e p u l l s o n t h e a c c e l e r a t olre v e r
(enginespeed startsto increase).Free play should
b e 1 1i 1 . 0m m ( 0 . 4 3t 0 . 0 4i n ) .
ACTUATORROD
ACTUATOR
CABLE
LOCKNUT
Disconnect
the 4Pconnectorfrom the actuator.
Disconnect the vacuumhosefrom the vacuumtank.

Pullout the vent hose.
LOCKNUTFREEPLAY:11 t 1.0mm
5. Removethe three mounting bolts and the actuator {0.43t 0.0i1in}
with the bracket.
VACUUM HOSE
lf free play is not within specs,loosenthe locknut.
and turn the adjustingnut as required.
NOTE: lf necessary,check the throttle cable free

play (seesection1I ), then recheckthe actuatorrod
free play.
5. Retightenthe locknut,and recheckthe free play.
CABLE 4PCONNECTOR
6. lf necessary,disconnectthe cableend from the link-

age over the acceleratorpedal,then turn the grom-
met 90' in the bulkhead,and removethe cable.
7. Installin the reverseorder of removal,and adjust

tree play at the actuator rod after connectingthe
cable(seenextcolumn).
23-216
rL-
trll
ActuatorSolenoidTest
1. the 4Pconnectorfrom the actuator.
Disconnect
ACTUATOR
2. Checkfor resistancebetweenthe terminalsaccord-

ing to the table.
Terminal
\ 1 2 3 4
{y ;rb"*"Q)---\
VENTSOLENOID
40 - 60()
o-- --o
VACUUIVI SOLENOIO
o- -o
30- 50()
SAFETY SOLENOID
o- --o
40 - 60c)
NOTE: Resistancewill varv slightly with tempera-

is at 70'F (20'C).
ture;specifiedresistance
SAFETYVALVE
VACUUM VALVE
+ To VACUUM
From VENT
HOSE TANK
{y
23-217
CruiseControl
ActuatorDisassembly
ACTUATORCABLE
ACTUATOR
BRACKET
CHECK
VALVE
@, WIRESUPPORTERACKET
ACTUATOR
Test,page23-215
SOI.ENOIDVALVES
Tesr.page 23-217
\9
o
I
elR
YAJ
e
FILTERCOVER
23-218
E
PowerDoorLocks
Y ComponentLocationIndex
NOTE(With keYlessentry system):
LED is faulty;
. lf the doors unlockor lock with the transmitter.but the LEDon the transmitterdoes not come on, the
replacethe transmatter.
(However,
. when you unlockthedoorswith the transmitter,the ceilinglight (middleposition)comeson tor 30 seconds.
if the audio unit is not installed,the light does not come on l
a lf any door is open,you cannotlockor unlockthe doorswith the transm'tter'
the horn
. The horn soundsonly the first time you press a transmitterbutton. (Pressingrepeatedlydoes not activate
agatn.l
doors relock
. lf vou unlockedthe doors with the trsnsmitter,but do not open any of the doors within 30 seconds,the
automaticsllv.
. The doorsdo not lockor unlockwith the transmitterif the ignitionkey is insertedin the ignitionswitch.
the transmitter
. lf you pressthe PANICbuttonfor more than two seconds,the horn soundsfor about 30 seconds,and
is in the ignitionswitch.)The panic mode is
LEDcomes on. (The panic mode will not be activatedif the ignition key
cancelledby pressingany of the transmitterbuttons.
transmltter'
o After replacingthe t;nsmitter battery.pressthe lockand unlockbuttonsfive or six timesto activatethe
RIGHTREARDOORLOCKACTUATOR LEFTREAROOORLOCKACTUATOR
Test, page 23-229 Test, page 23-229
Replacem€nt,section20 Replacement, section20
FRONTPASSENGER'S DOORLOCKACTUATOR
Test, page 23-229
Replacem€nt,section20
v AUDIOUNIT
{STEREORADIOTUNER)
keylossl
/Hasbuih-in
\tecorvorqrcu|l I
Replacemont.page 23-169
Input Test,page 23-226
Terminals,page23-228
LOCKACTUATOR
Test, page 23 229
Replacement, section20
DRIVER'SDOORLOCKSWITCH
Test,page 23'228
t-.a
KEYLESS TRANSMITTER
Codes,page23-231
StoringoI Transmitter
@ TesvReplacement,Page23 230 POWEBOOORLOCK
CONTROLUNTT
{y
\ql lnputTest,page23-224
23-219
F,,
PowerDoor Locks
CircuitDiagram(With KeylessEntrySystem)
UNDEFHOODFUSE/RELAY
BOX
No41(804) N0.42(40A)
WHT/BLK
WHT/RED
WNT/BLU
POWER
DOOR
LOCKCONTHOL
UNT
unLocx@
rocx@
BLK
GRN,4VHT
DOOFLOCK
LOCK
KNOB
KNOB
n GRN/ORN
] xev
WHT/FED I r--1--n1
I i-H__!J
l , l
i-A-r
I
LIJ I
FEARllro* L
LOCK PASSENGER'S
I
io'
lRsi^"s'
YEUFED gLK
BLK
G551 G551 G551
23-220
I
v ]GNITION
swrTcl.l
WHT/BLKBLK/YEL WHT/REC
|-+-_-+-l
|
'J
) Norq I UNDEF-DASH
r'ro.zg
(roA) (7.5A) FBOX
USE/RELAY
(
v
| f, | HORN
RELAY
t l
T
YEUREDBLK/YEL T RUNK
LIGHT
GFY
KEYLESSRECEIVER CIRCUlT
(lnlheaudioun()
T GRN/BED
BLU/RED
l*recnereo | *rrurorro
I CONTRoT UN|T
I coNTRoL
UN|T
tr(
t'---l-----"--------'7
I Y
r IL,.-)
| ,,u'rro
BLU/FED GRN LTG R N / F E D GRN/RED LTGRN/RED
I
ilt) d\
I
v-,
A I
A
Y,,, FIGHT
f*,o"
Il$'.i')""'
l::;=:-' I REAR REAR
I DoOF DOOR
I'r,t*rt*
liff.ii ; i l:xH
| :,.s!.
| | loe.
lccf op€n
loor c osed
8silsr.:,
l to*" l
SWITCH
ubseo:uooropenI
(Open :0oorclosed
,l
I I
BLK
lt3'tri' I
I
t_ I I-l
v oio, G401
G402 G402
23-221
PowerDoor Locks
CircuitDiagram(WithoutKeylessEntrySystem)
UNDEF.HOOD
FUSEiRELAY8OX
DOORLOCKKNOB
t l
DEIVER'S
DOOHLOCK BLU/WI-17
SWTCH
WHT/FED
BLUi
NED
POWER
DOOR
LOCK
CONTROL
UNIT
BLK BLK
I
I
I
G551 G55l
23- 2 2 2
\
Troubleshooting
sequence
NOTE:The numbersin the table show the troubleshooting
Itemto be inspected
:
o o
_9
t 3 .z
f
)
-o
3 F
o
{ p o
; o o : ;
: .g
e c 9 - ) =
E
3 € 3 n ' .z o
9 c o
Symptom E5 (J O Y o F < : IL
Powerdoor locksystemdoes not work at all. 1 2 G551 WHT/GRN
Doorsdon't lockwith driver's All doors 1 2 3 BLU,ryVHT

door lockknob switch. O n eo r m o r e YEUREDor
1 2
doors WHT/RED
Doorsdon't lockor unlock All doors GRN,ryVHT,

ry with driver'sdoor lockswitch. GRN/ORN,
1 3 2 YEUREDor
WHT/RED
O n eo r m o r e YEUREDor
2
doors WHT/RED
* The powerdoor locksystemworksproperlybut G401 or
GRNAVHT
1 2
the keylessentry system doesn't. G402 GRN/ORN
*: with keylessentrysystem
NOTE:
. When the remotetransmitterbutton is pressedthe first time, only the driver'sdoor will unlock.When the button is
Dressedthe secondtime, all the doorswill unlock.
. Thedoorswill relockautomatically after30 secondsifa door is notopened,orthe key isout ofthe ignitionswitch
. The keylessentrysystemwill not lockor unlockthe doorswhen the key is in the ignitionswitch.
!y
PowerDoor Locks
ControlUnit InputTest \
' t . Removethe
driver'sdoor panel(seesection20).
2. Disconnect
the 12Pconnectorfrom the controlunit.
lnspectthe connectorand socketterminalsto be surethey are all makinggood contact.
a lf the terminalsare bent,looseor corroded,repairthem as necessary, and recheckthe system.

. lf the terminalslook OK,makethe followinginputtestsat the connector.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
12PCONNECTOR
YEL/RED
GRN/WHT
1 2 1 5
1 I 12
BLU/WHT
*r With keylessentry system
23-224
t-
v
the l2P connectorfrom the power door lockcontrolunit.
Disconnect
CAUTION: To prevent damage to the actuator, apply battery voltage only momentarily.
Cavily Wire Test condition Test: Degiredresult Possiblecause if result is not obtained
Under all conditions Checkfor continuityto ground: . P o o rg r o u n d( G 5 5 1 )

BLK . An open in the wire
U n d e ra l l c o n d i t i o n s Checkfor voltageto ground: . Blown No. 51 {20A) fuse in the
't2 WHT/GRN Thereshouldbe batteryvoltage. under-hoodfuse/relaybox
Connectthe YEURED Checkdoor lockoperation: Blown No. 51 (20A) fuse in the

terminalto the WHT/ All passenger's
doorsshould under-hoodfuse/relaybox
GRNterminal,andthe untocK. Faultyactuator
YEURED An open in the wire
WHT/REO terminalto
the BLKterminal
momentarily.
connectthe BLU/RED Checkdoor lockoperation:
terminalto the WHT/ Driver'sdoor shouldunlock.
GRNterminal.and the
BLU/RED
WHT/RED terminalto
the BLKterminal
momentarily.
Connectthe WHT/RED Checkdoor lockoperation:
terminalto the WHT/ All passengerdoorsshouldIock.
ry G B Nt e r m i n a la, n dt h e
5 WHT/RED
YEUREDterminalto
the BLKterminal
momenranry.
Underall conditions. Checkfor continuitybetweenthe . An open in the wire
power door lockcontrolunit 12P
connectorNo.6terminaland audio
BLUI/EL unit 16PconnectorNo.3terminal:
*: With keylessentry system
the 12Pconnectorto the powerdoor lockcontrolunit.

Reconnect
Cavity Wire Test condition Test: Desiredresult Possiblecause if result is not obtained
Driver'sdoor lock Checkfor voltageto ground: Faultydriver'sdoor lockswitch

GRN/WHT Thereshouldbe 1 V or less. r o o r g r o u n ot ( l 5 5r ,
switchin LOCK
An open in the wire
Driver'sdoor lock
6 GRN/ORN
switchin UNLOCK
Driver'sdoor lockknob Checkfor voltageto ground: Faultydriver'sdoor lockactuator
7 BLU,Mr'HT in LOCK Thereshouldbe 1 V or less. P o o rg r o u n d{ G 5 5 1 )
An open in the wire
ty
23-225
PowerDoor Locks
Audio Unit (KeylessReceiverCircuitl Input Test (with keylessentry systeml
Removethe audio unit,then disconnectthe A and B connecto.s(seepage23-169).
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
. lf the terminalsare bent.looseor corroded,repairthem as necessary, and recheckthe system.

. lf the terminalslook OK, makethe followinginput testsat the connector'
- lf anv test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceat.
A CONNECTOR B CONNECTOR
AUDIOUNIT
{KEYLESSRECEIVER
CIRCUIT)
\
23-226
\.
v
the A and B connectorsfrom the audio unit
Disconnect
Cavity Wire Test condition Test: Desiredresult Possiblecauseif result is not obtain€d
Underall conditions Checkfor voltageto ground: . Blown No. 47 (7.5A) fuse in the
A4 WHTiBLU Thereshould be batteryvoltage. under-hood{use/relaybox
lgnition switch ACC {l} Checkfor voltageto ground: Blown No. 28 (10A) fuse in the
YEURED Thereshouldbe batteryvoltage. under-dashfuse/relaybox
An open in the wire
lgnitionswitchON (ll) Checkfor voltageto ground: . Blown No. 14 (7.5A) fuse in the
B6 BLfiEL There should be batteryvoltage. under-dashfuse/relaybox
Underatl conditions Checkfor continuityto ground: Poorground(G401,G402)

BLK There should be continuitv. An open in the wire
lgnitionkey inserted Checkfor voltageto ground: Poorground {G401.G402)

into the ignitionkeY Thereshouldbe 1 V or less. Faultyignitionkey switch
switch An open in the wire
BI BLU/RED Shortin the wire
lgnition key removed Checkfor voltageto ground:
from the ignitionkey Thereshouldbe 4 V or more.
switch
Checktor continuity betweenthe . An open in the wire
Under allconditions
audio unit 16PconnectorNo. 3 ter-
v B3 BLU//EL minal and power door lockcontrol
unit 12PconnectorNo. 6 terminal:
Ceiling light switch in Connectto ground: Blown No. 43 (7.5A) fuse in the
"middle position" The ceilinglight shouldcome on. under-hoodtuse/relaybox
LT GRN/ Blown ceilinglight bulb
B8
BLK Faultyceilinglight
An open in the wire
Checkfor voltageto ground: . Faulty door switch
LT GRN/ Eachdoor open,one at
814 Thereshouldbe 1 V or less. . An open in the wire
RED a Irme
Underall conditions Connectto ground: Blown No.52 (15A) fuse in the
Horn shouldsound. under-hoodfuse/relaybox
B16 GRY Faultyhorn
Faultyhorn relay
An open in the wire
the B connectoronly to the audio unit.

Reconnect
Cavity wire Tsst condition Test: Desiredresult Possiblscause if r93ult is not obtaingd
Driver'sdoor lock Checkfor voltageto ground: Poorground(G551)

switchin UNLOCK Thereshouldbe 1 V or less. Faultydriver'sdoor lockswitch
B9 GRN/ORN An open in the wire
Driver'sdoor lock Checkfor voltageto ground:
Shon in the wire
switchin LOCK Thereshouldbe 4 V or more.
Driver'sdoor lock Checkfor voltageto ground: Poorground (G551)
switchin UNLOCK Thereshouldbe 4 V or more. Faultydriver'sdoor lockswitch
v 8 1 0 GRN/WHT
Driver'sdoor lock Checkfo. voltageto ground:
An open in the wire
Short in the wire
switchin LOCK Thereshouldbe 1 V or less.
23-227
PowerDoor Locks
Audio Unit (keylessreceiver Driver's Door Lock Switch Test
circuitlTerminals
1. Removethe innerhandle(seesection20).
16PCONNECTOR
2. D i s c o n n e ctth e 3 P c o n n e c t o rf r o m t h e d o o r l o c k
Cavity Wire Dsstination

B1 BLU/RE
D lgnitionkey switch
'B2 LT GRN Trunk latchswitch
B3 BLU/YEL Unlock(Driver'sdoor) Checkfor continuitybetweenthe terminalsin each
B4 BLU Valetswitch switchpositionaccordingto the table.
*85 LT BLU Security(lN) Terminal
\ I 2
BLK/YEL N o . 1 4 ( 7 . 5A ) f u s e
Position
*87 ORN Security(D2)
LOCK o ----o
88 LTGRN/BLK C e i l i n gl i g h t
OFF
B9 G R N / O R N U n l o c k( A l ld o o r )
8 1 0 GRN^r'r'HTLock(Output) UNLOCK o o
* B 1 1 BLU^ll/HT LED O
*812 WHT/BLK Secufity(D0)
*Bl3 YEUBLU Security(D1)
B l 4 LT GRN/RED Door switch
815 BLK G r o un d ( G 4 0 1G
, 402)
DRIVER'S
GRY HOrn DOOR
LOCK
*i Forsecuritysystem(option) swtTcH
\
Y Driver'sDoor LockActuatorTest DoorLockActuatorTest
Passenger's
'1. Remove the passenger'sdoor panel {see section
1. Removethe driver'sdoor panel{seesection20).
20t.
2. the 4Pconnectorfrom the actuator.
Disconnect
the 2Pconnectorfrom the actuator.
Disconnect
NOTE:The front passenger'sdoor lock actuatoris

shown;the left rear and right rear door lock actua-
tors are similar.
v
Termin.l srdc ol
mele l.rminals
3. Checkfor continuity between the terminals in each TerminalsideoI maletorminals

knob switchpositionaccordingro the table
\ Terminal
3. Checkactuatoroperationby connectingpower and
Position \
ground accordingto the table. To preventdamage
LOCK o--l to the actuator,apply batteryvoltageonly momen-
UNLOCK tarily.
\ Terminal
4. Checkactuator operation by con.!€ct'ng power ano r-*r,r""----_\
ground accordingto the table.To p.went damage
to the actuator, apply battery voltage only momen- LOCK o o
tarilv. UNLOCK @
\ Terminal
-\ 1 2 4. lf the actuatorfailsto work properly,replaceit
;".ltfi
LOCK @
UNLOCK
{y
5. lf the actuatorfails to work properly, .eplace it.
23-229
PowerDoor Locks
TransmitterInspection/Replacement
NOTE:
. lf the doors unlockor lock with the transmitter,but the LEDon the transmitterdoes not come on, the LEDis faulty;
replacethe transmitter.
. lf any door is open,you cannotlockor unlockthe doorswith the transmitter.
. lf you unlockedwith the transmitter,but do not open any of the doors within 30 seconds.the doors relockautomati-
cally.
. The doorsdo not lockor unlockwith the transmitterif the ignitionkey is insertedin the ignitionswitch.
Door3cannot bo locked o.
unlockedwith the transmittor.
Pressthe lock or (rnlockbutton

