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COVER
24. Drain the coolant by loosening the radiator drain RADICÍ
INSURANCE
LANKA
cock (see page 10-7). WASHER
25. Drain the transmission fluid or oil. Replace the Exchange
washer with a new one and screw the drain screw 29. Remove the air conditioning compressor. NOTE: Do not
back in (see section 13,14). disconnect the air conditioning system hoses.
26. Drain the engine oil. Replace the washer with a new one
and screw the drain screw back in (see page 8-7).
27. Remove the shift rod and connecting rod (M/T).
28. Remove shift cable (A/T).
SHIFT ROD
CLAMP
COMPRESSOR
AIR CONDITIONING
CONNECTING
ROD
PIN
SPRINGS 8 mm
(continuation)
5-9
Engine removal/assembly
Disassembly (continued)
30. Disconnect the heated oxygen detector (HO2S) 34. Remove the half axles (see section 16). NOTE: Coat all
connector (B16A2, B16A4, B16A5 engines). precision machined surfaces with clean engine oil.
31. Disconnect exhaust pipe A. Put plastic bags on the ends of the axles.
Engines D15Z5, D15Z6, D16Y5 (KE, KG models) 35. Lower the jack.
D16Y7: 36. Remove the lower and upper radiator hoses and heater
hoses.
8´1.25 mm
22 Nm UPPER HOSE HOSE
Exchange COOLER HEATING
SEAL
Exchange
HO2S CONNECTOR
8´1.25 mm
22 Nm
Exchange
SEAL
Exchange
SEAL
Exchange TRANSMISSION HYDRAULIC FLUID
COOLER HOSE
EXHAUST
CONDUIT
AND SELF-LOCKING
NUT
8 x 1.25 mm 33 Nm SELF-LOCKING
16 Nm Exchange
NUT
Exchange
10 x 1.25 mm
5-10
38. Connect the chain hoist to the engine.
ENGINE SUSPENSION
07MAK - PY30100
Connect using
cylinder heads se
with an 8 x 1.25 mm screw.
SET
COMPENSATORS
ABOUT THE JACK
ENGINE
07KAK-SJ40101
(continuation)
5-11
Engine removal/assembly
Disassembly (continued)
39. Remove the left and right front hinge and bracket. 41. Remove the upper bracket.
UPPER
HOLDER
LEFT FRONT
HINGE 42. Remove the transmission hinge bracket. Then remove
NUT the transmission hinge.
Exchange
HINGE
TRANSMISSIONS
CURTAIN HOLDER
TRANSMISSIONS
RIGHT FRONT
HINGE/HOLDER
SCREW
Exchange
SCREWS
Exchange
5-12
Construction
PUMP HOLDER
AND POWER STEERING
REAR REINFORCEMENT
10´1.25 mm
44 Nm (4.5 kgf.m,
33 lbf.ft)
M/T:
12´1.25 mm
8´1.25 mm
57 Nm (5.8 kgf.m,
24 Nm (2.4 kgf.m,
42 lbf.ft)
17 lbf.ft)
A/T: 10´1.25 mm
10´1.25 mm 54 Nm (5.5 kgf.m, 40 lbf.ft)
44 Nm (4.5 kgf.m,
32 lbf.ft) 10´1.25 mm
44 Nm (4.5 kgf.m,
FRONT REINFORCEMENT 33 lbf.ft)
COMPRESSOR BRACKET
AIR CONDITIONING
12´1.25 mm
57 Nm (5.8 kgf.m,
42 lbf.ft) 8´1.25 mm
24 Nm (2.4 kgf.m,
17 lbf.ft) HOLDER
ALTERNATOR
10´1.25 mm
44 Nm (4.5 kgf.m,
33 lbf.ft)
(continuation)
5-13
Engine removal/assembly
Assembly (continued)
Bracket bolt torque specifications: Except for
B16A2, B16A4, B16A5, B16A6 engines:
HOLDER
10´1.25 mm PUMPS 10´1.25 mm
44 Nm AMPLIFIERS 54 Nm
MANAGEMENT SIDE HOLDER
ENGINE SUSPENSION
10´1.25 mm
8´1.25 mm HOLDER 44 Nm
24 Nm ALTERNATOR
REINFORCEMENT *3
- 10´1.25 mm
44 Nm HOLDER
- 10´1.25 mm
LEFT FRONT
44 Nm - 8´1.25 mm ENGINE SUSPENSION
24 Nm
FRONT REINFORCEMENT *2
HOLDER
COMPRESSOR
AIR CONDITIONING
FRONT
REINFORCEMENT *1
10´1.25 mm
54 Nm
10´1.25 mm
44 Nm
8´1.25 mm
24 Nm 10´1.25 mm
44 Nm * 1: D15Z7, D16Y5 engines and D16Y6, D16Y8
engines (mechanical transmission).