CQ
o
five or six times to r6sotthe
transmtter.
BATTERY
Replacethe transmitter battery

with a new one, and try to lock/
unlockthe doors with the trans,
mitter. Pressthe lock or unlock
button fiv6 or six times.
Rewriteand registerthe transmit-

ter cod€, then try to lock/unlock
the doors(seepage23-231).
23-230
\*
v Storing of Transmitter Codes
NOTE:
(lf a fifth code is stored'the code which was
. The codesof up to four transmitterscan be stored in the control unit
storedtirst will be erased.l
. Whenthe systementersthe registrationmode,all previouslystoredcodeswill be erased'
. The systemleavesthe registrationmode and returnsto the normalmode if you
- turn the valetswitchOFF.or
- turn the ignitionswitchOFF,or
- do not Dressthe transmitterbuttonfor more than 10 seconds'
Procedure:
1. lnsertthe ignitionkev into the

ignitionswitch.
2. Turn the ignition switch ON
flr).
VALETSWITCH
Within 1Oseconds,go to step3.
3. Pressand hold the valet switch NOTE:lf the tuner is turned ON, it will r-r . l-r l-l
lor at leastfive seconds. go off and come on againwhen the reg- I t ' t t t l
(Youwill hearthe soundof the istrationprocedureis completed
ry actuatorst! rningto UNLOCK.)
Within 10seconds,go to steP4.
4. Pressone of the transmrtter

buttons.
(Youwill hearthe soundof the
actuatorsturningto UNLOCK.)
NOTE: lf you want to registerthe codes

of more than one transmitter,repeatstep
4 within 10 secondswith the ne)dtrans-
mitter,
NOTE:Afterstoringits code,makesure TRANSMITTER

the transmitter works properly oy
Y repeatedlypressingone of its buttons.
(The system starts to work when You
pressany transmitter button six times )
23-231
v
SupplementalRestraintSystem (SRSI
SpeciafTools... 21'2
..........' Troubleshooting
Seff-diagnosticProcedures....... -....'24'13
Component/WiringLocations
fndex .'.............. """21'3 24-13
Readingthe DTC ........'.."...............'.
Description 2/t-5
................ Erasingthe DTGMemory ...."......"' 24-15
GircuitDiagram ..'.,,,..2+6 Troubleshooting Intermittent
Precautions/Procedures Faifures .'--..........24-15
GenerafPrecautions...."..................21'7 SRSUnit ldentification....'..."...'..'...24-16
Airbag Handlingand Storage ......".21-7 DiagnosticTroubleCode (DTCI
'96 - 97 Mode|s............'...
2/t-8
SRSUnit Precautions....'................. Chart- 24-17
DiagnosticTroubleCode (DTCI
lnspectionAfter Deployment '......'.24-8 '98 Model .....""""" """"" 24-19
2tt-9 chart -
WiringPrecautions".....",........"......
SRSIndicatorLight Wire
Backprobing SPring-loadedLock ......24'25
.-.,....2+S Connections
Connectors
Flowcharts .............24-26
Spring-loadedLock Connector......'2+10
Airbag
Spring-loaded Lock Connector with
2it-10
Built-inShortContact'......'......... Repfacement ....",..24-67
Disconnectingthe Airbag Disposaf .................24-70
Connector(s) ......21-11 CableReel
Steering-relatedPrecautions .. 2+12
-..--... Repfacement ..."....24'72
SRS Unit
Repfacement .'.......24-76
'c
\y
SpecialTools
Ref.No. Tool Numbel Description Oty PageReferencs
o 07HAZ- SG00400 DeploymentTool 1 24-70

07PAZ- 0010100 SCSServiceConnector 1 24-' t4
6, 071AZ - 5250200 SRSServiceConnector{2 0) 1 24-42
@- 07TAZ- 0010204 BackprobeAdapter,17 mm 24-30
*: Usewith the stackingpatchcordsfrom T/N 07SAZ- 0010004,BackprobeSet.
SRSINFLATOR @
SIMULATOR
07sAz - TB4011A
SNSSMULATOR
LEAOC
07TAZ-525011A
N O T E :T h e S R S S e r v i c eC o n n e c t o {r 2 O ) ,T / N 0 7 T A Z- 5 2 5 0 2 0 0 i, s n o t a v a i l a b l eI.n s t e a d ,u s e t h e S R S I n f l a t o r
Simulator,T/N 07SAZ- T8401'lA,and the SRS Simulator Lead C, T/N 07TAZ -525011A. When the SRS Service
L
Connector{2 O),T/N 07TAZ- 5250200,is calledfor, connectthe leadto one of the simulator's"2 0" iacks.
Locations
Gomponent/Wiring
v Airbag
lndex:With FrontPassenger's
SRSINDICATOBLIGHT{ln the gauge assemblv) To HORN

Troubleshooting,Page24-13
GaugesssemblY, section23
CABLEREEL
Replacement,
page 24-72
To ORIVER'SAIRBAG
ORIVER'SAIRBAG
ASSEMBLY
DASHBOABDWIRE HARNESS Replacement, FRONTPASSENGER'S AIRBAG
ro SRSINDICATORUGHT in page 24-67
ASSEMBLY
GAUGEASSEMBLY Disposal,page 24-70
Replacement,Page24-67
5P CONNECTOR Disposal,Page24-70
ry
sRSMAINHARNESS
ro CABII EEEL
2POONNECTOR
SERVICECHECK
coNNECTOn {2Pl
IBRN,BLKI
SRS MAIN HABNESS

SBS MAIN to FRONTPASSENGER'S
to UNDER.DASH AIREAG
BOX
FUSE/RELAY 2P CONNECTOR
2PCOT{NECTOR
SRSMAINHARNESS
to sRSUttlT
18PCONNECTOR
MAIN
MEMORYEMSE SIGNAL HARNESS
SRS MAIN I{ARNESS
to MAIN IMES)CONNECTOR EPI
WME HANNESS IGRY,GRYIot [GRN,GRNI
Y 3P OONNECTOR
SRS UNTT
MAINWIREHABNESS {lncludingsaling s€nsor
WIREHARNESS and imPactsensor)
to DASHBOARD Replacement, Page24-76
24PCONNESTOR
24-3
Component/Wiring
Locations
Airbag(Partof CANADAModel)
Index:Without FrontPassenger's \
SRSINDICATOR UGHT(ln the gaugeassembly)

page24-13
Troubleshooting, swtTcH
Gaugeassembly,section23
CABLEREEL
Replacement,
page 24-72 To CRUISECONTROL
sEt swtTcH
To DRIVER'SAIRBAG
DRIVER'SAIREAG
DASHEOARDWIREHARNESS ASSEMBLY
tO SRSINOICATOR
LIGHTiN Replacement.
GAUGEASSEMBLY page2+67
5P CONNECTOR Disposal,page 24-70
SERVICECHECK
CONNECTOR {2PI
IBRN,BLK]
SRSMAIN HARNESS
SRSMAIN SRS UNIT

to UNOER-DASH {lncludingsafingsensor
FUSE/RELAYBOX and impactsensor)
2P CONNECTOR Replacement,page 24-76
SRSMAIN HARNESS
to SRS UNIT
18PCONNECIOR
DUMMYRESISTOR
SRSMAIN HARNESS MEMORYERASESIGNAL
io MAIN {MESICONNECTOR I2PI
WIRE IGRY,GRYIo. [GRN,GRNI
HARNESS
3P CONNECTOR
24-4
I
Description
v
(and
seatbelt,is designedto help protectthe driver
The sRS is a saletydevicewhich,when used in conjunctionwith the
lrontpassenger)inafronta|lmpactexceedingacertainset|imit'ThesystemconsistsofthesRSunit(inc|udingsafin
(andlront passenger'sairbag)'
sensorand impactsensor),the cablereel,the driver'sairbag
ORIVER'SAIBBAG
CABLEREEL
Operation
ThemaincircuitintheSRsunitsensesandjudgestheforceofimpactand,ifnecessary,ignitesthein'|atorcharge(s
batteryvo|tageistooloworpowerisdisconnectedduetotheimpact,thevoltageregu|atorandtheback.uppowerci
will keepvoltageat a constantlevel'
respectively
Fol the SRSto operate:

v to the microprocessor'
{1) The impactsensormust activate,and sendelectricsignals
(2) The microprocessor mu$ compute the signals,and must send signalsto the airbaginflator(s)'
{3) The inflator(s)must igniteand deploythe airbag(s)'
*;_--l
ff*:
+
I
i*w- i
t t l
gsIF'-'"
Self-diagnosisSysiem
turned oN (ll)' the sRS indicatorlight comes
A self-diagnosis circuitis built into the sRs uniu when the ignitionswitch is
normally
on and golesoff afteraboutsix secondsif the systemis operating
if it comeson while driving,it indicatesan abnormal-
lf the light does not "o." on, o. do""-iot go ofi "ft", "i" ""condi, or
as possible'
itv in tn'" "y"t".. fne system must be inspectedand repairedas soon
{y Forbetterserviceabi|ity,thememorywilIstorethecauseofthema|function.andthedataIinkcircuitpassesonthe
mationfromthememorytothedata|inkconnector(DLc)'ThisinformationcanbereadwiththeHondaPGMTester
nectedto the DLC(16P).
24-5
CircuitDiagram
UNOERHOOD
FUSE/NETAY
80X
IGNITION
SWITCH
L
WHT/BIK
+-WHT
UNDER-
OASH
FUSE/RELAY
BOX
BLKffEL
J
SRSINDICATORCIBCUIT
{lnthegauge
ass€mblyl
SRSINOICATOR
t-tGHT
t1.4W)
Bfakesyst€mlight PGM-FI
passenge/s
airbag p8ss€nger's
aib8g DRIVER'S
AIRBAG
t l [**-*i-l INFLATOR
t l I lfrsEsATGE*s
I
! sytru%,
I Ii / rNFr.AroR
- \ i
I
BLK
GRY GRY
(GRN} IGRN}
10 14 1 13 6 TIVA) 3{VB)
SRS
UNIT
16 17 15 9 t8 I
GRY GRY
IGBN) IGRN)
I
t
LT8LU BRN 8RN
I
I t
t
l
l t l
V
f7
V
t.rTl
D DATATINK ECM/PCMSERVICE t " " t

CONNECTOR CHECK MEMORY
ERASE
{DLC)(16P) CONNECTOR (MES)
SIGNAL
CONNECTOR
I2PI
SRSUNITTERMINALS
G401 G80t
G402
Teminalsideof lnaleierminals
24-6
ti
\
res
Precautions/Procedu
GeneralPrecautions Airbag Handlingand Storage
v
Do not try to disassemblethe airbagassemblylt has no
. Carefullyinspectany SRSpart before you install it Do
serviceable parts. Once an airbag has been operated
not install any part that shows signs of being dropped
(deployed),it cannotbe repairedor reused.
or improperly handled,such as dents, cracksor defor-
maI|on:
Fortemporarystorageof the airbagassemblyduringser
- Airbagassemblies vice,pleaseobservethe followingprecautions:
- Cablereel
- S R Su n i t . Storethe removedairbagassemblywith the pad sur-
face up. The driver's {and front passenger's)airbag
connector(s)has (have)a built-in short contact{see
page24-11J.
!!@ r the airbagis improp€rlYstored face down,

i6ilEftil?eptoyment could propel the unit with enough
Iorceto causeserious iniurY.
r Use only a digital multimeterto checkthe system lf

it's not a Honda multimeter,make sure its output is
v 1OmA (0.01A) or lesswhen switchedto the smallest
value in the ohmmeterrange.A testerwith a higher
output could damagethe airbagcrrcultor causeaccl-
dentaldeploymentand possibleiniury.
) Do not install used SRS parts lrom anothervehicle

When makingSRSrepairs,useonly new pans'
AIRBAGCONNECTORS
r E x c e p tw h e n p e r f o r m i n ge l e c l r i c a il n s p e c t i o n s , {Withbuilt'inshortcontact)
alwaysdisconnectboth the negativecableand posi-
tive cable from the battery,and wait at least three
minutesbeforebeginningwork.
. R e p l a c e m e not f t h e c o m b i n a t i o nl i g h t a n d w i p e r /
w a s h e rs w i t c h e sa n d c r u i s ec o n t r o l s w i t c hc a n b e
. Store the removedairbagassemblyon a secureflat
donewithout removingthe steeringwheel: surfaceawav from any high heat source(exceeding
212'Ft1OO"CIand free of any oil, grease,detergentor
- F o r c o m b i n a t i o nl i g h t a n d w i p e r w a s h e rs w i t c h water,
replacement, seesection23
- For cruisecontrolsevresumeswitch replacement, CAUTION: lmproper handling ot storage can internally
seesection23. damagethe airbag assembly,making it inoperative'
lf you suspeqtthe airbag assembly has been damagGd,
. Wheneverthe ignition switch is ON tllr, or has been install a new unit, and refer to the Deployment/Disposal
turned OFFfor lessthan three minutes be carefulnot proceduresfor disposingof the damaged airbag.
t o b u m pt h e S R Su n i Ut h e a i r b a g ( sclo u l da c c i d e n t a l -
ly deployand causedamageor injury'
. Whenever the airbag(s)has(havelb€en activated,

{y reolacethe SRSunit.
24-7
Precautions/Procedu
res
SRSUnit Precautions lnspectionAfter Deployment
Takeextracarewhen paintingor doing body work in A f t e r a c o l l i s i o n i n w h i c h t h e a i r b a g ( s )w a s ( w e r e )
the area belowthe dashboard.Avoid directexposure deployed,replacethe SRSunit,and inspectthe following:
o f t h e S R Su n i t o r w i r i n gt o h e a tg u n s ,w e l d i n g ,o r
sprayingequipment. l. Inspectall the SRS wire harnesses.ReDlace,
don't
repair,any damagedharnesses.
D i s c o n n e ctth e a i r b a gc o n n e c t o r ( sb) e f o r ed i s c o n -
nectingSRSharnessconnectors(seepage24-11l,. 2. Inspectthe cablereelfor heatdamage.lf thereis any
damage,replacethe cablereel.
After any degreeof frontal body damage,or after a
collisionwithout airbagdeployment,inspectthe SRS 3. A f t e r t h e v e h i c l ei s c o m p l e t e l yr e p a i r e dt,u r n t h e
unit for physicaldamage.lf it is dented,cracked,or ignitionswitchon, lf the SRS indicatorlight comes
deformed,reDlaceit. on for aboutsix secondsand then goes off. the SRS
systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting.
Be surethe SRSunit is installedsecurely.
Do not disassemble
the SRSunit.
Store the SRS unit in a cool (lessthan about '104.F/

40'C)and dry (lessthan 80% humidity,no moisture)
place.Do not spill water or oil on the SRS unit, and
keepit awayfrom dust.
During installationor replacement,be carefulnot to

bump (impactwrench,hammer,etc.)the areaaround
the SRSunit. The airbag(s)could accidentally
deploy
and causedamageor injury.
24-8
\
I
Lock
BackprobingSPring-loaded
v Wiring Precautions
Connectors
. Neverattemptto modify,spliceor repairSRSwiring
. When checkingvoltageor resistanceon this type of
connectorthe first time, it is necessaryto removethe
NOTE:SRSwiring can be identifiedby specialyellow probes the wire side
retainerto inserttester from
outer Protectivecovering.
NOTE: lt is not necessaryto reinstallthe removed
retainer;the terminalswill stay lockedin the connec
tor housang.
Be sureto installthe harnesswiresso that they are not

Dinchedor interferingwith otherparts.
RETAINER
* Discardafterremoval.
v
To removethe retainer,insert a flat tip screwdrtver
betweenconnectorbody and retainer,and carefully
pry out the retainer'
NOTE;Takecarenot to breakthe connector'

FLATTIP
RETAINER SCREWDRIVER
M a k e s u r e a l l S R S g r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-to-
metalcontact.Poor groundingcan causeintermittent
Droblemsthat are difficultto diagnose.
RETAINER
24-9
Precautions/Procedu
res
Spring-loadedLock Connector Spring-loadedLock Connectorwith
Built-in Short Contact
SomeSRSsystemconnectorshavea spring-loaded
lock.
The driver's airbag (and front passenger.s)airbag has
Disconnecting ( h a v e )a s p r i n g - l o a d e d
l o c k c o n n e c t o rw i t h a b u i l t - i n
To releasethe lock,pull the spring-loaded
sleevetoward short contact.When this connectoris disconnected. the
the stopwhile holdingthe oppositehalfof the connector. p o w e r t e r m i n a la n d t h e g r o u n dt e r m i n a li n t h e a i r b a g
Thenpull the connectorhalvesapart. connectorare automatically shorted.
N O T E : B e s u r e t o p u l l o n t h e s l e e v ea n d n o t o n t h e Conneqtothalves disconnected:
connectorhalf.
SPRING.LOADED
SLEEVE GROUNOTERMINAL
D o n o t p u l l o nt h i s
halfot the connector.
Connecting
1. Holdthe pawl-sideconnectorhalf,and presson the

backof the sleeve,side connectorhalf in the direction
shown. As the two connector halves are pressed
together,the sleeveis pushedbackby the pawl.
SHORTCONTACT
NOTE:Do not touch the sleeve.
CASLEREELCONNECTOR
Connegtor halves connected:

GROUNDTERMINAL
Whenthe connectorhalvesarecompletelyconnected.
the pawl is released,and the spring loadedsleeve
locks the connector.
SPRING-LOAOED
SLE€VE
| 24-1O
It
v the AirbagGonnector(s)
Disconnecting
disconnect the nogltiv! blttrty
!u@ To provant accidenlal ai.bag dsploymsnl, turn the ignition switch oFF'
..lt-.. and wait th,ee minutes before disconnectingany sRs connostors'
(C' D)'
. the SRSmain harness(A)from the SRSunit' disconnectboth airbaqs
Beforedisconnecting
(B), the
disconnect driver'sairbag2P connector (C)'
. the cablereel2P con
Beforedisconnecting nector
1. Disconnectthe negativebatterycable,and wait at Front Passonger'sSids:

leastthrse minutes.
. Removethe glove box.then disconnectthe front pas-
the airbagconnector(sl.
Disconnect senger'sairbag2P connectorand SRSmain harness
2.
2P connector.
v
Driver's Side:
. Removethe accesspanel from the steeringwheel,

then disconnectthe driver'sairbag2P connectorand
cablereel2Pconnector.
AOCESSPANEL
t {y
Precautions/Procedu
res
Steering-related
Precautions
SteoringWheel and Cable ReolAlignment SteeringColumn Romoval
NOTE:To avoid misalignmentof the steeringwheel on GAUTION:

reassembly,make sure the wheels are turned straight . Betoro r€moving the steering column. first discon-
aheadbeforeremovingthe steeringwheel. nect tho connector between ihe cable 1a9l and tho
SRSmain harness.
. lf the steering column is going to be removed with-
out dismounting the ste€ring wheel, lock the stecr.
ing by turning the ignition key to o-LOCKposition. or
remove the key from the ignition so thal lhe steering
whed will not turn.
NOTE:
When the airbagassemblyand cablereel are discon-
nected.and the batteryis reconnectedand the igni-
tion switch is turned ON (ll), the SRS unit will store
this as an open in the driver'sairbaginflator,and the
S R S i n d i c a t o rl i g h t w i l l c o m e o n , I n s u c h a c a s e .
make sure to confirm the DTC,then clear the SRS
unit memorv.
For disconnectingthe spring-loadedlock type con-
Rotatethe cablereelclockwiseuntil it stops. nector, refer to page24-10.
Then rotateit counterclockwise (approximately two and
a halfturns) until the arrow mark on the cablereel label
pointsstraightup.
ARROWMARK
SRSMAINHARNESS
2PCONNECTOR
Do not replacethe originalsteeringwheelwith any other

d e s i g nb e c a u s ei t w i l l m a k e i t i m p o s s i b l et o p r o p e r l y
installthe airbag(only use genuineHonda replacement
parts).
After reassembly,confirm the wheels are still turned

straightaheadand that the steeringwheel spokeangle
is correct.lf minor spokeangleadjustmentis necessary,
do so only by adjustingthe tie-rods,not by removing
and repositioning the steeringwhee..
24-12
\)
Troubleshooting
Y Procedures
Self-diagnostic
to storethis intorma-
functionof the sRs systemallowsit to locatethe causesot systemproblemsand
The self-diagnostic
tion in mem-ory.Foreasiertroubleshooting,this datacan be retrievedvia a data link circuit'
.whenyouturntheignit|onsw|tchoN(||},thesRsindicatorwi||comeon.|fitgoesoffattersixseconds,thesys
normar.
in memory.and turns
. lf there is an abnormality,the systemlocatesand definesthe problem,storesthis information
thesRsindicator|ighton.Thedatawi||remaininthememoryevenwhentheignitionswitchisturnedof'orif
tery is disconnected.
(2P),and turn the ignitionswitch oN (ll)'
. when you connectthe scs serviceconnectorto the sewicecheckconnector
(DTC)by the numberol blinks'
the SR3 indicatorlight will indicatethe diagnostictroublecode
. After readingand recording the DTC, proceedwith the for this code'
troubleshooting
Precautions
its outputis 10 mA (0.01A)
. Useon|y a digita|mu|t|meterto checkthe system.|f it,s not a Hondamultimeter,makesure
with a higher output could damagethe
or lesswhen switchedto the smallestvalue in the ohmmeterrange.A tester
airbagcircuitor causeaccidentalairbagdeploymentand possibleiniury'
be caretulnot to bump the
r Wheneverthe ignitionswitchis oN (ll),or has beenturned oFF for lessthan three minutes,
deploy
SRSunit;the airbagscould accidentally and cause damage or injuries'
(and the front passenger'sairbag
. Beforevou removethe sRS main harness,disconnectthe driver'sairbagconnector
connector).
measuringvalueswon't be
. Make surethe batteryis sufficientlycharged(seesection23). lf the batteryis dead or low,
correct.
and do not connectthe terminals
. Do not touch a testerprobeto the terminalsin the sRS unit or harnessconnectors,
with a jumperwire. Useonly the backprobeset and the SCSserviceconnector'
For backprobingspring-losded locktype connectors,referto page24-9'
v
Readingthe DTC
Whenthe SRSindicatorlight is on, readthe DTCusingone of thesemethods:
(DLC),and follow the tester'sprompts' lf the tester
A. Connectthe HondaPGM Testerto the 16PData Link Connector
indicatesnoDTc,doub|e-checkbyjumpingtheservicecheckconnectorandwatchingthesRsindicator
next page).
HONDAPGMTESTER
{16P)
DATA LINKCONNECTOR
v
2+1'
Troubleshooting
B . The SRSindicatorlight can also indicatethe DTCby the numberof blinkswhen the SCSserviceconnectoris connect-
ed to the servicecheckconnector{2P}.
1 . Turn the ignitionswitchOFF,and wait for ten seconds.Then connectthe SCSserviceconnectorto the servicecheck
connector(2P).lf you do not wait ten seconds,the SRSunit will not be completelyresetand will not output DTCS.
SERVICE
CHECK
CONNECTOR(2PI
IGRY,GRYIor [GRN,GRNI
SCSSERVICECONNECTOR
07PAZ- (x)101(xt
Turn the ignitionswitchON (ll).The SRSindicatorlight comeson for aboutsix secondsand goesoff. Then it will indi-
cate the DTC:
- The DTCconsistsof a main code and a sub-code.
- Includingthe most recentproblem,up to three differentmalfunctionscan be indicated.
- In caseof a continuousfailure.the DTCwill be indicatedrepeatedly(seeexample1 below).
- ln caseof an intermittent
failure,the SRSindicatorlightwill indicatethe DTCone time,then it will stayon (seeexarn-
ple 2 below).
- lf both a continuousand an intermittentfailureoccur,both DTCswill be indicatedas continuousfailures.
* In casethe systemis normal{no DTC},the SRSindicatorlight will stay on (seeexample3}.
Readthe DTC.
Turn the ignitionswitch OFF,and wait for ten seconds.Then disconnectthe SCSserviceconnectorfrom the service
checkconnector{2P).
Ex8molosof DTCIndications:
1. Continuousfailure,SRSIndicatorLight is:
[.- , s --]
- l1'"*0" f - . f - - l F - t -4 t- --t F
M.in.ods ll) Sub,code l2l Main cod. (l) Sub.cod. (1)
!._.--!-
DTC2.1 oTc r.2 D T Cr . 1

Mosr roc€ntp.obt.m Thnd moll r66.t
Intermittentfailure,SRSIndicatorLightis:
l-ight 3rry3 on in e$ ot
oTc5.1
3. Normal(no failure),SRSIndicatorLight is:

\
Erasingthe DTCMemorY g Intermittent

Troubleshootin
\" Failures
To erase the DTC(s)from the SRS unit, use a Honda
lf therewas a malfunction,but it doesn'trecur,it will be
P G M T e s t e r{ s e et h e H o n d aP G M T e s t e rS R Sv e h i c l e
storedin the memory as an intermittentfailure.and the
SystemSupplement)or the followingprocedure'
SRSindicatorlight comeson.
1. Makesurethe ignitionswitchis OFF
After checkingthe DTC,troubleshoot as tollows:
2. Connectthe SCSserviceconnectorto the MES con-
nector(2P).Do not usea iumperwire "Readingthe DTc")
1. Readthe DTC(see
I L 2. E r a s et h e D T C m e m o r y ( s e e
" E r a s i n gt h e D T C
&
Memory").
3. With the shift leverin neutral,turn the ignitionswitch

ON (ll),and let the engineidle.
4. The SRSindicatorlight comeson for about six sec-

onds and goes off.
I 6.oc l<-
MEMORYEMSE coruruscron
ics senvtce ON
SIGNAL{MESICONNECTOR {2PI 07PAZ- 0010100
IGRY,GRYIor [GRN,GRNI --
t t
-J
The SRSindicatorlight comeson for aboutsix sec-
Y onds and goes off. Removethe SCS serviceconnec-
tor from the tat "onn"61or{2P)within four seconds
after the SRSindicatorlight went off.
Shakethe wire harnessand the connector,take a test
5. The SRSindicatorlight comeson again Reconnect quick braking,cornering),
drive (quickacceleration,
the SCS service connectorto the MES connector fully left and right,and
and turn the steering wheel
{2P)within the four secondsafterthe SRSindicator to find the cause
hold it there for five to ten seconds
light comeson.
of the intermittentfailure
The SRS indicatorlight goes off. Removethe SCS
(2P) l f t h e p r o b l e mr e c u r s t, h e S R Si n d i c a t o rl i g h t w i l l
s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o '
stay on.
within four seconds
7 . The SRSindicatorlight indicatesthat the memory ls
erasedbY blinkingtwo times.
8. Turn the ignition switch oFF, and wait for ten sec- --l ** F
::ff
onds.
4 sec or less
Blinkiog Problemrecurs,light staYson'
L .--
SRS indic.tor
figlrr lt|Il
failure.the sYs-
lf you can't duplicatethe intermittent
MES
CONNECTED tem is OK at thistime.
connactoi
to.minal! DISCONNECTED
24-15
Troubleshooting
SRS Unit ldentification
*: On '98 models,the troubleshootingprocedures
are differentfor eachtype of SBS unit. ldentifythe SRSunit in the vehi-
cle usingthe chartbelow,then follow the properflowchartin the followingpages.
'98 Model
SRSunits
MAKER IDENTIFICATION
PARTSNUMBER Remark
MARK*
77960-S04-A91 [/41 Driver'ssideSRSairbagonly
NEC Driver's& Passenger's
7 7 9 6 0 ,S 0 4- N 9 1 M1 side
SRSairbag
KEIHIN 77960-S04-N91 Driver's& Passenger's

side
M2
SRSairbag
SIEMENS 77960-S02-A82 Driver's& Passenger's
side
M3
SRSairbag
'96 - 97 Models
SRSunits
MAKER PARTSNUMBER Remark

77960-S04-C81 Driver'ssideSRSairbagonly
NEC Driver's& Passenger's
77960-S04-N8l side
SRSairbag
TAKATA Driver's& Passenger's

side
77960-S04-N82
SRSairbag
SIEMENS 77960-S02-A81 Driver's& Passenger's

side
SRSairbag,'97 Modelonty
24-16
-'96 - 97 Models
v DiagnosticTroubleCode (DTC)Chart
FaultySRSindicatorlight circuit
Faulty SRS indicator light circuit, internal

failure of SRS unit.Iaulty SRS power supply
1-1 ODenin the driver'sairbaginflator

lncreasedresistance in the driver'sairbag
Troubleshooting
inflator
Shortto anotherwire in the driver'salrbag
inflatoror decreasedresistance
Shortto Dowerin the driver'sairbaginflator
Shortto groundin the driver'sairbaginflator
With front passenger's airbag:
Open in the passenger's airbaginflator
Withoutfront Passenger's airbag:
Open in the dummy reslstor
lncreasedresistance in the passenger's airbag
inflator
v lncreased resistancein the dummy reslstor
With front passenger'sairbag:
Shortto anotherwire in the passenger's
airbaginflatoror decreasedresistance
Short to anotherwire in the dummy reslstor
or decreasedresistance
Shortto power in the passenger'sairbag
inflator
Shortto power in the dummy resistor
With front Passenger'sairbag:
Shortto ground in the passenger'sairbag
inflator
Shon to ground in the dummy resistor
v
(cont'd)
24-17
Troubleshooting
DiagnosticTroubleCode (DTCIChart-'96 -'97 Models (cont'dl \
SRSindicatorlight DTC Possiblecause Correctiveaction See page

5-1*'
Internal failure of the SRS unit

S R Su n i t
2 41 6
repracement
5 4
6-1
6-2 SRSunit
lnternalfailureof the SRSunit 24-16
reptacemenl
6-4
7-2 Internalfailureof the SRSunit S R Su n i t

24-76
replacement
comeson 8-1
8-2
8-3 Internalfailureof the SRSunit SRSunit
24-76
replacement
8-4
8-5
Internalfailureof the SRSunitor two failu.esat a
8-6 Troubleshooting 24-62
time
8-6*3 Internalfailureofthe SRSunit S R Su n i t

24-76
replacement
Internalfailureof the SRSunit S R Su n i t

24-16
repracement
FaultySRSpower supply(VBline) Troubleshooting 24-64
SRSunit replacementcode (SRSunit must not S R Su n i t
10-1 2476
be usedany longer) replacement
NOTE:
*11In caseof an intermittentfailureDTC9-1,it meanstherewas
an internalfailureof the SRSunit or a faulty SRSindica-
tor light circuit.Do the troubleshooting
for intermittentfailures(seepage24-15).
*2: lt both DTC9-2 and DTC5-1 are indicated,do the troubleshooting for DTC9-2.
*3: Apply to the '97 modelcoupeHX and DX.
*4: DTCcannotbe readwith a HondaPGMTester;checkby jumping
the SCSserviceconnector.
v DiagnosticTroubleCode(DTC)Ghart-'98 Model
NECSRSUnh
FaultySRSindicatorlight circuit
none*. I FaultySRSindicatorlight circuit,internal

(doesn't I fallureolsRs unit.JaultvSRSpowersupply
No DTC'r
{li9ht
comes on Faulty SRS power supply (VA line) Troubleshooting
Openin the driver'sairbaginflator

lncreasedresistancein the driver'sairbag
inflator
Shortto anotherwire in the driver'sairbag Troubleshooting
inflatoror decreasedtesistance
Shortto power in the driver'sairbaginflator
Shortto ground in the driver'sairbaginflator
Openin the passenger's airbaginflator
v Withoutfront Passenger's airbag:
Open in the dummy resistor
lncreasedresistancein the passonger's airbag
inflator
lncreasedresistanc€ in the dummy resistor
Shon to anotherwire in the passengers
24-52
Troubleshooting 24-59
Withoutfront passenger's airbag:
Shortto anotherwire in the dummy reslslor
or decreasedresistance
I With front Passenger's airbag:
St o.t to power in the passenger'sairbag
I
2-4 inflator
Withoutfront passenger's airbag:
Shortto power in the dummy resistor
With front Passenger's airbag:
Shon to ground in the passenger'sairbag
2-5 Inialor
tvnhout front Passenger's airbag:
Shortto ground in the dummy resistor
v
(cont'd)
24-19
Troubleshooting
DiagnosticTroubleCode(DTC)Chart-,9g Model (cont,dl
SRSindicator light DTC Possiblecause Correctiveaction Ses pago

5-1
Internalfailureof the SRSunit SRSunit
5-4 24-16
repracement
6-1

o-J replacement 24-76
6-4
7-2 Internalfailureof the SRSunit 5l|5 Unrt

replacement 24-76
comeson
8-1
a-2 24-76
repracement
Internalfailureof the SRSunit or two failures
8-6 Troubleshooting 24-62
at a time

reptacement 24-16
9-2*' *1 Internalfailureof the SRSunir SRS unit

24-76
reptacement
SRSairbagsdeployed(SRSunit must be SRSunit
l0-1 24-76
replaced) reptacement
NOTE:
r1: In caseof an intermittentfailureDTC9-1,it meansthere
was an internaltailureof the SRSunit or a faulty SRSindica-
tor light circuit.Do the troubleshooting for intermittentfailures(page24-15).
+2:In caseof an iniermittentfailu.e DTc 9-2, it meansthere was
an internalfailureof the power supply(vB line).Do the
troubleshooting for intermittentfailures.
*3: DTCcannotbe readwith a HondaPGMTester;check jumping
by the SCSserviceconnector,
\
KEIHINSRS Unit
Possiblecause Correctivesction Ses page