8´1.25 mm 10´1.25 mm
* 2: D15Z4, D15Z5 engines (automatic
24 Nm 44 Nm transmission).
* 3: Other engines.
5-14
Engine mounting: Except CVT/HONDA MULTI MATIC:
Install the motor in the reverse order of disassembly.
HINGE
Install the hinge bolts and nuts in the following order. An error in the TRANSMISSIONS
assembly sequence can cause increased noise and vibration and
reduce the life of the bushings.
HINGE
TRANSMISSIONS
UPPER
HOLDER
CURTAIN HOLDER
TRANSMISSIONS
(continuation)
5-15
Engine removal/assembly
Assembly (continued)
3. Install the rear hinge bracket. Then tighten the screws 4. Tighten the transmission hinge bracket bolts/nuts in the
in the numbered order as shown below (1-3). numbered order shown in the drawing (1-2).
- 12´1.25 mm 74 Nm
B16A2, B16A4, B16A5, B16A6 engines: Exchange
- 12´1.25 mm
- 12´1.25 mm 59 Nm
59 Nm Exchange
Exchange
- 14´1.5 mm
83 Nm
Exchange
- 12´1.25 mm 64 Nm
Engines D15Z4, D15Z5, (A/T) and engines D15Z7, Exchange
D16Y5 (CVT/HONDA MULTI MATIC):
5. Tighten the screws of the right front bracket/hinge in the
- 12´1.25 mm numbered order according to the drawing (---).
59 Nm
Exchange
CVT/HONDA MULTI MATIC:
- 10´1.25 mm
54 Nm
- 12´1.25 mm
59 Nm
Exchange
- 12´1.25 mm
59 Nm
Exchange
Other engines:
- 14´1.5 mm
83 Nm - 12´1.25 mm
Exchange 59 Nm
Exchange
- 10´1.25 mm
44 Nm
- 14´1.5 mm
83 Nm
Exchange
5-16
Except CVT/HONDA MULTI MATIC: 7. Adjust and recheck the following:
· Carefully clean with solvent or carbon remover the
areas where the axle shaft(s)
and connecting shaft contact the gearbox
(differential) and dry them with compressed air.
· Check that the locating rings of the ends of the half
axles and connecting shafts are in place.
- 12´1.25 mm 59 Nm
Exchange
- 10´1.25 mm 44 Nm
(continuation)
5-17
Engine removal/assembly
Assembly (continued)
Specification of the torque values of the screws/nuts of the hinges and brackets:
REAR SUSPENSION
5-18
Valve timing/cylinder head
6-3
Special preparations
6-4
VTEC solenoid valve
Troubleshooting Flow Chart (D15Z6, D16Y6, D16Y5, D16Z8
Engines)
The Malfunction Indicator Light (MIL) indicates Diagnostic Trouble Code (DTC) 21: VTEC Solenoid Circuit
Malfunction.
Please review pages 11-16 through 11-27 before beginning troubleshooting.
SIDE VIEW
PINS
NO Replace the solenoid valve
Did you measure 14-30W?
VTEC.