SRSindicator light DTC
none
(doesn't FaultySRSindicatorlight circuit Troubleshooting 24-26
doesn'tcome on
come on)
none*3 FaultvSRSindicatorlight circuit,internal
(doesn't failureoJSRSunit,taultySRSpower supply Troubleshooting 24-34
go off) (VB line)
Open in the driver'sairbaginflator 24-42
1-1
lncreasedresistancein the driver'sairbag 24-12
inflator
Short to another wire in the driver's airbag Troubleshooting 24-44
1-3 inflator or decreased resistance
Shortto power in the driver'sairbaginflator 24-46
1-4
24-48
comeson 1,5 Shortto ground in the driver'sairbaginflator
Openin the passenger's airbaginflator 24-50
lncreasedresistancein the passenger's airbag 24-50

inflator
Shon to anotherwire in the passenger's 24-52
2-3 Troubleshooting
Shortto power in the passenger's
airbag 24-54
ry inflator
Shortto groundin the passenger'sairbag 24-56
2-5
inflator
v
(cont'd)
24-21
'...-'--.
Troubleshooting
DiagnosticTroubleGode(DTG)Ghan-'98 Model {cont,d}
sRs indicarortighr I DTc Possiblocause Correstiveaction See page

5-1
lnternalfailureof the SRSunit S R Su n i t

24-76
5-3 replacement
5-4
6-2 SRSunit
Internalfailureof the SRSunit 24-76
6-3 replacement
6-4
comeson Internalfailureof the SRSunit SRSunit

24-76
replacement
1-3
8-'l
8-2 Internalfailureof the SRSunit SRSunit
24-76
replacement
8-6
9 - 1 + 1* 3 Internalfailureof the SRSunit -rI5 untr

24-76
replacement
9-2*, *3 Internalfailureof the SRSunit SRSunit

24-76
replacement
10-1 24-76
reolaced) replacement
NOTE:
*l: In caseof an intermittentfailureDTCg-1,
it meansthere was an internalfailureof the SRSunit or a faulty SRSindica-
tor light circuit.Do the troubleshooting for intermittentfailures(page24_15).
*2: In caseof an intermittentfairure
DTc 9-2, it meanstherewas an internarfairureof the power suppry(vB rine).Do the
*3; DTCcannotbe readwith a HondapGM
Tester;checkby jumpingthe SCSserviceconnector.
24-22
-'-'.-
.J
SIEMENSSRSUnit
Possiblecause Correctiveaction SeL page

SRSindicator light DTC
none
(doesn't FaultySRSindicatorlight circuit Troubleshooting 24-26
doesnt come on
c o m eo n )
none*, I FaultySRSindicatorlight circuit,internal
(doesn't failureof SRSunit,faulty SRSpowersupply Troubleshooting 24-34
go off) (VBline)
24 42
1,1 Openin the driver'sairbaginflator
Shortto anotherwire in the driver'sairbag 24-44
inflatoror decreasedresistance Troubleshooting
1-4 Shortto oower in the driver'sairbaginflator 24 46
24-44
comeson 1'5 Shortto ground in the driver'sairbaginflator
Openin the passenger's airbaginflator 24-50
2-1
Shortto anotherwire in the passenger's 24-52
zr
Troubleshooting
Shortto power in the passenger'sairbag 24-54
t-4
rnltaror
Shortto ground in the passenger's

alrbag 24-56
2-5 inflator
) l/
(cont'd)
24-23
Troubleshooting
DiagnosticTroubleCode {DTC)Chart-'98 Model (cont'dl
SRSindicatorlight DTC Possiblecause Correstiveaqtion See pago

5-l S R Su n i t
Internalfailureof the SRSunit 24-76
5-4 replacement
Internalfailureof the SRSunir S R Su n i t

6-4 24-76
replacement

24-76
replacement
7_?
comeson 8-1
a-2 Internal failure of the SRS unit SRSunit
reptacement 24-76
g _ l* r * 3 Internalfailureof the SRSunit S R Su n i t

24-76
reptacement
9-2*2 *3 l n t e r n afla i l u r eo f t h e S R Su n i t SRSunir

24-76
replacement
10-1 24-76
replaced) replacement
NOTE:
"1: ln caseof an intermittentfailure
DTC9-1,it meansthere was an internalfailureof the SRSunit or a faulty SFS indica-
tor light circuit.Do the troubleshooting for intermittentfailures{page24-15).
*2: In caseof an intermittentfairureDTc g-2,
it meanstherewas an internarfairureof the power suppry(vB rine).Do the
*3: DTCcannotbe readwith a HondapGN4
Tester;checkby jumpingthe SCSserviceconnector.
24-24
SRSIndicatorLightWire Connections
SRS Indicator Light Power Circuit
WIREHARNESS
OASHBOARO
C508 -+ To GAUGEASSEMBLY
To UNOER-DASH
FUSE/RELAYBOX <_
2OPCONNECTOR
C411, C412 : Torminalside of mslo t€rminsls

csor. csoz, csog. c801, c802, c8o7 : wire sidoot f.male to'minals
SRS Indicator Light Control Cilcuit
To SRSUNIT
tI
a.j MAIN WIREHARNESS
SRS MAIN HARNESS
GRY 8LU
IGRN)
c411
GRY I
|GRN) |
_ _ - lI l
+f;I? csol
t--qt
I To GAUGEASSEMBLY
To UNDER-DASH
FUSE/RELAYBOX
2P CONNECTOR
CsO1 : DASHAOARD WIREHARNESS 2OPCONNECTOR C8O2 : SRSMAIN HARNESS3P CONNECTOR

CSO8 : DASHBOABDWIREHARNESS5P CONNECTOR C412 : MAINWIREHARNESS 3P CONNECTOR
v C8O'l : SRSMAIN HARNESS2P CONNECTOR c411 : MAINWIREHARNESS 24P CONNECTOR
'l8P CONNECTOR C5O2 : DASHBOARDwlRE HARNESS2rtP CONNECTOR
C8O7 : SRSMAIN HARNESS
24-25
Troubleshooting
TheSRSIndicatorLight Doesn'tGomeOn
CAUTION:Wheneverthe ignition switch is ON (lll. or
has been turned OFF tor less than three minutes, be
caretul not to bump the SRS unit; the airbag(s)could
accidentally deployand causedamageor iniuries,
Checkthe power supply llu3e):

Turnthe ignitionswitchON (ll),and checkwhetherthe other
indicatorlightscome on or not {brakesystem,etc.).
Do the other indicator lights como on?
YES NO
Checkihe fuse:
Checkthe No.25 (7.5Alfuse in the undeFdashfuse/relav
box.
ls th6 fuse OK?
YES NO
))
Checktho bulb:
Replacethe No. 25 (7.5 A) Iuse, and checkthat the
SRSindicatorlightcomeson.
Doesthe SRSindicalor liqht come on?
I YES No
No. 25 (7.sAl FUSE
END
Checkthe wir€ harnessbetween fuse and gauge assemblyl

Checkfor an open in the wire harnessbetween fuse
No. 25 {7.5A) and the gaugeassembly,and repair.Check
that the sRs indicatorlaghtcomeson.
Doe3the SRSindicator liqhl come on?
II yEs No
END
Checkth€ SRSindicato.lightbutb:
2, Removethe gaugeassembly,
3. Checkfor blownSRSindicatorliohtbutb.
ls the SRSindicator light butb OK?
YES NO
Checkthe SRSindicatorlight circuit:

R e p l a c et h e b u l b , a n d r e c o n n e ctth e g a u g ea s s e m b l y
connectors. Thenturn the ignilionswitchON (tl).
Doesthe SRSindicator light come on?
YES No
:ND
lAl ro page24-27 lBl10 page24-27
, 24-26
I
$
T
J
Frompage24-26 Frompage24-26
I
(A) (B) DASHBOARDWIBEHARNESS
Chockthe SRSindicator light circuit:

1. Disconnectthe dashboardwire harness5P connoctor
from the gaugeassembly
2. Connecta voltmeterbetweenthe No l terminal(+) of
the 5Pconnectorand ground
3. Turnthe ignitionswitchON (ll).and measure
ls there 8.5 V or lgsi tor six soconds aftor the ignition
switch has beon tumed ON
F ulty SRS indicitor light circuit in th6 gauge a$embly;

r€place the SRS plinted circuit board in the 93uge
v
Chsckth. wir6 harnessot the SRSindicator light circuit ll l: MAIN WIREHANNESS
2, Disconnectthe main wire harness24P connectorfrom
the dashboardwire harness
3. Connecta voltmeterbetweenthe No 5 terminal {+) of
the mainwire harness24Pconnectorand ground
4. Turnthe ignitionON {ll),and measurevoltage
ls there 8.5 V or less for six seconds after the ignition
switch has beentumed oN llll?
Short to Dowor in the BLU wire ot the dashboard wire
DASHBOARDWIRE
HARNESS2iIP
CONNECTOR
To page 24-28 c411
(cont'd)
24-27
Troubleshooting
The SRS Indicator Light Doesn't Come On (cont'dl \
Frcm page24-27
Checkth€ wire harnessotthe SRSindicator light circuit (2):

2. Disconnect the SRSmain harness3P connoctorfrornthe
main wire harness,
3. Connecta voltmeterbetweenthe No. 1 terminal(+) of
the SRSmain harness3P connectorand ground.
4. Turnthe ignitionswitchON (ll),and measurevoltage.
ls there 8.5 V or less tor six seconds .tter the ignition
switch has be€n turnod ON llll?
SRSMAIN HARNESS
Shori lo powq in the BLU wire of lhe main wirs hrnolis: 3P CONNECTOR
c802
SRSUN]T
Checkthe wire harnossofthe SRSindicator circuit 13)i

'L Turn
2. Disconnectthe battery nagative cable, then the positive
cable.and wait threeminutes.
3. Disconnectthe drivor's(andfront passenger'slairbagcon-
necto(s)(s6epage2+11).
4. Disconnectthe SRS main harness18p connectorfrom
the SRSunit.
5. Connecta voltmeler betweenthe No. 6 terminal (+) ol
the SRSmain harness18Pconnectorand ground. SRSMAIN HARNESS
6. Turn the ignitionswitchON (ll),and measu.evoltage.There 16PCONNECTOR
shouldbe 0.5V or less.
SRSMAIN HARNESS18PCONNECTOR
SRSunit; roplacotho unit (seepaq6 2+
Short to power in the BLU wire of the SRS main harne$:
24-28
-'97 Models
J The SRSIndicatorLight Doesn'tGo Off -'96
CAUT|oN:whengve'theignitionswitchisoN(l|},olhasbeenturnedoFFfor|ossthanthreeminutes,becarolu|notto
or iniuries'
bump the SRSunit; the airbag(slcould accidentallydeploy and causedamage
Try to reproducotho SRSindicator light:

1. Erasethe DTCmemory (seepage24'15)
2. Turn the ignitionswitch OFF,and wait for ten seconds'
3. Turn th€ ianitionswitchON lll), and checkthat the SRSindi-
cator lighicomes on for about slx seconds and goes otf
Doesthe SRSindicator light stay on?
lntelmittent lailur6, sYstem is OK at lhis time See

Intormittent Failuroson Page2{_15.
ch6ck th6 No. 13 115Al .nd No. 23 (10 Al tuses:

2. Checkfortlown N o . 1 3( 1 5A ) a n dN o . 2 3( 1 0A ) f u s e si n
the under-dash fusekelaYbox.
Replacathe fuses, and erasethe memory No. 13 (15Al FUS€

L Replacethe luses.
2. Connectthe SCSserviceconnectorto the MES con-
nector,
3. Erasethe DTCmemory(seepage24-15)
4. Turn the ignitionswitchOFF,then disconnect the SCS
seryiceconnectorfrom the MES connector' SBS UNIT
v' 5. Turnthe ignitionswitchON lll)
Doesth. SRSindicator light go ofl aftol six soconds? SRSMAIN HARNESS
YES
Confirm tho OTC,snd continuo
Checklo. an open in the SRSmain harnoss{vA lino}:

1. Turn the ignitionswitchOFF
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes
3. Disconnectthe driver's (and Iront passenger's)airbag
connector(s) (seePage24_11).
4. Disconnectthe SRS main harness18Pconnectorfrom
the sRs unit.
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Co-nnect a voltmeterbetweenthe No 7 terminal (+) of
the SRSmain harnoss18Pconnectorand groLlno SRSMAIN HARNESS18PCONNECTOR
7. Turnthe ignitionswitchon
To page 24-30
ODonin th6 SRS main harne3slvA linol; roplacethe SRS
v
(cont'd)
24-29
,_
Troubleshooting
The SRS Indicator Light Doesn't Go Off -'96 - 97 Models (cont'd) \
From page 24-29 SRSUNIT

(A)
SRSMAIN HABNESS
18PCONNECTOR
Checkthe SRSunit:
Connectthe SRSmain harness'l8PconnectorterminalsNo.
6 and No.7 with a iumoerwire and
Faulty SRSunit or pool contact at tho SRSmain harness

18Pconnector;chockthe connoctor.
lfth€ connectoris OK, replacethe SRSunit.
07TAZ- @1020A
JUMPERWIRE
Wiresideot fsmaleterminals
t
OASHBOARDWIRE HARNESS
Frompage24-30
{B)
Chockthe SRSindicator circuit:

1. Turnthe ignitionswitchOFF
2. Removethe gaugeassemblY
NOTE:Do not disconnect the dashboardwire harness5P
connectorfrom the gauge assembly
4. Connectthe dashboardwire harness5P connectortermi-
nalsNo. 1 and No 5 with a jumperwire.
Do.s the SRSindicator light go otff
y;T7f;V4csoe
Llr.-L_v)fr
Fsulty SRS indic.tor light circuit in the g.uge ts3embly; BLU
replace the SRS printed circuil board in the gauge I IYEL
wire.sideof female
JUMPERWIRE termlnals
DASHBOARDWIREHARNESS
Check to. a short to ground in rhe SRS indicator light cir-

cuit:
2. Disconnectthe dashboardwire harness5P connector
3. Checkresistancebetweenthe No. 1 terminal ot the dash-
boardwire harness5P connectorand ground.Thereshould
be 1 Mo or more.
7o page 24-32
Wire side of female

Iermtnats
Checkfor an oDenin th6 SRSindicttor light circuit:
1. Checkresistance betweenthe No 6 terminalof the SRS
main harness18Pconnectorand No 1 terminalof the SRSMAIN HARNESS
,I8PCONNECTOR
dashboardwire harness5P connector;there should be
0 - 1 . 00 .
Wire side of female terminals
(D) (E)
To page24-33 To page24-33
DASHBOARDWIRE HARNESS
5P CONNECTOR
a.t
{cont'd}
24-31
Troubleshooting
The SRS Indicator Light Doesn,tGo Off - ,96 - 97 Models (cont'd)
Frompage24 3l
{c)
MAIN WIREHARNESS
Checkfor a shon to ground in the main wir6 harness:
1. Disconnectthe dashboardwire harness24p connector
from the main wire harness,
2. Checkresistance betweenthe No. 5 terminalof the main
wrre harness24Pconnectorand ground.Thereshouldbe
1 N40or more.
Short to ground in the dashboard wire harness; reoai.

the dashboerdwire harn6ss.
HARNESS
MAIN WIREHARNESS
3P CONNECTOR
Checktor a short to ground in the SRSmain harness:

'1. Disconnect
the SRSmain harness3p connectorfrom the
maanwire harness,
2. Checkresistance betweenthe No. i terminalofthe SRS
main harness3P Connector and ground,Thereshouldbe
1 MOor more.
Short to ground in the main wire ha.ness;r6peir the

main wire harnoss, SRS MAIN HARNESS
3P CONNECTOR
Short to ground in the SnS main harness;replacethe SRS

main harness. Wire side of female
terminals
\,1
DASHBOARDWIREHARNESS
From page 24-31 5P CONNECTOR
(D)
Checkthe SRSindic.to. circuit input voltag€:

1. Reconnectthe SRS main harness18Pconnectorto the
SRSunit.
2. Connecta voltmeterbetweenthe No 1 lerminal l+) o{f
the dashboard5Pconnectorand ground'
3. rurn theisnitionswitchol!!!!jl!lg!:ylly9!j399-
ls thorc 8.5 V or more lix secondsafter the ignhion swhch
has b€enlurned ON (fll7 -
YES NO
The problom ha3 dirappcared due to ditconnecting and

conncqting the connactor3. Bo sure all tgrminal3 makc
oood contact, and racheck the system {sco
iroubleshooting Intermittent Failuros on pago 24'151
Poor contect at tha SRSm.in harncss18Pconnoctor;chock

thc connectot.
. It tho conn6ctori3 OK, substitulc a known-good SRS unit'
and rochock.
. lf th. probl6m is 3till p.es€nt, tepltco the SRS m'in har'
ncss.
Frompage24-31
(E)
SRSMAIN HARNESS
18PCONNECTOR
c807
Checkfor an opsn in tha drshbo.rd wi.o harnos:
1. Oisconnectthe dashboardwire harness24P connector
lrom the mainwire harness
2. Checkresistancebetween the No O terminal of the SRS
main harness18Pconnectorand No 5 terminal of the
m a i n w i r e h a r n e s s2 4 P c o n n e c t o r t; h e r e s h o u l d b e
c411
MAINWIREHARNESS Terminalsideof maleterminals

24P CONNECTOR
Opon in tho BLU wir. ot the dGhboard wire harngis;
thc daahborrd wit6 ha]n.it.
SRSMAIN HARNESS
18PCONNECTOB
Chocktor an opon in tho main wire harness:

1. Disconnect the SRSmain harness3P connectorfrom the
main wire harness.
2. Checkresistancebetweenthe No. 6 terminal oI the SRS
main harness18Pconnectorand No l terminalof the
-
SRSmain harn6ss3P connector;there shouldbe 0 1 0 O
SRS MAIN HARNESS

3P CONNECTOR
Oocn in th€ BLU wi.o of tho mein wire hamess; repalr

thc msin wire haness.
)
Oo6n in tho SRS main ham6r; ropl.ce the SRS main har'
24-33
Troubleshooting
The SRS Indicator Light Doesn't Go Off - ,9g Model
CAUTION:Wheneverthe ignition switch is ON fll), or
has been turned OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator light:

1. Erasethe DTCmemory(seepage24-15).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson for aboutsix seconosano ooes
off.
Doesthe SRSindicator lioht stav on?
Inte.mitlent failure, systom b OK at thi3 tim6. See Trouble-

Int€rmittentFailur€3on page2+lS.
checkthe No. 23 {10Alfuse:

2. Checktor blown No. 23 (10 A) tuse in the under-dash
Replacethe fuse, and erassthe memory No. 23 {10A} FUSE

1 . R e p l a cteh e N o .2 3 ( 1 0A ) t u s e . FUSE/RELAY
BOX
2. Erasethe DTCmemory(seepage24,1S).
Doesth6 SRSindicstor light qo off after six seconds?
Check lor an oDen in the SRS main h.rn6ss [vB line):

1. Disconnectthe battervnegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe driver's (and front passenger's)airbag
connectorls) (seepage24'11).
3. Disconnectthe SRS main harness18Pconnectorlrom
the sRS unir. SRSMAIN HARNESS
4. Reconnectthe batterv positive cable, then reconnectthe 18PCONNECTOF
negativecable.
5. Connecta voltmeterbetweenthe No. 3 terminal (+) of
the SRSmain harness'18Pconnectorand oround.
6. Turnthe isnitionswitchON (il).
18P CONNECTOR
SRSMAIN HARNESS
Open in rhe SRS main harn63s (VB line); replace the
To page24-35
24-34
T
Frompage24_34
(A)
sBsUNIT
Checkthe SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo
adapt
6 and No.3 with a jumperwire and backprobe
Doesthe SRS indicato.light go oll?
YES NO
Faultv SRSunit or poor contact al the SRS main harnass

18Pconnector;checkthe connector.
lf the connectoris OK, replacothe SRSunit
SBS MAIN HARNESS18PCONNECTOR

Did fuse No. 23 (10A) blow?
YES NO
JUMPERWIRE
( Il )
f o p a g e 2 4 ?6
Wiresideot lemaletermanals
Check for a short to ground in the SRS indicator light cir'
cuit:
1. Turnthe ignitionswitchOFF. DASHBOARDWIREHARNESS
2. Disconnectthe dashboardwire harness5P connector 5P CONNECTOR
3. Checkresistance betweenthe No 1terminalofthedash
r nd ground There
b o a r dw i r e h a r n e s s5 P c o n n e c t o a
shouldbe 1 MO or more.
ls the resistanceas specitied?-
YES NO
(c)
Io page 24'37
Short to ground in the gtuge assembly;replacethe gauge
DASHBOARDWIRE HARNESS
5P CONNECTOR
c50a
l of female
(cont'd)
24-35
Troubleshooting
The SRS Indicator Light Doesn't Go Off -'98 Model (cont'dl
From page 24 35 OASHEOAROW|REHARNESS
(B) 5P CONNECTOR
Checkthe SRSindicator circuit:

2 . R e m o v et h e g a u g ea s s e m b l y D
. o n o t d i s c o n n e ctth e
dashboardwire harness5P connectorfrom the gauge

4. Connectthe dashboardwire harness5P connectortermi-
nalsNo. 1 and No.5 with a iumDerwire.
Do6sth6 SRSindicator liqht go oftT
YES NO
Faultv SRS indicator light circuit in the gauge assembly; OASHBOARDWIREHARNESS

roplaca the SRS printed circuit board in the gauge 5P CONNECTOR
assombly.
l;rfr-zr-cuo"
\J#
Bru
I IYEL
Checkfor an open in the SRSindicator light circuit: Wire side of female
1. Turnthe ignitionswitchOFF. JUMPER WtRE tormanats
from the gaugeassembly.
3. Checkresistancebetween the No. 6 termanalof the SRS
main harness18Pconnectorand No. 1 terminalof the SRSMAI[{ HARNESS
dashboardwire harness5P connectorithere should be 18PCONNECTOR
0 - 1 . 00 .
ls the resistancoas 3pecified?
YES NO
Wire sideot temaleterminals
(D) (E)
To page24-38 To page24-38 DASHBOARDWIRE HANNESS
5P CONNECTOR
, 24-36
[r.
\
From page24-35
(c)
Chockfor a short to ground in the main wiro harness:

from the main wire harness
2. Checkresistance beNveenthe No 5terminalofthedash_
bosrd wire harness24P connectorand ground There
shouldbe 1 MO or more.
Short to glound in the dashboard wire hamoss; repail

DASHEOARDWIRE
HARNESS24PCONNECTOR
OASHBOARD WIREHARNESS
24P CONNECTOR BLU
Wire sideof female

lermrnals
MAIN WIREHANNESS
3P CONNECTOR
Checkfor a short to ground in lhe SBS main hamess:

1. Disconnectthe SRSmain harness3P connectorfrom the
mainwire harness
2. Checkresistance betweenthe No. I terminalof the SRS
main harness3P connectorand ground Thereshouldbe
1 MO or more,
SRSMAIN HARNESS
3P CONNECTOR
Short to ground in tho main wire herness;rspair ihe

SRSMAIN HARNESS
3P CONNECTOR
c802
Short to glound in the SRS main harness;repl.ce the SRS
(cont'd)
24-37
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -'98 Model (cont,d)
Frompage24-36
rD) DASHBOARDWIREHARNESS
5P CONNECTOR
Checkthe SRSindicato. circuit input voltago:

'1. Reconnect
the SRS main harness1gPconnectorto the
SRSunit.
2. Connecta voltmeterbetweenthe No. I terminal{+) of
the dashboard5P connectorand ground.
3. Turn the ignition switch ON (lli, wait for six seconds,
then measure
ls there 8.5 V or moreT
The problem has disappeareddue to disconnectingand

connecting the connoctors. Be sure all terminals make
good contact, and recheckthe sy3tem ls6e Trouble-
Intermittent Failuleson paqe 24-
DASHBOARDWtREHARNESS
Poor contact ai the SRSmain h.rness 18p connector;check 5P CONNECTOR
the connoctor.
. lf ihe connector is OK, subslituto a known-good SRS unit,
c508
and recheck.
. It the problem is still presont, repbce the SRS main har-
ness.
Frompage24 36
Check lor an open in th€ dashboa.d wire narness:

SRSMAIN HARNESS
1, Disconnect the main wire harness 24P connector from
lAP CONNECTOB
the dashboard wire harness.
2 . C h e c k r e s i s t a n c eb e t w e e n t h e N o . 6 t e r m i n a l o f t h e S R S c807
main harness 18P connector and No. 5 terminal ofthe main
wire harness 24P connector; there should be 0 - 1.0 0.
ls the resistanceas sDecifiedT
YES NO
c411
Open in the BLU wire of the dashboard wire harness;

repairthe dashboardwire ha.noss.
Checktor an open in the main wire harnsss:
1. Disconnectthe SRSmain harness3p connectorfrom the
mainwire harness,
2. Checkresistance betweenthe No_6 term;nalof the SRS SRSMAIN HARNESS
mainharness18Pconnector and No. 1 terminalot the SRS 18PCONNECTOR
main harness3Pconnector;there shouldbe 0 _ 1.0O.
ls the resistance as soecified?
YES NO
Open in the BLU wire of the main wire harness;reDair c802

the main wire harn6ss.
SRSMAIN HARNESS
3P CONNECTOR
Open in the SRS main harnoss; replace the SRS main har-
243A
\
\
No DTC-'98 Model
CAUTION:Wheneverthe ignition switch is ON (ll), or
accidentallydeployand causedamageor iniuries'
Check the fu3e:

Check for blown No. 13 (15 A) {use in the under-dash fuse/
(A)To page24-40
R e p l a c et h e f u s e . T u r n t h e i g n i t i o n s w i t c h O N { l l ) , a n d c h e c k
thatthe luse doesn'tblow.
No. 13 (15A) FUSE
The problom has disappearedTest'driveth€ vehiclo and

s€eTroubleshootingIntermittentFailureson Page2+15'
Check for short to ground between the undet-dash fuse/

relay box and the SRSunit.
the positivecable,and wait for threeminutes
3, Disconnectthe driver's (and front passenger'sairbag)
connecto(s)(seePage24'11)
4 . Disconnectthe SRS main harness18Pconnectorlrom
the sRS unit.
5 . Checkresistance betweenthe No 7 terminalof the SRS sRs
main harness18Pconnectorand ground 18PCONNECTOR
Thereshouldbe 1 MO or more
ls the resistanceas specified?
FauftySRSunit; replacethe SRSunit {seepage21'761'
J {B) (cont'd)
To page24-40
24-39
Troubleshooting
No DTC-'98 Model (cont'd)
trom page 24-39
1B)
Chacktor short to ground in the SRSmain harness:

1. Disconnectthe SRSmain harness2P connectorfrom the
under-dashluse/relaybox.
2. Checkresistancebetween the No. 7 terminal of the SRS
main harness18Pconnectorand ground.Thereshould
be 1.0MO or more.
Short to ground in tho unde.-dash fuse/r6lay box;
Short to ground in the SRS main harnoss;.eplace thc SRS

mein halno3s. SRSMAIN HARNESS
2P CONNECTOR FUSE/RELAY
BOX
SRSMAIN HARNESS
18PCONNECTOR
c807
(A)Frompage24-39
Checklor an opgn in the SRSmain hrlness:

2. Disconnectthe battorynegativecable,th€n disconnect
3. Disconnectth6 driver's land front passenger's)airbag
conneclor(s) (seepage24-11).

negativecable.
6. Connect a voltmeter b€tween the No. 7 terminal oI the
SRSmain harness18Pconnectorand oround.
7. Turnthe ignitionswitchON (ll),and measure
SRS MAIN HARNESS

18P CONNECTOR
Poor conlact at ths SRS main harnoss 18P connoctor;
checkthe connoctoa, caoT
. lf the connector is OK, sub3tituta a known-good SRS
unit. and rschack.
' lf the p.oblem is still prosent, raplaca lhe SRS main
harness.
To page24 41
24-40
\
From page24'40
Checkfor an oDenin the SRSmain ha.ness:

2, Disconnectthe SRSmain harness2P connectorfrom the
undeFdashfuse/relay box.
3. Checkresistance betweenthe No. 1 terminalof the SRS
main harness2P connectorand No. 7 terminal of the
SRSmain harness18Pconnector.
Thereshouldbe 0 0.5o.
Poor contact at the SRS main harness2P connector;

checkthe connector.
. lf the connector is OK, substitute a known-good under' FUSE/RELAY
BOX
dash fu3e/relaybox, and recheck.
. It lhe problem is still present, replace the SnS main
harness.
SRSMAIN HARNESS
18PCONNECTOR
caoT
Open in the SRS main harness;replacethe SRS main har'
ness,
SRSMAIN HARNESS
2P CONNECTOR
24-41
Troubleshooting
DTC1-1and DTC1-2
CAUTION:Wheneverthe ignition switch is ON (tt),or DRIVER'SAIRBAG DRIVER'SAIRBAG
2P CONNECTOR ASSEMBLY
has besn tulned OFF lor less than three minut€s, be
carelul not to bump the SRS uniti the airbag(slcould
accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator lighti

1. Erasethe DTCmemory{seepage24,15i.
2. Turnthe ignitionswitchON {ll),andcheckthattheSRSindi-
catorlight comeson for aboutsix secondsand goesoff.
Doe3the SRSindicaror light stay on?
CABLEREEL
YES NO 2P CONNECTOR
Int€rmittem tailure, svstem is OK ai thb time. S6eTroublr

shooting Intermittent Failuroson page 2G15.
07TAZ- SZ5011A
Ch€cktor an opon in the driver's airbag inflator and SRSINFLATOR
1. Turnthe ignitionswitchOFF. SIMULATOR
2. Disconnectthe batterynegativecable,then disconnectthe {2 0 JACK)
positivecable,andwait for threeminutes. 07sAz - TB401rA
3. Disconnect the driver'sairbag2Pconnector from the cable
reel 2P connector,
CAUTION:Do not disconnectthe psssenger'sairbagcon-
nec{or,
4. Connectthe specialtool (2 O)to the cablereel2Pconnec
SRSSERVICE
tor. (2 0l
5. Beconnectthe battery positive cable,then reconnectthe
CoNNECTOR
negativecable. 07TAZ- 5250200
7. Readthe DTC(seepage24 13i.
ls DTC1-1 or DTC1-2 indicatod?
YES NO
Opon or increasedaesidancein the driver's airbag infla-

tor;.eplace th€ driver'sairbagessemblv(seepase 2+671. SRSMAIN HARNESS
2P CONNECTOR
Chocklor sn open in the cable reel: CABLE

l- Disconnectthe batterynegativecable,then disconnect REEL
the positivecable,and wait for threeminutes. 2P CONNECTOR
2. Disconnect the specialtool (2 0) Irom the cable reel 2P
connector.
3. Removethe dashboardlower cover,and disconnectthe
cablereel2P connectorfrom the SBSmain harness.
4. Connectthe specialtool (2 0) to the SRS main harness
2P connector. {cont,d} SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
fo page 24'43
SIMULATOR
t2 0 JACK)
07sM - T84011A
SRSSERVICE
CONNECTOR {2 O'
07TAZ- 5250200
24-42
1
Frcm page 24-42
Checkfor an opon in the cable loel (cont'd)

5. Reconnectthe batterv positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemorylseepage24-15).
7. Readthe DTC{seepage24-13).
ls DTC1-1 or DTC 1-2 indicated?
YES NO
Ooen or increased rcsisttnce in the cable reel; replace

the cable reel (see paq€ 24-721.
Checktor an oDenin ths SRSmain hamo3s:

2. Disconnoctthe front passenger'sairbag connectorftom
the SRSmain harness(withfront passenger's airbag)
the SRS unit. Do not disconnectthe specialtool (2 O)
from the SRSmaln harness2P connector'
4. Checkresistance betweenterminalsNo 1 and No 13 of
the SRSmain harness18Pconnector.
Thereshouldbe approx.2.0- 3.0o.
ls the residance as specitied?
YES NO
Poor contac't at the SRS main harnoss 18P connoctor;

chockthe connector.
. lf the connodor is OK. substitute a known_goodSRS
unh. and recheck.
.ll lhe problem b still prelenl, replacetho SRS main
haaness.
Op6n or increasedresi3tsncoin the SRS main harness;

replacethe hlmess,
24-43
Troubleshooting
DTC1-3
CAUTION:Wheneverthe ignition switch is ON (lll, ol DRIVER'SAIRBAG DRIVER'SAIRBAG
has been tu.ned OFF for less than three minutes, be 2P CONNECTOR ASSEMBLY
caretul not to bump the SRS unit; the airbag{s)could
accidentally deployand causedamageor iniuries.
Tryto r€producetha SRSindicator light:

2. Turnthe ignitionswitchON (ll),andcheckthattheSRSindi
Doesihe SRSindicator light stay on?
YES NO CABLE
REEL
2PCONNECTOR
lr e.mittent failure,systomis OK at this limo. S6eTrouble-
shooting Intermittent Feilureson page 2il-15.
Checklor a short to another wire in the driver's airbao infla-

07TAZ- SZ5011A
lor:
and SRSINFLATOR
SIMULATOR
the positivecable,and wait for threeminutes. 120 JACK)
07saz - T8401'tA
3. Disconnectthe driver's airbag 2P connectorlrom the
cablereel2P connector,
CAUTION:Do not disconnectthe passenger'sairbag
connector. a
4. Connectthe specialtool (2 0) to the cablereel2Pconnec- 5(\ sRssERvtcE
tor. \ \
5. Reconnect the baftervpositivecable,then reconnectthe \,/' coNNECToR12ol
negativecable. 07TAZ - 5250200
6. Erasethe DTCmemory(seepage24 15).
7. Beadthe DTClseepage24 13).
ls DTC1.3 indicatod?
YES NO
Short in the driver's airbag inflator; replacelhe driv-

er's airbag assembly(seepaqe 24-67). S8S MAIN HARNESS
2P CONNECTOR
CABLE
REEL
2P CONNECTOR
Checktor a short in the cable reel:

2. Disconnect the specialtool (2 0) from the cable reel 2P
SRSSIMULATOR
3. Removethe dashboardlower cover,and disconnect the
LEADC
cablereel2P connectorfrom the SRSmain harness,
07TAZ- SZ5011A
4. Connectthe spacialtool (2 0i to the SRS main harness
(cont'd) and SRSINFLATOR
2P connector,
SIMULATOR
120 JACK)
07sAz - TB4011A
or
To page24 45
,^F--.- SRSSERVICE
coNNECTOR{2 0)
07TAZ - 5250200
24-44
\
Frompage24-44
Checkfor a shon in the c.ble tool lcont'd):

negativecable.
6. Erasethe DTCmemorv(seepage24-15).
7. Readthe DTC{see page24-13).
Short in lhe cablo rool; replac€ the cable re6l (see
SRSUNIT
Chocktor a short in tho SRSmtin harn$s:

1. Disconnoctthe bafterynegativecable,then disconnect
the Dositivecable,and wait for threeminutes
2. Disconnect the front passenger's airbagconnectorfrom
the SRSmain harness(with front passengor'sairbag)
the SRS unit. Do not disconnectthe specialtool (2 0)
lrom the SRSmain harness2P connector'
4. Checkresistance betweenterminaisNo. 1 and No 13 of
the SRSmain harness18Pconnector.
Thereshouldbe aPDrox.2.0 - 3.00.
SRSuniu replac. th. SRSunit lse6 pagG2+
Short in the SRS main hamo3s;roplacetho SRS mtin har-
24-45
Troubleshooting
DTC1-4
DRIVER'SAIRBAG
CAUTION:Wheneverthe ignition switch is ON fll), or ASSEMBLY
carefulnot to bump the SRS unit; the airbag{s)could
accidentallydeployand causedamageor iniuries.
Try to reproducethe SRSindicator light:

1. ErasetheDTCmemory(seepage24 15).
2. Turnthe ignitionswitchON (ll),andcheckthattheSRSindi
catorlight comeson for aboutsix secondsand aoesoff,
Doesthe SRSindicrtor liqht stav on?
CAELEREEL
NO 2P CONNECTOR
Intormittentfailure,sydem is OK atthis time. S€eTrouble-

Inlermittent Failureson page 24-15.
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
Checkfor a shon to power in the driver's airbag inflator: and SRSINFLATOR
1. Turnthe ignitionswitchOFF. SIMULATOR
2. Disconnectthe batterynegatave cable,then disconnect {2 0 JACKI
the positivecable,and wait lor threeminutes. 07sAz - TB401lA
3. Disconnectthe driver's airbag 2P connectorfrom the
cablereel2P connector.
CAUTION: Do not disconnect the passong€r,s airbag
connactor.
4. Connectthe SRSserviceconnector(2 O)to the cablereel SRSSERVICE
2P connector. CoNNECTOR {2 0}
5. Reconnectthe battery posiitive cable,then reconnectthe 07TAZ- S250200
negativecable.
7. Readthe DTC(seepase24 t3).
Short to power in the driver's airbag intlator; replace

SRSMAIN HARNESS
2P CONNECTOR
CABLE
REEL
2P CONNECTOR
Check lor a short to power in the cable r€el:

1. Disconnect the battery negative cable, then disconnect
the positivecable,and wait for three minutes.
SRSSIMULATOR
2. Disconnectthe special tool (2 0) from the cable reel 2p
LEADC
07TAZ- SZ5011A
3. Remove the dashboard lower cover, and disconnect the
and SRSINFLATOR
cable reel 2P connector from the SRS main harness.
SIMULATOR
4. Connect the specjal tool (2 O) to the SRS main harness
2P connector, {2 0 JACK)
(cont,
07sAz - TB4011A
fo page24-41
---
"*" ,a"u,"a
GoNNECTOR{2 O)
07f az - s250200
24-46
L
\
Frompage24-46
Check for a short lo power in tho cable reel {cont'dl:

5 . R e c o n n e c tt h e b a t t e r y p o s i t i v e c a b l e , t h e n r e c o n n e c t t h e
n e g a t i v ec a b l e ,
6 . E r a s et h e D T C m e m o r y ( s e e p a g e 2 4 - 1 5 )
7. Readthe DTC(seePage24'13)
ls DTC 1nl indicated?
Short to power in the cable reel; replace the cable reel
SRSUNIT
Checkfor a short to power in th€ SRSmain hatness:

1.Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes'
2. Disconnectthe front passenger's airbagconnectorfrom
the SRSmain harness(withlront passenger's airbagi
3. Removethe specialtool (2 0ifrom the SRSmain harness
2Pconnector. 'l8P connectorlrom
4. Disconnectthe SRS main harness
the sRS unit.
5. Reconnect the batterYpositivecable,then reconnectthe
negativecable.
6. Co-nnecta voltmeterbetweenthe No 1 (+) terminal of
the SRSmain hatness18Pconnectorand bodv ground'
7.Turn the ignilion switch ON (llr, and measurevoltage'
Thereshouldbe 0.5V or less
L Turnthe ignitionswitchOFF.
9. connect; voltmeterbetweenthe No 13 (+) terminalof
the SRSmain harness18Pconnectorand bodyground
lO.Turn the ignitionswitch ON (ll), and measurevoltage
Thereshouldbe 0.5V or Iess
Short lo power in lhe SRS main harness;leplace the SRS
24-47
Troubleshooting
DTC1-5
DRIVER'SAIRAAG DRIVER'SAIRBAG
CAUTION:Wheneverthe ignition switch is ON (lll, or 2P CONNECTOR ASSEMBLY
has been turned OFF lor less than three minutes, be
caretulnot to bump the SRS unit; the airbag(s)could
accidentallydeploy and causedamagc or iniuries.
TrVto reproducetho SRSindicator lightl

1. Erasethe DTCmemory(Seepage24 15).
2. Turnthe ignitionswitchON {ll),andcheckthatthe SRSindi,
cator light comes on for about six seconds and goes off.
Do6sthe SRSindicator liqht 3tev on?
lmehittent tailure, svstem is OK at tfiis timc. See lrouble-

Intermittent Failureson Daqe24-15.
Checkfor a short to ground in the driver's airbag intlator:

3. Disconnectthe driver's airbag 2P connectorfrom the
cablereel2Pconnector.
CAUTION:Do not disconnoclthe passangei'3airbag a
connoctot,
4. Connectthe specialtool (2 0) to the cablereel2P connec, %.. sRssERvrcE
tor. \ \
\,/ CoNNECTOR t2 0l
5. Reconnectthe battery positive cable, then reconnectthe 07TAZ- 5250200
negativecable.
7. Readthe DTC{seepage24,13).
Short lo ground in the ddvo.'s airbag inflator; replacethe

SRSMAIN HARNESS
2P CONNECTOR
CABLE
REEL
Ch6ckfor a short to ground in the cable reet: 2P CONNECTOR
L Disconnectthe batterynegativecable,then disconnect
2. Disconnect the specialtool (2 0) from the cablereel 2P
connector,
3. Bemovethe dashboardlower cover,and disconnectthe
cablereel2Pconnectorfrom the SRSmain harness. SRSSIMULATOR
4. Connectthe Specialtool (2 O) to the SRSmain harness LEADC
2Pconnector(cont'd). 07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
{2 0 JACK)
07sAz - TB4o11A
To page24-49
^P*---.-
( -, sRssERvrcE
coNNECTOR
t20t
07TAZ - 5250200
24-48
\__
\
From pag€ 24-48
Ch.ck for ! Bhortto gtound in tho clble rool (cont'dl:

5. Reconnectthe batt€ry positive cable, then reconnectthe
negativecabl€.
6. Erasethe OTCmemory(seepage24-15).
7. Readth6 DTC{seepage24-13).
ls OIC 1-5 indicrtodT
YES NO
Short to ground in the ctble r.cl; t.Placo thc cable teol

{3o. psse 24-721.
SRSUNIT
Chcckfor a lhort to ground in tho SRSmain hlrn.ss:
the positivecable,and wait for three minutes'
o 2. Disconnectthe lront passenger'sairbag 2P connector

f r o m t h e S R S m a i n h a r n e s si w i t h t r o n t p a s s e n g e r ' s
airbag).
3 Removothe specialtool (2 0)Irom th6 SRSmain harness
2P connector.
4. Checkresistancebetweenthe No- 1 terminal of th€ SRS
main harness18Pconnectorand ground,and between
the No. 13terminalof the SRSmain harness18Pconnec-
tor and ground.
Thereshouldbe 1 Mo or more.
b th. r$bt.nc6 13 spocifiod?
YES
SRSunit;6pl.ce th. SRSunit l3eo page 2&
Shon to ground in tho SRS m.in harne3s;iopl.co the SRS

main hrrn.3s.
24-49
Troubleshooting
DTC2-1and DTC2-2 -Wath FrontPassenger's
Airbag
CAUTION: Whenever tho ignition switch is ON { }, or
has been turned OFF for less th8n thre€ minute3, be
accidentallydoploy and causedamage or iniuries.
Trv to reproducethe SRSindicstor light:

1. Erasethe DTCmemory(seepage24,15).
2. Turnthe ignitionswitchON (ll),and checkrhattheSRSindi-
YES NO
Intermiftcm tailure, 3ystem is OK at thb lime. S6e Trouble

shooting Intermittent Failureson pag6 2+15.
Checklor an open in the passenger'sairbag inllator:

2. Oisconnect the batterynegativecable,then disconnect
3. Disconnectthe front passenger'sairbag connector from
the SRSmain harness(seepage24-11).
4. Connectthe specialtool (2 O) to the SRSmain harness
2P connector.
CAUTION: Do not disconnocttho driver's airbag connec-
tor.
negativecable.
7. Readthe DTC(seepag€24-13).
ls DTC2-1 or DTC2-2 indic.t6d?
YES NO
SRSSERVICE
CoNNECTOR t2 0l
Open or increas€dresiitance in lhe prssenger's airbag 07TAZ- SZ5m00
intlator; replec6 the pa3sgnger'sairbag e3sombly lsee
page 24-67).
To page24'51
24-50
\
E\
From page 24-50
Chackfor rn ooen in ths SRSmain hatnossi

'1. Disconnectths bafteryn€gativecable,then disconnect
the positivecable,and wait tor threeminutes.
2. Disconnectthe driver's airbag 2P connectorlrom the
csblereel2Pconnector{seepage24-11).
the SRS unit. Do not disconnectthe specialtool {2 0)
from the SRSmain harness2P connector'
4. Check@sistancebe8voenthe No. 10 terminal and No. 14
terminalof the SRSmain harness18Pconnector.There
shouldbe aDorox.2.0 -3.0 o.
ls tho r4irtance a3 3pecifiad?
SRSUNIT
YES NO
'l8P connector;
Poor conlact at lhe SRS mtin ha]ngss
ch.ck tho conn€ctor.
. lf the connoctol is OK, subitituta . known-good SRS
unit, .nd rochcck.
.ll lh. probl6m is still ptesont, replsce the SRS main SRSMAIN
hatnas!!. 18PCONNECTOR
Opcn or incrarsad re3ist!nc6 in tha SRS m.in harnoss;

rcplac! tho harnots.
24-51
Troubleshooting
DTC2-3- With FrontPassenger's
Airbag t
CAUTION: Whsnevor the ignition switch is ON ([), or
has been turned OFFfor l6ss than th.6€ minut6s. be
caretul not to bump tho SRS unit; the airbags could
accidsntallydaploy and caus6damage or iniuries.
Tryto roproduc€tho SRSindic.to.light:

1. Erasethe DTCmemory (ssepage2+15).
2. Turn the ignitionswitchON { ), and checkthat the SRSindi-
c6torlight comeson for aboutsix secondsahd goes off.
Oo.3 tho SRSindic.tor light ltrv on7
Into.mitt.nt tailurc, rwtam b OK st thb tim6, S.e Troublo-

Intermittont Friluraa on gaqe 24-15.
FRONTPASSENGER'S
AIRBAG2P CONNECTOR
Chack to. . Bhon to another wir. or docroasod r$irtanca in

tho pr3sgngor'r airbag intlator:
2. Disconnectthe batterynegativecable.then disconnect
the positive cable.and wait for three minutes.
3. Disconn€ctthe tront passenggr'sairbag 2P connector
trom the SRSmain harn€ss{seepage24-11).
2P connector,
CAUTION: Do not dbconnect tho driver'r airbag connoc-
tor.
negativecable.
6. Erasethe DTCmemory(seepase24-15).
7. R6adthe DTC(see pag'e24-131.
Short to anothoi wi.e or docrgagodr63btancoin the par-

sangg/s airbf,g inflator; roplaco thg passongor,r ai.b6g
SRSSERVICE
To page 24-53 CoNNECTORt2 0)
07TAZ - 5250200
24-52
\ _
\
Frompage24-52
Chock for a lhort to anothor wiro or dacrcatad lotittancc in

th. SRSfi.in hamo3s:
1. Disconnectth6 batterynegativecable,then disconnect
the positivecable.and wait for three minutas' SRSMAIN HARNES9
2. Disconnectthe driver's airbag 2P connectorfrom the 18PCONNECTOR
cablereel2P conngctor. 'l8P conngctorfrom
3. Disconnectthe SRS main harn6ss
the SRSunit. Do not disconnectthe specialtool (2 O)from
the SRSmain hsrness2P connedor'
4. Checkresistance betweenthe No. 10terminaland No 14
terminal of the SRS main harness 18Pconnector' Thsre
shouldbg approx 2.0
b thc .eai3tlnca ss aPacifiad?
YES NO
F.ultv SRSunit; r.pl.c. th. SRSunh l3.e prge 2il'761
Short lo anolhar wiro or docrgatod rasist'nc' in th' SRS

mlin ha.n.!3; rcpllco th! SBq!q!L!g!9!a--
24-53
r-
Troubleshooting
DTC2-4 - With Front Passenger'sAirbag
CAUTION:Whenevertho ignition switch is ON (ll), or
has been turned OFF for less thar thrse minutes. be
careful not to bump the SRS unit; the airbsgs could
accidentallydeploy and caus€damag€ or iniu.ies,
Try to reproducotho SRSindicator light:

1. Erasethe DTCmemory (se€page24-15).
2. Turn the ignitionswitchON (ll),and checkthatthe SRSindi-
YES NO
lrtermittont fsilure, 3ystom is O|( at this time. Se€Trouble-

shooting Intormittent Failuroson pago 2{-15.
FRONTPASSENGER'S
Ch6ckfor a shon to powsr in the psssengor'sairbag infla- AIRBAG2P CONNECTON
lor:
2. Disconnoctthe bafterynegativecable,then disconnect
the positive cable,and wait tor three minutes.
3. Disconnectthe tront passenger'sairbag 2P connector
from the SRSmain harnesslseepage24'11)-
2P connector.
CAUIION: Oo not disconnestthe d.iver's airbag connoc-
tor.
5. Reconnect the batterypositivecable,then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24 15).
7. Readthe DTC(seepage24 13).
ls DTC2-4 indicat.d? HARNESS
2P CONNECTOR
YES NO
SBSSIMULATOR
LEADC
07TAZ- SZ5011A
.nd SRSINFLATOR
Short to pow.r in the p.$eng6r's airbag inflator; .cplace SIMULATOR
thg pa$enger's airbag a$ombly {s.e p.ge 24-67). (2 0 JACK)
07sAz - TBa011A
To page 24-55 /,4\ sRs SERV|CE

( - /,/ GoNNECTOR t2 0l
07TAZ- SZso200
24-54
N-_
a
Frompage24 54
Chocklor a short to oower in tho SRSmain harn€ss: SRS UNIT

the positivecable,and wait lor threeminutes.
2. Disconnectthe driv€r's airbag 2P connectorfrom the
cable reel 2P connector.
the SRSunit.
4. Removethe specialtool (2 O)from the SRSmain harness
2Pconnector,
5. Reconnectthe battery oositive cable, then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 10 (+) terminalol
SRSmain harness18Pconnectorand ground.
7. Turn the ignition switch ON (ll), and measurevoltage.
Thereshouldbe 0.5V or less.
L Connecta voltmeterbetweenthe No. 14 (+) terminalof
the SRS main harness18Pconnectorand ground,and
measurevohage.Thereshouldbe 0.5V or less.
SRSunit; rsDlacetho SRSunit (s€opage 24'76)
main harness;replace tha SRS
24-55
Troubleshooting
DTC2-5- With FrontPassenger's
Airbag
CAUTION: Whenever the ignition switch is ON 0ll. o.
has been turned OFF for less than thros minutos, be
aqcidentallydeploy and causedamage or iniuries.
Try to roproducetho SRSindicator light:

1. Erasethe DTCmemory (seepage24-1S).
2. Turn the ignitionswitchON 0t),and checkthat the SRSindi_
catorlight comeson for aboutsix secondsand aoesotf.
Doostho SRSindicator light stsy on7
YES NO
Intermittent feilurc, syrtem is OK at this timo, SeeTroubl.-

shooting Intormittont Failureaon page 24-lS.
Chockto. a short to ground in tho passongs/sairbagir ator:

the positivecablo,and wait for threeminutes.
3. Disconnectthe tront passengsr'sairbag 2p connoctor
from the SRSmain harness(seepage24,11).
4. Connectthe specialtool (2 0) to the SRS main harnass
2P connector,
CAUTTON:Do not disconnectthe drivor.sairbrg connec-
loa,
negativecable.
6. Erasethe DTCmemory {see page24,15).
7. Readthe DTC(seepage24-13).
b DTC2-5 indicatod?
YES NO
Shon to ground in the pa*lengart airbrg inflator;raplac6

the pa3r6nge/i ailb.g '3.ombly lsoo pago 2+67),
SRSSERVICE
CoNNECTOR(2 0l
To page24-57 07TAZ - 5250200
24-56
N-
\ I
From page 24-56
Cha.t to. a ahon to ground in th. SRSmrin harnda: SRSUNIT

1. Oisconnecithe banery negativecable,then disconnect
the positivecable,and wail tor threeminules.
2. Disconnectthe driver's airbag 2P connectortrom the
cable reel 2P connector.
3. Oisconnccl tha SRS main harnass 18P connector from
!\. s s u^n
a Rarnoyr thc sp6itl tool {2 O)from the SRSmain harness
2P @nn€ctor.
5 Checl resistancebetweenthe No 10terminaloftheSRS
maanharness18Pconnectorand ground,and between
rhe No. l4 terminalol the SRSmain harness18Pconnec'
lor and qround. There should be 1 MO or more.
b tha l.aaat|nc! !3
YES
Shon lo ground in th. SRS mein h.m6s; replacothe SRS

mlin ham6a.
24-57
- /
1.3T
Troubleshooting
DTC2-1and DTC2-2- Without Frontpassenger,s
Airbag
CAUTION:Wheneverrhe ignition switch is ON ( ), or
hrs been turned OFF for less than three minuies. be
cr.etul not to bump the SRS unit; the ailbag could acci.
dentally deploy and causedamage or injuries.
Try to reproducothe SRSindicstor light:

1. Erasethe DTCmemory{seepage2+15).
2. Turn the agnitionswitchON 0), and checkthattheSRSindi_
catorlight comeson tor abootsix secondsand goesoff. SRSUNIT
Doesthe SRSindicator lisht stav on?
lntormittent failu.e, system is OK at this time. See Trouble.

Inte.mittent F ilures on paq€ 24-15.
DUMMY RESISTOR
Check for .n open or increased rosistance in th€ dummy

lesistori
SRSMAIN HARNESS
2. Removethe dummy resistortrom the SRSmain harness
2P CONNECTOR
2P connector.
3. Checkthe resistance betweenthe A and g terminalsof
the dummy resistor.Thereshouldbe 1.5 2.50.
ls the r€sistanc€as sDecifiod?
DUMMY
REStSTOn
Checkfor an open or increasedrcsistancein the SRS main

harness:
1- Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threemtnutes.
2. Disconnectthe driver,s airbag 2p connectorfrom the
cablereel2P connector{seepage24-11).
3. Disconnectthe SRS main harness1gp connectorfrom
the sRs unit.
4. Connectthe dummy resjstorto the SRSmain harness2p
connector.
5. Checkresistance betweenthe No. l0terminal andNo. 14
terminalof the SFS main harness1gp connector.There SRSMAIN HARNESS
shouldbe approx.1.5- 2.50. 18PCONNECTOR
Poor contect at the SRS m.in hamess lBp connector;

ch€ckthe connector,
. It lhe connector is OK, substituto a known-good
SRS
unit. and recheck.
. It lhe problem is stilt present. replaco the SRS
main
haaness.
Open or incre.sed re3istancein tho SRS main harness;

th€ harness.
24-58
ffi
DTC2-3- Without FrontPassenger's
Airbag
CAUTION: whensver ths ignition switch is ON (ll), or
has been turned OFF tor l€3s than three minutes, be
careful nol to bump th€ SRS unit; lhe airbag could acci-
d€ntally daploy and caus€damag€ or iniuries.
Try to rep.oduc. th. SRSindicatot ligM:

1. Eraseth€ DTCmemory {seepage24-15).
2. Turn the ignitionswitchON (ll),and checkthat the SRSindi-
com6son lor aboutsix secondsand gogsoff
Doo! th. SRSindicltor light stey on?
SRSUNIT
lntarmittont leilure, 3ystam i3 OK at this time. See

Intormittgnt Failutoson page 2+15.
Chackfor a rhort to anothar wits or d6ctcarod ]$btance in

the dummy la5i3tor:
1. Turnthe ignitionswitchOFF. DUMMY RESISTOR
2. Remov6the dummy resistorfrom the SBSmain harness
2P connsctor.
3. Checktho resistancebetween the A and B tsrminals of
the dummv resistor.Thereshouldbe 1 5 - 2 5 0.
13tho rgsistancg as 3pocified?
SRSMAIN HARNESS
2P CONNECTOR
Chacklor a ahort to rnothd wile or dccreasedrelbtance in

the SRSmain harn6s: SRSUNIT
the Dositivecable,and wait for threemanutes
2. Disconnectthe driver's airbsg 2P connectorfrom the
cablereel2P connector(seepage24-111
the SRSunit.
NOTE: Do not connoctthe dummy resistorto the SRS
msin harness2P connector,
4. Checkresistancebetw€onthe No. 10 terminal and No. 14
terminalof the SRSmain harness18Pconnector'There
shouldbe 1 M0 or more.
SRSMAIN I.IARNESS
18PCONNECTOR
F.ulty SRSunit; lepl.co the SRSunit lso6 pege 24'76).
Short to anothar wirc ot decro.sed resbtence in the SRS

mrin hsrnoaa;taplacoths SRSmain harness.
24-59
- t
Troubleshooting
DTC2-4- Without FrontPassenger,s
Airbag I
CAUTION: Whenever the ignition switch is ON llll, or
has be6n turned OFF for less than ihreo minutes, be
careful not bump tha SRS unit; the sirbag could acci_
dentally doploy and cau3€damago or iniuries.
Try to rep.oducothe SRSindicator light:

1. Era€ethe DTCmemory {s6epage24-15).
2. Turnthe ignitionswitchON 0t),and checkthatthe SRSindi_
Do.i the SRSindic.tor light stly on?
YES NO
SRSUNIT
Intormltlont failur., 3yrtom b OK !t thb tim.. S.e Troubl6.
thooting Int.rmittent Failuroson p.g.2+tS.
Chockfor a short to power in th. SRSmjn h.rno3ii

1. Disconnectthe battery negativd cable, then disconnect
the positivecable,and wait for three minutes.
2. Disconnectthe driver.s airbag 2p connectorfrom the
cable reel 2P connector(seepsge 2+1.1). SBSMAIN HARNESS
3. Disconnectthg SRS main harnesslgp connectorfrom 18PCONNECTOR
the SRSunit.
4. Feconnectthe battery positive cable, th€n reconnectthe
negativecable.
5. Connecta voltmeter between th€ No. 10 (+) terminal ot
the SRSmain harness18pconnectorano grouno.
6. Turn the ignitionswitch ON ll, and moasurevoltage.
There should be 0.5 V or less.
7. Connecta voltmeterbetweenthe No. 14 (+) terminalof
the SRS main harness18p connectorand ground,and
measurevoltage.Thereshouldb6 0.5V or less.
Aro vohtgos as rpocili.d?
YES NO
F.uftySRSunit;replacethe SRSunit l.oo p ago2+761. I
Sho to power in tha SRS main harno!3 or tha dummy

r€si3tor; chcck tor contact betwoen tho dummy rosistor and
another wiro. It tharo is no contact. ,oplace tho SRS mrin
natnoss.
24-60
\
-
\
DTC2-5- Without FrontPassenger's

Airbag
CAUTION: when€ver the ignition switch i3 ON (ll), ot
has been tutned OFF fot less than thres minutos, be
careful not to bump the SRS unit; the sirbag could acci'
dentally deploy and causedamago or iniuries.
Try to reproducetho SRSindicator lightl

l. Erasethe DTCmemorvtseepsge24_15).
2. Turn the ignition switch ON (ll), and check thal lhe SRS indi-
catorliqht comeson for aboutsix secondsand go€soff
Oo.3 tho SRSindicator light .t!Y on?
SRSUN]T
Chockfor e short to ground in tho SBS main halne3si

the Dositivecable, and wait for three minutes'
2. Dis;onnectthe driver's airbag 2P connectorfrom the
cablereel2Pconnector(seepage24-11)
3. Disconnectthe SRS main harness18Pconnectorlrom
the sRS unit.
4. Checkresistancebelween No lO terminal of the SFS
main harness18Pconnectorand ground,and belween SRSMAIN HARNESS
the No. 14terminalof the SFS main harness18Pconnec_ 18PCONNECTOR
tor and ground. There should be 1 l\/toor more
FaultySRSunit; replacothe SRSunit {36epag.21-761
Short to ground in tho SRS main harnosi or the dummy

resistor;checklor conttc{ between the dummy rcablor and
ground. ll lhero b no contact, roplsco the SRS main har'
24-61
,tl
rr-
Troubleshooting
DTC8-6
CAUTION:Wheneverthe ignition switch is ON l ), or
hss been turnod OFFfor l€ss than thre€ minules, bs
carsful nol to bump the SRS unit; the airbags could
sccidentallydeploy and causodamage or iniulies.
Besidesindicatingan abnormalityin the SRS unit, DTC

8-6 may also indicatethat two problemsequivalentto
DTC'f-l and 2-4, 1-4 and 2-1,ot 1-4and 2-4 occurredat
the sametime, Proceedin the ordershown below.
Checkthe SRSmain harn$s:

the positivecable,and wait for thrceminutes.
2. Disconnectthe driver's airbag (and tront passenger,s
airbag)connecto(s) (see page 24-111.
the SRSunit.
negativecable.
6. Connect a voltmeter and measure voltage betlveen the sRs
No. 10 terminalof the SRSmain harnessl8p connector 18PCONNECTOR
and ground,and b€tweenthe No. '14terminaland ground.
Thereshould be approx.0 - 0.5 V.
Aro voltag.3 as spocifi.d?
YES NO
Short to powsr in tho SRS main h6rnoss; roplace the SRS

msin hamesl.
Checkthe SRSmein hr]ne3s rnd the csble recli

Connect a voltmoter and moasure voltage between the
No. 1 terminalof the SRS main harness18p connector
a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d
ground.Thereshouldbe aDprox.0-0.5V.
Aro voltag$ a3 apecifiod?
YES NO
FauftySRSunit; replacethe SRSunit {3cepage 2+761,
To page24-63(A)
24-62
\_
E1
Frompage24'62(Al
Chocktho ceble ro.l:

2. Disconneitthe cable reel 2P conn6clot f'om the SRS
matnharness.
4, Connect a voltmeter and measure vohaga b€treen the
No. 1 terminalof the sRS main harness18Pconnodtor
a n d q r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d
.,o'n'd- Thereshouldbe aoprox.O- O 5 V.
Short to power in the crbl6 toel; roplsco th' c'ble 16ol
Short to pow.l in tho SRS m.in hamoss; lopltc' th€ SRS
24-63
-/
Troubleshooting
DTC9-2
CAUTION: Whedover tho ignition switch is ON ([). o,
h!3 bsen turned OFF for less than thr€e minutes, bo
clrctul not to bump tho SRS unit; the airbag(sl could
lccidontally deploy and cau3edemage or iniuries.
Checkth6 tu3ei
2. Checkfor blown No. 23 (10 A) fuse in the underdash
(A) To page 24-65
Replace the fuse.Turnthe ignitionswitchON (ll), and check

that the fuse doesn't blow.
Thc problornhr3 dblppoa.ed. Tcat-drivethe vehicla ,nd

3eeTroubl*hooting Int.rmiftant F ilu..s on page2+15. No.23 110A) FUSE
FUSE/RELAYBOX
SRSUNIT
Chock tor 3hort to g.ound betwoan tho undgr-dashfus6/

reby box and tho SRSunii.
the positivocable, and wait lor three minutes.
3. Disconnectthe driver,s(and tront passengsr,s) airbag
connector{s) (seepage2/t-1'l).
4. Disconnectthe SRS main harnesslgp connectorlrom
the SRSunit.
5. Checkresistancebotweenthe No. 3 terminal of the SRS
main harness18Pconnectorand Oround.
Thereshouldbe 1 M0 or more.
SRSMAIIIIHARNESS,I8P CONNECTOB
SRSunh; replacsth. SRSunir {3oopage 2+761.
1B)
To page 24-65
24-64
fl
(B)from page24-64
ChaFktor lhort to ground in th. SRSm'in h'mo3t:

1. Disconnect the SRSmain harness2P connector{rom the
underdash fuse/r€laYbox.
2. aheck resistancebetweenthe No 3 terminal ot the SRS
main harness18Pconnectorand ground There should
be 1.0Mo or mor€
ls tho l.3itt nco .. 3P.cifi.4l-
YES NO
0t'@r
Short to gtound in tha undor'dtth fu3'/tolf,Y box;
r.of.ca th. und.rdssh rusolrelaV box.
-sho.t FUSE/RELAYBOX
m groundin th. sRs m.in htrnes;;r'plrct th' sRs
fiain h!mo$.
SRSMAIN HARI{ESS
(A) From page 24-64 18P CONNECTOR
Chackloa an opcn in lha SRSmain harne3s:

1. Turn the iqnitionswitchOFF
2. Disconne;tthe batterynegativecable,then disconnect
the positivecable,and wait tor threemrnutes'
3. Disconnectthe driver's (and lront passenger's) airbag
connector(seePage24-11).
/t. Disconnectthe SRS main harnessl8P connectorfrom
the sRs unit.
5. Reconnectthe battery positivo cabl€,then reconnectthe
neoativecable.
S. Co-nnecta voltmeter betlveon the No 3 terminal of the
SRSmain harness18Pconn€ctoranclgrouno'
7. Turnth€ ionitionswitchON {ll},and measure
SRSMAIN HARNESS
18P CONNECTOR
Poor contact st th€ SRS main harnasa 18P connoctor;

chrck tho conn6ctor'
. ll tha connactot b OK, 3ubltituta a known-good SRS
unit, and tschgck.
. It th. Droblem i. still pJcrent, ].pt.ce tho SRS mtin
To page 24-66 (cont'd)
24-65
."
froubleshooting
DTC9-2 (cont'd)
Frompage24-65
Chockfor an open in tho SRSmain harness:

2. oisconnecttheSRSmain harness2pconnectorlromthe
under-dashfuse/relaybox.
3. Checkresistancebotweenthe No. 2 terminal of the SRS
main harness2P connectorand No. 3 terminal of the
SRSmain harness18Pconnector.
Thereshouldbe 0 - 0.50.
Poor contsct at the SRS main harness2p conneclor:

chackthe connector.
. lf the connoctor is OK, 3ubstitute a known-good
under_
d.sh tuse/r€laybox, and r6chgck,
.lt the problem is still pro3ont, replace the
SRS mrin
hamess.
UNDER.DASI{
FUSE/RELAY
8OX
Open in tho SRS main harncs3;replacothe SRS main har-

nosli,
SRSMAIN HARNESS
18PCONNECTOR
Wire side of female

CaOl terminals
SRSMAIN HARNESS
2P CONNECTOR
i\
24-66
"L
Airbag
Replacement
F ont P[.Jrga/t Sld.:
After a coltisionin which the airbagswere deployed,the
airbagassemblissand the SRSunit must be replaced'
. Disconnectthe 2P connec'torbetween the tront p88-
sb'! r'..-eycd l*bag whh the oad sur' seng€r'saitbagand SRSmsin harnsss'
!@
iiFup. r tm ri6r9 b improPorly storod lac€ down'
NOTE: When disconnected,the airb8g connoctor ls
accidcnti d.plovnanl Gaald proprl lht unit with
f{u.V. shoned.
automatically FRONTPAS€EltlGER's
€nough to.6 to Glr !-iqt AIRBAG
2P @NNECIOR
CAUTION:
. Always disconnoctthc airblg connoctol(s) when the
harnessis disconnactad.
. Oo not disa3sembloor ttmper with ths airbag'
NOTE:
. Do not installusedSRSp8rtsfrom anothervehicle'
when repairing,usa onty new SRSparts'
Do
. CareJullyinspectthe airbag beforeyou installit
s i g n s o f b e i ng
not insiall 8n airbag that shows
such as dents' cracKs
droooedor improperlyhandled,
or deformation.
1. Disconnectthe battery negative cable' then discon-

at
nect the positive cable from the battery' and wa't
leastthtee minutes.
2. the airbagconnector(sl:
Disconnect
Driver's Side: 4. Removethe sirbag(s):

wheel'
. Removethe accesspanel from the steering Diivar's Side:
disconnectthe 2P connectorbetweenthe driv-
then
er's airbagand cablereel' o Removethe two Torx bolts using a Torx T30 bit'
then
is removethe drivers airbag'
NOTE:When disconnected,the airbag connector
shorted
automaticallY
DRIVER S
AIRBAG
TORXBOI-TS
U.. . Torr F0 bit.
) (cont'd)
DRIVER'SAIRBAG
2P CONNECTOR
24-67
.
Airbag
(cont'd)
Replacement
Front Passenger'sSide: CAUTION: B€ sure to instsl the SRSwiring so that it is
not pinched or intertsring with oth€r parts.
. Removethe three mounting nuts from the bracket,
then removethe harnesscliD. 4. Installthe new airbag(s):
. Liftthe front passenger'sairbagout of the dashboard
by coveringthe lid and dashboard\ /ith a cloth, and Driver'sSide: Placethe driver'sairbaginto the steering
pryingcarefullywith a flat-tipscrewdriver, wheel.and secureit with new Torx botrs.
N O T E :T h e l i d o f t h e a i r b a gh a s p a w l s o n i t s s i d e TORXBOLTS
which attachit to the dashboard. 9.8N.m ll.0 kgf.m,7.2lbtfrl
Replace.
DRIVER'SAIRBAG
Front Passenge.'sSide:
. P l a c et h e f r o n t p a s s e n g e r , a
s irbaginto the d6sh_
board.
. Tightenthe front passenger,s airbagmountingnuts.
AIRBAGMOUNTINGNUTS
9.8 N.m 11.0kgf.m,7.2lbf.ft)
Reolace.
2+68
5. Reconnectthe airbag connector(s). Driver's Side:
. Connectthe driver'sairbag2P connectorto the cable