YES
CONNECTOR AND ECM/PCM CONNECTOR ELECTRO-
(32-PIN) MAGNETIC VALVE
VTEC
VTS
Check the VTEC solenoid valve wires: GREEN//YELLOW
(continuation)
6-5
VTEC solenoid valve
Troubleshooting Flowchart (D15Z6, D16Y5, D16Y6, D16Z8 Engines)
(Continued)
ELECTROMAGNETIC CONNECTOR
VTEC VALVE
(Continued from page 6-5)
NO FIXING PREPARATION
Recheck the VTEC solenoid
Is the pressure less than 49 kPa?
valve. OIL PRESSURE GAUGE
07NAJ-PO70100
YES
FIXING PREPARATION
Check the VTEC Solenoid Valve: LOW PRESSURE GAUGE OIL PRESSURE GAUGE
07406-0070001 07NAJ-PO70100
1. Turn the ignition key to the OFF
position.
2. Disconnect the VTEC solenoid valve
connector.
3. Connect the positive battery terminal
to the GREEN/YELLOW wire contact. 4.
Start the engine and check the oil
pressure for the D16Y8 engine: at 5000
min-1. For other engines except D16Y8:
at 3000 rpm.
NO
Is the oil pressure higher on the D16Y8 engine Recheck the VTEC solenoid
than 390 kPa? valve.
YES
6-6
VTEC solenoid valve
Troubleshooting Flowchart (D15Z7 Engine)
The Malfunction Indicator Light (MIL) indicates Diagnostic Trouble Code (DTC) 21: VTEC Solenoid Circuit
Malfunction.
Please review pages 11-16 through 11-27 before beginning troubleshooting.
NO
Did you measure 14-30W? Replace the VTEC solenoid valve.
YES
CONNECTOR
ELECTRO-
CONNECTOR AND ECM MAGNETIC
(32-PIN) VTEC VALVE
(continuation)
6-7
VTEC solenoid valve
Troubleshooting Flowchart (D15Z7 Engine) (Continued)
CONNECTOR ELECTRO-
(Continued from page 6-7) VTEC SOLENOID VALVE
NO
Recheck the VTEC solenoid valve.
Is the pressure less than 49 kPa?
PREPARATION
YES FOR FIXING SCREW
PRESSURE GAUGE 10 mm
Check the VTEC Solenoid Valve: OILS 22 Nm
07NAJ-PO70100
1. Turn the ignition key to the OFF
position.
2. Disconnect the VTEC solenoid valve LOW PRESSURE
connector.
MANOMETER
3. Connect the positive battery terminal to
07406-0070001
the GREEN/YELLOW wire contact.
4. Start the engine and check the
engine oil pressure at 3000 min-1.
YES
6-8
VTEC solenoid valve
Troubleshooting Flowchart (D15Z7 Engine)
The Malfunction Indicator Light (MIL) indicates Diagnostic Trouble Code (DTC) 38: VTEC Solenoid Valve B
Circuit Malfunction.
Please review pages 11-16 through 11-27 before beginning troubleshooting.
(continuation)
6-9
VTEC solenoid valve
Troubleshooting Flowchart (D15Z7 Engine) (Continued)
CONNECTOR ELECTRO-
VTEC SOLENOID VALVE
(Continued from page 6-9)
YES Repair the RED wire short between CONNECTOR WITH SOCKETS,
Is the circuit closed? the ECM/PCM (A21) and the VTEC VIEW FROM THE DRIVERS SIDE
solenoid valve two-pin connector pin
#2.
SCREW
NO
Recheck the VTEC solenoid valve. 10 mm
Is the pressure less than 49 kPa?
PREPARATION FOR UP- 22 Nm
EASEMENT
YES
MANOMETER
OIL PRESSURE
Check the VTEC Solenoid Valve:
07NAJ-PO70100
1. Turn the ignition key to the OFF
position.
2. Disconnect the VTEC solenoid valve
LOW PRESSURE
connector.
3. Connect the positive battery terminal MANOMETER
to the RED wire contact. 07406-0070001
4. Start the engine and check the
engine oil pressure at 5000 min-1.
NO
Is the D16Y8 engine oil pressure Recheck the VTEC solenoid valve.
higher than 390 kPa?
YES
SCREW
Upload ECM/PCM guaranteed good and 10 mm
will recheck. If the indicated symptoms 22 Nm
disappear, replace the original ECM/ / PREPARATION FOR UP-
PCM. EASEMENT
MANOMETER
OIL PRESSURE
07NAJ-PO70100
6-10