Frod P.ss.nga/s Sidc:
reel2P connector,then installthe accesspanelon the
. Aftach ths ai.bag connector to the connector holder' steeringwheel.
then r€installths glove box.
RT'T ?ASSE'{GER'S AIRBAG
)
AIRBAG
DRIVEN'S
2PCONNECTOR
CONNECTOB
KOTD€R Connectthe batterypositivecable,then connectthe
negativecable.
1. After installingthe airbag,confirm proper system

operatlon:
. Turn the ignitionswitch ON (ll);the SRS indica-
tor light should come on for about six seconds
and then go off.
. Makesure both horn buttonswork'
24-69
1T
Airbag
Disposal
Beforescrappingany airbags(includingthose in a whole Front Pass€ngsr'sAirbag:
vehicleto be scrapped), the airbagsmust be deployed.lf
the vehicleis still within the warrantyperiod,beforeyou 4, Removethe glove box, then disconnectthe 2P con-
deploythe ai.bags,the HondaDistrictServiceManager nector between the front passenger'sairbag and
must giveapprovaland/orspecialinstructions, Onlyafter sRS main harness
FR.NTpAssENGER's
the airbagshavebeendeployed{as the resultof vehicle AIRBAG
collision,tor example),canthey be scrapped.
lf the airbagsappear intact {not deployed),treat them
with extremecaution.
Followthis procedure:
Deployingthe Airbags: In-vohicl€
NOTE:It an SRSvehicleis to be entirelyscrspped,its

airbagsshouldbe deployedwhile still in the vehicle.The
airbagsshould not be consideredas salvageablepans
and shouldneverbe installedin anothervehicle.
!@ confirm that esch airbag assemblyis

3.cursly mounted; otherwisg, soverg p€tsonal iniury
could result from doploymont.
l. Disconnectthe bafterynegativecable,then discon- SRSMAINHARNESS

nectthe positivecable.
5. Cut off the airbag connector,strip the ends of the
2. Confirmthat the specialtool is tunctioningproperly airbagwires,and connectthe deploymenttool alli-
by following the checkprocedureon the tool label gator clips to the airbag.Placethe deploymenttool
ot on page 24-7'l. at leastthirty teet (10meters)awayfrom the airbag,
Driver's Airbag: DRIVER'S FRONTPASSENGER'S

AIRBAG AIRBAG
3. Removethe accessDanel,then disconnectthe 2P

connecto. betweenthe driver's airbag and the cable
reel.
DRIVER'S
AIRBAG
2P CONNECTOR
BATTERY
t'4-70
I
Deployingthe Airbag: Out-ot-vehicle

Connecta 12 volt batteryto the tool:
N O T E : l f a n i n t a c t a i r b a g h a s b e e n r e m o v e df r o m a
. lf the green light on the tool comes on' the air- scraooedvehicle,or has been found defectiveor dam-
bag ignitercircuitis defectiveand cannotdeplov a g e d d u r i n g t r a n s i t ,s t o r a g eo r s e r v i c e ,i t s h o u l d b e
t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l deployedas follows:
Procedure.
tffi Posilion the airbag face up, outdoors on
. lf the red light on the tool comeson, the airbagis
iiffiat l"ast thirtv feet (10 ml trom anv obstacles
readYto be dePloYed.
or people.
7. P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h T h e a i r b a g
should deplov (deploymentis both highly audible
and visible;a loud noise and rapid inflalionof the
bag,followedbY slow deflation).
. lf the airbagsdeploy and the green light on the

tool comeson, continuewith this procedure
. lf an airbag doesn't deploy,yet the green light
comes ON. its igniter is delective Go to Dam
aged Airbag Specia\Procedure'
ri.,-.d .l.nlovment the airbag assem-

=E
F".n u"co-. hot enough to burn you wait thir- properlY
the 1. Confirmthat the specialtool is functioning
w'minut.s after deployment before touching procedure on thrs page or on
by followingthe check
assemulY.
the tool label.
) O 8. Disposeof the completeairbag assembly No

of it can be reused
and sealit securely,
Placeit in a sturdy plastic
part
bag'
2. Follow steps5, 6, 7, and 8 of the in-vehicledeploY
ment Procedure.
DamagedAitbag SpecialProcedure
CAUTION:
!!@ r an ailbag cannot be deployed' it should
. wear a lace shigtd and gloves when handling a not be treatgd as normal scrap; rt should still be
consid-
deploYedairbag. that can cause serl-
ered a potentiallY explosive device
r Wash your handsand rinse them well with ous iniury.
water after handling a deploYedailbag' proce
1. lf installedin a vehicle,follow the removal
AIRBAG
dure on Page24-67'
2. ln all cases.makea shortcircuitby twistingtogether
the two airbaginflatorwlres
packaging
3. Packagethe airbag in exactlythe same
that the new replacement part came In
"DAMAGEDAIRBAG
4. Mark the outside of the box
NOT DEPLOYED" sQ it does not get confusedwith
your Partsstock.
for
5 . C o n t a c ty o u r H o n d aD i s t r i c tS e r v i c eM a n a g e r
how and where to return it for disposal
DeploymentTool: CheckProcedure
protector
1. Connectthe yellow clips to both switch
handleson the tool; connectthe tool to a battery'
is
2. Pushthe operationswitch:green meansthe tool
OK; red meansthe tool is faultY
3. the batteryand the yellowclips'

Disconnect
24-71
T:
GableReel
Replacement
@ sto.e a remove airbag assembly with the Makesurethe wheelsare alignedstraightahead.
pad surface up. lf the 8irbag is improperly stored face
down, accidontaldeployment could prop€l the unit with 4. Removethe driver'sdashboardlowercover.
enough torce to causeserious iniury,
CAUTION: TORXBOLTS
Use a Torx T30 bh.
. Always dkconnest th6 airbag conneqtor(s)when the
harnsssis disconnected.
. Do not disassembleor tampor with the airbag.
N O T E :C a r e f u l l yi n s p e c tt h e a i r b a ga s s e m b l yb e f o r e
installingit. Do not installan airbagthat shows signsof
b e i n g d r o p p e do r i m p r o p e r l yh a n d l e d s, u c h a s d e n t s ,
cracksor deformation,
1. Disconnectthe batterynegativecabl€,then discon-

nectthe positivecablefrom the battery, and wait at
leastthreeminutes.
Removethe accesspanel from the steeringwheel,

DRIVER'SAIRBAG
then disconnectthe 2P connectorbetweenthe driv-
er's airbagand cablereel.
NOTE:When disconnected,
the airbagconnecrorts DRIVER'SDASHBOARDLOWERCOVER
automatically
shorted.
DRIVER'S 5. Removethe two Torx boltsfrom the steeringwheel.

AIRBAG and disconnectthe horn connector.Then remove
the driver'sairbag.
DRIVER'SAIRBAG
2P CONNECTOR
-El
6. Disconnect fromthe hornandcruise
the connectors 8. Romovetho columnrdverq
cont.olsevresumeswitches,then removethe steer-
ing wheel nut,
WHEEL
STEERING
CABLEREEL
2P CONNECTOR
1. Removethe steeringwheel using a steering wheel 9 . Disconnectthe 3P connectorbetweenthe main wire

puller. harnessand cablereelsub-harness, and the 2P con-
nectorbetlveenthe cablereeland SRSmain harness.
CABLEREEL
WHEELPULLER
STEERING
(Commercially-available)
CABLEREELSUB
HARNESS
SRSMAIN HARNESS 3P CONNECTOR
2P CONNECTOR
1 0 . R e m o v et h e c a b l er e e lf r o m t h e c o l u m n . (cont'd)
24-73
f
GableReel
Replacement(cont'd)
NOTE: r 3 , Installthe steeringcolumncovers.
. B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,t h e f r o n t
wheelsshouldbe alignedstraightahead. 1 4 . lf necessary,centerthe cable reel. (New replacement
. Be sure to lnstallthe harnesswires so that they cablereelscome centered.)Do this by first rotatingthe
are not pinchedor interferingwith other parts. cable reel clockwiseuntil it stops.Then rotate it coun-
. After reassembly,confirm that the wheels are terclockwise(approximatelytwo and a half turns) until
still turned straightaheadand that the steering the arrow markon the cablereellabelpointsstraight
wheel spokeangle is correct(roadtest).lf minor uD.
spokeangleadjustmentis necessary, do so only
by adjustingthe tie-rods,not by removing and
repositioning the steeringwheel.
1 1 . S e t t h e c a n c e ls l e e v es o t h a t t h e p r o i e c t i o n sa r e
alignedvenically. ARROWMARK
CANCEL
SLEEVE
PROJECTIONS
12. Carefullyinstallthe cable reel on the steeringcol

u m n s h a f t .T h e n c o n n e c t h e 3 p c o n n e c t o tro t h e 1 5 . I n s t a l lt h e s t e e r i n gw h e e l ,t h e n c o n n e c t h e h o r n
cablereel sub-harness, and connectthe 2p connec- connectorand cruisecontrolsevresumeswitchcon_
tor to the SRSmain harness. neclor. CRUISECONTROL
STEERING
WHEEL SET/RESUME
SRSMAIN HARNESS
€o'1
: _ - - - - - - - - - - - - - <
SRSUnit
Replacement I
CAUNON: 3. Removethe right sidecoverfrom the SRSunit.
. Beforo disconnesting any part of the SRS wire har-
ness,disconneetthe ailbag connector(s).
. During installation or rsplacement, do not bump
(impact wronch, hammor etc.) the aroa near tho SRS
SRSUNlT
unit.
NOTE:
. Do not damagethe SRSunit terminalsor connectors.
. Do not disassemblethe SRS unit; it has no service-
ableoarts.
. Storethe SRSunit in a clean,dry area.
. Do not useany SRSunit which has beensubjectedto
TORX
wateror showssignsof beingdroppedor improperly BOL?S
handled,suchas dents,cracksor deformation. U3ar Torx
T30 bit.
l. Disconnectthe batterynegativecable,then discon-
nectthe positivecablefrom the battery,andwaitat
leastthree minutes.
2. Disconnect
the airbagconnector{s}:
NOTE:When disconnected,
the airbagconnectoris
automatically
shorted.
RIGHTSIDE
COVER
Driver's Side:
o Removethe accesspanel from the steeringwheel. Removethe left side cover from the SRS unit. then l,---, $'
then disconnectthe 2P connectorbetweenthe driv- d i s c o n n e ctth e S R S m a i n h a r n e s s1 8 Pc o n n e c t o r
er's airbagand cablereel(seepage24-11). from the SRSunit,
Front Passenggr'sSidg: SRS UNIT

. Disconnectthe 2P connectorbetweenthe front pas-
senger'sairbagand SRS main harness(seepage 24-
11).
Removethe four Torx bolts from the SRSunit,then

pull out the SRSunit from the driver'sside, \-./ tt
r,i
6. lnstallthenew SRSunit. 9. Reconnecttho drivgr's airbr€ 2P :onnector lo the

cable reel 2P conn€ctor,than rernstallthe access
panelon the steeringr*reel-
1 0 . Reconnectthe front passenger'sai.bag conneclor

to the SRSmain harness.
the batterypositivecable,th€n lho n6ga-

1 1 . Reconnect
tive cable.
After installingthe SRSunit, confirmpropersystem

operation:Turn the ignitionswitchON (ll);the SRS
indicatorlight shouldcomeon for aboutsix seconds
and then go off.
TORXBOLTS
9.8 N.m 11.0kgf.m, 7.2 lbfft)
Uso a Torx T30 bh.
Replace.
SRSMAIN HARNESS
18PCONNECTOR
TORXBOLTS
9.8N.m(1.0kgtm.7.2lbtftl
Usoa TorxT30bit.
Replace.
7. Connectthe SRSmain harness18Pconnectorto the
SRSunit;push it into positionuntil it clicks
8. I n s t a l lt h e S R S u n i t c o v e r s( r i g h t a n d l e f t ) .M a k e
surethe coverssnaptogetherin the middle

Honda Civic Factory Service Manual US 1996 1997 1998 1999 2000 96 97 98 99 00

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Honda Civic Factory Service Manual US 1996 1997 1998 1999 2000 96 97 98 99 00

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GeneralInformation

GY-16P Midori GreenPearl

Vehicle ldentification Number Paint Code

U.S. 1996Model {4-doorSedanl

Lino, Body 8nd EngineTyp€

3; OX with ABS, HX with ABS

Line, Body and EnginoTyps

GY-T6P Midori GreenPearl

lHG EJ653*TL 800001

Lino, Body and EnginoTyp6

G-82P CypressGreen Pearl

Type ol Vohicl€ D16Y7i1600SOHC16-valves

Lino, Body and EnginoTypr

Dl6Y/: 1600SOHCl$valves Sequentisl

Lino, Body snd EngineTypo

Vehicle ldentification Number Paint Code

Vehicle ldentification Number EngineNumber

Manutaqturer,Make and EngineType

Line, Body lnd Engin€Typo

Vehicle ldentification Number NH-503P G.anadaBlackPearl

Lino, Body and EngineTyps

44RA: 4-speedAutomatic Transmission

L: East Liberty, Ohio Plant. U.S.A.

2HGEJ632 *WH 1 00001

Line, Body and EngineType

Vehicle ldentification Number

Line, Body and EngineType

3: DX with ABS,HX with ABS

Manutacturei. Make and

AIRBAGSEEOTHERSIDE. SUPPLEMENTAI- RESTRAINTSYSTEMISRSI

H: MONITORCAUTION f: PASSENGER AIRBAG CAUnON

tsF COOUNI, USE 'o'EO SOLUTION Model Ysar

e+l rr _9.,.' Evaporative Family: V H N 1 0 7 7B Y M A C

1. Placethe lift blocksas shown.

3. Raisethe hoisttolull height,and inspectlift pointstorsolidsupport.

Raisethe vehicle high enough to insert the safety

Adjust and place the safety stands so the vehicle

Center the jacking

Center the jack

It the vehicleneedsto be towed,call a professional tow- Front:

Flat-bedEquipment- The operator loads the vehicle on

Wh6d Lift Equipmont- The tow truck usestwo pivoting

Sling-typ6 Equipm€nt- The tow truck uses metal cables

lf the vehiclecannotbe transportedby flat-bed,it should

ManuslTransmission and CVT

Finaldrivengear Backlash 0.07- 0.130{0.0028 - 0.0051) 0.180(0.007r)

Springs Regulatorvalve spring A 1.8(0.071) 14.7(0.584) 87.8(3.4s7) 16.5

(1998) 4,180mm 164.6in

ITEM METRIC ENGLISH NOTES

No. LUBRICANONPOINIS LUBRICANT

NOTE:Lubricateall hinges,latchesand locksoncea year.

:6e e9fr9E : : ; e 3 E Etzl i ".6 dci6 BE

355 E,i ; o o ( , 3EF5FF €:i€EEE s9 l9

>5 ..>5 iE* 9 t d<.F>,-i .dee ? a :EE

'6 r. a :; osQQ + + ; + + < ot

E z En9 3 :b:: $sq 1b o. :3r , : Q@6A 6

> F > EI . . . . o ) .FEIbE; -i .0i55 I E*iC5: e>

1, Securethe hood as oDenas possible.

2.. Disconnectthe batterynegativeterminalfirst, then

3. Disconnectthe battery cables from the under-hood

the connectorsfrom the ECM/PCM.

6x1.0mm 6x1.0mm INTAKE AIR

10. Removethe evaporativeemission (EVAp)control